Chassis PDF

3 Chassis
30A GENERAL INFORMATION
31A FRONT AXLE COMPONENTS
33A REAR AXLE COMPONENTS
35A WHEELS AND TYRES
35B TYRE PRESSURE MONITOR
36A STEERING ASSEMBLY
37A MECHANICAL COMPONENT CONTROLS
37B ELECTRONIC PARKING BRAKE
38C ANTI-LOCK BRAKING SYSTEM
X45
FEBRUARY 2009 Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault.
specifications current when it was prepared.
The reproduction or translation in part of whole of the present document, as well as the use
The methods may be modified as a result of changes introduced by the manufacturer in the of the spare parts reference numbering system, are prohibited without the prior written
production of the various component units and accessories from which his vehicles are consent of Renault.
constructed."
© Renault s.a.s 2008

KOLEOS - Section 3 ContentsPage
KOLEOS - Section 3
Contents
Page
30A GENERAL INFORMATION 31A FRONT AXLE COMPONENTS
Brake circuit Operating Front brake disc shield:

diagram 30A-1 Removal - Refitting 31A-11
Brake circuit Precautions for Front brake disc: Removal -

repair 30A-2 Refitting 31A-13
Brake circuit Bleeding 30A-3 Front brake disc: Description 31A-15
Brake fluid: Specifications 30A-5 Hydraulic unit - master

cylinder brake pipe: Removal
Brake: Specifications 30A-6 - Refitting 31A-16
Underbody height: Hydraulic unit - underbody
Adjustment values 30A-7 union brake pipe: Removal -
Front axle: Adjustment Refitting 31A-22
values 30A-8 Hydraulic unit - front left-
Front axle: Adjusting 30A-10 hand calliper brake pipe:
Removal - Refitting 31A-27
Rear axle: Adjustment values 30A-11
Hydraulic unit - front right-
Rear axle: Adjusting 30A-12 hand calliper brake pipe:
Front driveshaft hub carrier:

31A FRONT AXLE COMPONENTS
Hub carrier-driveshaft
Front brake pads: Removal - assembly: Removal -
Refitting 31A-1 Refitting 31A-42
Front brake hose: Removal - Front hub carrier bearing:

Refitting 31A-3 Removal - Refitting 31A-47
Front brake calliper: Removal Spring and front shock

- Refitting 31A-5 absorber: Removal - Refitting 31A-49
Front brake calliper: Repair 31A-7 Front driveshaft lower arm:

Front brake calliper support:
Removal - Refitting 31A-9 Front driveshaft lower arm
ball joint: Check 31A-56
Contents
31A FRONT AXLE COMPONENTS 33A REAR AXLE COMPONENTS
Front axle sub-frame: Upper arm: Removal -

Removal - Refitting 31A-58 Refitting 33A-45
Front anti-roll bar: Removal - Rear axle sub-frame:

Refitting 31A-69 Removal - Refitting 33A-47
33A REAR AXLE COMPONENTS 35A WHEELS AND TYRES
Rear brake pads: Removal - Wheel: Removal - Refitting 35A-1

Refitting 33A-1
Wheel: Balancing 35A-3
Rear brake hose: Removal -
Refitting 33A-3 Tyres: Identification 35A-5
Rear brake caliper: Removal Tyres: Removal - Refitting 35A-6

- Refitting 33A-5 Tyre inflation pressure:
Rear brake calliper Identification 35A-8
mounting: Removal - Wheel rim: Identification 35A-9
Refitting 33A-7
Rear brake disc shield:

35B TYRE PRESSURE MONITOR
Rear brake disc: Removal -
Refitting 33A-13
SSPP: List and location of
Rear brake disc: Description 33A-14 components 35B-1
Rear brake lining: Removal - SSPP: Precautions for repair 35B-3

Refitting 33A-15
Tyre pressure monitor
Brake pipe: Removal - computer: Removal -
Refitting 33A-18 Refitting 35B-4
Shock absorber: Removal - Pressure sensor: Removal -

Refitting 33A-20 Refitting 35B-5
Rear suspension spring: Tyre pressure monitor

Removal - Refitting 33A-22 receiver: Removal - Refitting 35B-7
Rear wheel hub: Removal -

Refitting 33A-26
Rear stub-axle carrier: 36A STEERING ASSEMBLY

Steering: List and location of
Rear anti-roll bar tie rod: components 36A-1
Steering rack: Removal -
Rear anti-roll bar: Removal - Refitting 36A-2
Refitting 33A-42
Track rod: Removal -
Lower trailing link: Removal - Refitting 36A-12
Refitting 33A-43
Contents
36A STEERING ASSEMBLY 37A MECHANICAL COMPONENT CONTROLS
Axial ball joint linkage: Clutch circuit: Bleeding 37A-48

Clutch master cylinder:
Steering column: Removal - Removal - Refitting 37A-55
Refitting 36A-16
Clutch pedal switch:
Steering rack gaiter: Removal - Refitting 37A-61
Clutch circuit: Removal -
Bulkhead seal: Removal - Refitting 37A-66
Refitting 36A-27
Manual gearbox selector
Intermediate shaft: Removal cable: Removal - Refitting 37A-70
- Refitting 36A-33
Gear control unit: Removal -
Steering wheel: Removal - Refitting 37A-76
Refitting 36A-39
Automatic gear control cable:
Mechanical gear control

37A MECHANICAL COMPONENT CONTROLS cable: Adjustment 37A-84
Parking brake cables:

Master cylinder: Removal -
Refitting 37A-1
Brake servo: Removal -

Refitting 37A-7
37B ELECTRONIC PARKING BRAKE
Vacuum pump: Removal -
Refitting 37A-20
Assisted parking brake: List
Accelerator/brake pedal and location of components 37B-1
assembly: Removal -
Refitting 37A-23 Emergency handle: Removal
- Refitting 37B-3
Accelerator pedal: Removal -
Refitting 37A-28 Control unit: Removal -
Refitting 37B-4
Brake pedal: Removal -
Refitting 37A-31 Handle: Removal - Refitting 37B-8
Brake pedal switch: Removal

- Refitting 37A-34
Parking brake lever: Removal 38C ANTI-LOCK BRAKING SYSTEM

- Refitting 37A-37
ABS system: List and
Parking brake lever: location of components 38C-1
Adjusting 37A-38
Brake hydraulic assembly:
Clutch control: List and Removal - Refitting 38C-4
location of components 37A-40
Front wheel speed sensor:
Clutch pedal: Removal - Removal - Refitting 38C-8
Refitting 37A-42
Rear wheel speed sensor:
Clutch pedal position sensor: Removal - Refitting 38C-10
Contents
38C ANTI-LOCK BRAKING SYSTEM
Yaw speed and transversal

acceleration sensor:
Removal - Refitting 38C-12
Steering wheel angle sensor:

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

Refitting 38C-16
GENERAL INFORMATION
Brake circuit Operating diagram 30A
130805
(1) ABS hydraulic unit

(2) Front brake disc
(3) Master cylinder
(4) Brake servo
(5) Underbody connection
(6) Rear brake disc
(A) Rigid brake pipes
(B) Brake hoses
IMPORTANT
This is a diagram of the general principle, do not
use it as a reference for take-off points or circuit
allocation. When replacing components in a vehi-
cle's braking circuit, always mark the pipes before
removing them.
30A-1
GENERAL INFORMATION
Brake circuit Precautions for repair 30A
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.
130806
Parts identification:
- shape of steel or copper pipe end piece (A) ,
- shape of threaded housing on components (B) ,
- shape of unions (C) .
30A-2
GENERAL INFORMATION
Brake circuit Bleeding 30A
Essential equipment
pedal press
brake circuit bleeding device
Tightening torquesm
front bleed screws 10 Nm
rear bleed screws 10 Nm
Precautions to be taken before and during the brake

circuit bleeding operation:
- The ignition must be switched off to ensure that the
hydraulic unit solenoid valves do not operate.
- use brake fluid which conforms to the Renault stan-
dard (see Vehicle: Parts and ingredients for the re-
pairwork) (04B, Consumables - Products), 130807
- check the brake fluid levels in the brake circuit and the a Use locally produced containers to collect the used
bleeding device, brake fluid.
- the braking regulation circuit must be free of all hy-
draulic and electrical faults, Front and rear callipers:
- check that the pressure of the bleeding device is - 2 washer fluid containers (1) (1 litre),
between 1.5 bar and 2 bar.
- 4 mm diameter transparent pipes (2) ,
This procedure must be applied after one of the fol-
lowing components has been removed or replaced: - 4 pipettes (3) (part no: 00 00 081 501),
- the master cylinder,
- 2 T-unions (4) .
- the brake fluid,
- the hydraulic unit,
Note:
- a rigid pipe,
The new hydraulic unit is pre-filled.
- a hose,
When working on one of the following compo-
- the reservoir, nents, position a pedal press to limit the outflow
- a calliper. of brake fluid and prevent any air from entering
the master cylinder and the circuits downstream
of the master cylinder:
- hydraulic unit,
- pipes between the hydraulic unit and brake cal-
lipers,
- brake hoses,
- brake calliper.
Remove the pedal press before carrying out the
braking system bleeding procedure.
a Position the vehicle on a two-post lift (see Vehicle:

Towing and lifting) (02A, Lifting equipment).
a Switch off the vehicle ignition.
30A-3
GENERAL INFORMATION
Brake circuit Bleeding 30A
a Connect the brake circuit bleeding device (after a Remove the brake circuit bleeding device from
having received Renault approval) to the master cy- the master cylinder reservoir.
linder reservoir (see the instructions for the equip-
a Check pedal travel and resistance. If it is not correct,
ment).
finish bleeding the brake circuit with the help of a se-
a Pressurise the brake circuit. cond operator. Start the bleed operation by bleeding
the calliper that is the furthest away from the master
a Adjust the pressure to between 1.5 bar < P < 2 bar cylinder:
for 3 minutes to stabilise it in the braking circuit.
- hold down the brake pedal,
a Close the circuit between the bleed screw and the
brake fluid reservoir without letting the pressure fall. - open the circuit bleed screw to release the air from
the brake circuit,
- close the circuit bleed screw,
Note:
- release the brake pedal.
The circuit between the bleed screw and brake
fluid reservoir is closed in different ways depen- a Top up the brake fluid level in the reservoir, if neces-
ding on the type of equipment used: sary. Check the tightness of the front bleed screws
(10 Nm) and the rear bleed screws (10 Nm) and
- valve, make sure that the sealing caps are fitted.
- switch. a During a road test, trigger braking regulation to con-
firm that the brake pedal travel is correct.
a Fit the bleed containers to the four bleed screws of
the callipers. a Clean any traces of brake fluid present on the vehi-
cle with BRAKE CLEANER (see Vehicle: Parts
a Undo the calliper bleed screws: and ingredients for the repairwork) (04B, Consu-
- front left, mables - Products).
- front right,
- rear left-hand,
- rear right.
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,
- front right,
- rear left-hand,
- rear right.
a Undo the calliper bleed screw:
- front left,
- 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,
- rear left-hand,
- rear right.
a Close the bleed screw to dump the pressure in the
brake circuit.
30A-4
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

Using a mixture of two incompatible brake fluids in the
brake circuit may give rise to:
- significant risk of leaks mainly due deterioration of the
cups,
- impaired operation of the ESP system.
To 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)
(04B, Consumables - Products).
30A-5
GENERAL INFORMATION
Brake: Specifications 30A
FRONT BRAKE (mm)
Piston diameter 45 x 2
Disc diameter 320
Disc thickness 28
Minimum disc thickness (1) 26
Maximum disc run-out 0.035
Brake pad thickness 10.0
Wear limit of brake pad thickness 2
Rear brake (mm)
Piston diameter 42.86
Disc diameter 292
Drum diameter 172
Maximum drum diameter 173
Disc thickness 16
Minimum disc thickness (1) 14.0
Maximum disc run-out 0.070
Wear limit of brake pad thickness 1.5
Minimum thickness of disc lining 1.5
Master cylinder
Diameter 23.81
(1) Brake discs cannot be reground. The brake discs

must be replaced if they are excessively scratched or
worn.
30A-6
GENERAL INFORMATION
Underbody height: Adjustment values 30A
I - MEASURING POINTS
Note:
Measure the value unladen. Unladen means that
the fuel tank and engine coolant and oil reservoirs
are full. The emergency spare wheel, jack, hand
tools and carpets are in place.
131428
W1 = 779 mm ± 5 mm
(R1) Distance between the ground W2 = 785 mm ± 5 mm
and the front wheel axis.
(R2) Distance between the ground
and the rear wheel axis.
(W1) Distance between the ground
and the top of the front wheel
arch.
(W2) Distance between the ground
and the top of the rear wheel
arch.
II - VEHICLE IN WORKING CONDITION

Position VODM (Vehicle in working condition):
- Tank full,
- Empty vehicle (without luggage, etc.).
30A-7
GENERAL INFORMATION
Front axle: Adjustment values 30A
II - WHEEL ALIGNMENT
Note:
the fuel tank and the engine and lubricant coolant
reservoirs are full. The emergency spare wheel,
jack, hand tools and carpets are in place.
I - WHEEL ALIGNMENT: MEANING OF SYMBOLS
WARNING
Symbols used by RENAULT:
-: toe-out,
131429
+: toe-in.
Value
Toe-out: minus sign
2TR M9R
0˚05’ ± 0˚10’ 0˚05’ ± 0˚10’
III - CASTOR ANGLE
Not adjustable
131429
Toe-in: plus sign
131432
Value
2TR M9R
4˚40’ ± 0˚45’ 4˚35’ ± 0˚45’
Maximum right-left difference = 0˚36'

131430
30A-8
GENERAL INFORMATION
Front axle: Adjustment values 30A
IV - CAMBER
Not adjustable
131433
Value
-0˚30’ ± 0˚45’
Maximum right-left difference = 0˚33'
V - PIVOT
Not adjustable
131434
Value
2TR M9R
10˚30’ ± 0˚45’ 10˚35’ ± 0˚45’
30A-9
GENERAL INFORMATION
Front axle: Adjusting 30A
Essential equipment
steering wheel lock
Tightening torquesm
wheel alignment adjust- 88 N.m

ment lock nut
I - ADJUSTMENT VALUES
Note:
the fuel tank and the engine and oil coolant
jack, hand tools and carpets are in place. 131435
a Loosen the wheel alignment adjustment lock nut (1)
(see 30A, General information, Front axle: Ad- .
justment values, page 30A-8) . a Turn the track rod sleeve (2) to obtain the required
value.
II - ADJUSTMENT a After adjustment, torque tighten the wheel align-

ment adjustment lock nut (88 N.m).
a Before checking the axle assemblies on the test
bench, check the tyre inflation pressure (see 35A,
Wheels and tyres, Tyre inflation pressure: Identi-
fication, page 35A-8) (35A, Wheels and tyres).
1 - Castor angle
a Not adjustable.
2 - Camber
a Not adjustable.
3 - Pivot
a Not adjustable.
4 - Wheel alignment
a Set the wheels straight ahead.
a Lock the steering wheel using the steering wheel

lock.
a Adjust the wheel alignment by rotating the track rod

sleeves.
30A-10
GENERAL INFORMATION
Rear axle: Adjustment values 30A
II - WHEEL ALIGNMENT
Note:
the fuel tank and the engine and oil coolant reser-
voirs are full. The emergency spare wheel, jack,
hand tools and carpets are in place.
I - WHEEL ALIGNMENT: MEANING OF SYMBOLS
WARNING
Symbols used by RENAULT:
-: toe-out,
131430
+: toe-in.
Value
Toe-out: minus sign
±0.10’
0˚05’±
III - CAMBER
131429
Toe-in: plus sign
131433
Value
±0.30’
0˚50’±
131430
30A-11
GENERAL INFORMATION
Rear axle: Adjusting 30A
a
Tightening torquesm Note:
nut on the lower trailing 130N.m After the adjustment, remember to check the toe-
link on the rear axle in.
subframe
2 - Toe-in
nut of the rear stub axle 150N.m
carrier
I - ADJUSTMENT VALUES
Note:
the fuel tank and the engine and oil coolant
jack, hand tools and carpets are in place.
(see 3 0 A, General information, Rear axle:
Adjustment values, page 30A-11) .
131441
a If the toe-in exceeds the adjustment value, adjust it
using the adjusting screw (3) on the rear stub axle
II - ADJUSTMENT
carrier (4) .
a Before checking the axle assemblies on the test a After the adjustment, torque tighten the nut of the
bench, check the tyre inflation pressure (see 35A, rear stub axle carrier (150N.m).
Wheels and tyres, Tyre inflation pressure: Identi-
fication, page 35A-8) (35A, Wheels and tyres).
1 - Camber
131440
a If the camber exceeds the adjustment value, adjust it

using the adjusting screw (1) on the lower trailing
link (2) .
a After adjusting, torque tighten the nut on the lower

trailing link on the rear axle subframe (130N.m).
30A-12
FRONT AXLE COMPONENTS
Front brake pads: Removal - Refitting 31A
a Unclip:
Essential special tooling
- the clip (3) ,
Fre. 1190-01 Brake calliper piston return
tool. - the brake hose (4) from the shock absorber.
a Rotate the calliper upwards.
Tightening torquesm a Remove the brake pad.
guide pin bolt 29 N.m

REFITTING
Note: I - REFITTING PREPARATION OPERATION

When replacing a brake pad, it is essential to
a Always replace the guide pin bolt.
replace the brake pad on the opposite side as well.
a Check the brake pad thickness (see 30A, General
information, Brake: Specifications, page 30A-6)
REMOVAL (30A, General information).
a Replace any faulty parts.

I - REMOVAL PREPARATION OPERATION
a Clean:
Towing and lifting) (02A, Lifting equipment). - the calliper,
a Unlock the steering column. - the calliper mounting,
a Remove the front wheel (see 35A, Wheels and ty- - the calliper mounting bolts.
res, Wheel: Removal - Refitting, page 35A-1)
(35A, Wheels and tyres). a Push the piston fully into its housing using tool (Fre.
1190-01) part no. 77 11 223 715.
II - OPERATION FOR REMOVAL OF PART

CONCERNED 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.
II - REFITTING OPERATION FOR PART

CONCERNED
a Refit the brake pad, starting from the inside.
a Rotate the calliper downwards to return it to its origi-

nal position.
a Refit the new guide pin bolt.
a Torque tighten the guide pin bolt (29 N.m).
a Clip:
131446
- the brake hose to the shock absorber,
a Remove the lower guide pin bolt (1) while holding
the nut (2) . - the clip.
31A-1
Front brake pads: Removal - Refitting 31A
III - FINAL OPERATION.
a Refit the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) (35A,
Wheels and tyres).
IMPORTANT
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.
31A-2
Front brake hose: Removal - Refitting 31A
CONCERNED
Essential equipment
pedal press
Tightening torquesm
brake hose on the calli- 18 N.m

per
brake hose on the union 16 N.m
131448
a Undo the brake hose (1) at the union.
a Unclip:
- the union clip (2) ,
- the shock absorber clip (3) ,
- the brake hose.
a Remove:
- the brake hose bolt (4) on the calliper,
131447
- the brake hose.
WARNING REFITTING
Prepare for the flow of fluid, and protect the sur-
rounding components. I - REFITTING PREPARATION OPERATION
a
REMOVAL WARNING
In order to not damage the brake hose:

a Position the vehicle on a two-post lift (see Vehicle: - do not twist the hose,
a Set the wheels straight ahead. ding components.
a Remove the front wheel (see 35A, Wheels and ty-

res, Wheel: Removal - Refitting, page 35A-1) Note:
(35A, Wheels and tyres).
The hoses supplied as replacement parts are
a Fit the pedal press on the brake pedal to limit the encased in a spring to prevent them from being
amount of brake fluid running out. twisted during the refitting operation.
31A-3
Front brake hose: Removal - Refitting 31A
CONCERNED
a Refit the brake hose bolt on the calliper side.
a Manually pretighten the brake hose bolt on the calli-
per.
a Clip on:
- the brake hose,
- the clip on the shock absorber,
- the clip on the union.
a Refit the brake hose on the union side.
a Tighten to torque:
- the brake hose on the calliper (18 N.m),
- the brake hose on the union (16 N.m).

a Remove the pedal press from the brake pedal.
a Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-3) (see
30A, General information).
Wheels and tyres).
31A-4
Front brake calliper: Removal - Refitting 31A
CONCERNED
Essential equipment
pedal press
Tightening torquesm
guide pin bolts 29 N.m

per
brake calliper bolts 165 N.m
Note:
The callipers supplied as replacement parts are
pre-filled with brake fluid.
REMOVAL
131449
I - REMOVAL PREPARATION OPERATION a Remove:
Towing and lifting) (02A, Lifting equipment). - the brake hose (1) from the calliper,
- the guide pin bolt (2) while holding the nut (3) ,
WARNING - the brake pad,
rounding components. - the brake calliper bolts (4) ,
a Fit the pedal press on the brake pedal to limit the - the front brake calliper.
amount of brake fluid running out.
a Unlock the steering column. REFITTING
res, Wheel: Removal - Refitting, page 35A-1) I - REFITTING PREPARATION OPERATION
a Always replace the guide pin bolt.
a Check the condition of the gaiter and the calliper pis-

ton (replace defective parts).
a Clean the backplate and the calliper.
a Push the piston back until it is at the end of its bore.
WARNING

ding components.
31A-5
Front brake calliper: Removal - Refitting 31A
CONCERNED
a Set the front wheels straight.
a Without using a tool, screw the brake hose onto the
calliper as tightly as possible.
a Refit:
- the front brake calliper,
- the brake calliper bolts,
- the pads starting from the inside,
- the new guide pin bolts.
a Torque tighten
- the guide pin bolts (29 N.m),
- the brake hose on the calliper (18 N.m),
- the brake calliper bolts (165 N.m).

a Partially bleed the brake circuit if the compensation
reservoir was not completely emptied during the
operation.
a If necessary, bleed the circuit completely (see 30A,
General information, Brake circuit Bleeding,
page 30A-3) (30A, General information).
a Check the brake fluid level.
IMPORTANT

Wheels and tyres).
31A-6
Front brake calliper: Repair 31A
- the dust seal.

tool.
Essential equipment
pedal press
WARNING
rounding components.
REMOVAL 131451
I - REPAIR PREPARATION OPERATION a Remove the rectangular section seal from the calli-
per groove using a round edged spring blade (feeler
a Position the vehicle on a two-post lift (see Vehicle: gauge).
a Fit the pedal press on the brake pedal to limit the
amount of brake fluid running out. Note:
The whole calliper must systematically be repla-
a Remove:
ced if there are any scratches in the calliper bore.
- the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) (35A, a Clean the parts using methylated spirit.
Wheels and tyres),
- the brake calliper (see 31A, Front axle compo-
nents, Front brake calliper: Removal - Refitting, REFITTING
page 31A-5) .
I - REFITTING OPERATION FOR PART

II - REPAIR OPERATION FOR PART CONCERNED CONCERNED
a Refit:
- the rectangular section seal in the calliper groove,
- the piston (after having coated it with the grease

supplied in the repair kit) using tool (Fre. 1190-01),
- the dust seal.
II - FINAL OPERATION.
a Refit the brake calliper (see 31A, Front axle com-

ponents, Front brake calliper: Removal - Refit-
131450 ting, page 31A-5) .
a Remove:
- the piston using compressed air and taking care to
place a wooden block between the calliper and the a Bleed the brake circuit (see 30A, General informa-
piston to avoid damaging it. Any sign of impact on tion, Brake circuit Bleeding, page 30A-3) (see
the piston skirt makes it unfit for use, 30A, General information ).
31A-7
Front brake calliper: Repair 31A
Wheels and tyres).
IMPORTANT
31A-8
Front brake calliper support: Removal - Refitting 31A
a Suspend the brake calliper from the suspension
spring.
Tightening torquesm
calliper mounting bolts 165 N.m II - OPERATION FOR REMOVAL OF PART

CONCERNED
guide pin bolt 29 N.m
REMOVAL

a Remove:
Wheels and tyres),
- the front brake pad (see 31A, Front axle compo-
nents, Front brake pads: Removal - Refitting,
page 31A-1) .
131453
a Remove:
- the calliper mounting bolts (3) ,
- the calliper mounting.
I - REFITTING PREPARATION OPERATION

a Always replace the upper guide pin bolt.
a Clean:
- the calliper mounting,
- the hub carrier.
a Coat the calliper mounting bolt with HIGH
STRENGTH THREAD LOCK (see Vehicle: Parts
and ingredients for the repairwork) or a similar
product before refitting.
131452
a Remove the upper guide pin bolt (1) while holding

the nut (2) . II - REFITTING OPERATION FOR PART
CONCERNED
a Refit:
WARNING
- the calliper mounting,
In order to not damage the brake hose: - the calliper mounting bolts.
- do not tension the hose, a Torque tighten the calliper mounting bolts (165
- do not twist the hose, N.m).
- check that there is no contact with the surroun- a Refit:

ding components. - the calliper,
31A-9
Front brake calliper support: Removal - Refitting 31A
- the new upper guide pin bolt.
a Torque tighten the guide pin bolt (29 N.m).

a Refit:
page 31A-1) ,
Wheels and tyres).
IMPORTANT
31A-10
Front brake disc shield: Removal - Refitting 31A
CONCERNED
Tightening torquesm
bolts of the front hub 88 N.m

carrier bearing
REMOVAL

a Remove:
Wheels and tyres),
- the front brake hose (see 31A, Front axle compo-
nents, Front brake hose: Removal - Refitting,
page 31A-3) .
- the front brake pad (see 31A, Front axle compo- 131461
a Remove:
page 31A-1) ,
- the bolts (1) of the front hub carrier bearing,
- the front brake calliper (see 31A, Front axle com-
ponents, Front brake calliper: Removal - Refit- - the front hub carrier bearing (2) ,
ting, page 31A-5) ,
- the front brake disc guard (3) .
- the front brake calliper mounting (see 31A, Front
axle components, Front brake calliper support:
Removal - Refitting, page 31A-9) , REFITTING
- the brake disc (see 31A, Front axle components,
Front brake disc: Removal - Refitting, page 31A- I - REFITTING PREPARATION OPERATION
13) , a Always replace the bearing whenever a hub is remo-
- the front driveshaft hub carrier (see 31A, Front ved.
axle components, Front driveshaft hub carrier:
Removal - Refitting, page 31A-39) . II - REFITTING OPERATION FOR PART
CONCERNED
a Refit:
- the front brake disc guard,
- the front hub carrier bearing,
- the bolts of the front hub carrier bearing.
a Torque tighten the bolts of the front hub carrier
bearing (88 N.m).
31A-11
Front brake disc shield: Removal - Refitting 31A
a Refit:
- the front driveshaft hub carrier (see 31A, Front
Removal - Refitting, page 31A-39) ,
Front brake disc: Removal - Refitting, page 31A-
13) ,
ting, page 31A-5) ,
page 31A-1) ,
page 31A-1) .
Wheels and tyres).
IMPORTANT
31A-12
Front brake disc: Removal - Refitting 31A
CONCERNED
Note:
Brake discs cannot be reground. If there is exces-
sive scoring or wear, they will need to be replaced
(see 30A, General information, Brake: Specifica-
tions, page 30A-6) (30A, General information).
When replacing a brake disc, be sure to replace the
disc on the opposite side.
When replacing brake discs, you must replace the
brake pads.
REMOVAL

a Remove:
131455
Wheels and tyres), a Remove the brake disc.

nents, Front brake hose: Removal - Refitting, REFITTING
page 31A-3) .
- the front brake pad (see 31A, Front axle compo- I - REFITTING PREPARATION OPERATION
nents, Front brake pads: Removal - Refitting, a Clean the brake disc using brake cleaner.
page 31A-1) ,
II - REFITTING PART CONCERNED
ting, page 31A-5) , a Refit the brake disc.
Removal - Refitting, page 31A-9) .
31A-13
Front brake disc: Removal - Refitting 31A
a Refit:
ting, page 31A-5) ,
page 31A-1) ,
page 31A-3) .
Wheels and tyres).
IMPORTANT
31A-14
Front brake disc: Description 31A
I - PREPARATION OPERATION FOR CHECK
Position the vehicle on a two-post lift (see Vehicle:
Remove the wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
II - CHECKING OPERATION FOR PART

CONCERNED
Note:
Use a Palmer type tool to check the thickness of the
disc.
88310
Measure the thickness of the disc at 4 points in order
(90˚ apart).
Compare the values with those recommended by the
manufacturer (see 30A, General information, Brake:
Specifications, page 30A-6) .
III - FINAL OPERATION

Replace the discs if necessary (see 31A, Front axle
components, Front brake disc: Removal - Refitting,
page 31A-13) .
Refit the wheel (see 35A, Wheels and tyres, Wheel:
117057
Position the Palmer tool (1) to measure the disc thic-
kness.
31A-15
Hydraulic unit - master cylinder brake pipe: Removal - Refitting 31A
LEFT-HAND DRIVE
- the scoop under the scuttle panel grille (see Scoop
under scuttle panel grille: Removal - Refitting)
Essential equipment
(56A, Exterior equipment).
pedal press
Tightening torquesm
brake pipe unions on 16 N.m

the hydraulic unit

the master cylinder

the hydraulic unit

the master cylinder
WARNING
130896
a Remove the insulation (1) from the bulkhead (see

REMOVAL Bulkhead insulating material: Removal - Refit-
ting) (68A, Soundproofing).
a Position the vehicle on a two-post lift (see Vehicle: 2TR

a Disconnect the battery (see Battery : Removal -

Refitting) (80A, Battery).
a Remove the engine undertray.
a Drain the cooling system (see Cooling circuit:

Draining - Refilling) (19A, Cooling system).
a Position a pedal press on the brake pedal to limit

the outflow of brake fluid.
a Remove:
- the air filter box (see Air filter unit: Removal - Re-
fitting) (12A, Fuel mixture),
131552
- the windscreen wiper arm (see Windscreen wiper
arm: Removal - Refitting) (85A, Wiping - a Remove:
Washing),
- the scuttle panel half-grille (see Scuttle half-grille: - the clips (2) ,
Removal - Refitting) (56A, Exterior equipment),
- the vacuum hose (3) .
- the windscreen wiper mechanism (see Winds-
creen wiper mechanism: Removal - Refitting)
(85A, Wiping - Washing),
31A-16
LEFT-HAND DRIVE
130898
a Remove the clips (4) .
a Disconnect the heater matrix hoses.
a Remove the brake pipe between the hydraulic unit
and the underbody union (see 31A, Front axle
130900
components, Hydraulic unit - underbody union
brake pipe: Removal - Refitting, page 31A-22) . a Loosen the brake pipe unions (6) on the hydraulic
unit.
CONCERNED a Remove the brake pipes (7) between the hydraulic
unit and the master cylinder.
REFITTING

CONCERNED
a Refit:
- the brake pipes between the hydraulic unit and the

master cylinder,
- the brake pipe unions on the hydraulic unit,

130899
- the brake pipe unions on the master cylinder.
a Loosen the master cylinder brake pipe unions (5) .
WITHOUT ESP
a Torque tighten:
- the brake pipe unions on the hydraulic unit (16

N.m),
- the brake pipe unions on the master cylinder

(16 N.m),
31A-17
LEFT-HAND DRIVE
a Refit:
ESP 2 or ESP - the bulkhead insulation (see Bulkhead insulating

material: Removal - Refitting) (68A, Soundproo-
a Torque tighten: fing),
N.m), under scuttle panel grille: Removal - Refitting)
- the brake pipe unions on the master cylinder (56A, Exterior equipment),
(18 N.m). - the windscreen wiper mechanism (see Winds-
- the scuttle panel half-grille (see Scuttle half-grille:
II - FINAL OPERATION Removal - Refitting) (56A, Exterior equipment),
a Refit the brake pipe between the hydraulic unit and - the windscreen wiper arm (see Windscreen wiper
the underbody union (see 31A, Front axle compo- arm: Removal - Refitting) (85A, Wiping -
nents, Hydraulic unit - underbody union brake Washing),
pipe: Removal - Refitting, page 31A-22) . - the air filter box (see Air filter unit: Removal - Re-
a Connect the heater matrix hoses. fitting) (12A, Fuel mixture).
a Refit the clips. a Remove the pedal press.

tion, Brake circuit Bleeding, page 30A-3) .
2TR
a Fill and bleed the cooling system (see Cooling cir-
a Refit:
cuit: Draining - Refilling) (19A, Cooling system).
- the vacuum hose,
a Connect the battery (see Battery : Removal - Refit-
- the clips. ting) (80A, Battery).
a Refit the engine undertray.
31A-18
RIGHT-HAND DRIVE
Essential equipment
pedal press
Tightening torquesm

the hydraulic unit

the master cylinder

the hydraulic unit

the master cylinder
WARNING 130896
Prepare for the flow of fluid, and protect the sur- a Remove the insulation (1) from the bulkhead (see
rounding components. Bulkhead insulating material: Removal - Refit-
REMOVAL
2TR

a Remove:
- the engine cover,
- the air intake sleeve,
- the windscreen wiper arms (see Windscreen wi-
per arm: Removal - Refitting) (85A, Wiping -
Washing),
- the scuttle panel half-grille (see Scuttle half-grille: 130901
a Remove:
creen wiper mechanism: Removal - Refitting) - the clips (2) ,
31A-19
RIGHT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART - the brake pipe unions (4) on the master cylinder.
CONCERNED
WITHOUT ESP
a Torque tighten:
N.m),
(16 N.m),
ESP 2 or ESP
a Torque tighten:
130902 - the brake pipe unions on the hydraulic unit (18
a Undo the brake pipe unions (4) on the master cylin- N.m),
der.
(18 N.m).
II - FINAL OPERATION
2TR
a Refit:
- the vacuum hose (3) ,
- the clips (2) .
130903
a Undo the brake pipe unions (5) on the hydraulic unit.
a Remove the brake pipes (6) between the hydraulic
unit and the master cylinder.
REFITTING

CONCERNED
a Refit:
- the brake pipes (6) between the hydraulic unit and
the master cylinder,
- the brake pipe unions (5) on the hydraulic unit,
31A-20
RIGHT-HAND DRIVE
a Refit:
- the bulkhead insulation (see Bulkhead insulating
fing),
(56A, Exterior equipment),
Washing),
- the engine cover.
a Remove the pedal press.
ting) (80A, Battery).
31A-21
Hydraulic unit - underbody union brake pipe: Removal - Refitting 31A
LEFT-HAND DRIVE
Essential equipment
pedal press
Tightening torquesm

the hydraulic unit
underbody brake pipe 16 N.m

unions
WARNING
REMOVAL 130896
I - REMOVAL PREPARATION OPERATION Bulkhead insulating material: Removal - Refit-
a Position the vehicle on a two-post lift (see Vehicle: ting) (68A, Soundproofing).
a Disconnect the battery (see Battery : Removal - 2TR
a Remove:
arm: Removal - Refitting) (85A, Wiping -
Washing),
- the scoop under the scuttle panel grille (see Scoop 131552
under scuttle panel grille: Removal - Refitting) a Remove:
- the clips (3) ,
31A-22
LEFT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART - the brake pipe unions on the hydraulic unit,
CONCERNED
- the underbody brake pipe unions.
a Torque tighten:
N.m),
- the underbody brake pipe unions (16 N.m).
2TR
a Refit:
- the clips (2) .
a Refit:
130906 material: Removal - Refitting) (68A, Soundproo-
fing),
Washing).
130907 a Remove pedal press.
a Undo: a Bleed the brake circuit (see 30A, General informa-

- the underbody brake pipe unions (4) ,
- the brake pipe unions (5) on the hydraulic unit. ting) (80A, Battery).
a Remove the brake pipes between the hydraulic unit
and the underbody brake pipe unions.
REFITTING

CONCERNED
a Refit:
underbody unions,
31A-23
RIGHT-HAND DRIVE
Essential equipment
pedal press
Tightening torquesm

the hydraulic unit
underbody brake pipe 16 N.m

unions
WARNING
130896
REMOVAL a Remove the insulation (1) from the bulkhead (see
Bulkhead insulating material: Removal - Refit-

2TR


a Remove:
- the engine cover,
fitting) (12A, Fuel mixture).

Washing),

Removal - Refitting) (56A, Exterior equipment), 130901
- the windscreen wiper mechanism (see Winds- a Remove:

creen wiper mechanism: Removal - Refitting) - the clips (2) ,
31A-24
RIGHT-HAND DRIVE
a Remove the brake pipe between the hydraulic unit REFITTING
and the master cylinder (see 31A, Front axle com-
ponents, Hydraulic unit - master cylinder brake
pipe: Removal - Refitting, page 31A-16) (31A, I - REFITTING OPERATION FOR PART
Front axle components). CONCERNED
a Refit:
II - OPERATION FOR REMOVAL OF PART - the brake pipes between the hydraulic unit and the
CONCERNED underbody unions,
- the brake pipe unions on the hydraulic unit,
- the underbody brake pipe unions.
a Torque tighten:
N.m),
- the underbody brake pipe unions (16 N.m).
a Refit the brake pipe between the hydraulic unit and
the master cylinder (see 31A, Front axle compo-
nents, Hydraulic unit - master cylinder brake pi-
130909 pe: Removal - Refitting, page 31A-16) (31A, Front
a Remove the underbody brake pipe unions (4) . axle components).
2TR
a Refit:
- the vacuum hose,
- the clips.
a Refit:
fing),
130903 (85A, Wiping - Washing),
a - the scuttle panel half-grille (see Scuttle half-grille:
- the brake pipe unions (5) on the hydraulic unit, Removal - Refitting) (56A, Exterior equipment),
- the brake pipes (6) between the hydraulic unit and - the windscreen wiper arm (see Windscreen wiper
the underbody brake pipe unions. arm: Removal - Refitting) (85A, Wiping -
Washing),
31A-25
RIGHT-HAND DRIVE
- the engine cover.
31A-26
Hydraulic unit - front left-hand calliper brake pipe: Removal - Refitting 31A
LEFT-HAND DRIVE
Essential equipment
pedal press
Tightening torquesm
brake pipe union on the 16 N.m

hydraulic unit

brake hose
WARNING
REMOVAL

130896
Towing and lifting) (02A, Lifting equipment). a Remove the insulation (1) from the bulkhead (see
a Disconnect the battery (see Battery : Removal - ting) (68A, Soundproofing).

the outflow of brake fluid. 2TR

a Drain the cooling system (see Cooling circuit:
Draining - Refilling) (19A, Cooling system).
a Remove:
- the front left-hand wheel (see 35A, Wheels and ty-

(35A, Wheels and tyres),
- the engine cover,
131552
per arm: Removal - Refitting) (85A, Wiping - a Remove:
Washing),
- the clips (2) ,
31A-27
LEFT-HAND DRIVE
130898
a Disconnect the heater matrix hoses.
and the master cylinder (see 31A, Front axle com-
130915
pipe: Removal - Refitting, page 31A-16) (31A, a Undo the brake pipe union (7) on the hydraulic unit.
Front axle components).
a Remove the brake pipe (8) between the hydraulic
unit and the front left-hand brake hose.
CONCERNED
REFITTING

CONCERNED
a Refit:
- the brake pipe between the hydraulic unit and the

front left-hand brake hose,
- the brake pipe union on the hydraulic unit,
- the retaining clip,
- the brake pipe union on the brake hose.
a Torque tighten:
- the brake pipe union on the hydraulic unit (16

N.m),
- the brake pipe union on the brake hose (16

130914 N.m).
a Undo the brake pipe union (5) .
a Remove the retaining clip (6) . II - FINAL OPERATION
a Refit the brake pipe between the hydraulic unit and

pe: Removal - Refitting, page 31A-16) (31A, Front
axle components).
31A-28
LEFT-HAND DRIVE
2TR
a Refit:
- the vacuum hose,
- the clips.
a Refit:

fing),




Washing),
- the engine cover,


a Fill and bleed the cooling system (see Cooling cir-

cuit: Draining - Refilling) (19A, Cooling system).

31A-29
RIGHT-HAND DRIVE
CONCERNED
Essential equipment
pedal press
Tightening torquesm

hydraulic unit

brake hose
WARNING
REMOVAL
130914
I - REMOVAL PREPARATION OPERATION a Undo the brake pipe union (1) .

a Remove the retaining clip (2) .
a Position the vehicle on a two-post lift (see Position
of the attachment points) (02A, Lifting equipment).


a Remove:


Washing),
130916
- the scuttle half-grille (see Scuttle half-grille: Re-
a Undo the brake pipe union (3) on the hydraulic unit.
moval - Refitting) (56A, Exterior equipment),
- the windscreen wiper mechanism (see Winds- unit and the front left-hand brake hose.

31A-30
RIGHT-HAND DRIVE
REFITTING

CONCERNED
a Refit:

front left-hand brake hose,
a Torque tighten:

N.m),

N.m).
a Refit:




Washing),



31A-31
Hydraulic unit - front right-hand calliper brake pipe: Removal - Refitting 31A
LEFT-HAND DRIVE
Essential equipment
pedal press
Tightening torquesm

hydraulic unit

brake hose
WARNING
130896
REMOVAL a Remove the insulation (1) from the bulkhead (see
a Position the vehicle on a two-post lift (see Vehicle: 2TR



a Remove:
- the front right-hand wheel (see 35A, Wheels and

tyres, Wheel: Removal - Refitting, page 35A-1)
- the windscreen wiper arms (see Windscreen wi- 131552

per arm: Removal - Refitting) (85A, Wiping - a Remove:
Washing),
- clips (2) ,
- the scuttle panel half-grille (see Scuttle half-grille: - the vacuum hose (3) .


31A-32
LEFT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART REFITTING
CONCERNED

CONCERNED
a Refit:
front right-hand brake hose,
a Torque tighten:
N.m),
N.m).
130914
2TR
a Refit:
- the vacuum hose,
- the clips.
130920
unit and the front right-hand brake hose.
31A-33
LEFT-HAND DRIVE
a Refit:
fing),
Washing),
- the front right-hand wheel (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1)
31A-34
RIGHT-HAND DRIVE
Essential equipment
refrigerant charging station - the scoop under the scuttle panel grille (see Scoop
pedal press (56A, Exterior equipment).
Tightening torquesm

hydraulic unit

brake hose
pipe union bolt 4 N.m
WARNING
REMOVAL
I - REMOVAL PREPARATION OPERATION 130896

a Position the vehicle on a two-post lift (see Position
of the attachment points) (02A, Lifting equipment).
a Drain the refrigerant circuit using the refrigerant
charging station (see Coolant circuit Draining -
Refilling) 62A, Air conditioning).


a Remove:

- the engine cover,
fitting) (12A, Fuel mixture)

Washing),

31A-35
RIGHT-HAND DRIVE
2TR
130923
a Remove the bolt (5) from the pipe union.
a Disconnect the pipes (6) .
130901
a Remove:
- clips (2) ,
130922
a Disconnect the clutch pipe (4) .
31A-36
RIGHT-HAND DRIVE
CONCERNED
2TR
130924
130919
130925
a Unclip the petrol vapour absorber pipe at (7) .
a Unclip the petrol vapour absorber pipe at (8) .

and the master cylinder (see 31A, Front axle com- 130927
pipe: Removal - Refitting, page 31A-16) .
unit and the front right-hand brake hose.
31A-37
RIGHT-HAND DRIVE
REFITTING a Refit:
I - REFITTING OPERATION FOR PART material: Removal - Refitting) (86A, Soundproo-
CONCERNED fing),
a Refit:
- the brake pipe (12) between the hydraulic unit and (56A, Exterior equipment).
the front right-hand brake hose, - the windscreen wiper mechanism (see Winds-
- the brake pipe union (11) on the hydraulic unit,
- the retaining clip (10) , - the scuttle panel half-grille (see Scuttle half-grille:
- the brake pipe union (9) on the brake hose.
a Torque tighten: per arm: Removal - Refitting) (85A, Wiping -
Washing),
N.m), - the air filter box (see Air filter unit: Removal - Re-
N.m). - the air intake sleeve,
- the engine cover,
II - FINAL OPERATION - the front left-hand wheel (see 35A, Wheels and ty-
a Refit the brake pipe between the hydraulic unit and (35A, Wheels and tyres).
nents, Hydraulic unit - master cylinder brake pi- a Remove the pedal press.
pe: Removal - Refitting, page 31A-16) . a Bleed the brake circuit (see 30A, General informa-
2TR a Connect the battery (see Battery : Removal - Refit-

a Clip:
a Fill the refrigerant circuit using the refrigerant char-
- the petrol vapour absorber pipe at (8) , ging station (see Coolant circuit Draining - Refil-
ling) 62A, Air conditioning).
- the petrol vapour absorber pipe at (7)
a Check the sealing of the cooling system (see Air
conditioning: Check) (62A, Air conditioning).
a Connect the pipes (6) .
a Refit the pipe union bolt (5) .
a Torque tighten the pipe union bolt (4 N.m).
a Connect the clutch pipe (4) .
2TR
a Refit:
- the clips (2) .
31A-38
Front driveshaft hub carrier: Removal - Refitting 31A
Essential special tooling CONCERNED
Rou. 604-01 Hub locking tool. a
Tav. 1420-01 Screw jack for tools Tav. WARNING

1420, Tav.1050-04 , Tar.
1454, Tar. 1850. In order to prevent irreversible damage to the
front hub bearing:
Tav. 1050-04 Universal driveshaft pusher
tool (back-plate and claws, - Do not loosen or tighten the driveshaft nut when
without jack). the wheels are on the ground.
- Do not place the vehicle with its wheels on the
Tav. 476 Ball joint extractor. ground when the driveshaft has been loosened
or removed.
Tightening torquesm
wheel speed sensor bolt 10 N.m
shock absorber lower 142 N.m

nuts
lower arm ball joint nut 63 N.m
track rod ball joint nut 34 N.m
hub nut 125 N.m
REMOVAL

a Remove: 131458
a Remove:
Wheel: Removal - Refitting, page 35A-1) (35A, - the wheel speed sensor bolt (1) ,
Wheels and tyres), - the wheel speed sensor.
page 31A-3) .

page 31A-1) ,

ting, page 31A-5) ,

13) .
31A-39
131459 131460
a Remove: a Extract the track rod end using the (Tav. 476) (7) .
- the driveshaft cotter pin (2) , a Remove:
- the nut (3) from the hub using the (Rou. 604-01), - the lower arm ball joint,
- the track rod ball joint nut (4) , - the front driveshaft hub carrier.
- the lower arm ball joint nut (5) ,
- the shock absorber lower nuts (6) . REFITTING
a Remove the driveshaft from the hub carrier using the
(Tav. 1420-01) and (Tav. 1050-04), if necessary. I - REFITTING PREPARATION OPERATION
a Refit:
- the driveshaft on the hub carrier,
- the lower arm ball joint on the hub carrier,
- the track rod on the hub carrier,
- the shock absorber lower bolts and nuts,
- the lower arm ball joint nut,
- the track rod ball joint nut,
- the hub nut,
- the driveshaft cotter pin,
- the wheel speed sensor,
- the wheel speed sensor bolt.
a Torque tighten:
- the wheel speed sensor bolt (10 N.m),
- the shock absorber lower nuts (142 N.m),
- the lower arm ball joint nut (63 N.m),
- the track rod ball joint nut (34 N.m),
- the hub nut (125 N.m), using the (Rou. 604-01).
31A-40
a Refit:
13) ,
ting, page 31A-5) ,
page 31A-1) ,
page 31A-3) .
Wheels and tyres).
a Check the front axle geometry (see 30A, General
information, Front axle: Adjusting, page 30A-10)
(30A, General information).
31A-41
Hub carrier-driveshaft assembly: Removal - Refitting 31A
Tav. 476 Ball joint extractor.
Tightening torquesm
driveshaft bearing brac- 30 N.m

ket bolts [2TR]
driveshaft bearing brac- 25 N.m

ket bolts [M9R]

nuts
wheel speed sensor bolt 10 N.m

132612
guide pin bolts 29 N.m a Remove the guide pin bolt (1) while holding the nut
(2) .
REMOVING - REFITTING a Suspend the brake calliper from the suspension
spring.
a Position the vehicle on a two-post lift (see Vehicle: - the front brake calliper mounting (see 31A, Front
Towing and lifting) (02A, Lifting equipment). axle components, Front brake calliper support:
Refitting) (80A, Battery). - the brake disc (see 31A, Front axle components,
a Drain the gearbox (see Manual gearbox oil: Drai-
13) .
ning - Refilling) (21A, Manual gearbox).
a Repeat the operation on the opposite side.
a Remove:
Wheel: Removal - Refitting, page 35A-1) ,
- the front brake pads (see 31A, Front axle compo-
page 31A-1) .
31A-42
II - OPERATION FOR REMOVAL OF PART a Remove:
CONCERNED
- the lower arm ball joint,
- the hub carrier with its driveshaft.
1 - Left-hand side of the vehicle
2 - Right-hand side of the vehicle
132613
a Remove:
132615
- the wheel speed sensor bolt (3) , a Remove:
- the wheel speed sensor, - the wheel speed sensor bolt (7) ,
- the track rod ball joint nut (4) , - the wheel speed sensor,
- the lower arm ball joint nut (5) , - the track rod ball joint nut (8) ,
- the shock absorber lower nuts (6) . - the lower arm ball joint nut (9) ,
- the shock absorber lower nuts (10) .
132614
a Extract the track rod end using the (Tav. 476).
31A-43
M9R
132616

132618
a Remove the lower arm ball joint.
a Remove the driveshaft bearing bracket bolts (12) .
2TR
a Remove the hub carrier with its driveshaft.
REFITTING
a Clean and lubricate the driveshaft bearing bore into

which the bearing is inserted.
a Replace the O-ring at the bottom of the driveshaft

bearing if it is worn.
a Always replace:
- the differential output lip seals,
- the driveshaft bearing ring on the left-hand side if

fitted to the vehicle,
132617 - the guide pin bolts.
a Remove:
- the driveshaft bearing bracket bolts (11) , CONCERNED
- the driveshaft bearing bracket.
1 - Right-hand side of the vehicle
a Refit the hub carrier with its driveshaft.
31A-44
2TR
a Refit the driveshaft bearing bracket.
a Refit:
- the driveshaft bearing bracket bolts,
- the shock absorber lower nuts,

132619
- the track rod ball joint nut,
a
- the wheel speed sensor,
Note:
- the wheel speed sensor bolt. Check that the ring is correctly positioned on the
lower arm ball joint.
2TR
a Torque tighten the driveshaft bearing bracket
bolts [2TR] (30 N.m).
M9R
a Torque tighten the driveshaft bearing bracket
bolts [M9R] (25 N.m).
132619
a
a Torque tighten:
Note:
Check that the ring is correctly positioned on the
- the lower arm ball joint nut (63 N.m),
lower arm ball joint.
- the wheel speed sensor bolt (10 N.m).
2 - Left-hand side of the vehicle
a Refit: III - FINAL OPERATION
- the hub carrier with its driveshaft, a Refit:

- the callipers to their supports,
- the shock absorber lower nuts,
- the guide pin bolts.
a Torque tighten the guide pin bolts (29 N.m).
- the track rod ball joint nut, a Refit:
- the wheel speed sensor, - the brake disc (see 31A, Front axle components,
- the wheel speed sensor bolt. 13) ,
31A-45
- the front brake pads (see 31A, Front axle compo-
page 31A-1) ,
a Fill up the gearbox oil and check the level (see Ma-
nual gearbox oil: Draining - Refilling) (21A, Ma-
nual gearbox).
.
31A-46
Front hub carrier bearing: Removal - Refitting 31A
CONCERNED
Tightening torquesm
bolt of the front hub car- 88 N.m

rier bearing
WARNING
In order to prevent irreversible damage to the front

hub bearing:
- Do not loosen or tighten the driveshaft nut when
the wheels are on the ground.
- Do not place the vehicle with its wheels on the
ground when the driveshaft has been loosened or
removed.
REMOVAL

a Remove:

Wheels and tyres),

page 31A-3) .
- the front wheel speed sensor (see 38C, Anti-lock

braking system, Front wheel speed sensor: Re-
moval - Refitting, page 38C-8) (38C, Anti-lock
braking system),

page 31A-1) ,
- the front brake calliper (see 31A, Front axle com- 131462
ponents, Front brake calliper: Removal - Refit- a Remove:
ting, page 31A-5) ,
- the bolts (1) of the front hub carrier bearing,
- the hub carrier bearing (2) ,
Removal - Refitting, page 31A-9) , - the front brake disc guard (3) .
13) ,

31A-47
Front hub carrier bearing: Removal - Refitting 31A
REFITTING - the front brake calliper (see 31A, Front axle com-
ting, page 31A-5) ,
a Clean: nents, Front brake pads: Removal - Refitting,
page 31A-1) ,
- the inner and outer surfaces of the new bearing in
contact with the stub-axle carrier and the hub, - the front wheel speed sensor (see 38C, Anti-lock
braking system, Front wheel speed sensor: Re-
- the stub axle carrier surfaces in contact with the
new bearing,
braking system),
- the hub surfaces in contact with the new bearing.
WARNING page 31A-3) .
To ensure that the wheel speed sensor works - the front wheel (see 35A, Wheels and tyres,
properly, do not mark the sensor target on the Wheel: Removal - Refitting, page 35A-1) (35A,
bearing. Wheels and tyres).
WARNING
Do not press the bearing's internal bush so as to
avoid damaging the bearing (very high shrink-fit-
ting force).
Note:
It is essential to check the condition of the hub
surface and the hub carrier bore before refitting
the bearing. Replace the hub carrier if it is faulty.

CONCERNED
a Refit:
- the front brake disc guard,
- the hub carrier bearing,
- the bolts of the front hub carrier bearing.
a Torque tighten the bolt of the front hub carrier
bearing (88 N.m).

a Refit:
13) ,
31A-48
Spring and front shock absorber: Removal - Refitting 31A
CONCERNED
Essential equipment
spring compressor
spanner for shock absorber rod nut
Tightening torquesm
shock absorber rod nut 79 N.m
upper shock absorber 19 N.m

bolts

nuts
new nut on the anti-roll 84 N.m

bar tie rod
IMPORTANT
Consult the safety and cleanliness advice and ope- 131238
ration recommendations before carrying out any a Remove the clip (1) from the brake hose.
repair (see Front axle assemblies: Precautions
a Unclip the brake hose.
for repair) .
a Disconnect the connector (2) from the front wheel
speed sensor.
REMOVAL
a Unclip the wiring from the front wheel speed sensor
at (3) .
a Unlock the steering column.
a Remove the front wheels (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) .
31A-49
M9R
131239
a Remove the upper nut (4) from the anti-roll bar tie
rod. 131240
a Separate the anti-roll bar tie rod (5) from the shock a Unclip the clips (7) .
absorber.
a Move aside the manual priming pump (8) in order to
a Remove the lower bolts and nuts (6) from the shock access the upper shock absorber bolts (see Manual
absorber. priming pump: Removal - Refitting) (13A, Fuel
a Suspend the hub carrier. supply).
131241
a Remove cap (9) .
31A-50
132872 132874
a Remove: a Remove the shock absorber rod nut using the span-
ner for shock absorber rod nut (13) .
- the upper shock absorber bolts (10) ,
a Separate the components which make up the
- the spring-shock absorber assembly.
"spring-shock absorber" unit.
a Decompress the spring.
REFITTING

a
WARNING
To prevent any suspension asymmetry, replace
both of the shock absorbers on the same axle.
a Always replace:
- the shock absorber rod nut,
- the anti-roll bar tie-rod nut.
132873
a Position the spring on the spring compressor (11) .
a Compress the spring (12) until it is released.
31A-51
CONCERNED
132876
a Respect the order and direction of fitting for the
132875
constituent parts.
a Insert the spring in the neck of the cup.
a Refit the shock absorber rod nut using the spanner
a Align the lower end (14) of the spring on the cup of for shock absorber rod nut.
the tool (15) .
a Torque tighten the shock absorber rod nut (79
a Compress the spring. N.m).
a Decompress the spring.
a Remove the spring compressor.
a Refit:
- the "spring - shock absorber" assembly,
- the upper shock absorber bolts,
- the cap.
a Torque tighten the upper shock absorber bolts (19
N.m).
M9R
a Position the manual priming pump.
a Attach the clips.
a Refit:
- the lower shock absorber bolts and nuts,
- the new nut on the anti-roll bar tie rod.
a Torque tighten:
- the new nut on the anti-roll bar tie rod (84 N.m).
31A-52
a Connect the front wheel speed sensor connector.
a Refit:
- the wiring of the front wheel speed sensor,
- the brake hose,
- the clip.

a Refit the front wheels (see 35A, Wheels and tyres,
a Adjust the axle assemblies (see 30A, General infor-
mation, Front axle: Adjusting, page 30A-10) .
31A-53
Front driveshaft lower arm: Removal - Refitting 31A
CONCERNED
Essential equipment
component jack
Tightening torquesm
lower arm bolts 171 N.m
lower arm nut 142 N.m
anti-roll bar tie-rod lower 84 N.m

nut
WARNING
To prevent any damage, do not use the lower arm
as support for the lifting system.
131464
REMOVAL
a Remove the nut (3) from the lower arm ball joint.

131465
a Place the component jack under the subframe.
131463
a Remove the lower nut (1) from the anti-roll bar tie
rod.
a Position the anti-roll bar behind the vehicle.
31A-54
Front driveshaft lower arm: Removal - Refitting 31A
a Torque tighten:
- the lower arm bolts (171 N.m),
- the lower arm nut (142 N.m),
- the lower arm ball joint nut (63 N.m).

a Place the anti-roll bar in its original position.
a Refit the anti-roll bar tie rod lower nut.
a Torque tighten the anti-roll bar tie-rod lower nut
(84 N.m).
Wheels and tyres).
(30A, General information).
131466
a Remove:
- the bolts (4) from the lower arm,
- the nut (5) from the lower arm,
- the lower arm.
REFITTING

a Always replace the lower arm bolts.
a Leave the component jack under the subframe.
a Position the lower arm ball joint bolt head so that it
faces the front of the vehicle.

a Refit:
- the lower arm,
- the lower arm nut,
- the lower arm bolts,
- the lower arm ball joint in its housing,
- the lower arm ball joint nut.
a Remove the component jack.
Note:
When torque tightening the lower arm bolt and
nut, make sure that the wheel is placed on the
ground and that the vehicle is unladen.
31A-55
Front driveshaft lower arm ball joint: Check 31A
CHECKING 2 - Check the fitting of the lower arm ball joint
I - CHECKING PREPARATION OPERATION

a Remove:

- the lower arm ball joint (see 31A, Front axle com-
ponents, Front driveshaft lower arm: Removal -
Refitting, page 31A-54) .
II - CHECKING THE PART CONCERNED
1 - Checking the condition of the front driveshaft

lower arm ball joint gaiter
132627
a Manually check that the ball joint stud moves easily

and does not get jammed.
If the ball joint stud does not move easily, replace
the front driveshaft lower arm (see 31A, Front axle
components, Front driveshaft lower arm: Remo-
val - Refitting, page 31A-54) .
132626
a Check:
- the gaiter crimping on the front driveshaft lower

arm ball joint,
- that the gaiter of the lower arm ball joint gaiter of

the front driveshaft is not torn.
- that the grease starts to flow.
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-
31A-56
Front driveshaft lower arm ball joint: Check 31A
3 - Checking the longitudinal play of the lower arm
ball joint
132628
a Check the longitudinal play by pulling on the stud
manually.
If the longitudinal play values (axle side) at the ball
joint stud are incorrect, replace the front driveshaft
lower arm (see 3 1 A, Front axle components,
Front driveshaft lower arm: Removal - Refitting,
page 31A-54) .
The longitudinal play value of the lower arm ball joint
is 0 mm.

a Refit:
- the lower arm ball joint (see 31A, Front axle com-
ponents, Front driveshaft lower arm: Removal -
Refitting, page 31A-54) ,
.
31A-57
Front axle sub-frame: Removal - Refitting 31A
M9R
Essential equipment
component jack
Tightening torquesm
subframe bolts 94 N.m
acoustic tie-rod bolts 73 N.m
exhaust pipe rubber 14 N.m

mounting bush nuts
lower engine tie-bar bolt 155 N.m

on the engine
track rod ball joint nut 34 N.m 132629
lower nut of the anti-roll N.m a Remove the steering cover (1) .
bar tie rod84
universal joint bolt on 39 N.m

the steering box
REMOVING - REFITTING

a Remove:
- the wheel arch liners (see Front wheel arch liner:
Removal - Refitting) (55A, Exterior protection),
- the engine undertray.
132630
a Remove the cover (2) from the universal joint (do not
keep).
a Lock the steering column.
31A-58
M9R
132631 132632
a Remove: a Remove:
- the universal joint bolt (3) (do not keep), - the track rod ball joint nut (4) ,
- the universal joint nut, - the lower nut (5) from the anti-roll bar tie rod.
- the universal joint.
Note:
Swivel the universal joint to detach it from the
pinion; do not retract the intermediate shaft.
132633
a Remove the lower arm ball joint nut (6) .
31A-59
M9R
132634 132641
a Extract the track rod end using the (Tav. 476). a Unclip the wiring clips (9) .
132642
a Disconnect:
- the hose from the particle filter,
132640 - the particle filter upstream temperature sensor con-
nector (11) .
a Remove:
a Remove the rubber mounting bush nuts (12) from
- the bolt (7) from the lower engine tie-bar on the en-
the exhaust pipe.
gine,
a Unclip the clip (13) from the wiring.
- the bolt (8) from the turbocharger cooling pump.
31A-60
M9R
132645
a Remove:
- the acoustic tie-rod bolts (16) ,

- the acoustic tie-rod,
132643
- the subframe bolts (17) ,
a Unclip the clips (14) from the particle filter upstream
temperature sensor wiring. - the subframe, slowly.
132644 132646
a Unclip the hose clip (15) from the radiator hose. a Remove the subframe mountings.
a Place the component jack under the subframe.
a Extract the lower arm ball joints. REFITTING
a Always replace:
- the anti-roll bar tie rod lower nuts,

- the bolt from the universal joint.
31A-61
M9R
II - REFITTING OPERATION FOR PART a Torque tighten the lower arm ball joint nut (63
CONCERNED N.m).
a Refit the subframe mountings. a Refit:
a Degrease the surfaces of the body which are in con- - the anti-roll bar linkage lower nut,
tact with the subframe and the cross member using - the track rod ball joint nut.
surface cleaner.
a Torque tighten:
a Position the subframe using the component jack.
a Refit:
- the lower nut of the anti-roll bar tie rod84 (N.m).
- the subframe bolts,
- the acoustic tie-rod bolts.
Note:
Make sure that the tightening order of the sub-
frame bolts is respected (rear left-hand - rear
right-hand - front left-hand - front right-hand).
a Torque tighten:
- the subframe bolts (94 N.m),
- the acoustic tie-rod bolts (73 N.m).
a Refit the lower arm ball joint.
132638
a Remove the component jack. a Observe the direction of fitting for the universal joint
a Clip: cam nut and bolt.
- the hose clip on the radiator hose, a Refit:
- the clips of the particle filter upstream temperature - the universal joint,
sensor wiring, - the new universal joint bolt,
- the wiring clip. - the cam nut from the universal joint.
a Refit the rubber mounting bush nuts on the exhaust
pipe.
a Torque tighten the exhaust pipe rubber mounting
bush nuts (14 N.m).
a Connect:
- the particle filter upstream temperature sensor con-
nector,
- the particle filter hose.
a Clip on the wiring clips.
a Refit:
- the turbocharger cooling pump bolts,
- the lower engine tie-bar bolt on the engine.
a Torque tighten the lower engine tie-bar bolt on the
engine (155 N.m).
a Refit the lower arm ball joint nut.
31A-62
M9R
132639
a Check that the universal joint is in the correct posi-
tion.
a Torque tighten the universal joint bolt on the stee-
ring box (39 N.m).
a Refit the steering cover.

a Refit:
- the engine undertray,
.
31A-63
2TR
Essential equipment
component jack
Tightening torquesm
subframe bolts 94 N.m
acoustic tie-rod bolts 73 N.m
nuts of the exhaust pipe rubber moun-

ting bush14
N.m
lower engine tie-bar 110 N.m

retaining bracket bolt
lower engine tie-bar 110 N.m

bolts on the gearbox 132629
lower arm ball joint nut 63 N.m a Remove the steering cover (1) .
lower nut of the anti-roll N.m

bar tie rod84

the steering box

a Remove:
132630
- the engine undertray. keep).
a Lock the steering column.
31A-64
2TR
132631 132632
a Remove: a Remove:
- the universal joint bolt (3) (do not keep), - the track rod ball joint nut (4) ,
- the universal joint nut, - the lower nut (5) from the anti-roll bar tie rod.
Note:
Swivel the universal joint to detach it from the
pinion; do not retract the intermediate shaft.
132633
a Remove the lower arm ball joint nut (6) .
31A-65
2TR
132636
a Remove:
- the acoustic tie-rod bolts (10) ,

132634
- the subframe bolts (11) ,
- the subframe, slowly.
132635
132637
a Remove:
a Remove the subframe mountings.
- the bolt (7) from the lower engine tie-bar on the en-
gine,
- the lower engine tie-bar retaining bracket bolt (8) , REFITTING
- the lower engine tie-bar retaining bracket,
- the nuts (9) from the exhaust pipe rubber mounting
bush. a Always replace:
a Place the component jack under the subframe. - the anti-roll bar tie rod lower nuts,
a Extract the lower arm ball joints. - the bolt from the universal joint.
31A-66
2TR
II - REFITTING OPERATION FOR PART - the lower nut of the anti-roll bar tie rod84 (N.m).
CONCERNED
a Refit the subframe mountings.
a Degrease the surfaces of the body which are in con-
tact with the subframe and the cross member using
surface cleaner.
a Position the subframe using the component jack.
a Refit:
- the subframe bolts,
- the acoustic tie-rod bolts.
Note:
Make sure that the tightening order of the sub- 132638
frame bolts is respected (rear left-hand - rear
right-hand - front left-hand - front right-hand). a Observe the direction of fitting for the universal joint
cam nut and bolt.
a Torque tighten:
a Refit:
- the subframe bolts (94 N.m),
- the universal joint,
- the acoustic tie-rod bolts (73 N.m).
a Refit the lower arm ball joint. - the new universal joint bolt,
a Remove the component jack. - the cam nut from the universal joint.
a Refit:
- the nuts on the exhaust pipe rubber mounting
bush,
- the lower engine tie-bar retaining bracket,
- the lower engine tie-bar retaining bracket bolts,
- the lower engine tie-bar bolt on the gearbox.
a Torque tighten:
- the nuts of the exhaust pipe (rubber mounting
bush14 N.m),
- the lower engine tie-bar retaining bracket bolt
(110 N.m),
- the lower engine tie-bar bolts on the gearbox
(110 N.m).
a Refit the lower arm ball joint nut.
a Torque tighten the lower arm ball joint nut (63
N.m).
132639
a Refit:
- the anti-roll bar linkage lower nut, tion.
- the track rod ball joint nut. a Torque tighten the universal joint bolt on the stee-
a Torque tighten: ring box (39 N.m).
- the track rod ball joint nut (34 N.m), a Refit the steering cover.
31A-67
2TR
a Refit:
.
31A-68
Front anti-roll bar: Removal - Refitting 31A
M9R
REFITTING
Tightening torquesm
anti-roll bar bolts 24 N.m CONCERNED
a Refit:
REMOVAL - the anti-roll bar,

- the anti-roll bar bearings,
I - REMOVAL PREPARATION OPERATION - the anti-roll bar bolts,
a Position the vehicle on a two-post lift (see Vehicle: - the particle filter pressure sensor support.
Towing and lifting) (02A, Lifting equipment). a Torque tighten the anti-roll bar bolts (24 N.m).
a Remove:
Wheel: Removal - Refitting, page 35A-1) (35A, a Refit:
Wheels and tyres), - the front axle sub-frame (see 31A, Front axle
components, Front axle sub-frame: Removal -
- the engine undertray, Refitting, page 31A-58) ,
- the front axle subframe (see 31A, Front axle com- - the engine undertray,
ponents, Front axle sub-frame: Removal - Refit-
ting, page 31A-58) .
Wheels and tyres).
II - REMOVAL OF PART CONCERNED
131468
a Remove:
- the particle filter pressure sensor support (1) ,
- the anti-roll bar bolts (2) ,
- the anti-roll bar bearings (3) ,
- the anti-roll bar (4) .
31A-69
Front anti-roll bar: Removal - Refitting 31A
2TR
REFITTING
Tightening torquesm
anti-roll bar bolts 24 N.m CONCERNED
a Refit:
REMOVAL - the anti-roll bar,

- the anti-roll bar bearings,
I - REMOVAL PREPARATION OPERATION - the anti-roll bar bolts.

a Torque tighten the anti-roll bar bolts (24 N.m).
a Remove: a Refit:
- the front wheel (see 35A, Wheels and tyres, - the front axle sub-frame (see 31A, Front axle
Wheel: Removal - Refitting, page 35A-1) (35A, components, Front axle sub-frame: Removal -
Wheels and tyres), Refitting, page 31A-58) ,
- the front axle subframe (see 31A, Front axle com- Wheel: Removal - Refitting, page 35A-1) (35A,
ponents, Front axle sub-frame: Removal - Refit- Wheels and tyres).
131467
a Remove:
- the anti-roll bar bolts (1) ,
- the anti-roll bar bearings (2) ,
- the anti-roll bar (3) .
31A-70
REAR AXLE COMPONENTS
Rear brake pads: Removal - Refitting 33A

tool.
Tightening torquesm
calliper guide pin bolt 43 N.m
REMOVAL

a Remove the rear wheels (see 35A, Wheels and ty-
130928
a Remove the lower guide pin bolt (1) of the brake cal-
CONCERNED
liper.
a
WARNING

ding components.
Note:
When replacing brake pads, it is essential to
replace the pads on the opposite side.
130929
a Rotate the rear brake calliper upwards.

a Suspend the rear brake calliper.
a Remove the brake pads (2) from the brake calliper
mountings.
REFITTING

a Always replace the guide pin bolts.
33A-1
Rear brake pads: Removal - Refitting 33A
a Check the thickness of the brake pads (see 30A,
General information, Brake: Specifications, page
30A-6) .
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,
- the guide pin bolts.
130931
a The guide pin bolt rubber boots (3) must be correctly
positioned.
a Torque tighten the calliper guide pin bolt (43 N.m).

a Refit the rear wheels (see 35A, Wheels and tyres,
130930
IMPORTANT
a Push the calliper piston back using the tool (Fre.
1190-01) until it is at the end of its bore.
CONCERNED
a Refit the rear brake pads.
a Rotate the rear brake calliper downwards.
a Refit the new lower guide pin bolt.
33A-2
Rear brake hose: Removal - Refitting 33A
CONCERNED
Essential equipment
pedal press
Tightening torquesm

per
IMPORTANT
Consult the safety and cleanliness advice and ope-
ration recommendations before carrying out any
repair (see Rear axle assemblies: Precautions
for repair) .
WARNING
130808
a Undo the rear brake hose at the rear brake calliper
union (1) .
a Disconnect the rear brake hose from the rear brake
REMOVAL calliper.

130809
a Undo the rear brake hose at the pipe connection (2) .
a Remove:
- the brake hose clip (3) ,
- the brake hose (4) .
REFITTING

a Always replace the brake hose copper washers on
the calliper.
33A-3
Rear brake hose: Removal - Refitting 33A
a III - FINAL OPERATION.
WARNING a Remove the pedal press from the brake pedal.

In order to not damage the brake hose: tion, Brake circuit Bleeding, page 30A-3) .
- do not tension the hose, a Refit the rear wheels (see 35A, Wheels and tyres,
- do not twist the hose, Wheel: Removal - Refitting, page 35A-1) .
- check that there is no contact with the surroun- a Check the brake fluid level.
ding components.

CONCERNED
a Refit:
- the rear brake hose (4) ,
- the rear brake hose on the union (2) ,
- the brake hose clip (3) on the union,
a Torque tighten the brake hose on the union (16

N.m).
130810
Note:
Put the brake hose retaining pin (5) in the calliper
hole.
a Refit the brake hose on the calliper with the new

copper washers.
a Torque tighten the brake hose on the calliper (18

N.m).
33A-4
Rear brake caliper: Removal - Refitting 33A
tool.
Essential equipment
pedal press
Tightening torquesm
bolts on the brake calli- 43 N.m

per guide pins
brake hose union on the 18 N.m

calliper
REMOVAL

a Position the vehicle on a two-post lift (see Vehicle: 130808
a Undo the brake hose on the calliper at (1) .
res, Wheel: Removal - Refitting, page 35A-1) . a Disconnect the rear brake hose (2) from the rear
brake calliper.
WARNING

130812
a Remove:
- the rear brake calliper guide pin bolts (3) ,
- the rear brake calliper from the mounting,
- the rear brake pads.
33A-5
Rear brake caliper: Removal - Refitting 33A
REFITTING
a Always replace:
- the calliper guide pin bolts,
- the copper washers on the brake hose on the calli-

per.

rwork) (04B, Consumables - Products):
- the calliper supports,
- the callipers.
130931
a Ensure that the guide pin bolt rubber boots (4) are
correctly positioned.
- the bolts on the brake calliper guide pins (43
N.m),
- the brake hose union on the calliper (18 N.m).

a Check the brake fluid level.
130930
a Push the piston to the bottom of its housing using IMPORTANT

the (Fre. 1190-01). To avoid any accident, bring the pistons, brake
CONCERNED
a Refit:
- the rear brake pads,
- the rear brake calliper,
- the new guide pin bolts,
- the brake hose to the calliper, with new copper

washers.
33A-6
Rear brake calliper mounting: Removal - Refitting 33A
REFITTING
Tightening torquesm
brake calliper mounting 84 N.m
a Always replace the brake calliper guide pin bolts.
bolts
REMOVAL rwork) (04B, Consumables - Products):
- the calliper brackets,
I - REMOVAL PREPARATION OPERATION - the callipers.
Towing and lifting) (02A, Lifting equipment). II - REFITTING OPERATION FOR PART
CONCERNED
a Remove:
a Refit:
- the rear wheels (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) , - the calliper mounting,
- the rear brake calliper without disconnecting the - the calliper mounting bolts.
brake hose (see 33A, Rear axle components, a Torque tighten the brake calliper mounting bolts
Rear brake caliper: Removal - Refitting, page (84 N.m).
33A-5) .
a Suspend the rear brake calliper. III - FINAL OPERATION.

a Remove the rear brake pads (see 33A, Rear axle a Refit:
components, Rear brake pads: Removal - Refit-
- the rear brake pads (see 33A, Rear axle compo-
ting, page 33A-1) .
nents, Rear brake pads: Removal - Refitting,
page 33A-1) .
II - OPERATION FOR REMOVAL OF PART - the rear brake calliper (see 33A, Rear axle com-
CONCERNED ponents, Rear brake caliper: Removal - Refit-
ting, page 33A-5) ,
a
IMPORTANT
130815
a Remove:
- the rear brake calliper mounting bolts (1) ,

- the rear brake calliper mounting.
33A-7
Rear brake disc shield: Removal - Refitting 33A
4X2 TRANSMISSION
CONCERNED
Tightening torquesm
rear wheel hub bolts 88 N.m
rear wheel speed sen- 10 N.m

sor bolt
parking brake cable bolt 13 N.m
REMOVAL

a Remove:
- the rear brake calliper without disconnecting it from
the brake hose (see 33A, Rear axle components, 130816
Rear brake pads: Removal - Refitting, page 33A-
a Unhook the parking brake cable (1) from the parking
1) .
brake lever (2) .
a Remove the bolt (3) of the parking brake cable from
a Remove: the rear brake disc shield.
page 33A-1) ,
- the rear brake calliper mounting (see 33A, Rear
axle components, Rear brake calliper moun-
ting: Removal - Refitting, page 33A-7) ,
- the rear brake disc (see 33A, Rear axle compo-
nents, Rear brake disc: Removal - Refitting,
page 33A-13) ,
- the rear brake lining (see 33A, Rear axle compo-
nents, Rear brake lining: Removal - Refitting,
page 33A-15)
130817
a Remove:
- the rear wheel speed sensor bolt (4) ,
- the rear wheel speed sensor of the rear wheel hub,
- the rear wheel hub bolts (5) ,
- the rear wheel hub,
33A-8
4X2 TRANSMISSION
- the rear brake disc shield. II - FINAL OPERATION.
a Refit:
REFITTING
page 33A-15) ,
CONCERNED
page 33A-13) ,


page 33A-1) ,
- the rear brake calliper (see 33A, Rear axle com-

ponents, Rear brake pads: Removal - Refitting,
page 33A-1) ,

130818
IMPORTANT
a Refit:
- the rear brake lining connecting rods (6) on the rear pads and brake discs into contact by depressing
brake disc shield, the brake pad several times.
- the rear brake disc shield (7) ,
- the rear wheel hub, FOOT BRAKE MANUAL CONTROL
- the rear wheel hub bolts, a Adjust the parking brake cables (see 37A, Mechani-
cal component controls, Parking brake lever:
- the rear wheel speed sensor on the rear wheel hub, Adjusting, page 37A-38) .
- the rear wheel speed sensor bolt.
a Torque tighten:
- the rear wheel hub bolts (88 N.m),

FOOT BRAKE AUTO CONTROL
- the rear wheel speed sensor bolt (10 N.m).
a With the ignition on, push the handle to release the
a Refit:
assisted parking brake. Then pull the handle, so that
- the parking brake cable to the parking brake lever, automatic parking brake locking function is signalled
by a sound and the play compensation is set auto-
- the parking brake cable bolt on to the rear brake
disc shield, matically.
a Torque tighten the parking brake cable bolt (13

N.m) on the rear brake disc shield.
33A-9
4X4 TRANSMISSION
Rou. 604-01 Hub locking tool.
Tightening torquesm

sor bolt
REMOVAL

130816
a Remove:
- the rear wheel (see 35A, Wheels and tyres, a Unhook the parking brake cable (1) from the parking
Wheel: Removal - Refitting, page 35A-1) , brake lever (2) .
- the rear brake calliper without disconnecting the a Remove the parking brake cable bolt (3) from the
brake hose (see 33A, Rear axle components, rear brake disc shield.
1) .
a Remove:
page 33A-1) ,
page 33A-13) ,
page 33A-15)
130819
a Remove:
- the rear wheel speed sensor bolt (4) ,
- the rear wheel speed sensor of the rear wheel hub.
33A-10
4X4 TRANSMISSION
REFITTING

a Always replace the cotter pin.

CONCERNED
130828
a Position the tool (Rou. 604-01) on the rear wheel

hub.
a Remove:
- the cotter pin (5) ,
- the rear wheel hub nut (6) .
Note:
To avoid damaging the « rear brake lining - brake
disc shield » assembly, carefully remove the rear
wheel hub.
130818
a Refit:
- the rear brake lining connecting rods (8) on to the
rear brake disc shield (9) ,
- the rear brake disc shield,
- the rear wheel hub,

- the rear wheel hub bolts,
- the rear wheel speed sensor on the rear wheel hub,

a Torque tighten:

a Refit the rear wheel hub nut using the tool (Rou.
604-01).
130829 a Torque tighten the parking brake cable bolt (13
a Remove: N.m) on the rear brake disc shield.
- the rear wheel hub bolts (7) , a Refit the new cotter pin.
- the rear wheel hub, a Refit:
- the rear brake disc protector. - the parking brake cable to the parking brake lever,
33A-11
4X4 TRANSMISSION
- the parking brake cable bolt on to the rear brake
disc shield,
a Torque tighten the parking brake cable bolt (13

N.m) on the rear brake disc shield.
a Refit:
page 33A-15) ,
- the brake disc (see 33A, Rear axle components,

Rear brake disc: Removal - Refitting, page 33A-
13) ,


page 33A-1) ,

the brake hose (see 33A, Rear axle components,
1) ,
- the rear wheel (see 35A, Wheels and tyres,

IMPORTANT
FOOT BRAKE MANUAL CONTROL
a Adjust the parking brake cables (see 37A, Mechani-

Adjusting, page 37A-38) .

assisted parking brake. Then pull the handle, so that
automatic parking brake locking function is signalled
by a sound and the play compensation is set auto-
matically.
33A-12
Rear brake disc: Removal - Refitting 33A
REMOVAL REFITTING

a
Towing and lifting) (02A, Lifting equipment). Note:
Brake discs cannot be reground.
a Remove:
If there is excessive wear or scoring, the brake
- the rear wheels (see 35A, Wheels and tyres, discs must be replaced.
Wheel: Removal - Refitting, page 35A-1) , When replacing a brake disc, it is essential to
replace the following:
- the rear brake disc on the opposite side,
Rear brake caliper: Removal - Refitting, page - the brake pads.
33A-5) .
a Use a cleaning fountain to clean the discs.
a Suspend the rear brake calliper. a Dry the disc surfaces.
a Remove: a Clean using a wire brush and BRAKE CLEANER

- the rear brake pads (see 33A, Rear axle compo- rwork) (04B, Consumables - Products):
nents, Rear brake pads: Removal - Refitting, - the calliper supports,
page 33A-1) ,
- the callipers,
- the rear brake calliper mounting (see 33A, Rear - the guide pin bolts.
ting: Removal - Refitting, page 33A-7) .
CONCERNED
II - OPERATION FOR REMOVAL OF PART a Refit the rear brake disc.
CONCERNED
a Refit:
- the brake pads (see 33A, Rear axle components,
1) ,
Rear brake caliper: Removal - Refitting, page
33A-5) ,
a
IMPORTANT
130932
a Remove the rear brake disc (1) . the brake pad several times.
33A-13
Rear brake disc: Description 33A
I - PREPARATION OPERATION FOR CHECK
Position the vehicle on a two-post lift (see Vehicle:
Remove the rear wheel concerned (see 35A, Wheels
and tyres, Wheel: Removal - Refitting, page 35A-1) .
II - CHECKING OPERATION FOR PART

CONCERNED
Note:
Use a Palmer type tool to check the thickness of the
disc.
99582
Measure the thickness of the disc at 4 points in order
(90˚ apart).
Compare the values with those recommended by the
manufacturer (see 30A, General information, Brake:
Specifications, page 30A-6) .

Replace the discs if necessary (see 33A, Rear axle
components, Rear brake disc: Removal - Refitting,
page 33A-13) .
Refit the rear wheel concerned (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) .
117058
Position the Palmer tool (1) to measure the disc thic-
kness.
33A-14
Rear brake lining: Removal - Refitting 33A
CONCERNED
Essential equipment
diagnostic tool
Note:
After replacing the rear brake linings, it is ABSO-
LUTELY ESSENTIAL to run in the linings. Per-
form this running in operation by driving the
vehicle. Refer to the end of this procedure for a
more detailed explanation.
REMOVAL
131469
a Position the vehicle on a two-post lift (see Vehicle: - the side retainers (1) by rotating the connecting
Towing and lifting) (02A, Lifting equipment). rods (2) while pressing against the rear brake disc
shield on both sides,
a Release the parking brake.
- the lower return spring (3) ,
a Remove:
- the lower return spring adjuster (4) .
Wheels and tyres),
33A-5) .
a Remove:
page 33A-1) ,
axle components, Rear brake calliper moun- 131470
a Remove:
nents, Rear brake disc: Removal - Refitting, - the upper return springs, (5)
page 33A-13) .
- the upper return spring bracket (6) ,
- the brake linings (7) .
REFITTING
a Clean the parking brake linings and the rear brake

disc.
a Lightly lubricate the lower return spring adjuster (4) .
33A-15
131471 131472
a Check the thickness (A) of the rear brake lining:
a Check the diameter (B) of the rear brake drum:
- thickness of the disc lining: 3.25 mm,
- drum diameter: 172 mm,
- minimum thickness of the disc lining:1.5 mm.
- maximum diameter of drum wear: 173 mm.
Note:
The parking brake linings for the front side are
made out of different materials from those at the
rear. Do not mix them up when removing and
refitting.
131473
(C) For the right-hand side brake

(D) For the left-hand side brake
(1) Front of the vehicle
(2) Expanding the adjuster
33A-16
a Assemble the adjuster so that the threaded part is
expanded when rotating the adjuster in the direction
shown by the arrow. FOOT BRAKE MANUAL CONTROL

II - REFITTING PART CONCERNED Adjusting, page 37A-38) (37A, Mechanical compo-
nent controls).
a Refit:
a After replacing the parking brake linings, perform the
- the brake linings (7) , brake-in operation as follows:
- the upper return spring bracket (6) , - adjust the parking brake cables (see 37A, Mecha-
nical component controls, Parking brake lever:
- the upper return springs, (5) Adjusting, page 37A-38) (37A, Mechanical com-
ponent controls),
- the lower return spring adjuster (3) ,
- perform the parking brake break-in operation using
diagnostic tool by driving the vehicle under the
- the side retainers (1) by rotating the connecting
following conditions:
rods (2) while pressing against the rear brake disc
shield. • Vehicle speed: 25 mph (40 km/h),
• Parking brake lever operating force: 130N (5 not-

III - FINAL OPERATION ches),
• Distance: 200~233m,
a Refit:
• Braking time: 18~21sec.
page 33A-13) , Note:
To prevent the lining from overheating, allow a
cool-off period of approximately 5 minutes after
every break-in operation.
- the rear brake pads (see 33A, Rear axle compo- a After the break-in procedure, check the lever stroke
nents, Rear brake pads: Removal - Refitting, of the parking brake. If it does not conform to the
page 33A-1) , specifications, adjust again (see 37A, Mechanical
component controls, Parking brake lever: Adjus-
- the rear brake calliper (see 33A, Rear axle com- ting, page 37A-38) (37A, Mechanical component
ponents, Rear brake caliper: Removal - Refit- controls),
ting, page 33A-5) ,

Wheels and tyres). FOOT BRAKE AUTO CONTROL
a a With the ignition on, push the handle to release the

assisted parking brake. Then pull the handle so that
Note: the automatic parking brake locking function is si-
For safety reasons, it is strongly recommended: gnalled by a sound and the play compensation is set
automatically.
- to run in the brake linings with the help of two
people: a driver and a passenger who uses the a After replacement of the parking brake linings, per-
diagnostic tool, form the break-in operation as follows diagnostic
tool (see Fault finding: Programming)(37B, Elec-
- to perform the driving test on a road that is
tronic parking brake).
closed if possible, or as clear as possible.
33A-17
Brake pipe: Removal - Refitting 33A
Essential equipment
pedal press
Tightening torquesm
rear brake hose on the 16 N.m

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

Towing and lifting) (MR 388, 02A, Lifting equip-
ment). 130825
res, Wheel: Removal - Refitting, page 35A-1) . a Remove:
- the clips (5) from the rear brake hose (6) ,
WARNING - the rear brake hose.

Prepare for the flow of fluid, and protect the sur- a Detach the rigid brake pipe (7) from the rear stub
rounding components. axle carrier.
a Remove the rigid brake pipe.
a Fit the pedal press to the brake pedal to limit the
REFITTING
CONCERNED I - REFITTING PREPARATION OPERATION
a
WARNING
To avoid damaging the wheel speed sensor

cable:
- Do not tension the cable,
- Do not twist the cable,
- Check that there is no contact with the surroun-
ding components,
- Do not use tools that may damage the cable.

130809
CONCERNED
a Refit:
a Remove the rear brake hose clip (2) . - the rigid brake pipe in its initial position.
a Disconnect the rear brake hose (3) . - the rear brake hose (6) ,
33A-18
Brake pipe: Removal - Refitting 33A
- the clips (5) on the rear brake hose.
a Torque tighten the rear brake hose on the union
(16 N.m).
a Refit:
- the clip (2) on the rear brake hose.

33A-19
Shock absorber: Removal - Refitting 33A
Essential equipment
trolley jack
diagnostic tool
Tightening torquesm
bolt of the shock absor- 120N.m

ber
nut of the shock absor- 120N.m

ber
131474
WARNING a Position the trolley jack with a shim under the lower
To prevent any suspension asymmetry, replace seat of the spring.
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.
REMOVAL

131475
a Remove the lower bolt and nut (1) of the rear shock
absorber.
a Lower the trolley jack.
a Remove:
- the upper bolt and nut (2) of the rear shock absor-
ber,
- the rear shock absorber.
REFITTING

a Always replace the shock absorber nuts.
33A-20
Shock absorber: Removal - Refitting 33A
a Refit:
- the rear shock absorber,
- the new upper bolt and nut of the rear shock absor-
ber.
a Torque tighten the upper bolt of the shock absor-
ber (120N.m).
a Position the trolley jack under the lower seat of
spring.
a Fit the new lower bolt and nut of the rear shock ab-
sorber.
Note:
Tighten the lower nut of the shock absorber with
the wheels on the ground.

Wheels and tyres).
a Torque tighten the lower nut of the shock absorber
(120N.m).
a Adjust:
- the alignment (see 30A, General information,
Front axle: Adjusting, page 30A-10) (30A, Gene-
ral information),
- the neutral position of the steering wheel angle
sensor using the diagnostic tool (see Fault fin-
ding - Programming)(80B, Headlights)
33A-21
Rear suspension spring: Removal - Refitting 33A
Essential equipment
pedal press
trolley jack
diagnostic tool
Tightening torquesm
bolt of the upper arm on 150N.m

the rear stub axle carrier
lower trailing link bolt on 150 N.m 131498

a Unscrew the rear brake hose at the union (1) .
lower nut of the tie rod 110N.m
of the rear anti-roll bar a Remove the clip (3) from the rear brake hose.
upper nut of the tie rod 110N.m a Disconnect the rear brake hose (2) .
of the rear anti-roll bar
nut of the lower trailing 130N.m

link on the rear axle
subframe
upper arm bolt on the 130N.m

rear axle subframe
bolts on the rear brake 25N.m

hose bracket
bolt and the lower nut of 120N.m

the rear shock absorber
131499
REMOVAL a Remove:
I - REMOVAL PREPARATION OPERATION - the bolts (4) from the rear brake hose bracket,
a Position the vehicle on a two-post lift (see Vehicle: - the rear brake hose bracket (5) ,
- the rear wheel speed sensor of the rear stub axle
carrier (see 38C, Anti-lock braking system, Rear
wheel speed sensor: Removal - Refitting, page
38C-10) (38C, Anti-lock braking system).
a Place the pedal press on the brake pedal to limit the
XENON BULBS
a Remove the rear sensor of the headlight beam ad-

justment (see Headlight adjustment rear sensor:
Removal - Refitting) (80C, Xenon bulbs).
33A-22
CONCERNED
a
Note:
Remove and refit one suspension spring, then
remove and refit the suspension spring on the
other side to avoid the springs being suddenly
released.
131501
a Position the trolley jack with a shim under the lower
seat of the spring.
a Remove:
- the lower bolt and nut (9) of the tie rod of the rear
anti-roll bar,
- the lower bolt and nut (10) of the rear shock absor-
ber.
131500
a Undo:
- the bolt and nut (6) of the upper arm of the rear axle
subframe,
- the lower trailing link bolt and nut (7) of the rear
axle subframe,
- the upper bolt and nut (8) of the tie rod of the rear
anti-roll bar,
anti-roll bar,
ber.
131502
a Remove:
- the bolt and nut of the lower trailing link (11) ,
- the bolt and nut (12) of the upper arm.
a Remove the rear suspension spring.
REFITTING

a Always replace:
- the upper arm nut,
- the lower trailing link nut,
33A-23
- the lower nut of the tie rod of the rear anti-roll bar, a Lower the trolley jack.
- the rear shock absorber lower nut,

Note:
CONCERNED
a Torque tighten:
- the bolt of the upper arm on the rear stub axle
carrier (150N.m),
- the lower trailing link bolt on the rear stub axle
carrier (150 N.m),
- the lower nut of the tie rod of the rear anti-roll
bar (110N.m),
- the upper nut of the tie rod of the rear anti-roll
bar (110N.m),
- the nut of the lower trailing link on the rear axle
subframe (130N.m),
- the upper arm bolt on the rear axle subframe
131503
(130N.m).
a
Note: XENON BULBS
The lower elastic bearing (13) of the rear suspen- a Refit the headlight beam adjustment rear sensor
sion spring must be firmly inserted into the ope- (see Headlight adjustment rear sensor: Removal
ning of the rear stub axle carrier. - Refitting) (80C, Xenon bulbs).
a Refit the rear suspension spring by aligning the

lower end of widest section so it is positioned
between the lower elastic bearing and the rear stub a Refit:
axle carrier. - the rear wheel speed sensor (see 38C, Anti-lock
braking system, Rear wheel speed sensor: Re-
seat of the spring.
Braking System),
- the rear brake hose bracket,
Note:
- the bolts on the rear brake hose bracket,
This operation requires two technicians.
- the rear brake hose,
a Refit: - the brake hose on the union,
- the upper arm on to the rear stub-axle carrier, - the clip on the rear brake hose.
a Torque tighten:
- the new bolt and nut (12) on to the upper arm,
- the bolts on the rear brake hose bracket
- the lower trailing link of the rear stub-axle carrier, (25N.m),
- the new bolt and nut (11) of the lower trailing link, - the brake hose on the union (16 N.m).
- the new lower bolt and nut of the rear shock absor- III - FINAL OPERATION.
ber,
- the new lower bolt and nut of the tie rod of the rear tion, Brake circuit Bleeding, page 30A-3) (see
anti-roll bar. 30A, General information ).
33A-24
Wheels and tyres).
a Torque tighten the bolt and the lower nut of the
rear shock absorber (120N.m).
XENON BULBS
a Adjust:
- the headlights (see Front headlight: Adjusting)
(80B, Headlights),
- the headlight beam adjustment rear sensor (see
fault Finding - Programming)(80B, Headlights).
a Adjust:
Rear axle: Adjusting, page 30A-12) (30A, Gene-
ral information),
sensor using the diagnostic tool (see Fault fin-
ding - Programming) (80B, Headlights)
33A-25
Rear wheel hub: Removal - Refitting 33A
4X2 TRANSMISSION
CONCERNED
Tightening torquesm

sor bolt
REMOVAL

a Remove:
- the rear brake calliper without disconnecting the
brake hose (see 33A, Rear axle components,
33A-5) .
130817
a Remove:
a Remove:
- the rear brake pads (see 33A, Rear axle compo- - the rear wheel speed sensor bolt (1) ,
page 33A-1) , - the rear wheel speed sensor of the rear wheel hub,
- the rear brake calliper mounting (see 33A, Rear - the rear wheel hub bolts (2) ,
ting: Removal - Refitting, page 33A-7) - the rear wheel hub from the rear stub-axle carrier.
13) . REFITTING

CONCERNED
a Refit:
- the rear wheel hub to the rear stub-axle carrier,
- the rear wheel hub bolts,
- the rear wheel speed sensor on to the rear wheel

hub,
a Torque tighten:
33A-26
4X2 TRANSMISSION
a Refit:
13) ,
page 33A-1) ,
33A-5) ,
IMPORTANT
33A-27
4X4 TRANSMISSION
Tightening torquesm

sor bolt
wheel hub nut 125 N.m
REMOVAL

a Remove:
130819
Wheel: Removal - Refitting, page 35A-1) , a Remove:
- the rear brake calliper without disconnecting the - the rear wheel speed sensor bolt (1) ,
brake hose (see 33A, Rear axle components, - the rear wheel speed sensor from the rear wheel
Rear brake caliper: Removal - Refitting, page hub.
33A-5) .
a Remove:
page 33A-1) ,
ting: Removal - Refitting, page 33A-7)
13) .
130828
a Place the tool (Rou. 604-01) on the rear hub,
a Remove:
- the rear hub nut (3) ,
33A-28
4X4 TRANSMISSION
a Refit:
13)
ting: Removal - Refitting, page 33A-7)
page 33A-1) ,
33A-5) ,
130829
IMPORTANT
a Remove:
- the rear wheel hub bolts (4) , pads and brake discs into contact by depressing
- the rear wheel hub from the rear stub-axle carrier.
REFITTING
a Always replace the cotter pin.

CONCERNED
a Refit:
- the rear wheel hub to the rear stub-axle carrier,
- the rear wheel hub nuts,
- the rear wheel speed sensor on to the rear wheel

hub,
a Torque tighten:
a Refit the rear wheel hub nut using tool (Rou. 604-
01).
a Torque tighten the wheel hub nut (125 N.m).
a Refit the new cotter pin.
33A-29
Rear stub-axle carrier: Removal - Refitting 33A
4X2 TRANSMISSION
Essential equipment
pedal press
trolley jack
Tightening torquesm
rear stub axle carrier nut 150 N.m
bolt of the upper arm on 150 N.m

lower trailing link bolt on 150 N.m 131498

a Undo the rear brake hose at the union (1)
lower nut of the tie rod 110 N.m
of the rear anti-roll bar a Remove the mounting clip (2) from the rear brake
hose (3) .
upper nut of the tie rod 110 N.m
a Disconnect the rear brake hose.
nut of the lower trailing 130 N.m

subframe
upper arm bolt on the 130 N.m

rear axle subframe
bolts on the rear brake 25 N.m

hose bracket
rear shock absorber N.m

lower nut120
131499
REMOVAL a Remove:
- the bolts (4) from the rear brake hose bracket,

- the rear brake hose bracket (5) ,
Towing and lifting) (02A, Lifting equipment). - the rear brake calliper (see 33A, Rear axle com-
a Release the parking brake. ponents, Rear brake caliper: Removal - Refit-
ting, page 33A-5) ,
res, Wheel: Removal - Refitting, page 35A-1) . - the rear brake pads (see 33A, Rear axle compo-
page 33A-1) ,

page 33A-13) ,
33A-30
4X2 TRANSMISSION
- the rear wheel speed sensor of the rear stub axle
38C-10) ,
- the rear brake pipe (see 33A, Rear axle compo-
nents, Brake pipe: Removal - Refitting, page
33A-18) ,
XENON BULBS
a Remove the headlight beam adjustment rear sensor
(see Headlight adjustment rear sensor: Removal
- Refitting) (80C, Xenon bulbs).
131500
a Remove the parking brake cables from the underbo- a Undo:

dy (see 37A, Mechanical component controls, - the bolt and nut (6) of the upper arm of the rear axle
Parking brake cables: Removal - Refitting, page subframe,
37A-85) .
- the lower trailing link bolt and nut (7) on the rear
axle subframe,
Note:
It is not necessary to remove the parking brake anti-roll bar,
cables from the rear brake disc shield.
anti-roll bar,
II - OPERATION FOR REMOVAL OF PART - the lower bolt and nut (10) of the rear shock absor-
CONCERNED ber.
a Remove:
- the rear wheel hub (see 33A, Rear axle compo- WARNING
nents, Rear wheel hub: Removal - Refitting, To prevent any damage, do not use the rear axle
page 33A-26) , as suppor t for the lifting system.
- the "rear brake disc shield - rear brake lining - par-
king brake cable" assembly from the rear stub-axle
carrier.
Note:
released.
131501
seat of the spring.
a Remove:
- the lower bolt and nut of the tie rod of the rear anti-
roll bar (9) ,
33A-31
4X2 TRANSMISSION
- the lower bolt and nut (10) of the rear shock absor- REFITTING
ber.

a Always replace:
- the lower nut of the tie rod of the rear anti-roll bar,
- the rear shock absorber lower nut,
- the rear stub axle carrier nut.

CONCERNED
a Refit:
131502
- the rear stub axle carrier,
a Remove:
- the bolt and nut of the rear stub axle carrier.
- the lower trailing link bolt and nut (11) of the rear a Tighten to torque the rear stub axle carrier nut
stub axle carrier, (150 N.m).
- the upper arm bolt and nut (12) of the rear stub axle
carrier.
a Remove the rear suspension spring.
131503
a
Note:
The lower elastic bearing (14) of the rear suspen-
sion spring must be firmly inserted into the ope-
ning of the rear stub axle carrier.
a Refit the rear suspension spring by aligning the

lower end of widest section so it is positioned
between the lower elastic bearing and the rear stub
axle carrier.
131628 a Position the trolley jack with a shim under the lower
seat of the spring.
a Remove:
- the bolt and nut (13) of the rear stub axle carrier, Note:
- the rear stub axle carrier. This operation requires two people.
33A-32
4X2 TRANSMISSION
a Refit:
- the upper arm on to the rear stub-axle carrier, XENON BULBS

a Refit the headlight beam adjustment rear sensor
- the new bolt and nut on to the upper arm,
- the lower trailing link of the rear stub-axle carrier, - Refitting) (80C, Xenon bulbs).
- the new bolt and nut of the lower trailing link,
- the new lower bolt and nut of the rear shock absor- a Refit:
ber,
- the new lower bolt and nut of the tie rod of the rear nents, Brake pipe: Removal - Refitting, page
anti-roll bar. 33A-18) ,
a Lower the trolley jack. - the rear wheel speed sensor of the rear stub axle
38C-10) ,
Note:
page 33A-13) ,
a Torque tighten: - the rear brake calliper mounting (see 33A, Rear
- the bolt of the upper arm on the rear stub axle ting: Removal - Refitting, page 33A-7) ,
carrier (150 N.m),
- the lower trailing link bolt on the rear stub axle nents, Rear brake pads: Removal - Refitting,
carrier (150 N.m), page 33A-1) ,
ponents, Rear brake caliper: Removal - Refit-
bar (110 N.m),
ting, page 33A-5) ,
- the upper nut of the tie rod of the rear anti-roll - the rear brake hose bracket,
bar (110 N.m),
- the rear brake hose,
subframe (130 N.m),
- the brake hose on the union,
- The upper arm bolt on the rear axle subframe
(130 N.m). - the mounting clip on the rear brake hose.
a Torque tighten:
a Refit:
- the bolts on the rear brake hose bracket (25
- the "rear brake disc shield - rear brake lining - par- N.m),
carrier, - the brake hose on the union (16 N.m).
- the rear wheel arch (see 33A, Rear axle compo- Wheel: Removal - Refitting, page 35A-1) .
nents, Rear wheel hub: Removal - Refitting,
page 33A-26) . a Torque tighten ther rear shock absorber lower
nut120 (N.m).

XENON BULBS
a Refit the parking brake cables on to the underbody
a Adjust:
(see 37A, Mechanical component controls, Par-
king brake cables: Removal - Refitting, page - the headlights (see Front headlight: Adjusting)
37A-85) . (80B, Headlights),
33A-33
4X2 TRANSMISSION
Fault finding - Configuration and programming)
(80C, Xenon bulbs).

the automatic parking brake locking function is si-
gnalled by a sound and the play compensation is set
automatically.


a Adjust:
Rear axle: Adjusting, page 30A-12) ,
sensor (see Fault finding - Configuration and
programming) (80B, Headlights).
33A-34
4X4 TRANSMISSION
Essential equipment
pedal press
trolley jack
Tightening torquesm
rear stub axle carrier nut 150 N.m
bolt of the upper arm on 150 N.m 131498

a Undo the rear brake hose (1) at the union.
lower trailing link bolt on 150 N.m
a Remove the clip (2) from the rear brake hose (3) .


subframe

rear axle subframe
wheel hub nut 125 N.m

hose bracket
131499
a Remove:
nut1
REMOVAL - the rear brake calliper (see 33A, Rear axle com-
ting, page 33A-5) ,
a Position the vehicle on a two-post lift (see Vehicle: nents, Rear brake pads: Removal - Refitting,
Towing and lifting) (02A, Lifting equipment). page 33A-1) ,
a Release the parking brake. - the rear brake calliper mounting (see 33A, Rear
a Remove the rear wheels (see 35A, Wheels and ty- ting: Removal - Refitting, page 33A-7) ,
a Fit the pedal press on the brake pedal to limit the nents, Rear brake disc: Removal - Refitting,
amount of brake fluid running out. page 33A-13) ,
33A-35
4X4 TRANSMISSION
- the rear wheel speed sensor of the rear stub axle II - OPERATION FOR REMOVAL OF PART
carrier (see 38C, Anti-lock braking system, Rear CONCERNED
38C-10) ,
nents, Brake pipe: Removal - Refitting, page
33A-18) ,
XENON BULBS
a Remove the parking brake cables from the underbo- 131632

dy (see 37A, Mechanical component controls,
a Remove:
Parking brake cables: Removal - Refitting, page
37A-85) . - the cotter pin (6)
- the wheel hub nut (7) using the tool (Rou. 604-01)
Note: (8) ,
It is not necessary to remove the parking brake - the rear wheel hub (see 33A, Rear axle compo-
cables from the rear brake disc shield. nents, Rear wheel hub: Removal - Refitting,
page 33A-26) ,
carrier.
Note:
released.
33A-36
4X4 TRANSMISSION
ber.
131500
a Undo:
131502
subframe, a Remove:
- the lower trailing link bolt and nut (10) on the rear - the lower trailing link bolt and nut (14) of the rear
axle subframe, stub axle carrier,
anti-roll bar, - the upper arm bolt and nut (15) of the rear stub axle
carrier.
anti-roll bar, a Lower the trolley jack.
- the lower bolt and nut (13) of the rear shock absor- a Remove the rear suspension spring.
ber.
WARNING
To prevent any damage, do not use the rear axle
as support for the lifting system.
131501 131636
a Position the trolley jack with a shim under the lower a Remove:
seat of the spring.
a Remove: - the rear driveshaft of the rear stub axle carrier,
- the lower bolt and nut (12) of the tie rod of the rear - the rear axle bearing (16) of the rear stub axle car-
anti-roll bar, rier.
33A-37
4X4 TRANSMISSION
131503
Note:
The lower elastic bearing of the rear suspension
131628 spring (18) must be firmly inserted into the ope-
a Remove: ning of the rear stub axle carrier.
- the bolt and nut (17) of the rear stub axle carrier, a Refit the rear suspension spring by aligning the
- the rear stub axle carrier. lower end of the widest section so it is positioned
axle carrier.
REFITTING
seat of the spring.
a Always replace:
Note:
This operation requires two people.
- the lower nut of the tie rod of the rear anti-roll bar, a Refit:
- the rear shock absorber lower nut, - the upper arm on to the rear stub-axle carrier,
- the rear stub axle carrier nut,
- the cotter pin.
- the lower trailing link of the rear stub-axle carrier,
II - REFITTING OPERATION FOR PART - the new bolt and nut of the lower trailing link,
CONCERNED
- the new lower bolt and nut of the rear shock absor-
a Refit:
ber,
- the rear stub axle carrier,
- the new lower bolt and nut of the tie rod of the rear
- the bolt and nut of the rear stub axle carrier. anti-roll bar.
a Torque tighten the rear stub axle carrier nut (150
N.m). a Lower the trolley jack.
a Refit:
- the rear axle bearing on to the rear stub axle car- Note:
rier, Tighten the lower nut of the shock absorber with
- the rear driveshaft on to the rear stub axle carrier. the wheels on the ground.
33A-38
4X4 TRANSMISSION
a Torque tighten: - the rear brake calliper mounting (see 33A, Rear
carrier (150 N.m),
- the lower trailing link bolt on the rear stub axle - the rear brake pads (see 33A, Rear axle compo-
carrier (150 N.m), nents, Rear brake pads: Removal - Refitting,
page 33A-1) ,
bar (110 N.m), - the rear brake calliper (see 33A, Rear axle com-
ting, page 33A-5) ,
bar (110 N.m),
- the nut of the lower trailing link on the rear axle - the rear brake hose bracket,
subframe (130 N.m),
- the upper arm bolt on the rear axle subframe
(130 N.m). - the rear brake hose,
a Refit: - the brake hose on the union,
king brake cable" assembly to the rear stub-axle - the clip on the rear brake hose.
carrier, a Torque tighten:
- the rear wheel hub (see 33A, Rear axle compo-
nents, Rear wheel hub: Removal - Refitting, - the bolts on the rear brake hose bracket (25
page 33A-26) , N.m),
- the wheel hub nut using the tool (Rou. 604-01). - the brake hose on the union (16 N.m).
a Torque tighten the wheel hub nut (125 N.m). a Refit the rear wheels (see 35A, Wheels and tyres,
a Refit the new cotter pin. Wheel: Removal - Refitting, page 35A-1) .
a Torque tighten the shock absorber lower nut1 (20

III - FINAL OPERATION. N.m).
(see 37A, Mechanical component controls, Par-
king brake cables: Removal - Refitting, page XENON BULBS
37A-85) .
a Adjust:

XENON BULBS
(80B, Headlights),
(see Headlight adjustment rear sensor: Removal - the headlight beam adjustment rear sensor (see
- Refitting) (80C, Xenon bulbs). Fault finding - Configuration and programming)
(80C, Xenon bulbs).
a Refit:
nents, Brake pipe: Removal - Refitting, page FOOT BRAKE AUTO CONTROL
33A-18) ,
- the rear wheel speed sensor on to the rear stub
axle carrier (see 38C, Anti-lock braking system,
Rear wheel speed sensor: Removal - Refitting,
gnalled by a sound and the play compensation is set
page 38C-10) ,
automatically.
page 33A-13) ,
33A-39
4X4 TRANSMISSION


a Adjust:
33A-40
Rear anti-roll bar tie rod: Removal - Refitting 33A
CONCERNED
Tightening torquesm
a Refit:
rear anti-roll bar tie rod 110 N.m - the anti-roll bar tie-rod,
upper bolts and nuts
- the rear anti-roll bar tie rod upper bolts and nuts on
rear anti-roll bar tie rod 110 N.m both sides,
lower bolts and nuts
- the rear anti-roll bar tie rod lower bolts and nuts on
both sides.
REMOVAL a Torque tighten:
- the rear anti-roll bar tie rod upper bolts and nuts
I - REMOVAL PREPARATION OPERATION (110 N.m),
a Position the vehicle on a two-post lift (see Vehicle: - the rear anti-roll bar tie rod lower bolts and nuts
Towing and lifting) (02A, Lifting equipment). (110 N.m).

CONCERNED
130933
a Undo:
- the rear anti-roll bar tie rod upper bolts and nuts (1)
on both sides,
- the rear anti-roll bar tie rod lower bolts and nuts (2)
on both sides.
a Remove:
- the rear anti-roll bar tie rod upper bolts and nuts (1)
on both sides,
- the rear anti-roll bar tie rod lower bolts and nuts (2)
on both sides.
- the rear anti-roll bar tie-rod.
REFITTING

a Always replace the tie rod nuts of the rear anti-roll
bar.
33A-41
Rear anti-roll bar: Removal - Refitting 33A
Tightening torquesm
rear anti-roll bar nuts36 N.m
upper nuts of the anti- 110 N.m

roll bar tie rod
lower nuts of the anti-roll N.m

bar tie rod110
REMOVAL

a Position the vehicle on a two-post lift (see Vehicle: a Remove:
- the rear anti-roll bar mounting (4) ,
- the rear anti-roll bar,
CONCERNED
- the rubber bush (5) of the rear anti-roll bar.
REFITTING
a Always replace the nuts of the rear anti-roll bar.
a Check the condition of the rubber bushes.
a Replace the rubber bushes if they are damaged.

130933 CONCERNED
a Loosen the rear anti-roll bar tie rod lower bolts and
a Refit:
nuts (1) on both sides.
a Remove: - the rubber bushes of the rear anti-roll bar,
- the upper bolts and nuts of the rear anti-roll bar tie - the rear anti-roll bar,
rod (2) ,
- the rear anti-roll bar mounting,
- the rear anti-roll bar nuts (3) .
- the rear anti-roll bar nuts.
a Torque tighten the rear anti-roll bar nuts36 (N.m).
a Refit the upper bolts and nuts of the rear anti-roll bar
tie rod.
a Torque tighten:
- the upper nuts of the anti-roll bar tie rod (110

N.m),
- the lower nuts of the anti-roll bar tie rod110

(N.m).
33A-42
Lower trailing link: Removal - Refitting 33A
CONCERNED
Essential equipment
trolley jack
Tightening torquesm
nut of the lower trailing 130N.m

subframe

lower nut of the anti-roll N.m

bar tie rod110
upper nut of the anti-roll N.m

bar tie rod110
REMOVAL
130042
I - REMOVAL PREPARATION OPERATION a Loosen:

a Position the vehicle on a two-post lift (see Vehicle: - the lower trailing link bolt and nut on the rear axle
Towing and lifting) (02A, Lifting equipment). subframe (1) ,
a Remove the rear wheels (see 35A, Wheels and ty- - the lower trailing link bolt and nut (2) on the rear
res, Wheel: Removal - Refitting, page 35A-1) . stub axle carrier,
- the rear anti-roll bar tie-rod upper bolt and nut (3) of
XENON BULBS the rear anti-roll bar on both sides,
a Remove the headlight beam adjustment rear sensor - the lower bolt and nut (4) of the rear anti-roll bar tie
(see Headlight adjustment rear sensor: Removal rod.
130937
seat of the spring.
33A-43
Lower trailing link: Removal - Refitting 33A
- the new lower bolt and nut (4) of the rear anti-roll
bar tie rod.
a Torque tighten:

subframe (130N.m),

carrier (150 N.m),
- the lower nut of the anti-roll bar tie rod110

(N.m).
- the upper nut of the anti-roll bar tie rod110

(N.m).

130042
a Remove:
- the lower bolt and nut (4) of the rear anti-roll bar tie XENON BULBS
rod,
- the lower trailing link bolt and nut (2) of the rear (see Headlight adjustment rear sensor: Removal
stub axle carrier, - Refitting) (80C, Xenon bulbs).
- the lower trailing link bolt and nut (1) of the rear
axle subframe,
- the lower trailing link (5) .
(This operation requires two technicians). a Refit the rear wheels (see 35A, Wheels and tyres,
REFITTING
XENON BULBS
a Adjust:
a Always replace:
- the headlight wiring (see Front headlight: Adjus-
- the lower trailing link nuts,
ting) (80 B, Headlights)
- the rear anti-roll bar tie rod lower nut.
- the headlight beam adjustment rear sensor Fault
finding - Programming (80C, Xenon bulbs).
CONCERNED
a Fit the trolley jack with a shim under the lower seat
of the spring;
a Adjust:
a Refit:
- the lower trailing link (5) , - the alignment (see 30A, General information,
- the new lower trailing link bolt and nut (1) on to the
rear axle subframe, - the neutral position of the steering wheel angle
- the new lower trailing link bolt and nut (2) on to the sensor Fault Finding- Programming (80B, Hea-
rear stub axle carrier, dlights).
33A-44
Upper arm: Removal - Refitting 33A
Essential equipment
pedal press
trolley jack
Tightening torquesm

rear axle sub-frame

rear stub-axle carrier
130940
rear brake hose moun- 25 N.m a Remove:
ting bolts
- the bolts (4) from the rear brake hose mounting,
rigid pipe union on to 16 N.m
the rear brake hose - the rear brake hose mounting (5) ,
- the rear wheel speed sensor (see 38C, Anti-lock

REMOVAL braking system, Rear wheel speed sensor: Re-
moval - Refitting, page 38C-10)

CONCERNED

a Fit the pedal press to the brake pedal to limit the

outflow of brake fluid.
130042
130809 a Loosen:
a Undo the rigid pipe union (1) on the rear brake hose. - the bolt and nut (6) of the upper arm of the rear axle
subframe,
a Remove the clip (3) from the rear brake hose.
a Disconnect the rear brake hose (2) . carrier.
33A-45
Upper arm: Removal - Refitting 33A
CONCERNED

seat of the spring.
a Refit:
- the upper arm,
subframe,
carrier.

130937
a Torque tighten:
seat of the spring. - the upper arm bolt on the rear axle sub-frame
(130 N.m),
- the upper arm bolt on the rear stub-axle carrier

(150 N.m),
a Refit:

moval - Refitting, page 38C-10) ,
- the rear brake hose mounting (5) ,
- the rear brake hose mounting bolts (4) ,
- the rigid pipe union (1) on to the rear brake hose,
- the clip (3) on the rear brake hose.
130042 a Torque tighten:
a Remove: - the rear brake hose mounting bolts (25 N.m),

- the bolt and nut (6) of the upper arm of the rear axle - the rigid pipe union on to the rear brake hose
subframe, (16 N.m).
- the upper arm bolt and nut (7) of the rear stub axle a Bleed the brake circuit (see 30A, General informa-
carrier, tion, Brake circuit Bleeding, page 30A-3) .
- the upper arm. a Refit the rear wheels (see 35A, Wheels and tyres,
(This operation requires two technicians).
a Adjust:
REFITTING - the alignment (see 30A, General information,

I - REFITTING PREPARATION OPERATION - the neutral position of the steering wheel angle
sensor (see: Fault finding - Programming) (80B,
a Always replace the upper arm nuts. Headlights).
33A-46
Rear axle sub-frame: Removal - Refitting 33A
4X2 TRANSMISSION
a Remove:
Essential equipment - the rear wheels (see 35A, Wheels and tyres,
pedal press Wheel: Removal - Refitting, page 35A-1) ,
trolley jack - the silencer (see Silencer: Removal - Refitting)

(19B, Exhaust).
component jack
Tightening torquesm
upper bolt of the rear 120 N.m

shock absorber
rear axle subframe bolts 100 N.m

rear axle subframe

subframe
bolt and the nut of the 150 N.m

rear stub axle carrier
131498
lower trailing link bolt on 150 N.m a Remove the clip (2) from the rear brake hose (3) .


hose bracket

nut1
131499
REMOVAL a Remove:

Towing and lifting) (02A, Lifting equipment). - the rear wheel speed sensor (see 38C, Anti-lock
a Release the parking brake. moval - Refitting, page 38C-10) .
33A-47
4X2 TRANSMISSION
CONCERNED
XENON BULBS
131642
a Undo:
- the bolt and the nut (9) of the upper arm of the rear
axle subframe,
- the lower trailing link bolt and the nut (10) on the
131641
rear axle subframe,
a Remove clip (7) .
anti-roll bar,
a Disconnect the brake hose (8) .
a Remove the parking brake cables from the underbo- anti-roll bar,
Parking brake cables: Removal - Refitting, page - the lower bolt and nut (13) of the rear shock absor-
37A-85) . ber.
Note: WARNING
It is not necessary to remove the parking brake To prevent any damage, do not use the rear axle
cables from the rear brake disc shield. as suppor t for the lifting system.
131643

seat of the spring.
33A-48
4X2 TRANSMISSION
a Remove:
- the lower bolt and nut of the tie rod of the rear anti-
roll bar (12) ,
ber.
Note:
released.
131645
a Remove the bolt and the nut (16) from the rear stub
axle carrier.
a Position the component jack under the rear stub
axle carrier.
131644 Note:
a Remove: This operation requires two people.
- the lower trailing link bolt and the nut (14) of the a Remove:
rear stub axle carrier,
- the "rear stub-axle carrier - rear brake disc shield -
- the upper arm bolt and the nut (15) of the rear stub rear brake lining - rear brake disc - rear brake calli-
axle carrier.
per - parking brake cable" assembly,
- the "rear anti-roll bar - rear anti-roll bar tie rod" as-
a Remove the rear suspension spring. sembly.
33A-49
4X2 TRANSMISSION
REFITTING

a Always replace:
- the rear shock absorber nut,
- the rear stub axle carrier nut.

131646 CONCERNED
a Remove: a
- the lower trailing link bolt and the nut (10) from the
Note:
rear axle subframe,
- the lower trailing link,
a Refit:
- the bolt and the nut (9) of the upper arm of the rear
axle subframe, - the rear shock absorber on the rear axle subframe,
- the upper arm. - the new upper bolt and nut of the rear shock absor-
ber,
- the rear axle sub-frame with the rear shock absor-
ber,
- the rear axle subframe bolts.
a Torque tighten:
- the upper bolt of the rear shock absorber (120
N.m),
- the rear axle subframe bolts (100 N.m).
a Refit:
- the rear anti-roll bar - rear anti-roll bar tie rod as-
sembly,
131647 - the upper arm,
a Position the component jack under the rear axle - the new arm upper bolt and nut on the rear axle
subframe. subframe,
Note: - the new lower trailing link bolt and nut on the rear
This operation requires two people. axle subframe.
a Remove:
Note:
- the rear axle subframe bolts (17) , This operation requires two people.
ber, a Refit:
- the upper bolt and nut of the rear shock absorber, - the "rear stub-axle carrier - rear brake disc shield -
rear brake lining - rear brake disc - rear brake calli-
- the rear shock absorber of the rear axle subframe. per - parking brake cable" assembly,
33A-50
4X2 TRANSMISSION
- the new bolt and nut of the rear stub axle carrier. a Torque tighten:
- The upper arm bolt on the rear axle subframe
(130 N.m),
subframe (130 N.m)
- the bolt and the nut of the rear stub axle carrier
(150 N.m),
carrier (150 N.m),
carrier (150 N.m),
bar (110 N.m),
131503
a bar (110 N.m).
Note:
The lower elastic bearing of the rear suspension
spring (18) must be firmly inserted into the ope- a Refit the parking brake cables on to the underbody
ning of the rear stub axle carrier. (see 37A, Mechanical component controls, Par-
king brake cables: Removal - Refitting, page
a Refit the rear suspension spring by aligning the 37A-85) or (see 37A, Mechanical component con-
lower end of the widest section so it is positioned trols, Parking brake cables: Removal - Refitting,
between the lower elastic bearing and the rear stub page 37A-85) .
axle carrier.
a Position the trolley jack with a shim under the lower XENON BULBS
seat of the spring. a Refit the headlight beam adjustment rear sensor
Note:
a Refit: a Remove the brake hose.
- the upper arm on to the rear stub-axle carrier, a Refit:

- the brake hose on the union,
- the clip.
- the new bolt and nut of the lower trailing link, N.m).
- the new lower bolt and nut of the rear shock absor- a Refit:
ber,
- the new lower bolt and nut of the tie rod of the rear braking system, Rear wheel speed sensor: Re-
anti-roll bar. moval - Refitting, page 38C-10) ,
a Lower the trolley jack. - the rear brake hose bracket,

Note: - the rear brake hose,
Tighten the lower nut of the shock absorber with - the brake hose on the union,
the wheels on the ground. - the clip on the rear brake hose.
33A-51
4X2 TRANSMISSION
a Torque tighten:
N.m),
a Refit:
- the silencer (see Silencer: Removal - Refitting)
(19B, Exhaust).
N.m).
XENON BULBS
a Adjust:
(80B, Headlights),
(80C, Xenon bulbs).

electronic parking brake. Then pull the handle so
that the automatic parking brake locking function is
signalled by a sound and the play compensation is
set automatically.


a Adjust:
33A-52
4X4 TRANSMISSION
REMOVAL
Rou. 604-01 Hub locking tool. I - REMOVAL PREPARATION OPERATION

Essential equipment
pedal press a Release the parking brake.
trolley jack a Drain the rear final drive oil (see Rear axle oil: Drai-
ning - Refilling) (26A, Rear final drive).
component jack a Remove:
Tightening torquesm Wheel: Removal - Refitting, page 35A-1) ,
- the silencer (see Silencer: Removal - Refitting)
upper bolt of the rear 120 N.m
(19B, Exhaust).
shock absorber
a Uncouple the rear final drive propshaft (see Props-
rear axle subframe bolts 100 N.m haft: Removal - Refitting) (29A, Driveshafts).
upper arm bolt on the 130 N.m a Secure the propshaft with string.
rear axle subframe a Fit the pedal press on the brake pedal to limit the
subframe
bolt and nut of the rear 150 N.m

stub axle carrier




131498
wheel hub nut 125 N.m a Remove the clip (2) from the rear brake hose (3) .
brake hose on the union 16 N.m a Disconnect the rear brake hose.

hose bracket

nut1
33A-53
4X4 TRANSMISSION
a Remove the parking brake cables from the underbo-
Parking brake cables: Removal - Refitting, page
37A-85) .
Note:
It is not necessary to remove the parking brake
cables from the rear brake disc shield.

CONCERNED
131499
a Remove:

moval - Refitting, page 38C-10) .
XENON BULBS 131642
a Remove the headlight beam adjustment rear sensor a Undo:

(see Headlight adjustment rear sensor: Removal - the bolt and the nut (9) of the upper arm on the rear
- Refitting) (80C, Xenon bulbs). axle subframe,
- the lower trailing link bolt and the nut (10) on the
rear axle subframe,
anti-roll bar,
anti-roll bar,
ber.
WARNING
To prevent any damage, do not use the rear axle
as suppor t for the lifting system.
131641
a Remove clip (7) .
a Disconnect the brake hose (8) .
33A-54
4X4 TRANSMISSION
131643 131502
a Remove:
seat of the spring. - the lower trailing link bolt and nut (17) of the rear
stub axle carrier,
carrier.
a Remove:
- the rear suspension spring,
- the rear driveshaft of the rear stub axle carrier.
131632
a Remove:
- the wheel hub nut (15) using the tool (Rou. 604-01)
(16) .
a Remove:
anti-roll bar,
ber. 131628
a Remove the bolt and nut (19) from the rear stub axle
carrier.
Note:
released.
33A-55
4X4 TRANSMISSION
a Position the component jack under the rear stub
axle carrier.
Note:
a Remove:
rear brake lining - rear brake disc - rear brake calli-
- the rear final drive (see Rear axle assembly: Re-
moving - Refitting) ,
- the "rear anti-roll bar - rear anti-roll bar tie rod" as-
131647
sembly.
a Position the component jack under the rear axle
subframe.
Note:
a Remove:
- the rear axle subframe bolts (20) ,
ber,
- the bolt and the upper nut of the rear shock absor-
ber,
131642
- the rear shock absorber of the rear axle subframe.
a Remove:
- the lower trailing link bolt and nut (10) from the rear REFITTING
axle subframe,
- the lower trailing link, I - REFITTING PREPARATION OPERATION
- the bolt and nut (9) of the upper arm of the rear axle a Always replace:
subframe,
- the upper arm.
- the rear shock absorber nut,
- the rear stub axle carrier nut,
- the cotter pin.

CONCERNED
a
Note:
33A-56
4X4 TRANSMISSION
a Refit:
- the rear shock absorber on the rear axle subframe,
- the new upper bolt and nut of the rear shock absor-
ber,
ber,
- the rear axle subframe bolts.
a Torque tighten:
- the upper bolt of the rear shock absorber (120
N.m),
- the rear axle subframe bolts (100 N.m).
a Refit: 131503
- the rear anti-roll bar - rear anti-roll bar tie rod as- a
sembly,
Note:
- the rear final drive (see Rear axle assembly: Re-
moving - Refitting) (26A, Rear final drive), The lower elastic bearing (21) of the rear suspen-
sion spring must be firmly inserted into the ope-
- the upper arm,
ning of the rear stub axle carrier.
- the new arm upper bolt and nut on the rear axle
subframe, a Refit the rear suspension spring by aligning the
lower end of the widest section so it is positioned
- the new lower trailing link bolt and nut on the rear axle carrier.
axle subframe.
seat of the spring.
Note:
Note:
a Refit:
rear brake lining - rear brake disc - rear brake calli- a Refit:
- the upper arm on to the rear stub-axle carrier,
- the new bolt and nut of the rear stub axle carrier.
- the rear driveshaft on to the rear stub axle carrier. - the new bolt and nut on to the upper arm,
- the new bolt and nut of the lower trailing link,
- the new lower bolt and nut of the rear shock absor-
ber,
- the new lower bolt and nut of the tie rod of the rear
anti-roll bar.
Note:
33A-57
4X4 TRANSMISSION
a Torque tighten: - the brake hose on the union,
- The upper arm bolt on the rear axle subframe - the clip on the rear brake hose.
(130 N.m),
a Torque tighten:
subframe (130 N.m)
N.m),
- the bolt and nut of the rear stub axle carrier (150
N.m),
carrier (150 N.m),
N.m).
carrier (150 N.m),
a Refit:
bar (110 N.m), - the propshaft on the rear final drive (see Props-
haft: Removal - Refitting) (29A, Driveshafts),
bar (110 N.m). - the silencer (see Silencer: Removal - Refitting)
(19B, Exhaust).
a Refit the wheel hub nut using the tool (Rou. 604-01).
a Top up the rear final drive with oil (see Rear axle oil:
a Torque tighten the wheel hub nut (125 N.m).
Draining - Refilling) (26A, Rear final drive).
a Refit the new cotter pin.
XENON BULBS
a Adjust:
(see 37A, Mechanical component controls, Par- - the headlights (see Front headlight: Adjusting)
king brake cables: Removal - Refitting, page (80B, Headlights),
37A-85) . - the headlight beam adjustment rear sensor(see
(80C, Xenon bulbs).
XENON BULBS
a Remove the brake hose. assisted parking brake. Then pull the handle so that
a Refit: gnalled by a sound and the play compensation is set
- the brake hose on the union, automatically.
- the clip.
N.m).
a Refit:
- the rear wheel speed sensor (see 38C, Anti-lock cal component controls, Parking brake lever:
braking system, Rear wheel speed sensor: Re- Removal - Refitting, page 37A-37) .
moval - Refitting, page 38C-10) ,
- the rear brake hose, tion, Brake circuit Bleeding, page 30A-3) .
33A-58
4X4 TRANSMISSION
a Adjust:
33A-59
WHEELS AND TYRES
Wheel: Removal - Refitting 35A
a Check the condition of the tyre.
Tightening torquesm a Do not move or remove the balance weights.
wheel nuts 108 N.m II - REFITTING OPERATION FOR PART

CONCERNED
REMOVAL a Refit the wheel to the vehicle, positioning the valve

at the top.
I - REMOVAL PREPARATION OPERATION a Insert the wheel bolts.

a Remove the trim (depending on equipment level).

CONCERNED
a
Note:
Use sockets with protective sheaths in order to
avoid scratching the alloy wheel rims.
a Undo the wheel nuts, with the wheels on the ground.

a Raise the lift.
a Position the wheel valve at the top.
a Remove: 130945
- the wheel nuts, a Tighten the wheel bolts to bring all the bolt heads
into contact with the wheel.
- the wheel.
a Pretighten the wheel bolts to 30 N.m, with the wheel
suspended, starting with the lower nuts (1) and fi-
REFITTING nishing with the upper nuts (2) .
a Rotate the wheel through 180˚ to bring the valve into
I - REFITTING PREPARATION OPERATION the bottom position.
a Position the vehicle on its wheels.
130944
a Clean the mating surfaces between the wheel and
the hub carrier using a wire brush.
35A-1
WHEELS AND TYRES
Wheel: Removal - Refitting 35A
130945
a Torque tighten in order the wheel nuts (108 N.m).

a Refit the trim (depending on equipment level).
35A-2
WHEELS AND TYRES
Wheel: Balancing 35A
Essential equipment
pedal press
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 that the machine is recalibrated at the

intervals specified by the manufacturer.
Never grease the threaded shaft.

105870
Check the condition of the supports, centring com-
a To reproduce the exact vehicle wheel assembly, it is
ponents and mountings. essential to fit a ring (1) with a diameter of 66 mm on
the wheel balancer.
Replace any faulty parts (see manufacturer's ins-
tructions). a There are three types of weight:
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 pressures (see 35A, Wheels and ty-

res, Tyre inflation pressure: Identification, page
35A-8) .
a Always carry out a road test for a minimum distance

of 1 mile (2 km) before balancing the wheels, in or- 113742
der to remove any flat spots on the tread caused by
the vehicle being immobilised. (2) Steel wheel with flange
(3) Alloy wheel with flange
a After the road test:
(4) Alloy wheel without flange
- raise the vehicle immediately, a In some countries, the use of lead weights is forbid-
den; in this case it is recommended to use ZAMAK
- leave the four wheels hanging free,
weights instead.
- release the parking brake. Only use weights provided by the Parts Department.
35A-3
WHEELS AND TYRES
Wheel: Balancing 35A
a Position the vehicle on a two-post lift immediately af-
ter the road test (see Vehicle: Towing and lifting)
(MR 415, 02A, Lifting equipment).
a Fit a pedal press.
a Remove the wheels (see 35A, Wheels and tyres,

a Always clean the wheel, disc, and hub bearing surfa-

ces.
III - PROCEDURE FOR BALANCING THE WHEEL IN

QUESTION
a Make sure that the wheel balancer bearing surface

and all the centring equipment (ring, thrust plate,
etc.) are kept clean.
a Try not to scratch the (alloy) wheel rim with the

wheel tightening device. 100681
a Place the wheel on the wheel balancer, with the val-

ve at the top, then lock the wheel in place.
a Remove any stones trapped in the tyre tread.
a Enter the specific wheel parameters into 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 balance weights,
- repeat the balancing procedure.
a Repeat the operation until the wheel balance is 0 on

each plane of the wheel.
a Repeat this operation on the other vehicle wheels.
WARNING
105871
To avoid detachment of the balance weights, use
a The wheel is fitted on the wheel balancer as follows: only weights which correspond to the vehicle
wheel rims
- (5) wheel balancer back-plate,
- (6) ring 66 mm in diameter, IV - FINAL OPERATION.
a Refit the wheel on the vehicle in the position noted

- (7) wheel,
during removal (see 35A, Wheels and tyres,
- (8) wheel tightening device (certain alloy wheels Wheel: Removal - Refitting, page 35A-1) .
require a device 200 mm in diameter to ensure that a Remove the pedal press.
the wheel has been correctly tightened),
a Carry out a road test to confirm the customer com-
- outer wheel plane (9) . plaint is resolved.
35A-4
WHEELS AND TYRES
Tyres: Identification 35A
Example of tyre identification marking: 185/60 R 15 84
H.
101008
185 Tyre width in mm (l)
60 Ratio(h/w)
R Radial structure
15 Internal diameter in inches
84 Load index
H Speed code
Speed code table:
Maximum speed mph (km/h)
R 170
S 180
T 190
U 200
H 210
V 240
ZR above 240
35A-5
WHEELS AND TYRES
Tyres: Removal - Refitting 35A
REMOVAL

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

- the balance weights,
- the valve mechanism.

CONCERNED
TYRE PRESSURE SENS.

18885
a a Position the tyre lever approximately 15 cm from the
valve on the outside of the wheel rim in order to re-
WARNING
move the exterior bead from the tyre.
To avoid any damage to the sensor, make sure
the tyre bead never presses on the sensor. a Remove the exterior bead of the tyre, finishing at the
valve.
a Position the tyre lever approximately 15 cm from the

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
WITHOUT TYRE PRESSURE SENS.
a parts always to be replaced: Tyre valve (13,05,

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

TYRE PASTE (see Vehicle: Parts and ingre-
dients for the repairwork) (04B, Consumables -
18884 Products).
a Detach:
- the bead from the outside of the tyre, starting with CONCERNED
the side opposite the valve,
a Engage the lower tyre bead approximately 15 cm af-
- the bead from the inside of the tyre. ter the valve.
35A-6
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.

a Refit the valve mechanism.
a Inflate the tyre to the recommended pressure (see
35A, Wheels and tyres, Tyre inflation pressure:
Identification, page 35A-8) .
Note:
It is not necessary to drive the vehicle before and
after a new wheel is balanced.
a Balance the wheel (see 35A, Wheels and tyres,

Wheel: Balancing, page 35A-3) .
a Refit the wheel in question (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) .
35A-7
WHEELS AND TYRES
Tyre inflation pressure: Identification 35A
I - INFLATION
Essential equipment
diagnostic tool WARNING

If checking the pressure when hot, increase the tyre
inflation pressure by 0.2 to 0.3 bar above the
recommended pressure.
Tyre inflation pressure when cold (bar)

Tyre Wheel rim
Front Rear
225/60 R 17 99H 6 1/2 J 2.3 2.1
Tyre inflation pressure when cold (bar)

Emergency spare
Wheel rim
wheel
Front Rear
225/60 R 17 99H 6 1/2 J 2.3 2.1
T155/80 R 17 100M 6 1/2 J 2.3 2.3
The specified pressure values assume that the tyres

are cold.
II - CONFORMITY CHECK AND ADJUSTMENT

If the tyre size is changed, calibrate the electric power
assisted steering computer using the tool diagnostic
tool (see Replacement of components) (36B, Elec-
tric power steering).
Wheel offset:
- 17-inch alloy wheel rim: 40 mm,
- emergency spare wheel 17 x 4T: 30 mm.
For fitting chains (see Driver's handbook).
35A-8
WHEELS AND TYRES
Wheel rim: Identification 35A
IDENTIFICATION 2 - Installation diameter for the wheel bolts
1 - Marking
The wheel bolts are positioned with a pitch circle dia-
There are two types of identification marking on the meter of 114.3 mm (5 holes).
wheel rims:
- engraved marking for steel wheel rims, 3 - Rim run-out
- cast marking for alloy wheel rims. The maximum run-out is measured at the wheel rim
edge (7) .
The marking gives the main dimensional specifications
of the wheel rim. 0.3 mm
This marking may be:
4 - Out-of-roundness
- complete, for example 6 J 15 5 CH 36,
The maximum out-of-round value is measured on the
- simplified, for example 6 J 15.
tyre bead bearing surface.
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
There are 3 types of wheel rim edges (2) :
- those with two flat edges,
- those with two raised edges,
- those with one flat edge and one raised edge.
35A-9
TYRE PRESSURE MONITOR
SSPP: List and location of components 35B
TYRE PRESSURE SENS.
130954
The system is made up of:

- four pressure sensors built into the valves (one per
wheel); they transmit a radio frequency signal,
- four tyre pressure monitor receivers, for the purpose
of receiving and decoding the sensor signals and
transmitting them to the UCH,
- a computer that receives, decodes and processes in-
formation from the receivers, and then determines
which message to display,
- a display integrated into the instrument panel.
Note:
The position of the sensor on each wheel is auto-
matically identified by the UCH computer.
130955
Composition of the pressure sensor:
- a conventional valve,
- a pressure sensor,
35B-1
SSPP: List and location of components 35B
TYRE PRESSURE SENS.
- a specific radio frequency transmitter,
- a non-removable battery.
35B-2
SSPP: Precautions for repair 35B
TYRE PRESSURE SENS.
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 computer: Removal - Refitting 35B
TYRE PRESSURE SENS.
REMOVAL
a Remove the lower cover of the driver’s side dash-

board (see Dashboard: Removal - Refitting) (MR
393, 57A, Interior equipment).

CONCERNED
130960
a Remove the bolt (1) .
a Disconnect the connector (2) .
a Remove the tyre pressure monitor computer.
REFITTING

CONCERNED
a Refit the tyre pressure monitor computer.
a Connect the connector.
a Refit the tyre pressure monitor computer bolt.
a Refit the lower cover of the driver’s side dashboard

(see Dashboard: Removal - Refitting) (MR 393,
57A, Interior equipment).
35B-4
Pressure sensor: Removal - Refitting 35B
TYRE PRESSURE SENS.
- the tyre pressure sensor (2) .
Tightening torquesm
REFITTING
tyre pressure sensor 8 N.m
retaining nut
IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
ting recommendations before carrying out any
repair (see 35B, Tyre pressure monitor, SSPP:
Precautions for repair, page 35B-3) (35B, Tyre
pressure monitor system).
REMOVAL

Towing and lifting) (02A, Lifting equipment). a If necessary, replace the tyre pressure sensor nut
a Remove: (3) .
- the wheels (see 35A, Wheels and tyres, Wheel: a Always replace the following parts:
Removal - Refitting, page 35A-1) , - the mechanism (4) ,
- the tyres (see 35A, Wheels and tyres, Tyres: Re- - the cap (5) ,
moval - Refitting, page 35A-6) .
- the seal (6) .

CONCERNED II - REFITTING OPERATION FOR PART
CONCERNED
a Position the sensor in the valve opening, checking
that the seal is attached all around the edge of the
opening.
a Refit the tyre pressure sensor nut.
112627
a Remove:
- the tyre pressure sensor nut (1) ,
35B-5
Pressure sensor: Removal - Refitting 35B
TYRE PRESSURE SENS.
112628
a
WARNING
Hold the sensor in position on the wheel to pre-
vent it from turning during tightening.
a Torque tighten the tyre pressure sensor retaining

nut (8 N.m).
Note:
After using a tyre repair aerosol, remove the pro-
duct residue from the valve with a dry cloth or air
gun before refitting it on the wheel rim.

a Refit:
- the tyres (see 35A, Wheels and tyres, Tyres: Re-
moval - Refitting, page 35A-6) ,
- the wheels (see 35A, Wheels and tyres, Wheel:
35B-6
Tyre pressure monitor receiver: Removal - Refitting 35B
TYRE PRESSURE SENS.
CONCERNED
Tightening torquesm
tyre pressure monitor 11 N.m 1 - Front left-hand tyre pressure monitor receiver
receiver bolt
REMOVAL

a Remove:
- the front or rear wheel (on the side concerned) (see
35A, Wheels and tyres, Wheel: Removal - Refit-
ting, page 35A-1) ,
- the front wheel arch liner (side concerned) (see
Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection) or the rear wheel arch
liner (side concerned) (see Rear wheel arch liner:
Removal - Refitting) (55A, Exterior protection).
130956
a Remove the bolt (1) from the front left-hand tyre
pressure monitor receiver.
a Disconnect the connector (2) from the front left-hand
tyre pressure monitor receiver.
a Remove the front left-hand tyre pressure monitor re-
ceiver.
35B-7
TYRE PRESSURE SENS.
2 - Front right-hand tyre pressure monitor receiver 3 - Rear left-hand tyre pressure monitor receiver
130957 130958
a Remove the front right-hand tyre pressure monitor a Remove the bolt (5) from the rear left-hand tyre
receiver bolt (3) . pressure monitor receiver.
a Disconnect the connector (4) from the front right- a Disconnect the connector (6) from the rear left-hand
hand tyre pressure monitor receiver. tyre pressure monitor receiver.
a Remove the front right-hand tyre pressure monitor a Remove the rear left-hand tyre pressure monitor re-
receiver. ceiver.
35B-8
TYRE PRESSURE SENS.
4 - Rear right-hand tyre pressure monitor receiver - the front or rear wheel (on the side concerned) (see
ting, page 35A-1) .
130959
a Remove the bolt (7) from the rear right-hand tyre

pressure monitor receiver.
a Disconnect the connector (8) from the rear right-

hand tyre pressure monitor receiver.
a Remove the rear right-hand tyre pressure monitor

receiver.
REFITTING

CONCERNED
a Refit the tyre pressure monitor receiver (on the side

concerned).
a Connect the connector of the tyre pressure monitor

receiver (on the side concerned).
a Refit the bolt on the tyre pressure monitor receiver

(on the side concerned).
a Torque tighten the tyre pressure monitor receiver

bolt (11 N.m) (on the side concerned).
a Refit:
- the front wheel arch liner (side concerned) (see

Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection) or the rear wheel arch
liner (side concerned) (see Rear wheel arch liner:
35B-9
STEERING ASSEMBLY
Steering: List and location of components 36A
130964
(1) Steering box

(2) Track rod
(3) Axial ball joint linkage
36A-1
STEERING ASSEMBLY
Steering rack: Removal - Refitting 36A
M9R, and LEFT-HAND DRIVE
REFITTING
Tightening torquesm
steering box nuts 148 N.m
a Always replace the universal joint bolt
IMPORTANT
Consult the safety and cleanliness advice and ope- II - REFITTING OPERATION FOR PART
ration recommendations before carrying out any CONCERNED
repair (see Steering: Precautions for repair) . a Refit:
- the steering box,
REMOVAL - the steering box nuts.
a Torque tighten the steering box nuts (148 N.m).
a Position the vehicle on a two-post lift (see Vehicle: III - FINAL OPERATION
Towing and lifting) (02A, Lifting equipment). a Refit:
a Remove: - the front axle sub-frame (see 31A, Front axle
- the front wheels (see 35A, Wheels and tyres, components, Front axle sub-frame: Removal -
Wheel: Removal - Refitting, page 35A-1) , Refitting, page 31A-58) ,
- the front wheels (see 35A, Wheels and tyres,
- the front axle subframe (see 31A, Front axle com-
ting, page 31A-58) . a Adjust the front axle (see 30A, General informa-
tion, Front axle: Adjusting, page 30A-10) .
CONCERNED
131467
a Remove:
- the steering box nuts (1) ,

- the steering box.
36A-2
STEERING ASSEMBLY
M9R, and RIGHT-HAND DRIVE
CONCERNED
Tightening torquesm
a Refit:
steering box nuts 148 N.m - the steering box,
- the steering box nuts.
IMPORTANT a Torque tighten the steering box nuts (148 N.m).
ration recommendations before carrying out any III - FINAL OPERATION
repair (see Steering: Precautions for repair) .
a Refit:
- the front axle sub-frame (see 31A, Front axle
REMOVAL components, Front axle sub-frame: Removal -
I - REMOVAL PREPARATION OPERATION - the front wheels (see 35A, Wheels and tyres,
Towing and lifting) (02A, Lifting equipment). a Adjust the front axle (see 30A, General informa-
a Remove:
- the front axle subframe (see 31A, Front axle com-

CONCERNED
132725
a Remove:
- the steering box nuts (1) ,
- the steering box.
REFITTING

a Always replace the universal joint bolt.
36A-3
STEERING ASSEMBLY
2TR, and LEFT-HAND DRIVE
Tightening torquesm
nuts of the steering box 148 N.m
heat shield bolts 4 N.m
lower nuts of the anti-roll 84 N.m

bar tie rod
track rod ball joint nuts 34 N.m

the steering box
IMPORTANT
131514
a Remove the steering cover (1) .
CONCERNED
REMOVAL

131515
keep).
36A-4
STEERING ASSEMBLY
131516 132632
a Remove: a Remove:
- the universal joint bolt (3) (do not keep), - the track rod ball joint nuts (5) ,
- the universal joint nut (do not keep), - the lower nuts (4) from the anti-roll bar tie rod.
- the universal joint from the steering box.
a Remove the bulkhead seal (see 36A, Steering as- Note:
sembly, Bulkhead seal: Removal - Refitting, page
It is necessary to rotate the anti-roll bar on itself
36A-27) .
in order to make it easier to position the steering
box on the sub-frame cross member.
132713
a Extract the track rod end using the (Tav. 476) (6) .
a Tilt the anti-roll bar towards the rear of the vehicle.
36A-5
STEERING ASSEMBLY
a Remove the intermediate pipe (see Connector pi- - the lower nuts of the anti-roll bar tie rod.
pe: Removal - Refitting) .
CONCERNED
a Refit:
- the steering box, inserting it from the left-hand side

of the vehicle,
- the steering box nuts,
- the heat shield,
- the heat shield bolts.
a Torque tighten
- the nuts of the steering box (148 N.m),
132718
- the heat shield bolts (4 N.m).
a Remove:
a Refit the intermediate pipe (see Connector pipe:
- the bolts (7) ,
Removal - Refitting) .
- the heat shield (8) .
a Tilt the anti-roll bar back into its original position.
a Fit the track rod end in the hub carrier.

a Refit:
- the lower nuts of the anti-roll bar tie rod.
- the track rod ball joint nuts.
a Torque tighten:
- the lower nuts of the anti-roll bar tie rod (84

N.m),
- the track rod ball joint nuts (34 N.m).

a Refit the bulkhead seal (see 36A, Steering assem-
bly, Bulkhead seal: Removal - Refitting, page
36A-27) .
132724
a Remove:
- the steering box bolts (9) ,
- the steering box towards the left-hand side of the
vehicle.
REFITTING

132714
a Always replace:
a Observe the direction of fitting for the universal joint
- the universal joint cam nut and bolt, cam nut and bolt.
36A-6
STEERING ASSEMBLY
132715
tion.
a Refit:
- the universal joint on the steering box,
- the new universal joint bolt,
- the new cam nut on the universal joint.
a Tighten to torque the universal joint bolt on the
steering box (39 N.m).

a Refit:
- the steering cover,
a Adjust the front axle (see 30A, General informa-
36A-7
STEERING ASSEMBLY
2TR, and RIGHT-HAND DRIVE
Tightening torquesm
steering box bolts 148 N.m
heat shield bolts 4 N.m
lower nuts of the anti-roll 84 N.m

bar tie rod
track rod ball joint nuts 34 N.m

the steering box
IMPORTANT
repair (see Steering: Precautions for repair) . 131507
REMOVAL keep).

131508
a Remove:
- the universal joint bolt (3) (do not keep),

131506
- the universal joint nut (do not keep),
a Remove the bulkhead seal (see 36A, Steering as-

sembly, Bulkhead seal: Removal - Refitting, page
36A-27) .
36A-8
STEERING ASSEMBLY
a Remove the intermediate pipe (see Connector pi-
pe: Removal - Refitting) .
132632
a Remove:
132723
- the track rod ball joint nuts (4) ,
a Remove:
- the lower nuts (5) of the anti-roll bar tie rod.
- the bolts (7) ,
Note: - the heat shield (8) .
It is necessary to rotate the anti-roll bar on itself
in order to make it easier to position the steering
box on the sub-frame cross member.
132724
a Remove:
131478 - the steering box bolts (9) ,

a Extract the track rod end using the (Tav. 476) (6) .
- the steering box towards the right-hand side of the
a Tilt the anti-roll bar towards the rear of the vehicle. vehicle.
36A-9
STEERING ASSEMBLY
REFITTING

a Always replace:
- the universal joint cam nut and bolt,
- the lower nuts of the anti-roll bar tie rod.

CONCERNED
a Refit:
- the steering box, inserting it from the right-hand
side of the vehicle, 132714
- the steering box nuts, a Observe the direction of fitting for the universal joint
- the heat shield, cam nut and bolt.
- the heat shield bolts.
a Torque tighten
- the steering box bolts (148 N.m),
- the heat shield bolts (4 N.m).
a Refit the intermediate pipe (see Connector pipe:
Removal - Refitting) .
a Tilt the anti-roll bar back into its original position.
a Fit the track rod end in the hub carrier.
a Refit:
- the lower nuts of the anti-roll bar tie rod,
- the track rod ball joint nuts.
a Torque tighten:
- the lower nuts of the anti-roll bar tie rod (84
N.m),
- the track rod ball joint nuts (34 N.m).
132715
a Refit the bulkhead seal (see 36A, Steering assem-
bly, Bulkhead seal: Removal - Refitting, page
tion.
36A-27) .
a Refit:
- the universal joint on the steering box,


a Refit:
36A-10
STEERING ASSEMBLY
a Adjust the front axle (see 30A, General informa-
36A-11
STEERING ASSEMBLY
Track rod: Removal - Refitting 36A
Tightening torquesm
wheel alignment adjust- 88 N.m

ment lock nut
REMOVAL

a Remove the front wheel on the side concerned (see
35A, Wheels and tyres, Wheel: Removal - Refit- 131478
ting, page 35A-1) . a Extract the ball joint using (Tav. 476) (3) .

CONCERNED
131479
a Unscrew the track rod anti-clockwise and note the

number of turns for refitting.
131477
a Loosen the wheel alignment adjustment lock nut (1) a Remove the track rod.
.
a Remove the track rod ball joint nut (2) . REFITTING

CONCERNED
a Screw the track rod back in place by the number of
turns noted during removal.
36A-12
STEERING ASSEMBLY
Track rod: Removal - Refitting 36A
a refit:
- the track rod end in the hub carrier,
- the track rod end nut.
a Torque tighten:
- the wheel alignment adjustment lock nut (88
N.m).
a Refit the front wheel on the side concerned (see
ting, page 35A-1)
a
Note:
Always check the front axle geometry (adjust if
necessary) (see 3 0 A , General information,
Front axle: Adjustment values, page 30A-8) .
36A-13
STEERING ASSEMBLY
Axial ball joint linkage: Removal - Refitting 36A
Dir. 1741 Tool for locking steering rack.
Dir. 1305-01 Tool for removing/refitting 35

mm to 41 mm diameter axial
ball joints.
Tightening torquesm
axial ball joint 89 N.m

a Remove:
- the front wheel on the side in question (see 35A, 131480
Wheels and tyres, Wheel: Removal - Refitting,
page 35A-1) ,
- the track rod, (see 3 6 A, Steering assembly,
Track rod: Removal - Refitting, page 36A-12)
- the steering box gaiter (see 36A, Steering assem-
bly, Steering rack gaiter: Removal - Refitting,
page 36A-26)
Note:
During this operation, the steering unit must be in
place on the vehicle.
131481
a Set up the (1) (Dir. 1741) on the steering rack, at
the pinion end.
a Unlock the axial ball joint using tool (2) (Dir. 1305-
01).
a Remove the axial ball joint.
36A-14
STEERING ASSEMBLY
Axial ball joint linkage: Removal - Refitting 36A
REFITTING III - FINAL OPERATION.
a Refit:
I - REFITTING PREPARATION OPERATION - the steering box gaiter (see 36A, Steering assem-
bly, Steering rack gaiter: Removal - Refitting,
page 36A-26) ,
- the front wheel on the side concerned (see 35A,
Wheels and tyres, Wheel: Removal - Refitting,
page 35A-1)
a
Note:
Always check the front axle geometry (adjust if
necessary) (see 3 0 A , General information,
Front axle: Adjustment values, page 30A-8) .
131482
a Always replace:
- the washer (3) ,
- the gaiter.
Note:
Take care not to deform the gaiters: they could
be irreparably damaged.

CONCERNED
a Refit:
- the washer (3) ,
- the axial ball joint (4) .
a Torque tighten the axial ball joint (89 N.m) using

the tool (Dir. 1305-01).
a Remove the (Dir. 1741).
a Coat the following parts with lithium grease:
- the steering rack,
- the axial ball joint.
36A-15
STEERING ASSEMBLY
Steering column: Removal - Refitting 36A
LEFT-HAND DRIVE
a Remove:
Tightening torquesm - the driver's front airbag (see Driver's front airbag:
Removal - Refitting) (88C, Airbags and pretensio-
bolt connecting the 31 N.m ners),
steering column to the - the steering wheel (see 36A, Steering assembly,
intermediate shaft Steering wheel: Removal - Refitting, page 36A-
39) .
steering column nuts 17 N.m
and bolts

the steering box
IMPORTANT
IMPORTANT
To prevent the pyrotechnic components from being
permanently deactivated or triggered (airbags or
pretensioners), wait for at least 3 minutes after dis-
connecting the battery.
132750
IMPORTANT a Remove:
Never handle the pyrotechnic systems (pretensio- - the bolts (1) ,
ners or airbags) near to a source of heat or naked
flame - they may be triggered. - the half shell (2) ,
- the radio control satellite (see Radio control satel-
lite: Removal - Refitting) .
REMOVAL
IMPORTANT
To avoid any risk of triggering when working on
or near a pyrotechnic component (airbags or pre-
tensioners), lock the airbag computer using the
diagnostic tool.
When this function is activated, all the trigger
lines are inhibited and the airbag warning light on
the instrument panel lights up continuously (igni-
tion on).

36A-16
STEERING ASSEMBLY
LEFT-HAND DRIVE
CONCERNED
132751
a Remove:
131514
- the upper half shell (3) ,
- the lower half shell (4) ,
- the rotary switch (see Rotary switch: Removal -
Refitting) ,
- the steering column switch assembly (see Stee-
ring wheel controls assembly: Removal - Refit-
ting) (84A, Control - Signals),
- the dashboard lower cover on the driver's side (see
Dashboard: Removal - Refitting) (57A, Interior
equipment),
- the front air distribution duct (see Front air distri-
bution duct: Removal - Refitting) .
131515
keep).
36A-17
STEERING ASSEMBLY
LEFT-HAND DRIVE
131516 132753
a Remove: a Remove the steering column from the retainers (9) .
- the universal joint nut (do not keep).
132726
a Disconnect the connectors (10) .
a Remove:
132752 - the steering column,
a Remove the steering column bolts and nuts (8) from - the bolt (11) ,
the cross member. - the intermediate shaft.
Note:
The column cannot be set down directly on the
floor since the cable is not long enough.
36A-18
STEERING ASSEMBLY
LEFT-HAND DRIVE
REFITTING

a Always replace:
- the steering wheel nut,
- the steering wheel nut and bolt,
- the universal joint cam nut and bolt.

CONCERNED
a Refit:
131510
- the intermediate shaft,
- the bolt. a Observe the direction of fitting for the universal joint
cam nut and bolt.
a Torque tighten the bolt connecting the steering
column to the intermediate shaft (31 N.m).
a Connect the connector.
131511

132754 tion.
a Refit: a Fit the universal joint.

- the steering column,
a Refit the universal joint new bolt and cam nut.
- the steering column bolts and nuts.
a Position the universal joint cam nut and bolt.
Note: a Lock the cam nut in its housing (on the universal
Check that the steering column is held on the joint).
cross member using the front and rear retainers
(9) before tightening it. a Pretighten the universal joint bolt.
a Torque tighten the steering column nuts and bolts a Tighten to torque the universal joint bolt on the
(17 N.m). steering box (39 N.m).
36A-19
STEERING ASSEMBLY
LEFT-HAND DRIVE
a Refit:
bution duct: Removal - Refitting) (61A, Heating
system).
equipment),
Refitting) (84A, Controls - Signals),
- the lower cover,
- the upper cover,
lite: Removal - Refitting) ,
- the half shell,
- the bolts,
- the steering wheel (see 36A, Steering assembly,
Steering wheel: Removal - Refitting, page 36A-
39) ,
- the driver's front airbag (see Driver's front airbag:
Removal - Refitting) (88C, Airbags and seat belt
pretensioners).
a Configure the steering wheel angle sensor (see
Fault finding - Configurations and programming
(38C, Anti-lock braking system).
36A-20
STEERING ASSEMBLY
RIGHT-HAND DRIVE
Tightening torquesm
bolt connecting the 31 N.m Note:

steering column to the
If the airbag has been triggered, the steering
intermediate shaft
column must be replaced.
steering column nuts 17 N.m
and bolts
a Remove:
the steering box - the driver's front airbag (see Driver's front airbag:
ners),
IMPORTANT - the steering wheel (see 36A, Steering assembly,

Consult the safety and cleanliness advice and ope- Steering wheel: Removal - Refitting, page 36A-
ration recommendations before carrying out any 39) .
IMPORTANT
IMPORTANT
Never handle the pyrotechnic systems (pretensio-
flame - they may be triggered.
REMOVAL
a Unlock the steering column. a Remove:

- the bolts (1) ,
IMPORTANT - the half shell (2) ,
To avoid any risk of triggering when working on - the radio control satellite (see Radio control satel-
or near a pyrotechnic component (airbags or pre- lite: Removal - Refitting) .
diagnostic tool.
the instrument panel lights up continuously (igni-
tion on).
36A-21
STEERING ASSEMBLY
RIGHT-HAND DRIVE
132730
a Remove:
- the upper half shell,
- the upper half shell, 131507

a Remove the universal joint cover (6) (do not keep).
Refitting) ,


equipment),

bution duct: Removal - Refitting) .

131508
CONCERNED
a Remove:
- the universal joint nut (do not keep).
131506
36A-22
STEERING ASSEMBLY
RIGHT-HAND DRIVE
132734 132726
a Remove the steering column bolts and nuts (8) from a Disconnect the connectors (10) .
the cross member.
a Remove:
Note: - the steering column,
The column cannot be set down directly on the
floor since the cable is not long enough. - the bolt (11) ,
- the intermediate shaft.
REFITTING
a Always replace:
- the steering wheel nut,
- the steering column nut and bolt,
- the universal joint cam nut and bolt.

CONCERNED
a Refit:
132735 - the intermediate shaft,

a Remove the steering column from the retainers (9) . - the bolt.
a Torque tighten the bolt connecting the steering

column to the intermediate shaft (31 N.m).
a Connect the connectors.
36A-23
STEERING ASSEMBLY
RIGHT-HAND DRIVE
132736
a Refit:
- the steering column,
- the steering column nuts and bolts.
131511
Note: a Check that the universal joint is in the correct posi-
Check that the steering column is held on the tion.
cross member using the front and rear retainers a Fit the universal joint.
(9) before tightening it.
a Refit the universal joint new bolt and cam nut.
a Torque tighten the steering column nuts and bolts
(17 N.m). a Position the universal joint cam nut and bolt.
a Lock the cam nut in its housing (on the universal
joint).
a Pretighten the universal joint bolt.

a Refit:
bution duct: Removal - Refitting) (61A, Heating
131510
system).
a Observe the direction of fitting for the universal joint - the dashboard lower cover on the driver's side (see
cam nut and bolt. Dashboard: Removal - Refitting) (57A, Interior
equipment),

Refitting) (84A, Controls - Signals),
- the lower cover,
- the upper cover,
36A-24
STEERING ASSEMBLY
RIGHT-HAND DRIVE
lite: Removal - Refitting) ,
- the half shell,
- the bolts,
39) ,
Removal - Refitting) (88C, Airbags and seat belt
pretensioners).
Fault finding - Configurations and programming
36A-25
STEERING ASSEMBLY
Steering rack gaiter: Removal - Refitting 36A
REMOVAL - the large gaiter retaining clip (2) .
a Remove the gaiter (3) .
a Position the vehicle on a two-post lift (see Vehicle: REFITTING
a Remove: I - REFITTING PREPARATION OPERATION
- the front wheel (see 35A, Wheels and tyres, a Always replace the steering box gaiter.
Wheel: Removal - Refitting, page 35A-1) , a Coat the bearing face of the gaiter on the axial ball
- the track rod, (see 3 6 A, Steering assembly, joint with grease to prevent the gaiter from twisting.
- the wheel alignment adjustment lock nut. Note:
During this operation, the steering box must be in
II - OPERATION FOR REMOVAL OF PART place on the vehicle.
CONCERNED
Note:
Take care not to deform the gaiter: risk of irrever-
sible damage.

CONCERNED
a Refit:
- the gaiter in its original position,
- the gaiter retaining clips.

a Refit:
- the wheel alignment adjustment lock nut,
131483
- the wheel (see 35A, Wheels and tyres, Wheel:
a Check the axle geometry (see Axle assemblies:
Check) .
a If necessary, adjust the axle assemblies' geometry
(see 30A, General information, Front axle: Adjus-
131484
a Cut:
- the small gaiter retaining clip (1) ,
36A-26
STEERING ASSEMBLY
Bulkhead seal: Removal - Refitting 36A
LEFT-HAND DRIVE
Tightening torquesm

the steering box
REMOVAL

131515
a Remove the universal joint cover (2) (do not keep).
131514
a Remove the cover (1) from the steering column.
131516
a Remove:
36A-27
STEERING ASSEMBLY
LEFT-HAND DRIVE
CONCERNED
131505
a Remove the bulkhead seal.

131517
REFITTING
a Always refit the universal joint bolt and cam nut.

CONCERNED
a Refit the bulkhead seal.
131504
a Unclip the bulkhead seal (5) at (4) using a flat-blade
screwdriver.
131510

cam nut and bolt.
36A-28
STEERING ASSEMBLY
LEFT-HAND DRIVE
131511
tion.
a Refit:
- the new universal joint nut.
a Refit the steering column cover.
36A-29
STEERING ASSEMBLY
RIGHT-HAND DRIVE
Tightening torquesm

the steering box
REMOVAL

131508
a Remove:
- the universal joint bolt (3) (do not keep).
131506
a Remove the cover (1) from the steering column.
131507
keep).
36A-30
STEERING ASSEMBLY
RIGHT-HAND DRIVE
CONCERNED
131513
a Remove the bulkhead seal.
131509
REFITTING

a Always replace the universal joint bolt and cam nut.

CONCERNED
a Refit the bulkhead seal.
131512
a Unclip the bulkhead seal (5) at (4) using a flat-blade
screwdriver.
131510
cam nut and bolt.
36A-31
STEERING ASSEMBLY
RIGHT-HAND DRIVE
131511
tion.
a Refit:
- the new universal joint nut.
a Refit the steering column cover.
36A-32
STEERING ASSEMBLY
Intermediate shaft: Removal - Refitting 36A
RIGHT-HAND DRIVE
CONCERNED
Tightening torquesm
bolt connecting the 31 N.m

intermediate shaft

the steering box
REMOVAL

a Disconnect the battery (see Battery: Removal - Re-
fitting) (80A, Battery).
a Remove:
- the dashboard lower cover (see Dashboard: Re-
moval - Refitting) (57A, Interior equipment),
- the A-pillar air distribution duct (see A-pillar air
distribution duct: Removal - Refitting) (61A, 131507
Heating system), a Remove the cover (2) from the universal joint (do not
keep).
131506
131508
a Remove:
- the universal joint nut,
36A-33
STEERING ASSEMBLY
RIGHT-HAND DRIVE
131510

cam nut and bolt.
a Refit:
132746 - the universal joint,
a Remove:
- the bolt (4) connecting the steering column to the
- the cam nut from the universal joint.
intermediate shaft,
- the intermediate shaft (5) .
REFITTING
a Always replace the universal joint bolt.

CONCERNED
a Place the intermediate shaft in its initial position.
Note:
Take care not to separate the two sliding parts of
the intermediate shaft.
131511
Note: a Check that the universal joint is in the correct posi-

tion.
On a new intermediate shaft, the universal joint
cam nut is prefitted; do not remove the cover. a Torque tighten:
a Refit: - the bolt connecting the steering column to the

intermediate shaft (31 N.m),
- the bolt from the universal joint,
- the universal joint bolt on the steering box (39
- the intermediate shaft on the steering column. N.m).
36A-34
STEERING ASSEMBLY
RIGHT-HAND DRIVE
a Refit:
- the steering column cover,
distribution duct: Removal - Refitting) (61A,
Heating system),
moval - Refitting) (57A, Interior equipment).
36A-35
STEERING ASSEMBLY
LEFT-HAND DRIVE
Tightening torquesm
bolt connecting the 31 N.m

intermediate shaft

the steering box
REMOVAL

a Disconnect the battery (see Battery: Removal - Re-
a Remove:
131515
- the A-pillar air distribution duct (see A-pillar air a Remove the universal joint cover (2) (do not keep).
Heating system). a Set the wheels straight ahead.

CONCERNED
131516
a Remove:
131514
36A-36
STEERING ASSEMBLY
LEFT-HAND DRIVE
131510

cam nut and bolt.
132740
a Remove:
- the bolt (4) connecting the steering column to the

intermediate shaft,
- the intermediate shaft.
REFITTING
a Always replace the universal joint bolt and nut after

each removal.

CONCERNED
131511
a Place the intermediate shaft in its initial position.
tion.
Note:
a Refit:
Take care not to separate the two sliding parts of
the intermediate shaft. - the universal joint,

Note:
On a new intermediate shaft, the universal joint
cam nut is prefitted; do not remove the cover. a Torque tighten:
a Refit: - the bolt connecting the steering column to the

intermediate shaft (31 N.m),
- the intermediate shaft (5) on the steering column,
- the universal joint bolt on the steering box (39
- the bolt from the universal joint. N.m).
36A-37
STEERING ASSEMBLY
LEFT-HAND DRIVE
a Refit:
- the steering column cover,
Heating system),
36A-38
STEERING ASSEMBLY
Steering wheel: Removal - Refitting 36A
CONCERNED
Tightening torquesm
steering wheel nut 34 N.m
IMPORTANT
IMPORTANT
To avoid any risk of triggering when working on or
near a pyrotechnic component (airbags or preten-
sioners), lock the airbag computer using the dia-
gnostic tool.
When this function is activated, all the trigger lines
are inhibited and the airbag warning light on the ins-
trument panel lights up continuously (ignition on).
132747
a Remove:
IMPORTANT - the steering wheel nut (1) ,
Never handle the pyrotechnic systems (pretensio- - the steering wheel.
REFITTING
IMPORTANT I - REFITTING PREPARATION OPERATION

To prevent the pyrotechnic components from being a Always replace the steering wheel nut.
REMOVAL

a Remove the driver's front airbag (see Driver's front
airbag: Removal - Refitting) (88C, Airbags and
pretensioners).
36A-39
STEERING ASSEMBLY
Steering wheel: Removal - Refitting 36A
II - REFITTING OPERATION FOR PART a Torque tighten the steering wheel nut (34 N.m).
CONCERNED
a Refit the driver's front airbag (see Driver's front air-
bag: Removal - Refitting) (MR 415, 88C, Airbags
and pretensioners).
Configurations and Programming (38C, Anti-lock
braking system).
132748
132749
Note:
When refitting the steering wheel, align the (2) of
the rotary switch with the opening (3) in the stee-
ring wheel.
a Pass the wiring connectors through the opening in

the steering wheel.
a Move the steering wheel to its original position.
a Refit the new steering wheel nut.
36A-40
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting 37A
LEFT-HAND DRIVE
Tightening torquesm M9R
master cylinder nuts 18 N.m

the master cylinder
WARNING
REMOVAL

131242
a Disconnect the connector (1) from the turbocharging
pressure regulation solenoid valve.
a Unclip:
- the turbocharging pressure regulation solenoid val-
ve (2) from its support,
- the hoses of the turbocharging pressure regulation
solenoid valve from the battery tray (3) .
a Remove:
- the battery (see Battery : Removal - Refitting)
(80A, Battery),
- the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
- the air outlet pipe (4) from the air filter unit.
a Remove partially the bulkhead insulation (see Bulk-
head insulating material: Removal - Refitting)
(68A, Soundproofing).
37A-1
LEFT-HAND DRIVE
CONCERNED
131245
a Remove:
131243
- the brake pipe unions (7) on the master cylinder af-
a Disconnect the brake fluid level sensor connector (5)
ter having marked them,
.
- the master cylinder nuts (8) on the brake servo,
a Drain the brake fluid reservoir with a syringe.
- the master cylinder with the brake fluid reservoir (9)
.
6 SPEED MANUAL GBOX
REFITTING
131244
a Disconnect the clutch master cylinder supply hose
(6) from the brake fluid reservoir.
131246
a Always replace the master cylinder seal (10) .
a Coat the seal and the shaft (11) of the master cylin-
der with SILICONE grease (see Vehicle: Parts and
ingredients for the repairwork) (04B, Consuma-
bles - Products).
37A-2
LEFT-HAND DRIVE
II - REFITTING OPERATION FOR PART a Fill up the brake fluid reservoir.
CONCERNED
a Line up the master cylinder with the brake servo so tion, Brake circuit Bleeding, page 30A-3) .
that the pushrod goes into the master cylinder hou-
sing.
6 SPEED MANUAL GBOX
a Refit:
a Bleed the clutch circuit (see 37A, Mechanical com-
- the master cylinder with a new seal, ponent controls, Clutch circuit: Bleeding, page
37A-48) .
- the master cylinder nuts.
a Torque tighten the master cylinder nuts (18 N.m)
on the brake servo.
a Refit the brake pipe unions on the master cylinder.
a Torque tighten the brake pipe unions on the mas-
ter cylinder (16 N.m).
a Connect the connector on the brake fluid reservoir.
6 SPEED MANUAL GBOX

a Connect the clutch master cylinder supply hose on
the brake fluid reservoir.

a Refit:
fing).
- the air filter box air outlet pipe,
(80A, Battery).
M9R
a Clip:
solenoid valve on the battery tray,
ve on its support.
a Connect the turbocharging pressure regulation sole-
noid valve connector.
37A-3
RIGHT-HAND DRIVE
CONCERNED
Tightening torquesm
master cylinder nuts 18 N.m
the brake pipe unions 16 N.m

on the master cylinder
WARNING
REMOVAL

Refitting) (80A, Battery), 131247
a Remove: a Unfasten clips (1) .
- the windscreen wiper arms (see Windscreen wi- a Remove the vacuum pipe (2) from the brake servo.
Washing),
Removal - Refitting) (56A, Exterior accessories),
fing).
131248
a Disconnect the brake fluid level sensor connector (3)
.
a Unclip the clip (4) from the wiring of the brake fluid
reservoir
a Remove the master cylinder brake pipe unions (5) .
37A-4
RIGHT-HAND DRIVE
CONCERNED
6 SPEED MANUAL GBOX
a Line up the master cylinder with the brake servo so
a Disconnect the clutch master cylinder supply hose that the pushrod goes into the master cylinder hou-
(6) from the brake fluid reservoir. sing.
a Refit:
- the master cylinder with a new seal,
- the master cylinder nuts.
a Torque tighten the master cylinder nuts (18 N.m)
on the brake servo.
a Refit the brake pipe unions on the master cylinder.
a Torque tighten the brake pipe unions on the mas-
ter cylinder (16 N.m).
a Connect the brake fluid level sensor connector.
a Clip the wiring clip to the brake fluid reservoir.
6 SPEED MANUAL GBOX

a Connect the clutch master cylinder supply hose on
131249 the brake fluid reservoir.
a Remove:
- the master cylinder nuts (7) ,

a Refit the vacuum pipe on the brake servo.
- the master cylinder with the brake fluid reservoir.
a Tighten the clips.
REFITTING
a Refit:
fing).
Removal - Refitting) (56A, Exterior accessories),
131246
Washing),
a Always replace the master cylinder seal (8) . a Connect the battery (see Battery : Removal - Refit-
a Coat the seal and the master cylinder shaft (9) with
a Fill up the brake fluid reservoir.
SILICONE grease (see Vehicle: Parts and ingre-
dients for the repairwork) (04B, Consumables - a Bleed the brake circuit (see 30A, General informa-
Products). tion, Brake circuit Bleeding, page 30A-3) .
37A-5
RIGHT-HAND DRIVE
6 SPEED MANUAL GBOX

ponent controls, Clutch circuit: Bleeding, page
37A-48) .
37A-6
Brake servo: Removal - Refitting 37A
LEFT-HAND DRIVE
Tightening torquesm M9R
lock nut of the brake 19 N.m

servo pushrod
brake servo bracket nuts 14 N.m
brake servo nut 14 N.m
WARNING
REMOVAL

131242
a Disconnect the turbocharging pressure regulation
solenoid valve connector (1) .
a Unclip:
ve from its support (2) ,
solenoid valve at (3) from the battery tray.
a Remove:
(80A, Battery),
- the air filter box air outlet pipe,
- the brake master cylinder (see 37A, Mechanical
component controls, Master cylinder: Removal
- Refitting, page 37A-1) .
37A-7
LEFT-HAND DRIVE
CONCERNED
131521
a Remove:
- the brake servo nuts (8) ,
- the brake servo.
131519
a Disconnect the hose (5) from the brake servo.
131520
a Remove: 131522
a Remove:
- the brake pedal circlip (6) ,
- the nuts (9) from the brake servo bracket,
- the connector shaft (7) between the brake pedal
and the brake servo pushrod. - the bracket (10) from the brake servo.
37A-8
LEFT-HAND DRIVE
CONCERNED
a Refit:
- the new seal of the brake servo,
- the brake servo bracket,
- the brake servo bracket nuts.
a Torque tighten the brake servo bracket nuts (14

N.m).
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.
131523 a Refit:
- the brake servo on the vehicle,

a Remove the seal (11) from the brake servo.
REFITTING a Torque tighten the brake servo nut (14 N.m).
a Refit:
I - REFITTING PREPARATION OPERATION - the connector shaft (7) between the brake pedal
and the brake servo pushrod,
a Always replace the brake servo seal.
- the brake pedal circlip (6) .
AIR CON 01
a Connect the vacuum pipe on the brake servo.
a Refit:

131524 - Refitting, page 37A-1) ,
a Undo the lock nut (12) of the brake servo pushrod. - the air filter box air outlet pipe,
a Check that dimension L is between 150.7 and 157.7
mm.
a If dimension L is not correct, adjust the pushrod. fitting) (12A, Fuel mixture),
a Torque tighten the lock nut of the brake servo - the battery tray (see Battery tray: Removal - Re-
pushrod (19 N.m) fitting) (80A, Battery).
37A-9
LEFT-HAND DRIVE
M9R
a Clip:
solenoid valve on the battery tray,
ve on its support.
a Connect the turbocharging pressure regulation sole-
noid valve connector.
a Refit the battery (see Battery : Removal - Refit-

6 SPEED MANUAL GBOX

37A-48) .
37A-10
- the master cylinder (see 37A, Mechanical compo-
nent controls, Master cylinder: Removal - Refit-
Essential equipment
ting, page 37A-1) (37A, Mechanical component
refrigerant charging station controls),
- the air inlet sleeve (see Air filter unit: Removal -

Tightening torquesm Refitting) (Fuel mixture),
lock nut of the brake 19 N.m - the air filter box (see Air filter unit: Removal - Re-
servo pushrod fitting) (Fuel mixture),
brake servo nuts 14 N.m - the brake pipes between the hydraulic unit and the
electrical wiring bracket 10 N.m master cylinder (see 31A, Front axle compo-
bolts of the exhaust gas nents, Hydraulic unit - master cylinder brake pi-
pressure sensor pe: Removal - Refitting, page 31A-16) .
lifting eye bolts 25 N.m

AIR CON 01 or AIR CON 02
WARNING
REMOVAL

a Drain the refrigerant fluid circuit using the refrige-

rant charging station (see Coolant circuit Drai-
ning - Refilling) (62A, Air conditioning).
a Remove:
- the engine cover, 131525

a Remove the connecting pipe (1) (see Condenser -
Washing), compressor connecting pipe: Removal - Refit-
ting) .
- the scuttle half-grille (see Scuttle panel grille: Re-
(85A, Wiping - Washing). a Remove:
- the scoop under the scuttle panel grille (see Scoop - the heat shield from the turbocharger (see Turbo-
under scuttle panel grille: Removal - Refitting) charger: Removal - Refitting) (12B, Turbochar-
ging),
material: Removal - Refitting) (68A, Soundproo- - the oxygen sensor (see Oxygen sensor: Removal
fing), - Refitting) (13B, Diesel injection).
37A-11
CONCERNED
131520
a Remove:
131526
a Disconnect the exhaust gas pressure sensor con- and the brake servo pushrod.
nector (2) .
a Remove:
- the pipe (3) of the exhaust gas pressure sensor

from the lifting eye (see Turbocharger: Removal -
Refitting) (12B, Turbocharging),
- the lifting eye (4) ,
- the bolt (5) from the wiring bracket.
a Move aside the electrical wiring with the bracket.
6 SPEED MANUAL GBOX
a Remove the clutch master cylinder (see 37A, Me-

chanical component controls, Clutch master cy-
linder: Removal - Refitting, page 37A-55) .
131528
a Disconnect:
- the connector (8) from the brake light switch,
a Remove:
- the accelerator position sensor connector (9) .
Dashboard: Removal - Refitting) (57A, Interior AIR CON 01
equipment),
a Disconnect the connector (10) from the brake
switch.
Heating system).
37A-12
REFITTING

a Always replace the brake servo seal.
a Check the condition of the connecting shaft and re-
place it if it is damaged.
131529
a Remove:
131524
a Loosen the lock nut of the brake servo pushrod.
- the brake servo.
a Check that dimension L is between 150.7 and 157.7
mm.
a If dimension L is not correct, adjust the pushrod.
a Torque tighten the lock nut of the brake servo
pushrod (19 N.m).

CONCERNED
a
Note:
Refit:
- the brake servo with a new seal,
- the brake servo nuts.
a Torque tighten the brake servo nuts (14 N.m).
131530
a Refit:
a Remove the seal (12) from the brake servo.
- the connecting shaft between the brake pedal and
the brake servo pushrod,
- the brake pedal circlip.
a Connect:
- the brake light switch connector,
- the accelerator position sensor connector.
37A-13
AIR CON 01 AIR CON 01 or AIR CON 02
a Connect the brake switch connector. a Refit the expansion valve connecting pipe (see Ex-
pansion valve: Removal - Refitting) (62A, Air con-
ditioning).
III - FINAL OPERATION. a Refit:
a Refit: - the brake pipes between the hydraulic unit and the
master cylinder (see 31A, Front axle compo-
- the A-pillar air distribution duct (see A-pillar air nents, Hydraulic unit - master cylinder brake pi-
distribution duct: Removal - Refitting) (61A, pe: Removal - Refitting, page 31A-16) ,
Heating system),
- the dashboard lower cover on the driver's side (see fitting) (12A, Fuel mixture),
- the air inlet sleeve (see Air filter unit: Removal -
equipment).
Refitting) (12A, Fuel mixture),

6 SPEED MANUAL GBOX component controls, Master cylinder: Removal
- Refitting, page 37A-1) ,
a Refit the clutch master cylinder (see 37A, Mechani-
cal component controls, Clutch master cylinder: - the bulkhead insulation (see Bulkhead insulating
Removal - Refitting, page 37A-55) . material: Removal - Refitting) (68A, Soundproo-
fing),

a Refit: (56A, Exterior equipment),

- the wiring bracket bolts, creen wiper mechanism: Removal - Refitting)
(85A, Wiping - Washing).
- the lifting eye.
a Torque tighten: moval - Refitting) (56A, Exterior equipment),
- the electrical wiring bracket bolts of the ex- - the windscreen wiper arms (see Windscreen wi-
haust gas pressure sensor (10 N.m), per arm: Removal - Refitting) (85A, Wiping -
Washing),
- the lifting eye bolts (25 N.m).
- the engine cover.
a Refit the exhaust gas pressure sensor pipe on the lif-
ting eye (see Turbocharger: Removal - Refitting)
(12B, Turbocharging). ting) (80A, Battery).
a Connect the exhaust gas pressure sensor connec-

tor. AIR CON 01 or AIR CON 02

a Refit: ging station (see Coolant circuit Draining - Refil-
ling) (62A, Air conditioning).
- the oxygen sensor (see Oxygen sensor: Removal
- Refitting) (13B, Diesel injection),
- the heat shield on the turbocharger (see Turbo-

charger: Removal - Refitting) (12B, Turbochar- a Bleed the brake circuit (see 30A, General informa-
ging). tion, Brake circuit Bleeding, page 30A-3) .
37A-14
6 SPEED MANUAL GBOX

37A-48) .
37A-15
Essential equipment 6 SPEED MANUAL GBOX
refrigerant charging station a Remove the supply hose from the clutch master cy-
linder (see 37A, Mechanical component controls,
Clutch master cylinder: Removal - Refitting,
page 37A-55) .
Tightening torquesm
lock nut of the brake 19 N.m

servo pushrod
a Remove:
brake servo nuts 14 N.m - the brake master cylinder (see 37A, Mechanical
- Refitting, page 37A-1) ,
WARNING - the air inlet sleeve (see Air filter unit: Removal -
Prepare for the flow of fluid, and protect the sur- Refitting) (12A, Fuel mixture).
rounding components. - the air filter box (see Air filter unit: Removal - Re-
REMOVAL master cylinder (see 31A, Front axle compo-
pe: Removal - Refitting, page 31A-16) .
a Position the vehicle on a two-post lift (see Vehicle: AIR CON 01 or AIR CON 02
Towing and lifting) (02A, Lifting equipment). a Disconnect the connecting pipes from the expansion
valve (see Expansion valve: Removal - Refitting)
a Drain the refrigerant fluid circuit using the refrige- (62A, Air Conditioning).
rant charging station (see Coolant circuit Drai-
ning - Refilling) (62A, Air conditioning).
a Disconnect the battery (see Battery : Removal - a Remove:

Refitting) (80A, Battery). - the upper engine tie-bar (see Right-hand suspen-
ded engine mounting: Removal - Refitting)
a Remove: (19D, Engine mounting),
- the windscreen wiper arms (see Windscreen wi- - the dashboard lower cover on the driver's side (see
per arm: Removal - Refitting) (85A, Wiping - Dashboard: Removal - Refitting) (57A, Interior
equipment),
Washing),
- the scuttle half-grille (see Scuttle panel grille: Re- distribution duct: Removal - Refitting) (61A,
moval - Refitting) (56A, Exterior equipment), Heating system).


- the bulkhead insulation, partially (see Bulkhead

insulating material: Removal - Refitting) (68A,
Soundproofing).
37A-16
CONCERNED
131520
a Remove:
131529
- the connector shaft (2) between the brake pedal a Remove:
and the brake servo pushrod.
- the brake servo.
131528
a Remove:
131530
a Remove the seal (7) from the brake servo
- the accelerator position sensor connector (4) .
AIR CON 01
a Disconnect the connector (5) from the brake switch.
37A-17
REFITTING III - FINAL OPERATION.
a Refit:
a Always replace the brake servo seal. distribution duct: Removal - Refitting) (61A,
a Check the condition of the connecting shaft and re- Heating system),
place it if it is damaged. - the dashboard lower cover on the driver's side (see
equipment),
- the upper engine tie-bar (see Right-hand suspen-

ded engine mounting: Removal - Refitting)
(19D, Engine mounting).
a Connect the expansion valve connector pipes (see

Expansion valve: Removal - Refitting) (62A, Air
Conditioning).
131531
a Loosen the lock nut of the brake servo pushrod. a Refit:
a Check that dimension L is between 150.7 and 157.7 - the brake pipes between the hydraulic unit and the
mm. master cylinder (see 31A, Front axle compo-
a If dimension L is not correct, adjust the pushrod. pe: Removal - Refitting, page 31A-16) ,
a Torque tighten the lock nut of the brake servo
pushrod (19 N.m)
II - REFITTING OPERATION FOR PART - the air inlet sleeve (see Air filter unit: Removal -
CONCERNED Refitting) (12A, Fuel mixture),
a Refit: - the brake master cylinder (see 37A, Mechanical

- the brake servo with a new seal,
- the brake servo nuts.
a Torque tighten the brake servo nuts (14 N.m). 6 SPEED MANUAL GBOX
a Refit:
a Refit the supply hose on the clutch master cylinder
- the connecting shaft between the brake pedal and (see 37A, Mechanical component controls,
the brake servo pushrod, Clutch master cylinder: Removal - Refitting,
page 37A-55) .
a Connect:
- the accelerator position sensor connector,
a Refit:
- the brake light switch connector.
AIR CON 01
Soundproofing),
a Connect the brake switch connector.
37A-18
Washing).

ging station (see Coolant circuit Draining - Refil-
ling) (62A, Air conditioning).

6 SPEED MANUAL GBOX

37A-48) .
37A-19
Vacuum pump: Removal - Refitting 37A
M9R
Tightening torquesm
vacuum pump bolts 15 N.m
IMPORTANT
repair work (see Diesel injection: Precautions for
repair) (13B, Diesel injection).
IMPORTANT
During this operation, be sure to:

- refrain from smoking or bringing red hot objects
close to the working area,
- be careful of fuel splashes when disconnecting the 130263
union. a Disconnect:
- the vacuum pipe at (1) from the non-return valve,
- the vacuum pipe (2) from the non-return valve,
WARNING
To avoid any corrosion or damage, protect the - the vacuum pipe (3) from the EGR cooler bypass
areas on which fuel is likely to run. solenoid valve.
REMOVAL

a Remove:
- the engine cover,
(80A, Battery).
37A-20
M9R
- the vacuum pump.
REFITTING
a Be sure to replace the vacuum pump seal.
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.

CONCERNED
130335
a Disconnect: a Refit:
- the quick-release union (4) from the high pressure - the vacuum pump new seal,
pump diesel supply pipe,
- the quick-release union (5) from the diesel return - the vacuum pump,
pipe on the high pressure pump. - the vacuum pump bolts.
a Put blanking plugs in the openings.

CONCERNED
130337
a Torque tighten in order the vacuum pump bolts (15

N.m).
130336
a Remove: III - FINAL OPERATION.
- the vacuum pump bolts (6) , a Remove the blanking plugs from the openings.
37A-21
M9R
a Connect:
- the diesel return pipe quick release union to the
high pressure pump,
- the diesel supply pipe quick-release union to the
high pressure pump,
- the vacuum pipe on the EGR cooler by-pass sole-
noid valve,
- the vacuum pipe on the non-return valve,
- the non-return valve vacuum pipe on the brake ser-
vo.
a Refit:
(80A, Battery)
- the engine cover.
a Prime the diesel circuit using the manual priming
pump (see Manual priming pump: Removal - Re-
fitting) .
37A-22
Accelerator/brake pedal assembly: Removal - Refitting 37A
LEFT-HAND DRIVE
CONCERNED
Tightening torquesm
nuts of the brake-acce- 14 N.m

lerator pedal assembly
brake pedal protector 10 N.m

bolts
REMOVAL

a Remove:
equipment),
Heating system),
- the left-hand trim on the centre panel (see Centre 131142
front panel: Removal - Refitting) (57A, Interior a Remove:
equipment).
- the connector (2) from the mode flap motor,
- the connector (3) from the accelerator pedal posi-
tion sensor.
a Remove the mode flap motor (4) .
CRUISE CONTROL
131139
a Remove:
37A-23
LEFT-HAND DRIVE
- the connector shaft (7) between the brake pedal REFITTING


CONCERNED
a Refit:
- the brake pedal switch on the brake-accelerator
pedal assembly (see 37A, Mechanical compo-
nent controls, Brake pedal switch: Removal -
- the brake - accelerator pedal assembly,
- the nuts on the brake-accelerator pedal assembly.
a Torque tighten the nuts of the brake-accelerator
pedal assembly (14 N.m).
a Refit:
131143 - the brake pedal protector,
a Remove: - the brake pedal protector bolts.

a Torque tighten the brake pedal protector bolts (10
- the brake pedal protector bolts (8) , N.m).
- the brake pedal protector. a
IMPORTANT
downwards.
Refit:
- the brake pedal circlip,
- the mode flap motor.
a Connect:
131144
- the connector on the accelerator pedal position
a Remove: sensor,
- the connector on the mode flap motor,
- the nuts (9) from the brake - accelerator pedal as-
sembly, - the brake light switch connector.
- the brake - accelerator pedal assembly,

CRUISE CONTROL
- the brake pedal switch from the brake-accelerator a Connect the brake switch connector.
pedal assembly (see 37A, Mechanical compo-
Refitting, page 37A-34) .
37A-24
LEFT-HAND DRIVE
a Refit:
- the left-hand trim on the centre panel (see Centre
front panel: Removal - Refitting) (57A, Interior
equipment),
Heating system),
- the lower cover of the dashboard on the driver's
side (see Dashboard: Removal - Refitting) (57A,
Interior equipment).
37A-25
RIGHT-HAND DRIVE
Tightening torquesm
brake-accelerator pedal 14 N.m

assembly nuts
REMOVAL

IMPORTANT
To avoid any risk of triggering when working on
or near a pyrotechnic component (airbags or pre-
diagnostic tool.
the instrument panel lights up continuously (igni- 131140
tion on). a Disconnect:
a Disconnect the battery (see Battery: Removal - Re- - the connector (3) from the brake light switch,
fitting) (80A, Battery). - the position sensor connector (4) from the accele-
a Remove: rator pedal.
- the dashboard (see Dashboard: Removal - Refit-

ting) (57A, Interior equipment). CRUISE CONTROL
- the dashboard cross member (see Dashboard a Disconnect the brake switch connector (5) .
cross member: Removal - Refitting) (42A, Upper
front structure).
a Remove the brake pedal switch from the brake-ac-

celerator pedal assembly (see 37A, Mechanical
CONCERNED
component controls, Brake pedal switch: Remo-
a Unclip the electrical wiring from the brake-accelera-
tor pedal assembly.
131139
a Remove:
37A-26
RIGHT-HAND DRIVE
CRUISE CONTROL
a Connect the brake switch connector.
a Clip the electrical wiring on the brake-accelerator

pedal assembly.
IMPORTANT
downwards.
a Refit:
131141
- the brake pedal circlip,
a Remove:
- the nuts (6) from the brake-accelerator pedal as- III - FINAL OPERATION.
sembly,
a Refit:
- the brake-accelerator pedal assembly.
- the dashboard cross member (see Dashboard
REFITTING front structure).
ting) (57A, Interior equipment).


CONCERNED
a Refit:
- the brake-accelerator pedal assembly,
a Torque tighten the brake-accelerator pedal as-

sembly nuts (14 N.m).
a Refit the brake pedal switch on the brake-accelera-

tor pedal assembly (see 37A, Mechanical compo-
Refitting, page 37A-34)
a Connect:
37A-27
Accelerator pedal: Removal - Refitting 37A
LEFT-HAND DRIVE
Tightening torquesm
accelerator pedal nuts 5 N.m
REMOVAL

a Remove:
- the dashboard lower trim on the driver's side (see
Front air distribution duct: Removal - Refitting)
(61A, Heating system),
console lower fascia: Removal - Refitting) (57A,
131147
II - OPERATION FOR REMOVAL OF PART a Remove:

CONCERNED - the accelerator pedal nuts (2) ,
- the accelerator pedal from the brake-accelerator
pedal assembly.
REFITTING

CONCERNED
a Refit:
- the accelerator pedal on the brake-accelerator pe-
dal assembly.
- the accelerator pedal nuts.
a Torque tighten the accelerator pedal nuts (5 N.m).

a Connect the accelerator pedal position sensor con-
nector.
131149 II - FINAL OPERATION.

a Disconnect the accelerator pedal position sensor a Refit:
connector (1) .
Interior equipment),
- the dashboard lower trim on the driver's side (see
Front air distribution duct: Removal - Refitting)
(61A, Heating System),
37A-28
RIGHT-HAND DRIVE
Tightening torquesm
brake-accelerator pedal 14 N.m

assembly nuts
REMOVAL


a Remove: 131146
a Disconnect:
Dashboard: Removal - Refitting) (57A, Interior - the brake light switch connector (3) ,
equipment),
- the accelerator pedal sensor connector (4) .
- the A-pillar air distribution duct (see Front air dis-
tribution duct: Removal - Refitting) (61A, Hea- CRUISE CONTROL
ting system).

CONCERNED
131145
a Remove:

131147
and the brake servo pushrod. a Remove the accelerator pedal nuts (6) .
37A-29
RIGHT-HAND DRIVE
a Connect:
CRUISE CONTROL
a Connect the accelerator pedal position sensor con-
nector.
a Refit:
- the A-pillar air distribution duct (see Front air dis-
tribution duct: Removal - Refitting) (61A, Hea-
ting system),
131148 Dashboard: Removal - Refitting) (57A, Interior
equipment),
a Remove:
- the nuts (7) from the brake-accelerator pedal as- ting) (80A, Battery).
sembly,

pedal assembly.
Note:
It is not necessary to remove the brake-accelera-
tor pedal assembly.
REFITTING

CONCERNED
a Refit:
dal assembly,
a Torque tighten the brake-accelerator pedal as-
sembly nuts (14 N.m).
a Refit the accelerator pedal nuts.

a Refit:
37A-30
Brake pedal: Removal - Refitting 37A
LEFT-HAND DRIVE
- the accelerator pedal of the brake-accelerator pe-
dal assembly,
Tightening torquesm
- the brake pedal.
REFITTING
REMOVAL
CONCERNED
a Refit:
Towing and lifting) (02A, Lifting equipment). - the brake pedal,
a Remove: - the accelerator pedal on the brake-accelerator pe-

dal assembly,
Dashboard: Removal - Refitting) (57A, Interior - the accelerator pedal nuts.
equipment), a Torque tighten the accelerator pedal nuts (5 N.m).
- the A pillar air distribution duct (see A-pillar air
distribution duct: Removal - Refitting) ,(61A, II - FINAL OPERATION.
Heating),
a Refit:
console lower fascia: Removal - Refitting) (57A, - the brake - accelerator pedal assembly (see 37A,
Mechanical component controls, Accelerator/
brake pedal assembly: Removal - Refitting,
- the brake - accelerator pedal assembly (see 37A, page 37A-23) ,
page 37A-23) .
distribution duct: Removal - Refitting) ,(61A,
CONCERNED
Heating),
equipment).
131147
a Remove:
- the accelerator pedal nuts (1) ,
37A-31
RIGHT-HAND DRIVE
CONCERNED
Tightening torquesm
REMOVAL

IMPORTANT
To prevent the pyrotechnic components from
being permanently deactivated or triggered (air-
bags or pretensioners), wait for at least 3 minu-
tes after disconnecting the battery.

a Remove: 131147
- the dashboard (see Dashboard: Removal - Refit- a Remove:

ting) (57A, Interior equipment), - the accelerator pedal nuts (1) ,
pedal assembly,
front structure),
- the brake pedal.
- the brake - accelerator pedal assembly (see 37A,
brake pedal assembly: Removal - Refitting, REFITTING
page 37A-23) .

CONCERNED
a Refit:
- the brake pedal,
dal assembly,
- the accelerator pedal nuts.
a Refit:
page 37A-23) .
front structure),
37A-32
RIGHT-HAND DRIVE
ting) (57A, Interior equipment).
37A-33
Brake pedal switch: Removal - Refitting 37A
REMOVAL II - OPERATION FOR REMOVAL OF PART
CONCERNED

CRUISE CONTROL
a Remove:
equipment),
Heating).
LEFT-HAND DRIVE
a
page 37A-23) . 131250
a Remove:
- the brake light switch (1) by rotating it a quarter turn
anticlockwise,
- the brake switch (2) by rotating it a quarter turn an-
ticlockwise.
37A-34
REFITTING
WITHOUT CRUISE CONTROL
CONCERNED
131252
a Position the brake pedal switches.
131251 a Press on the brake pedal switches (4) until the end
a Remove the brake light switch (3) by rotating it a of the piston touches the rubber stop (5) .
quarter turn anticlockwise.
a Rotate the brake pedal switches a quarter of a turn
clockwise.
a Measure the dimension (A) between the rubber stop

and the end of the piston.
a Adjust the dimension (A) between 0.74 mm and

1.96 mm.
LEFT-HAND DRIVE
a Refit:

page 37A-23) ,


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.
37A-35
a Refit:
Heating),
equipment).
37A-36
Parking brake lever: Removal - Refitting 37A
REFITTING
Tightening torquesm
parking brake lever nuts 14 N.m CONCERNED
a Refit:
REMOVAL - the parking brake lever,

- the parking brake lever nuts.
I - REMOVAL PREPARATION OPERATION a Torque tighten the parking brake lever nuts (14
N.m).
a Position the vehicle on a two-post lift (see Vehicle: a Connect:
- the parking brake switch connector,
a Remove the centre console (see Centre console:
- the parking brake cable to the parking brake com-
Removal - Refitting) (MR 416, 57A, Interior equip-
pensator.
ment).
a Refit the adjustment nut.

CONCERNED
a Adjust the parking brake (see 37A, Mechanical
component controls, Parking brake lever: Adjus-
a Refit the centre console (see Centre console: Re-
moval - Refitting) (MR 416, 57A, Interior equip-
ment).
131253
a Remove the adjustment nut (1) to completely loosen

the parking brake cable.
a Separate the parking brake cable from the parking

brake compensator (2) .
a Disconnect the connector (3) from the parking brake

switch.
a Remove:
- the nuts (4) from the parking brake lever,
- the parking brake lever.
37A-37
Parking brake lever: Adjusting 37A
ADJUSTMENT
a Fit the rear brake disc using the wheel nuts.
a Check:
- that the cables slide freely,
- the travel of the parking brake cables and engage
them fully on the rear internal drum type disc.
131256
a Remove the plug (3) from the rear brake disc adjust-
ment opening.
131254
a Remove the cup holder (1) .
131257
a Turn:
- the adjustment mechanism (4) in the direction of

(A) until it locks.
131255 - the adjustment mechanism 7 notches from the loc-

ked position,
a Raise the parking brake lever until the lock nut (2)
can be accessed. - the rear brake disc to check the absence of trac-
tion.
Note: a Refit the plug on the rear brake disc adjustment ope-
Always replace the lock nut if it was removed. ning.
a Adjust the lock nut in order to loosen the cable com-

pletely. Note:
a Release the parking brake lever. The standard number of notches is 7 or 8.
37A-38
Parking brake lever: Adjusting 37A
a Adjust the parking brake cable.
- activate the parking brake lever with a force of 294
N about ten times minimum,
- adjust the parking brake lever travel by turning the
adjustment nut,
- activate the parking brake lever with a force of 196
N,
- check if the lever travel corresponds to the number
of notches specified,
- turn the rear brake disc with the released parking
brake lever,
- check for the absence of traction.
37A-39
Clutch control: List and location of components 37A
6 SPEED MANUAL GBOX
No. Description
(1) Hydraulic clutch control pipe
(2) Connecting hose (in a unit with the clutch control pipe)
(3) Clutch hydraulic shock absorber
(4) Connecting pipe
(5) Clutch master cylinder
(6) Clutch master cylinder supply hose
LEFT-HAND DRIVE
131485
No. Description
(1) Clutch control pipe
(2) Clutch hydraulic shock absorber
(3) Connecting pipe
37A-40
Clutch control: List and location of components 37A
6 SPEED MANUAL GBOX
No. Description
(4) Clutch master cylinder
(5) Clutch master cylinder supply hose
RIGHT-HAND DRIVE
131486
37A-41
Clutch pedal: Removal - Refitting 37A
LEFT-HAND DRIVE, and 6 SPEED MANUAL GBOX
Tightening torquesm
clutch pedal nuts 14 N.m
REMOVAL

a Remove:
- the dashboard lower cover on the driver's side (see 131537
Lower section of dashboard trim: Removal -
Refitting) (57A, Interior equipment), a Disconnect the connector (2) from the clutch pedal
switch.
Heating system), CRUISE CONTROL
a Disconnect the connector (3) from the clutch pedal
II - OPERATION FOR REMOVAL OF PART switch.
CONCERNED

a Disconnect the position sensor connector (4) from
the clutch pedal.
131532
a Separate the clutch master cylinder ball joint (1)
from the clutch pedal.
37A-42
a Connect the clutch pedal switch connector.
CRUISE CONTROL

a Connect the clutch pedal position sensor connector.
a Place the clutch cylinder ball joint on the clutch pe-

dal.
a Refit:
131534
a Remove:
- the accelerator pedal nuts (5) , Heating system),
- the clutch pedal. - the dashboard lower cover on the driver's side (see
Refitting) (57A, Interior equipment).
a Remove the clutch pedal position sensor from the ting) (80A, Battery).
clutch pedal (see 37A, Mechanical component
controls, Clutch pedal position sensor: Removal
REFITTING

CONCERNED

a Refit the clutch pedal position sensor on the clutch
pedal (see 37A, Mechanical component controls,
Clutch pedal position sensor: Removal - Refit-
a Refit:
- the clutch pedal,
- the clutch pedal nuts.
a Torque tighten the clutch pedal nuts (14 N.m).
37A-43
RIGHT-HAND DRIVE, and 6 SPEED MANUAL GBOX
a Remove:
Tightening torquesm - the driver's front airbag (see Driver's front airbag:
clutch pedal nuts 14 N.m ners),
REMOVAL 39) (36A, Steering assembly),
I - REMOVAL PREPARATION OPERATION lite: Removal - Refitting) (86A, Radio),
a Unlock the steering column. - the rotary switch (see Rotary switch: Removal -
Refitting) (84A, Controls - Signalling),
IMPORTANT - the steering column switch assembly (see Stee-
Never handle the pyrotechnic systems (preten- ring wheel controls assembly: Removal - Refit-
sioners or airbags) near to a source of heat or ting) (84A, Controls - Signalling),
naked flame - they may be triggered. - the dashboard lower cover on the driver's side (see
Dashboard: Removal - Refitting) (61A, Heating
system),
IMPORTANT
bags or pretensioners), wait for at least 3 minu- Heating system),
tes after disconnecting the battery. - the right-hand trim from the centre front panel,
a Disconnect the battery (see Battery : Removal - - the steering column from the dashboard cross
Refitting) (80A, Battery). member (see 36A, Steering assembly, Steering
column: Removal - Refitting, page 36A-16) (36A,
Steering assembly).
Note:
It is not necessary to remove the steering column
from the steering box.
37A-44
CONCERNED
a Disconnect the position sensor connector (4) from
the clutch pedal.
a Unclip the electrical wiring from the clutch.
131536
a Separate the clutch master cylinder ball joint (1)
from the clutch pedal.
131538
a Remove:
- the accelerator pedal nuts (5) ,
- the clutch pedal.

a Remove the position sensor from the clutch pedal
(see 37A, Mechanical component controls,
Clutch pedal position sensor: Removal - Refit-
131533
switch.
CRUISE CONTROL
switch.
37A-45
REFITTING - the rotary switch (see Rotary switch: Removal -

Refitting) (84A, Controls - Signalling),
I - REFITTING OPERATION FOR PART - the radio control satellite (see Radio control satel-
CONCERNED lite: Removal - Refitting) (86A, Radio),
FOOT BRAKE AUTO CONTROL Steering wheel: Removal - Refitting, page 36A-
39) (36A, Steering assembly),
a Refit the clutch pedal position sensor on the clutch
pedal (see 37A, Mechanical component controls, - the driver's front airbag (see Driver's front airbag:
Clutch pedal position sensor: Removal - Refit- Removal - Refitting) (88C, Airbags and pretensio-
ting, page 37A-47) . ners),
a Adjust the neutral position of the steering wheel an-
a Refit: gle sensor (see Fault finding - Configurations and
- the clutch pedal, programming (80C, Xenon bulbs).
- the clutch pedal nuts.
a Torque tighten the clutch pedal nuts (14 N.m).
CRUISE CONTROL

a Connect the clutch pedal position sensor connector.
a Fit the clutch cylinder ball joint on the clutch pedal.
a Refit:
- the steering column on the dashboard cross mem-
ber (see 36A, Steering assembly, Steering colu-
mn: Removal - Refitting, page 36A-16) (36A,
Steering assembly),
- the centre front panel right-hand trim
Heating system).
Dashboard: Removal - Refitting) (61A, Heating
system),
ting) (84A, Controls - Signalling),
37A-46
Clutch pedal position sensor: Removal - Refitting 37A
FOOT BRAKE AUTO CONTROL, and 6 SPEED MANUAL GBOX
a Remove:
Tightening torquesm - the clutch pedal position sensor nuts (2) ,

- the clutch pedal position sensor (3) .
clutch pedal position 8 N.m
sensor nuts
REFITTING
REMOVAL I - REFITTING OPERATION FOR PART

CONCERNED
I - REMOVAL PREPARATION OPERATION a Refit:
a Disconnect the battery (see Battery : Removal - - the clutch pedal position sensor,
- the clutch pedal position sensor nuts.
a Remove:
a Torque tighten the clutch pedal position sensor
- the dashboard lower cover on the driver's side (see nuts (8 N.m).
a Reconnect the clutch pedal position sensor connec-
Refitting) (57A, Interior equipment),
tor.
- the centre front panel side trim.
RIGHT-HAND DRIVE
a Remove the A-pillar air distribution duct (see A- RIGHT-HAND DRIVE
pillar air distribution duct: Removal - Refitting) a Refit the A-pillar air distribution duct (see A-pillar air
(61A, Heating system). distribution duct: Removal - Refitting) (61A, Hea-
ting system).
II - OPERATION FOR REMOVAL OF PART a Refit:

CONCERNED - the centre front panel side trim,
Refitting) (57A, Interior equipment).
131535

position sensor.
37A-47
Clutch circuit: Bleeding 37A
ND5 or ND8
There are two types of equipment used to bleed the
clutch circuit:
Essential equipment
a ARC50 via the brake fluid reservoir.
brake circuit bleeding device
a Syringe via the bleed hole located on the clutch sla-
hydraulic circuit bleed syringe ve cylinder.
Bleed in the event of: There are two procedures used to bleed the clutch
- dead travel, circuit:
- pedal at mid-travel, a If no parts of the clutch hydraulic circuit are remo-

ved:
- pedal to the floor,
- Carry out the bleed operation using the ARC50 via
- poor gear changing. the brake fluid reservoir or using a new syringe via
the bleed hole located on the clutch slave cylinder.
I - PRECAUTIONS DURING REPAIR a If no parts of the clutch hydraulic circuit are remo-
ved:
Risks relating to contamination. - Only carry out the bleed operation using a new sy-
ringe by injecting the brake fluid via the bleed hole
a The hydraulic clutch system is very sensitive to con- on the clutch slave cylinder.
tamination. The risks caused by contamination are:
- impossible to change gears, Note:
- damage to or destruction of the clutch system, - Even the tiniest air bubble in the circuit can
cause faulty operation (pedal failing to return
- leaks on the hydraulic circuit.
properly, crunching sound when changing gear,
All the operations on the hydraulic clutch circuit sys- etc.).
tem must be carried out under excellent cleanliness
- Incorrect bleeding can lead to incorrect detec-
conditions. This ensures that no impurities enter the
tion of faults and unnecessary part replace-
hydraulic circuit during the operation.
ments.
The cleanliness principles apply to all components
of the hydraulic clutch circuit.
Consumables required for the repair:
Items causing contamination are:
a Bleed the clutch circuit using approved (see Vehi-
- metal or plastic swarf, cle: Parts and ingredients for the repairwork)
brake fluid (04B, consumables - products).
- fibres:
• cardboard, II - PREPARATION STAGE
• brushes, a Position the vehicle on a two-post lift (see Vehicle:
• paper, Towing and lifting) (02A, Lifting equipment).
• 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.
37A-48
ND5 or ND8
There are several versions of bleed screw: Bleed screw with a clip.
Screw type bleed screw.
112868
a To open the bleed screw, press and hold the clip (4)
113919 while pulling by one notch.
a To open the bleed screw, hold the plastic union (1)
using a ring spanner and undo the bleed screw (2) . Bleed screw with a clip.
Half-turn bleed screw.
107280
a To open the bleed screw, lift the clip (5) while pulling
114335 by one notch.
a To open the bleed screw, fully turn the bleed screw
(3) by hand.
37A-49
ND5 or ND8
Bleed screw with two clips. 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.
113732
a Refit the bleed plug.
a To open the bleed screw, lower the clip (6) and lift
the clip (7) while pulling by one notch. a Top up the brake fluid level in the master cylinder re-
servoir after disconnecting the bleed device.
III - BLEED PROCEDURE IF NO PARTS OF THE a Disengage and engage the clutch quickly around
HYDRAULIC CIRCUIT ARE REMOVED twenty times.
a Check that the clutch system is operating correctly.
1 - Bleed using the ARC50. a Repeat the bleed operation if necessary.
a Keep the clutch pedal in the upper position using a a Check the adjustment of the switch. (see 37A, Me-
strap attached to the steering wheel to ensure conti- chanical component controls, Clutch pedal
nuity of the hydraulic circuit during the bleed opera- switch: Removal - Refitting, page 37A-61) (37A,
tion. mechanical control elements).
Note:
Take care not to disrupt the adjustment of the
clutch start of travel switch.
37A-50
ND5 or ND8
2 - Bleed using a new syringe. IV - BLEED PROCEDURE IF PARTS OF THE
HYDRAULIC CIRCUIT ARE REMOVED.
a Keep the clutch pedal in the upper position using a
strap attached to the steering wheel to ensure conti- a
nuity of the hydraulic circuit during the bleed opera-
WARNING
tion.
The slave cylinder pipe must be disconnected
from its take-off point on the brake fluid reservoir,
to avoid any foreign matter penetrating inside the
Note:
brake system hydraulic circuit.
WARNING
a Remove the bleed plug from the clutch slave cylin- Prepare for the flow of fluid and protect the sur-
der. rounding components.
a Connect a transparent pipe of sufficient length to the

bleed hole (at least thirty centimeters) in order to pla- Note:
ce it at the same height as the reservoir.
Prefill the hydraulic circuit pipe equipped with a
a Open the bleed screw. filter.
Position the filter head facing downwards to
a Fill the brake fluid master cylinder reservoir until bra-
ensure that it fills.
ke fluid flows out of the bleed screw.
Note:
The transparent pipe must remain at the same
height as the master cylinder reservoir to prevent
air from entering inside the clutch circuit.
a Connect a new hydraulic circuit bleed syringe

filled with a useful volume of 60 ml of approved 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 Top up the brake fluid level in the master cylinder re-

servoir.
a Disengage and engage the clutch quickly around

twenty times.
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-61) (37A,
mechanical control elements).
37A-51
ND5 or ND8
There are several versions of pipe with and without Filling position for pipe with filter.
a filter:
Pipe without filter.
141810
Filling position for pipe with filter.

141812
Filling position for pipe with filter.
141813
a Prefill the clutch pipe using the syringe.
a Plug the prefilled pipe on the clutch slave cylinder
141811 end to stop any brake fluid from escaping.
37A-52
ND5 or ND8
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.
Note:
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.

141809
a Prefill the hydraulic tappet using the new syringe (by a Fill the brake fluid master cylinder reservoir until bra-
gravity). ke fluid flows out of the bleed screw.
a Refit the part(s) concerned.
Note:
The transparent pipe must remain at the same
height as the master cylinder reservoir to prevent
air from entering inside the clutch circuit.
a Connect a new 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 Top up the brake fluid level in the master cylinder re-

servoir.
a Disengage and engage the clutch quickly around

twenty times.
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-61) (37A,
mechanical control elements).
37A-53
ND5 or ND8
VI - FINAL OPERATION
a Remove the vehicle from the two-post lift (see Vehi-
cle: Towing and lifting) (02A, Lifting equipment).
37A-54
Clutch master cylinder: Removal - Refitting 37A
Emb. 1797 24 mm socket for removing
and refitting clutch master
cylinder
WARNING
REMOVAL

Towing and lifting) (02A, Lifting equipment). a Disconnect the supply hose (1) from the clutch mas-
a Disconnect the battery (see Battery : Removal - ter cylinder.
Refitting) (80A, Battery). a Remove the retaining clip (2) from the connecting pi-
a Remove: pe.
- the windscreen wiper arms (see Windscreen wi- a Disconnect the end of the clutch control pipe (3) .
Washing),
Soundproofing).
131536
a Remove:
- the lower cover from the dashboard on the driver's
- the lower trim from the dashboard on the driver's
side (see A-pillar air distribution duct: Removal
- Refitting) (61A, Heating system).
a Separate the clutch master cylinder rod (4) from the
clutch pedal.
37A-55
REFITTING

CONCERNED
132859
a Turn the clutch master cylinder a quarter of a turn
clockwise using the tool (Emb. 1797) (5) .
a Remove the clutch master cylinder.
132858
a Position the clutch master cylinder.
a Refit the clutch master cylinder by turning it a quarter
of a turn anticlockwise using the tool (Emb. 1797).
Note:
The master cylinder has a foolproofing device, it
only fits in one position.
a Refit:
- the clutch master cylinder rod on the clutch pedal,
- the lower trim on the dashboard on the driver's side
(see A-pillar air distribution duct: Removal - Re-
fitting) (61A, Heating system),
- the lower cover on the dashboard driver's side (see
equipment).
a Connect the end of the clutch control pipe on the
clutch master cylinder.
a Refit the clip on the connecting pipe.
a Connect the supply hose on the clutch master cylin-
der.
a Bleed the hydraulic clutch circuit (see 37A, Mecha-
nical component controls, Clutch circuit: Blee-
ding, page 37A-48) .
a Refit:
Soundproofing),
37A-56
Washing).
a Check that the hydraulic clutch system is operating
correctly.
a Refit the battery (see 80A, Battery, Battery: Remo-
val - Refitting).
37A-57
Emb. 1797 24 mm socket for removing
and refitting clutch master
cylinder
WARNING
REMOVAL

a Position the vehicle on a two-post lift (see Vehicle: a
WARNING
a Remove:
- the battery (see Battery : Removal - Refitting) rounding components.
(80A, Battery)
a Disconnect the supply hose (1) from the clutch mas-
- the battery tray (see Battery tray: Removal - Re- ter cylinder.
a Remove the clip (2) from the connecting pipe.
fitting) (12A, Fuel mixture). a Disconnect the end of the clutch control pipe (3) .
37A-58
REFITTING

CONCERNED
132858
132856 a Position the clutch master cylinder.
a Remove:
a Refit the clutch master cylinder by turning it a quarter
- the dashboard lower cover on the driver's side (see of a turn anticlockwise using the tool (Emb. 1797)
Dashboard: Removal - Refitting) (57A, Interior (5) .
equipment),
- the lower trim from the dashboard on the driver's Note:
side (see A-pillar air distribution duct: Removal
- Refitting) (61A, Heating system). The master cylinder is fitted with a foolproofing
device; there is only one possible position.
a Separate the clutch master cylinder rod (4) from the
clutch pedal. a Refit:
- the clutch master cylinder rod on the clutch pedal,
- the lower trim of the dashboard on the driver's side
(see A-pillar air distribution duct: Removal - Re-
fitting) (61A, Heating system).
equipment).
a Connect the end of the clutch control pipe on the
clutch master cylinder.
a Refit the clip on the connecting pipe.
a Connect the supply hose on the clutch master cylin-
der.
132857
a Remove the clutch master cylinder by turning it a
quarter of a turn clockwise using the (Emb. 1797) (5)
. a Bleed the hydraulic clutch circuit (see 37A, Mecha-
nical component controls, Clutch circuit: Blee-
ding, page 37A-48) .
a Refit:
37A-59
(80A, Battery).
37A-60
Clutch pedal switch: Removal - Refitting 37A
REMOVAL REFITTING
I - REMOVAL PREPARATION OPERATION I - REFITTING OPERATION FOR PART

CONCERNED
a Remove:

equipment),

Heating system),
- the clutch pedal (see 37A, Mechanical compo-

nent controls, Clutch pedal: Removal - Refit-

CONCERNED
132861
a Position the clutch pedal switch (1) .
a Depress the clutch pedal switch until the end of the
piston touches the rubber stop (3) .
a Measure the dimension (A) between the rubber stop
and the end of the piston when the clutch pedal is
fully depressed.
a If the dimension (A) is outside the limits, turn the
clutch pedal switch carefully to adjust the dimension
between 0.74 mm and 1.96 mm.
132863
a Remove the clutch pedal switch (1) by turning it a

quarter of a turn anticlockwise.
CRUISE CONTROL

37A-61
CRUISE CONTROL
132862
a Position the clutch pedal switch (2) .
a Depress the clutch pedal switch until the end of the

a Measure the dimension (B) between the rubber stop

and the end of the piston when the clutch pedal is
fully depressed.
a If the dimension (B) is outside the limits, turn the

clutch pedal switch carefully to adjust the dimension
a Refit:

ting, page 37A-42) ,

Heating system),
- the lower cover of the dashboard on the driver's


37A-62
REMOVAL II - OPERATION FOR REMOVAL OF PART

CONCERNED
IMPORTANT
Never handle the pyrotechnic systems (preten-
sioners or airbags) near to a source of heat or
naked flame - they may be triggered.
IMPORTANT
bags or pretensioners), wait for at least 3 minu-
tes after disconnecting the battery.

a Remove: 132863
ners),
CRUISE CONTROL
Steering wheel: Removal - Refitting, page 36A- a Remove the clutch pedal switch (2) by turning it a
39) (36A, Steering assembly), quarter of a turn anticlockwise.

lite: Removal - Refitting) (86A, Radio),

Refitting) (84A, Control - Signals),

ting) (84A, Controls - Signals),

equipment),

Heating system),
- the right-hand trim of the central front panel,
- the steering column of the dashboard cross mem-

Steering assembly),

37A-63
REFITTING
CRUISE CONTROL
CONCERNED
132862
132861 a Position the clutch pedal switch (2) .

a Position the clutch pedal switch (1) . a Depress the clutch pedal switch until the end of the
a Depress the clutch pedal switch until the end of the piston touches the rubber stop (4) .
a Measure the dimension (B) between the rubber stop
a Measure the dimension (A) between the rubber stop and the end of the piston when the clutch pedal is
and the end of the piston when the clutch pedal is fully depressed.
fully depressed.
a If the dimension (B) is outside the limits, turn the
a If the dimension (A) is outside the limits, turn the clutch pedal switch carefully to adjust the dimension
clutch pedal switch carefully to adjust the dimension between 0.74 mm and 1.96 mm.
a Refit:

ting, page 37A-42) ,
- the steering column of the dashboard cross mem-

Steering assembly),
- the right-hand trim of the central front panel,

Heating system),
37A-64
equipment),
ting) (84A, Controls - Signals),
Refitting) (84A, Control - Signals),
39) (36A, Steering assembly),
ners).
a Adjust the neutral position of the steering wheel an-
gle sensor (see Fault finding - Configurations and
programming) (80C, Xenon bulbs).
37A-65
Clutch circuit: Removal - Refitting 37A
CONCERNED
WARNING
REMOVAL

a Remove:
- the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
(80A, Battery) 132866
a
fitting) (80A, Battery), WARNING
- the air filter box (see Air filter unit: Removal - Re- Prepare for the flow of fluid, and protect the sur-
fitting) (12A, Fuel mixture). rounding components.
a Remove the clip (1) from the connecting pipe (2)
between the clutch master cylinder and the hydraulic
damper (3) .
a Disconnect the connecting pipe from the hydraulic
damper.
a Remove the clip (4) from the clutch control pipe (5)
on the hydraulic damper.
a Disconnect the clutch control pipe from the hydraulic
damper.
a Unclip the clutch hydraulic damper from its support
(6) .
37A-66
37A-48) .
a Refit:
fitting) (12A, Fuel mixture)
(80A, Battery)
132867
a Remove the clip (7) from the clutch control pipe on wheel arch liner: Removal - Refitting) (55A, Ex-
the clutch slave cylinder on the gearbox. terior protection),
a Disconnect the clutch control pipe from the clutch - the front left-hand wheel (see 35A, Wheels and ty-
slave cylinder. res, Wheel: Removal - Refitting, page 35A-1)
a Unclip the clutch control pipe from its clip (8) .
a Remove the clutch control pipe.

a Fit plugs into the openings.
REFITTING

CONCERNED
a Refit:
- the clutch control pipe, taking care not to damage

anything,
- the clutch hydraulic damper on its support.
a Connect:
- the clutch control pipe on the slave cylinder side,
- the clutch control pipe on the hydraulic damper si-

de.
a Refit:
- the clutch control pipe onto its clip,
- the clutch control pipe clip onto the clutch slave cy-
linder,
- the clutch control pipe clip onto the hydraulic dam-
per.
a Connect the connecting pipe onto the hydraulic

damper.
a Refit the connecting pipe clip between the clutch
master cylinder and the hydraulic damper.
37A-67
CONCERNED
WARNING
REMOVAL

a Remove:
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
(80A, Battery) 132864
a
fitting) (80A, Battery), WARNING
- the air filter box (see Air filter unit: Removal - Re- Prepare for the flow of fluid, and protect the sur-
fitting) (12A, Fuel mixture). rounding components.
a Remove the clip (1) from the connecting pipe (2)
between the clutch master cylinder and the hydraulic
damper (3) .
a Disconnect the connecting pipe from the hydraulic
damper.
a Remove the clip (4) from the connecting hose (5) on
the hydraulic damper.
a Disconnect the connecting hose from the hydraulic
damper.
a Unclip the clutch shock damper from its support (6) .
37A-68
37A-48) .
a Refit:
(80A, Battery),
132865 wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
a Remove the clip (7) from the clutch control pipe on
the clutch slave cylinder on the gearbox (8) . - the front left-hand wheel (see 35A, Wheels and ty-
a Disconnect the clutch control pipe from the clutch (35A, Wheels and tyres).
slave cylinder.
a Unclip the clutch control pipe from its clip (9) .
a Remove the clutch control pipe.
a Fit plugs into the openings.
REFITTING

CONCERNED
a Refit:
- the clutch control pipe, taking care not to damage

anything,
- the clutch hydraulic damper on its support.
a Connect:
- the clutch control pipe on the slave cylinder side,
- the connecting hose on the hydraulic damper side.
a Refit:
- the clutch control pipe on its clip,
- the clutch control pipe clip on the clutch slave cylin-

der,
- the connecting hose clip on the hydraulic damper.
a Connect the connecting pipe on the hydraulic dam-

per.
a Refit the connecting pipe clip between the clutch

master cylinder and the hydraulic damper.
37A-69
Manual gearbox selector cable: Removal - Refitting 37A
M9R, and 6 SPEED MANUAL GBOX
Tightening torquesm
heater matrix water out- 25 N.m

let pipe bolt
wiring channel bolts 10 N.m
REMOVAL

IMPORTANT
To prevent the vehicle from falling, lash it to the
vehicle lift using a strap.
a Remove: 131656
a Remove:
(80A, Battery) - the bolt (3) from the heater matrix water outlet ho-
se.
fitting) (80A, Battery). - the heater matrix water outlet pipe (4) .
131655
a Remove:
- the bolts (1) from the wiring channel,
- the wiring channel (2) .
a Disconnect the manual gearbox control cable from
the gear control unit (see 37A, Mechanical compo-
nent controls, Gear control unit: Removal - Refit-
37A-70
II - OPERATION FOR REMOVAL OF PART - the gear lever cable (6) from the upper bracket of
CONCERNED control cable B (9) by pulling on the locking brac-
kets (10) .
4X2 TRANSMISSION
131657
131659
a Unclip:
- the manual gearbox control cable from the lower
bracket (11) of the control cable,
- the control cable stop (12) from the manual gear-
box.
131658
a Unclip:
- the cable (5)
- gear lever A while by pressing the brackets (7) ,
- the cable (6) from the selector lever by pressing the

brackets (7) ,
- the gear lever cable (5) from the upper bracket of

control cable A (8) by pulling on the locking brac-
kets (10) ,
37A-71
4X4 TRANSMISSION a Connect the manual gearbox control cable to the

gear control unit (see 37A, Mechanical component
controls, Gear control unit: Removal - Refitting,
page 37A-76) (Mechanical component controls).
a Adjust the selector lever cable (see Gear control
unit: Adjusting) (Mechanical component controls).
a Refit:
- the heater matrix water outlet pipe,
- the heater matrix water outlet pipe bolt.
a Torque tighten the heater matrix water outlet pipe
bolt (25 N.m).
a Refit:
- the wiring channel,
- the wiring channel bolts.
a Torque tighten the wiring channel bolts (10 N.m).
a Refit:
131660 fitting) (80A, Battery),
a Unclip: - the battery (see Battery : Removal - Refitting)
- the manual gearbox control cable from the lower (80A, Battery).
- the control cable stop (14) from the manual gear-
box.
a Remove the manual gearbox control cable.
REFITTING

CONCERNED
a Refit the manual gearbox control cable.
a Clip:
- the manual gearbox control cable on the lower

bracket of the control cable,
- the control cable stop of the manual gearbox,
- the gear lever cable on the upper bracket of control

cable A,
- the gear lever cable on the upper bracket of control

cable B,
- the gear lever cable on gear lever A,
- the selector lever cable on the selector lever.
37A-72
2TR, and 6 SPEED MANUAL GBOX
CONCERNED
Tightening torquesm
battery tray bracket 28 N.m

mounting bolts
REMOVAL

a Remove:
(80A, Battery)
131657
132484
a Remove:
- the bolts (1) from the battery tray bracket,
- the battery tray bracket (2) .
the gear control unit (see 37A, Mechanical compo- 131658
ting, page 37A-76) . a Unclip:
- the cable (3) from the gear lever A by pressing on

the brackets (5) ,
- the cable (4) from the gear lever by pressing on the

brackets (5) ,
- the gear lever cable (3) from the upper bracket of

control cable A (6) by pulling on the locking brac-
kets (8) ,
37A-73
- the selector lever cable (4) from the upper bracket
of control cable B (7) by pulling on the locking brac-
kets (8) . 4X4 TRANSMISSION
4X2 TRANSMISSION
131660
a Unclip:
131659 - the manual gearbox control cable from the lower
a Unclip: bracket (11) of the control cable,
- the manual gearbox control cable from the lower - the stop (12) from the manual gearbox control ca-
bracket (9) of the control cable, ble.
- the stop (10) from the manual gearbox control ca-
ble.
a Remove the manual gearbox control cable.
REFITTING

CONCERNED
a Refit the manual gearbox control cable.
a Clip:
- the manual gearbox control cable on the lower

- the control cable stop on the manual gearbox,
- the selector lever cable on the upper bracket of

control cable A,
- the selector lever cable on the upper bracket of

control cable B,
- the gear lever cable on gear lever A,
- the selector lever cable on the selector lever.
37A-74
a Connect the manual gearbox control cable to the
page 37A-76) .
a Adjust the selector lever cable (see 37A, Mechani-
cal component controls, Mechanical gear con-
trol cable: Adjustment, page 37A-84) .
a Refit:
- the battery tray bracket,
- the battery tray bracket bolts.
a Tighten to torque the battery tray bracket moun-
ting bolts (28 N.m).
a Refit:
(80A, Battery).
37A-75
Gear control unit: Removal - Refitting 37A
6 SPEED MANUAL GBOX
Tightening torquesm
gear control unit bolts 7 N.m
REMOVAL

Removal - Refitting) (57A, Interior equipment).

CONCERNED
131662
a Remove:
- the bolts (7) from the gear control unit,
- the gear control unit.
REFITTING

CONCERNED
a Refit:
- the gear control unit,
- the bolts on the gear control unit.
131661
a Unclip: a Torque tighten the gear control unit bolts (7 N.m).
- the selector lever cable (1) from the gear control a Clip:
unit by pressing on the brackets (3) ,
- the gear lever cable stop on the gear control unit by
- the selector cable stop (4) from the gear control pulling on the locking bracket,
unit by pulling on the locking bracket (6) ,
- the gear lever cable on the gear control unit,
- the cable (2) from the gear control unit gear lever
by pressing on the brackets (3) , - the selector lever cable stop on the gear control
unit by pulling on the locking bracket,
- the gear lever cable stop (5) from the gear control
unit by pulling on the locking bracket (6) . - the selector lever cable on the gear control unit.
a Adjust the selector lever cable (see 37A, Mechani-
cal component controls, Mechanical gear con-
trol cable: Adjustment, page 37A-84) .
37A-76
6 SPEED AUTO GBOX or VARIABLE GEARBOX
Tightening torquesm
gear control unit bolts 6 N.m
REMOVAL


CONCERNED
131664
a Unclip:
- the connector (3) from the gear control unit,
- the automatic gearbox control cable stop (4) from
the gear control unit.
a Move aside the automatic gearbox control cable.
131663
a Unclip the automatic gearbox control cable (1) from
the lever of the gear control unit (2) .
131665
a Remove:
- the gear control unit bolts (5) ,
37A-77
6 SPEED AUTO GBOX or VARIABLE GEARBOX
REFITTING

CONCERNED
a Refit:
- the gear control unit bolts,
a Torque tighten the gear control unit bolts (6 N.m).
a Clip:
- the automatic gearbox control cable stop onto the

gear control unit,
- the connector onto the gear control unit.
131666
a Clip:
- the automatic gearbox control cable onto the gear

control unit lever by positioning the ribbed side (6)
upwards,
- the automatic gearbox control cable stop onto the

gear control unit.


37A-78
Automatic gear control cable: Removal - Refitting 37A
VARIABLE GEARBOX
a Unclip:
Tightening torquesm - the automatic gearbox control cable from the multi-
function switch lever (3) .
automatic gearbox con- 14 N.m
trol cable nut - the automatic gearbox control cable from the upper
bracket (4) of the control cable.
REMOVAL

IMPORTANT
To prevent the vehicle from falling, lash it to the
vehicle lift using a strap.
a Remove:
- the air inlet pipe (see Air filter unit: Removal - Re- 131674
a Unclip:
- the automatic gearbox control cable from the lower
(80A, Battery)
- the battery tray (see Battery : Removal - Refit-
ting) (80A, Battery). - the cover (6) of the automatic gearbox control ca-
ble.
a Disconnect the automatic gearbox control cable
from the gear control unit (see 37A, Mechanical a Remove the automatic gearbox control cable.
component controls, Gear control unit: Removal
REFITTING

CONCERNED
CONCERNED
a Refit the automatic gearbox control cable.
a Clip:
- the automatic gearbox control cable cover,

- the automatic gearbox control cable on the lower
- the automatic gearbox control cable on the upper
- the automatic gearbox control cable on the multi-
function switch lever.
a Refit:
131673 - the sheath stop on the automatic gearbox control
a Remove: cable,
- the nut (1) of the automatic gearbox control cable, - the nut on the automatic gearbox control cable.
- the sheath stop (2) from the automatic gearbox a Torque tighten the automatic gearbox control ca-
control cable. ble nut (14 N.m).
37A-79
VARIABLE GEARBOX
II - FINAL STEP
a Connect the automatic gearbox control cable on the
page 37A-76) .
a Adjust the multifunction switch (see Multifunction
switch: Adjusting) (23A, Automatic gearbox).
a Remove:
- the battery tray (see Battery : Removal - Refit-
ting) (80A, Battery),
(80A, Battery)
- the air inlet pipe (see Air filter unit: Removal - Re-
37A-80
6 SPEED AUTO GBOX
Tightening torquesm
automatic gearbox con- 14 N.m

trol cable nut
heater matrix water inlet 25 N.m

pipe bolt
heater matrix water out- 25 N.m

let pipe bolt
wiring channel bolts 10 N.m
REMOVAL

131667
a Remove:
IMPORTANT
To prevent the vehicle from falling, lash it to the - the bolts (1) from the wiring channel,
vehicle lift using a strap. - the wiring channel (2) .
a Remove:
(80A, Battery)
the gear control unit (see 37A, Mechanical compo-
131668
a Remove:
- the bolt (3) from the heater matrix water outlet pipe,
- the heater matrix water outlet pipe (4) .
37A-81
6 SPEED AUTO GBOX
a Unclip:
- the automatic gearbox control cable from the multi-
function switch lever,
- the automatic gearbox control cable from the upper
bracket (9) of the control cable.
4X2 TRANSMISSION
131669
a Remove:
- the bolt (5) from the heater matrix inlet pipe, 131671
- the heater matrix inlet pipe (6) . a Unclip:

- the automatic gearbox control cable from the lower
II - OPERATION FOR REMOVAL OF PART bracket (11) of the control cable,
CONCERNED - the stop (10) from the control cable of the automa-
tic gearbox.
131670
a Remove:
- the nut (7) from the automatic gearbox control ca-
ble,
- the sheath stop (8) from the automatic gearbox
control cable.
37A-82
6 SPEED AUTO GBOX
- the automatic gearbox control cable nut.
4X4 TRANSMISSION a Torque tighten the automatic gearbox control ca-

ble nut (14 N.m).
a Refit:
- the heater matrix water inlet pipe,
- the bolt of the heater matrix water inlet pipe.
a Torque tighten the heater matrix water inlet pipe
bolt (25 N.m).
a Refit:
- the heater matrix water outlet pipe,
- the bolt of the heater matrix water outlet pipe.
a Torque tighten the heater matrix water outlet pipe
bolt (25 N.m).
a Refit:
- the wiring channel,
131672 - the wiring channel bolts.

a Unclip: a Torque tighten the wiring channel bolts (10 N.m).
- the automatic gearbox control cable from the lower a Connect the manual gearbox control cable to the
bracket (12) of the control cable, gear control unit (see 37A, Mechanical component
- the stop (13) from the control cable of the automa- page 37A-76) .
tic gearbox.
a Adjust the multifunction switch (see Multifunction
switch: Adjusting) (23A, Automatic gearbox).
a Refit:
a Remove the automatic gearbox control cable.
REFITTING - the battery (see Battery : Removal - Refitting)
(80A, Battery).
CONCERNED:
a Refit the automatic gearbox control cable.
a Clip:
- the automatic gearbox control cable on the lower
- the stop of the automatic gearbox control cable,
- the automatic gearbox control cable on the upper
- the automatic gearbox control cable onto the multi-
function switch lever.
a Refit:
- the control cable sheath stop on the automatic
gearbox,
37A-83
Mechanical gear control cable: Adjustment 37A
6 SPEED MANUAL GBOX
132945
a Unlock the selector lever cable by pressing on the
adjustment clip (1) and pushing it downwards.
132946
a Clip the selector lever cable onto the gear lever (2)
of the gear control unit.
a Push the pin (3) (3 mm) on the gear control unit and
the selector lever of the gear control unit.
a Put the gear control unit in 4th gear.
a Lock the selector lever cable by compressing the ad-
justment clip (1) .
a Remove the pin (3) .
a Check that this gear selection is correct.
37A-84
Parking brake cables: Removal - Refitting 37A
CONCERNED
Essential equipment
diagnostic tool a
WARNING
To avoid damaging the parking brake cable pro-
Tightening torquesm
tectors and causing premature wear of the sys-
parking brake cable on 6 N.m tem, do not handle the cables with a tool.
the underbody
a Note the parking brake cable routing for refitting.
near the rear stub axle
carrier bracket
bolt of the parking brake 6 N.m

cable on the rear stub
axle carrier
parking brake cable on 13 N.m

the rear brake disc
shield
REMOVAL

a Remove:
131701
Wheel: Removal - Refitting, page 35A-1) , a Separate the parking brake cable (1) from the par-
king brake lever (2) .
the brake hose (see 33A, Rear axle components, a Remove the bolt (3) from the parking brake cable.
33A-5) .
a Remove:
page 33A-1) ,
page 33A-13) ,
131702
nents, Rear brake lining: Removal - Refitting, a Remove the parking brake cable bolt (4) from the
page 33A-15) . rear stub axle carrier.
37A-85
131703 131705
a Remove the parking brake cable bolt (5) near the a Lift up the stopper (9) .
rear stub axle carrier support.
a Disconnect the right-side of the parking brake cable
from its clip (10) .
a Remove:
- the bolts (11) from the right-hand section of the par-
king brake cable,
- the right-hand section of the parking brake cable.
REFITTING

a Always replace the clip (10) on the right-side of par-
king brake cable.
131704
a Disconnect the left-hand section (6) of the parking
brake cable from its clip (7) .
CONCERNED
a Remove:
a Refit the parking brake cables.
- the bolts (8) from the left-hand section of the par-
king brake cable, a Refit:
- the right-hand section of the parking brake cable. - the right-hand section of the parking brake cable,
- the bolts from the right-hand section of the parking
brake cable,
- the right-hand section of the parking brake cable,
- the bolts from the left-hand section of the parking
brake cable.
a Torque tighten the parking brake cable on the un-
derbody (6 N.m).
a Connect the right-side of the parking brake cable
onto its new clip.
a Press the stopper.
a Connect the left-side of the parking brake cable onto
its new clip.
37A-86
a Refit:
- the parking brake cable bolt near the rear stub axle
carrier bracket,
- the bolt of the parking brake cable on the rear stub

axle carrier.
a Torque tighten:
- the parking brake cable bolt near the rear stub

axle carrier bracket (8 N.m),
- the bolt of the parking brake cable on the rear

stub axle carrier (6 N.m).
a Refit:
- the parking brake cable to the parking brake lever,
- the bolt of the parking brake cable on to the rear

brake disc shield.
a Torque tighten the parking brake cable on the rear

brake disc shield (13 N.m).
a Follow the brake cable routing noted during removal.
a Refit:

page 33A-15) ,

page 33A-13) ,


page 33A-1) ,

ting, page 33A-5) .

set automatically.
a Carry out a complete check and clear any faults ge-

nerated using the diagnostic tool. Configure the
new brake control unit (see Fault Finding - Repla-
cement of components) (37B, Automatic parking
brake).
37A-87
Tightening torquesm
parking brake cable 6 N.m

bolts on the underbody

near the rear stub axle
carrier support
bolt of the parking brake 6 N.m

cable on the rear stub
axle carrier

on the rear brake disc 131679
protector a Remove:
- the clips (1) of the silencer front heat shield,
REMOVAL - the silencer heat shield.

I - REMOVAL PREPARATION OPERATION CONCERNED
a Position the vehicle on a two-post lift (see Vehicle: a
WARNING
a Release the parking brake. To avoid damaging the parking brake cable pro-
tectors and causing premature wear of the sys-
a Remove: tem, do not handle the cables with a tool.
- the rear wheels (see 35A, Wheels and tyres, a Note the parking brake cable routing for refitting.

33A-5) .
a Remove:

page 33A-1) ,


page 33A-13) , 131680
a Separate the parking brake cable (2) from the par-
king brake lever (3) .
page 33A-15) . a Remove the bolt (4) from the parking brake cable.
37A-88
131681 131684
a Remove the cup holder (5) . a Disconnect the parking brake cables on the parking
brake compensator (8) .
131682
a Loosen the adjustment nut (6) to completely loosen
the parking brake cable.
131685
a Remove the parking brake cables through the un-
derbody openings (9) .
131683
a Remove the rear cover (7) from the centre console.
37A-89
- the parking brake cables.
REFITTING

a If the adjustment nut (6) has been removed, replace
it with a new one.

CONCERNED
a Refit the parking brake cables.
a Refit:
131686
- the parking brake cable bolts on the underbody,
a Remove the parking brake cable bolt (10) from the
rear stub axle carrier. - the parking brake cable bolt near the rear stub axle
carrier support,
- the bolt of the parking brake cable on the rear stub
axle carrier.
a Torque tighten:
- the parking brake cable bolts on the underbody
(6 N.m),
- the parking brake cable bolt near the rear stub
axle carrier support (8 N.m),
- the bolt of the parking brake cable on the rear
stub axle carrier (6 N.m).
a Refit:
- the parking brake cable through the openings of
131687 the underbody
a Remove the parking brake cable bolt (11) near the - the parking brake cable to the parking brake lever,
rear stub axle carrier support.
- the bolt of the parking brake cable on the rear bra-
ke disc protector.
a Torque tighten the parking brake cable bolt on the
rear brake disc protector (13 N.m).
a Follow the brake cable routing noted during removal.
a Connect the parking brake cables on the parking
brake compensator.
a Refit the rear cover on the centre console.

a Refit:
- the silencer heat shield,
131688
- the clips of the silencer front heat shield.
a Remove:
- the parking brake cable bolts (12) from the under- nents, Rear brake lining: Removal - Refitting,
body, page 33A-15) ,
37A-90
page 33A-13) ,
page 33A-1) ,
ting, page 33A-5) .
- the cup holder,
37A-91
ELECTRONIC PARKING BRAKE
Assisted parking brake: List and location of components 37B
I - LIST OF COMPONENTS 2 - Emergency handle
No. Description
(1) Control unit
(2) Emergency handle
(3) Unit
(4) Clutch pedal position sensor
II - LOCATION OF COMPONENTS
1 - Control unit
131690
The emergency handle is integrated into the control
unit.
3 - Unit
131689
131691
37B-1
Assisted parking brake: List and location of components 37B
4 - Clutch pedal position sensor
131692
To remove the clutch pedal position sensor (see 37A,
Mechanical component controls, Clutch pedal po-
sition sensor: Removal - Refitting, page 37A-47) .
37B-2
Emergency handle: Removal - Refitting 37B
131693
a
Note:
The emergency handle (1) is integrated into the
control unit.
37B-3
Control unit: Removal - Refitting 37B
- the left-hand side C-pillar lower trim (see C-pillar
lower trim: Removal - Refitting) (71A, Body inter-
Essential equipment
nal trim),
diagnostic tool - the left-hand section of the luggage compartment
side box (see Luggage compartment floor
lining: Removal - Refitting) (71A, Body internal
Tightening torquesm trim),
- the receiver (see Tuner-amplifier: Removal - Re-
nuts of the electronic 6 N.m fitting) (86A, Radio).
parking brake control
unit
electronic parking brake 6 N.m
a
cable bracket bolts
WARNING
the cover nuts on the 4 N.m
electronic parking brake To avoid damaging the parking brake cable pro-
control unit tectors and causing premature wear of the sys-
tem, do not handle the cables with a tool.
bolt of the electronic 14 N.m
parking brake cable on a For vehicles fitted with a manual gearbox: before re-
the rear left-hand side of moving the control unit, always save the clutch data
the fuel tank (see Fault finding - Replacement of components)
(37B, Electronic parking brake).
bolt of the electronic 14 N.m
parking brake cable on
the front left-hand side
of the fuel tank
parking brake cable 6 N.m

bolts on the underbody
REMOVAL

Towing and lifting) (02A, Lifting equipment). 131694
a Release the parking brake. a Remove the parking brake cable bolts (1) from the
underbody.
a Remove:
- the rear centre luggage compartment floor (see

Luggage compartment floor lining: Removal -
Refitting) (71A, Body internal trim),
- the front luggage compartment floor box (see Lug-

gage compartment floor lining: Removal - Refit-
ting) (71A, Body internal trim),
- the rear luggage compartment floor (see Luggage

compartment floor lining: Removal - Refitting)
(71A, Body internal trim),
- the front centre luggage compartment floor (see

37B-4
131695 131698
a Disconnect the left-hand section (2) of the parking a Remove the bolt of the electronic parking brake (7)
brake cable from its clip (3) . on the rear left-hand face of the fuel tank.
a Let the electronic parking brake cable hang freely.
131696
a Lift up the stopper (4) .
a Disconnect the right-side of the parking brake cable

from its clip (5) .
131699
a Remove:
- the cover nuts (8) from the electronic parking brake
control unit,
- the cover (9) from the electronic parking brake con-
trol unit.
131697
a Remove the parking brake cable bolt (6) on the

front-left side of the fuel tank.
37B-5
132022
a Fit the electronic parking brake control unit - electro-

nic parking brake cable assembly
a Refit:
131700
- the nuts of the electronic parking brake control unit,
a the connector (10) from the electronic parking brake
control unit. - the electronic parking brake cable bracket,
a Remove: - the bolts on to the electronic parking brake cable
bracket.
- the bolt (11) from the electronic parking brake ca-
ble support, a Tighten to torque:
- the electronic parking brake cable bracket, - the nuts of the electronic parking brake control
- the nuts (12) from the electronic parking brake con- unit (6 N.m),
trol unit, - the electronic parking brake cable bracket bolts
- the electronic parking brake control unit - electronic (6 N.m).
parking brake cable assembly. a Connect the connector to the electronic parking bra-
ke control unit.
Note: a Refit:
The electronic parking brake cable cannot be - the cover on the electronic parking brake control
separated from the electronic parking brake con- unit.
trol unit.
- the cover nuts on the electronic parking brake con-
trol unit.
REFITTING
a Torque tighten the cover nuts on the electronic
parking brake control unit (4 N.m).
a Refit:
a Always replace the clip on the right-side of parking
brake cable. - the left-side of the parking brake cable into its clip,
- the right-side of the parking brake cable into its new

clip,
- the bolt of the electronic parking brake cable on the
rear left-hand side of the fuel tank.
- the bolt of the electronic parking brake bolt on the
front left-hand side of the fuel tank.
- the parking brake cable bolts on the underbody.
37B-6
- the bolt of the electronic parking brake cable on

the rear left-hand side of the fuel tank (14 N.m),
- the bolt of the electronic parking brake cable on

the front left-hand side of the fuel tank (14 N.m),
- the parking brake cable bolts on the underbody

(6 N.m).
a Observe the parking brake cable routing noted du-

ring removal.
a Refit:
- the receiver (see Tuner-amplifier: Removal - Re-

fitting) (86A, Radio).
- the left-hand section of the luggage compartment

side box (see Luggage compartment floor
lining: Removal - Refitting) (71A, Body internal
trim),
- the left-hand side C-pillar lower trim (see C-pillar

lower trim: Removal - Refitting) (71A, Body inter-
nal trim),
- the front centre luggage compartment floor (see

- the rear luggage compartment floor (see Luggage

compartment floor lining: Removal - Refitting)
(71A, Body internal trim),
- the front luggage compartment floor box (see Lug-

gage compartment floor lining: Removal - Refit-
ting) (71A, Body internal trim),
- the rear centre luggage compartment floor (see


set automatically.
a Carry out a complete check and clear any faults ge-

nerated using the diagnostic tool. Configure the
new brake control unit see (Fault finding - Replace-
ment of components).
37B-7
Handle: Removal - Refitting 37B
REMOVAL REFITTING
I - REMOVAL PREPARATION OPERATION I - REFITTING OPERATION FOR PART

CONCERNED
a Remove the centre console (see Centre console: a Refit:
- the electronic parking brake lever,
- the bolts of the electronic parking brake lever.
CONCERNED a Connect the electronic parking brake handle con-
nector.
131706
131707
a Disconnect the connector (2) from the electronic

parking brake lever (1) .
a Remove:
- the bolts (3) from the electronic parking brake le-

ver,
- the electronic parking brake lever,
37B-8
ANTI-LOCK BRAKING SYSTEM
ABS system: List and location of components 38C
ESP 2 or ESP
131488
No. Description
(1) Hydraulic unit
(2) Steering wheel angle sensor
(3) Injection computer
(4) Automatic transmission computer (depending on version)
(5) 4WS control unit (4WS vehicle only)
(6) ESP warning light on the instrument panel
(7) Diagnostic socket
(8) Brake light switch
(9) Lateral acceleration and yaw speed sensor
(10) Vehicle speed
(11) Wheel speed sensor
(12) HDC switch (4WS vehicle only)
(13) Battery
38C-1
ESP 2 or ESP
No. Description
(14) ESP inhibitor switch
(15) Brake lights switch
(16) Master cylinder
38C-2
WITHOUT ESP
131487
No. Description
(1) Hydraulic unit
(2) ABS warning light on the instrument panel
(3) Diagnostic socket
(4) Lateral acceleration sensor (4WS vehicle only)
(5) Vehicle speed
(6) Wheel speed sensor
(7) Battery
(8) Brake light switch
(9) Master cylinder
38C-3
Brake hydraulic assembly: Removal - Refitting 38C
LEFT-HAND DRIVE
Essential equipment
pedal press
Tightening torquesm
brake pipe unions (4) on 16 N.m

the hydraulic unit

the hydraulic unit
(without ESP)

the hydraulic unit (with
ESP)
hydraulic brake unit 9 N.m

bolts
131551
REMOVAL a Remove the bulkhead insulation (1) (see Bulkhead

Soundproofing).
Towing and lifting) (02A, Lifting equipment). II - OPERATION FOR REMOVAL OF PART
CONCERNED
a Place the pedal press on the brake pedal. 2TR
a Remove:
- the engine cover,
Washing),
131552
a Remove:
- clips (2) ,
38C-4
LEFT-HAND DRIVE
2TR
a Refit:
- the vacuum hose,
- the clips.
a Refit:
132648 fing),
a Undo: - the scoop under the scuttle panel grille (see Scoop
- the brake pipe unions (4) on the hydraulic unit, (56A, Exterior equipment),
- the brake pipe unions (5) on the hydraulic unit. - the windscreen wiper mechanism (see Winds-
a Disconnect the connector (6) . (85A, Wiping - Washing),
a Remove: - the scuttle half-grille (see Scuttle half-grille: Re-

- the bolts (7) from the hydraulic brake unit,
- the hydraulic brake unit (8) . arm: Removal - Refitting) (85A, Wiping -
Washing),
- the engine cover.
REFITTING
I - REFITTING OPERATION FOR PART a Bleed the brake circuit (see 30A, General informa-
CONCERNED tion, Brake circuit Bleeding, page 30A-3) .
a Refit:
- the hydraulic brake unit,
- the hydraulic brake unit bolts.
a Connect the hydraulic brake unit connector.
a Refit:
- the brake pipe unions (4) on the hydraulic unit.
a Torque tighten:
- the brake pipe unions (4) on the hydraulic unit

(16 N.m),

(without ESP) (16 N.m),

(with ESP) (18 N.m),
- the hydraulic brake unit bolts (9 N.m).
38C-5
RIGHT-HAND DRIVE
CONCERNED
Essential equipment
pedal press
Tightening torquesm

the hydraulic unit

the hydraulic unit
(without ESP)

ESP)
brake hydraulic unit 9 N.m

bolts
131539
REMOVAL
a Undo:
a Position the vehicle on a two-post lift (see Vehicle: a Disconnect the connector (3) .
a Remove:
a Disconnect the battery (see Battery : Removal - - the bolts (4) from the hydraulic brake unit,
- the hydraulic brake unit.
a Place the pedal press on the brake pedal.
REFITTING
a Remove:
- the air intake sleeve, I - REFITTING OPERATION FOR PART

CONCERNED
- the air filter box (see Air filter unit: Removal - Re- a Refit:
- the hydraulic brake unit,
- the bolts on the hydraulic brake unit.
Washing), a Connect the hydraulic brake unit connector.
a Refit:
moval - Refitting) (56A, Exterior equipment), - the brake pipe unions (2) on the hydraulic unit,
creen wiper mechanism: Removal - Refitting) a Torque tighten:
(16 N.m),
under scuttle panel grille: Removal - Refitting) - the brake pipe unions (2) on the hydraulic unit
(56A, Exterior equipment). (without ESP) (16 N.m),
38C-6
RIGHT-HAND DRIVE
(with ESP) (18 N.m),
- the brake hydraulic unit bolts (9 N.m).
a Refit:
Washing),
- the air intake sleeve.
tion, Brake circuit Bleeding, page 30A-3)
38C-7
Front wheel speed sensor: Removal - Refitting 38C
Tightening torquesm
front wheel speed sen- 10 N.m

sor bolt
REMOVAL

a Remove:
- the front wheel arch liner (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion).
131489
a Remove:
CONCERNED - the front wheel speed sensor bolt (1) ,
a - the front wheel speed sensor.
WARNING

cable:
- Check that there is no contact with the surroun-
ding components,
131490
a Unclip the front wheel speed sensor cable at (2) .
REFITTING

CONCERNED
a Connect the front wheel speed sensor connector.
38C-8
Front wheel speed sensor: Removal - Refitting 38C
a Clip on the front wheel speed sensor cable.
a Refit the front wheel speed sensor.
a Torque tighten the front wheel speed sensor bolt
(10 N.m).
a Refit:
- the front wheel arch liner (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
38C-9
Rear wheel speed sensor: Removal - Refitting 38C
CONCERNED
Tightening torquesm
rear wheel speed sen- 10 N.m 4X2 TRANSMISSION

sor bolt
REMOVAL

a Remove the rear wheel (see 35A, Wheels and ty-
a
WARNING

cable:
- Check that there is no contact with the surroun- 130830
ding components, a Remove the bolt (1) from the rear wheel speed sen-
sor.
a Unclip the stub axle carrier cable.
38C-10
Rear wheel speed sensor: Removal - Refitting 38C
REFITTING
4X4 TRANSMISSION
CONCERNED
a Connect the speed sensor connector.
a Clip on the cable of the rear wheel speed sensor at
(4) .
a Refit the rear wheel speed sensor bolt.
a Torque tighten the rear wheel speed sensor bolt
(10 N.m).
a Refit the rear wheel (see 35A, Wheels and tyres,
130831
a Remove the bolt (2) from the rear wheel speed sen-
sor.
a Unclip the stub axle carrier cable.
130832
a Disconnect the connector (3) from the rear wheel

speed sensor.
a Unclip the cable from the wheel speed sensor at (4) .
a Remove the wheel speed sensor.
38C-11
Yaw speed and transversal acceleration sensor: Removal - Refitting 38C
Tightening torquesm REAR SEATS AIR DUCT
lateral acceleration and 6 N.m

yaw sensor nuts
REMOVAL
131544
a Remove the duct (2) from the floor.
131543
a Remove the lower cover (1) .
38C-12
Yaw speed and transversal acceleration sensor: Removal - Refitting 38C
CONCERNED
ESP 2 or ESP
WITHOUT ESP
131546
a Remove nuts (5) .

131545
a Remove nuts (3) . a Disconnect the connector (6) .
a Remove the lateral acceleration and yaw sensor.
REFITTING

CONCERNED
a Refit the lateral acceleration and yaw sensor.
a Connect the lateral acceleration and yaw sensor

connector.
a Refit the lateral acceleration and yaw sensor nuts.
a Torque tighten the lateral acceleration and yaw

sensor nuts (6 N.m).
REAR SEATS AIR DUCT

a Refit the floor duct.
a Refit the lower cover.
38C-13
Steering wheel angle sensor: Removal - Refitting 38C
ESP 2 or ESP
Essential equipment
IMPORTANT
diagnostic tool Never handle the pyrotechnic systems (pretensio-
REMOVAL

a Remove:
ners),
39) ,
131547 - the steering column covers (see Dashboard: Re-
Note: - the rotary switch (see Rotary switch: Removal -

Refitting) (84A, Control - Signal).
The steering wheel angle sensor is located on the
steering column and clipped onto the rotary switch.
IMPORTANT
To prevent any accidental triggering whilst working
on or near a pyrotechnic component (airbags or
pretensioners), lock the airbag computer using the
diagnostic tool.
When this function is activated, all the trigger lines
are inhibited and the airbag warning light on the ins-
trument panel lights up continuously (ignition on).
IMPORTANT
pretensioners), wait for at least 3 min after discon-
necting the battery.
38C-14
Steering wheel angle sensor: Removal - Refitting 38C
ESP 2 or ESP
II - OPERATION FOR REMOVAL OF PART REFITTING
CONCERNED

CONCERNED
131548
131550
a Clip the steering wheel angle sensor onto the rotary

switch by placing the rotor (4) into its original posi-
tion.
a Refit the bolts of the steering wheel angle sensor.
a Refit:

Refitting) (84A, Control - Signal),
- the steering column covers (see Dashboard: Re-

131549 - the steering wheel (see 36A, Steering assembly,

a Remove:
39) ,
- the bolts (1) from the steering wheel angle sensor,
- the steering wheel angle sensor (3) from the rotary Removal - Refitting) (88C, Airbags and pretensio-
switch by unclipping it at (2) . ners).


Fault finding - Configurations and Programming)
38C-15
Braking computer: Removal - Refitting 38C
Essential equipment
pedal press
Tightening torquesm
braking computer bolts 9 N.m

the hydraulic unit

the hydraulic unit
(without ESP)

ESP)
131551
REMOVAL
a Remove the bulkhead insulation (1) (see Bulkhead
Soundproofing).
Refitting) (80A, Battery). CONCERNED
a Place the pedal press on the brake pedal.

a Remove: 2TR

Washing),
creen wiper motor: Removal - Refitting) (85A,
Wiping - Washing),
131552
a Remove:
- the clips (2) ,
38C-16
Braking computer: Removal - Refitting 38C
a Torque tighten the braking computer bolts (9
N.m).
a Connect the braking computer connector.
a Refit the brake pipe unions on the hydraulic unit.
a Torque tighten:

(16 N.m),

(without ESP) (18 N.m),

(with ESP) (16 N.m).
2TR
a Refit:
131553
- the clips (2) .
a Refit:

fing),
132648
a Undo the brake pipe unions (4) and (5) on the hy- under scuttle panel grille: Removal - Refitting)
draulic unit. (56A, Exterior equipment).
a Disconnect the connector (6) . - the windscreen wiper mechanism (see Winds-
creen wiper motor: Removal - Refitting) (85A,
a Remove:
Wiping - Washing),
- the bolts (7) ,
- the braking computer (8) . moval - Refitting) (56A, Exterior equipment),

REFITTING arm: Removal - Refitting) (85A, Wiping -
Washing).
I - REFITTING OPERATION FOR PART a Remove the pedal press from the brake pedal.
CONCERNED
a Refit:
tion, Brake circuit Bleeding, page 30A-3)
- the braking computer,
- the braking computer bolts. ting) (80A, Battery).
38C-17

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3 Chassis

30A GENERAL INFORMATION

31A FRONT AXLE COMPONENTS

33A REAR AXLE COMPONENTS

35A WHEELS AND TYRES

35B TYRE PRESSURE MONITOR

36A STEERING ASSEMBLY

37A MECHANICAL COMPONENT CONTROLS

37B ELECTRONIC PARKING BRAKE

38C ANTI-LOCK BRAKING SYSTEM

FEBRUARY 2009 Edition Anglaise

© Renault s.a.s 2008

30A GENERAL INFORMATION 31A FRONT AXLE COMPONENTS

Brake circuit Operating Front brake disc shield:

Brake circuit Precautions for Front brake disc: Removal -

Brake circuit Bleeding 30A-3 Front brake disc: Description 31A-15

Brake fluid: Specifications 30A-5 Hydraulic unit - master

Front driveshaft hub carrier:

Front brake hose: Removal - Front hub carrier bearing:

Front brake calliper: Removal Spring and front shock

Front brake calliper: Repair 31A-7 Front driveshaft lower arm:

31A FRONT AXLE COMPONENTS 33A REAR AXLE COMPONENTS

Front axle sub-frame: Upper arm: Removal -

Front anti-roll bar: Removal - Rear axle sub-frame:

33A REAR AXLE COMPONENTS 35A WHEELS AND TYRES

Rear brake pads: Removal - Wheel: Removal - Refitting 35A-1

Rear brake caliper: Removal Tyres: Removal - Refitting 35A-6

Rear brake disc shield:

Rear brake lining: Removal - SSPP: Precautions for repair 35B-3

Shock absorber: Removal - Pressure sensor: Removal -

Rear suspension spring: Tyre pressure monitor

Rear wheel hub: Removal -

Rear stub-axle carrier: 36A STEERING ASSEMBLY

36A STEERING ASSEMBLY 37A MECHANICAL COMPONENT CONTROLS

Axial ball joint linkage: Clutch circuit: Bleeding 37A-48

Mechanical gear control

Parking brake cables:

Brake servo: Removal -

Brake pedal switch: Removal

Parking brake lever: Removal 38C ANTI-LOCK BRAKING SYSTEM

38C ANTI-LOCK BRAKING SYSTEM

Yaw speed and transversal

Steering wheel angle sensor:

Braking computer: Removal -

(1) ABS hydraulic unit

brake circuit bleeding device

front bleed screws 10 Nm

rear bleed screws 10 Nm

Precautions to be taken before and during the brake

a Position the vehicle on a two-post lift (see Vehicle:

a Switch off the vehicle ignition.

a Carry out the previous operation on the callipers:

1 - Topping up the level

2 - Approved brake fluid

Disc diameter 320

Minimum disc thickness (1) 26

Maximum disc run-out 0.035

Brake pad thickness 10.0

Wear limit of brake pad thickness 2

Rear brake (mm)

Piston diameter 42.86

Disc diameter 292

Drum diameter 172