6 - Air Conditioning

6
Air conditioning
61A
HEATING AIR CONDITIONING
62A
X95
JUNE 2008
"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed." All copyrights reserved by Renault. The reproduction or translation in part of whole of the present document, as well as the use of the spare parts reference numbering system, are prohibited without the prior written consent of Renault.
Edition Anglaise
Renault s.a.s 2008
MEGANE III - Section 6ContentsPage
MEGANE III - Section 6

Contents
Page
61A
HEATING Heating: List and location of components Cabin lter: Removal Retting C-pillar intermediate air distribution duct: Removal Retting Rear air distribution duct: Removal - Retting Recirculation control cable: Removal - Retting Air distribution cable: Removal - Retting Air mixing cable: Removal Retting Air distribution unit: Removal - Retting Heater matrix: Removal Retting Fan assembly: Removal Retting Heating resistor relays: Removal - Retting Heating resistor unit: Removal - Retting Passenger compartment fan assembly control unit: Removal - Retting Control panel: Removal Retting Front side air distribution duct: Removal - Retting Front central air distribution duct: Removal - Retting
61A
HEATING A-pillar air distribution duct: Removal - Retting Recirculation motor: Removal - Retting Mixer motor: Removal Retting
61A-1 61A-9
61A-67 61A-68 61A-73 61A-81
61A-13 61A-14 61A-15 61A-16 62A 61A-21 61A-26 61A-32 61A-39 61A-48 61A-50
Distribution motor: Removal Retting Passenger compartment temperature sensor: Removal - Retting
61A-85
AIR CONDITIONING Air conditioning: Precautions for repair Air conditioning: Parts and consumables for the repair work Air conditioning: Operating diagram Air conditioning: Check Heating and ventilation system diagnostic tool: Use Coolant circuit check 62A-3 62A-6 62A-7 62A-8 62A-11 62A-16 62A-23
62A-1
62A-2
61A-54 61A-57 61A-61 61A-66
Coolant circuit Draining Relling Condenser: Removal Retting Compressor: Removal Retting Expansion valve: Removal Retting
Contents
62A
AIR CONDITIONING Evaporator: Cleaning Expansion valve - condenser connecting pipe: Removal Retting Expansion valve/ intermediate pipe connecting pipe: Removal - Retting Pressure sensor: Removal Retting Evaporator sensor: Removal - Retting Condenser - compressor connecting pipe: Removal Retting Compressor/intermediate pipe connecting pipe: Removal - Retting 62A-30
62A-32
62A-38 62A-42 62A-43
62A-46
62A-51
HEATING Heating: List and location of components

B95 or D95 or E95 or K95, and CLIMATE CONTROL I - LIST OF COMPONENTS The air conditioning system consists of: - a control panel (1) , - a mixing motor (2) , - a distribution motor (3) , - a cabin filter (4) , - an expansion valve (5) , - a recirculation motor (6) , - a recirculation control cable (7) , - a cooling fan assembly (8) ,
61A
- a front side air distribution duct (15) , - a front right-hand side intermediate air distribution duct (16) , - a front left-hand side intermediate air distribution duct (17) , - a front centre air distribution duct (18) , - a front left-hand footwell air distribution duct (19) , - a front right-hand footwell air distribution duct (20) , - a rear left-hand footwell air distribution duct (21) , - a rear right-hand footwell air distribution duct (22) . EQT LEVEL EA4, and ELEC PARKING BRAKE
- a passenger compartment fan assembly control unit (9) , - a mixing motor (10) , - an evaporator sensor (11) , - a heater matrix (12) , - a heating resistor relay (13) , - a heating resistor (14) , II - LOCATION OF COMPONENTS - a rear intermediate air distribution duct (23) , - a rear air distribution duct (24) .
133409
61A-1

B95 or D95 or E95 or K95, and CLIMATE CONTROL
61A
133410
61A-2

61A
133406
61A-3

61A
EQT LEVEL EA4, and ELEC PARKING BRAKE
133404
61A-4

B95 or D95 or E95 or K95, and AIR CONDITIONING I - LIST OF COMPONENTS The air conditioning system consists of: - a control panel (1) , - an air distribution cable (2) , - a cabin filter (3) , - an expansion valve (4) , - a recirculation motor (5) , - a recirculation control cable (6) , - a cooling fan assembly (7) , - a passenger compartment fan assembly control unit (8) , - an evaporator sensor (9) , - a heater matrix (10) , - a heating resistor relay (11) , - a heating resistor (12) , - an air mixing cable (13) , - a front side air distribution duct (14) , II - LOCATION OF COMPONENTS
61A
- a front right-hand side intermediate air distribution duct (15) , - a front left-hand side intermediate air distribution duct (16) , - a front centre air distribution duct (17) , - a front left-hand footwell air distribution duct (18) , - a front right-hand footwell air distribution duct (19) , - a rear left-hand footwell air distribution duct (20) , - a rear right-hand footwell air distribution duct (21) .
- a rear intermediate air distribution duct (22) , - a rear air distribution duct (23) .
133405
61A-5

B95 or D95 or E95 or K95, and AIR CONDITIONING
61A
133407
61A-6

61A
133406
61A-7

61A
133404
61A-8
HEATING Cabin filter: Removal - Refitting

B95 or D95 or E95 or K95, and LEFT-HAND DRIVE
61A
REMOVAL
I - REMOVAL PREPARATION OPERATION a Remove: - the glovebox (see Glovebox: Removal - Refitting) ( 57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) .
REFITTING
I - REFITTING PREPARATION OPERATION a Check there are no foreign bodies in the cabin filter housing and clean thoroughly if necessary. II - REFITTING OPERATION FOR PART CONCERNED a Refit: - the cabin filter, - the cabin filter flap,
II - OPERATION FOR REMOVAL OF PART CONCERNED
- the bolts on the cabin filter flap. a Fit the electrical wiring on the cabin filter flap. III - FINAL OPERATION a Refit: - the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment).
135675
a Remove the electrical wiring (1) from the cabin filter flap after marking its routing. a Remove: - the bolts (2) from the cabin filter flap, - the cabin filter flap.
Note: Foreign bodies (leaves, insects etc.) are likely to accumulate in the passenger compartment lter. Remove the lter with care so as to prevent foreign bodies getting into the evaporator. a Remove the cabin filter.
61A-9

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE
61A
Tightening torquesm clutch pedal nuts 21 N.m
REMOVAL
I - REMOVAL PREPARATION OPERATION a Unclip the centre console right-hand trim a Remove: - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment).
137154
a Remove the nuts (5) from the clutch pedal. Note: Do not disconnect the clutch pedal connectors. a Move the clutch pedal aside. Note: Do not put any strain on the hydraulic clutch pipes. a Route the hydraulic clutch pipes under the distribution unit.
137690
a Unclip the hydraulic clutch pipes (1) . a Move the hydraulic clutch pipes aside. a Unclip the clutch pedal wiring (2) .
61A-10

61A
136999
a Tilt the clutch pedal in the direction of the arrow. a Fit the clutch pedal in the footwell.
135675
a Mark the wiring (3) on the cabin filter flap. a Move aside the wiring of the cabin filter flap. a Remove: - the bolts (4) from the cabin filter flap, - the cabin filter flap. Note: Foreign bodies (leaves, insects etc.) are likely to accumulate around the cabin lter. Remove the lter with care so as to prevent foreign bodies getting into the evaporator.
REFITTING
I - REFITTING PREPARATION OPERATION a Check there are no foreign bodies in the cabin filter housing and clean thoroughly if necessary. II - REFITTING OPERATION FOR PART CONCERNED a Refit: - the cabin filter, - the cabin filter flap, - the bolts on the cabin filter flap. a Fit the electrical wiring on the cabin filter flap.
61A-11

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE III - FINAL OPERATION a Fit: - the clutch pedal, - the hydraulic clutch pipes. a Refit the clutch pedal nuts. a Torque tighten the clutch pedal nuts (21 N.m). a Clip: - the clutch pedal wiring, - the hydraulic clutch pipes. a Refit: - the glovebox (see Glovebox: Removal - Refitting) ( 57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment), a Clip on the centre console right-hand trim.
61A
61A-12
HEATING
C-pillar intermediate air distribution duct: Removal - Refitting
B95 or D95 or E95 or K95, and EQT LEVEL EA4, and ELEC PARKING BRAKE Essential special tooling Car. 1363 Set of trim removal levers. II - FINAL OPERATION
61A
a Refit the dashboard (see Dashboard: Removal Refitting) (57A, Interior equipment). a Connect the battery (see Battery : Removal - Refitting) (80A, Battery).
REMOVAL
I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery : Removal Refitting) (80A, Battery). a Remove the dashboard (see Dashboard: Removal - Refitting) (57A, Interior equipment). II - OPERATION FOR REMOVAL OF PART CONCERNED
137016
a Remove: - the clip (1) from the C-pillar intermediate air distribution duct using the tool (Car. 1363), - the C-pillar intermediate air distribution duct.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED a Refit: - the C-pillar intermediate air distribution duct, - the clip of the C-pillar intermediate air distribution duct.
61A-13
HEATING Rear air distribution duct: Removal - Refitting

B95 or D95 or E95 or K95, and EQT LEVEL EA4, and ELEC PARKING BRAKE
61A
REMOVAL
I - REMOVAL PREPARATION OPERATION a Remove the centre console (see Centre console: Removal - Refitting) (57A, Interior equipment). II - OPERATION FOR REMOVAL OF PART CONCERNED
136378
a Remove the bolts (1) from the rear air distribution duct. a Unclip (2) the rear air distribution duct from the centre console. a Remove the rear air distribution duct from the centre console.
136377
a Unclip the rear section of the centre console.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED a Refit the rear air distribution duct on the centre console. a Clip the rear air distribution duct to the centre console. a Refit the rear air distribution duct bolts. II - FINAL OPERATION a Refit the centre console (see Centre console: Removal - Refitting) (57A, Interior equipment).
61A-14
HEATING Recirculation control cable: Removal - Refitting

B95 or D95 or E95 or K95
61A
REMOVAL
137024
a Unclip the wiring at (2) . a Remove the recirculation cable.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED a Refit the recirculation cable.
137028
a Clip on the recirculation cable. II - FINAL OPERATION a Refit the dashboard (see Dashboard: Removal Refitting) (57A, Interior equipment). a Connect the battery (see Battery : Removal - Refitting) (80A, Battery).
a Unclip the wiring at (1) .
61A-15
HEATING Air distribution cable: Removal - Refitting

B95 or D95 or E95 or K95, and LEFT-HAND DRIVE, and AIR CONDITIONING
61A
REMOVAL
I - REMOVAL PREPARATION OPERATION a Remove: - the glovebox (see Glovebox: Removal - Refitting) ( 57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment). RADIO NO 01 or RADIO NO 02 or RADIO NO 03 or RADIO NO 04 or RADIO NO 05 a Remove the radio (see Car radio: Removal - Refitting) (86A, Radio).
135677
a Squeeze the centring pins (2) while pushing the control panel.
RADIO NO 06 or RADIO NO 07 a Remove the radio navigation system (see Radio navigation system: Removal - Refitting) (83C, Onboard telematics system).
135659
a Tilt the control panel. a Unclip the air mixing cable from the control panel at (3) . a Move aside the control panel.
135676
a Remove the bolts (1) from the control panel.
61A-16

B95 or D95 or E95 or K95, and LEFT-HAND DRIVE, and AIR CONDITIONING II - OPERATION FOR REMOVAL OF PART CONCERNED a Clip:
61A
- the air mixing cable to the control panel, - the control panel centring pins. a Refit the control panel bolts. a Check that the air distribution control can move along its whole stroke. RADIO NO 06 or RADIO NO 07 a Refit the radio navigation system (see Radio navigation system: Removal - Refitting) (83C, Onboard telematics system).
135658
a Unclip the air distribution cable from the control panel at (4) .
RADIO NO 01 or RADIO NO 02 or RADIO NO 03 or RADIO NO 04 or RADIO NO 05 a Refit the radio (see Car radio: Removal - Refitting) (86A, Radio).
a Refit: - the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment).
136994
a Unclip the air distribution cable from the distribution unit at (5) . a Mark the routing of the air distribution cable. a Remove the air distribution cable.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED a Refit the air distribution cable. a Clip the air distribution control cable onto: - the distribution unit, - the control panel. II - FINAL OPERATION a Fit the control panel.
61A-17

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and AIR CONDITIONING a Remove: Tightening torquesm dashboard cross member reinforcement upper bolts dashboard cross member reinforcement lower bolts 21 N.m
61A
- the lower bolts from the dashboard cross member reinforcement, - the upper bolts from the dashboard cross member reinforcement, - the dashboard cross member reinforcement. 21 N.m
REMOVAL
I - REMOVAL PREPARATION OPERATION a Remove: - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment), - the front footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment).
135676
RADIO NO 01 or RADIO NO 02 or RADIO NO 03 or RADIO NO 04 or RADIO NO 05 a Remove the radio (see Car radio: Removal - Refitting) (86A, Radio).
RADIO NO 06 a Remove the radio navigation system (see Radio navigation system: Removal - Refitting) (83C, Onboard telematics system).
135677
a Squeeze the centring pins (2) while pushing the control panel.
FR AND RR PROX RADAR a Disconnect the connector from the parking distance control buzzer.
a Unclip the wiring from the dashboard cross member reinforcement.
61A-18

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and AIR CONDITIONING
61A
135659
a Tilt the control panel. a Unclip the air mixing cable from the control panel at (3) . a Move aside the control panel. II - OPERATION FOR REMOVAL OF PART CONCERNED
136990
a Unclip the air distribution cable from the distribution unit at (5) . a Mark the routing of the air distribution cable. a Remove the air distribution cable.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED a Refit the air distribution cable. a Clip: - the air distribution cable on the distribution unit, - the air distribution cable on the control panel.
135658
II - FINAL OPERATION a Fit the control panel. a Clip: - the air mixing cable to the control panel, - the control panel centring pins. a Clip the air mixing cable onto the control panel. a Clip on the control panel centring pins. a Refit the control panel bolts. a Check that the air distribution control can move along its whole stroke. a Refit: - the dashboard cross member stiffener,
61A-19

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and AIR CONDITIONING - the upper bolts of the dashboard cross member reinforcement, - the lower bolts of the dashboard cross member reinforcement. a Tighten to torque: - the dashboard cross member reinforcement upper bolts (21 N.m), - the dashboard cross member reinforcement lower bolts (21 N.m). a Clip on the dashboard cross member reinforcement wiring.
61A
FR AND RR PROX RADAR a Connect the parking distance control buzzer connector.
RADIO NO 06 a Refit the radio navigation system (see Radio navigation system: Removal - Refitting) (83C, Onboard telematics system).
a Refit: - the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment), - the front footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment).
61A-20
HEATING Air mixing cable: Removal - Refitting

61A
REMOVAL
I - REMOVAL PREPARATION OPERATION a Remove: - the glovebox (see Glovebox: Removal - Refitting) ( 57A, Interior equipment), - the front left-hand footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment). RADIO NO 01 or RADIO NO 02 or RADIO NO 03 or RADIO NO 04 or RADIO NO 05 a Remove the radio (see Car radio: Removal - Refitting) (86A, Radio).
135677
a Squeeze the centring pins (2) while pushing the control panel. a Tilt the control panel . II - OPERATION FOR REMOVAL OF PART CONCERNED
135659
a Unclip the air mixing cable from the control panel at (3) .
135676
61A-21

61A
RADIO NO 06 or RADIO NO 07 a Refit the radio navigation system (see Radio navigation system: Removal - Refitting) (83C, On board telematics system).
a Refit: - the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment), - the front left-hand footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment).
136993
a Unclip the air mixing cable from the distribution unit. a Mark the routing of the air mixing cable. a Remove the air mixing cable.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED a Refit the air mixing cable. a Clip the air mixing cable onto: - the distribution unit, - the control panel. II - FINAL OPERATION a Fit the control panel. a Clip the air mixing cable onto the control panel. a Clip on the centring pins. a Refit the control panel bolts. a Check that the air distribution control can move along its whole stroke.
61A-22

61A
Tightening torquesm dashboard cross member reinforcement upper bolts dashboard cross member reinforcement lower bolts 21 N.m
21 N.m
FR AND RR PROX RADAR
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Disconnect the connector from the parking distance control buzzer.
137019
a Unclip the left-hand centre console trim. a Remove: - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment), - the front left-hand footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment).
135692
a Remove the lower bolts (1) from the dashboard cross member reinforcement.
RADIO NO 01 or RADIO NO 02 or RADIO NO 03 or RADIO NO 04 or RADIO NO 05 a Remove the radio (see Car radio: Removal - Refitting) (86A, Radio).
61A-23

61A
135677
a Squeeze the centring pins (4) while pushing the control panel. a Tilt the control panel.
135693
a Remove: - the upper bolts (2) from the dashboard cross member reinforcement, - the dashboard cross member reinforcement.
135659
a Unclip the air mixing cable (5) from the control panel.
135676
61A-24

B95 or D95 or E95 or K95, and LEFT-HAND DRIVE, and AIR CONDITIONING a Tighten to torque:
61A
- the dashboard cross member reinforcement upper bolts (21 N.m), - the dashboard cross member reinforcement lower bolts (21 N.m). a Clip on the wiring of the dashboard cross member reinforcement. FR AND RR PROX RADAR a Connect the parking distance control buzzer connector.
RADIO NO 01 or RADIO NO 02 or RADIO NO 03 or RADIO NO 04 or RADIO NO 05

136993
a Unclip the air mixing cable (6) from the distribution unit. a Mark the routing of the air mixing cable. a Remove the air mixing cable.
a Refit the radio (see Car radio: Removal - Refitting) (86A, Radio).
RADIO NO 06 or RADIO NO 07 a Refit the radio navigation system (see Radio navigation system: Removal - Refitting) (83C, On board telematics system).
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED a Refit the air mixing cable. a Clip: - the air mixing cable onto the distribution unit, - the air mixing cable onto the control panel. II - FINAL OPERATION a Fit the control panel. a Clip on the centring pins of the control panel. a Refit the control panel bolts. a Check that the air mixing control can move along its whole stroke. a Refit: - the dashboard cross member reinforcement, - the upper bolts of the dashboard cross member reinforcement, - the lower bolts of the dashboard cross member reinforcement.
a Refit: - the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment). - the front left-hand footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment). a Clip on the left-hand centre console trim.
61A-25
HEATING Air distribution unit: Removal - Refitting

B95 or D95 or K95 Essential special tooling Ms. 583 Hose clamp pliers. Essential equipment refrigerant charging station F4R Tightening torquesm clip of the air lter unit air outlet pipe 5.5 N.m a Remove:
61A
- the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the windscreen wiper mechanism (see Windscreen wiper mechanism: Removal - Refitting) (85A, Wiping - Washing).
- the lifting eye of the cylinder head, - the turbocharger heat shield nuts. WARNING To prevent the surrounding components from overheating, do not damage (tear, pierce, bend, etc.) a heat shield. Any damaged heat shields must be replaced. a Remove the turbocharger heat shield.
IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 62A, Air conditioning, Air conditioning: Precautions for repair, page 62A-1) .
Note: Use fuel blanking plugs with part no. 77 01 208 229 or 77 01 476 857 to plug any openings exposed to the open air. Do not use any which have already been used to plug a fuel circuit.
REMOVAL
I - REMOVAL PREPARATION OPERATION a Remove the front engine cover.
WARNING Consult the device's operating manual to avoid incorrect use. a Drain the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-8) . a Disconnect the battery (see Battery : Removal Refitting) (80A, Battery). a Remove: - the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping Washing), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment),
61A-26

B95 or D95 or K95
61A
F4R
F9Q or K9K a Remove the clips from the bulkhead heat shield.
WARNING To prevent the surrounding components from overheating, do not damage (tear, pierce, bend, etc.) a heat shield. Any damaged heat shields must be replaced. a Move the bulkhead heat shieldto one side.
136467
a Remove: - the bulkhead upper heat shield bolts (1) , - the bulkhead upper heat shield clips (2) .
WARNING T prevent the surrounding components from o overheating, do not damage (tear, pierce, bend, etc.) a heat shield. Any damaged heat shields must be replaced. a Remove the bulkhead upper heat shield.
F9Q a Remove: - the battery (see Battery : Removal - Refitting) (80A, Battery), - the diesel injection computer (see Diesel injection computer: Removal - Refitting) (13B, Diesel injection), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting) (12B, Turbocharging). WARNING
136487
a Remove the bolts (3) from the expansion valve connecting pipe bracket.
In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe. a Uncouple the connecting pipes from the expansion valve. a Remove the connecting pipes from the expansion valve. a Remove the connecting pipe seals. a Insert the blanking plugs.
61A-27

B95 or D95 or K95
61A
F4R
135707
a Loosen the clip (4) of the air outlet pipe on the air filter unit.
137157
a Unclip the vacuum pipe (6) from the brake servo.
135796
a Remove the bolts (5) from the air inlet pipe on the throttle valve.
134643
a Disconnect the connector (7) of the turbocharging pressure regulation valve control solenoid valve. a Detach the turbocharging pressure regulation valve control solenoid valve. a Remove the air outlet pipe from the air filter box.
a Fit the tool (Ms. 583) on the heater matrix hoses. a Disconnect the heater matrix hoses.
61A-28

B95 or D95 or K95 a Remove: - the dashboard (see Dashboard: Removal - Refitting) (57A, Interior equipment), - the front side air distribution duct (see 61A, Heating, Front side air distribution duct: Removal Refitting, page 61A-61) , - the dashboard cross member (see Dashboard cross member: Removal - Refitting) (42A, Upper front structure). II - OPERATION FOR REMOVAL OF PART CONCERNED - the cabin filter, - the expansion valve, - the recirculation motor, - the air recirculation control cable, - the fan assembly, - the fan assembly control unit, - the evaporator sensor, - the heater matrix, - heater resistor relays, - the heating resistor, - the air mixing cable.
61A
CLIMATE CONTROL a Remove the following components from the distribution unit: - the left-hand mixer motor, - the right-hand mixer motor, - the distribution motor,
137642
a Disconnect the supply connector (8) from the distribution unit. a Unclip the electrical wiring from the distribution unit. a Separate the electrical wiring from the distribution unit. a Remove the distribution unit. Note: T nd the location of components (see 61A, o Heating, Heating: List and location of components, page 61A-1) .
- the cabin filter, - the expansion valve, - the recirculation motor, - the air recirculation control cable, - the fan assembly, - the fan assembly control unit, - the evaporator sensor, - the heater matrix, - heater resistor relays,
AIR CONDITIONING a Remove the following components from the distribution unit: - the air distribution cable, - the heating resistor.
61A-29

B95 or D95 or K95
61A
REFITTING
I - REFITTING PREPARATION OPERATION a parts always to be replaced: refrigerant pipe seal (30,02,02,52). 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 tted to the vehicle.
- the heating resistor.
AIR CONDITIONING a Refit the following components onto the distribution unit: - the air distribution cable, - the cabin filter, - the expansion valve, - the recirculation motor,
WARNING T avoid any leaks, check that the pipe surface is o sound before positioning the new seal. The surface must be clean and scratch free. a Remove the blanking plugs. a Lubricate the seals using recommended air conditioning oil to make fitting easier (see 62A, Air condit i o n i n g , Air conditioning: Parts and consumables for the repair work, page 62A-2) . a Fit new seals to the refrigerant connecting pipes. II - REFITTING OPERATION FOR PART CONCERNED CLIMATE CONTROL a Refit the following components onto the distribution unit: - the left-hand mixer motor, - the right-hand mixer motor, - the distribution motor, - the cabin filter, - the expansion valve, - the recirculation motor, - the air recirculation control cable, - the fan assembly, - the fan assembly control unit, - the evaporator sensor, - the heater matrix, - heater resistor relays,
- the air recirculation control cable, - the fan assembly, - the fan assembly control unit, - the evaporator sensor, - the heater matrix, - heater resistor relays, - the heating resistor, - the air mixing cable.
a Refit the distribution unit. a Fit the wiring on the distribution unit. a Clip the wiring onto the distribution unit. a Connect the supply connector of the distribution unit. III - FINAL OPERATION a Refit: - the dashboard cross member (see Dashboard cross member: Removal - Refitting) (42A, Upper front structure), - the front side air distribution duct (see 61A, Heating, Front side air distribution duct: Removal Refitting, page 61A-61) , - the dashboard (see Dashboard: Removal - Refitting) (57A, Interior equipment). a Connect the heater matrix hoses. a Remove the tool (Ms. 583) from the heater matrix hoses.
61A-30

B95 or D95 or K95 - the turbocharger heat shield, F4R a Refit: - the air outlet pipe to the air filter unit, - the air inlet pipe to the throttle valve. a Clip on the turbocharging pressure regulation valve control solenoid valve. a Connect the connector of the turbocharging pressure regulation valve control solenoid valve. a Clip on the brake servo vacuum pipe. a Torque tighten the clip of the air filter unit air outlet pipe (5.5 N.m). Note: a Connect the connecting pipes to the expansion valve. F9Q or K9K a Fit the heat shield to the bulkhead. a Refit the heat shield bolts. a Perform the following operations: - the turbocharger heat shield nuts,
61A
- the lifting eye of the cylinder head.
a Connect the battery (see Battery : Removal - Refitting) (80A, Battery). a Fill and bleed the cooling circuit (see Cooling circuit: Draining - Refilling) (19A, Cooling).
A summary table gives the quantities of refrigerant in the system according to the engine type (see 62A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-2) .
- refill the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-8) , - check for leaks (see 62A, Air conditioning, Coolant circuit check, page 62A-7) . a Check that the air conditioning system is operating correctly (see 62A, Air conditioning, Air conditioning: Check, page 62A-3) . a Refit: - the windscreen wiper mechanism (see Windscreen wiper mechanism: Removal - Refitting) (85A, Wiping - Washing), - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping Washing), - the engine cover.
F9Q a Refit: - the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting) (12B, Turbocharging), - the battery tray (see Battery : Removal - Refitting) (80A, Battery), - the diesel injection computer (see Diesel injection computer: Removal - Refitting) (13B, Diesel injection), - the battery (see Battery : Removal - Refitting) (80A, Battery).
F4R a Refit: - the bulkhead upper heat shield, - the bulkhead upper heat shield bolts, - the bulkhead upper heat shield clips,
61A-31
HEATING Heater matrix: Removal - Refitting

B95 or D95 or E95 or K95, and LEFT-HAND DRIVE Essential special tooling Ms. 583 Hose clamp pliers.
61A
Tightening torquesm dashboard cross member reinforcement upper bolts dashboard cross member reinforcement lower bolts clip of the air lter unit air outlet pipe 21 N.m
21 N.m
5.5 N.m
REMOVAL
135796
I - OPERATION FOR REMOVAL OF PART CONCERNED a Switch off the ignition. a Remove the engine style cover. F4R
a Remove the bolts (2) from the air inlet pipe on the throttle valve.
135707
137157
a Disconnect the brake servo vacuum pipe (3) .
61A-32

61A
134643
135692
a Disconnect the connector from the turbocharging pressure regulation valve control solenoid valve. a Unclip the turbocharger pressure regulation valve control solenoid valve at (4) . a Remove the air outlet pipe from the air filter box.
a Fit the tool (Ms. 583) on the heater matrix hoses. a Unclip the centre console left-hand trim. a Remove: - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment), - the front left-hand footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) .
135693
61A-33

B95 or D95 or E95 or K95, and LEFT-HAND DRIVE II - OPERATION FOR REMOVAL OF PART CONCERNED - the heater matrix trim.
61A
135694
a Remove the clips (7) from the heater matrix rigid pipes. WARNING Prepare for the ow of uid, and protect the surrounding components. a Put a protective cover on the floor carpet. a Position a container to collect the coolant under the rigid pipes. a Move the heater matrix rigid pipes aside. a Remove the seals from the heater matrix rigid pipes. a Take the heater matrix out of its housing. a Remove the heater matrix.
135696
REFITTING
I - REFITTING PREPARATION OPERATION a parts always to be replaced: heater matrix coolant pipe seal (30,02,01,46) a Always replace the heater matrix rigid pipe clips. WARNING To avoid any leaks, check that the pipe surface is sound before positioning the new seal. The surface must be clean and scratch free.
II - REFITTING OPERATION FOR PART CONCERNED a Refit: - the heater matrix in its housing, - the heater matrix trim. a Fit: - new seals on the heater matrix rigid pipes,
135695
- the heater matrix rigid pipes on the heater matrix. a Refit new clips on the rigid pipes of the heater matrix.
a Remove: - the heater matrix trim bolts (8) ,
61A-34

B95 or D95 or E95 or K95, and LEFT-HAND DRIVE a Remove: - the container for recovering coolant under the rigid pipes, - the protective cover on the floor carpet. III - FINAL OPERATION a Refit: - the dashboard cross member reinforcement, - the upper bolts on the dashboard cross member reinforcement, - the lower bolts on the dashboard cross member reinforcement. a Tighten to torque: - the dashboard cross member reinforcement upper bolts (21 N.m), - the dashboard cross member reinforcement lower bolts (21 N.m). a Refit: - the front left-hand footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the instrument panel lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment). a Clip on the centre console left-hand trim. a Remove the tool (Ms. 583) from the heater matrix hoses. F4R a Refit: - the air outlet pipe to the air filter unit, - the air inlet pipe to the throttle valve. a Clip on the turbocharging pressure regulation valve control solenoid valve. a Connect: - the connector on the turbocharging pressure regulation valve control solenoid valve, - the vacuum pipe from the brake servo. a Torque tighten the clip of the air filter unit air outlet pipe (5.5 N.m). a Fill up and bleed the cooling system (see Cooling circuit: Draining - Refilling) (19A, Cooling). a Refit the engine style cover.
61A
61A-35

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE Essential special tooling Ms. 583 Hose clamp pliers.
61A
Tightening torquesm clip of the air lter unit air outlet pipe 5.5 N.m
REMOVAL
I - REMOVAL PREPARATION OPERATION a Switch off the ignition. a Remove the front engine cover. F4R
135796
a Loosen the bolts (2) of the air inlet pipe on the throttle valve.
135707
137157
a Disconnect the brake servo vacuum pipe (3) .
61A-36

61A
135694
a Remove the clips (5) from the heater matrix rigid pipes.
134643
a Disconnect the connector of the turbocharging pressure regulation valve control solenoid valve. a Unclip the turbocharger pressure regulation valve control solenoid valve at (4) . a Remove the air outlet pipe from the air filter box.
WARNING Prepare for the ow of uid, and protect the surrounding components. a Put a protective cover on the floor carpet. a Position a container to collect the coolant under the rigid pipes. a Move the heater matrix rigid pipes aside. a Remove the seals from the heater matrix rigid pipes
a Fit the tool (Ms. 583) on the heater matrix hoses. a Unclip the centre console left-hand trim. a Remove: - the glovebox (see Glovebox: Removal - Refitting) ( 57A, Interior equipment), - the front left-hand footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) .
135695
a Remove: - the heater matrix trim bolts (6) ,
61A-37

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE - the heater matrix trim. a Remove:
61A
- the container for recovering coolant under the rigid pipes, - the protective cover on the floor carpet. III - FINAL OPERATION a Refit: - the front left-hand footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment). a Clip on the centre console left-hand trim. a Remove the tool (Ms. 583) from the heater matrix hoses. F4R
135696
a Refit: - the air outlet pipe to the air filter unit, - the air inlet pipe to the throttle valve. a Clip on the turbocharging pressure regulation valve control solenoid valve. a Connect:
a Take the heater matrix out of its housing. a Remove the heater matrix.
REFITTING
I - REFITTING PREPARATION OPERATION a parts always to be replaced: heater matrix coolant pipe seal (30,02,01,46) a Always replace the heater matrix rigid pipe clips. WARNING T avoid any leaks, check that the pipe surface is o sound before positioning the new seal. The surface must be clean and scratch free.
- the connector on the turbocharging pressure regulation valve control solenoid valve, - the vacuum pipe from the brake servo. a Torque tighten the clip of the air filter unit air outlet pipe (5.5 N.m).
a Fill up and bleed the cooling system (see Cooling circuit: Draining - Refilling) (19A, Cooling). a Refit the engine cover.
II - REFITTING OPERATION FOR PART CONCERNED a Refit: - the heater matrix in its housing, - the heater matrix trim. a Fit: - new seals on the rigid pipes of the heater matrix, - the heater matrix rigid pipes on the heater matrix. a Refit new clips on the rigid pipes of the heater matrix.
61A-38
HEATING Fan assembly: Removal - Refitting

B95 or D95 or E95 or K95, and LEFT-HAND DRIVE Essential special tooling Ms. 1909 Tool for removal - retting of Valo fan assembly
61A
REMOVAL
I - REMOVAL PREPARATION OPERATION a Remove: - the glovebox (see Glovebox: Removal - Refitting) ( 57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the cabin filter (see 61A, Heating, Cabin filter: Removal - Refitting, page 61A-9) , - the front side air distribution duct (see 61A, Heating, Front side air distribution duct: Removal Refitting, page 61A-61) . a Remove the side air distribution duct (see 61A, Heating, Front side air distribution duct: Removal Refitting, page 61A-61) .
137641
a Disconnect the recirculation motor connector. a Mark the routing of the recirculation motor wiring. a Separate the wiring from the recirculation motor. a Remove: - the bolts (2) from the air recirculation duct, - the air recirculation duct. II - OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the connector from the passenger compartment fan assembly motor passing through the cabin filter housing.
137028
a Unclip the recirculation control cable.
61A-39

61A
137676
137678
a Position the turbine of the passenger compartment fan assembly in such a way as to align the holes (3) required to fit the tool (Ms. 1909).
a Push and turn the tool (Ms. 1909) anticlockwise to unlock the passenger compartment fan assembly.
137679 137677
a Position the tool (Ms. 1909) and turn it slightly from left to right so that the 3 rods of tool MS 1909 coincide with the 3 holes of the turbine.
a Remove the fan assembly from its housing while taking care not to damage the turbine. Note: To avoid making the fan assembly motor unstable, position the assembly horizontally while protecting it from any impact.
61A-40

61A
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
137681
a Fit the tool (Ms. 1909) (4) on the passenger compartment fan assembly.
137683
a Check that the clip is correctly positioned (5) in relation to the turbine of the passenger compartment fan assembly.
137682
a Align the clip of the tool (Ms. 1909) along the shaft.
137686
a Refit the fan assembly in its housing by turning the tool 45.
61A-41

61A
137677
a Push the fan assembly until it is fully inserted in its housing. a Turn the tool (Ms. 1909) clockwise to lock the passenger compartment fan assembly. a Remove the (Ms. 1909). a Connect the passenger compartment fan assembly connector. II - FINAL OPERATION a Refit the air recirculation duct. a Fit the recirculation motor wiring. a Connect the recirculation motor connector. a Clip on the recirculation control cable. a Refit the side air distribution duct (see 61A, Heating, Front side air distribution duct: Removal - Refitting, page 61A-61) . a Refit: - the front side air distribution duct (see 61A, Heating, Front side air distribution duct: Removal Refitting, page 61A-61) , - the cabin filter (see 61A, Heating, Cabin filter: Removal - Refitting, page 61A-9) , - the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment).
61A-42

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE Essential special tooling Ms. 1909 Tool for removal - retting of Valo fan assembly
61A
Tightening torquesm steering column bolts 21 N.m
REMOVAL
I - REMOVAL PREPARATION OPERATION a Unclip the right-hand centre console trim. a Remove: - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment), - the cabin filter (see 61A, Heating, Cabin filter: Removal - Refitting, page 61A-9) .
134365
a Disconnect the steering column connectors (2) . a Fit a block of approximately 440 mm between the steering column and the floor.
134366 136716
a Remove the nuts (3) from the steering column. a Remove the block between the steering column and the floor.
a Remove: - the cover bolts (1) under the steering wheel, - the cowlings under the steering wheel. a Disconnect the steering column switch assembly connectors.
61A-43

61A
137636
137641
a Lower the steering column in the footwell. Note: Ver tically lower the steering column and do not apply pressure to the universal joints. a Check that the cross piece (4) does not leave the bearing.
a Disconnect the recirculation motor connector. a Mark the routing of the recirculation motor wiring. a Separate the wiring from the recirculation motor. a Remove: - the bolts (6) from the air recirculation duct, - the air recirculation duct. II - OPERATION FOR REMOVAL OF PART CONCERNED a Disconnect the passenger compartment fan assembly motor connector passing through the cabin filter housing.
137028
a Unclip the recirculation control cable (5) .
61A-44

61A
137676
137678
a Position the turbine of the passenger compartment fan assembly in such a way as to align the holes (7) required to fit the tool (Ms. 1909).
a Push and turn the tool (Ms. 1909) anticlockwise to unlock the passenger compartment fan assembly.
137677
137679
a Position the tool (Ms. 1909) and turn it slightly from left to right so that the 3 rods of the tool (Ms. 1909) coincide with the 3 holes of the turbine.
a Remove the passenger compartment fan assembly from its housing while taking care not to damage the turbine.
Note: To avoid making the passenger compartment fan assembly motor unstable, position the assembly horizontally while protecting it from any impact.
61A-45

61A
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
137681
a Fit the tool (Ms. 1909) (8) on the passenger compartment fan assembly.
137683
a Check that the clip (9) is correctly positioned in relation to the turbine of the passenger compartment fan assembly.
137682
a Align the clip of the tool (Ms. 1909) along the shaft.
137686
a Refit the passenger compartment fan assembly in its housing by turning the tool 45.
61A-46

61A
- the steering column switch assembly connectors. a Refit: - the cowlings under the steering wheel, - the cabin filter (see 61A, Heating, Cabin filter: Removal - Refitting, page 61A-9) , - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment). a Clip on the right-hand centre console trim.
137687
a Push the passenger compartment fan assembly until it is fully inserted in its housing. a Turn the tool (Ms. 1909) clockwise to lock the passenger compartment fan assembly. a Remove the (Ms. 1909). a Connect the passenger compartment fan assembly connector. II - FINAL OPERATION a Refit the air recirculation duct. a Fit the recirculation motor wiring. a Connect the recirculation motor connector. a Clip on the recirculation control cable. a Check that the recirculation control can move along its whole stroke. a Fit a block of approximately 440 mm between the steering column and the floor. a Refit the steering column. a Refit the steering column bolts. a Torque tighten the steering column bolts (21 N.m). a Remove the block between the steering column and the floor. a Check the condition of the steering column bearings. a Connect: - the electric steering column lock connector, - the steering column connectors,
61A-47
HEATING Heating resistor relays: Removal - Refitting

61A
REMOVAL
I - REMOVAL PREPARATION OPERATION a Switch off the ignition.
137019
a Unclip the left-hand centre console trim. II - OPERATION FOR REMOVAL OF PART CONCERNED
136384
a Unclip the cover from the heating resistor relay unit at (2) .
136383 137635
a Unclip the heating resistor relay unit from the distribution unit at (1) . a Separate the heating resistor relay unit from the distribution unit.
a Remove the heating resistor relays (3) .
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED a Refit the heating resistor relays.
61A-48
HEATING Heating resistor relays: Removal - Refitting

B95 or D95 or E95 or K95 a Clip: - the cover of the heating resistor relay unit, - the heating resistor relay unit onto the distribution unit. II - FINAL OPERATION a Clip on the left-hand centre console trim.
61A
61A-49
HEATING Heating resistor unit: Removal - Refitting

61A
Tightening torquesm dashboard cross member reinforcement upper bolts dashboard cross member reinforcement lower bolts 21 N.m
21 N.m
REMOVAL
I - OPERATION FOR REMOVAL OF PART CONCERNED a Switch off the ignition.
135692
137019
a Unclip the centre console left-hand trim. a Remove: - the instrument panel lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment), - the front left-hand footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) .
135693
FR AND RR PROX RADAR a Disconnect the connector from the parking distance control buzzer.
61A-50

B95 or D95 or E95 or K95, and LEFT-HAND DRIVE II - OPERATION FOR REMOVAL OF PART CONCERNED
61A
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED a Refit the heating resistor. II - FINAL OPERATION a Refit: - the dashboard cross member reinforcement, - the upper bolts on the dashboard cross member reinforcement, - the lower bolts on the dashboard cross member reinforcement. a Tighten to torque: - the dashboard cross member reinforcement upper bolts (21 N.m), - the dashboard cross member reinforcement lower bolts (21 N.m).
136380
a Disconnect the connector (3) from the heating resistor.
a Unclip the wiring from the dashboard cross member reinforcement. FR AND RR PROX RADAR a Connect the parking distance control buzzer connector.
a Refit: - the front left-hand footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the instrument panel lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment). a Clip on the centre console left-hand trim.
136381
a Remove: - the heating resistor bolts (4) , - the heating resistor.
61A-51

61A
REMOVAL
I - REMOVAL PREPARATION OPERATION a Switch off the ignition. a Unclip the centre console left-hand trim. a Remove: - the glovebox (see Glovebox: Removal - Refitting) ( 57A, Interior equipment), - the front footwell air distribution duct on the lefthand side (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) . II - OPERATION FOR REMOVAL OF PART CONCERNED
136381
a Remove the bolts (2) from the heating resistor.
136380
a Disconnect the connector (1) from the heating resistor.
136382
a Take the heating resistor out of its housing. a Remove the heating resistor.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED a Refit the heating resistor. a Connect the heating resistor connector.
61A-52

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE II - FINAL OPERATION a Refit: - the front footwell air distribution duct on the lefthand side (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment). a Clip on the centre console left-hand trim.
61A
61A-53
HEATING
Passenger compartment fan assembly control unit: Removal - Refitting B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE
61A
REMOVAL
I - REMOVAL PREPARATION OPERATION a Remove: - the glovebox (see Glovebox: Removal) ( 57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) .
II - FINAL OPERATION a Refit: - the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the glovebox (see Glovebox: Removal) (57A, Interior equipment).
136991
a Unclip the control unit (1) from the passenger compartment fan assembly. a Disconnect the connector (2) from the passenger compartment fan assembly control unit.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED a Connect the blower unit control unit connector. a Clip on the passenger compartment fan assembly control unit.
61A-54
HEATING
Passenger compartment fan assembly control unit: Removal - Refitting B95 or D95 or E95 or K95, and LEFT-HAND DRIVE
61A
Tightening torquesm pedal assembly nuts brake pedal impacter bolt 21 N.m 21 N.m
REMOVAL
I - REMOVAL PREPARATION OPERATION a Unclip the centre console left-hand trim. a Remove: - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment), - the front left-hand footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) .
109879
a Remove: - the dual safety connecting shaft ring, - the dual safety connecting shaft (2) .
134662
a Remove the brake pedal impacter bolt (1) .

134696
a Remove the nuts (3) from the brake pedal. Note: Do not disconnect the connectors from the brake pedal - accelerator assembly and replace the brake light switch in the event of an impact.
61A-55
HEATING
Passenger compartment fan assembly control unit: Removal - Refitting B95 or D95 or E95 or K95, and LEFT-HAND DRIVE a Partially remove the brake pedal - accelerator assembly. II - OPERATION FOR REMOVAL OF PART CONCERNED
61A
- a new dual safety connecting shaft, - the dual safety connecting shaft rubber ring, - the pedal assembly nuts. a Torque tighten the pedal assembly nuts (21 N.m). a Refit: - the brake pedal impacter, - a new brake pedal impacter bolt. a Torque tighten the brake pedal impacter bolt (21 N.m). a Refit: - the front left-hand footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment). a Clip on the centre console left-hand trim.
136991
a Unclip the passenger compartment fan assembly control unit at (4) . a Disconnect the connector (5) from the passenger compartment fan assembly control unit.
REFITTING
I - REFITTING PREPARATION OPERATION a parts always to be replaced: Connecting shaft between the brake pedal and the brake servo pushrod (30,03,02,07). a Part which must always be replaced: Brake pedal impacter bolt. II - REFITTING OPERATION FOR PART CONCERNED a Connect the connector to the passenger compartment fan assembly control unit. a Clip on the passenger compartment fan assembly control unit. III - FINAL OPERATION a Refit: - the accelerator - brake pedal assembly,
61A-56
HEATING Control panel: Removal - Refitting

61A
Essential equipment diagnostic tool
REMOVAL
I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery : Removal Refitting) (80A, Battery). a Remove the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment). AIR CONDITIONING, and RADIO NO 01 or RADIO NO 02 or RADIO NO 03 or RADIO NO 04 or RADIO NO 05 a Remove the radio (see Car radio: Removal - Refitting) (86A, Radio).
135677
a Squeeze the centring pins while pushing the control panel (2) . AIR CONDITIONING
AIR CONDITIONING, and RADIO NO 06 or RADIO NO 07 a Remove the radio navigation system (see Radio navigation system: Removal - Refitting) (83C, Onboard telematics system).
135659
a Tilt the control panel. II - OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the air mixing cable from the control panel at (3) . a Move aside the control panel.
135676
61A-57

61A
CLIMATE CONTROL
135658
135678
a Tilt the control panel. a Disconnect the control panel connector (6) .
135657
a Disconnect the connectors (5) from the control panel. a Remove the control panel.
135679
a Move aside the control panel. a Disconnect the control panel connector (7) . a Remove the control panel.
61A-58

61A
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED AIR CONDITIONING a Refit the control panel. a Connect the control panel connectors. a Clip the air distribution cable onto the control panel. a Fit the control panel in its housing. a Clip the air mixing cable onto the control panel.
CLIMATE CONTROL
135678
a Connect the connector (9) to the control panel.
a Clip on the centring pins. a Refit the control panel bolts. II - FINAL OPERATION a Refit the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment). AIR CONDITIONING, and RADIO NO 01 or RADIO NO 02 or RADIO NO 03 or RADIO NO 04 or RADIO NO 05
135679
a Refit the radio (see Car radio: Removal - Refitting) (86A, Radio).
a Connect the connector (8) to the control panel. a Refit the control panel in its housing.
AIR CONDITIONING, and RADIO NO 06 or RADIO NO 07 a Refit the radio navigation system (see Radio navigation system: Removal - Refitting) (83C, On board telematics system).
a Connect the battery (see Battery : Removal - Refitting) (80A, Battery).
61A-59

B95 or D95 or E95 or K95 a Apply the after repair procedure using the diagnostic tool : - connect the diagnostic tool, - select "Climate control computer", - go to repair mode, - display the "Before/after repair procedure" for the computer selected, - carry out the operations described in the "After repair procedure" section.
61A
61A-60
HEATING Front side air distribution duct: Removal - Refitting

B95 or D95 or E95 or K95, and LEFT-HAND DRIVE Essential special tooling Car. 1363 Set of trim removal levers. Right-hand side Note: The front left-hand side air distribution duct cannot be separated from the dashboard cross member for removal (see Dashboard cross member: Removal - Retting) (42A, Front upper structure).
61A
REMOVAL
I - REMOVAL PREPARATION OPERATION Right-hand side a Remove: - the glovebox (see Glovebox: Removal - Refitting) ( 57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) . RADIO NO 07 a Remove: - the receiver (see Tuner-amplifier: Removal - Refitting) (86A, Radio), - the navigation computer (see Navigation computer: Removal - Refitting) (83C, On-board telematics system).
135683
a Remove: - the clip (1) from the front side air distribution duct using the tool (Car. 1363), - the front side air distribution duct (2) .
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED Right-hand side a Refit: - the front side air distribution duct, - the front side air distribution duct clip. II - FINAL OPERATION Right-hand side RADIO NO 07 a Refit: - the navigation computer (see Navigation computer: Removal - Refitting) (83C, On-board telematics system),
61A-61

B95 or D95 or E95 or K95, and LEFT-HAND DRIVE - the receiver (see Tuner-amplifier: Removal - Refitting) (86A, Radio).
61A
a Refit: - the front footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment).
61A-62

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE Essential special tooling Car. 1363 Set of trim removal levers.
61A
Note: The front right-hand side air distribution duct cannot be separated from the dashboard cross member for removal (see Dashboard cross member: Removal - Retting) (42A, Front upper structure).
REMOVAL
Left-hand side
137018
a Remove: - the glovebox (see Glovebox: Removal - Refitting) ( 57A, Interior equipment), - the front left-hand footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the UCH (see UCH: Removal - Refitting) (87B, Interconnection unit).
a Cut the plastic clip (2) on the passenger compartment fuse and relay box. a Unclip the passenger compartment fuse and relay box plate from the dashboard cross member (3) . a Separate the passenger compartment fuse and relay box plate from the dashboard cross member.
137000
a Disconnect the connectors (1) from the passenger compartment fuse and relay box.
61A-63

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE II - OPERATION FOR REMOVAL OF PART CONCERNED Left-hand side III - FINAL OPERATION Left-hand side
61A
a Fit the passenger compartment fuse and relay support plate on the dashboard cross member. a Clip the passenger compartment fuse and relay support plate onto the dashboard cross member. a Refit a new plastic retaining clip on the passenger compartment fuse and relay support plate. a Connect the connectors to the passenger compartment fuse and relay support plate. a Refit: - the UCH (see UCH: Removal - Refitting) (87B, Interconnection unit), - the front left-hand footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment).
137022
a Use the tool (Car. 1363) to remove the clip (4) from the front side air distribution duct. a Unclip the front side air distribution duct. a Remove the front side air distribution duct.
REFITTING
I - REFITTING PREPARATION OPERATION Left-hand side a Part which must always be replaced: Plastic retaining clip for the passenger compartment fuse and relay support plate. II - REFITTING OPERATION FOR PART CONCERNED Left-hand side a Refit the front side air distribution duct. a Clip on the front side air distribution duct. a Refit the front side air distribution duct clip.
61A-64

J95
61A
REMOVAL
REMOVAL PREPARATION OPERATION Front right-hand side air distribution duct: a Disconnect the battery (see Battery: Removal - Refitting) . a Remove: - the airbag inhibitor switch (see Inhibitor switch: Removal - Refitting) , - the glovebox (see Glovebox: Removal - Refitting) . RADIO NO 07 a Remove: - the receiver (see Tuner-amplifier: Removal - Refitting) , - the receiver support bolts, - the receiver support.
61A-65
HEATING
Front central air distribution duct: Removal - Refitting
61A
REMOVAL
137638
a Remove the front centre air distribution duct bolts (1) . a Unclip the front centre air distribution duct at (2) . a Remove the front centre air duct.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED a Refit the front centre air duct. a Clip on the front centre air duct. a Refit the front centre air duct bolts. II - FINAL OPERATION a Refit the dashboard (see Dashboard: Removal Refitting) (57A, Interior equipment). a Connect the battery (see Battery : Removal - Refitting) (80A, Battery).
61A-66
HEATING A-pillar air distribution duct: Removal - Refitting

B95 or D95 or E95 or K95 Essential special tooling Car. 1363 Set of trim removal levers. 2 - Passenger side
61A
REMOVAL
1 - Driver's side a Remove the instrument panel lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment).
2 - Passenger side a Remove the glovebox (see Glovebox: Removal Refitting) (57A, Interior equipment).
135680
a Remove: - the clip (3) from the A-pillar air duct,
1 - Driver's side
- the A-pillar air duct (4) .
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED a Refit: - the A-pillar air duct, - the A-pillar air duct clip.
II - FINAL OPERATION
1 - Driver's side a Refit the instrument panel lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment).
135689
a Remove: - the clip (1) from the A-pillar air duct, using the tool (Car. 1363), - the A-pillar air duct (2) . 2 - Passenger side a Refit the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment).
61A-67
HEATING Recirculation motor: Removal - Refitting

61A
REMOVAL
I - REMOVAL PREPARATION OPERATION a Remove: - the glovebox (see Glovebox: Removal - Refitting) ( 57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) . RADIO NO 07 a Remove: - the receiver (see Tuner-amplifier: Removal - Refitting) (86A, Radio), - the navigation computer (see Navigation computer: Removal - Refitting) (83C, On-board telematics system).
137641
a Disconnect the recirculation motor connector. a Mark the routing of the recirculation motor wiring. a Separate the wiring from the recirculation motor. a Remove:
a Remove the front side air distribution duct (see 61A, Heating, Front side air distribution duct: Removal - Refitting, page 61A-61) .
- the bolts (2) from the air recirculation duct, - the air recirculation duct.
137633 137028
a Remove: - the bolts (3) from the air recirculation motor,
a Unclip the recirculation control cable (1) .
61A-68

B95 or D95 or E95 or K95, and LEFT-HAND DRIVE - the air recirculation motor. a Refit:
61A
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED a Refit: - the air recirculation motor, - the air recirculation duct. a Fit the recirculation motor wiring. a Connect the recirculation motor connector. II - FINAL OPERATION a Clip on the recirculation control cable. RADIO NO 07 a Refit: - the receiver (see Tuner-amplifier: Removal - Refitting) (86A, Radio), - the navigation computer (see Navigation computer: Removal - Refitting) (83C, On-board telematics system).
- the front side air distribution duct (see 61A, Heating, Front side air distribution duct: Removal Refitting, page 61A-61) , - the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment). a Apply the after repair procedure using the diagnostic tool : - connect the diagnostic tool, - select "Climate control computer", - go to repair mode, - display the "Before/after repair procedure" for the computer selected, - select "air recirculation flap motor" in the "List of components stored by this computer" section, - carry out the operations described in the "After repair procedure" section.
61A-69

61A
Tightening torquesm steering column bolts 21 N.m
REMOVAL
I - REMOVAL PREPARATION OPERATION a Unclip the centre console right-hand trim. a Remove the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment).
134365
a Disconnect the steering column connectors (2) and the steering column electric lock. a Fit a block of approximately 440 mm between the steering column and the floor.
136716
a Remove: - the cover bolts (1) under the steering wheel, - the cowlings under the steering wheel. a Disconnect the steering column switch assembly connectors.
134366
a Remove the nuts (3) from the steering column. a Remove the block between the steering column and the floor.
61A-70

61A
137636
a Lower the steering column in the footwell.

137641
Note: Ver tically lower the steering column and do not put apply pressure to the universal joints. a Check that the cross piece does not leave the bearing.
a Disconnect the recirculation motor connector. a Mark the routing of the recirculation motor wiring. a Separate the wiring from the recirculation motor. a Remove: - the bolts (6) from the air recirculation duct, - the air recirculation duct.
137028
a Unclip the recirculation control cable at (5) . a Remove: - the bolts (7) from the air recirculation motor,
137633
61A-71

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE - the air recirculation motor.
61A
a Apply the after repair procedure using the diagnostic tool : - connect the diagnostic tool, - select "Climate control computer",
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED a Refit: - the air recirculation motor, - the air recirculation duct. a Fit the recirculation motor wiring. a Connect the recirculation motor connector.
- go to repair mode, - display the "Before/after repair procedure" for the computer selected, - select "air recirculation flap motor" in the "List of components stored by this computer" section, - carry out the operations described in the "After repair procedure" section.
II - FINAL OPERATION a Clip on the recirculation control cable. a Check that the recirculation control can move along its whole stroke. a Refit the steering column. a Fit a block of approximately 440 mm between the steering column and the floor. a Refit the steering column bolts. a Torque tighten the steering column bolts (21 N.m). a Remove the block between the steering column and the floor. a Check the condition of the steering column bearings. a Connect: - the electric steering column lock connector, - the steering column connectors, - the steering column switch assembly connectors. a Refit: - the cowlings under the steering wheel, - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment). a Clip on the centre console right-hand trim.
61A-72
HEATING Mixer motor: Removal - Refitting

B95 or D95 or E95 or K95, and LEFT-HAND DRIVE, and CLIMATE CONTROL
61A
Tightening torquesm pedal assembly nuts brake pedal impacter bolt 21 N.m 21 N.m
REMOVAL
I - REMOVAL PREPARATION OPERATION 1 - Right-hand mixing motor a Remove: - the glovebox (see Glovebox: Removal - Refitting) ( 57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) . 2 - Left-hand mixing motor a Unclip the centre console left-hand trim. a Remove: - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment), - the front left-hand footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) . a Remove the brake pedal impacter bolt (1) .
134662
109879
a Remove: - the dual safety connecting shaft rubber ring, - the dual safety connecting shaft (2) .
61A-73

61A
II - OPERATION FOR REMOVAL OF PART CONCERNED 1 - Right-hand mixing motor
134696
a Remove the nuts (3) from the brake pedal. Note: Do not disconnect the connectors from the brake pedal - accelerator assembly and replace the brake light switch in the event of an impact. a Partially remove the brake pedal - accelerator assembly. a Mark the routing of the mixing motor wiring. a Disconnect the connector (4) from the air mixing motor. a Remove: - the bolts (5) from the air mixing motor, - the air mixing motor.
135682
61A-74

B95 or D95 or E95 or K95, and LEFT-HAND DRIVE, and CLIMATE CONTROL 2 - Left-hand mixing motor
61A
REFITTING
I - REFITTING PREPARATION OPERATION
1 - Right-hand mixing motor
137640
a Mark the routing of the mixing motor wiring. a Disconnect the connector (6) from the air mixing motor. a Remove: - the bolts (7) from the air mixing motor, - the air mixing motor.
137014
a Move the tie rod so that the flat surface (8) of the right-hand mixing motor recess is positioned at 90 in relation to the distribution unit reference axis (9) . 2 - Left-hand mixing motor a parts always to be replaced: Connecting shaft between the brake pedal and the brake servo pushrod (30,03,02,07). a part which must always be replaced: Brake pedal impacter bolt.
137015
a Move the tie rod so that the flat surface (10) of the left-hand mixing motor recess is positioned at 90 in relation to the edge of the distribution unit reference axis (11) .
61A-75

B95 or D95 or E95 or K95, and LEFT-HAND DRIVE, and CLIMATE CONTROL II - REFITTING OPERATION FOR PART CONCERNED Right-hand and left-hand mixing motor a Refit the mixing motor. a Connect the air mixing motor connector. a Fit the electrical wiring of the mixing motor. III - FINAL OPERATION 1 - Right-hand mixing motor a Refit: - the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment). 2 - Left-hand mixing motor a Refit: - the accelerator - brake pedal assembly, - the dual safety connecting shaft, - the dual safety connecting shaft rubber ring, - the pedal assembly nuts. a Torque tighten the pedal assembly nuts (21 N.m). a Refit: - the impacter, - the impacter bolt. a Torque tighten the brake pedal impacter bolt (21 N.m). a Refit: - the front left-hand air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment). a Clip on the centre console left-hand trim.
61A
a Apply the after repair procedure using the diagnostic tool : - connect the diagnostic tool, - select "Climate control computer", - go to repair mode, - display the "Before/after repair procedure" for the computer selected, - select "Left-hand air mixing flap motor or Righthand air mixing flap motor" in the "List of components stored by this computer" section, - carry out the operations described in the "After repair procedure" section.
61A-76

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and CLIMA CONTROL TE
61A
REMOVAL
I - REMOVAL PREPARATION OPERATION 1 - Right-hand mixing motor a Unclip the centre console right-hand trim a Remove: - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) .
137154
a Remove the clutch pedal nuts (3) . Note: Do not disconnect the connectors from the clutch pedal. a Remove the clutch pedal from its threaded rods in the direction of the arrow. Note: Do not apply pressure to the hydraulic clutch pipes. a Pass the hydraulic clutch pipes under the distribution unit.
137690
a Unclip the hydraulic clutch pipes (1) . a Move the hydraulic clutch pipes aside. a Unclip the clutch pedal wiring at (2) .
61A-77

61A
II - OPERATION FOR REMOVAL OF PART CONCERNED 1 - Right-hand mixing motor
136999
a Tilt the clutch pedal in the direction of the arrow. a Put the clutch pedal in the footwell.
135682
2 - Left-hand mixing motor a Remove the glovebox (see Glovebox: Removal Refitting) (57A, Interior equipment).
a Mark the routing of the mixing motor wiring. a Disconnect the air mixing motor connector. a Remove: - the bolts (4) from the air mixing motor, - the air mixing motor.
61A-78

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and CLIMA CONTROL TE 2 - Left-hand mixing motor 2 - Left-hand mixing motor
61A
137015
a Move the tie rod so that the flat surface (9) of the mixing motor recess is positioned at 90 in relation to the distribution unit reference axis.
137640
a Mark the routing of the mixing motor wiring. a Disconnect the air mixing motor connector. a Remove: - the bolts (5) from the air mixing motor, - the air mixing motor.
II - REFITTING OPERATION FOR PART CONCERNED a Refit the mixing motor. a Connect the air mixing motor connector. a Fit the electrical wiring of the mixing motor. III - FINAL OPERATION 1 - Right-hand mixing motor a Fit:
REFITTING
I - REFITTING PREPARATION OPERATION 1 - Right-hand mixing motor
- the clutch pedal, - the hydraulic clutch pipes. a Refit the clutch pedal nuts. a Torque tighten the clutch pedal nuts (21 N.m). a Clip: - the clutch pedal wiring, - the hydraulic clutch pipes. a Refit: - the glovebox (see Glovebox: Removal - Refitting) ( 57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) ,
137014
a Move the tie rod so that the flat surface (6) of the mixing motor recess is positioned at 90 in relation to the distribution unit reference axis (7) .
- the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment). a Clip on the centre console right-hand trim.
61A-79

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and CLIMA CONTROL TE 2 - Left-hand mixing motor a Refit the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment). a a Apply the after repair procedure using the diagnostic tool : - connect the diagnostic tool, - select "Climate control computer", - go to repair mode, - display the "Before/after repair procedure" for the computer selected, - select "Right-hand air mixing flap motor" in the "List of components stored by this computer" section, - carry out the operations described in the "After repair procedure" section.
61A
61A-80
HEATING Distribution motor: Removal - Refitting

61A
REFITTING
Essential equipment diagnostic tool I - REMOVAL PREPARATION OPERATION
REMOVAL
I - REMOVAL PREPARATION OPERATION a Remove: - the glovebox (see Glovebox: Removal - Refitting) ( 57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) . II - OPERATION FOR REMOVAL OF PART CONCERNED
137012
a Move the tie rod so that the flat surface (3) of the distribution motor recess is positioned at 90 in relation to the distribution unit reference axis (4) . II - REFITTING OPERATION FOR PART CONCERNED a Refit the distribution motor. a Connect the distribution motor connector. a Fit the electrical wiring of the distribution motor. III - FINAL OPERATION a Refit: - the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment).
136385
a Mark the routing of the motor wiring. a Disconnect the connector (1) from the distribution motor. a Remove: - the bolts (2) from the distribution motor, - the distribution motor.
a Apply the after repair procedure using the diagnostic tool : - connect the diagnostic tool, - select "Climate control computer", - go to repair mode, - display the "Before/after repair procedure" for the computer selected, - select "Footwell air distribution flap motor" in the "List of components stored by this computer" section, - carry out the operations described in the "After repair procedure" section.
61A-81

61A
REMOVAL
I - REMOVAL PREPARATION OPERATION a Unclip the right-hand centre console trim. a Remove: - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment),
137154
- the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) .
a Remove the clutch pedal nuts (3) . Note: Do not disconnect the connectors from the clutch pedal. a Detach the clutch pedal from its threaded rods. Note: Do not apply pressure to the hydraulic clutch pipes. a Pass the hydraulic clutch pipes under the distribution unit.
137690
a Unclip the clutch hydraulic pipes (1) . a Move the clutch hydraulic pipes aside. a Unclip the wiring (2) from the clutch pedal.
61A-82

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and CLIMA CONTROL TE - the distribution motor.
61A
REFITTING
I - REFITTING PREPARATION OPERATION
136999
137012
a Tilt the clutch pedal the in the direction of the movement arrow. a Put the clutch pedal in the footwell. II - OPERATION FOR REMOVAL OF PART CONCERNED
a Move the tie rod so that the flat surface (6) of the distribution motor recess is positioned at 90 in relation to the distribution unit reference axis (7) . II - REFITTING OPERATION FOR PART CONCERNED a Refit the distribution motor. a Connect the distribution motor connector. a Fit the electrical wiring of the distribution motor. III - FINAL OPERATION a Fit: - the clutch pedal, - the hydraulic clutch pipes. a Refit the clutch pedal nuts. a Torque tighten the clutch pedal nuts (21 N.m). a Clip: - the clutch pedal wiring, - the hydraulic clutch pipes. a Refit:
136385
a Mark the routing of the distribution motor wiring. a Disconnect the connector (4) from the distribution motor. a Remove: - the bolts (5) from the distribution motor,
- the front right-hand A-pillar air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment). a Clip on the centre console right-hand trim.
61A-83

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and CLIMA CONTROL TE a Apply the after repair procedure using the diagnostic tool : - connect the diagnostic tool, - select "Climate control computer", - go to repair mode, - display the "Before/after repair procedure" for the computer selected, - select "Footwell air distribution flap motor" in the "List of components stored by this computer" section, - carry out the operations described in the "After repair procedure" section.
61A
61A-84
HEATING
Passenger compartment temperature sensor: Removal - Refitting
61A
REMOVAL
OPERATION FOR REMOVAL OF PART CONCERNED
137688
a Unclip the passenger compartment temperature sensor from the interior rear view mirror trim at (2) .
137004
a Remove the interior rear view mirror trim.
REFITTING
REFITTING OPERATION FOR PART CONCERNED a Clip the passenger compartment temperature sensor onto the interior rear view mirror trim. a Connect the passenger compartment temperature sensor connector. a Refit the interior rear view mirror trim.
137003
a Disconnect the passenger compartment temperature sensor connector (1) .
61A-85
AIR CONDITIONING Air conditioning: Precautions for repair

I - SAFETY IMPORTANT IMPORTANT The following must be worn when handling refrigerant: - gloves, - protective goggles (with side shields if possible). In the event of refrigerant uid coming into contact with the eyes, rinse well with clean water continuously for 15 minutes. If possible, have an eye rinse unit available. If refrigerant comes into contact with your eyes, consult a doctor immediately. Inform the doctor that the burns were caused by R134A refrigerant. In the event of contact with other unprotected parts of the body (event though the safety advice has been observed), rinse well with clean water continuously for 15 minutes.
62A
To prevent refrigerant from leaking, never repair a faulty air conditioning circuit component. Replace all faulty components. It is essential to follow the routing of the connecting pipes. Ensure that the refrigerant connecting pipes are correctly fitted so that they will not come into contact with metal parts in the engine compartment.
WARNING In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe.
WARNING To avoid damaging the surface of the air conditioning pipes when removing the seals, do not use a tool with a metallic end piece.
IMPORTANT Work requiring the use of refrigerant must be carried out in a well-ventilated area. The refrigerant must not be stored in a shaft, a pit, a hermetically sealed room, etc. Refrigerants are colourless and odourless uids. Refrigerant is heavier than air. As a result there is a risk of asphyxia for those working close to the ground and less than 5 m away from the working area (pit, well, air vents, etc.). Switch on gas extraction systems. At temperatures above 100C, the refrigerant will decompose and produce a highly irritant gas. WARNING IMPORTANT It is forbidden to smoke close to an open coolant circuit. II - GENERAL RECOMMENDATIONS It is possible to place components in the drying oven after painting or to carry out work near the system if the temperature does not exceed 80C. Lubricants are not mutually compatible: always observe the types and quantities of oil for each compressor even when topping up as this could damage the cold loop components. Always close the oil cans again after use to keep moisture out and never use oil contained in a can that has been open for a long time (viscous appearance).
WARNING To prevent moisture from entering the system, place plugs on the cold loop components which are open to the air.
WARNING To avoid any leaks, check that the pipe surface is sound before positioning the new seal. The surface must be clean and scratch free.
62A-1
AIR CONDITIONING
Air conditioning: Parts and consumables for the repair work
B95 or D95 or E95 or K95 For the oil part number (see Vehicle: Parts and consumables for repair) (04B, Consumables - Products).
62A
Table of vehicle refrigerant capacities according to their engines and various specifications. Engine Refrigerant capacity (g) Type of compressor Type of original oil Type of After-Sales oil Quantity of oil (ml)
K4M F4R K9K M9R F9Q H4J M4R VALEO DCS-S7EC ZXL 100 PG 150 20 480 35 6 SEL 14C ND-OIL 8 SANDEN SP10 110 10
Table of quantities of oil to add when replacing components: Operation on the air conditioning circuit Circuit oil change Split pipe or other rapid leak Replacement of a pipe Replacement of a condenser Replacement of an evaporator or distribution unit Replacement of the lter or dehydrator reservoir Removing - Retting a compressor Replacement of a compressor Standard replacement of a compressor Replacement of a compressor and one or more air conditioning circuit component(s) Standard replacement of a compressor and replacement of one or more refrigerant circuit component(s) Quantity of oil (ml orcc) Measure the volume recovered and add the same quantity of new oil 100 Quantity recovered +10 Quantity recovered +30 Quantity recovered +30 Quantity recovered +15 Quantity recovered None added Top up as necessary None added Top up as necessary
62A-2
AIR CONDITIONING Air conditioning: Check
62A
Equipment required Dual-sensor temperature measuring device
Note: When performing RENAULT maintenance, check the air conditioning system at the end of the vehicle's maintenance program so that the engine will be cold. I - PREPARATION OPERATION FOR THE MEASUREMENT DEVICE a Check that the measurement device functions properly (see the device's instruction manual). a Set units to C. a Set the device's sensitivity to 0.1C.
119358
a Check the two sensors T1 and T2 in order to calculate the correction () to be applied to the measurement (T1 - T2). the two sensors must indicate the same measurement under the same conditions. Check the sensors by: - bringing the ends of the 2 sensors together until they touch, - placing the sensors in the air flow of an air vent, - setting the passenger compartment fan assembly to top speed. - waiting for the value to become stable. - recording the correction value ().
Note: It is not necessary to start the vehicle. The device display is in mode (T) = (T1 - T2).
119360
a Set the reading mode to (T) = (T1 - T2) WARNING Note the difference and sign as soon as the temperature becomes stable. Calculate the correction () = - (T1 - T2) to be applied to the measurement (T). Examples: If (T1 - T2) = - 0.3C, correct the measurement (T) by () = + 0.3C If (T1 - T2) = + 0.3C, correct the measurement (T) by () = - 0.3C
62A-3

II - VEHICLE PREPARATION OPERATION a Put the vehicle in the shade, where the temperature is greater than or equal to 15C minimum. a Close the bonnet. a Open the front windows. a Start the engine and let it idle. a Set the air conditioning controls with: - recirculation mode in the external position, - the ventilation distribution in "face" mode, - the temperature control to coldest temperature setting in front (and at the back, if it exists), - the speed of the passenger compartment fan assembly set to maximum (switch off the rear control if it exists), - the front side and centre air vents open with the vanes in a neutral position, - the air conditioning system must be turned on (indicator light illuminated). a Wait 5 minutes with the engine idling before taking any measurements. III - MEASUREMENTS
62A
- wait for the value to become stable. - record the T3 temperature value. - close the bonnet if it was opened.
119357
a Record the air temperature at the left air vent (T1), and at the right air vent (T2). - fit sensor T1 in the left air vent (1) . - fit sensor T2 in the right air vent (2) . a Record the differences in temperature once the (T) value has stabilised: - between T3 and the higher of values T1 or T2, (T3 - highest value). - record this difference in temperature. - between T1 and T2 (read the (T) value (T1-T2) display mode). - record the difference in temperature (T) according to the correction () to be applied to the measurement. a If the (T)=(T1-T2) measurement is unstable, follow the procedure below: Note:
119359
a Record the air temperature at the scuttle panel grille (T3). - open the bonnet, depending on the vehicle, to access the scuttle panel grille. - place the sensor where air is drawn through the scuttle panel grille.
Depending on the vehicle's air conditioning system programming, this check method may not be applicable because the engine cooling fan assembly has been activated. Its operation renders the () value between T1 and T2 unstable. To eliminate this error, the fan assembly must be activated for the entire period over which temperature T1 and T2 measurements are recorded.
62A-4

a Activate the engine cooling fan assembly operation by modifying the engine speed. - stabilise the engine speed at 2000 rpm while T1 and T2 temperature measurements are being recorded. - check that the engine cooling fan assembly operating. - record the temperatures by following the instructions given in the paragraph MEASUREMENTS. IV - FAULT FINDING PROCEDURE a The following two following conditions must be met: - the difference between T3 and the higher of the two values T1 or T2, must be greater than or equal to 5C, - the difference between T1 and T2 must be less than or equal to 2C. Note: If one of these two conditions is not met, then the air conditioning system is not working properly. Should this be the case, refer to the fault nding procedure for the air conditioning system for the vehicle concerned.
62A
62A-5
AIR CONDITIONING Heating and ventilation system diagnostic tool: Use

TO CARRY OUT FAULT FINDING ON A HEATING AND AIR CONDITIONING SYSTEM CIRCUIT: with a thermostatic expansion valve:
62A
104964
a Use the AIRCODIAG tool to carry out fault finding on: - loss of refrigerant pressure or to check the correct pressure of the refrigerant in the circuit. - refrigerant fluid circuit overpressure. - a blocked dehydrator filter. a Refer to the equipment handbook.
62A-6
AIR CONDITIONING Coolant circuit check
62A
a Check the sealing of the refrigerant circuit using the electronic trace detector (follow the trace of the circuit as closely as possible, to limit variations due to other gases). Note:
IMPORTANT Consult the safety and cleanliness advice and operation recommendations before carrying out any repair (see 62A, Air conditioning, Air conditioning: Precautions for repair, page 62A-1) .
If replacing a defective part (see 62A, Air conditioning). 2 - Trace detectors a WARNING
Note: After any work on air conditioning circuit leaks on the Laguna II, Vel Satis and Espace IV check that , lling fault DF033 Refrigerant is not present, using the diagnostic tool. If it is present, clear it. The compressor cannot operate until the fault is cleared. There are several types of detector: - electronic detectors, - trace detectors.
Consult the device's operating manual to avoid incorrect use.
WARNING To avoid damaging the cold loop components (corrosions, etc.), do not use dye if the traces reveal that some product has already been injected. a Check for dye on the cold loop components with the ultraviolet light. a Inject the dye. a Start the engine. a Let the air conditioning system run for 15 minutes. a Switch off the engine. a Check the refrigerant circuit sealing by scanning the circuit with the ultraviolet light. Note: If replacing a defective part (see 62A, Air conditioning). a Affix a label (supplied with the dye capsule), to indicate that dye has been used (as close as possible to the filler valves).
Note: To carry out an after repair check, use the procedure for the electronic detector (1). To carr out a y more thorough check for leaks, use a trace detector (2). Check that the air conditioning system is operating correctly (see 62A, Air conditioning, Air conditioning: Check, page 62A-3) . REFRIGERANT CIRCUIT SEALING CHECKING OPERATION 1 - Electronic detectors: a WARNING Consult the device's operating manual to avoid incorrect use. a Switch on the electronic detector. a Start the engine. a Let the air conditioning system run for 15 minutes. a Switch off the engine.
62A-7
AIR CONDITIONING Coolant circuit Draining - Refilling
62A
Essential equipment refrigerant charging station
IMPORTANT Consult the safety and cleanliness advice and operation recommendations before carrying out any repair (see 62A, Air conditioning, Air conditioning: Precautions for repair, page 62A-1) .
WARNING Consult the device's operating manual to avoid incorrect use.
WARNING To avoid damaging the cold loop components (corrosions, etc.), do not use dye if the traces reveal that some product has already been injected.
Note: A summary table gives the quantities of refrigerant in the system according to the engine type (see 62A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A2) .
62A-8

I - RECOVERING REFRIGERANT FLUID a Note: - The air conditioning circuit is tted with a single rell valve; some lling equipment only require the use of a high-pressure hose (see the lling equipment instructions). - Depending on the situation, run the system for a few minutes before recovering the coolant to improve drainage.
62A
- drain for the first time (note down the value), - wait 15 minutes, - run the engine until the cooling fan is triggered twice, - switch off the engine, - drain for the second time (note down the value), - repeat the cycles until the relative pressure is equal to or less than 0 bar, - add together the values of the various draining operations; the fill is confirmed as being correct if the volume of refrigerant fluid is the specified fill +35g or -100g. Scenario C: - drain for the first time (note down the value), - wait 2 hours, - repeat the cycles until the relative pressure is equal to or less than 0 bar, - add together the values of the various draining operations; the fill is confirmed as being correct if the volume of refrigerant fluid is the specified fill +35g or -100g. II - CREATING A VACUUM a It is essential to carry out vacuum extraction correctly before loading, otherwise the air conditioning will not work properly. There are two scenarios to consider: - the vacuum will be created immediately after draining (scenario A), - vacuum created after an interval of several hours or days (scenario B). Scenario A: - creation of a vacuum takes 20 minutes. Scenario B: - creation of a vacuum takes 45 minutes to eliminate any trace of moisture. a Test the seal once the vacuum has been created (some stations do this automatically). III - FILLING a Fill up the refrigerant circuit using the refrigerant charging station.
Note: It is essential to follow these procedures to prevent: - gas escaping when the circuit is opened, - pollution of the environment through the release of gas into the atmosphere when the circuit is opened or when a vacuum is created. When draining or checking the refrigerant fill load, three scenarios are to be taken into account: - the engine is running and the air conditioning is in operation (A), - the engine is running but the air conditioning is not in operation (B), - the engine is not running nor is the air conditioning in operation (C). a Scenario A: - Operate the air conditioning until the cooling fan assembly is triggered twice, - switch off the engine, - drain for the first time (note down the original value), - wait 15 minutes, - check that the relative pressure is no more than 0 bar, - repeat the cycles until the relative pressure is equal to or less than 0 bar, - add together the values of the various draining operations; the fill is confirmed as being correct if the volume of refrigerant fluid is the specified fill +35g or -100g. Scenario B: - run the engine until the cooling fan is triggered twice, - switch off the engine,
62A-9

a Top up the oil with the recommended type and volume of oil and refrigerant, depending on the work carried out (see 6 2 A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-2) . a Check there are no leaks using the electronic detector (see 62A, Air conditioning, Coolant circuit check, page 62A-7) . WARNING After injecting dye into the refrigerant, be sure to indicate this on a label (supplied with the dye capsule), and the date of the operation. Position the label so it is visible near to the cold loop ller valve. a Check that the air conditioning system is operating correctly (see 62A, Air conditioning, Air conditioning: Check, page 62A-3) .
62A
62A-10
AIR CONDITIONING Condenser: Removal - Refitting

62A
Note: Use blanking plugs for the fuel circuits with part numbers 77 01 208 229 or 77 01 476 857 to plug any openings exposed to the open air. The must y be clean. Do not use any which have already been used to plug a fuel circuit.
REMOVAL
I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
WARNING Consult the device's operating manual to avoid incorrect use. a Drain the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-8) . a Remove: - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the front sections of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection).
62A-11

62A
135786
135784
a Unclip: - the central deflector (1) , - the left-hand side deflector (2) , - the right-hand side deflector (3) . a Remove - the audible warning (see Horn: Removal - Refitting) (82A, Horn), - the left-hand headlight (see Front headlight: Removal - Refitting) (80B, Headlights), - the side support of the left-hand front panel (see Front end panel side support: Removal - Refitting) (42A, Upper front structure).
135783
62A-12

B95 or D95 or E95 or K95 II - OPERATION FOR REMOVAL OF PART CONCERNED
62A
135670 135672
a Disconnect the pressure sensor connector (4) .
a Remove the bolt (5) securing the bracket for the condenser - expansion valve connecting pipe to the condenser. WARNING In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe. a Disconnect the condenser - expansion valve connecting pipe from the condenser. a Remove the seals from the condenser - expansion valve connecting pipe. a Insert the blanking plugs.
62A-13

62A
135671
135674
a Remove the bolt (6) securing the bracket for the compressor - condenser connecting pipe from the condenser. WARNING In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe. a Disconnect the compressor - condenser connecting pipe from the condenser. a Remove the seal from the compressor condenser connecting pipe. a Insert the blanking plugs.
a Remove the condenser in accordance with the direction of the arrow.
REFITTING
I - REFITTING PREPARATION OPERATION a parts always to be replaced: refrigerant pipe seal (30,02,02,52).
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 tted to the vehicle.
WARNING To avoid any leaks, check that the pipe surface is sound before positioning the new seal. The surface must be clean and scratch free. a Remove the blanking plugs. a Lubricate its new seals using recommended air conditioning oil to make fitting easier (see 62A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-2) . a Fit new seals to the refrigerant connecting pipes.
62A-14

B95 or D95 or E95 or K95 II - REFITTING OPERATION FOR PART CONCERNED a Refit: - the condenser, - the connecting pipes to the condenser. a Connect the pressure sensor connector. III - FINAL OPERATION a Refit: - the side support of the left-hand front panel (see Front end panel side support: Removal - Refitting) (42A, Upper front structure), - the left-hand headlight (see Front headlight: Removal - Refitting) (80B, Headlights), - the audible warning (see Horn: Removal - Refitting) (82A, Horn). a Clip: - the right-hand side deflector, - the left-hand side deflector, - the central deflector. a Refit: - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the front sections of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres).
62A
Note: A summary table gives the quantities of refrigerant in the system according to the engine types (see 62A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-2) . a Fill up the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-8) . a Check for leaks (see 62A, Air conditioning, Coolant circuit check, page 62A-7) . a Check the air conditioning system is operating correctly (see 62A, Air conditioning, Air conditioning: Check, page 62A-3) .
62A-15
AIR CONDITIONING Compressor: Removal - Refitting

B95 or D95 or E95 or K95, and K4M or K9K a Remove: Essential equipment refrigerant charging station
62A
- the front right-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres), - the front right-hand wheel arch liner partially (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the lower engine tie-bar (see Lower engine tiebar: Removal - Refitting) (19D, Engine mounting).
WARNING WARNING To prevent moisture from entering the system, place plugs on the cold loop components which are open to the air. In order to prevent the accessories belt from being prematurely ruptured, do not damage (hit, force with a tool, etc.) the plastic pulley of the compressor. a Remove the accessories belt (see Accessories belt: Removal - Refitting) (11A, Top and front of engine).
REMOVAL
I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). WARNING Consult the device's operating manual to avoid incorrect use. a Drain the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-8) . a Disconnect the battery (see Battery : Removal Refitting) (80A, Battery). a Remove the front engine cover.
136473
a Remove the connecting pipe bracket bolts (1) .
WARNING In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe. a Move aside the compressor connecting pipes. a Remove the connecting pipe seals. a Fit blanking plugs on the openings of the connecting pipes and the compressor.
62A-16

B95 or D95 or E95 or K95, and K4M or K9K II - OPERATION FOR REMOVAL OF PART CONCERNED
62A
a Lubricate the new seals using recommended air conditioning oil to make fitting easier (see 62A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-2) . a Fit new seals to the refrigerant connecting pipes. II - REFITTING OPERATION FOR PART CONCERNED a Refit the compressor. a Connect the compressor connector. III - FINAL OPERATION a Refit: - the connecting pipes to the compressor, - the accessories belt (see Accessories belt: Removal - Refitting) (11A, Top and front of engine),
136473
a Disconnect the compressor connector (2) . a Move the engine towards the rear of the vehicle. a Remove: - the compressor bolts (3) , - the compressor.
- the lower engine tie-bar (see Lower engine tiebar: Removal - Refitting) (19D, Engine mounting), - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front right-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres). a Connect the battery (see Battery : Removal - Refitting) (80A, Battery).
REFITTING
Note: A summary table gives the quantities of refrigerant in the system according to the engine types (see 62A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-2) . a Fill up the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-8) . a Check for leaks (see 62A, Air conditioning, Coolant circuit check, page 62A-7) . a Check that the air conditioning system is operating correctly (see 62A, Air conditioning, Air conditioning: Check, page 62A-3) . a Refit the engine cover.
WARNING T avoid any leaks, check that the pipe surface is o sound before positioning the new seal. The surface must be clean and scratch free. a Remove the blanking plugs.
62A-17

B95 or D95 or E95 or K95, and F4R or F9Q a Remove: Essential equipment refrigerant charging station - the engine cover,
62A
- the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the headlights (see Front headlight: Removal Refitting) (80B, Headlights), - the front bumper supports (see Front bumper support: Removal - Refitting) (42A, Front upper structure), - the frontal impact cross member (see Front impact cross member: Removal - Refitting) (41A, Front lower structure), - the audible warning (see Horn: Removal - Refitting) (82B, Horn),
- the bonnet catch (see Bonnet latch: Removal Refitting) (52A, Non-side opening element mechanisms). WARNING In order to prevent the accessories belt from being prematurely ruptured, do not damage (hit, force with a tool, etc.) the plastic pulley of the compressor. a Remove the accessories belt (see Accessories belt: Removal - Refitting) (11A, Top and front of engine).
REMOVAL
I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). WARNING Consult the device's operating manual to avoid incorrect use. a Drain the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-8) . a Disconnect the battery (see Battery : Removal Refitting) (80A, Battery).
62A-18

B95 or D95 or E95 or K95, and F4R or F9Q
62A
135882
135296
a Remove the bolts (1) from the engine wiring channel.
a Remove the lower bolts (4) from the front end panel. a Tilt the front end panel slightly towards the front of the vehicle. a Remove the intercooler air outlet pipe (see Intercooler air outlet pipe: Removal - Refitting) (12B, Turbocharging).
135719
a Remove: - the upper bolts (2) from the front end panel, - the front end panel clips (3) .
62A-19

B95 or D95 or E95 or K95, and F4R or F9Q
62A
F4R
136473
135700
a Remove the connecting pipe bracket bolts (6) on the compressor. WARNING In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe. a Uncouple the connecting pipes from the compressor. a Move aside the compressor connecting pipes. a Remove the connecting pipe seals. a Fit blanking plugs on the openings of the connecting pipes and the compressor.
a Remove the bolt (5) of the intermediate pipe compressor connecting pipe retaining bracket from the engine block. a Remove the bolt of the compressor - condenser connecting pipe retaining bracket bolt from the compressor.
62A-20

B95 or D95 or E95 or K95, and F4R or F9Q II - OPERATION FOR REMOVAL OF PART CONCERNED
62A
a Lubricate the new seals using recommended air conditioning oil to make fitting easier (see 62A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-2) . a Fit new seals to the refrigerant connecting pipes. II - REFITTING OPERATION FOR PART CONCERNED a Refit the compressor. a Connect the compressor connector. III - FINAL OPERATION a Refit the connecting pipes to the compressor. F4R a Refit: - the retaining bracket of the intermediate pipe compressor connecting pipe on the engine block,
136473
a Disconnect the compressor connector (7) . a Remove: - the compressor bolts (8) , - the compressor.
- the retaining bracket of the compressor condenser connecting pipe on the compressor.
a Refit the intercooler air outlet pipe (see Intercooler air outlet pipe: Removal - Refitting) (12B, Turbocharging). a Fit the front end panel. a Refit the engine wiring channel. a Refit:
REFITTING
- the bonnet catch (see Bonnet latch: Removal Refitting) (52A, Non-side opening element mechanisms), - the front impact cross member (see Front impact cross member: Removal - Refitting) (41A, Front lower structure), - the front bumper supports (see Front bumper support: Removal - Refitting) (42A, Front upper structure), - the headlights (see Front headlight: Removal Refitting) (80B, Headlights), - the accessories belt (see Accessories belt: Removal - Refitting) (11A, Top and front of engine), - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection),
WARNING T avoid any leaks, check that the pipe surface is o sound before positioning the new seal. The surface must be clean and scratch free. a Remove the blanking plugs.
62A-21

B95 or D95 or E95 or K95, and F4R or F9Q - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres). a Connect the battery (see Battery : Removal - Refitting) (80A, Battery). Note: A summary table gives the quantities of refrigerant in the system according to the engine types (see 62A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-2) . a Fill up the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-8) . a Check for leaks (see 62A, Air conditioning, Coolant circuit check, page 62A-7) . a Check that the air conditioning system is operating correctly (see 62A, Air conditioning, Air conditioning: Check, page 62A-3) . a Refit the engine cover.
62A
62A-22
AIR CONDITIONING Expansion valve: Removal - Refitting

B95 or D95 or E95 or K95, and F9Q or K4M or K9K or M4R or M9R
62A
- the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment). F9Q
a Remove: - the battery (see Battery : Removal - Refitting) (80A, Battery), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting) (12A, Turbocharging).
REMOVAL
I - REMOVAL PREPARATION OPERATION a Remove the front engine cover.
136471
WARNING Consult the device's operating manual to avoid incorrect use. a Drain the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-8) . a Disconnect the battery (see Battery : Removal Refitting) (80A, Battery). a Remove: - the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping Washing), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment),
a Remove the nut (1) of the retaining bracket (2) from the intermediate pipe - expansion valve connecting pipe.
62A-23

B95 or D95 or E95 or K95, and F9Q or K4M or K9K or M4R or M9R
62A
136467
a Remove the clips (3) from the bulkhead heat shield. WARNING T prevent the surrounding components from o overheating, do not damage (tear, pierce, bend, etc.) a heat shield. Any damaged heat shields must be replaced. a Move the bulkhead heat shieldto one side.
136487
a Remove the connecting pipe bracket bolts (4) from the expansion valve. WARNING In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe. a Uncouple the connecting pipes from the expansion valve. a Remove the connecting pipes from the expansion valve. a Remove the connecting pipe seals. a Fit blanking plugs on the openings of the connecting pipes and the expansion valve.
62A-24

B95 or D95 or E95 or K95, and F9Q or K4M or K9K or M4R or M9R II - OPERATION FOR REMOVAL OF PART CONCERNED
62A
a Fit new seals to the refrigerant connecting pipes. II - REFITTING OPERATION FOR PART CONCERNED a Refit the expansion valve. III - FINAL OPERATION a Refit the connecting pipes on the expansion valve. a Fit the heat shield to the bulkhead. a Refit the retaining bracket of the intermediate pipe - expansion valve connecting pipe. F9Q a Refit: - the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting) (12A, Turbocharging),
136465
a Remove: - the bolts (5) from the expansion valve, - the expansion valve.
- the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the battery (see Battery : Removal - Refitting) (80A, Battery).
REFITTING
I - REFITTING PREPARATION OPERATION a parts always to be replaced: refrigerant pipe seal (30,02,02,52). 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 tted to the vehicle.
a Refit: - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the windscreen wiper arms (see Windscreen wiper blade: Removal - Refitting) (85A, Wiping Washing). a Connect the battery (see Battery : Removal - Refitting) (80A, Battery). Note:
WARNING T avoid any leaks, check that the pipe surface is o sound before positioning the new seal. The surface must be clean and scratch free. a Remove the blanking plugs. a Lubricate the seals using air conditioning oil to make fitting easier (see 62A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-2) .
A summary table gives the quantities of refrigerant in the system according to the engine types (see 62A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-2) . a Fill up the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-8) . a Check for leaks (see 62A, Air conditioning, Coolant circuit check, page 62A-7) .
62A-25

B95 or D95 or E95 or K95, and F9Q or K4M or K9K or M4R or M9R a Check that the air conditioning system is operating correctly (see 62A, Air conditioning, Air conditioning: Check, page 62A-3) . a Refit the engine cover.
62A
62A-26

B95 or D95 or E95 or K95, and F4R a Remove: Essential equipment refrigerant charging station
62A
- the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping Washing), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the cylinder head lifting eye, - the turbocharger heat shield nuts. WARNING To prevent the surrounding components from overheating, do not damage (tear, pierce, bend, etc.) a heat shield. Any damaged heat shields must be replaced. a Remove:
- the turbocharger heat shield, - the bulkhead upper heat shield bolts, - the bulkhead upper heat shield clips. WARNING To prevent the surrounding components from overheating, do not damage (tear, pierce, bend, etc.) a heat shield. Any damaged heat shields must be replaced. a Remove the bulkhead upper heat shield.
REMOVAL
I - REMOVAL PREPARATION OPERATION a Remove the front engine cover. WARNING Consult the device's operating manual to avoid incorrect use. a Drain the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-8) . a Disconnect the battery (see Battery : Removal Refitting) (80A, Battery).
62A-27

B95 or D95 or E95 or K95, and F4R
62A
136487
a Remove the connecting pipe bracket bolts (1) from the expansion valve. a Remove: WARNING In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe. a Disconnect the upper heat shield from the bulkhead. a Remove the bulkhead upper heat shield. a Remove the connecting pipe seals. a Fit blanking plugs on the openings of the connecting pipes and the expansion valve. I - REFITTING PREPARATION OPERATION - the bolts (2) from the expansion valve, - the expansion valve.
136465
REFITTING
a parts always to be replaced: refrigerant pipe seal (30,02,02,52). 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 tted to the vehicle.
WARNING To avoid any leaks, check that the pipe surface is sound before positioning the new seal. The surface must be clean and scratch free. a Remove the blanking plugs. a Lubricate the seals using air conditioning oil to make fitting easier (see 62A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-2) .
62A-28

B95 or D95 or E95 or K95, and F4R a Fit new seals to the refrigerant connecting pipes. II - REFITTING OPERATION FOR PART CONCERNED a Refit the expansion valve. III - FINAL OPERATION a Refit the connecting pipes on the expansion valve. a Refit: - the turbocharger heat shield, - the cylinder head lifting eye, - the bulkhead upper heat shield, - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping Washing). a Connect the battery (see Battery : Removal - Refitting) (80A, Battery). Note: A summary table gives the quantities of refrigerant in the system according to the engine types (see 62A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-2) . a Fill up the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-8) . a Check for leaks (see 62A, Air conditioning, Coolant circuit check, page 62A-7) . a Check that the air conditioning system is operating correctly (see 62A, Air conditioning, Air conditioning: Check, page 62A-3) . a Refit the engine cover.
62A
62A-29
AIR CONDITIONING Evaporator: Cleaning

62A
CLEANING
a Remove the cabin filter (see 61A, Heating, Cabin filter: Removal - Refitting, page 61A-9) . a Apply AIR CONDITIONING CLEANER (see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products) using an extension piece. a Leave the product to work for 15 minutes. a Refit the cabin filter (see 61A, Heating, Cabin filter: Removal - Refitting, page 61A-9) . a Activate the low speed motor-driven fan assembly for 5 min.
62A-30
AIR CONDITIONING Evaporator: Cleaning

62A
CLEANING
a Remove the evaporator sensor (see 62A, Air conditioning, Evaporator sensor: Removal - Refitting, page 62A-43) . a Apply AIR CONDITIONING CLEANER (see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products) using an extension piece. a Leave the product to work for 15 minutes. a Refit the evaporator sensor (see 62A, Air conditioning, Evaporator sensor: Removal - Refitting, page 62A-43) . a Activate the low speed motor-driven fan assembly for 5 min.
62A-31
AIR CONDITIONING
Expansion valve - condenser connecting pipe: Removal - Refitting
62A
- the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the right-hand headlight (see Front headlight: Removal - Refitting) (80B, Headlights), - the front panel support,
IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 62A, Air conditioning, Air conditioning: Precautions for repair, page 62A-1) . - the windscreen washer bottle (see Windscreen washer bottle: Removal - Refitting) (85A, Wiping - Washing) - the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping Washing), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment).
Note: Use blanking plugs for the fuel circuits with part numbers 77 01 208 229 or 77 01 476 857 to plug any openings exposed to the open air. The must y be clean. Do not use any which have already been used to plug a fuel circuit. F9Q a Remove: - the battery (see Battery : Removal - Refitting) (80A, Battery), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting) (12B, Turbocharging).
REMOVAL
I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Remove the engine cover. WARNING Consult the device's operating manual to avoid incorrect use. a Drain the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-8) . a Disconnect the battery (see Battery : Removal Refitting) (80A, Battery). a Remove: - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection),
F9Q or K4M or K9K or M4R or M9R a Remove the clips from the bulkhead heat shield.
WARNING To prevent the surrounding components from overheating, do not damage (tear, pierce, bend, etc.) a heat shield. Any damaged heat shields must be replaced. a Move the bulkhead heat shieldto one side.
62A-32
AIR CONDITIONING
62A
F4R a Remove: - the cylinder head lifting eye, - the turbocharger heat shield nuts. WARNING T prevent the surrounding components from o overheating, do not damage (tear, pierce, bend, etc.) a heat shield. Any damaged heat shields must be replaced. a Remove: - the turbocharger heat shield, - the bulkhead upper heat shield bolts, - the bulkhead upper heat shield clips. WARNING T prevent the surrounding components from o overheating, do not damage (tear, pierce, bend, etc.) a heat shield. Any damaged heat shields must be replaced. a Remove the bulkhead upper heat shield. II - OPERATION FOR REMOVAL OF PART CONCERNED
135297
a Remove the bolt (2) from the front right-hand side member tie rod. a Move the front right-hand side member tie rod towards the wheel arch.
136481 135303
a Loosen the front right-hand bolt on the subframe at (1) .
a Remove the bolt (3 ) from the support of the condenser - expansion valve connecting pipe on the front right-hand panel.
62A-33
AIR CONDITIONING
62A
136475
136484
a Remove the plastic nut (4) from the support for the condenser - expansion valve connecting pipe on the front right-hand side member.
a Remove the bolt (6) securing the support for the condenser - expansion valve connecting pipe on the front right-hand side member reinforcement.
136479
a Remove the bolt (5) securing the condenser - expansion valve connecting pipe to the front panel.
62A-34
AIR CONDITIONING
62A
136469
136485
a Unclip the condenser - expansion valve connecting pipe on the front right-hand side member and on the bulkhead at (7) .
62A-35
AIR CONDITIONING
62A
- the condenser - expansion valve connecting pipe, - the seals from the condenser - expansion valve connecting pipe. a Disconnect: - the condenser - expansion valve connecting pipe from the expansion valve, - the condenser - expansion valve connecting pipe from the condenser. a Fit blanking plugs on: - the condenser, - the expansion valve, - the condenser - expansion valve connecting pipe.
136487
REFITTING
WARNING To avoid any leaks, check that the pipe surface is sound before positioning the new seal. The surface must be clean and scratch free.
135670
a Remove: - the bolt (8) for the condenser - expansion valve connecting pipe bracket on the expansion valve, - the bolt (9) for the condenser - expansion valve connecting pipe bracket on the condenser.
a Remove the blanking plugs. a Lubricate the seals using air conditioning oil to make fitting easier (see 62A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-2) . a Fit the new seals on the condenser - expansion valve connecting pipe. II - REFITTING OPERATION FOR PART CONCERNED a Refit the condenser - expansion valve connecting pipe.
WARNING In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe. a Remove:
62A-36
AIR CONDITIONING
B95 or D95 or E95 or K95 a Clip the condenser - expansion valve connecting pipe onto the front right-hand side member and onto the bulkhead. III - FINAL OPERATION a Fit the side member tie rod. F4R a Refit: - the bulkhead upper heat shield, - the turbocharger heat shield, - the cylinder head lifting eye. Note:
62A
- the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping Washing), a Connect the battery (see Battery : Removal - Refitting) (80A, Battery).
A summary table gives the quantities of refrigerant in the system according to the engine types (see 62A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-2) . a Fill up the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-8) . a Check for leaks (see 62A, Air conditioning, Coolant circuit check, page 62A-7) .
F9Q or K4M or K9K or M4R or M9R a Fit the heat shield to the bulkhead.
F9Q a Refit: - the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting) (12B, Turbocharging), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the battery (see Battery : Removal - Refitting) (80A, Battery).
a Check that the air conditioning system is operating correctly (see 62A, Air conditioning, Air conditioning: Check, page 62A-3) . a Refit the engine cover.
a Refit: - the windscreen washer bottle (see Windscreen washer bottle: Removal - Refitting) (85A, Wiping - Washing) - the front panel support, - the right-hand headlight (see Front headlight: Removal - Refitting) (80B, Headlights), - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres).
62A-37
AIR CONDITIONING
Expansion valve/intermediate pipe connecting pipe: Removal - Refitting B95 or D95 or E95 or K95
62A
- the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment). F9Q
a Remove: - the battery (see Battery : Removal - Refitting) (80A, Battery), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting) (12B, Turbocharging).
WARNING To prevent moisture from entering the system, place plugs on the cold loop components which are open to the air. F9Q or K4M or K9K or M4R or M9R a Remove the clips from the bulkhead heat shield. Note: Use blanking plugs for the fuel circuits with part numbers 77 01 208 229 or 77 01 476 857 to plug any openings exposed to the open air. The must y be clean. Do not use any which have already been used to plug a fuel circuit. WARNING To prevent the surrounding components from overheating, do not damage (tear, pierce, bend, etc.) a heat shield. Any damaged heat shields must be replaced. a Move the bulkhead heat shieldto one side.
REMOVAL
I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Remove the front engine cover. WARNING Consult the device's operating manual to avoid incorrect use. a Drain the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-8) . a Disconnect the battery (see Battery : Removal Refitting) (80A, Battery). a Remove: - the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping Washing), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment),
62A-38
AIR CONDITIONING
62A
F4R a Remove: - the cylinder head lifting eye, - the turbocharger heat shield nuts. WARNING T prevent the surrounding components from o overheating, do not damage (tear, pierce, bend, etc.) a heat shield. Any damaged heat shields must be replaced. a Remove: - the turbocharger heat shield, - the bulkhead upper heat shield bolts, - the bulkhead upper heat shield clips. WARNING T prevent the surrounding components from o overheating, do not damage (tear, pierce, bend, etc.) a heat shield. Any damaged heat shields must be replaced. a Remove the bulkhead upper heat shield.
136471
a Remove the nut (1) from the retaining bracket (2) of the expansion valve - intermediate pipe connecting pipe.
136490
a Remove the bolt (3) from the retaining bracket of the expansion valve - intermediate pipe connecting pipe.
62A-39
AIR CONDITIONING
62A
F4R
136492
134713
a Remove the bolt (6) from the expansion valve - intermediate pipe connecting pipe bracket on the intermediate connecting pipe. WARNING In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe. a Disconnect: - the expansion valve - intermediate pipe connecting pipe to the expansion valve, - the expansion valve - intermediate pipe connecting pipe from the intermediate connecting pipe. a Remove: - the expansion valve - intermediate pipe connecting pipe, - the seals from the expansion valve and connecting pipes. a Fit the blanking plugs on the openings of the connecting pipes and on the expansion valve.
a Remove the nut (4) securing the expansion valve intermediate pipe connecting pipe on the bulkhead support.
136487
a Remove the bolt (5) from the expansion valve - intermediate pipe connecting pipe bracket on the expansion valve.
62A-40
AIR CONDITIONING
62A
REFITTING
F9Q I - REFITTING PREPARATION OPERATION a parts always to be replaced: refrigerant pipe seal (30,02,02,52). 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 tted to the vehicle. a Refit: - the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting) (12B, Turbocharging), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the battery (see Battery : Removal - Refitting) (80A, Battery).
WARNING T avoid any leaks, check that the pipe surface is o sound before positioning the new seal. The surface must be clean and scratch free. a Remove the blanking plugs. a Lubricate the seals using air conditioning oil to make fitting easier (see 62A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-2) . a Fit new seals on the expansion valve - intermediate pipe connecting pipe. II - REFITTING OPERATION FOR PART CONCERNED a Refit the expansion valve - intermediate pipe connecting pipe on the expansion valve and on the intermediate connecting pipe. III - FINAL OPERATION F4R a Refit: - the bulkhead upper heat shield, - the turbocharger heat shield, - the cylinder head lifting eye. a Refit: - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting) (85A, Wiping Washing), a Connect the battery (see Battery : Removal - Refitting) (80A, Battery).
Note: A summary table gives the quantities of refrigerant in the system according to the engine types (see 62A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-2) . a Fill up the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-8) . a Check for leaks (see 62A, Air conditioning, Coolant circuit check, page 62A-7) . F9Q or K4M or K9K or M4R a Fit the heat shield to the bulkhead. a Check that the air conditioning system is operating correctly (see 62A, Air conditioning, Air conditioning: Check, page 62A-3) . a Refit the engine cover.
62A-41
AIR CONDITIONING Pressure sensor: Removal - Refitting

62A
Tightening torquesm pressure sensor 9 N.m
Note: An automatic shut-off valve isolates the circuit from the outside during removal; do not drain the refrigerant from the circuit.
REMOVAL
135672
I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Remove: - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection).
a Disconnect the pressure sensor connector (1) . a Remove the pressure sensor (2) from the condenser.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED a Refit the pressure sensor. a Torque tighten the pressure sensor (9 N.m). a Connect the pressure sensor connector.
II - FINAL OPERATION a Refit: - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres).
62A-42
AIR CONDITIONING Evaporator sensor: Removal - Refitting

62A
II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm dashboard cross member reinforcement upper bolts dashboard cross member reinforcement lower bolts 21 N.m
21 N.m
REMOVAL
I - REMOVAL PREPARATION OPERATION a Remove: - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment), - the front left-hand footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the lower bolts from the dashboard cross member reinforcement, - the upper bolts from the dashboard cross member reinforcement, - the dashboard cross member reinforcement.
137648
a Remove the evaporator sensor (1) by turning it a quarter of a turn anti-clockwise.
137649
a Take the evaporator sensor out of its housing. a Cut the wires (2) of the evaporator sensor (see Wiring: Repair) (Technical Note 6015A, 88A, Wiring).
62A-43

62A
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED a Solder the wires of the evaporator sensor (see Wiring: Repair) (Technical Note 6015A, 88A, Wiring). a Fit the evaporator sensor in its housing. a Clip on the evaporator sensor by turning it a quarter of a turn clockwise. II - FINAL OPERATION a Refit: - the dashboard cross member stiffener, - the upper bolts of the dashboard cross member reinforcement, - the lower bolts of the dashboard cross member reinforcement. a Tighten to torque: - the dashboard cross member reinforcement upper bolts (21 N.m), - the dashboard cross member reinforcement lower bolts (21 N.m). a Refit: - the front left-hand footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-67) , - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting) (57A, Interior equipment).
62A-44

B95 or D95 or K95, and RIGHT-HAND DRIVE
62A
REMOVAL
I - REMOVAL PREPARATION OPERATION a Remove the glovebox (see Glovebox: Removal Refitting) (57A, Interior equipment). II - OPERATION FOR REMOVAL OF PART CONCERNED
137649
a Cut the wires (2) of the evaporator sensor (see Wiring: Repair) (Technical Note 6015A, 88A, Wiring).
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED a Solder the wires of the evaporator sensor (see Wiring: Repair) (Technical Note 6015A, 88A, Wiring). a Refit the evaporator sensor. a Clip on the evaporator sensor by turning it a quarter of a turn clockwise. II - FINAL OPERATION
137648
a Refit the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment).
a Unclip the evaporator sensor (1) by turning it a quarter of a turn anti-clockwise. a Remove the evaporator sensor.
62A-45
AIR CONDITIONING
Condenser - compressor connecting pipe: Removal - Refitting
62A
- the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the right-hand headlight (see Front headlight: Removal - Refitting) (80B, Headlights), - the front panel support,
IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 62A, Air conditioning, Air conditioning: Precautions for repair, page 62A-1) . - the windscreen washer bottle (see Windscreen washer bottle: Removal - Refitting) (85A, Wiping - Washing).
F4R or F9Q a Remove:
- the headlights (see Front headlight: Removal Refitting) (80B, Headlights), - the front bumper supports (see Front bumper support: Removal - Refitting) (42A, Front upper structure), - the audible warning (see Horn: Removal - Refitting) (82B, Horn), - the front impact cross member (see Front impact cross member: Removal - Refitting) (41A, Front lower structure), - the bonnet catch (see Bonnet latch: Removal Refitting) (52A, Non-side opening element mechanisms).
REMOVAL
I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Remove the front engine cover. WARNING Consult the device's operating manual to avoid incorrect use. a Drain the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-8) . a Disconnect the battery (see Battery : Removal Refitting) (80A, Battery). a Remove: - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection),
135882
62A-46
AIR CONDITIONING
62A
135719
135296
62A-47
AIR CONDITIONING
B95 or D95 or E95 or K95 II - OPERATION FOR REMOVAL OF PART CONCERNED
62A
F4R a Remove the bolt from the support of the compressor - condenser connecting pipe on the compressor. a Remove the bolt from the support of the compressor - condenser connecting pipe on the lower cross member.
136481
a Remove the bolt (5) securing the support for the compressor - condenser connecting pipe to the front panel.
135670
a Remove the bolt (7) securing the bracket for the compressor - condenser connecting pipe from the condenser. WARNING In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe. a Disconnect: - the compressor - condenser connecting pipe from the compressor,
136473
a Remove the bolt (6) securing the bracket for the compressor - condenser connecting pipe to the compressor.
- the compressor - condenser connecting pipe on the condenser. a Remove: - the compressor - condenser connecting pipe, - the compressor - condenser connecting pipe seals. a Fit blanking plugs on the openings: - of the condenser,
62A-48
AIR CONDITIONING
B95 or D95 or E95 or K95 - of the compressor, - of the compressor - condenser connecting pipe. a Refit:
62A
- the bonnet catch (see Bonnet latch: Removal Refitting) (52A, Non-side opening element mechanisms), - the impact cross member (see Front impact cross member: Removal - Refitting) (41A, Front lower structure), - the audible warning (see Horn: Removal - Refitting) (82B, Horn), - the front bumper supports (see Front bumper support: Removal - Refitting) (42A, Front upper structure), - the headlights (see Front headlight: Removal Refitting) (80B, Headlights).
REFITTING
a Refit: - the windscreen washer bottle (see Windscreen washer bottle: Removal - Refitting) (85A, Wiping - Washing), - the front panel support, - the right-hand headlight (see Front headlight: Removal - Refitting) (80B, Headlights), - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres). a Connect the battery (see Battery : Removal - Refitting) (80A, Battery). Note: A summary table gives the quantities of refrigerant in the system according to the engine types (see 62A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-2) . a Fill up the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-8) . a Check for leaks (see 62A, Air conditioning, Coolant circuit check, page 62A-7) . a Check that the air conditioning system is operating correctly (see 62A, Air conditioning, Air conditioning: Check, page 62A-3) .
WARNING T avoid any leaks, check that the pipe surface is o sound before positioning the new seal. The surface must be clean and scratch free. a Remove the blanking plugs. a Lubricate the seals using air conditioning oil to make fitting easier (see 62A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-2) . a Fit the new seals on the compressor - condenser connecting pipe. II - REFITTING OPERATION FOR PART CONCERNED a Refit the compressor-condenser connecting pipe. III - FINAL OPERATION F4R or F9Q a Refit the intercooler air outlet pipe (see Intercooler air outlet pipe: Removal - Refitting) (12B, Turbocharging). a Fit the front end panel. a Refit the wiring channel for the engine cooling fan assembly. a Refit the engine wiring channel.
62A-49
AIR CONDITIONING
B95 or D95 or E95 or K95 a Refit the engine cover.
62A
62A-50
AIR CONDITIONING
Compressor/intermediate pipe connecting pipe: Removal - Refitting
62A
- the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the headlights (see Front headlight: Removal Refitting) (80B, Headlights), - the front bumper supports (see Front bumper support: Removal - Refitting) (42A, Front upper structure), - the audible warning (see Horn: Removal - Refitting) (82B, Horn), - the frontal impact cross member (see Front impact cross member: Removal - Refitting) (41A, Front lower structure), - the bonnet catch (see Bonnet latch: Removal Refitting) (52A, Non-side opening element mechanisms).
REMOVAL
I - REMOVAL PREPARATION OPERATION a Remove the front engine cover. WARNING Consult the device's operating manual to avoid incorrect use. a Drain the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-8) . a Disconnect the battery (see Battery : Removal Refitting) (80A, Battery). F4R or F9Q a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Remove: - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres),
135882
62A-51
AIR CONDITIONING
62A
135719
135296
62A-52
AIR CONDITIONING
B95 or D95 or E95 or K95 II - OPERATION FOR REMOVAL OF PART CONCERNED F4R
62A
136492
a Remove the bolt (7) securing the intermediate pipe - compressor connecting pipe bracket on the intermediate pipe.
135700
a Remove the bolt (5) of the intermediate pipe compressor connecting pipe retaining bracket on the engine block.
WARNING In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe. a Disconnect: - the intermediate pipe - compressor connecting pipe from the compressor, - the intermediate pipe - compressor connecting pipe from the intermediate pipe. a Remove: - the intermediate pipe - compressor connecting pipe, - the seals on the intermediate pipe compressor connecting pipe. a Fit blanking plugs on the connecting pipe and on the compressor.
136473
a Remove the bolt (6) securing the intermediate pipe - compressor connecting pipe bracket to the compressor.
62A-53
AIR CONDITIONING
62A
REFITTING
a Refit: - the bonnet catch (see Bonnet latch: Removal Refitting) (52A, Non-side opening element mechanisms), - the frontal impact cross member (see Front impact cross member: Removal - Refitting) (41A, Front lower structure), - the front bumper supports (see Front bumper support: Removal - Refitting) (42A, Front upper structure), - the audible warning (see Horn: Removal - Refitting) (82B, Horn), - the headlights (see Front headlight: Removal Refitting) (80B, Headlights), - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres).
WARNING T avoid any leaks, check that the pipe surface is o sound before positioning the new seal. The surface must be clean and scratch free. a Remove the blanking plugs. a Lubricate the seals using air conditioning oil to make fitting easier (see 62A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-2) . a Fit new seals on the intermediate pipe compressor connecting pipe. II - REFITTING OPERATION FOR PART CONCERNED a Refit the intermediate pipe - compressor connecting pipe. F4R a Refit the retaining bracket for the intermediate pipe - compressor connecting pipe on the engine block.
a Connect the battery (see Battery : Removal - Refitting) (80A, Battery).
Note: A summary table gives the quantities of refrigerant in the system according to the engine types (see 62A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-2) . a Fill up the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-8) . a Check for leaks (see 62A, Air conditioning, Coolant circuit check, page 62A-7) . a Check that the air conditioning system is operating correctly (see 62A, Air conditioning, Air conditioning: Check, page 62A-3) . a Refit the engine cover.
III - FINAL OPERATION F4R or F9Q a Refit the intercooler air outlet pipe (see Intercooler air outlet pipe: Removal - Refitting) (12B, Turbocharging). a Fit the front end panel. a Refit the engine wiring channel.
62A-54

6 - Air Conditioning

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6 - Air Conditioning

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6

HEATING AIR CONDITIONING

Renault s.a.s 2008

MEGANE III - Section 6ContentsPage

MEGANE III - Section 6

61A-67 61A-68 61A-73 61A-81

61A-54 61A-57 61A-61 61A-66

62A-38 62A-42 62A-43

HEATING Heating: List and location of components

HEATING Heating: List and location of components

HEATING Heating: List and location of components

HEATING Heating: List and location of components

EQT LEVEL EA4, and ELEC PARKING BRAKE

HEATING Heating: List and location of components

EQT LEVEL EA4, and ELEC PARKING BRAKE

HEATING Heating: List and location of components

HEATING Heating: List and location of components

HEATING Heating: List and location of components

EQT LEVEL EA4, and ELEC PARKING BRAKE

HEATING Cabin filter: Removal - Refitting

II - OPERATION FOR REMOVAL OF PART CONCERNED

HEATING Cabin filter: Removal - Refitting

Tightening torquesm clutch pedal nuts 21 N.m

HEATING Cabin filter: Removal - Refitting

II - OPERATION FOR REMOVAL OF PART CONCERNED

HEATING Cabin filter: Removal - Refitting

HEATING Rear air distribution duct: Removal - Refitting

a Unclip the rear section of the centre console.

HEATING Recirculation control cable: Removal - Refitting

a Unclip the wiring at (2) . a Remove the recirculation cable.

a Unclip the wiring at (1) .

HEATING Air distribution cable: Removal - Refitting

a Remove the bolts (1) from the control panel.

HEATING Air distribution cable: Removal - Refitting

HEATING Air distribution cable: Removal - Refitting

a Remove the bolts (1) from the control panel.

a Unclip the wiring from the dashboard cross member reinforcement.

HEATING Air distribution cable: Removal - Refitting

HEATING Air distribution cable: Removal - Refitting

HEATING Air mixing cable: Removal - Refitting

a Remove the bolts (1) from the control panel.

HEATING Air mixing cable: Removal - Refitting

HEATING Air mixing cable: Removal - Refitting

FR AND RR PROX RADAR

a Disconnect the connector from the parking distance control buzzer.

a Unclip the wiring from the dashboard cross member reinforcement.

HEATING Air mixing cable: Removal - Refitting

II - OPERATION FOR REMOVAL OF PART CONCERNED

a Remove the bolts (3) from the control panel.

HEATING Air mixing cable: Removal - Refitting

RADIO NO 01 or RADIO NO 02 or RADIO NO 03 or RADIO NO 04 or RADIO NO 05

HEATING Air distribution unit: Removal - Refitting

HEATING Air distribution unit: Removal - Refitting

HEATING Air distribution unit: Removal - Refitting

a Unclip the vacuum pipe (6) from the brake servo.

HEATING Air distribution unit: Removal - Refitting

HEATING Air distribution unit: Removal - Refitting

- the heating resistor.

HEATING Air distribution unit: Removal - Refitting

- the lifting eye of the cylinder head.

HEATING Heater matrix: Removal - Refitting

a Disconnect the brake servo vacuum pipe (3) .

HEATING Heater matrix: Removal - Refitting

HEATING Heater matrix: Removal - Refitting