Technical Note 3666E

Technical Note 3666E
DE0T
Basic manual: Workshop Repair Manuals 315 and 350
Reminder of the main information
applying to both Espace and Avantime
(Supplement to Avantime Workshop
Repair Manual)
77 11 306 758
JULY 2002
"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
EDITION ANGLAISE
All copyrights reserved by RENAULT.
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."
Copying or translating, in part or in full, of this document or use of the service part
reference numbering system is forbidden without the prior written authority of
RENAULT.
© RENAULT 2002
Contents
Page
Page
19 EXHAUST
Catalytic converter
35 WHEELS AND TYRES
19-1
Technical specifications
Balancing
Emergency spare wheel winch
35-1
35-3
35-4
30 CHASSIS
General information
Tightening torques
Parts to be replaced
30-1
30-2
30-9
31 FRONT AXLE
Lower arm
Lower arm rubber bushes
Lower arm ball joint
Brake pads
Front brake callipers
Brake disc
Power assisted steering rack
Steering column
36-1
36-2
61 HEATING
31-1
31-4
31-6
31-9
31-11
31-13
Passenger compartment filter
33-1
33-3
33-6
33-7
33-8
33-9
33-10
33-11
61-1
62 AIR CONDITIONING
Recirculation motor
Ventilation fan motor
33 REAR AXLE COMPONENTS
Rear axle
Brake pads
Rear brake calliper
Brake disc
Stub-axle assembly
Shock absorber
Spring
Longitudinal arm Silentbloc rubber
mounting
36 STEERING ASSEMBLY
62-1
62-2
EXHAUST
119
Catalytic converter
EXCESSIVE NOISE FROM THE EXHAUST SYSTEM
Test the vehicle to locate the source of the noise (as
required, on customer request). Then attempt to
reproduce the fault with the vehicle stationary. To do
this, you must accelerate sharply to cover the wide
range of engine noises.
Once you have reproduced the fault:
– ensure that the exhaust system is not in contact with
the vehicle body,
– check the alignment, conformity and condition of the
exhaust assembly,
– try to eliminate the noise by exerting pressure on the
faulty exhaust system or heat shield.
If the noise is located at the catalytic converter, you
must remove it and carry out the following checks:
– inspect the inner walls (monolith melted),
– listen for noise after shaking the converter vigorously
(monolith melted or foreign body present).
If the monolith has melted, you must find out why (see
Section 14 Checks to be made before emissions
control) and check that particles from the catalytic
converter have not blocked up the downstream
exhaust system.
Only replace the catalytic converter if one of the above
faults is present.
19-1
19
GENERAL INFORMATION
230
General diagram of braking circuits
30
NOTE:
The diagram below shows the general principle; in no case should it be taken as reference for the take-off points
and circuit allocations. When replacing one of the components of the brake circuit on a vehicle, always mark the
pipes before removing them so that they can be connected back in their original positions.
BRAKING
with ABS
30-1
FRONT
AXLE
GENERAL INFORMATION
Tightening torques (in daNm)
30-2
30
FRONT
AXLE
GENERAL INFORMATION
Tightening torques (in daNm)
(*) direction of fitting
30-3
30
REAR
AXLE
GENERAL INFORMATION
Tightening torques (in daNm)
30-4
30
REAR
AXLE
GENERAL INFORMATION
Tightening torques (in daNm)
30-5
30
GENERAL INFORMATION
Tightening torques (in daNm)
30
DIMENSIONS
TIGHTENING TORQUES
-
0.6 to 0.8
Front calliper hoses
M 10 X 100
1.7
Rear slave cylinder hoses
M 10 X 100
1.7
Master cylinder output
M 10 X 100
Bleed screw
or
1.7
M 12 X 100
Compensator inlet
M 12 X 100
1.7
Compensator outlets
M 10 X 100
1.7
ABS hydraulic unit inlets and outlets
M 10 X 100
or
M 12 X 100
30-6
1.7
GENERAL INFORMATION
Parts to be replaced when they have been removed
–
–
–
–
–
–
–
–
–
Axial ball joint stop.
Balance weight hook.
Hub bearing.
Driveshaft bearing / gaiter.
Calliper guide bolts,
Brake servo self-locking nuts,
Brake nut and stub-axle mounting bolt.
Steering rack mounting bolts.
Axle components self-locking mounting nuts.
30-7
30
FRONT AXLE
331
Lower arm
31
SPECIAL TOOLING REQUIRED
T. Av. 476
Ball joint extractor
EQUIPMENT REQUIRED
Ball joint setter
22 mm 12-sided socket
– the brake calliper (see the relevant section) and
attach it to the spring so as not to damage the pipe.
TIGHTENING TORQUES (in daNm)
Shock absorber base mounting bolt
M 16 X 200
20
Axle sub-frame rubber bushing
mounting
point A
point B
21
12
Lower ball joint
6.5
Steering ball joint
4
Anti-roll bar tie-rod
4
Brake calliper guide bolt
3.5
Wheel bolt
10
REMOVAL
Remove:
– the wheel,
– the track rod end (using tool T. Av. 476 if necessary),
Fit a protective piece to the driveshaft gaiter (wheel
side).
31-1
FRONT AXLE
Lower arm
Slacken the lower arm ball joint nut and release the
ball joint using a ball joint setter if necessary.
31
Detach the stub-axle carrier from the shock absorber
base, taking care not to damage the lower arm ball
joint gaiter.
Detach and suspend the stub-axle carrier / driveshaft
assembly.
Remove the shock absorber base mountings.
Slacken the two arm mountings (A) and (B) on the
sub-frame and release it.
To remove bolt (A) it will be necessary to use a 22 mm
12-sided socket.
31-2
FRONT AXLE
Lower arm
REFITTING
The nut and bolt from point (A) and the nut from point
(B) of the lower arm must always be replaced and the
tightening torques MUST be observed.
Refit nut and bolt assemblies (A) and (B) and tighten to
torque before refitting the arm ball joint.
Proceed in the reverse order to removal.
Take care not to damage the driveshaft gaiter.
Depress the brake pedal repeatedly to bring the piston
into contact with the brake shoes.
Check the front axle geometry and adjust the wheel
alignment if necessary.
31-3
31
FRONT AXLE
Lower arm rubber bushes
31
SPECIAL TOOLING REQUIRED
T. Av. 1274
Tool for replacing lower arm
rubber bushes
T. Av. 1274-01 Additional bushing for point B
bush
To ensure that the bushes are correctly positioned in
relation to the lower arm, they are replaced one after
the other: bush (1) then (2).
REFITTING
WARNING:
During these operations, the threaded rod of the ball
joint must always be pointed downwards.
REPLACEMENT
BUSH 1
Fit the two bushes (A) under the arm.
Extract and refit bush (1) using a press.
Insert the latter until the refitting ring comes into
contact with the arm bearing face.
REMOVAL
31-4
FRONT AXLE
Lower arm rubber bushes
BUSH 2
31
In this position, fit centring washer (F) and tighten the
assembly (nut / washer).
Fit the two bushes (A) under the arm.
Extract bush (2) using a press and bush (B) from kit
T. Av. 1274-01.
REMOVAL
F
Spacer ring T. Av. 1274-01
REFITTING
Then place the assembly on the two bushes (A).
Refitting bush (2) is carried out in two stages:
At the press, insert the bush until the spacer comes
into contact with the arm bearing face.
1.
Fit assembly (E) on the manipulator:
– bush (B),
– spacer (T. Av. 1274-01),
– new bush,
– threaded rod (screwed onto the manipulator),
– washer,
– nut.
2.
At one end, insert the manipulator into the guide
tube and, at the other end, fit stack (E) into the
bearing shell bore.
NOTE:
Remove the O-rings and sand down the lower
section of the guide tube using abrasive paper, if
necessary.
31-5
FRONT AXLE
Lower arm ball joint
31
IMPORTANT
No more than one ball joint may be replaced on the same arm. For this reason, the replacement ball joints are
marked with a notch on the bearing face of the unit (reaming).
●
Unmarked ball joint
standard part: replacement possible
●
Ball joint with notch
part previously replaced: new replacement prohibited, the lower arm MUST be
replaced completely
SPECIAL TOOLING REQUIRED
T. Av. 476
Ball joint extractor
T. Av. 1261
Lower arm ball joint removal/
refitting tool
T. Av. 1261-01 Additional bush for refitting the
ball joint
EQUIPMENT REQUIRED
Ball joint setter
TIGHTENING TORQUES (in daNm)
Shock absorber base mounting bolt
M16 X 200
20
Lower ball joint
6.5
Track rod end
4
Brake calliper guide bolt
3.5
Wheel bolt
10
REMOVAL
Remove:
– the wheel,
– the track rod end using tool T. Av. 476 (if necessary),
31-6
FRONT AXLE
Lower arm ball joint
– the brake calliper (see the relevant Section).
31
Remove the shock absorber base mountings.
Detach the stub-axle carrier from the shock absorber
base, then separate and suspend the stub-axle carrier
/ driveshaft assembly.
Attach the calliper to the spring so as not to damage
the pipe,
Fit a protective piece to the driveshaft gaiter.
Extract the ball joint from the arm using tool
T. Av. 1261.
Slacken the lower arm ball joint nut and release the
ball joint using a ball joint setter if necessary.
To fit tool T. Av. 1261, remove the burr from the sides
of the arm using a file if necessary.
31-7
FRONT AXLE
Lower arm ball joint
31
After the operations have been completed, depress
the brake pedal several times to bring the piston into
contact with the pads.
REFITTING
Fit the new ball joint (with notch) using tool T. Av. 1261
inserting washer (A) and spacer (B) (T. Av. 1261-01).
APPEARANCE OF THE REPLACEMENT BALL
JOINT
Replacement ball joint with notch (C) on the bearing
face (seen from below).
REMINDER
Tool T. Av. 1261 in place for refitting the ball joint.
Proceed in the reverse order to removal.
Take care not to damage the driveshaft gaiter.
Observe the tightening torques.
31-8
●
Ball joint without notch → replacement possible.
●
Ball joint with notch → replacement forbidden (part
already replaced).
FRONT AXLE
Brake pads
31
SPECIAL TOOLING REQUIRED
Fre. 823
Tool for pushing calliper pistons
back
CHECKING
TIGHTENING TORQUES (in daNm)
Wheel bolt
Brake calliper guide bolt
Check:
– the condition and mounting of the piston dust cover
and its retaining ring,
– the condition of the guide dust cover (2) (pillars).
10
3.5
REMOVAL
REFITTING
Disconnect the wear warning light wire.
Push back the slave cylinder piston using tool
Fre. 823.
Push back the piston by manually sliding the calliper
towards the outside.
Remove the guide bolts (1) using two spanners.
Do not reuse the bolts.
Release the sliding calliper.
Remove the soundproofing pad.
Remove the pads.
31-9
FRONT AXLE
Brake pads
Fit the new shoes assembled with their spring,
observing the order of tightening.
The shoe with the wear warning light wire fitted inside.
Replace the soundproofing pad, the arrow points
towards the front of the vehicle.
Position the calliper and fit the new lower guide bolt.
Press on the calliper and fit the upper guide bolt.
Tighten the guide bolts to torque starting with the lower
bolt.
Reconnect the wear warning light wire observing its
routing.
Press the brake pedal several times in order to
bring the piston into contact with the brake shoes.
31-10
31
FRONT AXLE
Front brake callipers
31
REFITTING
TIGHTENING TORQUES (in daNm)
Wheel bolt
10
Calliper yoke mounting bolt
10
Guide bolt
Retighten the slave cylinder.
Remove the pedal press.
3.5
Slacken the slave cylinder bleed screw and wait for the
brake fluid to flow out (check that the compensation
reservoir level is sufficient).
REMOVAL
Retighten the bleed screw.
Fit a pedal press to the brake pedal to restrict the flow
of brake fluid.
Check the condition of the pads and change them if
they are oily.
Release the brake pipe at the wheel cylinder end.
Remove the brake pads (see the relevant information).
Undo the slave cylinder on the hose (be prepared for
brake fluid to flow out).
Bleed the brake fluid circuit partially only if the
compensation reservoir is not completely emptied
during the operation, otherwise bleed it completely.
Press the brake pedal several times in order to
bring the piston into contact with the brake pads.
Check the condition of the hose and replace it if
necessary (see Replacing a hose).
If the calliper is being replaced, the hose must be
replaced.
31-11
FRONT AXLE
Front brake callipers
31
REPAIR
The complete calliper must automatically be
changed if the calliper bore is scored.
Remove the brake calliper.
Remove the rubber dust seal.
Remove the compressed air piston, inserting a
wooden block between the calliper and the piston to
prevent damage to the piston: any trace of damage to
the piston skirt will render it unusable.
Clean the parts using methylated spirits.
Replace any faulty parts with original parts and then
refit the seal, piston, dust seal and its retaining strip.
Using a flexible strip with a rounded edge (such as a
feeler gauge), remove the rectangular section seal
from the calliper groove.
31-12
FRONT AXLE
Brake discs
Brake discs cannot be reground. If they are too heavily
worn or are scratched they must be replaced.
31
– the two disc mounting bolts (B) using a 30 mm torx
driver,
TIGHTENING TORQUES (in daNm)
Wheel bolt
10
Brake yoke mounting bolt
10
Brake disc mounting bolt
1.5
REMOVAL
Remove:
– the brake pads (see the relevant information),
– the two yoke mounting bolts (A),
– the disc.
REFITTING
Clean the disc / hub mating face of any traces of
LOCTITE.
Position the disc on the hub and fit it with the two bolts
(B).
Coat the yoke bolts with LOCTITE FRENBLOC and
tighten them to torque.
Press the brake pedal several times in order to
bring the piston into contact with the brake pads.
31-13
REAR AXLE COMPONENTS
433
Rear axle
Place the vehicle on axle stands.
TIGHTENING TORQUES (in daNm)
Longitudinal arm mounting nut
9
Shock absorber lower bolt
2.5
Shock absorber upper bolt
6
Wheel bolt
Transverse guide bar
33
Remove:
– the two rear wheels,
– the two brake drums.
Disconnect the handbrake cables:
– from the lever,
– from the drum end piece,
– from the longitudinal arm.
10
6
REMOVAL
Fit a pedal press to prevent brake fluid from flowing
out.
Put the car on a four-post lift and raise the lift.
Disconnect the brake pipes from the longitudinal arm.
Place a large axle stand with a rubber cross piece
under the emergency spare wheel and lower the lift
slightly.
Remove:
– the two shock absorber lower mounting bolts,
– the bolt mounting the transverse guide bar onto the
axle. Do not touch the brake limiter (vehicle not fitted
with ABS).
Lower the lift again and remove the springs.
Place a component jack under the axle.
Remove the longitudinal arm mounting bolts.
Release the axle.
33-1
REAR AXLE COMPONENTS
Rear axle
REFITTING
Proceed in the reverse order to removal.
Tighten the flexible joint mountings to torque, with
the vehicle under load.
Set the vehicle to height (H5) = 408 mm measured
between the 3 rd line floor cross member and the
ground.
To do this:
– compress the rear axle assembly using straps,
– or load the vehicle;
this measurement corresponds to the vehicle having 4
people on board, 5 seats, a full fuel tank and 50 kg.
Check measurement (H5).
Bleed the brake circuit.
Check the rear axle geometry if necessary (no
adjustment possible).
33-2
33
BREMBO
BRAKES
REAR AXLE COMPONENTS
Brake pads (disc)
33
SPECIAL TOOLING REQUIRED
Fre. 1190
BREMBO brake calliper piston
return spanner
TIGHTENING TORQUES (in daNm)
Wheel bolt
10
Secondary pillar bolt
3.5
Primary pillar bolt
7
REMOVAL
– the pad retaining shaft (2) using a pin punch,
– the spring (3),
Remove:
– the pin (1),
– secondary pillar mounting bolt (A).
33-3
BREMBO
BRAKES
REAR AXLE COMPONENTS
Brake pads (disc)
Pivot the calliper around primary pillar (B) (see
previous page).
33
REFITTING
Push the piston back, tightening it using tool Fre. 1190
until it is at the bottom of its bore.
NOTE:
To fit the tool, slacken primary pillar mounting bolt (B) if
necessary.
Remove the outer brake pad then the inner.
CHECKING
Check:
– the condition and fitting of the dust seal, the piston
and the springs,
– the calliper's freedom of movement on its primary
pillar.
Fit new linings, beginning with the interior.
WARNING:
It is ESSENTIAL to position lateral springs (R)
correctly.
33-4
BREMBO
BRAKES
REAR AXLE COMPONENTS
Brake pads (disc)
33
Depress the brake pedal repeatedly to bring the piston
into contact with the brake shoes.
Reset the calliper in its operating position and fit
secondary pillar mounting bolt (A) coated in LOCTITE
FRENBLOC, then tighten it to torque.
NOTE:
If primary pillar mounting bolt (B) has been removed, it
must be refitted, coated with LOCTITE FRENBLOC
and tightened to torque.
Check the handbrake adjustment.
The levers (C) must detach between the 1st and 2 nd
notch of the control lever travel and remain detached
on the 2nd notch.
Position brake pad retaining shaft (2) passing it
through the spring buckles (3).
Then clip the retaining shaft with a pin punch.
Refit safety mounting pin (1).
33-5
BREMBO
BRAKES
REAR AXLE COMPONENTS
Rear brake calliper
REFITTING
TIGHTENING TORQUES (in daNm)
Wheel bolt
33
Proceed in the reverse order to removal.
10
Secondary pillar bolt
3.5
Retighten the hose.
Primary pillar bolt
7
Check the condition of the linings. Replace them if
they are greasy.
REMOVAL
Refit the pads (see the relevant information).
Fit a pedal press to prevent brake fluid from escaping.
The primary and secondary pillar bolts should be
coated with LOCTITE FRENBLOC then tightened to
torque.
Release the brake pipe at the wheel cylinder end.
Press the brake pedal several times to bring the piston
into contact with the pads.
Remove:
– the brake pads (see the relevant information),
– the handbrake cable,
– primary pillar mounting bolt (B).
– secondary pillar mounting bolt (A).
Bleed the brake circuit.
Unscrew the hose.
Check the condition of the hose and replace it if
necessary (see Replacing a hose).
Always replace the hose if replacing the calliper.
33-6
REAR AXLE COMPONENTS
Brake discs
33
Brake discs cannot be reground. If they are too heavily worn or are scratched they must be replaced.
– the two disc mounting bolts (B) using a 30 mm torx
driver.
TIGHTENING TORQUES (in daNm)
Wheel bolt
10
Brake disc mounting bolt
1.5
Secondary pillar bolt
3.5
Primary pillar bolt
7
REMOVAL
REFITTING
Position the disc on the hub and fit it with the two bolts
(B).
Fit the new brake pads.
Coat the secondary pillar bolt with LOCTITE
FRENBLOC and tighten it to torque.
Remove:
– the brake pads (see the relevant information),
Press the brake pedal several times in order to bring
the piston into contact with the pads.
33-7
REAR AXLE COMPONENTS
Stub-axle assembly (disc)
33
TIGHTENING TORQUES (in daNm)
Stub-axle nut
17
Wheel bolt
10
Stub-axle mounting bolt
3
Secondary pillar bolt
3.5
REMOVAL
Remove:
– the brake calliper / pads assembly (A),
– the brake disc and hub (B) (see relevant information),
REFITTING
Proceed in the reverse order to removal.
If the stub-axle bolts are being reused, they must be
coated with LOCTITE FRENBLOC.
Tighten the stub-axle bolts in the order of 1-2-3-4-5-6
(see previous page) to a torque of 3 daNm.
Tighten stub-axle nut to a torque of 17 daNm.
– the six stub-axle mounting bolts,
– the wheel speed sensor bolt (if fitted to the vehicle).
33-8
REAR AXLE COMPONENTS
Shock absorber
33
REFITTING
TIGHTENING TORQUES (in daNm)
Upper mounting bolt
6
Lower mounting bolt
2.5
Fit the shock absorber and its mountings.
Set the vehicle to height (H5) = 408 mm measured
between the 3rd line chassis cross member and the
ground.
REMOVAL
To do this:
– compress the rear axle assembly using straps,
– or load the vehicle;
this measurement corresponds to the vehicle having 4
people on board, 5 seats, a full fuel tank and 50 kg.
Check measurement (H5).
Put the vehicle on a four-post lift.
Place a large axle stand under the emergency spare
wheel (see the Rear axle section) and lower the lift
slightly.
Tighten the two bolts to the recommended torque, with
the vehicle laden.
Remove:
– the lower mounting,
– the upper mounting,
– the shock absorber.
33-9
REAR AXLE COMPONENTS
Spring
TIGHTENING TORQUE (in daNm)
Lower shock absorber bolt
2.5
REMOVAL
Put the vehicle on a ramp lift.
Place an axle stand under the rear emergency spare
wheel (see the Rear axle section) and lower the lift
slightly.
Remove the shock absorber lower mounting bolts.
Lower the lift and move the axle away until the springs
detach.
Remove the springs.
REFITTING
Proceed in the reverse order to removal.
For spring indexing, examine the upper retainer
(boss).
Tighten the shock absorber lower mountings to torque,
with the vehicle laden (see the information on the
shock absorbers).
33-10
33
REAR AXLE COMPONENTS
Longitudinal arm Silentbloc rubber mounting
The rubber blocks are replaced at the press, with the
rear axle removed.
PRECAUTION FOR FITTING RUBBER BLOCKS
Refit the rubber block, taking care to position it as in
the diagram.
The arm mounting passage axis is offset towards the
rear of the vehicle in relation to the axis of the rubber
block.
33-11
33
WHEELS AND
TYRES
535
Specifications
35
WHEEL RIMS
The identification marking of the wheel rims comes in two forms:
●
Engraved markings for steel rims.
●
Cast marking for alloy rims.
The marking gives the main dimensional specifications of the wheel rim.
The marking may be complete:
Example: 5 1/2 J 14 4 CH 36
or in abbreviated form
Example: 5 1/2 J 14
TYPE OF
RIM
5 1/2 J 14
4 CH 36
A
B
C
D
E
F
WIDTH (in
inches)
RIM
PROFILE
∅ NOMINAL (in
inches). under tyre
bead
Number
of holes
Tyre bead
profile
Offset in
mm
51/2
J
14
4
CH
36
The 4 wheel bolts are 108 mm in diameter.
Maximum run-out: 1.2 mm measured on the rim
edge (at G).
Maximum eccentricity: 0.8 mm measured on the
pressure face of the tyre beads.
35-1
WHEELS AND TYRES
Specifications
TYRES
The identification marking can be in two forms for the same type of tyre.
Example:
or
185
185/70
185/70
/
1
185
/
1
1
185
2
70
H
R
R
14
14
88 H
70
H
R
14
2
3
4
5
70
R
14
88
H
2
4
5
6
3
Tyre width in mm
height
Ratio h/w
width
4
R
Radial structure
5
14
Internal diameter in inches. Corresponds to the diameter of the rim.
6
88
Load index 88 (560 kg)
3
H
Speed code 130 mph (210 km/h) maximum
Some speed symbols:
Maximum speed
mph
R
S
T
U
H
V
Z R + than
170
180
190
200
210
240
240
Types of structure:
Cross ply
Radial
Bias belted
No marking
R
B (Bias belted)
35-2
35
WHEELS AND TYRES
Balancing
BALANCE WEIGHTS
Only use weights supplied by the Parts Department
which are:
– secured to the metal rims by hooks (hooks
incorporated in the weight),
– secured by hooks (flat hooks) or self adhesive for
alloy wheels.
A Steel rim
B Aluminium rim
35-3
35
WHEELS AND TYRES
Emergency spare wheel winch
35
Remove:
– the tailgate seal at the carpet,
– the winch metal tab.
REMOVAL
Remove one of the wheel arch liners (see Section 7).
Detach the carpet (see Section 7) and fit a shim to
access the winch bolts.
Remove the 5 winch mounting bolts.
REFITTING
To refit, proceed in the reverse order to removal.
Check that the mechanism is working correctly and fit
the emergency spare wheel fully inside.
Remove the emergency wheel.
35-4
STEERING ASSEMBLY
636
Power assisted steering rack
36
The obstruction of the steering rack requires that the sub-frame and axle be detached from the body and
that specifically-designed tools T. Av. 1233-01 be used.The steering rack must be removed through the lefthand side.
SPECIAL TOOLING REQUIRED
T. Av. 1233-01 Kit for operating on the subframe/axle
Dir.
1303-01 Steering rack adjusting tool
Dir.
1408
Dir.
1282-01 17 mm spanner for high-pressure
steering column tube
Dir.
1282-02 19 mm spanner for low-pressure
steering column tube
Steering column adjustment tool
REMOVAL
TIGHTENING TORQUES (in daNm)
Steering ball joint nut
4
Universal joint bolt
2.5
Sub-frame mounting bolt: front ∅ 10
rear ∅ 12
7
High-pressure hose on valve
2.2
Low-pressure hose on valve
3
Anti-roll bar tie-rod nut
4
Gear selector fork bolt
3
Wheel bolt
F engines
Z-G engines
Remove:
– the wheels,
– the left-hand wheel arch protector,
– the track rod ends (tool T. Av. 476 if necessary),
– the anti-roll bar tie-rod lower ball joint nuts.
Slacken the lower arm ball joint nuts.
3.5
11
Steering rack sub-frame mounting nut
Engine tie-bar
Set the vehicle wheels straight.
5
15
10
36-1
STEERING ASSEMBLY
Steering column
36
SPECIAL TOOLING REQUIRED
Dir. 1408
Steering column adjustment tool
TIGHTENING TORQUES (in daNm)
Steering wheel nut
4.5
Driver's frontal airbag bolt
0.5
Steering column universal joint eccentric
bolt
2.5
Steering column mounting nuts
1.5
The steering column is sold complete. Components
are not sold separately.
REMOVAL
Remove:
– the driver's frontal airbag attached by two bolts
behind the steering wheel and disconnect its
connector (A).
– horn connector (B),
– cruise control connector (C) (if fitted),
WARNING:
When removing the steering wheel, the airbag /
pretensioner system must be deactivated (see
the Steering wheel section).
If these instructions are not followed the system
may not operate normally and could even be
triggered accidentally.
36-2
STEERING ASSEMBLY
Steering column
– the steering wheel nut (it must be replaced when
refitting),
– the steering wheel, ensuring that the wires are not
pinched.
Immobilise the rotary switch with adhesive tape to
prevent it from moving off-centre.
– the lower LH console;
Remove:
– the radio remote control,
– the steering wheel upper and lower cowlings,
36-3
36
STEERING ASSEMBLY
Steering column
36
Disconnect the connectors:
– ignition switch,
– screen wash / wipe combined switch,
– lighting stalk.
– the material cover or automatic transmission
repeater surround (if fitted to the vehicle),
– the under-steering wheel console (disconnect the
lighting dimmer switch),
Detach the carpet to access the column seal.
Release the column seal. Important, this is composed
of two lips:
– one for soundproofing,
– the other for the bulkhead.
– the steering surround and disconnect the automatic
transmission repeater (if fitted to the vehicle) to
access the column mountings.
Remove the clip to disconnect the gearshift safety
cable (if the vehicle is fitted with automatic
transmission).
36-4
STEERING ASSEMBLY
Steering column
Set the wheels straight and remove the steering
column universal joint eccentric bolt and nut through
the passenger compartment.
Remove the column mounting nuts and bolts and
remove the column/stalk switching assembly.
36-5
36
STEERING ASSEMBLY
Steering column
36
Refit the driver’s frontal airbag
REFITTING (special notes)
Refit the steering column.
IMPORTANT:
Refit the steering column universal joint and its nut.
IMPORTANT:
As the lower section of the steering column slides,
the position of the universal joint must be adjusted
on the steering rack.
●
Connect then bolt the driver's frontal airbag to the
steering wheel (tightening torque 0.5 daNm).
●
The airbag / pretensioner system must be
reactivated (see the Steering wheel section).
Fit the column seal.
Use a spatula or a length of string to refit the outer lip.
In the passenger compartment, place tool Dir. 1408 on
the lower section of the column.
Refit the yoke mounting and tighten to torque. Remove
the tool.
Proceed in the reverse order to removal.
IMPORTANT:
Tighten the column mounting bolts to a torque of
1.5 daNm.
With the wheels set straight, if the steering column is
locked by the ignition switch, the steering wheel is
positioned at its centre point.
Check that the rotary switch is still immobilised by the
adhesive tape. If it is not, or if there is some doubt,
recentre the steering ( see the Steering wheel
section).
Remove the adhesive tape.
Refit the steering wheel using a new bolt and tighten to
a torque of 4.5 daNm.
36-6
HEATING
761
Passenger compartment filter
61
REPLACEMENT
The two filter cartridges must be replaced at the
same time.
Disconnect the battery and the connector from the
wiper motor.
Put the wipers into vertical position by moving the
motor rods directly.
Remove the soundproofing pads.
Remove the shock absorber cage housing closing
plates.
Insert the new filter element, with the tab on the
outside by clipping it into its diagonal housing.
Take hold of the tab and remove the old cartridge
through the same route as the closure panel.
Refit the closure panels with their soundproofing.
Reconnect the electric motor connector.
WARNING:
Connect the battery; carry out the necessary
programming (see Section 8).
The blades return to the zero position when the
ignition is switched on.
61-1
AIR CONDITIONING
862
Recirculation motor
RECIRCULATION MOTOR
REFITTING
The recirculation control positions the air inlet flap
according to position of the recycling control button or
the requirements determined by the See Clear button.
Proceed in the reverse order to removal.
62
No adjustment is necessary, disconnecting the battery
means that the motor is reinitialised when the battery
is reconnected and the system is operational.
The flap is moved by a stepper motor which can be
accessed once the upper section of the dashboard
and the closure panel have been removed.
REMOVAL
IMPORTANT:
Disconnect the battery, this is very important for
adjustment.
Disconnect the motor concerned.
Disconnect the flap control linkage.
Remove the three mounting bolts, disconnect the
linkage carefully and remove the motor.
62-1
AIR CONDITIONING
Ventilation fan motor
62
VENTILATION FAN MOTOR
Remove the housing mounting bolts of the ventilation
fan concerned.
REMOVAL
Disconnect the motor.
Disconnect the battery.
Disengage the retaining clip using a workshopprepared hook.
Remove the dashboard front panel.
Remove the display cluster.
Remove the upper section of the soundproofing, so
that the ventilation unit cover is removed.
Remove the housing mounting bolts of the ventilation
fan concerned, and disconnect the motor.
REFITTING
Proceed in the reverse order to removal.
62-2
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