MR388LOGAN3
MR388LOGAN3
X90
"The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault.
specifications current when it was prepared.
The reproduction or translation in part of whole of the present document, as well as the use
The methods may be modified as a result of changes introduced by the manufacturer in the of the spare parts reference numbering system, are prohibited without the prior written
production of the various component units and accessories from which his vehicles are consent of Renault.
constructed."
L90 - Section 3
Contents
108548
IMPORTANT
This is a general system diagram, do not use it as a
reference for take-off points or circuit allocation.
When replacing a vehicle's braking circuit compo-
nents, always mark the pipes before removing them 105586
as they must be reconnected in their original posi-
tions.
IMPORTANT
This is a general system diagram, do not use it as a
reference for take-off points or circuit allocation.
When replacing a vehicle's braking circuit compo-
nents, always mark the pipes before removing them
as they must be reconnected in their original posi-
tions.
30A-1
GENERAL INFORMATION
Brake circuit connection and piping 30A
L90
WARNING
- The pipes between the master cylinder, callipers
and the hydraulic assembly are connected using
threaded unions with a metric thread.
- Therefore, only parts listed in the Parts Catalogue
for this vehicle should be used.
78491
Parts identification:
- shape of steel or copper pipe end piece (A),
- shape of connecting points on components (B),
- shape of unions (C): 11 mm Allen key.
30A-2
GENERAL INFORMATION
Brake fluid 30A
BRAKE FLUID REPLACEMENT INTERVAL
Our braking technology, and in particular the disc bra-
kes (hollow pistons which conduct little heat, have a low
volume of fluid in the cylinder, sliding callipers avoiding
the need for a fluid reserve in the least cooled area of
the wheel), has allowed us to prevent the risk of
« vapour lock » as far as possible, even with heavy bra-
king (mountainous area). However, current brake fluids
are subject to slight deterioration during the first months
of use due to slight humidity intake. This is why it is re-
commended that you change the brake fluid: see the
warranty and servicing book for the vehicle.
30A-3
GENERAL INFORMATION
Braking circuit bleed 30A
- the front left-hand circuit,
Essential equipment - the rear left-hand circuit,
brake circuit bleeding device (approved by Renault) - the front right-hand circuit.
Torque tighten the bleed screw (6 Nm).
diagnostic tool
With the engine switched off, check the pedal travel;
if it is not correct, start this bleeding procedure again.
Tightening torquesm Top up the brake fluid level in the reservoir after dis-
connecting the bleeding device. Check the sealing of
bleed screw 6 Nm the bleed screws and ensure that the sealing covers
are in place.
Precautions to be taken when bleeding the braking cir-
cuit: During a road test, trigger braking regulation to con-
firm that the brake pedal travel is correct. If the pedal
- Check the brake fluid levels in the braking circuit and travel becomes incorrect during the road test, apply
the bleeding device. the braking regulation circuit bleeding procedure.
- The brake regulation circuit must be free of all hydrau-
lic and electrical faults.
WARNING
Special precaution to be taken when bleeding the
braking circuit: the ignition should not be swit-
ched on so that the hydraulic unit solenoid valves
are not activated (if fitted to the vehicle).
30A-4
GENERAL INFORMATION
Braking circuit bleed 30A
II - BLEEDING THE BRAKING REGULATION
CIRCUIT
This procedure is to be applied after a road test with
braking regulation in which the pedal travel becomes
incorrect.
Mount the vehicle on a two-post lift.
Referring to the equipment instruction manual, con-
nect:
- tool brake circuit bleeding device (approved by
Renault) to the vehicle braking circuit,
- the diagnostic tool.
Fit the draining jars to the bleed screws.
Bleed the regulation circuit using the diagnostic to-
ol.
Run command SC006 « hydraulic assembly and
brake circuits bleed ».
Follow the instructions on the diagnostic tool.
Note:
Depress and release the brake pedal alternately
(pumping action) throughout the bleeding proce-
dure.
30A-5
GENERAL INFORMATION
Brake: Specifications 30A
Engine
Piston diameter 48 52
Disc thickness 12 12
Diameter 20.6
Stroke 32
30A-6
GENERAL INFORMATION
Anti-roll bars: Specifications 30A
L90
Front anti-roll bar diameter: 24.5 mm.
30A-7
GENERAL INFORMATION
Front axle tightening torque 30A
1
9
7 4
6
3 2 5
109718
(1) Mounting nut attaching « spring and shock absorber » assembly to body 44
30A-8
GENERAL INFORMATION
Front axle tightening torque 30A
11
17
16
15 4
14
18
13 12
109719
30A-9
GENERAL INFORMATION
Rear axle tightening torque 30A
2
7
1
5 3
109717
(7) Mounting bolts of the brake backing plate on the rear axle 80
30A-10
GENERAL INFORMATION
Brake system tightening torque 30A
I -FRONT AND REAR BRAKES
Description Tightening
torque
(Nm)
II - BRAKE CONTROL
Description Tightening
torque
(Nm)
30A-11
GENERAL INFORMATION
Steering tightening torque 30A
Description Tightening
Description Tightening torque
torque (Nm)
(Nm)
Steering rack bolt 105
Securing nuts for 21
Track rod end nut 37
steering column
Axial ball joint 34
Universal joint bolt 21
Description Tightening
torque
(Nm)
30A-12
GENERAL INFORMATION
Underbody height 30A
MEASURING POINTS
W2
R1 R2
109317
Measurement (R1) is taken between the ground and
the front wheel axis.
(R2) is taken between the ground and the rear wheel
axis. 108937
Measurement (W2) is taken at the rear, between the
ground and the rubber bushing mounting shaft on the
bearing.
W1
108936
Measurement (W1) is taken at the front between the
ground and the underside of the sub-frame at the hole
in the centre of the lower arm.
30A-13
GENERAL INFORMATION
Values and adjustments for the front axle assemblies 30A
Before taking axles to the test bench, you must check 2 - Close (or toe-in)
the inflation pressure of the tyres (see 35A, Wheels
and tyres, Tyre inflation pressure).
WARNING
When checking the axle values, the vehicle must be
unloaded (no luggage, persons in the vehicle) with
half a tank of fuel.
Take care to position the steering wheel straight
ahead during wheel alignment adjustment, in such a
way as not to offset the angular position of the front
wheels with the straight-ahead position. The stee-
ring wheel being offset in relation to the position of
the wheels is cause for the vehicle to be returned by
the customer. 93011-1
Adjust the vehicle level in accordance with the spe-
cifications before checking the geometry of the
wheels. If the vehicle level is not in accordance with WARNING
the specifications, try to adjust it by lowering or rai- Signs convention in use above, + = close (or toe-in).
sing the bodywork.
II - CASTOR ANGLE
I -SIGNS CONVENTION
Not adjustable.
1 - Opening
93012
93011
Value Position of front axle (mm)
III - CAMBER
Not adjustable.
30A-14
GENERAL INFORMATION
Values and adjustments for the front axle assemblies 30A
93013 93011
Value Position of front axle (mm) Value Position of front axle (mm)
Not adjustable.
VI - POSITION FOR TIGHTENING RUBBER BUSHES
See 31A, Front carrying components, lower arm.
93014
V - WHEEL ALIGNMENT
30A-15
GENERAL INFORMATION
Values and adjustments for the rear axle assemblies 30A
Before taking axles to the test bench, you must check 2 - Close (or toe-in)
the inflation pressure of the tyres (see 35A, Wheels
and tyres, Tyre inflation pressure).
WARNING
When checking the axle values, the vehicle must be
unloaded (no luggage, persons in the vehicle) with
half a tank of fuel.
Take care to position the steering wheel straight
ahead during wheel alignment adjustment, in such a
way as not to offset the angular position of the front
wheels with the straight-ahead position. The stee-
ring wheel being offset in relation to the position of
the wheels is cause for the vehicle to be returned by
the customer. 93011-1
Adjust the vehicle level in accordance with the spe-
cifications before checking the geometry of the
wheels. If the vehicle level is not in accordance with WARNING
the specifications, try to adjust it by lowering or rai- Signs convention in use above, + = close (or toe-in).
sing the bodywork.
II - CAMBER
I -SIGNS CONVENTION
Not adjustable.
1 - Opening
93013-1
93011
Value Position of rear axle
30A-16
GENERAL INFORMATION
Values and adjustments for the rear axle assemblies 30A
93011-1
30A-17
GENERAL INFORMATION
Vehicle handling: Fault finding 30A
L90
Shimmy*: steering wheel vibration between 62.5 and I -BRAKING
75 mph (100 and 120 km/hour).
Cause Brake Irre- Brake Brake Brake Brake Irre- Brake Air in Bra- Bra-
/ pad gular disc disc calli- disc gular servo the king king
symp- wear brake fog- wear per corro- brake failure bra- cir- cir-
tom pad ging pis- sion disc king cuit cuit
wear ton wear circuit inter- exter-
sei- nal nal
zing lea- lea-
kage kage
Noise x x x x
when
bra-
king
Per- x x x
mane
nt
noise
Brake x x x
chat-
ter
Pedal x x x
vibra-
tions
Hard x x
pedal
Soft x x x x
pedal
Spong x x x
y
pedal
Pedal x x x
to the
floor
Per- x x
mane
nt bra-
king
30A-18
GENERAL INFORMATION
Vehicle handling: Fault finding 30A
L90
II - STEERING
Caus Insuf- Air in Play Pres- Drive Stee- Stee- Front Assis Brak Tyre
e/ ficien the in the sure belt ring ring axle tance e fault
symp t powe stee- fault ten- colu colu angle elec- slave
tom powe r ring on sion mn mn fault tro- cylin-
r assis pump fault dete- asse (cas- nic der
assis ted outlet riora- mbly tor mana sei-
ted stee- tion fault angle geme zing
stee- ring ) nt (pis-
ring cir- fault ton
oil cuit or
level cylin-
der)
Noise x x x x
Vibra- x x x
tions
Jud- x x x
derin
g
Poor x x x
return
to
stee-
ring
wheel
cen-
tre
Hydra x x x
ulic
varia-
ble
power
assis-
ted
stee-
ring
low
speed
assis-
tance
fault
30A-19
GENERAL INFORMATION
Vehicle handling: Fault finding 30A
L90
Caus Insuf- Air in Play Pres- Drive Stee- Stee- Front Assis Brak Tyre
e/ ficien the in the sure belt ring ring axle tance e fault
symp t powe stee- fault ten- colu colu angle elec- slave
tom powe r ring on sion mn mn fault tro- cylin-
r assis pump fault dete- asse (cas- nic der
assis ted outlet riora- mbly tor mana sei-
ted stee- tion fault angle geme zing
stee- ring ) nt (pis-
ring cir- fault ton
oil cuit or
level cylin-
der)
Hydra x
ulic or
elec-
tric
high
speed
varia-
ble
power
assis-
ted
stee-
ring
exces
sive
assis-
tance
Hydra x x
ulic or
elec-
tric
varia-
ble
power
assis-
ted
stee-
ring
assis-
tance
fault
Stab- x x
lised
speed
pull
Bra- x x x
king
pull
30A-20
GENERAL INFORMATION
Vehicle handling: Fault finding 30A
L90
III - WHEELS AND TYRES
Cause/ Incor- Tyre Defor- Tyre Non Wheel Front Bra- Stee-
symp- rect infla- mation tread confor- align- axle king ring
tom tyre tion or wear fault mity of ment and (see (see
balan- pres- on tyre fault suspen- table for table for
cing sure wheels size sion « Braki « Steeri
fault and ng » ng »
(see
tyres
table for
« Front
axle
and
suspen
sion »
Vibra- x x x x x
tions
x x x x x x
Shimmy
*
Poor x x x x
roadhol-
ding
Prema- x x x x
ture tyre
wear
Irregu- x x x x x x
lar tyre
wear
30A-21
GENERAL INFORMATION
Vehicle handling: Fault finding 30A
L90
IV - AXLES AND SUSPENSION
Caus Shoc Dete- Con- Sus- Sus- Wear Ali- Fault Hub- Imba- Axle Bra-
e/ k riora- tact pen- pen- in gnme in car- lance asse king
symp absor tion with sion sion anti- nt asse rier betw mbly (see
tom ber of sur- shoc sprin roll fault mbly bea- een angle table
defor sprin roun- k g bar in or ring right faults for
matio g and ding absor state or front tigh- dete- and « Bra
n shoc parts ber bea- or tenin riora- left king
k wear rings rear g of tion sus- »
absor axles sub- pen-
ber frame sion
asse or
mbly front
moun axle
tings parts
on
the
body
Noise x x x x x x x
Vibra- x x x x
tions
Shim x x x
my*
Poor x x x x
road-
hol-
ding
30A-22
GENERAL INFORMATION
Vehicle handling: Fault finding 30A
L90
Rear axle and suspension
Caus Shoc Dete- Con- Sus- Sus- Wear Whee Fault Hub- Imba- Axle Bra-
e/ k riora- tact pen- pen- in l ali- in car- lance asse king
symp absor tion with sion sion anti- gnme asse rier betw mbly (see
tom ber of sur- shoc sprin roll nt mbly bea- een angle table
defor sprin roun- k g bar fault or ring right faults for
matio g and ding absor state or tigh- dete- and « Bra
n shoc parts ber bea- tenin riora- left king
k wear rings g of tion sus- »
absor sub- pen-
ber frame sion
asse or
mbly front
moun axle
tings parts
on
the
body
Noise x x x x x x x
Vibra- x x x x
tion
Shim x x x
my*
Poor x x x x
road-
hol-
ding
Wheel alignment is out by more than 6mm Right or left stub axle carrier twisted
30A-23
FRONT AXLE ASSEMBLIES
Brake pads 31A
Fit the new pads, starting with the interior.
Tightening torquesm
WARNING
guide pin bolt 34 Nm - Attach the wheel sensor wiring, if they have
become unclipped (if the vehicle is fitted with
wheel bolts 105 Nm
wheel sensors).
When replacing the brake pads, it is essential to repla- - Do not damage the brake hose.
ce the brake pads on the opposite side
- Do not twist the brake hose.
Unlock the steering wheel. - the guide pin bolt (34 Nm),
IMPORTANT
1 Depress the brake pedal several times to bring
the pistons, the brake pads and discs into con-
tact.
Note:
The brake fluid level must be between the
« MIN » and « MAX » markings on the reservoir.
108349
Remove the lower guide pin bolt (1).
Rotate the calliper upwards.
Remove the pads.
Check the condition of the braking components.
Replace any faulty parts.
Clean the calliper mountings and callipers.
REFITTING
Bush the piston back until it is at the end of its bore.
31A-1
FRONT AXLE ASSEMBLIES
The brake pipe 31A
Essential equipment
pedal press
1
Tightening torquesm
bleed screw 6 Nm
IMPORTANT
Be sure to follow the order of operations for the pro-
cedure described below.
108922
Unscrew:
- the pipe union (1), which frees the hose from the
splines,
WARNING
Check condition of brake pipe. Replace if neces-
sar y.
REFITTING
108919
Refit the brake hose at the calliper end.
REMOVAL
WARNING
Fit the pedal press tool to the brake pedal to restrict
the outflow of brake fluid. Do not twist the brake hose, and straighten the
wheels as steering lock makes it easier for the
unit to become twisted.
WARNING Make sure that there is no contact between the
Prepare for brake fluid outflow, to prevent brake hose and the surrounding components.
damage to the mechanical parts and bodywork
around the braking system.
Note:
The hoses supplied as spare parts are encased
in a spring to prevent them from being twisted
during fitting.
Torque tighten:
31A-2
FRONT AXLE ASSEMBLIES
The brake pipe 31A
Position the female end of the brake hose on the re-
taining bracket without straining it by twisting.
Make sure that the end piece engages freely into the
bracket splines.
Mount:
- the spring,
- the rigid pipe on the brake hose, making sure that
the hose is not twisted when the rigid pipe is
screwed on.
Bleeding the circuit (see 30A, General Vehicle In-
formation, Braking circuit bleed).
Torque tighten the bleed screw (6 Nm).
31A-3
FRONT AXLE ASSEMBLIES
Brake calliper 31A
Essential equipment
pedal press 1
Tightening torquesm
brake pipe 17 Nm
bleed screw 6 Nm
Note:
The callipers supplied as replacement parts are 108349
pre-filled. Remove:
- the guide pin bolts (1),
REMOVAL - the brake calliper,
Mount the vehicle on a two-post lift. - the brake pads,
Check the condition of the braking components (re-
WARNING place faulty parts).
Take precautions for brake fluid outflow, to pre- Clean the calliper mountings and callipers.
vent damage to the mechanical parts and
bodywork around the braking system.
REFITTING
Unlock the steering column.
Bush the piston back until it is at the end of its bore.
Fit tool pedal press to the brake pedal to restrict the
outflow of brake fluid. Fit the pads, starting with the interior.
Remove the front wheels. Refit:
Release the brake hose from the brake calliper. - the calliper,
- the guide pin bolt.
Torque tighten:
- the guide pin bolts (34 Nm),
- the brake pipe (17 Nm).
WARNING
- Attach the wheel sensor wiring, if it has become
unclipped (if the vehicle is fitted with them).
- Do not twist the brake pipe.
31A-4
FRONT AXLE ASSEMBLIES
Brake calliper 31A
- the wheel bolts (105 Nm).
Bleed the brake circuit partially if the limiter reservoir
is not completely emptied during the procedure.
Otherwise bleed the circuit completely (see 30A, Ge-
neral information, Bleeding the braking circuit).
IMPORTANT
Depress the brake pedal several times to bring
the pistons, the brake pads and discs into con-
tact.
Note:
The brake fluid level must be between the
« MIN » and « MAX » markings on the reservoir.
31A-5
FRONT AXLE ASSEMBLIES
Brake calliper mount 31A
Tightening torquesm
REMOVAL 2
Mount the vehicle on a two-post lift.
Unlock the steering column.
Remove the front wheels.
108350
1
Remove:
- the brake pads,
- the calliper mounting bolts, (2)
- the calliper mounting.
Check the condition of the braking components (re-
place faulty parts).
Clean the calliper mountings and callipers.
REFITTING
Push the piston so that it is at the bottom of its hou-
sing.
Coat the calliper mounting with a LOCTITE FREN-
BLOC type product before fitting.
108349
Refit:
Remove the guide pin bolts (1).
- the calliper mounting,
Suspend the brake calliper from the suspension
spring. - the calliper mounting bolts.
Torque tighten calliper mounting bolt (105 Nm).
Fit the pads, starting with the interior.
31A-6
FRONT AXLE ASSEMBLIES
Brake calliper mount 31A
Refit:
- the calliper,
- the guide pin bolts.
WARNING
- Attach the brake hose and wheel speed sensor
wiring if they have been unclipped.
- Do not damage the brake hose.
- Do not twist the brake hose.
IMPORTANT
Depress the brake pedal several times to bring
the pistons, the brake pads and discs into con-
tact.
Note:
The brake fluid level must be between the
« MIN » and « MAX » markings on the reservoir.
31A-7
FRONT AXLE ASSEMBLIES
Brake discs 31A
Tightening torquesm
REMOVAL
Mount the vehicle on a two-post lift.
Unlock the steering column. 2
Remove the front wheels.
108921
Remove
- the calliper mounting,
- the disc mounting bolts, (2)
- the disc.
Clean the calliper mountings and callipers.
REFITTING
Proceed in the reverse order to removal.
1
WARNING
- Attach the wheel sensor wiring, if it has become
unclipped (if the vehicle is fitted with wheel sen-
sors).
- Do not damage the brake pipe.
108350
- Do not twist the brake pipe.
31A-8
FRONT AXLE ASSEMBLIES
Brake discs 31A
Torque tighten wheel bolts (105 Nm).
IMPORTANT
Depress the brake pedal several times to bring
the pistons, the brake pads and discs into con-
tact.
Note:
The brake fluid level must be between the
« MIN » and « MAX » markings on the reservoir.
31A-9
FRONT AXLE ASSEMBLIES
Hub carrier 31A
Essential special tooling
Tightening torquesm
3
shock absorber base 105 Nm
bolts
108350
lower ball joint bolt 62 Nm
REMOVAL 2
Mount the vehicle on a two-post lift.
Unlock the steering wheel.
Remove the front wheel on the side concerned. 6
Unscrew the mounting bracket of the speed sensor
108921
cable (if fitted).
Remove the front brake calliper support bolts (1).
Unclip the wheel speed sensor (if fitted on the vehi-
cle). Hang the « calliper - front brake calliper support »
assembly on the suspension spring.
Remove:
- the hub nut (5) using tool (Rou. 604-01),
- the mounting (6) bolts of the disk,
- the disc,
- the nut (2) of the track rod end,
- the bolt (3) of the lower ball joint,
- the lower mounting (4) bolts of the shock absorber.
31A-10
FRONT AXLE ASSEMBLIES
Hub carrier 31A
Extract the ball joints using tool (Tav. 476).
Remove the stub axle carrier of the front driveshaft,
by pivoting it towards the vehicle interior or using to-
ols (Tav. 1050-04) and (Tav. 1420-01) if necessary.
IMPORTANT
Take care to avoid injury from the base of the
shock absorber when it comes out of the stub
axle carrier.
REFITTING
Proceed in the reverse order to removal.
Note:
Smear the calliper support bolts with LOCTITE
FRENBLOC or similar type product before fitting.
Torque tighten:
- the shock absorber base bolts (105 Nm),
- the lower ball joint bolt (62 Nm),
- thetrack rod end nut (37 Nm),
- the brake disk mounting bolts (14 Nm),
- the hub nut (280 Nm),
- the brake calliper support mounting bolts (105
Nm),
- the wheel mounting bolts (105 Nm).
IMPORTANT
Depress the brake pedal several times to bring
the pistons, the brake pads and discs into con-
tact.
31A-11
FRONT AXLE ASSEMBLIES
Hub-carrier bearing 31A
Essential special tooling
Tightening torquesm
WARNING
The bearing is instrumented. Take care not to mark
the wheel speed sensor target whilst refitting (if fit- 101230
ted on vehicle).
Extract the lower bush from the hub using a jaw ex-
tractor (1).
REMOVAL Place the jaws of the extractor into the throat of the
Remove the hub carrier (see 31A, Front carrier internal bush of the hub to pull it out.
components, Hub carrier). Remove the bearing retaining circlip.
31A-12
FRONT AXLE ASSEMBLIES
Hub-carrier bearing 31A
20787 101934
Remove the bearing by pressing on the internal bush Refit the sensor carrier (if fitted).
with a tube with external diameter of 65 mm.
Position the sensor carrier at (X) or 35˚ ± 5 from the
vertical axle of the hub carrier, as this position cor-
WARNING responds with the centre of the housing (if fitted).
Do not press on the sensor carrier (if fitted on the
vehicle).
REFITTING
WARNING
Do not move the vehicle without its driveshafts
torque tightened on the hub, as to do so could
destroy the wheel bearings and damage the ABS
target.
WARNING
- Be sure to check the condition of the hub sur-
face and the hub carrier bore before refitting the
bearing. Replace the hub carrier if it is defective.
Clean:
- the inner and outer surfaces of the new bearing
20788
in contact with the stub axle carrier and the hub,
Press on the external bearing bush with a tube of an
- the stub axle carrier surfaces in contact with the
external diameter of 70 mm.
new bearing,
- the hub surfaces in contact with the new bea-
ring. WARNING
Do not grip the inner bearing bush, to avoid
damaging the bearing (significant force is requi-
red for fitting).
31A-13
FRONT AXLE ASSEMBLIES
Hub-carrier bearing 31A
Refit the bearing retaining circlip.
20789
31A-14
FRONT AXLE ASSEMBLIES
Spring and shock absorber assembly 31A
Essential equipment
1
spring compressor
Tightening torquesm
REMOVAL
Mount the vehicle on a two-post lift. 108350
Remove the mounting (2) bolts of the calliper sup-
port, hang them up.
WARNING
Remove the bolts (1)of the shock absorber base.
Make sure the colours of the springs and shock
absorbers are identical with the spare parts. Remove the shock absorber base from the stub axle
carrier, pushing on the stub axle carrier.
Unlock the steering wheel.
Hang up the stub axle carrier.
Disconnect the battery, starting with the negative ter-
minal.
Remove the front wheels.
Unscrew the mounting bracket of the speed sensor
cable (if fitted).
Unclip the wheel speed sensors (if fitted on the vehi-
cle).
108978
Remove:
- the shock absorber cage with a male Allen key and
a ring spanner,
- the cage (3),
- the « spring and shock absorber » assembly.
31A-15
FRONT AXLE ASSEMBLIES
Spring and shock absorber assembly 31A
Mount the appropriate cups on the spring compres-
sor and position the assembly on the spring.
Detach the spring from the cups by compressing the
spring.
95435
Note:
108980 When replacing the spring, ensure the positio-
Remove the shock absorber rod with a male Allen ning and orientation of the spring and the tool
key and a ring spanner. cups are correct to facilitate refitting.
Separate the various components of the "spring and Apply grease between the ends of the spring and
shock absorber" assembly. its stops.
REFITTING
Put the spring compressor in a vice.
31A-16
FRONT AXLE ASSEMBLIES
Spring and shock absorber assembly 31A
108979
Insert the spring in the groove of the cup.
31A-17
FRONT AXLE ASSEMBLIES
Spring and shock absorber assembly 31A
Decompress the spring.
Remove the spring compressor.
Proceed in the reverse order to removal.
WARNING
- Fix the wheel speed sensor wiring, if it has
come undone (if fitted on vehicle).
- Do not twist the brake hose.
Torque tighten:
- the shock absorber nut on the body (44 Nm),
- the shock absorber base bolts (105 Nm),
- the wheel mounting bolts (105 Nm).
WARNING
Connect the battery starting with the positive ter-
minal ; perform the necessary programming (see
80A, Battery: removal - refit).
108981
108978
31A-18
FRONT AXLE ASSEMBLIES
Lower suspension arm 31A
Essential special tooling
Essential equipment
jack
Tightening torquesm
WARNING
Do not grip lower arm with a lifting system.
REMOVAL
Mount the vehicle on a two-post lift.
5
Unlock the steering wheel. 4
Remove:
- the front wheel, 107934
Remove:
- the sub-frame tie-rod lower mounting bolt (4).
31A-19
FRONT AXLE ASSEMBLIES
Lower suspension arm 31A
REFITTING
Proceed in the reverse order to removal.
WARNING
The arms bolts must be replaced.
X1
W1
109835
WARNING Refit the lower ball joint into the stub axle carrier.
When refitting, position the lower arm to obtain a
centre-to-centre distance measurement (X1) = 24
mm between the bottom of the ball joint (6) of the
lower arm and the above of the sub-frame at the
level of the hole at the lower arm centre (W1), for
tightening the rubber bushes without forcing.
31A-20
FRONT AXLE ASSEMBLIES
Lower suspension arm 31A
Refit and torque tighten:
- thelower sub-frame tie-rod mounting nut (62
Nm),
- the sub-frame tie-rod upper bolt (21 Nm),
- the anti-roll bar reduction linkage ball joint nuts
( 35 Nm),
- thelower ball joint nut (62 Nm),
- the front wheels and the front wheel bolts (105
Nm).
Note:
Fit the anti-roll bar linkage with tool (Sus. 1413)
and the adapter (Sus.1734).
WARNING
Adjust the axles (see 30A, General Vehicle
Information, Value and adjustment of the front
axle).
31A-21
FRONT AXLE ASSEMBLIES
Anti-roll bar 31A
Essential special tooling
jack
4
Tightening torquesm
REFITTING
1
Proceed in the reverse order to removal.
108351 WARNING
Remove the special mounting (1) bolts of the heat The sub-frame bolts must be replaced.
shield.
Move the heat shield slightly to one side (2) to be
able to unscrew the anti-roll bar right-hand bearing WARNING
nut. Firstly position the central bearings with their
bolts.
WARNING Lift the lower arm with a jack.
All damaged heat shields must be replaced. Fit the anti-roll bar linkage with tool (Sus. 1413)
and the tool (Sus. 1734).
Torque tighten:
WARNING
The tightening order of the anti-roll bar must be
followed.
31A-22
FRONT AXLE ASSEMBLIES
Axle sub-frame 31A
Fit the steering wheel lock.
Essential special tooling
In the passenger compartment, remove the steering
Mot. 1199-01 Exhaust pipe cutter column universal joint bolt and nut.
Tav. 476 Ball joint extractor Strap the radiator to the front upper cross member.
Remove
Essential equipment - the wheels,
safety belt - the two side wheel arch liners.
jack
3
Tightening torquesm
4
sub-frame mounting 105 Nm
bolts
WARNING
Do not grip lower arm with a lifting system.
REMOVAL
Mount the vehicle on a two-post lift.
IMPORTANT
- During this operation, secure the vehicle to the
lift with a strap safety belt, to prevent it from
becoming unbalanced.
- For the fitting procedure of thesafety belt, see
02A, Lifting equipment, Underbody lift:
safety.
31A-23
FRONT AXLE ASSEMBLIES
Axle sub-frame 31A
DIRECTION ASSISTEE
107926 1
107924
9
8
6
108353 10
Remove:
- the sub-frame tie-rod upper bolts (7),
107921
- the exhaust pipe nuts at the level of the exhaust
Remove the mounting (9) and (10) bolt of the engine
manifold (5),
tie-bar on the engine.
- the exhaust pipe rubber mounting at the catalytic
converter level, Put a jack on the fixed engine guard using a safety
belt.
- the exhaust pipe from the manifold to the cut,
Remove:
- the steering ball joint nuts (8),
- the sub-frame mounting bolts on the body (2) and
- the lower ball joint bolts (6). (1),
Extract the four ball joints using tool (Tav. 476). - the sub-frame.
31A-24
FRONT AXLE ASSEMBLIES
Axle sub-frame 31A
Torque tighten in order:
- the sub-frame mounting bolts (105 Nm),
- the sub-frame tie-rod upper bolts (21 Nm),
WARNING
Be sure to follow the sub-frame tightening order.
REFITTING
WARNING
Adjust the axles (see 30A, General Vehicle
Information, Value and adjustment of the front
axle).
DIRECTION ASSISTEE
Fill up the power assisted steering oil circuit (type:
ELFRENAULTMATIC D2).
Bleed the circuit by turning the steering wheel from
11 lock to lock with the engine switched off in the first
instance.
Bleed the circuit by turning the steering wheel from
lock to lock with the engine running.
109241
Top up the level of oil in the reservoir.
Put two M12 threaded rods (11) of the tool (Tav.
Check that there are no leaks.
1747) in the position of the sub-frame front mounting
bolts, to guide the sub-frame when it is refitted.
WARNING
- Check the position of the radiator on the lower
cross member.
- Straighten the wheels.
- You must replace the sub-frame bolts, and the
nut and bolt of the steering column universal
joint.
31A-25
REAR AXLE ASSEMBLIES
Brake pipe 33A
II - REAR RIGHT-HAND RIGID BRAKE PIPE
Essential equipment
pedal press
4
Tightening torquesm 3
rigid brake pipe union on 14 Nm
the rear axle
108928
REMOVAL
Unscrew:
Mount the vehicle on a two-post lift.
- the rigid brake pipe at the rear axle (3),
Fit the pedal press tool to the brake pedal to restrict
the outflow of brake fluid. - the rigid brake pipe at the brake cylinder(4)
Unclip the rear axle rigid brake pipe.
I -REAR LEFT-HAND RIGID BRAKE PIPE Remove the rigid brake pipe.
2 REFITTING
1 Proceed in the reverse order to removal.
Torque tighten:
- the rigid brake pipe union on the rear axle (14
Nm),
- the rigid brake pipe union at the cylinder (14
Nm),
WARNING
Do not twist the brake hose.
108927 Make sure that there is no contact between the
Unscrew: brake hose and the surrounding components.
- the rigid brake pipe from the rear axle (1), It is essential to replace the rigid pipe mounting
clips.
- the rigid brake pipe at the brake cylinder (2)
Unclip the rear axle rigid brake pipe. Bleeding the circuit (see 30A, General Vehicle In-
formation, Braking circuit bleed).
Remove the rigid brake pipe.
33A-1
REAR AXLE ASSEMBLIES
Rear brake lining 33A
DIRECTION MANUELLE, and BASIC HEATING
rear hub nut 175 Nm Brake shoes must be replaced by complete axle -
never fit shoes of differing makes or grades.
wheel bolts 105 Nm
REMOVAL
Composition of brake (automatic incremented
Mount the vehicle on a two-post lift.
compensation).
Slacken the handbrake cables as much as possible.
D
C
2
98992
33A-2
REAR AXLE ASSEMBLIES
Rear brake lining 33A
DIRECTION MANUELLE, and BASIC HEATING
Proceed in the reverse order to removal.
WARNING
The brake mechanism components are different
on the left and right-hand sides, so it is important
not to mix them.
Note:
On the left-hand brake: the bolt thread has a right
pitch.
F 1 On the right-hand brake: the bolt thread has a left
5 pitch.
3
B ADJUSTMENT
X1
A
D
C
98994
Remove:
- the upper retaining spring (1) removing the rear
brake lining first with brake shoe pliers,
- the incremented compensator system spring (5),
- the side retainers (3) holding the connecting rod
against the brake backing plate,
- the incremented play compensation lever (F),
98992
Remove each brake shoe base (D) alternately from With the help of a screwdriver, adjust the brake shoe
fixed point (C). diametric setting using the linkage to a diameter (X1)
Unclip the parking brake cable from the brake lining. of 179.4 mm ± 0.25.
Remove the linings (B) and (A). Carry out the same adjustment on the other side.
REFITTING
Lightly grease the support linkage lever thread (F).
33A-3
REAR AXLE ASSEMBLIES
Rear brake lining 33A
DIRECTION MANUELLE, and BASIC HEATING
98992-2
Adjust the handbrake if the lever remains between
the first and second parking brake travel position
(see 37A, Mechanical component controls, Par-
king brake cables).
Refit the drum.
Adjust the brake shoes by repeatedly depressing the
brake pedal.
Make sure that the incremented compensator sys-
tem is working properly (you should hear the drums
click).
Torque tighten:
- therear hub nut (175 Nm),
- the wheel bolts (105 Nm).
33A-4
REAR AXLE ASSEMBLIES
Rear brake lining 33A
DIRECTION ASSISTEE, and AIR CONDITIONING
REMOVAL
Tightening torquesm
2
F
1
3
5
B
A
86561
4
Slacken the handbrake cables as much as possible.
Remove:
- the brake drum (see 33A, Rear axle components,
D Brake drum).
C 1 - the lower spring (1), then the upper spring (2) with
brake shoe pliers.
108343
IMPORTANT
(A) Leading shoe
Brake shoes must be replaced by complete axle -
(B) Trailing shoe never fit shoes of differing makes or grades.
(C) Fixed point Place the pliers on the slave cylinder pistons.
33A-5
REAR AXLE ASSEMBLIES
Rear brake lining 33A
DIRECTION ASSISTEE, and AIR CONDITIONING
R
E
T
A H
86559
A Remove the leading shoe:
Note:
On the left-hand brake: the bolt thread has a right
pitch.
On the right-hand brake: the bolt thread has a left
pitch.
Mount:
- the trailing shoe and secure it,
33A-6
REAR AXLE ASSEMBLIES
Rear brake lining 33A
DIRECTION ASSISTEE, and AIR CONDITIONING
- the support control lever directing the threaded
pushrod hollow section on the adjustment lever si-
de,
- the leading shoe and secure it.
ADJUSTMENT
86557
Torque tighten:
33A-7
REAR AXLE ASSEMBLIES
Brake cylinder 33A
Torque tighten:
Remove:
- the brake drum (see 33A, Rear axle components,
Brake drum).
- the upper return spring using brake shoe pliers (see
33A, Rear axle components, Rear brake
linings).
Separate the shoes.
108341
Unscrew:
- the rigid pipe union (1) on the slave cylinder (take
precautions for brake fluid outflow),
- the cylinder mounting bolts on the (2) brake backing
plate.
Remove the brake cylinder.
REFITTING
Remove any dust from the drums, the brake linings
and the brake back plates using brake cleaner.
Proceed in the reverse order to removal.
33A-8
REAR AXLE ASSEMBLIES
Brake drum 33A
Fit:
Essential special tooling
- the drum,
Tav. 1050-04 Universal driveshaft
- the nut.
pusher tool (back-plate
and claws, without Torque tighten the hub nut (17.5 daNm).
jack).
Fit the hub cover plug.
Tav. 1420-01 Spare hydraulic screw Adjust the brake shoes by repeatedly depressing the
for Tav.1420, Tav.1050- brake pedal.
02, Tav.1050-04 and
Tav.1454.
IMPORTANT
The two brake drums must be of the same dia-
Tightening torquesm meter, if one is reground, the other must also be
reground. The maximum diameter is etched on
hub nut 17.5 daNm the drum.
wheel bolts 10.5 daNm Refit the wheel and torque tighten the wheel bolts
(10.5 daNm).
REMOVAL
Position the vehicle on a two-post lift.
Release the parking brake lever.
2
1
109374
Remove:
- the wheel concerned,
- the hub cover (1) using a chisel and a hammer,
- the hub nut (2),
- the drum (3) using tools(Tav. 1050-04) and (Tav.
1420-01), if necessary.
REFITTING
Remove any dust from the drums, the shoes and the
flanges using a brake cleaner.
Adjust the handbrake if the lever remains between
the first and second position of the parking brake tra-
vel (see 37A, Mechanical component controls,
Parking brake cables).
33A-9
REAR AXLE ASSEMBLIES
Bearing 33A
Torque tighten:
CHECKING
Use a dial gauge fixed on the drum to check that the
end float is 0 to 0.03 mm max.
REMOVAL
Remove the drum (see 33A, Rear carrier elements,
Brake drum).
2
1
109373
Note:
Check that the tube is properly pressing against
the external bearing ring.
REFITTING
Lift the bearing until it presses onto the shoulder
using a tube of an external diameter of 50 mm and a
press.
Fit:
- a new clip,
33A-10
REAR AXLE ASSEMBLIES
Spring 33A
Essential equipment
jack
Tightening torquesm
3
REMOVAL
Mount the vehicle on a two-post lift.
Remove the rear wheels. 108924
Remove spring (3) and its lower mounting.
WARNING
If the upper mounting is unclipped, replace it.
WARNING
Take a measurement at the same time.
REFITTING
2 1 Refit:
108341 - the lower mounting on the rear axle (positioning the
Position tool jack(2) in contact, with a shim, under guide correctly),
the spring collar, without restricting its movement. - the spring with its upper mounting in the marked lo-
Mark the position where the spring is fitted. cation, starting at the top.
Remove the shock absorber lower mounting bolt (1). Set up the jack tool, with a shim, under the spring
cup.
Remove tool jack.
Compress the rear axle so that the lower shock ab-
sorber mounting can be pretightened.
WARNING
The shock absorber mountings are only to be
tightened with the vehicle wheels on the ground.
33A-11
REAR AXLE ASSEMBLIES
Shock absorber 33A
Tightening torquesm
108341
WARNING Raise the vehicle and remove the shock absorber
- Never grip the rear axle with a lifting system. lower bolt (3).
- If replacing a shock absorber, the shock absorber Remove the shock absorber.
on the opposite side must be replaced.
WARNING
REMOVAL
Take a measurement at the same time.
Mount the vehicle on a two-post lift.
REFITTING
Proceed in the reverse order to removal
Torque tighten:
33A-12
REAR AXLE ASSEMBLIES
Rear axle assembly 33A
L90, and K7J or K7M
Essential equipment
safety belt
pedal press
jack
Tightening torquesm 8
bearing mounting bolts 62 Nm
REMOVAL
Release the parking brake.
IMPORTANT
2
- During this operation, secure the vehicle to the
lift with a strap safety belt, to prevent it from
becoming unbalanced. 1
- For the fitting procedure of thesafety belt, see
02A, Lifting equipment, Underbody lift:
safety.
Remove:
33A-13
REAR AXLE ASSEMBLIES
Rear axle assembly 33A
L90, and K7J or K7M
3
3 4
108341 108931
Bring tool jack(3) into contact with a shim, under the Fit the jack(3) tool at the centre of the rear axle.
right-hand spring cup, without forcing it. Trim the rear axle at jack with a safety belt(6).
Mark the position where the spring is fitted.
Remove the shock absorber lower mounting bolt (4)
with a long dowel.
Remove the jack tool.
11
12
7
5
108923
Loosen the bearing bolts (7).
Lower the rear axle with the jack.
108924
WARNING
If the upper support is unclipped, replace it.
33A-14
REAR AXLE ASSEMBLIES
Rear axle assembly 33A
L90, and K7J or K7M
WARNING
Do one side at a time.
WARNING
The shock absorber mountings are only to be
tightened with the vehicle wheels on the ground.
33A-15
REAR AXLE ASSEMBLIES
Locking the axle in position 33A
Essential equipment
safety belt
jack
Tightening torquesm
REMOVAL
Release the rubber bush nut. 3312
Position the rear axle using tool jack, to obtain a
Remove the rear axle assembly (see 33A, Rear car-
measurement between the centre of the rear hub
rier components, Rear axle assembly.
and the rear side member corresponding with a
length of 8.2 mm ± 3.
IMPORTANT Torque tighten the bush mounting bolts (125 Nm).
108932
Remove:
REFITTING
Proceed in the reverse order to removal
33A-16
WHEELS AND TYRES
Tyre inflation pressure: Identification 35A
I -INFLATION
Cold inflation pressure (bar).
WARNING
If checking the pressure when warm, assume a
pressure increase of 0.2 to 0.3 bar and never
deflate the tyres.
35A-1
WHEELS AND TYRES
Wheel rim: Identification 35A
The wheel rims are marked in one of two ways:
4 Number of holes 4
1
2
100988
35A-2
WHEELS AND TYRES
Identification of tyres 35A
Example of tyre identification marking: 205/55 R 16 91
V.
101008
R Radial structure
91 Load index
V Speed code
R 106 (170)
S 112 (180)
T 118 (190)
U 124 (200)
H 130 (210)
V 149 (240)
ZR abov e 149
(240)
35A-3
WHEELS AND TYRES
Balancing 35A
I -PREREQUISITES FOR WHEEL BALANCING To reproduce the exact vehicle wheel assembly, it is
essential to fit a 60 mm diameter cylindrical centring
Wheel balancing is a measurement operation. device on the wheel balancer.
Several conditions must be met to achieve a reliable re-
sult in a single operation.
The wheel balancer must be installed in accordance
with the manufacturer's instructions.
2
Never grease the threaded shaft.
Check the condition of the supports, centring compo-
nents and mountings.
Replace any faulty parts (see manufacturer's instruc-
tions).
The wheel and the wheel balancer must be clean.
1 - Wheel
Clean the bearing and centring faces.
Remove any gravel trapped in the tyre treads.
Clean the wheels.
105870
2 - Wheel balancer
Be careful to keep the contact surface of the wheel ba- 3
lancing machine and all the alignment accessories
(bush, thrust plate, etc.) clean.
1
II - WHEEL REMOVAL AND WHEEL BALANCING
4
1 - Driver's observation
If the wheels are not correctly balanced this causes the
steering wheel and/or the vehicle floor to vibrate.
The vibrations occur at between 56 mph (90 km/h) and
93 mph (150 km/h).
WARNING
Perform a road test of at least 1.25 miles (2 km)
before the wheel balancing operation to prevent a
flat spot forming on the tread when the vehicle is 105871
stationary.
The wheel is fitted on the wheel balancer as follows:
After the road test: - (1) wheel balancer back-plate,
- lift the vehicle immediately,
- (2) ring, diameter 60 mm,
- leave the four wheels suspended,
- (3) wheel,
- release the parking brake.
- (4) wheel locking tool.
Remove the wheels, positioning the valves upwards.
After switching on the wheel balancer and entering the
Be sure to clean the wheel, disc, and hub bearing sur- specific wheel parameters, select the « end » balan-
faces. cing mode.
35A-4
WHEELS AND TYRES
Balancing 35A
100681 88659
Check that the wheel is not deformed because of acci- (6) Alloy wheel rim
dental impact. If it is, replace the deformed compo-
nents.
Start the wheel balancer and check that the wheel ba-
lance is below 5 g (dynamic) and 10 g (static).
2 - Balance weights
35A-5
STEERING ASSEMBLY
Steering rack 36A
DIRECTION MANUELLE
- the front wheels,
Essential special tooling
- the lateral wheel arch liners,
Tav. 476 Ball joint extractor
- the nuts (6) from where the exhaust pipe goes
Essential equipment down from the exhaust manifold,
107921
REMOVAL
Loosen the support (1) mounting bolts.
Mount the vehicle on a two post lift.
Straighten the wheels. Remove the mounting (2) bolt of the torque reaction
on the gearbox.
Remove the steering column universal joint bolt (to
the side of the pedals). Pivot the support (3).
5
4
108934
6
Fit a jack(4) to support the axle assembly sub-frame
rear.
107926
Replace the two front mounting bolts of the axle as-
sembly sub-frame by two rods of tool (TAV. 1747) (5)
Remove:
to lower the front of the axle assembly sub-frame sli-
- the engine undertray, ghtly.
36A-1
STEERING ASSEMBLY
Steering rack 36A
DIRECTION MANUELLE
Torque tighten:
- the axle assembly sub-frame bolts (105 Nm),
7 - the torque reaction support bolts on the gear-
box (105 Nm),
- the steering rack bolts (105 Nm),
- the track rod end nut ((37 Nm)),
- the steering column universal joint bolt (21 Nm),
- the wheel mounting bolts (105 Nm).
WARNING
You must check the front axle assembly angles
(adjust if necessary) (see 30A, General Vehicle
Information, Front axle assembly values and
adjustments).
107934
Remove:
- the upper mounting (7) bolts of the axle assembly
sub-frame tie-rod,
- the rear axle assembly sub-frame mounting bolts.
Lower the axle assembly sub-frame with the jack.
Remove the steering rack to the left.
REFITTING
Proceed in the reverse order to removal.
WARNING
Check that the radiator bottom slots onto the front
cross member of the axle assembly sub-frame
when it is refitted.
36A-2
STEERING ASSEMBLY
Axial ball joint linkage 36A
Essential special tooling
Tightening torquesm 1
2
axial ball joint 34 Nm
Note:
3
During this operation, the steering rack must be
in place on the vehicle.
36A-3
STEERING ASSEMBLY
Axial ball joint linkage 36A
Retighten the ball joint housing by the number of ro-
tations noted during removal.
Refit the track rod end.
Torque tighten:
- the wheel alignment adjustment lock nut (50
Nm),
- the track rod end nut ((37 Nm)),
- the wheel mounting bolts (105 Nm).
Adjust the front axle assembly (see 07B, General
Vehicle Information, Axle assembly values and
adjustment).
36A-4
STEERING ASSEMBLY
Steering column 36A
Essential equipment
2
diagnostic tool
Tightening torquesm 4
steering column moun- 21 Nm
ting nuts
IMPORTANT
Before working on a safety system component or
near one, you must lock the air bag computer with
diagnostic tool (see 88C, Air bag and pretensio-
ners, Air bag computer locking procedure). 3
When this function is activated, all the trigger lines 108914
are inhibited and the air bag warning light on the
instrument panel lights up continuously (ignition on).
REMOVAL
Set the vehicle wheels straight.
Disconnect the battery, starting with the negative ter-
minal.
Remove the dashboard, the shell and the steering
wheel (see 57A, Interior equipment, Dashboard).
1
107849
Unclip the engine immobiliser (2) with a flathead
screwdriver.
Disconnect the connector (3) of the starter switch
with a flathead screwdriver.
Remove:
- the mounting (4) bolts of the steering column,
108913
- the steering column.
Remove the steering column universal joint bolt (1).
36A-5
STEERING ASSEMBLY
Steering column 36A
7
5
108915
Open the ignition switch wiring retaining clip. REFITTING
Remove the ignition switch bolt . Proceed in the reverse order to removal.
WARNING
- The steering wheel should enter the splines
8 freely (the splines have foolproofing devices).
- Do not damage the foolproofing splines.
- The steering wheel bolt must be replaced each
time it is removed.
Note:
- Be sure to replace the steering column universal
joint bolt and eccentric nut each time they are
106522
removed.
Insert the key into the ignition switch and turn it a - On a new steering column, the steering column
quarter turn (8). universal joint cam nut is pre-fitted.
36A-6
STEERING ASSEMBLY
Steering column 36A
Ensure that the steering column universal joint cam
nut and bolt are fitted the right way round.
Finger tighten the cam nut and the fork bolt.
Lock the cam nut in its housing (aperture on the stee-
ring column universal joint).
Torque tighten:
- the steering column mounting nuts (21 Nm),
- the steering column universal joint bolt (21 Nm).
WARNING
36A-7
STEERING ASSEMBLY
Bulkhead seal 36A
REMOVAL
Remove the front axle sub-frame (see 31A, Front
carrier components, Axle assembly sub-frame).
101352
Unclip the bulkhead seal using a screwdriver.
REFITTING
Proceed in the reverse order to removal.
36A-8
POWER ASSISTED STEERING
Power assisted steering rack 36B
DIRECTION ASSISTEE
Essential equipment
jack
Tightening torquesm
1
2
107921
36B-1
POWER ASSISTED STEERING
Power assisted steering rack 36B
DIRECTION ASSISTEE
REFITTING
Proceed in the reverse order to removal.
WARNING
Check that the radiator bottom slots onto the front
cross member of the axle assembly sub-frame
when it is refitted.
Torque tighten:
5
- the axle assembly sub-frame bolts (105 Nm),
4
- the torque reaction support bolts on the gear-
box (35 Nm),
108934 - the steering rack bolts (105 Nm),
Fit a jack(4) to support the axle assembly sub-frame - the track rod end nut ((37 Nm)),
rear.
- the steering column universal joint bolt (21 Nm),
Replace the two front mounting bolts of the axle as-
- the high pressure union on the rack (21 Nm),
sembly sub-frame by two rods of tool (Tav. 1747) (5)
to lower the front of the axle assembly sub-frame sli- - the low pressure union on the rack (21 Nm),
ghtly.
- the wheel mounting bolts (105 Nm).
WARNING
7 You must check the front axle assembly angles
(adjust if necessary) (see 30A, General Vehicle
Information, Front axle assembly values and
adjustments).
36B-2
POWER ASSISTED STEERING
Steering column 36B
Essential equipment
2
diagnostic tool
Tightening torquesm 4
steering column moun- 21 Nm
ting nuts
IMPORTANT
Before working on a safety system component or
near one, you must lock the air bag computer with
diagnostic tool (see 88C, Air bag and pretensio-
ners, Air bag computer locking procedure). 3
When this function is activated, all the trigger lines 108914
are inhibited and the air bag warning light on the
instrument panel lights up continuously (ignition on).
REMOVAL
Set the vehicle wheels straight.
Disconnect the battery, starting with the negative ter-
minal.
Remove the dashboard, the shell and the steering
wheel (see 57A, Interior equipment, Dashboard).
1
107849
Unclip the engine immobiliser (2) with a flathead
screwdriver.
Disconnect the connector (3) of the starter switch
with a flathead screwdriver.
Remove:
- the mounting (4) bolts of the steering column,
108913
- the steering column.
Remove the steering column universal joint bolt (1).
36B-3
POWER ASSISTED STEERING
Steering column 36B
7
5
108915
Open the ignition switch wiring retaining clip. REFITTING
Remove the ignition switch bolt . Proceed in the reverse order to removal.
WARNING
- The steering wheel should enter the splines
8 freely (the splines have foolproofing devices).
- Do not damage the foolproofing splines.
- The steering wheel bolt must be replaced each
time it is removed.
Note:
- Be sure to replace the steering column universal
joint bolt and eccentric nut each time they are
106522
removed.
Insert the key into the ignition switch and turn it a - On a new steering column, the steering column
quarter turn (8). universal joint cam nut is pre-fitted.
36B-4
POWER ASSISTED STEERING
Steering column 36B
Ensure that the steering column universal joint cam
nut and bolt are fitted the right way round.
Finger tighten the cam nut and the fork bolt.
Lock the cam nut in its housing (aperture on the stee-
ring column universal joint).
Torque tighten:
- the steering column mounting nuts (21 Nm),
- the steering column universal joint bolt (21 Nm).
WARNING
36B-5
POWER ASSISTED STEERING
Power assisted steering pump 36B
AIR CONDITIONING
Fit caps to the pipe and power assisted steering
pump openings to avoid impurities getting into them.
Tightening torquesm
REMOVAL
Mount the vehicle on a two post lift.
Remove:
108929
108929
Remove:
Unconnect the inlet hose (3).
- the three mounting (1) bolts on the alternator sup-
Loosen the high pressure pipe union from the pump. port - power assisted steering pump - compressor,
Remove the high pressure pipe from the pump. - the power assisted steering pump.
36B-6
POWER ASSISTED STEERING
Power assisted steering pump 36B
AIR CONDITIONING
REFITTING
Proceed in the reverse order to removal.
Torque tighten:
- the power assisted steering pump mounting
bolts (21 Nm),
- the high pressure union on the power assisted
steering (21 Nm),
WARNING
Torque tighten first the two bolts on the accesso-
ries belt side, then the bolts on the other side.
WARNING
Replace any belt that has been removed.
When replacing the belt, be sure to replace the
tension wheels and idler pulleys.
36B-7
POWER ASSISTED STEERING
Power assisted steering pump 36B
BASIC HEATING
Tightening torquesm
REMOVAL
Mount the vehicle on a two post lift.
Remove:
- the engine undertray,
- the accessories belt (see 11A, Top and front of 1
engine, Accessories belt),
- the front bumper (see 55A, External protection,
Front bumper). 109225
109235
Remove:
- the mounting (1) bolts on the alternator support -
power assisted steering pump - compressor,
- the power assisted steering pump.
REFITTING
Proceed in the reverse order to removal.
36B-8
POWER ASSISTED STEERING
Power assisted steering pump 36B
BASIC HEATING
Torque tighten:
- the power assisted steering pump mounting
bolts (21 Nm),
- the high pressure union on the power assisted
steering (21 Nm).
WARNING
Torque tighten first the two bolts on the accesso-
ries belt side, then the bolts on the other side.
WARNING
Replace any belt that has been removed.
When replacing the belt, be sure to replace the
tension wheels and idler pulleys.
36B-9
POWER ASSISTED STEERING
Power assisted steering pump pulley 36B
L90, and K7J or K7M
REMOVAL
Remove the power assisted steering pump (see
36B, Power assisted steering, Power assisted
steering pump).
Use the press with a jaw extractor.
REFITTING
1
18159
Follow the pulley fitting dimension measurement, X
= 25.4 mm ± 0.4.
90317
Fit the pulley with tool (Dir. 1083-01)(1) until you
reach the measured fitting dimension (smear plenty
of grease onto the threading and the point on the pul-
ley).
36B-10
POWER ASSISTED STEERING
Power assisted steering pump: Checking 36B
Essential special tooling
Tightening torquesm
Note:
If the vehicle is not fitted with air conditioning, the
power assisted steering pump is located below
the alternator, but the procedure remains the
same.
AIR CONDITIONING
WARNING
Protect the alternator from power assisted stee-
ring oil outflow.
36B-11
POWER ASSISTED STEERING
Power assisted steering pump: Checking 36B
Remove the hose clamp.
WARNING
Be sure to replace the O-rings removed from the
power assisted steering unions.
36B-12
MECHANICAL ELEMENT CONTROLS
Master cylinder 37A
REFITTING
Tightening torquesm
6 7
master cylinder pipe 14 Nm
unions
WARNING
Take precautions for brake fluid outflow, to pre-
vent damage to the mechanical parts and
bodywork around the braking system.
4
108920
REMOVAL Clip the brake fluid reservoir onto the master cylinder
correctly.(6)
Mount the vehicle on a two-post lift.
WARNING
Be sure to replace the master cylinder seal (7).
108344
Remove:
37A-1
MECHANICAL ELEMENT CONTROLS
Brake compensator 37A
- the brake limiter mounting bolts (12 Nm).
Essential special tooling
Check the brake limiter.
Fre. 1085-01 Brake pressure gauge
0 -250 bar. Replaces
Fre.1085 CHECKING
I -CHECKING PRINCIPLE
Tightening torquesm The pressure is read in an X pattern by comparing
the rear and front wheel pressure.
brake limiter piping 14 Nm
unions
Note:
brake limiter mounting 12 Nm
bolts It is essential to check both circuits.
Front right/rear left and front left/rear right.
Vehicles fitted with ABS do not have a brake limiter.
Block the pedal to limit the flow. The setting enables the rear pressure to be adjusted
according to the front pressure.
The adjustment is made simultaneously in on cir-
REMOVAL cuits.
Mount the vehicle on a two-post lift.
If the pressure is incorrect for one of the two circuits,
replace the limiter.
1
2
108925
REFITTING
Proceed in the reverse order to removal.
Drain the brake circuit (see 30A, General informa-
tion, Draining the braking circuit ).
Torque tighten:
- the brake limiter piping unions (14 Nm),
37A-2
MECHANICAL ELEMENT CONTROLS
Brake compensator 37A
II - CHECK
Note:
The pressure difference between the two rear
wheels should be lower than 4 bar, regardless of
the load on the rear axle.
1 - No balance:
WARNING
The fuel tank needs to be full if carrying out his
procedure.
37A-3
MECHANICAL ELEMENT CONTROLS
Brake compensator 37A
2 - With balance:
Perform the pressure checks using the following two
loads:
- For a rear axle load of 425 kg and a pressure of100
bar at the front, a pressure of between 27.7 and
39.6 bar is required,
- For a rear axle load of 550 kg and a pressure of100
bar at the front, a pressure of between 45.4 and
57.3 bar is required,
ADJUSTMENT
108342
Turn nut (4) until the correct value is obtained.
37A-4
MECHANICAL ELEMENT CONTROLS
Brake servo 37A
Tightening torquesm
WARNING
Prepare for brake fluid outflow, to prevent damage
to the mechanical parts and bodywork around the 108348
braking system.
Remove, on the passenger side, the dual safety
shaft (2) between the brake servo pushrod and the
brake pedal.
REMOVAL
Remove the master cylinder (see 37A, Mechanical
component controls, Master cylinder).
3
4
108933
Remove the brake servo anti-return valve. (1)
109449
Remove insulating foam special nuts. (4)
Gently move the insulating foam aside.
Remove:
- the brake servo mounting nuts (3) on the passen-
ger side (nuts securing the pedal assembly to the
brake servo),
- the brake servo.
37A-5
MECHANICAL ELEMENT CONTROLS
Brake servo 37A
REFITTING
X1
91101
WARNING
Replace the dual safety brake pedal/master con-
necting shaft during every operation. It has a
plastic spring ring which can only be released
once.
Grease the dual safety shaft before fitting.
Insert the dual safety shaft from left to right.
Clip the dual safety shaft to the brake servo pus-
hrod by tilting it upwards from the bottom.
Torque tighten:
- the brake servo mounting nuts (21 Nm).
- the master cylinder nuts (21 Nm),
- the master cylinder pipe unions (14 Nm),
Drain the brake circuit (see 30A, General informa-
tion, Draining the braking circuit ).
37A-6
MECHANICAL ELEMENT CONTROLS
Brake servo non-return valve 37A
REMOVAL
3
1
2
108933
Disconnect the vacuum pipe at the brake servo end
(1).
Pull and turn the non-return valve (3) to extract it
from the rubber sealing washer.
Unclip the vacuum pipe at the inlet manifold end (2).
REFITTING
Check the condition of the rubber sealing washer
and the non-return valve.
Replace any faulty parts.
Proceed in the reverse order to removal.
37A-7
MECHANICAL ELEMENT CONTROLS
Brake pedal 37A
L90, and K7J or K7M
108790
REMOVAL
108348
Unclip the stop light switch (1) from the brake pedal
by turning it anticlockwise a quarter of a turn.
Remove the safety clevis pin (2) linking the brake pe-
dal to the master cylinder.
37A-8
MECHANICAL ELEMENT CONTROLS
Brake pedal 37A
L90, and K7J or K7M
REFITTING THE SENSOR
6
5
3
4
108436
It is essential to pull carefully on the end of the switch
so that measurement (X) is between 13 mm mini-
mum and 14 mm maximum.
108103
Remove the nut (3) from the pedal assembly shaft. WARNING
- The switch must be replaced if the piston (5) for
Move the pedal assembly pivot (4) to the left until the
the brake pedal position switch (6) is extracted
brake pedal can come out.
completely.
Remove the brake pedal .
- The switch must be replaced if the work on the
piston involves three adjustments.
REFITTING
Depress the brake pedal.
Coat the shaft with grease.
Position the switch on the pedal assembly.
Proceed in the reverse order to removal.
Turn the brake pedal switch a quarter turn clockwise.
Support the brake pedal as it returns.
Note:
Connect the connector.
Do not hit the pedal assembly shaft with a ham-
mer to get it to go back into place. Check that the assembly works correctly.
WARNING
Change the safety clevis pin linking the brake
pedal and the master cylinder every time work is
carried out on it. It has a plastic spring ring that
can only be used once.
Grease the safety clevis pin before fitting it.
Insert the safety clevis pin from left to right.
Clip the safety clevis pin to the servo unit pushrod
by folding it upwards.
37A-9
MECHANICAL ELEMENT CONTROLS
Accelerator pedal 37A
L90, and K7J or K7M
Tightening torquesm
REMOVAL
2
108918
Remove:
- the circlip (3) using a screwdriver,
- the pedal shaft.
1
Note:
109450
Memorise which way round the mounting goes in
Unscrew the special nut (2) from the insulating foam relation to the pedal and the position of the
around the left-hand accelerator pedal mounting nut. washers.
Remove:
- the accelerator pedal mounting nuts(1), REFITTING
- the pedal, Proceed in the reverse order to removal.
- the accelerator cable at the pedal end by moving it Torque tighten the pedal mounting bracket nuts
upwards and sliding the cable end-piece towards (21 Nm).
the central console.
37A-10
MECHANICAL ELEMENT CONTROLS
Clutch/brake pedal assembly 37A
Tightening torquesm
REMOVAL
1 3
7
4
2
109449
108348 Remove:
Disconnect the brake pedal light switch connector - the steering column universal joint bolt(4),
(1).
Remove: - the pedal assembly bracket mounting bolts (3),
- the safety clevis pin linking the brake pedal to the - the pedal assembly.
master cylinder (2),
If necessary, cut the insulating foam to withdraw it.
- the clutch cable from its slot on the pedal, lifting the
pedal and bringing the cable up at right-angles to
the pedal.
108917
37A-11
MECHANICAL ELEMENT CONTROLS
Clutch/brake pedal assembly 37A
REFITTING
Replace the insulating foam. X2
Refit
X1
- the insulating foam through the slot,
- the brake light switch (see 37A, Mechanical com-
ponent controls, brake light switch).
Proceed in the reverse order to removal.
WARNING 6
Change the safety clevis pin linking the brake
pedal and the master cylinder every time work is
carried out on it. It has a plastic spring ring that
109400
can only be used once.
The adjustment of the slack in the clutch control ca-
Grease the safety clevis pin before fitting it. ble is carried out at the gearbox end, using the nut
Insert the safety clevis pin from left to right. (6).
Clip the safety clevis pin to the servo unit pushrod Clutch pedal at rest.
by folding it upwards. The amount of slack can be measured with a ruler in
two places:
Torque tighten:
- Between the sleeve stop and the end of the clutch
- the pedal assembly mounting bracket nuts (21
control cable = (X1)60 mm ± 5.
Nm),
- Between the sleeve stop and the end of the clutch
- the steering column universal joint bolt (21 Nm). fork = (X2)86 mm ± 5.
Check that the clutch cable fits perfectly in the groo-
ve provided for it on the pedal.
Check that the wipers operate correctly.
With the pedal at rest, clutch engaged position, pull
on the cable at the clutch fork on the gearbox.
The cable must have at least 2 cm of slack.
37A-12
MECHANICAL ELEMENT CONTROLS
Brake light switch 37A
REMOVAL I -WHEN REMOVING AND REFITTING THE SENSOR
1
2 3
x
4
108348 108436
Disconnect the brake pedal position sensor connec- It is essential to pull carefully on the end of the switch
tor (1). so that measurement(X) is between 13 mm mini-
mum and 14 mm maximum.
Turn the brake pedal position sensor (2) anticlockwi-
se a quarter of a turn.
WARNING
Remove the brake pedal position sensor.
- The switch must be replaced if the piston (4) for
the brake pedal position switch (3) is extracted
REFITTING completely.
- The switch must be replaced if the work on the
piston involves three adjustments.
Note:
The brake pedal switch has an automatic adjust- Depress the brake pedal.
ment feature, adapting to the pedal position. Position the switch on the pedal assembly.
Turn the brake pedal switch a quarter turn clockwise.
Support the brake pedal as it returns.
Connect the connector.
37A-13
MECHANICAL ELEMENT CONTROLS
Brake light switch 37A
II - WHEN FITTING A NEW SENSOR
6
5
108436
Make sure that measurement (X) is at least 13 mm.
If (X) is of another value, apply the procedure for the
switch removed.
WARNING
- The switch must be replaced if the piston (5) for
the brake pedal position switch (6) is extracted
completely.
- The switch must be replaced if the work on the
piston involves three adjustments.
37A-14
MECHANICAL ELEMENT CONTROLS
Parking brake cables 37A
Tightening torquesm
2
drum nuts 175 Nm
REMOVAL
Mount the vehicle on a two post lift.
108347
Unclip:
- the cable (3) from its housing,
- the sheath from its stop on the body (2) using a pair
of pliers,
- the wheel hub flange sheath.
1
Remove the cable from the retaining clips.
Remove the parking brake cable.
REFITTING
Proceed in the reverse order to removal.
Apply the parking brake lever five times to condition
the cables for normal use.
98992
Remove:
ADJUSTMENT
- the wheel in question,
A badly adjusted parking brake:
- the drum cap,
- prevents the correct operation of the automatic
- the drum nut, compensation system for the brake shoes,
- the brake drum, - and causes long brake pedal travel.
- the brake cable (1) using a pair of pliers and a
screwdriver,
WARNING
- the centre console (see 57A, Mechanisms and ac-
The brake cables should not be re-tensioned to
cessories, interior equipment) or the cover (de-
correct this fault since it will quickly recur.
pending on the equipment).
37A-15
MECHANICAL ELEMENT CONTROLS
Parking brake cables 37A
The parking brake is not a wear compensation. Ad-
just the parking brake only when the following are re-
placed:
- shoes,
5
- the cables,
- the parking brake lever.
Note:
Any other adjustment except in the above cases
is not permitted.
108343
Check the operation of the compensation system by
rotating the notched sector (5) (ensure it turns in both
directions), then turn it back by 5 to 6 teeth.
4
109448
Lower the parking brake lever.
Undo the adjusting nut as far as it will go (4).
Remove:
- the two rear wheels,
- the two drums.
98992
Make sure:
- that the cables slide freely,
- that the lever position against is correct.
Progressively tighten the cables at the level of the
central adjusting nut (4) in such a way as the levers
(6) release the parking brake between the first and
second notches of the lever movement and remain
remains released in the second notch.
Fit the drums.
37A-16
MECHANICAL ELEMENT CONTROLS
Parking brake cables 37A
Torque tighten:
- the drum nuts (175 Nm),
- the wheel mounting bolts (105 Nm).
With the vehicle on its wheels, adjust the brake
linings by pressing the brake pedal firmly and pro-
gressively for a number of times while listening for
the automatic compensation system clicking.
Check the lever movement (seven positions).
Release the parking brake.
Check that the wheels turn freely.
37A-17
MECHANICAL ELEMENT CONTROLS
Parking brake lever 37A
Adjust the parking brake if the lever remains
between the first and second handbrake lever move-
Tightening torquesm ment positions (see 37A, Control of mechanical
components, parking brake cable).
parking brake lever 21 Nm
mounting bolts
REMOVAL
Remove the centre console (see 57A, Mechanisms
and accessories, interior equipment) or the cover
(depending on the equipment).
108347
3
109447
REFITTING
Proceed in the reverse order to removal.
Torque tighten the parking brake lever mounting
bolts (21 Nm).
37A-18
MECHANICAL ELEMENT CONTROLS
Exploded view of clutch control components 37A
L90, and K7J or K7M, and JH1 or JH3
Exploded view
109143
This control has no automatic take-up.
X2
X1
109400
The adjustment of the clutch control cable guard is by
the gearbox side end, by turning the nut (1).
Clutch pedal released.
Measurement of the guard can be done in two places:
- Between the sleeve stop and the end of the clutch
control cable (X1) = 60 mm ± 5.
- Between the sleeve stop and the end of the clutch fork
(X2) = 86 mm ± 5.
37A-19
MECHANICAL ELEMENT CONTROLS
Clutch control: Adjusting 37A
L90, and K7J or K7M, and JH1 or JH3
X2
109400
The adjustment of the clutch control cable guard is by
the gearbox side end, by turning the nut (1).
Clutch pedal released.
Measurement of the guard can be done in two pla-
ces:
- Between the sleeve stop and the end of the clutch
control cable (X) = 60 mm ± 5.
- Between the sleeve stop and the end of the clutch
fork (X2) = 86 mm ± 5.
37A-20
MECHANICAL ELEMENT CONTROLS
Clutch pedal 37A
L90, and K7J, and JH1 – L90, and K7M, and JH3
108790
REMOVAL
Disengage the cable from its slot, lifting the pedal 1
and bringing the cable up at right-angles to the pe-
dal.
108103
37A-21
MECHANICAL ELEMENT CONTROLS
Clutch pedal 37A
L90, and K7J, and JH1 – L90, and K7M, and JH3
Remove the clutch pedal (3).
REFITTING
Coat the shaft with grease.
Note:
Do not hit the shaft with a hammer to get it to go
back into place.
X2
X1
109400
37A-22
MECHANICAL ELEMENT CONTROLS
Clutch cable 37A
L90, and K7J or K7M, and JH1 or JH3
Remove the complete cable via the engine compart-
ment.
REFITTING
Thread the cable into the passenger compartment
via the engine compartment.
Fit the cable into the notch (1) of the pedal.
Note:
Check that the cable is perfectly set into the spe-
cially designed pedal throat.
X2
108550
X1
REMOVAL
In the engine compartment, disconnect the cable
from the clutch fork.
1 109400
The adjustment of the clutch control cable guard is
by the gearbox side end, by turning the nut (2).
Clutch pedal released.
Measurement of the guard can be done in two pla-
ces:
- Between the sleeve stop and the end of the clutch
control cable (X1) = 60 mm ± 5.
- Between the sleeve stop and the end of the clutch
fork (X2) = 86 mm ± 5.
108551
37A-23
MECHANICAL ELEMENT CONTROLS
External gear control: Description 37A
L90, and K7J or K7M, and JH1 or JH3
108552
L90 vehicles are fitted with a gearbox control linkage.
WARNING
It is important not to untighten the control linkage
adjustment flange nut.
102896
To select reverse gear, return to neutral and select re-
verse like any other gear.
37A-24
MECHANICAL ELEMENT CONTROLS
External gear control 37A
L90, and K7J or K7M, and JH1 or JH3
14747
108556
REMOVAL
Put the vehicle on a two-post lift.
1 108351
Cut off the exhaust line using tool (Mot. 1199-01)
between the two cutting points located about 130 cm
from the exhaust manifold.
Disconnect the connectors of the oxygen sensor
downstream from the catalytic converter.
Remove the clips from the oxygen sensor connector
downstream from the catalytic converter.
107931
Remove the gearbox control gaiter.
Remove nut (1) from the gearbox control linkage.
WARNING
It is important not to untighten the control linkage
adjustment flange nut.
37A-25
MECHANICAL ELEMENT CONTROLS
External gear control 37A
L90, and K7J or K7M, and JH1 or JH3
107926
Remove:
108352
Remove:
- the heat shield (3),
REFITTING
Smear grease over the fixing bearings of the control
linkage.
Proceed in the reverse order to removal.
37A-26
MECHANICAL ELEMENT CONTROLS
Gearbox control assembly 37A
L90, and K7J or K7M, and JH1 or JH3
14747
108555
REMOVAL
Put the vehicle on a two-post lift.
This operation is carried out after having removed 108351
the centre console (see 57A, Interior equipment,
Cut off the exhaust line using tool (Mot. 1199-01)
Centre console).
between the two cutting points located about 130 cm
from the exhaust manifold.
Disconnect the downstream oxygen sensor from the
catalytic converter.
Remove the clips from the oxygen sensor connector
downstream from the catalytic converter.
37A-27
MECHANICAL ELEMENT CONTROLS
Gearbox control assembly 37A
L90, and K7J or K7M, and JH1 or JH3
A
3
A
1
A 3
107926 108354
Remove the mounting (3) nuts of the control unit.
Remove:
Press the notches (A) of the control unit to unclip the
- the catalytic converter mountings (1) on the ex- control unit from the body.
haust manifold,
Remove the control unit from underneath the vehi-
- the catalytic converter by unclipping the rubber cle.
mountings.
REFITTING
Proceed in the reverse order to removal.
108352
Remove:
37A-28
ANTI-LOCK BRAKING SYSTEM
Introduction 38C
The vehicle is fitted with a BOSCH 8.0. ABS system.
The BOSCH 8.0 system comprises the anti-lock bra-
king system uniquely associated with an Electronic
Braking Distribution.
IMPORTANT
After any operations on the ABS, the vehicle must
be road tested to confirm the repair
38C-1
ANTI-LOCK BRAKING SYSTEM
ABS system without ESP: Description 38C
The vehicle is equipped with the BOSCH 8.0 system
which consists of the anti-lock braking system only.
IMPORTANT
After any work on the ABS system, the vehicle must
be road tested to confirm the repair.
30
29
28 27
109927
The ABS system consists of:
- a brake servo assembly (30),
A
- a pump assembly comprising:
• a hydraulic pump (27), B M
• a pressure modulation unit (eight solenoid valves), L
C
• a computer, (28),
D K
- four wheel sensors (29).
J
E
G H
109928
38C-2
ANTI-LOCK BRAKING SYSTEM
ABS system without ESP: Description 38C
Track Description
(A) Braking pressure from master
(3) Solenoid valve supply (+ before ignition
cylinder
feed)
(B) wheel sensor signal
(4) Solenoid valve earths and computer
(C) Diagnostic socket
(5) Front-left speed sensor supply
(D) Supply (+ before ignition feed)
(6) Rear-left speed sensor supply
(E) Supply (+ after ignition feed)
(7) Not used
(F) Brake lights sensor signal
(8) Rear-right speed sensor supply
(G) Wire connection
(9) Front-right speed sensor supply
(H) Hydraulic connection
(10) Front-right speed sensor signal
(I) Pump assembly (hydraulic unit,
(11) line K (diagnostic)
computer)
(12) Brake fault warning light
(J) Diagnostic socket
(13) Not used
(K) Brake fault war ning light
(14) Not used
(L) ABS system fault warning light
(15) Not used
(M) Regulated braking pressure on
wheel(s) concerned (16) Front-left speed sensor supply
109805
Track Description
38C-3
ANTI-LOCK BRAKING SYSTEM
Hydraulic assembly without ESP: Introduction 38C
ABOUT THE BOSCH 8.0 ABS SYSTEM
The ABS system pump assembly is equipped with a
26-track computer.
Note:
The computer is a single unit with the pump assem-
bly.
6 5 4 3
102311
38C-4
ANTI-LOCK BRAKING SYSTEM
Hydraulic assembly without ESP 38C
Essential equipment
pedal press
4
Tightening torquesm
4
hydraulic unit mounting 8 Nm
bolts on its support
REMOVAL
Disconnect the battery, starting with the negative ter-
minal.
109802
Fit a pedal press to the brake pedal to restrict the Unscrew:
outflow of brake fluid.
- the rigid pipe unions on the hydraulic unit (4),
- the hydraulic unit mounting bolts (5).
Remove the two hydraulic unit support mounting
bolts.
2 REFITTING
Proceed in the reverse order to removal
WARNING
Position the earth terminal wire facing
downwards to optimise the hydraulic unit compu-
ter connector sealing.
1 3
109803
Disconnect the hydraulic unit connector by lifting the
mounting bracket (1).
Unclip:
- the hydraulic unit connector cable (2),
- the rigid brake pipe (3).
38C-5
ANTI-LOCK BRAKING SYSTEM
Hydraulic assembly without ESP 38C
Torque tighten:
- the hydraulic unit mounting bolts on its support
(8 Nm),
- the hydraulic unit support mounting bolts (22
Nm),
- the rigid pipe unions on the hydraulic unit (14
Nm).
WARNING
Connect the battery starting with the positive ter-
minal; carry out the necessary programming (see
80A, Electrical equipment, Battery).
Note:
Following the replacement of the hydraulic unit
computer: Carry out the necessary programming
(see 38C, ABS system, configuration).
38C-6