You are on page 1of 135

Chassis

GENERAL INFORMATION
FRONT AXLE ELEMENTS
REAR AXLE ELEMENTS
WHEELS AND TYRES
STEERING ASSEMBLY
MECHANICAL ELEMENT CONTROLS
ELECTRONICALLY CONTROLLED
HYDRAULIC SYSTEM

BG0A - BG0B - BG0D - BG0G - KG0A - KG0B - KG0D - KG04


77 11 297 382

NOVEMBER 2000

EDITION ANGLAISE

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

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 2000

Chassis

Contents
Page

30

GENERAL INFORMATION
Dimensions of the main braking components
Tightening torques (in daNm)
Axles and suspension
Underbody height
Parts to be replaced when they are removed
Brake fluid
Brake unions and pipes
Influence of angles
Angle testing principle
Front axle testing and adjustment
Front axle fault finding
Brake fault finding

31

FRONT AXLE ELEMENTS


Lower wishbone
Brake pads
Brake caliper
Brake disc
Stub-axle carrier
Spring and shock absorber assembly
Spring and shock absorber
Anti-roll bar
Sub-frame axle

33

30-1
30-2
30-7
30-9
30-10
30-10
30-11
30-12
30-13
30-14
30-15
30-16

31-1
31-3
31-4
31-5
31-6
31-7
31-9
31-11
31-14

REAR AXLE ELEMENTS


Brake pads
Rear brake caliper
Rear hub-disc
Rear stub-axle carrier
Rear shock absorber
Rear spring
Rear axle

33-1
33-3
33-4
33-5
33-6
33-7
33-8

35 WHEELS AND TYRES


Technical specifications
Wheel balancing
Tyre pressure monitoring system
Tyres

35-1
35-4
35-5
35-13

36 STEERING ASSEMBLY
Axial ball joint
Steering box
Steering column
Retractable shaft
Variable power-assisted steering
Power assisted steering pump

36-1
36-4
36-8
36-13
36-14
36-15

37 MECHANICAL ELEMENT CONTROL


Master cylinder
Brake servo
Air filter - Brake servo non-return valve
Emergency braking assistance
Brake pedal position sensor
Handbrake control
Brake pipe
Exploded view of clutch master and slave
cylinders
Clutch master cylinder
Clutch slave cylinder
Clutch control pipes
Clutch pedal
Control unit
External gear control

37-1
37-3
37-9
37-10
37-14
37-15
37-17
37-18
37-19
37-21
37-25
37-26
37-27
37-33

ELECTRONICALLY CONTROLLED

38 HYDRAULIC SYSTEM

MK60 Electronic Stability Programme

38-1

GENERAL INFORMATION
130
Dimensions of the main braking components

30

BGOA
BGOB
BGOR

BK/GOG
BK/GOA
BK/GOB
BK/GOR

BGOD
KGOD

57

57

60

Diameter of discs

280

300

308

Thickness of discs

24

26

28

21.5

23.5

25.5

Thickness of brake pads (including mounting)

17

17.5

17.5

Minimum thickness of brake pads (including mounting)

0.07

0.07

0.07

38

38

38

Diameter of discs

274

300

300

Thickness of discs

11

11

11

Minimum disc thickness*

8.5

8.5

8.5

Thickness of brake pads (including mounting)

16

16

16

Minimum thickness of brake pads (including mounting)

7.5

7.5

7.5

23.8

23.8

23.8

FRONT BRAKES (values in mm)


Slave cylinder diameter

Minimum disc thickness*

Maximum disc run-out

REAR BRAKES (values in mm)


Slave cylinder diameter

MASTER CYLINDER (values in mm)


Diameter

(*)

Brake discs cannot be reground. If they are too heavily worn or are scratched they must be replaced.

30-1

FRONT AXLE

10.5

6.2

28

11

3.7

1.5

2.1

4.4

4.4

GENERAL INFORMATION
Tightening torques (in daN.m)

30-2

30

FRONT AXLE

10.5

10.5

18

2.1

2.1

GENERAL INFORMATION
Tightening torques (in daN.m)

30-3

30

FRONT AXLE

18

10.5

18

18

GENERAL INFORMATION
Tightening torques (in daN.m)

30-4

30

FRONT AXLE

28

10.5

10.5

1.4

1.4

GENERAL INFORMATION
Tightening torques (in daN.m)

30-5

30

GENERAL INFORMATION
Tightening torques (in daN.m)

30

DIMENSIONS

TIGHTENING TORQUES

0.6 to 0.8

Front caliper hoses

M 10 x 100

1.4

Rear arm hoses

M 10 x 100

1.4

Rear wheel cylinder supply

M 10 x 100

1.4

Master cylinder output

M 10 x 100
or
M 12 x 100

1.4

ABS hydraulic assembly inputs and outputs

M 12 x 100
M 10 x 100

1.4

Bleed bolt

30-6

GENERAL INFORMATION
Axles and suspension

30-7

30

GENERAL INFORMATION
Axles and suspension
FRONT AXLE

The front axle is a MAC PHERSON type known as


AUSTRAL with a single sheet lower arm and antipercussion effect.

It has spiral springs tilted on a rotating stop, anti-roll


bar and telescopic, hydraulic shock absorbers.

The austral arm decouples the longitudinal stresses


from the lateral stresses.
The result is an axle that is longitudinally flexible for
filtering road noise and laterally taut to ensure that the
wheel plane is well guided.
The front of the arm hinge is angled back to combat
nose diving when braking and acceleration weight
transfer.
The gap between the axle anchorage points reduces
stresses on the body and gives better control of axle
deformations. The car's reactions are enhanced and
rubber fittings last longer.

REAR AXLE, a flexible axle known as the H axle


This type of axle provides higher or equivalent
standards of comfort, handling and acoustics as the
4 bar axle.
It also features two innovations in set-up and
technology for the way joints are fitted to the body.
These are vertical axis joints.
The supple stiffness is arranged on a 40 axis in
relation to the car's longitudinal axis.
This reduces wheel toe-out grip when it slips, reducing
axle understeer.
This technology retains all the handling of a 4 bar axle.

30-8

30

GENERAL INFORMATION
Underbody height
The underbody height is measured, vehicle unladen,
on a level surface (preferably a four-post lift):
full fuel tank,
tyre pressures correct.

Measure dimensions:
H1 and H2 for the front
H4 and H5 for the rear
and calculate the difference.

H1 and H4: distance from the wheel axis to the


ground.

H1 - H2 = 122.5 3.5 mm

30

H4 - H5 = 105 3.5mm

H2: distance from the head of the bolts at mounting


point A on the austral arm to the ground.

These values vary inversely with the vehicle's ride


height. When the vehicle is lowered, these values
increase and vice-versa.

H5: distance from the rear axle mounting to the


ground.

30-9

GENERAL INFORMATION
Parts to be replaced when they have been removed

30

Axial ball joint stop.


Weight balance hook.
Hub bearing.
Driveshaft gaiter bearing.
Stub-axle brake nut.
Mounting bolts:
steering box,
front axle sub-frame,
rear axle.

Brake fluid
BRAKE FLUID REPLACEMENT INTERVAL
Braking technology, in particular for disc brakes (hollow pistons which transmit little heat, low volume of fluid in the
cylinder, sliding calipers avoiding the need for a fluid reservoir in the least cooled area of the wheel), has allowed us
to avoid the risk of vapour lock as far as possible, even if the brakes are used intensively (in mountainous areas).
Modern brake fluids still degrade slightly during the first few months of use due to a small uptake of humidity and
replacement of the fluid is therefore recommended:
see the vehicle's Servicing Handbook.
Topping up the level:
Wear of the brake pads and shoes will cause a gradual drop in the fluid level in the reservoir. This drop should not be
compensated for since the level will rise again when the pads are changed. The level should not however be
allowed to fall below the minimum mark.
Approved brake fluids:
Mixing two incompatible brake fluids in the circuit will cause a risk of major leaks, mainly due to deterioration of the
cups. To avoid such risks, it is important to use only those brake fluids which have been tested and approved by our
Technical Department and which conform to standard SAE J 1703 dot 4.

30-10

GENERAL INFORMATION
Brake unions and pipes
The connection of the pipes between the master
cylinder, caliper, compensator and the hydraulic
assembly is made using threaded unions with a
METRIC THREAD.
Consequently, only parts specified in the Parts
Catalogue for this vehicle should be used.
Identification of parts:
SHAPE of the ends of PIPES in steel or copper (A).
SHAPE of the THREADED LOCATIONS on
components (B).
pipe UNIONS coloured GREEN or BLACK: external
hexagon measuring 11 mm or 12 mm (C).

30-11

30

GENERAL INFORMATION
Influence of angles

30

The influence of different angles on track-keeping and vehicle tyre wear.

CAMBER
The comparison between the left and right angles is vital. A difference of more than one degree between the
two dimensions leads to a deviation from the straight that has to be corrected at the steering wheel and causes
abnormal wear on the tyres.
The value of this angle is usually slight: in the region of 1.

CASTOR
The comparison between the left and right angles is vital. A difference of more than one degree leads to a
deviation from the straight that has to be corrected at the steering wheel and causes abnormal wear on the tyres.
This is characterised by drifting with the speed being stabilised on the side where the angle is smallest.

STEERING HEIGHT
This travel affects the parallelism variation during suspension travel.
Different parallelism variations between the right-hand and left-hand wheels (without the steering wheel changing
position):
drift to one side on acceleration,
drift the other side under braking,
track changes on uneven road surfaces.

PARALLELISM
This adjustment has little effect on road holding.
Note:
a significant toe-out excess leads to symmetrical wear on the inside of both tyres,
a significant toe-in excess leads to symmetrical wear on the outside of both tyres.

30-12

GENERAL INFORMATION
Angle testing principle

30

PRELIMINARY CHECKS
Before checking the axle angles, you must check the
following points and remedy them if necessary:
Identical tyres on the same axle:
dimensions,
pressure,
degree of wear.
Joints:
condition of cushions and elastic bearings,
ball joint gaps,
bearing gaps.
Wheel run-out: (compensated for by reading
devices).

In this position, install the measuring devices and


begin checking.

Underbody height symmetry (condition of the


suspension).

When adjusting parallelism, be aware of the


symmetry of the ball joint box X lengths with the
steering links.

DETERMINING THE STEERING CENTRE POINT


The steering centre point must be set before
checking and adjusting the front axle in order to
avoid drifting problems.

Remove the keys from the immobiliser ignition


switch.

Set the steering wheel (A) to the "immobiliser"


position: the steering centre point is then set.

30-13

GENERAL INFORMATION
Front axle checking and adjustment

30

CHRONOLOGICAL ORDER OF OPERATIONS


The geometric design of the front axles means that
modifying one of the angles (castor, camber, pivot,
parallelism and variation affects the value of the other
angles to varying degrees (the castor angle has the
most influence).
It is therefore essential to work in the following
order:
position the device on the vehicle according to the
manufacturer's instructions,
locate the steering centre point (see preceding
paragraph) and lock the steering wheel,
raise the vehicle underbody,
compensate for wheel rim run-out,
place the vehicle on pivotal plates,
set the brake pedal press,
adjust the suspension to bring the vehicle to its
maximum height,
check that the X lengths on the ball joint units are
symmetrical with the steering links,

X lengths are symmetrical:


the dimension (A) must be evenly distributed.

X lengths are asymmetrical:


plot the dimensions (A) on the right-hand and lefthand side, subtract them from one another and
distribute the result with half on each side.
Example:
Right-hand side value: 16
Left-hand side value: 10
16 - 10 = 6
6: 2=3
Adjust the steering links to balance the dimensions (A)
on both sides:
A = 13

plot the A values on the reading scale.

once in this position, set the pivotal plates to zero,


and check the following in order:
the castor,
the pivot,
the camber,
the parallelism.

30-14

GENERAL INFORMATION
Front axle checking and adjustment

30

ADJUSTING THE PARALLELISM


There are several situations that can arise:
Parallelism

Distribution

Correction to be made

OK

Not OK

Make the same number of turns with the adjuster (or sockets)
but in the opposite direction on the left and right to get the
same value (A) on both sides.

NOT OK

OK

Adjust the parallelism to the same value on the right and left,
ensuring that there are always identical values (A) on both
sides.

NOT OK

Not OK

First balance the A values on each side then adjust the


parallelism according to the case number

Front axle fault finding


FAULTS

POSSIBLE CAUSES
Bent arm
Bent side member or axle sub-frame

Castor problems

Bent arm

Correct camber + pivot but


Camber problems
Pivot problems

Bent side member or axle sub-frame

Correct camber
but
Pivot problems

Bent stub-axle carrier

Correct pivot
but
Camber problems

Bent stub-axle carrier

Parallelism variation problems

See castor

Bent arm
Bent side member
Incorrect parallelism more than 6 mm

Bent right or left stub-axle carrier

30-15

GENERAL INFORMATION
Brake fault finding
I

30

EFFECTS ON THE PEDAL


FAULTS

POSSIBLE CAUSES

Hard pedal:
Heavy pressure produces only weak deceleration

Servo-assistance failure
Brake shoes may be:
dirty,
frozen, not in good order,
heated up, prolonged braking with the pedal
constantly depressed (descending a mountain),
not in good order,
Jammed piston
Crushed pipes

Elastic pedal

Presence of air in the circuit: incorrect bleeding

Note: the level of assistance on current vehicles has


been improved meaning that it gives the impression of
an elastic pedal. Whether it involves a fault or normal
use, there are two tests to be carried out
1.

Vehicle running
Judgement test: pedal travel/deceleration
relationship

2.

Stationary vehicle, engine not running


Complementary test to pedal bleeding: pump the
brake pedal five times to empty the brake servo,
before noting the result of the test

Internal leak in the brake circuit


Lack of fluid in the tank (leak from the brake
circuit to the outside)

Spongy pedal

Automatic adjustment: handbrake cable is too taut

Test to be performed on a stationary vehicle with the


engine turned off

Significant asymmetrical wear of brake shoes


(bevelled or hollow)

Note: you need to pump the brake pedal five times to


empty the brake servo, before noting the result of the
test

Too much linkage to the master cylinder

Pedal to the floor

Hydraulic leak (check seal)

Test to be performed on a stationary vehicle with the


engine turned off

Faulty seal between two circuits of the master


cylinder

Note: you need to pump the brake pedal five times to


empty the brake servo, before noting the result of the
test

Boiling fluid

30-16

Fluid is boiling or heated up

GENERAL INFORMATION
Brake fault finding
II

30

EFFECTS ON HANDLING
FAULTS

POSSIBLE CAUSES

Brakes engage

Brake shoes need to be relieved


Brake shoes are slightly dirty
Springs need to be changed

Brakes judder

Brake discs are too bent


Brake discs are not of even thickness
Abnormal deposit on the brake discs
(oxidisation between the brake shoe and the brake
disc)

Drifting on braking (front)

Front axle suspension, check steering


Jammed piston
Tyres (wear - pressure)
Crushed pipes*
* IMPORTANT: on vehicles with front axle negative
offset, drifting to one side results from a fault in the
circuit on the opposite side

Braking offset (rear)

Jammed piston
Automatic adjustment: handbrake cable is too taut
NOTE: automatic compensation is operated via the
brake pedal, if there is no abnormal tension in the
handbrake cable when it is not in use
Recall spring

Brakes heat up

Insufficient linkage to the master cylinder does


not allow the master cylinder to return to rest
Jammed or slow piston
Crushed pipes
Jammed handbrake control
Poor adjustment of the handbrake control

30-17

131

FRONT AXLE ELEMENTS


Lower wishbone
SPECIAL TOOLING REQUIRED
T.Av.476

Ball joint extractor

TIGHTENING TORQUES (in daN.m)


Mounting elastic bearings onto
axle sub-frame

Point A

18

Point B

18

Lower ball joint

11

Stabiliser bar linkage

4.4

Steering ball joint

3.7

Wheel bolts
Steering shaft yoke bolts

10.5
2.1

IMPORTANT: if the bolts from the sub-frame or the


arms are removed, they must be replaced and
tightened to the torque.
REMOVAL
both aluminium side members,

Put the vehicle on a two-post lift.


Remove:
the engine undertray,
the lower mountings of the bumpers,
the wheels.
Fit a steering wheel immobiliser.
Remove:
the front mudguards,
both left-hand tie-rods,
the right-hand tie-rod,
the mounting bracket bolts of the brake pipe and ABS
sensor,
the linkage for the xenon lamp position sensor if fitted
to the vehicle at (A),

the stabiliser bar return tie-rod nut,


the lower ball joint nut.

31-1

31

FRONT AXLE ELEMENTS


Lower wishbone

31

Slacken both sub frame tie-rod mounting bolts on the


body at (B).

REFITTING
Replace the bolts on:
the arms,
the sub-frame,
the steering rack fork.

Remove:
the steering shaft yoke bolt,
the torque reaction arm bolts,
the acoustic damper bolts and the sub-frame rear
mounting bolts.

Torque tighten them in the reverse order to removal.


IMPORTANT: fitting the steering rack fork bolt
requires adjustment of the steering column (see
the chapter on steering).
NOTE: if the vehicle is fitted with them, it is necessary
to initialise the XENON lamps (see chapter 80
"Initialisation").

Tilt the sub-frame forwards and remove both mounting


bolts from the lower wishbone.

31-2

FRONT AXLE ELEMENTS


Brake pads

31

SPECIAL TOOLING REQUIRED


Fre.823

Brake caliper piston return tool

REFITTING

TIGHTENING TORQUES (in daN.m)


Pillar bolt
Wheel bolts

IMPORTANT: make sure the brake pipe and ABS


sensor wiring are properly mounted if they have been
unfastened.

0.7
10.5

REMOVAL
Remove:
the spring on the front face of the caliper,
the shock absorber brake pipe,

Check the condition of the braking elements.


Push the piston back using the tool Fre. 823 until it is
at the bottom of its bore.
Fit new linings, beginning with the inner.
Refit:
the pillar bolts starting with the lowest one,
the spring on the front face of the caliper starting at
the bottom.

the two plugs at the end of the pillars,


both pillar bolts.
Hang up the caliper and remove the pads.

Refit the caliper in the reverse order to removal.


IMPORTANT: before starting the engine, depress
the brake pedal repeatedly to establish contact
between the pads and the brake discs.

31-3

FRONT AXLE ELEMENTS


Front brake calipers

Remove the piston using compressed air, inserting a


wooden block between the caliper and the piston to
prevent damage to the piston, any trace of damage to
the piston skirt will render it unusable

TIGHTENING TORQUES (in daN.m)


Pillar bolt

0.7

Hose mounting bracket bolt

0.3

Wheel bolt

31

10.5

REMOVAL

Put the vehicle on a two-post lift.


Remove the front wheels.
Fit a pedal press to prevent the escape of brake fluid.
Remove:
the spring on the front face of the caliper,
the hose mounting bracket on the caliper,
the brake pipe on the caliper,
the two plugs at the end of the pillars,
both pillar bolts,
the caliper.

Using a flexible strip with a rounded edge (such as a


feeler gauge), remove the rectangular section seal
from the caliper groove.

Check the condition of the brake pipe and replace it if


necessary. The brake pipe must also be replaced
when the caliper is replaced.
REFITTING
Push the piston back using the tool Fre. 823 until it is
at the bottom of its bore.
Proceed in the reverse order from removal.
IMPORTANT: before starting the engine, depress
the brake pedal repeatedly to establish contact
between the pads and the brake discs.
If the compensation reservoir is not completely
emptied during the operation, bleed the brake circuit
partially, if not bleed it completely (see bleeding
method).
REPAIR
The complete caliper must automatically be changed if
the caliper bore is scored.
Remove the rubber dust seal.

31-4

FRONT AXLE ELEMENTS


Brake discs

31

TIGHTENING TORQUES (in daN.m)


Brake disc mounting bolt

1.5

Caliper yoke bolt

10.5

Wheel bolt

10.5

REMOVAL
Put the vehicle on a two-post lift,
Remove:
the front wheels,
the caliper (see pad removal method).
Hang up the caliper.
IMPORTANT: make sure the brake pipe and ABS
sensor wiring are properly secured if they have
been unfastened.
Remove:
the two brake disc mounting bolts,

the disc.
REFITTING
Proceed in the reverse order from removal.
IMPORTANT: before starting the engine, depress
the brake pedal repeatedly to establish contact
between the pads and the brake discs.

31-5

FRONT AXLE ELEMENTS


Stub-axle carrier

31

SPECIAL TOOLING REQUIRED


T.Av.476

Ball joint extractor

Rou. 604-01

Wheel hub locking tool

TIGHTENING TORQUES (in daN.m)


Shock absorber lower bolt

18

Lower ball joint nut

11

Steering tie rod ball joint nut

3.7

Brake disc mounting bolt

1.5

Caliper yoke bolt

10.5

Hub nut

28

Wheel bolt

10.5

the disc,
the steering tie rod ball joint nut,
the lower ball joint nut,
the shock absorber base mounting bolts,

REMOVAL
Put the vehicle on a two-post lift.
Remove the front wheels.
Unclip the ABS sensor on the stub-axle carrier.
Remove the caliper (see brake pad removal).
Hang up the caliper.
the stub-axle carrier.

Remove:
the hub nut,

REFITTING
Proceed in the reverse order from removal.
The caliper fork bolts must be coated with a product
such as FRENEBLOC before they are put back.
IMPORTANT: before starting the engine, depress
the brake pedal repeatedly to establish contact
between the pads and the brake discs.
NOTE: if the vehicle is fitted with them, it is necessary
to initialise the XENON lamps (see chapter 80
"Initialisation").

the two bolts on the caliper bracket,

31-6

FRONT AXLE ELEMENTS


Spring and shock absorber assembly

31

SPECIAL TOOLING REQUIRED


T.Av.476

Ball joint extractor

TIGHTENING TORQUES (in daN.m)


Shock absorber upper mounting bolt

2.1

Shock absorber rod nut

4.4

Shock absorber lower bolt

18

Lower ball joint nut

11

Stabiliser bar tie-rod nut


Wheel bolt

4.4
10.5

REMOVAL
Put the vehicle on a two-post lift,
Remove the front wheels.
Unfasten the shock absorber brake pipe.
Left-hand side
Remove the mounting pins from the wheel arch cover.
Make a cut in the cover to allow access to the shock
absorber upper mounting bolts.

Remove:
the upper mounting of the stabiliser bar return tie-rod,
the steering tie rod nut,
the shock absorber lower bolts.

31-7

FRONT AXLE ELEMENTS


Spring and shock absorber assembly

31

Right-hand side

REFITTING

Remove the mounting pins from the wheel arch cover.

IMPORTANT: make sure the brake pipe and ABS


sensor wiring are properly mounted if they have
been unfastened.

Raise then slide the right-hand cover under the lefthand cover.
Take out the cover from the wing side.
Remove:
the shock absorber rod nut and its upper stop,
the two shock absorber upper mounting bolts on the
body,
the shock absorber and spring assembly.

Proceed in the reverse order from removal.


Torque tighten.
NOTE: if the vehicle is fitted with them, it is necessary
to initialise the XENON lamps (see chapter 80
"Initialisation").

31-8

FRONT AXLE ELEMENTS


Spring and Shock Absorber
EQUIPMENT REQUIRED
Compressor spring
Removal tool for the shock absorber rod nut

TIGHTENING TORQUES (in daN.m)


Shock absorber rod nut

4.4

REMOVAL
Place the appropriate cups on the compression tool
and position the assembly on the spring.

Press down on the spring until it detaches onto the cup


mountings.
Using the tool, remove the shock absorber rod nut.

31-9

31

FRONT AXLE ELEMENTS


Spring and Shock Absorber

31

Follow the order and the direction of fitting of the


constituent parts.

Separate the elements that make up the spring and


shock absorber assembly.
REFITTING
Precautions to take before assembly:
Shock absorbers are stored horizontally. Under these
conditions, it is possible that shock absorbers
designed to work vertically become drained.
As a result,you just need to manually pump the shock
absorber rod a few times in a vertical position before
fitting the spring.
When the spring is to be replaced, maintain the
position of the spring and the tool cups in order to put it
back easily.

Torque tighten the new nut.


Press down on the spring and retrieve the tool.

31-10

FRONT AXLE ELEMENTS


Stabiliser bar
SPECIAL TOOLING REQUIRED
T.Av.476

Steering ball joint extractor


EQUIPMENT REQUIRED
Component jack

TIGHTENING TORQUES (in daN.m)


Stabiliser bar bearing bolt

2.1

tie-rod bolt between sub-frame and body

6.2

Sub-frame bolt

10.5

Acoustic tie rod bolt

2.1

Stabiliser bar tie-rod nut

4.4

Steering ball joint

3.7

Aluminium side member bolt

4.4

Aluminium side member tie-rod bolt

4.4

Wheel bolt
Steering shaft yoke bolt

10.5
2.1

IMPORTANT: if the bolts from the sub-frame are


removed, they must be replaced and torque
tightened.

both aluminium side members,

REMOVAL
Put the vehicle on a two-post lift.
Disconnect the battery.
Remove:
the engine undertray,
the lower mountings of the bumpers,
the wheels.
Fit a steering immobiliser.
Remove:
the front mudguards,
both left-hand tie-rods and the right-hand tie-rod,
the mounting bracket bolts of the brake pipe and ABS
sensor.
the linkage for the Xenon lamp position sensor if
fitted to the vehicle at (A),
the stabiliser bar return tie-rod nuts.

31-11

31

FRONT AXLE ELEMENTS


Stabiliser bar

31

Place a component jack under the sub-frame.

Slacken both sub frame tie-rod mounting bolts on the


body at (B).

Unclip the brake pipes and ABS sensor wiring from the
sub-frame and the tie-rods.
Remove:
the steering shaft yoke bolt,
the torque reaction arm bolts,
the accoustic damper bolts and the sub-frame rear
mounting bolts.

Remove:
both sub-frame tie-rod mounting bolts on the body,
and lower the sub-frame by 20 cm.

31-12

FRONT AXLE ELEMENTS


Stabiliser bar
the four stabiliser bar bolts.

REFITTING
Replace the sub-frame bolts and torque tighten them
using the opposite procedure to removal.
IMPORTANT: steering column timing is required to
replace the steering rack fork bolt (see the chapter
on steering).
NOTE: if the vehicle is fitted with them, it is necessary
to initialise the XENON lamps (see chapter 80
"Initialisation").

31-13

31

FRONT AXLE ELEMENTS


Sub-frame axle

31

TIGHTENING TORQUES (in daN.m)


Stabiliser bar bearing bolt

2.1

Tie-rod bolt between sub-frame and body

6.2

Sub-frame bolt

10.5

Acoustic tie rod bolt

2.1

Stabiliser bar tie-rod nut

4.4

Steering ball joint

3.7

Aluminium side member bolt

4.4

Aluminium side member tie-rod bolt

4.4

Wheel bolt
Steering shaft yoke bolt

10.5
2.1

IMPORTANT: if the bolts and nuts from the front


axle are removed, they must be replaced and
torque tightened.

Unclip the ABS sensors from the lower wishbone and


the sub-frame.

REMOVAL

Remove:
both aluminium side members,

Put the vehicle on a two-post lift.


Disconnect the battery.
Remove:
the engine undertray,
the lower mountings of the bumpers,
the wheels.
Fit a steering immobiliser.
Remove:
the front mudguards,
both left-hand tie-rods and the right-hand tie-rod,
the mounting bracket bolts of the brake pipe and ABS
sensor.
the linkage for the Xenon lamp position sensor if
fitted to the vehicle at (A),

the stabiliser bar return tie-rod nuts,


the steering ball joint nuts.

31-14

FRONT AXLE ELEMENTS


Sub-frame axle

31

Slacken both sub frame tie-rod mounting bolts on the


body at (B).

Unclip the brake pipes and ABS sensor wiring from the
sub-frame and the tie-rods.
Remove the lower wishbone nuts.

Remove both sub-frame tie-rod mounting bolts on the


body and remove the sub-frame.

Place hose clamps on the steering pipes.


When the sub-frame has been removed, remove its
fittings.

Remove:
the steering shaft yoke bolt,
the mounting bolt on the power-assisted steering
pipe,
the torque reaction arm bolts,
the accoustic damper bolts and the sub-frame rear
mounting bolts.

Place a component jack under the sub-frame.

31-15

FRONT AXLE ELEMENTS


Sub-frame axle

REFITTING
Fit the new sub-frame.
Replace the sub-frame bolts and torque tighten them
using the opposite procedure to removal.
IMPORTANT: steering column timing is required to
replace the steering rack fork bolt (see the chapter
on steering).
NOTE: if the vehicle is fitted with them, it is necessary
to initialise the XENON lamps (see chapter 80
"Initialisation").

31-16

31

REAR AXLE ELEMENTS


133
Brake pads

33

SPECIAL TOOLING REQUIRED


Fre. 1190-01

Rear brake caliper piston return tool

EQUIPMENT REQUIRED
Ratchet socket wrench

FACOM REF 68 PE

Hexagon socket

FACOM REF EH 107

"Low torque" torque wrench


Fit new linings, beginning with the interior.

TIGHTENING TORQUES (in daN.m)


Wheel bolt

IMPORTANT: the interior lining is fitted with a retaining


spring. It is vital to insert this into the caliper piston.

10.5

Pillar bolt

0.7

Remove the two rear wheels.


Unclip the handbrake cables from the rear axle.
REMOVAL
Remove:
the outer spring on the caliper,
the two plugs at the end of the pillars,
both pillar bolts.
Hang up the caliper and remove the brake pads.
REFITTING
Push the piston back, tightening it using tool
Fre. 1190-01.

Starting with the lower bolt on the pillar, raise the


caliper onto its flange.
Put the two plugs back on the pillars.

33-1

REAR AXLE ELEMENTS


Brake pads
Make sure that the pipe bend and the rear caliper are
20 mm apart.

Refitting the spring:

insert the spring into the base of the caliper,


position the spring at the top of the caliper using a
screwdriver.

Clip the handbrake cables.


Refit the wheels.
IMPORTANT: before starting the engine, depress the
brake pedal repeatedly to establish contact between
the brake pads and the brake discs.

33-2

33

REAR AXLE ELEMENTS


Front brake calipers

33

SPECIAL TOOLING REQUIRED


Fre. 1190-01

Rear brake caliper piston return


tool
REPAIR

TIGHTENING TORQUES (in daN.m)


Wheel bolt

The rear caliper piston is not replaceable. Only the


protective gaiter on the piston and the pillar bolts with
their gaiters can be changed.

10.5

Pillar bolt

0.7

Yoke bolt

10.5

Clean the parts using methylated spirits.


Replace all faulty parts with original parts and begin
reassembling:

REMOVAL
Remove the wheels.
Fit a pedal press to prevent brake fluid from escaping.
Unclip the handbrake cables from the rear axle.
Release the brake pipe from the caliper.

the dust seal,


the pillar bolts,
the pillar gaiters.
IMPORTANT: before starting the engine, depress the
brake pedal repeatedly to establish contact between
the brake pads and the brake discs.

Remove:

the outer spring on the caliper,


the handbrake cable from the caliper,
the brake pipe on the caliper,
the two plugs at the end of the two pillars,
both pillar bolts.

Take off the caliper and the brake pads.


Check the condition of the brake pipe and replace it if
necessary.

REFITTING
Push the piston back, tightening it using tool
Fre. 1190-01.
Proceed in the reverse order from removal.
If the compensation reservoir is not completely
emptied during the operation, bleed the brake circuit
partially, if not bleed it completely (see bleeding
method).

33-3

REAR AXLE ELEMENTS


Rear hub-disc

33

SPECIAL TOOLING REQUIRED


Fre. 1190-01

Rear brake caliper piston return


tool

These vehicles are fitted with an integrated bearing


hub.

TIGHTENING TORQUES (in daN.m)


Wheel bolt

10.5

Pillar bolt

0.7

Yoke bolt

10.5

Hub nut

28

Since the bearing and the brake disc are inseparable


from one another, it is necessary to replace them as a
whole in the event of a fault.

REMOVAL
Remove:
the wheels,
the brake caliper (see brake pad method),
the two bolts on the caliper bracket,
the hub cover plug,
the hub nut (using a 36 mm dowel).
the hub-disc.

REFITTING
Proceed in the reverse order from removal.
IMPORTANT: before starting the engine, depress the
brake pedal repeatedly to establish contact between
the brake pads and the brake discs.

33-4

REAR AXLE ELEMENTS


Rear stub-axle carrier

33

SPECIAL TOOLING REQUIRED


Fre. 1190-01

Rear brake caliper piston return


tool
the four stub-axle carrier bolts (D),

TIGHTENING TORQUES (in daN.m)


Wheel bolt
Pillar bolt

10.5
0.7

Caliper yoke bolt

10.5

Stub-axle nut

28

Stub-axle carrier bolt

10.5

REMOVAL
Remove the wheel (side in question).
According to the method, remove:
the brake caliper (see brake pad method),
the caliper bracket (bolt C)

the stub-axle carrier

REFITTING
Proceed in the reverse order from removal.
IMPORTANT: before starting the engine, depress the
brake pedal repeatedly to establish contact between
the brake pads and the brake discs.

the hub cover plug disc,


the stub-axle nut,
the brake hub-disc,

33-5

REAR AXLE ELEMENTS


Rear shock absorber

33

EQUIPMENT REQUIRED
Component jack

TIGHTENING TORQUES (in daN.m)


Shock absorber lower bolt

10.5

Shock absorber upper bolt

10.5

IMPORTANT: don't remove the two lower


mountings from the shock absorbers at the same
time, to avoid violently releasing the springs.

REMOVAL
Put the vehicle on a two-post lift.
Remove:
the wheels,
the covers of the spring cups (A).
Place a component jack under the spring's lower cup.
Do the same for the other shock absorber.
Remove:
the shock absorber lower bolt (B),
REFITTING
Proceed in the reverse order from removal.
IMPORTANT: the shock absorber mounting bolts must
be tightened with the wheel to the floor to ensure the
elastic joints function properly.
NOTE: if the vehicle is fitted with them, it is necessary
to initialise the XENON lamps (see chapter 80
"Initialisation").

the shock absorber upper mounting bolt.

33-6

REAR AXLE ELEMENTS


Rear spring

33

EQUIPMENT REQUIRED
Component jack
Locate the position of the spring for easier assembly.
TIGHTENING TORQUE (in daN.m)
Shock absorber lower bolt

10.5

IMPORTANT: don't remove the two lower


mountings from the shock absorbers at the same
time, to avoid violently releasing the springs.

REMOVAL
Put the vehicle on a two-post lift.
Remove:
the wheels,
the covers of the spring cups (A).
Place a component jack under the spring's lower cup.
Remove:
the shock absorber lower bolt (B),
Lower the rear axle, press down and remove the
spring.

REFITTING
Proceed in the reverse order to removal observing the
position of the spring.
NOTE: if the vehicle is fitted with them, it is necessary
to initialise the XENON lamps (see chapter 80
"Initialisation").

33-7

REAR AXLE ELEMENTS


Rear axle assembly

33

EQUIPMENT REQUIRED
Component jack

TIGHTENING TORQUES (in daN.m)


Wheel bolt
Pillar bolt

10.5
0.7

Caliper yoke bolt

10.5

Hub nut

28

Stub-axle carrier bolt

10.5

Brake union
Shock absorber lower bolt
Rear axle mounting bolt

1.4
10.5
8

IMPORTANT: The rear axle mounting bolts must


automatically be replaced and tightened to the
recommended torque to avoid slackening or
deterioration of the bolts.

Remove the brake tubes all along the axle (if replacing
the rear axle);
Place a component jack under the spring's lower cup.
Remove the shock absorber lower bolt (B).

REMOVAL
Put the vehicle on a two-post lift.
Remove:
the wheels,
the covers of the rear axle spring cups (A),
the rear axle brake pipe connections.
Disconnect the handbrake cables.
Remove:
the ABS sensors,
the linkage for the Xenon lamp position sensor in (1)
(if the vehicle is fitted with it),
the brake caliper (if replacing the rear axle),
the caliper brackets (if replacing the axle) in (C),
the hub brake discs with a 36 mm dowel (if replacing
the rear axle).

33-8

REAR AXLE ELEMENTS


Rear axle assembly
ATTENTION: locate the position of the spring for
easier assembly (see rear spring removal method).
Lower the rear axle, press down and remove the
springs.
Place the component jack with its mounting plate at
the centre of the rear axle.
Horizontal arm;
Remove both rear axle mounting bolts, and remove the
axle with the help of another person.

REFITTING
Proceed in the reverse order from removal.
Bleed the brakes (see bleeding method).
IMPORTANT: before starting the engine, depress the
brake pedal repeatedly to establish contact between
the brake pads and the brake discs.
NOTE: if the vehicle is fitted with them, it is necessary
to initialise the XENON lamps (see chapter 80
"Initialisation").

33-9

33

135

WHEELS AND TYRES


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 simplified:
Example: 5 1/2 J 14

WHEEL
RIM
TYPE

WIDTH
(in inches)

RIM
PROFILE

NOMINAL (in
inches). under
tyre bead

Number
of holes

Tyre bead
profile

Offset in
mm

5 1/2 J 14
4 CH 36

5 1/2

14

CH

36

The wheel bolts are recorded for a diameter of:


four mounting bolts: 100 mm
five mounting bolts: 108 mm
Maximum run-out: measured on the rim edge (in G).
It varies according to the type of wheel rim.

35-1

WHEELS AND TYRES


Specifications

35

TYRES
The identification marking can come in two forms for the same type of tyre.

Example: 185/70 H R 14
Or
185/70 R 88 H

185

1
185

70

14

70

14

88

185

Tyre width in mm (S)

70

h/S ratio

Radial structure

14

Diameter in inches . It corresponds to the wheel rim diameter

88

Load index 88 (560 kg)

Speed code 210 km/h maxi

height
Section

Some speed symbols:

Maximum speed
R
S
T
U
H
V
Z + de

Types of structure:
Diagonal
Radial
Bias belted

No marking
R
B (Bias belted)

35-2

Km/h
170
180
190
200
210
240
240

WHEELS AND TYRES


Specifications

Type

Rim

Wheel rim
run-out

Wheel
tightening
torque
(daNm)

Tyres

35
Pressure
when cold
(bar)
Front

Rear

10.5

195/65R15H
205/55R16V(1)

2.3

2.2

6.5J16 (1)

10.5

205/55R16V

2.5

2.2

6.5J16*
7J17*

0.3

10.5

205/55R16
225/45R17V
205/60R16V

2.3

2.2

KG0A
KG0B
KG0R
KG0G

6.5 J 16

10.5

205/55R16V

2.3

2.2

BG0D
KG0D

6.5J16*
7J17*

0.3

10.5

205/55R16V
205/60R16V
225/45R17V

2.7

2.2

BG0A
BG0B
BG0R

6.5J15
6.5J16 (1)

BG0G
BG0A
BG0B
BG0R
BG0G

KG0A
KG0B
KG0R
KG0G

The tyre pressures are values for motorway use.


* alloy wheel rim
(1) Surmount
For vehicles fitted with automatic transmission, increase the front pressure by 0.1 bar.
Tyre pressures must be checked when cold. The increase in temperature during driving increases the pressure by
0.2 to 0.3 bar.
If the pressure is checked when warm, take into account this increase in pressure and never deflate the tyres.
Refer to the Driver's Handbook for the conditions for fitting chains.

35-3

WHEELS AND TYRES


Wheel balancing

BALANCE WEIGHTS
Only use weights provided by the Parts Department:
attached to the steel wheel rims by hooks (hooks are
built into the weights),
fitted using hooks (flat hooks) or self adhesive for
alloy wheels.
A Metal rim
B Aluminium alloy

35-4

35

WHEELS AND TYRES


Tyre pressure monitoring system

35

DESCRIPTION
The system is made up of:
four pressure sensors (1) incorporated into the valves (one per wheel). They transmit a radio signal,
a transmitter (2) under the vehicle which receives and decodes the signals from the sensors and transmits it to the
UCH,
the UCH (3) which receives and processes the signals from the transmitter (2) and determines the message to be
displayed,
a display (4) (separate or integrated into the instrument panel).

35-5

WHEELS AND TYRES


Tyre pressure monitoring system

35

GENERAL INFORMATION

The tyre monitoring system enables:

This system means that the tyre pressure of the


vehicle's four tyres can be permanently monitored (the
emergency spare wheel is not monitored).

the tyre pressure to be shown when the ignition


is switched on to an accuracy of 0.1 bar.
the driver to be alerted when:
the pressure is lower than 0.6 bar,
the pressure is too high,
a tyre has an abnormal leak,
a tyre is faulty,
there is a difference in pressure between the
right-hand and left-hand tyres.

This system uses the following to function:


four pressure sensors (incorporating the inflation
valve) in each of the vehicle's wheels (except for the
emergency spare wheel),
a transmitter under the vehicle,
an electronic control as part of the UCH,
warning lights showing the type of fault,
a display showing the car to pinpoint the tyre in
question. On the top of the range instrument panel,
the pressure values are displayed each time the
vehicle starts up and when there is an alert.
Special notes
Each sensor may be identified by a coloured ring
around the valve:
Green = front left
Yellow = front right
Red = rear left
Black = rear right
IMPORTANT: it is vital that this colour code be
followed in order to read the right information in the
right place and on the vehicle displays (according to
features). Each sensor is recognised by the UCH
using a unique code. When a sensor needs to be
replaced, the UCH needs to know this code according
to its position on the vehicle and identifies it by the
correct coloured ring (see the "sensor replacement"
chapter).

35-6

WHEELS AND TYRES


Tyre pressure monitoring system
The pressure sensor comprises:
a classical valve,
a pressure sensor,
a specific radio transmitter,
a non-replaceable battery.

Note: the battery belonging to the pressure sensor valve cannot be replaced.

Reminder: each sensor is identified by a particular colour. When a valve or


tyre is being replaced or a wheel being removed, it is vital to follow the
colours:
Green = front left
Yellow = front right
Red = rear left
Black = rear right

35-7

35

WHEELS AND TYRES


Tyre pressure monitoring system
OPERATION
The sensors (supplied by an integral battery) measure the pressure in the
tyres at regular intervals and transmit this information along with a code that
identifies them by radio.
Programming a sensor in the UCH
Note: The UCH is capable of recognising a second set of four wheel sensors.
It is important to maintain the colours in their correct positions.

35-8

35

WHEELS AND TYRES


Tyre pressure monitoring system
RADIO RECEIVER
OPERATION
The receiver under the vehicle receives messages
from the pressure sensors.
It transmits them via a wired connection to the UCH,
which controls the information components on the
instrument panel, having first processed the signals to
detect potential leaks (puncture) or poor inflation.

The information is passed on to the driver:


by warning lights displaying the type of fault (burst
tyre, deflated tyre, etc.)
by a display showing the car and pinpointing the tyre
in question
by a display on the top of the range instrument panel
that shows the pressure values each time the vehicle
starts up and when there is an alert (refer to
chapter 83).

35-9

35

WHEELS AND TYRES


Tyre pressure monitoring system

35

THE PRESENCE OF A PRESSURE MONITORING SENSOR IN THE WHEELS MEANS THAT PRECAUTIONS
MUST BE TAKEN WHEN REMOVING AND REFITTING TYRES. IF THIS ADVICE IS NOT FOLLOWED IT WILL
LEAD TO DAMAGE TO THE SENSOR AND RESULT IN FAILURE OF THE PRESSURE SYSTEM MONITORING
SYSTEM TO FUNCTION.
PROGRAMMING PRESSURE SENSORS IN THE
UCH

TIGHTENING TORQUES (in daN.m)


Tyre monitoring system sensor

4.25 0.75

Reminder: Each sensor is identified by a specific


colour:
Green = front left
Yellow = front right
Red = rear left
Black = rear right

REMOVAL AND REFITTING


The tyre must be removed from the rim and then
refitted when a sensor is replaced. See tyre removal
and refitting method.

There are several methods for programming a sensor


code in the UCH. A fault-finding tool must be used for
these operations (except XR25):
manual writing of the valve code. This is shown on a
label on the sensor,
programming the code using the "Ms.1607 valve
exciter tool",
programming by driving the vehicle.

MANUAL VALVE CODE PROGRAMMING (WRITING


THE CODE)

18886

1 Using the fault-finding tool, establish communication


with the tyre pressure monitoring system.
2 Select the command mode then specific
command menus,
3 Confirm line SC 001: programming a valve code
4 Key in the maximum six-digit code as shown on the
label on the sensor.
5 Enter the wheel position fitted with this sensor on
the vehicle
6 Enter the wheel's season of use (the summer set is
used as the default if the vehicle only has one set of
wheels)
Note: the procedure is identical for programming the
four valves using the SC 002: programming codes
for the four valves command

35-10

WHEELS AND TYRES


Tyre pressure monitoring system

35

AUTOMATIC VALVE CODE PROGRAMMING USING


THE VALVE EXCITER (Ms. 1706)

AUTOMATIC PROGRAMMING OF THE VALVE


CODE BY DEFLATING A TYRE

Reminder: The valve sends a message to the


transmitter which includes: its code, its pressure and
its condition. The transmitter decodes this information
and informs the UCH.

8
9
10
11
12
13
14
15
16

Using the fault-finding tool, establish


communication with the tyre pressure
monitoring system.
Select thecommand mode then specific
command menus
Confirm the line SC 001: programming a valve
code
On the tool, choose the position on the vehicle of
the valve to be memorised.
Press tool Ms. 1607 against the tyre under the
valve concerned.
Press the switch on the Ms.1607 tool.
Wait until the indicator light comes on to signify that
programming is completed.
The fault finding tool signals that the valve code
has been received.
Enter the wheel position fitted with this sensor on
the vehicle
Enter the wheel's season of use (the summer set
is used as the default if the vehicle only has one set
of wheels)

Note: the procedure is identical for programming the


four valves using the SC 002: programming the four
valve codes command. Programming is carried out
on the left-hand front wheel, front right-hand wheel,
rear right wheel and rear left wheel.

35-11

When the vehicle is running, the valve sends a


message every minute under normal conditions and
every 10 seconds if its condition is: condition 2 (leak).
When the vehicle is stationary, the valve sends a
message every hour when operating normally and
every quarter of an hour if it detects a leak.
It is possible to change the condition of the valve by
creating a leak:
stationary vehicle: wait quarter of an hour for each
wheel in this case,
vehicle running at over 12 mph (20 km/h).
This operation can only be carried out for one
wheel at a time.
1 Using the fault finding tool with the ignition on,
establish communication with the tyre pressure
monitoring system.
2 Create a leak of about 1 bar on a tyre
3 Select the command mode then specific
command menus,
4 Confirm line SC 001: programming a valve code
5 Carry out a road test
6 Enter the wheel position fitted with this sensor on
the vehicle
7 Enter the wheel's season of use (the summer set is
used as the default if the vehicle only has one set of
wheels)
8 Reinflate the tyre
9 Repeat the operation for each valve to be
memorised.

WHEELS AND TYRES


Tyre pressure monitoring system
IMPORTANT
It is important to make checks after one or more valve
codes have been programmed:
MEMORISING CODES
The codes appear in the Parameters menu: each
valve code must be different.
SEASON
Information is displayed on the instrument panel in the
Status menu; ET 007 Set of wheels selected;
summer or winter.
If the vehicle only has one set of wheels, select
summer.
If the UCH has memorised two codes, the season will
automatically be selected the first time it runs.
To modify the season using the fault finding tool:
1 select command mode, Parameterisation and
enter: VP 002 Selecting a set of wheels.
2 Move the cursor to the winter button
3 Press enter, select the type of climate using the up
and down arrows then confirm,
4 Use the blue button to confirm again, the memory
window opens. Select yes to confirm.

RECOMMENDED PRESSURES FOR THE


VEHICLE
The maximum and minimum pressures recommended
for the vehicle are shown on the Parameters menu.
To change the recommended pressure, select
Command mode, Parameterisation, VP 009
Enter recommended pressures.

35-12

35

WHEELS AND TYRES


Tyres

35

REPLACEMENT
THE PRESENCE OF A PRESSURE MONITORING SENSOR IN THE WHEELS MEANS THAT PRECAUTIONS
MUST BE TAKEN WHEN REMOVING AND REFITTING TYRES. IF THIS ADVICE IS NOT FOLLOWED IT WILL
LEAD TO DAMAGE TO THE SENSOR AND RESULT IN FAILURE OF THE PRESSURE SYSTEM MONITORING
SYSTEM TO FUNCTION.
REMOVAL
Detaching the bead from the outside of the tyre

Taking off the outer tyre bead

When detaching the wheel rim bead, it is essential to


begin on the opposite side to the valve and to make
sure that the tyre bead does not pull on the sensor at
any time. It is important to follow this recommendation
as the sensor could be destroyed.

Place the tyre lever about 15 cm away from the valve


and take off the bead, finishing by the valve. When
performing this operation, make sure the tyre bead
does not pull on the sensor.

Detaching the bead from inside the tyre

Taking off the inner tyre bead

Detaching the bead from the inside is not difficult. All


the same, it involves making sure that the outer bead
does not pull on the sensor.

The method is the same as the preceding paragraph.

35-13

WHEELS AND TYRES


Tyres
REPLACEMENT
When a tyre is replaced, the following parts must be
replaced:
the seal (1),
the mechanism (2),
the cap (3).

REFITTING
When the tyre is refitted to the wheel rim, the beads
must be correctly lubricated. Insert the inner bead
about 15 cm after the valve. Put the tyre back on the
wheel rim finishing with the valve and making sure not
to pull on the pressure sensor.
Carry out the same steps as above for the outer bead,
taking care not to pull on the sensor. Reinflate the tyre
to the recommended pressure.

35-14

35

STEERING ASSEMBLY
136
Axial ball joint

36

The axial ball joint is replaced with the steering box in position on the vehicle. In fact, the Dir. 1305 tool enables the
axial ball joints to be slackened via the wheel arch.

36-1

STEERING ASSEMBLY
Axial ball joint

36

SPECIAL TOOLING REQUIRED


Dir. 1305 -01 Axial ball joint removal/refitting tool
Dir. 1306 -02 SMI steering rack support tool
T. Av. 476

Ball joint extractor


Turn the wheels so the rack teeth are freed on the
valve side.

TIGHTENING TORQUES (in daN.m)


Wheel bolt

10.5

Steering ball joint nut

3.7

Parallelism adjustment sleeve bolt

Axial ball joint

Fit tool Dir. 1306-02.


In this position, release the axial ball joint using tool
Dir. 1305-01.

Put the vehicle on a two-post lift.

REMOVAL
Disconnect the track rod end using tool T.Av. 476.
Slacken the bolt on the parallelism adjustment sleeve
and slacken the track rod end while holding the axial
ball joint using an open wrench.
Make a mark or count the number of turns of thread
taken up so the parallelism can be readjusted on
refitting.
Take off the plastic retaining clips for the gaiter and
remove the gaiter.

36-2

STEERING ASSEMBLY
Axial ball joint

36

Refit the following to the rack (4):


the stop washer (2),
the stop (3),
the axial ball joint (1) whose threads have been
coated with LOCTITE FRENBLOC.

REFITTING
NOTE: Before refitting the new tie-rods, pass
a12 x 100 tap over the threads at the ends of the
steering rack in order to remove any trace of LOCTITE
from the original fitting and so prevent seizure of the
threaded sections on refitting.
Always replace them all (2). If the ball joint notch (1)
has not deteriorated, it can be reused.

Before finally tightening the axial ball joint using tool


Dir. 1305, check that the tabs on the locking ring (2)
align with the flats (B) on the rack.
Put the gaiter back with new clips.
Screw back the ball joint housing to the same number
of turns used when removing it.
Reconnect the ball joint.
Check and adjust the parallelism, then torque tighten
the adjustment sleeve.

36-3

STEERING ASSEMBLY
Steering rack

36-4

36

STEERING ASSEMBLY
Steering rack
SPECIAL TOOLING REQUIRED
Mot. 453-01 Set of 2 hose clamps for general use
T. Av. 476

Ball joint extractor


EQUIPMENT REQUIRED
Component jack

TIGHTENING TORQUES (in daN.m)


Steering rack bolt

18

Mounting bolt on the power-assisted


steering pipe

Heat shield bolt

Tie-rod bolt between sub-frame and body

6.2

Sub-frame bolt

10.5

Acoustic tie rod bolt

2.1

Stabiliser bar tie-rod nut

4.4

Steering ball joint nut

3.7

Engine tie-bar bolt on the sub-frame

10.5

Aluminium side member bolt

4.4

Aluminium side member tie-rod bolt

4.4

Wheel bolt
Steering shaft yoke bolt

10.5

both aluminium side members,

2.1

IMPORTANT: if the bolts from the sub-frame or the


arms are removed from the steering rack, they
must be replaced and torque tightened.
REMOVAL
Put the vehicle on a two-post lift.
Disconnect the battery.
Remove:
the engine undertray,
the lower mountings of the bumpers,
the wheels.
Fit a steering immobiliser.
Remove:
the front mudguards,
both left-hand tie-rods,
the right-hand tie-rod,

36-5

36

STEERING ASSEMBLY
Steering rack

36

Place a component jack under the sub-frame.

the return stabiliser bar tie-rod nuts,


the steering ball joint nuts.

Slacken both sub frame tie-rod mounting bolts on the


body at (B).

Unclip the brake pipes and sensor wiring from the subframe and the tie-rods.

Position the Mot. 453-01 hose clamps.


Remove:
the steering shaft yoke bolt,
the mounting bolt on the power-assisted steering
pipe,
the torque reaction arm bolts,
the acoustic damper bolts and the sub-frame rear
mounting bolts.

36-6

STEERING ASSEMBLY
Steering rack

36

Remove:
the rack heat shield,
the steering rack.

Remove both sub-frame tie-rod mounting bolts on the


body at B, and lower the sub-frame by 20 cm.

Tilt the stabiliser bar forwards.


REFITTING
Replace the sub-frame and steering rack bolts, and
torque tighten them using the opposite procedure to
removal.
Refit the heat shield correctly.
Fill the power-assisted steering and bleed it.
IMPORTANT: steering column timing is required to
replace the steering rack fork bolt (see the "Steering
column" chapter).

36-7

STEERING ASSEMBLY
Steering Column

36-8

36

STEERING ASSEMBLY
Steering Column

36

SPECIAL TOOLING REQUIRED


Dir.1594

Steering shim

TIGHTENING TORQUES (in daN.m)


Yoke bolt

2.1

Mounting bolt on the steering column

2.1

Electric lock bolt

0.8

Lower casing bolt

0.2

Steering wheel bolt

4.4

Put the vehicle on a two-post lift.


Set the vehicle wheels straight.
Unlock the column.

REMOVAL
Before performing any operation on the air bag
systems, lock the electronic unit using the fault
finding tools. This opens the electronic lock on the
column (see chapter 88).

the two column mounting bolts.


the upper casing with trim strip on the instrument
panel,

Remove:
the air bag cushion,

the lower casing.


the air bag connectors,
the connectors in the steering wheel,
the steering wheel bolt,

36-9

STEERING ASSEMBLY
Steering Column
Disconnect the connectors from the switch assembly.

36

the electric lock mounting bolt.

Remove:
the mounting bolt from the switch assembly. This can
be reached by centring the air bag sensor on its
middle point.

IMPORTANT: the electric lock bolt has a left-hand


thread. This undoes in a clockwise direction, when the
column is unlocked.

Remove the electric lock.


In the engine compartment, remove the yoke bolt and
nut from the steering box.
If the nut is jammed, turn the bolt a few times, then tap
it to unlock the nut.

36-10

STEERING ASSEMBLY
Steering Column

36

Remove the gaiter from the steering column on the


front scuttle panel in the passenger compartment.
Remove:
the mounting bolt on the instrument panel (A),
the two mounting bolts from the steering column (B),
the steering column.

Refit the column in the vehicle.


Position the steering column gaiter on the front scuttle
panel, after correctly positioning the plastic locking
ring.

REFITTING
IMPORTANT: the steering yoke bolt and steering
wheel bolt must be replaced and torque tightened
every time they are removed.
Position the column shim Dir. 1594 to centre it and to
ensure it is locked (the shaft (1) ring must be visible in
front of the shim).

Refit:
the steering shaft yoke, torque tightened (2,1 daN.m)
the two mounting bolts on the steering column,
the bolt on the instrument panel,
the electric lock with its left-hand thread bolt,
the rotary switch.
NOTE: the cover (C) on the yoke nut is not to be
replaced during reassembly.

36-11

STEERING ASSEMBLY
Steering Column
Rotary switch features

36

Each time it is removed the steering wheel bolt


must be replaced and torque tightened (4.4 daNm).

Make sure the wheels are still straight.


Reconnect the connectors in the steering wheel and
on the air bag cushion.

Check that point "0" on the rotary switch is opposite


the index.

Refit the air bag cushion.


Once all the operations have been carried out, take off
the steering column shim Dir. 1594.

Reconnect the connectors to the switches.


Put back the two casings and the steering wheel.
IMPORTANT: the steering wheel is fitted with splines.
It has to be properly inserted to prevent the hub from
being destroyed.

36-12

Unlock the air bag electronic unit and test it for faults.
Check that the electric lock is working properly and
that the column locks when the ignition is switched off.

STEERING ASSEMBLY
Retractable shaft

36

These vehicles are fitted with a non removable retractable shaft - steering wheel shaft - steering column assembly. If
it is impossible to tighten the eccentric bolt of the universal joint or after an accident, check that the length of the
shaft is correct, otherwise replace the assembly (see "Steering column" chapter).

CHECKING

Left-hand drive
L = 329.5 1 mm

Right-hand drive
L = 321.1 1 mm

36-13

STEERING ASSEMBLY
Variable power assisted steering

36

The variable hydraulic power assisted steering system is designed to provide superior power steering to the
Constant Assistance Steering during stopping manoeuvres and to progressively alleviate the assistance when the
vehicle speed increases.
At high speed, it makes the steering much steadier than Constant Assistance Steering.

DESCRIPTION
For the hydraulic part:
a power assisted steering pump
a component jack
a valve controlled by an electromechanical actuator
a reservoir
pipes
For the electric part:
a function incorporated into the UCH
vehicle speed information
an actuator

REMOVAL
The method for removing the variable assistance steering box is identical to the removal method for the constant
assistance steering box described previously.

36-14

ENGINES
F9Q-F4P

STEERING ASSEMBLY
Power steering pump
SPECIAL TOOLING REQUIRED
Mot. 453-01

Hose clamps

Put the vehicle on a two-post lift.

REMOVAL
Remove:
the two mounting bolts of the power steering
reservoir,
the front right-hand mudguard,
the accessories belt.
Fit a clamp Mot. 453-01 to the supply pipe.
Disconnect the supply and high pressure pipes.
Expect fluid to drain from the power-assisted steering.
Remove the three pump mounting bolts and remove
the pump.

REFITTING
Follow the reverse procedure to removal, maintaining
belt tension (see chapter 07 "Accessories Belt
Tension")
Fill and bleed the circuit turning from lock to lock with
the engine running.

36-15

36

ENGINES
F4P-F9Q

STEERING ASSEMBLY
Power steering pump

36

SPECIAL TOOLING REQUIRED


Dir. 1083-01

Tool for fitting the pulley.

PULLEY REPLACEMENT

REFITTING

REMOVAL
According to the way it is assembled, remove the
pulley after raising it to a level with the end of the shaft.

Grasp the pulley with tool Dir. 1083-01 until you reach
the level it was pulled up to when it was removed
(liberally grease the threading and the pad on the
pulley).

Use the press with extractor type FACOM U 53T.

Press the pulley on to dimension.


X = 31.65 3 mm.

36-16

K4M ENGINE

STEERING ASSEMBLY
Power steering pump
SPECIAL TOOLING REQUIRED
Mot. 453-01

Hose clamps

Put the vehicle on a two-post lift.

REMOVAL
Remove:
the two mounting bolts from the power steering
reservoir and put them on one side,
the injection ramp protection (two nuts),
the accessories belt using an Allen key which allows
the tensioner to be blocked after it is tilted.

36-17

36

K4M ENGINE

STEERING ASSEMBLY
Power steering pump

Fit a clamp Mot. 453-01 to the supply pipe.

36

Remove the pump completely (three bolts).

Disconnect the supply and high pressure pipes.


Expect fluid to drain from the power-assisted steering.
IMPORTANT: as the alternator is located below the
pump it is necessary to protect it against the flow of
power steering fluid.
Disconnect the fuel supply pipe on the injector gallery
to remove the pump fastening Torx bolt (T40).

REFITTING
Proceed in the reverse order from removal.
Fill and bleed the circuit turning from lock to lock with
the engine running.

36-18

KM4 ENGINE

STEERING ASSEMBLY
Power steering pump

36

SPECIAL TOOLING REQUIRED


T. Ar. 1094

Differential bearing extractor

Dir. 1083 -01

Tool for fitting the pulley.

REPLACING THE HUB


Place the pump on the bench, in a vice.
Fit tool T. Ar. 1094 and remove the hub.

Maintain the fitting dimension by inserting a 39.2 mm


shim between the hub and the pump body, when
reassembling it.

NOTE: insert a bolt (1) between the pump shaft and


the pushrod of tool T. Ar. 1094.
Fit the hub (new) and press it in using tool
Dir. 1083-01. Coat it beforehand with multifunction
grease to aid refitting.
NOTE: insert a block (2) of approximately 25 mm
between tool Dir. 1083-01 and the hub.

A Hub
B Power assisted steering pump
X = 39.2 mm

36-19

L7X Engine

STEERING ASSEMBLY
Power steering pump

36

SPECIAL TOOLING REQUIRED


Mot. 453-01

Hose clamps

REMOVAL

REFITTING

Place the vehicle on a lift.

Proceed in the reverse order to removal retaining the


tightening torques.

Remove:
the plastic covers on top of the engine,
the two mounting bolts of the power steering
reservoir mounting,
the accessories belt: to do this follow the method in
chapter 07,
the four mounting bolts of the pulley on the assisted
steering pump.
Place Mot. 453-01 clamps on the hoses to be
removed.
Remove:
the supply hose on the power assisted steering
pump,
the pressure hose,
the three mounting bolts of the assisted steering
pump,
the power assisted steering pump.
NOTE: Expect power steering fluid to drain during this
manipulation: protect the alternator.

36-20

Refit the accessories belt as shown in chapter 07.


Fill and bleed the circuit turning from lock to lock with
the engine running.

L7X Engine

STEERING ASSEMBLY
Power steering pump

36

SPECIAL TOOLING REQUIRED


T. Ar. 1094

Differential bearing extractor

Dir. 1083 -01

Tool for fitting the pulley.

REPLACING THE HUB


Place the pump on the bench, in a vice.
Fit tool T. Ar. 1094 and remove the hub.

Press the hub until the dimension is X = 41.5 mm.

NOTE: insert a bolt (1) between the pump shaft and


the pushrod of tool T. Ar. 1094.
Fit the hub (new) and press it in using tool
Dir. 1083-01. Coat it beforehand with multifunction
grease to aid refitting.

36-21

STEERING ASSEMBLY
Power steering pump

36

SPECIAL TOOLING REQUIRED


Dir.

803

Dir. 1 204

Metric thread connector


Pressure measuring connector

Mot. 453-01 Hose clamps


Fre. 1 085
or

Pressure measuring gauge

Fre.

244-03

Fre.

284-06 Connecting pipe

METHOD WITHOUT PRESSOSTAT


Place a Mot. 453-01 clamp on the supple low
pressure pipework of the pump.
Disconnect the high pressure pipes (expect oil to drain
out).

Connect the pressure gauge Fre. 1085 or Fre. 244-03.

36-22

STEERING ASSEMBLY
Power steering pump
PRESSOSTAT METHOD

36

Remove the connector Dir. 803 or Dir. 1204 and the


pressure gauge by cutting of the pump supply with a
Mot. 453-01 (V6 Engine) clamp.

On the rigid pipework (high pressure) at the pump


outlet, remove the pressostat and connect the
pressure measuring connector Dir. 1204 and the oil
pressure gauge Fre. 1 085 or Fre. 244-03.

Reconnect the high pressure pipes or the pressostat


(as required) and take off the Mot. 453-01 clamp.
Fill up the tank.

Expect oil to drain out.


ALL TYPES
Remove the clamp Mot. 453-01.
Adjust the pump to the correct level and run the engine
to check the pressure.
Wheels set straight, whatever the engine speed, the
pressure should not exceed: 5 to 7 bars.
Wheels turned completely to one side, to maintain
them, the maximum pressure needs to be: 86 to
93 bars for the K4M engine and 96 to 103 bars for
Engines F4P, F9Q and L7X.
This operation should not be prolonged to avoid a
significant raise in oil temperature.

36-23

MECHANICAL ELEMENT
137 CONTROLS
Master cylinder

37

the master cylinder mounting nuts on the brake


servo.

TIGHTENING TORQUES (in daN.m)


Brake tank bolt

0.35

Brake pipe

1.4

Master cylinder mounting nuts

2.1

Place the vehicle on a lift.


IMPORTANT: drain out the brake fluid to prevent
the mechanical parts and bodywork around the
braking system from deteriorating.

REMOVAL
Remove:
the air resonator box,
the expansion bottle,
the brake fluid level connector,
the mounting bolt of the tank on the master
cylinder (1).

Change the brake fluid in the tank and remove it with a


cloth.
Remove:
the pressure sensor connector on the master
cylinder,
the brake pipes on the master cylinder after having
located them,

37-1

MECHANICAL ELEMENT CONTROLS


Master cylinder
REFITTING
NOTE: when the master cylinder is removed, its
seal must automatically be replaced (A) by a new
one when it is refitted.

Align the master cylinder with the brake servo so that


push rod (P) enters the master cylinder housing.
Refit:
the brake pipes according to their markings,
the brake fluid tank by pressing down on it to click it
into the master cylinder,
the brake fluid tank mounting bolt.
Bleed the braking system (see bleeding method).

37-2

37

UNITS
JH3 - JR5

MECHANICAL ELEMENT CONTROLS


Brake servo

In the passenger compartment, remove:


the brake pedal yoke shaft of the push rod on the
brake servo,

TIGHTENING TORQUES (in daN.m)


Brake tank bolt

0.35

Brake pipe

1.4

Master cylinder mounting nuts

2.1

Brake servo mounting nuts

2.9

37

REMOVAL
Place the vehicle on a lift.
IMPORTANT: drain out the brake fluid to prevent
the mechanical parts and bodywork around the
braking system from deteriorating.
Remove:
the master cylinder (see method),
the non-return valve on the brake servo,
the brake servo connectors.

the two brake servo mounting nuts.

Remove the brake servo.

37-3

UNIT DP0

MECHANICAL ELEMENT CONTROLS


Brake servo

37

the modular connector mounting bracket.

TIGHTENING TORQUES (in daN.m)


Brake tank bolt

0.35

Brake pipe

1.4

Master cylinder mounting nuts

2.1

Modular connector mounting bolt

Brake servo mounting nuts

2.9

REMOVAL
Place the vehicle on a lift.
IMPORTANT: drain out the brake fluid to prevent
the mechanical parts and bodywork around the
braking system from deteriorating.
Remove:
the master cylinder (see method),
the non-return valve on the brake servo,
the brake servo connectors.
In the passenger compartment, remove:
the brake pedal yoke shaft of the push rod on the
brake servo,
the two brake servo mounting nuts.

Remove the brake servo.

37-4

UNIT PK6

MECHANICAL ELEMENT CONTROLS


Brake servo

In the passenger compartment, remove:


the brake pedal yoke shaft of the push rod on the
brake servo,

TIGHTENING TORQUES (in daN.m)


Brake tank bolt

0.35

Brake pipe

1.4

Master cylinder mounting nuts

2.1

Brake servo mounting nuts

2.9

37

Place the vehicle on a lift.


IMPORTANT: drain out the brake fluid to prevent
the mechanical parts and bodywork around the
braking system from deteriorating.
REMOVAL
Remove:
the air filter hose,
the air filter unit,
the fuse holder unit,
the master cylinder (see method),
the non-return valve on the brake servo,
the brake servo connectors.
the two brake servo mounting nuts.

the wiper motor (see method chapter 85)


Remove the brake servo.

37-5

UNIT SU1

MECHANICAL ELEMENT CONTROLS


Brake servo
the wiper motor (see method chapter 85)

TIGHTENING TORQUES (in daN.m)


Brake tank bolt

0.35

Brake pipe

1.4

Master cylinder mounting nuts

2.1

Brake servo mounting nuts

2.9

Inlet manifold

37

In the passenger compartment, remove:


the brake pedal yoke shaft of the push rod on the
brake servo,

0.5 + 0.8

Place the vehicle on a lift.


IMPORTANT: drain out the brake fluid to prevent
the mechanical parts and bodywork around the
braking system from deteriorating.

REMOVAL
Remove:
the air filter hoses,
the inlet manifold,
the air filter unit,
the fuse holder unit,
the master cylinder (see method),
the non-return valve on the brake servo,
the brake servo connectors.

the two brake servo mounting nuts.

Remove the brake servo.

37-6

MECHANICAL ELEMENT CONTROLS


Brake servo
REFITTING
Before refitting, check:
The dimension L = 165.5 mm (left-hand drive)
L = 122 mm (right-hand drive)
Adjustable using the rod (C)

Follow the opposite procedure to removal to


reassemble the brake servo and the master cylinder.

37-7

37

MECHANICAL ELEMENT CONTROLS


Brake servo

37

SPECIAL TOOLING REQUIRED


Mot.

453-01

Hose clamps

EQUIPMENT REQUIRED
Vacuum pump

CHECKING SEALING
When checking the sealing of the brake servo, ensure the seal between the brake servo and the master cylinder is
perfect. If there is a leak, replace the seal (A).

The sealing of the brake servo is checked on the


vehicle when the hydraulic circuit is in operating
condition.

If the vacuum drops by more than 33 mbar in


15 seconds, there is a leak located either:
at the non-return valve (replace it),

Connect the vacuum pump between the brake servo


and the vacuum source (inlet manifold) using a "T"
union and the shortest possible pipe.

or at the pushrod diaphragm (replace the brake


servo).

Run the engine at idle speed for one minute.

If the brake servo is not operational the braking system


will operate but the force required at the pedal to
obtain the equivalent deceleration as for assisted
braking is considerably higher.

Clamp the pipe (clamp Mot. 453-01) between the "T"


union and the vacuum source.
Turn the engine off.

37-8

MECHANICAL ELEMENT CONTROLS


Brake servo air filter - Non-return valve

37

REPLACING THE NON-RETURN VALVE


This operation may be carried out on the vehicle.
REPLACING THE AIR FILTER
REMOVAL
Disconnect the brake servo vacuum supply tube.
Pull the non-return valve while twisting it to release it
from the rubber sealing washer.

REFITTING
Check the condition of the rubber sealing washer and
the non-return valve.
Replace any faulty parts.
It is not necessary to remove the brake servo to
change the air filter (F).

Refit the assembly into position.

Under the pedal mounting, use a screwdriver or a


metal hook to remove the worn filter (F).
Cut the new filter at A (see diagram) and fit it around
the rod, then press it into position, checking that it fills
the complete opening to prevent any non filtered air
from passing through.

37-9

MECHANICAL ELEMENT CONTROLS


Emergency braking assistance

37

PREAMBLE
The emergency braking assistance is a supplementary mechanism to the ABS system.

DESCRIPTION
The emergency braking assistance functions thanks to two technological features. One relies on the use of
electronic components (electronic EBA). The other on the use of mechanical components (mechanical EBA).
The EBA (electronic):
has a brake servo fitted with an interrupter to detect the action of the driver on the pedal,
a movement sensor,
a master cylinder.
It is controlled by the ABS computer.
The EBA (mechanical):
has a brake servo fitted with a valve that reacts to the speed of pedal depression.
In both cases, detecting the pedal depression speed generates pressure in the brake circuit, via the braking
amplifier, particularly when superimposed on the pressure exerted by the driver.
The maximum pressure is limited by the level of depression being exerted in the amplifier.

OPERATING PRINCIPLE
The emergency braking assistance enables the system to recognise a situation and act immediately to provide the
best possible stopping distance.
Speed of depression on the brake pedal detects the emergency brakes; in this situation, the brake assist instantly
gathers maximum power and reaches the ABS regulation as quickly as possible.
The ABS braking is then maintained until the driver releases the brake pedal.
The system works conventionally for current brakes.

37-10

MECHANICAL ELEMENT CONTROLS


Emergency braking assistance

: Without emergency braking assistance


: With emergency braking assistance

37-11

37

MECHANICAL ELEMENT CONTROLS


Emergency braking assistance

37

BRAKE SERVO

EBA (mechanical)

EBA (electronic)

An inert mechanical valve inside the brake servo (with


a more tightly coiled spring to maintain extra
assistance), activates the stress amplifier in the brake
servo and increases hydraulic pressure, according to
the speed of depression on the brake pedal.

REMOVAL
The brake servo is removed in the same way for an
electronic emergency braking assistance and a
mechanical emergency braking assistance.
The only difference is in disconnecting the
connections, see brake servo removal.

When braking, the driver applies pressure to the brake


pedal which activates the movement sensor (1) and
the deactivation interrupter (2).
The computer determines the speed of pedal
depression and balances it against the two following
coefficients:
correction by pedal position,
correction by vehicle speed.
If the results exceeds a certain reference level, and the
deactivation sensor is active, the computer will
activate the brake servo assistance electrovalve which
gives out its maximum power. If not, the brake servo
continues to function conventionally. The EBA is
deactivated as soon as the driver releases the brake
pedal.

37-12

MECHANICAL ELEMENT CONTROLS


Emergency braking assistance
DIAPHRAGM MOVEMENT SENSOR

37

REFITTING
IMPORTANT: replace the seal before refitting the
diaphragm movement sensor.
Position the sensor on the brake servo and press
down on it to clip it on.

REMOVAL
Disconnect the sensor.
Push back the sensor mounting clip and remove it
using a small screwdriver.

37-13

MECHANICAL ELEMENT CONTROLS


Brake pedal position sensor
REMOVAL
On the brake pedal mounting:
Disconnect the brake pedal position sensor.
Make a quarter turn anticlockwise.
Remove the brake pedal position sensor.

REFITTING
The brake pedal position sensor has automatic
adjustment which adapts according to the pedal
position.
Before refitting it, it needs to be pulled up to its
minimum position.

REFITTING
Put the sensor in its housing and make a quarter turn
clockwise.
Reconnect the connector of the brake pedal position
switch.

37-14

37

MECHANICAL ELEMENT CONTROLS


Handbrake control
Disconnect the connectors.

TIGHTENING TORQUES (in daN.m)


Handbrake mounting nuts

Remove:
The central console,
the handbrake control lever mountings,

2.1

REMOVAL
In the passenger compartment
Remove:
the gear shift lever gaiter,
the handbrake gaiter,
the RENAULT card,
the two bolts in front of the central dashboard,

the handbrake control lever cables,


the handbrake control lever.

REFITTING
Proceed in the reverse order from removal.
the two bolts behind the central console.

37-15

37

MECHANICAL ELEMENT CONTROLS


Handbrake control
ADJUSTMENT

Wheel adjustment

Poor handbrake adjustment:


prevents the automatic compensation system for the
rear brake pads from functioning properly,
and causes long brake pedal travel.

Remove the two rear wheels.

The brake cables should not be re-tensioned to


correct this fault since it will quickly occur again.

37

Ensure:
the cables slide freely,
the handbrake levers move properly and are at their
lowest point.

The handbrake should not be used to adjust play, it


should only be adjusted when replacing:
pads,
cables,
the handbrake control lever.
Any other adjustment except in the above cases is
not permitted.
Adjustments are made in the passenger compartment
on the centre console.
Central adjustment
In the central armrest, lift the adjustment flap and
adjust the nut on the brake lever.

Adjust the handbrake so that the socket is in contact


with the lever without moving it.
Make further adjustments so that the levers shift
between the 1st and 2 nd notches of the handbrake
lever travel, and stay shifted to the 2nd notch.
Then refit the wheels.

37-16

MECHANICAL ELEMENT CONTROLS


The brake pipe

37

PRECAUTIONS TO BE TAKEN WHEN REMOVING - REFITTING A BRAKE CYLINDER OR A BRAKE PIPE.


For safety reasons and to ensure that the brake pipe is not twisted and is not liable to touch a suspension
component the following order of operations must be observed:

REMOVAL

REFITTING

Slacken the union (1) (pipe wrench) between the rigid


pipe and the hose (2) until the spring (3) becomes
slack which releases the hose from the splines (4).

Fit the caliper to the brake and screw the hose onto it,
then torque tighten to 1.4 daN.m.
The brake pipes are fitted when the axle assembly is in
position:
Wheels suspended (suspension in place)
Axle in line (wheels straight)
Position the female end of the hose on the retaining
bracket (5), without twisting it and check that the end
piece (4) fits freely into the splines of the bracket, then
fit:
the spring (3),
the rigid pipe to the hose, checking that the hose
does not turn when the assembly is screwed
together.
Torque tighten the union.
Bleed the brake circuit.

Remove the hose from the caliper and if necessary


remove the caliper.

37-17

MECHANICAL ELEMENT
137 CONTROLS
Exploded view of clutch master and slave cylinders

37-18

37

MECHANICAL ELEMENT CONTROLS


Clutch master cylinder
REMOVAL
Disconnect the battery
In the passenger compartment
Disconnect the ball joint from the transmitter on the
clutch pedal.
In the engine compartment
Bleed the brake fluid reservoir until the level is under
the master supply port.
Place a cloth under this port then disconnect the brake
fluid reservoir pipe and fit plugs.
Remove the master-slave connecting pipe holding
clip (1) on the master.
Place a cloth under the master then disconnect the
connecting pipe on the master and position plugs at
each port.
Remove the scuttle panel sender by making a quarter
clockwise turn (bayonet type mounting) using tool
Emb. 1596.

37-19

37

MECHANICAL ELEMENT CONTROLS


Clutch master cylinder

37

REFITTING
Check the condition of the seals.
Proceed in the reverse order from removal.
The master is fitted with a foolproofing device. There is
only one position.

Fill the brake fluid reservoir.


Check that the clutch system is working properly.

Add brake fluid to the reservoir.


bleed the hydraulic circuit:
connect a tube to opening (C) linked to a tank filled
with brake fluid,
lift up the clip (2),
unclip the tube to the first notch,
fit the bleeding device,
activate the bleeding device,
wait until the air is completely expelled from the
hydraulic circuit,
clip the tube back onto the clutch slave cylinder.

37-20

PK6

MECHANICAL ELEMENT CONTROLS


Clutch slave cylinder
Remove the gearbox.

TIGHTENING TORQUES (in daN.m)


Retaining bolt of the slave on the clutch
housing

37

Disconnect the clutch slave cylinder union (C) by


removing the clip (3).

0.9

REMOVAL
The clutch slave cylinder can only be removed after
removing the gearbox.
Disconnect the master-slave connecting pipe by
releasing the clip (2) located on the union (C).

Remove the three mounting bolts (B) of the clutch


slave cylinder then remove it.

WARNING: never operate the system when the


slave is removed (even if it is connected to the
clutch pedal). There is a risk that the hydraulic
piston and the slave stop will be ejected.

37-21

PK6

MECHANICAL ELEMENT CONTROLS


Clutch slave cylinder

37

REFITTING
Check the condition of the seals.
Proceed in the reverse order from removal.
Torque tighten the two slave mounting bolts (B) to
0.9 daN.m.

Fill the brake fluid reservoir.


Check that the clutch system is working properly.

NB: to avoid damaging the slave, do not coat the


gearbox output shaft with grease.
NB: to avoid leaks, replace the slave after
replacing the clutch mechanism.
Add brake fluid to the reservoir.
Bleed the hydraulic circuit:
connect a tube to opening (C) linked to a tank filled
with brake fluid,
lift up the clip (2),
unclip the tube to the first notch,
fit the bleeding device,
activate the bleeding device,
wait until the air is completely expelled from the
hydraulic circuit.
clip the tube back onto the clutch slave cylinder.

37-22

JR - JH

MECHANICAL ELEMENT CONTROLS


Clutch slave cylinder
REMOVAL

TIGHTENING TORQUES (in daN.m)


Retaining bolt of the slave on the clutch
housing

37

Disconnect the clutch slave cylinder union (C) by


removing the two bolts (A).

0.9

REMOVAL
NOTE: The clutch slave cylinder (C) can only be
removed after removing the gearbox, see chapter 21.

Remove the two mounting bolts (B) of the clutch slave


cylinder then remove it.

WARNING: never operate the system when the


slave is removed (even if it is connected to the
clutch pedal). There is a risk that the hydraulic
piston and the slave stop will be ejected.

37-23

JR - JH

MECHANICAL ELEMENT CONTROLS


Clutch slave cylinder

37

REFITTING
Check the condition of the seals.
Proceed in the reverse order from removal.
Torque tighten the two slave mounting bolts (A) and
(B) to 0.9 daN.m.

Fill the brake fluid reservoir.


Check that the clutch system is working properly.

NB: to avoid damaging the slave, do not coat the


gearbox output shaft with grease.
NB: to avoid leaks, replace the slave after
replacing the clutch mechanism.
Add brake fluid to the reservoir.
bleed the hydraulic circuit:
connect a tube to opening (C) linked to a tank filled
with brake fluid,
lift up the clip (2),
unclip the tube to the first notch,
fit the bleeding device,
activate the bleeding device,
wait until the air is completely expelled from the
hydraulic circuit,
clip the tube back onto the clutch slave cylinder.

37-24

MECHANICAL ELEMENT CONTROLS


Clutch control pipes
REMOVAL

REFITTING

Disconnect the battery.

Check the condition of the seals.

Drain the brake fluid reservoir until the liquid level is


below the master cylinder supply port.

Refitting is the reverse of removal.

Place a cloth under this port then disconnect the brake


fluid reservoir pipe and fit plugs.
Remove the master-slave connecting pipe mounting
clip on the master.
Place a cloth under the master then disconnect the
connecting pipe on the master and position plugs at
each port.

37

IMPORTANT:
When refitting:
do not damage the various pipes,
take care to connect them correctly,
position the various mounting clips correctly.
Add brake fluid to the reservoir.
Bleed the hydraulic circuit:
connect a tube to opening (C) linked to a tank filled
with brake fluid,
lift up the clip (2),
pull the pipe to the first notch,
fit the bleeding device,
activate the bleeding device,
wait until the air is completely expelled from the
hydraulic circuit,
clip the pipe back onto the clutch slave cylinder.

Disconnect the master-slave connecting pipe by


releasing the clip (2) located on the union (C).

Fit plugs to the ports.


Carefully remove the master-slave connecting pipe
taking care not to damage anything.

Fill the brake fluid reservoir.


Check that the clutch system is working properly.

37-25

MECHANICAL ELEMENT CONTROLS


Clutch pedal

TIGHTENING TORQUES (in daN.m)


Plate nut

3.4

REMOVAL
Disconnect the battery
Set the vehicle wheels straight.
Remove the ball joint from the clutch sender pedal.
Remove:
the three plate nuts (A),
the two pedal sensor connectors (B).

REFITTING
To refit, proceed in the reverse order to removal.
Torque tighten the nuts to 3.4 daN.m.

37-26

37

MECHANICAL ELEMENT CONTROLS


The control unit
EXPLODED VIEW
EXTERNAL CONTROL CABLES ON UNIT JR/JH

EXTERNAL CONTROL CABLES ON UNIT PK

37-27

37

JR - JH

MECHANICAL ELEMENT CONTROLS


The control unit
In the engine compartment:

TIGHTENING TORQUES (in daN.m)


Unit mounting bolt

37

Remove:
the resonator unit (C),

REMOVAL
First remove the centre console before performing this
operation (see relevant chapter).

the external gear control mounting bolt,

Under the vehicle:


Disconnect the oxygen sensor (A).
Remove:
the exhaust system (see chapter 19),
the two mounting bolts on the heat shield,
the heat shield (B).

the external gear control cable with the control unit.


REFITTING
To refit, proceed in the reverse order to removal.
18614

37-28

PK

MECHANICAL ELEMENT CONTROLS


The control unit
In the engine compartment:

TIGHTENING TORQUES (in daN.m)


Unit mounting bolt

37

Remove the relay housing (C).

REMOVAL
First remove the centre console before performing this
operation (see relevant chapter).

Take off the clips (D) from the external gear control
cables (E).

Under the vehicle:


Remove:
the exhaust system (see chapter 19),
the two mounting bolts on the heat shield,
the heat shield (B).

18614

37-29

PK

MECHANICAL ELEMENT CONTROLS


The control unit
Remove the gear selection control cable with the
control unit.

REFITTING
To refit, proceed in the reverse order to removal.

37-30

37

MECHANICAL ELEMENT CONTROLS


The control unit
EXPLODED VIEW
EXTERNAL CONTROL CABLES ON UNIT DP0/SU1

37-31

37

DP0/SU1

MECHANICAL ELEMENT CONTROLS


The control unit

37

TIGHTENING TORQUES (in daN.m)


Unit mounting bolt

SPECIAL FEATURE:
When the vehicle is immobilised, it is possible to
unlock the gear selector lever by pressing the button
under the gaiter.

Cut out the circular shape under the unit using a blade.
Take out the unit cable.
Remove the control unit (A).

REMOVAL
First remove the centre console before performing this
operation.
Under the vehicle:
Disconnect the oxygen sensor (A) (if fitted).
Remove:
the exhaust system (see chapter 19),
the two mounting bolts on the heat shield,
the heat shield (B).

REFITTING
To refit, proceed in the reverse order to removal.
IMPORTANT: position the cables properly.

37-32

DP0

MECHANICAL ELEMENT CONTROLS


External gear control

37

REMOVAL OF THE GEAR CHANGE AND GEAR


SELECTION CABLES

REMOVAL
Under the vehicle:
Disconnect the oxygen sensor (A).
Remove:
the exhaust system (see chapter 19),
the two mounting bolts on the heat shield,
the heat shield (B).

Unclip:
the ball joint (1) of the multifunction switch cable
(MFC),
the cable (2) of the multifunction switch by releasing
the sleeve stop.

Cut out the circular shape under the unit using a blade.

NOTE: do not move the orange ring during this


operation. It may be broken when removing or refitting.
Where necessary, do not replace the control cable as
the absence of this part does not affect the operation
of the system.

In the engine compartment:


Remove the resonator unit (C).

Remove the external gear control cable.

37-33

DP0

MECHANICAL ELEMENT CONTROLS


External gear control
REFITTING
To refit, proceed in the reverse order to removal.
Adjust the gear selection cable at the multifunction
switch.
Press on the collar (T), then lock it in position using the
clip.
Refit the cable to the multifunction switch ball joint in
position N of the gear selector and the
multifunction switch.
Fasten the collar clip (T) to lock it in position. The
adjustment has been made.

37-34

37

SU1

MECHANICAL ELEMENT CONTROLS


External gear control

REMOVAL OF THE GEAR CHANGE AND GEAR


SELECTION CABLES

37

Unclip:
the ball joint (1) of the multifunction switch cable
(MFC),
the cable (2) of the multifunction switch by releasing
the sleeve stop.

REMOVAL
Under the vehicle:

NOTE: do not move the orange ring during this


operation. It may be broken when removing or refitting.
Where necessary, do not replace the control cable as
the absence of this part does not affect the operation
of the system.

Remove:
the exhaust system (see chapter 19),
the two mounting bolts on the heat shield,
the heat shield (B).

Cut out the circular shape under the unit using a blade.
In the engine compartment:
Remove the external gear control cable.

Remove the engine protection (C).

37-35

SU1

MECHANICAL ELEMENT CONTROLS


External gear control
REFITTING
To refit, proceed in the reverse order to removal.
Adjust the gear selection cable at the multifunction
switch.
Press on the collar (T), then lock it in position using the
clip.
Refit the cable to the multifunction switch ball joint in
position N of the gear selector and the
multifunction switch.
Fasten the collar clip (T) to lock it in position. The
adjustment has been made.

37-36

37

ELECTRONICALLY CONTROLLED
138 HYDRAULIC SYSTEM
ESP MK 60

1
2
3
4

Hydraulic pump with pressure modulation unit


ABS computer; ESP (Electronic Stability Program)
Wheel sensor
Accelerometer, lateral sensor.

38-1

38

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM


ESP MK 60

1
2
3
4
5
6
7
8

Hydraulic assembly
Wheel sensor
Steering wheel angle sensor
Lateral speed and acceleration sensor
Engine management computer
Motorised throttle body
Pressure sensor
CAN connection

38-2

38

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM


ESP MK 60

1
2
3
4
5
6
7
8
9
A

Hydraulic assembly
Computer
Mechanical component based braking amplifier
Steering wheel angle sensor
Lateral speed sensor
Vehicle speed
CAN network
Wheel sensor
Diagnostic socket
Private CAN network

38-3

38

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM


ESP MK 60

38

PREAMBLE
The ESP (Electronic Stability Program) is a supplementary mechanism to the ABS system.

DESCRIPTION
ESP (Electronic Stability Program) is made up of the following components:
an amplifier assembly fitted with: EBA (Emergency Braking Assistance), master cylinder with pressure sensor,
a pump assembly made up of:
a hydraulic pump,
a pressure modulation unit (twelve solenoid valves),
an electronic computer.
a steering wheel angle sensor,
the lateral speed and acceleration sensor,
the four wheel sensors.

OPERATING PRINCIPLE
The ESP (Electronic Stability Program) establishes reference conditions for the vehicle and applies corrective
braking action when these references are deviated from.
The reference conditions are continually monitored from measurements taken from the vehicle and refer to the
desired level of performance.
These measurements are:
wheel speed,
steering wheel angle.
These reference conditions are compared to the actual condition of the vehicle, determined by measuring:
the lateral speed,
the lateral acceleration.
The (Electronic Stability Program) makes use of the differences between these performances to calculate the
braking action to apply independently to one or more wheels according to a specific distribution strategy.
The resultant forces applied by the braking activate rotation torques on the vehicle which replace it on a course
correspondent with the desired performance.

38-4

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM


ESP MK 60

38

When does ESP (Electronic Stability Program) intervene?

Steering selected by the driver

Where is the vehicle going?

Calculation of the driver's intention

Course noted

Determine DIFFERENCE in COURSE

CORRECTIVE MEASURES
BRAKES AND ENGINE

38-5

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM


ESP MK 60
HYDRAULIC ASSEMBLY

Remove:
the wheels,
the left mudguard,
the front of the right-hand mudguard,
the long surface connections,
the bumper,
the air regulator unit (L7X engine),
the pre-postheating unit (F9Q engine),
the ABS connector,

TIGHTENING TORQUES (in daN.m)


Brake pipes on assembly

1.4

Aluminium side member tie-rod bolts

4.4

Aluminium side member bolts

4.4

The MK 60 hydraulic assembly is made up of twelve


solenoid valves (compared to eight in an ABS
assembly).
The computer is fitted with a more powerful processor
(it manages more parameters).

the upper ABS pipes,


the lower ABS pipes,

The hydraulic assembly is positioned on the front lefthand side of the vehicle, behind the front bumper.

IMPORTANT: MARK 60 hydraulic units fitted with


ESP and non-fitted MARK 60 hydraulic units look
alike. It is vital to check the type of hydraulic unit
on the vehicle before replacing it.
REMOVAL
Disconnect the battery.

38-6

38

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM


ESP MK 60
REFITTING

the mounting clips of the pipes on the mounting,

Proceed in the reverse order from removal.


Bleed the braking system (see method).

both left-hand tie-rods.


Unscrew but do not remove the two front bolts of the
aluminium side member.

Remove:
the three ABS mounting bolts,
the three mounting bolts of the ABS assembly on its
mounting,
the ABS assembly.

38-7

38

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM


ESP MK 60

38

ABS COMPUTER

REFITTING

REMOVAL

When a new computer is being fitted, remember to


attach the interconnection fork (B) between the
assembly and the computer.

Removing the computer does not necessarily involve


removing the entire assembly from the vehicle.
Remove:
the two mounting bolts on the hydraulic pump,

the computer.
IMPORTANT: when it is being removed, the
hydraulic pump (A) must be pressed onto the
pressure modulation unit.

38-8

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM


ESP MK 60

38

Allocation of tracks in ABS ESP (Electronic Stability Program) with electronic EBA (Emergency Braking
Assistance)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26

27
28
29
30
31
32
33
34
35
36
37
38

Pump assembly battery supply


line DIAG K
pedal displacement signal*
after ignition supply
pedal sensor earth*
lateral acceleration signal sensor**
5 volt supply pedal displacement sensor*
not connected*
not connected*
not connected*
CAN H line
split CAN H (not connected)
not connected*
split CAN L (not connected)
CAN L line
earth
active amplifier solenoid supply*
5 volt pressure sensor supply
pressure sensor earth
pressure sensor signal
not connected*
not connected*
not connected*
lateral speed and acceleration sensor earth*
private CAN L line
lateral speed and acceleration sensor supply*

39
40
41
42
43
44
45
46
47

normally open switch*


joint switch*
private CAN H line
normally closed switch*
active amplifier solenoid control*
solenoid valve battery supply
front right-hand wheel speed sensor earth
front right-hand wheel sensor signal/supply
relay control for turning off the brake lights*
rear left-hand wheel sensor signal/supply
rear left-hand wheel speed sensor earth
ON/OFF ASR (traction control)control and ESP
(Electronic Stability Program)
tachometry
lateral speed sensor signal*
brake light switch
rear right-hand wheel speed sensor earth
rear right-hand wheel sensor signal/supply
not connected*
front left-hand wheel sensor signal/supply
front left-hand wheel speed sensor earth
earth

Allocation of tracks in ABS ESP (Electronic


Stability Program) with mechanical EBA
(Emergency Braking Assistance)
* track not connected
** lateral speed and acceleration sensor earth

38-9

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM


ESP MK 60
STEERING WHEEL ANGLE SENSOR
The ESP (Electronic Stability Program) uses a steering
wheel angle sensor to measure the course determined
by the driver. This information is processed as a driver
command.
The steering wheel angle sensor is more than a simple
sensor. It can be considered to be a computer in its
own right. It has two processors which, being surplus
to requirements, ensure that the information delivered
on a private CAN network is reliable.

the air bag connectors,


the connectors in the steering wheel,
the steering wheel bolt,

This sensor is situated on the steering column and is


clipped onto the rotary switch assembly.
Set the vehicle wheels straight.
REMOVAL
Before performing any operation on the air bag
systems, lock the electronic unit using the fault
finding tools. This opens the electronic lock on the
column (see chapter 88).
Remove:
the air bag cushion,

38-10

38

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM


ESP MK 60

38

Lift up the upper and lower clips in pairs by gently


tilting the body of the sensor.
Remove the steering wheel angle sensor
REFITTING
If the sensor is new, remove its pin and keep the
yellow line visible in the middle of the window.
Centre the sensor using guides.
Lock the four clips.
Proceed in the reverse order from removal.
IMPORTANT: the steering wheel splines are fitted with
foolproofing devices. The steering wheel must fit
back into the splines easily. Take care not to
damage them.
the two column mounting bolts,
the upper casing with trim strip on the instrument
panel,

Each time it is removed the steering wheel bolt


must be replaced and torque tightened (4.4 daNm).

the lower casing.


Disconnect the connector on the steering wheel angle
switch.

38-11

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM


ESP MK 60
STEERING WHEEL ANGLE SENSOR
CALIBRATION
Switch on the ignition.
Set the steering wheel to angle greater than 4,
corresponding to about 1 cm on the circumference of
the steering wheel rim. This activates the sensor.
Position the vehicle with the right wheel horizontal
(with an angle tolerance of 15).
Establish communication with the ESP (Electronic
Stability Program) computer using the fault finding tool
and launch the sensor calibration procedure.
When the operation has been successfully completed,
delete the errors from the computer.
Switch off the ignition.

38-12

38

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM


ESP MK 60

38

Remove:
the two mounting nuts from the lateral speed and
acceleration sensor plate,

LATERAL SPEED AND ACCELERATION SENSOR

These two sensors are on the centre console, in front


of the handbrake control lever.
the plate end of the lateral speed and acceleration
sensor.

TIGHTENING TORQUES (in daN.m)


Sensor nut

REFITTING
Proceed in the reverse order from removal.

REMOVAL
In the passenger compartment
Remove:
the gear shift lever gaiter,
the handbrake gaiter,
the plate above the central console.
Disconnect the connectors.

38-13

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM


ESP MK 60

38

WHEEL SENSORS

at the back in the wheel arches behind the


mudguards.
REMOVAL
REFITTING
Using a flat screwdriver, free the plate end of the
sensor in (G).

Clip on the sensors

Pull the sensor out.

Connect the connectors in the same order they were


removed.
Check the air gap on a target turn with a set of shims
(non adjustable).
Front Z = 0.6 mm 0.5
Rear Z = 0.8 mm 0.5
NOTE: It is vital to make sure the connectors are
perfectly connected to prevent risk of breakdown.
The sensor must be fitted manually. Do not knock it
when installing it.
Don't pull the ABS wiring or it could be destroyed.

Disconnect the sensors:


at the front on the sensor end plates,

38-14

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM


ESP MK 60
PRESSURE SENSOR

It informs the computer of the hydraulic pressure in the


master cylinder
REMOVAL
TIGHTENING TORQUES (in daN.m)
Pressure sensor

2.5

Place the vehicle on a lift.


Attach the pedal lock to prevent fluid from escaping.
IMPORTANT: drain out the brake fluid to prevent
the mechanical parts and bodywork around the
braking system from deteriorating.
Remove:
the air filter hose,
the expansion bottle.
Fill up the new sensor using a syringe to avoid
forming an air bubble in the circuit.
Note: when it has been filled up, the brake fluid
should form a dome on the sensor opening.
Remove the pressure sensor using a cloth and replace
it immediately with the new one.
REFITTING
Proceed in the reverse order from removal.

38-15

38

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM


ESP MK 60
The wheel ABS hydraulic valve block can be removed in a similar way to the ESP hydraulic valve block.
there is no lateral speed and acceleration sensor,
steering wheel angle sensor,
or hydraulic pressure sensor,

NOTE: MARK 60 hydraulic units and MARK 60 hydraulic units fitted with ESP look alike.
It is vital to check the type of hydraulic unit on the vehicle before replacing it.

38-16

38

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM


ESP MK 60

38

BLEEDING PROCEDURE
NOTE: the hydraulic unit is pre-filled.
This bleeding procedure must be used when one of the following components has been removed:
the hydraulic unit,
the master cylinder,
the pipework (between the hydraulic unit and the master cylinder).
NOTE: the braking circuit with ABS must not have any faults and must operate correctly. If it does not, the ABS
circuit must be repaired from both a hydraulic and electrical point of view.
1)

Bleed the braking circuit in the normal way using your foot or a bleeding kit.
NOTE: if, after a road test with ABS regulation, the pedal travel is not correct, bleed the hydraulic unit.

2)

Bleeding the hydraulic unit


IMPORTANT: follow the correct order for bleeding by starting with the right-hand rear brake, then the rear left,
the front left then the front right.
a)

Bleed the rear right-hand brake by bleeding the hydraulic unit secondary circuit using the diagnostic tool:
position the bleed container and the hose, open the brake bleed bolt,
pump the brake pedal (approximately ten times),
keep the brake pedal depressed and start the bleed command with the fault finding tool (refer to the "fault
finding assistance" section"),
pump the brake pedal during the diagnostic bleed phase,
at the end of the bleed cycle using the diagnostic tool, continue to pump the brake pedal and close the
brake bleed screw.'

b)

Follow the procedure as described in a) for the left-hand rear brake, the front left and the front right.

c)

Check the pedal travel and if it is incorrect, restart the bleeding procedure.

IMPORTANT: ensure there is sufficient brake fluid in the reservoir.

38-17