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6 Air conditioning

61A HEATING

62A AIR CONDITIONING

X95

APRIL 2009 Edition Anglaise

"The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault.
specifications current when it was prepared.
The reproduction or translation in part of whole of the present document, as well as the use
The methods may be modified as a result of changes introduced by the manufacturer in the of the spare parts reference numbering system, are prohibited without the prior written
production of the various component units and accessories from which his vehicles are consent of Renault.
constructed."

© Renault s.a.s 2008


MEGANE III - Section 6ContentsPage

MEGANE III - Section 6

Contents

Page

61A HEATING 61A HEATING

Heating: List and location of Front side air distribution


components 61A-1 duct: Removal - Refitting 61A-132

Cabin filter: Removal - Front central air distribution


Refitting 61A-19 duct: Removal - Refitting 61A-141

C-pillar intermediate air A-pillar air distribution duct:


distribution duct: Removal - Removal - Refitting 61A-142
Refitting 61A-27
Recirculation motor:
Rear air distribution duct: Removal - Refitting 61A-146
Removal - Refitting 61A-28
Mixer motor: Removal -
Recirculation control cable: Refitting 61A-158
Removal - Refitting 61A-29
Distribution motor: Removal -
Air distribution cable: Refitting 61A-174
Removal - Refitting 61A-31
Passenger compartment
Air mixing cable: Removal - temperature sensor:
Refitting 61A-42 Removal - Refitting 61A-182

Air distribution unit: Removal External temperature sensor:


- Refitting 61A-54 Removal - Refitting 61A-183

Heater matrix: Removal -


Refitting 61A-69

Fan assembly: Removal - 62A AIR CONDITIONING


Refitting 61A-83
Air conditioning: List and
Heating resistor relays:
location of components 62A-1
Removal - Refitting 61A-102
Air conditioning: Precautions
Heating resistor unit:
for repair 62A-3
Removal - Refitting 61A-106
Air conditioning: Parts and
Passenger compartment fan
consumables for the repair
assembly control unit:
work 62A-4
Removal - Refitting 61A-117
Air conditioning: Operating
Control panel: Removal -
diagram
Refitting 61A-124
Contents

62A AIR CONDITIONING

Air conditioning: Check 62A-5

Coolant circuit check 62A-8

Coolant circuit Draining -


Refilling 62A-9

Condenser: Removal -
Refitting 62A-12

Compressor: Removal -
Refitting 62A-21

Expansion valve: Removal -


Refitting 62A-33

Evaporator: Cleaning 62A-47

Expansion valve - condenser


connecting pipe: Removal -
Refitting 62A-49

Expansion valve -
intermediate pipe connecting
pipe at the expansion valve
outlet: Removal - Refitting 62A-65

Pressure sensor: Removal -


Refitting 62A-77

Evaporator sensor: Removal


- Refitting 62A-79

Condenser - compressor
connecting pipe: Removal -
Refitting 62A-85

Compressor/intermediate
pipe connecting pipe:
Removal - Refitting 62A-95
HEATING
Heating: List and location of components 61A
B95 or D95 or E95 or K95, and CLIMATE CONTROL
I - LIST OF COMPONENTS - a front right-hand side intermediate air distribution
duct (16) ,
The air conditioning system consists of:
- a front left-hand side intermediate air distribution duct
- a control panel (1) ,
(17) ,
- a mixing motor (2) ,
- a front centre air distribution duct (18) ,
- a distribution motor (3) ,
- a front left-hand footwell air distribution duct (19) ,
- a cabin filter (4) ,
- a front right-hand footwell air distribution duct (20) ,
- an expansion valve (5) ,
- a rear left-hand footwell air distribution duct (21) ,
- a recirculation motor (6) ,
- a rear right-hand footwell air distribution duct (22) .
- a recirculation control cable (7) ,
- a cooling fan assembly (8) ,
EQT LEVEL EA4, and ELECTRONIC PARKING
- a passenger compartment fan assembly control unit BRAKE
(9) ,
- a mixing motor (10) ,
- a rear intermediate air distribution duct (23) ,
- an evaporator sensor (11) ,
- a rear air distribution duct (24) .
- a heater matrix (12) ,
- a heating resistor relay (13) ,
- a heating resistor (14) ,
- a front side air distribution duct (15) , II - LOCATION OF COMPONENTS

133409

61A-1
HEATING
Heating: List and location of components 61A
B95 or D95 or E95 or K95, and CLIMATE CONTROL

133410

61A-2
HEATING
Heating: List and location of components 61A
B95 or D95 or E95 or K95, and CLIMATE CONTROL

133406

61A-3
HEATING
Heating: List and location of components 61A
B95 or D95 or E95 or K95, and CLIMATE CONTROL

EQT LEVEL EA4, and ELECTRONIC PARKING


BRAKE

133404

61A-4
HEATING
Heating: List and location of components 61A
B95 or D95 or E95 or K95, and AIR CONDITIONING
I - LIST OF COMPONENTS - a front right-hand side intermediate air distribution
duct (15) ,
The air conditioning system consists of:
- a front left-hand side intermediate air distribution duct
- a control panel (1) , (16) ,
- an air distribution cable (2) , - a front centre air distribution duct (17) ,
- a cabin filter (3) , - a front left-hand footwell air distribution duct (18) ,
- an expansion valve (4) , - a front right-hand footwell air distribution duct (19) ,
- a recirculation motor (5) , - a rear left-hand footwell air distribution duct (20) ,
- a recirculation control cable (6) , - a rear right-hand footwell air distribution duct (21) .
- a cooling fan assembly (7) ,
EQT LEVEL EA4, and ELECTRONIC PARKING
- a passenger compartment fan assembly control unit
BRAKE
(8) ,

- an evaporator sensor (9) ,

- a heater matrix (10) , - a rear intermediate air distribution duct (22) ,

- a rear air distribution duct (23) .


- a heating resistor relay (11) ,

- a heating resistor (12) ,

- an air mixing cable (13) ,

- a front side air distribution duct (14) , II - LOCATION OF COMPONENTS

133405

61A-5
HEATING
Heating: List and location of components 61A
B95 or D95 or E95 or K95, and AIR CONDITIONING

133407

61A-6
HEATING
Heating: List and location of components 61A
B95 or D95 or E95 or K95, and AIR CONDITIONING

133406

61A-7
HEATING
Heating: List and location of components 61A
B95 or D95 or E95 or K95, and AIR CONDITIONING

EQT LEVEL EA4, and ELECTRONIC PARKING


BRAKE

133404

61A-8
HEATING
Heating: List and location of components 61A
J95, and AIR CONDITIONING
I - LIST OF COMPONENTS - a rear right-hand footwell air distribution duct (18)
(see C-pillar air distribution duct: Removal - Refit-
The air conditioning system consists of:
ting) .
- a control panel (1) (see 61A, Heating, Control pa-
nel: Removal - Refitting, page 61A-124) , REAR SEATS VENTILATOR
- an air distribution cable (2) (see 61A, Heating, Air - rear side intermediary air distribution ducts (19) (see
distribution cable: Removal - Refitting, page 61A- Rear side intermediate air distribution duct: Re-
31) , moval - Refitting) ,
- a cabin filter (3) (see 61A, Heating, Cabin filter: Re- - rear side air distribution ducts (20) (see Rear side air
moval - Refitting, page 61A-19) , distribution duct: Removal - Refitting) .
- an expansion valve (4) (see 62A, Air conditioning,
Expansion valve: Removal - Refitting, page 62A-
33) ,
- a recirculation motor (5) (see 61A, Heating, Recir-
culation motor: Removal - Refitting, page 61A-
146) ,
- a recirculation control cable (6) (see 61A, Heating,
Recirculation control cable: Removal - Refitting,
page 61A-29) ,

- a cooling fan assembly (7) (see 61A, Heating, Fan


assembly: Removal - Refitting, page 61A-83) ,
- a passenger compartment fan assembly control unit
(8) (see 61A, Heating, Passenger compartment
fan assembly control unit: Removal - Refitting,
page 61A-117) ,
- an evaporator sensor (9) (see 62A, Air conditio-
ning, Evaporator sensor: Removal - Refitting,
page 62A-79) ,
- a heater matrix (10) (see 61A, Heating, Heater ma-
trix: Removal - Refitting, page 61A-69) ,
- heater resistor relay (11) (see 61A, Heating, Hea-
ting resistor relays: Removal - Refitting, page
61A-102) ,

- a heating resistor (12) (see 61A, Heating, Heating


resistor unit: Removal - Refitting, page 61A-106) ,
- an air mixing cable (13) (see 61A, Heating, Air
mixing cable: Removal - Refitting, page 61A-42) ,
- front side air distribution ducts (14) (see 61A, Hea-
ting, Front side air distribution duct: Removal -
Refitting, page 61A-132) ,

- a front left-hand footwell air distribution duct (15) (see


61A, Heating, A-pillar air distribution duct: Remo-
val - Refitting, page 61A-142) ,
- a front right-hand footwell air distribution duct (16)
(see 61A, Heating, A-pillar air distribution duct:
Removal - Refitting, page 61A-142) ,
- a rear left-hand footwell air distribution duct (17) (see
C-pillar air distribution duct: Removal - Refitting) ,

61A-9
HEATING
Heating: List and location of components 61A
J95, and AIR CONDITIONING
II - POSITION OF THE COMPONENTS

139037

61A-10
HEATING
Heating: List and location of components 61A
J95, and AIR CONDITIONING

139038

61A-11
HEATING
Heating: List and location of components 61A
J95, and AIR CONDITIONING

139041

61A-12
HEATING
Heating: List and location of components 61A
J95, and AIR CONDITIONING

REAR SEATS VENTILATOR

139040

61A-13
HEATING
Heating: List and location of components 61A
J95, and CLIMATE CONTROL
I - LIST OF COMPONENTS - a rear right-hand footwell air distribution duct (19)
(see C-pillar air distribution duct: Removal - Refit-
The air conditioning system comprises:
ting) .
- a control panel (1) (see 61A, Heating, Control pa-
nel: Removal - Refitting, page 61A-124) ,
REAR SEATS VENTILATOR
- a mixing motor (2) (see 61A, Heating, Mixer motor:
- rear side intermediary air distribution ducts (20) (see
Removal - Refitting, page 61A-158) ,
Rear side intermediate air distribution duct: Re-
- a distribution motor (3) (see 61A, Heating, Distribu- moval - Refitting) ,
tion motor: Removal - Refitting, page 61A-174) ,
- rear side air distribution ducts (21) (see Rear side air
- a cabin filter (4) (see 61A, Heating, Cabin filter: Re- distribution duct: Removal - Refitting) .
moval - Refitting, page 61A-19) ,
- an expansion valve (5) (see 62A, Air conditioning,
Expansion valve: Removal - Refitting, page 62A-
33) ,
- a recirculation motor (6) (see 61A, Heating, Recir-
culation motor: Removal - Refitting, page 61A-
146) ,
- a recirculation control cable (7) (see 61A, Heating,
Recirculation control cable: Removal - Refitting,
page 61A-29) ,
- a cooling fan assembly (8) (see 61A, Heating, Fan
assembly: Removal - Refitting, page 61A-83) ,
- a passenger compartment fan assembly control unit
(9) (see 61A, Heating, Passenger compartment
fan assembly control unit: Removal - Refitting,
page 61A-117) ,
- an air mixing flap motor (10) (see 61A, Heating,
Mixer motor: Removal - Refitting, page 61A-158) ,
- an evaporator sensor (11) (see 62A, Air conditio-
ning, Evaporator sensor: Removal - Refitting,
page 62A-79) ,
- a heater matrix (12) (see 61A, Heating, Heater ma-
trix: Removal - Refitting, page 61A-69) ,
- heater resistor relay (13) (see 61A, Heating, Hea-
ting resistor relays: Removal - Refitting, page
61A-102) ,
- a heating resistor (14) (see 61A, Heating, Heating
resistor unit: Removal - Refitting, page 61A-106) ,
- front side air distribution ducts (15) (see 61A, Hea-
ting, Front side air distribution duct: Removal -
Refitting, page 61A-132) ,
- a front left-hand footwell air distribution duct (16) (see
61A, Heating, A-pillar air distribution duct: Remo-
val - Refitting, page 61A-142) ,
- a front right-hand footwell air distribution duct (17)
(see 61A, Heating, A-pillar air distribution duct:
Removal - Refitting, page 61A-142) ,
- a rear left-hand footwell air distribution duct (18) (see
C-pillar air distribution duct: Removal - Refitting) ,

61A-14
HEATING
Heating: List and location of components 61A
J95, and CLIMATE CONTROL
II - LOCATION OF COMPONENTS

139039

61A-15
HEATING
Heating: List and location of components 61A
J95, and CLIMATE CONTROL

139036

61A-16
HEATING
Heating: List and location of components 61A
J95, and CLIMATE CONTROL

139041

61A-17
HEATING
Heating: List and location of components 61A
J95, and CLIMATE CONTROL

REAR SEATS VENTILATOR

139040

61A-18
HEATING
Cabin filter: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE

REMOVAL II - OPERATION FOR REMOVAL OF PART


CONCERNED

I - REMOVAL PREPARATION OPERATION


a

Note:
There are 2 possibilities:
- the passenger compartment filter flap is bolted
onto the air distribution unit,
- the passenger compartment filter flap is clipped
onto the air distribution unit.

a Remove:
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 57A, Interior equipment),
- the front right-hand A-pillar air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) .

135675
a Remove the electrical wiring (1) from the cabin filter
flap after marking its routing.
a Remove the passenger compartment filter flap bolts
(2) .
a Unclip the passenger compartment filter flap.

Note:
Foreign bodies (leaves, insects etc.) are likely to
accumulate in the passenger compartment filter.
Remove the filter with care so as to prevent
foreign bodies getting into the evaporator.

a Remove the passenger compartment filter.

61A-19
HEATING
Cabin filter: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE
II - REFITTING OPERATION FOR PART
CONCERNED

141543
a Mark the passenger compartment filter fitting direc-
tion. 141543
a Refit:
a Remove the passenger compartment filter.
- the passenger compartment filter in accordance
with the mark,
REFITTING
- the passenger compartment filter flap,

I - REFITTING PREPARATION OPERATION a Fit the electrical wiring on the passenger compart-
ment filter flap.
a Check there are no foreign bodies in the passenger
compartment filter housing and clean thoroughly if
necessary. III - FINAL OPERATION
a Refit:
- the front right-hand A-pillar air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,
- the glovebox (see Glovebox: Removal - Refit-
ting) (57A, Interior equipment).

61A-20
HEATING
Cabin filter: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE

REMOVAL II - OPERATION FOR REMOVAL OF PART


CONCERNED
a

Note:
There are 2 possible types of fitting:
- the passenger compartment filter flap is bolted
onto the air distribution unit,
- the passenger compartment filter flap is clipped
onto the air distribution unit.

I - REMOVAL PREPARATION OPERATION


a Remove the glovebox (see Glovebox: Removal -
Refitting) (57A, Exterior equipment).

138645
a Remove the electrical wiring (2) from the passenger
compartment filter flap after marking its routing.
a Remove the passenger compartment filter flap bolts
(3) .
a Unclip the passenger compartment filter flap.
a Remove the passenger compartment filter flap.

Note:
Foreign bodies (leaves, insects, etc.) are likely to
accumulate in the passenger compartment filter.
Remove the filter with care so as to prevent
138642 foreign bodies getting into the evaporator.
a Unclip the right-hand centre console side trim (1) .

61A-21
HEATING
Cabin filter: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE
II - REFITTING OPERATION FOR PART
CONCERNED

141543
a Mark the passenger compartment filter fitting direc-
tion. 141543
a Refit:
a Remove the passenger compartment filter.
- the passenger compartment filter in accordance
with the mark,
REFITTING
- the passenger compartment filter flap.

I - REFITTING PREPARATION OPERATION a Fit the electrical wiring on the passenger compart-
ment filter flap.
a Check there are no foreign bodies in the passenger
compartment filter housing and clean thoroughly if
necessary. III - FINAL OPERATION
a Refit the glovebox (see Glovebox: Removal - Refit-
ting) (57A, Exterior equipment).
a Clip on the right-hand centre console side trim.

61A-22
HEATING
Cabin filter: Removal - Refitting 61A
RIGHT-HAND DRIVE
a

Note:
There are 2 possibilities:
- the passenger compartment filter flap is bolted
onto the air distribution unit,
- the passenger compartment filter flap is clipped
onto the air distribution unit.

REMOVAL

I - REMOVAL PREPARATION OPERATION

a Unclip the centre console side faces.

a Remove:
137154
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte- a Unclip the clutch pedal wiring.
rior equipment),
a Remove the clutch pedal nuts (2) .
- the front right-hand A-pillar air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re- Note:
moval - Refitting, page 61A-142) .
Do not disconnect the connectors from the clutch
pedal switches.
5 SPEED MANUAL GBOX or 6 SPEED MANUAL
a Move the clutch pedal aside.
GBOX

Note:
Do not apply pressure to the hydraulic clutch
pipes.

a Pass the hydraulic pipes under the distribution unit.

137690

a Unclip the clutch hydraulic pipes at (1) .

a Move the clutch hydraulic pipes aside.

61A-23
HEATING
Cabin filter: Removal - Refitting 61A
RIGHT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART
CONCERNED

136999
a Tilt the clutch pedal in the direction of the arrow.
138645
a Put the clutch pedal in the footwell.
a Remove the electrical wiring (3) from the passenger
compartment filter flap after marking its routing.
a Remove the passenger compartment filter flap bolts
(4) .
a Unclip the passenger compartment filter flap.
a Remove the passenger compartment filter flap.

Note:
Foreign bodies (leaves, insects etc.) are likely to
accumulate in the passenger compartment filter.
Remove the filter with care so as to prevent
foreign bodies getting into the evaporator.

61A-24
HEATING
Cabin filter: Removal - Refitting 61A
RIGHT-HAND DRIVE
II - REFITTING OPERATION FOR PART
CONCERNED

141543
a Mark the passenger compartment filter fitting direc-
tion. 141543
a Refit:
a Remove the passenger compartment filter.
- the passenger compartment filter in accordance
with the mark,
REFITTING
- the passenger compartment filter flap.

I - REFITTING PREPARATION OPERATION a Fit the electrical wiring on the passenger compart-
ment filter flap.
a Check there are no foreign bodies in the passenger
compartment filter housing and clean thoroughly if
necessary. III - FINAL OPERATION

5 SPEED MANUAL GBOX or 6 SPEED MANUAL


GBOX
a Fit:
- the clutch pedal,
- the hydraulic clutch pipes.
a Clip:
- the clutch pedal wiring,
- the hydraulic clutch pipes.

a Refit:
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),
- the front right-hand A-pillar air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) .

61A-25
HEATING
Cabin filter: Removal - Refitting 61A
RIGHT-HAND DRIVE
a Clip on the centre console side faces.

61A-26
HEATING
C-pillar intermediate air distribution duct: Removal - Refitting 61A
B95 or D95 or E95 or K95, and EQT LEVEL EA4, and ELECTRONIC PARKING BRAKE
II - FINAL OPERATION
Essential special tooling
a Refit the dashboard (see Dashboard: Removal -
Car. 1363 Set of trim removal levers. Refitting) (57A, Interior equipment).
a Connect the battery (see Battery : Removal - Refit-
REMOVAL ting) (80A, Battery).

I - REMOVAL PREPARATION OPERATION

a Disconnect the battery (see Battery : Removal -


Refitting) (80A, Battery).

a Remove the dashboard (see Dashboard: Removal


- Refitting) (57A, Interior equipment).

II - OPERATION FOR REMOVAL OF PART


CONCERNED

137016

a Remove:

- the clip (1) from the C-pillar intermediate air distri-


bution duct using the tool (Car. 1363),
- the C-pillar intermediate air distribution duct.

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED
a Refit:

- the C-pillar intermediate air distribution duct,


- the clip of the C-pillar intermediate air distribution
duct.

61A-27
HEATING
Rear air distribution duct: Removal - Refitting 61A
B95 or D95 or E95 or K95, and EQT LEVEL EA4, and ELECTRONIC PARKING BRAKE

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Remove the centre console (see Centre console:
Removal - Refitting) (57A, Interior equipment).

II - OPERATION FOR REMOVAL OF PART


CONCERNED

136378
a Remove the bolts (1) from the rear air distribution
duct.
a Unclip (2) the rear air distribution duct from the cen-
tre console.
a Remove the rear air distribution duct from the centre
console.

136377 REFITTING
a Unclip the rear section of the centre console.
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit the rear air distribution duct on the centre con-
sole.
a Clip the rear air distribution duct to the centre conso-
le.
a Refit the rear air distribution duct bolts.

II - FINAL OPERATION
a Refit the centre console (see Centre console: Re-
moval - Refitting) (57A, Interior equipment).

61A-28
HEATING
Recirculation control cable: Removal - Refitting 61A
B95 or D95 or E95 or K95

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).
a Remove the dashboard (see Dashboard: Removal
- Refitting) (57A, Interior equipment).

II - OPERATION FOR REMOVAL OF PART


CONCERNED

137024
a Unclip the wiring at (2) .
a Remove the recirculation cable.

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED
a Refit the recirculation cable.

137028 a Clip on the recirculation cable.


a Unclip the wiring at (1) .
II - FINAL OPERATION
a Refit the dashboard (see Dashboard: Removal -
Refitting) (57A, Interior equipment).
a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).

61A-29
HEATING
Recirculation control cable: Removal - Refitting 61A
J95

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).
a Remove the dashboard (see Dashboard: Removal
- Refitting) (57A, Interior equipment).

II - OPERATION FOR REMOVAL OF PART


CONCERNED

137024
a Unclip the recirculation control cable.
a Remove the recirculation control cable.

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED
a Refit the recirculation control cable.

137028 a Clip on the recirculation control cable.


a Unclip the recirculation control cable.
II - FINAL OPERATION
a Refit the dashboard (see Dashboard: Removal -
Refitting) (57A, Interior equipment).
a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).

61A-30
HEATING
Air distribution cable: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE, and AIR CONDITIONING

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Remove:
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 57A, Interior equipment),
- the front right-hand A-pillar air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,
- the centre front panel (see Centre front panel: Re-
moval - Refitting) (57A, Interior equipment).

RADIO NO 01 or RADIO NO 02 or RADIO NO 03 135677


or RADIO NO 04 or RADIO NO 05 a Squeeze the centring pins (2) while pushing the con-
trol panel.
a Remove the radio (see Car radio: Removal - Refit-
ting) (86A, Radio).

RADIO NO 06 or RADIO NO 07
a Remove the radio navigation system (see Radio na-
vigation system: Removal - Refitting) (83C, On-
board telematics system).

135659
a Tilt the control panel.
a Unclip the air mixing cable from the control panel at
(3) .
a Move aside the control panel.

135676
a Remove the bolts (1) from the control panel.

61A-31
HEATING
Air distribution cable: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE, and AIR CONDITIONING
II - OPERATION FOR REMOVAL OF PART a Clip:
CONCERNED
- the air mixing cable to the control panel,
- the control panel centring pins.
a Refit the control panel bolts.
a Check that the air distribution control can move
along its whole stroke.

RADIO NO 06 or RADIO NO 07
a Refit the radio navigation system (see Radio navi-
gation system: Removal - Refitting) (83C, On-
board telematics system).

135658
a Unclip the air distribution cable from the control pa- RADIO NO 01 or RADIO NO 02 or RADIO NO 03
nel at (4) . or RADIO NO 04 or RADIO NO 05
a Refit the radio (see Car radio: Removal - Refitting)
(86A, Radio).

a Refit:
- the centre front panel (see Centre front panel: Re-
moval - Refitting) (57A, Interior equipment),
- the front right-hand A-pillar air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,
- the glovebox (see Glovebox: Removal - Refit-
ting) (57A, Interior equipment).
136994
a Unclip the air distribution cable from the distribution
unit at (5) .
a Mark the routing of the air distribution cable.
a Remove the air distribution cable.

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED
a Refit the air distribution cable.
a Clip the air distribution control cable onto:
- the distribution unit,
- the control panel.

II - FINAL OPERATION
a Fit the control panel.

61A-32
HEATING
Air distribution cable: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and AIR CONDITIONING
a Remove:

Tightening torquesm - the lower bolts from the dashboard cross member
reinforcement,
dashboard cross mem- 21 N.m - the upper bolts from the dashboard cross member
ber reinforcement upper reinforcement,
bolts
- the dashboard cross member reinforcement.
dashboard cross mem- 21 N.m
ber reinforcement lower
bolts

REMOVAL

I - REMOVAL PREPARATION OPERATION

a Remove:

- the dashboard lower trim (see Lower section of


dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),

- the front footwell air distribution duct (see 61A, 135676


Heating, A-pillar air distribution duct: Removal
a Remove the bolts (1) from the control panel.
- Refitting, page 61A-142) ,

- the centre front panel (see Centre front panel: Re-


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

RADIO NO 01 or RADIO NO 02 or RADIO NO 03


or RADIO NO 04 or RADIO NO 05
a Remove the radio (see Car radio: Removal - Refit-
ting) (86A, Radio).

RADIO NO 06
135677
a Remove the radio navigation system (see Radio na- a Squeeze the centring pins (2) while pushing the con-
vigation system: Removal - Refitting) (83C, On- trol panel.
board telematics system).

FR AND RR PROX RADAR


a Disconnect the connector from the parking distance
control buzzer.

a Unclip the wiring from the dashboard cross member


reinforcement.

61A-33
HEATING
Air distribution cable: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and AIR CONDITIONING

135659
a Tilt the control panel.
a Unclip the air mixing cable from the control panel at
(3) .
a Move aside the control panel.
136990
a Unclip the air distribution cable from the distribution
II - OPERATION FOR REMOVAL OF PART unit at (5) .
CONCERNED
a Mark the routing of the air distribution cable.
a Remove the air distribution cable.

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED
a Refit the air distribution cable.
a Clip:
- the air distribution cable on the distribution unit,
- the air distribution cable on the control panel.
135658
a Unclip the air distribution cable from the control pa- II - FINAL OPERATION
nel at (4) . a Fit the control panel.
a Clip:
- the air mixing cable to the control panel,
- the control panel centring pins.
a Clip the air mixing cable onto the control panel.
a Clip on the control panel centring pins.
a Refit the control panel bolts.
a Check that the air distribution control can move
along its whole stroke.
a Refit:
- the dashboard cross member stiffener,

61A-34
HEATING
Air distribution cable: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and AIR CONDITIONING
- the upper bolts of the dashboard cross member
reinforcement,

- the lower bolts of the dashboard cross member


reinforcement.

a Tighten to torque:

- the dashboard cross member reinforcement


upper bolts (21 N.m),

- the dashboard cross member reinforcement


lower bolts (21 N.m).

a Clip on the dashboard cross member reinforcement


wiring.

FR AND RR PROX RADAR

a Connect the parking distance control buzzer con-


nector.

RADIO NO 01 or RADIO NO 02 or RADIO NO 03


or RADIO NO 04 or RADIO NO 05

a Refit the radio (see Car radio: Removal - Refitting)


(86A, Radio).

RADIO NO 06

a Refit the radio navigation system (see Radio navi-


gation system: Removal - Refitting) (83C, On-
board telematics system).

a Refit:

- the centre front panel (see Centre front panel: Re-


moval - Refitting) (57A, Interior equipment),

- the front footwell air distribution duct (see 61A,


Heating, A-pillar air distribution duct: Removal
- Refitting, page 61A-142) ,

- the dashboard lower trim (see Lower section of


dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment).

61A-35
HEATING
Air distribution cable: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE, and AIR CONDITIONING

Tightening torquesm

nuts of the dashboard 21 N.m


cross member reinforce-
ment

dashboard cross mem- 21 N.m


ber reinforcement lower
bolts

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Remove:
- the central console (see Centre console: Remo-
val - Refitting) (57A, Interior equipment),
- the dashboard lower trim (see Lower section of
138648
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment), a Remove the upper nuts (1) from the dashboard
cross member reinforcement.
- the inhibitor switch (see Inhibitor switch: Remo-
val - Refitting) (88C, Airbag and pretensioners),
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 55A, Interior equipment),
- the centre front panel (see Centre front panel: Re-
moval - Refitting) (57A, Interior equipment).

FR AND RR PROX RADAR


a Disconnect the connector from the parking distance
control buzzer.

138653
a Remove:
- the lower bolts (2) from the dashboard cross mem-
ber reinforcement,
- the dashboard cross member reinforcement.

61A-36
HEATING
Air distribution cable: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE, and AIR CONDITIONING
II - OPERATION FOR REMOVAL OF PART
CONCERNED

138500
a Remove the bolts (3) from the control panel.
138497

138599
138499
a Squeeze the centring pins (4) while pushing the con-
a Unclip the air distribution cable (5) from the control
trol panel.
panel in order, as shown by the directional arrows.
a Tilt the control panel .

61A-37
HEATING
Air distribution cable: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE, and AIR CONDITIONING

FR AND RR PROX RADAR


a Connect the parking distance control buzzer con-
nector.

a Refit:
- the centre front panel (see Centre front panel: Re-
moval - Refitting) (57A, Interior equipment),
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 55A, Interior equipment),
- the inhibitor switch (see Inhibitor switch: Remo-
val - Refitting) (88C, Airbag and pretensioners),
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),

138504 - the central console (see Centre console: Remo-


val - Refitting) (57A, Interior equipment).
a Unclip the air distribution cable from the distribution
unit at (6) .
a Mark the routing of the air distribution cable.
a Remove the air distribution cable.

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED
a Refit the air distribution cable.
a Clip the air distribution control cable onto:
- the distribution unit,
- the control panel.

II - FINAL OPERATION
a Fit the control panel.
a Clip on the centring pins of the control panel.
a Refit the control panel bolts.
a Check that the air distribution control can move
along its whole stroke.
a Refit the dashboard cross member reinforcement.
a Tighten to torque:
- the upper nuts of the dashboard cross member
reinforcement (21 N.m),
- the dashboard cross member reinforcement
lower bolts (21 N.m).

61A-38
HEATING
Air distribution cable: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE, and AIR CONDITIONING

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Remove:
- the central console (see Centre console: Remo-
val - Refitting) (57A, Interior equipment),
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),
- the inhibitor switch (see Inhibitor switch: Remo-
val - Refitting) (88C, Airbag and pretensioners),
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 55A, Interior equipment),
- the centre front panel (see Centre front panel: Re-
moval - Refitting) (57A, Interior equipment).

138599
a Squeeze the centring pins (2) while pushing the con-
trol panel.
a Tilt the control panel .

138500
a Remove the bolts (1) from the control panel.

61A-39
HEATING
Air distribution cable: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE, and AIR CONDITIONING
II - OPERATION FOR REMOVAL OF PART
CONCERNED

138504
a Unclip the air distribution cable from the distribution
138497 unit at (4) .
a Mark the routing of the air distribution cable.
a Remove the air distribution cable.

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED
a Refit the air distribution cable.
a Clip the air distribution control cable onto:
- the distribution unit,
- the control panel.

II - FINAL OPERATION
a Fit the control panel.
a Clip on the centring pins of the control panel.
138499
a Refit the control panel bolts.
a Unclip the air distribution cable (3) from the control
panel in order, as shown by the directional arrows. a Check that the air distribution control can move
along its whole stroke.
a Refit:
- the centre front panel (see Centre front panel: Re-
moval - Refitting) (57A, Interior equipment),
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 55A, Interior equipment),
- the inhibitor switch (see Inhibitor switch: Remo-
val - Refitting) (88C, Airbag and pretensioners),

61A-40
HEATING
Air distribution cable: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE, and AIR CONDITIONING
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),
- the central console (see Centre console: Remo-
val - Refitting) (57A, Interior equipment).

61A-41
HEATING
Air mixing cable: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and AIR CONDITIONING

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Remove:
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 57A, Interior equipment),
- the front left-hand footwell air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,
- the centre front panel (see Centre front panel: Re-
moval - Refitting) (57A, Interior equipment).

RADIO NO 01 or RADIO NO 02 or RADIO NO 03 135677


or RADIO NO 04 or RADIO NO 05 a Squeeze the centring pins (2) while pushing the con-
trol panel.
a Remove the radio (see Car radio: Removal - Refit-
ting) (86A, Radio). a Tilt the control panel .

II - OPERATION FOR REMOVAL OF PART


CONCERNED

RADIO NO 06 or RADIO NO 07
a Remove the radio navigation system (see Radio na-
vigation system: Removal - Refitting) (83C, On-
board telematics system).

135659
a Unclip the air mixing cable from the control panel at
(3) .

135676
a Remove the bolts (1) from the control panel.

61A-42
HEATING
Air mixing cable: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and AIR CONDITIONING

RADIO NO 06 or RADIO NO 07
a Refit the radio navigation system (see Radio navi-
gation system: Removal - Refitting) (83C, On
board telematics system).

RADIO NO 01 or RADIO NO 02 or RADIO NO 03


or RADIO NO 04 or RADIO NO 05
a Refit the radio (see Car radio: Removal - Refitting)
(86A, Radio).

a Refit:
- the centre front panel (see Centre front panel: Re-
136993
moval - Refitting) (57A, Interior equipment),

a Unclip the air mixing cable from the distribution unit. - the front left-hand footwell air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
a Mark the routing of the air mixing cable. moval - Refitting, page 61A-142) ,
a Remove the air mixing cable. - the glovebox (see Glovebox: Removal - Refit-
ting) (57A, Interior equipment).
REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED
a Refit the air mixing cable.
a Clip the air mixing cable onto:
- the distribution unit,
- the control panel.

II - FINAL OPERATION
a Fit the control panel.
a Clip the air mixing cable onto the control panel.
a Clip on the centring pins.
a Refit the control panel bolts.
a Check that the air distribution control can move
along its whole stroke.

61A-43
HEATING
Air mixing cable: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE, and AIR CONDITIONING

Tightening torquesm RADIO NO 06 or RADIO NO 07


a Remove the radio navigation system (see Radio na-
dashboard cross mem- 21 N.m
vigation system: Removal - Refitting) (83C, On-
ber reinforcement upper
board telematics system).
bolts

dashboard cross mem- 21 N.m


ber reinforcement lower
bolts
FR AND RR PROX RADAR
a Disconnect the connector from the parking distance
REMOVAL control buzzer.

I - REMOVAL PREPARATION OPERATION


a Unclip the wiring from the dashboard cross member
reinforcement.

137019

a Unclip the left-hand centre console trim.

a Remove:

- the dashboard lower trim (see Lower section of


dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment), 135692
a Remove the lower bolts (1) from the dashboard
- the front left-hand footwell air distribution duct (see
cross member reinforcement.
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,

- the centre front panel (see Centre front panel: Re-


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

RADIO NO 01 or RADIO NO 02 or RADIO NO 03


or RADIO NO 04 or RADIO NO 05

a Remove the radio (see Car radio: Removal - Refit-


ting) (86A, Radio).

61A-44
HEATING
Air mixing cable: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE, and AIR CONDITIONING

135677
a Squeeze the centring pins (4) while pushing the con-
trol panel.
a Tilt the control panel.

135693
II - OPERATION FOR REMOVAL OF PART
a Remove: CONCERNED
- the upper bolts (2) from the dashboard cross mem-
ber reinforcement,
- the dashboard cross member reinforcement.

135659
a Unclip the air mixing cable (5) from the control panel.

135676
a Remove the bolts (3) from the control panel.

61A-45
HEATING
Air mixing cable: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE, and AIR CONDITIONING
a Tighten to torque:
- the dashboard cross member reinforcement
upper bolts (21 N.m),
- the dashboard cross member reinforcement
lower bolts (21 N.m).
a Clip on the wiring of the dashboard cross member
reinforcement.

FR AND RR PROX RADAR


a Connect the parking distance control buzzer con-
nector.

RADIO NO 01 or RADIO NO 02 or RADIO NO 03


or RADIO NO 04 or RADIO NO 05
a Refit the radio (see Car radio: Removal - Refitting)
136993
(86A, Radio).
a Unclip the air mixing cable (6) from the distribution
unit.
a Mark the routing of the air mixing cable.
a Remove the air mixing cable. RADIO NO 06 or RADIO NO 07
a Refit the radio navigation system (see Radio navi-
REFITTING gation system: Removal - Refitting) (83C, On
board telematics system).
I - REFITTING OPERATION FOR PART
CONCERNED
a Refit the air mixing cable. a Refit:
a Clip: - the centre front panel (see Centre front panel: Re-
moval - Refitting) (57A, Interior equipment).
- the air mixing cable onto the distribution unit,
- the front left-hand footwell air distribution duct (see
- the air mixing cable onto the control panel. 61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,
II - FINAL OPERATION - the dashboard lower trim (see Lower section of
a Fit the control panel. dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment).
a Clip on the centring pins of the control panel.
a Clip on the left-hand centre console trim.
a Refit the control panel bolts.
a Check that the air mixing control can move along its
whole stroke.
a Refit:
- the dashboard cross member reinforcement,
- the upper bolts of the dashboard cross member
reinforcement,
- the lower bolts of the dashboard cross member
reinforcement.

61A-46
HEATING
Air mixing cable: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE, and AIR CONDITIONING

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Remove:
- the central console (see Centre console: Remo-
val - Refitting) (57A, Interior equipment),
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),
- the inhibitor switch (see Inhibitor switch: Remo-
val - Refitting) (88C, Airbag and pretensioners),
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 55A, Interior equipment),
- the centre front panel (see Centre front panel: Re-
moval - Refitting) (57A, Interior equipment).

138599
a Squeeze the centring pins (2) while pushing the con-
trol panel.
a Tilt the control panel .

138500
a Remove the bolts (1) from the control panel.

61A-47
HEATING
Air mixing cable: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE, and AIR CONDITIONING
II - OPERATION FOR REMOVAL OF PART
CONCERNED

138503
a Unclip the air mixing flap cable from the distribution
138496 unit at (4) .
a Mark the routing of the air mixing cable.
a Remove the air mixing cable.

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED
a Refit the air mixing cable.
a Clip the air mixing cable onto:
- the distribution unit,
- the control panel.

II - FINAL OPERATION
a Fit the control panel.
a Clip on the centring pins.
138498
a Refit the control panel bolts.
a Unclip the air mixing flap control cable (3) from the
control panel in order, as shown by the directional a Check that the air distribution control can move
arrows. along its whole stroke.
a Refit:
- the centre front panel (see Centre front panel: Re-
moval - Refitting) (57A, Interior equipment),
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 55A, Interior equipment),
- the inhibitor switch (see Inhibitor switch: Remo-
val - Refitting) (88C, Airbag and pretensioners),

61A-48
HEATING
Air mixing cable: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE, and AIR CONDITIONING
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),
- the central console (see Centre console: Remo-
val - Refitting) (57A, Interior equipment).

61A-49
HEATING
Air mixing cable: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE, and AIR CONDITIONING

Tightening torquesm FR AND RR PROX RADAR


a Disconnect the connector from the parking distance
nuts of the dashboard 21 N.m
control buzzer.
cross member reinforce-
ment

dashboard cross mem- 21 N.m


ber reinforcement lower
bolts

REMOVAL

I - REMOVAL PREPARATION OPERATION

a Remove:

- the central console (see Centre console: Remo-


val - Refitting) (57A, Interior equipment),

- the dashboard lower trim (see Lower section of


dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),

- the inhibitor switch (see Inhibitor switch: Remo-


val - Refitting) (88C, Airbag and pretensioners),

- the glovebox (see Glovebox: Removal - Refit- 138640


ting) ( 55A, Interior equipment), a Unclip the wiring from the dashboard cross member
reinforcement at (2) .
- the centre front panel (see Centre front panel: Re-
a Remove the lower bolts (3) from the dashboard
moval - Refitting) (57A, Interior equipment).
cross member reinforcement.

138642

a Unclip the left-hand centre console side trim (1) .

61A-50
HEATING
Air mixing cable: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE, and AIR CONDITIONING

138639 138599
a Remove: a Squeeze the centring pins (7) while pushing the con-
trol panel.
- the dashboard cross member flange upper bolts (4)
. a Tilt the control panel .
- the brake pedal impactor (5) ,
- the dashboard cross member reinforcement.

138500
a Remove the bolts (6) from the control panel.

61A-51
HEATING
Air mixing cable: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE, and AIR CONDITIONING
II - OPERATION FOR REMOVAL OF PART
CONCERNED

138503
a Unclip the air mixing flap cable from the distribution
138496 unit at (9) .
a Mark the routing of the air mixing cable.
a Remove the air mixing cable.

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED
a Refit the air mixing cable.
a Clip the air mixing cable onto:
- the distribution unit,
- the control panel.

II - FINAL OPERATION
a Fit the control panel.

138498
a Clip on the centring pins of the control panel.

a Unclip the air mixing flap control cable (8) from the a Refit the control panel bolts.
control panel in order, as shown by the directional a Check that the air mixing control can move along its
arrows. whole stroke.
a Refit:
- the dashboard cross member reinforcement,
- the brake pedal impacter.
a Tighten to torque:
- the upper nuts of the dashboard cross member
reinforcement (21 N.m),

61A-52
HEATING
Air mixing cable: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE, and AIR CONDITIONING
- the dashboard cross member reinforcement
lower bolts (21 N.m).
a Clip the wiring onto the dashboard cross member
reinforcement.

FR AND RR PROX RADAR


a Connect the parking distance control buzzer con-
nector.

a Refit:
- the centre front panel (see Centre front panel: Re-
moval - Refitting) (57A, Interior equipment),
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 55A, Interior equipment),
- the inhibitor switch (see Inhibitor switch: Remo-
val - Refitting) (88C, Airbag and pretensioners),
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),
- the central console (see Centre console: Remo-
val - Refitting) (57A, Interior equipment).
a Clip on the left-hand centre console side trim.

61A-53
HEATING
Air distribution unit: Removal - Refitting 61A
B95 or D95 or K95
- the scoop under the scuttle panel grille (see Scoop
Essential special tooling under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),
Ms. 583 Hose clamp pliers.
- the windscreen wiper mechanism (see Winds-
Essential equipment creen wiper mechanism: Removal - Refitting)
(85A, Wiping - Washing).
refrigerant charging station
F4R
Tightening torquesm a Remove:

clip of the air filter unit 5.5 N.m - the lifting eye of the cylinder head,
air outlet pipe - the turbocharger heat shield nuts.

WARNING
IMPORTANT
To prevent the surrounding components from
To avoid all risk of damage to the systems, apply overheating, do not damage (tear, pierce, bend,
the safety and cleanliness instructions and opera-
etc.) a heat shield.
tion recommendations before carrying out any
repair (see 62A, Air conditioning, Air conditio- Any damaged heat shields must be replaced.
ning: Precautions for repair, page 62A-3) .
a Remove the turbocharger heat shield.

Note:
Use fuel blanking plugs with part no. 77 01 208 229
or 77 01 476 857 to plug any openings exposed to
the open air. Do not use any which have already
been used to plug a fuel circuit.

REMOVAL

I - REMOVAL PREPARATION OPERATION

a Remove the front engine cover.

WARNING
Consult the device's operating manual to avoid
incorrect use.

a Drain the refrigerant circuit using the refrigerant


charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) .

a Disconnect the battery (see Battery : Removal -


Refitting) (80A, Battery).

a Remove:

- the windscreen wiper arms (see Windscreen wi-


per arm: Removal - Refitting) (85A, Wiping -
Washing),

- the scuttle panel grille (see Scuttle panel grille:


Removal - Refitting) (56A, Exterior equipment),

61A-54
HEATING
Air distribution unit: Removal - Refitting 61A
B95 or D95 or K95

F4R F9Q or K9K

a Remove the clips from the bulkhead heat shield.

WARNING
To prevent the surrounding components from
overheating, do not damage (tear, pierce, bend,
etc.) a heat shield.
Any damaged heat shields must be replaced.

a Move the bulkhead heat shieldto one side.

136467

a Remove:

- the bulkhead upper heat shield bolts (1) ,

- the bulkhead upper heat shield clips (2) .

WARNING
To prevent the surrounding components from
overheating, do not damage (tear, pierce, bend,
etc.) a heat shield.
Any damaged heat shields must be replaced.

a Remove the bulkhead upper heat shield.

F9Q 136487

a Remove: a Remove the bolts (3) from the expansion valve con-
necting pipe bracket.
- the battery (see Battery : Removal - Refitting)
(80A, Battery),
WARNING
- the diesel injection computer (see Diesel injection
computer: Removal - Refitting) (13B, Diesel in- In order to avoid any refrigerant leaks, do not
jection), damage (deform, twist, etc.) the pipe.

- the battery tray (see Battery tray: Removal - Re- a Uncouple the connecting pipes from the expansion
fitting) (80A, Battery), valve.

- the intercooler air inlet pipe (see Intercooler air in- a Remove the connecting pipes from the expansion
let pipe: Removal - Refitting) (12B, Turbochar- valve.
ging).
a Remove the connecting pipe seals.

a Insert the blanking plugs.

61A-55
HEATING
Air distribution unit: Removal - Refitting 61A
B95 or D95 or K95

F4R

135707
a Loosen the clip (4) of the air outlet pipe on the air fil-
ter unit.
137157

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

135796
a Remove the bolts (5) from the air inlet pipe on the
throttle valve. 134643

a Disconnect the connector (7) of the turbocharging


pressure regulation valve control solenoid valve.
a Detach the turbocharging pressure regulation valve
control solenoid valve.

a Remove the air outlet pipe from the air filter box.

a Fit the tool (Ms. 583) on the heater matrix hoses.


a Disconnect the heater matrix hoses.

61A-56
HEATING
Air distribution unit: Removal - Refitting 61A
B95 or D95 or K95
a Remove: - the cabin filter,
- the dashboard (see Dashboard: Removal - Refit- - the expansion valve,
ting) (57A, Interior equipment),
- the front side air distribution duct (see 61A, Hea- - the recirculation motor,
ting, Front side air distribution duct: Removal -
Refitting, page 61A-132) , - the air recirculation control cable,

- the dashboard cross member (see Dashboard - the fan assembly,


cross member: Removal - Refitting) (42A, Upper
front structure). - the fan assembly control unit,

- the evaporator sensor,


II - OPERATION FOR REMOVAL OF PART
CONCERNED - the heater matrix,

- heater resistor relays,

- the heating resistor,

- the air mixing cable.

CLIMATE CONTROL

a Remove the following components from the distribu-


tion unit:

- the left-hand mixer motor,

- the right-hand mixer motor,

- the distribution motor,


137642

a Disconnect the supply connector (8) from the distri- - the cabin filter,
bution unit.
- the expansion valve,
a Unclip the electrical wiring from the distribution unit.
- the recirculation motor,
a Separate the electrical wiring from the distribution
unit. - the air recirculation control cable,
a Remove the distribution unit.
- the fan assembly,

Note: - the fan assembly control unit,


To find the location of components (see 61A, - the evaporator sensor,
Heating, Heating: List and location of compo-
nents, page 61A-1) . - the heater matrix,

- heater resistor relays,


AIR CONDITIONING
- the heating resistor.
a Remove the following components from the distribu-
tion unit:
- the air distribution cable,

61A-57
HEATING
Air distribution unit: Removal - Refitting 61A
B95 or D95 or K95

REFITTING - the heating resistor.

I - REFITTING PREPARATION OPERATION


a parts always to be replaced: refrigerant pipe seal
(30,02,02,52). AIR CONDITIONING

a Refit the following components onto the distribution


WARNING unit:
Do not remove the blanking plugs from each
- the air distribution cable,
component until the last moment.
Also, do not remove the components from their - the cabin filter,
packaging until they are to be fitted to the vehi- - the expansion valve,
cle.
- the recirculation motor,

WARNING - the air recirculation control cable,


To avoid any leaks, check that the pipe surface is - the fan assembly,
sound before positioning the new seal. The sur-
face must be clean and scratch free. - the fan assembly control unit,

- the evaporator sensor,


a Remove the blanking plugs.

a Lubricate the seals using recommended air conditio- - the heater matrix,
ning oil to make fitting easier (see 62A, Air condi- - heater resistor relays,
t i o n i n g , Air conditioning: Parts and
consumables for the repair work, page 62A-4) . - the heating resistor,

a Fit new seals to the refrigerant connecting pipes. - the air mixing cable.

II - REFITTING OPERATION FOR PART


CONCERNED
a Refit the distribution unit.

CLIMATE CONTROL a Fit the wiring on the distribution unit.

a Refit the following components onto the distribution a Clip the wiring onto the distribution unit.
unit:
a Connect the supply connector of the distribution unit.
- the left-hand mixer motor,
- the right-hand mixer motor, III - FINAL OPERATION
- the distribution motor, a Refit:
- the cabin filter, - the dashboard cross member (see Dashboard
cross member: Removal - Refitting) (42A, Upper
- the expansion valve,
front structure),
- the recirculation motor,
- the front side air distribution duct (see 61A, Hea-
- the air recirculation control cable, ting, Front side air distribution duct: Removal -
Refitting, page 61A-132) ,
- the fan assembly,
- the dashboard (see Dashboard: Removal - Refit-
- the fan assembly control unit,
ting) (57A, Interior equipment).
- the evaporator sensor,
a Connect the heater matrix hoses.
- the heater matrix,
a Remove the tool (Ms. 583) from the heater matrix
- heater resistor relays, hoses.

61A-58
HEATING
Air distribution unit: Removal - Refitting 61A
B95 or D95 or K95
- the turbocharger heat shield,

F4R - the turbocharger heat shield nuts,


a Refit:
- the lifting eye of the cylinder head.
- the air outlet pipe to the air filter unit,
- the air inlet pipe to the throttle valve.
a Clip on the turbocharging pressure regulation valve
control solenoid valve.
a Connect the battery (see Battery : Removal - Refit-
a Connect the connector of the turbocharging pressu- ting) (80A, Battery).
re regulation valve control solenoid valve.
a Fill and bleed the cooling circuit (see Cooling cir-
a Clip on the brake servo vacuum pipe.
cuit: Draining - Refilling) (19A, Cooling).
a Torque tighten the clip of the air filter unit air out-
let pipe (5.5 N.m).
Note:
A summary table gives the quantities of refrige-
rant in the system according to the engine type
a Connect the connecting pipes to the expansion val-
(see 62A, Air conditioning, Air conditioning:
ve.
Parts and consumables for the repair work,
page 62A-4) .
F9Q or K9K
a Perform the following operations:
a Fit the heat shield to the bulkhead.
a Refit the heat shield bolts. - refill the refrigerant circuit using the refrigerant
charging station (see 62A, Air conditioning,
Coolant circuit Draining - Refilling, page 62A-9)
,

F9Q - check for leaks (see 62A, Air conditioning, Coo-


lant circuit check, page 62A-8) .
a Refit:
- the intercooler air inlet pipe (see Intercooler air in- a Check that the air conditioning system is operating
let pipe: Removal - Refitting) (12B, Turbochar- correctly (see 62A, Air conditioning, Air conditio-
ging), ning: Check, page 62A-5) .
- the battery tray (see Battery : Removal - Refit-
ting) (80A, Battery), a Refit:

- the diesel injection computer (see Diesel injection - the windscreen wiper mechanism (see Winds-
computer: Removal - Refitting) (13B, Diesel in- creen wiper mechanism: Removal - Refitting)
jection),
(85A, Wiping - Washing),
- the battery (see Battery : Removal - Refitting)
(80A, Battery). - the scoop under the scuttle panel grille (see Scoop
under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),

- the scuttle panel grille (see Scuttle panel grille:


F4R Removal - Refitting) (56A, Exterior equipment),
a Refit: - the windscreen wiper arms (see Windscreen wi-
- the bulkhead upper heat shield, per arm: Removal - Refitting) (85A, Wiping -
Washing),
- the bulkhead upper heat shield bolts,
- the bulkhead upper heat shield clips, - the engine cover.

61A-59
HEATING
Air distribution unit: Removal - Refitting 61A
J95
- the scoop under the centre section of the scuttle
Essential special tooling panel grille (see Scoop under scuttle panel
grille: Removal - Refitting) (56A, Exterior equip-
Ms. 583 Hose clamp pliers.
ment).

Essential equipment a Undo the clips on the air outlet pipe of the air filter
unit.
refrigerant charging station a Remove the air outlet pipe from the air filter box.

Tightening torquesm F9Q

turbocharger air inlet 8 N.m


pipe bolts

air filter box air outlet 6 N.m


pipe clips

IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 62A, Air conditioning, Air conditio-
ning: Precautions for repair, page 62A-3) .

Note:
Use fuel blanking plugs with part no. 77 01 208 229
or 77 01 476 857 to plug any openings exposed to
the open air. Do not use any which have already 137477
been used to plug a fuel circuit.
a Remove:
- the bolts (1) from the cylinder head lifting eye,
REMOVAL - the cylinder head lifting eye.

I - REMOVAL PREPARATION OPERATION

a Remove the front engine cover.

WARNING
Consult the device's operating manual to avoid
incorrect use.

a Drain the refrigerant circuit using the refrigerant


charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) .

a Disconnect the battery (see Battery: Removal - Re-


fitting) (80A, Battery).

a Remove:
- the centre section of the scuttle panel grille (see
Scuttle panel grille: Removal - Refitting) (56A,
Exterior equipment),

61A-60
HEATING
Air distribution unit: Removal - Refitting 61A
J95

M9R K9K

139563
139155
a Unclip the wiring (2) from the cylinder head lifting
eye. a the bolt (4) from the turbocharger air inlet pipe.
a Remove:
- the bolts (3) from the cylinder head lifting eye,
- the cylinder head lifting eye.

139154

a Remove:

- the bolts (5) from the turbocharger air inlet pipe,

- the turbocharger air inlet pipe.

61A-61
HEATING
Air distribution unit: Removal - Refitting 61A
J95

F9Q

135640
a Remove the bolts (8) from the turbocharger air inlet
135638
pipe.

a Remove the bolt (6) from the intermediate air pipe a Disconnect the intermediate air pipe between the air
between the air filter unit and the turbocharger on filter unit and the turbocharger from the turbocharger
the exhaust gas recirculation assembly. air inlet pipe by pivoting it.
a Remove:
- the intermediate air pipe between the air filter unit
and the turbocharger,
- the turbocharger air inlet pipe.

135639
a Loosen the bolt (7) of the intermediate air pipe
between the air filter unit and the turbocharger on
the turbocharger air inlet pipe.

61A-62
HEATING
Air distribution unit: Removal - Refitting 61A
J95

M9R K9K
a Remove the intercooler air inlet pipe (see Intercoo-
ler air inlet pipe: Removal - Refitting) (12B, Turbo-
charging).

139564

a Remove the bolts (9) from the turbocharger air inlet


pipe.

138672
a Remove the nut (11) from the retaining bracket on
the « intermediate pipe - expansion valve » connec-
ting pipe.

139567

a Remove:

- the bolts (10) from the turbocharger air inlet pipe,

- the turbocharger air inlet pipe.

61A-63
HEATING
Air distribution unit: Removal - Refitting 61A
J95

H4J

139617
a Remove the clips (1 2) from the bulkhead heat
shield. 139616
a Remove:
WARNING
- the bulkhead upper heat shield bolts (13) ,
To prevent the surrounding components from
overheating, do not damage (tear, pierce, bend, - the bulkhead upper heat shield clips (14) .
etc.) a heat shield.
Any damaged heat shields must be replaced. WARNING
To prevent the surrounding components from
a Move the bulkhead heat shieldto one side. overheating, do not damage (tear, pierce, bend,
etc.) a heat shield.
Any damaged heat shields must be replaced.

a Remove the bulkhead upper heat shield.

61A-64
HEATING
Air distribution unit: Removal - Refitting 61A
J95

136487 141542
a Remove the bolts (15) from the expansion valve a Fit the (Ms. 583) on the heater matrix hoses (16) .
connecting pipe bracket.
a Disconnect the heater matrix hoses.
a Remove:
WARNING
- the dashboard (see Dashboard: Removal - Refit-
In order to avoid any refrigerant leaks, do not
ting) (57A, Interior equipment),
damage (deform, twist, etc.) the pipe.
- the dashboard cross member (see Dashboard
a Uncouple the connecting pipes from the expansion cross member: Removal - Refitting) (42A, Upper
valve. front structure).
a Remove the connecting pipes from the expansion
valve.
a Fit blanking plugs on the expansion valve and on the
connecting pipes.

61A-65
HEATING
Air distribution unit: Removal - Refitting 61A
J95
II - OPERATION FOR REMOVAL OF PART - heater resistor relays,
CONCERNED
- the heating resistor,
- the air mixing cable.

CLIMATE CONTROL
a Remove the following components from the distribu-
tion unit:
- the left-hand mixer motor,
- the right-hand mixer motor,
- the distribution motor,
- the cabin filter,
- the expansion valve,
- the recirculation motor,
- the air recirculation control cable,
139118
- the fan assembly,
a Disconnect the supply connector (17) from the distri-
bution unit. - the fan assembly control unit,
a Unclip the electrical wiring from the distribution unit. - the evaporator sensor,
a Separate the electrical wiring from the distribution - the heater matrix,
unit.
- heater resistor relays,
a Remove the distribution unit.
- the heating resistor.

Note:
To find the location of components (see 61A,
Heating, Heating: List and location of compo-
nents, page 61A-1) . REFITTING

I - REFITTING PREPARATION OPERATION


AIR CONDITIONING
a
a Remove the following components from the distribu-
tion unit: WARNING
- the air distribution cable, Do not remove the blanking plugs from each
component until the last moment.
- the cabin filter,
Also, do not remove the components from their
- the expansion valve, packaging until they are to be fitted to the vehi-
cle.
- the recirculation motor,
- the air recirculation control cable,
- the fan assembly, WARNING
To avoid any leaks, check that the seal and the
- the fan assembly control unit, pipe surface are in good condition. The seal and
- the evaporator sensor, the surface must be clean and scratch free.

- the heater matrix, a Remove the blanking plugs.

61A-66
HEATING
Air distribution unit: Removal - Refitting 61A
J95
II - REFITTING OPERATION FOR PART a Fit the wiring on the distribution unit.
CONCERNED
a Clip the wiring onto the distribution unit.

a Connect the supply connector of the distribution unit.


CLIMATE CONTROL
a Refit the following components onto the distribution
unit: III - FINAL OPERATION

- the left-hand mixer motor, a Refit:

- the right-hand mixer motor, - the dashboard cross member (see Dashboard
cross member: Removal - Refitting) (42A, Upper
- the distribution motor, front structure),
- the cabin filter, - the dashboard (see Dashboard: Removal - Refit-
- the expansion valve, ting) (57A, Interior equipment).

- the recirculation motor, a Connect the heater matrix hoses.


- the air recirculation control cable, a Remove the (Ms. 583) from the heater matrix hoses.
- the fan assembly, a Connect the connecting pipes to the expansion val-
- the fan assembly control unit, ve.

- the evaporator sensor, a Fit the heat shield to the bulkhead.

- the heater matrix,


H4J
- heater resistor relays,
a Refit the bulkhead upper heat shield.
- the heating resistor.

a Refit the retaining bracket on the « intermediate pipe


- expansion valve » connecting pipe.
AIR CONDITIONING
a Refit the following components onto the distribution
unit: K9K

- the air distribution cable, a Refit the intercooler air inlet pipe (see Intercooler
air inlet pipe: Removal - Refitting) (12B, Turbo-
- the cabin filter, charging).
- the expansion valve,
- the recirculation motor,
- the air recirculation control cable,
- the fan assembly, M9R

- the fan assembly control unit, a Refit:

- the evaporator sensor, - the turbocharger air inlet pipe,

- the heater matrix, - the turbocharger air inlet pipe bolts.


- heater resistor relays,
- the heating resistor,
- the air mixing cable.
K9K

a Refit:
a Refit the distribution unit. - the turbocharger air inlet pipe,

61A-67
HEATING
Air distribution unit: Removal - Refitting 61A
J95
- the turbocharger air inlet pipe bolts. a Fill up and bleed the cooling system (see Cooling
circuit: Draining - Refilling) (19A, Cooling).

Note:
A summary table gives the quantities of refrige-
F9Q
rant in the system according to the engine type
a Refit: (see 62A, Air conditioning, Air conditioning:
Parts and consumables for the repair work,
- the turbocharger air inlet pipe, page 62A-4) .
- the intermediate air pipe between the air filter unit
a Perform the following operations:
and the turbocharger on the turbocharger air inlet
pipe, - refill the refrigerant circuit using the refrigerant
charging station (see 62A, Air conditioning,
- the bolts from the turbocharger air inlet pipe, Coolant circuit Draining - Refilling, page 62A-9)
- the bolt from the intermediate pipe between the air ,
filter unit and the turbocharger on the turbocharger - check for leaks (see 62A, Air conditioning, Coo-
air inlet pipe, lant circuit check, page 62A-8) .
- the bolt for the intermediate air pipe between the air a Check that the air conditioning system is operating
filter unit and the turbocharger on the exhaust gas correctly (see 62A, Air conditioning, Air conditio-
recirculation assembly. ning: Check, page 62A-5) .

a Torque tighten the turbocharger air inlet pipe a Refit:


bolts (8 N.m). - the centre section of the scuttle panel grille (see
Scuttle panel grille: Removal - Refitting) (56A,
Exterior equipment),
- the scoop under the centre section of the scuttle
panel grille (see Scoop under scuttle panel
M9R grille: Removal - Refitting) (56A, Exterior equip-
ment),
a Refit:
- the engine cover.
- the lifting eye of the cylinder head,

- the bolts on the cylinder head lifting eye.

a Clip the wiring onto the cylinder head lifting eye.

F9Q

a Refit:

- the lifting eye of the cylinder head,

- the bolts on the cylinder head lifting eye.

a Refit the air filter unit air outlet pipe.

a Torque tighten the air filter box air outlet pipe


clips (6 N.m).

a Connect the battery (see Battery: Removal - Refit-


ting) (80A, Battery).

61A-68
HEATING
Heater matrix: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE

Essential special tooling

Ms. 583 Hose clamp pliers.

Tightening torquesm

dashboard cross mem- 21 N.m


ber reinforcement upper
bolts

dashboard cross mem- 21 N.m


ber reinforcement lower
bolts

clip of the air filter unit 5.5 N.m


air outlet pipe

REMOVAL
135796
I - OPERATION FOR REMOVAL OF PART a Remove the bolts (2) from the air inlet pipe on the
CONCERNED throttle valve.
a Switch off the ignition.
a Remove the engine style cover.

F4R

135707
137157
a Loosen the clip (1) of the air outlet pipe on the air fil-
a Disconnect the brake servo vacuum pipe (3) .
ter unit.

61A-69
HEATING
Heater matrix: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE

134643 135692
a Disconnect the connector from the turbocharging a Remove the lower bolts (5) from the dashboard
pressure regulation valve control solenoid valve. cross member reinforcement.
a Unclip the turbocharger pressure regulation valve
control solenoid valve at (4) .
a Remove the air outlet pipe from the air filter box.

a Fit the tool (Ms. 583) on the heater matrix hoses.


a Unclip the left-hand centre console trim.
a Remove:
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),
- the front left-hand footwell air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) .

135693
a Remove:
- the upper bolts (6) from the dashboard cross mem-
ber reinforcement,
- the dashboard cross member reinforcement.

61A-70
HEATING
Heater matrix: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART - the heater matrix trim.
CONCERNED

135694

a Remove the clips (7) from the heater matrix rigid pi-
pes.

WARNING 135696

Prepare for the flow of fluid, and protect the sur- a Take the heater matrix out of its housing.
rounding components.
a Remove the heater matrix.
a Put a protective cover on the floor carpet.
a Position a container to collect the coolant under the REFITTING
rigid pipes.
a Move the heater matrix rigid pipes aside. I - REFITTING PREPARATION OPERATION
a Remove the seals from the heater matrix rigid pipes. a parts always to be replaced: heater matrix coo-
lant pipe seal (30,02,01,46)
a Always replace the heater matrix rigid pipe clips.

WARNING
To avoid any leaks, check that the pipe surface is
sound before positioning the new seal. The sur-
face must be clean and scratch free.

II - REFITTING OPERATION FOR PART


CONCERNED
a Refit:

- the heater matrix in its housing,


- the heater matrix trim.
a Fit:

- new seals on the heater matrix rigid pipes,


135695 - the heater matrix rigid pipes on the heater matrix.
a Remove:
a Refit new clips on the rigid pipes of the heater ma-
- the heater matrix trim bolts (8) , trix.

61A-71
HEATING
Heater matrix: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE
a Remove: a Refit the engine style cover.
- the container for recovering coolant under the rigid
pipes,
- the protective cover on the floor carpet.

III - FINAL OPERATION


a Refit:
- the dashboard cross member reinforcement,
- the upper bolts on the dashboard cross member
reinforcement,
- the lower bolts on the dashboard cross member
reinforcement.
a Tighten to torque:
- the dashboard cross member reinforcement
upper bolts (21 N.m),
- the dashboard cross member reinforcement
lower bolts (21 N.m).
a Refit:
- the front left-hand footwell air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,
- the instrument panel lower trim (see Lower sec-
tion of dashboard trim: Removal - Refitting)
(57A, Interior equipment).
a Clip on the left-hand centre console trim.
a Remove the tool (Ms. 583) from the heater matrix
hoses.

F4R
a Refit:
- the air outlet pipe of the air filter unit,
- the air inlet pipe to the throttle valve.
a Clip on the turbocharging pressure regulation valve
control solenoid valve.
a Connect:
- the connector on the turbocharging pressure regu-
lation valve control solenoid valve,
- the vacuum pipe from the brake servo.
a Torque tighten the clip of the air filter unit air out-
let pipe (5.5 N.m).

a Fill up and bleed the cooling system (see Cooling


circuit: Draining - Refilling) (19A, Cooling).

61A-72
HEATING
Heater matrix: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE

Essential special tooling

Ms. 583 Hose clamp pliers.

Tightening torquesm

clip of the air filter unit 5.5 N.m


air outlet pipe

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Switch off the ignition.
a Remove the front engine cover.

F4R
135796
a Loosen the bolts (2) of the air inlet pipe on the thrott-
le valve.

135707
a Loosen the clip (1) of the air outlet pipe on the air fil-
ter unit.

137157
a Disconnect the brake servo vacuum pipe (3) .

61A-73
HEATING
Heater matrix: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART
CONCERNED

135694

a Remove the clips (5) from the heater matrix rigid pi-
pes.
134643
a Disconnect the connector from the turbocharging WARNING
pressure regulation valve control solenoid valve. Prepare for the flow of fluid, and protect the sur-
a Unclip the turbocharger pressure regulation valve rounding components.
control solenoid valve at (4) .
a Put a protective cover on the floor carpet.
a Remove the air outlet pipe from the air filter box.
a Position a container to collect the coolant under the
rigid pipes.
a Move the heater matrix rigid pipes aside.
a Fit the tool (Ms. 583) on the heater matrix hoses.
a Remove the seals from the heater matrix rigid pipes
a Unclip the centre console left-hand trim.
a Remove:
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 57A, Interior equipment),
- the front left-hand footwell air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) .

135695

a Remove:
- the heater matrix trim bolts (6) ,

61A-74
HEATING
Heater matrix: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE
- the heater matrix trim. a Remove:
- the container for recovering coolant under the rigid
pipes,
- the protective cover on the floor carpet.

III - FINAL OPERATION


a Refit:
- the front left-hand footwell air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,
- the glovebox (see Glovebox: Removal - Refit-
ting) (57A, Interior equipment).
a Clip on the left-hand centre console trim.
a Remove the tool (Ms. 583) from the heater matrix
hoses.

F4R
135696 a Refit:
a Take the heater matrix out of its housing. - the air outlet pipe of the air filter unit,
a Remove the heater matrix. - the air inlet pipe to the throttle valve.
a Clip on the turbocharging pressure regulation valve
REFITTING control solenoid valve.
a Connect:
I - REFITTING PREPARATION OPERATION - the connector on the turbocharging pressure regu-
lation valve control solenoid valve,
a parts always to be replaced: heater matrix coo-
lant pipe seal (30,02,01,46) - the vacuum pipe from the brake servo.
a Always replace the heater matrix rigid pipe clips. a Torque tighten the clip of the air filter unit air out-
let pipe (5.5 N.m).

WARNING
To avoid any leaks, check that the pipe surface is
sound before positioning the new seal. The sur- a Fill up and bleed the cooling system (see Cooling
face must be clean and scratch free. circuit: Draining - Refilling) (19A, Cooling).
a Refit the engine cover.
II - REFITTING OPERATION FOR PART
CONCERNED
a Refit:

- the heater matrix in its housing,


- the heater matrix trim.
a Fit:

- new seals on the heater matrix rigid pipes,


- the heater matrix rigid pipes on the heater matrix.
a Refit new clips on the rigid pipes of the heater ma-
trix.

61A-75
HEATING
Heater matrix: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE

Essential special tooling

Ms. 583 Hose clamp pliers.

Tightening torquesm

upper nuts on the dash- 21 N.m


board cross member
reinforcement

lower bolts on the dash- 21 N.m


board cross member
reinforcement

air filter box air outlet 6 N.m


pipe clips

REMOVAL
141542
I - REMOVAL PREPARATION OPERATION a Fit the (Ms. 583) on the heater matrix hoses (1) .
a Switch off the ignition. a Remove:
a Remove: - the dashboard lower trim (see Lower section of
- the engine cover, dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),
- the centre section of the scuttle panel grille (see
Scuttle panel grille: Removal - Refitting) (56A, - the front left-hand footwell air distribution duct (see
Exterior equipment), 61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) .
- the scoop under the centre section of the scuttle
panel grille (see Scoop under scuttle panel a Unclip the left-hand panel from the centre console.
grille: Removal - Refitting) (56A, Exterior equip-
ment).
FR AND RR PROX RADAR
a Undo the clips on the air outlet pipe of the air filter
a Disconnect the connector from the parking distance
unit.
control buzzer.
a Remove the air outlet pipe from the air filter box.

61A-76
HEATING
Heater matrix: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART
CONCERNED

135694

a Remove the clips (7) from the heater matrix rigid pi-
pes.
138640

a Unclip the wiring from the dashboard cross member WARNING


reinforcement at (2) . Prepare for the flow of fluid, and protect the sur-
rounding components.
a Remove the lower bolts (3) from the dashboard
cross member reinforcement. a Put a protective cover on the floor carpet.
a Position a container to collect the coolant under the
rigid pipes.
a Move the heater matrix rigid pipes aside.
a Remove the seals from the heater matrix rigid pipes.

138639

a Remove:

- the upper nuts (4) from the dashboard cross mem-


ber reinforcement,
135695
- the brake pedal impacter (5) , a Remove:
- the dashboard cross member reinforcement. - the heater matrix trim bolts (8) ,

61A-77
HEATING
Heater matrix: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE
- the heater matrix trim. a Remove:
- the container for recovering coolant under the rigid
pipes,
- the protective cover on the floor carpet.

III - FINAL OPERATION


a Refit:
- the dashboard cross member reinforcement,
- the brake pedal impacter,
a Tighten to torque:
- the upper nuts on the dashboard cross member
reinforcement (21 N.m),
- the lower bolts on the dashboard cross member
reinforcement (21 N.m).
a Clip on the dashboard cross member reinforcement
wiring.

135696
FR AND RR PROX RADAR
a Take the heater matrix out of its housing.
a Connect the parking distance control buzzer con-
a Remove the heater matrix. nector.

REFITTING
a Refit:
I - REFITTING PREPARATION OPERATION - the front left-hand footwell air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
a parts always to be replaced: heater matrix coo-
moval - Refitting, page 61A-142) ,
lant pipe seal (30,02,01,46).
- the dashboard lower trim (see Lower section of
a Always replace the heater matrix rigid pipe clips. dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment).

WARNING a Clip on the left-hand panel of the centre console.


To avoid any leaks, check that the seal and the a Remove the (Ms. 583) from the heater matrix hoses.
pipe surface are in good condition. The seal and
the surface must be clean and scratch free. a Refit the air outlet pipe onto the air filter unit.
a Torque tighten the air filter box air outlet pipe
clips (6 N.m).
II - REFITTING OPERATION FOR PART
CONCERNED a Fill up and bleed the cooling system (see Cooling
circuit: Draining - Refilling) (19A, Cooling).
a Refit:
a Refit:
- the heater matrix in its housing, - the scoop under the centre section of the scuttle
- the heater matrix trim. panel grille (see Scoop under scuttle panel
grille: Removal - Refitting) (56A, Exterior equip-
a Fit: ment),

- new seals on the heater matrix rigid pipes, - the centre section of the scuttle panel grille (see
Scuttle panel grille: Removal - Refitting) (56A,
- the heater matrix rigid pipes on the heater matrix. Exterior equipment),
a Refit new clips on the heater matrix rigid pipes. - the engine cover.

61A-78
HEATING
Heater matrix: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE

61A-79
HEATING
Heater matrix: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE
a Remove:
Essential special tooling
- the glovebox (see Glovebox: Removal - Refit-
Ms. 583 Hose clamp pliers. ting) ( 57A, Interior equipment),
- the front left-hand footwell air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
Tightening torquesm moval - Refitting, page 61A-142) .

air filter unit air outlet 6 N.m


pipe clips II - OPERATION FOR REMOVAL OF PART
CONCERNED

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Switch off the ignition.
a Remove:

- the engine cover,


- the centre section of the scuttle panel grille (see
Scuttle panel grille: Removal - Refitting) (56A,
Exterior equipment),
- the scoop under the centre section of the scuttle
panel grille (see Scoop under scuttle panel 135694
grille: Removal - Refitting) (56A, Exterior equip- a Remove the clips (2) from the heater matrix rigid pi-
ment). pes.
a Undo the clips on the air outlet pipe of the air filter
unit. WARNING
a Remove the air outlet pipe from the air filter box. Prepare for the flow of fluid, and protect the sur-
rounding components.

a Put a protective cover on the floor carpet.


a Position a container to collect the coolant under the
rigid pipes.
a Move the heater matrix rigid pipes aside.
a Remove the seals from the heater matrix rigid pipes.

141542

a Fit the (Ms. 583) on the heater matrix hoses (1) .


a Unclip the left panel from the centre console.

61A-80
HEATING
Heater matrix: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE

REFITTING

I - REMOVAL PREPARATION OPERATION

a parts always to be replaced: heater matrix coo-


lant pipe seal (30,02,01,46).

a Always replace the heater matrix rigid pipe clips.

WARNING
To avoid any leaks, check that the seal and the
pipe surface are in good condition. The seal and
the surface must be clean and scratch free.

II - REFITTING OPERATION FOR PART


CONCERNED

a Refit:

135695 - the heater matrix in its housing,


a Remove:
- the heater matrix trim.
- the heater matrix trim bolts (3) ,
a Fit:
- the heater matrix trim.
- new seals on the heater matrix rigid pipes,

- the heater matrix rigid pipes on the heater matrix.

a Refit new clips on the heater matrix rigid pipes.

a Remove:

- the container for recovering coolant under the rigid


pipes,

- the protective cover on the floor carpet.

III - FINAL OPERATION

a Refit:

- the front left-hand footwell air distribution duct (see


61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,

- the glovebox (see Glovebox: Removal - Refit-


ting) (57A, Interior equipment).
135696
a Take the heater matrix out of its housing. a Clip on the left-hand panel of the centre console.

a Remove the heater matrix. a Remove the (Ms. 583) from the heater matrix hoses.

a Refit the air outlet pipe onto the air filter unit.

a Torque tighten the air filter unit air outlet pipe


clips (6 N.m).

a Fill up and bleed the cooling system (see Cooling


circuit: Draining - Refilling) (19A, Cooling).

61A-81
HEATING
Heater matrix: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE
a Refit:
- the scoop under the centre section of the scuttle
panel grille (see Scoop under scuttle panel
grille: Removal - Refitting) (56A, Exterior equip-
ment),
- the centre section of the scuttle panel grille (see
Scuttle panel grille: Removal - Refitting) (56A,
Exterior equipment),
- the engine cover.

61A-82
HEATING
Fan assembly: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE

Essential special tooling

Ms. 1909 Tool for removal - refitting of


Valéo fan assembly

REMOVAL

I - REMOVAL PREPARATION OPERATION

a Move the seat as far back as possible.

a Switch off the ignition.

a Remove:

- the glovebox (see Glovebox: Removal - Refit-


ting) ( 57A, Interior equipment),

- the front right-hand A-pillar air distribution duct (see


61A, Heating, A-pillar air distribution duct: Re- 137641
moval - Refitting, page 61A-142) , a Disconnect the recirculation motor connector.

- the cabin filter (see 61A, Heating, Cabin filter: Re- a Mark the routing of the recirculation motor wiring.
moval - Refitting, page 61A-19) , a Separate the wiring from the recirculation motor.

- the front side air distribution duct (see 61A, Hea- a Remove:
ting, Front side air distribution duct: Removal - - the bolts (2) from the air recirculation duct,
Refitting, page 61A-132) .
- the air recirculation duct.
a Remove the side air distribution duct (see 61A, Hea-
ting, Front side air distribution duct: Removal - II - OPERATION FOR REMOVAL OF PART
Refitting, page 61A-132) .
CONCERNED
a Disconnect the connector from the passenger com-
partment fan assembly motor passing through the
cabin filter housing.

137028

a Unclip the recirculation control cable.

61A-83
HEATING
Fan assembly: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE

137676 137678
a Position the turbine of the passenger compartment a Push and turn the tool (Ms. 1909) anticlockwise to
fan assembly in such a way as to align the holes (3) unlock the passenger compartment fan assembly.
required to fit the tool (Ms. 1909).

137679
137677 a Remove the fan assembly from its housing while ta-
a Position the tool (Ms. 1909) and turn it slightly from king care not to damage the turbine.
left to right so that the 3 rods of tool MS 1909 coinci-
de with the 3 holes of the turbine.
Note:
To avoid making the fan assembly motor unsta-
ble, position the assembly horizontally while pro-
tecting it from any impact.

61A-84
HEATING
Fan assembly: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED

137681
a Fit the tool (Ms. 1909) (4) on the passenger com- 137683
partment fan assembly. a Check that the clip is correctly positioned (5) in rela-
tion to the turbine of the passenger compartment fan
assembly.

137682
a Align the clip of the tool (Ms. 1909) along the shaft.
137686
a Refit the fan assembly in its housing by turning the
tool 45˚.

61A-85
HEATING
Fan assembly: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE

137677

a Push the fan assembly until it is fully inserted in its


housing.

a Turn the tool (Ms. 1909) clockwise to lock the pas-


senger compartment fan assembly.
a Remove the (Ms. 1909).

a Connect the passenger compartment fan assembly


connector.

II - FINAL OPERATION

a Refit the air recirculation duct.


a Fit the recirculation motor wiring.
a Connect the recirculation motor connector.

a Clip on the recirculation control cable.


a Refit the side air distribution duct (see 61A, Heating,
Front side air distribution duct: Removal - Refit-
ting, page 61A-132) .

a Refit:
- the front side air distribution duct (see 61A, Hea-
ting, Front side air distribution duct: Removal -
Refitting, page 61A-132) ,

- the cabin filter (see 61A, Heating, Cabin filter: Re-


moval - Refitting, page 61A-19) ,
- the front right-hand A-pillar air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,
- the glovebox (see Glovebox: Removal - Refit-
ting) (57A, Interior equipment).

61A-86
HEATING
Fan assembly: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE

Essential special tooling

Ms. 1909 Tool for removal - refitting of


Valéo fan assembly

Tightening torquesm

steering column bolts 21 N.m

REMOVAL

I - REMOVAL PREPARATION OPERATION

a Unclip the right-hand centre console trim.

a Remove:

- the dashboard lower trim (see Lower section of 134365


dashboard trim: Removal - Refitting) (57A, Inte- a Disconnect the steering column connectors (2) .
rior equipment),
a Fit a block of approximately 440 mm between the
- the cabin filter (see 61A, Heating, Cabin filter: Re- steering column and the floor.
moval - Refitting, page 61A-19) .

134366
a Remove the nuts (3) from the steering column.
136716
a Remove the block between the steering column and
a Remove: the floor.

- the cover bolts (1) under the steering wheel,

- the cowlings under the steering wheel.

a Disconnect the steering column switch assembly


connectors.

61A-87
HEATING
Fan assembly: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE

137636 137641
a Lower the steering column in the footwell. a Disconnect the recirculation motor connector.
a Mark the routing of the recirculation motor wiring.
Note: a Separate the wiring from the recirculation motor.
Ver tically lower the steering column and do not a Remove:
apply pressure to the universal joints.
- the bolts (6) from the air recirculation duct,
a Check that the cross piece (4) does not leave the
- the air recirculation duct.
bearing.

II - OPERATION FOR REMOVAL OF PART


CONCERNED
a Disconnect the passenger compartment fan assem-
bly motor connector passing through the cabin filter
housing.

137028
a Unclip the recirculation control cable (5) .

61A-88
HEATING
Fan assembly: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE

137676 137678
a Position the turbine of the passenger compartment
a Push and turn the tool (Ms. 1909) anticlockwise to
fan assembly in such a way as to align the holes (7)
unlock the passenger compartment fan assembly.
required to fit the tool (Ms. 1909).

137677 137679
a Position the tool (Ms. 1909) and turn it slightly from
a Remove the passenger compartment fan assembly
left to right so that the 3 rods of the tool (Ms. 1909)
from its housing while taking care not to damage the
coincide with the 3 holes of the turbine.
turbine.

Note:
To avoid making the passenger compartment fan
assembly motor unstable, position the assembly
horizontally while protecting it from any impact.

61A-89
HEATING
Fan assembly: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED

137681
a Fit the tool (Ms. 1909) (8) on the passenger com- 137683
partment fan assembly. a Check that the clip (9) is correctly positioned in rela-
tion to the turbine of the passenger compartment fan
assembly.

137682
a Align the clip of the tool (Ms. 1909) along the shaft.
137686
a Refit the passenger compartment fan assembly in its
housing by turning the tool 45˚.

61A-90
HEATING
Fan assembly: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE
- the steering column switch assembly connectors.
a Refit:
- the cowlings under the steering wheel,
- the cabin filter (see 61A, Heating, Cabin filter: Re-
moval - Refitting, page 61A-19) ,
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment).
a Clip on the right-hand centre console trim.

137687
a Push the passenger compartment fan assembly un-
til it is fully inserted in its housing.
a Turn the tool (Ms. 1909) clockwise to lock the pas-
senger compartment fan assembly.
a Remove the (Ms. 1909).
a Connect the passenger compartment fan assembly
connector.

II - FINAL OPERATION
a Refit the air recirculation duct.
a Fit the recirculation motor wiring.
a Connect the recirculation motor connector.
a Clip on the recirculation control cable.
a Check that the recirculation control can move along
its whole stroke.
a Fit a block of approximately 440 mm between the
steering column and the floor.
a Refit the steering column.
a Refit the steering column bolts.
a Torque tighten the steering column bolts (21 N.m).
a Remove the block between the steering column and
the floor.
a Check the condition of the steering column bearings.
a Connect:
- the electric steering column lock connector,
- the steering column connectors,

61A-91
HEATING
Fan assembly: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE

Essential special tooling

Ms. 1909 Tool for removal - refitting of


Valéo fan assembly

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Remove the glovebox (see Glovebox: Removal -
Refitting) (57A, Interior equipment).

RADIO NO 07
a Remove:
- the receiver (see Tuner-amplifier: Removal - Re-
fitting) (86A, Radio),
- the bolts from the receiver mounting,
- the receiver mounting. 137028
a Unclip the air recirculation control cable.

RADIO NO 04 or RADIO NO 05
a Remove:
- the offset multimedia socket computer (see Offset
multimedia socket computer: Removal - Refit-
ting) (86A, Radio),
- the offset multimedia socket computer mounting
bolts,
- the offset multimedia socket computer mounting.

a Remove the cabin filter (see 61A, Heating, Cabin


filter: Removal - Refitting, page 61A-19) .

138646
a Mark the routing of the air recirculation motor wiring
(1) .

61A-92
HEATING
Fan assembly: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE

137641 137676
a Remove: a Position the turbine of the passenger compartment
fan assembly in such a way as to align the holes (4)
- the bolts (2) from the air recirculation duct,
required to fit the tool (Ms. 1909).
- the air recirculation duct.
a Separate the wiring from the air recirculation motor.

137677
a Position the (Ms. 1909) and turn it slightly from left to
138647 right so that the three rods of the (Ms. 1909) coinci-
de with the three holes of the turbine.
a Disconnect the air recirculation motor connector (3) .

II - OPERATION FOR REMOVAL OF PART


CONCERNED
a Disconnect the connector from the passenger com-
partment fan assembly motor via the passenger
compartment filter housing.

61A-93
HEATING
Fan assembly: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED

137681
137678 a Fit the tool (Ms. 1909) (5) on the passenger com-
partment fan assembly.
a Push and turn the tool (Ms. 1909) anticlockwise to
unlock the passenger compartment fan assembly.

137682
a Align the clip of the tool (Ms. 1909) along the shaft.
137679

a Remove the passenger compartment fan assembly


from its housing while taking care not to damage the
turbine.

Note:
To avoid making the passenger compartment fan
assembly motor unstable, position the assembly
horizontally and protect it from impact.

61A-94
HEATING
Fan assembly: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE

137683 137687
a Check that the clip is correctly positioned (6) in rela- a Push the passenger compartment fan assembly un-
tion to the turbine of the passenger compartment fan til it is fully inserted in its housing.
assembly.
a Turn the tool (Ms. 1909) clockwise to lock the pas-
senger compartment fan assembly.

a Remove the (Ms. 1909).

a Connect the passenger compartment fan assembly


connector.

II - FINAL OPERATION

a Connect the air recirculation motor connector.

a Refit the air recirculation duct.

a Clip on the air recirculation control cable.

a Check that the recirculation control can move along


its whole stroke.

a Refit the cabin filter (see 61A, Heating, Cabin filter:


Removal - Refitting, page 61A-19) .

137686
RADIO NO 04 or RADIO NO 05
a Refit the passenger compartment fan assembly in its
housing by turning the tool 45˚. a Refit:

- the offset multimedia socket computer mounting,

- the offset multimedia socket computer (see Offset


multimedia socket computer: Removal - Refit-
ting) (86A, Radio).

61A-95
HEATING
Fan assembly: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE

RADIO NO 07
a Refit:
- the receiver mounting,
- the receiver (see Tuner-amplifier: Removal - Re-
fitting) (86A, Radio).

a Refit the glovebox (see Glovebox: Removal - Refit-


ting) (57A, Interior equipment).

61A-96
HEATING
Fan assembly: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE

Essential special tooling

Ms. 1909 Tool for removal - refitting of


Valéo fan assembly

Tightening torquesm

steering column nuts 21 N.m

REMOVAL

I - REMOVAL PREPARATION OPERATION

a Unclip the right-hand panel from the centre console.

a Remove:

- the dashboard lower trim (see Lower section of 134365


dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment), a Disconnect:

- the passenger compartment filter (see 61A, Hea- - the steering column connectors (2) ,
ting, Cabin filter: Removal - Refitting, page 61A-
19) . - the electric steering column lock connector.

a Fit a block of approximately 440 mm between the


steering column and the floor.

141576

a Remove:

- the cover bolts (1) under the steering wheel, 137655

- the cowlings under the steering wheel. a Remove the nuts (3) from the steering column.

a Disconnect the steering column switch assembly a Remove the block between the steering column and
connectors. the floor.

61A-97
HEATING
Fan assembly: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE

138654 138646
a Lower the steering column in the footwell. a Mark the routing of the air recirculation motor wiring
(5) .

Note:
Ver tically lower the steering column and do not
apply pressure to the universal joints.

a Check that the cross piece (4) does not leave the
bearing.

137641
a Remove:
- the bolts (6) from the air recirculation duct,
- the air recirculation duct.
a Separate the wiring from the air recirculation motor.
137028
a Unclip the air recirculation control cable.

61A-98
HEATING
Fan assembly: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE

138647 137677
a Position the (Ms. 1909) and turn it slightly from left to
a Disconnect the air recirculation motor connector (7) .
right so that the three rods of the (Ms. 1909) coinci-
de with the three holes of the turbine.
II - OPERATION FOR REMOVAL OF PART
CONCERNED

a Disconnect the connector from the passenger com-


partment fan assembly motor via the passenger
compartment filter housing.

137678
a Push and turn the tool (Ms. 1909) anticlockwise to
unlock the passenger compartment fan assembly.

137676

a Position the turbine of the passenger compartment


fan assembly in such a way as to align the holes (8)
required to fit the tool (Ms. 1909).

61A-99
HEATING
Fan assembly: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE

137679 137682

a Remove the passenger compartment fan assembly a Align the clip of the tool (Ms. 1909) along the shaft.
from its housing while taking care not to damage the
turbine.

Note:
To avoid making the passenger compartment fan
assembly motor unstable, position the assembly
horizontally and protect it from impact.

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED

137683
a Check that the clip is correctly positioned (10) in re-
lation to the turbine of the passenger compartment
fan assembly.

137681

a Fit the tool (Ms. 1909) on the passenger compart-


ment fan assembly.

61A-100
HEATING
Fan assembly: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE
II - FINAL OPERATION
a Position the air recirculation duct.
a Fit the air recirculation motor wiring.
a Connect the air recirculation motor connector.
a Refit the air recirculation duct.
a Clip on the recirculation control cable.
a Check that the recirculation control can move along
its whole stroke.
a Fit a block of approximately 440 mm between the
steering column and the floor.
a Refit the steering column.
a Torque tighten the steering column nuts (21 N.m).
a Remove the block between the steering column and
the floor.
a Check the condition of the steering column bearings.
137686 a Connect:

a Refit the passenger compartment fan assembly in its - the electric steering column lock connector,
housing by turning the tool 45˚. - the steering column connectors,
- the steering column switch assembly connectors.
a Refit:
- the cowlings under the steering wheel,
- the cabin filter (see 61A, Heating, Cabin filter: Re-
moval - Refitting, page 61A-19) ,
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment).
a Clip on the right-hand panel of the centre console.

137687

a Push the passenger compartment fan assembly un-


til it is fully inserted in its housing.

a Turn the tool (Ms. 1909) clockwise to lock the pas-


senger compartment fan assembly.

a Remove the (Ms. 1909).

a Connect the passenger compartment fan assembly


connector.

61A-101
HEATING
Heating resistor relays: Removal - Refitting 61A
B95 or D95 or E95 or K95

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Switch off the ignition.

137019
136384
a Unclip the left-hand centre console trim.
a Unclip the cover from the heating resistor relay unit
II - OPERATION FOR REMOVAL OF PART at (2) .
CONCERNED

136383
137635
a Unclip the heating resistor relay unit from the distri- a Remove the heating resistor relays (3) .
bution unit at (1) .
a Separate the heating resistor relay unit from the dis- REFITTING
tribution unit.

I - REFITTING OPERATION FOR PART


CONCERNED

a Refit the heating resistor relays.

61A-102
HEATING
Heating resistor relays: Removal - Refitting 61A
B95 or D95 or E95 or K95
a Clip:
- the cover of the heating resistor relay unit,
- the heating resistor relay unit onto the distribution
unit.

II - FINAL OPERATION
a Clip on the left-hand centre console trim.

61A-103
HEATING
Heating resistor relays: Removal - Refitting 61A
J95

REMOVAL II - OPERATION FOR REMOVAL OF PART


CONCERNED
a

Note:
There are 2 possible fittings for the heating resis-
tor relays:
- 1000 Watt resistor : 1 relay unit located on the
left of the centre console (see 61A, Heating,
Heating: List and location of components,
page 61A-1) ,
- 1800 Watt resistor : 2 relay units located on
the right and left of the centre console (see 61A,
Heating, Heating: List and location of compo-
nents, page 61A-1) .

I - REMOVAL PREPARATION OPERATION

138894
a Unclip the heating resistor relay unit from the distri-
bution unit.
a Separate the heating resistor relay unit from the dis-
tribution unit.

138642
a Unclip the left-hand or right-hand panel (1) of the
centre console.

136384
a Unclip the cover (2) from the heating resistor relay
unit.

61A-104
HEATING
Heating resistor relays: Removal - Refitting 61A
J95

136383
a Remove the heating resistor relays (3) .

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED
a Refit the heating resistor relays.
a Clip:
- the cover of the heating resistor relay unit,
- the heating resistor relay unit onto the distribution
unit.

II - FINAL OPERATION
a Clip on the left-hand or right-hand panel of the cen-
tre console.

61A-105
HEATING
Heating resistor unit: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE

Tightening torquesm

dashboard cross mem- 21 N.m


ber reinforcement upper
bolts

dashboard cross mem- 21 N.m


ber reinforcement lower
bolts

REMOVAL

I - OPERATION FOR REMOVAL OF PART


CONCERNED

a Switch off the ignition.

135692
a Remove the lower bolts (1) from the dashboard
cross member reinforcement.

137019

a Unclip the centre console left-hand trim.

a Remove:

- the instrument panel lower trim (see Lower sec-


tion of dashboard trim: Removal - Refitting)
(57A, Interior equipment),

- the front left-hand footwell air distribution duct (see


61A, Heating, A-pillar air distribution duct: Re-
135693
moval - Refitting, page 61A-142) .
a Remove:
- the upper bolts (2) from the dashboard cross mem-
FR AND RR PROX RADAR
ber reinforcement,
a Disconnect the connector from the parking distance - the dashboard cross member reinforcement.
control buzzer.

a Unclip the wiring from the dashboard cross member


reinforcement.

61A-106
HEATING
Heating resistor unit: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART REFITTING
CONCERNED

I - REFITTING OPERATION FOR PART


CONCERNED
a Refit the heating resistor.

II - FINAL OPERATION
a Refit:
- the dashboard cross member reinforcement,
- the upper bolts on the dashboard cross member
reinforcement,
- the lower bolts on the dashboard cross member
reinforcement.
a Tighten to torque:
- the dashboard cross member reinforcement
upper bolts (21 N.m),
- the dashboard cross member reinforcement
lower bolts (21 N.m).
136380
a Unclip the wiring from the dashboard cross member
a Disconnect the connector (3) from the heating resis- reinforcement.
tor.

FR AND RR PROX RADAR


a Connect the parking distance control buzzer con-
nector.

a Refit:
- the front left-hand footwell air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,
- the instrument panel lower trim (see Lower sec-
tion of dashboard trim: Removal - Refitting)
(57A, Interior equipment).
a Clip on the centre console left-hand trim.

136381
a Remove:
- the heating resistor bolts (4) ,
- the heating resistor.

61A-107
HEATING
Heating resistor unit: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Switch off the ignition.
a Unclip the centre console left-hand trim.
a Remove:
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 57A, Interior equipment),
- the front footwell air distribution duct on the left-
hand side (see 61A, Heating, A-pillar air distribu-
tion duct: Removal - Refitting, page 61A-142) .

II - OPERATION FOR REMOVAL OF PART


CONCERNED

136381

a Remove the bolts (2) from the heating resistor.

136380
a Disconnect the connector (1) from the heating resis-
tor.

136382

a Take the heating resistor out of its housing.


a Remove the heating resistor.

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED
a Refit the heating resistor.
a Connect the heating resistor connector.

61A-108
HEATING
Heating resistor unit: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE
II - FINAL OPERATION
a Refit:
- the front footwell air distribution duct on the left-
hand side (see 61A, Heating, A-pillar air distribu-
tion duct: Removal - Refitting, page 61A-142) ,
- the glovebox (see Glovebox: Removal - Refit-
ting) (57A, Interior equipment).
a Clip on the centre console left-hand trim.

61A-109
HEATING
Heating resistor unit: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Tightening torquesm

nuts on the heating 8 N.m 1 - First fitting


resistor terminals

Note:
There are two possible fittings for the heating resis-
tors:
- a 1000 Watt fitting,
- an 1800 Watt fitting for "extreme cold" climates.

REMOVAL

I - REMOVAL PREPARATION OPERATION

1 - Operation common to both fittings


a Unclip the left-hand panel from the centre console.
a Remove the glovebox (see Glovebox: Removal -
Refitting) (57A, Interior equipment). 136380
a Disconnect the connector (1) from the heating resis-
2 - Second fitting for "extreme cold" climates tor.

a Disconnect the battery (see Battery : Removal -


Refitting) (80A, Battery).

136381
a Remove the bolts (2) from the heating resistor.

61A-110
HEATING
Heating resistor unit: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE

136382 141540
a Unclip the heating resistor terminal strip (5) by pres-
a Take the heating resistor out of its housing.
sing on the clips (6) .
a Remove the heating resistor. a Remove the terminal strip from the heating resistor.

2 - Second fitting

a Mark the terminal fittings on the heating resistor.

141539
a Remove the bolts (7) from the heating resistor.

141538

a Remove the nuts (3) from the heating resistor termi-


nals.

a Remove the terminal (4) from the heating resistor.

61A-111
HEATING
Heating resistor unit: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE
2 - Second fitting for "extreme cold" climates
a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).

141541
a Take the heating resistor out of its housing.
a Remove the heating resistor.

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED

1 - First fitting
a Refit the heating resistor.
a Connect the heating resistor connector.

2 - Second fitting
a Refit the heating resistor.
a Fit:
- the terminal strip on the heating resistor,
- the terminal on the heating resistor.
a Refit the nuts on the heating resistor terminals.
a Torque tighten the nuts on the heating resistor
terminals (8 N.m).

II - FINAL OPERATION

1 - Operation common to both fittings


a Refit the glovebox (see Glovebox: Removal - Refit-
ting) (57A, Interior equipment).
a Clip on the left-hand panel of the centre console.

61A-112
HEATING
Heating resistor unit: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE

Tightening torquesm FR AND RR PROX RADAR


a Disconnect the connector from the parking distance
nuts on the heating 8 N.m
control buzzer.
resistor terminals

upper nuts on the dash- 21 N.m


board cross member
reinforcement

lower bolts on the dash- 21 N.m


board cross member
reinforcement

Note:
There are two possible fittings for the heating resis-
tors:
- a 1000 Watt fitting,
- an 1800 Watt fitting for "extreme cold" climates.

REMOVAL

I - REMOVAL PREPARATION OPERATION

138640
1 - Operation common to both fittings
a Unclip the wiring from the dashboard cross member
reinforcement at (2) .
a Remove the lower bolts (3) from the dashboard
cross member reinforcement.

138642
a Unclip the left-hand panel (1) from the centre conso-
le.
a Remove the dashboard lower trim (see Lower sec-
tion of dashboard trim: Removal - Refitting)
(57A, Interior equipment).

61A-113
HEATING
Heating resistor unit: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART
CONCERNED

1 - First fitting

138639
a Remove:
- the upper nuts (4) from the dashboard cross mem-
ber reinforcement,
136380
- the brake pedal impactor (5) ,
a Disconnect the connector (6) from the heating resis-
- the dashboard cross member reinforcement. tor.

2 - Second fitting for "extreme cold" climates


a Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).

136381
a Remove the bolts (7) from the heating resistor.

61A-114
HEATING
Heating resistor unit: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE

136382 141540
a Unclip the heating resistor terminal strip (10) by
a Take the heating resistor out of its housing.
pressing on the clips (11) .
a Remove the heating resistor. a Remove the terminal strip from the heating resistor.

2 - Second fitting

a Mark the terminal fittings on the heating resistor.

141539
a Remove the bolts (12) from the heating resistor.

141538

a Remove the nuts (8) from the heating resistor termi-


nals.

a Remove the terminal (9) from the heating resistor.

61A-115
HEATING
Heating resistor unit: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE
a Tighten to torque:
- the upper nuts on the dashboard cross member
reinforcement (21 N.m),
- the lower bolts on the dashboard cross member
reinforcement (21 N.m).
a Clip on the dashboard cross member reinforcement
wiring.

FR AND RR PROX RADAR


a Connect the parking distance control buzzer con-
nector.

a Refit the dashboard lower trim (see Lower section


of dashboard trim: Removal - Refitting) (57A, In-
terior equipment).
a Clip on the left-hand panel of the centre console.
141541

a Take the heating resistor out of its housing. 2 - Second fitting for "extreme cold" climates
a Remove the heating resistor. a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).
REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED

1 - First fitting

a Refit the heating resistor.

a Connect the heating resistor connector.

2 - Second fitting

a Refit the heating resistor.

a Fit:
- the terminal strip on the heating resistor,

- the terminal on the heating resistor.

a Refit the nuts on the heating resistor terminals.

a Torque tighten the nuts on the heating resistor


terminals (8 N.m).

II - FINAL OPERATION

1 - Operation common to both fittings


a Refit the dashboard cross member reinforcement.

61A-116
HEATING
Passenger compartment fan assembly control unit: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE

REMOVAL II - FINAL OPERATION


a Refit:

I - REMOVAL PREPARATION OPERATION - the front right-hand A-pillar air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
a Remove: moval - Refitting, page 61A-142) ,
- the glovebox (see Glovebox: Removal) (57A, In-
- the glovebox (see Glovebox: Removal) ( 57A, In- terior equipment).
terior equipment),

- the front right-hand A-pillar air distribution duct (see


61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) .

II - OPERATION FOR REMOVAL OF PART


CONCERNED

136991

a Unclip the control unit (1) from the passenger com-


partment fan assembly.

a Disconnect the connector (2) from the passenger


compartment fan assembly control unit.

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED

a Connect the blower unit control unit connector.

a Clip on the passenger compartment fan assembly


control unit.

61A-117
HEATING
Passenger compartment fan assembly control unit: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE

Tightening torquesm

pedal assembly nuts 21 N.m

brake pedal impacter 21 N.m


bolt

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Unclip the centre console left-hand trim.
a Remove:
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),
- the front left-hand footwell air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re- 109879
moval - Refitting, page 61A-142) .
a Remove:

- the dual safety connecting shaft ring,

- the dual safety connecting shaft (2) .

134662
a Remove the brake pedal impacter bolt (1) .

134696

a Remove the nuts (3) from the brake pedal.

Note:
Do not disconnect the connectors from the
« brake pedal - accelerator» assembly and
replace the brake light switch in the event of an
impact.

61A-118
HEATING
Passenger compartment fan assembly control unit: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE
a Partially remove the « brake pedal - accelerator » - a new dual safety connecting shaft,
assembly.
- the dual safety connecting shaft rubber ring,
- the pedal assembly nuts.
II - OPERATION FOR REMOVAL OF PART
CONCERNED a Torque tighten the pedal assembly nuts (21 N.m).
a Refit:
- the brake pedal impacter,
- a new brake pedal impacter bolt.
a Torque tighten the brake pedal impacter bolt (21
N.m).
a Refit:
- the front left-hand footwell air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment).
a Clip on the centre console left-hand trim.

136991
a Unclip the passenger compartment fan assembly
control unit at (4) .
a Disconnect the connector (5) from the passenger
compartment fan assembly control unit.

REFITTING

I - REFITTING PREPARATION OPERATION


a parts always to be replaced: Connecting shaft
between the brake pedal and the brake servo
pushrod (30,03,02,07).
a Part which must always be replaced: Brake pe-
dal impacter bolt.

II - REFITTING OPERATION FOR PART


CONCERNED
a Connect the connector to the passenger compart-
ment fan assembly control unit.
a Clip on the passenger compartment fan assembly
control unit.

III - FINAL OPERATION


a Refit:
- the « accelerator - brake pedal » assembly,

61A-119
HEATING
Passenger compartment fan assembly control unit: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE

REMOVAL

I - REMOVAL PREPARATION OPERATION

a Remove the glovebox (see Glovebox: Removal -


Refitting) (57A, Interior equipment).

II - OPERATION FOR REMOVAL OF PART


CONCERNED

136991
a Fit the passenger compartment fan assembly con-
trol unit in its housing.
a Push the passenger compartment fan assembly
control unit downwards in the direction of the arrow
(4) while holding the tab (5) .
a Clip on the tab (5) of the passenger compartment
fan assembly control unit by pushing it towards the
front of the vehicle.

136991 II - FINAL OPERATION

a Unclip the tab (1) of the passenger compartment fan a Refit the glovebox (see Glovebox: Removal - Refit-
assembly control unit by pushing it towards the rear ting) (57A, Interior equipment).
of the vehicle.

a Push the passenger compartment fan assembly


control unit upwards in the direction of the arrow (2)
while holding the tab (1) .

a Remove the passenger compartment fan assembly


control unit from its housing.

a Disconnect the connector (3) from the passenger


compartment fan assembly control unit.

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED

a Connect the passenger compartment fan assembly


control unit connector.

61A-120
HEATING
Passenger compartment fan assembly control unit: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE

Tightening torquesm

pedal assembly nuts 21 N.m

brake pedal impacter 21 N.m


nut

REMOVAL

I - REMOVAL PREPARATION OPERATION

138639
a Remove:
- the brake pedal impacter nut (2) ,
- the brake pedal impacter.

138642
a Unclip the left-hand panel (1) of the centre console.
a Remove the dashboard lower trim (see Lower sec-
tion of dashboard trim: Removal - Refitting)
(57A, Interior equipment).

109879
a Remove:
- the rubber ring (3) from the dual safety connecting
shaft,
- the dual safety connecting shaft (4) .

61A-121
HEATING
Passenger compartment fan assembly control unit: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART
CONCERNED

134696
a Remove the nuts (5) from the brake pedal.
136991
a Unclip the tab (6) of the passenger compartment fan
Note: assembly control unit by pushing it towards the rear
Do not disconnect the connectors from the of the vehicle.
« brake pedal - accelerator » assembly and a Push the passenger compartment fan assembly
replace the brake light switch in the event of an control unit upwards in the direction of the arrow (7)
impact. while holding the tab (6) .
a Partially remove the « brake pedal - accelerator » a Remove the passenger compartment fan assembly
assembly. control unit from its housing.
a Disconnect the connector (8) from the passenger
compartment fan assembly control unit.

REFITTING

I - REFITTING PREPARATION OPERATION


a parts always to be replaced: Connecting shaft
between the brake pedal and the brake servo
pushrod (30,03,02,07).

II - REFITTING OPERATION FOR PART


CONCERNED
a Connect the passenger compartment fan assembly
control unit connector.

61A-122
HEATING
Passenger compartment fan assembly control unit: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE

136991

a Fit the passenger compartment fan assembly con-


trol unit in its housing.

a Push the passenger compartment fan assembly


control unit downwards in the direction of the arrow
(9) while holding the tab (10) .

a Clip on the tab (10) of the passenger compartment


fan assembly control unit by pushing it towards the
front of the vehicle.

III - FINAL OPERATION

a Refit:

- the « accelerator - brake pedal » assembly,

- a new dual safety connecting shaft,

- the dual safety connecting shaft rubber ring,

- the pedal assembly nuts.

a Torque tighten the pedal assembly nuts (21 N.m).

a Refit:

- the brake pedal impacter,

- the brake pedal impacter nut.

a Torque tighten the brake pedal impacter nut (21


N.m).

a Refit the dashboard lower trim (see Lower section


of dashboard trim: Removal - Refitting) (57A, In-
terior equipment).

a Clip on the left-hand panel of the centre console.

61A-123
HEATING
Control panel: Removal - Refitting 61A
B95 or D95 or E95 or K95

Essential equipment

diagnostic tool

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).

a Remove the centre front panel (see Centre front


panel: Removal - Refitting) (57A, Interior equip-
ment). 135677
a Squeeze the centring pins while pushing the control
panel (2) .
AIR CONDITIONING, and RADIO NO 01 or RADIO
NO 02 or RADIO NO 03 or RADIO NO 04 or
RADIO NO 05 AIR CONDITIONING

a Remove the radio (see Car radio: Removal - Refit-


ting) (86A, Radio).

AIR CONDITIONING, and RADIO NO 06 or RADIO


NO 07

a Remove the radio navigation system (see Radio na-


vigation system: Removal - Refitting) (83C, On-
board telematics system).

135659
a Tilt the control panel .
II - OPERATION FOR REMOVAL OF PART a Unclip the air mixing cable from the control panel at
CONCERNED
(3) .
a Move aside the control panel.

135676

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

61A-124
HEATING
Control panel: Removal - Refitting 61A
B95 or D95 or E95 or K95

CLIMATE CONTROL

135658
a Unclip the air distribution cable from the control pa-
nel at (4) .

135678

a Tilt the control panel .

a Disconnect the control panel connector (6) .

135657
a Disconnect the connectors (5) from the control pa-
nel.
a Remove the control panel.

135679

a Move aside the control panel.

a Disconnect the control panel connector (7) .

a Remove the control panel.

61A-125
HEATING
Control panel: Removal - Refitting 61A
B95 or D95 or E95 or K95

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED

AIR CONDITIONING
a Refit the control panel.
a Connect the control panel connectors.
a Clip the air distribution cable onto the control panel.
a Fit the control panel in its housing.
a Clip the air mixing cable onto the control panel.

CLIMATE CONTROL

135678
a Connect the connector (9) to the control panel.

a Clip on the centring pins.


a Refit the control panel bolts.
a Check the correct operation of the control panel.

II - FINAL OPERATION
a Refit the centre front panel (see Centre front panel:
Removal - Refitting) (57A, Interior equipment).

AIR CONDITIONING, and RADIO NO 01 or RADIO


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

135679 a Refit the radio (see Car radio: Removal - Refitting)


(86A, Radio).
a Connect the connector (8) to the control panel.
a Refit the control panel in its housing.

AIR CONDITIONING, and RADIO NO 06 or RADIO


NO 07
a Refit the radio navigation system (see Radio navi-
gation system: Removal - Refitting) (83C, On
board telematics system).

a Connect the battery (see Battery : Removal - Refit-


ting) (80A, Battery).

61A-126
HEATING
Control panel: Removal - Refitting 61A
B95 or D95 or E95 or K95
a Apply the after repair procedure using the diagnos-
tic tool :
- connect the diagnostic tool,
- select "Climate control computer",
- go to repair mode,
- display the "Before/after repair procedure" for the
computer selected,
- carry out the operations described in the "After re-
pair procedure" section.

61A-127
HEATING
Control panel: Removal - Refitting 61A
J95

Essential equipment

diagnostic tool

REMOVAL

I - REMOVAL PREPARATION OPERATION

a Remove:

- the central console (see Centre console: Remo-


val - Refitting) (57A, Interior equipment),

- the dashboard lower trim (see Lower section of


dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),

- the inhibitor switch (see Inhibitor switch: Remo- 138599

val - Refitting) (88C, Airbag and pretensioners), a Squeeze the centring pins (2) while pushing the con-
trol panel.
- the glovebox (see Glovebox: Removal - Refit-
a Tilt the control panel .
ting) ( 57A, Interior equipment),

- the centre front panel (see Centre front panel: Re-


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

II - OPERATION FOR REMOVAL OF PART


CONCERNED

138500

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

61A-128
HEATING
Control panel: Removal - Refitting 61A
J95

AIR CONDITIONING

138497

138496

138499
a Unclip the air distribution cable (4) from the control
138498
panel in the order of the arrows.

a Unclip the air mixing cable (3) from the control panel
in the order of the arrows.

61A-129
HEATING
Control panel: Removal - Refitting 61A
J95

CLIMATE CONTROL

138502
a Disconnect the connectors (5) from the control pa-
nel.
138596
a Remove the control panel.
a Disconnect the connectors (6) from the control pa-
nel.

a Remove the control panel.

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED

AIR CONDITIONING

a Refit the control panel.


a Connect the control panel connectors.

a Clip:

- the air distribution cable on the control panel,


- the air mixing cable onto the control panel.

a Fit the control panel in its housing.

CLIMATE CONTROL
a Connect the control panel connectors.

61A-130
HEATING
Control panel: Removal - Refitting 61A
J95
a Fit the control panel in its housing.

a Clip on the centring pins.


a Refit the control panel bolts.
a Check the correct operation of the control panel.

II - FINAL OPERATION
a Refit:
- the centre front panel (see Centre front panel: Re-
moval - Refitting) (57A, Interior equipment),
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 57A, Interior equipment),
- the inhibitor switch (see Inhibitor switch: Remo-
val - Refitting) (88C, Airbag and pretensioners),
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),
- the central console (see Centre console: Remo-
val - Refitting) (57A, Interior equipment).
a Apply the After repair procedure using the diagnos-
tic tool :
- connect the diagnostic tool,
- select "Climate control computer",
- go to repair mode,
- display the "Before/After repair procedure" for the
computer selected,
- carry out the operations described in the "After re-
pair procedure" section.

61A-131
HEATING
Front side air distribution duct: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART
Essential special tooling CONCERNED
Car. 1363 Set of trim removal levers.
Right-hand side

Note:
The front left-hand side air distribution duct cannot
be separated from the dashboard cross member for
removal (see Dashboard cross member: Remo-
val - Refitting) (42A, Front upper structure).

REMOVAL

I - REMOVAL PREPARATION OPERATION

Right-hand side
a Remove:
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 57A, Interior equipment),
- the front right-hand A-pillar air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
135683
moval - Refitting, page 61A-142) .
a Remove:

RADIO NO 07 - the clip (1) from the front side air distribution duct
using the tool (Car. 1363),
a Remove:
- the front side air distribution duct (2) .
- the receiver (see Tuner-amplifier: Removal - Re-
fitting) (86A, Radio),
REFITTING
- the navigation computer (see Navigation compu-
ter: Removal - Refitting) (83C, On-board telema-
tics system). I - REFITTING OPERATION FOR PART
CONCERNED

Right-hand side
a Refit:
- the front side air distribution duct,
- the front side air distribution duct clip.

II - FINAL OPERATION

Right-hand side

RADIO NO 07
a Refit:
- the navigation computer (see Navigation compu-
ter: Removal - Refitting) (83C, On-board telema-
tics system),

61A-132
HEATING
Front side air distribution duct: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE
- the receiver (see Tuner-amplifier: Removal - Re-
fitting) (86A, Radio).

a Refit:
- the front footwell air distribution duct (see 61A,
Heating, A-pillar air distribution duct: Removal
- Refitting, page 61A-142) ,
- the glovebox (see Glovebox: Removal - Refit-
ting) (57A, Interior equipment).

61A-133
HEATING
Front side air distribution duct: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE

Essential special tooling

Car. 1363 Set of trim removal levers.

Note:
The front right-hand side air distribution duct cannot
be separated from the dashboard cross member for
removal (see Dashboard cross member: Remo-
val - Refitting) (42A, Front upper structure).

REMOVAL

I - REMOVAL PREPARATION OPERATION

Left-hand side
137018
a Remove: a Cut the plastic clip (2) on the passenger compart-
ment fuse and relay box.
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 57A, Interior equipment), a Unclip the passenger compartment fuse and relay
box plate from the dashboard cross member (3) .
- the front left-hand footwell air distribution duct (see a Separate the passenger compartment fuse and re-
61A, Heating, A-pillar air distribution duct: Re- lay box plate from the dashboard cross member.
moval - Refitting, page 61A-142) ,

- the UCH (see UCH: Removal - Refitting) (87B, In-


terconnection unit).

137000

a Disconnect the connectors (1) from the passenger


compartment fuse and relay box.

61A-134
HEATING
Front side air distribution duct: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART III - FINAL OPERATION
CONCERNED
Left-hand side
Left-hand side a Fit the passenger compartment fuse and relay sup-
port plate on the dashboard cross member.
a Clip the passenger compartment fuse and relay sup-
port plate onto the dashboard cross member.
a Refit a new plastic retaining clip on the passenger
compartment fuse and relay support plate.
a Connect the connectors to the passenger compart-
ment fuse and relay support plate.
a Refit:
- the UCH (see UCH: Removal - Refitting) (87B, In-
terconnection unit),
- the front left-hand footwell air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,
- the glovebox (see Glovebox: Removal - Refit-
ting) (57A, Interior equipment).

137022

a Use the tool (Car. 1363) to remove the clip (4) from
the front side air distribution duct.

a Unclip the front side air distribution duct.

a Remove the front side air distribution duct.

REFITTING

I - REFITTING PREPARATION OPERATION

Left-hand side

a Part which must always be replaced: Plastic re-


taining clip for the passenger compartment fuse
and relay support plate.

II - REFITTING OPERATION FOR PART


CONCERNED

Left-hand side

a Refit the front side air distribution duct.

a Clip on the front side air distribution duct.

a Refit the front side air distribution duct clip.

61A-135
HEATING
Front side air distribution duct: Removal - Refitting 61A
J95

Tightening torquesm

steering column nuts 21 N.m

REMOVAL

I - REMOVAL PREPARATION OPERATION

1 - Front right-hand side air distribution duct:

a Remove the airbag inhibitor switch (see Inhibitor


switch: Removal - Refitting) (88C, Airbag and pre-
tensioners).

LEFT-HAND DRIVE
a Remove the glovebox (see Glovebox: Removal -
Refitting) (57A, Interior equipment). 134365
a Disconnect:

RADIO NO 07 - the steering column connectors (1) ,

a Remove the receiver (see Tuner-amplifier: Remo- - the electric steering column lock,
val - Refitting) (86A, Radio). - the steering column control connectors.
a Move the seat as far back as possible.
a Fit a block of approximately 440 mm between the
steering column and the floor.
RADIO NO 04 or RADIO NO 05

a Remove:
- the offset multimedia socket computer (see Offset
multimedia socket computer: Removal - Refit-
ting) (86A, Radio),

- the offset multimedia socket computer mounting


bolts,

- the offset multimedia socket computer mounting.

RIGHT-HAND DRIVE
a Remove:

- the dashboard lower trim (see Lower section of 137655


dashboard trim: Removal - Refitting) (57A, Inte- a Remove the nuts (2) from the steering column.
rior equipment),
a Remove the block between the steering column and
- the cowlings under the steering wheel. the floor.

61A-136
HEATING
Front side air distribution duct: Removal - Refitting 61A
J95

138654 138641
a Lower the steering column in the footwell. a Remove:
- the cover bolts (4) under the steering wheel,
Note: - the cowlings under the steering wheel.
Ver tically lower the steering column and do not
apply pressure to the universal joints.

a Check that the cross piece (3) does not leave the
bearing.

2 - Front left-hand side air distribution duct:

LEFT-HAND DRIVE
a Remove the dashboard lower trim (see Lower sec-
tion of dashboard trim: Removal - Refitting)
(57A, Interior equipment).

134365
a Disconnect:
- the steering column connectors (5) ,
- the electric steering column lock,
- the steering column control connectors.
a Move the seat as far back as possible.
a Fit a block of approximately 440 mm between the
steering column and the floor.

61A-137
HEATING
Front side air distribution duct: Removal - Refitting 61A
J95

134366 138654
a Remove the nuts (6) from the steering column. a Lower the steering column in the footwell.
a Remove the block between the steering column and
the floor.
Note:
Vertically lower the steering column and do not
apply pressure to the universal joints.

a Check that the cross piece (7) does not leave the
bearing.

RIGHT-HAND DRIVE
a Remove the glovebox (see Glovebox: Removal -
Refitting) (57A, Interior equipment).

RADIO NO 04 or RADIO NO 05

a Remove:

- the offset multimedia socket computer (see Offset


multimedia socket computer: Removal - Refit-
ting) (86A, Radio),

- the offset multimedia socket computer mounting


bolts,

- the offset multimedia socket computer mounting.

61A-138
HEATING
Front side air distribution duct: Removal - Refitting 61A
J95
II - OPERATION FOR REMOVAL OF PART - the electric steering column lock,
CONCERNED
- the steering column control connectors.

a Refit:
- the cowlings under the steering wheel,

- the dashboard lower trim (see Lower section of


dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment).

LEFT-HAND DRIVE

RADIO NO 04 or RADIO NO 05
a Refit:

- the offset multimedia socket computer mounting,

- the offset multimedia socket computer (see Offset


139057 multimedia socket computer: Removal - Refit-
a Disconnect: ting) (86A, Radio).

- the front side air distribution duct from the air distri-
bution unit at (8) ,
- the front side air distribution duct from the air vent
at (9) . RADIO NO 07
a Remove the front side air distribution duct. a Refit the receiver (see Tuner-amplifier: Removal -
Refitting) (86A, Radio).
REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED a Refit:

a Refit the front side air distribution duct. - the glovebox (see Glovebox: Removal - Refit-
ting) ( 57A, Interior equipment),

II - FINAL OPERATION - the airbag inhibitor switch (see Inhibitor switch:


Removal - Refitting) (88C, Airbag and pretensio-
ners).
1 - Front right-hand side air distribution duct:

RIGHT-HAND DRIVE
a Refit the steering column.
2 - Front left-hand side air distribution duct:
a Fit a block of approximately 440 mm between the
steering column and the floor.
RIGHT-HAND DRIVE
a Torque tighten the steering column nuts (21 N.m).
a Remove the block between the steering column and
the floor. RADIO NO 04 or RADIO NO 05

a Connect: a Refit:
- the steering column connectors, - the offset multimedia socket computer mounting,

61A-139
HEATING
Front side air distribution duct: Removal - Refitting 61A
J95
- the offset multimedia socket computer (see Offset
multimedia socket computer: Removal - Refit-
ting) (86A, Radio).

a Refit the glovebox (see Glovebox: Removal - Refit-


ting) (57A, Interior equipment).

LEFT-HAND DRIVE
a Refit the steering column.
a Fit a block of approximately 440 mm between the
steering column and the floor.
a Torque tighten the steering column nuts (21 N.m).
a Remove the block between the steering column and
the floor.
a Connect:
- the steering column connectors,
- the electric steering column lock,
- the steering column control connectors.
a Refit:
- the cowlings under the steering wheel,
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment).

61A-140
HEATING
Front central air distribution duct: Removal - Refitting 61A
B95 or D95 or E95 or K95

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).
a Remove the dashboard (see Dashboard: Removal
- Refitting) (57A, Interior equipment).

II - OPERATION FOR REMOVAL OF PART


CONCERNED

137638
a Remove the front centre air distribution duct bolts (1)
.
a Unclip the front centre air distribution duct at (2) .
a Remove the front centre air duct.

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED
a Refit the front centre air duct.
a Clip on the front centre air duct.
a Refit the front centre air duct bolts.

II - FINAL OPERATION
a Refit the dashboard (see Dashboard: Removal -
Refitting) (57A, Interior equipment).
a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).

61A-141
HEATING
A-pillar air distribution duct: Removal - Refitting 61A
B95 or D95 or E95 or K95
2 - Passenger side
Essential special tooling

Car. 1363 Set of trim removal levers.

REMOVAL

I - REMOVAL PREPARATION OPERATION

1 - Driver's side

a Remove the instrument panel lower trim (see Lower


section of dashboard trim: Removal - Refitting)
(57A, Interior equipment).

2 - Passenger side

a Remove the glovebox (see Glovebox: Removal -


Refitting) (57A, Interior equipment).
135680

II - OPERATION FOR REMOVAL OF PART a Remove:


CONCERNED
- the clip (3) from the A-pillar air duct,

1 - Driver's side - the A-pillar air duct (4) .

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED

a Refit:

- the A-pillar air duct,

- the A-pillar air duct clip.

II - FINAL OPERATION

1 - Driver's side

a Refit the instrument panel lower trim (see Lower


135689 section of dashboard trim: Removal - Refitting)
(57A, Interior equipment).
a Remove:

- the clip (1) from the A-pillar air duct, using the tool 2 - Passenger side
(Car. 1363),
a Refit the glovebox (see Glovebox: Removal - Refit-
- the A-pillar air duct (2) . ting) (57A, Interior equipment).

61A-142
HEATING
A-pillar air distribution duct: Removal - Refitting 61A
J95

REMOVAL II - OPERATION FOR REMOVAL OF PART


CONCERNED

I - REMOVAL PREPARATION OPERATION


1 - Left-hand side

1 - Left-hand side

LEFT-HAND DRIVE
a Remove the dashboard lower trim (see Lower sec-
tion of dashboard trim: Removal - Refitting)
(57A, Interior equipment).

RIGHT-HAND DRIVE
a Remove the glovebox (see Glovebox: Removal -
Refitting) (57A, Interior equipment).

2 - Right-hand side
138675

LEFT-HAND DRIVE a Remove:

a Remove the glovebox (see Glovebox: Removal - - the bolts (1) of the front footwell air distribution
Refitting) (57A, Interior equipment). duct,
- the front footwell air distribution duct.

RIGHT-HAND DRIVE
a Remove the dashboard lower trim (see Lower sec-
tion of dashboard trim: Removal - Refitting)
(57A, Interior equipment).

61A-143
HEATING
A-pillar air distribution duct: Removal - Refitting 61A
J95
2 - Right-hand side

RIGHT-HAND DRIVE
LEFT-HAND DRIVE

139117
138986 a Unclip the front footwell air distribution duct (3) .
a Remove:
- the bolts (2) of the front footwell air distribution
duct,
- the front footwell air distribution duct. REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED
a Refit the A-pillar air distribution duct.

II - FINAL OPERATION

1 - Left-hand side

LEFT-HAND DRIVE
a Refit the dashboard lower trim (see Lower section
of dashboard trim: Removal - Refitting) (57A, In-
terior equipment).

RIGHT-HAND DRIVE
a Refit the glovebox (see Glovebox: Removal - Refit-
ting) (57A, Interior equipment).

61A-144
HEATING
A-pillar air distribution duct: Removal - Refitting 61A
J95
2 - Right-hand side

LEFT-HAND DRIVE
a Refit the glovebox (see Glovebox: Removal - Refit-
ting) (57A, Interior equipment).

RIGHT-HAND DRIVE
a Refit the dashboard lower trim (see Lower section
of dashboard trim: Removal - Refitting) (57A, In-
terior equipment).

61A-145
HEATING
Recirculation motor: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Essential equipment

diagnostic tool

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Remove:
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 57A, Interior equipment),
- the front right-hand A-pillar air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) .

RADIO NO 07
a Remove:
- the receiver (see Tuner-amplifier: Removal - Re- 137641
fitting) (86A, Radio),
a Disconnect the recirculation motor connector.
- the navigation computer (see Navigation compu-
ter: Removal - Refitting) (83C, On-board telema- a Mark the routing of the recirculation motor wiring.
tics system). a Separate the wiring from the recirculation motor.
a Remove:
- the bolts (2) from the air recirculation duct,
a Remove the front side air distribution duct (see 61A,
- the air recirculation duct.
Heating, Front side air distribution duct: Remo-
val - Refitting, page 61A-132) .

137633

137028 a Remove:
a Unclip the recirculation control cable (1) . - the bolts (3) from the air recirculation motor,

61A-146
HEATING
Recirculation motor: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE
- the air recirculation motor. a Refit:
- the front side air distribution duct (see 61A, Hea-
REFITTING ting, Front side air distribution duct: Removal -
Refitting, page 61A-132) ,

I - REFITTING OPERATION FOR PART - the front right-hand A-pillar air distribution duct (see
CONCERNED 61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,
a Refit:
- the glovebox (see Glovebox: Removal - Refit-
- the air recirculation motor, ting) (57A, Interior equipment).
- the air recirculation duct. a Apply the after repair procedure using the diagnos-
a Fit the recirculation motor wiring. tic tool :

a Connect the recirculation motor connector. - connect the diagnostic tool,


- select "Climate control computer",
II - FINAL OPERATION - go to repair mode,
a Clip on the recirculation control cable. - display the "Before/after repair procedure" for the
computer selected,
RADIO NO 07 - select "air recirculation flap motor" in the "List of
a Refit: components stored by this computer" section,

- the receiver (see Tuner-amplifier: Removal - Re- - carry out the operations described in the "After re-
fitting) (86A, Radio), pair procedure" section.

- the navigation computer (see Navigation compu-


ter: Removal - Refitting) (83C, On-board telema-
tics system).

61A-147
HEATING
Recirculation motor: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE

Essential equipment

diagnostic tool

Tightening torquesm

steering column bolts 21 N.m

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Unclip the centre console right-hand trim.
a Remove the dashboard lower trim (see Lower sec-
tion of dashboard trim: Removal - Refitting)
(57A, Interior equipment).

134365
a Disconnect the steering column connectors (2) and
the steering column electric lock.
a Fit a block of approximately 440 mm between the
steering column and the floor.

136716
a Remove:
- the cover bolts (1) under the steering wheel,
- the cowlings under the steering wheel.
a Disconnect the steering column switch assembly
connectors. 134366
a Remove the nuts (3) from the steering column.
a Remove the block between the steering column and
the floor.

61A-148
HEATING
Recirculation motor: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART
CONCERNED

137636
a Lower the steering column in the footwell.
137641
a Disconnect the recirculation motor connector.
Note:
a Mark the routing of the recirculation motor wiring.
Ver tically lower the steering column and do not
put apply pressure to the universal joints. a Separate the wiring from the recirculation motor.

a Check that the cross piece does not leave the bea- a Remove:
ring. - the bolts (6) from the air recirculation duct,
- the air recirculation duct.

137028
a Unclip the recirculation control cable at (5) .
137633

a Remove:
- the bolts (7) from the air recirculation motor,

61A-149
HEATING
Recirculation motor: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE
- the air recirculation motor. a Apply the after repair procedure using the diagnos-
tic tool :
- connect the diagnostic tool,
REFITTING
- select "Climate control computer",
- go to repair mode,
I - REFITTING OPERATION FOR PART
CONCERNED - display the "Before/after repair procedure" for the
computer selected,
a Refit: - select "air recirculation flap motor" in the "List of
components stored by this computer" section,
- the air recirculation motor,
- carry out the operations described in the "After re-
- the air recirculation duct. pair procedure" section.

a Fit the recirculation motor wiring.

a Connect the recirculation motor connector.

II - FINAL OPERATION

a Clip on the recirculation control cable.

a Check that the recirculation control can move along


its whole stroke.

a Refit the steering column.

a Fit a block of approximately 440 mm between the


steering column and the floor.

a Refit the steering column bolts.

a Torque tighten the steering column bolts (21 N.m).

a Remove the block between the steering column and


the floor.

a Check the condition of the steering column bearings.

a Connect:

- the electric steering column lock connector,

- the steering column connectors,

- the steering column switch assembly connectors.

a Refit:

- the cowlings under the steering wheel,

- the dashboard lower trim (see Lower section of


dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment).

a Clip on the centre console right-hand trim.

61A-150
HEATING
Recirculation motor: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE

Essential equipment

diagnostic tool

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Remove:
- the inhibitor switch (see Inhibitor switch: Remo-
val - Refitting) (88C, Airbag and pretensioners),
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 57A, Interior equipment),
- the front right-hand A-pillar air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) .

137028
RADIO NO 07
a Unclip the recirculation control cable.
a Remove:
- the receiver (see Tuner-amplifier: Removal - Re- II - OPERATION FOR REMOVAL OF PART
fitting) (86A, Radio), CONCERNED
- the bolts from the receiver mounting,
- the receiver mounting.

RADIO NO 04 or RADIO NO 05
a Remove:
- the offset multimedia socket computer (see Offset
multimedia socket computer: Removal - Refit-
ting) (86A, Radio),
- the offset multimedia socket computer mounting
bolts,
- the offset multimedia socket computer mounting.

138646
a Mark the routing of the air recirculation motor wiring
(1) .

61A-151
HEATING
Recirculation motor: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE

CLIMATE CONTROL

138595

a Remove:

137641 - the bolts (4) from the air recirculation motor,


a Remove: - the air recirculation motor.
- the bolts (2) from the air recirculation duct,
- the air recirculation duct.
a Separate the wiring from the air recirculation motor.
AIR CONDITIONING

138647
a Disconnect the air recirculation motor connector (3) . 139116

a Remove:
- the bolts (5) from the air recirculation motor,
- the air recirculation motor.

61A-152
HEATING
Recirculation motor: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE

REFITTING - display the « before/after repair procedure » for the


computer selected,

I - REFITTING OPERATION FOR PART - select « Air recirculation flap motor » in the « List of
CONCERNED components controlled by this computer » section,

a Refit the air recirculation motor. - carry out the operations described in the « After re-
pair procedure » section.
a Position the air recirculation duct.
a Fit the air recirculation motor wiring.
a Connect the air recirculation motor connector.
a Refit the air recirculation duct.

II - FINAL OPERATION
a Clip on the recirculation control cable.

RADIO NO 04 or RADIO NO 05
a Refit:
- the offset multimedia socket computer mounting,
- the offset multimedia socket computer (see Offset
multimedia socket computer: Removal - Refit-
ting) (86A, Radio).

RADIO NO 07
a Refit:
- the receiver (see Tuner-amplifier: Removal - Re-
fitting) (86A, Radio),
- the receiver mounting.

a Refit:
- the front right-hand A-pillar air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 57A, Interior equipment),
- the inhibitor switch (see Inhibitor switch: Remo-
val - Refitting) (88C, Airbags and pretensioners).
a Apply the after repair procedure using the diagnos-
tic tool :
- connect the diagnostic tool,
- select « Climate control computer » ,
- go to repair mode,

61A-153
HEATING
Recirculation motor: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE

Tightening torquesm

steering column nuts 21 N.m

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Move the seat as far back as possible.
a Unclip the right-hand panel from the centre console.
a Remove the dashboard lower trim (see Lower sec-
tion of dashboard trim: Removal - Refitting)
(57A, Interior equipment).

134365

a Disconnect:

- the steering column connectors (2) ,

- the electric steering column lock connector.

a Fit a block of approximately 440 mm between the


steering column and the floor.

141576
a Remove:
- the cover bolts (1) under the steering wheel,
- the cowlings under the steering wheel.
a Disconnect the steering column switch assembly
connectors.

137655

a Remove the nuts (3) from the steering column.

a Remove the block between the steering column and


the floor.

61A-154
HEATING
Recirculation motor: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART
CONCERNED

138654
a Lower the steering column in the footwell.
138646
a Mark the routing of the air recirculation motor wiring
Note: (5) .
Ver tically lower the steering column and do not
apply pressure to the universal joints.

a Check that the cross piece (4) does not leave the
bearing.

137641
a Remove:
- the bolts (6) from the air recirculation duct,
- the air recirculation duct.
137028
a Separate the wiring from the air recirculation motor.
a Unclip the recirculation control cable.

61A-155
HEATING
Recirculation motor: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE

AIR CONDITIONING

138647
a Disconnect the air recirculation motor connector (7) .
139116
CLIMATE CONTROL a Remove:
- the bolts (9) from the air recirculation motor,
- the air recirculation motor.

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED
a Refit the air recirculation motor.
a Position the air recirculation duct.
138595
a Fit the air recirculation motor wiring.
a Remove:
a Connect the air recirculation motor connector.
- the bolts (8) from the air recirculation motor,
a Refit the air recirculation duct.
- the air recirculation motor.

II - FINAL OPERATION
a Clip on the recirculation control cable.
a Check that the recirculation control can move along
its whole stroke.
a Refit the steering column.
a Fit a block of approximately 440 mm between the
steering column and the floor.
a Torque tighten the steering column nuts (21 N.m).

61A-156
HEATING
Recirculation motor: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE
a Remove the block between the steering column and
the floor.
a Check the condition of the steering column bearings.
a Connect:
- the electric steering column lock connector,
- the steering column connectors,
- the steering column switch assembly connectors.
a Refit:
- the cowlings under the steering wheel,
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment).
a Clip on the right-hand panel of the centre console.

61A-157
HEATING
Mixer motor: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE, and CLIMATE CONTROL

Essential equipment

diagnostic tool

Tightening torquesm

pedal assembly nuts 21 N.m

brake pedal impacter 21 N.m


bolt

REMOVAL

I - REMOVAL PREPARATION OPERATION

1 - Right-hand mixing motor


a Remove: 134662
- the glovebox (see Glovebox: Removal - Refit- a Remove the brake pedal impacter bolt (1) .
ting) ( 57A, Interior equipment),
- the front right-hand A-pillar air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) .

2 - Left-hand mixing motor


a Unclip the centre console left-hand trim.
a Remove:
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),
- the front left-hand footwell air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) .

109879
a Remove:
- the dual safety connecting shaft rubber ring,
- the dual safety connecting shaft (2) .

61A-158
HEATING
Mixer motor: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE, and CLIMATE CONTROL
II - OPERATION FOR REMOVAL OF PART
CONCERNED

1 - Right-hand mixing motor

134696
a Remove the nuts (3) from the brake pedal.

Note:
135682
Do not disconnect the connectors from the a Mark the routing of the mixing motor wiring.
« brake pedal - accelerator » assembly and
replace the brake light switch in the event of an a Disconnect the connector (4) from the air mixing mo-
impact. tor.
a Remove:
a Partially remove the « brake pedal - accelerator »
assembly. - the bolts (5) from the air mixing motor,
- the air mixing motor.

61A-159
HEATING
Mixer motor: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE, and CLIMATE CONTROL
2 - Left-hand mixing motor REFITTING

I - REFITTING PREPARATION OPERATION

1 - Right-hand mixing motor

137640
137014
a Mark the routing of the mixing motor wiring.
a Move the tie rod so that the flat surface (8) of the ri-
a Disconnect the connector (6) from the air mixing mo-
ght-hand mixing motor recess is positioned at 90˚ in
tor.
relation to the distribution unit reference axis (9) .
a Remove:
- the bolts (7) from the air mixing motor, 2 - Left-hand mixing motor
- the air mixing motor.
a parts always to be replaced: Connecting shaft
between the brake pedal and the brake servo
pushrod (30,03,02,07).

a part which must always be replaced: Brake pe-


dal impacter bolt.

137015

a Move the tie rod so that the flat surface (10) of the
left-hand mixing motor recess is positioned at 90˚ in
relation to the edge of the distribution unit reference
axis (11) .

61A-160
HEATING
Mixer motor: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE, and CLIMATE CONTROL
II - REFITTING OPERATION FOR PART a Apply the after repair procedure using the diagnos-
CONCERNED tic tool :
- connect the diagnostic tool,
Right-hand and left-hand mixing motor - select "Climate control computer",

a Refit the mixing motor. - go to repair mode,


- display the "Before/after repair procedure" for the
a Connect the air mixing motor connector.
computer selected,
a Fit the electrical wiring of the mixing motor. - select "Left-hand air mixing flap motor or Right-
hand air mixing flap motor" in the "List of compo-
nents stored by this computer" section,
III - FINAL OPERATION
- carry out the operations described in the "After re-
pair procedure" section.
1 - Right-hand mixing motor

a Refit:

- the front right-hand A-pillar air distribution duct (see


61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,

- the glovebox (see Glovebox: Removal - Refit-


ting) (57A, Interior equipment).

2 - Left-hand mixing motor

a Refit:

- the « accelerator - brake pedal » assembly,

- the dual safety connecting shaft,

- the dual safety connecting shaft rubber ring,

- the pedal assembly nuts.

a Torque tighten the pedal assembly nuts (21 N.m).

a Refit:

- the impacter,

- the impacter bolt.

a Torque tighten the brake pedal impacter bolt (21


N.m).

a Refit:

- the front left-hand air distribution duct (see 61A,


Heating, A-pillar air distribution duct: Removal
- Refitting, page 61A-142) ,

- the dashboard lower trim (see Lower section of


dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment).

a Clip on the centre console left-hand trim.

61A-161
HEATING
Mixer motor: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and CLIMATE CONTROL

Essential equipment

diagnostic tool

Tightening torquesm

clutch pedal nuts 21 N.m

REMOVAL

I - REMOVAL PREPARATION OPERATION

1 - Right-hand mixing motor

a Unclip the centre console right-hand trim


137154
a Remove:
a Remove the clutch pedal nuts (3) .
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
Note:
rior equipment),
Do not disconnect the connectors from the clutch
- the front right-hand A-pillar air distribution duct (see pedal.
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) . a Remove the clutch pedal from its threaded rods in
the direction of the arrow.

Note:
Do not apply pressure to the hydraulic clutch
pipes.

a Pass the hydraulic clutch pipes under the distribu-


tion unit.

137690

a Unclip the hydraulic clutch pipes (1) .

a Move the hydraulic clutch pipes aside.

a Unclip the clutch pedal wiring at (2) .

61A-162
HEATING
Mixer motor: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and CLIMATE CONTROL
II - OPERATION FOR REMOVAL OF PART
CONCERNED

1 - Right-hand mixing motor

136999
a Tilt the clutch pedal in the direction of the arrow.
a Put the clutch pedal in the footwell.

135682
2 - Left-hand mixing motor
a Mark the routing of the mixing motor wiring.
a Remove the glovebox (see Glovebox: Removal -
a Disconnect the air mixing motor connector.
Refitting) (57A, Interior equipment).
a Remove:
- the bolts (4) from the air mixing motor,
- the air mixing motor.

61A-163
HEATING
Mixer motor: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and CLIMATE CONTROL
2 - Left-hand mixing motor 2 - Left-hand mixing motor

137015
a Move the tie rod so that the flat surface (9) of the
mixing motor recess is positioned at 90˚ in relation to
the distribution unit reference axis.

137640 II - REFITTING OPERATION FOR PART


CONCERNED
a Mark the routing of the mixing motor wiring.
a Refit the mixing motor.
a Disconnect the air mixing motor connector.
a Connect the air mixing motor connector.
a Remove:
a Fit the electrical wiring of the mixing motor.
- the bolts (5) from the air mixing motor,
- the air mixing motor. III - FINAL OPERATION

REFITTING 1 - Right-hand mixing motor


a Fit:
I - REFITTING PREPARATION OPERATION
- the clutch pedal,
- the hydraulic clutch pipes.
1 - Right-hand mixing motor
a Refit the clutch pedal nuts.
a Torque tighten the clutch pedal nuts (21 N.m).
a Clip:
- the clutch pedal wiring,
- the hydraulic clutch pipes.
a Refit:
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 57A, Interior equipment),
- the front right-hand A-pillar air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,

137014 - the dashboard lower trim (see Lower section of


dashboard trim: Removal - Refitting) (57A, Inte-
a Move the tie rod so that the flat surface (6) of the
rior equipment).
mixing motor recess is positioned at 90˚ in relation to
the distribution unit reference axis (7) . a Clip on the centre console right-hand trim.

61A-164
HEATING
Mixer motor: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and CLIMATE CONTROL
2 - Left-hand mixing motor
a Refit the glovebox (see Glovebox: Removal - Refit-
ting) (57A, Interior equipment).
a
a Apply the after repair procedure using the diagnos-
tic tool :
- connect the diagnostic tool,
- select "Climate control computer",
- go to repair mode,
- display the "Before/after repair procedure" for the
computer selected,
- select "Right-hand air mixing flap motor" in the "List
of components stored by this computer" section,
- carry out the operations described in the "After re-
pair procedure" section.

61A-165
HEATING
Mixer motor: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE, and CLIMATE CONTROL

Essential equipment

diagnostic tool

Tightening torquesm

pedal assembly nuts 21 N.m

upper nuts on the dash- 21 N.m


board cross member
reinforcement

lower bolts on the dash- 21 N.m


board cross member
reinforcement

REMOVAL
138640

I - REMOVAL PREPARATION OPERATION a Unclip the wiring from the dashboard cross member
reinforcement at (1) .
1 - Right-hand mixer motor a Remove the lower bolts (2) from the dashboard
a Remove: cross member reinforcement.

- the inhibitor switch (see Inhibitor switch: Remo-


val - Refitting) (88C, Airbag and pretensioners),

- the glovebox (see Glovebox: Removal - Refit-


ting) (57A, Interior equipment).

a Unclip the right-hand panel from the centre console.

2 - Left-hand mixer motor

a Unclip the left-hand panel from the centre console.

a Remove:

- the dashboard lower trim (see Lower section of


dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),

- the front left-hand footwell air distribution duct (see


61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) .
138639

a Remove:
FR AND RR PROX RADAR
- the upper nuts (3) from the dashboard cross mem-
a Disconnect the connector from the parking distance ber reinforcement,
control buzzer.
- the brake pedal impacter (4) ,

- the dashboard cross member reinforcement.

61A-166
HEATING
Mixer motor: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE, and CLIMATE CONTROL

109879 137156
a Remove: a Remove the nuts (7) from the brake pedal.
- the rubber ring (5) from the dual safety connecting
shaft, Note:
- the dual safety connecting shaft (6) . Do not disconnect the connectors from the
« brake pedal - accelerator» assembly and
replace the brake light switch in the event of an
impact.

a Partially remove the « brake pedal - accelerator »


assembly.

61A-167
HEATING
Mixer motor: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE, and CLIMATE CONTROL
II - REFITTING OPERATION FOR PART 2 - Left-hand mixer motor
CONCERNED

1 - Right-hand mixer motor

139240
a Disconnect the connector (11) from the air mixing
motor.
138645 a Remove:
a Mark the routing of the air mixing motor wiring (8) . - the bolts (12) from the air mixing motor,
- the air mixing motor.

138644

a Disconnect the connector (9) from the air mixing mo-


tor.

a Remove:

- the bolts (10) from the air mixing motor,

- the air mixing motor.

61A-168
HEATING
Mixer motor: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE, and CLIMATE CONTROL

REFITTING In the event of replacement

I - REFITTING PREPARATION OPERATION

1 - Right-hand mixer motor

In the event of replacement

139239
a Move the tie rod so that the flat surface (14) of the
left-hand mixing motor recess is positioned at 90˚ in
relation to the edge of the distribution unit reference
axis.

II - REFITTING OPERATION FOR PART


138598 CONCERNED
a Move the tie rod so that the flat surface (13) of the ri-
ght-hand mixing motor recess is positioned at 90˚ in
Right-hand and left-hand mixing motor
relation to the distribution unit reference axis.
a Refit the mixing motor.
2 - Left-hand mixer motor a Connect the air mixing motor connector.
a parts always to be replaced: Connecting shaft a Fit the electrical wiring of the mixing motor.
between the brake pedal and the brake servo
pushrod (30,03,02,07).
III - FINAL OPERATION

1 - Right-hand mixer motor


a Refit:
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 57A, Interior equipment),
- the inhibitor switch (see Inhibitor switch: Remo-
val - Refitting) (88C, Airbags and pretensioners).
a Clip on the right-hand panel of the centre console.

2 - Left-hand mixer motor


a Refit:
- the « accelerator - brake pedal » assembly,
- a new dual safety connecting shaft,

61A-169
HEATING
Mixer motor: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE, and CLIMATE CONTROL
- the dual safety connecting shaft rubber ring.

a Torque tighten the pedal assembly nuts (21 N.m).

a Refit:

- the dashboard cross member reinforcement,

- the brake pedal impacter.

a Torque tighten:

- the upper nuts on the dashboard cross member


reinforcement (21 N.m),

- the lower bolts on the dashboard cross member


reinforcement (21 N.m).

a Clip on the dashboard cross member reinforcement


wiring.

FR AND RR PROX RADAR

a Connect the parking distance control buzzer con-


nector.

a Refit:

- the front left-hand footwell air distribution duct (see


61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,

- the dashboard lower trim (see Lower section of


dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment).

a Clip on the left-hand panel of the centre console.

3 - Programming the left-hand or right-hand mixing


motor

a Apply the after repair procedure using the diagnos-


tic tool :

- connect the diagnostic tool,

- select « Climate control computer » ,

- go to repair mode,

- display the « before/after repair procedure » for the


computer selected,

- select « Left-hand air mixing flap motor or Right-


hand air mixing flap motor » in the « List of compo-
nents controlled by this computer » section,

- carry out the operations described in the « After re-


pair procedure » section.

61A-170
HEATING
Mixer motor: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE, and CLIMATE CONTROL
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Essential equipment

diagnostic tool 1 - Right-hand mixer motor

REMOVAL

I - REMOVAL PREPARATION OPERATION

Right-hand mixer motor


a Unclip the right-hand panel from the centre console.
a Remove:
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),
- the front right-hand footwell air distribution duct
(see 61A, Heating, A-pillar air distribution duct:
Removal - Refitting, page 61A-142) ,
- the clutch pedal position sensor (see Clutch pedal
position sensor: Removal - Refitting) (37A, Me-
chanical component controls).
138645

Left-hand mixer motor a Mark the routing of the air mixing motor wiring (1) .
a Remove the glovebox (see Glovebox: Removal -
Refitting) (57A, Interior equipment).
a Unclip the left-hand panel from the centre console.

138644

a Disconnect the connector (2) from the air mixing mo-


tor.

a Remove:

- the bolts (3) from the air mixing motor,

- the air mixing motor.

61A-171
HEATING
Mixer motor: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE, and CLIMATE CONTROL
2 - Left-hand mixer motor REFITTING

I - REFITTING PREPARATION OPERATION

1 - Right-hand mixer motor

In the event of replacement

139240
a Disconnect the connector (4) from the air mixing mo-
tor.
a Remove:
- the bolts (5) from the air mixing motor,
- the air mixing motor.
138598
a Move the tie rod so that the flat surface (6) of the ri-
ght-hand mixing motor recess is positioned at 90˚ in
relation to the distribution unit reference axis.

61A-172
HEATING
Mixer motor: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE, and CLIMATE CONTROL
2 - Left-hand mixer motor 2 - Left-hand mixer motor
a Refit the glovebox (see Glovebox: Removal - Refit-
In the event of replacement ting) (57A, Interior equipment).
a Clip on the left-hand panel of the centre console.

3 - Programming the left-hand or right-hand mixing


motor
a Apply the after repair procedure using the diagnos-
tic tool :
- connect the diagnostic tool,
- select « Climate control computer » ,
- go to repair mode,
- display the « before/after repair procedure » for the
computer selected,
- select « Left-hand air mixing flap motor or Right-
hand air mixing flap motor » in the « List of compo-
nents controlled by this computer » section,
- carry out the operations described in the « After re-
pair procedure » section.

139239

a Move the tie rod so that the flat surface (7) of the
mixing motor recess is positioned at 90˚ in relation to
the distribution unit reference axis.

II - REFITTING OPERATION FOR PART


CONCERNED

a Refit the mixing motor.

a Connect the air mixing motor connector.

a Fit the electrical wiring of the mixing motor.

III - FINAL OPERATION

1 - Right-hand mixer motor

a Refit:

- the clutch pedal position sensor (see Clutch pedal


position sensor: Removal - Refitting) (37A, Me-
chanical component controls).

- the front right-hand footwell air distribution duct


(see 61A, Heating, A-pillar air distribution duct:
Removal - Refitting, page 61A-142) ,

- the dashboard lower trim (see Lower section of


dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),

a Clip on the right-hand panel of the centre console.

61A-173
HEATING
Distribution motor: Removal - Refitting 61A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE, and CLIMATE CONTROL

REFITTING
Essential equipment
I - REMOVAL PREPARATION OPERATION
diagnostic tool

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Remove:
- the glovebox (see Glovebox: Removal - Refit-
ting) ( 57A, Interior equipment),
- the front right-hand A-pillar air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) .

II - OPERATION FOR REMOVAL OF PART 137012


CONCERNED a Move the tie rod so that the flat surface (3) of the dis-
tribution motor recess is positioned at 90˚ in relation
to the distribution unit reference axis (4) .

II - REFITTING OPERATION FOR PART


CONCERNED
a Refit the distribution motor.
a Connect the distribution motor connector.
a Fit the electrical wiring of the distribution motor.

III - FINAL OPERATION


a Refit:
- the front right-hand A-pillar air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,
- the glovebox (see Glovebox: Removal - Refit-
ting) (57A, Interior equipment).

136385 a Apply the after repair procedure using the diagnos-


tic tool :
a Mark the routing of the motor wiring.
- connect the diagnostic tool,
a Disconnect the connector (1) from the distribution
motor. - select "Climate control computer",
a Remove: - go to repair mode,
- the bolts (2) from the distribution motor, - display the "Before/after repair procedure" for the
computer selected,
- the distribution motor.
- select "Footwell air distribution flap motor" in the
"List of components stored by this computer" sec-
tion,
- carry out the operations described in the "After re-
pair procedure" section.

61A-174
HEATING
Distribution motor: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and CLIMATE CONTROL

Essential equipment

diagnostic tool

Tightening torquesm

clutch pedal nuts 21 N.m

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Unclip the right-hand centre console trim.
a Remove:
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),
137154
- the front right-hand A-pillar air distribution duct (see
a Remove the clutch pedal nuts (3) .
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) .
Note:
Do not disconnect the connectors from the clutch
pedal.

a Detach the clutch pedal from its threaded rods.

Note:
Do not apply pressure to the hydraulic clutch
pipes.

a Pass the hydraulic clutch pipes under the distribu-


tion unit.

137690
a Unclip the clutch hydraulic pipes (1) .
a Move the clutch hydraulic pipes aside.
a Unclip the wiring (2) from the clutch pedal.

61A-175
HEATING
Distribution motor: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and CLIMATE CONTROL
- the distribution motor.

REFITTING

I - REFITTING PREPARATION OPERATION

136999 137012
a Tilt the clutch pedal the in the direction of the move- a Move the tie rod so that the flat surface (6) of the dis-
ment arrow. tribution motor recess is positioned at 90˚ in relation
a Put the clutch pedal in the footwell. to the distribution unit reference axis (7) .

II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART


CONCERNED CONCERNED
a Refit the distribution motor.
a Connect the distribution motor connector.
a Fit the electrical wiring of the distribution motor.

III - FINAL OPERATION


a Fit:
- the clutch pedal,
- the hydraulic clutch pipes.
a Refit the clutch pedal nuts.
a Torque tighten the clutch pedal nuts (21 N.m).
a Clip:
- the clutch pedal wiring,
- the hydraulic clutch pipes.
a Refit:

136385 - the front right-hand A-pillar air distribution duct (see


61A, Heating, A-pillar air distribution duct: Re-
a Mark the routing of the distribution motor wiring.
moval - Refitting, page 61A-142) ,
a Disconnect the connector (4) from the distribution
- the dashboard lower trim (see Lower section of
motor.
dashboard trim: Removal - Refitting) (57A, Inte-
a Remove: rior equipment).
- the bolts (5) from the distribution motor, a Clip on the centre console right-hand trim.

61A-176
HEATING
Distribution motor: Removal - Refitting 61A
B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and CLIMATE CONTROL
a Apply the after repair procedure using the diagnos-
tic tool :
- connect the diagnostic tool,
- select "Climate control computer",
- go to repair mode,
- display the "Before/after repair procedure" for the
computer selected,
- select "Footwell air distribution flap motor" in the
"List of components stored by this computer" sec-
tion,
- carry out the operations described in the "After re-
pair procedure" section.

61A-177
HEATING
Distribution motor: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE, and CLIMATE CONTROL

Essential equipment

diagnostic tool

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Remove the glovebox (see Glovebox: Removal -
Refitting) (57A, Interior equipment).

II - OPERATION FOR REMOVAL OF PART


CONCERNED

138643
a Disconnect the connector (2) from the distribution
motor.
a Remove:
- the bolts (3) from the distribution motor,
- the distribution motor.

138645
a Mark the routing of the distribution motor wiring (1) .

61A-178
HEATING
Distribution motor: Removal - Refitting 61A
J95, and LEFT-HAND DRIVE, and CLIMATE CONTROL

REFITTING - carry out the operations described in the "After re-


pair procedure" section.

I - REFITTING PREPARATION OPERATION

In the event of replacement

138597

a Move the tie rod so that the flat surface (4) of the dis-
tribution motor recess is positioned at 90˚ in relation
to the distribution unit reference axis.

II - REFITTING OPERATION FOR PART


CONCERNED
a Refit the distribution motor.
a Connect the distribution motor connector.
a Fit the electrical wiring of the distribution motor.

III - FINAL OPERATION


a Refit the glovebox (see Glovebox: Removal - Refit-
ting) (57A, Interior equipment).
a Apply the after repair procedure using the diagnos-
tic tool :
- connect the diagnostic tool,
- select "Climate control computer",
- go to repair mode,
- display the "Before/After repair procedure" for the
computer selected,
- select "Footwell air distribution flap motor" in the
"List of components controlled by this computer"
section,

61A-179
HEATING
Distribution motor: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE, and CLIMATE CONTROL

Essential equipment

diagnostic tool

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Remove:
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),
- the front footwell air distribution duct (see 61A,
Heating, A-pillar air distribution duct: Removal
- Refitting, page 61A-142) ,
- the clutch pedal position sensor (see Clutch pedal
position sensor: Removal - Refitting) (37A, Me-
chanical component controls). 138643
a Disconnect the connector (2) from the distribution
II - OPERATION FOR REMOVAL OF PART motor.
CONCERNED
a Remove:
- the bolts (3) from the distribution motor,
- the distribution motor.

138645
a Mark the routing of the distribution motor wiring (1) .

61A-180
HEATING
Distribution motor: Removal - Refitting 61A
J95, and RIGHT-HAND DRIVE, and CLIMATE CONTROL

REFITTING - select "Climate control computer",


- go to repair mode,
I - REFITTING PREPARATION OPERATION - display the "Before/After repair procedure" for the
computer selected,
In the event of replacement - select "Footwell air distribution flap motor" in the
"List of components controlled by this computer"
section,
- carry out the operations described in the "After re-
pair procedure" section.

138597
a Move the tie rod so that the flat surface (4) of the dis-
tribution motor recess is positioned at 90˚ in relation
to the distribution unit reference axis.

II - REFITTING OPERATION FOR PART


CONCERNED
a Refit the distribution motor.
a Connect the distribution motor connector.
a Fit the electrical wiring of the distribution motor.

III - FINAL OPERATION


a Refit:
- the clutch pedal position sensor (see Clutch pedal
position sensor: Removal - Refitting) (37A, Me-
chanical component controls).
- the front footwell air distribution duct (see 61A,
Heating, A-pillar air distribution duct: Removal
- Refitting, page 61A-142) ,
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),
a Apply the after repair procedure using the diagnos-
tic tool :
- connect the diagnostic tool,

61A-181
HEATING
Passenger compartment temperature sensor: Removal - Refitting 61A
REMOVAL

OPERATION FOR REMOVAL OF PART


CONCERNED

138649
a Unclip the passenger compartment temperature
sensor (3) from the interior rear view mirror trim.

138651 REFITTING
a Remove the interior rear view mirror trim (1) .
REFITTING OPERATION FOR PART CONCERNED
a Clip the passenger compartment temperature sen-
sor onto the interior rear view mirror trim.
a Connect the passenger compartment temperature
sensor connector.
a Refit the interior rear view mirror trim.

138650
a Disconnect the passenger compartment temperatu-
re sensor connector (2) .

61A-182
HEATING
External temperature sensor: Removal - Refitting 61A
Note:
The exterior temperature sensor is located in the
door mirror on the right-hand side.

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Remove:
- the right-hand door mirror glass (see Door mirror
glass: Removal - Refitting) (56A, Exterior equip-
ment),
- the right-hand door mirror casing (see Door mirror
casing: Removal - Refitting) (56A, Exterior equip-
ment).

II - OPERATION FOR REMOVAL OF PART 138676


CONCERNED a Remove the exterior temperature sensor (2) from its
mounting.

138670
a Unclip the right-hand door mirror mounting to remo- 138674
ve the sensor by pressing on the clips (1) . a Cut the wires (3) of the exterior temperature sensor
(see Wiring: Repair) (Technical Note 6015A, 88A,
Wiring).

61A-183
HEATING
External temperature sensor: Removal - Refitting 61A
REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED
a Solder the wires of the exterior temperature sensor
(see Wiring: Repair) (Technical Note 6015A, 88A,
Wiring).
a Refit the exterior temperature sensor onto its moun-
ting.
a Clip on the right-hand door mirror mounting.

II - FINAL OPERATION
a Refit:
- the right-hand door mirror casing (see Door mirror
casing: Removal - Refitting) (56A, Exterior equip-
ment),
- the right-hand door mirror glass (see Door mirror
glass: Removal - Refitting) (56A, Exterior equip-
ment).

61A-184
AIR CONDITIONING
Air conditioning: List and location of components 62A

139042

No. Description

(1) Compressor (see 62A, Air conditioning, Compressor: Removal - Refit-


ting, page 62A-21)

(2) « Compressor - condenser » connecting pipe (see 62A, Air conditioning,


Condenser - compressor connecting pipe: Removal - Refitting, page
62A-85)

(3) Condenser (see 62A, Air conditioning, Condenser: Removal - Refitting,


page 62A-12)

(4) Dehydrator reservoir filter

(5) « Condenser - expansion valve » connecting pipe (see 62A, Air conditio-
ning, Expansion valve - condenser connecting pipe: Removal - Refit-
ting, page 62A-49)

(6) « Expansion valve - intermediate pipe » connecting pipe (see 62A, Air con-
ditioning, Expansion valve - intermediate pipe connecting pipe at the
expansion valve outlet: Removal - Refitting, page 62A-65)

62A-1
AIR CONDITIONING
Air conditioning: List and location of components 62A
No. Description

(7) « Intermediate pipe - compressor » connecting pipe (see 62A, Air conditio-
ning, Compressor/intermediate pipe connecting pipe: Removal - Refit-
ting, page 62A-95)

(8) Pressure sensor (see 62A, Air conditioning, Pressure sensor: Removal -
Refitting, page 62A-77)

62A-2
AIR CONDITIONING
Air conditioning: Precautions for repair 62A
I - SAFETY

IMPORTANT
IMPORTANT To prevent refrigerant from leaking, never repair a
faulty air conditioning circuit component.
The following must be worn when handling refrige-
rant: Replace all faulty components.

- gloves, It is essential to follow the routing of the connecting pi-


pes.
- protective goggles (with side shields if possible).
Ensure that the refrigerant connecting pipes are cor-
In the event of refrigerant fluid coming into contact
rectly fitted so that they will not come into contact with
with the eyes, rinse well with clean water conti-
metal parts in the engine compartment.
nuously for 15 minutes. If possible, have an eye
rinse unit available.
If refrigerant comes into contact with your eyes, WARNING
consult a doctor immediately. Inform the doctor that In order to avoid any refrigerant leaks, do not
the burns were caused by R134A refrigerant. damage (deform, twist, etc.) the pipe.
In the event of contact with other unprotected parts
of the body (event though the safety advice has
been observed), rinse well with clean water conti-
nuously for 15 minutes. WARNING
To avoid damaging the surface of the air conditio-
ning pipes when removing the seals, do not use a
tool with a metallic end piece.
IMPORTANT
Work requiring the use of refrigerant must be car-
ried out in a well-ventilated area.
WARNING
The refrigerant must not be stored in a shaft, a pit, To prevent moisture from entering the system,
a hermetically sealed room, etc. place plugs on the cold loop components which are
Refrigerants are colourless and odourless fluids. open to the air.

Refrigerant is heavier than air. As a result there is a risk


of asphyxia for those working close to the ground and
less than 5 m away from the working area (pit, well, air WARNING
vents, etc.). To prevent any leaks, check that the seal and sur-
Switch on gas extraction systems. face of the pipe are in good condition. The seal and
the surface must be clean and free from scratches.
At temperatures above 100˚C, the refrigerant will de-
compose and produce a highly irritant gas.

WARNING
IMPORTANT Lubricants are not mutually compatible: always
It is forbidden to smoke close to an open refrigerant observe the type and quantity of oil recommended
circuit. for each compressor even when topping up as this
could damage the cold loop components.

II - GENERAL RECOMMENDATIONS Always close the oil cans again after use to keep
moisture out and never use oil contained in a can
It is possible to place components in the drying oven that has been open for a long time (viscous appea-
after painting or to carry out work near the system if the rance).
temperature does not exceed 80˚C.

62A-3
AIR CONDITIONING
Air conditioning: Parts and consumables for the repair work 62A
For the oil part number (see Vehicle: Parts and con-
sumables for repair) (04B, Consumables - Products).

Table of vehicle refrigerant capacities according to their engines and various specifications.

Engine Refrigerant capacity Type of compres- Type of ori- Type of Quantity of


(g) sor ginal oil After-Sales oil (ml)
oil

K4M

F4R

K9K
480 ± 35 6 SEL 14C ND-OIL 8 110 ± 10
SANDEN
M9R
SP10
F9Q

H4J

M4R 510 ± 35 VALEO DCS-S7EC ZXL 100 PG 150 0/+ 20

Table of quantities of oil to add when replacing components:

Operation on the air conditioning circuit Quantity of oil (ml or cm 3)

Circuit oil change Measure the volume recovered and add the
same quantity of new oil

Split pipe or other rapid leak 100

Replacement of a pipe Quantity recovered +10

Replacement of a condenser Quantity recovered +30

Replacement of an evaporator or distribution unit Quantity recovered +30

Replacement of the filter or dehydrator reservoir Quantity recovered +15

Removing - Refitting a compressor Quantity recovered

Replacement of a compressor None added

Standard replacement of a compressor Top up as necessary

Replacement of a compressor and one or more air conditio- None added


ning circuit component(s)

Standard replacement of a compressor and replacement of Top up as necessary


one or more refrigerant circuit component(s)

62A-4
AIR CONDITIONING
Air conditioning: Check 62A
Equipment required

Dual-sensor temperature measuring device

Note:
When performing RENAULT maintenance, check
the air conditioning system at the end of the vehi-
cle's maintenance program so that the engine will
be cold.

I - PREPARATION OPERATION FOR THE


MEASUREMENT DEVICE
a Check that the measurement device functions pro-
perly (see the device's instruction manual).
a Set units to ˚C.
119358
a Set the device's sensitivity to 0.1˚C.
a Check the two sensors T1 and T2 in order to calcu-
late the correction (∆) to be applied to the measure-
ment (T1 - T2). the two sensors must indicate the
same measurement under the same conditions.
Check the sensors by:

- bringing the ends of the 2 sensors together until


they touch,

- placing the sensors in the air flow of an air vent,

- setting the passenger compartment fan assembly


to top speed.

- waiting for the value to become stable.

- recording the correction value (∆).

Note:
It is not necessary to start the vehicle. The
device display is in mode (∆T) = (T1 - T2).
119360
a Set the reading mode to (∆T) = (T1 - T2)
WARNING
Note the difference and sign as soon as the tem-
perature becomes stable.
Calculate the correction (∆) = - (T1 - T2) to be
applied to the measurement (∆T).
Examples:
If (T1 - T2) = - 0.3˚C, correct the measurement
(∆T) by (∆) = + 0.3˚C
If (T1 - T2) = + 0.3˚C, correct the measurement
(∆T) by (∆) = - 0.3˚C

62A-5
AIR CONDITIONING
Air conditioning: Check 62A
II - VEHICLE PREPARATION OPERATION - wait for the value to become stable.
a Put the vehicle in the shade, where the temperature - record the T3 temperature value.
is greater than or equal to 15˚C minimum.
- close the bonnet if it was opened.
a Close the bonnet.
a Open the front windows.
a Start the engine and let it idle.
a Set the air conditioning controls with:
- recirculation mode in the external position,
- the ventilation distribution in "face" mode,
- the temperature control to coldest temperature set-
ting in front (and at the back, if it exists),
- the speed of the passenger compartment fan as-
sembly set to maximum (switch off the rear control
if it exists),
- the front side and centre air vents open with the va-
nes in a neutral position,
- the air conditioning system must be turned on (indi-
cator light illuminated).
a Wait 5 minutes with the engine idling before ta-
119357
king any measurements.
a Record the air temperature at the left air vent (T1),
and at the right air vent (T2).
III - MEASUREMENTS
- fit sensor T1 in the left air vent (1) .
- fit sensor T2 in the right air vent (2) .
a Record the differences in temperature once the (∆T)
value has stabilised:
- between T3 and the higher of values T1 or T2, (T3
- highest value).
- record this difference in temperature.
- between T1 and T2 (read the (∆T) value (T1-T2)
display mode).
- record the difference in temperature (∆T) accor-
ding to the correction (∆) to be applied to the
measurement.
a If the (∆T)=(T1-T2) measurement is unstable, follow
the procedure below:

Note:
119359 Depending on the vehicle's air conditioning sys-
a Record the air temperature at the scuttle panel grille tem programming, this check method may not be
(T3). applicable because the engine cooling fan
assembly has been activated. Its operation ren-
- open the bonnet, depending on the vehicle, to ac- ders the (∆Τ) value between T1 and T2 unstable.
cess the scuttle panel grille. To eliminate this error, the fan assembly must be
- place the sensor where air is drawn through the activated for the entire period over which tempe-
scuttle panel grille. rature T1 and T2 measurements are recorded.

62A-6
AIR CONDITIONING
Air conditioning: Check 62A
a Activate the engine cooling fan assembly operation
by modifying the engine speed.
- stabilise the engine speed at 2000 rpm while T1
and T2 temperature measurements are being re-
corded.
- check that the engine cooling fan assembly opera-
ting.
- record the temperatures by following the instruc-
tions given in the paragraph MEASUREMENTS.

IV - FAULT FINDING PROCEDURE


a The following two following conditions must be met:
- the difference between T3 and the higher of the two
values T1 or T2, must be greater than or equal to
5˚C,
- the difference between T1 and T2 must be less
than or equal to 2˚C.

Note:
If one of these two conditions is not met, then the
air conditioning system is not working properly.
Should this be the case, refer to the fault finding
procedure for the air conditioning system for the
vehicle concerned.

62A-7
AIR CONDITIONING
Coolant circuit check 62A
a Check the sealing of the refrigerant circuit using the
electronic trace detector (follow the trace of the cir-
Essential equipment
cuit as closely as possible, to limit variations due to
diagnostic tool other gases).

Note:
IMPORTANT If replacing a defective part (see 62A, Air condi-
Consult the safety and cleanliness advice and ope- tioning).
ration recommendations before carrying out any
repair (see 62A, Air conditioning, Air conditio-
ning: Precautions for repair, page 62A-3) . 2 - Trace detectors
a

WARNING
Note: Consult the device's operating manual to avoid
After any work on air conditioning circuit leaks on incorrect use.
the Laguna II, Vel Satis and Espace IV, check that
filling fault DF033 Refrigerant is not present, using
the diagnostic tool. If it is present, clear it. The WARNING
compressor cannot operate until the fault is cleared. To avoid damaging the cold loop components
(corrosions, etc.), do not use dye if the traces
There are several types of detector: reveal that some product has already been injec-
ted.
- electronic detectors,
a Check for dye on the cold loop components with the
- trace detectors.
ultraviolet light.
a Inject the dye.
Note: a Start the engine.
To carry out an after repair check, use the proce- a Let the air conditioning system run for 15 minutes.
dure for the electronic detector (1). To carry out a
more thorough check for leaks, use a trace detector a Switch off the engine.
(2). a Check the refrigerant circuit sealing by scanning the
circuit with the ultraviolet light.
Check that the air conditioning system is operating cor-
rectly (see 62A, Air conditioning, Air conditioning:
Check, page 62A-5) . Note:
If replacing a defective part (see 62A, Air condi-
REFRIGERANT CIRCUIT SEALING CHECKING tioning).
OPERATION
a Affix a label (supplied with the dye capsule), to indi-
cate that dye has been used (as close as possible to
1 - Electronic detectors: the filler valves).

WARNING
Consult the device's operating manual to avoid
incorrect use.

a Switch on the electronic detector.

a Start the engine.

a Let the air conditioning system run for 15 minutes.

a Switch off the engine.

62A-8
AIR CONDITIONING
Coolant circuit Draining - Refilling 62A
Essential equipment

refrigerant charging station

IMPORTANT
Consult the safety and cleanliness advice and ope-
ration recommendations before carrying out any
repair (see 62A, Air conditioning, Air conditio-
ning: Precautions for repair, page 62A-3) .

WARNING
Consult the device's operating manual to avoid
incorrect use.

WARNING
To avoid damaging the cold loop components (cor-
rosions, etc.), do not use dye if the traces reveal
that some product has already been injected.

Note:
A summary table gives the quantities of refrigerant
in the system according to the engine type (see
62A, Air conditioning, Air conditioning: Parts
and consumables for the repair work, page 62A-
4) .

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

62A-10
AIR CONDITIONING
Coolant circuit Draining - Refilling 62A
a Top up the oil with the recommended type and volu-
me of oil and refrigerant, depending on the work car-
ried out (see 6 2 A, Air conditioning, Air
conditioning: Parts and consumables for the re-
pair work, page 62A-4) .
a Check there are no leaks using the electronic de-
tector (see 62A, Air conditioning, Coolant circuit
check, page 62A-8) .

WARNING
After injecting dye into the refrigerant, be sure to
indicate this on a label (supplied with the dye
capsule), and the date of the operation.
Position the label so it is visible near to the cold
loop filler valve.

a Check that the air conditioning system is operating


correctly (see 62A, Air conditioning, Air conditio-
ning: Check, page 62A-5) .

62A-11
AIR CONDITIONING
Condenser: Removal - Refitting 62A
B95 or D95 or E95 or K95
- the front sections of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
Essential equipment
(55A, Exterior protection),
refrigerant charging station - the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).

IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 62A, Air conditioning, Air conditio-
ning: Precautions for repair, page 62A-3) .

Note:
Use blanking plugs for the fuel circuits with part
numbers 77 01 208 229 or 77 01 476 857 to plug
any openings exposed to the open air. They must
be clean. Do not use any which have already been
used to plug a fuel circuit.

WARNING
To prevent moisture from entering the system,
place plugs on the cold loop components which are
open to the air.

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

WARNING
Consult the device's operating manual to avoid
incorrect use.

a Drain the refrigerant circuit using the refrigerant


charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) .

XENON BULBS
a Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).

a Remove:
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),

62A-12
AIR CONDITIONING
Condenser: Removal - Refitting 62A
B95 or D95 or E95 or K95

135786

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

62A-13
AIR CONDITIONING
Condenser: Removal - Refitting 62A
B95 or D95 or E95 or K95
II - OPERATION FOR REMOVAL OF PART
CONCERNED

135670
a Remove the bolt (5) securing the bracket for the
135672 « condenser - expansion valve » connecting pipe to
a Disconnect the pressure sensor connector (4) . the condenser.

WARNING
In order to avoid any refrigerant leaks, do not
damage (deform, twist, etc.) the pipe.

a Disconnect the « condenser - expansion valve »


connecting pipe from the condenser.
a Insert the blanking plugs.

62A-14
AIR CONDITIONING
Condenser: Removal - Refitting 62A
B95 or D95 or E95 or K95

135671 135674
a Remove the bolt (6) securing the bracket for the a Remove the condenser in accordance with the di-
« compressor - condenser » connecting pipe from rection of the arrow.
the condenser.

REFITTING
WARNING
In order to avoid any refrigerant leaks, do not
damage (deform, twist, etc.) the pipe. I - REFITTING PREPARATION OPERATION

a
a Disconnect the « compressor - condenser » connec-
ting pipe from the condenser. WARNING
a Insert the blanking plugs. Do not remove the blanking plugs from each
component until the last moment.
Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

WARNING
To avoid any leaks, check that the seal and the
pipe surface are in good condition. The seal and
the surface must be clean and scratch free.

a Remove the blanking plugs.

II - REFITTING OPERATION FOR PART


CONCERNED

a Refit:

- the condenser,

- the connecting pipes to the condenser.

a Connect the pressure sensor connector.

62A-15
AIR CONDITIONING
Condenser: Removal - Refitting 62A
B95 or D95 or E95 or K95
III - FINAL OPERATION
a Refit
- the side support of the left-hand front panel (see
Front end panel side support: Removal - Refit-
ting) (42A, Upper front structure),

- the left-hand headlight (see Front headlight: Re-


moval - Refitting) (80B, Headlights),
- the audible warning (see Horn: Removal - Refit-
ting) (82A, Horn).
a Clip:
- the right-hand side deflector,

- the left-hand side deflector,


- the central deflector.
a Refit:

- the front bumper (see Front bumper: Removal -


Refitting) (55A, Exterior protection),
- the front sections of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres).

XENON BULBS

a Connect the battery (see Battery : Removal - Refit-


ting) (80A, Battery).

Note:
A summary table gives the quantities of refrige-
rant in the system according to the engine types
(see 62A, Air conditioning, Air conditioning:
Parts and consumables for the repair work,
page 62A-4) .

a Fill up the refrigerant circuit using the refrigerant


charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) .
a Check for leaks (see 62A, Air conditioning, Coo-
lant circuit check, page 62A-8) .
a Check the air conditioning system is operating cor-
rectly (see 62A, Air conditioning, Air conditio-
ning: Check, page 62A-5) .
a Adjust the headlights (see Front headlight: Adjus-
ting) (80B, Headlights).

62A-16
AIR CONDITIONING
Condenser: Removal - Refitting 62A
J95

Essential equipment

refrigerant charging station

IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 62A, Air conditioning, Air conditio-
ning: Precautions for repair, page 62A-3) .

WARNING
To prevent moisture from entering the system,
place plugs on the cold loop components which are
open to the air.

Note:
Use blanking plugs for the fuel circuits with part
numbers 77 01 208 229 or 77 01 476 857 to plug
any openings exposed to the open air. They must
be clean. Do not use any which have already been
used to plug a fuel circuit.

REMOVAL
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).

WARNING
Consult the device's operating manual to avoid
incorrect use.

a Drain the refrigerant circuit using the refrigerant


charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) .

a Remove:

- the front wheels (see Wheel: Removal - Refitting)


(35A, Wheels and tyres),

- the front section of the front wheel arch liners (see


Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),

- the front bumper (see Front bumper: Removal -


Refitting) (55A, Exterior protection).

62A-17
AIR CONDITIONING
Condenser: Removal - Refitting 62A
J95

138677 138678

a Unclip:

- the central deflector (1) ,

- the left-hand side deflector (2) ,

- the right-hand side deflector (3) .

OPERATION FOR REMOVAL OF PART


CONCERNED

138679

135672

a Disconnect the pressure sensor connector (4) .

62A-18
AIR CONDITIONING
Condenser: Removal - Refitting 62A
J95

135670 138725
a Remove the bolt (5) securing the bracket for the a Remove the bolt (6) securing the bracket for the
« condenser - expansion valve » connecting pipe to « compressor - condenser » connecting pipe from
the condenser. the condenser.

WARNING WARNING
In order to avoid any refrigerant leaks, do not In order to avoid any refrigerant leaks, do not
damage (deform, twist, etc.) the pipe. damage (deform, twist, etc.) the pipe.

a Disconnect the « condenser - expansion valve » a Disconnect the « compressor - condenser » connec-
connecting pipe from the condenser. ting pipe from the condenser.
a Insert the blanking plugs. a Insert the blanking plugs.

62A-19
AIR CONDITIONING
Condenser: Removal - Refitting 62A
J95
III - FINAL OPERATION
a Clip:
- the right-hand side deflector,
- the left-hand side deflector,
- the central deflector.
a Refit:
- the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
- the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres).

Note:
A summar y table gives the quantity of refrigerant
138671 in the system according to the engine type (see
a Remove the condenser in the direction of the ar- 62A, Air conditioning, Air conditioning: Parts
rows. and consumables for the repair work, page
62A-4) .

REFITTING a Perform the following operations:


- refill the refrigerant circuit using the refrigerant
charging station (see 62A, Air conditioning,
I - REFITTING PREPARATION OPERATION
Coolant circuit Draining - Refilling, page 62A-9)
a ,
- check for leaks (see 62A, Air conditioning, Coo-
WARNING
lant circuit check, page 62A-8) .
Do not remove the blanking plugs from each
component until the last moment. a Check the air conditioning system is operating cor-
rectly (see 62A, Air conditioning, Air conditio-
Also, do not remove the components from their ning: Check, page 62A-5) .
packaging until they are to be fitted to the vehi-
cle.

WARNING
To avoid any leaks, check that the seal and the
pipe surface are in good condition. The seal and
the surface must be clean and scratch free.

a Remove the blanking plugs.

II - REFITTING OPERATION FOR PART


CONCERNED

a Refit:

- the condenser,

- the connecting pipe on the condenser.

a Connect the pressure sensor connector.

62A-20
AIR CONDITIONING
Compressor: Removal - Refitting 62A
B95 or D95 or E95 or K95
a Remove:
Essential equipment - the engine cover,

refrigerant charging station - the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
- the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
IMPORTANT (55A, Exterior protection),

To avoid all risk of damage to the systems, apply - the front bumper (see Front bumper: Removal -
the safety and cleanliness instructions and opera- Refitting) (55A, Exterior protection),
tion recommendations before carrying out any - the headlights (see Front headlight: Removal -
repair: Refitting) (80B, Headlights),
- (see 62A, Air conditioning, Air conditioning:
- the front bumper supports (see Front bumper
Precautions for repair, page 62A-3) , support: Removal - Refitting) (42A, Front upper
- (see Vehicle: Precautions for repair) (01D, structure),
Mechanical introduction). - the audible warning (see Horn: Removal - Refit-
ting) (82B, Horn),
- the front impact cross member (see Front impact
cross member: Removal - Refitting) (41A, Front
WARNING
lower structure),
To prevent moisture from entering the system,
place plugs on the cold loop components which are - the bonnet catch (see Bonnet latch: Removal -
open to the air. Refitting) (52A, Non-side opening element mecha-
nisms).

WARNING
Note:
In order to prevent the accessories belt from
Use blanking plugs for the fuel circuits with part being prematurely ruptured, do not damage (hit,
numbers 77 01 208 229 or 77 01 476 857 to plug force with a tool, etc.) the plastic pulley of the
any openings exposed to the open air. They must compressor.
be clean. Do not use any which have already been
used to plug a fuel circuit. a Remove the accessories belt (see Accessories
belt: Removal - Refitting) (11A, Top and front of
engine).

REMOVAL

I - REMOVAL PREPARATION OPERATION

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


Towing and lifting) (02A, Lifting equipment).

WARNING
Consult the device's operating manual to avoid
incorrect use.

a Drain the refrigerant circuit using the refrigerant


charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) .

a Disconnect the battery (see Battery : Removal -


Refitting) (80A, Battery).

62A-21
AIR CONDITIONING
Compressor: Removal - Refitting 62A
B95 or D95 or E95 or K95

135882 135296
a Remove the bolts (1) from the engine wiring chan- a Remove the lower bolts (4) from the front end panel.
nel.
a Tilt the front end panel slightly towards the front of
the vehicle.

F4R or F9Q or K9K or M9R


a Remove the intercooler air outlet pipe (see Inter-
cooler air outlet pipe: Removal - Refitting) (12B,
Turbocharging).

135719
a Remove:
- the upper bolts (2) from the front end panel,
- the front end panel clips (3) .

62A-22
AIR CONDITIONING
Compressor: Removal - Refitting 62A
B95 or D95 or E95 or K95

F4R

136473
a Remove the connecting pipe bracket bolts (6) on the
135700
compressor.

a Remove the bolt (5) of the « intermediate pipe -


compressor» connecting pipe retaining bracket WARNING
from the engine block. In order to avoid any refrigerant leaks, do not
a Remove the bolt of the « compressor - condenser » damage (deform, twist, etc.) the pipe.
connecting pipe retaining bracket bolt from the com-
pressor. a Uncouple the connecting pipes from the compres-
sor.
a Move aside the compressor connecting pipes.
a Fit blanking plugs on the openings of the connecting
pipes and the compressor.

62A-23
AIR CONDITIONING
Compressor: Removal - Refitting 62A
B95 or D95 or E95 or K95
II - OPERATION FOR REMOVAL OF PART
CONCERNED

142163

136473 a Remove the bolts (10) from the compressor.


a Disconnect the compressor connector (7) .
a Remove the bolts (8) from the compressor.

a Move aside the wiring.


M4R
a Remove the compressor.

REFITTING

I - REFITTING PREPARATION OPERATION

WARNING
Do not remove the blanking plugs from each
component until the last moment.
Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

WARNING
To avoid any leaks, check that the seal and the
142162
pipe surface are in good condition. The seal and
a Disconnect the compressor connectors (9) . the surface must be clean and scratch free.

a Remove the blanking plugs.

a Check the condition of the seals on the refrigerant


connecting pipes.

62A-24
AIR CONDITIONING
Compressor: Removal - Refitting 62A
B95 or D95 or E95 or K95
II - REFITTING OPERATION FOR PART - the accessories belt (see Accessories belt: Re-
CONCERNED moval - Refitting) (11A, Top and front of engine),
a Refit the compressor. - the front bumper (see Front bumper: Removal -
a Connect the compressor connector. Refitting) (55A, Exterior protection),

- the front section of the front wheel arch liners (see


M4R Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),
a Connect the compressor connectors.
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres).

a Fit the wiring. a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).

III - FINAL OPERATION


a Refit the connecting pipes to the compressor. Note:
A summary table gives the quantities of refrige-
rant in the system according to the engine types
F4R
(see 62A, Air conditioning, Air conditioning:
a Refit: Parts and consumables for the repair work,
page 62A-4) .
- the retaining bracket of the « intermediate pipe -
compressor » connecting pipe on the engine block,
a Fill up the refrigerant circuit using the refrigerant
- the retaining bracket of the « compressor - charging station (see 62A, Air conditioning, Coo-
condenser » connecting pipe on the compressor. lant circuit Draining - Refilling, page 62A-9) .

a In the event of replacement, apply the after repair


procedure:

- Switch on the ignition,


F4R or F9Q or K9K or M9R
- Check that the air conditioning is off,
a Refit the intercooler air outlet pipe (see Intercooler
air outlet pipe: Removal - Refitting) (12B, Turbo- - Switch the ventilation to speed 2,
charging).
- Put the temperature setting at minimum,

- Select the air recirculation position,


a Fit the front end panel. - Start the engine.
a Refit the engine wiring channel.
- Run the air conditioning in manual mode (in the
a Refit: case of climate control do not press auto),
- the bonnet catch (see Bonnet latch: Removal - - Run the engine at idle speed for 3 minutes with air
Refitting) (52A, Non-side opening element mecha- conditioning,
nisms),
- Switch off the engine.
- the front impact cross member (see Front impact
cross member: Removal - Refitting) (41A, Front a Check for leaks (see 62A, Air conditioning, Coo-
lower structure), lant circuit check, page 62A-8) .
- the front bumper supports (see Front bumper
a Check that the air conditioning system is operating
support: Removal - Refitting) (42A, Front upper
correctly (see 62A, Air conditioning, Air conditio-
structure),
ning: Check, page 62A-5) .
- the headlights (see Front headlight: Removal -
Refitting) (80B, Headlights), a Refit the engine cover.

- the audible warning (see Horn: Removal - Refit- a Adjust the headlights (see Front headlight: Adjus-
ting) (82B, Horn), ting) (80B, Headlights).

62A-25
AIR CONDITIONING
Compressor: Removal - Refitting 62A
J95
- the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
Essential equipment
(55A, Exterior protection),
refrigerant charging station
- the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
IMPORTANT - the audible warning (see Horn: Removal - Refit-
To avoid all risk of damage to the systems, apply ting) (82B, Horn),
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any - the front impact cross member (see Front impact
repair (see 62A, Air conditioning, Air conditio- cross member: Removal - Refitting) (41A, Front
ning: Precautions for repair, page 62A-3) . lower structure),

- the cooling radiator air deflectors,


WARNING - the headlights (see Front headlight: Removal -
To prevent moisture from entering the system, Refitting) (80B, Headlights).
place plugs on the cold loop components which are
open to the air.

Note:
Use blanking plugs for the fuel circuits with part
numbers 77 01 208 229 or 77 01 476 857 to plug
any openings exposed to the open air. They must
be clean. Do not use any which have been used to
plug a fuel circuit.

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Remove the front engine cover.
138656
WARNING
a Remove:
Consult the device's operating manual to avoid
incorrect use. - the bonnet supports (1) ,
a Drain the refrigerant circuit using the refrigerant - the accessories belt (see Accessories belt: Re-
charging station (see 62A, Air conditioning, Coo- moval - Refitting) (11A, Top and front of engine).
lant circuit Draining - Refilling, page 62A-9) .
a Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery). F9Q or H4J or K9K or M9R
a Remove: a Remove the intercooler air outlet pipe (see Inter-
- the engine undertray bolts, cooler air outlet pipe: Removal - Refitting) (12B,
Turbocharging).
- the engine undertray,
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),

62A-26
AIR CONDITIONING
Compressor: Removal - Refitting 62A
J95

K9K M9R

135883 138488
a Unclip the expansion bottle top hose (2) from the a Remove the rigid cooling hose bolts (4) on the front
front end panel. end panel.

140184
a Unclip the degassing hose from the front end panel
at (5) .

138486
a Unclip the bonnet cable at (3) .
a Remove the bonnet cable.

62A-27
AIR CONDITIONING
Compressor: Removal - Refitting 62A
J95

H4J

139053
a Remove:
138363 - the bolts (8) of the engine wiring channel,
a Remove the bolt (6) from the front end panel winds- - the bonnet catch (see Bonnet latch: Removal -
creen washer reservoir. Refitting) (52A, Non-side opening element mecha-
nisms).

140184
a Unclip the degassing hose from the front end panel
at (7) .

a Unclip the remaining wiring from the front end panel.

62A-28
AIR CONDITIONING
Compressor: Removal - Refitting 62A
J95

139052 136473
a Remove the connecting pipe bracket bolts (10) .

WARNING
In order to avoid any refrigerant leaks, do not
damage (deform, twist, etc.) the pipe.

a Move aside the compressor connecting pipes.


a Fit blanking plugs on the openings of the connecting
pipes and the compressor.

135646
a Remove the front end panel bolts (9) .
a Tilt the front end panel.

62A-29
AIR CONDITIONING
Compressor: Removal - Refitting 62A
J95
II - OPERATION FOR REMOVAL OF PART
CONCERNED
M4R or M9R

138724
138724
a Disconnect the compressor connector (11) .
a Remove:
a Unclip the compressor wiring at (12) .
- the compressor bolts (14) ,

- the compressor.

REFITTING

I - REFITTING PREPARATION OPERATION

WARNING
Do not remove the blanking plugs from each
component until the last moment.
Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.
136473

a Remove: WARNING
- the compressor bolts (13) , To avoid any leaks, check that the seal and the
pipe surface are in good condition. The seal and
- the compressor. the surface must be clean and scratch free.

a Remove the blanking plugs.

62A-30
AIR CONDITIONING
Compressor: Removal - Refitting 62A
J95
II - REFITTING OPERATION FOR PART a Refit:
CONCERNED
- the accessories belt (see Accessories belt: Re-
a Refit the compressor. moval - Refitting) (11A, Top and front of engine),
a Connect the compressor connector. - the bonnet supports,

a Clip on the compressor wiring. - the headlights (see Front headlight: Removal -
Refitting) (80B, Headlights),

III - FINAL OPERATION - the cooling radiator air deflectors,

a Refit the connecting pipes to the compressor. - the front impact cross member (see Front impact
cross member: Removal - Refitting) (41A, Front
a Fit the front end panel. lower structure),
a Refit: - the audible warning (see Horn: Removal - Refit-
ting) (82B, Horn),
- the engine wiring channel,
- the front bumper (see Front bumper: Removal -
- the bonnet catch (see Bonnet latch: Removal -
Refitting) (55A, Exterior protection),
Refitting) (52A, Non-side opening element mecha-
nisms). - the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),
H4J
- the front wheels (see Wheel: Removal - Refitting)
a Clip the degassing hose onto the front end panel. (35A, Wheels and tyres),
a Refit the windscreen washer bottle bolt. - the engine undertray.
a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).

M9R Note:
a Refit the rigid cooling hose on the front end panel. A summary table gives the quantities of refrige-
rant in the system according to the engine types
a Clip the degassing hose onto the front end panel. (see 62A, Air conditioning, Air conditioning:
Parts and consumables for the repair work,
page 62A-4) .

a Fill up the refrigerant circuit using the refrigerant


K9K charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) .
a Clip the expansion bottle top hose on the front end
panel. a In the event of replacement, apply the after repair
procedure:
- Switch on the ignition,
- Check that the air conditioning is off,
a Clip:
- Switch the ventilation to speed 2,
- the bonnet cable on the front end panel,
- Put the temperature setting at minimum,
- the wiring on the front end panel.
- Select the air recirculation position,

F9Q or H4J or K9K or M9R - Start the engine.

a Refit the intercooler air outlet pipe (see Intercooler - Run the air conditioning in manual mode (in the
air outlet pipe: Removal - Refitting) (12B, Turbo- case of climate control do not press auto),
charging). - Run the engine at idle speed for 3 minutes with air
conditioning,
- Switch off the engine.

62A-31
AIR CONDITIONING
Compressor: Removal - Refitting 62A
J95
a Check for leaks (see 62A, Air conditioning, Coo-
lant circuit check, page 62A-8) .
a Check that the air conditioning system is operating
correctly (see 62A, Air conditioning, Air conditio-
ning: Check, page 62A-5) .
a Refit the engine cover.
a Adjust the headlights (see Front headlight: Adjus-
ting) (80B, Headlights).

62A-32
AIR CONDITIONING
Expansion valve: Removal - Refitting 62A
B95 or D95 or E95 or K95, and F9Q or K4M or K9K or M4R or M9R
- the scoop under the scuttle panel grille (see Scoop
under scuttle panel grille: Removal - Refitting)
Essential equipment
(56A, Exterior equipment).
refrigerant charging station
F9Q
a Remove:
IMPORTANT
- the battery (see Battery : Removal - Refitting)
To avoid all risk of damage to the systems, apply
(80A, Battery),
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any - the battery tray (see Battery tray: Removal - Re-
repair (see 62A, Air conditioning, Air conditio- fitting) (80A, Battery),
ning: Precautions for repair, page 62A-3) .
- the intercooler air inlet pipe (see Intercooler air in-
let pipe: Removal - Refitting) (12B, Turbochar-
ging).
WARNING
To prevent moisture from entering the system,
place plugs on the cold loop components which are
open to the air.

Note:
Use blanking plugs for the fuel circuits with part
numbers 77 01 208 229 or 77 01 476 857 to plug
any openings exposed to the open air. They must
be clean. Do not use any which have already been
used to plug a fuel circuit.

REMOVAL

I - REMOVAL PREPARATION OPERATION

a Remove the front engine cover.

136471
WARNING
a Remove the nut (1) of the retaining bracket (2) from
Consult the device's operating manual to avoid
the « intermediate pipe - expansion valve » connec-
incorrect use.
ting pipe.
a Drain the refrigerant circuit using the refrigerant
charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) .

a Disconnect the battery (see Battery : Removal -


Refitting) (80A, Battery).

a Remove:

- the windscreen wiper arms (see Windscreen wi-


per arm: Removal - Refitting) (85A, Wiping -
Washing),

- the scuttle panel grille (see Scuttle panel grille:


Removal - Refitting) (56A, Exterior equipment),

62A-33
AIR CONDITIONING
Expansion valve: Removal - Refitting 62A
B95 or D95 or E95 or K95, and F9Q or K4M or K9K or M4R or M9R

136467
a Remove the clips (3) from the bulkhead heat shield.

WARNING
To prevent the surrounding components from
136487
overheating, do not damage (tear, pierce, bend,
etc.) a heat shield. a Remove the bolts (4) from the expansion valve con-
necting pipe bracket.
Any damaged heat shields must be replaced.

a Move the bulkhead heat shieldto one side. WARNING


In order to avoid any refrigerant leaks, do not
damage (deform, twist, etc.) the pipe.

a Uncouple the connecting pipes from the expansion


valve.
a Remove the connecting pipes from the expansion
valve.
a Fit the blanking plugs on the openings of the con-
necting pipes and on the expansion valve.

62A-34
AIR CONDITIONING
Expansion valve: Removal - Refitting 62A
B95 or D95 or E95 or K95, and F9Q or K4M or K9K or M4R or M9R
II - OPERATION FOR REMOVAL OF PART III - FINAL OPERATION
CONCERNED
a Refit the connecting pipes on the expansion valve.

a Fit the heat shield to the bulkhead.

a Refit the retaining bracket of the « intermediate pipe


- expansion valve » connecting pipe.

F9Q

a Refit:

- the intercooler air inlet pipe (see Intercooler air in-


let pipe: Removal - Refitting) (12B, Turbochar-
ging),

- the battery tray (see Battery tray: Removal - Re-


fitting) (80A, Battery),

- the battery (see Battery : Removal - Refitting)


(80A, Battery).

136465
a Refit:
a Remove:
- the scoop under the scuttle panel grille (see Scoop
- the bolts (5) from the expansion valve, under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),
- the expansion valve.
- the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
REFITTING
- the windscreen wiper arms (see Windscreen wi-
per blade: Removal - Refitting) (85A, Wiping -
I - REFITTING PREPARATION OPERATION Washing).
a a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).
WARNING
Do not remove the blanking plugs from each
component until the last moment. Note:
Also, do not remove the components from their A summary table gives the quantities of refrige-
packaging until they are to be fitted to the vehi- rant in the system according to the engine types
cle. (see 62A, Air conditioning, Air conditioning:
Parts and consumables for the repair work,
page 62A-4) .
WARNING
a Fill up the refrigerant circuit using the refrigerant
To avoid any leaks, check that the seal and the
charging station (see 62A, Air conditioning, Coo-
pipe surface are in good condition. The seal and
lant circuit Draining - Refilling, page 62A-9) .
the surface must be clean and scratch free.
a Check for leaks (see 62A, Air conditioning, Coo-
a Remove the blanking plugs. lant circuit check, page 62A-8) .
a Check that the air conditioning system is operating
II - REFITTING OPERATION FOR PART correctly (see 62A, Air conditioning, Air conditio-
CONCERNED ning: Check, page 62A-5) .

a Refit the expansion valve. a Refit the engine cover.

62A-35
AIR CONDITIONING
Expansion valve: Removal - Refitting 62A
B95 or D95 or E95 or K95, and F4R
a Remove:
Essential equipment - the windscreen wiper arms (see Windscreen wi-
per arm: Removal - Refitting) (85A, Wiping -
refrigerant charging station Washing),
- the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
IMPORTANT
To avoid all risk of damage to the systems, apply - the scoop under the scuttle panel grille (see Scoop
the safety and cleanliness instructions and opera- under scuttle panel grille: Removal - Refitting)
tion recommendations before carrying out any (56A, Exterior equipment),
repair (see 62A, Air conditioning, Air conditio- - the lifting eye of the cylinder head,
ning: Precautions for repair, page 62A-3) .
- the turbocharger heat shield nuts.

WARNING
WARNING
To prevent moisture from entering the system, To prevent the surrounding components from
overheating, do not damage (tear, pierce, bend,
place plugs on the cold loop components which are
etc.) a heat shield.
open to the air.
Any damaged heat shields must be replaced.

a Remove:
Note:
- the turbocharger heat shield,
Use blanking plugs for the fuel circuits with part
- the bulkhead upper heat shield bolts,
numbers 77 01 208 229 or 77 01 476 857 to plug
any openings exposed to the open air. They must - the bulkhead upper heat shield clips.
be clean. Do not use any which have already been
used to plug a fuel circuit.
WARNING
To prevent the surrounding components from
REMOVAL overheating, do not damage (tear, pierce, bend,
etc.) a heat shield.
I - REMOVAL PREPARATION OPERATION Any damaged heat shields must be replaced.
a Remove the front engine cover. a Remove the bulkhead upper heat shield.

WARNING
Consult the device's operating manual to avoid
incorrect use.

a Drain the refrigerant circuit using the refrigerant


charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) .
a Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).

62A-36
AIR CONDITIONING
Expansion valve: Removal - Refitting 62A
B95 or D95 or E95 or K95, and F4R
II - OPERATION FOR REMOVAL OF PART
CONCERNED

136487
a Remove the bolts (1) from the expansion valve con-
necting pipe bracket. 136465

a Remove:
WARNING
- the bolts (2) from the expansion valve,
In order to avoid any refrigerant leaks, do not
damage (deform, twist, etc.) the pipe. - the expansion valve.

a Uncouple the connecting pipes from the expansion


valve. REFITTING
a Remove the bulkhead upper heat shield.
a Fit the blanking plugs on the openings of the con- I - REFITTING PREPARATION OPERATION
necting pipes and on the expansion valve.
a

WARNING
Do not remove the blanking plugs from each
component until the last moment.
Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

WARNING
To avoid any leaks, check that the seal and the
pipe surface are in good condition. The seal and
the surface must be clean and scratch free.

a Remove the blanking plugs.

II - REFITTING OPERATION FOR PART


CONCERNED

a Refit the expansion valve.

62A-37
AIR CONDITIONING
Expansion valve: Removal - Refitting 62A
B95 or D95 or E95 or K95, and F4R
III - FINAL OPERATION
a Refit the connecting pipes on the expansion valve.
a Refit:
- the turbocharger heat shield,
- the lifting eye of the cylinder head,
- the bulkhead upper heat shield,
- the scoop under the scuttle panel grille (see Scoop
under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),
- the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
- the windscreen wiper arms (see Windscreen wi-
per arm: Removal - Refitting) (85A, Wiping -
Washing).
a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).

Note:
A summary table gives the quantities of refrige-
rant in the system according to the engine types
(see 62A, Air conditioning, Air conditioning:
Parts and consumables for the repair work,
page 62A-4) .

a Fill up the refrigerant circuit using the refrigerant


charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) .
a Check for leaks (see 62A, Air conditioning, Coo-
lant circuit check, page 62A-8) .
a Check that the air conditioning system is operating
correctly (see 62A, Air conditioning, Air conditio-
ning: Check, page 62A-5) .
a Refit the engine cover.

62A-38
AIR CONDITIONING
Expansion valve: Removal - Refitting 62A
J95
a Remove:
Essential equipment - the centre section of the scuttle panel grille (see
Scuttle panel grille: Removal - Refitting) (56A,
refrigerant charging station Exterior equipment),
- the scoop under the centre section of the scuttle
panel grille (see Scoop under scuttle panel
Tightening torquesm grille: Removal - Refitting) (56A, Exterior equip-
ment).
turbocharger air inlet 8 N.m
pipe bolts a Undo the clips on the air outlet pipe of the air filter
unit.
air filter box air outlet 6 N.m
pipe clips a Remove the air outlet pipe from the air filter box.

F9Q
IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 62A, Air conditioning, Air conditio-
ning: Precautions for repair, page 62A-3) .

WARNING
To prevent moisture from entering the system,
place plugs on the cold loop components which are
open to the air.

Note:
Use blanking plugs for the fuel circuits with part
numbers 77 01 208 229 or 77 01 476 857 to plug
any openings exposed to the open air. They must
be clean. Do not use any which have already been 137477
used to plug a fuel circuit. a Remove:
- the bolts (1) from the cylinder head lifting eye,
REMOVAL - the lifting eye of the cylinder head.

I - REMOVAL PREPARATION OPERATION

a Remove the front engine cover.

WARNING
Consult the device's operating manual to avoid
incorrect use.

a Drain the refrigerant circuit using the refrigerant


charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) .
a Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).

62A-39
AIR CONDITIONING
Expansion valve: Removal - Refitting 62A
J95

M9R K9K

139563
139155
a Unclip the wiring (2) from the cylinder head lifting
a Remove the bolts (4) from the turbocharger air inlet
eye.
pipe.
a Remove:
- the bolts (3) from the cylinder head lifting eye,
- the lifting eye of the cylinder head.

139154

a Remove:

- the bolts (5) from the turbocharger air inlet pipe,

- the turbocharger air inlet pipe.

62A-40
AIR CONDITIONING
Expansion valve: Removal - Refitting 62A
J95

F9Q

135640
a Remove the bolts (8) from the turbocharger air inlet
135638
pipe.

a Remove the bolt (6) from the intermediate air pipe a Disconnect the intermediate air pipe between the air
between the air filter unit and the turbocharger on filter unit and the turbocharger from the turbocharger
the exhaust gas recirculation assembly. air inlet pipe by pivoting it.
a Remove:
- the intermediate air pipe between the air filter unit
and the turbocharger,
- the turbocharger air inlet pipe.

135639
a Loosen the bolt (7) of the intermediate air pipe
between the air filter unit and the turbocharger on
the turbocharger air inlet pipe.

62A-41
AIR CONDITIONING
Expansion valve: Removal - Refitting 62A
J95

M9R K9K
a Remove the intercooler air inlet pipe (see Intercoo-
ler air inlet pipe: Removal - Refitting) (12B, Turbo-
charging).

139564

a Remove the bolts (9) from the turbocharger air inlet


pipe.

138672
a Remove the nut (11) from the retaining bracket on
the « intermediate pipe - expansion valve » connec-
ting pipe.

139567

a Remove:

- the bolts (10) from the turbocharger air inlet pipe,

- the turbocharger air inlet pipe.

62A-42
AIR CONDITIONING
Expansion valve: Removal - Refitting 62A
J95

H4J

139617
a Remove the clips (1 2) from the bulkhead heat
shield. 139616
a Remove:
WARNING
- the bulkhead upper heat shield bolts (13) ,
To prevent the surrounding components from
overheating, do not damage (tear, pierce, bend, - the bulkhead upper heat shield clips (14) .
etc.) a heat shield.
Any damaged heat shields must be replaced. WARNING
To prevent the surrounding components from
a Move the bulkhead heat shieldto one side. overheating, do not damage (tear, pierce, bend,
etc.) a heat shield.
Any damaged heat shields must be replaced.

a Remove the bulkhead upper heat shield.

62A-43
AIR CONDITIONING
Expansion valve: Removal - Refitting 62A
J95
II - OPERATION FOR REMOVAL OF PART
CONCERNED

136487
a Remove the bolts (15) from the expansion valve
connecting pipe bracket. 136465

a Remove:
WARNING - the bolts (16) from the expansion valve,
In order to avoid any refrigerant leaks, do not
damage (deform, twist, etc.) the pipe. - the expansion valve.

a Uncouple the connecting pipes from the expansion


valve. REFITTING
a Remove the connecting pipes from the expansion
valve. I - REMOVAL PREPARATION OPERATION
a Fit the blanking plugs on the openings of the con-
a
necting pipes and on the expansion valve.
WARNING
Do not remove the blanking plugs from each
component until the last moment.
Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

WARNING
To avoid any leaks, check that the seal and the
pipe surface are in good condition. The seal and
the surface must be clean and scratch free.

a Remove the blanking plugs.

II - REFITTING OPERATION FOR PART


CONCERNED

a Refit the expansion valve.

62A-44
AIR CONDITIONING
Expansion valve: Removal - Refitting 62A
J95
III - FINAL OPERATION
a Refit the connecting pipes on the expansion valve. F9Q
a Fit the heat shield to the bulkhead. a Refit:
- the turbocharger air inlet pipe,
H4J
- the intermediate air pipe between the air filter unit
a Refit the bulkhead upper heat shield. and the turbocharger on the turbocharger air inlet
pipe,
- the bolts from the turbocharger air inlet pipe,
a Refit the retaining bracket on the « intermediate pipe - the bolt from the intermediate air pipe between the
- expansion valve » connecting pipe. air filter unit and the turbocharger on the turbochar-
ger air inlet pipe,

K9K - the bolt for the intermediate air pipe between the air
filter unit and the turbocharger on the exhaust gas
a Refit the intercooler air inlet pipe (see Intercooler recirculation assembly.
air inlet pipe: Removal - Refitting) (12B, Turbo-
charging). a Torque tighten the turbocharger air inlet pipe
bolts (8 N.m).

M9R
M9R
a Refit:
a Refit:
- the turbocharger air inlet pipe,
- the lifting eye of the cylinder head,
- the turbocharger air inlet pipe bolts.
- the bolts on the cylinder head lifting eye.
a Clip the wiring on the cylinder head lifting eye.

K9K
a Refit:
F9Q
- the turbocharger air inlet pipe,
a Refit:
- the turbocharger air inlet pipe bolts.
- the lifting eye of the cylinder head,
- the bolts on the cylinder head lifting eye.

a Refit the air outlet pipe onto the air filter unit.
a Torque tighten the air filter box air outlet pipe
clips (6 N.m).
a Refit:
- the scoop under the centre section of the scuttle
panel grille (see Scoop under scuttle panel
grille: Removal - Refitting) (56A, Exterior equip-
ment),
- the centre section of the scuttle panel grille (see
Scuttle panel grille: Removal - Refitting) (56A,
Exterior equipment).

62A-45
AIR CONDITIONING
Expansion valve: Removal - Refitting 62A
J95
a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).

Note:
A summary table gives the quantities of refrige-
rant in the system according to the engine types
(see 62A, Air conditioning, Air conditioning:
Parts and consumables for the repair work,
page 62A-4) .

a Perform the following operations:


- refill the refrigerant circuit using the refrigerant
charging station (see 62A, Air conditioning,
Coolant circuit Draining - Refilling, page 62A-9)
,
- check for leaks (see 62A, Air conditioning, Coo-
lant circuit check, page 62A-8) .
a Check that the air conditioning system is operating
correctly (see 62A, Air conditioning, Air conditio-
ning: Check, page 62A-5) .
a Refit the engine cover.

62A-46
AIR CONDITIONING
Evaporator: Cleaning 62A
LEFT-HAND DRIVE

IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 62A, Air conditioning, Air conditio-
ning: Precautions for repair, page 62A-3) .

CLEANING
a Remove the cabin filter (see 61A, Heating, Cabin
filter: Removal - Refitting, page 61A-19) .
a Apply the AIR CONDITIONING CLEANER (see Ve-
hicle: Parts and ingredients for the repairwork)
(04B, Consumables - Products).
a Leave the product to work for 15 minutes.
a Refit the cabin filter (see 61A, Heating, Cabin filter:
Removal - Refitting, page 61A-19) .
a Activate the low speed motor-driven fan assembly
for 5 min.

62A-47
AIR CONDITIONING
Evaporator: Cleaning 62A
RIGHT-HAND DRIVE

IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 62A, Air conditioning, Air conditio-
ning: Precautions for repair, page 62A-3) .

CLEANING
a Remove the evaporator sensor (see 62A, Air condi-
tioning, Evaporator sensor: Removal - Refitting,
page 62A-79) .
a Apply the AIR CONDITIONING CLEANER (see Ve-
hicle: Parts and ingredients for the repairwork)
(04B, Consumables - Products).
a Leave the product to work for 15 minutes.
a Refit the evaporator sensor (see 62A, Air conditio-
ning, Evaporator sensor: Removal - Refitting,
page 62A-79) .
a Activate the low speed motor-driven fan assembly
for 5 min.

62A-48
AIR CONDITIONING
Expansion valve - condenser connecting pipe: Removal - Refitting 62A
B95 or D95 or E95 or K95
- the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
Essential equipment
- the right-hand headlight (see Front headlight: Re-
refrigerant charging station
moval - Refitting) (80B, Headlights),

- the front panel support,


IMPORTANT
To avoid all risk of damage to the systems, apply - the windscreen washer bottle (see Windscreen
the safety and cleanliness instructions and opera- washer bottle: Removal - Refitting) (85A, Wiping
tion recommendations before carrying out any - Washing)
repair (see 62A, Air conditioning, Air conditio-
ning: Precautions for repair, page 62A-3) . - the windscreen wiper arms (see Windscreen wi-
per arm: Removal - Refitting) (85A, Wiping -
Washing),

WARNING - the scuttle panel grille (see Scuttle panel grille:


To prevent moisture from entering the system, Removal - Refitting) (56A, Exterior equipment),
place plugs on the cold loop components which are
open to the air. - the scoop under the scuttle panel grille (see Scoop
under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment).

Note:
F9Q
Use blanking plugs for the fuel circuits with part
numbers 77 01 208 229 or 77 01 476 857 to plug a Remove:
any openings exposed to the open air. They must
be clean. Do not use any which have already been - the battery (see Battery : Removal - Refitting)
used to plug a fuel circuit. (80A, Battery),

- the battery tray (see Battery tray: Removal - Re-


REMOVAL fitting) (80A, Battery),

I - REMOVAL PREPARATION OPERATION - the intercooler air inlet pipe (see Intercooler air in-
let pipe: Removal - Refitting) (12B, Turbochar-
a Position the vehicle on a two-post lift (see Vehicle: ging).
Towing and lifting) (02A, Lifting equipment).
a Remove the engine cover.

WARNING
Consult the device's operating manual to avoid F9Q or K4M or K9K or M4R or M9R
incorrect use.
a Remove the clips from the bulkhead heat shield.
a Drain the refrigerant circuit using the refrigerant
charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) . WARNING
a Disconnect the battery (see Battery : Removal - To prevent the surrounding components from
Refitting) (80A, Battery). overheating, do not damage (tear, pierce, bend,
etc.) a heat shield.
a Remove:
Any damaged heat shields must be replaced.
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
a Move the bulkhead heat shieldto one side.
- the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),

62A-49
AIR CONDITIONING
Expansion valve - condenser connecting pipe: Removal - Refitting 62A
B95 or D95 or E95 or K95

F4R
a Remove:
- the lifting eye of the cylinder head,
- the turbocharger heat shield nuts.

WARNING
To prevent the surrounding components from
overheating, do not damage (tear, pierce, bend,
etc.) a heat shield.
Any damaged heat shields must be replaced.

a Remove:
- the turbocharger heat shield,
- the bulkhead upper heat shield bolts,
- the bulkhead upper heat shield clips.
135297

a Remove the bolt (2) from the front right-hand side


WARNING
member tie rod.
To prevent the surrounding components from
overheating, do not damage (tear, pierce, bend, a Move the front right-hand side member tie rod to-
etc.) a heat shield. wards the wheel arch.
Any damaged heat shields must be replaced.

a Remove the bulkhead upper heat shield. II - OPERATION FOR REMOVAL OF PART
CONCERNED

136481

135303 a Remove the bolt (3 ) from the support of the


a Loosen the front right-hand bolt on the subframe at « condenser - expansion valve » connecting pipe on
(1) . the front right-hand panel.

62A-50
AIR CONDITIONING
Expansion valve - condenser connecting pipe: Removal - Refitting 62A
B95 or D95 or E95 or K95

136475 136484
a Remove the plastic nut (4) from the support for the a Remove the bolt (6) securing the support for the
« condenser - expansion valve » connecting pipe on « condenser - expansion valve » connecting pipe on
the front right-hand side member. the front right-hand side member reinforcement.

136479
a Remove the bolt (5) securing the « condenser - ex-
pansion valve » connecting pipe to the front panel.

62A-51
AIR CONDITIONING
Expansion valve - condenser connecting pipe: Removal - Refitting 62A
B95 or D95 or E95 or K95

136469

136485
a Unclip the « condenser - expansion valve » connec-
ting pipe on the front right-hand side member and on
the bulkhead at (7) .

62A-52
AIR CONDITIONING
Expansion valve - condenser connecting pipe: Removal - Refitting 62A
B95 or D95 or E95 or K95
a Disconnect:
- the « condenser - expansion valve » connecting
pipe from the expansion valve,
- the « condenser - expansion valve » connecting
pipe from the condenser.
a Fit blanking plugs on:

- the condenser,
- the expansion valve,
- the « condenser - expansion valve » connecting pi-
pe.

REFITTING

I - REFITTING PREPARATION OPERATION


a
136487
WARNING
Do not remove the blanking plugs from each
component until the last moment.
Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

WARNING
To avoid any leaks, check that the seal and the
pipe surface are in good condition. The seal and
the surface must be clean and scratch free.

a Remove the blanking plugs.

II - REFITTING OPERATION FOR PART


CONCERNED

a Refit the « condenser - expansion valve » connec-


ting pipe.
135670
a Clip the « condenser - expansion valve » connecting
a Remove: pipe onto the front right-hand side member and onto
- the bolt (8) for the « condenser - expansion valve » the bulkhead.
connecting pipe bracket on the expansion valve,
- the bolt (9) for the « condenser - expansion valve » III - FINAL OPERATION
connecting pipe bracket on the condenser. a Fit the side member tie rod.

WARNING F4R
In order to avoid any refrigerant leaks, do not
damage (deform, twist, etc.) the pipe. a Refit:
- the bulkhead upper heat shield,
a Remove the « condenser - expansion valve » con-
necting pipe. - the turbocharger heat shield,

62A-53
AIR CONDITIONING
Expansion valve - condenser connecting pipe: Removal - Refitting 62A
B95 or D95 or E95 or K95
- the lifting eye of the cylinder head. a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).

Note:
A summary table gives the quantities of refrige-
F9Q or K4M or K9K or M4R or M9R rant in the system according to the engine types
a Fit the heat shield to the bulkhead. (see 62A, Air conditioning, Air conditioning:
Parts and consumables for the repair work,
page 62A-4) .

a Fill up the refrigerant circuit using the refrigerant


charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) .
F9Q
a Check for leaks (see 62A, Air conditioning, Coo-
a Refit: lant circuit check, page 62A-8) .
- the intercooler air inlet pipe (see Intercooler air in- a Check that the air conditioning system is operating
let pipe: Removal - Refitting) (12B, Turbochar- correctly (see 62A, Air conditioning, Air conditio-
ging), ning: Check, page 62A-5) .

- the battery tray (see Battery tray: Removal - Re- a Refit the engine cover.
fitting) (80A, Battery), a Adjust the headlights (see Front headlight: Remo-
val - Refitting) (80B, Headlights).
- the battery (see Battery : Removal - Refitting)
(80A, Battery).

a Refit:

- the windscreen washer bottle (see Windscreen


washer bottle: Removal - Refitting) (85A, Wiping
- Washing)

- the front panel support,

- the right-hand headlight (see Front headlight: Re-


moval - Refitting) (80B, Headlights),

- the front bumper (see Front bumper: Removal -


Refitting) (55A, Exterior protection),

- the front section of the front wheel arch liners (see


Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),

- the front wheels (see Wheel: Removal - Refitting)


(35A, Wheels and tyres).

- the scoop under the scuttle panel grille (see Scoop


under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment),

- the scuttle panel grille (see Scuttle panel grille:


Removal - Refitting) (56A, Exterior equipment),

- the windscreen wiper arms (see Windscreen wi-


per arm: Removal - Refitting) (85A, Wiping -
Washing),

62A-54
AIR CONDITIONING
Expansion valve - condenser connecting pipe: Removal - Refitting 62A
J95
a Drain the refrigerant circuit using the refrigerant
charging station (see 62A, Air conditioning, Coo-
Essential equipment
lant circuit Draining - Refilling, page 62A-9) .
refrigerant charging station a Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).
a Remove:
Tightening torquesm
- the front wheels (see Wheel: Removal - Refitting)
subframe front bolt 105 N.m (35A, Wheels and tyres),
- the front section of the front wheel arch liners (see
turbocharger air inlet 8 N.m Front wheel arch liner: Removal - Refitting)
pipe bolts (55A, Exterior protection),
air filter box air outlet 6 N.m - the front bumper (see Front bumper: Removal -
pipe clips Refitting) (55A, Exterior protection),
- the windscreen washer bottle (see Windscreen
washer bottle: Removal - Refitting) (85A, Wiping
IMPORTANT - Washing),
To avoid all risk of damage to the systems, apply - the centre section of the scuttle panel grille (see
the safety and cleanliness instructions and opera- Scuttle panel grille: Removal - Refitting) (56A,
tion recommendations before carrying out any Exterior equipment),
repair (see 62A, Air conditioning, Air conditio-
ning: Precautions for repair, page 62A-3) . - the scoop under the centre section of the scuttle
panel grille (see Scoop under scuttle panel
grille: Removal - Refitting) (56A, Exterior equip-
ment).
WARNING a Undo the clips on the air outlet pipe of the air filter
To prevent moisture from entering the system, unit.
place plugs on the cold loop components which are a Remove the air outlet pipe from the air filter box.
open to the air.

Note:
Use blanking plugs for the fuel circuits with part
numbers 77 01 208 229 or 77 01 476 857 to plug
any openings exposed to the open air. They must
be clean. Do not use any which have already been
used to plug a fuel circuit.

REMOVAL

I - REMOVAL PREPARATION OPERATION

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


Towing and lifting) (02A, Lifting equipment).

a Remove the front engine cover.

WARNING
Consult the device's operating manual to avoid
incorrect use.

62A-55
AIR CONDITIONING
Expansion valve - condenser connecting pipe: Removal - Refitting 62A
J95

F9Q M9R

137477 139563
a Remove: a Unclip the wiring (2) from the cylinder head lifting
eye.
- the bolts (1) from the cylinder head lifting eye,
a Remove:
- the lifting eye of the cylinder head.
- the bolts (3) from the cylinder head lifting eye,
- the lifting eye of the cylinder head.

62A-56
AIR CONDITIONING
Expansion valve - condenser connecting pipe: Removal - Refitting 62A
J95

K9K F9Q

135638
139155
a Remove the bolt (6) from the intermediate air pipe
a Remove the bolts (4) from the turbocharger air inlet
between the air filter unit and the turbocharger on
pipe.
the exhaust gas recirculation assembly.

139154 135639

a Remove: a Loosen the bolt (7) of the intermediate air pipe


between the air filter unit and the turbocharger on
- the bolts (5) from the turbocharger air inlet pipe, the turbocharger air inlet pipe.

- the turbocharger air inlet pipe.

62A-57
AIR CONDITIONING
Expansion valve - condenser connecting pipe: Removal - Refitting 62A
J95

M9R

135640
a Remove the bolts (8) from the turbocharger air inlet
pipe.
139564
a Disconnect the intermediate air pipe between the air a Remove the bolts (9) from the turbocharger air inlet
filter unit and the turbocharger from the turbocharger pipe.
air inlet pipe by pivoting it.
a Remove:
- the intermediate air pipe between the air filter unit
and the turbocharger,
- the turbocharger air inlet pipe.

139567

a Remove:
- the bolts (10) from the turbocharger air inlet pipe,
- the turbocharger air inlet pipe.

62A-58
AIR CONDITIONING
Expansion valve - condenser connecting pipe: Removal - Refitting 62A
J95

F9Q or K9K or M9R H4J


a Remove the fuel filter (see Fuel filter: Removal -
Refitting) (13A, Fuel supply).

F9Q
a Remove the intercooler air inlet pipe (see Intercoo-
ler air inlet pipe: Removal - Refitting) (12B, Turbo-
charging).

139616
a Remove:
- the bolts (12) from the upper heat shield,
- the clips (13) from the upper heat shield.

WARNING
To prevent the surrounding components from
overheating, do not damage (tear, pierce, bend,
etc.) a heat shield.
Any damaged heat shields must be replaced.

139617
a Remove the upper heat shield.

a Remove the clips (1 1) from the bulkhead heat


shield.

WARNING
To prevent the surrounding components from
overheating, do not damage (tear, pierce, bend,
etc.) a heat shield.
Any damaged heat shields must be replaced.

a Move the bulkhead heat shieldto one side.

62A-59
AIR CONDITIONING
Expansion valve - condenser connecting pipe: Removal - Refitting 62A
J95
II - OPERATION FOR REMOVAL OF PART
CONCERNED

135303
a Loosen the subframe front right-hand bolt at (14) .
136484
a Remove the « condenser - expansion valve » con-
necting pipe mounting bolt (16) from the windscreen
washer reservoir mounting.

135297
a Remove the bolt (15) from the front right-hand side
member tie rod.
a Move the front right-hand side member tie rod to- 136475
wards the wheel arch.
a Remove the plastic nut (17) from the support for the
« condenser - expansion valve » connecting pipe on
the front right-hand side member.

62A-60
AIR CONDITIONING
Expansion valve - condenser connecting pipe: Removal - Refitting 62A
J95

136479 139618
a Remove the bolt (18) securing the « condenser - ex-
pansion valve » connecting pipe to the front panel.

136485
a Unclip the « condenser - expansion valve » connec-
ting pipe on the front right-hand side member (19)
and on the bulkhead at (20) .

62A-61
AIR CONDITIONING
Expansion valve - condenser connecting pipe: Removal - Refitting 62A
J95
- the « condenser - expansion valve » connecting
pipe from the expansion valve,

- the « condenser - expansion valve » connecting


pipe from the condenser.

a Remove the « condenser - expansion valve » con-


necting pipe.

a Fit blanking plugs on:

- the condenser,

- the expansion valve,

- the « condenser - expansion valve » connecting pi-


pe.

REFITTING

I - REFITTING PREPARATION OPERATION


136487
a

WARNING
Do not remove the blanking plugs from each
component until the last moment.
Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

WARNING
To avoid any leaks, check that the seal and the
pipe surface are in good condition. The seal and
the surface must be clean and scratch free.

a Remove the blanking plugs.

II - REFITTING OPERATION FOR PART


CONCERNED
135670
a Remove: a Refit the « condenser - expansion valve » connec-
ting pipe.
- the bolt (21) for the « condenser - expansion
valve » connecting pipe bracket on the expansion a Clip the « condenser - expansion valve » connecting
valve, pipe on the front right-hand side member and on the
- the bolt (22) for the « condenser - expansion bulkhead.
valve » connecting pipe bracket on the condenser.
III - FINAL OPERATION
WARNING
a Fit the side member tie rod.
In order to avoid any refrigerant leaks, do not
damage (deform, twist, etc.) the pipe. a Torque tighten the subframe front bolt (105 N.m).

a Disconnect: a Fit the heat shield to the bulkhead.

62A-62
AIR CONDITIONING
Expansion valve - condenser connecting pipe: Removal - Refitting 62A
J95

H4J F9Q
a Refit the upper heat shield. a Refit:
- the turbocharger air inlet pipe,

- the intermediate air pipe between the air filter unit


and the turbocharger on the turbocharger air inlet
F9Q or K9K or M9R pipe,
a Refit the fuel filter (see Fuel filter: Removal - Refit- - the bolts from the turbocharger air inlet pipe,
ting) (13A, Fuel supply).
- the bolt from the intermediate air pipe between the
air filter unit and the turbocharger on the turbochar-
ger air inlet pipe,
- the bolt for the intermediate air pipe between the air
K9K filter unit and the turbocharger on the exhaust gas
recirculation assembly.
a Refit the intercooler air inlet pipe (see Intercooler
air inlet pipe: Removal - Refitting) (12B, Turbo- a Torque tighten the turbocharger air inlet pipe
charging). bolts (8 N.m).

M9R M9R
a Refit:
a Refit:
- the turbocharger air inlet pipe,
- the lifting eye of the cylinder head,
- the turbocharger air inlet pipe bolts.
- the bolts on the cylinder head lifting eye.
a Clip the wiring on the cylinder head lifting eye.

K9K
a Refit:
F9Q
- the turbocharger air inlet pipe,
- the turbocharger air inlet pipe bolts. a Refit:

- the lifting eye of the cylinder head,


- the bolts on the cylinder head lifting eye.

a Refit the air outlet pipe onto the air filter unit.

a Torque tighten the air filter box air outlet pipe


clips (6 N.m).
a Refit:
- the windscreen washer bottle (see Windscreen
washer bottle: Removal - Refitting) (85A, Wiping
- Washing),
- the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),

62A-63
AIR CONDITIONING
Expansion valve - condenser connecting pipe: Removal - Refitting 62A
J95
- the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
- the scoop under the centre section of the scuttle
panel grille (see Scoop under scuttle panel
grille: Removal - Refitting) (56A, Exterior equip-
ment),
- the centre section of the scuttle panel grille (see
Scuttle panel grille: Removal - Refitting) (56A,
Exterior equipment).
a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).

Note:
A summary table gives the quantities of refrige-
rant in the system according to the engine types
(see 62A, Air conditioning, Air conditioning:
Parts and consumables for the repair work,
page 62A-4) .

a Perform the following operations:


- refill the refrigerant circuit using the refrigerant
charging station (see 62A, Air conditioning,
Coolant circuit Draining - Refilling, page 62A-9)
,
- check for leaks (see 62A, Air conditioning, Coo-
lant circuit check, page 62A-8) .
a Check that the air conditioning system is operating
correctly (see 62A, Air conditioning, Air conditio-
ning: Check, page 62A-5) .
a Refit the engine cover.

62A-64
AIR CONDITIONING
Expansion valve - intermediate pipe connecting pipe at the expansion valve outlet: Removal - Refitting
62A
B95 or D95 or E95 or K95
- the scoop under the scuttle panel grille (see Scoop
under scuttle panel grille: Removal - Refitting)
Essential equipment
(56A, Exterior equipment).
refrigerant charging station
F9Q
a Remove:
IMPORTANT
To avoid all risk of damage to the systems, apply - the battery (see Battery : Removal - Refitting)
the safety and cleanliness instructions and opera- (80A, Battery),
tion recommendations before carrying out any - the battery tray (see Battery tray: Removal - Re-
repair (see 62A, Air conditioning, Air conditio- fitting) (80A, Battery),
ning: Precautions for repair, page 62A-3) .
- the intercooler air inlet pipe (see Intercooler air in-
let pipe: Removal - Refitting) (12B, Turbochar-
ging).
WARNING
To prevent moisture from entering the system,
place plugs on the cold loop components which are
open to the air.
F9Q or K4M or K9K or M4R or M9R
a Remove the clips from the bulkhead heat shield.
Note:
Use blanking plugs for the fuel circuits with part WARNING
numbers 77 01 208 229 or 77 01 476 857 to plug To prevent the surrounding components from
any openings exposed to the open air. They must overheating, do not damage (tear, pierce, bend,
be clean. Do not use any which have already been etc.) a heat shield.
used to plug a fuel circuit.
Any damaged heat shields must be replaced.

a Move the bulkhead heat shieldto one side.


REMOVAL

I - REMOVAL PREPARATION OPERATION


a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Remove the front engine cover.

WARNING
Consult the device's operating manual to avoid
incorrect use.

a Drain the refrigerant circuit using the refrigerant


charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) .
a Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).
a Remove:
- the windscreen wiper arms (see Windscreen wi-
per arm: Removal - Refitting) (85A, Wiping -
Washing),
- the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),

62A-65
AIR CONDITIONING
Expansion valve - intermediate pipe connecting pipe at the expansion valve outlet: Removal - Refitting
62A
B95 or D95 or E95 or K95
II - OPERATION FOR REMOVAL OF PART
CONCERNED
F4R
a Remove:
- the lifting eye of the cylinder head,
- the turbocharger heat shield nuts.

WARNING
To prevent the surrounding components from
overheating, do not damage (tear, pierce, bend,
etc.) a heat shield.
Any damaged heat shields must be replaced.

a Remove:
- the turbocharger heat shield,
- the bulkhead upper heat shield bolts,
- the bulkhead upper heat shield clips.

WARNING 136471
To prevent the surrounding components from a Remove the nut (1) from the retaining bracket (2) of
overheating, do not damage (tear, pierce, bend, the « expansion valve - intermediate pipe » connec-
etc.) a heat shield. ting pipe.
Any damaged heat shields must be replaced.

a Remove the bulkhead upper heat shield.

136490
a Remove the bolt (3) from the retaining bracket of the
« expansion valve - intermediate pipe » connecting
pipe.

62A-66
AIR CONDITIONING
Expansion valve - intermediate pipe connecting pipe at the expansion valve outlet: Removal - Refitting
62A
B95 or D95 or E95 or K95

F4R

136492
a Remove the bolt (6) from the « expansion valve - in-
termediate pipe » connecting pipe bracket on the in-
134713 termediate connecting pipe.
a Remove the nut (4) securing the « expansion valve -
intermediate pipe » connecting pipe on the bulkhead WARNING
support.
In order to avoid any refrigerant leaks, do not
damage (deform, twist, etc.) the pipe.

a Disconnect:
- the « expansion valve - intermediate pipe » con-
necting pipe to the expansion valve,
- the « expansion valve - intermediate pipe » con-
necting pipe from the intermediate connecting pipe.
a Remove the « expansion valve - intermediate pipe »
connecting pipe.
a Fit the blanking plugs on the openings of the con-
necting pipes and on the expansion valve.

136487

a Remove the bolt (5) from the « expansion valve - in-


termediate pipe » connecting pipe bracket on the ex-
pansion valve.

62A-67
AIR CONDITIONING
Expansion valve - intermediate pipe connecting pipe at the expansion valve outlet: Removal - Refitting
62A
B95 or D95 or E95 or K95

REFITTING - the battery tray (see Battery tray: Removal - Re-


fitting) (80A, Battery),

I - REFITTING PREPARATION OPERATION - the battery (see Battery : Removal - Refitting)


(80A, Battery).
a

WARNING
Do not remove the blanking plugs from each a Refit:
component until the last moment.
- the scoop under the scuttle panel grille (see Scoop
Also, do not remove the components from their under scuttle panel grille: Removal - Refitting)
packaging until they are to be fitted to the vehi- (56A, Exterior equipment),
cle.
- the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
WARNING - the windscreen wiper arms (see Windscreen wi-
To avoid any leaks, check that the seal and the per arm: Removal - Refitting) (85A, Wiping -
pipe surface are in good condition. The seal and Washing),
the surface must be clean and scratch free. a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).
a Remove the blanking plugs.

Note:
II - REFITTING OPERATION FOR PART
CONCERNED A summary table gives the quantities of refrige-
rant in the system according to the engine types
a Refit the « expansion valve - intermediate pipe »
(see 62A, Air conditioning, Air conditioning:
connecting pipe on the expansion valve and on the
Parts and consumables for the repair work,
intermediate connecting pipe.
page 62A-4) .

III - FINAL OPERATION a Fill up the refrigerant circuit using the refrigerant
charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) .
F4R
a Check for leaks (see 62A, Air conditioning, Coo-
a Refit: lant circuit check, page 62A-8) .

- the bulkhead upper heat shield, a Check that the air conditioning system is operating
correctly (see 62A, Air conditioning, Air conditio-
- the turbocharger heat shield, ning: Check, page 62A-5) .
- the lifting eye of the cylinder head. a Refit the engine cover.

F9Q or K4M or K9K or M4R

a Fit the heat shield to the bulkhead.

F9Q
a Refit:
- the intercooler air inlet pipe (see Intercooler air in-
let pipe: Removal - Refitting) (12B, Turbochar-
ging),

62A-68
AIR CONDITIONING
Expansion valve - intermediate pipe connecting pipe at the expansion valve outlet: Removal - Refitting
62A
J95
a Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).
Essential equipment
a Remove:
refrigerant charging station
- the centre section of the scuttle panel grille (see
Scuttle panel grille: Removal - Refitting) (56A,
Exterior equipment),
Tightening torquesm
- the scoop under the centre section of the scuttle
turbocharger air inlet 8 N.m panel grille (see Scoop under scuttle panel
pipe bolts grille: Removal - Refitting) (56A, Exterior equip-
ment),
air filter box air outlet 6 N.m
pipe clips - the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
- the front section of the front wheel arch liners (see
IMPORTANT Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera- - the front bumper (see Front bumper: Removal -
tion recommendations before carrying out any Refitting) (55A, Exterior protection),
repair (see 62A, Air conditioning, Air conditio- - the right-hand headlight (see Front headlight: Re-
ning: Precautions for repair, page 62A-3) . moval - Refitting) (80B, Headlights).
a Undo the clips on the air outlet pipe of the air filter
unit.
WARNING a Remove the air outlet pipe from the air filter box.
To prevent moisture from entering the system,
place plugs on the cold loop components which are
open to the air. F9Q

Note:
Use blanking plugs for the fuel circuits with part
numbers 77 01 208 229 or 77 01 476 857 to plug
any openings exposed to the open air. They must
be clean. Do not use any which have already been
used to plug a fuel circuit.

REMOVAL

I - REMOVAL PREPARATION OPERATION

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


Towing and lifting) (02A, Lifting equipment).

a Remove the front engine cover.

137477
WARNING
a Remove:
Consult the device's operating manual to avoid
incorrect use. - the bolts (1) from the cylinder head lifting eye,
- the lifting eye of the cylinder head.
a Drain the refrigerant circuit using the refrigerant
charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) .

62A-69
AIR CONDITIONING
Expansion valve - intermediate pipe connecting pipe at the expansion valve outlet: Removal - Refitting
62A
J95

M9R K9K

139563
139155
a Unclip the wiring (2) from the cylinder head lifting
a Remove the bolt (4) from the turbocharger air inlet
eye.
pipe.
a Remove
- the bolts (3) from the cylinder head lifting eye,
- the lifting eye of the cylinder head.

139154

a Remove:

- the bolts (5) from the turbocharger air inlet pipe,

- the turbocharger air inlet pipe.

62A-70
AIR CONDITIONING
Expansion valve - intermediate pipe connecting pipe at the expansion valve outlet: Removal - Refitting
62A
J95

F9Q

135640
a Remove the bolts (8) from the turbocharger air inlet
135638
pipe.

a Remove the bolt (6) from the intermediate air pipe a Disconnect the intermediate air pipe between the air
between the air filter unit and the turbocharger on filter unit and the turbocharger from the turbocharger
the exhaust gas recirculation assembly. air inlet pipe by pivoting it.
a Remove:
- the intermediate air pipe between the air filter unit
and the turbocharger,
- the turbocharger air inlet pipe.

135639
a Loosen the bolt (7) of the intermediate air pipe
between the air filter unit and the turbocharger on
the turbocharger air inlet pipe.

62A-71
AIR CONDITIONING
Expansion valve - intermediate pipe connecting pipe at the expansion valve outlet: Removal - Refitting
62A
J95

M9R K9K
a Remove the intercooler air inlet pipe (see Intercoo-
ler air inlet pipe: Removal - Refitting) (12B, Turbo-
charging).

139564 139617

a Remove the bolt (9) from the turbocharger air inlet a Remove the clips (11) from the bulkhead heat
pipe. shield.

WARNING
To prevent the surrounding components from
overheating, do not damage (tear, pierce, bend,
etc.) a heat shield.
Any damaged heat shields must be replaced.

a Move the bulkhead heat shieldto one side.

139567

a Remove:

- the bolts (10) from the turbocharger air inlet pipe,

- the turbocharger air inlet pipe.

62A-72
AIR CONDITIONING
Expansion valve - intermediate pipe connecting pipe at the expansion valve outlet: Removal - Refitting
62A
J95
II - OPERATION FOR REMOVAL OF PART
CONCERNED
H4J

139616
a Remove:
- the bulkhead upper heat shield bolts (12) ,
- the bulkhead upper heat shield clips (13) .
138672
a Remove the nut (14) from the retaining bracket of
WARNING
the « expansion valve - intermediate pipe » connec-
To prevent the surrounding components from ting pipe.
overheating, do not damage (tear, pierce, bend,
etc.) a heat shield.
Any damaged heat shields must be replaced.

a Remove the bulkhead upper heat shield.

139058
a Remove the bolt (15) from the retaining bracket of
the « expansion valve - intermediate pipe » connec-
ting pipe.

62A-73
AIR CONDITIONING
Expansion valve - intermediate pipe connecting pipe at the expansion valve outlet: Removal - Refitting
62A
J95

136487 138673
a Remove the bolt (16) from the « expansion valve - a Remove the bolt (17) from the « expansion valve -
intermediate pipe » connecting pipe bracket on the intermediate pipe » connecting pipe bracket on the
expansion valve. intermediate connecting pipe.

WARNING
In order to avoid any refrigerant leaks, do not
damage (deform, twist, etc.) the pipe.

a Disconnect:
- the « expansion valve - intermediate pipe » con-
necting pipe to the expansion valve,
- the « expansion valve - intermediate pipe » con-
necting pipe from the intermediate connecting pipe.
a Remove the « expansion valve - intermediate pipe »
connecting pipe.
a Fit the blanking plugs on the openings of the con-
necting pipes and on the expansion valve.

62A-74
AIR CONDITIONING
Expansion valve - intermediate pipe connecting pipe at the expansion valve outlet: Removal - Refitting
62A
J95

REFITTING
K9K
I - REFITTING PREPARATION OPERATION
a Refit:
a
- the turbocharger air inlet pipe,
WARNING - the turbocharger air inlet pipe bolts.
Do not remove the blanking plugs from each
component until the last moment.
Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle. F9Q
a Refit:

WARNING - the turbocharger air inlet pipe,


To avoid any leaks, check that the seal and the - the intermediate air pipe between the air filter unit
pipe surface are in good condition. The seal and and the turbocharger on the turbocharger air inlet
the surface must be clean and scratch free. pipe,

a Remove the blanking plugs. - the bolts from the turbocharger air inlet pipe,
- the bolt from the intermediate air pipe between the
air filter unit and the turbocharger on the turbochar-
II - REFITTING OPERATION FOR PART
ger air inlet pipe,
CONCERNED
- the bolt for the intermediate air pipe between the air
a Refit the « expansion valve - intermediate pipe »
filter unit and the turbocharger on the exhaust gas
connecting pipe on the expansion valve and on the
recirculation assembly.
intermediate connecting pipe.
a Torque tighten the turbocharger air inlet pipe
bolts (8 N.m).
III - FINAL OPERATION
a Fit the heat shield to the bulkhead.

H4J
M9R
a Refit the bulkhead upper heat shield.
a Refit:
- the lifting eye of the cylinder head,
- the bolts on the cylinder head lifting eye.

K9K a Clip the wiring on the cylinder head lifting eye.

a Refit the intercooler air inlet pipe (see Intercooler


air inlet pipe: Removal - Refitting) (12B, Turbo-
charging).
F9Q
a Refit:
- the lifting eye of the cylinder head,
M9R
- the bolts on the cylinder head lifting eye.
a Refit:
- the turbocharger air inlet pipe,
- the turbocharger air inlet pipe bolts. a Refit the air outlet pipe onto the air filter unit.
a Torque tighten the air filter box air outlet pipe
clips (6 N.m).

62A-75
AIR CONDITIONING
Expansion valve - intermediate pipe connecting pipe at the expansion valve outlet: Removal - Refitting
62A
J95
a Refit:
- the scoop under the centre section of the scuttle
panel grille (see Scoop under scuttle panel
grille: Removal - Refitting) (56A, Exterior equip-
ment),
- the centre section of the scuttle panel grille (see
Scuttle panel grille: Removal - Refitting) (56A,
Exterior equipment),
- the right-hand headlight (see Front headlight: Re-
moval - Refitting) (80B, Headlights),
- the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
- the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres).
a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).

Note:
A summary table gives the quantities of refrige-
rant in the system according to the engine types
(see 62A, Air conditioning, Air conditioning:
Parts and consumables for the repair work,
page 62A-4) .

a Perform the following operations:


- refill the refrigerant circuit using the refrigerant
charging station (see 62A, Air conditioning,
Coolant circuit Draining - Refilling, page 62A-9)
,
- check for leaks (see 62A, Air conditioning, Coo-
lant circuit check, page 62A-8) .
a Check that the air conditioning system is operating
correctly (see 62A, Air conditioning, Air conditio-
ning: Check, page 62A-5) .
a Refit the engine cover.

62A-76
AIR CONDITIONING
Pressure sensor: Removal - Refitting 62A
Tightening torquesm

pressure sensor 9 N.m

IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 62A, Air conditioning, Air conditio-
ning: Precautions for repair, page 62A-3) .

Note:
An automatic shut-off valve isolates the circuit from
the outside during removal; do not drain the refrige-
rant from the circuit.
138677

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Remove:
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
- the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),
- the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).

138678
a Unclip:
- the central deflector (1) ,
- the right-hand side deflector (2) .

62A-77
AIR CONDITIONING
Pressure sensor: Removal - Refitting 62A
II - OPERATION FOR REMOVAL OF PART
CONCERNED

135672

a Disconnect the pressure sensor connector (3) .

a Remove the pressure sensor from the condenser.

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED

a Refit the pressure sensor.

a Torque tighten the pressure sensor (9 N.m).

a Connect the pressure sensor connector.

II - FINAL OPERATION

a Clip:

- the right-hand side deflector,

- the central deflector.

a Refit:

- the front bumper (see Front bumper: Removal -


Refitting) (55A, Exterior protection),

- the front section of the front wheel arch liners (see


Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),

- the front wheels (see Wheel: Removal - Refitting)


(35A, Wheels and tyres).

62A-78
AIR CONDITIONING
Evaporator sensor: Removal - Refitting 62A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Tightening torquesm

dashboard cross mem- 21 N.m


ber reinforcement upper
bolts

dashboard cross mem- 21 N.m


ber reinforcement lower
bolts

IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 62A, Air conditioning, Air conditio-
ning: Precautions for repair, page 62A-3) .

REMOVAL
137648
I - REMOVAL PREPARATION OPERATION
a Remove the evaporator sensor (1) by turning it a
a Remove: quarter of a turn anti-clockwise.
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),
- the front left-hand footwell air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,
- the lower bolts from the dashboard cross member
reinforcement,
- the upper bolts from the dashboard cross member
reinforcement,
- the dashboard cross member reinforcement.

137649
a Take the evaporator sensor out of its housing.
a Cut the wires (2) of the evaporator sensor (see Wi-
ring: Repair) (Technical Note 6015A, 88A, Wiring).

62A-79
AIR CONDITIONING
Evaporator sensor: Removal - Refitting 62A
B95 or D95 or E95 or K95, and LEFT-HAND DRIVE

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED
a Solder the wires of the evaporator sensor (see Wi-
ring: Repair) (Technical Note 6015A, 88A, Wiring).
a Fit the evaporator sensor in its housing.
a Clip on the evaporator sensor by turning it a quarter
of a turn clockwise.

II - FINAL OPERATION
a Refit:
- the dashboard cross member stiffener,
- the upper bolts of the dashboard cross member
reinforcement,
- the lower bolts of the dashboard cross member
reinforcement.
a Tighten to torque:
- the dashboard cross member reinforcement
upper bolts (21 N.m),
- the dashboard cross member reinforcement
lower bolts (21 N.m).
a Refit:
- the front left-hand footwell air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment).

62A-80
AIR CONDITIONING
Evaporator sensor: Removal - Refitting 62A
RIGHT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Tightening torquesm

dashboard cross mem- 21 N.m


ber reinforcement upper
bolts

dashboard cross mem- 21 N.m


ber reinforcement lower
bolts

IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 62A, Air conditioning, Air conditio-
ning: Precautions for repair, page 62A-3) .

REMOVAL
137648
I - REMOVAL PREPARATION OPERATION
a Unclip the evaporator sensor by turning it a quarter
a Remove the glovebox (see Glovebox: Removal - of a turn anti-clockwise.
Refitting) (57A, Interior equipment).
a Remove the evaporator sensor.
a Unclip the left-hand panel from the centre console.

E95
a Remove:
- the lower bolts from the dashboard cross member
reinforcement,
- the upper bolts on the dashboard cross member
reinforcement,
- the dashboard cross member reinforcement.

137649
a Cut the wires of the evaporator sensor (see Wiring:
Repair) (Technical Note 6015A, 88A, Wiring).

62A-81
AIR CONDITIONING
Evaporator sensor: Removal - Refitting 62A
RIGHT-HAND DRIVE

REFITTING

I - REFITTING OPERATION FOR PART


CONCERNED
a Solder the wires of the evaporator sensor (see Wi-
ring: Repair) (Technical Note 6015A, 88A, Wiring).
a Refit the evaporator sensor.
a Clip on the evaporator sensor by turning it a quarter
of a turn clockwise.

II - FINAL OPERATION

E95
a refit:
- the dashboard cross member reinforcement,
- the upper bolts on the dashboard cross member
reinforcement,
- the lower bolts on the dashboard cross member
reinforcement.
a Tighten to torque:
- the dashboard cross member reinforcement
upper bolts (21 N.m),
- the dashboard cross member reinforcement
lower bolts (21 N.m).

a Refit the glovebox (see Glovebox: Removal - Refit-


ting) (57A, Interior equipment).
a Clip on the left-hand panel of the centre console.

62A-82
AIR CONDITIONING
Evaporator sensor: Removal - Refitting 62A
J95, and LEFT-HAND DRIVE

Tightening torquesm

upper nuts on the dash- 21 N.m


board cross member
reinforcement

lower bolts on the dash- 21 N.m


board cross member
reinforcement

IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 62A, Air conditioning, Air conditio-
ning: Precautions for repair, page 62A-3) .

REMOVAL 138640

a Unclip the wiring from the dashboard cross member


I - REMOVAL PREPARATION OPERATION reinforcement at (1) .
a Remove:
a Remove the lower bolts (2) from the dashboard
- the dashboard lower trim (see Lower section of cross member reinforcement.
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment),
- the front left-hand footwell air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) .
a Unclip the left-hand panel from the centre console.

FR AND RR PROX RADAR


a Disconnect the connector from the parking distance
control buzzer.

138639

a Remove:

- the upper bolts (3) from the dashboard cross mem-


ber reinforcement,

- the brake pedal impacter (4) ,

- the dashboard cross member reinforcement.

62A-83
AIR CONDITIONING
Evaporator sensor: Removal - Refitting 62A
J95, and LEFT-HAND DRIVE
II - OPERATION FOR REMOVAL OF PART REFITTING
CONCERNED

I - REFITTING OPERATION FOR PART


CONCERNED
a Solder the wires of the evaporator temperature sen-
sor (see Wiring: Repair) (Technical Note 6015A,
88A, Wiring).
a Refit the evaporator sensor.
a Clip on the evaporator sensor by turning it a quarter
of a turn clockwise.

II - FINAL OPERATION
a Refit:
- the dashboard cross member reinforcement,
- the brake pedal impacter.
a Tighten to torque:
- the upper nuts on the dashboard cross member
reinforcement (21 N.m),
137648
- the lower bolts on the dashboard cross member
a Unclip the evaporator sensor (5) by turning it a quar- reinforcement (21 N.m).
ter of a turn anti-clockwise.
a Clip on the dashboard cross member reinforcement
wiring.

FR AND RR PROX RADAR


a Connect the parking distance control buzzer con-
nector.

a Refit:
- the front left-hand footwell air distribution duct (see
61A, Heating, A-pillar air distribution duct: Re-
moval - Refitting, page 61A-142) ,
- the dashboard lower trim (see Lower section of
dashboard trim: Removal - Refitting) (57A, Inte-
rior equipment).
a Clip on the left-hand panel of the centre console.

137649
a Take the evaporator sensor out of its housing.
a Cut the wires (6) of the evaporator sensor (see Wi-
ring: Repair) (Technical Note 6015A, 88A, Wiring).

62A-84
AIR CONDITIONING
Condenser - compressor connecting pipe: Removal - Refitting 62A
B95 or D95 or E95 or K95
- the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
Essential equipment
- the right-hand headlight (see Front headlight: Re-
refrigerant charging station moval - Refitting) (80B, Headlights),
- the front panel support,

IMPORTANT - the windscreen washer bottle (see Windscreen


washer bottle: Removal - Refitting) (85A, Wiping
To avoid all risk of damage to the systems, apply
- Washing).
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any - the headlights (see Front headlight: Removal -
repair (see 62A, Air conditioning, Air conditio- Refitting) (80B, Headlights),
ning: Precautions for repair, page 62A-3) .
- the front bumper supports (see Front bumper
support: Removal - Refitting) (42A, Front upper
structure),
WARNING - the audible warning (see Horn: Removal - Refit-
To prevent moisture from entering the system, ting) (82B, Horn),
place plugs on the cold loop components which are - the front impact cross member (see Front impact
open to the air. cross member: Removal - Refitting) (41A, Front
lower structure),
- the bonnet catch (see Bonnet latch: Removal -
Note: Refitting) (52A, Non-side opening element mecha-
nisms).
Use blanking plugs for the fuel circuits with part
numbers 77 01 208 229 or 77 01 476 857 to plug
any openings exposed to the open air. They must
be clean. Do not use any which have already been
used to plug a fuel circuit.

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Remove the front engine cover.

WARNING
Consult the device's operating manual to avoid
incorrect use.

a Drain the refrigerant circuit using the refrigerant


charging station (see 62A, Air conditioning, Coo- 135882
lant circuit Draining - Refilling, page 62A-9) . a Remove the bolts (1) from the engine wiring chan-
a Disconnect the battery (see Battery : Removal - nel.
Refitting) (80A, Battery).
a Remove:
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
- the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),

62A-85
AIR CONDITIONING
Condenser - compressor connecting pipe: Removal - Refitting 62A
B95 or D95 or E95 or K95
II - OPERATION FOR REMOVAL OF PART
CONCERNED

135719

a Remove: 136481

- the upper bolts (2) from the front end panel, a Remove the bolt (5) securing the support for the
« compressor - condenser » connecting pipe to the
- the front end panel clips (3) . front panel.

136473
135296
a Remove the bolt (6) securing the bracket for the
a Remove the lower bolts (4) from the front end panel. « compressor - condenser » connecting pipe to the
compressor.
a Tilt the front end panel slightly towards the front of
the vehicle.

a Remove the intercooler air outlet pipe (see Inter-


cooler air outlet pipe: Removal - Refitting) (12B,
Turbocharging).

62A-86
AIR CONDITIONING
Condenser - compressor connecting pipe: Removal - Refitting 62A
B95 or D95 or E95 or K95
- of the « compressor - condenser » connecting pi-
pe.
F4R
a Remove the bolt from the support of the
« compressor - condenser » connecting pipe on the REFITTING
compressor.

a Remove the bolt from the support of the I - REFITTING PREPARATION OPERATION
« compressor - condenser » connecting pipe on the
lower cross member. a

WARNING
Do not remove the blanking plugs from each
component until the last moment.
Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

WARNING
To avoid any leaks, check that the seal and the
pipe surface are in good condition. The seal and
the surface must be clean and scratch free.

a Remove the blanking plugs.

II - REFITTING OPERATION FOR PART


CONCERNED

a Refit the « compressor-condenser » connecting pi-


pe.

135671
F4R
a Remove the bolt (7) securing the bracket for the
« compressor - condenser » connecting pipe from a Refit the mounting bolt of the « compressor -
the condenser. condenser » connecting pipe on the compressor.

a Refit the mounting bolt of the « compressor -


WARNING condenser » connecting pipe on the lower cross
In order to avoid any refrigerant leaks, do not member.
damage (deform, twist, etc.) the pipe.

a Disconnect:

- the « compressor - condenser » connecting pipe


from the compressor, III - FINAL OPERATION
- the « compressor - condenser » connecting pipe a Refit the intercooler air outlet pipe (see Intercooler
on the condenser. air outlet pipe: Removal - Refitting) (12B, Turbo-
charging).
a Remove the « compressor - condenser » connec-
ting pipe. a Fit the front end panel.
a Fit blanking plugs on the openings:
a Refit the wiring channel for the engine cooling fan
- of the condenser, assembly.

- of the compressor, a Refit the engine wiring channel.

62A-87
AIR CONDITIONING
Condenser - compressor connecting pipe: Removal - Refitting 62A
B95 or D95 or E95 or K95
a Refit:
- the bonnet catch (see Bonnet latch: Removal -
Refitting) (52A, Non-side opening element mecha-
nisms),
- the impact cross member (see Front impact cross
member: Removal - Refitting) (41A, Front lower
structure),
- the audible warning (see Horn: Removal - Refit-
ting) (82B, Horn),
- the front bumper supports (see Front bumper
support: Removal - Refitting) (42A, Front upper
structure),
- the headlights (see Front headlight: Removal -
Refitting) (80B, Headlights).
- the windscreen washer bottle (see Windscreen
washer bottle: Removal - Refitting) (85A, Wiping
- Washing),
- the front panel support,
- the right-hand headlight (see Front headlight: Re-
moval - Refitting) (80B, Headlights),
- the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
- the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres).
a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).

Note:
A summary table gives the quantities of refrige-
rant in the system according to the engine types
(see 62A, Air conditioning, Air conditioning:
Parts and consumables for the repair work,
page 62A-4) .

a Fill up the refrigerant circuit using the refrigerant


charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) .
a Check for leaks (see 62A, Air conditioning, Coo-
lant circuit check, page 62A-8) .
a Check that the air conditioning system is operating
correctly (see 62A, Air conditioning, Air conditio-
ning: Check, page 62A-5) .
a Refit the engine cover.
a Adjust the headlights (see Front headlight: Adjus-
ting) (80B, Headlights).

62A-88
AIR CONDITIONING
Condenser - compressor connecting pipe: Removal - Refitting 62A
J95
- the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
Essential equipment
(55A, Exterior protection),
refrigerant charging station - the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
- the audible warning (see Horn: Removal - Refit-
IMPORTANT ting) (82B, Horn),
To avoid all risk of damage to the systems, apply
- the front impact cross member (see Front impact
the safety and cleanliness instructions and opera-
cross member: Removal - Refitting) (41A, Front
tion recommendations before carrying out any
lower structure),
repair (see 62A, Air conditioning, Air conditio-
ning: Precautions for repair, page 62A-3) . - the cooling radiator air deflectors,
- the headlights (see Front headlight: Removal -
Refitting) (80B, Headlights).
WARNING
To prevent moisture from entering the system,
place plugs on the cold loop components which are
open to the air.

Note:
Use blanking plugs for the fuel circuits with part
numbers 77 01 208 229 or 77 01 476 857 to plug
any openings exposed to the open air. They must
be clean. Do not use any which have already been
used to plug a fuel circuit.

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment). 138656
a Remove the bonnet supports (1) .
a Remove the front engine cover.

F9Q or H4J or K9K or M9R


WARNING
a Remove the intercooler air outlet pipe (see Inter-
Consult the device's operating manual to avoid
cooler air outlet pipe: Removal - Refitting) (12B,
incorrect use.
Turbocharging).
a Drain the refrigerant circuit using the refrigerant
charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) .
a Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).
a Remove:
- the engine undertray bolts,
- the engine undertray,
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),

62A-89
AIR CONDITIONING
Condenser - compressor connecting pipe: Removal - Refitting 62A
J95

K9K M9R

135883 138488
a Unclip the expansion bottle top hose (2) from the a Remove the rigid cooling hose bolts (4) from the
front end panel. front end panel.

140184
a Unclip the degassing hose from the front end panel
at (5) .

138486
a Unclip the bonnet cable at (3) .
a Remove the bonnet cable.

62A-90
AIR CONDITIONING
Condenser - compressor connecting pipe: Removal - Refitting 62A
J95

H4J

139053
a Remove:
138363 - the bolts (8) of the engine wiring channel,
a Remove the bolt (6) from the front end panel winds- - the bonnet catch (see Bonnet latch: Removal -
creen washer reservoir. Refitting) (52A, Non-side opening element mecha-
nisms).

140184
a Unclip the degassing hose from the front end panel
at (7) .

a Unclip the remaining wiring from the front end panel.

62A-91
AIR CONDITIONING
Condenser - compressor connecting pipe: Removal - Refitting 62A
J95
II - OPERATION FOR REMOVAL OF PART
CONCERNED

139052

136473
a Remove the bolt (10) securing the bracket for the
« compressor - condenser » connecting pipe to the
compressor.

135646
a Remove the front end panel bolts (9) .
a Tilt the front end panel.

136481
a Remove the « compressor - condenser » connec-
ting pipe bolt (11) from the windscreen washer re-
servoir mounting.

62A-92
AIR CONDITIONING
Condenser - compressor connecting pipe: Removal - Refitting 62A
J95

REFITTING

I - REFITTING PREPARATION OPERATION

WARNING
Do not remove the blanking plugs from each
component until the last moment.
Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

WARNING
To avoid any leaks, check that the seal and the
pipe surface are in good condition. The seal and
the surface must be clean and scratch free.

135671 a Remove the blanking plugs.


a Remove the bolt (12) securing the bracket for the
« compressor - condenser » connecting pipe from
the condenser. II - REFITTING OPERATION FOR PART
CONCERNED

WARNING a Refit the « compressor-condenser » connecting pi-


pe.
In order to avoid any refrigerant leaks, do not
damage (deform, twist, etc.) the pipe. a Connect:
a Disconnect: - the « compressor - condenser » connecting pipe
- the « compressor - condenser » connecting pipe on the compressor,
from the compressor,
- the « compressor - condenser » connecting pipe
- the « compressor - condenser » connecting pipe on the condenser.
on the condenser.
a Remove the « compressor - condenser » connec-
III - FINAL OPERATION
ting pipe.
a Fit blanking plugs on the openings of the a Fit the front end panel.
« compressor - condenser » connecting pipe and
the compressor. a Refit:

- the engine wiring channel,

- the bonnet catch (see Bonnet latch: Removal -


Refitting) (52A, Non-side opening element mecha-
nisms).

H4J

a Clip the degassing hose on the front end panel.

a Refit the windscreen washer bottle bolt.

62A-93
AIR CONDITIONING
Condenser - compressor connecting pipe: Removal - Refitting 62A
J95
a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).
M9R

a Refit the rigid cooling hose on the front end panel. Note:
a Clip the degassing hose on the front end panel. A summary table gives the quantities of refrige-
rant in the system according to the engine types
(see 62A, Air conditioning, Air conditioning:
Parts and consumables for the repair work,
page 62A-4) .

K9K a Perform the following operations:

a Clip the expansion bottle top hose on the front end - fill the refrigerant circuit using the refrigerant char-
panel. ging station (see 62A, Air conditioning, Coolant
circuit Draining - Refilling, page 62A-9) ,
- check for leaks (see 62A, Air conditioning, Coo-
lant circuit check, page 62A-8) .
a Clip: a Check that the air conditioning system is operating
correctly (see 62A, Air conditioning, Air conditio-
- the bonnet cable on the front end panel, ning: Check, page 62A-5) .
- the wiring on the front end panel. a Refit the engine cover.
a Adjust the headlights (see Front headlight: Adjus-
F9Q or H4J or K9K or M9R ting) (80B, Headlights).

a Refit the intercooler air outlet pipe (see Intercooler


air outlet pipe: Removal - Refitting) (12B, Turbo-
charging).

a Refit:

- the bonnet supports,

- the headlights (see Front headlight: Removal -


Refitting) (80B, Headlights),

- the cooling radiator air deflectors,

- the front impact cross member (see Front impact


cross member: Removal - Refitting) (41A, Front
lower structure),

- the audible warning (see Horn: Removal - Refit-


ting) (82B, Horn),

- the front bumper (see Front bumper: Removal -


Refitting) (55A, Exterior protection),

- the front section of the front wheel arch liners (see


Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),

- the front wheels (see Wheel: Removal - Refitting)


(35A, Wheels and tyres),

- the engine undertray.

62A-94
AIR CONDITIONING
Compressor/intermediate pipe connecting pipe: Removal - Refitting 62A
B95 or D95 or E95 or K95
- the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
Essential equipment
- the headlights (see Front headlight: Removal -
refrigerant charging station Refitting) (80B, Headlights),
- the front bumper supports (see Front bumper
support: Removal - Refitting) (42A, Front upper
IMPORTANT structure),
To avoid all risk of damage to the systems, apply
- the audible warning (see Horn: Removal - Refit-
the safety and cleanliness instructions and opera-
ting) (82B, Horn),
tion recommendations before carrying out any
repair (see 62A, Air conditioning, Air conditio- - the front impact cross member (see Front impact
ning: Precautions for repair, page 62A-3) . cross member: Removal - Refitting) (41A, Front
lower structure),
- the bonnet catch (see Bonnet latch: Removal -
WARNING Refitting) (52A, Non-side opening element mecha-
nisms).
To prevent moisture from entering the system,
place plugs on the cold loop components which are
open to the air.

Note:
Use blanking plugs for the fuel circuits with part
numbers 77 01 208 229 or 77 01 476 857 to plug
any openings exposed to the open air. They must
be clean. Do not use any which have already been
used to plug a fuel circuit.

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Remove the front engine cover.
135882
a Remove the bolts (1) from the engine wiring chan-
WARNING nel.
Consult the device's operating manual to avoid
incorrect use.

a Drain the refrigerant circuit using the refrigerant


charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) .
a Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).
a Remove:
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
- the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),

62A-95
AIR CONDITIONING
Compressor/intermediate pipe connecting pipe: Removal - Refitting 62A
B95 or D95 or E95 or K95

F4R or F9Q or H4J or K9K or M9R


a Remove the intercooler air outlet pipe (see Inter-
cooler air outlet pipe: Removal - Refitting) (12B,
Turbocharging).

II - OPERATION FOR REMOVAL OF PART


CONCERNED

F4R

135719
a Remove:
- the upper bolts (2) from the front end panel,
- the front end panel clips (3) .

135700
a Remove the bolt (5 ) of the « intermediate pipe -
compressor » connecting pipe retaining bracket on
the engine block.

135296
a Remove the lower bolts (4) from the front end panel.
a Tilt the front end panel slightly towards the front of
the vehicle.

62A-96
AIR CONDITIONING
Compressor/intermediate pipe connecting pipe: Removal - Refitting 62A
B95 or D95 or E95 or K95

136473 136492
a Remove the bolt (6) securing the « intermediate pipe a Remove the bolt (7) securing the « intermediate pipe
- compressor » connecting pipe bracket to the com- - compressor » connecting pipe bracket on the inter-
pressor. mediate pipe.

WARNING
In order to avoid any refrigerant leaks, do not
damage (deform, twist, etc.) the pipe.

a Disconnect:
- the « intermediate pipe - compressor » connecting
pipe from the compressor,
- the « intermediate pipe - compressor » connecting
pipe from the intermediate pipe.
a Remove the « intermediate pipe - compressor »
connecting pipe.
a Fit blanking plugs on the connecting pipe and on the
compressor.

62A-97
AIR CONDITIONING
Compressor/intermediate pipe connecting pipe: Removal - Refitting 62A
B95 or D95 or E95 or K95

REFITTING - the front bumper supports (see Front bumper


support: Removal - Refitting) (42A, Front upper
structure),
I - REFITTING PREPARATION OPERATION
- the audible warning (see Horn: Removal - Refit-
a ting) (82B, Horn),
WARNING - the headlights (see Front headlight: Removal -
Do not remove the blanking plugs from each Refitting) (80B, Headlights),
component until the last moment. - the front bumper (see Front bumper: Removal -
Also, do not remove the components from their Refitting) (55A, Exterior protection),
packaging until they are to be fitted to the vehi- - the front section of the front wheel arch liners (see
cle. Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),

WARNING - the front wheels (see Wheel: Removal - Refitting)


(35A, Wheels and tyres).
To avoid any leaks, check that the seal and the
pipe surface are in good condition. The seal and a Adjust the headlights (see Front headlight: Remo-
the surface must be clean and scratch free. val - Refitting) (80B, Headlights).
a Connect the battery (see Battery : Removal - Refit-
a Remove the blanking plugs.
ting) (80A, Battery).

II - REFITTING OPERATION FOR PART


CONCERNED Note:

a Refit the « intermediate pipe - compressor » con- A summary table gives the quantities of refrige-
necting pipe. rant in the system according to the engine types
(see 62A, Air conditioning, Air conditioning:
Parts and consumables for the repair work,
F4R page 62A-4) .
a Refit the retaining bracket for the « intermediate pipe a Fill up the refrigerant circuit using the refrigerant
- compressor » connecting pipe on the engine block. charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) .
a Check for leaks (see 62A, Air conditioning, Coo-
lant circuit check, page 62A-8) .
III - FINAL OPERATION a Check that the air conditioning system is operating
correctly (see 62A, Air conditioning, Air conditio-
ning: Check, page 62A-5) .
F4R or F9Q or H4J or K9K or M9R
a Refit the engine cover.
a Refit the intercooler air outlet pipe (see Intercooler
air outlet pipe: Removal - Refitting) (12B, Turbo-
charging).

a Fit the front end panel.


a Refit the engine wiring channel.
a Refit:
- the bonnet catch (see Bonnet latch: Removal -
Refitting) (52A, Non-side opening element mecha-
nisms),
- the front impact cross member (see Front impact
cross member: Removal - Refitting) (41A, Front
lower structure),

62A-98
AIR CONDITIONING
Compressor/intermediate pipe connecting pipe: Removal - Refitting 62A
J95
- the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
Essential equipment
(55A, Exterior protection),
refrigerant charging station - the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
- the audible warning (see Horn: Removal - Refit-
IMPORTANT ting) (82B, Horn),
To avoid all risk of damage to the systems, apply
- the front impact cross member (see Front impact
the safety and cleanliness instructions and opera-
cross member: Removal - Refitting) (41A, Front
tion recommendations before carrying out any
lower structure),
repair (see 62A, Air conditioning, Air conditio-
ning: Precautions for repair, page 62A-3) . - the cooling radiator air deflectors,
- the headlights (see Front headlight: Removal -
Refitting) (80B, Headlights).
WARNING
To prevent moisture from entering the system,
place plugs on the cold loop components which are
open to the air.

Note:
Use blanking plugs for the fuel circuits with part
numbers 77 01 208 229 or 77 01 476 857 to plug
any openings exposed to the open air. They must
be clean. Do not use any which have previously
been used to plug a fuel circuit.

REMOVAL

I - REMOVAL PREPARATION OPERATION


a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment). 138656
a Remove the bonnet supports (1) .
a Remove the front engine cover.

F9Q or H4J or K9K or M9R


WARNING
a Remove the intercooler air outlet pipe (see Inter-
Consult the device's operating manual to avoid
cooler air outlet pipe: Removal - Refitting) (12B,
incorrect use.
Turbocharging).
a Drain the refrigerant circuit using the refrigerant
charging station (see 62A, Air conditioning, Coo-
lant circuit Draining - Refilling, page 62A-9) .
a Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).
a Remove:
- the engine undertray bolts,
- the engine undertray,
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),

62A-99
AIR CONDITIONING
Compressor/intermediate pipe connecting pipe: Removal - Refitting 62A
J95

K9K M9R

135883 138488
a Unclip the expansion bottle top hose (2) from the a Remove the rigid cooling hose bolts (4) from the
front end panel. front end panel.

140184
a Unclip the degassing hose (5) from the front end pa-
nel.

138486
a Unclip the bonnet cable at (3) .
a Remove the bonnet cable.

62A-100
AIR CONDITIONING
Compressor/intermediate pipe connecting pipe: Removal - Refitting 62A
J95

H4J

139053
a Remove:
138363 - the bolts (8) of the engine wiring channel,
a Remove the bolt (6) from the front end panel winds- - the bonnet catch (see Bonnet latch: Removal -
creen washer reservoir. Refitting) (52A, Non-side opening element mecha-
nisms).

140184
a Unclip the degassing hose from the front end panel
at (7) .

a Unclip the remaining wiring from the front end panel.

62A-101
AIR CONDITIONING
Compressor/intermediate pipe connecting pipe: Removal - Refitting 62A
J95
II - OPERATION FOR REMOVAL OF PART
CONCERNED

139052

136473
a Remove the bolt (10) securing the « intermediate
pipe - compressor » connecting pipe bracket to the
compressor.

135646
a Remove the front end panel bolts (9) .
a Tilt the front end panel.

62A-102
AIR CONDITIONING
Compressor/intermediate pipe connecting pipe: Removal - Refitting 62A
J95

REFITTING

I - REFITTING PREPARATION OPERATION

WARNING
Do not remove the blanking plugs from each
component until the last moment.
Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.

WARNING
To avoid any leaks, check that the seal and the
pipe surface are in good condition. The seal and
the pipe surface must be clean and scratch free.

138673 a Remove the blanking plugs.


a Remove the bolt (11) securing the « intermediate
pipe - compressor » connecting pipe bracket on the
II - REFITTING OPERATION FOR PART
intermediate pipe. CONCERNED

a Refit the « intermediate pipe - compressor » con-


WARNING necting pipe.
In order to avoid any refrigerant leaks, do not
damage (deform, twist, etc.) the pipe. a Connect:

a Disconnect: - the « intermediate pipe - compressor » connecting


pipe on the compressor,
- the « intermediate pipe - compressor » connecting
pipe from the compressor, - the « intermediate pipe - compressor » connecting
- the « intermediate pipe - compressor » connecting pipe on the « expansion valve - intermediate pipe »
pipe from the « expansion valve - intermediate connecting pipe.
pipe » connecting pipe.
a Remove the « intermediate pipe - compressor » III - FINAL OPERATION
connecting pipe.
a Fit the front end panel.
a Fit blanking plugs on the openings of the connecting
pipes and the compressor. a Refit:

- the engine wiring channel,

- the bonnet catch (see Bonnet latch: Removal -


Refitting) (52A, Non-side opening element mecha-
nisms).

H4J

a Clip the degassing hose on the front end panel.

a Refit the windscreen washer bottle bolt.

62A-103
AIR CONDITIONING
Compressor/intermediate pipe connecting pipe: Removal - Refitting 62A
J95
a Connect the battery (see Battery : Removal - Refit-
ting) (80A, Battery).
M9R

a Refit the rigid cooling hose on the front end panel. Note:
a Clip the degassing hose on the front end panel. A summary table gives the quantities of refrige-
rant in the system according to the engine types
(see 62A, Air conditioning, Air conditioning:
Parts and consumables for the repair work,
page 62A-4) .

K9K a Perform the following operations:

a Clip the expansion bottle top hose on the front end - fill the refrigerant circuit using the refrigerant char-
panel. ging station (see 62A, Air conditioning, Coolant
circuit Draining - Refilling, page 62A-9) ,
- check for leaks (see 62A, Air conditioning, Coo-
lant circuit check, page 62A-8) .
a Clip: a Check that the air conditioning system is operating
correctly (see 62A, Air conditioning, Air conditio-
- the bonnet cable on the front end panel, ning: Check, page 62A-5) .
- the wiring on the front end panel. a Refit the engine cover.
a Adjust the headlights (see Front headlight: Adjus-
F9Q or H4J or K9K or M9R ting) (80B, Headlights).

a Refit the intercooler air outlet pipe (see Intercooler


air outlet pipe: Removal - Refitting) (12B, Turbo-
charging).

a Refit:

- the bonnet supports,

- the headlights (see Front headlight: Removal -


Refitting) (80B, Headlights),

- the cooling radiator air deflectors,

- the front impact cross member (see Front impact


cross member: Removal - Refitting) (41A, Front
lower structure),

- the audible warning (see Horn: Removal - Refit-


ting) (82B, Horn),

- the front bumper (see Front bumper: Removal -


Refitting) (55A, Exterior protection),

- the front section of the front wheel arch liners (see


Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),

- the front wheels (see Wheel: Removal - Refitting)


(35A, Wheels and tyres),

- the engine undertray.

62A-104