203 1995 2002 Renault Megane Mégane Factory Service Manual

General
SPECIFICATIONS
LIFTING
TOWING
LUBRICANTS CONSUMABLES
DRAINING, RE-FILLING
VALUES AND SETTINGS
BA0A - BA0E - BA0F - BA0G - BA0L - BA0U
77 11 176 201 APRIL 1995 Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the All copyrights reserved by the Regie Nationale des Usines Renault.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The methods may be modified as a result of changes introduced by the reference numbering system is forbidden without the prior written authority of the
manufacturer in the production of the various component units and accessories Regie Nationale des Usines Renault.
from which his vehicles are constructed."
C Régie Nationale des Usines Renault S.A. 1995

SECTION VIEW
General
Contents
Page
01 SPECIFICATIONS
Engine - Clutch - Gearbox 01-1
Vehicle identification 01-2
02 LIFTING
Trolley jack - Axle stands 02-1
Vehicle lifts 02-2
03 TOWING
All types 03-1
04 LUBRICANTS - CONSUMABLES
Packaging 04-1
05 DRAINING, RE-FILLING
Engine 05-1
Gearbox 05-3
Power assisted steering 05-4
07 VALUES AND SETTINGS

Dimensions 07-1
Capacity - Grades 07-2
Belt tension 07-5
Accessories belt tension 07-7
Timing belt tension 07-13
Tightening the cylinder head 07-15
Dimensions of the main braking
components 07-17
Values for checking the front axle
geometry 07-18
Values for checking the rear axle
geometry 07-21
Underbody heights 07-22
Brake limiter 07-23
SPECIFICATIONS
Engine- Clutch - Gearbox 01
Engine
Type of manual gearbox and
Vehicle type Clutch type
automatic transmission
Type Capacity
180 DST 3050

BA0E E7J 1390 JB1
180 CP 3300
BA0F
K7M 1598 200 HR 4000 JB1
BA0L
BA0G F3R 1998 215 HRN 4000 JB3
BA0A 200 HRV 4600

F8Q 1870 JB1
BA0U 200 HRV 3100
BA0F K7M 1598 - AD4
VEHICLE IDENTIFICATION
Example : BA0E
B: Body type (example 5 door hatchback)

A: Project code (example 64)
0E : Engine suffix (example E7J 764)
01-1
SPECIFICATIONS
Vehicle identification 01
LOCATION OF THE VEHICLE IDENTIFICATION • near to the emergency spare wheel (B) with a
PLATE duplicate label of the oval plate on the lower
section of the passenger door (C).
Two possible locations on the vehicle:
• in the engine compartment (A),
98517R
98485-1R
98516R
01-2
SPECIFICATIONS
REGIE NATIONALE DES
A
USINES RENAULT S.A.
8
B e000-00/00000-0000-00 9
0000
1 VF0000000 00 000 000 10
2 00000000 00 000 000 11
3 0000 kg 0000000 12
4 0000 kg 13
5 1 - 0000 kg 14
6 7
2 - 0000 kg Renault
1 VF0000000
2 00000000 9
8 0000
7 00 000 000 10
14 00 000 000 11
13 0000000
12
01-3
SPECIFICATIONS
It shows:
At A : the name of the manufacturer,
At B : the E.E.C. approval number
At 1 : the type mines of the vehicle preceded by the world manufacturers identification code (VF1 corre-
sponds to RENAULT FRANCE),
At 2 : the chassis number,
At 3 : the maximum permissible weight,
At 4 : the maximum permitted total train weight,
At 5 : the maximum permitted weight on the front axle,
At 6 : the maximum permitted weight on the rear axle,
At 7 : the first figure indicates the gearbox or factory options,
the second figure indicates the equipment level,
At 8 : the vehicle type,
At 9 : the technical equipment code,
At 10 : additional factory optional equipment,
At 11 : the equipment level,
At 12 : the paint code,
At 13 : a letter describing the factory of manufacture followed by the fabrication number,
At 14 : the trim code.
NOTE : Depending on the country of export, certain details might not be given. The plate described above
shows all possible information.
ALLOCATION OF TECHNICAL EQUIPMENT CODES
The equipment code, the three letters which appear in (9), must be documented for vehicle identification
reasons (ordering spare parts, warranty claim, etc.)
01-4
LIFTING
Trolley jack - Axle stands 02
Safety symbol (special precautions to be taken when carrying out operations).
SPECIAL TOOLING REQUIRED
Cha. 280 -02 Adaptable cross piece for trolley

jack
Cha. 408 -01
or Adaptable socket for trolley jack
Cha. 408 -02
If a trolley jack is used, appropriate axle AXLE STANDS

stands must always be used.
When putting the vehicle on axle stands, they
must be positioned:
- either under the reinforcements designed for
It is forbidden to lift the vehicle by supporting its lifting the vehicle using the vehicle’s jack,
weight under the front suspension arm or under - or under the points located behind the
the V shaped part of the rear axle. reinforcements.
Depending on the type of trolley jack, use sockets Axle stands are positioned at the rear when the
Cha. 408-01 or Cha. 408-02 to position the cross vehicle is lifted from the side.
piece Cha. 280-02.
To lift the front or rear, support the vehicle’s

weight under the vehicle’s jacking points .
TROLLEY JACK USED FROM THE SIDE
Use cross piece Cha. 280-02.
Take the weight under the sill, level with the front
door.
Position the flange correctly in the groove of the

cross piece.
98699R
85679-1G7
98336G
02-1
LIFTING
Vehicle lifts 02
SAFETY INSTRUCTIONS These must be positioned in line with the vehicle’s
jacking points. They must be clipped into the
Several scenarios should be considered: holes in the body sill.
1 - WHEN REMOVING COMPONENTS
In general, never use a 2 post lift, if a four post lift 2 - SPECIAL CASE - REMOVING AND REFITTING
can be used. THE ENGINE AND TRANSMISSION ASSEMBLY
If this is not possible, position the lifting pads In this special case, the body of the vehicle must
under the body sill, level with the vehicle’s jacking be firmly attached to the arms of the two post lift
points. using the special pads.
FOG
Reference FOG 449 8111 - 449 8411
or
FRONT
CHEMICO
Reference 39 2550 0001
or
SCHENCH
Reference 776 684
98703S
REAR
98704S
02-2
TOWING
All types 03
OBSERVE THE LEGAL TOWING REQUIREMENTS OF THE COUNTRY YOU ARE IN.
NEVER USE THE DRIVESHAFTS FOR TOWING THE VEHICLE.
The towing points may only be used for towing the vehicle on the road. They should never be used for remo-
ving the vehicle from a ditch or for any other similar breakdown operation or to lift the vehicle, either direct-
ly or indirectly.
FRONT REAR
98705S 98702S
03-1
LUBRICANTS - CONSUMABLES
Packaging 04
DESCRIPTION PACKAGING PART NUMBER
LUBRICANTS
• MOLYKOTE "BR2" 1 kg tin 77 01 421 145

for main bearing journal faces, thrust pad
guide tubes, clutch fork pads, lower suspension
arm bearings, torsion bar splines, steering box,
driveshaft splines.
• MOLYKOTE "33 Medium"

tubular rear axle rings 100 g tube 77 01 028 179
anti-roll bar rings.
• ANTI-SEIZE
(high temperature grease) Turbo etc. 80 ml tube 77 01 422 307
• "MOBIL CVJ" 825 Black star

or MOBIL EXF57C 180 g sachet 77 01 366 100
for driveshaft joints
• MULTIPURPOSE LUBRICANT
wheel sensor Aerosol 77 01 422 308
MECHANICAL SEALANTS
• Perfect-seal "LOWAC" 100 g tube 77 01 417 404

coating fluid for seals.
• Mastic 1.5 kg tin 77 01 421 161

for sealing exhaust pipe unions.
• HARDENER KIT Kit 77 01 421 080

("CAF 4/60 THIXO")
for sealing sides of bearing caps.
• AUTO joint blue 100 g tube 77 01 396 227

sealing paste. 45 g tube 77 01 397 027
04-1
Packaging 04
MECHANICAL SEALANTS
• AUTO joint grey 100 g tube 77 01 422 750

sealing paste.
• LOCTITE 518 24 ml syringe 77 01 421 162

for sealing the gearbox housing.
• Leak detector Aerosol 77 11 143 071
ADHESIVES
• "LOCTITE - FRENETANCH" 24 cc bottle 77 01 394 070

stops bolts coming loose and allows them to be
undone.
• "LOCTITE - FRENBLOC" 24 cc bottle 77 01 394 071

locks bolts.
• "LOCTITE SCELBLOC" 24 cc bottle 77 01 394 072

for bonding bearings.
• "LOCTITE AUTOFORM" 50 cc bottle 77 01 400 309

for bonding the flywheel to the crankshaft.
CLEANING AGENTS - LUBRICANTS
• "NETELEC" 150 g aerosol 77 01 408 464

unseizes, lubricates.
• NC1 cleaner Aerosol 77 01 422 379

electrical contact cleaner
• Carburettor cleaner 250 ml can 77 01 393 112

300 ml aerosol 77 01 393 111
• Injector cleaner 355 ml can 77 01 423 189
• Super concentrated unseizing agent 500 ml aerosol 77 01 408 466
• "DECAPJOINT " (FRAMET) for cleaning the Aerosol 77 01 405 952

gasket faces of aluminium cylinder heads
• Brake cleaner 400 ml aerosol 77 01 421 282
04-2
Packaging 04
VARNISHES
• "CIRCUIT PLUS" Bottle 77 01 421 135

varnish for repairing heated screens
• "CONTACT PLUS" Kit 77 01 422 752

varnish for repairing rear screen supply termi-
nals
BRAKES
• Brake fluid 0.5 litre bottle DOT 4 77 01 421 940
04-3
Engine 05
TOOLING REQUIRED
Engine drain plug spanner
DRAINING: plug(1) FILLING: plug(2)
F3R - F8Q ENGINES F8Q ENGINE
98486R 98489R
E7J - K7M ENGINE F3R ENGINE
98701R 98487R
05-1
Engine 05
FILLING: plug(2)
K7M ENGINE
98437R
E7J ENGINE
98700R
05-2
Gearbox 05
DRAINING: plug(1)
FILLING: plug(2)
F3R - F8Q ENGINE
98486R1
E7J - K7M ENGINE
98701R1
05-3
Power assisted steering 05
CHECKING THE LEVEL K7M ENGINE
POWER ASSISTED STEERING PUMP LEVEL
For topping up or filling, use ELF RENAULTMATIC

D2 or MOBIL ATF 220 oil.
The level, when correct, should be visible between

the MINI and MAXI marks on the reservoir (1).
F8Q ENGINE
98437R1
E7J ENGINE
98489R1
F3R ENGINE
98700R1
98487R1
05-4
VALUES AND SETTINGS
Dimensions 07
98336R2
* Unladen
** Depending on version
Dimensions in metres
07-1
VALUES AND SETTINGS
Capacity - Grades 07
Capacity
Components Grade
in litres
Petrol engine After E.E.C. countries

(oil) draining
-15°C
-30°C -20°C -10°C 0°C +10°C +20 °C +30°C
CCMC-G4 15W40 - 15W50
CCMC-G5 10W30 - 10W40 -

10W50
CCMC-G5 5W30
E7J
3,5 CCMC-G5 5W40 - 5W50
K7M
F3R 5,5
Other countries
(plus 0.5 litres -15°C

for the oil -30°C -20°C -10°C 0°C +10°C +20 °C +30°C
filter)
API SG 15W40
API SH 15W40
API SG 10W40
API SH 10W40
API SG 10W30
API SH 10W30
API SG 5W30
API SH 5W30
07-2
VALUES AND SETTINGS
Capacity
Components Grade
in litres
Diesel engine After E.E.C. countries

(oil) draining
-15°C +15°C
-30°C -20°C -10°C 0°C +10°C +20 °C +30°C
CCMC-PD2 15W40
CCMC-PD2 10W40
F8Q 5
Other countries
(plus 0.5 litres

for the oil -15°C +15°C
filter)
-30°C -20°C -10°C 0°C +10°C +20 °C +30°C
API CD 15W40
API CD 10W40
API CD 10W30
07-3
VALUES AND SETTINGS
Capacity in
Components Grade Features
litres
Manual gearbox
All countries: TRANSELF TRX 75 W 80 W
( API GL5 or MIL-L 2105 C or D standards)
JB1 3 .4
JB3 3 .4
Automatic
transmission
ELF RENAULT MATIC D2 (D20104)
AD4 4 or use: MOBIL ATF 220 (D20104 or D21412)
TEXAMATIC 4011
Normal : 0.7 SAE J 1703 Brake fluids must be approved by the Technical
Brake circuit
ABS : 1 and DOT 3 Department
Fuel tank approximately Unleaded

60 petrol/diesel
Power assisted Separate ELF RENAULT MATIC

steering reservoir D2 or
1.1 MOBIL ATF 220
Cooling circuit GLACÉOL RX

(type D)
F3R 7 Only add coolant
F8Q 7 .5
E7J - K7M 6
07-4
VALUES AND SETTINGS
Belt tension 07
Mot. 1273 Tool for checking belt tension
96601R
A Sensor Calibrating the device

B Display
C Connecting lead The device is set in the factory, however it must be
D Calibration checking plate recalibrated every six months.
Principle Procedure
The sensor, through the adjusting button (1), the Resetting zero:
pressure device (2) and the outer lugs (3), applies a
constant force to the belt. - switch the device on (button E) with the adjus-
ting button (1) fully screwed in,
The reaction from the belt is measured using a - if 0 is displayed, do not touch anything,
test piece (4) fitted with strain gauges. - if nothing is displayed, check the condition of
the 9 volt battery in the device ,
Any movement on the gauges creates a variation - if a value other than 0 is displayed, adjust screw
in their electrical resistance. This variation, once it (F) until 0 is displayed.
has been converted by the device, is displayed on
the display in SEEM units (US).
07-5
VALUES AND SETTINGS
Belt tension 07
Checking the calibration
Switch the device on (button E).
Position the calibration spring plate (Z) on the sensor as shown on the diagram (checking value engraved to-
wards the top, (A) minimum value, (B) maximum value).
Tighten the adjusting button (1) until it goes "CLICK - CLICK - CLICK".
Check that a value X between the values (A and B) (A ≤ X ≤ B) is displayed.
Note: it may be necessary to perform several preliminary tests in order to obtain the correct value.
If the correct value if still not obtained after several attempts, contact SEEM.
NOTE : each device has its own calibration spring plate and they are not interchangeable.
96602R
1 Adjusting button GENERAL INSTRUCTIONS:

A
Calibration plate checking value - Never refit a belt which has been removed, re-
B
Z Calibration plate place it.
- Never retighten a belt for which the tension

SEEM reading is between the fitting value and the
minimum operating value.
For further information contact your After Sales
Head Office. - When checking, if the tension is below the mi-
nimum operating value, replace the belt.
07-6
VALUES AND SETTINGS
Accessories belt tension 07
GROOVED BELT
Tensioning process
Engine cold (ambient temperature).
Fit the new belt.
Position the sensor of Mot. 1273.
Turn the adjusting button of the sensor until it disengages (three ’’CLICKS’’).
Tension the belt until the recommended fitting value is displayed on Mot. 1273 .
Lock the tensioner, check it, adjust the value.
Turn the crankshaft over three times.
Check that the tension value is within the fitting tension tolerance, otherwise readjust it.
NOTE :
Never refit a belt which has been removed.
Replace the belt, if the tension is below the minimum operating tension.
Small cuts or cracks do not mean that the belt has to be replaced.
07-7
VALUES AND SETTINGS
E7J / K7M
ENGINES
ALTERNATOR AND POWER ASSISTED STEERING AIR CONDITIONING
98706R
98707R
Multitoothed Multitoothed
Multitoothed
Tension air power assisted
alternator belt
(US=SEEM unit) conditioning steering belt
(2)
belt (1) (3)
Fitting 110 ± 7 84 ± 6 84 ± 6
Minimum
75 52 52
operating
A Crankshaft
B Alternator
C Power assisted steering pump
D Air conditioning compressor
T Tensioner
→ Tension check point
07-8
VALUES AND SETTINGS
F3R
ENGINE
ALTERNATOR AND POWER ASSISTED STEERING AIR CONDITIONING
98751R 98752R
Multitoothed Multitoothed
Tension air power assisted
(US=SEEM unit) conditioning steering belt
belt (2) (1)
Fitting 109 ± 3 107 ± 3
Minimum
62 62
operating
A Crankshaft
B Alternator
E Water pump
T Tensioner
07-9
F8Q ENGINE
VALUES AND SETTINGS
Power assisted
steering Accessories belt tension 07
ALTERNATOR AND POWER ASSISTED STEERING
98751R
Tension Multitoothed power

(US=SEEM unit) assisted steering belt (1)
Fitting 97 ± 3
Minimum operating 67
A Crankshaft
B Alternator
E Water pump
T Tensioner
07-10
F8Q ENGINE
VALUES AND SETTINGS
Air conditioning
SPECIAL NOTES FOR REMOVING THE Remove the mounting bolt for the diesel pipe re-
ACCESSORIES BELT taining bracket and move it.
REMOVAL
Disconnect the battery.
Before removing the accessories belt, check the

value of the tension.
The tension measured must be between 61 and 77

SEEM units.
98837R2
Slacken bolt (A) then bolt (B), until the shoulder is

exceeded, whilst holding the automatic tensio-
ning plate using a 9 mm socket (eg. : FACOM J
151 ratchet), then slacken the belt by moving the
ratchet in the direction of the arrow.
99706R
A Crankshaft
B Alternator
E Water pump
G Roller
T Tensioner
98837-1R2
Remove :
- the lower timing cover,
- the belt.
07-11
F8Q ENGINE
VALUES AND SETTINGS
Air conditioning
REFITTING
Refitting is the reverse of removal.
The belt is tensioned by bringing the automatic

tensioner up against the bolt (B), without forcing
it, using a 9 mm socket (eg. : FACOM J151 rat-
chet).
98837-1R3
Check the tension of the accessories belt with the

previously listed values.
NOTE: never refit a belt which has been removed.
07-12
VALUES AND SETTINGS
Timing belt tension 07
Tensioning process E7J and K7M engine
Engine cold (ambient temperature).
Fit the new belt.
Position the sensor of Mot. 1273.
Turn the adjusting button of the sensor until it di-

sengages (three "CLICKS").
Tension the belt until the recommended fitting

value is displayed on Mot. 1273.
Lock the tensioner, check it and adjust the value.
Turn the crankshaft over three times .
Check that the tension value is within the fitting

tension tolerance (± 10%), otherwise readjust it.
98708R
NOTE :
Belt tension (in SEEM units)
Never refit a belt which has been removed.
Fitting: 30 S.U
Replace the belt if the tension is below the mini-
mum operating tension. Minimum operating : 26 S.U.
07-13
VALUES AND SETTINGS
Timing belt tension 07
F3R engine F8Q engine
96528R1 99175R
Belt tension (n SEEM units) Belt tension (in SEEM units)
Fitting: 29 S.U. Fitting: 38 S.U.
Minimum operating : 27 S.U. Minimum operating: 36 S.U.
07-14
VALUES AND SETTINGS
Tightening the cylinder head 07
E ENGINE K ENGINE
METHOD FOR TIGHTENING THE CYLINDER HEAD METHOD FOR TIGHTENING THE CYLINDER HEAD
Using engine oil, lubricate the threads and under Using engine oil, lubricate the threads and under
the heads of the bolts. the heads of the bolts.
REMINDER: to ensure that the bolts are correctly REMINDER: to ensure that the bolts are correctly
tightened, use a syringe to remove any oil which tightened. Use a syringe to remove any oil which
may be in the cylinder head mounting holes. may be in the cylinder head mounting holes.
Tighten the bolts in the order given below: Tighten the bolts in the order given below:
8 4 1 5 9 8 4 1 5 9
7 3 2 6 10 7 3 2 6 10
90 775 90 775
1st tightening to 2 daN.m. 1st tightening to 2 daN.m.
2nd tightening (angle) : 97° ± 2°. 2nd tightening (angle) : 100° ± 6°.
Wait at least 3 minutes. Wait at least 3 minutes.
Slacken bolts 1 and 2 then tighten to 2 daN.m. Slacken bolts 1 and 2 then tighten to 2 daN.m.
2nd tightening (angle) : 97° ± 2°. 2nd tightening (angle) : 110° ± 6°.
Repeat the slackening and retightening opera- Repeat the slackening and retightening opera-
tion for bolts 3, 4, 5, and 6 then 7, 8, 9 and 10. tion for bolts 3, 4, 5, and 6 then 7, 8, 9 and 10.
There is no cylinder head retightening operation. There is no cylinder head retightening operation.
07-15
VALUES AND SETTINGS
Tightening the cylinder head 07
F ENGINE (diesel) F ENGINE (petrol)
METHOD FOR TIGHTENING THE CYLINDER HEAD METHOD FOR TIGHTENING THE CYLINDER HEAD
All bolts must be systematically renewed after re- All bolts must be systematically renewed after re-
moval. moval.
Using engine oil, lubricate the threads and under Using engine oil, lubricate the threads and under
the heads of the bolts. the heads of the bolts.
REMINDER: to ensure that the bolts are correctly REMINDER: to ensure that the bolts are correctly
tightened. Use a syringe to remove any oil which tightened. Use a syringe to remove any oil which
may be in the cylinder head mounting holes. may be in the cylinder head mounting holes.
Tighten the bolts in the order given below: Tighten the bolts in the order given below:
8 4 1 5 9
7 3 2 6 10
90 775
81528-1S
1st tightening to 3 daN.m. 1st tightening to 3 daN.m.
2nd tightening (angle) : 50° ± 4° 2nd tightening (angle) : 50° ± 4°
Wait at least 3 minutes. Wait at least 3 minutes.
Slacken bolts 1 and 2 then perform a 1st tighte- Slacken bolts 1 and 2 by 180° then perform :
ning to 2.5 daN.m. 1st retightening to 2.5 daN.m.
2nd tightening (angle) : 123° ± 7°.
2nd tightening (angle) : 213° ± 7°.
Repeat the slackening and retightening operation
Repeat the slackening and retightening operation for bolts 3-4, 5-6, 7-8, 9-10.
for bolts 3-4, 5-6, 7-8, 9-10.
There is no cylinder head retightening operation.
There is no cylinder head retightening operation.
07-16
VALUES AND SETTINGS
Dimensions of the main braking components 07
BA0A
BA0E
BA0F BA0G
BA0L
BA0U
FRONT BRAKE (dimensions in mm)
Slave cylinder diameter 48 48 48
Disc diameter 238 238 259
Disc thickness 12 20 20.60
Minimum disc thickness 10.3 18.3 19
Lining thickness (including backing plate) 18 18 18
Minimum lining thickness (including backing plate) 7 6.5 6
Maximum disc run-out 0.07 0.07 0.07
REAR BRAKE (dimensions in mm)
Slave cylinder diameter 17.5 17.5 17.5
Drum diameter 203.2 203.2 203.2
Maximum drum diameter after regrinding 204.4 204.4 204.4
MASTER CYLINDER (dimensions in mm)
Diameter 20.6 20.6 20.6
Brakes discs cannot be repaired. They must be replaced if large scratches or excessive wear occur.
07-17
VALUES AND SETTINGS
Values for checking the front axle geometry 07
E7J ENGINE - TUBULAR AXLE - MANUAL STEERING
ANGLES VALUES POSITION OF FRONT ADJUSTMENT

AXLE
CASTOR
2°30’ H5-H2= 76.5 mm

2° H5-H2= 96.5 mm
1°30’ ± 30’ H5-H2= 116.5 mm NOT ADJUSTABLE
1° H5-H2= 136.5 mm
0°30’ H5-H2= 156.5 mm
Maximum left /
right difference =
1°
93012-1S
CAMBER
1°14’ H1-H2= 33 mm
- 0°08’ H1-H2= 90 mm
± 30’ H1-H2= 109 mm NOT ADJUSTABLE
0°25’
0°30’ H1-H2= 188 mm
Maximum left /
right difference =
93013-1S 1°
KING PIN INCLINATION
11°10’ H1-H2= 33 mm
13°01’ H1-H2= 90 mm
13°29’ ± 30’ H1-H2= 109 mm
NOT ADJUSTABLE
14°29’ H1-H2= 188 mm
Maximum left /
right difference =
93014-1S 1°
PARALLELISM
Adjustable by
(For 2 wheels)
rotating track
rod sleeves
(toe-out)
1 turn= 30’
UNLADEN (3 mm)
10’ ± 10’
(1 ± 1 mm)
93011-1S
RUBBER BUSHES
- UNLADEN -
81603S1
07-18
VALUES AND SETTINGS
E7J - E7M - F8Q ENGINE - TUBULAR AXLE - POWER ASSISTED STEERING

AXLE
CASTOR
4°30’ H5-H2= 76.5 mm

4° H5-H2= 96.5 mm
3°30’ ± 30’ H5-H2= 116.5 mm NOT ADJUSTABLE
3° H5-H2= 136.5 mm
2°30’ H5-H2= 156.5 mm
Maximum left /
right difference =
1°
93012-1S
CAMBER
1°35’ H1-H2= 22 mm
- 0°20’ H1-H2= 102 mm
- 0°35’
- 0°30’ H1-H2= 188 mm
Maximum left /
right difference =
93013-1S 1°
10°45’ H1-H2= 22 mm
13°21’ H1-H2= 102 mm
13°48’ ± 30’ H1-H2= 122 mm
NOT ADJUSTABLE
14°32’ H1-H2= 188 mm
Maximum left /
right difference =
93014-1S 1°
PARALLELISM
Adjustable by
(For 2 wheels)
rotating track
rod sleeves
(toe-out)
1 turn= 30’
UNLADEN (3 mm)
10’ ± 10’
(1 ± 1 mm)
93011-1S
RUBBER BUSHES
- UNLADEN -
81603S1
07-19
VALUES AND SETTINGS
F3R ENGINE - 4 BAR AXLE - POWER ASSISTED STEERING

AXLE
CASTOR
4°30’ H5-H2= 71,5 mm

4° H5-H2= 91,5 mm
3°30’ ± 30’ H5-H2= 111,5 mm NOT ADJUSTABLE
3° H5-H2= 131,5 mm
2°30’ H5-H2= 151,5 mm
Maximum left /
right difference =
1°
93012-1S
CAMBER
1°35’ H1-H2= 22 mm
- 0°20’ H1-H2= 102 mm
- 0°37’
- 0°30’ H1-H2= 188 mm
Maximum left /
right difference =
93013-1S 1°
10°45’ H1-H2= 22 mm
13°20’ H1-H2= 102 mm
13°53’ ± 30’ H1-H2= 122 mm
NOT ADJUSTABLE
14°32’ H1-H2= 188 mm
Maximum left /
right difference =
93014-1S 1°
PARALLELISM
Adjustable by
(For 2 wheels)
rotating track
rod sleeves
(toe-out)
1 turn= 30’
UNLADEN (3 mm)
10’ ± 10’
(1 ± 1 mm)
93011-1S
RUBBER BUSHES
- UNLADEN -
81603S1
07-20
VALUES AND SETTINGS
Values for checking the rear axle geometry 07
VALUES POSITION OF REAR ADJUSTMENT
AXLE
ANGLES
REAR AXLE TUBULAR AND 4 TUBULAR AND 4
TUBULAR 4 BAR BAR REAR AXLE BAR REAR AXLE
CAMBER
- 1° ± 15’ - 0°50’ ± 15’ UNLADEN NOT ADJUSTABLE
93013-2S
PARALLELISM
- 50’ ± 20’ - 30’ ± 20’

(Toe- in) (Toe-in)
UNLADEN NOT ADJUSTABLE
or or
- 5 ± 2mm - 3 ± 2mm
93011-2S
RUBBER BUSHES
- UNLADEN -
81603S1
07-21
VALUES AND SETTINGS
Underbody heights 07
Axle type Tubular axle 4 bar axle
Vehicle type BA0A - BA0E - BA0F - BA0L - BA0U BA0G
Wheel diameter (inches) 13" 14"
H1 - H2 (mm) 121 ± 5 123.5 ± 5
H4 - H5 (mm) 44.5 ± 11 52 ± 11
07-22
VALUES AND SETTINGS
Brake limiter 07
These vehicles are fitted with limiters which are load sensitive.
They are checked and adjusted when :

- the vehicle is unladen,
- the fuel tank is full,
- the driver is in the vehicle.
Control pressure (Bar)

Vehicle Fuel tank
type
Front Rear
BA0G
100 72 +0
-8
BA0A
BA0E
BA0F Full 100 62 +0
-8
BA0L
BA0U
90966S
07-23
Engine and peripherals
ENGINE AND PERIPHERALS
TOP AND FRONT OF ENGINE
FUEL MIXTURE
FUEL SUPPLY - PUMPS
ANTIPOLLUTION
STARTING CHARGING
IGNITION - INJECTION
cont INJECTION (Fault finding)
COOLING - EXHAUST - FUEL TANK
77 11 176 211 SEPTEMBER 1995 Edition Anglaise
C Régie Nationale des Usines Renault S.A.1995

EXPLODED VIEW
PRJ1005
Engine and
peripherals
Contents
Page Page
10 ENGINE AND PERIPHERALS 13 FUEL SUPPLY - PUMPS -

PREHEATING
Consumables 10-1
Identification 10-1 Fuel supply
Oil consumption 10-2 Fuel cut-out on impact 13-1
Oil pressure 10-3 Fuel gallery 13-3
Engine - Gearbox 10-4 Injectors 13-8
Engine and transmission assembly 10-19 Fuel filter 13-9
Sump 10-43 Pump flow 13-10
Supply pressure 13-11
Diesel equipment
Specifications 13-15
Description of the pump 13-16
11 TOP AND FRONT OF ENGINE Tightening torques (in daN.m) 13-17
Special notes 13-18
Timing belt 11-1 Idle speed settings 13-20
Cylinder head gasket 11-12 Microswitches 13-22
Pump 13-23
Pump - timing 13-27
Coded solenoid valve 13-28
Operating diagram 13-29
Pre-post-heating unit 13-30
Injector holder - heater plug 13-36
Fuel filter 13-37
Coolant temperature sensor 13-39
12 FUEL MIXTURE
Inlet - exhaust manifolds 13-40
Specifications 12-1
Throttle body 12-7 Pump
Inlet manifold 12-15 Brake assistance vacuum pump 13-41
Exhaust manifold 12-18 Mechanical power assisted steering
Manifolds 12-20 pump 13-42
Contents
Page Page
14 ANTIPOLLUTION 17 IGNITION - INJECTION

(continued)
Fuel vapour recirculation 14-1
Oil vapour rebreathing 14-9 Injection strategy / automatic
Exhaust gas recirculation (EGR) 14-13 transmission 17-28
Catalytic converter 14-19 Injection strategy / air conditioning 17-29
Catalytic converter - oxygen sensor 14-21 Idle speed correction 17-32
Test for the presence of lead 14-22 Idle speed adaptive correction 17-33
Richness regulation 17-34
Adaptive richness correction 17-36
Operating wiring diagram 17-39
16 STARTING - CHARGING
Alternator 16-1 19 COOLING - EXHAUST- FUEL TANK -
Starter motor 16-9 ENGINE SUSPENSION
COOLING
Specifications 19-1
Filling - bleeding 19-2
17 IGNITION - INJECTION Checking 19-3
Radiator 19-4
IGNITION Diagram 19-6
Power module 17-1
Static ignition 17-2 Exhaust
Spark plugs 17-5 General 19-12
Catalytic converter 19-15
Injection Exhaust pipe assembly 19-16
General 17-6
Location of components 17-12 Fuel tank
Special notes on semi-sequential Fuel tank 19-19
injection 17-17 Filler neck 19-23
Special notes on sequential injection 17-19 Gauge 19-25
Injection fault warning light 17-24 Pump and sender unit 19-26
Engine immobiliser function 17-25
Computer configuration as a Engine suspension
function of the gearbox type 17-26 Suspended engine mountings 19-29
Engine mounting pads 19-32
Consumables 10
Type Quantity Components
RHODORSEAL 5661
Coat Driveshaft roll pin holes
e.g.- CAF 4/60 THIXO
Loctite FRENBLOC
Coat Brake caliper mounting bolts
Brake and sealing resin
Loctite FRENETANCH
Coat Crankshaft pulley mounting bolts
Brake and sealing resin
Paste for exhaust pipe Coat Exhaust sealing
Identification
Vehicle Manual Capacity Bore Stroke

Engine Ratio
type gearbox (cm 3) (mm) (mm)
BA0E E7J 764 JB1 1 390 75.8 77 9.5/1
BA0G F3R 750 JB3 1 998 82.7 93 9.8/1
BA0F K7M 803 AD4 1 598 79.5 80,5 9.7/1
BA0F K7M 702 9.7/1

JB1 1 598 79.5 80,5
BA0L K7M 720 9.5/1
BA0A
F8Q 620 JB1 1 870 80 93 21.5/1
BA0U
Refer to the correct engine Workshop Repair Manual for the type of engine to repaired:
Engine
E7J F3R K7M
Document
E engine X
F engine (E) X
K engine (E) underway X
10-1
Oil consumption 10
TESTING METHOD Ask the driver to return the vehicle after 1 000 km
(620 miles) during which time the oil level should
Oil consumption of 1 litre for 1 000 km (620 be monitored regularly with the dipstick.
miles) is acceptable.
When the vehicle is returned, check the drain and
Check there is no external oil leak from the en- filling plugs have not been tampered with.
gine.
Under the same conditions:
For accurate testing, certain conditions must be
observed when draining the engine oil : - engine warm,
- the engine should be warm, - dipstick and filling plug removed.
- the dipstick and filling plug should be removed. Drain the oil and use a measuring cylinder to
check the amount of oil collected.
Drain the engine and leave the oil running out for
15 minutes minimum. Calculate the oil consumption in litres per
1 000 km (620 miles) if the mileage is different.
Refit the drain plug and "seal" it (spot of paint co-
vering the plug and the sump) in order to check at
a later date that it has not been removed.
Use a measuring cylinder to check the amount of

oil required to fill the engine:
Engines:
E7J 2.75 litres

K7M 3 litres
F3R 5.5 litres
F8Q 5 litres
Refit the filling plug and seal it.
10-2
Oil pressure 10
SPECIAL TOOLING
Mot. 836 -05 Oil pressure testing kit
SPECIAL EQUIPMENT
Long 22 mm socket
CHECKING ENGINE CHECK
The oil pressure must be checked when the engine E and K engines
is warm (approximately 80°C).
Idle 1 bar
Composition of the kit Mot. 836-05. 3 000 rpm. 3 bar
F engine
1 000 rpm. 1.2 bar

3 000 rpm. 3.5 bar.
87363R1
USE
F engine E and K engine
B+F C+E+F
10-3
E7J engine
Engine - Gearbox 10
SPECIAL TOOLING
B.Vi. 31-01 Set of punches

Mot. 1202 Hose clip pliers
T.Av. 476 Ball joint extractor
SPECIAL EQUIPMENT
Load positioning tool (example : NAUDER 1805)
TIGHTENING TORQUES (in daN.m) Left hand side of the vehicle
Brake caliper bolts 3.5 Remove:

Shock absorber base bolt 17 - track rod end using tool T.Av. 476,
- the three bolts of the driveshaft gaiter,
Track rod end nut 3.5
- the two bolts from the shock absorber base,
Driveshaft gaiter bolt 2.5 - the two bolts from the brake caliper then
Wheel bolts 9 secure it to the shock absorber spring,
Engine tie-bar bolt : - the bolt from the lower ball joint,
- on the gearbox 6.5 - the complete hub assembly and the
- on the sub-frame 7.5 driveshaft.
Right hand engine mounting nut 4.5
Left hand gearbox mounting nut 4.5
Right hand side of the vehicle
REMOVAL Remove the pins from the right hand driveshaft

using tool B.Vi. 31-01.
Put the vehicle on a 2 post lift.
Remove:
Drain the gearbox. - the track rod end using tool T.Av. 476,
- the upper shock absorber bolt and slacken the
Disconnect the battery. nut on the lower bolt without removing it.
Remove: Remove the driveshaft from the gearbox.

- the bonnet,
- the front wheels.
10-4
E7J engine
Engine - Gearbox 10
Remove: Disconnect the reversing light.
- the catalytic converter,
- the gearbox selector rod, Remove:
- the nuts (1) from the engine and gearbox - the power assisted steering pump,
mountings,
- the nuts (2) engine tie-bar mounting,
98747R
PRJ1001 - the power assisted steering reservoir,

- the air filter,
- the accelerator cable from the throttle body,
- the power assisted steering pipe mountings - the clutch cable from the gearbox,
from the gearbox, - hoses (4), (5), (6) and (7),
98749R
- the speedometer.
98711R
10-5
E7J engine
Engine - Gearbox 10
- the relay plate and the engine connection unit - the earth strap,
connector. - the pipe from the canister solenoid valve,
- the injection computer and secure it to the
engine,
- the starter feed wire from the battery.
Disconnect the injection feed wire located in the

scuttle panel.
98756R
Remove the pipe from the brake servo.
Disconnect the thermistor and the fan unit feed.

98754R
Remove:
- the absolute pressure sensor,
- the ignition module, Position the load positioning tool.
- the fuel pipes,
Lift the engine to remove the three bolts and the
engine tie-bar mounting.
Remove the engine.
REFITTING
Fill the gearbox and the cooling circuit and bleed

the circuit (see section 19).
NOTE: ensure the heat shields are correctly

positioned.
98714R
10-6
K7M engine
Engine - Gearbox 10
SPECIAL TOOLING

SPECIAL EQUIPMENT
TIGHTENING TORQUES (in daN.m) Left hand side of the vehicle
Brake caliper mounting bolt 3.5 Remove:

Shock absorber base bolt 17 - track rod end using tool T.Av. 476,
- the three bolts of the driveshaft gaiter,
Driveshaft gaiter mounting bolt 2.5 - the two bolts from the brake caliper then
Wheel bolts 9 secure it to the shock absorber spring,
Engine tie-bar bolt : - the bolt from the lower ball joint,
- on the gearbox 6.5 - the complete hub assembly and the
- on the sub-frame 7.5 driveshaft.
REMOVAL Remove the pins from the right hand driveshaft

Remove:
Drain the gearbox. - the track rod end using tool T.Av. 476,
Disconnect the battery. nut on the lower bolt without removing it.
Remove: Remove the driveshaft from the gearbox.

- the bonnet,
- the front wheels.
10-7
K7M engine
Engine - Gearbox 10
Remove: Disconnect the reversing light.
- the heat shield from the exhaust manifold
- the catalytic converter, Remove:
- the gearbox selector rod, - the acoustic tie-rod between the two shock
- the nuts (1) from the engine and gearbox absorber turrets,
mountings, - the air filter,
- the nuts (2) from the engine tie-bar mounting, - the accelerator cable from the throttle body,
- the clutch cable from the gearbox,
- the hoses (4), (5), (6), (7) and (8),
PRJ1001 99167R
- the power assisted steering pipe mountings - the expansion bottle and secure it to the
from the gearbox, wheelarch,
- the fuel supply and return pipes,
- the brake servo pipe,
- the earth strap.
Disconnect:
- the power assisted steering and air
conditioning pressostats,
- the compressor supply and the fan unit
supply,
- the temperature switch sensor.
98749R
- the speedometer.
10-8
K7M engine
Engine - Gearbox 10
Remove: Remove:
- the relay plate and the engine connection unit - the accessories belt,
connector, - the power assisted steering pump pulley.
Move the power assisted steering pump and the

the air conditioning compressor away (without
opening the circuits).
Secure the low pressure pipe for the compressor

to the air filter mounting.
Position the load positioning tool.
Lift the engine to remove the three bolts, the

engine tie-bar mounting and the gearbox
mounting.
Remove the engine.
REFITTING

98756R
Fill the gearbox and the cooling circuit and bleed

- the pipe from the canister solenoid valve, the circuit (see section 19).
- the injection computer and secure it to the
engine,
- the starter motor feed wire from the battery.
Disconnect the injection feed wire located in the Fit the brake caliper bolts with Loctite
scuttle panel. FRENBLOC and tighten to the correct
torque.
Press the brake pedal several times to bring the

pistons back into contact with the pads.

positioned.
98754R
10-9
F engine (E)
Engine - Gearbox 10
SPECIAL TOOLING
B. Vi. 31 -01 Roll pin punches

Mot. 1289 -03 Fork for centring suspended
engine mounting limiter
SPECIAL EQUIPMENT
Load positioning tool (example: NAUDER 1805)
TIGHTENING TORQUES (in daN.m) REMOVAL
Brake caliper mounting bolts 3.5 Put the vehicle on a two post lift.
Shock absorber base bolts 17 Disconnect the battery.

Driveshaft gaiter mounting bolts 2.5
Drain the gearbox.
Wheel bolts 9
Remove:
Engine tie-bar bolt 4.5 to 6.5
- the front wheels,
Suspended engine mounting bolt - the front right hand and left hand
on gearbox 4 mudguards.
Nut for suspended engine mounting

pad on front left hand side member 7.5
Front right hand suspended engine
mounting cover bolt on engine 4
mounting movement limiter bolt 6
Nut for engine mounting pad on front
right hand suspended engine
mounting cover 4.5
98710R
10-10
F (E) engine
Engine - Gearbox 10
Left hand side of the vehicle Unclip the reversing light wiring loom from the
sub-frame.
Remove:
- track rod end using tool T.Av. 476,
- the three bolts for the driveshaft gaiter,
- the two bolts from the brake caliper then
secure it to the shock absorber spring,
- the bolt from the lower ball joint,
- the complete hub assembly and the
driveshaft.
Remove the pins from the right hand driveshaft 98898R

Remove: Drain the cooling circuit through the lower

- the track rod end using tool T.Av. 476, radiator hose at the water pump end.
nut on the lower bolt without removing it. Remove:
- the air filter as well as the sleeve and its
Remove the driveshaft from the gearbox. mounting,
- the tie-bar between the shock absorber
Remove: turrets,
- the exhaust downpipe, - the accelerator and clutch cables,
- the gearbox selector rod, - the brake servo pipe,
- the power assisted steering pipe mountings - the two heating hoses,
on the gearbox. - the lower expansion bottle hose,
- hoses (1), (2) and (3),
99222R1
98749R
10-11
F (E) engine
Engine - Gearbox 10
- the relay plate and the engine connection unit Remove the fuel supply and return pipes.
connector,
Remove the absolute pressure sensor.
Disconnect:
- the air conditioning and power assisted
steering pressostats,
- the compressor and fan unit supply,
- the temperature switch sensor and the oxygen
sensor,
- the canister bleed pipe.
Remove:
- the expansion bottle,
- the injection computer mounting,
- the accessories belt (see section 11),
- the power assisted steering pulley.
Remove the three bolts (1) from the power

assisted steering pump and the four bolts (2) from
the air conditioning compressor.
98756R
- the earth strap,

- the suspended engine mounting cover cap.
Disconnect:
- the injection computer and unclip it from the
computer mounting,
- the injection feed wire located in the scuttle
panel,
- the starter motor feed.
99502-3R
98754R
10-12
F (E) engine
Engine - Gearbox 10
Move the power assisted steering pump and the ADJUSTING THE LONGITUDINAL MOVEMENT
air conditioning compressor away (without LIMITER
opening the circuits).
Slacken the two limiter bolts (E).
Remove the air conditioning low pressure pipe
clip on the suspended gearbox mounting. Insert the fork for centring the limiter Mot. 1289-
03 into the openings in the suspended engine
Remove the bonnet. mounting cover.
Remove the engine tie-bar.
99166-1R
99308R4 Tighten the two limiter bolts (E) to a torque of

6 daN.m.
Position the load positioning tool. Fill the gearbox and cooling circuit and bleed the
circuit (see section 19).
Lift the engine to remove the suspended engine
mountings adn gearbox.
Remove the engine. Fit the brake caliper bolts with Loctite
FRENBLOC and tighten to the correct tor-
que.

REFITTING pistons back into contact with the pads.
Refitting is the reverse of removal. NOTE: ensure the heat shields are correctly
positioned.
For the accessories belt tension (see section 07).
Fit the suspended engine mounting cover and the

movement limiter assembly.
10-13
F8Q engine
Engine - Gearbox 10
SPECIAL TOOLING
B. Vi. 31 -01 Roll pin punches

Mot. 1311-06 Tool for removing fuel pipes
SPECIAL EQUIPMENT
Brake caliper mounting bolt 3.5 Put the vehicle on a two post lift.
Shock absorber base bolt 17 Disconnect the battery.

Track rod end 3.5
Remove:
Lower ball joint nut 6.5 - the bonnet,
- the engine undertray.
Driveshaft gaiter mounting bolt 2.5
Wheel bolts 9 Drain:
- the gearbox.
Engine tie-bar bolt 6 - the cooling circuit through the lower radiator
Suspended engine mounting bolt hose (radiator end).
on gearbox 5.5
Remove:
Bolt for suspended engine mounting - the front wheels,
pad on front left hand side member 2.5 - the front right hand and left hand
mudguards.
mounting cover bolt on engine 4
mounting movement limiter bolt 6
98710R
10-14
F8Q engine
Engine - Gearbox 10
- the air inlet sleeve, the air filter and its - the preheating unit (secure it to the engine),
mounting, - the accelerator and clutch cables,
- the cooling assembly (see section 19 - the altimetric sensor corrector,
"Radiator"), - the relay plate and the engine connection unit
- the alternator belt (see section 16 electrical connector,
"Alternator").
Disconnect the compressor feed wire (if fitted).
Remove:
- the compressor mounting bolts (if fitted) and
secure it to the front cross member,
- the power assisted steering pump pulley,
- the oil filter,
- the power assisted steering pump mounting
bolts as well as the power assisted steering
pipe bracket bolt.
Move the pump away and secure it to the sub-

frame.
Disconnect:
- the heating hoses on the thermostat
mounting,
98756R
- the fuel supply pipe on the diesel filter using

tool Mot. 1311-06,
98904R1

- the pipes and connectors on the fast idle and
EGR solenoid valves,
99461R
- the connector on the diesel filter.
10-15
F8Q engine
Engine - Gearbox 10
Remove: Right hand side of the vehicle
- the diesel return union on the injection pump,
- the earth strap, Remove:
- the tie-rod between the shock absorber - the pins from the driveshaft using tool B.Vi.
turrets, 31-01,
- the battery mounting bracket. - the upper bolt from the shock absorber base
and slacken the lower bolt.
Disconnect the feed wire from the preheating
unit in the scuttle panel as well as the starter
motor feed. Tilt the stub axle carrier and release the
driveshaft.
Remove:
- the exhaust pipe,
- the gear control on the gearbox side,
- the power assisted steering pipe mountings
from the gearbox,
98754R 98749R
Left hand side of the vehicle
Remove:
- track rod end using tool T.Av. 476,
- the three bolts for the driveshaft gaiter,
- the two bolts from the brake caliper then
secure it to the shock absorber spring,
- the bolt from the lower ball joint,
- the complete hub assembly and the
driveshaft.
10-16
F8Q engine
Engine - Gearbox 10
- the oil radiator pipes on the heat exchanger. Remove:
- the cover cap as well as the front right hand
suspended engine mounting cover and the
movement limiter,
99183-1R
99308R1
Slacken, without removing, bolt (A) and remove

bolt (B) from the engine tie-bar. - the gearbox mounting.
Remove the shock absorber (two bolts C) as well

as the rear mounting (D) on the gearbox.
99308R2
99309R3
Remove the engine - gearbox assembly by tilting
it slightly on the gearbox side using the load
Position the load positioning tool on the engine positioning tool.
lifting rings.
10-17
F8Q engine
Engine - Gearbox 10
REFITTING
Fit the suspended engine mounting cover and

movement limiter assembly.
ADJUSTING THE LONGITUDINAL MOVEMENT

LIMITER
Slacken the two limiter bolts (E).
Insert the fork for centring the limiter Mot. 1289-

03 into the openings in the suspended engine
mounting cover.
99174-2R
Tighten the two limiter bolts (E) to a torque of

6 daN.m.
Fill the gearbox and cooling circuit and bleed the

circuit (see section 19).
Apply RHODORSEAL 5661 (e.g.- CAF 4/60 THIXO )

to the holes for the driveshaft roll pins.
Fit the brake caliper bolts with Loctite

FRENBLOC and tighten to the correct tor-
que.


positioned.
10-18
ENGINES AND PERIPHERALS
E7J Engine
Engine and transmission assembly 10
SPECIAL TOOLING
Mot. 1040-01 Dummy cradle for removing and

refitting the engine and
transmission assembly
TIGHTENING TORQUES (in daN.m) - the connectors of the ignition module and the
HT coil wire,
Front sub-frame mounting bolt 6 - the oxygen sensor connector,
Rear sub-frame mounting bolt 11 - the accelerator and clutch cables.
Upper shock absorber cup mounting bolt 3
Wheel bolts 9 Drain:
Brake caliper mounting bolt 3.5 - the cooling circuit,
Universal steering joint mounting bolt 3.5 - the engine if necessary,
- the gearbox (by removing the cover) if
necessary.
REMOVAL Remove:
- the earth strap,
Put the vehicle on a 2 post lift. - the air filter,
- the nut and the eccentric bolt (1) (remove
Disconnect: using a roll pin punch) from the steering shaft
- the battery, yoke after having pushed the protector back.
- the relay plate and the engine connection unit
electrical connector,
98756R 97390-1R
10-19
E7J Engine
SPECIAL NOTES FOR VEHICLES FITTED WITH A Disconnect:
DRIVER’S AIRBAG - the heating hoses on the engine,
IMPORTANT
To avoid any risks of destroying the rotary switch

under the steering wheel, comply with the
following instructions:
• Before removing the steering column and the

rack, the steering wheel MUST be immobilised
with the wheels straight using a "steering
wheel locking" tool, throughout the whole
operation.
• Any doubts about whether the steering wheel

is centred means that the steering wheel will
have to be removed so that the centring
method described in section 88 "Airbag" can
be applied.
REMINDER: in this case, only qualified, trained

98711R1
staff can carry out this operation.
Remove: - the fuel, absolute pressure and canister pipes,

- the expansion bottle (secure it to the engine),
- the upper right hand mounting bracket of the
radiator and unclip it (left hand side), then
keep it to one side by securing it to the
engine.
98714R1
98753R - the brake servo pipe.
10-20
E7J Engine
Remove the battery mounting bracket. - the brake calipers and secure them to the
body,
Disconnect the injection feed wire in the scuttle - catalytic converter,
panel as well as the starter motor feed. - the two exhaust heat shields,
99612R
- the gear control on the gearbox side, turn it

over and secure to the exhaust pipe,
- the horn,
98754R - the sub-frame-body tie rods,
- the front bumper.
Remove:
- the computer strap and secure it to the
engine,
- the wheels,
- the right hand and left hand mudguards,
PRJ1002
98710R
10-21
E7J Engine
PREPARATION OF TOOL MOT. 1040-01 Remove:
- the upper shock absorber bolts,
Fit the wheel pins into the lower holes (G). - the four sub-frame mounting bolts.
This is secured to the sub-frame by hooks (I).
PRJ1003
Remove the engine and transmission assembly by

92442R lifting the body.
Secure tool Mot. 1040-01 underneath the sub-

frame.
98757S
98755R Tie the spring - shock absorber units together

using rope.
Lower the 2 post lift until the tool comes into

contact with the floor.
10-22
E7J Engine
REFITTING
The engine sub-frame can be easily aligned with

the bodywork by positioning the two
approximately 100 mm long threaded rods into
the two front mountings of the body sub-frame .
If the vehicle has manual steering, position the

shock absorber mountings into the holes (A), and
into holes (B) for power assisted steering.
92114-1R
Tighten all bolt, nuts and screws to the

recommended torques.
Fit the caliper mounting bolts using Loctite

FRENBLOC and tighten them to the correct
torque.

Fill:
- the cooling circuit and bleed it (see section
19),
- the engine and gearbox if required.
NOTE:
- check the steering shaft yoke spacer is in place
when refitting,
- ensure the heat shields are correctly
positioned.
10-23
K7M engine
/ AT
SPECIAL TOOLING

TIGHTENING TORQUES (in daN.m)
Front sub-frame mounting bolt 6

Rear sub-frame mounting bolt 11
Wheel bolts 9
Brake caliper mounting bolt 3.5
Universal steering joint mounting bolt 3.5
Engine mounting pad nut on front
left hand side member mounting 7.5
REMOVAL
Disconnect the battery. 98710R
Drain:
- the cooling circuit from the lower radiator - the front bumper,
hose,
- the engine if necessary.
Remove:
- the front wheels,
- the left and right hand mudguards,
- the sub-frame-body tie rods,
- the brake calipers and attach them to the
body,
PRJ1002
10-24
K7M engine
/ AT
- the heat shield from the exhaust manifold, Remove the battery mounting bracket.
- the catalytic converter (disconnect the oxygen
sensor) and attach the exhaust pipe to the Disconnect:
body, - the injection feed wire in the scuttle panel
- the horn, and the starter feed wire,
- the tie rod between the shock absorber - the fuel supply and return pipes using tool
turrets, Mot. 1311-06, unclipping them from their
- the air filter, mounting,
- the earth strap,
- the expansion bottle and attach it to the
engine.
Disconnect:
- the accelerator cable and the kickdown switch
connector,
connectors,
99461R
- the heater hoses on the thermostat.
Unclip the radiator and hold it to one side by

attaching it to the engine.
98756R2
- the automatic transmission computer

connector,
- the canister pipe.
10-25
K7M engine
/ AT
Remove: Fit a block between the automatic transmission
- the automatic transmission gear selector and the left hand sub-frame.
control,
- the nut and eccentric bolt (1) (use a roll pin Remove the mounting nut for the rubber
punch) from the steering yoke after pushing mounting pad on the front left hand side member
the protector back. mounting.
Using a copper hammer, tap the stud to release it

from the suspended mounting on the left hand
side.
PREPARATION OF TOOL MOT. 1040-01
Fit the wheel pins into the lower holes (G).
97390-1R
SPECIAL NOTES FOR VEHICLES FITTED WITH A

DRIVER’S AIRBAG
IMPORTANT

92442R
operation.

be applied.

10-26
K7M engine
/ AT
Secure tool Mot. 1040-01 under the sub-frame. Remove the engine and transmission assembly by
lifting the body.
98755R 99588S
Lower the 2 post lift until the tool comes into Tie the spring - shock absorber units together
contact with the floor. using rope.
Remove:
- the four sub-frame mounting bolts.
PRJ1003
10-27
K7M engine
/ AT
REFITTING Tighten all bolt, nuts and screws to the
the bodywork by positioning the two Fit the caliper mounting bolts using Loctite
approximately 100 mm long threaded rods into FRENBLOC and tighten them to the correct
the two front mountings of the body sub-frame . torque.
Tighten the sub-frame mounting bolts to a torque Press the brake pedal several times to bring the
of : pistons back into contact with the pads.
• 6 daN.m at the front,
• 11 daN.m at the rear. Fill:
Refitting is the reverse of removal. 19),
shock absorber mountings into the holes (A), and NOTE:
into holes (B) for power assisted steering. - check the steering shaft yoke spacer is in place
when refitting,
positioned.
92114-1R
10-28
F3R engine
SPECIAL TOOLING

Mot. 1159 Tool for securing the engine on the
sub-frame
Mot. 1289-03 Fork for centring suspended engine
mounting limiter
Front sub-frame mounting bolt 6 Put the vehicle on a 2 post lift.
Rear sub-frame mounting bolt 11 Remove the engine undertray.

Wheel bolts 9
Drain:
Brake caliper bolt 3.5
- the cooling circuit from the lower radiator
Universal steering joint mounting bolt 3 hose, water pump end,
Nut for mounting rubber mounting pad

on front left hand side member mounting 7.5
Bolt mounting front right hand suspended
engine mounting cover on engine 4
Mounting bolt for front right hand
suspended engine mounting
movement limiter 6
98898R2
- the engine and gearbox if necessary.
10-29
F3R engine
Remove: - the gear control at the gearbox end (turn it
- the front wheels, over and attach it to the exhaust pipe),
- the right and left hand mudguards, - the front bumper,
98710R PRJ1002
- the air inlet sleeve, the air filter and its

mounting.
- the brake calipers and the ABS sensors (attach
them to the body), Disconnect:
- the sub-frame-body tie rods, - the relay plate and the engine connection unit
- the exhaust downpipe (disconnect the oxygen electrical connector,
sensor),
- the horn,
- the two exhaust heat shields,
99612R 98756R
10-30
F3R engine
- the accelerator and clutch cables, Remove:
- the heater hoses on the thermostat mounting. - the suspended engine mounting cap,
- the injection computer mounting and attach
Remove the battery mounting bracket. it to the engine,
- the expansion bottle and attach it to the
Disconnect: engine,
- the injection feed wire in the scuttle panel - the absolute pressure sensor,
and the starter feed, - the accessories belt (see section 11).
Unclip the power assisted steering reservoir.
Disconnect the compressor feed wire (if fitted).
Remove:
- the four mounting bolts for the air
conditioning compressor (if fitted), move it to
one side and attach it to the front of the
vehicle,
- the earth strap,
- the nut and eccentric bolt (1) (use a roll pin
punch) from the steering yoke after pushing
the protector back.
98754R

- the connectors for the fan, the relays, the
thermistor and the pressostat,
- the pipe on the canister,
- the upper and lower radiator hoses,
- the fuel return and supply pipes, unclipping
them from their mounting.
97390-1R
10-31
F3R engine
SPECIAL NOTES FOR VEHICLES FITTED WITH A Fit tool Mot. 1159.
DRIVER’S AIRBAG
IMPORTANT


operation.

be applied.
99024R2
Diagram for drilling tool Mot. 1159. (For

NOTE: cut the base of tool Mot. 1159 to 30 mm. instructions on use, refer to page 10-33).
99028R
99023R2
10-32
F3R engine
Fit the bracket of tool Mot. 1159 (water pipe Remove the nut then using a copper hammer, tap
mounting bolt). the stud to release it from the suspended
mounting on the left hand side.
99310R
99308R3
Remove the right hand suspended engine

mounting cover and the movement limiter. PREPARATION OF TOOL MOT. 1040-01
Fit the wheel pins into the lower holes (G).
99308R1
Fit a block between the gearbox and the left hand

sub-frame.
92442R
10-33
F3R engine
Attach the cooling assembly to the front face.
Secure tool Mot. 1040-01 under the sub-frame.
lifting the body.
98755R

99178S
Remove:
- the four sub-frame mounting bolts. Tie the spring - shock absorber units together
using rope.
NOTE: for an operation requiring separation of

the engine - gearbox - sub-frame, note the
position of tool Mot. 1159 carefully.
PRJ1003
10-34
F3R engine
REFITTING ADJUSTING THE LONGITUDINAL MOVEMENT
LIMITER
the bodywork by positioning the two Slacken the two limiter bolts (E).
the two front mountings of the body sub-frame . Insert the centring fork tool Mot. 1289-03 into the
openings in the suspended mounting cover.
Tighten the sub-frame mounting bolts to a torque

of :
• 11 daN.m at the rear.

99166-1R
Tighten the two limiter mounting bolts (E) to a

torque of 6 daN.m.

92114-1R

When the left and right hand suspended FRENBLOC and tighten them to the correct
mountings are refitted, remember to remove the torque.
block under the gearbox and tool Mot. 1159
Fill:
19),
NOTE:
when refitting,
positioned.
10-35
F8Q engine
SPECIAL TOOLING

Mot. 1159 Tool for securing the engine on the
sub-frame
Mot. 1311-06 Tool for removing the fuel pipe
TIGHTENING TORQUES (in daN.m) Drain:

- the cooling circuit from the lower radiator
Front sub-frame mounting bolt 6 hose (radiator end),
- the engine and gearbox if necessary.
Rear sub-frame mounting bolt 11
Upper shock absorber cup mounting bolt 3 Remove:
- the front wheels,
Wheel bolts 9 - the right hand left hand mudguards,
Brake caliper bolt 3.5
Universal steering joint mounting bolt 3
Nut for mounting rubber mounting pad
on front left hand side member mounting 7.5
Bolt mounting front right hand suspended
engine mounting cover on engine 4
Nut mounting suspended engine
mounting cover on rubber mounting pad 4.5
REMOVAL

98710R
Remove the engine undertray.

- the brake calipers and attach them to the
Disconnect the battery. body,
- the sub-frame-body tie rods,
10-36
F8Q engine
- the front bumper, - the nut and eccentric bolt (1) (use a roll pin
punch) from the steering yoke after pushing
the protector back.
PRJ1002
- the air inlet sleeve, the air filter and its 97390-1R
mounting,
- the exhaust downpipe,
- the two exhaust heat shields,
SPECIAL NOTES FOR VEHICLES FITTED WITH A
DRIVER’S AIRBAG
IMPORTANT


99612R operation.

- the gear control at the gearbox end (turn it have to be removed so that the centring
over and attach it to the exhaust pipe), method described in section 88 "Airbag" can
- the horn be applied.
- the expansion bottle (attach it to the engine)
- the earth strap REMINDER: in this case, only qualified, trained
10-37
F8Q engine
Remove: - the feed wire for the preheating unit in the
- the preheating unit (attach it to the engine), scuttle panel and the starter feed.
- the fuel return union on the injection pump.
Disconnect:
- the fuel supply pipe on the diesel fuel filter
using tool Mot. 1311-06,
98754R
- the heater hoses on the thermostat mounting,
99461R
- the altimetric sensor connector,

electrical connector,
98904R1
98756R
10-38
F8Q engine
- the pipes and connectors for the fast idle and Fit tool Mot. 1159.
EGR solenoid valves,
- the accelerator and clutch cables,
- the diesel fuel filter connector,
- the compressor feed wire (if fitted).
Remove:
- the cooling assembly (see section 19
"Radiator"),
- the alternator belt (see section 16),
- the compressor mounting bolts (if fitted) and
attach it to the front cross member.
NOTE: cut the base of tool Mot. 1159 to 30 mm.
99024R2
Remove the oil filter.
Unclip the alternator wiring and move it to one

side.
Diagram for drilling tool Mot. 1159. (For

instructions on use, refer to page 10-40).
99023R2
99028R
10-39
F8Q engine
Fit the bracket of tool Mot. 1159. - the suspended engine mounting cover on the
right hand side and the movement limiter.
99310R 99308R1
Fit a block between the gearbox and the left hand

sub-frame.
Remove:
- the oil radiator deflector and the oil radiator Remove the nut then using a copper hammer, tap
and attach it to the engine, the stud to release it from the suspended
mounting on the left hand side.
99172R 99308R3
10-40
F8Q engine
PREPARATION OF TOOL MOT. 1040-01 Remove:
Fit the wheel pins into the lower holes (G). - the four sub-frame mounting bolts.
PRJ1003

92442R lifting the body.
Secure tool Mot. 1040-01 under the sub-frame.
99178S
Tie the spring - shock absorber units together

98755R using rope.

10-41
F8Q engine
REFITTING ADJUSTING THE LONGITUDINAL MOVEMENT
LIMITER
the bodywork by positioning the two Slacken the two limiter bolts (E).
the two front mountings of the body sub-frame . Insert the centring fork tool Mot. 1289-03 into the
openings in the suspended mounting cover.
Tighten the sub-frame mounting bolts to a torque

of :
• 11 daN.m at the rear.

99174-2R
Tighten the two limiter mounting bolts (E) to a

torque of 6 daN.m.


FRENBLOC and tighten them to the correct
torque.
92114-1R Press the brake pedal several times to bring the

When the left and right hand suspended Fill:

mountings are refitted, remember to remove the - the cooling circuit and bleed it (see section
block under the gearbox and tool Mot. 1159 19),
NOTE:
when refitting,
positioned.
10-42
E7J engine
Sump 10

EQUIPMENT REQUIRED
Engine support tool

(example : DESVIL M300)
TIGHTENING TORQUES (in daN.m) - the right hand driveshaft pin using tool B.Vi.
31-01, then tilt the hub to release the
Wheel bolt 9 driveshaft from the gearbox and attach it to
Track rod end nut 3.5 the steering,
Shock absorber base bolt 17
Engine tie bar bolt:
- on gearbox 6.5
- on sub-frame 7.5
Sump bolt 0.7 to 0.9
Oil pump bolt 2.5
Tie bar bolt on gearbox 2.5
Tie bar bolt on engine 5
REMOVAL
Drain the engine oil. 98746-1S
Remove:
- the catalytic converter, - the engine - gearbox tie bar,
- the front right hand wheel,
- the track rod end using tool
T.Av. 476,
lower bolt (do not remove it),
10-43
E7J engine
Sump 10
- nuts (1) for the engine and gearbox mounting Remove:
pads, - the canister solenoid valve pipe,
- nuts (2) for the tie bar mounting,
98714R2
PRJ1001
- the fuel pipes and their mounting on the right
hand side member and the inlet manifold,
- the air filter. - the power assisted steering reservoir,
- the speedo gear from the gearbox.
Fit the engine support tool, for example DESVIL Lift the engine by the two lifting rings (4) and (5)
M300. so that the three bolts (6) on mounting (7) may be
removed and then remove the engine by lifting it
out.
98750R
PRJ1004
10-44
E7J engine
Sump 10
Remove the two power assisted steering pipe Remove:
bolts on the sub-frame. - the sump bolts then release the sump,
- the sump, in the direction shown by the
arrow.
99311R
Lift the engine using the lifting ring (5) at the

timing end to ensure dimension (A) is 25 cm
between the sub-frame and the edge of the 98748S
cylinder block.
Clean the sump before applying a bead of

RHODORSEAL 5661 , width 3 mm.
98746R
99179S
NOTE : remember to renew the two rubber seals

at the edge of the sump.
10-45
E7J engine
Sump 10
REFITTING
An input chamfer on the sunwheel facilitates the

fitting of new roll pins.
Seal the ends with RHODORSEAL 5661 .
74937-4S
Fill the engine with oil.
10-46
K7M engine ENGINE AND PERIPHERALS
aluminium
sump Sump 10
REMOVAL
To remove the aluminium sump, the engine and

transmission assembly must be removed.
REFITTING

RHODORSEAL 5661 (eg- CAF 4/60 TIXO), width 3
mm.
99179S

10-47
K7M engine
steel sump Sump 10

Mot. 453-01 Hose clamp pliers
Mot. 1311-06 Tool for removing fuel pipe
EQUIPMENT REQUIRED
Engine support tool

TIGHTENING TORQUES (in daN.m) Remove:

- the front wheels,
Wheel bolt 9 - the right hand mudguard,
Track rod nut 3.5
Engine tie bar bolt:
- on gearbox 6.5
- on sub-frame 7.5
Oil pump bolt 2.5
Tie bar bolt on gearbox 2.5
Tie bar bolt on engine 5
REMOVAL

98710R
Remove the expansion bottle and position it

below the level of the upper radiator hose on the - the catalytic converter (disconnect the oxygen
thermostat. sensor connector),
- the gearbox control at the gearbox end.
Disconnect the upper radiator hose on the
thermostat and clamp it using tool Mot. 453-01.
10-48
K7M engine
steel sump Sump 10
On the left hand side of the vehicle Remove:
- the engine - gearbox tie bar,
Remove: - nuts (1) for the engine and gearbox mounting
- the track rod end using tool T.Av. 476, pads,
- the three gaiter bolts, - nuts (2) for the tie bar mounting,
- the shock absorber base bolts.
Release the driveshaft from the gearbox taking

care to protect the spider.
Attach the driveshaft to the body.
On the right hand side of the vehicle
Remove:
- the driveshaft roll pin using punches B.Vi. 31-
01,
lower bolt.
Tilt the hub and release the driveshaft from the

gearbox.
Attach the driveshaft to the steering.
PRJ1001
- the tie bar between the shock absorber

turrets,
- the earth strap,
- the speedo gear from the gearbox,
- the power assisted steering reservoir.
Disconnect:
- the canister pipe,
- the oil vapour rebreathing pipe,
- the throttle potentiometer connector,
98746-1S
10-49
K7M engine
steel sump Sump 10
- the fuel supply and return pipes using tool
Mot. 1311-06.
99461R 99585R
Fit the lifting bracket (A) (locally made) to the Fit the engine support tool (for example: DESVIL
engine block. 300).
98750S
Release the clutch cable from the side member.
99182R
10-50
K7M engine
steel sump Sump 10
Remove the two mounting bolts for the power - using lifting ring (5) at the timing end to
assisted steering pipe on the sub-frame and move obtain dimension (A) of 26 cm approximately
the pipe to one side. between the sub-frame and the edge of the
cylinder block.
99311R
Lift the engine:

- using the two lifting rings (4) and (5) so that
the three bolts (6) may be removed and
remove the mounting (7) from the bottom,
98746R
NOTE : check that the main wiring for the engine

connection unit does not jam between the 5th
gear housing and the side member when the
engine is lifted.
Remove:
- the sump bolts then release the sump,
- the sump in the direction shown by the arrow.
98750R
PRJ1004 98748S
10-51
K7M engine
steel sump Sump 10
REFITTING

RHODORSEAL 5661 (eg- CAF 4/60 TIXO), width 3
mm.
99179S

10-52
F engine
Sump 10
EQUIPMENT REQUIRED
Engine support tool


- the two exhaust downpipe bolts,
Sump bolt 1.2 to 1.5 - the engine tie bar bolt (1),
Suspended engine mounting cover nut 4.5 - the engine - gearbox tie bar (2).
REMOVAL
Drain the engine.
Remove:
- the tie bar between the shock absorber
turrets,
- the plastic cap for the suspended engine
mounting cover.
98902R2
Fit the engine support tool (for example : DESVIL
M300).
NOTE : bolt (3) is removed with a 50 star shaped
socket (for example: EX 250 - FACOM, shortened
to dimension X = 13 mm) and an 8 combination
wrench.
98982S
98903S
10-53
F engine
Sump 10
Remove:
- the two mounting bolts for the power assisted
steering pipe on the sub-frame and move it to
one side,
99311R
- the sump bolts then release the sump,

- the nut from the suspended engine mounting
cover.
Lift the engine using the engine support tool then

remove the sump.
REFITTING
Fill the engine with oil.
10-54
E7J - K7M ENGINE
Timing belt 11
Mot. 591-02 Index

Mot. 591-04 Angular wrench for angular tightening
Mot. 1135-01 Tool for tensioning timing belt
(in daN.m) - the crankshaft sprocket, immobilising the star-

TIGHTENING TORQUES or ter gear with a large screwdriver,
- the timing cover.
(in degrees)
Wheel bolt 9
Crankshaft pulley 2 daN.m + 68° ± 6°
Timing belt tensioner nut 5
REMOVAL
Remove:
- the power assisted steering belt,
- the alternator drive belt,

98745R3
- the front right protector at the end of the
wheel arch,
Set the engine to the timing adjustment position.
Align reference marks ( L ) on the sprockets with

the fixed reference marks ( M ).
Slacken nut ( O ) then slacken the tensioner before

removing the belt.
98710R
11-1
E7J - K7M ENGINE
Timing belt 11
ADJUSTING THE TIMING
DI1101R1
(1) direction in which tensioner tightens
11-2
E7J - K7M ENGINE
Timing belt 11
REFITTING
There is an arrow on the back of the belt showing

the direction of rotation and two marks for adjus-
tment.
Align the reference marks (marks N) on the belt

with those on the sprockets ( L ) and the casings
( M ).
Ensure the belt is fitted in the correct direction

and begin positioning it on the crankshaft
sprocket.
By moving the tensioner using tool Mot. 1135-01,

tighten the belt until the fitting tension is obtai-
ned (see section 07 Timing belt tension ).
Tighten tensioner nut ( O ) to 5 daN.m.
It is vital to tighten the tensioner nut to 5 daN. m

to avoid any loosening of the tensioner which
could damage the engine.
NOTE
- To refit the crankshaft pulley, tighten the
crankshaft pulley bolt to 2 daN.m plus an angle
of 68° ± 6°.
- To tension the accessories belt (see section 07

accessories belt tension).
11-3
F3R ENGINE
Timing belt 11
Mot. 1054 TDC pin
Mot. 1289-03 Fork for centring suspended

mounting limiter
EQUIPMENT REQUIRED
Star socket ST X 14 FACOM for example

Engine support tool DESVIL M300 for example
Wheel bolt 9
Crankshaft pulley bolt 12
Engine suspended mounting bolt 6
Cylinder head suspended mounting bolt 2
Engine suspended mounting cover bolt 4
Timing belt tensioner nut 4
97295R1
REMOVAL
Put the vehicle on a 2 post lift. Remove:

- the front right protector at the end of the
Remove: wheel arch,
- the computer and its mounting,
- the accessories belt in the following manner:

Slacken the tensioner (4) by the central bolt,
using a 7 mm allen key, by a quarter turn (cut
the end of the tool to approximately 12 mm)
while holding the outer nut with a 22 mm open
wrench.
Slackening the tensioner using the 22 mm wrench

automatically damages the adjustment teeth,
destroying the air conditioning and/or power as-
sisted steering mounting.
98710R
11-4
F3R ENGINE
Timing belt 11
- the crankshaft pulley bolt, Note : the timing belt is captive on its mounting.
- the tie bar between the shock absorber turrets. Remove the TDC plug.
Fit the engine support tool DESVIL M300 for Turn the crankshaft to the timing adjustment po-
example. sition (see diagram below) and insert the TDC pin
Mot. 1054.
98982R
Remove:
- the plastic protector from the suspended en-
gine mounting cover,
- the suspended mounting and cover,
- bolts (1) from the fuel pipe mounting,
- the two timing covers (2) and (3),
99501-4R
- the suspended mounting support (4) on the cy-

linder head.
98897R
11-5
F3R ENGINE
Timing belt 11
For the method for tensioning the belt (see sec-
tion 07 Timing belt).
Lock the tensioner at 4 daN.m.
Refitting is then the reverse of removal.
Fit the limiter assembly with the suspended moun-
ting cover.
ADJUSTING THE LONGITUDINAL MOVEMENT

LIMITER
Slacken limiter bolts (E).

Insert the limiter centring fork Mot. 1289-03 into
98901R
the openings in the suspended mounting cover.
Slacken the tensioner (T) and remove the belt.
Note : if the tensioner nut is slackened by more
than one turn, it may disengage.
REFITTING
Check that pin Mot. 1054 is in position.

Position the belt, ensuring :
- the fitting direction arrow (C) is located bet-
ween the intermediate shaft sprocket and the
tensioner,
- the reference marks on the belt are aligned
with the marks on the sprockets (engine remo-
ved or crankshaft output pulley removed) bet-
ween (A) and (B) 61 teeth.
Pretension the timing belt by tightening one bolt
(D) on the inner timing cover.
99166-1R
Tighten the 2 bolts (E) to a torque of 5 to

6.5 daN.m.
99501R
11-6
F8Q ENGINE
Timing belt 11
Mot. 1054 TDC pin

Mot. 1289-03 Fork for centring suspended
mounting limiter
EQUIPMENT REQUIRED

- the acoustic tie bar between the shock absor-

TIGHTENING TORQUES (en daN.m)
ber turrets,
Wheel bolt 9 - the right hand suspended mounting cap.

Crankshaft pulley bolt 12 Position the engine support tool DESVIL M300
Suspended mounting limiter bolt 6 for example.
Suspended mounting cover bolt 4
Tensioner nut 5
REMOVAL

Remove:
- the protection at the end of the wheel arch,
98982R
98710R
11-7
F8Q ENGINE
Timing belt 11
Remove: - the lower timing casing (1),
- the suspended mounting cover and the move-
ment limiter, - the alternator drive belt (see section 16
"Removing the alternator"),
Turn the crankshaft to position the camshaft ti-

ming reference mark in the timing window.
89120-2S
99309R2
99176G
11-8
F8Q ENGINE
Timing belt 11
Fit the TDC pin , Mot.1054.
99183R
Remove:
- the fuel pipe mounting bolts (A),
- the timing covers (2) and (3).
99176R
11-9
F8Q ENGINE
Timing belt 11
Slacken the tensioner and remove the belt.
Note : if the tensioner nut is slackened by more than one turn, it may disengage.
REFITTING (special notes)
Check that tool Mot. 1054 is in position.
Fit the belt, aligning the reference marks on the pulleys and belt.
Injection pump reference mark: B (BOSCH), R (LUCAS DIESEL)
92600R1
11-10
F8Q ENGINE
Timing belt 11
Tighten the timing belt by tightening one bolt (B) ADJUSTING THE LONGITUDINAL MOVEMENT
on the inner timing cover. LIMITER
Slacken limiter bolts (4).

99175-1R
99174-2R1
Fit tool Mot. 1273 and tension the belt until the
fitting tension is obtained (see section 07, Timing Tighten the limiter bolts (4) to a torque of
belt tension ). 5.5 daN.m.
Tighten the tensioner nut to 5 daN.m. Check the injection pump timing (see section 13,
injection pump).
It is vital to tighten the tensioner nut to 5 daN. m
to avoid any loosening of the tensioner which
could damage the engine.
Refit the crankshaft pulley and ensure the bolt is

tightened to a torque of 12 daN.m.
Fit the suspended mounting cover assembly and

the movement limiter.
11-11
E7J - K7M ENGINE
Cylinder head gasket 11
Mot. 588 Retaining flange

Mot. 591-02 Index
Mot. 591-04 Angular wrench for angular tightening
EQUIPMENT REQUIRED
(in daN.m)
TIGHTENING TORQUES or
(in degrees)
Wheel bolt 9
Crankshaft pulley 2 daN.m + 68° ± 6°
Timing tensioner nut 5
REMOVAL
Remove:
- the timing belt (see section 11, timing belt), 98714R3
- the air filter,

Release the wiring from the cylinder head.
- the rocker box cover,
Remove the upper mounting bolt for the dipstick ,
- the earth strap, the brake servo pipes and the absolute pressure
sensor, together with the accelerator cable.
- the fuel pipes,
- the canister solenoid valve pipe.
Disconnect the throttle body connections.
11-12
E7J - K7M ENGINE
Drain the cooling circuit via the lower radiator
hose and the cylinder block via the drain bolt.
98745R1
- the exhaust heat shield,
92073R1 - the exhaust downpipe,
- the cylinder head bolts except bolt (F) which

Remove: should be slackened off only (use a 12 star
socket, for example ST X 12 FACOM ), then
- the thermostat hose, pivot the cylinder head around this bolt,
- the connectors for the sensors,
92106R
98711R3
- hoses 4,5,6, and 7,
- the upper alternator mounting,
11-13
E7J - K7M ENGINE
- the cylinder head, the gasket.
Fit the liner retaining flanges

Mot. 588 (except K7M).
92062R
CLEANING
It is very important not to scratch the gasket faces

of parts in aluminium.
Use Décapjoint to dissolve any gasket remaining

on the metal.
Apply the product to the area to be cleaned; wait

approximately ten minutes then remove using a
wooden spatula.
Gloves should be worn during this operation.
Remember that this operation should be carried

out with extreme care to avoid the risk of foreign
bodies being introduced into the oilways bringing
oil under pressure to the rocker shaft (oilways are
located in both the cylinder head and the cylinder
block).
If this recommendation is not observed there is a

risk that the rocker jets may become blocked and
damage may occur rapidly to the rocker cams and
tappets.
11-14
E7J - K7M ENGINE
CHECKING THE GASKET FACE Position the cylinder head gasket.
Use a straight edge and a set of shims to check for Refit the cylinder head, lubricate the threads and
gasket face deformation. the bearing faces under the heads of the bolts
with engine oil.
Maximum bow 0.05 mm.
Note : check the length of the bolts for the
The cylinder head may not be re-ground.
cylinder head, the shorter ones are used on the
inlet side.
Cylinder head tightening (see section 07, cylinder

head tightening).
For refitting the timing belt, (see section 11-

Timing belt).
Fill and bleed the cooling circuit, (see section 19).
87474S
REFITTING (Special notes)
Remove the liner retaining flanges Mot. 588

(except K7M).
Wipe the gasket faces of the cylinder block and

the cylinder head.
Check the centring dowel is present (G).
98713R
11-15
F3R ENGINE
Mot. 591-04 Angular wrench for tightening the cylinder head

Mot. 591-02 Index
Mot. 1054 TDC pin
Mot. 1159 Engine support tool

Mot. 1289-03 Fork for centring the suspended engine mounting limiter
EQUIPMENT REQUIRED
Allen key for cylinder head bolts ST 10L FACOM for example
Star shaped elbowed allen key T50 FACOM for example
Front right suspended engine

mounting cover nut 3 to 4.5
Wheel bolt 9
Tensioner nut 4
Suspended engine mounting cover bolt 4
Suspended engine mounting limiter bolt 6
Crankshaft pulley 12
Bolt mounting suspended engine
mounting on cylinder head 2
98898R
REMOVAL
Remove the 2 bolts (1) and slacken bolt (2) of the
Put the vehicle on a 2 post lift. coil mounting then slide it downwards.
Drain the cooling circuit from the lower radiator

hose at the water pump end.
11-16
F3R ENGINE
Disconnect:
- the pinking sensor,
- the cylinder reference sensor,
- the absolute pressure sensor and its pipe,
- the idle speed valve,
- the air and coolant sensors,
- the throttle potentiometer,
- the injectors,
- the canister solenoid valve pipe,
- the oil vapour rebreathing pipe,

98899R

Remove:
- the accelerator cable,
- the timing belt (see section 11-Timing belt),
- the fuel supply and return pipes (gallery end),
- the spark plug caps.
- the coolant temperature sensor (9).
Remove:
- the air filter,
- hoses 3, 4, 5, 6, 7, 8,
98900S
99222R
11-17
F3R ENGINE
- the earth strap, Lift the engine slightly.
- the timing belt tensioner (10), Fit tool Mot. 1159 under the oil pump.
- the two bolts (11) mounting the upper inner ti- Note : cut the base of tool Mot. 1159 to 30 mm.
ming cover,
96529R1 99023R2
- the exhaust strut,
- mounting bolt (12) for the water hose.
99024R2
99025R
11-18
F3R ENGINE
Diagram for drilling tool Mot. 1159 for use with Remove:
BA0X (diameter 10.5 mm).
- the throttle body,
- the fuel gallery.
Note : ensure that seals (13) do not fall off when

removing the pump,
99028R
Fit the bracket of tool Mot. 1159 under the water

pump.
99215R
- the cylinder head bolts, using a 10 mm, long allen

key, FACOM ST10L for example.
- the cylinder head.
99310R
Remove the engine support tool DESVIL M300 for

example.
11-19
F3R ENGINE
CLEANING
It is very important not to scratch the gasket faces

of parts in aluminium.

on the metal.

wooden spatula.
Gloves should be worn during this operation.
Remember that this operation should be carried

out with extreme care to avoid the risk of foreign
bodies being introduced into the oilways bringing
oil under pressure to the camshaft (oilways are
located in both the cylinder head and the cylinder
block).

risk that the rocker jets may become blocked and
damage may occur rapidly to the rocker cams and
tappets.
CHECKING THE GASKET FACE
Use a straight edge and a set of shims to check for

gasket face deformation.
87474S
11-20
F3R ENGINE
REFITTING (special notes) ADJUSTING THE LONGITUDINAL MOVEMENT
LIMITER
The cylinder head is centred by two dowels.
99026R
Tighten the cylinder head (see section tightening

the cylinder head).
Fit the limiter assembly plus the suspended engine

mounting cover.
99166-1R
Tighten the 2 bolts (E) to a torque of 5 to

6.5 daN.m.
Fill and bleed the cooling circuit (see section 19).
Adjust the accelerator cable.
11-21
F8Q ENGINE
Mot. 251-01 Dial gauge mounting

Mot. 252-01 Pressure plate for measuring cylinder liner protrusion

Mot. 591-02 Index
Mot. 591-04 Angular wrench for tightening the cylinder head
Mot. 1054 TDC pin
Mot. 1159 Tool for retaining the engine on the sub-frame

Mot. 1281-01 Oil filter wrench
Mot. 1289-03 Fork for centring suspended engine mounting limiter
EQUIPMENT REQUIRED

Star socket EX 255 FACOM for example
Remove:
- the timing belt (see section 11 - timing belt),
Wheel bolt 9 - bolts (A) mounting the tensioner, together

with bolt (B) for the alternator drive belt ten-
Crankshaft pulley bolt 12 sion strut mounting,
Suspended engine mounting cover bolt 6
Suspended engine mounting limiter bolt 4
Tensioner nut 5
REMOVAL
Drain the cooling circuit via the lower radiator

hose (radiator end). 99174R
11-22
F8Q ENGINE
- the exhaust flange at the manifold outlet,
- the air filter,
- the earth strap,
- the fuel return union on the injection pump,

together with the mounting bracket on the
manifold,
- the mounting bolts for the inner timing cover

on the engine block.
99023R2
95658-4R
Fit tool Mot. 1159 under the oil pump.
Note : cut the base of tool Mot. 1159 to 30 mm.
99024R2
Remove the oil filter.
Release the wiring from the alternator and move

the wiring to one side.
11-23
F8Q ENGINE
Diagram for drilling tool Mot. 1159 (diameter 10.5
mm).
99028R
Fit the bracket of tool Mot. 1159 under the water

98904S
pump.
- the 2 oil vapour rebreathing hoses on the decan-

ter,
- the preheater plug connector,
- the injection pump connectors,
- the solenoid valve pipes,
- the fuel supply pipe to the diesel fuel filter using

tool Mot. 1311-06
99310R
Disconnect:
- the thermostat hoses,
- the connectors for the sensors,
99461R
Remove the cylinder head bolts using the star

socket 55 tool EX 255 FACOM for example.
11-24
F8Q ENGINE
Release the cylinder head by separating the lower CLEANING
part of the inner camshaft housing; do this wi-
thout pivoting the cylinder head, as it is centred It is very important not to scratch the gasket faces
by 2 dowels (C). of parts in aluminium.

on the metal.

wooden spatula.
99173-1R
Use a syringe to remove any oil in the mounting

holes for the cylinder head.
This is necessary to ensure the bolts can be tighte-

ned correctly.
99180S
Protect the pipe bringing oil up so that foreign

bodies are not allowed to enter the oilways brin- Gloves should be worn during this operation.
ging oil into the cylinder head.

risk that the oilways may become blocked and da-
mage may occur rapidly to the camshaft.
11-25
F8Q ENGINE
CHECKING THE GASKET FACE
Use a straight edge and a set of shims to check for

gasket face deformation.
99173R
Measure the piston protrusion.
ONLY TAKE INTO ACCOUNT THE DIMENSION FOR

THE PISTON WITH THE MAXIMUM PROTRUSION
For a maximum piston protrusion :

99181S
- less than 0.868, use a gasket marked by a tab
with 2 holes,
DETERMINING THE THICKNESS OF THE GASKET
- between 0.868 and 1.000, use a gasket marked by
Checking piston protrusion a tab with 1 hole,
Clean the piston crowns to eliminate any deposits. - greater than 1.000, use a gasket marked by a tab
with 3 holes.
Turn the crankshaft in the normal operating direc-
tion by one turn to bring piston No. 1 close to
TDC.
Place tool Mot. 252-01 on the piston.
Fit tool Mot. 251-01 with a dial gauge to the pres-

sure plate Mot. 252-01. The pin of the dial gauge
should be touching the cylinder block; determine
the TDC for the piston.
NOTE : all measurements should be made in the

longitudinal axis of the engine to eliminate errors
due to piston tilt.
11-26
F8Q ENGINE
Fit the gasket selected previously. It is centred by 2

dowels (C).
99173-1R
Positions the pistons halfway in the barrels to

avoid any contact with the valves when the cylin-
der head is tightened.
Centre the cylinder head on its dowels.
Lubricate under the heads and the threads of the

mounting bolts.
Tighten the cylinder head (see section 07- tighte-

ning the cylinder head).
Refit the timing belt.
Fill and bleed the cooling circuit (see section 19).
11-27
FUEL MIXTURE
Specifications 12
Engine
Depollution
Vehicle Gearbox
Bore Stroke Capacity Catalytic standard
Type Suffix Ratio
(mm) (mm) (cm 3) converter
BA0E JB1 E7J 764 75.8 77 1 390 9.1/1 C44 EU 96
Tests carried out at idle speed*

Engine
Fuel ***
Engine Emission of pollutants ** (minimum octane
speed rating)
Type Suffix (rpm.) CO (%) CO 2 (%) HC (ppm) Lambda (λ)
0.3 14.5 100

E7J 764 750±50 0.97<λ<1.03 Unleaded (OR 95)
maximum minimum maximum
Engine
Homologation RENAULT No.
Computer Supplier’s No.
No. (G70*)
Type Suffix
E7J 764 SIEMENS 35 tracks (FENIX 3) S 111 730 108 B 77 00 864 451 77 00 874 461
* For a coolant temperature greater than 80°C and at stable engine speed of 2 500 rpm for
approximately 30 seconds.
** For legislative values, refer to specification for individual country.
*** Compatible with OR 91 unleaded.
Temperature in °C (± 1°) 0 20 40 80 90
Air temperature sensor

7 470 3 060 1 315
Type CTN - -
to 11 970 to 4 045 to 1 600
Resistance in Ohms
Coolant temperature sensor

3 060 1 315
Type CTN - 300 to 370 210 to 270
to 4 045 to 1 600
Resistance in Ohms
12-1
FUEL MIXTURE
Specifications 12
DESCRIPTION MAKE/TYPE SPECIAL NOTES
Computer SIEMENS FENIX 3 35 tracks
Injection Regulated monopoint injection
Ignition Advance laws integral in injection computer

Ignition power module
Pinking sensor
Plugs EYQUEM FC 52 LS Gap: 0.9 mm

NGK BCP 5 ES Tightening torque: 2.5 to 3 daN.m
Fuel filter Mounted in front of the fuel tank under the vehicle
Fuel pump WALBRO Submerged in fuel tank

Flow: 50 litres/hour minimum
Pressure: 1.06 bar
Pressure regulator Pressure 1.06 bar (non-adjustable)
Solenoid injector Voltage: 12 V

Resistance : ≈ 2 Ω
Throttle body BOSCH Diameter 36 mm
Idle speed regulation Non-adjustable

micromotor Integral no load switch
Fuel vapour recirculation

canister CAN 10 Voltage: 12 V
Solenoid valve Resistance : ≈ 34.5 Ω
Heated oxygen sensor NGK Voltage at 850°C

Rich mixture : > 625 mvolt
Lean mixture: 0 to 80 mvolt
Tightening torque: 4.5 daN.m
Fault finding Throttle potentiometer

Idle speed regulation: 15≤#17≤30
Full load: 192≤#17≤ 210
Adaptive richness
operation: 112≤#30≤ 160
Adaptive richness
idle speed: 104≤#31≤ 160
12-2
FUEL MIXTURE
Specifications 12
Engine
Depollution
Vehicle Gearbox
Type Suffix Ratio
BA0F Manual K7M 702 79.5 80.5 1598 9.7/1 C45 EU 96
BA0F Automatic K7M 703 79.5 80.5 1598 9.7/1 C45 EU 96
BA0L Manual K7M 720 79.5 80.5 1598 9/1 C45 EU 96

Engine
Fuel ***
Engine Emission of pollutants** (minimum octane
speed rating)
702 0.3 14.5 100

K7M 720±50 0.97<λ<1.03 Unleaded (OR 95)
720 maximum minimum maximum
0.3 14.5 100

K7M 703 750±50 0.97<λ<1.03 Unleaded (OR 95)
Engine
No. (G70*)
Type Suffix
K7M 702 SIEMENS 55 tracks (FENIX 5) S 105 300 101 D 77 00 860 319 77 00 863 499
K7M 703 SIEMENS 55 tracks (FENIX 5) S 105 300 201 C 77 00 860 337 77 00 869 818
K7M 720 SIEMENS 55 tracks (FENIX 5) S 105 300 104 B 77 00 864 454 77 00 865 827
Temperature in °C (± 1°) 0 20 40 80 90

7 470 3 060 1 315
Type CTN - -
to 11 970 to 4 045 to 1 600
Resistance in Ohms

3 060 1 315
Type CTN - 300 to 370 210 to 270
to 4 045 to 1 600
Resistance in Ohms
12-3
FUEL MIXTURE
Specifications 12
Injection Semi-sequential regulated multipoint injection
Ignition Static with two dual output coils

Power module integral in computer
One pinking sensor
Plugs EYQUEM FC 52 LS Gap: 0.9 mm

CHAMPION C10YC Tightening torque: 2.5 to 3 daN.m
Air filter Replace every other oil change
Replace at major service

Flow: 80 litres/hour minimum for regulated
pressure of 3 bars and voltage of 12 V
Pressure regulator Regulated pressure

Zero vacuum: 3 ± 0.2 bars
Vacuum of 500 mbar : 2.5 ± 0.2 bars
Solenoid injector SIEMENS Voltage: 12 V

Resistance : 14.5 ± 1 Ω
Throttle body PIERBURG Diameter 44 mm

714 186
Idle speed regulation stepping

motor
EGR (K7M 703) solenoid valve PIERBURG Voltage: 12 V

72213000 Resistance : 30 ± 3 Ω

canister CAN 10
Solenoid valve DELCO REMY Voltage: 12 V
Resistance : 35 ± 5 Ω
Heated oxygen sensor NGK Voltage at 850°C

Rich mixture: > 625 mvolt
Fault finding FICHE n° 27 Throttle potentiometer

CODE D13 Idle speed regulation: 5 ≤ #17 ≤ 47
SELECTOR ON S8 Full load: 164 ≤ #17 ≤ 253
R.C.O. idle speed: 4 % ≤ #12 ≤ 14 % (K7M 720)
6 % ≤ #12 ≤ 15 % (K7M 702/703 in P and N)
10 % ≤ #12 ≤ 20 % (K7M 703 in D)
Adaptive R.C.O
idle speed: - 2.4 % ≤ #21 ≤ + 6.2%
Adaptive richness
operation: 0 ≤ #30 ≤ 208
Adaptive richness
idle speed: 100 ≤ #31 ≤ 255 (K7M 720)
104 ≤ #31 ≤ 255 (K7M 702/703)
12-4
FUEL MIXTURE
Specifications 12
Engine
Depollution
Vehicle Gearbox
Type Suffix Ratio
BA0G Manual F3R 750 82.7 93 1998 9.8/1 C47 EU 96

Engine
Fuel ***
Engine Emission of pollutants ** (minimum octane
speed rating)
0.3 14.5 100

F3R 750 770±50 0.97<λ<1.03 Unleaded (OR 95)
Engine
No. (G70*)
Type Suffix
F3R 750 SIEMENS 55 tracks (FENIX 5) S 103 717 101 B 77 00 868 299 77 00 874 462
Temperature in °C (± 1°) 0 20 40 80 90

7 470 3 060 1 315
Type CTN - -
to 11 970 to 4 045 to 1 600
Resistance in Ohms

3 060 1 315
Type CTN - 300 to 370 210 to 270
to 4 045 to 1 600
Resistance in Ohms
12-5
FUEL MIXTURE
Specifications 12
Injection Sequential regulated multipoint injection
Ignition Static with two dual output coils

Power module integral in computer
One pinking sensor
Plugs EYQUEM C 52 LS Gap: 0.9 mm

CHAMPION N7YCX Tightening torque: 2.5 to 3 daN.m
BOSCH W7DCO
Air filter Replace every other oil change
Replace at major service

Flow: 80 litres/hour minimum for regulated
pressure of 3 bars and voltage of 12 V
Pressure regulator WEBER Regulated pressure

BOSCH Zero vacuum: 3 ± 0.2 bars
Vacuum of 500 mbar : 2.5 ± 0.2 bars
Solenoid injector SIEMENS Voltage: 12 V

Resistance: 14.5 ± 1 Ω
Throttle body SOLEX Reference: 127 F3R 751 without AC - F3R 750
Diameter 60 mm Reference: 132 F3R 751 AC
Idle speed regulation solenoid HITACHI Voltage: 12 V

AESP 207-17 Resistance: 9.5 ± 1 Ω

canister CAN 10
Solenoid valve DELCO REMY Voltage: 12 V
Resistance: 35 ± 5 Ω
Heated oxygen sensor BOSCH LSH 25 Voltage at 850°C

Rich mixture: > 625 mvolt
Fault finding FICHE n° 27 Throttle potentiometer

CODE D13 Idle speed regulation: 8 ≤ #17 ≤ 38
SELECTOR ON S8 Full load: 188 ≤ #17 ≤ 245
R.C.O. idle speed: 20 % ≤ #12 ≤ 40 % (F3R 750)
18 % ≤ #12 ≤ 38 % (F3R 751)
Adaptive R.C.O
idle speed: - 6.2 % or - 8.6 ≤ #21 ≤ + 6.2 %
Adaptive richness
operation: 82 ≤ #30 ≤ 224
Adaptive richness idle speed: 32 ≤ #31 ≤ 224
12-6
FUEL MIXTURE
E7J engine
Throttle body 12
PRESENTATION Connector (C)
Throttle potentiometer operation
1 Earth
2 + 5 V feed
4 Throttle position information (voltage
changes between 0 and 5 V)
5 Not used
The throttle body has two sections:
• The upper section is known as the injection

section (D).
• The lower section is known as the throttle

section (E).
NOTE : when the unit is removed, the two sections

are joined together by plastic clips. Squeeze the
end of the clips to separate the two sections.
94542R
1 Air temperature sensor

2 Fuel pressure regulator
3 Fuel return to fuel tank
4 Fuel supply
5 Throttle opening motor
6 Monopoint injector
Connector (A)
Injector and air temperature sensor operations
1 and 4 Air temperature sensor

2 +monopoint injector
3 - monopoint injector
Connector (B)
Idle speed regulation and low load switch

operations
94543-2R3
1 + or - Motor feed
2 - or + Motor feed
3 and 4 Low load switch
12-7
FUEL MIXTURE
E7J engine
Throttle body 12
REMOVAL AIR TEMPERATURE SENSOR
Remove the air filter. REMOVAL
Disconnect: Remove the air filter.

- connectors (A) (B) and (C),
- the fuel supply pipes (1) and return pipes (2), Disconnect the connector.
- the accelerator control cable (3).
Remove bolt (1) and lift cover (2).
Remove the mounting bolts (4) and remove the
throttle body. Release the wires from mounting (3).
Remove the connector (4) after releasing hooks

(5).
94544R 94541R
REFITTING REFITTING
Replace the seals between the manifold and the Check the connectors are correctly clipped in.
throttle body.
Reconnect:
- the fuel supply and return pipes, ensuring the
connectors are correctly clipped back together,
- the accelerator control and refit the air filter.
12-8
FUEL MIXTURE
E7J engine
Throttle body 12
INJECTOR IDLE SPEED REGULATION MOTOR
REMOVAL REMOVAL
Remove the air filter. Remove the air filter.
Remove the air temperature cover (see previous The motor may be removed without having to
page). remove the throttle body. Access to the bolts is
made easier however by removing the mounting
Remove the injector (6) from its housing. bolts for the throttle body and releasing it
without disconnecting the fuel pipes.
Disconnect the motor connector.
Remove the mounting bolts and remove the

motor.
94539R 94540S
REFITTING REFITTING
Replace the O rings and lubricate them. No adjustment may be made. However, ignition
on, if the low load switch bargraph on the XR25 is
Fit the injector and cover so that they are correctly not illuminated, fit a shim between the throttle
aligned and mount the assembly. stop and the micromotor to obtain the no load
switch position.
Turn the ignition on then off; the micromotor

should position itself in the cold start position.
REMOVING - REFITTING THE FUEL PRESSURE Repeat the operation without the shim, then
REGULATOR check the position of the throttle, ignition on,
engine not running, using the XR25 and #17.
The fuel pressure regulator cannot be adjusted if
it is faulty. The upper section of the throttle body
must be renewed.
12-9
FUEL MIXTURE
E7J engine
Throttle body 12
THROTTLE POTENTIOMETER
The throttle potentiometer is set in the factory

and cannot be repaired.
If there is a fault, renew the throttle body section.
REMOVAL
Remove the air filter and the complete

monopoint throttle body assembly (see previous
pages).
Remove the upper section of the throttle body

and the idle speed regulation motor.
94538S
REFITTING
Renew the seals.
Refit the throttle body peripherals.
Check:
- the connectors are correctly connected,
- on the XR25 :
• the bargraphs are present for :
- low load,
- full load.
• the throttle position using the XR25 and
#17.
Refit the air filter.
12-10
FUEL MIXTURE
K7M engine
Throttle body 12
TIGHTENING TORQUES (in daN.m) Disconnect :
- the accelerator cable (5),
Throttle body mounting bolt - the throttle position potentiometer connector
on inlet manifold 2 (6),
- the idle speed regulation stepping motor
connector (7).
REMOVAL
Remove the acoustic tie bar.
Disconnect:
- the air temperature sensor (1),
- the oil vapour rebreathing pipe (2) on the
rocker box cover.
Slacken the clips (3) mounting the air sleeve (4) to

the air filter and the throttle body, then remove
the sleeve.
99357R
Remove the four bolts mounting the throttle

body and remove the throttle body.
99359R
99358-1R
12-11
FUEL MIXTURE
K7M engine
Throttle body 12
To make the operation easier, remove the throttle
body to remove the potentiometer and the idle
speed regulation stepping motor.
99363S
The throttle position potentiometer is not

adjustable.
REFITTING
Renew the seal between the throttle body and

the manifold.
The remaining refitting operations are the reverse

of removal.
12-12
FUEL MIXTURE
F3R engine
Throttle body 12
TIGHTENING TORQUES (in daN.m) Remove the air filter and the air sleeve.
Throttle body mounting bolt

on inlet manifold 2
Throttle potentiometer mounting bolt 0.2
REMOVAL
Remove the three bolts mounting the unit to the

air filter.
99238R
Disconnect :
- the oil vapour rebreathing pipe (5),
- the two water hoses (6) which heat the
throttle body after clamping them using tool
Mot. 453-01.
Remove the four mounting bolts for the throttle

body and remove it.
Remove the heat shield between the throttle

body and the manifold.
99213R
Disconnect:
- the throttle position potentiometer (8).
Slacken the clip mounting the air sleeve (2) to the

throttle body.
99239R
12-13
FUEL MIXTURE
F3R engine
Throttle body 12
NOTE : the throttle position potentiometer (7)
may only be removed after removing the throttle
body (non-adjustable).
99223R
REFITTING
Remove the seals bonded on the heat shield for

the throttle body and renew them (it is not
necessary to bond them into position again).
12-14
FUEL MIXTURE
E7J engine
Inlet manifold 12
TIGHTENING TORQUES (in daN.m) REFITTING
Manifold nuts 2.5 When refitting, replace the manifold gasket and
bleed the cooling circuit.
REMOVAL
To remove the manifold, the throttle body must

be removed (see previous pages).
There are no special notes for removal.
The inlet manifold is fitted with an electrical

heater (2) with a PTC type resistance (positive
temperature coefficient).
This is mounted in the inlet manifold, opposite

the throttle, and is secured by a circlip.
The heater is fed via a relay by the computer up to

a coolant temperature of 68°C.
If the coolant temperature sensor is faulty, the

heater is permanently fed.
PRM1202
1 Retaining circlip.
2 Electrical heater.
3 Seal.
12-15
FUEL MIXTURE
K7M engine
Inlet manifold 12
EGR solenoid valve mounting bolt 1

Inlet manifold bolt and nut 2.5
EGR steel pipe bolt 1
NOTE : the fuel gallery must be removed

beforehand (refer to section 13 "Fuel gallery").
REMOVAL
Disconnect the air temperature sensor (1).
Slacken the two clips (2) mounting the air sleeve

to the throttle body and the air filter and remove
the sleeve.
99357R
K7M 703 engine
From the EGR solenoid valve, disconnect (8) :

- the hose (9) going to the manifold,
- the electrical connector (10).
Remove the 2 bolts mounting the solenoid valve

(8), then remove the valve.
99359R1
Disconnect:
- the throttle position potentiometer connector
(6),
- the idle speed regulation stepping motor
connector (7).
99358R
12-16
FUEL MIXTURE
K7M engine
Inlet manifold 12
Unscrew the steel pipe (11) which goes to the Remove the manifold.
manifold from the EGR solenoid valve mounting
(release the clip first).
All engine types
Remove the two bolts from under the manifold

which mount the wiring retaining bracket.
99371R
REFITTING
Renew all gaskets and seals which have been

removed.

99460R
Remember to reclip the clip mounting the EGR
From the manifold, disconnect: pipe.
- the pipe (12) connected to the absolute
pressure sensor,
- the pipe (13) connected to the brake servo,
- the fuel supply and return pipes.
Disconnect the two hoses from the canister bleed

solenoid valve (14).
Remove the four lower mounting nuts then the

five upper mounting bolts.
12-17
FUEL MIXTURE
E7J engine
Exhaust manifold 12
Manifold nuts 2
REMOVAL
After removing the heat shield from the manifold,

remove the mountings.
99093R
99092S
REFITTING
Renew the gasket systematically.
12-18
FUEL MIXTURE
K7M engine
Exhaust manifold 12
Manifold mounting nut 2

EGR steel pipe bolt 1
REMOVAL
Remove the heat shield.
99356R
Remove the exhaust manifold.
REFITTING
Renew the manifold gasket.

99355R

Remove:
- the two nuts (1) connecting the exhaust
manifold to the exhaust downpipe,
- nut (2) for the steel pipe connecting the EGR
solenoid valve and the manifold; first remove
clips (3) (K7M 703),
- the seven nuts mounting the manifold.
12-19
FUEL MIXTURE
F3R engine
Manifolds 12
Throttle body mounting bolt

on manifold 2
Manifold mounting nut on cylinder head 2
Manifold mounting stud on cylinder head 1
Strengthening bracket mounting
bolt on exhaust manifold 4
NOTE : the fuel gallery must be removed

beforehand (refer to section 13 "Fuel gallery").
The inlet manifold may be removed by itself, but

removing the exhaust manifold requires the inlet
manifold to be removed.
99229-2R
If the manifold gasket is renewed, both manifolds
must be removed.
From below the vehicle:
Use rope to attach the exhaust chamber to the

body.
Remove:
REMOVAL - the 2 mounting bolts (2) securing the
downpipe to the exhaust manifold,
Put the vehicle on a 2 post lift. - bolt (3) securing the exhaust manifold to the
strengthening bracket.
From above the vehicle:
Remove the upper and lower mounting nuts (1)

for the inlet manifold (the 2 nuts (B) at each end
only secure the exhaust manifold).
Remove the inlet manifold.
99228R
12-20
FUEL MIXTURE
F3R engine
Manifolds 12
From above the vehicle:
Remove the 2 bolts (B).
DI1207
Remove the exhaust manifold.
REFITTING
The manifold gasket should be fitted with the

metal side against the manifold (crimped side
against the cylinder head).
12-21
FUEL SUPPLY
Fuel cut-out on impact 13
AIM • For diesel engines, between the + feed and
the fuel shut off (or the coded solenoid valve
The aim of this function is to avoid a fire after an if the vehicle is fitted with an engine
accident due to a fuel leak. To accomplish this, all immobiliser).
components which pump fuel from the fuel tank
are stopped during and after the impact. They
may only be started again by a mechanical action OPERATION
performed by the driver or repair mechanic.
During the impact, the inertia switch ball leaves its
DESCRIPTION seat and breaks the electrical current.
The system comprises an inertia switch which may For petrol engines, the + feed to the pump relay
be reset, which: control circuit (236) is cut. The pump and the
- detects the impact (1), injectors are thus no longer fed electrically.
- cuts the electrical circuit. The fuel in the fuel tank is therefore isolated.
For diesel engines, the + feed to the fuel shut off

or the coded solenoid valve is cut.
The pump can no longer take up fuel, there is no
high pressure any more. Any risk of fire due to
high pressure diesel spray over the engine is
removed.
RESETTING THE SWITCH AND SWITCH

OPERATION
To reset the inertia switch, press the top to

reposition the ball in its seat.
IMPORTANT:
• for petrol engines, after resetting the switch,
the computer memory MUST be erased using
the XR25. The injection computer will
memorise a pump relay fault when the system
is triggered.
99511R • for diesel engines, after resetting the switch,

the passenger compartment connection unit
It is mounted: memory MUST be erased using the XR25. This
unit will memorise a break in feed to the
• For petrol engines, between track 1 of the coded solenoid valve.
pump relay (236) and the + feed.
13-1
FUEL SUPPLY
Fuel cut-out on impact 13
WIRING DIAGRAM
PRJ99472
Key
120 Injection computer

199 Fuel pump
236 Fuel pump relay
246 Fuel shut off
927 Inertia switch
13-2
FUEL SUPPLY
K7M engine
Fuel gallery 13

unions
TIGHTENING TORQUES (in daN.m) - the fuel supply pipes (6) and return pipes (7)
using the small section tool Mot. 1311-06 (the
Fuel gallery mounting bolt on manifold 0.8 fuel supply pipe uses a removal tool
connected to the union fitted on the vehicle).
REMOVAL
Disconnect:
- the oil vapour rebreathing pipes (1) and the
fuel vapour recirculation pipes (2),
- the connectors for the injectors (3) and the
canister bleed solenoid valve (4),
- on the manifold, the pipe (5) connecting the
pressure regulator to the manifold vacuum,
99375R
99372R
99370R
13-3
FUEL SUPPLY
K7M engine
Fuel gallery 13
To remove the unions, fit tool Mot. 1311-06 To remove an injector, remove clips (8) then pull
between the two parts (A) and (B). the injectors.
Press on the tool to lift the two retaining claws

then pull the union.
99373R
REFITTING
Renew the O rings at the base of the injectors (if

the injector has been removed, also renew the
99461R1 seal at the head of the injector).
The fuel supply and return unions should click

Remove the three gallery mounting bolts then when they are correctly connected.
remove the gallery.
99369R
13-4
FUEL SUPPLY
F3R engine
Fuel gallery 13
TIGHTENING TORQUES (in daN.m) Slacken the clip mounting the air sleeve to the
throttle body.
Throttle body mounting bolt on manifold 2
Fuel gallery mounting nut 1 Remove the three nuts mounting the air filter.
REMOVAL
Disconnect:
- the pressure sensor (3),
- the throttle potentiometer (4),
- the cylinder reference sensor (6),
- the fuel vapour recirculation pipe (11),
- the brake servo vacuum pipe (10),
- from the manifold, the pressure sensor
vacuum pipe (7).
99213R1
Remove the filter and the air sleeve.
Disconnect:
- the oil vapour rebreathing pipe (9),
- the coolant temperature sensor (2),
- the idle speed regulation solenoid valve (5).
99238R1
13-5
FUEL SUPPLY
F3R engine
Fuel gallery 13
Remove the four bolts mounting the throttle Remove:
body (do not disconnect the coolant hoses which - the two fuel gallery mounting nuts,
warm the throttle body). - the earth strap (15).
Remove the heat shield between the throttle

body and the manifold.
99229R
99239-1R Remove the fuel gallery by sliding it along the

inlet manifold.
Unclip the wiring and the pipe mounted on the

manifold and tilt the assembly towards the
injection computer.
Disconnect the injectors.
Remove the wiring mounting.
Disconnect:
- the fuel supply pipe (17) on the flywheel end,
marked by a green ring,
- the return pipe to the fuel tank (18) at the
timing end, marked by a red ring,
- the vacuum pipe (19) for the fuel pressure
regulator.
99229-1S
13-6
FUEL SUPPLY
F3R engine
Fuel gallery 13
REFITTING
Ensure the two plastic spacers are present. They

should be located on the two gallery mounting
studs between the studs and the cylinder head.
Remove the seals bonded on the throttle body

heat shield, then renew them (they do not need
to be bonded when refitting).
99215S
13-7
FUEL SUPPLY
F3R engine
Injectors 13
The injectors fitted to this type of engine are of IMPORTANT : there are no special notes for
the type "SIEMENS DEKA 2". removing the injectors. The fuel gallery must
however be removed beforehand since the fuel in
They are mounted on the fuel gallery.Each the gallery would enter the cylinder concerned.
injector is sealed by two O rings. When any operation involves removal of an
injector, new O rings and flat seals under the
Fuel circulates permanently around the gallery must be fitted.
circumference of the injector body. This fuel
washing prevents bubbles of fuel vapour forming
and aids warm starting.
NOTE : when refitting the upper seal, use the

tapered ring provided with the kit of seals.
INJECTOR DETAIL
96507R
1 Connector
2 O rings
3 Upper O ring retaining circlip
4 Filter
5 Metal body
6 Winding
13-8
FUEL SUPPLY
Fuel filter 13
Mot. 1265 Pliers for removing quick release

unions
LOCATION
The fuel filter is located under the vehicle in front

of the fuel tank.
96420R3
Remove bolt (3) and remove the fuel filter.
99214R
REPLACEMENT REFITTING
Replace the fuel filter at each major service. Observe the direction of fuel flow (marked by an
arrow on the filter).
REMOVAL
Reconnect the pipes by hand (it is not necessary to
Before removing the filter, take precautions to use tool Mot. 1265).
catch the fuel which will run out (do not clamp
the pipes as they will be damaged). Ensure the quick release unions are correctly
connected.
Remove the clips (1).
Refit the safety clips (1).
Disconnect the pipes with quick release unions (2)
using tool Mot. 1265.
13-9
FUEL SUPPLY
Pump flow 13

unions
EQUIPMENT REQUIRED
1 measuring cylinder 2000 ml
It is recommended to check the fuel pump flow CHECKING THE PUMP FLOW
using the fuel return pipe connected to the sender
unit assembly. Lift the rear seat.
Remove the plastic cover.
Remove the clip (1).
Use tool Mot. 1265 to disconnect the fuel return

pipe (2) (marked by a red quick release union).
Connect an 8 mm semi-rigid pipe to the quick

release union and insert the other end of the pipe
into the 0-2000 ml measuring cylinder.
Shunt terminals (3) and (5) of the fuel pump relay

(located in the engine fuse box). In a period of
one minute the pump flow should be a minimum
of :
- 1.3 litres for F3R - K7M engines,
- 0.83 litres for E7J engines,
for a voltage of 12 Volts.
97163R8 NOTE : when refitting, ensure the quick release

unions are correctly connected.
IMPORTANT If the flow is low, check the feed voltage to the

pump (a drop of approximately 10% is caused for
During this operation the following points must a drop in voltage of 1 Volt).
be observed:
• Do not smoke and keep all heat sources away

from the working area.
• Take precautions to guard against fuel spray

due to the residual pressure in the pipes when
they are removed.
13-10
FUEL SUPPLY
E7J engine
Supply pressure 13
CHECKING THE FUEL SUPPLY PRESSURE
Mot. 1311-01 Fuel pressure test kit
Disconnect the fuel supply pipe (1) from the The pressure should be 1.06 bar.
throttle body and insert the 0 - 10 bars pressure
gauge and the three way union from the test kit
Mot. 1311-01. Checking the pump safety valve
If the fuel pressure is correct, feed the fuel pump

and clamp the pipe with the two position valve
for a brief moment. The pressure should stabilise
at approximately 3 bars.
99089R

(B) in the engine connection unit (see diagram on
page 13-2).
98756R1
13-11
FUEL SUPPLY
K7M engine
Supply pressure 13
Mot. 1311-01 Fuel pressure test kit (with 0 ;+ 10 bars

pressure gauge included)
Mot. 1311-04 T piece (J union)
Disconnect:
- the oil vapour rebreathing pipes and the fuel
vapour recirculation pipes,
99375R
Connect the T piece Mot. 1311-04 to the gallery,

then reconnect the fuel supply pipe to the T piece.
99372S
- the fuel supply pipe using small section tool

Mot. 1311-06 (method described in section 13
"Fuel gallery").
99376R
13-12
FUEL SUPPLY
K7M engine
Supply pressure 13
Fit the 0 ; 10 bars pressure gauge and the hose
Mot. 1311-01.
99366R
Shunt terminals (3) and (5) on the fuel pump relay

located in the engine fuse box (see diagram on
page 13-2).
The pressure should be 3 bars ± 0.2.
When a vacuum of 500 mbars is applied to the

pressure regulator, the fuel pressure should be
2.5 bars ± 0.2.
CHECKING THE PUMP SAFETY VALVE (under the

same conditions as previously)

(see diagram on page 13-2).
When the fuel return pipe is clamped briefly, the

pressure should stabilise between 4.5 and 7.5
bars.
13-13
FUEL SUPPLY
F3R engine
Supply pressure 13
Mot. 1311-01 Fuel pressure test kit (with 0 ;+

10 bars pressure gauge included)
When a vacuum of 500 mbars is applied to the

fuel pressure regulator, the pressure should be
2.5 bars ± 0.2.
CHECKING THE PUMP SAFETY VALVE (under the

same conditions as previously)

(see diagram on page 13-2).
When the fuel return pipe is clamped briefly by

the two position valve, the pressure should
stabilise between 4.5 and 7.5 bars.
99217R1
Disconnect the rear fuel pipe.
Fit the three way valve (1) from tool Mot. 1311-01
and connect the 0 ; + 10 bars pressure gauge.

located in the engine fuse box.
The pressure should be 3 bars ± 0.2.
13-14
DIESEL EQUIPMENT
Specifications 13
Engine
Depollution
Vehicle Gearbox
Type Suffix Ratio
BA0U JB3 F8Q 620 80 93 1 870 21.5/1 None EU93
BA0A JB3 F8Q 620 80 93 1 870 21.5/1 C25 EU96
ENGINE SPEED (rpm.) SMOKE OPACITY
Maximum with
Idle speed Maximum no load Homologation value Legal maximum
load
825 ± 25 5 200 ± 100 4 600 ± 100 1.24 m -1 (40 %) 2 m -1 (55 %)
DESCRIPTION MAKE /TYPE SPECIAL NOTES
Injection pump BOSCH Rotary pump with:

Pumps R598-2 and R598-3 differ VE 4/8F 2300R598 - separate idle lever
in that a coded fuel shut off VE 4/8F 2300R 598-1* - solenoid controlled load dependence (ALFB)
valve has been added VE 4/8F 2300R 598-2 - post-heating and EGR cut-out microswitch
VE 4/8F 2300R 598-3* - air conditioning cut-out microswitch*
Pump timing obtained by 8mm Pump piston lift: 0.82 ± 0.04 mm

diameter TDC pin (Mot. 1079) (the setting value is stamped on the load lever)
Injector holders BOSCH KCA 17 S 42 Tightening torque : 7 daN.m
Injectors BOSCH
Test: 130 +8 bars
DNOSD 302 -5
Maximum gap: 8 bars
Fuel filter PURFLUX Priming pump

The filter is fitted with an electrical fuel heater
EGR solenoid valve Voltage: 12 volts

Resistance : 10 ± 5 Ω
Fuel pipes External diameter : 6 mm

Internal diameter : 2.5 mm
Length: 400 mm
Pre-heating unit NAGARES With pre-post-heating function and cold start

functions and fast idle solenoid
Heater plugs BOSCH Current: 15 A approximately after 8 seconds

heating
Tightening torque : 2 daN.m
13-15
DIESEL EQUIPMENT
Description of the pump 13
99337R2
1 Load dependence control solenoid valve (ALFB)

2 Fuel shut off solenoid
3 Microswitch for cutting post-heating and exhaust gas recirculation (EGR)
4 Air conditioning microswitch
5 Residual flow stop screw (anti-stall)
6 Maximum engine speed stop screw (no adjustment may be made except at a Renault Injection Centre)
7 Normal idle speed adjustment stop screw
8 Fast idle speed adjustment stop screw
9 Coded solenoid valve electronic unit
13-16
DIESEL EQUIPMENT
Tightening torques (in daN.m) 13
PRJ1301
13-17
DIESEL EQUIPMENT
Special notes 13
ALFB (solenoid controlled load dependence) c) If both the coolant and air temperature
sensors are faulty, the solenoid valve is fed
for 200 seconds when the ignition is
ROLE turned on.
To eliminate the action of LFB load dependence LOCATION

(internal drop in pressure in the pump and
therefore advance), depending on the engine Coolant temperature sensor (1) (black connector)
temperature and atmospheric pressure.
OPERATION
1. Control by pre-post-heating unit
a) As long as the coolant temperature is <

29°C, the solenoid valve is fed when the
ignition is turned on.
b) If the coolant temperature sensor is faulty,

the solenoid valve is fed when the ignition
is turned on depending on the air
temperature (the air temperature sensor
is located in the pre-post-heating unit).
Coolant temperature sensor faulty

98904R
SPECIFICATIONS
Temperature in °C Resistance Ω
25 2 610 to 2 990
80 310 to 350
DI1301
13-18
DIESEL EQUIPMENT
Special notes 13
2. Control by altimetric capsule LOCATION
At altitude, when atmospheric pressure is Altimetric capsule (741)

approximately 925 ± 20 mbars, the ALFB
solenoid valve is fed via a relay and the
altimetric capsule.
KEY
257 Pre-heating unit

597 Engine fuse box
711 ALFB solenoid valve mounted on injection
pump
741 Altimetric capsule
743 Altimetric relay
99334R
PRJ99257
13-19
DIESEL EQUIPMENT
Idle speed settings 13
These adjustments must be made when the engine is warm, after the cooling fan assemblies have operated at
least twice.
99337R3
ADJUSTING THE IDLE SPEED AND THE RESIDUAL Remove the 4 mm shim then accelerate sharply
FLOW (anti-stall) twice.
Slacken the residual flow screw two turns and Check the idle speed setting is correct; if necessary
check that the load lever is touching the screw. adjust the idle speed again and recheck the
residual flow setting.
Adjust the idle speed to 825 ± 25 rpm using screw
(1). The idle speed and anti-stall function must be set
correctly since they have a direct effect on engine
Fit a 4mm shim between the load lever (2) and behaviour at idle speed and during deceleration
the residual flow screw (3). (hesitation, idle speed remains operative, etc...).
Adjust the engine speed to 1 150 ± 25 rpm using

the residual flow screw (3).
13-20
DIESEL EQUIPMENT
Idle speed settings 13
ADJUSTING THE FAST IDLE SPEED
Set the separate idle speed lever (4) against the

fast idle screw (5), then adjust the engine speed to
950 ± 25 rpm using this screw (5).
ADJUSTING THE POSITION OF THE FAST IDLE

CABLE GRIP (when the idle speed and residual
flow settings are correct )
Check that the separate idle speed lever (4) is

against the idle speed screw (1).
Hold the cable taut.
Position the cable grip at a distance of :

- 6 mm ± 1 (without air conditioning)
from lever (4)
- 2 mm ± 1 (with air conditioning)
from lever (4)
NOTE : vehicles fitted with the air conditioning

option are fitted with a fast idle control
diaphragm operated pneumatically by a solenoid
valve. Fast idle is obtained during post-heating or
when air conditioning is selected (see operating
diagram in the pre-heating section).
ADJUSTING THE DECELERATION DAMPER (6)
When the adjustments above have been made,

the deceleration damper must be adjusted as
described below.
Slacken screws (7) to release the lever (A).
Fit a 1 mm shim between the deceleration damper

and the lever (A).
Push lever (A) on the deceleration damper to the

stop.
Ensure the load lever (2) remains in contact with

the residual flow screw (3).
Tighten the screws (7) in this position.
Remove the adjusting shim and ensure there is

contact between the load lever (2) and the
residual flow screw (3).
13-21
DIESEL EQUIPMENT
Microswitches 13
1 Microswitch for cutting out post-heating and
EGR
2 Microswitch for cutting out air conditioning
(if operational)
The post-heating cut-out microswitch (1) is also

used for cutting EGR .
In order to meet depollution standards this

microswitch requires precise adjustment.
Fit a shim between the anti-stall screw (residual

flow) and the load lever.
99337R1
Microswitch Shim thickness Microswitch Resistance

(Ω)
(mm) position
18.2 closed 0
EGR
infinity
19.2 open
(tracks B1 and C1)
17.5 closed 0
CA
infinity
18.5 open
(tracks B2 and C2)
Adjustment is made by moving the microswitch after slackening the

two mounting bolts.
13-22
DIESEL EQUIPMENT
Pump 13
B.Vi. 868 Wrench for removing high

pressure pipe
Mot. 909-02 12 sided wrench for removing
injection pump mounting
Mot. 997 Socket for removing injector
holder
Mot. 1053 Pump pulley extractor
Mot. 1054 TDC pin
Mot. 1200 Pump pulley retaining tool
REMOVAL Immobilise the engine using tool Mot. 1054. To do

this, turn the engine so that the camshaft sprocket
Battery disconnected, remove: index is aligned with the timing cover reference
- the suspended engine mounting housing (1), mark.
- the injection pump pulley housing (2).
DI1302-1 99183R
Disconnect the fuel supply pipe at the injection

pump end.
13-23
DIESEL EQUIPMENT
Pump 13
Fit the pump pulley retaining tool Mot. 1200. Remove:
- the fuel return pipe,
- the high pressure pipe using tool B.Vi. 868,
- the connections,
- the fast idle control,
- the four rear mounting bolts,
99333-1R
Remove the pump sprocket mounting nut.
Release the sprocket from the cone using tool

Mot. 1053 (fit two plastic clips before removing 99336-1R
the sprocket).
- the three injection pump mounting bolts; to

make removing the lower bolt easier, use tool
Mot. 909-02.
Remove the pump (retain the key from the drive

cone).
99333R
13-24
DIESEL EQUIPMENT
Pump 13
92600R2
B BOSCH pump
R LUCAS DIESEL pump
C keyway to be used
13-25
DIESEL EQUIPMENT
Pump 13
REFITTING (Special notes)
To facilitate refitting the lower injection pump

mounting bolt, remove the injector holder for
cylinder n° 4 (when refitting, the copper seal and
the flame arresting washer must be systematically
renewed).
IMPORTANT : depending on equipment, the

pump drive sprocket has a different position.
There are two position markers and two
differently aligned keyways.
Fit the pump ensuring the key fits into the

sprocket (reference C).
Tighten the pump mounting nut to the

recommended torque (see previous pages).
Carry out pump timing (see method below).
13-26
DIESEL EQUIPMENT
Pump - timing 13
CHECKING THE PUMP TIMING
In place of the plug (1) insert the dial gauge

mounting Mot. 856 and attach a dial gauge with
socket.
99183R
Check the pump piston lift shown on the dial

gauge ; it should be 0.82 ± 0.04 mm. If it is not,
rotate the pump to obtain the required piston lift.
99336R IMPORTANT : after tightening the pump

mounting bolts, turn the engine over twice.
Immobilise the engine once more to check the
Zero the dial gauge to BDC on the injection pump pump timing.
piston.
Immobilise the engine using tool Mot. 1054. To do

this, turn the engine so that the camshaft sprocket
index is aligned with the timing cover reference
mark.
DI1303-1
13-27
DIESEL EQUIPMENT
Coded solenoid valve 13
REPLACEMENT
Mot. 1372 Kit for removing self shearing

bolts from computers
REMOVAL
This operation must be carried out with the

ignition turned off.
Remove the oil vapour decanter (1).
99780R
Remove the computer.
REFITTING
Use the self shearing bolts available from the Parts

Department.
Composition of kit Mot. 1372 :

DI1410-1 - one 4 mm diameter drill (4)
- one number 6 extractor(3)
- one drilling tube (2)
Fit the drilling tube (2) from kit Mot. 1372 into the
computer.
NOTE :
Use: - take care to remember to replace the plastic
- the 4 mm diameter drill from kit Mot. 1372 to cover on the solenoid valve nut,
drill the two bolts (drilling depth - lightly oil the drill to facilitate drilling.
approximately 3 mm),
- the number 6 extractor from the kit Mot. 1372
to remove the bolts.
13-28
DIESEL EQUIPMENT
Operating diagram 13
PRJ99256
13-29
DIESEL EQUIPMENT
Pre-post-heating unit 13
DIAGRAM KEY Connector (A)
104 Ignition switch + Bat + before ignition feed

163 Starter
171 Air conditioning clutch
206 Air conditioning trifunction pressure switch
247 Instrument panel Connector (B)
251 Bi-function coolant temperature switch
1 Feed to heater plugs 1 and 3
257 Pre-heating unit 2 Feed to heater plugs 2 and 4
398 EGR solenoid valve
412 Fast idle solenoid valve (AC version)
597 Engine fuse box
Connector (C)
642 AC / pre-heating separation diode
645 Passenger compartment fuse box A1 / S2 Load dependence solenoid valve
680 Pre-heating unit n° 1 control
681 Pre-heating unit n° 2 A2 / PC Load lever microswitch information
682 Pre-heating unit n° 3
A3 / CTN CTN type sensor coolant temperature
683 Pre-heating unit n° 4 information
711 Diesel fuel pump
B1/+APC + after ignition feed
741 Altimetric capsule
743 Altimetric relay B2 / DEM Starter information
777 Power feed for fuse box B3 / Tem Pre-heating warning light control (via
earth)
IDENTIFICATION OF CONNECTORS C1 / S1 Not used
C2 / -Bat Earth
C3 / Clim Fast idle solenoid valve control during

post-heating phase
92206-2R
13-30
DIESEL EQUIPMENT
LOCATION Coolant temperature sensor (1) (black connector)
Pre-post-heating unit (A)
This unit has two diodes to prevent the feeding of

the heater plugs when the air conditioning system
is operating and also has a CTN type air
temperature sensor.
98904R
SPECIFICATIONS
99335R Temperature in °C ± 1 Resistance Ω
25 2 610 to 2 990
B Air conditioning diaphragm control solenoid
valve on injection pump (fast idle)
80 310 to 350
C EGR control solenoid valve
13-31
DIESEL EQUIPMENT
PRINCIPLE OF OPERATION FOR GAS PRE-POST- 3. "Post-heating" while the engine is running
HEATING
Post-heating has two phases:
1. "Pre-heating" when the ignition is turned on
a) Fixed post-heating
a) Variable pre-heating
After the engine has been started, the
The time period during which the warning plugs are for for 10 seconds.
light is illuminated and the heater plugs
are fed is dependent on the coolant b) Variable post-heating
temperature.
Variable post-heating begins when fixed
post-heating has ended.
During this phase, the plugs are fed

alternately 1 - 3 and 2 - 4 depending on
the coolant temperature.
DI1304
If the coolant temperature sensor is faulty,

the heater plugs are fed systematically for
14 seconds.
b) Fixed pre-heating
After the pre-heating warning light has

DI1305
extinguished (variable pre-heating), the
plugs remain fed for up to 8 seconds
before the engine is started. If the coolant temperature sensor is faulty,
the heater plugs are fed systematically for
2. Starting 30 seconds.
The plugs remain fed while the starter is Variable post-heating may be
activated. interrupted:
- finally when the coolant temperature
> 65°C,
- momentarily when the unit receives
full load information (post-heating
microswitch opens) for more than 1
second ; post-heating begins again
when the engine returns to idle speed
or low load (microswitch closes).
13-32
DIESEL EQUIPMENT
FAULT FINDING
1. The pre-heating warning light does not operate
TEST SOLUTION
Earth the warning light output of connector (C) using

a 2 A fuse when the ignition is turned on (track B3).
• The fuse blows. The warning light wiring in the instrument panel is in
short circuit. Repair the wiring.
• The warning light does not illuminate. The bulb is blown or the wiring is faulty.
Replace the bulb or repair the wiring.
• The warning light does illuminate. Check:

- + battery on connector (A),
- + after ignition on connector (C),
- battery earth on connector (C).
If the feed is correct, replace the pre-post-heating

unit.
2. The pre-heating warning light only operates for a fraction of a second when the ignition is turned on.
TEST SOLUTION
Disconnect connector (B) and test the pre-heating:
• The warning light illuminates and there is a Check the plugs circuit. If it is correct, check and
voltage at the connector outputs (B). replace the faulty plug(s).
Replace the pre-post-heating unit.

• The warning light illuminates and there is no
voltage at the connector outputs (B).
Check the before ignition feed to the pre-heating

• The pre-heating warning light illuminates for a unit.
fraction of a second only.
13-33
DIESEL EQUIPMENT
FAULT FINDING
3. There is no fast idle when engine is cold (with air conditioning option)
TEST SOLUTION
Run the air conditioning.
• The fast idle operates Check the connections at the pre-post-heating unit
(connector C).
Ensure continuity between track C3 of connector (C)

and track 1 on the solenoid valve.
Replace the pre-post-heating unit (ensure the

warning light operates correctly when the ignition is
turned on).
• The fast idle does not operate. If the fast idle solenoid valve opens the pneumatic
circuit, repair the circuit between the vacuum pump,
the solenoid valve and the diaphragm.
If the solenoid valve does not open the circuit,

measure the voltage between the 2 tracks on the
solenoid valve connector.
• 12 volts
Replace the solenoid valve after testing the
connections.
• 0 volt
Ensure the following continuities :
- between track 2 on the connector and earth,
- between track 1 and track C3 of the pre-post-
heating unit.
13-34
DIESEL EQUIPMENT
FAULT FINDING
4. Engine operation fault (difficulty in starting, idle speed unstable, noise...)
Check:
- the feed to the pre-post-heating unit :
• +before ignition at connector A.
• +after ignition on track B1 of connector C.
• earth on track C2 of connector C.
- at the pump connector, the resistance of the ALFB solenoid valve (between earth and track
A1) : 7Ω ± 0.5,
- the coherence of the temperature reading given by the coolant temperature sensor,
Temperature (°C) 25 80
Resistance (Ω) 2 610 to 2 990 310 to 350
- the adjustment and operation of the post-heating microswitch,
- the coherence of the open or closed status of the altimetric capsule switch according to the altimetric
pressure of the test site (the switch should be closed for a pressure > 925 ± 20 mbars).
If the fault persists carry out a complete re-adjustment of the pump.
13-35
DIESEL EQUIPMENT
Injector holder - heater plug 13
SPECIFICATIONS Position of the flame arresting washer
Injector holder (A)
Injector nose
94952R1
To pre-combustion chamber
Heater plug (B)
Current: 15A after 8 seconds heating

DI1306
Tightening torque : 2 daN.m
1+2 Injector holder assembly.
3 Seal between the injector holder assembly

and the cylinder head.
4 Flame arresting washer.
5 Injector protector.
The injector holder assembly is screwed into the

cylinder head.
In order to remove the injector high pressure

pipes, use wrench B.Vi. 868 . To remove the
injector holder assembly, use the 27 mm long
socket Mot. 997.
The following tightening torques must be

observed:
- lower section (2) on upper section (1) of the
injector holder : 7 ± 1 daN.m,
- injector holder on cylinder head: 7 ± 1 daN.m.
Each time an injector holder is removed, the

copper seal and the flame arresting washer must
be renewed.
13-36
DIESEL EQUIPMENT
Fuel filter 13
LOCATION DIAGRAM
99332R
1 Fuel filter
2 Electric heater
3 Hand priming unit
The electric diesel fuel heater and the thermostat

are integral in the head of the filter.
PRJ99258
Operating temperature
Electrical circuit closes: 0°C

449 Electric heater
Electrical circuit opens: from 8°C 450 Diesel heating relay
597 Engine fuse box
Heater power: 150 W 645 Passenger compartment fuse box
Principle of the electric heater
The heater has heated studs. They are ceramic,

made from barium titanate which has a positive
temperature coefficient, meaning that its
resistance increases as its temperature increases.
13-37
DIESEL EQUIPMENT
Fuel filter 13
REMOVAL - REFITTING (Special notes)
To remove the filter assembly use tool Mot. 1311-

06 for the quick release unions.
When refitting, refit the quick release unions by

hand and ensure they click back together correctly
(two O rings ensure sealing).
99332S
99461R
13-38
DIESEL EQUIPMENT
Coolant temperature sensor 13
LOCATION DIAGRAM
Temperature sensor (1) (black connector)
98904R DI1307
The sensor has two functions SPECIFICATIONS
• Thermistor (tracks 2 and 3) : Thermistor

i.e. a resistance which varies with coolant
temperature. The tracks are connected to the Temperature in °C ± 1 Resistance Ω
pre-post-heating unit.
25 2 610 to 2 990
• Temperature switch (tracks 1 and 4) :
for operating the EGR solenoid valve. 80 310 to 350
Temperature switch
Temperature in °C ± 1 Switch status
30 closed
20 open
13-39
DIESEL EQUIPMENT
Inlet - exhaust manifolds 13
PRJ1302
Tightening torques (in daN.m) Then remove the ten mounting nuts for the
manifolds to release them.
Manifold mounting nuts 2.5
REFITTING
REMOVAL
Vehicle on a lift, battery disconnected, remove:
- the bar between the shock absorber turrets, Renew:
- • the air inlet pipes, - the manifold gasket,
- the two exhaust downpipe gaskets.
• the oil vapour rebreathing pipes,
• the EGR control pipe (if fitted),
- bolt (1) on the inlet manifold.
From under the vehicle:
Remove:
- the engine undertray,
- the exhaust downpipe.
13-40
PUMP
F8Q engine
Brake assistance vacuum pump 13
M.S. 870 Vacuum gauge
Renew the drive dog systematically when

replacing the pump.
CHECKING
Engine warm, at 4 000 rpm, the minimum vacuum

should be 700 mbars (525 mmHg) in 3 seconds.
PRJ1303
13-41
PUMP
Mechanical power assisted steering pump 13
REPLACING THE PULLEY FILLING THE CIRCUIT
REMOVAL Oil grade to be used:

ELF RENAULTMATIC D2
Remove the component by removing the three or MOBILATF 220
bolts.
Capacity : 1.1 litres
Fill the reservoir to the top.
Move the steering wheel gently in both

directions.
Top up the level.
Start the engine and move the steering wheel

gently from full lock to full lock.
Top up the level.
98829R
REFITTING
91662-1S
The oil should be visible to the level of the

MAXIMUM line.
13-42
PUMP
E and K engines
without AC Mechanical power assisted steering pump 13
REMOVAL
Slacken the tensioner nut and lock nut assembly

(A).
Release the two upper mounting bolts (B) and (C)

for the pump.
96047-1R
REFITTING
Insert bolt (B).
Refit :
96047R - the pump,
- the belt,
Remove bolt (D) using a half moon polygon - the supply and high pressure pipes.
wrench.
Remove clamp Mot. 453-01.
Remove the belt.
Adjust the belt tension (see section "Adjustment
Fit clamp Mot. 453-01 to the supply pipe. values").
Disconnect the supply and high pressure pipes. Fill and bleed the circuit by moving the steering
wheel gently from lock to lock.
Remove the upper pump mounting bolt (C).
Remove the pump.
13-43
PUMP
F8Q engine
with AC Mechanical power assisted steering pump 13
REMOVAL - the supply pipe and the high pressure pipe,

- the three pump mounting bolts.
Remove the belt (see corresponding section).
Fit clamp Mot. 453-01 to the supply pipe.
Remove:
- the pulley (three bolts),
99174-1R 99170R
- the wiring mounting and the high pressure Remove the pump.
pipe by removing bolt (2),
REFITTING
99171R
13-44
PUMP
F3R engine
with AC Mechanical power assisted steering pump 13
REMOVAL - the three pump mounting bolts.
Remove the belt (see corresponding section).
Fit clamp Mot. 453-01 to the supply pipe.
Remove:
- the pulley (three bolts),
99502R
Remove the pump.
REFITTING
99502-1R1

- the wiring mounting,
- the supply pipe and the high pressure pipe,
99058S
13-45
PUMP
Mechanical power assisted steering pump 13
CHECKING THE OIL PRESSURE

Dir. 1204 Pressure test union
Dir. 803 Metric thread union
Fre. 1085
or Pressure gauge
Fre. 244-03
Fre. 284-06 Connecting pipe
Fit clamp Mot. 453-01 to the low pressure pump Connect pressure gauge Fre. 1085 (or Fre. 244-03
hose. + Fre. 284-06).
Disconnect the high pressure pipe (take Remove clamp Mot. 453-01.
precautions to catch the oil which will run out).
Top up the pump level and run the engine to
Insert union Dir. 803 (metric thread) between the check the pressure.
pipe and the pump.
For engines where it is fitted, remove the Wheels in straight line:

pressostat on the rigid pipe (high pressure).
Regardless of engine speed, the pressure should
Connect the pressure test union not exceed 5 to 7 bars.
Dir. 1204 and the oil pressure gauge
Fre. 1085 (or Fre. 244-03 + Fre. 284-06).
Full lock to one side:
Hold the steering at full lock, the maximum

pressure should be 79 to 86 bars.
This operation should not be prolonged to avoid a

high increase in the oil temperature.
Remove union Dir. 803 and pressure gauge

Fre. 1085 or Fre. 244-03 , cutting the supply to the
pump with clamp Mot. 453-01.
Reconnect the high pressure pipe and remove

clamp Mot. 453-01.
Top up the oil in the reservoir.
77840R1
13-46
ANTIPOLLUTION
E7J engine
Fuel vapour recirculation 14
CIRCUIT OPERATIONAL DIAGRAM
98170R
1 Throttle body
2 Canister bleed solenoid valve
3 Canister
A Pipe from fuel tank for recirculation of fuel vapour

B Breather
C Take-off downstream of throttle
14-1
ANTIPOLLUTION
K7M engine
99232R
1 Inlet manifold
2 Canister
3 RCO control solenoid valve
4 Fuel vapour recirculation pipe
5 Oil vapour rebreathing pipe
6 T piece connecting the oil vapour rebreathing pipe (5) and fuel vapour recirculation pipe (4)
7 Oil vapour rebreathing and fuel vapour recirculation pipe
R Pipe from fuel tank

MA Breather opening
14-2
ANTIPOLLUTION
F3R engine
99230R
1 Inlet manifold
2 Canister
3 RCO control solenoid valve
R Pipe from fuel tank

MA Breather opening
14-3
ANTIPOLLUTION
OPERATING PRINCIPLE CONDITIONS FOR CANISTER BLEEDING
The fuel tank is connected to the outside through During richness regulation
the canister.
Coolant temperature greater than:
Fuel vapour is retained by the active carbon in the - + 55°C (F3R engine),
canister. - + 15°C (K7M engine),
- + 70°C (E7J engine).
So that the fuel vapour contained in the canister
does not evaporate into the atmosphere when Air temperature greater than:
the fuel tank is opened, a valve isolates the canis- - - 10°C (F3R engine),
ter from the fuel tank when the fuel filler cap is - + 10°C (K7M engine),
removed. - + 20°C (E7J engine).
The fuel vapour contained in the canister is elimi- No load position not recognised (if the throttle
nated and burnt by the engine. position sensor is faulty, the non-recognition of
the no load condition is replaced by an engine
To do this, a pipe connects the canister and the in- speed condition
let manifold. A solenoid valve is located on this engine speed R > 1500 rpm.).
pipe to control bleeding of the canister.
Outside richness regulation
The operating principle for the solenoid valve is to
give a variable passage diameter (depending on No load position not recognised.
an RCO signal from the injection computer). Coolant temperature less than +15°C for F3R and
K7M engines (no condition for E7J engine).
The variation in the selection of passage diameter
for the fuel vapour in the solenoid valve results If the oxygen sensor is faulty, the canister is bled
from the balance between a magnetic field crea- when there is no no load.
ted by the feed to the coil and the force of a re-
turn spring ensuring the valve remains closed. The cyclical opening ratio for the canister bleed
solenoid valve may be seen using the XR25 and
#23. The solenoid valve is closed for #23 = 0.7 %
(minimum value) except for E7J engines (no #23).
14-4
ANTIPOLLUTION
LOCATION - REMOVAL E7J engine
CANISTER BLEED SOLENOID VALVE The valve is mounted on the inlet manifold.
F3R engine
The valve is mounted at the front right on the

same mounting as the computer.
99782S
99218S
K7M engine
The valve is mounted on the inlet manifold.
99361S
14-5
ANTIPOLLUTION
CANISTER Remove the canister.
This is located at the front of the vehicle.
REMOVAL
Remove the computer mounting.
Disconnect:
- the pipe (1) connected to the fuel tank (use
clamp Mot. 1265),
- the pipe (2) connected to the solenoid valve.
99220R
99219R
From under the vehicle:
Remove the two mounting bolts for the canister

(pass the wrench between the mudguard skirt and
the bumper).
14-6
ANTIPOLLUTION
CANISTER - FUEL TANK CONNECTION The sealing valve isolates the canister when the
fuel filler cap is removed.
The canister is connected to the fuel tank filler
neck by a quick release union. When the fuel filler cap is in position, the valve is
open and the fuel vapour may be absorbed by the
canister.
99216R
In the filler neck, a separate circuit connects the

quick release union to the sealing valve.
99212R1
14-7
ANTIPOLLUTION
CHECKING THE OPERATION OF THE CANISTER At idle speed, check by connecting a pressure
BLEED VALVE gauge (- 3 ; +3 bars) (Mot. 1311-01) to the "CAN"
outlet on the solenoid valve, that there is no
A malfunction in the system could cause the idle vacuum (in the same manner, check the command
speed to be unstable or the engine to stall. value read by the XR25 using #23 remains at a
minimum X = 0.7 % for F3R and K7M engines). Is
Check the circuit conforms (see diagrams). there a vacuum ?
Take care to check that the pipe marked "CAN" YES Ignition off, use a vacuum pump to apply a
on the solenoid valve is connected to the canister. vacuum of 500 mbars to the solenoid valve
at (C). The vacuum should not vary by more
Check the condition of the pipes up to the fuel than 10 mbars in 30 seconds.
tank. Does the pressure vary?
YES The solenoid valve is faulty, renew

it. Air must also be blown into the
pipe connecting the solenoid valve
to the canister to eliminate any
particles of active carbon.
NO There is an electrical fault - check

the circuit.
NO Under bleeding conditions (engine not at

idle speed, engine warm), there should be
an increase in the vacuum (at the same
time, the value for #23 on the XR25 should
increase for F3R and K7M engines).
The fuel tank breather pipe can also be checked.

After removing the filler cap, use a vacuum pump
to apply a vacuum to the pipe at (B). If a vacuum
can be applied to the pipe this shows that the
overfilling valve is correctly sealed.
97393R4 As soon as the filler cap is replaced, however, the

vacuum should disappear quickly as the pipe is no
longer blocked and the internal degassing
1 Inlet manifold chambers in the fuel tank are connected.
2 Canister bleed solenoid valve
3 Canister
4 Fuel tank
14-8
ANTIPOLLUTION
E7J engine
Oil vapour rebreathing 14
PRESENTATION OF THE CIRCUIT
94563R3
Upstream rebreathing circuit
1 Take-off on air filter

2 Filter - nozzle connecting pipe
3 6 mm diameter nozzle
Downstream rebreathing circuit
4 1.5 mm diameter nozzle

5 Restriction to T union connecting pipe
6 T union
7 Take-off on inlet manifold
8 To canister bleed
CHECKING
To guarantee correct operation of the

antipollution system, the oil vapour rebreathing
circuit should be kept clean and in good
condition.
Check the nozzles are present and correct.
14-9
ANTIPOLLUTION
K7M engine
99231R
1 Cylinder head
2 Manifold
3 Oil vapour rebreathing pipe connected upstream of the throttle body (the circuit is used for average and
high loads)
4 Oil vapour rebreathing pipe connected downstream of the throttle body
6 T piece connecting the oil vapour rebreathing pipe (4) and fuel vapour recirculation pipe (5)
7 Oil vapour rebreathing pipe and fuel vapour recirculation pipe
8 Air duct
9 5 mm diameter nozzle
CHECKING
To guarantee correct operation of the antipollution system, the oil vapour rebreathing circuit should be kept
clean and in good condition.
Check the nozzle is present and correct.
14-10
ANTIPOLLUTION
F3R engine
DI1407-1
1 Inlet manifold
2 Throttle body
3 Oil vapour rebreathing pipe (connected to throttle body)
4 Oil decanter
5 Oil vapour rebreathing pipe from the engine to the decanter
The restrictions upstream and downstream of the oil vapour rebreathing system are moulded into the
throttle body.
CHECKING
To guarantee correct operation of the antipollution system, the oil vapour rebreathing circuit should be kept
clean and in good condition.
14-11
ANTIPOLLUTION
F8Q engine
DI1410
1 Oil vapour decanter
To guarantee correct operation of the antipollution system, the oil vapour rebreathing circuit should be
kept clean and in good condition.
The oil vapour rebreathing pipes have no restrictions.
14-12
ANTIPOLLUTION
K7M engine
Exhaust gas recirculation (EGR) 14
This system is only fitted to the K7M 703 engine.
99377R
1 Cylinder head A Exhaust gas to EGR solenoid valve

2 EGR solenoid valve (operated by an RCO B Exhaust gas circulation to inlet manifold
signal)
3 Mounting for EGR solenoid valve
4 Vacuum reservoir
5 Filter unit
6 Inlet manifold
7 Exhaust manifold
14-13
ANTIPOLLUTION
K7M engine
TIGHTENING TORQUES (in daN.m) Remove the two mounting bolts for the EGR
solenoid valve, then remove the valve.
Mounting bolt for EGR solenoid valve 2.2
EGR solenoid valve bolt 1
Steel pipe bolts for EGR solenoid valve 1
REMOVING THE EGR SOLENOID VALVE
Disconnect:
- the air temperature sensor connector (1),
- the oil vapour rebreathing pipe (2).
Slacken the two clips (3) mounting the air duct (4)
and remove it.
Disconnect the accelerator cable (8).
99358R1
REFITTING THE EGR SOLENOID VALVE
Renew the seal.
SPECIAL NOTES
To remove the two steel pipes connecting the EGR

solenoid valve mounting to the exhaust manifold
and the inlet manifold, unclip the two clips (9) on
either side of each pipe.
99359R2
From the solenoid valve, disconnect:

- the vacuum pipe (5),
- the electrical connector (6).
14-14
ANTIPOLLUTION
K7M engine
PURPOSE OF THE EGR SYSTEM
Recirculation of exhaust gas, or EGR, is used to

reduce the nitrous oxide (NOx) content of exhaust
gas.
The formation of nitrous oxide takes place at very

high temperatures in the engine combustion
chambers when driving under heavy loads.
By reducing the temperature of the combustion

chambers, the amount of nitrous oxide produced
is reduced. The simplest means of reducing the
combustion chamber temperature is to introduce
inert gas into the chamber.
Exhaust gas is made up of used inert gasses, so it is

recirculated into the inlet manifold in the correct
amount at the right time.
SOLENOID VALVE OPERATING PRINCIPLE DI1408-1
The EGR solenoid valve is operated by an RCO

signal from the injection computer. The RCO
signal modulates the opening in the solenoid
valve and this permits more or less exhaust gas to
be channelled to the inlet manifold.
Depending on this signal, the solenoid valve

applies to diaphragm (A) a quantified amount of
the manifold vacuum. Diaphragm (A) moves and
pulls valve (B) which permits the passage of
exhaust gas (by vacuum) to the inlet manifold.
14-15
ANTIPOLLUTION
K7M engine
OPERATING CONDITIONS FOR THE EGR SOLENOID CHECKING THE SEALING AND OPERATION OF THE
VALVE EGR SOLENOID VALVE
The EGR system is operational if the following After the cooling fan has operated at least once,
conditions are met: stop the engine and turn the ignition off.
• coolant temperature greater than 20°C, Disconnect the electrical connector.
• air temperature greater than 5°C, Supply a 12 V feed directly to the solenoid valve.
• no load position not recognised and throttle Disconnect the pipe (D) connected to the vacuum
position less than a set threshold, dependent reservoir from the solenoid valve. In its place
on engine speed (at 1024 rpm the throttle connect a vacuum pump.
position must be greater than 59 seen
using # 17 ; Create a vacuum of 300 mbars. The pressure
at 5120 rpm the throttle position must be should not drop by more than 2 mbars per second
greater than 103 seen using # 17), (120 mbars per minute).
• manifold vacuum greater than a certain Eliminate the vacuum to return the solenoid valve
threshold. to atmospheric pressure.
The EGR solenoid valve is not operated if a fault is Run the engine at idle speed.
detected with the :
- air temperature sensor, Create a vacuum of 300 mbars again, the engine
- manifold pressure sensor, should run at idle speed, but unsteadily. If this is
- throttle potentiometer, not the case, replace the solenoid valve assembly.
- EGR system.
Erase the computer memory after the operation.
A status bargraph on the XR25 visualises
operation of the EGR solenoid valve by the
computer.
It is however better to carry out a road test to

show this status. A test with the vehicle stationary,
engine operating under low loads is not
sufficient.
A faulty component in the EGR system will cause

an obvious worsening of the exhaust gas values.
14-16
ANTIPOLLUTION
K7M engine
CLEANING THE EGR SOLENOID VALVE (if there is a This ensures that any possible impurities are
fault) removed the way they entered the valve.
In certain cases, a deviation in the nitrous oxide IMPORTANT: do not blow compressed air on the
value at the exhaust may be noted due to the fact EGR solenoid valve diaphragm.
that the EGR solenoid valve has become
contaminated. If this is noted, we recommend Refit the pipes to the solenoid.
that at approximately 50000 miles( 80 000 km),
the EGR solenoid valve is cleaned to ensure correct Renew:
depollution. - the O ring on union (C),
- the filter unit.
Remove as much contamination from the EGR
solenoid valve as possible then blow out with Refit the solenoid to the valve.
compressed air.
Remove the two mounting bolts securing the

solenoid to the valve. Remove the solenoid
(ensure that no impurities enter the EGR valve
diaphragm area).
99374R
Remove all the pipes from the solenoid.

DI1409-1
With no electrical feed, blow compressed air in
through union (C).
With 12 V feed, blow compressed air in through

union (B).
14-17
ANTIPOLLUTION
F8Q engine
Depollution for this engine uses recirculation to the inlet of some of the exhaust
gasses.
Recirculation of the exhaust gas reduces the combustion temperatures to reduce the
formation of nitrous oxides (NOx).
Recirculation is only permitted under certain load and temperature conditions.
99259R
1 Inlet manifold
2 Exhaust manifold
3 EGR valve
4 Air filter
5 EGR solenoid
6 Microswitch (on injection pump)
7 Vacuum pump
8 Injection pump load lever
9 Brake servo
14-18
ANTIPOLLUTION
Diesel engine
Catalytic converter 14
To meet the requirements of the EURO 96
standard, this vehicle is fitted with an oxidation
catalytic converter.
ROLE
The converter deals with the following three

pollutants at the same time:
- hydrocarbons (HC),
- carbon monoxide (CO),
- particulates, by a chemical oxidation reaction.
99781R
FUEL
No specific fuel is required for correct operation.

CHECKING THE CATALYTIC CONVERTER
CONSTITUTION The performance of the catalytic converter on the

exhaust gas is difficult to check. The maximum
The converter comprises: temperature of the exhaust gas from a diesel
engine is not sufficient to melt the monolith (in
- a monolith (1) in a honeycomb ceramic. A comparison to petrol engines).
substance containing precious metals is
deposited on the walls of the honeycomb
(mainly platinum),
- a metal jacket (2) retaining the monolith in its

shell,
- a shell (3) with inlet and outlet cones,

optimising the distribution of exhaust gas
flow.
14-19
ANTIPOLLUTION
Diesel engine
FAULT FINDING
Faults which may cause a customer complaint due

to the catalytic converter.
1. Catalytic converter polluted by an

accumulation of soot, causing poor efficiency
of the converter.
Cause :
- prolonged town driving,
- air filter dirty,
- poor operation of the EGR system
- injection pump fault, etc.
Customer complaint:
- lack of power,
- large amount of smoke.
Solution:
De-contamination of the exhaust pipe by hard
driving on open roads.
2. Loss of efficiency due to premature aging of

the monolith*
Cause :
- injection incorrectly set,
- oil vapour rebreathing fault, etc.
Customer complaint:
Abnormal engine operation.
Solution:
Replace the catalytic converter.
(*) By prolonged operation at exhaust gas

temperatures which are too high (greater
than 800°C).
14-20
ANTIPOLLUTION
Petrol engine
Catalytic converter - oxygen sensor 14
CHECKS TO BE MADE BEFORE THE ANTI- CHECKING ANTI-POLLUTION STANDARDS
POLLUTION TEST
Run the engine until the engine cooling fan has
Ensure: operated twice.
- the ignition system is operating correctly
(correct spark plugs, correctly set plug gap, Connect a correctly calibrated four gas analyser to
high voltage leads in good condition and the exhaust tail pipe.
correctly connected).
Keep the engine speed at 2500 rpm for
- the injection system is operating correctly approximately 30 seconds then let the engine
(supply is correct - check using the XR25). return to idle speed and note the pollutant values.
- the exhaust pipe is correct and is sealed. CO ≤ 0.3 %

CO 2 ≥ 14.5 %
- the EGR is operating correctly. HC ≤ 100 ppm
0,97 ≤ λ ≤ 1.03
Check the vehicle history if possible (run out of
fuel, lack of power, use of incorrect fuel). 1
NOTE : λ = ————
richness
λ > 1 → lean mixture

λ < 1 → rich mixture
If, after these tests, the values are correct, the

antipollution system is correct.
If the values are not correct, additional tests must

be carried out:
- Check the condition of the engine (condition

of the oil, valve clearances, timing, etc,...),
- Check the correct operation of the oxygen

sensor (see section 17) ,
- test for the presence of lead (see following

page).
If the test for the presence of lead is positive, en-

sure the vehicle uses two or three full tanks of un-
leaded fuel before replacing the oxygen sensor.
If, after all these tests have been carried out, the
values still do not conform, the catalytic converter
must be replaced.
14-21
ANTIPOLLUTION
Petrol engine
Test for the presence of lead 14
This test is only possible using the Nauder lead test kit.
To obtain a test kit, contact your After Sales Head Office.
Part numbers: - For the complete kit: T900

- For a set of 40 test papers : T 900/1
93703S
METHOD
Detecting lead at the exhaust
a - Conditions for the test:
- Engine not running

- Exhaust pipe warm but not burning.
- Do not perform the test if the temperature is below 0 °C.
b - If necessary, use a dry cloth to clean the inside of the exhaust pipe to remove soot deposits.
c - Wearing the gloves, moisten a test paper slightly with distilled water (if the paper becomes too wet, it
will lose its efficiency).
d - Apply the moistened test paper to the cleaned section of the exhaust pipe and hold it there with
slight pressure for approximately one minute.
e - Remove the test paper and leave it to dry. If lead is present, the paper will be a red or pinkish colour.
ATTENTION : The test for lead should be carried out on the exhaust tail pipe. It should never be carried out
on the oxygen sensor.
14-22
STARTING - CHARGING
Alternator 16
IDENTIFICATION
ENGINE ALTERNATOR CURRENT
F3R Valéo A 11 VI - 59 75 A
F8Q Valéo A 13 VI 45 110 A
F3R CA
Valéo A 13 VI - 57 110 A
F8Q CA
Valéo A 11 VI - 61 75 A
K7M
Valéo A 13 VI 105 110 A
E7J Valéo A 13 VI 104 80 A

110 A
Valéo A 13 VI 105
CHECKING
After 15 minutes warming up with a voltage of 13.5 volts.
engine rpm 75 apms 80 apms 110 apms
1000 46 54 57
2000 68 75 94
3000 71 80 105
4000 72 82 108
16-1
STARTING - CHARGING
Alternator 16
OPERATION - FAULT FINDING The customer complains of a charging fault and
the warning light operates correctly.
These vehicles are fitted with alternators with in-
ternal ventilation, an integral regulator and a If the regulated voltage is less than 13.5 V, check
warning light on the instrument panel which ope- the alternator. The fault could be caused by:
rates as follows :
- a destroyed diode,
- when the ignition is turned on, the warning
light illuminates, - a cut phase,
- when the engine starts, the warning light ex- - track contamination or wear.
tinguishes,
Checking the voltage
- if the warning light illuminates again when
the engine is running, there is a "charging" Connect a voltmeter across the battery terminals
fault. and read the battery voltage.
Start the engine and increase the engine speed

LOOKING FOR FAULTS until the voltmeter needle stabilises at the
regulated voltage.
The warning light does not illuminate when the
ignition is turned on. This voltage should be between 13.5 V and 14.8 V.
Check: Connect as many consumers as possible, the

- the electrical connections are correct, regulated voltage should remains between 13.5 V
- the bulb is not blown (to do this, earth the cir- and 14.8 V.
cuit; the bulb should illuminate).
IMPORTANT: if arc welding is carried out on the
The warning light illuminates when the engine is vehicle, the battery and the regulator must be
running disconnected.
There is a charging fault which could be due to:
- the alternator drive belt being broken or the

charging cable being cut,
- internal damage to the alternator (rotor, sta-

tor, diodes or brushes),
- regulator fault,
- an excess voltage.
16-2
STARTING - CHARGING
E 7 J and
K 7 M engines
Alternator 16
Mot. 1273 Tool for testing belt tension

T. Av. 476 Ball joint extractor
TIGHTENING TORQUES (in daN.m) - the alternator drive belt, together with bolt (3)
and shaft (4), removing through opening (5),
Upper shock absorber mounting bolt 3
Wheel bolts 9
REMOVAL
With the vehicle on a 2 post lift, disconnect:
- the battery,
- the alternator electrical connections.
Remove:
- the power assisted steering belt by slackening
the three bolts (1) and the nuts (2) for the ten-
sioner,
98745R2

- the track rod end (6) using tool T. Av. 476,
98747R1
98712R
16-3
STARTING - CHARGING
E 7 J and
K 7 M engines
Alternator 16
- the two upper shock absorber mounting bolts
(7).
98709R1
Press downwards on the front axle assembly to

make removing the alternator easier through the
front right hand wheel arch.
REMOVAL
Special notes:
- do not refit the old drive belt, renew it,
- refer to section 07 for tension values.
16-4
STARTING - CHARGING
F 3 R engine
Alternator 16
REMOVAL
(there are no special notes for engines fitted with
power assisted steering)
To release the alternator shaft the following must

be removed:
- the mounting bolts (1) for the coils,
- the two bolts (2) from the coil mounting.
Slacken bolt (3) then slide the mounting down.
98899R1
REFITTING
16-5
STARTING - CHARGING
F 8 Q engine
with AC
Alternator 16
REMOVAL
Remove:
Disconnect:
- the battery, - the lower timing cover,
- the alternator electrical connections. - the belt,
- the alternator mounting bolts,
Remove the mounting bolt for the diesel fuel pipe - the alternator.
retaining bracket and move it to one side.
REFITTING (Special note)

The belt is tensioned by moving the automatic
tensioner plate against the stop at bolt (B), wi-
thout forcing it, using a 9 mm wrench (Eg. :
FACOM J 151 ratchet ).
98837R
Slacken bolt (A) then bolt (B), to just past the

shoulder, while holding the automatic tensioner
plate with a 9 mm wrench (Eg. : FACOM J 151 rat-
chet), then slacken the belt by moving the ratchet
in the direction of the arrow.
98837-1R1
NOTE : do not refit a belt once it has been remo-

ved.
98837-1R
16-6
STARTING - CHARGING
Alternator 16
FAULT FINDING
OPTIMA 5800 diagnostic station
CHECKING THE CHARGING CIRCUIT USING THE DIAGNOSTIC STATION
The OPTIMA 5800 diagnostic station is used to test the alternator by measuring the voltage and current flow,
with and without electrical consumers.
NOTE : the ampermetric clamp on the station is of the inductive type (measuring range : 0 to 1000 A). It may
be positioned without disconnecting the battery, which allows computers to retain their memory and set-
tings.
Depending on the engine, the ampermetric clamp may be positioned in different locations (the diagnostic
station will detect incorrect positioning) :
- F3R, F8Q engines : directly at the alternator output, the arrow on the clamp pointing towards the alterna-
tor.
- E7J, K7M engines : on the cable connecting the positive battery terminal to the alternator (this cable
crosses the battery compartment partition).
Measurements are made in three stages:

- measurement of battery voltage, ignition off,
- measurement with no consumers of the regulated voltage and current flow,
- measurement with the maximum number of consumers of the regulated voltage and current flow.
At the end of the test, the values noted will form the basis of a diagnostic report message:
- Battery voltage no load < 12.3 V = battery discharged.
Without consumers:
- Regulated voltage > 14.8 V = > regulator faulty,
- (Regulated voltage no load < 13.2 V) or (charging current < 2 A = > charging fault).
With consumers:
- Regulated voltage > 14.8 V = > regulator faulty,
- Regulated voltage < 12.7 V = > check the alternator flow with reference to its specifications:
Engine E7J K7M F3R F8Q
Without air conditioning 75 (45) 75 (50) 75 (50) 75 (50)
With air conditioning / 110 (80) 110 (80) 110 (80)
Notes for the table: - Current values in Amps.

- The value in brackets corresponds to the minimum flow which should be
supplied by the alternator when all consumers are connected.
16-7
STARTING - CHARGING
Alternator 16
FAULT FINDING (cont)
If the measured flow is too low, check:
- if the alternator is worn (brushes....),

- the battery connections,
- the engine earth strap,
- the conformity of the alternator,
- the belt tension.
If the flow measured is correct and the regulated voltage is too low, the alternator is not at fault.
The fault is caused by :
- the vehicle having too many consumers or,

- the battery being discharged.
16-8
STARTING - CHARGING
Starter motor 16
VEHICLE ENGINE STARTER
VALÉO D 6 R A 133
BA0E E7J
MITSUBICHI M 002 T 48381
BA0F - BA0L K7M VALÉO D 6 R A 133
VALÉO D 6 R A 133
BA0G F3R
BOSCH 0001107047
BOSCH 000 1110114

BA0G - BA0A F8Q
BOSCH B 001115006
REMOVAL
Engine Location of dowel
There are no special notes for removing and refit-
E7J/K7M Y
ting the starter.
F3R Z
Check the centring dowel (B) is present, which F8Q
should be located in the position shown on the ta-
ble.
86070R1
16-9
STARTING - CHARGING
Starter motor 16
FAULT FINDING
OPTIMA 5800 diagnostic station
CHECKING THE STARTER USING THE DIAGNOSTIC STATION
The starter may be tested using the OPTIMA 5800 diagnostic station, by measuring the battery voltage and
the current used during the starting phase. The following operating faults may be detected:
- battery fault (voltage drops when the starter is activated),

- starter jammed (the current used is too high),
- starter fault (the current used is too low).
To carry out the test the vehicle must be prevented from starting:
- E7J, K7M engines : disconnect the engine speed sensor (on the clutch bellhousing),
- F3R engines : disconnect the engine speed sensor (on the gearbox),
- F8Q engines : disconnect the fuel shut off on the pump and insulate the terminal.
NOTE :
- an open circuit on the engine speed sensor or the ignition creates a fault which is memorised in the injec-
tion computer. Erase this fault using the XR25 (see injection section),
- if the vehicle is fitted with an immobiliser, just lock the doors using the PLIP.
16-10
IGNITION
E7J engine
Power module 17
The injection computer incorporates the ignition
advance calculation function and sends a control
signal (5 V) to the ignition power module.
97351R
3 track connector
A + after ignition
B Ignition power module earth
C Not used
2 track connector
A Not used
B Control signal
17-1
IGNITION
F3R - K7M
engines Static ignition 17
The differences between static ignition with two They have a foolproofing device (K7M engine):
coils and distributed ignition are:
- on their base to prevent them being fitted in-
- the high voltage distributor is no longer used, correctly to the rocker box cover,
- two dual output coils are used. - at the retaining clips for the high voltage
leads.
PRESENTATION They are colour coded on the 3 track electrical

connectors.
The system comprises:
Coil (2) has a black electrical connector. This coil
- the injection computer (the ignition power provides the sparks for cylinders 1 and 4 at the
stage is integrated into the computer), same time. It is controlled by track 28 on the injec-
- two dual output coils, tion computer.
- four spark plugs,
- an anti-interference condenser. Coil (3) has a grey electrical connector. This coil
provides the sparks for cylinders 2 and 3 at the
same time. It is controlled by track 29 on the injec-
DESCRIPTION - OPERATING PRINCIPLE tion computer.
COMPUTER Both coils are connected to an anti-interference

condenser (1).
The injection computer (120), depending on the
information received from various sensors, but
principally depending on the engine speed and
load, determines: F3R engine
- the number of degrees of advance to be used

and consequently the ignition point,
- which cylinders are at TDC and consequently

the ignition coil to be operated.
The spark is created at the two cylinders at TDC by

cutting the earth to the coil concerned.
COILS
There are two coils. They are of the dual output

type.
98900-1R
They are controlled separately by the computer.
They create two sparks at the same time.
17-2
IGNITION
F3R - K7M
K7M engine DIAGRAM
99365R
Electrical connector
Track Allocation
+anti-interference
1
condenser
2 +after ignition
3 coil control via computer
Coil connector track identification
Inscription on connector + -
PRJ99029
Connector
Track number 1 2 3 KEY TO COMPONENTS

597 Engine fuse box
Resistance 663 Dual output ignition coil for cylinders
Test to be made 1 and 4
between tracks 664 Dual output ignition coil for cylinders
K7M engine F3R engine 2 and 3
679 Anti-interference condenser, connected to
1 - 2 0.5 Ω 0.2 Ω coil:
1 - 3 1Ω 1Ω - 664 for F3R engines
- 663 for K7M engines (dotted line)
2 - 3 1Ω 1Ω
HT - HT 10 kΩ 8 kΩ
17-3
IGNITION
F3R - K7M
SPECIAL NOTES FOR THE FLYWHEEL NOTE : advance correction depending on the si-
gnal from the pinking sensor is dealt with in sec-
Description tion 17 Injection.
The flywheel has 60 regularly spaced teeth. Two Cylinder 1 is at the flywheel end.
teeth have been removed to create a fixed marker
gap at 84° or 14 teeth before TDC for cylinders 1
and 4. There are therefore in fact only 58 teeth.
86065-3R
Cylinders 1 and 4 are at TDC when the arrow (A)

passes in front of the engine speed sensor (169).
Cylinders 2 and 3 are at TDC when the arrow (B)

passes in front of the engine speed sensor (169).
Operating principle
The computer knows that TDC for cylinders 1 and

4 is located on the rising edge of the 15th tooth
after the fixed gap. Consequently, depending on
the amount of advance to be used, the computer
knows exactly where to locate the ignition point
by counting the number of teeth.
TDC for cylinders 2 and 3 is located on the rising

edge of the 45th tooth after the fixed gap.
17-4
IGNITION
E7J - K7M -F3R
engines Spark plugs 17
Engine Make Type
EYQUEM FC 52 LS
E7J
NGK BCP 5ES
EYQUEM FC 52 LS
K7M
CHAMPION C10YC
EYQUEM C 52 LS
F3R CHAMPION N7Y CX
BOSCH W7DCO
Flat base with seal
Gap 0.9 mm
Tightening torque 2.5 to 3 daN.m
17-5
INJECTION
E7J engine
General 17
SPECIAL NOTES FOR BOSCH MONOPOINT INJECTION
• Use the XR25 with the latest cassette and fiche n° 28.
Read the computer Part Number using code G70*.
Erase the memory using code G0**.
• Injection warning light operational (see principle of ignition section).
• Maximum engine speed before ignition cut-out: 6 500 rpm.
• Corrected idle speed after operation of the air conditioning: 900 rpm.
• Corrected idle speed with wheels at full lock (power assisted steering pressostat information) : 825 rpm.
• Canister bleed solenoid valve controlled by RCO signal depending on engine operating conditions (the
valve is not operated for no load).
• If there is a fault with the absolute pressure sensor, the manifold pressure is recreated depending on the
throttle position and the engine speed.
• Reading of the default values from the air temperature sensor (#03) or coolant temperature sensor (#02),
not the values taken in defect mode by the computer when they are recognised as being faulty.
• There is a+after ignition input (track 30) to inform the computer that the ignition has been turned off
while it remains fed for a few seconds to reposition the idle speed micromotor.
(Avoids false detection of a fault in the engine immobiliser system).
FITTING A 2ND GENERATION ENGINE IMMOBILISER REQUIRES A SPECIAL PROCEDURE FOR REPLACING THE
COMPUTER.
17-6
INJECTION
E7J engine
General 17
LOCATION OF COMPONENTS
2 Coolant temperature sensor (white connector)
3 TDC sensor
4 Fuel vapour recirculation solenoid valve
5 Ignition power module
6 Idle speed regulation micromotor
7 Throttle position potentiometer
8 Absolute pressure sensor
NOTES:
• the injector and the air temperature sensor are integral in the upper section of the throttle body (see sec-
tion 12),
• the pinking sensor is located under the inlet manifold,
• the diagnostic socket is located in the passenger compartment connection unit.
17-7
INJECTION
K7M engine
General 17
SPECIAL NOTES FOR MULTIPOINT INJECTION
• 55 track SIEMENS FENIX 5 computer.
• Semi-sequential multipoint injection. Injectors controlled in pairs (injectors for cylinders 1 and 4 then
injectors for cylinders 2 and 3).
• Static ignition with two coils.
• Canister bleed solenoid controlled by RCO signal.
• EGR solenoid valve controlled by RCO signal (K7M 703).
• Idle speed correction depending on:

- air conditioning,
- heated windscreen,
- power assisted steering pressostat.
• Injection warning light on instrument panel operational.
• Use fault finding fiche N° 27.
COMPUTER.
17-8
INJECTION
K7M engine
General 17
2 Pinking sensor
3 Coolant temperature sensor
4 TDC sensor
7 Idle speed regulation stepping motor
11 Canister
12 Coil for cylinders 1 - 4
14 Fuel pump relay
15 Anti-interference condenser
16 Air filter
17 Oxygen sensor
18 Power assisted steering pressostat
20 Vacuum reservoir
21 EGR air filter
17-9
INJECTION
F3R engine
General 17
SPECIAL NOTES FOR MULTIPOINT INJECTION
• 55 track SIEMENS FENIX 5 computer.
• Injection cylinder by cylinder (sequential).
• Static ignition with two coils.
• Canister bleed solenoid controlled by RCO signal.
• Idle speed correction depending on:

- battery voltage,
- air conditioning,
- heated windscreen.
• Injection warning light on instrument panel operational.
• Use fault finding fiche N° 27.
• Computer configuration depending on gearbox type (manual gearbox or automatic transmission).
COMPUTER.
17-10
INJECTION
F3R engine
General 17
2 Pinking sensor
4 TDC sensor
6 Cylinder reference sensor
7 Idle speed regulation solenoid valve
11 Canister
14 Fuel pump relay
16 Air filter
17 Oxygen sensor
17-11
INJECTION
K7M engine
Location of components 17
1 Injection computer 3 Coolant temperature sensor
99364R 99360R
2 Pinking sensor
(tightening torque: 2.5 daN.m) 4 TDC sensor
99460-1R 99368R
17-12
INJECTION
K7M engine
5 Fuel vapour recirculation solenoid valve 12 Coil for cylinders 1-4
13 Coil for cylinders 2-3
99365R1
99361R

9 Air temperature sensor 17 Oxygen sensor
10 Absolute pressure sensor (tightening torque: 4.5 daN.m)
99359R3 99355-1R
17-13
INJECTION
K7M engine
99362R
99358-2R
17-14
INJECTION
F3R engine
1 Injection computer 3 Coolant temperature sensor (clipped)
5 Fuel vapour recirculation solenoid valve 6 Cylinder reference sensor (see removal in
sub-section "Special notes for sequential in-
jection")
8 Throttle position potentiometer (non-
adjustable)
9 Air temperature sensor (clipped)
99218-1R
99238R2
2 Pinking sensor
(tightening torque : 2.5 daN.m)
13 Coil for cylinders 2 - 3 4 TDC sensor
98900-1R1 99221R
17-15
INJECTION
F3R engine
17 Oxygen sensor
(tightening torque: 4.5 daN.m)
99224R
17-16
INJECTION
K7M engine
Special notes on semi-sequential injection 17
OPERATING PRINCIPLE
The K7M engine is fitted with semi-sequential injection.
Injection of fuel is carried out simultaneously to cylinders 1 - 4 and cylinders 2 - 3.
To do this, the two pairs of injectors are connected to two injection computer tracks:
- the injectors for cylinders 1 and 4 are connected to computer track 4 ,
- the injectors for cylinders 2 and 3 are connected to computer track 30 .
For each cylinder, there is one injection per revolution, i.e. two per cycle. These injections take place during
the compression and exhaust phases.
The injection computer uses the same system as that used to control the ignition coils for determining when
to control which injector. By analysing the signal from the flywheel, it knows the TDC point for cylinders 1 - 4
and cylinders 2 - 3 (see principle in section 17 "Ignition"). By counting the number of teeth, the engine phases
preceding TDC maybe determined.
17-17
INJECTION
K7M engine
Special notes on semi-sequential injection 17
TDC TDC TDC
cylinder 1
inlet compression expansion exhaust
TDC TDC
cylinder 2
compression expansion exhaust inlet
TDC TDC
cylinder 3
exhaust inlet compression expansion
TDC TDC TDC
cylinder 4
expansion exhaust inlet compression
computer track 12 V
N° 4
0V
computer track 12 V
N° 30
0V
1revolution 1revolution
1 cycle
Ignition
injection of petrol
17-18
INJECTION
F3R engine
Special notes on sequential injection 17
PRESENTATION DESCRIPTION
The F3R engine is fitted with sequential injection. The cylinder reference sensor (A) is located at the
end of the camshaft. It is mounted by three bolts
Injection of fuel is not carried out simultaneously on to the cylinder head.
to all four cylinders as with conventional injection,
but cylinder after cylinder when they are at the The sensor is opposite a long target of 180°. This is
start of the inlet phase. mounted on the end of the camshaft.
To do this, it is necessary for: If the target is located within the sensor air gap,
- each injector to be connected separately to 12 V is sent to the computer.
the computer (injector n° 1 is at the flywheel
end), If the target is not in the sensor airgap, 0 V is sent
- the computer to know which cylinder is at the to the computer.
inlet phase.
To determine the cylinder at the inlet phase, the

computer uses 2 sensors:
- the TDC sensor,
- the cylinder reference sensor.
The TDC sensor allows the computer to determine

the engine speed, and to know which cylinders
are at TDC:
- cylinders 1 and 4 at TDC,
- cylinders 2 and 3 at TDC.
The cylinder reference sensor allows the computer

to know which of the two cylinders at TDC is at
the start of the inlet phase.
99238R3
DEFECT MODE IN THE CASE OF A FAULT WITH THE

CYLINDER REFERENCE SENSOR
SENSOR OPERATING PRINCIPLE
The system remains in sequential injection. The
cycle 1 - 3 - 4 - 2 is retained. The sensor is supplied with 12 Volts. The computer
sends it a 5 V feed on track 2.
When fuel is injected for the first time, or at the
beginning of the starting phase, the computer Depending on the position of the target, the sen-
decides arbitrarily to inject fuel to cylinder n° 1 sor closes the circuit and earths this voltage (the
when cylinders 1 and 4 are at TDC. computer receives 0 V), or the sensor leaves the
circuit open (the computer receives 12 V).
Two possibilities may then arise:
- the system is phased correctly,
- the system is out of phase by one revolution.
Operation of the engine is not greatly affected.
17-19
INJECTION
F3R engine
PRINCIPLE FOR RECOGNISING THE CYLINDER AT THE INLET PHASE
Depending on the signal from the TDC sensor, the computer knows at what moment cylinders 1 and 4 are at
TDC and at what moment cylinders 2 and 3 are at TDC. (For further explanations refer to section 17
"Ignition").
Cylinders 1 and 4 are at TDC,
- if the signal from the cylinder reference sensor is 0 Volts, cylinder 4 is at the start of the inlet phase,
- if the signal from the cylinder reference sensor is 12 Volt, cylinder 1 is at the start of the inlet phase.
Cylinders 2 and 3 are at TDC,
- if the signal from the cylinder reference sensor is 0 Volts, cylinder 3 is at the start of the inlet phase,
- if the signal from the cylinder reference sensor is 12 Volt, cylinder 2 is at the start of the inlet phase.
LOGIC
Cylinder at TDC Signal from cylinder

Cylinder at start of inlet phase
reference sensor
12 Volt 1
1 - 4
0 Volts 4
12 Volt 2
2 - 3
0 Volts 3
17-20
INJECTION
F3R engine
98406R1
A 1 rotation of the crankshaft

B 1 rotation of the camshaft
C TDC 1 - 4
D TDC 2 - 3
1 Cylinder 1 at inlet
5 Gap in flywheel
6 84° or 14 teeth
7 30 teeth
X Flywheel target
Y Camshaft target
Z Voltage from cylinder reference sensor
NOTE : All values are given in TDC degrees.
17-21
INJECTION
F3R engine
1. REMOVING THE CYLINDER REFERENCE 3. ADJUSTING THE SENSOR / TARGET GAP
SENSOR
Slacken the bolt mounting the sensor without
Disconnect the sensor touching the sensor then retighten it to a torque
of 0.8 daN.m.
Remove:
- the cylinder reference sensor (A) (one bolt), By slackening the bolt the sensor is released. A
- the cover (B) (three bolts). spring in the cover pushes the sensor against the
target.
Target (C) is secured on the end of the camshaft
by a spring ring. When the bolt is tightened the sensor is secured. It
has two small plastic pips which touch the target.
To release the target from the camshaft: These pips wear as the engine turns. There is no
longer contact between the two components and
• Rest a copper hammer behind the target. the gap is set.
• Use a mallet to tap the hammer gently.
• Remove the target (C) and the plastic

protective cover (D).
2. REFITTING THE CYLINDER REFERENCE SENSOR
IMPORTANT : the order of operations described

below MUST be observed. Not following the
method could cause incorrect operation and / or
damage to the sensor.
Refit :
- the sensor to the cover, push it upwards and

tighten to a torque of 0.15 daN.m,
- the protective plastic cover,
- the target (this has a foolproofing device.

Check its position before fitting to the end of
the camshaft),
- the cover with the sensor. Tighten the three

cover bolts to a torque of 1 daN.m.
17-22
INJECTION
F3R engine
1 REMOVAL 2 REFITTING
DI1701 DI1702
3 ADJUSTMENT
DI1703
CYLINDER REFERENCE SENSOR CONNECTIONS
TRACK ALLOCATION
1 Earth
2 Information to injection computer on track 42
3 +after ignition
17-23
INJECTION
Injection fault warning light 17
PRINCIPLE FOR ILLUMINATION OF THE INJECTION FAULT WARNING LIGHT ON THE INSTRUMENT PANEL
• Vehicle without engine immobiliser system
When the ignition is turned on, the warning light illuminates for 3 seconds then extinguishes.
• Vehicle with engine immobiliser system deactivated
When the ignition is turned on, the warning light illuminates for 3 seconds then extinguishes.
When the doors are unlocked, the red immobiliser warning light, which was previously flashing, extin-
guishes. When the ignition is turned on, it illuminates for 3 seconds then extinguishes.
• Vehicle with engine immobiliser system activated
When the ignition is turned on, the computer does not identify the code and the vehicle cannot be star-
ted. The injection warning light illuminates for 3 seconds then extinguishes.
Before the ignition is turned on, the red immobiliser warning light flashes. When the ignition is turned
on, this light flashes twice as fast.
If a fault in the immobiliser system is detected when the engine is running, the injection warning light
will flash in the engine speed range from idle speed to 1 500 rpm approximately.
• Fault with an injection system component
Faults in the following components cause the warning light to illuminate:

- absolute pressure sensor,
- throttle position potentiometer,
- injectors,
- idle speed regulation stepping motor (K7M engine),
- idle speed regulation valve (F3R engine),
- no vehicle speed information when the vehicle is moving,
- EGR solenoid valve (K7M 703 engine),
- automatic transmission computer → injection computer (F3R - K7M engines).
17-24
INJECTION
Engine immobiliser function 17
This vehicle is fitted with a 2nd generation engine immobiliser system.
REPLACING THE INJECTION COMPUTER
The computers are supplied uncoded but are capable of being programmed with a code.
When replacing the computer, the vehicle code must be programmed in and then check that the immobiliser
system is operational.
To do this, carry out the following operations:
• Vehicle fitted with a PLIP engine immobiliser system
- Lock and unlock the doors using the PLIP.

- Turn the ignition on for a few seconds.
- Lock the doors using the PLIP, the immobiliser function is operational.
• Vehicle fitted with a coded key engine immobiliser system
Turn the ignition on for a few seconds then turn it off again.
CHECKING THE IMMOBILISER FUNCTION
• Vehicle fitted with a PLIP engine immobiliser system
- Turn the ignition off, lock the doors from inside the vehicle using the PLIP. The red immobiliser
warning light should flash.
- Turn the ignition on, The red immobiliser warning light should flash twice as fast.
• Vehicle fitted with a coded key engine immobiliser system
Remove the key from the ignition switch, after 10 seconds the red immobiliser warning light should flash.
TESTING AN UNCODED INJECTION COMPUTER FROM STOCK OR FROM A VEHICLE NOT FITTED WITH AN
IMMOBILISER SYSTEM
To avoid coding the injection computer before the test, it is vital to cut the + 12 V before ignition feed to the
immobiliser system. Remove the passenger compartment connection unit fuse (F39) (for more details, refer
to section 82).
NOTE : if the injection computer has been coded by mistake, a method exists for decoding it (refer to section
82).
SPECIAL NOTES
Using the XR25 it is possible to see if the injection computer is coded. The computer is uncoded if bargraph 2
right hand side is illuminated and if *22 = 2 DEF
A CODED COMPUTER FITTED TO A VEHICLE WITH AN ENGINE IMMOBILISER MAY NOT BE USED FOR TESTING
ANOTHER VEHICLE, REGARDLESS OF WHETHER THIS VEHICLE HAS AN ENGINE IMMOBILISER OR NOT.
17-25
INJECTION
F3R engine
Computer configuration as a function of the gearbox type 17
CONFIGURING THE COMPUTER DEPENDING ON GEARBOX TYPE (MANUAL OR AUTOMATIC)
Each time the injection computer is replaced, the gearbox type for the vehicle must be programmed (manual
or automatic). The computer is designed to operate with both these types of gearbox.
Procedure for configuring the computer:
Connect the XR25
ISO selector on S8
Turn the ignition on
Enter D13 then
For a vehicle fitted with a manual gearbox:
Enter G60*
For a vehicle fitted with an automatic transmission:
Enter G50*
The display shows:
If the configuration has not been programmed
then once the configuration is

complete
After programming the configuration, turn the ignition off to store it in the memory. Memorisation is effec-
tive after the ignition has been turned off, once the computer has left the monitoring mode.
The monitoring mode varies from 30 seconds to 13 minutes.
17-26
INJECTION
F3R engine
Computer configuration as a function of the gearbox type 17
To check that storing has been correctly carried out, turn the ignition on using fault finding fiche n° 27, bar-
graph 20 LH side should be extinguished, bargraph 19 RH or LH side should be illuminated.
There is a method for configuring the computer which does not require the use of the XR25. To do this:
- turn the ignition on,

- start the engine,
- accelerate the engine to a speed greater than 2500 rpm for 10 seconds,
- turn the ignition off,
- turn the ignition on again and start the engine,
- accelerate the engine to a speed greater than 2500 rpm for 10 seconds,
- turn the ignition off.
The memorisation procedure is the same as that described previously.
NOTE : the configuration procedure using the XR25 may be used to reconfigure an incorrectly configured
computer (automatic transmission instead of manual gearbox). The procedure which does not use the XR25
will however only work for an unconfigured blank injection computer from stock.
17-27
INJECTION
Injection strategy / Automatic transmission 17
AUTOMATIC TRANSMISSION COMPUTER CONNECTION TO INJECTION COMPUTER
"Park"/"Neutral" position and torque reduction information.
These two items of information are sent on one track of the injection computer.
Signal transmitted
Change to "drive"
Position P/N
5V
Position "drive"
0V
Torque reduction changing down
Torque reduction changing up

1 2
Nominal
advance
- 25°
1. In the "Park" or "Neutral" position, you can check whether the voltage, measured using a voltmeter
between track 7 and earth is actually approximately 5 V.
As soon as the "drive" (or "other") position is reached, the voltage drops to approximately 0.
2. From the "drive" position and while driving, the automatic transmission computer sends:
- a long pulse for changing up a gear,
- two short pulses for changing down a gear.
The injection computer, in both cases, to smooth the gear change, retards the advance by 25° compared
to the initial advance, for the complete period of torque reduction if the vehicle speed is greater than 6
mph (10 km/h).
The advance returns to the initial setting:

- at once for changing up a gear,
- progressively for changing down a gear.
17-28
INJECTION
Injection strategy / air conditioning 17
AIR CONDITIONING / INJECTION COMPUTER CONNECTION
The electrical connection:
- from the air conditioning computer to the injection computer is by one wire. This track only transmits the
information that the air conditioning is operating. The injection computer deduces that the air
conditioning has been selected:
track 6 F3R engine
track 5 K7M engine
track 34 E7J engine
- from the injection computer to the air conditioning computer is by one wire. This track transmits the
compressor operation authorisation and prevention information :
track 51 F3R - K7M engines
track 20 E7J engine
PROGRAMMING FOR OPERATION OF THE COMPRESSOR
During certain operating phases, the injection computer prevents operation of the compressor.
Starting the engine

The compressor is prevented from operating for 10 seconds after the engine has been started.
Thermal protection
The compressor clutch is prevented from engaging if the coolant temperature is greater than or equal to :
- + 115°C (F3R and E7J engines)
- + 120°C (K7M engine)
Over-revving protection
The compressor may not operate if the engine speed is greater than :
- 6 000 rpm (F3R engine),
- 5 600 rpm (K7M engine),
- 5 400 rpm (E7J engine).
OPERATING PRINCIPLE
1. Idle speed regulation.
2. Air conditioning operation information becomes ON for the first time since the ignition was turned on.
The driver must select air conditioning from the control panel.
The idle speed is increased to:

F3R engine 900 rpm
K7M engine 850 rpm
E7J engine 900 rpm
The injection computer prevents the compressor from operating to assist the increase in idle speed.
3. 2 to 5 seconds after receiving the information for air conditioning operation ON, the computer authorises
operation of the compressor and increases the idle speed regulation solenoid valve percentage opening.
The idle speed does not increase.
17-29
INJECTION
4. Air conditioning operation information becomes OFF, the injection computer, anticipating the drop in
load due to the releasing of the compressor clutch, reduces the percentage opening of the idle speed
regulation solenoid valve then authorises the release of the compressor clutch and transmits the clutch
feed authorisation information OFF. The engine runs at fast idle speed.
(If the air conditioning computer has not received the compressor cut-out authorisation 2 seconds after
transmitting the air conditioning operation information OFF, it cuts the compressor itself).
5. Following prevention of compressor operation by the injection computer (clutch feed authorisation OFF),
the injection computer anticipates the drop in load due to the release of the clutch and reduces the per-
centage opening of the idle speed regulation solenoid valve. The compressor clutch is released by the air
conditioning computer.
6. Air conditioning operation information becomes OFF, the operation is similar to that described in point
4.
The engine is running at fast idle speed. To return to normal idle speed, the computer must detect that
the driver has turned the air conditioning off at the control panel. It deduces this state from the air
conditioning operation information if it is OFF for longer than :
- 15 seconds for K7M and E7J engines,
- 40 seconds for F3R engine,
shown by the letter X on the next page.
17-30
INJECTION
AC ON X
running (12 V)
OFF
(0 V)
Released
Compressor 1 2 3 4 3 5 3 6
status
Engaged
Clutch OFF
authorisation (12V)
by
injection ON
computer (0V)
(% opening)
2 to 5 s
Idle speed
regulation
valve
(time)
(rpm)
Idle fast
speed
nominal
(time)
17-31
INJECTION
Idle speed correction 17
POWER ASSISTED STEERING PRESSOSTAT - INJECTION COMPUTER CONNECTION (K7M and E7J engines)
The injection computer receives information from the power assisted steering pressostat. This depends on the
pressure in the hydraulic circuit. The higher the pressure, the more energy is used by the power assisted
steering pump.
The injection computer, to compensate for this energy use, increases the percentage opening of the idle
speed regulation stepping motor for the K7M engine or adjusts the idle speed micromotor for the E7J
engine.
The information is received on track 13 (K7M engine) and track 8 (E7J engine) on the injection computer.
Pressostat closed, the computer receives an earth. The idle speed is adjusted to 820 rpm for the K7M engine
and 825 rpm for the E7J engine.
IDLE SPEED CORRECTION DEPENDING ON THE BATTERY VOLTAGE (F3R engine)
This correction compensates for the drop in voltage due to operation of consumers when the battery is poorly
charged. To do this, the idle speed is increased, allowing the alternator to rotate more and consequently
increase the charging voltage.
The lower the voltage, the greater the degree of correction. Correction of the engine speed is therefore
variable. It begins when the voltage drops to below 12.7 Volts. Correction begins at the nominal engine
speed and may reach a maximum of 910 rpm.
IDLE SPEED CORRECTION DEPENDING ON HEATED WINDSCREEN INFORMATION
The E7J engine has no heated windscreen.
If the heated windscreen function is selected, the computer receives + 12 V information :

on track 6 for K7M engines
on track 5 for F3R engines.
If the coolant temperature is less than 60°C, the idle speed is set to :
- 1 000 rpm (F3R engine)
- 850 rpm (K7M engine)
17-32
INJECTION
Idle speed adaptive correction 17
PRINCIPLE ( K7M and F3R engines)
The E7J engine has no idle speed adaptive correction and no #12 function.
Under normal warm engine operating conditions, the RCO idle speed value using #12 varies between an up-
per and a lower value to obtain the nominal idle speed.
If the engine operating conditions are different (running in, engine contaminated...) the RCO idle speed va-
lue may be situated close to the upper or lower value.
Adaptive correction (#21) for the RCO idle speed (#12) allows compensation to be made for slow variations
in the engine’s air requirements, in order to recentre the RCO value (#12) to a nominal average value.
This correction is only operational if the coolant temperature is greater than 80°C, 20 seconds after starting
the engine and if the engine is in the nominal idle speed regulation phase.
RCO IDLE SPEED VALUES AND ADAPTIVE CORRECTION
Engine Engine Engine Engine Engine

F3R 750 F3R 751 K7M 702 K7M 703 K7M 720
Nominal idle X = 750 rpm.

X = 770 rpm. X = 770 rpm. X = 720 rpm. X = 720 rpm.
speed (#06) in P and N
10 %≤X≤20 %
R.C.O. idle speed in D
20 %≤X≤40 % 18 %≤X≤38 % 6 %≤X≤15 % 4 %≤X≤14 %
(#12) 6 %≤X≤15 %
in P and N
Adaptive idle Threshold: Threshold: Threshold: Threshold: Threshold:

speed - min : - 8.6 % - min : - 8.6 % - min : - 2.4 % - min : - 2.4 % - min : - 2.4 %
(#21) - max : +6.2 % - max : +6.2 % - max : +6.2 % - max : +6.2 % - max : +6.2 %
Minimum threshold for the F3R engine 750 (- 8.6 %) : this value is taken from the definitive setting. The first
versions to be marketed have a threshold of - 6.2 %.
INTERPRETATION OF THE GATE VALUES
If there is an excess of air (air leak, throttle stop incorrectly set...) the idle speed increases, the RCO idle speed
value for #12 decreases to return to the nominal idle speed; the RCO idle speed adaptive correction value for
#21 reduces to recentre the RCO idle speed for #12.
If there is a lack of air (pollution, etc.), the strategy is reversed:

The RCO idle speed for #12 increases and adaptive correction for #21 also increases, in order to recentre #12
to a nominal average value.
IMPORTANT : after erasing the computer memory (disconnecting the battery), the engine must be allowed to
run at idle speed before returning the vehicle to the customer so that the adaptive correction may correctly
reset itself.
17-33
INJECTION
Richness regulation 17
OXYGEN SENSOR VOLTAGE (#05)
Reading #05 on the XR25 : the value read is the voltage sent to the computer by the oxygen sensor; it is ex-
pressed in Volts (the value actually varies between 0 and 1 000 millivolts).
When the engine is in the loop phase, the voltage value should oscillate rapidly and should be between
50±50 mV (lean mixture) and 850 ± 50 mV (rich mixture) and vice versa.
The smaller the gap between the upper and lower oscillating values, the poorer the information from the
sensor (the gap is usually at least 500 mV).
RICHNESS CORRECTION (#35)
The value given under # 35 on the XR25 represents the average value of richness corrections made by the
computer depending on the richness of the burnt mixture as seen by the oxygen sensor (the oxygen sensor ac-
tually analyses the oxygen content of the exhaust gases directly from the richness of the burnt mixture).
The richness correction has a centre point of 128 with thresholds of 0 and 255 (experience has shown that un-
der normal operating conditions # 35 is located close to 128 with only a small amount of variation).
- Value less than 128 : request for mixture to be made leaner

- Value greater than 128 : request for mixture to be made richer
ENTRY INTO RICHNESS REGULATION MODE
Loop phase
Richness regulation begins after the timed starting period :

- for no load if the coolant temperature has reached:
• 25°C for E7J engines,
• 40°C for K7M engines,
• 35°C for F3R engines.
- outside no load conditions if the coolant temperature is greater than :

• + 20°C for K7M engines,
• + 15°C for F3R engines,
there is no coolant temperature condition for E7J engines.
The timed starting period is dependent on the coolant temperature:

- at 20°C it is a maximum of :
• 45 seconds for E7J engines,
• 1 minute for K7M engines,
• 2 minutes for F3R engines,
- at 80°C it is a maximum of :
• 9 seconds for E7J engines,
• 16 seconds for K7M engines,
• 1 minute for F3R engines.
if richness regulation has not yet started, #35 = 128
17-34
INJECTION
Richness regulation 17
Non-loop mode
When richness regulation is occurring, the operating phases when the computer ignores the voltage in-
formation from the oxygen sensor are:
- Full load: #35 = variable and greater than 128

- Sharp acceleration: #35 = variable and greater than 128
- Sharp deceleration with no load information (injection cut) : #35 = 128
- Oxygen sensor fault: #35 = 128
DEFECT MODE IN THE EVENT OF AN OXYGEN SENSOR FAULT
If the voltage from the oxygen sensor is incorrect (# 05 varies only slightly or not at all) during richness regu-
lation, the computer will only enter defect mode (# 35 = 128) if the fault has been present for 3 to 5 minutes.
The fault will be memorised in this case only.
If an oxygen sensor fault is present and recognised and if the fault has already been stored, the system enters
the open loop mode directly (# 35 = 128).
17-35
INJECTION
Adaptive richness correction 17
PRINCIPLE
In the loop mode (see section 17 "Richness regulation"), richness regulation (# 35), corrects the injection ti-
ming to give fuel metering which is as close as possible to richness 1. The correction value is close to 128, with
limit values of 0 and 255.
Variations may affect the components of the injection system and the correction may drift towards 0 or 255,
to ensure richness 1 is obtained.
Adaptive correction allows the injection mapping to be adjusted to recentre the richness regulation to 128
and to ensure a constant authority of correction to make the mixture leaner or richer.
Adaptive correction to richness regulation has two parts:
- Adaptive correction for average and high engine loads (#30)
- Adaptive correction for idle speed and low engine loads (#31).
Adaptive corrections take 128 as the average value after initialisation (erasing the memory ) and have the
following threshold values:
F3R engine K7M 702/703 engine K7M 720 engine E7J engine
82 ≤ #30 ≤ 224 0 ≤ #30 ≤ 208 0 ≤ #30 ≤ 208 112 ≤ #30 ≤ 160
32 ≤ #31 ≤ 224 104 ≤ #31 ≤ 255 100 ≤ #31 ≤ 255 104 ≤ #31 ≤ 160
Adaptive correction only takes place when the engine is warm, in the loop phase (#35 variable) and for a
specified manifold pressure range.
The engine must have operated in the loop mode for several pressure zones in order that adaptive correc-
tion begins to change to compensate for the variations in engine operating richness.
Following reinitialisation of the computer (return to 128 for # 30 and # 31) a special road test must therefore
be carried out.
17-36
INJECTION
ROAD TEST
Conditions :
- Engine warm (coolant temperature > 70° C)

- Do not exceed engine speed 4 300 rpm F3R engine
and 4 000 rpm K7M engine
For this test, start from a fairly low engine speed, in 3rd or 4th gear using progressive acceleration to stabilise
the required pressure for 10 seconds in each zone (see table).
NOTE: For the F3R engine, for example, for zone n° 1, try to maintain the average of 355 mb for at least 10 se-
conds.
Pressure zones to cover during the test (# 01)
Zone n° 1 Zone n° 2 Zone n° 3 Zone n° 4 Zone n° 5

(mbars) (mbars) (mbars) (mbars) (mbars)
300 410 500 590 680 870

F3R
Average 355 Average 455 Average 545 Average 635 Average 775
280 390 510 620 740 930

K7M
Average 335 Average 450 Average 565 Average 680 Average 835
Following this test the corrections will be operational.
# 31 varies more significantly for idle speed and low loads and # 30 for average and high loads, but both are
operational over all of the manifold pressure ranges.
The test should be followed by a normal, varied drive, covering 3 to 6 miles (5 to 10 km).
After the test, read the values for # 30 and # 31. Initially 128, they should now have changed.If they have not
changed, repeat the test, taking care to ensure the test conditions are correctly observed.
17-37
INJECTION
Special notes for the E7J engine
A road test should be carried out after which the engine should be allowed to idle for a few minutes. The va-
lues for #30 and #31 should have changed.
During the road test, stabilise the engine speed for a few moments between 2 000 rpm and 4 400 rpm and the
manifold pressure between 400 and 700 mbars.
Condition #31 : if engine speed < 1 000 rpm and if the manifold pressure < 450 mbars, #31 should be mo-
dified.
INTERPRETING VALUES GATHERED AFTER A ROAD TEST
If there is a lack of fuel (injectors dirty, fuel pressure and flow too low...), richness regulation # 35 increases to
obtain the richness as close as possible to richness 1 and adaptive correction # 30 and # 31 increases until the
richness correction returns to oscillate around 128.
If there is an excess of fuel, the situation is reversed:

Richness regulation # 35 reduces and adaptive correction # 30 and # 31 also reduces to recentre the richness
correction (# 35) around 128.
NOTE: the analysis which may be made using # 31 remains difficult since this correction mainly operates for
idle speed and low loads and is also very sensitive.
Hasty conclusions should not therefore be drawn from this gate value, rather the position of # 30 should be
examined.
The information from these two gates gives an idea about the engine operation richness, and may be used as
a guide for fault finding. For them to be of use during fault finding, conclusions may only be drawn if the va-
lues are at the minimum or maximum correction thresholds, and if both values have drifted in the same direc-
tion.
IMPORTANT : # 30 and # 31 should only be examined and analysed after a customer complaint, an opera-
ting fault and if they are at the threshold with the value for # 35 also offset (# 35 varies above 175 or be-
low 80).
17-38
INJECTION
Operating wiring diagram 17
KEY TO OPERATIONAL WIRING DIAGRAMS (E7J, F3R, K7M)
COMPONENT NO DESCRIPTION
109 On board computer

119 Automatic transmission computer
146 Pinking sensor (located under the inlet manifold for E7J engine)
149 TDC sensor
193 to 196 Injectors
218 Fuel pump
225 Diagnostic socket
228 Idle speed regulation micromotor
236 Fuel pump relay (in engine fuse box)
238 Injection feed locking relay
242 Oxygen sensor
247 Instrument panel
250 Vehicle speed sensor
310 Ignition power module
319 Air conditioning control panel
398 Exhaust gas recirculation solenoid valve (EGR)
437 Throttle body heater (under throttle body)
565 Throttle body assembly
597 Engine fuse box
645 Passenger compartment connection unit
663 Dual ignition coil n°1 (cylinders 1 and 4)
664 Dual ignition coil n° 2 (cylinders 2 and 3)
679 Radio anti-interference condenser
746 Cylinder reference sensor
772 Heater relay (in engine fuse box)
777 Power fuse board (near battery)
927 Inertia switch
MF Rear right hand electrical earth

MH Engine electrical earth (located on the cylinder block between the starter and the al-
ternator for the E7J engine)
17-39
INJECTION
E7J engine
PRJ99528
17-40
INJECTION
E7J engine
COMPUTER TRACK ALLOCATION
Track ALLOCATION
1 Power earth
2 Electronic earth
3 Vehicle speed information
4 + before ignition (permanent) computer memory
5 Canister bleed signal (sequential earth period)
6 Pump relay control (via track N° 2)
7 Locking relay control (via track N° 2)
8 Diagnostic line for erasing the memory and power assisted steering pressostat information
9 Throttle position potentiometer information (pin N° 4 on 222)
10 Heater relay command
11 TDC sensor signal (track B)
12 Rev counter information at instrument panel
13 Connection with injection fault warning light on instrument panel
14 Air temperature information
15 Coolant temperature information
16 + 5 V feed for absolute pressure sensor and throttle potentiometer
Common earth for absolute pressure sensor, throttle potentiometer and coolant temperature
17
sensor
18 Emission of diagnostic signal to diagnostic socket
19 Main computer feed via injection locking relay
20 Air conditioning compressor command
21 Injector control via earth
22 Not used
23 + or - feed to idle speed micromotor (pin N° 1)
24 + or - feed to idle speed micromotor (pin N° 2)
17-41
INJECTION
E7J engine
Track ALLOCATION
25 No load information input
26 Not used
27 Power module command
28 TDC sensor signal input (track A)
29 Immobiliser coded line input via decoder unit
30 + 12 V information when ignition turned on
31 Pinking sensor noise signal input
32 + 12 V after ignition information
33 Voltage information dependent on manifold pressure seen by sensor (on track B)
34 Air conditioning compressor operation request input
35 Voltage from oxygen sensor input
17-42
INJECTION
K7M engine
PRJ99475
17-43
INJECTION
K7M engine
Track ALLOCATION
1 Not used
2 Power earth n° 1
3 Power earth n° 2
4 Command for injector n° 2 and n° 3 via earth
Air conditioning on - off information and request for compressor operation authorisation
5
(0 - 12 V)
6 Heated windscreen information (0 - 12 V)
7 Park / Neutral / torque reduction information (0 - 5 V) (K7M 703)
8 Pinking sensor signal
9 Stepping motor control (0 - 12 V)
10 EGR solenoid valve control (0 - 12 V) (K7M 703)
Bi-directional diagnostic line K used for entry into fault finding mode
(looking for computer), emission of diagnostic signals from computer, application of command
11
modes (G..*), erasing the memory (G0**)
and ending fault finding (G13*)
13 Power assisted steering pressostat information
14 Not used
15 Coolant temperature sensor information
16 Manifold pressure information transcribed by absolute pressure sensor
17 Voltage information from oxygen sensor
18 Earth
19 Throttle position potentiometer information
20 Air temperature sensor information
21 Not used
22 Not used
23 Not used
24 + 12 V after ignition
17-44
INJECTION
K7M engine
Track ALLOCATION
25 Not used
26 Not used
27 Not used
28 Command for coil for cylinders 1 and 4
30 Command for injector n° 1 and n° 4 via earth (n° 1 flywheel end)
31 Pinking sensor screened cable
32 +12 V before ignition
34 TDC sensor signal (track A)
35 Stepping motor command (0 - 12 V)
37 Immobiliser coded line input
Uni-directional diagnostic line L for entry into diagnostic mode only

38
(looking for computer)
39 Not used
41 Throttle angle information for automatic transmission computer
42 RCO control (sequential earth period for canister bleed solenoid valve RCO)
43 Command for injection fault warning light on instrument panel
44 Common earth for pinking sensor and coolant temperature sensor and absolute pressure sensor
45 + 5 V feed for absolute pressure sensor and throttle position potentiometer
46 Common earth for air temperature sensor and throttle position potentiometer
47 Not used
48 Command (via earth) for fuel pump relay and engine speed information
49 Not used
17-45
INJECTION
K7M engine
Track ALLOCATION
50 Fuel flow information for on board computer
Air conditioning compressor clutch operation prevention command

51
(0 V → authorisation ; 12 V → prevention)
52 Monitoring of injector feed and fuel pump feed from relay (236)
53 Not used
54 Not used
55 Not used
17-46
INJECTION
F3R engine
PRJ99473
17-47
INJECTION
F3R engine
Track ALLOCATION
1 Not used
2 Power earth n° 1
3 Power earth n° 2
4 Command for injector n° 3 via earth
5 Heated windscreen information (0 - 12 V)
Air conditioning on - off information and request for compressor operation authorisation
6
(0 - 12 V)
7 Park / Neutral / torque reduction information (0 - 5 V) (F3R 751)
8 Pinking sensor signal
9 Not used
10 Not used
Bi-directional diagnostic line K used for entry into fault finding mode
(looking for computer), emission of diagnostic signals from computer, application of command
11
modes (G..*), erasing the memory (G0**)
and ending fault finding (G13*)
13 Fuel flow information for on board computer
14 Not used
15 Coolant temperature sensor information
16 Manifold pressure information transcribed by absolute pressure sensor
17 Voltage information from oxygen sensor
18 Oxygen sensor earth
19 Throttle position potentiometer information
20 Air temperature sensor information
21 Not used
22 Not used
23 Not used
24 + 12 V after ignition
17-48
INJECTION
F3R engine
Track ALLOCATION
25 Command for injector n° 2 via earth
26 Command for injection fault warning light on instrument panel
27 Not used
30 Command for injector n° 4 via earth (timing end)
31 Pinking sensor screened cable
32 +12 V before ignition
34 TDC sensor signal (track A)
35 Immobiliser coded line input
36 Not used
37 Not used
Uni-directional diagnostic line L for entry into diagnostic mode only

38
(looking for computer)
39 Not used
40 Not used
41 Throttle angle information for automatic transmission computer
42 Cylinder reference sensor information
43 Engine speed information
44 Common earth for pinking sensor and coolant temperature sensor and absolute pressure sensor
45 + 5 V feed for absolute pressure sensor and throttle position potentiometer
46 Common earth for air temperature sensor and throttle position potentiometer
47 Not used
48 Command (via earth) for fuel pump relay (236)
49 Not used
17-49
INJECTION
F3R engine
Track ALLOCATION
50 R.C.O. command (sequential earth period) for canister bleed solenoid
Air conditioning compressor clutch operation prevention command

51
(0 V → authorisation ; 12 V → prevention)
52 Monitoring of injector feed and fuel pump feed from relay (236)
53 Command for injector n° 1 via earth (flywheel end)
54 R.C.O. command (sequential earth period) for idle speed regulation valve
55 Not used
17-50
COOLING
Specifications 19
VOLUME AND GRADE OF COOLANT
Engine Volume (in litres) Grade
F8Q 7.5
GLACEOL RX (type D)
F3R 7
use coolant only
E7J - K7M 6
THERMOSTAT
Engine type Begins to open (in °C) Fully open (in °C) Travel (in mm)
E7J - K7M - F8Q - F3R 89 101 7.5
19-1
COOLING
Filling - bleeding 19
There is no water control valve.
Coolant circulates continuously in the heater

matrix, assisting with engine cooling.
FILLING
The following bleed screws must be opened:

- on the top of the radiator,
- on the heating hose,
- on the thermostat mounting(except E7J- K7M
engines ).
Fill the circuit at the expansion bottle opening.
Close the bleed screws as soon as fluid runs out in

a continuous jet.
Start the engine (2 500 rpm).
Adjust the level by overflow for approximately

4 minutes.
Close the expansion bottle.
BLEEDING
Let the engine run for 20 minutes at

2 500 rpm,until the engine cooling fan operates
(time required for automatic degassing).
Check the fluid level is close to the "Maximum"

mark.
NEVER OPEN THE BLEED SCREWS WHEN THE

ENGINE IS RUNNING.
TIGHTEN THE EXPANSION BOTTLE CAP WHEN THE

ENGINE IS WARM.
19-2
COOLING
Checking 19
M.S. 554-07 Kit for checking cooling circuit sealing

M.S. 554-01 Adaptor for M.S. 554-05
M.S. 554-06 Adaptor for M.S. 554-05
1 - Checking the cooling circuit sealing 2 - Checking the rating of the expansion bottle
cap
Replace the expansion bottle cap with tool M.S.
554-01. If fluid passes through the expansion bottle cap
valve, the cap must be replaced.
To this, connect tool M.S. 554-07.
On the pump M.S. 554-07 fit tool M.S. 554-06 and
Let the engine warm up then turn the ignition off. fit this to the valve to be checked.
Pump to put the circuit under pressure. Increase the pressure which should stabilise at the
calibration value for the cap valve, with a test to-
Stop pumping at 0.1 bar less than the rating value lerance of ± 0.1 bar.
of the expansion bottle cap.
Valve rating value:
The pressure should not drop. If it does, look for
the leak.
Engine Valve colour Rating (in bar)
Slowly unscrew the union of tool M.S. 554-07 to
decompress the cooling circuit, then remove tool
F8Q - E7J Brown 1.2
M.S. 554-01 and refit the expansion bottle cap fit-
ted with a new seal. K7M - F3R Blue 1.6
97871R
19-3
COOLING
F8Q ENGINE / AC
Radiator 19
REMOVAL - the bolts and nut from the dehydrating bottle,
Disconnect:
- the battery,
- the connectors for the fan, the relays and the
thermistor.
Drain the cooling circuit from the lower radiator

hose (radiator end).
Remove:
- the two bolts (A) from the radiator mounting
brackets on the upper cross member,
99177R
- the two indicators,

- the mounting bolts from the radiator half
grilles and unclip them at (B).
98836-1R
98836R3
19-4
COOLING
F8Q ENGINE / AC
Radiator 19
Unclip the grille at (D) using a screwdriver and re- Unclip the power assisted steering reservoir.
lease the sides by lifting the tabs at (E).
Remove:
- the 4 mounting bolts from the fan mounting
on the radiator and remove it,
- the 4 mounting bolts for the condenser on the
radiator,
99611R
99187R1
- the radiator.
Remove the 6 mounting bolts for the upper cross

member and remove it. REFITTING
Fill and bleed the cooling circuit.
98838R
Disconnect the upper radiator hose by removing

the air filter inlet sleeve.
19-5
COOLING
F8Q ENGINE
Diagram 19
99417R
1 Engine Water pump

2 Radiator
3 Expansion bottle with degassing after ther-
mostat Thermostat
4 Heater matrix
5 Thermostat mounting Bleed valve
6 Oil temperature exchanger
7 3 mm diameter restriction Temperature switch
8 6 mm diameter restriction
The rating of the expansion bottle cap is 1.2 bar
(brown).
19-6
COOLING
F8Q ENGINE / AC
Diagram 19
99416R
1 Engine Water pump

2 Radiator
mostat Thermostat
4 Heater matrix

(brown).
19-7
COOLING
F3R ENGINE
Diagram 19
99415R
1 Engine Water pump

2 Radiator
mostat Thermostat
4 Heater matrix
6 Throttle body
(blue).
19-8
COOLING
E7J ENGINE
Diagram 19
99414R
1 Engine Water pump

2 Radiator
mostat Thermostat
4 Heater matrix
6 Inlet manifold
(brown).
19-9
COOLING
K7M ENGINE
Diagram 19
99413R
1 Engine Water pump

2 Radiator
mostat Thermostat
4 Heater matrix
Temperature switch

(blue).
19-10
COOLING
K7M ENGINE / AT
Diagram 19
99412R
1 Engine Water pump

2 Radiator
mostat Thermostat
4 Heater matrix
6 Automatic transmission oil temperature ex-
changer Temperature switch
8 6 mm diameter restriction The rating of the expansion bottle cap is 1.6 bar
(blue).
19-11
EXHAUST
General 19
The catalytic converter reaches high temperatures EXHAUST PIPE MOUNTINGS UNDER THE BODY
during operation and consequently the vehicle
should never be parked in an area where there is The exhaust pipe is attached under the body using
combustible material which could come into rubber mountings.
contact with the exhaust and pose a fire risk.
These may generally be released by hand by lif-
Under certain conditions, this type of material ting the exhaust pipe.
could catch fire.
In certain cases however, the retaining bolts for
mounting (A) under the body may have to be
IMPORTANT: slackened to release the rubber mountings more
easily.
- sealing between the exhaust manifold gasket
face and the catalytic converter must be per-
fect,
- any seals removed MUST be renewed (especial-

ly at the catalytic converter flange),
- during removal and refitting the catalytic

converter should not be subjected to repeated
mechanical impacts as it may be damaged.
99225R
CUTTING THE EXHAUST PIPE
The exhaust pipes are of monoblock construction.

This means there is no break between the inlet to
the catalytic converter or the expansion chamber
and the silencer outlet.
If one of the components requires replacement as

an After Sales operation, the exhaust pipe must
be cut.
To do this:
- mark up the cutting line correctly,
- use the cutting tool Mot. 1199,
- fit the After Sales sleeve.
19-12
EXHAUST
General 19
MARKING UP THE CUTTING LINE USING TOOL MOT. 1199
The cutting line is marked by two punched marks Fit tool Mot. 1199 to the exhaust pipe.
in the exhaust pipe.
99226-1R 99226R
There are a maximum (depending on engine) of Slacken the chain as far as possible (unscrew) and
two cutting zones on the exhaust pipe, located pass it around the pipe. Attach the chain to the
between the catalytic converter and the expan- tool.
sion chamber and between the expansion cham-
ber and the silencer. Tighten and pivot the tool around the pipe, while
tightening the chain (screw in) as cutting proceeds
The distance between the two markers is 90 mm. (do not tighten the tool on the pipe too much to
To cut the pipe, mark the centre point (D) bet- ensure it cuts without deforming the pipe).
ween the two markers (P1 and P2).
P1 D P2
90 mm
DI1901
19-13
EXHAUST
General 19
POSITIONING THE AFTER SALES SLEEVE Once a clip has been fitted once, do not re-use it.
95478R1 99227S
To avoid any leaks from the exhaust, it is impor- The nut on the clip has a groove (A) to ensure the
tant to position the sleeve over the two exhaust clip is tightened to the correct torque. When tigh-
pipes correctly. This means that the pipe should fit tening, when this groove is no longer visible, it
against the lugs inside the sleeve. clicks and the nut is then tightened correctly (2.5
daN.m).
Begin by positioning the sleeve on the old section
of the exhaust pipe then adjust the diameter of
the clip by tightening it gently. NOTE:
Check the positioning of the pipe on the lugs. there are 2 sleeves of different diameters :
- 50 mm diameter : F3R- K7M - E7J engines
Fit the new replaced part. - 45 mm diameter : F8Q engine
Before fitting the sleeve on the pipe, mastic may

be applied to the inner ring of the sleeve to pre- IMPORTANT:
vent a leak.
- check there is no contact between the exhaust
(Exhaust mastic Part Number : 77 01 421 161 pipe and the body,
SODICAM).
- check the exhaust pipe heat shields are in good
IMPORTANT : the bolt and nut assembly on the condition and are all present.
sleeve must be aligned vertically to avoid any risk
of contact with the body.
19-14
EXHAUST
NOISE FROM THE EXHAUST PIPE
The vehicle should be tested in order to localise

the source of the noise (if necessary with the cu-
stomer present). The fault should then be repro-
duced when the vehicle is stationary, if possible.
To do this, accelerate sharply in order to cover a
wide range of engine resonance.
Having reproduced the noise:
- ensure there is no contact between the

exhaust pipe and the vehicle body,
- check the alignment, conformity and

condition of the exhaust system,
- attempt to eliminate the noise noted by

tightening the exhaust pipe or the heat
shields at fault.
If the noise is found to be caused by the catalytic

converter, remove it and carry out the following
checks:
- visual examination of the inside of the shell

(melted monolyth).
- listen to the catalytic converter after shaking

it (split monolyth or foreign body present).
If the monolyth has melted, the cause must be

determined (see chapter 14: checks to be made
before the anti-pollution test) and check that
catalytic particles have not blocked the exhaust
system further down the pipe.
Only if one of the observations specified above is

noted should the catalytic converter be replaced.
19-15
EXHAUST
Exhaust pipe assembly 19
PRESENTATION OF EXHAUST PIPES AND CUTTING ZONES
E7J engine K7M engine
99233R 99237R
1 Expansion chamber
2 Silencer
ZC Exhaust pipe cutting zone
19-16
EXHAUST
F3R engine F8Q engine

without catalytic converter
99236R 99235R
1 Catalytic converter
2 Expansion chamber
3 Silencer
19-17
EXHAUST
F8Q engine
with catalytic converter
99234R
1 Catalytic converter
2 Silencer
19-18
FUEL TANK
Fuel tank 19
EQUIPMENT REQUIRED
INTAIRCO pneumatic pump for draining the fuel tank

(petrol or diesel), (see EQUIPMENT 95 catalogue).
Piston pump 333 (for draining diesel fuel tank).
Mot. 1199 Exhaust pipe cutting tool
Mot. 1265
Pliers for removing quick release
unions
Mot 1265-01
IMPORTANT :
during the complete removal and refitting opera-
tion, do not smoke and keep all heat sources
away from the working area.
DRAINING THE FUEL TANK (petrol version) Fit a pipe onto outlet (A) long enough to empty
into a container outside the vehicle.
Remove the plastic access cover (under the rear
right hand seat).
Note : the INTAIRCO pneumatic pump may also be
Remove the clip (if fitted). used (see EQUIPMENT 95 catalogue) or piston
pump 333. Refer to your After Sales Head Office
Disconnect the quick release union (1), Mot. 1265 for more details.
(see below for details on fitting the pliers).
97163R2
19-19
FUEL TANK
Fuel tank 19
In the engine compartment, disconnect the fuel DRAINING THE FUEL TANK (diesel version)
pump relay (identifiable as it has larger section
wires , 5 mm2 , on tracks 3 and 5) located in the As there is no electric fuel pump, a pump must be
engine connection unit. used to drain the fuel tank.
Use for example:

- the INTAIRCO pneumatic pump (see
EQUIPMENT 95 catalogue ),
99641S
98756R1
- piston pump 333. Refer to your After Sales
B - Fuel relay Head Office for more details.
Shunt tracks 3 and 5 and allow the fuel to run out

until it is only pumped out intermittently.
Disconnect the shunt.
Reconnect the relay.
76003S
19-20
FUEL TANK
Fuel tank 19
REMOVING THE FUEL TANK (petrol or diesel ver- Remove the heat shields (3) and (4) and the strut
sions) (5).
Vehicle on a 2 post lift.
Disconnect the electrical connector (2) and the

quick release unions , Mot. 1265 or Mot. 1265-01
(see below for positioning the pliers).
99090R
Measure dimension X before releasing the hand-

brake adjuster.
97163R4
Lift the vehicle.
Remove the silencer, use the pipe cutting tool

Mot. 1199 (see Exhaust section).
99091R
Slacken the adjuster to release the left and right

hand cables (release the plastic cable stop with
care).
19-21
FUEL TANK
Fuel tank 19
Disconnect the pipes from the fuel tank filler neck
using tool Mot. 1265.
99216S
Fit a jack under the fuel tank.
Remove the 3 mounting bolts at the front of the 96420R2

fuel tank.
Slacken the mounting bolts for the rear mounting Mot. 1265 : 8 mm diameter pipe.
sufficiently to allow the fuel tank to be released. Mot. 1265-01 : 10 mm diameter pipe (diesel fuel
supply circuit).
IMPORTANT:
when removing the fuel tank, release the brake
pipes sufficiently to avoid deforming them. REFITTING
Take care not to compress the pipes (risk of a

leak).
Fit the quick release unions by hand and ensure

they click together correctly (two O rings ensure
sealing).
Take care to ensure the heat shields are correctly

refitted.
19-22
FUEL TANK
Filler neck 19
UNLEADED PETROL DIESEL
DI1903 DI1904
PRG19.3 DI1905
1 - Filler neck outlet - fuel passage A - Overfilling valve

2 - Degassing when filling B - Excess - insufficient pressure safety valve
3 - Breather C - Restriction valve
4 - Connection to canister (petrol vapour) D - Valve preventing leaks if the vehicle is turned
over
19-23
FUEL TANK
Filler neck 19
ROLE OF THE VALVES The fuel tank has a sealed filler cap and a ventila-
tion circuit.
A) Over-filling valve
The filler neck for unleaded fuel has:
When the fuel filler cap is removed, the valve
is closed, locking a volume of air in the brea- - an opening which is narrower and incompati-
ther chamber. This prevents fuel from ente- ble with a leaded fuel pump nozzle (lead would
ring this chamber. pollute the depollution system: the oxygen
sensor and catalytic converter),
When the filler cap is replaced, the valve
opens and the fuel tank breather is again - a valve blocking the filling opening (C) (to pre-
connected to the canister. vent fuel vapour evaporating or fuel coming
out of the tank).
B) Excess - insufficient pressure safety valve
If the fuel vapour recirculation circuit is

blocked, this valve prevents the fuel tank from
excess pressure (the fuel tank would other-
wise inflate) or insufficient pressure (as fuel is
used, the fuel tank would be crushed).
C) Restriction valve
This valve prevents leaded fuel from entering

the fuel tank.
D) Valve preventing leaks if the vehicle is turned

over
If the vehicle is turned over, this valve pre-

vents the fuel tank from emptying, either
through the pipe to the canister or the brea-
ther pipe (Diesel). 99212R
Refitting the fuel filler cap releases the over-filling

valve (A), allowing the tank to breathe through
the breather.
19-24
FUEL TANK
Gauge 19
For petrol engines, the pump and gauge sender
unit are an inseparable assembly.
For diesel engines, there is no pump submerged in

the fuel tank, there is only a gauge sender unit.
For removing the gauge sender unit refer to the

section FUEL TANK "Pump - sender unit".
Checking the gauge sender unit
Value between terminals

Display
A1 and B1 (in Ω)
4/4 7 maximum
3/4 54.5 ± 7
1/2 98 ± 10
1/4 155 ± 16
Minimum 300 ± 20
Ensure the resistance varies by moving the float.
Display Height H (in mm)
4/4 48
3/4 90
1/2 133
1/4 147
Minimum 190
Measuring the height H
With the gauge sender unit removed, place it on a

flat surface.
H is the height measured between the float pin
and the working surface.
NOTE : these value are given for information only.
19-25
FUEL TANK
Pump and sender unit 19
Mot. 1264-01 Wrench for removing the pump -

sender unit nut.
unions (petrol engine)
Mot. 1265-01 Pliers for removing quick release
unions (diesel engine)
IMPORTANT :
During all operations on the fuel tank or fuel sup-
ply circuit, it is vital to:
- avoid smoking and keep all heat sources away
from the working area,
- take precautions against fuel splashes due to
the residual pressure in the fuel pipes when
they are removed.
REMOVAL
The fuel tank does not need to be removed to re-

move the pump and sender unit assembly. It may
be reached from inside the vehicle as follows :
- disconnect the battery,
- lift the rear bench seat,

97163R5
- remove the plastic cover,
- disconnect the electrical connector (1),
- remove the clips (2).
19-26
FUEL TANK
Use pliers Mot. 1265 (petrol engine) or Mot. 1265- Remove the mounting nut (5) using tool
01 (diesel engine) to disconnect: Mot. 1264-01 (release the nut, remove the tool
then slacken the nut by hand and remove it).
- the fuel supply pipe (3) (marked by a green
quick release union), Remove the pump and sender unit assembly.
- the fuel return pipe (4) (marked by a red quick

release union and an arrow (B)).
99367S
NOTE : if several hours may elapse between remo-

ving and refitting the pump and sender unit as-
sembly, refit the nut to the fuel tank to prevent it
from distorting.
96420R1
19-27
FUEL TANK
REFITTING
Check the seal is not damaged and renew it if ne-

cessary.
First fit the seal on the fuel tank before refitting

the assembly.
Position the pump and sender unit assembly (ar-

row (F) should be aligned with the longitudinal
axis of the vehicle, pointing backwards).
Fit the nut and tighten it to a torque of

3.5 daN.m.
Clip the fuel pipes back together (tools Mot. 1265

or Mot. 1265-01 do not need to be used).
Refit the safety clips (2).
Reconnect the electrical connector .
Refit the plastic cover.
ALLOCATION OF CONNECTOR TRACKS
TRACK ALLOCATION
A1 Earth
A2 Low fuel warning light
B1 Gauge information to instrument panel
B2 Not used
C1 Pump
C2 Pump
19-28
ENGINE SUSPENSION
F ENGINES
Suspended engine mountings 19
ADJUSTING THE LONGITUDINAL MOVEMENT LIMITER FOR F ENGINES

Insert the limiter centring fork Mot. 1289-03 into the openings on the suspended engine mounting cover.
Tighten the two bolts (E) to a torque of 5 to 6.5 daN.m.
F engine (petrol) F engine (diesel)
99174-2R
99166-1R1
19-29
ENGINE SUSPENSION
F3R ENGINE
99308R
* Tighten the stud to 6 daN.m

** Tighten the nut to 4 daN.m
19-30
ENGINE SUSPENSION
F8Q ENGINE
99309R1
* Tighten the stud to 6 daN.m

** Tighten the nut to 4 daN.m
19-31
ENGINE SUSPENSION
E7J/K7M ENGINE
Engine mounting pads 19
PRG19.1
19-32
ENGINE SUSPENSION
K7M ENGINE / AT
Engine mounting pads 19
PRG19.2
19-33
Transmission
CLUTCH
MANUAL GEARBOX
AUTOMATIC TRANSMISSION
DRIVESHAFTS
77 11 176 221 SEPTEMBER 1995 Edition Anglaise
C Régie Nationale des Usines Renault S.A. 1995

EXPLODED VIEW
PRG20.1
Transmission
Contents
Page Page
20 CLUTCH 23 AUTOMATIC TRANSMISSION

Identification 20-1 Section view 23-1
Section views 20-3 Use 23-2
Exploded views 20-3 Identification 23-3
Consumables 20-4 Gear ratios 23-3
Fault finding 20-5 Gear change thresholds 23-4
Mechanism - Plate 20-13 Consumables 23-5
Thrust pad - Fork 20-14 Parts to be systematically replaced 23-5
Oil 23-5
Oil change frequencies 23-6
Fault warning light 23-6
Draining 23-7
Filling - levels 23-8
Oil pressure 23-8
Hydraulic distributor 23-9
Automatic transmission (Removal -
Refitting) 23-15
Differential output seal 23-20
Wiring 23-23
Wiring diagram 23-27
Checking the "timing point" on the
21 MANUAL GEARBOX
converter 23-29
Identification 21-1
Ratios 21-2
Capacity -Lubricants 21-3
Special notes 21-4
Consumables 21-5 29 DRIVESHAFTS
Parts to be systematically replaced 21-5
Fault finding 21-6 Consumables 29-1
Gearbox (Removal - Refitting) 21-9 Driveshafts 29-2
5th gear on the vehicle 21-19 Front transverse driveshafts 29-9
Differential output seal 21-23 Gaiter on wheel end 29-10
Speedometer drive gear 21-26 Gaiter on gearbox end 29-17
Bearing gaiter 29-24
CLUTCH
Identification 20
ENGINE
MECHANISM PLATE
TYPE
E7J
85873S 90693R4 76906R
180 DST 3050 26 splines BC= White

E = 8.5 mm BU= Blue
D = 181.5 mm R = Red
N = Black
E7J
85873S 90693R3 76906R
180 CP 3300 26 splines V = Green

E = 8.3 mm G = Grey blue
D = 181.5 mm B = White
20-1
CLUTCH
Identification 20
ENGINE
MECHANISM PLATE
TYPE
K7M
85873S 90693R5 76906R
200 HR 4000 26 splines R = Light pink

D = 200 mm
E = 8.3 mm
F8Q
85873S 90693R6 76906R
200 HRV 3100 26 splines R = Red

D = 200 mm V = Green
E = 8.3 mm J = Yellow
20-2
CLUTCH
Section views 20
Dry operating cable controlled monodisc clutch.
Clutch plate with diaphragm.
Rubber hub mounted clutch plate.
Self-centring guided and constant pressure thrust

pad.
Automatic wear adjustment.
DI2001
Exploded view
PRD2004
20-3
CLUTCH
Consumables 20
Type Packaging Part number Component
Splines of the right hand sunwheel

Fork pivot
MOLYKOTE BR2 1 kg tin 77 01 421 145
Thrust pad guide CLUTCH
Fork pads
LOCTITE 518 24 ml syringe 77 01 421 162 Housing assembly surfaces
20-4
CLUTCH
Fault finding 20
KEY The clutch is slipping :
- when stopped, handbrake on, at 2000 to
Fault found 3000 rpm, impossible to stall the engine
when letting the clutch in,
- with 4th or 5th gear engaged, the engine
Check seems to race.
Operations to be Check the travel of

carried out the fork (1)
INCORRECT CORRECT
Check the
clearance
CORRECT INCORRECT
Check the
automatic
Check the condition adjustment device
of the cable and the
anti-noise rubber
washer (2)
INCORRECT CORRECT
INCORRECT CORRECT
Repair the
automatic
Replace the Check the condition adjustment
faulty parts of the pedal and the device
assistance spring (*)
CORRECT INCORRECT
Check the Replace the Check the condition

condition of the faulty parts of the clutch
fork
INCORRECT CORRECT OILY WORN
Replace the Check the Replace the clutch and Replace the
fork condition of the repair the leak clutch
pins and support
points
(*) Depending on version (2) Grommet placed on the end of the clutch
(1) See "Removal - Refitting" chapter cable on the gearbox end
20-5
CLUTCH
Fault finding 20
The gearbox clunks.
Clutch pedal fully pressed down :
- vehicle stationary,
- engine running.
Check the automatic

adjustment system
INCORRECT CORRECT
Toothed sector
jammed or spring Check the condition of
broken the cable and the anti-
noise rubber washer (1)
INCORRECT INCORRECT CORRECT
Check the condition

Replace the faulty of the pedal
parts
CORRECT
INCORRECT CORRECT
Replace the faulty Replace the clutch fork or

parts check that it is correctly
positioned
Clutch operation
CORRECT INCORRECT
Clutch stuck
Replace the faulty parts

Free the clutch
Rare case, may occur

after the vehicle has been
stopped for a long time (1) Grommet placed on the end of the clutch cable on
(several months) the gearbox end
20-6
CLUTCH
Fault finding 20
The gearbox clunks in 1st or
reverse gear only when
cold:
- vehicle stationary,
- engine running.
Check the grade

of the
gearbox oil
INCORRECT CORRECT
Check the internal

Change the oil
parts of the gearbox
20-7
CLUTCH
Fault finding 20
The gears are difficult to
engage :
- vehicle moving.
Check the travel of

the fork (1)
INCORRECT CORRECT
Check the gearbox

Check the clearance
control lever
INCORRECT CORRECT INCORRECT CORRECT
Check the Replace the Check the internal

automatic faulty parts parts of the
adjustment device gearbox
Check the condition

CORRECT INCORRECT of the cable and the
anti-noise rubber
washer (2)
Check the INCORRECT CORRECT
condition of the
clutch
Repair the Replace the Check the condition

automatic faulty parts of the pedal and the
adjustment assistance spring (*)
device
CORRECT INCORRECT
Check the condition Replace the

of the fork faulty parts
INCORRECT CORRECT
Replace the Check the condition

fork of the pins and
support points
(*) Depending on version (2) Grommet positioned on the end of the clutch
(1) See "Removal - Refitting" chapter cable on the gearbox end
20-8
CLUTCH
Fault finding 20
Impossible to change gear
Check the condition

of the gear control
lever
CORRECT INCORRECT
Replace the faulty

Check the clutch control parts
INCORRECT CORRECT
Replace the faulty

parts
Check the condition

of the clutch
CORRECT INCORRECT
Check the internal Replace the faulty

parts of the gearbox parts
20-9
CLUTCH
Fault finding 20
Juddering
Check the travel of

the fork(1) CORRECT
INCORREC
Check the condition
of the gearbox
mountings
Check the clearance
INCORRECT CORRECT
INCORRECT CORRECT Change the clutch Change the

plate and repair mountings, check
the leak the engine
mountings are
Check the tight and check
automatic that the gearbox is
clearance device properly mounted
on the engine
Check the condition
CORRECT INCORRECT of the cable and the
anti-noise rubber
washer (2)
Check the INCORREC CORRECT
condition of the
clutch
Repair the Replace the Check the condition

automatic faulty parts of the pedal and
adjustment assistance spring (*)
device
CORRECT INCORRECT
Check the condition Replace the

of the fork faulty parts
INCORRECT CORRECT
Replace the Check the

fork condition of the
pins and support
points
(*) Depending on version (2) Grommet positioned on the end of the clutch
(1) See "Removal - Refitting" chapter cable on the gearbox side.
20-10
CLUTCH
Fault finding 20
Pedal is stiff
Check the condition of

the pedal and assistance
spring (*)
CORRECT INCORRECT
Check the clutch control Repair the faulty

and cable routing parts
INCORRECT CORRECT
Replace the faulty Check the condition

parts of the clutch and that
the thrust pad slides
freely
(*) Depending on version
20-11
CLUTCH
Fault finding 20
Whistling when The clutch pedal The clutch pedal goes to
letting the clutch out clunks the floor
Clutch thrust pad Grease the clutch Check the toothed

seized pedal pin sector
INCORRECT CORRECT INCORRECT CORRECT

Replace the thrust pad
Toothed sector
Pedal pin worn
broken
Replace the clutch Replace the faulty

pedal pin and parts
bearings
Check the cable
INCORRECT CORRECT
Replace the Check the fork, the

cable thrust pad and the
clutch
20-12
CLUTCH
Mechanism - Plate 20
REPLACEMENT
This operation is performed after the gearbox has been removed.
Mot. 582 Locking piece

Plus the tooling for removing the gearbox
TIGHTENING TORQUES (in daN.m) REFITTING
Diameter 7mm mechanism bolt for Degrease the mounting face of the flywheel.
160 and 180 diameter clutch 1.8
Position the plate (hub offset fitted on the gear-
Diameter 8mm mechanism bolt for
box end).
diameter 215 clutch 2.25
Centre it using the tool supplied in the replace-
ment kit.
REMOVAL
Fit:
- the locking piece Mot. 582,
- the centring device (to prevent the friction
plate falling out).
Remove the mounting bolts from the mechanism

and remove the mechanism and the clutch plate.
Check and replace any faulty parts.
95414S
Progressively tighten in a star arrangement, then

lock the mechanism mounting bolts at the correct
torque.
Remove the locking piece Mot. 582.
Coat with MOLYKOTE BR2 grease:

- the guide tube,
- the fork pads.
99055R
20-13
CLUTCH
Thrust pad - Fork 20
REPLACING
This operation is performed after the gearbox has

been removed.
REMOVAL
Pull out:
- the thrust pad by tilting the fork,
- the rubber protector and pull the fork to-
wards the inside of the clutch housing.
REFITTING
Coat the sides of the guide tube and the fork pads
with MOLYKOTE BR2.
Position the fork and replace the rubber protec-

tor.
Put the thrust pad on the guide tube by placing

the lugs (A) into the fork.
99054R
Ensure that it slides freely.
NOTE : when performing an operation which

does not require the gearbox to be removed or af-
ter fitting the gearbox, DO NOT LIFT the fork
since the lug (A) may be removed from the thrust
pad.
20-14
CLUTCH
Thrust pad Fork 20
After the gearbox has been refitted, position the
cable on the clutch fork, reset the toothed sector
and check that the play compensation device
works.
Check the clutch travel.
The fork travel should be:

X = 27.4 to 30.7 mm
97758-1R
20-15
MANUAL GEARBOX
Identification 21
B64 vehicles are fitted with JB or JC type gearboxes
MR "B.V. JB" and MR "B.V. JC" cover the complete repair process for these components.
87227G
NEW IDENTIFICATION PLATE
At A : the gearbox type A J B0 0 0 0 B

At B : the gearbox suffix
At C : the fabrication number D X X0 0 0 0 0 C
At D : the factory of manufacture E
At E : a notch when the gearbox is assembled with
an E engine
At F : the letter preceding fabrication numbers F
greater than 999999
21-1
MANUAL GEARBOX
Ratios 21
JB1
Step Speedo Reverse
Suffix Vehicle 1st 2nd 3rd 4th 5th
down gear
54 15
BA0E
95 61 11 21
41 43
129 BA0U 15 21 28 30 39 11
68 BA0A 26
56 19 37 29 31 39
119 120 BA0L 15 11 22
123 124 BA0F 58 37 41
Gearbox JB1
Suffix 95 119 123
AC X X X
JB3
Step Speedo Reverse
down gear
15 21 11 22 28 30 42 11
106 BA0G 26
61 19 34 41 37 29 31 39
JC5
Step Speedo Reverse
down gear
17 21 11 21 35 41
35 BA09
56 19 41 43 28 34 31 11
26
15 21 11 22 37 34 39 39
25 BA0H
61 18 37 41 35 32
21-2
MANUAL GEARBOX
Capacity - Lubricants 21
CAPACITY (in litres)
5-speed gearbox
JB1 3.4
JB3 3.4
JC5 3.1
Viscosity - Grade
TRX 75W 80W
CHECKING THE LEVEL
92081S
Fill up to the level of the aperture.
21-3
MANUAL GEARBOX
Special notes 21
Gearboxes: GEAR LAYOUT
JB1 5 forward gears
JB3
JC5 1 reverse gear
are fitted with BORG-WARNER synchros.
R 1 3 5
Special notes on the JB3 gearbox
The JC5 gearbox differs from the JB3 gearbox in

the following ways :
- wider teeth on the gears in 1st, 2nd, 3rd and 2 4
4th, B.V. JB - JC
- rings under the gears in 2nd, 3rd and 4th,
- offset dog gears on the idle gears in 1st, 2nd
and 4th, To engage reverse gear, lift the locking ring (A)
- a new 65.5 mm diameter 1st and 2nd synchro, and move the lever.
- the use of tapered bearings on the primary and
secondary shafts,
- a guide tube with a double seal on the housing
and clutch shaft which can be removed without
opening the gearbox,
- mechanism and clutch housing reinforced ,
- wider torque teeth on the final drive .
DI2118
21-4
MANUAL GEARBOX
Consumables 21
JB and JC
TYPE PACKAGING PART NUMBER COMPONENT
Clutch shaft splines

Fork pivot
MOLYKOTE BR2 1 kg tin 77 01 421 145 Thrust pad guide Clutch
Fork pads
Loctite 518 24 ml syringe 77 01 421 162 Housing assembly faces
Threaded plugs and switches

RHODORSEAL 5661 Bearing plugs
100 g tube 77 01 404 452
Eg : CAF 4/60 THIXO Ends of roll pins on driveshafts
LOCTITE FRENBLOC Primary and secondary shaft nuts

(locking and sealing 24 cc bottle 77 01 394 071 5th gear fixed gear and hub
resin) Differential lock drive stud
Parts to be systematically replaced
When they have been removed:

- lip seals,
- O rings
- thrust pad guide tubes,
- secondary shaft and differential nuts,
- speedo gear and its pin,
- speedo crown wheel,
- roll pins,
- rings under the gears.
21-5
MANUAL GEARBOX
Diagnostic 21
Grinding noise when Clunking when each gear is
engaging a gear engaged
(after checking clutch)
Remove the gearbox Remove the gearbox
Check the synchro and Check the synchros

the synchro spring of and the synchro hubs
the faulty gear
Impossible to engage gears

(after checking the clutch)
Check the
adjustment of
the selection
linkage
Correct Incorrect
Adjust the linkage

Condition
of the parts of
the linkage
Correct Incorrect
KEY
Remove the gearbox Replace the faulty
parts Operations to be
carried out
Check the gearbox Adjust the linkage

locking system
Check
21-6
MANUAL GEARBOX
Diagnostic 21
Abnormal noises when driving
• Stop the vehicle

• Engine running
• Gear lever in neutral
The noise
No
stops
Clutch fully depressed
Amount
of clearance
The noise
stops
Correct Incorrect
Yes Yes
Check the toothed
sector of the clutch
pedal and the
Oil level cable
Remove the gearbox

and repair it
Check The noise

driveshafts stops
Correct Incorrect Yes No
Check Replace the

wheel driveshafts
bearings No
Check the thrust

Correct Incorrect pad, cable and Look for the
plate noise in the
engine
Remove the Replace the Look for the noise in

gearbox and wheel bearings Replace the faulty the engine
repair it parts
21-7
MANUAL GEARBOX
Diagnostic 21
Gears jump out
Check
engine and
gearbox
mountings
Correct Incorrect
Adjust the Tighten the bolts or Gear sticking

linkage replace the
mountings
Adjust the
control
Correct Incorrect
Correct Incorrect

parts
Check the locking

system of the hubs
Adjust the linkage Check the
and sliding gears Adjust the gearbox
parts forming
control
the control
Correct Incorrect

and check: parts
- the locking balls

- the forks
- the locking plungers
Adjust the linkage
21-8
MANUAL GEARBOX
All engines
Gearbox (Removal - Refitting) 21
B.Vi. 31-01 Set of pins


- the two mounting bolts from the caliper by se-
Bolts of the rear linkage of the suspended curing the caliper to the suspension spring to
engine mountings (tie-bar) 6 avoid stretching the pipe,
Bolts for securing battery mounting on body 2
- the three mounting bolts of the driveshaft gai-
Driveshaft gaiter mounting bolt 2.4 ter.
Gearbox mounting bolt 3.5
Gearbox control rod bolt 2.8
Stub-axle key nut 6
Support mounting bolts 4.5
Wheel bolts 9
Caliper guide bolts 2.7
REMOVAL
- Put the vehicle on a two post lift.

- Disconnect the battery.
- Remove the front wheels.
- Remove the engine undertray.
- Drain the gearbox.
LEFT HAND SIDE OF THE VEHICLE:

92122R2
Remove:
- the wheel arch (protection),
- the track rod end using tool T.Av. 476.
85965R
21-9
MANUAL GEARBOX
All engines
Gearbox (Removal - Refitting) 21
Remove : RIGHT HAND SIDE OF THE VEHICLE:
- the bolt (1),
- the 2 mounting bolts (2) from the base of the Remove the driveshaft pins using tool B.Vi. 31-01
shock absorber,
90130R2 91755-1R2
- the stub-axle carrier driveshaft assembly by re-

leasing the lower ball joint, Remove the bolts from the base of the shock ab-
- the sub-frame-side member tie rod (A). sorber.
98712R1
99070R1
Tilt the stub-axle carrier and release the drives-
Check that the driveshaft rollers cannot be remo- haft.
ved by hand. If this is the case, when refitting, Remove the stub-axle carrier driveshaft assembly
check that the needles have not fallen into the by releasing the lower ball joint.
gearbox. Remove and secure the brake caliper.
Remove the mudguard.
Remove the sub-frame body tie rod.
21-10
MANUAL GEARBOX
E and K
engines Gearbox (Removal - Refitting) 21
Special notes for E7J - K7M engines REFITTING
Remove the engine/gearbox assembly from above Coat the sides of the guide tube and the fork pads
(see Workshop Repair Manual Chap. 10). with MOLYKOTE BR2 grease.
Once the engine and transmission assembly is sui- Position the fork on the notches of the clutch
tably clear, remove the bolts from around the thrust pad.
gearbox.
Connect the engine to the gearbox.
Release the gearbox from the engine by removing
the pin (C). Check that the rings (C) for centring the engine-
gearbox are present and are in the correct posi-
tion.
86308R2
86415R2
Refit:
- the heat shield,
- the exhaust downpipe.
Refit the other components by carrying out the re-

moval operations in reverse (see Workshop Repair
Manual Chapter 10).
21-11
MANUAL GEARBOX
E and K
engines Gearbox (Removal - Refitting) 21
IMPORTANT Position the driveshaft with respect to the sun-
Fit the bolt (V) and the starter motor centring do- wheel, pivot the stub-axle carrier and engage the
wel (D) correctly : driveshaft into the sunwheel using the shouldered
pin B.Vi. 31-01 in order to align the holes.
E and K engines
74937-4S
86070R3
A chamfer on the leading edge of the sunwheel

Reconnect the speedo cable, ensuring that the clip makes it easier to fit new roll pins.
is the correct way round.
Seal the ends (RHODORSEAL 5661).
Fill with fluids.
Fit the caliper mounting bolts with Loctite

FRENBLOC and tighten to the correct torque.

pistons back into contact with the brake pads.
92108-1S Tighten all nuts and bolts to the recommended

torques.
Fill the gearbox with oil.
21-12
MANUAL GEARBOX
F
engine Gearbox (Removal - Refitting) 21
Special notes for the F engine Remove gear control, bolt (F).
Under the vehicle, remove the 2 mounting bolts

(B) from the power assisted steering pipe clamps.
98749R1
85966R1
Remove the 2 bolts (H) from the engine-gearbox
tie-rod.
Disconnect:
- the wires from the starter motor,
- the reversing light switch,
- the speedo cable.
Remove the engine/gearbox mounting nut.
98902R
Slacken the 2 mounting bolts (C) on the engine

from the engine-gearbox tie-rod.
85812-1R
21-13
MANUAL GEARBOX
F
Slacken but do not remove bolt (B) then remove Remove :
mounting bolt (C) from the suspended engine - the air filter sleeve,
mounting rod. - the tie-rod from the shock absorber turret,
- the clutch cable.
99309R
89204S
Remove the rear mounting.
Position the engine support tool and take the
Remove shock absorber actuator (on version F8Q). weight of the engine and transmission assembly.
Remove :
- the expansion bottle,
- the air filter mounting.
Release the wiring.
98750S
99213S
21-14
MANUAL GEARBOX
F
Remove the upper mounting assembly on the Remove the heat shield.
gearbox end .
99309S1 98827S
Remove : Remove gear lever return spring.

- the bolts around the gearbox,
- the starter motor, Move and secure the gear lever towards the rear.
- the connectors linked to the gearbox.
Remove the exhaust downpipe.
98865R2
21-15
MANUAL GEARBOX
F
Remove the steering box mounting bolts. Release the steering box and the steering column
(be careful not to damage the clip (C)).
98868-1R
Remove the mounting bolts of the power assisted

steering pipes from the sub-frame.
Secure the steering box to the side members.
97390-1R1
Special notes for vehicles fitted with driver’s
AIRBAG Remove the horn.
ATTENTION : From above:

to prevent any damage being done to the rota-
ting switch under the steering wheel, please fol- Secure the cooling assembly to the upper cross
low these instructions : member.
- before releasing the steering column and the
rack, the steering wheel MUST be immobilised, Remove the upper mounting bolt from the bum-
wheels straight, using the "steering wheel per then the bolts located in the wheel arches.
locking" tool throughout the duration of the
repair,
- any doubts regarding the correct centring of
the rotating switch means that the steering
wheel has to be removed so as to apply the
centring method as described in chapter 88
"AIR-BAG".
REMINDER: in this case, only qualified personnel

who have received specific training may under-
take this work.
98836R1
21-16
MANUAL GEARBOX
F
Position the sub-frame support trolley and lower REFITTING
the vehicle.
Coat the sides of the guide tube and the fork pads
with MOLYKOTE BR2 grease.
Position the fork on the notches of the clutch

thrust pad.
Offer the gearbox up using the component jack.
Connect the engine to the gearbox.
Check that the dowels for centring the engine-

gearbox are present and are in the correct posi-
tion.
98755R1
Remove the sub-frame by loosening the 4 moun-

ting bolts.
Be careful not to forget to remove the power as-

sisted steering pipe mounting from the sub-
frame.
Under the vehicle :

- position the component jack under the gearbox
without lifting it,
- release the gearbox and the engine by remo-
ving the studs (C).
86415S
Refit:
- the assembled support,
- the sub-frame,
- the steering.
Refit:
- the heat screen,
- the suspended engine mounting bar.
Refit the other components by carrying out the re-

moval operations in reverse.
86308R2
21-17
MANUAL GEARBOX
F
F engine Position the driveshaft with respect to the sun-
wheel, pivot the stub-axle carrier, engaging the
driveshaft into the sunwheel using the shouldered
pin B.Vi. 31-01 in order to align the holes.
86070-1R1
Check the adjustments of the upper mountings

(refer to chapter 10). 74937-4S
Ensure that the movement limiter is mounted the A chamfer on the leading edge of the sunwheel
correct way round: the nuts should be fitted on facilitates makes it easier to fit new roll pins.
the exhaust pipe side.
Seal the ends (RHODORSEAL 5661).
Fill with fluids.
Fit the caliper mounting bolts with Loctite

FRENBLOC and tighten to the correct torque.

Tighten all nuts and bolts to the recommended

92661S torques.
21-18
MANUAL GEARBOX
5th gear on the vehicle 21
B.Vi. 28-01 Extractor body

B.Vi. 31-01 Set of pins for extracting and
fitting 5 mm diameter roll pins
B.Vi. 1003 5th gear hub extractor
B.Vi. 1007 Claws for B.Vi. 28-01
TIGHTENING TORQUES (In daN.m) CONSUMABLES
Loctite FRENBLOC :
Primary shaft nut 13.5 Primary shaft nut
Secondary shaft bolt
Secondary shaft bolt 6.3 5th fixed gear
5th gear hub
REMOVAL Position:
- a draining container under the rear housing
Put the vehicle on a 2 post lift. and remove the housing,
- a wooden block between the 5th gear fork
Remove the front left hand wheel. and the drive pinion to absorb the backlash;
then remove the pin from the fork using B.Vi.
Remove the protection from the wheel arch. 31.01.
Remove the sub-frame-side member tie-rod. SPECIAL NOTE

Do not pull the 5th gear fork pin outwards since
Remove the engine undertray. the locking ball will fall into the gearbox, for safe-
ty, engage a gear (3rd or 4th).
Drain the gearbox Removing the pin can be made easier by slightly
bending the pin of tool B.Vi. 31.01 in order to
The rear housing must be removed along the hori- prevent the gearbox being lifted.
zontal axis of the gearbox since it contains a lubri-
cation nozzle (A) which enters the primary shaft.
87180R 85979R
21-19
MANUAL GEARBOX
Lock the gearbox by putting the gear lever in 1st On the primary shaft :
gear and the gearbox in 5th gear by sliding the
5th gear fork inwards along its shaft. Remove the 5th gear fork and the sliding gear, ta-
king care not to pull the 5th gear pin outwards.
Extract the synchro hub using tool B.Vi. 1170.
93912-1R 93190S1
Release and remove the primary shaft nut and the Position the sliding gear of tool B.Vi. 1170 as if to
secondary shaft bolt (65). change into 5th gear and turn it so that the
splines of the sliding gear are opposite the splines
Put the gearbox in neutral. of the hub .
Extract the 5th gear assembly.
86045S
21-20
MANUAL GEARBOX
On the secondary shaft: REFITTING
Remove the shouldered washer (64). On the secondary shaft:
Apply 3 drops of Loctite FRENBLOC to the splines

of the fixed gear.
Fit the shouldered washer (64).
On the primary shaft :
Refit in the correct order (21) (shoulder facing the

ring (22), (23), (24) and (8)).
Put the fork on the sliding gear (26) fitted with

(25).
Apply 3 drops of Loctite FRENBLOC to the hub and

PRG21.1 replace the sliding gear hub and fork assembly.
Fit the synchro ring bosses in the lugs on the hub.

Extract the fixed gear using B.Vi. 28-01 fitted with
its claws B.Vi. 1007.
88575R 86045R1
Put the gear lever in 1st gear and the gearbox in

5th gear by sliding the 5th gear fork on its shaft.
Apply 3 drops of Loctite FRENBLOC:

- to the primary shaft nut (27) and tighten it to
a torque of 13.5 daN.m,
- on bolt (65) and tighten it to a torque of 6.3
daN.m to fit the fixed gear securely.
21-21
MANUAL GEARBOX
Put a wooden block between the 5th gear fork Fit the rear housing by engaging nozzle (A) into
and the drive gear to take the backlash and refit a the primary shaft.
new pin into the 5th gear fork using B.Vi. 31-01
complying with the assembly direction, the split Tighten the mounting bolts to a torque of 2.4
should be pointing towards the rear housing. daN.m.
90498-1S
87180R
Check that the rear housing does not leak when

the engine is running.
85979R1
Fit a new O-ring to ensure that the rear housing is

sealed.
Return the gearbox to neutral and check that all

gears can be engaged.
If any problems occur, check that reverse gear is

not engaged.
21-22
MANUAL GEARBOX
Differential output seal 21
B.Vi. 31-01 Set of pins

B.Vi. 945 Mandrel for fitting differential seals
B.Vi. 1058 Mandrel for fitting differential seals
(JB3 tapered bearings)
TIGHTENING TORQUES (in daN.m) CONSUMABLES
Loctite FRENBLOC :
Brake caliper mounting bolt 2.7 Brake caliper mounting bolt
Shock absorber base mounting bolts 17 RHODORSEAL 5661 (Eg. CAF 4/60 THIXO) :
Ends of driveshaft pins
Track rod end 3.5
MOLYKOTE BR2 :
Wheel bolts 9 Right hand sunwheel splines
REMOVAL Remove :
- the track rod end (tool T.Av. 476),
Drain the gearbox.
Put the front of the side being worked on on axle

stands.
Remove the wheel.
Extract the driveshaft pins using tool B.Vi. 31-01.
85965R
91755R
21-23
MANUAL GEARBOX
- the two mounting bolts (A) of the brake assem- REFITTING
bly.
1. JB1 - JB3 gearboxes
The seal is refitted using tool B.Vi. 945 comprising:

- a seal protector (A),
- a tool for positioning the seal (B).
2.7 daN.m
90149R1
Secure the caliper to the suspension spring to pre-

vent the pipe being damaged.
Slacken the lower bolt (3) from the base of the

shock absorber and remove the upper bolt (4).
86095R
Tilt the stub-axle carrier and release the driveshaft
(take care not to "damage" the gaiters during this
operation). METHOD
Remove the O-ring from the sunwheel. Put the oiled protector (A) onto the sunwheel and
position the oiled seal (C) with the tool (B).
Tap the base of the lip seal using a pin extractor
and a small hammer in order to extract it from its
housing .
When the seal is released, remove it using pliers

taking care not to damage the splines of the sun-
wheel.
86122R
86031S
21-24
MANUAL GEARBOX
Continue in the same way but using tool B.Vi. Fit new roll pins and seal the ends with
1058 and protector (A) of B.Vi. 945. RHODORSEAL 5661 (Eg. CAF 4/60 THIXO).
Tighten the nuts and bolts to the recommended

torques.
Refit the brake caliper and coat the bolts with

Loctite FRENBLOC.
92111R
Fit the O-ring to the sunwheel and coat the splines

with grease N° 20.
Position the driveshaft with respect to the sun-

wheel.
Pivot the stub-axle carrier, engaging the drives-

haft into the sunwheel using pin B.Vi. 31-01 to
align the holes.
74937-3S
21-25
MANUAL GEARBOX
Speedometer drive gear 21
REPLACEMENT REFITTING
1st case : Refit a new speedo gear using a pair of flat nose
Only the speedo gear or the pin is damaged. pliers.
The gear and its pin should be refitted by hand.

REMOVAL The pin must be correctly positioned with respect
to the key lugs on the gear due to the elasticity of
The gearbox does not have to be completely dis- the lips of the pin.
mantled.
Release the left hand driveshaft.
Remove the sunwheel spider. Correct Incorrect
Rotate the differential by hand so that the speedo

gear is accessible.
Unclip the pin by pulling it vertically using a pair

of long nose pliers.
Using these pliers, remove the gear from its hou-

sing.
86053S
Ensure that it is correctly clipped in.
Refit the sunwheel spider.
2nd case :
The speedo gear and crown wheel are damaged
The gearbox has to be removed and the final drive

88577S
has to be dismantled.
21-26
Section view 23
TYPE AD4 AUTOMATIC TRANSMISSION
DI2302
23-1
Use 23
DRIVING
The automatic transmission is lubricated under

pressure and therefore this only occurs if the en-
gine is running.
As a result, and with the risk of serious damage,

the following instructions must be complied with:
- never drive with the ignition off (going down-

hill for example), we cannot stress enough how
dangerous this practice is.
- never push a vehicle (eg. : to reach a petrol

pump), except by following the instructions in
the "Towing" paragraph.
In addition, the vehicle is only driven if the engine

is running. It is therefore impossible to start the
engine of a vehicle with automatic transmission
by pushing it.
TOWING
In all cases, it is preferable to tow the vehicle on a

trailer or with the front wheels off the ground.
However, if this is not possible, the vehicle can be
towed at a speed below 25 mph (40 km/h and
over a maximum distance of 30 miles (50 km) (le-
ver in N).
23-2
Identification 23
TRANS-
STEP ELECTRONIC
VEHICLE MISSION ENGINE CONVERTER RATIO SPEEDO
DOWN UNIT*
TYPE
BA0 AD4 013 K7M 227 69/77 19/65 22/20 114
* For identifying with the XR25 test kit, see MR TA.A.
Gear ratios
Gear 1st 2nd 3rd 4th Reverse
Gear reduction 2.71 1.55 1 0.68 2.11
Overall reduction 10.35 5.92 3.82 2,6 8.06
Speed in km/h at 1000 rpm. with

10.19 17.83 27.66 40.79 13.11
1.76 m tyres
23-3
Gear change thresholds 23
ACCELER- 1 2 2 3 3 4 4 3 3 2 2 1
VEHICLES TRANS- ATOR
MISSION TYPE POSITION A B A B A B A B A B A B
PL 16 20 40 46 64 73 50 59 32 34 7 15
BA0 AD4 PF 41 49 76 95 126 149 107 127 65 81 28 32
RC 52 96 158 146 90 48
The figures given in the table represent the average theoretical speed values for changing gear in km/h
tolerances = ± 10 %.
PL : No load.
PF : Full load.
RC : Kickdown (changing to a lower gear).
A : Gear change thresholds are set lower down. Gears change at a lower speed. Switch (1) is not activated
and the warning light EXC is extinguished.
B : Gear change thresholds are set higher up. Gears change at a higher speed. Switch (1) is activated and the
warning light EXC is illuminated.
98597R
23-4
Consumables 23
DESCRIPTION COMPONENT AFFECTED
RHODORSEAL 5661
Seals the driveshaft pins
(Eg : CAF 4/60 THIXO)
- Sunwheel splines
MOLYKOTE BR2 grease
- Converter centrer
Loctite FRENBLOC Brake caliper mounting bolt
Parts to be systematically replaced
Parts to be replaced after they have been

removed :
- roll pin,
- lock nuts,
- copper seals.
Oil
AD4 automatic transmission uses two grades of oil and has two levels.
MECHANISM : ELF RENAULTMATIC D2 (D20104).
In emergency, use:
- MOBIL ATF 220 D (D 20104 or D 21412).

- TEXAMATIC 4011.
FINAL DRIVE: TRANSELF TRX 75W 80W.
23-5
Oil change frequencies 23
The mechanism is drained during the major service.
The oil level must be checked every 10000 miles (15 000 km) in case there is a slight oil leak.
The final drive is never drained ; it is filled for life.
The strainer is no longer replaced (NT 2261A).
Only the level may change due to a slight leak.
Oil capacity
TOTAL volume
MECHANISM 5.7 l
FINAL DRIVE 1l
NOTE : if the automatic transmission is replaced, only check the oil level since the transmission is supplied by
the Parts Department full of oil.
Fault warning light
MESSAGE FROM THE ELECTRONIC FAULT

WARNING LIGHT
Oil temperature < - 20 °C or > + 140 °C
Normal operation :
• Vehicle moving or stationary, warning light
• The warning light is not illuminated during flashes at a rate of approximately 1 flash per
normal operation whether the vehicle is being second, in this case, reduce the performance
started, engine running or when the vehicle is requirement by moderating acceleration.
stationary.
Presence of a fault :
• Vehicle stopped, engine running, or when

driving, warning light permanently illuminated
• Vehicle moving, warning light illuminates and

extinguishes without action at the ignition key.
• Vehicle moving, warning light illuminates

briefly.
23-6
Draining 23
SPECIAL TOOLING REQUIRED Final drive:
B.Vi. 1213 Automatic transmission drain Filling and topping up are performed through
spanner plug (C) which overflows when the level is
MS 1019-10 XR25 test kit exceeded.
DRAINING
Mechanism :
Mechanism sump with two plugs:
A : Top-up plug.
B : Drain plug (triangular socket).
Draining is performed by removing plug (B).
94882R
Reminder:
The final drive is never drained, it is filled for life.
94882R2
23-7
Filling - Levels 23
FILLING - TOPPING UP Before starting:
- if the gearbox has been drained, fill it with 3.5
Filling is performed though tube (D). litres of oil,
- if you are simply checking the level, you must
add 0.5 litre of the recommended type of oil.
1 - Vehicle on a 4 post lift, transmission at am-

bient temperature.
2 - Start the engine with the selector lever in the

Park position.
3 - Connect the XR25 test kit and enter:
D 1 4 then # 0 4
4 - Raise the vehicle and allow the engine to run

until it reaches a temperature of 60 °C.
5 - When the desired temperature has been rea-

ched, open the top-up plug; allow the excess
oil to overflow (must be more than 0.1 litre)
for approximately 20 seconds. Replace the
94845R1 plug
Use a funnel fitted with a 15/100 filter so as to 6 - If the volume of oil which flowed out is less
prevent any impurities entering. than 0.1 litre, the level is not correct. Repeat
the operation.
The level MUST be checked in accordance with the
following method:
In this case, add 1 litre of the recommended oil
and allow the transmission to cool down between
successive operations.
Oil pressure
The transmission is fitted with an oil pressure

take-off. Connect the B.Vi. 1215 to check the
automatic transmission pressure sensor only.
The oil pressure cannot be altered.
Its value is determined by the electronic compu-

ter.
94845-1R
23-8
Hydraulic Distributor 23
TIGHTENING TORQUES (In daN.m) For versions with ABS
Remove the mounting nut (C) from the ABS

Strainer mounting bolts 0.5 electro-pump assembly on the rubber mounting.
Sump mounting bolts 1
Mounting bolts for engine mounting
dampers on side member 2
Rear support mounting bolts 6.5
Wheel bolts 9
Strainer mounting bolts 0.5
Distributor mounting bolts 0.5
REMOVAL
Put the vehicle on a 2 post lift. 94933R
Put the lever in the "P" (Park) position.

Remove the front left hand wheel and remove the
Drain the automatic transmission (mechanismsec- plastic shield from the wheel arch (in order to be
tion; drain plug with triangular socket). able to remove the two rear mounting bolts of
the automatic transmission sump at a later stage).
Remove:
Using the component jack, raise the automatic
- the expansion bottle, transmission.
- the air filter,
- the two upper bolts (A) of the engine moun-
ting damper and slacken the other two (B), wi-
thout removing them.
94933-1R 94887S
23-9
Remove: This extra travel is required to release the drive
from the control sector of the manual valve.
- the sump from the automatic transmission,
- the strainer and its seal (bolt 1),
94841R
92084R
Disconnect the sealed connector cable by pressing
on the locking ring.
- the gear control cable from the selector (2) so
that the lever can be moved past the "Park" po-
sition.
94925S
99586R
23-10
Remove the sealed connector after having remo- Remove the 16 mounting bolts from the hydraulic
ved the bolt (3). distributor. The bolts marked (*) remain in place
and secure the distributor closing plate.
94848-1R 94841-1R2
Remove the manual valve selector (4) by firstly re- Push the gear control selector in fully and release
leasing at (A) and then at (B). the hydraulic distributor by releasing the modula-
ting solenoid valve from the sump (5).
Extract the manual valve from the hydraulic distri-
butor.
94848R 91724R
23-11
Ensure that the inserts (6) and the filter (7) have
stayed in position in the sump’s hydraulic circuit.
91724R
Replace the 16 bolts for mounting the distributor

94852R2 onto the sump and tighten them to a torque of
0.5 daN.m. in accordance with the order shown.
REFITTING
Ensure that the supply tube F1 (8), the modulating

solenoid valve filter (7), and the circuit inserts (6)
are in place.
94841-1R1
94852R1
Engage the hydraulic distributor.
Push the gear control selector in fully taking care

to engage the modulating solenoid valve into the
sump (5) correctly.
23-12
Refit the manual valve and the selector (4) by en- Fit a new strainer and new seal.
gaging firstly part (A) and then part (B).
Tighten to a torque of 0.5 daN.m.
94840R
91350R4
Replace the sump (Ensure that the seals are not
Refit the sealed connector fitted with its O-ring damaged and check that the magnet is present).
and bolt (3).
Tighten the bolts to a torque of 1 daN.m.
Refit the automatic transmission.
Replace the bolts of the transmission mounting

dampers.
94848-1R
94933-1S
Reconnect the sealed connector.
Refit the gear selector.
23-13
On versions with ABS
Refit the mounting nut (C) from the ABS electro-

pump unit on the rubber mounting.
94933R
Refit:
- the plastic shield in the front left wheel arch,
- the front left hand wheel,
- the air filter,
- the expansion bottle.
Fill with oil and check the level.
NOTE :every time the hydraulic distributor is re-

placed or removed, replace the modulating sole-
noid valve filter, the strainer and its seal.
23-14
K7M
ENGINE
Automatic transmission (Removal - Refitting) 23
REMOVING FROM UNDERNEATH
Mot. 1040-01 Dummy cradle for removing-

Mot. 1202 Hose clamp pliers
TIGHTENING TORQUES (in daN.m) - the left and right hand mudguards,
Sub-frame front mounting bolts 6

Sub-frame rear mounting bolts 11
Shock absorber upper cup mounting bolts 3
Wheel bolts 9
Brake caliper mounting bolts 3.5
Steering universal joint mounting bolt 3.5
Nut for mounting rubber engine mounting
onto front left side-member mounting 4.5
Put the vehicle on a two post lift.

98710S
Drain:
- the cooling circuit through the lower radiator - the sub-frame-body tie-rods,
hose (radiator end), - the brake calipers and secure them to the body,
- the engine if necessary. - the front bumper,
Remove:
- the front wheels,
PRG23.1
23-15
K7M
ENGINE
- the heat shield from the exhaust manifold, Disconnect:
- the catalytic converter (disconnect the oxygen - the injection supply wire located in the scuttle
sensor) and secure the exhaust pipe to the panel as well as the starter motor supply,
body, - the fuel inlet and outlet hoses using Mot. 1311-
- the horn, 06, unclip them from their support,
- the acoustic tie-rod between the shock
absorber turrets,
- the air filter,
- the earth strap,
- the expansion bottle and secure it to the
engine.
Disconnect:
- the accelerator cable as well as the kickdown
switch connector,
- the relay plate and the electrical connectors
from the engine connection unit,
99461R
- the heating pipes on the thermostat.
Unclip the radiator and move it away by securing

it to the engine.
98756R
- the connector from the automatic transmission

computer,
- the canister pipe.
Remove the battery mounting bracket.
23-16
K7M
ENGINE
Remove: Remove the nut (A), then, using a copper
- the automatic transmission selector control, hammer, hit the stud in the left hand suspended
- the nut and eccentric bolt (4) (remove it using mounting in order to remove it.
the pin extractor) from the steering shaft yoke
after having pushed back the protector.
PRG23.2
PREPARING TOOL MOT. 1040-01

97390-1S
Position the roller pin in the lower holes (G).
SPECIAL NOTES FOR VEHICLES FITTED WITH
DRIVER’S AIRBAG It is then secured to the sub-frame using the T-
pieces (I).
ATTENTION :
to prevent any damage being done to the rota-
ting switch under the steering wheel, please fol-
low these instructions :
Before releasing the steering column and the
rack, the steering wheel MUST be immobilised,
wheels straight, using the "steering wheel
locking" tool throughout the duration of the re-
pair. Any doubts regarding the correct centring of
the rotating switch means that the steering
wheel has to be removed so as to apply the cen-
tring method as described in chapter 88 "AIR-
BAG".
REMINDER: in this case, only qualified personnel
who have received specific training may under-
take this work.
Put a wedge between the automatic transmission

and the front left hand sub-frame.
92442R
23-17
K7M
ENGINE
Secure Mot. 1040-01 under the sub-frame. Extract the engine and transmission assembly by
lifting the body.
Secure the spring-shock absorber assembly with
rope.
98755R
Lower the final drive until the tool touches the

ground. 99588S
Remove: Separate the engine and transmission assembly

- the shock absorber upper mounting bolts, from the sub-frame by removing:
- the sub-frame mounting bolts. - the upper radiator hose,
- the power assisted steering reservoir and the
pump,
- the power assisted steering pipe mounting on
the automatic transmission.
Unclip the wiring loom from the sub-frame.
Position the lifting tool.
Remove:
- the right hand mounting,
- the engine tie-bar.
Release the driveshafts.
PRG23.3
23-18
K7M
ENGINE
Lift the engine from the sub-frame. - the converter bolts
- the bolts around the gearbox and the TDC sen-
sor.
Separate the automatic transmission from the en-

gine.
Refit the converter by positioning it with respect

to the mounting bolts.
Tighten the bolts around the automatic transmis-

sion.
Aligning the engine sub-frame with the body will

be made easier by positioning two approximately
100 mm long threaded rods in the two front sub-
frame-body mountings.
91131S
Tighten the sub-frame front mounting bolts to a

Separate the gearbox from the engine by : torque of 6 daN.m. and to a torque of 11 daN.m at
- removing the starter motor, the rear.
- removing the bolts from the automatic trans-
mission sump. Tighten all nuts and bolts to the re-
commended torque.
Remove:
- the hoses on the exchanger, Fit the caliper mounting bolts using Loctite
FRENBLOC and tighten them to the correct tor-
que.

Fill:
- the cooling circuit and purge it (see chapter 19),
- the engine with oil if necessary.
NOTE : check that the steering shaft yoke spacer is

in place when refitting.
99586R2
23-19
1) REPLACING A LEFT OR RIGHT HAND LIP SEAL
PRG23.4
B. Vi. 1322 Tool for fitting differential

output seals
REMOVAL Using a screwdriver, remove the seal taking care

not to damage the differential bolt as well as the
Using a screwdriver, remove the protective shield output shaft.
(A).
97725R 97746S
The shield is fitted tight.
23-20
REFITTING 2) REPLACING THE O-RING
The lip seal (oiled) is positioned using tool B.Vi. The principle is the same on both sides, but only
1322 (this determines the correct position of the one side must be removed at a time.
seal).
B. Vi. 1323 Tool for fitting differential

output seals
Special notes:
The is no flange on the driveshaft outputs, but ins-
tead a simple splined end piece protected by a
shield.
95791-5R
Refit the protective heat shield in the opposite or-

der to removal using a 45 mm diameter socket.
97746-1S
23-21
REMOVAL Replace the O-ring on the nut, cleaning the seat
properly and lubricating the new seal with final
Drain the final drive and remove the shield, as ex- drive oil.
plained in paragraph 1.
Locate the position of the nut (F) with respect to

the sump by putting a mark on one of the teeth
and on the face of the sump.
Remove bolt (D) and the locking plate (E) from the
nut using tool B.Vi. 1323, remove the nut, coun-
ting the number of turns it takes.
95791-6R
REFITTING
Refit the nut, turning the same number of turns as

when it was removed.
Align the marks made on the nut and the sump.
Replace the bolt (D) and the locking plate (E).
95791-2R Refit the shield after having replaced the lip seal if
necessary (see paragraph 1).
Fill the final drive with oil.
23-22
Wiring 23
The new generation of A4.2 automatic transmission is fitted with monoblock wiring which means that many
of the intermediate connectors are no longer required. As a result, the method for repairing sensors or
switches is different.
PRG23.5
1 - 55 track connector on the automatic transmission computer

2 - Oil pressure sensor
3 - Electro-hydraulic interface (sealed connector)
4 - Inter engine unit connection
5 - Injection/diagnostic connector
6 - Pressure sensor connector
7 - Speed sensor
8 - Multifunction switch
23-23
Wiring 23
REPAIRING COMPONENTS If one of the insulations or one of the continuities
is not assured, replace the multifunction switch
Most of the components comprising the mono- and refer to note 8074 for the repair procedure.
block wiring are not directly interchangeable.
Only the pressure sensor can be replaced without Refer to notes 8074 and 8075 for repairing the
having to cut the cable. speed sensor and using the locally made lifting
plate.
REPAIRING THE MULTIFUNCTION SWITCH
99613S4
99585S
Initially, this is checked with the 55 track connec-
tor using the bornier Sus. 1228 and the table be-
low. NOTE: remember to distribute the connection
joints.
If this checking procedure highlights a fault, sec-
tion the cable 15 cm from the switch and check
between the section and the 55 track connector.
See the wiring diagram and table below.
LEVER POSITION ASSURED CONTINUITIES ASSURED INSULATIONS
Terminals 51 and 52 / Earth

P/N Terminal 44 / Earth
Terminal 27 / Terminal 46
Terminals 44, 51 and 52 /
R Terminal 27 / Terminal 46
Earth
Terminals 44, 51 and 52 /
D None Earth
3 Terminal 51 / Earth
Terminal 44 / Earth
2 Terminals 51 and 52 / Earth
1 Terminal 52 / Earth
23-24
Wiring 23
Removing the wiring assembly is specific to the
AD4 A4.2.
99613S
99182S
REMOVAL
Fit the engine support tool with the support
Put the vehicle on a two post lift. bracket on the left hand side.
Remove the front left hand wheel.
From the wheel arch:
Remove:
- the earth wire from the multifunction sensor,
- the multifunction sensor mounting bolt (A).
98750R1
Remove the engine torque traction link on the

gearbox side.
Remove the speed sensor (mounting bolt (B)).
99586R1 Remove gear selector control ball joint (C).
Remove all the wiring assembly, taking note of its
On the vehicle: position and mountings so that is refitted
- position the lifting plate (tool made locally as correctly.
described on the next page). Disconnect the 52 track connector and the
connector in the inter engine unit.
23-25
Wiring 23
REFITTING
Replace the wiring without securing it.

Refit:
- the speed sensor,
- the multifunction sensor.
Refit the mounting on the gearbox side.
Remove the engine support tool.
Reconnect all the components.
Secure the wiring using its clips.
LIFTING PLATE
99613S1
Disconnect the connectors from the pressure sen-

sor and the diagnostic/injection socket.
Disconnect the sealed connector switch.
99585R
There are two possible solutions for manufactu-

ring this plate.
1) By modifying the existing plate on the E7J en-

gine (air filter support plate mounted onto the
cylinder head).
99613S2
2) By having it manufactured locally
Parts list: - 1 plate of thickness 4 or
Remove the wiring. 5 mm in semi-hard steel,
- 2 HEX M8 × 20 bolts (collar
bolts).
23-26
Wiring diagram 23
104 - Ignition switch
119 - Automatic transmission computer
120 - Injection computer
129 - ECO/PERF selector switch
160 - Stop switch
163 - Starter motor
225 - Diagnostic socket
247 - Double headlight relay
250 - Speed sensor
303 - Automatic transmission selector lighting
319 - Air conditioning control panel
535 - ECO/PERF selector switch warning light
569 - 4 speed automatic transmission kickdown
597 - Engine fuse box
645 - Passenger compartment connection unit
754 - Electrical/hydraulic interface
779 - Automatic transmission multifunction switch
780 - Automatic transmission turbine or vehicle speed sensor
781 - Line pressure sensor
R22 - Engine/automatic transmission
R34 - Engine/dashboard
MH - Engine electric earth
MJ - Front right pillar electric earth
23-27
Wiring diagram 23
98463S
23-28
Checking the "timing point" on the converter 23
Put the vehicle on a two post lift.
Lift the vehicle until the wheels are a few centime-

tres off the ground.
Connect the XR25 .
Put the ISO switch on S8.
Enter the A4.2 transmission code :
D 1 4
then #06 to display the engine speed.
Accelerate fully with the brake fully on.
The engine speed should stabilise to :

- K7M engine: 2430 rpm.
If this value is not correct, replace the converter.
A timing point which is more than 200 rpm. below

the specified value requires the automatic trans-
mission to be replaced.
NOTE : for all diagnostic questions, refer to MR

TA.A, "General".
23-29
DRIVESHAFTS
Consumables 29
TYPE QUANTITY COMPONENT CONCERNED
Loctite SCELBLOC Coating Stub axle splines
RHODORSEAL 5661
Coating Driveshaft roll pins on gearbox end
(example : CAF 4/60 THIXO)
MOLYKOTE BR2 Coating Seal splines on gearbox end
FRENBLOC Coating Brake caliper bolt
MOBIL CVJ 825 320 g GE 86 seal

Black Star 140 g AC 1700 seal
or 160 g RC 490 seal
MOBIL EXF 57C 130 g GI 62 seal
Allocation of seals on vehicles
Right hand Left hand Wheel Gearbox

SEALS
driveshaft driveshaft end end
GE 86 X X X
AC 1700 X X X
RC 490 X X
GI 62 X X
GI 69 X X
29-1
DRIVESHAFTS
Driveshafts 29
Rou. 604 -01 Hub immobiliser

T.Av. 602 Driveshaft puller
T.Av. 1050-01 Hub extractor
B.Vi. 31-01 Roll pin punch
TIGHTENING TORQUES (in daN.m) Left hand side
Driveshaft nut 25 Drain the gearbox.

Gaiter mounting bolt on gearbox 2.5
Remove the three bolts
Wheel bolt 9
Shock absorber base nut 17
Brake caliper mounting bolt 10
Track rod end nuts 3.5
REMOVAL
Remove:
- the brake assembly (suspend it from the chas-
sis so as not to damage the brake pipe),
- the driveshaft nut: tool Rou. 604-01. 85678R1
Right hand side
Remove the pin: tool B.Vi. 31-01.
94338-1R 91755R
29-2
DRIVESHAFTS
Driveshafts 29
On both sides Remove the lower mounting bolt on the shock ab-
sorber base and extract the driveshaft
Remove:
- the track rod end nut : tool T.Av. 476,
85965-1R
- the upper mounting bolt of the shock absor-

ber base. 96353S
These vehicles are fitted with bonded driveshafts.

They therefore have to be pushed back using tool
T.Av. 1050-01. Take care not to "damage" the gaiters during this
operation.
REFITTING
NOTE : the Parts Department now supplies dri-

veshafts fitted with protectors and accompanied
with assembly instructions. These instructions
must be complied with in order to ensure correct
assembly of maximum QUALITY, given that the
slightest knock to these gaiters will result in the
rubber splitting in time and will lead to the dri-
veshaft being destroyed.
94421-3R
29-3
TRANSMISSION
Driveshafts 29
COMPULSORY ASSEMBLY INSTRUCTIONS
DI2905
29-4
DRIVESHAFTS
Driveshafts 29
Never remove the cardboard protectors before Left hand side
the driveshaft is fitted onto the vehicle. Remove the plastic protector from the bearing
gaiter and engage the driveshaft as horizontally
as possible.
91630R 85677S
Never use a sharp object which might "damage"

the gaiter.
91629R
29-5
DRIVESHAFTS
Driveshafts 29
Right hand side On both sides
With the protector in place, coat the splines of the Coat the splines of the stub axle with Loctite
seal on the gearbox side with MOLYKOTE BR2 SCELBLOC.
grease.
Position the driveshaft with respect to the sun-

wheel and engage it.
Check its position with the angled pin of tool B.Vi.

31-01.
Fit two new roll pins : tool B.Vi. 31-01. Seal the pin
holes with RHODOSEAL 5661 (eg. : CAF 4/60
THIXO).
NOTE : chamfers on the leading edges of the sun-

wheels make it easier to fit new roll pins.
91749S
Insert the driveshaft stub axle into the hub.
It should enter freely until the thread shows allo-

wing the stub axle nut to be fitted.
If any problems arise, use tool T. Av. 602.
74937-4S
96353R
29-6
DRIVESHAFTS
Driveshafts 29
On the left hand side
Clean the face of the gaiter on the gearbox, refit

the gaiter and the plate.
Position the gaiter as horizontally as possible and

tighten the three bolts to the correct torque.
96353-1S1
Refit:
- the two bolts at the base of the shock
absorber on the stub axle carrier and tighten
them to the correct torque,
- the track rod end, tighten the nut to the
correct torque.
Tighten the driveshaft nut to the correct torque: 85678R1

tool Rou. 604-01.
85876-1R
29-7
DRIVESHAFTS
Driveshafts 29
On both sides With the vehicle on its wheels, remove the card-
board protectors by tearing them in accordance
Position the brake calipers, coat the bolts with with the diagram.
Loctite FRENBLOC and tighten to the correct tor-
que.
Lower the vehicle back down onto its wheels.
91693R 91633S
And never use a sharp object which might "da-

mage" the gaiter.
91631S 91632R

piston back into contact with the linings.
If the left hand driveshaft has been replaced, refill

the gearbox with oil.
29-8
DRIVESHAFTS
Front transverse driveshafts 29
ABS TARGET
ABS targets cannot be removed (sintered steel).
The Parts Department supplies replacement machined driveshafts fitted with ABS targets.
29-9
TRANSMISSION
GE 86 seal
Gaiter on wheel end 29
T. Av. 1256 Pliers for crimping OETIKER clips

T. Av. 1168 Pliers for CAILLAU clips
1 Stub axle cup REMOVAL

2 Spider
3 and 5 Retaining clips Remove the gaiter from the gearbox side, refer-
4 Yoke shaft ring to the method below.
6 Thermoplastic gaiter
7 Retaining star Unclip the small clip using tool T. Av. 1168.
A ABS ring (option)
98825R
93033R
29-10
DRIVESHAFTS
GE 86 seal
Saw the existing large clip taking care not to da- REFITTING
mage the channel of the stub axle cup.
Empty the content of the grease sachet into the
gaiter and into the stub axle cup.
93034S 93035S
Cut the gaiter NOTE : the amount of grease, given in the

"Consumables" chapter must be complied with.
Push the gaiter and insert it correctly into the

channel of the stub axle cup and then into the
tube channel.
93036S
Remove as much grease as possible.

93037S
29-11
DRIVESHAFTS
GE 86 seal
93038S
Position the ends of the gaiter.
92305R1
Work the seal by hand to check that both ends are

correctly positioned and to expel the air.
Fit the clips and tighten them with the tool corre-
sponding to the type of clips supplied in the kit
(CAILLAU or OETIKER).
29-12
DRIVESHAFTS
AC 1700 seal
T. Av. 1256 Pliers for crimping OETIKER clips

T. Av. 1168 Pliers for CAILLAU clips
A driveshaft can be partially repaired on the

wheel side:
- replacing the seal,
- replacing the gaiter.
CONSTANT VELOCITY JOINT ON THE WHEEL END
1 Stub axle cup

2 Balls
3 Ball cage
4 Locking ring
5 Driveshaft
6 Gaiter 78616R
7 Ball hub
A ABS ring (option)
REFITTING
Put onto the shaft:

- the small collar,
- the gaiter (3).
Insert the ball seal (1) fitted with its locking ring
(new) on the splines of the shaft until it presses up
against the shaft grooved section (B).
98824R
REMOVAL
Cut the clips and the gaiter along the whole

length.
Remove as much grease as possible
Move the locking ring (7) and simultaneously tap

the front face of the ball hub several times with a
mallet (5). 78615R2
Then separate the seal from the driveshaft.
29-13
TRANSMISSION
AC 1700 seal

Empty the contents of the grease sachet into the
gaiter and into the stub axle cup.
NOTE : the amount of grease, given in the

Insert the lips of the gaiter into the channels of

the cup (1) and the driveshaft (5).
98824R
Fit the clips and tighten them with the tool corre-
sponding to the type of clips supplied in the kit
(CAILLAU or OETIKER).
29-14
DRIVESHAFTS
AC 1700 and GE 86
seals Gaiter on wheel end 29
CAILLAU CLIP
T.Av. 1168 Pliers for CAILLAU clips
DI2903
93039R 93040S
NOTE : CAILLAU clips cannot be reused.
29-15
DRIVESHAFTS
AC 1700 and GE 86
seals Gaiter on wheel end 29
OETIKER CLIPS SPECIAL TOOLING REQUIRED
T.Av. 1256 Pliers for crimping OETIKER clips
96048S
POSITION 1 - Precrimping and positioning the clip
DI2901
Put the connecting bar (A) in the lower notch and close the pliers fully. The precrimped clip slides onto the
gaiter and can be positioned.
POSITION 2 - Crimping
DI2902
Put the connecting bar (A) in the upper notch and close the pliers fully.
29-16
DRIVESHAFTS
RC 490 seal
Gaiter on gearbox end 29
SEAL ON RIGHT HAND DRIVESHAFT
T.Av. 1034 Pliers for crimping driveshaft

clips
1 Yoke Cut the retaining clip and the gaiter along its
2 Spider whole length.
3 Metal retaining cover
4 Rubber gaiter
5 Retaining clip
6 Driveshaft
7 Metal insert
92045S
Remove as much grease as possible

92303R
Ease off the metal retaining cover.
REMOVAL
Unclip the three points of the metal cover with

the pliers.
92046S
92044S
29-17
DRIVESHAFTS
RC 490 seal
Remove the yoke. Never using thinners for cleaning these compo-
nents.
With a press, extract the triaxe component by

using a FACOM U53G type extractor tool.
89145S
NOTE : as the yoke does not have a stop tab, it

can be removed without using force.
Do not remove the rollers from their respective

journals since the rollers and the needles match
each other and should never be interchanged.
90388S
Remove the circlips (depending on the model).
REFITTING
Lubricate the driveshaft and slide on:

- a new retaining clip,
- the rubber gaiter (4) with the metal insert (7)
and the metal retaining cover (3).
90387S 92048-1R
29-18
DRIVESHAFTS
RC 490 seal
Refit the triaxe component onto the splined shaft. Distribute the quantity of grease into the gaiter
and yoke.

Position:
- the gaiter and its metal insert into the metal
retaining cover,
- the metal retaining cover by sliding it up until
it touches the guide plate on the yoke.
In this position, form three crimps in the holes des-

igned for this purpose on the guide plate.
90389S
Replace the retaining circlips or make three crim-

ping points at 120° by pressing the metal from the
splines onto the driveshaft.
92050S
Insert a blunt rod with a rounded end between

the gaiter and the shaft in order to expel the air
inside the seal.
90391S
Grease the yoke and engage it onto the triaxe

component.
29-19
DRIVESHAFTS
RC 490 seal
92051R 88601R
Extend or shorten the seal until it reaches a length

of A = 156 ± 1 mm (dimension between the end
of the gaiter and the machined face of the largest
part of the yoke).
In this position, remove the rod
Fit the clip onto the gaiter and tighten it using

tool T.Av. 1034.
92052R
29-20
DRIVESHAFTS
GI 62 seal
1 and 3 Retaining clips Using pliers, remove each end of the retainer
2 Rubber gaiter plate (C), then remove the yoke.
4 Yoke
5 Spider
6 Metal cover
7 Driveshaft
98823R 74655R
Do not remove the rollers from their respective

REMOVAL journals since the rollers and the needles match
each other and should never be interchanged.
Cut the crimped clip and the gaiter along its
whole length. Never use thinners to clean these components.
Remove as much grease as possible. Depending on the assembly, remove the circlips
75936-1S1
90387S
29-21
DRIVESHAFTS
GI 62 seal
With a press, extract the triaxe component by Replace the retaining circlips or make three crim-
using an extractor tool. ping points at 120° by pressing the metal from the
splines onto the driveshaft.

90388S
REFITTING
Lubricate the driveshaft and slide on the new ring

and gaiter. 90391S
Refit the triaxe component on the splined shaft.
Put a shim (B) of thickness 2.5 mm, manufactured

according to the following diagram, between the
retainer plate and the yoke.
90389S 74867R1
29-22
DRIVESHAFTS
GI 62 seal
With a copper hammer, carefully put the plate in- Insert a blunt rod with a rounded end between
to its original position, then remove the shim (B). the gaiter and the shaft in order to expel the air
inside the seal.
Extend or shorten the seal until it reaches a length

of A = 153 ± 1 mm (dimension between the end
of the gaiter and the machined face of the largest
part of the yoke).
74867R
Position the lips of the gaiter in the grooves of the

driveshaft and on the metal cover.
90390R
In this position, remove the rod and fit the retai-

ning clip.
Tighten it with tool T. Av. 1034.
98823R1
88601R
29-23
DRIVESHAFTS
GI 69 seal
Bearing gaiter 29
T.Av. 944 Mandrel for fitting bearing onto

shaft
REMOVAL
Never use thinners to clean these components.
Depending on the assembly, remove the circlips
90388S
Remove the gaiter and bearing assembly in the

same way as the triaxe component.
90387S
With a press, extract the triaxe component by

using a FACOM U53T type extractor tool.
85933S
29-24
DRIVESHAFTS
GI 69 seal
Bearing gaiter 29
REFITTING
To be in the correct position on the shaft, the bea-

ring must be fitted so as to obtain a dimension L
between the front part of the bearing and the
end of the shaft.
L = 118 ± 0.2 mm (JB1 gearbox)

L = 123.2 ± 0.2 mm (JB3 gearbox)
This dimension is obtained using tool T.Av. 944

when its end is level with the shaft.
86197S
85884-1R1
To avoid damaging the bearing which contains a

lip seal, therefore to avoid the risk of leaks, do
not fit the bearing using a hammer but instead
use a press which provides progressive pressure.
29-25
DRIVESHAFTS
GI 69 seal
Bearing gaiter 29
In addition, the driveshaft is held in place on the
press by channel (G) with a FACOM U53T type
tool to avoid damaging the seal on the wheel
side.
86198R
Fit the triaxe component onto the splined shaft

and refit the retaining circlips (depending on as-
sembly).
29-26
GENERAL
General diagram of braking circuits
30
FRONT GENERAL
AXLE Tightening torques (in daN.m)
30
TUBULAR GENERAL
REAR AXLE Tightening torques (in daN.m)
30
4 BAR REAR GENERAL
AXLE Tightening torques (in daN.m)
30
GENERAL
Tightening torques (in daN.m)
30
GENERAL
Measuring points
30
GENERAL
Uderbody heights / Consumables
30
GENERAL
Parts to be renewed when they are removed / Brake fluid
30
GENERAL
Brake unions and pipes / Rear torsion bar marking
30
GENERAL
Specifications for: the front anti-roll bars / the rear anti-roll bar / the rear suspension bars
30
GENERAL
Influence of angles
30
GENERAL
Principle for checking angles
30
GENERAL
Checking - adjusting the front axle assembly
30
GENERAL
Checking - adjusting the front axle assembly
30
GENERAL
Fault finding for braking
30
GENERAL
30
GENERAL
30
GENERAL
Bleeding the brake circuit
30
GENERAL
Bleeding the brake circuit
30
FRONT AXLE
Lower arm
31
FRONT AXLE
Lower arm / Rubber bushes for stell lower arms
31
FRONT AXLE
Lower arm ball joint
31
LUCAS FRONT AXLE
(Girling) Brake pads
31
LUCAS FRONT AXLE
(Girling) Brake pads
31
FRONT AXLE
Brake Caliper
31
FRONT AXLE
Brake Caliper
31
FRONT AXLE
Brake disc
31
FRONT AXLE
Stub axle carrier bearing
31
FRONT AXLE
31
FRONT AXLE
31
FRONT AXLE
31
FRONT AXLE
Stub axle carrier
31
FRONT AXLE
Spring and shock absorber assembly
31
FRONT AXLE
Spring and shock absorber assembly
31
TOOLING FRONT AXLE
Sus. 1052 Spring and shock absorber assembly
31
TOOLING FRONT AXLE
31
TOOLING FRONT AXLE
31
TOOLING FRONT AXLE
31
With spring FRONT AXLE
compressor Spring and shock absorber
31
With spring FRONT AXLE
compressor Spring and shock absorber
31
FRONT AXLE
Anti-roll bar
31
FRONT AXLE
Engine cradle
31
F engine FRONT AXLE
Engine cradle
31
F engine FRONT AXLE
Engine cradle
31
F engine FRONT AXLE
Engine cradle
31
REAR AXLE
Rear axle assembly
33
REAR AXLE
Brake drum
33
REAR AXLE
Brake drum
33
REAR AXLE
Brake cylinder
33
BENDIX REAR AXLE
203X38 Brake linings (drum)
33
BENDIX REAR AXLE
33
BENDIX REAR AXLE
33
BENDIX REAR AXLE
33
BENDIX REAR AXLE
33
BENDIX REAR AXLE
33
BENDIX REAR AXLE
33
REAR AXLE
Bearing
33
REAR AXLE
Bearing
33
REAR AXLE
Shock absorber
33
REAR AXLE
Anti-roll bar for tubular rear axle
33
REAR AXLE
Half shaft for tubular rear axle
33
REAR AXLE
Rings for tubular rear axle
33
REAR AXLE
33
REAR AXLE
33
REAR AXLE
33
REAR AXLE
Suspension arms for tubular rear axle
33
REAR AXLE
Suspension arms for tubular rear axle
33
REAR AXLE
Underbody heights for tubular rear axle
33
REAR AXLE
Torsion bars for four bar rear axle
33
REAR AXLE
Torsion bars for four bar rear axle
33
REAR AXLE
Underbody heights for four bar rear axle
33
REAR AXLE
33
REAR AXLE
33
REAR AXLE
33
TUBULAR REAR REAR AXLE
AXLE Suspension arm bearings
33
TUBULAR REAR REAR AXLE
33
FOUR BAR REAR REAR AXLE
33
WHEELS AND TYRES
Specifications
35
WHEELS AND TYRES
Specifications
35
WHEELS AND TYRES
Specifications
35
WHEELS AND TYRES
Wheel balancing
35
STEERING ASSEMBLY
Axial ball joint
36
STEERING ASSEMBLY
Axial ball joint
36
STEERING ASSEMBLY
Axial ball joint
36
STEERING ASSEMBLY
Axial ball joint
36
STEERING ASSEMBLY
Manual steering rack
36
STEERING ASSEMBLY
Manual steering rack
36
STEERING ASSEMBLY
Power assisted steering unit
36
STEERING ASSEMBLY
36
STEERING ASSEMBLY
36
STEERING ASSEMBLY
36
STEERING ASSEMBLY
36
STEERING ASSEMBLY
Gaiter
36
STEERING ASSEMBLY
Steering pushrod
36
STEERING ASSEMBLY
Steering column
36
STEERING ASSEMBLY
Steering column
36
STEERING ASSEMBLY
Steering column
36
STEERING ASSEMBLY
Steering column
36
STEERING ASSEMBLY
Steering column
36
STEERING ASSEMBLY
Steering column
36
STEERING ASSEMBLY
Retractable shaft
36
MECHANICAL ELEMENT CONTROLS
Master cylinder
37
Master cylinder
37
Brake servo
37
Brake servo
37
Air filter - Brake servo non-return valve
37
Handbrake control lever
37
37
37
Handbrake
37
Handbrake
37
Brake pipes
37
Braking compensator
37
Braking compensator
37
Braking compensator
37
Clutch cable
37
Clutch pedal
37
Clutch pedal
37
Automatic clutch adjustment
37
37
37
External gear control
37
37
37
37
37
37
37
AUTOMATIC MECHANICAL ELEMENT CONTROLS
TRANSMISSION Gear selector
AD4
37
Gear selector
37
Gear selector
37
Gear selector
37
ELECTRONICALLY CONTROLED HYDRAULIC SYSTEMS
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Teves ABS
38
Fault-finding - Preliminary
38
Fault-finding - XR25 fiche
38
Fault-finding - XR25 fiche
38
Fault-finding - Interpreting the XR25 bargraphs
38
38
38
38
38
38
38
38
38
38
38
38
38
Fault-finding - Checking the conformity
38
Fault-finding - Customer complaints
38
Fault-finding - Fault charts
38
38
38
38
38
38
38
38
38
38
38
38
38
38
38
38
Fault-finding - Assitance
38
HEATING
General
61
HEATING
General
61
HEATING
Operating principle
61
HEATING
Operating principle
61
HEATING
Fault finding - Customer complaints
61
HEATING
Fault finding - Fault charts
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
Control panel
61
HEATING
Control cables
61
HEATING
Particle filter
61
HEATING
Fan
61
HEATING
Fan
61
HEATING
Fan
61
HEATING
Fan
61
HEATING
Radiator
61
HEATING
Distribution unit
61
HEATING
Distribution unit
61
HEATING
Distribution unit
61
HEATING
Distribution unit
61
HEATING
Distribution unit
61
HEATING
Distribution unit
61
HEATING
Distribution unit
61
HEATING
Distribution unit
61
HEATING
Distribution unit
61
HEATING
Distribution unit
61
HEATING
Resistance unit
61
AIR CONDITIONING
General
62
AIR CONDITIONING
General
62
AIR CONDITIONING
General
62
AIR CONDITIONING
General
62
AIR CONDITIONING
Operating principle
62
AIR CONDITIONING
Operating principle
62
AIR CONDITIONING
Fault finding - Customer complaints
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
Wiring diagram
62
AIR CONDITIONING
Wiring diagram
62
AIR CONDITIONING
Wiring diagram
62
AIR CONDITIONING
Wiring diagram
62
AIR CONDITIONING
Wiring diagram
62
AIR CONDITIONING
Fan
62
AIR CONDITIONING
Evaporator
62
F3R ENGINE AIR CONDITIONING
Compressor
62
F8Q ENGINE AIR CONDITIONING
Compressor
62
AIR CONDITIONING
Compressor oil level
62
AIR CONDITIONING
Condenser
62
AIR CONDITIONING
Condenser
62
AIR CONDITIONING
Expansion valve
62
AIR CONDITIONING
Dehydrating bottle
62
AIR CONDITIONING
Connecting pipes
62
AIR CONDITIONING
Connecting pipes
62
AIR CONDITIONING
Electrical control
62
AIR CONDITIONING
Electrical control
62
AIR CONDITIONING
Electrical control
62
BATTERY
Special notes
80
BATTERY
Special notes
80
HEADLIGHTS
Lens units
80
HEADLIGHTS
Lens units
80
HEADLIGHTS
Lens units
80
HEADLIGHTS
Remote adjustment
80
HEADLIGHTS
Remote adjustment
80
HEADLIGHTS
Remote adjustment
80
HEADLIGHTS
Indicator lights
80
HEADLIGHTS
Fog lights
80
REAR AND INTERIOR LIGHTING
Rear lights
81
Rear lights
81
Courtesy light
81
Courtesy light
81
Courtesy light
81
Fuses
81
Fuses
81
Fuses
81
Fuses
81
ELECTRICAL SYSTEMS
Alarm
82
ELECTRICAL SYSTEMS
Alarm
82
ELECTRICAL SYSTEMS
Alarm
82
ELECTRICAL SYSTEMS
Alarm
82
ELECTRICAL SYSTEMS
Alarm
82
ELECTRICAL SYSTEMS
Alarm
82
ELECTRICAL SYSTEMS
Alarm
82
ELECTRICAL SYSTEMS
Alarm
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
Alarm fault finding
82
ELECTRICAL SYSTEMS
General notes on the immobiliser system
82
ELECTRICAL SYSTEMS
PLIP immobiliser system
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
PLIP immobiliser system - petrol engine
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
PLIP immobiliser system - diesel engine
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
Coded key immobiliser system
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
Coded key immobiliser system - petrol engine
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
Coded key immobiliser system - diesel engine
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
ELECTRICAL SYSTEMS
82
INSTRUMENT PANEL
Dashboard
83
INSTRUMENT PANEL
Dashboard
83
INSTRUMENT PANEL
Dashboard
83
INSTRUMENT PANEL
Dashboard
83
INSTRUMENT PANEL
Dashboard
83
INSTRUMENT PANEL
Dashboard
83
INSTRUMENT PANEL
Dashboard
83
INSTRUMENT PANEL
Dashboard
83
INSTRUMENT PANEL
Dashboard
83
INSTRUMENT PANEL
Instrument panel
83
WITHOUT INSTRUMENT PANEL
ADAC Instrument panel
83
WITHOUT INSTRUMENT PANEL
83
INSTRUMENT PANEL
Instrument panel
83
WITH INSTRUMENT PANEL
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
INSTRUMENT PANEL
Instrument panel
83
INSTRUMENT PANEL
Instrument panel
83
INSTRUMENT PANEL
Instrument panel
83
INSTRUMENT PANEL
Instrument panel
83
INSTRUMENT PANEL
Instrument panel
83
INSTRUMENT PANEL
Instrument panel
83
INSTRUMENT PANEL
Fuel level sensor
83
INSTRUMENT PANEL
Fuel level sensor
83
INSTRUMENT PANEL
Fuel level sensor
83
INSTRUMENT PANEL
Oil level sensor
83
INSTRUMENT PANEL
83
CONTROLS - SIGNALS
Wiper stalk
84
CONTROLS - SIGNALS
Wiper stalk
84
CONTROLS - SIGNALS
Lights stalk
84
CONTROLS - SIGNALS
Lights stalk
84
CONTROLS - SIGNALS
Stalk mounting
84
CONTROLS - SIGNALS
Rotary switch under steering wheel
84
CONTROLS - SIGNALS
Rotary switch under steering wheel
84
CONTROLS - SIGNALS
Ignition switch
84
CONTROLS - SIGNALS
Dashboard switches
84
CONTROLS - SIGNALS
Dashboard switches
84
CONTROLS - SIGNALS
Switches on door panel
84
CONTROLS - SIGNALS
84
CONTROLS - SIGNALS
84
CONTROLS - SIGNALS
84
CONTROLS - SIGNALS
Roof console switch
84
CONTROLS - SIGNALS
Centre console switches
84
CONTROLS - SIGNALS
Centre console switches
84
LOWER INTERIOR ACCESSORIES
Door switch
84
Cigar lighter
84
Lighting rheostat
84
Clock
84
Clock
84
WIPERS
Front wipers
85
WIPERS
Front wipers
85
WIPERS
Front wipers
85
WIPERS
Front wipers
85
WIPERS
Front wipers
85
WIPERS
Front wipers
85
WIPERS
Rear wiper
85
WIPERS
Rear wiper
85
WIPERS
Washer pump
85
WIPERS
Washer pump
85
ELECTRICAL ASSISTANCE EQUIPMENT
Passenger compartment connection unit
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
WIRING
Heated rear screen
88
WIRING
Heated rear screen
88
WIRING
Heated rear screen
88
WIRING
External rear view mirror
88
WIRING
88
WIRING
88
WIRING
88
WIRING
Infrared remote control (PLIP)
88
WIRING
Infrared remote control (PLIP)
88
WIRING
Airbags and seat belt pretensioners
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
F3R engine INJECTION
Fault finding - Introduction
17
17
Fault finding - XR25 fiche
17
17
17
Fault finding - Interpretation of XR25 bargraphs
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
Fault finding - Customer complaints with OPTIMA station
17
Fault finding - Chart with OPTIMA station
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
Fault finding - Customer complaints without OPTIMA station
17
Fault finding - Chart without OPTIMA station
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
Fault finding - Checking conformity
17
17
17
17
17
17
17
17
17
17
Fault finding - Assitance
17
17
17
E7J 764 INJECTION
engine Fault finding - Introduction
17
E7J 764 INJECTION
engine Fault finding - Introduction
17
E7J 764 INJECTION
engine Fault finding - XR25 fiche
17
E7J 764 INJECTION
engine Fault finding - XR25 fiche
17
E7J 764 INJECTION
engine Fault finding - Interpretation of XR25 bargraphs
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
engine Fault finding - Chart with OPTIMA station
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
engine Fault finding - Customer complaints without OPTIMA station
17
E7J 764 INJECTION
engine Fault finding - Chart without OPTIMA station
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
engine Fault finding - Checking conformity
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
E7J 764 INJECTION
engine Fault finding - Assistance
17
E7J 764 INJECTION
17
E7J 764 INJECTION
17
K7M engine INJECTION
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
Fault finding - Customer complaints with OPTIMA station
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
Fault finding - Customer complaints without OPTIMA station
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
Fault finding - Assistance
17
17
17
Panels
GENERAL
LOWER STRUCTURE
UPPER SIDE STRUCTURE
UPPER REAR STRUCTURE
OPENINGS OTHER THAN SIDE DOORS
77 11 192 972 FEBRUARY 1997 Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault.
The methods may be modified as a result of changes by the manufacturer in the reference numbering system is forbidden without the prior written authority of
production of the various component units and accessories from which his vehicles Renault.
are constructed".
C Renault 1997
Bodywork
Contents
Pages
40 GENERAL 44 UPPER REAR STRUCTURE

Opening clearances 40-1 A Hydraulic pump bracket 44-1
Description of parts 40-3 B Rear wing panel 44-2
Sub-frame dimensions 40-5 C Lights bracket 44-7
Central floor 40-6 D Wing panel closing device 44-10
Main bodywork dimensions 40-7 E Right-hand wing panel trim 44-11
F Wing panel trim 44-18
G Rear lights bracket strengthener 44-21
H Wing panel drip moulding 44-23
I Rear end panel assembly 44-27
41 LOWER STRUCTURE J Interior right-hand wheel arch 44-31
K Upper rear floor extender 44-35
A Front jacking pad 41-1 L Lower rear floor extender 44-37
B Sill panel stiffener 41-2 M Rear side member extender 44-39
C Rear seat belt mounting N Hood compartment rear partition
strengthener 41-3 assembly 44-41
D Extreme rear crossmember 41-4
43 UPPER SIDE STRUCTURE

A Windscreen frame 43-1
B Frame upright trim 43-3 48 OPENINGS OTHER THAN SIDE DOORS
C "A" post assembly 43-5
D "A" post trim strengthener 43-8 Boot 48-1
E "A" post trim (scuttle side) 43-9 Hood cover 48-2
F "B" post strengthener 43-10
G "B" post trim with rear section of sill
panel 43-12
H "B" post trim only 43-15
I Wing panel upper front trim
assembly 43-17
J Partial sill panel 43-19
GENERAL
Opening clearances 40
11632R
40-1
GENERAL
1 4
12488R
2 12490R
12489R
3 12487R
12491R
40-2
GENERAL
Description of parts 40
PRS4043
1 Windscreen frame
2 Hood cover lid (composite)
3 Rear end panel assembly
4 Lights bracket
5 Rear wing panel
6 Sill panel
7 "A" post assembly
8 Front jacking pad
40-3
GENERAL
Description of parts 40
PRS4044
9 Post finisher 19 Hydraulic pump bracket

10 Right-hand panel finisher 20 Left-hand panel finisher
11 Interior right-hand wheel arch 21 Wing panel closing device
12 Lights bracket strengthener 22 Wing panel upper finisher
13 Wing panel drip moulding 23 "B" post strengthener
14 Upper rear floor extender 24 Door sill stiffener
15 Side member extender 25 "A" post trim strengthener
16 Lower rear floor extender 26 Frame upright finisher
17 Hood compartment rear partition 27 Windscreen frame crossmember
18 Interior left-hand wheel arch 28 Seat belt mounting strengthener
40-4
GENERAL
Sub-frame dimensions 40
DIMENS DIMENSI DIMENS
DESCRIPTION DIAMETER SLOPE
ION X ON Y ION Z
A Front sub-frame rear mounting 203 402.5 71 M 12 0

B Rear axle front mounting 1966 634.12 70 M 12 0
C Front sub-frame front mounting - 593 412 237.5 M 10 0
E Rear shock absorber upper mounting 2194 503.2 (65) 259 M 14 y: 90°
F Front shock absorber upper mounting 15.7 477.8 636.7 8.5 x: 3°45 ; y: 7°
(interior)
Front shock absorber upper mounting 5.5 610.8 654.2 8.5 x: 3°45 ; y: 7°
(exterior)
G Front side member rear end 880 369 7 18.5 x: 1°
H Front side member front end - 547.5 467.4 236.5 10.2 x 12.2 0
J Rear side member rear end G 2826 484.6 231 12.2 0
Rear side member rear end D 2788 483 231 14.5 0
L Extreme rear crossmember (skirt) G 2937 394.5 170 14.25 x: 90° ; y: 10°15
Extreme rear crossmember (skirt) D 2916 397 170 14.25 x: 90° ; y: 12°30
M Crossmember under the central floor 937 375 1.5 14.5 0
Front engine mounting 247 483.5 514 M 10 0
Rear engine mounting 113 483.5 514 M 10 0
99312R1
40-5
GENERAL
Central floor 40
INTRODUCTION
The central floor of the E64 vehicle is identical to

that of the B64 and about the same length. The
E64 part can be obtained from the B64 part by
cutting the rear section by 112 mm as shown on
the diagram below.
The complete changing of this part is a basic ope-

ration to be carried out in the event of an impact
underneath the vehicle when coming off the
road.
PRM41201-4R
In this case, these additional parts must be orde-
red:
- the tunnel strengthener assembly,
- the instrument panel console bracket and
sheath end.
This part can be partially changed by cutting as

described in the following pages in the event of a
side impact in addition to a sill panel or an "A"
post.
COMPOSITION OF PART
1 Central floor
2 Tunnel strengthener
3 Console bracket
4 Sheath end
PRM41201-3R
40-6
GENERAL
Main bodywork dimensions 40
NOTE: these dimensions are measured in the centreline of the various welded nuts.
PRE4001
PRE4002
40-7
GENERAL
Main bodywork dimensions 40
11970 12034
12033 12032
40-8
LOWER STRUCTURE
Front jacking pad 41 A
INTRODUCTION 1 CONNECTION TO THE FRONT SIDE
CROSSMEMBER
The changing of this part is an additional opera-
tion to the changing of the front side crossmem-
ber. Thickness of the panels concerned (mm)
COMPOSITION OF THE REPLACEMENT PART Front jacking pad 2.5

Side crossmember 1
Part only.
Unpicking
3 MAG weld seams

30 mm long
Welding
PRE4101
11994
41-1
LOWER STRUCTURE
Sill panel stiffener 41 B
INTRODUCTION Welding

tion to the changing of an "A" post or a sill panel
in the event of a side collision.
COMPOSITION OF THE REPLACEMENT PART 12059
Complete part with reel.
NOTE: at (A), welding of 3 thicknesses.
PRE4102
1 CONNECTION TO SILL PANEL CLOSER

12058
Thickness of the panels concerned (mm)
Sill panel stiffener 1.5

Sill panel closer 1.8
Unpicking
77 spot welds on 1.5 mm thickness
41-2
LOWER STRUCTURE
Rear seat belt mounting strengthener 41 C

tion to the changing of the front section of the
rear floor.
COMPOSITION OF THE REPLACEMENT PART
Part only.
12037
A = 90 mm
PRE4103
1 CONNECTION TO THE FRONT SECTION OF THE

REAR FLOOR
Mounting strengthener 2
Front section of rear floor 0.7
12036
Unpicking
4 MAG weld seams 20 mm long

41-3
LOWER STRUCTURE
Extreme rear crossmember 41 D
INTRODUCTION

tion to the changing of a rear end panel assembly.
The edge of the rear panel must be folded back.
11976
Part only.
PRE4104
11977
41-4
Windscreen frame 43 A
The changing of this part is a basic operation to be

carried out in the event of a side collision or rollo-
ver.
This part is partially changed in addition to chan-

ging of the "A" post.

12079
Part only.
PRE4301
12080
1 CONNECTION TO THE "A" POST
Frame 1.5
"A" post 1.25
Unpicking
1 MAG weld seam 90 mm long

43-1
Windscreen frame 43 A
2 CONNECTION TO THE FRAME UPRIGHT Welding
FINISHER
Opening frame 1.5

Opening finisher 2
Strengthener securing connecting arch 1
Unpicking
112 spot welds 1.5 mm panel thickness 12081

Partial cut off
150 mm on 1.5 mm thickness
43-2
Frame upright finisher 43 B
INTRODUCTION

tion to the changing of the "A" post and the
windscreen frame.
For safety reasons, the finisher must not be cut.
Part only.
PRE4302
43-3
Frame upright finisher 43 B
1 CONNECTION TO THE OPENING LOWER 2 CONNECTION TO THE OPENING UPPER
CROSSMEMBER CROSSMEMBER
Thickness of the panels concerned (mm) Thickness of the panels concerned (mm)
Opening finisher 2 Opening finisher 2

Lower crossmember 1.2 Upper crossmember 0.9
Unpicking Unpicking
2 MAG weld seams 30 mm long 2 spot welds on

2 MAG weld seams 20 mm long 2 mm thickness
Welding Welding
12009 12052
43-4
"A" post assembly 43 C
INTRODUCTION 1 CONNECTION TO THE SILL PANEL CLOSING
PLATE
The replacement of this part is a basic operation
to be carried out in the event of a front side colli- Thickness of the panels concerned (mm)
sion.
Sill panel 2
It is obtained by cutting the sill panel observing Sill panel stiffener 1.5
the dimensions. Sill panel closer 1.8
For reasons of stability, the strengthener must not

be cut. Unpicking
COMPOSITION OF THE REPLACEMENT PART 14 spot welds on 2 mm thickness
Complete part including:

- "A" post,
- "A" post upper finisher, 345 mm on 2 mm thickness
- strengthener tube,
- "B" post finisher,
- sill panel,
- "B" post finisher strengthener, Welding
- sill panel blanking piece.
NOTE: it is possible to change just the "A" post .

The sill panel must be unpicked.
12050
PRE4303
NOTE: welding of 3 thicknesses.
43-5
2 CONNECTION TO THE OPENING FINISHER
Post upper finisher 1.25

Strengthener securing connecting arch 1
Opening finisher 2
12051 Unpicking

4 spot welds on 1mm thickness
Welding
12003
43-6
3 CONNECTION TO THE POST FINISHER
(SCUTTLE SIDE)
"A" post 1.5

Post finisher 1.2
Sill panel 2
12054
Unpicking
27 spot welds on 1.5mm thickness

3 MAG plug welds
Welding
12004
NOTE: at (A), welding of 3 thicknesses

at (B), welding of 4 thicknesses
43-7
"A" post finisher strengthener 43 D
INTRODUCTION 1 CONNECTION TO THE "A" POST FINISHER
(SCUTTLE SIDE)
tion to the changing of the "A" post finisher. Thickness of the panels concerned (mm)
Finisher strengthener 1.5

Post finisher 1.2
Part only. Unpicking
Welding
PRE4304
11973
43-8
"A" post finisher (scuttle side) 43 E
INTRODUCTION
The design of the vehicle is such that the scuttle

side and the "A" post finisher are in one piece.
Also, when one of these parts is changed, the part
supplied by the Parts Department has to be par-
tially cut.

tion to changing of the "A" post. On the right-
hand side, the scuttle side upper strengthener,
which must be ordered separately, must also be
changed.
1 Scuttle side ("A" post finisher)

2 Scuttle side upper strengthener
PRE4305
43-9
"B" post strengthener 43 F
INTRODUCTION 1 CONNECTION TO THE SILL PANEL CLOSER

tion to the changing of the wing panel. Thickness of the panels concerned (mm)
Post finisher 1.5


Welding
PRE4306
12055
NOTE: welding of 3 thicknesses
43-10
"B" post strengthener 43 F
2 CONNECTION TO THE FRONT SECTION OF THE
REAR FLOOR
Post finisher 1.5

Rear floor 0.7
12041
Unpicking

200 mm at 1.5 mm thickness
Welding
12042 12091
43-11
"B" post finisher with sill panel rear section 43 G
INTRODUCTION

tion to the changing of the wing panel.
To maintain stiffness, the strengthener must not

be cut.
NOTE: the "B" post strengthener must be remo-

ved in order to gain access to the interior spot
welds.
It is possible to change just the "B" post finisher.
Complete part including:

- "A"post,
- "B" post finisher finisher,
- sill panel,
- "B" post finisher strengthener,
- sill panel blanking piece,
- "A" post upper finisher,
- strengthener tube.
PRE4307
43-12
1 CONNECTION TO THE PANEL FRONT UPPER 2 CONNECTION TO THE PANEL REAR FINISHER
FINISHER ASSEMBLY
Post finisher 1.5 Sill panel 2

Upper finisher 1.5 Rear finisher 0.9
Unpicking
Unpicking
8 spot welds on 2 mm thickness
10 spot welds on 1.5 mm thickness 1 MAG weld seam 20 mm long
Welding
Welding
12049
12075
43-13
3 CONNECTION TO THE SILL PANEL STIFFENER
Sill panel 2
Unpicking
12043
345 mm at 2 mm thickness
Welding
NOTE: welding of 3 thicknesses
12048
12048
43-14
"B" post finisher only 43 H
1 CONNECTION TO THE PANEL FRONT UPPER 2 CONNECTION TO SILL PANEL STIFFENER
FINISHER ASSEMBLY
Post finisher 1.5 Post finisher 1.5

Upper finisher 1.5 Sill panel stiffener 1.5
Unpicking Unpicking
10 spot welds on 1.5 mm thickness 11 spot welds on 1.5 mm thickness

Welding Welding
12074
12075
12074
12075
43-15
"B" post finisher only 43 H
3 CONNECTION TO THE REAR SECTION OF THE
SILL PANEL
Post finisher 1.5

Sill panel 2
Unpicking
Welding
12073
12073
43-16
Wing panel front upper finisher assembly 43 I
INTRODUCTION 1 CONNECTION TO THE "B" POST FINISHER

tion to the changing of: Thickness of the panels concerned (mm)
- side panel,
- "B" post finisher, Upper finisher 1,5
- side panel finisher. Post finisher 1,5
COMPOSITION OF THE REPLACEMENT PART Unpicking

Complete part including stiffener. 1 MAG weld seam 15 mm long
Welding
PRE4308
12076
12076
43-17
Wing panel front upper finisher assembly 43 I
2 CONNECTION TO THE PANEL REAR FINISHER
Exterior finisher panel 1,5

Interior finisher panel 1,5
Rear finisher 0,9
12077
Unpicking
Welding
12077
12078
12078
43-18
Partial sill panel 43 J
INTRODUCTION
The changing of this part is a basic operation to

be carried out in the event of a side impact.
It is obtained by cutting the sill panel observing

the dimensions.
Part only.
PRE4309
43-19
Partial sill panel 43 J
1 CONNECTION TO THE PARTIAL CUT OFFS 2 CONNECTION TO THE SILL PANEL CLOSER AND
STIFFENER
Sill panel 2 Sill panel 2

Unpicking Unpicking

2 x 345 mm at 2 mm thickness
Welding Welding
12056 12057
43-20
Hydraulic pump bracket 44 A
The replacement of this part is an additional ope-

ration to the changing of the interior wheel arch.
Part only.
12006
12006
PRE4401
1 CONNECTION TO THE REAR WHEEL ARCH
Hydraulic pump bracket 1.5 12005
Unpicking
12005
44-1
Rear wing panel 44 B
INTRODUCTION 1 CONNECTION TO THE "B" POST FINISHER

to be carried out in the event of a rear collision. Thickness of the panels concerned (mm)
Wing panel 0.8

Post finisher 1.5
COMPOSITION OF THE REPLACEMENT PART Interior finisher panel 1.5
Lower inlet side member closing
Part including: plate 1.5
- bumper support plate,
- panel stiffener.
Unpicking
180 mm braze
Welding
PRE4402
12177
44-2
2 CONNECTION TO THE LOWER EXTERIOR SIDE 3 CONNECTION TO THE REAR PANEL FINISHER
MEMBER
Wing panel 0.8 Wing panel 0.8

Sill panel 2 Panel finisher 0.9
Sill panel stiffener 1.5 Rear end panel 0.7
Unpicking Unpicking
1 MAG weld seam 75 mm long 38 spot welds on 0.8 mm thickness
30 mm braze
Welding
Welding
12067
12176
44-3
4 CONNECTION TO THE TANK FILLER NECK
Bracket 0.8
Wing panel 0.9
12174 Unpicking
Welding
12175
12173
44-4
5 CONNECTION TO THE LIGHTS BRACKET
Wing panel 0.8

Lights bracket 0.7
Unpicking 12066
Welding
12060
44-5
6 CONNECTION TO THE WING PANEL DRIP
MOULDING
Wing panel 0.8

Panel drip moulding 1.25
Unpicking 12008
1 70 mm braze
1 30 mm braze
Welding
12065
12011
12065
44-6
Lights bracket 44 C
INTRODUCTION 1 CONNECTION TO THE REAR END PANEL

tion to the changing of a wing panel or the rear Thickness of the panels concerned
end panel.
Lights bracket 0.7
Rear end panel 0.7
Lights support strengthener 1
Welding
PRE4403
12020
44-7
Lights bracket 44 C
2 CONNECTION TO THE WING PANEL DRIP 3 CONNECTION TO THE LIGHTS BRACKET
MOULDING STRENGTHENER
Lights bracket 0.7
Lights bracket 0.7 Lights bracket strengthener 1
Panel drip moulding 1.25 Panel drip moulding 1.25
Unpicking
Unpicking 3 spot welds on 0.7 mm thickness
A 25 mm braze
Welding
Welding
12022
12021
NOTE: at (A), welding of 3 thicknesses
44-8
Lights bracket 44 C
4 CONNECTION TO THE WING PANEL
Lights bracket 0.7

Wing panel 0.8
12066
Unpicking

Welding
12060
44-9
Wing panel closing device 44 D
INTRODUCTION 1 CONNECTION TO THE WING PANEL Finisher

tion to the changing of the wing panel finisher. Thickness of the panels concerned (mm)
Closing device 0.75

Panel finisher 0.9

1 MAG weld seam 25 mm thickness
Welding
PRE4404
12010
12010
44-10
Right-hand wing panel finisher 44 E
INTRODUCTION 1 CONNECTION TO THE FRONT UPPER FINISHER
ASSEMBLY
tion to the changing of a wing panel. Thickness of the panels concerned (mm)
NOTE: if the sill panel is not changed, a partial cut Panel finisher 0.9
must be made in the lower section of the exterior Upper exterior finisher 1.5
wheel arch. Upper interior finisher 1.5
Unpicking

COMPOSITION OF THE REPLACEMENT PART 2 MAG weld seams 20 mm long
Part only.
Welding
12038
PRE4405
44-11
2 CONNECTION TO THE BOOT CENTRE
PARTITION STRENGTHENER
Panel finisher 0.9

Partition strengthener 0.75
11995
Unpicking
Welding
11997
11982
44-12
3 CONNECTION TO THE REAR END PANEL 4 CONNECTION TO THE FLOOR EXTENDER
Panel finisher 0.9 Panel finisher 0.9

Rear end panel 0.7 Upper extender 1
Lower extender 1
Unpicking Unpicking
Welding Welding
12063 12062
NOTE: welding of 3 thicknesses. NOTE: welding of 3 thicknesses.
44-13
5 CONNECTION TO THE HOOD COMPARTMENT
PARTITIONS ASSEMBLIES
Panel partition 0.9

Boot rear partition 0.7
Boot rear upper connection 1
12024
Unpicking
Welding
12061
11983
44-14
Welding
12023
12064
6 CONNECTION TO THE INTERIOR WHEEL ARCH
Thickness of the panels concerned

Panel finisher 0.9
Interior wheel arch 0.7
Wheel arch upper section 1
Unpicking

11996
44-15
Welding
11998
12040
7 CONNECTION TO THE REAR SIDE MEMBER

ASSEMBLY
Panel finisher 0.9

Rear side strengthener 0.7
Unpicking

11981
44-16
8 PARTIAL CUT OFF
Panel finisher 0.9

Rear side strengthener 0.7
Unpicking
200 mm on 0.9 mm thickness
Welding
12039
44-17
Wing panel finisher 44 F
INTRODUCTION 1 CONNECTION TO THE HOOD COMPARTMENT
UPPER PARTITION
tion to the changing of a wing panel. Thickness of the panels concerned (mm)
NOTE: if the sill panel is not changed, a cut must Panel finisher 0.9
be made in the the lower section of the exterior Upper partition 1
wheel arch. Balancer bracket 1.5
The description of the changing of the left-hand

panel finisher only includes the connections which Unpicking
are different from the changing of the right-hand 4 spot welds on 0.9 mm thickness.
panel finisher. 1 MAG weld seam 20 mm long
1 spot weld on 1.5 mm thickness

Complete part including including balancer

bracket. Welding
12025
PRE4406
44-18
Welding
11990
11988
2 CONNECTION TO THE REAR BOOT PARTITION
Panel finisher 0.9

Rear boot partition 0.7
12007
Unpicking
44-19
3 CONNECTION TO THE INTERIOR WHEEL ARCH 4 CONNECTION TO THE HYDRAULIC PUMP
BRACKET
Panel finisher 0.9 Panel finisher 0.9

Wheel arch 0.7 Pump bracket 1.5
Unpicking Unpicking
18 spot welds on 0.9 mm thickness 3 MAG weld seams 15 mm long
Welding Welding
11987 11989
44-20
Rear lights bracket strengthener 44 G
INTRODUCTION 1 CONNECTION TO THE REAR LIGHTS BRACKET

tion to the changing of the rear lights bracket. Thickness of the panels concerned (mm)
Rear lights strengthener 1

Rear lights bracket 0.7
Drip panel moulding 1.25

Welding
PRE4407
12085
44-21
Rear lights bracket strengthener 44 G
2 CONNECTION TO THE WING Drip panel
moulding
Rear lights strengthener 1

Drip moulding panel 1.25
12017
Unpicking
Welding
12084
44-22
Wing Drip panel moulding 44 H
INTRODUCTION

carried out in the event of a rear impact.
In addition to the changing of this part, the rear

light bracket strengthener must also be changed.

tion to the changing of the wing panel or a lights
bracket.
Part only.
PRE4408
44-23
1 CONNECTION TO THE WING PANEL 2 CONNECTION TO THE HOOD COMPARTMENT
REAR PARTITION DRIP MOULDING
Drip panel moulding 1.25 Drip panel moulding 1.25

Wing panel 0.8 D drip moulding partition 1.25
Compartment upper partition 1
Compartment rear partition 0.7
Unpicking
Unpicking
70 mm braze
30 mm braze
3 30 mm brazes
Welding
Welding
12065
12018
44-24
3 CONNECTION TO THE REAR LIGHTS BRACKET
STRENGTHENER

Rear lights bracket strengthener 1
Unpicking 11993
Welding
11992
44-25
4 CONNECTION TO THE REAR LIGHTS BRACKET

Unpicking 11991
25 mm brazes
12019
NOT: at (A), welding of 3 thicknesses.
44-26
Rear end panel assembly 44 I
INTRODUCTION 1 CONNECTION TO THE REAR FLOOR UPPER
EXTENDER
carried out in the event of a rear collision. Thickness of the panels concerned (mm)
End panel 0.7

COMPOSITION OF THE REPLACEMENT PART Upper extender 1
Assembled part with:

- end panel, Unpicking
- end panel finisher.
Welding
12070
PRE4409
44-27
2 CONNECTION TO THE REAR FLOOR LOWER 3 CONNECTION TO THE WING PANEL FINISHER
EXTENDER
End panel 0.7 End panel 0.7

Lower extender 1 Finisher 0.9
Unpicking Unpicking
Welding Welding
12069
12087
44-28
4 CONNECTION TO THE REAR LIGHTS BRACKET 5 CONNECTION TO THE REAR LIGHTS BRACKET
STRENGTHENER
End panel 0.7 End panel 0.7

Rear lights bracket strengthener 1 Rear lights bracket 0.7
Unpicking
Unpicking

1 spot weld on 1 mm thickness

Welding
Welding
12088
12086
44-29
12089
12068
44-30
Right-hand interior wheel arch 44 J
INTRODUCTION

tion to the changing of a wing panel finisher.

- wheel arch upper component,
- interior wheel arch.
PRE4410
44-31
1 CONNECTION TO THE REAR PARTITION 2 CONNECTION TO THE REAR PARTITION
STRENGTHENER
Interior wheel arch 0.7 Wheel arch 0.7

Central boot partition 0.75 Rear partition strengthener 0.75
Unpicking Unpicking
Welding Welding
12098 12097
44-32
3 CONNECTION TO THE REAR SECTION OF THE 4 CONNECTION TO THE REAR CROSSMEMBER
REAR FLOOR
Interior wheel arch 0.7 Interior wheel arch 0.7

Rear section of the rear floor 0.75 Rear crossmember 0.8
Unpicking Unpicking

1 MAG spot weld Ø 8 mm
Welding
Welding
12000
11999
44-33
5 CONNECTION TO THE HOOD COMPARTMENT
REAR PARTITION
Upper interior wheel arch 1

Compartment rear upper partition 1
12096
Unpicking
Welding
12035
44-34
Rear floor upper extender 44 K
INTRODUCTION 1 CONNECTION TO THE WING PANEL

tion to the changing of a rear end panel assembly. Thickness of the panels concerned (mm)
Rear floor extender 1

Wing panel 0.9
Welding
PRE4411
12095
44-35
Rear floor upper extender 44 K
2 CONNECTION TO THE REAR CROSSMEMBER 3 CONNECTION TO THE REAR SIDE MEMBER
EXTENDER
Rear floor extender 1 Rear floor extender 1

Rear crossmember 0.8 Rear side member extender 1
Unpicking Unpicking
27 spot welds on 1 mm thickness 4 spot welds on 1 mm thickness
Welding Welding
12094 12093
44-36
Rear floor lower extender 44 L
INTRODUCTION 1 CONNECTION TO THE SIDE PANEL

tion to the changing of a rear end panel assembly. Thickness of the panels concerned (mm)

Wing panel 0.7
Assembled part with strengthener. Unpicking
Welding
PRE4412
12047
44-37
Rear floor lower extender 44 L
2 CONNECTION TO THE REAR CROSSMEMBER

Rear crossmember 0.8
Strengthener 2.5
12090
Unpicking
Welding
12092
44-38
Rear side member extender 44 M
INTRODUCTION

tion to the changing of a rear end panel assembly.
Part only.
PRE4413
44-39
Rear side member extender 44 M
1 CONNECTION TO THE REAR FLOOR EXTENDER 2 CONNECTION TO THE REAR CROSSMEMBER
Rear side member extender 1 Rear side member extender 1

Rear floor extender 1 Rear crossmember 0.8
Unpicking Unpicking
4 spot welds on 1 mm thickness 7 spot welds on 1 mm thickness
Welding Welding
12046 12045
44-40
Hood compartment rear partition assembly 44 N
INTRODUCTION 1 CONNECTION TO THE REAR PARTITION
STRENGTHENER
tion to the changing of the side drip moulding or Thickness of the panels concerned (mm)
the interior wheel arch
Rear partition strengthener 0.85

Unpicking
- compartment rear partition,
- compartment upper rear partition 37 spot welds on 0.7 mm thickness
- central drip moulding,
- hinge strengtheners.
1450 mm at 0.7 mm thickness
Welding
11986
PRE4414
44-41
Welding
12082
11984
2 CONNECTION TO THE LEFT-HAND REAR SIDE NOTE: triple layer welding (on the left-hand side
PARTITION only).

Rear side partition 1.5
Rear partition strengthener 0.85
Unpicking
44-42
3 CONNECTION TO THE RIGHT-HAND PANEL 4 CONNECTION TO THE RIGHT-HAND INTERIOR
TRIM WHEEL ARCH (UPPER SECTION)
Compartment upper rear partition 1 Compartment upper rear partition 1

Panel trim 0.9 Wheel arch 1
Unpicking Unpicking
Welding Welding
12014 12083
NOTE: at (A), triple layer welding.
44-43
5 CONNECTION TO THE LEFT-HAND PANEL TRIM
Compartment upper rear partition 1

Panel trim 0.9
Balancer bracket 1.5
11979
Unpicking
17 spot welds on 0,7 mm thickness
1 MAG welds seam 20 mm long
1 spot weld on 2.2 mm thickness
Welding
11978
NOTE: at (A), triple layer welding.
44-44
6 CONNECTION TO THE WING PANEL
Compartment upper rear partition 1

Wing panel 0.8
Unpicking
Welding
11985
44-45
Boot 48
PRE4801
12472S
Disconnect and remove the electrical wiring.
Remove the nuts.
NOTE: the light unit must be removed in order to

gain access to the lower mounting bolts. When re-
fitting the struts, seal using preformed mastic for
detachable components.
48-1
Hood cover 48
PRE4802
12473S 12474S
Disconnect the electrical wiring.
Separate the rams.
Remove the bolts.
48-2
Mechanisms and accessories
SIDE DOOR MECHANISMS
MECHANISMS OF OPENINGS OTHER

THAN SIDE DOORS
GLAZING
EXTERIOR ACCESSORIES
UPPER INTERIOR ACCESSORIES
are constructed".
C Renault 1997
Mechanisms and
accessories
Contents
Pages
51 SIDE DOOR MECHANISMS
Front door window mechanism 51-1

Quarter light mechanism 51-4
52 MECHANISMS OF OPENINGS
OTHER THAN SIDE DOORS
Complete manual or
electrohydraulic hood 52-1
Front hood locks 52-7
Complete hydraulic system 52-10
Hydraulic system (pipes) 52-13
Hydraulic system reservoir 52-16
54 GLAZING
Front door windows 54-1
Quarter light 54-5
56 EXTERIOR ACCESSORIES
Exterior mirror 56-1
58 UPPER INTERIOR ACCESSORIES

Road box 58-1
Front door window mechanism 51
PRE5101
REMOVAL
After removing the interior trim, the side impact

bar and the window, compress the window
mechanism rings.
12280S
Remove the window mechanism.
12279R
Disconnect the motor connector.
Remove the window mechanism mounting bolts.
51-1
PRE5103
CHANGING THE MOTOR
12285R
Turn the motor shaft until the mounting bolt (3) is

accessible.
Remove the mounting bolts.
12286R
After removing the window mechanism, mark the

position of the stop (1).
Remove the stop.
Open the motor cover mounting plates (2) and 12284R

remove the motor.
Detach the toothed ring.
Remove the mounting bolt (4).
51-2
REFITTING
Secure the motor and engage the toothed wheel.
Connect the motor and operate the window

mechanism.
Position the stop (1) at the marks and tighten it.
Refit the window mechanism - window assembly.
The tightening torque for all of the bolts is 8 N.m.
ADJUSTMENT
See section 54.
51-3
Quarter light mechanism 51
PRE5102
REMOVAL
After removing the seat, the rear bench seat

12296S
backrest, the interior trim and the window,
disconnect the motor connector.
- the window .
ADJUSTMENT
See section 54
12295R
Remove:
- the window mechanism mountings (1),
51-4
MECHANISMS OF OPENINGS OTHER THAN SIDE DOORS
Complete manual or electrohydraulic hood 52
PRE5201
REMOVAL Place the hood in the neutral position (front sec-

tion beyond the pushing point), rear roof arch
Before carrying out any work, protect the rear vertical.
wings.
Immobilise the hood cover (electrohydraulic
Remove the seat cushion, the bench seat backrest hood).
and the quarter light trims
12449
12556R
Remove the rear connecting crossmember moun-

ting bolts (1).
52-1
WARNING: for vehicles fitted with an electrohy- Remove:
draulic mechanism, the hydraulic system MUST - the front connecting crossmember mounting
NEVER be operated after removal of the connec- bolts (2),
ting crossmembers (risk of losing the basic hood - the connecting crossmember.
adjustment). It is therefore ESSENTIAL to operate
the hood MANUALLY . Disconnect the hood microswitch wiring.
12172-1R 12292R
To do this, open the hydraulic unit bolt (A) as far Remove the main bearing mounting bolts (3).
as possible.
12294R
52-2
12293R
Remove the upper main ram clamp (4).
Separate the main ram from the frame.

12292R
Fold the hood.
Remove:
- the third main bearing mounting bolt,
- the hood (2 people).
NOTE: do not loosen the main bearing backing

plate mounting bolts (B) (basic adjustment).
12291R
Remove the pin (5) then the clamp (6).
Separate the ram from the rear roof arch (electro-

hydraulic mechanism).
NOTE: for reasons of clarity, the main bearing has

been disengaged from the body.
52-3
REFITTING
Fit the folded hood in its housing.
Secure the main bearing without tightening it.
Close and lock the hood.
Tighten the main bearing mounting bolts (3) to a

torque of 20 N.m.
Fold the hood.
Position the rear roof arch ram, secure it to the

clamp (6) and the pin (5) (electrohydraulic mecha-
nism).
Place the hood in the neutral position, rear roof

arch vertical.
Connect the hood microswitch wiring.
Fit the main ram and clamp it.
Position the connecting crossmember and tighten

the mounting bolts to a torque of 20 N.m.
Tighten the hydraulic unit bolt and operate the

electrohydraulic system several times (opening -
closing) in order to bleed the hydraulic circuit
(automatic bleeding).
52-4
MAIN BEARINGS BACKING PLATES
REMOVAL - REFITTING
12430R
12440R
Removal - refitting without tightening bolts (B)
ADJUSTMENT
Adjustment is carried out before refitting the

connecting crossmember, with the hood closed
and locked and the vehicle on an even surface.
Tools required:
- spirit level approximately 200 mm long, 12451
- Spanner wrench (example: disker tightening
spanner),
- wooden shim made on site.
Place the spirit level in the centre of the sill panel.
Mark the position of the bubble in the spirit level

in felt tip pen.
52-5
Tilt the main bearing using the spanner wrench
until the bubble corresponds to the marks pre-
viously made on the the glass.
12441S
Secure the shim under the spirit level using adhe-

sive strips.
12292R
Tighten the backing plate bolts (B) and the main

bearing bolts (3) to a torque of 20 N.m.
This operation is to be carried out by two people.
Check the alignment of the hood in relation to

the windscreen aperture seal.
Open the hood, pull the handle downwards and

check the free insertion of the front frame guide
pins in the locks.
12442S
and secure the assembly to the main bearing.
52-6
Front hood locks 52
12432R
PRE5202
Unscrew the pin (1) and remove the locking han-

dle.
REMOVAL OF THE LOCKING PLATE
Unclip and remove the cover.
Place the hood in the neutral position.
12431S
Remove the front frame cover clips.
Fold the hood in its housing.

12429R
Immobilise the hood cover in the case of the elec-

trohydraulic model. Remove the locking plate bolts (2).
52-7
Front hood locks 52
REFITTING
Refit the locking plate and tighten the mounting

bolts (2) 8 N.m.
Clip and clamp the front frame cover.
Secure the handle.
REMOVAL OF THE FRONT LOCKS
12427R
Remove the bolts (1).
REFITTING
12434R
Refit the locks.
Remove the sun visors, the brackets.
Detach the roof console.
Detach the roof crossmember trim.
52-8
Front hood locks 52
ADJUSTMENT
Hood closed and locked.
12428R
12435R
The front part of the hood is positioned by mo-

ving part (2) in order to obtain dimension A = 4
mm.
Tighten the bolts (3) to a torque of 8 N.m.
Refit the trim, the console, the sun visors.
52-9
Complete hydraulic system 52
PRE5203
REMOVAL Remove the connecting crossmember.
After removing:
- the bench seat cushion and backrest,
- the quarter light trims,
- the boot side fittings
open the hood cover and immobilise it.
12290R
Disconnect the wiring (1).
Remove the clips (2) and remove the ram.

12172-1R
Open the bolt (A) as far as possible.
52-10
Remove:
- the main bearing mounting bolts (see section
52).
12293R1
12291R
- the main ram upper clamp. Remove the rear roof arch ram pin (5) then the
clamp (6). Separate the ram.
Separate the main ram from the frame.
Fold the hood.
Disconnect the hood microswitch wiring (left-

hand side)
Detach the hydraulic pipes.
Remove the main bearing mounting bolts.
Raise and immobilise the main bearings in order

to detach the hydraulic system clearance hole.
12289R
Remove:
- the electric relays bracket,
- the lower yoke nut (3),
- the ram.
52-11
REFITTING
Insert the rams - pipes assemblies through the

clearance holes in the following order:
1 right-hand side assembly
2 left-hand side assembly
3 hood cover assembly.
Refit the pump.
After refitting all of the components, close the hy-

draulic unit bolt and operate the electrohydraulic
system several times (opening - closing) in order to
purge the hydraulic circuit.
WARNING: when work is carried out on the hy-

draulic system, follow the recommendations be-
low and keep everything clean.
12172-1R1 • Before removal, clean the pipe unions, their

environment and the reservoir carefully.
Disconnect the wiring.
• Place the system on thick paper. Do not use a
Remove: fluffy cloth.
- the housing,
- the pump mounting bolts (4), • Cover the system carefully if the work is not
- the pump. carried out immediately.
Remove the rams - pipes assemblies in the follo- • Do not remove the replacement parts from
wing order: their packaging until immediately before they
1 hood cover assembly are fitted.
2 left-hand side assembly
3 right-hand side assembly. • Do not blow with compressed air when the
hydraulic system is open.
ONLY use ESSO UNIVIS J26 OIL for filling the hy-
draulic system.
52-12
Hydraulic system (pipes) 52
PRE5204
REMOVAL Remove:
- the pump connectors (1) and wiring,
After removing the complete system, mark the co-
lour of the connectors (1) on the solenoid valves.
12298R
B = blue 12297R
R = red
- the pump bolts (2) and bracket.
52-13
Diagram of fitting of pipes at the pump end
12299R
Unscrew the mounting bolts (3) of the pipe

concerned on the pump distributor (example:
pipe (E) for the hood cover ram).
Remove the pipe from the pump distributor.
Unscrew the union (4) on the ram.
Proceed in the same manner for the pipe (N) as

well as for the other groups of pipes. 12433S
REFITTING Insert the pie union into the corresponding ope-

ning.
Coat the O-ring with hydraulic oil (change it if ne-
cessary). Tighten the bolts to a torque of 7 N.m.
NOTE: the hydraulic pipes are supplied in pairs
and are marked with letters at the unions.
12486S
52-14
Diagram of fitting of pipes at the ram end
Pipe Piston rod Piston base end Rams
E X Hood cover
N X Hood cover
A X Left-hand main ram
W X Left-hand main ram
B X Right-hand main ram
X X Right-hand main ram
R X Left-hand rear roof arch
P X Left-hand rear roof arch
S X Right-hand rear roof

arch
O X Right-hand rear roof

arch
Tighten the pipe unions to a torque of 15 N.m.
Refit the pump bracket.
Clip the solenoid valve control connectors (1) and the pump wiring.
52-15
Hydraulic system reservoir 52
PRE5205
REMOVAL REFITTING
Coat the O-ring with hydraulic oil.
Fit the seal in the oil reservoir groove.
Position the reservoir on the pump.
Tighten the bolts (2) to a torque of 7 N.m.
IMPORTANT: the hood must be closed when the

hydraulic system is filled.
Fill the reservoir with ESSO UNIVIS J26 oil (capaci-

ty 0.75 l).
The oil level must be between the MINIMUM and

MAXIMUM marks.
The hydraulic system is of the "AUTOMATIC

BLEED" type. The oil level MUST be checked with
the hood open, hood cover closed.
12297-1R
Check the oil level and top up if necessary.

Remove:
- the filler bolt (1) and drain, Switch on the ignition, apply the handbrake.
- the reservoir mounting bolts (2).
Operate the hood switch.
Open and close the hood several times.
The bleeding process is completed when move-

ment is regular and without jolts with a constant
level of pump noise.
52-16
GLAZING
Front door window 54
PRE5401
REMOVAL
12277-1R
After removing the interior trim,
- the window mounting bolts (3).
Tilt the window towards the rear and remove it.
REMOVAL OF THE REAR SLIDER
12276R
remove:
- the side impact bar bolts (1) ,
- the interior weatherstrip,
- the rear guide shoe bolt (2) , 12281R
Remove the slider blanking piece and mountings

(4).
54-1
GLAZING
FIXED WINDOW ADJUSTING THE WINDOWS
The hood must be folded for the fixed window,

two operators are required to adjust the movable
window.
The door must be adjusted correctly and the

upper movable window stops must be in the
uppermost position.
FIXED WINDOW
12281-1R
Remove the window mounting bolts (5) and the

window pillar mounting bolts (6).
12438R
With the door closed (1st notch), position the

pillar at dimension A = 30 mm high and B = 6
mm from the edge of the windscreen aperture
seal.
12278S
Tilt the assembly (window/pillar) and remove the

window.
54-2
GLAZING
Tighten the mounting bolts (5).
Tightening torque of all mounting bolts 8 N.m.
MOVABLE WINDOW
12281-1R1
Tighten the upper pillar bolt (6).
Open the door and tighten the lower pillar

mounting (6).
12277-2R
12281-1R2
12469R
Position the fixed window fully in the pillar
groove. Fit the window flush with the fixed window pillar
seal (C).
Fit the window flush with the pillar seal (A) and
with a protrusion (B = 1 mm) with the exterior The height of the window is adjusted by moving
mirror seal. the stop (7) of the window mechanism toothed
wheel.
54-3
GLAZING
Place the front upper stop (8) in contact with the Place the rear upper stop (8) in contact with the
lower window pad and tighten it. lower window pad and tighten it.
Close and lock the hood. Tighten the rear guide shoe bolt (2).
Close the door. Tighten the window mounting bolts (3).
12470R
12277-3R1
Position the window at the dimensions:
D = 55 mm (window/weatherstrip) Tighten the rear slider bolt (4).
E = 10 mm (window/frame)
Open the door.
Visually check that the window is aligned with the
hood seals. Push the rear slider gently towards the exterior of
the door.
Tighten the nut (4).
Open and close the window several times. Check

that the window is positioned correctly (aligned)
in relation to the hood seals.
12277-3R
54-4
GLAZING
Quarter light 54
Open the window by approximately 10 cm.
Remove the window.
ADJUSTMENT
The hood must be open, the movable door

window must be closed and correctly adjusted
with the window weatherstrip in place.
PRE5402
REMOVAL
After removing the seat, rear bench seat backrest,

interior trim, remove:
- the weatherstrip and the sealing felt,
12439R
Position the quarter light at a distance of A = 20

mm between the door window and the seal
retaining rail.
12295-2R
- the mounting nuts (1).
54-5
GLAZING
Quarter light 54
Place the quarter light seal in contact with the
door window at the bottom (B).
Tighten the upper mounting bolts (3).
12295-1R
Make flush the line: quarter light/movable door

window (adjustment is by the stops (2)).
Tighten the window mounting bolts (1). 12295R1
Open the door to the 1st notch, place the quarter

light seal in contact with the door window at the
top (C).
Tighten the lower mounting bolts (4).
12439R1
54-6
Exterior mirror 56
12288R
Remove:
- the bolt (1), the cover and the blanking piece.
12287R
- the mounting nuts (2).
56-1
Road box 58
12478R
PRE5801
Fit:
ASSEMBLY - the clamps to the cover (C),
- the compartment cover to the frame (B) and
secure it using bolts (HEX M5×12).
Degrease the foam strip (D) positioning grooves

(heptane surface cleaner).
Glue the strips.
12477R
Position the side panels (A) on the frame (B) and

secure them using bolts (HEX M4×8).
58-1
Road box 58
Unclip the seat belts.
Remove the bench seat backrest.
Clip the seat belt.
Fit:
- the carpet
- the road box (2 people).
12468
With the hood folded and the hood cover open,

remove:
- the mounting nuts,
12476R
Secure it using the milled bolts and the crossed

nuts.
12467
- the bench seat cushion mounting bolts,

- the cushion.
58-2
Road box 58
CHANGING THE BLIND LOCKING MOTOR
12475R 12479R
Close the hood cover. After removing the road box, disconnect the
motor harness (1).
Check the clearance (5 mm) between the
compartment and the hood cover. Detach the locking rod (2).
If necessary, adjust the clearance using the nut (1). Remove the mounting bolt (3).
Connect the electrical wiring (A).
58-3
Sealing and soundproofing
BODY SEALING
are constructed".
C Renault 1997
Sealing and
soundproofing
Contents
Pages
64 WINDOW SEALING
Windscreen pillar seal 64-1
BODY SEALING
Windscreen pillar seal 64
Engage the seal in the retaining formed section
groove.
12436R
PRE6401
Slide the seal so that the end (A) is positioned with
the corner of the windscreen aperture.
REMOVAL - REFITTING
After removing the front locks and the trims, re-
move the seal. Check the sideways alignment with the hood seal.
A clearance of 1 mm must be obtained between

the seals (longitudinal clearance).
12437S
Moisten the seal (glass cleaner, soapy water).
64-1
Trims and upholstery
INTERIOR BODY TRIMS
TRIMS OF OPENINGS OTHER THAN SIDE DOORS
are constructed".
C Renault 1997
Trims and
upholstery
Contents
Pages
71 INTERIOR BODY TRIMS

Quarter light trims 71-1
TRIMS OF OPENINGS OTHER

73 THAN SIDE DOORS
Exterior hood trim 73-1

Padding 73-5
Interior hood trim 73-7
INTERIOR BODY TRIMS
Quarter light trims 71
PRE7101 12283R
REMOVAL Remove:
- the cover and the nuts (1),
After removing the seat, the rear bench seat ba- - the clips (2) and the bolt (3).
ckrest and the seat belt, unclip the insert.
Unclip the fittings.
12282S
Unclip the insert.
71-1
Exterior hood trim 73
PRE7301
REMOVAL Fold the hood in its housing.
Before carrying out any work, protect the seats Immobilise the hood cover in the case of the elec-
and the rear wings. trohydraulic model.
Open the hood, raise the front section beyond the

pushing point (neutral position).
12432R
12431S Unscrew the pin (1) and remove the locking han-
dle.
Remove the front frame cover clamps. Unclip and remove the cover.
73-1
12452 12454
Unseat the front crossmember seal (2). Remove the upper side tensioning strap bolt (7).
Remove:
- the bolt (3) and the seal (4) from the main
frame,
12455
12453
Unseat the side formed section (8) from the front

crossmember.
- the front formed section tightening wrench

(5).
Unseat the frame front formed section (6).
73-2
12456 12458
Remove the rivet (9) from the side tensioning ca- Unseat:
ble, remove the cable and the exterior trim. - the rear frame seal (11),
- the rear formed section (12) from the rear
Place the rear frame in a vertical position. frame.
Remove the exterior trim.
12457
Remove the rivet (10) from the main control rod

side tensioning strap.
73-3
REMOVAL
Place the rear frame in a vertical position.
Seat the rear formed section (12) in the rear

frame.
Rivet (Ø 4×12) the side tensioning strap (10) to

the main control rod.
Pass the side tensioning cable (9) into the exterior

trim, rivet it (Ø 3×8) to the front crossmember.
Seat:
- the side formed section (8) on the front cross-
member,
- the front formed section (6) on the front
frame.
Fold the hood.
Clip the front formed section tightening wrench

(5).
Place the hood in the neutral position.
Secure:
- the side tensioning strap (7) to the main
frame,
- the main frame seal (4).
Place the rear frame in a vertical position.
Seat:
- the rear seal (12) on the rear frame,
- the front crossmember side seal (2).
Clip and clamp the front frame cover, secure the

handle, close the hood.
Adjustment of the windscreen aperture seal -

front crossmember side seal.
A clearance of 1 mm must be obtained between

the two seals by sliding the side seal.
In the event of sideways offset, slide the winds-

creen aperture seal as necessary after unseating it
at the front locks.
73-4
Padding 73
PRE7302
Removal Unseat the front formed section (2).
After removing the exterior hood trim, remove

the front formed section tightening wrench (1).
12461
12460
Remove the tensioning strap bolts (3), remove the

rivets (4).
Place the hood in neutral.
73-5
Padding 73
12462
Remove:
- the bolts (5),
- the padding pulling to disengage the formed
section (6) from the rear roof arch groove.
REFITTING
Engage the formed section (6) in the rear roof

arch groove and pull the padding aligning it at
the same time.
Tighten the bolt (5).
Rivet the tensioning strap (4) to the roof arches

and tighten it at the front (3) on the frame (Ø
3×10).
Seat the front formed section (2) in the groove,

align the padding.
Fit the front formed section tightening wrench

(1).
73-6
Interior hood trim 73
PRE7303
REMOVAL
After removing the exterior trim and the pad-

ding, remove the tensioning strap and interior
trim bolts (1), (2).
12463
12459
73-7
12464 12465
Remove the interior trim tensioning cable bolts Unseat the front frame front formed section (6).
(3).
Fold the hood.
12466
12495
Unclip the auxiliary roof arch and main roof arch

formed sections (7).
Remove the handle (4) and the rivet (5). Remove the trim pulling it to detach the formed
section (6) from the rear roof arch groove.
73-8
REFITTING
Engage the formed section (8) in the main roof

arch groove.
Rivet (Ø 3×10) the tensioning strap (2) and the in-

terior trim to the main roof arch.
Clip the formed sections (7) to the main roof arch

and the auxiliary roof arch.
Fit the interior trim tensioning cable (3).
Rivet (Ø 3×10) the tensioning strap (1) and the in-

terior trim to the rear frame.
Fold the hood, seat the front formed section (6),

align the trim.
Fit the handles (4) without tightening the bolts.

Rivet the interior trim (5) to the front crossmem-
ber.
Tighten the handle mounting bolts.
73-9
GENERAL
Engine - Clutch - Gearbox
40
GENERAL
Vehicle identification
40
GENERAL
40
GENERAL
40
GENERAL
Trolley jack - Axle stands
40
GENERAL
Underbody lift
40
GENERAL
Towing
40
GENERAL
Dimensions and engines
40
GENERAL
Description of parts (exploded views)
40
GENERAL
Description of parts (exploded views)
40
GENERAL
Key to symbols
40
GENERAL
Key to symbols
40
GENERAL
Opening clearances
40
GENERAL
Opening clearances
40
GENERAL
Opening clearances
40
GENERAL
Opening clearances
40
GENERAL
Collision fault finding
40
GENERAL
40
GENERAL
40
GENERAL
Sub-frame dimensions
40
GENERAL
40
GENERAL
Repair bench
40
GENERAL
Repair bench
40
GENERAL
Repair bench
40
GENERAL
Repair bench
40
GENERAL
Repair bench
40
GENERAL
Repair bench
40
GENERAL
Repair bench
40
GENERAL
Repair bench
40
GENERAL
Repair bench
40
GENERAL
Repair bench
40
GENERAL
Special tooling
40
LOWER STRUCTURE
Front end cross member (A)
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
Front panel (B)
41
LOWER STRUCTURE
Front panel (B)
41
LOWER STRUCTURE
Front panel (B)
41
LOWER STRUCTURE
Front side member, closure panel (C)
41
LOWER STRUCTURE
Front side member, closure panel (C)
41
LOWER STRUCTURE
Front side member, front section (D)
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
Front half unit (E)
41
LOWER STRUCTURE
Front half unit (E)
41
LOWER STRUCTURE
Front half unit (E)
41
LOWER STRUCTURE
Front half unit (E)
41
LOWER STRUCTURE
Front side cross member (F)
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
Front side member, rear section (G)
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
Front side member extension (H)
41
LOWER STRUCTURE
Front side member extension (H)
41
LOWER STRUCTURE
Front cross member under front seat (I)
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
Rear cross member under front seat (J)
41
LOWER STRUCTURE
Rear cross member under front seat (J)
41
LOWER STRUCTURE
Centre floor (K)
41
LOWER STRUCTURE
Centre floor (K)
41
LOWER STRUCTURE
Centre floor (K)
41
LOWER STRUCTURE
Centre floor (K)
41
LOWER STRUCTURE
Centre floor (K)
41
LOWER STRUCTURE
Centre floor (K)
41
LOWER STRUCTURE
Centre floor (K)
41
LOWER STRUCTURE
Tunnel reinforcement assembly (L)
41
LOWER STRUCTURE
Tunnel reinforcement assembly (L)
41
LOWER STRUCTURE
Sill panel stiffener (M)
41
LOWER STRUCTURE
Inner sill panel (N)
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
Rear floor, front part section (O)
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
Rear floor, rear part section (P)
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
Cross member under rear seat (Q)
41
LOWER STRUCTURE
Rear side member assembly (R)
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
Rear side member, part section (S)
41
LOWER STRUCTURE
Rear end cross member (T)
41
LOWER STRUCTURE
Rear end cross member (T)
41
LOWER STRUCTURE
Rear floor unit (U)
41
LOWER STRUCTURE
Rear floor unit (U)
41
LOWER STRUCTURE
Rear floor unit (U)
41
LOWER STRUCTURE
Rear floor unit (U)
41
UPPER FRONT STUCTURE
Wing (A)
42
Upper front cross member, centre section (B)
42
Lock mounting (C)
42
Upper side front cross member (D)
42
Upper side front cross member (D)
42
Headlight carrier panel (E)
42
Headlight carrier panel (E)
42
Upper cowl side panel reinforcement (F)
42
42
42
Cowl side panel (pillar lining) (G)
42
42
42
42
Wheel arch (H)
42
Wheel arch (H)
42
Wheel arch (H)
42
Wheel arch (H)
42
Plenum chamber (I)
42
Plenum chamber (I)
42
Plenum chamber closure panel (J)
42
Windscreen aperture lower cross member, part section (K)
42
Windscreen aperture lower cross member, part section (K)
42
Bulkhead, part section (L)
42
Bulkhead, part section (L)
42
Front pillar (A)
43
Front pillar (A)
43
Front pillar (A)
43
Front pillar (A)
43
Windscreen pillar lining (B)
43
Windscreen pillar lining (B)
43
Front pillar lining (cowl side panel) (C)
43
43
43
Centre pillar (D)
43
Centre pillar (D)
43
Centre pillar (D)
43
Centre pillar lining (E)
43
43
43
Body side, front section (F)
43
Top of body (G)
43
Top of body (G)
43
Top of body (G)
43
Sill panel, complete (H)
43
43
43
43
43
Sill panel, part section (I)
43
Sill panel, part section (I)
43
Body side, rear section (J)
43
Wing panel (A)
44
Wing panel (A)
44
Wing panel (A)
44
Wing panel (A)
44
Wing panel (A)
44
Wing panel lower rain channel (B)
44
44
44
Wing panel rain channel complete (C)
44
Wing panel rain channel complete (C)
44
Tailgate balancer ball joint (D)
44
Rear quarter panel lining, part section (E)
44
44
44
44
44
44
Lights mounting (F)
44
Lights mounting (F)
44
Lights mounting (F)
44
Lights mounting (F)
44
Rear inner wheel arch (G)
44
44
44
44
Exterior wheel arch, part section (H)
44
Exterior wheel arch, part section (H)
44
Rear end panel assembly (I)
44
44
44
Rear end panel (J)
44
Rear end panel (J)
44
TOP OF BODY
Roof (A)
45
TOP OF BODY
Roof (A)
45
TOP OF BODY
Roof (A)
45
TOP OF BODY
Roof (A)
45
TOP OF BODY
Roof front cross member (B)
45
TOP OF BODY
Roof rear cross member (C)
45
TOP OF BODY
Roof bow (D)
45
BODY PROTECTION
Sub-frame protection (A)
46
BODY PROTECTION
Front wing interior protection (B)
46
BODY PROTECTION
Front wing interior protection (B)
46
BODY PROTECTION
Rear wing interior protection (C)
46
SIDE OPENING ELEMENTS
Front and rear doors
47
NON-SIDE OPENING ELEMENTS
Bonnet (A)
48
Bonnet hinges (B)
48
Tailgate (C)
48
Tailgate (C)
48
Tailgate (C)
48
GENERAL
Safety (A)
50
GENERAL
Tooling (B)
50
GENERAL
Tooling (B)
50
SIDE OPENING ELEMENT MECHANISMS
Window winder handle on front and rear doors (A)
51
Door opening handle - inside door (B)
51
Rear door locking knob (C)
51
Front door exterior handle (D)
51
Front door exterior handle (D)
51
Front door barrel (E)
51
Front door lock (F)
51
Front door lock (F)
51
Rear door lock (G)
51
Rear door lock (G)
51
Front door window winder (H)
51
Front door window winder (H)
51
Rear door window winder (I)
51
51
51
NON-SIDE OPENING ELEMENT MECHANISMS
Bonnet release (A)
52
Tailgate lock and striker plate (B)
52
52
52
Tailgate lock barrel (C)
52
Tailgate balancer (D)
52
Sunroof (E)
52
Sunroof (E)
52
Sunroof (E)
52
Sunroof (E)
52
Sunroof motor (F)
52
Sunroof panel (G)
52
Sunroof panel (G)
52
Sunroof panel (G)
52
Adjusting the sunroof panel (G)
52
Shield (I)
52
Interior sunroof screen (J)
52
Interior sunroof screen (J)
52
Drain channel mounting (K)
52
Sunroof panel drive bar (L)
52
Sunroof panel drive bar (L)
52
WINDOWS
Windscreen (A)
54
WINDOWS
Windscreen (A)
54
WINDOWS
Windscreen (A)
54
WINDOWS
Windscreen (A)
54
WINDOWS
Windscreen (A)
54
WINDOWS
Front door window (B)
54
WINDOWS
Front door window (B)
54
WINDOWS
Rear door window (C)
54
WINDOWS
54
WINDOWS
Rear quarter panel window (D)
54
WINDOWS
Rear screen (E)
54
WINDOWS
Rear screen (E)
54
WINDOWS
Rear screen (E)
54
EXTERIOR PROTECTION
Front bumper (A)
55
EXTERIOR PROTECTION
Front bumper (A)
55
EXTERIOR PROTECTION
Rear bumper (B)
55
EXTERIOR PROTECTION
Rear bumper (B)
55
EXTERIOR PROTECTION
Rear bumper (B)
55
EXTERIOR PROTECTION
Side protection strips (C)
55
EXTERIOR PROTECTION
55
EXTERIOR PROTECTION
55
EXTERIOR PROTECTION
Roof trim (D)
55
EXTERIOR PROTECTION
Roof trim (D)
55
EXTERIOR PROTECTION
Rear spoiler (E)
55
EXTERIOR PROTECTION
Radiator grille (F)
55
EXTERIOR PROTECTION
Radiator grille (F)
55
EXTERIOR PROTECTION
Scuttle panel grille (G)
55
EXTERIOR PROTECTION
Scuttle panel grille (G)
55
EXTERIOR PROTECTION
Headlight washer jet (H)
55
Side monogramme (A)
56
External rear view mirror (B)
56
Rear view mirror glass (C)
56
Rear view mirror glass (C)
56
Rear view mirror plastic housing (D)
56
External temperatur sensor (E)
56
Front wing interior protector (F)
56
Front wing interior protector (F)
56
Rear wheel protective shield (G)
56
Tailgate trim (H)
56
Tailgate trim (H)
56
Dashboard (A)
57
Dashboard (A)
57
Dashboard (A)
57
Dashboard (A)
57
Dashboard (A)
57
Dashboard (A)
57
Dashboard (A)
57
Dashboard (A)
57
Dashboard (A)
57
Dashboard (A)
57
Console (B)
57
Glovebox cover (C)
57
Door switch (D)
57
Grab handle (A)
58
Front sun visor (B)
58
Roof console (C)
58
Interior rear view mirror (D)
58
INTERIOR SAFETY ACCESSORIES
Height adjustment mechanism (A)
59
Front seat belts (B)
59
59
59
Rear seat belts (C)
59
Rear seat belts (C)
59
Exterior side impact absorber (D)
59
Interior side impact absorber (E)
59
BODY SEALING
Body side upper seal (A)
64
OPENING ELEMENT SEALING
Door frame seals (A)
65
WINDOW SEALING
Front window guide (A)
66
WINDOW SEALING
Front door exterior weatherstrip (B)
66
WINDOW SEALING
Front door interior weatherstrip (C)
66
WINDOW SEALING
Rear door surround (D)
66
WINDOW SEALING
Rear door surround (D)
66
WINDOW SEALING
Rear door fixed pillar guide (E)
66
WINDOW SEALING
Rear door interior weatherstrip (F)
66
INTERIOR BODY TRIM
Upper centre pillar lining (A)
71
INTERIOR BODY TRIM
71
INTERIOR BODY TRIM
Lower centre pillar and valance lining (B)
71
INTERIOR BODY TRIM
Rear lower valance lining (C)
71
INTERIOR BODY TRIM
Rear upper valance lining (D)
71
INTERIOR BODY TRIM
Windscreen pillar lining (E)
71
INTERIOR BODY TRIM
Headlining (F)
71
INTERIOR BODY TRIM
Headlining (F)
71
INTERIOR BODY TRIM
Headlining (F)
71
INTERIOR BODY TRIM
Rear wheel arch lining (G)
71
INTERIOR BODY TRIM
Rear quarter panel lining (H)
71
INTERIOR BODY TRIM
Rear quarter panel lining (H)
71
INTERIOR BODY TRIM
Rear end panel lining (I)
71
INTERIOR BODY TRIM
Rear wing panel lining (J)
71
INTERIOR BODY TRIM
Rear wing panel lining (J)
71
SIDE OPENING ELEMENTS TRIM
Door trim mountings (A)
72
Door trim mountings (A)
72
Front door trim (B)
72
Front door trim (B)
72
Front door trim (B)
72
Rear door trim (C)
72
Rear door trim (C)
72
NON-SIDE OPENING ELEMENTS TRIM
Bonnet lining (A)
73
REAR PARCEL SHELF
Rear side shelf (A)
74
FRONT SEAT FRAMES AND RUNNERS
Complete seat (A)
75
Runners and raising mechanism (B)
75
Raising mechanism (C)
75
REAR SEAT FRAMES AND RUNNERS
Complete seatback (A)
76
FRONT SEAT TRIM
Seatback trim (A)
77
FRONT SEAT TRIM
Seatback trim (A)
77
FRONT SEAT TRIM
Seatback trim (A)
77
FRONT SEAT TRIM
Seat squab trim (B)
77
FRONT SEAT TRIM
Seat squab trim (B)
77
REAR SEAT TRIM
1/3 - 2/3 seat squad trim (A)
78
REAR SEAT TRIM
One piece seat squad trim (B)
78
REAR SEAT TRIM
1/3 - 2/3 seatback trim (C)
78
REAR SEAT TRIM
78
REAR SEAT TRIM
78
REAR SEAT TRIM
One piece seatback trim (D)
78
SEAT ACCESSORIES
Head restraint guide and lock control button
79
Sheet metal work
GENERAL
LOWER STRUCTURE
TOP OF BODY
KA0X
77 11 204 192 MARCH 1999 Edition Anglaise
The methods may be modified as a result of changes introduced by the reference numbering system is forbidden without the prior written authority of
manufacturer in the production of the various component units and accessories Renault.
C Renault 1999
EXPLODED VIEW
DI4017R
Sheet metal work
Contents
Page Page
40 GENERAL 44 UPPER REAR STRUCTURE

Dimensions 40-1 A Rear wing panel 44-1
Engine and equipment 40-2 B Rear lights mounting 44-10
Identification 40-2 C Upper side drip moulding 44-12
Using symbols 40-3 D Rear pillar reinforcement 44-15
Key to symbols 40-5 E Rear inner wheel arch 44-20
Description of parts (exploded) 40-6 F Rear quarter panel lining assembly 44-21
Opening clearances 40-7 G Outer wheel arch 44-27
H Rear end panel 44-31
41 LOWER STRUCTURE
45 TOP OF BODY
A Absorber support mounting 41-1
B Rear floor base 41-2 A Roof 45-1
C Rear floor base support 41-5 B Roof acoustic cross member 45-6
D Rear floor base front stiffener 41-7 C Roof bow 45-8
E Rear end pillar lower reinforcement 41-8 D Roof rear cross member 45-10
F Rear end cross member assembly 41-11
G Rear floor unit 41-14
47 SIDE OPENING ELEMENTS

A Rear door panel 47-1

A Top of body 43-1 48 NON-SIDE OPENING ELEMENTS
A Tailgate 48-1
GENERAL
Dimensions 40
15309R
* Unladen.
40-1
GENERAL
Engine and equipment 40
Engine
Vehicle
Version
type Capacity Idle speed
Type Ratio Injection Fuel type
(cm 3) (rpm)
KA0M Non- Unleaded

1.4 l E7J 9.5/1 Multipoint 1390
KA0V adjustable 95 or 98 (1)
KA0W 1.4 l Non- Unleaded

K4J 10/1 Multipoint 1390
KA0D 16 V adjustable 95 or 98 (1)
KA04 1.6 l Non- Unleaded

K4M 10/1 Multipoint 1598
KA0B 16 V adjustable 95 or 98 (1)
KA0J
1.9 l D F8Q 21.5/1 Indirect 1870 825±50 Diesel
VA0J
KA05
VA05
850±50
KA0N 1.9 l F9Q
18.3/1 Direct 1870 Non- Diesel
VA0N Dti Turbo
adjustable
KA01
VA01
(1) If necessary, unleaded fuel with an octane rating of 91 may be used.
Identification
Tyre inflation pressure -

cold (bar) (1)
Vehicle Rim Tyres
Front Rear
KA0M/KA0V
5.5 J 14 175/70 R 14 2.2 2.0
KA0W/KA0D
KA04/KA0B 6.0 J 15 185/60 R 15 2.2 2.0
KA0J/VA0J 6.0 J 15 175/70 R 14 2.2 2.0
KA0N/VA0N
KA05/VA05 6.0 J 15 185/60 R 15 2.2 2.0
KA01/VA01
(1) Fully laden and motorway use.
Tightening torque for wheel nuts : 9 daN.m

Rim run-out: 1.2 mm
40-2
GENERAL
Using symbols 40
The following indications are found in the section
diagrams :
The part in black is the one which will

be removed in the operation
are the part numbers corresponding to

1 and 7 the list on the introduction page
are the thicknesses (in mm) of the

e = 1 + 1 panels affected by the spot weld
This arrow on the diagram designates

the access point for the unpicking of
spot welds (see specific cases)
11644R1
The above diagram shows parts on the vehicle for

which a section of the panel butt welding joint is It also indicates the logical sequence of operations
shown by the diagrams which follow. in the symbols which follow each diagram.
This dashed line shows the centre line Example :

of the sections
place of operation and logical sequence
The point shows the exact position of
the weld join
This letter designates the drawing

F - G - corresponding to the section (It is gi-
H - I - J ven in one of the upper corners of
each drawing )
spot welding
weldable mastic
G
unpicking with grinder
7
CAA11538R8 e = 1+1
40-3
GENERAL
Using symbols 40
SPECIFIC CASES Under diagram I
site of operation and order of operations

J
➜ ➝
1st opera- unpicking apply weld fil-

tion with grinder let
chisel the edge 2nd opera-
2 1 tion
CAA11537-1R6 D
In this example, there is no direct access for remo-

ving part 1. The spot welds should be unpicked
through part 2, which should be kept.
I 10354R
2 1
In this particular case, the arrow indicates that

➝ ➜ the joint is made by arc welding (MIG).
E
CAQ11697-1R5
➜ ➝
This arrow indicates that it is necessary

to cut the part it crosses before acces-
sing the joint.
The references which follow indicate different 10349R

operations :
➜ unpicking
In this example, the joint is
➝ welding made by bonding.
40-4
GENERAL
Key to symbols 40
Plug welding.
Chiselling
Under MAG gas protection.
Grind back beads or spot welds. Crimping of exterior door panels.

Straight grinding wheel with 75 mm
diameter bakelite impregnated disc,
thickness 1.8 to 3.2 mm.
Safety symbol.
Grind back spot welds. This means that the welding operation
20 000 rpm straight grinder with 10 or 16 in question concerns one or more of the
mm diameter spherical burr. vehicle’s vital safety components.
Drill spot welds. Body solder - lead fill.

Hardened steel bit. Speed of rotation 800 Hot air torch.
to 1 000 rpm. Nozzle output temperature 600° min.
Slipper+ 33 % tin solder + tallow.
Note : to a large extent, body solder
Unpicking filling compensates for the heat
distortion caused by welding.
Cleaning surfaces to be welded. Application of weldable mastic.

100 mm diameter fibre disc. This mastic conducts electricity, applied
between two panels to be spot welded,
it ensures the seal between the panels
Cutting with a saw. and avoids corrosion of the spot welds.
Pneumatic power hacksaw.
- Cutting out part by grinding off flange Application of aluminium paint.

or grinding back remaining traces of This is to be applied to the joint faces of
spot weld. each of the parts to be plug welded.
- Finish surface after welding. The paint conducts electricity and is is
- Angle grinder equipped with a rubber resistant to high temperatures. It
pad and a 120 to 180 mm diameter provides anti-corrosion protection
fibre disc grain size P36. around the plug welds.
Unsoldering.
Apply a fillet of extruded mastic
• from a manual or pneumatic spray
MAG stitch weld gun.
Note : to obtain a good quality weld we • one or two pot mastic for crimped
recommend the use of a gas consisting and butt joints.
of argon + 15 % CO2. This is
considered to be an active gas (MAG). Spray on sealer
• spray gun.
• two pot anti-gravel and anti-
corrosion mastic.
Spot weld
40-5
GENERAL
Description of parts (exploded view) 40
PRE4005
290 Roof 304 Base support

* 291 Roof rear cross member 305 Base stiffener
292 Absorber support * 306 Sill panel
293 Rear end panel * 307 Front pillar
294 Lights mounting * 308 Body side, front section
295 Tailgate 309 Rear floor unit
* 296 Wing panel 310 Rear pillar reinforcement
* 297 Top of body * 311 Rear quarter panel lining assembly
* 298 Rear door 312 Inner wheel arch
* 299 Rear door panel 313 Stretcher extension
300 Rear end pillar lower reinforcement 314 Roof cross member support
* 301 Rear end cross member * 315 Wing panel drip moulding
302 Emergency spare wheel mounting sup- 316 Speaker support
port 317 Roof stiffener
303 Rear floor base
* Parts for which repaired areas must be electro zinc plated
40-6
GENERAL
15072R2
40-7
GENERAL
1 3
15348R 15344R
2 4
15342R 15345R
40-8
GENERAL
5 7
15343R 15346R
15347R
40-9
LOWER STRUCTURE
Absorber support mounting 41 A
INTRODUCTION
Basic operation for a rear impact.
This part is mounted by three M8 nuts on the rear

end panel.
COMPOSITION OF PART FROM PARTS

DEPARTMENT
Single part.
PRE4105
251a01-15362
41-1
LOWER STRUCTURE
Rear floor base 41 B
This part may be replaced in two ways: PARTS CONCERNED (thickness in mm) :
A completely, as a complementary operation to 1 Rear floor base 0.8

the rear end cross member. 2 Rear end cross member 0.8
3 Rear end pillar lower reinforcement 1
B by part section, as a complementary operation 4 Rear floor 0.7
to the rear end pillar lower reinforcement. 5 Body side lining 0.7
6 Rear inner wheel arch 0.8
The method described only contains descriptions 7 Rear floor base side side-member 1
of joints specific to the part concerned. Joints with 8 Rear floor base intermediate stiffener 0.8
complementary parts are not included. 9 Rear floor base front stiffener 0.8
These are dealt with in their respective section (re-

fer to the contents page).

DEPARTMENT
Single part.
PRE4106
or
41-2
LOWER STRUCTURE
C
1
CAA11538R3b
251b01-15363
A D
4 1
1 1
CAA11536-4R1
CAS13033R1
B E
5 1
2 1
CAF11547-2R4
CAR11700R6
41-3
LOWER STRUCTURE
F I
1 1
1
5 8
CAA11538R3a CAW13605-4R2
G J
1
1 1
6
CAA11538R4 CAA11536-3R5
H K 1 9 1
CAA11538-1R6 CAS13028R4
41-4
LOWER STRUCTURE
Rear floor base support 41 C
INTRODUCTION PARTS CONCERNED (thickness in mm) :
The replacement of this part is a complementary 1 Rear floor base side side-member 1
operation to the rear floor base. 2 Rear floor base intermediate stiffener 0.8
3 Rear floor base front stiffener 0.8
The method described only contains descriptions 4 Rear floor 0.7
of joints specific to the part concerned. Joints with 5 Rear side member 1.2
complementary parts are not included.


DEPARTMENT
Part assembled with:

- rear floor base side side-member,
- rear floor base intermediate stiffener,
- rear floor base front stiffener.
PRE4107
41-5
LOWER STRUCTURE
Rear floor base support 41 C
B
1
4 2
TOI14637-4R5
251c01-15364
A 1
C
3
1
4
CAT13327R3 CAA11538R5
41-6
LOWER STRUCTURE
Rear floor base front stiffener 41 D
INTRODUCTION
The replacement of this part is a complementary

operation to the rear floor base support.
The method described only contains descriptions

of joints specific to the part concerned. Joints with


DEPARTMENT
Single part.
251d01-15364-1
A
1
2
PRE4108
CAA11538R1
PARTS CONCERNED (thickness in mm) :
1 Rear floor base front stiffener 0.8

2 Rear floor 0.7
41-7
LOWER STRUCTURE
Rear end pillar lower reinforcement 41 E
INTRODUCTION

operation to the rear end cross member.



DEPARTMENT
Part assembled with welded nuts.
PRE4109

2 Rear end cross member 0.8
3 Body side lining 0.7
4 Rear end pillar lining 1
5 Rear floor 0.7
6 Rear side member 1.2
7 Lights mounting 0.7
41-8
LOWER STRUCTURE
C 8
CAD11545R4
251e01-15365
D
A 8
1
CAA11536-2R7
CAA11537R4
E
B
1
1
3
CAA11536R7
CAN11689R4
41-9
LOWER STRUCTURE
CAA11538-1R7
251e02-15366
F H
2 1
CAA11537R2 CAA11538-1R7
41-10
LOWER STRUCTURE
Rear end cross member assembly 41 F
INTRODUCTION

operation to the rear end panel.



DEPARTMENT

- striker plate reinforcement,
- central reinforcement.
PRE4110

3 Rear floor base 0.8
4 Rear floor 0.7
5 Tailgate striker plate central
reinforcement 1.2
6 Rear floor central reinforcement 0.8
41-11
LOWER STRUCTURE
C
6
1 5
251f01-15367 CAS13024-4R5
A D
2 1
1 4
CAN11689R5 CAA11537-1R1a
B E
1 1 6
CAA11538-1R8 CAA11536-1R2
41-12
LOWER STRUCTURE
1 2
CAA11537-1R5
251f02-15363-1
1 3
CAR11700-1R4
41-13
LOWER STRUCTURE
Rear floor unit 41 G
INTRODUCTION
The replacement of this part is identical to the me-

thod described in the basic manual (M.R. 313 -
Section 41). Only the joints at the rear end pillar
lower reinforcements are different, which are des-
cribed in this document (section 41-E).



DEPARTMENT

- side member assemblies,
- floor assembly,
- cross member under the floor,
- floor base assembly,
- rear end cross member assembly,
- rear end pillar reinforcement.
PRE4111
41-14
Top of body 43 A
INTRODUCTION

operation to the replacement of the roof for a
front side impact.


fer to the contents page) and MR 313 for the front
section.

DEPARTMENT
Part assembled with welded pin.
PRE4310
or
1 Body side 0.77

2 Rear quarter panel lining 0.7
3 Rear pillar upper reinforcement 1
4 Rear pillar lower reinforcement 1
5 Stretcher lining 1.2
6 Centre pillar reinforcement 1.5
7 Rear corner reinforcement 1.2
9 Rear upper side drip moulding 1
43-1
Top of body 43 A
B
2
3
1
253a01-15317 CAE11546-6R5
A
1 C
5
3
1
CAS13033R3
CAE11546-2R7
D
5
CAB11539R8
43-2
Top of body 43 A
E
2 1
CAQ11697R1
F
2 7 1
CAT13326-1R1
G 8
2
7
TOW15255-3R1
43-3
Top of body 43 A
J
9
CAB11540-1R7
253a02-15319
I
1
CAB11540-1R3
43-4
Rear wing panel 44 A
This part may be replaced in two ways: 1 Wing panel 0.8

• by part section as a basic operation for a rear 3 Sill panel closure panel 1.5
side impact (see diagram), 4 Rear pillar reinforcement 1
• completely, as a complementary operation to 5 Rear outer wheel arch 0.7
the roof. 6 Rear upper side drip moulding 1
7 Lights moulding 0.7
The method described only contains descriptions 8 Rear end pillar lining 1
of joints specific to the part concerned. Joints with 9 Rear end panel 1
complementary parts are not included. 10 Rear end pillar lower reinforcement 1


DEPARTMENT

- striker plate reinforcement,
- pin to be welded 3 x2.9,
- soundproofing,
- bumper mounting reinforcement assembly.
PRE4415
or
44-1
C
2 1
CAQ11697R6a
254a03-15385
D
A
1
2
4
1
CAE11546-8R1
CAS13033R4
E
B
2
4
1 5 2
1
CAE11546-2R1
CAE11546-6R5
44-2
F H
1
1 4
CAB11539R6 CAS13033R3
or
G
2
CAQ11697R3
44-3
J
1
CAS13033R4
or
254a01-15368
I 1
➝ CAN11691R7
44-4
M
1
5
10
CAI11550R2
254a02-15382
N
K
1
1 5 5
CAI11550R2
TOA14581R6
O
L 5
9
5
CAI11550R7
CAB11539R8
44-5
Q
1 7
CAB11540-1R1
254a05-15381
P
6
CAB11540-1R7
44-6
COMPLETE REPLACEMENT
(with removal of the roof) S
1 1
CAS13033R1
or
254a07-15384
R
11
4
1
CAE11546-2R7
44-7
254a06-15387 254a04-15386
T U
1
1 5
6
CAB11540-1R3 CAB11539R6
44-8
V
1
5
CAE11546-2R3
1 1
CAS13033R1
or
44-9
Rear lights mounting 44 B
INTRODUCTION

operation to the wing panel.



DEPARTMENT
Single part.
254b01-15380
A
2
PRE4416
CAA11536-2R7

4 Rear end panel 1
44-10
Rear lights mounting 44 B
B E
5 1
3 1
2
TOK14644-1R2 CAB11539R5
C F
3 1 4
5
1
CAB11539R5 CAE11546-8R2
D G
5
2
1
2
CAE11546-8R2 CAA11536-2R3
44-11
Upper side drip moulding 44 C
INTRODUCTION

operation to the rear wing panel.



DEPARTMENT

- balancer ball joint,
- parcel shelf mounting.
PRE4423

44-12
3 4 1
CAJ11551-1R5
254c01-15378
A C
4 1
3 1
CAA11536R1 CAV13466R1
44-13
3
2
1
CAE11546-8R2
254c02-15379
D
1
CAT13319-1R7
44-14
Rear pillar reinforcement 44 D
The replacement of this part is a complementary 1 Rear pillar lower reinforcement 1

operation to the rear wing panel for a rear side 2 Rear pillar upper reinforcement 1
impact. 3 Rear quarter panel lining 0.7
4 Rear outer wheel arch 0.7
The method described only contains descriptions 6 Sill panel closure panel 1.5
of joints specific to the part concerned. Joints with 7 Seat belt mounting reinforcement 1.5
complementary parts are not included. 8 Stretcher lining 1.2


DEPARTMENT

- upper pillar reinforcement,
- mounting nuts,
- lower pillar reinforcement,
- acoustic plug.
PRE4417
NOTE : for this operation the upper part of the

reinforcement must be unpicked on the new part.
44-15
B
1 2
CAN11689R5
254d01-15377
C
A
1
1 2
CAO11694R7
CAA11536R5
D
1
CAW13602R7
44-16
E
CAN11689R3
254d02-15376
F
G
5
4
1
1
CAA11538R6
CAT13327R5
44-17
H 6 4
REAR PILLAR UPPER REINFORCEMENT
CAF11547-2R1
I
1 254d03-15374
7 A
CAS13024-1R4
2 8
CAN11689R5
J
4 1
CAA11536R6
44-18
B
CAJ11551R3
8 2 3
CAD11545-2R2
2 8
CAN11689R5
44-19
Rear inner wheel arch 44 E
INTRODUCTION

operation to the replacement of a wing panel
with rear quarter panel lining or a rear floor unit.
For details of the operation refer to the basic ma-

nual (M.R. 313).

DEPARTMENT
Welded stud.
PRE4418
1 Right hand side

2 Left hand side
44-20
Rear quarter panel lining assembly 44 F
The replacement of this part is a complementary 1 Body side lining 0.7

operation to a complete wing panel. 2 Rear quarter panel lining 0.7
3 Centre pillar lining 1.2
The method described only contains descriptions 4 Front sill closure panel 1.5
of joints specific to the part concerned. Joints with 5 Rear sill closure panel 0.8
complementary parts are not included. 6 Rear inner wheel arch 0.8
7 Seat belt mounting reinforcement 1.5
These are dealt with in their respective section (re- 8 Stretcher lining 1.2
fer to the contents page). 9 Rear floor base 0.8
10 Rear floor 0.7
COMPOSITION OF PART FROM PARTS 12 Rear end pillar lower reinforcement 1
DEPARTMENT

- outer wheel arch,
- seat mounting reinforcement,
- connecting bracket,
- rear end pillar lining assembly,
- upper corner reinforcement assembly.
PRE4419
or
NOTE : to avoid replacing the part located behind

the sill panel, cut the front lower section of the li-
ning, see section (C) in the diagram below.
44-21
B
1 5
CAA11536-1R2
254f01-15375
C
or 1 1
A
1
CAA11537-1R1a
5
CAW13602R7 D
1
TOA14581R4
44-22
TOD14617R4
254f04-15371
F
Ga
1 3
1 7 4
CAA11536R2
CAQ11697-2R1a
G
1
TOA14581R3
44-23
254f02-15373 254f03-15372-1
H I
8 1
11
1
TOB14593R5
CAA11537R2
J 11
12
CAW13603-2R8
44-24
K N
12 6
1 1
CAT13319-1R2 CAA11538-1R2
L O
6 1
CAA11538-1R4 CAQ11697R6a
M P
11
10
CAA11538-1R4 CAT13319-1R2
44-25
Q
11
2 1
TOK14646-3R5
44-26
Outer wheel arch 44 G
INTRODUCTION
This part can be replaced in two ways:

• by part section A , complementary to the rear
end pillar,
• by part section B , complementary to the wing
panel.



DEPARTMENT
PRE4421
- outer wheel arch,
- seat mounting reinforcement, SECTION B : complementary to rear wing panel.
- connecting bracket,
- rear end pillar lining assembly,
- upper corner reinforcement assembly.
or

4 Rear floor base 0.8
5 Rear floor 0.7
7 Seat belt mounting reinforcement 1.5
PRE4420
SECTION A : complementary to rear end pillar

reinforcement.
44-27
COMPLEMENTARY TO REAR END PILLAR
REINFORCEMENT B
CAA11536-3R7
C 3
254g01-15372 2
or
A 2
1
CAT13321-1R7
1
D
1
2
CAP11696-1R4
1
CAA11538-1R1
44-28
E
1
CAA11538-1R8
CAA11538-1R7
1 1
CAA11536-2R5
44-29
COMPLEMENTARY TO REAR WING PANEL
B
➜
➝
1
1
TOB14593-1R2
➝
254g02-15370
or
C
7 1
A
1
➝
CAA11536-1R1a
➜
TOB14593-1R7
44-30
Rear end panel 44 H
INTRODUCTION

for a rear impact.



254h01-15369
DEPARTMENT
Part assembled with rear end panel lower reinfor- or

cement.
1 4
3
PRE4422
TOK14644-1R1
1 Rear end panel 1

6 Rear end panel inner reinforcement 1
7 Tailgate striker plate reinforcement 1.2
8 Rear wing panel 1
44-31
Rear end panel 44 H
B E
3
5
CAA11536-2R8 CAB11539R7
C F
4
4
6
1 1
CAB11539R7 CAE11546-2R8
D
4
5
1
CAE11546-2R8
44-32
Rear end panel 44 H
H
4 5 1
CAT13326-1R6
254h02-15383
I
G 5 1
1
2
8 CAQ11697R6
CAI11550R1
7 1
CAE11546-8R4
44-33
TOP OF BODY
Roof 45 A
INTRODUCTION

for a side impact or a roll-over.

DEPARTMENT
PRE4501R
1 Roof 0.7
2 Front roof cross member 0.7
3 Windscreen pillar lining 1.5
4 Body side 0.77
5 Centre pillar reinforcement 1.5
7 Rear roof cross member 0.7
10 Stretcher lining 1.2
11 Centre pillar lining 1.2
12 Rear end pillar lining 0.9
45-1
TOP OF BODY
Roof 45 A
B
1
CAT13326-1R8
255a01-15311
C 4
A 1
2 CAT13326-3R3
CAQ11697R8
D
1 4
TOA14580-1R6
45-2
TOP OF BODY
Roof 45 A
E
1 3 4
CAP11696-2R2
255a02-15312
F
H
1 8
1 4 3 11
TOP15254R2
CAA11536R5
G
1 5 3
CAP11696-2R2
45-3
TOP OF BODY
Roof 45 A
I L
1 6 12
9 6 4 1
CAW13602R2 TOP15254R1
J M
7 1
4 9 1
CAN11689R1a CAP11696-2R1
K N
4 6 1 4 5 1
CAP11696-2R1 CAP11696-2R1
45-4
TOP OF BODY
Roof 45 A
O
4 10 1
CAP11696-2R1
255a03-15312
P A= 70 mm
B= 500 mm
C= 500 mm
D= 300 mm
E
6 7 1
CAJ11551-1R5
15342R1
Bead C
NOTE : apply a bead of adhesive mastic (C) in

zones (B) and (D) of the basic diagram, to rein-
force the roof where the roof bars are mounted.
45-5
TOP OF BODY
Roof acoustic cross member 45 B
INTRODUCTION

roll-over.
For reasons of standardisation, the Parts

Department only supplies parts for the version wi-
thout sunroof.Where a sunroof is fitted originally,
the roof and the centre roof cross member must
be cut according to the diagram below.
These cuts must also be made to fit a sunroof as an

accessory. PRE4502
IMPORTANT : the roof cross member has a struc-

tural reinforcement function. For the version with
For sunroof
sunroof, the sunroof frame fulfils this function.
When fitting a sunroof as an accessory it is re-
commended that only sunroofs approved by the PARTS CONCERNED (thickness in mm) :
Renault accessories department are used.
1 Acoustic cross member 0.7
The method described only contains descriptions 2 Centre pillar reinforcement 1.5


DEPARTMENT
Single part.
45-6
TOP OF BODY
Roof acoustic cross member 45 B
LEFT HAND SIDE RIGHT HAND SIDE
255b01-15313 255b02-15316
A B
2 1
2 1
CAA11536-3R6 CAA11536-5R6
45-7
TOP OF BODY
Roof bow 45 C
INTRODUCTION

roll-over.



DEPARTMENT
Single part.
PRE4503
Bows (A) and (B) are mounted by rivets.

Bow (C) is spot welded.
1 Roof bow 0.7

2 Rear pillar upper reinforcement 1
3 Roof bow support 1.2
45-8
TOP OF BODY
Roof bow 45 C
BOWS A and B
255c02-15314
255c01-15315
B
A = rivet diameter 4.8 mm
(joint with bow support)
2 1
CAA11536-3R6
45-9
TOP OF BODY
Roof rear cross member 45 D
INTRODUCTION

roll-over.

complementary parts are not included. These are
dealt with in their respective section (refer to the
contents page).

DEPARTMENT
Single part.
PRE4504
1 Roof rear cross member 0.7

45-10
TOP OF BODY
Roof rear cross member 45 D
B
3
CAA11538-1R2
255d01-15318
C
A
1
1 3
2
TOD14617R4
CAT13318R2
45-11
Rear door panel 47 A
INTRODUCTION

for a side impact.
This part may be partially replaced (see cut and

method below).
NOTE : the original panels have MIG welded an-

chorage points. In repair, these points are not
made (sections A on the diagram below).

DEPARTMENT

- soundproofing,
- stiffener.
PRE4701
or
1 Door panel 0.7

2 Door box section 0.7
3 Door frame 0.8
47-1
257a04-15322 257a06-15324
A A
1 2
1 2
TOB14587R5 TOB14587R1
47-2
C
1 2
➝
➜
TOB14587R1
➜
257a01-15320
➝
or
B D
1 2
➝➞
➜ 1
CAB11539R4
TOB14587R1
47-3
E
1
CAS13033R3
47-4
G
1
CAS13033R3
257a03-15321
or H
1 2
F
3 1 ➜
TOB14587R2
➜
CAQ11697R6a
47-5
Tailgate 48 A
- the headlining plugs using a screwdriver (torx
20).
PRE4803
REMOVAL
99621R2
Remove the trim and disconnect the various wi-
ring harnesses (see sections 52 and 71).
Unclip the tailgate balancers at (A).
Remove:
- the third stop light, Remove the mounting nuts and remove the
- the rear screen washer jet pipe, hinges (B) (two persons required for this opera-
- the wiring harness, tion).
NOTE : if the tailgate or the roof is being repla-

ced, retain the height adjustment shims located
under the hinges (B).
To do this, use a cutting tool to destroy the finis-

hing seal around the shims and retain them.
The hinges are welded on the tailgate, so these

shims of thickness 1 mm are used to adjust the
clearance between the roof and the tailgate.
99386R1
48-1
Tailgate 48 A
REFITTING PROCEDURE FOR ADJUSTING THE STRIKER PLATE
99621R 11295R1
IMPORTANT NOTE : before beginning the adjustments below,

slacken the lock striker plate mounting bolt (C), so
When refitting the hinges, remember to ensure there is no resistance to closing.
sealing between the sealing washers (under the
mounting nuts) and the roof panel.
To do this, use plugging mastic Part Number 77 11

170 230 (refer to Technical Note 396A).
To adjust the tailgate and its lock after refitting,

observe the opening clearances 4, 6 and 7 descri-
bed in section 40.
This adjustment must be made with the tailgate

fully fitted.
48-2
Tailgate 48 A
PRE4803R
The adjustment operation is carried out with two

persons. To do this, hook the lock on the striker
plate and press the tailgate against the lower
stops (D) and (E).
At the same time, from inside the vehicle, tighten

the striker plate mounting bolt.
At the end of the adjustment operation, apply a

bead of paint joint mastic around the three visible
faces of the adjusting shims for the hinges.
Carry out an operation to paint these beads.
48-3
Mechanisms and accessories
WINDOWS
EXTERIOR PROTECTION
KA0X
C Renault 1999
EXPLODED VIEW
PRG50.1R
Mechanisms and
accessories
Contents
Page
52 NON-SIDE OPENING ELEMENT

MECHANISMS
Tailgate lock barrel 52-1

Rear screen wiper motor 52-3
54 WINDOWS
Rear door sliding window 54-1
Rear screen 54-3
Rear quarter panel window 54-6
55 EXTERIOR PROTECTION
Rear bumper 55-1
Number plate lights mounting 56-1
59 INTERIOR SAFETY ACCESSORIES

Front seat belts 59-1
Rear seat belts 59-3
Tailgate lock barrel 52 A
PRE5206
REMOVAL
Remove:
- the tailgate inner trim (see section 73A),
15418R
- the two mounting bolts (A),

- the lock control linkage (B),
- the motor connector (C).
52-1
Tailgate lock barrel 52 A
15416R
Remove:
- the mounting bolt (D),
- the retaining clip (E) using a small flat blade
screwdriver.
REFITTING
NOTES:
Fit the clip (E) using an 8 mm pipe wrench, to

make refitting easier.
Systematically renew the seal (F) each time the

lock barrel is removed.
This seal fits into lug (G) in place of the old seal.
52-2
Rear screen wiper motor 52 B
PRE5207
REMOVAL - the wiper mounting nut (A),

- the wiper using tool Elé. 1294-01,
Remove: - the three motor mounting bolts (B),
- the tailgate inner trim (see section 73A), - the motor feed connector.
NOTE : when replacing a tailgate, remember to

retain, before refitting, the sealing ring (C) fitted
to the tailgate panel.
15418R1
52-3
Rear screen wiper motor 52 B
REFITTING THE REAR SCREEN WIPER
Clean the splines on the shaft using a wire brush.
Check the splines on the arm.
Refit the wiper arm, aligning the upper part of

the arm with the circular mark on the lower right
hand corner of the rear screen.
Refit the nut and torque tighten it to 10 daN.m (±

20 %) using a torque wrench.
Check it operates correctly.
Refit the cover over the nut.
NOTE : if, while the wiper arm was removed, the

motor turned, return it to the "park" position be-
fore refitting the wiper arm.
52-4
WINDOWS
Rear door sliding window 54 A
REMOVAL REFITTING
PRE5409 14871R
These plastic pin type clips are mounted in two

holes in the glass.
To fit the clips on the window :

- place section (1) against the edge of the win-
dow,
- push the "pin" (2) into the hole in the win-
dow.
99151R1
The metal runner at the bottom of the window

has been removed.
The drive rail mounting on the window for the

window raise has been ensured by new clips.
The fitting method for this new design is descri-

bed below.
54-1
WINDOWS
Rear door sliding window 54 A
14872R 99156R1
IMPORTANT : ensure that mounting pin (A) is The two mounting bolts (B) are tightened with
flush with the outer surface of the window and the window in the raised position.
that it fits correctly in the inside of the mounting
hole.
To do this, fit the mounting bolts (B) and tighten
This will press progressively against the window as them through the openings in the door box sec-
the mounting bolt (B) is tightened. tion (C) observing the tightening torque given be-
low.
TIGHTENING TORQUE (in daN.m)
Window raise rail mounting bolt 0.4
IMPORTANT: when mounting the window on the

raise rail, the original bolts provided for this pur-
pose must be used.
54-2
WINDOWS
Rear screen 54 B
Remove:
- the third stop light cover,
- the wiper arm using tool Elé. 1294-01 (see sec-
tion 52B).
Disconnect the heated screen grid and flatten the

metal tabs against the glass using two strips of
masking tape.
98858
PRE5410
INTRODUCTION
There is no trim around the contour of the screen.
The fitting clearances recommended between the

glass and the vehicle metal panels must be obser-
ved using the positioning shims (1).
REMOVAL
15072G
IMPORTANT : stick a strip of masking tape around

the edge of the glass to protect the painted areas
when the cutting tool is used.
Pierce the bead of adhesive using a threader tool

(A) inclined as far as possible (B) to make retaining
the wire easier between the glass and the tailgate
lip.
15400S
54-3
WINDOWS
Rear screen 54 B
BONDING AND FITTING THE SCREEN
15402R
IMPORTANT: when cutting the bead, the wire will 15401R1

cut the positioning shims and the index pin (C).
Because of this, points of resistance will be met in
these areas during the operation. After removing the screen, remove the positio-
ning shims and flatten off the bead of mastic
The shims must be replaced after every removal using a cutting tool.
operation.
The index pin is no longer used for correctly refit-

ting the screen.
54-4
WINDOWS
Rear screen 54 B
90989S
Preparation of the bonding areas is described in

the general method for bonding windows,
15404R1 Technical Note n° 371A.
Fit the shims from the Parts Department (1)

After applying the bead of adhesive to the win-
These shims are in two sections: dow, offer up the window, centring it in relation
- section (1) ensures the height positioning of to the window washer jet and the reference mark
the window at the bottom only on the window.
- section (2) ensures the depth positioning of
the window in the tailgate frame. Rest the bottom of the window on the height po-
sitioning shims (1) (see above).
Fit parts (2) of the shim into holes (E) in the tail-
gate and rest part (1) on the edge of the tailgate Flatten the window against the depth positioning
lip. shims (2).
Fit part (2) into tailgate holes (D) only. Hold the upper part of the window using strips of
masking tape while the adhesive dries .
NOTE: Remember to remove the height adjus-

tment section (1) when the vehicle is no longer im-
mobilised.
54-5
WINDOWS
Rear quarter panel window 54 C
Remove:
- the front quarter panel lining (see section
71C),
- the rear quarter panel lining (see section
71D),
- the lower quarter panel lining (see section
71E).
PRE5411
INTRODUCTION
There is no trim around the contour of the win-

dow.
The fitting clearances recommended between the

glass and the vehicle metal panels must be obser-
ved using the positioning shims (1).
REMOVAL
15406R
IMPORTANT : Apply a strip of masking tape

around the edge of the glass to protect the pain-
ted areas when the cutting tool is used, including
the door seal.
Fit the cutting wire using the threader tool (A) as

shown above.
IMPORTANT: when cutting the bead, the wire will

cut the positioning shims.
Because of this, points of resistance will be met in

these areas during the operation.
The shims must be replaced after every removal

operation.
15413-3S
54-6
WINDOWS
BONDING AND FITTING THE WINDOW
15404R1
15405R Fit the shims from the Parts Department (1).
These shims are in two sections:

After removing the window, remove the parts (B) - section (1) ensures the height and length posi-
of the retaining clips for the inner linings fitted tioning of the window at the bottom and the
onto the wing panel lip. rear,
- section (2) ensures the depth positioning of
Remove the positioning shims and flatten the ma- the window.
stic bead using a cutting tool.
Refit the clips (B).
IMPORTANT: before refitting the window, if ne-

cessary, refit the door seal under the window.
15403R1
54-7
WINDOWS
Fit the shim part (2) in holes (E).
Rest part (1) on the edge of the quarter panel win-

dow lip.
Fit part (2) only into hole (D).
90989S
Preparation of the bonding areas is described in

the general method for bonding windows,
Technical Note n° 371A.
After applying the bead of adhesive to the win-

dow, offer up and set the window against the
shims mounted at (E).
Rest the lower part of the window on the height

positioning shims (1).
Flatten the window against the depth positioning

shims (2).
Hold the upper part of the window using strips of

masking tape while the adhesive dries .
NOTE:remember to remove the height adjus-

tment section (1) when the vehicle is no longer im-
mobilised.
54-8
EXTERIOR PROTECTION
Rear bumper 55 A
PRE5505
REMOVAL
15410R
15415R1 - the mudguard shield mounting bolts (C),

- the side mounting bolts (D) for the bumper.
Remove: At (1) release the index pin (E) for the rear wing
- the upper mounting bolts (A), panel.
- the lower mounting bolts (B),
At (2) push the bumper towards the rear of the ve-
hicle and remove it from its location between the
retaining bracket (F) and the wing panel.
55-1
EXTERIOR PROTECTION
Rear bumper 55 A
15412R 15411R
View of the bumper side lugs which clip onto the NOTES:
retaining bracket (F) (see previous page).
The retaining brackets (F) clip onto the wing panel
View of the index pin (E) on the bumper. using clips (G).
The two supports (H) are screwed at (I) to the rear

end panel and are clipped at (J).
Use unpicking pliers to remove these parts.
SPECIAL NOTES FOR REFITTING
Before refitting, ensure all the clips (K) are present

on the supports (H).
Also ensure that parts (F) and (H) are correctly

clipped in before refitting the bumper.
55-2
Number plate lights mounting 56 A
PRE5610
REMOVAL
Remove the inner tailgate trim (see section 73A).

15407R
Using unpicking pliers, remove the two clips (B)

and release the lights mounting.
Remove the two connectors (C) for the number

plate lights.
IMPORTANT : before refitting the support, ensure

the seal (D) and where it fits on the tailgate are
clean.
Ensure the clips are present (E).
15418R2
Remove:
- the two mounting bolts (A),
- the tailgate lock barrel (see section 52A).
56-1
Front seat belts 59 A
RECOMMENDATIONS FOR FITTING SEAT BELT INERTIA REELS
IMPORTANT
These vehicles are fitted with a new passive safety assembly comprising, amongst other components, new
front air bags and specific front seat belts with a new programmed restraint system (SRP).
The programmed restraint system is not calibrated in the same way according to whether the seat belts are
fitted with an SRP air bag or not (the Part Number for each part must be checked before replacement).
It is strictly forbidden:
- to fit new SRP air bag cushions and / or their specific seat belts to vehicles originally fitted with old type
equipment,
- to fit components from an old type system to a vehicle fitted with this new restraint system.
NOTE : for more information on fitting the new SRP seat belts, refer to the instructions below.
Following the triggering of the pretensioners, the

front seat belt or belts must be systematically re-
placed (if there was any doubt about whether the
seat belt was being worn, it must be replaced).
New SRP programmed restraint system.
This new force limiter system L.E.I. is integral in

the inertia reel.
The force limitation applied to the diagonal strap

of the seat belt occurs by controlled release of the
strap (1), ensured by the plastic deformation of a
torsion bar (2) integrated into the inertia reel.
14340R
59-1
Front seat belts 59 A
15396S
59-2
Rear seat belts 59 B
REMOVAL REMOVING THE THIRD SEAT BELT INERTIA REEL
Remove:
- the front quarter panel lining (see section
71C),
- the rear quarter panel lining (see section
71D),
- the lower quarter panel lining (see section
71E).
15414R
Pull on the lining / inertia reel assembly to release

the clip (C).
Using a screwdriver with a Torx 40 socket, slacken

the mounting bolt (B).
PRE5901
NOTE : the inertia reel is positioned on the roof
using the index pin (D).
The strap guide (E) and the plastic housing (F) can-
not be removed.
If the inertia reel is being replaced, the complete

third seat belt assembly must be replaced, which is
available from the Parts Department.
TIGHTENING TORQUE (in daN.m)
Seat belt mounting bolt 2.5
15413-3R1
- the inertia reel mounting bolt (A),

- the seat belt strap lower mounting bolt (B).
59-3
Sealing and soundproofing
OPENING ELEMENT SEALING
KA0X
C Renault 1999
EXPLODED VIEW
DI60.1R
Sealing and
soundproofing
Contents
Page
65 OPENING ELEMENT SEALING

Rear door pillar seal 65-1
OPENING ELEMENTS SEALING
Rear door pillar seal 65 A
PRE6501R
REMOVAL
15403R
Remove the rear quarter panel window (see sec-

tion 54C).
Using unpicking pliers, remove the three retaining

clips (A).
Remove the seal.
NOTE : the retaining clips are located in plastic

holders (B) mounted to the body.
65-1
Upholstery and trim
INTERIOR BODY TRIM
KA0X
C Renault 1999
EXPLODED VIEW
PRG70.1R
Upholstery and trim
Contents
Page
71 INTERIOR BODY TRIM

Boot carpet 71-1
Headlining 71-2
Front rear quarter panel lining 71-5
Rear rear quarter panel lining 71-6
Lower rear quarter panel lining 71-7
Wheel arch lining 71-8

73
Tailgate lining 73-1

INTERIOR BODY TRIM
Boot carpet 71 A
PRE7108
REMOVAL
15409R
Tilt the rear seats forwards.
Use unpicking pliers to remove the retaining clips

(A) and (B).
Remove the passenger compartment carpet.
71-1
INTERIOR BODY TRIM
Headlining 71 B
PRE7114
INTRODUCTION
This headlining is bonded to the roof using a single pot adhesive used for bonding windows.
The rear side edges of the headlining are held in place with velcro (1).
REMOVAL
After removing the front and rear head restraints,

protect the seats and remove:
- the four door seals,
- the boot seal,
- the windscreen pillar linings (A),
- the upper centre pillar linings (B),
- the front rear quarter panel linings (C) (see
section 71C),
- the rear rear quarter panel linings (D) (see sec-
tion 71D),
- the sun visors and their retaining clips,
- the grab handles and their blanking plugs for
the driver’s position,
- the roof console (E),
- the courtesy lights,
- the rear speaker grilles (F),
- the tailgate mounting plugs (G),
- the centre retaining clip (H),
- the third rear seat belt (see section 59B).
PRE7113
71-2
INTERIOR BODY TRIM
Headlining 71 B
15408R
Gently pull the rear edges of the headlining to re-

lease the velcro strips at the side (1).
15419R
Using equipment for manually removing bonded
windows (pulling handle, unpicking tool, cutting
wire), working progressively from the front to the NOTES:
rear, cut the beads of adhesive between the hea-
dlining and the roof panel (two persons required The headlining does not need to be released to re-
for this operation). move the plugs (I).
Remove the headlining through the tailgate. Remove the surrounding trim and the rear clips
and plugs to release the velcro strips " (J).
Pull the headlining slightly to one side.

IMPORTANT: during this operation, take care not
to cut the foam wedge at the rear of the cut-out Remove the stop (K).
for the roof console.
Remove the blanking plug (I).
Do not fold the headlining during this operation
if it is not to be renewed.
71-3
INTERIOR BODY TRIM
Headlining 71 B
Flatten the beads of adhesive on the roof panel REFITTING
and on the headlining in the case of a removal /
refitting operation using a cutting tool such as a Apply adhesive to the headlining as shown oppo-
mastic knife. site, observing the dimensions for positioning the
beads of adhesive below:
A = 155 mm B = 125 mm
C = 445 mm D = 275 mm
E = 300 mm F = 270 mm
G = 130 mm
NOTE: Use a single pot polyurethane adhesive of

the additional 310 ml cartridge type.
Bring the headlining in through the tailgate.
Centre it in relation to the cut outs for the sun vi-

sors and the grab handles.
Flatten the headlining against the roof panel in

the bonding areas at the rear side retaining clips
(A) (see previous pages).
First fit the sun visor retaining clips and the rear
tailgate mounting plugs (G) and (H) (see previous
pages).
15421R
Refit the vehicle trim.
71-4
INTERIOR BODY TRIM
Front rear quarter panel lining 71 C
REMOVAL
PRE7109
Remove:
- the upper seat belt mounting,
- the rear door seal (partially, in the area where
it touches the lining).
15413R
Unclip (1) the lining to release the clips (A) and

clips (B).
Pull the lining (2) upwards to release it from its lo-

cation on the lower rear quarter panel lining.
71-5
INTERIOR BODY TRIM
Rear rear quarter panel lining 71 D
REMOVAL
PRE7110
Remove:
it touches the lining).
15413-1R
- the three mounting bolts (A).
Unclip the lining at (1) to release it from the lower

rear quarter panel lining and at (2) to release the
clips(B).
71-6
INTERIOR BODY TRIM
Lower rear quarter panel lining 71 E
REMOVAL
15413-2R
PRE7111 - the mounting bolts (A), (B) and (C).
Unclip the lining at (D) and (E) and (F).

Tilt the rear seat forwards.
Separate the two brackets (G) to remove the seat
Remove: belt strap.
it touches the lining),
- the front rear quarter panel lining (see section
71C),
- the rear rear quarter panel lining (see section
71D),
- the rear seat striker plate,
- the centre shelf,
71-7
INTERIOR BODY TRIM
Wheel arch lining 71 F
REMOVAL - the boot inner sill lining (covers and bolts (A)),
PRE7112
15413-3R
Remove:
- the front rear quarter panel lining (see section - clips (B) ; to do this, turn each clip a quarter
71C), turn using a flat blade screwdriver.
- the rear rear quarter panel lining (see section
71D), Unscrew:
- the lower rear quarter panel lining (see sec- - the two mounting bolts (C) for the can carrier
tion 71E), strap,
- the compact disc player mounting (if fitted), - the two mounting nuts for the light (D).
Release the lining from its location under the boot

carpet.
15415R
71-8
Tailgate lining 73 A
PRE7305
REMOVAL
15417R
Remove:
- the two mounting bolts (A) for the closing
handle,
- the retaining clips (B), (to remove these clips,
turn each clip a quarter turn using a flat blade
screwdriver),
- the lining.
73-1
GENERAL
Dimensions
40
GENERAL
Description of parts (exploded view)
40
GENERAL
40
GENERAL
Opening clearances
40
GENERAL
Opening clearances
40
GENERAL
Symbols for methods
40
GENERAL
Collision diagnosis
40
GENERAL
40
GENERAL
40
GENERAL
Reper bench
40
GENERAL
Reper bench
40
LOWER STRUCTURE
Rear end cross member (A)
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
Rear side member extension (B)
41
LOWER STRUCTURE
Rear side member extension (B)
41
LOWER STRUCTURE
Connecting gusset (C)
41
LOWER STRUCTURE
Connecting gusset (C)
41
Rear wing panel (A)
44
Rear wing panel (A)
44
Rear wing panel (A)
44
Wing panel drip moulding (B)
44
44
44
Rear quarter panel lining (C)
44
44
44
44
44
Centre rear shelf (D)
44
Centre rear shelf (D)
44
Lights mounting (E)
44
Lights mounting (E)
44
Lights mounting (E)
44
Rear inner wheel arch (F)
44
Rear inner wheel arch (F)
44
Rear pillar reinforcement (G)
44
Rear pillar reinforcement (G)
44
Rear end panel assembly (H)
44
44
44
Panel extension (I)
44
Panel extension (I)
44
Boot lid
48
NON-SIDE OPENING ELEMENTS MECHANISMS
Boot lid lock barrel
52
WINDOWS
Rear screen (A)
54
WINDOWS
Rear screen (A)
54
EXTERIOR PROTECTION
Adhesive protective strips preventing body edge Bumper wear (A)
55
Boot lid trim (A)
56
Rear seat belt (A)
59
INTERIOR BODY TRIM
Rear inner sill upper lining (A)
71
INTERIOR BODY TRIM
Rear inner sill upper lining (B)
71
INTERIOR BODY TRIM
Wheel arch lining (C)
71
INTERIOR BODY TRIM
Rear wing lining (D)
71
TRAYS AND REAR SHELF
Rear shelf (A)
74
Rear shelf (A)
74
GENERAL
40
GENERAL
Opening clearances
40
GENERAL
Opening clearances
40
GENERAL
40
LOWER STRUCTURE
Centre floor (A)
41
Top of body (A)
43
Top of body (A)
43
Top of body (A)
43
Top of body (A)
43
Top of body (A)
43
Sill panel, complete (B)
43
43
43
43
Sill panel, part section (under door) (C)
43
Body side, rear section (D)
43
Body side, rear section (D)
43
Wing panel (A)
44
Wing panel (A)
44
Wing panel (A)
44
Wing panel (A)
44
Wing panel (A)
44
Wing panel (A)
44
Wing panel (A)
44
Wing panel (A)
44
Wing panel rain channel complete (B)
44
Wing panel rain channel complete (B)
44
Door pillar inner reinforcement (C)
44
44
44
Sill panel horizontal partition (D)
44
Sill panel horizontal partition (D)
44
Rear quarter panel lining (E)
44
44
44
44
44
44
44
Centre rear shelf (F)
44
Centre rear shelf (F)
44
Lights mounting (G)
44
Lights mounting (G)
44
Lights mounting (G)
44
Interior wheel arch (H)
44
Exterior wheel arch, part section (I)
44
Rear end panel assembly (J)
44
44
44
TOP OF BODY
Roof (A)
45
TOP OF BODY
Roof (A)
45
TOP OF BODY
Roof (A)
45
Boot lid (A)
48
Front door exterior handle (A)
51
Sunroof (A)
52
Sunroof (A)
52
Sunroof (A)
52
Sunroof (A)
52
Sunroof (A)
52
Sunroof (A)
52
Sunroof motor (B)
52
Sunroof motor (B)
52
Sunroof motor relay (B)
52
Sunroof panel (C)
52
Sunroof panel (C)
52
Sunroof panel (C)
52
Sunroof panel (C)
52
Shield (D)
52
Interior sunroof screen (E)
52
Interior sunroof screen (E)
52
Sunroof panel drive bar (F)
52
WINDOWS
Rear screen (A)
54
WINDOWS
Rear screen (A)
54
WINDOWS
Rear screen (A)
54
WINDOWS
Rear screen (A)
54
WINDOWS
Opening rear quarter panel window (B)
54
WINDOWS
Opening rear quarter panel window (B)
54
EXTERIOR PROTECTION
Front spoiler (A)
55
EXTERIOR PROTECTION
Front spoiler (A)
55
EXTERIOR PROTECTION
Rear spoiler (B)
55
EXTERIOR PROTECTION
Rear spoiler (B)
55
EXTERIOR PROTECTION
Rear spoiler (B)
55
EXTERIOR PROTECTION
Rear spoiler (B)
55
Boot lid trim (A)
56
Boot lid trim (A)
56
Door switch anti-theft bracket (A)
57
Front seat belts (A)
59
59
59
Interior side impact absorber (B)
59
WINDOW SEALING
Front door exterior weatherstrip and guide (A)
66
WINDOW SEALING
Front door interior weatherstrip and guide (B)
66
INTERIOR BODY TRIM
71
INTERIOR BODY TRIM
Rear inner sill lining (B)
71
INTERIOR BODY TRIM
Upper rear quarter panel lining (C)
71
INTERIOR BODY TRIM
Lower rear quarter panel lining (D)
71
INTERIOR BODY TRIM
Rear wing panel lining (E)
71
Front door trim (A)
72
FRONT SEAT TRIM
Seatback trim (A)
77
FRONT SEAT TRIM
Seatback trim (A)
77
FRONT SEAT TRIM
Seat squab trim (B)
77
FRONT SEAT TRIM
Release cables (C)
77
FRONT SEAT TRIM
Release cables (C)
77
REAR SEAT TRIM
Rear seat squab trim (A)
78
REAR SEAT TRIM
Rear seat squab trim (A)
78
REAR SEAT TRIM
1/3 - 2/3 seatback trim (B)
78
REAR SEAT TRIM
1/3 - 2/3 seatback trim (B)
78
GENERAL
Identification and equipment
40
GENERAL
Dimensions
40
GENERAL
Symbols for methods
40
GENERAL
Opening clearances
40
GENERAL
Opening clearances
40
GENERAL
40
GENERAL
Repair bench
40
GENERAL
Repair bench
40
LOWER STRUCTURE
Centre floor (A)
41
LOWER STRUCTURE
Front seat adjusting base (B)
41
LOWER STRUCTURE
Front seat adjusting base (B)
41
LOWER STRUCTURE
Rear seat adjusting bases (C)
41
LOWER STRUCTURE
Rear seat adjusting bases (C)
41
UPPER FRONT STRUCTURE
Wing (A)
42
Plenum chamber (B)
42
Plenum chamber (B)
42
Windscreen aperture lower cross member, part section (C)
42
42
42
Rear wing panel (A)
44
Rear wing panel (A)
44
Rear wing panel (A)
44
Rear quarter panel lining, part section (B)
44
Rear quarter panel lining, part section (B)
44
Lights mounting (C)
44
Lights mounting (C)
44
Lights mounting (C)
44
Rear end panel (D)
44
Rear end panel (D)
44
Rear end panel (D)
44
Tailgate
48
Tailgate
48
Tailgate
48
Tailgate
48
GENERAL
Safety (A)
50
GENERAL
Safety (A)
50
GENERAL
Tooling (B)
50
GENERAL
Tooling (B)
50
Rear door locking button (A)
51
Front door electric window (B)
51
Rear door electric window (C)
51
Rear door electric window (C)
51
Front door theft-proof pillar (D)
51
Tailgate lock an stricker plate (A)
52
Tailgate lock an stricker plate (A)
52
Tailgate lock barel (B)
52
Tailgate lock barel (B)
52
Sunroof (C)
52
Sunroof (C)
52
Sunroof (C)
52
Sunroof (C)
52
Sunroof (C)
52
Sunroof (C)
52
Sunroof (C)
52
Sunroof (C)
52
Sunroof motor (D)
52
Sunroof motor (D)
52
Sunroof motor (D)
52
Sunroof motor (D)
52
Moving panel (E)
52
Moving panel (E)
52
Moving panel (E)
52
Deflector (F)
52
Moving panel drive bar (G)
52
Moving panel drive bar (G)
52
Screen (H)
52
Screen (H)
52
Screen (H)
52
WINDOWS
Front door sliding window (A)
54
WINDOWS
Front door sliding window (A)
54
WINDOWS
Front door fixed window (B)
54
WINDOWS
54
WINDOWS
54
WINDOWS
Rear screen (D)
54
WINDOWS
Rear screen (D)
54
WINDOWS
Rear screen (D)
54
WINDOWS
Rear quarter panel window (E)
54
WINDOWS
Rear quarter panel window (E)
54
EXTERIOR PROTECTION
Adhesive protective strips preventing body edge - bumper wear (A)
55
EXTERIOR PROTECTION
Roof trim strips (B)
55
EXTERIOR PROTECTION
Roof trim strips (B)
55
Exterior rear view mirror (A)
56
Exterior rear view mirror (A)
56
Front door pillar trim (B)
56
Front door pillar trim (B)
56
Rear door front pillar trim (C)
56
56
56
Rear door rear pillar trim (D)
56
Rear door rear pillar trim (D)
56
Upper section of dashboard (A)
57
Upper section of dashboard (A)
57
Lower section of dashboard (B)
57
Lower section of dashboard (B)
57
Console (C)
57
Door switch anti-theft bracket (D)
57
Dashboard (E)
57
Dashboard (E)
57
Dashboard (E)
57
Dashboard (E)
57
Dashboard (E)
57
Dashboard (E)
57
Dashboard (E)
57
Dashboard (E)
57
Dashboard (E)
57
Dashboard (E)
57
Dashboard (E)
57
Dashboard (E)
57
Dashboard (E)
57
Dashboard (E)
57
Dashboard (E)
57
Dashboard (E)
57
Interior side impact absorber (A)
59
Exterior side impact absorber (B)
59
Front seat belt (C)
59
Front seat belt (C)
59
Rear seat belt (D)
59
3rd rear seat belt (E)
59
WINDOW SEALING
Front door exterior weatherstrip (A)
66
WINDOW SEALING
Front window guide (B)
66
WINDOW SEALING
Front window guide (B)
66
WINDOW SEALING
Rear door exterior weatherstrip (C)
66
WINDOW SEALING
Rear door exterior weatherstrip (C)
66
WINDOW SEALING
Rear window guide (D)
66
WINDOW SEALING
Rear window guide (D)
66
INTERIOR BODY TRIM
Rear wheel arch lining (A)
71
INTERIOR BODY TRIM
71
INTERIOR BODY TRIM
71
INTERIOR BODY TRIM
71
INTERIOR BODY TRIM
71
INTERIOR BODY TRIM
71
INTERIOR BODY TRIM
71
INTERIOR BODY TRIM
Luggage compartment sill lining (D)
71
INTERIOR BODY TRIM
Rear inner sill lower lining (E)
71
INTERIOR BODY TRIM
Upper centre pillar lining (F)
71
INTERIOR BODY TRIM
Lower centre pillar lining (G)
71
INTERIOR BODY TRIM
Front inner sill lining (H)
71
INTERIOR BODY TRIM
Windscreen pillar lining (I)
71
INTERIOR BODY TRIM
Luggage compartment carpet (J)
71
INTERIOR BODY TRIM
Dummy floor storage covers (K)
71
INTERIOR BODY TRIM
Dummy floor storage covers (K)
71
INTERIOR BODY TRIM
Dummy floor storage cover carpet (L)
71
INTERIOR BODY TRIM
Dummy floor storage cover carpet (L)
71
INTERIOR BODY TRIM
Battery tray (M)
71
Front door lining (A)
72
Front door lining (A)
72
Rear door lining (B)
72
Rear door lining (B)
72
Tailgate lining (A)
73
Tailgate lining (A)
73
Rear side shelf (A)
74
Complete seat (A)
75
Front seat runners (B)
75
Adjusting bases (C)
75
Adjusting bases (C)
75
Adjusting bases (C)
75
Seat back frame (D)
75
Adjusting bases and runners (A)
76
76
76
Seat belt stalks (B)
76
Seat belt stalks (B)
76
FRONT SEAT TRIM
Seatback trim (A)
77
FRONT SEAT TRIM
Seatback trim (A)
77
FRONT SEAT TRIM
Seatback trim (A)
77
FRONT SEAT TRIM
Seat squab trim (B)
77
FRONT SEAT TRIM
Seat squab trim (B)
77
REAR SEAT TRIM
Seat squab trim (A)
78
REAR SEAT TRIM
Seat squab trim (A)
78
REAR SEAT TRIM
Seat squab trim (A)
78
REAR SEAT TRIM
Centre seatback trim (B)
78
REAR SEAT TRIM
78
REAR SEAT TRIM
78
REAR SEAT TRIM
Side seatback trim (C)
78
REAR SEAT TRIM
Side seatback trim (C)
78
Special Features of the 4x4
Sheet Metal Work

Mechanisms and Accessories
Trim and upholstery
JA0C - JA1F
For all parts not dealt with in this Technical Note refer to Workshop Repair Manual M.R. 312.
77 11 295 482 APRIL 2000 EDITION ANGLAISE
The methods may be modified as a result of changes introduced by the manufacturer reference numbering system is forbidden without the prior written authority of Renault.
in the production of the various component units and accessories from which his
vehicles are constructed."
© RENAULT 2000
Contents
Page Page
Sheet Metal Work 44 UPPER REAR STRUCTURE
A Rear wing panel 44-1

F Light support 44-3
40 GENERAL J End panel 44-9
K Lower hinge mounting
Dimensions 40-1 reinforcement 44-20
Lifting equipment 40-2 L Upper hinge mounting
Towing 40-3 support 44-23
Key to symbols 40-4 M Lower hinge mounting
Description of parts (exploded view) 40-5 support 44-26
Opening clearances 40-8 N Luggage compartment lid stop mounting
Collision fault finding 40-13 support 44-28
Sub-frame dimensions 40-16
Body jig bench 40-18
Special tooling 40-29
48 NON-SIDE OPENING ELEMENTS
C Tailgate 48-1
D Luggage compartment lid 48-3
41 LOWER STRUCTURE
P Rear floor 41-1

S Rear side member 41-5
T Rear end cross member 41-7 Mechanisms and Accessories
V Front towing ring mounting
reinforcement 41-10
W Rear towing ring bracket 41-12
X Bearing rear mounting support 41-13
Y
50 GENERAL
Bearing front mounting support 41-15
Z Acceleration sensor mounting 41-16 A Tooling 50-1
AA Central floor rear reinforcement 41-18
52 NON-SIDE OPENING ELEMENT

42 UPPER FRONT STRUCTURE
MECHANISMS
A Wing 42-1
A Luggage compartment lid and rear
screen locks 52-1
B Luggage compartment lid exterior handle 52-3
F Front section of the body side 43-1

H Complete sill panel 43-4
Contents
Page
54 WINDOWS
A Rear screen 54-1
55 EXTERIOR PROTECTION
A Front bumper protector 55-1

B Front and rear valance protectors 55-3
C Front wing extender 55-5
D Rear wing extender 55-8
E Front bumper (central section) 55-10
F Rear bumper 55-13
G Front and rear door panels 55-14
H Luggage compartment lid embellishers 55-16
A Rear corner wing extender 56-1

B Rear windscreen wiper arm 56-2
C Rack embellishers 56-4
Trim and upholstery
73 NON-SIDE OPENING ELEMENTS TRIM
A Luggage compartment lid trim 73-1

140
GENERAL INFORMATION
Dimensions 40
Turning circle between walls: 11.20 m.
* Unladen. For vehicles with roof racks, add 7.5 cm.
40-1
GENERAL INFORMATION
Means of lifting 40
IMPORTANT: before fitting the lifting pads under POSITION OF THE LIFTING PADS
the body flange, you must fold the valance
protector flaps (A) by unclipping them to the
outside.
Rear protector Front
18111R
Front protector
18109S
Rear
18112R
18110S
40-2
GENERAL INFORMATION
Towing 40
OBSERVE THE TOWING REQUIREMENTS OF THE COUNTRY YOU ARE IN.
NEVER USE THE DRIVESHAFTS AS ATTACHMENT POINTS.
The towing points may only be used for towing the vehicle on the road. They should never be used for removing the
vehicle from a ditch or for any other similar breakdown operation or to lift the vehicle, either directly or indirectly.
FRONT REAR
18128S 16892S
40-3
GENERAL INFORMATION
Key to Symbols 40
Chiselling Crimping of exterior door panels.
Safety symbol.
Grind back beads or spot welds Straight
This means that the welding operation in
grinding wheel with a 75 mm diameter
question concerns one or more of the
Bakelite disc, 1.8 to 3.2 mm thickness.
vehicle's vital safety components.
Grind back spot welds. Body solder - lead fill.

Straight grinding wheel 20 000 rpm fitted Hot air torch.
with a spherical burr Ø 10 or 16 mm. Nozzle output temperature min. 600˚
Handle + 33% tin solder + tallow
Drill spot welds. Note: to a large extent, body solder filling
Hardened steel bit. Speed of rotation 800 to compensates for the heat distortion caused
1 000 rpm. by welding.
Drill < Ø 8 mm
Steel drill bit Application of weldable mastic.
Speed of rotation 800 to 1000 rpm. This mastic is a conductor, interposed
between two spot welding sheets, it ensures
Drill > Ø 8 mm the seal between the sheets and avoids
Tapered burr corrosion of the spot weld
Speed of rotation 800 to 1000 rpm.
Cleaning surfaces to be welded.

Fibre disc Ø 100 mm Application of aluminium paint.
This is to be applied to the joint faces of each
of the parts to be plug welded. This paint is
Cutting with a saw. conductive and can withstand high
Pneumatic power hacksaw. temperatures; it gives anti-corrosion
protection around welds
Cut out part by grinding off flange or grinding
back remaining traces of spot weld. Weld
finish refining Angle grinder fitted with a
rubber pad and a fibre disc Ø 120 to 180 mm Apply a fillet of extruded mastic
grain P36 ● from a manual or pneumatic spray gun.
● one or two pot mastic for crimped and butt
joints.
Unsoldering.
MAG stitch weld

Apply mastic by spraying
Note: to ensure high quality welding, we
● spray gun.
recommend that you use gas composed of
● anti-chipping and anti-corrosion in two
Argon + 15% CO2 which is considered an
parts
active gas (MAG)
Apply a bead of extruded adhesive mastic

Resistance spot welding ● from a manual or pneumatic spray gun.
● adhesive mastic in one or two parts
Plug welding. Thermal cleaning of extruded or spray

Under MAG gas protection. mastic
40-4
GENERAL INFORMATION
LOWER STRUCTURE
PRF4021
1 Front towing ring mounting reinforcement (41-V)

2 Acceleration sensor mounting (41-Z)
3 Front bearing mounting support (41-Y)
4 Rear bearing mounting support (41-X)
5 Central floor rear reinforcement (41-AA)
6 Rear side member (41-S)
7 Rear towing ring bracket (41-W)
8 Rear floor (41-P)
9 Rear end cross member (41-T)
40-5
GENERAL INFORMATION
UPPER STRUCTURE
PRF4022
10 Light support (44-F)

11 End panel (44-J)
12 Luggage compartment lid stop mounting support (44-N)
13 Upper hinge mounting support (44-L)
14 Lower hinge mounting support (44-M)
15 Rear wing panel (44-A)
16 Lower hinge mounting reinforcement (44-K)
17 Complete sill panel (43-H)
18 Body side front section (43-F)
40-6
GENERAL INFORMATION
REMOVABLE COMPONENTS
PRF4023
19 Front wing (42-A)

20 Tailgate (48-C)
21 Luggage compartment lid (48-D)
40-7
GENERAL INFORMATION
40-8
GENERAL INFORMATION
16842R
40-9
GENERAL INFORMATION
16885-1R
40-10
GENERAL INFORMATION
40-11
GENERAL INFORMATION
40-12
GENERAL INFORMATION
Collision fault finding 40
Before carrying out repairs to the bodywork of a car, even if the damage seems slight, it is
necessary to carry out a series of tests:
● VISUAL INSPECTION
This inspection involves the examination of the sub-frame of the vehicle where mechanical
components are mounted and in the crumple zones or vulnerable areas in order to detect folds
where materials have been deformed.
● TRAMMEL GAUGE CHECK

The visual inspection may be completed using a trammel gauge which will allow measurement
of certain deformations by symmetrical comparisons (for more detail on each point to check, see
the repair bench paragraph below).
NOTE: to make the marking easier, the reference points located on the left of the vehicle are
marked by a capital letter (e.g.: A) and the reference points opposite these with the same
function are shown by the same letter with an additional index (e.g.: A')
● AXLE GEOMETRY CHECK

It is the only check which determines whether the impact suffered by the vehicle has or has not
affected its road holding.
Important: in borderline cases, it is essential not to neglect checking the axle assembly
components which may also have been damaged.
On principle, no welded component in the body shell may be replaced without ensuring that the
subframe was not affected by the impact.
40-13
GENERAL INFORMATION
GAUGE POINTS
16890R 17512R
Point C
Point M
Front sub-frame front mounting.
Start point for checking points (A) and (B).
It is necessary to remove the front bumper rear
protector and both horns to access this point.
16891R 17512R1
Point A Point H
Sub-frame rear mounting. Front end of front side member.

It is necessary to remove the engine undertray to
access this point.
40-14
GENERAL INFORMATION
16887R1
Point B1
Rear axle assembly guide.
18127R
Point U
Rear end panel side end.
40-15
GENERAL INFORMATION
DESCRIPTION X Y Z DIAMETER ANGLE%
A Front sub-frame left hand rear mounting 203 - 402.5 71 16.5 0
A' Front sub-frame right hand rear mounting 203 402.5 71 16.5x18.5 0
B Rear axle left hand front mounting 1966 - 634.12 70 M12 0
B Rear axle right hand front mounting 1966 634.12 70 M12 0
B1 Rear axle assembly left hand guide 1916 - 634.1 70 18.5 0
B1' Rear axle assembly right hand guide 1916 634.1 70 18.5 0
C Front left sub-frame front mounting - 593 - 412 237.5 M10 0
C' Front sub-frame right hand front mounting - 593 412 237.5 M10 0
D Rear sub-frame left hand rear mounting 2710 - 470 227.5 M12 X: 1˚30
D' Rear sub-frame right hand rear mounting 2710 470 227.5 M12 X: 1˚30
Left hand front shock absorber mounting support X: 3˚45

F 5.5 - 610.8 654.2 8.7
(external) Y: 7˚12
Right hand front shock absorber mounting support X: 3˚45

F' 5.5 610.8 654.2 8.7
(external) Y: 7˚12
Left hand front shock absorber mounting support X: 3˚45

F1 15.7 - 477.8 636.7 8.7
(interior) Y: 7˚12
Right hand front shock absorber mounting support X: 3˚45

F1' 15.7 477.8 636.7 8.7
(interior) Y: 7˚12
G Left hand front side member rear end 880 - 369 7 18.5 X: 1˚
G' Right hand front side member rear end 880 369 7 18.5 X: 1˚
H Left hand front side member front end - 547.5 - 467.4 236.5 10.2x 12.5 0
H' Right hand front side member front end - 547.5 467.4 236.5 10.2x 12.5 0
J Left hand rear side member rear end 2938 - 485 231 16.5 0
J' Right hand rear side member rear end 2900 483 231 16.5 0
X: 90˚
L Rear end panel cross member (left hand side) 3049 - 394.5 170 14.25
Y: 10˚15
X: 90˚
L' Rear end panel cross member (right hand side) 3028 397 170 14.25
Y: 12˚30
M Cross member under centre floor (left hand side) 937 - 375 1.5 14.5 0
M' Cross member under centre floor (right hand side) 937 375 1.5 14.5 0
P Engine mounting - 247 483.5 514 M10 0
P1 Engine mounting (interior side) - 113 483.5 514 M10 0
P2 Engine mounting (exterior side) - 150 552.5 514 M10 0
S Left hand front driveshaft mounting 943 - 88.5 38 M8 X: 6˚
S' Right hand front driveshaft mounting 942.5 41.5 38 M8 X: 6˚
T Left hand rear driveshaft mounting 1697 - 72.5 1 M8 X: 3˚
T' Right hand rear driveshaft mounting 1699 57.5 1 M8 X: 3˚
U Rear end panel (left hand side) 3070 - 640 137.5 6.2 0
U' Rear end panel (right hand side) 3070 640 137.5 6.2 0
40-16
GENERAL INFORMATION
40-17
GENERAL INFORMATION
Repair Bench 40
I - PRINCIPLE REFERENCE POINTS FOR SETTING VEHICLE TRIM LEVEL
A - FRONT SUB-FRAME REAR MOUNTING
It is the main front reference point.
99249R1 16891R
1 - Front mechanical units removed 2 - Front mechanical units in place
NOTE: The bracket covers the sub-frame mounting bolt.

on the left hand side the hole is round,
on the right hand side it is a slot.
NOTE: the two sides are not symmetrical, on the right
When replacing the rear section of the side member, hand side the mounting is set on the rubber mounting.
this reference point is replaced provisionally by
point (M), located on the seat cross member, point (A) If the rear of the vehicle is being rebuilt, these two
being used to position the replaced component. points alone may be used to align and support the
front of the vehicle.
It may be used for a light rear impact without removing

the rear axle.
40-18
GENERAL INFORMATION
Repair Bench 40
I - PRINCIPLE REFERENCE POINTS FOR SETTING VEHICLE TRIM LEVEL (cont.)
B - REAR SUB-FRAME FRONT MOUNTING
It is the main rear reference point.
99251R1
1 - Front mechanical units removed
The bracket rests under the rear axle assembly

mounting unit and is centred in the sub-frame 16887R2
mounting hole.
2 - Front mechanical units in place
If replacing the complete rear side member or the rear
floor unit, this reference point is replaced by point (M),
The bracket covers the sub-frame mounting bolt.
located on the seat cross member, point (B) being
used to position the replaced component.
If the front section is being rebuilt, these two points
alone can be used to align and support the rear of the
vehicle.
40-19
GENERAL INFORMATION
Repair Bench 40
II - ADDITIONAL REFERENCE POINTS FOR SETTING VEHICLE TRIM LEVEL
These are the provisional reference points which replace the main points, when they have been affected by the
impact.
M - SUPPORT UNDER FRONT FLOOR G - FRONT SIDE MEMBER REAR END

(seat cross member)
16890R 16890R1
Point M is also used to position the replaced part. This point is also used as a positioning reference when
replacing a rear section of the front side member.
These points enable the vehicle to be supported in addition to the main reference point on the impact side and allow
only relatively accurate alignment of the vehicle.
IMPORTANT NOTE: these reference points should only be used in the cases mentioned above. They are not
required when both the main reference points (points A and B) are correct.
This additional reference function may also be filled by the front side member ends check points for a rear impact
and vice versa.
40-20
GENERAL INFORMATION
Repair Bench 40
III - REFERENCE POINTS FOR POSITIONING REPLACED PARTS
C - FRONT SUB-FRAME FRONT MOUNTING
17632R 17512R
1 - Front mechanical units removed 2 - Front mechanical units in place
The bracket rests under the front cross member and is The bracket covers the sub-frame mounting bolt.
centred in the sub-frame mounting hole.
It is used:
It is used when replacing: – following a frontal collision for a slight impact,
– the lower front cross member, – for fault finding for the jig inspection of the front
– the assembled front, section.
– a side member, part section,
– a half unit. It is necessary to remove the bumper to access the
reference point.
40-21
GENERAL INFORMATION
Repair Bench 40
III - REFERENCE POINTS FOR POSITIONING REPLACED PARTS (cont.)
S - DRIVESHAFT FRONT MOUNTING T - DRIVESHAFT REAR MOUNTING
17627R
2 - Mechanical units removed only
The bracket rests against the rear connecting arches

17896R and is centred in the driveshaft bracket mounting hole.
It is used when replacing:

1 - Mechanical units removed only
– the complete centre floor,
– the partial centre floor.
The bracket rests against the front connecting arches
and is centred in the driveshaft bracket mounting hole.
It is used when replacing:

– the complete centre floor,
– the partial centre floor.
40-22
GENERAL INFORMATION
Repair Bench 40
F - FRONT SHOCK ABSORBER UPPER MOUNTING P - ENGINE MOUNTING
17630R
17964R
The bracket rests under the shock absorber cup and is

centred in the shock absorber mounting holes. The bracket is positioned from above the engine
mounting and is centred in the mounting holes of the
It is used when replacing: pad.
– a wheel arch,
– a front half unit. It should be used with the mechanical units removed
to replace a front half unit.
It is also used when straightening.
40-23
GENERAL INFORMATION
Repair Bench 40
D - REAR SUB-FRAME REAR MOUNTING
17629R 17723-1R
1 - Rear mechanical units removed 2 - Rear sub-frame in place
The bracket rests under the rear side member and is The bracket covers the sub-frame mounting bolt.
centred in the sub-frame mounting hole.
It should be used in the event of a rear collision for a
It is used when replacing: small impact.
– the side member, part section,
– a rear unit.
40-24
GENERAL INFORMATION
Repair Bench 40
J - REAR SIDE MEMBER END L - END OF REAR END CROSS MEMBER
17629R1 17629R2
The bracket rests under the side member and is The bracket rests vertically against the rear end cross
centred in the pilot hole. member, and is then centred in the punching hole.
It should be used with the sub-frame in place to realign It should be used when replacing the rear end panel
a side member. assembly with or without the sub-frame.
It should be used with the mechanical units removed,

under the same conditions, to replace a side member.
40-25
GENERAL INFORMATION
Repair Bench 40
BLACKHAWK
40-26
GENERAL INFORMATION
Repair Bench 40
CELETTE
40-27
GENERAL INFORMATION
Repair Bench 40
IV - SPECIAL TOOLING
BLACKHAWK
Special heads for MS System
Order from: BLACKHAWK S.A.

Centre Eurofret
Rue de Rheinfeld
67100 STRASBOURG
Supplier’s Part No.: REN 87 998

additional to basic kit REN 87 995.
CELETTE
Special heads for System MZ
Order from: CELETTE S.A.

B.P. 9
38026 VIENNE
Supplier’s Part No.: 715.304

additional to kit 715.330.
For "Sevenne" benches, it will be necessary to order

belts with part number 715.SANGLE. These are not
delivered in the basic kit.
Please see the supplier's advice for fitting.
40-28
GENERAL INFORMATION
Special tooling 40
FRONT FACE JIG
18125R
Points (A) and (B) are the reference points for positioning the jig on the
vehicle.
The user must ensure that these points are correct when fault finding is
carried out before fitting.
Points (C), (D), (E) and (F) help with the mounting and positioning of the
replaced components.
If points (A) or (B) can no longer be used as a reference (detected during a
fault finding inspection), the positioning points on the side opposite the
impact fulfil this function.
40-29
GENERAL INFORMATION
Special tooling 40
17563R
Car. 1546
Parts Stores reference:
00 00 154 600
IMPORTANT: the front face jig is not specific to the

4x4, it is also used for the new Scenic models.
40-30
GENERAL INFORMATION
Special tooling 40
REAR FACE JIG
18124R
This tool is mainly intended for fitting the luggage

compartment lid hinge mountings.
Points (A) and (B) are the reference points to position

the jig on the vehicle.
The user must ensure that these points are correct

when fault finding is carried out before fitting.
Points (C), (D), (E) and (F) help with the mounting and
positioning of the replaced components.
NOTE: when fitting the jig to the vehicle, begin by

inserting the left hand side. 18122R
Car. 1563
Parts Stores reference:
00 00 156 300
40-31
141
LOWER STRUCTURE
Rear floor 41 P
INTRODUCTION PARTS CONCERNED (thickness in mm):
The replacement of this part is a complementary 1 Rear floor 0.7

operation to the replacement of the rear end panel or a 2 Rear floor rear section 0.7
rear side member for a rear impact. 3 Rear centre cross member 1
This operation is carried out partially (see procedure 5 Rear inner wheel arch 0.7
below):
– for the right rear section (according to cut A-A),
– for the left rear section (according to cut B-B).
The complete replacement method for this part is the

same as for the basic vehicle.
In the operation described below, only descriptions of

the joints specific to the part concerned are given.
The information on the additional parts will be dealt

with in their appropriate chapters (see contents).
COMPOSITION OF THE PART FROM THE PARTS

DEPARTMENT

– floor,
– mounting connecting arch.
PRF4112
41-1
LOWER STRUCTURE
Rear floor 41 P
On the vehicle:
On the Parts Department

part
41-2
LOWER STRUCTURE
Rear floor 41 P
641P3-17958
41-3
LOWER STRUCTURE
Rear floor 41 P
641P1-17959
On the vehicle:
On the Parts Department

part
41-4
LOWER STRUCTURE
Rear side member 41 S
INTRODUCTION

operation to the replacement of the rear end panel.
This operation is carried out partially (see cut A-A and

the method given below):
The complete replacement method for this part is the

same as for the basic vehicle.


The repair bench must be used.

DEPARTMENT

– indentation ring,
– mounting reinforcement on the towing ring bracket
(right hand side),
– side member reinforcement, rear section,
– side seatback mounting reinforcement,
– bolt for welding.
PARTS CONCERNED (thickness in mm):

2 Rear floor 0.7
41-5
LOWER STRUCTURE
Rear side member 41 P
S
IMPORTANT: The side member must only be cut after

the rear mounting reinforcement on the towing ring
bracket, in zone X1.
41-6
LOWER STRUCTURE
Rear end cross member 41 S
T
INTRODUCTION

operation to the replacement of the rear end panel.



DEPARTMENT

– striker stiffener,
– welded nut reinforcements.

2 Striker stiffener. 1.2
3 Rear floor 0.7
4 Tail wheel arch 1.2
6 Rear end cross member reinforcement 1.2
41-7
LOWER STRUCTURE
Rear end cross member 41 P
T
641T1-17956
41-8
LOWER STRUCTURE
Rear end cross member 41 P
T
641T2-17955
41-9
LOWER STRUCTURE
Front towing ring mounting reinforcement 41 V
INTRODUCTION

operation to the replacement of the front end cross
member.
For standardisation purposes, the cross member is

delivered by the Parts Department without a
reinforcement.
It will be necessary to screw the towing ring bracket to

the cross member to position the reinforcement.



DEPARTMENT
Part delivered alone
1 Front end cross member reinforcement 2.5

2 Front end cross member 1.5
3 Front end cross member closure panel 1.2
41-10
LOWER STRUCTURE
Front towing ring mounting reinforcement 41 V
641V1-17954
41-11
LOWER STRUCTURE
Rear towing ring bracket 41 W
P
INTRODUCTION REMOVAL OF THE REAR TOWING RING
BRACKET
The replacement of this part is a basic operation for a
right hand rear collision.
The rear towing ring bracket is bolted to the right hand

rear side member and to the lower section of the end
panel.
This may help with positioning when replacing the rear

end panel.

DEPARTMENT
Assembled part with threaded roller.
Remove:
– the two mounting bolts (A) passing through the side
member and their reinforcement,
– the mounting bolt (B) on the lower section of the end
panel.
PRF4115
41-12
LOWER STRUCTURE
Bearing rear mounting support 41 S
X
INTRODUCTION

operation to the replacement of the centre floor.
For standardisation purposes, the floor is delivered by

the Parts Department without the bearing rear
mounting support.
It will be necessary to fit the support after fitting the

centre floor.



DEPARTMENT
Part delivered alone.
PRF4116
1 Bearing rear mounting support 1

2 Sleeve stop 1.5
3 Tunnel stiffener 1
4 Centre floor 1
41-13
LOWER STRUCTURE
Bearing rear mounting support 41 P
X
641Y1-17627-1
41-14
LOWER STRUCTURE
Bearing front mounting support 41 P
Y
INTRODUCTION

For standardisation purposes, the floor is delivered by

the Parts Department without the bearing front
mounting support.
It will be necessary to fit the support after fitting the

centre floor.


644X1-17896-1

DEPARTMENT
PRF4117
1 Bearing front mounting support 1

2 Front cross member under the front seat 1.5
41-15
LOWER STRUCTURE
Acceleration sensor mounting 41 S
Z
INTRODUCTION

For standardisation purposes, the centre floor is

delivered by the Parts Department without the
acceleration sensor mounting.



DEPARTMENT
1 Acceleration sensor mounting 1.2

2 Front seat height adjuster 1.5
3 Front seat height adjuster reinforcement 1.5
4 Centre floor 1
5 Tunnel stiffener 1
41-16
LOWER STRUCTURE
Acceleration sensor mounting 41 P
Z
X1 = 122 mm
41-17
LOWER STRUCTURE
Central floor rear reinforcement 41 AA
INTRODUCTION

operation to the replacement of the centre floor or the
cross member.
For standardisation purposes, these parts are

delivered by the Parts Department without the rear
floor reinforcement.



DEPARTMENT
641Z1-17951
PRF4119
1 Central floor rear reinforcement 1.5

2 Sill panel closure panel component 1.8
3 Cross member 1.2
5 Centre floor 1
41-18
LOWER STRUCTURE
Central floor rear reinforcement 41 AA
41-19
142
Wing 42 S
A
INTRODUCTION
The replacement of this part is a basic operation for a frontal or side impact.
This is a detachable structure component.
It will first be necessary to remove:

– the side section of the scuttle panel grille (see section 55-G of the basic
Workshop Repair Manual),
– the front section of the valance, partially (see section 55-B),
– the front wing extender (see section 55-C),
– both sections of the front mudguard (see section 56-F of the basic
Workshop Repair Manual).
42-1
Wing 42 S
A
17564-1R
REMOVAL
Apply two strips of masking tape to the components around the wing, to
prevent the paintwork from being scratched during refitting.
Remove:
– nuts (A) and (B) (open the door),
– bolts (C), (D), (E) and nuts (F) and (G).
Separate the wing from the soundproofing mastic at (H) (see Technical
Note 412A).
REFITTING
NOTE: when refitting, re-apply sealant (detachable components sealing
mastic) between the mounting pads on the wing and the front pillar.
ADJUSTMENT
Fit all the mountings without tightening before beginning to adjust the play and
flush-fittings (see section 40).
REPAIR
REMINDER: see Technical Notes 392A and 473A for how to repair wings
(Noryl).
42-2
143
Body side front section 43 S
F
INTRODUCTION

following a front side collision.
The method for replacing this part has not changed,

see basic Workshop Repair Manual.
For standardisation purposes, the front section of the

body side is delivered by the Parts Department without
the welded pins on the bottom section for mounting the
plastic fittings panels and without the drillings for
mounting the longitudinal flaps.
It will be necessary to fit the riveted pins (pin rivets)

and to make the drillings after the part has been
replaced.
The number of rivets required will depend on the

location of the cut on the sill panel.
The dimensions of the drillings to be carried out are

listed below.
43-1
F
17963R
A = Ø 2.5 mm
43-2
F
17962R
A = Ø 2.5 mm
B = Ø 5 mm
NOTE: the plastic valance may be used as a drilling jig

for holes (B).
43-3
Complete sill panel 43 S
H
INTRODUCTION

following a side collision.
For the method for replacing this part, see the basic
Workshop Repair Manual.
The sill panel is delivered by the Parts Department

with the welded pins for mounting the plastic fittings
panels.
The dimensions of the holes drilled are given for your

information in sections 43-F and 44-A.

DEPARTMENT

– Front pillar hinge reinforcement,
– Centre pillar hinge reinforcement,
– Welded studs,
– welded pins.
PRF4302
43-4
144
Rear wing panel 44 S
A
INTRODUCTION
The replacement of this part is a basic operation for a

rear side impact.
For the method for replacing this part, see the basic
Workshop Repair Manual.
The rear wing panel is delivered by the Parts

Department with the welded pins for mounting the
plastic fittings panels.
The dimensions of the holes drilled and and the

welded pins are given below for your information.

DEPARTMENT

– bumper side mounting reinforcement,
– striker plate stiffener, rear door,
– plate cage,
– plate,
– sound-deadening material,
– fuel pipe unit (right side).
– welded nuts,
– lower blanking cover,
– welded pins.
PRF4418
44-1
Rear wing panel 44 S
A
17961R
A = Ø 2,5 mm
44-2
Light support 44 P
F
INTRODUCTION PARTS CONCERNED (thickness in mm):
This part is replaced in addition to replacing: 1 Light support 1

– case n˚ 1: the rear end panel and the rear end pillar 2 Rear end pillar 1
for a rear impact, 3 Rear wing panel 0.8
– case n˚ 2: the rear wing panel and the rear end pillar 4 Tail wheel arch 1.2
for a rear side impact. 5 Upper hinge mounting support reinforcement 2
6 Upper hinge mounting support 3
This operation can only be carried out by partial 7 Light support reinforcement 1
cutting. 8 Rear end cross member 0.8
9 End panel upper cross member 1
The rear face jig Car. 1563 (part no. 00 00 156 300)
must be used.
The Parts Department supplies the light support (1)

without the rear end pillar (2).
In both cases, it will be necessary to order the rear end

pillar to carry out the operation.

the connections specific to the rear end pillar and the
part concerned according to cases 1 and 2 are given.


DEPARTMENT
Assembled part with upper hinge mounting support

reinforcement (left hand side).
PRF4419
44-3
Light support 44 P
F
CAA11536-4R6
644F1-17997
CAN11689R5
CAT13326-1R3
44-4
Light support 44 P
F
CAA11536R4
CAA11536R6A
CAF11547R5
44-5
Light support 44 P
F
CASE N˚ 1 (with removal of the end panel)
TOB14594R1
644F2-17990
CAQ11697R6A
TOT18086-2R6
CAA11536-2R2
44-6
Light support 44 P
F
CASE N˚ 2 (with removal of the wing panel)
TOA14581R3
644F3-17996
CAA11538R6
TOH14634-5R1
TOS18024R8
44-7
Light support 44 S
F
TOD14614R7
CAB11539R5
44-8
End panel 44 P
J
INTRODUCTION COMPOSITION OF THE PART FROM THE PARTS
DEPARTMENT
following a rear collision. Part assembled with:
– end panel upper cross member,
The rear face jig Car. 1563 (part no. 00 00 156 300) – bumper mounting angle brackets,
must be used. – angle bracket supports,
– light support reinforcement,
There are two methods of carrying out this operation: – end panel lower cross member,
– side member contact reinforcement,
1 - Partial – end panel reinforcement,
following cut A-A. For the left hand side, it will be – welded nuts.
necessary to remove the lower hinge reinforcement
(see section 44-K).
2 - Complete
In this case it will be necessary to leave the light
support reinforcement on the vehicle, opposite the
impact and to remove on the unused Parts
Department light support reinforcement (see
REMINDER 1 in the method below).
On the other hand, it will also be necessary to fold the

metal panel of the upper section of the end panel and
the rear end cross member, to ease insertion when
fitting the part on the vehicle (see REMINDER 2 in the
method described below).
NOTE: in the event of complete replacement where

the left hand light support reinforcement remains on
the vehicle (for example, in case of a right hand side
impact), it is not necessary to remove the lower hinge
reinforcement completely. It is sufficient to grind the PRF4420
welding bead to the upper section of the end panel
(see REMINDER 3 in the method described below).
the joints specific to the part concerned are given. 1 End panel upper cross member 1
2 Light support reinforcement, 1
Information on parts to which this is additional, will be 3 Tail wheel arch 1.2
dealt with in their respective sections (see contents). 4 Rear wing panel 0.8
5 End panel lower cross member 1
6 Light support 1
7 Rear end pillar 1
9 Striker stiffener. 1.2
10 Lower hinge reinforcement 3
11 Bumper mounting angle brackets 1.8
44-9
End panel 44 P
J
1 - Partial (left hand side)
CAE11546-2R1
644J2-17994
CAE11546-5R1
CAE11546-5R1
CAF11547-3R
44-10
End panel 44 P
J
TOA15608-1R3
644J3-17998
TOI18020-2R1
CAA11536R6A
TOI18020-2R1
44-11
End panel 44 P
J
TOA15608-1R2 TOD14617-2R3
TOA15608-1R5 TOA14581R4
44-12
End panel 44 P
J
TOB14593-1R1
644J4-17998-3
TOB14592R6
TOC14610-4R2
TOM14654-3R6
44-13
End panel 44 S
J
TOS18024-3R3
TOC14608-2R3
44-14
End panel 44 P
J
CAE11546-2R8
644J1-17995
CAB11539R7A CAE11546-2R8
44-15
End panel 44 P
J
CAS13033R1
644J5-17993
CAI11550R5
44-16
End panel 44 P
J
2 - Complete
REMINDER 1: it is necessary to remove the light

support reinforcement on the Parts Department part
(side opposite impact).
CAA11536R3
644J6-17992
CAN11689R5 TOC14609-1R4
44-17
End panel 44 P
J
REMINDER 2: it is necessary to fold the metal panel of
the upper section of the end panel and the rear end
cross member to ease insertion when fitting.
18014R1
644J7-17994-1
18015R1
44-18
End panel 44 S
J
REMINDER 3: in the event of complete replacement
where the left hand light support remains in place (for
example, in case of a right hand side impact), it is not
necessary to remove the lower hinge reinforcement
completely. It is sufficient to grind the welding bead to
the upper section of the end panel (see section H').
644J8-17998-2
TOI18020-4R1
44-19
Lower hinge reinforcement 44 S
K
INTRODUCTION

operation to the replacement of the left hand light
support and the end panel for a rear impact.
The rear face jig Car. 1563 (Parts Department

part no. 00 00 156 300) must be used.



DEPARTMENT
PRF4421
1 Lower hinge reinforcement 3

6 Light support 1
44-20
Lower hinge mounting reinforcement 44 P
K
TOA15608-1R3
644K1-17998-1
TOI18020-2R1 TOA15608-1R2
44-21
Lower hinge mounting reinforcement 44 S
K
TOA15608-1R5
TOI18020-2R1
44-22
Upper hinge mounting support 44 S
L
INTRODUCTION

operation to the replacement of the complete left hand
light support.
For standardisation purposes, the left hand light

support is delivered by the Parts Department without
the upper hinge mounting.




DEPARTMENT

– upper hinge mounting angle bracket,
– upper hinge mounting angle bracket reinforcement.
PRF4422
1 Upper hinge mounting 3

2 Upper hinge mounting reinforcement 2
3 Light support 1
44-23
Upper hinge mounting support 44 P
L
TOF15607-2R7
644L1-17991
CAS13025-4R5
44-24
Upper hinge mounting support 44 S
L
644L2-17989
TOL18021R5
44-25
Lower hinge mounting support 44 M
S
INTRODUCTION

operation to the replacement of the left hand light
support.
For standardisation purposes, the left hand light

support is delivered by the Parts Department without
the lower hinge mounting support.
The rear face jig Car. 1563 (Parts Departme




DEPARTMENT
Assembled part with lower hinge (bolted).
PRF4424
1 Lower hinge mounting support 5

2 Light support 1
44-26
Lower hinge mounting support 44 M
P
CAA11536-4R8
644M1-17988
TOB18017R6
44-27
Luggage compartment lid stop mounting support 44 N
INTRODUCTION

operation to the replacement of the complete end
panel or the right hand side end panel, part section.
For standardisation purposes, the end panel is

delivered by the Parts Department without the luggage
compartment lid stop mounting support.




DEPARTMENT
PRF4423
1 Luggage compartment lid stop mounting 1.5

2 Bumper mounting angle brackets 1.8
5 Bumper mounting angle bracket support 1.8
44-28
Luggage compartment lid stop mounting support 44 N
TOT18025-3R5
644N1-17987
TOA15608-1R5
TOT18026-3R7
44-29
NON-SIDE OPENING148ELEMENTS
Tailgate 48 P
C
REFITTING
Before refitting it will be necessary to reseal between

the roof rear cross member and the hinges using
beading mastic.
Stick two strips of masking tape to the edge of the

tailgate, to prevent the paintwork from being scratched
during refitting.
Refit in reverse order to removal.
PRF4802
REMOVAL
Remove:
– the third brake light,
– the de-icing connections (B),
– the washer jet and disconnect.
Release:
– wiring harness (A),
– the two upper mounting protectors (C),
– the two hinge nuts (E),
– the balancers by removing the locking clips (D),
– the tailgate (this operation should be carried out be
two people for safety reasons).
48-1
Tailgate 48 P
C
SETTINGS
16876R
17631S Suppression of beading and adjustment of the

stiffness of closure are carried out at lock (G) and
The peripheral play is adjusted via the upper closure striker plate (H).
mountings (A).
These adjustments must not influence the peripheral
NOTE: before beginning the sequence of adjustments, play previously adjusted.
it will be necessary to loosen the striker plate and lock
mountings to prevent the tailgate becoming locked in NOTE: in all cases, you should begin by adjusting the
the closed position, when checking the peripheral play. contact surfaces at the hinges. See section 40 for
peripheral play.
16831R
48-2
Luggage compartment lid 48 P
D
INTRODUCTION Remove:
– the luggage compartment lid interior trim (see
The part is delivered by the Parts Department section 73-A),
assembled with: – the emergency spare wheel protector,
– the casing (polyester composite), – the emergency spare wheel,
– the inner metal frame, – the upper extension on the left hand rear wing panel
– the outer panel (Xénoy). (see section 56-A),
– the left hand lower embellisher strip on the luggage
See Workshop Repair Manual 502 for the repair compartment lid (see section 55-H),
methods for plastics. – the left hand rear wing extender
(see section 55-D),
– the right hand lower embellisher strip on the luggage
compartment lid (see section 55-H),
– the electric supply cable
(see section 73-A),
– the windscreen wiper arm (see section 56-B),
– the windscreen wiper stop,
– the wiper motor,
– the tailgate closure lock
(see section 52-A),
– the lower tailgate seal,
– the luggage compartment lid handle and lock (see
section 52-A and B),
– the lower balancer,
– the tailgate surround seal,
– the rear floor lining,
– the left hand rear wing interior trim,
PRF4803
REMOVAL
● with hinges (detailed method below),

● without hinges, remove only bolts (A) and (B).
Disconnect the electric supply cable in the left hand

rear wing lining.
17514R
– the five mounting bolts (A) on the lower hinge.
48-3
D
17515R 17628R
Remove the four mounting bolts (B) from the upper – the two mounting bolts (D) on the lower hinge body,
hinge. if necessary.
WARNING: at this moment, a second person is

needed. REFITTING
Refit in reverse order to removal.
REMINDER: when refitting the hinges, ensure that the

mating surfaces are sealed with beading mastic (see
Technical Note n˚ 396A).
17517R
Remove:
– the three mounting bolts (C) from the upper hinge,
48-4
D
SETTINGS
In all cases, always begin by adjusting the hinges on

the body at mounting points (E), (F) and (G).
IMPORTANT: it is necessary to fit the peripheral

components and position the emergency spare wheel
to check that the luggage compartment lid is flush.
17514-1R
17517-1R
17628-1R
48-5
D
IMPORTANT:
Mountings (B1) and (H1) are used as chain guides and

only allow height adjustment.
For additional adjustment settings, these mountings

may be replaced by points (B2) and (H2) respectively.
The beading and the closure stiffness are adjusted at

the lock (I) and the closure striker plate (J), as well as
via the lower stops (K) and (L).
17515-1R
16786R
17514-1R1
The peripheral play is adjusted via mountings (H) and

(B). See section 40 for the setting values.
48-6
D
SPECIAL FEATURE OF ADJUSTING THE LOWER
STOP
Position the lower stop (L) and the two bolts (M).
Leave the central bolt loose.
16878R
17516-1R
Close the cover.
Pull tab (1) to the exterior (the stop comes into contact
with the lower beading of the casing and allows play to
be eliminated).
Open the luggage compartment lid.
Cut the tab and tighten the central bolt.
NOTE: it is recommended that you order a new lower

stop (K) for this operation. However, it is possible to
17516R use the old stop (without tab), but adjustment of the
lower section will be more difficult.
48-7
150
GENERAL
Tooling 50 P
A
18174R
99799S
Special tool for removing the rear screen wiper arm.

Unclipping pliers.
"Fir-tree" clips and interior trim clips such as on

door panels, soundproofing mats and mudguard
mountings can be removed easily using these pliers.
Door window winder handles can also be removed

(first apply some pull-off tape to the main point with the
door lining so that this is not damaged during
removal).
The heads of the clips are not deformed and can

therefore be reused after removal due to the flat and
bevelled nose allowing easy access without damaging
the clips.
50-1
152 MECHANISMS
NON-SIDE OPENING ELEMENT
Rear screen and luggage compartment lid locks 52 A
NOTE: it is possible to unlock the rear screen lock

manually (without removing the trim) and the luggage
compartment lid lock (after removing the trim).
REAR SCREEN LOCK LUGGAGE COMPARTMENT LID LOCK
After folding the rear seats, After removing the trim (section 73-A),
18080R 16832R
move the lug (A) using a locally manufactured tool move lug (B) using a small screwdriver.
(welding rod), This operation requires the help of a
person outside the vehicle.
52-1
REMOVING THE REAR SCREEN LOCK REMOVING THE REAR SCREEN STRIKER PLATE
After removing the trim (section 73-A),
16876S
Remove the two mounting screws.
The arrows indicate the adjustment options.

16831R1
disconnect connector (A).

REFITTING
Remove the two mounting screws (B).
To refit, proceed in the reverse order to removal.
52-2
REMOVING THE LUGGAGE COMPARTMENT LID
LOCK AND STOP
After removing the trim (section 73),
16786R1
Disconnect the connector from the lock.
16785-1R
Using a flat-nosed pliers, apply light pressure to the
stop (C) and remove the lock.
Remove:
– the two mounting bolts on the stop,
REFITTING
Check that the lock operates correctly.
16877R
– the two mounting bolts on the lock.
52-3
REMOVING THE STRIKER PLATE AND THE PAD REFITTING
ON THE BODY
WARNING: If removing the striker plate and the pad

at the same time, the striker plate is no longer
supported.
16878S
Remove:
– the two striker plate bolts,
– the two pad bolts.
NOTE: the movement arrows indicate the adjustment

options.
52-4
Luggage compartment lid exterior handle 52 B
REMOVAL
After removing the luggage compartment lid trim

(section 73-A), 16787S
Remove the handle.
REFITTING
16785R
remove the handle mounting bolt (A).
Disconnect the connector from handle (B).
52-5
WINDOWS154
Rear screen 54 P
A
18076R
APPEARANCE AND OPENING CLEARANCES 1 Location of the adjustment stops.
18067R
16884-1R
A = 3 ± 2 mm 2 Adjustment stop
B = 5.5 ± 3 mm 3 Adhesive tape
IMPORTANT: it is vital that you fit the four self- Refer to Technical Note 371A for information on how
adhesive adjustment stops (part no. 82 00 048 913) to to prepare and bond the windscreen.
the rear window surround, before bonding it.
54-1
155
EXTERIOR PROTECTION
Front bumper protection 55 P
A
REMOVAL
16882R
– the upper mounting bolts (B),
17591R
Remove:
– the lower mounting bolts (A),
16881R
– the two bolts attached to the towing brackets (C).
55-1
EXTERIOR PROTECTION
Front bumper protection 55 S
A
18078R
Pull manually on the two ends of the protection to

release the part.
REFITTING
55-2
EXTERIOR PROTECTION
Front and rear valance protections 55 S
B
NOTE: it is not possible to remove the front protection section without first removing the rear protection section.
55-3
EXTERIOR PROTECTION
Front and rear valance protections 55 P
B
REMOVING THE REAR PROTECTION SECTION REMOVE THE FRONT PROTECTION SECTION
18111R1 18112R1
Remove: Remove:
– the lower mounting clips, – the lower mounting clips,
18065-1R 17543R
– the three upper mounting clips. – the upper mounting clips,

– the mountings (B).
Protect the rear wing extender using masking tape.
Protect the front wing extender using masking tape.
Using unclipping pliers and a flat screwdriver, release
the valance protection. Using unclipping pliers, remove the valance protection.
REFITTING
55-4
EXTERIOR PROTECTION
Front wing extender 55 S
C
PRF5515
NOTE: it is necessary to prepare a tool to remove the wing extender retaining

brackets.
18113R
Cut the end of an extrusion nozzle (≈ 15 mm), heat

gently and flatten the end in a vice (≈ 40 mm).
55-5
EXTERIOR PROTECTION
Front wing extender 55 P
C
REMOVAL
After removing the front valance protector

(section 55-B),
17595R1
Remove the mounting bolts (B).
17598R
Remove mounting screws (A).
Protect the wing using masking tape and then release

the extender using the special pliers.
Disconnect the side repeater.
17599R
Remove:
– the front section of the mudguard,
– the mounting bolt (C).
Disconnect the connector (D) from the fog light wiring

harness.
55-6
EXTERIOR PROTECTION
Front wing extender 55 P
C
REFITTING
16835-1R
Unclip the detachable cover upwards, then remove the

mounting bolt (E).
Protect the wing extender and the bumper using

masking tape.
18079R
Insert the locally manufactured tool between the two

sections at (1) then at (2), to unclip the retaining Offer up the extender ensuring that the wing guide (G)
brackets (F) below. and retaining brackets are positioned correctly, then
continue in the reverse order to removal.
16835R 16835R1
Pull on the extender to release it to the front.
55-7
EXTERIOR PROTECTION
Rear wing extender 55 P
D
PRF5516 17541R
REMOVING THE RIGHT HAND EXTENDER – two mounting bolts (B),

– the fuel filler flap,
After removing the rear section of the valance
protector (section 55-B),
18065R 17516-2R
Remove: – two mounting bolts (C),

– mounting bolt (A),
55-8
EXTERIOR PROTECTION
Rear wing extender 55 P
D
17544R 18066R
– mounting bolts (D), At the same time pull backwards (G) to release the
retaining brackets and the extender.
REMOVING THE LEFT HAND EXTENDER
Special note
It will be necessary to remove the left hand cover lower

embellisher strip (section 55-H).
The operations are continued in the same manner as

for the right hand rear extender.
REFITTING
17592R
– three mounting bolts (E).
Unclip the three retaining brackets (F) using a locally

manufactured tool (section 55-C).
55-9
EXTERIOR PROTECTION
Front bumper (central section) 55 P
E
INTRODUCTION COMPLETE REMOVAL
There are two methods for removing the bumper: After removing the bumper protector (section 55-A)
– complete removal of the part, and the front wing extenders (section 55-D),
– partial removal allowing access to the lens unit
mountings.
17591R
Remove:
– the lower mounting bolts (A),
16882R2
– the central mounting bolt (B).
Release the bumper.
55-10
EXTERIOR PROTECTION
Front bumper (central section) 55 P
E
PARTIAL REMOVAL INCLUDING THE CENTRAL Remove:
BUMPER AND THE EXTENDER – the front section of the mudguard,
– the mounting bolt (E),
After removing the bumper protector
(section 55-A), Disconnect the connector (F) from the fog light wiring
harness.
17598R1 16882R1
remove mounting bolts (C) and (D). Remove the central mounting bolts (G).
Protect the wing using masking tape and then, release Partially release the wing extender unit with the
the extender using the unclipping pliers. bumper.
Disconnect the side repeater.
17599R1
55-11
EXTERIOR PROTECTION
Front bumper (central section) 55 S
E
REFITTING
17596R
Offer up the upper section of the bumper impact

absorber above the two guides (H).
ADAPTING THE PART FROM THE PARTS

DEPARTMENT FOR FITTING THE FRONT BUMPER
PROTECTOR (section 55-A)
NOTE: it is necessary to drill the central bumper when

this has a protector.
18078R1
A Ø 10 mm
B Ø 17 mm
C Cut according to the markings
55-12
EXTERIOR PROTECTION
Rear bumper 55 P
F
17897R
REMOVAL
– the four upper mounting bolts (B),
– the luggage compartment lid balancers and its
After removing the rear wing extenders
mounting ball joint (C).
(section 55-D),
WARNING: the balancer acts as a door check strap. It
is necessary hold the cover using string.
Release the bumper.
REFITTING
18062R
Remove:
– the three lower mounting bolts (A),
55-13
EXTERIOR PROTECTION
Front and rear door panels 55 G
S
PRF5519
55-14
EXTERIOR PROTECTION
Front and rear door panels 55 G
P
REMOVING THE FRONT DOOR PANEL REMOVING THE REAR DOOR PANEL
18063R 18064R
Remove the blanking cover (A), and the panel Remove the blanking cover (B), and the panel
mounting bolt. mounting bolt.
17597S 17542S
Protect the door using masking tape and then release Protect the door using masking tape and then release
the panel using the unclipping pliers. the panel using the unclipping pliers.
55-15
EXTERIOR PROTECTION
Luggage compartment lid embellishers. 55 P
H
REMOVAL
After removing the emergency spare wheel,

17602S
Protect the luggage compartment lid using masking

tape and then release the embellisher using the
unclipping pliers (six clips).
Disconnect the registration plate light connector.
17600R
remove the lower mounting bolts (A).
17601S
REFITTING
55-16
156
Rear wing corner extender 56 P
A
Extender embellisher (B)
It is possible to remove this part, which avoids masking

before painting.
REMOVAL
16879-1R
Apply pressure to the retaining brackets (C).
At the same time pull on the part which is held by the

double sided adhesive tape (D).
REFITTING
Apply double sided adhesive tape to the front

embellisher before reclipping it.
Check that the seals are positioned correctly (E).
17823R To refit, proceed in the reverse order to removal.
Remove:
– the rear light,
– the two mounting bolts (A).
– the lower clip using a small flat screwdriver,
– the upper clip using the special clamp.
56-1
Rear windscreen wiper arm 56 S
B
PRF5606
WARNING: Use the special tool Elé. 1552 to remove the rear screen wiper arm.
56-2
Rear windscreen wiper arm 56 S
B
REMOVAL
After removing the emergency spare wheel,
16834R
remove the nut cover, unscrew the mounting nut on

the arm by one turn, insert the tool.
1 Extractor bolt (wedged on the loosened nut)

2 Short bend clip
3 Long bend clip
After unlocking the arm, remove the extractor then

complete the operation manually.
REFITTING
Tightening torque for the nut 11 ± 1 N.m
56-3
Rack embellishers 56 S
C
PRF5607
56-4
Rack embellishers 56 S
C
REPLACEMENT
Use one of the window bonding kits to assemble this

part.
18173R
Level down the residual seals, degrease using

heptane then apply red primer to both sections. Apply
glue to (A).
Refit and insert the spacer (B), the embellisher and the
mounting bolt (C). To pad the casing correcting use
masking tape.
56-5
NON-SIDE OPENING 173
ELEMENTS TRIM
Luggage compartment lid trim 73 A
REMOVING THE CENTRAL TRIM
16784R
Loosen the wing nut (B).
Remove:
– the emergency spare wheel protector,
– the mounting bolts (C).
16782R
Remove the protective sheath and disconnect the

connector (A).
16783R
Remove the trim using unclipping pliers (nine clips).
73-1
Luggage compartment lid trim 73 A
REMOVING THE LOCK COVER
16830R
Remove the two mounting bolts (D).
Release the cover.
REFITTING
After checking that the locks operate correctly,

proceed in the reverse order to removal.
73-2

203 1995 2002 Renault Megane Mégane Factory Service Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

203 1995 2002 Renault Megane Mégane Factory Service Manual

Uploaded by

Copyright:

Available Formats

General

VALUES AND SETTINGS

BA0A - BA0E - BA0F - BA0G - BA0L - BA0U

77 11 176 201 APRIL 1995 Edition Anglaise

C Régie Nationale des Usines Renault S.A. 1995

07 VALUES AND SETTINGS

180 DST 3050

BA0G F3R 1998 215 HRN 4000 JB3

BA0A 200 HRV 4600

BA0F K7M 1598 - AD4

B: Body type (example 5 door hatchback)

• in the engine compartment (A),

ALLOCATION OF TECHNICAL EQUIPMENT CODES

SPECIAL TOOLING REQUIRED

Cha. 280 -02 Adaptable cross piece for trolley

If a trolley jack is used, appropriate axle AXLE STANDS

To lift the front or rear, support the vehicle’s

TROLLEY JACK USED FROM THE SIDE

Use cross piece Cha. 280-02.

Position the flange correctly in the groove of the

1 - WHEN REMOVING COMPONENTS

NEVER USE THE DRIVESHAFTS FOR TOWING THE VEHICLE.

• MOLYKOTE "BR2" 1 kg tin 77 01 421 145

• MOLYKOTE "33 Medium"

• "MOBIL CVJ" 825 Black star

• Perfect-seal "LOWAC" 100 g tube 77 01 417 404

• Mastic 1.5 kg tin 77 01 421 161

• HARDENER KIT Kit 77 01 421 080

• AUTO joint blue 100 g tube 77 01 396 227

• AUTO joint grey 100 g tube 77 01 422 750

• LOCTITE 518 24 ml syringe 77 01 421 162

• Leak detector Aerosol 77 11 143 071

• "LOCTITE - FRENETANCH" 24 cc bottle 77 01 394 070

• "LOCTITE - FRENBLOC" 24 cc bottle 77 01 394 071

• "LOCTITE SCELBLOC" 24 cc bottle 77 01 394 072

• "LOCTITE AUTOFORM" 50 cc bottle 77 01 400 309

CLEANING AGENTS - LUBRICANTS

• "NETELEC" 150 g aerosol 77 01 408 464

• NC1 cleaner Aerosol 77 01 422 379

• Carburettor cleaner 250 ml can 77 01 393 112

• Injector cleaner 355 ml can 77 01 423 189

• Super concentrated unseizing agent 500 ml aerosol 77 01 408 466

• "DECAPJOINT " (FRAMET) for cleaning the Aerosol 77 01 405 952

• Brake cleaner 400 ml aerosol 77 01 421 282

• "CIRCUIT PLUS" Bottle 77 01 421 135

• "CONTACT PLUS" Kit 77 01 422 752

• Brake fluid 0.5 litre bottle DOT 4 77 01 421 940

Engine drain plug spanner

DRAINING: plug(1) FILLING: plug(2)

F3R - F8Q ENGINES F8Q ENGINE

E7J - K7M ENGINE F3R ENGINE

F3R - F8Q ENGINE

E7J - K7M ENGINE

POWER ASSISTED STEERING PUMP LEVEL

For topping up or filling, use ELF RENAULTMATIC

The level, when correct, should be visible between

Petrol engine After E.E.C. countries

-30°C -20°C -10°C 0°C +10°C +20 °C +30°C

CCMC-G4 15W40 - 15W50

CCMC-G5 10W30 - 10W40 -

(plus 0.5 litres -15°C

Diesel engine After E.E.C. countries

(plus 0.5 litres

Fuel tank approximately Unleaded