Renault

3 Chassis
30A GENERAL INFORMATION
31A FRONT AXLE COMPONENTS
33A REAR AXLE COMPONENTS
35A WHEELS AND TYRES
36A STEERING ASSEMBLY
36B POWER ASSISTED STEERING
37A MECHANICAL COMPONENT CONTROLS
38C ANTI-LOCK BRAKING SYSTEM
X35
JANUARY 2009 Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault.
specifications current when it was prepared.
The reproduction or translation in part of whole of the present document, as well as the use
The methods may be modified as a result of changes introduced by the manufacturer in the of the spare parts reference numbering system, are prohibited without the prior written
production of the various component units and accessories from which his vehicles are consent of Renault.
constructed."
© Renault s.a.s 2008

SYMBOL - THALIA - Section 3ContentsPage
SYMBOL - THALIA - Section 3
Contents
Page
30A GENERAL INFORMATION 31A FRONT AXLE COMPONENTS
Brake circuit Operating Front axle assemblies:

diagram 30A-1 Precautions for repair 31A-1
Brake circuit Precautions for Front brake pads: Removal -

repair 30A-2 Refitting 31A-3
Brake circuit Bleeding 30A-4 Front brake hose: Removal -

Refitting 31A-5
Brake circuit Tightening
torque 30A-6 Front brake calliper: Removal
- Refitting 31A-7
Rigid brake pipe: Repair 30A-11
Front brake calliper: Repair 31A-9
Brake fluid: Specifications 30A-16
Front brake calliper support:
Brake: Specifications 30A-17 Removal - Refitting 31A-11
Steering: Tightening torque 30A-19 Front brake disc shield:
Axle assemblies: Check 30A-20 Removal - Refitting 31A-13
Underbody height: Front brake disc: Removal -

Adjustment values 30A-21 Refitting 31A-15
Front axle: Tightening torque 30A-24 Front brake disc: Description 31A-17
Front axle: Adjustment Front driveshaft hub carrier:

values 30A-26 Removal - Refitting 31A-18
Front axle: Adjusting 30A-28 Front hub carrier bearing:

Removal - Refitting 31A-21
Rear axle: Tightening torque 30A-29
Spring and front shock
Rear axle: Adjustment values 30A-30 absorber: Removal - Refitting 31A-24
Front driveshaft lower arm:

Front driveshaft lower arm

ball joint: Removal - Refitting 31A-31
Front driveshaft lower arm

ball joint: Check 31A-33
Contents
31A FRONT AXLE COMPONENTS 35A WHEELS AND TYRES
Front axle sub-frame: Tyre inflation pressure:

Removal - Refitting 31A-34 Identification 35A-14
Front anti-roll bar: Removal - Wheel rim: Identification 35A-15

Refitting 31A-38
36A STEERING ASSEMBLY

33A REAR AXLE COMPONENTS
Steering: Precautions for
Rear axle assemblies: repair 36A-1
Precautions for repair 33A-1
Steering rack: Removal -
Rear brake lining: Removal - Refitting 36A-3
Refitting 33A-2
Track rod: Removal -
Rear brake cylinder: Refitting 36A-6
Axial ball joint linkage:
Rear brake drum: Removal - Removal - Refitting 36A-8
Refitting 33A-7
Steering column: Removal -
Rear brake drum: Refitting 36A-10
Description 33A-9
Steering rack gaiter:
Rear suspension spring: Removal - Refitting 36A-13
Bulkhead seal: Removal -
Rear drum bearing: Removal Refitting 36A-14
- Refitting 33A-12
Intermediate shaft: Removal
Rear stub-axle carrier: - Refitting 36A-15
Steering column adjustment
Rear axle rubber bearing: handle Removal - Refitting 36A-17
Steering wheel: Removal -
Complete rear axle: Removal Refitting 36A-19
- Refitting 33A-19
36B POWER ASSISTED STEERING

35A WHEELS AND TYRES
Power assisted steering
Wheel: Removal - Refitting 35A-1 pump: Checking 36B-1
Wheel: Balancing 35A-4 Power-assisted steering

circuit: Bleeding 36B-5
pneumatic: Precautions for
repair 35A-7 Power assisted steering
pump: Removal - Refitting 36B-7
Tyres: Identification 35A-8
Tyres: Removal - Refitting 35A-9
Tyres: Repair 35A-11

Contents
36B POWER ASSISTED STEERING 37A MECHANICAL COMPONENT CONTROLS
Power assisted steering Automatic gear control cable:

pump assembly: Removal - Removal - Refitting 37A-32
Refitting 36B-15
Automatic gear control cable:
Power assisted steering Adjusting 37A-33
pipes: Removal - Refitting 36B-18
Gear control unit: Removal -
Refitting 37A-35
Gear control unit: Adjusting 37A-43

37A MECHANICAL COMPONENT CONTROLS
Parking brake cables:
Master cylinder: Removal -
Refitting 37A-1
Brake servo non-return

valve: Removal - Refitting 37A-3 38C ANTI-LOCK BRAKING SYSTEM
Brake servo: Removal -
Refitting 37A-4 ABS system: Precautions for
repair 38C-1
Vacuum pump: Removal -
Refitting 37A-6 Brake hydraulic assembly:
Removal - Refitting 38C-2
Pedal yoke: Removal -
Refitting 37A-7 Front wheel speed sensor:
Accelerator pedal: Removal -
Refitting 37A-9 Rear wheel speed sensor:
Accelerator pedal cable:
Brake pedal: Removal -

Refitting 37A-14
Brake pedal switch: Removal

- Refitting 37A-15
Parking brake lever: Removal

- Refitting 37A-17
Parking brake lever:

Adjusting 37A-19
Braking assistance circuit:

Check 37A-20
Clutch control: List and

location of components 37A-22
Clutch cable: Removal -

Refitting 37A-24
Clutch pedal: Removal -

Refitting 37A-26
Clutch circuit: Bleeding 37A-29

GENERAL INFORMATION
Brake circuit Operating diagram 30A
« X » braking system with load-sensitive « X » braking system with ABS
compensator
108548
IMPORTANT
This is a diagram of the general principle, do not
use it as a reference for take-off points or circuit
allocation. When replacing components in a vehi-
cle's braking circuit, always mark the pipes before 105586
removing them.
IMPORTANT
This is a diagram of the general principle, do not
use it as a reference for take-off points or circuit
allocation. When replacing components in a vehi-
cle's braking circuit, always mark the pipes before
removing them.
30A-1
GENERAL INFORMATION
Brake circuit Precautions for repair 30A
I - SAFETY III - GENERAL RECOMMENDATIONS
When replacing brake pads, always replace the pads

1 - Advice to be followed before any operation on the other side as well.
For an operation requiring the use of a lift, follow the When replacing a disc, always replace the disc on the
safety advice (see Vehicle: Towing and lifting) (02A, opposite side.
Lifting equipment).
When replacing brake discs, you must replace the bra-
The brake regulation circuit must be free of all hydrau- ke pads.
lic and electrical faults.
In case of incorrect handling, the brake fluid can cause
serious injury and damage. Follow the manufacturer's WARNING
instructions for brake fluid.
In order not to damage the brake hose:
To prevent dust from entering the master cylinder re-
servoir and the brake circuit, the plug must be removed - do not tension the hose,
just before filling and closed immediately afterwards, - do not twist the hose,
- check that there is no contact with the surrounding
2 - Instructions to be followed during the operation components.
Do not press on the brake pedal during work on the
brake system.
If, during work on the brake system, any damage on IMPORTANT
any part is observed, it must be repaired before driving To avoid any accident, bring the pistons, brake pads
the vehicle again. and brake discs into contact by depressing the
Brake fluid is highly corrosive. Ensure any brake fluid brake pad several times.
spilt on parts of the vehicle is cleaned off.
Always replace the rigid brake pipe clips.
Use brake fluids that comply with the Renault standard
(see Precautions for repair) . Reminder:
Check the brake fluid levels in the braking circuit and - The pipes between the master cylinder, callipers and
the bleeding device. the hydraulic assembly are connected using threaded
unions with a metric thread.
Check that the pressure of the bleeding device is
between 1.5 bar and 2 bar. - Therefore, only parts specified in the Parts Catalogue
for this vehicle should be used.
II - CLEANLINESS
1 - Advice to be followed before any operation

Protect any bodywork components that risk being da-
maged by brake fluid with a cover.
2 - Instructions to be followed during the operation

Clean around the braking system with BRAKE CLEA-
NER (see Vehicle: Parts and ingredients for the re-
pairwork) (04B, Consumables - Products).
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
Do not allow friction materials to come into contact with

grease, oil or other lubricants and cleaning products
which are mineral oil based. 78491
30A-2
GENERAL INFORMATION
Brake circuit Precautions for repair 30A
Parts identification:
- shape of steel or copper pipe end piece (A),
- shape of connecting points on components (B),
- shape of unions (C): 11 mm hexagonal.
Precautions to be taken before and during the brake
circuit bleeding operation:
- use brake fluid which conforms to the Renault stan-
dard (see Vehicle: Parts and ingredients for the re-
pairwork) (04B, Consumables - Products),
- check the brake fluid levels in the brake circuit and the
bleeding device,
- the braking regulation circuit must be free from all hy-
draulic and electrical faults,
- check that the pressure of the bleeding device is
between 1.5 bars and 2 bars.
30A-3
GENERAL INFORMATION
Brake circuit Bleeding 30A
Essential equipment
pedal press
brake circuit bleeding device
IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 30A, General information, Brake cir-
cuit Precautions for repair, page 30A-2) .
This procedure must be applied after one of the fol-

lowing components has been removed or replaced:
- the master cylinder,
- the brake fluid,
- the hydraulic unit, 115993
- a rigid pipe, a Use locally produced containers to collect the used

brake fluid.
- a hose,
- the reservoir, Front and rear callipers:
- a calliper. - 2 washer fluid containers (1) (1 litre),
- 4 mm diameter transparent pipes (2) ,

WARNING
Switch off the vehicle ignition so as not to activate - 4 pipettes (3) (part no: 00 00 081 501),
the hydraulic unit solenoid valves when bleeding the
brake circuit. - 2 T-unions (4) .
Note:
WARNING
The new hydraulic unit is pre-filled.
The level must be between the « MIN » and
« MAX » markings on the reservoir. When working on one of the following compo-
nents, position a pedal press to limit the outflow
of brake fluid and prevent any air from entering
the master cylinder and the circuits downstream
of the master cylinder:
- hydraulic unit,
- pipes between the hydraulic unit and brake cal-
lipers,
- brake hoses,
- brake calliper.
Remove the pedal press before carrying out the
braking system bleeding procedure.
a Position the vehicle on a two-post lift (see Vehicle:

Towing and lifting) (02A, Lifting equipment).
a Switch off the vehicle ignition.
30A-4
GENERAL INFORMATION
Brake circuit Bleeding 30A
a Connect the brake circuit bleeding device (after a Remove the brake circuit bleeding device from
having received Renault approval) to the master cy- the master cylinder reservoir.
linder reservoir (see the instructions for the equip-
a Check pedal travel and resistance. If it is not correct,
ment).
finish bleeding the brake circuit with the help of a se-
a Pressurise the brake circuit. cond operator. Start the bleed operation by bleeding
the calliper that is the furthest away from the master
a Adjust the pressure to between 1.5 bar < P < 2 bar cylinder:
for 3 minutes to stabilise it in the braking circuit.
- hold down the brake pedal,
a Close the circuit between the bleed screw and brake
fluid reservoir without dumping the pressure. - open the circuit bleed screw to release the air from
the brake circuit,
- close the circuit bleed screw,
Note:
- release the brake pedal.
The circuit between the bleed screw and brake
fluid reservoir is closed in different ways depen- a Top up the brake fluid level in the reservoir, if neces-
ding on the type of equipment used: sary. Check the sealing of the front and rear bleed
screws and ensure that the sealing covers are in pla-
- valve, ce (see 30A, General information, Brake circuit
- switch. Tightening torque, page 30A-6) .
a During a road test, trigger braking regulation to con-
a Fit the bleed containers to the four bleed screws of
firm that the brake pedal travel is correct.
the callipers.
a Clean off any traces of brake fluid on the vehicle
a Undo the calliper bleed screws: using BRAKE CLEANING PRODUCT (see Vehi-
- front left-hand, cle: Parts and ingredients for the repairwork)
- front right-hand,
- rear left-hand,
- rear right-hand.
a Open the circuit between the bleed screw and brake
fluid reservoir and allow the liquid to run until all the
air bubbles have been released.
a Tighten the bleed screws in the following order:
- front left-hand,
- front right-hand,
- rear left-hand,
- rear right-hand.
a Undo the calliper bleed screw:
- front left-hand,
- allow the fluid to run until all the air bubbles have
been released,
- tighten the bleed screw on the calliper.
a Carry out the previous operation on the callipers:

- front right-hand,
- rear left-hand,
- rear right-hand.
a Close the bleed screw to dump the pressure in the
brake circuit.
30A-5
GENERAL INFORMATION
Brake circuit Tightening torque 30A
I - FRONT BRAKES
135206
No. Description Tightening torque (Nm)
(1) Guide pin bolts 28
(2) Calliper bleed screw 6
(3) Calliper mounting bolt 100
(4) Disc bolt 14
30A-6
GENERAL INFORMATION
II - REAR BRAKES
135207
No. Description Tightening torque (N.m)
(5) Rear brake cylinder bolt 15
(6) Rear brake cylinder bleed screw 6
30A-7
GENERAL INFORMATION
III - BRAKE CONTROL
ANTI-LOCK BRAKES
135204
(7) Hydraulic unit bolt on its mounting 8
(8) Hydraulic unit mounting bolt 8
(9) Front wheel speed sensor bolt 8
(10) Rear wheel speed sensor bolt 7
(11) Brake hose union on calliper 16
(12) Brake hose union on the ABS unit rigid pipe 13
(13) Brake pipe unions on hydraulic unit 13
(14) Underbody rigid brake pipe unions 13
(15) Brake hose unions 13
(16) Brake hose union on brake cylinder 13
(17) Rigid brake pipe unions on master cylinder 13
30A-8
GENERAL INFORMATION
NO ANTI-LOCK BRAKES
135205
(18) Brake hose union on calliper 17
(19) Brake hose union on rigid pipe 13
(20) Rigid pipe union between master cylinder and brake calliper 13
(21) Rigid pipe unions between master cylinder and compensator 13
(22) Rigid pipe unions between brake compensator and brake 13

hose
(23) Brake hose unions 13
(24) Rigid pipes unions between brake hose and wheel cylinder 13
(25) Brake compensator bolt 21
- Brake compensator mounting bolt 21
30A-9
GENERAL INFORMATION
135210 135211
(26) Master cylinder nuts 12
(27) Brake servo nuts 24
(28) Parking brake lever nuts 8
30A-10
GENERAL INFORMATION
Rigid brake pipe: Repair 30A
Tightening torquesm
brake pipe bolts 8 Nm
underbody unions 6 Nm
(female/male)
This procedure applies to copper pipes diameter 4.7

mm.
Note:
This procedure does not apply to:
- hybrid pipes (pipe + hose), 128666
- pipes with diameters 6 mm and 8 mm.
REPAIR
I - PIPE PREPARATION OPERATION

a
WARNING
To avoid causing a breakdown in hydraulic brake
circuit , do not squash or bend the rigid pipe
when cutting.
a Cut the pipe to the recommended length using a

128643
tube cutter (see Garage equipment catalogue).
128665
a Put the nuts or bolts on the pipe before forming the

rivets.
II - MAKING THE RIVETS
Note:
To make the rivets, fit the rivet press in a vice.
30A-11
GENERAL INFORMATION
a Fit the pipe in the rivet press (see Garage Equip-
ment Catalogue).
a Adjust the length of the pipe to be shaped.
a Torque tighten the press end piece(40 Nm).
III - CHECKING THE RIVETS
128668
a Visually check that the internal diameter of the pipe

is not oval-shaped.
128667
128645
a Check that the diameter of the end panel is not oval

shaped using a sliding calliper.
128669
Correct diameter if (X1) = (X2)
a Visually inspect:
- the uniformity of the rivets' diameter,
IV - PREPARATION OF THE PIPE BEFORE
- the rivet centring in relation to the pipe shaft.
BENDING
Note:
Impurities may spread inside the pipe while the
rivets are being made.
a Blow inside the pipe in both directions using a com-

pressed air gun.
a Put plugs on the bolts or nuts at the ends of the pipe.
a Put the original pipe on a flat base plate that is the

length of the pipe.
30A-12
GENERAL INFORMATION
128659
a Measure the dimensions (X3) (in mm) curve after
curve, between each curve radius « centre » (1) of
the old pipe.
30A-13
GENERAL INFORMATION
128814
a
WARNING
To avoid weakening the pipe, either bend once or
bend progressively by increasing the bend (that
is, by continually decreasing the curve radius).
Do not install a rigid pipe on a vehicle that may
have been bended and then unbended alternati-
vely to reach the correct curve radius.
Note:
During the bending operation, the required angle
should be passed slightly in order to compensate
for material elasticity.
a Shape the pipe using a bender, curve after curve,

while respecting the original shape of the pipe.
30A-14
GENERAL INFORMATION
V - CHECKING BENDING VI - REFITTING THE PIPE
a
Note:
When refitting the rigid brake pipe:
- respect the original routing as much as possi-
ble,
- adjust the pipe routing by hand when fitting
inside the clips.
WARNING
Contact points between the rigid brake pipe and
the surrounding components could cause
128664 damage to the pipe. In order to avoid these con-
tacts, adjust the pipe routing by hand.
128670
a Check the out-of-roundness of the outer diameter at 128644
the centre of the curve radius (2) using a sliding cal-
a Torque tighten the brake pipe bolts (8 Nm).
liper (the out-of-roundness of the outer diameter is
correct if it is less than 10% flattening):
- nominal diameter of the pipe: 4.75 mm,
- minimum diameter after bending: 4.30 mm.
128646
a Torque tighten the underbody unions (female/ma-
le) (6 Nm).
30A-15
GENERAL INFORMATION
Brake fluid: Specifications 30A
BRAKE FLUID REPLACEMENT INTERVAL
Our braking technology, and in particular the disc bra-
kes (hollow pistons which conduct little heat, have a
low volume of fluid in the cylinder, sliding callipers avoi-
ding the need for a fluid reserve in the least cooled
area of the wheel), has allowed us to prevent the risk of
« vapour lock » as far as possible, even with heavy
braking (mountainous area). However, current brake
fluids are subject to minor deterioration during the first
months of use due to slight humidity intake. This is why
it is recommended that you change the brake fluid: see
maintenance booklet for the vehicle.
1 - Topping up the level

Wear of the brake pads will result in a gradual drop in
the fluid level in the reservoir.
Do not top up the fluid, as the level will rise again when
the pads are next changed. The brake fluid level must
not fall below the minimum mark.
2 - Approved brake fluid

Mixing two incompatible brake fluids in the brake circuit
may lead to:
- serious risk of leakage due mainly to deterioration of
the cups,
- deterioration in the operation of the ESP system.
To prevent such risks, it is essential to use only brake
fluids that comply with the RENAULT standard (see
Vehicle: Parts and ingredients for the repairwork) .
30A-16
GENERAL INFORMATION
Brake: Specifications 30A
K4M K4J/BVM D4F
K4J/BVA K7M K7J
K9K
Front brake (mm)
Piston diameter 48
Disc diameter 259 238
Disc thickness 20.6 20 12
Minimum disc thickness 17.7 10.5
Maximum disc run-out 0.03
Brake pad thickness 13

(including backplate)
Minimum pad thickness 8.7

(including backplate)
K4J/SSABS D4F/SSABS D4F/ABS

K4M/SSABS K7J/SSABS K4J/ABS
K7M/SSABS K4M/ABS
K9K/SSABS K7J/ABS
K7M/ABS
K9K/ABS
Rear brake (mm)
Slave cylinder diameter 17.5 19 17.5
Drum diameter 203.2
Maximum drum wear dia- 204.45

meter
Drum pad thickness 5.5 5.5 -

(including support)
Minimum drum pad thic- 2.4 2.4 -

kness (including support)
Primary pad thickness - - 4.6

(excluding support)
Minimum primary pad - - 2.4

thickness (excluding sup-
port)
30A-17
GENERAL INFORMATION
Brake: Specifications 30A
K4J/SSABS D4F/SSABS D4F/ABS
K4M/SSABS K7J/SSABS K4J/ABS
K7M/SSABS K4M/ABS
K9K/SSABS K7J/ABS
K7M/ABS
K9K/ABS
Secondary pad thickness - - 3.3

(excluding support)
Minimum secondary pad - - 2.4

thickness (excluding sup-
port)
30A-18
GENERAL INFORMATION
Steering: Tightening torque 30A
135197
(1) Steering wheel bolt 44
(2) Steering column bolts 21
(3) universal joint bolt on the steering box 21
(4) Steering box bearing bolts 50
(5) Axial ball joint 79
(6) Wheel alignment lock nut 53
(7) Track rod nut 37
- Wheel bolts 105
30A-19
GENERAL INFORMATION
Axle assemblies: Check 30A
a Lock the slip plates of the lift.
a Position the vehicle on a lift (see Vehicle: Towing

and lifting) .
a Check the condition of the following components:
- track rods,
- axial ball joint linkages,
- subframe,
- lower arm rubber bushes,
- lower arm ball joints (see 31A, Front axle compo-

nents, Front driveshaft lower arm ball joint:
Check, page 31A-33) ,
- shock absorbers,
- tyres,
a Check:
- the tyre size (see 35A, Wheels and tyres, Tyres:

Identification, page 35A-8) ,
- the tyre inflation pressure (see 35A, Wheels and

tyres, Tyre inflation pressure: Identification,
page 35A-14) .
a Put the vehicle in the VODM position (vehicle in run-

ning order) (see 30A, General information, Under-
body height: Adjustment values, page 30A-21) :
- tank full,
- vehicle empty (without luggage, etc.).
a Consult:
- the front axle geometry values (see 30A, General

information, Front axle: Adjustment values,
page 30A-26) ,
- the rear axle geometry values (see 30A, General

information, Rear axle: Adjustment values,
page 30A-30) .
a Refer to the user manual for the geometry tester.
a Check the geometry using the geometry tester.
a If there is an inconsistency between the manufactu-

rer's values and the measured values:
a Adjust the front axle (see 30A, General informa-

tion, Front axle: Adjusting, page 30A-28)
30A-20
GENERAL INFORMATION
Underbody height: Adjustment values 30A
I - MEASURING POINTS
132538
Radius under load: 1 - Front height (W1)
- : (R1) Distance between the ground and the front
wheel axle.
- : (R 2) Distance between the ground and the rear
wheel axle.
108936
30A-21
GENERAL INFORMATION
139111 139110
(w1) : Height between the ground and the side mem- (w2) : Height between the ground and the shaft of the
ber (the measuring point is located directly in line with rubber bush on the bearing.
the stub axle carrier).
II - MEASURING PROCEDURE
2 - Rear height (W2)
Note:
For measurements (w1) a n d (w2) , take into
account the height difference between the plates
and the lift.
Measure the heights:

- R1,
- R2,
- W1 right-hand and left-hand,
- W2 right-hand and left-hand.
Note:
The value of Wx to be entered into the geometry
bench is the average of the W1 heights, right-hand
and left-hand and of the W2 heights, right-hand and
108937 left-hand.
Specific case:
Note:
If the measuring points are located in empty space
(between the rails and the lift), use a bar.
30A-22
GENERAL INFORMATION
a - Plate higher than the lift: (w2) = 240 mm
Note:
The position of the vehicle varies according to:
- the weight of the engine,
- the springs and shock absorbers,
- the tyres,
- the amount of fuel in the tank.
126087
Measure the heights (1) , (2) , (3) .
Example: (1) = 13 cm, (2) = 8 cm, (3) = 10 cm.
Calculate the height Wx:
Wx = height (1) + height (3) - height (2) ,
Wx = 15 cm.
b - Plate lower than the lift:
126088
Measure the heights (1) , (2) , (3) .
Example: (1) = 8 cm, (2) = 10 cm, (3) = 4 cm,
Calculate the height Wx:
Wx = height (1) + height (2) + height (3) ,
Wx = 22 cm.
III - VEHICLE IN RUNNING ORDER

VODM (Vehicle in working order) position:
- Tank full,
- Empty vehicle (without luggage, etc.).
(w1) = 170 mm
30A-23
GENERAL INFORMATION
Front axle: Tightening torque 30A
109718
(1) Shock absorber spring cup nut 62
(2) Lower arm bolts 105
(3) Acoustic tie-rod nut on lower arm 62
(4) Track rod end nut 37
(5) Rear subframe bolt 105
(6) Anti-roll bar bearing bolt 35
(7) Acoustic tie-rod on side member 21
(8) Shock absorber base bolts 105
- Front sub-frame bolt 62
30A-24
GENERAL INFORMATION
Front axle: Tightening torque 30A
109719
(9) Shock absorber rod nut 21
(10) Anti-roll bar nut on wheel side 14
(11) Lower arm ball joint bolt 62
(12) Driveshaft nut 280
(13) Wheel bolt 105
(14) Wheel alignment lock nut 53
(15) Disc bolt 14
30A-25
GENERAL INFORMATION
Front axle: Adjustment values 30A
I - WHEEL ALIGNMENT: MEANING OF SYMBOLS II - WHEEL ALIGNMENT
WARNING
Symbols used by RENAULT:

- toe-out: -,
- toe-in: +.
Toe-out: minus sign
93011
Value (for two wheels) Position of vehicle
- 0’10’ ± 15’ Vehicle in running order
III - CASTOR ANGLE

Not adjustable.
93011
Toe-in: plus sign
93012
93011-1
Value Vehicle position (mm)
+ 2˚57’± 30’ Vehicle in running order

Maximum left - right dif-
ference = 30’
IV - CAMBER
Not adjustable.
30A-26
GENERAL INFORMATION
Front axle: Adjustment values 30A
93013
Value Position of vehicle
- 0˚26’ ± 1˚ Vehicle in running order
V - PIVOT
Not adjustable.
93014
+ 10˚52’ ± 30’ Vehicle in running order

Maximum right - left dif-
ference = 40’
30A-27
GENERAL INFORMATION
Front axle: Adjusting 30A
2 - Castor angle
Essential equipment a Not adjustable.
steering wheel lock

3 - Camber
a Not adjustable.
Tightening torquesm
4 - Pivot
wheel alignment adjust- 53 N.m
ment lock nuts a Not adjustable.
I - ADJUSTMENT PREPARATION STAGE
a Check the geometry (see 30A, General informa-

tion, Axle assemblies: Check, page 30A-20) .
II - ADJUSTMENT OPERATION
1 - Wheel alignment
a Set the wheels straight ahead.
a Lock the steering wheel using a steering wheel

lock.
a Adjust the wheel alignment by rotating the track rod

sleeves.
121364
a Loosen the wheel alignment adjustment lock nut (1)

.
a Turn the track rod sleeve (2) to the required value.
a After adjustment, torque tighten the wheel align-

ment adjustment lock nuts (53 N.m).
30A-28
GENERAL INFORMATION
Rear axle: Tightening torque 30A
135203
(1) Rubber bearing bolt 62
(2) Rear axle nut 62
(3) Shock absorber lower bolt 105
(4) Shock absorber upper nut 21
(5) Stub-axle carrier bolt 53
(6) Brake drum nut 175
30A-29
GENERAL INFORMATION
Rear axle: Adjustment values 30A
I - WHEEL ALIGNMENT: MEANING OF SYMBOLS II - WHEEL ALIGNMENT
WARNING
Symbols used by RENAULT:

- toe-out: -,
- toe-in: +.
Toe-out: minus sign
93011
Value (for two wheels) Position of vehicle
+ 0˚39’ ± 15’ Vehicle in running order
III - CAMBER
93011
Toe-in: plus sign
93013-1

93011-1
- 1˚04’ ± 15’ Vehicle in running order
30A-30
FRONT AXLE COMPONENTS
Front axle assemblies: Precautions for repair 31A
I - SAFETY a - Brake pads
When replacing brake pads, always replace the pads

1 - Advice to be followed before any operation on the other side as well.
For an operation requiring the use of a lift, follow the

safety advice (see Vehicle: Towing and lifting) (02A, b - Brake disc
Lifting equipment).
When replacing a disc, always replace the disc on the
opposite side.
When replacing brake discs, you must replace the bra-
Do not press on the brake pedal during work on the ke pads.
brake system.
If, during work on the brake system, any damage on c - Brake hose
any part is observed, it must be repaired before driving
the vehicle again.
Brake fluid is highly corrosive. Ensure any brake fluid WARNING

spilt on parts of the vehicle is cleaned off.
In case of incorrect handling, the brake fluid can cause
- do not tension the hose,
serious injury and damage. Follow the manufacturer's
instructions for brake fluid. - do not twist the hose,
II - CLEANLINESS components.


NER (see Vehicle: Parts and ingredients for the re-
pairwork) (04B, Consumables - Products).
WARNING
Do not allow friction materials to come into contact with

grease, oil or other lubricants and cleaning products
which are mineral oil based.
126339
III - GENERAL RECOMMENDATIONS
To avoid the premature damage of the brake hose by
friction, observe the following procedure before unclip-
1 - Braking ping the hose:
- set the wheels straight ahead,
IMPORTANT - mark the position of the cap (1) on the base of the
To avoid any accident, bring the pistons, brake pads shock absorber using a permanent marker pen,
and brake discs into contact by depressing the - Unclip the cap (1) from the base of the shock absor-
brake pad several times. ber.
31A-1
Front axle assemblies: Precautions for repair 31A
Observe the following procedure before clipping the If a shock absorber is replaced, the shock absorber on
brake hose back on: the opposite side must also be replaced.
- set the wheels straight ahead, Check that the spring compressor tool is operating cor-
rectly.
- clip the cap (1) back on to the base of the shock ab-
sorber by aligning the marks made using the perma- In the interests of safety, do not leave a spring com-
nent marker pen. pressed in the spring compressor tool.
During assembly and removing operations, the surface
2 - Bearing, hub carrier and the protection paint must not be damaged.
When removing a hub, it is essential to replace the There must be no impacts during operations. Any han-
bearing with a new one. dling hooks and tightening or positioning clamps
should be equipped with rubber or plastic in order to
avoid damage on the springs.
WARNING It is recommended to replace springs if:
In order to prevent irreversible damage to the front - the paint is damaged,

hub bearing: - the springs are dented.
- Do not loosen or tighten the driveshaft nut when They are not usually symmetrical in shape and care
the wheels are on the ground. should be taken to assemble them the right way round.
- Do not place the vehicle with its wheels on the This can be done using the coloured marking's posi-
ground when the driveshaft has been loosened or tion.
removed.
WARNING
To prevent the suspension spring from prematurely
WARNING breaking, do not damage the anti-corrosion protec-
To ensure that the wheel speed sensor works pro- tion.
perly, do not mark the sensor target on the bearing.
It is essential to check the condition of the hub and 4 - Anti-roll bar

bearing surface and the hub carrier bore before refit-
During fitting and removal operations, the surface and
ting the bearing.
protective paint should not be damaged.
Replace any damaged hub carrier. There must be no impacts during operations. Any han-
Use SURFACE CLEANER (see Vehicle: Parts and dling hooks, tightening or positioning clamps should be
ingredients for the repairwork) (04B, Consumables - equipped with rubber or plastic parts so as to avoid da-
Products) to clean: maging the anti roll bar.
- the new bearing's internal and external surfaces It is recommended to replace the anti-roll bar if:
which are in contact with the hub carrier and the hub, - the paint is damaged,
- the hub carrier surfaces in contact with the new bea- - the anti roll bar has dents in it.
ring,
- the hub surfaces in contact with the new bearing.

Note:
Replace any component whose contact surfaces have the most critical and sensitive zones are in the main
deep scratches or cracks. elbows.
3 - Suspension spring
5 - Front axle
When replacing the spring, ensure that the positioning
and orientation of the spring and the tool cups are cor-
rect. WARNING
When replacing a spring, always replace the spring on To prevent any damage, do not use the lower arm
the opposite side. as support for the lifting system.
31A-2
Front brake pads: Removal - Refitting 31A
II - OPERATION FOR REMOVAL OF PART
Essential special tooling CONCERNED
Fre. 1842 Front brake calliper piston
return tool
Tightening torquesm
guide pin lower bolt 28 Nm
IMPORTANT
Consult the safety and cleanliness advice and ope-
ration recommendations before carrying out any
repair (see 31A, F ront axle components, Front
axle assemblies: Precautions for repair, page
31A-1) .
WARNING
In order not to damage the brake hose: 133689
- do not tension the hose, a Remove the guide pin lower bolt (1) .
- do not twist the hose, a Tip the brake calliper upwards.
components.
REMOVAL
I - REMOVAL PREPARATION OPERATION

a Remove the front wheel (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) .
125052
a Remove the brake pads.
REFITTING
I - REFITTING PREPARATION OPERATION
a Always replace the guide pin lower bolts.
31A-3
Front brake pads: Removal - Refitting 31A
a Clean using a wire brush and BRAKE CLEANER III - FINAL OPERATION
(see Vehicle: Parts and ingredients for the repai-
a Refit the front wheel (see 35A, Wheels and tyres,
rwork) (04B, Consumables - Products):
Wheel: Removal - Refitting, page 35A-1) .
- the calliper supports,
- the callipers. IMPORTANT
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.
123095
a Push the piston (after coating it with grease from the
repair kit) using the (Fre. 1842) (2) until it is at the
end of its bore.
II - REFITTING OPERATION FOR PART

CONCERNED
a Refit:
- the brake pads on the brake calliper mounting,
- the brake calliper.
a Torque tighten the guide pin lower bolt (28 Nm).
WARNING

- do not twist the hose,
- check that there is no contact with the surroun-
ding components.
31A-4
Front brake hose: Removal - Refitting 31A
CONCERNED
Essential equipment
pedal press
Tightening torquesm
brake hose union on the 16 N.m

calliper

rigid pipe union
IMPORTANT
31A-1) .
133699
WARNING a Undo:
- the hose union (1) from the rigid pipe,
- the hose union (2) on the calliper.
REMOVAL a Remove the brake hose (3) .
I - REMOVAL PREPARATION OPERATION REFITTING

I - REFITTING OPERATION FOR PART
a Set the wheels straight ahead. CONCERNED
a Position a pedal press on the brake pedal to limit a Set the wheels straight ahead.
the outflow of brake fluid.
a Refit the brake hose at the calliper end.
res, Wheel: Removal - Refitting, page 35A-1) . a Torque tighten the brake hose union on the calli-
per (16 N.m).
a Refit the brake hose on the rigid pipe union.
a Torque tighten the brake hose union on the rigid

pipe union (13 N.m).
WARNING

ding components.
31A-5
Front brake hose: Removal - Refitting 31A
II - FINAL OPERATION
a Remove the pedal press from the brake pedal.
a Bleed the brake circuit (see 30A, General informa-
tion, Brake circuit Bleeding, page 30A-4) .
31A-6
Front brake calliper: Removal - Refitting 31A
Fre. 1842 Front brake calliper piston
return tool
Essential equipment
pedal press
Tightening torquesm
guide pin upper bolt 28 N.m

calliper
IMPORTANT
axle assemblies: Precautions for repair, page 133689
31A-1) .
a Undo the brake hose union (1) of the calliper.
a Remove:
WARNING - the brake pads (see 31A, Front axle compo-

nents, Front brake pads: Removal - Refitting,
page 31A-3) ,
- the upper bolt (2) of the brake calliper guide pin,
REMOVAL - the brake calliper.
I - REMOVAL PREPARATION OPERATION REFITTING

Towing and lifting) (02A, Lifting equipment). I - REFITTING PREPARATION OPERATION
a Position a pedal press on the brake pedal to limit a Always replace the guide pin bolts.
the outflow of brake fluid. a Check:
- the condition of the calliper gaiter,
- the condition of the calliper if it has any deep scrat-
ches or cracks.
a Replace any faulty parts (see 31A, Front axle com-
ponents, Front brake calliper: Repair, page 31A-
9) .
a Clean using a wire brush and BRAKE CLEANER
- the calliper supports,
- the callipers.
a Push the brake calliper piston using the tool (Fre.
1842).
31A-7
Front brake calliper: Removal - Refitting 31A
CONCERNED
a Refit:
- the brake hose to the calliper,
- the brake calliper to the calliper mounting.
a Tighten to torque:
- the guide pin upper bolt (28 N.m),
- the brake hose union on the calliper (16 N.m).
III - FINAL OPERATION

a Refit:
- the brake pads (see 31A, Front axle compo-
page 31A-3) ,
- the front wheel (see 35A, Wheels and tyres,
IMPORTANT
31A-8
Front brake calliper: Repair 31A
II - REPAIR OPERATION FOR PART CONCERNED
Essential special tooling
Fre. 1190-01 Brake calliper piston return

tool.
Essential equipment
pedal press
IMPORTANT
31A-1) . 81546
a Remove the piston using compressed air, making

sure to insert a wooden block between the calliper
WARNING and the piston to avoid damaging it. Any trace of im-
Prepare for the flow of fluid, and protect the sur- pact on the end panel will render the piston unfit for
rounding components. use.
a Remove the dust seal.

REPAIR
I - REPAIR PREPARATION OPERATION

a Position the pedal press on the brake pedal to limit
the outflow of brake fluid.
a Remove:
Wheel: Removal - Refitting, page 35A-1) ,
- the front brake calliper (see 31A, Front axle com-
ponents, Front brake calliper: Removal - Refit-
ting, page 31A-7) .
81545
a Remove the rectangular section seal from the calli-

per groove with a round edged spring blade (feeler
gauge).
WARNING
The whole calliper must systematically be repla-
ced if there are any scratches in the calliper bore.
a Clean the parts using methylated spirit.
31A-9
Front brake calliper: Repair 31A
REFITTING

CONCERNED
a Refit:
- the new rectangular section seal in the calliper
groove,
- the piston (after having smeared it with the grease
supplied in the repair kit) using the (Fre. 1190-01),
- the dust seal.
II - FINAL OPERATION.
a Refit:
- the brake calliper (see 31A, Front axle compo-
nents, Front brake calliper: Removal - Refitting,
page 31A-7) ,
a Remove the pedal press.
IMPORTANT

31A-10
Front brake calliper support: Removal - Refitting 31A
CONCERNED
Tightening torquesm
new b rake calliper 100 N.m

mounting bolts
new guide pin bolts 28 N.m
IMPORTANT
31A-1) .
REMOVAL

Towing and lifting) (02A, Lifting equipment). 119218
a Remove: a Remove:
- the front wheel (see 35A, Wheels and tyres, - the brake calliper mounting bolts (1) ,
- the brake calliper mounting.
- the front brake pads (see 31A, Front axle compo-
page 31A-3) , REFITTING
- the guide pin bolts.
a Hang the brake calliper from the suspension spring.
a Clean using a wire brush and BRAKE CLEANER
- the calliper mounting,
- the calliper,
- the hub carrier.
a Always replace:
- the calliper mounting bolts,
- the guide pin bolts.

CONCERNED
a Refit the brake calliper mounting.
a Torque tighten the new brake calliper mounting
bolts (100 N.m).

a Fit the calliper on the mounting.
31A-11
Front brake calliper support: Removal - Refitting 31A
a Torque tighten the new guide pin bolts (28 N.m).
a Refit:
page 31A-3) ,
IMPORTANT
31A-12
Front brake disc shield: Removal - Refitting 31A
a Remove the brake disc (see 31A, Front axle com-
ponents, Front brake disc: Removal - Refitting,
Tightening torquesm page 31A-15) .
calliper mounting bolts 100 N.m

CONCERNED
IMPORTANT
31A-1) .
REMOVAL

a Remove:

138290
- the front brake pads (see 31A, Front axle compo- a Remove:
page 31A-3) . - the front brake disc protector bolts (2) ,
- the front brake disc protector.
REFITTING

a parts always to be replaced: Front brake calliper
mounting bolt (13,03,03,08).
a Using a wire brush and SURFACE CLEANER (see
Vehicle: Parts and ingredients for the repai-
rwork) (04B, Consumables - Products) clean the
hub carrier.

CONCERNED
a Refit the front brake disc protector.

119218
a Refit:
a Remove the calliper mounting bolts (1) .
- the brake disc (see 31A, Front axle components,
a Hang the "calliper mounting - brake calliper" assem- Front brake disc: Removal - Refitting, page 31A-
bly on the suspension spring. 15) ,
31A-13
Front brake disc shield: Removal - Refitting 31A
- the "brake calliper mounting - brake calliper" as-
sembly.
a Torque tighten the calliper mounting bolts (100
N.m).
a Refit:
page 31A-3) ,
IMPORTANT
31A-14
Front brake disc: Removal - Refitting 31A
CONCERNED
Essential equipment
parts washer
Brake discs cannot be reground. If there is excessive

scoring or wear, they will need to be replaced (see
30A, General information, Brake: Specifications,
page 30A-17) .
IMPORTANT
31A-1) .
REMOVAL

133698
Towing and lifting) (02A, Lifting equipment). a Remove:
a Set the wheels straight ahead. - the brake disc bolts (1) ,
a Remove: - the brake disc.

Wheel: Removal - Refitting, page 35A-1) , REFITTING
nents, Front brake pads: Removal - Refitting, I - REFITTING PREPARATION OPERATION
page 31A-3) ,
a Clean the brake discs using a parts washer.
- the brake calliper mounting (see 31A, Front axle
a Dry the surface of the discs.
components, Front brake calliper support: Re-
moval - Refitting, page 31A-11) . a Clean the mating faces of the disc on the hub using
a wire brush and BRAKE CLEANER (see Vehicle:
Parts and ingredients for the repairwork) (04B,
Consumables - Products).
a Always replace the brake disc bolts.

CONCERNED
a Refit the brake disc with new bolts.
31A-15
Front brake disc: Removal - Refitting 31A
a Refit:
- the brake calliper mounting (see 31A, Front axle
components, Front brake calliper support: Re-
moval - Refitting, page 31A-11) ,
page 31A-3) ,
IMPORTANT
31A-16
Front brake disc: Description 31A
I - PREPARATION OPERATION FOR CHECK
Position the vehicle on a two-post lift (see Vehicle:
Remove the wheel (see 35A, Wheels and tyres,
II - CHECKING OPERATION FOR PART

CONCERNED
Note:
Use a Palmer type tool to check the thickness of the
disc.
88310
Measure the thickness of the disc at 4 points in order
(90˚ apart).
Compare the values with those recommended by the
manufacturer (see 30A, General information, Brake:
Specifications, page 30A-17) .

Replace the discs if necessary (see 31A, Front axle
components, Front brake disc: Removal - Refitting,
page 31A-15) .
Refit the wheel (see 35A, Wheels and tyres, Wheel:
Removal - Refitting, page 35A-1) .
117057
Position the Palmer tool (1) to measure the disc thic-
kness.
31A-17
Front driveshaft hub carrier: Removal - Refitting 31A
Essential special tooling res, Wheel: Removal - Refitting, page 35A-1) .
Rou. 604-01 Hub locking tool.
Tav. 476 Ball joint extractor.
Tav. 1050-04 Universal driveshaft pusher

tool (back-plate and claws,
without jack).
Tav. 1420-01 Screw jack for tools Tav.

1420, Tav.1050-04 , Tar.
1454, Tar. 1850.
Tightening torquesm
shock absorber lower 105 N.m

bolts
lower arm ball joint nut 62 N.m
track rod end nut 37 N.m

133688
hub nut 280 N.m a Remove:
brake calliper mounting 100 N.m - the brake calliper mounting bolts (1) ,
bolts
- the"brake calliper mounting - brake calliper" as-
sembly.
a Hang the "brake calliper mounting - brake calliper"
IMPORTANT
assembly on the suspension spring.
ration recommendations before carrying out any a Remove the brake disc (see 31A, Front axle com-
repair (see 31A, F ront axle components, Front ponents, Front brake disc: Removal - Refitting,
axle assemblies: Precautions for repair, page page 31A-15) .
31A-1) .
WARNING

components.
REMOVAL

31A-18
WHEEL DISC PROT
122712
a Remove the hub nut using the tool (Rou. 604-01).
133693
a Remove: WARNING
- the disc protector bolts (2) ,
In order to prevent irreversible damage to the
- the brake disc protector. front hub bearing:
- Do not loosen or tighten the driveshaft nut when
the wheels are on the ground.
- Do not place the vehicle with its wheels on the
II - OPERATION FOR REMOVAL OF PART ground when the driveshaft has been loosened
CONCERNED or removed.
ANTI-LOCK BRAKES
a Unclip the wheel speed sensor.
31A-19
- the track rod end.
- the shock absorber lower bolts (105 N.m),
- the lower arm ball joint nut (62 N.m),
- the track rod end nut (37 N.m),
- the hub nut (280 N.m), using the (Rou. 604-01).
WARNING
In order to prevent irreversible damage to the

front hub bearing:
ground when the driveshaft has been loosened
or removed.
133687
a Remove:
ANTI-LOCK BRAKES
- the nut (3) from the track rod end,
- the track rod end (4) using the tool (Tav. 476), a Clip on the wheel speed sensor.
- the lower arm ball joint nut (5) ,

- the bolts (6) from the base of the shock absorber.
a Remove the lower ball joint from the hub carrier.
a Detach the driveshaft from the hub carrier using the
tool (Tav. 1050-04) and (Tav. 1420-01).
WHEEL DISC PROT
a Remove the front driveshaft hub carrier.
a Refit the disc protector.
REFITTING

a Refit:
a Always replace:
- the brake calliper mounting bolts, Front brake disc: Removal - Refitting, page 31A-
- the track rod end nut, 15) ,
- the lower ball joint nut, - the"brake calliper mounting - brake calliper" as-
sembly.
- the hub nut,
a Torque tighten the brake calliper mounting bolts
- the shock absorber base nuts. (100 N.m).

CONCERNED
a Refit:
IMPORTANT
- the hub carrier,
- the driveshaft in the hub carrier, pads and brake discs into contact by depressing
- the lower arm ball joint on the hub carrier, the brake pad several times.
31A-20
Front hub carrier bearing: Removal - Refitting 31A
a Hang the "brake calliper mounting - brake calliper"
assembly on the suspension spring.
Tightening torquesm
a Remove:
new bolts of the brake 100 N.m - the brake disc (see 31A, Front axle components,
calliper mounting Front brake disc: Removal - Refitting, page 31A-
15) ,
- the front driveshaft hub carrier (see 31A, Front
IMPORTANT axle components, Front driveshaft hub carrier:
To avoid all risk of damage to the systems, apply Removal - Refitting, page 31A-18) .
repair (see 31A, F ront axle components, Front ANTI-LOCK BRAKES
axle assemblies: Precautions for repair, page a Remove the wheel speed sensor (see 38C, Anti-
31A-1) . lock braking system, Front wheel speed sensor:
Removal - Refitting, page 38C-4) .
WARNING
In order not to damage the brake hose: II - OPERATION FOR REMOVAL OF PART
- do not tension the hose, CONCERNED

components.
WARNING
In order to prevent irreversible damage to the front

hub bearing:
ground when the driveshaft has been loosened or
removed.
REMOVAL
101933
I - REMOVAL PREPARATION OPERATION a Remove the elastic ring from the driveshaft hub car-
rier.
a Remove:

- the calliper mounting (see 31A, Front axle com-

ponents, Front brake calliper support: Removal
- Refitting, page 31A-11) .
31A-21
20786 20787
a Remove the hub with a press, applying pressure a Remove the front hub carrier bearing by applying
with a tube with an external diameter of 47 mm. pressure to the internal bush with a tube of an exter-
nal diameter of 60 mm.
REFITTING
a Always replace:
- the brake calliper mounting bolts,
- the track rod end nut,
- the lower ball joint nut,
- the hub nut,
- the shock absorber lower nuts.
a Use SURFACE CLEANER (see Vehicle: Parts

and consumables for repair) (04B, Consumables -
Products) to clean:
101230
a Place the extractor jaws in the groove of the internal - the internal and external surfaces of the bearing, in
bush. contact with the hub carrier and the hub,
a Remove the internal bush from the hub, applying - the hub carrier surfaces in contact with the hub car-
pressure on the hub with a tube with an external dia- rier bearing,
meter of 33 mm.
- the hub surfaces in contact with the bearing.
a Check the condition of the hub surface and the bore

of the hub carrier in contact with the bearing.
a Replace any component whose contact surfaces

have deep scratches or cracks.
31A-22
CONCERNED
WARNING
Do not press the bearing's internal bush so as to
avoid damaging the bearing (very high shrink-fit-
ting force).
20789
a Refit:
- the hub using a tube with an external diameter of

42 mm,
- the elastic ring on the front driveshaft hub carrier.

20788
ANTI-LOCK BRAKES
a Refit the wheel speed sensor (see 38C, Anti-lock

braking system, Front wheel speed sensor: Re-
moval - Refitting, page 38C-4) .
a Refit:
- the front driveshaft hub carrier (see 31A, Front

axle components, Front driveshaft hub carrier:
Removal - Refitting, page 31A-18) ,

Front brake disc: Removal - Refitting, page 31A-
15) ,
- the"brake calliper mounting - brake calliper" as-

sembly.
115568 a Torque tighten the new bolts of the brake calliper

mounting (100 N.m).
a Press on the external bush using a tube with an ex-
ternal diameter of 64 mm. a Set the wheels straight ahead.
a Apply a fitting force of 50,000 N to ensure that the a Refit the front wheel (see 35A, Wheels and tyres,
bearing is correctly fitted on the hub carrier shoulder. Wheel: Removal - Refitting, page 35A-1) .
31A-23
Spring and front shock absorber: Removal - Refitting 31A
CONCERNED
Essential equipment
safety strap(s)
spring compressor
spanner for shock absorber rod nut
Tightening torquesm
new shock absorber rod 21 N.m

nut

nuts
shock absorber cup nut 62 N.m
IMPORTANT
the safety and cleanliness instructions and opera- 133687
tion recommendations before carrying out any a Remove the lower nuts (1) from the shock absorber.
a Attach the hub carrier to the body using a safety
strap(s).
31A-1) .
REMOVAL

133704
a Remove:
- the shock absorber cup nut (2) ,
- the « spring - shock absorber » assembly.
31A-24
III - SPRING REMOVAL OPERATION REFITTING

a Always replace the nut of the shock absorber rod.
Note:
When removing/refitting springs, you must not
strike the springs as this could damage their sur-
face treatments.
95436
a Position the appropriate cups on the spring com-
pressor.
a Position the spring compressor - cup assembly on
the spring.
a Compress the spring using the spring compressor
until the spring detaches.
95435
a Replace the faulty components of the filter unit
a Place the spring compressor in the vice equipped
with jaws.
a Compress the spring.
96049
a Remove the nut from the shock absorber rod using a
spanner for shock absorber rod nut.
a Decompress the spring.
a Separate the various components of the spring -
shock absorber assembly.
31A-25
102201
a Insert the spring in the neck of the cup
96049-1
101939
a Torque tighten the new shock absorber rod nut
a Fit the consecutive parts in the correct order and (21 N.m).
orientation.
a Decompress the spring.
a Remove the spring compressor.
31A-26
CONCERNED
a Refit the spring - shock absorber assembly.
- the shock absorber lower nuts (105 N.m),
- the shock absorber cup nut (62 N.m).

31A-27
Front driveshaft lower arm: Removal - Refitting 31A
Sus. 1413 Rubber mounting compres-

sor for fitting anti-roll bars.
(wheel side).
Tightening torquesm
lower ball joint nut 62 N.m
IMPORTANT
31A-1) .
133687
REMOVAL
a Remove the lower ball joint nut (1) .
I - REMOVAL PREPARATION OPERATION a Remove the lower ball joint from the front driveshaft
a Position the vehicle on a two-post lift (see Vehicle: hub carrier.
a Remove the front wheel on the side concerned (see WARNING
35A, Wheels and tyres, Wheel: Removal - Refit-
To prevent any damage, do not use the lower
ting, page 35A-1) .
ar m as support for the lifting system.
133690
a Remove the wheel arch liner. 133685
a Remove:
- the subframe tie-rod bolt (3) ,
- the subframe tie-rod nut (4) ,
31A-28
- the subframe tie-rod.
119346
a Compress the anti-roll bar rubber mounting bush on

the wheel side using the (Sus. 1413).
a Remove:
- the anti-roll bar nut on the wheel side,
- the rubber mounting bush from the anti-roll bar on
the wheel side.
31A-29
CONCERNED
WARNING
REFITTING

CONCERNED
a Refit:
- the front driveshaft lower arm,
- the front driveshaft lower arm nuts.
a Fit the lower ball joint on the front driveshaft hub car-
rier.
a Ensure that the bush is correctly positioned on the
lower ball joint.
133700
a Torque tighten the lower ball joint nut (62 N.m).
a Refit the subframe tie-rod.
a Refit:
- the anti-roll bar rubber mounting bush on the wheel
side,
- the anti-roll bar bolt on the wheel side.
a Refit the anti-roll bar nut on the wheel side.
a Refit:
- the front wheel arch liner,
- the front wheel on the side concerned (see 35A,
Wheels and tyres, Wheel: Removal - Refitting,
page 35A-1)
a Check the front axle geometry (see 30A, General
information, Axle assemblies: Check, page 30A-
20) .
133701
Note:
Ensure that direction of fitting for the front drives-
haft lower arm bolts is correct.
a Remove:
- the front driveshaft lower arm nuts (5) ,
- the front driveshaft lower arm.
31A-30
Front driveshaft lower arm ball joint: Removal - Refitting 31A
CONCERNED
Tightening torquesm
lower ball joint nut on 113 N.m

the front driveshaft
lower arm
lower ball joint nut on 62 N.m

the front driveshaft hub-
carrier
IMPORTANT
31A-1) .
REMOVAL
133687
I - REMOVAL PREPARATION OPERATION a Remove the lower ball joint nut (1) .
a Position the vehicle on a two-post lift (see Vehicle: a Remove the lower ball joint from the front driveshaft
Towing and lifting) (02A, Lifting equipment). hub carrier.
WARNING
133691
a Remove:
- the lower ball joint nuts (2) on the lower arm,
31A-31
Front driveshaft lower arm ball joint: Removal - Refitting 31A
- the lower ball joint.
REFITTING

CONCERNED
a Refit the lower ball joint.
a Refit the lower ball joint on the front driveshaft hub
carrier.
a Torque tighten the lower ball joint nut on the front
driveshaft lower arm (113 N.m).
a Check that the plastic ring is correctly positioned on
the lower arm ball joint.
a Torque tighten the lower ball joint nut on the front
driveshaft hub-carrier (62 N.m).
20) .
31A-32
Front driveshaft lower arm ball joint: Check 31A
CHECKING 3 - Checking the play of the lower arm ball joint
CHECKING THE FRONT DRIVESHAFT LOWER

ARM BALL JOINT

1 - Check the condition of the lower arm ball joint

gaiter
a Check:
- the gaiter crimping on the front driveshaft lower

arm ball joint,
- that the gaiter is not torn.
If the front driveshaft lower arm ball joint gaiter is in

poor condition and not crimped, replace the front dri-
veshaft lower arm ball joint (see 31A, Front axle
components, Front driveshaft lower arm ball 117494
joint: Removal - Refitting, page 31A-31) .
a Check that there is no play in the front driveshaft
lower arm ball joint:
2 - Check the fitting of the lower arm ball joint - from a position underneath the vehicle,
- using both hands, hold the front driveshaft lower
arm as close as possible to the wheel,
- push downwards several times.
If there is play in the front driveshaft lower arm ball
joint, replace the front driveshaft lower arm ball joint
(see 31A, Front axle components, Front drives-
haft lower arm: Removal - Refitting, page 31A-28)
.
133691
a Check:
- that the « front driveshaft lower arm ball joint - front

driveshaft lower arm bolt - front driveshaft hub
carrier » assembly is correctly positioned,
- the tightening torque of the nuts of the front drives-

haft lower arm ball joint (see 30A, General infor-
mation, Front axle: Tightening torque, page
30A-24) .
31A-33
Front axle sub-frame: Removal - Refitting 31A
Essential equipment
safety strap(s)
component jack
Tightening torquesm
subframe front bolts 62 N.m
subframe rear bolts 105 N.m
lower arm ball joint nuts 62 N.m
steering box bearing 50 N.m

bolts
IMPORTANT
Consult the safety and cleanliness advice and ope- 133690
ration recommendations before carrying out any a Remove the wheel arch liner (1) .
31A-1) .
JB1 or JB3
REMOVAL

a Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).
a Remove:
- the engine undertray bolts,
- the engine undertray,
- the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
- the front wheels (see 35A, Wheels and tyres,
134005
a Move aside the gaiter (2) of the gear selection linka-

ge.
a Remove the nut (3) from the gear selection linkage.
a Move aside the gear selection linkage.
31A-34
D4F
134007
a Remove the bolts (5) from the front bumper diffuser

133994 on the sub-frame.
a Remove the bolts (4) from the power-assisted stee-
ring pipe brackets on the subframe. II - OPERATION FOR REMOVAL OF PART
CONCERNED
a Remove the rear suspended engine mounting (see

Lower engine tie-bar: Removal - Refitting) (19D,
Engine mounting).
K7J
a Remove the expansion chamber (see Expansion
chamber: Removal - Refitting) (19B, Exhaust).
133687
a Remove:
- the lower arm ball joint bolts (6) ,
- the lower arm ball joints.
31A-35
133995 134004
a Remove: a Remove:
- the bolts (7) of the steering box bearings, - the subframe bolts (9) ,
- the steering box bearings.
- the sub-frame.
a Strap the steering box to the vehicle body using a
safety strap(s).
III - STRIPPING THE PART CONCERNED
a Remove:
- the subframe tie-rods
- the lower arms from the front driveshaft (see 31A,

Front axle components, Front driveshaft lower
arm: Removal - Refitting, page 31A-28) .
- the anti-roll bar (see 31A, Front axle compo-

nents, Front anti-roll bar: Removal - Refitting,
page 31A-38) .
REFITTING
a Degrease the body surfaces that make contact with

the sub-frame and cross member using SURFACE
CLEANER (see Vehicle: Parts and ingredients
133685 for the repairwork) (04B, Consumables - Pro-
ducts).
a Remove the subframe tie-rod bolt (8) .
a Position a component jack under the sub-frame. a Always replace:
a Strap the sub-frame to the component jack. - the lower ball joint nuts,
- the subframe bolts.
II - REBUILDING THE PART CONCERNED
a Refit:
- the anti-roll bar (see 31A, Front axle compo-

nents, Front anti-roll bar: Removal - Refitting,
page 31A-38) ,
31A-36
- the front driveshaft lower arms (see 31A, Front - the gear selection linkage gaiter.
axle components, Front driveshaft lower arm:
- the sub-frame tie rods.
a Refit:
- the wheel arch liner,
III - REFITTING OPERATION FOR PART
CONCERNED - the front bumper (see Front bumper: Removal -
a Refit the sub-frame using the component jack.
a Remove:
- the subframe strap,
- the component jack.
a Connect the battery (see Battery : Removal - Refit-
a Tighten to torque: ting) .
- the subframe front bolts (62 N.m). a Adjust the front axle (see 30A, General informa-
tion, Front axle: Adjusting, page 30A-28) .
- the subframe rear bolts (105 N.m).
a Refit the lower arm ball joints.
a Torque tighten the lower arm ball joint nuts (62
N.m).
a Remove the safety strap(s) from the steering box.
a Fit the steering box.
a Refit the steering box bearings.
a Torque tighten the steering box bearing bolts (50
N.m).
a Refit the rear suspended engine mounting (see
Lower engine tie-bar: Removal - Refitting) (19D,
Engine mounting).
IV - FINAL OPERATION
a Refit the front bumper diffuser on the subframe.
K7J
a Refit the expansion chamber (see Expansion
chamber: Removal - Refitting) (19B, Exhaust).
D4F
a Refit the bolts of the power-assisted steering pipe
brackets on the subframe.
JB1 or JB3
a Refit:
- the gear selection linkage,
31A-37
Front anti-roll bar: Removal - Refitting 31A
Sus. 1413 Rubber mounting compres-
sor for fitting anti-roll bars.
(wheel side).
Sus. 1414 Fork for installing anti-roll bar

central bearings.
Anti-roll bar specifications:
Bar colour ø of the bar in mm
Green 23
White 23
Orange 24
IMPORTANT
119346
tion recommendations before carrying out any a Compress the anti-roll bar rubber mounting bush on
repair (see 31A, F ront axle components, Front the wheel side using the (Sus. 1413).
axle assemblies: Precautions for repair, page a Remove:
31A-1) .
- the anti-roll bar nut on the wheel side,
REMOVAL - the (Sus. 1413),

- the anti-roll bar rubber mounting bush.
a Remove the front wheels (see 35A, Wheels and ty-
110813
a Remove:
- the bolts of the anti-roll bar bearings using the tool
(Sus. 1414),
31A-38
Front anti-roll bar: Removal - Refitting 31A
- the anti-roll bar bearings,
- the anti-roll bar,
- the anti-roll bar bolt on the wheel side,
- the anti-roll bar rubber mounting bush.
REFITTING

CONCERNED
a Refit the anti-roll bar.
a Fit the anti-roll bar bearings into the subframe neck.
119346
a Refit the anti-roll bar nut on the wheel side.
a Remove the tool (Sus. 1413).
a Refit the front wheels (see 35A, Wheels and tyres,
110813
a Fit the (Sus. 1414) on the anti-roll bar.
a Lift the (Sus. 1414).
a Refit:
- the anti-roll bar rubber mounting bush on the wheel
side,
- the anti-roll bar bolt on the wheel side.
31A-39
REAR AXLE COMPONENTS
Rear axle assemblies: Precautions for repair 33A
I - SAFETY 3 - Suspension spring
For an operation requiring the use of a lift, follow the When replacing the spring, ensure that the positioning
safety advice (see Vehicle: Towing and lifting) (02A, and orientation of the spring and the spring compres-
Lifting equipment). sor tool cups are correct.
Brake fluid is highly corrosive. Ensure any brake fluid Check that the spring compressor tool is operating cor-
spilt on parts of the vehicle is cleaned off. rectly.
II - CLEANLINESS WARNING
To prevent the suspension spring from prematurely
breaking, do not damage the anti-corrosion protec-
tion.
NER (see Vehicle: Parts and ingredients for the re- In the interests of safety, do not leave a spring com-
pairwork) (04B, Consumables - Products). pressed in the spring compressor tool.
4 - Rear axle
WARNING
The shock absorber mountings are only to be tightened
Prepare for the flow of fluid, and protect the sur- with the vehicle wheels on the ground.
Always replace the shock absorber upper mounting
nut.
WARNING
1 - Braking
To prevent any damage, do not use the rear axle as
Replace all the brake pads on one axle at the same ti- support for the lifting system.
me. Never mix brake pads of different brands or quali-
ty.
Lightly coat the threading on the support linkage with WARNING

GREASE BR 2 + (see Vehicle: Parts and ingredients To prevent the components of the rear axle from
for the repairwork) (04B, Consumables - Products). deteriorating (rubber bushes, brake hoses, etc.) do
not remove the two shock absorbers at the same
The brake mechanism components are different on the
time. Proceed one side at a time.
left and right-hand sides, so it is essential not to confu-
se them. On the left-hand brake: the bolt thread has a
right-hand thread. On the right-hand brake: the bolt has
a left-hand thread.
Adjust the brake pads by depressing the brake pedal

repeatedly.
IMPORTANT
To avoid brake imbalance, both drums must be of
the same diameter. Regrinding one drum necessi-
tates regrinding of the opposite drum.
2 - Rear brake drums, rear brake pads
Remove all dust from the drums and the backplates

using brake cleaner.
To ensure the wheel speed sensor operates correctly,
do not mark the sensor target on the drum's magnetic
ring gear.
33A-1
Rear brake lining: Removal - Refitting 33A
CONCERNED
Essential equipment
parts washer
IMPORTANT
Replace all of the brake pads on one axle at the same

time. Never mix brake pads of different brands or qua-
lity.
REMOVAL

118110
a Release the parking brake. a Remove:
a Remove: - the lower return spring (1) using brake shoe pliers,
- the rear wheels (see 35A, Wheels and tyres, - the parking brake cable (2) from the lever.
- the rear brake drums (see 33A, Rear axle compo-
nents, Rear brake drum: Removal - Refitting,
page 33A-7) .
33A-2
a Lightly grease the support linkage thread.
Note:
The brake mechanism components are different
on the left and right-hand sides, so it is essential
not to confuse them.
Note:
On the left-hand brake: the bolt thread has a
right-hand thread.
On the right-hand brake: the bolt has a left-hand
thread.

CONCERNED
a Refit:
- the linkage between the brake shoes,
- the upper return spring,
- the brake shoes,
- the side retainer springs of the brake shoes, kee-

ping the connecting rod in contact with the brake
86560 backing plate,
a Fit pliers (3) onto the slave cylinder pistons.
- the lower return spring using brake shoe pliers.
a Remove:
- the side retainer springs (4) of the brake shoes,
keeping the connecting rod (5) in contact with the
brake backing plate (6) ,
- the brake shoes (7) ,
- the upper return spring,
- the linkage (8) .
REFITTING

a Remove any dust from the drums and flanges using
a parts washer.
116013
a Check that the parking brake cable is correctly posi-

tioned on the parking brake lever.
a Remove the pliers from the slave cylinder pistons.
33A-3
86557
a Use a screwdriver to adjust the brake shoe diameter
with the linkage to obtain a diameter of 202 mm.
a Carry out the same adjustment on the other side.
a Adjust the handbrake if the lever stops between the
first and second positions of the parking brake le-
ver's travel (see 37A, Mechanical component con-
trols, Parking brake lever: Adjusting, page 37A-
19) .

a Refit:
- the rear brake drums (see 33A, Rear axle compo-
page 33A-7) ,
- the rear wheels (see 35A, Wheels and tyres,
a Adjust the brake pads by depressing the brake pedal
repeatedly.
a Check that the automatic wear take-up system is
operating correctly (clicking noise from the drums
when the brake pedal is repeatedly depressed).
33A-4
Rear brake cylinder: Removal - Refitting 33A
CONCERNED
Essential equipment
pedal press
parts washer
Tightening torquesm
rear brake cylinder bolt 15 N.m

on the flange
rigid brake pipe union 13 N.m

on the rear brake cylin-
der
IMPORTANT
133621
a Undo the rigid brake pipe union (1) on the rear brake
cylinder.
WARNING
a Fit a cap on the rigid brake pipe union.
rounding components. a Remove:
- the bolts (2) of the rear brake cylinder on the flan-

REMOVAL ge,
- the rear brake cylinder.

a Position the vehicle on a two-post lift (see Vehicle: REFITTING
a Release the parking brake.
a Remove:
a Remove any dust from the drums and flanges using
- the rear wheel (see 35A, Wheels and tyres, a parts washer.
a Check the condition of the brake cylinder boots and
- the rear brake drum (see 33A, Rear axle compo- pistons (replace any faulty parts).
page 33A-7) ,
- the rear brake pads (see 33A, Rear axle compo- CONCERNED
nents, Rear brake lining: Removal - Refitting,
page 33A-2) . a Refit:
a Fit a pedal press. - the rear brake cylinder,
- the rigid brake pipe union on the rear brake cylin-

der.
- the rear brake cylinder bolt on the flange (15
N.m),
33A-5
Rear brake cylinder: Removal - Refitting 33A
- the rigid brake pipe union on the rear brake cy-
linder (13 N.m).

a Refit:
- the rear brake pads (see 33A, Rear axle compo-
page 33A-2) ,
- the rear brake drum (see 33A, Rear axle compo-
page 33A-7) ,
a Adjust the brake pads by depressing the brake pedal
repeatedly.
33A-6
Rear brake drum: Removal - Refitting 33A
CONCERNED
Essential equipment
parts washer
Tightening torquesm
brake drum nut 175 N.m
IMPORTANT
When replacing a brake drum, it is essential to replace

the drum on the opposite side.
When replacing the brake drums, it is essential to re-
place the brake linings.
109709
IMPORTANT a Remove the cap (1) from the brake drum.
To avoid brake imbalance, both drums must be of
the same diameter. Regrinding one drum necessi-
tates regrinding of the opposite drum.
REMOVAL

a Remove the rear wheel (see 35A, Wheels and ty-
109710
a Remove:
- the brake drum nut (2) ,
- the brake drum (3) .
33A-7
Rear brake drum: Removal - Refitting 33A
REFITTING

a Check the internal diameter of the drum (see 33A,
Rear axle components, Rear brake drum: Des-
cription, page 33A-9) .
a Using a parts washer, clean:
- the brake drum linings,
- the drum,
- the stub axle.
Note:
Do not apply grease to the following compo-
nents:
- drum,
- stub axle,
- nut, cap.
a Always replace:
- the brake drum nut,
- the brake drum cap.

CONCERNED
a Refit the brake drum.
a Torque tighten the brake drum nut (175 N.m).
a Refit the brake drum cap.

a Refit the rear wheel (see 35A, Wheels and tyres,
33A-8
Rear brake drum: Description 33A
Essential equipment Replace the rear drums if necessary (see 33A, Rear
axle components, Rear brake drum: Removal - Re-
sliding calliper fitting, page 33A-7) .
Refit the rear wheel (see 35A, Wheels and tyres,
I - PREPARATION OPERATION FOR CHECK Wheel: Removal - Refitting, page 35A-1) .
Position the vehicle on a two-post lift (see Vehicle:

Remove:
- the rear wheel (see 35A, Wheels and tyres, Wheel:

nents, Rear brake drum: Removal - Refitting, page
33A-7) .
II - CHECKING OPERATION FOR PART

CONCERNED
Note:
To check the internal diameter of the drum, use a
sliding calliper type tool for drums.
116995
Position the sliding calliper to measure the internal

diameters of the brake drum.
Measure the interior diameters of the brake drum on

the perpendicular axes (1) and (2) .
Compare the values with those recommended by the
manufacturer (see 30A, General information, Brake:
Specifications, page 30A-17) .
33A-9
Rear suspension spring: Removal - Refitting 33A
CONCERNED
Essential equipment
component jack
Tightening torquesm

bolt
IMPORTANT
repair (see Rear axle components: Removal -
Refitting) .
WARNING
To prevent the components of the rear axle from 133616
deteriorating (rubber bushes, brake hoses, etc.) do a Fit a component jack under the lower suspension
not remove the two shock absorbers at the same spring cup.
time. Proceed one side at a time.
a Mark the position where the springs are fitted.
a Remove the lower bolt (1) from the shock absorber.
REMOVAL

a Remove the rear wheels (see 35A, Wheels and ty-
108924
a Remove the spring (2) with its lower mounting by re-
moving the component jack.
33A-10
Rear suspension spring: Removal - Refitting 33A
REFITTING

a Always replace the shock absorber lower bolts.

CONCERNED
a Refit:
- the lower mounting on the rear axle (positioning the
guide correctly),
- the spring with its upper support in their housing as
marked.
a Put the component jack under the shock absorber
cup.
a Compress the rear axle so that the shock absorber
lower bolt can be tightened.
a Torque tighten the shock absorber lower bolt (105
N.m).

a Remove the component jack.
a Refit the rear wheels (see 35A, Wheels and tyres,
33A-11
Rear drum bearing: Removal - Refitting 33A
REFITTING
IMPORTANT
the safety and cleanliness instructions and opera- a Use SURFACE CLEANER (see Vehicle: Parts
tion recommendations before carrying out any and ingredients for the repairwork) (04B, Consu-
repair (see 33A, Rear axle components, Rear mables - Products) to clean:
33A-1) . - the internal and external surfaces of the new bea-
ring in contact with the drum and the stub axle,
- the drum surfaces in contact with the bearing,
REMOVAL
- the stub-axle surfaces in contact with the bearing.
a Always check the surface condition of the following
components:
- bore of the drum in contact with the bearing,
- the stub axle.
a Remove:
a Replace all faulty components.
- the rear wheel (see 35A, Wheels and tyres,
page 33A-7) .

CONCERNED
121332
a
Note:
Take care not to press the ABS target (3) when
refitting the bearing.
121333 II - REFITTING OPERATION FOR PART

CONCERNED
a From the drum, remove:
a
- the rubber ring (1) from the rear drum bearing,
WARNING
- the bearing from the rear drum using a tube with a
diameter between 34 mm and 47 mm and using a Do not press the bearing's internal bush so as to
hydraulic press, using the bearing internal bush (2) avoid damaging the bearing (very high shrink-fit-
for support. ting force).
33A-12
Rear drum bearing: Removal - Refitting 33A
a Fit the bearing until it rests on the shoulder using a
tube with a diameter between 37 mm and 51 mm
and using a hydraulic press.
a Refit the rubber ring.

a Refit:
page 33A-7) ,
33A-13
Rear stub-axle carrier: Removal - Refitting 33A
Essential equipment
component jack
Tightening torquesm
new bolts of the rear 53 N.m

stub axle carrier
new lower bolt of the 105 N.m

rear shock absorber
WARNING
To avoid damaging the parking brake cable protec-
tors and causing premature wear of the system, do
not handle the cables with a tool.
133616
IMPORTANT a Fit a component jack.

Consult the safety and cleanliness advice and ope- a Remove the lower bolt (1) from the rear shock ab-
ration recommendations before carrying out any sorber.
repair (see 33A, Rear axle components, Rear
axle assemblies: Precautions for repair, page a Move aside the rear shock absorber.
33A-1) .

REMOVAL CONCERNED

a Remove:
page 33A-7) ,
page 33A-2) ,
133619
a Remove:
- the boltsof the rear stub axle carrier,
- the rear stub axle carrier.
33A-14
Rear stub-axle carrier: Removal - Refitting 33A
REFITTING

a Clean the stub axle carrier using SURFACE CLEA-
NER.
a Always replace:
- the stub axle carrier bolts,
- the stub-axle nut,
- the shock absorber lower bolt.

CONCERNED
a Refit the rear stub axle carrier.
a Torque tighten the new bolts of the rear stub axle
carrier (53 N.m).

a Refit the rear shock absorber.
a Torque tighten the new lower bolt of the rear
shock absorber (105 N.m).
a Remove the component jack.
a Refit:
page 33A-2) ,
page 33A-7) ,
33A-15
Rear axle rubber bearing: Removal - Refitting 33A
Tav. 1420-01 Screw jack for tools Tav.

1420, Tav.1050-04 , Tar.
1454, Tar. 1850.
Tar. 1454 Rear axle rubber bush repla-

cement tool.
IMPORTANT
33A-1) .
REMOVAL
135768
a Measure the dimension (X) between the rubber
a Position the vehicle on a two-post lift (see Vehicle: bush and the rear axle.
Towing and lifting) (02A, Lifting equipment). a Mark the position of the rubber bush on the rear
a Remove the rear axle (see 33A, Rear axle compo- axle.
nents, Complete rear axle: Removal - Refitting,
page 33A-19) .

CONCERNED
135769
a Remove:
- the rear axle bearing nut (1) ,
- the rear axle bearing.
33A-16
a Lower the jack rod using the handle.
Note:
When the jack rod reaches end of travel, loosen
the handle, then repeat the two previous steps.
a Remove:
- the rubber bush,
- the (Tar. 1454).
REFITTING

a Always replace the nut of the rear axle bearing.

CONCERNED
14556
a Fit the rubber bush on the rear axle, aligning the
marks.
135767
a Assemble the jack's support (2) of the tool (Tav.

1420-01).
a Fit the tool's (Tar. 1454) components in the following
order:
- the jack (Tav. 1420-01) (1) on its support (2) ,

- the spacer (3) on the rear axle,
- the cup (5) of the tool (Tar. 1454),

- the cup (6) of the tool,
- the support (2) with the jack (1) .

a Put the jack rod in contact with the cup.
33A-17
135767
a Refit the jack on its support as far as possible.
a Fit the components of the tool (Tav. 1420-01) in the

following order:
- the jack (Tav. 1420-01) on its support,
- the spacer on the rear axle,
- the cup of the tool (Tar. 1454),
- the cup of the tool,
- the support with the jack.
a Put the jack rod in contact with the cup.
a Lower the jack rod using the handle while checking

the dimension (X) between the axle and the rubber
bush.
Note:
When the jack's rod reaches end of travel, loosen
the handle, then repeat the two previous steps.
a Remove the tool (Tar. 1454).
a Refit the rear axle (see 33A, Rear axle compo-

nents, Complete rear axle: Removal - Refitting,
page 33A-19) .
a Check the geometry of the axle assemblies (see

30A, General information, Axle assemblies:
Check, page 30A-20) .
33A-18
Complete rear axle: Removal - Refitting 33A
Essential equipment
pedal press
component jack
safety strap(s)
Tightening torquesm
stub axle carrier bolts 53 N.m
wheel speed sensor bolt 6.5 N.m
rear axle nuts 62 N.m
brake pipe unions on 13 N.m

the wheel cylinders
brake pipe unions on 13 N.m

the brake hoses
new lower bolts of the 105 N.m 134012

shock absorber
a Remove:
- the heat shield bolts (1) ,

IMPORTANT
- the heat shield.
33A-1) .
WARNING
WARNING
REMOVAL
121334
I - REMOVAL PREPARATION OPERATION a Loosen the nut (2) of the compensator of the parking
brake cables.
Towing and lifting) (02A, Lifting equipment). a Remove the parking brake cables from the compen-
sator.
a Position a pedal press on the brake pedal to limit
the outflow of brake fluid. a Unclip the parking brake cables from the fuel tank.
33A-19
NO ANTI-LOCK BRAKES ANTI-LOCK BRAKES
108926 134085
a Unclip the brake compensator rod (3) from the rear a Disconnect the connectors (5) from the wheel speed
axle. sensors.
a Undo the rigid brake pipe unions (4) from the brake
hoses.
33A-20
CONCERNED
ANTI-LOCK BRAKES
133616
133621
a Fit a component jack.
a Undo the brake pipe unions (6) on the brake cylin-
ders. a Remove the shock absorber lower bolts (7) .
a Unclip the brake pipes from the rear axle. a Lower the component jack.
a Remove the suspension springs.
108923
a Attach the rear axle to the component jack using a
safety strap(s).
a Remove:
- the rear axle nuts (8) ,
- the rear axle.
33A-21
III - DISMANTLING
ANTI-LOCK BRAKES
135521
a Remove:
- the brake pipe clips,

134084
a Remove: - the bolts (10) of the stub axle carriers,
- the clips of the wiring for the wheel speed sensors, - the "stub axle carrier - brake drum" assemblies.
- the bolts (9) of the wheel speed sensors,
- the wheel speed sensor. REFITTING
a Always replace:
- the bolts of the shock absorbers on the rear axle,
- the bolts of the stub axle carriers.
WARNING

ding components.
II - REFITTING
a Refit:
- the "stub axle carrier - brake drum" assemblies,
- the brake pipe clips.

a Torque tighten the stub axle carrier bolts (53 N.m).
33A-22
ANTI-LOCK BRAKES a Clip the parking brake cables onto the fuel tank.
a Refit: a Refit the parking brake cables to the fuel tank.

a Adjust the parking brake cables (see 37A, Mechani-
- the clips of the wiring for the wheel speed sensors,
cal component controls, Parking brake lever:
- the wheel speed sensors. Adjusting, page 37A-19) .
a Torque tighten the wheel speed sensor bolt (6.5 a Refit the rear wheels (see 35A, Wheels and tyres,
N.m). Wheel: Removal - Refitting, page 35A-1) .
20) .
CONCERNED
a Refit the rear axle on a component jack.
a Attach the rear axle to the component jack using a
safety strap(s).
a Refit the rear axle onto the vehicle.
Note:
These operations require two people.
a Torque tighten the rear axle nuts (62 N.m).
ANTI-LOCK BRAKES
a Connect the wheel speed sensor connectors.

a Refit the brake pipes on the wheel cylinders.
a Torque tighten the brake pipe unions on the wheel
cylinders (13 N.m).
NO ANTI-LOCK BRAKES
a Clip the brake compensator rod to the rear axle.
a Refit the brake pipes on the brake hoses.
a Torque tighten the brake pipe unions on the brake
hoses (13 N.m).
a Refit:
- the suspension springs,
- the shock absorbers.
a Torque tighten the new lower bolts of the shock
absorber (105 N.m).
33A-23
WHEELS AND TYRES
Wheel: Removal - Refitting 35A
Tightening torquesm
wheel bolts 105 N.m
The removal - refitting procedure is the same for alloy

and steel wheels.
REMOVAL

a Remove the trim.

a Position the wheel so that the valve is at the top.
a Mark the position of the wheel on the hub. 113180
a Strike around the edge of the tyre walls (1) several
times using a mallet on the inner and outer surfaces
Note: of the wheel to detach the wheel.
This mark is necessary for: a Remove:
- marking the initial position of the wheel rim on - the wheel bolts,
the hub,
- the wheel.
- perform the balancing operation.

CONCERNED
a Loosen the wheel bolts with the wheel on the

ground.
Note:
Use sockets with protective sheaths in order to
avoid scratching the alloy wheel rims.
a Raise the lift.

a Remove:
- the wheel bolts,
- the wheel.
If the wheel cannot be removed after the bolt has

been undone:
a Position all the wheel bolts.

a Tighten the wheel bolts to bring all the bolt heads
into contact with the wheel.
a Undo the wheel bolts by one turn.
35A-1
WHEELS AND TYRES
If this procedure does not work:
132525
132526 a Coat the wheel-mating face (3) with COPPER ANTI-
a Strike the inner surface of the wheel (2) using a mal- SEIZE AGENT (see Vehicle: Parts and consuma-
let and a wooden block to detach it. bles for repair) (04B, Consumables - Products).
a Align the mark on the wheel with the mark made on
the hub when it was removed.
Note:
a Fit the wheel to the vehicle, positioning the valve at
Do not strike the surface of the wheel using the top.
excessive force as this may damage it.
a Insert the wheel bolts.
a Remove:
- the wheel bolts,
- the wheel.
REFITTING
a Clean the hub carrier using a wire brush.
Note:
There are two types of wheel bolts for aluminium
and steel wheel rims; do not swap them.
a Check the condition of the tyre.
a Do not move or remove the balance weights.

113180
II - REFITTING OPERATION FOR PART a Tighten the wheel bolts to bring all the bolt heads
CONCERNED into contact with the wheel.
a Clean the "wheel - hub carrier" contact surfaces a Pre-tighten the wheel bolts to 30 Nm, with the wheel
using a wire brush. hanging, starting with the bottom bolts.
35A-2
WHEELS AND TYRES
a Rotate the wheel through 180˚ to bring the valve into
the bottom position.
a Position the vehicle on its wheels.
a Torque tighten in order the wheel bolts (105 N.m).
a Refit the trim piece.
35A-3
WHEELS AND TYRES
Wheel: Balancing 35A
I - PREREQUISITES FOR WHEEL BALANCING
a Wheel balancing is a measurement operation.
Several conditions must be met to achieve a reliable
result in a single operation.
The wheel balancer must be installed in accordance
with the manufacturer's instructions.
It is essential to calibrate the balancer according to
the frequency recommended by the manufacturer.
Do not grease the threaded shaft.
Check the condition of the supports, centring com-
ponents and mountings.
Replace any faulty parts (see manufacturer's ins-
tructions).
The wheel and the wheel balancer must be clean.
Driver's perception
a If the wheels are not correctly balanced this causes 105870
the steering wheel and/or the vehicle floor to vibrate. a
These vibrations appear between 54 mph (90 km/h)
Note:
and 90 mph (150 km/h).
The ring is available from the supplier of the
equipment used.
II - BALANCING PREPARATION OPERATION
a Adjust the tyre pressure (see 35A, Wheels and ty- To reproduce the exact vehicle wheel assembly, use
res, Tyre inflation pressure: Identification, page a ring (1) of diameter:
35A-14) . a 60 mm
a Always carry out a road test for a minimum distance a There are three types of weight:
of 1 mile (2 km) before balancing the wheels, in or-
der to remove any flat spots on the tread caused by
the vehicle being immobilised.
a Actions to be carried out immediately after the test
drive:
- Position the vehicle on a two-post vehicle lift (see
Vehicle: Towing and lifting) ,
- raise the vehicle,
- leave the four wheels hanging free,
- release the parking brake.
35A-4
WHEELS AND TYRES
113742 105871
a The wheel is fitted on the wheel balancer as follows:
(2) Steel wheel with flange
- (5) ring,
(3) Alloy wheel with flange
(4) Alloy wheel without flange - (6) wheel balancer back-plate,
- (7) wheel tightening device (certain alloy wheels
a In some countries, the use of lead weights is forbid-
require a device 200 mm in diameter to ensure that
den; in this case it is recommended to use ZAMAK
the wheel has been correctly tightened),
weights instead.
- (8) outer wheel plane,
Only use weights provided by the Parts Department.
a Remove the wheels (see 35A, Wheels and tyres, - (9) wheel.
a Always clean the wheel, disc, and hub bearing surfa-
ces.
III - PROCEDURE FOR BALANCING THE WHEEL IN

QUESTION
a Make sure that the wheel balancer bearing surface
and all the centring equipment (ring, thrust plate,
etc.) are kept clean.
a Try not to scratch the (alloy) wheel rim with the
wheel tightening device.
100681
a Place the wheel on the wheel balancer, with the val-
ve at the top, then lock the wheel in place.
a Remove any stones trapped in the tyre tread.
35A-5
WHEELS AND TYRES
a Enter the specific wheel parameters when starting
the wheel balancer.
a Start the wheel balancer and check the wheel balan-
ce, which should be 0 g on each plane of the wheel.
a If this is not the case, remove the old wheel balan-
cing weights and repeat the wheel balancing proce-
dure, checking that the wheel balance equals 0 on
each wheel plane.
WARNING
To avoid detachment of the balance weights, use
only weights which correspond to the vehicle
wheel rims.
a Refit the wheel (see 3 5 A, Wheels and tyres,
35A-6
WHEELS AND TYRES
pneumatic: Precautions for repair 35A
I - CLEANLINESS
Clean:
- the tyre bead,
- the tyre bead/wheel rim contact surface.
Remove any grit trapped in the tyre treads.
Clean the bearing surfaces on:
- the wheels,
- the discs,
- the hubs.
II - GENERAL RECOMMENDATIONS
WARNING
If checking the pressure when hot, increase the tyre
inflation pressure by 0.2 to 0.3 bar above the
recommended pressure.
WARNING
In order to remove any flat spots on the tread after
the vehicle has stopped, it is essential to carry out a
road test for a minimum distance of 1 mile (2 km)
before balancing the wheels.
WARNING
To avoid detachment of the balance weights, use
only weights which correspond to the vehicle wheel
rims
35A-7
WHEELS AND TYRES
Tyres: Identification 35A
Example of a tyre identification mark: 205/65 R 15 91 Speed code table:
V.
Code Maximum
speed in
mph (km/h)
R 170
S 180
T 190
U 200
H 210
V 240
ZR above 240
W 270
Y 300
101008
123448
205 Tyre width in mm (L)
65 Height/width ratio
R Radial structure
15 Internal diameter in inches (c)
91 Load index
V Speed code
35A-8
WHEELS AND TYRES
Tyres: Removal - Refitting 35A
REMOVAL

a Remove the wheel in question (see 35A, Wheels
and tyres, Wheel: Removal - Refitting, page 35A-
1) .
a Remove the balance weights.

CONCERNED
18885
a Position the tyre lever approximately 15 cm from the
valve on the outside of the wheel rim.
a Remove the exterior bead of the tyre, finishing at the
valve.
a Position the tyre lever approximately 15 cm from the
valve on the outside of the wheel rim in order to re-
move the bead from inside the tyre.
a Remove the interior bead of the tyre, finishing at the
valve.
REFITTING
18884
a Lift off the bead from the outside of the tyre, starting I - REFITTING PREPARATION OPERATION
with the side opposite the valve.
a Correctly lubricate the two tyre beads using the tyre
a Detach the bead from the inside of the tyre.
paste.

CONCERNED
a Engage the lower tyre bead approximately 15 cm af-
ter the valve.
a Finish fitting the tyre at the valve.
a Fit the exterior bead approximately 15 cm after the
valve using the tyre lever.
a Inflate the tyre to 3.5 bar to press the tyre beads
against the wheel rim.

a Balance the wheel (see 35A, Wheels and tyres,
Wheel: Balancing, page 35A-4) .
35A-9
WHEELS AND TYRES
Tyres: Removal - Refitting 35A
35A-10
WHEELS AND TYRES
Tyres: Repair 35A
Perforation
LCV load index less 6 3
There are two types of perforation: than or equal to
- single perforation: perforation caused by nail etc. not 121
requiring a reinforced tyre boot and which can be re-
HGV load index 10 3
paired when the tyres are cold,
122 to 177 (inc.)
- damage: rubber detachment etc. requiring repair and
reinforcement of damaged plies. LV: Light Vehicle
LCV: Light Commercial Vehicle
This repair method only covers single perforations.
HGV: Heavy Goods Vehicle
Tyre areas
* If the diameter of the puncture is greater than these fi-
gures, replace the tyre.
The tyre cannot be repaired if:
- a compulsory marking has been worn away (see 35A,
Wheels and tyres, Tyres: Identification, page 35A-
8) ,
- the interior of the tyre shows signs of under-inflation
or overloading,
- the rubber shows signs of chemical damage (hydro-
carbons and other corrosive substances),
- incorrect and irreversible repairs have previously
been made to the tyre,
- the carcass has been damaged,
- cuts or circumferential wear (cracks) are visible on the
interior or exterior of the tyre,
- the tyre bead has been damaged (ply visible),
123449
- the tyre's bead wires are visible, damaged or defor-
med,
Areas which cannot be repaired:
- the tyre shows an irregular wear pattern which may
- tyre bead (1) , impair vehicle handling,
- shoulder (3) . - the repair requires two tyre boots to be overlapped,
Areas which can be repaired: - the manufacturer has expressly prohibited any re-
- sidewall (2) , pairs, in writing,
- crown (4) . - there is damage to the shoulder area (junction

between the sidewall and the crown),
Perforation table *
- the angle of the perforation channel (hole) is greater
than 15˚.
Area
Crown: max Sidewall:

Ø in mm max Ø in
mm
LV speed rating 6 3
less than or equal
to T
LV speed rating 6 0
greater than or
equal to H
35A-11
WHEELS AND TYRES
Tyres: Repair 35A
119741
Tyre inflation kit
using the tyre inflation kit, supplied with vehicles or

available from retailers, will leave a film on the inner
surface of the tyre.
119740
Before carrying out the repair, clean the inner surface a Choose the size of plug (mushroom type plug) de-
of the tyre and the valve with water. pending on the size of the hole.
If the tyre cannot be cleaned in this way, contact the

tyre supplier for details of cleaning products which can II - REPAIR OPERATION
be used.
REPAIR
I - REPAIR PREPARATION OPERATION

a Remove the wheel (see 35A, Wheels and tyres,

a Inflate the tyre.
a Locate the perforation on the exterior of the tyre and 119742

mark it with chalk. a Use a drill fitted with a suitable bit, perpendicular to
the surface of the tyre, to bore the interior then the
a Remove the tyre. exterior of the perforation channel.
a Locate the perforation on the interior of the tyre and
mark it with chalk.
a Remove the foreign body which caused the punctu-

re.
a Determine the direction of the perforation channel.
a Determine the size of the hole:
- measure the size of the foreign body,
- measure the extent of the damage to the tyre.
35A-12
WHEELS AND TYRES
Tyres: Repair 35A
119743 119746
a Carefully scrape the rubber seal around the perfora- a Fit the (mushroom type) plug via the interior of the
tion, to the size of the base of the plug (mushroom tyre by pulling on it using pliers.
type plug).
a Press gently on the base of the mushroom plug, in-
side the tyre.
Note: a Refit the tyre.
If the rubber seal is damaged during this opera- a Inflate the tyre (see 35A, Wheels and tyres, Tyre
tion, replace the tyre. inflation pressure: Identification, page 35A-14) .
a Remove any dust and remaining particles of rubber
using a clean, dry cloth.
119747
a Cut the protruding end of the stalk without pulling on
119744 it.
a Apply the solution to the scraped surface. a Check the tyre seal.
Note: III - FINAL OPERATION.
Respect the required drying time for the solution. a Balance the wheel (see 35A, Wheels and tyres,
Wheel: Balancing, page 35A-4) .
a Refit the wheel (see 35A, Wheels and tyres,
35A-13
WHEELS AND TYRES
Tyre inflation pressure: Identification 35A
WARNING
If checking the pressure when hot, increase the tyre
inflation pressure by 0.2 to 0.3 bar above the
recommended pressure.
Tyre inflation pressure when cold (bar)
Engine Tyre Front Rear

Emergency
spare wheel
Normal Motorway Normal Motorway
175/65 R 14 1.9 2.0 1.8 2.0 2.0

82T
D4F
185/55 R 15 1.9 2.0 1.8 2.0 2.0
82H
175/65 R 14 1.9 2.0 1.8 2.0 2.0

82T
K7J
185/55 R 15 1.9 2.0 1.8 2.0 2.0
82H
175/65 R 14 2.2 2.3 2.0 2.1 2.3

82T
K4J
185/55 R 15 2.2 2.3 2.0 2.1 2.3
82H
175/65 R 14 2.2 2.3 2.0 2.1 2.3

82T
K4M
185/55 R 15 2.2 2.3 2.0 2.1 2.3
82H
175/65 R 14 2.2 2.3 2.0 2.1 2.3

82T
K9K
185/55 R 15 2.2 2.3 2.0 2.1 2.3
82H
Wheel offset:
- 14-inch alloy wheel rim: 36 mm,
- 15-inch alloy wheel rim: 43 mm,
- steel wheel rim: 36 mm.
35A-14
WHEELS AND TYRES
Wheel rim: Identification 35A
IDENTIFICATION 2 - Installation diameter for the wheel bolts
1 - Marking
The wheel bolts are positioned with a pitch circle dia-
There are two types of identification marking on the meter of:
wheel rims:
- 5 holes: 108 mm,
- engraved marking for steel wheel rims, - 4 holes: 100 mm.
- cast marking for alloy wheel rims.
The marking gives the main dimensional specifications 3 - Rim run-out
of the wheel rim. The maximum run-out is measured at the wheel rim
This marking may be: edge (7) .
- complete, for example 6 J 15 5 CH 36, Steel wheel rims: 0.8 mm
- simplified, for example 6 J 15. Alloy wheel rims: 0.3 mm
4 - Out-of-roundness
Wheel type 6 J 15
The maximum out-of-round value is measured on the
1 Width (in inches) 6 tyre bead bearing surface.
2 Rim edge profile J Steel wheel rims: 0.7 mm

Alloy wheel rims: 0.3 mm
3 Nominal diameter (in inches) 15
4 Number of holes 5
5 Anchorage profile of the tyre CH
6 Offset (in mm) 36
100988
There are 3 types of wheel rim edges (2) :
- those with two flat edges,
- those with two raised edges,
- those with one flat edge and one raised edge.
35A-15
STEERING ASSEMBLY
Steering: Precautions for repair 36A
I - SAFETY 3 - Axial ball joint

For an operation requiring the use of a lift, follow the
safety advice (see Vehicle: Towing and lifting) (02A,
Lifting equipment).
2 - Instruction to be followed during the operation
IMPORTANT
Wear protective gloves during the operation.
II - GENERAL RECOMMENDATIONS
101355
To ensure correct operation and performance of the The axial ball joint limiters (1) are colour coded for fool-
system, do not attempt to repair any components other proofing purposes. When removing or replacing the
than those supplied in After-Sales. axial ball joint, check that the limiter with the correct co-
To ensure the quality of the repair, only use the tooling lour code is refitted.
recommended by the manufacturer.
4 - Electrical wiring
1 - Steering column Ensure that the electrical wiring is clean and correctly
routed.
WARNING
5 - Brake hose
In order not to damage the steering wheel or stee-
ring column, the steering wheel-column foolproofing
devices must be aligned.
WARNING
Manoeuvre the « steering column - intermediate
shaft » assembly by holding each section (one hand on In order not to damage the brake hose:
the column and the other on the intermediate shaft). If - do not tension the hose,
the steering column is not handled correctly, there is a
risk that the steering column or intermediate shaft - do not twist the hose,
could fall, which could destroy the system. - check that there is no contact with the surrounding
Do not rest the steering column on the adjustment han- components.
dle.
2 - Steering box
The steering box should not be carried by the gaiters,
as this may damage them.
36A-1
STEERING ASSEMBLY
Steering: Precautions for repair 36A
126339
To avoid the premature damage of the brake hose by
friction, observe the following procedure before unclip-
ping the hose:
- mark the position of the cap (1) on the base of the
shock absorber using a permanent marker pen,
- Unclip the cap (1) from the base of the shock absor-
ber.
Observe the following procedure before clipping the
brake hose back on:
- clip the cap (1) back on to the base of the shock ab-
sorber by aligning the marks made using the perma-
nent marker pen.
36A-2
STEERING ASSEMBLY
Steering rack: Removal - Refitting 36A
D4F
Tightening torquesm
track rod end nuts 37 N.m
universal joint nut 21 N.m
bolts of the steering box 50 N.m

bearings
IMPORTANT
repair (see 36A, Steering assembly, Steering:
Precautions for repair, page 36A-1) .
REMOVAL 133994
a Remove the bolts (1) from the power-assisted stee-

I - REMOVAL PREPARATION OPERATION ring pipes on the subframe.

a Remove:
- the front wheels (see 35A, Wheels and tyres, II - OPERATION FOR REMOVAL OF PART
Wheel: Removal - Refitting, page 35A-1) , CONCERNED
- the lower engine tie-bar (see Lower engine tie-
bar: Removal - Refitting) (19D, Engine moun-
ting).
125719
a Undo the power-assisted steering pipe unions (2) on

the steering box.
36A-3
STEERING ASSEMBLY
133993 134002
a Remove the bulkhead seal (3) . a Remove the track rod end nuts (5) .
133767 112619
a Remove: a Extract the ball joint using (Tav. 476).
- the universal joint nut (4) ,
- the universal joint shaft.
36A-4
STEERING ASSEMBLY
D4F
a Refit the power-assisted steering pipes on the sub-
frame.
a Refit:
- the lower engine tie-bar (see Lower engine tie-
bar: Removal - Refitting) (19D, Engine moun-
ting),
133995
a Remove: Wheel: Removal - Refitting, page 35A-1) .
- the bolts (6) of the steering box bearings,
- the steering box bearings.
a Tilt the engine forward.
a Remove the steering box.
REFITTING
a Always replace:
- the track rod end nuts,
- the universal joint nut and bolt.

CONCERNED
a Tilt the engine forward.
a Refit:
- the steering box,
- the steering box bearings,
- the track rod ball joints,
- the track rod end nuts (37 N.m),
- the universal joint nut (21 N.m),
- the bolts of the steering box bearings (50 N.m).
a Connect the power-assisted steering pipes.
36A-5
STEERING ASSEMBLY
Track rod: Removal - Refitting 36A
Tightening torquesm
track rod ball joint nut 37 N.m
wheel alignment adjus- 53 N.m

ting lock nut
IMPORTANT
REMOVAL
I - REMOVAL PREPARATION OPERATION 122722
a Position the vehicle on a two-post lift (see Vehicle: a Loosen the wheel alignment adjustment lock nut (1)
Towing and lifting) (02A, Lifting equipment). .
res, Wheel: Removal - Refitting, page 35A-1) . a Remove the track rod ball joint nut (2) .
122713
a Extract the ball joint using (3) (Tav. 476).
a Unscrew the track rod anti-clockwise and note the

number of turns for refitting.
a Remove the track rod.
36A-6
STEERING ASSEMBLY
Track rod: Removal - Refitting 36A
REFITTING

CONCERNED
a Screw the track rod back in place by the number of
turns noted during removal.
a Fit the track rod end in the hub carrier.
a Refit the track rod ball joint nut.
- the track rod ball joint nut (37 N.m),
- the wheel alignment adjusting lock nut (53
N.m).
a Check the axle geometry (see 30A, General infor-
mation, Axle assemblies: Check, page 30A-20) .
a If necessary, adjust the geometry of the axle assem-
blies (see 30A, General information, Front axle:
Adjusting, page 30A-28) .
36A-7
STEERING ASSEMBLY
Axial ball joint linkage: Removal - Refitting 36A
2 - Right-hand axial ball joint linkage
Dir. 1306-01 Tool for locking steering rack

(TRW).
Dir. 1305-01 Tool for removing/refitting 35

mm to 41 mm diameter axial
ball joints.
Tightening torquesm
axial ball joint 79 N.m
IMPORTANT
133997
a Cut the clip (1) on the gaiter of the left-hand steering

REMOVAL box.
a Move the left-hand steering gaiter to one side.
a Remove the gaiter from the right-hand steering box
(see 36A, Steering assembly, Steering rack gai-
ter: Removal - Refitting, page 36A-13) .
a Remove:
- the front wheels (see 35A, Wheels and tyres, II - OPERATION FOR REMOVAL OF PART
Wheel: Removal - Refitting, page 35A-1) , CONCERNED
- the track rod (see 36A, Steering assembly, Track a Lock the wheels to disengage the rack teeth on the
rod: Removal - Refitting, page 36A-6) . rotary valve side.
a Set up the (Dir. 1306-01) on the steering rack, at the
1 - Left-hand axial ball joint linkage pinion end.
a Remove the gaiter from the left-hand steering box
(see 36A, Steering assembly, Steering rack gai-
ter: Removal - Refitting, page 36A-13) .
102206
a Fit the (Dir. 1305-01).

a Unlock the axial ball joint using tool (Dir. 1305-01).
36A-8
STEERING ASSEMBLY
Axial ball joint linkage: Removal - Refitting 36A
a Remove the axial ball joint. 3 - Right-hand and/or left-hand axial ball joint
linkage
REFITTING a Refit:
- the track rod (see 36A, Steering assembly, Track
I - REFITTING PREPARATION OPERATION rod: Removal - Refitting, page 36A-6) ,
a Always replace the following after each removal
operation:
- the washer of the axial ball joint,
mation, Axle assemblies: Check, page 30A-20) .
- the steering box gaiter, a If necessary, adjust the geometry of the axle assem-
- the steering box clips. blies (see 30A, General information, Front axle:

CONCERNED
109875
a Refit:
- a new washer (2) ,
- the axial ball joint (3) .
a Torque tighten the axial ball joint (79 N.m) using
the tool (Dir. 1305-01).
1 - Right-hand axial ball joint linkage

a Refit the right-hand side steering box gaiter (see
36A, Steering assembly, Steering rack gaiter:
a Fit the left-hand steering box gaiter.
a Refit a new clip on the left-hand steering box gaiter.
2 - Left-hand axial ball joint linkage

a Refit the left-hand steering box gaiter (see 36A,
Steering assembly, Steering rack gaiter: Remo-
val - Refitting, page 36A-13) .
36A-9
STEERING ASSEMBLY
Steering column: Removal - Refitting 36A
CONCERNED
Essential equipment
diagnostic tool
Tightening torquesm
universal joint nut 24 N.m
IMPORTANT
REMOVAL

133767
Towing and lifting) (02A, Lifting equipment). a Remove the bulkhead seal (1) .
a Lock the airbag computer using the diagnostic tool
(see Fault finding - Replacement of components) a Remove:
(88C, Airbag and pretensioners).
- the universal joint nut (1) ,
Refitting) (80A, Battery). - the universal joint shaft,
a Remove: - the universal joint.

- the driver's front airbag (see Driver's front airbag:
Removal - Refitting) (88C, Airbags and pretensio-
ners),
- the steering wheel (see 36A, Steering assembly,
Steering wheel: Removal - Refitting, page 36A-
19) ,
- the steering column switch assembly (see Stee-
ring wheel controls assembly: Removal - Refit-
ting) (84A, Control - Signals).
133766
a Remove the bolts (3) of the steering column on the

dashboard cross member.
36A-10
STEERING ASSEMBLY
III - STRIPPING OPERATION FOR PART
CONCERNED
a Remove:
- the antenna/transponder ring (see Transponder
ring: Removal - Refitting) (82A, Immobiliser),
- the ignition switch (see Ignition switch: Removal

- Refitting) (82A, Immobiliser).
REFITTING
I - REBUILDING OPERATION FOR PART

CONCERNED
a Refit:
- Refitting) (82A, Immobiliser),

133761 - Refitting) .
a Remove the bolts (4) of the steering column on the
dashboard cross member. II - REFITTING PREPARATION OPERATION
a Always replace the steering universal joint bolt and

nut.

CONCERNED
a Refit the steering column.
a Connect:
- the ignition switch connector,

- the antenna/transponder ring.
a Clip on the ignition switch connector.
a Refit:
- the universal joint,

a Torque tighten the universal joint nut (24 N.m).
133762
a Unclip the starter switch connector. a Fit the bulkhead seal.
a Disconnect:
- the ignition switch connector (5) ,
a Refit:
- the antenna/transponder ring connector (5) .
- the steering column switch assembly (see Stee-
a Remove the steering column.
ring wheel controls assembly: Removal - Refit-
ting) (84A, Control - Signals),
19) ,
36A-11
STEERING ASSEMBLY
ners).
ting) (80A, Battery).
a Unlock the airbag computer using the diagnostic
tool (see Fault finding - Replacement of compo-
nents) (88C, Airbag and pretensioners).
36A-12
STEERING ASSEMBLY
Steering rack gaiter: Removal - Refitting 36A
REMOVAL - the retaining clip.
a Clean the contact surfaces between the steering box
I - REMOVAL PREPARATION OPERATION and the gaiter using SURFACE CLEANER (see Ve-
hicle: Parts and ingredients for the repairwork)
a Position the vehicle on a two-post lift (see Vehicle: (04B, Consumables - Products).
a Use SILICONE GREASE (see Vehicle: Parts and
a Remove: ingredients for the repairwork) (04B, Consuma-
bles - Products) to coat the mating face of the gaiter
on the axial ball joint to prevent the gaiter from twis-
ting.
rod: Removal - Refitting, page 36A-6) ,
Note:
- the wheel alignment adjustment lock nut.
Be sure to centre the steering to ensure the air in
the gaiters is equalised.
CONCERNED
Note:
Be careful not to damage the gaiters: risk of irre-
versible damage.

CONCERNED
a Refit:
- the new steering box gaiter,
- the new retaining clip.

a Refit:
- the wheel alignment adjustment lock nut,
rod: Removal - Refitting, page 36A-6) ,
- the wheel (see 35A, Wheels and tyres, Wheel:
118883
a
Note: mation, Axle assemblies: Check, page 30A-20) .
When removing the steering gaiter, blast the gai- a If necessary, adjust the geometry of the axle assem-
ter surfaces with compressed air to eliminate any blies (see 30A, General information, Front axle:
impurities that could enter the steering box. Adjusting, page 30A-28) .
a Cut the gaiter retaining clip (1) .

a Remove the gaiter (2) .
REFITTING

a Always replace:
- the steering box gaiter,
36A-13
STEERING ASSEMBLY
Bulkhead seal: Removal - Refitting 36A
REFITTING
IMPORTANT
the safety and cleanliness instructions and opera- a Always replace the clip of the bulkhead seal.
CONCERNED
a Refit:
REMOVAL - the bulkhead seal,
- a new clip on the bulkhead seal.
Towing and lifting) (02A, Lifting equipment). a Refit:
- the steering box (see 36A, Steering assembly,
a Remove: Steering rack: Removal - Refitting, page 36A-3) ,
- the front wheels (see 35A, Wheels and tyres, - the engine undertray,
- the steering box (see 36A, Steering assembly,

Steering rack: Removal - Refitting, page 36A-3) .

CONCERNED
133997
a Cut the clip (1) .
a Remove the bulkhead seal (2) .
36A-14
STEERING ASSEMBLY
Intermediate shaft: Removal - Refitting 36A
Essential equipment
diagnostic tool
IMPORTANT
REMOVAL

133768
a Lock the airbag computer using the diagnostic tool
(see Fault finding - Replacement of components) a Remove:
a Disconnect the battery (see Battery : Removal - - the lower cover bolts (1) ,
- the lower cover,
a Remove:
- the front wheels (see 35A, Wheels and tyres, - the steering column (see 36A, Steering assem-
Wheel: Removal - Refitting, page 35A-1) , bly, Steering column: Removal - Refitting, page
36A-10) .
- the engine undertray.

CONCERNED
a Remove:
ners),
19) ,
133991
a Make a mark between the column and the interme-

diate shaft.
a Remove the intermediate shaft (2) .
36A-15
STEERING ASSEMBLY
Intermediate shaft: Removal - Refitting 36A
REFITTING

CONCERNED
a Refit:
- the intermediate shaft, whilst paying attention to
the mark,
- the steering column (see 36A, Steering assem-
bly, Steering column: Removal - Refitting, page
36A-10) ,
- the lower cover,
19) ,
ners).
a Refit:
a Unlock the computer using the diagnostic tool (see
Fault finding - Replacement of components)
36A-16
STEERING ASSEMBLY
Steering column adjustment handle Removal - Refitting 36A
CONCERNED
IMPORTANT
REMOVAL
133998
a Remove:
- the nut (2) of the adjustment handle shaft,
- the locking mechanism (3) ,
- the adjustment handle.
133768
a Remove:
- the lower cover bolts (1) ,
- the lower cover.
36A-17
STEERING ASSEMBLY
Steering column adjustment handle Removal - Refitting 36A
REFITTING III - FINAL OPERATION
a Refit the lower cover.
127583
(4) Handle
(5) Indexed adjustment plates
(6) Connection shaft
(7) Locking mechanism
(8) Adjustment handle shaft nut
a Always replace the nut of the adjustment handle

shaft.
Note:
When the handle is refitted, ensure the two
indexed adjustment plates and retaining spring
are correctly positioned.

CONCERNED
a Refit:
- the adjustment handle,
- the locking mechanism.
Note:
The amount of effort required to operate the
mechanism is determined by how much the han-
dle is tightened. Test to determine the correct
tightening.
36A-18
STEERING ASSEMBLY
Steering wheel: Removal - Refitting 36A
REFITTING
Essential equipment
diagnostic tool
a Always replace the steering wheel bolt.
Tightening torquesm WARNING

In order not to damage the steering wheel or
steering wheel bolt 44 N.m
steering column, the steering wheel-column fool-
proofing devices must be aligned.
REMOVAL
CONCERNED
I - REMOVAL PREPARATION OPERATION a Refit the steering wheel with a new bolt.
a Lock the airbag computer using the diagnostic tool a Torque tighten the steering wheel bolt (44 N.m).
(see Fault finding - Replacement of components)
a Disconnect the battery (see Battery : Removal - III - FINAL OPERATION

a Refit the driver's airbag (see Driver's front airbag:
a Remove the driver's airbag (see Driver's front air- Removal - Refitting) (88C, Airbags and pretensio-
bag: Removal - Refitting) (88C, Airbags and pre- ners).
tensioners). a Connect the battery (see Battery : Removal - Refit-
II - OPERATION FOR REMOVAL OF PART a Unlock the airbag computer using the diagnostic
CONCERNED tool (see Fault finding - Replacement of compo-
nents) (88C, Airbags and pretensioners).
134001
a Remove:
- the steering wheel bolt (1) ,
- the steering wheel.
36A-19
POWER ASSISTED STEERING
Power assisted steering pump: Checking 36B
D4F or K4J or K4M
Ms. 583 Hose clamp pliers.
Dir. 1204 Union for measuring pres-

sure in power assisted stee-
ring high pressure pipes.
Fre. 244-03 Braking circuit pressure

gauge: from 0 to 160 bar.
Tightening torquesm
pressostat 12 N.m
IMPORTANT
tion recommendations before carrying out any 125743
repair (see 36A, Steering assembly, Steering: a Disconnect the pressostat connector (1) .
a Remove the pressostat.
a Fit the (Dir. 1204) in place of the pressostat.
CHECKING
a Connect the (Fre. 244-03) to the (Dir. 1204).
I - PREPARATION OPERATION FOR CHECK a Remove the hose clamp (Ms. 583).
a Position the vehicle on a two-post lift (see Vehicle: a Bleed the power-assisted steering circuit (see 36B,
Towing and lifting) (02A, Lifting equipment). Power assisted steering, Power-assisted stee-
a Remove: ring circuit: Bleeding, page 36B-5) .

II - TEST OPERATION
a Start the engine.
- the front right-hand wheel (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) , a Check the pressure of the power-assisted steering
pump, with the steering wheel stationary and
- the front right-hand wheel arch liner (see Front
straight ahead.
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection). The value must not exceed 5 to 7 bar.
a Check the pressure of the power-assisted steering
WARNING pump with the steering wheel at full lock.
Prepare for the flow of fluid, and protect the sur- The maximum value must be between 79 and 86
rounding components. bar.
a Fit a hose clamp (Ms. 583) on the low pressure pipe a Switch off the engine.
of the power-assisted steering pump to limit the out-
flow.
a Fit a hose clamp (Ms. 583) on the low pressure pipe
flow.
a Remove the (Fre. 244-03) then its adapter (Dir.
1204).
36B-1
D4F or K4J or K4M
a Refit the pressostat.
a Torque tighten the pressostat (12 N.m).
a Connect the pressostat connector.
a Remove the hose clamp (Ms. 583).
a Bleed the power-assisted steering circuit (see 36B,
Power assisted steering, Power-assisted stee-
ring circuit: Bleeding, page 36B-5) .
a Refit:
terior protection),
tyres, Wheel: Removal - Refitting, page 35A-1) ,
36B-2
K9K, and BASIC HEATING
Dir. 803 Power assisted steering

pump pressure gauge adap-
ter. Non-metric thread.
Fre. 244-03 Braking circuit pressure

gauge: from 0 to 160 bar.
Fre. 284-06 Brake pressure gauge con-

necting hose Fre.244-03
Fre.1085-01.
IMPORTANT
To avoid any risk of damaging the systems, apply
tion recommendations before carrying out the
repair (see Vehicle: Towing and lifting) (02A, Lif- 24736
ting equipment).
a Remove the bolt (1) from the high pressure pipe
bracket on the power-assisted steering pump.
CHECKING
a Undo the union (2) from the high pressure pipe on
the power-assisted steering pump.
a Position the vehicle on a two-post lift (see Vehicle: a Fit the tool (Dir. 803) between the power-assisted
Towing and lifting) (02A, Lifting equipment). steering pump and the high pressure pipe union (2) .
a Remove: a Connect the (Fre. 244-03) and the (Fre. 284-06) to

- the engine undertray bolts, the (Dir. 803).
- the engine undertray. a Remove the hose clamp (Ms. 583).

WARNING Power assisted steering, Power-assisted stee-
Prepare for the flow of fluid, and protect the sur- ring circuit: Bleeding, page 36B-5) .
a Fit a hose clamp (Ms. 583) on the low pressure pipe II - TEST OPERATION
flow. a Start the engine.

pump, with the steering wheel stationary and
straight ahead.
The value must not exceed 5 to 7 bar.

pump with the steering wheel at full lock.
The maximum value must be between 79 and 86

bar.
a Switch off the engine.
36B-3
flow.
a Remove the (Fre. 244-03), (Fre. 284-06) and (Dir.
803).
a Refit the high pressure pipe union on the power-as-
sisted steering pump.
a Remove the hose clamp (Ms. 583).
a Refit the engine undertray.
36B-4
Power-assisted steering circuit: Bleeding 36B
BLEEDING
a Position the vehicle on a two-post lift (see Vehicle: K9K, and AIR CONDITIONING or CLIMATE CON-
Towing and lifting) (02A, Lifting equipment). TROL
a Raise the vehicle until the front wheels are lifted off
the ground.
K9K, and BASIC HEATING – D4F or K4J or K4M or

K7J or K7M
132527
a Remove:
- the front left-hand wheel (see 35A, Wheels and ty-

res, Wheel: Removal - Refitting, page 35A-1) ,
132479
a Fill the power-assisted steering reservoir (1) . - the front left-hand wheel arch liner (see Front
terior protection).
a Fill the power-assisted steering reservoir (1) .
a Start the vehicle.
a Top up the power-assisted steering fluid.
WARNING
To avoid damaging the power-assisted steering
system, do not keep the steering at full lock.
a Repeat the following operation three times:
- turn the steering wheel to the left to lock the stee-

ring,
- turn the steering wheel to the right to lock the stee-

ring.
36B-5
Power-assisted steering circuit: Bleeding 36B
a Top up the power-assisted steering fluid.
WARNING
The level must be between the « MIN » and
« MAX » markings on the reservoir.
K9K, and AIR CONDITIONING or CLIMATE CON-

TROL
a Refit:
- the front left-hand wheel arch liner (see Front
terior protection),
36B-6
Power assisted steering pump: Removal - Refitting 36B
Mot. 1448 Long nose pliers for hose

clips.
IMPORTANT
REMOVAL

24736
a Remove:
- the engine cover, (1) .
- the engine undertray bolts, a Remove:
- the engine undertray, - the low pressure pipe clip using the tool (Mot.
1448),
tyres, Wheel: Removal - Refitting, page 35A-1) , - the low pressure pipe (1) from the power-assisted
steering pump.
wheel arch liner: Removal - Refitting) (55A, Ex- a Fit a blanking plug on the opening of the power-as-
terior protection), sisted steering pump.
- the accessories belt (see Accessories belt: Re- a Remove:
moval - Refitting) (11A, Top and front of engine).
- the bolt (2) of the high pressure pipe bracket,
- the high pressure pipe union (3) on the power-as-
a Fit blanking plugs on the high-pressure pipe union
and on the opening of the power-assisted steering
pump.
36B-7
IV - REFITTING OPERATION FOR PART
CONCERNED
a
WARNING
Do not remove the blanking plugs from each
component until the last moment.
Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.
a Refit:
- the power-assisted steering pump,
- the high-pressure pipe equipped with a new seal
on the power-assisted steering pump,
- the low pressure pipe on the power-assisted stee-
ring pump,
- the low pressure pipe clip using the tool (Mot.
24736 1448).
a Remove the hose clamp (Ms. 583) from the low
pressure pipe.
V - FINAL OPERATION
a Refit:
- the accessories belt (see Accessories belt: Re-
moval - Refitting) (11A, Top and front of engine),
terior protection),
- the engine cover.
24761
a Remove: a Check that there are no leaks.
- the bolts (4) from the power-assisted steering

pump,
- the power-assisted steering pump.
III - REFITTING PREPARATION OPERATION

a Always replace the O-ring of the high pressure pipe.
36B-8
D4F

clips.
IMPORTANT
REMOVAL

132706
a Remove:
a Remove the nut (1) from the bracket of the high
- the engine undertray bolts, pressure pipe on the alternator.
terior protection),
126258
a Remove the high pressure pipe union (2) on the
power-assisted steering pump.
a Fit blanking plugs on the high-pressure pipe union
and on the opening of the power-assisted steering
pump.
36B-9
D4F
- the power-assisted steering pump pulley.
133049
a Fit a hose clamp (Ms. 583) on the low pressure pipe. 133045
a Remove:
- the low pressure pipe clip (3) using the tool (Mot.
1448),
- the low pressure pipe from the power-assisted
steering pump.
a Fit a blanking plug on the opening of the power-as-

133047
a Remove:

pump,
REFITTING
133048
a Remove: I - REFITTING PREPARATION OPERATION

- the power-assisted steering pump pulley bolts (4) , a Always replace the O-ring of the high pressure pipe.
36B-10
D4F
CONCERNED
a
WARNING
cle.
a Refit:
- the power-assisted steering pump pulley,
ring pump,
1448).
pressure pipe.
a Refit the high pressure pipe on the power-assisted
steering pump.

a Refit:
terior protection),
a Check that there are no leaks.
36B-11
K4J or K4M or K7J or K7M

clips.

a Remove:
terior protection),
- the engine tie-bar (see Lower engine tie-bar: Re-
moval - Refitting) (19D, Engine mounting),
- the left-hand suspended engine mounting (see
Left-hand suspended engine mounting: Remo- 132680
val - Refitting) (19D, Engine mounting), a Unclip the engine wiring (1) from the multifunction
- the right-hand suspended engine mounting (see support.
Right-hand suspended engine mounting: Re-
36B-12
134596 116167
of the power-assisted steering pump.
a Separate the low pressure pipe clip (2) using the tool
(Mot. 1448).
a Disconnect the power-assisted steering pump low
pressure pipe.
a Undo the union (3) of the high pressure pipe.
a Insert the blanking plugs.
134609
a Remove:

pump,
REFITTING
a Always replace the O-ring of the high pressure pipe.
36B-13
CONCERNED
a
WARNING
cle.
a Refit:
- the high pressure pipe together with a new O-ring
on the power-assisted steering pump,
ring pump,
1448).
pressure pipe.

a Refit:
- the right-hand suspended engine mounting (see
Right-hand suspended engine mounting: Re-
- the left-hand suspended engine mounting (see Ri-
ght-hand suspended engine mounting: Remo-
val - Refitting) (19D, Engine mounting),
- the engine tie-bar (see Lower engine tie-bar: Re-
moval - Refitting) ,
terior protection),
tyres, Wheel: Removal - Refitting, page 35A-1) .
36B-14
Power assisted steering pump assembly: Removal - Refitting 36B
K9K

clips.
IMPORTANT
REMOVAL

a Disconnect the battery (see Battery : Removal - 132532
a Disconnect the pump assembly connectors, taking
a Remove: care not to damage the locking systems.
res, Wheel: Removal - Refitting, page 35A-1) ,
terior protection).
132527
a Fit a hose clamp (Ms. 583) on the low pressure pipe.
a Separate the clip (1) of the low pressure pipe on the

pump assembly reservoir using the tool (Mot. 1448).
a Remove the low pressure pipe to drain the pump as-

sembly reservoir.
36B-15
K9K
132528 132533
a Remove the bolt (2) from the high pressure pipe a Remove:
bracket on the pump assembly.
- the bolts (3) from the pump assembly mounting,
a Disconnect the high pressure pipe from the pump
assembly. - the pump assembly with its mounting.
Note:
Do not remove the pump assembly from its
mounting.
REFITTING
a Always replace the high pressure pipe's O-ring.
Note:
The pump assembly is sold with its mounting.

CONCERNED
a Refit the pump assembly with its mounting.

a Fit a new O-ring on the high pressure pipe.
a Connect:
- the high pressure pipe on the pump assembly,

- the low pressure pipe on the pump assembly reser-
voir, aligning the mark on the pipe with the mark on
the reservoir.
36B-16
K9K
a Refit the clip on the low pressure pipe using the tool
(Mot. 1448).
pressure pipe.
a Connect the pump assembly connectors.
a Lock the connectors.
a Push and pull on the connectors to check the condi-
tion of the connections.

a Fill the pump assembly reservoir with power-assis-
ted steering fluid (see Vehicle: Parts and ingre-
dients for the repairwork) (04B, Consumables -
Products).
a Refit:
terior protection),
36B-17
Power assisted steering pipes: Removal - Refitting 36B
D4F
clips. 1 - Low pressure pipe between the reservoir and
the power-assisted steering pump
Mot. 1453 Multiple-adjusting engine
mounting support with retai-
ning straps.
Essential equipment
safety strap(s)
IMPORTANT
REMOVAL

134613
Towing and lifting) (02A, Lifting equipment). a Undo the clip (1) of the low pressure pipe using the
tool (Mot. 1448).
a Remove:
a Drain the power-assisted steering reservoir.
- the battery (see Battery : Removal - Refitting)
(80A, Battery),
- the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
134260
a Remove the bolt (2) from the mounting of the oxygen
sensor connector.
36B-18
D4F
132994 133049
a Remove the tachograph heat shield (3) . a Undo the clip (5) of the low pressure pipe using the
tool (Mot. 1448).
a Fit blanking plugs on the opening of the power-as-
a Remove the low pressure pipe between the reser-
voir and the power-assisted steering pump.
2 - High pressure pipe between the power-assisted

steering pump and the steering box
a Remove:
- the air inlet pipe,
- the air filter box (see Air filter unit: Removal - Re-
fitting) (12A, Fuel mixture),
terior protection).
133046
a Remove the bolt (4) from the bracket of the low pres-
sure pipe on the power-assisted steering pump
mounting.
36B-19
D4F
125743 132988
a Remove the nut (6) from the bracket of the high a Remove the bolt (9) from the bracket of the high
pressure pipe on the alternator. pressure pipe on the gearbox.
a Disconnect the pressostat connector (7) .
125719
126258 a Remove the high pressure pipe union (10) on the

steering box.
a Remove the high pressure pipe union (8) on the
power-assisted steering pump.
36B-20
D4F
132704
a Fit:
- the (Mot. 1453),
- a safety strap(s) on the tool (Mot. 1453).
a Remove the left-hand suspended engine mounting
(see Left-hand suspended engine mounting: Re-
moval - Refitting) (19D, Engine mounting).
132995
a Remove:
- the earth bolt (11) on the gearbox,
- the high pressure pipe between the power-assisted
steering pump and the steering box.
36B-21
D4F
3 - High pressure pipe between the steering box
and the reservoir
a Remove:
- the air inlet pipe,
fitting) (12A, Fuel mixture).
133780
a Disconnect the brake fluid reservoir connector (14) .
a Unclip:
- the wiring from the vehicle body,
125719 - the steering fluid reservoir from the vehicle body.

a Remove:
- the bolt (12) of the high pressure pipe bracket on
the steering box,
- the unions (13) of the high pressure pipes on the
steering box.
134613
a Separate the clip (15) of the high pressure pipe

using the tool (Mot. 1448).
a Disconnect the high pressure pipe from the reser-

voir.
36B-22
D4F
1 - Low pressure pipe between the reservoir and
a Refit:
- the low pressure pipe,
- the low pressure pipe clip on the power-assisted

steering pump using the tool (Mot. 1448),
- the tachograph heat shield,

- the oxygen sensor connector mounting,
- the low pressure pipe clip on the reservoir using the

tool (Mot. 1448).

a Refit:

133994 steering pump and the steering box,
a Remove: - the earth on the gearbox,
- the bolts (16) of the high pressure pipe brackets on - the left-hand suspended engine mounting (see
the subframe, Left-hand suspended engine mounting: Remo-
- the high pressure pipe between the steering box val - Refitting) (19D, Engine mounting).
and the reservoir. a Remove the tool (Mot. 1453).
a Connect the pressostat connector.

REFITTING
a Refit:
I - REFITTING PREPARATION OPERATION - the front right-hand wheel arch liner (see Front
High pressure pipe between the power-assisted terior protection),
steering pump and the steering box - the front right-hand wheel (see 35A, Wheels and
a Always replace the O-rings on the power-assisted tyres, Wheel: Removal - Refitting, page 35A-1) ,
steering pipes.
CONCERNED - the air inlet pipe.
a
3 - High pressure pipe between the steering box
WARNING and the reservoir
a Refit:
- the high pressure pipe between the steering box
and the reservoir,
cle. - the high pressure pipe clip on the reservoir using
the tool (Mot. 1448),
- the power-assisted steering fluid reservoir.
a Connect the connector on the brake fluid reservoir.

a Clip the wiring onto the body.
36B-23
D4F
a Refit:
- the air inlet pipe.

a Refit:
(80A, Battery).
36B-24

clips.
IMPORTANT
REMOVAL

a Position the vehicle on a two-post lift (see Vehicle: 138294
Towing and lifting) (02A, Lifting equipment). a Disconnect the level sensor connector (1) from the
brake fluid reservoir.
a Remove:
(80A, Battery),
- the engine cover.

CONCERNED
1 - Low pressure pipe between the reservoir and

a Remove:
- the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
138293
- the front bumper (see Front bumper: Removal - a Move the power-assisted steering fluid reservoir
Refitting) (55A, Exterior protection). upwards by pressing on the tab (2) .
a Loosen the clip of the low pressure pipe (3) on the
power-assisted steering fluid reservoir using the tool
(Mot. 1448).
a Drain the power-assisted steering fluid reservoir.
36B-25
138295 138292
a Loosen the low pressure pipe clip (4) on the power-
assisted steering pump using the tool (Mot. 1448).
a Fit blanking plugs into all openings.
138296
a Unclip the low pressure pipe:
- from the left-hand suspended engine mounting at
(5) ,
- from the engine cooling radiator at (6) .
a Remove the power-assisted steering low pressure
pipe.
36B-26
a Remove:
tion),
Refitting) (55A, Exterior protection).
138295
a Remove:
- the power-assisted steering pump high pressure
pipe bracket bolt (8) ,
- the union (9) from the power-assisted steering
pump high pressure pipe.
138294
a Disconnect the level sensor connector (7) from the
a Move the power-assisted steering fluid reservoir to
one side.
a Fit a hose clamp (Ms. 583) on the pipes of the
power-assisted steering fluid reservoir.
138298
a Remove the bolt (10) from the bracket of the high
pressure pipe on the gearbox.
36B-27
- the bolt from the bracket of the high pressure pipe
on the gearbox.
138296
a Remove the bolt (11) from the bracket of the high 138291
pressure pipe on the gearbox.
a Remove:
- the nut (14) from the bracket of the high pressure
pipe on the steering box,
- the power-assisted steering high pressure pipe.
138297
a Remove:
- the low pressure pipe union (12) on the steering

box,
- the high pressure pipe union (13) on the steering

box,

Left-hand suspended engine mounting: Remo-
val - Refitting) (19D, Engine mounting),
36B-28
3 - Low pressure pipe between the steering box
and the reservoir
138293
a Move the power-assisted steering fluid reservoir
138294 upwards by pressing on the tab (17) .
a Disconnect the brake fluid level sensor connector
a Loosen the clip (18) of the low pressure pipe on the
(16) .
power-assisted steering fluid reservoir using the tool
(Mot. 1448).
a Drain the power-assisted steering fluid reservoir.
a Loosen the low pressure pipe clip (19) on the power-
assisted steering fluid reservoir using the tool (Mot.
1448).
a Disconnect the power-assisted steering pipes from
the tank.
a Remove the power-assisted steering fluid reservoir.
36B-29
REFITTING

a parts always to be replaced: Power-assisted
steering pipe seal (13,04,04,22).

CONCERNED
WARNING
cle.
138291 1 - Low pressure pipe between the reservoir and

a Remove the nut (20) from the bracket of the low the power-assisted steering pump
pressure pipe on the steering box. a Refit:
ring pump,

1448).
a Clip the low pressure pipe:

- onto the engine cooling system radiator,
- onto the left-hand suspended engine mounting.
a Connect the low pressure pipe onto the power-as-

sisted steering fluid reservoir.
a Refit:
- the low pressure pipe clip on the power-assisted
steering fluid reservoir using the tool (Mot. 1448),

138297 liner: Removal - Refitting) (55A, Exterior protec-
a Remove: tion),
- the high pressure pipe union (21) on the steering - the front wheels (see 35A, Wheels and tyres,
box, Wheel: Removal - Refitting, page 35A-1) .
- the steering box unions (22) ,

- the low pressure pipe union (23) on the steering steering pump and the steering box
box,
a Refit:
- the power-assisted steering low pressure pipe.
a Fit blanking plugs into all openings. steering pump and the steering box,
36B-30
Left-hand suspended engine mounting: Remo-
val - Refitting) (19D, Engine mounting).
a Remove the hose clamp (Ms. 583) from the pipes of
the power-assisted steering fluid reservoir.
a Refit:
- the power assisted steering fluid reservoir,
tion),
a Connect the level sensor connector to the brake fluid
reservoir.
3 - Low pressure pipe between the steering box

and the reservoir
a Refit:
- the low pressure pipe between the steering box
and the reservoir,
- the clips of the power-assisted steering pipes on
the power-assisted steering fluid reservoir using
the tool (Mot. 1448),
- the steering box unions,
- the low pressure pipe union on the steering box,
- the high pressure pipe union on the steering box,
- the power-assisted steering fluid reservoir.
a Connect the level sensor connector to the brake fluid
reservoir.

a Refit:
(80A, Battery),
- the engine cover.
a Fill the power-assisted steering circuit fluid reservoir
(see Vehicle: Parts and consumables for repair)
(04B, Consumables - Products).
a Check that there are no leaks.
36B-31
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting 37A
Tightening torquesm JH3 or JR5
a Disconnect the clutch master cylinder pipe on the
master cylinder nuts 12 N.m
brake pipe unions 13 N.m a Insert the blanking plugs.
WARNING
a Remove the brake fluid reservoir by pulling it
Prepare for the flow of fluid, and protect the sur- upwards.
a Fit blanking plugs on the openings of the brake fluid
reservoir.
REMOVAL
CONCERNED

a Remove:

(80A, Battery),

fitting) (80A, Battery).
133779
a Position a container to catch any brake fluid remai-
ning in the master cylinder which may run out.
a Undo the brake pipe unions (4) on the master cylin-
der.
133780
a Disconnect the brake fluid level sensor connector (1)

.
a Remove the brake fluid reservoir plug (2) .
a Drain the brake fluid reservoir (3) using a syringe.
37A-1
Master cylinder: Removal - Refitting 37A
a Refit the master cylinder.
a Torque tighten the master cylinder nuts (12 N.m).
a Refit the brake pipes to the master cylinder.
a Torque tighten the brake pipe unions (13 N.m).
a Remove the blanking plugs from the brake fluid re-
servoir.
a Refit the brake fluid reservoir onto the master cylin-
der.
JH3 or JR5
a Remove the blanking plugs.
a Connect the clutch master cylinder pipe on the brake
fluid reservoir.
133778
a Remove: a Refit:
- the master cylinder nuts (5) , - the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery)
- the master cylinder (6) .
- the battery (see Battery: Removal - Refitting)
a Fit blanking plugs on the openings of the master cy-
(80A, Battery),
linder.
- the brake fluid filler cap.
REFITTING a Connect the brake fluid level sensor connector.

112622
a Always replace the master cylinder seals (7) .

CONCERNED
a Remove the blanking plugs from the master cylin-
der.
37A-2
Brake servo non-return valve: Removal - Refitting 37A
REMOVAL REFITTING
REMOVAL STAGE FOR THE PART CONCERNED. I - REFITTING PREPARATION OPERATION

a Check the condition of the non-return valve (see
37A, Mechanical component controls, Braking
assistance circuit: Check, page 37A-20) .
a Replace any faulty parts.

CONCERNED
a Refit the non-return valve on the vacuum pipe.
a Connect the non-return valve onto the brake servo.
133779
a Pull and turn the non-return valve (1) to release it
from the rubber sealing washer.
133777
a Separate the non-return valve clip.
a Remove the non-return valve.
37A-3
Brake servo: Removal - Refitting 37A
Tightening torquesm
brake servo nuts 24 N.m
WARNING
REMOVAL
a Remove:

(80A, Battery),
- the battery tray (see Battery tray: Removal - Re- 133774

fitting) (80A, Battery). a Remove the nuts (2) from the pedal assembly soun-
dproofing.
- the master cylinder (see 37A, Mechanical compo-
nent controls, Master cylinder: Removal - Refit-
ting, page 37A-1) ,
- the expansion bottle nuts.
a Remove the expansion bottle.

CONCERNED
133772
a Remove:
- the clip (3) of the brake servo shaft,
- the brake servo shaft.
133779
a Disconnect the non-return valve pipe (1) from the

brake servo.
37A-4
Brake servo: Removal - Refitting 37A
CONCERNED
a Refit the brake servo.
a Torque tighten the brake servo nuts (24 N.m).
a Refit:
- the brake servo shaft,
- the clip of the brake servo shaft,
- the nuts of the pedal assembly soundproofing.

a Refit:
- the expansion bottle,
- the master cylinder (see 37A, Mechanical compo-
nent controls, Master cylinder: Removal - Refit-
ting, page 37A-1) ,
133770
a Remove:
- the brake servo nuts (4) , (80A, Battery).
- the brake servo.
REFITTING
109206
a Check the presence and condition of the brake ser-

vo seal (5) .
a Replace the brake servo seal if necessary.
37A-5
Vacuum pump: Removal - Refitting 37A
K9K
a Connect the non-return valve pipe onto the vacuum
pump.
Tightening torquesm
vacuum pump bolts 21 Nm III - FINAL OPERATION

a Refit the engine cover.
REMOVAL

a Remove the front engine cover.

CONCERNED
134594
a Disconnect the non-return valve pipe (1) from the
vacuum pump.
a Remove:
- the vacuum pump bolts (2) ,
- the vacuum pump.
REFITTING

a Always replace the vacuum pump seal.

CONCERNED
a Refit the vacuum pump.
a Torque tighten the vacuum pump bolts (21 Nm).
37A-6
Pedal yoke: Removal - Refitting 37A
Tightening torquesm JH3 or JR5
brake servo nuts 24 N.m
REMOVAL

a Remove:
- the brake pedal switch (see 37A, Mechanical

component controls, Brake pedal switch: Re-
moval - Refitting, page 37A-15) ,
- the steering column (see 36A, Steering assem-

bly, Steering column: Removal - Refitting, page
36A-10) .
119307
CONCERNED a Unclip the clutch master cylinder ball joint (1) .
JB1 or JB3
133772
108551
a Remove:
a Remove the cable from the clutch pedal housing, by
lifting the clutch pedal and placing the cable perpen- - the clip (2) on the brake servo shaft,
dicular to the clutch pedal.
- the brake servo connecting shaft.
37A-7
Pedal yoke: Removal - Refitting 37A
- the brake pedal (see 37A, Mechanical compo-
nent controls, Brake pedal: Removal - Refitting,
page 37A-14) .
REFITTING

CONCERNED
a In the event of replacement, refit:
- the brake pedal (see 37A, Mechanical compo-
nent controls, Brake pedal: Removal - Refitting,
page 37A-14) ,
- the clutch pedal (see 37A, Mechanical compo-
nent controls, Clutch pedal: Removal - Refit-
ting, page 37A-26) .
a Refit the pedal yoke.
a Torque tighten the brake servo nuts (24 N.m).
133774
a Refit the soundproofing material.
a Remove:
a Refit:
- the nuts (3) of the pedal soundproofing,
- the brake servo connecting shaft,
- the pedal assembly soundproofing (4) .
- the clip on the brake servo shaft.
JB1 or JB3
a Refit the clutch cable in the notch of the clutch pedal.
JH3 or JR5
a Clip on the clutch master cylinder ball joint.
a Refit:
133770 - the steering column (see 36A, Steering assem-
a Remove: bly, Steering column: Removal - Refitting, page
36A-10) ,
- the brake servo nuts (5) ,
- the brake pedal switch (see 3 7 A, Mechanical
- the pedal yoke. component controls, Brake pedal switch: Re-
moval - Refitting, page 37A-15) .
a In the event of replacement, remove:
- the clutch pedal (see 37A, Mechanical compo-
nent controls, Clutch pedal: Removal - Refit- a Connect the battery (see Battery : Removal - Refit-
ting, page 37A-26) , ting) (80A, Battery).
37A-8
Accelerator pedal: Removal - Refitting 37A
K4J or K4M or K7J or K7M, and PETROL VEHICLE, and 5 SPEED MANUAL GBOX
REMOVAL REFITTING
REFITTING OPERATION FOR PART CONCERNED

OPERATION FOR REMOVAL OF PART
CONCERNED a Refit:
- the accelerator pedal,
- the accelerator cable onto the accelerator pedal.
133769
a Unclip the accelerator cable (1) from the accelerator

pedal.
133775
a Remove:
- the nut (2) ,
- the accelerator pedal.
37A-9
L35, and D4F – L35, and K9K, and FLEXFUEL VEHICLE – L35, and K4M, and 4 SPEED AUTO GBOX
Essential equipment K9K, and 700 or 712 or 718 or 728 or 734 – D4F
diagnostic tool
REMOVAL
REMOVAL PREPARATION OPERATION
K9K, and 740 – K4M
133769
a Unclip the cable (3) on the accelerator pedal.
a Remove:
- the accelerator pedal nuts,
24750
a Disconnect the accelerator pedal potentiometer con-
nector (1) . REFITTING
a Remove:
- the accelerator pedal nuts (2) , I - REFITTING OPERATION FOR PART
CONCERNED
a Refit the accelerator pedal.
K9K, and 740 – K4M
a Connect the accelerator pedal connector.
K9K, and 700 or 712 or 718 or 728 or 734 – D4F
a Clip the accelerator cable onto the accelerator pe-

dal.
37A-10
L35, and D4F – L35, and K9K, and FLEXFUEL VEHICLE – L35, and K4M, and 4 SPEED AUTO GBOX
a Using the diagnostic tool, check that the accelera-
tor assembly operates correctly.
37A-11
Accelerator pedal cable: Removal - Refitting 37A
REMOVAL
K7J or K7M
OPERATION FOR REMOVAL OF PART
CONCERNED
107356
a Disconnect the accelerator cable ball joint (2) from
133769 the throttle valve.
a Unclip the cable (1) on the accelerator pedal.
a Remove the adjusting clip (3) from the accelerator
a Push the sleeve stop of the accelerator cable into cable.
the engine compartment.
a Remove the accelerator cable from the lifting eye.
37A-12
Accelerator pedal cable: Removal - Refitting 37A
K4J or K4M K4J or K4M

a Refit the accelerator pedal cable to the intake distri-
butor.
K7J or K7M
a Refit the accelerator pedal cable to the lifting eye.
a Refit:
- the accelerator pedal cable on the throttle valve,
- the accelerator cable adjusting clip.
a Adjust the accelerator pedal cable by fully depres-
sing the accelerator pedal.
116660
a Disconnect the accelerator cable (4) from the throttle

valve.
a Remove the adjusting clip (5) from the accelerator

cable.
a Remove the accelerator cable from the intake distri-

butor.
a Unclip the accelerator pedal cable from the body.
a Remove the accelerator pedal cable via the engine

compartment.
REFITTING

CONCERNED
a Fit the accelerator pedal cable into the passenger

compartment via the engine compartment.
a Clip the accelerator pedal cable onto the body.
a Fit the accelerator pedal cable into the notch on the

accelerator pedal.
37A-13
Brake pedal: Removal - Refitting 37A
Tightening torquesm
brake pedal shaft nut 21 N.m
REMOVAL

a Switch off the ignition.
a Remove the brake pedal brake light switch (see
37A, Mechanical component controls, Brake pe-
dal switch: Removal - Refitting, page 37A-15) .

CONCERNED
133769
a Remove the nut (2) from the pedal assembly shaft.
a Extract the pedal assembly shaft.

a Remove the brake pedal.
REFITTING
a Check the condition of the parts.
a Always replace faulty parts.

a Coat the shaft with MULTIPURPOSE GREASE
(see Vehicle: Parts and consumables for repair)
(04B, Consumables - Products).
133772
a Remove: II - REFITTING OPERATION FOR PART
CONCERNED
- the clip (1) of the brake pedal shaft from the brake
servo, a Refit:
- the brake pedal shaft from the brake servo. - the brake pedal,
- the pedal assembly shaft,
- the pedal shaft on the servo,
- the clip of the pedal shaft onto the servo.

a Torque tighten the brake pedal shaft nut (21 N.m).

a Refit the brake light switch of the brake pedal (see
37A, Mechanical component controls, Brake pe-
dal switch: Removal - Refitting, page 37A-15) .
37A-14
Brake pedal switch: Removal - Refitting 37A
WARNING
The switch must be replaced if the brake pedal
position switch piston is extracted completely.
REMOVAL

a Switch off the ignition.

CONCERNED
133771
a Turn the brake light switch (2) a quarter of a turn
anti-clockwise.
a Remove the brake light switch.
133776
a Disconnect the brake light switch connector (1) .
37A-15
Brake pedal switch: Removal - Refitting 37A
REFITTING a Carefully support the return of the brake pedal.
I - REFITTING PREPARATION OPERATION Note:

The brake pedal switch has an automatic adjust-
ment feature, adapting to the pedal position. The
automatic adjustment makes a clicking noise
when in operation.
a Connect the brake light switch connector.

a Check that the brake light switch is operating cor-
rectly:
- depress the brake pedal to switch on the lights,
- release the brake pedal to switch off the lights.
108436
a
WARNING
To avoid damaging the multifunction switch (3) :

- handle the switch with care,
- only activate the piston (4) during the adjust-
ment phase,
- do not perform more than 3 adjustments to
dimension (X) ,
- do not separate the piston from the switch.
Replace the switch:
- if the piston is separated from the switch
- if more than 3 consecutive adjustments to
dimension (X) have been performed.
a Measure dimension (X) of the piston (4) . If dimen-

sion (X) is less than 17 mm, carefully pull the end of
the piston to between minimum 17 mm and maxi-
mum 18 mm.

CONCERNED
a Depress the brake pedal by hand.
a Position the brake light switch on the pedal assem-
bly.
a Lock the brake light switch by turning it a quarter of
a turn clockwise.
37A-16
Parking brake lever: Removal - Refitting 37A
REMOVAL - the parking brake trim (4) .
MANUAL REAR WINDOW WINDER

a Remove the floor carpet to access the handbrake le-
ver (see Floor carpet: Removal - Refitting) (71A,
Body internal trim).

CONCERNED
134012
a Remove:
- the bolts (1) from the heat shield,
- the heat shield (2) .
ELEC. REAR WINDOW SW.
121334
a Loosen the adjustment nut (5) of the parking brake.
a Unclip the parking brake cables (6) from the com-
pensator.
133367
a Remove:
- the parking brake trim bolts (3) ,
37A-17
Parking brake lever: Removal - Refitting 37A
a Adjust the parking brake lever (see 37A, Mechani-
a Refit the heat shield.
134019
a Disconnect the parking brake switch connector (7) .
a Remove:
- the nuts (8) from the parking brake switch,
- the parking brake lever.
REFITTING

CONCERNED
a Refit the parking brake lever.
a Connect the connector on the parking brake switch.
a Clip the parking brake cables to the compensator.
a Refit the compensator adjustment nut.
MANUAL REAR WINDOW WINDER

a Refit the floor carpet (see Floor carpet: Removal -
Refitting) (71A, Body internal trim).
ELEC. REAR WINDOW SW.

a Refit the parking brake trim.
37A-18
Parking brake lever: Adjusting 37A
A poorly adjusted parking brake: II - OPERATION FOR ADJUSTMENT OF PART
CONCERNED
- prevents correct operation of the automatic compen-
sation system for the brake shoes,
- causes premature wear of brake shoes.
ADJUSTMENT
I - ADJUSTMENT PREPARATION OPERATION


a Apply and release the parking brake five times to

bring the cables into their normal conditions of use.
a Put the parking brake lever into the released posi-

tion.
a Check that the rear wheels turn freely. If they do not, 121334
check the following components and if necessary re- a Loosen the nut (3) to loosen the parking brake ca-
pair: bles.
- the parking brake cables, a Position the parking brake lever at the 2nd notch.
- the wheel cylinders, a Move the adjustment nut until the drum can no lon-
ger be turned by hand.
- the automatic compensation system.
a Pull the brake lever several times.
a The drum must turn freely. If not, move the adjust-
ment nut gradually until the drum can turn freely.
a Refit:
- the heat shield,
134012
a Remove:
- the bolts (1) from the heat shield,
37A-19
Braking assistance circuit: Check 37A
III - CHECKING THE BRAKE SERVO SEALING
122228
There is no “RENAULT” tool to check the braking as- 133779
sistance circuit.
a Disconnect the brake servo non-return valve.
Use a vacuum pump, adapting the end pieces, part
nos. 77 01 349 942 and 77 00 105 874 with a pipe, part
a Connect a vacuum pump directly to the brake servo.
no. 82 00 027 352 or 82 00 376 245.
a Activate the vacuum pump a few times.
CHECKING
a Check that the vacuum does not fall by more than 33
mbar in 15 seconds. If it does, the leak may be lo-
cated:
a Remove the expansion bottle nuts.
- on the non-return valve seal, in this case change
a Remove the expansion bottle.
the non-return valve seal (see 37A, Mechanical
component controls, Brake servo non-return
II - CHECKING THE SEALS valve: Removal - Refitting, page 37A-3) ,
a When checking the brake servo seal, ensure that
there is a perfect seal between this and the master - on the pushrod membrane; in this case, replace the
cylinder. brake servo (see 37A, Mechanical component
controls, Brake servo: Removal - Refitting,
a If there is a leak in this area, replace the seal
between the master cylinder and the brake servo. page 37A-4) .
The brake servo seal must be checked on the vehi-

cle. The hydraulic circuit must be in operation. IV - CHECKING THE BRAKE SERVO NON-RETURN
VALVE
K9K
a Disconnect the non-return valve on the vacuum

pump side but leave it connected on the brake servo
side.
37A-20
Braking assistance circuit: Check 37A
a Check the following values:
D4F or K4J or K4M or K7J or K7M - 550 mbar in 5 seconds at an engine speed of 700
rpm,
a Disconnect the non-return valve on the inlet mani-
- 700 mbar in 3 seconds and 900 mbar in 5 se-
fold side but leave it connected to the servo.
conds at an engine speed of 4050 rpm.
a Replace the vacuum pump if the values are different
(see 37A, Mechanical component controls, Va-
cuum pump: Removal - Refitting, page 37A-6) .
a Connect the non-return valve to the vacuum pump.
VI - FINAL OPERATION
a Refit the expansion bottle.
122866
a Connect a vacuum pump to the end of the non-re-

turn valve.
a Activate the vacuum pump a few times.
a Check to see if the pressure drops. If it does, there is

a hole in the non-return valve. Change the non-re-
turn valve (see 37A, Mechanical component con-
trols, Brake servo non-return valve: Removal -
Refitting, page 37A-3) .
D4F or K4J or K4M or K7J or K7M
a Connect the non-return valve to the intake distribu-

tor.
V - CHECKING THE VACUUM PUMP
K9K
a Connect the external vacuum pump to the engine

vacuum pump.
a Start the engine.
37A-21
Clutch control: List and location of components 37A
DP0 or JB1 or JB3 or JH3 or JR5
JH3 or JR5
121114
No. Description
(1) Clutch slave cylinder (clutch thrust bearing)
(2) Hydraulic clutch control pipes
(3) Filter
(4) Clutch master cylinder
(5) Brake fluid supply duct
(6) Brake fluid reservoir
(7) Clutch pedal
JB1 or JB3
121113
37A-22
Clutch control: List and location of components 37A
DP0 or JB1 or JB3 or JH3 or JR5
No. Description
(1) Clutch fork
(2) Clutch control cable
(3) Brake - clutch pedal
37A-23
Clutch cable: Removal - Refitting 37A
JB1 or JB3
REMOVAL

a Remove:
(80A, Battery),

CONCERNED
121978
a Unclip the cable from its clips (3) .
a Press on the pedal to bring the cable back into the
passenger compartment.
24747
a Remove:
- the clutch control cable from the sleeve stop (1) ,
- the clutch control cable from the clutch fork (2) .
108551
a Remove the cable from the pedal housing (4) , by lif-
ting the pedal and placing the cable perpendicular to
the pedal.
a Push the cable sleeve stop into the engine compart-
ment.
37A-24
Clutch cable: Removal - Refitting 37A
JB1 or JB3
REFITTING

CONCERNED
a From the engine compartment, fit the clutch cable in
the passenger compartment.
a Fit the cable into the notch in the pedal.
Note:
Check that the cable is perfectly positioned in the
groove provided for it on the pedal.
a Fit the cable onto the clutch fork.

a Press the clutch pedal to clip the cable sleeve stop
into position on the bulkhead.
a Fasten the clutch cable onto its clips.
a Refit:
(80A, Battery).
37A-25
Clutch pedal: Removal - Refitting 37A
5 SPEED MANUAL GBOX
REMOVAL
JB1 or JB3
JB1 or JB3
108551
a Remove the clutch cable from the pedal housing, by
lifting the pedal and placing the cable perpendicular
24747
to the pedal.
a Remove the clutch control cable from the sleeve

stop (1) to loosen the cable.
37A-26
5 SPEED MANUAL GBOX
CONCERNED
JH3 or JR5
133758
119307
a Remove the nut (3) from the pedal assembly shaft.
a Unclip the clutch master cylinder ball joint (2) .
a Remove the shaft to release the clutch pedal.
a Remove:
- the bolt (4) ,
- the clutch pedal.
REFITTING

CONCERNED
a Refit:
- the clutch pedal,
- the clutch pedal shaft.
JH3 or JR5
a Clip on the clutch master cylinder ball joint.
JB1 or JB3
a Refit:
- the clutch cable into the pedal housing,
37A-27
5 SPEED MANUAL GBOX
- the control cable into the sleeve stop.
37A-28
Clutch circuit: Bleeding 37A
JH3 or JR5
II - BLEED OPERATION
Essential equipment
1 - Bleed procedure using the brake circuit
brake circuit bleeding device bleeding tool
a Keep the clutch pedal in the upper position.
Note: a Connect the brake circuit bleeding device to the

There are two methods of bleeding the clutch cir-
cuit: a Connect the power supply wires of the brake circuit
bleeding device to the battery.
- the method using the brake circuit bleeding
device is recommended by Renault. It prevents
impurities from being introduced into the clutch cir-
cuit.
- the method without a bleed tool.
Note:
- Even the tiniest air bubble in the circuit can cause
faulty operation (pedal failing to return properly,
crunching sound when changing gear, etc.).
- Incorrect bleeding can lead to incorrect detection
of faults and unnecessary part replacements.
Note:
The clutch circuit must be bled with approved brake
fluid (see Vehicle: Parts and ingredients for the
repairwork) (04B, Consumables - Products).
WARNING
BLEEDING
I - BLEED PREPARATION OPERATION

a Remove:
37A-29
JH3 or JR5
2 - Bleed procedure without bleed tool
a Keep the clutch pedal in the upper position.
24810
a Remove the bleed plug (1) .
a Connect a transparent pipe to the bleed hole running

to an empty container placed under the bleed hole.
a Press and hold the clip (2) .
WARNING
Do not pull the clip. If it is incorrectly handled in
any way, the pipe will need to be replaced.
a Pull out the clutch control pipe by one notch.
a Pressurise the clutch control circuit.
a Let the fluid run until all air bubbles have been re-
leased.
a Push back the clutch circuit pipe. When the pipe

locks, a safety click should be heard.
a Remove:
- the brake circuit bleeding device,
- the transparent pipe from the bleed hole.
a Push the plug back into the bleed hole.
a Top up the brake fluid level in the master cylinder re-

servoir if necessary.
a Disengage and engage the clutch quickly around

twenty times.
a Check that the clutch system is operating correctly.
a Repeat the bleed operation if necessary.
37A-30
JH3 or JR5
a Remove the transparent pipe from the bleed hole.
a Push the plug back into the bleed hole.
a Top up the brake fluid level in the master cylinder re-
servoir if necessary.
a Disengage and engage the clutch quickly around
twenty times.
a Check that the clutch system is operating correctly.
a Repeat the bleed operation if necessary.

a Refit the engine undertray.
24810
a Remove the bleed plug (1) .
a Connect a transparent pipe to the bleed hole running

to an empty container placed under the bleed hole.
a Tighten the transparent pipe to the bleed hole using
a hose clip to ensure there is a perfect seal.
a Push and hold the metal clip.
WARNING
Do not pull the clip. If it is incorrectly handled in
any way, the pipe will need to be replaced.
a Pull out the clutch control pipe by one notch.
a Fill the brake fluid master cylinder reservoir until bra-

ke fluid flows out of the bleed screw.
a Bring the transparent pipe to the same height as the
master cylinder reservoir.
Note:
The transparent pipe must be at the same height
as the master cylinder to prevent air entering the
clutch circuit.
a Connect a syringe containing 60 cc ofapproved li-

quid to the end of the transparent pipe.
a Slowly inject the entire contents of the syringe into
the circuit, without injecting any air from the top part
of the syringe.
a Push back the clutch circuit pipe. When it locks, a
safety click should be heard.
37A-31
Automatic gear control cable: Removal - Refitting 37A
DP0
REMOVAL II - FINAL OPERATION

a Refit the gear control unit (see 37A, Mechanical
component controls, Gear control unit: Removal
- Refitting, page 37A-35) .
a Position the vehicle on a two-post lift (see Vehicle: a Adjust the automatic gearbox control cable (see
Towing and lifting) (02A, Lifting equipment). 37A, Mechanical component controls, Automatic
gear control cable: Adjusting, page 37A-33) .
a Place the gear selector in the Neutral position.
a Refit:
a Remove:
(80A, Battery), - the battery (see Battery : Removal - Refitting)
(80A, Battery).
- the gear control unit (see 37A, Mechanical com-

ponent controls, Gear control unit: Removal -
Refitting, page 37A-35) .

CONCERNED
2304
a Remove:
- the clip (1) of the cable on the gear control unit,
- the automatic gearbox control cable.
REFITTING

CONCERNED
a Refit:
- the cable on the gear control unit,
- the clip of the automatic gearbox control cable.
37A-32
Automatic gear control cable: Adjusting 37A
DP0
WARNING
The automatic gearbox control cable is adjusted
with the gear selector and the multifunction switch
in the DRIVE position.
ADJUSTMENT

a Remove:
(80A, Battery),
127732
a Lift the lock (2) upwards. In this position, the cable
end is free to slide axially.
127730
a Unlock the cable end by pushing the sliding tab (1) in
the direction of the arrow until it clicks.
127738
a Put the gearbox output lever (3) in the DRIVE posi-
tion, placing the lever parallel to the mark (4) on the
multifunction switch.
37A-33
Automatic gear control cable: Adjusting 37A
DP0
127731
a Press the lock in the direction of the arrow (5) to re-
lease the sliding tab.
a Lock the cable end by pressing the sliding tab in the
direction of the arrow (6) until it clicks.

a Refit:
(80A, Battery).
a Check that the system and gear selection are wor-
king correctly.
37A-34
Gear control unit: Removal - Refitting 37A
DP0
Tightening torquesm
gear control unit nuts 12 N.m
REMOVAL

a Move the gear lever to the Neutral position.
a Remove:
(80A, Battery),
- the central console (see Centre console: Remo- 133880
val - Refitting) (57A, Interior equipment).
133881
133884 a Remove the bolts (2) from the exhaust pipe rubber
mounting bushes.
a Remove the exhaust pipe clip (1) .
a Disconnect the downstream oxygen sensor connec- a Let the exhaust pipe rest on the rear axle.
tor.
37A-35
DP0
CONCERNED
133882
a Remove:
110245
- the heat shield clips (3) ,
110243
a Remove:
- the end of the automatic gearbox control cable
from the multifunction switch ball joint by pressing
at (5) ,
- the control cable sleeve stop from the automatic
gearbox connector support by pulling the catch at
(6) .
37A-36
DP0
a Refit:
- the central console (see Centre console: Remo-
val - Refitting) (57A, Interior equipment),
(80A, Battery).
133883
a Remove:
- the gear control unit nuts (6) ,
- the gear control unit.
REFITTING

a When refitting the exhaust pipe rubber mountings,
make sure that they are perfectly in line with the axis
of the vehicle.

CONCERNED
a Refit the gear control unit.
a Torque tighten the gear control unit nuts (12 N.m)
a Clip the control cable into the sleeve stop.
a Clip the cable end piece to the multifunction switch
ball joint.
a Check that the system and gear selection are wor-
king correctly.

a Refit:
- the heat shield,
- the exhaust pipe,
- the exhaust pipe clip.
a Connect the downstream oxygen sensor connector.
37A-37
JB1 or JB3
CONCERNED
Tightening torquesm
control unit nuts 12 N.m
control linkage bolt 28 N.m
REMOVAL

133992
a Unclip the gaiter (3) from the gear control unit.
133882
a Remove:
- the heat shield (2) ,
134006
a Remove:
- the nut (4) of the gearbox control linkage on the
control lever,
- the gearbox control linkage.
37A-38
JB1 or JB3
134011
a Loosen the bolt of the exhaust pipe clip.
a Remove:
- the gear control unit nuts (8) ,
- the gear control unit.
REFITTING

CONCERNED
a Refit:
- the gear control unit,
- the gear control linkage,
- the exhaust pipe clip.
- the control unit nuts (12 N.m),
- the control linkage bolt (28 N.m).
a Refit:
- the gaiter of the gear control unit,
- the gaiter of the gear control linkage.
37A-39
JH3 or JR5
CONCERNED
Tightening torquesm
gear control unit nuts 12 N.m
REMOVAL

a Remove:
(80A, Battery),
118882
133882
a Remove:
- the heat shield. 110243
a Loosen the exhaust pipe clip. a Remove:
- the end of the gear control cable from the multi-
function switch ball joint by pressing at (2) ,
- the control cable sleeve stop from the automatic
gearbox connector support by pulling the catch at
(3) .
37A-40
JH3 or JR5
REFITTING
133992
a Unclip the gaiter from the gear control unit.
103113
Note:
Always replace the clip of the gearbox control
cable each time it is removed.
Note:
The gear control unit must always be in neutral
position to facilitate the anchoring of the control
cables on the gearbox.

CONCERNED
a Refit the gear control unit.
133883 a Torque tighten the gear control unit nuts (12 N.m).
a Remove: a Clip:
- the gear control unit nuts (4) , - the gaiter of the gear control unit,
- the gear control unit. - the sleeve stops of the gear selection and control
cables on the gearbox.
a Clip the cables onto the ball joints.
Note:
No adjustment of the gear control cables is requi-
red.
37A-41
JH3 or JR5
a Refit:
- the heat shield,
(80A, Battery).
37A-42
Gear control unit: Adjusting 37A
JB1 or JB3
Bvi. 1133-01 Shim blocking gearbox input

lever in 1st gear.
Tightening torquesm
linkage adjustment nut 28 N.m
ADJUSTMENT

a Engage first gear.
121339
a Remove the nut (3) .
133882
a Remove:
37A-43
Gear control unit: Adjusting 37A
JB1 or JB3
18728
121338
a Position a 9 mm thick adjustment shim between the

gear lever lower stop and the lower rail of the unit.
a Hold the gear control lever against the shim.
a Torque tighten the linkage adjustment nut (28

N.m).
a Check the adjustment value.
a Clearance noted at the bottom of the lever Y (in

mm):
- first gear engaged = Y1,

18727
a Position the (Bvi. 1133-01) between the control le- - second gear engaged = Y2.
ver (4) and the gearbox casing.
Y average = (Y1 + Y2) / 2
7 < Y average < 10
Note:
It is preferable to be closer to the maximum value
of the adjustment inter val.
a Remove the shim.
a Check gear changes.
37A-44
Parking brake cables: Removal - Refitting 37A
CONCERNED
WARNING
REMOVAL

a Fit:
- the vehicle on a two-post lift (see Vehicle: Towing
and lifting) (02A, Lifting equipment),
- the parking brake lever in the released position.
a Remove:
- the brake drums (see 33A, Rear axle compo-
nents, Rear brake drum: Removal - Refitting, 121334
page 33A-7) .
a Loosen the compensator adjustment nut (3) .
134012
121334
a Remove:
a Unclip the left-hand (4) and right-hand (5) parking
- the heat shield clips (1) , brake cable sleeve stops.
37A-45
Parking brake cables: Removal - Refitting 37A
121329
a Unclip the parking brake cables at (6) and (7) .
121330
a Pass the parking brake cables into the guides (10) .
a Remove the parking brake cables:
REFITTING

CONCERNED
a Fit the parking brake cables by passing them into the

guides and into the rear brake drum flanges.
a Clip the ends of the parking brake cables onto the

rear brake pads.
121331
a Attach the cables to the fuel tank.
a Unclip the end of the parking brake cables at (8) . a Fit the cables to the compensator.
a Unclip the sleeve stops at (9) and extract the parking a Refit the compensator nut.
brake cables from the rear drum flanges.
a Adjust the parking brake cables (see 37A, Mechani-

a Refit:
- the heat shield,
- the brake drums (see 33A, Rear axle compo-

page 33A-7) .

37A-46
ANTI-LOCK BRAKING SYSTEM
ABS system: Precautions for repair 38C
2 - Hydraulic unit
Essential equipment
pedal press WARNING

Switch off the vehicle ignition so as not to activate
diagnostic tool the hydraulic unit solenoid valves when bleeding the
brake circuit.
I - SAFETY
3 - Wheel speed sensor
- If a lift must be used for an operation, respect the sa-
fety instructions (see Vehicle: Towing and lifting)
(02A, Lifting equipment). WARNING
To ensure that the wheel speed sensor works pro-
- Protect any bodywork components which could be perly, do not mark the sensor target on the bearing.
damaged by brake fluid with covers.
- to ensure there is no risk of sparks, do not place any

metallic objects on the battery. WARNING
- Brake fluid is highly corrosive. Carefully clean any In order to prevent irreversible damage to the front
brake fluid spilt on parts of the vehicle. hub bearing:
II - CLEANLINESS
- Clean around the braking system with BRAKE ground when the driveshaft has been loosened or
CLEANER (see Vehicle: Parts and ingredients for removed.
the repairwork) (04B, Consumables - Products).
- If a component is being replaced by a new one, do not 4 - Brake servo

remove the new component from its packaging until its
is ready to be fitted onto the vehicle.
IMPORTANT
To avoid breaking the connection between the
WARNING brake servo pushrod and the brake pedal, check
that the safety clevis pin is locked onto the brake
servo pushrod by tilting it from the top downwards.
- During an operation which requires the braking circuit

to be opened, position a pedal press on the brake pe-
dal to limit the outflow of brake fluid.
- After any operation on the ABS, it is essential to con-

firm the repair with a road test and a check using the
diagnostic tool.
1 - Yaw speed and lateral acceleration sensor
The sensor must be fitted facing the vehicle's direction

of travel (as shown by the arrow).
Be sure to replace any sensor which has sustained an

impact.
38C-1
Brake hydraulic assembly: Removal - Refitting 38C
Essential equipment D4F
pedal press
Tightening torquesm
hydraulic unit bolts on 8 N.m

its support
rigid brake pipe unions 13 N.m

on the hydraulic brake
unit
IMPORTANT
To avoid all risk of damage to the systems, apply 134081
the safety and cleanliness instructions and opera- a Disconnect:
repair (see 38C, Anti-lock braking system, ABS - the oil vapour rebreathing pipe,
system: Precautions for repair, page 38C-1) . - the non-return valve pipe on the intake distributor.
REMOVAL

a Fit a pedal press on the brake pedal to limit the out-
flow of brake fluid.
K4J or K7J
a Remove the air filter unit (see Air filter unit: Remo-
val - Refitting) (12A, Fuel mixture).
134083
a Remove the clips from the bulkhead soundproofing
(1) .
a Move aside the bulkhead soundproofing (2) .

CONCERNED
a Disconnect the connector from the hydraulic brake
unit.
38C-2
Brake hydraulic assembly: Removal - Refitting 38C
a Torque tighten the hydraulic unit bolts on its sup-
port (8 N.m).
a Refit:
- the "support - hydraulic brake unit" assembly,
- the rigid brake pipe unions on the hydraulic brake
unit.
a Torque tighten the rigid brake pipe unions on the
hydraulic brake unit (13 N.m).
a Connect the hydraulic brake unit connector.
a Refit the bulkhead soundproofing.
134082
a Undo the rigid brake pipe unions (3) on the hydraulic
unit. D4F
a Connect:
- the non-return valve pipe on the intake distributor,
- the oil vapour rebreathing pipe.
K4J or K7J
a Refit the air filter unit (see Air filter unit: Removal -
Refitting) (12A, Fuel mixture).

109802
a Remove:
- the bolts (4) of the hydraulic brake unit support,
- the "support - hydraulic brake unit" assembly,
- the hydraulic brake unit bolts,
- the hydraulic brake unit from its support.
a Put blanking plugs in the openings.
REFITTING

CONCERNED
a Only remove the blanking plugs at the last moment.
a Refit the hydraulic brake unit on its support.
38C-3
Front wheel speed sensor: Removal - Refitting 38C
REMOVAL

a Remove:
- the front wheel arch liner (see Front wheel arch
tion).

CONCERNED
134079
a Unclip the connector (3) from the wheel speed sen-

sor wiring at (4) .
a Disconnect the wheel speed sensor connector.
a Remove the wheel speed sensor.
REFITTING

CONCERNED
WARNING
134080
a Remove the wheel speed sensor bolt (1) . To avoid damaging the wheel speed sensor
cable:
a Unpick the wheel speed sensor wiring at (2) .
- Do not tension the cable,
- Do not twist the cable,
- Check that there is no contact with the surroun-
ding components,
- Do not use tools that may damage the cable.
a Refit the wheel speed sensor.
a Connect the wheel speed sensor connector.
a Clip:
- the wheel speed sensor connector,
- the wheel speed sensor wiring,
- the wheel speed sensor.
38C-4
Front wheel speed sensor: Removal - Refitting 38C
a Refit:
- the front wheel arch liner (see Front wheel arch
tion),
38C-5
Rear wheel speed sensor: Removal - Refitting 38C
Tightening torquesm
wheel speed sensor bolt 6.5 N.m
REMOVAL

a Remove the rear wheel (see 35A, Wheels and ty-

CONCERNED
134085
a Unclip the wheel speed sensor connector (2) .
a Disconnect the wheel speed sensor connector (2) .
a Remove the wheel speed sensor.
REFITTING

CONCERNED
WARNING
To avoid damaging the wheel speed sensor

cable:
134084
a Remove the wheel speed sensor bolt (1) . - Do not tension the cable,
- Do not twist the cable,
- Check that there is no contact with the surroun-
ding components,
- Do not use tools that may damage the cable.
a Refit the wheel speed sensor.
a Torque tighten the wheel speed sensor bolt (6.5

N.m).
a Connect the wheel speed sensor connector.
a Clip:
- the wheel speed sensor connector,
- the wheel speed sensor wiring.
38C-6
Rear wheel speed sensor: Removal - Refitting 38C
a Refit the rear wheel (see 35A, Wheels and tyres,
38C-7

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3 Chassis

30A GENERAL INFORMATION

31A FRONT AXLE COMPONENTS

33A REAR AXLE COMPONENTS

35A WHEELS AND TYRES

36A STEERING ASSEMBLY

36B POWER ASSISTED STEERING

37A MECHANICAL COMPONENT CONTROLS

38C ANTI-LOCK BRAKING SYSTEM

JANUARY 2009 Edition Anglaise

© Renault s.a.s 2008

SYMBOL - THALIA - Section 3

30A GENERAL INFORMATION 31A FRONT AXLE COMPONENTS

Brake circuit Operating Front axle assemblies:

Brake circuit Precautions for Front brake pads: Removal -

Brake circuit Bleeding 30A-4 Front brake hose: Removal -

Underbody height: Front brake disc: Removal -

Front axle: Adjustment Front driveshaft hub carrier:

Front axle: Adjusting 30A-28 Front hub carrier bearing:

Front driveshaft lower arm:

Front driveshaft lower arm

Front driveshaft lower arm

31A FRONT AXLE COMPONENTS 35A WHEELS AND TYRES

Front axle sub-frame: Tyre inflation pressure:

Front anti-roll bar: Removal - Wheel rim: Identification 35A-15

36A STEERING ASSEMBLY

36B POWER ASSISTED STEERING

Wheel: Balancing 35A-4 Power-assisted steering

Tyres: Removal - Refitting 35A-9

Tyres: Repair 35A-11

36B POWER ASSISTED STEERING 37A MECHANICAL COMPONENT CONTROLS

Power assisted steering Automatic gear control cable:

Gear control unit: Adjusting 37A-43

Brake servo non-return

Brake pedal: Removal -

Brake pedal switch: Removal

Parking brake lever: Removal

Parking brake lever:

Braking assistance circuit:

Clutch control: List and

Clutch cable: Removal -

Clutch pedal: Removal -

Clutch circuit: Bleeding 37A-29

When replacing brake pads, always replace the pads

1 - Advice to be followed before any operation

2 - Instructions to be followed during the operation

Do not allow friction materials to come into contact with

brake circuit bleeding device

This procedure must be applied after one of the fol-

- a rigid pipe, a Use locally produced containers to collect the used

- 4 mm diameter transparent pipes (2) ,

a Position the vehicle on a two-post lift (see Vehicle:

a Switch off the vehicle ignition.

a Carry out the previous operation on the callipers:

No. Description Tightening torque (Nm)

(1) Guide pin bolts 28

(2) Calliper bleed screw 6

(3) Calliper mounting bolt 100

(4) Disc bolt 14

No. Description Tightening torque (N.m)

(5) Rear brake cylinder bolt 15

(6) Rear brake cylinder bleed screw 6

No. Description Tightening torque (N.m)

(7) Hydraulic unit bolt on its mounting 8