TECHNICAL NOTE BLUE

EDITION ANGLAISE
FEBRUARY 2004
77 11 324 882 4400AService 00429

MEGANE II See list on next page

37A BRAKE SERVO

OTS: 0AAF MARK: B5

Other sub-section concerned: 999

●
Engine: XXX Basic manual:
●
Gearbox: XXX Workshop Repair Manual: 364

The vehicle cut-offs are given as guidelines only.

Before starting any work, it is ESSENTIAL to check that the vehicle is affected by
OTS 0AAF

●
Countries with PGCS
Network with ICM: Refer to the list of OTS operations to be carried out in ICM.

Network without ICM: If square B5 on the blue label is not marked with a cross, contact your primary
network who will check in the ICM.
If square A2 on the blue label is marked with a cross, the vehicle is affected and
the operation has already been carried out through OTS 0AAG (NT 4327C).

●
Countries without PGCS
All networks: If square B5 on the blue label is not marked with a cross, the vehicle is affected.
If square A2 on the blue label is marked with a cross, the vehicle is affected and
the operation has already been carried out through OTS 0AAG (NT 4327C).

FRANCE
Members of the RENAULT Network who are qualified to apply this OTS:
●
All of the network except RENAULT Relais agents
RENAULT Relais agent: should a customer come to your dealership, we would ask you to send them to a trained
member of the RENAULT Network.

"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer
in the production of the various component units and accessories from which his
vehicles are constructed".
All copyrights reserved by RENAULT.
Copying or translating, in part or in full, of this document or use of the service part
reference numbering system is forbidden without the prior written authority of
RENAULT.

© RENAULT 2004
 137A CONTROLS
MECHANICAL COMPONENT
Brake servo 37A
LIST OF VEHICLES CONCERNED

Vehicle Type from to Vehicle Type from to

MEGANE II BM0 B D 000005 D 010956 MEGANE II BM0 U D 000084 D 011461

E 000021 E 008335 E 000050 E 008076
BM0 C D 000019 D 011494 BM1 G D 000728 D 011488
E 000001 E 008331 E 000537 E 007277
BM0 F D 000018 D 011491 CM0 B E 000008 E 008998
E 000003 E 008320 CM0 C E 000002 E 008985
BM0 G D 000006 D 011496 CM0 F E 000001 E 008993
E 000015 E 008338 CM0 G E 000007 E 009001
BM0 H D 000143 D 011397 CM0 H E 000336 E 002428
E 000183 E 004458 CM0 J E 000267 E 008994
BM0 J D 000483 D 011372 CM0 U E 000078 E 008997
E 000136 E 008336 CM1 G E 001079 E 008916
SM0 F D 000001 D 000005

37A-2
 MECHANICAL COMPONENT CONTROLS
Brake servo 37A
TECHNICAL INFORMATION Special notes on F9Q and K9K engines
– Remove:
●
Preventive operation The turbocharging regulation solenoid valve
– Replace the brake servo. (F9Q engine only).
●
The EGR valve using tool
Description of the operation Part No. 77 11 381 729
● ●
If square A2 on the blue label is marked with a cross, Both gearbox control ball joints.
●
the operation has already been carried out through The gearbox control cable sleeve stop support.
OTS 0AAG (NT 4327C). – Disconnect the brake fluid warning light connector.
– Do not replace the brake servo but issue a request – Remove the brake servo vacuum valve.
for reimbursement under warranty or an individual – Partially remove the soundproofing material from the
claim, depending on the country. bulkhead.
– Disconnect the clutch master cylinder pipe.
– Remove the gearbox upper control ball joint (except
WARNING
F9Q and K9K engines).
The following procedure avoids the need to remove
– From inside the passenger compartment, remove the
the master cylinder and bleed the brake circuit.
brake pedal yoke pin from the brake servo pushrod.
It is ESSENTIAL to follow it scrupulously.

REMOVAL
– Remove the covers.

WARNING
Switch off the engine.
Switch off all the electrical consumers.
Allow 1 minute for the electronic systems to switch
off.
Wait for the engine cooling fan to shut off completely.

– Disconnect the battery, starting with the negative

terminal.
– Remove:
– The battery.
– The air resonator unit (only on K4J engine).
– The battery tray.
– The injection computer.
– The air intake duct.
– The air duct.
A – Brake pedal clevis pin
– The air filter unit.
– The brake pedal position switch on the pedal
assembly.
– Drain the brake fluid reservoir using a syringe until
the fluid level is below the level of the clutch master
cylinder supply port.

37A-3
 MECHANICAL COMPONENT CONTROLS
Brake servo 37A
– Remove both nuts securing the master cylinder to
the brake servo.
– Tilt the master cylinder forwards to disconnect it from
the brake servo, taking care not to pinch the brake
hoses.
– Remove both mounting bolts from the brake
servo (B).

C – Retaining clip
D – Separator clip

– From inside the passenger compartment, position

the pushrod on the brake servo and on the brake
pedal.
– Depress the brake pedal to connect the pushrod and
the servo.
B – Brake servo mounting bolts – Refit the brake pedal yoke pin (A).

REFITTING WARNING
– Refit the new brake servo but do not fit the pushrod Make sure that the brake pedal clevis pin locks on to
to it. the pushrod.
– Tighten both brake servo mounting bolts to a torque
of 2.1 daNm.
– Refit the master cylinder to the brake servo.
– Tighten both master cylinder nuts to a torque of
5 daNm.
– Check the position and tightness of retaining clip (C)
on the bulkhead, and the brake hoses in the clip.
– Check that separator clip (D) is present.

37A-4
 MECHANICAL COMPONENT CONTROLS
Brake servo 37A
Preparing brake pedal position switch (E) before – Reconnect the battery, starting with the positive
refitting. terminal.
Note: the brake pedal position switch has automatic – Check the operation of the brake pedal position
adjustment which is adapted to the brake pedal switch.
position.
– It is ESSENTIAL to be careful when pulling the end
WARNING
of piston (F) on brake pedal position switch (E) to
Carry out the necessary programming according to
obtain measurement (X) of between 17 mm
the Battery: advice section in Technical Note
minimum and 18 mm maximum.
3682A or 6002A.

WARNING – Carry out a road test.

– The switch must be replaced if the brake pedal
position switch piston is extracted completely.
– The switch must be replaced if handling of the
piston results in three adjustments being made.
Marking the vehicle after work has been carried
out
– Affix a blue label, Part No.: 49 39 031 070, to the
driver's side front shock absorber turret.
– Tick square B5 using a marker pen.

E – Brake pedal position switch

F – Adjustment piston
X – Adjustment measurement value of 17 mm to 18 mm

– Fully depress the brake pedal with your hand.

– Refit the brake pedal position switch to the pedal
assembly and tighten it one quarter-turn clockwise.
– Release the pedal, following its travel with your hand.
– Connect the connector to the brake pedal position
switch.
– Top up the brake fluid.
– Refit the removed components in the reverse order
to removal.

37A-5
 MECHANICAL COMPONENT CONTROLS
Brake servo 37A
CLAIM COMPLETION AND CODING Destination of removed parts
– Other countries: return to manufacturer.
When to take action
– The first time the vehicle is brought into the Accounts procedure
workshop. – Request for reimbursement or individual claim,
depending on the country.
Tooling required – Nature of expense: OTS
– Conventional. – Expense code: 91
– 1 EGR valve removal tool Part no. 77 11 381 729 – Parts at cost price.
– Labour at contractual warranty rate.
– Closure date: 31/12/2006
Parts required
OTS code: 0AAF
Left-hand drive (0 = Figure zero)
Quantity and description of parts Part No.
1 Brake servo kit 77 01 208 000

Right-hand drive
Quantity and description of parts Part No.
1 Brake servo kit 77 01 208 001

Time required
If the brake servo has been replaced through
OTS 0AAG
Code Description Time
0095 Vehicle checked 0.1
TOTAL 0.1

All engines except K4J

Code Description Time
0096 Application of OTS 0.2
3161 Replacing the brake servo 1.1
0129 Basic road test 0.5
TOTAL 1.8

K4J engine
Code Description Time
0096 Application of OTS 0.2
3240 Replacing the brake servo 0.8
0129 Basic road test 0.5
TOTAL 1.5

37A-6