6 - Air Conditioning

© Renault s.a.s 2008

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

The methods may be modified as a result of changes introduced by the manufacturer in theproduction of the various component units and accessories from which his vehicles areconstructed."

All copyrights reserved by Renault.

The reproduction or translation in part of whole of the present document, as well as the useof the spare parts reference numbering system, are prohibited without the prior writtenconsent of Renault.

JUNE 2008 Edition Anglaise

X95

6 Air conditioning

61A HEATING

62A AIR CONDITIONING

MEGANE III - Section 6

Contents

Page

MEGANE III - Section 6ContentsPage

61A HEATING

Heating: List and location of components 61A-1

Cabin filter: Removal - Refitting 61A-9

C-pillar intermediate air distribution duct: Removal - Refitting 61A-13

Rear air distribution duct: Removal - Refitting 61A-14

Recirculation control cable: Removal - Refitting 61A-15

Air distribution cable: Removal - Refitting 61A-16

Air mixing cable: Removal - Refitting 61A-21

Air distribution unit: Removal - Refitting 61A-26

Heater matrix: Removal - Refitting 61A-32

Fan assembly: Removal - Refitting 61A-39

Heating resistor relays: Removal - Refitting 61A-48

Heating resistor unit: Removal - Refitting 61A-50

Passenger compartment fan assembly control unit: Removal - Refitting 61A-54

Control panel: Removal - Refitting 61A-57

Front side air distribution duct: Removal - Refitting 61A-61

Front central air distribution duct: Removal - Refitting 61A-66

A-pillar air distribution duct: Removal - Refitting 61A-67

Recirculation motor: Removal - Refitting 61A-68

Mixer motor: Removal - Refitting 61A-73

Distribution motor: Removal - Refitting 61A-81

Passenger compartment temperature sensor: Removal - Refitting 61A-85


Air conditioning: Precautions for repair 62A-1

Air conditioning: Parts and consumables for the repair work 62A-2

Air conditioning: Operating diagram

Air conditioning: Check 62A-3

Heating and ventilation system diagnostic tool: Use 62A-6

Coolant circuit check 62A-7

Coolant circuit Draining - Refilling 62A-8

Condenser: Removal - Refitting 62A-11

Compressor: Removal - Refitting 62A-16

Expansion valve: Removal - Refitting 62A-23

61A HEATING

Contents

Evaporator: Cleaning 62A-30

Expansion valve - condenser connecting pipe: Removal - Refitting 62A-32

Expansion valve/intermediate pipe connecting pipe: Removal - Refitting 62A-38

Pressure sensor: Removal - Refitting 62A-42

Evaporator sensor: Removal - Refitting 62A-43

Condenser - compressor connecting pipe: Removal - Refitting 62A-46

Compressor/intermediate pipe connecting pipe: Removal - Refitting 62A-51


61A-1

HEATINGHeating: List and location of components

B95 or D95 or E95 or K95, and CLIMATE CONTROL

61AI - LIST OF COMPONENTS

The air conditioning system consists of:

- a control panel (1) ,

- a mixing motor (2) ,

- a distribution motor (3) ,

- a cabin filter (4) ,

- an expansion valve (5) ,

- a recirculation motor (6) ,

- a recirculation control cable (7) ,

- a cooling fan assembly (8) ,

- a passenger compartment fan assembly control unit(9) ,

- a mixing motor (10) ,

- an evaporator sensor (11) ,

- a heater matrix (12) ,

- a heating resistor relay (13) ,

- a heating resistor (14) ,

- a front side air distribution duct (15) ,

- a front right-hand side intermediate air distributionduct (16) ,

- a front left-hand side intermediate air distribution duct(17) ,

- a front centre air distribution duct (18) ,

- a front left-hand footwell air distribution duct (19) ,

- a front right-hand footwell air distribution duct (20) ,

- a rear left-hand footwell air distribution duct (21) ,

- a rear right-hand footwell air distribution duct (22) .

- a rear intermediate air distribution duct (23) ,

- a rear air distribution duct (24) .

II - LOCATION OF COMPONENTS

EQT LEVEL EA4, and ELEC PARKING BRAKE

133409

61A-2



61A

133410

61A-3



61A

133406

61A-4



61A


133404

61A-5


B95 or D95 or E95 or K95, and AIR CONDITIONING

61AI - LIST OF COMPONENTS

The air conditioning system consists of:

- a control panel (1) ,

- an air distribution cable (2) ,

- a cabin filter (3) ,

- an expansion valve (4) ,

- a recirculation motor (5) ,

- a recirculation control cable (6) ,

- a cooling fan assembly (7) ,

- a passenger compartment fan assembly control unit(8) ,

- an evaporator sensor (9) ,

- a heater matrix (10) ,

- a heating resistor relay (11) ,

- a heating resistor (12) ,

- an air mixing cable (13) ,

- a front side air distribution duct (14) ,

- a front right-hand side intermediate air distributionduct (15) ,

- a front left-hand side intermediate air distribution duct(16) ,

- a front centre air distribution duct (17) ,

- a front left-hand footwell air distribution duct (18) ,

- a front right-hand footwell air distribution duct (19) ,

- a rear left-hand footwell air distribution duct (20) ,

- a rear right-hand footwell air distribution duct (21) .

- a rear intermediate air distribution duct (22) ,

- a rear air distribution duct (23) .

II - LOCATION OF COMPONENTS


133405

61A-6



61A

133407

61A-7



61A

133406

61A-8



61A


133404

61A-9

HEATINGCabin filter: Removal - Refitting

B95 or D95 or E95 or K95, and LEFT-HAND DRIVE

61AREMOVAL

I - REMOVAL PREPARATION OPERATION

a Remove:

- the glovebox (see Glovebox: Removal - Refit-ting) ( 57A, Interior equipment),

- the front right-hand A-pillar air distribution duct (see61A, Heating, A-pillar air distribution duct: Re-moval - Refitting, page 61A-67) .

II - OPERATION FOR REMOVAL OF PART CONCERNED

a Remove the electrical wiring (1) from the cabin filterflap after marking its routing.

a Remove:

- the bolts (2) from the cabin filter flap,

- the cabin filter flap.

a Remove the cabin filter.

REFITTING

I - REFITTING PREPARATION OPERATION

a Check there are no foreign bodies in the cabin filterhousing and clean thoroughly if necessary.

II - REFITTING OPERATION FOR PART CONCERNED

a Refit:

- the cabin filter,

- the cabin filter flap,

- the bolts on the cabin filter flap.

a Fit the electrical wiring on the cabin filter flap.

III - FINAL OPERATION

a Refit:

- the front right-hand A-pillar air distribution duct (see61A, Heating, A-pillar air distribution duct: Re-moval - Refitting, page 61A-67) ,

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

135675

Note:

Foreign bodies (leaves, insects etc.) are likely toaccumulate in the passenger compartment filter.Remove the filter with care so as to preventforeign bodies getting into the evaporator.

61A-10


B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE

61A

REMOVAL


a Unclip the centre console right-hand trim

a Remove:

- the dashboard lower trim (see Lower section ofdashboard trim: Removal - Refitting) (57A, Inte-rior equipment),



a Unclip the hydraulic clutch pipes (1) .

a Move the hydraulic clutch pipes aside.

a Unclip the clutch pedal wiring (2) .

a Remove the nuts (5) from the clutch pedal.

a Move the clutch pedal aside.

a Route the hydraulic clutch pipes under the distribu-tion unit.

Tightening torquesm

clutch pedal nuts 21 N.m

137690

137154

Note:

Do not disconnect the clutch pedal connectors.

Note:

Do not put any strain on the hydraulic clutchpipes.

61A-11



61A

a Tilt the clutch pedal in the direction of the arrow.

a Fit the clutch pedal in the footwell.


a Mark the wiring (3) on the cabin filter flap.

a Move aside the wiring of the cabin filter flap.

a Remove:

- the bolts (4) from the cabin filter flap,

- the cabin filter flap.

REFITTING


a Check there are no foreign bodies in the cabin filterhousing and clean thoroughly if necessary.


a Refit:

- the cabin filter,

- the cabin filter flap,

- the bolts on the cabin filter flap.

a Fit the electrical wiring on the cabin filter flap.

136999

135675

Note:

Foreign bodies (leaves, insects etc.) are likely toaccumulate around the cabin filter. Remove thefilter with care so as to prevent foreign bodiesgetting into the evaporator.

61A-12



61AIII - FINAL OPERATION

a Fit:

- the clutch pedal,

- the hydraulic clutch pipes.

a Refit the clutch pedal nuts.

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

a Clip:

- the clutch pedal wiring,


a Refit:




a Clip on the centre console right-hand trim.

61A-13

HEATINGC-pillar intermediate air distribution duct: Removal - Refitting

B95 or D95 or E95 or K95, and EQT LEVEL EA4, and ELEC PARKING BRAKE

61A

REMOVAL


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

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


a Remove:

- the clip (1) from the C-pillar intermediate air distri-bution duct using the tool (Car. 1363),

- the C-pillar intermediate air distribution duct.

REFITTING

I - REFITTING OPERATION FOR PART CONCERNED

a Refit:

- the C-pillar intermediate air distribution duct,

- the clip of the C-pillar intermediate air distributionduct.

II - FINAL OPERATION

a Refit the dashboard (see Dashboard: Removal -Refitting) (57A, Interior equipment).

a Connect the battery (see Battery : Removal - Refit-ting) (80A, Battery).

Essential special tooling

Car. 1363 Set of tr im removal levers.

137016

61A-14

HEATINGRear air distribution duct: Removal - Refitting

B95 or D95 or E95 or K95, and EQT LEVEL EA4, and ELEC PARKING BRAKE

61AREMOVAL


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


a Unclip the rear section of the centre console.

a Remove the bolts (1) from the rear air distributionduct.

a Unclip (2) the rear air distribution duct from the cen-tre console.

a Remove the rear air distribution duct from the centreconsole.

REFITTING


a Refit the rear air distribution duct on the centre con-sole.

a Clip the rear air distribution duct to the centre conso-le.

a Refit the rear air distribution duct bolts.


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

136377

136378

61A-15

HEATINGRecirculation control cable: Removal - Refitting

B95 or D95 or E95 or K95

61AREMOVAL





a Unclip the wiring at (1) .

a Unclip the wiring at (2) .

a Remove the recirculation cable.

REFITTING


a Refit the recirculation cable.

a Clip on the recirculation cable.




137028

137024

61A-16

HEATINGAir distribution cable: Removal - Refitting

B95 or D95 or E95 or K95, and LEFT-HAND DRIVE, and AIR CONDITIONING

61AREMOVAL


a Remove:



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

a Remove the radio (see Car radio: Removal - Refit-ting) (86A, Radio).

a Remove the radio navigation system (see Radio na-vigation system: Removal - Refitting) (83C, On-board telematics system).

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

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

a Tilt the control panel.

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

a Move aside the control panel.

RADIO NO 01 or RADIO NO 02 or RADIO NO 03or RADIO NO 04 or RADIO NO 05

RADIO NO 06 or RADIO NO 07

135676

135677

135659

61A-17



61AII - OPERATION FOR REMOVAL OF PART CONCERNED

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

a Unclip the air distribution cable from the distributionunit at (5) .

a Mark the routing of the air distribution cable.

a Remove the air distribution cable.

REFITTING


a Refit the air distribution cable.

a Clip the air distribution control cable onto:

- the distribution unit,

- the control panel.


a Fit the control panel.

a Clip:

- the air mixing cable to the control panel,

- the control panel centring pins.

a Refit the control panel bolts.

a Check that the air distribution control can movealong its whole stroke.

a Refit the radio navigation system (see Radio navi-gation system: Removal - Refitting) (83C, On-board telematics system).

a Refit the radio (see Car radio: Removal - Refitting)(86A, Radio).

a Refit:

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



135658

136994



61A-18


B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and AIR CONDITIONING

61A

REMOVAL


a Remove:


- the front footwell air distribution duct (see 61A,Heating, A-pillar air distribution duct: Removal- Refitting, page 61A-67) ,




a Disconnect the connector from the parking distancecontrol buzzer.

a Unclip the wiring from the dashboard cross memberreinforcement.

a Remove:

- the lower bolts from the dashboard cross memberreinforcement,

- the upper bolts from the dashboard cross memberreinforcement,

- the dashboard cross member reinforcement.



Tightening torquesm

dashboard cross mem-ber reinforcement upperbolts

21 N.m

dashboard cross mem-ber reinforcement lowerbolts

21 N.m


RADIO NO 06

FR AND RR PROX RADAR

135676

135677

61A-19



61A






a Unclip the air distribution cable from the distributionunit at (5) .

a Mark the routing of the air distribution cable.

a Remove the air distribution cable.

REFITTING


a Refit the air distribution cable.

a Clip:

- the air distribution cable on the distribution unit,

- the air distribution cable on the control panel.



a Clip:

- the air mixing cable to the control panel,

- the control panel centring pins.

a Clip the air mixing cable onto the control panel.

a Clip on the control panel centring pins.



a Refit:

- the dashboard cross member stiffener,

135659

135658

136990

61A-20



61A- the upper bolts of the dashboard cross memberreinforcement,

- the lower bolts of the dashboard cross memberreinforcement.

a Tighten to torque:

- the dashboard cross member reinforcementupper bolts (21 N.m),

- the dashboard cross member reinforcementlower bolts (21 N.m).

a Clip on the dashboard cross member reinforcementwiring.

a Connect the parking distance control buzzer con-nector.


a Refit the radio navigation system (see Radio navi-gation system: Removal - Refitting) (83C, On-board telematics system).

a Refit:



- the dashboard lower trim (see Lower section ofdashboard trim: Removal - Refitting) (57A, Inte-rior equipment).



RADIO NO 06

61A-21

HEATINGAir mixing cable: Removal - Refitting


61AREMOVAL


a Remove:


- the front left-hand footwell air distribution duct (see61A, Heating, A-pillar air distribution duct: Re-moval - Refitting, page 61A-67) ,






a Tilt the control panel .





135676

135677

135659

61A-22



61A

a Unclip the air mixing cable from the distribution unit.

a Mark the routing of the air mixing cable.

a Remove the air mixing cable.

REFITTING


a Refit the air mixing cable.

a Clip the air mixing cable onto:

- the distribution unit,

- the control panel.




a Clip on the centring pins.



a Refit the radio navigation system (see Radio navi-gation system: Removal - Refitting) (83C, Onboard telematics system).


a Refit:




136993



61A-23



61A

REMOVAL


a Unclip the left-hand centre console trim.

a Remove:








a Remove the lower bolts (1) from the dashboardcross member reinforcement.

Tightening torquesm


21 N.m


21 N.m

137019




135692

61A-24



61A

a Remove:

- the upper bolts (2) from the dashboard cross mem-ber reinforcement,






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

135693

135676

135677

135659

61A-25



61A

a Unclip the air mixing cable (6) from the distributionunit.

a Mark the routing of the air mixing cable.

a Remove the air mixing cable.

REFITTING


a Refit the air mixing cable.

a Clip:

- the air mixing cable onto the distribution unit,

- the air mixing cable onto the control panel.



a Clip on the centring pins of the control panel.


a Check that the air mixing control can move along itswhole stroke.

a Refit:

- the dashboard cross member reinforcement,

- the upper bolts of the dashboard cross memberreinforcement,





a Clip on the wiring of the dashboard cross memberreinforcement.




a Refit:




a Clip on the left-hand centre console trim.

136993




61A-26

HEATINGAir distribution unit: Removal - Refitting

B95 or D95 or K95

61A

REMOVAL


a Remove the front engine cover.

a Drain the refrigerant circuit using the refrigerantcharging station (see 62A, Air conditioning, Coo-lant circuit Draining - Refilling, page 62A-8) .


a Remove:

- the windscreen wiper arms (see Windscreen wi-per arm: Removal - Refitting) (85A, Wiping -Washing),

- the scuttle panel grille (see Scuttle panel grille:Removal - Refitting) (56A, Exterior equipment),

- the scoop under the scuttle panel grille (see Scoopunder scuttle panel grille: Removal - Refitting)(56A, Exterior equipment),

- the windscreen wiper mechanism (see Winds-creen wiper mechanism: Removal - Refitting)(85A, Wiping - Washing).

a Remove:

- the lifting eye of the cylinder head,

- the turbocharger heat shield nuts.

a Remove the turbocharger heat shield.


Ms. 583 Hose clamp pliers.

Essential equipment

refrigerant charging station

Tightening torquesm

clip of the air filter unitair outlet pipe

5.5 N.m

IMPORTANT

To avoid all risk of damage to the systems, applythe safety and cleanliness instructions and opera-tion recommendations before carrying out anyrepair (see 62A, Air conditioning, Air conditio-ning: Precautions for repair, page 62A-1) .

Note:

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

WARNING

Consult the device's operating manual to avoidincorrect use.

F4R

WARNING

To prevent the surrounding components fromoverheating, do not damage (tear, pierce, bend,etc.) a heat shield.

Any damaged heat shields must be replaced.

61A-27


B95 or D95 or K95

61A

a Remove:

- the bulkhead upper heat shield bolts (1) ,

- the bulkhead upper heat shield clips (2) .

a Remove the bulkhead upper heat shield.

a Remove:

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

- the diesel injection computer (see Diesel injectioncomputer: Removal - Refitting) (13B, Diesel in-jection),

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

- the intercooler air inlet pipe (see Intercooler air in-let pipe: Removal - Refitting) (12B, Turbochar-ging).

a Remove the clips from the bulkhead heat shield.

a Move the bulkhead heat shieldto one side.

a Remove the bolts (3) from the expansion valve con-necting pipe bracket.

a Uncouple the connecting pipes from the expansionvalve.

a Remove the connecting pipes from the expansionvalve.

a Remove the connecting pipe seals.

a Insert the blanking plugs.

F4R

136467

WARNING



F9Q

F9Q or K9K

WARNING



136487

WARNING

In order to avoid any refrigerant leaks, do notdamage (deform, twist, etc.) the pipe.

61A-28


B95 or D95 or K95

61A

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

a Remove the bolts (5) from the air inlet pipe on thethrottle valve.

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

a Disconnect the connector (7) of the turbochargingpressure regulation valve control solenoid valve.

a Detach the turbocharging pressure regulation valvecontrol solenoid valve.

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

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

a Disconnect the heater matrix hoses.

F4R

135707

135796

137157

134643

61A-29


B95 or D95 or K95

61Aa Remove:

- the dashboard (see Dashboard: Removal - Refit-ting) (57A, Interior equipment),

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

- the dashboard cross member (see Dashboardcross member: Removal - Refitting) (42A, Upperfront structure).


a Disconnect the supply connector (8) from the distri-bution unit.

a Unclip the electrical wiring from the distribution unit.

a Separate the electrical wiring from the distributionunit.

a Remove the distribution unit.

a Remove the following components from the distribu-tion unit:

- the air distribution cable,

- the cabin filter,

- the expansion valve,

- the recirculation motor,

- the air recirculation control cable,

- the fan assembly,

- the fan assembly control unit,

- the evaporator sensor,

- the heater matrix,

- heater resistor relays,

- the heating resistor,

- the air mixing cable.

a Remove the following components from the distribu-tion unit:

- the left-hand mixer motor,

- the right-hand mixer motor,

- the distribution motor,

- the cabin filter,




- the fan assembly,





- the heating resistor.

137642

Note:

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

AIR CONDITIONING

CLIMATE CONTROL

61A-30


B95 or D95 or K95

61AREFITTING


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

a Remove the blanking plugs.

a Lubricate the seals using recommended air conditio-ning oil to make fitting easier (see 62A, Air condi-t i o n i n g , Air conditioning: Parts andconsumables for the repair work, page 62A-2) .

a Fit new seals to the refrigerant connecting pipes.


a Refit the following components onto the distribution unit:

- the left-hand mixer motor,

- the right-hand mixer motor,

- the distribution motor,

- the cabin filter,




- the fan assembly,






a Refit the following components onto the distribution unit:

- the air distribution cable,

- the cabin filter,




- the fan assembly,





- the heating resistor,

- the air mixing cable.

a Refit the distribution unit.

a Fit the wiring on the distribution unit.

a Clip the wiring onto the distribution unit.

a Connect the supply connector of the distribution unit.


a Refit:

- the dashboard cross member (see Dashboardcross member: Removal - Refitting) (42A, Upperfront structure),


- the dashboard (see Dashboard: Removal - Refit-ting) (57A, Interior equipment).

a Connect the heater matrix hoses.

a Remove the tool (Ms. 583) from the heater matrixhoses.

WARNING

Do not remove the blanking plugs from eachcomponent until the last moment.

Also, do not remove the components from theirpackaging until they are to be fitted to the vehi-cle.

WARNING

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

CLIMATE CONTROL

AIR CONDITIONING

61A-31


B95 or D95 or K95

61A

a Refit:

- the air outlet pipe to the air filter unit,

- the air inlet pipe to the throttle valve.

a Clip on the turbocharging pressure regulation valvecontrol solenoid valve.

a Connect the connector of the turbocharging pressu-re regulation valve control solenoid valve.

a Clip on the brake servo vacuum pipe.

a Torque tighten the clip of the air filter unit air out-let pipe (5.5 N.m).

a Connect the connecting pipes to the expansion val-ve.

a Fit the heat shield to the bulkhead.

a Refit the heat shield bolts.

a Refit:

- the intercooler air inlet pipe (see Intercooler air in-let pipe: Removal - Refitting) (12B, Turbochar-ging),

- the battery tray (see Battery : Removal - Refit-ting) (80A, Battery),

- the diesel injection computer (see Diesel injectioncomputer: Removal - Refitting) (13B, Diesel in-jection),

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

a Refit:

- the bulkhead upper heat shield,

- the bulkhead upper heat shield bolts,

- the bulkhead upper heat shield clips,

- the turbocharger heat shield,

- the turbocharger heat shield nuts,

- the lifting eye of the cylinder head.


a Fill and bleed the cooling circuit (see Cooling cir-cuit: Draining - Refilling) (19A, Cooling).

a Perform the following operations:

- refill the refrigerant circuit using the refrigerantcharging station (see 62A, Air conditioning,Coolant circuit Draining - Refilling, page 62A-8),

- check for leaks (see 62A, Air conditioning, Coo-lant circuit check, page 62A-7) .

a Check that the air conditioning system is operatingcorrectly (see 62A, Air conditioning, Air conditio-ning: Check, page 62A-3) .

a Refit:

- the windscreen wiper mechanism (see Winds-creen wiper mechanism: Removal - Refitting)(85A, Wiping - Washing),




- the engine cover.

F4R

F9Q or K9K

F9Q

F4R

Note:

A summary table gives the quantities of refrige-rant in the system according to the engine type(see 62A, Air conditioning, Air conditioning:Parts and consumables for the repair work,page 62A-2) .

61A-32

HEATINGHeater matrix: Removal - Refitting


61A

REMOVAL

I - OPERATION FOR REMOVAL OF PART CONCERNED

a Switch off the ignition.

a Remove the engine style cover.


a Remove the bolts (2) from the air inlet pipe on thethrottle valve.

a Disconnect the brake servo vacuum pipe (3) .



Tightening torquesm


21 N.m


21 N.m


5.5 N.m

F4R

135707

135796

137157

61A-33



61A

a Disconnect the connector from the turbochargingpressure regulation valve control solenoid valve.

a Unclip the turbocharger pressure regulation valvecontrol solenoid valve at (4) .



a Unclip the centre console left-hand trim.

a Remove:


- the front left-hand footwell air distribution duct (see61A, Heating, A-pillar air distribution duct: Re-moval - Refitting, page 61A-67) .


a Remove:



134643 135692

135693

61A-34




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

a Put a protective cover on the floor carpet.

a Position a container to collect the coolant under therigid pipes.

a Move the heater matrix rigid pipes aside.

a Remove the seals from the heater matrix rigid pipes.

a Remove:

- the heater matrix trim bolts (8) ,

- the heater matrix trim.

a Take the heater matrix out of its housing.

a Remove the heater matrix.

REFITTING


a parts always to be replaced: heater matrix coo-lant pipe seal (30,02,01,46)

a Always replace the heater matrix rigid pipe clips.


a Refit:

- the heater matrix in its housing,


a Fit:

- new seals on the heater matrix rigid pipes,

- the heater matrix rigid pipes on the heater matrix.

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

135694

WARNING

Prepare for the flow of fluid, and protect the sur-rounding components.

135695

135696

WARNING


61A-35



61Aa Remove:

- the container for recovering coolant under the rigidpipes,

- the protective cover on the floor carpet.


a Refit:


- the upper bolts on the dashboard cross memberreinforcement,

- the lower bolts on the dashboard cross memberreinforcement.




a Refit:


- the instrument panel lower trim (see Lower sec-tion of dashboard trim: Removal - Refitting)(57A, Interior equipment).

a Clip on the centre console left-hand trim.


a Refit:




a Connect:

- the connector on the turbocharging pressure regu-lation valve control solenoid valve,

- the vacuum pipe from the brake servo.


a Fill up and bleed the cooling system (see Coolingcircuit: Draining - Refilling) (19A, Cooling).

a Refit the engine style cover.

F4R

61A-36



61A

REMOVAL





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

a Disconnect the brake servo vacuum pipe (3) .



Tightening torquesm


5.5 N.m

F4R

135707

135796

137157

61A-37



61A

a Disconnect the connector of the turbocharging pres-sure regulation valve control solenoid valve.

a Unclip the turbocharger pressure regulation valvecontrol solenoid valve at (4) .




a Remove:




a Remove the clips (5) from the heater matrix rigid pi-pes.

a Put a protective cover on the floor carpet.

a Position a container to collect the coolant under therigid pipes.

a Move the heater matrix rigid pipes aside.

a Remove the seals from the heater matrix rigid pipes

a Remove:

- the heater matrix trim bolts (6) ,

134643

135694

WARNING

Prepare for the flow of fluid, and protect the sur-rounding components.

135695

61A-38



61A- the heater matrix trim.

a Take the heater matrix out of its housing.

a Remove the heater matrix.

REFITTING


a parts always to be replaced: heater matrix coo-lant pipe seal (30,02,01,46)

a Always replace the heater matrix rigid pipe clips.


a Refit:

- the heater matrix in its housing,


a Fit:

- new seals on the rigid pipes of the heater matrix,

- the heater matrix rigid pipes on the heater matrix.

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

a Remove:

- the container for recovering coolant under the rigidpipes,

- the protective cover on the floor carpet.


a Refit:





a Refit:




a Connect:

- the connector on the turbocharging pressure regu-lation valve control solenoid valve,

- the vacuum pipe from the brake servo.


a Fill up and bleed the cooling system (see Coolingcircuit: Draining - Refilling) (19A, Cooling).

a Refit the engine cover.

135696

WARNING


F4R

61A-39

HEATINGFan assembly: Removal - Refitting


61A

REMOVAL


a Remove:



- the cabin filter (see 61A, Heating, Cabin filter: Re-moval - Refitting, page 61A-9) ,

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

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

a Unclip the recirculation control cable.

a Disconnect the recirculation motor connector.

a Mark the routing of the recirculation motor wiring.

a Separate the wiring from the recirculation motor.

a Remove:

- the bolts (2) from the air recirculation duct,

- the air recirculation duct.


a Disconnect the connector from the passenger com-partment fan assembly motor passing through thecabin filter housing.


Ms. 1909 Tool for removal - refitting ofValéo fan assembly

137028

137641

61A-40



61A

a Position the turbine of the passenger compartmentfan assembly in such a way as to align the holes (3)required to fit the tool (Ms. 1909).

a Position the tool (Ms. 1909) and turn it slightly fromleft to right so that the 3 rods of tool MS 1909 coinci-de with the 3 holes of the turbine.

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

a Remove the fan assembly from its housing while ta-king care not to damage the turbine.

137676

137677

137678

137679

Note:

To avoid making the fan assembly motor unsta-ble, position the assembly horizontally while pro-tecting it from any impact.

61A-41



61AREFITTING


a Fit the tool (Ms. 1909) (4) on the passenger com-partment fan assembly.

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

a Check that the clip is correctly positioned (5) in rela-tion to the turbine of the passenger compartment fanassembly.

a Refit the fan assembly in its housing by turning thetool 45˚.

137681

137682

137683

137686

61A-42



61A

a Push the fan assembly until it is fully inserted in itshousing.

a Turn the tool (Ms. 1909) clockwise to lock the pas-senger compartment fan assembly.

a Remove the (Ms. 1909).

a Connect the passenger compartment fan assemblyconnector.


a Refit the air recirculation duct.

a Fit the recirculation motor wiring.

a Connect the recirculation motor connector.

a Clip on the recirculation control cable.

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

a Refit:





137677

61A-43



61A

REMOVAL


a Unclip the right-hand centre console trim.

a Remove:


- the cabin filter (see 61A, Heating, Cabin filter: Re-moval - Refitting, page 61A-9) .

a Remove:

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

- the cowlings under the steering wheel.

a Disconnect the steering column switch assemblyconnectors.

a Disconnect the steering column connectors (2) .

a Fit a block of approximately 440 mm between thesteering column and the floor.

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

a Remove the block between the steering column andthe floor.


Ms. 1909 Tool for removal - refitting ofValéo fan assembly

Tightening torquesm

steering column bolts 21 N.m

136716

134365

134366

61A-44



61A

a Lower the steering column in the footwell.

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

a Unclip the recirculation control cable (5) .




a Remove:




a Disconnect the passenger compartment fan assem-bly motor connector passing through the cabin filterhousing.

137636

Note:

Ver tically lower the steering column and do notapply pressure to the universal joints.

137028

137641

61A-45



61A

a Position the turbine of the passenger compartmentfan assembly in such a way as to align the holes (7)required to fit the tool (Ms. 1909).

a Position the tool (Ms. 1909) and turn it slightly fromleft to right so that the 3 rods of the tool (Ms. 1909)coincide with the 3 holes of the turbine.

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

a Remove the passenger compartment fan assemblyfrom its housing while taking care not to damage theturbine.

137676

137677

137678

137679

Note:

To avoid making the passenger compartment fanassembly motor unstable, position the assemblyhorizontally while protecting it from any impact.

61A-46



61AREFITTING


a Fit the tool (Ms. 1909) (8) on the passenger com-partment fan assembly.

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

a Check that the clip (9) is correctly positioned in rela-tion to the turbine of the passenger compartment fanassembly.

a Refit the passenger compartment fan assembly in itshousing by turning the tool 45˚.

137681

137682

137683

137686

61A-47



61A

a Push the passenger compartment fan assembly un-til it is fully inserted in its housing.

a Turn the tool (Ms. 1909) clockwise to lock the pas-senger compartment fan assembly.

a Remove the (Ms. 1909).

a Connect the passenger compartment fan assemblyconnector.


a Refit the air recirculation duct.




a Check that the recirculation control can move alongits whole stroke.


a Refit the steering column.

a Refit the steering column bolts.

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


a Check the condition of the steering column bearings.

a Connect:

- the electric steering column lock connector,

- the steering column connectors,

- the steering column switch assembly connectors.

a Refit:

- the cowlings under the steering wheel,



a Clip on the right-hand centre console trim.

137687

61A-48

HEATINGHeating resistor relays: Removal - Refitting


61AREMOVAL



a Unclip the left-hand centre console trim.


a Unclip the heating resistor relay unit from the distri-bution unit at (1) .

a Separate the heating resistor relay unit from the dis-tribution unit.

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

a Remove the heating resistor relays (3) .

REFITTING


a Refit the heating resistor relays.

137019

137635

136384

136383

61A-49

HEATINGHeating resistor relays: Removal - Refitting


61Aa Clip:

- the cover of the heating resistor relay unit,

- the heating resistor relay unit onto the distributionunit.


a Clip on the left-hand centre console trim.

61A-50

HEATINGHeating resistor unit: Removal - Refitting


61A

REMOVAL

I - OPERATION FOR REMOVAL OF PART CONCERNED



a Remove:

- the instrument panel lower trim (see Lower sec-tion of dashboard trim: Removal - Refitting)(57A, Interior equipment),





a Remove:



Tightening torquesm


21 N.m


21 N.m

137019


135692

135693

61A-51




a Disconnect the connector (3) from the heating resis-tor.

a Remove:

- the heating resistor bolts (4) ,


REFITTING


a Refit the heating resistor.


a Refit:


- the upper bolts on the dashboard cross memberreinforcement,

- the lower bolts on the dashboard cross memberreinforcement.






a Refit:


- the instrument panel lower trim (see Lower sec-tion of dashboard trim: Removal - Refitting)(57A, Interior equipment).


136380

136381


61A-52



61AREMOVAL




a Remove:


- the front footwell air distribution duct on the left-hand side (see 61A, Heating, A-pillar air distribu-tion duct: Removal - Refitting, page 61A-67) .


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

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

a Take the heating resistor out of its housing.

a Remove the heating resistor.

REFITTING


a Refit the heating resistor.

a Connect the heating resistor connector.

136380

136381

136382

61A-53



61AII - FINAL OPERATION

a Refit:

- the front footwell air distribution duct on the left-hand side (see 61A, Heating, A-pillar air distribu-tion duct: Removal - Refitting, page 61A-67) ,



61A-54

HEATINGPassenger compartment fan assembly control unit: Removal - Refitting


61AREMOVAL


a Remove:

- the glovebox (see Glovebox: Removal) ( 57A, In-terior equipment),



a Unclip the control unit (1) from the passenger com-partment fan assembly.

a Disconnect the connector (2) from the passengercompartment fan assembly control unit.

REFITTING


a Connect the blower unit control unit connector.

a Clip on the passenger compartment fan assemblycontrol unit.


a Refit:


- the glovebox (see Glovebox: Removal) (57A, In-terior equipment).

136991

61A-55



61A

REMOVAL



a Remove:



a Remove the brake pedal impacter bolt (1) .

a Remove:

- the dual safety connecting shaft ring,

- the dual safety connecting shaft (2) .

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

Tightening torquesm

pedal assembly nuts 21 N.m

brake pedal impacterbolt

21 N.m

134662

109879

134696

Note:

Do not disconnect the connectors from the« brake pedal - accelerator » assembly andreplace the brake light switch in the event of animpact.

61A-56



61Aa Partially remove the « brake pedal - accelerator »

assembly.


a Unclip the passenger compartment fan assemblycontrol unit at (4) .

a Disconnect the connector (5) from the passengercompartment fan assembly control unit.

REFITTING


a parts always to be replaced: Connecting shaftbetween the brake pedal and the brake servopushrod (30,03,02,07).

a Part which must always be replaced: Brake pe-dal impacter bolt.


a Connect the connector to the passenger compart-ment fan assembly control unit.

a Clip on the passenger compartment fan assemblycontrol unit.


a Refit:

- the « accelerator - brake pedal » assembly,

- a new dual safety connecting shaft,

- the dual safety connecting shaft rubber ring,

- the pedal assembly nuts.

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

a Refit:

- the brake pedal impacter,

- a new brake pedal impacter bolt.

a Torque tighten the brake pedal impacter bolt (21N.m).

a Refit:




136991

61A-57

HEATINGControl panel: Removal - Refitting


61A

REMOVAL



a Remove the centre front panel (see Centre frontpanel: Removal - Refitting) (57A, Interior equip-ment).





a Squeeze the centring pins while pushing the controlpanel (2) .




Essential equipment

diagnostic tool

AIR CONDITIONING, and RADIO NO 01 or RADIONO 02 or RADIO NO 03 or RADIO NO 04 orRADIO NO 05

AIR CONDITIONING, and RADIO NO 06 or RADIONO 07

135676

135677

AIR CONDITIONING

135659

61A-58



61A


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

a Remove the control panel.


a Disconnect the control panel connector (6) .


a Disconnect the control panel connector (7) .

a Remove the control panel.

135658

135657

CLIMATE CONTROL

135678

135679

61A-59



61AREFITTING


a Refit the control panel.

a Connect the control panel connectors.

a Clip the air distribution cable onto the control panel.

a Fit the control panel in its housing.


a Connect the connector (8) to the control panel.

a Refit the control panel in its housing.

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

a Clip on the centring pins.



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




AIR CONDITIONING

CLIMATE CONTROL

135679

135678

AIR CONDITIONING, and RADIO NO 01 or RADIONO 02 or RADIO NO 03 or RADIO NO 04 orRADIO NO 05

AIR CONDITIONING, and RADIO NO 06 or RADIONO 07

61A-60



61Aa Apply the after repair procedure using the diagnos-

tic tool :

- connect the diagnostic tool,

- select "Climate control computer",

- go to repair mode,

- display the "Before/after repair procedure" for thecomputer selected,

- carry out the operations described in the "After re-pair procedure" section.

61A-61

HEATINGFront side air distribution duct: Removal - Refitting


61A

REMOVAL


Right-hand side

a Remove:



a Remove:

- the receiver (see Tuner-amplifier: Removal - Re-fitting) (86A, Radio),

- the navigation computer (see Navigation compu-ter: Removal - Refitting) (83C, On-board telema-tics system).


Right-hand side

a Remove:

- the clip (1) from the front side air distribution ductusing the tool (Car. 1363),

- the front side air distribution duct (2) .

REFITTING


Right-hand side

a Refit:

- the front side air distribution duct,

- the front side air distribution duct clip.


Right-hand side

a Refit:

- the navigation computer (see Navigation compu-ter: Removal - Refitting) (83C, On-board telema-tics system),



Note:

The front left-hand side air distribution duct cannotbe separated from the dashboard cross member forremoval (see Dashboard cross member: Remo-val - Refitting) (42A, Front upper structure).

RADIO NO 07

135683

RADIO NO 07

61A-62



61A- the receiver (see Tuner-amplifier: Removal - Re-fitting) (86A, Radio).

a Refit:



61A-63



61A

REMOVAL


Left-hand side

a Remove:



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

a Disconnect the connectors (1) from the passengercompartment fuse and relay box.

a Cut the plastic clip (2) on the passenger compart-ment fuse and relay box.

a Unclip the passenger compartment fuse and relaybox plate from the dashboard cross member (3) .

a Separate the passenger compartment fuse and re-lay box plate from the dashboard cross member.



Note:

The front right-hand side air distribution duct cannotbe separated from the dashboard cross member forremoval (see Dashboard cross member: Remo-val - Refitting) (42A, Front upper structure).

137000

137018

61A-64




Left-hand side

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

a Unclip the front side air distribution duct.

a Remove the front side air distribution duct.

REFITTING


Left-hand side

a Part which must always be replaced: Plastic re-taining clip for the passenger compartment fuseand relay support plate.


Left-hand side

a Refit the front side air distribution duct.

a Clip on the front side air distribution duct.

a Refit the front side air distribution duct clip.


Left-hand side

a Fit the passenger compartment fuse and relay sup-port plate on the dashboard cross member.

a Clip the passenger compartment fuse and relay sup-port plate onto the dashboard cross member.

a Refit a new plastic retaining clip on the passengercompartment fuse and relay support plate.

a Connect the connectors to the passenger compart-ment fuse and relay support plate.

a Refit:

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



137022

61A-65


J95

61AREMOVAL

REMOVAL PREPARATION OPERATION

Front right-hand side air distribution duct:

a Disconnect the battery (see Battery: Removal - Re-fitting) .

a Remove:

- the airbag inhibitor switch (see Inhibitor switch:Removal - Refitting) ,

- the glovebox (see Glovebox: Removal - Refit-ting) .

a Remove:

- the receiver (see Tuner-amplifier: Removal - Re-fitting) ,

- the receiver support bolts,

- the receiver support.

RADIO NO 07

61A-66

HEATINGFront central air distribution duct: Removal - Refitting


61AREMOVAL





a Remove the front centre air distribution duct bolts (1).

a Unclip the front centre air distribution duct at (2) .

a Remove the front centre air duct.

REFITTING


a Refit the front centre air duct.

a Clip on the front centre air duct.

a Refit the front centre air duct bolts.




137638

61A-67

HEATINGA-pillar air distribution duct: Removal - Refitting


61A

REMOVAL


1 - Driver's side

a Remove the instrument panel lower trim (see Lowersection of dashboard trim: Removal - Refitting)(57A, Interior equipment).

2 - Passenger side

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


1 - Driver's side

a Remove:

- the clip (1) from the A-pillar air duct, using the tool(Car. 1363),

- the A-pillar air duct (2) .

2 - Passenger side

a Remove:

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

- the A-pillar air duct (4) .

REFITTING


a Refit:

- the A-pillar air duct,

- the A-pillar air duct clip.


1 - Driver's side

a Refit the instrument panel lower trim (see Lowersection of dashboard trim: Removal - Refitting)(57A, Interior equipment).

2 - Passenger side

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



135689

135680

61A-68

HEATINGRecirculation motor: Removal - Refitting


61A

REMOVAL


a Remove:



a Remove:



a Remove the front side air distribution duct (see 61A,Heating, Front side air distribution duct: Remo-val - Refitting, page 61A-61) .

a Unclip the recirculation control cable (1) .





a Remove:



a Remove:

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

Essential equipment

diagnostic tool

RADIO NO 07

137028

137641

137633

61A-69



61A- the air recirculation motor.

REFITTING


a Refit:

- the air recirculation motor,






a Refit:



a Refit:




a Apply the after repair procedure using the diagnos-tic tool :





- select "air recirculation flap motor" in the "List ofcomponents stored by this computer" section,


RADIO NO 07

61A-70



61A

REMOVAL


a Unclip the centre console right-hand trim.

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

a Remove:

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

- the cowlings under the steering wheel.

a Disconnect the steering column switch assemblyconnectors.

a Disconnect the steering column connectors (2) andthe steering column electric lock.


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


Essential equipment

diagnostic tool

Tightening torquesm

steering column bolts 21 N.m

136716

134365

134366

61A-71



61A

a Lower the steering column in the footwell.

a Check that the cross piece does not leave the bea-ring.

a Unclip the recirculation control cable at (5) .





a Remove:



a Remove:

- the bolts (7) from the air recirculation motor,

137636

Note:

Ver tically lower the steering column and do notput apply pressure to the universal joints.

137028

137641

137633

61A-72



61A- the air recirculation motor.

REFITTING


a Refit:

- the air recirculation motor,






a Check that the recirculation control can move alongits whole stroke.

a Refit the steering column.


a Refit the steering column bolts.

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


a Check the condition of the steering column bearings.

a Connect:

- the electric steering column lock connector,

- the steering column connectors,

- the steering column switch assembly connectors.

a Refit:

- the cowlings under the steering wheel,








- select "air recirculation flap motor" in the "List ofcomponents stored by this computer" section,


61A-73

HEATINGMixer motor: Removal - Refitting

B95 or D95 or E95 or K95, and LEFT-HAND DRIVE, and CLIMATE CONTROL

61A

REMOVAL


1 - Right-hand mixing motor

a Remove:



2 - Left-hand mixing motor


a Remove:



a Remove the brake pedal impacter bolt (1) .

a Remove:


- the dual safety connecting shaft (2) .

Essential equipment

diagnostic tool

Tightening torquesm

pedal assembly nuts 21 N.m

brake pedal impacterbolt

21 N.m

134662

109879

61A-74



61A

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

a Partially remove the « brake pedal - accelerator »assembly.



a Mark the routing of the mixing motor wiring.

a Disconnect the connector (4) from the air mixing mo-tor.

a Remove:

- the bolts (5) from the air mixing motor,

- the air mixing motor.

134696

Note:

Do not disconnect the connectors from the« brake pedal - accelerator » assembly andreplace the brake light switch in the event of animpact.

135682

61A-75



61A2 - Left-hand mixing motor


a Disconnect the connector (6) from the air mixing mo-tor.

a Remove:



REFITTING



a Move the tie rod so that the flat surface (8) of the ri-ght-hand mixing motor recess is positioned at 90˚ inrelation to the distribution unit reference axis (9) .


a parts always to be replaced: Connecting shaftbetween the brake pedal and the brake servopushrod (30,03,02,07).

a part which must always be replaced: Brake pe-dal impacter bolt.

a Move the tie rod so that the flat surface (10) of theleft-hand mixing motor recess is positioned at 90˚ inrelation to the edge of the distribution unit referenceaxis (11) .

137640137014

137015

61A-76



61AII - REFITTING OPERATION FOR PART CONCERNED

Right-hand and left-hand mixing motor

a Refit the mixing motor.

a Connect the air mixing motor connector.

a Fit the electrical wiring of the mixing motor.



a Refit:




a Refit:

- the « accelerator - brake pedal » assembly,

- the dual safety connecting shaft,


- the pedal assembly nuts.

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

a Refit:

- the impacter,

- the impacter bolt.

a Torque tighten the brake pedal impacter bolt (21N.m).

a Refit:

- the front left-hand air distribution duct (see 61A,Heating, A-pillar air distribution duct: Removal- Refitting, page 61A-67) ,








- select "Left-hand air mixing flap motor or Right-hand air mixing flap motor" in the "List of compo-nents stored by this computer" section,


61A-77


B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and CLIMATE CONTROL

61A

REMOVAL



a Unclip the centre console right-hand trim

a Remove:



a Unclip the hydraulic clutch pipes (1) .

a Move the hydraulic clutch pipes aside.

a Unclip the clutch pedal wiring at (2) .

a Remove the clutch pedal nuts (3) .

a Remove the clutch pedal from its threaded rods inthe direction of the arrow.

a Pass the hydraulic clutch pipes under the distribu-tion unit.

Essential equipment

diagnostic tool

Tightening torquesm


137690

137154

Note:

Do not disconnect the connectors from the clutchpedal.

Note:

Do not apply pressure to the hydraulic clutchpipes.

61A-78



61A

a Tilt the clutch pedal in the direction of the arrow.

a Put the clutch pedal in the footwell.






a Disconnect the air mixing motor connector.

a Remove:



136999

135682

61A-79





a Disconnect the air mixing motor connector.

a Remove:



REFITTING



a Move the tie rod so that the flat surface (6) of themixing motor recess is positioned at 90˚ in relation tothe distribution unit reference axis (7) .


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


a Refit the mixing motor.

a Connect the air mixing motor connector.

a Fit the electrical wiring of the mixing motor.



a Fit:

- the clutch pedal,




a Clip:



a Refit:





137640

137014

137015

61A-80





a






- select "Right-hand air mixing flap motor" in the "Listof components stored by this computer" section,


61A-81

HEATINGDistribution motor: Removal - Refitting


61A

REMOVAL


a Remove:




a Mark the routing of the motor wiring.

a Disconnect the connector (1) from the distributionmotor.

a Remove:

- the bolts (2) from the distribution motor,

- the distribution motor.

REFITTING


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


a Refit the distribution motor.

a Connect the distribution motor connector.

a Fit the electrical wiring of the distribution motor.


a Refit:








- select "Footwell air distribution flap motor" in the"List of components stored by this computer" sec-tion,


Essential equipment

diagnostic tool

136385

137012

61A-82



61A

REMOVAL


a Unclip the right-hand centre console trim.

a Remove:



a Unclip the clutch hydraulic pipes (1) .

a Move the clutch hydraulic pipes aside.

a Unclip the wiring (2) from the clutch pedal.

a Remove the clutch pedal nuts (3) .

a Detach the clutch pedal from its threaded rods.

a Pass the hydraulic clutch pipes under the distribu-tion unit.

Essential equipment

diagnostic tool

Tightening torquesm


137690

137154

Note:

Do not disconnect the connectors from the clutchpedal.

Note:

Do not apply pressure to the hydraulic clutchpipes.

61A-83



61A

a Tilt the clutch pedal the in the direction of the move-ment arrow.

a Put the clutch pedal in the footwell.


a Mark the routing of the distribution motor wiring.

a Disconnect the connector (4) from the distributionmotor.

a Remove:

- the bolts (5) from the distribution motor,

- the distribution motor.

REFITTING


a Move the tie rod so that the flat surface (6) of the dis-tribution motor recess is positioned at 90˚ in relationto the distribution unit reference axis (7) .


a Refit the distribution motor.

a Connect the distribution motor connector.

a Fit the electrical wiring of the distribution motor.


a Fit:

- the clutch pedal,




a Clip:



a Refit:




136999

136385

137012

61A-84



61Aa Apply the after repair procedure using the diagnos-

tic tool :





- select "Footwell air distribution flap motor" in the"List of components stored by this computer" sec-tion,


61A-85

HEATINGPassenger compartment temperature sensor: Removal - Refitting


61AREMOVAL

OPERATION FOR REMOVAL OF PART CONCERNED

a Remove the interior rear view mirror trim.

a Disconnect the passenger compartment temperatu-re sensor connector (1) .

a Unclip the passenger compartment temperaturesensor from the interior rear view mirror trim at (2) .

REFITTING

REFITTING OPERATION FOR PART CONCERNED

a Clip the passenger compartment temperature sen-sor onto the interior rear view mirror trim.

a Connect the passenger compartment temperaturesensor connector.

a Refit the interior rear view mirror trim.

137004

137003

137688

62A-1

AIR CONDITIONINGAir conditioning: Precautions for repair 62A

I - SAFETY

Refrigerant is heavier than air. As a result there is a riskof asphyxia for those working close to the ground andless than 5 m away from the working area (pit, well, airvents, etc.).

Switch on gas extraction systems.

At temperatures above 100˚C, the refrigerant will de-compose and produce a highly irritant gas.

II - GENERAL RECOMMENDATIONS

It is possible to place components in the drying ovenafter painting or to carry out work near the system if thetemperature does not exceed 80˚C.

It is essential to follow the routing of the connecting pi-pes.

Ensure that the refrigerant connecting pipes are cor-rectly fitted so that they will not come into contact withmetal parts in the engine compartment.

IMPORTANT

The following must be worn when handling refrige-rant:

- gloves,

- protective goggles (with side shields if possible).

In the event of refrigerant fluid coming into contactwith the eyes, rinse well with clean water conti-nuously for 15 minutes. If possible, have an eyerinse unit available.

If refrigerant comes into contact with your eyes,consult a doctor immediately. Inform the doctor thatthe burns were caused by R134A refrigerant.

In the event of contact with other unprotected partsof the body (event though the safety advice hasbeen observed), rinse well with clean water conti-nuously for 15 minutes.

IMPORTANT

Work requiring the use of refrigerant must be car-ried out in a well-ventilated area.

The refrigerant must not be stored in a shaft, a pit,a hermetically sealed room, etc.

Refrigerants are colourless and odourless fluids.

IMPORTANT

It is forbidden to smoke close to an open coolantcircuit.

IMPORTANT

To prevent refrigerant from leaking, never repair afaulty air conditioning circuit component.

Replace all faulty components.

WARNING


WARNING

To avoid damaging the surface of the air conditio-ning pipes when removing the seals, do not use atool with a metallic end piece.

WARNING

To prevent moisture from entering the system,place plugs on the cold loop components which areopen to the air.

WARNING

To avoid any leaks, check that the pipe surface issound before positioning the new seal. The surfacemust be clean and scratch free.

WARNING

Lubricants are not mutually compatible: alwaysobserve the types and quantities of oil for eachcompressor even when topping up as this coulddamage the cold loop components.

Always close the oil cans again after use to keepmoisture out and never use oil contained in a canthat has been open for a long time (viscous appea-rance).

62A-2

AIR CONDITIONINGAir conditioning: Parts and consumables for the repair work


62AFor the oil part number (see Vehicle: Parts and con-sumables for repair) (04B, Consumables - Products).

Table of vehicle refrigerant capacities according to their engines and various specifications.

Table of quantities of oil to add when replacing components:

Engine Refrigerant capacity(g)

Type of compres-sor

Type of ori-ginal oil

T y p e o fAfter-Salesoil

Quantity ofoil (ml)

K4M

480 ±±±± 356 SEL 14C ND-OIL 8 SANDEN

SP10

110 ±±±± 10

F4R

K9K

M9R

F9Q

H4J

M4R VALEO DCS-S7EC ZXL 100 PG 150 ±±±± 20

Operation on the air conditioning circuit Quantity of oil (ml orcc)

Circuit oil change Measure the volume recovered and add thesame quantity of new oil

Split pipe or other rapid leak 100

Replacement of a pipe Quantity recovered +10

Replacement of a condenser Quantity recovered +30

Replacement of an evaporator or distribution unit Quantity recovered +30

Replacement of the filter or dehydrator reservoir Quantity recovered +15

Removing - Refitting a compressor Quantity recovered

Replacement of a compressor None added

Standard replacement of a compressor Top up as necessary

Replacement of a compressor and one or more air conditio-ning circuit component(s)

None added

Standard replacement of a compressor and replacement ofone or more refrigerant circuit component(s)

Top up as necessary

62A-3

AIR CONDITIONINGAir conditioning: Check 62A

I - PREPARATION OPERATION FOR THE MEASUREMENT DEVICE

a Check that the measurement device functions pro-perly (see the device's instruction manual).

a Set units to ˚C.

a Set the device's sensitivity to 0.1˚C.

a Set the reading mode to (∆T) = (T1 - T2)

a Check the two sensors T1 and T2 in order to calcu-late the correction (∆) to be applied to the measure-ment (T1 - T2). the two sensors must indicate the same measurement under the same conditions. Check the sensors by:

- bringing the ends of the 2 sensors together untilthey touch,

- placing the sensors in the air flow of an air vent,

- setting the passenger compartment fan assemblyto top speed.

- waiting for the value to become stable.

- recording the correction value (∆).

Equipment required

Dual-sensor temperature measuring device

Note:

When performing RENAULT maintenance, checkthe air conditioning system at the end of the vehi-cle's maintenance program so that the engine willbe cold.

119360

119358

Note:

It is not necessary to start the vehicle. Thedevice display is in mode (∆T) = (T1 - T2).

WARNING

Note the difference and sign as soon as the tem-perature becomes stable.

Calculate the correction (∆) = - (T1 - T2) to beapplied to the measurement (∆T).

Examples:

If (T1 - T2) = - 0.3˚C, correct the measurement(∆T) by (∆) = + 0.3˚C

If (T1 - T2) = + 0.3˚C, correct the measurement(∆T) by (∆) = - 0.3˚C

62A-4


II - VEHICLE PREPARATION OPERATION

a Put the vehicle in the shade, where the temperatureis greater than or equal to 15˚C minimum.

a Close the bonnet.

a Open the front windows.

a Start the engine and let it idle.

a Set the air conditioning controls with:

- recirculation mode in the external position,

- the ventilation distribution in "face" mode,

- the temperature control to coldest temperature set-ting in front (and at the back, if it exists),

- the speed of the passenger compartment fan as-sembly set to maximum (switch off the rear controlif it exists),

- the front side and centre air vents open with the va-nes in a neutral position,

- the air conditioning system must be turned on (indi-cator light illuminated).

a Wait 5 minutes with the engine idling before ta-king any measurements.

III - MEASUREMENTS

a Record the air temperature at the scuttle panel grille (T3).

- open the bonnet, depending on the vehicle, to ac-cess the scuttle panel grille.

- place the sensor where air is drawn through thescuttle panel grille.

- wait for the value to become stable.

- record the T3 temperature value.

- close the bonnet if it was opened.

a Record the air temperature at the left air vent (T1), and at the right air vent (T2).

- fit sensor T1 in the left air vent (1) .

- fit sensor T2 in the right air vent (2) .

a Record the differences in temperature once the (∆T) value has stabilised:

- between T3 and the higher of values T1 or T2, (T3- highest value).

- record this difference in temperature.

- between T1 and T2 (read the (∆T) value (T1-T2)display mode).

- record the difference in temperature (∆T) accor-ding to the correction (∆) to be applied to themeasurement.

a If the (∆T)=(T1-T2) measurement is unstable, followthe procedure below:

119359

119357

Note:

Depending on the vehicle's air conditioning sys-tem programming, this check method may not beapplicable because the engine cooling fanassembly has been activated. Its operation ren-ders the (∆Τ) value between T1 and T2 unstable.To eliminate this error, the fan assembly must beactivated for the entire period over which tempe-rature T1 and T2 measurements are recorded.

62A-5


a Activate the engine cooling fan assembly operation by modifying the engine speed.

- stabilise the engine speed at 2000 rpm while T1and T2 temperature measurements are being re-corded.

- check that the engine cooling fan assembly opera-ting.

- record the temperatures by following the instruc-tions given in the paragraph MEASUREMENTS.

IV - FAULT FINDING PROCEDURE

a The following two following conditions must be met:

- the difference between T3 and the higher of the twovalues T1 or T2, must be greater than or equal to5˚C,

- the difference between T1 and T2 must be lessthan or equal to 2˚C.

Note:

If one of these two conditions is not met, then theair conditioning system is not working properly.Should this be the case, refer to the fault findingprocedure for the air conditioning system for thevehicle concerned.

62A-6

AIR CONDITIONINGHeating and ventilation system diagnostic tool: Use 62A

TO CARRY OUT FAULT FINDING ON A HEATING AND AIR CONDITIONING SYSTEM CIRCUIT:

with a thermostatic expansion valve:

a Use the AIRCODIAG tool to carry out fault finding on:

- loss of refrigerant pressure or to check the correctpressure of the refrigerant in the circuit.

- refrigerant fluid circuit overpressure.

- a blocked dehydrator filter.

a Refer to the equipment handbook.

104964

62A-7

AIR CONDITIONINGCoolant circuit check 62A

There are several types of detector:

- electronic detectors,

- trace detectors.

Check that the air conditioning system is operating cor-rectly (see 62A, Air conditioning, Air conditioning:Check, page 62A-3) .

REFRIGERANT CIRCUIT SEALING CHECKING OPERATION

1 - Electronic detectors:

a

a Switch on the electronic detector.

a Start the engine.

a Let the air conditioning system run for 15 minutes.

a Switch off the engine.

a Check the sealing of the refrigerant circuit using theelectronic trace detector (follow the trace of the cir-cuit as closely as possible, to limit variations due toother gases).

2 - Trace detectors

a

a Check for dye on the cold loop components with theultraviolet light.

a Inject the dye.

a Start the engine.

a Let the air conditioning system run for 15 minutes.

a Switch off the engine.

a Check the refrigerant circuit sealing by scanning thecircuit with the ultraviolet light.

a Affix a label (supplied with the dye capsule), to indi-cate that dye has been used (as close as possible tothe filler valves).

Essential equipment

diagnostic tool

IMPORTANT

Consult the safety and cleanliness advice and ope-ration recommendations before carrying out anyrepair (see 62A, Air conditioning, Air conditio-ning: Precautions for repair, page 62A-1) .

Note:

After any work on air conditioning circuit leaks onthe Laguna II, Vel Satis and Espace IV, check thatfilling fault DF033 Refrigerant is not present, usingthe diagnostic tool. If it is present, clear it. Thecompressor cannot operate until the fault is cleared.

Note:

To carry out an after repair check, use the proce-dure for the electronic detector (1). To carry out amore thorough check for leaks, use a trace detector(2).

WARNING


Note:

If replacing a defective part (see 62A, Air condi-tioning).

WARNING


WARNING

To avoid damaging the cold loop components(corrosions, etc.), do not use dye if the tracesreveal that some product has already been injec-ted.

Note:

If replacing a defective part (see 62A, Air condi-tioning).

62A-8

AIR CONDITIONINGCoolant circuit Draining - Refilling 62A

Essential equipment


IMPORTANT

Consult the safety and cleanliness advice and ope-ration recommendations before carrying out anyrepair (see 62A, Air conditioning, Air conditio-ning: Precautions for repair, page 62A-1) .

WARNING


WARNING

To avoid damaging the cold loop components (cor-rosions, etc.), do not use dye if the traces revealthat some product has already been injected.

Note:

A summary table gives the quantities of refrigerantin the system according to the engine type (see62A, Air conditioning, Air conditioning: Partsand consumables for the repair work, page 62A-2) .

62A-9


I - RECOVERING REFRIGERANT FLUID

a

When draining or checking the refrigerant fill load, three scenarios are to be taken into account:

- the engine is running and the air conditioning is inoperation (A),

- the engine is running but the air conditioning is notin operation (B),

- the engine is not running nor is the air conditioningin operation (C).

a Scenario A:

- Operate the air conditioning until the cooling fanassembly is triggered twice,

- switch off the engine,

- drain for the first time (note down the original va-lue),

- wait 15 minutes,

- check that the relative pressure is no more than 0bar,

- repeat the cycles until the relative pressure is equalto or less than 0 bar,

- add together the values of the various drainingoperations; the fill is confirmed as being correct ifthe volume of refrigerant fluid is the specified fill+35g or -100g.

Scenario B:

- run the engine until the cooling fan is triggered twi-ce,


- drain for the first time (note down the value),

- wait 15 minutes,

- run the engine until the cooling fan is triggered twi-ce,


- drain for the second time (note down the value),



Scenario C:

- drain for the first time (note down the value),

- wait 2 hours,



II - CREATING A VACUUM

a It is essential to carry out vacuum extraction correct-ly before loading, otherwise the air conditioning willnot work properly.

There are two scenarios to consider:

- the vacuum will be created immediately after drai-ning (scenario A),

- vacuum created after an interval of several hoursor days (scenario B).

Scenario A:

- creation of a vacuum takes 20 minutes.

Scenario B:

- creation of a vacuum takes 45 minutes to elimina-te any trace of moisture.

a Test the seal once the vacuum has been created(some stations do this automatically).

III - FILLING

a Fill up the refrigerant circuit using the refrigerantcharging station.

Note:

- The air conditioning circuit is fitted with a singlerefill valve; some filling equipment only requirethe use of a high-pressure hose (see the fillingequipment instructions).

- Depending on the situation, run the system fora few minutes before recovering the coolant toimprove drainage.

Note:

It is essential to follow these procedures to pre-vent:

- gas escaping when the circuit is opened,

- pollution of the environment through the releaseof gas into the atmosphere when the circuit isopened or when a vacuum is created.

62A-10


a Top up the oil with the recommended type and volu-me of oil and refrigerant, depending on the work car-ried out (see 6 2 A, Air conditioning, Airconditioning: Parts and consumables for the re-pair work, page 62A-2) .

a Check there are no leaks using the electronic de-tector (see 62A, Air conditioning, Coolant circuitcheck, page 62A-7) .


WARNING

After injecting dye into the refrigerant, be sure toindicate this on a label (supplied with the dyecapsule), and the date of the operation.

Position the label so it is visible near to the coldloop filler valve.

62A-11

AIR CONDITIONINGCondenser: Removal - Refitting


62A

REMOVAL


a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).


a Remove:

- the front wheels (see Wheel: Removal - Refitting)(35A, Wheels and tyres),

- the front sections of the front wheel arch liners (seeFront wheel arch liner: Removal - Refitting)(55A, Exterior protection),

- the front bumper (see Front bumper: Removal -Refitting) (55A, Exterior protection).

Essential equipment


IMPORTANT


Note:

Use blanking plugs for the fuel circuits with partnumbers 77 01 208 229 or 77 01 476 857 to plugany openings exposed to the open air. They mustbe clean. Do not use any which have already beenused to plug a fuel circuit.

WARNING


WARNING


62A-12



62A

a Unclip:

- the central deflector (1) ,

- the left-hand side deflector (2) ,

- the right-hand side deflector (3) .

a Remove

- the audible warning (see Horn: Removal - Refit-ting) (82A, Horn),

- the left-hand headlight (see Front headlight: Re-moval - Refitting) (80B, Headlights),

- the side support of the left-hand front panel (seeFront end panel side support: Removal - Refit-ting) (42A, Upper front structure).

135786

135783

135784

62A-13




a Disconnect the pressure sensor connector (4) .

a Remove the bolt (5) securing the bracket for the« condenser - expansion valve » connecting pipe tothe condenser.

a Disconnect the « condenser - expansion valve »connecting pipe from the condenser.

a Remove the seals from the « condenser - expansionvalve » connecting pipe.


135672

135670

WARNING


62A-14



62A

a Remove the bolt (6) securing the bracket for the« compressor - condenser » connecting pipe fromthe condenser.

a Disconnect the « compressor - condenser » connec-ting pipe from the condenser.

a Remove the seal from the « compressor -condenser » connecting pipe.


a Remove the condenser in accordance with the di-rection of the arrow.

REFITTING




a Lubricate its new seals using recommended air con-ditioning oil to make fitting easier (see 62A, Air con-ditioning, Air conditioning: Parts andconsumables for the repair work, page 62A-2) .


135671

WARNING


135674

WARNING



WARNING


62A-15



62AII - REFITTING OPERATION FOR PART CONCERNED

a Refit:

- the condenser,

- the connecting pipes to the condenser.

a Connect the pressure sensor connector.


a Refit:

- the side support of the left-hand front panel (seeFront end panel side support: Removal - Refit-ting) (42A, Upper front structure),

- the left-hand headlight (see Front headlight: Re-moval - Refitting) (80B, Headlights),

- the audible warning (see Horn: Removal - Refit-ting) (82A, Horn).

a Clip:

- the right-hand side deflector,

- the left-hand side deflector,

- the central deflector.

a Refit:

- the front bumper (see Front bumper: Removal -Refitting) (55A, Exterior protection),

- the front sections of the front wheel arch liners (seeFront wheel arch liner: Removal - Refitting)(55A, Exterior protection),

- the front wheels (see Wheel: Removal - Refitting)(35A, Wheels and tyres).

a Fill up the refrigerant circuit using the refrigerantcharging station (see 62A, Air conditioning, Coo-lant circuit Draining - Refilling, page 62A-8) .

a Check for leaks (see 62A, Air conditioning, Coo-lant circuit check, page 62A-7) .

a Check the air conditioning system is operating cor-rectly (see 62A, Air conditioning, Air conditio-ning: Check, page 62A-3) .

Note:

A summary table gives the quantities of refrige-rant in the system according to the engine types(see 62A, Air conditioning, Air conditioning:Parts and consumables for the repair work,page 62A-2) .

62A-16

AIR CONDITIONINGCompressor: Removal - Refitting

B95 or D95 or E95 or K95, and K4M or K9K

62A

REMOVAL






a Remove:

- the front right-hand wheel (see Wheel: Removal -Refitting) (35A, Wheels and tyres),

- the front right-hand wheel arch liner partially (seeFront wheel arch liner: Removal - Refitting)(55A, Exterior protection),

- the lower engine tie-bar (see Lower engine tie-bar: Removal - Refitting) (19D, Engine moun-ting).

a Remove the accessories belt (see Accessoriesbelt: Removal - Refitting) (11A, Top and front ofengine).

a Remove the connecting pipe bracket bolts (1) .

a Move aside the compressor connecting pipes.


a Fit blanking plugs on the openings of the connectingpipes and the compressor.

Essential equipment


IMPORTANT


WARNINGTo prevent moisture from entering the system,place plugs on the cold loop components which areopen to the air.

Note:


WARNING


WARNING

In order to prevent the accessories belt frombeing prematurely ruptured, do not damage (hit,force with a tool, etc.) the plastic pulley of thecompressor.

136473

WARNING


62A-17


B95 or D95 or E95 or K95, and K4M or K9K


a Disconnect the compressor connector (2) .

a Move the engine towards the rear of the vehicle.

a Remove:

- the compressor bolts (3) ,

- the compressor.

REFITTING




a Lubricate the new seals using recommended airconditioning oil to make fitting easier (see 62A, Airconditioning, Air conditioning: Parts and consu-mables for the repair work, page 62A-2) .



a Refit the compressor.

a Connect the compressor connector.


a Refit:

- the connecting pipes to the compressor,

- the accessories belt (see Accessories belt: Re-moval - Refitting) (11A, Top and front of engine),

- the lower engine tie-bar (see Lower engine tie-bar: Removal - Refitting) (19D, Engine moun-ting),

- the front right-hand wheel arch liner (see Frontwheel arch liner: Removal - Refitting) (55A, Ex-terior protection),

- the front right-hand wheel (see Wheel: Removal -Refitting) (35A, Wheels and tyres).






136473

WARNING



WARNING


Note:


62A-18


B95 or D95 or E95 or K95, and F4R or F9Q

62A

REMOVAL





a Remove:

- the engine cover,


- the front section of the front wheel arch liners (seeFront wheel arch liner: Removal - Refitting)(55A, Exterior protection),


- the headlights (see Front headlight: Removal -Refitting) (80B, Headlights),

- the front bumper supports (see Front bumpersupport: Removal - Refitting) (42A, Front upperstructure),

- the frontal impact cross member (see Front im-pact cross member: Removal - Refitting) (41A,Front lower structure),

- the audible warning (see Horn: Removal - Refit-ting) (82B, Horn),

- the bonnet catch (see Bonnet latch: Removal -Refitting) (52A, Non-side opening element mecha-nisms).

a Remove the accessories belt (see Accessoriesbelt: Removal - Refitting) (11A, Top and front ofengine).

Essential equipment


IMPORTANT



Note:


WARNING


WARNING

In order to prevent the accessories belt frombeing prematurely ruptured, do not damage (hit,force with a tool, etc.) the plastic pulley of thecompressor.

62A-19



62A

a Remove the bolts (1) from the engine wiring chan-nel.

a Remove:

- the upper bolts (2) from the front end panel,

- the front end panel clips (3) .

a Remove the lower bolts (4) from the front end panel.

a Tilt the front end panel slightly towards the front ofthe vehicle.

a Remove the intercooler air outlet pipe (see Inter-cooler air outlet pipe: Removal - Refitting) (12B,Turbocharging).

135882

135719

135296

62A-20



62A

a Remove the bolt (5) of the « intermediate pipe -compressor » connecting pipe retaining bracketfrom the engine block.

a Remove the bolt of the « compressor - condenser »connecting pipe retaining bracket bolt from the com-pressor.

a Remove the connecting pipe bracket bolts (6) on thecompressor.

a Uncouple the connecting pipes from the compres-sor.

a Move aside the compressor connecting pipes.


a Fit blanking plugs on the openings of the connectingpipes and the compressor.

F4R

135700

136473

WARNING


62A-21




a Disconnect the compressor connector (7) .

a Remove:

- the compressor bolts (8) ,

- the compressor.

REFITTING




a Lubricate the new seals using recommended airconditioning oil to make fitting easier (see 62A, Airconditioning, Air conditioning: Parts and consu-mables for the repair work, page 62A-2) .



a Refit the compressor.

a Connect the compressor connector.


a Refit the connecting pipes to the compressor.

a Refit:

- the retaining bracket of the « intermediate pipe -compressor » connecting pipe on the engine block,

- the retaining bracket of the « compressor -condenser » connecting pipe on the compressor.

a Refit the intercooler air outlet pipe (see Intercoolerair outlet pipe: Removal - Refitting) (12B, Turbo-charging).

a Fit the front end panel.

a Refit the engine wiring channel.

a Refit:

- the bonnet catch (see Bonnet latch: Removal -Refitting) (52A, Non-side opening element mecha-nisms),

- the front impact cross member (see Front impactcross member: Removal - Refitting) (41A, Frontlower structure),



- the accessories belt (see Accessories belt: Re-moval - Refitting) (11A, Top and front of engine),



136473

WARNING



WARNING


F4R

62A-22



62A- the front wheels (see Wheel: Removal - Refitting)(35A, Wheels and tyres).






Note:


62A-23

AIR CONDITIONINGExpansion valve: Removal - Refitting

B95 or D95 or E95 or K95, and F9Q or K4M or K9K or M4R or M9R

62A

REMOVAL





a Remove:



- the scoop under the scuttle panel grille (see Scoopunder scuttle panel grille: Removal - Refitting)(56A, Exterior equipment).

a Remove:



- the intercooler air inlet pipe (see Intercooler air in-let pipe: Removal - Refitting) (12A, Turbochar-ging).

a Remove the nut (1) of the retaining bracket (2) fromthe « intermediate pipe - expansion valve » connec-ting pipe.

Essential equipment


IMPORTANT


WARNING


Note:


WARNING


F9Q

136471

62A-24



62A

a Remove the clips (3) from the bulkhead heat shield.


a Remove the connecting pipe bracket bolts (4) fromthe expansion valve.

a Uncouple the connecting pipes from the expansionvalve.

a Remove the connecting pipes from the expansionvalve.


a Fit blanking plugs on the openings of the connectingpipes and the expansion valve.

136467

WARNING



136487

WARNING


62A-25




a Remove:

- the bolts (5) from the expansion valve,

- the expansion valve.

REFITTING




a Lubricate the seals using air conditioning oil to makefitting easier (see 62A, Air conditioning, Air condi-tioning: Parts and consumables for the repairwork, page 62A-2) .



a Refit the expansion valve.


a Refit the connecting pipes on the expansion valve.


a Refit the retaining bracket of the « intermediate pipe- expansion valve » connecting pipe.

a Refit:

- the intercooler air inlet pipe (see Intercooler air in-let pipe: Removal - Refitting) (12A, Turbochar-ging),



a Refit:



- the windscreen wiper arms (see Windscreen wi-per blade: Removal - Refitting) (85A, Wiping -Washing).




136465

WARNING



WARNING


F9Q

Note:


62A-26



62Aa Check that the air conditioning system is operating

correctly (see 62A, Air conditioning, Air conditio-ning: Check, page 62A-3) .


62A-27


B95 or D95 or E95 or K95, and F4R

62A

REMOVAL





a Remove:




- the cylinder head lifting eye,


a Remove:



- the bulkhead upper heat shield clips.


Essential equipment


IMPORTANT



Note:


WARNING


WARNING



WARNING



62A-28



62A

a Remove the connecting pipe bracket bolts (1) fromthe expansion valve.

a Disconnect the upper heat shield from the bulkhead.



a Fit blanking plugs on the openings of the connectingpipes and the expansion valve.


a Remove:

- the bolts (2) from the expansion valve,

- the expansion valve.

REFITTING





136487

WARNING


136465

WARNING



WARNING


62A-29



62Aa Fit new seals to the refrigerant connecting pipes.


a Refit the expansion valve.


a Refit the connecting pipes on the expansion valve.

a Refit:






- the windscreen wiper arms (see Windscreen wi-per arm: Removal - Refitting) (85A, Wiping -Washing).






Note:


62A-30

AIR CONDITIONINGEvaporator: Cleaning


62A

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

filter: Removal - Refitting, page 61A-9) .

a Apply AIR CONDITIONING CLEANER (see Vehi-cle: Parts and ingredients for the repairwork)(04B, Consumables - Products) using an extensionpiece.

a Leave the product to work for 15 minutes.

a Refit the cabin filter (see 61A, Heating, Cabin filter:Removal - Refitting, page 61A-9) .

a Activate the low speed motor-driven fan assemblyfor 5 min.

IMPORTANT


62A-31

AIR CONDITIONINGEvaporator: Cleaning


62A

CLEANINGa Remove the evaporator sensor (see 62A, Air condi-

tioning, Evaporator sensor: Removal - Refitting,page 62A-43) .

a Apply AIR CONDITIONING CLEANER (see Vehi-cle: Parts and ingredients for the repairwork)(04B, Consumables - Products) using an extensionpiece.

a Leave the product to work for 15 minutes.

a Refit the evaporator sensor (see 62A, Air conditio-ning, Evaporator sensor: Removal - Refitting,page 62A-43) .

a Activate the low speed motor-driven fan assemblyfor 5 min.

IMPORTANT


62A-32

AIR CONDITIONINGExpansion valve - condenser connecting pipe: Removal - Refitting


62A

REMOVAL



a Remove the engine cover.



a Remove:




- the right-hand headlight (see Front headlight: Re-moval - Refitting) (80B, Headlights),

- the front panel support,

- the windscreen washer bottle (see Windscreenwasher bottle: Removal - Refitting) (85A, Wiping- Washing)




a Remove:






Essential equipment


IMPORTANT


WARNING


Note:


WARNING


F9Q

F9Q or K4M or K9K or M4R or M9R

WARNING



62A-33



62A

a Remove:



a Remove:





a Loosen the front right-hand bolt on the subframe at(1) .

a Remove the bolt (2) from the front right-hand sidemember tie rod.

a Move the front right-hand side member tie rod to-wards the wheel arch.


a Remove the bolt (3 ) from the support of the« condenser - expansion valve » connecting pipe onthe front right-hand panel.

F4R

WARNING



WARNING



135303

135297

136481

62A-34



62A

a Remove the plastic nut (4) from the support for the« condenser - expansion valve » connecting pipe onthe front right-hand side member.

a Remove the bolt (5) securing the « condenser - ex-pansion valve » connecting pipe to the front panel.

a Remove the bolt (6) securing the support for the« condenser - expansion valve » connecting pipe onthe front right-hand side member reinforcement.

136475

136479

136484

62A-35



62A

a Unclip the « condenser - expansion valve » connec-ting pipe on the front right-hand side member and onthe bulkhead at (7) .

136469

136485

62A-36



62A

a Remove:

- the bolt (8) for the « condenser - expansion valve »connecting pipe bracket on the expansion valve,

- the bolt (9) for the « condenser - expansion valve »connecting pipe bracket on the condenser.

a Remove:

- the « condenser - expansion valve » connecting pi-pe,

- the seals from the « condenser - expansion valve »connecting pipe.

a Disconnect:

- the « condenser - expansion valve » connectingpipe from the expansion valve,

- the « condenser - expansion valve » connectingpipe from the condenser.

a Fit blanking plugs on:

- the condenser,


- the « condenser - expansion valve » connecting pi-pe.

REFITTING





a Fit the new seals on the « condenser - expansionvalve » connecting pipe.


a Refit the « condenser - expansion valve » connec-ting pipe.

136487

135670

WARNING


WARNING



WARNING


62A-37



62Aa Clip the « condenser - expansion valve » connecting

pipe onto the front right-hand side member and ontothe bulkhead.


a Fit the side member tie rod.

a Refit:



- the cylinder head lifting eye.


a Refit:




a Refit:

- the windscreen washer bottle (see Windscreenwasher bottle: Removal - Refitting) (85A, Wiping- Washing)














F4R


F9Q

Note:


62A-38

AIR CONDITIONINGExpansion valve/intermediate pipe connecting pipe: Removal - Refitting


62A

REMOVAL






a Remove:




a Remove:






Essential equipment


IMPORTANT


WARNING


Note:


WARNING


F9Q


WARNING



62A-39



62A

a Remove:



a Remove:






a Remove the nut (1) from the retaining bracket (2) ofthe « expansion valve - intermediate pipe » connec-ting pipe.

a Remove the bolt (3) from the retaining bracket of the« expansion valve - intermediate pipe » connectingpipe.

F4R

WARNING



WARNING



136471

136490

62A-40



62A

a Remove the nut (4) securing the « expansion valve -intermediate pipe » connecting pipe on the bulkheadsupport.

a Remove the bolt (5) from the « expansion valve - in-termediate pipe » connecting pipe bracket on the ex-pansion valve.

a Remove the bolt (6) from the « expansion valve - in-termediate pipe » connecting pipe bracket on the in-termediate connecting pipe.

a Disconnect:

- the « expansion valve - intermediate pipe » con-necting pipe to the expansion valve,

- the « expansion valve - intermediate pipe » con-necting pipe from the intermediate connecting pipe.

a Remove:

- the « expansion valve - intermediate pipe » con-necting pipe,

- the seals from the expansion valve and connectingpipes.

a Fit the blanking plugs on the openings of the con-necting pipes and on the expansion valve.

F4R

134713

136487

136492

WARNING


62A-41



62AREFITTING





a Fit new seals on the « expansion valve - intermedia-te pipe » connecting pipe.


a Refit the « expansion valve - intermediate pipe »connecting pipe on the expansion valve and on theintermediate connecting pipe.


a Refit:



- the cylinder head lifting eye.


a Refit:




a Refit:









WARNING



WARNING


F4R

F9Q or K4M or K9K or M4R

F9Q

Note:


62A-42

AIR CONDITIONINGPressure sensor: Removal - Refitting


62A

REMOVAL



a Remove:



- the front bumper (see Front bumper: Removal -Refitting) (55A, Exterior protection).


a Disconnect the pressure sensor connector (1) .

a Remove the pressure sensor (2) from the conden-ser.

REFITTING


a Refit the pressure sensor.

a Torque tighten the pressure sensor (9 N.m).

a Connect the pressure sensor connector.


a Refit:




Tightening torquesm

pressure sensor 9 N.m

IMPORTANT


Note:

An automatic shut-off valve isolates the circuit fromthe outside during removal; do not drain the refrige-rant from the circuit.

135672

62A-43

AIR CONDITIONINGEvaporator sensor: Removal - Refitting


62A

REMOVAL


a Remove:



- the lower bolts from the dashboard cross memberreinforcement,

- the upper bolts from the dashboard cross memberreinforcement,



a Remove the evaporator sensor (1) by turning it aquarter of a turn anti-clockwise.

a Take the evaporator sensor out of its housing.

a Cut the wires (2) of the evaporator sensor (see Wi-ring: Repair) (Technical Note 6015A, 88A, Wiring).

Tightening torquesm


21 N.m


21 N.m

IMPORTANT


137648

137649

62A-44



62AREFITTING


a Solder the wires of the evaporator sensor (see Wi-ring: Repair) (Technical Note 6015A, 88A, Wiring).

a Fit the evaporator sensor in its housing.

a Clip on the evaporator sensor by turning it a quarterof a turn clockwise.


a Refit:

- the dashboard cross member stiffener,

- the upper bolts of the dashboard cross memberreinforcement,





a Refit:



62A-45


B95 or D95 or K95, and RIGHT-HAND DRIVE

62A

REMOVAL




a Unclip the evaporator sensor (1) by turning it a quar-ter of a turn anti-clockwise.

a Remove the evaporator sensor.

a Cut the wires (2) of the evaporator sensor (see Wi-ring: Repair) (Technical Note 6015A, 88A, Wiring).

REFITTING


a Solder the wires of the evaporator sensor (see Wi-ring: Repair) (Technical Note 6015A, 88A, Wiring).

a Refit the evaporator sensor.

a Clip on the evaporator sensor by turning it a quarterof a turn clockwise.



IMPORTANT


137648

137649

62A-46

AIR CONDITIONINGCondenser - compressor connecting pipe: Removal - Refitting


62A

REMOVAL






a Remove:






- the windscreen washer bottle (see Windscreenwasher bottle: Removal - Refitting) (85A, Wiping- Washing).

a Remove:




- the front impact cross member (see Front impactcross member: Removal - Refitting) (41A, Frontlower structure),



Essential equipment


IMPORTANT


WARNING


Note:


WARNING


F4R or F9Q

135882

62A-47



62A

a Remove:






135719 135296

62A-48




a Remove the bolt (5) securing the support for the« compressor - condenser » connecting pipe to thefront panel.

a Remove the bolt (6) securing the bracket for the« compressor - condenser » connecting pipe to thecompressor.

a Remove the bolt from the support of the« compressor - condenser » connecting pipe on thecompressor.

a Remove the bolt from the support of the« compressor - condenser » connecting pipe on thelower cross member.

a Remove the bolt (7) securing the bracket for the« compressor - condenser » connecting pipe fromthe condenser.

a Disconnect:

- the « compressor - condenser » connecting pipefrom the compressor,

- the « compressor - condenser » connecting pipeon the condenser.

a Remove:

- the « compressor - condenser » connecting pipe,

- the « compressor - condenser » connecting pipeseals.

a Fit blanking plugs on the openings:

- of the condenser,

136481

136473

F4R

135670

WARNING


62A-49



62A- of the compressor,

- of the « compressor - condenser » connecting pi-pe.

REFITTING





a Fit the new seals on the « compressor - condenser »connecting pipe.


a Refit the « compressor-condenser » connecting pi-pe.




a Refit the wiring channel for the engine cooling fanassembly.


a Refit:


- the impact cross member (see Front impact crossmember: Removal - Refitting) (41A, Front lowerstructure),



- the headlights (see Front headlight: Removal -Refitting) (80B, Headlights).

a Refit:

- the windscreen washer bottle (see Windscreenwasher bottle: Removal - Refitting) (85A, Wiping- Washing),










WARNING



WARNING


F4R or F9Q

Note:


62A-50



62Aa Refit the engine cover.

62A-51

AIR CONDITIONINGCompressor/intermediate pipe connecting pipe: Removal - Refitting


62A

REMOVAL






a Remove:










Essential equipment


IMPORTANT


WARNING


Note:


WARNING


F4R or F9Q

135882

62A-52



62A

a Remove:






135719 135296

62A-53




a Remove the bolt (5) of the « intermediate pipe -compressor » connecting pipe retaining bracket onthe engine block.

a Remove the bolt (6) securing the « intermediate pipe- compressor » connecting pipe bracket to the com-pressor.

a Remove the bolt (7) securing the « intermediate pipe- compressor » connecting pipe bracket on the inter-mediate pipe.

a Disconnect:

- the « intermediate pipe - compressor » connectingpipe from the compressor,

- the « intermediate pipe - compressor » connectingpipe from the intermediate pipe.

a Remove:

- the « intermediate pipe - compressor » connectingpipe,

- the seals on the « intermediate pipe -compressor » connecting pipe.

a Fit blanking plugs on the connecting pipe and on thecompressor.

F4R

135700

136473

136492

WARNING


62A-54



62AREFITTING





a Fit new seals on the « intermediate pipe -compressor » connecting pipe.


a Refit the « intermediate pipe - compressor » con-necting pipe.

a Refit the retaining bracket for the « intermediate pipe- compressor » connecting pipe on the engine block.





a Refit:














WARNINGDo not remove the blanking plugs from eachcomponent until the last moment.


WARNING


F4R

F4R or F9Q

Note:


6 - Air Conditioning

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Transcript of 6 - Air Conditioning