Chassis 2002+ clio

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Chassis

GENERAL INFORMATION

FRONT AXLES

REAR AXLES

STEERING ASSEMBLY

POWER ASSISTED STEERING

MECHANICAL COMPONENTS CONTROLS

ANTI-LOCK BRAKING SYSTEM

77 11 315 170

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

The methods may be modified as a result of changes introduced by the manufacturerin the production of the various component units and accessories from which hisvehicles are constructed".

FEBRUARY 2002

All copyrights reserved by Renault.

Edition Anglaise

Copying or translating, in part or in full, of this document or use of the service partreference numbering system is forbidden without the prior written authority of Renault.

© RENAULT 1997

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This Workshop Repair Manual covers the phase 2 CLIO II vehicles

(1.6 16V K4M engine) defined below:

(1) Manufacture: country of manufacture.The letter in brackets indicates the factory code that appears as the first character in the fabrication number of the

label on the vehicle.

Refer to Technical Note 3627A for more information about the selection of Workshop Repair Manuals available forthe CLIO II range.

Vehicle typeManufacture

(1)Technical

SpecificationMarket Commercial names

Turkey specification- 4-door with boot

Turkey (R) No

multiplexWorldwide

Renault Symbol

(Russia)Renault Clio

for the rest of the world

CCEE specification

- 4-door Clio with bootTurkey (R) No

multiplex

● Central Europe:

Hungary, Slovenia,

Slovakia, the

Czech Republic,

Poland

● Greece

● DOM TOM

Renault Thalia

(Central European

countries and Greece)

Renault Symbol

(DOM TOM)

Persian Gulf specification

- 4-door Clio with bootTurkey (R)

No

multiplex

Saudi Arabia,

Bahrain, Dubai,

United Arab

Emirates, Kuwait,

Oman, Qatar

Renault Clio

Mexico specification

- 5-door ClioMexico No

multiplexMexico Renault Clio

Colombia - Venezuela

specification

- 5-door Clio

4-door Clio with boot

Colombia

(M) No

multiplex

Colombia

VenezuelaRenault Symbol

South Cone Common

Market specification- 5-door Clio

- 4-door Clio with boot

Argentina (L)Brazil (J)

Nomultiplex

ArgentinaBrazil

Renault Clio

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Chassis

Contents

Page

30A

31A

33A

GENERAL INFORMATION

General diagram of braking circuits 30A-1

Tightening torques (in daNm) 30A-2

Features of the anti-roll bars 30A-6

Structure and dimensions of themain braking components 30A-8

Brake pipes and unions 30A-9

Brake fluid 30A-9

Bleeding the brake circuit

without ABS 30A-10

Underbody heights 30A-12

FRONT AXLES

Lower arm 31A-1Lower arm rubber bushes 31A-2

Lower arm ball joint 31A-3

Brake linings 31A-4

Brake calliper 31A-5

Brake disc 31A-6

Stub-axle bearing 31A-7

Spring/shock absorber assembly 31A-9

Anti-roll bar 31A-10

Sub-frame axle 31A-12

REAR AXLE

Rear axle 33A-1

Shock absorber 33A-4

Spring 33A-5

Brake drum 33A-6

Brake cylinder 33A-8

Brake lining (drum) 33A-9

Bearing 33A-11

Rubber bushes 33A-12

Page

36A

36B

37A

38C

STEERING ASSEMBLY

Axial ball joint 36A-1

POWER ASSISTED STEERING

Steering rack 36B-1

Gaiter 36B-3

Steering pushrod 36B-4

Manual power steering pump 36B-5

Steering column 36B-6

Retractable shaft 36B-12

MECHANICAL COMPONENTSCONTROL

Master cylinder 37A-1

Brake servo 37A-3

Air filter - Brake servo non-return

valve 37A-5

Handbrake control lever 37A-6

Handbrake control 37A-8

Brake pipes 37A-10

Brake limiter 37A-11Clutch release control 37A-15

Clutch automatic wear system 37A-16

External gear control 37A-17

Brake cable 37A-21


Introduction 38C-1

Hydraulic unit 38C-8

Wheel speed sensor 38C-11

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GENERAL INFORMATION

General diagram of braking circuits 30A

30A-1

130AGENERAL INFORMATION

General diagram of braking circuits

NOTE: the diagram below shows the general principle ; in no case should it be taken as reference for the

circuit connections and allocations. When replacing one of the brake circuit components on a vehicle,

always mark the pipes before removing them so that they can be connected back in their original positions.

"X" TYPE BRAKING

With load sensitive compensator

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GENERAL INFORMATION

Tightening torques (in daNm) 30A

30A-2

FRONTAXLE Tightening torques (in daNm)

DI3035R

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GENERAL INFORMATION


30A-3

FRONTAXLE

DI3034R1

* Fitting direction must be observed

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GENERAL INFORMATION


30A-4

REAR AXLE

DI3041

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GENERAL INFORMATION


30A-5

REAR AXLE

DI3042

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GENERAL INFORMATION


30A-6

REAR AXLE

DI3043

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GENERAL INFORMATION


30A-7

DIMENSIONS TIGHTENING TORQUES

Bleed screw

Front calliper hosesRear arm hoses

-

M 10 × 100M 10 × 100

0.6 to 0.8

1.41.4

Rear wheel cylinder supply

M 10 × 100

or

M 12 × 100

1.4

Master cylinder outlets

M 10 × 100

or

M 12 × 100

1.4

Compensator inlet

M 10 × 100

or

M 12 × 100

1.4

Compensator outlets

M 10 × 100

or

M12 × 100

1.4

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GENERAL INFORMATION

Dimensions of the main braking components 30A

30A-8

Dimensions of the main braking components

(1) 4.6 mm (primary pad)

(2) 3.3 mm (secondary pad)

L/B B1R

FRONT BRAKE (in mm)

Slave cylinder diameter Disc diameter

Disc thickness

Minimum disc thickness

Brake pad thickness (including mounting)

Minimum brake pad thickness (including mounting)

Maximum disc run-out

54259

20.6

17.6

18.2

6

0.07

REAR BRAKE (in mm)

Slave cylinder diameter

Drum diameter Maximum drum wear diameter Disc diameter

Disc thicknessMinimum disc thickness

Pad width

17.5

203.2204.2

-

--

36.7

Brake pad thickness (including mounting)4.6 (1)

3.3 (2)

Minimum brake pad thickness (including mounting) 2

MASTER CYLINDER (in mm)

Diameter 20.6

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GENERAL INFORMATION

Brake unions and pipes 30A

30A-9

Brake unions and pipes

The connection of the pipes between the master

cylinder, callipers, compensator, and hydraulic

assembly is made by threaded unions with metricthread.

Consequently, only parts specified in the Parts

Catalogue for this vehicle should be used.

Identification of parts:

– SHAPE of the steel or copper PIPE end piece (A),

– SHAPE of THREADED CASINGS on components

(B),

– Pipe UNIONS coloured GREEN or BLACK: external

hexagon measuring 11 mm or 12 mm (C).

Brake fluid

BRAKE FLUID REPLACEMENT INTERVAL

Our brake technology, in particular our disc brakes (hollow pistons which transmit little heat, small quantity of liquid

in the cylinder, with sliding callipers which prevent an accumulation of liquid in the least cooled area of the wheel)

has allowed us to minimize the risk of vapor lock, even in the event of intensive brake use (e.g., in mountainous

areas).

Modern brake fluids still degrade slightly during the first few months of use due to a small uptake of moisture and

replacement of the fluid is therefore recommended (refer to vehicle's Warranty and Servicing Handbook).

Topping up the level

Wear of the brake pads and shoes will cause a gradual drop in the fluid level in the reservoir. This drop should not be

compensated for since the level will rise again when the pads are changed. The level should not however be

allowed to fall below the minimum mark.

Approved brake fluids:

Mixing two incompatible brake fluids in the circuit will cause a risk of major leaks, mainly due to deterioration of the

cups. To avoid such risks, it is essential to use only brake fluids which have been tested and approved by ourlaboratories and which are in accordance with Standard SAE J 1703 DOT 4.

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GENERAL INFORMATION

Bleeding the brake circuit without ABS 30A

30A-10

Bleeding the brake circuit without ABS

For vehicles fitted with a brake servo, it is

important that the assistance device is not

activated during bleeding, whatever method is

used.

Bleeding is carried out on a four-post lift with the

wheels on the ground.

Connect the bleed device to the bleed screws of the:

– master cylinder,

– slave cylinder,

– compensator.

Fill the device with compressed air at a supply point

(min 5 bar).

Connect the filling system to the brake fluid reservoir.

For vehicles fitted with X-type brake circuits,

proceed as follows:

Open:

– the bleed screw of the rear right wheel and let the

fluid flow out for around 20 seconds, – the bleed screw of the front left wheel and let the

fluid flow out for around 20 seconds.

Ignore the air bubbles in the bleed device pipes.

Proceed in the same way for the rear left wheel and

the front right wheel.

Check the firmness of the brake pedal by pushing it

down (press several times).

Repeat the bleeding operation if necessary.

Top up the brake fluid level in the reservoir after the

device has been disconnected.

(For information on bleeding the ABS brake circuit,

refer to section 38C).

EQUIPMENT REQUIRED

Bleed device approved by Renault

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FRONT AXLE

Lower suspension arm 31A

31A-1

131A FRONT AXLE

Lower suspension arm

REMOVAL

Put the vehicle on a two-post lift.

Remove both wheels.

Remove the mounting nuts for the anti-roll bar on thelower wishbones.

Release the anti-roll bar downwards.

Remove:

– the nut and key on the stub-axle carrier,

– the two mounting bolts for the wishbone on the sub-frame,

– the arm.

REFITTING

NOTE: ensure the plastic protective washer (A) is

present on the lower ball joint shaft.

Refit:

– the arm,

– the two bolts, without tightening them,

– the ball joint shaft in the stub-axle carrier and tighten

the key nut.

Refit the anti-roll bar and fit the mounting nuts using

tool Sus. 1414-01 (see method in anti-roll bar section).

This tool allows the rubber mounting to be compressed

to fit the nut.

NOTE: apply force to the suspension and tighten the

wishbone and anti-roll bar bearing nuts to the

recommended torque (tightening position: vehicle

unladen).

SPECIAL TOOLING REQUIRED

Sus. 1414-01 Rubber mounting compressor

TIGHTENING TORQUES (in daNm)

Wheel bolt 9

Lower wishbone nuts on sub-frame 9

Key nuts on stub-axle carrier 5.5

Anti-roll bar bearing nuts 1.5

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FRONT AXLE

Lower arm rubber bushes 31A

31A-2

Lower arm rubber bushes

REPLACEMENT

To ensure that the bushes are correctly positioned in

relation to the lower arm, they are replaced one after

the other.

On the press, remove one of the worn bushes using a

tube of external diameter 30 mm.

Refit the new bush, ensuring that dimension

A = 146.5 mm.

Remove the second bush on the press and proceed in

the same manner as for the first bush, ensuring the

new bush is fitted so that dimension A = 146.5 mm.

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FRONT AXLE

Lower arm ball joint 31A

31A-3

Lower arm ball joint

REMOVAL

If the gaiter is damaged, the complete ball joint

must be replaced.

Proceed in the same manner as for removing the

lower wishbone.

Slacken but do not remove the two mounting bolts (3)

for the wishbone on the sub-frame.

Remove:

– the two ball joint mounting bolts (4), – the ball joint.

REFITTING

NOTE: ensure the plastic protective washer (A) ispresent on the lower ball joint shaft.

Fit the ball joint and torque tighten the mountings.

Then proceed in the same manner as for refitting the

lower wishbone.

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FRONT AXLE

Brake pads 31A

31A-4

Brake pads

REMOVAL

Push back the piston by manually sliding the calliper

towards the outside.

Remove the guide bolts (7) using two spanners.

Do not clean the bolts.

Release:

– the sliding calliper,

– the brake shoes.

Checking

Check:

– the condition and mounting of the piston dust cover

and its retaining ring,

– the condition of the guide dust cover (8).

REFITTING

Push back the slave cylinder piston using tool

Fre. 823.

Fit new brake pads.

Position the calliper and fit the lower guide bolt (7)coated with Loctite FRENBLOC.

Push on the calliper and fit the upper guide bolt coated

in Loctite FRENBLOC.

Tighten the guide bolts to torque starting with the lower

bolt.

Reconnect the wear warning light wire (if fitted).

Press the brake pedal several times to bring the

piston into contact with the brake shoes.


Fre. 823 Rear brake calliper piston return

tool


Wheel bolt 9

Brake calliper guide bolt 4

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FRONT AXLE

Brake callipers 31A

31A-5

Brake callipers

REMOVAL

Fit a pedal press in the driver's compartment (this

limits the flow of brake fluid).

Release the brake pipe at the wheel cylinder end.

Remove the brake pads (see previous page).

Remove the two mounting bolts for the calliper on the

stub axle carrier.

Completely release the brake pipe by turning thecalliper.

Check the condition of the hose and replace it ifnecessary.

REFITTING

Fit the pipe onto the calliper.

Remove the pedal press.

To check the correct operation of the calliper cylinder,

slacken the bleed screw and wait for brake fluid to run

out.

Retighten the bleed screw.

Refit the calliper on the stub axle carrier and tighten

the bolts to the recommended torque.

Refit the pads and the wheel cylinder (follow the

method described previously).

REPAIR

NOTE: if there are any scratches in the calliper bore,

the complete calliper must be replaced.

To do this:

– remove the brake calliper,

– remove the rubber dust seal,

– remove the compressed air piston taking care to

place a wooden block between the calliper and the

piston to prevent damaging the piston: the piston will

not be useable if there is any evidence of impact

damage on the skirt,

– remove the seal from the calliper groove using a

flexible rounded edge blade (eg feeler gauge).

Clean the parts using methylated spirits.

Replace any faulty parts with original parts and then

refit the seal, piston and dust seal.


Wheel bolt 9

Brake calliper guide bolt 4

Brake calliper mounting bolt 10

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FRONT AXLE

Brake discs 31A

31A-6

Brake discs

Brake discs cannot be reground. If they are too

heavily worn or are scratched they must be

replaced.

REMOVAL

Remove:

– the two mounting bolts (A) of the brake assembly,

– the two disc mounting bolts (B) using torx driver

(T40),

– the disc.

REFITTING

Position the disc on the hub and fit it with the two

bolts (B).

Fit the brake calliper, coat the bolts with

Loctite FRENBLOC and tighten to torque.

NOTE: when a brake disc is replaced, the brake shoes

must also be renewed.

Press the brake pedal several times to bring thepiston into contact with the brake shoes.


Wheel bolt 9


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FRONT AXLE

Stub-axle carrier bearing 31A

31A-7

Stub-axle carrier bearing

REMOVAL

Disconnect the battery.

Remove:

– the wheel, – the brake calliper and attach it to the spring so as not

to damage the pipe,

– the track rod end using tool T. Av. 476,

– the driveshaft nut,

Push the driveshaft back using tool T. Av. 1050-02.

Remove:

– the brake disc.

– the nut and the key from the lower ball joint,

– the two bolts of the shock absorber base, – the hub - stub-axle carrier - bearing assembly.

Using the press, remove the hub.

Remove the lower bush from the hub using an

extractor with jaws and tool Rou. 15-01.

Remove the locking spring ring from the stub axle

carrier.

Using the press, remove the rest of the bearing bypressing on the inner race using a tube of the same

diameter.


Rou. 15-01 Puller protection cup

Rou. 604-01 Hub locking tool

T. Av. 476 Ball joint extractor

T. Av. 1050-02 Driveshaft extractor


Driveshaft nut 28

Wheel bolt 9

Shock absorber base nuts 18


Steering ball joint nut 3.7

Key nut on stub axle carrier 5.5

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FRONT AXLE

Stub-axle carrier bearing 31A

31A-8

REFITTING

Using the press fit the bearing into the stub-axle carrier

with the aid of a tube with an exterior diameter of

70 mm and a bore of 66 mm: apply the pressure to the

outer race.

WARNING:do not use the inner race for support so as

to avoid damaging the bearing as a significant force is

used for fitting.

Fit a new locking spring ring.

Coat each sealing lip of the bearing with multipurpose

grease.

Using the press, fit them with the aid of a tube with an

external diameter of 48 mm and an internal diameter

of 42 mm: apply the pressure to the inner bearing

race.

Refit the hub - stub-axle carrier - bearing assembly to

the vehicle.

Then proceed in the reverse order to removal

observing the tightening torques.

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FRONT AXLE

Spring and shock absorber assembly 31A

31A-9

Spring and shock absorber assembly

REMOVAL

Put the vehicle on a four-post lift.

Remove:

– the wheels;

– the mounting bolts of the shock absorber base.

NOTE: disconnect the ABS sensor wiring if this is fitted

on the base of the shock absorber.

Remove the upper shock absorber nut in the engine

compartment.

Remove the shock absorber and spring assembly.

Replacing a shock absorber

To refit the shock absorber, put the shock absorber in a

vice and compress the spring using the spring

compressor.

Remove the spring retaining nut.

Remove the spring and the intermediate parts.

If necessary, replace the shock absorber pad and therotating stop.

When refitting, ensure that the constituent parts are in

their correct locations and decompress the spring.

NOTE: apply grease between the ends of the spring

and its stops.

REFITTING

Proceed in the reverse order to removal observing thetightening torques.

EQUIPMENT REQUIRED

Spring compressor


Shock absorber base mounting bolt 18

Rebound stop nut 6

Wheel bolt 9

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FRONT AXLE

Anti-roll bar 31A

31A-10

Anti-roll bar

REMOVAL

Put the vehicle on a four-post lift.

Remove:

– the two lower bolts from the exhaust downpipe, – the two sub-frame reinforcements,

– the two rubber mounting nuts at the ends of the anti-

roll bar,

– the two bolts from the central bearings on the bar.

Check the condition of the bearings and the rubber

mountings and replace them if necessary.

REFITTING

Refit:

– the rubber mounting nuts using tool Sus. 1414-01.


Sus. 1413 Central bearing compressor

Sus. 1414-01 Rubber mounting compressor


Central bearing bolt 3

Securing nut for rubber mounting 1.5

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FRONT AXLE

Anti-roll bar 31A

31A-11

Anti-roll bar

– the central bearing bolts using tool Sus. 1413,

– the two sub-frame reinforcements,

– the lower bolts on the exhaust downpipe.

Rubber bush locking position: UNLADEN.

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FRONT AXLE

Engine sub-frame 31A

31A-12

Engine sub-frame

REMOVAL



Remove the wheels.

Disconnect the track rod ends using tool T. Av. 476.

Remove the key on the stub-axle carrier.

Release but do not remove the mudguards to gain

access to the upper bolt of the sub-frame - side

member tie rod.

Remove:

– the exhaust downpipe and attach the catalytic

converter,

– the bolt (engine side) for the engine tie-bar.

– the gear control by removing the two bolts at the end

of it; to do this, it will be necessary to remove the

catalytic converter heat shield and the gaiter,

gearbox side.


Mot. 1390 Support for engine - gearbox

assembly removal/refitting

operations



Wheel bolt 9


Steering column universal joint eccentric

bolt 2.5

Sub-frame mounting bolt

– front ∅∅∅∅ 10 6

– rear ∅∅∅∅ 12 10.5

Sub-frame - side member tie-rod nut 3

Key nut on stub axle carrier 5.5

Engine tie-bar 6.5

Steering box mounting bolts 5

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FRONT AXLE

Engine sub-frame 31A

31A-13

Remove:

– the two nuts from the heat shield of the steering rack,

– the mounting nuts from the steering rack and attach

the rack to the exhaust manifold.

Fit tool Mot. 1390 under the sub-frame.

Lower the lift until the tool touches the ground.

Remove the sub-frame mounting bolts.

Carefully raise the lift.

REFITTING

Replace the engine sub-frame mounting bolts as a

matter of course and ensure they are tightened to the

correct torque.

Proceed in the reverse order to removal.

NOTE: the engine sub-frame is fitted to the body in the

following manner:

– fit two pins in place of the front mounting bolts,

– offer up the sub-frame,

– tighten, but do not lock, the rear mounting bolts

(begin with the longest rear right hand bolt),

– replace the pins with mounting bolts at the front,

– tighten the four mounting bolts to the correct torque,

beginning at the rear, – refit the heat shields correctly.

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REAR AXLE

Rear axle assembly 33A

33A-1

133AREAR AXLE

Rear axle assembly

REMOVAL


Remove the two rear wheels.

Fit a pedal press to limit the amount of brake fluid

which will run out.

Disconnect the two brake fluid rigid pipes.

Remove the compensator rod by removing the rear

axle retaining clip.

In the passenger compartment, loosen the handbrake

cable (see the procedure described in Section 37A

Mechanical Components Controls).

Underneath the vehicle, remove the two rear heat

shields and unclip the brake cables from body shell

(A).


Axle assembly mounting nut 5.5

Wheel bolts 9

Shock absorber upper nut 2

Shock absorber base mounting nut 10.5

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REAR AXLE


33A-2

NOTE: undo rubber bearing studs (B) without

removing them.

Position the hydraulic jack.

Remove the shock absorber lower bolts using a bar as

a lever.

Remove the springs as you go along.

NOTE: before removing the second bolt, make sure

that there are two people to keep the rear axle in

place. With the bolt removed, tilt the axle until it is

balanced.

Remove the six rear axle bearing mounting nuts on the

body shell.

Remove the axle completely making sure it is

balanced on the components mounting.

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REAR AXLE


33A-3

REFITTING

Balance the rear axle on the component jack and turn

the bearing mountings so that positioning pin (A) is at

the top.

Insert the axle past the mounting bolts and refit the six

nuts.

Tilt the rear axle (two people) to fit the shock absorber

springs and bolts in place.

Then proceed in the reverse order to removalobserving the tightening torques.

Refit the heat shields correctly.

Bleed the brake circuit.

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REAR AXLE

Shock absorber 33A

33A-4

Shock absorber

REMOVAL


Put the vehicle down on its wheels and in the luggage

compartment, remove:

– the shock absorber socket cap,

– nut (1) and rubber bush (2).

Lift the vehicle and remove the shock absorber lower

bolt.

IMPORTANT: do one side at a time.

REFITTING

Proceed in the reverse order to removal observing the

tightening torques.


Shock absorber upper nut 2


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REAR AXLE

Spring 33A

33A-5

Spring

REMOVAL


Lift the vehicle and remove the shock absorber lower

bolt.

NOTE: use a bar inserted in the axle assembly as a

lever, to make removing the lower shock absorber bolt

easier.

Remove the spring by levering the bottom of the axle

assembly to free it.

IMPORTANT: do one side at a time.

REFITTING


tightening torque.

TIGHTENING TORQUE (in daNm)


IMPORTANT: when refitting the spring, it is

essential to position it correctly; it has a green mark(1) which should be at the top and facing backwards.

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REAR AXLE

Brake drum 33A

33A-6

Brake drum

The two brake drums must be of the same diameter, if one is reground, the other must also be reground.

Never exceed the diameter marked on the drum.

REMOVAL

Remove the hub plug using tools Rou. 943 +Emb. 880.

Release the handbrake, slacken the secondary

handbrake cables to allow the lever to move back.

Insert a screwdriver through one of the wheel

mounting holes in the drum and push the handbrake

lever to release the lug from the brake shoe ( E ).

Help the lever to slacken by pushing it towards the

rear.

Remove:

– the nut and stub axle washer,

– the drum.

SPECIAL TOOLING REQUIREDEmb. 880 Inertia extraction tool

Rou. 943 Hub cover plug extractor


Wheel bolts 9

Hub nut 17.5

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REAR AXLE

Brake drum 33A

33A-7

REFITTING

Remove any dust from the drum and the linings using

brake cleaner.

Fit:

– the drum,

– the washer and the nut, and tighten to torque,

– the plug.

Adjust:

– the linings by repeatedly pressing the brake pedal,

– the handbrake (see Section 37A Mechanical

Components Control).

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REAR AXLE

Brake cylinder 33A

33A-8

Brake cylinder

REMOVAL

Remove:

– the brake drum (see corresponding paragraph),

– the upper return spring (see the Brake lining

paragraph).

Separate the shoes.

Undo:

– the rigid pipe union on the brake slave cylinder usinga pipe wrench,

– the two cylinder mounting bolts on the backing plateand remove it.

Check the condition of the shoes; if they have traces of

oil then replace them.

REFITTING

Remove any dust from the drums and the linings using

brake cleaner.


To check the correct operation of the caliper cylinder,

slacken the bleed screw and wait for brake fluid to run

out.

Bleed the brake circuit (see Section 30A, whether the

system is fitted with ABS or not).

Adjust the linings by repeatedly pressing the brake

pedal.

Check the cut-off pressure (see Section 37A

"Mechanical Components Controls").


Wheel bolts 9

Hub nut 17.5

Bleed screw 0.6 to 0.8

Pipe bolt 1.4

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REAR AXLE

Brake linings (drum) 33A

33A-9

Brake linings (drum)

RAI brake conponents (automatic wear take up

system).

A Leading shoe

B Trailing shoe

C Fixed pointP Base of brake shoe

F RAI wear take up system

1 Upper return spring

2 Lower return spring (for base)

3 Side retainer

4 Handbrake lever return spring

REMOVAL

Brake shoes must be replaced on the complete

axle - never fit shoes of differing makes or grades.

Remove:

– the brake drum (see corresponding paragraph),

– lower spring (2) using brake shoe pliers.

Using adjustable pliers, remove the shoe sideretaining springs.

In turn, pass each brake shoe base over the fixed

point. Squeeze the bases of the shoes together to

separate the ends at the wheel cylinder end.

Separate the brake backing plate assembly (RAI and

shoes) then remove it, after having unclipped the

handbrake cable.


Emb. 880 Inertia extraction tool



Wheel bolts 9

Hub nut 17.5

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REAR AXLE

Brake linings (drum) 33A

33A-10

REFITTING

Present the assembly to the vehicle.

Attach the handbrake cable to the lever.

Squeeze the bases of the shoes together and position

the other ends on the wheel cylinder pistons. Take

care not to damage the covers.

Position the shoes on the fixed point (C).

Fit the side retainers (3).

Remove the pliers from the wheel cylinder pistons then

refit the lower spring (2).

ADJUSTMENT

Using a screwdriver, adjust the brake shoe diameter

using the notched segment.

Refit the drums without tightening the nuts.

Centre the linings by repeatedly pressing the

brake pedal (approximately 20 times).

Ensure that the RAI is operating correctly(characteristic click of the brake drums).

Remove the drums.

Ensure:

– that the cables slide freely,

– that handbrake levers (L) are correctly positioned

against the shoes.

Progressively tighten the cables at the central adjustorso that levers (L) begin to move between the 1st and

2nd notch of the control lever travel and remain

detached on the 2nd notch.

Lock the lock nut on the central adjuster.

Refit:

– the drums and tighten the nuts to a torque of

17.5 daNm,

– the plugs.

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REAR AXLE

Bearing 33A

33A-11

Bearing

CHECKING

Check the end float using a dial gauge mounted on the

drum: 0 to 0.03 mm maximum.

REMOVAL

Remove: – the hub plug using tools Rou. 943 + Emb. 880,

– the brake drum (see corresponding paragraph).

From the drum, remove:

– the bearing retaining clip,

– the bearing using a tube.

REFITTING

Using a tube and a press, fit the bearing until it

touches the shoulder.

Fit:

– a new clip,

– the drum on the pre-lubricated stub axle,

– a new lock nut and tighten to torque,

– the hub cover plug.

Adjust:

– the linings by repeatedly pressing the brake pedal,

– the handbrake (see Section 37A Mechanical

Components Control).


Emb. 880 Inertia extraction tool



Hub nut 17.5

Wheel bolts 9

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REAR AXLE

Rubber bushes 33A

33A-12

Rubber bushes

REMOVAL

Place the vehicle on a two-post lift.

Remove:

– the compensator rod by removing the rear axle

retaining clip (if fitted),

– the three compensator mounting bolts and unclip the

rigid brake pipes on the first support (if fitted).


T. Ar. 1454 Tool for removing/refitting rear

axle rubber bushes

T. Av. 1420 Tool kit

T. Av. 1420-01 Spare hydraulic screw for tool

T. Av. 1420


Nuts for mounting the axle to the body

shell 6

Rubber bush bolts 7

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REAR AXLE

Rubber bushes 33A

33A-13

Position the component jack.

Undo but do not remove the two rubber bush bolts.

Remove the six rear axle clevis mounting nuts on the

body shell.

Lower the axle using the component jack in order to

fully free the rubber bushes.

Fully remove the clevis mountings from the axle on the

body shell.

Measure dimension X before removing the bush.

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REAR AXLE

Rubber bushes 33A

33A-14

To remove / refit the rear axle rubber bushes, the

following tooling is required:

– the three rings (A), (B), (C) and spacer (D) which

make up T. Ar. 1454,

– the two threaded rods and two flanges from the

tooling kit T. Av. 1420,

– the spare hydraulic screw for T. Av. 1420-01 which is

adapted for T. Av. 1420.

Fit the necessary tooling to the bush to be removed, ie:

rings (A), (C) and spacer (D) from T. Ar. 1454 as well

as T. Av. 1420 and 1420-01.

NOTE: twp people will be required to fit the tooling in

place.

Then remove the rubber bushing using the jack.

IMPORTANT: when removing the bush, avoid fully

screwing the threaded rod of the jack, it is advisable to

unscrew it again and tighten the jack using the knurled

section (this makes the jack thrust axis move back).Then tighten again, to fully remove the rubber bush.

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REAR AXLE

Rubber bushes 33A

33A-15

REFITTING

Fit the necessary tooling to the bush to be refitted, ie:

rings (A), (B) and spacer (D) from T. Ar. 1454 as well

as T. Av. 1420 and1420-01.

NOTE: two people will be required to fit the tooling in

place.

Then refit the rubber bushing using the jack.

Reposition the bush at dimension X taken before

removal and position slot (1) in the rubber bush at thetop.

IMPORTANT: when refitting the bush, avoid fully

screwing the threaded rod of the jack, it is advisable to

unscrew it again and tighten the jack using the knurled

section (this makes the jack thrust axis move back).

Then tighten again, to fully refit the rubber bush.

The rest of the operations should be performed in the

reverse order to removal.

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STEERING ASSEMBLY

Axial ball joint 36A

36A-1

136A STEERING ASSEMBLY

Axial ball joint


REMOVAL

Disconnect the track rod end using tool T.Av. 476.

Slacken the bolt on the parallelism adjustment sleeve

and slacken the track rod end while holding the axial

ball joint using an open wrench.

Make a mark or count the number of turns of thread

taken up so that the wheel alignment can be

readjusted on refitting.

Remove the plastic retaining clip for the gaiter and

remove the gaiter.

Turn the wheels so the rack teeth are freed on the

valve side.

Fit tool Dir.1306.

In this position, release the axial ball joint using tool

Dir. 1305-01.


Dir. 1305-01 Axial ball joint removal/refitting

tool

Dir. 1306 SMI steering rack support tool



Wheel bolt 9


Wheel alignment adjustment sleeve bolt 1.7

Axial ball joint 5

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STEERING ASSEMBLY

Axial ball joint 36A

36A-2

REFITTING

Assembly (2) MUST be replaced as a matter of

course.

NOTE: assembly (2) is only fitted if the vehicle has

manual steering.

Refit the following to the rack (3):

– the stop washer assembled with the locking ring (2),

– the new axial ball joint (1) having lightly coated the

threads with LOCTITE FRENBLOC ensuring that the

air evacuation opening is not blocked.

Before finally tightening the axial ball joint using tool

Dir. 1305-01, check that the tabs of the locking ring (2)

are in line with the flat surfaces (B) of the steering rack

(in the case of manual steering).

Tighten the axial ball joint to the recommended torque.

Centre the steering to balance the air in the gaiters.

Fit a new gaiter and secure it with a new clip (after

greasing the gaiter bearing surface on the axial ball

joint).

CHECKING

Gently press on the gaiter to check that the other

gaiter inflates which indicates the air is circulating

correctly.

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POWER-ASSISTED STEERING

Steering rack 36B

36B-1

236BPOWER-ASSISTED STEERING

Steering rack


REMOVAL

Remove the front wheels.

Fit a clamp Mot. 453-01 to each of the pipes from the

oil reservoir.

NOTE: never tighten the high pressure pipes.

Cut the rubber gaiter retaining clip and push the gaiter

back towards the bulkhead.

Disconnect the ball joints using tool T.Av. 476.

Remove the universal joint eccentric bolt.

Disconnect the oxygen sensor.

Remove the exhaust downpipe.

Remove the bolt (engine side) from the engine tie bar

and pivot the engine and transmission assembly

forwards.

Insert a retaining block.

Disconnect the high and low pressure pipes on thesteering rack (take precautions to catch the oil) and

the nut on the pipe retaining bracket.


Mot. 453-01 Hose clamp pliers

T.Av. 476 Ball joint extractor


Wheel bolt 9


Steering rack mounting bolts 5


bolt 2.5

Torque reaction arm bolt 6.5

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Steering rack 36B

36B-2

Remove:

– the two nuts on the heat shield for the right hand

steering rack bearing,

– the steering rack mounting nuts and remove it from

the timing side.

NOTE:

– do not remove the pipes between the valve and

cylinder,

– fit plugs to the steering rack openings to prevent the

introduction of impurities.

REFITTING


tightening torques.

Fill the circuit with oil.

Turn the wheels from left to right (engine not running)

to distribute the oil in the circuit.

Repeat the operation with the engine running then top

up the level.

If a new steering rack is being fitted, fit the track rod

ends in the position noted on removal.

To do this, slacken the bolt on the wheel alignment

adjustment sleeve and slacken the track rod end while

holding the axial ball joint using an open wrench.

Make a mark or count the number of turns of thread

taken up so the parallelism can be preadjusted on

refitting.

Check the parallelism.

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Gaiter 36B

36B-3

Gaiter

The gaiter MUST be replaced by a new gaiter

whenever an axial ball joint is removed.

Fitting the gaiter

Use a guard on the axial ball joint to prevent damage

to the gaiter during fitting.

Coat the gaiter bearing face on the axial ball joint with

grease to prevent the gaiter twisting.

Secure the gaiter with a new clip (supplied with the

gaiter).

NOTE: the steering MUST be at the centre point to

balance the air.

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Steering rack pinion 36B

36B-4

Steering rack pinion

ADJUSTMENT

If the steering rack pinion is noisy, before considering replacing the steering rack, check that the pinion is

correctly adjusted.

1. Determining the source of the noise

Hold the steering rack on the pinion side and check for

sidewards play (up and down). If the clearance is

followed by knocking, the noise originates from the

pinion rod.

2. Adjusting for SMI steering assemblies

Release the adjusting nut (1) by straightening the bent

over edges (A) on the nut collar.

Check when driving that the steering returns to the

centre point.

Maximum adjustment allowed: 1 notch.

Lock the nut again in the two lugs opposite the housing

by bending over the nut collar.

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Manual power steering pump 36B

36B-5

Manual power steering pump


REMOVAL


Remove:

– the front right wheel along with the right mudguard,

– the accessories belt.

Fit a Mot. 453-01 clamp to the supply pipe.

Disconnect the high pressure and supply pipes, be

prepared for the flow of power steering fluid.

IMPORTANT: as the alternator is located below the

pump it is necessary to protect it against the flow of

power assisted steering fluid.

Disconnect the pump pressure switch connector.

Remove:

– the three power assisted steering pump pulley bolts,

– the three power assisted steering pump mountingbolts,

– the power assisted steering pump.

REFITTING


Fill and bleed the circuit by turning the steering wheel

from lock to lock with the engine running.


Mot.453-01 Hose clamp pliers

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Steering column 36B

36B-6

Steering column

REMOVAL


Vehicle without air bag:

Remove the centre cover from the steering wheel (clip-

on fitting).

Remove:

– the driver's air bag cushion by the two Torx bolts

(T30) (tightening torque 0.5 daNm) located behind

the steering wheel and disconnect the connector (D),

– the steering wheel bolt,

– the steering wheel after setting the wheels straight,

– the half shells (three bolts).

Disconnect the stalk switches (wipers and lights) and

the rotary switch connector.

IMPORTANT: It is not permitted to handle the

pyrotechnic systems (air bags and pretensioners) near

a source of heat or flame as there is a risk of

triggering.

IMPORTANT: whenever the steering wheel is

removed, it is essential to disconnect the connector

from

air bag (D). The air bag has a connector which short

circuits if it is disconnected to prevent accidental

triggering.

Before removing the assembly, it is essential to mark

the position of the rotary switch:

– by ensuring that the wheels are straight during

removal in order to position the ribbon connector at

the centre,

– and checking that the 0 mark of the rotary switch iscorrectly positioned facing the fixed index mark (E).

VALEO ASSEMBLY

LUCAS ASSEMBLY



bolt 2.5

Steering wheel bolt 4.5

Steering column mounting nuts 2

Air bag mounting bolt 0.5

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Steering column 36B

36B-7

Unscrew the bolt (C), then tap sharply on the

screwdriver to unlock the cone and disconnect the

assembly from the steering column.

Remove the cover by:

– first of all pulling back the windscreen pillars. To do

this, remove the trim by a sufficient amount in order

to press the upper clip, move the pillar (1) away and

unclip the cover (2).

– removing the two side bolts,

– removing the three upper bolts (next to the

windscreen). Then remove the cover completely,

proceeding as shown in the diagrams.

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Steering column 36B

36B-8

Remove the immobiliser transponder ring.

Remove the instrument panel (six bolts),

disconnecting the four connectors.

Disconnect the connector.

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Steering column 36B

36B-9

In the engine compartment:

– remove the air duct,

– remove the mounting nuts of the expansion bottle

and move the bottle to gain access to the steering

column universal joint.

Remove the universal joint eccentric bolt.

Remove the six mounting bolts from the steering

column and pull off the bulkhead gaiter.

Remove the steering column.

REFITTING

Refit the steering column.

Fit the gaiter on the bulkhead, having tied the flaps and

the universal joint together with string.

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Steering column 36B

36B-10

Pull the tab, cut the string to fit the gaiter in place.

Refitting is then the reverse of removal.

Check the instrument panel connectors are correctly

reconnected.

Special notes for refitting

Ensure that the wheels are still straight.

Check that the rotary switch is correctly positioned by

making sure that the rotary switch 0 mark is correctly

located facing the fixed index mark (E).

Fit the whole assembly on the steering column and

connect the various connectors.

Continue refitting and do not lock bolt (C) until the two

half shells are refitted, so that the stalks may be

aligned with the dashboard and the instrument panel.

This operation is made easier by a cut-out section

giving access to bolt (C) in the lower half shell.

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Steering column 36B

36B-11

Replace the steering wheel bolt whenever it is

removed (pre-bonded bolt).

Observe the correct tightening torque (4.5 daNm).

IMPORTANT: before reconnecting the driver's air bag,

the procedure for checking the correct operation of the

system must be carried out:

– check that the air bag warning light on the instrument

panel is lit when the ignition is switched on,

– connect a dummy ignition module to the driver's air

bag connector and check that the warning light goes

out,

– switch off the ignition, connect the air bag cushion in

place of the dummy igniter and fit the cushion to the

steering wheel (tightening torque 0.5 daNm),

– switch on the ignition, check that the air bag warninglight comes on for 3 seconds when the ignition is

switched on and then goes out permanently.

If the warning light does not operate as described

above, refer to the Fault finding section and check the

system using XRBAG (Elé. 1288).

WARNING: If these instructions are not followed

the system may not operate normally and could

even cause accidental triggering.

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Retractable shaft 36B

36B-12

Retractable shaft

REMOVAL - REFITTING

These vehicles are fitted with a non-removable retractable shaft - steering wheel shaft - steering column assembly. If

the eccentric bolt of the universal joint needs to be tightened, check that the length of the shaft is correct, otherwise

replace the assembly (see the Steering column section).

CHECKING

L = 416.63 ±±±± 1.5 mm

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MECHANICAL ELEMENT CONTROLS

Master cylinder 37A

37A-1

137AMECHANICAL ELEMENT CONTROLS

Master cylinder

REMOVAL


Disconnect the brake fluid level detector connector.

Remove the injection computer (depending on

version).

Unclip and release the power assisted steeringreservoir towards the engine.

Drain and remove, by pulling up, the brake fluidreservoir (take care to catch the fluid which will run

out).

Remove:

– the pipes and mark their position,

– the two brake servo mounting nuts.

REFITTING


Check the length of the pushrod.

Dimension X = 22.3 mm.

Depending on model, adjust using pin (P).

NOTE: these vehicles are fitted with a master cylinder

which is built into the brake servo. The brake servoseal is directly linked to the master cylinder. During any

operation, a new seal (A) must be fitted.

Align the master cylinder with the brake servo so that

push rod (P) enters the master cylinder housingcorrectly.


Hydraulic pipe unions 1.4

Brake servo mounting nut 1.8

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Master cylinder 37A

37A-2

Fill the brake fluid reservoir and bleed the brake circuit.

MASTER CYLINDER (REPLACEMENT)

The kit sold by the Parts Department comprises:

– a master cylinder (four outputs or two outputs if

Anti-lock braking system),

– two plugs (A),

– two mounting nuts (B).

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Brake servo 37A

37A-3

Brake servo

The brake servo cannot be repaired. Operations are

only allowed on:

– the air filter,

– the non-return valve.

REMOVAL

Disconnect and remove the battery.

Remove:

– the master cylinder (following the method described

previously), – the battery protection plate (four bolts, one nut),

– the two mounting nuts for the expansion bottle andmove it towards the engine.

Disconnect the flexible vacuum union on the brake

servo.

In the passenger compartment:

– remove shaft (A) from the yoke connecting the brakepedal to the push rod by using the clip,

– remove the four brake servo mounting nuts,

– Remove the brake servo.

REFITTING

Before refitting, check:

– dimension L = 104.8 mm,

– dimension X = 22.3 mm.




Brake servo mounting nut 1.8

Brake servo on bulkhead 2.3

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Brake servo 37A

37A-4

CHECKING SEALING

Check the sealing of the brake servo, ensuring a perfect seal between it and the master cylinder. If there is a leak,

replace seal (A) (see method described on page 37-1).

Seal checking must be performed on the vehicle.

Fit tool Mot. 1311-01 between the brake servo and the

vacuum source (inlet manifold).

To do this:

– completely remove the vacuum pipe,

– recover assembly (1) non-return valve / flexible hoseby removing the clip,

– connect the pipes to the T union, the vacuum

pressure gauge and assembly (1) (use union B of kit

Mot. 1311-01 and a wormdrive clamp (2)).

– fit the mounting by connecting the valve to the brake

servo at one section and the manifold outlet pipe at

the other.

NOTE: make sure the closure valve is on the manifold

side.

Run the engine at idle speed for 1 minute.

Close the valve and switch off the engine.

The circuit vacuum is approximately 613 mbar , if thevacuum drops to 33 mbar in 15 seconds, there is a

leak which could be either: – at the non-return valve (replace it),

– or at the pushrod diaphragm (replace the brake

servo).


Mot. 1311-01 Pressure gauge and unions for

pressure tapping

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Brake servo air filter - Non-return valve 37A

37A-5

Brake servo air filter - Non-return valve

REPLACING THE AIR FILTER

It is not necessary to remove the brake servo to

replacee air filter (F).

Under the pedal mounting, use a screwdriver or a

metal hook to remove the worn filter (F). Cut the new

filter at A (see diagram) and fit it around the rod, then

press it into position, checking that it fills the opening

completely to prevent any non-filtered air from passing

through.

REPLACING THE NON-RETURN VALVE

This operation may be carried out on the vehicle.

REMOVAL

Disconnect the brake servo vacuum supply tube.

Pull and turn the non-return valve to release it from the

rubber sealing washer.

REFITTING

Check the condition of the rubber sealing washer and

the non-return valve.

Replace any faulty parts.

Refit the assembly into position.

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Handbrake control lever 37A

37A-6

Handbrake control lever

REMOVAL

Place the vehicle on a lift.

Release the handbrake.

Remove the central console (two screws) and plastic

cover (2) of the lever.

Undo handbrake adjustment nut (1) marking

dimension X (approximately 20 mm), to release the

cable.

Lift the vehicle and remove the exhaust pipe heat

shield (four bolts).

Release the two cables at the compensator.

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Handbrake control lever 37A

37A-7

Handbrake control lever

In the passenger compartment, remove the two

handbrake mounting nuts and disconnect the

connector.

Remove the hand brake.

REFITTING


Remember to reconnect the handbrake connector.

Retighten the handbrake adjusting nut observing the

measurement (approximately 20 mm).

If necessary, adjust the lever travel (see the

information on Adjusting the control).


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Handbrake control 37A

37A-8

Handbrake control

ADJUSTMENT

Incorrect adjustment of the handbrake where the

cable is too tight:

– prevents the correct operation of the automatic

compensation system for the brake shoes,

– and causes spongy brake pedal travel.

The cables should not be re-tensioned to correct

this fault since it will quickly occur again.

The handbrake is not for play compensation, it

should only be adjusted when replacing:

– brake shoes,

– the cables,

– the control lever.

Any other adjustment except in the above cases is

not permitted.

Put the vehicle on a lift and undo nut (1) to fully release

the cable and therefore, the central compensator (see

the method previously described).

Remove:

– the two rear wheels,

– the two drums.

Check the operation of the automatic compensation

system by rotating notched segment (D) (ensure it

turns in both directions), then turn it back by 5 to

6 teeth.

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Handbrake control 37A

37A-9

Ensure:

– that the cables slide freely,

– that the handbrake levers (B) are in the correct

position against the brake shoes.

Progressively tighten the cables at the central adjuster

so that levers (B) start to move between the 1st and

2nd notch of the control lever travel and remain

applied from the 2nd notch.

Tighten the lock nut.

Fit the drums.

With the vehicle on its wheels, adjust the brake shoes

by pressing the brake pedal firmly and progressively

for a number of times while listening for the automatic

compensation system clicking.

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Brake pipes 37A

37A-10

Brake pipes

These vehicles have brake pipes without a copper seal. The seal is by contact at the bottom of the cone of the

shoulder (Y) on the pipe.

PRECAUTIONS TO BE TAKEN WHEN REMOVING - REFITTING A BRAKE CYLINDER OR A BRAKE PIPE.

For safety reasons and to ensure that the brake pipe is not twisted and is not liable to touch a suspension

component, the following order of operations must be observed:

REMOVAL

Unscrew union (1) (pipe wrench) from the rigid pipe onhose (2) when spring (3) is slack, which frees the hose

from splines (4).

Remove the hose from the caliper and if necessary

remove the caliper.

REFITTING

Fit the caliper to the brake and screw the hose onto it,then torque tighten to 1.4 daNm.

The brake pipes are fitted when the axle assembly is in

position:

● Wheels suspended (suspension in place).

● Axle assembly aligned (wheels straight).

Position the female end of the hose on the retaining

bracket (5), without twisting it and check that the end

piece (4) fits freely into the splines of the bracket, then

fit:

– the spring (3),

– the rigid pipe to the hose, checking that the hose

does not turn when the assembly is screwed

together.

Torque tighten the union.



X = 1.4

Z = 1.4

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Brake compensator 37A

37A-11

Brake compensator

CHECKING PRINCIPLE

These vehicles are fitted with a load sensitive braking

compensator.

The pressure is read in an X pattern, by comparing

the pressure at the rear wheels with a given pressure

at the front wheels.

The dual compensator has two totally separate bodies

which act in an X pattern on one front wheel and one

rear wheel.

Both circuits must be checked.

I : front right / rear left.

II : front left / rear right.

Load-sensitive compensators

For load sensitive compensators, the adjustment

allows alteration of the rear pressure depending on the

front pressure.

The adjustment is made to both bodies; if the pressure

is incorrect on one of them, replace the compensator.

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37A-12


REMOVAL

Fit a pedal press to limit the amount of brake fluid

which will run out.

Remove the compensator rod by removing the

retaining clip on the rear axle.

Disconnect the brake pipes (at the compensator), and

mark their positions.

Remove the heat shield (one bolt, two quick release

clips).


Fre. 244-03

Pressure gauge for checking

the compensator ratingor

Fre. 1085-01


Hydraulic unions 1.4

Compensator mounting bolt 1.8

Rod adjustment bolt 1

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37A-13

Remove the compensator (two bolts).

Undo, but do not remove, compensator retaining

bracket mounting bolt (1).

REFITTING


Reconnect the pipes to the compensator, taking care

to refit them as marked when removed.

Bleed and check the circuit (see the Checking -

Adjusting section).


ADJUSTMENT

To adjust the brake compensator, undo bolt (1) and

adjust the position of rod (2) in the sleeve.

NOTE: do not alter the position of nut (3).

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37A-14

CHECKING

Connect two pressure gauges Fre. 244-03 or

Fre. 1085-01:

– one at the front right-hand side,

– one at the rear left-hand side.

Bleed the pressure gauges via screw (P).

Gradually depress the brake pedal until the

pressure at the front wheels is at the setting

pressure (see table of values, section 07B). Read

the corresponding pressure at the rear wheels;

correct it if necessary.

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Clutch release control 37A

37A-15

Clutch release control

● CLUTCH CABLE

REMOVAL

In the engine compartment, disconnect the cable from

the fork.

Passenger compartment side, disconnect the cable at

the pedal by removing the end from its housing in the

slack take-up section.

Remove the cable sleeve stop from the bulkhead.

Remove the complete cable via the engine

compartment.

REFITTING

From the engine compartment, thread the cable

through the bulkhead.

Fit the cable end piece into position on the wear

compensation sector.

Fit the cable onto the clutch fork.

Adjustment can be made automatically by pressing the

pedal.

● CLUTCH PEDAL

REMOVAL

In the engine compartment, disconnect the cable from

the fork.

Passenger compartment side, remove:

– the cable at the pedal by removing the end from its

housing in the slack take-up section.

– stiffener (1),

– pedal mounting shaft nut (2).

Remove the pedal.

REFITTING


Fit the cable end piece into its housing on wear

compensation sector (3).

In the engine compartment, fit the cable onto the

clutch fork.

Adjustment can be made automatically by pressing the

pedal.

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Clutch automatic wear take-up system 37A

37A-16

Clutch automatic wear take-up system

SPECIAL NOTES

In order to ensure the assembly operates correctly,

check that:

– the notched sector pivots about its pin,

– the ratchets return to the rest position freely,

– the cable is always taut on the fork and there is at

least 2 cm of slack,

– the fork travel is between:

X = 27 to 30 mm

There should be a preliminary check before any

operation on the clutch itself.

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External gear control 37A

37A-17

External gear control

REMOVAL


In the vehicle, release the console gaiter.

Under the vehicle:

– release primary exhaust pipe (1),

– remove heat shields (2).

Remove:

– the lever / linkage mounting nut,

– the four control unit mounting nuts.


Nut for mounting gearbox onto body 1.5

Screw for clip mounting the linkage onto

the fork 2

Bolt for mounting the linkage onto the

fork 3

Linkage/lever mounting nut 3

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37A-18

REMOVING the control linkage

After removing the linkage / lever connecting nut,

remove the linkage / selector connecting bolt.

REFITTING



Coat the lever joints and the linkage pin with

33 Médium grease.

Ensure the fork is fitted correctly: offset on gearbox

side.

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37A-19

ADJUSTMENT

Remove the collector or the engine undertray.

Select 1st gear.

Slacken bolt (V).

Fit shim B. Vi. 1133 to take up any play.

At the same time pull the end of the shim downwards

and pivot it through approximately 45°°°° until it touches

the notch on the housing.


B. Vi. 1133 Selector lever 1st gear locking tool


Linkage mounting clip bolt on fork 2

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37A-20

Press the lower lever gate against the gearbox ramp,

inserting a 9 mm shim.

In this position, tighten bolt (V).

Check the play which results from this (Y), which

should be between 7 and 10 mm.

Remove shim B. Vi. 1133.

Check the gears engage correctly.

Refit the collector or the engine undertray.

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Brake cables 37A

37A-21

Brake cables

REMOVAL

Place the vehicle on a lift. Release the handbrake.

Remove the central console (two screws) and plastic

cover (2) for the lever.

Undo handbrake adjustment nut (1) marking

dimension X (approximately 20 mm), to release the

cable.

Lift the vehicle and remove the exhaust pipe heat

shield (four bolts).

Release the two cables at the compensator.

Remove the cable guides.


Fre. 1499 Tool for removing the handbrake

sleeve

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Brake cables 37A

37A-22

Insert tool Fre. 1499 in the cable sleeve stop by

passing the cable through the tool tube first.

Insert the tool until it crushes the cable end.

Remove the cable.

REFITTING


Retighten the handbrake adjusting nut observing the

20 mm measurement.

If necessary, adjust the lever travel (see the

information on Adjusting the control).

Refit the heat shield correctly.

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Introduction 38C

38C-1

138CANTI-LOCK BRAKING SYSTEM

Introduction

This vehicle is fitted with BOSCH ABS 5.3 of the four channel additional type; the conventional braking equipmentand the ABS equipment are separate.

SPECIAL NOTES

The system comprises four speed sensors. Each hydraulic braking channel is linked with a sensor at each wheel.The front wheels are therefore regulated separately. The rear wheels however are regulated at the same time and inthe same way according to the select low principle (the first wheel tending to lock causes immediate regulation onthe complete axle assembly).

On this vehicle, the brake limiter is not fitted (for versions fitted with ABS) and its role is performed by a specificprogram located in ABS unit computer called EBD (Electronic Braking Distribution).

WARNING: if the ABS fuse is removed, do not brake sharply during road tests as the EBD function is no longeractive (the pressure is the same in the front and rear) and there is a risk of slewing.

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Introduction 38C

38C-2

LOCATION OF THE BOSCH ABS COMPONENTS

1 Hydraulic unit2 Master cylinder3 Brake servo4 Brake fluid level warning light

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Introduction 38C

38C-3

HYDRAULIC REGULATION UNIT

A Inlet from master cylinderB Left rear wheelC Right rear wheel

D Front right wheelE Left front wheel

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Introduction 38C

38C-4

WIRING DIAGRAM

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Introduction 38C

38C-5

WIRING DIAGRAM KEY

104 Ignition switch

118 ABS computer

120 Injection computer

150 Rear right wheel sensor

151 Left rear wheel sensor

152 Front right wheel sensor

153 Front left wheel sensor

160 Brake switch

225 Diagnostic socket

247 Instrument panel

645 Passenger compartment connection unit

777 Power feed fuse rack

R2 Instrument panel / rear left

R67 Front of engine / Engine

R101 Right-hand side member / Right-hand headlight

R107 Instrument panel / Front of engine

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Introduction 38C

38C-6

31-TRACK CONNECTOR

A Micro-spring connected to earth (terminal 19) pins 20 and 21 (ABS and brake fluid level indicators) in the eventof connector becoming disconnected.

Allocation of connector tracks

Track Description

1 Rear right-hand earth sensor

2 Rear right-hand sensor signal

3 Front right-hand earth sensor

4 Not connected

5 Front right-hand sensor signal

6 Front left-hand sensor signal

7 Front left-hand sensor signal

8 Rear left-hand earth sensor

9 Rear left-hand sensor signal

10 Not connected

11 Diagnostic line K

12 Diagnostic line L

13 Not connected

14 Brake lights switch signal

Track Description

15 + After ignition computer supply

16 Pump motor earth

17 + Battery feed (solenoid valves andpump motor)

18 + Battery feed (solenoid valves andpump motor)

19 Electronic earth20 Not connected

21 ABS fault warning light

22 Not connected

25 Not connected

26 Front right-hand wheel speed output(depending on equipment)

27 Not connected

31 Not connected

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Introduction 38C

38C-7

DIAGNOSTIC SOCKET

4 Chassis earth

5 Electronic earth

7 Diagnostic line K

15 Diagnostic line L

16 + Battery

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Hydraulic unit 38C

38C-8

K4M ENGINES Hydraulic unit

HYDRAULIC UNIT

REMOVAL



Remove the front right-hand wheel.

Fit a pedal press to limit the amount of brake fluidwhich will run out.

From above:

Disconnect the computer connector.

Remove the two earth bolts.

Disconnect the six pipes from the hydraulic unit,marking their position for refitting.

Remove the hydraulic unit upper mounting bolt.

From below:

Remove: – the exhaust downpipe, – the exhaust manifold heat shield (three bolts), – the two hydraulic unit lower mounting bolts,

– the hydraulic unit via the wheel arch.

REFITTING


Refit the heat shield correctly.

NOTE: the computer must not be removed, if faulty,replace the entire hydraulic unit.


Pipe unions M10 X 100M12 X 100

1.41.4

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Hydraulic unit 38C

38C-9

CHECKING THE HYDRAULIC CIRCUIT

NOTE: Two people are required. Put the vehicle on a two-post lift.

When the vehicle is on the lift, lift the wheel requiring testing. One person must stay in the passenger compartment,at the driver's position, equipped with a NXR unit. With the ignition on, with the vehicle in neutral, and in actuatorcontrol mode. Depress the brake pedal.The second operator must apply a torque to the wheel to try and rotate it. The operator in the passenger compartmentstarts an engine / pump test (8) in the NXR unit. This command carries out ten cycles: Fall and rise in pressure of thewheel tested. The anti-lock braking system is activated by the wheel locking and unlocking alternately ten times.The

jerky movement of the wheel, noted qualitatively by the operator, signify that the hydraulic circuit for this wheel iscorrectly connected.At the end of the test, the operator in the passenger compartment releases the brake pedal.

Carry out the same check on the three other wheels.

BLEEDING PROCEDURE

NOTE: the hydraulic unit is supplied prefilled.

This bleeding procedure must be used when one of the following components has been removed: – the hydraulic unit, – the master cylinder, – the pipes between the hydraulic unit and the master cylinder.

1. Carry out a conventional bleed of the circuit outside the brake adjustment circuit

Precautions to be taken during this braking circuit bleeding operation: – The vehicle ignition must be off to ensure that the hydraulic unit solenoid valves do not operate. – Check the brake fluid levels of the braking circuit and the bleeding device.

Connect the bleeding device to the braking circuit, paying attention to the features of this equipment (refer to theoperating instructions).

Bleed the circuit by opening the bleed screws in the following order (remember to close them after the operation): – rear right-hand circuit, – front left-hand circuit, – rear left-hand circuit, – front right-hand circuit.

Check the pedal travel and if it is incorrect, restart the bleeding procedure.Top up the brake fluid level in the reservoir having disconnected the bleeding device. Check the tightness of the bleedscrews and that the sealing caps are all present.

During a road test, trigger brake control to confirm that the brake pedal travel is correct.

NOTE: the braking circuit is the X type, therefore it is possible to carry out an isolated bleeding operation on a singlecircuit (when the hose, calliper etc. are being replaced).

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Hydraulic unit 38C

38C-10

2. Bleeding the brake adjustment circuit

This bleed must only be carr ied out if the brake pedal travel, judged to be correct at the end of a conventional bleed(confirmed by a road test with hydraulic unit regulation in operation), becomes incorrect.This procedure must be used if the hydraulic unit is suspected of containing air (whether or not it has been removed).

Precautions to be taken during this braking circuit bleeding operation – Check the brake fluid levels of the braking circuit and the bleeding device.

Connect (refer to the operating instructions): – the bleeding device to the vehicle braking circuit, – the diagnostic tool.

Carry out a Conventional bleed.

Repeat these operations (1) on each circuit following the described order (2):

(1) Operations to carry out: – Open the bleed screw, – After extracting the air, close the bleed screw. – Activate the circuit solenoid valves using the diagnostic tool. – Each time the solenoid valve is activated, brake slowly, then release the pedal when the solenoid valve is no longer

active.

(2) Bleed the circuits in the following order: – rear right-hand side (NXR tool command: 1506; CLIP tool control: rear right-hand bleed circuit), – rear left-hand (NXR tool command: 1505; CLIP tool control: rear left-hand bleed circuit,

– front left-hand (NXR tool command: 1503; CLIP tool command: front left wheel bleed circuit), – front right-hand (NXR tool command: 1504; CLIP tool command: front right wheel bleed circuit).

During a road test, trigger brake control to confirm that the brake pedal travel is correct.

Top up the brake fluid level in the reservoir having disconnected the bleeding device. Check the tightness of thebleed screws and that the sealing caps are all present.

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Wheel speed sensor 38CWheel speed sensor

CHECKING

a) Check the resistance of the connections from thecomputer connector to the 2-track speed sensorconnector.

b) Carry out a visual inspection of the teeth (26 teeth)on the target. If the teeth are faulty, replace thesensor.

c) Check the air gap using a set of feeler gauges. Onlythe front teeth cab be checked.

Front air gap: 0.1 < Z < 1.9 mm

Chassis 2002+ clio

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