MR427MEGANE6.pdf

6

Air conditioning 61A

HEATING

62A

AIR CONDITIONING

X95 APRIL 2009 "The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed."

Edition Anglaise

All copyrights reserved by Renault. The reproduction or translation in part of whole of the present document, as well as the use of the spare parts reference numbering system, are prohibited without the prior written consent of Renault.

© Renault s.a.s 2008

MEGANE III - Section 6

MEGANE III - Section 6ContentsPage

Contents Page

61A

HEATING Heating: List and location of components Cabin filter: Removal Refitting C-pillar intermediate air distribution duct: Removal Refitting Rear air distribution duct: Removal - Refitting Recirculation control cable: Removal - Refitting

61A

61A-1 61A-19

61A-27 61A-28 61A-29

HEATING Front side air distribution duct: Removal - Refi tting

61A-132

Front central air distribution duct: Removal - Refi tting

61A-141

A-pillar air distribution duct: Remo val - Refitting

61A-142

Recirculation motor: Remo val - Refitting

61A-146

Mixer motor: Removal Refitting

61A-158

Distribution motor: Removal Removal Refitting

61A-174

61A-182 61A-183

Air distribution cable: Removal - Refitting

61A-31

Air mixing cable: Removal Refitting

61A-42

Passenger compartment temperature sensor: Remo val - Refitting

Air distribution unit: Removal - Refitting

61A-54

External temperature sensor: Remo val - Refitting

Heater matrix: Removal Refitting

61A-69

Fan assembly: Removal Refitting Heating resistor relays: Removal - Refitting Heating resistor unit: Removal - Refitting Passenger compartment fan assembly control unit: Removal - Refitting Control panel: Removal Refitting

62A 62A

AIR AIR COND CONDIT ITIO IONI NING NG

61A-83 61A-102 61A-106

61A-117 61A-124

Air conditioning: List and location of components

62A-1

Air conditioning: Precautions for repair

62A-3

Air conditioning: Parts and consumables for the repair work

62A-4

Air conditioning: Operating diagram

Contents

62A

AIR AIR COND CONDIT ITIO IONI NING NG Air conditioning: Check

62A-5

Coolant circuit check

62A-8

Coolant circuit Draining Refilling

62A-9

Condenser: Removal Refitting

62A-12

Compressor: Compressor : Removal Removal Refitting

62A-21

Expansion valve: Removal Refitting

62A-33

Evaporator: Cleaning

62A-47

Expansion valve - condenser connecting pipe: Removal Refitting

62A-49

Expansion valve intermediate pipe connecting pipe at the expansion valve outlet: Removal - Refitting

62A-65

Pressure sensor: Removal Refitting

62A-77

Evaporator sensor: Removal - Refitting

62A-79

Condenser - compressor connecting pipe: Removal Refitting

62A-85

Compressor/intermediate pipe connecting pipe: Removal - Refitting

62A-95

HEATING Heating: List and location of components components

61A

B95 or D95 or E95 or K95, and an d CLIMATE CLIMATE CONTROL

I - LIST OF COMPONENTS

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

The air conditioning system consists of:

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

- a control control panel panel (1) , - a mixing mixing moto motorr (2) ,

- a front centre centre air distribution distribution duct duct (18) ,

- a distributi distribution on motor motor (3) ,

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

- a cabin cabin filter filter (4) ,

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

- an expansio expansion n valve valve (5) ,

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

- a recirculat recirculation ion motor motor (6) ,

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

- a recirculation recirculation control control cable (7) , - a cooling cooling fan fan assembly assembly (8) ,

EQT LE VEL EA4, and ELECTRONIC EL ECTRONIC PARKING BRAKE

- a passenger compartment compartment fan assembly assembly control unit unit (9) , - a mixing mixing moto motorr (10) , - an evaporator evaporator sensor (11) , - a heater heater matri matrix x (12) ,

- a rear intermediate intermediate air distribution distribution duct (23) , - a rear air distrib distribution ution duct duct (24) .

- a heating heating resistor resistor relay relay (13) , - a heating heating resisto resistorr (14) , - a front side air air distribution distribution duct duct (15) ,

II - LOCATION OF COMPONENTS COMPONENTS

133409

61A-1


61A


133410

61A-2

HEATING Heating: List and location of components

61A

B95 or D95 or E95 or K95, and CLIMATE CONTROL

133406

61A-3


61A


EQT LEVEL EA4, and ELECTRONIC PARKING BRAKE

133404

61A-4


61A

B95 or D95 or E95 or K95, and AIR CONDITIONING


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

The air conditioning system consists of: - a control control panel panel (1) ,

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

- an air distribution distribution cable cable (2) ,

- a front centre centre air distribution distribution duct duct (17) ,

- a cabin cabin filter filter (3) ,

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

- an expansio expansion n valve valve (4) ,

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

- a recirculat recirculation ion motor motor (5) ,

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

- a recirculation recirculation control control cable (6) ,

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

- a cooling cooling fan fan assembly assembly (7) , EQT LEV EL EA4, and ELECTRONIC EL ECTRONIC PARKING BRAKE

- a passenger compartment compartment fan assembly assembly control unit unit (8) , - an evaporator evaporator sensor (9) , - a heater heater matri matrix x (10) , - a heating heating resistor resistor relay relay (11) ,

- a rear intermediate intermediate air distribution distribution duct (22) , - a rear air distrib distribution ution duct duct (23) .

- a heating heating resisto resistorr (12) , - an air mixin mixing g cable cable (13) , - a front side air air distribution distribution duct duct (14) ,

II - LOCATION OF COMPONENTS COMPONENTS

133405

61A-5


61A


133407

61A-6


61A


133406

61A-7


61A


EQT LEVEL EA4, and ELECTRONIC PARKING BRAKE

133404

61A-8


61A

J95, and AIR CONDITIONING


- a rear right-hand footwell footwell air distribution distribution duct (18) (see C-pillar air distribution duct: Removal - Refitting) .

The air conditioning system consists of: - a control control panel (1) (see 61A , Heating , Control panel: Removal - Refitting, page 61A-124) ,

REAR SEATS SEATS VENTILA VE NTILAT TOR

- an air distribut distribution ion cable cable (2) (see 61A , Heating, Air distribution cable: Removal - Refitting , page 61A31) ,

- rear side intermediary intermediary air distribution distribution ducts (19) (see Rear side intermediate air distribution duct: Removal - Refitting) ,

- a cabin cabin filter filter (3) (see 61A, Heating, Cabin filter: Removal - Refitting, page 61A-19 ) ,

- rear side air distribut distribution ion ducts (20) (see Rear side air distribution duct: Removal - Refitting) .

- an expansio expansion n valve valve (4) (see 62A, Air conditioning, Expansion valve: Removal - Refitting , page 62A33) , - a recirculat recirculation ion motor motor (5) (see 61A, Heating, Recirculation motor: Removal - Refitting , page 61A146) , - a recirculation recirculation control cable (6) (see 61A, Heating, Recirculation control cable: Removal - Refitting , page 61A-29 ) , - a cooling cooling fan assembl assembly y (7) (see 61A, Heating, Fan assembly: Removal - Refitting , page 61A-83 ) , - a passenger compartment compartment fan assembly assembly control unit unit 61 A , Heating, Passenger compartment (8) (see 61A fan assembly control unit: Removal - Refitting , page 61A-117) , - an evaporato evaporatorr sensor (9) (see 62 A, Air conditioning, Evaporator sensor: Removal - Refitting , page 62A-79 ) , - a heater heater matrix matrix (10) (see 61A, Heating, Heater matrix: Removal - Refitting , page 61A-69 ) , - heater heater resistor resistor relay relay (11) (see 61 A, Heating, Heating resistor relays: Removal - Refitting , page 61A-102 ) , - a heating heating resist resistor or (12) (see 61A , Heating, Heating resistor unit: Removal - Refitting , page 61A-106 ) , - an air mixing mixing cable cable (13) (see 6 1 A , Heating, Air mixing cable: Removal - Refitting , page 61A-42 ) , - front side air distribution distribution ducts (14) (see 61A , Heating , Front side air distribution duct: Removal Refitting, page 61A-132) , - a front left-hand footwell air distribution distribution duct (15) (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting , page 61A-142) , - a front right-hand right-hand footwell air distributio distribution n duct (16) (see 61A 61 A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - a rear left-hand footwell footwell air distribution distribution duct (17) (see C-pillar air distribution duct: Removal - Refitting ) ,

61A-9


61A


II - POSITION OF THE COMPONENTS

139037

61A-10


61A


139038

61A-11


61A


139041

61A-12


61A


REAR SEATS VENTILATOR

139040

61A-13


61A

J95, and CLIMATE CONTROL


- a rear right-hand footwell air distribution duct (19) (see C-pillar air distribution duct: Removal - Refitting) .

The air conditioning system comprises: - a control panel (1) (see 61A , Heating , Control panel: Removal - Refitting, page 61A-124) , - a mixing motor (2) (see 61A , Heating, Mixer motor: Removal - Refitting, page 61A-158 ) , - a distribution motor (3) (see 61A, Heating, Distribution motor: Removal - Refitting , page 61A-174 ) , - a cabin filter (4) (see 61A, Heating, Cabin filter: Removal - Refitting, page 61A-19 ) ,

REAR SEATS VENTILATOR - rear side intermediary air distribution ducts (20) (see Rear side intermediate air distribution duct: Removal - Refitting) , - rear side air distribution ducts (21) (see Rear side air distribution duct: Removal - Refitting) .

- an expansion valve (5) (see 62A, Air conditioning, Expansion valve: Removal - Refitting , page 62A33) , - a recirculation motor (6) (see 61A, Heating, Recirculation motor: Removal - Refitting , page 61A146) , - a recirculation control cable (7) (see 61A, Heating, Recirculation control cable: Removal - Refitting , page 61A-29 ) , - a cooling fan assembly (8) (see 61A, Heating, Fan assembly: Removal - Refitting , page 61A-83 ) , - a passenger compartment fan assembly control unit (9) (see 61A , Heating, Passenger compartment fan assembly control unit: Removal - Refitting , page 61A-117) , - an air mixing flap motor (10) (see 61A , Heating, Mixer motor: Removal - Refitting , page 61A-158) , - an evaporator sensor (11) (see 62A , Air conditioning, Evaporator sensor: Removal - Refitting , page 62A-79 ) , - a heater matrix (12) (see 61A, Heating, Heater matrix: Removal - Refitting , page 61A-69 ) , - heater resistor relay (13) (see 61 A, Heating, Heating resistor relays: Removal - Refitting , page 61A-102 ) , - a heating resistor (14) (see 61A , Heating, Heating resistor unit: Removal - Refitting , page 61A-106 ) , - front side air distribution ducts (15) (see 61A , Heating , Front side air distribution duct: Removal Refitting, page 61A-132) , - a front left-hand footwell air distribution duct (16) (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting , page 61A-142) , - a front right-hand footwell air distribution duct (17) (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - a rear left-hand footwell air distribution duct (18) (see C-pillar air distribution duct: Removal - Refitting ) ,

61A-14


61A


II - LOCATION OF COMPONENTS

139039

61A-15


61A


139036

61A-16


61A


139041

61A-17


61A


REAR SEATS VENTILATOR

139040

61A-18

HEATING Cabin filter: Removal - Refitting

61A

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

REMOVAL

II - OPERATION FOR REMOVAL OF PART CONCERNED

I - REMOVAL PREPARATION OPERATION a

Note: There are 2 possibilities: - the passenger compartment filter flap is bolted onto the air distribution unit, - the passenger compartment filter flap is clipped onto the air distribution unit. a

Remove: - the glovebox (see Glovebox: Removal - Refitting ) ( 57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) .

135675 a

Remove the electrical wiring (1 ) from the cabin filter flap after marking its routing.

a

Remove the passenger compartment filter flap bolts ( 2) .

a

Unclip the passenger compartment filter flap. Note: Foreign bodies (leaves, insects etc.) are likely to accumulate in the passenger compartment filter. Remove the filter with care so as to prevent foreign bodies getting into the evaporator.

a

61A-19

Remove the passenger compartment filter.


61A


II - REFITTING OPERATION FOR PART CONCERNED

141543 a

Mark the passenger compartment filter fitting direction.

a


141543 a

- the passenger compartment filter in accordance with the mark,

REFITTING

- the passenger compartment filter flap, a

I - REFITTING PREPARATION OPERATION a

Refit:

Check there are no foreign bodies in the passenger compartment filter housing and clean thoroughly if necessary.

Fit the electrical wiring on the passenger compartment filter flap.

III - FINAL OPERATION a

Refit: - the front right-hand A-pillar air distribution duct (see 61A , Heating , A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment).

61A-20


61A

J95, and LEFT-HAND DRIVE

REMOVAL


a

Note: There are 2 possible types of fitting: - the passenger compartment filter flap is bolted onto the air distribution unit, - the passenger compartment filter flap is clipped onto the air distribution unit.


Remove the glovebox (see Glovebox: Removal Refitting) (57A, Exterior equipment).

138645 a

Remove the electrical wiring (2) from the passenger compartment filter flap after marking its routing.

a


a

Unclip the passenger compartment filter flap.

a

Remove the passenger compartment filter flap. Note:

138642 a

Unclip the right-hand centre console side trim (1) .

61A-21

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


61A



141543 a


a


141543 a


REFITTING

- the passenger compartment filter flap. a


Refit:




Refit the glovebox (see Glovebox: Removal - Refitting ) (57A, Exterior equipment).

a

Clip on the right-hand centre console side trim.

61A-22


61A

RIGHT-HAND DRIVE a

Note: There are 2 possibilities: - the passenger compartment filter flap is bolted onto the air distribution unit, - the passenger compartment filter flap is clipped onto the air distribution unit.

REMOVAL I - REMOVAL PREPARATION OPERATION a

Unclip the centre console side faces.

a

Remove: - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment),

137154 a

Unclip the clutch pedal wiring.

a

Remove the clutch pedal nuts (2 ) .

- the front right-hand A-pillar air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) .

5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX

Note: Do not disconnect the connectors from the clutch pedal switches. a

Move the clutch pedal aside. Note: Do not apply pressure to the hydraulic clutch pipes.

a

137690 a

Unclip the clutch hydraulic pipes at (1) .

a

Move the clutch hydraulic pipes aside.

61A-23

Pass the hydraulic pipes under the distribution unit.


61A

RIGHT-HAND DRIVE


136999 a

Tilt the clutch pedal in the direction of the arrow.

a

Put the clutch pedal in the footwell.

138645 a

Remove the electrical wiring (3) from the passenger compartment filter flap after marking its routing.

a


a

Unclip the passenger compartment filter flap.

a

Remove the passenger compartment filter flap. Note: Foreign bodies (leaves, insects etc.) are likely to accumulate in the passenger compartment filter. Remove the filter with care so as to prevent foreign bodies getting into the evaporator.

61A-24


61A

RIGHT-HAND DRIVE


141543 a


a


141543 a


REFITTING

- the passenger compartment filter flap. a


Refit:



III - FINAL OPERATION 5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX a

Fit: - the clutch pedal, - the hydraulic clutch pipes.

a

Clip: - the clutch pedal wiring, - the hydraulic clutch pipes.

a

Refit: - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A , Heating , A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) .

61A-25

HEATING Cabin filter: Removal - Refitting RIGHT-HAND DRIVE a

Clip on the centre console side faces.

61A-26

61A

HEATING C-pillar intermediate air distribution duct: Removal - Refitting

61A

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

II - FINAL OPERATION

Essential special tooling Car. 1363

a

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

a

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

Set of trim removal levers.


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

a

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


137016 a

Remove: - the clip (1 ) from the C-pillar intermediate air distribution 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 distribution duct.

61A-27

HEATING Rear air distribution duct: Removal - Refitting

61A

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


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


136378

136377 a

a

Remove the bolts ( 1 ) from the rear air distribution duct.

a

Unclip (2 ) the rear air distribution duct from the centre console.

a

Remove the rear air distribution duct from the centre console.

REFITTING

Unclip the rear section of the centre console.

I - REFITTING OPERATION FOR PART CONCERNED a

Refit the rear air distribution duct on the centre console.

a

Clip the rear air distribution duct to the centre console.

a

Refit the rear air distribution duct bolts.

II - FINAL OPERATION a

61A-28

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

HEATING Recirculation control cable: Removal - Refitting

61A

B95 or D95 or E95 or K95



a



137024 a

Unclip the wiring at ( 2) .

a

Remove the recirculation cable.

REFITTING I - REFITTING OPERATION FOR PART CONCERNED

137028 a

a

Refit the recirculation cable.

a

Clip on the recirculation cable.

Unclip the wiring at (1) .



a


61A-29

HEATING Recirculation control cable: Removal - Refitting

61A

J95



a



137024 a

Unclip the recirculation control cable.

a

Remove the recirculation control cable.


137028 a

a

Refit the recirculation control cable.

a

Clip on the recirculation control cable.




a


61A-30

HEATING Air distribution cable: Removal - Refitting

61A

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


Remove: - the glovebox (see Glovebox: Removal - Refitting ) ( 57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment). 135677

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

a

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

Squeeze the centring pins (2 ) while pushing the control panel.

RADIO NO 06 or RADIO NO 07 a

Remove the radio navigation system (see Radio navigation system: Removal - Refitting ) (83C, Onboard telematics system).

135659 a

Tilt the control panel.

a

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

a

Move aside the control panel.

135676 a

Remove the bolts (1) from the control panel.

61A-31


61A



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 move along its whole stroke.


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

135658 a

Unclip the air distribution cable from the control panel at (4) .


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

a

Refit: - the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A , Heating , A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment).

136994 a

Unclip the air distribution cable from the distribution unit at (5) .

a

Mark the routing of the air distribution cable.

a

Remove the air distribution cable.


Refit the air distribution cable.

a

Clip the air distribution control cable onto: - the distribution unit, - the control panel.


Fit the control panel.

61A-32


61A

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

Remove: - the lower bolts from the dashboard cross member reinforcement,

Tightening torques m dashboard cross member reinforcement upper bolts

21 N.m

dashboard cross member reinforcement lower bolts

21 N.m

- the upper bolts from the dashboard cross member reinforcement, - the dashboard cross member reinforcement.


Remove: - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment), - the front footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting , page 61A-142 ) ,

135676 a

Remove the bolts (1 ) from the control panel.

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



RADIO NO 06 a

135677


a

FR AND RR PROX RADAR a

Disconnect the connector from the parking distance control buzzer.

a

Unclip the wiring from the dashboard cross member reinforcement.

61A-33



61A

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

135659 a


a

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

a


136990


a

Unclip the air distribution cable from the distribution unit at ( 5) .

a


a




a

Clip: - the air distribution cable on the distribution unit, - the air distribution cable on the control panel.

135658 a




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


a


a

Refit: - the dashboard cross member stiffener,

61A-34

HEATING Air distribution cable: Removal - Refitting B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and AIR CONDITIONING - the upper bolts of the dashboard cross member reinforcement, - the lower bolts of the dashboard cross member reinforcement. a

Tighten to torque: -the dashboard cross member reinforcement upper bolts (21 N.m) , -the dashboard cross member reinforcement lower bolts (21 N.m) .

a

Clip on the dashboard cross member reinforcement wiring.


Connect the parking distance control buzzer connector.


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

RADIO NO 06 a

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

a

Refit: - the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment), - the front footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting , page 61A-142 ) , - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment).

61A-35

61A


61A

J95, and RIGHT-HAND DRIVE, and AIR CONDITIONING

Tightening torques m nuts of the dashboard cross member reinforcement

21 N.m


21 N.m


Remove: - the central console (see Centre console: Removal - Refitting) (57A, Interior equipment), - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment),

138648 a

- the inhibitor switch (see Inhibitor switch: Removal - Refitting) (88C, Airbag and pretensioners),

Remove the upper nuts (1 ) from the dashboard cross member reinforcement.

- the glovebox (see Glovebox: Removal - Refitting ) ( 55A, Interior equipment), - the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment). FR AND RR PROX RADAR a


138653 a

Remove: - the lower bolts (2) from the dashboard cross member reinforcement, - the dashboard cross member reinforcement.

61A-36


61A



138500 a


138497

138599 a

Squeeze the centring pins (4) while pushing the control panel.

a

Tilt the control panel .

138499 a

61A-37

Unclip the air distribution cable (5 ) from the control panel in order, as shown by the directional arrows.


61A




a

Refit: - the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment), - the glovebox (see Glovebox: Removal - Refitting) ( 55A, Interior equipment), - the inhibitor switch (see Inhibitor switch: Removal - Refitting ) (88C, Airbag and pretensioners), - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment),

138504 a

Unclip the air distribution cable from the distribution unit at (6) .

a


a




a




a

Clip on the centring pins of the control panel.

a


a


a

Refit the dashboard cross member reinforcement.

a

Tighten to torque: - the upper nuts of the dashboard cross member reinforcement (21 N.m), -the dashboard cross member reinforcement lower bolts (21 N.m) .

61A-38

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


61A

J95, and LEFT-HAND DRIVE, and AIR CONDITIONING


Remove: - the central console (see Centre console: Removal - Refitting) (57A, Interior equipment), - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment), - the inhibitor switch (see Inhibitor switch: Removal - Refitting) (88C, Airbag and pretensioners), - the glovebox (see Glovebox: Removal - Refitting ) ( 55A, Interior equipment), - the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment).

138599 a


a


138500 a


61A-39


61A

J95, and LEFT-HAND DRIVE, and AIR CONDITIONING


138504 138497

a

Unclip the air distribution cable from the distribution unit at ( 4) .

a


a




a




a


a


a


a

Refit:

138499 a

Unclip the air distribution cable (3) from the control panel in order, as shown by the directional arrows.

- the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment), - the glovebox (see Glovebox: Removal - Refitting) ( 55A, Interior equipment), - the inhibitor switch (see Inhibitor switch: Removal - Refitting ) (88C, Airbag and pretensioners),

61A-40

HEATING Air distribution cable: Removal - Refitting J95, and LEFT-HAND DRIVE, and AIR CONDITIONING - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment), - the central console (see Centre console: Removal - Refitting) (57A, Interior equipment).

61A-41

61A

HEATING Air mixing cable: Removal - Refitting

61A



Remove: - the glovebox (see Glovebox: Removal - Refitting ) ( 57A, Interior equipment), - the front left-hand footwell air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment). 135677



a


a


II - OPERATION FOR REMOVAL OF PART CONCERNED RADIO NO 06 or RADIO NO 07 a


135659 a

135676 a


61A-42



61A



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



a

Refit:

136993 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.

I - REFITTING OPERATION FOR PART CONCERNED Refit the air mixing cable.

a

Clip the air mixing cable onto:

- the front left-hand footwell air distribution duct (see 61A , Heating , A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment).

REFITTING

a

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

- the distribution unit, - the control panel.



a


a

Clip on the centring pins.

a


a


61A-43


61A


RADIO NO 06 or RADIO NO 07


21 N.m


21 N.m

a


FR AND RR PROX RADAR

REMOVAL

a


a


I - REMOVAL PREPARATION OPERATION

137019 a

Unclip the left-hand centre console trim.

a

Remove: - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment), - the front left-hand footwell air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) ,

135692 a




61A-44

Remove the lower bolts (1 ) from the dashboard cross member reinforcement.


61A


135677

135693 a

Remove:

a


a



- the upper bolts (2) from the dashboard cross member reinforcement, - the dashboard cross member reinforcement.

135659 a

135676 a


61A-45

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


61A

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

Tighten to torque: - the dashboard cross member reinforcement upper bolts (21 N.m) , - the dashboard cross member reinforcement lower bolts (21 N.m) .

a

Clip on the wiring of the dashboard cross member reinforcement.



RADIO NO 01 or RADIO NO 02 or RADIO NO 03 or RADIO NO 04 or RADIO NO 05 136993 a

Unclip the air mixing cable (6) from the distribution unit.

a


a


a


RADIO NO 06 or RADIO NO 07

REFITTING

a


a

Refit:


Refit the air mixing cable.

a

Clip:


- the air mixing cable onto the distribution unit,

- the front left-hand footwell air distribution duct (see 61A , Heating , A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) ,

- the air mixing cable onto the control panel.


- the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment).

a


a


a


a

Check that the air mixing control can move along its whole stroke.

a

Refit:

a

- the dashboard cross member reinforcement, - the upper bolts of the dashboard cross member reinforcement, - the lower bolts of the dashboard cross member reinforcement.

61A-46

Clip on the left-hand centre console trim.


61A



Remove: - the central console (see Centre console: Removal - Refitting) (57A, Interior equipment), - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment), - the inhibitor switch (see Inhibitor switch: Removal - Refitting) (88C, Airbag and pretensioners), - the glovebox (see Glovebox: Removal - Refitting ) ( 55A, Interior equipment), - the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment).

138599 a


a


138500 a


61A-47


61A



138503 138496

a

Unclip the air mixing flap cable from the distribution unit at ( 4) .

a


a




a

Clip the air mixing cable onto: - the distribution unit, - the control panel.



a


a


a


a

Refit:

138498 a

Unclip the air mixing flap control cable (3) from the control panel in order, as shown by the directional arrows.

- the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment), - the glovebox (see Glovebox: Removal - Refitting) ( 55A, Interior equipment), - the inhibitor switch (see Inhibitor switch: Removal - Refitting ) (88C, Airbag and pretensioners),

61A-48

HEATING Air mixing cable: Removal - Refitting J95, and RIGHT-HAND DRIVE, and AIR CONDITIONING - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment), - the central console (see Centre console: Removal - Refitting) (57A, Interior equipment).

61A-49

61A


61A

J95, and LEFT-HAND LEFT-HAND DRIVE, and AIR CONDITIONING


Tightening torques m nuts of the dashboard cross member reinforcement

21 N.m


21 N.m

a



Remove: - the central console (see Centre console: Removal - Refitting) (57A, Interior equipment), - the dashboard lower lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment), - the inhibitor inhibitor switch (see (see Inhibitor switch: Removal - Refitting) (88C, Airbag and pretensioners), - the glovebox glovebox (see Glovebox: Removal - Refitting ) ( 55A, Interior equipment), - the centre front front panel (see (see Centre front panel: Removal - Refitting) (57A, Interior equipment).

138640 a

Unclip the wiring from the dashboard cross member reinforcement at ( 2) .

a


138642 a

Unclip the left-hand centre console side trim (1) .

61A-50


61A


138639 a

138599

Remove:

a

- the dashboard cross member flange flange upper bolts (4 ) .


a


- the brake pedal pedal impactor impactor (5 ) , - the dashboard cross member reinforcement. reinforcement.

138500 a


61A-51


61A



138503 138496

a

Unclip the air mixing flap cable from the distribution unit at ( 9) .

a


a




a

Clip the air mixing cable onto: - the distribut distribution ion unit, unit, - the control panel.


138498 a

Unclip the air mixing flap control cable (8) from the control panel in order, as shown by the directional arrows.

a


a


a


a

Check that the air mixing control can move along its whole stroke.

a

Refit: - the dashboard dashboard cross member reinforceme reinforcement, nt, - the brake brake pedal impacter. impacter.

a

Tighten to torque: - the upper upper nuts of the dashboard cross member reinforcement reinforcement (21 N.m) N.m ),

61A-52

HEATING Air mixing cable: Removal - Refitting J95, and LEFT-HAND LEFT-HAND DRIVE, and AIR CONDITIONING -the dashboard cross member reinforcement lower bolts (21 N.m) . a

Clip the wiring onto the dashboard cross member reinforcement.



a

Refit: - the centre front front panel (see (see Centre front panel: Removal - Refitting ) (57A, Interior equipment), - the glovebox glovebox (see Glovebox: Removal - Refitting ) ( 55A, Interior equipment), - the inhibitor inhibitor switch (see (see Inhibitor switch: Removal - Refitting) (88C, Airbag and pretensioners), - the dashboard lower lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment), - the central console (see Centre console: Removal - Refitting) (57A, Interior equipment).

a

Clip on the left-hand centre console side trim.

61A-53

61A

HEATING Air distribution unit: Removal - Refitting

61A

B95 or D95 or K95 - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment),

Essential special tooling Ms. 583

Hose clamp pliers.

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

Essential equipment refrigerant charging station

F4R

Tightening torques m clip of the air filter unit air outlet pipe

a

- the lifting lifting eye of the cylinder cylinder head, head,

5.5 N.m

- the turbocharger turbocharger heat shield shield nuts. nuts.

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

IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see 62 A , Air conditioning, Air conditioning: Precautions for repair , page 62A-3) .

Any damaged heat shields must be replaced. a

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


Remove:

Remove the front engine cover.

WARNING Consult the device's operating manual to avoid incorrect use. a

Drain the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-9) .

a


a

Remove: - the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting ) (85A, Wiping Washing), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment),

61A-54

Remove the turbocharger heat shield.


61A

B95 or D95 or K95

F4R

F9Q or K9K a

Remove the clips from the bulkhead heat shield.

WARNING To prevent the surrounding components from overheating, do not damage (tear, pierce, bend, etc.) a heat shield. Any damaged heat shields must be replaced. a

Move the bulkhead heat shieldto one side.

136467 a

Remove: - the bulkhead upper heat shield bolts (1) , - the bulkhead upper heat shield clips (2) .

WARNING To prevent the surroun ding compone nts from overheating, do not damage (tear, pierce, bend, etc.) a heat shield. Any damaged heat shields must be replaced. a

Remove the bulkhead upper heat shield.

F9Q a

136487 a

Remove:

Remove the bolts ( 3) from the expansion valve connecting pipe bracket.

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

WARNING In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe.

- the diesel injection computer (see Diesel injection computer: Removal - Refitting ) (13B, Diesel in jection), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery),

a

Uncouple the connecting pipes from the expansion valve.

- the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting ) (12B, Turbocharging).

a

Remove the connecting pipes from the expansion valve.

a

Remove the connecting pipe seals.

a

Insert the blanking plugs.

61A-55


61A

B95 or D95 or K95

F4R

135707 a

Loosen the clip (4) of the air outlet pipe on the air filter unit. 137157 a

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

135796 a

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

134643 a

Disconnect the connector (7 ) of the turbocharging pressure regulation valve control solenoid valve.

a

Detach the turbocharging pressure regulation valve control 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.

61A-56


61A

B95 or D95 or K95 a

Remove:

- the cabin filter,

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

- the expansion valve,

- the front side air distribution duct (see 61A , Heating , Front side air distribution duct: Removal Refitting, page 61A-132 ) ,

- the recirculation motor,

- the dashboard cross member (see Dashboard cross member: Removal - Refitting ) (42A, Upper front structure).

- the fan assembly,

- the air recirculation control cable,

- the fan assembly control unit, - the evaporator sensor,


- the heater matrix, - heater resistor relays, - the heating resistor, - the air mixing cable.

CLIMATE CONTROL a

Remove the following components from the distribution unit: - the left-hand mixer motor, - the right-hand mixer motor, - the distribution motor,

137642 a

Disconnect the supply connector (8) from the distribution unit.

a

Unclip the electrical wiring from the distribution unit.

a

Separate the electrical wiring from the distribution unit.

a

Remove the distribution unit.

- the cabin filter, - the expansion valve, - the recirculation motor, - the air recirculation control cable, - the fan assembly,

Note:

- the fan assembly control unit,

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

- the evaporator sensor, - the heater matrix, - heater resistor relays,

AIR CONDITIONING a

Remove the following components from the distribution unit: - the air distribution cable,

61A-57

- the heating resistor.


61A

B95 or D95 or K95

REFITTING



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

AIR CONDITIONING a

WARNING Do not remove the blanking plugs from each component until the last moment.

Refit the following components onto the distribution unit: - the air distribution cable, - the cabin filter,

Also, do not remove the components from their packaging until they are to be fitted to the vehicle.

- the expansion valve, - the recirculation motor, - the air recirculation control cable,

WARNING To avoid any leaks, check that the pipe surface is sound before positioning the new seal. The surface must be clean and scratch free.

- the fan assembly control unit, - the evaporator sensor,

a

Remove the blanking plugs.

a

Lubricate the seals using recommended air conditioning oil to make fitting easier (see 62A , Air condit i o n i n g , Air conditioning: Parts and consumables for the repair work , page 62A-4) .

a

- the fan assembly,

- the heater matrix, - heater resistor relays, - the heating resistor,

Fit new seals to the refrigerant connecting pipes.

- the air mixing cable.

II - REFITTING OPERATION FOR PART CONCERNED CLIMATE CONTROL a

Refit the following components onto the distribution unit:

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.

- the left-hand mixer motor, - the right-hand mixer motor,

III - FINAL OPERATION

- the distribution motor,

a

- the cabin filter,

- the dashboard cross member (see Dashboard cross member: Removal - Refitting ) (42A, Upper front structure),

- the expansion valve, - the recirculation motor,

- the front side air distribution duct (see 61A , Heating, Front side air distribution duct: Removal Refitting, page 61A-132 ) ,

- the air recirculation control cable, - the fan assembly,

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

- the fan assembly control unit, - the evaporator sensor, - the heater matrix,

Refit:

a

Connect the heater matrix hoses.

a

Remove the tool (Ms. 583) from the heater matrix hoses.

- heater resistor relays,

61A-58


61A

B95 or D95 or K95 - the turbocharger heat shield, F4R a

- the turbocharger heat shield nuts,

Refit: - the lifting eye of the cylinder head.

- the air outlet pipe to the air filter unit, - the air inlet pipe to the throttle valve. a

Clip on the turbocharging pressure regulation valve control solenoid valve.

a

Connect the connector of the turbocharging pressure regulation valve control solenoid valve.

a

Clip on the brake servo vacuum pipe.

a

Torque tighten the clip of the air filter unit air outlet pipe (5.5 N.m).

a


a

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

Note:

a

A summary table gives the quantities of refrigerant in the system according to the engine type (see 62A , Air conditioning, Air conditioning: Parts and consumables for the repair work , page 62A-4 ) .

Connect the connecting pipes to the expansion valve.

F9Q or K9K a

Fit the heat shield to the bulkhead.

a

Refit the heat shield bolts.

a

- refill the refrigerant circuit using the refrigerant charging station (see 62A , Air conditioning, Coolant circuit Draining - Refilling , page 62A-9) , - check for leaks (see 62A, Air conditioning, Coolant circuit check , page 62A-8) .

F9Q a

Refit: - the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting ) (12B, Turbocharging), - the battery tray (see Battery : Removal - Refitting ) (80A, Battery),

a

Check that the air conditioning system is operating correctly (see 62A, Air conditioning, Air conditioning: Check , page 62A-5) .

a

Refit:

- the diesel injection computer (see Diesel injection computer: Removal - Refitting ) (13B, Diesel in jection), - the battery (see Battery : Removal - Refitting ) (80A, Battery).

- the windscreen wiper mechanism (see Windscreen wiper mechanism: Removal - Refitting ) (85A, Wiping - Washing), - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment),

F4R a

Perform the following operations:

Refit:

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

- the bulkhead upper heat shield, - the bulkhead upper heat shield bolts, - the bulkhead upper heat shield clips,

- the engine cover.

61A-59


61A

J95 - the scoop under the centre section of the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment).


Hose clamp pliers.


a

Undo the clips on the air outlet pipe of the air filter unit.

a


Tightening torques m

F9Q

turbocharger air inlet pipe bolts

8 N.m

air filter box air outlet pipe clips

6 N.m


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

137477 a

Remove: - the bolts (1 ) from the cylinder head lifting eye,

REMOVAL

- the cylinder head lifting eye.





a

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

a

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

61A-60


61A

J95

M9R

K9K

139563 a

a

Unclip the wiring (2 ) from the cylinder head lifting eye.

139155 a

the bolt (4 ) from the turbocharger air inlet pipe.

Remove: - the bolts (3 ) from the cylinder head lifting eye, - the cylinder head lifting eye.

139154 a

Remove: - the bolts (5 ) from the turbocharger air inlet pipe, - the turbocharger air inlet pipe.

61A-61


61A

J95

F9Q

135640 a

Remove the bolts (8 ) from the turbocharger air inlet pipe.

a

Disconnect the intermediate air pipe between the air filter unit and the turbocharger from the turbocharger air inlet pipe by pivoting it.

a

Remove:

135638 a

Remove the bolt (6) from the intermediate air pipe between the air filter unit and the turbocharger on the exhaust gas recirculation assembly.

- the intermediate air pipe between the air filter unit and the turbocharger, - the turbocharger air inlet pipe.

135639 a

Loosen the bolt (7) of the intermediate air pipe between the air filter unit and the turbocharger on the turbocharger air inlet pipe.

61A-62


61A

J95

M9R

K9K a

Remove the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting ) (12B, Turbocharging).

139564 a

Remove the bolts (9) from the turbocharger air inlet pipe.

138672 a

139567 a

Remove: - the bolts (10) from the turbocharger air inlet pipe, - the turbocharger air inlet pipe.

61A-63

Remove the nut (11) from the retaining bracket on the « intermediate pipe - expansion valve » connecting pipe.


61A

J95

H4J

139617 a

Remove the clips (1 2) from the bulkhead heat shield.

139616 a

WARNING To prevent the surroun ding compone nts from overheating, do not damage (tear, pierce, bend, etc.) a heat shield.

- the bulkhead upper heat shield bolts (13) , - the bulkhead upper heat shield clips (14) .



Remove:



61A-64



61A

J95

136487 a

Remove the bolts (15) from the expansion valve connecting pipe bracket.


141542 a

Fit the (Ms. 583) on the heater matrix hoses (16) .

a

Disconnect the heater matrix hoses.

a

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

a


a


a

Fit blanking plugs on the expansion valve and on the connecting pipes.

61A-65

- the dashboard cross member (see Dashboard cross member: Removal - Refitting ) (42A, Upper front structure).


61A

J95


- heater resistor relays, - the heating resistor, - the air mixing cable.

CLIMATE CONTROL a

Remove the following components from the distribution unit: - the left-hand mixer motor, - the right-hand mixer motor, - the distribution motor, - the cabin filter, - the expansion valve, - the recirculation motor, - the air recirculation control cable,

139118 a

- the fan assembly,

Disconnect the supply connector (17) from the distribution unit.

- the fan assembly control unit,

a

Unclip the electrical wiring from the distribution unit.

- the evaporator sensor,

a

Separate the electrical wiring from the distribution unit.

- the heater matrix,

a

- heater resistor relays,

Remove the distribution unit.


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

REFITTING I - REFITTING PREPARATION OPERATION

AIR CONDITIONING a

Remove the following components from the distribution unit:

a


- the air distribution cable, - the cabin filter,


- the expansion valve, - the recirculation motor, - the air recirculation control cable,

WARNING To avoid any leaks, check that the seal and the pipe surface are in good condition. The seal and the surface must be clean and scratch free.

- the fan assembly, - the fan assembly control unit, - the evaporator sensor, - the heater matrix,

a

61A-66



61A

J95

II - REFITTING OPERATION FOR PART CONCERNED CLIMATE CONTROL a

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.

Refit the following components onto the distribution unit:


- the left-hand mixer motor,

a

Refit: - the dashboard cross member (see Dashboard cross member: Removal - Refitting ) (42A, Upper front structure),

- the right-hand mixer motor, - the distribution motor, - the cabin filter,

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

- the expansion valve, - the recirculation motor,

a

Connect the heater matrix hoses.

- the air recirculation control cable,

a

Remove the (Ms. 583) from the heater matrix hoses.

- the fan assembly,

a

Connect the connecting pipes to the expansion valve.

a


- the fan assembly control unit, - the evaporator sensor, - the heater matrix,

H4J

- heater resistor relays, - the heating resistor.

a

Refit the bulkhead upper heat shield.

a

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

AIR CONDITIONING a

Refit the following components onto the distribution unit: - the air distribution cable,

K9K a

- the cabin filter,

Refit the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting) (12B, Turbocharging).

- the expansion valve, - the recirculation motor, - the air recirculation control cable, M9R

- the fan assembly, - the fan assembly control unit,

a

Refit:

- the evaporator sensor,

- the turbocharger air inlet pipe,

- the heater matrix,

- the turbocharger air inlet pipe bolts.

- heater resistor relays, - the heating resistor, - the air mixing cable. K9K a a

Refit the distribution unit.

Refit: - the turbocharger air inlet pipe,

61A-67


61A

J95 - the turbocharger air inlet pipe bolts.

a

Fill up and bleed the cooling system (see Cooling circuit: Draining - Refilling) (19A, Cooling). Note: A summary table gives the quantities of refrigerant in the system according to the engine type (see 62A , Air conditioning, Air conditioning: Parts and consumables for the repair work , page 62A-4 ) .

F9Q a

Refit: - the turbocharger air inlet pipe, - the intermediate air pipe between the air filter unit and the turbocharger on the turbocharger air inlet pipe,

a

- refill the refrigerant circuit using the refrigerant charging station (see 62A , Air conditioning, Coolant circuit Draining - Refilling , page 62A-9) ,

- the bolts from the turbocharger air inlet pipe, - the bolt from the intermediate pipe between the air filter unit and the turbocharger on the turbocharger air inlet pipe,

a

- check for leaks (see 62A, Air conditioning, Coolant circuit check , page 62A-8) .

- the bolt for the intermediate air pipe between the air filter unit and the turbocharger on the exhaust gas recirculation assembly.

a


Torque tighten the turbocharger air inlet pipe bolts (8 N.m).

a

Refit:

Refit:

- the engine cover.

- the lifting eye of the cylinder head, - the bolts on the cylinder head lifting eye. a

Clip the wiring onto the cylinder head lifting eye.

F9Q a

- the centre section of the scuttle panel grille (see Scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment), - the scoop under the centre section of the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment),

M9R a


Refit: - the lifting eye of the cylinder head, - the bolts on the cylinder head lifting eye.

a

Refit the air filter unit air outlet pipe.

a

Torque tighten the air filter box air outlet pipe clips (6 N.m).

a

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

61A-68

HEATING Heater matrix: Removal - Refitting

61A



Hose clamp pliers.


21 N.m


21 N.m

clip of the air filter unit air outlet pipe

5.5 N.m

REMOVAL 135796

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 the throttle valve.

F4R

135707 a

Loosen the clip (1) of the air outlet pipe on the air filter unit.

137157 a

61A-69

Disconnect the brake servo vacuum pipe (3) .


61A


134643 a

Disconnect the connector from the turbocharging pressure regulation valve control solenoid valve.

a

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

a


a


a

Unclip the left-hand centre console trim.

a

Remove:

135692 a


- the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment), - the front left-hand footwell air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) .

135693 a

Remove: - the upper bolts (6) from the dashboard cross member reinforcement, - the dashboard cross member reinforcement.

61A-70


61A



- the heater matrix trim.

135694 a

Remove the clips (7) from the heater matrix rigid pipes. 135696

WARNING Prepare for the flow of fluid, and protect the surrounding components.

a

Take the heater matrix out of its housing.

a

Remove the heater matrix.

a

Put a protective cover on the floor carpet.

a

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

REFITTING

a

Move the heater matrix rigid pipes aside.

I - REFITTING PREPARATION OPERATION

a

Remove the seals from the heater matrix rigid pipes.

a

parts always to be replaced: heater matrix coolant pipe seal (30,02,01,46)

a

Always replace the heater matrix rigid pipe clips.

WARNING To avoid any leaks, check that the pipe surface is sound before positioning the new seal. The surface must be clean and scratch free. II - REFITTING OPERATION FOR PART CONCERNED a

Refit: - the heater matrix in its housing, - the heater matrix trim.

a

Fit: - new seals on the heater matrix rigid pipes,

135695 a

Remove:

- the heater matrix rigid pipes on the heater matrix. a

- the heater matrix trim bolts (8) ,

61A-71

Refit new clips on the rigid pipes of the heater matrix.

HEATING Heater matrix: Removal - Refitting B95 or D95 or E95 or K95, and LEFT-HAND DRIVE a

Remove:

a

- the container for recovering coolant under the rigid pipes, - the protective cover on the floor carpet.


Refit: - the dashboard cross member reinforcement, - the upper bolts on the dashboard cross member reinforcement, - the lower bolts on the dashboard cross member reinforcement.

a


a

Refit: - the front left-hand footwell air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the instrument panel lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment).

a


a


F4R a

Refit: - the air outlet pipe of the air filter unit, - the air inlet pipe to the throttle valve.

a


a

Connect: - the connector on the turbocharging pressure regulation valve control solenoid valve, - the vacuum pipe from the brake servo.

a


a

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

61A-72

Refit the engine style cover.

61A


61A

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


Hose clamp pliers.

Tightening torques m clip of the air filter unit air outlet pipe

5.5 N.m



a


F4R 135796 a

Loosen the bolts (2 ) of the air inlet pipe on the throttle valve.

135707 a

Loosen the clip (1) of the air outlet pipe on the air filter unit.

137157 a

61A-73

Disconnect the brake servo vacuum pipe (3) .


61A



135694 a

Remove the clips ( 5) from the heater matrix rigid pipes.

134643 a

Disconnect the connector from the turbocharging pressure regulation valve control solenoid valve.

a

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

a


a


a

Unclip the centre console left-hand trim.

a

Remove:

WARNING Prepare for the flow of fluid, and protect the surrounding components. a


a


a


a

Remove the seals from the heater matrix rigid pipes

- the glovebox (see Glovebox: Removal - Refitting ) ( 57A, Interior equipment), - the front left-hand footwell air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) .

135695 a

Remove: - the heater matrix trim bolts (6) ,

61A-74


61A

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE - the heater matrix trim.

a

Remove: - the container for recovering coolant under the rigid pipes, - the protective cover on the floor carpet.


Refit: - the front left-hand footwell air distribution duct (see 61A , Heating , A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment).

a


a


F4R 135696

a

Refit:

a


- the air outlet pipe of the air filter unit,

a


- the air inlet pipe to the throttle valve. a


a

Connect:

REFITTING I - REFITTING PREPARATION OPERATION a

a

- the connector on the turbocharging pressure regulation valve control solenoid valve,

parts always to be replaced: heater matrix coolant pipe seal (30,02,01,46) Always replace the heater matrix rigid pipe clips.

WARNING To avoid any leaks, check that the pipe surface is sound before positioning the new seal. The surface must be clean and scratch free.

- the vacuum pipe from the brake servo. a


a


a

Refit the engine cover.

II - REFITTING OPERATION FOR PART CONCERNED a

Refit: - the heater matrix in its housing, - the heater matrix trim.

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 matrix.

61A-75


61A



Hose clamp pliers.

Tightening torques m upper nuts on the dashboard cross member reinforcement

21 N.m

lower bolts on the dashboard cross member reinforcement

21 N.m


6 N.m

REMOVAL 141542



a

Remove:

a


a


- the engine cover, - the centre section of the scuttle panel grille (see Scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment), - the scoop under the centre section of the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment). a


a


- the front left-hand footwell air distribution duct (see 61A , Heating , A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) . a

Unclip the left-hand panel from the centre console.


61A-76



61A



135694 a


138640 a

Unclip the wiring from the dashboard cross member reinforcement at (2) .

a


WARNING Prepare for the flow of fluid, and protect the surrounding components. a


a


a


a


138639 a

Remove: - the upper nuts (4) from the dashboard cross member reinforcement, 135695

- the brake pedal impacter (5 ) ,

a

Remove: - the heater matrix trim bolts (8) ,

- the dashboard cross member reinforcement.

61A-77


61A

J95, and LEFT-HAND DRIVE - the heater matrix trim.

a



Refit: - the dashboard cross member reinforcement, - the brake pedal impacter,

a

Tighten to torque: - the upper nuts on the dashboard cross member reinforcement (21 N.m), - the lower bolts on the dashboard cross member reinforcement (21 N.m).

a

135696 a


a





a

Refit:


parts always to be replaced: heater matrix coolant pipe seal (30,02,01,46).

a




Refit:

- the front left-hand footwell air distribution duct (see 61A , Heating , A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment). a

Clip on the left-hand panel of the centre console.

a


a

Refit the air outlet pipe onto the air filter unit.

a


a


a

Refit:

- the heater matrix in its housing,

- the scoop under the centre section of the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment),

- the heater matrix trim. a

Fit:

- the heater matrix rigid pipes on the heater matrix.

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

Refit new clips on the heater matrix rigid pipes.

- the engine cover.

- new seals on the heater matrix rigid pipes,

a

61A-78

HEATING Heater matrix: Removal - Refitting J95, and LEFT-HAND DRIVE

61A-79

61A


61A

J95, and RIGHT-HAND DRIVE a


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

Hose clamp pliers.

- the front left-hand footwell air distribution duct (see 61A , Heating , A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) .

Tightening torques m air filter unit air outlet pipe clips

Remove:

6 N.m




a

Remove: - the engine cover, - the centre section of the scuttle panel grille (see Scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment), - the scoop under the centre section of the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment).

a

a

135694 a


WARNING Prepare for the flow of fluid, and protect the surrounding components.

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


a


a


a


141542 a


a

Unclip the left panel from the centre console.


61A-80


61A

J95, and RIGHT-HAND DRIVE

REFITTING I - REMOVAL PREPARATION OPERATION a

parts always to be replaced: heater matrix coolant pipe seal (30,02,01,46) .

a




- the heater matrix in its housing,

135695 a

Refit:

Remove:


- the heater matrix trim bolts (3) ,

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 heater matrix rigid pipes.

a



Refit: - the front left-hand footwell air distribution duct (see 61A , Heating , A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment).

135696 a


a


a


a


a


a

Torque tighten the air filter unit air outlet pipe clips (6 N.m).

a


61A-81

HEATING Heater matrix: Removal - Refitting J95, and RIGHT-HAND DRIVE a

Refit: - the scoop under the centre section of the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment), - the centre section of the scuttle panel grille (see Scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment), - the engine cover.

61A-82

61A

HEATING Fan assembly: Removal - Refitting

61A



Tool for removal - refitting of Valéo fan assembly


Move the seat as far back as possible.

a


a

Remove: - the glovebox (see Glovebox: Removal - Refitting ) ( 57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) ,

a

137641 a

Disconnect the recirculation motor connector.

- the cabin filter (see 61A, Heating, Cabin filter: Removal - Refitting, page 61A-19 ) ,

a

Mark the routing of the recirculation motor wiring.

a

Separate the wiring from the recirculation motor.

- the front side air distribution duct (see 61A , Heating , Front side air distribution duct: Removal Refitting, page 61A-132) .

a

Remove:

Remove the side air distribution duct (see 61A, Heating, Front side air distribution duct: Removal Refitting, page 61A-132 ) .

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

II - OPERATION FOR REMOVAL OF PART CONCERNED a

137028 a


61A-83

Disconnect the connector from the passenger compartment fan assembly motor passing through the cabin filter housing.


61A


137676 a

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

137678 a

Push and turn the tool (Ms. 1909) anticlockwise to unlock the passenger compartment fan assembly.

137679 137677 a

a

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

Remove the fan assembly from its housing while taking care not to damage the turbine. Note: To avoid making the fan assembly motor unstable, position the assembly horizontally while protecting it from any impact.

61A-84


61A



137681 a

Fit the tool (Ms. 1909) (4 ) on the passenger compartment fan assembly.

137683 a

Check that the clip is correctly positioned (5) in relation to the turbine of the passenger compartment fan assembly.

137682 a

Align the clip of the tool (Ms. 1909) along the shaft. 137686 a

61A-85

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

HEATING Fan assembly: Removal - Refitting B95 or D95 or E95 or K95, and LEFT-HAND DRIVE

137677 a

Push the fan assembly until it is fully inserted in its housing.

a

Turn the tool (Ms. 1909) clockwise to lock the passenger compartment fan assembly.

a

Remove the (Ms. 1909).

a

Connect the passenger compartment fan assembly connector.


Refit the air recirculation duct.

a

Fit the recirculation motor wiring.

a

Connect the recirculation motor connector.

a


a

Refit the side air distribution duct (see 61A, Heating, Front side air distribution duct: Removal - Refitting, page 61A-132) .

a

Refit: - the front side air distribution duct (see 61A , Heating , Front side air distribution duct: Removal Refitting, page 61A-132) , - the cabin filter (see 61A, Heating, Cabin filter: Removal - Refitting, page 61A-19 ) , - the front right-hand A-pillar air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the glovebox (see Glovebox: Removal - Refitting ) (57A, Interior equipment).

61A-86

61A


61A




Tightening torques m steering column bolts

21 N.m


Unclip the right-hand centre console trim.

a


134365 a

Disconnect the steering column connectors (2) .

a

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

- the cabin filter (see 61A, Heating, Cabin filter: Removal - Refitting, page 61A-19 ) .

134366 136716 a

Remove:

a

Remove the nuts (3 ) from the steering column.

a

Remove the block between the steering column and the floor.

- the cover bolts (1 ) under the steering wheel, - the cowlings under the steering wheel. a

Disconnect the steering column switch assembly connectors.

61A-87


61A


137636 a

Lower the steering column in the footwell. Note: Vertically lower the steering column and do not apply pressure to the universal joints.

a

137641 a


a


a


a

Remove: - the bolts (6 ) from the air recirculation duct,

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

- the air recirculation duct.


137028 a

Unclip the recirculation control cable (5) .

61A-88

Disconnect the passenger compartment fan assembly motor connector passing through the cabin filter housing.


61A


137676 a


137678 a


137677 a

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

137679 a

Remove the passenger compartment fan assembly from its housing while taking care not to damage the turbine.

Note: To avoid making the passenger compartment fan assembly motor unstable, position the assembly horizontally while protecting it from any impact.

61A-89


61A



137681 a


137683 a

Check that the clip (9) is correctly positioned in relation to the turbine of the passenger compartment fan assembly.

137682 a

Align the clip of the tool (Ms. 1909) along the shaft. 137686 a

61A-90

Refit the passenger compartment fan assembly in its housing by turning the tool 45˚.


61A

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE - the steering column switch assembly connectors. a

Refit: - the cowlings under the steering wheel, - the cabin filter (see 61A, Heating, Cabin filter: Removal - Refitting, page 61A-19 ) , - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment).

a

137687 a

Push the passenger compartment fan assembly until it is fully inserted in its housing.

a


a


a




a


a


a


a

Check that the recirculation control can move along its whole stroke.

a


a

Refit the steering column.

a

Refit the steering column bolts.

a

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

a


a

Check the condition of the steering column bearings.

a

Connect: - the electric steering column lock connector, - the steering column connectors,

61A-91

Clip on the right-hand centre console trim.


61A





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

RADIO NO 07 a

Remove: - the receiver (see Tuner-amplifier: Removal - Refitting) (86A, Radio), - the bolts from the receiver mounting, - the receiver mounting.

137028 a

Unclip the air recirculation control cable.


Remove: - the offset multimedia socket computer (see Offset multimedia socket computer: Removal - Refitting ) (86A, Radio), - the offset multimedia socket computer mounting bolts, - the offset multimedia socket computer mounting.

a

Remove the cabin filter (see 61A , Heating, Cabin filter: Removal - Refitting, page 61A-19 ) .

138646 a

61A-92

Mark the routing of the air recirculation motor wiring ( 1) .


61A


137641 a

Remove:

137676 a

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


- the air recirculation duct. a

Separate the wiring from the air recirculation motor.

137677 a

138647 a

Disconnect the air recirculation motor connector (3) .


Disconnect the connector from the passenger compartment fan assembly motor via the passenger compartment filter housing.

61A-93

Position the (Ms. 1909) and turn it slightly from left to right so that the three rods of the (Ms. 1909) coincide with the three holes of the turbine.


61A



137681 137678 a

a



137682 a

137679 a


Note: To avoid making the passenger compartment fan assembly motor unstable, position the assembly horizontally and protect it from impact.

61A-94

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


61A


137683 a


137687 a


a


a


a



Connect the air recirculation motor connector.

a


a

Clip on the air recirculation control cable.

a


a

Refit the cabin filter (see 61A , Heating, Cabin filter: Removal - Refitting, page 61A-19 ) .

137686 a



Refit: - the offset multimedia socket computer mounting, - the offset multimedia socket computer (see Offset multimedia socket computer: Removal - Refitting) (86A, Radio).

61A-95

HEATING Fan assembly: Removal - Refitting J95, and LEFT-HAND DRIVE

RADIO NO 07 a

Refit: - the receiver mounting, - the receiver (see Tuner-amplifier: Removal - Refitting) (86A, Radio).

a

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

61A-96

61A


61A




Tightening torques m steering column nuts

21 N.m


Unclip the right-hand panel from the centre console.

a


134365 a

- the passenger compartment filter (see 61A , Heating , Cabin filter: Removal - Refitting, page 61A19) .

Disconnect: - the steering column connectors (2 ) , - the electric steering column lock connector.

a


141576 a

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

a

137655

- the cowlings under the steering wheel.

a



a


61A-97


61A


138654 a

Lower the steering column in the footwell.

138646 a


Note: Vertically lower the steering column and do not apply pressure to the universal joints. a


137641 a

Remove: - the bolts (6 ) from the air recirculation duct, - the air recirculation duct.

a

137028 a

Unclip the air recirculation control cable.

61A-98



61A


138647 a

Disconnect the air recirculation motor connector (7) .

137677 a

Position the (Ms. 1909) and turn it slightly from left to right so that the three rods of the (Ms. 1909) coincide with the three holes of the turbine.


Disconnect the connector from the passenger compartment fan assembly motor via the passenger compartment filter housing.

137678 a

137676 a


61A-99



61A


137679 a


137682 a

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

Note: To avoid making the passenger compartment fan assembly motor unstable, position the assembly horizontally and protect it from impact.


137683 a

137681 a

Fit the tool (Ms. 1909) on the passenger compartment fan assembly.

61A-100



61A



137686 a

a

Position the air recirculation duct.

a

Fit the air recirculation motor wiring.

a


a


a


a


a


a


a

Torque tighten the steering column nuts (21 N.m) .

a


a


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, - the cabin filter (see 61A, Heating, Cabin filter: Removal - Refitting, page 61A-19 ) , - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment).

a

137687 a


a


a


a


61A-101

Clip on the right-hand panel of the centre console.

HEATING Heating resistor relays: Removal - Refitting

61A




137019 a

136384

Unclip the left-hand centre console trim. a


Unclip the cover from the heating resistor relay unit at ( 2) .

136383 137635

Remove the heating resistor relays (3) .

a

Unclip the heating resistor relay unit from the distribution unit at (1) .

a

a

Separate the heating resistor relay unit from the distribution unit.


61A-102

Refit the heating resistor relays.

HEATING Heating resistor relays: Removal - Refitting B95 or D95 or E95 or K95 a

Clip: - the cover of the heating resistor relay unit, - the heating resistor relay unit onto the distribution unit.



61A-103

61A

HEATING Heating resistor relays: Removal - Refitting

61A

J95

REMOVAL


a

Note: There are 2 possible fittings for the heating resistor relays: - 1000 Watt resistor : 1 relay unit located on the left of the centre console (see 61 A , Heating, Heating: List and location of components , page 61A-1) , - 1800 Watt resistor : 2 relay units located on the right and left of the centre console (see 61A, Heating, Heating: List and location of components, page 61A-1) .


138894 a

Unclip the heating resistor relay unit from the distribution unit.

a

Separate the heating resistor relay unit from the distribution unit.

138642 a

Unclip the left-hand or right-hand panel (1 ) of the centre console.

136384 a

61A-104

Unclip the cover (2 ) from the heating resistor relay unit.

HEATING Heating resistor relays: Removal - Refitting J95

136383 a

Remove the heating resistor relays (3) .


Refit the heating resistor relays.

a

Clip: - the cover of the heating resistor relay unit, - the heating resistor relay unit onto the distribution unit.


Clip on the left-hand or right-hand panel of the centre console.

61A-105

61A

HEATING Heating resistor unit: Removal - Refitting

61A



21 N.m


21 N.m

REMOVAL I - OPERATION FOR REMOVAL OF PART CONCERNED a

Switch off the ignition. 135692 a


137019 a


a

Remove: - the instrument panel lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment), - the front left-hand footwell air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) .

135693 a

Remove: - the upper bolts (2) from the dashboard cross member reinforcement,



a


61A-106



61A


REFITTING



Refit the heating resistor.


Refit: - the dashboard cross member reinforcement, - the upper bolts on the dashboard cross member reinforcement, - the lower bolts on the dashboard cross member reinforcement.

a

Tighten to torque: - the dashboard cross member reinforcement upper bolts (21 N.m) , - the dashboard cross member reinforcement lower bolts (21 N.m) .

136380 a

Disconnect the connector (3) from the heating resistor.

a




a

Refit: - the front left-hand footwell air distribution duct (see 61A , Heating , A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the instrument panel lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment).

a

136381 a

Remove: - the heating resistor bolts (4 ) , - the heating resistor.

61A-107

Clip on the centre console left-hand trim.


61A




a


a

Remove: - the glovebox (see Glovebox: Removal - Refitting ) ( 57A, Interior equipment), - the front footwell air distribution duct on the lefthand side (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting , page 61A-142 ) .


136381 a

Remove the bolts (2 ) from the heating resistor.

136380 a

Disconnect the connector (1) from the heating resistor.

136382 a

Take the heating resistor out of its housing.

a

Remove the heating resistor.



a

Connect the heating resistor connector.

61A-108

HEATING Heating resistor unit: Removal - Refitting B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE


Refit: - the front footwell air distribution duct on the lefthand side (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting , page 61A-142 ) , - the glovebox (see Glovebox: Removal - Refitting ) (57A, Interior equipment).

a


61A-109

61A


61A



Tightening torques m nuts on the heating resistor terminals

8 N.m

1 - First fitting

Note: There are two possible fittings for the heating resistors: - a 1000 Watt fitting, - an 1800 Watt fitting for "extreme cold" climates.

REMOVAL I - REMOVAL PREPARATION OPERATION 1 - Operation common to both fittings a


a


136380 a

2 - Second fitting for "extreme cold" climates a

Disconnect the connector (1 ) from the heating resistor.


136381 a

61A-110



61A


136382 a


a


141540 a

Unclip the heating resistor terminal strip (5 ) by pressing on the clips (6 ) .

a

Remove the terminal strip from the heating resistor.

2 - Second fitting a

Mark the terminal fittings on the heating resistor.

141539 a

141538 a

Remove the nuts (3) from the heating resistor terminals.

a

Remove the terminal (4) from the heating resistor.

61A-111



61A



141541 a


a


REFITTING I - REFITTING OPERATION FOR PART CONCERNED 1 - First fitting a


a




a

Fit: - the terminal strip on the heating resistor, - the terminal on the heating resistor.

a

Refit the nuts on the heating resistor terminals.

a

Torque tighten the nuts on the heating resistor terminals (8 N.m) .

II - FINAL OPERATION 1 - Operation common to both fittings a


a


61A-112



61A



Tightening torques m nuts on the heating resistor terminals

8 N.m

upper nuts on the dashboard cross member reinforcement

21 N.m


21 N.m

a


Note: There are two possible fittings for the heating resistors: - a 1000 Watt fitting, - an 1800 Watt fitting for "extreme cold" climates.

REMOVAL I - REMOVAL PREPARATION OPERATION 138640

1 - Operation common to both fittings a


a


138642 a

Unclip the left-hand panel (1) from the centre console.

a

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

61A-113


61A


II - OPERATION FOR REMOVAL OF PART CONCERNED 1 - First fitting

138639 a

Remove: - the upper nuts (4) from the dashboard cross member reinforcement, 136380

- the brake pedal impactor (5 ) ,

a


Disconnect the connector (6 ) from the heating resistor.



136381 a

61A-114



61A


136382 a


a


141540 a

Unclip the heating resistor terminal strip (10) by pressing on the clips ( 11) .

a

Remove the terminal strip from the heating resistor.


Mark the terminal fittings on the heating resistor.

141539 a

141538 a

Remove the nuts (8) from the heating resistor terminals.

a

Remove the terminal (9) from the heating resistor.

61A-115

Remove the bolts (12) from the heating resistor.


61A

J95, and LEFT-HAND DRIVE a

Tighten to torque: - the upper nuts on the dashboard cross member reinforcement (21 N.m), - the lower bolts on the dashboard cross member reinforcement (21 N.m).

a



141541 a


a


a


a

Refit the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment).

a



REFITTING I - REFITTING OPERATION FOR PART CONCERNED 1 - First fitting a


a




a

Fit: - the terminal strip on the heating resistor, - the terminal on the heating resistor.

a

Refit the nuts on the heating resistor terminals.

a

Torque tighten the nuts on the heating resistor terminals (8 N.m) .

II - FINAL OPERATION 1 - Operation common to both fittings a

Refit the dashboard cross member reinforcement.

61A-116


HEATING Passenger compartment fan assembly control unit: Removal - Refitting

61A


REMOVAL


- the front right-hand A-pillar air distribution duct (see 61A , Heating , A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) ,


Refit:

Remove: - the glovebox (see Glovebox: Removal) ( 57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) .


136991 a

Unclip the control unit (1) from the passenger compartment fan assembly.

a

Disconnect the connector (2 ) from the passenger compartment fan assembly control unit.


Connect the blower unit control unit connector.

a

Clip on the passenger compartment fan assembly control unit.

61A-117

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


61A


Tightening torques m pedal assembly nuts

21 N.m

brake pedal impacter bolt

21 N.m



a

Remove: - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment), - the front left-hand footwell air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) .

109879 a

Remove: - the dual safety connecting shaft ring, - the dual safety connecting shaft (2) .

134662 a

Remove the brake pedal impacter bolt (1) . 134696 a

Remove the nuts (3 ) from the brake pedal.

Note: Do not disconnect the connectors from the « brake pedal - accelerator» assembly and replace the brake light switch in the event of an impact.

61A-118


61A

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

Partially remove the « brake pedal - accelerator » 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 (21 N.m) .

a

Refit: - the front left-hand footwell air distribution duct (see 61A , Heating , A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment).

a

136991 a

Unclip the passenger compartment fan assembly control unit at (4) .

a



parts always to be replaced: Connecting shaft between the brake pedal and the brake servo pushrod (30,03,02,07) .

a

Part which must always be replaced: Brake pedal impacter bolt.


Connect the connector to the passenger compartment fan assembly control unit.

a

Clip on the passenger compartment fan assembly control unit.


Refit: - the « accelerator - brake pedal » assembly,

61A-119



61A





136991

136991 a

Unclip the tab (1) of the passenger compartment fan assembly control unit by pushing it towards the rear of the vehicle.

a

Push the passenger compartment fan assembly control unit upwards in the direction of the arrow (2) while holding the tab (1) .

a

Remove the passenger compartment fan assembly control unit from its housing.

a


a

Fit the passenger compartment fan assembly control unit in its housing.

a

Push the passenger compartment fan assembly control unit downwards in the direction of the arrow ( 4) while holding the tab (5) .

a

Clip on the tab (5) of the passenger compartment fan assembly control unit by pushing it towards the front of the vehicle.



Connect the passenger compartment fan assembly control unit connector.

61A-120

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


61A



21 N.m

brake pedal impacter nut

21 N.m

REMOVAL I - REMOVAL PREPARATION OPERATION

138639 a

Remove: - the brake pedal impacter nut (2) , - the brake pedal impacter.

138642 a

Unclip the left-hand panel (1) of the centre console.

a


109879 a

Remove: - the rubber ring (3 ) from the dual safety connecting shaft, - the dual safety connecting shaft (4) .

61A-121


61A



134696 a

Remove the nuts (5) from the brake pedal.

136991

Note: Do not disconnect the connectors from the « brake pedal - accelerator » assembly and replace the brake light switch in the event of an impact. a


a

Unclip the tab ( 6 ) of the passenger compartment fan assembly control unit by pushing it towards the rear of the vehicle.

a

Push the passenger compartment fan assembly control unit upwards in the direction of the arrow (7) while holding the tab ( 6) .

a

Remove the passenger compartment fan assembly control unit from its housing.

a

Disconnect the connector ( 8 ) from the passenger compartment fan assembly control unit.




61A-122

Connect the passenger compartment fan assembly control unit connector.

HEATING Passenger compartment fan assembly control unit: Removal - Refitting J95, and LEFT-HAND DRIVE

136991 a

Fit the passenger compartment fan assembly control unit in its housing.

a

Push the passenger compartment fan assembly control unit downwards in the direction of the arrow (9) while holding the tab (10) .

a

Clip on the tab (10) of the passenger compartment fan assembly control unit by pushing it towards the front of the vehicle.


Refit: - the « accelerator - brake pedal » assembly, - a new dual safety connecting shaft, - the dual safety connecting shaft rubber ring, - the pedal assembly nuts.

a


a

Refit: - the brake pedal impacter, - the brake pedal impacter nut.

a

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

a


a


61A-123

61A

HEATING Control panel: Removal - Refitting

61A


Essential equipment diagnostic tool



a

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

135677 a

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

Squeeze the centring pins while pushing the control panel ( 2 ) .

AIR CONDITIONING


AIR CONDITIONING, and RADIO NO 06 or RADIO NO 07 a


135659


a


a


a


135676 a


61A-124


61A


CLIMATE CONTROL

135658 a


135678 a


a

Disconnect the control panel connector (6 ) .

135657 a

Disconnect the connectors (5) from the control panel.

a

Remove the control panel.

135679 a


a

Disconnect the control panel connector (7 ) .

a


61A-125


61A


REFITTING I - REFITTING OPERATION FOR PART CONCERNED AIR CONDITIONING 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


CLIMATE CONTROL 135678 a

Connect the connector (9 ) to the control panel.

a


a


a

Check the correct operation of the control panel.


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

AIR CONDITIONING, and RADIO NO 01 or RADIO NO 02 or RADIO NO 03 or RADIO NO 04 or RADIO NO 05 135679 a

Connect the connector (8) to the control panel.

a

Refit the control panel in its housing.

a


AIR CONDITIONING, and RADIO NO 06 or RADIO NO 07 a


a


61A-126

HEATING Control panel: Removal - Refitting B95 or D95 or E95 or K95 a

Apply the after repair procedure using the diagnostic tool : - connect the diagnostic tool , - select "Climate control computer", - go to repair mode, - display the "Before/after repair procedure" for the computer selected, - carry out the operations described in the "After repair procedure" section.

61A-127

61A


61A

J95



Remove: - the central console (see Centre console: Removal - Refitting) (57A, Interior equipment), - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment), - the inhibitor switch (see Inhibitor switch: Removal - Refitting) (88C, Airbag and pretensioners), - the glovebox (see Glovebox: Removal - Refitting ) ( 57A, Interior equipment),

138599 a


a




138500 a


61A-128


61A

J95

AIR CONDITIONING

138497

138496

138499 a

138498 a

Unclip the air mixing cable (3) from the control panel in the order of the arrows.

61A-129

Unclip the air distribution cable (4 ) from the control panel in the order of the arrows.


61A

J95

CLIMATE CONTROL

138502 a

a

Disconnect the connectors (5) from the control panel. Remove the control panel.

138596 a

Disconnect the connectors (6 ) from the control panel.

a


REFITTING I - REFITTING OPERATION FOR PART CONCERNED AIR CONDITIONING a

Refit the control panel.

a


a

Clip: - the air distribution cable on the control panel, - the air mixing cable onto the control panel.

a


CLIMATE CONTROL a

61A-130


HEATING Control panel: Removal - Refitting J95 a


a


a


a

Check the correct operation of the control panel.


Refit: - the centre front panel (see Centre front panel: Removal - Refitting) (57A, Interior equipment), - the glovebox (see Glovebox: Removal - Refitting ) ( 57A, Interior equipment), - the inhibitor switch (see Inhibitor switch: Removal - Refitting) (88C, Airbag and pretensioners), - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment), - the central console (see Centre console: Removal - Refitting) (57A, Interior equipment).

a

Apply the After repair procedure using the diagnostic tool : - connect the diagnostic tool , - select "Climate control computer", - go to repair mode, - display the "Before/After repair procedure" for the computer selected, - carry out the operations described in the "After repair procedure" section.

61A-131

61A

HEATING Front side air distribution duct: Removal - Refitting

61A





Right-hand side Note: The front left-hand side air distribution duct cannot be separated from the dashboard cross member for removal (see Dashboard cross member: Removal - Refitting) (42A, Front upper structure).

REMOVAL I - REMOVAL PREPARATION OPERATION Right-hand side a


135683 a

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

RADIO NO 07 a

Remove:

Remove: - the receiver (see Tuner-amplifier: Removal - Refitting) (86A, Radio), - the navigation computer (see Navigation computer: Removal - Refitting) (83C, On-board telematics system).

- the front side air distribution duct (2) .

REFITTING I - REFITTING OPERATION FOR PART CONCERNED Right-hand side a

Refit: - the front side air distribution duct, - the front side air distribution duct clip.

II - FINAL OPERATION Right-hand side RADIO NO 07 a

Refit: - the navigation computer (see Navigation computer: Removal - Refitting) (83C, On-board telematics system),

61A-132

HEATING Front side air distribution duct: Removal - Refitting B95 or D95 or E95 or K95, and LEFT-HAND DRIVE - the receiver (see Tuner-amplifier: Removal - Refitting) (86A, Radio).

a

Refit: - the front footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting , page 61A-142 ) , - the glovebox (see Glovebox: Removal - Refitting ) (57A, Interior equipment).

61A-133

61A


61A




Note: The front right-hand side air distribution duct cannot be separated from the dashboard cross member for removal (see Dashboard cross member: Removal - Refitting) (42A, Front upper structure).

REMOVAL I - REMOVAL PREPARATION OPERATION Left-hand side 137018 a

Remove:

a

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

Cut the plastic clip (2 ) on the passenger compartment fuse and relay box.

a

Unclip the passenger compartment fuse and relay box plate from the dashboard cross member (3) .

a

Separate the passenger compartment fuse and relay box plate from the dashboard cross member.

- the front left-hand footwell air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the UCH (see UCH: Removal - Refitting) (87B, Interconnection unit).

137000 a

Disconnect the connectors (1) from the passenger compartment fuse and relay box.

61A-134


61A



III - FINAL OPERATION Left-hand side

Left-hand side

a

Fit the passenger compartment fuse and relay support plate on the dashboard cross member.

a

Clip the passenger compartment fuse and relay support plate onto the dashboard cross member.

a

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

a

Connect the connectors to the passenger compartment fuse and relay support plate.

a

Refit: - the UCH (see UCH: Removal - Refitting) (87B, Interconnection unit), - the front left-hand footwell air distribution duct (see 61A , Heating , A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment).

137022 a

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

a

Unclip the front side air distribution duct.

a

Remove the front side air distribution duct.

REFITTING I - REFITTING PREPARATION OPERATION Left-hand side a

Part which must always be replaced: Plastic retaining clip for the passenger compartment fuse and relay support plate.

II - REFITTING OPERATION FOR PART CONCERNED 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.

61A-135


61A

J95


21 N.m

REMOVAL I - REMOVAL PREPARATION OPERATION 1 - Front right-hand side air distribution duct: a

Remove the airbag inhibitor switch (see Inhibitor switch: Removal - Refitting) (88C, Airbag and pretensioners).

LEFT-HAND DRIVE a


134365 a

- the steering column connectors (1 ) ,

RADIO NO 07 a

Disconnect:

- the electric steering column lock,

Remove the receiver (see Tuner-amplifier: Removal - Refitting) (86A, Radio).

- the steering column control connectors. a


a




RIGHT-HAND DRIVE a


137655 a


a



61A-136


61A

J95

138654 a


138641 a

Remove: - the cover bolts (4 ) under the steering wheel,

Note:


Vertically lower the steering column and do not apply pressure to the universal joints. a


2 - Front left-hand side air distribution duct: LEFT-HAND DRIVE a


134365 a

Disconnect: - the steering column connectors (5 ) , - the electric steering column lock, - the steering column control connectors.

a


a


61A-137


61A

J95

134366 a

Remove the nuts (6) from the steering column.

a


138654 a


Note: Vertically lower the steering column and do not apply pressure to the universal joints. a

Check that the cross piece (7 ) does not leave the bearing.

RIGHT-HAND DRIVE a



Remove: - the offset multimedia socket computer (see Offset multimedia socket computer: Removal - Refitting) (86A, Radio), - the offset multimedia socket computer mounting bolts, - the offset multimedia socket computer mounting.

61A-138


61A

J95


- the electric steering column lock, - the steering column control connectors. a

Refit: - the cowlings under the steering wheel, - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment).

LEFT-HAND DRIVE RADIO NO 04 or RADIO NO 05 a

Refit: - the offset multimedia socket computer mounting, - the offset multimedia socket computer (see Offset multimedia socket computer: Removal - Refitting) (86A, Radio).

139057 a

Disconnect: - the front side air distribution duct from the air distribution unit at (8) , - the front side air distribution duct from the air vent at ( 9) .

a

Remove the front side air distribution duct.

RADIO NO 07 a

Refit the receiver (see Tuner-amplifier: Removal Refitting) (86A, Radio).

a

Refit:


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

Refit the front side air distribution duct.

- the airbag inhibitor switch (see Inhibitor switch: Removal - Refitting) (88C, Airbag and pretensioners).

II - FINAL OPERATION 1 - Front right-hand side air distribution duct: RIGHT-HAND DRIVE a


a


a


a


a

Connect:

2 - Front left-hand side air distribution duct: RIGHT-HAND DRIVE RADIO NO 04 or RADIO NO 05 a

- the steering column connectors,

Refit: - the offset multimedia socket computer mounting,

61A-139

HEATING Front side air distribution duct: Removal - Refitting J95 - the offset multimedia socket computer (see Offset multimedia socket computer: Removal - Refitting ) (86A, Radio).

a


LEFT-HAND DRIVE a


a


a

Torque tighten the steering column nuts (21 N.m).

a


a

Connect: - the steering column connectors, - the electric steering column lock, - the steering column control connectors.

a


61A-140

61A

HEATING Front central air distribution duct: Removal - Refitting B95 or D95 or E95 or K95



a



137638 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.


Refit the front centre air duct.

a

Clip on the front centre air duct.

a

Refit the front centre air duct bolts.



a

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

61A-141

61A

HEATING A-pillar air distribution duct: Removal - Refitting

61A


2 - Passenger side



REMOVAL I - REMOVAL PREPARATION OPERATION 1 - Driver's side a

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

2 - Passenger side a

Remove the glovebox (see Glovebox: Removal Refitting) (57A, Interior equipment). 135680


a

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

1 - Driver's side

- the A-pillar air duct (4) .


Refit: - the A-pillar air duct, - the A-pillar air duct clip.

II - FINAL OPERATION 1 - Driver's side a

135689 a

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

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

2 - Passenger side a

- the A-pillar air duct (2) .

61A-142



61A

J95

REMOVAL



1 - Left-hand side

1 - Left-hand side LEFT-HAND DRIVE a


RIGHT-HAND DRIVE a


2 - Right-hand side 138675 a

LEFT-HAND DRIVE a


Remove: - the bolts (1 ) of the front footwell air distribution duct, - the front footwell air distribution duct.

RIGHT-HAND DRIVE a


61A-143


61A

J95

2 - Right-hand side RIGHT-HAND DRIVE LEFT-HAND DRIVE

139117 138986 a

a

Unclip the front footwell air distribution duct (3) .

Remove: - the bolts (2 ) of the front footwell air distribution duct, - the front footwell air distribution duct.


Refit the A-pillar air distribution duct.

II - FINAL OPERATION 1 - Left-hand side LEFT-HAND DRIVE a


RIGHT-HAND DRIVE a

61A-144


HEATING A-pillar air distribution duct: Removal - Refitting J95

2 - Right-hand side LEFT-HAND DRIVE a


RIGHT-HAND DRIVE a


61A-145

61A

HEATING Recirculation motor: Removal - Refitting

61A






RADIO NO 07 a

Remove: - the receiver (see Tuner-amplifier: Removal - Refitting) (86A, Radio), - the navigation computer (see Navigation computer: Removal - Refitting) (83C, On-board telematics system).

137641 a


a


a


a

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

a

Remove the front side air distribution duct (see 61A, Heating , Front side air distribution duct: Removal - Refitting, page 61A-132) .

- the air recirculation duct.

137633 137028 a

a

Unclip the recirculation control cable (1) .

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

61A-146


61A

B95 or D95 or E95 or K95, and LEFT-HAND DRIVE - the air recirculation motor.

a

Refit:

REFITTING

- the front side air distribution duct (see 61A , Heating, Front side air distribution duct: Removal Refitting, page 61A-132 ) ,

I - REFITTING OPERATION FOR PART CONCERNED

- the front right-hand A-pillar air distribution duct (see 61A , Heating , A-pillar air distribution duct: Removal - Refitting, page 61A-142) ,

a

Refit:

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

- the air recirculation motor, - the air recirculation duct. a


Apply the after repair procedure using the diagnostic tool :

a


- connect the diagnostic tool ,

a

- select "Climate control computer",


- go to repair mode,


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

RADIO NO 07 a

Refit:

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

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

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

- the navigation computer (see Navigation computer: Removal - Refitting) (83C, On-board telematics system).

61A-147


61A



Tightening torques m steering column bolts

21 N.m


Unclip the centre console right-hand trim.

a

Remove the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment). 134365 a

Disconnect the steering column connectors (2) and the steering column electric lock.

a


136716 a

Remove: - the cover bolts (1 ) under the steering wheel, - the cowlings under the steering wheel.

a


134366 a


a


61A-148


61A



137636 a

Lower the steering column in the footwell. 137641

Note: Vertically lower the steering column and do not put apply pressure to the universal joints. a

Check that the cross piece does not leave the bearing.

a


a


a


a


137028 a

Unclip the recirculation control cable at (5) .

137633 a

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

61A-149


61A

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE - the air recirculation motor.

a

Apply the after repair procedure using the diagnostic tool : - connect the diagnostic tool ,

REFITTING

- select "Climate control computer", - go to repair mode,



Refit:

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

- the air recirculation motor,


- the air recirculation duct. a


a




a


a


a


a

Refit the steering column bolts.

a

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

a


a


a

Connect: - the electric steering column lock connector, - the steering column connectors, - the steering column switch assembly connectors.

a


a

Clip on the centre console right-hand trim.

61A-150


61A




Remove: - the inhibitor switch (see Inhibitor switch: Removal - Refitting) (88C, Airbag and pretensioners), - the glovebox (see Glovebox: Removal - Refitting ) ( 57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) . 137028

RADIO NO 07 a

a

Remove: - the receiver (see Tuner-amplifier: Removal - Refitting) (86A, Radio),



- the bolts from the receiver mounting, - the receiver mounting.



138646 a

61A-151



61A


CLIMATE CONTROL

138595 a

- the bolts (4 ) from the air recirculation motor,

137641 a

Remove:

Remove:

- the air recirculation motor.

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

Separate the wiring from the air recirculation motor. AIR CONDITIONING

138647 a

139116

Disconnect the air recirculation motor connector (3) . a

Remove: - the bolts (5 ) from the air recirculation motor, - the air recirculation motor.

61A-152


61A


REFITTING

- display the « before/after repair procedure » for the computer selected,

I - REFITTING OPERATION FOR PART CONCERNED

- select « Air recirculation flap motor » in the « List of components controlled by this computer » section,

a

Refit the air recirculation motor.

a


a


a


a


- carry out the operations described in the « After repair procedure » section.




Refit: - the offset multimedia socket computer mounting, - the offset multimedia socket computer (see Offset multimedia socket computer: Removal - Refitting ) (86A, Radio).

RADIO NO 07 a

Refit: - the receiver (see Tuner-amplifier: Removal - Refitting) (86A, Radio), - the receiver mounting.

a

Refit: - the front right-hand A-pillar air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the glovebox (see Glovebox: Removal - Refitting ) ( 57A, Interior equipment), - the inhibitor switch (see Inhibitor switch: Removal - Refitting) (88C, Airbags and pretensioners).

a

Apply the after repair procedure using the diagnostic tool : - connect the diagnostic tool , - select « Climate control computer » , - go to repair mode,

61A-153


61A



21 N.m



a


a


134365 a

Disconnect: - the steering column connectors (2 ) , - the electric steering column lock connector.

a


141576 a

Remove: - the cover bolts (1 ) under the steering wheel, - the cowlings under the steering wheel.

a


137655 a


a


61A-154


61A



138654 a

Lower the steering column in the footwell. 138646 a

Note:


Vertically lower the steering column and do not apply pressure to the universal joints. a


137641 a


137028 a


a

61A-155



61A


AIR CONDITIONING

138647 a

Disconnect the air recirculation motor connector (7) . 139116

CLIMATE CONTROL

a



138595 a


a

Refit the air recirculation motor.

a


a


a


a




a


a


a


a


61A-156

HEATING Recirculation motor: Removal - Refitting J95, and RIGHT-HAND DRIVE a


a


a

Connect: - the electric steering column lock connector, - the steering column connectors, - the steering column switch assembly connectors.

a


a


61A-157

61A

HEATING Mixer motor: Removal - Refitting

61A

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



21 N.m

brake pedal impacter bolt

21 N.m

REMOVAL I - REMOVAL PREPARATION OPERATION 1 - Right-hand mixing motor a

Remove:

134662

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

a

Remove the brake pedal impacter bolt (1 ) .

- the front right-hand A-pillar air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) .

2 - Left-hand mixing motor a


a


109879 a

Remove: - the dual safety connecting shaft rubber ring, - the dual safety connecting shaft (2) .

61A-158


61A


II - OPERATION FOR REMOVAL OF PART CONCERNED 1 - Right-hand mixing motor

134696 a

Remove the nuts (3) from the brake pedal. Note:

135682

Do not disconnect the connectors from the « brake pedal - accelerator » assembly and replace the brake light switch in the event of an impact. a


a

Mark the routing of the mixing motor wiring.

a

Disconnect the connector (4 ) from the air mixing motor.

a

Remove: - the bolts (5 ) from the air mixing motor, - the air mixing motor.

61A-159


61A


REFITTING

2 - Left-hand mixing motor


1 - Right-hand mixing motor

137640 a


a

Disconnect the connector (6) from the air mixing motor.

a


137014 a

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



a

part which must always be replaced: Brake pedal impacter bolt.

137015 a

61A-160

Move the tie rod so that the flat surface (10) of the left-hand mixing motor recess is positioned at 90˚ in relation to the edge of the distribution unit reference axis (11) .


61A



a


Right-hand and left-hand mixing motor

- select "Climate control computer",

a

Refit the mixing motor.


a

Connect the air mixing motor connector.


a

Fit the electrical wiring of the mixing motor.

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



1 - Right-hand mixing motor a

Refit: - the front right-hand A-pillar air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the glovebox (see Glovebox: Removal - Refitting ) (57A, Interior equipment).


Refit: - the « accelerator - brake pedal » assembly, - the dual safety connecting shaft, - the dual safety connecting shaft rubber ring, - the pedal assembly nuts.

a


a

Refit: - the impacter, - the impacter bolt.

a

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

a

Refit: - the front left-hand air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting , page 61A-142 ) , - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment).

a


61A-161


61A

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


Tightening torques m clutch pedal nuts

21 N.m

REMOVAL I - REMOVAL PREPARATION OPERATION 1 - Right-hand mixing motor a

Unclip the centre console right-hand trim

a

Remove:

137154 a

- the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) .

Remove the clutch pedal nuts (3 ) . Note: Do not disconnect the connectors from the clutch pedal.

a

Remove the clutch pedal from its threaded rods in the direction of the arrow. Note: Do not apply pressure to the hydraulic clutch pipes.

a

137690 a

Unclip the hydraulic clutch pipes (1) .

a

Move the hydraulic clutch pipes aside.

a

Unclip the clutch pedal wiring at (2) .

61A-162

Pass the hydraulic clutch pipes under the distribution unit.


61A


II - OPERATION FOR REMOVAL OF PART CONCERNED 1 - Right-hand mixing motor

136999 a

Tilt the clutch pedal in the direction of the arrow.

a

Put the clutch pedal in the footwell. 135682



a


a

Disconnect the air mixing motor connector.

a


61A-163


61A




137015 a

137640 a


a

Disconnect the air mixing motor connector.

a


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



a


a



REFITTING





Refit the clutch pedal nuts.

a

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

a


a

Refit: - the glovebox (see Glovebox: Removal - Refitting) ( 57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A , Heating , A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment).

137014 a

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

a

61A-164


HEATING Mixer motor: Removal - Refitting B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and CLIMATE CONTROL



a a

Apply the after repair procedure using the diagnostic tool : - connect the diagnostic tool , - select "Climate control computer", - go to repair mode, - display the "Before/after repair procedure" for the computer selected, - select "Right-hand air mixing flap motor" in the "List of components stored by this computer" section, - carry out the operations described in the "After repair procedure" section.

61A-165

61A


61A

J95, and LEFT-HAND DRIVE, and CLIMATE CONTROL



21 N.m

upper nuts on the dashboard cross member reinforcement

21 N.m


21 N.m

REMOVAL 138640

I - REMOVAL PREPARATION OPERATION 1 - Right-hand mixer motor a

a


a


Remove: - the inhibitor switch (see Inhibitor switch: Removal - Refitting) (88C, Airbag and pretensioners), - the glovebox (see Glovebox: Removal - Refitting ) (57A, Interior equipment).

a


2 - Left-hand mixer motor a


a

Remove: - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment), - the front left-hand footwell air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) . a


138639


Remove: - the upper nuts (3) from the dashboard cross member reinforcement, - the brake pedal impacter (4 ) , - the dashboard cross member reinforcement.

61A-166


61A


109879 a

Remove:

137156 a

- the rubber ring (5 ) from the dual safety connecting shaft,

Remove the nuts (7 ) from the brake pedal. Note:

- the dual safety connecting shaft (6) .

Do not disconnect the connectors from the « brake pedal - accelerator» assembly and replace the brake light switch in the event of an impact. a

61A-167



61A



2 - Left-hand mixer motor

1 - Right-hand mixer motor

139240

138645 a

a


a

Remove:

Mark the routing of the air mixing motor wiring ( 8) .

- the bolts (12) from the air mixing motor, - the air mixing motor.

138644 a


a

Remove: - the bolts (10) from the air mixing motor, - the air mixing motor.

61A-168


61A


REFITTING

In the event of replacement

I - REFITTING PREPARATION OPERATION 1 - Right-hand mixer motor In the event of replacement

139239 a

138598 a

Move the tie rod so that the flat surface (13) of the right-hand mixing motor recess is positioned at 90˚ in relation to the distribution unit reference axis.



Move the tie rod so that the flat surface (14) of the left-hand mixing motor recess is positioned at 90˚ in relation to the edge of the distribution unit reference axis.

II - REFITTING OPERATION FOR PART CONCERNED Right-hand and left-hand mixing motor a


a


a


III - FINAL OPERATION 1 - Right-hand mixer motor a

Refit: - the glovebox (see Glovebox: Removal - Refitting) ( 57A, Interior equipment), - the inhibitor switch (see Inhibitor switch: Removal - Refitting) (88C, Airbags and pretensioners).

a



Refit: - the « accelerator - brake pedal » assembly, - a new dual safety connecting shaft,

61A-169

HEATING Mixer motor: Removal - Refitting J95, and LEFT-HAND DRIVE, and CLIMATE CONTROL - the dual safety connecting shaft rubber ring. a


a

Refit: - the dashboard cross member reinforcement, - the brake pedal impacter.

a

Torque tighten: -the upper nuts on the dashboard cross member reinforcement (21 N.m), -the lower bolts on the dashboard cross member reinforcement (21 N.m).

a




a

Refit: - the front left-hand footwell air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment).

a


3 - Programming the left-hand or right-hand mixing motor a

Apply the after repair procedure using the diagnostic tool : - connect the diagnostic tool , - select « Climate control computer » , - go to repair mode, - display the « before/after repair procedure » for the computer selected, - select « Left-hand air mixing flap motor or Righthand air mixing flap motor » in the « List of components controlled by this computer » section, - carry out the operations described in the « After repair procedure » section.

61A-170

61A


61A

J95, and RIGHT-HAND DRIVE, and CLIMATE CONTROL



1 - Right-hand mixer motor

REMOVAL I - REMOVAL PREPARATION OPERATION Right-hand mixer motor a


a

Remove: - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment), - the front right-hand footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the clutch pedal position sensor (see Clutch pedal position sensor: Removal - Refitting ) (37A, Mechanical component controls). 138645

Left-hand mixer motor

a

a


a


Mark the routing of the air mixing motor wiring (1 ) .

138644 a

Disconnect the connector (2 ) from the air mixing motor.

a


61A-171


61A


REFITTING


I - REFITTING PREPARATION OPERATION 1 - Right-hand mixer motor In the event of replacement

139240 a


a

Remove: - the bolts (5 ) from the air mixing motor, - the air mixing motor. 138598 a

61A-172

Move the tie rod so that the flat surface (6) of the right-hand mixing motor recess is positioned at 90˚ in relation to the distribution unit reference axis.


61A





a



3 - Programming the left-hand or right-hand mixing motor a

Apply the after repair procedure using the diagnostic tool : - connect the diagnostic tool , - select « Climate control computer » , - go to repair mode, - display the « before/after repair procedure » for the computer selected, - select « Left-hand air mixing flap motor or Righthand air mixing flap motor » in the « List of components controlled by this computer » section, - carry out the operations described in the « After repair procedure » section.

139239 a

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



a


a


III - FINAL OPERATION 1 - Right-hand mixer motor a

Refit: - the clutch pedal position sensor (see Clutch pedal position sensor: Removal - Refitting ) (37A, Mechanical component controls). - the front right-hand footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment),

a


61A-173

HEATING Distribution motor: Removal - Refitting

61A


REFITTING Essential equipment I - REMOVAL PREPARATION OPERATION

diagnostic tool




137012 a

Move the tie rod so that the flat surface (3) of the distribution motor recess is positioned at 90˚ in relation to the distribution unit reference axis (4) .


Refit the distribution motor.

a

Connect the distribution motor connector.

a

Fit the electrical wiring of the distribution motor.


Refit: - the front right-hand A-pillar air distribution duct (see 61A , Heating , A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the glovebox (see Glovebox: Removal - Refitting) (57A, Interior equipment).

136385 a

Mark the routing of the motor wiring.

a

Disconnect the connector (1 ) from the distribution motor.

a

a

Apply the after repair procedure using the diagnostic tool : - connect the diagnostic tool , - select "Climate control computer",

Remove:


- the bolts (2 ) from the distribution motor,


- the distribution motor.

- select "Footwell air distribution flap motor" in the "List of components stored by this computer" section, - carry out the operations described in the "After repair procedure" section.

61A-174


61A



Tightening torques m clutch pedal nuts

21 N.m


Unclip the right-hand centre console trim.

a

Remove: - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment), - the front right-hand A-pillar air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) .

137154 a

Remove the clutch pedal nuts (3 ) . Note: Do not disconnect the connectors from the clutch pedal.

a

Detach the clutch pedal from its threaded rods. Note: Do not apply pressure to the hydraulic clutch pipes.

a

137690 a

Unclip the clutch hydraulic pipes (1) .

a

Move the clutch hydraulic pipes aside.

a

Unclip the wiring (2) from the clutch pedal.

61A-175

Pass the hydraulic clutch pipes under the distribution unit.


61A

B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and CLIMATE CONTROL - the distribution motor.

REFITTING I - REFITTING PREPARATION OPERATION

136999 a

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

a

Put the clutch pedal in the footwell.

137012 a

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



a


a


a




a

Refit the clutch pedal nuts.

a

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

a


a

- the front right-hand A-pillar air distribution duct (see 61A , Heating , A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) ,

136385 a

Mark the routing of the distribution motor wiring.

a


a

Remove: - the bolts (5 ) from the distribution motor,

Refit:

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

61A-176


HEATING Distribution motor: Removal - Refitting B95 or D95 or E95 or K95, and RIGHT-HAND DRIVE, and CLIMATE CONTROL a

Apply the after repair procedure using the diagnostic tool : - connect the diagnostic tool , - select "Climate control computer", - go to repair mode, - display the "Before/after repair procedure" for the computer selected, - select "Footwell air distribution flap motor" in the "List of components stored by this computer" section, - carry out the operations described in the "After repair procedure" section.

61A-177

61A


61A






138643 a


a

Remove: - the bolts (3 ) from the distribution motor, - the distribution motor.

138645 a

Mark the routing of the distribution motor wiring (1) .

61A-178


61A


REFITTING


I - REFITTING PREPARATION OPERATION In the event of replacement

138597 a

Move the tie rod so that the flat surface (4) of the distribution motor recess is positioned at 90˚ in relation to the distribution unit reference axis.



a


a




a

Apply the after repair procedure using the diagnostic tool : - connect the diagnostic tool , - select "Climate control computer", - go to repair mode, - display the "Before/After repair procedure" for the computer selected, - select "Footwell air distribution flap motor" in the "List of components controlled by this computer" section,

61A-179


61A




Remove: - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment), - the front footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting , page 61A-142 ) , - the clutch pedal position sensor (see Clutch pedal position sensor: Removal - Refitting ) (37A, Mechanical component controls).


138643 a


a

Remove: - the bolts (3 ) from the distribution motor, - the distribution motor.

138645 a

Mark the routing of the distribution motor wiring (1) .

61A-180


61A


REFITTING

- select "Climate control computer", - go to repair mode,


- display the "Before/After repair procedure" for the computer selected,


- select "Footwell air distribution flap motor" in the "List of components controlled by this computer" section, - carry out the operations described in the "After repair procedure" section.

138597 a

Move the tie rod so that the flat surface (4) of the distribution motor recess is positioned at 90˚ in relation to the distribution unit reference axis.



a


a



Refit: - the clutch pedal position sensor (see Clutch pedal position sensor: Removal - Refitting ) (37A, Mechanical component controls). - the front footwell air distribution duct (see 61A, Heating, A-pillar air distribution duct: Removal - Refitting , page 61A-142 ) , - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment),

a


61A-181

HEATING Passenger compartment temperature sensor: Removal - Refitting

61A

REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED

138649 a

138651 a

Unclip the passenger compartment temperature sensor ( 3) from the interior rear view mirror trim.

REFITTING

Remove the interior rear view mirror trim (1) .

REFITTING OPERATION FOR PART CONCERNED a

Clip the passenger compartment temperature sensor onto the interior rear view mirror trim.

a

Connect the passenger compartment temperature sensor connector.

a

Refit the interior rear view mirror trim.

138650 a

Disconnect the passenger compartment temperature sensor connector (2) .

61A-182

HEATING External temperature sensor: Removal - Refitting

61A

Note: The exterior temperature sensor is located in the door mirror on the right-hand side.


Remove: - the right-hand door mirror glass (see Door mirror glass: Removal - Refitting ) (56A, Exterior equipment), - the right-hand door mirror casing (see Door mirror casing: Removal - Refitting ) (56A, Exterior equipment).


138676 a

Remove the exterior temperature sensor (2) from its mounting.

138670 a

Unclip the right-hand door mirror mounting to remove the sensor by pressing on the clips (1) .

138674 a

61A-183

Cut the wires ( 3) of the exterior temperature sensor (see Wiring: Repair) (Technical Note 6015A, 88A, Wiring).

HEATING External temperature sensor: Removal - Refitting REFITTING I - REFITTING OPERATION FOR PART CONCERNED a

Solder the wires of the exterior temperature sensor (see Wiring: Repair) (Technical Note 6015A, 88A, Wiring).

a

Refit the exterior temperature sensor onto its mounting.

a

Clip on the right-hand door mirror mounting.


Refit: - the right-hand door mirror casing (see Door mirror casing: Removal - Refitting ) (56A, Exterior equipment), - the right-hand door mirror glass (see Door mirror glass: Removal - Refitting ) (56A, Exterior equipment).

61A-184

61A

AIR CONDITIONING Air conditioning: List and location of components

62A

139042

No.

Description

(1)

Compressor (see 62A , Air conditioning, Compressor: Removal - Refitting , page 62A-21)

(2)

« Compressor - condenser » connecting pipe (see 62A , Air conditioning, Condenser - compressor connecting pipe: Removal - Refitting , page 62A-85 )

(3)

Condenser (see 62A , Air conditioning, Condenser: Removal - Refitting , page 62A-12 )

(4)

Dehydrator reservoir filter

(5)

« Condenser - expansion valve » connecting pipe (see 62A , Air conditioning , Expansion valve - condenser connecting pipe: Removal - Refitting , page 62A-49)

(6)

« Expansion valve - intermediate pipe » connecting pipe (see 62A, Air conditioning , Expansion valve - intermediate pipe connecting pipe at the expansion valve outlet: Removal - Refitting , page 62A-65)

62A-1

AIR CONDITIONING Air conditioning: List and location of components

62A

No.

Description

(7)

« Intermediate pipe - compressor » connecting pipe (see 62A, Air conditioning , Compressor/intermediate pipe connecting pipe: Removal - Refitting , page 62A-95)

(8)

Pressure sensor (see 62A , Air conditioning, Pressure sensor: Removal Refitting, page 62A-77)

62A-2

AIR CONDITIONING Air conditioning: Precautions for repair

62A

I - SAFETY IMPORTANT To prevent refrigerant from leaking, never repair a faulty air conditioning circuit component.

IMPORTANT The following must be worn when handling refrigerant:

Replace all faulty components.

- gloves,

It is essential to follow the routing of the connecting pipes.

- protective goggles (with side shields if possible).

Ensure that the refrigerant connecting pipes are correctly fitted so that they will not come into contact with metal parts in the engine compartment.

In the event of refrigerant fluid coming into contact with the eyes, rinse well with clean water continuously for 15 minutes. If possible, have an eye rinse unit available. If refrigerant comes into contact with your eyes, consult a doctor immediately. Inform the doctor that the burns were caused by R134A refrigerant.


In the event of contact with other unprotected parts of the body (event though the safety advice has been observed), rinse well with clean water continuously for 15 minutes.

WARNING To avoid damaging the surface of the air conditioning pipes when removing the seals, do not use a tool with a metallic end piece.

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

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

The refrigerant must not be stored in a shaft, a pit, a hermetically sealed room, etc. Refrigerants are colourless and odourless fluids. Refrigerant is heavier than air. As a result there is a risk of asphyxia for those working close to the ground and less than 5 m away from the working area (pit, well, air vents, etc.). Switch on gas extraction systems. At temperatures above 100˚C, the refrigerant will decompose and produce a highly irritant gas.

WARNING To prevent any leaks, check that the seal and surface of the pipe are in good condition. The seal and the surface must be clean and free from scratches.

WARNING Lubricants are not mutually compatible: always observe the type and quantity of oil recommended for each compressor even when topping up as this could damage the cold loop components.

IMPORTANT It is forbidden to smoke close to an open refrigerant circuit. II - GENERAL RECOMMENDATIONS It is possible to place components in the drying oven after painting or to carry out work near the system if the temperature does not exceed 80˚C .

62A-3

Always close the oil cans again after use to keep moisture out and never use oil contained in a can that has been open for a long time (viscous appearance).

AIR CONDITIONING Air conditioning: Parts and consumables for the repair work

62A

For the oil part number (see Vehicle: Parts and consumables for repair ) (04B, Consumables - Products).

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

Refrigerant capacity (g)

Type of compressor

Type of original oil

480 ± 35

6 SEL 14C

ND-OIL 8

510 ± 35

VALEO DCS-S7EC

ZXL 100 PG

Type of After-Sales oil

Quantity of oil (ml)

K4M F4R K9K M9R

SANDEN SP10

110 ± 10

F9Q H4J M4R

150 0/+ 20

Table of quantities of oil to add when replacing components: Operation on the air conditioning circuit

Quantity of oil (ml or cm 3)

Circuit oil change

Measure the volume recovered and add the same quantity of new oil

Split pipe or other rapid leak

100

Replacement of a pipe

Quantity recovered +10

Replacement of a condenser


Replacement of an evaporator or distribution unit


Replacement of the fi lter or dehydrator reservoir


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 conditioning circuit component(s)

None added

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

Top up as necessary

62A-4

AIR CONDITIONING Air conditioning: Check

62A

Equipment required Dual-sensor temperature measuring device

Note: When performing RENAULT maintenance, check the air conditioning system at the end of the vehicle's maintenance program so that the engine will be cold.

I - PREPARATION OPERATION FOR THE MEASUREMENT DEVICE a

Check that the measurement device functions properly (see the device's instruction manual).

a

Set units to ˚C.

a

Set the device's sensitivity to 0.1˚C.

119358 a

Check the two sensors T1 and T2 in order to calculate the correction ( ∆ ) to be applied to the measurement (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 until they touch, - placing the sensors in the air flow of an air vent, - setting the passenger compartment fan assembly to top speed. - waiting for the value to become stable. - recording the correction value ( ∆).

Note:

119360 a

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

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

WARNING Note the difference and sign as soon as the temperature becomes stable. Calculate the correction ( ∆) = - (T1 - T2) to be applied 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-5

AIR CONDITIONING Air conditioning: Check II - VEHICLE PREPARATION OPERATION a

- wait for the value to become stable.

Put the vehicle in the shade, where the temperature is 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:

62A

- record the T3 temperature value. - close the bonnet if it was opened.

- recirculation mode in the external position, - the ventilation distribution in "face" mode, - the temperature control to coldest temperature setting in front (and at the back, if it exists), - the speed of the passenger compartment fan assembly set to maximum (switch off the rear control if it exists), - the front side and centre air vents open with the vanes in a neutral position, - the air conditioning system must be turned on (indicator light illuminated). a

Wait 5 minutes with the engine idling before taking any measurements.

119357 a

III - MEASUREMENTS

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) according to the correction ( ∆ ) to be applied to the measurement.

a

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

119359 a

Record the air temperature at the scuttle panel grille (T3). - open the bonnet, depending on the vehicle, to access the scuttle panel grille. - place the sensor where air is drawn through the scuttle panel grille.

62A-6

Depending on the vehicle's air conditioning system programming, this check method may not be applicable because the engine cooling fan assembly has been activated. Its operation renders the ( ∆Τ) value between T1 and T2 unstable. To eliminate this error, the fan assembly must be activated for the entire period over which temperature T1 and T2 measurements are recorded.

AIR CONDITIONING Air conditioning: Check a

Activate the engine cooling fan assembly operation by modifying the engine speed. - stabilise the engine speed at 2000 rpm while T1 and T2 temperature measurements are being recorded. - check that the engine cooling fan assembly operating. - record the temperatures by following the instructions 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 two values T1 or T2, must be greater than or equal to 5˚C, - the difference between T1 and T2 must be less than or equal to 2˚C. Note: If one of these two conditions is not met, then the air conditioning system is not working properly. Should this be the case, refer to the fault finding procedure for the air conditioning system for the vehicle concerned.

62A-7

62A

AIR CONDITIONING Coolant circuit check a


62A

Check the sealing of the refrigerant circuit using the electronic trace detector (follow the trace of the circuit as closely as possible, to limit variations due to other gases). Note:

IMPORTANT Consult the safety and cleanliness advice and operation recommendations before carrying out any repair (see 62 A , Air conditioning, Air conditioning: Precautions for repair , page 62A-3) .

If replacing a defective part (see 62A, Air conditioning ).

2 - Trace detectors a

WARNING Consult the device's operating manual to avoid incorrect use.

Note: After any work on air conditioning circuit leaks on the Laguna II, Vel Satis and Espace IV, check that filling fault DF033 Refrigerant is not present, using the diagnostic tool. If it is present, clear it. The compressor cannot operate until the fault is cleared.

WARNING To avoid damaging the cold loop components (corrosions, etc.), do not use dye if the traces reveal that some product has already been injected.

There are several types of detector: - electronic detectors, a

Check for dye on the cold loop components with the ultraviolet light .

a

Inject the dye.

Note:

a

Start the engine.

To carry out an after repair check, use the procedure for the electronic detector (1) . To carry out a more thorough check for leaks, use a trace detector (2).

a

Let the air conditioning system run for 15 minutes.

a

Switch off the engine.

a

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

- trace detectors.

Check that the air conditioning system is operating correctly (see 62A , Air conditioning, Air conditioning: Check, page 62A-5) .

REFRIGERANT CIRCUIT SEALING CHECKING OPERATION

Note: If replacing a defective part (see 62A, Air conditioning ). a

1 - Electronic detectors: 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.

62A-8

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

AIR CONDITIONING Coolant circuit Draining - Refilling


IMPORTANT Consult the safety and cleanliness advice and operation recommendations before carrying out any repair (see 62 A , Air conditioning, Air conditioning: Precautions for repair , page 62A-3) .


WARNING To avoid damaging the cold loop components (corrosions, etc.), do not use dye if the traces reveal that some product has already been injected.

Note: A summary table gives the quantities of refrigerant in the system according to the engine type (see 62A , Air conditioning, Air conditioning: Parts and consumables for the repair work , page 62A4) .

62A-9

62A

AIR CONDITIONING Coolant circuit Draining - Refilling

62A

I - RECOVERING REFRIGERANT FLUID

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

a

- wait 15 minutes, Note:

- run the engine until the cooling fan is triggered twice,

- If the air conditioning circuit is fitted with a single filler valve, some filling equipment only requires the use of the high pressure pipe (refer to the filling station instructions).

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

- Depending on the situation, run the system for a few minutes before recovering the coolant to improve drainage.

- repeat the cycles until the relative pressure is equal to or less than 0 bar, - add together the values of the various draining operations; the fill is confirmed as being correct if the volume of refrigerant fluid is the specified fill +35g or -100g.

Note: It is essential to follow these procedures to prevent:

Scenario C:

- gas escaping when the circuit is opened,

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

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

- wait 2 hours, - repeat the cycles until the relative pressure is equal to or less than 0 bar,

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

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

- the engine is running and the air conditioning is in operation (A), - the engine is running but the air conditioning is not in operation (B), - the engine is not running nor is the air conditioning in operation (C). a

II - CREATING A VACUUM a

Scenario A:

It is essential to carry out vacuum extraction correctly before loading, otherwise the air conditioning will not work properly.

- Operate the air conditioning until the cooling fan assembly is triggered twice,

There are two scenarios to consider:

- Switch off the engine,

- vacuum created immediately after discharge (scenario A),

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

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

- wait 15 minutes,

Scenario A:

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

- creation of a vacuum takes 20 minutes.

- repeat the cycles until the relative pressure is equal to or less than 0 bar , - add together the values of the various draining operations; the fill is confirmed as being correct if the volume of refrigerant fluid is the specified fill +35g or -100g .

Scenario B: - creation of a vacuum takes 45 minutes to eliminate any trace of moisture. a

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

Scenario B: - run the engine until the cooling fan is triggered twice,

III - FILLING a

- Switch off the engine,

62A-10

Fill up the refrigerant circuit using the refrigerant charging station .

AIR CONDITIONING Coolant circuit Draining - Refilling a

Top up the oil with the recommended type and volume of oil and refrigerant, depending on the work carried out (see 6 2 A, Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-4) .

a

Check there are no leaks using the electronic detector (see 62A, Air conditioning, Coolant circuit check, page 62A-8) .

WARNING After injecting dye into the refrigerant, be sure to indicate this on a label (supplied with the dye capsule), and the date of the operation. Position the label so it is visible near to the cold loop filler valve. a

Check that the air conditioning system is operating correctly (see 62A, Air conditioning, Air conditioning: Check, page 62A-5) .

62A-11

62A

AIR CONDITIONING Condenser: Removal - Refitting

62A

B95 or D95 or E95 or K95 - the front sections of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting ) (55A, Exterior protection),


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


Note: Use blanking plugs for the fuel circuits with part numbers 77 01 208 229 or 77 01 476 857 to plug any openings exposed to the open air. They must be clean. Do not use any which have already been used to plug a fuel circuit.



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



XENON BULBS a


a

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

62A-12


62A


135786

135784 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 - Refitting) (82A, Horn), - the left-hand headlight (see Front headlight: Removal - Refitting) (80B, Headlights),

135783

62A-13

- the side support of the left-hand front panel (see Front end panel side support: Removal - Refitting) (42A, Upper front structure).


62A



135670 135672 a

a

Disconnect the pressure sensor connector (4) .

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

WARNING In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe. a

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

a


62A-14


62A


135671 a

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

a

a

Remove the condenser in accordance with the direction of the arrow.

REFITTING


135674


Disconnect the « compressor - condenser » connecting pipe from the condenser.

a




WARNING To avoid any leaks, check that the seal and the pipe surface are in good condition. The seal and the surface must be clean and scratch free. a



Refit: - the condenser, - the connecting pipes to the condenser.

a

62A-15

Connect the pressure sensor connector.

AIR CONDITIONING Condenser: Removal - Refitting B95 or D95 or E95 or K95


Refit - the side support of the left-hand front panel (see Front end panel side support: Removal - Refitting ) (42A, Upper front structure), - the left-hand headlight (see Front headlight: Removal - Refitting) (80B, Headlights), - the audible warning (see Horn: Removal - Refitting ) (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 (see Front wheel arch liner: Removal - Refitting ) (55A, Exterior protection), - the front wheels (see Wheel: Removal - Refitting ) (35A, Wheels and tyres).

XENON BULBS a

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

a

Note: A summary table gives the quantities of refrigerant in the system according to the engine types (see 62A , Air conditioning, Air conditioning: Parts and consumables for the repair work , page 62A-4) . a

Fill up the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning, Coolant circuit Draining - Refilling, page 62A-9) .

a

Check for leaks (see 62A , Air conditioning, Coolant circuit check , page 62A-8) .

a

Check the air conditioning system is operating correctly (see 62 A , Air conditioning, Air conditioning: Check, page 62A-5) .

a

Adjust the headlights (see Front headlight: Adjusting) (80B, Headlights).

62A-16

62A

AIR CONDITIONING Condenser: Removal - Refitting J95





REMOVAL a




a

Remove: - the front wheels (see Wheel: Removal - Refitting ) (35A, Wheels and tyres), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting ) (55A, Exterior protection), - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection).

62A-17

62A


62A

J95

138677

138678 a

Unclip: - the central deflector (1) , - the left-hand side deflector (2) , - the right-hand side deflector (3 ) .

OPERATION FOR REMOVAL OF PART CONCERNED

138679

135672 a

62A-18



62A

J95

135670 a

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

138725 a


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


a

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

a

Disconnect the « compressor - condenser » connecting pipe from the condenser.

a


a


62A-19


62A

J95


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 section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting ) (55A, Exterior protection), - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres). Note: A summary table gives the quantity of refrigerant in the system according to the engine type (see 62A , Air conditioning, Air conditioning: Parts and consumables for the repair work , page 62A-4 ) .

138671 a

Remove the condenser in the direction of the arrows.

REFITTING

a

- refill the refrigerant circuit using the refrigerant charging station (see 62A , Air conditioning, Coolant circuit Draining - Refilling, page 62A-9) ,



- check for leaks (see 62A, Air conditioning, Coolant circuit check , page 62A-8) . a





Refit: - the condenser, - the connecting pipe on the condenser.

a



62A-20

Check the air conditioning system is operating correctly (see 62 A , Air conditioning, Air conditioning: Check , page 62A-5) .

AIR CONDITIONING Compressor: Removal - Refitting

62A

B95 or D95 or E95 or K95 a

Essential equipment

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

refrigerant charging station

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

IMPORTANT

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

To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair:

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

- (see 62A , Air conditioning, Air conditioning: Precautions for repair , page 62A-3) ,

- the front bumper supports (see Front bumper support: Removal - Refitting ) (42A, Front upper structure),

- (see Vehicle: Precautions for repair) (01D, Mechanical introduction).

- the audible warning (see Horn: Removal - Refitting) (82B, Horn), - the front impact cross member (see Front impact cross member: Removal - Refitting ) (41A, Front lower structure),


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

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


a


Remove:




a


62A-21

Remove the accessories belt (see Accessories belt: Removal - Refitting ) (11A, Top and front of engine).


62A


135882 a

Remove the bolts (1) from the engine wiring channel.

135296 a

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

a

Tilt the front end panel slightly towards the front of the vehicle.

F4R or F9Q or K9K or M9R a

135719 a

Remove: - the upper bolts (2) from the front end panel, - the front end panel clips (3) .

62A-22

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


62A


F4R

136473 a

135700 a

a

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

Remove the connecting pipe bracket bolts (6) on the compressor.


Uncouple the connecting pipes from the compressor.

a

Move aside the compressor connecting pipes.

a

Fit blanking plugs on the openings of the connecting pipes and the compressor.

62A-23


62A



142163 136473 a

Disconnect the compressor connector (7) .

a

Remove the bolts (8) from the compressor.

M4R

a

Remove the bolts (10) from the compressor.

a

Move aside the wiring.

a

Remove the compressor.


WARNING Do not remove the blanking plugs from each component until the last moment. Also, do not remove the components from their packaging until they are to be fitted to the vehicle.


142162 a

Disconnect the compressor connectors (9) . a


a

Check the condition of the seals on the refrigerant connecting pipes.

62A-24


62A



Refit the compressor.

a

Connect the compressor connector.

- the accessories belt (see Accessories belt: Removal - Refitting) (11A, Top and front of engine), - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting ) (55A, Exterior protection),

M4R a

Connect the compressor connectors.

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

a

Fit the wiring.



Note:

Refit the connecting pipes to the compressor.

A summary table gives the quantities of refrigerant in the system according to the engine types (see 62A , Air conditioning, Air conditioning: Parts and consumables for the repair work , page 62A-4 ) .

F4R a

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

a


a

In the event of replacement, apply the after repair procedure:

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

- Switch on the ignition, F4R or F9Q or K9K or M9R a

- Check that the air conditioning is off,

Refit the intercooler air outlet pipe (see Intercooler air outlet pipe: Removal - Refitting ) (12B, Turbocharging).

- Switch the ventilation to speed 2, - Put the temperature setting at minimum, - Select the air recirculation position,

a

Fit the front end panel.

a

Refit the engine wiring channel.

a

Refit:

- Start the engine. - Run the air conditioning in manual mode (in the case of climate control do not press auto),

- the bonnet catch (see Bonnet latch: Removal Refitting) (52A, Non-side opening element mechanisms), - the front impact cross member (see Front impact cross member: Removal - Refitting ) (41A, Front lower structure), - the front bumper supports (see Front bumper support: Removal - Refitting ) (42A, Front upper structure), - the headlights (see Front headlight: Removal Refitting) (80B, Headlights), - the audible warning (see Horn: Removal - Refitting ) (82B, Horn),

- Run the engine at idle speed for 3 minutes with air conditioning, - Switch off the engine. a

Check for leaks (see 62A , Air conditioning , Coolant circuit check , page 62A-8) .

a


a


a

Adjust the headlights (see Front headlight: Adjusting ) (80B, Headlights).

62A-25


62A

J95 - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting ) (55A, Exterior protection),




- the audible warning (see Horn: Removal - Refitting) (82B, Horn), - the front impact cross member (see Front impact cross member: Removal - Refitting ) (41A, Front lower structure), - the cooling radiator air deflectors,


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

Note: Use blanking plugs for the fuel circuits with part numbers 77 01 208 229 or 77 01 476 857 to plug any openings exposed to the ope n air. They must be clean. Do not use any which have been used to plug a fuel circuit.



a

Remove the front engine cover. 138656


a

- the bonnet supports (1) ,

a


a


a

Remove:

Remove:

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

F9Q or H4J or K9K or M9R a

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

62A-26



62A

J95

K9K

M9R

135883 a

Unclip the expansion bottle top hose (2) from the front end panel.

138488 a

Remove the rigid cooling hose bolts ( 4) on the front end panel.

140184 a

138486 a

Unclip the bonnet cable at (3) .

a

Remove the bonnet cable.

62A-27

Unclip the degassing hose from the front end panel at ( 5) .


62A

J95

H4J

139053 a

138363 a

Remove the bolt (6) from the front end panel windscreen washer reservoir.

140184 a

Unclip the degassing hose from the front end panel at (7) .

a

Unclip the remaining wiring from the front end panel.

62A-28

Remove: - the bolts (8 ) of the engine wiring channel, - the bonnet catch (see Bonnet latch: Removal Refitting) (52A, Non-side opening element mechanisms).


62A

J95

139052

136473 a

Remove the connecting pipe bracket bolts (10 ) .


Move aside the compressor connecting pipes.

a


135646 a

Remove the front end panel bolts (9) .

a

Tilt the front end panel.

62A-29


62A

J95


M4R or M9R

138724 a

Disconnect the compressor connector (11) .

a

Unclip the compressor wiring at (12) .

138724 a

Remove: - the compressor bolts (14) , - the compressor.


WARNING Do not remove the blanking plugs from each component until the last moment. Also, do not remove the components from their packaging until they are to be fitted to the vehicle. 136473 a

Remove:


- the compressor bolts (13) , - the compressor. a

62A-30



62A

J95


a

Refit:

a

Refit the compressor.

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

a

Connect the compressor connector.

- the bonnet supports,

a

Clip on the compressor wiring.

- the headlights (see Front headlight: Removal Refitting) (80B, Headlights), - the cooling radiator air deflectors,


Refit the connecting pipes to the compressor.

a


a

Refit:

- the front impact cross member (see Front impact cross member: Removal - Refitting ) (41A, Front lower structure), - the audible warning (see Horn: Removal - Refitting) (82B, Horn),

- the engine wiring channel,


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


H4J a

Clip the degassing hose onto the front end panel.

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

a

Refit the windscreen washer bottle bolt.

- the engine undertray. a

M9R a

Refit the rigid cooling hose on the front end panel.

a

Clip the degassing hose onto the front end panel.

Note: A summary table gives the quantities of refrigerant in the system according to the engine types (see 62A , Air conditioning, Air conditioning: Parts and consumables for the repair work , page 62A-4 ) . a


a

In the event of replacement, apply the after repair procedure:

K9K a


Clip the expansion bottle top hose on the front end panel.

- Switch on the ignition, a

- Check that the air conditioning is off,

Clip:

- Switch the ventilation to speed 2,

- the bonnet cable on the front end panel,

- Put the temperature setting at minimum,

- the wiring on the front end panel.

- Select the air recirculation position, - Start the engine.



- Run the air conditioning in manual mode (in the case of climate control do not press auto), - Run the engine at idle speed for 3 minutes with air conditioning, - Switch off the engine.

62A-31

AIR CONDITIONING Compressor: Removal - Refitting J95 a


a


a


a


62A-32

62A

AIR CONDITIONING Expansion valve: Removal - Refitting

62A

B95 or D95 or E95 or K95, and F9Q or K4M or K9K or M4R or M9R - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment).


F9Q a


Remove: - the battery (see Battery : Removal - Refitting) (80A, Battery), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting ) (12B, Turbocharging).


Note: Use blanking plugs for the fuel circuits with part numbers 77 01 208 229 or 77 01 476 857 to plug any openings exposed to the ope n air. They must be clean. Do not use any which have already been used to plug a fuel circuit.




a

a


a


a

Remove: - the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting ) (85A, Wiping Washing), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment),

62A-33

Remove the nut ( 1) of the retaining bracket (2 ) from the « intermediate pipe - expansion valve » connecting pipe.


62A

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

136467 a

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


136487 a



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



a


a

Fit the blanking plugs on the openings of the connecting pipes and on the expansion valve.

62A-34


62A

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



Refit the connecting pipes on the expansion valve.

a


a

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

F9Q a

Refit: - the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting ) (12B, Turbocharging), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the battery (see Battery : Removal - Refitting) (80A, Battery).

136465 a

Remove:

a

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

- the bolts (5 ) from the expansion valve, - the expansion valve.

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

REFITTING

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


a


a


A summary table gives the quantities of refrigerant in the system according to the engine types (see 62A , Air conditioning, Air conditioning: Parts and consumables for the repair work, page 62A-4 ) . a


a


a


a



Refit the expansion valve.

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



Refit:

62A-35


62A

B95 or D95 or E95 or K95, and F4R a

Essential equipment

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




- the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment), - the lifting eye of the cylinder head, - the turbocharger heat shield nuts.




Note:

- the turbocharger heat shield,

Use blanking plugs for the fuel circuits with part numbers 77 01 208 229 or 77 01 476 857 to plug any openings exposed to the open air. They must be clean. Do not use any which have already been used to plug a fuel circuit.

- the bulkhead upper heat shield bolts, - the bulkhead upper heat shield clips.



Remove:

Any damaged heat shields must be replaced.


a



a


62A-36



62A

B95 or D95 or E95 or K95, and F4R


136487 a


136465 a


Remove: - the bolts (2 ) from the expansion valve, - the expansion valve.

a


a


a







62A-37


AIR CONDITIONING Expansion valve: Removal - Refitting B95 or D95 or E95 or K95, and F4R



a

Refit: - the turbocharger heat shield, - the lifting eye of the cylinder head, - the bulkhead upper heat shield, - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting ) (85A, Wiping Washing).

a

Connect the battery (see Battery : Removal - Refitting) (80A, Battery). Note: A summary table gives the quantities of refrigerant in the system according to the engine types (see 62A , Air conditioning, Air conditioning: Parts and consumables for the repair work , page 62A-4) .

a


a


a


a


62A-38

62A


62A

J95 a

Essential equipment

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


- the scoop under the centre section of the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment).

Tightening torques m turbocharger air inlet pipe bolts

8 N.m


6 N.m

a


a


F9Q




137477 a


REMOVAL

- the lifting eye of the cylinder head.





a


62A-39


62A

J95

M9R

K9K

139563 a


a

Remove:

139155 a


- the bolts (3 ) from the cylinder head lifting eye, - the lifting eye of the cylinder head.

139154 a


62A-40


62A

J95

F9Q

135640 a


a


a

Remove:

135638 a



135639 a


62A-41


62A

J95

M9R

K9K a


139564 a


138672 a

139567 a


62A-42

Remove the nut (11) from the retaining bracket on the « intermediate pipe - expansion valve » connecting pipe.


62A

J95

H4J

139617 a


139616 a


- the bulkhead upper heat shield bolts (13) , - the bulkhead upper heat shield clips (14) .



Remove:



62A-43



62A

J95


136487 a


136465 a


Remove: - the bolts (16) from the expansion valve, - the expansion valve.

a


REFITTING

a



a


a





62A-44



62A

J95



a


F9Q a


H4J a

- the intermediate air pipe between the air filter unit and the turbocharger on the turbocharger air inlet pipe,


- the bolts from the turbocharger air inlet pipe, a

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

- the bolt from the intermediate air pipe between the air filter unit and the turbocharger on the turbocharger air inlet pipe, - the bolt for the intermediate air pipe between the air filter unit and the turbocharger on the exhaust gas recirculation assembly.

K9K a

Refit the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting ) (12B, Turbocharging).

a


M9R a

M9R


a

Refit: - the lifting eye of the cylinder head,


- the bolts on the cylinder head lifting eye. a

Clip the wiring on the cylinder head lifting eye.

K9K a

Refit: F9Q

- the turbocharger air inlet pipe, - the turbocharger air inlet pipe bolts.

a


a


a


a

Refit: - the scoop under the centre section of the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment), - the centre section of the scuttle panel grille (see Scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment).

62A-45

AIR CONDITIONING Expansion valve: Removal - Refitting J95 a


a

Perform the following operations: - refill the refrigerant circuit using the refrigerant charging station (see 62A , Air conditioning, Coolant circuit Draining - Refilling, page 62A-9 ) , - check for leaks (see 62A, Air conditioning, Coolant circuit check , page 62A-8) .

a


a


62A-46

62A

AIR CONDITIONING Evaporator: Cleaning LEFT-HAND DRIVE


CLEANING a

Remove the cabin filter (see 61A , Heating, Cabin filter: Removal - Refitting, page 61A-19 ) .

a

Apply the AIR CONDITIONING CLEANER (see Vehicle: Parts and ingredients for the repairwork ) (04B, Consumables - Products).

a

Leave the product to work for 15 minutes.

a

Refit the cabin filter (see 61A, Heating, Cabin filter: Removal - Refitting, page 61A-19) .

a

Activate the low speed motor-driven fan assembly for 5 min.

62A-47

62A

AIR CONDITIONING Evaporator: Cleaning RIGHT-HAND DRIVE


CLEANING a

Remove the evaporator sensor (see 62A, Air conditioning, Evaporator sensor: Removal - Refitting , page 62A-79 ) .

a

Apply the AIR CONDITIONING CLEANER (see Vehicle: Parts and ingredients for the repairwork ) (04B, Consumables - Products).

a

Leave the product to work for 15 minutes.

a

Refit the evaporator sensor (see 62A, Air conditioning, Evaporator sensor: Removal - Refitting , page 62A-79 ) .

a

Activate the low speed motor-driven fan assembly for 5 min.

62A-48

62A

AIR CONDITIONING Expansion valve - condenser connecting pipe: Removal - Refitting

62A

B95 or D95 or E95 or K95 - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection),

Essential equipment

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


- the front panel support,


- the windscreen washer bottle (see Windscreen washer bottle: Removal - Refitting ) (85A, Wiping - Washing) - the windscreen wiper arms (see Windscreen wiper 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 Scoop under scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment).

Note: F9Q


a

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

REMOVAL

- the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting ) (12B, Turbocharging).



a

Remove the engine cover.


Remove:

F9Q or K4M or K9K or M4R or M9R a


a


a

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




62A-49



62A


F4R a

Remove: - the lifting eye of the cylinder head, - the turbocharger heat shield nuts.


Remove: - the turbocharger heat shield, - the bulkhead upper heat shield bolts, - the bulkhead upper heat shield clips.

135297


a

Remove the bolt (2 ) from the front right-hand side member tie rod.

a

Move the front right-hand side member tie rod towards the wheel arch.




136481 135303 a

a

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

62A-50

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


62A


136475 a

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

136484 a

136479 a

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

62A-51

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

AIR CONDITIONING Expansion valve - condenser connecting pipe: Removal - Refitting B95 or D95 or E95 or K95

136469

136485 a

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

62A-52

62A


62A

B95 or D95 or E95 or K95 a

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

a

Fit blanking plugs on: - the condenser, - the expansion valve, - the « condenser - expansion valve » connecting pipe.


136487





135670 a

Remove:

a

Refit the « condenser - expansion valve » connecting pipe.

a

Clip the « condenser - expansion valve » connecting pipe onto the front right-hand side member and onto the bulkhead.

- 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.



Fit the side member tie rod.

F4R a

Remove the « condenser - expansion valve » connecting pipe.

62A-53

Refit: - the bulkhead upper heat shield, - the turbocharger heat shield,


62A

B95 or D95 or E95 or K95 - the lifting eye of the cylinder head.

a

Connect the battery (see Battery : Removal - Refitting ) (80A, Battery). Note: A summary table gives the quantities of refrigerant in the system according to the engine types (see 62A , Air conditioning, Air conditioning: Parts and consumables for the repair work , page 62A-4 ) .

F9Q or K4M or K9K or M4R or M9R a


a


a


- the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting ) (12B, Turbocharging),

a


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

a


a

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

F9Q a

Refit:

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

a

Refit: - the windscreen washer bottle (see Windscreen washer bottle: Removal - Refitting ) (85A, Wiping - Washing) - the front panel support, - the right-hand headlight (see Front headlight: Removal - Refitting) (80B, Headlights), - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting ) (55A, Exterior protection), - the front wheels (see Wheel: Removal - Refitting ) (35A, Wheels and tyres). - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting ) (85A, Wiping Washing),

62A-54


62A

J95 a


a


a

Remove:


Tightening torques m subframe front bolt

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

105 N.m

turbocharger air inlet pipe bolts

8 N.m


6 N.m

- the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting ) (55A, Exterior protection), - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the windscreen washer bottle (see Windscreen washer bottle: Removal - Refitting ) (85A, Wiping - Washing),


- the centre section of the scuttle panel grille (see Scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment), - the scoop under the centre section of the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment).


a


a





a



62A-55


62A

J95

F9Q

M9R

137477 a

Remove:

139563 a

Unclip the wiring ( 2 ) from the cylinder head lifting eye.

a

Remove:



62A-56


62A

J95

K9K

F9Q

135638

139155 a


a

139154 a

Remove:

Remove the bolt ( 6) from the intermediate air pipe between the air filter unit and the turbocharger on the exhaust gas recirculation assembly.

135639 a

- the bolts (5 ) from the turbocharger air inlet pipe, - the turbocharger air inlet pipe.

62A-57

Loosen the bolt (7 ) of the intermediate air pipe between the air filter unit and the turbocharger on the turbocharger air inlet pipe.


62A

J95

M9R

135640 a


a


a

Remove:

139564 a



139567 a


62A-58


62A

J95

F9Q or K9K or M9R a

H4J

Remove the fuel filter (see Fuel filter: Removal Refitting) (13A, Fuel supply).

F9Q a

Remove the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting) (12B, Turbocharging).

139616 a

Remove: - the bolts (12) from the upper heat shield, - the clips (13) from the upper heat shield.

WARNING To prevent the surrounding components from overheating, do not damage (tear, pierce, bend, etc.) a heat shield. Any damaged heat shields must be replaced. 139617 a

a




62A-59

Remove the upper heat shield.


62A

J95


135303 a

Loosen the subframe front right-hand bolt at (14) .

136484 a

Remove the « condenser - expansion valve » connecting pipe mounting bolt (16) from the windscreen washer reservoir mounting.

135297 a

Remove the bolt (15) from the front right-hand side member tie rod.

a

Move the front right-hand side member tie rod towards the wheel arch.

136475 a

62A-60

Remove the plastic nut (17 ) from the support for the « condenser - expansion valve » connecting pipe on the front right-hand side member.


62A

J95

136479 a

139618

Remove the bolt (18) securing the « condenser - expansion valve » connecting pipe to the front panel.

136485 a

62A-61

Unclip the « condenser - expansion valve » connecting pipe on the front right-hand side member (19) and on the bulkhead at (20) .


62A

J95 - the « condenser - expansion valve » connecting pipe from the expansion valve, - the « condenser - expansion valve » connecting pipe from the condenser. a

Remove the « condenser - expansion valve » connecting pipe.

a

Fit blanking plugs on: - the condenser, - the expansion valve, - the « condenser - expansion valve » connecting pipe.

REFITTING

136487




135670 a

Remove: -the bolt (21) for the « condenser - expansion valve » connecting pipe bracket on the expansion valve,



Refit the « condenser - expansion valve » connecting pipe.

a

Clip the « condenser - expansion valve » connecting pipe on the front right-hand side member and on the bulkhead.

-the bolt (22) for the « condenser - expansion valve » connecting pipe bracket on the condenser.

III - FINAL OPERATION WARNING In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe. a

Disconnect:

a

Fit the side member tie rod.

a

Torque tighten the subframe front bolt (105 N.m) .

a


62A-62


62A

J95

H4J a

F9Q

Refit the upper heat shield.

a

Refit: - the turbocharger air inlet pipe, - the intermediate air pipe between the air filter unit and the turbocharger on the turbocharger air inlet pipe,

F9Q or K9K or M9R a

Refit the fuel filter (see Fuel filter: Removal - Refitting) (13A, Fuel supply).

- the bolts from the turbocharger air inlet pipe, - the bolt from the intermediate air pipe between the air filter unit and the turbocharger on the turbocharger air inlet pipe, - the bolt for the intermediate air pipe between the air filter unit and the turbocharger on the exhaust gas recirculation assembly.

K9K a

Refit the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting ) (12B, Turbocharging).

a

M9R a

Refit:


M9R a




- the bolts on the cylinder head lifting eye. a


K9K a

Refit: F9Q

- the turbocharger air inlet pipe, - the turbocharger air inlet pipe bolts.

a


a


a


a

Refit: - the windscreen washer bottle (see Windscreen washer bottle: Removal - Refitting ) (85A, Wiping - Washing), - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection),

62A-63

AIR CONDITIONING Expansion valve - condenser connecting pipe: Removal - Refitting J95 - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting ) (55A, Exterior protection), - the front wheels (see Wheel: Removal - Refitting ) (35A, Wheels and tyres), - the scoop under the centre section of the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment), - the centre section of the scuttle panel grille (see Scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment). a


a


a


a


62A-64

62A

AIR CONDITIONING Expansion valve - intermediate pipe connecting pipe at the expansion valve outlet: Removal - Refitting

62A

B95 or D95 or E95 or K95 - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment).


F9Q a


Remove: - the battery (see Battery : Removal - Refitting) (80A, Battery), - the battery tray (see Battery tray: Removal - Refitting) (80A, Battery), - the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting ) (12B, Turbocharging).

WARNING To prevent moisture from entering the system, place plugs on the cold loop components which are open to the air. F9Q or K4M or K9K or M4R or M9R a


Note:






a




a


a

Remove: - the windscreen wiper arms (see Windscreen wiper arm: Removal - Refitting ) (85A, Wiping Washing), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment),

62A-65



62A


F4R a


Remove: - the lifting eye of the cylinder head, - the turbocharger heat shield nuts.


Remove: - the turbocharger heat shield, - the bulkhead upper heat shield bolts, - the bulkhead upper heat shield clips.


136471 a

Remove the nut ( 1) from the retaining bracket (2) of the « expansion valve - intermediate pipe » connecting pipe.



136490 a

62A-66

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


62A


F4R

136492 a

134713 a

Remove the nut (4) securing the « expansion valve intermediate pipe » connecting pipe on the bulkhead support.

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


Disconnect: - the « expansion valve - intermediate pipe » connecting pipe to the expansion valve, - the « expansion valve - intermediate pipe » connecting pipe from the intermediate connecting pipe.

a

Remove the « expansion valve - intermediate pipe » connecting pipe.

a


136487 a

Remove the bolt (5) from the « expansion valve - intermediate pipe » connecting pipe bracket on the expansion valve.

62A-67


62A


REFITTING

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


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

a


a

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




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



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

III - FINAL OPERATION F4R a

a


a


a


a


Refit: - the bulkhead upper heat shield, - the turbocharger heat shield, - the lifting eye of the cylinder head.

F9Q or K4M or K9K or M4R a


F9Q a

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


Refit:

Refit: - the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting ) (12B, Turbocharging),

62A-68


62A

J95 a


a

Remove:


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

Tightening torques m turbocharger air inlet pipe bolts

8 N.m


6 N.m

- the scoop under the centre section of the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment), - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting ) (55A, Exterior protection),


- the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the right-hand headlight (see Front headlight: Removal - Refitting) (80B, Headlights).


a


a


F9Q




a



a



62A-69

- the lifting eye of the cylinder head.


62A

J95

M9R

K9K

139563 a


a

Remove

139155 a

Remove the bolt (4 ) from the turbocharger air inlet pipe.


139154 a


62A-70


62A

J95

F9Q

135640 a


a


a

Remove:

135638 a



135639 a


62A-71


62A

J95

M9R

K9K a


139617

139564 a

Remove the bolt (9) from the turbocharger air inlet pipe.

a

Remove the clips ( 11) from the bulkhead heat shield.


139567 a


62A-72



62A

J95


H4J

139616 a

Remove: - the bulkhead upper heat shield bolts (12) , - the bulkhead upper heat shield clips (13) . 138672


a

Remove the nut (14) from the retaining bracket of the « expansion valve - intermediate pipe » connecting pipe.



139058 a

62A-73

Remove the bolt ( 15) from the retaining bracket of the « expansion valve - intermediate pipe » connecting pipe.


62A

J95

136487 a

Remove the bolt (16) from the « expansion valve intermediate pipe » connecting pipe bracket on the expansion valve.

138673 a

Remove the bolt (17) from the « expansion valve intermediate pipe » connecting pipe bracket on the intermediate connecting pipe.


Disconnect: - the « expansion valve - intermediate pipe » connecting pipe to the expansion valve, - the « expansion valve - intermediate pipe » connecting pipe from the intermediate connecting pipe.

a

Remove the « expansion valve - intermediate pipe » connecting pipe.

a


62A-74


62A

J95

REFITTING K9K


a

a





F9Q a

- the intermediate air pipe between the air filter unit and the turbocharger on the turbocharger air inlet pipe, - the bolts from the turbocharger air inlet pipe,


- the bolt from the intermediate air pipe between the air filter unit and the turbocharger on the turbocharger air inlet pipe,


- the bolt for the intermediate air pipe between the air filter unit and the turbocharger on the exhaust gas recirculation assembly.

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




H4J a



Refit:

M9R


a


a

K9K a


Refit the intercooler air inlet pipe (see Intercooler air inlet pipe: Removal - Refitting ) (12B, Turbocharging). F9Q a


M9R a

- the bolts on the cylinder head lifting eye.

Refit: - the turbocharger air inlet pipe, - the turbocharger air inlet pipe bolts.

a


a


62A-75


J95 a

Refit: - the scoop under the centre section of the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment), - the centre section of the scuttle panel grille (see Scuttle panel grille: Removal - Refitting ) (56A, Exterior equipment), - the right-hand headlight (see Front headlight: Removal - Refitting) (80B, Headlights), - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting ) (55A, Exterior protection), - the front wheels (see Wheel: Removal - Refitting ) (35A, Wheels and tyres).

a


a


a


a


62A-76

62A

AIR CONDITIONING Pressure sensor: Removal - Refitting

62A

Tightening torques m pressure sensor

9 N.m


Note: An automatic shut-off valve isolates the circuit from the outside during removal; do not drain the refrigerant from the circuit. 138677



a

Remove: - the front wheels (see Wheel: Removal - Refitting ) (35A, Wheels and tyres), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting ) (55A, Exterior protection), - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection).

138678 a

Unclip: - the central deflector (1) , - the right-hand side deflector (2 ) .

62A-77

AIR CONDITIONING Pressure sensor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED

135672 a


a

Remove the pressure sensor from the condenser.


Refit the pressure sensor.

a

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

a



Clip: - the right-hand side deflector, - the central deflector.

a

Refit: - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting ) (55A, Exterior protection), - the front wheels (see Wheel: Removal - Refitting ) (35A, Wheels and tyres).

62A-78

62A

AIR CONDITIONING Evaporator sensor: Removal - Refitting

62A




21 N.m


21 N.m


REMOVAL 137648


a

Remove:

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

- the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment), - the front left-hand footwell air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the lower bolts from the dashboard cross member reinforcement, - the upper bolts from the dashboard cross member reinforcement, - the dashboard cross member reinforcement.

137649 a

Take the evaporator sensor out of its housing.

a

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

62A-79

AIR CONDITIONING Evaporator sensor: Removal - Refitting B95 or D95 or E95 or K95, and LEFT-HAND DRIVE


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

a

Fit the evaporator sensor in its housing.

a

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


Refit: - the dashboard cross member stiffener, - the upper bolts of the dashboard cross member reinforcement, - the lower bolts of the dashboard cross member reinforcement.

a


a

Refit: - the front left-hand footwell air distribution duct (see 61A , Heating, A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment).

62A-80

62A


62A

RIGHT-HAND DRIVE



21 N.m


21 N.m


REMOVAL 137648



a


a

Unclip the evaporator sensor by turning it a quarter of a turn anti-clockwise.

a

Remove the evaporator sensor.

E95 a

Remove: - the lower bolts from the dashboard cross member reinforcement, - the upper bolts on the dashboard cross member reinforcement, - the dashboard cross member reinforcement.

137649 a

62A-81

Cut the wires of the evaporator sensor (see Wiring: Repair ) (Technical Note 6015A, 88A, Wiring).

AIR CONDITIONING Evaporator sensor: Removal - Refitting RIGHT-HAND DRIVE


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

a

Refit the evaporator sensor.

a


II - FINAL OPERATION E95 a

refit: - the dashboard cross member reinforcement, - the upper bolts on the dashboard cross member reinforcement, - the lower bolts on the dashboard cross member reinforcement.

a


a


a


62A-82

62A


62A


Tightening torques m upper nuts on the dashboard cross member reinforcement

21 N.m


21 N.m


REMOVAL

138640 a


a




a




138639 a

Remove: - the upper bolts (3) from the dashboard cross member reinforcement, - the brake pedal impacter (4 ) , - the dashboard cross member reinforcement.

62A-83


62A


REFITTING



Solder the wires of the evaporator temperature sensor (see Wiring: Repair) (Technical Note 6015A, 88A, Wiring).

a

Refit the evaporator sensor.

a



Refit: - the dashboard cross member reinforcement, - the brake pedal impacter.

a

Tighten to torque: - the upper nuts on the dashboard cross member reinforcement (21 N.m),

137648 a

- the lower bolts on the dashboard cross member reinforcement (21 N.m).

Unclip the evaporator sensor (5) by turning it a quarter of a turn anti-clockwise. a




a

Refit: - the front left-hand footwell air distribution duct (see 61A , Heating , A-pillar air distribution duct: Removal - Refitting, page 61A-142 ) , - the dashboard lower trim (see Lower section of dashboard trim: Removal - Refitting ) (57A, Interior equipment).

a

137649 a

Take the evaporator sensor out of its housing.

a

Cut the wires (6) of the evaporator sensor (see Wiring: Repair) (Technical Note 6015A, 88A, Wiring).

62A-84


AIR CONDITIONING Condenser - compressor connecting pipe: Removal - Refitting

62A

B95 or D95 or E95 or K95 - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection),

Essential equipment

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


- the front panel support,


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


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

- the headlights (see Front headlight: Removal Refitting) (80B, Headlights), - the front bumper supports (see Front bumper support: Removal - Refitting ) (42A, Front upper structure),

- the front impact cross member (see Front impact cross member: Removal - Refitting ) (41A, Front lower structure), - the bonnet catch (see Bonnet latch: Removal Refitting) (52A, Non-side opening element mechanisms).




a




a


a

Remove:

135882 a

- the front wheels (see Wheel: Removal - Refitting ) (35A, Wheels and tyres), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting ) (55A, Exterior protection),

62A-85

Remove the bolts (1 ) from the engine wiring channel.


62A



135719 a

Remove:

136481 a

- the upper bolts (2) from the front end panel, - the front end panel clips (3) .

136473

135296 a

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

a


a


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

a

62A-86

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


62A

B95 or D95 or E95 or K95 - of the « compressor - condenser » connecting pipe.

F4R a

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

a

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






135671 a


F4R a

Refit the mounting bolt of th e « compressor condenser » connecting pipe on the compressor.

a

Refit the mounting bolt of th e « compressor condenser » connecting pipe on the lower cross member.


Disconnect: - the « compressor - conden ser » connecting pipe from the compressor, - the « compressor - conden ser » connecting pipe on the condenser.

a

a

Refit the « compressor-condenser» connecting pipe.

Remove the « compressor - condenser » connecting pipe. Fit blanking plugs on the openings:



a


a

Refit the wiring channel for the engine cooling fan assembly.

a


- of the condenser, - of the compressor,

62A-87

AIR CONDITIONING Condenser - compressor connecting pipe: Removal - Refitting B95 or D95 or E95 or K95 a

Refit: - the bonnet catch (see Bonnet latch: Removal Refitting) (52A, Non-side opening element mechanisms), - the impact cross member (see Front impact cross member: Removal - Refitting ) (41A, Front lower structure), - the audible warning (see Horn: Removal - Refitting ) (82B, Horn), - the front bumper supports (see Front bumper support: Removal - Refitting ) (42A, Front upper structure), - the headlights (see Front headlight: Removal Refitting) (80B, Headlights). - the windscreen washer bottle (see Windscreen washer bottle: Removal - Refitting ) (85A, Wiping - Washing), - the front panel support, - the right-hand headlight (see Front headlight: Removal - Refitting) (80B, Headlights), - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting ) (55A, Exterior protection), - the front wheels (see Wheel: Removal - Refitting ) (35A, Wheels and tyres).

a


a


a


a


a


a


62A-88

62A


62A



- the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the audible warning (see Horn: Removal - Refitting) (82B, Horn),


- the front impact cross member (see Front impact cross member: Removal - Refitting ) (41A, Front lower structure), - the cooling radiator air deflectors, - the headlights (see Front headlight: Removal Refitting) (80B, Headlights).




a


138656 a


Remove the bonnet supports (1) .

F9Q or H4J or K9K or M9R


a

a


a


a

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

62A-89



62A

J95

K9K

M9R

135883 a


138488 a

Remove the rigid cooling hose bolts (4 ) from the front end panel.

140184 a

138486 a


a


62A-90

Unclip the degassing hose from the front end panel at ( 5) .


62A

J95

H4J

139053 a

138363 a


140184 a


a


62A-91



62A

J95


139052 136473 a

Remove the bolt ( 10) securing the bracket for the « compressor - condenser » connecting pipe to the compressor.

135646 a


a


136481 a

62A-92

Remove the « compressor - condenser » connecting pipe bolt ( 11) from the windscreen washer reservoir mounting.


62A

J95



WARNING To avoid any leaks, check that the seal and the pipe surface are in good condition. The seal and the surface must be clean and scratch free. 135671 a



a


Refit the « compressor-condenser» connecting pipe.

a

Connect:

Disconnect:

- the « compressor compressor - condenser condenser » connecting pipe on the compressor,

- the « compressor - conden ser » connecting pipe from the compressor,

- the « compressor compressor - condenser condenser » connecting pipe on the condenser.

- the « compressor - conden ser » connecting pipe on the condenser. a

Remove the « compressor - condenser » connecting pipe.

a

Fit blanking plugs on the openings of the « compressor - condenser co ndenser » connecting co nnecting pipe and the compressor.




a

Refit: - the engine engine wiring wiring channel, channel, - the bonnet bonnet catch catch (see Bonnet latch: Removal Refitting) (52A, Non-side opening element mechanisms).

H4J a

Clip the degassing hose on the front end panel.

a


62A-93


62A

J95 a

M9R


a

Refit the rigid cooling hose on the front end panel.

Note:

a



K9K a

a

Perform the following operations: - fill the refrigerant circuit using the refrigerant charging station (see 62A, Air conditioning conditioning, Coolant circuit Draining - Refilling , page 62A-9) ,

Clip the expansion bottle top hose on the front end panel.

- check check for leaks leaks (see 62A , Air conditioning, Coolant circuit check , page 62A-8) . a

Clip:

a


a


a

Adjust the headlights (see Front headlight: Adjusting ) (80B, Headlights).

- the bonnet cable cable on the front end panel, - the wiring on the front front end panel.



a

Refit: - the bonnet supports, supports, - the headlights headlights (see Front headlight: Removal Refitting) (80B, Headlights), - the cooling radiator radiator air deflectors, - the front impact impact cross member (see Front impact cross member: Removal - Refitting ) (41A, Front lower structure), - the audible warning warning (see Horn: Removal - Refitting ) (82B, Horn), - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the front section of the front wheel arch liners liners (see Front wheel arch liner: Removal - Refitting ) (55A, Exterior protection), - the front wheels wheels (see Wheel: Removal - Refitting ) (35A, Wheels and tyres), - the engine undertray undertray..

62A-94

AIR CONDITIONING Compressor/intermediate Compressor/intermediate pipe connecting pipe: Removal - Refitting

62A

B95 or D95 or E95 or K95 - the front front bumper bumper (see Front bumper: Removal Refitting) (55A, Exterior protection),

Essential equipment

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


- the front bumper bumper supports supports (see Front bumper support: Removal - Refitting ) (42A, Front upper structure),


- the audible audible warning warning (see Horn: Removal - Refitting) (82B, Horn), - the front impact impact cross member (see Front impact cross member: Removal - Refitting ) (41A, Front lower structure), - the bonnet bonnet catch catch (see Bonnet latch: Removal Refitting) (52A, Non-side opening element mechanisms).


Note: Use blanking plugs for the fuel circuits with part numbers 77 01 208 229 or 77 01 476 857 to plug any openings exposed ex posed to the ope n air. They must be clean. Do not use any which have already been used to plug a fuel circuit.



a


135882 a



a


a

Remove: - the front wheels wheels (see Wheel: Removal - Refitting ) (35A, Wheels and tyres), - the front section of the front wheel arch liners liners (see Front wheel arch liner: Removal - Refitting ) (55A, Exterior protection),

62A-95

Remove the bolts (1 ) from the engine wiring channel.


62A


F4R or F9Q or H4J or K9K or M9R a


II - OPERATION FOR REMOVAL OF PART CONCERNED F4R

135719 a

Remove: - the upper bolts (2) from the front end panel, - the front end end panel clips clips (3) .

135700 a

135296 a

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

a


62A-96

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


62A


136473 a

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

136492 a

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


Disconnect: - the « intermediate intermediate pipe - compressor » connecting pipe from the compressor, - the « intermediate intermediate pipe - compressor » connecting pipe from the intermediate pipe.

a

Remove the « intermediate pipe - compressor » connecting pipe.

a

Fit blanking plugs on the connecting pipe and on the compressor.

62A-97

AIR CONDITIONING Compressor/intermediate pipe connecting pipe: Removal - Refitting

62A


REFITTING

- the front bumper supports (see Front bumper support: Removal - Refitting ) (42A, Front upper structure),


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

a


- the headlights (see Front headlight: Removal Refitting) (80B, Headlights), - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection),


- the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting ) (55A, Exterior protection), - the front wheels (see Wheel: Removal - Refitting ) (35A, Wheels and tyres).



a

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

a



Note: A summary table gives the quantities of refrigerant in the system according to the engine types (see 62A , Air conditioning, Air conditioning: Parts and consumables for the repair work , page 62A-4 ) .

Refit the « intermediate pipe - compressor » connecting pipe.

F4R a

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


a


a


a


a


F4R or F9Q or H4J or K9K or M9R a


a


a


a

Refit: - the bonnet catch (see Bonnet latch: Removal Refitting) (52A, Non-side opening element mechanisms), - the front impact cross member (see Front impact cross member: Removal - Refitting ) (41A, Front lower structure),

62A-98


62A



- the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection), - the audible warning (see Horn: Removal - Refitting) (82B, Horn),


- the front impact cross member (see Front impact cross member: Removal - Refitting ) (41A, Front lower structure), - the cooling radiator air deflectors, - the headlights (see Front headlight: Removal Refitting) (80B, Headlights).


Note: Use blanking plugs for the fuel circuits with part numbers 77 01 208 229 or 77 01 476 857 to plug any openings exposed to the ope n air. They must be clean. Do not use any which have previously been used to plug a fuel circuit.


a


138656 a


Remove the bonnet supports (1) .

F9Q or H4J or K9K or M9R


a

a


a


a

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

62A-99



62A

J95

K9K

M9R

135883 a


138488 a

Remove the rigid cooling hose bolts (4 ) from the front end panel.

140184 a

138486 a


a


62A-100

Unclip the degassing hose ( 5 ) from the front end panel.


62A

J95

H4J

139053 a

138363 a


140184 a


a


62A-101



62A

J95


139052 136473 a

135646 a


a


62A-102

Remove the bolt ( 10) securing the « intermediate pipe - compressor » connecting pipe bracket to the compressor.


62A

J95



WARNING To avoid any leaks, check that the seal and the pipe surface are in good condition. The seal and the pipe surface must be clean and scratch free. 138673 a

Remove the bolt (11) securing the « intermediate pipe - compressor » connecting pipe bracket on the intermediate pipe.


a


Refit the « intermediate pip e - compressor » connecting pipe.

a

Connect: - the « intermediate pipe - compressor » connecting pipe on the compressor,

Disconnect: - the « intermediate pipe - compressor » connecting pipe from the compressor,

- the « intermediate pipe - compressor » connecting pipe on the « expansion valve - intermediate pipe » connecting pipe.

- the « intermediate pipe - compressor » connecting pipe from the « expansion valve - intermediate pipe » connecting pipe. a

Remove the « intermediate pipe - compressor » connecting pipe.

a





a

Refit: - the engine wiring channel, - the bonnet catch (see Bonnet latch: Removal Refitting) (52A, Non-side opening element mechanisms).

H4J a


a


62A-103

MR427MEGANE6.pdf

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