6

Air conditioning
61A

HEATING AIR CONDITIONING CLIMATE CONTROL MANUAL AIR CONDITIONING

62A

62B

62C

X84, and J84

77 11 322 082 JUNE 2003
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.

Edition Anglaise

"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."

Renault s.a.s. 2005

Scnic II - Section 6 ContentsPage

Scnic II - Section 6
Contents
Page

61A

HEATING General information Parts description Front air distribution duct: Removal - Retting Central air distribution duct: Removal - Retting Rear air distribution duct: Removal - Retting Control panel: Removal Retting Control panel: Connection Recirculation control cable: Removal - Retting Air distribution cable: Removal - Retting Air mixing cable: Removal Retting Air distribution unit: Removal - Retting Heater matrix: Removal Retting Fan assembly: Removal Retting Passenger compartment fan assembly control unit: Removal - Retting Heating resistor unit: Removal - Retting Heating resistor relays: Removal - Retting 61A-1 61A-2 61A-4 61A-6 61A-7 61A-10 61A-14 61A-15 61A-19 61A-23 61A-24 61A-25 61A-29

62A

AIR CONDITIONING General information Maintenance Parts description Consumables Safety advice Air conditioning: Check Coolant circuit check Cabin lter: Removal Retting Condenser: Removal Retting Dehydration canister: Removal - Retting Compressor: Removal Retting Calibrated opening: Removal - Retting Connection bracket Evaporator: Removal Retting Condenser - compressor connecting pipe: Removal Retting Condenser - evaporator connecting pipe: Removal Retting Dehydration canister evaporator connecting pipe: Removal - Retting 62A-1 62A-2 62A-4 62A-6 62A-7 62A-8 62A-10 62A-12 62A-13 62A-15 62A-16 62A-18 62A-19 62A-22

62A-24

61A-30 61A-31 61A-35

62A-25

62A-28

Contents

62A

AIR CONDITIONING Dehydration canister compressor connecting pipe: Removal - Retting Pressure sensor: Removal Retting

62A-30 62A-32

62B

CLIMATE CONTROL Operating principle Parts description Control panel: Removal Retting Control panel: Connection Power module: Removal Retting Recirculation motor: Removal - Retting Mixer motor: Removal Retting Distribution motor: Removal Retting Passenger compartment temperature sensor: Removal - Retting External temperature sensor: Removal - Retting Insolation sensor: Removal Retting 62B-1 62B-3 62B-4 62B-8 62B-10 62B-12 62B-13 62B-15

62B-17 62B-19 62B-21

62C

MANUAL AIR CONDITIONING Parts description Control panel: Removal Retting Control panel: Connection 62C-1 62C-2 62C-6

HEATING General information

61A

104758

Rear seat footwell heater vent (1) (2) (3) (4) (5) Side vents Side window demisting vents Windscreen demister outlets Central air vents Footwell heater outlet

104148

61A-1

HEATING Parts description

Air distribution ducts (1)

61A
Right rear footwell air duct Right intermediate duct Right front footwell air duct Left front footwell air duct Left intermediate duct Left rear footwell air duct

(2) (3) (4) (5) (6)

6 5
102222

Heating unit

11 13 12

8 9 10

107379

(10) (7) (8) (9) Passenger compartment lter Heating resistor unit Heater radiator (11)

Heater radiator pipe Power module

61A-2

HEATING Parts description

(12) (13) Distribution unit Engine cooling fan

61A

61A-3

HEATING Front air distribution duct: Removal - Refitting

DG

61A

REMOVAL

REFITTING
Proceed in the reverse order to removal.

1 2 3
104102

Remove the lower trim (see 57A Interior equipment ). Unclip at (1) . Disconnect the air duct at (2) then (3) .

5 4 6
104103

Remove the glovebox (see 57A Interior equipment ). Unclip at (4) . Disconnect the air duct at (5) then (6) .

61A-4

HEATING Front air distribution duct: Removal - Refitting

DD

61A

REMOVAL

REFITTING
Proceed in the reverse order to removal.

1 3 2
104394

Remove the lower trim (see 57A Interior equipment ). Unclip at (1) . Disconnect the air duct at (2) then (3) .

6
104393

Remove the glovebox (see 57A Interior equipment ). Unclip at (4) . Disconnect the air duct at (5) then (6) .

61A-5

HEATING Central air distribution duct: Removal - Refitting

61A

Equipment required diagnostic tool Operations are symmetrical for both sides of the vehicle.

REMOVAL

IMPORTANT Before carrying out any wok on a safety system component, lock the air bag computer using the (diagnostic tool) (see 88C, Air bag and pretensioner, Air bag computer locking procedure ). When this function is activated, all the trigger lines are inhibited and the air bag warning light on the instrument panel lights up continuously (ignition on). Disconnect the battery, starting with the negative terminal. Remove the front seat ( (see 75A, Front seat frames and runners) ). Remove: - the front air distribution duct (see 61A, Heating, Front air distribution duct: Removal - Refitting, page 61A-4) , - the carpet (partially).

104201

Extract the intermediate air distribution duct (2) from the rear air distribution duct (3) by tilting it towards the interior.

REFITTING
Proceed in the reverse order to removal. WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A Battery: removal - retting ).

104219

Remove the protector (1) .

61A-6

HEATING Rear air distribution duct: Removal - Refitting

61A

Equipment required diagnostic tool

REMOVAL

IMPORTANT Before carrying out any work on a safety system component, lock the air bag computer using the (diagnostic tool) (see 88C, Air bag and pretensioner, Air bag computer locking procedure ). When this function is activated, all the trigger lines are inhibited and the air bag warning light on the instrument panel lights up continuously (ignition on). Disconnect the battery, starting with the negative terminal.

104217

Unclip the retaining pin (1) (depending on the side being removed). Partially remove the front carpet.

104219

Unclip the side trim (2) .

104148

Note: An aerial is clipped on the driver's side trim (depending on equipment level).

Remove: - the driver and front passenger seats ( (see 75A, Front seat frames and runners) ), - the driver's and passenger front door sill lining (front section) ( (see 71A, Body interior trim) ), - the driver's and passenger front door sill lining (centre section) ( (see 71A, Body interior trim) ), - the driver's and passenger under-seat storage compartments ( (see 71A, Body interior trim) ).

61A-7

HEATING Rear air distribution duct: Removal - Refitting

61A

7 5

104209

104201

Unclip the front half-floor (3) .

Remove the attachment (5) . Lift the rear air distribution duct (6) . Extract the rear air distribution duct (6) from the intermediate air distribution duct (7) .

10

9 4 8
104221

Note: Depending on the equipment level, the ventilation ducts may mean the seat height adjuster has to be removed. Unclip the seat connector from the clip. Remove the mounting bolts (4) .
104200

Remove the attachment (8) . Lift the rear air distribution duct (9) . Extract the rear air distribution duct (9) from the intermediate air distribution duct (10) .

61A-8

HEATING Rear air distribution duct: Removal - Refitting

REFITTING
Proceed in the reverse order to removal. WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery: removal - retting ).

61A

IMPORTANT Unlock the air bag computer using the fault nding tool (see 88C, Air bag and pretensioners, Air bag computer locking procedure ).

61A-9

HEATING Control panel: Removal - Refitting

Special tooling required Ms. 1639 Ms. 1544 Ms. 1373 Tool for removing radio - CD player Tool for removing Carminat Becker radio Tool for removing radio or chronotachograph

61A

REMOVAL
Disconnect the battery starting with the negative terminal.

104031

Remove the spring (1) . Unclip the gear lever gaiter.

104030

Remove the gear lever knob.

104032

Unclip the upper trim from the gear lever. Disconnect the connector.

61A-10

HEATING Control panel: Removal - Refitting

61A

103603

Remove the clip using clip removal pliers (on both sides).

2
104034

Remove (depending on the equipment level): - the CD changer using tool (Ms. 1639) , - the radio-navigation unit using tool (Ms. 1544) , - the audio equipment using tool (Ms. 1373) . Disconnect the various connectors. Remove the two bolts (2) .

104033

Remove the three bolts. Unclip the gear lever trim.

61A-11

HEATING Control panel: Removal - Refitting

61A

104035

104036

Remove the two bolts (3) from the air conditioning control panel.

103811

Carefully unclip the centre plate (the mounting clips are shown in the diagram below). Disconnect the various connectors. Tilt the heating control panel. Remove the control panel by tilting it.

104659

Disconnect the connector (4) from the heating control panel.

61A-12

HEATING Control panel: Removal - Refitting

61A

6 5

102011

Remove the heater control panel cables. Disconnect at (5) . Withdraw the bracket (6) . Remove ball joint (7) .

REFITTING
To refit, proceed in the order of removal. WARNING - Do not damage the control cables during these operations. - Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).

Note: - The recirculation control cable is black. - The distribution control cable is white. - The mixing control cable is grey. - The heating control panel control cables do not need to be adjusted.

61A-13

HEATING Control panel: Connection

61A

A1

A6

B1

B9
102337

Control panel track A1 A2 A3 A4 A5 A6 B1 B2 B3 B4 B5 B6 B7 B8 B9

Allocation Earth Speed 1 control Speed 2 control Speed 3 control Speed 4 control Not used Fan assembly speed signal 0 + after ignition feed Electric heated rear screen activation request Electric heated rear screen warning light control Earth + after ignition feed + side lights feed

Actuator sensor track Resistor unit track 1 connector A Resistor unit track 2 connector A Resistor unit track 3 connector A Resistor unit track 4 connector A UCH UCH UCH UCH UCH Lighting dimmer

61A-14

HEATING Recirculation control cable: Removal - Refitting

DG

61A

Tightening torquesm casing reinforcement plate mounting bolts 2.1 daNm

REMOVAL
Disconnect the battery, starting with the negative terminal. Extract the heater control panel (see 61A, Heating, Control panel: Removal - Refitting, page 61A-10) . Remove the lower trim ( (see 57A, Interior accessories) ). Note: The air recirculation control cable is black.
104118

2 1

Unclip the electric wiring harness attached to the casing reinforcement plate. Remove the five casing reinforcement plate mounting bolts (4) .

102011

Remove the air recirculation cable (black) from the heater control panel. Disconnect at (1) . Take out the bracket (2) . Extract the ball joint (3) .

5 6 7
104102

Unclip at (5) . Remove the air duct at (6) then at (7) . Remove the brake pedal assembly (see 37A, Mechanical component controls ).

61A-15

HEATING Recirculation control cable: Removal - Refitting

DG

61A

9 8

10

12 11
104660 104672

Remove: - the two mounting bolts (8) , - the heater matrix pipes retaining bracket. Note: The retaining bracket has a ball joint on its upper section (9) : to remove it, pull at (1 0) , until it stops against the brake pedal mounting nut, then pull sharply downwards.

Unclip the sheath stop (11) then remove it. Extract the ball joint (12) . Remove the air recirculation control cable.

REFITTING
Proceed in the reverse order to removal. Torque tighten the casing reinforcement plate mounting bolts ( 2.1 daNm ) . WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery, removal - retting ).

Note: The cable does not need adjustment.

61A-16

HEATING Recirculation control cable: Removal - Refitting

DD

61A

REMOVAL
Disconnect the battery, starting with the negative terminal. Extract the heater control panel (see 61A, Heating, Control panel: Removal - Refitting, page 61A-10) . Remove the lower trim ( (see 57A, Interior accessories) ). Note: The air recirculation control cable is black.

2 1

3 6 4 5
104393

Unclip at (4) . Disconnect the air duct at (5) then (6) . Remove the brake pedal assembly (see 37A, Mechanical components control ).

102011

Remove the air recirculation cable (black) from the heater control panel. Disconnect at (1) . Take out the bracket (2) . Extract the ball joint (3) .

61A-17

HEATING Recirculation control cable: Removal - Refitting

DD

61A

9 12 11
104660 104672

Remove: - the two mounting bolts (7) , - the heater matrix pipes retaining bracket. Note: The retaining bracket has a ball joint on its upper section (8) : to remove it, pull at (9) , until it stops against the brake pedal mounting nut, then pull sharply downwards.

Unclip the sheath stop (11) then remove it. Extract the ball joint (12) . Remove the air recirculation control cable.

REFITTING
Proceed in the reverse order to removal. WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery: removal - retting ).

Note: The cable does not need adjustment.

61A-18

HEATING Air distribution cable: Removal - Refitting

DG

61A

Tightening torquesm casing reinforcement plate mounting bolts 2.1 daNm

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove the heater control panel (see 61A, Heating, Control panel: Removal - Refitting, page 61A-10) . Remove the lower trim ( (see 57A, Interior accessories) ). Note: The air distribution control cable is white.
104118

2 1

Unclip the electric wiring harness attached to the casing reinforcement plate. Remove the five casing reinforcement plate mounting bolts (4) .

102011

Remove the air distribution cable (white) from the heater control panel. Disconnect at (1) . Take out the bracket (2) . Extract the ball joint (3) .

5 6 7
104102

Unclip at (5) . Disconnect the air duct at (6) then (7) .

61A-19

HEATING Air distribution cable: Removal - Refitting

DG

61A

8 9

104673

Unclip the sheath stop (8) , then extract it. Extract the ball joint (9) . Remove the air distribution control cable.

REFITTING
Proceed in the reverse order to removal. Torque tighten the casing reinforcement plate mounting bolts ( 2.1 daNm ) . WARNING Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).

Note: The cable does not need adjustment.

61A-20

HEATING Air distribution cable: Removal - Refitting

DD

61A

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove the heater control panel (see 61A, Heating, Control panel: Removal - Refitting, page 61A-10) . Remove the lower trim ( (see 57A, Interior accessories) ). Note: The air distribution control cable is white.

2 1

3 6 4

104393

Unclip at (4) . Disconnect the air duct at (5) then (6) .

102011

Remove the air distribution cable (white) from the heater control panel. Disconnect at (1) . Take out the bracket (2) . Extract the ball joint (3) .

7 8

104673

Unclip the sheath stop (7) , then remove it. Extract the ball joint (8) . Remove the distribution control cable.

61A-21

HEATING Air distribution cable: Removal - Refitting

DD

61A

REFITTING
Proceed in the reverse order to removal. WARNING Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).

Note: The cable does not need adjustment.

61A-22

HEATING Air mixing cable: Removal - Refitting

REMOVAL
Extract the heater control panel (see 61A, Heating, Control panel: Removal - Refitting, page 61A-10) . Remove: - the lower trim (left-hand drive) ( (see 57A, Interior accessories) ), - the glovebox (right-hand drive) ( (see 57A, Interior accessories) ;). Note: The air mixing control cable is grey.

61A

2 1

104661

Unclip the sheath stop (4) then rotate it to remove it. Extract the ball joint (5) . Remove the mixing control cable.

REFITTING
Proceed in the reverse order to removal.
102011

Remove the (grey) cable from the heater control panel. Disconnect at (1) . Take out the bracket (2) . Extract the ball joint (3) .

Note: The cable does not need adjustment.

61A-23

HEATING Air distribution unit: Removal - Refitting

REFITTING
Equipment required diagnostic tool IMPORTANT IMPORTANT Before doing any work on safety system components, lock the airbag computer using the (diagnostic tool) ( (see 88C, Airbag and Pretensioners) ). When this function is activated all the trigger lines are inhibited and the airbag warning light on the instrument panel lights up continuously (ignition on).

61A

To refit, proceed in the reverse order of removal.

Unlock the computer using the (diagnostic tool) ( (see 88C, Airbag and Pretensioners) ).

WARNING Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).

REMOVAL

104115

Remove: - the dashboard ( (see 57A, Interior accessories) ), - the passenger compartment reinforcement cross member ( (see 42A, Upper front structure) ), - the air distribution unit.

61A-24

HEATING Heater matrix: Removal - Refitting

DG Special tooling required Ms. 554-07 Cooling system tester kit (complete)

61A

Tightening torquesm dashboard cross member reinforcement plate mounting bolts 2.1 daNm

REMOVAL
Fit a hose clamp on each water hose at the bulkhead in the engine compartment.

2 3 4
104102

Unclip at (2) . Disconnect the air duct at (3) then at (4) .

1
104028

Remove the lower trim (1) ( (see 57A, Interior accessories) ).

104118

Remove: - the five mounting bolts (5) , - the dashboard cross member reinforcement plate.

61A-25

HEATING Heater matrix: Removal - Refitting

DG

61A

104110

104109

Remove: - the heater radiator pipe clamp bolts (6) , - the heater radiator - air distribution unit mounting bolts (7) . Note: Unlock the clamp (8) , then lift it to take it out of the heating unit.

Put a protective cover on the carpet. Remove the two heater radiator jubilee clip bolts (9) . Put a container in place to collect the coolant. Remove: - the heater radiator and its pipes, - the heater radiator jubilee clips. Remove: - the heater radiator pipes by pulling them towards the front of the vehicle, - the heater radiator.

REFITTING
Be sure to replace the radiator seals. Proceed in the reverse order to removal. Torque tighten the dashboard cross member reinforcement plate mounting bolts ( 2.1 daNm ) . Perform the following operations: - fill up, - bleed the cooling circuit (see 19A, Cooling ). Check the sealing using tool (Ms. 554-07) .

61A-26

HEATING Heater matrix: Removal - Refitting

DD Special tooling required Ms. 554-07 Cooling system tester kit (complete)

61A

Tightening torquesm dashboard cross member reinforcement plate mounting bolts 2.1 daNm

REMOVAL
Fit a hose clamp on each water hose at the bulkhead in the engine compartment. Remove the glovebox ( (see 57A, Interior accessories) ).
104118

Remove: - the five mounting bolts (4) , - the dashboard cross member reinforcement plate.

3
104393

Unclip at (1) . Disconnect the air duct at (2) then at (3) .

61A-27

HEATING Heater matrix: Removal - Refitting

DD Perform the following operations: - fill up,

61A

- bleed the cooling circuit (see 19A, Cooling ). Check the sealing using tool (Ms. 554-07) .

7 6
104660

Put a protective cover on the carpet. Remove: - the heater radiator pipe clamp bolts (5) , - the heater radiator - air conditioning unit mounting bolts (6) , - the two heater radiator jubilee clip bolts (7) .

Note: Unlock the clamp (8) , then lift it to take it out of the heating unit. Put a container in place to collect the coolant. Remove: - the heater radiator and its pipes, - the heater radiator jubilee clips. Remove: - the heater radiator ducts by pulling them towards the front of the vehicle, - the heater radiator.

REFITTING
Be sure to replace the radiator seals. Proceed in the reverse order to removal. Torque tighten the dashboard cross member reinforcement plate mounting bolts ( 2.1 daNm ) .

61A-28

HEATING Fan assembly: Removal - Refitting

REMOVAL
Disconnect the battery starting with the negative terminal. Remove the dashboard ( (see 57A, Interior accessories) ).

61A

2 3
104114

Remove: - the two mounting bolts (1) , - the fan assembly connection (2) . Pull the tab (3) . Remove the fan assembly by lifting it.

REFITTING
To refit, proceed in the reverse order of removal. WARNING Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).

61A-29

HEATING
Passenger compartment fan assembly control unit: Removal - Refitting

61A

REMOVAL
Disconnect the battery( (see Battery : Removal Refitting) . Remove the dashboard( (see Dashboard: Removal - Refitting) .

104671

Remove the mounting bolt (1) . Press on the bracket (2) . Remove the air conditioning blower resistor unit (3) from its housing. Move the wiring harness slightly to one side. Remove: - the connector on the blower unit, - the passenger compartment blower resistor unit.

REFITTING
Refit: - the passenger compartment blower resistor unit, - the connector on the blower unit. Refit the dashboard( (see Dashboard: Removal Refitting) . Connect the battery( (see Battery : Removal - Refitting) .

61A-30

HEATING Heating resistor unit: Removal - Refitting

DG

61A

Tightening torquesm heating resistor unit mounting bolts 0.2 daNm

REMOVAL
Disconnect the battery, starting with the negative terminal.

2 3

104662

Remove: - the heating resistor unit connector (2) , - the two mounting bolts (3) .

1
104028

Remove the lower trim (1) ( (see 57A, Interior accessories) ).

102340

Extract the heating resistor unit.

61A-31

HEATING Heating resistor unit: Removal - Refitting

DG

61A

REFITTING
Proceed in the reverse order to removal. WARNING Connect the battery; carry out the necessary programming ( (see 80A, Battery) ). Torque tighten the heating resistor unit mounting bolts ( 0.2 daNm ) .

61A-32

HEATING Heating resistor unit: Removal - Refitting

DD

61A

Tightening torquesm heating resistor unit mounting bolts to torque 0.2 daNm

REMOVAL
Disconnect the battery starting with the negative terminal.

2 3

104662

Remove: - the heating resistor unit connector (2)

- the two mounting bolts (3)

104308

Remove the glove compartment (1) ( (see 57A, Interior accessories) ).

102340

Remove the heating resistor unit.

61A-33

HEATING Heating resistor unit: Removal - Refitting

DD

61A

REFITTING
To refit, proceed in the reverse order to removal. WARNING Connect the battery; carry out the necessary programming ( (see 80A, Battery) ). Tighten the heating resistor unit mounting bolts to torque ( 0.2 daNm ) .

61A-34

HEATING Heating resistor relays: Removal - Refitting

DG Special tooling required Ms. 1639 Ms. 1544 Ms. 1373 Tool for removing radio - CD player Tool for removing Carminat Becker radio Tool for removing radio or chronotachograph

61A

The heating resistors can be accessed from underneath the dashboard.

REMOVAL
Disconnect the battery starting with the negative terminal.

104031

Remove the spring (1) . Unclip the gear lever gaiter.

104030

Remove the gear lever knob.

104032

Unclip the upper trim from the gear lever. Disconnect the connector.

61A-35

HEATING Heating resistor relays: Removal - Refitting

DG

61A

103603

Remove the clip using clip removal pliers (on both sides).

2
104034

Remove (depending on equipment level): - the CD changer using tool (Ms. 1639) , - the radio-navigation unit using tool (Ms. 1544) , - the audio equipment using tool (Ms. 1373) . Disconnect the various connectors. Remove the two bolts (2) .

104033

Remove the three bolts. Unclip the gear lever trim.

61A-36

HEATING Heating resistor relays: Removal - Refitting

DG

61A

104035

103853

Remove cover bolts (3) .

103811

Carefully unclip the centre panel (the fastening clips are illustrated above). Disconnect the various connectors.

104043

Unclip the door sill lining.

61A-37

HEATING Heating resistor relays: Removal - Refitting

DG

61A

104044

104046

Unclip the side panel.

Open the glove compartment beyond its point of resistance. Remove the glove compartment.

104045

Remove the two bolts (4) .

104047

Press from inside to unfasten the headlight adjustment control.

61A-38

HEATING Heating resistor relays: Removal - Refitting

DG

61A

104048

103851

Remove (depending on equipment level): - both parking brake lever bolts (5) , - the coin holder. Disconnect the connectors.

Remove fuse box (7) .

6
103852

Remove the UCH.

104049

Remove: - the bolt (6) , - the lower trim under the steering wheel.

61A-39

HEATING Heating resistor relays: Removal - Refitting

DG

61A

104668

Press lug (8) . Remove the heating resistor relay located behind the UCH.

REFITTING
To refit, proceed in the reverse order of removal. WARNING Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).

61A-40

HEATING Heating resistor relays: Removal - Refitting

DD Special tooling required Ms. 1639 Ms. 1544 Ms. 1373 Tool for removing radio - CD player Tool for removing Carminat Becker radio Tool for removing radio or chronotachograph

61A

REMOVAL
Disconnect the battery starting with the negative terminal.

104031

Remove the spring (1) . Unclip the gear lever gaiter.

104030

Remove the gear lever knob.

104032

Unclip the upper trim from the gear lever. Disconnect the connector.

61A-41

HEATING Heating resistor relays: Removal - Refitting

DD

61A

103603

Remove the clip using clip removal pliers (on both sides).

2
104034

Remove (depending on equipment level): - the CD changer using tool (Ms. 1639) , - the radio-navigation unit using tool (Ms. 1544) , - the audio equipment using tool (Ms. 1373) . Disconnect the various connectors. Remove the two bolts (2) .

104033

Remove the three bolts. Unclip the gear lever trim.

61A-42

HEATING Heating resistor relays: Removal - Refitting

DD

61A

104035

104308

Remove the front door sill lining (front section).

103811

Carefully unclip the centre panel (the fastening clips are illustrated above). Disconnect the various connectors.

104309

Remove the side panel.

61A-43

HEATING Heating resistor relays: Removal - Refitting

DD

61A

5 3

104310

104311

Remove the two bolts (3) .

Remove the two bolts (5) .

104312

104095

Remove both glove compartment bolts (4) .

Unclip the fuse box from the glove compartment.

61A-44

HEATING Heating resistor relays: Removal - Refitting

DD

61A

REFITTING
To refit, proceed in the reverse order of removal. WARNING Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).

7
104096

Remove: - the bolt (6) , - the UCH (7) .

104665

Remove the heater relay resistor unit (8) by pressing at (9) .

61A-45

AIR CONDITIONING General information

INFORMATION ON THE FLUID A label in the engine compartment details the specifications of the refrigerant fluid (refer to the Air conditioning - new R134a refrigerant booklet ).

62A

104112

For retrieval, vacuum extraction and refilling the R134A gas, use only the high-pressure hose from the filling station.

Note: - Plugs must be tted to the disconnected air conditioning hoses to prevent moisture from entering the system. - Do not remove the plugs from the replacement parts until last. - Check for leaks, with the engine running and the air conditioning and blower at their maximum settings, during the ve minutes following relling. - The instructions for adding oil ( (see 62A, Air conditioning) ) must be strictly adhered to when work is being carried out on the components of the air conditioning circuit. - When replacing valves, the tightening torque must be adhered to strictly 0.8 daNm .

62A-1

AIR CONDITIONING Maintenance

62A

Equipment required lling station Recommended annual operations: - clean and blast the engine cooling condenser and radiator, - to ensure that the cold air blower unit's condensed water outlet is not blocked. To check that the refrigerant system has been filled regularly, refer to the Warranty and Servicing booklet.

WARNING It is mandatory to follow the safety instructions whilst working on the cold circuit( (see Safety instructions) . I - AIR CONDITIONING CONTROL ANTIBACTERIAL CLEANER

Note: T reat the air conditioning system with a special cleaner after each winter period or extended period of non-usage to prevent odour when the system is in operation. Spray the entire aerosol of cleaner, fitted with a nozzle, through the passenger compartment filter duct. WARNING Spraying the cleaning product through the air inlet is strictly forbidden as it could damage the air conditioning blower. Leave to work for 15 minutes . Operate the ventilation fan very slowly for 5 minutes .

62A-2

AIR CONDITIONING Maintenance

II - RECOVERING REFRIGERANT FLUID - turn the engine off,

62A

- drain for the first time (note down the value), Note: - The air conditioning circuit is tted with a single rell valve, some lling equipment requires only the use of the high pressure pipe ( refer to the lling station instructions ). - Depending on the scenario, run the system for a few minutes before recovering the coolant to improve drainage. - wait 15 minutes , - run the engine until the cooling fan assembly is triggered twice, - drain for the second time (note down the value), - start the draining cycles again if the relative pressure is above 0 bar , - add together the values of the various draining operations, the load is confirmed as being correct if the amount of refrigerant is the specified load + 35 g or - 100 g . Scenario C: These procedures must be followed in order to avoid: - gas escaping when the circuit is opened, - damaging the environment by releasing gas into the atmosphere when the circuit is opened or during creation of a vacuum. - drain for the first time (note down the value), - wait 2 hours , - start the draining cycles again if the relative pressure is above 0 bar , - add together the values of the various draining operations, the load is confirmed as being correct if the amount of refrigerant is the specified load + 35 g or - 100 g . III - CREATION OF A VACUUM It is essential to create a sound vacuum before loading, otherwise the air conditioning will be faulty. There are two scenarios to consider: - the vacuum should be created immediately after draining (scenario A ), - the creation of a vacuum should be carried out after a delay of several hours or days (scenario B). Scenario A: - the creation of a vacuum lasts 20 minutes . Scenario B: - creating the vacuum takes 45 minutes to remove any residual moisture. Test the sealing once the vacuum has been created (some stations do this automatically). IV - FILLING Top up the oil with the recommended type and quantity of oil, depending on the work carried out. Refill the system. Empty the pipes on the (filling station) . Check that the system is operating correctly. Check for leaks.

IMPORTANT

There are three possible scenarios to consider when recovering refrigerant or checking the refrigerant load: - the engine and air conditioning work (Scenario A), - the engine works but not the air conditioning (Scenario B), - neither the engine nor the air conditioning work (Scenario C). Scenario A: - Operate the air conditioning until the cooling fan assembly is triggered twice, - turn the engine off, - drain for the first time (note down the original value), - wait 15 minutes , - check that the relative pressure is no more than 0 bar , - start the draining cycles again if the relative pressure is above 0 bar , - add together the values of the various draining operations, the load is confirmed as being correct if the amount of refrigerant is the specified load + 35 g or - 100 g . Scenario B: - run the engine until the cooling fan assembly is triggered twice,

62A-3

AIR CONDITIONING Parts description

62A

17

14

11

7 11 20 18 13

19

11

15 11

11

8 9

12

11

2 4 5

16

10
103112

(6) (1) (2) (3) (4) (5) Compressor Condenser Dehydration canister Pressure sensor Sized port pressure relief valve (7) (8) (9) (10) (11)

Evaporator Passenger compartment fan Engine cooling fan Engine radiator High-pressure uid Low-pressure vapour

62A-4

AIR CONDITIONING Parts description

(12) (13) (14) (15) (16) (17) (18) (19) (20) High-pressure vapour Filler valve Passenger compartment Engine compartment External air Towards air mixing unit Scuttle panel External or recirculated air Hose bracket on the scuttle panel

62A

62A-5

AIR CONDITIONING Consumables

62A
Type of oil Quantity of oil (in ml)

Table of vehicle refrigerant capacities according to their engines and various specifications: Engine K4J engine K4M engine F4R engine K9K engine F9Q engine 550 g DELPHI 6 CVC 135 PLANETELF PAG 488 or SANDEM SP 10 Refrigerant capacity (g) Type of compressor

150 ml

62A-6

AIR CONDITIONING Safety advice

62A

IMPORTANT The following must be worn when handling refrigerant uid: gloves, protective eyewear (with side shields where possible). - In the event of refrigerant uid coming into contact with the eyes, rinse thoroughly with clean water for 15 minutes . - Keep eyewash available if possible. - If refrigerant gets into your eyes, consult a doctor immediately. Inform the doctor that the burns were caused by refrigerant R134A . - If the uid comes into contact with other unprotected parts of the body (even though the safety instructions were followed), rinse thoroughly with clean water for 15 minutes .

IMPORTANT - Repairing any faulty components of the air conditioning system is strictly prohibited. - All faulty components must be replaced. The correct routing of the pipes must be observed. Ensure that the refrigerant piping is correctly fitted so that it will not come into contact with metal parts in the engine compartment.

IMPORTANT Smoking is strictly prohibited in the vicinity of a refrigerant uid circuit.

IMPORTANT - Any work involving refrigerant uid must be carried out in a well-ventilated area. - The refrigerant must not be stored in a well, a pit, a hermetically sealed room, etc. - Refrigerant uids are colourless and odourless. The specific gravity of refrigerant fluid is higher than that of air and it falls to the ground. This results in a risk of asphyxiation. Consequently, when working on the system ensure that there are no pits, wells, ventilation shafts, etc. any nearer than 5 m away, and start up the gas extraction equipment. At temperatures above 100C , caused by a hot spot for example, the refrigerant fluid decomposes and produces a highly irritant gas.

IMPORTANT It is forbidden to carry out welding or brazing on: - components of the air conditioning system when these are in place, - the vehicle, due to the risk of overheating a component of the air conditioning system. 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 80C .

62A-7

AIR CONDITIONING Air conditioning: Check

CA or CAREG

62A
Equipment required

diagnostic tool

Fault finding Symptoms Components No cold air Air too cold Inefcient operation Fuses Air distribution Air ow Recirculation ap Passenger compartment fan Lack of refrigerant Compressor belt (condition or tension) Wiring harness assembly Sensor signal Pressure sensor Cooling fan Compressor clutch relay Compressor clutch Compressor Expansion valve Dehydration canister Control panel 1 1 1 1 2 3 4 4 5 5 5 5 6 1 2 3 4 1 1 1 2 2 2 3 4 4 5 5 5 6

IMPORTANT Be sure to follow the safety instructions (see 62A, Air conditioning, Safety advice, page 62A-7) .

The fault finding table applies to all air conditioning systems (automatic or not) and must be used as a reference, since some listed components are not found on all versions in use (refer to specific workshop repair manuals). The numbers indicate the most common causes of faults (repeated where there is more than one cause):

WARNING Be sure to follow the cleanliness instructions( (see Precautions) .

PRELIMINARY CHECK
Check: - the battery voltage ( (see 8, Electrical equipment) ),

62A-8

AIR CONDITIONING Air conditioning: Check

CA or CAREG - the cleanliness of the passenger compartment filter (see 62A, Air conditioning, Cabin filter: Removal - Refitting, page 62A-12) .

62A

CHECK THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM

Start the engine. Switch on the air conditioning control or activate the supply to the compressor clutch directly. Turn the cold air control to its maximum setting. Switch the air distribution control to the centre and side vents, and activate air recirculation mode. Close all the vents except one side air vent. Activate the highest ventilation speed. Check that the vent outlet temperature is below 10C in approximately 1 min , at an ambient temperature of 25C .

SYSTEM IDENTIFICATION
Identify the vehicle's air conditioning system (read the family, program number, etc.), using the (diagnostic tool) . Consult the fault finding documents relevant to the system identified.

62A-9

AIR CONDITIONING Coolant circuit check

Leak screening table Component Detection area Part to be replaced after rst check Condenser Evaporator Compressor Dehydration canister Inlet or outlet Connection bracket Inlet or outlet Inlet or outlet Pipes Pipes Pipes Pipes

62A
Part to be replaced after lling and second check Condenser Connection bracket and/or evaporator Compressor Dehydration canister

There are two types of device for detecting leaks: - electronic sensors, - tracer detectors.

II - TRACER DETECTORS Leak detection by tracer involves adding a dye to the refrigerant and locating the points where fluid is being lost using an ultraviolet light. IMPORTANT Safety instructions must be followed when working on the air conditioning circuit (see 62A, Air conditioning, Safety advice, page 62A-7) .

Note: Use the electronic detector and then the tracer detector to check for leaks.

I - ELECTRONIC DETECTORS

WARNING The procedure described must be followed.

WARNING Always refer to user instructions for the device before carrying out any work. This device is used to measure variations in the quantity of refrigerant in the air: it emits an audible signal depending on the extent of the variation. The device must be initialised before the check is carried out. To do this: - immobilise the device, - calibrate the device at one point in the compartment. This point then acts as a scale for detecting rates of contamination. This device is highly sensitive: when a leak is detected, only follow the line of the circuit as closely as possible to limit variations due to other gases. This device only detects relatively substantial leaks. Note: This leak-detection procedure should only be used as a last resor t for leaks that cannot be found .

WARNING Make sure that the sensor at the end of the rod is kept extremely clean and in good condition.

62A-10

AIR CONDITIONING Coolant circuit check

1 - Adding dye to the circuit

62A

105944

The refrigerant fluid leak-detection procedure is based on the use of a dye available in the form of a throwaway capsule (1) : leak traces are revealed using an ultraviolet light (2) . The dye remains in the air conditioning system. It is possible to check the condition of the cold loop using an ultraviolet light without adding a new capsule. If there is nothing to indicate that dye has been used previously (label, etc.): - place a cloth, - release a small jet of refrigerant through the two valves, - shine the ultraviolet light inside the valves, - check for fluorescent traces.

105944

Fit the system for adding the dye to the low-pressure valve, and using union (3) for vehicles fitted with a single valve. Add the dye to the circuit. Run the air conditioning for approximately 15 minutes .

2 - Leak-detection procedure Carry out an initial check (with the engine stopped) by sweeping the circuit with an ultraviolet light.

Note: Use an adjustable mirror wherever access is difcult. Carefully clean the outside of the refrigerant circuit. Run the air conditioning until the leak can be detected (if no leak is detected, check the condition of the evaporator).

WARNING It is forbidden to introduce dye into the cold loop if uorescent traces appear.

WARNING Add a measure of detection dye if there are no fluorescent traces and a label. Affix a label. Record the date on which the dye was added. After the dye has been used in the refrigerant uid, it is essential that the reason for using the dye and the date of the operation are marked on a label (provided with the dye capsule). The label must be placed near the cold loop lling valves (shock absorber turret) where it is visible.

62A-11

AIR CONDITIONING Cabin filter: Removal - Refitting

Located in front of the air intake, the cabin filter filters and cleans the air before it is admitted into the passenger compartment.

62A

REMOVAL
Remove the engine covers.

1
106340

Note: Foreign bodies (leaves, insects etc.) are likely to accumulate in the passenger compartment lter. Remove the lter with care so as to prevent foreign bodies getting into the evaporator. Remove: - the cabin filter access flap (1) , - the passenger compartment filter. Note: Break the rigid sections of the lter in order to remove it. Check for foreign bodies in the passenger compartment filter housing, and clean thoroughly if necessary.

REFITTING
Refit: - the passenger compartment filter, - the cabin filter access flap. Note: Be sure not to damage the ltering section. Refit the engine covers.

62A-12

AIR CONDITIONING Condenser: Removal - Refitting

62A

Equipment required lling station

Tightening torquesm pipe unions 0.8 daNm

REMOVAL
Mount the vehicle on a two post lift. Disconnect the battery, starting with the negative terminal. Drain the refrigerant circuit using the (filling station) tool. Remove: - the front bumper ( Workshop Repair Manual 371 (see 5, Mechanisms and accessories) ), - the frontal impact cross member ( Workshop Repair Manual 371 (see 4, Panelwork) ), - the upper cross member ( Workshop Repair Manual 371 (see 4, Panelwork) ). F9Q or K9K Remove: - the two air-air heat exchanger air hoses, - the air-air heat exchanger.

104107

Unscrew the condenser pipe unions (1) . Disconnect the pipes. Cap the apertures. Remove the condenser by lifting its four retaining brackets (2) .

REFITTING
Proceed in the reverse order to removal. Check that the condenser is properly secured. Replace the seals. Lubricate with air conditioning oil to make fitting easier. Torque tighten the pipe unions ( 0.8 daNm ) . Note: When replacing a condenser, add 30 ml o f approved oil to the quantity retrieved.

62A-13

AIR CONDITIONING Condenser: Removal - Refitting

Fill up the refrigerant circuit using the (filling station) tool. WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see Workshop Repair Manual 370 (see 80A, Battery) .

62A

Note: - Check that the air conditioning is working properly (see Workshop Repair Manual 372, Fault nding ). - Look for leaks (see 6 2 A, Air conditioning, Coolant circuit check, page 62A-10) .

62A-14

AIR CONDITIONING Dehydration canister: Removal - Refitting

REFITTING
Equipment required lling station Note: Tightening torquesm pipe union mounting bolts 0.8 daNm

62A

Proceed in the reverse order to removal.

When replacing a canister, add 15 ml of approved oil to the quantity retrieved. Replace the seals. Lubricate with approved air conditioning oil to make fitting easier. Torque tighten the pipe union mounting bolts ( 0.8 daNm ) . Fill up the refrigerant circuit using the (filling station) tool. WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see Workshop Repair Manual 370 (see 80A, Battery) ).

REMOVAL
Mount the vehicle on a two post lift. Disconnect the battery, starting with the negative terminal. Drain the refrigerant circuit using the (filling station) tool. Remove: - the front bumper ( Workshop Repair Manual 371 (see 5, Mechanisms and accessories) ), - the frontal impact cross member ( Workshop Repair Manual 371 (see 4, Panelwork) ), - the upper cross member ( Workshop Repair Manual 371 (see 4, Panelwork) ).

Note: - Check that the air conditioning is working properly (see Workshop Repair Manual 372, Fault nding ). - Look for leaks (see 6 2 A, Air conditioning, Coolant circuit check, page 62A-10) .

104107

Unscrew the canister pipe unions (1) . Disconnect the pipes. Cap the apertures. Lift the canister out.

62A-15

AIR CONDITIONING Compressor: Removal - Refitting

62A

Equipment required lling station

Tightening torquesm pipe union mounting bolts compressor mounting bolts reinforcement plate mounting bolts 0.8 daNm 2.5 daNm 2.1 daNm

REMOVAL
Mount the vehicle on a two post lift. Disconnect the battery, starting with the negative terminal. Drain the refrigerant circuit using tool (filling station) . Remove: - the front bumper ( Workshop Repair Manual 371 (see 5, Mechanisms and accessories) ), - the frontal impact cross member ( Workshop Repair Manual 371 (see 4, Panelwork) ), - the upper cross member ( Workshop Repair Manual 371 (see 4, Panelwork) ).

104097

Remove the accessories belt using the auto tensioner at (2) .

104111

Unscrew the compressor pipe unions (3) . Disconnect the pipes. Cap the apertures.

104119

Remove the reinforcement plate (1) .

62A-16

AIR CONDITIONING Compressor: Removal - Refitting

62A

Fill up the refrigerant circuit using the (filling station) tool. WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see Workshop Repair Manual 370 (see 80A, Battery) ).

6
Note:

- When replacing the compressor, do not add any oil. - Check that the air conditioning is working properly (see Workshop Repair Manual 372, Fault nding ). - Look for leaks (see 6 2 A, Air conditioning, Coolant circuit check, page 62A-10) .
104106

Disconnect the compressor connectors (4) and the pressure sensor connectors (5) . Remove: - the three compressor mounting bolts (6) , - the compressor.

REFITTING

WARNING Be sure to replace any belt removed (see Workshop Repair Manual 370 (see 1, Engine and peripherals) ). When replacing the belt, be sure to replace the tension wheels and idler pulleys. Proceed in the reverse order to removal. Replace the seals. Lubricate with approved air conditioning oil to make fitting easier. Torque tighten: - the pipe union mounting bolts ( 0.8 daNm ) , - the compressor mounting bolts ( 2.5 daNm ) , - the reinforcement plate mounting bolts ( 2.1 daNm ) .

62A-17

AIR CONDITIONING Calibrated opening: Removal - Refitting

62A

Note: - The calibrated choke (1) is designed as a part that cannot be replaced. - Replace the pipe connecting the condenser to the evaporator if the calibrated choke is faulty ( (see 62A, Air conditioning) ).

1
102128

19330

62A-18

AIR CONDITIONING Connection bracket

62A

Equipment required lling station

Tightening torquesm connecting ange pipe union mounting bolts 0.8 daNm 0.8 daNm

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove the engine covers. Drain the refrigerant circuit using the (filling station) tool. Remove: - the cowl grille (see Workshop Repair Manual 370 (see 85A, Wiping - Washing) ), - the air filter access panel, - the plenum chamber partition. F4R or K4J Remove the air inlet manifold (see Workshop Repair Manual 370, Fuel mixture, Air inlet ).

104120

Unscrew the soundproofing screen mounting (1) .

104105

Unscrew the pipe unions (2) . Disconnect the pipes. Cap the apertures.

62A-19

AIR CONDITIONING Connection bracket

62A

102228

Remove the two connecting flange mounting bolts (3) . Refit one pipe union bolt to extract the connecting flange. Remove the evaporator pipe O-rings.

62A-20

AIR CONDITIONING Connection bracket

REFITTING
WARNING

62A

Connect the battery, starting with the positive terminal; carry out the necessary programming ( Workshop Repair Manual 370 (see 80A, Battery) ).

102227

Refit the O-rings on the pipes (4) . Proceed in the reverse order to removal. Gradually retighten the two connecting flange mounting bolts so that the connecting flange is uniformly fitted on the pipes. Check that the contact faces of the seal on the connecting flange are in good condition. Replace the seals. Lubricate with approved air conditioning oil to make fitting easier. Torque tighten: - the connecting flange ( 0.8 daNm ) , - the pipe union mounting bolts ( 0.8 daNm ) . Fill up the refrigerant circuit using the (filling station) tool.

Note: When replacing a connecting ange, add 10 ml of recommended oil to the quantity of oil retrieved. - Check that the air conditioning is working properly (see Workshop Repair Manual 372, Fault nding ). - Look for leaks (see 6 2 A, Air conditioning, Coolant circuit check, page 62A-10) .

62A-21

AIR CONDITIONING Evaporator: Removal - Refitting

62A

Equipment required diagnostic tool lling station

Tightening torquesm evaporator unit mounting bolts pipe union mounting bolts 0.65 daNm 0.8 daNm

1
104100

Remove: Note: The evaporator is supplied mounted in its housing. - the bolts (1) , - the dashboard cross member ( (see 42A, Upper front structure) ).

REMOVAL
IMPORTANT Lock the computer using (diagnostic tool) ( (see 8 , Electrical equipment) ) before carrying out any interventions to the airbag system. Disconnect the battery starting with the negative terminal. Drain the refrigerant circuit using tool (filling station) . Remove the connection flange ( (see 62A, Air conditioning) ). Fit the plugs into the ports. Attach hose clamps to the cooling circuit heater matrix pipes at the bulkhead. Remove:
104110

- the heater matrix pipes, - the dashboard ( (see 57A, Interior accessories) ).

Remove: - the two bolts (2) from the heater matrix pipe bracket, - the bracket. Put a container in place to collect the coolant. Remove: - both heater matrix pipe mounting clips (3) , - the pipes from their guides in the distributor housing, - the air conditioning unit, - the condensation evacuation pipe,

62A-22

AIR CONDITIONING Evaporator: Removal - Refitting

- the cabin filter, - the control cables (if the vehicle has them), - the mixing motor (if the vehicle has one), - the timing motor (if the vehicle has one), - the recycling motor (if the vehicle has one), - the fan assembly, - the heater radiator, - the electrical resistors or the power module, - the heating resistor unit and electrical harness.

62A

REFITTING
To refit, proceed in the reverse order of removal. Note: It is essential to ret the electrical harness correctly to avoid any possible damage. Oil the pipe seals with the approved oil. Tighten to torque: - the evaporator unit mounting bolts ( 0.65 daNm ), - the pipe union mounting bolts ( 0.8 daNm ) , Fill the refrigerant circuit using the tool (filling station) . WARNING Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).

Note: - When replacing the evaporator, add 30 ml of approved oil to the quantity recovered. - Check that the air conditioning system is operating correctly (see 62A, Air conditioning, Air conditioning: Check, page 62A-8) . - Check for leaks (see 62A, Air conditioning, Coolant circuit check, page 62A-10) .

62A-23

AIR CONDITIONING
Condenser - compressor connecting pipe: Removal - Refitting

62A

Equipment required lling station

Tightening torquesm pipe union mounting bolts 0.8 daNm

REMOVAL
Mount the vehicle on a two post lift. Disconnect the battery, starting with the negative terminal. Drain the refrigerant circuit using the (filling station) tool.
104111

Remove: - the front bumper ( Workshop Repair Manual 371 (see 5, Mechanisms and accessories) ), - the frontal impact cross member ( Workshop Repair Manual 371 (see 4, Panelwork) ), - the up per cross member ( Workshop Repair Manual 371 (see 4, Panelwork) ).

Unscrew the compressor pipe union (2) . Disconnect the pipe. Cap the condenser aperture. Remove the compressor - condenser connecting pipe.

REFITTING
Proceed in the reverse order to removal. Replace the seals. Lubricate with approved air conditioning oil to make fitting easier. Torque tighten the pipe union mounting bolts ( 0.8 daNm ) . WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming ( Workshop Repair Manual 370 (see 80A, Battery) ).

Note: - When replacing a pipe, add 10 ml of the recommended oil to the amount of oil retrieved. - Check that the air conditioning is working properly ( Workshop Repair Manual 372, Fault nding ). - Look for leaks ( (see 62A, Air conditioning) ).

104107

Unscrew the condenser pipe union (1) . Disconnect the pipe. Cap the condenser aperture.

62A-24

AIR CONDITIONING
Condenser - evaporator connecting pipe: Removal - Refitting

62A

Equipment required lling station

Tightening torquesm pipe union mounting bolts reinforcement plate mounting bolts 0.8 daNm 2.1 daNm

REMOVAL
Mount the vehicle on a two post lift. Disconnect the battery, starting with the negative terminal. Drain the refrigerant circuit using the (filling station) tool. Remove: - the front bumper ( Workshop Repair Manual 371 (see 5, Mechanisms and accessories) ), - the cowl grille ( Workshop Repair Manual 370 (see 8, Electrical equipment) ), - the air filter access panel, - the plenum chamber partition. F4R or K4J Remove the air inlet manifold ( Workshop Repair Manual 370 (see 1, Engine and peripherals) ).

104119

Remove the reinforcement plate (1) .

2
104106

Disconnect the pressostat (2) . Remove the pressostat.

62A-25

AIR CONDITIONING
Condenser - evaporator connecting pipe: Removal - Refitting

62A

3
104107

104120

Unscrew the condenser pipe union (3) . Disconnect the pipe. Cap the condenser aperture. Remove the pipe from the retaining bracket (4) .

Unscrew the bulkhead soundproofing mounting (6) .

104105

5
104104

Unscrew the pipe union (7) from the connecting flange. Disconnect the pipe.

Unclip the pipe from the retaining brackets (5) .

Cap the connecting flange aperture. Remove the condenser - evaporator connecting pipe.

62A-26

AIR CONDITIONING
Condenser - evaporator connecting pipe: Removal - Refitting
REFITTING
Proceed in the reverse order to removal. Replace the seals. Lubricate with approved air conditioning oil to make fitting easier. Torque tighten: - the pipe union mounting bolts ( 0.8 daNm ) , - the reinforcement plate mounting bolts ( 2.1 daNm ) . Note: When replacing a pipe, add 10 ml of the recommended oil to the amount of oil retrieved. Fill up the refrigerant circuit using the (filling station) tool. WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see Workshop Repair Manual 370 (see 80A, Battery) ).

62A

Note: - Check that the air conditioning is working properly (see Workshop Repair Manual 372, Fault nding ). - Look for leaks ( (see 62A, Air conditioning) ).

62A-27

AIR CONDITIONING
Dehydration canister - evaporator connecting pipe: Removal - Refitting

62A

Equipment required lling station

Tightening torquesm pipe union mounting bolts 0.8 daNm

REMOVAL
Disconnect the battery, starting with the negative terminal. Drain the refrigerant circuit using the (filling station) tool. Remove: - the cowl grille ( Workshop Repair Manual 370 (see 8, Electrical equipment) ), - the air filter access panel, - the plenum chamber partition. F4R or K4J Remove the air inlet manifold( (see Air inlet) . Unclip the bulkhead soundproofing (2) .
104120

104105

Unscrew the pipe union (3) . Disconnect the pipe. Cap the connecting flange aperture.

1
104107

Remove the evaporator - dehydration canister connecting pipe.

Unscrew the dehydration canister pipe union (1) . Disconnect the pipe. Cap the dehydration canister aperture.

REFITTING
Proceed in the reverse order to removal. Replace the seals.

62A-28

AIR CONDITIONING
Dehydration canister - evaporator connecting pipe: Removal - Refitting

62A

Lubricate with approved air conditioning oil to make fitting easier. Torque tighten the pipe union mounting bolts ( 0.8 daNm ) . Note: When replacing a pipe, add 10 ml of recommended oil to the quantity of oil retrieved. Fill up the refrigerant circuit using the (filling station) tool. WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see Workshop Repair Manual 370 (see 80A, Battery) ).

Note: - Check that the air conditioning is working properly (see Workshop Repair Manual 372, Fault nding ), - Look for leaks (see 6 2 A, Air conditioning, Coolant circuit check, page 62A-10) .

62A-29

AIR CONDITIONING
Dehydration canister - compressor connecting pipe: Removal - Refitting

62A

Equipment required lling station

Tightening torquesm pipe union mounting bolts 0.8 daNm

REMOVAL
Mount the vehicle on a two post lift. Disconnect the battery, starting with the negative terminal. Drain the refrigerant circuit using the (filling station) tool. Remove the front bumper ( Workshop Repair Manual 371 (see 5, Mechanisms and accessories) ). Unscrew the compressor pipe union (2) . Disconnect the pipe. Cap the compressor aperture. Remove the compressor - dehydration canister connecting pipe.
104111

REFITTING
Proceed in the reverse order to removal. Replace the seals. Lubricate with the recommended oil to aid fitting. Torque tighten the pipe union mounting bolts ( 0.8 daNm ) .

1
104107

Note: When replacing a pipe, add 10 ml of the recommended oil to the amount of oil retrieved.

Unscrew the canister pipe union (1) . Disconnect the pipe. Cap the dehydration canister aperture.

62A-30

AIR CONDITIONING
Dehydration canister - compressor connecting pipe: Removal - Refitting

62A

Fill up the refrigerant circuit using the (filling station) tool. WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see Workshop Repair Manual 370 (see 80A, Battery) ).

Note: - Check that the air conditioning is working properly (see Workshop Repair Manual 372, Fault nding ). - Look for leaks (see 6 2 A, Air conditioning, Coolant circuit check, page 62A-10) .

62A-31

AIR CONDITIONING Pressure sensor: Removal - Refitting

62A

Tightening torquesm pressure sensor valve 0.9 daNm 0.8 daNm

REMOVAL
Mount the vehicle on a two post lift. Disconnect the battery, starting with the negative terminal.

Note: An automatic closure valve isolates the circuit from the atmosphere during removal; do not drain the refrigerant circuit.
82822

Remove the front bumper ( Workshop Repair Manual 371 (see 8, Electrical equipment) ).

The engine injection computer controls the engine cooling fans according to the refrigerant circuit high pressure and the vehicle speed.

REFITTING
Proceed in the reverse order to removal. Replace the seals. Torque tighten the pressure sensor ( 0.9 daNm ) . WARNING Connect the battery; carry out the necessary programming (see Workshop Repair Manual 370 (see 80A, Battery) ).

Note:

- Check that the air conditioning is working properly (see Workshop Repair Manual 372, Fault nding ).
104106

Disconnect the pressure sensor (1) . Remove the pressure sensor. The pressure sensor fitted at the condenser outlet protects the refrigerant circuit. - low pressure cut off: 2 bar , - high pressure cut-off: 27 bar . The pressure sensor informs the engine injection computer of the refrigerant circuit pressure.

- If there is no cold air, look for leaks. (see 62A, Air conditioning, Coolant circuit check, page 62A-10) . - When replacing the valve, torque tighten the valve ( 0.8 daNm ) .

62A-32

CLIMATE CONTROL Operating principle

Only special features of climate control are described in this section . For sections not dealt with ( (see 62A, Air conditioning) ) and ( (see 62C, Manual air conditioning) ). I - POWER MODULE In automatic climate control, there are eight ventilation speeds. II - FLAP CONTROL MOTORS

62B
2

1
104115

102237

The fan assembly power module is controlled by a voltage modulated by the air conditioning computer. This control voltage is always 12 V , it is the control signal (square signal) which varies: - the amplitude and frequency do not change, - but the cyclic ratio changes.

104114

These motors are located in the climate control unit and act on different flaps to direct the flow according to certain criteria: - the mixer motor (1) is used for mixing the hot and cold air, - the distribution motor (2) directs the air flow into the passenger compartment via the vents, - the recirculation motor (3) allows the air in the passenger compartment to be reused by isolating it from the external air.

62B-1

CLIMATE CONTROL Operating principle

III - PASSENGER COMPARTMENT TEMPERATURE SENSOR

62B

IV - EXTERNAL TEMPERATURE SENSOR

101624 101716

It is a negative temperature thermistor located in the right-hand rear-view mirror. V - INSOLATION SENSOR This sensor informs the computer of the intensity of sunlight to correct the air flow to the air vents.

19398

This sensor supplies information on the interior temperature. It is a negative temperature coefficient thermistor located behind the rear-view mirror.

104069

It is located in the centre of the dashboard.

62B-2

CLIMATE CONTROL Parts description

AUTOMATIC AIR CONDITIONING CONTROL UNIT

62B

5 7 6 1

2 3 4

107379

(1) (2) (3) (4) (5) (6) (7)

Passenger compartment lter Heating resistor unit Heater radiator Heater radiator pipes Power module Distribution unit Engine cooling fan

62B-3

CLIMATE CONTROL Control panel: Removal - Refitting

Special tooling required Ms. 1639 Ms. 1544 Ms. 1373 Tool for removing radio - CD player Tool for removing Carminat Becker radio Tool for removing radio or chronotachograph

62B

Tightening torquesm climate control panel mounting bolt to torque 0.2 daNm

REMOVAL
Disconnect the battery starting with the negative terminal. Remove the spring (1) . Unclip the gear lever gaiter.
104031

104030

Remove the gear lever knob.

104032

Unclip the upper trim from the gear lever. Disconnect the connector.

62B-4

CLIMATE CONTROL Control panel: Removal - Refitting

62B

2
103603

Remove the side clip using an unclipping tool Carry out this operation on both sides.

104034

Remove (depending on equipment level): - the CD changer with tool (Ms. 1639) , - the radio-navigation unit using tool (Ms. 1544) , - the audio equipment using tool (Ms. 1373) . Disconnect the various connectors. Remove the two bolts (2) .

104033

Remove the three bolts. Unclip the lower trim from the gear lever.

62B-5

CLIMATE CONTROL Control panel: Removal - Refitting

62B
3

104035

104036

Remove both screws (3) from the heater control. Remove the control panel.

103811

Carefully unclip the centre plate (the mounting clips are shown in the diagram below). Disconnect the various connectors.
104116

Disconnect the heater control panel connector.

62B-6

CLIMATE CONTROL Control panel: Removal - Refitting

REFITTING
To refit, proceed in the reverse order of removal. WARNING Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).

62B

Note: - The recirculation control cable is black. - The distribution control cable is white. - The mixer cable is grey. - The cables require no adjustment. Tighten the climate control panel mounting bolt to torque ( 0.2 daNm ) .

62B-7

CLIMATE CONTROL Control panel: Connection

62B

101618

Control panel 12-track Blue connector track A A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 Allocation CAN L Not used Spare Insolation sensor supply Interior temperature sensor supply Computer earth CAN H Not used + 12 V side lights + 12 V accessories + 12 V before ignition 0 V sensor supply (insolation and interior temperature) Sensor or actuator track Track 2 of the insolation sensor Track 4 of the interior temperature sensor Protection and switch Unit LH side lights fuse ( 7.5 A ) Passenger compartment fuse ( 15 A ) Passenger compartment fuse ( 20 A ) Track 1 of the insolation sensor and track 5 of the interior temperature sensor

62B-8

CLIMATE CONTROL Control panel: Connection

Automatic control panel Black 18 track B B1 B2 B3 B4 B5 B6 B7 track connector Allocation Recirculation motor control Not used Spare Spare Spare Spare Fan assembly module control

62B
Sensor or actuator track Track 5 of the recirculation motor Track 6 of the passenger compartment fan assembly module 6-track connector Track 2 of the mixer and distribution motors track 1 of the distribution motor (winding B2) Track 6 of the distribution motor (winding A2) Track 3 of the distribution motor (winding B1) Track 4 of the distribution motor (winding A1) Track 1 of the mix motor er (winding B2) Track 6 of the mix motor er (winding A2) Track 3 of the mix motor er (winding B1) Track 4 of the mix motor er (winding A1)

B8 B9 B10 B11 B12 B13 B14 B15 16 B B17 B18

Mixer and distribution motors supply 12 V Mixer and distribution engine earth Recirculation engine earth Distribution motor control Distribution motor control Distribution motor control Distribution motor control Mixer motor control Mixer motor control Mixer motor control Mixer motor control

62B-9

CLIMATE CONTROL Power module: Removal - Refitting

DG The power module controls the speed of the blower depending on the requirements determined by the automatic control. It can be accessed from underneath the instrument panel.

62B
3

REMOVAL
Disconnect the battery starting with the negative terminal.

104117

Remove the bolt (2) . Press bracket (3) . Remove the power module (4) .

REFITTING
1
104063

To refit, proceed in the reverse order to removal. WARNING Connect the battery; carry out the necessary programming ( (see 8, Electrical equipment) ).

Remove the glovebox ( (see 57A, Interior accessories) ) (1) .

62B-10

CLIMATE CONTROL Power module: Removal - Refitting

DD

62B
3

REMOVAL
Disconnect the battery starting with the negative terminal.

1
104394

104117

Disconnect the two connectors. Remove the bolt (2) .

Remove: - the lower housing ( (see 5, Mechanisms and accessories) ), - the front air distribution duct (1) , - the steering column ( (see 3, Chassis) ).

Press the bracket (3) . Remove the power module (4) .

REFITTING
To refit, proceed in the reverse order to removal. WARNING Connect the battery; carry out the necessary programming ( (see 8, Electrical equipment) ).

62B-11

CLIMATE CONTROL Recirculation motor: Removal - Refitting

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove the dashboard ( Workshop Repair Manual 371 (see 5, Mechanisms and accessories) ).

62B

104114

Remove: - the connector, (1) - the two mounting bolts (2) , - the mixer motor. (3)

REFITTING
Proceed in the reverse order to removal. WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming ( Workshop Repair Manual 370 , see 80A, Battery, Battery: Remove and Ret).

62B-12

CLIMATE CONTROL Mixer motor: Removal - Refitting

DG

62B

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove the glovebox ( Workshop Repair Manual 371 (see 5, Mechanisms and accessories) ).

2 3
104113

Remove: - the connector, (1) - the two mounting bolts (2) , - the mixer motor. (3)

REFITTING
Proceed in the reverse order to removal. WARNING Connect the battery; carry out the necessary programming ( Workshop Repair Manual 370 (see 8, Electrical equipment) ).

62B-13

CLIMATE CONTROL Mixer motor: Removal - Refitting

DD

62B

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove the lower trim ( Workshop Repair Manual 371 (see 5, Mechanisms and accessories) ).

104391

Remove: - the connector (1) , - the two mounting bolts (2) , - the mixer motor. (3)

REFITTING
Proceed in the reverse order to removal. WARNING Connect the battery; carry out the necessary programming ( Workshop Repair Manual 370 (see 8, Electrical equipment) ).

62B-14

CLIMATE CONTROL Distribution motor: Removal - Refitting

DG

62B

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove the glovebox ( Workshop Repair Manual 371 (see 5, Mechanisms and accessories) ).

1 3

104113

Remove: - the connector, (1) - the two mounting bolts (2) , - the distribution motor. (3)

REFITTING
Proceed in the reverse order to removal. WARNING Connect the battery; carry out the necessary programming ( Workshop Repair Manual 370 (see 8, Electrical equipment) ).

62B-15

CLIMATE CONTROL Distribution motor: Removal - Refitting

DD

62B

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove: - the lower trim ( Workshop Repair Manual 371 (see 5, Mechanisms and accessories) ). - the front air distribution duct, - the steering column ( Workshop Repair Manual 370 (see 3, Chassis) ).

1 3

104113

Remove: - the connector (1) , - the two mounting bolts (2) , - the distribution motor. (3)

REFITTING
Proceed in the reverse order to removal. WARNING Connect the battery; carry out the necessary programming ( Workshop Repair Manual 370 (see 8, Electrical equipment) ).

62B-16

CLIMATE CONTROL
Passenger compartment temperature sensor: Removal - Refitting

62B

Location

19398

Note: The passenger compartment temperature sensor is located in the lower shell of the interior rear-view mirror.

101716

Unclip the lower shell of the interior rear-view mirror.

REMOVAL

101717 101715

Disconnect the passenger compartment temperature sensor connector (1) . Remove the passenger compartment temperature sensor.

Disconnect the battery, starting with the negative terminal. Unclip the upper shell.

62B-17

CLIMATE CONTROL
Passenger compartment temperature sensor: Removal - Refitting

62B

REFITTING
Proceed in the reverse order to removal. WARNING Connect the battery; carry out the necessary programming ( Workshop Repair Manual 370 (see 8, Electrical equipment) ).

62B-18

CLIMATE CONTROL External temperature sensor: Removal - Refitting

Special tooling required Car. 1363 Trim removal lever

62B

The exterior temperature sensor is located in the door mirror on the right-hand side. Check the resistance of the temperature sensor Approximate temperature (C) Between 0 and 5 Between 6 and 10 Between 11 and 15 Between 16 and 20 Between 21 and 25 Between 26 and 30 Between 31 and 35 Between 36 and 40 Sensor resistance () Between 5400 and 6200 Between 4400 and 5400 Between 3700 and 4400 Between 3000 and 3700 Between 2500 and 3000 Between 2100 and 2500 Between 1700 and 2100 Between 1450 and 1700
101623

Remove the door mirror shell by pressing the lugs (1) .

REMOVAL

101624

Unclip the sensor from its mounting.

101622

Cut the wires.

Remove the reflective glass using tool (Car. 1363) .

REFITTING
Solder both temperature sensor wires and insulate them with heat shrink sleeves. Refit the shell and reflector.

62B-19

CLIMATE CONTROL External temperature sensor: Removal - Refitting

62B

62B-20

CLIMATE CONTROL Insolation sensor: Removal - Refitting

REMOVAL
Disconnect the battery, starting with the negative terminal.

62B

104069

Remove the insolation sensor from above. Disconnect the insolation sensor.

REFITTING
Proceed in the reverse order to removal. WARNING Connect the battery; carry out the necessary programming ( Workshop Repair Manual 370 (see 8, Electrical equipment) ).

62B-21

MANUAL AIR CONDITIONING Parts description

Manual climate control unit

62C

2 1

3 9 8 5 4

107379

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Passenger compartment lter Distribution unit Heating resistor unit Heater radiator Heater radiator pipes Power module Passenger compartment fan Evaporator Evaporator ange

62C-1

MANUAL AIR CONDITIONING Control panel: Removal - Refitting

Special tooling required Ms. 1639 Ms. 1544 Ms. 1373 Tool for removing radio - CD player Tool for removing Carminat Becker radio Tool for removing radio or chronotachograph

62C

Tightening torquesm climate control panel mounting bolt to torque 0.2 daNm

REMOVAL
Disconnect the battery starting with the negative terminal. Remove the spring (1) . Unclip the gear lever gaiter.
104031

104030

Remove the gear lever knob.

104032

Unclip the upper trim from the gear lever. Disconnect the connector.

62C-2

MANUAL AIR CONDITIONING Control panel: Removal - Refitting

62C

103603

Remove the side clip using clip removal pliers (on both sides).

104034

Remove (depending on the equipment level): - the CD changer with tool (Ms. 1639) , - the radio-navigation unit using tool (Ms. 1544) , - the audio equipment using tool (Ms. 1373) .

Disconnect the various connectors. Remove the two bolts (3) .

104033

Remove the three bolts (2) . Unclip the gear lever trim.

62C-3

MANUAL AIR CONDITIONING Control panel: Removal - Refitting

62C
4

104035

104036

Remove both bolts from the heating control panel (4) . Remove the control panel.

103811

Carefully unclip the centre panel (the fastening clips are displayed in the diagram). Disconnect the various connectors.
104659

Disconnect the heater control panel connector.

62C-4

MANUAL AIR CONDITIONING Control panel: Removal - Refitting

62C

102011

Unclip at (5) . Remove the bracket (6) . Remove ball joint (7) . Remove the heater control panel cables.

REFITTING
To refit, proceed in the reverse order of removal. Note: - The recirculation control cable is black. - The distribution control cable is white. - The mixer cable is grey. - The cables require no adjustment. Tighten the climate control panel mounting bolt to torque ( 0.2 daNm ) . WARNING Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).

62C-5

MANUAL AIR CONDITIONING Control panel: Connection

CONTROL PANEL

62C

A1

A6

B1

B9
102337

Control panel track A1 A2 A3 A4 A5 A6 B1 B2 B3 B4 B5 B6 B7 B8 B9

Allocation Earth Speed 1 control Speed 2 control Speed 3 control Speed 4 control Not used Fan assembly speed signal 0 + after ignition feed Request for operation of the rear screen de-icer Rear screen de-icer operation indicator light control Earth Air conditioning indicator light return Air conditioning request + before ignition Not used

Sensor or actuator track Resistor unit track 1 connector A Resistor unit track 2 connector A Resistor unit track 3 connector A Resistor unit track 4 connector A UCH UCH UCH UCH UCH Relay/fuse box -

62C-6