Professional Documents
Culture Documents
GENERAL INFORMATION
FRONT AXLE ELEMENTS
REAR AXLE ELEMENTS
WHEELS AND TYRES
STEERING ASSEMBLY
MECHANICAL ELEMENT CONTROLS
ELECTRONICALLY CONTROLLED
HYDRAULIC SYSTEM
NOVEMBER 2000
EDITION ANGLAISE
"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
reference numbering system is forbidden without the prior written authority of Renault.
RENAULT 2000
Chassis
Contents
Page
30
GENERAL INFORMATION
Dimensions of the main braking components
Tightening torques (in daNm)
Axles and suspension
Underbody height
Parts to be replaced when they are removed
Brake fluid
Brake unions and pipes
Influence of angles
Angle testing principle
Front axle testing and adjustment
Front axle fault finding
Brake fault finding
31
33
30-1
30-2
30-7
30-9
30-10
30-10
30-11
30-12
30-13
30-14
30-15
30-16
31-1
31-3
31-4
31-5
31-6
31-7
31-9
31-11
31-14
33-1
33-3
33-4
33-5
33-6
33-7
33-8
35-1
35-4
35-5
35-13
36 STEERING ASSEMBLY
Axial ball joint
Steering box
Steering column
Retractable shaft
Variable power-assisted steering
Power assisted steering pump
36-1
36-4
36-8
36-13
36-14
36-15
37-1
37-3
37-9
37-10
37-14
37-15
37-17
37-18
37-19
37-21
37-25
37-26
37-27
37-33
ELECTRONICALLY CONTROLLED
38 HYDRAULIC SYSTEM
38-1
GENERAL INFORMATION
130
Dimensions of the main braking components
30
BGOA
BGOB
BGOR
BK/GOG
BK/GOA
BK/GOB
BK/GOR
BGOD
KGOD
57
57
60
Diameter of discs
280
300
308
Thickness of discs
24
26
28
21.5
23.5
25.5
17
17.5
17.5
0.07
0.07
0.07
38
38
38
Diameter of discs
274
300
300
Thickness of discs
11
11
11
8.5
8.5
8.5
16
16
16
7.5
7.5
7.5
23.8
23.8
23.8
(*)
Brake discs cannot be reground. If they are too heavily worn or are scratched they must be replaced.
30-1
FRONT AXLE
10.5
6.2
28
11
3.7
1.5
2.1
4.4
4.4
GENERAL INFORMATION
Tightening torques (in daN.m)
30-2
30
FRONT AXLE
10.5
10.5
18
2.1
2.1
GENERAL INFORMATION
Tightening torques (in daN.m)
30-3
30
FRONT AXLE
18
10.5
18
18
GENERAL INFORMATION
Tightening torques (in daN.m)
30-4
30
FRONT AXLE
28
10.5
10.5
1.4
1.4
GENERAL INFORMATION
Tightening torques (in daN.m)
30-5
30
GENERAL INFORMATION
Tightening torques (in daN.m)
30
DIMENSIONS
TIGHTENING TORQUES
0.6 to 0.8
M 10 x 100
1.4
M 10 x 100
1.4
M 10 x 100
1.4
M 10 x 100
or
M 12 x 100
1.4
M 12 x 100
M 10 x 100
1.4
Bleed bolt
30-6
GENERAL INFORMATION
Axles and suspension
30-7
30
GENERAL INFORMATION
Axles and suspension
FRONT AXLE
30-8
30
GENERAL INFORMATION
Underbody height
The underbody height is measured, vehicle unladen,
on a level surface (preferably a four-post lift):
full fuel tank,
tyre pressures correct.
Measure dimensions:
H1 and H2 for the front
H4 and H5 for the rear
and calculate the difference.
H1 - H2 = 122.5 3.5 mm
30
H4 - H5 = 105 3.5mm
30-9
GENERAL INFORMATION
Parts to be replaced when they have been removed
30
Brake fluid
BRAKE FLUID REPLACEMENT INTERVAL
Braking technology, in particular for disc brakes (hollow pistons which transmit little heat, low volume of fluid in the
cylinder, sliding calipers avoiding the need for a fluid reservoir in the least cooled area of the wheel), has allowed us
to avoid the risk of vapour lock as far as possible, even if the brakes are used intensively (in mountainous areas).
Modern brake fluids still degrade slightly during the first few months of use due to a small uptake of humidity and
replacement of the fluid is therefore recommended:
see the vehicle's Servicing Handbook.
Topping up the level:
Wear of the brake pads and shoes will cause a gradual drop in the fluid level in the reservoir. This drop should not be
compensated for since the level will rise again when the pads are changed. The level should not however be
allowed to fall below the minimum mark.
Approved brake fluids:
Mixing two incompatible brake fluids in the circuit will cause a risk of major leaks, mainly due to deterioration of the
cups. To avoid such risks, it is important to use only those brake fluids which have been tested and approved by our
Technical Department and which conform to standard SAE J 1703 dot 4.
30-10
GENERAL INFORMATION
Brake unions and pipes
The connection of the pipes between the master
cylinder, caliper, compensator and the hydraulic
assembly is made using threaded unions with a
METRIC THREAD.
Consequently, only parts specified in the Parts
Catalogue for this vehicle should be used.
Identification of parts:
SHAPE of the ends of PIPES in steel or copper (A).
SHAPE of the THREADED LOCATIONS on
components (B).
pipe UNIONS coloured GREEN or BLACK: external
hexagon measuring 11 mm or 12 mm (C).
30-11
30
GENERAL INFORMATION
Influence of angles
30
CAMBER
The comparison between the left and right angles is vital. A difference of more than one degree between the
two dimensions leads to a deviation from the straight that has to be corrected at the steering wheel and causes
abnormal wear on the tyres.
The value of this angle is usually slight: in the region of 1.
CASTOR
The comparison between the left and right angles is vital. A difference of more than one degree leads to a
deviation from the straight that has to be corrected at the steering wheel and causes abnormal wear on the tyres.
This is characterised by drifting with the speed being stabilised on the side where the angle is smallest.
STEERING HEIGHT
This travel affects the parallelism variation during suspension travel.
Different parallelism variations between the right-hand and left-hand wheels (without the steering wheel changing
position):
drift to one side on acceleration,
drift the other side under braking,
track changes on uneven road surfaces.
PARALLELISM
This adjustment has little effect on road holding.
Note:
a significant toe-out excess leads to symmetrical wear on the inside of both tyres,
a significant toe-in excess leads to symmetrical wear on the outside of both tyres.
30-12
GENERAL INFORMATION
Angle testing principle
30
PRELIMINARY CHECKS
Before checking the axle angles, you must check the
following points and remedy them if necessary:
Identical tyres on the same axle:
dimensions,
pressure,
degree of wear.
Joints:
condition of cushions and elastic bearings,
ball joint gaps,
bearing gaps.
Wheel run-out: (compensated for by reading
devices).
30-13
GENERAL INFORMATION
Front axle checking and adjustment
30
30-14
GENERAL INFORMATION
Front axle checking and adjustment
30
Distribution
Correction to be made
OK
Not OK
Make the same number of turns with the adjuster (or sockets)
but in the opposite direction on the left and right to get the
same value (A) on both sides.
NOT OK
OK
Adjust the parallelism to the same value on the right and left,
ensuring that there are always identical values (A) on both
sides.
NOT OK
Not OK
POSSIBLE CAUSES
Bent arm
Bent side member or axle sub-frame
Castor problems
Bent arm
Correct camber
but
Pivot problems
Correct pivot
but
Camber problems
See castor
Bent arm
Bent side member
Incorrect parallelism more than 6 mm
30-15
GENERAL INFORMATION
Brake fault finding
I
30
POSSIBLE CAUSES
Hard pedal:
Heavy pressure produces only weak deceleration
Servo-assistance failure
Brake shoes may be:
dirty,
frozen, not in good order,
heated up, prolonged braking with the pedal
constantly depressed (descending a mountain),
not in good order,
Jammed piston
Crushed pipes
Elastic pedal
Vehicle running
Judgement test: pedal travel/deceleration
relationship
2.
Spongy pedal
Boiling fluid
30-16
GENERAL INFORMATION
Brake fault finding
II
30
EFFECTS ON HANDLING
FAULTS
POSSIBLE CAUSES
Brakes engage
Brakes judder
Jammed piston
Automatic adjustment: handbrake cable is too taut
NOTE: automatic compensation is operated via the
brake pedal, if there is no abnormal tension in the
handbrake cable when it is not in use
Recall spring
Brakes heat up
30-17
131
Point A
18
Point B
18
11
4.4
3.7
Wheel bolts
Steering shaft yoke bolts
10.5
2.1
31-1
31
31
REFITTING
Replace the bolts on:
the arms,
the sub-frame,
the steering rack fork.
Remove:
the steering shaft yoke bolt,
the torque reaction arm bolts,
the acoustic damper bolts and the sub-frame rear
mounting bolts.
31-2
31
REFITTING
0.7
10.5
REMOVAL
Remove:
the spring on the front face of the caliper,
the shock absorber brake pipe,
31-3
0.7
0.3
Wheel bolt
31
10.5
REMOVAL
31-4
31
1.5
10.5
Wheel bolt
10.5
REMOVAL
Put the vehicle on a two-post lift,
Remove:
the front wheels,
the caliper (see pad removal method).
Hang up the caliper.
IMPORTANT: make sure the brake pipe and ABS
sensor wiring are properly secured if they have
been unfastened.
Remove:
the two brake disc mounting bolts,
the disc.
REFITTING
Proceed in the reverse order from removal.
IMPORTANT: before starting the engine, depress
the brake pedal repeatedly to establish contact
between the pads and the brake discs.
31-5
31
Rou. 604-01
18
11
3.7
1.5
10.5
Hub nut
28
Wheel bolt
10.5
the disc,
the steering tie rod ball joint nut,
the lower ball joint nut,
the shock absorber base mounting bolts,
REMOVAL
Put the vehicle on a two-post lift.
Remove the front wheels.
Unclip the ABS sensor on the stub-axle carrier.
Remove the caliper (see brake pad removal).
Hang up the caliper.
the stub-axle carrier.
Remove:
the hub nut,
REFITTING
Proceed in the reverse order from removal.
The caliper fork bolts must be coated with a product
such as FRENEBLOC before they are put back.
IMPORTANT: before starting the engine, depress
the brake pedal repeatedly to establish contact
between the pads and the brake discs.
NOTE: if the vehicle is fitted with them, it is necessary
to initialise the XENON lamps (see chapter 80
"Initialisation").
31-6
31
2.1
4.4
18
11
4.4
10.5
REMOVAL
Put the vehicle on a two-post lift,
Remove the front wheels.
Unfasten the shock absorber brake pipe.
Left-hand side
Remove the mounting pins from the wheel arch cover.
Make a cut in the cover to allow access to the shock
absorber upper mounting bolts.
Remove:
the upper mounting of the stabiliser bar return tie-rod,
the steering tie rod nut,
the shock absorber lower bolts.
31-7
31
Right-hand side
REFITTING
Raise then slide the right-hand cover under the lefthand cover.
Take out the cover from the wing side.
Remove:
the shock absorber rod nut and its upper stop,
the two shock absorber upper mounting bolts on the
body,
the shock absorber and spring assembly.
31-8
4.4
REMOVAL
Place the appropriate cups on the compression tool
and position the assembly on the spring.
31-9
31
31
31-10
2.1
6.2
Sub-frame bolt
10.5
2.1
4.4
3.7
4.4
4.4
Wheel bolt
Steering shaft yoke bolt
10.5
2.1
REMOVAL
Put the vehicle on a two-post lift.
Disconnect the battery.
Remove:
the engine undertray,
the lower mountings of the bumpers,
the wheels.
Fit a steering immobiliser.
Remove:
the front mudguards,
both left-hand tie-rods and the right-hand tie-rod,
the mounting bracket bolts of the brake pipe and ABS
sensor.
the linkage for the Xenon lamp position sensor if
fitted to the vehicle at (A),
the stabiliser bar return tie-rod nuts.
31-11
31
31
Unclip the brake pipes and ABS sensor wiring from the
sub-frame and the tie-rods.
Remove:
the steering shaft yoke bolt,
the torque reaction arm bolts,
the accoustic damper bolts and the sub-frame rear
mounting bolts.
Remove:
both sub-frame tie-rod mounting bolts on the body,
and lower the sub-frame by 20 cm.
31-12
REFITTING
Replace the sub-frame bolts and torque tighten them
using the opposite procedure to removal.
IMPORTANT: steering column timing is required to
replace the steering rack fork bolt (see the chapter
on steering).
NOTE: if the vehicle is fitted with them, it is necessary
to initialise the XENON lamps (see chapter 80
"Initialisation").
31-13
31
31
2.1
6.2
Sub-frame bolt
10.5
2.1
4.4
3.7
4.4
4.4
Wheel bolt
Steering shaft yoke bolt
10.5
2.1
REMOVAL
Remove:
both aluminium side members,
31-14
31
Unclip the brake pipes and ABS sensor wiring from the
sub-frame and the tie-rods.
Remove the lower wishbone nuts.
Remove:
the steering shaft yoke bolt,
the mounting bolt on the power-assisted steering
pipe,
the torque reaction arm bolts,
the accoustic damper bolts and the sub-frame rear
mounting bolts.
31-15
REFITTING
Fit the new sub-frame.
Replace the sub-frame bolts and torque tighten them
using the opposite procedure to removal.
IMPORTANT: steering column timing is required to
replace the steering rack fork bolt (see the chapter
on steering).
NOTE: if the vehicle is fitted with them, it is necessary
to initialise the XENON lamps (see chapter 80
"Initialisation").
31-16
31
33
EQUIPMENT REQUIRED
Ratchet socket wrench
FACOM REF 68 PE
Hexagon socket
10.5
Pillar bolt
0.7
33-1
33-2
33
33
10.5
Pillar bolt
0.7
Yoke bolt
10.5
REMOVAL
Remove the wheels.
Fit a pedal press to prevent brake fluid from escaping.
Unclip the handbrake cables from the rear axle.
Release the brake pipe from the caliper.
Remove:
REFITTING
Push the piston back, tightening it using tool
Fre. 1190-01.
Proceed in the reverse order from removal.
If the compensation reservoir is not completely
emptied during the operation, bleed the brake circuit
partially, if not bleed it completely (see bleeding
method).
33-3
33
10.5
Pillar bolt
0.7
Yoke bolt
10.5
Hub nut
28
REMOVAL
Remove:
the wheels,
the brake caliper (see brake pad method),
the two bolts on the caliper bracket,
the hub cover plug,
the hub nut (using a 36 mm dowel).
the hub-disc.
REFITTING
Proceed in the reverse order from removal.
IMPORTANT: before starting the engine, depress the
brake pedal repeatedly to establish contact between
the brake pads and the brake discs.
33-4
33
10.5
0.7
10.5
Stub-axle nut
28
10.5
REMOVAL
Remove the wheel (side in question).
According to the method, remove:
the brake caliper (see brake pad method),
the caliper bracket (bolt C)
REFITTING
Proceed in the reverse order from removal.
IMPORTANT: before starting the engine, depress the
brake pedal repeatedly to establish contact between
the brake pads and the brake discs.
33-5
33
EQUIPMENT REQUIRED
Component jack
10.5
10.5
REMOVAL
Put the vehicle on a two-post lift.
Remove:
the wheels,
the covers of the spring cups (A).
Place a component jack under the spring's lower cup.
Do the same for the other shock absorber.
Remove:
the shock absorber lower bolt (B),
REFITTING
Proceed in the reverse order from removal.
IMPORTANT: the shock absorber mounting bolts must
be tightened with the wheel to the floor to ensure the
elastic joints function properly.
NOTE: if the vehicle is fitted with them, it is necessary
to initialise the XENON lamps (see chapter 80
"Initialisation").
33-6
33
EQUIPMENT REQUIRED
Component jack
Locate the position of the spring for easier assembly.
TIGHTENING TORQUE (in daN.m)
Shock absorber lower bolt
10.5
REMOVAL
Put the vehicle on a two-post lift.
Remove:
the wheels,
the covers of the spring cups (A).
Place a component jack under the spring's lower cup.
Remove:
the shock absorber lower bolt (B),
Lower the rear axle, press down and remove the
spring.
REFITTING
Proceed in the reverse order to removal observing the
position of the spring.
NOTE: if the vehicle is fitted with them, it is necessary
to initialise the XENON lamps (see chapter 80
"Initialisation").
33-7
33
EQUIPMENT REQUIRED
Component jack
10.5
0.7
10.5
Hub nut
28
10.5
Brake union
Shock absorber lower bolt
Rear axle mounting bolt
1.4
10.5
8
Remove the brake tubes all along the axle (if replacing
the rear axle);
Place a component jack under the spring's lower cup.
Remove the shock absorber lower bolt (B).
REMOVAL
Put the vehicle on a two-post lift.
Remove:
the wheels,
the covers of the rear axle spring cups (A),
the rear axle brake pipe connections.
Disconnect the handbrake cables.
Remove:
the ABS sensors,
the linkage for the Xenon lamp position sensor in (1)
(if the vehicle is fitted with it),
the brake caliper (if replacing the rear axle),
the caliper brackets (if replacing the axle) in (C),
the hub brake discs with a 36 mm dowel (if replacing
the rear axle).
33-8
REFITTING
Proceed in the reverse order from removal.
Bleed the brakes (see bleeding method).
IMPORTANT: before starting the engine, depress the
brake pedal repeatedly to establish contact between
the brake pads and the brake discs.
NOTE: if the vehicle is fitted with them, it is necessary
to initialise the XENON lamps (see chapter 80
"Initialisation").
33-9
33
135
35
WHEEL RIMS
The identification marking of the wheel rims comes in two forms:
The marking gives the main dimensional specifications of the wheel rim.
The marking may be complete:
Example: 5 1/2 J 14 4 CH 36
or simplified:
Example: 5 1/2 J 14
WHEEL
RIM
TYPE
WIDTH
(in inches)
RIM
PROFILE
NOMINAL (in
inches). under
tyre bead
Number
of holes
Tyre bead
profile
Offset in
mm
5 1/2 J 14
4 CH 36
5 1/2
14
CH
36
35-1
35
TYRES
The identification marking can come in two forms for the same type of tyre.
Example: 185/70 H R 14
Or
185/70 R 88 H
185
1
185
70
14
70
14
88
185
70
h/S ratio
Radial structure
14
88
height
Section
Maximum speed
R
S
T
U
H
V
Z + de
Types of structure:
Diagonal
Radial
Bias belted
No marking
R
B (Bias belted)
35-2
Km/h
170
180
190
200
210
240
240
Type
Rim
Wheel rim
run-out
Wheel
tightening
torque
(daNm)
Tyres
35
Pressure
when cold
(bar)
Front
Rear
10.5
195/65R15H
205/55R16V(1)
2.3
2.2
6.5J16 (1)
10.5
205/55R16V
2.5
2.2
6.5J16*
7J17*
0.3
10.5
205/55R16
225/45R17V
205/60R16V
2.3
2.2
KG0A
KG0B
KG0R
KG0G
6.5 J 16
10.5
205/55R16V
2.3
2.2
BG0D
KG0D
6.5J16*
7J17*
0.3
10.5
205/55R16V
205/60R16V
225/45R17V
2.7
2.2
BG0A
BG0B
BG0R
6.5J15
6.5J16 (1)
BG0G
BG0A
BG0B
BG0R
BG0G
KG0A
KG0B
KG0R
KG0G
35-3
BALANCE WEIGHTS
Only use weights provided by the Parts Department:
attached to the steel wheel rims by hooks (hooks are
built into the weights),
fitted using hooks (flat hooks) or self adhesive for
alloy wheels.
A Metal rim
B Aluminium alloy
35-4
35
35
DESCRIPTION
The system is made up of:
four pressure sensors (1) incorporated into the valves (one per wheel). They transmit a radio signal,
a transmitter (2) under the vehicle which receives and decodes the signals from the sensors and transmits it to the
UCH,
the UCH (3) which receives and processes the signals from the transmitter (2) and determines the message to be
displayed,
a display (4) (separate or integrated into the instrument panel).
35-5
35
GENERAL INFORMATION
35-6
Note: the battery belonging to the pressure sensor valve cannot be replaced.
35-7
35
35-8
35
35-9
35
35
THE PRESENCE OF A PRESSURE MONITORING SENSOR IN THE WHEELS MEANS THAT PRECAUTIONS
MUST BE TAKEN WHEN REMOVING AND REFITTING TYRES. IF THIS ADVICE IS NOT FOLLOWED IT WILL
LEAD TO DAMAGE TO THE SENSOR AND RESULT IN FAILURE OF THE PRESSURE SYSTEM MONITORING
SYSTEM TO FUNCTION.
PROGRAMMING PRESSURE SENSORS IN THE
UCH
4.25 0.75
18886
35-10
35
8
9
10
11
12
13
14
15
16
35-11
35-12
35
35
REPLACEMENT
THE PRESENCE OF A PRESSURE MONITORING SENSOR IN THE WHEELS MEANS THAT PRECAUTIONS
MUST BE TAKEN WHEN REMOVING AND REFITTING TYRES. IF THIS ADVICE IS NOT FOLLOWED IT WILL
LEAD TO DAMAGE TO THE SENSOR AND RESULT IN FAILURE OF THE PRESSURE SYSTEM MONITORING
SYSTEM TO FUNCTION.
REMOVAL
Detaching the bead from the outside of the tyre
35-13
REFITTING
When the tyre is refitted to the wheel rim, the beads
must be correctly lubricated. Insert the inner bead
about 15 cm after the valve. Put the tyre back on the
wheel rim finishing with the valve and making sure not
to pull on the pressure sensor.
Carry out the same steps as above for the outer bead,
taking care not to pull on the sensor. Reinflate the tyre
to the recommended pressure.
35-14
35
STEERING ASSEMBLY
136
Axial ball joint
36
The axial ball joint is replaced with the steering box in position on the vehicle. In fact, the Dir. 1305 tool enables the
axial ball joints to be slackened via the wheel arch.
36-1
STEERING ASSEMBLY
Axial ball joint
36
10.5
3.7
REMOVAL
Disconnect the track rod end using tool T.Av. 476.
Slacken the bolt on the parallelism adjustment sleeve
and slacken the track rod end while holding the axial
ball joint using an open wrench.
Make a mark or count the number of turns of thread
taken up so the parallelism can be readjusted on
refitting.
Take off the plastic retaining clips for the gaiter and
remove the gaiter.
36-2
STEERING ASSEMBLY
Axial ball joint
36
REFITTING
NOTE: Before refitting the new tie-rods, pass
a12 x 100 tap over the threads at the ends of the
steering rack in order to remove any trace of LOCTITE
from the original fitting and so prevent seizure of the
threaded sections on refitting.
Always replace them all (2). If the ball joint notch (1)
has not deteriorated, it can be reused.
36-3
STEERING ASSEMBLY
Steering rack
36-4
36
STEERING ASSEMBLY
Steering rack
SPECIAL TOOLING REQUIRED
Mot. 453-01 Set of 2 hose clamps for general use
T. Av. 476
18
6.2
Sub-frame bolt
10.5
2.1
4.4
3.7
10.5
4.4
4.4
Wheel bolt
Steering shaft yoke bolt
10.5
2.1
36-5
36
STEERING ASSEMBLY
Steering rack
36
Unclip the brake pipes and sensor wiring from the subframe and the tie-rods.
36-6
STEERING ASSEMBLY
Steering rack
36
Remove:
the rack heat shield,
the steering rack.
36-7
STEERING ASSEMBLY
Steering Column
36-8
36
STEERING ASSEMBLY
Steering Column
36
Steering shim
2.1
2.1
0.8
0.2
4.4
REMOVAL
Before performing any operation on the air bag
systems, lock the electronic unit using the fault
finding tools. This opens the electronic lock on the
column (see chapter 88).
Remove:
the air bag cushion,
36-9
STEERING ASSEMBLY
Steering Column
Disconnect the connectors from the switch assembly.
36
Remove:
the mounting bolt from the switch assembly. This can
be reached by centring the air bag sensor on its
middle point.
36-10
STEERING ASSEMBLY
Steering Column
36
REFITTING
IMPORTANT: the steering yoke bolt and steering
wheel bolt must be replaced and torque tightened
every time they are removed.
Position the column shim Dir. 1594 to centre it and to
ensure it is locked (the shaft (1) ring must be visible in
front of the shim).
Refit:
the steering shaft yoke, torque tightened (2,1 daN.m)
the two mounting bolts on the steering column,
the bolt on the instrument panel,
the electric lock with its left-hand thread bolt,
the rotary switch.
NOTE: the cover (C) on the yoke nut is not to be
replaced during reassembly.
36-11
STEERING ASSEMBLY
Steering Column
Rotary switch features
36
36-12
Unlock the air bag electronic unit and test it for faults.
Check that the electric lock is working properly and
that the column locks when the ignition is switched off.
STEERING ASSEMBLY
Retractable shaft
36
These vehicles are fitted with a non removable retractable shaft - steering wheel shaft - steering column assembly. If
it is impossible to tighten the eccentric bolt of the universal joint or after an accident, check that the length of the
shaft is correct, otherwise replace the assembly (see "Steering column" chapter).
CHECKING
Left-hand drive
L = 329.5 1 mm
Right-hand drive
L = 321.1 1 mm
36-13
STEERING ASSEMBLY
Variable power assisted steering
36
The variable hydraulic power assisted steering system is designed to provide superior power steering to the
Constant Assistance Steering during stopping manoeuvres and to progressively alleviate the assistance when the
vehicle speed increases.
At high speed, it makes the steering much steadier than Constant Assistance Steering.
DESCRIPTION
For the hydraulic part:
a power assisted steering pump
a component jack
a valve controlled by an electromechanical actuator
a reservoir
pipes
For the electric part:
a function incorporated into the UCH
vehicle speed information
an actuator
REMOVAL
The method for removing the variable assistance steering box is identical to the removal method for the constant
assistance steering box described previously.
36-14
ENGINES
F9Q-F4P
STEERING ASSEMBLY
Power steering pump
SPECIAL TOOLING REQUIRED
Mot. 453-01
Hose clamps
REMOVAL
Remove:
the two mounting bolts of the power steering
reservoir,
the front right-hand mudguard,
the accessories belt.
Fit a clamp Mot. 453-01 to the supply pipe.
Disconnect the supply and high pressure pipes.
Expect fluid to drain from the power-assisted steering.
Remove the three pump mounting bolts and remove
the pump.
REFITTING
Follow the reverse procedure to removal, maintaining
belt tension (see chapter 07 "Accessories Belt
Tension")
Fill and bleed the circuit turning from lock to lock with
the engine running.
36-15
36
ENGINES
F4P-F9Q
STEERING ASSEMBLY
Power steering pump
36
PULLEY REPLACEMENT
REFITTING
REMOVAL
According to the way it is assembled, remove the
pulley after raising it to a level with the end of the shaft.
Grasp the pulley with tool Dir. 1083-01 until you reach
the level it was pulled up to when it was removed
(liberally grease the threading and the pad on the
pulley).
36-16
K4M ENGINE
STEERING ASSEMBLY
Power steering pump
SPECIAL TOOLING REQUIRED
Mot. 453-01
Hose clamps
REMOVAL
Remove:
the two mounting bolts from the power steering
reservoir and put them on one side,
the injection ramp protection (two nuts),
the accessories belt using an Allen key which allows
the tensioner to be blocked after it is tilted.
36-17
36
K4M ENGINE
STEERING ASSEMBLY
Power steering pump
36
REFITTING
Proceed in the reverse order from removal.
Fill and bleed the circuit turning from lock to lock with
the engine running.
36-18
KM4 ENGINE
STEERING ASSEMBLY
Power steering pump
36
A Hub
B Power assisted steering pump
X = 39.2 mm
36-19
L7X Engine
STEERING ASSEMBLY
Power steering pump
36
Hose clamps
REMOVAL
REFITTING
Remove:
the plastic covers on top of the engine,
the two mounting bolts of the power steering
reservoir mounting,
the accessories belt: to do this follow the method in
chapter 07,
the four mounting bolts of the pulley on the assisted
steering pump.
Place Mot. 453-01 clamps on the hoses to be
removed.
Remove:
the supply hose on the power assisted steering
pump,
the pressure hose,
the three mounting bolts of the assisted steering
pump,
the power assisted steering pump.
NOTE: Expect power steering fluid to drain during this
manipulation: protect the alternator.
36-20
L7X Engine
STEERING ASSEMBLY
Power steering pump
36
36-21
STEERING ASSEMBLY
Power steering pump
36
803
Dir. 1 204
Fre.
244-03
Fre.
36-22
STEERING ASSEMBLY
Power steering pump
PRESSOSTAT METHOD
36
36-23
MECHANICAL ELEMENT
137 CONTROLS
Master cylinder
37
0.35
Brake pipe
1.4
2.1
REMOVAL
Remove:
the air resonator box,
the expansion bottle,
the brake fluid level connector,
the mounting bolt of the tank on the master
cylinder (1).
37-1
37-2
37
UNITS
JH3 - JR5
0.35
Brake pipe
1.4
2.1
2.9
37
REMOVAL
Place the vehicle on a lift.
IMPORTANT: drain out the brake fluid to prevent
the mechanical parts and bodywork around the
braking system from deteriorating.
Remove:
the master cylinder (see method),
the non-return valve on the brake servo,
the brake servo connectors.
37-3
UNIT DP0
37
0.35
Brake pipe
1.4
2.1
2.9
REMOVAL
Place the vehicle on a lift.
IMPORTANT: drain out the brake fluid to prevent
the mechanical parts and bodywork around the
braking system from deteriorating.
Remove:
the master cylinder (see method),
the non-return valve on the brake servo,
the brake servo connectors.
In the passenger compartment, remove:
the brake pedal yoke shaft of the push rod on the
brake servo,
the two brake servo mounting nuts.
37-4
UNIT PK6
0.35
Brake pipe
1.4
2.1
2.9
37
37-5
UNIT SU1
0.35
Brake pipe
1.4
2.1
2.9
Inlet manifold
37
0.5 + 0.8
REMOVAL
Remove:
the air filter hoses,
the inlet manifold,
the air filter unit,
the fuse holder unit,
the master cylinder (see method),
the non-return valve on the brake servo,
the brake servo connectors.
37-6
37-7
37
37
453-01
Hose clamps
EQUIPMENT REQUIRED
Vacuum pump
CHECKING SEALING
When checking the sealing of the brake servo, ensure the seal between the brake servo and the master cylinder is
perfect. If there is a leak, replace the seal (A).
37-8
37
REFITTING
Check the condition of the rubber sealing washer and
the non-return valve.
Replace any faulty parts.
It is not necessary to remove the brake servo to
change the air filter (F).
37-9
37
PREAMBLE
The emergency braking assistance is a supplementary mechanism to the ABS system.
DESCRIPTION
The emergency braking assistance functions thanks to two technological features. One relies on the use of
electronic components (electronic EBA). The other on the use of mechanical components (mechanical EBA).
The EBA (electronic):
has a brake servo fitted with an interrupter to detect the action of the driver on the pedal,
a movement sensor,
a master cylinder.
It is controlled by the ABS computer.
The EBA (mechanical):
has a brake servo fitted with a valve that reacts to the speed of pedal depression.
In both cases, detecting the pedal depression speed generates pressure in the brake circuit, via the braking
amplifier, particularly when superimposed on the pressure exerted by the driver.
The maximum pressure is limited by the level of depression being exerted in the amplifier.
OPERATING PRINCIPLE
The emergency braking assistance enables the system to recognise a situation and act immediately to provide the
best possible stopping distance.
Speed of depression on the brake pedal detects the emergency brakes; in this situation, the brake assist instantly
gathers maximum power and reaches the ABS regulation as quickly as possible.
The ABS braking is then maintained until the driver releases the brake pedal.
The system works conventionally for current brakes.
37-10
37-11
37
37
BRAKE SERVO
EBA (mechanical)
EBA (electronic)
REMOVAL
The brake servo is removed in the same way for an
electronic emergency braking assistance and a
mechanical emergency braking assistance.
The only difference is in disconnecting the
connections, see brake servo removal.
37-12
37
REFITTING
IMPORTANT: replace the seal before refitting the
diaphragm movement sensor.
Position the sensor on the brake servo and press
down on it to clip it on.
REMOVAL
Disconnect the sensor.
Push back the sensor mounting clip and remove it
using a small screwdriver.
37-13
REFITTING
The brake pedal position sensor has automatic
adjustment which adapts according to the pedal
position.
Before refitting it, it needs to be pulled up to its
minimum position.
REFITTING
Put the sensor in its housing and make a quarter turn
clockwise.
Reconnect the connector of the brake pedal position
switch.
37-14
37
Remove:
The central console,
the handbrake control lever mountings,
2.1
REMOVAL
In the passenger compartment
Remove:
the gear shift lever gaiter,
the handbrake gaiter,
the RENAULT card,
the two bolts in front of the central dashboard,
REFITTING
Proceed in the reverse order from removal.
the two bolts behind the central console.
37-15
37
Wheel adjustment
37
Ensure:
the cables slide freely,
the handbrake levers move properly and are at their
lowest point.
37-16
37
REMOVAL
REFITTING
Fit the caliper to the brake and screw the hose onto it,
then torque tighten to 1.4 daN.m.
The brake pipes are fitted when the axle assembly is in
position:
Wheels suspended (suspension in place)
Axle in line (wheels straight)
Position the female end of the hose on the retaining
bracket (5), without twisting it and check that the end
piece (4) fits freely into the splines of the bracket, then
fit:
the spring (3),
the rigid pipe to the hose, checking that the hose
does not turn when the assembly is screwed
together.
Torque tighten the union.
Bleed the brake circuit.
37-17
MECHANICAL ELEMENT
137 CONTROLS
Exploded view of clutch master and slave cylinders
37-18
37
37-19
37
37
REFITTING
Check the condition of the seals.
Proceed in the reverse order from removal.
The master is fitted with a foolproofing device. There is
only one position.
37-20
PK6
37
0.9
REMOVAL
The clutch slave cylinder can only be removed after
removing the gearbox.
Disconnect the master-slave connecting pipe by
releasing the clip (2) located on the union (C).
37-21
PK6
37
REFITTING
Check the condition of the seals.
Proceed in the reverse order from removal.
Torque tighten the two slave mounting bolts (B) to
0.9 daN.m.
37-22
JR - JH
37
0.9
REMOVAL
NOTE: The clutch slave cylinder (C) can only be
removed after removing the gearbox, see chapter 21.
37-23
JR - JH
37
REFITTING
Check the condition of the seals.
Proceed in the reverse order from removal.
Torque tighten the two slave mounting bolts (A) and
(B) to 0.9 daN.m.
37-24
REFITTING
37
IMPORTANT:
When refitting:
do not damage the various pipes,
take care to connect them correctly,
position the various mounting clips correctly.
Add brake fluid to the reservoir.
Bleed the hydraulic circuit:
connect a tube to opening (C) linked to a tank filled
with brake fluid,
lift up the clip (2),
pull the pipe to the first notch,
fit the bleeding device,
activate the bleeding device,
wait until the air is completely expelled from the
hydraulic circuit,
clip the pipe back onto the clutch slave cylinder.
37-25
3.4
REMOVAL
Disconnect the battery
Set the vehicle wheels straight.
Remove the ball joint from the clutch sender pedal.
Remove:
the three plate nuts (A),
the two pedal sensor connectors (B).
REFITTING
To refit, proceed in the reverse order to removal.
Torque tighten the nuts to 3.4 daN.m.
37-26
37
37-27
37
JR - JH
37
Remove:
the resonator unit (C),
REMOVAL
First remove the centre console before performing this
operation (see relevant chapter).
37-28
PK
37
REMOVAL
First remove the centre console before performing this
operation (see relevant chapter).
Take off the clips (D) from the external gear control
cables (E).
18614
37-29
PK
REFITTING
To refit, proceed in the reverse order to removal.
37-30
37
37-31
37
DP0/SU1
37
SPECIAL FEATURE:
When the vehicle is immobilised, it is possible to
unlock the gear selector lever by pressing the button
under the gaiter.
Cut out the circular shape under the unit using a blade.
Take out the unit cable.
Remove the control unit (A).
REMOVAL
First remove the centre console before performing this
operation.
Under the vehicle:
Disconnect the oxygen sensor (A) (if fitted).
Remove:
the exhaust system (see chapter 19),
the two mounting bolts on the heat shield,
the heat shield (B).
REFITTING
To refit, proceed in the reverse order to removal.
IMPORTANT: position the cables properly.
37-32
DP0
37
REMOVAL
Under the vehicle:
Disconnect the oxygen sensor (A).
Remove:
the exhaust system (see chapter 19),
the two mounting bolts on the heat shield,
the heat shield (B).
Unclip:
the ball joint (1) of the multifunction switch cable
(MFC),
the cable (2) of the multifunction switch by releasing
the sleeve stop.
Cut out the circular shape under the unit using a blade.
37-33
DP0
37-34
37
SU1
37
Unclip:
the ball joint (1) of the multifunction switch cable
(MFC),
the cable (2) of the multifunction switch by releasing
the sleeve stop.
REMOVAL
Under the vehicle:
Remove:
the exhaust system (see chapter 19),
the two mounting bolts on the heat shield,
the heat shield (B).
Cut out the circular shape under the unit using a blade.
In the engine compartment:
Remove the external gear control cable.
37-35
SU1
37-36
37
ELECTRONICALLY CONTROLLED
138 HYDRAULIC SYSTEM
ESP MK 60
1
2
3
4
38-1
38
1
2
3
4
5
6
7
8
Hydraulic assembly
Wheel sensor
Steering wheel angle sensor
Lateral speed and acceleration sensor
Engine management computer
Motorised throttle body
Pressure sensor
CAN connection
38-2
38
1
2
3
4
5
6
7
8
9
A
Hydraulic assembly
Computer
Mechanical component based braking amplifier
Steering wheel angle sensor
Lateral speed sensor
Vehicle speed
CAN network
Wheel sensor
Diagnostic socket
Private CAN network
38-3
38
38
PREAMBLE
The ESP (Electronic Stability Program) is a supplementary mechanism to the ABS system.
DESCRIPTION
ESP (Electronic Stability Program) is made up of the following components:
an amplifier assembly fitted with: EBA (Emergency Braking Assistance), master cylinder with pressure sensor,
a pump assembly made up of:
a hydraulic pump,
a pressure modulation unit (twelve solenoid valves),
an electronic computer.
a steering wheel angle sensor,
the lateral speed and acceleration sensor,
the four wheel sensors.
OPERATING PRINCIPLE
The ESP (Electronic Stability Program) establishes reference conditions for the vehicle and applies corrective
braking action when these references are deviated from.
The reference conditions are continually monitored from measurements taken from the vehicle and refer to the
desired level of performance.
These measurements are:
wheel speed,
steering wheel angle.
These reference conditions are compared to the actual condition of the vehicle, determined by measuring:
the lateral speed,
the lateral acceleration.
The (Electronic Stability Program) makes use of the differences between these performances to calculate the
braking action to apply independently to one or more wheels according to a specific distribution strategy.
The resultant forces applied by the braking activate rotation torques on the vehicle which replace it on a course
correspondent with the desired performance.
38-4
38
Course noted
CORRECTIVE MEASURES
BRAKES AND ENGINE
38-5
Remove:
the wheels,
the left mudguard,
the front of the right-hand mudguard,
the long surface connections,
the bumper,
the air regulator unit (L7X engine),
the pre-postheating unit (F9Q engine),
the ABS connector,
1.4
4.4
4.4
The hydraulic assembly is positioned on the front lefthand side of the vehicle, behind the front bumper.
38-6
38
Remove:
the three ABS mounting bolts,
the three mounting bolts of the ABS assembly on its
mounting,
the ABS assembly.
38-7
38
38
ABS COMPUTER
REFITTING
REMOVAL
the computer.
IMPORTANT: when it is being removed, the
hydraulic pump (A) must be pressed onto the
pressure modulation unit.
38-8
38
Allocation of tracks in ABS ESP (Electronic Stability Program) with electronic EBA (Emergency Braking
Assistance)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
38-9
38-10
38
38
38-11
38-12
38
38
Remove:
the two mounting nuts from the lateral speed and
acceleration sensor plate,
REFITTING
Proceed in the reverse order from removal.
REMOVAL
In the passenger compartment
Remove:
the gear shift lever gaiter,
the handbrake gaiter,
the plate above the central console.
Disconnect the connectors.
38-13
38
WHEEL SENSORS
38-14
2.5
38-15
38
NOTE: MARK 60 hydraulic units and MARK 60 hydraulic units fitted with ESP look alike.
It is vital to check the type of hydraulic unit on the vehicle before replacing it.
38-16
38
38
BLEEDING PROCEDURE
NOTE: the hydraulic unit is pre-filled.
This bleeding procedure must be used when one of the following components has been removed:
the hydraulic unit,
the master cylinder,
the pipework (between the hydraulic unit and the master cylinder).
NOTE: the braking circuit with ABS must not have any faults and must operate correctly. If it does not, the ABS
circuit must be repaired from both a hydraulic and electrical point of view.
1)
Bleed the braking circuit in the normal way using your foot or a bleeding kit.
NOTE: if, after a road test with ABS regulation, the pedal travel is not correct, bleed the hydraulic unit.
2)
Bleed the rear right-hand brake by bleeding the hydraulic unit secondary circuit using the diagnostic tool:
position the bleed container and the hose, open the brake bleed bolt,
pump the brake pedal (approximately ten times),
keep the brake pedal depressed and start the bleed command with the fault finding tool (refer to the "fault
finding assistance" section"),
pump the brake pedal during the diagnostic bleed phase,
at the end of the bleed cycle using the diagnostic tool, continue to pump the brake pedal and close the
brake bleed screw.'
b)
Follow the procedure as described in a) for the left-hand rear brake, the front left and the front right.
c)
Check the pedal travel and if it is incorrect, restart the bleeding procedure.
38-17