scenic ii pt3 transmission

© Renault s.a.s 2008

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

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

All copyrights reserved by Renault.

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

77 11 322 042 FEBRUARY 2009 Edition Anglaise

X84, and J84

2 Transmission

20A CLUTCH

21A MANUAL GEARBOX

23A AUTOMATIC GEARBOX

29A DRIVESHAFTS

Scénic II - Section 2

Contents

Page

Scénic II - Section 2ContentsPage

20A CLUTCH

Clutch: Precautions for repair 20A-1

Identification 20A-2

Mechanism / Disk: Removal - Refitting 20A-4

Clutch thrust bearing: Removal - Refitting 20A-14

21A MANUAL GEARBOX

Manual gearbox: Parts and consumables for the repair work 21A-1

Identification 21A-2

Manual gearbox: Specifications 21A-3

Manual gearbox oil: Specifications 21A-12

Manual gearbox oil: Draining - Refilling 21A-13

Manual gearbox: Removal - Refitting 21A-21

Differential output seal: Removal - Refitting 21A-45

Input shaft lip seal: Removal - Refitting 21A-56


Automatic gearbox: Precautions for repair 23A-1

Automatic gearbox: Identification 23A-3

Automatic gearbox: Specifications 23A-5

Automatic gearbox: List and location of components 23A-7

Automatic gearbox: Parts and consumables for the repair work 23A-10

Automatic gearbox: Removal - Refitting 23A-12

Automatic gearbox oil: Draining - Refilling 23A-24

Hydraulic distributor: Removal - Refitting 23A-31

Solenoid valves: Removal 23A-40

Hydraulic distribution wiring: Removal - Refitting 23A-41

Hydraulic distributor internal wiring: Removal - Refitting 23A-48

Flow regulation solenoid valve: Removal - Refitting 23A-54

Differential output seal: Removal - Refitting 23A-56

Multifunction switch: Removal - Refitting 23A-62

Contents

Multifunction switch: Adjusting 23A-66

Speed sensor: Removal - Refitting 23A-68

Pressure sensor: Removal - Refitting 23A-69

Gearbox temperature sensor: Removal - Refitting 23A-72

Oil pressure switch: Removal - Refitting 23A-73

Converter seal: Removal - Refitting 23A-77

Automatic transmission connector: Removal - Refitting 23A-79

Automatic transmission computer: Removal - Refitting 23A-81

Automatic transmission control unit: Removal - Refitting 23A-84

29A DRIVESHAFTS

Driveshaft: Precautions for repair 29A-1

Front left-hand wheel driveshaft: Removal - Refitting 29A-2

Front right-hand wheel driveshaft: Removal - Refitting 29A-3


20A-1

CLUTCHClutch: Precautions for repair 20A

Before removing the clutch, check:

- The direction of fitting for the clutch plate.

Before refitting the clutch, check:

- The flywheel friction track (no scratches or bluestains),

- The crankshaft bearing (no sticking),

- The engine and gearbox seals (replace if necessary),

- The sliding action of the clutch plate on the outputshaft,

- The thrust bearing guide and the clutch fork (no wearor scratches).

During refitting check the following:

Check the direction of the clutch plate.

Centre the clutch plate using the tool (Emb. 1518)

Gradually torque tighten the clutch pressure platebolts.

After refitting, check:

- The clutch play (for a cable operated vehicle),

- Bleeding of the hydraulic circuit (for vehicles with hy-draulic controls).

Essential special tooling

Emb. 1518 Set of clutch disc centr ingmandrels

WARNING

To prevent the clutch from juddering or slipping, donot grease the output shaft or the clutch plate hub.

20A-2

CLUTCHIdentification 20A

Pressure plate

Drive plate

Plate external diameter: 200 mm

Plate thickness: 6.9 mm

Number of splines: 26

Colour of the springs (1) and (2) : Grey

Pressure plate

Drive plate

Plate outer diameter: 215 mm



K4J or K4M

102143

102142

K9K

102143

102142

20A-3

CLUTCHIdentification 20A

Colour of springs (3) : Red and Black

Colour of springs: (4) Grey

Pressure plate

Drive plate

Plate outer diameter: 239 mm



F4R or F9Q or M9R

22428

22429

20A-4

CLUTCHMechanism / Disk: Removal - Refitting

F4R or F9Q

20A

REMOVALa Remove the gearbox (see 21A, Manual gearbox,

Manual gearbox: Removal - Refitting, page 21A-21) .

a Lock the engine using tool (Mot. 1677) (1) .

a Remove the pressure plate mounting bolts.

a Remove the friction plate.

a Replace any faulty parts.

REFITTING

EMB. 1604

a

a Lock the base plate of the (Emb. 1604) in a vice.


Mot. 1677 Flywheel locking tool.

Emb. 1604 Clutch compression tool forresetting retrofit system.


Tightening torquesm

pressure plate moun-ting bolts

1.2 daNm

16180

19919

Note:

For automatic wear compensation mechanisms,compress the clutch pressure plate using tool(Emb. 1604).

20754

20A-5


F4R or F9Q

20A

a Fit the pressure plate onto the base, then fit thethrust bearing (1) and the nut (2) .

a Tighten the nut (2) fully.

a Insert the circlip pliers at (3) .

a Compress the springs (4) .

a Slacken off the nut (2) completely (springs com-pressed).

a Release the pressure plate.

20755

20756

20757

20759

20A-6


F4R or F9Q

20A

a Remove the pressure plate from the base plate(checking that the springs are properly com-pressed).

a Position the driven plate (small hub diameter (5) onflywheel end).

CENTRING

a Centre the clutch plate using the (Emb. 1518).

a Refit the pressure plate on the flywheel.

a Gradually tighten the pressure plate mountingbolts (1.2 daNm).

20758

WARNING

Clean the clutch shaft splines and refit theassembly without lubricant.

Degrease the friction face of the flywheel.

102695

22695

20A-7


JH3 or JR5

20A

REMOVAL

a Remove the gearbox (see 21A, Manual gearbox,Manual gearbox: Removal - Refitting, page 21A-21) .

a Lock the engine using the (Mot. 582-01) (1) .

a Remove the pressure plate mounting bolts.

a Remove the friction plate.

a Replace any faulty parts.


Mot. 582-01 Flywheel locking tool.


Tightening torquesm


2 daNm

16180

20A-8


JH3 or JR5

20AREFITTING

a Clean the clutch shaft splines.

a Refit the assembly without lubricant.

a Position the clutch plate with the shoulder on the

flywheel end b (1) .


a Screw into place gradually in a radial pattern.

a Torque tighten the pressure plate mounting bolts(2 daNm).

a Remove tool (Mot. 582-01).

95414

118975

20A-9


M9R, and PK4

20A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a Remove:

- the « engine - gearbox » assembly (see Engine/gearbox assembly: Removal - Refitting) (MR370, 10A, Engine and peripherals),

- the gearbox (see 21A, Manual gearbox, Manualgearbox: Removal - Refitting, page 21A-21) .

II - REMOVAL OPERATION FOR PART CONCERNED

a Fit the (Mot. 1431) (1) .

a Remove

- the mechanism bolts ,

- the mechanism,

- the friction plate.

REFITTING

I - REFITTING PREPARATIONS OPERATION

a

a Place the base of tool (Emb. 1604) in a vice.


Mot. 1431 Flywheel locking tool.

Emb. 1604 Clutch compression tool forresetting retrofit system.

Emb. 1780 Set of clutch disc centr ingmandrels.

Tightening torquesm


12 Nm

114917

19919

Note:

For automatic wear compensation mechanisms,compress the clutch pressure plate using tool(Emb. 1604).

20754

20A-10


M9R, and PK4

20A

a Fit the pressure plate onto the base, then fit thethrust bearing (2) and the nut (3) .

a Tighten the nut fully.

a Insert the circlip pliers at (4) .

a Compress the springs (5) .

a Slacken off the nut (3) completely (springs com-pressed).

a Release the pressure plate.

20755

20756

20757

20759

20A-11


M9R, and PK4

20A

a Remove the pressure plate from the base plate(checking that the springs are properly com-pressed).

a Position the driven plate (small hub diameter (6) onflywheel end).

II - REFITTING OPERATION

Centring

a Refit the clutch plate.

a Centre the clutch plate using tool (Emb. 1780) (2)Emb. 1780 .

a Refit the pressure plate on the flywheel.

a Fit the (Mot. 1431).

a Tighten the pressure plate bolts until contact is ma-de.

a Gradually tighten to torque the pressure platemounting bolts (12 Nm).

III - FINAL OPERATION.

a Remove tool (Mot. 1431).

a Refit:

- the gearbox (see 21A, Manual gearbox, Manualgearbox: Removal - Refitting, page 21A-21) ,

- the « engine - gearbox » assembly (see Engine/gearbox assembly: Removal - Refitting) (MR370, 10A, Engine and peripherals).

20758

Note:

Clean the clutch shaft splines and refit theassembly without lubricant.

Degrease the friction face of the flywheel.

102695

114916

20A-12


K9K, and TL4

20A

REMOVAL


a Remove the gearbox (see 21A, Manual gearbox,Manual gearbox: Removal - Refitting, page 21A-21) .

II - OPERATION FOR REMOVAL OF PART CONCERNED

a Lock the engine using the (1) (Mot. 582-01).

a Slide the bolts (2) out of the mechanism.

a Remove the mechanism.

a Remove the clutch plate.

REFITTING

I - REFITTING PREPARATION OPERATION

a Degrease the flywheel friction face.

a Clean the clutch shaft splines.


Mot. 582-01 Flywheel locking tool.

Emb. 1780 Set of clutch disc centr ingmandrels.

Tightening torquesm

clutch pressure platebolts

12 N.m

123518

102143

117628

20A-13


K9K, and TL4

20AII - REFITTING OPERATION FOR PART CONCERNED

a Position the clutch plate.


a Tighten to torque and in order the clutch pressureplate bolts (12 N.m).

a Position the clutch plate with the section (10) againstthe flywheel.

III - FINAL OPERATION

a Remove the (Mot. 582-01) then the (Emb. 1780).

a Refit the gearbox (see 21A, Manual gearbox, Ma-nual gearbox: Removal - Refitting, page 21A-21) .

108798

102143

117628

20A-14

CLUTCHClutch thrust bearing: Removal - Refitting

JH3 or JR5 or ND0

20A

REMOVAL

a Remove:


- the two hydraulic union bolts (1) ,

- the hydraulic union,

- the two clutch thrust bearing mounting bolts (2) onthe clutch housing,

- the clutch thrust bearing.

a Remove:


- the hydraulic union clip (1) ,

- the hydraulic union,

- the two clutch thrust bearing mounting bolts (2) onthe clutch housing,


REFITTING

a To refit, proceed in the reverse order of removal.

a Torque tighten:

- the hydraulic union mounting bolts (0.9 daNm),

- the bolts mounting the clutch thrust bearing tothe clutch housing (2.1 daNm).

Tightening torquesm

hydraulic union moun-ting bolts

0.9 daNm

bolts mounting theclutch thrust bearing tothe clutch housing

2.1 daNm

JH3 or JR5

18439

ND0

101223

JH3 or JR5

20A-15


JH3 or JR5 or ND0

20A

a Torque tighten the clutch thrust bearing mountingbolts on the clutch housing (2.1 daNm).

a

a Bleed the clutch control ( (see 37A, Mechanicalcomponent controls) ).

ND0

WARNINGTo avoid damaging the clutch slave cylinder, donot lubricate the clutch shaft.

Never operate the system while the slave cylin-der is removed.

Note:

Always replace the hydraulic union.

20A-16


PK4

20A

REMOVAL


a Remove:

- the « engine - gearbox » assembly (see Engine/gearbox assembly: Removal - Refitting) (MR370, 10A, Engine and peripherals),

- the gearbox (see 21A, Manual gearbox, Manualgearbox: Removal - Refitting, page 21A-21) .

a Remove the hydraulic union retaining clip (1) .

a Unclip the clutch hydraulic pipe.

a Move the hydraulic union away.


a Remove:

- the bolts (2) mounting the clutch thrust bearing onthe clutch housing,


REFITTING


a Check the condition of the input shaft seal. Replaceit if necessary.

Tightening torquesm

bolts mounting theclutch thrust bearing onthe clutch housing

21 Nm

114915

114914

WARNING

To avoid damaging the clutch slave cylinder, donot lubricate the clutch shaft.

Always replace the clutch thrust bearing with anew one when the clutch is replaced.

20A-17


PK4

20AII - REFITTING OPERATION FOR PART CONCERNED

a Refit the new clutch thrust bearing.

a Tighten the bolts mounting the clutch thrust bearingon the clutch housing until they just make contact.

a Tighten to torque the bolts mounting the clutchthrust bearing on the clutch housing (21 Nm).


a Refit the clip.

a Connect the hydraulic union.

a Position the clutch hydraulic pipe.

a Refit:


- the « engine - gearbox » assembly (see Engine/gearbox assembly: Removal - Refitting) (MR370, 10A, Engine and peripherals).

a Bleed the clutch control (see Clutch circuit: Blee-ding) (MR 370, 37A, Mechanical component con-trols).

114914

21A-1

MANUAL GEARBOXManual gearbox: Parts and consumables for the repair work

M9R, and 700, and PK4

21A

Parts always to be replaced when they have been re-moved:

- lock rings,

- differential output seals,

- input shaft output seal,

- pins.

- hydraulic tappet.

Type Packaging Part no. Component

GEARBOX OIL Immerse all parts

SILICONE ADHESIVE SEA-LANT

100g cartridge 77 11 227 484 Housing assembly

LOCTITE 518 24 ml syringe 77 01 421 162 Switch threading

21A-2

MANUAL GEARBOXIdentification


21A

105538

(1) Identification label

(2) Identification inscription

21A-3

MANUAL GEARBOXManual gearbox: Specifications

PK4

21AI - IDENTIFICATION

II - GEAR RATIOS

PF6 gearbox

105538

(1) Identification label

(2) Etching.

Suffix 1st 2nd 3rd 4th 5th 6th Finaldrive

Reversegear

Tacho-meter

001 11/43 19/40 31/40 45/40 45/31 51/28 15/73 27/47 23/17

002 11/43 19/40 31/40 45/40 45/31 51/28 15/73 27/47 23/17

003 11/46 17/38 31/43 41/40 41/31 47/30 16/67 27/47 none

004 11/46 17/38 31/43 41/40 41/31 47/30 16/67 27/47 none

005 11/46 17/38 31/43 41/40 41/31 47/30 16/71 27/47 none

006 11/46 17/38 31/43 41/40 41/31 47/30 16/71 27/47 none

007 11/46 17/38 31/43 41/40 41/31 47/30 16/67 27/47 24/18

008 11/46 17/38 31/43 41/40 41/31 47/30 16/67 27/47 none

009 11/46 17/38 31/43 41/40 41/31 47/28 16/67 27/47 24/18

010 11/46 17/38 31/43 41/40 41/31 47/28 16/67 27/47 none

011 11/43 19/40 31/43 41/40 41/31 47/28 16/67 27/47 24/18

012 11/43 19/40 31/43 41/40 41/31 47/28 16/67 27/47 none

013 11/46 17/38 31/43 41/40 41/31 47/28 16/71 27/47 none

014 11/46 17/38 31/43 41/40 41/31 47/28 16/71 27/47 none

021 11/46 17/38 31/43 41/40 41/31 47/28 16/71 27/47 none

022 11/46 17/38 31/43 41/40 41/31 47/28 16/71 27/47 none

21A-4


PK4

21A

PK4 gearbox

PA0 gearbox

023 11/43 31/43 41/40 41/31 47/28 16/67

024 11/43 31/43 41/40 41/31 47/28 16/67


Reversegear

Tacho-meter

001 11/43 19/40 31/43 43/44 43/35 46/31 18/59 27/47 none

002 11/43 19/40 31/43 43/44 43/35 46/31 18/62 27/47 none

004 11/43 19/40 31/43 41/40 41/31 47/30 19/64 27/47 none

005 11/43 19/40 31/43 43/44 43/35 46/31 19/73 27/47 none

006 11/43 19/40 31/43 43/44 43/35 46/31 18/59 27/47 none

007 11/43 19/40 31/43 43/44 43/35 46/31 19/64 27/47 none

008 11/43 19/40 29/43 39/43 39/35 41/31 17/64 27/47 none

009 11/43 19/40 31/43 43/44 43/35 46/31 18/62 27/47 none

012 11/43 19/40 31/43 41/40 41/31 47/30 17/64 27/47 none

013 11/43 19/40 31/43 43/44 43/35 46/31 18/62 27/47 none

014 11/43 19/40 31/43 38:39 38/31 47/30 19/73 27/47 none

015 11/43 19/40 31/43 38/39 38/31 46/31 18/62 27/47 none

016 11/43 19/40 29/43 39/43 39/35 41/32 19/73 27/47 none

017 11/43 19/40 29/43 39/43 39/35 41/29 17/64 27/47 none

018 13/40 19:37 31/43 38:39 38/31 46/31 16/71 27/47 none

019 13/40 19/37 31/43 38/39 38/31 46/31 16/71 27/47 none

020 11/43 19/40 31/43 38/39 38/31 46/31 19/64 27/47 none

022 11/43 19/40 31/43 43/44 43/35 46/31 18/62 27/47 none


Reversegear

001 11/43 19/40 31/43 41/40 41/31 47/28 16/67 27/47

002 11/43 19/40 31/43 41/40 41/31 47/28 16/67 27/47

003 11/46 17/38 31/43 41/40 41/31 47/30 16/67 27/47


Reversegear

Tacho-meter

21A-5


PK4

21A

004 11/46 17/38 31/43 41/40 41/31 47/30 16/67 27/47

005 11/46 17/38 31/43 41/40 41/31 47/30 16/71 27/47

006 11/46 17/38 31/43 41/40 41/31 47/30 16/71 27/47

007 11/46 17/38 31/43 41/40 41/31 47/28 16/71 27/47

008 11/46 17/38 31/43 41/40 41/31 47/28 16/71 27/47

009 11/46 17/38 31/43 41/40 41/31 47/28 16/67 27/47

010 11/46 17/38 31/43 41/40 41/31 47/28 16/67 27/47


Reversegear

21A-6


JH3 or JR5


A marking (1) on the gearbox casing indicates:

- (A) Gearbox type

- (B) Gearbox suffix

- (C) Fabrication number

- (D) Factory of manufacture

II - GEAR RATIOS

109167

19860

Suffix First Second Third Fourth Fifth Reversegear

Finaldrive

Tacho-meter

JA3 sequential gearbox

JA3-001 11/41 21/43 28/39 34/35 39/32 11/39 14:61 None

JA5 sequential gearbox

JA5-001 11/41 21/43 28/37 35/34 41/31 11/39 16/55 None

JH1 manual gearbox

JH1 -004 11/37 22/41 28/37 34/35 39/32 11/39 14/59 21/19

JH1 -013 11/37 22/41 28/37 34/35 39/32 11/39 15/61 21/19

JH1 -014 11/37 22/41 28/37 30/29 39/32 11/39 15/58 21/19

JH1 -015 11/37 22/41 28/37 30/29 41/31 11/39 15/56 21/19

JH1 -016 11/37 22/41 28/37 34/35 39/32 11/39 14/59 None

JH1 -017 11/37 22/41 28/37 34/35 39/32 11/39 15/61 None

JH1-019 11/37 22/41 28/37 34/35 39/32 14/59 14/59 21/19

JH1 -018 11/37 22/41 28/37 30/29 41/31 11/39 15/56 21/19

JH1 -020 11/41 21/43 28/39 34/35 39/31 11/39 14/59 None

JH1-021 11/41 21/43 28/39 34/35 39/31 11/39 14/59 None

21A-7


JH3 or JR5

21A

JH1 -053 11/41 21/43 28/39 34/35 39/31 11/39 14/59 22/18

JH1-054 11/41 21/43 28/39 34/35 39/31 11/39 15/56 21/19

JH1-055 11/37 21:41 28/37 34/35 39/31 11/39 16/55 21/19

JH3 manual gearbox

JH3-050 11/41 21/43 28/39 34/35 39/31 11/39 15/56 21/19

JH3-052 11/41 21/43 28/39 34/35 39/32 11/39 14/59 22/18

JH3-053 11/37 22/41 28/37 30/29 42:41 11/39 15/58 22/18

JH3-054 11/41 21/43 28/37 30/29 41/31 11/39 14/63 22/18

JH3-055 11/41 21/43 28/37 30/29 39/31 11/39 14/63 22/18

JH3-056 11/41 21/43 28/37 30/29 41/31 11/39 14:61 22/18

JH3-057 11/41 21/43 28/39 34/35 39/31 11/39 14/59 None

JH3-058 11/41 21/43 28/39 34/35 39/32 11/39 14/59 22/18

JH3-059 11:45 22:47 28/39 34/35 37/33 11/39 14/69 22/18

JH3-060 11/41 21/43 28/39 34/35 39/31 11/39 14/59 22/18

JH3-061 11/41 21/43 28/39 34/35 39/31 11/39 14:61 22/18

JH3-062 11/41 21/43 28/39 34/35 39/31 11/39 14:61 22/18

JH3-063 11/41 21/43 28/39 34/35 39/32 11/39 14:61 22/18

JH3-064 11/41 21/43 28/39 34/35 39/32 11/39 14/59 22/18

JH3-065 11/41 21/43 28/39 34/35 39/32 11/39 14/59 22/18

JH3-066 11/41 21/43 28:29 34/35 39/31 11/39 14/63 22/18

JH3-067 11/37 22/41 28/37 34/35 39/32 11/39 14/63 22/18

JH3-068 11/41 21/43 28/39 34/35 39/32 11/39 14/59 22/18

JH3-071 11/41 21/43 28/37 30/29 39/31 11/39 14/63 22/18

JH3-072 11/41 21/43 28/37 34/35 39/32 11/39 14/59 22/18

JH3-105 11/41 21/43 28/39 31/34 37/33 11/39 14/59 None

JH3-106 11/41 21/43 28/39 34/35 39/32 11/39 14/63 None

JH3-128 11/41 21/43 28/39 34/35 39/32 11/39 14:61 None

JH3-129 11/41 21/43 28/39 31/34 37/33 11/39 15/61 None

JH3-131 11/41 21/43 28/39 31/34 37/33 11/39 15/58 None

JH3-132 11/37 22/41 28/37 30/29 42:41 11/39 15/58 None


Finaldrive

Tacho-meter

21A-8


JH3 or JR5

21A

JH3-137 11/41 21/43 28/39 31/34 37/33 11/39 14/59 None

JH3-141 11/37 22/41 28/37 30/29 42:41 11/39 15/58 None

JH3-142 11/41 21/43 28/39 31/34 37/33 11/39 15/61 None

JH3-143 11/41 21/43 28/39 31/34 37/33 11/39 15/61 None

JH3-144 11/41 21/43 28/39 31/34 37/33 11/39 15/61 None

JH3-145 11/37 22/41 28/37 30/29 42/31 11/39 16/57 None

JH3-150 11/37 22/41 28/37 30/29 42:41 11/39 15/58 None

JH3-154 11/41 21/43 28/39 31/34 37/33 11/39 16/61 None

JH3-155 11/41 21/43 28/39 31/34 37/33 11/39 15/58 None

JH3-156

JH3-160 11/41 22/41 28/37 30/29 42/31 11/39 15/58 22/18

JH3-166 11/41 21/43 28/37 30/29 42/31 11/39 16/55 None

JH3-169 11/41 21/43 28/39 34/35 39/31 11/39 14/59 None

JH3-170 11/41 21/43 28/39 34/35 39/32 11/39 14/63 None

JH3-171 11/37 22/41 28/37 34/35 39/31 11/39 15/61 None

JH3-172 11/41 21/43 28/39 31/34 37/33 11/39 15/61 None

JH3-173 11/41 21/43 28/39 31/34 37/33 11/39 15/61 None

JH3-174 11/37 22/41 28/37 30/29 42/31 11/39 15:68 None

JH3-175 11/37 22/41 28/37 30/29 42/31 11/39 15:68 None

JH3-176 11/41 21/43 28/39 34/35 39/32 11/39 14:61 None

JH3-177 11/41 21/43 28/39 31/34 37/33 11/39 15/61 None

JH3-179 11/41 21/43 28/39 31/34 37/33 11/39 15:68 None

JH3-183 11/41 21/43 28/39 34/35 39/32 11/39 14/59 None

JH3-184 11/41 21/43 28/39 34/35 39/32 11/39 15/58 None

JH3-185 11/41 21/43 28/39 34/35 39/32 11/39 15/58 None

JH3-186 11/41 21/43 28/39 34/35 39/32 11/39 15/58 None

JH3-187 11/41 21/43 28/39 34/35 39/32 11/39 15/58 None

JH3-189 11/37 22/41 28/37 30/29 42/31 11/39 15/56 None

JH3-190 11/37 22/41 28/37 30/29 42/31 11/39 15/56 None

JH3-193 11/41 21/43 28/37 30/29 42/31 11/39 16/55 21/19


Finaldrive

Tacho-meter

21A-9


JH3 or JR5

21A

JR5 manual gearbox

JR5-003 11/37 22/41 28/37 34/35 39/32 11/39 15/61 None

JR5-004 11/41 21/43 28/37 35/34 41/31 11/39 16/55 None

JR5-008 11/41 21/43 29:39 31/34 37/33 11:39 15/58 None

JR5-015 11/41 21/43 28/39 31/34 37/33 11/39 15/58 None

JR5-016 11/41 21/43 28/37 35/34 41/31 11/39 16/55 None

JR5-017 11/41 21/43 28/39 31/34 37/33 11/39 15/61 None

JR5-018 11/37 22/41 28/37 34/35 39/32 11/39 15/61 None

JR5-113 11/41 21/43 28/37 35/34 41/31 11/39 16/57 None

JR5-116 11/41 21/43 28/37 35/34 41/31 11/39 16/55 21/19

JR5-124 11/41 21/43 28/37 35/34 41/31 11/39 16/55 None

JR5-126 11/37 21:41 28/37 35/34 42/31 11/39 15/58 21/19

JR5-144 11/37 21:41 28/37 35/34 42/31 11/39 15/58 21/18

JR5-145 11/41 21/43 28/37 35/34 41/31 11/39 16/55 21/19

JR5-147 11/41 21/43 28/37 35/34 42/31 11/39 15/58 22/18

JR5-149 11/41 21/43 28/39 31/34 42/31 11/39 15/58 22/18

JR5-151 11/41 21/43 28/37 35/34 39/31 11/39 14/63 22/18

JR5-152 11/41 21/43 28/37 35/34 39/32 11/39 14/63 None

JR5-158 11/41 21/43 28/37 35/34 42/31 11/39 15/61 22/18

JR5-165 11/41 21/43 28/37 35/34 42/31 11/39 14/69 22/18

JR5-166 11/41 21/43 28/37 35/34 42/31 11/39 16/57 22/18

JR5-168 11/41 21/43 28/37 35/34 41/31 11/39 14/69 None

JR5-169 11/41 21/43 28/37 35/34 42/31 11/39 14:73 22/18

JR5-170 11/41 21/43 28/37 35/34 42/31 11/39 14/69 22/18

JR5-175 11/41 21/43 28/37 35/34 42/31 11/39 15/56 None

JR5-184

JR5-193 11/41 21/43 28/37 35/34 41/31 11/39 17/56 None


Finaldrive

Tacho-meter

21A-10


TL4


II - GEAR RATIOS

111646

(1) Identification plate

(2) Etching


Reversegear

000 11/41 19/37 31/41 40/39 38/29 47/30 15/59 11/28

001 11/41 19/37 31/41 40/39 38/29 47/30 15/56 11/28

002 11/41 19/37 31/41 40/39 38/29 47/30 16/57 11/28

003 11/35 19/37 29/43 34/41 38/39 39/34 16/69 11/23

008 11/37 19/37 28/39 35/39 35/32 43/33 15/59 11/25

013 11/41 19/37 31/41 40/39 38/29 47/30 15/59 11/28

014 11/41 19/37 31/41 40/39 38/29 47/30 15/59 11/28

015 11/41 19/40 31/45 35/39 35/32 43/33 16/71 11/28

016 11/41 19/40 31/45 35/39 35/32 43/33 16/71 11/28

017 11/37 19/37 28/39 35/39 35/32 43/33 16/69 11/25

018 11/41 19/37 31/41 40/39 38/29 47/30 16/66 11/28

019 11/41 19/40 31/45 35/39 35/32 43/33 15/71 11/28

020 11/41 19/40 31/45 35/39 35/32 43/33 16/71 11/28

021 11/41 19/40 31/45 35/39 35/32 43/33 15/71 11/28

022 11/41 19/37 31/41 40/39 38/29 47/30 15/59 11/28

024 11/35 19/37 29/43 34/41 35/34 37/30 16/69 11/23

026 11/41 19/37 29/43 40/39 38/29 47/30 15/59 11/28

21A-11


TL4

21A

027 11/41 19/37 31/41 40/38 39/29 47/30 14/59 11/28

028 11/41 19/40 31/45 35/28 39/34 41/30 14/64 11/28

029 11/41 19/40 31/45 38/39 35/32 43/33 15/71 11/28

030 11/41 19/40 31/45 35/39 35/32 41/30 16/71 11/28

031 11/37 19/40 27/41 34/41 35/34 37/30 16/69 11/23

032 11/37 19/37 28/39 35/39 35/32 43/33 16/66 11/28

033 11/37 19/37 28/39 35/39 35/32 43/33 16/69 11/28

034 11/41 19/37 31/41 40/39 38/29 47/30 16/66 11/39

035 11/41 19/40 31/45 35/39 35/32 43/33 16/69 11/28

036 11/41 19/40 31/45 35/38 39/34 41/30 14/64 11/28

037 11/41 19/40 31/45 35/28 39/34 41/30 15/71 11/28

038 11/41 19/40 31/45 35/39 35/32 43/33 14/64 11/28

039 11/37 19/37 28/39 35/39 35/32 43/33 16/69 11/25

040 11/41 19/37 31/41 40/39 38/29 47/30 15/56 11/28

041 11/41 19/37 31/41 40/39 38/29 47/30 16/66 11/39

042 11/41 19/40 31/45 35/39 35/32 41/30 15/71 11/39

045 11/41 19/37 31/41 40/39 38/29 47/30 15/59 11/28


Reversegear

21A-12

MANUAL GEARBOXManual gearbox oil: Specifications

5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX

21AI - VEHICLE/GEARBOX TYPE/OIL TYPE CORRELATIONS:

II - STANDARDS AND PART NUMBERS OF THE VARIOUS RECOMMENDED OILS:

III - IDENTIFICATION OF OIL FOR STANDARD EXCHANGE PK1 GEARBOXES:

GEARBOX TYPE TYPE OF OIL FORGEARBOX

JBX

JCX

JRX

JHX

NDX

TL4

T R A N S E L F TRJ75W80

or

TRANSELF NFJ75W80

PKX

PFX

VMX

NEX

NGX

N0X

UNX

TRANSELF TRX75W80

or

TRANSELF NFP75W80

ZFX T R A N S E L F L D75W80

DESIGNATION STANDARD PART NUM-BER

TRANSELF

TRX 75W80

or

TRANSELF

NFP 75W80

APIGL4,

MIL-L-2105C or D

77 11 143 534

(5 litres)

TRANSELF

TRJ 75W80

or

TRANSELF

NFJ 75W80

APIGL4,

MIL-L-2105C or D

May be orde-red from ELF

TRANSELF

LD 75W80

APIGL4,

MIL-L-2105

May be orde-red from ELF

Note:

For standard exchange PK1 gearboxes, the oil type(TRZ or TRP) is shown on a label.

These two oils are replaced by TRX 75W80 or NFP75W80.

21A-13

MANUAL GEARBOXManual gearbox oil: Draining - Refilling

PK4

21A

CAPACITY

I - OIL CHANGE

a Unscrew the drain plug (1) using the (Mot. 1018).

a Let the oil run into a drain tray.

a Refit the new seal on the plug, positioning the groo-ve (2) towards the plug.

a Torque tighten the drain plug (24 N.m).

II - FILLING

a Undo the filler cap (3) .


Mot. 1018 Sump plug tool.

Tightening torquesm

drain plug 24 N.m

Gearbox type Capacity in litres

PK4 2.4

114652

113764

114772

21A-14


PK4

21A

a Fill the gearbox until the oil overflows via the oil fillercap opening using a syringe containing the recom-mended oil (see 21A, Manual gearbox, Manualgearbox oil: Specifications, page 21A-12) (Tech-nical Note 6012A, 04A, Lubricants).

a Tighten the filler cap.

92081

21A-15


TL4

21A

CAPACITY

I - OIL CHANGE





II - FILLING




Tightening torquesm

drain plug 24 N.m


TL4 2

113928

113764

113928

21A-16


TL4

21A



92081

21A-17


ND0

21A

CAPACITY

I - OIL CHANGE





II - FILLING




Tightening torquesm

drain plug 24 N.m


ND0 2.1

101532

113764

101532

21A-18


ND0

21A

a Fill the gearbox to overflow via the oil filler cap ope-ning using a syringe containing the recommendedoil (see 21A, Manual gearbox, Manual gearboxoil: Specifications, page 21A-12) (Technical Note6012A, 04A, Lubricants).


92081

21A-19


JH3 or JR5

21A

CAPACITY

I - OIL CHANGE









Tightening torquesm

drain plug 24 N.m


JH3 2.8

JR5 2.5

JH3

109488

JR5

110256

113764

21A-20


JH3 or JR5

21AII - FILLING

a Undo the filler cap (4) .a Undo the filler cap (5) .



JH3

18749

JR5

110256

92081

21A-21

MANUAL GEARBOXManual gearbox: Removal - Refitting

K4J, and 730, and JH3 – K4M, and 782, and JR5 – K9K, and 722 or 728, and JR5

21AREMOVAL

a Position the vehicle on a two-post lift.

a Disconnect the battery, starting with the negativeterminal.

a Remove the scuttle grille ( (see 85A, Wiping -Washing) ).

a Remove:

- the two air filter access panel mounting bolts (1) ,

- the air filter access panel,

- the scuttle panel partition mounting bolt (2) .

a Remove:

- the scuttle panel partition mounting bolts (3) ,

- the scuttle panel partition,

- the scuttle panel,

- the engine undertray.

a Drain the gearbox.

a Remove:

- the front wheels,


Rou. 604-01 Hub locking tool.

Tav. 476 Ball joint extractor.

Mot. 1453 Multiple-adjusting enginemounting support with retai-ning straps.

Essential equipment

component jack

Tightening torquesm

wheel bolts 13 daNm

driveshaft nut 28 daNm

lower ball joint nut 6.2 daNm

track rod end nut 3.7 daNm

anti-roll bar ball joint nut 4.4 daNm

side panel mountingbolts

2.1 daNm

starter and gearbox bellhousing bolts

4.4 daNm

engine tie-bar bolts onthe engine

10.5 daNm

engine tie-bar bolts onthe subframe

10.5 daNm

gearbox suspendedmounting bolts

18 daNm

suspended mountingnut on the rubber pad

6.2 daNm

cooling radiator crossmember front mountingbolts

10.5 daNm

gearbox drain plug 2.5 daNm

gearbox filler plug 0.3 daNm

battery cover mountingbolts

0.4 daNm

104343

104246

21A-22



21A- the engine covers,

- the battery,

- the battery mounting,

- the injection computer with its support,

- the air flowmeter,

- the air inlet pipe.

a Remove the wiring harness mountings.

a Unclip the gear control cables from the gearbox.

a Disconnect:

- the ABS sensor wiring,

- the xenon bulb adjustment sensor wiring harnes-ses (if fitted to the vehicle).

a Remove the wheel arch liners.

I - LEFT-HAND SIDE OF THE VEHICLE

a Remove:

- the hub nut using the (Rou. 604-01),

- the track rod end using the (Tav. 476),

- the anti-roll bar ball joint,

- the lower ball joint.

a Release the stub axle carrier from the driveshaft.

a Remove the left-hand driveshaft.

101821

104086

102129

21A-23



21AII - RIGHT-HAND SIDE OF THE VEHICLE

a Remove:




- the lower ball joint,

- the relay bearing bracket.


a Remove the right-hand driveshaft.

a Attach the cooling radiator assembly to the uppercross member using rope.

a Remove the side stiffeners.

a Remove the cooling radiator cross member.

101819

101212

102009

21A-24



21A

a Remove the catalytic converter support from theclutch housing.

a Remove the engine tie-bar.

a Disconnect the reversing connector.

a Disconnect the TDC sensor.

106199

102115

106204

106200

21A-25



21A

a Disconnect:

- the starter (4) ,

- the diesel fuel pressure sensor (5) .

a Disconnect the earth strap from the gearbox.

a Disconnect the oil level sensor.

a Remove:

- the starter mounting bolts (6) ,

- the starter.

a Drain the brake fluid reservoir down to the clutchmaster cylinder pipe union using a syringe.

106205

106203

106201

14853

21A-26



21A

a Disconnect the hydraulic union by removing the clip(7) .

a Set up the engine support tool (Mot. 1453).

a Remove the gearbox support rubber pad.

a Remove:

- the three gearbox support bolts,

- the gearbox support.

101701

102449

106195

106194

21A-27



21A

a Remove the upper gearbox bell housing bolts.

a Position the component jack under the gearbox

a Remove:

- the lower gearbox bell housing bolts,

- the gearbox.

106193

21A-28



21AREFITTING

a

a Check that the engine - gearbox centring rings are inplace and correctly positioned.


a Torque tighten:

- the wheel bolts (13 daNm),

- the driveshaft nut (28 daNm),

- the lower ball joint nut (6.2 daNm),

- the track rod end nut (3.7 daNm),

- the anti-roll bar ball joint nut (4.4 daNm),

- the side panel mounting bolts (2.1 daNm),

- the starter and gearbox bell housing bolts (4.4daNm),

- the engine tie-bar bolts on the engine (10.5daNm),

- the engine tie-bar bolts on the subframe (10.5daNm),

- the gearbox suspended mounting bolts (18daNm),

- the suspended mounting nut on the rubber pad(6.2 daNm),

- the cooling radiator cross member front moun-ting bolts (10.5 daNm),

- the gearbox drain plug (2.5 daNm),

- the gearbox filler plug (0.3 daNm).

a Top up the gearbox oil.

a Torque tighten the battery cover mounting bolts(0.4 daNm).

WARNING

Do not coat:

- the gearbox output shaft with grease to avoiddamaging the clutch slave cylinder,

- the clutch shaft splines.

Note:

To avoid any risk of leakage, the hydraulic unionmust always be replaced after the clutch pres-sure plate is replaced.

WARNING

Be sure to bleed the hydraulic clutch circuit in accordance with the following instructions:

- Add brake fluid to the reservoir.

- Bleed the hydraulic circuit ( (see 37A, Mechani-cal component controls) ).

- Top up the brake fluid level.

WARNING

Connect the battery; carry out the necessary pro-gramming ( (see 8, Electrical equipment) ).

21A-29


F4R, and 770 – F9Q, and 812

21A

REMOVAL



a Refit the scuttle panel grille (see Scuttle panelgrille: Removal - Refitting) (MR 371, 55A, Exterioraccessories).

a Remove:



- the mounting bolt (2) from the scuttle panel parti-tion.





Essential equipment

component jack

Tightening torquesm

driveshaft nut 280 Nm

lower ball joint nut 62 Nm

track rod end nut 37 Nm

anti-roll bar ball joint nut 44 Nm

side panel mountingbolts

21 Nm


44 Nm

engine tie-bar bolts onthe engine

180 Nm


105 Nm

gearbox suspendedmounting bolts

180 Nm


44 Nm

steering shaft yokemounting stud

21 Nm

cooling radiator crossmember front mountingbolts

105 Nm

cooling radiator crossmember rear mountingbolts

21 Nm

subframe cross mem-ber mounting bolts

62 Nm

subframe rear moun-ting bolts

140 Nm

subframe tie-rod moun-ting bolts

105 Nm

gearbox drain plug 25 Nm

gearbox filler plug 3 Nm

wheel mounting bolts 130 Nm


4 Nm

104343

Tightening torquesm

21A-30


F4R, and 770 – F9Q, and 812

21A

a Remove:


- the scuttle panel,



a Remove:

- the front wheels,

- the engine covers,

- the battery,

- the battery mounting,

- the injection computer with its support,

- the air flowmeter,

- the air inlet pipe.

a Remove the wiring harness mountings.

a Unclip the gear control cables from the gearbox.

104246

101821

104085

21A-31


F4R, and 770 – F9Q, and 812

21A

a Disconnect the heat exchanger - turbocharger air pi-pe.

a Remove the air filter hose.

a Disconnect:

- the ABS sensor wiring,


a Remove the wheel arch liners.

I - LEFT-HAND SIDE OF THE VEHICLE

a Remove:





a Remove the stub-axle carrier from the driveshaft.

a Remove the driveshaft.

F9Q

102244

102129

21A-32


F4R, and 770 – F9Q, and 812


a Remove:




- the lower ball joint,

- the relay bearing bracket.

a Remove the stub-axle carrier from the driveshaft.



a Remove the side stiffeners.

a Remove:

- the cooling radiator cross member.

- the catalytic converter support from the clutch hou-sing,

- the starter mounting bolts,

- the starter.

101819

101212

102009

21A-33


F4R, and 770 – F9Q, and 812

21A

a Remove the engine upper tie-bar.

a Remove the lower engine tie-bar.

a Remove the steering shaft yoke.

a Remove the sub-frame angle bracket (4) .

102452

102312

101354

101208

21A-34


F4R, and 770 – F9Q, and 812

21A

a Strap the sub-frame to the component jack.

a Remove the sub-frame.

101209

21A-35


F4R, and 770 – F9Q, and 812

21A

a Disconnect:

- the reversing connector,

- the TDC sensor.

a Drain the brake fluid reservoir down to the clutchmaster cylinder pipe union using a syringe.

a Disconnect the hydraulic union by removing clip (5) .

a Set up the engine support tool (Mot. 1453).

a Remove:

- the gearbox support rubber pad,

- the gearbox suspended mounting,

- the upper gearbox bell housing bolts.

a Position the component jack under the gearbox

a Remove:


- the gearbox.

102485

101701

102449

102112

21A-36


F4R, and 770 – F9Q, and 812

21AREFITTING

a

a Check that the engine - gearbox centring rings are inplace and correctly positioned.

a Proceed in the reverse order to removal.

a Always replace the steering shaft yoke stud after re-moval.

a Torque tighten:

- the driveshaft nut (280 Nm),

- the lower ball joint nut (62 Nm),

- the track rod end nut (37 Nm),

- the anti-roll bar ball joint nut (44 Nm),

- the side panel mounting bolts (21 Nm),

- the starter and gearbox bell housing bolts (44Nm),

- the engine tie-bar bolts on the engine (180 Nm),

- the engine tie-bar bolts on the subframe (105Nm),

- the gearbox suspended mounting bolts (180Nm),

- the suspended mounting nut on the rubber pad(44 Nm),

- the steering shaft yoke mounting stud (21 Nm),

- the cooling radiator cross member front moun-ting bolts (105 Nm),

- the cooling radiator cross member rear moun-ting bolts (21 Nm),

- the subframe cross member mounting bolts (62Nm),

- the subframe rear mounting bolts (140 Nm),

- the subframe tie-rod mounting bolts (105 Nm),

- the gearbox drain plug (25 Nm),

- the gearbox filler plug (3 Nm),

- the wheel mounting bolts (130 Nm).


a Connect the battery, starting with the positive termi-nal.

a Torque tighten the battery cover mounting bolts(4 Nm).

WARNING

Do not coat:

- the gearbox output shaft with grease, to avoiddamaging the clutch slave cylinder,

- the clutch shaft splines.

Note:

To avoid leaks, the hydraulic union must alwaysbe replaced after the clutch mechanism is repla-ced.

WARNING

For information on refitting the sub-frame (see31A, Front carrier components, Axle assem-bly sub-frame).

WARNING

Be sure to bleed the hydraulic clutch circuit in accordance with the following instructions:

- Add brake fluid to the reservoir.

- Bleed the hydraulic circuit (see 37A, Mechani-cal component controls, Clutch circuit: Blee-ding).

- Top up the brake fluid level.

WARNING

Carry out the necessary programming (see 80A,Battery: Removal - Refitting).

21A-37



21A

REMOVAL


a Remove the « engine - gearbox » assembly (seeEngine/gearbox assembly: Removal - Refitting)(MR 370, 10A, Engine and peripherals).


a Disconnect the connector (1) from the reverse gearswitch.

a Unpick the reverse gear switch wiring harness fromthe gearbox.

a Unpick the wiring harness (2) from the Top DeadCentre sensor and the oil level sensor on the gear-box.

a Unclip the breather pipe from the gearbox.

Tightening torquesm

gearbox mounting bolts 44 Nm

starter mounting bolts 44 Nm

115004

115005

21A-38



21A

a Remove:

- the starter mounting bolts (3) ,

- the gearbox mounting bolts (4) ,

- the gearbox.

REFITTING

I - REFITTING OPERATION FOR PART CONCERNED

a Refit:

- the gearbox,

- the gearbox mounting bolts,

- the starter mounting bolts.

a Torque tighten:

- the gearbox mounting bolts (44 Nm),

- the starter mounting bolts (44 Nm).

II - FINAL OPERATION.

a Connect the reverse gear switch connector.

a Clip:

- the reverse gear switch wiring harness to the gear-box,

- the TDC sensor and oil level sensor wiring harnessto the gearbox.

a Clip the breather pipe onto the gearbox.

a Refit the « engine - gearbox » assembly (see Engi-ne/gearbox assembly: Removal - Refitting) (MR370, 10A, Engine and peripherals).

115211

115210

21A-39


TL4

21A

REMOVAL

REMOVAL PREPARATION OPERATION

a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (MR 370, 02, Lifting equip-ment).

a Remove:

- the battery (see Battery : Removal - Refitting)(MR 370, 80A, Battery),

- the diesel injection computer (see Diesel injectioncomputer: Removal - Refitting) (MR 370, 13B,Diesel injection),

- the battery tray (see Battery tray: Removal - Re-fitting) (MR 370, 80A, Battery),

- the air filter box (see Air filter unit: Removal - Re-fitting) (MR 370, 12A, Fuel mixture),

- the engine cover,


a Drain the gearbox (see 21A, Manual gearbox, Ma-nual gearbox oil: Draining - Refilling, page 21A-13) .

a Remove:

- the front section of the left and right-hand wheelarch liners (see Front wheel arch liner: Removal- Refitting) (MR 371, 55A, Exterior protection),

- the front bumper (see Front bumper: Removal -Refitting) (MR 371, 55A, Exterior protection).

a Attach the cooling assembly using a safetystrap(s).

a Remove:

- the radiator mounting cross member (see Radiatorsupport cross member: Removal - Refitting)(MR 371, 41A, Front lower structure),

- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand wheel driveshaft: Remo-val - Refitting, page 29A-3) ,

- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand wheel driveshaft: Remo-val - Refitting, page 29A-2) ,

- the rear suspended engine mounting (see Lowerengine tie-bar: Removal - Refitting) (MR 370,19D, Engine mounting).



Bvi. 1718 Support plate for the gearboxremoval/refitting tool.

Essential equipment

safety strap(s)

component jack

Tightening torquesm

gearbox bolts 44 Nm

gearbox nuts 44 Nm

starter bolts 44 Nm

nut on the gearboxexhaust strut

21 Nm

bolts on the gearboxexhaust strut

21 Nm

115217

21A-40


TL4

21A

a Remove:

- the bolts from the gearbox exhaust strut,

- the nut to the gearbox exhaust strut,

- the support strut (1) from the gearbox,

- the front axle subframe (see Front axle sub-fra-me: Removal - Refitting) (MR 370, 31A, Frontaxle components),

- the scuttle panel grille (see Scuttle panel grille:Removal - Refitting) (MR 371, 56A, Exterior equi-pment).

a Fit the (Mot. 1453) with a safety strap(s).

a Remove the left-hand suspended engine mounting(see Left-hand suspended engine mounting: Re-moval - Refitting) (MR 370, 19D, Engine moun-ting).

a Disconnect the clutch control pipe (2) by pressing onthe clip (3) .

117776 104865

112868

21A-41


TL4

21A

a Unclip the two gear control cables (4) from the gear-box at:

- the anchoring ball joints (5) ,

- the cable sleeve stops (6) .

a Disconnect the reverse gear sensor connector (7) .

a Unclip the breather pipe from the gearbox.

a Remove:

- the upper bolt (8) from the starter,

- the gearbox upper bolts (9) .

118832

101743

117335

116340

21A-42


TL4

21A

a Disconnect the engine speed and position sensorconnector.

a Remove:

- the bolt from the engine speed and position sensor,

- the engine speed and position sensor (10) .

a Remove:

- the earth wiring bolt,

- the earth wiring (11) ,

- the starter lower bolt,

- the gearbox lower bolts.

a Fit the (Bvi. 1718) on a component jack.

a Fit:

- the (Bvi. 1718) and the component jack under thegearbox,

- the bracket (12) using the nuts (13) ,

118894 116440

116711

21A-43


TL4

21A

a Tap the hole (14) using a self-tapping bolt (Part no.:77 03 002 244) to attach the gearbox to the supportusing the rod (15) .

a Fit:

- the shim (16) ,

- the shim (17) ,

- the rod (15) using the bracket (18) and the bolt (14).

a Tighten the rod (15) in an anti-clockwise direction toprevent the gearbox from tilting.

a

a Remove the gearbox using the (Bvi. 1718).

REFITTING

I - REFITTING PREPARATIONS OPERATION

a

a Replace the left-hand and right-hand differential out-put seals (see 21A, Manual gearbox, Differentialoutput seal: Removal - Refitting, page 21A-45) .

a Refit the gearbox studs.

116713 118833

Note:

Make sure that the air conditioning compressorpulley does not rest against the impact absorbermounting unit on the right-hand side of the vehi-cle when the engine and transmission assemblyis lowered.

WARNING

Do not grease the clutch shaft splines.

WARNING

To prevent leaks, replace the slave cylinder afterreplacing the clutch pressure plate.

WARNING

It is essential to replace the differential output lipseal each time the driveshafts are removed.

21A-44


TL4

21Aa Check the condition of the centring devices on the

gearbox.

II - REFITTING OPERATION FOR PART CONCERNED

a Position the gearbox using the (Bvi. 1718).

a Refit a gearbox bolt.

a Remove the (Bvi. 1718) from the gearbox.

a Refit the gearbox lower bolts.

a Torque tighten:

- the gearbox bolts (44 Nm),

- the gearbox nuts (44 Nm).

a Refit:

- the starter lower bolt,

- the earth wiring,

- the earth wiring bolt,

- the speed and position sensor,

- the engine speed and position sensor bolt,

a Connect the engine speed and position sensor con-nector.

a Refit:

- the gearbox upper bolts,

- the starter upper bolt.

a Torque tighten the starter bolts (44 Nm).

a Clip the breather pipe onto the gearbox.

a Connect the reverse gear sensor connector.

a Clip the gear control cables on the gearbox.

a Connect the clutch control pipe.

a Refit the left-hand suspended engine mounting (seeLeft-hand suspended engine mounting: Remo-val - Refitting) (MR 370, 19D, Engine mounting).

a Remove the (Mot. 1453) and the safety strap(s).


a Refit:

- the scuttle panel grille (see Scuttle panel grille:Removal - Refitting) (MR 371, 56A, Exterior equi-pment),

- the front axle subframe (see Front axle sub-fra-me: Removal - Refitting) (MR 370, 31A, Frontaxle components),

- the support strut on the gearbox,

- the nut to the gearbox exhaust strut,

- the bolts to the gearbox exhaust strut.

a Torque tighten:

- the nut on the gearbox exhaust strut (21 Nm),

- the bolts on the gearbox exhaust strut (21 Nm).

a Refit:

- the rear suspended engine mounting (see Lowerengine tie-bar: Removal - Refitting) (MR 370,19D, Engine mounting),



- the radiator mounting cross member (see Radiatorsupport cross member: Removal - Refitting)(MR 371, 41A, Front lower structure).

a Remove the safety strap(s) from the cooling as-sembly.

a Refit:

- the front bumper (see Front bumper: Removal -Refitting) (MR 371, 55A, Exterior protection),

- the front section of the left and right-hand wheelarch liners (see Front wheel arch liner: Removal- Refitting) (MR 371, 55A, Exterior protection).

- the air filter box (see Air filter unit: Removal - Re-fitting) (MR 370, 12A, Fuel mixture),


- the diesel injection computer (see Diesel injectioncomputer: Removal - Refitting) (MR 370, 13B,Diesel injection),

- the engine cover.

a Perform the following operations:

- fill the gearbox (see 21A, Manual gearbox, Ma-nual gearbox oil: Draining - Refilling, page 21A-13) ,

- bleed the clutch circuit (see Clutch circuit: Blee-ding) (MR 370, 37A, Mechanical component con-trols).

a Refit:

- the engine undertray,

- the battery (see Battery : Removal - Refitting)(MR 370, 80A, Battery).

21A-45

MANUAL GEARBOXDifferential output seal: Removal - Refitting

JH3 or JR5

21A

REMOVAL



a Remove the engine undertray.


a Remove:

- the wheel,

- the wheel arch liner,

- the hub nut,

- the track rod end,



a Disconnect:

- the wheel speed sensor connector,


a Remove the relay bearing bracket.


REPLACING THE SEAL

a Tap the base of the lip seal using a drift and a smallhammer to pivot it in its housing.

a Remove the seal with pliers, taking care not to da-mage the splines of the sunwheel.


Bvi. 1666 Tool for fitting differentialseals.

Tightening torquesm

wheel bolts 13 daNm




hub nut 28 daNm

relay bearing bracketnut

2.1 daNm

engine tie-bar bolts 10.5 daNm

subframe - engine tie-bar bolts

10.5 daNm


0.4 daNm

102129

101819

21A-46


JH3 or JR5

21AREFITTING

a Lubricate the seal.

a Insert the seal onto the splined part of the sunwheel.

a Refit the seal using the (Bvi. 1666), with the markingA on the right-hand side and marking B on the left-hand side.

a Position the driveshaft in relation to the sunwheel.


a Torque tighten:





- the hub nut (28 daNm),

- the relay bearing bracket nut (2.1 daNm),

- the engine tie-bar bolts (10.5 daNm),

- the subframe - engine tie-bar bolts (10.5 daNm).



21503

WARNING


21A-47


ND0

21A

REMOVAL





a Remove:

- the wheel,

- the wheel arch liner,

- the hub nut,

- the track rod end,



a Disconnect:

- the wheel speed sensor connector,




REPLACING THE SEAL

a Tap the base of the lip seal using a drift and a smallhammer to pivot it in its housing.

a Remove the dislodged seal with pliers, taking carenot to damage the sunwheel splines.


Bvi. 1689 Differential output seal fittingtool.

Tightening torquesm

wheel bolts 13 daNm




hub nut 28 daNm

relay bearing bracketnut

2.1 daNm

engine tie-bar bolts 18 daNm

subframe - engine tie-bar bolts

10.5 daNm


0.4 daNm

102129

101819

21A-48


ND0

21AREFITTING

a Oil the seal before inserting it onto the splined part ofthe sunwheel.

a Refit the seal using the tool (Bvi. 1689), with themarking A on the right-hand side and marking B onthe left-hand side.

a Position the driveshaft in relation to the sunwheel.


a Torque tighten:






- the relay bearing bracket nut (2.1 daNm),

- the engine tie-bar bolts (18 daNm),

- the subframe - engine tie-bar bolts (10.5 daNm).



102260

WARNING


21A-49



21A

REMOVAL


a Remove:


- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand wheel driveshaft: Remo-val - Refitting, page 29A-2) .

II - OPERATION FOR REMOVAL OF PART CONCERNED (RIGHT-HAND SIDE)

a Remove the protective ring (1) from the driveshaft.

III - OPERATION FOR REMOVAL OF PART CONCERNED (LEFT-HAND SIDE)

a Extract the seal using a screwdriver, taking care notto damage the casing.


Bvi. 1774 Right-hand transmission sealfitting tool.

Bvi. 1719 Left-hand side differential oilseal fitting tool

Bvi. 1419 Bearing cage positioning tool.

21490

106885

21A-50



21AREFITTING

I - REFITTING OPERATION FOR PART CONCERNED (RIGHT-HAND SIDE)

a Refit the right-hand seal using the (Bvi. 1774) (1) .

a Clean the driveshaft using degreaser.

a Slide on the protective ring (2) and clip it onto the dri-veshaft.

II - REFITTING OPERATION FOR PART CONCERNED (LEFT-HAND SIDE)

a Refit the left-hand seal using the (Bvi. 1719) (2) and (Bvi. 1419) (3) .

21493

Note:

Do not lubricate the seal.

21494

106886

21A-51



21AIII - FINAL OPERATION.

a Refit:


- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand wheel driveshaft: Remo-val - Refitting, page 29A-3) .

a Top up the gearbox (see 21A, Manual gearbox,Manual gearbox oil: Draining - Refilling, page21A-13) .

21A-52


TL4

21A

REMOVAL


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

a Remove:

- the engine undertray bolts,



1 - When replacing the differential output seal on the left-hand side

a Remove:

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


2 - When replacing the differential output seal on the right-hand side

a Remove:

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

- the front right-hand wheel driveshaft (see 29A, Dri-veshafts, Front right-hand wheel driveshaft:Removal - Refitting, page 29A-3) .

II - REMOVAL OPERATION FOR THE DIFFERENTIAL OUTPUT SEAL

Left-hand differential output seal

Right-hand differential output seal

a Tap the base of the lip seal using a roll pin punchand a small hammer to release it and make it turn inits housing.

a Remove the lip seal using a large screwdriver, ta-king care not to damage the differential housing.


Bvi. 1854 Differential output seal fittingtool TL4

Essential equipment

roll pin punch

125894

125896

21A-53


TL4

21AREFITTING


a parts always to be replaced: Differential outputseal (12,01,05,10).

21A-54


TL4

21AII - REFITTING OPERATION FOR THE DIFFERENTIAL OUTPUT SEAL

Refitting the right-hand side differential output seal

Refitting the left-hand side differential output seal.

a The new differential output seal is refitted using the tool (Bvi. 1854) (1) consisting of:

- a mandrel (2) for the right-hand side,

- a mandrel (3) for the left-hand side.

a Oil the internal surface of the new differential outputseal.

a Fit:

- the new differential output seal on the gearbox,

- the mandrel (2) or (3) of the tool (Bvi. 1854) on thenew differential output seal.

a Tap the tool (1) with a copper hammer to fit the newdifferential output seal fully.

III - FINAL OPERATION

1 - Refitting the left-hand driveshaft

a Refit:


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

2 - Refitting the right-hand driveshaft

a Refit:


103191

125895

125893

21A-55


TL4

21A- the front right-hand wheel (see Wheel: Removal -Refitting) (35A, Wheels and tyres).

3 - Final operation

a Fill the gearbox and check the level (see 21A, Ma-nual gearbox, Manual gearbox oil: Draining - Re-filling, page 21A-13) .

a Refit the engine undertray.

21A-56

MANUAL GEARBOXInput shaft lip seal: Removal - Refitting


21A

REMOVAL


a Remove:

- the « engine - gearbox assembly » (see Engine/gearbox assembly: Removal - Refitting) (MR370, 10A, Engine and peripherals),


- the clutch thrust bearing (see 20A, Clutch, Clutchthrust bearing: Removal - Refitting, page 20A-14) .


a Drill a hole in the seal, using a 2.5 mm drill bit.

a Fit a bolt in seal (1) .

a Extract the seal (1) using pliers.

REFITTING


a Fit a new seal with its protector using the (Bvi.1236).

a Remove the protector.


a Refit:

- the clutch thrust bearing (see 20A, Clutch, Clutchthrust bearing: Removal - Refitting, page 20A-14) ,


- the « engine - gearbox assembly » (see Engine/gearbox assembly: Removal - Refitting) (MR370, 10A, Engine and peripherals).


Bvi. 1236 Primary shaft oil seal fittingtool.

WARNING

Do not scratch the shaft or mating face.

20714

18061

23A-1

AUTOMATIC GEARBOXAutomatic gearbox: Precautions for repair

AJ0

23AI - TECHNICAL SPECIFICATIONS

Weight: 100 kg

The AJ0 is fitted with systems known as: "Shift Lock"and "Lock Up".

"Shift Lock" inhibits movement of the gear selector le-ver unless the brake pedal is depressed simultaneous-ly. To unlock the lever when the battery is faultyand carry out repair operations, refer to the Dri-ver's Handbook.

The aim of converter Lock Up is to connect the auto-matic gearbox directly to the engine. This function iscarried out by a "mini clutch" in the converter. Lock Upis controlled by the automatic gearbox computer.

As the automatic gearbox is lubricated under pressure,lubrication is only provided when the engine is running.

As a result of this fact, and to avoid serious damage, it is essential to comply with the following instructions:

- never allow the vehicle to coast with the ignition swit-ched off (e.g. when going down a hill); we cannotstress too strongly the harm that this may cause,

- never push the vehicle (i.e. to get to a petrol station,unless the precautions in the Towing section havebeen taken).

In addition, the vehicle is only under traction if the engi-ne is running. It is therefore impossible to start the en-gine of a vehicle with an automatic gearbox by pushingthe vehicle.

II - TOWING

III - STORING COMPONENTS THAT HAVE BEEN REMOVED

Store components that have been removed in storagecontainers so as not to damage or misplace them.

WARNING

Vehicles should preferably be moved on a flatbed ortowed with the front wheels raised. If this is not pos-sible, towing may be carried out in exceptional cir-cumstances at a speed below 15 mph (25 km/h)and for a maximum distance of 30 miles (50 km)(gear lever in Neutral).

WARNING

Towing weight (trailer, caravan, boat, etc.): (see theDriver's Handbook).

116357

23A-2

AUTOMATIC GEARBOXAutomatic gearbox: Precautions for repair

DP0

23AI - PRECAUTIONS DURING REPAIR

Weight: 70 kg

Vehicles fitted with DP0 automatic transmissions usesystems called « Shift lock » and « Lock up » .

The purpose of the « Shift Lock » function is to preventthe gear lever from being moved without the brake pe-dal being simultaneously depressed.

The purpose of the « Lock up » or converter lockup isto connect the automatic transmission directly to theengine. This function is carried out by a « mini clutch »in the converter.

The « Lock up » is driven by the automatic transmis-sion computer.

As the automatic gearbox is lubricated under pressure,lubrication is only provided when the engine is running.

Consequently, and to avoid serious damage, it is es-sential to comply with the following instructions:

- never allow the vehicle to coast with the ignition swit-ched off (i.e. when going down a hill); the damage thatthis may cause cannot be stressed highly enough,

- never push the vehicle (e.g. to get to a petrol station,unless the precautions in the « Towing » section havebeen taken).

The vehicle only has drive when the engine is running.It is therefore impossible to start the engine in a vehiclewith an automatic transmission by pushing the vehicle.

II - TOWING

The vehicle should preferably be towed in all cases ona tow truck or with the front wheels raised.

Nonetheless, if this is impossible, in exceptional cir-cumstances the vehicle may be towed at low speed(maximum 12mph (20 km/h) over a maximum distan-ce of 18 miles (30 km) (lever in N position).

Note:

For repair operations when the battery is faulty,refer to the notice on board the vehicle.

23A-3

AUTOMATIC GEARBOXAutomatic gearbox: Identification

AJ0

23A

The gearbox is identified by an engraved marking (1)located underneath the gearbox and by a self-adhesivelabel (2) on the hydraulic distributor casing.

117777

23A-4

AUTOMATIC GEARBOXAutomatic gearbox: Identification

DP0

23A

The automatic transmission series number can befound in two places: on a label on the hydraulic distri-butor cover (1) and etched onto the outer casing (2) onthe wheel side.

117304

23A-5

AUTOMATIC GEARBOXAutomatic gearbox: Specifications

F9Q, and DP0

23A

Gearbox Gearboxsuffix

1st 2nd 3rd 4th Final drive Lowering

DP0 083 2.724 1.499 1.000 0.710 25/68 52 : 67

23A-6

AUTOMATIC GEARBOXAutomatic gearbox: Specifications

AJ0

23A

Gearbox Suffix

AJ0 001

Gear ratios (epicyclic gear train output)

1st 2nd 3rd 4th 5th 6th Reversegear

4.199 2.405 1.583 1.161 0.855 0.685 3.457

Speeds in mph (km/h) at 1000 rpm (Tyre: 205/60R 16)

1st 2nd 3rd 4th 5th 6th Reversegear

8.989 15.696 23.842 32.506 44.119 55.037 10.918

23A-7

AUTOMATIC GEARBOXAutomatic gearbox: List and location of components

AJ0

23A

117734

(1) AJ0 gearbox

(2) Oil overflow pipe

(3) Level-setting plug

(4) Torque converter

(5) Filler pipe closure panel

(6) Oil cooler

(7) Output speed sensor

(8) Input speed sensor

(9) Multifunction switch

(10) Control lever

(11) Electrical wiring

(12) Hydraulic pressure measure-ment plug

(13) Hydraulic distributor O-rings

(14) Hydraulic distributor

(15) Hydraulic distributor casing seal

(16) Hydraulic distributor housing118831

(17) Solenoid valve

(18) Automatic gearbox oil tempera-ture sensor

(19) Pressure sensor

23A-8


DP0

23A

127735

(1) DP0 gearbox

(2) Oil overflow pipe

(3) Level-setting cap

(4) Hydraulic distributor

(5) Hydraulic distributor casing seal

(6) Hydraulic distributor housing

(7) Torque converter

(8) Control pinion

(9) Vehicle speed sensor

(10) Multifunction switch

(11) Output lever

(12) Filler plug

(13) Connector support

(14) Sleeve stop

(15) Filter pad

(16) Input speed sensor

(17) Heat exchanger

(18) Output speed sensor

(19) Control solenoid valve

(20) Pressure sensor

13787

(21) Modulating solenoid valve

(22) « Lock up » solenoid valve(converter lock-up)

(23) Selector solenoid valve 4

23A-9


DP0

23A (24) Selector solenoid valve 3





13785

(29) Green connector (multifunctionswitch)

(30) Yellow connector (electrohydrau-lic interface)

(31) Green connector (line pressure)

(32) Yellow connector (turbo inputspeed)

(33) Blue connector (output speed)

23A-10

AUTOMATIC GEARBOXAutomatic gearbox: Parts and consumables for the repair work

DP0

23A

The following parts must be replaced with new ones af-ter being removed:

- the self-locking nuts,

- the seals,

- the rubber seals,

- the converter bolts.

Description Component concerned

BR2 + grease Converter centring fitting

High resistance threadlock Brake calliper bolt

23A-11

AUTOMATIC GEARBOXAutomatic gearbox: Parts and consumables for the repair work

AJ0

23AI - PARTS ALWAYS TO BE REPLACED

Parts to be replaced with new ones if removed:

- the self-locking nuts,

- the differential output seals,

- the converter seal,

- O-rings,

- the four hydraulic distributor O-rings,

- the converter nuts,

- the hydraulic distributor metal casing seal,

- the level-setting plug seal.

II - CONSUMABLE FOR REPAIR

Description Component Part no.

BR2 + grease Convertercentring fit-ting

77 01 421 145

23A-12

AUTOMATIC GEARBOXAutomatic gearbox: Removal - Refitting

K4M, and 761 – F4R, and 771

23A

REMOVALa Position the vehicle on a two-post lift.

a Remove the engine covers.


a Remove the scuttle grille ( (see 85A, Wiping -Washing) ).





Bvi. 1531 Tool for centring the torqueconverter for the automatictransmission converter.

Essential equipment

component jack

Tightening torquesm

wheel bolts 13 daNm

brake calliper guide pinbolts

0.7 daNm




10.5 daNm


4.4 daNm

suspended mountingnut on the gearbox

4.4 daNm


drive plate convertermounting nut

3.7 daNm

modular connectormounting bolts

2 daNm

engine speed sensormounting bolts

1 daNm

engine tie-bar bolts on Fengines

18 daNm

engine tie-bar bolts on Kengines

10.5 daNm


18 daNm


0.4 daNm

101821

Tightening torquesm

23A-13


K4M, and 761 – F4R, and 771

23A

a Remove:




a Remove:


- the scuttle panel partition,

- the air intake sleeve,

- the battery,

- the battery tray,

- the injection computer and its support,

- the air inlet pipe,

- the wiring harness mountings.

a Remove:

- the multifunction switch cable ball joint (4) ,

- the wiring (5) from the multifunction switch cable,unlocking the cable sleeve stop,


a Disconnect:

- the engine speed sensor,

- the connector (6) by detaching the connector slide.

a Remove the mounting bolts (7) from the modularconnector support plate.

104343

104246

103409

WARNING

Protect the connector by sliding it into a water-proof plastic bag.

23A-14


K4M, and 761 – F4R, and 771

23A

a Remove the engine speed sensor.

a Remove the engine speed sensor.

a Fit the hose clamps.

a Disconnect the heat exchanger.

a Unclip the wiring harness from the gearbox.

a Remove:

- the two bolts (8) from the starter,



a Remove:

- the wheels,

- the wheel arch liners.

a Disconnect:

- the ABS system sensor wiring,

- the discharge bulb beam adjustment sensor wiring(if fitted to the vehicle).

K4M

103753

F4R

103420

103423

Note:

The discharge bulb beam adjustment sensor isfitted onto the left-hand lower wishbone.

23A-15


K4M, and 761 – F4R, and 771

23AI - LEFT-HAND SIDE OF THE VEHICLE

a Remove:



- the anti-roll bar ball joint using the (Tav. 476),



a Remove the left-hand driveshaft.

a Remove:

- the clip (10) from the gearbox computer wiring har-ness,

- the side reinforcement (9)

a Open the gearbox computer wiring harness moun-ting bracket (11) .

a Disconnect the connector (12) from the gearboxcomputer.

102129

103412

103413

23A-16


K4M, and 761 – F4R, and 771


a Remove:

- the hub nut using tool (Rou. 604-01),


- the anti-roll bar ball joint using the (Tav. 476),




a Remove the right-hand driveshaft.


a Remove the side stiffener.

102129

103418

101212

23A-17


K4M, and 761 – F4R, and 771

23A

a Remove the cooling radiator lower cross member.

a Remove:

- the exhaust mounting nuts (13) ,

- the engine tie-bar.

a Remove:

- the lower engine - manifold strut,

- the starter mounting bolt (15) ,

- the starter,

- the three converter nuts.

102009

103421

103418

Note:

The converter nuts are accessed by removingthe starter. Rotate the crankshaft clockwise toaccess the three starter plate - converter connec-ting nuts and remove them.

23A-18


K4M, and 761 – F4R, and 771

23A

a Remove the upper studs (16) from the gearbox bellhousing.

a Open the cover (13) .

a Remove cover (14) .

a Fit the (Mot. 1453).

a Remove the gearbox support rubber pad.

a Fit the component jack under the gearbox.

a Remove:


- the studs,

- the converter - starter plate bolts,

- the automatic transmission,

a Secure the converter with string to prevent it beingdislodged.

REFITTING

a

103423

102449

13790

WARNING

- Do not reuse the converter mounting nuts or theinertia flywheel nuts if they have been removed:always use new nuts.

- Check that the centring rings are in place.

23A-19


K4M, and 761 – F4R, and 771

23A

a Refit the inertia flywheel on the converter using tool(Bvi. 1531) ;.


When refitting the automatic transmission on the en-gine, make sure that the converter is properly enga-ged on the input shaft pin.

16361

WARNING

Check that the centring dowels are in place.

23A-20


K4M, and 761 – F4R, and 771

23A

a The distance between the base of the threading (17)and the engine coupling face (18) should be 17 mm.

a Torque tighten:


- the brake calliper guide pin bolts (0.7 daNm),



- the engine tie-bar bolts on the subframe (10.5daNm),

- the starter and gearbox bell housing bolts (4.4daNm),

- the suspended mounting nut on the gearbox(4.4 daNm),


- the drive plate converter mounting nut (3.7daNm),

- the modular connector mounting bolts (2daNm),

- the engine speed sensor mounting bolts (1daNm),

- the engine tie-bar bolts on F engines (18 daNm),

- the engine tie-bar bolts on K engines (10.5daNm),

- the suspended mounting nut on the rubber pad(18 daNm).

a Fill up the automatic transmission and check the le-vel (see Filling - Levels) .

a If replacing the oil, reset the auto-adaptives usingcommand RZ005: « Clear auto-adaptives » andreset the automatic transmission computer oilageing counter with command CF074: « Enter dateof gearbox oil change » .

After using command RZ005, it is important to carryout a test drive performing all gear changes, both upand down, several times in order to store the newvalues.


13790

WARNING


23A-21


M9R, and AJ0

23A

REMOVAL

a In order to remove and refit the automatic gearbox,the "engine - gearbox" assembly must be removed(see Engine/gearbox assembly: Removal - Refit-ting) (10A, Engine and peripherals).

a Separate the pipes and wirings fixed all around theautomatic gearbox.

a Remove the starter (see Starter: Removal - Refit-ting) (16A, Starting - Charging).

a Remove the nuts from the converter (1) through thestarter opening.

a Lift the engine using a workshop hoist and a loadpositioner.

a Remove:

- the bolts and nuts from the automatic gearbox bellhousing (2) ,

- the automatic gearbox using a workshop hoistand a load positioner.

Essential equipment

workshop hoist

diagnostic tool

Tightening torquesm

gearbox bell housingbolts

44 Nm

converter nuts 44 Nm

Note:

Replacing the automatic gearbox AJ0 requiresthe automatic gearbox computer to be replaced(see 23A , Automatic gearbox, A utomatictransmission computer: Removal - Refitting,page 23A-81) .

118394

118393

118394

23A-22


M9R, and AJ0

23AREFITTING

a Check that the drive plate is not damaged or runout(0.2 mm permitted runout).

a Check that the torque converter is coupled correctlyonto the automatic gearbox using a flat ruler and atape measure. The distance (X) between the con-verter maintenance bolt bead and the cover shouldbe at least 20.5 mm.

a Mount the gearbox and finger tighten the automaticgearbox bell housing bolts.

11911

Note:

Failure to observe this procedure can lead to thedestruction of the gearbox.

118394

Note:

Align the converter blots with their location on thedrive plate before fitting the automatic gearbox.

23A-23


M9R, and AJ0

23A

a Position the converter retaining nuts (3) through thestarter opening.

a Tighten to torque:

- the gearbox bell housing bolts (44 Nm),

- the converter nuts (44 Nm).

a Refit the starter (see Starter: Removal - Refitting)(16A, Starting - Charging).


a Refit the engine - gearbox assembly (see Engine/gearbox assembly: Removal - Refitting) (10A,Engine and peripherals).

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

a Perform the programming procedure using the dia-gnostic tool (see Fault finding - Replacement ofcomponents) (23A, Automatic gearbox).

118393

23A-24

AUTOMATIC GEARBOXAutomatic gearbox oil: Draining - Refilling

DP0

23A

I - OIL SERVICE

a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) .


1 - Former assembly

a Remove:

- the level-setting plug (1) ,

- the oil overflow pipe (2) .

2 - New assembly

a Remove:


- the oil overflow pipe (4) using (5) an 8 mm Allenkey.

Essential equipment

diagnostic tool

Tightening torquesm

oil overflow pipe (oldassembly)

25 N.m

oil overflow pipe (newassembly)

9 N.m

level-setting plug (oldassembly)

25 N.m

level-setting plug (newassembly)

35 N.m

Gearbox

Oil capacity (adjust until over-flows) (litre)

Drain capacity Total capacity

DP0 3.5 6

WARNING

For both assemblies, when draining - refilling or top-ping up the oil level, it is essential to put the gearcontrol lever in Park « P » position.

IMPORTANT

Wear heat protective gloves during the operation.

Note:

Drain the automatic transmission oil when the oilis warm (60˚C maximum), in order to remove asmany impurities as possible.

2316

107912

23A-25


DP0

23Aa Let the oil flow.

a Refit the new oil overflow pipe for the new assembly.

a Torque tighten:

- the oil overflow pipe (old assembly) (25 N.m),

- the oil overflow pipe (new assembly) (9 N.m).

a Fit a new seal on the level-setting plug with the sealgroove facing the top-up cap.

a Refit the level-setting plug.

a Torque tighten:

- the level-setting plug (old assembly) (25 N.m),

- the level-setting plug (new assembly) (35 N.m).

II - FILLING

a Position the vehicle on a horizontal surface.

a Unclip the gear lever control cable (7) on the gear-box by:

- squeezing the gear lever control cable clip at (A) ,

- pulling the pin at (B) ,

- lifting the gear lever cable at (C) .

Note:

Always replace the oil overflow pipe each time itis removed for the new assembly.

113764

110245

101743

23A-26


DP0

23A

a Remove the filler cap (8) .

a Use a funnel with a 15:100 filter to prevent impuritiesfrom entering the system.

a Fill the automatic gearbox with 3.5 litres of new re-commended oil (see Automatic gearbox oil: Spe-ci f icat ions ) (Technical Note 6012A, 04A,Lubricants).

a Refit the filler cap.

a Fit the gear lever control cable.

a Run the engine at idle speed.

a Connect the diagnostic tool.

a Establish dialogue with the automatic transmissioncomputer.

a Monitor the automatic transmission oil temperatureparameter.

a Wait for the temperature to reach 60˚C ±±±± 1.

1 - Former assembly

a Remove the level-setting plug (9) , leaving the engi-ne running.

2 - New assembly

a Remove the level-setting plug (10) , leaving the en-gine running.

a If the oil does not flow out or the quantity collected is below 0.1 litres :

- Switch off the engine,

- refit the level-setting plug,

- unclip the gear lever control cable,

- remove the filler plug,

- add 0.5 litre of oil,

- refit the filler plug fitted with a new seal,

103407

2316

107912

23A-27


DP0

23A- fit the gear lever control cable,

- let the automatic transmission cool to 50˚C,

- run the engine at idle speed,

- connect the diagnostic tool,

- establish dialogue with the automatic transmissioncomputer,

- monitor the automatic gearbox oil temperature pa-rameter,

- wait for the temperature to reach 60˚C ±±±± 1,

- remove the level-setting plug (9) or (10) .

a Repeat these operations until more than 0.1 litres ofoil is recovered in the container.

a Refit the level plug fitted with a new seal.

a Torque tighten:

- the level-setting plug (old assembly) (25 N.m),

- the level-setting plug (new assembly) (35 N.m).

3 - Level

a

Note:

When replacing the oil, reset the electronic oilageing counter (within the computer) (see Faultfinding - Replacement of components) (MR366, 23A, Automatic transmission).

Note:

To fill up the automatic transmission oil, apply thefilling procedure using 0.5 litres of oil instead of3.5 litres.

23A-28


AJ0

23A

Capacity

I - DRAINING

a Position the vehicle on a lift.

a The control lever must be in the Park position whendraining, filling or checking the level.


a Remove:


- the oil overflow pipe (2) .

a Let the oil flow.

a Refit and torque tighten the overflow pipe (8 N.m).

a Refit and torque tighten the level-setting plug (7.5N.m).

Essential equipment

diagnostic tool

Tightening torquesm

overflow pipe 8 N.m

level-setting plug 7.5 N.m

filler pipe closure panelbolt

6 N.m

Gearbox

Oil capacity (adjust until over-flows) (litre)

Drain capacity Total capacity

AJ0 3.5 7.6

Note:

The level must be checked at a temperature of 40˚C±±±± 2.

Note:

The automatic transmission oil should preferably bechanged when the oil is warm (approximately 60˚Cmaximum) in order to remove as many impurities aspossible.

118160

23A-29


AJ0

23AII - FILLING

a Filling is carried out through an internal pipe in themechanism housing (3) .

a Remove the pipe closure panel (4) .

a Use a flexible pipe fitted with a funnel (with a 1:100filter) (5) and connect it to the filling pipe (6) .

III - FILLING PROCEDURE

a The control lever must be in the Park position

a Fill the automatic gearbox with 3.2 litres of new oilrecommended by the manufacturer (see Automaticgearbox oil: Specifications) (Technical Note6012A, 04A, Lubricants).



a Establish dialogue with the automatic gearbox com-puter.


117251

116343

116345

23A-30


AJ0

23Aa Wait for the temperature to reach 40˚C ±±±± 2.

a Place a container under the level-setting plug.

a Remove only the level plug, leaving the engine run-ning.

a If the oil does not flow out or the quantity collected is below 0.1 litres :


- refit the level plug,



- run the engine at idle speed,


- place a container under the level-setting plug ,

- remove the level plug.

a Repeat these operations until more than 0.1 litres ofoil is recovered in the container.


a Refit the closure panel and torque tighten the fillerpipe closure panel bolt (6 N.m).

IV - LEVEL CHECKING PROCEDURE OUTSIDE OIL CHANGE - FILLING OPERATIONS

a

a Fill the automatic transmission with 0.5 litre of newoil.



a Establish dialogue with the automatic gearbox com-puter.


a Wait for the temperature to reach 40˚C ±±±± 2.

a Place a container under the level-setting plug.

a Remove only the level plug, leaving the engine run-ning.

a If the oil does not flow out or the quantity collected is less than 0.1 litre :


- refit the level plug,



- Run the engine at idle speed,


- place the container under the level plug,

- remove the level plug.

a Repeat these operations until more than 0.1 litre ofoil is recovered in the container.


a Refit the closure panel and tighten the filler pipeclosure panel bolt (6 N.m).

118161

WARNING

It is essential to shift the selector lever to thePark position.

23A-31

AUTOMATIC GEARBOXHydraulic distributor: Removal - Refitting

DP0

23A

REMOVAL


a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (MR 364, 02A, Lifting equip-ment).

a Drain the automatic gearbox oil (see 23A, Automa-tic gearbox, Automatic gearbox oil: Draining -Refilling, page 23A-24) .

a Remove:


- the battery tray (see Battery tray: Removal - Re-fitting) (MR 364, 80A, Battery).

a Separate the control cable from the multifunctionswitch (1) by pressing on (A) .

a Remove:

- the front left-hand wheel (see Wheel: Removal -Refitting) (MR 364, 35A, Wheels and tyres),

- the front section of the front left-hand wheel archliner (see Front wheel arch liner: Removal - Re-fitting) (MR 365, 55A, Exterior protection).


Bvi. 1462 Ball plate adjusting screw.

Tightening torquesm

hydraul ic d is t ributorbolts

7.5 Nm

locating ball spring brac-ket bolt

9 Nm

locating ball spring bolt 8 Nm

hydraul ic d is t ributorcover bolts

10 Nm

110245

110243

23A-32


DP0

23A

a Unclip the wiring harness (3) on the left-hand sidestiffener.

a Remove:

- the left-hand side reinforcement bolts (2) ,

- the left-hand side stiffener.

a Disconnect the electric coolant pump connector.

a Remove the clips (4) from the electric coolant pumpmounting.

a Move aside the electric coolant pump (5)

103412

F9Q, and 803

117330

23A-33


DP0

23AII - OPERATION FOR REMOVAL OF PART CONCERNED

a Remove the hydraulic distributor cover bolts (6) (oilmay flow out).

a Remove the hydraulic distributor bolts (7) .

a Disconnect the hydraulic distributor solenoid valveconnectors (8) .

a Remove the hydraulic distributor.

REFITTING


a Fit the hydraulic distributor with its reinforcementplate, centring it using the bolts (6) and (7) .

a

a Refit the other bolts on the hydraulic distributor.

a Tighten to torque and in order the hydraulic distri-butor bolts (7.5 Nm).

110233

110232

13789

110227

WARNING

Check that the distributor slide is properly enga-ged with the notched sector lug (9) .

23A-34


DP0

23AADJUSTING THE LEAF SPRING LEVER

a Put the multifunction switch lever in the first positionselected using a hose clip and a bolt (11) in the me-chanism housing.

a Remove the bolt (10) .

a Fit the locating ball spring by fitting the bearing (12)into the groove (15) for the notched sector (16) cor-responding to first selected.

a Fit without tightening the locating ball spring bracketbolt (13) .

a Fit the (Bvi. 1462) (14) in place of the bolt (10) .

a Screw the tool in fully whilst holding the locating ballspring.

a Tighten to torque the locating ball spring bracketbolt (9 Nm).

a Remove the (Bvi. 1462).

a Refit the locating ball spring bolt (10) .

a Torque tighten the locating ball spring bolt (8 Nm).

a Refit the hydraulic distributor cover complete with anew seal.

a Torque tighten the hydraulic distributor coverbolts (10 Nm).

II - FINAL OPERATION

a Fit the electric coolant pump.

a Refit the clips on the electric coolant pump moun-ting.

a Connect the electric coolant pump connector.

a Clip the wiring harness on the left-hand side stiffe-ner.

a Refit:

- the left-hand side stiffener,

- the left-hand side stiffener bolts,

- the front section of the front left-hand wheel archliner (see Front wheel arch liner: Removal - Re-fitting) (MR 365, 55A, Exterior protection),

- the front left-hand wheel (see Wheel: Removal -Refitting) (MR 364, 35A, Wheels and tyres).

a Adjust the automatic gearbox control cable (seeAutomatic gear control cable: Adjusting)(MR364, 37A, Mechanical component controls).

a Refit:


- the battery (see Battery : Removal - Refitting)(MR 364, 80A, Battery).

a Perform the following operations:

- fill the automatic gearbox (see 23A, Automaticgearbox, Automatic gearbox oil: Draining - Re-filling, page 23A-24) ,

110229

119433

F9Q, and 803

23A-35


DP0

23A- the necessary programming (see Fault finding -Configuration and programming) (MR 366, 23A,Automatic transmission).

23A-36


M9R, and AJ0

23A

REMOVAL


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



a Remove the front bumper (see Front bumper: Re-moval - Refitting) (55A, Exterior protection).

a Drain the cooling system (see Cooling circuit:Draining - Refilling) (19A, Cooling).

a Rotate the intercooler air inlet pipe clip, on the turbo-charger side.

a Remove the air pipe bolts at the intercooler inlet.

a Loosen the clip on the intercooler air inlet pipe on theexchanger side.

a Disconnect the intercooler air inlet pipe on the ex-changer side.

a Remove the air pipe at the intercooler inlet.

Essential equipment

diagnostic tool

Tightening torquesm

hydraul ic d is t ributorbolts

8 Nm

hydraul ic d is t ributorhousing bolts8 Nm

.

113282

113155

119834

23A-37


M9R, and AJ0

23A

a Remove the cooling assembly.

a Disconnect:

- the cooling radiator bottom hose (1) ,

- the oil/water cooler outlet and inlet hoses (2) .

a Unclip all the hoses from their support (3) .

a Move all the hoses aside to facilitate access.

a Place a clean container under the automatic gear-box to collect the oil.

a Remove:

- the hydraulic distributor housing bolts,

- the hydraulic distributor housing,

- the hydraulic distributor housing seal.

106275

118391

117250

23A-38


M9R, and AJ0

23A

a Loosen the hydraulic distributor bolts (5 bolts size70.1 mm (4) and 4 bolts size 50.8 mm (5) ).

a Detach the internal wiring connector (6) .

a Remove the hydraulic distributor bolts.

a Tilt the hydraulic distributor slightly when removing itin order to disconnect the automatic gear lever (7) .

a Remove the hydraulic distributor O-rings (8) .

REFITTING

a Clean the joint faces using SURFACE CLEANER(see Vehicle: Parts and ingredients for the repai-rwork) (04B, Consumables - Products) on the auto-matic gearbox and on the hydraulic distributorhousing, taking care not to damage the contact sur-faces.

a Always replace:

- the hydraulic distributor O-rings,


- the air pipe seal at the intercooler inlet on the turbo-charger side.

a Refit the new hydraulic distributor O-rings.

a Tilt the hydraulic distributor slightly when refitting it inorder to engage it with the automatic gearbox lever(9) .

a Torque tighten the hydraulic distributor bolts (8Nm).

a Connect the hydraulic distributor connector (10) .

117254

117253

117254

23A-39


M9R, and AJ0

23A

a Fit the hydraulic distributor metal housing (11) withits new seal.

a Torque tighten the hydraulic distributor housingbolts8 Nm (.)

a Remove the intercooler air inlet pipe seal on the tur-bocharger side using a .

a

a Fit a new seal to the intercooler air inlet pipe on theturbocharger side.


a Fill the automatic gearbox (see 23A, Automaticgearbox, Automatic gearbox oil: Draining - Refil-ling, page 23A-24) .

a Refit the engine undertray.

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

a When replacing the hydraulic distributor, carry outthe necessary operations using the diagnostic tool(see Fault finding - Replacement of components)(23A, Automatic gearbox).

117250

115068

115069

Note:

Check that the intercooler air inlet pipe seal onthe turbocharger side is fitted in its groove theright way round.

23A-40

AUTOMATIC GEARBOXSolenoid valves: Removal

DP0

23A

REMOVAL

a Remove the hydraulic distributor (see 23A, Auto-matic gearbox, Hydraulic distributor: Removal -Refitting, page 23A-31)

a Remove:

- the mounting bolt (9) to remove the solenoid valves(3) and (4) ,

- the mounting bolt (10) to remove the solenoid valve(5) ,

- the mounting bolt and the retaining bracket (11) toremove the solenoid valves (6) and (7) ,



- the mounting bolt (14) to remove the solenoid valve(1) .

REFITTING


WARNING

Work as cleanly as possible to prevent foreignbodies from entering the system.

13787

(1) Modulating solenoid valve

(2) « Lock up » solenoid valve (loc-kup converter)

(3) Sequence solenoid valve 4






Note:

Apply vaseline to the solenoid valve seals toease fitting.

23A-41

AUTOMATIC GEARBOXHydraulic distribution wiring: Removal - Refitting

DP0

23AREMOVAL



a Remove:



- the multifunction connector (see 23A, Automaticgearbox, Automatic transmission connector:Removal - Refitting, page 23A-79) .


a Remove the hydraulic distributor (see 23A, Auto-matic gearbox, Hydraulic distributor: Removal -Refitting, page 23A-31)


a Remove the cable feed opening locking clip (1) witha screwdriver.

a Remove:

- the electronic interface connector (2) ,

- the cable by feeding the electro-hydraulic interfaceconnector via the cable feed opening.

REFITTING


a Refit:

- the cable by feeding the electro-hydraulic interfaceconnector via the cable feed opening,

- the electro-hydraulic interface connector,

- the cable feed opening locking clip with a screwdri-ver.


a Refit:

- the hydraulic distributor (see 23A , Automaticgearbox, Hydraulic distributor: Removal - Refit-ting, page 23A-31)

- the multifunction connector (see 23A, Automaticgearbox, Automatic transmission connector:Removal - Refitting, page 23A-79) ,



117300

103248

23A-42


DP0

23Aa Top up the automatic transmission (see 23A, Auto-

matic gearbox, Automatic gearbox oil: Draining -Refilling, page 23A-24) .

23A-43


M9R, and AJ0

23A

REMOVAL


a Remove:

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

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

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


a Drain the gearbox (see 23A, Automatic gearbox,Automatic gearbox oil: Draining - Refilling, page23A-24) .



a Rotate the clip on the air pipe at the intercooler inletat the turbocharger end.


a Loosen the clip on the air pipe at the intercooler inletat the exchanger end.

a Disconnect the air pipe at the intercooler inlet at theexchanger end.

Essential equipment

diagnostic tool

Tightening torquesm

wiring routing retainerbolt

7 N.m

hydraul ic d is t ributorhousing bolts

8 Nm.

113282

113155

119834

23A-44


M9R, and AJ0

23A


a Disconnect:






a Remove:




a Disconnect the internal wiring connector (4) .

106275

118391

117250

117254

23A-45


M9R, and AJ0

23A

a Remove the protection plate from the wiring (5) .

a Remove the cable routing retaining bolt (6) .

a Disconnect the connectors (7) from the hydraulicdistributor wiring.

a Remove the hydraulic distributor wiring (8) .

REFITTING

a Clean the joint faces using SURFACE CLEANER(see Vehicle: Parts and ingredients for the repai-rwork) (04B, Consumables - Products) on the auto-matic gearbox and the hydraulic distributor housing,taking care not to damage the contact surfaces.

a Always replace the hydraulic distributor housingseal.

a Fit the wiring (9) .

a Connect the hydraulic distributor wiring connectors.

a Pass the wiring through the inside of the automaticgearbox.

a Torque tighten the wiring routing retainer bolt (7N.m) (10) .

118390

118388

118388

23A-46


M9R, and AJ0

23A

a Connect the internal wiring connector (11) .

a Fit the hydraulic distributor housing with of a newseal.

a Torque tighten the hydraulic distributor housingbolts (8 Nm.)

a Remove the intercooler air inlet pipe seal at the tur-bocharger end using a .

a

a Refit a new seal to the intercooler air inlet pipe at theturbocharger end.


117254

117250

115068

115069

Note:

Check that the intercooler air inlet pipe seal atthe turbocharger end is fitted in its groove theright way round.

23A-47


M9R, and AJ0

23Aa Fill the automatic gearbox with oil and check the le-

vel (see 2 3 A, Automatic gearbox, Automaticgearbox oil: Draining - Refilling, page 23A-24) .

a Refit:


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


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

a Connect the diagnostic tool for the programmingprocedure (see Fault finding - Replacement ofcomponents) (23A, Automatic gearbox).

23A-48

AUTOMATIC GEARBOXHydraulic distributor internal wiring: Removal - Refitting

AJ0

23AREMOVAL

REMOVAL PREPARATION OPERATION


a Remove:

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


- the air filter unit (see Air filter unit: Removal - Re-fitting) (12A, Fuel mixture),

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



- the front wheel arch liners (see Front wheel archliner: Removal - Refitting) (55A, Exterior protec-tion),

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

-

23A-49


M9R, and AJ0

23A

REMOVAL



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

a Remove:



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

a Drain:

- the automatic gearbox (see 23A, Automatic gear-box, Automatic gearbox oil: Draining - Refilling,page 23A-24) ,

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

- the refrigerant circuit (see Coolant circuit Drai-ning - Refilling) (62A, Air conditioning).


a Remove the bolts (1) from the air pipe at the turbo-charger outlet.

Essential equipment

oil recovery container

Tightening torquesm

hydraul ic d is t ributorinternal wiring earthbolts

8 N.m

retaining bolt for thetemperature sensor

8 Nm

hydraul ic d is t ributorhousing bolts

8 Nm 113282

113155

23A-50


M9R, and AJ0

23A





a Move the cooling and air pipes (2) aside from the tur-bocharger (3) .

a Fit a oil recovery container beneath the automaticgearbox.

a Remove:

- the hydraulic distributor housing (4) ,


119834

106275

118391

117250

23A-51


M9R, and AJ0

23AII - OPERATION FOR REMOVAL OF PART CONCERNED

a Move the retaining clips (5) from the internal wiring.

a Disconnect:

- the connector (6) from the external wiring,

- the connectors (7) from the pressure sensors.

a Disconnect the solenoid valve connectors (8) .

a Remove:

- the bolts (9) from the earths,

- the bolt (10) from the temperature sensor,

- the temperature sensor retaining plate,

- the earth terminal (10) ,

- the hydraulic distribution internal wiring.

REFITTING


a Clean the joint faces using SURFACE CLEANER(see Vehicle: Parts and ingredients for the repai-rwork) (04B, Consumables - Products) on the auto-matic gearbox and the hydraulic distributor housing,taking care not to damage the contact surfaces.

a Always replace the hydraulic distributor housingseal.

II - REFITTING OPERATION FOR PART CONCERNED

a Fit the hydraulic distributor internal wiring.

118831

118831

23A-52


M9R, and AJ0

23A

a

a Refit:

- the bolts (11) to the earths,

- the earth terminal (12) ,

- the temperature sensor retaining plate,

- the bolt (12) to the temperature sensor.


- the hydraulic distributor internal wiring earthbolts (8 N.m),

- the retaining bolt for the temperature sensor (8Nm).

a Connect the connectors to the solenoid valves.

a Connect:

- the pressure sensor connectors,

- the external wiring connector.

a Fit the maintenance clips for the internal wiring.


a Refit:

- a new seal on the hydraulic distributor housing,

- the hydraulic distributor housing.

a Torque tighten the hydraulic distributor housingbolts (8 Nm).


118831

Note:

The earth terminal at (12) must be positionedbetween the distributor and the temperature sen-sor retaining plate so that the earth terminal doesnot break when the bolt is tightened.

115068

23A-53


M9R, and AJ0

23A

a

a Refit a new seal to the intercooler air inlet pipe at theturbocharger end.

a Fit the cooling and air pipes onto the turbochargeroutlet.

a Refit the air pipe bolts at the turbocharger outlet.

a Refit the cooling assembly.

a Refit:

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


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

a Refill:

- the cooling system (see Cooling circuit: Draining- Refilling) (19A, Cooling),

- the refrigerant circuit (see Coolant circuit Drai-ning - Refilling) (62A, Air conditioning),

- the automatic gearbox (see 23A, Automatic gear-box, Automatic gearbox oil: Draining - Refilling,page 23A-24) .

115069

Note:

Check that the intercooler air inlet pipe seal atthe turbocharger end is fitted in its groove theright way round.

23A-54

AUTOMATIC GEARBOXFlow regulation solenoid valve: Removal - Refitting

DP0

23A

REMOVALa Position the vehicle on a two-post lift.



a Remove:

- the two solenoid valve bolts (1) ,

- radiator flow control solenoid valve (2) .

REFITTING


Tightening torquesm

exchanger flow controlsolenoid valve moun-ting bolt

1 daNm


0.4 daNm

Note:

The radiator flow control solenoid valve can beremoved without draining or removing the auto-matic transmission.

103434

13786-1

23A-55

AUTOMATIC GEARBOXFlow regulation solenoid valve: Removal - Refitting

DP0

23Aa Torque tighten the exchanger flow control sole-

noid valve mounting bolt (1 daNm).


WARNING


23A-56

AUTOMATIC GEARBOXDifferential output seal: Removal - Refitting

DP0

23A

REMOVALa This operation is done after removing the correspon-

ding driveshaft ( (see 29A, Driveshafts) ).


a Remove the battery cover.



a Drain the automatic transmission through the plug(1) .

a Remove the faulty differential output seal using ascrewdriver or a hook, taking care not to scratch thecontact faces.


Bvi. 1459 Fitting right-hand transmis-sion output seal.

Bvi. 1460 Fitting left-hand transmissionoutput seal.

Tightening torquesm

wheel bolts 13 daNm


bolts mounting the tor-que reaction on the sub-frame

10.5 daNm

engine tie-bar bolts on Kengines

10.5 daNm

engine tie-bar bolts on Fengines

18 daNm


hub nut 28 daNm


0.4 daNm

13791

WARNING

Do not drop the seal spring into the automatictransmission.

23A-57


DP0

23AREFITTING

a Fit the seal using the (Bvi. 1459) or the (Bvi. 1460).

a Guide the assembly until the tool is resting on theautomatic transmission casing.


a Torque tighten:



- the bolts mounting the torque reaction on thesub-frame (10.5 daNm),

- the engine tie-bar bolts on K engines (10.5daNm),

- the engine tie-bar bolts on F engines (18 daNm),


- the hub nut (28 daNm).

a

Fill the automatic transmission and check the level(see Filling - Levels) .


WARNING


23A-58


F9Q, and DP0

23A

REMOVAL


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

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

a Remove:





a Remove:

- the right-hand differential output seal using ascrewdriver, without scratching the contact surfa-ces,

- the left-hand differential output seal using ascrewdriver, without scratching the contact surfa-ces.

REFITTING


a Refit:

- the right-hand differential output seal using the(Bvi. 1459) (1) ,

- the left-hand differential output seal using the (Bvi.1460) (2) .


Bvi. 1459 Fitting right-hand transmis-sion output seal.

Bvi. 1460 Fitting left-hand transmissionoutput seal.

117291

117293

23A-59


F9Q, and DP0

23AII - FINAL OPERATION

a Refit:



a Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting).

a Fill the automatic transmission (see 23A, Automaticgearbox, Automatic gearbox oil: Draining - Refil-ling, page 23A-24) .

23A-60


AJ0

23A

REMOVAL



a Disconnect the battery (see Battery : Removal -Refitting) (MR 370, 80A, Battery).

a Remove:





a Remove:

- the right-hand differential output seal using ascrewdriver, without scratching the contact surfa-ces,

- the left-hand differential output seal using ascrewdriver, without scratching the contact surfa-ces.

REFITTING


a Refit:

- the right-hand differential output seal using the to-ols from the kit (Bvi. 1804) (1) ,

- the left-hand differential output seal using the toolsfrom the kit (Bvi. 1804) (1) and the spacer (2) .


Bvi. 1804 Kit for fitting differential andconverter seals (AJ0).

118354

118353

23A-61


AJ0

23AII - FINAL OPERATION.

a Refit:



a Connect the battery (see Battery : Removal - Refit-ting) (MR 370, 80A, Battery).

a Fill the automatic transmission (see 23A, Automaticgearbox, Automatic gearbox oil: Draining - Refil-ling, page 23A-24) .

a Carry out the necessary programming, following re-moval of the battery (see : Battery - Initialisation))(MR 372, 80A, Battery).

23A-62

AUTOMATIC GEARBOXMultifunction switch: Removal - Refitting

DP0

23A

REMOVAL

a Shift the lever to neutral: « N » .


a Remove:


- the battery,

- the battery tray,


- the air filter box,


a Disconnect:


- the control cable from the sheath stop (2) on themodular connector support.

a Remove the lever and the two mounting bolts (3)from the multifunction switch.

a Disconnect the modular connector (4) by releasingthe connector slide mechanism.

a Remove the three mounting bolts (5) from the modu-lar connector support plate.

a Remove the two modular connector mounting platebolts.

a Remove the green connector (6) from the multifunc-tion switch (12 track).

Tightening torquesm

selector lever nut 1 daNm

101821

103409

13785

23A-63


DP0

23AREFITTING

a Move the multifunction switch to the neutral position« N » .

a Torque tighten the selector lever nut (1 daNm).

a Adjust the multifunction switch (see 23A, Automaticgearbox, Multifunction switch: Adjusting, page23A-66)

a Check that the system and gear selection are wor-king correctly.


23A-64


AJ0

23A

REMOVAL


a Move the gear lever to position N.

a Remove:

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

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

- the protection plate from the multifunction switch.

a Disconnect:

- the control cable ball joint on the multifunctionswitch (1) using an open-jawed spanner size 12mm,

- the gear lever nut (2) ,

- the gear lever on the multifunction switch.


a Remove:

- the multifunction switch connector (3) ,

- the multifunction switch (4) .

REFITTING


a Move the multifunction switch to the N position.

a Fit the multifunction switch bolts without tighteningthem.


Bvi. 1805 Multifunction switch adjust-ment lever (AJ0)

Tightening torquesm

mult i funct ion switchbolts

6 Nm

gear lever nut17 Nm

118389

118388

23A-65


AJ0

23A

a Position the (Bvi. 1805) (5) .

a Align the tool shaft with the relevant hole on the mul-tifunction switch (6) .

a Torque tighten the multifunction switch bolts (6Nm) (7) .

a Remove the (Bvi. 1805).

a Connect the multifunction switch connector.


a Refit the gear lever on the multifunction switch.

a Torque tighten the gear lever nut17 (Nm).

a Refit:

- the control cable to N position,

- the protection plate to the multifunction switch,



a Check that the gear selection is working correctly.

118387

23A-66

AUTOMATIC GEARBOXMultifunction switch: Adjusting

AJ0

23A

Adjust the multifunction switch using the tool (Bvi.1805) when removing and refitting the multifunctionswitch or during fault finding.

a With the multifunction switch loosened and in posi-tion "N", place the tool (Bvi. 1805) (1) on the controllever and align the shaft of the tool opposite the rele-vant hole on the multifunction switch (2) .

a Torque tighten the multifunction switch bolts (6Nm) (3) .

a Remove the.


Bvi. 1805 Multifunction switch adjust-ment lever (AJ0)

Tightening torquesm


6 Nm

118387

23A-67

AUTOMATIC GEARBOXMultifunction switch: Adjusting

DP0

23A

ADJUSTMENT

a Put the multifunction switch into the Neutral position.

a Place the test probes of an ohmmeter on the multi-function switch position check tabs.

a Turn the multifunction switch by hand until the elec-tric contact is closed (resistance at contact terminalsto be measured 0 Ω with a tolerance of 60 Ω)

a Torque tighten the multifunction switch bolts (10N.m).

a Check that the resistance at the contact terminals isstill 0 Ω with a tolerance of 60 Ω after tightening.


Tightening torquesm


10 N.m

110242

23A-68

AUTOMATIC GEARBOXSpeed sensor: Removal - Refitting

DP0

23A

REMOVAL





a Disconnect the connector (1) .

a Remove the output speed sensor (2) .

REFITTING


a Torque tighten the output speed sensor mountingbolt (1 daNm).


Tightening torquesm

output speed sensormounting bolt

1 daNm


0.4 daNm

Note:

The speed sensor can be removed without drai-ning or removing the automatic gearbox.

103417

Note:

When replacing a sensor, always remove thegearbox connector (see 23A, Automatic gear-box, A utomatic transmission connector:Removal - Refitting, page 23A-79) .

WARNING


13786-1

WARNING


23A-69

AUTOMATIC GEARBOXPressure sensor: Removal - Refitting

DP0

23A

REMOVAL


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

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

a Remove:

- the front left-hand wheel (see 35A, Wheels and ty-res, Wheel: Removal - Refitting),

- the front left-hand wheel arch liner (see MR Bo-dywork, 55A, Exterior protection, Wheel archliner: Removal - Refitting),


a Remove:

- the battery tray (see 80, Battery, Battery tray: Re-moval - Refitting),

- the air filter unit (see 12A, Fuel mixture, Air filterunit: Removal - Refitting).

a Disconnect the modular connector (1) by pulling thesliding (2) .

a Disconnect the gearbox connector from the moun-ting plate by pulling the slide (3) .

a Remove the gearbox connector mounting bolts (4)from the plate.

Tightening torquesm

pressure sensor moun-ting bolts

8 N.m

pressure sensor wiringharness mounting bolts

8 N.m

gearbox connec to rmounting bolts

20 N.m

110246

110225

23A-70


DP0

23A

a Remove the green connector (3-track) (5) from thegearbox connector on the mounting plate.

a Release the pressure sensor wiring harness fromthe automatic transmission wiring duct.


a Remove:

- the wiring harness mounting bolt (6) ,

- the pressure sensor mounting bolts (7) ,

- the pressure sensor (8) .

REFITTING


a Refit:

- the pressure sensor,

- the pressure sensor mounting bolts,

- the wiring harness mounting bolt.


- the pressure sensor mounting bolts (8 N.m),

- the pressure sensor wiring harness mountingbolts (8 N.m).

a Connect the pressure sensor harness from the auto-matic transmission wiring duct.

110224

110251

WARNING


23A-71


DP0

23AII - FINAL OPERATION

a Refit the gearbox connector mounting plate moun-ting bolts.

a Torque tighten the gearbox connector mountingbolts (20 N.m).

a Connect the gearbox connector on the mountingplate by pulling out the slide.

a Refit:

- the air filter unit (see 12A, Fuel mixture, Air filterunit: Removal - Refitting),

- the battery protective base (see 80A, Battery, Bat-tery tray: Removal - Refitting),

a Connect the modular connector by reinserting theslide.

a Refit the battery shield (see 80A, Battery, Batterytray: Removal - Refitting).

a Refit:

- the front left-hand wheel arch liner (see 55A, Bo-dywork, Exterior protection, Wheel arch liner:Removal - Refitting),


- the front left-hand wheel (see 35A, Wheels and ty-res, Wheel: Removal - Refitting).

a Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting).

a Check the gearbox oil level (see 23A, Gearbox oil:Draining - Filling).

23A-72

AUTOMATIC GEARBOXGearbox temperature sensor: Removal - Refitting

M9R, and AJ0

23AThe gearbox temperature sensor can only be replacedwith the hydraulic distributor internal wiring (see 23A,Automatic gearbox, Hydraulic distributor internalwiring: Removal - Refitting, page 23A-48) .

a

118831

(1) Gearbox temperature sensor

Note:

In order to avoid breakage of the earth terminal(2) when the bolt is tightened, position it betweenthe distributor and the retaining plate of the gear-box temperature sensor.

23A-73

AUTOMATIC GEARBOXOil pressure switch: Removal - Refitting

M9R, and AJ0

23A

REMOVAL


a Remove:







a Drain the refrigerant circuit (see Coolant circuitDraining - Refilling) (62A, Air conditioning).






Essential equipment

diagnostic tool

Tightening torquesm

oil pressure switch con-cerned

4 Nm

hydraul ic d is t ributorhousing bolts8 Nm

.

113282

113155

119834

23A-74


M9R, and AJ0

23A


a Disconnect:






a Remove:




a Disconnect the oil pressure switch connector (4) .

a The oil pressure switch (5) concerned.

106275

118391

117250

118831

23A-75


M9R, and AJ0

23AREFITTING

a Clean the joint faces using SURFACE CLEANER(see Vehicle: Parts and ingredients for the repai-rwork) (04B, Consumables - Products) on the auto-matic gearbox and on the hydraulic distributorhousing taking care not to damage the contact surfa-ces.

a Always replace:

- the hydraulic distributor housing seal,

- the intercooler air inlet pipe seal at the turbochar-ger end.

a Refit the oil pressure switch (6) concerned.

a Torque tighten the oil pressure switch concerned(4 Nm).

a Connect the oil pressure switch connector.

a Fit the hydraulic distributor housing with its new seal.

a Torque tighten the hydraulic distributor housingbolts8 Nm (.)


117254

117250

115068

23A-76


M9R, and AJ0

23A

a

a Fit a new seal to the intercooler air inlet pipe at theturbocharger end.


a Fill the automatic gearbox with oil and check the le-vel (see 2 3 A, Automatic gearbox, Automaticgearbox oil: Draining - Refilling, page 23A-24) .

a Refit:



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

a Perform the programming procedures using the dia-gnostic tool (see Fault finding - Replacement ofcomponents) (23A, Automatic gearbox).

115069

Note:

Check that the intercooler air inlet pipe seal atthe turbocharger end is fitted on its groove theright way round.

23A-77

AUTOMATIC GEARBOXConverter seal: Removal - Refitting

DP0

23A

REMOVAL

a This operation is carried out after the automatictransmission and converter have been removed.

a Remove the converter by withdrawing it as far aspossible without deviating from its axis.

a Using tool (Mot. 587), remove the seal, taking carenot to scratch the contact faces.

REFITTINGa

a Refit:

- the new pre-lubricated seal to the end, using the(Bvi. 1457),

- the converter.

a The distance between the base of the threading (1)and the engine coupling face (2) should be 17 mm.



Mot. 587 Oil seal extractor

Bvi. 1457 Fitting converter lip seal.

WARNING

The converter contains a large amount of oil,which may spill when it is being removed.

WARNING

- Work as cleanly as possible to prevent foreignbodies penetrating the system.

- Lubricate all the contact faces.

13790

23A-78

AUTOMATIC GEARBOXConverter seal: Removal - Refitting

AJ0

23A

REMOVAL

a This operation is carried out with the gearbox andconverter removed.

a Remove the converter seal (1) using a screwdriver,taking care not to damage the input shaft splines.

REFITTING

a Refit the seal using the (2) contained in the kit (Bvi.1804)

a Refit the converter (3) .

a Check that the converter is correctly inserted using asurfaced ruler and a steel rule.

a Check that the distance (X) between the bead andthe ruler is at least 20.5 mm.

a Refit the gearbox (see: Automatic gearbox: Remo-val - Refitting).


Bvi. 1804 Kit for fitting differential andconverter seals (AJ0).

117248

11954

117252

11911

23A-79

AUTOMATIC GEARBOXAutomatic transmission connector: Removal - Refitting

DP0

23AConnector numbering

REMOVAL



a Shift the lever to neutral: « N » .


a Remove:


- the battery,

Tightening torquesm


0.4 daNm

13785

(1) Green connector (multifunctionswitch)

(2) Yellow connector (electrohydrau-lic interface)

(3) Green connector (line pressure)

(4) Yellow connector (turbo speed)

(5) Blue connector (exchanger flowcontrol solenoid valve)

Note:

These connectors may be removed separately fromthe gearbox connector when certain componentsare replaced.

103248

101821

23A-80

AUTOMATIC GEARBOXAutomatic transmission connector: Removal - Refitting

DP0

23A- the battery tray,


- the air filter box,


a Disconnect:


- the wiring (7) from the multifunction switch cable,unlocking the cable sleeve stop,

- the gearbox connector (8) by releasing the connec-tor slide valve.

a Remove:

- the three mounting bolts (9) from the gearbox con-nector support plate,

- the two gearbox connector mounting bolts,

- the connector of the colour concerned from thegearbox connector.

a Follow the five wiring harnesses connected to thegearbox connector.

a Remove the five wiring harnesses.

These wiring harnesses are either connected via aconnector to or directly to the components. If theyare connected to a component directly, the compo-nent should also be removed.

REFITTING



103409

WARNING


23A-81

AUTOMATIC GEARBOXAutomatic transmission computer: Removal - Refitting

DP0

23A

The computer is located behind the left-hand wheelarch.

REPLACEMENTa

a Use the following procedure.

a Read the oil ageing value from the memory of thecomputer being replaced using parameter PR133:« Oil ageing counter » and note down the value.

a Replace the computer.

a Enter the oil ageing value in the memory of the newcomputer using command CF320: « Oil ageingcounter report » .

a Confirm entry using the parameter « Oil ageingcounter » .

a Enter the After Sales operation date using commandCF320 « Enter After-Sales operation date » .

a Carry out a road test so that the new computer sto-res the programming.

REMOVAL




a Remove the front bumper.

a Disconnect the computer connector.

a Remove the resonator .

a Remove:

- the two computer mounting nuts ,

- the computer.

Tightening torquesm


0.4 daNm

Note:

When the automatic gearbox computer is repla-ced, it is necessary to enter the age of the auto-matic gearbox oil stored in the memory of thecomputer to be replaced in the memory of thenew computer.

103414

103415

23A-82


DP0

23AREFITTING



REPLACING THE COMPUTER

WARNING


23A-83


AJ0

23A

REMOVAL



a Disconnect the battery (see Battery : Removal -Refitting) (MR 370, 80A, Battery).

a Remove the front bumper (see Front bumper: Re-moval - Refitting) (MR 371, 55A, Exterior protec-tion).


a Remove:

- the automatic transmission computer nuts,

- the automatic transmission computer (1) .

a Disconnect the computer connector.

REFITTING


a Connect the computer connector.

a Refit:

- the computer,

- the computer nuts.


a Refit the front bumper (see Front bumper: Remo-val - Refitting) (MR 371, 55A, Exterior protection).

a Connect the battery (see Battery : Removal - Refit-ting) (MR 370, 80A, Battery).

a Carry out the necessary programming, following re-moval of the battery (see Battery - Initialisation))(MR 372, 80A, Battery).

a Connect the diagnostic tool for programming pro-cedures (see Replacement of components)) (MR372, 23A, Automatic transmission).

Essential equipment

diagnostic tool

103415

23A-84

AUTOMATIC GEARBOXAutomatic transmission control unit: Removal - Refitting

DP0

23A

I - REMOVAL

1 - In the engine compartment




a Remove:

- the battery,

- the cowl grille ( (see 85A, Wiping - Washing) ).

a Remove:




a Remove:


- the scuttle panel partition.

a Disconnect the computer connectors.

a Remove:

- the battery tray bolts (4) ,

- the battery tray,

- the computer with its support,

- the air filter outlet duct.

Tightening torquesm

control unit mountingnuts

2.1 daNm

104343

104246

101822

23A-85


DP0

23A

a Unclip:

- the control cable (5) from the gearbox lever balljoint,

- the control cable from the sleeve stop.

2 - In the passenger compartment

a Unclip the gear lever gaiter.

a Rotate the part (6) clockwise.

a Remove the gear lever knob by lifting it.

a Remove the mounting bolts (7) from the central con-sole.

a Unclip:

- the mounting brackets (8) ,

- the clip (9) .

105107

105109

105110

104033

23A-86


DP0

23A


a Remove:

- the three control unit mounting bolts (11) ,

- the three bulkhead seal mounting bolts,


a Disconnect:

- the exhaust pipe from the exhaust manifold,

- the centre bracket.

a Move the exhaust pipe to one side.

a Disconnect the oxygen sensor connector.

a Remove the heat shield mounting bolts.

a Move the heat shield towards the rear of the vehicleto gain access to the gearbox control cable routing(12) .

a Remove the « control unit-cable » assembly via thepassenger compartment.

II - REFITTING


a Torque tighten the control unit mounting nuts (2.1daNm).

ADJUSTING THE CONTROL CABLE

a - In the passenger compartment

a Put the lever in « Drive » position.

b - In the engine compartment

a Put the gearbox lever in « Drive » position.

a Clip the control cable into the sleeve stop.

105108

WARNING

Do not open the automatic transmission controlunit, this could cause damage (infrared system).

105105

23A-87


DP0

23A

a Slide on part (13) by compressing the control cablespring.

a Unlock the adjustment mechanism by sliding thecatch (14) .

a Adjust the length of the cable accordingly.

a Fit the end of the control cable (5) on the gearbox le-ver ball joint.

a Lock the adjustment mechanism by pushing thecatch (14) back to its original position.


104733

104736

105107

WARNING

Connect the battery; carry out the necessary pro-gramming ( (see 80A, Battery) ).

23A-88


F9Q, and DP0

23A

REMOVAL


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

a Carefully mark the position of the automatic gearboxcontrol lever before the operation: if not, position thegear selector and the multifunction switch in neutral« N » .


a Remove the battery (see 80A, Battery, Battery: Re-moval - Refitting).

a Remove:


- the control cable from the sheath stop (2) on themodular connector support.

a Remove the diagnostic socket access cover (3) .

a Turn the part (4) a quarter of a turn.

a Remove the part.

a Remove the control unit lever knob (5) by lifting it.


Mot. 1495-01 22 mm socket for removing/refitting oxygen sensors.

Tightening torquesm

exhaust bracket nuts 21 Nm

oxygen sensor 45 Nm

103408

103424

103425

23A-89


F9Q, and DP0

23A

a Unclip the console trim (6) .


a Open the glove compartment.

a Unclip the handbrake surround trim at (8) and (9) .

a Unclip the lower cover (10) .

a Unclip the cigarette lighter mounting.

a Disconnect the cigarette lighter connector.

103426

103427

101322

101319

101321

23A-90


F9Q, and DP0

23A

a Disconnect the heated seat connectors (if fitted tothe vehicle).

a Remove the two front seats (see MR 365 Bo-dywork, 75A, Front seat frames and runners,Complete front seat: Removal - Refitting).

a Remove the bolts from the console (11) .

a Remove:

- the console carefully (12) ,

- the gear lever console.


a Remove the sensor (14) using the (Mot. 1495-01).

a Remove the nuts (15) from the exhaust bracket.

a Remove the bolts (16) from the rubber mountingbush.

101320

101504

101793

101818

23A-91


F9Q, and DP0

23A

a Remove:

- the bolt (17) ,

- the front section of the heat shield.

a Pull back the carpet.

a Remove the soundproofing (18) .

a Remove the protector (19) .


a Remove the bolts (20) from the automatic gearboxcontrol unit.

a Hold the control lever rod steady and release thecontrol unit clips.

a Take out the « unit-control cable » assembly.

102117

103428

103429

103431

23A-92


F9Q, and DP0

23AREFITTING


a Position the « unit-control cable » assembly.

a Hold the control lever rod steady and lock the controlunit clips.

a Refit the bolts (21) to the automatic gearbox controlunit.

II - FINAL OPERATION

a Refit the protector (22) .

a Refit the soundproofing (23) .

a Pull the carpet forwards.

103431

103429

103428

23A-93


F9Q, and DP0

23A

a Refit:

- the front section of the heat shield,

- the bolt (24) .

a Refit the bolts (25) to the rubber mounting bush.

a Refit the nuts (26) to the exhaust bracket.

a Torque tighten the exhaust bracket nuts (21 Nm).

a Refit the oxygen sensor (27) .

a Torque tighten the oxygen sensor (45 Nm).

a Connect the connector (28) .

102117

101818

101793

101504

23A-94


F9Q, and DP0

23Aa Refit the two front seats (see MR 365 Bodywork,

75A, Front seat frames and runners, Completefront seat: Removal - Refitting).

a Refit:

- the centre console,

- the centre console bolts.

a Connect the heated seat connectors (if fitted to thevehicle).

a Connect the cigarette lighter connector.

a Clip on the cigarette lighter mounting.

a Clip on the handbrake surround trim.

a Connect the connector (29) .

a Clip on the console trim (30) .

a Refit the control unit lever knob (31) by lowering it.

a Fit the part.

a Turn the part a quarter of a turn.

a Refit the diagnostic socket access cover.

101321

103427

103426

103424

23A-95


F9Q, and DP0

23A

a Refit:

- the sheath stop control cable (32) on the modularconnector support,

- the multifunction switch cable ball joint (33) .

a Refit the battery (see 80A, Battery, Battery: Remo-val - Refitting).

a Refit the engine covers.

103408

23A-96


AJ0

23A

I - REMOVAL

1 - In the engine compartment




a Remove:

- the battery,

- the cowl grille ( (see 85A, Wiping - Washing) ).

a Remove:

- the two air filter access panel mounting bolts,


- the scuttle panel partition mounting bolt.

a Remove:

- the scuttle panel partition mounting bolts,

- the scuttle panel partition.

a Disconnect the computer connectors.

a Remove:

- the battery tray bolts ,

- the battery tray,

- the computer with its support,

- the air filter outlet duct.

Tightening torquesm

control unit mountingnuts

2.1 daNm

104343

104246

101822

23A-97


AJ0

23A

a Unclip:

- the control cable from the gearbox lever ball joint,

- the control cable from the sleeve stop.

2 - In the passenger compartment

a Unclip the gear lever gaiter.

a Rotate part clockwise.

a Remove the gear lever knob by lifting it.

a Remove the mounting bolts from the central console.

a Unclip:

- the mounting brackets ,

- the clip.

105107

105109

105110

104033

23A-98


AJ0

23A

a Disconnect the connector.

a Remove:

- the three control unit mounting bolts ,

- the three bulkhead seal mounting bolts,


a Disconnect:

- the exhaust pipe from the exhaust manifold,

- the centre bracket.

a Move the exhaust pipe to one side.

a Disconnect the oxygen sensor connector.

a Remove the heat shield mounting bolts.

a Move the heat shield towards the rear of the vehicleto gain access to the gearbox control cable routing.

a Remove the « control unit-cable » assembly via thepassenger compartment.

II - REFITTING


a Torque tighten the control unit mounting nuts (2.1daNm).

ADJUSTING THE CONTROL CABLE

a - In the passenger compartment

a Put the lever in « Drive » position.

b - In the engine compartment

a Put the gearbox lever in « Drive » position.

a Clip the control cable into the sleeve stop.

105108

WARNING

Do not open the automatic transmission controlunit, this could cause damage (infrared system).

105105

23A-99


AJ0

23A

a Slide on part by compressing the control cablespring.

a Unlock the adjustment mechanism by sliding thecatch.

a Adjust the length of the cable accordingly.

a Fit the end of the control cable on the gearbox leverball joint.

a Lock the adjustment mechanism by pushing thecatch back to its original position.


104733

104736

105107

WARNING

Connect the battery; carry out the necessary pro-gramming ( (see 80A, Battery) ).

29A-1

DRIVESHAFTSDriveshaft: Precautions for repair 29A

Note:

A gearbox oil leak at the driveshaft may destroy it.

Note:

Grease the base of the bearing using BR 2 +grease to prevent the bearing from sticking.

Make sure that the O-ring is correctly positioned inthe base of the relay bearing, if the bearing hasone.

Note:

Always replace:

- the O-ring, if fitted to the bearing,

- the relay bearing support plate,

- the left-hand driveshaft locking spring ring, if thedriveshaft has one,

- the seals whenever the driveshaft is removed.

WARNING

In order to prevent irreversible damage to the front hub bearing:

- Do not loosen or tighten the driveshaft nut whenthe wheels are on the ground.

- Do not place the vehicle with its wheels on theground when the driveshaft has been loosened orremoved.

29A-2

DRIVESHAFTSFront left-hand wheel driveshaft: Removal - Refitting 29A

REMOVAL

I - WHEEL SIDE


a Remove:

- the front left-hand wheel,

- the hub nut using tool (Rou. 604-01).

a Disconnect the wheel speed sensor.

a Remove:

- the track rod end nut (1) ,

- the stub axle carrier ball joint using the (Tav. 476),

- the upper nut of the anti-roll bar (2) ,

- the lower ball joint stud (3) .

a Push back the driveshaft from the stub axle carrierby pivoting the stub axle carrier.

a Remove the driveshaft (wheel side).

II - GEARBOX SIDE


a Remove the driveshaft (gearbox side).

REPLACEMENT

a

a With the protector in place, coat the splines of theseal on the gearbox side with MOLYKOTE BR2.

a Position and insert the driveshaft into the final drivesunwheel.

a Insert the stub-axle into the hub.

The driveshaft must go in freely until it protrudesenough for the hub nut to be mounted.


a Torque tighten:





- the anti-roll bar nut (4.4 daNm),

- the driveshaft bearing bolts (4.4 daNm),

a Fill and check the gearbox oil level (see 21A, Ma-nual gearbox, Manual gearbox oil: Draining - Re-filling, page 21A-13) .




Tightening torquesm

wheel bolts 13 daNm

hub nut 28 daNm



anti-roll bar nut 4.4 daNm

driveshaft bearing bolts 4.4 daNm

101213

JH3 or JR5 or ND0

Note:

Check the condition of the contact surfaces ofthe lip seal.

Always replace the differential output lip seal(see 21A, Manual gearbox, Differential outputseal: Removal - Refitting, page 21A-45) .

29A-3

DRIVESHAFTSFront right-hand wheel driveshaft: Removal - Refitting 29A

REMOVAL

I - WHEEL SIDE


a Remove:

- the front right-hand wheel,

- the hub nut using tool (Rou. 604-01).

a Disconnect the wheel speed sensor.

a Remove:

- the track rod end nut (1) ,

- the stub axle carrier ball joint using the (Tav. 476),

- the upper nut from the anti-roll bar (2) ,

- the lower ball joint stud (3) .

a Push back the driveshaft from the stub axle carrierby pivoting the stub axle carrier.

a Remove the driveshaft (wheel side).

II - GEARBOX SIDE


a Remove the two bolts (4) from the driveshaft bea-ring.

a Remove the driveshaft (gearbox side).




Tightening torquesm

wheel bolts 13 daNm

hub nut 28 daNm



anti-roll bar nut 4.4 daNm

driveshaft bearing bolts 4.4 daNm

101213

JH3 or JR5 or ND0

101819

Note:

If the bearing is seized in the relay bearing, thebearing must be replaced.

29A-4

DRIVESHAFTSFront right-hand wheel driveshaft: Removal - Refitting 29A

REPLACEMENT

a Clean and grease the bearing hole into which thebearing will be inserted.

a With the protector in place, coat the splines of theseal on the gearbox side with MOLYKOTE BR2.

a Position and insert the driveshaft into the final drivesunwheel.

a Insert the stub-axle into the hub.

The driveshaft must go in freely until it protrudesenough for the hub nut to be mounted.


a Torque tighten:





- the anti-roll bar nut (4.4 daNm),

- the driveshaft bearing bolts (4.4 daNm),

a Fill and check the gearbox oil level (see 21A, Ma-nual gearbox, Manual gearbox oil: Draining - Re-filling, page 21A-13) .

REMOVING THE RELAY SHAFT BEARING

a Remove the complete driveshaft.

a Remove the bearing using a press.

a Take care not to score the contact surface of the lipseal on the relay shaft.

REFITTING

a Lubricate the contact surface of the shaft into whichthe bearing is inserted.

a Insert the new bearing.

a Fit the bearing to the end using a tube, so that itrests on the inner bearing race.

a Clean and grease the bearing hole into which thebearing will be inserted.

a Refit the driveshaft.

Note:

- Replace the O-ring at the base of the relay shaftbearing if it is damaged.

- Check the condition of the contact surfaces ofthe lip seal.

- The differential output lip seal must always bereplaced (see 21A, Manual gearbox, Differen-tial output seal: Removal - Refitting, page21A-45) .

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scenic ii pt3 transmission

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