Manual service Renault Scenic 2 Trans Misie

2

Transmission 20A

CLUTCH

21A

MANUAL GEARBOX

23A

AUTOMATIC GEARBOX

29A

DRIVESHAFTS

X84, and J84 77 11 322 042

JUNE 2003

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

© Renault 2004

Edition Anglaise

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

Scénic II - Section 2

Scénic II - Section 2 ContentsPage

Contents

20A

21A

23A

CLUTCH Identification

20A-1

Hydraulic distributor

23A-12

Mechanism / Plate

20A-3

Clutch thrust bearing

20A-7

Automatic gearbox: Removal - Refitting

23A-17

Flywheel

20A-9

Drive plate

23A-26

Differential output gasket

23A-28

Converter seal

23A-30

Multifunction switch

23A-31

Computer

23A-33

Speed sensor

23A-35

Flow regulation solenoid valve

23A-36

Solenoid valves: Removal

23A-38

Gearbox connector

23A-39

MANUAL GEARBOX Gears

21A-1

Lubricants

21A-2

Consumables

21A-4

Parts to be replaced systematically

21A-5

Manual gearbox: Removal Refitting Differential output seal

21A-6 21A-22 29A

23A

AUTOMATIC GEARBOX

AUTOMATIC GEARBOX

DRIVESHAFTS Identification

29A-1

Consumables

29A-2

Gears

23A-1

Front left-hand driveshaft

29A-3

Lubricants

23A-2

Front right-hand driveshaft

29A-4

Consumables

23A-3

Parts to be replaced systematically

23A-4

Changing the oil

23A-5

Filling - Levels

23A-7

Checking the converter setting point

23A-10

Line pressure measurement

23A-11

CLUTCH Identification

20A Colour of springs (1) and (2): Grey

K4J or K4M Mechanism

K9K Mechanism

102143

Plate 102143

1 Plate

3

2

4 102142

Plate external diameter: 200 mm Plate thickness: 6.9 mm Number of splines: 26

102142

Plate external diameter: 215 mm Plate thickness: 6.8 mm Number of splines: 26

20A-1

CLUTCH Identification

20A Number of splines: 21

Colour of springs (3): Red and Black Colour of springs (4): Grey

F4R or F9Q Mechanism

22428

Plate

22429

Plate external diameter: 239 mm Plate thickness: 7.8 mm

20A-2

CLUTCH Mechanism / Plate

20A

F4R or F9Q

REFITTING

Special tooling required Mot. 1677

Flywheel locking tool (F engines)

Emb. 1604

Clutch compression tool for rearming the adjustment system

Emb. 1518

Set of clutch plate centring mandrels

EMB. 1604

Tightening torquesm mechanism mounting bolts

1.2 daNm 19919

REMOVAL Remove the gearbox (Section Manual gearbox, Manual gearbox: Removal - Refitting, page 21A-6).

Note: For mechanisms with automatic take-up, compress the clutch mechanism using tool (Emb. 1604).

1 16180

Lock the engine using tool (Mot. 1677)(1) . Remove the mechanism mounting bolts.

20754

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

Remove the friction plate. Replace any faulty parts.

20A-3

CLUTCH Mechanism / Plate

20A

F4R or F9Q

2

3 1

20757

Insert the circlip pliers at (3).

20755

Mount the mechanism on the base, then fit the thrust ball bearing (1) and the nut (2).

4

20759

Compress the springs (4). Loosen the nut (2) completely (springs compressed). Release the mechanism.

20756

Tighten the nut (2) fully.

20A-4

CLUTCH Mechanism / Plate

20A

F4R or F9Q CENTRING

20758

Remove the mechanism from the base (checking that the springs are properly compressed).

22695

Centre the clutch plate using tool (Emb. 1518). Refit the mechanism on the flywheel.

WARNING

Gradually torque tighten the mechanism mounting bolts (1.2 daNm).

Clean the clutch shaft splines and refit the assembly without lubricant. Degrease the friction face of the flywheel.

5

102695

Mount the plate (small hub diameter (5) on flywheel side).

20A-5

CLUTCH Mechanism / Plate

20A

K4J or K4M or K9K, and 722 or 728

REFITTING

Special tooling required Mot. 582-01

Flywheel locking tool (K engines)

Emb. 1518

Set of clutch plate centring mandrels

Tightening torquesm mechanism mounting bolts

2 daNm

REMOVAL Remove the gearbox (Section Manual gearbox, Manual gearbox: Removal - Refitting, page 21A-6).

95414

Clean the clutch shaft splines. Refit the assembly without lubricant. Mount the clutch plate. Centre the clutch plate using tool (Emb. 1518). Screw into place gradually in a radial pattern. Torque tighten the mechanism mounting bolts (2 daNm). Remove tool (Mot. 582-01).

1 16180

Lock the engine using tool (Mot. 582-01)(1). Remove the mechanism mounting bolts. Remove the friction plate. Replace any faulty parts.

20A-6

CLUTCH Clutch thrust bearing

20A

ND0

Tightening torquesm hydraulic union mounting bolts

0.9 daNm

clutch thrust bearing clutch housing mounting bolts

2.1 daNm

2

REMOVAL JH3 or JR5

1 1

101223

Remove: - the gearbox (Section Manual gearbox, Manual gearbox: Removal - Refitting, page 21A-6),

2

- the hydraulic union clip (1), - the hydraulic union, - the two clutch thrust bearing - clutch housing mounting bolts (2), 18439

- the clutch thrust bearing.

Remove: - the gearbox (Section Manual gearbox, Manual gearbox: Removal - Refitting, page 21A-6), - the two hydraulic union bolts (1), - the hydraulic union,

REFITTING

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

Proceed in the reverse order to removal.

- the clutch thrust bearing. JH3 or JR5 Torque tighten: - the hydraulic union mounting bolts (0.9 daNm), - the clutch thrust bearing - clutch housing mounting bolts (2.1 daNm).

20A-7

CLUTCH Clutch thrust bearing

ND0 Torque tighten the clutch thrust bearing - clutch housing mounting bolts (2.1 daNm).

WARNING To avoid damaging the clutch slave cylinder, do not lubricate the clutch shaft. Never operate the system while the slave cylinder is removed.

Note: Always replace the hydraulic union. Bleed the clutch control ( Mechanical element controlsSection).

20A-8

20A

CLUTCH Flywheel

20A

Special tooling required F4R or F9Q Mot. 582-01

Flywheel locking tool (K engines)

Mot. 1677

Flywheel locking tool (F engines)

Tightening torquesm flywheel mounting bolts

6.5 daNm

REMOVAL Remove:

9

- the gearbox (Section Manual gearbox, Manual gearbox: Removal - Refitting, page 21A-6), - the clutch mechanism (Section Clutch, Mechanism / Plate, page 20A-3).

22698

K4J or K4M or K9K

Lock the engine using tool (Mot. 1677)(9). Remove: - the engine flywheel mounting bolts, - the flywheel, - the tool (Mot. 1677)(9). Note: The engine flywheel is of the double damper flywheel type.

REFITTING

8

Clean the threads for the flywheel mounting bolts on the crankshaft. 22698

Lock the engine using tool (Mot. 582-01)(8).

Degrease the bearing face of the flywheel on the crankshaft. Check the condition of the flywheel.

Remove: - the flywheel mounting bolts, - the flywheel, - the tool (Mot. 582-01).(8)

20A-9

CLUTCH Flywheel

20A Always replace the mounting bolts with new ones. Coat the new bolts of the flywheel with LOCTITE FRENETANCH.

K9K

7

2

5

10

4

6

3 1

23325

23326

Tighten in the correct order and to the correct torque value the flywheel mounting bolts (6.5 daNm).

11

101356

WARNING Do not remove the flywheel drive plate mounting bolts (10). Refit the spacer (11) observing the direction of fitting of the chamfer on the flywheel side.

20A-10

MANUAL GEARBOX Gears

21A

JH3 Suffix

105

106

137

142

143

144

Differential ratio

14/59

14/63

14/59

15/61

15/61

15/61

First

11/41

11/41

11/41

11/41

11/41

11/41

Second

21/43

21/43

21/43

21/43

21/43

21/43

Third

28/39

28/39

28/39

28/39

28/39

28/39

Fourth

31/34

34/35

31/34

31/34

31/34

31/34

Fifth

37/33

39/32

37/33

37/33

37/33

37/33

Reverse

11/39

11/39

11/39

11/39

11/39

11/39

JR5 Suffix

103

104

110

125

Differential ratio

15/58

15/61

15/58

14/63

First

11/41

11/41

11/41

11/41

Second

21/43

21/43

21/43

21/43

Third

28/37

28/39

28/37

26/37

Fourth

35/34

31/34

35/34

35/34

Fifth

41/31

37/33

41/31

39/32

Reverse

11/39

11/39

11/39

11/39

ND0 Suffix

002

013

015

Differential ratio

15/58

14/57

16/70

First

12/41

14/49

14/49

Second

19/35

18/35

18/35

Third

31/39

28/39

28/39

Fourth

38/36

36/38

36/38

Fifth

45/33

42/34

52/45

Sixth

48/29

49/33

56/41

Reverse

12/38

14/46

14/46

21A-1

MANUAL GEARBOX Lubricants

21A

JH3 or JR5 or ND0, and LONG CHASSIS or STANDARD CHASSIS Capacity (in litres) JR5

2.5

JH3

2.8

ND0

2.1

JH3 or JR5

I - QUALITY, VISCOSITY STANDARD CHASSIS TRANSELF TRJ 75 W80 to be ordered from ELF.

2 JH3 or JR5, and LONG CHASSIS TRANSELF TRT 75 W80 to be ordered from ELF.

1 18749

ND0, and LONG CHASSIS TRANSELF TRJ 75 W80 to be ordered from ELF.

(1)

Drain plug

(2)

Filler plug

5 II - LEVEL CHECK IN THE EVENT OF LEAKAGE

92081

Fill up to the level of the aperture.

2176

21A-2

MANUAL GEARBOX Lubricants

21A

JH3 or JR5 or ND0, and LONG CHASSIS or STANDARD CHASSIS

ND0

WARNING Removing the breather valve (5) to fill the gearbox with oil is prohibited.

5 101532

(3)

Drain plug

(4)

Filler plug

5 101221

21A-3

MANUAL GEARBOX Consumables

21A

JH3 or JR5 or ND0

Type

Packaging

Part no.

Component

MOLYKOTE BR2

1 kg can

77 01 421 145

Splines

LOCTITE 518

24 ml syringe

77 01 421 162

JH/JR housing assembly faces

LOCTITE 5970

300 ml syringe

77 11 219 705

NDO housing assembly faces

RHODORSEAL 5661

100 g tube

77 01 404 452

Threaded plugs and switches

21A-4

MANUAL GEARBOX Parts to be replaced systematically Replace the following parts after removal: - the lip seals, - the O-rings.

21A-5

21A

MANUAL GEARBOX Manual gearbox: Removal - Refitting

21A

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

REMOVAL

Special tooling required

Mount the vehicle on a two post lift. Rou. 604-01

Hub locking tool

Tav. 476

Ball joint extractor

Mot. 1453

Multiple-adjusting engine mounting support with retaining straps

Disconnect the battery, starting with the negative terminal. Remove the cowl grille ( Wiping / WashingSection).

Equipment required

2

jack

1 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 mounting bolts

2.1 daNm

gearbox edge and starter bolts

4.4 daNm

engine tie-bar bolts on the engine

10.5 daNm

engine tie-bar bolts on the sub-frame

10.5 daNm

gearbox suspended mounting bolts

6.2 daNm

suspended mounting nut on the rubber pad

18 daNm

cooling radiator cross member front mounting bolts

10.5 daNm

gearbox drain plug

(2.5 daNm)

gearbox filler plug

0.3 daNm

battery cover mounting bolts

0.4 daNm

104343

Remove: - the two air filter access panel mounting bolts (1), - the air filter access panel, - the plenum chamber partition mounting bolt (2).

3

104246

Remove: - the plenum chamber partition mounting bolts (3), - the plenum chamber partition, - the plenum chamber, - the engine undertray. Drain the gearbox. Remove: - the front wheels, - the engine covers,

21A-6

MANUAL GEARBOX Manual gearbox: Removal - Refitting

21A

K4J, and 730 – K4M, and 782 – K9K, and 722 or 728 - the battery,

Disconnect:

- the battery mounting,

- the ABS sensor wiring,

- the injection computer with its support,

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

- the air flowmeter.

Remove the wheel arch liners.

- the air inlet pipe.

I - LEFT-HAND SIDE OF VEHICLE

101821

Remove the electrical harness mountings. 102129

Remove: - the hub nut using tool (Rou. 604-01), - the track rod end using tool (Tav. 476), - the anti-roll bar ball joint, - the lower ball joint. Release the stub axle carrier from the driveshaft. Remove the left-hand driveshaft.

104086

Unclip the gear control cables from the gearbox.

21A-7

MANUAL GEARBOX Manual gearbox: Removal - Refitting

21A

K4J, and 730 – K4M, and 782 – K9K, and 722 or 728 II - RIGHT-HAND SIDE OF VEHICLE

101212 101819

Remove the side stiffeners.

Remove: - the hub nut using tool (Rou. 604-01), - the track rod end using tool (Tav. 476), - the anti-roll bar ball joint, - the lower ball joint. - the relay bearing bracket. Release the stub axle carrier from the driveshaft. Remove the right-hand driveshaft. Attach the cooling radiator assembly to the upper cross member using rope. 102009

Remove the cooling radiator cross member.

21A-8

MANUAL GEARBOX Manual gearbox: Removal - Refitting

21A

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

106204

Disconnect the reversing connector.

106199

Remove the catalytic converter support from the clutch housing.

106200

Disconnect the TDC sensor.

102115

Remove the engine tie-bar.

21A-9

MANUAL GEARBOX Manual gearbox: Removal - Refitting

21A

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

5 4 106201

Disconnect the oil level sensor.

106205

Disconnect: - the starter (4), - the diesel fuel pressure sensor (5).

6 14853

Remove: 106203

Disconnect the earth strap from the gearbox.

- the starter mounting bolts (6), - the starter. Drain the brake fluid reservoir down to the clutch master cylinder pipe union using a syringe.

21A-10

MANUAL GEARBOX Manual gearbox: Removal - Refitting

21A

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

7

101701

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

106195

Remove the gearbox support rubber pad.

102449

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

106194

Remove: - the three gearbox support bolts, - the gearbox support.

21A-11

MANUAL GEARBOX Manual gearbox: Removal - Refitting K4J, and 730 – K4M, and 782 – K9K, and 722 or 728

106193

Remove the gearbox edge upper bolts. Set up the jack under the gearbox Remove: - the gearbox edge lower bolts, - the gearbox.

21A-12

21A

MANUAL GEARBOX Manual gearbox: Removal - Refitting

21A

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

REFITTING WARNING WARNING

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

Do not coat:

- Add brake fluid to the reservoir.

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

- Bleed the hydraulic circuit ( Mechanical element controlsSection).

- the clutch shaft splines.

- Top up the brake fluid level.

Note:

WARNING

To avoid any risk of leakage, the hydraulic union must always be replaced after the clutch mechanism is replaced.

Connect the battery; carry out the necessary programming (Section Electrical equipment).

Check that the engine-gearbox centring rings are in place and correctly positioned. Proceed in the reverse order to removal. 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 gearbox edge and starter bolts (4.4 daNm), - the engine tie-bar bolts on the engine (10.5 daNm), - the engine tie-bar bolts on the sub-frame (10.5 daNm), - the gearbox suspended mounting bolts (6.2 daNm), - the suspended mounting nut on the rubber pad (18 daNm), - the cooling radiator cross member front mounting bolts (10.5 daNm), - the gearbox drain plug ((2.5 daNm)), - the gearbox filler plug (0.3 daNm). Top up the gearbox oil.

21A-13

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

MANUAL GEARBOX Manual gearbox: Removal - Refitting

21A

F4R, and 770 – F9Q, and 812 Special tooling required

Tightening torquesm

Rou. 604-01

Hub locking tool

Tav. 476

Ball joint extractor

Mot. 1453

Multiple-adjusting engine mounting support with retaining straps

subframe rear mounting bolts

140 N.m

subframe tie-rod mounting bolts

105 N.m

gearbox drain plug

25 N.m

gearbox filler plug

Equipment required

3 N.m

wheel mounting bolts

jack

130 Nm

battery cover mounting bolts

4 N.m

Tightening torquesm driveshaft nut

280 N.m

REMOVAL Put the vehicle on a two-post lift.

lower ball joint nut

62 N.m

track rod end nut

(37 N.m)

ball joint nut from the anti-roll bar

44 N.m

side panel mounting bolts

21 N.m

gearbox edge and starter motor bolts

44 N.m

engine tie-bar bolts to the engine

180 N.m

engine tie-bar bolts on the sub-frame

105 N.m

gearbox suspended mounting bolt

44 N.m

suspended mounting nut on the support

180 N.m

steering shaft mounting bolt

Disconnect the battery, starting with the negative terminal. Remove the scuttle panel grille (see MR 371 Bodywork, 55A, Exterior Protection, Scuttle Panel Grille).

2

1

104343

Remove:

yoke

21 N.m

cooling radiator cross member front mounting bolts

105 N.m

cooling radiator cross member rear mounting bolts

21 N.m

subframe cross-member mounting bolts

62 N.m

- the two air filter access panel mounting bolts(1), - the air filter access panel, - the plenum chamber partition mounting bolt(2).

21A-14

MANUAL GEARBOX Manual gearbox: Removal - Refitting

21A

F4R, and 770 – F9Q, and 812

3

104246

Remove: - the plenum chamber partition mounting bolts(3), - the plenum chamber, - the engine undertray.

101821

Remove the electrical harness mountings.

Drain the gearbox. 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.

104085

Unclip the gear control cables from the gearbox.

21A-15

MANUAL GEARBOX Manual gearbox: Removal - Refitting

21A

F4R, and 770 – F9Q, and 812 I - LEFT-HAND SIDE OF THE VEHICLE F9Q

102129 102244

Remove:

Disconnect the heat exchanger - turbocharger air pipe.

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

Remove the air filter hose.

- the anti-roll bar ball joint,

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

- the lower ball joint. Remove the stub-axle carrier from the driveshaft. Disconnect:

Remove the driveshaft.

- the ABS sensor wiring, - the discharge bulb adjustment sensor wiring harnesses (if fitted). Remove the wheel arch liners.

21A-16

MANUAL GEARBOX Manual gearbox: Removal - Refitting

21A

F4R, and 770 – F9Q, and 812 II - RIGHT-HAND SIDE OF THE VEHICLE

101212 101819

Remove the side stiffeners.

Remove: - the hub nut using tool (Rou. 604-01), - the track rod end using tool (Tav. 476), - the anti-roll bar ball joint, - the lower ball joint. - the relay bearing bracket. Remove the stub-axle carrier from the driveshaft. Remove the driveshaft. Attach the cooling radiator assembly to the upper cross member using rope. 102009

Remove: - the cooling radiator cross member. - the catalytic converter support from the clutch housing, - the starter mounting bolts, - the starter motor.

21A-17

MANUAL GEARBOX Manual gearbox: Removal - Refitting

21A

F4R, and 770 – F9Q, and 812

101354

Remove the steering shaft fork.

102452

Remove the engine upper tie-bar.

4

101208

Remove the sub-frame angle bracket (4).

102312

Remove the engine lower tie-bar.

21A-18

MANUAL GEARBOX Manual gearbox: Removal - Refitting

21A

F4R, and 770 – F9Q, and 812

101209

Strap the sub-frame to the jack. Remove the sub-frame.

21A-19

MANUAL GEARBOX Manual gearbox: Removal - Refitting

21A

F4R, and 770 – F9Q, and 812

102449

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

102485

Disconnect: - the reversing connector, - the TDC sensor. Drain the brake fluid reservoir down to the clutch master cylinder pipe union using a syringe.

5 102112

Remove: - the gearbox support rubber pad, - the gearbox suspended mounting, - the gearbox edge upper bolts. Position jack underneath the gearbox. Remove: - the gearbox edge lower bolts, 101701

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

21A-20

- the gearbox.

MANUAL GEARBOX Manual gearbox: Removal - Refitting

21A

F4R, and 770 – F9Q, and 812

REFITTING

- the subframe rear mounting bolts (140 N.m), - the subframe tie-rod mounting bolts (105 N.m), - the gearbox drain plug (25 N.m),

WARNING

- the gearbox filler plug (3 N.m), Do not coat:

- the wheel mounting bolts (130 Nm).

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

Top up the gearbox oil.

- the clutch shaft splines.

WARNING

Note:

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

To avoid leaks, the hydraulic union must always be replaced after the clutch mechanism is replaced.

- Add brake fluid to the reservoir.

Check that the engine / gearbox centering rings are in place and correctly positioned. Proceed in the reverse order to removal.

- Bleed the circuit (see 37A, Mechanical Component Controls, Clutch Circuit: Bleeding). - Top up the brake fluid level. Connect the battery, starting with the positive terminal.

WARNING WARNING

To refit the sub-frame (see 31A, Front Lifting Components, Axle sub-frame). Always replace the steering shaft yoke stud after removal. Tighten to torque: - the driveshaft nut (280 N.m), - thelower ball joint nut (62 N.m), - the track rod end nut ((37 N.m)), - theball joint nut from the anti-roll bar (44 N.m), - the side panel mounting bolts (21 N.m), - the gearbox edge and starter motor bolts (44 N.m), - the engine tie-bar bolts to the engine (180 N.m), - the engine tie-bar bolts on the sub-frame (105 N.m), - the gearbox suspended mounting bolt (44 N.m), - thesuspended mounting nut on the support (180 N.m), - the steering shaft yoke mounting bolt (21 N.m), - the cooling radiator cross member front mounting bolts (105 N.m), - the cooling radiator cross member rear mounting bolts (21 N.m), - the subframe cross-member mounting bolts (62 N.m),

21A-21

Carry out the necessary programming (see 80A, Battery: Remove and Refit). Torque tighten the battery cover mounting bolts (4 N.m).

MANUAL GEARBOX Differential output seal

21A

JH3 or JR5 Special tooling required Bvi. 1666

Differential seal fitting tool

Tightening torquesm wheel bolts

13 daNm

lower ball joint nut

6.2 daNm

track rod end nut

3.7 daNm

anti-roll bar ball joint nut

4.4 daNm

hub nut

28 daNm

relay bearing bracket nut

2.1 daNm

engine - engine tie-bar bolts

10.5 daNm

sub-frame - engine tiebar bolts

10.5 daNm

battery cover mounting bolts

0.4 daNm

102129

Remove the relay bearing bracket.

REMOVAL Put the vehicle on a two-post lift. Disconnect the battery starting with the negative terminal. Remove the engine undertray. Drain the gearbox. Remove: - the wheel, - the wheel arch liner, 101819

- the hub nut,

Remove the driveshaft.

- the track rod end,

REPLACING THE SEAL

- the anti-roll bar ball joint,

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

- the lower ball joint.

Remove the seal with pliers, taking care not to damage the splines of the sunwheel.

Disconnect: - the wheel speed sensor connector, - the xenon headlight adjustment sensor wiring harnesses (if fitted).

21A-22

MANUAL GEARBOX Differential output seal JH3 or JR5

REFITTING

21503

Oil the seal. Insert the seal onto the splined part of the sunwheel. Refit the seal using the tool (Bvi. 1666), with the marking A on the right-hand side and marking B on the left-hand side. Position the driveshaft in relation to the sunwheel. To refit, proceed in the reverse order of removal. Tighten to torque: - the wheel bolts (13 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 hub nut (28 daNm), - the relay bearing bracket nut (2.1 daNm), - the engine - engine tie-bar bolts (10.5 daNm), - the sub-frame - engine tie-bar bolts (10.5 daNm). Top up the gearbox oil.

WARNING Connect the battery; carry out the necessary programming (Section Electrical equipment). Torque-tighten the battery cover mounting bolts (0.4 daNm).

21A-23

21A

MANUAL GEARBOX Differential output seal

21A

ND0 Special tooling required Bvi. 1689

Differential oil seal fitting tool

Tightening torquesm wheel bolts

13 daNm

lower ball joint nut

6.2 daNm

track rod end nut

3.7 daNm

anti-roll bar ball joint nut

4.4 daNm

hub nut

28 daNm

relay bearing bracket nut

2.1 daNm

engine - engine tie-bar bolts

18 daNm

sub-frame - engine tiebar bolts

10.5 daNm

battery cover mounting bolts

0.4 daNm

102129

Remove the relay bearing bracket.

REMOVAL Put the vehicle on a two-post lift. Disconnect the battery starting with the negative terminal. Remove the engine undertray. Drain the gearbox. Remove: - the wheel, - the wheel arch liner, 101819

- the hub nut,

Remove the driveshaft.

- the track rod end,

REPLACING THE SEAL

- the anti-roll bar ball joint,

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

- the lower ball joint.

Remove the dislodged seal with pliers, taking care not to damage the sunwheel splines.

Disconnect: - the wheel speed sensor connector, - the xenon headlight adjustment sensor wiring harnesses (if fitted).

21A-24

MANUAL GEARBOX Differential output seal ND0

REFITTING

102260

Oil the seal before inserting it onto the splined part of the sunwheel. Refit the seal using the tool (Bvi. 1689), with the marking A on the right-hand side and marking B on the left-hand side. Position the driveshaft in relation to the sunwheel. To refit, proceed in the reverse order of removal. Tighten to torque: - the wheel bolts (13 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 hub nut (28 daNm), - the relay bearing bracket nut (2.1 daNm), - the engine - engine tie-bar bolts (18 daNm), - the sub-frame - engine tie-bar bolts (10.5 daNm). Top up the gearbox oil.

WARNING Connect the battery; carry out the necessary programming (Section Electrical equipment). Torque-tighten the battery cover mounting bolts (0.4 daNm).

21A-25

21A

AUTOMATIC GEARBOX Gears

23A

DP0

DP0 Suffix

056

057

059

061

Step-down

52/67

52/67

52/67

52/67

Final drive

20/73

20/73

20/73

23/70

23A-1

AUTOMATIC GEARBOX Lubricants DP0 The DP0 automatic gearbox is greased for life and does not require any maintenance: It is only necessary to top up the level in the event of a slight leak. I - OIL SPECIFIED: ELF RENAULT MATIC D3 SYN (can be ordered from ELF) DEXRON III standard II - CAPACITY IN LITRES Total volume: 6 litres.

23A-2

23A

AUTOMATIC GEARBOX Consumables DP0

Description

Component concerned

Grease

Converter centring fitting

MOLYKOTE BR2 LOCTITE FRENBLOC

Flywheel mounting bolt

23A-3

23A

AUTOMATIC GEARBOX Parts to be replaced systematically DP0 The following parts must be replaced after being removed: - self-locking nuts, - the seals, - rubber seals, - converter bolts.

23A-4

23A

AUTOMATIC GEARBOX Changing the oil

23A

DP0 former assembly Tightening torquesm old assembly topping-up cap

25 N.m

old assembly overflow pipe

35 N.m

new assembly toppingup cap

35 N.m

new assembly overflow pipe

9 N.m

2

1 2316

WARNING

The cap has two functions:

For both assemblies, when changing engine oil or topping up, the control lever must be in Parkingposition.

- the topping-up plug (1), - the overflow pipe (2).

The engine oil change and topping-up plugs have evolved. The top-up and bleeding checking procedures are the same for both fittings. It is preferable to change the automatic transmission oil when it is warm (60˚C maximum), in order to remove as many impurities as possible. Mount the vehicle on a lift. Remove the engine undertray.

23A-5

Remove the assembly (1) and (2) to carry out the complete gearbox oil change. Remove only the cap (1) for topping-up.

AUTOMATIC GEARBOX Changing the oil DP0 New assembly

4 5

3

107912

Remove: - the cap again (3). - the overflow pipe (4)using an Allen key (5) with diameter of 8mm Let the oil flow. Note: Always replace the overflow pipe (4) each time it is removed. Refit the new overflow pipe. Tighten to torque: - the old assembly topping-up cap (25 N.m) - the old assembly overflow pipe (35 N.m) - the new assembly topping-up cap (35 N.m) - the new assembly overflow pipe (9 N.m) Carry out filling and top up of the gearbox oil (see 23A, Gearbox, Filling - Top up).

23A-6

23A

AUTOMATIC GEARBOX Filling - Levels

23A

DP0

Equipment required Diagnostic tool

Tightening torquesm plug

2

35 N.m

WARNING It is essential to shift the control lever to the Parking position. I - FILLING

101822

Disconnect the computer connectors. Remove the battery tray mounting bolts(2). Remove: - the battery tray, - the computer mounting. Remove the turbocharger pressure regulation solenoid valve (if fitted on the vehicle).

1

103407

3

Fill through the hole (1). Use a funnel with a 15/100 filter to prevent impurities from entering the system. II - FILLING PROCEDURE Park the vehicle on level ground. Disconnect the battery, starting with the negative terminal.

110245

Remove the gearbox control(3).

23A-7

AUTOMATIC GEARBOX Filling - Levels

23A

DP0 Former assembly

B

A C

4 2316

A Open the plug again (4). New assembly 101743

Unclip the lever cable on the gearbox: - clip the gearbox control at (A), - pull the pin at (B), - raise the gearbox control at (C). Fill the automatic transmission with 3.5 litres of new oil. Proceed in the reverse order to removal Connect the battery, starting with the positive terminal.

5

WARNING carry out the necessary programming (see 80A, Battery: Remove and Refit) Run the engine at idle speed.

107912

Open the plug again (5).

Connect the Diagnostic tool ( CLIP ). Establish dialogue with the automatic transmission computer. Monitor the gearbox oil temperature parameter. Once a temperature of 60˚C +/- 1 is reached, open the level-setting plug.

23A-8

AUTOMATIC GEARBOX Filling - Levels

23A

DP0 III - LEVEL CHECKING PROCEDURE OUTSIDE FILLING OPERATIONS

Note: The level must be checked following the method described below: Park the vehicle on level ground. Fill the automatic transmission with 0.5 litre of new oil. Run the engine at idle speed. Connect theDiagnostic tool (CLIP). Establish dialogue with the automatic transmission computer. Monitor the gearbox oil temperature parameter. 13792

Position a container, if the oil does not flow out or the quantity collected is below 0.1 litre.

Once a temperature of 60˚C +/- 1 is reached, open the level-setting plug.

- switch the engine off,

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

- add 0.5 litre of oil, - let the automatic transmission cool to 50˚C,

- switch the engine off,

- run the engine at idle speed,

- add 0.5 litre of oil,

- connect the Diagnostic tool ( CLIP ).

- let the automatic transmission cool to 50˚C,

- establish dialogue with the automatic transmission computer,

- run the engine at idle speed,

- monitor the automatic gearbox oil temperature parameter. - when the temperature reaches 60˚C ± 1 open the top-up plug,

- connect the Diagnostic tool ( CLIP ). - establish dialogue with the automatic transmission computer, - monitor the automatic gearbox oil temperature parameter.

- position a container. Repeat these operations until more than 0.1 litre of oil is obtained in the container.

- when the temperature reaches 60˚C ± 1, open the top-up plug,

Refit the plug again. - position a container.

Torque tighten the plug (35 N.m).

Repeat these operations until more than 0.1 litre of oil is obtained in the container.

Note: When the oil is replaced, the electronic oil ageing counter must be reset (inside the computer). Enter the oil change date using the command CF074« Enter the gearbox oil change date »using the Diagnostic tool (CLIP).

23A-9

AUTOMATIC GEARBOX Checking the converter setting point

23A

DP0 A setting point outside the tolerance requires the converter to be replaced.

Equipment required Diagnostic tool

Note: A setting point which is too low may be linked to a lack of engine power.

Mount the vehicle on a two post lift. Lift the vehicle until the wheels are raised off the ground by a few centimetres. Connect the Diagnostic tool (« CLIP »). Establish dialogue with the automatic transmission computer, Monitor the automatic gearbox oil temperature parameter. Carry out the check at an oil temperature of between 60˚C and 80˚C. Start the engine and put the lever in D. Monitor the engine speed parameter: Establish dialogue with the computer. Accelerate fully keeping the brakes applied. The front wheels should not rotate.

WARNING - The full load position must not be held for more than 5 seconds. Beyond this, there is a high risk of destroying the converter or the automatic transmission. - Once the measurement has been taken, release the accelerator and keep the brakes on until the engine speed stabilises to idle speed (there is a risk of damaging the automatic transmission if this is not complied with).

K4M The engine speed must be stablised at 2700 ±150 rpm.

F4R The engine speed should stabilise at 2500 ±150 rpm.

23A-10

AUTOMATIC GEARBOX Line pressure measurement DP0 Special tooling required Bvi. 1215-01

Automatic transmission oil pressure gauge kit

Some fault finding procedures on the automatic gearbox involve taking the line pressure using a pressure gauge. The pressure measurement tapping is located close to the pressure sensor.

1

103420

Remove the bolt (1) to take the line pressure. Remove the pressure tapping union (466-06) from the kit (Bvi. 1215-01) (Workshop Repair Manual 372 « Fault finding »).

23A-11

23A

AUTOMATIC GEARBOX Hydraulic distributor

23A

DP0 Special tooling required Bvi. 1462

Ball plate adjusting screw Equipment required

Diagnostic tool

Tightening torquesm distributor bolts

mounting

0.75 daNm

ball detent plate bracket mounting bolt (12)

0.9 daNm

ball detent plate mounting bolt

0.8 daNm

cover mounting bolts

1 daNm

rechargeable battery

4 daNm

1

13792

Drain the automatic transmission through plug (1). Remove:

reinforcement mounting bolts

plate

2.1 daNm

battery cover mounting bolts

0.4 daNm

- the wheels, - the air intake sleeve, - the wheel arch liner.

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

23A-12

AUTOMATIC GEARBOX Hydraulic distributor

23A

DP0

4

6

2 5

3 101821

103412

Remove the electric wiring harness (5) on the side stiffener.

Move the electric wiring harness aside: - from the battery (2),

Remove:

- from the battery tray (3),

- the bolts (6) on the side stiffener plate,

- from the injection computer (4).

- the side stiffener.

Remove: - the battery, - the computer, - the battery mounting.

7

14783

Remove the four retaining bolts (7) on the hydraulic distributor cover (be careful as oil may run out).

23A-13

AUTOMATIC GEARBOX Hydraulic distributor

23A

DP0 ADJUSTING THE BALL DETENT PLATE

13788

Remove the seven mounting bolts on the hydraulic distributor. Disconnect the solenoid valve connectors. Remove the hydraulic distributor.

REFITTING

13789

Fit the distributor and centre it using bolts (4) and (5). Refit the other bolts. Tighten to torque and in the correct order the distributor mounting bolts (0.75 daNm).

23A-14

14782

Hold the multifunction switch lever in the end position (first selected) using a plastic clip and a bolt in the mechanism housing.

AUTOMATIC GEARBOX Hydraulic distributor

23A

DP0

10

9

8

12 13788-1

14785

Position the ball detent plate bracket mounting bolt (12) but do not tighten it. Position the tool (Bvi. 1462) in place and fit the bolt (8). Screw the tool in fully whilst holding the ball detent plate. Tighten to torque the ball detent plate bracket mounting bolt (12) (0.9 daNm).

10

Remove the tool (Bvi. 1462).

11

Remove the ball detent plate mounting bolt (8).

2318

Remove the bolts (8). Position the ball detent plate by placing the roller (9) in the hollow (11) of the sector (10) corresponding to the first gear selected position.

23A-15

Tighten to torque the ball detent plate mounting bolt (0.8 daNm). When replacing the oil distributor, the auto-adaptives must be reset using command RZ005: « Erase auto-adaptives » and the oil age counter of the

AUTOMATIC GEARBOX Hydraulic distributor DP0 automatic transmission computer must be reset using the Diagnostic tool, use command CF074: « Enter date of gearbox oil change ». After using command RZ005, it is important to carry out a test drive performing all gear changes, both up and down, several times in order to store the new values. Torque tighten: - the cover mounting bolts (1 daNm), - the rechargeable battery (4 daNm), - the reinforcement plate mounting bolts (2.1 daNm). Proceed in the reverse order to removal. WARNING Connect the battery; carry out the necessary programming (Section Electrical equipment). Torque tighten the battery cover mounting bolts (0.4 daNm). Fill the gearbox.

23A-16

23A

AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting

23A

K4M, and 761 – F4R, and 771 Special tooling required

Tightening torquesm

Rou. 604-01

Hub locking tool

Tav. 476

Ball joint extractor

Mot. 1453

Multiple-adjusting engine mounting support with retaining straps

Bvi. 1531

suspended mounting nut on the rubber pad

18 daNm

battery cover mounting bolts

0.4 daNm

REMOVAL Mount the vehicle on a two post lift.

Inertia wheel centring tool for automatic transmission converter

Remove the engine covers.

Equipment required jack

Tightening torquesm wheel bolts

13 daNm

brake calliper guide pin bolts

0.7 daNm

track rod end nut

3.7 daNm

lower ball joint nut

6.2 daNm

engine tie-bar on the sub-frame

10.5 daNm

gearbox edge and starter bolts

4.4 daNm

gearbox suspended mounting nut

4.4 daNm

track rod end nut

6.2 daNm

converter - starter plate mounting nut

3.7 daNm

modular connector support bolts

2 daNm

engine speed sensor mounting bolts

1 daNm

engine tie-bar bolts on F engine

18 daNm

engine tie-bar bolts on K engine

10.5 daNm

101821

Disconnect the battery, starting with the negative terminal. Remove the cowl grille ( Wiping / WashingSection).

1

2

104343

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

23A-17

AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting

23A

K4M, and 761 – F4R, and 771 - the air filter access panel, - the plenum chamber partition mounting bolt (2).

5

6

3

7

4

104246

Remove: - the plenum chamber partition mounting bolts (3),

103409

- the plenum chamber partition,

Remove:

- the air intake sleeve,

- the multifunction switch cable ball joint (4),

- the battery, - the battery tray,

- the multifunction switch cable wiring loom (5) by releasing the sheath stop,

- the injection computer and its support,

- the electrical harness mountings.

- the air inlet pipe,

Disconnect:

- the electrical harness mountings.

- the engine speed sensor, - the connector (6) by releasing the connector slide. Remove the modular connector support plate mounting bolts (7). WARNING Protect the connector by sliding it into a waterproof plastic bag.

23A-18

AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting

23A

K4M, and 761 – F4R, and 771

K4M

8 103753

Remove the engine speed sensor. 103423

Remove: - the two starter bolts (8), F4R

- the engine undertray. Drain the gearbox. Remove: - the wheels, - the wheel arch liners. Disconnect: - the ABS system sensor wiring, - the discharge bulb beam adjustment sensor wiring (if fitted on vehicle). Note: The discharge bulb beam adjustment sensor is fitted onto the left-hand lower wishbone.

103420

Remove the engine speed sensor.

Fit the hose clamps. Disconnect the heat exchanger. Unclip the gearbox wiring harness.

23A-19

AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting

23A

K4M, and 761 – F4R, and 771 I - LEFT-HAND SIDE OF VEHICLE

10

9

103412 102129

Remove:

Remove:

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

- the clip (10) from the gearbox computer wiring harness,

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

- the side stiffener (9).

- the anti-roll bar ball joint using tool (Tav. 476), - the lower ball joint. Release the stub axle carrier from the driveshaft. Remove the left-hand driveshaft.

11

12

103413

Open the gearbox computer wiring harness mounting bracket (11). Disconnect the gearbox computer connector (12).

23A-20

AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting

23A

K4M, and 761 – F4R, and 771 II - RIGHT-HAND SIDE OF VEHICLE

103418 102129

Remove:

Remove the relay bearing bracket. Release the stub axle carrier from the driveshaft.

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

Remove the right-hand driveshaft.

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

Attach the cooling radiator assembly to the upper cross member using rope.

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

101212

Remove the side stiffener.

23A-21

AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting

23A

K4M, and 761 – F4R, and 771

102009

Remove the cooling radiator lower cross member.

15

103418

Remove: - the lower engine - manifold strut, - the starter mounting bolt (15), - the starter, - the three converter nuts. Note:

14

The converter nuts are accessed by removing the star ter. Rotate the crankshaft clockwise to access the three starter plate - converter connecting nuts and remove them.

13 103421

Remove: - the exhaust mounting nuts (13), - the engine tie-bar.

23A-22

AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting

23A

K4M, and 761 – F4R, and 771

16

103423

13790

Attach the converter with string to stop it being detached.

Remove the gearbox upper edge studs (16).

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

14

- Check that the centring rings are in place.

13 102449

Open the cover (13). Remove the cover (14). Set up tool (Mot. 1453). Remove the gearbox support rubber pad. Fit the jack tool beneath the gearbox. Remove: - the gearbox edge lower bolts, - the studs, - the converter - starter plate bolts, - the automatic transmission,

23A-23

AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting K4M, and 761 – F4R, and 771

16361

Refit the inertia flywheel on the converter using tool (Bvi. 1531);. Proceed in the reverse order to removal. WARNING Check that the centring dowels are in place. When refitting the automatic transmission on the engine, make sure that the converter is properly engaged on the input shaft pin.

23A-24

23A

AUTOMATIC GEARBOX Automatic gearbox: Removal - Refitting

23A

K4M, and 761 – F4R, and 771 adaptives » and the automatic transmission computer oil ageing counter must be reset using command CF074: « Enter date of gearbox oil change ». After using command RZ005, it is important to carry out a test drive using all the gear ratio shifts, both up and down, several times in order to store the new values. WARNING Connect the battery; carry out the necessary programming (Section Electrical equipment). Torque tighten the battery cover mounting bolts (0.4 daNm).

17 18 13790

The distance between the base of the threading (17) and the engine mating face (18) should be 17 mm. Torque tighten: - the wheel bolts (13 daNm), - the brake calliper guide pin bolts (0.7 daNm), - the track rod end nut (3.7 daNm), - the lower ball joint nut (6.2 daNm), - the engine tie-bar on the sub-frame (10.5 daNm), - the gearbox edge and starter bolts (4.4 daNm), - the gearbox suspended mounting nut (4.4 daNm), - the track rod end nut (6.2 daNm), - the converter - starter plate mounting nut (3.7 daNm), - the modular connector support bolts (2 daNm), - the engine speed sensor mounting bolts (1 daNm), - the engine tie-bar bolts on F engine (18 daNm), - the engine tie-bar bolts on K engine (10.5 daNm), - the suspended mounting nut on the rubber pad (18 daNm). Fill up the automatic transmission and check the level (Section Automatic gearbox, Filling - Levels, page 23A-7). When changing the oil, the auto-adaptives must be reset using command RZ005: «Clear auto-

23A-25

AUTOMATIC GEARBOX Drive plate

23A

K4M, and 761 – F4R, and 771 Special tooling required K4M Mot. 1677

Flywheel locking tool (F engines)

Mot. 582-01

Flywheel locking tool (K engines) Equipment required

1

1

Diagnostic tool

Tightening torquesm drive plate bolts (F engine)

4.5 daNm + 50˚ +/- 5

drive plate bolts (K engine)

5.5 daNm + 50˚ +/- 5

battery cover mounting bolts

0.4 daNm

1 1

103752

This operation can be performed after the automatic transmission has been removed.

Position the tool (Mot. 582-01).

REMOVAL Remove: F4R

- the bolts (1), - the drive plate, - the tool (Mot. 1677).

1

REFITTING

1

Check that the drive plate is not damaged (warping tolerance 0.2 mm on the external diameter). Fit the drive plate, ensuring it is correctly positioned in relation to the centring pin (2).

2 2

Note:

1

- Systematically replace the drive plate bolts.

1

- Apply LOCTITE threads.

FRENBLOC to the bolt

Tighten the bolts on the drive plate. 103245

Position the tool (Mot. 1677) to immobilise the starter motor ring gear.

23A-26

AUTOMATIC GEARBOX Drive plate K4M, and 761 – F4R, and 771

F4R Angular and torque tighten the drive plate bolts (F engine) (4.5 daNm + 50˚ +/- 5) locking the starter motor ring gear using tool (Mot. 1677).

K4M Angular and torque tighten the drive plate bolts (K engine) (5.5 daNm + 50˚ +/- 5) locking the starter motor ring gear using tool (Mot. 582-01).

Proceed in the reverse order to removal. WARNING Connect the battery; carry out the necessary programming (Section Electrical equipment). Connect the Diagnostic tool to check conformity. Torque tighten the battery cover mounting bolts (0.4 daNm).

23A-27

23A

AUTOMATIC GEARBOX Differential output gasket

23A

DP0 Special tooling required Bvi. 1459

Right-hand transmission output seal fitting tool

Bvi. 1460

Left-hand transmission output seal fitting tool

Tightening torquesm wheel bolts lower ball joint nut

13 daNm 6.2 daNm

1

bolts for mounting engine tie-bar on the sub-frame

10.5 daNm

engine tie-bar bolts on K engine

10.5 daNm

engine tie-bar bolts on F engine

18 daNm

Drain the automatic transmission through the plug (1).

3.7 daNm

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

track rod end nut hub nut battery cover mounting bolts

13791

28 daNm 0.4 daNm

WARNING Do not drop the seal spring into the automatic transmission.

REMOVAL This operation is performed after removing the corresponding driveshaft ( DriveshaftsSection). Mount the vehicle on a two post lift. Remove the battery cover. Disconnect the battery, starting with the negative terminal. Remove the engine undertray.

23A-28

AUTOMATIC GEARBOX Differential output gasket DP0

REFITTING Fit the seal using tool (Bvi. 1459) or tool (Bvi. 1460). Guide the assembly until the tool is resting on the automatic transmission casing. Proceed in the reverse order to removal. Torque tighten: - the wheel bolts (13 daNm), - the lower ball joint nut (6.2 daNm), - the bolts for mounting engine tie-bar on the sub-frame (10.5 daNm), - the engine tie-bar bolts on K engine (10.5 daNm), - the engine tie-bar bolts on F engine (18 daNm), - the track rod end nut (3.7 daNm), - the hub nut (28 daNm).

WARNING Connect the battery; carry out the necessary programming (Section Electrical equipment). Fill the automatic transmission and check the level (Section Automatic gearbox, Filling - Levels, page 23A-7). Torque tighten the battery cover mounting bolts (0.4 daNm).

23A-29

23A

AUTOMATIC GEARBOX Converter seal

23A

DP0 Special tooling required Mot. 587

Seal extractor

Bvi. 1457

Converter assembly

lip

seal

REMOVAL This operation is carried out after the automatic transmission and converter have been removed. Remove the converter by withdrawing it as far as possible without deviating from the shaft.

1

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

2

Using tool (Mot. 587), remove the seal, taking care not to scratch the contact faces.

13790

The distance between the base of the thread (1) and the face of the engine coupling (2) must measure 17 mm.

REFITTING

Proceed in the reverse order to removal. WARNING - Work as cleanly as possible to prevent foreign bodies penetrating the system. - Oil all the contact faces. Refit: - the new pre-lubricated seal to the end, using tool (Bvi. 1457), - the converter.

23A-30

AUTOMATIC GEARBOX Multifunction switch

23A

DP0

Tightening torquesm selector lever nut multifunction mounting bolts

4

2 1 daNm

switch

1 daNm

battery cover mounting bolts

0.4 daNm

5

REMOVAL

1

Set to neutral « N ».

3

103409

Disconnect: - the multifunction switch cable ball joint (1), - the control cable from the sheath stop (2) on the modular connector support. Remove the lever and the two multifunction switch mounting bolts (3). Disconnect the modular connector (4) by releasing the connector slide mechanism.

101821

Remove the three modular connector support plate mounting bolts (5).

Disconnect the battery, starting with the negative terminal. Remove: - the air intake sleeve, - the battery, - the battery tray, - the injection computer and its support,

6

- the air filter box, - the electric wiring harness mountings.

13785

Remove the two modular connector plate mounting bolts. Remove the green connector (6) from the multifunction switch (12-track).

23A-31

AUTOMATIC GEARBOX Multifunction switch

23A

DP0

REFITTING Set the multifunction switch to neutral « N ». Adjust the multifunction switch. Proceed in the reverse order to removal. Tighten to torque the selector lever nut (1 daNm). Check that the system and gear selection are working correctly. ADJUSTING THE MULTIFUNCTION SWITCH With the selector shaft in neutral, place two electric terminals on the position control tabs.

103411

Set the multimeter to the « ohmmeter » position. Turn the multifunction switch by hand until the electrical contact is closed (resistance at contact terminals: 0 Ω). Tighten to torque the multifunction switch mounting bolts (1 daNm). WARNING After tightening, the electrical contact must be closed 0 Ω. Check that the system and gear selection are working correctly. WARNING Connect the battery; carry out the necessary programming (Section Electrical equipment). Tighten to torque the battery cover mounting bolts (0.4 daNm).

23A-32

AUTOMATIC GEARBOX Computer

23A

DP0

Tightening torquesm battery cover mounting bolts

4

0.4 daNm

The computer is located behind the left-hand wheel arch.

REMOVAL Put the vehicle on a two-post lift. Remove the engine covers. Disconnect the battery starting with the negative terminal.

3

Remove the front bumper.

103415

Remove: - the two computer mounting nuts (3), - the computer (4).

REFITTING To refit, proceed in the reverse order to removal.

1 WARNING Connect the battery; carry out the necessary programming (Section Electrical equipment).

2 Tighten to torque the battery cover mounting bolts (0.4 daNm) 103414

Disconnect the computer connector (1).

REPLACING THE COMPUTER

Remove the resonator (2). Note: When the automatic gearbox computer is replaced, it is necessar y to enter the age of the automatic gearbox oil stored in the memory of the computer to be replaced in the memory of the new computer. Use the following procedure. Read the oil ageing value from the memory of the computer being replaced using parameter PR133: « Oil ageing counter » and note down the value. Replace the computer.

23A-33

AUTOMATIC GEARBOX Computer DP0 Call up the oil ageing value in the memory of the new computer using command CF320: « Oil ageing counter report ». Confirm entry using the « Oil ageing counter » parameter. Enter the after-sales operation date using command CF320 « Enter after-sales operation date ». Carry out a road test so that the new computer stores the programming.

23A-34

23A

AUTOMATIC GEARBOX Speed sensor

23A

DP0

Tightening torquesm output speed sensor mounting bolt

1 daNm

battery cover mounting bolts

0.4 daNm

REMOVAL Mount the vehicle on a two post lift. Remove the engine covers.

2

Disconnect the battery, starting with the negative terminal.

13786-1

Note: Remove the output speed sensor (2).

The speed sensor can be removed without draining or removing the automatic transmission.

REFITTING Remove the engine undertray.

Proceed in the reverse order to removal. Tighten to torque the output speed sensor mounting bolt (1 daNm). WARNING Connect the battery; carry out the necessary programming (Section Electrical equipment). Tighten to torque the battery cover mounting bolts (0.4 daNm).

1

103417

Disconnect the connector (1).

Note: When replacing a sensor, always remove the gearbox connector (Section Automatic gearbox, Gearbox connector, page 23A-39).

WARNING Protect the connector by sliding it into a waterproof plastic bag.

23A-35

AUTOMATIC GEARBOX Flow regulation solenoid valve

23A

DP0

Tightening torquesm radiator flow control solenoid valve mounting bolt

1 daNm

battery cover mounting bolts

0.4 daNm

REMOVAL Put the vehicle on a two-post lift. Remove the engine covers. Disconnect the battery starting with the negative terminal. Note: 103434

The radiator flow control solenoid valve can be removed without draining or removing the automatic gearbox.

2

1

13786-1

Remove: - the two solenoid valve bolts (1), - radiator flow control solenoid valve (2).

REFITTING To refit, proceed in the reverse order to removal.

23A-36

AUTOMATIC GEARBOX Flow regulation solenoid valve DP0 Tighten to torque the radiator flow control solenoid valve mounting bolt (1 daNm). WARNING Connect the battery; carry out the necessary programming (Section Electrical equipment). Tighten to torque the battery cover mounting bolts (0.4 daNm).

23A-37

23A

AUTOMATIC GEARBOX Solenoid valves: Removal DP0

WARNING Work as cleanly as possible to prevent foreign bodies from entering the system.

REMOVAL

2

1

3

4

5

6

7

8 13787

(1)

Modulating solenoid valve

(2)

« Lock up » solenoid valve (converter by-pass)

(3)

Sequence solenoid valve 4

(4)

Sequence solenoid valve 3

(5)

Sequence solenoid valve 1

(6)

Sequence solenoid valve 2

(7)

Sequence solenoid valve 6

(8)

Sequence solenoid valve 5

Note: This operation can be performed after the hydraulic distributor has been removed.

23A-38

23A

AUTOMATIC GEARBOX Gearbox connector

23A

DP0 Connector numbering Tightening torquesm battery cover mounting bolts

0.4 daNm

1

2 1

3

2 4

3 5

4 5

13785

(1)

Green connector (multifunction switch)

(2)

Yellow connector (electrohydraulic interface)

(3)

Green connector (line pressure)

(4)

Yellow connector (turbine speed)

(5)

Blue connector (radiator flow control solenoid valve)

103248

REMOVAL Put the vehicle on a two-post lift. Remove the engine covers. Select neutral « N »

Note: These connectors may be removed separately from the gearbox connector when certain components are replaced.

101821

Disconnect the battery starting with the negative terminal. Remove: - the air intake duct, - the battery,

23A-39

AUTOMATIC GEARBOX Gearbox connector

23A

DP0

REFITTING

- the battery tray,

To refit, proceed in the reverse order to removal.

- the injection computer and its mounting, - the air filter unit,

WARNING Connect the battery; carry out the necessary programming (Section Electrical equipment).

- the wiring harness mountings.

Tighten to torque the battery cover mounting bolts (0.4 daNm)

7

8

9

103409

Disconnect: - the multifunction switch cable ball joint (6), - the wiring harness (7) from the multifunction switch cable by loosening the sleeve stop, - the unit connector (8) by releasing the slider on the connector. Remove: - the three mounting bolts (9) from the unit connector support plate, - the two unit connector mounting bolts, - the connector of the colour indicated on the gearbox connector. Follow the five wiring harnesses connected to the gearbox connector. Remove the five wiring harnesses. These wiring harnesses are either connected to components directly or via a connector. If they are connected to a component directly, the component should also be removed.

23A-40

DRIVESHAFTS Identification

29A

MECHANICAL GEARBOX DRIVESHAFTS JR5 - JH3 - ND0 - DP0

102209

Drive joint Vehicle type

Engines

Gearbox

Left-hand transmission

Right-hand transmission

Wheel end

Gearbox side

Wheel end

Gearbox side

JM0U - JM1N JM05

F4R 770

ND0 015

EBJ 95

TJ 92

EBJ 95

TJ 92

JM0U - JM1N JM1M - JM05

F4R 771

DP0 056

EBJ 92

RC 463

EBJ 92

RC 462

JM0U - JM05

F4R 771

DP0 059

EBJ 92

RC 463

EBJ 92

RC 462

JM0W

F4R 776

ND0 013

EBJ 95

TJ 92

EBJ 95

TJ 92

JM0G - JM1G JM12

F9Q 812

ND0 002

EBJ 95

TJ 92

EBJ 95

TJ 92

JM0B - JM0H JM1A

K4J 730

JH3 106

AC 2000i

Gi 2000i

AC 2000i

Gi 2001

JM0C - JM0J JM1B

K4M 782

JR5 104

AC 2000i

Gi 2000i

AC 2000i

Gi 2001

JM0C - JM0J JM1B

K4M 782

JR5 125

AC 2000i

Gi 2000i

AC 2000i

Gi 2001

JM0C - JM1B JMOJ

K4M 761

DP0 057

BJ 87

RC 463

BJ 87

RC 462

JMOF

K9K 722

JR5 103

BJ 87

RC 465

BJ 87

RC 462

JM13 - JMO2

K9K 728

JR5 110

EBJ 92

RC 465

EBJ 92

RC 462

JM13 - JMO2

K9K 728

JR5 131

EBJ 92

RC 465

EBJ 92

RC 462

29A-1

DRIVESHAFTS Consumables

29A

Component concerned

Type of product

Quantity

Gearbox side seal splines

MOLYKOTE BR2 grease

Coat

Brake calliper bolt

FRENBLOC cement

Coat

RC 462 seal

110 cm 3

RC 463 seal

110 cm 3

RC 465 seal

110 cm 3

EBJ 82 seal

MOBIL CVJ 825 Black Star or MOBIL EXF 57C grease

70 cm 3

EBJ 92 seal

105 cm 3

EBJ 95 seal

110 cm 3

TJ 92 seal

135 cm 3

29A-2

DRIVESHAFTS Front left-hand driveshaft

29A

Remove the driveshaft (wheel end).

Special tooling required Rou. 604-01

Hub locking tool

Tav. 476

Ball joint extractor

II - GEARBOX SIDE JH3 or JR5 or ND0 Drain the gearbox (see 21A, Manual gearbox).

Tightening torquesm wheel bolts

13 daNm

hub nut

28 daNm

Remove the driveshaft (gearbox side).

REPLACEMENT

track rod end nut

3.7 daNm

lower ball joint nut

6.2 daNm

anti-roll bar nut

4.4 daNm

Note:

driveshaft bearing bolts

4.4 daNm

Check the condition of the contact surfaces of the lip seal. Systematically replace the differential outlet lip seal (see 21A, Manual gearbox, differential outlet seal).

REMOVAL I - WHEEL END

With the protector in place, coat the splines of the gearbox side seal with MOLYKOTE BR2.

Mount the vehicle on a two post lift.

Position and insert the driveshaft into the axle sunwheel.

Remove: - the left front wheel,

Insert the stub-axle into the hub.

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

The driveshaft must go in freely until it protrudes enough for the hub nut to be mounted.

Disconnect the wheel speed sensor.

Proceed in the reverse order to removal. Torque tighten:

2

- the wheel bolts (13 daNm),

1

- the hub nut (28 daNm), - the track rod end nut (3.7 daNm), - the lower ball joint nut (6.2 daNm),

3

- the anti-roll bar nut (4.4 daNm), - the driveshaft bearing bolts (4.4 daNm), Fill the gearbox with oil (see 21A, Manual gearbox). 101213

Remove: - the track rod end nut (1), - the stub axle carrier ball joint using tool (Tav. 476), - the anti-roll bar upper nut (2), - the lower ball joint stud (3). Push back the driveshaft from the stub axle carrier by swinging round the stub axle carrier.

29A-3

DRIVESHAFTS Front right-hand driveshaft

29A

Remove the driveshaft (wheel end).

Special tooling required Rou. 604-01

Hub locking tool

Tav. 476

Ball joint extractor

II - GEARBOX SIDE JH3 or JR5 or ND0 Drain the gearbox.

Tightening torquesm wheel bolts

13 daNm

hub nut

28 daNm

track rod end nut

3.7 daNm

lower ball joint nut

6.2 daNm

anti-roll bar nut

4.4 daNm

driveshaft bearing bolts

4.4 daNm

REMOVAL I - WHEEL END Mount the vehicle on a two post lift. Remove:

4

- the front right wheel, - the hub nut using tool (Rou. 604-01). Disconnect the wheel speed sensor.

101819

Remove both the driveshaft bearing bolts (4).

1

Remove the driveshaft (gearbox side).

2

Note: If the bearing is seized in the relay bearing, it must be replaced.

3

REPLACEMENT Clean and grease the bearing hole housing the bearing. 101213

Remove:

Note:

- the track rod end nut (1), - the stub axle carrier ball joint using tool (Tav. 476), - the anti-roll bar upper nut (2),

- Replace the O-ring at the base of the relay shaft bearing if it is damaged.

- the lower ball joint stud (3).

- Check the condition of the contact surfaces of the lip seal.

Push back the driveshaft from the stub axle carrier by swinging round the stub axle carrier.

- Systematically replace the differential outlet lip seal (see 21A, Manual gearbox).

29A-4

DRIVESHAFTS Front right-hand driveshaft With the protector in place, coat the splines of the gearbox side seal with MOLYKOTE BR2.

29A

REFITTING

Position and insert the driveshaft into the axle sunwheel. Insert the stub-axle into the hub. The driveshaft must go in freely until it protrudes enough for the hub nut to be mounted.

Lubricate the contact surface of the shaft into which the bearing is inserted. Insert the new bearing. Fit the bearing to the end using a tube, so that it rests on the inner bearing race.

Proceed in the reverse order to removal.

Clean and grease the bearing hole housing the bearing.

Torque tighten:

Refit the driveshaft.

- the wheel bolts (13 daNm), - the hub nut (28 daNm), - the track rod end nut (3.7 daNm), - the lower ball joint nut (6.2 daNm), - the anti-roll bar nut (4.4 daNm), - the driveshaft bearing bolts (4.4 daNm), Fill the gearbox with oil (see 21A, Manual gearbox).

REMOVING THE RELAY SHAFT BEARING

100642

Remove the whole driveshaft. Remove the bearing using a press. Take care not to score the contact surface of the lip seal on the relay shaft.

29A-5