Dacia Duster Electrical Equipment Repair

Dacia Duster Electrical Equipment service manual covers all petrol and diesel engines, years 2009 to 2017. Workshop manual repair of Dacia Duster Electrics.

Electrical equipment

BATTERY

80A

HEADLIGHTS

80B

REAR LIGHTING

81A

INTERIOR LIGHTING

81B

FUSES

81C

ENGINE IMMOBILISER

82A

HORN

82B

INSTRUMENT PANEL

83A

CONTROL – SIGNALS

84A

WIPING – WASHING

85A

RADIO

86A

X79

NOVEMBER 2009 EDITION ANGLAISE

PASSENGER COMPARTMENT CONNECTION UNIT

87B

ELECTRIC WINDOWS – SUNROOF

87D

ENGINE COMPARTMENT CONNECTION UNIT

87G

WIRING HARNESS

88A

AIR BAG AND PRETENSIONERS

88C

X79

NOVEMBER 2009 EDITION ANGLAISE

DUSTER – Chapitre 8

Contents

Pages

BATTERY

80A

Battery: Precautions for the

repair 80A-1

Battery: Removal – Refitting 80A-2

HEADLIGHTS

80B

Headlight assembly:

Exploded view 80B-1

Headlight: Removal –

Refitting 80B-2

Headlight: Adjustment 80B-3 Headlight bulb: Removal –

Refitting 80B-5

Front fog light bulb: Removal

– Refitting 80B-6

Front fog light: Removal –

Refitting 80B-7

Side indicator: Removal –

Refitting 80B-8

Remote headlight beam adjustment actuator:

Removal – Refitting 80B-9

REAR LIGHTING

Rear light assembly:

81A

Exploded view 81A-1

Rear wing light: Removal –

Refitting 81A-2

Rear light bulb: Removal –

Refitting 81A-3

3rd brake light: Removal –

Refitting 81A-4

High level brake light bulb:

Removal – Refitting 81A-5

Number plate light: Removal

– Refitting 81A-6

INTERIOR LIGHTING

81B

Interior lighting: List and

location of components 81B-1

Interior light: Removal –

Refitting 81B-3

Door switch: Removal –

Refitting 81B-4

Storage compartment light:

Removal – Refitting 81B-5

Luggage compartment light:

Removal – Refitting 81B-6

81C

FUSES

 

84A

CONTROL – SIGNALS

 
 

Fuses: List and location of

   

Central door locking switch:

 

components

81C-1

 

Removal – Refitting

84A-9

       

Remote headlight beam

 
       

adjustment control: Removal

 

82A

– Refitting 84A-10

ENGINE IMMOBILISER

Exterior rear view mirror

 

Immobiliser system: List and

   

control switch: Removal –

 

location of components

82A-1

 

Refitting

84A-12

Ignition switch: Removal –

   

Heated rear screen switch:

 

Refitting

82A-3

 

Removal – Refitting

84A-13

Transponder ring: Removal –

   

Heated seat pad switch:

 

Refitting

82A-5

 

Removal – Refitting

84A-14

Battery for remote door

       

locking control: Removal –

       

Refitting 82A-7

85A

WIPING – WASHING

 

HORN

82B

Audible warning: Removal –

Refitting 82B-1

INSTRUMENT PANEL

83A

Instrument panel: Removal –

Refitting 83A-1

CONTROL – SIGNALS

84A

Rotary switch: Removal –

Refitting 84A-1

Steering column switch

assembly: Removal – Refitting

84A-2

Front screen washer jet: Removal – Refitting

85A-15

Screen wiper switch: Removal – Refitting

84A-5

Rear screen washer jet: Removal – Refitting

85A-16

Signals and lighting switch: Removal – Refitting

84A-6

Windscreen washer reservoir: Removal – Refitting

85A-17

Hazard warning lights switch:

     

Removal – Refitting

84A-8

   

Wiping and washing: List and

location of components 85A-1

Windscreen wiper blade:

Removal – Refitting 85A-3

Windscreen wiper arm:

Removal – Refitting 85A-4

Windscreen wiper motor:

Removal – Refitting 85A-5

Windscreen wiper mechanism: Removal –

Refitting 85A-8

Rear screen wiper arm:

Removal – Refitting 85A-11

Rear screen wiper motor:

Removal – Refitting 85A-12

Screen washer pump:

Removal – Refitting 85A-14

RADIO

86A

Radio: List and location of

components 86A-1

Radio: Removal – Refitting 86A-3 Radio aerial: Removal –

Refitting 86A-4

Front speakers: Removal –

Refitting 86A-5

Rear speakers: Removal –

Refitting 86A-6

Radio control satellite:

Removal – Refitting 86A-7

WIRING HARNESS

Wiring: Precautions for the

88A

repair 88A-3

Front bumper wiring:

Removal – Refitting 88A-4

Engine wiring: Removal –

Refitting 88A-5

Passenger compartment front wiring: Removal –

Refitting 88A-25

Passenger compartment rear

wiring: Removal – Refitting 88A-33

PASSENGER COMPARTMENT CONNECTION UNIT

87B

UCH: Removal – Refitting 87B-1

87D

ELECTRIC WINDOWS – SUNROOF

 
 

Electric window: List and location of components

87D-1

 

Front electric window switch: Removal – Refitting

87D-2

 

Rear electric window switch: Removal – Refitting

87D-3

ENGINE COMPARTMENT CONNECTION UNIT

87G

Engine compartment connection unit: List and

location of components 87G-1

WIRING HARNESS

88A

Computers: List and location

of components 88A-1

Diagnostic socket: List and

location of components 88A-2

AIRBAG AND PRETENSIONERS

Airbag and pretensions:

88C

List and location of

components 88C-1

Airbag and pretensioners:

Precautions for the repair 88C-3

Airbag computer: Removal –

Refitting 88C-4

Driver’s frontal airbag:

Removal – Refitting 88C-6

Passenger’s frontal airbag:

Removal – Refitting 88C-9

Front (chest-level) side

airbag: Removal – Refitting 88C-12

Side impact sensor: Removal

– Refitting 88C-14

Front seat belt buckle:

Removal – Refitting 88C-16

Rear seat belt buckle:

Removal – Refitting 88C-17

Front side seat belt: Removal

  • Refitting 88C-18

Rear side seat belt: Removal

  • Refitting 88C-22

AIR BAG AND PRETENSIONERS

88C

Rear centre seat belt:

Removal – Refitting 88C-23

Seat belt reminder warning

light: Removal – Refitting 88C-26

– SAFETY

IMPORTANT

To avoid all risk of sparks, ensure that all electrical consumers are fully switched off.

When a battery is being charged inside a building, switch off the charger before connecting or disconnecting the battery.

Do not place any metallic items on the battery as this may create a short circuit across the terminals.

Never hold a naked flame, welding gun, blowtorch, cigarette or lighted match near to a battery.

  1. – DANGER: RISK FROM ACID LINKED TO HANDLING

Sulphuric acid is a highly aggressive and toxic substance which corrodes most metals.

When handling batteries, it is very important to take the following precautions:

  • protect your eyes by wearing goggles,
  • wear acid-proof gloves and clothing.

II – GENERAL RECOMMENDATIONS

IMPORTANT

A battery contains sulphuric acid, a dangerous sub- stance.

If acid splashes on to your clothing, rinse all con- taminated areas thoroughly in water.

If it comes into contact with the skin or eyes, seek medical attention.

WARNING

These vehicles are equipped with a battery with low water consumption. Topping up the electrolyte is therefore prohibited.

  1. – DANGER: RISK OF EXPLOSION LINKED TO CHARGING AND TO INCORRECT TIGHTENING OF THE TERMINALS.

WARNING

Before disconnecting the battery:

  • wait for the motor-driven fan assembly to stop,
  • wait for the computer to finish saving (1 minute).

IMPORTANT

To prevent damaging the battery or even causing it to explode, do not place any heat sources or create any sparks near a charging battery.

WARNING

Some vehicles are only fitted with « TB » (low height) batteries. To avoid damaging the bonnet, only refit a battery which is identical to the battery originally fitted.

When a battery is charging, oxygen and hydrogen are produced. The mixture of these two gases is explosive.

WARNING

Incorrect tightening could cause heating of con- tacts, starting or charging faults, sparking, or could cause the battery to explode.

The smallest of sparks or heat sources can cause an explosion. The explosion is so strong that the battery can shatter and spray the acid into the surrounding at- mosphere.

People nearby are at risk (exploded fragments, acid splashes). Acid splashes are dangerous. They also damage clothing.

Safeguarding against the danger of explosion, which can be caused by handling a battery carelessly, must be taken very seriously.

REMOVAL

IMPORTANT

Consult the safety and cleanliness advice and oper- ation recommendations before carrying out any repair (see 80A, Battery, Battery: Precautions for the repair, page 80A-1) .

– OPERATION FOR REMOVAL OF PART CONCERNED

  1. – DISCONNECTING

Tightening torquesm

battery bracket bolt

12 Nm

bolt on the positive bat- tery terminal

6 N.m

negative battery termi- nal nut

6 N.m

I – REMOVAL PREPARATION OPERATION

a Switch off the ignition.

a Undo the negative battery terminal nut (1) .

128781

Note:

WARNING

Before disconnecting the battery:

  • wait for the motor-driven fan assembly to stop,
  • wait for the computer to finish saving (1 minute).

Mark the position of the negative battery termi- nal.

a Remove the negative battery terminal.

WARNING

The visual indicator cannot be considered reli- able in After-Sales; do not use it to determine the state of the battery.

– REMOVAL

24729

a Remove the cover (2) from the positive battery ter- minal.

a Remove:

  • the battery clamp bolt (4) ,
  • the mounting clamp (5) ,
  • the battery.

24730

– REPLACEMENT

a Check that the battery needs replacing (see Techni- cal Note 6014A, Checking the charging circuit, 16A, Starting-charging, Checking the charging circuit: Tests).

REFITTING

I – REFITTING PREPARATION OPERATION

a Check the battery (see Technical Note 9860A, 80A, Battery).

24730

a Loosen the bolt (3) of the positive battery terminal.

Note:

Mark the position of the positive battery terminal.

a Remove the positive battery terminal.

II – REFITTING OPERATION FOR PART CONCERNED

  1. – REFITTING

a Position the battery in its housing.

a Refit:

    • the battery mounting clamp,
    • the battery bracket bolt.

a Torque tighten the battery bracket bolt (12 Nm).

a Push the positive battery terminal fully onto the bat- tery terminal post.

WARNING

Poor contact may cause starting or charging faults, create sparks and cause the battery to explode (see 80A, Battery, Battery: Precau- tions for the repair, page 80A-1) .

a Torque tighten the bolt on the positive battery ter- minal (6 N.m).

a Refit the positive terminal cover.

– CONNECTION

a Push the negative battery terminal fully onto the bat- tery terminal post.

WARNING

Poor contact may cause starting or charging faults, create sparks and cause the battery to explode (see 80A, Battery, Battery: Precautions for the repair, page 80A-1) .

a Torque tighten the negative battery terminal nut (6 N.m).

 

143999

1

Main beam headlight bulbs

(see 80B, Headlights, Headlight bulb: Removal – Refitting, page 80B-5)

2

Side light bulb

3

Direction indicator bulb

4

Dipped beam headlight bulb

5

Headlight beam adjustment actuator

(see 80B, Headlights, Remote headlight beam adjustment actuator: Removal – Refitting, page 80B-9)

6

Headlight

(see 80B , Headlights, Headlight: Removal – Refitting, page 80B-2)

Location and specifications (tightening torques, parts always to be replaced, etc.) (see 80B, Headlights, Headlight assembly: Exploded view, page 80B-1)

REMOVAL

– REMOVAL PREPARATION OPERATION

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

a Switch off the ignition.

a Remove the front bumper (see Front bumper as- sembly: Exploded view) (55A, Exterior protection).

– REMOVAL OPERATION

a Disconnect the headlight connector.

a Remove (see 80B, Headlights, Headlight assembly: Exploded view, page 80B-1) :

    • the headlight beam adjustment actuator,
    • the headlight.

When replacing the headlight

a Remove the headlight bulbs (see 80B, Headlights, Headlight assembly: Exploded view, page 80B-1)

.

REFITTING

– REFITTING PREPARATION OPERATION

When replacing the headlight

a Refit the headlight bulbs (see 80B, Headlights, Headlight assembly: Exploded view, page 80B-1)

– REFITTING OPERATION

a Proceed in the reverse order to removal.

a Adjust the headlights (see 80B, Headlights, Head- light: Adjustment, page 80B-3) .

Equipment required

headlight adjustment and checking tool

ADJUSTMENT

I – PREPARATION OPERATION FOR CHECK

a Place the vehicle on a level horizontal working area.

a Do not apply the parking brake.

a Check and inflate the tyres (see ) (35A, Wheels and tyres).

a Open the bonnet.

a Check:

  • that the luggage compartment is empty,
  • that the headlights are clean.

III – ADJUSTMENT OPERATION

  1. – Beam adjustment

Note:

Do not get into the vehicle throughout the opera- tion.

a Position the headlight beam adjustment control at 0.

a Switch on the dipped headlights.

II – TEST OPERATION

a

WARNING

Consult the device’s operating manual to avoid incorrect use.

a Place the headlight adjustment and checking tool adjusted to -1% in front of the vehicle.

a Using the headlight adjustment and checking tool, check the headlight beam adjustment.

145209

a Use the headlight adjustment and checking tool

to adjust the headlight beam by using the screw (1) .

– Horizontal adjustment

145210

a Use the headlight adjustment and checking tool to horizontally adjust the headlight by using the screw (2) .

IV – FINAL OPERATION

a Close the bonnet.

Location and specifications (tightening torques, parts always to be replaced, etc.) (see 80B, Headlights, Headlight assembly: Exploded view, page 80B-1)

Note:

The operation for removing – refitting the bulbs does not require the headlight to be removed.

REMOVAL

– REMOVAL PREPARATION OPERATION

a Switch off the ignition.

– REMOVAL OPERATION

a Remove the headlight bulbs (see 80B, Headlights, Headlight assembly: Exploded view, page 80B-1)

.

REFITTING

– REFITTING PREPARATION OPERATION

a

WARNING

To prevent any breakages, handle the bulb by its base. If you should touch the glass, clean it with alcohol and a lint-free cloth.

– REFITTING OPERATION

a Proceed in the reverse order to removal.

REMOVAL

– REMOVAL PREPARATION OPERATION

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

– REMOVAL OPERATION

a Disconnect the front fog light connector (3) .

144539

a Remove:

  • the clips (1) ,
  • the front wheel arch side liner.

145207

a Remove the front fog light bulb anticlockwise.

REFITTING

a

144837

a Remove the bolts (2) .

a Move aside the front wheel arch liner.

145206

Note:

When replacing a bulb, only use approved bulbs.

a Proceed in the reverse order to removal.

REMOVAL

– REMOVAL PREPARATION OPERATION

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

a Remove the front bumper (see Front bumper as- sembly: Exploded view) (55A, Exterior protection).

– REMOVAL OPERATION

145208

a Adjust the front fog lights using a screwdriver.

a Disconnect the front fog light connector (1).

a Remove:

  • the bolts (2) from the front fog light,
  • the front fog light.

When replacing the front fog light

144838

a Remove the front fog light bulb (see 80B, Headlights, Front fog light bulb: Removal – Refitting, page 80B-6).

REFITTING

REFITTING OPERATION

When replacing the front fog light

a Refit the front fog light bulb (see 80B, Headlights, Front fog light bulb: Removal – Refitting, page 80B-6) .

a Proceed in the reverse order to removal.

Special tooling required

Car. 1363 Set of trim removal levers.

REMOVAL

OPERATION FOR REMOVAL OF PART CONCERNED

a Unclip the side indicator using the (Car. 1363).

118608

a Disconnect the bulb holder connector (1) by turning it a quarter of a turn anti-clockwise.

REFITTING

REFITTING OPERATION FOR PART CONCERNED

a Connect the bulb holder connector by turning it a quarter of a turn clockwise.

a Clip on the side indicator.

HEADLIGHTS

80B

Remote headlight beam adjustment actuator: Removal – Refitting

Location and specifications (tightening torques, parts always to be replaced, etc.) (see 80B, Headlights, Headlight assembly: Exploded view, page 80B-1)

REMOVAL

– REMOVAL PREPARATION OPERATION

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

a Switch off the ignition.

a Remove:

  • the front bumper (see Front bumper assembly: Exploded view) and (see Exterior body front trim assembly: Exploded view) (55A, Exterior protection),
  • the headlight (see 80B, Headlights, Headlight as- sembly: Exploded view, page 80B-1)

– REMOVAL OPERATION

a Remove the headlight beam adjustment actuator by turning it a quarter of a turn clockwise (see 80B, Headlights, Headlight assembly: Exploded view, page 80B-1) .

REFITTING

REFITTING OPERATION

a Proceed in the reverse order to removal.

a Adjust the headlights (see 80B, Headlights, Head- light: Adjustment, page 80B-3) .

 

144000

1

Brake light and side light bulb

(see 81A , Rear lighting, Rear light bulb: Removal – Refitting, page 81A-3)

2

Direction indicator bulb

3

Fog or reversing light bulb

4

Rear light

(see 81 A, Rear lighting, Rear wing light: Removal – Refitting, page 81A-2)

Location and specifications (tightening torques, parts always to be replaced, etc.) (see 81A, Rear lighting, Rear light assembly: Exploded view, page 81A-1)

REMOVAL

– REMOVAL PREPARATION OPERATION

a Switch off the ignition.

Rear light on the wing (right-hand side)

a Remove

  • the jack cover,
  • the jack.

– REMOVAL OPERATION

a Remove (see 81A, Rear lighting, Rear light as- sembly: Exploded view, page 81A-1) :

    • the nuts of the rear light on the wing,
    • the rear light on the wing.

a Disconnect the connector from the rear light on the wing (see 81A, Rear lighting, Rear light assem- bly: Exploded view, page 81A-1) .

When replacing the rear light on the wing

a Remove the bulbs from the rear light on the wing (see 81A, Rear lighting, Rear light assembly: Exploded view, page 81A-1).

REFITTING

a Proceed in the reverse order to removal.

REMOVAL

– REMOVAL PREPARATION OPERATION

a Switch off the ignition.

a Remove the rear light on the wing (see 81A, Rear lighting, Rear light assembly: Exploded view, page 81A-1).

– REMOVAL OPERATION

145583

a Unclip the bulb holder by pressing on the clips (1) .

– Brake light and side light bulb

a Remove the brake light and side light bulb (see 81A, Rear lighting, Rear light assembly: Exploded view, page 81A-1) .

– Direction indicator bulb

a Remove the direction indicator bulb (see 81A, Rear lighting, Rear light assembly: Exploded view, page 81A-1) .

– Fog or reversing light bulb

a Remove the fog or reversing light bulb (see 81A, Rear lighting, Rear light assembly: Exploded view, page 81A-1) .

REFITTING

a Proceed in the reverse order to removal.

REMOVAL

OPERATION FOR REMOVAL OF PART CONCERNED

125456

a Unclip the high level brake light cover by pressing at

(1) .

125457

a Disconnect the high level brake light connector (2) .

a Remove:

  • the high level brake light screws (3) ,
  • the high level brake light ,
  • the high level brake light bulb (see 81A, Rear light- ing, High level brake light bulb: Removal – Refit- ting, page 81A-5) .

REFITTING

REFITTING OPERATION FOR PART CONCERNED

a Refit:

  • the high level brake light bulb (see 81A, Rear light- ing, High level brake light bulb: Removal – Refit- ting, page 81A-5) ,
  • the high level brake light ,
  • the high level brake light screws.

a Connect the high level brake light connector.

a Clip on the high level brake light cover.

REMOVAL

– REMOVAL PREPARATION OPERATION

125456

a Unclip the high level brake light cover by pressing at

(1) .

a Disconnect the high level brake light connector.

– OPERATION FOR REMOVAL OF PART CONCERNED

II – FINAL OPERATION.

a Connect the high level brake light connector.

a Clip on the high level brake light cover.

a Remove:

  • the bulb holder (2) by turning it clockwise,
  • the high level brake light bulb (3) .

REFITTING

I – REFITTING OPERATION FOR PART CONCERNED

a Refit:

  • the high level brake light bulb,
  • the bulb holder by turning it anti-clockwise.

125457

REMOVAL

– REMOVAL PREPARATION OPERATION

a Switch off the ignition.

– OPERATION FOR REMOVAL OF PART CONCERNED

a Unclip the number plate light using a small flat-blade screwdriver.

a Disconnect the connector for the number plate lights.

a Remove the number plate light.

REFITTING

REFITTING OPERATION FOR PART CONCERNED

a Connect the connector for the number plate lights.

a Clip on the number plate light.

2 – PASSENGER COMPARTMENT FUSE BOX

  1. – LIST OF COMPONENTS

  1. – LOCATION OF COMPONENTS 1 – UCH

No.

Description

(1)

UCH

(2)

Passenger compartment fuse box

(3)

Front courtesy light

(4), (5)

Rear courtesy light

(6)

Storage compartment light

(7), (8), (9), (10)

Luggage compartment light

(11), (12)

Door switch

(13), (14), (15)

Luggage compartment switch

Passenger compartment fuse box (2)

– FRONT COURTESY LIGHT

107820

UCH (1)

107848

Front courtesy light (3)

117675

– STORAGE COMPARTMENT LIGHT 6 – DOOR SWITCH

Storage compartment light (6)

– LUGGAGE COMPARTMENT LIGHT

Luggage compartment light (10)

118607

144648

Side door switch (11)

7 – LUGGAGE COMPARTMENT SWITCH

Luggage compartment switch (15)

108624

144628

 

Special tooling required

Car. 1363 Set of trim removal levers.

REMOVAL

OPERATION FOR REMOVAL OF PART CONCERNED

Front courtesy light

108749

a Unclip the translucent cover (1) using a flat-blade screwdriver or tool (Car. 1363), inserting it into the notch (2) .

108748

a Press on the clip (3) using the tool (Car. 1363) to re- move the courtesy light.

a Disconnect the connector.

REFITTING

REFITTING OPERATION FOR PART CONCERNED

a Connect the connector.

a Refit the courtesy light.

a Clip the translucent cover in place.

 

REMOVAL

OPERATION FOR REMOVAL OF PART CONCERNED

Side door switch

a Remove the sealing gaiter.

108624

REFITTING

REFITTING OPERATION FOR PART CONCERNED

Side door switch

a Connect the connector.

a Clip the switch.

a Refit the sealing gaiter.

108622

a Remove the switch (1) by squeezing the three clips

(2) .

a Disconnect the connector.

 

REMOVAL

Special tooling required

Car. 1363 Set of trim removal levers.

OPERATION FOR REMOVAL OF PART CONCERNED

a

a Connect the storage compartment light switch con- nector.

a Clip the storage compartment light connector.

a Connect the storage compartment light connector.

a Clip on the storage compartment light.

Note:

It is not necessary to remove the dashboard.

107807

a Unclip the storage compartment light using the (Car.

1363).

a Disconnect the storage compartment light connec- tor.

Note:

The glove compartment light switch can also be removed.

a Unclip the storage compartment light connector.

a Disconnect the storage compartment light switch connector.

REFITTING

OPERATION FOR REFITTING PART CONCERNED

a

Note:

When replacing a bulb, use an approved C5W

bulb.

Special tooling required

Car. 1363 Set of trim removal levers.

REMOVAL

REMOVAL OPERATION

144648

a Unclip the luggage compartment light (4) using tool

(Car. 1363).

a Disconnect the luggage compartment light connec- tor.

REFITTING

REFITTING OPERATION

a Connect the luggage compartment light connector.

a Clip the luggage compartment light in place.

– LIST OF COMPONENTS

No.

Description

(1)

Passenger compartment fuse box

(2),(3)

Engine compartment fuse and relay box

  1. – LOCATION OF COMPONENTS
    1. – PASSENGER COMPARTMENT FUSE BOX

Passenger compartment fuse box (1)

107820

117677

This unit is located in the passenger compartment, on the left-hand side of the dashboard.

Remove the cover to access the passenger compart- ment fuse box.

– ENGINE COMPARTMENT FUSE AND RELAY BOX

24729

Unclip the cover to access the passenger compartment fuse and relay box.

Engine compartment fuse and relay box

– OLD ENGINE COMPARTMENT FUSE AND RELAY BOX

Unclip the cover to gain access to the unit.

24730

107847

Engine compartment fuse and relay box (3)

107845

2 – IGNITION SWITCH

  1. – LIST OF COMPONENTS

No.

Description

(1)

Antenna/Transponder ring

(2)

Ignition switch

(3)

UCH

(4)

Ignition key

  1. – LOCATION OF COMPONENTS

1 – ANTENNA/TRANSPONDER RING

Ignition switch (2)

3 – UCH

107851

Antenna/transponder ring (1)

108537

UCH (3)

107848

4 – IGNITION KEY

Ignition key (4)

107869

REMOVAL

– REMOVAL PREPARATION OPERATION

a Disconnect the battery (see 80A, Battery, Battery: Removal – Refitting, page 80A-2) .

a Remove the transponder ring (see 82A, Engine im- mobiliser, Transponder ring: Removal – Refit- ting, page 82A-5) .

– OPERATION FOR REMOVAL OF PART CONCERNED

107851

a Unclip the connector from its support at (1) and (2) from underneath the dashboard.

107849

a Unclip the connector using a flat-blade screwdriver.

a Remove the bolt (3) .

a Move the ignition key to position (5) .

a Tilt the retaining lugs (4) .

a Remove switch.

REFITTING

I – REFITTING PREPARATION OPERATION

a Always replace the switch bolt.

127941

a Check that the ignition key is in position (5) .

– REFITTING OPERATION FOR PART CONCERNED

a Refit:

    • the switch,
    • the switch bolt.

a Clip:

    • the connector to the switch,
    • the connector for the switch on its mounting.

– FINAL OPERATION.

a Refit the transponder ring (see 82A, Engine immo- biliser, Transponder ring: Removal – Refitting, page 82A-5) .

a Connect the battery (see 80A, Battery, Battery: Re- moval – Refitting, page 80A-2) .

REMOVAL

I – REMOVAL PREPARATION OPERATION

a Switch off the ignition.

Note:

The steering wheel does not need to be removed.

a Remove the upper half cowling.

II – OPERATION FOR REMOVAL OF PART CONCERNED

107814

a Remove:

  • both bolts (1) ,
  • the lower half-shell at (2) .

107813

108537

a Disconnect the connector (3) from the transponder ring (4) .

a Remove the transponder ring.

REFITTING

– REFITTING OPERATION FOR PART CONCERNED

a Refit the transponder ring.

a Connect the transponder ring connector.

– FINAL OPERATION.

a Refit:

    • the upper half-shell,
    • the lower half-shell,
    • the two lower half-shell bolts.

ENGINE IMMOBILISER

82A

Battery for remote door locking control: Removal – Refitting

REMOVAL

OPERATION FOR REMOVAL OF PART CONCERNED

107867

a Remove the battery (3) using a flat-blade screwdriv- er.

a Remove the bolt (1) .

107868

REFITTING

– REFITTING PREPARATION OPERATION

a

WARNING

To ensure that the remote control operates cor- rectly, take care not to damage the battery con- tacts.

Only handle the new battery with dry, grease-free hands or wearing clean gloves to avoid any risk of dirt and oxidation on the battery.

– REFITTING OPERATION FOR PART CONCERNED

a Fit the battery (3) respecting the polarity.

107869

a Open the key with a flat-blade screwdriver at (2) .

– FINAL OPERATION.

a Close the key.

a Refit the bolt (1) .

a Tighten the bolt.

 

Tightening torquesm

horn bolt 21 N.m

REMOVAL

– REMOVAL PREPARATION OPERATION

a Remove the front bumper (see Front bumper as- sembly: Exploded view) .

– OPERATION FOR REMOVAL OF PART CONCERNED

  1. – Monotonal horn

Left-hand side

Right-hand side

145584

a Disconnect the connector (5) .

a Remove:

  • the bolt of the monotonal horn (6) ,
  • the horn.

– Bitonal horn

a

Note:

The bitonal horn is composed of two horns, which are fitted symmetrically on each side of the vehicle.

145584

145585

a Disconnect the connector of the bitonal horn (7) .

a Remove:

  • the bolt of the bitonal horn (8) ,
  • the bitonal horn.

REFITTING

– REFITTING OPERATION FOR PART CONCERNED

a Proceed in the reverse order to removal.

a Torque tighten the horn bolt (21 N.m).

– FINAL OPERATION

a Refit the front bumper.

When replacing the instrument panel, the following must be noted on the warranty booklet:

  • that the instrument panel has been replaced,
  • the mileage indicated by the instrument panel removed.

REMOVAL

I – REMOVAL PREPARATION OPERATION

a When replacing the instrument panel, read the mile- age indicated on the instrument panel and note it in the warranty booklet (see insert in the introduction)

a Switch off the ignition.

125471

a Unclip the central trim assembly (3) , starting at the bottom.

a Unclip the trims (4) .

125472

a Remove the two lower bolts (1) .

a Unclip:

107813

  • the lower half-shell in the direction of the arrow (2) ,
  • the upper half-shell.

II – OPERATION FOR REMOVAL OF PART CONCERNED

107816

a Remove the bolts (5) of the instrument panel frame.

107818

127939

a Unclip the instrument panel frame at (6) and (7) .

107819

a Remove the bolts (8) from the instrument panel.

a Unclip the instrument panel.

a Disconnect the connectors from the instrument pan- el.

REFITTING

– REFITTING OPERATION FOR PART CONCERNED

a Connect the connectors to the instrument panel.

a Clip on the instrument panel.

a Refit the instrument panel bolts.

– FINAL OPERATION

a Clip in place the instrument panel frame.

a Refit the bolts of the instrument panel frame.

a Clip on:

  • the trims,
  • the centre trim.

a Clip on:

  • the upper half-shell,
  • the lower half-shell.

a Refit the two lower bolts.

– CHECKING AFTER REPAIR

a Switch on the ignition.

a Check the operation of the instrument panel.

a Set the time (see Clock: Before/after repair proce- dure) .

CONTROL – SIGNALS

84A

Rotary switch: Removal – Refitting

REMOVAL

– REMOVAL PREPARATION OPERATION

a Set the wheels straight ahead.

a Lock the airbag computer (see Fault finding – Re- placement of components) (88C, Airbags and pre- tensioners).

a Disconnect the battery (see 80A, Battery, Battery: Removal – Refitting, page 80A-2) .

a Remove the steering column switch assembly (see 84A, Control – Signals, Steering column switch assembly: Removal – Refitting, page 84A-2) .

– OPERATION FOR REMOVAL OF PART CONCERNED

REFITTING

  1. – REFITTING PREPARATION OPERATION

a Check that the rotary switch tape is correctly centred (2.5 rotations on each side).

Note:

If the rotary switch is being replaced, the new part is supplied ready centred with an adhesive label which will tear off when the wheel is turned for the first time (wheels must be straight when fitting).

a Ensure that the wheels are set straight ahead.

– REFITTING OPERATION FOR PART CONCERNED

a Refit:

    • the bolts to the lighting stalk,
    • the bolts to the wiper stalk.

a Remove:

    • the bolts (1) from the wiper stalk,
    • the bolts (2) from the lighting stalk.

108743

– FINAL OPERATION

a Refit the steering column switch assembly (see 84A, Control – Signals, Steering column switch as- sembly: Removal – Refitting, page 84A-2) .

a Connect the battery (see 80A, Battery, Battery: Re- moval – Refitting, page 80A-2) .

a Unlock the airbag computer (see Fault finding – Re- placement of components) (88C, Airbag and pre- tensioners).

– CHECKING AFTER REPAIR

a Switch on the ignition.

a Check the operation of the rotary switch:

    • turn the steering wheel to the left until it stops,
    • turn the steering wheel to the right until it stops,
    • bring the steering wheel back to the central posi- tion,
    • check that there are no faults on the instrument panel.

 

REMOVAL

I – REMOVAL PREPARATION OPERATION

a Set the wheels straight ahead.

a Lock the airbag computer (see Fault finding – Re- placement of components) (88C, Airbags and pre- tensioners).

a Switch off the ignition.

a Disconnect the battery (see 80A, Battery, Battery: Removal – Refitting, page 80A-2) .

a Remove:

  • the driver’s frontal airbag (see 88C, Air bag and Pretensioners, Driver’s frontal airbag: Removal
    • Refitting, page 88C-6) ,
  • the steering wheel (see Steering wheel: Removal
    • Refitting) (36A, Steering).

a Unclip the upper half-shell.

II – OPERATION FOR REMOVAL OF PART CONCERNED

107814

a Remove the two lower bolts (1) .

107813

a Unclip the lower half-shell in the direction of the ar- row (2) .

107815

a Loosen the bolts (3) securing the rotary switch.

a Tap the head of a screwdriver to unlock the cone and release the steering column assembly.

a Connect the various connectors.

a Remove the adhesive tape.

Note:

Continue refitting and do not tighten bolt until the two half-shells are refitted so that the stalks can be aligned with the instrument panel and dash- board. This operation is made easier by a cut-out section giving access to the bolt in the lower half- shell.

a Clip on:

  • the upper half-shell,
  • the lower half-shell.

a

Note:

108743

a Refit the two lower bolts.

a Position the stalks in alignment with the instrument panel and dashboard.

a Tighten the bolts (3) securing the rotary switch.

Before removing the assembly, it is essential to mark the position of the rotary switch by immobil- ising the rotary switch rotor with adhesive tape.

a Partially remove the steering column switch assem- bly to disconnect its connectors.

a Remove the steering wheel control assembly.

REFITTING

– REFITTING PREPARATION OPERATION

a The steering wheel bolt must always be replaced.

a Ensure that the wheels are still straight.

a Check that the switch tape is correctly centred (2.5 rotations on each side).

Note:

If the rotary switch is being replaced, the new part is supplied ready centred with an adhesive label which will tear off when the wheel is turned for the first time (wheels must be straight when fitting).

– REFITTING OPERATION FOR PART CONCERNED

a Engage the steering assembly on the steering col- umn.

– FINAL OPERATION

a Refit:

    • the steering wheel (see Steering wheel: Removal

– Refitting) (36A, Steering),

    • the driver’s front airbag (see 88C, Air bag and Pre- tensioners, Driver’s frontal airbag: Removal – Refitting, page 88C-6) .

a Connect the battery (see 80A, Battery, Battery: Removal – Refitting, page 80A-2) .

a Unlock the airbag computer (see Fault finding – Replacement of components) (88C, Airbag and pre-tensioners).

a Carry out a function test on the steering column switch assembly.

– CHECKING AFTER REPAIR

a Switch on the ignition.

a Check the operation of the rotary switch:

    • turn the steering wheel to the left until it stops,
    • turn the steering wheel to the right until it stops,
    • bring the steering wheel back to the central posi- tion,
    • check that there are no faults on the instrument panel.

CONTROL – SIGNALS

84A

Steering column switch assembly: Removal – Refitting

REMOVAL

– REMOVAL PREPARATION OPERATION

a Switch off the ignition.

a Remove the transponder ring (see 82A, Engine im- mobiliser, Transponder ring: Removal – Refit- ting, page 82A-5) .

– OPERATION FOR REMOVAL OF PART CONCERNED

108742

a Remove the two bolts (1) from the wiping stalk.

a Remove the wiping stalk from its support.

a Disconnect the connector.

REFITTING

– REFITTING OPERATION FOR PART CONCERNED

a Connect the connector.

a Refit:

    • the wiping stalk onto its support,
    • the bolts to the wiping stalk.

– FINAL OPERATION.

a Refit the transponder ring (see 82A, Engine immo- biliser, Transponder ring: Removal – Refitting, page 82A-5) .

REMOVAL

I – REMOVAL PREPARATION OPERATION

a Switch off the ignition.

Note:

The steering wheel does not need to be removed.

a Remove the upper half cowling.

II – OPERATION FOR REMOVAL OF PART CONCERNED

107814

a Remove:

  • both bolts (1) ,
  • the lower half-shell at (2) .

107813

108741

a Remove the two bolts (3) from the lighting stalk.

a Remove the lighting stalk and its mounting.

a Disconnect the connector.

REFITTING

– REFITTING OPERATION FOR PART CONCERNED

a Connect the connector.

a Refit:

    • the lighting stalk on its support,
    • the two bolts on the lighting stalk.

– FINAL OPERATION

a Refit:

    • the upper half-shell,
    • the lower half-shell,
    • the two bolts of the lower half-shell.

REMOVAL

– REMOVAL PREPARATION OPERATION

a Remove the radio (see 86A, Radio, Radio: Remov- al – Refitting, page 86A-3) .

125726

a Unclip the central trim assembly, starting at the bot- tom.

– OPERATION FOR REMOVAL OF PART CONCERNED

125727

a Disconnect the hazard warning lights switch connec- tor (1) .

a Unclip the hazard warning light switch by moving clips.

REFITTING

– REFITTING OPERATION FOR PART CONCERNED

a Clip on the hazard warning light switch.

a Connect the hazard warning lights switch connector.

– FINAL OPERATION

a Clip on the central trim assembly, starting at the top.

a Refit the radio (see 86A, Radio, Radio: Removal – Refitting, page 86A-3) .

REMOVAL

– REMOVAL PREPARATION OPERATION

a Remove the radio (see 86A, Radio, Radio: Remov- al – Refitting, page 86A-3) .

125726

a Unclip the central trim assembly, starting at the bot- tom.

– OPERATION FOR REMOVAL OF PART CONCERNED

125727

a Disconnect the connector (1) from the central door locking switch.

a Unclip the central locking switch by moving clips.

REFITTING

– REFITTING OPERATION FOR PART CONCERNED

a Clip the door locking switch.

a Connect the central door locking switch connector.

– FINAL OPERATION

a Clip on the central trim assembly, starting at the top.

a Refit the radio (see 86A, Radio, Radio: Removal – Refitting, page 86A-3) .

REMOVAL

OPERATION FOR REMOVAL OF PART CONCERNED

108639

a Retract the sealing sleeve (1) from the left-hand ac- tuator.

a Unclip the end piece of the left-hand actuator sheath

(2) .

a Remove:

  • the cable (3) from the left-hand actuator,
  • the sealing sleeve (1) .

a Retract the sealing sleeve (1) from the right-hand actuator.

a Unclip the end piece of the right-hand actuator sheath (2) .

a Remove:

  • the cable (3) from the right-hand actuator,
  • the sealing sleeve (1) .

a Unpick the « cables – sheaths » assembly. Note down the position of fitting.

a Unclip the adjustment knob.

a Remove the bolts (4) .

a Remove:

109243

109244

    • the adjustment control through the dashboard,
    • the « control – cables – sheaths» assembly from the vehicle interior. Note down the position of fit- ting.

REFITTING

– REFITTING OPERATION FOR PART CONCERNED

a Refit:

    • the « control – cables – sheaths» assembly from the vehicle interior,
    • the adjustment control,
    • the adjustment control bolts.

a Clip on the adjustment knob.

a Clip on the « cables – sheaths » assembly.

a Refit the sealing sleeves.

a Position the cable stop on the right-hand actuator.

a Pull the sheath end piece backwards and clip it onto the right-hand actuator.

a Position the right-hand actuator sealing sleeve.

a Refit the cable stop on the left-hand actuator.

a Pull the sheath end piece backwards and clip it onto the left-hand actuator.

a Position the left-hand actuator sealing sleeve.

– FINAL OPERATION.

a Adjust the headlights (see Halogen headlight: Ad- justment) .

CONTROL – SIGNALS

84A

Exterior rear view mirror control switch: Removal – Refitting

2 ELECTRICALLY ADJUSTABLE EXTERNAL REAR VIEW MIRRORS

REMOVAL

OPERATION FOR REMOVAL OF PART CONCERNED

a Unclip the door mirror switch (1) .

a Disconnect the door mirror switch connector.

REFITTING

107824

REFITTING OPERATION FOR PART CONCERNED

a Connect the door mirror switch connector.

a Clip on the door mirror switch.

 

REMOVAL

– REMOVAL PREPARATION OPERATION

a Remove the radio (see 86A, Radio, Radio: Remov- al – Refitting, page 86A-3) .

– OPERATION FOR REMOVAL OF PART CONCERNED

125727

a Disconnect the connector (1) from the rear screen de-icing switch.

a Unclip the heated rear screen switch by moving the clips.

REFITTING

– REFITTING OPERATION FOR PART CONCERNED

a Clip on the heated rear screen switch.

a Connect the connector to the heated rear screen switch.

– FINAL OPERATION.

a Clip on the central trim assembly, starting at the top.

a Refit the radio (see 86A, Radio, Radio: Removal – Refitting, page 86A-3) .

 

FRONT SEAT WITH HEATING

REMOVAL

– REMOVAL PREPARATION OPERATION

24693

a Remove:

    • the bolt (1) from the exterior runner cover,
    • the exterior runner cover.

– OPERATION FOR REMOVAL OF PART CONCERNED

a Unclip the heated seat cover switch (2) .

a Disconnect the heated seat cover switch connector.

REFITTING

– REFITTING OPERATION FOR PART CONCERNED

a Connect the heated seat cover switch connector.

a Clip on the heated seat cover switch.

– FINAL OPERATION.

a Refit:

    • the exterior runner cover,
    • the exterior runner cover bolt.

2 – PASSENGER COMPARTMENT FUSE BOX

    1. – LIST OF COMPONENTS

No.

Description

(1)

UCH

(2)

Passenger compartment fuse box

(3)

Windscreen wiper switch

(4)

Windscreen wiper motor

(5)

Rear screen wiper motor

(6)

Washer pump

(7)

Windscreen washer bottle

    1. – LOCATION OF COMPONENTS 1 – UCH

Passenger compartment fuse box (2)

– WINDSCREEN WIPER SWITCH

107820

UCH (1)

107848

Windscreen wiper switch (3)

107815

– WINDSCREEN WIPER MOTOR

Windscreen wiper motor (4)

– REAR SCREEN WIPER MOTOR

Rear screen wiper motor (5)

145587

145807

– WASHER PUMP

Washer pump (6)

– WINDSCREEN WASHER BOTTLE

Windscreen washer bottle (7)

108635

108635

REMOVAL

OPERATION FOR REMOVAL OF PART CONCERNED

a Lift the wiper arm.

a Swivel the blade so it is perpendicular to the wiper arm.

118618

a Squeeze the clips (1) and move downwards at the same time (2) .

a Remove the blade.

REFITTING

REFITTING OPERATION FOR PART CONCERNED

a Clip the blade onto the wiper arm.

a Lower the wiper arm.

REMOVAL

Tightening torquesm

wiper arm nuts 16 N.m

– REMOVAL PREPARATION OPERATION

a Switch on the ignition.

– OPERATION FOR REMOVAL OF PART CONCERNED

WARNING

To ensure that the wiper arms can travel smoothly, the wiper motor must be initialised.

a Turn the wiper stalk from (0) to (1), and then from (1) to (0).

a Switch off the ignition.

a Remove the windscreen wiper arm nuts (8) .

a Remove the wiper arms using the.

REFITTING

– REFITTING OPERATION FOR PART CONCERNED

a Switch on the ignition.

140942

a Mark the position of the wiper arms (3) .

a Fold back the nut covers (4) .

140941

WARNING

To ensure that the wiper arms can travel smoothly, the wiper motor must be initialised.

a Turn the wiper stalk from (0) to (1), and then from (1) to (0).

a Switch off the ignition.

a Refit:

  • the wiper arms in the position marked before re- moval,
  • the wiper arm nuts.

a Torque tighten the wiper arm nuts (16 N.m).

– FINAL OPERATION

a Fit the nut covers.

REMOVAL

Tightening torquesm

windscreen wiper motor 8 N.m

bolts

windscreen wiper motor 16 N.m

shaft nut

– REMOVAL PREPARATION OPERATION

a

– OPERATION FOR REMOVAL OF PART CONCERNED

WARNING

To ensure that the wiper arms can travel smoothly, the wiper motor must be initialised.

a Turn the wiper stalk from (0) to (1), and then from (1) to (0).

a Remove the wiper arms (see 85A, Wiping – Wash- ing, Windscreen wiper arm: Removal – Refitting, page 85A-4) .

a Disconnect the battery (see 80A, Battery, Battery: Removal – Refitting, page 80A-2) .

a Remove:

  • the scuttle panel grille,
  • the front windscreen wiper mechanism (see 85A, Wiping – Washing, Windscreen wiper mecha- nism: Removal – Refitting, page 85A-8) .

108001

a Remove the windscreen wiper motor shaft nut (1) .

108002

a Unclip the windscreen wiper motor connector (2) .

REFITTING

I – REFITTING PREPARATION OPERATION

a Connect:

    • the windscreen wiper motor,
    • the battery (see 80A, Battery, Battery: Removal – Refitting, page 80A-2) .

WARNING

To ensure that the wiper arms can travel smoothly, the wiper motor must be initialised.

a Turn the wiper stalk from (0) to (1), and then from (1) to (0).

a Disconnect:

    • the battery (see 80A, Battery, Battery: Removal – Refitting, page 80A-2) ,
    • the windscreen wiper motor.

121577

a Remove the windscreen wiper motor shaft nut (3) .

121576

a Unclip the windscreen wiper motor connector (4) .

a Remove:

  • the bolts from the windscreen wiper motor,
  • the windscreen wiper motor.

– REFITTING OPERATION FOR PART CONCERNED

a Refit:

    • the windscreen wiper motor,
    • the windscreen wiper motor bolts.

a Torque tighten the windscreen wiper motor bolts (8 N.m).

a Clip the windscreen wiper motor connector.

108001

a Position the linkages as shown in the above illustra- tion.

121577

a Position the linkages as shown in the above illustra- tion.

a Refit the windscreen wiper motor shaft nut.

a Torque tighten the windscreen wiper motor shaft nut (16 N.m).

– FINAL OPERATION

a Refit:

    • the windscreen wiper mechanism (see 85A, Wip- ing – Washing, Windscreen wiper mechanism: Removal – Refitting, page 85A-8) ,
    • the scuttle panel grille.

a Connect the battery (see 80A, Battery, Battery: Re- moval – Refitting, page 80A-2) .

WARNING

To ensure that the wiper arms can travel smoothly, the wiper motor must be initialised.

a Turn the wiper stalk from (0) to (1), and then from (1) to (0).

a Refit the wiper arm (see 85A, Wiping – Washing, Windscreen wiper arm: Removal – Refitting, page 85A-4) .

Tightening torquesm

windscreen wiper mech- 8 N.m

anism bolts

windscreen wiper mech- 8 N.m

anism nuts

REMOVAL

I – REMOVAL PREPARATION OPERATION

a

WARNING

To ensure that the wiper arms can travel smoothly, the wiper motor must be initialised.

a Turn the wiper stalk from (0) to (1), and then from (1) to (0).

a Disconnect the battery (see 80A, Battery, Battery: Removal – Refitting, page 80A-2) .

a Remove the wiper arms (see 85A, Wiping – Wash- ing, Windscreen wiper arm: Removal – Refitting, page 85A-4) .

a Remove the nut covers (2) .

a Remove the engine compartment seal (3) .

121522

107996

a Remove the nut covers (1) .

107995

II – OPERATION FOR REMOVAL OF PART CONCERNED

a Remove:

  • the two scuttle half-grille bolts (4) ,
  • the right-hand scuttle half-grille (5) .

a Remove the left-hand scuttle half-grille (6) .

107997

107998

107999

a Disconnect the windscreen wiper motor connector (7) .

Note:

The windscreen wiper motor mechanism mount- ings (8) are fragile: the threads are plastic.

a Remove:

  • the windscreen wiper mechanism bolts (8) ,
  • the windscreen wiper mechanism bolt (9) ,
  • the washers.

121578

a Disconnect the windscreen wiper motor connector

(10) .

a Remove:

  • the windscreen wiper mechanism bolts (11) ,
  • the front windscreen wiper mechanism bolts (12) ,
  • the washers.

a Remove the windscreen wiper mechanism.

REFITTING

– REFITTING OPERATION FOR PART CONCERNED

a Refit:

    • the windscreen wiper mechanism,
    • the washers,
    • the windscreen wiper mechanism bolts,
    • the windscreen wiper mechanism bolts.

a Torque tighten:

the windscreen wiper mechanism bolts (8 N.m),

    • the windscreen wiper mechanism nuts (8 N.m).

a Connect the windscreen wiper motor connector.

– FINAL OPERATION

a Refit:

    • the left-hand scuttle half-grille,
    • the right-hand scuttle half-grille,
    • the two scuttle panel grille side bolts,
    • the engine compartment seal,
    • the windscreen wiper mechanism bolt covers.

a Connect the battery (see 80A, Battery, Battery: Re- moval – Refitting, page 80A-2) .

WARNING

To ensure that the wiper arms can travel smoothly, the wiper motor must be initialised.

a Turn the wiper stalk from (0) to (1), and then from (1) to (0).

a Refit the wiper arm (see 85A, Wiping – Washing, Windscreen wiper arm: Removal – Refitting, page 85A-4) .

 

REAR SCREEN WIPER

Special tooling required

Ele. 1781 Tool for removing windscreen wiper arms

REMOVAL

– REMOVAL PREPARATION OPERATION

a Switch on the ignition.

WARNING

To ensure that the wiper arms can travel smoothly, the wiper motor must be initialised.

a Turn the wiper stalk from (0) to (1), and then from (1) to (0).

a Switch off the ignition.

a Mark the position of the wiper arm.

– REMOVAL OPERATION

REFITTING

  1. – REFITTING PREPARATION OPERATION

a Switch on the ignition.

WARNING

To ensure that the wiper arms can travel smoothly, the wiper motor must be initialised.

a Turn the wiper stalk from (0) to (1), and then from (1) to (0).

a Switch off the ignition.

– REFITTING OPERATION

a Refit the rear screen wiper blade.

a Refit:

    • the wiper arm,
    • the wiper arm nut.

a Fit the nut cover.

a Pull down the nut cover (5) .

a Remove the nut (6) from the wiper arm.

a Remove the wiper arm using the (Ele. 1781).

145588

a Remove the rear screen wiper blade (see Rear screen wiper blade: Removal – Refitting) .

REMOVAL

– REMOVAL PREPARATION OPERATION

a Switch on the ignition.

– OPERATION FOR REMOVAL OF PART CONCERNED

WARNING

To ensure that the wiper arms can travel smoothly, the wiper motor must be initialised.

a Move the wiper stalk from (0) to (1), then from (1) to (0).

a Switch off the ignition.

a Remove:

  • the rear screen wiper arm (see 85A, Wiping – Washing, Rear screen wiper arm: Removal – Re- fitting, page 85A-11) ,
  • the tailgate trim (see Tailgate trim: Removal – Re- fitting) (MR 389, 73A, Non-side opening elements trim).

125478

a Disconnect the supply connector (1) from the rear screen wiper motor.

Note:

Take care not to damage the outer skin and door box section with the drill bit. Retrieve the rivet bodies in the door box section.

a Drill out the rivets (2) (see MR 400, 40A, General in- formation ).

a Remove the rear screen wiper motor.

REFITTING

– REFITTING PREPARATION OPERATION

a Replace the seal (3) if necessary.

125465

– REFITTING OPERATION FOR PART CONCERNED

a Position and rivet the rear screen wiper motor (see

MR 400, 40A, General information).

a Connect the rear screen wiper motor supply connec- tor.

– FINAL OPERATION.

a Switch on the ignition.

WARNING

To ensure that the wiper arms can travel smoothly, the wiper motor must be initialised.

a Move the wiper stalk from (0) to (1), then from (1) to (0).

a Switch off the ignition.

a Refit:

  • the tailgate trim (see Tailgate trim: Removal – Re- fitting) (MR 389, 73A, Non-side opening elements trim),
  • the rear screen wiper arm (see 85A, Wiping – Washing, Rear screen wiper arm: Removal – Re- fitting, page 85A-11) .

 

LEFT-HAND DRIVE

REMOVAL

– REMOVAL PREPARATION OPERATION

a Remove the windscreen washer bottle (see 85A, Wiping – Washing, Windscreen washer reser- voir: Removal – Refitting, page 85A-17) .

– OPERATION FOR REMOVAL OF PART CONCERNED

a Check that the assembly works correctly.

Note:

Adjust the position of the windscreen washer jets if necessary using a needle.

118886

a Disconnect the windscreen washer pump (1) from the bottle.

a Disconnect the windscreen washer pump pipes.

REFITTING

– REFITTING OPERATION FOR PART CONCERNED

a Connect the windscreen washer pump pipes.

a Fit the windscreen washer pump onto the bottle.

– FINAL OPERATION

a Refit the windscreen washer bottle (see 85A, Wip- ing – Washing, Windscreen washer reservoir: Removal – Refitting, page 85A-17) .

 

REMOVAL

– REMOVAL PREPARATION OPERATION

a Disconnect the jet supply pipe.

– OPERATION FOR REMOVAL OF PART CONCERNED

108636

REFITTING

– REFITTING OPERATION FOR PART CONCERNED

a Clip the washer jet.

– FINAL OPERATION

a Connect the jet supply pipe.

a Check that the assembly works correctly.

a Adjust the position of the rear windscreen washer jet if necessary using a needle.

118887

a Unclip the windscreen washer jet by prising the clips

    1. using a flat screwdriver.

Note:

Take care not to damage the paintwork on the bonnet.

 

REAR SCREEN WIPER

Special tooling required

Car. 1363 Set of trim removal levers.

REMOVAL

I – REMOVAL PREPARATION OPERATION II – REMOVAL OPERATION

126625

a Unclip the rear screen washer jet (2) using tool (Car.

1363).

a Disconnect the rear screen washer jet supply pipe.

REFITTING

– REFITTING OPERATION

a Connect the rear screen washer jet supply pipe.

a Clip the rear screen washer jet.

– FINAL OPERATION

 

LEFT-HAND DRIVE

REMOVAL

  1. – REMOVAL PREPARATION OPERATION

– the right-hand scuttle half-grille (4) .

– OPERATION FOR REMOVAL OF PART CONCERNED

a Detach the pipe at (1) .

108636

108635

a Disconnect the connector (5) from the windscreen washer pump.

a Remove:

  • the bolt (6) from the windscreen washer bottle,
  • the windscreen washer bottle by pulling it in the di- rection of the arrow (7) .

a Drain the windscreen washer bottle.

a Disconnect the windscreen washer pump from the bottle.

REFITTING

a Remove the engine compartment seal (2) .

a Remove:

– the side bolt (3) from the scuttle half-grille,

107996

107997

– REFITTING OPERATION FOR PART CONCERNED

a Fit the windscreen washer pump onto the bottle.

a Refit:

    • the windscreen washer bottle,
    • the windscreen washer bottle bolt.

– FINAL OPERATION.

a Connect the windscreen washer pump connector.

a refit:

    • the right-hand scuttle half-grille,
    • the side bolt to the scuttle half-grille,
    • the engine compartment seal.

a Clip the pipe at (1) .

a Fill-up the windscreen washer bottle.

2 – AERIAL

  1. – LIST OF COMPONENTS

No.

Description

(1)

Radio

(2)

Aerial

(3)

Front speakers

(4),(5)

Rear speakers

  1. – LOCATION OF COMPONENTS 1 – RADIO

107821

The radio aerial (2) is located on the roof

– FRONT SPEAKERS

127943

107939

– REAR SPEAKERS

118610

REMOVAL

– REMOVAL PREPARATION OPERATION

a Switch off the ignition.

– OPERATION FOR REMOVAL OF PART CONCERNED

a Remove the radio (1) using the two.

a

119085

REFITTING

– REFITTING PREPARATION OPERATION

a

Note:

Ensure that the ignition is switched off.

– REFITTING OPERATION FOR PART CONCERNED

a Connect the various connectors.

a Fit the wiring in the position marked during removal.

a Refit the radio in its housing.

WARNING

To ensure correct operation:

  • do not pinch the aerial cable,
  • do not bend the aerial cable,
  • do not force the aerial cable when refitting.

WARNING

To prevent any risk of noise, premature wear, short circuits, etc. after the refitting operation, mark the wiring routing and how to connect the connectors.

Mark the routing of the wiring behind the radio.

a Disconnect the connectors.

 

REMOVAL

– REMOVAL PREPARATION OPERATION

a

Note:

The radio aerial is located on the front roof.

a Remove:

  • front courtesy light (see 81B, Interior lighting, In- terior light: Removal – Refitting, page 81B-3) ,
  • the headlining partially (see Headlining: Removal

– Refitting) (MR 389, 71A, Body internal trim).

– OPERATION FOR REMOVAL OF PART CONCERNED

a Remove the radio aerial (2) .

REFITTING

Note:

To remove the radio aerial cable, remove the dashboard (see Dashboard: Removal – Refit- ting) (MR 389, 57A, Interior equipment).

127943

a Remove the radio aerial nut (1) .

108724

REFITTING OPERATION FOR PART CONCERNED

a Refit the radio aerial.

a Connect the radio aerial cable connector.

a Refit the radio aerial nut.

FINAL OPERATION

a Disconnect the connector from the radio aerial ca- ble.

a Refit:

  • the headlining (see Headlining: Removal – Refit- ting) (MR 389, 71A, Body internal trim),
  • front courtesy light (see 81B, Interior lighting, In- terior light: Removal – Refitting, page 81B-3) .

REMOVAL

– REMOVAL PREPARATION OPERATION

  1. – OPERATION FOR REMOVAL OF PART CONCERNED

a Unclip the front speaker grille (1) .

107939

a Remove:

  • the bolts (2) from the front speaker,
  • the front speaker.

a Disconnect the front speaker connector.

REFITTING

– REFITTING OPERATION FOR PART CONCERNED

a Connect the front speaker connector.

a Refit:

    • the front speaker,
    • the front speaker bolts.

– FINAL OPERATION.

a Clip on the front speaker grille.

107940

REMOVAL

– REMOVAL PREPARATION OPERATION

  1. – OPERATION FOR REMOVAL OF PART CONCERNED

a Unclip the rear speaker grille (1) .

118610

a Remove:

  • the bolts (2) ,
  • the speaker.

a Disconnect the connector.

REFITTING

– REFITTING OPERATION FOR PART CONCERNED

a Connect the connector.

a Refit:

    • the speaker,
    • the bolts.

– FINAL OPERATION.

a Clip in the rear speaker grille.

107940

REMOVAL

– REMOVAL PREPARATION OPERATION

a Switch off the ignition.

a Remove the radio control satellite bolt (2) .

144762

144761

a Remove the bolts (1) from the shells under the steer- ing wheel.

a Put the steering column into the lower position.

a Remove the upper cover.

a Place the steering column in the upper position.

a Remove the lower cover.

– REMOVAL OPERATION

a

a Disconnect the radio control satellite connector.

a Remove the radio control satellite.

REFITTING

– REFITTING OPERATION

a Connect the radio control satellite connector.

a Refit the radio control satellite.

– FINAL OPERATION

a Proceed in the reverse order to removal.

Note:

The steering column switch assembly does not need to be removed.

Equipment required

Diagnostic tool

REMOVAL

– REMOVAL PREPARATION OPERATION

a

Note:

If replacing the UCH, it is essential to display the configurations using Diagnostic tool.

a Switch off the ignition.

a Disconnect the battery (see 80A, Battery, Battery: Removal – Refitting, page 80A-2) .

– OPERATION FOR REMOVAL OF PART CONCERNED

a

Note:

The UCH is secured onto its mounting.

REFITTING

– REFITTING OPERATION FOR PART CONCERNED

a Refit:

    • the UCH,
    • the UCH bolt.

a Connect the connectors.

107861

a Disconnect the connectors (1) .

a Remove:

    • the UCH bolt (2) ,
    • the UCH.

107848

– FINAL OPERATION.

a Connect the battery (see 80A, Battery, Battery: Re- moval – Refitting, page 80A-2) .

a If the UCH has to be replaced, carry out the neces- sary operations (see Fault finding – Replacement of components) (87B, Passenger compartment connection unit).

 

ELECTRIC FRONT WINDOW or FRONT ONE-TOUCH ELECTRIC WINDOW – ELECTRIC FRONT WINDOW or

FRONT ONE-TOUCH ELECTRIC WINDOW, and ELECTRIC REAR WINDOW

2 – FRONT WINDOW WINDER SWITCHES

  1. – LIST OF COMPONENTS

No.

Description

(1)

Passenger compartment fuse box

(2)

Front window winder switches

No.

Description

(3)

Rear electric window switches

(4)

Child lock switch

  1. – LOCATION OF COMPONENTS

1 – PASSENGER COMPARTMENT FUSE BOX

Front window winder switches (2)

3 – REAR WINDOW WINDER SWITCHES

107823

Passenger compartment fuse box (1)

107820

Rear electric window switches (3)

117676

 

ELECTRIC FRONT WINDOW or FRONT ONE-TOUCH ELECTRIC WINDOW

REMOVAL

– REMOVAL PREPARATION OPERATION

a Remove the radio (see 86A, Radio, Radio: Remov- al – Refitting, page 86A-3) .

– OPERATION FOR REMOVAL OF PART CONCERNED

125726

a Unclip the central trim assembly, starting at the bot- tom.

125727

a Disconnect the front left window winder switch con- nector (1) or the front right window winder switch connector (2) .

a Unclip the front window winder switch by pressing the clips.

REFITTING

– REFITTING OPERATION FOR PART CONCERNED

a Clip on the front window winder switch.

a Connect the connector.

– FINAL OPERATION

a Clip on the central trim assembly, starting at the top.

a Refit the radio (see 86A, Radio, Radio: Removal – Refitting, page 86A-3) .

 

ELECTRIC REAR WINDOW

REMOVAL

– REMOVAL PREPARATION OPERATION

a Unclip the rear window winder switch plate.

– OPERATION FOR REMOVAL OF PART CONCERNED

109801

REFITTING

– REFITTING OPERATION FOR PART CONCERNED

a Clip on the rear window winder switch.

a Reconnect the rear window winder switch connec- tor.

– FINAL OPERATION.

a Clip on the rear window winder switch plate.

109800

a Disconnect the rear window winder switch connec- tor.

a Unclip the rear window winder switch by pressing the clips (1) .

– LIST OF COMPONENTS

No.

Description

(1)

New engine compartment connection unit

(2)

Old engine compartment connection unit

  1. – LOCATION OF COMPONENTS
  2. – NEW ENGINE COMPARTMENT FUSE AND RELAY BOX

Vehicles concerned:

B90 or F90 or K90 or U90 – L90, with a sales release date after 17/05/2005

H79

Engine compartment connection unit (1)

– OLD ENGINE COMPARTMENT FUSE AND RELAY BOX

24730

24729

Unclip the cover to access the engine compartment connection unit.

107847

Unclip the cover to access the engine compartment connection unit.

Engine compartment connection unit (2)

107845

 

No.

Description

Procedure

1

Passenger compartment fuse box

 

2

UCH

(see 87 B, P assenger compartment connection unit, UCH: Removal – Refitting, page 87B-1) (13B, Diesel injec- tion)

3

Engine compartment fuse and relay box

 

4

ABS-ESP computer

 

5

Airbag computer

(see 88C, Air bag and Pretensioners, Airbag computer: Removal – Refitting, page 88C-4)

6

Radio

(see 86A, Radio, Radio: Removal – Refitting, page 86A-3)

7

Injection computer

(see Diesel injection computer: Removal – Refitting)

145104

– LIST OF COMPONENTS

Mark

Description

(1)

Diagnostic socket

  1. – LOCATION OF COMPONENTS DIAGNOSTIC SOCKET

107831

The diagnostic socket (1) is located in the glovebox.

– SAFETY

    1. – Potentially dangerous components

Do not leave any unused +12V connectors exposed to the air without any protection (see Connector: Sealing and locking) (Technical Note 6015A, 88A, Wiring).

Check that there is no contact between the wiring and the fuel and brake pipes.

Avoid mounting the wiring in areas with a temperature above 100˚C.

– Advice to be followed before any operation

Before carrying out any work on the wiring, disconnect the battery.

WARNING

To prevent damaging the connectors, consult the disconnection procedure (see Connector: Disconnection and reconnection) (Technical Note 6015A, 88A, Wiring).

WARNING

To prevent any risk of noise, premature wear, short circuits, etc. after the refitting operation, mark the wiring routing and how to connect the connectors.

– Instructions to be followed during the operation

WARNING

To prevent any damage during the removal opera- tion, check that the wiring is free from its mountings (retaining clip, plastic clip, adhesive tape, connec- tor, etc.).

To prevent the wiring from being damaged, check that the surrounding area is not mechanically harmful (e.g.: door windows, sharp corners, burrs, studs, etc.).

The wiring should be at least 30 mm away from any moving components (belt, pulley, steering column, etc.).

Depending on the surrounding area, check that the un- used connectors respect the necessary sealing con- straints (see Connector: Sealing and locking) (Technical Note 6015A, 88A, Wiring).

All of the connections (connectors) used in the engine compartment are sealed; do not remove the seal from around the connectors.

– GENERAL RECOMMENDATIONS

Do not connect an earth to a stud with insulating pro- tection (paint,etc.).

Do not use more than two earth terminals on the same point.

Do not use power earths on the same point as elec- tronic earths.

To prevent water flowing into the connectors, make a low point just on the wiring routing (just before the con- nector).

For connections between fixed and mobile compo- nents, secure the wiring on the fixed part.

Overlapping of the battery feed wires (positive and negative) causes disruption; they must be secured separately.

Wiring mountings:

  • use plastic clips, ensuring that the colour coding is re- spected,

-do not use steel clips that are not protected with rub- ber,

  • keep the clips integrated into the wiring during a re- placement operation,
  • do not leave steering wheel wires without protection. Check that:
  • the shunts are correctly secured,
  • the connectors are correctly housed and locked. Wiring routing:
  • when it is visible it must be aesthetically pleasing, and resemble the routing marked during removal,
  • prohibit wiring routing in grooves and overlaps (risk of wear through friction),
  • prohibit mounting several wires on the same clip,
  • do not lock the connectors or wiring in areas that are sensitive to drilling (number plate etc.).

 

a Unclip the front bumper wiring at (2) .

IMPORTANT

To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 88A, Wiring harness, Wiring: Precau- tions for the repair, page 88A-3) .

WARNING

To prevent any damage during the removal oper- ation, check that the wiring is free from its mount- ings (retaining clip, plastic clip, adhesive tape, connector, etc.).

a Remove the front bumper wiring.

REFITTING

WARNING

To avoid damaging the connectors, consult the dis- connection procedures (see Connector: Discon- nection and reconnection) (Technical Note 6015A, 88A, Wiring).

REMOVAL

– REMOVAL PREPARATION OPERATION

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

a Switch off the ignition.

a Disconnect the battery (see 80A, Battery, Battery: Removal – Refitting, page 80A-2) .

a Remove the front bumper (see Front bumper as- sembly: Exploded view) (55A, Exterior protection).

– REMOVAL OPERATION

a

WARNING

To prevent any risk of noise, premature wear, short circuits, etc. after the refitting operation, mark the wiring routing and how to connect the connectors.

a Disconnect the front fog light connectors (1) . 145081

– REFITTING PREPARATION OPERATION

a If replacing with more complete wiring, immobilise the unused connectors (see Connector: Sealing and locking) (Technical Note 6015A, 88A, Wiring).

– REFITTING OPERATION

a Proceed in the reverse order to removal.

a Connect the battery (see 80A, Battery, Battery: Re- moval – Refitting, page 80A-2) .

– CHECKING AFTER REPAIR

a Switch on the ignition.

a Check the operation of all front bumper electrical components.

 

Equipment required

indelible pencil

Diagnostic tool

WARNING

To prevent any damage to the connectors, consult the disconnection procedures (see Connectors: Disconnection and reconnection) (Technical Note 6015A, 88A, Wiring).

 

Tightening torquesm

manual gearbox earth 24 N.m

cable bolt

earth cable nuts 8 N.m

Note:

For information on instrument connectors (see

Visu-Schéma).

 

IMPORTANT

To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair:

  • (See Wiring: Precautions for repair) (88A, Wir- ing),
  • (see Vehicle: Precautions for repair) (01D, Mechanical introduction).

    1. Symbol for an earth

IMPORTANT

To prevent any accidental triggering during an oper- ation on or near to a passive safety component, apply the procedure for deactivating the safety sys- tems (see 88C, Air bag and Pretensioners, Air- bag and pretensioners: Precautions for the repair, page 88C-3) (88C, Airbag and pretension- ers)

144441

    1. Symbol for a mounting (clip, clamp, etc.)

IMPORTANT

Never handle the pyrotechnic systems (pretension- ers or airbags) near to a source of heat or naked flame – they may be triggered.

    1. Symbol for a female connector (connection of 2 wires)
    2. Symbol for a male connector (connection of 2 wires)

REMOVAL

WARNING

To prevent damage to the wiring harness when refitting, observe the original routing.

I – REMOVAL PREPARATION OPERATION

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

a Switch off the ignition.

a Disconnect the battery (see 80A, Battery, Battery: Removal – Refitting, page 80A-2) (80A, Battery).

145231

a Remove:

  • the air resonator (1) (see Air resonator: Removal

– Refitting) (12A, Fuel mixture),

  • the cover to access the engine compartment fuse and relay box (2) ,
  • the closure component (3) of the engine compart- ment fuse and relay box,
  • the engine undertray bolts,
  • the engine undertray.

Note:

Mark the position of the fuses and relays before removal.

a Unclip the fuse holders and the engine harness re- lays from their mountings.

If replacing the engine wiring

a Remove the fuses.

II – REMOVAL OPERATION

145233

WIRING HARNESS

88A

Engine wiring: Removal – Refitting

K4M

145234

a Disconnect all the connectors.

a Unclip the engine wiring where indicated.

145235

a Disconnect all the connectors.

a Unclip the engine wiring where indicated.

145237

a Disconnect all the connectors.

a Unclip the engine wiring where indicated.

a

Note:

145232

Before removing the earth terminal, mark its position using a indelible pencil by drawing a line on the earth terminal and on the gearbox casing.

When reassembling, improper positioning of the earth terminal on the gearbox casing could result in damage to the earth terminal or earth wiring.

a Remove the earth terminals.

WARNING

To prevent any damage during the removal oper- ation, check that the wiring is free from its mount- ings (retaining clip, plastic clip, adhesive tape, connector, etc.).

a Remove the engine wiring.

REFITTING

– REFITTING PREPARATION OPERATION

If replacing the engine wiring

a Refit the fuses.

a If replacing with a complete wiring harness, lock the unused connectors (see Connectors: Sealing and locking) (Technical Note 6015A, 88A, Wiring).

– REFITTING OPERATION

a Proceed in the reverse order to removal.

Note:

Refit the earth terminal, aligning the indelible marks on the gearbox casing.

When reassembling, improper positioning of the earth terminal on the gearbox casing could result in damage to the earth terminal or earth wiring.

a Torque tighten:

the manual gearbox earth cable bolt (24 N.m),

  • the earth cable nuts (8 N.m).

a Connect the battery (see 80A, Battery, Battery: Re- moval – Refitting, page 80A-2) (80A, Battery).

– TEST OPERATION

a Switch on the ignition.

a Connect the Diagnostic tool.

a Check that there are no faults.

 

Equipment required

indelible pencil

Diagnostic tool

WARNING

To prevent any damage to the connectors, consult the disconnection procedures (see Connectors: Disconnection and reconnection) (Technical Note 6015A, 88A, Wiring).

 

Tightening torquesm

manual gearbox earth 24 N.m

cable bolt

earth cable nuts 8 N.m

Note:

For information on instrument connectors (see

Visu-Schéma).

 

IMPORTANT

To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair:

  • (See Wiring: Precautions for repair) (88A, Wir- ing),
  • (see Vehicle: Precautions for repair) (01D, Mechanical introduction).

    1. Symbol for an earth

IMPORTANT

To prevent any accidental triggering during an oper- ation on or near to a passive safety component, apply the procedure for deactivating the safety sys- tems (see 88C, Air bag and Pretensioners, Air- bag and pretensioners: Precautions for the repair, page 88C-3) (88C, Airbag and pretension- ers)

144441

    1. Symbol for a mounting (clip, clamp, etc.)

IMPORTANT

Never handle the pyrotechnic systems (pretension- ers or airbags) near to a source of heat or naked flame – they may be triggered.

    1. Symbol for a female connector (connection of 2 wires)
    2. Symbol for a male connector (connection of 2 wires)

REMOVAL

WARNING

To prevent damage to the wiring harness when refitting, observe the original routing.

I – REMOVAL PREPARATION OPERATION

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

a Switch off the ignition.

a Disconnect the battery (see 80A, Battery, Battery: Removal – Refitting, page 80A-2) (80A, Battery).

a Remove:

  • the cover to access the engine compartment fuse and relay box (1) ,
  • the closure component (2) of the engine compart- ment fuse and relay box,
  • the front bumper (see Front bumper assembly: Exploded view) (55A, Exterior protection),
  • the right-hand headlight (see 80B, Headlights, Headlight assembly: Exploded view, page 80B-

1) (80B, Headlights),

  • the engine cover,
  • the engine undertray bolts,
  • the engine undertray.

Note:

Mark the position of the fuses and relays before removal.

a Unclip the fuse holders and the engine harness re- lays from their mountings.

If replacing the engine wiring

a Remove the fuses.

145238

II – REMOVAL OPERATION

a Disconnect all the connectors.

a Unclip the engine wiring where indicated.

145243

145245

145246

145247

a Disconnect all the connectors.

a Unclip the engine wiring where indicated.

145248

145239

145240

145241

a Disconnect all the connectors.

a Unclip the engine wiring where indicated.

a

REFITTING

– REFITTING PREPARATION OPERATION

If replacing the engine wiring

a Refit the fuses.

145242

Note:

Before removing the earth terminal, mark its position using a indelible pencil by drawing a line on the earth terminal and on the gearbox casing.

When reassembling, improper positioning of the earth terminal on the gearbox casing could result in damage to the earth terminal or earth wiring.

a Remove the earth terminals.

WARNING

To prevent any damage during the removal oper- ation, check that the wiring is free from its mount- ings (retaining clip, plastic clip, adhesive tape, connector, etc.).

a Remove the engine wiring.

a If replacing with a complete wiring harness, lock the unused connectors (see Connectors: Sealing and locking) (Technical Note 6015A, 88A, Wiring).

– REFITTING OPERATION

a Proceed in the reverse order to removal.

Note:

Refit the earth terminal, aligning the indelible marks on the gearbox casing.

When reassembling, improper positioning of the earth terminal on the gearbox casing could result in damage to the earth terminal or earth wiring.

a Torque tighten:

the manual gearbox earth cable bolt (24 N.m),

  • the earth cable nuts (8 N.m).

a Connect the battery (see 80A, Battery, Battery: Re- moval – Refitting, page 80A-2) (80A, Battery).

– TEST OPERATION

a Switch on the ignition.

a Connect the Diagnostic tool.

a Check that there are no faults.

 

Equipment required

Diagnostic tool

Note:

For information on instrument connectors (see

Visu-Schéma).

    1. Symbol for an earth

IMPORTANT

To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair:

  • (See Wiring: Precautions for repair) (88A, Wir- ing),
  • (see Vehicle: Precautions for repair) (01D, Mechanical introduction).

IMPORTANT

To prevent any accidental triggering during an oper- ation on or near to a passive safety component, apply the procedure for deactivating the safety sys- tems (see 88C, Air bag and Pretensioners, Air- bag and pretensioners: Precautions for the repair, page 88C-3) (88C, Airbag and pretension- ers)

144441

    1. Symbol for a mounting (clip, clamp, etc.)

Tightening torquesm

earth nuts 8 N.m

    1. Symbol for a female connector (connection of 2 wires)
    2. Symbol for a male connector (connection of 2 wires)

IMPORTANT

Never handle the pyrotechnic systems (pretension- ers or airbags) near to a source of heat or naked flame – they may be triggered.

WARNING

To prevent damage to the wiring harness when refitting, observe the original routing.

WARNING

To prevent any damage to the connectors, consult the disconnection procedures (see Connectors: Disconnection and reconnection) (Technical Note 6015A, 88A, Wiring).

  1. Passenger compartment front wiring section on the dashboard cross member
  2. Passenger compartment front wiring section in the engine compartment
  3. Passenger compartment front wiring section on the floor
  4. Passenger compartment front wiring section in the front doors
  5. Passenger compartment front wiring section in the roof

REMOVAL

– REMOVAL PREPARATION OPERATION

a Lock the airbag computer using the Diagnostic tool (see Fault finding – Replacement of components) (88C, Airbags and pretensioners).

a Disconnect the battery (see 80A, Battery, Battery: Removal – Refitting, page 80A-2) (80A, Battery).

144392

– Passenger compartment front wiring section on the dashboard cross member

a Remove the dashboard (see Dashboard: Removal

– Refitting) (57A, Interior equipment).

– Passenger compartment front wiring section in the engine compartment.

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

a Remove:

    • the scuttle panel grille,
    • the front bumper (see Front bumper assembly: Exploded view) (55A, Exterior protection),
    • the headlights (see 80B, Headlights, Headlight assembly: Exploded view, page 80B-1) (80B, Headlights),
    • the front right-hand wheel arch liner (see Exterior body front trim assembly: Exploded view) (55A, Exterior protection),
    • the engine compartment fuse and relay box cover,
    • the expansion bottle (see Expansion bottle: Re- moval – Refitting) (19A, Cooling).

– Passenger compartment front wiring section on the floor

a Remove:

    • the front seats (see Front seat assembly: Ex- ploded view) (75A, Front seat frames and mecha- nisms),
    • the central console (see Centre console: Remov- al – Refitting) (57A, Interior equipment),
    • the floor carpet (see Roof trim assembly: Explod- ed view) (71A, Body internal trim),
    • the B-pillar trim (see Interior body side trim as- sembly: Exploded view) (71A, Body internal trim).

– Passenger compartment front wiring section in the front doors

a Remove the front side door trim (see Front side door trim: Removal – Refitting) (72A, Side opening elements trim).

– Passenger compartment front wiring section in the roof

a Remove:

    • the windscreen pillar trim (see Interior body side trim assembly: Exploded view) (71A, Body inter- nal trim).
    • the headlining partially (see Roof trim assembly: Exploded view) (71A, Body internal trim).

– REMOVAL OPERATION

  1. – Passenger compartment front wiring section on the dashboard cross member

a Disconnect all the connectors.

a Unclip the wiring section where indicated.

a Remove the earth terminals where indicated.

a Remove the wiring section.

144393

– Passenger compartment front wiring section in the engine compartment

144397

a Disconnect all the connectors.

a Unclip the wiring section where indicated.

a Remove the earth terminals where indicated.

a Remove the wiring section.

144398

– Passenger compartment front wiring section on the floor

a Disconnect all the connectors.

a Unclip the wiring section where indicated.

a Remove the earth terminals where indicated.

a Remove the wiring section.

144394

– Passenger compartment front wiring section on the floor

a Disconnect all the connectors.

a Unclip the wiring section where indicated.

a Remove the earth terminals where indicated.

a Remove the wiring section.

144396

– Passenger compartment front wiring section in the roof

a Disconnect all the connectors.

a Unclip the wiring section where indicated.

a Remove the earth terminals where indicated.

a Remove the wiring section.

REFITTING

REFITTING OPERATION

a Proceed in the reverse order to removal.

a Torque tighten the earth nuts (8 N.m).

a Connect the battery (see 80A, Battery, Battery: Re- moval – Refitting, page 80A-2) (80A, Battery).

a Unlock the airbag computer using the Diagnostic tool (see Fault finding – Replacement of compo- nents) (88C, Airbags and pretensioners).

144399

    1. Symbol for an earth

IMPORTANT

To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair:

  • (See Wiring: Precautions for repair) (88A, Wir- ing),
  • (see Vehicle: Precautions for repair) (01D, Mechanical introduction).

IMPORTANT

To prevent any accidental triggering during an oper- ation on or near to a passive safety component, apply the procedure for deactivating the safety sys- tems (see 88C, Air bag and Pretensioners, Air- bag and pretensioners: Precautions for the repair, page 88C-3) (88C, Airbag and pretension- ers)

144441

    1. Symbol for a mounting (clip, clamp, etc.)

Tightening torquesm

earth nuts 8 N.m

    1. Symbol for a female connector (connection of 2 wires)
    2. Symbol for a male connector (connection of 2 wires)

IMPORTANT

Never handle the pyrotechnic systems (pretension- ers or airbags) near to a source of heat or naked flame – they may be triggered.

WARNING

To prevent damage to the wiring harness when refitting, observe the original routing.

WARNING

To prevent any damage to the connectors, consult the disconnection procedures (see Connectors: Disconnection and reconnection) (Technical Note 6015A, 88A, Wiring).

Note:

For information on instrument connectors (see

Visu-Schéma).

  1. Passenger compartment rear wiring section on the floor
  2. Passenger compartment rear wiring section under the floor
  3. Passenger compartment rear wiring section on the body
  4. Passenger compartment rear wiring section in the rear doors
  5. Passenger compartment rear wiring section in the tailgate
  6. Passenger compartment rear wiring section in the wheel arches

REMOVAL

– REMOVAL PREPARATION OPERATION

a Disconnect the battery (see 80A, Battery, Battery: Removal – Refitting, page 80A-2) (80A, Battery).

144400

– Passenger compartment rear wiring section on the floor

a Remove:

    • the floor carpet (see Roof trim assembly: Explod- ed view) (71A, Body internal trim),
    • the B-pillar trim (see Interior body side trim as- sembly: Exploded view) (71A, Body internal trim).

a Lift up the rear bench seat base.

– Passenger compartment rear wiring section under the floor.

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

a Move the fuel tank away (see Fuel tank: Removal – Refitting) (19C, Tank).

– Passenger compartment rear wiring section on the body

a Remove (see Interior body side trim assembly: Exploded view) (71A, Body internal trim):

    • the C-pillar trims,
    • the parcel shelf side trims,
    • the upper C-pillar trims,
    • the luggage compartment side trims.

a Partially remove the headlining (see Roof trim as- sembly: Exploded view) (71A, Body internal trim).

– Passenger compartment rear wiring section in the rear doors

a Remove the rear side door trim (see Rear side door trim: Removal – Refitting) (72A, Side opening ele- ment trim).

– Passenger compartment rear wiring section in the tailgate

a Remove the tailgate trim (see ) (73A, Non-side opening elements trim).

– Passenger compartment rear wiring section in the wheel arches

a Remove:

    • the rear wheels (see Wheel: Removal – Refitting) (35A, Wheels and tyres)
    • the ABS sensor cover.

– REMOVAL OPERATION

  1. – Passenger compartment rear wiring section on the floor

a Disconnect all the connectors.

a Unclip the wiring section where indicated.

a Remove the earth terminals where indicated.

a Remove the wiring section.

144401

– Passenger compartment rear wiring section under the floor.

a Disconnect all the connectors.

a Unclip the wiring section where indicated.

a Remove the earth terminals where indicated.

a Remove the wiring section.

144406

– Passenger compartment rear wiring section on the body

Left-hand side

144404

Right-hand side

a Disconnect all the connectors.

a Unclip the wiring section where indicated.

a Remove the earth terminals where indicated.

a Remove the wiring section.

144408

– Passenger compartment rear wiring section in the rear doors

a Disconnect all the connectors.

a Unclip the wiring section where indicated.

a Remove the earth terminals where indicated.

a Remove the wiring section.

144402

– Passenger compartment rear wiring section in the tailgate

a Disconnect all the connectors.

a Unclip the wiring section where indicated.

a Remove the earth terminals where indicated.

a Remove the wiring section.

144410

– Passenger compartment rear wiring section in the wheel arches

a Disconnect all the connectors.

a Unclip the wiring section where indicated.

a Remove the earth terminals where indicated.

a Remove the wiring section.

REFITTING

REFITTING OPERATION

a Proceed in the reverse order to removal.

a Torque tighten the earth nuts (8 N.m).

a Connect the battery (see 80A, Battery, Battery: Re- moval – Refitting, page 80A-2) (80A, Battery).

144459

2 – PASSENGER’S FRONT AIRBAG

  1. – LIST OF COMPONENTS

No.

Description

(1)

Driver’s front airbag

(2)

Passenger front airbag

(3)

Front side airbag

(4)

Airbag computer

(5)

Side impact sensor

(6)

Inhibitor switch

  1. – LOCATION OF COMPONENTS 1 – DRIVER’S FRONT AIRBAG

Driver’s front airbag (1)

107811

Passenger front airbag (2)

– FRONT SIDE AIRBAG

Front side airbag (3)

107809

118625

– AIRBAG COMPUTER 6 – INHIBITOR SWITCH

Airbag computer (4)

– SIDE IMPACT SENSOR

Side impact sensor (5)

107830

118624

Inhibitor switch (6)

107802

Equipment required

Diagnostic tool

– PRECAUTIONS FOR REPAIR

IMPORTANT

All operations on airbag and pretensioner systems must be carried out by qualified trained personnel.

The airbags have a pyrotechnic gas generator, with an ignition module and bag which must not be sep- arated.

The pretensioners have a pyrotechnic gas genera- tor and an igniter which must, under no circum- stances, be separated.

IMPORTANT

Never handle the pyrotechnic systems (pretension- ers or airbags) near to a source of heat or naked flame – they may be triggered.

IMPORTANT

To prevent any accidental triggering whilst working on or near a pyrotechnic component (airbags or pretensioners), lock the airbag computer using the Diagnostic tool.

When this function is activated, all the trigger lines are inhibited and the airbag warning light on the instrument panel lights up continuously (ignition on).

(see Fault finding – Replacement of compo- nents) (88C, Airbag and pretensioners).

When working underneath the vehicle (on the body- work, sill panel, etc.) or for certain operations involving removal or refitting of seat trims, it is essential to lock the airbag computer using the Diagnostic tool and to disconnect the battery (see 80A, Battery, Battery: Re- moval – Refitting, page 80A-2) .

The pyrotechnic systems (pretensioners and airbags) must be checked using the Diagnostic tool :

  • after an accident,
  • after theft or attempted theft of the vehicle,
  • before selling a used vehicle.

– TRIGGERING OF THE SAFETY SYSTEMS

IMPORTANT

In order to prevent interference with the deployment of the airbags:

  • do not fit a cover to the front seats,
  • do not place objects in the area of deployment.

After detection of an impact, the airbag computer locks definitively and the « airbag fault » warning light is illu- minated on the instrument panel. The airbag computer and the side impact sensors must always be replaced.

IMPORTANT

To eliminate the risk of any accident, do not reuse pyrotechnic components.

It is essential to destroy pretensioners or airbags before scrapping a vehicle or a part only (see Air- bags and pretensioners: Recycling – Destruc- tion) .

– DURABILITY OF THE PYROTECHNIC COMPONENTS

The precautions which recommended that pyrotechnic components (airbags and pretensioners) were re- placed 10 years after the registration of the vehicle have now been lifted.

Pyrotechnic components (airbags and pretensioners) do not therefore require any maintenance.

IMPORTANT

To prevent the pyrotechnic components from being permanently deactivated or triggered (airbags or pretensioners), check the airbag computer using the Diagnostic tool.

 

REMOVAL

IMPORTANT

Consult the safety and cleanliness advice and oper- ation recommendations before carrying out any repair (see 88C, Air bag and Pretensioners, Air- bag and pretensioners: Precautions for the repair, page 88C-3) .

II – OPERATION FOR REMOVAL OF PART CONCERNED

I – REMOVAL PREPARATION OPERATION

a

a Disconnect the connector (1) .

a Remove:

  • the three airbag computer bolts (2) ,
  • the airbag computer.

107830

Equipment required

Diagnostic tool

Tightening torquesm

airbag computer bolts 8 N.m

a Lock the airbag computer (see Fault finding – Re- placement of components) (88C, Airbags and pre- tensioners).

IMPORTANT

To avoid any risk of triggering when working on or near a pyrotechnic component (airbags or pre- tensioners), lock the airbag computer using the diagnostic tool.

When this function is activated, all the trigger lines are inhibited and the airbag warning light on the instrument panel lights up continuously (igni- tion on).

a Switch off the ignition.

a Disconnect the battery (see 80A, Battery, Battery: Removal – Refitting, page 80A-2) .

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

REFITTING

– REFITTING OPERATION

a Refit:

    • the airbag computer,
    • the three airbag computer bolts.

a Torque tighten the airbag computer bolts (8 N.m).

a Connect the connector.

– FINAL OPERATION

a Refit the centre console (see Centre console: Re- moval – Refitting) (57A, Interior equipment).

a Connect the battery (see 80A, Battery, Battery: Re- moval – Refitting, page 80A-2) .

a If the airbag computer is being replaced, carry out the necessary operations using the Diagnostic tool (see Fault finding – Replacement of components) (88C, Airbags and pretensioners).

IMPORTANT

To avoid a fault with or even triggering of pyro- technic components (airbags or pretensioners), check the airbag computer using the diagnostic tool.

a Unlock the airbag computer (see Fault finding – Re- placement of components) (88C, Airbag and pre- tensioners).

IMPORTANT

Consult the safety and cleanliness advice and oper- ation recommendations before carrying out any repair (see 88C, Air bag and Pretensioners, Air- bag and pretensioners: Precautions for the repair, page 88C-3) .

REMOVAL

– REMOVAL PREPARATION OPERATION

a

IMPORTANT

To avoid any risk of triggering when working on or near a pyrotechnic component (airbags or pre- tensioners), lock the airbag computer using the diagnostic tool.

When this function is activated, all the trigger lines are inhibited and the airbag warning light on the instrument panel lights up continuously (igni- tion on).

IMPORTANT

Never handle the pyrotechnic systems (preten- sioners or airbags) near to a source of heat or naked flame – they may be triggered.

a Lock the airbag computer (see Fault finding – Re- placement of components) (88C, Airbags and pre- tensioners).

a Switch off the ignition.

a Disconnect the battery (see 80A, Battery, Battery: Removal – Refitting, page 80A-2) .

– OPERATION FOR REMOVAL OF PART CONCERNED

a Turn the steering wheel one quarter of a turn.

133234

133233

133235

a Unclip the driver’s front airbag by separating the clips (6) in the direction of the arrow (7) using a flat- blade screwdriver via the back of the steering wheel.

a

IMPORTANT

To prevent the any component from being thrown upwards, store the airbag with the inflatable cushion facing upwards.

133236

a Remove the driver’s front airbag.

REFITTING

– REFITTING PREPARATION OPERATION

a

IMPORTANT

After a seat belt pyrotechnic component is trig- gered, it is essential to replace certain parts (see 88C, Air bag and Pretensioners , Airbag and pretensioners: Precautions for the repair, page 88C-3) .

– REFITTING OPERATION FOR PART CONCERNED

a Connect the connector onto the driver’s front airbag.

a Clip the safety cover onto the driver’s front airbag connector.

a Refit the driver’s front airbag

a Clip the driver’s front airbag onto the steering wheel.

– FINAL OPERATION

a Connect the battery (see 80A, Battery, Battery: Re- moval – Refitting, page 80A-2) .

a

Note:

IMPORTANT

To eliminate the risk of any accident, do not reuse pyrotechnic components.

It is essential to destroy pretensioners or airbags before scrapping a vehicle or a part only (see Airbags and pretensioners: Recycling – Destruction) .

101920

IMPORTANT

To avoid a fault with or even triggering of pyro- technic components (airbags or pretensioners), check the airbag computer using the diagnostic tool.

a Unlock the airbag computer (see Fault finding – Re- placement of components) (88C, Airbag and pre-

The airbag has a connector which short circuits if disconnected, to prevent accidental triggering.

a Unclip the safety cover from the driver’s front airbag connector.

a Disconnect the connector (8) from the driver’s front airbag.

tensioners).

REMOVAL

IMPORTANT

Consult the safety and cleanliness advice and oper- ation recommendations before carrying out any repair (see 88C, Air bag and Pretensioners, Air- bag and pretensioners: Precautions for the repair, page 88C-3) .

– REMOVAL PREPARATION OPERATION

a

    • the steering wheel (see Steering wheel: Removal

– Refitting) (36A, Steering assembly),

Equipment required

Diagnostic tool

    • the steering column switch assembly (see 84A, Control – Signals, Steering column switch as- sembly: Removal – Refitting, page 84A-2) ,
    • the instrument panel (see 83A, Instrument panel, Instrument panel: Removal – Refitting, page 83A-1) ,

Tightening torquesm

passenger’s frontal air- 8 N.m

bag module nuts

    • the radio (see 86A, Radio, Radio: Removal – Re- fitting, page 86A-3) ,
    • the dashboard (see Dashboard: Removal – Refit- ting) (57A, Interior equipment).

– OPERATION FOR REMOVAL OF PART CONCERNED

107806

IMPORTANT

To avoid any risk of triggering when working on or near a pyrotechnic component (airbags or pre- tensioners), lock the airbag computer using the diagnostic tool.

When this function is activated, all the trigger lines are inhibited and the airbag warning light on the instrument panel lights up continuously (igni- tion on).

a

WARNING

To prevent damage to the wiring harness when refitting, observe the original routing.

IMPORTANT

Never handle the pyrotechnic systems (preten- sioners or airbags) near to a source of heat or naked flame – they may be triggered.

a Lock the airbag computer (see Fault finding – Re- placement of components) (88C, Airbags and pre- tensioners).

a Switch off the ignition.

a Disconnect the battery (see 80A, Battery, Battery: Removal – Refitting, page 80A-2) .

a Remove:

– the driver’s frontal airbag (see 88C, Air bag and Pretensioners, Driver’s frontal airbag: Removal

– Refitting, page 88C-6) ,

Mark the wiring routing at the airbag module.

a Remove the nuts (1) of the passenger’s frontal air- bag module.

REFITTING

I – REFITTING PREPARATION OPERATION

a

107809

101920

a Unlock the passenger’s frontal airbag connector (3) at (5) .

a Disconnect:

  • the passenger’s frontal airbag module connector (3) ,
  • the earth terminal (4) .

a Remove the passenger’s frontal airbag module.

a parts always to be replaced: Passenger’s frontal airbag mounting on dashboard

  1. – REFITTING OPERATION FOR PART CONCERNED

IMPORTANT

After a seat belt pyrotechnic component is trig- gered, it is essential to replace certain parts (see 88C, Air bag and Pretensioners , Airbag and pretensioners: Precautions for the repair, page 88C-3) ).

a

IMPORTANT

To prevent the airbag triggering, connect the earth wire before the igniter connector.

a Connect the following to the passenger’s frontal air- bag:

  • the earth terminal,
  • the passenger frontal airbag module connector.

a Lock the passenger frontal airbag connector.

a Refit:

  • the passenger’s frontal airbag module,
  • the new nuts of the passenger’s frontal airbag mod- ule.

a Tighten to torque the passenger’s frontal airbag module nuts (8 N.m).

a Refit the wiring at the passenger’s frontal airbag module in the position marked during removal.

– FINAL OPERATION

a Refit:

    • the dashboard (see Dashboard: Removal – Refit- ting) (57A, Interior equipment),
    • the radio (see 86A, Radio, Radio: Removal – Re- fitting, page 86A-3) ,
    • the instrument panel (see 83A, Instrument panel, Instrument panel: Removal – Refitting, page 83A-1) ,
    • the steering column switch assembly (see 84A, Control – Signals, Steering column switch as- sembly: Removal – Refitting, page 84A-2) ,
    • the steering wheel (see Steering wheel: Removal
      • Refitting) (36A, Steering assembly),
    • the driver’s frontal airbag (see 88C, Air bag and Pretensioners, Driver’s frontal airbag: Removal
      • Refitting, page 88C-6) .

a Connect the battery (see 80A, Battery, Battery: Re- moval – Refitting, page 80A-2) .

IMPORTANT

To prevent the pyrotechnic components from being permanently deactivated or triggered (air- bags or pretensioners), check the airbag com- puter using the Diagnostic tool.

a Unlock the airbag computer (see Fault finding – Re- placement of components) (88C, Airbag and pre- tensioners).

IMPORTANT

To eliminate the risk of any accident, do not reuse pyrotechnic components.

It is essential to destroy pretensioners or airbags before scrapping a vehicle or a part only (see Airbags and pretensioners: Recycling – Destruction) .

Tightening torquesm

side airbag nuts 10 N.m

The front (chest level) side airbag is mounted on the back of each front seat at the door side.

When it inflates, the airbag tears open the cover of the module and the foam and unclips the seat cover.

IMPORTANT

Consult the safety and cleanliness advice and oper- ation recommendations before carrying out any repair (see 88C, Air bag and Pretensioners, Air- bag and pretensioners: Precautions for the repair, page 88C-3) .

REMOVAL

– REMOVAL PREPARATION OPERATION

a

IMPORTANT

To avoid any risk of triggering when working on or near a pyrotechnic component (airbags or pre- tensioners), lock the airbag computer using the diagnostic tool.

When this function is activated, all the trigger lines are inhibited and the airbag warning light on the instrument panel lights up continuously (igni- tion on).

IMPORTANT

Never handle the pyrotechnic systems (preten- sioners or airbags) near to a source of heat or naked flame – they may be triggered.

a Lock the airbag computer (see Fault finding – Re- placement of components) (88C, Airbags and pre- tensioners).

a Switch off the ignition.

– OPERATION FOR REMOVAL OF PART CONCERNED

a Disconnect:

20998

101920

a Disconnect the battery (see 80A, Battery, Battery: Removal – Refitting, page 80A-2) .

a Remove:

  • the complete front seat (see Complete front seat: Removal – Refitting) (75A, Front seat frames and runners),
  • the front seat back trim (see Front seatback trim: Removal – Refitting) (77A, Front seat trim).
  • the front side airbag connector (1) by unclipping the safety cover,
  • the earth terminal (2) .

a Connect:

    • the earth terminal,
    • the front side airbag connector.

– FINAL OPERATION

a Refit:

    • the front seat back trim (see Front seatback trim: Removal – Refitting) (77A, Front seat trim),
    • the complete front seat (see Complete front seat: Removal – Refitting) (75A, Front seat frames and runners).

a Connect the battery (see 80A, Battery, Battery: Re- moval – Refitting, page 80A-2) .

a Remove:

  • the front side airbag nuts (3) ,
  • the front side airbag.

118621

IMPORTANT

To avoid a fault with or even triggering of pyro- technic components (airbags or pretensioners), check the airbag computer using the diagnostic tool.

a Unlock the airbag computer (see Fault finding – Re- placement of components) (88C, Airbag and pre- tensioners).

REFITTING

IMPORTANT

To eliminate the risk of any accident, do not reuse pyrotechnic components.

It is essential to destroy pretensioners or airbags before scrapping a vehicle or a part only.

– REFITTING PREPARATION OPERATION

a

IMPORTANT

After a seat belt pyrotechnic component is trig- gered, it is essential to replace certain parts.

(see 88C, Air bag and Pretensioners, Airbag and pretensioners: Precautions for the repair, page 88C-3) .

a Always replace the nuts for the front chest-level air- bag.

– REFITTING OPERATION FOR PART CONCERNED

a Refit:

    • the front chest-level side airbag,
    • the new nuts of the front side airbag.

a Torque tighten the side airbag nuts (10 N.m).

(see Airbags and pretensioners: Recycling – De- struction) .

IMPORTANT

To prevent the airbag triggering, connect the earth wire before the igniter connector.

REMOVAL

IMPORTANT

Consult the safety and cleanliness advice and oper- ation recommendations before carrying out any repair (see 88C, Air bag and Pretensioners, Air- bag and pretensioners: Precautions for the repair, page 88C-3) .

  1. – REMOVAL PREPARATION OPERATION

a

– OPERATION FOR REMOVAL OF PART CONCERNED

IMPORTANT

Tightening torquesm

side impact sensor bolt 8 N.m

To avoid any risk of triggering when working on or near a pyrotechnic component (airbags or pre- tensioners), lock the airbag computer using the diagnostic tool.

When this function is activated, all the trigger lines are inhibited and the airbag warning light on the instrument panel lights up continuously (igni- tion on).

a Lock the airbag computer (see Fault finding – Re- placement of components) (88C, Airbags and pre- tensioners).

a Switch off the ignition.

a Disconnect the battery (see 80A, Battery, Battery: Removal – Refitting, page 80A-2) .

a Remove the B-pillar trim (see B-pillar trim: Remov- al – Refitting) (71A, Body internal trim).

118624

a Loosen the side impact sensor bolt (1) by 6 turns.

a Remove the side impact sensor from its housing at (2) .

a Disconnect the connector (3) from the side impact sensor.

REFITTING

– REFITTING PREPARATION OPERATION

a parts always to be replaced: Side impact sen- sors

  1. – REFITTING OPERATION FOR PART CONCERNED

a Connect the side impact sensor connector.

a Fit the side impact sensor.

a Torque tighten the side impact sensor bolt (8 N.m).

– FINAL OPERATION

a Refit the B-pillar trim (see B-pillar trim: Removal – Refitting) (71A, Body internal trim).

a Connect the battery (see 80A, Battery, Battery: Re- moval – Refitting, page 80A-2) .

IMPORTANT

To avoid a fault with or even triggering of pyro- technic components (airbags or pretensioners), check the airbag computer using the diagnostic tool.

a Unlock the airbag computer (see Fault finding – Re- placement of components) (88C, Airbag and pre- tensioners).

REFITTING

Tightening torquesm

the buckle nut 25 N.m

REMOVAL

– REMOVAL PREPARATION OPERATION

a Remove:

    • the bolt (1) ,
    • the casing (2) .

– OPERATION FOR REMOVAL OF PART CONCERNED

a Remove:

    • the nut (3) ,
    • the seat belt buckle.

108291

108293

– REFITTING PREPARATION OPERATION

a Coat the threads of the front seat belt buckle bolts with HIGH STRENGTH THREAD LOCK (see Vehi-

cle: Parts and consumables for the repair) (MR 388, 04B, Parts and consumables).

– REFITTING OPERATION FOR PART CONCERNED

a Refit the buckle nut.

a Torque tighten the buckle nut (25 N.m).

– FINAL OPERATION

a Refit:

    • the casing
    • the cover bolt.

REFITTING

Tightening torquesm

bolts of the rear seat 21 N.m

belt stalks

REMOVAL

– REMOVAL PREPARATION OPERATION

a Remove the single unit rear bench seat base (see ) .

a Remove the single unit rear bench seatback (see ) .

a Remove the 1/3 or 2/3 rear bench seatback (see )

– REMOVAL OPERATION

  1. – REFITTING PREPARATION OPERATION

a Coat the threads of the rear seat belt stalk bolts us- ing HIGH STRENGTH THREAD LOCK (see Vehi-

cle: Parts and consumables for the repair) (04B, Consumables – Products).

– REFITTING OPERATION

a Proceed in the reverse order to removal.

a Torque tighten the bolts of the rear seat belt stalks (21 N.m).

a Remove:

  • the bolts (1) ,
  • the stalks of the rear seat belts.

145192

REMOVAL

Equipment required

Diagnostic tool

– REMOVAL PREPARATION OPERATION

a

Tightening torquesm

bolts of the height adjustment mechanism

21 N.m

inertia reel bolt

21 N.m

bolt of the seat belt return mechanism

21 N.m

bolt of the seat belt lower mounting

21 N.m

IMPORTANT

To avoid any risk of triggering when working on or near a pyrotechnic component (airbags or pre- tensioners), lock the airbag computer using the diagnostic tool.

When this function is activated, all the trigger lines are inhibited and the airbag warning light on the instrument panel lights up continuously (igni- tion on).

a Lock the airbag computer using the Diagnostic tool (see Fault finding – Replacement of components) (88C, Airbags and pretensioners).

IMPORTANT

To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 88C, Air bag and Pretensioners, Air- bag and pretensioners: Precautions for the repair, page 88C-3) .

a Switch off the ignition.

a Disconnect the battery (see 80A, Battery, Battery: Removal – Refitting, page 80A-2) .

– OPERATION FOR REMOVAL OF PART CONCERNED

IMPORTANT

Never handle the pyrotechnic systems (pretension- ers or airbags) near to a source of heat or naked flame – they may be triggered.

IMPORTANT

To eliminate the risk of any accident, do not reuse pyrotechnic components.

It is essential to destroy pretensioners or airbags before scrapping a vehicle or a part only (see Air- bags and pretensioners: Recycling – Destruc- tion) .

a Remove:

      • the cover of the seat belt lower bolt,
      • the seat belt lower bolt (1) .

108517

Note:

The seat belt must be handled by the inertia reel mechanism (risk of damaging the strap).

a Remove:

  • the cover of the seat belt upper bolt,
  • the seat belt upper bolt (2) .

WARNING

To prevent any risk of noise, premature wear, short circuits, etc. after the refitting operation, mark the wiring routing and how to connect the connectors.

108515

a

101920

a Remove the lower B-pillar trim (see B-pillar trim: Removal – Refitting) (71A, Body internal trim).

Mark the wiring routing at the front side seat belt in- ertia reel.

a Unclip the inertia reel connector safety clip.

a Disconnect the inertia reel connector.

a Refit the wiring at the front side seat belt inertia reel in the position marked during removal

a Connect the inertia reel connector.

a Clip on the inertia reel connector safety clip.

a Refit:

– the B-pillar trim (see B-pillar trim: Removal – Re- fitting) (71A, Body internal trim),

a Remove:

108519

a

Note:

Check that the seat belt is not twisted between the inertia reel and the front side seat belt return mechanism.

Refit the front side seat belt return mechanism

  • the bolt (3) from the inertia reel,
  • the inertia reel.

a Remove the height adjustment mechanism (de- pending on the vehicle equipment).

REFITTING

– REFITTING PREPARATION OPERATION

a parts always to be replaced: Front seat belt iner- tia reel bolt

a Always replace the return mechanism bolts and the lower mounting bolts of the front side seat belt.

– REFITTING OPERATION FOR PART CONCERNED

a Refit the height adjustment mechanism (depending on the vehicle equipment).

a Torque tighten the bolts of the height adjustment mechanism (21 N.m).

a Refit:

  • the inertia reel,
  • the inertia reel bolt.

a Tighten to torque the inertia reel bolt (21 N.m).

a Torque tighten the bolt of the seat belt return mechanism ( 21 N.m)

a

Note:

Check that the seat belt is not twisted between the front side seat belt return mechanism and the front side seat belt lower mounting.

Refit the lower mounting for the front side seat belt.

a Torque tighten the bolt of the seat belt lower mounting (21 N.m).

a Refit:

  • the cover of the seat belt upper bolt,
  • the cover of the seat belt lower bolt.

– FINAL OPERATION

a Connect the battery (see 80A, Battery, Battery: Re- moval – Refitting, page 80A-2) .

IMPORTANT

To avoid a fault with or even triggering of pyro- technic components (airbags or pretensioners), check the airbag computer using the diagnostic tool.

a Unlock the airbag computer using the Diagnostic tool (see Fault finding – Replacement of compo- nents) (88C, Airbags and pretensioners).

IMPORTANT

To eliminate the risk of any accident, do not reuse pyrotechnic components.

It is essential to destroy pretensioners or airbags before scrapping a vehicle or a part only (see Airbags and pretensioners: Recycling – Destruction) .

– CHECKING AFTER REPAIR

a Check the correct operation by unrolling the front side seat belt by 300 mm and letting it return twice

a Check that the front side seat belt locks correctly by pulling the front side seat belt strap with increasing speed 200 to 300 mm maximum until the inertia reel locks.

a Switch on the ignition.

a Check that there are no faults on the instrument pan- el.

Tightening torquesm

rear side seat belt bolts 21 N.m

REMOVAL

– REMOVAL PREPARATION OPERATION

a Remove (see ) :

    • the rear bench seat base,
    • the rear side seat belt lower bolt,
    • the single unit rear bench seatback.

a Remove the parcel shelf structure trim (see Interior body side trim assembly: Exploded view) .

– REMOVAL OPERATION

II – REFITTING OPERATION

a Proceed in the reverse order to removal.

a Torque tighten the rear side seat belt bolts (21 N.m).

a Remove:

  • the rear side seat belt inertia reel bolt (1) ,
  • the rear side seat belt.

REFITTING

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I – REFITTING PREPARATION OPERATION

a Coat the threads of the side seat belt bolts using

HIGH STRENGTH THREAD LOCK (see Vehicle:

Parts and consumables for the repair) (04B, Con- sumables – Products).

REMOVAL

Tightening torquesm

rear centre seat belt bolt

21 N.m

rear centre seat belt guide bolt

21 N.m

seat belt return mecha- nism bolt

21 N.m

REMOVAL PREPARATION OPERATION

OPERATION FOR REMOVAL OF PART CONCERNED

a Remove:

  • the single unit rear bench seat base (see Single unit rear bench seat base: Removal – Refitting) (76A, Rear seat frames and runners),
  • the 1/3 or 2/3 rear bench seatback (see 1/3 and 2/ 3 rear bench seatback: Removal – Refitting) (76A, Rear seat frames and runners) or the single unit rear bench seatback (see Single unit rear bench seatback: Removal – Refitting) (76A, Rear seat frames and runners).

a Pull down the 2/3 rear bench seatback (see 1/3 and 2/3 rear bench seatback: Removal – Refitting) (76A, Rear seat frames and runners) or the single unit rear bench seatback (see Single unit rear bench seatback: Removal – Refitting) (76A, Rear seat frames and runners).

a Remove the rear quarter panel trim (see Quarter panel trim: Removal – Refitting) (71A, Body inter- nal trim).

a Remove:

  • the rear centre seat belt bolt (2) ,
  • the rear centre seat belt.

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a parts always to be replaced: rear centre seat belt mounting

II – REFITTING OPERATION FOR PART CONCERNED

a Refit:

  • the rear centre seat belt,
  • the rear centre seat belt bolt.

a Torque tighten the rear centre seat belt bolt (21 N.m).

a Remove:

  • the rear centre seat belt guide bolt (3) ,
  • the rear centre seat belt guide (4) ,
  • the rear centre seat belt bolts (5) ,
  • the rear centre seat belt.

REFITTING

I – REFITTING PREPARATION OPERATION

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a

Note:

Check that the seat belt is not twisted between the inertia reel and the rear centre seat belt return mechanism.

a Refit:

  • the rear centre seat belt guide,
  • the rear centre seat belt guide bolt.

a Torque tighten the rear centre seat belt guide bolt (21 N.m).

a Refit the rear centre seat belt return mechanism.

a Torque tighten the seat belt return mechanism bolt (21 N.m).

a parts always to be replaced: rear centre seat belt mounting

a Coat the threads of the rear centre seat belt return mechanism bolts with HIGH STRENGTH THREAD LOCK (see Vehicle: Parts and consumables for the repair) (04B, Parts and consumables).

III – FINAL OPERATION

a Refit:

  • the 1/3 or 2/3 rear bench seatback (see 1/3 and 2/ 3 rear bench seatback: Removal – Refitting) (76A, Rear seat frames and runners) or the single unit rear bench seatback (see Single unit rear bench seatback: Removal – Refitting) (76A, Rear seat frames and runners),
  • the single unit rear bench seat base (see Single unit rear bench seat base: Removal – Refitting) (76A, Rear seat frames and runners).

a Refit the rear quarter panel trim (see Quarter panel trim: Removal – Refitting) (71A, Body internal trim).

a Fit the 2/3 rear bench seatback (see 1/3 and 2/3 rear bench seatback: Removal – Refitting) (76A, Rear seat frames and runners) or the single unit rear bench seatback (see Single unit rear bench seat- back: Removal – Refitting) (76A, Rear seat frames and runners).

 

WITH SEAT BELT NOT SECURED WARNING or ALOUCP

REMOVAL

REMOVAL OPERATION

a Switch off the ignition.

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a Disconnect the connector from the seat belt remind- er warning light (2) .

a Unclip the central trim starting at the bottom.

a Remove the dashboard central trim.

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REFITTING

REFITTING OPERATION

a Proceed in the reverse order to removal.

CHECKING AFTER REPAIR

a Switch on the ignition.

a Check that the seat belt reminder warning light illu- minates.

a Fasten the seat belts.

a Check that the warning light goes out.

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a Unclip the seat belt reminder warning light (1) .