6 Air conditioningphilch.free.fr/clio/clio3/MR392CLIO6.pdfCLIO III - Section 6 Contents Pages CLIO...

© Renault s.a.s 2007

"The repair procedures given by the manufacturer in this document are based on thetechnical specifications current when it was prepared.

The procedures may be modified as a result of changes introduced by the manufacturer inthe production of the various component units and accessories from which the vehicles areconstructed".

All rights reserved by Renault.

Copying or translating, in part or in full, of this document or use of the service part referencenumbering system is forbidden without the prior written authority of Renault.

JULY 2009 EDITION ANGLAISE

X85

6 Air conditioning

61A HEATING

62A AIR CONDITIONING

CLIO III - Section 6

Contents

Pages

CLIO III - Section 6ContentsPages

61A HEATING

Heating: List and location of components 61A-1

Cabin filter: Removal - Refitting 61A-17

Rear air distribution duct: Removal - Refitting 61A-19

Recirculation control cable: Removal - Refitting 61A-22

Air distribution cable: Removal - Refitting 61A-31

Air mixing cable: Removal - Refitting 61A-41

Distribution unit: Removal - Refitting 61A-50

Heater matrix: Removal - Refitting 61A-66

Fan assembly: Removal - Refitting 61A-73

Heating resistor relays: Removal - Refitting 61A-87

Heating resistors: Removal - Refitting 61A-90

Passenger compartment fan assembly control unit: Removal - Refitting 61A-91

Control panel: Removal - Refitting 61A-98

Front side air distribution duct: Removal - Refitting 61A-101

Front centre air distribution duct: Removal - Refitting 61A-104

Front footwell air distribution duct: Removal - Refitting 61A-106

Recirculation motor: Removal - Refitting 61A-116

Mixing motor: Removal - Refitting 61A-120

Distribution motor: Removal - Refitting 61A-126

Passenger compartment temperature sensor: Removal - Refitting 61A-131

Exterior air temperature sensor: Removal - Refitting 61A-133

Solar radiation sensor: Removal - Refitting 61A-134


Air conditioning: Precautions for the repair 62A-1

Air conditioning: Parts and consumables for the repair 62A-2

Air conditioning: List and location of components 62A-3

Air conditioning: Check 62A-6

Refrigerant circuit: Check 62A-9

61A HEATING

Contents

Refrigerant circuit: Draining - Filling 62A-10

Condenser: Removal - Refitting 62A-13

Dehydrator reservoir: Removal - Refitting 62A-17

Compressor: Removal - Refitting 62A-21

Expansion valve: Removal - Refitting 62A-26

Evaporator: Removal - Refitting 62A-30

Evaporator: Cleaning 62A-31

Expansion valve - intermediate pipe connecting pipe at the expansion valve outlet: Removal - Refitting 62A-32

Dehydrator reservoir - expansion valve connecting pipe: Removal - Refitting 62A-36

Expansion valve - compressor connecting pipe: Removal - Refitting 62A-41

Pressure sensor: Removal - Refitting 62A-46

Compressor - condenser connecting pipe: Removal - Refitting 62A-47

Compressor - intermediate pipe connecting pipe: Removal - Refitting 62A-51


61A-1

HEATINGHeating: List and location of components

LEFT-HAND DRIVE

61A

No. Description

(1) Control panel

(2) Cabin filter

(3) Rear air distribution duct

(4) Recirculation control cable

(5) Air distribution cable

(6) Air mixing cable

(7) Air distribution unit

(8) Heater matrix

(9) Fan assembly

(10) Heating resistor relay

(11) Heating resistors:

(12) Blower control unit.

(13) Front side air distribution duct

(14) Front central air distribution duct

(15) A-pillar air distribution duct

(16) External temperature sensor

CLIMATE CONTROL

No. Description

(17) Passenger compartment temperature sensor

(18) Solar radiation sensor

61A-2


LEFT-HAND DRIVE

61A

112842

112763

112729

112730

61A-3


LEFT-HAND DRIVE

61A

112843

112762

112766

112754

61A-4


LEFT-HAND DRIVE

61A

The evaporator is supplied already assembled in thedistribution unit. (7)

112759

112733

112743

113535

61A-5


LEFT-HAND DRIVE

61A

113534

112764

112752

112754

112403

112844

61A-6


LEFT-HAND DRIVE

61A

112742

112952

CLIMATE CONTROL

101716

112394

61A-7


LEFT-HAND DRIVE

61ACLIMATE CONTROL

CLIMATE CONTROL

No. Description

(19) Motor-driven fan assembly control unit

(20) Mixing motor

(21) Wiring harnesses

(22) Recirculation motor

(23) Distribution motor

(24) Fan assembly

(25) Cabin filter

(26) Heater matrix pipes

(27) Heater matrix

(28) Heater resistance


(30) Heater matrix pipe mounting bracket

61A-8


LEFT-HAND DRIVE

61A

113438

61A-9


RIGHT-HAND DRIVE

61A

No. Description

(1) Control panel

(2) Cabin filter

(3) Rear air distribution duct

(4) Recirculation control cable

(5) Air distribution cable

(6) Air mixing cable


(8) Heater matrix

(9) Fan assembly

(10) Heating resistor relay


(12) Blower control unit.

(13) Front side air distribution duct

(14) Front central air distribution duct

(15) A-pillar air distribution duct

(16) External temperature sensor

CLIMATE CONTROL

No. Description

(17) Passenger compartment temperature sensor

(18) Solar radiation sensor

61A-10


RIGHT-HAND DRIVE

61A

112842

112850

112729

112730

61A-11


RIGHT-HAND DRIVE

61A

112843

112848

112845

112754

61A-12


RIGHT-HAND DRIVE

61A

The evaporator is supplied already assembled in thedistribution unit. (7)

112759

112851

112839

113537

61A-13


RIGHT-HAND DRIVE

61A

113534

112846

112752

112754

112403

61A-14


RIGHT-HAND DRIVE

61A

112852

112844

112952

CLIMATE CONTROL

101716

61A-15


RIGHT-HAND DRIVE

61A

CLIMATE CONTROL

112394

CLIMATE CONTROL

No. Description

(19) Motor-driven fan assembly control unit

(20) Mixing motor

(21) Wiring harnesses

(22) Recirculation motor

(23) Distribution motor

(24) Fan assembly

(25) Cabin filter

(26) Heater matrix pipes

(27) Heater matrix



(30) Heater matrix pipe mounting bracket

61A-16


RIGHT-HAND DRIVE

61A

113438

61A-17

HEATINGCabin filter: Removal - Refitting

LEFT-HAND DRIVE

61A

REMOVAL

I - REMOVAL PREPARATION OPERATION

a Remove the clutch pedal (see Clutch pedal: Re-moval - Refitting) (MR392, 37A, Mechanical com-ponent controls).

II - OPERATION FOR REMOVAL OF PART CONCERNED

a Unclip the passenger compartment filter at (1) .

a Remove the cabin filter.

REFITTING

I - REFITTING PREPARATION OPERATION

a Check for foreign bodies in the passenger compart-ment filter housing, and clean thoroughly if neces-sary.

II - REFITTING OPERATION FOR PART CONCERNED

a Engage the upper section of the base of the filter intothe distribution unit.

a Clip the lower section of the filter base onto the dis-tribution unit.

III - FINAL OPERATION

a Refit the clutch pedal (see Clutch pedal: Removal -Refitting) (MR 392, 37A, Mechanical componentcontrols).

Note:

The cabin filter is located in the passenger side A-pillar.

SCHOOL VEHICLE

117576

Note:

Foreign bodies (leaves, insects etc.) are likely toaccumulate in the cabin filter. Remove the cabinfilter with care so as to prevent foreign bodiesgetting into the evaporator.

SCHOOL VEHICLE

61A-18

HEATINGCabin filter: Removal - Refitting

RIGHT-HAND DRIVE

61AREMOVAL

OPERATION FOR REMOVAL OF PART CONCERNED

a Unclip the passenger compartment filter at (1) .

a Remove the passenger compartment filter.

REFITTING


a Check for foreign bodies in the cabin filter housing,and clean thoroughly if necessary.


a Refit the cabin filter.

112850

Note:

Foreign bodies (leaves, insects etc.) are likely toaccumulate in the passenger compartment filter.Remove the filter with care so as to prevent for-eign bodies getting into the evaporator.

112850

61A-19

HEATINGRear air distribution duct: Removal - Refitting 61A

REMOVAL


a Lock the airbag computer using the Diagnostic tool(see Fault finding - Replacement of components)(MR 394, 88C, Airbags and pretensioners).

a Disconnect the battery (see Battery: Removal - Re-fitting) (MR 392, 80A, Battery).

a Remove the centre console (see Centre console:Removal - Refitting) (MR 393, 57A, Interior equip-ment).

a Unclip the trim at the base of the dashboard at (1)and (2) .

1 - Rear left-hand air distribution duct

a Remove the driver's seat (see Complete front seat:Removal - Refitting) (MR 393, 75A, Front seatframes and runners).

a Partially pull to one side the carpet underneath thedriver's seat.

2 - Rear right-hand air distribution duct

a Remove the front passenger seat (see Completefront seat: Removal - Refitting) (MR 393, 75A,Front seat frames and runners).

a Partially move the carpet under the front passengerseat to one side.



a Remove the clip (3) from the rear left-hand air distri-bution duct.

a Lift away the rear left-hand air distribution duct at (4).

a Remove the rear left-hand air distribution duct.

Equipment required

Diagnostic tool

112366

112729

61A-20



a Remove the clip (5) from the rear right-hand air dis-tribution duct.

a Lift away the rear right-hand air distribution duct at(6) .

a Remove the rear right-hand air distribution duct.

REFITTING

I - REFITTING OPERATION FOR PART CONCERNED


a Refit:

- the rear left-hand air distribution duct,

- the rear left-hand air distribution duct clip (7) .

112730

112729

61A-21



a Refit:

- the rear right-hand air distribution duct,

- the rear right-hand air distribution duct clip (8) .

II - FINAL OPERATION.


a Position the carpet underneath the driver's seat.

a Refit the driver's seat (see Complete front seat:Removal - Refitting) (MR 393, 75A, Front seatframes and runners).


a Fit the carpet under the front passenger seat.

a Refit the front passenger seat (see Complete frontseat: Removal - Refitting) (MR 393, 75A, Frontseat frames and runners).

a Clip on the dashboard lower trim.

a Refit the centre console (see Centre console: Re-moval - Refitting) (MR 393, 57A, Interior equip-ment).

a Connect the battery (see Battery: Removal - Refit-ting) (MR 392, 80A, Battery).

a Unlock the airbag computer using the Diagnostictool (see Fault finding - Replacement of compo-nents) (MR 394, 88C, Airbags and pretensioners).

112730

61A-22

HEATINGRecirculation control cable: Removal - Refitting

LEFT-HAND DRIVE, and AIR CONDITIONING or STANDARD HEATING

61A

REMOVAL


a Partially remove seal (1) .

a Remove the side panel (2) .

a Remove the bolt (3) from the base of the dashboard.

a Unclip the trim piece (4) from the driver's side dash-board lower cover.

a Remove the bolts (5) from the lower cover.

a Remove the lower cover (6) .

a Disconnect the connectors (depending on equip-ment level).


Special tooling required

Car. 1363 Set of tr im removal levers.

112378

112379

112380

112381

61A-23



61A

a Unclip the trim at (7) and (8) at the base of the dash-board.

a Remove the radio (see Radio: Removal - Refitting)(MR 392, 86A, Radio).

a Remove the radio navigation system (see Radionavigation: Removal - Refitting) (MR 392, 83C,On-board telematics system).

a Unclip the glovebox using the (Car. 1363).

a Unclip the centre trim piece beginning with the uppersection.

a Disconnect the connectors.

112366

RADIO NO. 01 or RADIO NO. 02 or RADIO NO. 03or RADIO NO. 04 or RADIO NO. 05 or RADIO NO.06

NAVIGATION AID 1

WITHOUT NAVIGATION AID, and VEHICLE WITH-OUT RADIO

112389

112390

61A-24



61A

a Remove the air conditioning control panel bolts (9) .

a Move the air conditioning control panel away fromthe dashboard.


a Remove the air recirculation control cable from thecontrol panel.

a Disconnect at (10) .

a Remove the bracket (11) .

a Extract the ball joint (12) .

a Unclip the cable sleeve stop (13) from the distribu-tion unit.

a Remove:

- the ball joint on the air recirculation flap (14) ,

- the air recirculation control cable.

112842

102011

112843

Note:

Note the route of the air recirculation controlcable.

61A-25



61AREFITTING


a Refit the air recirculation control cable.

a Refit the ball joint on the air recirculation flap (16) .

a Clip the cable sleeve stop (15) onto the distributionunit.

a Refit the air recirculation control cable on the controlpanel.

a Clip the sleeve stop at (17) .

a Refit the ball joint (18) .


a Position the air conditioning control panel on thedashboard.

a Refit the air conditioning control panel bolts (19) .

a Connect the central trim connectors.

a Clip in the centre trim piece beginning with the lowersection.

a Refit the radio (see Radio: Removal - Refitting)(MR 392, 86A, Radio).

a Refit the radio navigation system (see Radio navi-gation: Removal - Refitting) (MR 392, 83C, On-board telematics system).

a Clip on the glovebox.



112843

102011

112842


NAVIGATION AID 1


61A-26



61Aa Refit:

- the lower cover,

- the lower cover bolts,

- the bolts to the base of the dashboard.

a Clip on the driver's side dashboard lower cover trimpiece.

a Refit:

- the side panel,

- the seal.

61A-27


RIGHT-HAND DRIVE, and AIR CONDITIONING or STANDARD HEATING

61A

REMOVAL


a Remove:

- the glovebox (see Glovebox: Removal - Refit-ting) (MR 393, 57A, Interior equipment),

- the centre console (see Centre console: Removal- Refitting) (MR 393, 57A, Interior equipment).









112366

WITHOUT NAVIGATION AID, and RADIO NO. 01or RADIO NO. 02 or RADIO NO. 03 or RADIO NO.04 or RADIO NO. 05 or RADIO NO. 06

NAVIGATION AID 1


112389

112390

61A-28



61A




a Remove the air recirculation control cable from thecontrol panel.




a Unclip the cable sleeve stop (7) from the distributionunit.

a Remove:

- the ball joint on the air recirculation flap (8) ,

- the air recirculation control cable.

112842

102011

112843

Note:

Note the route of the air recirculation controlcable.

61A-29



61AREFITTING


a Refit the ball joint on the air recirculation flap (10) .


a Refit the air recirculation control cable for the controlpanel.










a Clip the glovebox in position.


a Refit:

- the centre console (see Centre console: Removal- Refitting) (MR 393, 57A, Interior equipment),

112843

102011

112842


NAVIGATION AID 1


61A-30



61A- the glovebox (see Glovebox: Removal - Refit-ting) (MR 393, 57A, Interior equipment),

61A-31

HEATINGAir distribution cable: Removal - Refitting


61A

REMOVAL


a Remove:











112366


NAVIGATION AID 1


112389

112390

61A-32



61A


a Move the air conditioning control panel to one side.


a Remove the air conditioning control panel air distri-bution control cable.

a Detach at (4) .

a Move the bracket (5) to one side.



a Remove:

- the ball joint (8) on the distribution flap,

- the air distribution control cable.

112842

102011

112762

Note:

Note the route of the air distribution control cable.

61A-33



61AREFITTING


a Refit:


- the ball joint (10) on the distribution flap.

a Clip the sleeve stop (9) onto the distribution unit.

a Refit the air conditioning control panel air distributioncontrol cable.




a Position the air conditioning control panel.

a Refit the bolts (13) for the air conditioning controlpanel onto the dashboard.







a Refit:


112762

102011

112842


NAVIGATION AID 1


61A-34



61A- the glovebox (see Glovebox: Removal - Refit-ting) (MR 393, 57A, Interior equipment),

61A-35



61A

REMOVAL











112366


NAVIGATION AID 1


112389

112390

61A-36



61A



a Partially remove the seal (4)

a Remove the side panel (5)



112842

112378

112379

112380

61A-37



61A

a Remove the bolts (8) from the driver's side dash-board lower cover.

a Take out the driver's side dashboard lower cover (9).

a Disconnect the connectors from the driver's sidedashboard lower cover (depending on the equip-ment level).

a Lift the carpet to access the stiffener bolts.

a Unclip the fuse box (10) from the dashboard beamstiffener plate.

a Remove:

- the bolts (11) from the dashboard beam stiffenerplate,

- the dashboard beam stiffener plate.


a Remove the air conditioning control panel distribu-tion control cable.




112381 112853

102011

61A-38



61A


a Remove:

- the ball joint (16) on the air distribution flap,


REFITTING


a Refit:


- the ball joint (18) on the air distribution flap.


a Refit the air conditioning control panel air distributioncontrol cable.



112848

Note:

Note the route of the air distribution control cable.

112848

102011

61A-39



61AII - FINAL OPERATION.

a Refit:

- the dashboard beam stiffener plate.

- the bolts (21) from the dashboard beam stiffenerplate.

a Torque tighten the dashboard beam stiffener platebolts (21 Nm).

a Clip the fuse box (22) onto the dashboard beam stiff-ener plate.

a Refit the floor carpet.










112853

Note:

Check that the floor carpet reaches under theaccelerator pedal end-stop.

112842


NAVIGATION AID 1


61A-40



61Aa Connect the connectors to the driver's side dash-

board lower cover (depending on the equipment lev-el).

a Refit:

- the driver's side dashboard lower cover,

- the bolts from the driver's side dashboard cover.


a Refit:

- the bolts to the base of the dashboard,

- the side panel,

- the seal.

61A-41

HEATINGAir mixing cable: Removal - Refitting


61A

REMOVAL











112378

112379

112380

112381

61A-42



61Aa Remove the centre console (see Centre console:

Removal - Refitting) (MR 393, 57A, Interior equip-ment).

a unclip the trim at (7) and (8) at the base of the dash-board.



a Unclip the glovebox using the (Car. 1363). a Unclip the centre trim piece beginning with the uppersection.


112366


NAVIGATION AID 1


112389

112390

61A-43



61A




a Remove the air conditioning control panel air mixingcontrol cable.





a Remove:

- the ball joint (14) on the air mixing flap,

- the air mixing control cable.

112842

102011

112761

112766

Note:

Note the route of the air mixing control cable.

61A-44



61AREFITTING


a Refit:


- the ball joint (15) on the air mixing flap.


a Refit the air conditioning control panel air mixingcontrol cable.







a Clip on the centre trim starting at the top.


112766

112761

102011

112842


61A-45



61A





a connect the connectors to the driver's side dash-board lower cover (depending on the equipment lev-el).

a Refit:

- the driver's side dashboard lower cover,

- the bolts from the driver's side dashboard lowercover.


a Refit:

- the bolts to the base of the dashboard,

- the side panel,

- the seal.

NAVIGATION AID 1


61A-46



61A

REMOVAL


a Remove:











112366


NAVIGATION AID 1


112389

112390

61A-47



61A




a Remove the air conditioning control panel air mixingcontrol cable.





a Remove:

- the ball joint (8) on the air mixing flap,


112842

102011

112845

Note:

Note the route of the air mixing control cable.

61A-48



61AREFITTING


a Refit:


- the ball joint (10) on the air mixing flap.


a Refit the air conditioning control panel air mixingcontrol cable.












a Refit:


112845

102011

112842


NAVIGATION AID 1


61A-49



61A- the glovebox (see Glovebox: Removal - Refit-ting) (MR 393, 57A, Interior equipment).

61A-50

HEATINGDistribution unit: Removal - Refitting

AIR CONDITIONING

61A

REMOVAL


a Drain the refrigerant circuit using the refrigerantcharging station (see 62A, Air conditioning, Re-frigerant circuit: Draining - Filling, page 62A-10) .



a Remove:

- the engine cover,

- the windscreen wiper arms (see Windscreen wip-er arm: Removal - Refitting) (MR 392, 85A, Wip-ing - Washing),

- the scuttle panel grille (see Scuttle panel grille:Removal - Refitting) (MR 393, 56A, Exteriorequipment),

- the scoop under the scuttle panel grille (see Scoopunder the scuttle panel grille: Removal - Refit-ting) (MR 393, 56A, Exterior equipment).

a Fit hose clamps (Ms. 583) to the heater matrix hosesat (1) .

a Remove:

- the heater matrix hose clips,

- the heater matrix hoses.


Ms. 583 Pipe clamps.


Equipment required

refrigerant charging station

Diagnostic tool

IMPORTANT

Consult the safety and cleanliness advice and oper-ation recommendations before carrying out anyrepair (see 62A, Air conditioning, Air condition-ing: Precautions for the repair, page 62A-1) .

112744

61A-51


AIR CONDITIONING

61A

a Remove the mountings from the bulkhead sound-proofing.

a Lift away the bulkhead soundproofing.

a Remove the bolts (2) from the pipe unions on the ex-pansion valve.

a Separate the pipe unions from the expansion valve.

a Fit plugs into the openings.

a Remove:

- the driver's front airbag (see Driver's frontal air-bag: Removal - Refitting) (MR 392, 88C, Airbagand pretensioners),

- the steering wheel (see Steering wheel: Removal- Refitting) (MR 392, 36B, Power-assisted steer-ing),

- the steering column switch assembly (see Steer-ing column switch assembly: Removal - Refit-ting) (MR 392, 84A, Control - Signals).


a Remove the radio navigation system (see Radionavigation: Removal - Refitting) (MR392, 83C,On-board telematics system).


a Remove:


- the control panel (see 61A, Heating, Control pan-el: Removal - Refitting, page 61A-98) ,


- the A-pillar trims (see Windscreen pillar trim: Re-moval - Refitting) (MR 393, 71A, Body internaltrim),

- the tweeter speakers (see Tweeter: Removal -Refitting) (MR 392, 86A, Radio),

- the offset multimedia socket computer (see Offsetmultimedia socket computer: Removal - Refit-ting) ,

- the dashboard (see Dashboard: Removal - Refit-ting) (MR 393, 57A, Interior equipment),

- the front side air distribution ducts (see 61A, Heat-ing, Front side air distribution duct: Removal -Refitting, page 61A-101) ,

- the front centre air distribution duct (see 61A, Heat-ing, Front centre air distribution duct: Removal- Refitting, page 61A-104) ,

- the steering column (see Steering column: Re-moval - Refitting) (MR 392, 36B, Power-assistedsteering),

112745

WARNING

In order to avoid any refrigerant leaks, do notdamage (deform, twist, etc.) the pipe.

WARNING

To prevent moisture from entering the system,place plugs on the cold loop components whichare open to the air.


NAVIGATION AID 1


61A-52


AIR CONDITIONING

61A- the front wings (see Front wing: Removal - Refit-ting) (MR 393, 42A, Upper front structure),

- the front doors (see Front side door: Removal -Refitting) (MR 393, 47A, Side doors),

- the dashboard cross member (see Dashboardcross member: Removal - Refitting) (MR 393,42A, Upper front structure).


a Separate the C-pillar air distribution ducts from thedistribution unit.

a Disconnect:

- the heating resistor connector,

- the blower assembly control unit connector.

a Remove the distribution unit.

a Remove:

- the bolts (3) from the heater matrix pipe bracket onthe distribution unit,

- the bolt (4) from the heater matrix pipe bracket.

a Unclip the heater matrix pipe bracket.

a Remove:

- the heater matrix pipe bracket on the distributionunit,

- the heater matrix pipes,

- the bolts (5) from the heater matrix,

- the heater matrix.

112735

61A-53


AIR CONDITIONING

61A

a Remove:

- the heating resistor bolts,

- the heating resistor (6) .

a Disconnect the blower assembly connector.

a Press on the blower assembly tab.

a Turn the blower assembly towards the right.

a Remove:

- the blower assembly (7) ,

- the expansion valve (8) ,

- the cabin filter (9) ,

- the evacuation ring (10) ,

- the anti-rotation pad (11) ,

- the fan assembly control unit (12) ,

- the glovebox air distribution duct (13) ,

- the control cables (14) .

118798

61A-54


AIR CONDITIONING

61AREFITTING


a Check that the parts are in good condition and re-place any defective parts, if necessary.

a Refit:

- the cabin filter,

- the anti-rotation pad,

- the evacuation ring,

- the glovebox air distribution duct,

- the blower assembly,

- the expansion valve,

- the fan assembly control unit,

- the heating resistor,

- the heater matrix,

- the heater matrix pipes.

a Clip the heater matrix pipe bracket onto the heatermatrix.

a Refit:

- the heater matrix pipe bracket bolt on the heatermatrix,


- the bolts for the heater matrix pipe retaining brack-et on the distribution unit.


a Connect the C-pillar air distribution ducts onto thedistribution unit.

a Refit the distribution unit.

a Connect:




a Refit:

- the dashboard cross member (see Dashboardcross member: Removal - Refitting) (MR 393,42A, Upper front structure),


- the front wings (see Front wing: Removal - Refit-ting) (MR 393, 42A, Upper front structure),











a Clip the storage compartment in position.

a Refit the radio navigation system (see Radio navi-gation: Removal - Refitting) (MR 392, 83C, Onboard telematics system).


NAVIGATION AID 1

61A-55


AIR CONDITIONING

61A


a Refit:

- the steering column switch assembly (see Steer-ing column switch assembly: Removal - Refit-ting) (MR 392, 84A, Control - Signals),



- the heater matrix hoses,

- the heater matrix hose clips.

a Remove the hose clamps (Ms. 583) from the heatermatrix hoses.

a

a Replace the seals.

a Lubricate the seals using recommended air condi-tioning oil to make fitting easier.

a Fit the pipe unions to the expansion valve.

a Refit the bolts to the pipe unions on the expansionvalve.

a Tighten the pipe union bolts.

a Fit the bulkhead soundproofing.

a Refit:

- the bulkhead soundproofing mountings,

- the scoop under the scuttle panel grille (see Scoopunder the scuttle panel grille: Removal - Refit-ting) (MR 393, 56A, Exterior equipment),



- the engine cover.



a Perform the following operations:

- top up the coolant (see Cooling system: Draining- Refilling) (MR 392, 19A, Cooling),

- bleed the cooling system (see Cooling system:Draining - Refilling) (MR 392, 19A, Cooling).

a Check the cooling system (see Engine coolingsystem: Check) (MR 392, 19A, Cooling).

a Fill up the refrigerant circuit using the refrigerantcharging station (see 62A, Air conditioning, Re-frigerant circuit: Draining - Filling, page 62A-10) .

a Check that the air conditioning system is operatingcorrectly (see 62A, Air conditioning, Air condi-tioning: Check, page 62A-6) .

a Check for leaks (see 62A, Air conditioning, Refrig-erant circuit: Check, page 62A-9) .


WARNING

To avoid any leaks, check that the pipe surface issound before positioning the new seal. The sur-face must be clean and scratch free.

Note:

A summary table gives the quantity of refrigerantin the system according to the engine type (see62A, Air conditioning, Air conditioning: Partsand consumables for the repair, page 62A-2) .

61A-56


STANDARD HEATING

61A

REMOVAL



a Place hose clamps (Ms. 583) on the heater matrixhoses at (1) .

a Remove:




a Remove:





a Remove the radio navigation system (see Radionavigation: Removal - Refitting) (MR 392, 83C,On board telematics system).


a Remove:














Equipment required

Diagnostic tool

112744


NAVIGATION AID 1


61A-57


STANDARD HEATING

61A- the front wings (see Front wing: Removal - Refit-ting) (MR 393, 42A, Upper front structure),





a Disconnect:




a Remove:


- the bolt (3) from the heater matrix pipe bracket.


a Remove:





112735

61A-58


STANDARD HEATING

61A

a Remove the heating resistor (5) .




a Remove:




- the control cables (9) .

REFITTING



a Refit:

- the cabin filter,



- the control cables,



- the heater matrix pipes.


a Refit:



- the bolts from the heater matrix pipe bracket on thedistribution unit.


a Connect the C-pillar air distribution ducts to the dis-tribution unit.


a Connect:


118797

61A-59


STANDARD HEATING

61A- the blower assembly control unit connector.


a Refit:

















a Refit:







a Remove the hose clamps (Ms. 583).







NAVIGATION AID 1


61A-60


CLIMATE CONTROL

61A

REMOVAL





a Remove:

- the engine cover,



- the scoop under the scuttle panel grille (see Scoopunder the scuttle panel grille: Removal - Refit-ting) (MR 393, 56A, Exterior equipment).

a Fit hose clamps (Ms. 583) to the heater matrix hosesat (1) .

a Remove:






Equipment required


Diagnostic tool

IMPORTANT


112744

61A-61


CLIMATE CONTROL

61A



a Remove the bolts (2) from the pipe unions on the ex-pansion valve.

a Separate the pipe unions from the expansion valve.


a Remove:







a Remove:





- the solar radiation detector (see 61A, Heating, So-lar radiation sensor: Removal - Refitting, page61A-134) ,






112745

WARNING


WARNING



NAVIGATION AID 1


61A-62


CLIMATE CONTROL

61A- the steering column (see Steering column: Re-moval - Refitting) (MR 392, 36B, Power-assistedsteering),






a Disconnect:


- the motors and blower assembly control unit feedwiring connector.


a Remove:


- the bolts (4) from the heater matrix pipe bracket.


a Remove:





112735

61A-63


CLIMATE CONTROL

61A

a Remove:

- the heating resistor bolts,

- the heating resistor (6) .




a Remove:


- the distribution motor (8) ,


- the expansion valve (10) ,


- the evacuation ring (12) ,

- the anti-rotation pad (13) ,

- the air mixing motor (14) ,

- the wiring (15) ,

- the recirculation motor (16) ,

- the glovebox air distribution duct (17) .

REFITTING



a Refit:


- the cabin filter,

- the anti-rotation pad,

- the evacuation ring,



- the glovebox air distribution duct,

- the recirculation motor,

- the air mixing motor,

- the distribution motor,

- the wiring,



118799

61A-64


CLIMATE CONTROL

61A- the heater matrix pipes.


a Refit:



- the bolts from the heater matrix pipe bracket on thedistribution unit.


a Connect the C-pillar air distribution ducts onto thedistribution unit.


a Connect:


- the motors and blower assembly control unit feedwiring connector.


a Refit:


















a Refit:






a Remove the hose clamps (Ms. 583) from the heatermatrix hoses.


NAVIGATION AID 1


61A-65


CLIMATE CONTROL

61Aa

a Replace the seals.

a Lubricate the seals using recommended air condi-tioning oil to make fitting easier.

a Fit the pipe unions to the expansion valve.

a Refit the bolts to the pipe unions on the expansionvalve.

a Tighten the pipe union bolts.


a Refit:


- the scoop under the scuttle panel grille (see Scoopunder the scuttle panel grille: Removal - Refit-ting) (MR 393, 56A, Exterior equipment),



- the engine cover.










WARNING

To avoid any leaks, check that the pipe surface issound before positioning the new seal. The sur-face must be clean and scratch free. Note:

A summary table gives the quantity of refrigerantin the system according to the engine type (see62A, Air conditioning, Air conditioning: Partsand consumables for the repair, page 62A-2) .

61A-66

HEATINGHeater matrix: Removal - Refitting

LEFT-HAND DRIVE

61A

REMOVAL



a Remove:





a Partially remove the door seal. (4)



Tightening torquesm

dashboard cross mem-ber reinforcement bolts

21 N.m

112744

112366

112378

61A-67


LEFT-HAND DRIVE

61A


a Remove the bolt (6) from the lower trim on the baseof the dashboard on the driver's side.

a Unclip the trim (7) .

a Remove the bolts (8) from the dashboard lower trimon the driver's side.

a Remove the dashboard lower trim on the driver'sside (9) .


a Unclip:

- the fuse and relay box (10) ,

- the heating resistor relays (11) .

a Lift the carpet to access the dashboard cross mem-ber reinforcement bolts.

112379

112380

112381

113535

61A-68


LEFT-HAND DRIVE

61A

a Remove:

- the dashboard cross member reinforcement bolts(12) ,

- the dashboard cross member reinforcement (13) .

a Put a protective cover on the carpet.


a Remove:

- the bolts (14) from the heater matrix pipe bracketon the distribution unit,

- the heater matrix pipe bracket on the distributionunit.

- the heater matrix bolts (15) .

a Remove the bolt (16) from the heater matrix pipebracket.

a Put a container in place to recover the coolant.

a Move the heater matrix and its piping to one side.

a Unclip the heater matrix pipe bracket (17) on theheater matrix.

a Remove the heater matrix.

112753

112735

112733

109612

61A-69


LEFT-HAND DRIVE

61AREFITTING


a Replace the seals (18) between the pipes and theheater matrix.


a Refit:



- the heater matrix bolts.


a Refit:


- the bolts from the heater matrix pipe bracket on thedistribution unit,

- the bolt from the heater matrix pipe bracket.


a Refit:

- the dashboard cross member reinforcement,

- the bolts from the dashboard cross member rein-forcement.

a Torque tighten the dashboard cross member rein-forcement bolts (21 N.m).


a Clip on:

- heater resistor relays,

- the fuse and relay box.

a Connect the dashboard lower trim connectors on thedriver's side.

a Fit the dashboard lower trim on the driver's side.

a Refit:

- the dashboard lower trim bolts on the driver's side,

- the dashboard lower trim bolt.


a Refit:

- the side panel,

- the door seal.


a Refit:









109611

WARNING


Note:


61A-70


RIGHT-HAND DRIVE

61A

REMOVAL



a Remove:





a Remove the glovebox (see Glovebox: Removal -Refitting) (MR 393, 57A, Interior equipment).

a Put a protective cover on the carpet.


a Remove:

- the bolts (4) from the heater matrix pipe bracket onthe heater matrix,


- the heater matrix bolts (5) .



112744

112366

112735

61A-71


RIGHT-HAND DRIVE

61A

a Remove the bolt (6) from the heater matrix pipebracket.

a Put a container in place to recover the coolant.

a Move the heater matrix and its piping to one side.

a Unclip the heater matrix pipe bracket (7) on the heat-er matrix.

a Remove the heater matrix.

REFITTING


a Replace the seals (8) between the pipes and theheater matrix.


a Refit the heater matrix.


a Refit:


- the bolts from the heater matrix pipe bracket on thedistribution unit,

- the bolt from the heater matrix pipe bracket.


a Refit the glovebox (see Glovebox: Removal - Refit-ting) (MR 393, 57A, Interior equipment).


112851

109612

109611

WARNING


61A-72


RIGHT-HAND DRIVE

61Aa Refit the centre console (see Centre console: Re-

moval - Refitting) (MR 393, 57A, Interior equip-ment).

a Refit:



- the heater matrix bolts,








61A-73

HEATINGFan assembly: Removal - Refitting

LEFT-HAND DRIVE

61A

REMOVAL


a Remove:


- the front right-hand A-pillar air distribution duct (see61A, Heating , Front footwell air distributionduct: Removal - Refitting, page 61A-106) .

a Remove:


- the dashboard cross member reinforcement tie-rod.


a Disconnect the blower assembly connector (2) .

Tightening torquesm

the dashboard crossmember reinforcementbolts

8 Nm

112403

112737

61A-74


LEFT-HAND DRIVE

61A

a Press on the tab at (3) .

a Gently lift away the blower assembly.

a Turn the blower assembly until the tab is facingdownwards (4) .

a Pivot the blower assembly around the cross memberat (5) .

a Remove the blower assembly.

112839

112841

112840

61A-75


LEFT-HAND DRIVE

61AREFITTING




a Refit the blower.

a Connect the blower assembly connector (8) .

112840

112841

112839

Note:

When the blower assembly is replaced, it clickswhen it is locked in position.

112737

61A-76


LEFT-HAND DRIVE


a Refit:

- the dashboard cross member tie-rod,

- the dashboard cross member reinforcementbolts (8 Nm).

a Refit:

- the front right-hand A-pillar air distribution duct (see61A, Heating , Front footwell air distributionduct: Removal - Refitting, page 61A-106) ,

- the glovebox (see Glovebox: Removal - Refit-ting) (MR 393, 57A, Interior equipment).

61A-77


RIGHT-HAND DRIVE

61A

REMOVAL


a Lock the airbag computer using the Diagnostic tool(see Fault finding - Replacement of compo-nents)(MR 394, 88C, Airbags and pretensioners).


a Remove:







a Disconnect the inhibitor switch.

Equipment required

Diagnostic tool

112366

112378

112379

61A-78


RIGHT-HAND DRIVE

61A






a Remove the steering column (see Steering col-umn: Removal - Refitting) (MR 392, 36B, Power-assisted steering).

a Unclip the fuse box (10) from the dashboard crossmember stiffener.

a Lift the floor carpet.

a Remove:

- the bolts (9) for the dashboard cross member stiff-ener,

- the dashboard cross member stiffener.

112380

112381

112853

61A-79


RIGHT-HAND DRIVE

61A

a Remove:

- the bolts (11) from the driver's side front footwell airdistribution duct,

- the driver's side front footwell air distribution duct.

a Remove:

- the bolts (12) for the dashboard cross member con-nection piece,

- the dashboard cross member connection piece.

112852

112403

61A-80


RIGHT-HAND DRIVE

61AII - OPERATION FOR REMOVAL OF PART CONCERNED

a Disconnect the motor-driven fan assembly connec-tor (13) .

a Press on the tab (14) .



a Pivot the blower assembly around the cross member(16) .


112839

112841

112840

61A-81


RIGHT-HAND DRIVE

61AREFITTING


a Pivot the blower assembly around the cross member(17) .


a Refit the blower.



a Refit:

- the dashboard cross member connection piece,

112840

112841

112839

Note:


112403

61A-82


RIGHT-HAND DRIVE

61A- the bolts (20) for the dashboard cross member con-nection piece.

a Refit:


- the bolts (21) from the driver's side front footwell airdistribution duct

a Refit:

- the dashboard cross member stiffener,

- the bolts (22) for the dashboard cross member stiff-ener plate,

a Clip the fuse box (23) onto the dashboard crossmember stiffener.

a Refit the steering column (see Steering column:Removal - Refitting) (MR 392, 36B, Power-assist-ed steering).


a Connect the connectors to the driver's side dash-board lower cover (depending on the equipment lev-el).

a Position the driver's side dashboard lower cover.

a Refit:

- the bolts from the driver's side dashboard lowercover,



a Connect the inhibitor switch.

a Refit:

- the side panel,

112852

112853

Note:


61A-83


RIGHT-HAND DRIVE

61A- the seal.


a Refit:



- the driver's front airbag (see Driver's frontal air-bag: Removal - Refitting) (MR 392, 88C, Airbagand pretensioners).



61A-84


LEFT-HAND DRIVE, and SCHOOL VEHICLE

61A

REMOVAL



a Remove:

- the driving school electric control unit (see Drivingschool repeater electrical control unit: Removal- Refitting) (MR 392, 84A, Control - Signals),

- the interior cover (1) behind the Driving schoolelectric control unit,

- the glovebox (2) (see Glovebox: Removal - Refit-ting) (MR 393, 57A, Interior equipment),

- the front right-hand A-pillar air distribution duct (see61A, Heating , Front footwell air distributionduct: Removal - Refitting, page 61A-106) .

a From the instructor's side, remove:

- the brake and clutch pedal shaft (3) ,

- the nuts (4) from the pedal assembly.


a Disconnect the motor-driven fan assembly connec-tor (5) .

Tightening torquesm

pedal assembly nuts 21 Nm

brake and clutch pedalshaft

35 Nm

112915

113202

112737

61A-85



61A

a Press on the tab at (6) .





112839

112841

117356

61A-86



61AREFITTING


a Refit the blower.


a Position the blower assembly in its housing with thetab downwards.

a Turn the blower assembly until the tab (6) is facingupwards.



a To the instructor's side, refit:

- the pedal assembly nuts,

- the brake and clutch pedal shaft.

a Torque tighten:

- the pedal assembly nuts (21 Nm),

- the brake and clutch pedal shaft (35 Nm).

a Refit:

- the front right-hand A-pillar air distribution duct (see61A , Heating, Front footwell air distributionduct: Removal - Refitting, page 61A-106) ,


- the interior cover behind the driving school electriccontrol unit,

- the driving school electric control unit (see Drivingschool repeater electrical control unit: Removal- Refitting) (MR 392, 84A, Control - Signals),


117356

Note:


61A-87

HEATINGHeating resistor relays: Removal - Refitting

LEFT-HAND DRIVE

61AREMOVAL









112378

112379

112380

112381

61A-88


LEFT-HAND DRIVE


a Remove:

- the heating resistor relay box cover (7) ,

- the heater resistor relays.

REFITTING


a Refit:


- the heating resistor relay box cover (8) .

II - FINAL OPERATION

a Connect the connectors to the driver's side dash-board lower cover.


a Refit:



a Clip the trim piece onto the driver's side dashboardlower cover.

a Refit:

- the side panel,

- the seal.

113535

113535

61A-89


RIGHT-HAND DRIVE

61AREMOVAL




a Unclip the heater resistor relay box from the dash-board cross member

a Remove:

- the heating resistor relay box cover (1) ,

- the heater resistor relays.

REFITTING


a Refit:


- the heating resistor relay box cover (2) .

a Clip the heater resistor relay box on the dashboardcross member



113537

113537

61A-90

HEATINGHeating resistors: Removal - Refitting 61A

REMOVAL





a Disconnect the connector (3) from the heating resis-tors.

a Remove:

- the bolts (4) from the heater resistors,

- the heater resistors.

REFITTING


a Refit:

- the heater resistors.

- the bolts (6) from the heater resistors.

a Connect the connector (5) to the heating resistors.




112366

113534

113534

61A-91

HEATINGPassenger compartment fan assembly control unit: Removal - Refitting

LEFT-HAND DRIVE

61AREMOVAL


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

a Partially remove the seal (1) .



a Unclip the trim piece (4) from the driver's side dash-board lower cover

a Remove the bolts from the driver's side dashboardlower cover.



112378

112379

112380

112381

61A-92


LEFT-HAND DRIVE

61A

a

Second type of fitting

a Remove the bolts from the lower half cover.

a Unclip the half covers.

a Pull the lower half cowling out from the steering col-umn adjustment handle.

a Disconnect:

- the connectors of the steering column switch as-sembly,

- the starter switch connector,

a Unclip the connector wiring from the steering columnswitch assembly.

a Disconnect the connector (6) from the electric steer-ing column lock.

a Remove the steering column bolts (7) .

a

a Fit a block of approximately 20 cm on the floor underthe bolt of the intermediate shaft (8) in order to dis-connect the steering column connections (9) .

CLIMATE CONTROL

Note:

For vehicles equipped with climate control, there are two types of fitting for the passenger com-partment fan assembly control unit:

- the first type of fitting has two connectors on thepassenger compartment fan assembly controlunit,

- the second type of fitting has only one connec-tor on the passenger compartment fan assem-bly control unit.

113335

112299

112874

Note:

The column cannot be set down directly on thefloor since the wiring of the steering column con-nectors is not long enough.

61A-93


LEFT-HAND DRIVE

61A

a Remove the steering column from the pre-supports(10) to set it down on the block.

a Disconnect the three connectors (11) while holdingthe steering column on the block.

a Remove the steering column in the footwell.


a Disconnect the connector (12) from the fan assem-bly control unit.

a Remove:

- the fan assembly control unit bolts (13) ,

- the fan assembly control unit.

a Replace the control unit of the passenger compart-ment fan assembly (see Technical Note 6015A,Repairing electrical wiring).

112876

112874

AIR CONDITIONING or STANDARD HEATING

112755

112764

61A-94


LEFT-HAND DRIVE

61A

1 - First type of fitting

a Disconnect the connectors (14) from the fan assem-bly control unit.

a Remove:



2 - Second type of fitting

a Disconnect the connector (16) from the fan assem-bly control unit.

a Remove:

- the bolt (17) from the fan assembly control unit,

- the fan assembly control unit in the direction of thearrows (18) and (19) .

CLIMATE CONTROL

112731

144079

144078

61A-95


LEFT-HAND DRIVE

61AREFITTING


a Refit:


- the bolts of the fan assembly control unit.

a Connect the fan assembly control unit connector.



a Refit:


- the fan assembly control unit bolts.



a Refit:


- the fan assembly control unit bolt.


Second type of fitting

a Fit the steering column on a block of approximately20 cm on the floor under the intermediate shaft bolt.

a Connect the three steering column connectors, hold-ing the steering column on the block.

a Position the steering column in its pre-supports.

a Refit the steering column bolts.

a Connect the electric steering column lock connector.

a Connect:

- the connectors of the steering column switch as-sembly,

- the starter switch connector,

a Clip on the connector wiring for the steering columnswitch assembly.

a Fit the lower half cover.

a Clip on the half covers.

a Refit the bolts to the lower half cover.



a Refit:




a Refit:

- the side panel,

- the seal.

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


CLIMATE CONTROL

CLIMATE CONTROL

61A-96


RIGHT-HAND DRIVE

61AREMOVAL


a Remove the glovebox (see Glovebox: Removal -Refitting) (57A, Interior equipment).


a Disconnect the connector (1) from the fan assemblycontrol unit.

a Remove:



a Replace the control unit of the passenger compart-ment fan assembly (see Technical Note 6015A,Repairing electrical wiring).

a


a Disconnect the connectors (3) from the fan assem-bly control unit.

a Remove:




112846

Note:

When repairing the wiring, ensure the wiring iscut 10 cm from the fan assembly control unit.

CLIMATE CONTROL

Note:

For vehicles equipped with climate control, there are two types of fitting for the passenger com-partment fan assembly control unit:

- the first type of fitting has two connectors on thepassenger compartment fan assembly controlunit,

- the second type of fitting has only one connec-tor on the passenger compartment fan assem-bly control unit.

112731

61A-97


RIGHT-HAND DRIVE

61A2 - Second type of fitting

a Disconnect the connector (5) from the fan assemblycontrol unit.

a Remove:

- the bolt (6) from the fan assembly control unit,

- the fan assembly control unit in the direction of thearrows (7) and (8) .

REFITTING


a Refit:





a Connect the fan assembly control unit connectors.

a Refit:





a Refit:


- the fan assembly control unit bolt.


a Refit the glovebox (see Glovebox: Removal - Refit-ting) (57A, Interior equipment).

144079

144078


CLIMATE CONTROL

61A-98

HEATINGControl panel: Removal - Refitting 61A

REMOVAL











112366


NAVIGATION AID 1


112389

112390

61A-99



a Remove the mounting bolts (3) from the air condi-tioning control panel.

a Move the air conditioning control panel to one side.

a Disconnect the air conditioning control panel con-nectors.

a Disconnect the connector (4) from the air condition-ing control panel.

a Remove the control panel control cables.


a Pull back lug (6) .


a Remove the air conditioning control panel.

REFITTING


a Refit the control panel control cables.

a Insert the ball joint at (8) .


112842

CLIMATE CONTROL


109869

102011


102011

61A-100


a Connect the air conditioning control panel connector(10) .

a Connect the air conditioning control panel connec-tors.

a Refit the air conditioning control panel.



a Connect the connectors.







109869

CLIMATE CONTROL

112842


NAVIGATION AID 1


61A-101

HEATINGFront side air distribution duct: Removal - Refitting 61A

REMOVAL




a Remove:

- the driver's front airbag (see Driver's frontal air-bag: Removal - Refitting) (MR 392, 88C Airbagand pretensioners),


- the steering column switch assembly (see Steer-ing column switch assembly: Removal - Refit-ting) (MR 392, 84A, Control - signals).




a Remove:







- the dashboard (see Dashboard: Removal - Refit-ting) (MR 393, 57A, Interior equipment).


1 - Front left-hand side air distribution duct:

a Remove:

- the clip (1) ,

- Remove the front left-hand side air distributionduct.



Equipment required

Diagnostic tool


NAVIGATION AID 1


112752

61A-102


2 - Front right-hand side air distribution duct:

a Remove:

- the clip (2) ,

- the front right-hand side air distribution duct.

REFITTING


1 - Front left-hand side air distribution duct:

a Refit:

- the front left-hand side air distribution duct.

- the clip (3) .

2 - Front right-hand side air distribution duct:

a Refit:

- the front right-hand side air distribution duct.

- the clip (4) .


a Refit:









112754

112752

112754


61A-103




a Refit:

- the steering column switch assembly (see Steer-ing column switch assembly: Removal - Refit-ting) (MR 392, 84A, Control - signals),


- the driver's front airbag (see Driver's frontal air-bag: Removal - Refitting) (MR 392, 88C Airbagand pretensioners).



NAVIGATION AID 1


61A-104

HEATINGFront centre air distribution duct: Removal - Refitting 61A

REMOVAL


a Lock the airbag computer using the Diagnostic tool(see Fault finding - Replacement of components(MR 394, 88C, Airbags and pretensioners).


a Remove:

- the driver's front airbag (see Driver's frontal air-bag: Removal - Refitting) (MR 392, 88C Airbagand pretensioners),


- the steering column switch assembly (see Steer-ing column switch assembly: Removal - Refit-ting) (MR 392, 84A, Control - signals).




a Remove:







- the dashboard (see Dashboard: Removal - Refit-ting) (MR 393, 57A, Interior equipment).


a Move the front centre air distribution duct wiring har-ness (1) to one side.

a Remove:

- the bolts (2) from the front centre air distributionduct,

- the front centre air distribution duct.



Equipment required

Diagnostic tool


NAVIGATION AID 1


112403

61A-105

HEATINGFront centre air distribution duct: Removal - Refitting 61A

REFITTING


a Refit:

- the front centre air distribution duct.

- the front centre air distribution duct bolts (3) .

a Position the front centre air distribution duct wiringharness (4) .


a Refit:











a Refit:

- the steering column switch assembly (see Steer-ing column switch assembly: Removal - Refit-ting) (MR 392, 84A, Control - signals),


- the driver's front airbag (see Driver's frontal air-bag: Removal - Refitting) (MR 392, 88C Airbagand pretensioners).


a Unlock the airbag computer using the Diagnostictool (see Fault finding - Replacement of compo-nents (MR 394, 88C, Airbags and pretensioners).

112403


NAVIGATION AID 1


61A-106

HEATINGFront footwell air distribution duct: Removal - Refitting

LEFT-HAND DRIVE

61A

REMOVAL


1 - Driver's side


a Unclip the dashboard lower trim at (1) and (2) .



a Remove the bolt (5) from the dashboard lower trimon the driver's side.

a Unclip the trim (6) .

Tightening torquesm


21 Nm

112366

112378

112379

112380

61A-107


LEFT-HAND DRIVE

61A


a Remove the dashboard lower trim (8) on the driver'sside.


a Unclip:

- the fuse and relay box (9) ,

- the heating resistor relays (10) .


a Remove:


- the dashboard cross member reinforcement (12) .

2 - Passenger side


112381

113535

112753

61A-108


LEFT-HAND DRIVE


1 - Driver's side

a Remove:

- the bolts (13) from the front footwell air distributionduct on the driver's side,


2 - Passenger side

a Remove:

- the bolts (14) from the front footwell air distributionduct on the passenger side,

- the passenger side front footwell air distributionduct.

112844

112742

61A-109


LEFT-HAND DRIVE

61AREFITTING


1 - Driver's side

a Refit:


- the front footwell air distribution duct bolts (15) onthe driver's side.

2 - Passenger side

a Refit:


- the front footwell air distribution duct bolts (16) onthe passenger side.


1 - Driver's side

a Refit:


- the dashboard reinforcement bolts.

a Torque tighten the dashboard cross member rein-forcement bolts (21 Nm).


a Clip on:


- the fuse and relay box.



112844

112742

Note:


61A-110


LEFT-HAND DRIVE

61Aa Refit:


- the dashboard lower trim bolt on the driver's side.

a Fit the dashboard lower trim piece on the driver'sside.

a Refit:

- the side panel,

- the door seal.



2 - Passenger side


61A-111


RIGHT-HAND DRIVE

61A

REMOVAL


1 - Driver's side

a Lock the airbag computer using the Diagnostic tool(see Fault finding - Replacement of compo-nents)(MR 394, 88C, Airbags and pretensioners).




a Move the side panel to one side.



Equipment required

Diagnostic tool

Tightening torquesm


21 Nm

112366

112378

112379

61A-112


RIGHT-HAND DRIVE

61A

a Remove the dashboard lower trim bolt (5) .

a Undo the dashboard lower trim piece (6) on the driv-er's side.


a Remove the dashboard lower trim (8) on the driver'sside.



a Unclip the fuse holder unit (9) .

a Remove:


- the dashboard cross member reinforcement.

2 - Passenger side


112380

112381

112853

61A-113


RIGHT-HAND DRIVE


1 - Driver's side

a Remove:

- the bolts (11) from the front footwell air distributionduct on the driver's side,


2 - Passenger side

a Remove:

- the bolts (12) from the front footwell air distributionduct on the passenger side,


112852

112844

61A-114


RIGHT-HAND DRIVE

61AREFITTING


1 - Driver's side

a Refit:


- the front footwell air distribution duct bolts (13) onthe driver's side.

2 - Passenger side

a Refit:


- the front footwell air distribution duct bolts (14) onthe passenger side.


1 - Driver's side

a Refit:


- the dashboard reinforcement bolts.

a Torque tighten the dashboard cross member rein-forcement bolts (21 Nm).

a Clip the fuse and relay box into place.




a Refit:


112852

112844

Note:


61A-115


RIGHT-HAND DRIVE

61A- the dashboard lower trim bolt.

a Fit the dashboard lower trim piece on the driver'sside.


a Refit:

- the side panel,

- the door seal.



a Unlock the airbag computer using the Diagnostictool (see Fault finding - Replacement of compo-nents)(MR 394, 88C, Airbags and pretensioners).

2 - Passenger side


61A-116

HEATINGRecirculation motor: Removal - Refitting

LEFT-HAND DRIVE, and CLIMATE CONTROL

61A

REMOVAL


a Lock the airbag computer using the Diagnostic tool(see Fault finding - Replacement of compo-nents)(MR 394, 88C, Airbag and pretensioners).


a Remove:



- the steering column switch (see Steering columnswitch assembly: Removal - Refitting) assembly(MR 392, 84A, Controls-Signals),





a Unclip the fuse holder (3) .

a Move the fuse holder to one side.

a Remove:



Equipment required

Diagnostic tool

112366

112753

61A-117




a Disconnect the connector (5) from the recirculationmotor (6) .

a Remove:

- the bolts (7) from the recirculation motor,

- the recirculation motor.

REFITTING


a Refit:


- the recirculation motor bolts (8) ,

a Connect the connector (9) to the recirculation motor.

112734

112734

61A-118




a Refit:


- the dashboard cross member reinforcement bolts(10) .

a Clip on the fuse holder (11) .



a Refit:



- the steering column switch (see Steering columnswitch assembly: Removal - Refitting) assembly(MR 392, 84A, Controls-Signals),


- the driver's front airbag (see Driver's frontal air-bag: Removal - Refitting) (MR 392, 88C, Airbagand pretensioners).


a Unlock the airbag computer using the Diagnostictool (see Fault finding - Replacement of compo-nents)(MR 394, 88C, Airbag and pretensioners).

112753

Note:


61A-119


RIGHT-HAND DRIVE

61AREMOVAL




a Disconnect the connector (2) from the recirculationmotor (1) .

a Remove:


- the recirculation motor.

REFITTING


a Refit:



a Connect the connector (5) to the recirculation motor.



112734

112734

61A-120

HEATINGMixing motor: Removal - Refitting


61A

REMOVAL








Tightening torquesm

dashboard cross mem-ber reinforcement bolt

21 Nm

112366

112378

112379

112380

61A-121



61A





a Unclip the fuse holder unit (9) .


a Remove:



112381 112753

61A-122




a Disconnect the connector (11) from the mixer motor.

a Remove:

- the bolts (12) from the air mixing motor,

- the air mixing motor.

REFITTING


a Refit:


- the air mixing motor bolts (13) .

a Connect the connector (14) to the mixer motor.

112732

112732

61A-123




a Refit:


- the bolts (15) from the dashboard cross memberstiffener.

a Torque tighten the dashboard cross member rein-forcement bolt (21 Nm).

a Clip in the fuse holder unit (16) .




a Refit:

- the driver's side dashboard lower cover bolts,



a Refit:

- the side panel,

- the seal.



112753

Note:

Check the presence of the rubber filter block onthe dashboard cross member reinforcementplate before refitting.

Note:


61A-124


RIGHT-HAND DRIVE, and CLIMATE CONTROL

61AREMOVAL


a Remove:





a Disconnect the connector (3) from the mixer motor.

a Remove:

- the bolts (4) from the air mixing motor,

- the air mixing motor.

112366

112734

61A-125



61AREFITTING


a Refit:


- the air mixing motor bolts (5) .

a Connect the connector (6) to the mixer motor.



a Refit:


- the glovebox (see Glovebox: Removal - Refit-ting) (MR 393, 57A, Interior equipment)).

112734

61A-126

HEATINGDistribution motor: Removal - Refitting


61AREMOVAL





a Disconnect the connector (3) from the distributionmotor.

a Remove:

- the bolts (4) from the distribution motor,

- the distribution motor.

REFITTING


a Refit:



a Connect the connector (5) to the distribution motor.




112366

112743

112743

61A-127



61A

REMOVAL


a Lock the airbag computer using the Diagnostic tool(see Fault finding - Replacement of components)(MR 394, 88C, Airbags and seat belt pretensioners).








Equipment required

Diagnostic tool

112366

112378

112379

112380

61A-128



61A

a Remove the bolts (7) of the driver's side dashboardlower cover.



a Remove the dashboard lower cover on the driver'sside (see Dashboard: Removal - Refitting) (MR393, 57A, Interior equipment).


a Unclip the fuse holder (9) .


a Remove:



112381 112853

61A-129




a Disconnect the connector (11) from the distributionmotor.

a Remove:


- the distribution motor.

REFITTING


a Refit:



a Connect the connector (14) to the distribution motor.

112743

112743

61A-130




a Refit:


- the bolts (15) from the dashboard cross memberstiffener.

a Clip on the fuse holder (16) .




a Refit:





a Refit:

- the side panel,

- the seal.



a Unlock the airbag computer using the Diagnostictool (see Fault finding - Replacement of compo-nents) (MR 394, 88C, Airbags and seat belt preten-sioners).

112853

Note:

Check the presence of the rubber filter block onthe dashboard cross member reinforcementplate before refitting

Note:


61A-131

HEATINGPassenger compartment temperature sensor: Removal - Refitting 61A

REMOVAL


a Unclip the upper casing.

a Unclip the lower casing (1) .


a Disconnect the passenger compartment tempera-ture sensor connector (2) .

a Remove:

- the passenger compartment temperature sensorbolts located inside the lower cover,

- the passenger compartment temperature sensor.

101715

101716

101717

61A-132

HEATINGPassenger compartment temperature sensor: Removal - Refitting 61A

REFITTING


a Refit:

- the passenger compartment temperature sensor,

- the passenger compartment temperature sensorbolts located inside the lower cover.

a Connect the passenger compartment temperaturesensor connector (3) .


a Clip on:

- the lower cowling

- the upper cover.

101717

61A-133

HEATINGExterior air temperature sensor: Removal - Refitting 61A

REMOVAL


a Remove:

- the door mirror glass (see Door mirror glass: Re-moval - Refitting) ,

- the door mirror casing (see Door mirror casing:Removal - Refitting) .


a Unclip the exterior temperature sensor using a flat-blade screwdriver.

REFITTING


a Replace the exterior temperature sensor (see Tech-nical Note 6015A, Electrical wiring repair, 88A,Wiring).

a Clip on the exterior temperature sensor.


a Refit:

- the door mirror glass (see Door mirror glass: Re-moval - Refitting) ,

- the door mirror casing (see Door mirror casing:Removal - Refitting) .

112954

61A-134

HEATINGSolar radiation sensor: Removal - Refitting

CLIMATE CONTROL

61A

REMOVAL


a Unclip the display mounting using tool (Car. 1597).


a Remove the solar radiation sensor (1) from under-neath the dashboard.

a Disconnect the solar radiation sensor.

a Remove the solar radiation sensor.


Car. 1597 Trim removal lever.

112393

112394

61A-135

HEATINGSolar radiation sensor: Removal - Refitting

CLIMATE CONTROL

61AREFITTING


a Connect the solar radiation sensor.

a Refit the solar radiation sensor (2) .


a Clip on the display mounting.

112394

62A-1

AIR CONDITIONINGAir conditioning: Precautions for the repair

AIR CONDITIONING or CLIMATE CONTROL

62AI - SAFETY

Refrigerant is heavier than air. As a result there is a riskof asphyxia for those working close to the ground andless than 5 m away from the working area (pit, well, airvents, etc.).

Switch on gas extraction systems.

At temperatures above 100˚C, the refrigerant will de-compose and produce a highly irritant gas.

II - GENERAL RECOMMENDATIONS

It is possible to place components in the drying ovenafter painting or to carry out work near the system if thetemperature does not exceed 80˚C.

It is essential to follow the routing of the connectingpipes.

Ensure that the refrigerant connecting pipes are cor-rectly fitted so that they will not come into contact withmetal parts in the engine compartment.

IMPORTANT

The following must be worn when handling refrige-rant:

- gloves,

- protective goggles (with side shields if possible).

In the event of refrigerant fluid coming into contactwith the eyes, rinse well with clean water continu-ously for 15 minutes. If possible, have an eye rinseunit available.

If refrigerant comes into contact with your eyes,consult a doctor immediately. Inform the doctor thatthe burns were caused by R134A refrigerant.

In the event of contact with other unprotected partsof the body (event though the safety advice hasbeen observed), rinse well with clean water continu-ously for 15 minutes.

IMPORTANT

Work requiring the use of refrigerant must be car-ried out in a well-ventilated area.

The refrigerant must not be stored in a shaft, a pit,a hermetically sealed room, etc.

Refrigerants are colourless and odourless fluids.

IMPORTANT

It is forbidden to smoke close to an open refrigerantcircuit.

IMPORTANT

To prevent refrigerant from leaking, never repair afaulty air conditioning circuit component.

Replace all faulty components.

WARNING

In order to avoid any refrigerant leaks, do not dam-age (deform, twist, etc.) the pipe.

WARNING

To avoid damaging the surface of the air condition-ing pipes when removing the seals, do not use atool with a metallic end piece.

WARNING

To prevent moisture from entering the system,place plugs on the cold loop components which areopen to the air.

WARNING

To prevent any leaks, check that the seal and sur-face of the pipe are in good condition. The seal andthe surface must be clean and free from scratches.

WARNING

Lubricants are not mutually compatible: alwaysobserve the type and quantity of oil recommendedfor each compressor even when topping up as thiscould damage the cold loop components.

Always close the oil cans again after use to keepmoisture out and never use oil contained in a canthat has been open for a long time (viscous appear-ance).

62A-2

AIR CONDITIONINGAir conditioning: Parts and consumables for the repair


62ATo find out the oil part numbers (see Vehicle: Partsand consumables for the repair) (MR 392, 04B, Con-sumables - Products).

Table of vehicle refrigerant capacities according to their engines and various features.

Table of quantities of oil to add when replacing components:

Engine Refrigerant capacity (g) Type of compressor Type of oil Quantity of oil(ml)

D4F

510 ±±±± 35

SANDEN SD6V12 PAG SP10 135 ±±±± 10K4M

K4J

K9K

M4RDELPHY 5CVC

PLANETELFPAG 488

150 ±±±± 10F4R

Operation on the air conditioning circuit Quantity of oil (ml or cc)

Circuit oil change Measure the volume recovered and add thesame quantity of new oil

Split hose or other rapid leak 100

Replacing a hose Quantity recovered + 10

Replacement of a condenser Quantity recovered + 30

Replacement of an evaporator Quantity recovered + 30

Replacement of the dehydrator canister Quantity recovered + 15

Removing and refitting a compressor Quantity recovered

Replacing a compressor None added

Standard replacement of a compressor Top up as necessary

Replacement of a compressor and one or more componentsof the heating and air conditioning system

None added

Standard replacement of a compressor and replacement ofone or more heating and air conditioning circuit components

Top up as necessary

62A-3

AIR CONDITIONINGAir conditioning: List and location of components


62A

No. Description

(1) Dehydrator reservoir

(2) Compressor

(3) Pressure sensor

(4) Condenser

(5) Condenser/compressor connecting pipe

(6) Dehydration canister/pressure relief valve connectingpipe

D4F or K4J or K4M

No. Description

(7) Pressure relief valve/compressor connecting pipe

F4R or K9K or M4R

No. Description

(8) Expansion valve/intermediate pipe connecting pipe

(9) Compressor - intermediate pipe connecting pipe

No. Description

(10) Expansion valve

62A-4



62A

All the components shown in the diagram are locatedin the engine compartment.

D4F or K4J or K4M

113434

62A-5



62A

All the components shown in the diagram are locatedin the engine compartment.

Remove the pipe unions to access the expansion valve(10) .

F4R or K9K or M4R

113435

112745

62A-6

AIR CONDITIONINGAir conditioning: Check


62A

I - PREPARATION OPERATION FOR THE MEASUREMENT DEVICE

a Check that the measurement device functions prop-erly (see the device's instruction manual).

a Set units to ˚C.

a Set the device's sensitivity to 0.1˚C.

a Set the reading mode to (∆T) = (T1 - T2)

a Check the two sensors T1 and T2 in order to calcu-late the correction (∆) to be applied to the measure-ment (T1 - T2). the two sensors must indicate the same measurement under the same conditions. Check the sensors by:

- bringing the ends of the 2 sensors together untilthey touch,

- placing the sensors in the air flow of an air vent,

- setting the passenger compartment fan assemblyto top speed.

- waiting for the value to become stable.

- recording the correction value (∆).

Equipment required

Dual-sensor temperature measuring device

Note:

When performing RENAULT maintenance, checkthe air conditioning system at the end of the vehi-cle's maintenance program so that the engine willbe cold.

119360

119358

Note:

It is not necessary to start the vehicle. Thedevice display is in mode (∆T) = (T1 - T2).

WARNING

Note the difference and sign as soon as the tem-perature becomes stable.

Calculate the correction (∆) = - (T1 - T2) to beapplied to the measurement (∆T).

Examples:

If (T1 - T2) = - 0.3˚C, correct the measurement(∆T) by (∆) = + 0.3˚C

If (T1 - T2) = + 0.3˚C, correct the measurement(∆T) by (∆) = - 0.3˚C

62A-7



62AII - VEHICLE PREPARATION OPERATION

a Put the vehicle in the shade, where the temperatureis greater than or equal to 15˚C minimum.

a Close the bonnet.

a Open the front windows.

a Start the engine and let it idle.

a Set the air conditioning controls with:

- recirculation mode in the external position,

- the ventilation distribution in "face" mode,

- the temperature control to coldest temperature set-ting in front (and at the back, if it exists),

- the speed of the passenger compartment fan as-sembly set to maximum (switch off the rear controlif it exists),

- the front side and centre air vents open with thevanes in a neutral position,

- the air conditioning system must be turned on (indi-cator light illuminated).

a Wait 5 minutes with the engine idling before tak-ing any measurements.

III - MEASUREMENTS

a Record the air temperature at the scuttle panel grille (T3).

- open the bonnet, depending on the vehicle, to ac-cess the scuttle panel grille.

- place the sensor where air is drawn through thescuttle panel grille.

- wait for the value to become stable.

- record the T3 temperature value.

- close the bonnet if it was opened.

a Record the air temperature at the left air vent (T1), and at the right air vent (T2).

- fit sensor T1 in the left air vent (1) .

- fit sensor T2 in the right air vent (2) .

a Record the differences in temperature once the (∆T) value has stabilised:

- between T3 and the higher of values T1 or T2, (T3- highest value).

- record this difference in temperature.

- between T1 and T2 (read the (∆T) value (T1-T2)display mode).

- record the difference in temperature (∆T) accord-ing to the correction (∆) to be applied to the mea-surement.

a If the (∆T)=(T1-T2) measurement is unstable, followthe procedure below:

119359

119357

Note:

Depending on the vehicle's air conditioning sys-tem programming, this check method may not beapplicable because the engine cooling fanassembly has been activated. Its operation ren-ders the (∆Τ) value between T1 and T2 unstable.To eliminate this error, the fan assembly must beactivated for the entire period over which temper-ature T1 and T2 measurements are recorded.

62A-8



62Aa Activate the engine cooling fan assembly operation

by modifying the engine speed.

- stabilise the engine speed at 2000 rpm while T1and T2 temperature measurements are being re-corded.

- check that the engine cooling fan assembly operat-ing.

- record the temperatures by following the instruc-tions given in the paragraph MEASUREMENTS.

IV - FAULT FINDING PROCEDURE

a The following two following conditions must be met:

- the difference between T3 and the higher of the twovalues T1 or T2, must be greater than or equal to5˚C,

- the difference between T1 and T2 must be lessthan or equal to 2˚C.

Note:

If one of these two conditions is not met, then theair conditioning system is not working properly.Should this be the case, refer to the fault findingprocedure for the air conditioning system for thevehicle concerned.

62A-9

AIR CONDITIONINGRefrigerant circuit: Check


62A

There are several types of detector:

- electronic detectors,

- trace detectors.

Check that the air conditioning system is operating cor-rectly (see 62A, Air conditioning, Air conditioning:Check, page 62A-6) .

REFRIGERANT CIRCUIT SEALING CHECKING OPERATION

1 - Electronic detectors:

a

a Switch on the electronic detector.

a Start the engine.

a Let the air conditioning system run for 15 minutes.

a Switch off the engine.

a Check the sealing of the refrigerant circuit using theelectronic trace detector (follow the trace of the cir-cuit as closely as possible, to limit variations due toother gases).

2 - Trace detectors

a

a Check for dye on the cold loop components with theultraviolet light.

a Inject the dye.

a Start the engine.

a Let the air conditioning system run for 15 minutes.

a Switch off the engine.

a Check the refrigerant circuit sealing by scanning thecircuit with the ultraviolet light.

a Affix a label (supplied with the dye capsule), to indi-cate that dye has been used (as close as possible tothe filler valves).

Equipment required

Diagnostic tool

IMPORTANT


Note:

After any work on air conditioning circuit leaks onthe Laguna II, Vel Satis and Espace IV, check thatfilling fault DF033 Refrigerant is not present, usingthe Diagnostic tool. If it is present, clear it. Thecompressor cannot operate until the fault is cleared.

Note:

To carry out an after repair check, use the proce-dure for the electronic detector (1). To carry out amore thorough check for leaks, use a trace detector(2).

WARNING

Consult the device's operating manual to avoidincorrect use.

Note:

If replacing a defective part (see 62A, Air condi-tioning).

WARNING


WARNING

To avoid damaging the cold loop components(corrosions, etc.), do not use dye if the tracesreveal that some product has already beeninjected.

Note:

If replacing a defective part (see 62A, Air condi-tioning).

62A-10

AIR CONDITIONINGRefrigerant circuit: Draining - Filling


62A

Equipment required


IMPORTANT


WARNING


WARNING

To avoid damaging the cold loop components (cor-rosions, etc.), do not use dye if the traces revealthat some product has already been injected.

Note:

A summary table gives the quantities of refrigerantin the system according to the engine type (see62A, Air conditioning, Air conditioning: Partsand consumables for the repair, page 62A-2) .

62A-11



62AI - RECOVERING REFRIGERANT FLUID

a

When draining or checking the refrigerant fill load, three scenarios are to be taken into account:

- the engine is running and the air conditioning is inoperation (A),

- the engine is running but the air conditioning is notin operation (B),

- the engine is not running nor is the air conditioningin operation (C).

a Scenario A:

- Operate the air conditioning until the cooling fanassembly is triggered twice,

- Switch off the engine,

- drain for the first time (note down the original val-ue),

- wait 15 minutes,

- check that the relative pressure is no more than 0bar,

- repeat the cycles until the relative pressure is equalto or less than 0 bar,

- add together the values of the various draining op-erations; the fill is confirmed as being correct if thevolume of refrigerant fluid is the specified fill +35gor -100g.

Scenario B:

- run the engine until the cooling fan is triggeredtwice,


- drain for the first time (note down the value),

- wait 15 minutes,

- run the engine until the cooling fan is triggeredtwice,


- drain for the second time (note down the value),



Scenario C:

- drain for the first time (note down the value),

- wait 2 hours,



II - CREATING A VACUUM

a It is essential to carry out vacuum extraction correct-ly before loading, otherwise the air conditioning willnot work properly.

There are two scenarios to consider:

- vacuum created immediately after discharge (sce-nario A),

- vacuum created after an interval of several hoursor days (scenario B).

Scenario A:

- creation of a vacuum takes 20 minutes.

Scenario B:

- creation of a vacuum takes 45 minutes to elimi-nate any trace of moisture.

a Test the seal once the vacuum has been created(some stations do this automatically).

III - FILLING

a Fill up the refrigerant circuit using the refrigerantcharging station.

Note:

- If the air conditioning circuit is fitted with a sin-gle filler valve, some filling equipment onlyrequires the use of the high pressure pipe (referto the filling station instructions).

- Depending on the situation, run the system fora few minutes before recovering the coolant toimprove drainage.

Note:

It is essential to follow these procedures to pre-vent:

- gas escaping when the circuit is opened,

- pollution of the environment through the releaseof gas into the atmosphere when the circuit isopened or when a vacuum is created.

62A-12



62Aa Top up the oil with the recommended type and vol-

ume of oil and refrigerant, depending on the workcarried out (see 62A, Air conditioning, Air condi-tioning: Parts and consumables for the repair,page 62A-2) .

a Check there are no leaks using the electronic de-tector (see 62A, Air conditioning, Refrigerant cir-cuit: Check, page 62A-9) .


WARNINGAfter injecting dye into the refrigerant, be sure toindicate this on a label (supplied with the dyecapsule), and the date of the operation.

Position the label so it is visible near to the coldloop filler valve.

62A-13

AIR CONDITIONINGCondenser: Removal - Refitting


62A

REMOVAL


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



a Remove:

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

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

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

a Remove the headlights (see Halogen headlight:Removal - Refitting) (80B, Headlights).

a Remove the headlights (see Xenon headlight: Re-moval - Refitting) (80C, Xenon bulbs).

a Remove the front impact cross member (see Frontimpact cross member: Removal - Refitting) (41A,Front lower structure).

a Remove the intercooler (see Intercooler: Removal- Refitting) (12B, Turbocharging).

a Remove air deflectors.


1 - The condenser and the cooling radiator cannot be separated

a Remove the « cooling radiator - condenser » as-sembly (see Cooling radiator: Removal - Refit-ting) (19A, Cooling).

Equipment required


compressed air nozzle

Note:

Before removal, use DIALOGYS to check how thecondenser is fitted and arranged.

There are 2 possibilities:

- the condenser and cooling radiator cannot be sep-arated,

- the condenser and cooling radiator can be sepa-rated.

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 62A, Air conditioning, Air conditioning:Precautions for the repair, page 62A-1) ,

- (see Vehicle: Precautions for the repair) (01D,Mechanical introduction).

WITHOUT DISCHARGE LAMPS

DISCHARGE LAMPS

K9K – D4F, and 784

62A-14



62A2 - The condenser and the cooling radiator can be separated

a Remove:

- the bolts (1) from the connecting pipes on the dehy-drator reservoir,

- the connecting pipe bolt (2) from the condenser.

a Remove:

- the connecting pipes on the dehydrator reservoir,

- the connecting pipe on the condenser.


a Disconnect the pressure sensor connector (3) .

a Remove:

- the bolts (4) from the condenser,

- the condenser.

REFITTING


a

112747

WARNING


WARNING


Note:

Use blanking plugs for the fuel circuit with partno. 77 01 208 228 or 77 01 476 857 to plug anyopenings exposed to the open air. They must beclean. Do not use any which have already beenused to plug a fuel circuit.

116803

WARNING

Do not remove the blanking plugs from eachcomponent until the last moment.

Also, do not remove the components from theirpackaging until they are to be fitted to the vehi-cle.

62A-15



62A

a Clean the surface and seal of the pipe using EN-GINE CLEANER (see Vehicle: Parts and con-sumables for the repair) (04B, Consumables -Products).

a Use a compressed air nozzle to blow on the sur-face and the seal of the connecting pipe.

a Lubricate the surface of the connecting pipe and theseal with air conditioning oil (see 62A, Air condi-tioning, Air conditioning: Parts and consum-ables for the repair, page 62A-2) .

a Remove the blanking plugs.


1 - The condenser and the cooling radiator cannot be separated

a Refit the « cooling radiator - condenser » assembly(see Cooling radiator: Removal - Refitting) (19A,Cooling).

2 - The condenser and cooling radiator can be separated

a Refit:

- the condenser,

- the condenser bolts.

a Connect the pressure sensor connector.

a Fit:

- the connecting pipes on the dehydrator reservoir,

- the connecting pipe on the condenser.

a Refit:

- the dehydrator reservoir connecting pipe bolts,

- the connecting pipe bolt on the condenser.

a Tighten:

- the dehydrator reservoir connecting pipe bolts,

- the connecting pipe bolt on the condenser.


a Refit the air deflectors.

a Refit the intercooler (see Intercooler: Removal -Refitting) (12B, Turbocharging).


a Refit the headlights (see Halogen headlight: Re-moval - Refitting) (80B, Headlights).

143880

143882

K9K – D4F, and 784

WITHOUT DISCHARGE LAMPS

62A-16



62A

a Refit the headlights (see Xenon headlight: Remov-al - Refitting) (80C, Xenon bulbs).





a Refit:

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


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

DISCHARGE LAMPS

Note:

A summary table gives the quantities of refriger-ant in the system according to the engine type(see 62A, Air conditioning, Air conditioning:Parts and consumables for the repair, page62A-2) .

62A-17

AIR CONDITIONINGDehydrator reservoir: Removal - Refitting


62A

REMOVAL





a Remove:





a Remove:

- the headlights (see Halogen headlight: Removal- Refitting) (80B, Headlights),

- the front impact cross member (see Front impactcross member: Removal - Refitting) (41A, Frontlower structure).

a Remove:

- the headlights (see Xenon headlight: Removal -Refitting) (80C, Xenon bulbs),


a Remove the air deflector.

Equipment required



IMPORTANT




K9K – D4F, and 784

F4R or M4R, and WITHOUT DISCHARGE LAMPS

F4R or M4R, and DISCHARGE LAMPS

62A-18




a Remove the dehydrator reservoir connecting pipebolts (1) .

a Move aside the connecting pipes.

a Plug the openings on the connecting pipes and de-hydrator reservoir.

a Remove:

- the dehydrator reservoir retaining clip bolts (2) ,

- the dehydrator reservoir.

REFITTING


a


112747

WARNING


WARNING

Plugs must be fitted on the hoses to preventmoisture from entering the system.

Note:


WARNING



143880

62A-19



62A





a Refit:

- the dehydrator reservoir,

- the dehydrator reservoir retaining clip (3) bolts.

a Tighten the dehydrator reservoir retaining clip bolts.

a Fit the connecting pipes to the dehydrator reservoir.

a Refit the dehydrator reservoir connecting pipe bolts(4) .

a Tighten the connecting pipe bolts.


a Refit the air deflector.

a Refit:


- the headlights (see Halogen headlight: Removal- Refitting) (80B, Headlights),

143882

112747


62A-20



62A

a Refit:


- the headlights (see Xenon headlight: Removal -Refitting) (80C, Xenon bulbs),






a Refit:





K9K – D4F, and 784

Note:


62A-21

AIR CONDITIONINGCompressor: Removal - Refitting


62A

REMOVAL





a Remove:

- the engine cover,




- the accessories belt (see Accessories belt: Re-moval - Refitting) (11A, Top and front of engine).


a Remove the headlights (see Halogen headlight:Removal - Refitting) (80B, Headlights).

a Remove the headlights (see Xenon headlight: Re-moval - Refitting) (80C, Xenon bulbs).




a

Equipment required



IMPORTANT




K9K – D4F, and 784



F4R or M4R

WARNING


WARNING


Note:

Use blanking plugs for the fuel circuits with partno. 77 01 208 229 or 77 01 476 857 to plug anyopenings exposed to the open air; They must beclean. Do not use any which have already beenused to plug a fuel circuit.

62A-22



62A

a Remove the bolts (1) from the connecting pipes onthe compressor.


a Plug the openings on the connecting pipes and com-pressor.

a Disconnect the compressor connector (3) .

a Remove:

- bolts (2) and (4) from the compressor,

- the compressor.

a Remove the bolt (5) from the expansion valve - com-pressor connecting pipe.

D4F or K4J or K4M or K9K

112748

112749

F4R or M4R

116879

62A-23



62A

a Disconnect the compressor connector (6) .

a Remove the bolts (7) from the connecting pipes onthe compressor.


a Plug the openings on the connecting pipes and com-pressor.

a Remove:

- the compressor bolts (8) ,

- the compressor.

REFITTING


a





116878

WARNING



143880

143882

62A-24



62AII - REFITTING OPERATION FOR PART CONCERNED

a Refit:

- the compressor,

- the compressor bolts.

a Tighten the compressor bolts.

a Refit the expansion valve - compressor connectingpipe bolt.

a Connect the connector to the compressor.

a Position the compressor connecting pipes.

a Refit the compressor connecting pipe bolts.





a Refit the headlights (see Xenon headlight: Remov-al - Refitting) (80C, Xenon bulbs).

a Refit the headlights (see Halogen headlight: Re-moval - Refitting) (80B, Headlights).


a Refit the accessories belt (see Accessories belt:Removal - Refitting) (11A, Top and front of engine).


a

Fill up the refrigerant circuit using the refrigerantcharging station (see 62A, Air conditioning, Re-frigerant circuit: Draining - Filling, page 62A-10) .

a In the event of replacement, apply the after repair procedure:

- Switch on the ignition,

- Check that the air conditioning is off,

- Switch the ventilation to speed 2,

- Put the temperature setting at minimum,

- Select the air recirculation position,

- Start the engine.

- Run the air conditioning in manual mode (in thecase of climate control do not press auto),

- Run the engine at idle speed for 3 minutes with airconditioning,

- Switch off the engine.



a Refit:



F4R or M4R

F4R or M4R



K9K – D4F, and 784

Note:

A summary table gives the quantity of refrigerantin the system according to the engine type (see62A, Air conditioning, Air conditioning: Partsand consumables for the repair, page 62A-2)

62A-25



62A- the front wheels (see Wheel: Removal - Refitting)(35A, Wheels and tyres),

- the engine cover.

62A-26

AIR CONDITIONINGExpansion valve: Removal - Refitting


62A

REMOVAL




a Remove:

- the engine cover,

- the windscreen wiper arms (see Windscreen wip-er arm: Removal - Refitting) (85A, Wiping -Washing),

- the scuttle panel grille (see Scuttle panel grille:Removal - Refitting) (56A, Exterior equipment),

- the scoop under the scuttle panel grille (see Scoopunder the scuttle panel grille: Removal - Refit-ting) (56A, Exterior equipment).



a Remove the bolts (1) from the expansion valve con-necting pipes.

a Remove the connecting pipes from the expansionvalve.

a Plug the openings of the connecting pipes and ex-pansion valve.

Equipment required



IMPORTANT




112745

WARNING


WARNING


Note:

Use blanking plugs for the fuel circuits with partno. 77 01 208 229 or 77 01 476 857 to plug anyopenings exposed to the open air. They must beclean. Do not use any which have already beenused to plug a fuel circuit.

62A-27




a Remove:

- the bolts (2) from the expansion valve,

- the expansion valve.

REFITTING


a





112740

WARNING

Do not lose the bolt when removing it: if the boltfalls into the engine compartment, it will generatea noise which will be heard by the customer. Theengine will need to be removed in order torecover the bolt.

WARNING



143880

143882

62A-28




a Refit:


- the expansion valve bolts (3) on the distributionunit.

a Tighten the expansion valve bolts.


a Fit the expansion valve connecting pipes.

a Refit the expansion valve connecting pipe bolts (4) .







a Refit:


- the scoop under the scuttle panel grille (see Scoopunder the scuttle panel grille: Removal - Refit-ting) (56A, Exterior equipment),

112740

Note:

Gradually retighten the expansion valve mount-ing bolts so that the expansion valve is uniformlypositioned on the air conditioning pipes.

112745

Note:


62A-29



62A- the scuttle panel grille (see Scuttle panel grille:Removal - Refitting) (56A, Exterior equipment),


- the engine cover.

62A-30

AIR CONDITIONINGEvaporator: Removal - Refitting


62A

REMOVAL

OPERATION FOR REMOVAL OF PART CONCERNED

a Remove the distribution unit (see 61A, Heating,Distribution unit: Removal - Refitting, page 61A-50) .

REFITTING

REFITTING OPERATION FOR PART CONCERNED

a Refit the distribution unit (see 61A, Heating, Distri-bution unit: Removal - Refitting, page 61A-50) .

112759

Note:

The evaporator is supplied already assembled inthe distribution unit. (1)

62A-31

AIR CONDITIONINGEvaporator: Cleaning


62Aa

REMOVAL

a Remove the cabin filter (see 61A, Heating, Cabinfilter: Removal - Refitting, page 61A-17) .

a Apply the air conditioning cleaner using an exten-sion piece.

a Spray the entire aerosol.

a Leave the product to work for 15 minutes.

a Run the fan assembly very slowly for 5 minutes.

a Remove the cabin filter (see 61A, Heating, Cabinfilter: Removal - Refitting, page 61A-17) .

a Apply the air conditioning cleaner.

a Spray the entire aerosol.

a Leave the product to work for 15 minutes.

a Run the fan assembly slowly for 5 minutes.

REFITTING

a Refit the cabin filter.

a Clip on the cabin filter.

WARNING

Do not spray the cleaner via the air inlet, as thiscould damage the fan assembly.

LEFT-HAND DRIVE

112763

RIGHT-HAND DRIVE

112850

62A-32

AIR CONDITIONINGExpansion valve - intermediate pipe connecting pipe at the expansion valve outlet: Removal - Refitting

F4R or K9K or M4R, and AIR CONDITIONING or CLIMATE CONTROL

62A

REMOVAL



a Remove:

- the engine cover,




- the bulkhead soundproofing mountings.



a Remove the connecting pipe bolt (1) on the expan-sion valve.

a Remove the pipe from the expansion valve.

a Plug the openings.


Mot. 1410 Set of refrigerant pipe uniond isconnec t ion sockets.(dimensions in inches): 5/16,3/8, 1/2, 5/8, 3/4, 7/8.

Equipment required



IMPORTANT




Note:

Be careful not to bend the soundproofing whenmoving away from the bulkhead.

112849

WARNING

Do not lose the bolt when removing it: if the boltfalls into the engine compartment, it will generatea noise which will be heard by the customer. Theengine will need to be removed in order torecover the bolt.

WARNINGIn order to avoid any refrigerant leaks, do notdamage (deform, twist, etc.) the pipe.

WARNING


Note:


62A-33



62A

a Remove the connecting pipe retaining clip nut (2) .

a Uncouple the expansion valve - intermediate pipeconnecting pipe from the compressor - intermediatepipe connecting pipe using the (Mot. 1410) at (3) .

a Plug the openings.

a Remove the expansion valve - intermediate pipeconnecting pipe.

REFITTING


a


113048

WARNING


Note:


WARNING



143880

62A-34



62A





a Refit the expansion valve - intermediate pipe con-necting pipe.

a Couple the expansion valve - intermediate pipe con-necting pipe to the compressor - intermediate pipeconnecting pipe at (4) .

a Refit the pipe retaining clip nut (5) ,

143882

113048

62A-35



62A

a Fit the connecting pipe to the expansion valve.

a Refit the connecting pipe bolt (6) on the expansionvalve.

a Tighten the connecting pipe bolt.





a Refit:

- the bulkhead soundproofing,





- the engine cover.

112849

Note:


62A-36

AIR CONDITIONINGDehydrator reservoir - expansion valve connecting pipe: Removal - Refitting


62A

REMOVAL



a Remove the front engine cover.


a Remove:








a Remove:

- the compressor pipe - intermediate pipe (see 62A,Air conditioning, Compressor - intermediatepipe connecting pipe: Removal - Refitting, page62A-51) ,

- the expansion valve pipe - intermediate pipe (see62A, Air conditioning, Expansion valve - inter-mediate pipe connecting pipe at the expansionvalve outlet: Removal - Refitting, page 62A-32) .

a Remove the expansion valve - compressor pipe(see 62A, Air conditioning, Expansion valve -compressor connecting pipe: Removal - Refit-ting, page 62A-41) .

a Remove the front end panel (see Front end panel:Removal - Refitting) (42A, Upper front structure).

Equipment required



IMPORTANT




K9K – D4F, and 784

F4R or K9K or M4R, and AIR CONDITIONING orCLIMATE CONTROL

D4F or K4J or K4M, and AIR CONDITIONING orCLIMATE CONTROL

62A-37







a Remove the connecting pipe from the expansionvalve.

a Plug the openings on the connecting pipe and ex-pansion valve.

a Remove the connecting pipe bolt (2) on the dehydra-tor reservoir.

a Remove the connecting pipe on the dehydrator res-ervoir.

a Plug the openings on the connecting pipe and dehy-drator reservoir.

a Unclip the expansion valve - dehydrator reservoirconnecting pipe from the body.

a Remove the expansion valve - dehydrator reservoirconnecting pipe.

112745

WARNING


WARNING


Note:


112747

WARNING


WARNING


Note:


62A-38



62AREFITTING


a






a Refit the expansion valve - dehydrator reservoir con-necting pipe.

a Clip the expansion valve - dehydrator reservoir con-necting pipe to the body.

WARNING



143880

143882

62A-39



62A

a Fit the connecting pipe to the dehydrator reservoir.

a Refit the connecting pipe bolt (3) on the dehydratorreservoir.





a Refit the bulkhead soundproofing mountings.


a Refit the front end panel (see Front end panel: Re-moval - Refitting) (42A, Upper front structure).

a Refit the expansion valve - compressor pipe (see62A, Air conditioning, Expansion valve - com-pressor connecting pipe: Removal - Refitting,page 62A-41) .

a Refit:

- the expansion valve pipe - intermediate pipe (see62A, Air conditioning, Expansion valve - inter-mediate pipe connecting pipe at the expansionvalve outlet: Removal - Refitting, page 62A-32) ,

- the compressor pipe - intermediate pipe (see 62A,Air conditioning, Compressor - intermediatepipe connecting pipe: Removal - Refitting, page62A-51) .






112747

112745

D4F or K4J or K4M

F4R or K9K or M4R

D4F, and 784 – K9K

Note:


62A-40



62Aa Refit:







- the engine cover.

62A-41

AIR CONDITIONINGExpansion valve - compressor connecting pipe: Removal - Refitting

D4F or K4J or K4M, and AIR CONDITIONING or CLIMATE CONTROL

62A

REMOVAL





a Remove:







a Move the air intake sleeve to one side (1) .

Equipment required



IMPORTANT




112029

62A-42







a Remove the connecting pipe from the expansionvalve.

a Plug the openings on the connecting pipe and ex-pansion valve.

a Remove the bolt (3) securing the connecting pipe onthe compressor.

a Remove the connecting pipe from the compressor.

a Plug the openings on the connecting pipe and com-pressor.

112849

WARNING


WARNING


Note:


112748

WARNING


WARNING


Note:


62A-43



62A

a Remove:

- the connecting pipe retaining clip nut (4) ,

- the compressor - expansion valve connecting pipe.

REFITTING


a





112746

WARNING



143880

143882

62A-44




a Refit:

- the compressor - expansion valve connecting pipe,

- the connecting pipe retaining clip nut (5) ,

a Fit the connecting pipe union to the compressor.

a Refit the bolt (6) securing the connecting pipe on thecompressor.

a Tighten the compressor connecting pipe bolt.



a Tighten the expansion valve connecting pipe bolt.


a Refit the bulkhead soundproofing mountings.


a Fit the air intake sleeve (8) .


112746

112748

112849

112029

62A-45



62Aa Fill up the refrigerant circuit using the refrigerant

charging station (see 62A, Air conditioning, Re-frigerant circuit: Draining - Filling, page 62A-10) .



a Refit:






- the windscreen wiper arms (see Windscreen wip-er arm: Removal - Refitting) (85A, Wiping -Washing).

Note:


62A-46

AIR CONDITIONINGPressure sensor: Removal - Refitting


62AREMOVAL


a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (MR 392, 02A, Lifting equip-ment).

a Remove:

- the front wheels (see Wheel: Removal - Refitting)(MR 392, 35A, Wheels and tyres),

- the front wheel arch liners (see Front wheel archliner: Removal - Refitting) (MR 393, 55A, Exteriorprotection),

- the front bumper (see Front bumper: Removal -Refitting) (MR 393, 55A, Exterior protection).


a Disconnect the pressure sensor connector (1) .

a Remove the pressure sensor.

REFITTING


a Refit the pressure sensor.

a Tighten the pressure sensor.

a Connect the pressure sensor connector (2) .


a Refit:

- the front bumper (see Front bumper: Removal -Refitting) (MR 393, 55A, Exterior protection),

- the front wheel arch liners (see Front wheel archliner: Removal - Refitting) (MR 393, 55A, Exteriorprotection),

- the front wheels (see Wheel: Removal - Refitting)(MR 392, 35A, Wheels and tyres),

112750

Note:

An automatic shut-off valve isolates the circuitfrom the outside during removal; do not drain therefrigerant from the circuit.

112750

62A-47

AIR CONDITIONINGCompressor - condenser connecting pipe: Removal - Refitting


62A

REMOVAL





a Remove:







a Remove the connecting pipe bolt (1) on the con-denser.

a Remove the connecting pipe from the condenser.

a Plug the openings on the connecting pipe and con-denser.

Equipment required



IMPORTANT




D4F, and 784 – K9K

112747

WARNING


WARNING


Note:


62A-48



62A




a Remove the compressor-condenser connectingpipe.

REFITTING


a


112748

WARNING


WARNING


Note:


WARNING



143880

62A-49



62A





a Fit the connecting pipe to the compressor.


a Tighten the compressor connecting pipe bolt.

a Fit the condenser connecting pipe.

a Refit the bolt (4) securing the connecting pipe on thecondenser.

a Tighten the condenser connecting pipe bolt.

143882

112748

112747

62A-50



62AIII - FINAL OPERATION







a Refit:




D4F, and 784 – K9K

Note:


62A-51

AIR CONDITIONINGCompressor - intermediate pipe connecting pipe: Removal - Refitting


62A

REMOVAL





a Remove:







a Remove:

- the engine tie-bar (1) (see Right-hand suspend-ed engine mounting: Removal - Refitting) (19D,Engine mounting),

- the nut (2) from the pipe retaining clip on the body.

a Uncouple the expansion valve - intermediate pipeconnecting pipe from the compressor - intermediatepipe connecting pipe using the (Mot. 1410) at (3) .



Mot. 1410 Set of refrigerant pipe uniond isconnec t ion sockets.(dimensions in inches): 5/16,3/8, 1/2, 5/8, 3/4, 7/8.

Equipment required



IMPORTANT




K9K

113048

WARNING


Note:


62A-52



62A




a Remove the compressor - intermediate pipe con-necting pipe.

REFITTING


a


112748

WARNING


WARNING


Note:


WARNING



143880

62A-53



62A





a Fit the connecting pipe to the compressor.



a Couple the expansion valve - intermediate pipe con-necting pipe to the compressor - intermediate pipeconnecting pipe at (6) .

a Refit the body mounted pipe retaining clip nut (7) .

143882

112748

113048

62A-54



62AIII - FINAL OPERATION



a Refit the engine tie-bar (see Right-hand suspend-ed engine mounting: Removal - Refitting) (19D,Engine mounting).





a Refit:




K9K

Note:


6 Air conditioningphilch.free.fr/clio/clio3/MR392CLIO6.pdfCLIO III - Section 6 Contents Pages CLIO...

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Transcript of 6 Air conditioningphilch.free.fr/clio/clio3/MR392CLIO6.pdfCLIO III - Section 6 Contents Pages CLIO...