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Technical Note 3690A KM0B - KM0C - KM0F - KM0G - KM0H KM0J - KM0O - KM0U - KM02

Basic manual: Workshop Repair Manual 364

Special notes on Mgane Estate

77 11 319 162

Edition 4 - NOVEMBER 2005


All rights reserved by RENAULT s.a.s.

EDITION ANGLAISE

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

Copying or translating, in part or in full, of this document or use of the service part reference numbering system is prohibited without the prior written authority of RENAULT s.a.s.

Renault s.a.s. 2005

Contents
Page Page

01A VEHICLE MECHANICAL


SPECIFICATIONS
Engine - Gearbox Dimensions 01A-1 01A-2

81A REAR LIGHTS


Rear light Connection Registration plate light High-level brakelight 81A-1 81A-2 81A-3 81A-4

21A MANUAL GEARBOX


Ratios 21A-1

85A WIPERS - WASHERS


Rear screen wiper Rear screen wiper motor mechanism 85A-1 85A-3

23A AUTOMATIC GEARBOX


Ratios 23A-1

86C RADIO
Aerial 86C-1

30A GENERAL INFORMATION


Brakes Anti-roll bars: Specifications Front axle tightening torques (in daNm) Front axle values and settings Rear axle values and settings Underbody height 30A-1 30A-2 30A-3 30A-6 30A-8 30A-9

87C OPENING ELEMENTS


MANAGEMENT
Rear screen opening switch Tailgate opening switch Tailgate lock Keyless vehicle: Tailgate lock connection Fuel filler flap locking motor 87C-1 87C-2 87C-3 87C-4 87C-5

35A WHEELS AND TYRES


Specifications 35A-1

88C AIRBAG AND PRETENSIONER


Rear pyrotechnic seat belt retractor Side curtain airbag 88C-1 88C-3

37A MECHANICAL COMPONENT


CONTROLS
Control lever Control cables 37A-1 37A-2

MECHANICAL SPECIFICATIONS FOR THE VEHICLE 101A Engine-Gearbox Assembly


Engine Vehicle type Type KM0B KM0C KM0F KM0G KM0H KM0J KM0L KM0U KM0Y KM00 KM02 KM1A KM1B KM1D KM1G KM1M K4J K4M 761 K9K F9Q K4J K4M 761 F9Q F4R 771 K4M F9Q K9K 729 K4J K4M 761 F9Q F9Q F4R 771 KM1N F4R 770 771 VEHICLE IDENTIFICATION Example: KM00 K K M : Type of bodywork : Estate : Project code 1998 804 800 770 1998 1870 1870 730 760 1598 1398 764 808 728 1461 1598 1870 804 770 1998 1870 722 800 730 760 1598 1461 1870 1398 Suffix 730 760 1598 1398 Cubic capacity (cm 3)

01A
JH3 JH3 DP0 JR5 ND0 JH3 DP0 DP0 ND0 ND0 DP0 JH3 ND0 JR5 DP0 JH3 JH3 DP0 ND0 ND0 ND0 DP0 ND0 DP0

Gearbox type

00 : Engine suffix

01A-1

Edition 3

MECHANICAL SPECIFICATIONS FOR THE VEHICLE Dimensions

01A

Dimensions in metres A B C D E F (unladen) G H 0.842 2.686 0.972 4.500 1.518 1.467 1.514 1.777

01A-2

Edition 3

MANUAL GEARBOX 121A Gears

21A
ND0 008 14/57 13/41 19/34 31/37 40/34 47/31 50/27 37/38 014 16/70 13/41 18/35 28/39 36/38 52/45 56/41 37/38 016 14/57 14/49 18/35 28/39 36/38 52/45 56/41 37/38

JH3 Suffix Cylinder torque First Second Third Fourth Fifth Sixth Reverse gear 105 14/59 11/41 21/43 28/39 31/34 37/33 11/39 142 15/61 11/41 21/43 28/39 31/34 37/33 11/39 102 15/56 11/41 21/43 28/37 35/34 41/31 11/39

JR5 108 15/56 11/41 21/43 28/37 35/34 42/31 11/39 001 15/58 13/41 19/34 31/37 40/34 3447/31 50/27 37/38

21A-1

Edition 2

AUTOMATIC TRANSMISSION 223A Gears


DP0

23A

X84, K84, K9K, DP0 Suffix 046 047 049 050 051 052 053 054 For removing and refitting the gearbox (see MR 364 Mechanical systems, 23 A, Automatic transmission, Automatic transmission: Removal Refitting.) Deceleration 52/67 52/67 52/67 52/67 52/67 52/67 52/67 52/67 Final drive 20/73 21/73 21/73 21/73 23/70 21/73 20/73 20/73

Edition 2

23A-1

GENERAL INFORMATION 130A Brake: Technical specifications

30A
54 280 24 21.8 0.07 18 6

Engines of all types FRONT BRAKE (mm) Piston diameter Disc diameter Thickness of discs Minimum disc thickness (1) Maximum disc run-out Thickness of brake pads (including mounting) Minimum thickness of brake pads (including mounting)

REAR BRAKE (mm) Piston diameter Disc diameter Thickness of discs Minimum disc thickness (1) Maximum disc run-out Thickness of brake pads (including mounting) Minimum thickness of brake pads (including mounting) 34 270 10 6.5 0.07 16 6

MASTER CYLINDER (mm) Diameter Stroke 23.8 36

(1) Brake discs cannot be repaired. If they are too heavily worn or are scratched they must be replaced. Brake fluid conforms with SAE J 1703 DOT 4 standards. For optimum braking, RENAULT recommends a brake fluid with low viscosity in cold conditions (maximum 750 mm2/s at -40C).

30A-1

GENERAL INFORMATION Anti-roll bars: Features


I - FRONT AXLE Bar diameter (mm) 20 Marking Yellow

30A

II - REAR AXLE

F4R or F9Q and K9K / DPO Bar dimension (mm) X: 15.7 Y: 41.3 K4J or K4M and K9K / JR5 Bar dimension (mm) X: 15.9 Y: 38

30A-2

GENERAL INFORMATION Tightening torques (in daNm) for the front axle

30A

Tightening torques (1) bolt attaching "spring and shock absorber" assembly to body lower arm bolt sub-frame stud bolt rear cross member bolt bolt attaching anti-roll bar mounting to sub-frame radiator cross member front mounting bolt calliper mounting bolt radiator cross member rear mounting nut bolt attaching steering rack mounting to sub-frame

2.1 daNm 7 daNm 10.5 daNm 6.2 daNm 2.1 daNm 10.5 daNm 10.5 daNm 2.1 daNm 10.5 daNm

(2) (3) (4) (5) (6) (7) (8)

30A-3

GENERAL INFORMATION Tightening torques (in daNm) for the front axle

30A

Tightening torques (8) (9) shock absorber nut anti-roll bar reduction gearing linkage ball joint nut base of the shock absorber bolt sub-frame tie-rod bolt lower arm ball joint bolt driveshaft nut wheel bolt track rod end nut side stiffener mounting bolt on the radiator cross member 6.2 daNm

4.4 daNm 10.5 daNm 10.5 daNm 6 daNm 28 daNm 11 daNm 3.7 daNm

(10) (11) (12) (13) (14) (15)

2.1 daNm

30A-4

GENERAL INFORMATION Tightening torques (in daNm) for the rear axle

30A

Tightening torques (1) (2) (3) (4) (5) stub-axle nut calliper mounting bolt Pillar bolt bearing mounting bolt shock absorber lower mounting bolt shock absorber upper mounting bolt (6) (7) brake pipe nut bearing and rear axle mounting bolt nut under-rear axle protection mounting bolt 22 daNm 10.5 daNm 3.6 daNm 6.2 daNm 10.5 daNm 6.2 daNm 1.4 daNm 12.5 daNm 0.8 daNm

30A-5

GENERAL INFORMATION Values and adjustments for the front axle assemblies
WARNING If adjusting the running gear, program the torque and steering wheel angle sensor with the fault finding tool (see "fault finding manual"). II - CAMBER Not adjustable.

30A

I - CASTOR Not adjustable.

Values 038' 30' - 001' 30' Position of front axle (mm) W2 - W1 = 94 W2 - W1 = 75 W2 - W1 = 62 W2 - W1 = 46 - 012' 30' - 016' 30' Maximum right/left difference = 30'

Position of front axle (mm) R1 - W1 = 118 R1 - W1 = 125 R1 - W1 = 146 R1 - W1 = 158

Values 430' 30' 506' 30' 542' 30' 618' 30' Maximum right/left difference = 30'

30A-6

GENERAL INFORMATION Values and adjustments for the front axle assemblies
III - SWIVEL Not adjustable. IV - WHEEL ALIGNMENT

30A

Adjustable by rotating the track rod sleeves.

Values 1058' 30' 1106' 30' 1131' 30' 1145' 30' Maximum right/left difference = 30'

Position of front axle (mm) R1 - W1 = 118 R1 - W1 = 125 R1 - W1 = 146 R1 - W1 = 158

Values (For two wheels) toe-out 010' 10' 15-inch wheel rims: 1.1 mm 1.1 mm 16-inch wheel rims: 1.2 mm 1.2 mm 17-inch wheel rims: 1.3 mm 1.3 mm

Position of front axle (mm)

Unladen

V - POSITION FOR TIGHTENING RUBBER BUSHES For tightening rubber bushes, see Section 31A "Front axle" in Workshop Repair Manual 364.

30A-7

GENERAL INFORMATION Values and adjustments for the rear axle assemblies
I - CAMBER Not adjustable. Il - WHEEL ALIGNMENT Not adjustable.

30A

Values - 130' 20'

Position of rear axle Unladen

Values (For two wheels) Toe-in - 040' 20' 15-inch wheel rims: - 4.5 mm 2.3 mm 16-inch wheel rims: - 4.8 mm 2.4 mm 17-inch wheel rims: - 5 mm 2.6 mm

Position of rear axle

Unladen

III - POSITION FOR TIGHTENING RUBBER BUSHES For tightening rubber bushes, see 33A "Rear axle" Section in Workshop Repair Manual 364.

30A-8

GENERAL INFORMATION Underbody height


MEASURING POINTS

30A

The dimension (W2) is measured from the ground to the mounting axis of the rubber bush on the bearing. The dimension (R1) is measured from the ground to the front wheel axis. The dimension (R2) is measured from the ground to the rear wheel axis.

The dimension (W1) is measured from the ground to the underside of the sub-frame rear cross member mounting bolt head.

30A-9

WHEELS AND TYRES 235A Specifications


I - INFLATION Inflation pressure when cold (in bar), during fully loaded use and/or on motorway. WARNING If checking the pressure when hot, assume a pressure increase of 0.2 to 0.3 bar and never deflate the tyres.

35A

Inflation pressure when cold (in bar) Engine Wheel rim 6.5 J 15 K4J 6.5 J 16* 6.5 J 17* 6.5 J 15 K4M 6.5 J 16* 6.5 J 17* 6.5 J 15 K9K 6.5 J 16* 6.5 J 17* 6.5 J 15 F4R 6.5 J 16* 6.5 J 17* 6.5 J 15 F9Q 6.5 J 16* 6.5 J 17* * Alloy wheel rim The pressure values given are "motorway" values. Tyres Front 195/65 R15T 205/55 R16V 205/50 R17V 195/65 R15H 205/55 R16V 205/50 R17V 195/65 R15T 205/55 R16V 205/50 R17V 195/65 R15H 205/55 R16V 205/50 R17V 195/65 R15T 205/55 R16V 205/50 R17V 2.2 2.2 2.2 2.3 2.3 2.4 2.2 2.2 2.4 2.4 2.4 2.5 2.4 2.4 2.5 Rear 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

35A-1

WHEELS AND TYRES Specifications


Il - CONFORMITY CHECK WARNING If the size of the tyres changes, check the calibration of the Electric Power Assisted Steering computer: configuration CF088 using the fault finding tool (refer to the "fault finding manual").

35A

Tightening torque of the wheel bolts (11 daNm). Maximum rim runout checked on the external diameter of the wheel rim: steel wheel rim: 0.8 mm, alloy wheel rim: 0.3 mm, Maximum run-out checked on the surface of the wheel rim: 0.7 mm. Wheel rim offset: steel wheel rim: 45 mm, alloy wheel rim: 49 mm. For fitting chains, refer to the "driver's handbook" for the vehicle.

III - SPECIAL FEATURES OF VEHICLES FITTED WITH TYRE INFLATION PRESSURE MONITOR SYSTEMS The UCH is programmed for each set of four tyres. The system automatically recognizes the set of tyres fitted to the vehicle.

35A-2

MECHANICAL ELEMENT CONTROLS 337A Control lever


Tightening torque parking brake control mounting nuts 8 daNm REFITTING Note: The nut (3) must be replaced.

37A

REMOVAL Remove the centre console (see the Interior equipment Section).

Refit: the parking brake lever, the parking brake lever mounting nuts. Tighten the parking brake lever mounting nuts to the required torque (8 daNm). Refit the parking brake wiring clip. Reconnect the parking brake connector. Refit the parking brake cables at the parking brake lever end. Refit nut (3). Tighten nut (3) to obtain a dimension of (17 mm). Operate the parking brake to activate the adjustment. Check the stroke of the lever. Refit the centre console (see the Interior equipment Section).

Remove nut (3). Remove the parking brake cables from their housing (1). Remove: the parking brake lever mounting nuts (2), the parking brake lever. Disconnect the switch.

37A-1

MECHANICAL ELEMENT CONTROLS Control cables


REMOVAL Put the vehicle on a two-post lift. REFITTING Note: The nut (1) must be replaced.

37A

Refit the parking brake cables into their housing. Note: When replacing the parking brake cable sheaths, pull the parking brake control several times before adjusting the 17 mm dimension. Check the correct positioning of the handbrake cable thrust bearings at the bodywork end. Refit the parking brake cables: on the brake calliper side (refer to Rear axle Section). on the parking brake lever side (refer to Mechanical element controls, Control lever Section). Replace the nut. Remove nut (1). Remove the parking brake cables: on the parking brake lever side (refer to Mechanical element controls, Control lever Section). on the brake calliper side (refer to Rear axle Section). Remove the parking brake cables from their housing. Tighten the nut to obtain a dimension of 17 mm. Operate the parking brake to activate the adjustment. Check the stroke of the lever.

37A-2

REAR LIGHTING 181A Rear light


REMOVAL Remove the rear light access flap.

81A

Unclip the bulb mounting by pressing on the tab (2) in order to access the bulbs.

Remove: the three nuts (1), the rear light (partially).

REFITTING Proceed in the reverse order to removal.

Disconnect the rear light connector. Remove the rear light.

81A-1

Edition 2

REAR LIGHTING Connection

81A

Track 1 2 3 4 5 6 Fog light Indicator Earth Side light

Description

Reversing light Brake light

Note: Track numbers are read from right to left.

81A-2

Edition 2

REAR LIGHTING Registration plate light


REMOVAL

81A

Remove the registration plate light using a flat-blade screwdriver. Disconnect the connector.

REFITTING Proceed in the reverse order to removal.

81A-3

Edition 2

REAR LIGHTING High level brake light


REMOVAL

81A

Unclip the strut upwards. Unclip the central trim. Disconnect the brake light connector.

Unclip the side trim panels.

Remove: the two bolts, the two clips (1). Unclip the jet. Remove: the jet, the brake light.

Note: The vehicles are fitted with a diode-type brake light.

REFITTING Remove the strut mounting bolts. Proceed in the reverse order to removal.

81A-4

Edition 2

WIPERS - WASHERS 285A Rear screen wiper


Tightening torques wiper arm nut motor mounting nuts Special tooling required El. 1781 Tool for removing the rear screen wiper arm 1.2 daNm 0.8 daNm

85A

REMOVING THE NON-OPENING REAR SCREEN WIPER MOTOR Move the rear screen wiper selector switch to put the wiper motor in park position. move the selector switch from status 0 to 1. move the selector switch from status 1 to 0. Disconnect the battery (see MR 364, 80A Battery, Battery: Removal - Refitting). Remove the tailgate trim (see Technical Note 0586A, 73A Non-side opening element trim, Tailgate trim). Disconnect the motor connector. Remove: the motor mounting bolts (1), the motor. REFITTING THE NON-OPENING REAR SCREEN WIPER MOTOR

Mark the position of the wiper arm. Remove: the wiper arm nut cover, the nut, the wiper arm with the El. 1781.

Replace the seal whenever the motor is removed. Clean the motor shaft splines.

85A-1

Edition 2

WIPERS - WASHERS Rear screen wiper


Refit the rear screen wiper motor. Clean the motor shaft splines.

85A

REMOVING THE NON-OPENING REAR SCREEN WIPER MOTOR Move the rear screen wiper selector switch to put the wiper motor in park position. move the selector switch from status 0 to 1. move the selector switch from status 1 to 0. Disconnect the battery (see MR 364, 80A Battery, Battery: Removal - Refitting). Remove the tailgate trim (see Technical Note 0586A, 73A Non-side opening element trim, Tailgate trim).

Refit the wiper arm in the position marked before it was removed. Tighten the wiper arm nut to torque (1.2 daNm). Connect the battery (see MR 364, 80A Battery, Battery: Removal - Refitting). Check that the wiper operates correctly. REFITTING THE NON-OPENING REAR SCREEN WIPER MOTOR Refit the wiper motor. Tighten the motor mounting bolts to torque (0.8 daNm). Connect the connector. Refit the tailgate trim (see Technical Note 0586A, 73A Non-side opening element trim, Tailgate trim). Connect the battery (see MR 364, 80A Battery, Battery: Removal - Refitting). Check that the wiper operates correctly. Disconnect the connector (2). Remove: the motor mounting bolts (3), the motor.

85A-2

Edition 2

WIPERS - WASHERS Rear wiper motor mechanism


Tightening torques wiper arm nut mechanism external nut mechanism internal nut 1.2 daNm 0.65 daNm 0.45 daNm

85A

Special tooling required El. 1781 Tool for removing the rear screen wiper arm

REMOVAL Move the rear screen wiper selector switch to put the wiper motor in park position. move the selector switch from status 0 to 1. move the selector switch from status 1 to 0. Disconnect the battery (see MR 364, 80A Battery, Battery: Removal - Refitting). Remove the tailgate trim (see Technical Note 0586A, 73A Non-side opening element trim, Tailgate trim). Remove: the nut cap (2), the nut (3), the trim (4). Open the rear screen.

Remove: the nut (5), the mechanism. Remove: the wiper arm nut cover, the nut, the wiper arm with the El. 1781.

85A-3

Edition 2

WIPERS - WASHERS Rear wiper motor mechanism


REFITTING NOTE When replacing the opening rear screen, it is essential to check the opening clearances before following the procedure (see General information). Adjusting the wiper mechanism

85A

Position the mechanism, observing the 63 mm measurement (A) between the trim and the edge of the rear screen. Partially tighten the nut (7).

The seal (6) must be replaced.

85A-4

Edition 2

WIPERS - WASHERS Rear wiper motor mechanism

85A

Centre the mechanism in relation to the mounting bolt (8). Torque tighten: nut (7) to 0.65 daNm, nut (8) to 0.45 daNm.

Clean the motor shaft splines. Position the wiper arm 46 mm (measurement B) away from the edge of the rear screen.

Note: Close the opening rear screen (the mechanism is positioned on the motor plate). Operate the rear screen wiper to engage the mechanism on the motor plate.

Note: The wiper arm adjustment can be refined by pressing the mechanism as shown in the illustration above.

85A-5

Edition 2

RADIO 386C Aerial


REMOVAL

86C

Remove the headlining (see Section 71A of MR 365). Remove the mounting nut (1).

Disconnect the aerial cable from its support.

REFITTING Proceed in the reverse order to removal.

86C-1

Edition 2

DOOR LOCKING SYSTEM 487C Rear screen opening switch


REMOVAL Note: It is not necessary to remove the tailgate moulding to perform this operation. CONNECTION

87C

Protect the edge of the opening control with masking tape. Unclip the control with a flat-blade screwdriver. Disconnect the connector.

Track 1 2 Earth

Description

Opening control

REFITTING Proceed in the reverse order to removal.

Note: The tailgate opening control is a unipolar switch. The opening control can be checked with an ohmmeter.

87C-1

Edition 2

DOOR LOCKING SYSTEM Tailgate opening switch


REMOVAL Note: It is not necessary to remove the tailgate moulding to perform this operation. CONNECTION

87C

Protect the edge of the opening control with masking tape. Unclip the control with a flat-blade screwdriver. Disconnect the connector.

Track 1 2

Description Opening control Earth

REFITTING Proceed in the reverse order to removal.

Note: The tailgate opening control is a unipolar switch. The opening control can be checked with an ohmmeter.

87C-2

Edition 2

DOOR LOCKING SYSTEM Tailgate lock


REMOVAL

87C

Remove screws (2). Note: If there is an electrical fault, the tailgate can be opened manually. Unlock the tailgate lock by pushing tab (1) with a screwdriver. This operation is performed from inside the vehicle. Disconnect the battery, starting with the negative terminal. Remove the tailgate trim (see Section 73A of Technical Note 586A). Press clip (3). Remove the lock. Disconnect the connector from the lock.

REFITTING NOTE Connect the battery; carry out the necessary programming (see the Battery Section.) Proceed in the reverse order to removal.

87C-3

Edition 2

DOOR LOCKING SYSTEM


Keyless vehicle: Tailgate lock connection

87C

Track 1 2 3 4 Motor supply Motor supply

Description

Opening sensor (body flange sensor) Earth

Note: The tailgate opening control is a unipolar switch. The opening control can be checked with an ohmmeter.

87C-4

Edition 2

DOOR LOCKING SYSTEM


Fuel filler flap locking motor
REMOVAL Fuel filler flap locking/unlocking is controlled simultaneously with the driver's door. Remove the right-hand wheel arch liner (see Section 71A of Technical Note 586A). REFITTING

87C

Remove: the fuel filler flap motor connector (1), the motor mounting nut (2) (to the left of the flap in the outer wheel arch), the motor.

NOTE Moderately tighten the nut on the plastic thread of the motor. Proceed in the reverse order to removal.

Note: If there is an electrical fault, the motor can be activated manually.

87C-5

Edition 2

DOOR LOCKING SYSTEM Starter aerials

87C

Vehicles with the hands-free system have three starting aerials for the card: one front detection aerial (1) located behind the front panel of the dashboard, an aerial (2) in the rear section of the centre console, an aerial (3) at the rear section of the floor. Note: The opening aerials have no effect on the immobiliser system. The aerials are identical and interchangeable. They require no programming.

REMOVAL

87C-6

Edition 2

DOOR LOCKING SYSTEM Starter aerials


Unfasten clips (4) to detach the aerial. NOTE The starting aerial clips (4) are very fragile. II - REAR AERIAL

87C

Slightly loosen the carpet in the luggage compartment.

Unclip the face (see Engine Immobiliser, Pressure Button Section, page 82A-16). I - CENTRAL AERIAL Unclip the aerial (5) by pressing the clips.

Remove the central console (see Section on Central Console).

87C-7

Edition 2

DOOR LOCKING SYSTEM Opener aerials


Vehicles equipped with the hands-free system have presence sensors and opener aerials to identify the card: an opener aerial (1) situated in each exterior handle, an opener aerial (2) situated in the rear bumper, a presence sensor in each handle.

87C

Note: The start aerials (3) have no effect on unlocking the vehicle. On the other hand, the vehicle cannot be locked with the Close buttons situated on the outside handles if the card is within the start zone. Motion sensors are built into the presence sensors.

87C-8

Edition 2

DOOR LOCKING SYSTEM Opener aerials


REMOVAL

87C

In order to operate in hands-free mode, vehicles must be equipped with an opener aerial in the tailgate trim.

For operation in hands-free mode, the door handles must be fitted with: presence sensors (1) with a reflector on the handle to detect the user's hand, a locking button (2), an opening aerial incorporated in the handle (3). Note: Only vehicles with the hands-free function have a locking button (2). Note: After a period of non-use of approximately 72 hours, the presence sensors become deactivated. The unlock request is then detected by a motion sensor. The presence sensor and motion sensor are a single unit. To remove the handles, see MR 365 Bodywork.

Remove the tailgate trim (see Technical Note 0586A Section 55A-B). Disconnect aerial connector. Remove the aerial.

REFITTING Proceed in the reverse order to removal.

87C-9

Edition 2

DOOR LOCKING SYSTEM Opener aerials: Connection

87C

Presence and movement sensors (connector 2) Track 1 2 3 Description Sensor signal Earth Power supply + before ignition

Opener aerial and lock button (connector 3) Track 1 2 3 4 Description Opener aerial Opener aerial Locking signal Locking earth connection

Note: The locking button is a simple switch. It can be tested with an ohmmeter between tracks 3 and 4. The opener aerial resistance is approximately 0.2 .

87C-10

Edition 2

AIRBAG AND PRETENSIONERS 588C Rear pyrotechnic seatbelt retractor


Equipment required Diagnostic tool

88C

Tightening torques inertia reel mounting bolt fitting mounting bolt 2.1 daNm 2.1 daNm

The rear seat belts (side seats) are fitted with pyrotechnic inertia reels.

REMOVAL IMPORTANT Before doing any work on a safety system component, lock the airbag computer with the diagnostic tool (see the Electrical equipment Section). When this function is activated all the trigger lines are inhibited, and the airbag warning light on the instrument panel is lit continuously (when the ignition is on). Remove: the rear quarter panel lining, the rear parcel shelf trim.

Disconnect the connector (2). Remove: the inertia reel bolt (3), the seatbelt retractor. IMPORTANT To scrap a pretensioner that has not been triggered, see the Airbag and pretensioners, Airbag and pretensioner computer Section in MR 364.

Remove seat belt lower mounting bolt (1).

88C-1

Edition 2

AIRBAG AND PRETENSIONERS Rear pyrotechnic seatbelt retractor


REFITTING Proceed in the reverse order to removal. NOTE Once a pretensioner has been triggered, certain parts must be replaced (see the Airbag and pretensioners, Airbag and pretensioner computer Section in MR 364). Ensure that the wiring is correctly routed using the wiring mounting points. Tighten to torque: the pretensioner mounting bolt (2.1 daNm), the seat belt fitting mounting bolt (2.1 daNm). IMPORTANT Check the airbag computer with the diagnostic tool. If everything is correct, unlock the airbag computer, otherwise refer to the fault finding manual.

88C

88C-2

Edition 2

AIRBAG AND PRETENSIONERS Side curtain airbag


Equipment required Diagnostic tool

88C

Tightening torques Curtain airbag mounting bolt 0.8 daNm

The side curtain airbag is mounted behind the headlining. The airbag detaches the headlining when it deploys.

REMOVAL IMPORTANT Before doing any work on a safety system component, lock the airbag computer with the diagnostic tool (see the Electrical equipment Section). When this function is activated all the trigger lines are inhibited and the airbag warning light on the instrument panel lights up (ignition on). Remove the headlining (see MR 365, Section 71A).

The curtain section (3) is clipped to the body.

Disconnect the module connector (1). Remove the module mounting bolts (2).

To unclip the curtain: pull down (4) the curtain to lower the clip mounted on the body, pull up (5) the curtain to remove the clip from the upper section.

88C-3

Edition 2

AIRBAG AND PRETENSIONERS Side curtain airbag

88C

To unclip the curtain: raise (6) the assembly. IMPORTANT To scrap an airbag that has not been triggered, see the Airbag and pretensioners, Airbag and pretensioner computer Section in MR 88C-39).

Use the following replacement parts: a curtain airbag, a plate (part no.: 82 00 277 635), two special rivets (part no.: 77 03 072 050), a tube of adhesive (part no.: 77 11 171 805). Note: The plates on the right and left-hand sides are identical.

REFITTING NOTE If a curtain airbag module is triggered, the damage to the first mounting is such that a plate, supplied as a replacement part, must always be fitted. Once a curtain airbag has been triggered, certain parts must be replaced (see the Airbag and pretensioners, Airbag and pretensioner computer Section in MR 364). I - FITTING THE PLATE

88C-4

Edition 2

AIRBAG AND PRETENSIONERS Side curtain airbag


Cut away the plate (7) damaged by the triggering of the curtain airbag. Apply an anti-corrosion paint treatment to the area of the cut. Clean the bonding surfaces. Degrease the bonding surfaces. II - FITTING THE MODULE

88C

Position the airbag without tightening the mounting bolts.

Fit the airbag, starting with the support (8). Fit all of the clips. Tighten to torque the curtain airbag mounting bolts (0.8 daNm). Reconnect the connector, ensuring that it locks into place properly. IMPORTANT Check the airbag computer with the diagnostic tool. If everything is correct, unlock the airbag computer, otherwise refer to the MR.

Apply the supplied activator and then coat the plate with adhesive. Fit the plate. Rivet the plate. If everything is OK, unlock the airbag computer; if not, refer to the fault finding manual. NOTE The adhesive and rivets are specific and must under no circumstances be replaced by other components with different part numbers. Inject wax into hollow body parts (see Bodywork Manual 365).

88C-5

Edition 2

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