Renault

2 Transmission
20A CLUTCH
21A MANUAL GEARBOX
23A AUTOMATIC GEARBOX
29A DRIVESHAFTS
X95
APRIL 2009 Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault.
specifications current when it was prepared.
The reproduction or translation in part of whole of the present document, as well as the use
The methods may be modified as a result of changes introduced by the manufacturer in the of the spare parts reference numbering system, are prohibited without the prior written
production of the various component units and accessories from which his vehicles are consent of Renault.
constructed."
© Renault s.a.s 2008

MEGANE III - Section 2ContentsPage
MEGANE III - Section 2
Contents
Page
20A CLUTCH 23A AUTOMATIC GEARBOX
Clutch: Specifications 20A-1 Automatic gearbox:

Specifications 23A-5
Mechanism / Disk: Removal -
Refitting 20A-5 Automatic gearbox: List and
location of components 23A-6
Clutch thrust bearing:
Removal - Refitting 20A-22 Automatic gearbox: Removal
- Refitting 23A-8
Automatic gearbox oil:

Draining - Refilling 23A-17
21A MANUAL GEARBOX
Gearbox oil sump: Removal -
Manual gearbox oil: Refitting 23A-22
Specifications 21A-1
Hydraulic distributor:
Manual gearbox oil: Draining Removal - Refitting 23A-24
- Refilling 21A-2
Hydraulic distribution wiring:
Differential output seal: Removal - Refitting 23A-33
Removal - Refitting 21A-10
Hydraulic distributor internal
Manual gearbox: Removal - wiring: Removal - Refitting 23A-39
Refitting 21A-24
Gearbox oil cooler: Removal
Input shaft lip seal: Removal - Refitting 23A-48
- Refitting 21A-76
Additional gearbox oil cooler:
Reverse gear switch: Removal - Refitting 23A-52
Gearbox oil coolant pipe:
Differential output seal:

23A AUTOMATIC GEARBOX Removal - Refitting 23A-64
Multifunction switch:
Automatic gearbox: Removal - Refitting 23A-68
Precautions for repair 23A-1
Multifunction switch:
Automatic gearbox: Adjusting 23A-71
Identification 23A-3
Contents
23A AUTOMATIC GEARBOX
Speed sensor: Removal -

Refitting 23A-73
Oil pressure switch: Removal

- Refitting 23A-77
Automatic gearbox
converter: Removal -
Refitting 23A-82
Converter seal: Removal -

Refitting 23A-88
Automatic transmission
computer: Removal -
Refitting 23A-93
29A DRIVESHAFTS
Driveshaft: Precautions for

repair 29A-1
Front left-hand wheel

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

driveshaft: Removal -
Refitting 29A-18
Relay shaft bearing:

Front driveshaft gaiter on

wheel side: Removal -
Refitting 29A-38
Front right-hand driveshaft

gaiter on gearbox side:
Front left-hand driveshaft

gaiter on gearbox side:
CLUTCH
Clutch: Specifications 20A
F4R or F9Q or K4M or K9K
K4M, and 858

K4M, and 848
Pressure plate
Pressure plate
106504
132330
Drive plate
Drive plate
102142
102142
Plate outer diameter: 216 mm
Plate thickness: 6.9 mm Plate thickness: 7.0 mm
Number of grooves: 24 Number of grooves: 24
20A-1
CLUTCH
K9K, and 830 or 834 K9K, and 832 or 836
Pressure plate Pressure plate
108795 22428
Drive plate Drive plate
102142 123820
Plate outer diameter: 216 mm Plate outer diameter: 225 mm
20A-2
CLUTCH
F4R, and 870 F4R, and 874
Pressure plate Pressure plate
22428 22428
Drive plate Drive plate
123820 123820
Plate outer diameter: 239 mm Plate outer diameter: 239 mm
20A-3
CLUTCH
F9Q
Pressure plate
22428
Drive plate
123820
Plate thickness: 7.8 mm
Number of grooves: 24
20A-4
CLUTCH
Mechanism / Disk: Removal - Refitting 20A
ND4 or PK4
- the front section of the front wheel arch liners (see
Essential special tooling Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),
Mot. 1431 Flywheel locking tool.
- the engine undertray bolts,
Emb. 1761 Clutch pressure plate remo-
val/refitting kit - the engine undertray,
Emb. 1604 Clutch compression tool for - the front bumper (see Front bumper: Removal -
resetting retrofit system. Refitting) (55A, Exterior protection).
a Remove:
Emb. 1780 Set of clutch disc centring
mandrels. - the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
Mot. 1677 Flywheel locking tool.
- the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
Tightening torquesm
- the starter (see Starter: Removal - Refitting)
clutch pressure plate 12 N.m (16A, Starting - Charging).
bolts
a Drain the manual gearbox (see 21A, Manual gear-

IMPORTANT box, Manual gearbox oil: Draining - Refilling,
To avoid all risk of damage to the systems, apply page 21A-2) .
the safety and cleanliness instructions and opera-
a Remove:
tion recommendations before carrying out any
repair (see Clutch: Precautions for repair) . - the front left-hand driveshaft (see 29A, Drives-
hafts, Front left-hand wheel driveshaft: Remo-
val - Refitting, page 29A-2) ,
REMOVAL
- the front right-hand driveshaft (see 29A, Drives-
hafts, Front right-hand wheel driveshaft: Remo-
I - REMOVAL PREPARATION OPERATION val - Refitting, page 29A-18) ,
a Position the vehicle on a two-post lift (see Vehicle:
- the differential output seals (see 21A, Manual
Towing and lifting) (02A, Lifting equipment).
gearbox, Differential output seal: Removal - Re-
a Remove: fitting, page 21A-10) ,
- the engine cover, - the radiator mounting cross member (see Radiator
support cross member: Removal - Refitting)
(41A, Front lower structure),
- the engine undertray,
- the front axle subframe (see Front axle sub-fra-
- the battery (see Battery : Removal - Refitting) me: Removal - Refitting) (31A, Front axle compo-
(80A, Battery), nents),
- the battery tray (see Battery tray: Removal - Re- - the scuttle panel grille (see Scuttle panel grille:
fitting) (80A, Battery), Removal - Refitting) (56A, Exterior equipment),
a Disconnect the clutch hydraulic pipe from the slave - the scoop under the scuttle panel grille (see Scoop
cylinder (see Clutch circuit: Removal - Refitting) under scuttle panel grille: Removal - Refitting)
(37A, Mechanical component controls). (56A, Exterior equipment),
a Unclip the control cables from the gearbox (see Ma-
- the left-hand suspended engine mounting (see
nual gearbox selector cable: Removal - Refitting)
Left-hand suspended engine mounting: Remo-
(37A, Mechanical component controls).
val - Refitting) (19D, Engine mounting),
a Remove:
- the manual gearbox (see 21A, Manual gearbox,
- the front wheels (see Wheel: Removal - Refitting) Manual gearbox: Removal - Refitting, page 21A-
(35A, Wheels and tyres), 24) .
20A-5
CLUTCH
ND4 or PK4
II - OPERATION FOR REMOVAL OF PART
CONCERNED
115523
134623
a Position the (1) (Mot. 1431).
a Remove three pressure plate retaining bolts at 120˚
intervals.
111077
a Replace these three bolts by the (Emb. 1761) com-
prising: an assembly of three bolts, three spacers
and three nuts to hold the pressure plate in place.
a Place the three spacers in contact using the nuts.
a Gradually remove the six remaining bolts.
20A-6
CLUTCH
ND4 or PK4
a Degrease the flywheel friction face with SURFACE
CLEANER (see Vehicle: Parts and ingredients
for the repairwork) (04B, Consumables - Pro-
ducts).
Note:
The following procedure is to be used only if refit-
ting the old pressure plate.
The automatic compensation must be repositio-
ned at its starting point.
If the old pressure plate is being refitted, apply the

following procedure
111078
a
Note:
These instructions must be respected to prevent
twisting the plate.
a Unscrew and gradually remove by quarter turns the

three nuts of tool (Emb. 1761), one by one. 19919
a Remove: a
- the clutch pressure plate, Note:
- the clutch plate. For automatic wear compensation mechanisms,
compress the clutch pressure plate using tool
REFITTING (Emb. 1604).
I - REFITTING PREPARATION OPERATION

a Always replace the clutch pressure plate bolts.
a Clean the clutch shaft splines with SURFACE
ducts).
20A-7
CLUTCH
ND4 or PK4
20754 20756
a Place the base of tool (Emb. 1604) in a vice. a Tighten the nut (4) fully.
20757
a Fit a circlip clamp at (5) .
20755
a Fit the pressure plate onto the base plate then the
thrust ball bearing or bronze ring (3) and the nut (4) .
20A-8
CLUTCH
ND4 or PK4
II - REFITTING OPERATION FOR PART
CONCERNED
20759
a Compress the spring (6) to reprime the automatic
compensation.
a Slacken off the nut (4) completely (springs com-
pressed).
a Release the pressure plate.
102695
a Fit the friction plate (with the small diameter of the
hub at the flywheel end (7) ).
20758
a Remove the pressure plate from the base plate (ma-
king sure that the springs are correctly compressed).
134621
a Centre the clutch plate using the (Emb. 1780) (8) .
a Refit the clutch mechanism to the flywheel.
a Torque tighten the clutch pressure plate bolts (12
N.m).
a Remove:
- the (Emb. 1780),
- the (Mot. 1677).
20A-9
CLUTCH
ND4 or PK4
III - FINAL OPERATION a Refit:
a Refit: - the battery tray (see Battery tray: Removal - Re-

fitting) (80A, Battery),
- the battery (see Battery : Removal - Refitting)
Manual gearbox: Removal - Refitting, page 21A-
(80A, Battery),
24) ,
a Fill the manual gearbox (see 21A, Manual gearbox,
- the left-hand suspended engine mounting (see Manual gearbox oil: Draining - Refilling, page
21A-2) .
a Refit:
- the scoop under the scuttle panel grille (see Scoop
under scuttle panel grille: Removal - Refitting)
(56A, Exterior equipment), - the engine cover.
- the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),

me: Removal - Refitting) (31A, Front axle compo-
nents),
- the radiator mounting cross member (see Radiator


fitting, page 21A-10) ,

- the front left-hand driveshaft (see 29A, Drives-


(16A, Starting - Charging),

tion),
- the front wheels (see Wheel: Removal - Refitting)

a Connect the clutch hydraulic pipe to the slave cylin-

der (see Clutch circuit: Removal - Refitting) (37A,
Mechanical component controls).
a Bleed the clutch control (see Clutch circuit: Blee-

ding) (37A, Mechanical component controls).
a Clip the control cables onto the gearbox (see Ma-

a Adjust the gearbox control cables (see Mechanical

gear control cable: Adjustment) (37A, Mechanical
component controls).
20A-10
CLUTCH
JH3 or JR5 or TL4
- the battery (see Battery: Removal - Refitting)
Essential special tooling (80A, Battery),
Mot. 1677 Flywheel locking tool. - the battery tray (see Battery tray: Removal - Re-
mandrels. - the air filter unit (see Air filter unit: Removal - Re-
fitting) (12A, Fuel mixture),
a Disconnect the clutch hydraulic pipe from the slave

Tightening torquesm cylinder (see Clutch circuit: Removal - Refitting)
clutch pressure plate 12 N.m
bolts a Unclip the control cables from the gearbox (see Ma-
clutch pressure plate 15 N.m (37A, Mechanical component controls).
bolts
a Remove:
IMPORTANT (35A, Wheels and tyres),
To avoid all risk of damage to the systems, apply - the front section of the front wheel arch liners (see
the safety and cleanliness instructions and opera- Front wheel arch liner: Removal - Refitting)
tion recommendations before carrying out any (55A, Exterior protection),
repair (see Clutch: Precautions for repair) .
Note: - the front bumper (see Front bumper: Removal -
When fitting the clutch plate, the "RENAULT part Refitting) (55A, Exterior protection).
number" should be visible when the plate is in posi-
tion. box, Manual gearbox oil: Draining - Refilling,
page 21A-2) .
a Remove:
IMPORTANT
To prevent the vehicle from falling, lash it to the
vehicle lift using a strap.
- the lower engine tie-bar (see Lower engine tie-
bar: Removal - Refitting) (19D, Engine moun-
REMOVAL ting),
- the crankshaft position sensor (see Crankshaft

I - REMOVAL PREPARATION OPERATION position sensor: Removal - Refitting) (17B, Pe-
trol injection),
Towing and lifting) (02A, Lifting equipment). - the front left-hand driveshaft (see 29A, Drives-
a Remove:
- the engine cover,
- the windscreen wiper arms (see Windscreen wi- hafts, Front right-hand wheel driveshaft: Remo-
per arm: Removal - Refitting) (85A, Wiping - val - Refitting, page 29A-18) ,
Washing),
- the scuttle panel grille (see Scuttle panel grille: gearbox, Differential output seal: Removal - Re-
Removal - Refitting) (56A, Exterior equipment), fitting, page 21A-10) ,
- the scoop under the scuttle panel grille (see Scoop - the radiator mounting cross member (see Radiator
under scuttle panel grille: Removal - Refitting) support cross member: Removal - Refitting)
(56A, Exterior equipment), (31A, Front axle components),
20A-11
CLUTCH
JH3 or JR5 or TL4
nents), K9K, and TL4

24) .

CONCERNED
JH3 or JR5
134217
a Lock the flywheel using tool (Mot. 1677) (4) .
a Remove:
- the bolts (3) from the « mechanism - disc » assem-
bly,
- the « pressure plate - disc » assembly.
134558
a Lock the flywheel using tool (Mot. 1677) (1) .
a Remove:
bly,
20A-12
CLUTCH
JH3 or JR5 or TL4
CONCERNED
K4M, and TL4
136594 132331
a Lock the flywheel using tool (Mot. 1677). a Fit the clutch plate, with the face (6) to the clutch
a Remove: pressure plate end.
bly,
JH3 or JR5
REFITTING

a Use SURFACE CLEANER (see Vehicle: Parts
and ingredients for the repairwork) (04B, Consu-
mables - Products) to clean and degrease:
- the flywheel friction face,
- the clutch shaft splines.
WARNING
Do not grease the clutch shaft splines.
134557
20A-13
CLUTCH
JH3 or JR5 or TL4
a Refit the clutch mechanism.
K9K, and TL4
TL4
N.m) gradually in a radial pattern.
JH3 or JR5

N.m) gradually in a radial pattern.
a Remove the (Emb. 1780) and (Mot. 1677).
III - FINAL OPERATION

a Refit:
134219 - the manual gearbox (see 21A, Manual gearbox,

24) ,
K4M, and TL4 - the front axle subframe (see Front axle sub-fra-
nents),
(31A, Front axle components),
position sensor: Removal - Refitting) (17B, Pe-
trol injection),
136590
a Centre the clutch plate using the (Emb. 1780) (9) . ting).
20A-14
CLUTCH
JH3 or JR5 or TL4
a Fill up the manual gearbox (see 21A, Manual gear-
box, Manual gearbox oil: Draining - Refilling,
page 21A-2) .
a Refit:
- the front bumper (see Front bumper: Removal -

Refitting) (55A, Exterior protection),

Front wheel arch liner: Removal - Refitting)
a Connect the clutch hydraulic pipe to the slave cylin-

der (see Clutch circuit: Removal - Refitting) (37A,
Mechanical component controls).

ding) (37A, Mechanical component controls).
a Clip the control cables onto the gearbox (see Ma-

a Adjust the gearbox control cables (see Mechanical

a Refit:

- the air filter unit (see Air filter unit: Removal - Re-
- the battery tray (see Battery tray: Removal - Re-


(80A, Battery),

(56A, Exterior equipment),

- the windscreen wiper arms (see Windscreen wi-

per arm: Removal - Refitting) (85A, Wiping -
Washing),
- the engine cover.
20A-15
CLUTCH
M9R, and PK4
a Remove:
Essential special tooling
Mot. 1431 Flywheel locking tool. hafts, Front left-hand wheel driveshaft: Remo-
mandrels. - the front right-hand driveshaft (see 29A, Drives-
Tightening torquesm - the differential output seals (see 21A, Manual

clutch pressure plate 12 N.m fitting, page 21A-10) ,
bolts - the radiator mounting cross member (see Radiator
IMPORTANT me: Removal - Refitting) (31A, Front axle compo-
To avoid all risk of damage to the systems, apply nents),
the safety and cleanliness instructions and opera- - the centre section of the scuttle panel grille (see
tion recommendations before carrying out any Scuttle panel grille: Removal - Refitting) (56A,
repair (see Clutch: Precautions for repair) . Exterior equipment),
- the scoop under the centre section of the scuttle
REMOVAL panel grille (see Scoop under scuttle panel
grille: Removal - Refitting) (56A, Exterior equip-
ment),
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle: Left-hand suspended engine mounting: Remo-
Towing and lifting) (02A, Lifting equipment). val - Refitting) (19D, Engine mounting),
IMPORTANT Manual gearbox: Removal - Refitting, page 21A-
To prevent the vehicle from falling, lash it to the 24) .
a Remove:
- the engine cover,
(80A, Battery),
tion),
(16A, Starting - Charging).
page 21A-2) .
20A-16
CLUTCH
M9R, and PK4
CONCERNED
111077
134623
a Position the (Mot. 1431) (1) .
a Remove the clutch pressure plate bolts (2) .
115523
a Replace the three bolts (2) using the tool (A) inclu-
ding:
- three bolts,
- three nuts,
- three spacers.
a Place the three spacers in contact using the nuts.
a Gradually remove the six remaining bolts (3) .
20A-17
CLUTCH
M9R, and PK4
mables - Products) to clean and degrease:
- the clutch shaft splines,
- the flywheel friction face.
Note:
The following procedure is to be used only if refit-
ting the old pressure plate.
The automatic compensation must be repositio-
ned at its starting point
If the old pressure plate is being refitted, apply the

following procedure
111078
a
Note:
These instructions must be respected to prevent
twisting the plate.
a Gradually unscrew by quarter turns the three nuts of

the tool, one by one.
a Remove:
19919
- the,
a
- the clutch pressure plate,
- the clutch plate. Note:
For automatic wear compensation mechanisms,
REFITTING compress the clutch pressure plate using tool.

a Always replace the clutch pressure plate bolts.
20A-18
CLUTCH
M9R, and PK4
20754 20756
a Place the base of toolin a vice. a Tighten the nut (4) fully.
20757
a Fit a circlip clamp at (6) .
20755
a Fit the pressure plate onto the base plate then the
thrust ball bearing or bronze ring (4) and the nut (5) .
20A-19
CLUTCH
M9R, and PK4
CONCERNED
20759
a Compress the spring (7) to reprime the automatic
compensation.
a Slacken off the nut (4) completely (springs com-
pressed).
a Release the pressure plate.
102695
a Fit the friction plate (with the small diameter of the
hub at the flywheel end (8) ).
20758
a Remove the pressure plate from the base plate, ma-
king sure that the springs are correctly compressed.
134621
a Refit the clutch pressure plate to the flywheel.
N.m).
a Remove:
- the (Emb. 1780),
- the.
20A-20
CLUTCH
M9R, and PK4
a Refit:
24) ,
panel grille (see Scoop under scuttle panel
ment),
- the centre section of the scuttle panel grille (see
Scuttle panel grille: Removal - Refitting) (56A,
Exterior equipment),
nents),
tion),
(80A, Battery).
page 21A-2) .
a Refit:
- the engine cover.
20A-21
CLUTCH
Clutch thrust bearing: Removal - Refitting 20A
JH3 or JR5 or ND4 or PK4 or TL4
Tightening torquesm val - Refitting, page 29A-18) ,
clutch thrust bearing 21 N.m - the differential output seals (see 21A, Manual
bolts gearbox, Differential output seal: Removal - Re-
REMOVAL
I - REMOVAL PREPARATION OPERATION - the radiator mounting cross member (see Radiator
a Position the vehicle on a two-post lift (see Vehicle: (31A, Front axle components),
a Remove: bar: Removal - Refitting) (19D, Engine moun-
- the engine cover, ting),
- the engine undertray bolts, - the front axle subframe (see Front axle sub-fra-
- the engine undertray, nents),
- the battery (see Battery: Removal - Refitting) - the left-hand suspended engine mounting (see
(80A, Battery), Left-hand suspended engine mounting: Remo-
- the battery tray (see Battery tray: Removal - Re- val - Refitting) (19D, Engine mounting),
fitting) (80A, Battery), - the manual gearbox (see 21A, Manual gearbox,
- the air filter unit (see Air filter unit: Removal - Re- Manual gearbox: Removal - Refitting, page 21A-
fitting) (12A, Fuel mixture), 24) .
- the hydraulic clutch control pipe (see Clutch cir-

cuit: Removal - Refitting) (37A, Mechanical com- II - OPERATION FOR REMOVAL OF PART
ponent controls). CONCERNED
Washing),
Refitting) (55A, Exterior protection).
a Drain the gearbox (see 21A, Manual gearbox, Ma-
nual gearbox oil: Draining - Refilling, page 21A-2)
. 134625
a Remove: a Remove:
- the bolts (1) from the clutch thrust bearing,
val - Refitting, page 29A-2) , - the clutch thrust bearing.
20A-22
CLUTCH
Clutch thrust bearing: Removal - Refitting 20A
REFITTING a Refit:
I - REFITTING PREPARATION OPERATION Refitting) (55A, Exterior protection),
a Always replace the clutch thrust bearing. - the front section of the front wheel arch liners (see
Note: - the front wheels (see Wheel: Removal - Refitting)
To obtain optimum bleeding, pre-fill the clutch (35A, Wheels and tyres),
thrust bearing when refitting the thrust bearing. - the scoop under the scuttle panel grille (see Scoop
CONCERNED - the scuttle panel grille (see Scuttle panel grille:
a Refit a new clutch thrust bearing.
a Torque tighten the clutch thrust bearing bolts (21 per arm: Removal - Refitting) (85A, Wiping -
N.m). Washing),
III - FINAL OPERATION cuit: Removal - Refitting) (37A, Mechanical com-
ponent controls),
a Refit:
- the manual gearbox (see 21A, Manual gearbox, ding) (37A, Mechanical component controls).
24) , a Refit:
- the left-hand suspended engine mounting (see - the air filter unit (see Air filter unit: Removal - Re-
Left-hand suspended engine mounting: Remo- fitting) (12A, Fuel mixture),
val - Refitting) (19D, Engine mounting), - the battery tray (see Battery tray: Removal - Re-
me: Removal - Refitting) (31A, Front axle compo- - the battery (see Battery: Removal - Refitting)
nents), (80A, Battery),
- the lower engine tie-bar (see Lower engine tie- - the engine undertray,
- the engine cover.
ting),
val - Refitting, page 29A-2) .
a Fill the gearbox (see 21A, Manual gearbox, Ma-
.
20A-23
MANUAL GEARBOX
Manual gearbox oil: Specifications 21A
5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX
I - VEHICLE/GEARBOX TYPE/OIL TYPE III - IDENTIFICATION OF OIL FOR STANDARD
CORRELATIONS: EXCHANGE PK1 GEARBOXES:
GEARBOX TYPE TYPE OF OIL FOR Note:

GEARBOX
For standard exchange PK1 gearboxes, the oil type
JBX TRANSELF TRJ (TRZ or TRP) is shown on a label.
75W80 These two oils are replaced by TRX 75W80 or NFP
JCX
or 75W80.
JRX
TRANSELF NFJ
JHX
75W80
NDX
TL4
PKX TRANSELF TRX

75W80
PFX
or
VMX
TRANSELF NFP
NEX
75W80
NGX
N0X
UNX
ZFX TRANSELF LD
75W80
II - STANDARDS AND PART NUMBERS OF THE

VARIOUS RECOMMENDED OILS:
DESIGNATION STANDARD PART NUM-

BER
TRANSELF APIGL4, 77 11 143 534

TRX 75W80 MIL-L-2105 (5 litres)
C or D
or
TRANSELF
NFP 75W80
TRANSELF APIGL4, May be orde-

red from ELF
TRJ 75W80 MIL-L-2105
C or D
or
TRANSELF
NFJ 75W80
TRANSELF APIGL4, May be orde-

red from ELF
LD 75W80 MIL-L-2105
21A-1
MANUAL GEARBOX
Manual gearbox oil: Draining - Refilling 21A
JH3 or JR5
Mot. 1018 Sump plug tool.
Essential equipment
oil recovery container
torque wrench
8 mm square drain plug socket
Tightening torquesm
drain plug 25 N.m
Gearbox type Capacity (litres)
JH3 2.7
136474
JR5 2.4 a Remove the drain plug (1) using the (Mot. 1018).
a Let the oil run into the oil recovery container.
I - PARTS AND CONSUMABLES FOR THE REPAIR
a Part for repair:
- the manual gearbox drain plug seal.
a Consumables for repair:
- Manual gearbox oil (see 21A, Manual gearbox,
Manual gearbox oil: Specifications, page 21A-1)
(Technical Note 6012A, 04B, Lubricants).
II - DRAINING OPERATION
a Remove:
- the engine undertray.
a Position the oil recovery container under the gear-
box.
113764
a Refit a new seal on the drain plug with the groove (2)
facing the plug.
a Refit the drain plug fitted with its new seal.
a Torque tighten the drain plug (25 N.m) using a tor-
que wrench fitted with a 8 mm square drain plug
socket.
21A-2
MANUAL GEARBOX
JH3 or JR5
III - FILLING
135244
a Undo the filler cap (3) .
92081
a Fill the gearbox using a syringe containing recom-
mended oil (see 21A, Manual gearbox, Manual
gearbox oil: Specifications, page 21A-1) (04A, Lu-
bricants) until the oil overflows out of the filler cap
hole.
a Refit the filler cap.
a Wipe any oil run-off with a cloth.
a Remove the oil recovery container.
a Refit the engine undertray.
21A-3
MANUAL GEARBOX
ND4
Essential equipment
torque wrench
Tightening torquesm
drain plug 24 N.m
CAPACITY
Type Capacity
(litres) 134618
ND4 2.1 l a Unscrew the drain plug (1) using the (Mot. 1018).
a Let the oil flow out of the gearbox in the oil recovery
I - PARTS AND CONSUMABLES FOR THE REPAIR container.
a Part for repair:
- gearbox oil (see 21A, Manual gearbox, Manual
gearbox oil: Draining - Refilling, page 21A-2)
(Technical Note 6012A, 04A, Lubricants).
a Remove:
a Fit the oil recovery container under the manual
gearbox.
113764
facing the plug.

socket.
21A-4
MANUAL GEARBOX
ND4
III - FILLING
134180
92081
gearbox oil: Draining - Refilling, page 21A-2)
(04A, Lubricants) until the oil overflows out of the
filler cap hole.
21A-5
MANUAL GEARBOX
TL4
Essential equipment
torque wrench
Tightening torquesm
drain plug 24 N.m
CAPACITY
Gearbox type Capacity (litres)

136488
TL4 1.9
a Remove the drain plug (1) using the (Mot. 1018).
I - PARTS AND CONSUMABLES FOR THE REPAIR a Let the oil flow out of the gearbox in the oil recovery
a Part for repair: container.

- Gearbox oil (see 21A, Manual gearbox, Manual
gearbox oil: Specifications, page 21A-1) (Tech-
nical Note 6012A, 04A, Lubricants).
a Remove:
box.
113764
facing the plug.

socket.
21A-6
MANUAL GEARBOX
TL4
III - FILLING
136503
92081
gearbox oil: Specifications, page 21A-1) (04A, Lu-
bricants) until the oil overflows out of the filler cap
hole.
21A-7
MANUAL GEARBOX
PK4
Essential equipment
Tightening torquesm
drain plug 24 N.m
CAPACITY
Gearbox type Capacity in litres
PK4 2.4
PARTS AND INGREDIENTS FOR THE 134243
REPAIRWORK a Unscrew the drain plug (1) using the (Mot. 1018).
a Part for repair: a Let the oil run into the oil recovery container.
a Consumables for the repair:
- gearbox oil (see 21A, Manual gearbox, Manual
gearbox oil: Specifications, page 21A-1) (Tech-
nical Note 6012A, 04A, Lubricants).
I - DRAINING OPERATION
a Remove:
- the engine cover,
box.
113764
a Refit:
- the new seal on the drain plug, positioning the
groove (2) towards the cap,
- the drain plug fitted with its new seal.
a Torque tighten the drain plug (24 N.m).
21A-8
MANUAL GEARBOX
PK4
II - FILLING
114772
92081

gearbox oil: Specifications, page 21A-1) (Techni-
cal Note 6012A, 04A, Lubricants) until the oil over-
flows out of the filler cap hole.
a Refit:
- the engine cover.
21A-9
MANUAL GEARBOX
Differential output seal: Removal - Refitting 21A
JH3 or JR5
Essential special tooling CONCERNED
Bvi. 1666 Tool for fitting differential
seals. Right-hand differential output seal
Essential equipment
roll pin punch
REMOVAL

a Remove:
page 21A-2) .
125563
1 - When replacing the differential output seal on

the left-hand side Left-hand differential output seal
a Remove:
- the front left-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),

the right-hand side
a Remove:
- the front right-hand wheel (see Wheel: Removal -
- the front right-hand wheel driveshaft (see 29A, Dri-
veshafts, Front right-hand wheel driveshaft:
Removal - Refitting, page 29A-18) .
125569
a Tap the base of the differential output seal using a
roll pin punch and a small hammer to detach it and
rotate it in its housing.
a Remove the seal with a screwdriver, taking care not
to damage the differential housing.
21A-10
MANUAL GEARBOX
JH3 or JR5
REFITTING

a parts always to be replaced: Differential output
seal (12,01,05,10).
21A-11
MANUAL GEARBOX
JH3 or JR5
II - REFITTING OPERATION FOR PART Refitting the left-hand side differential output seal.
CONCERNED
103191
Refitting the right-hand side differential output seal

125562
a Refit a new differential output seal using the tool

(Bvi. 1666) (1) composed of:
- a mandrel (2) for the right-hand side,
- a mandrel (3) for the left-hand side.
a Lubricate the internal surface of the differential out-

put seal.
a Fit:
- a differential output seal on the gearbox,
- the mandrel (2) or (3) of the tool (Bvi. 1666) on the

new differential output seal.
a Tap the tool (Bvi. 1666) (1) with a copper hammer

125570
to fit the new differential output seal fully.

the left-hand side
a Refit:


Refitting) (35A, Wheels and tyres).
21A-12
MANUAL GEARBOX
JH3 or JR5
the right-hand side
a Refit:

page 21A-2) .
21A-13
MANUAL GEARBOX
ND4
REFITTING
Bvi. 1689 Differential output seal fitting I - REFITTING PREPARATION OPERATION

tool.
seal (12,01,05,10).
Essential equipment
roll pin punch and ingredients for the repairwork) (04B, Consu-
mables - Products) to clean:
REMOVAL - the mating face of the differential output seal,

- the propeller shaft.
a Remove:
a Drain the gearbox (see 21A, Manual gearbox, Ma-
.
1 - When replacing a differential output seal on the

left-hand side
a Remove:

right-hand side
a Remove:

CONCERNED
a Tap the base of the differential output seal using a
roll pin punch and a small hammer to rotate it in its
housing.
a Remove the differential output seal using pliers, ta-
king care not to damage the splines on the su-
nwheel.
21A-14
MANUAL GEARBOX
ND4
II - REFITTING OPERATION FOR PART III - FINAL OPERATION
CONCERNED
Left-hand side left-hand side
a Refit:
a Top up the gearbox (see 21A, Manual gearbox,
Manual gearbox oil: Draining - Refilling, page
21A-2) .

right-hand side
a Refit:
134617 val - Refitting, page 29A-18) .
Right-hand side Refitting) (35A, Wheels and tyres).
21A-2) .
134618
a Lubricate the differential output seal before inserting
it onto the splined part of the sunwheel.
a Refit a new differential output seal using the tool
(Bvi. 1689).
21A-15
MANUAL GEARBOX
TL4
Bvi. 1854 Differential output seal fitting
tool TL4 Left-hand differential output seal
Essential equipment
roll pin punch
REMOVAL

a Remove:
page 21A-2) .
125894

the left-hand side Right-hand differential output seal
a Remove:

the right-hand side
a Remove:
125896
a Tap the base of the lip seal using a roll pin punch
and a small hammer to release it and make it turn in
its housing.
a Remove the lip seal using a large screwdriver, ta-
king care not to damage the differential housing.
21A-16
MANUAL GEARBOX
TL4
REFITTING

seal (12,01,05,10).
21A-17
MANUAL GEARBOX
TL4
II - REFITTING OPERATION FOR PART Refitting the left-hand side differential output seal.
CONCERNED
103191
Refitting the right-hand side differential output seal

125893
a The new differential output seal is refitted using the
tool (Bvi. 1854) (1) consisting of:
- a mandrel (2) for the right-hand side,
- a mandrel (3) for the left-hand side.
a Oil the internal surface of the new differential output
seal.
a Fit:
- the new differential output seal on the gearbox,
- the mandrel (2) or (3) of the tool (Bvi. 1854) on the
new differential output seal.
a Tap the tool (1) with a copper hammer to fit the new
differential output seal fully.

125895
1 - Refitting the left-hand driveshaft

a Refit:
2 - Refitting the right-hand driveshaft

a Refit:
21A-18
MANUAL GEARBOX
TL4
3 - Final operation
a Fill the manual gearbox oil and check the level (see
21A, Manual gearbox, Manual gearbox oil: Drai-
ning - Refilling, page 21A-2) .
21A-19
MANUAL GEARBOX
PK4
Bvi. 1719 Left-hand side differential oil
seal fitting tool Right-hand differential output seal
Bvi. 1419 Bearing cage positioning tool.
Bvi. 1774 Right-hand transmission seal

fitting tool.
REMOVAL

a Remove the engine undertray.
a Drain the manual gearbox oil (see 21A, Manual
gearbox, Manual gearbox oil: Draining - Refil-
ling, page 21A-2) .

the left-hand side 95579
a Remove:
Left-hand differential output seal

the right-hand side
a Remove:
106885
a Remove the seal with a screwdriver, taking care not
to damage the housing.
21A-20
MANUAL GEARBOX
PK4
REFITTING 2 - Refitting the right-hand side differential output

seal

seal (12,01,05,10).
mables - Products) to clean:
- the differential output seal mating faces,
- the propeller shaft.

CONCERNED
1 - Refitting the left-hand side differential output

seal.
21491
a The right-hand side differential output seal is made
up of:
- a seal (3) ,
- a deflector-protector (4) .
Note:
The seal (3) cannot be separated from the
deflector-protector (4) .
Note:
The seal is fitted with the deflector-protector.
They will only be separated when the driveshaft
is in place.
106886
a Refit a new left-hand differential output seal using
the tools (Bvi. 1719) (1) and (Bvi. 1419) (2) .
21A-21
MANUAL GEARBOX
PK4
1 - Refitting the right-hand driveshaft

a Fit the relay bearing seal.
Note:
Check that the seal is fully inserted into its
groove.
a Refit the front right-hand driveshaft (see 29A, Dri-

veshafts, Front right-hand wheel driveshaft: Re-
moval - Refitting, page 29A-18) .
Note:
Make sure that the O-ring is correctly positioned
in the base of the relay bearing, if the bearing
has one.
21492
21493
a Fit a new right-hand differential output seal (seal
pressed onto the deflector-protector) using the tool
(Bvi. 1774) (5) .
Note:
Do not lubricate the seal when fitting it.
With the new seal fitted, leave the deflector-pro-
tector pressed into the seal. The deflector-protec-
tor protects the seal lips when the driveshaft is
refitted.
21A-22
MANUAL GEARBOX
PK4
a - Driveshaft WITH CLIP GROOVE b - Driveshaft WITHOUT CLIPPING GROOVE
21494 21494
a Pull the deflector-protector (4) .
a Remove the deflector-protector by cutting it.
2 - Refitting the left-hand driveshaft

a Refit the front left-hand driveshaft (see 29A, Drives-
hafts, Front left-hand wheel driveshaft: Removal
- Refitting, page 29A-2) .
3 - Final operation
page 21A-2) .
a Refit:
- the front wheel concerned (see Wheel: Removal -
113496
a Pull the deflector-protector (4) .
a Clip the deflector-protector into the clipping groove
(6) .
Note:
If you do not pull the deflector-protector, the seal
lips do not make contact with the driveshaft and
a correct seal cannot be guaranteed.
21A-23
MANUAL GEARBOX
Manual gearbox: Removal - Refitting 21A
K4M, and JH3
REMOVAL
Ms. 583 Hose clamp pliers. I - REMOVAL PREPARATION OPERATION
Mot. 1453 Multiple-adjusting engine a Position the vehicle on a two-post lift (see Vehicle:
mounting support with retai- Towing and lifting) (02A, Lifting equipment).
ning straps. a Remove:
Mot. 1453-01 Additional winder nut on - the engine cover,
engine lift support Mot. 1453.
Bvi. 1718 Support plate for the gearbox per arm: Removal - Refitting) (85A, Wiping -
removal/refitting tool. Washing),
Essential equipment Removal - Refitting) (56A, Exterior equipment),
safety strap(s)
indelible pencil (56A, Exterior equipment),
component jack (80A, Battery),
Tightening torquesm fitting) (80A, Battery),
- the air filter box (see Air filter unit: Removal - Re-
stud on the engine 7 N.m
fitting) (12A, Fuel mixture).
stud on the gearbox 7 N.m a Loosen the clip on the throttle valve air inlet pipe.
manual gearbox nuts 44 N.m a Disconnect the air outlet pipe from the air filter unit.
a Remove the air outlet pipe from the air filter box.
manual gearbox lower 44 N.m
bolts
manual gearbox earth 24 N.m

cable bolt
manual gearbox upper 44 N.m

bolts
left-hand suspended 62 N.m

engine mounting cover
bolts on the manual
gearbox

engine mounting rubber
pad mounting bolt
air filter unit air inlet pipe 6 N.m

clip
IMPORTANT
21A-24
MANUAL GEARBOX
K4M, and JH3
134553 136542
a Fit the tool (Ms. 583) on the hydraulic clutch supply

pipe at the outlet of the brake fluid reservoir.
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
a Remove the hydraulic clutch pipe (see Clutch cir-

cuit: Removal - Refitting) (37A, Mechanical com-
ponent controls).
a Disconnect the reverse gear switch connector.
a Remove:
- the manual gearbox breather pipe,

109149 Front wheel arch liner: Removal - Refitting)
a Unclip:
- the gear selector cables on the manual gearbox by
pushing at (1) , - the engine undertray,
- the control cables by pushing at (2) . - the front bumper (see Front bumper: Removal -
a Move the manual gearbox selector cables aside. Refitting) (55A, Exterior protection).
page 21A-2) .
a Remove:
21A-25
MANUAL GEARBOX
K4M, and JH3
ting),
trol injection),
- the front axle subframe (see Front axle sub-fra- 135947
me: Removal - Refitting) (31A, Front axle compo- a Unclip the battery wiring channel at (3) .
nents).
a Move aside the battery wiring channel.
135935
134554
a Fit the (Mot. 1453) fitted with the (Mot. 1453-01)
with a safety strap(s). a Remove the bolt (4) of the rubber pad mounting from
the left-hand suspended engine mounting on the
manual gearbox.
a Slightly lower the manual gearbox.
21A-26
MANUAL GEARBOX
K4M, and JH3
CONCERNED
134548
a
134554
a Remove: Note:
- the bolts (5) of the left-hand suspended engine Before removing the earth terminal, mark its
mounting rubber pad cover on the manual gearbox, position using a indelible pencil by drawing a
line on the earth terminal and on the gearbox
- the left-hand suspended engine mounting cover on casing.
the manual gearbox.
When reassembling, improper positioning of the
earth terminal on the gearbox casing could result
in damage to the earth terminal or ear th cable.
a Remove the manual gearbox earth cable bolt (7) .

a Remove the earth cable from the manual gearbox.
135243
a Remove the manual gearbox upper bolts (6) .
21A-27
MANUAL GEARBOX
K4M, and JH3
134555 134549
a Fit:
- the (Bvi. 1718) to a component jack,
- the (Bvi. 1718) and the component jack under the
manual gearbox.
a Tighten the rod anti-clockwise to avoid tilting the ma-
nual gearbox.
134548
a Remove:
- the manual gearbox nuts (9) and (10) ,
- the manual gearbox using the component jack
and (Bvi. 1718).
a When replacing the manual gearbox, remove the re-
134543 verse gear switch (see 21A, Manual gearbox, Re-
verse gear switch: Removal - Refitting, page
a Remove the lower bolts (8) from the manual gear-
21A-87) .
box.
21A-28
MANUAL GEARBOX
K4M, and JH3
REFITTING a Torque tighten the manual gearbox upper bolts

(44 N.m).
I - REFITTING PREPARATION OPERATION a Refit the left-hand suspended engine mounting co-
ver on the manual gearbox.
a
a Torque tighten the left-hand suspended engine
Note: mounting cover bolts on the manual gearbox (62
If a stud loosens during this operation, coat it N.m).
with FRENETANCHE.
Tighten to torque: III - FINAL OPERATION
- the stud on the engine (7 N.m), a Bring into contact the left-hand suspended engine
mounting cover on the left-hand suspended engine
- the stud on the gearbox (7 N.m).
mounting rubber pad using the tool (Mot. 1453) fit-
ted with the tool (Mot. 1453-01).
Replacing the manual gearbox a Refit the bolt of the left-hand suspended engine
a Refit the reverse gear switch (see 21A, Manual mounting rubber pad mounting on the manual gear-
gearbox, Reverse gear switch: Removal - Refit- box.
ting, page 21A-87) .
mounting rubber pad mounting bolt (62 N.m).
Note: a Fit the battery wiring channel.
To fit the tool (Bvi. 1718) on the new manual
a Clip on the battery wiring channel.
gearbox, follow the same steps as for the remo-
val operation. a Remove the tool (Mot. 1453) fitted with the tool
(Mot. 1453-01) using the safety strap(s).
a Fit the new manual gearbox on the (Bvi. 1718).
a Refit:
II - REFITTING OPERATION FOR PART - the front axle subframe (see Front axle sub-fra-
CONCERNED me: Removal - Refitting) (31A, Front axle compo-
nents),
a Ensure that the « engine - gearbox » centring rings
are in place and correctly positioned. - the radiator mounting cross member (see Radiator
a Fit the manual gearbox using the component jack
and the (Bvi. 1718).
- the new differential output seals (see 21A, Manual
a Refit the manual gearbox nuts.
a Torque tighten the manual gearbox nuts (44 N.m). fitting, page 21A-10) ,
a Remove the tool (Bvi. 1718) : - the front right-hand driveshaft (see 29A, Drives-
- from the manual gearbox,
- from the component jack.
a Refit the manual gearbox lower bolts. hafts, Front left-hand wheel driveshaft: Remo-
a Torque tighten the manual gearbox lower bolts
(44 N.m). - the crankshaft position sensor (see Crankshaft
a It is essential to refit the earth cable respecting the
trol injection),
marks made during disassembly.
a Refit the earth cable bolt on the manual gearbox.
a Torque tighten the manual gearbox earth cable ting),
bolt (24 N.m).
a Refit the manual gearbox upper bolts. (16A, Starting - Charging).
21A-29
MANUAL GEARBOX
K4M, and JH3
a Fill the manual gearbox (see 21A, Manual gearbox, - the engine cover.
21A-2) .
a Refit:
- the hydraulic clutch pipe (see Clutch circuit: Re-
moval - Refitting) (37A, Mechanical component
controls),
a Remove the tool (Ms. 583) from the hydraulic clutch
supply pipe at the outlet of the brake fluid reservoir.
a Bleed the hydraulic clutch circuit (see Clutch cir-
cuit: Bleeding) (37A, Mechanical component con-
trols).
a Fit the manual gearbox gear selector cables.
a Clip on the manual gearbox gear selector cables.
a Adjust the manual gearbox gear selector cables
(see Mechanical gear control cable: Adjustment)
a Connect the reverse gear switch connector.
a Refit the air outlet pipe onto the air filter unit.
a Connect the air outlet pipe of the air filter unit.
a Torque tighten the air filter unit air inlet pipe clip
(6 N.m).
a Refit:
(80A, Battery),
Washing),
21A-30
MANUAL GEARBOX
K9K, and TL4
Bvi. 1718 Support plate for the gearbox

removal/refitting tool.
Essential equipment
indelible pencil
component jack
Tightening torquesm
manual gearbox nuts 44 N.m
manual gearbox bolts 44 N.m

cable bolt
135508
REMOVAL a Disconnect the connector (1) from the turbocharging

pressure regulation solenoid valve.
a Move aside the turbocharging pressure regulation
solenoid valve wiring.
a Remove:
- the engine cover,

(80A, Battery),

fitting) (80A, Battery).
J95
a Remove:

135506
- the centre section of the scoop under the scuttle
panel grille (see Scoop under scuttle panel a Unclip the battery wiring channel (2) from the left-
grille: Removal - Refitting) (56A, Exterior equip- hand suspended engine mounting.
ment). a Move the battery wiring channel away from the left-
hand suspended engine mounting.
a Remove the air filter unit (see Air filter unit: Remo-
val - Refitting) (12A, Fuel mixture).
21A-31
MANUAL GEARBOX
K9K, and TL4
134484 134224
a Unclip: a Unclip the following from the manual gearbox:
- the gear control cables (3) from the selector ball - the engine wiring channel (5) ,
joints using an open-jawed spanner,
- the manual gearbox breather pipe (6) .
- the gear control cables (4) from their support,
a Move aside the manual gear selector cables.
a Disconnect the reverse gear switch connector.
a Remove:
ponent controls).
trol injection).
21A-32
MANUAL GEARBOX
K9K, and TL4
nents).
K9K, and 830 or 832
134214
a
Note:
Before removing the earth terminal, mark its
position using a indelible pencil by drawing a
casing.
in damage to the earth terminal or earth wiring.
a Remove the earth cable bolt (7) from the manual

gearbox.
a Remove: 134216
a Remove:
(16A, Starting - Charging), - the catalytic converter downstream strut bolts (9) ,
- the front wheels (see Wheel: Removal - Refitting) - the nut (10) from the catalytic converter downs-
(35A, Wheels and tyres), tream strut,
- the front section of the front wheel arch liners (see - the catalytic converter downstream strut.
(55A, Exterior protection).
page 21A-2) .
a Remove:
21A-33
MANUAL GEARBOX
K9K, and TL4
K9K, and 836
140652
a Remove the nut (11) of the particle filter temperature
sensor wiring bracket.
a Move aside the particle filter temperature sensor wi-
ring.
a Unclip the rail protector drain pipe from the manual

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

CONCERNED
a Remove the manual gearbox bell housing bolts.
21A-34
MANUAL GEARBOX
K9K, and TL4
tilting the manual gearbox.
a Remove:
- the nuts from the manual gearbox,
- the manual gearbox using the component jack and
the (Bvi. 1718),
- the clutch thrust bearing (see 20A, Clutch, Clutch
thrust bearing: Removal - Refitting, page 20A-
22) .
REFITTING

a parts always to be replaced: Clutch thrust bea-
ring (12,03,01,04).
WARNING
116711
To avoid damaging the slave cylinder, do not coat
the gearbox output shaft with grease.
WARNING
a Check that the centring dowelsare in place.
116713
a Fit:
- the component jack fitted with the (Bvi. 1718) un-
der the mechanical gearbox,
- the bracket (12) using the nuts (13) ,
- the support (14) ,
- the pin (15) ,
- the rod (16) using the bracket (17) and the bolt (18)
.
a Tighten the rod (16) anti-clockwise in order to avoid
21A-35
MANUAL GEARBOX
K9K, and TL4
If replacing the manual gearbox
K9K, and 836
a Fit the particle filter temperature sensor wiring.
a Refit the nut of the particle filter temperature sensor

wiring bracket.
K9K, and 830 or 832
a Refit:
- the catalytic converter downstream strut,
- the catalytic converter downstream strut bolts,
116712 - the catalytic converter downstream strut nut.

a
Note:
To fit the tool onto the new manual gearbox, fol-
low the same steps as for the removal operation. a Connect the reverse gear switch connector.
a Fit the new manual gearbox on the component jack a Refit:

fitted with the (Bvi. 1718).
II - REFITTING OPERATION FOR PART nents),
CONCERNED
a Refit: - the radiator mounting cross member (see Radiator
- a new clutch thrust bearing (see 20A, Clutch,
Clutch thrust bearing: Removal - Refitting, page
20A-22) ,
- the manual gearbox using the component jack Refitting) (55A, Exterior protection),
and (Bvi. 1718).
- new differential output seals (see 21A, Manual
a Remove the component jack fitted with the (Bvi.
1718) from the manual gearbox.
a Torque tighten:
- the manual gearbox nuts (44 N.m),
- the manual gearbox bolts (44 N.m). val - Refitting, page 29A-2) ,
III - FINAL OPERATION - the front right-hand wheel driveshaft (see 29A, Dri-
a Refit the left-hand suspended engine mounting (see Removal - Refitting, page 29A-18) .
val - Refitting) (19D, Engine mounting). a Fill up the manual gearbox (see 21A, Manual gear-
a Clip the rail protector drain pipe onto the manual box, Manual gearbox oil: Draining - Refilling,
gearbox. page 21A-2) .
21A-36
MANUAL GEARBOX
K9K, and TL4
a Refit:
- the front section of the front wheel arch liners (see J95
a Refit:
- the starter (see Starter: Removal - Refitting) ment),
Exterior equipment).
Note:
Refit the earth terminal, aligning the indelible
marks on the gearbox casing.
When reassembling, improper positioning of the a Refit:
earth terminal on the gearbox casing could result - the battery tray (see Battery tray: Removal - Re-
in damage to the earth terminal or earth wiring. fitting) (80A, Battery),
a Torque tighten the manual gearbox earth cable - the battery (see Battery : Removal - Refitting)
bolt (24 N.m). (80A, Battery),
a Clip the following on the manual gearbox: - the engine cover.

- the engine harness channel.
a Refit:
trol injection),
ponent controls).
trols).
a Fit the manual gear selector cables.

a Clip:
- the gear selector cables onto their mounting,
- the gear selector cables onto the gear selector ball
joints.
a Fit the battery wiring channel on the left-hand sus-
pended engine mounting.
a Fit the turbocharging pressure regulation solenoid
valve wiring.
a Connect the turbocharging pressure regulation sole-
noid valve connector.
a Refit the air filter unit (see Air filter unit: Removal -
Refitting) (12A, Fuel mixture).
21A-37
MANUAL GEARBOX
F4R, and PK4
Essential special tooling fitting) (12A, Fuel mixture).
Bvi. 1718 Support plate for the gearbox
Mot. 1453 Multiple-adjusting engine

mounting support with retai-
ning straps.
Mot. 1453-01 Additional winder nut on

engine lift support Mot. 1453.
Essential equipment
component support
component jack
safety strap(s)
Tightening torquesm
manual gearbox nuts 44 N.m 138083
manual gearbox lower 44 N.m a Disconnect the connector (1) from the reverse gear
bolts switch.
a Unclip the wiring (2) from the reverse gear connec-
manual gearbox upper 44 N.m tor.
bolts
earth strap bolt on the 24 N.m

gearbox
REMOVAL

IMPORTANT
a Remove:
21926
a Disconnect the downstream oxygen sensor connec-
- the engine cover, tor (3) .
(80A, Battery),
21A-38
MANUAL GEARBOX
F4R, and PK4
134244 138082
a Unclip: a
- the gear selector cables from the selector ball joints Note:
(4) using an open-jawed spanner,
- the gear selector cables from their mounting (5) ,
position using an indelible marker by drawing a
- the manual gearbox breather pipe. line on the earth terminal and on the gearbox
casing.
a Remove:
When refitting, improper positioning of the earth
- the hydraulic clutch control pipe (see Clutch cir- terminal on the gearbox casing could result in
cuit: Removal - Refitting) (37A, Mechanical com- damage to the earth terminal or earth cable.
ponent controls).
a Remove the bolt (6) from the earth strap on the gear-
box.

page 21A-2) (21A, Manual gearbox).
a Remove:





21A-39
MANUAL GEARBOX
F4R, and PK4
- the front right-hand driveshaft (see 29A, Drives- II - OPERATION FOR REMOVAL OF PART
hafts, Front right-hand wheel driveshaft: Remo- CONCERNED
ting),
nents).
a Remove:
Washing),
136539
val - Refitting) (19D, Engine mounting)
.
136499
a Remove:
- the upper bolts (7) from the manual gearbox,
- the lower bolts (8) from the manual gearbox.
21A-40
MANUAL GEARBOX
F4R, and PK4
Replacing the manual gearbox
a Refit:
- the crankshaft position sensor on the manual gear-

box (see Crankshaft position sensor: Removal -
Refitting) (17B, Petrol injection),
- the reverse gear switch on the manual gearbox

(see 2 1 A , Manual gearbox, Reverse gear
switch: Removal - Refitting, page 21A-87) .
Note:
To fit the tool (Bvi. 1718) on the new manual
gearbox, follow the same steps as for the remo-
val operation.

and the tool (Bvi. 1718).
106615
a Fit the component support fitted with the tool (Bvi. CONCERNED
1718) (9) on the contact pins and tighten the bolt
(Bvi. 1718) of the tool (10) .
a Remove:
- the nuts from the manual gearbox,
and (Bvi. 1718).
a In the event of a replacement, remove the following
from the manual gearbox:
- the reverse gear switch (see 21A, Manual gear-
box, Reverse gear switch: Removal - Refitting,
page 21A-87) ,
position sensor: Removal - Refitting) .
REFITTING
I - REFITTING PREPARATION OPERATION 123407

a a Fit the manual gearbox using the component sup-
port and the (Bvi. 1718).
WARNING
To avoid damaging the slave cylinder, do not coat a Refit the gearbox nuts.
a Torque tighten the manual gearbox nuts (44 N.m).
a Remove the component support fitted with the
WARNING (Bvi. 1718).
Do not grease the clutch shaft splines. a Refit the manual gearbox lower bolts.
a Check that there are centring rings in place on the a Torque tighten the manual gearbox lower bolts
manual gearbox. (44 N.m).
21A-41
MANUAL GEARBOX
F4R, and PK4
III - FINAL OPERATION a Refit:
a Refit: - the hydraulic clutch control pipe (see Clutch cir-
- the front left-hand suspended engine mounting
ponent controls),
(see Left-hand suspended engine mounting:
Removal - Refitting) , - the earth strap bolt on the gearbox.
- the manual gearbox upper bolts. a Torque tighten the earth strap bolt on the gearbox
(24 N.m).
a Torque tighten the manual gearbox upper bolts
(44 N.m). a Clip:
a Remove the tool (Mot. 1453) fitted with the tool - the manual gearbox breather pipe,
- the gearbox selector cables on their mounting and
a Refit: on the gearbox selector ball joints,
- the starter (see Starter: Removal - Refitting) - the reverse gear switch wiring,
a Connect:
- the reverse gear switch connector,
nents). - the downstream oxygen sensor connector.
- the engine tie-bar (see Lower engine tie-bar: Re- a Refit:
moval - Refitting) (19D, Engine mounting),
- new differential output seals (see 21A, Manual fitting) (12A, Fuel mixture),
(80A, Battery),
val - Refitting, page 29A-18)
- the engine cover,
hafts, Front left-hand wheel driveshaft: Remo- - the engine undertray.
val - Refitting, page 29A-2)
- the front section of the wheel arch liners (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
Washing).
page 21A-2) .
21A-42
MANUAL GEARBOX
F9Q, and ND4
Essential equipment
component support
Tightening torquesm
REMOVAL

a Remove:
135541
a Unclip:
- the gear selector cables (2) from the gear selector
- the engine cover, ball joints using an open-jawed spanner,
- the battery (see Battery : Removal - Refitting) - the gear control cables (3) from their support.
(80A, Battery),
a Remove:
fitting) (80A, Battery), - the hydraulic clutch control pipe (see Clutch cir-
- the air filter box (see Air filter unit: Removal - Re- ponent controls).

page 21A-2) .
a Remove:


tion),


135545 - the differential output seals (see 21A, Manual
a Disconnect the connector (1) from the reverse gear gearbox, Differential output seal: Removal - Re-
switch. fitting, page 21A-10) ,
21A-43
MANUAL GEARBOX
F9Q, and ND4
- the front bumper (see Front bumper: Removal - - the clutch thrust bearing (see 20A, Clutch, Clutch
Refitting) (55A, Exterior protection), thrust bearing: Removal - Refitting, page 20A-
22) .
(31A, Front axle components), REFITTING
bar: Removal - Refitting) (19D, Engine moun- I - REFITTING PREPARATION OPERATION
ting),
- the front axle subframe (see Front axle sub-fra- ring (12,03,01,04)
nents),
WARNING
Left-hand suspended engine mounting: Remo- To avoid damaging the slave cylinder, do not coat
val - Refitting) (19D, Engine mounting). the gearbox output shaft with grease.
WARNING

CONCERNED
a Refit:

20A-22) ,
- the manual gearbox using the component sup-

port.
a Tighten to torque:
- the manual gearbox nuts (44 N.m),

134177
- the manual gearbox bolts (44 N.m).
a Remove:
a Remove the component support.
- the bolts (4) from the manual gearbox control
mounting,
- the manual gearbox control mounting.
a Refit:
II - OPERATION FOR REMOVAL OF PART - the manual gearbox control mounting,
CONCERNED
a Remove the manual gearbox bell housing bolts. Left-hand suspended engine mounting: Remo-
a Fit a component support beneath the manual
gearbox. - the front axle subframe (see Front axle sub-fra-
a Remove the manual gearbox nuts. me: Removal - Refitting) (31A, Front axle compo-
nents),
a Remove:
- the manual gearbox using the component sup- bar: Removal - Refitting) (19D, Engine moun-
port, ting),
21A-44
MANUAL GEARBOX
F9Q, and ND4
- the wheel arch liners (see Front wheel arch liner:
Removal - Refitting) (55A, Exterior protection),
ponent controls).
a Clip:
- the gear selector cables onto their mounting,
- the gear selector cables onto the gear selector ball
joints.
a Refit:
(80A, Battery),
- the engine cover.
21A-45
MANUAL GEARBOX
K4M, and TL4
REMOVAL
Ms. 583 Hose clamp pliers. I - REMOVAL PREPARATION OPERATION
Mot. 1672 Lower engine support. a Position the vehicle on a two-post lift (see Vehicle:
Mot. 1720 Engine stand.
a Remove:
Bvi. 1718 Support plate for the gearbox - the engine cover,
Mot. 1453 Multiple-adjusting engine (80A, Battery),
mounting support with retai- - the battery tray (see Battery tray: Removal - Re-
ning straps. fitting) (80A, Battery),
Mot. 1453-01 Additional winder nut on - the air filter box (see Air filter unit: Removal - Re-
engine lift support Mot. 1453. fitting) (12A, Fuel mixture).
a Loosen the clip of the air filter unit air outlet pipe at
Essential equipment the throttle valve.
indelible pencil a Disconnect the air filter unit air outlet pipe at the
throttle valve.
component jack
a Remove the air filter unit air outlet pipe at the throttle
safety strap(s) valve.
Tightening torquesm

bolts

cable bolt

bolts
bolts of the left-hand 62 N.m

suspended engine
mounting support on the
gearbox

engine mounting rubber
pad mounting bolt 136551
a Disconnect the connector (1) from the reverse gear
clip on the throttle valve 6 N.m switch.
air inlet pipe
IMPORTANT
21A-46
MANUAL GEARBOX
K4M, and TL4
B95 or D95
136620
136542
a Fit the tool (Ms. 583) on the hydraulic clutch master
cylinder supply pipe at the outlet of the brake fluid re-
servoir.
WARNING
101743
a Unclip:
- the gear selector cables from the manual gearbox
by pushing at (2) ,
- the gear selector cables from the manual gearbox
by pulling at (3) .
a Move the manual gearbox selector cables aside.
21A-47
MANUAL GEARBOX
K4M, and TL4
J95 ting),
trol injection).
139363
a Fit the tool (Ms. 583) on the hydraulic clutch master (31A, Front axle components),
cylinder supply pipe at the outlet of the brake fluid re-
servoir.
nents).
WARNING
a Remove:

controls),


- the engine undertray bolts, 139365
- the engine undertray, a Remove the lower bolt (4) from the manual gearbox.


page 21A-2) .
a Remove:

21A-48
MANUAL GEARBOX
K4M, and TL4
139361
a Fit the (Mot. 1672) fitted with the (Mot. 1720).
136627
136612
a Unclip the downstream oxygen sensor wiring from
the manual gearbox at (5) and (6) .
21A-49
MANUAL GEARBOX
K4M, and TL4
CONCERNED
135947
a Unclip the battery wiring channel at (7) .
136554
a Remove:
- the left-hand suspended engine mounting support
bolts (9) on the manual gearbox,
- the left-hand suspended engine mounting support
on the manual gearbox.
135948
a Remove the bolt (8) of the left-hand suspended en-
gine mounting rubber pad on the manual gearbox.
a Slightly lower the manual gearbox.
136583
21A-50
MANUAL GEARBOX
K4M, and TL4
136629 116711
a
Note:
housing.
in damage to the earth terminal or earth wiring.
a Remove the earth wire bolt (11) on the manual gear-

box.
116713
a Fit:
- the (Bvi. 1718) and the component jack under the

manual gearbox,
- the bracket (12) using the nuts (13) ,
- the support (14) ,
- the pin (15) ,
- the rod (16) using the bracket (17) and the bolt (18)
.
21A-51
MANUAL GEARBOX
K4M, and TL4
a Tighten the rod anti-clockwise in order to avoid tilting
the manual gearbox.
136592
139364
box.
138088
a Remove:
- the manual gearbox nuts (20) and (21) ,

and (Bvi. 1718).
a The clutch thrust bearing (see 20A, Clutch, Clutch

thrust bearing: Removal - Refitting, page 20A-22)
.

verse gear switch (see 21A, Manual gearbox, Re-
21A-87) .
21A-52
MANUAL GEARBOX
K4M, and TL4
REFITTING a Torque tighten the bolts of the left-hand suspen-

ded engine mounting support on the gearbox (62
N.m).
a parts always to be replaced: Clutch thrust bea- III - FINAL OPERATION

ring (12,03,01,04)
a Bring the left-hand suspended engine mounting sup-
a port on the gearbox into contact with the left-hand
suspended engine mounting rubber pad using the
WARNING (Mot. 1453) equipped with the (Mot. 1453-01).
the gearbox output shaft with grease. a Refit the bolt of the left-hand suspended engine
mounting rubber pad on the manual gearbox.
WARNING mounting rubber pad mounting bolt (62 N.m).
Do not grease the clutch shaft splines. a Fit the battery wiring channel.
a Refit the reverse gear switch (see 21A, Manual a Clip:
gearbox, Reverse gear switch: Removal - Refit-
ting, page 21A-87) . - the battery wiring channel,
a Check that the centring dowelsare in place. - the downstream oxygen sensor wiring onto the me-
chanical gearbox.
a Remove the tool (Mot. 1453) fitted with the tool
CONCERNED
a Refit:
a Refit a new clutch thrust bearing (see 20A, Clutch,
Clutch thrust bearing: Removal - Refitting, page - the front axle subframe (see Front axle sub-fra-
20A-22) . me: Removal - Refitting) (31A, Front axle compo-
nents),
and the (Bvi. 1718). - the radiator mounting cross member (see Radiator
a Refit the manual gearbox nuts. (31A, Front axle components),
a Remove the tool (Bvi. 1718) : gearbox, Differential output seal: Removal - Re-
- the manual gearbox,
- from the component jack. hafts, Front left-hand wheel driveshaft: Remo-
a Refit the manual gearbox lower bolts.
a Torque tighten the manual gearbox lower bolts
(44 N.m).
marks made during disassembly. position sensor: Removal - Refitting) (17B, Pe-
a Refit the earth cable bolt on the manual gearbox. trol injection),
a Torque tighten the manual gearbox earth cable - the lower engine tie-bar (see Lower engine tie-
bolt (24 N.m). bar: Removal - Refitting) (19D, Engine moun-
ting),
a Refit the manual gearbox upper bolts.
a Torque tighten the manual gearbox upper bolts (16A, Starting - Charging).
(44 N.m).
a Refit the left-hand suspended engine mounting sup- box, Manual gearbox oil: Draining - Refilling,
port on the gearbox. page 21A-2) .
21A-53
MANUAL GEARBOX
K4M, and TL4
a Refit:
controls).
a Remove the tool (Ms. 583) on the hydraulic clutch
supply pipe at the outlet of the brake fluid reservoir.
trols).
a Fit the manual gearbox gear selector cables.
a Clip on the manual gearbox gear selector cables.
a Adjust the gear control cables (see Mechanical
a Connect the air filter unit air outlet pipe to the throttle
valve.
a Torque tighten the clip on the throttle valve air in-
let pipe (6 N.m).
a Refit:
(80A, Battery),
- the engine cover.
21A-54
MANUAL GEARBOX
K9K, and JR5
Essential special tooling panel grille (see Scoop under scuttle panel
Emb. 1797 24 mm socket for removing
ment).
and refitting clutch master
cylinder
Essential equipment a Remove the air filter unit (see Air filter unit: Remo-
val - Refitting) (12A, Fuel mixture).
indelible pencil
component jack
Tightening torquesm
reverse gear switch 23 N.m
manual gearbox studs 6.5 N.m

bolts

bolts

cable bolt
135508
REMOVAL
a Disconnect the connector from the turbocharging
pressure regulation solenoid valve (1) .
a Move aside the turbocharging pressure regulation
solenoid valve wiring.
a Remove:
- the engine cover,
(80A, Battery),
J95
a Remove:
21A-55
MANUAL GEARBOX
K9K, and JR5
135415 135416
a Unclip the battery wiring channel from the left-hand
suspended engine mounting (2) .
a Remove the battery wiring channel from the left-
hand suspended engine mounting.
109149
a Unclip the manual gear selector cables by:

- unclipping the anchoring ball joints (3) from the ma-
nual gear selector,
- pinching the manual gear selector at (A) ,
- lifting the manual gear selector (4) from the manual
gear selector mounting.
a Move aside the manual gear selector cables.
a Remove:
21A-56
MANUAL GEARBOX
K9K, and JR5
ponent controls).
trol injection).
135846
a
Note:
136633 line on the earth terminal and on the gearbox
a Unclip the following from the manual gearbox: housing.
- the engine wiring channel (10) , When reassembling, improper positioning of the
- the manual gearbox breather pipe (11) . in damage to the earth terminal or ear th wiring.
a Remove the earth cable bolt (12) from the gearbox

housing.
a Remove:
page 21A-2) .
a Remove:
21A-57
MANUAL GEARBOX
K9K, and JR5
fitting, page 21A-10) , K9K, and 830

nents).
135851
a Remove:
- the catalytic converter downstream strut bolts (15) ,
- the nut (16) from the catalytic converter downs-
tream strut,
- the catalytic converter downstream strut.
135848
switch.
a Unclip the reverse gear switch wiring from the ma-
nual gearbox at (14) .
21A-58
MANUAL GEARBOX
K9K, and JR5
CONCERNED
K9K, and 834
135850
140652
a Remove the nut (17) of the particle filter temperature
sensor wiring bracket.
a Move aside the particle filter temperature sensor wi-
ring.
a Remove the left-hand suspended engine mounting

(see Left-hand suspended engine mounting: Re-
moval - Refitting) (19D, Engine mounting).
134555
a Fit a component jack (19) beneath the manual
gearbox.
21A-59
MANUAL GEARBOX
K9K, and JR5
Replacing the manual gearbox
verse gear switch from the gearbox using the tool
(Emb. 1797).
a Refit the reverse gear switch on the new manual
gearbox.
a Torque tighten the reverse gear switch (23 N.m)
using the (Emb. 1797).

CONCERNED
a Refit a new clutch thrust bearing (see 20A, Clutch,
20A-22) .
a Fit the new manual gearbox using the component
jack.
a Refit the manual gearbox studs.
135852 a Torque tighten the manual gearbox studs (6.5
N.m).
a Remove:
- the lower bolts (20) from the manual gearbox,
- the nuts from the manual gearbox, a Refit the manual gearbox lower bolts.
- the manual gearbox using the component jack, a Torque tighten the manual gearbox lower bolts
(44 N.m).
- the manual gearbox studs, a Remove the component jack from the manual
gearbox.
thrust bearing: Removal - Refitting, page 20A- a Refit the manual gearbox upper bolts.
22) . a Torque tighten the manual gearbox upper bolts
(44 N.m).
REFITTING
a Refit the left-hand suspended engine mounting (see
I - REFITTING PREPARATION OPERATION Left-hand suspended engine mounting: Remo-
val - Refitting) (19D, Engine mounting).
ring (12,03,01,04).
K9K, and 834
a Fit the particle filter temperature sensor wiring.
WARNING
To avoid damaging the slave cylinder, do not coat a Refit the nut of the particle filter temperature sensor
wiring bracket.
WARNING
Do not grease the clutch shaft splines. K9K, and 830
a Refit:
a Check that there are centring rings in place on the
new manual gearbox. - the catalytic converter downstream strut,
21A-60
MANUAL GEARBOX
K9K, and JR5
- the catalytic converter downstream strut bolts, a Clip the following on the manual gearbox:
- the catalytic converter downstream strut nut. - the manual gearbox breather pipe,
- the engine wiring channel.
a Refit:
a Clip the reverse gear switch wiring on the manual
gearbox.
a Connect the reverse gear switch connector. trol injection),
a Refit: - the hydraulic clutch control pipe (see Clutch cir-

- the front axle subframe (see Front axle sub-fra- ponent controls).
nents), a Bleed the hydraulic clutch circuit (see Clutch cir-
- the radiator mounting cross member (see Radiator trols).
(31A, Front axle components), a Refit the engine undertray.
- the front bumper (see Front bumper: Removal - a Fit the manual gear selector cables.
Refitting) (55A, Exterior protection), a Clip the manual gear selector cables:
- new differential output seals (see 21A, Manual - on the sheath stop,
fitting, page 21A-10) , - on the anchoring ball joints.
- the front left-hand driveshaft (see 29A, Drives- a Fit the battery wiring channel on the left-hand sus-
hafts, Front left-hand wheel driveshaft: Remo- pended engine mounting.
a Fit the turbocharging pressure regulation solenoid
- the front right-hand wheel driveshaft (see 29A, Dri- valve wiring.
Removal - Refitting, page 29A-18) . a Connect the turbocharging pressure regulation sole-
noid valve connector.
box, Manual gearbox oil: Draining - Refilling, a Refit the air filter housing (see Air filter unit: Remo-
page 21A-2) . val - Refitting) (12A, Fuel mixture).
a Refit:
J95
Front wheel arch liner: Removal - Refitting) a Refit:
(55A, Exterior protection), - the centre section of the scoop under the scuttle
- the front wheels (see Wheel: Removal - Refitting) panel grille (see Scoop under scuttle panel
(35A, Wheels and tyres), grille: Removal - Refitting) (56A, Exterior equip-
ment),
(16A, Starting - Charging). - the centre section of the scuttle panel grille (see
Note:
Refit the earth terminal, at the mark made by the
indelible pencil on the gearbox casing.
a Refit:
earth terminal on the gearbox housing could - the battery tray (see Battery tray: Removal - Re-
result in damage to the earth terminal or earth fitting) (80A, Battery),
cable. - the battery (see Battery : Removal - Refitting)
(80A, Battery),
a Torque tighten the manual gearbox earth cable
bolt (24 N.m). - the engine cover.
21A-61
MANUAL GEARBOX
M9R, and PK4
Essential special tooling Front wheel arch liner: Removal - Refitting)
Mot. 1448 Long nose pliers for hose
clips. - the front bumper (see Front bumper: Removal -
Essential equipment
- the headlights (see Front headlight: Removal -
refrigerant charging station Refitting) (80B, Headlights).
B95 or D95
Tightening torquesm
a Remove the front bumper supports (see Front bum-
manual gearbox nuts 44 N.m per support: Removal - Refitting) (42A, Front up-
per structure).
bolts

bolts a Remove:
- the audible warning (see Horn: Removal - Refit-

REMOVAL ting) (82B, Horn),
- the front impact cross member (see Front impact

I - REMOVAL PREPARATION OPERATION cross member: Removal - Refitting) (41A, Front
lower structure),
Towing and lifting) (02A, Lifting equipment). - the air deflectors,
a Remove the front engine cover. - the bonnet catch (see Bonnet latch: Removal -
Refitting) (52A, Non-side opening element mecha-
J95 nisms),
a Remove: - the intercooler air outlet pipe (see Intercooler air

outlet pipe: Removal - Refitting) (12B, Turbo-
- the centre section of the scuttle panel grille (see charging).
Exterior equipment), a Drain:
- the scoop under the centre section of the scuttle - the refrigerant circuit using a refrigerant charging
panel grille (see Scoop under scuttle panel station (see Coolant circuit Draining - Refilling)
grille: Removal - Refitting) (56A, Exterior equip- (62A, Air conditioning),
ment).
21A-2) ,
a Remove: - the cooling system (see Cooling circuit: Draining
- the battery (see Battery: Removal - Refitting) - Refilling) (19A, Cooling).
(80A, Battery),
- the engine oil (if necessary) (see Engine oil: Drai-
- the battery tray (see Battery tray: Removal - Re- ning - Refilling) (10A, Engine and peripherals).
a Remove:
fitting) (12A, Fuel mixture), - the front right-hand driveshaft (see 29A, Drives-
- the engine undertray bolts, val - Refitting, page 29A-18) ,
- the front wheels (see Wheel: Removal - Refitting) hafts, Front left-hand wheel driveshaft: Remo-
(35A, Wheels and tyres), val - Refitting, page 29A-2) ,
21A-62
MANUAL GEARBOX
M9R, and PK4

ting),
- the air resonator (see Air resonator: Removal -

Refitting) (12A, Fuel mixture),

ponent controls).

- the right-hand suspended engine mounting (see

Right-hand suspended engine mounting: Re-
140254
a Disconnect the coolant temperature sensor connec-
- the « engine - gearbox » assembly (see Engine/ tor (3) .
gearbox assembly: Removal - Refitting) (10A,
Engine and peripherals),

140019
a Unclip the cooling hose (4) from the water chamber.
123412
a Remove the bolt (1) from the wiring on the manual

gearbox mounting.
a Unclip the engine wiring from the manual gearbox at

(2) .
21A-63
MANUAL GEARBOX
M9R, and PK4
140247 140250
a Separate the clip (5) of the water chamber hose
using the tool (Mot. 1448).
a Disconnect the hose from the water chamber.
a Unclip the engine wiring at (6) .
a Disconnect the leak return pipe from the high pres-
sure pump (7) .
140251
a Remove:
- the bolts (8) from the exhaust gas recirculation pipe
heat shield,
- the exhaust gas recirculation pipe heat shield,
- the manual gearbox breather pipe.
21A-64
MANUAL GEARBOX
M9R, and PK4
CONCERNED
140253
a Remove the upper nuts (10) on the manual gearbox.
140245
verse gear switch (see 21A, Manual gearbox, Re-
21A-87) .
REFITTING

a
WARNING
WARNING
a Check that there are centring rings in place on the

140244 manual gearbox.
a Remove:
- the lower bolts (9) from the manual gearbox, If replacing the manual gearbox
a Refit the reverse gear switch on the manual gearbox
- the lower bolts (9) from the manual gearbox.
(see 21A, Manual gearbox, Reverse gear switch:

CONCERNED
21A-65
MANUAL GEARBOX
M9R, and PK4
a Refit: - the front left-hand driveshaft (see 29A, Drives-
- the manual gearbox lower bolts,
- the manual gearbox upper bolts.
a Tighten to torque: hafts, Front right-hand wheel driveshaft: Remo-
- the manual gearbox lower bolts (44 N.m), val - Refitting, page 29A-18) ,
- the manual gearbox upper bolts (44 N.m). - the intercooler air outlet pipe (see Intercooler air
charging),
a Refit: - the bonnet catch (see Bonnet latch: Removal -
- the manual gearbox breather pipe, nisms),
- the exhaust gas recirculation pipe heat shield.
- the air deflectors,
a Connect the leak return pipe to the high pressure
pump. - the front impact cross member (see Front impact
cross member: Removal - Refitting) (41A, Front
a Clip on the engine wiring. lower structure),
a Connect the hose to the water chamber.
a Fit the clip on the water chamber hose using the tool ting) (82B, Horn).
(Mot. 1448).
a Clip the cooling hose onto the water chamber.
B95 or D95
a Connect the coolant temperature sensor connector.
a Refit the front bumper supports (see Front bumper
a Clip the engine wiring on the manual gearbox.
support: Removal - Refitting) (42A, Front upper
a Refit: structure).
- the wiring on the manual gearbox mounting,

a Refit:
- the « engine - gearbox » assembly (see Engine/
gearbox assembly: Removal - Refitting) (10A, - the headlights (see Front headlight: Removal -
Engine and peripherals), Refitting) (80B, Headlights),
- the right-hand suspended engine mounting (see - the front bumper (see Front bumper: Removal -
Right-hand suspended engine mounting: Re- Refitting) (55A, Exterior protection),
- the radiator mounting cross member (see Radiator - the front section of the front wheel arch liners (see
support cross member: Removal - Refitting) Front wheel arch liner: Removal - Refitting)
(31A, Front axle components), (55A, Exterior protection),
- the hydraulic clutch control pipe (see Clutch cir- - the front wheels (see Wheel: Removal - Refitting)
cuit: Removal - Refitting) (37A, Mechanical com- (35A, Wheels and tyres),
ponent controls).
Refitting) (12A, Fuel mixture), - the air filter unit (see Air filter unit: Removal - Re-
- the lower engine tie-bar (see Lower engine tie- fitting) (12A, Fuel mixture),
ting), - the battery tray (see Battery tray: Removal - Re-
gearbox, Differential output seal: Removal - Re- - the battery (see Battery: Removal - Refitting)
fitting, page 21A-10) , (80A, Battery).
21A-66
MANUAL GEARBOX
M9R, and PK4
J95
a Refit:
ment),
a Perform the following operations:

- fill the engine oil (if necessary) (see Engine oil:
Draining - Refilling) (10A, Engine and periphe-
rals),
- fill up and bleed the cooling system (see Cooling
circuit: Draining - Refilling) (19A, Cooling),
- fill up the manual gearbox (see 21A, Manual gear-
page 21A-2) ,
- fill the refrigerant circuit using a refrigerant char-
ging station (see Coolant circuit Draining - Re-
filling) (62A, Air conditioning).
a Refit the engine cover.
21A-67
MANUAL GEARBOX
H4J, and TL4
a Remove the front engine cover.
Mot. 1720 Engine stand.

J95
Mot. 1672 Lower engine support.
a Remove:
Mot. 1913 Conversion support stud for
Mot. 1720 tool - the centre section of the scuttle panel grille (see
Essential equipment
indelible pencil - the scoop under the centre section of the scuttle
component jack grille: Removal - Refitting) (56A, Exterior equip-
ment).
rivet gun
Tightening torquesm
a Remove:
(80A, Battery),
cable bolt
bolts for the left-hand 62 N.m
suspended engine - the air filter unit (see Air filter unit: Removal - Re-
mounting rubber pad fitting) (12A, Fuel mixture),
cover
- the intercooler air outlet pipe (see Intercooler air
central bolt for the left- 62 N.m outlet pipe: Removal - Refitting) (12B, Turbo-
hand suspended engine charging).
mounting rubber pad
support
lower engine tie-bar bolt 180 N.m

on the front axle sub-
frame

on the lower engine tie-
bar support
IMPORTANT
REMOVAL
I - REMOVAL PREPARATION OPERATION 136551
a Position the vehicle on a two-post lift (see Vehicle: a Disconnect the connector (1) from the reverse gear
Towing and lifting) (02A, Lifting equipment). switch.
21A-68
MANUAL GEARBOX
H4J, and TL4
136620 139509
a Unclip: a Remove the bolts (4) from the starter.
- the gear control cables (2) from the selector ball a Remove the starter.
joints using an open-jawed spanner,
- the gear control cables (3) from their support.
a Move the gear control cables away from the manual
gearbox.
a Remove:
controls),
138532
a Drain the manual gearbox oil (see 21A, Manual a Remove:
ling, page 21A-2) . - the bolt (5) for the lower engine tie-bar from the
front axle subframe,
- the bolt (6) for the lower engine tie-bar from the
lower engine tie-bar support,
- the lower engine tie-bar,
trol injection),
21A-69
MANUAL GEARBOX
H4J, and TL4
nents).
139249
a Unclip the following from the manual gearbox moun-

ting:
- the hose (9) between the water chamber and the

electric coolant pump,
- the electric coolant pump wiring (10) .
139266
a Drill out the rivet (7) on the battery wiring channel.
a Unclip the battery wiring channel (8) .
139258
a Remove the bolt (11) from the power and injection

wiring support on the manual gearbox.
a Move the power and injection wiring support away

from the manual gearbox.
21A-70
MANUAL GEARBOX
H4J, and TL4
139321 139253
a Remove: a Remove the bolt (13) of the left-hand suspended en-
- the bolt (12) of the intercooler air outlet pipe retai- gine mounting rubber pad support from the left-hand
ning bracket, suspended engine mounting cover.
- the intercooler air outlet pipe retaining bracket from a Slightly lower the manual gearbox.
the cylinder block.

CONCERNED
139327
a Fit the tool (Mot. 1720) equipped with the (Mot.

1672) and (Mot. 1913).
WARNING
It is strictly forbidden to apply any pressure to the

engine oil sump. Damage to the sump will irrepa-
rably damage the engine by: 136554
- blocking the strainer, a Remove:

- raising the oil level above maximum, with a risk - the bolts for the left-hand suspended engine moun-
of engine racing. ting rubber pad cover,
21A-71
MANUAL GEARBOX
H4J, and TL4
- the cover from the left-hand suspended engine
mounting rubber pad.
139268
a
139504
a Remove the upper bolt (14) from the manual gear- Note:
box. Before removing the earth terminal, mark its
casing.
in damage to the earth terminal or ear th wiring.
a Remove the manual gearbox earth cable bolt (15) .

21A-72
MANUAL GEARBOX
H4J, and TL4
139320 139504
a Fit a component jack beneath the manual gearbox.
a Tighten the rod anti-clockwise to avoid tilting the ma-
nual gearbox.
139242
a Remove:
- the manual gearbox nuts (17) ,
139241 - the manual gearbox using the component jack,
box.
22) .
If replacing the gearbox

a Remove:
- the bolt of the electric coolant pump hose and elec-
tric coolant pump wiring support,
21A-73
MANUAL GEARBOX
H4J, and TL4
- the electric coolant pump hose and electric coolant
pump wiring support.
REFITTING

ring (12,03,01,04).
WARNING
WARNING
136554
a Torque tighten in order the bolts for the left-hand
suspended engine mounting rubber pad cover
If replacing the gearbox (62 N.m).
a Refit the electric coolant pump hose and electric

coolant pump wiring support.
a Bring the left-hand suspended engine mounting rub-
ber pad cover into contact on the left-hand suspen-
ded engine mounting rubber pad using the tool (Mot.
CONCERNED
1720) equipped with the (Mot. 1672) and (Mot.
a Refit: 1913).
a Refit the central bolt of the left-hand suspended en-
gine mounting rubber pad support on the left-hand
suspended engine mounting rubber pad cover.
20A-22) ,
a Torque tighten the central bolt for the left-hand
- the manual gearbox using the component jack. suspended engine mounting rubber pad support
(62 N.m).
a Remove the component jack from the manual
gearbox. a Remove the tool (Mot. 1720) equipped with the
(Mot. 1672) and (Mot. 1913).
a Tighten to torque:
a Refit the intercooler air outlet pipe retaining bracket
- the manual gearbox nuts (44 N.m), on the cylinder block.
- the manual gearbox bolts (44 N.m) a Fit the power and injection wiring support on the ma-
nual gearbox.
marks made during disassembly. a Refit the bolt of the power and injection wiring sup-
port on the manual gearbox.
a Refit the earth cable bolt on the manual gearbox.
a Clip the following on the mounting on the manual
gearbox:
a Torque tighten the manual gearbox earth cable
bolt (24 N.m). - the hose between the water chamber and the elec-
tric coolant pump,
a Refit the left-hand suspended engine mounting rub-
ber pad cover on the manual gearbox. - the electric coolant pump wiring.
21A-74
MANUAL GEARBOX
H4J, and TL4
a Fit the battery wiring channel. a Refit:
a Clip on the battery wiring channel. - the intercooler air outlet pipe (see Intercooler air
a Fit a new rivet on the battery wiring channel using a
charging),
rivet gun.
a Refit:
nents),
(80A, Battery).
- new differential output seals (see 21A, Manual J95
gearbox, Differential output seal: Removal - Re- a Refit:
- the front right-hand driveshaft (see 29A, Drives- panel grille (see Scoop under scuttle panel
hafts, Front right-hand wheel driveshaft: Remo- grille: Removal - Refitting) (56A, Exterior equip-
val - Refitting, page 29A-18) , ment),
- the front left-hand driveshaft (see 29A, Drives- - the centre section of the scuttle panel grille (see
hafts, Front left-hand wheel driveshaft: Remo- Scuttle panel grille: Removal - Refitting) (56A,
val - Refitting, page 29A-2) , Exterior equipment).
trol injection),
- the lower engine tie-bar.
- fill up the manual gearbox (see 21A, Manual gear-
a Tighten to torque: box, Manual gearbox oil: Draining - Refilling,
- the lower engine tie-bar bolt on the front axle page 21A-2) ,
sub-frame (180 N.m), - bleed the clutch control circuit (see Clutch circuit:
- the lower engine tie-bar bolt on the lower engi- Bleeding) (37A, Mechanical component controls).
ne tie-bar support (180 N.m). a Refit the engine cover.
a Fit the starter.
a Refit:
- the starter bolts,
controls).
a Fit the control cables on the manual gearbox.
a Clip on the gear control cables.
21A-75
MANUAL GEARBOX
Input shaft lip seal: Removal - Refitting 21A
JH3 or JR5
Essential special tooling (4) Key

(5) Sender
Bvi. 1445 Tool for extracting and fitting
JB gearbox guide tube.
Bvi. 1828
Bvi. 1828 Rivet set and plate for remo-
ving/refitting JH1 gearbox
guide tube
Tightening torquesm
clip on the throttle valve 6 N.m

air inlet pipe
IMPORTANT
Note:
The lip seal and the primary shaft bearing are built 122820
into the thrust bearing guide tube.
(6) Snap rivet
(7) Pressure plate
a The thrust pad guide tube is removed using the (Bvi.

Bvi. 1445 1445) and (Bvi. 1828).
Note:
The gauge (5) is not used for the JH gearbox.
REMOVAL

a Remove:
- the engine cover,

Washing),
99057
(1) Tightening clamp
(2) Sleeve
(3) Split ring (56A, Exterior equipment),
21A-76
MANUAL GEARBOX
JH3 or JR5
- the battery (see Battery : Removal - Refitting) - the manual gearbox (see 21A, Manual gearbox,
(80A, Battery), Manual gearbox: Removal - Refitting, page 21A-
24) ,
fitting) (80A, Battery), - the clutch thrust bearing (see 20A, Clutch, Clutch
22) .
a Loosen the clip on the throttle valve air inlet pipe.
a Disconnect the air outlet pipe from the air filter unit. CONCERNED
a Remove:
- the air outlet pipe to the air filter unit,
page 21A-2) .
a Remove:
(16A, Starting - Charging), 98934
- the lower engine tie-bar (see Lower engine tie- a Position the manual gearbox on the support.
ting), a Adjust the adjustable support if necessary.

trol injection).
- the radiator mounting cross member (see Radiator 122821
(31A, Front axle components), a Gently remove the guide tube with a press using the
snap rivet (6) , section (A) of the (Bvi. 1828) on the
- the front axle subframe (see Front axle sub-fra- guide tube end.
nents), a Degrease the guide tube.
21A-77
MANUAL GEARBOX
JH3 or JR5
REFITTING
I - REFITTING OPERATION FOR PART

CONCERNED
122822
a In order, fit the following on the guide tube:
- the pressure plate (7) of the (Bvi. 1828),
- the tightening clamp (1) of the (Bvi. 1445).
122821
a Immobilise the tightening clamp using the key (4) of
the (Bvi. 1445). a Refit the new guide tube with a press until the snap
rivet is flush (6) on the (Bvi. 1445) with the housing,
a Tighten the nut firmly. on the guide tube section side (B) .
II - FINAL OPERATION
a Refit:
22) ,
24) ,

nents),
122823
a Position the sleeve (2) and the split ring in place (3) - the radiator mounting cross member (see Radiator
with the (Bvi. 1445). support cross member: Removal - Refitting)
a Gently remove the guide tube by moving the upper
nut (8) . - the differential output seals (see 21A, Manual


trol injection).
21A-78
MANUAL GEARBOX
JH3 or JR5
ting),
page 21A-2) .
a Refit:
- the air outlet pipe from the air filter unit.
a Connect the air outlet pipe of the air filter unit.
a Torque tighten the clip on the throttle valve air in-
let pipe (6 N.m).
a Refit:
(80A, Battery),
Washing),
- the engine cover.
21A-79
MANUAL GEARBOX
ND4
a Replace the lip seal after opening the gearbox (see
Clutch housing: Removal - Refitting) .
21A-80
MANUAL GEARBOX
TL4
Essential special tooling support cross member: Removal - Refitting)
Bvi. 1601 Pr imary shaft oil seal fitting
tool. - the front axle subframe (see Front axle sub-fra-
nents),
REMOVAL
I - REMOVAL PREPARATION OPERATION Washing),
a Position the vehicle on a two-post lift (see Vehicle: - the scuttle panel grille (see Scuttle panel grille:
Towing and lifting) (02A, Lifting equipment). Removal - Refitting) (56A, Exterior equipment),
a Remove: - the scoop under the scuttle panel grille (see Scoop
- the engine cover, (56A, Exterior equipment),
- the battery (see Battery : Removal - Refitting) - the left-hand suspended engine mounting (see
(80A, Battery), Left-hand suspended engine mounting: Remo-
fitting) (80A, Battery), - the manual gearbox (see 21A, Manual gearbox,
- the air filter unit (see Air filter unit: Removal - Re- 24) ,
- the hydraulic clutch release bearing (see 20A,
- the engine undertray bolts, Clutch, Clutch thrust bearing: Removal - Refit-

trol injection),


page 21A-2) .
a Remove:

21A-81
MANUAL GEARBOX
TL4
II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART
CONCERNED CONCERNED
18061
a Fit a new input shaft lip seal, fitted with its protector,
using the (2) .
a Remove the protector from the new input shaft lip
seal.
123822
a Insert the (Bvi. 1601) and tap it gently with a rubber
a
mallet to ensure it is inserted fully.
Note:
Do not drill too deeply as this risks damaging the III - FINAL OPERATION
deflector positioned behind the input shaft lip
a Refit:
seal.
- the hydraulic clutch release bearing (see 20A,
a Drill a hole in the input shaft lip seal (1) , using a drill Clutch, Clutch thrust bearing: Removal - Refit-
bit with a diameter of 2.5 mm. ting, page 20A-22) ,
a Fit a bolt in the input shaft lip seal (1) .
a Remove the input shaft lip seal (1) with a pair of Manual gearbox: Removal - Refitting, page 21A-
pliers. 24) ,
REFITTING Left-hand suspended engine mounting: Remo-
val - Refitting) ,
I - REFITTING PREPARATION OPERATION - the scoop under the scuttle panel grille (see Scoop
a
Note: - the scuttle panel grille (see Scuttle panel grille:
When refitting the input shaft lip seal, take care Removal - Refitting) (56A, Exterior equipment),
not to damage either the shaft or the contact sur-
face of the lip seal. - the windscreen wiper arms (see Windscreen wi-
Washing),
nents),
21A-82
MANUAL GEARBOX
TL4
- fill and check the gearbox oil level (see 21A, Ma-
nual gearbox, Manual gearbox oil: Draining -
Refilling, page 21A-2) ,
- bleed the clutch control circuit (see Clutch circuit:
Bleeding) (37A, Mechanical component controls).
a Refit:
trol injection),
(80A, Battery),
- the engine cover.
21A-83
MANUAL GEARBOX
PK4
Essential special tooling hafts, Front right-hand wheel driveshaft: Remo-
Bvi. 1236 Pr imary shaft oil seal fitting val - Refitting, page 29A-18) ,
tool.
REMOVAL fitting, page 21A-10) ,

a Position the vehicle on a two-post lift (see Vehicle: ting),
IMPORTANT
nents),
vehicle lift using a strap. - the starter (see Starter: Removal - Refitting)
a Remove:
- the engine undertray bolts, - the windscreen wiper arms (see Windscreen wi-
Washing),
- the engine cover,
- the battery (see Battery: Removal - Refitting) Removal - Refitting) (56A, Exterior equipment),
(80A, Battery),
fitting) (80A, Battery), under scuttle panel grille: Removal - Refitting)
fitting) (12A, Fuel mixture), - the left-hand suspended engine mounting (see
- the hydraulic clutch control pipe (see Clutch cir- Left-hand suspended engine mounting: Remo-
cuit: Removal - Refitting) (37A, Mechanical com- val - Refitting) (19D, Engine mounting),
ponent controls).
a Drain the manual gearbox oil (see 21A, Manual Manual gearbox: Removal - Refitting, page 21A-
gearbox, Manual gearbox oil: Draining - Refil- 24) ,
ling, page 21A-2) .
a Remove: - the clutch thrust bearing (see 20A, Clutch, Clutch

- the front wheels (see Wheel: Removal - Refitting) 22) .

(55A, Exterior protection), CONCERNED
- the front bumper (see Front bumper: Removal - a Use a drill bit with a diameter of 2.5 mm to drill a
Refitting) (55A, Exterior protection), hole in the input shaft lip seal.
(31A, Front axle components), Note:
- the front left-hand driveshaft (see 29A, Drives- Do not drill too deeply as this risks damaging the
hafts, Front left-hand wheel driveshaft: Remo- deflector positioned behind the input shaft lip
val - Refitting, page 29A-2) , seal.
21A-84
MANUAL GEARBOX
PK4
CONCERNED
18061
a Fit a new input shaft lip seal, fitted with its protector,
using the (Bvi. 1236).
20714 a Remove the protector.
a Fit a bolt in the input shaft lip seal (1) . a Insert the (Bvi. 1236) and tap it gently with a rubber
a Remove the input shaft lip seal (1) with a pair of mallet to ensure it is inserted fully.
pliers.
REFITTING a Refit:
I - REFITTING PREPARATION OPERATION thrust bearing: Removal - Refitting, page 20A-
22) ,
a
Note: Manual gearbox: Removal - Refitting, page 21A-
When refitting the input shaft lip seal, take care 24) ,
not to damage either the shaft or the input shaft - the left-hand suspended engine mounting (see
lip seal mating face. Left-hand suspended engine mounting: Remo-
Washing),
nents),
ting),
21A-85
MANUAL GEARBOX
PK4
(35A, Wheels and tyres).
a Fill the manual gearbox (see 21A, Manual gearbox,
21A-2) .
a Refit:
ponent controls),
(80A, Battery),
- the engine cover,
21A-86
MANUAL GEARBOX
Reverse gear switch: Removal - Refitting 21A
JH3 or JR5
REFITTING
Tightening torquesm
reverse gear switch 23 N.m CONCERNED
a Apply some SILICONE ADHESIVE SEALANT (see
Vehicle: Parts and ingredients for the repai-
REMOVAL rwork) (04B, Consumables - Products) to the threa-
ding of the reverse gear switch.
a Refit the reverse gear switch.
a Torque tighten the reverse gear switch (23 N.m).
a Disconnect the battery (see Battery : Removal - II - FINAL OPERATION

Refitting) (80A, Battery).
a Top up the manual gearbox oil (see 21A, Manual
a Remove:
ling, page 21A-2) .
- the engine undertray bolts, a Refit the engine undertray.
- the engine undertray. a Connect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
page 21A-2) .

CONCERNED
135848

switch.
a Remove the reverse gear switch.
21A-87
MANUAL GEARBOX
ND4
REMOVAL

a Remove:

CONCERNED
135545
switch.
a Remove the reverse gear switch (2) .
REFITTING

CONCERNED
a Apply RESIN ADHESIVE (see Vehicle: Parts and
ingredients for the repairwork) (04B, Consuma-
bles - Products) to the threading of the reverse gear
switch.
21A-88
MANUAL GEARBOX
TL4
REFITTING
Emb. 1797 24 mm socket for removing I - REFITTING OPERATION FOR PART

and refitting clutch master CONCERNED
cylinder
Tightening torquesm using the tool (Emb. 1797).
REMOVAL a Refit:
a Remove: (80A, Battery).

(80A, Battery),


CONCERNED
134484

switch.
a Remove the reverse gear switch using the tool

(Emb. 1797).
21A-89
MANUAL GEARBOX
PK4
REFITTING
Emb. 1797 24 mm socket for removing I - REFITTING OPERATION FOR PART

and refitting clutch master CONCERNED
cylinder
Tightening torquesm using the tool (Emb. 1797).
REMOVAL a Refit:
a Remove: (80A, Battery).

(80A, Battery),


CONCERNED
115004

switch.
a Remove the reverse gear switch using the tool

(Emb. 1797).
21A-90
AUTOMATIC GEARBOX
Automatic gearbox: Precautions for repair 23A
FK0
As the automatic gearbox is lubricated under pressure,
lubrication is only provided when the engine is running.
As a result of this fact, and to avoid serious damage, it
is essential to comply with the following instructions:
- never allow the vehicle to coast with the ignition swit-
ched off (e.g. when going down a hill). We cannot
stress enough the harm that this may cause,
- never push the vehicle (e.g. to get to a petrol station,
unless the recommended precautions have been ta-
ken (see Vehicle: Towing and lifting) (02A, Lifting
equipment).
In addition, the vehicle is only under traction if the engi-
ne is running. It is therefore impossible to start the en-
gine of a vehicle with an automatic gearbox by pushing
the vehicle.
Always use the recommended CVT oil (see Automatic
gearbox oil: Specifications) (Technical Note 6012,
04A, Lubricants).
Removal must always be carried out in a clean and
dust-free environment.
Do not use a cotton (or fabric) cloth, always use lint-
free paper.
Before removal:
- always clean the outside of the CVT before any ope-
ration,
- mark the position of the components to ensure they
are refitted correctly.
Operations on the CVT must be carried out with bare
hands or wearing vinyl gloves.
When removing internal components from the CVT,
make sure you have clean hands.
23A-1
AUTOMATIC GEARBOX
Automatic gearbox: Precautions for repair 23A
AJ0
I - SPECIFICATIONS Store removed parts in storage containers so as not to
damage or misplace them.
Weight: 100 kg
The AJ0 is fitted with systems known as: "Shift Lock" III - CHECKING LEVELS
and "Lock Up".
Always move the control level to the Park position
"Shift Lock" inhibits movement of the gear selector le- when checking levels.
ver unless the brake pedal is depressed simultaneous-
ly. To unlock the lever when the battery is faulty
and carry out repair operations, refer to the Dri-
ver's Handbook.
The aim of converter Lock Up is to connect the auto-
matic gearbox directly to the engine. This function is
carried out by a "mini clutch" in the converter. Lock Up
is controlled by the automatic gearbox computer.
As the automatic gearbox is lubricated under pressure,

lubrication is only provided when the engine is running.
As a result of this fact, and to avoid serious damage, it
is essential to comply with the following instructions:
- never allow the vehicle to coast with the ignition swit-

ched off (e.g. when going down a hill); we cannot
stress too strongly the harm that this may cause,
- never push the vehicle (e.g. to get to a petrol station,
unless the recommended precautions have been ta-
ken (see Vehicle: Towing and lifting) (02A, Lifting
equipment).
In addition, the vehicle is only under traction if the engi-
ne is running. It is therefore impossible to start the en-
gine of a vehicle with an automatic gearbox by pushing
the vehicle.
II - STORING REMOVED PARTS
116357
23A-2
AUTOMATIC GEARBOX
Automatic gearbox: Identification 23A
FK0
129975
The gearbox is identified by an engraved marking (1)
located on the top of the gearbox and by a self-adhesi-
ve label (2) affixed to the side of the gearbox.
23A-3
AUTOMATIC GEARBOX
Automatic gearbox: Identification 23A
AJ0
117777
The automatic gearbox is identified by an engraved
marking (1) located underneath the automatic gearbox
as well as by a self-adhesive label (2) on the hydraulic
distributor housing.
23A-4
AUTOMATIC GEARBOX
Automatic gearbox: Specifications 23A
AJ0
Gearbox Suffix
008
AJ0 012
015
Gear ratios (epicyclic gear train output)
1st 2nd 3rd 4th 5th 6th Reverse gear
4.2 2.405 1.583 1.161 0.855 0.685 3.457
23A-5
AUTOMATIC GEARBOX
Automatic gearbox: List and location of components 23A
FK0
138923
(20) Selector shaft ring
(1) Cap
(21) Manual slide valve
(2) Seal
(22) Timing seal
(3) Breather pipe
(23) Front left-hand differential out-
(4) Multifunction switch put seal
(5) Gearbox oil filter (24) Hydraulic distributor wiring retai-
(6) Seal ning clip
(7) Gearbox oil cooler (25) Hydraulic distributor wiring
(8) Output speed sensor (26) Lower housing seal
(9) Output speed sensor seal (27) Drain plug seal
(10) Front left-hand differential out- (28) Drain plug
put seal (29) Lower cover
(11) Gearbox (30) Converter
(12) Pulley ratio linkage (31) Converter seal
(13) Pulley ratio linkage spring (32) Input speed sensor seal
(14) Hydraulic distributor (33) Input speed sensor
(15) Oil strainer retaining bracket
(16) Seal
(17) Oil strainer
(18) Lock washer
(19) Control lever
23A-6
AUTOMATIC GEARBOX
Automatic gearbox: List and location of components 23A
AJ0
117734
(1) AJ0 gearbox

(2) Oil overflow pipe
(3) Level-setting plug
(4) Torque converter
(5) Filler pipe closure panel
(6) Oil cooler
(7) Output speed sensor
(8) Input speed sensor
(9) Multifunction switch
(10) Control lever
(11) Electrical wiring
(12) Hydraulic pressure measure-
ment plug
(13) Hydraulic distributor O-rings
(14) Hydraulic distributor
(15) Hydraulic distributor casing seal 118831
(16) Hydraulic distributor housing
(17) Solenoid valves
(18) Gearbox oil temperature sensor
(19) Pressure sensors
23A-7
AUTOMATIC GEARBOX
Automatic gearbox: Removal - Refitting 23A
FK0
a Remove the « engine - automatic gearbox » assem-
Essential special tooling bly (see Engine/gearbox assembly: Removal -
Refitting) (10A, Engine and cylinder block assem-
bly).
clips.
Mot. 1390 Support for removing/refitting

the engine - gearbox assem-
bly.
Essential equipment
workshop hoist
Tightening torquesm
automatic gearbox bell 62 N.m

housing bolts
converter nuts 44 N.m
IMPORTANT
During this operation, be sure to: 141109

- refrain from smoking or bringing red hot objects a Disconnect the output speed sensor connector (1)
close to the working area, from the automatic gearbox.
- be careful of fuel splashes when disconnecting the a Unclip the wiring at (2) .
union.
IMPORTANT
Wear goggles with side protectors for this opera-
tion.
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.
REMOVAL

23A-8
AUTOMATIC GEARBOX
FK0
141110 141111
a Disconnect: a Disconnect the automatic gearbox hydraulic distri-
butor connector (6) .
- the input speed sensor connector (3) from the auto-
matic gearbox, a Remove:
- the multifunction switch connector (4) . - the automatic gearbox electrical wiring at (8) ,
a Unclip the automatic gearbox wiring at (5) . - the automatic gearbox oil cooler hose clips (7)
using the (Mot. 1448).
a Disconnect the coolant hoses from the automatic
gearbox oil cooler.
138619
a Remove:
- the bolts (9) from the automatic gearbox oil cooler
hose mounting,
23A-9
AUTOMATIC GEARBOX
FK0
- the automatic gearbox oil cooler hose mounting
(10) ,
- the automatic gearbox oil gauge,
130021
a Secure the converter with string to prevent it from
being dislodged.
REFITTING
141112
a Remove: I - REFITTING PREPARATION OPERATION
- the converter nuts (11) by rotating the crankshaft a Check that the drive plate is not damaged or runout
clockwise, (0.2 mm permitted runout).
- the « engine - automatic gearbox » assembly from a Always replace the converter nuts.
the (Mot. 1390) using a workshop hoist.
II - OPERATION FOR REMOVAL OF PART a Remove the string immobilising the converter.
CONCERNED
a Remove:
- the automatic gearbox bell housing bolts,
- the automatic gearbox.
23A-10
AUTOMATIC GEARBOX
FK0
CONCERNED
130023
a Check that torque converter is correctly coupled to
the continuously variable gearbox using a rule and a 141113
straightedge. The distance between the converter
retaining bolt bead and the housing must be at least
14.4 mm.
141114
a Position the converter bolts (12) opposite the holes

(13) in the drive plate.
a Refit:
- the automatic gearbox,
- the automatic gearbox bell housing bolts.
a Torque tighten the automatic gearbox bell hou-

sing bolts (62 N.m).
23A-11
AUTOMATIC GEARBOX
FK0
a Refit:
- the « engine - automatic gearbox » assembly on
the (Mot. 1390) using a workshop hoist,
- the new converter nuts by rotating the crankshaft
clockwise.
a Torque tighten the converter nuts (44 N.m).
a Refit:
- the automatic gearbox oil cooler hose mounting,
- the automatic gearbox oil gauge.
a Clip the coolant hoses on the automatic gearbox oil
cooler hose mounting.
a Connect the coolant hoses to the automatic gearbox
oil cooler.
a Fit the cooling hose clips on the automatic gearbox
oil cooler using the (Mot. 1448).
a Connect the automatic gearbox hydraulic distributor
connector.
a Clip the automatic gearbox wiring in place.
a Connect:
- the multifunction switch connector,
- the input speed sensor connector to the automatic
gearbox,
- the output speed sensor connector to the automa-
tic gearbox.
a Refit the « engine - automatic gearbox » assembly
(see Engine/gearbox assembly: Removal - Refit-
ting) (10A, Engine and cylinder block assembly).
23A-12
AUTOMATIC GEARBOX
M9R, and AJ0
Essential equipment
refrigerant charging station - the front bumper (see Front bumper: Removal -
workshop hoist
load balancer Refitting) (80B, Headlights).
Tightening torquesm B95 or D95

automatic gearbox bell 44 N.m
per support: Removal - Refitting) (42A, Front up-
housing bolts and nuts
per structure).
converter retaining nuts 44 N.m
REMOVAL a Remove:

I - REMOVAL PREPARATION OPERATION ting) (82B, Horn),
a Position the vehicle on a two-post lift (see Vehicle: - the front impact cross member (see Front impact
Towing and lifting) (02A, Lifting equipment). cross member: Removal - Refitting) (41A, Front
lower structure),
a Remove the front engine cover.
- the bonnet catch (see Bonnet latch: Removal -

J95 Refitting) (52A, Non-side opening element mecha-
a Remove: nisms),
charging).
a Drain:
panel grille (see Scoop under scuttle panel - the refrigerant circuit using a refrigerant charging
grille: Removal - Refitting) (56A, Exterior equip- station (see Coolant circuit Draining - Refilling)
ment). (62A, Air conditioning),
- the engine cooling system (see Cooling circuit:

Draining - Refilling) (19A, Cooling),
a Remove: - the automatic gearbox (see 23A, Automatic gear-

box, Automatic gearbox oil: Draining - Refilling,
- the battery (see Battery : Removal - Refitting) page 23A-17) .
(80A, Battery),
a Remove:
- the air filter unit (see Air filter unit: Removal - Re- val - Refitting, page 29A-18) ,
- the engine undertray bolts, hafts, Front left-hand wheel driveshaft: Remo-
- the front wheels (see Wheel: Removal - Refitting) bar: Removal - Refitting) (19D, Engine moun-
(35A, Wheels and tyres), ting),
23A-13
AUTOMATIC GEARBOX
M9R, and AJ0

CONCERNED
118394
a Remove all hoses and wiring fitted on the automatic
gearbox bell housing.
a Support:
- the « engine - gearbox » assembly using a works-
hop hoist and a load balancer,
- the gearbox using an additional workshop hoist
fitted with a load balancer.
a Remove:
- the bolts and nuts from the automatic gearbox bell
housing,
- the automatic gearbox using the workshop hoist
fitted with the load balancer.
118393
a Remove the retaining nuts from the converter (1) via
the starter opening.
23A-14
AUTOMATIC GEARBOX
M9R, and AJ0
REFITTING - the « engine - gearbox » assembly (see Engine/

ting),

11911
a Check: charging),
- the distance (X) using a ruler. This distance must - the bonnet catch (see Bonnet latch: Removal -
be 20.4 ± 0.5 mm, Refitting) (52A, Non-side opening element mecha-
nisms),
- the drive plate (see Drive plate: Removal - Refit-
ting) (10A, Engine and cylinder block assembly). - the air deflectors,
II - REFITTING OPERATION FOR PART cross member: Removal - Refitting) (41A, Front
CONCERNED lower structure),
a - the audible warning (see Horn: Removal - Refit-
ting) (82B, Horn).
Note:
Before fitting the gearbox on the engine, position
the converter studs opposite the holes on the B95 or D95
drive plate. a Refit the front bumper supports (see Front bumper
a Refit the automatic gearbox on the engine using two structure).
workshop hoist and two load balancer.
a Torque tighten:
- the automatic gearbox bell housing bolts and
a Refit:
nuts (44 N.m),
- the converter retaining nuts (44 N.m).
Refitting) (80B, Headlights),
a Refit:
- the starter (see Starter: Removal - Refitting) Front wheel arch liner: Removal - Refitting)
(16A, Starting - Charging), (55A, Exterior protection),
23A-15
AUTOMATIC GEARBOX
M9R, and AJ0
(80A, Battery).
J95
a Remove
ment),

- fill the refrigerant circuit (see Coolant circuit Drai-
ning - Refilling) (62A, Air conditioning),
- fill up the automatic gearbox oil (see 23A, Automa-
tic gearbox, Automatic gearbox oil: Draining -
Refilling, page 23A-17) (23A, Automatic gearbox).
23A-16
AUTOMATIC GEARBOX
Automatic gearbox oil: Draining - Refilling 23A
M4R, and FK0
I - DRAINING PREPARATION OPERATION
Essential equipment a Position the vehicle on a four-post lift (see Vehicle:
a Remove:
diagnostic tool - the engine undertray bolts,
Tightening torquesm a Fit a oil recovery container under the gearbox.
drain plug 34 N.m
II - DRAINING STAGE
IMPORTANT
Consult the safety and cleanliness advice and ope-
ration recommendations before carrying out any
repair (see 23A, Automatic gearbox, Automatic
gearbox: Precautions for repair, page 23A-1) .
Note:
When draining, filling or checking the oil level,
always shift the gear lever to the Park position.
Perform the operation on a flat surface.
Note:
The oil level must be checked at a temperature
between 70˚C and 80˚C.
129978
a Remove:
Capacity (litres) Oil specified: - the drain plug,
7.6 (1) S e e Technical Note - the drain plug seal.

6012A a Let the oil flow out of the gearbox into the oil reco-
4.7 (2)
very container.
0.7 (3)
a Refit:
- (1): Total gearbox capacity.
- the new drain plug seal,
- (2): Filling value after draining.
- the drain plug.
- (3): Filling value after removal of universal joint wi-
a Torque tighten the drain plug (34 N.m).
thout draining.
a Refit:
a Remove the oil recovery container from under the
gearbox.
FILLING OPERATION
a Remove the oil level dipstick from the gearbox.
23A-17
AUTOMATIC GEARBOX
M4R, and FK0
a Use a flexible pipe fitted to a funnel (with a 1/100 fil-
ter)and connect it to the gearbox dipstick guide tube.
a Fill the automatic gearbox with 4 litres of oil.
Note:
The dipstick includes two possible checks: a cold
oil level check and a hot oil level check.
The level check is performed with the dipstick
clipped on.
Note:
Use lint-free paper to wipe the gauge.
a Check by clipping the dipstick that the oil level is

between the minimum and maximum on the cold
side with the engine switched off.
a Set the level between the minimum and maximum
on the cold side.
a Run the engine at idle speed.
a Firmly apply the parking brake.
a Slowly pass the gear lever once through all of its po-
sitions P/R/N/D.
a Connect the diagnostic tool.
a Establish dialogue with the automatic transmission
computer.
a Monitor the automatic transmission oil temperature
parameter.
a Wait until the temperature is between 70˚C and
80˚C.
a Check by clipping the dipstick that the oil level is
between the minimum and maximum on the hot si-
de.
a Top up the oil level if necessary.
a Clip on the oil level dipstick.
a Disconnect the diagnostic tool.
23A-18
AUTOMATIC GEARBOX
M9R, and AJ0
a Remove:
Essential equipment - the engine undertray bolts,
oil recovery container - the engine undertray.
diagnostic tool a Fit a oil recovery container under the gearbox.
Tightening torquesm
oil overflow pipe 8 N.m
level-setting plug 8 N.m
WARNING
To ensure that the gearbox oil level is correct, the
gear lever must be in the Park position during the
draining and filling operations.
Note:
The level must be checked at a temperature of 40˚C
± 2.
Note:
134877
The automatic transmission oil should preferably be
changed when the oil is warm (approximately 60˚C a Remove:
maximum) in order to remove as many impurities as
possible. - the level plug (1) ,
- the oil overflow pipe (2) using a 5 mm Allen key.
a Let the oil flow out of the gearbox into the oil reco-
Capacity (litres) Oil specified: very container.
7.6(1) (see Automatic gear- a Refit the oil overflow pipe.

box oil: Specifica-
3.5(2) tions) (Technical Note a Torque tighten the oil overflow pipe (8 N.m).
6012A, 04A, Lubri- a Refit the level-setting plug.
cants).
a Torque tighten the level-setting plug (8 N.m).
- (1): Total capacity
- (2): Capacity after oil draining
FILLING
DRAINING I - FILLING PREPARATION OPERATION
a
I - DRAINING PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle: Note:
Towing and lifting) (02A, Lifting equipment). The gearbox is filled via the output speed sensor,
a The control lever must be in the Park position when which is located near to the automatic gearbox
draining, filling or checking the level. wiring connector.
23A-19
AUTOMATIC GEARBOX
M9R, and AJ0
a Remove: a Monitor the automatic transmission oil temperature
parameter.
(80A, Battery), a Wait for the temperature to reach 40˚C ± 2.
- the battery tray (see Battery tray: Removal - Re- a Place a container under the level-setting plug.
- the output speed sensor (see 23A, Automatic

gearbox, Speed sensor: Removal - Refitting,
page 23A-73) .
118161
a Remove the level plug, leaving the engine running.
a Measure the quantity of oil collected.
141564 If there was no oil flow or if the quantity collected is

a Use a flexible pipe fitted with a funnel (with a less than 0.1 l
1:100filter) (3) and connect it to the filling pipe (4) . a Switch off the engine.
a Refit the level plug.
II - FILLING OPERATION
a Remove:
a It is essential to shift the selector lever to the Park
position.
(80A, Battery),
a Fill the automatic gearbox with 3.2 L of new oil. - the battery tray (see Battery tray: Removal - Re-
a Refit: fitting) (80A, Battery),
- the output speed sensor (see 23A, Automatic - the output speed sensor (see 23A, Automatic
gearbox, Speed sensor: Removal - Refitting, gearbox, Speed sensor: Removal - Refitting,
page 23A-73) , page 23A-73) .
a Add 0.5 L of oil to the automatic gearbox.
fitting) (80A, Battery), a Refit:
- the battery (see Battery : Removal - Refitting) - the output speed sensor (see 23A, Automatic
(80A, Battery). gearbox, Speed sensor: Removal - Refitting,
page 23A-73) ,
a Run the engine at idle speed.
a Connect the diagnostic tool. fitting) (80A, Battery),
a Establish dialogue with the automatic transmission - the battery (see Battery : Removal - Refitting)
computer. (80A, Battery).
23A-20
AUTOMATIC GEARBOX
M9R, and AJ0
a Let the automatic gearbox cool to 30˚C. a Connect the diagnostic tool.
a Run the engine at idle speed. a Monitor the automatic transmission oil temperature
a Wait for the automatic gearbox oil temperature to parameter.
reach 40˚C ± 2. a Wait for the temperature to reach 40˚C ± 2.
a Place a container under the level-setting plug.
a Repeat these operations until there is more than 0.1
L of oil in the container. a Measure the quantity of oil collected.
a Refit the level-setting plug.

If there was no oil flow or if the quantity collected is
a Torque tighten the level-setting plug (8 N.m).
less than 0.1 l
III - FINAL OPERATION a Switch off the engine.
a Refit the engine undertray. a Refit the level plug.
a Remove:
IV - CHECKING THE LEVEL OUTSIDE OIL CHANGE
OPERATIONS - the battery (see Battery : Removal - Refitting)
(80A, Battery),
a Remove:
- the engine undertray bolts, fitting) (80A, Battery),
a It is essential to shift the selector lever to the Park gearbox, Speed sensor: Removal - Refitting,
position. page 23A-73) .

Note:
a Refit:
The gearbox is filled via the output speed sensor,
which is located near to the automatic gearbox - the output speed sensor (see 23A, Automatic
wiring connector. gearbox, Speed sensor: Removal - Refitting,
page 23A-73) ,
a Remove:
- the battery (see Battery : Removal - Refitting) fitting) (80A, Battery),
(80A, Battery),
- the battery tray (see Battery tray: Removal - Re- (80A, Battery).
a Let the automatic gearbox cool to 30˚C.
gearbox, Speed sensor: Removal - Refitting, a Run the engine at idle speed.
page 23A-73) .
a Wait for the automatic gearbox oil temperature to
reach 40˚C ± 2.
a Refit:
gearbox, Speed sensor: Removal - Refitting, a Remove the level plug, leaving the engine running.
page 23A-73) ,
a Repeat these operations until there is more than 0.1
- the battery tray (see Battery tray: Removal - Re- L of oil in the container.
a Refit the level-setting plug.
(80A, Battery). a Torque tighten the level-setting plug (8 N.m).
a Run the engine at idle speed. a Refit the engine undertray.
23A-21
AUTOMATIC GEARBOX
Gearbox oil sump: Removal - Refitting 23A
FK0
CONCERNED
Tightening torquesm
oil sump bolts 8 N.m
IMPORTANT
REMOVAL

IMPORTANT
To prevent the vehicle from falling, lash it to the 130041
a Remove:
a Remove the engine undertray. - the sump bolts (1) ,
a Drain the automatic gearbox (see 23A, Automatic
- the sump (2) ,
gearbox, Automatic gearbox oil: Draining - Refil-
ling, page 23A-17) . - the sump seal,
- the sump magnets.
REFITTING
a Always replace:
- the sump bolts,
- the sump seal.
a Clean the magnets.

CONCERNED
a Refit:
- the sump magnets,
- the new seal on the sump,

- the sump,
- the sump bolts,
a Torque tighten the oil sump bolts (8 N.m).
23A-22
AUTOMATIC GEARBOX
Gearbox oil sump: Removal - Refitting 23A
FK0
a Top up the automatic gearbox (see 23A, Automatic
ling, page 23A-17) .
23A-23
AUTOMATIC GEARBOX
Hydraulic distributor: Removal - Refitting 23A
FK0
CONCERNED
Tightening torquesm
hydra u l i c d i s t ributor 8 Nm
bolts
control lever nut 22 N.m
mounting bracket bolts 8 N.m

on the control valve unit
bolts of the oil strainer 8 N.m
IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera- 138871
repair (see 23A, Automatic gearbox, Automatic a Remove:
gearbox: Precautions for repair, page 23A-1) . - the bolts (1) from the oil strainer,
- the oil strainer (2) ,
REMOVAL - the oil strainer O-ring.

a Remove:
- the front left-hand wheel arch liner (see Front
terior protection).
a Drain the automatic gearbox oil (see 23A, Automa-
tic gearbox, Automatic gearbox oil: Draining - 138872
Refilling, page 23A-17) . a Remove:
a Remove the gearbox oil sump (see 23A, Automatic - the mounting bracket bolts (3) from the control val-
gearbox, Gearbox oil sump: Removal - Refitting, ve unit,
page 23A-22) .
- the mounting bracket (4) from the control valve
unit,
- the control lever nut (5) ,
- the control lever (6) .
a Disconnect the connectors (7) .
23A-24
AUTOMATIC GEARBOX
FK0
138873
a Fit a round rod (8) with a 3 mm diameter (minimum
length 55 mm) in the stop hole of the control valve
unit linkage to immobilise the pulley ratio linkage (9)
.
138875
a Remove:
- the seal (13) between the housing and the hydrau-

lic distributor,
- the round rod with a 3 mm diameter (minimum

length 55 mm) from the stop hole of the control val-
ve unit linkage.
138874
a Remove:
- the hydraulic distributor bolts (10) ,
- the hydraulic distributor (11) ,
- the selector shaft ring,
- the slide valve (12) .
138876
a Remove:
- the control valve unit linkage by lifting it upwards,
- the return spring (14) in the valve unit.
23A-25
AUTOMATIC GEARBOX
FK0
REFITTING a Torque tighten the mounting bracket bolts on the

control valve unit (8 N.m).
I - REFITTING PREPARATION OPERATION a Refit:
a Clean the joint faces using SURFACE CLEANER - the new oil strainer O-ring,
(see Vehicle: Parts and ingredients for the repai- - the oil strainer,
rwork) (04B, Consumables - Products) on the auto-
matic gearbox and on the hydraulic distributor - the bolts of the oil strainer.
housing, taking care not to damage the contact sur- a Torque tighten the bolts of the oil strainer (8 N.m).
faces.
a Remove the round rod with a 3 mm diameter (mini-
a Always replace: mum length 55 mm) from the stop hole of the control
- the hydraulic distributor housing seal. valve unit linkage.
- the hydraulic distributor O-ring,

- the wiring O-ring.
a Refit:
- the gearbox oil sump (see 23A, Automatic gear-
box, Gearbox oil sump: Removal - Refitting,
CONCERNED
page 23A-22) ,
a Refit the hydraulic distributor internal wiring (see - the front left-hand wheel arch liner (see Front
23A, Automatic gearbox, Hydraulic distributor
internal wiring: Removal - Refitting, page 23A-39) terior protection),
a Refit: - the front left-hand wheel (see Wheel: Removal -
- the return spring in the valve unit, Refitting) (35A, Wheels and tyres),
- the control valve unit linkage. - the engine undertray.
a Fit a round rod with a 3 mm diameter (minimum

length 55 mm) in the stop hole of the control valve
unit linkage to immobilise the pulley ratio linkage.
a Refit:
- the seal between the housing and the hydraulic dis-
tributor,
- the slide valve,
- the hydraulic distributor,
- the hydraulic distributor bolts.
a Torque tighten the hydraulic distributor bolts (8
Nm).
a Connect the connectors.
a Refit:
- the selector shaft ring,
- the control lever,
- the control lever nut.
a Torque tighten the control lever nut (22 N.m).
a Refit:
- the mounting bracket on the control valve unit,
- the mounting bracket bolts on the control valve
unit.
23A-26
AUTOMATIC GEARBOX
M9R, and AJ0

clips.
Tightening torquesm
hydra u l i c d i s t ributor 8 N.m

bolts

panel bolts
REMOVAL

Towing and lifting) (02A, Lifting equipment). 138656
a Remove:
a Remove:
- the bonnet supports (1) ,
- the engine cover,
- the battery (see Battery : Removal - Refitting) ting) (82B, Horn),
(80A, Battery), - the front impact cross member (see Front impact
- the battery tray (see Battery tray: Removal - Re- cross member: Removal - Refitting) (41A, Front
fitting) (80A, Battery), lower structure),
(35A, Wheels and tyres), - the bonnet catch (see Bonnet latch: Removal -
- the front section of the front wheel arch liners (see nisms),
(55A, Exterior protection), - the intercooler air outlet pipe (see Intercooler air
- the engine undertray bolts, charging).


- the intercooler air inlet pipe (see Intercooler air in-

let pipe: Removal - Refitting) (12B, Turbochar-
ging).
a Drain:
- the cooling system (see Cooling circuit: Draining

- Refilling) (19A, Cooling).
- the automatic gearbox (see 23A, Automatic gear-

page 23A-17) .
23A-27
AUTOMATIC GEARBOX
M9R, and AJ0
138486 140185
a Unclip the bonnet catch cable (2) on the front end a Unclip the connector (4) from the front end panel.
panel.
a Move aside the bonnet catch wiring.
140184
a Unclip the degassing hose (5) from the front end pa-
nel.
138369
a Remove the bolts (3) from the engine wiring harness
channel.
23A-28
AUTOMATIC GEARBOX
M9R, and AJ0
138488 138492
a Remove the rigid cooling hose bolts (6) from the a Remove the lower bolts (8) from the front end panel.
front end panel.
a Move aside the front end panel.
138484
141563
a Remove the upper bolts (7) from the front end panel.
a Remove the gearbox oil coolant pipe hose clips (9)
a Disconnect the hoses from the gearbox oil coolant
pipes.
23A-29
AUTOMATIC GEARBOX
M9R, and AJ0
141562 117250
a Remove the cooling radiator bottom hose clip (10) a Place a container under the automatic gearbox to
using the tool (Mot. 1448). collect the oil.
a Disconnect the bottom hose from the cooling radia- a Remove:

tor. - the bolts from the hydraulic distributor panel,
- the hydraulic distributor panel,
- the seal on the hydraulic distributor panel.
140273
a Remove the clip (11) from the thermoplunger unit

hose using the (Mot. 1448).
a Disconnect the hose (12) from the thermoplunger
unit.
a Unclip all of the cooling hoses.
a Move aside all of the cooling hoses to facilitate ac-
cess to the hydraulic distributor panel.
23A-30
AUTOMATIC GEARBOX
M9R, and AJ0
II - OPERATION FOR REMOVAL OF PART REFITTING
CONCERNED

mables - Products) to clean the hydraulic distributor
panel joint faces:
- on the automatic gearbox,
- on the hydraulic distributor panel.
a Always replace:
- the hydraulic distributor O-rings,
- the hydraulic distributor panel casing seal.

CONCERNED
a Refit the new hydraulic distributor O-rings.
117254
a Loosen the hydraulic distributor bolts (A) and (B) .
a Disconnect the connector (C) between the hydraulic

distributor internal wiring and the hydraulic distribu-
tor wiring.
a Remove:
- the hydraulic distributor bolts (A) and (B) ,
- the hydraulic distributor.
117254
a Tilt the hydraulic distributor slightly when refitting it in
order to engage it with the automatic gearbox lever
(14) .
a Connect the internal wiring connector.
a Torque tighten the hydraulic distributor bolts (8
N.m).

a Refit:
- a new seal on the hydraulic distributor panel hou-
117253 sing,
a Remove the hydraulic distributor O-rings (13) . - the hydraulic distributor panel.
23A-31
AUTOMATIC GEARBOX
M9R, and AJ0
a Torque tighten the hydraulic distributor panel - the engine undertray,
bolts (8 N.m).
a Clip on all of the thermoplunger unit hoses. Front wheel arch liner: Removal - Refitting)
a Connect the hose to the thermoplunger unit.
a Refit the hose clip on the thermoplunger unit using
the (Mot. 1448).
a Connect the cooling radiator bottom hose. fitting) (80A, Battery),
a Refit the cooling radiator bottom hose clip using the - the battery (see Battery : Removal - Refitting)
(Mot. 1448). (80A, Battery).
a Connect the gearbox oil coolant pipe hoses. a Perform the following operations:
a Refit the gearbox oil coolant pipe hose clips using - fill up and bleed the cooling system (see Cooling
the (Mot. 1448). circuit: Draining - Refilling) (19A, Cooling),
a Fit the front end panel. - fill up the automatic gearbox (see 23A, Automatic
gearbox, Automatic gearbox oil: Draining - Re-
a Refit:
filling, page 23A-17) .
- the lower bolts from the front end panel,
- the front end panel upper bolts,
- the rigid cooling hose bolts on the front end panel.
a Clip:
- the degassing hose on the front end panel,
- the connector on the front end panel.
a Refit the bolts of the engine wiring channel.
a Fit the bonnet catch cable.
a Clip the bonnet catch cable on the front end panel.
a Refit:
outlet pipe: Removal - Refitting) ,
nisms),
lower structure),
ting) (82B, Horn),
- the bonnet supports,
ging),
23A-32
AUTOMATIC GEARBOX
Hydraulic distribution wiring: Removal - Refitting 23A
M9R, and AJ0

clips.
Tightening torquesm

panel bolts
REMOVAL

a Remove: 138656
a Remove:
- the engine cover,
- the bonnet supports (1) ,
(80A, Battery), - the audible warning (see Horn: Removal - Refit-
ting) (82B, Horn),
- the battery tray (see Battery tray: Removal - Re- - the front impact cross member (see Front impact
lower structure),
(35A, Wheels and tyres), - the air deflectors,
- the front section of the front wheel arch liners (see - the bonnet catch (see Bonnet latch: Removal -
Front wheel arch liner: Removal - Refitting) Refitting) (52A, Non-side opening element mecha-
(55A, Exterior protection), nisms),
- the engine undertray bolts, outlet pipe: Removal - Refitting) (12B, Turbo-
charging).



ging).
a Drain:


page 23A-17) .
23A-33
AUTOMATIC GEARBOX
M9R, and AJ0
138486 140185
panel.
140184
nel.
138369
channel.
23A-34
AUTOMATIC GEARBOX
M9R, and AJ0
138488 138492
front end panel.
138484
141563
pipes.
23A-35
AUTOMATIC GEARBOX
M9R, and AJ0
141562 117250
using the (Mot. 1448). collect the oil.
tor.
- the bolts from the hydraulic distributor panel,
140273

a Disconnect the hose (12) from the thermoplunger 140181
unit.
a Unclip the ball joint (13) of the cable on the multi-
a Unclip all of the cooling hoses. function switch using an open-jawed spanner.
a Move aside all of the cooling hoses to facilitate ac- a Unlock and detach the cable sleeve stop (14) from
cess to the hydraulic distributor panel. its mounting.
23A-36
AUTOMATIC GEARBOX
M9R, and AJ0
II - OPERATION FOR REMOVAL OF PART a Remove:
CONCERNED
- the retaining bracket bolts from the hydraulic distri-
butor wiring,
- the hydraulic distributor wiring.
REFITTING

panel joint faces:
a Always replace the hydraulic distributor panel seal.

CONCERNED
118831 a Fit the hydraulic distributor wiring.
a Disconnect the connector (15) between the hydrau- a Refit the retaining bracket bolts on the hydraulic dis-
lic distributor internal wiring and the hydraulic distri- tributor wiring.
butor wiring. a Clip the hydraulic distributor wiring supply connec-
tor.
a Connect the hydraulic distributor wiring connectors.
a Refit the wiring routing retaining bolt.
a Connect the connector between the hydraulic distri-
butor internal wiring and the hydraulic distributor wi-
ring.

a Refit and lock the cable sleeve stop in its mounting.
a Clip the cable ball joint onto the multifunction switch.
a Refit:
- a new hydraulic distributor panel seal.
- the hydraulic distributor panel.
a Torque tighten the hydraulic distributor panel
bolts (8 N.m).
a Clip on all of the cooling hoses.
118388
a Remove the cable routing retaining bolt (16) .
a Disconnect the connectors (17) and (18) from the the (Mot. 1448).
hydraulic distributor wiring.
a Connect the cooling radiator bottom hose.
a Unclip the supply connector (18) from the hydraulic a Refit the cooling radiator bottom hose clip using the
distributor wiring. (Mot. 1448).
23A-37
AUTOMATIC GEARBOX
M9R, and AJ0
a Connect the gearbox oil coolant pipe hoses. a Perform the following operations:
a Refit the gearbox oil coolant pipe hose clips using - fill up and bleed the cooling system (see Cooling
the (Mot. 1448). circuit: Draining - Refilling) (19A, Cooling),
a Fit the front end panel. - fill up the automatic gearbox (see 23A, Automatic
a Refit: filling, page 23A-17) .
- the rigid cooling hose bolts on the front end panel.
a Clip:
- the connector on the front end panel.
a Clip the bonnet catch cable on the front end panel.
a Refit:
outlet pipe: Removal - Refitting) ,
nisms),
lower structure),
ting) (82B, Horn),
ging),
(80A, Battery).
23A-38
AUTOMATIC GEARBOX
Hydraulic distributor internal wiring: Removal - Refitting 23A
FK0
REMOVAL
a Disconnect the gearbox connector.
a Remove:
- the gearbox oil sump (see 23A, Automatic gear-

box, Gearbox oil sump: Removal - Refitting,
page 23A-22) ,
- the hydraulic distributor (see 2 3 A , Automatic

gearbox, Hydraulic distributor: Removal - Refit-
138869
II - OPERATION FOR REMOVAL OF PART a Always replace the wiring O-ring (3) .
CONCERNED

CONCERNED
138868
a Remove:
- the wiring clip (1) on the sump, 138870
- the wiring (2) . a Refit:
- the wiring by placing the bornier locking lug (4) in

REFITTING the position (5) indicated in the illustration,
- the clip,
- the hydraulic distributor (see 2 3 A , Automatic
a Clean the joint faces using SURFACE CLEANER gearbox, Hydraulic distributor: Removal - Refit-
(see Vehicle: Parts and ingredients for the repai- ting, page 23A-24) ,
rwork) (04B, Consumables - Products) on the auto-
matic gearbox and on the hydraulic distributor - the gearbox oil sump (see 23A, Automatic gear-
housing, taking care not to damage the contact sur- box, Gearbox oil sump: Removal - Refitting,
faces. page 23A-22) .
23A-39
AUTOMATIC GEARBOX
M9R, and AJ0

J95
clips.
Tightening torquesm

panel bolts
REMOVAL

a Remove:
- the engine cover,

138656
a Remove the bonnet supports (1) .
- the engine undertray bolts, a Remove:
ting) (82B, Horn),
- the front bumper (see Front bumper: Removal - - the front impact cross member (see Front impact
Refitting) (55A, Exterior protection), cross member: Removal - Refitting) (41A, Front
- the headlights (see Front headlight: Removal - lower structure),
Refitting) (80B, Headlights), - the air deflectors,
B95 or D95 Refitting) (52A, Non-side opening element mecha-
nisms),
per support: Removal - Refitting) (42A, Front up- - the intercooler air outlet pipe (see Intercooler air
per structure). outlet pipe: Removal - Refitting) (12B, Turbo-
charging).
a Remove the intercooler air inlet pipe (see Intercoo-

ler air inlet pipe: Removal - Refitting) (12B, Turbo-
charging).
a Drain:

- Refilling) (19A, Cooling)
page 23A-17) .
23A-40
AUTOMATIC GEARBOX
M9R, and AJ0
J95
138486
a Unclip the bonnet catch cable (2) on the front end
panel. 140185
a Move aside the bonnet catch wiring. a Unclip the remaining connector (4) from the front
end panel.
138369
channel.
23A-41
AUTOMATIC GEARBOX
M9R, and AJ0
B95 or D95 B95 or D95
141397 141399
a Unclip the remaining connector (5) from the front a Unclip the hose from the front end panel (7) .
end panel.
140184
nel.
138488
a Remove the rigid cooling hose bolts (8) from the
front end panel.
23A-42
AUTOMATIC GEARBOX
M9R, and AJ0
- the front end panel upper bolts (11) .
J95
138484
138492
a Remove the lower bolts (12) from the front end pa-
nel.
B95 or D95
141563

135719
a Remove:
- the front end panel clips (10) , pipes.
23A-43
AUTOMATIC GEARBOX
M9R, and AJ0
141562 117250

tor. - the bolts from the hydraulic distributor panel,
140273

unit.
a Move aside all of the cooling hoses to facilitate ac-
cess to the hydraulic distributor panel.
23A-44
AUTOMATIC GEARBOX
M9R, and AJ0
CONCERNED
118831
a Disconnect the solenoid valve connections (20) .

118831
a Lift the internal wiring retaining clips (17) . a Remove:
a Disconnect: - the retaining bolts (21) from the earths,
- the connector (18) between the hydraulic distribu- - the temperature sensor retaining plate bolts (22) ,
tor internal wiring and the hydraulic distributor wi-
ring, - the temperature sensor retaining plate.
- the pressure sensor connections (19) . a Disconnect the temperature sensor from the hydrau-
lic distributor.
a Remove:
- the bolts (23) from the retaining plate of the hydrau-

lic distributor internal wiring,
- the hydraulic distributor internal wiring.
a Unclip the internal wiring retaining plate on the con-

nector between the hydraulic distributor internal wi-
ring and the hydraulic distributor wiring.
REFITTING

panel joint faces:
a Always replace the hydraulic distributor panel seal.
23A-45
AUTOMATIC GEARBOX
M9R, and AJ0
a Clip the internal wiring retaining plate on the connec- - the front end panel upper bolts.
tor between the hydraulic distributor internal wiring
and the hydraulic distributor wiring.
B95 or D95
II - REFITTING OPERATION FOR PART a Refit the front end panel clips.
CONCERNED
a Fit the hydraulic distributor internal wiring.
a Refit the bolts on the hydraulic distributor internal wi-
ring retaining plate. a Refit the rigid cooling hose bolts on the front end pa-
nel.
a Connect the temperature sensor on the hydraulic
distributor.
a Refit: B95 or D95
- the temperature sensor retaining plate, a Clip the hose on the front end panel.
- the temperature sensor retaining plate bolt fitted
with an earth terminal,
- the earth retaining bolts.
a Clip:
a Connect:
- the solenoid valve connections,
- the remaining connector on the front end panel.
- the pressure sensor connections,
- the connector between the hydraulic distributor in- a Refit the bolts of the engine wiring channel.
ternal wiring and the hydraulic distributor wiring.
a Pull down the retaining clips on the hydraulic distri-
butor internal wiring. a Clip the bonnet catch cable on the front end panel.
a Refit:
a Refit: outlet pipe: Removal - Refitting) ,
- a new hydraulic distributor panel seal.
- the hydraulic distributor panel, Refitting) (52A, Non-side opening element mecha-
nisms),
a Torque tighten the hydraulic distributor panel
bolts (8 N.m). - the air deflectors,
a Connect the hose to the thermoplunger unit. cross member: Removal - Refitting) (41A, Front
lower structure),
the (Mot. 1448). - the audible warning (see Horn: Removal - Refit-
a Connect the cooling radiator bottom hose. ting) (82B, Horn).
a Refit the cooling radiator bottom hose clip using the

(Mot. 1448). J95
a Connect the gearbox oil coolant pipe hoses. a Refit the bonnet supports.
a Refit the gearbox oil coolant pipe hose clips using
the (Mot. 1448).
a Fit the front end panel.
a Refit the intercooler air inlet pipe (see Intercooler
a Refit:
air inlet pipe: Removal - Refitting) (12B, Turbo-
- the lower bolts from the front end panel, charging).
23A-46
AUTOMATIC GEARBOX
M9R, and AJ0
B95 or D95
a Refit the front bumper supports (see Front bumper
structure).
a Refit:
circuit: Draining - Refilling) (19A, Cooling)
- fill up the automatic gearbox (see 23A, Automatic
filling, page 23A-17) .
23A-47
AUTOMATIC GEARBOX
Gearbox oil cooler: Removal - Refitting 23A
FK0
Ms. 583 Hose clamp pliers.

clips.
Tightening torquesm
automatic gearbox oil 4.2 N.m

cooler bolts
IMPORTANT
repair (see Engine cooling: Precautions for
repair) .
138877
a Disconnect the main connector (1) from the automa-

REMOVAL tic gearbox.
I - REMOVAL PREPARATION OPERATION II - OPERATION FOR REMOVAL OF PART

a Position the vehicle on a two-post lift (see Vehicle: CONCERNED
a Remove:
terior protection),
(80A, Battery),
138878
a Position the (Ms. 583) on the coolant hoses (2) of

the automatic gearbox oil cooler.
a Using the (Mot. 1448), separate the clips (3) on the

coolant hoses of the automatic gearbox oil cooler.
a Disconnect the coolant hoses from the automatic

gearbox oil cooler.
23A-48
AUTOMATIC GEARBOX
FK0
a Refit the clips on the oil hoses of the automatic gear-
box oil cooler.
a Tighten the clip bolts on the oil hoses of the automa-
tic gearbox oil cooler.
a Refit:
- the new seal on the automatic gearbox oil cooler,
- the oil cooler with its pipes,
- the automatic gearbox oil cooler bolts.
a Torque tighten the automatic gearbox oil cooler
bolts (4.2 N.m).

a Connect the coolant hoses to the automatic gearbox
oil cooler.
a Using the (Mot. 1448), refit the clips on the coolant
hoses of the automatic gearbox oil cooler.
138879 a Remove the tools (Ms. 583) on the coolant hoses of
a Remove: the gearbox oil cooler.
a Connect the automatic gearbox main connector.
- the automatic gearbox oil cooler bolts (4) ,
a Clip the automatic gearbox main connector onto its
- the oil cooler with its pipes,
support.
- the automatic gearbox oil cooler seal.
a Refit:
a Undo the clips (5) on the oil hoses of the gearbox oil
cooler.
a Disconnect the gearbox oil cooler hoses.
a Fit two blanking plugs on the oil hoses of the gear- (80A, Battery),
box oil cooler. - the front left-hand wheel arch liner (see Front
REFITTING terior protection),
I - REFITTING PREPARATION OPERATION Refitting) (35A, Wheels and tyres),
a Clean the joint faces using SURFACE CLEANER - the engine undertray.
(see Vehicle: Parts and ingredients for the repai-
rwork) (04B, Consumables - Products).
a Lubricate the seal with automatic gearbox oil (CVT).
a Always replace:
- the automatic gearbox oil cooler seal,
- the automatic gearbox oil filter.

CONCERNED
a Remove the blanking plugs on the oil hoses of the
gearbox oil cooler.
a Connect the oil hoses to the automatic gearbox oil
cooler.
23A-49
AUTOMATIC GEARBOX
M9R, and AJ0

clips.
Tightening torquesm
gearbox oil cooler bolts 4 N.m
REMOVAL

a Remove:
123935
- the engine undertray bolts, a Remove the gearbox oil coolant pipe hose clips (2)
- the engine undertray, using the (Mot. 1448).
- the front section of the front left-hand wheel arch a Disconnect the gearbox oil coolant pipe hoses on
liner (see Front wheel arch liner: Removal - Re- the gearbox oil cooler.
fitting) (55A, Exterior protection).
123936
141560
a Remove:
a Fit the tools (Ms. 583) (1) on the gearbox oil coolant
pipe hoses. - the gearbox oil cooler bolts (3) ,
a Drain the automatic gearbox (see 23A, Automatic - the gearbox oil cooler,
ling, page 23A-17) . - the gearbox oil cooler O-ring.
23A-50
AUTOMATIC GEARBOX
M9R, and AJ0
REFITTING
a Clean the joint faces of the gearbox oil cooler using

SURFACE CLEANER (see Vehicle: Parts and in-
gredients for the repairwork) (04B, Consumables
- Products):
- on the gearbox oil cooler.
a parts always to be replaced: gearbox oil cooler

seal (12,09,01,04)

CONCERNED
a Refit:
- a new O-ring on the gearbox oil cooler,
- the gearbox oil cooler.
a Torque tighten the gearbox oil cooler bolts (4

N.m).
a Connect the gearbox oil coolant pipe hoses on the

gearbox oil cooler.

the (Mot. 1448).
a Remove the tools (Ms. 583) from the gearbox oil

coolant pipe hoses.
- bleed the cooling system (see Cooling circuit:

Draining - Refilling) (19A, Cooling),
- top up the automatic gearbox oil (see 23A, Auto-

matic gearbox, Automatic gearbox oil: Draining
- Refilling, page 23A-17) .
a Refit:
- the front section of the front left-hand wheel arch

liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection),

23A-51
AUTOMATIC GEARBOX
Additional gearbox oil cooler: Removal - Refitting 23A
FK0
II - REMOVAL OPERATION FOR THE ADDITIONAL
COOLER
Tightening torquesm
oil hose clips 2 N.m
IMPORTANT
repair) .
REMOVAL

a Remove:
- the engine undertray, 141305
a Loosen the 2 hose clips (1) on the automatic gear-
box additional oil cooler end.
a Prepare for the outflow of automatic gearbox oil.
wheel arch liner: Removal - Refitting) (55A, Ex- a Disconnect the two hoses on the automatic gearbox
terior protection), additional oil cooler end.
- the battery (see Battery : Removal - Refitting) a Fit a blanking plug on either end of the automatic
(80A, Battery), gearbox additional oil cooler.
- the battery tray (see Battery tray: Removal - Re- a Wipe the excess oil off the ends of the automatic
fitting) (80A, Battery) gearbox additional oil cooler.
23A-52
AUTOMATIC GEARBOX
FK0
III - REMOVAL OPERATION FOR THE ADDITIONAL
COOLER HOSES
141304
a Unclip (2) the automatic gearbox additional oil coo-
ler. 141309
a Loosen the 2 hose clips (4) on the automatic gear-
a Remove (3) the automatic gearbox additional oil
box oil cooler end.
cooler.
a Prepare for the outflow of automatic gearbox oil.
a Disconnect the two hoses on the automatic gearbox
oil cooler end.
a Fit a blanking plug on either end of the automatic
gearbox oil cooler, and on the automatic gearbox oil
hoses.
a Remove the two automatic gearbox oil hoses.
a Wipe the excess oil off the ends of the automatic
gearbox oil cooler.
23A-53
AUTOMATIC GEARBOX
FK0
REFITTING II - REFITTING OPERATION FOR THE ADDITIONAL

COOLER HOSES
a
WARNING
Failure to observe the following procedure could
cause irreparable damage to the automatic gear-
box.
Note:
Oil hoses must be fitted in a given direction. Con-
sequently, the hoses are marked with their cor-
rect fitting direction.
141310
141311
a Check the presence and condition of the two double

retaining clips on the two automatic gearbox oil ho-
ses.
a Always replace:
- the tightening clips on the two automatic gearbox

oil hoses.
23A-54
AUTOMATIC GEARBOX
FK0
141308 141307
a Fit the hoses up to the marks (7) on the two oil cooler
pipes on the automatic gearbox end and align them
(7) .
141296
a Identify the oil hose fitting direction:
- The full rectangles (5) drawn on the hoses are fitted

on the oil cooler end.
- The empty rectangles (6) drawn on the hoses are

fitted on the additional oil cooler end.
a Fit new clips on both hoses, taking into account the

final fitting direction of the clips (4) .
a Remove the blanking plugs from the gearbox oil

cooler.
23A-55
AUTOMATIC GEARBOX
FK0
141302 141298
a Clip the two hoses in the double retaining clip in line

with the marks (9) on the hoses.
III - REFITTING OPERATION FOR THE ADDITIONAL

COOLER
141303
a Position the clips in relation to the mark (8) on the
cooler oil hoses on the automatic gearbox end.
141304
a Refit (10) the gearbox additional oil cooler.
a Fit new clips on both hoses, taking into account the

final fitting direction of the clips.
a Remove the blanking plugs from the gearbox addi-

tional oil cooler.
23A-56
AUTOMATIC GEARBOX
FK0
141306 141300
a Fit the hoses up to the marks (11) on the two auto-
matic gearbox additional oil cooler pipes and align
them (12) .
141301
a Position the clips in relation to the mark (13) on the
automatic gearbox additional oil cooler hoses.
23A-57
AUTOMATIC GEARBOX
FK0
IV - FINAL OPERATION
a Refit:
terior protection),
fitting) (80A, Battery)
(80A, Battery),
a Top up the automatic gearbox oil (see 23A, Auto-
matic gearbox, Automatic gearbox oil: Draining -
Refilling, page 23A-17) .
141299
a Remove the vehicle from the two-post lift (see Vehi-
a Clip the two hoses on the additional cooler end in the cle: Towing and lifting) (02A, Lifting equipment).
double retaining clip in line with the marks (14) on
the hoses.
141312
a Check the cleanliness of the hoses after fitting the
hose and automatic gearbox additional oil cooler as-
sembly.
a Torque tighten the oil hose clips (2 N.m) on the
gearbox oil cooler (15) and on the gearbox additio-
nal oil cooler (16) .
23A-58
AUTOMATIC GEARBOX
Gearbox oil coolant pipe: Removal - Refitting 23A
FK0
clips.
IMPORTANT
repair) .
REMOVAL

a Remove:
- the engine undertray, 138878

gearbox oil coolant pipes (2) from the gearbox oil
cooler (3) .
wheel arch liner: Removal - Refitting) (55A, Ex- a Remove the gearbox oil coolant pipes from the gear-
terior protection). box oil cooler.
a Drain the cooling system (see Cooling circuit:

Draining - Refilling) (19A, Cooling).
138761
gearbox oil coolant pipes from the multifunction sup-
port.
a Remove the gearbox oil coolant pipes from the mul-
tifunction support.
23A-59
AUTOMATIC GEARBOX
FK0
138880

gearbox oil coolant pipes of the coolant outlet unit.
a Remove the gearbox oil coolant pipes from the coo-

lant outlet unit.
REFITTING

CONCERNED
a Connect the gearbox oil coolant pipes to the coolant

outlet unit.
a Using the (Mot. 1448), fit the clips on the gearbox oil
coolant pipes of the coolant outlet unit.
a Refit the gearbox oil coolant pipes on the multifunc-

tion support.
a Using the (Mot. 1448), fit the clips on the gearbox oil
coolant pipes of the multifunction support.
a Connect the gearbox oil coolant pipes to the gear-

box oil cooler.
a Using the (Mot. 1448), refit the clips on the gearbox

oil coolant pipes of the gearbox oil cooler.
a Refit:

terior protection),

23A-60
AUTOMATIC GEARBOX
M9R, and AJ0

clips.
Tightening torquesm

on its mounting
REMOVAL

a Remove: 141560
a Fit the tools (Ms. 583) (1) on the gearbox oil coolant
Refitting) (35A, Wheels and tyres), pipe hoses at the radiator end.
- the engine undertray bolts, a Remove the gearbox oil coolant pipe hose clips at
the radiator end (2) using the (Mot. 1448).
a Disconnect the hoses (3) from the gearbox oil coo-
- the front section of the front left-hand wheel arch lant pipes at the radiator end.
fitting) (55A, Exterior protection).
138601
a Remove the bolt (4) mounting the lower engine tie
bar on its support.
23A-61
AUTOMATIC GEARBOX
M9R, and AJ0
CONCERNED
123935
a Remove the gearbox oil coolant pipe hose clips at
141561 the cooler end (6) using the (Mot. 1448).
a Disconnect the gearbox oil coolant pipes at the coo-
ler end (7) from the gearbox oil cooler hoses.
Note:
When removing the gearbox coolant pipes, do
not bend or damage the pipes.
a Remove the gearbox oil coolant pipes by tilting the

engine backwards.
REFITTING

CONCERNED
a Fit the gearbox oil coolant pipes by tilting the engine
backwards.
123937
a Connect the gearbox oil coolant pipe hoses at the
cooler end on the gearbox oil cooler.
a Remove the bolts (5) from the gearbox oil coolant pi-
pes. a Refit the gearbox oil coolant pipe hose clips at the
cooler end using the (Mot. 1448).
a Refit the bolts on the gearbox oil coolant pipes.
a Refit the bolt mounting the lower engine tie bar on its
support.
a Torque tighten the lower engine tie-bar bolt on its
mounting (180 N.m).
23A-62
AUTOMATIC GEARBOX
M9R, and AJ0
a Connect the gearbox oil coolant pipe hoses at the
radiator end.
a Refit the gearbox oil coolant pipe hose clips at the
radiator end using the (Mot. 1448).
a Remove the tools (Ms. 583) from the gearbox oil
coolant pipe hoses.
a Bleed the cooling system (see Cooling circuit:
Draining - Refilling) (19A, Cooling).
a Refit:
- the front section of the front left-hand wheel arch
fitting) (55A, Exterior protection),
23A-63
AUTOMATIC GEARBOX
FK0
Bvi. 1856 Tool for fitting CVT converter
and differential seals
IMPORTANT
REMOVAL
I - REMOVAL PREPARATION OPERATION 129986

a Position the vehicle on a two-post lift (see Vehicle: a Remove the differential output seal (1) on the side
Towing and lifting) (02A, Lifting equipment). concerned using a screwdriver, without scratching
the contact surfaces.
IMPORTANT
To prevent the vehicle from falling, lash it to the REFITTING
CONCERNED
a Drain the automatic gearbox (see 23A, Automatic
ling, page 23A-17) .
a Remove:
- the wheel on the side concerned (see Wheel: Re-
moval - Refitting) (35A, Wheels and tyres),
- the front wheel driveshaft on the side concerned
(see 29A, Driveshafts, Front right-hand wheel
driveshaft: Removal - Refitting, page 29A-18) or
(see 29A, Driveshafts, Front left-hand wheel dri-
veshaft: Removal - Refitting, page 29A-2) .
129987
a Refit the differential output seal on the side concer-
ned using the tool (Bvi. 1856) (2) .
a Refit:
- the front wheel driveshaft on the side concerned
(see 29A, Driveshafts, Front right-hand wheel
driveshaft: Removal - Refitting, page 29A-18) or
veshaft: Removal - Refitting, page 29A-2) ,
- the front wheel on the side concerned (see Wheel:
Removal - Refitting) (35A, Wheels and tyres).
23A-64
AUTOMATIC GEARBOX
FK0
a Top up the automatic transmission oil (see 23A,
Automatic gearbox, Automatic gearbox oil: Drai-
ning - Refilling, page 23A-17) .
23A-65
AUTOMATIC GEARBOX
AJ0
REFITTING
Bvi. 1804 Kit for fitting differential and

converter seals (AJ0). I - REFITTING OPERATION FOR PART
CONCERNED
REMOVAL

a Remove:
a Drain the automatic gearbox oil (see 23A, Automa-
tic gearbox, Automatic gearbox oil: Draining -
a Remove:
val - Refitting, page 29A-18) , 118354


CONCERNED
a Remove:
- the right-hand differential output seal using a
screwdriver, without scratching the contact surfa-
ces,
- the left-hand differential output seal using a
screwdriver, without scratching the contact surfa-
ces.
118353
a Refit:
- the right-hand differential output seal using the to-

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

(1) and the spacer (2) from the kit (Bvi. 1804).
23A-66
AUTOMATIC GEARBOX
AJ0
a Refit:
a Top up the automatic transmission (see 23A, Auto-
23A-67
AUTOMATIC GEARBOX
Multifunction switch: Removal - Refitting 23A
FK0
a Remove the multifunction switch bolts (3) .
Tightening torquesm a Lift up the multifunction switch (4) .

a Move the multifunction switch aside.
multifunction switch 6 Nm
bolts a Detach the multifunction switch lever from the gear-
box control linkage.
IMPORTANT REFITTING
ration recommendations before carrying out any I - REFITTING OPERATION FOR PART
repair (see 23A, Automatic gearbox, Automatic CONCERNED
a Fit the multifunction switch lever into the automatic
gearbox control linkage.
REMOVAL a Position the multifunction switch.
a Refit:
- the multifunction switch,
a Shift the gear lever to Neutral.
- the multifunction switch bolts.
a Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery). a Adjust the multifunction switch (see 23A, Automatic
gearbox, Multifunction switch: Adjusting, page
a Remove: 23A-71) .
- the battery (see Battery : Removal - Refitting) a Torque tighten the multifunction switch bolts (6
(80A, Battery), Nm).
- the battery tray (see Battery tray: Removal - Re- a Connect the multifunction switch connector.
a Fit the wiring support.

CONCERNED
a Refit:
(80A, Battery).
a Connect the battery (see Battery : Removal - Refit-
138621
a Move aside the wiring support (1) .

a Disconnect the multifunction switch connector (2) .
23A-68
AUTOMATIC GEARBOX
AJ0
Bvi. 1805 Multifunction switch adjust-
ment lever (AJ0)
Tightening torquesm
multifunction switch 6 N.m

bolts
REMOVAL

a Shift the gear selector to the N position.
a Remove:
(80A, Battery),
fitting) (80A, Battery). 118388
a Remove:
- the hydraulic distributor wiring routing retaining bolt
- the hydraulic distributor wiring retaining bracket

bolt from the gearbox at the multifunction switch
connector,
- the hydraulic distributor wiring retaining bracket

from the gearbox at the multifunction switch con-
nector.
a Move aside the hydraulic distributor wiring.
a Disconnect the multifunction switch connector (4) .
a Remove:
- the multifunction switch bolts (5) ,
140181 - the multifunction switch.

a Unclip the ball joint (1) of the cable on the multifunc-
tion switch using an open-jawed spanner.
REFITTING
a Unlock and detach the cable sleeve stop (2) from its
mounting.
CONCERNED
a Check that the multifunction switch is in the N posi-

tion.
a Refit the multifunction switch.
23A-69
AUTOMATIC GEARBOX
AJ0
118387
a Position the (Bvi. 1805) (6) .
a Align the tool shaft with the hole provided on the
multifunction switch (7) .
a Torque tighten the multifunction switch bolts (6
N.m) (8) .
a Remove the (Bvi. 1805).
a Connect the multifunction switch connector.
a Refit:
- the hydraulic distributor wiring retaining bracket on
the gearbox at the multifunction switch connector,
- the hydraulic distributor wiring routing retaining
bolt.
a Refit and lock the cable sleeve stop in its mounting.
a Clip the cable ball joint onto the multifunction switch.
a Refit:
(80A, Battery).
23A-70
AUTOMATIC GEARBOX
Multifunction switch: Adjusting 23A
AJ0
Bvi. 1805 Multifunction switch adjust-

ment lever (AJ0)
Tightening torquesm
multifunction switch 6 Nm
bolts
Adjust the multifunction switch using the tool (Bvi.

1805) when removing and refitting the multifunction
switch or during fault finding.
118387
a With the multifunction switch loosened and in posi-
tion "N", place the tool (Bvi. 1805) (1) on the control
lever and align the shaft of the tool opposite the rele-
vant hole on the multifunction switch (2) .
Nm) (3) .
a Remove the.
23A-71
AUTOMATIC GEARBOX
Multifunction switch: Adjusting 23A
FK0
Tightening torquesm
multifunction switch 6 N.m

bolts
IMPORTANT
Adjust the multifunction switch using a 3 mm offset

wrench when removing and refitting the multifunction
switch (see 23A, Automatic gearbox, Multifunction
switch: Removal - Refitting, page 23A-68) or during
fault finding.
ADJUSTMENT
130037
a Loosen the multifunction switch bolts (1) .
a Position a 3 mm (2) Allen key on the control lever
and align the shaft of the tool opposite the relevant
hole on the multifunction switch (3) .
N.m).
a Remove the Allen key (2) .
23A-72
AUTOMATIC GEARBOX
Speed sensor: Removal - Refitting 23A
FK0
CONCERNED
Tightening torquesm
input speed sensor bolt 6 N.m 1 - Input speed sensor
output speed sensor 6 N.m

bolt
IMPORTANT
REMOVAL

129993
1 - Input speed sensor a Disconnect the input speed sensor connector (1) .
a Remove:
(80A, Battery),
- the battery tray (see Battery : Removal - Refit-
2 - Output speed sensor

129994
a Remove:
- the input speed sensor bolt (2) ,
- the input speed sensor (3) ,
- the O-ring from the input speed sensor.
23A-73
AUTOMATIC GEARBOX
FK0
2 - Output speed sensor 2 - Output speed sensor
a Refit:
- the new O-ring on the output speed sensor,
- the output speed sensor,
- the output speed sensor bolt.
a Torque tighten the output speed sensor bolt (6
N.m).
a Connect the output speed sensor connector.
1 - Input speed sensor

a Refit:
- the battery tray (see Battery : Removal - Refit-
ting) (80A, Battery),
(80A, Battery).
129995
a Disconnect the output speed sensor connector (4) . ting) (80A, Battery).
a Remove:
- the output speed sensor bolt (5) ,
- the output speed sensor (6) , a Connect the battery (see Battery : Removal - Refit-
- the O-ring from the output speed sensor.
REFITTING
a Always replace the sensor O-rings.

CONCERNED
a Refit:
- the new O-ring on the input speed sensor,
- the input speed sensor,
- the input speed sensor bolt.
a Torque tighten the input speed sensor bolt (6

N.m).
a Connect the input speed sensor connector.
23A-74
AUTOMATIC GEARBOX
AJ0
Tightening torquesm
input speed sensor bolt 6 N.m
output speed sensor 6 N.m

bolt
REMOVAL
a Remove:

(80A, Battery),

118388
II - OPERATION FOR REMOVAL OF PART a Disconnect the output speed sensor connector (3) .
CONCERNED
a Remove:
- the output speed sensor bolt (4) ,
- the output speed sensor.
REFITTING

a Always replace the speed sensor O-ring.

CONCERNED

a Refit:
- the input speed sensor,
- the input speed sensor bolt.
a Torque tighten the input speed sensor bolt (6
N.m).
118388 a Connect the input speed sensor connector.
a Disconnect the input speed sensor connector (1) .
a Remove:
a Refit:
- the input speed sensor bolt (2) , - the output speed sensor,
- the input speed sensor. - the output speed sensor bolt.
23A-75
AUTOMATIC GEARBOX
AJ0
a Torque tighten the output speed sensor bolt (6
N.m).
a Connect the output speed sensor connector.

a Refit:
(80A, Battery).
23A-76
AUTOMATIC GEARBOX
Oil pressure switch: Removal - Refitting 23A
M9R, and AJ0

clips.
Tightening torquesm
oil pressure switch 4 N.m

panel bolts
REMOVAL

138656
a Remove: a Remove:
- the engine cover, - the bonnet supports (1) ,

ting) (82B, Horn),
(80A, Battery),
- the battery tray (see Battery tray: Removal - Re- cross member: Removal - Refitting) (41A, Front
fitting) (80A, Battery), lower structure),
- the front wheels (see Wheel: Removal - Refitting) - the air deflectors,
- the front section of the front wheel arch liners (see Refitting) (52A, Non-side opening element mecha-
Front wheel arch liner: Removal - Refitting) nisms),
(55A, Exterior protection), - the intercooler air outlet pipe (see Intercooler air
charging).



ging).
a Drain:


page 23A-17) .
23A-77
AUTOMATIC GEARBOX
M9R, and AJ0
138486 140185
panel.
140184
nel.
138369
channel.
23A-78
AUTOMATIC GEARBOX
M9R, and AJ0
138488 138492
front end panel.
138484
141563
pipes.
23A-79
AUTOMATIC GEARBOX
M9R, and AJ0
141562 117250
tor.
- the bolts from the hydraulic distributor panel,

CONCERNED
140273

unit.
a Move aside all of the cooling hoses to facilitate ac- 118831
cess to the hydraulic distributor panel. a Disconnect the oil pressure switch connector (13) .
23A-80
AUTOMATIC GEARBOX
M9R, and AJ0
a Remove the oil pressure switch concerned. - the connector on the front end panel.

REFITTING
I - REFITTING PREPARATION OPERATION a Clip the bonnet catch cable on the front end panel.
a Use SURFACE CLEANER (see Vehicle: Parts a Refit:
mables - Products) to clean the hydraulic distributor - the intercooler air outlet pipe (see Intercooler air
panel joint faces: outlet pipe: Removal - Refitting) ,
- on the hydraulic distributor panel. Refitting) (52A, Non-side opening element mecha-
nisms),
a Always replace the hydraulic distributor panel hou-
sing seal. - the air deflectors,

II - REFITTING OPERATION FOR PART cross member: Removal - Refitting) (41A, Front
CONCERNED lower structure),
a Refit the oil pressure switch concerned.
a Torque tighten the oil pressure switch (4 N.m). ting) (82B, Horn),
a Connect the oil pressure switch connector.
III - FINAL OPERATION - the intercooler air inlet pipe (see Intercooler air in-
a Refit: ging),
- a new hydraulic distributor panel seal, - the headlights (see Front headlight: Removal -
- the hydraulic distributor panel. Refitting) (80B, Headlights),
a Torque tighten the hydraulic distributor panel - the front bumper (see Front bumper: Removal -
bolts (8 N.m). Refitting) (55A, Exterior protection),
a Refit the hose clip on the thermoplunger unit using Front wheel arch liner: Removal - Refitting)
the (Mot. 1448). (55A, Exterior protection),
a Connect the cooling radiator bottom hose.
a Refit the cooling radiator bottom hose clip using the (35A, Wheels and tyres),
(Mot. 1448).
a Connect the gearbox oil coolant pipe hoses. fitting) (80A, Battery),
the (Mot. 1448).
(80A, Battery).
a Fit the front end panel.
a Refit:
- fill up the automatic gearbox (see 23A, Automatic
- the rigid cooling hose bolts on the front end panel. gearbox, Automatic gearbox oil: Draining - Re-
a Clip: filling, page 23A-17) .
- the degassing hose on the front end panel, a Refit the engine cover.
23A-81
AUTOMATIC GEARBOX
Automatic gearbox converter: Removal - Refitting 23A
AJ0
a The removal-refitting method for the automatic gear-
box converter is included in the method for removing
the converter seal (see 23A, Automatic gearbox,
Converter seal: Removal - Refitting, page 23A-
88) .
23A-82
AUTOMATIC GEARBOX
FK0
REFITTING
IMPORTANT
CONCERNED
REMOVAL

a Remove:
- the engine - gearbox assembly (see Engine/gear-
box assembly: Removal - Refitting) (10A, Engi-
ne and peripherals),
box, Automatic gearbox: Removal - Refitting,
page 23A-8) .
130029
CONCERNED a Refit the automatic gearbox converter.
a Remove the gearbox converter.
130030
a Check that the converter lugs (1) are engaged in the
drive sprocket holes (2) .
23A-83
AUTOMATIC GEARBOX
FK0
130023
a Check:
- that the converter correctly is inserted using a rule
and a straightedge,
- that the distance between the mating face and the
rule is at least 14.4 mm.
a Refit:
page 23A-8) ,
ne and peripherals).
23A-84
AUTOMATIC GEARBOX
M9R, and AJ0
a Remove:
Essential equipment - the engine cover,
refrigerant charging station - the centre section of the scuttle panel grille (see
REMOVAL - the scoop under the centre section of the scuttle
I - REMOVAL PREPARATION OPERATION grille: Removal - Refitting) (56A, Exterior equip-
ment),
Towing and lifting) (02A, Lifting equipment). - the battery (see Battery : Removal - Refitting)
(80A, Battery),
IMPORTANT - the battery tray (see Battery tray: Removal - Re-

vehicle lift using a strap. - the air filter unit (see Air filter unit: Removal - Re-
ting) (82B, Horn),
lower structure),
nisms),
charging).
WARNING
Consult the device's operating manual to avoid
incorrect use.
a Drain:
- the refrigerant circuit using a refrigerant charging
station (see Coolant circuit Draining - Refilling)
(62A, Air conditioning),
23A-85
AUTOMATIC GEARBOX
M9R, and AJ0
- the engine cooling system (see Cooling circuit: II - OPERATION FOR REMOVAL OF PART
Draining - Refilling) (19A, Cooling), CONCERNED
page 23A-17) .
a Remove:
ting),
117252
- the right-hand suspended engine mounting (see a Remove the converter (1) .
REFITTING
Engine and peripherals), I - REFITTING OPERATION FOR PART
CONCERNED
(16A, Starting - Charging), a Refit the converter.
page 23A-8) .
23A-86
AUTOMATIC GEARBOX
M9R, and AJ0
II - FINAL OPERATION - the intercooler air outlet pipe (see Intercooler air
charging),

nisms),

lower structure),

ting) (82B, Horn),



11911 Front wheel arch liner: Removal - Refitting)
a Check the distance (X) using a ruler. This distance
must be 20.4 ± 0.5 mm. - the front wheels (see Wheel: Removal - Refitting)
a Refit: (35A, Wheels and tyres),
- the automatic gearbox (see 23A, Automatic gear- - the engine undertray,
page 23A-8) ,
(16A, Starting - Charging), - the battery tray (see Battery tray: Removal - Re-
gearbox assembly: Removal - Refitting) (10A, - the battery (see Battery : Removal - Refitting)
Engine and peripherals), (80A, Battery),
- the right-hand suspended engine mounting (see - the scoop under the centre section of the scuttle
Right-hand suspended engine mounting: Re- panel grille (see Scoop under scuttle panel
moval - Refitting) (19D, Engine mounting), grille: Removal - Refitting) (56A, Exterior equip-
ment),
Refitting) (12A, Fuel mixture), - the centre section of the scuttle panel grille (see
- the lower engine tie-bar (see Lower engine tie- Exterior equipment).
ting), a Fill up and bleed the cooling system (see Cooling
circuit: Draining - Refilling) (19A, Cooling).
support cross member: Removal - Refitting) a Refill:
- the refrigerant circuit (see Coolant circuit Drai-
- the front right-hand driveshaft (see 29A, Drives- ning - Refilling) (62A, Air conditioning),
val - Refitting, page 29A-18) , - the automatic gearbox oil (see 23A, Automatic
- the front left-hand driveshaft (see 29A, Drives- filling, page 23A-17) (23A, Automatic gearbox).
val - Refitting, page 29A-2) , a Refit the engine cover.
23A-87
AUTOMATIC GEARBOX
Converter seal: Removal - Refitting 23A
FK0
Bvi. 1856 Tool for fitting CVT converter
and differential seals
IMPORTANT
REMOVAL

a Remove:
130027
ne and peripherals), a Remove the converter seal (1) using a screwdriver,
taking care not to scratch the contact surfaces.
page 23A-8) , REFITTING
- the automatic gearbox converter (see 23A, Auto-
matic gearbox, Automatic gearbox converter: I - REFITTING PREPARATION OPERATION
a Always replace the converter seal with a new seal.
a Check and clean the mating face of the gearbox
converter seal.
23A-88
AUTOMATIC GEARBOX
FK0
CONCERNED
130028
a Refit the converter seal using the tool (Bvi. 1856) (2)
.

a Refit:
matic gearbox, Automatic gearbox converter:
Removal - Refitting, page 23A-82) ,
page 23A-8) ,
ne and peripherals).
23A-89
AUTOMATIC GEARBOX
AJ0
a Remove:
- the engine cover,
Bvi. 1804 Kit for fitting differential and
converter seals (AJ0). - the centre section of the scuttle panel grille (see
Essential equipment
refrigerant charging station panel grille (see Scoop under scuttle panel
ment),
REMOVAL
(80A, Battery),
a Position the vehicle on a two-post lift (see Vehicle: fitting) (80A, Battery),
IMPORTANT
vehicle lift using a strap. - the engine undertray,
ting) (82B, Horn),
lower structure),
nisms),
charging).
WARNING
Consult the device's operating manual to avoid
incorrect use.
a Drain:
- the refrigerant circuit using a refrigerant charging
station (see Coolant circuit Draining - Refilling)
(62A, Air conditioning),
23A-90
AUTOMATIC GEARBOX
AJ0
- the engine cooling system (see Cooling circuit: II - OPERATION FOR REMOVAL OF PART
Draining - Refilling) (19A, Cooling), CONCERNED
page 23A-17) .
a Remove:
ting),
117248
- the right-hand suspended engine mounting (see a Remove the converter seal (1) using a screwdriver,
Right-hand suspended engine mounting: Re- taking care not to damage the input shaft splines.
REFITTING
(16A, Starting - Charging), a parts always to be replaced: Converter seal (12,
07,02,21)
box, Automatic gearbox: Removal - Refitting, a Check and clean the converter seal mating face on
page 23A-8) , the gearbox using SURFACE CLEANER (see Ve-
hicle: Parts and ingredients for the repairwork)
(04B, Consumables - Products).
matic gearbox, Automatic gearbox converter:
23A-91
AUTOMATIC GEARBOX
AJ0
II - REFITTING OPERATION FOR PART - the intercooler air outlet pipe (see Intercooler air
CONCERNED outlet pipe: Removal - Refitting) (12B, Turbo-
charging),

nisms),

lower structure),

ting) (82B, Horn),

11954
a Refit a new seal on the converter using the (Bvi. - the front bumper (see Front bumper: Removal -
1804) from the kit (2) . Refitting) (55A, Exterior protection),

III - FINAL OPERATION Front wheel arch liner: Removal - Refitting)
a Refit:
- the automatic gearbox converter (see 23A, Auto- - the front wheels (see Wheel: Removal - Refitting)
matic gearbox, Automatic gearbox converter: (35A, Wheels and tyres),
Removal - Refitting, page 23A-82) ,
box, Automatic gearbox: Removal - Refitting, - the air filter unit (see Air filter unit: Removal - Re-
page 23A-8) , fitting) (12A, Fuel mixture),
- the starter (see Starter: Removal - Refitting) - the battery tray (see Battery tray: Removal - Re-
(16A, Starting - Charging) fitting) (80A, Battery),
- the « engine - gearbox » assembly (see Engine/ - the battery (see Battery : Removal - Refitting)
gearbox assembly: Removal - Refitting) (10A, (80A, Battery),
- the right-hand suspended engine mounting (see panel grille (see Scoop under scuttle panel
Right-hand suspended engine mounting: Re- grille: Removal - Refitting) (56A, Exterior equip-
moval - Refitting) (19D, Engine mounting), ment),
- the lower engine tie-bar (see Lower engine tie- Exterior equipment).
ting), a Fill up and bleed the cooling system (see Cooling
circuit: Draining - Refilling) (19A, Cooling).
support cross member: Removal - Refitting) a Refill:
- the refrigerant circuit (see Coolant circuit Drai-
- the front right-hand driveshaft (see 29A, Drives- ning - Refilling) (62A, Air conditioning),
val - Refitting, page 29A-18) , - the automatic gearbox oil (see 23A, Automatic
- the front left-hand driveshaft (see 29A, Drives- filling, page 23A-17) (23A, Automatic gearbox).
val - Refitting, page 29A-2) , a Refit the engine cover.
23A-92
AUTOMATIC GEARBOX
Automatic transmission computer: Removal - Refitting 23A
FK0
REFITTING
IMPORTANT
CONCERNED
repair (see 23A, Automatic gearbox, Automatic a Refit:
- the automatic transmission computer,
- the automatic transmission computer nuts.
REMOVAL a Connect the automatic transmission computer con-
nector.
a Position the vehicle on a two-post lift (see Vehicle: II - FINAL OPERATION
Towing and lifting) (02A, Lifting equipment). a Refit:
a Disconnect the battery (see Battery : Removal - - the front right-hand wheel arch liner (see Front
Refitting) (80A, Battery). wheel arch liner: Removal - Refitting) (55A, Ex-
a Remove: terior protection),
- the front right-hand wheel arch liner (see Front a Connect the battery (see Battery : Removal - Refit-
wheel arch liner: Removal - Refitting) (55A, Ex- ting) (80A, Battery).
terior protection).

CONCERNED
138620
a Disconnect the connector (1) from the automatic
transmission computer.
a Remove:
- the automatic transmission computer nuts (2) ,
- the automatic transmission computer (3) .
23A-93
AUTOMATIC GEARBOX
AJ0
II - REMOVAL OPERATION FOR THE PART
CONCERNED
Essential equipment
diagnostic tool
REMOVAL

a Remove:
- the front bumper (see Front bumper: Removal - 140183
a Disconnect the connector (1) from the automatic
- the left-hand headlight (see Front headlight: Re- transmission computer.
moval - Refitting) (80B, Headlights),
a Remove:
Refitting) (12A, Fuel mixture). - the automatic transmission computer nuts (2) ,
- the automatic transmission computer.
REFITTING

CONCERNED
a Refit the automatic transmission computer.
a Connect the automatic transmission computer con-

nector.
a Refit:
- the left-hand headlight (see Front headlight: Re-

moval - Refitting) (80B, Headlights),

23A-94
AUTOMATIC GEARBOX
AJ0
a Apply the after repair procedure using the diagnos-
tic tool :
- connect the diagnostic tool,
- select « Gearbox computer » ,
- go to repair mode,
- display the « Before/After repair procedure » for
the computer selected,
- carry out the operations described in the « After re-
pair procedure » section.
23A-95
DRIVESHAFTS
Driveshaft: Precautions for repair 29A
GENERAL RECOMMENDATIONS
1 - Advice to be followed before any operation

For an operation requiring the use of a lift, follow the
safety advice (see Vehicle: Towing and lifting) (02A,
Lifting equipment).
2 - Instructions to be followed during the operation
WARNING
In order to prevent irreversible damage to the front

hub bearing:
- Do not loosen or tighten the driveshaft nut when
the wheels are on the ground.
- Do not place the vehicle with its wheels on the
ground when the driveshaft has been loosened or
removed.
Lubricate the base of the driveshaft bearing with BR2 +

GREASE (see Vehicle: Parts and ingredients for
the repairwork) (04B, Consumables - Products) to
prevent the bearing from sticking.
Always replace the differential output seals every time
a driveshaft is removed.
Check for oil leaks from the gearbox. An oil leak can
damage a driveshaft.
29A-1
DRIVESHAFTS
Front left-hand wheel driveshaft: Removal - Refitting 29A
PK4
Essential special tooling Refitting) (35A, Wheels and tyres).
Rou. 604-01 Hub locking tool. a Drain the manual gearbox (see 21A, Manual gear-
Tav. 476 Ball joint extractor. page 21A-2) .
Tav. 1420-01 Screw jack for tools Tav.

1420, Tav.1050-04 , Tar. II - OPERATION FOR REMOVAL OF PART
1454, Tar. 1850. CONCERNED
Tav. 1050-04 Universal driveshaft push

back tool (plate and claws
without ram).
Emb. 880 Pin extractor.
Tav. 1813 Clipped driveshaft extractor

jaw
Tightening torquesm
shock absorber base 180 N.m

nuts
track rod end nut 37 N.m
hub nut 280 N.m
bolt of the brake hose 8 N.m

and wheel speed sensor
134508
wiring support
a Unclip:
- the wheel speed sensor wiring at (1) ,
WARNING - the front brake hose at (2) .

hub bearing:
removed.
REMOVAL

a Remove:
29A-2
DRIVESHAFTS
PK4
134507 134502
a Remove: a Push back the front left-hand driveshaft from the
- the bolt (3) of the brake hose and wheel speed sen- stub axle carrier using the assembled tools (Tav.
sor wiring support, 1420-01) and (Tav. 1050-04).
- the brake hose and wheel speed sensor wiring

support (4) ,
- the nut (5) from the hub, immobilising the hub using
the (Rou. 604-01),
- the nut (6) from the track rod end,
- the track rod end from the hub carrier using the tool
(Tav. 476),
- the shock absorber base bolts.
134501
a Detach the front left-hand driveshaft on the gearbox

side using the tool (Emb. 880) fitted with the tool
(Tav. 1813).
a Remove:
- the front left-hand driveshaft.
- the left-hand differential output seal (see 21A, Ma-

nual gearbox, Differential output seal: Removal
29A-3
DRIVESHAFTS
PK4
REFITTING III - FINAL OPERATION

I - REFITTING PREPARATION OPERATION box, Manual gearbox oil: Draining - Refilling,
page 21A-2) .
a parts always to be replaced: Front wheel hub nut
(13,02,03,20). a Refit:
CONCERNED - the engine undertray.
a Refit the left-hand differential output seal (see 21A,
Manual gearbox, Differential output seal: Remo-
Note:
When removing, if there is threadlock on the spli-
nes of the universal joint and the universal joint
nut, apply threadlock to the splines of the univer-
sal joint and the universal joint nut when refitting.
a Fit the front left-hand driveshaft into the gearbox as

horizontally as possible.
a Engage the driveshaft into the hub carrier.
Note:
The driveshaft must fit freely into the hub carrier
until it protrudes enough for the hub nut to be fit-
ted.
a Refit the shock absorber base bolts.

a Torque tighten the shock absorber base nuts (180
N.m).
a Position the track rod.

a Torque tighten the track rod end nut (37 N.m).
a Refit a new hub nut.
a Torque tighten the hub nut (280 N.m) while immobi-

lising the hub using the tool (Rou. 604-01).
a Refit:
support,
- the bolt of the brake hose and wheel speed sensor
wiring support.
a Torque tighten the bolt of the brake hose and

wheel speed sensor wiring support (8 N.m).
a Clip:
- the wheel speed sensor wiring,
- the brake hose.
29A-4
DRIVESHAFTS
TL4
Essential special tooling Refitting) (35A, Wheels and tyres).
Rou. 604-01 Hub locking tool. a Drain the manual gearbox (see 21A, Manual gear-
Tav. 476 Ball joint extractor. page 21A-2) .

1420, Tav.1050-04 , Tar. II - OPERATION FOR REMOVAL OF PART
1454, Tar. 1850. CONCERNED

without ram).

jaw
Tightening torquesm

bolts
hub nut 280 N.m

134508
wiring support
a Unclip:
- the wheel speed sensor wiring at (1) ,
WARNING - the front brake hose at (2) .

hub bearing:
removed.
REMOVAL

a Remove:
29A-5
DRIVESHAFTS
TL4
134507 134502
a Remove:
a Push back the front left-hand driveshaft from the
- the bolt (3) of the brake hose and wheel speed sen- stub axle carrier using the assembled tools (Tav.
sor wiring support, 1420-01) and (Tav. 1050-04).
support,
the (Rou. 604-01),
(Tav. 476),
- the shock absorber base studs (6) .
134501
a Detach the front left-hand driveshaft on the gearbox

side using the tool (Emb. 880) fitted with the tool
(Tav. 1813).
a Remove the front left-hand driveshaft.
a Remove the left-hand side differential output seal

(see 21A, Manual gearbox, Differential output
seal: Removal - Refitting, page 21A-10) .
29A-6
DRIVESHAFTS
TL4
REFITTING III - FINAL OPERATION

I - REFITTING PREPARATION OPERATION box, Manual gearbox oil: Draining - Refilling,
page 21A-2) .
(13,02,03,20). a Refit:
II - REFITTING OPERATION FOR PART Refitting) (35A, Wheels and tyres),
CONCERNED - the engine undertray.
a Refit a new left-hand differential output seal (see
21A, Manual gearbox, Differential output seal:
Note:

a Insert the front left-hand driveshaft into the hub car-
rier.
Note:
The driveshaft must fit freely into the stub-axle
carrier until it protrudes enough for the hub nut to
be fitted.
a Refit the shock absorber base bolts

a Torque tighten the shock absorber base bolts
(180 N.m).
lising the hub using tool (Rou. 604-01).
a Refit:
support,
wiring support.
a Clip:
- the brake hose.
29A-7
DRIVESHAFTS
ND4
II - REMOVAL OPERATION FOR PART
Rou. 604-01 Hub locking tool.
Tav. 476 Ball joint extractor.

1420, Tav.1050-04 , Tar.
1454, Tar. 1850.

without ram).
Tightening torquesm

nuts
hub nut 280 N.m

134508
bolt of the the brake 8 N.m
a Unclip:
hose and wheel speed
sensor wiring support - the wheel speed sensor wiring (1) ,
- the brake hose (2) .
a Remove:
WARNING
- the bolt (3) of the brake hose and wheel speed sen-
In order to prevent irreversible damage to the front sor wiring support,
hub bearing:
- Do not loosen or tighten the driveshaft nut when support,
- Do not place the vehicle with its wheels on the the (Rou. 604-01),
removed.
- the track rod end from the stub axle carrier using
the (Tav. 476),
REMOVAL
- the shock absorber base bolts (6) .

a Remove:
page 21A-2) .
29A-8
DRIVESHAFTS
ND4
a Engage the driveshaft into the stub axle carrier.
Note:
be fitted.
a Refit:
- the shock absorber base bolts,
- the shock absorber base nuts.
N.m).
134502
a Push back the front left-hand driveshaft from the a Refit the brake hose and wheel speed sensor wiring
support.
stub axle carrier using the assembled tools (Tav.
1420-01) and (Tav. 1050-04). a Tighten the bolt of the the brake hose and wheel
speed sensor wiring support (8 N.m).
a Remove:
a Clip:
- the brake hose,
nual gearbox, Differential output seal: Removal - the wheel speed sensor wiring.
REFITTING a Fill up the manual gearbox (see 21A, Manual gear-
page 21A-2) .
a Refit:
(13,02,03,20).
CONCERNED
a Refit the left-hand differential output seal (see 21A,

Note:
a Fit the driveshaft into the gearbox as horizontally as

possible.
29A-9
DRIVESHAFTS
JH3 or JR5
Essential special tooling box, Manual gearbox oil: Draining - Refilling,
page 21A-2) .
Tav. 476 Ball joint extractor. II - OPERATION FOR REMOVAL OF PART

CONCERNED
1420, Tav.1050-04 , Tar.
1454, Tar. 1850.

without ram).

jaw
Tightening torquesm

bolts
hub nut 280 N.m

134508
brake hose retaining N.m a Unclip the wiring from the wheel speed sensor at (1)
bracket bolt8 .
a Remove the bolt (2) from the brake hose retaining
bracket.
WARNING
a Move aside the brake hose retaining bracket.
hub bearing:
removed.
REMOVAL

a Remove:
29A-10
DRIVESHAFTS
JH3 or JR5
134507 134501
a Remove: a Extract the front left-hand driveshaft from the ma-
- the hub nut (3) by immobilising the hub using the nual gearbox using the tool (Emb. 880) fitted with
tool (Rou. 604-01), the tool (Tav. 1813).
- the track rod end nut (4) . a Remove:
a Detach the track rod end using the (Tav. 476).
a Remove the shocker absorber base bolts (5) .
nual gearbox, Differential output seal: Removal
REFITTING

(13,02,03,20).

CONCERNED
a Refit a left-hand differential output seal (see 21A,

134502
a Push back the front left-hand driveshaft (6) from the Note:
stub axle carrier (7) (Tav. 1420-01) and (Tav. 1050- When removing, if there is threadlock on the spli-
04). nes of the universal joint and the universal joint
a Remove the front left-hand driveshaft, on the wheel nut, apply threadlock to the splines of the univer-
side. sal joint and the universal joint nut when refitting.
29A-11
DRIVESHAFTS
JH3 or JR5
a Insert the front left-hand driveshaft into the gearbox,
moving it straight in horizontally until it clips.
Note:
Pull on the driveshaft slightly to verify that it is
properly clipped into the gearbox.
a Insert the front left-hand driveshaft into the stub axle

carrier.
Note:
be fitted.

(180 N.m).
a Fit the retaining bracket of the brake hose.
a Refit the bolt of the brake hose retaining bracket.
a Torque tighten the brake hose retaining bracket
bolt8 (N.m).
a Clip on the wheel speed sensor wiring harness.

page 21A-2) .
a Refit:
29A-12
DRIVESHAFTS
FK0
a Remove:
Tav. 476 Ball joint extractor. Refitting) (35A, Wheels and tyres).
Tav. 1420-01 Screw jack for tools Tav. a Fit a oil recovery container.
1420, Tav.1050-04 , Tar.
1454, Tar. 1850.
Tav. 1050-04 Universal driveshaft push CONCERNED
without ram).

jaw
Essential equipment
Tightening torquesm

bolts
hub nut 280 N.m
bolt of the brake hose 8 N.m 134508

and wheel speed sensor a Unclip:
wiring support
- the wheel speed sensor wiring (1) ,
a Remove:
WARNING
sor wiring support,
hub bearing: - the brake hose and wheel speed sensor wiring
- Do not loosen or tighten the driveshaft nut when support,
- Do not place the vehicle with its wheels on the the (Rou. 604-01),
removed. - the nut (5) from the track rod end,
the tool (Tav. 476),
REMOVAL
- the bolts and the nuts (6) from the shock absorber
base.
a Push back the driveshaft from the stub axle carrier
a Position the vehicle on a two-post lift (see Vehicle: using the assembled tools (Tav. 1420-01) and (Tav.
Towing and lifting) (02A, Lifting equipment). 1050-04).
29A-13
DRIVESHAFTS
FK0
Note:
The driveshaft must fit freely into the stub axle
be fitted.
a Refit:
(180 N.m).
a Refit the hub nut.
138622
a Remove the front left-hand driveshaft from the auto- a Refit the brake hose and wheel speed sensor wiring
matic gearbox using the assembled tools (Tav. support.
1813) (7) and (Emb. 880) (8) a Tighten the bolt of the brake hose and wheel
speed sensor wiring support (8 N.m).
REFITTING a Clip:
- the brake hose,
- the wheel speed sensor wiring.
a Always replace:
- the universal joint nut, III - FINAL OPERATION
- the differential output seal (see 23A, Automatic a Refit the front left-hand wheel (see Wheel: Removal
gearbox, Differential output seal: Removal - Re- - Refitting) .
fitting, page 23A-64) .
a Top up the automatic transmission (see 23A, Auto-
II - REFITTING OPERATION FOR PART Refilling, page 23A-17) . (Put back the quantity
CONCERNED equivalent to the quantity recovered).
a a Refit the engine undertray.
Note:
During removal, if there is threadlock on the spli-
sal joint and universal joint nut when refitting.

possible.
29A-14
DRIVESHAFTS
AJ0
Tightening torquesm

bolts
hub nut 280 N.m

wiring support
WARNING
In order to prevent irreversible damage to the front 134508

hub bearing: a Unclip:
- Do not loosen or tighten the driveshaft nut when - the wheel speed sensor wiring at (1) ,
- the front brake hose at (2) .
removed.
REMOVAL

a Remove:
134507
a Remove:
sor wiring support,

support,
29A-15
DRIVESHAFTS
AJ0
the (Rou. 604-01),
(Tav. 476),
141561
134502
a Push the front left-hand driveshaft back from the hub
carrier by pivoting the hub carrier.
123937
a Remove the bolts (7) from the gearbox oil coolant pi-
pes.
a Move aside the gearbox oil coolant pipes.
29A-16
DRIVESHAFTS
AJ0
(180 N.m).
a Refit:
support,
wiring support.
a Clip:
141565
- the brake hose.
a
Note: III - FINAL OPERATION

Do not apply pressure to the gearbox oil coolant a Refit:
pipes. - the engine undertray,
a Disengage the front left-hand driveshaft from the - the front left-hand wheel (see Wheel: Removal -
gearbox using a lever (8) . Refitting) (35A, Wheels and tyres).
a Remove the front left-hand driveshaft.
REFITTING

(13,02,03,20)

CONCERNED
a Fit the gearbox oil coolant pipes.
a Refit the bolts on the gearbox oil coolant pipes.
Note:
ted.
a Engage the driveshaft into the hub carrier.

29A-17
DRIVESHAFTS
Front right-hand wheel driveshaft: Removal - Refitting 29A
PK4
page 21A-2) .

CONCERNED
1420, Tav.1050-04 , Tar.
1454, Tar. 1850.

without ram).
Tightening torquesm
relay bearing bolt 21 N.m

bolts
hub nut 280 N.m
wheel speed sensor 8 N.m

wiring support bolt
134506
a Unclip:
WARNING - the wheel speed sensor wiring at (1) ,
hub bearing:
removed.
REMOVAL

a Remove:

29A-18
DRIVESHAFTS
PK4
134505 134503
a Remove: a Remove the driveshaft relay bearing bolt (7) .
sor wiring support,
support,
the (Rou. 604-01),
(Tav. 476),
134504
a Push back the front right-hand driveshaft from the
1420-01) and (Tav. 1050-04).
a Remove:
- the front right-hand driveshaft.
- the right-hand differential output seal (see Diffe-
rential output seal: Removal - Refitting) .
29A-19
DRIVESHAFTS
PK4
REFITTING a Torque tighten the shock absorber base bolts

(180 N.m).
I - REFITTING PREPARATION OPERATION a Position the track rod.
a parts always to be replaced: Front wheel hub nut a Torque tighten the track rod end nut (37 N.m).
(13,02,03,20). a Refit a new hub nut.
a parts always to be replaced: relay bearing brac- a Torque tighten the hub nut (280 N.m) while immobi-
ket bolt (13,01,01,11). lising the hub using the tool (Rou. 604-01).
a Refit:
Note: - the brake hose and wheel speed sensor wiring
support,
Always replace the relay bearing self-threading
bolt with a classic tapered-end bolt or a cylindri- - the bolt of the brake hose and wheel speed sensor
cal-pilot bolt every time the right-hand driveshaft wiring support.
is removed (except if the entire relay bearing is
replaced, in which case it is supplied with a self- a Torque tighten the wheel speed sensor wiring
threading bolt). support bolt (8 N.m).
a Clip:
a Clean and grease the driveshaft relay bearing bore
into which the bearing is inserted with BR2+ - the wheel speed sensor wiring,
GREASE (see Vehicle: Parts and ingredients for - the brake hose.
the repairwork) (04B, Consumables - Products).

CONCERNED
a Refit a new right-hand differential output seal (see page 21A-2) .
Differential output seal: Removal - Refitting) .
a Refit:
Note: Refitting) (35A, Wheels and tyres),
When removing, if there is threadlock on the spli- - the engine undertray.
a Fit the front right-hand driveshaft into the gearbox as

a Refit:
- the front right-hand driveshaft into the relay bea-
ring,
- a new relay bearing bolt.
a Torque tighten the relay bearing bolt (21 N.m).

a Insert the front right-hand driveshaft into the hub car-
rier.
Note:
ted.
29A-20
DRIVESHAFTS
TL4
page 21A-2) .

CONCERNED
1420, Tav.1050-04 , Tar.
1454, Tar. 1850.

without ram).
Tightening torquesm

bolts
hub nut 280 N.m
wheel speed sensor 8 N.m

support bolt
134506
a Unclip:
WARNING - the wheel speed sensor wiring at (1) ,
- the brake hose at (2)
hub bearing:
removed.
REMOVAL

a Remove:

29A-21
DRIVESHAFTS
TL4
134505 134503
a Remove:
a Remove the driveshaft relay bearing bolt (7) .
sor wiring support,
support,
the (Rou. 604-01),
(Tav. 476),
134504

1420-01) and (Tav. 1050-04).
a Remove:
- the front right-hand driveshaft,
- the right-hand differential output seal (see 21A,

Manual gearbox, Differential output seal: Re-
29A-22
DRIVESHAFTS
TL4
REFITTING a Torque tighten the shock absorber base bolts

(180 N.m).
I - REFITTING PREPARATION OPERATION a Position the track rod.
a parts always to be replaced: Front wheel hub nut a Torque tighten the track rod end nut (37 N.m).
(13,02,03,20). a Refit a new hub nut.
a parts always to be replaced: relay bearing brac- a Torque tighten the hub nut (280 N.m) while immobi-
ket bolt (13,01,01,11). lising the hub using tool (Rou. 604-01).
a Refit:
Note: - the brake hose and wheel speed sensor wiring
Always replace the relay bearing self-threading support,
bolt with a classic tapered-end bolt or a cylindri- - the bolt of the brake hose and wheel speed sensor
cal-pilot bolt every time the right-hand driveshaft
wiring support.
replaced, in which case it is supplied with a self- a Torque tighten the wheel speed sensor support
threading bolt). bolt (8 N.m).
a Clip:
a Clean and grease the driveshaft relay bearing bore
into which the bearing is inserted with BR2+ - the wheel speed sensor wiring,
GREASE (see Vehicle: Parts and ingredients for
- the brake hose.
the repairwork) (04B, Consumables - Products).

CONCERNED a Fill up the manual gearbox (see 21A, Manual gear-
a Refit the new right-hand differential output seal (see
page 21A-2) .
Removal - Refitting, page 21A-10) . a Refit:
Note: Refitting) (35A, Wheels and tyres),
When removing, if there is threadlock on the spli- - the engine undertray.

a Fit the front right-hand driveshaft into the gearbox as

a Refit:
ring,
rier.
Note:
ted.
29A-23
DRIVESHAFTS
ND4
page 21A-2) .

CONCERNED
1420, Tav.1050-04 , Tar.
1454, Tar. 1850.

without ram).
Tightening torquesm

nuts
hub nut 280 N.m
bolt of the wheel speed 8 N.m

sensor wiring support
134506
a Unclip:
WARNING - the wheel speed sensor wiring (1) ,
hub bearing: a Remove:
- Do not loosen or tighten the driveshaft nut when - the bolt (3) of the brake hose and wheel speed sen-
the wheels are on the ground. sor wiring support,
- Do not place the vehicle with its wheels on the - the brake hose and wheel speed sensor wiring
ground when the driveshaft has been loosened or support,
removed. - the nut (4) from the hub, immobilising the hub using
the (Rou. 604-01),
- the track rod end nut (5) ,
REMOVAL
the (Tav. 476),
- the shock absorber base bolts (6) .
a Remove:

29A-24
DRIVESHAFTS
ND4
REFITTING
a parts always to be replaced: relay bearing brac-

ket bolt (13,01,01,11).

(13,02,03,20).
Note:
Always replace the relay bearing self-tapping bolt
with a classic tapered-end bolt or a cylindrical-
pilot bolt every time the right-hand driveshaft is
removed (except if the entire relay bearing is
replaced, in which case it is supplied with a self-
tapping bolt).
134504 a Clean the bore of the driveshaft relay bearing into

which the bearing will be fitted using SURFACE
1420-01) and (Tav. 1050-04).
ducts).
a Lubricate the bore of the driveshaft relay bearing

into which the bearing is fitted using BR2+GREASE

CONCERNED
a Refit the right-hand differential output seal (see 21A,

Note:
134503
a Remove: possible.
- the bolt (7) for the driveshaft relay bearings, a Refit:
- the front right-hand driveshaft, - the driveshaft into the relay bearing,
- the right-hand differential output seal (see 21A, - a new relay bearing bolt.
moval - Refitting, page 21A-10) . a Torque tighten the relay bearing bolt (21 N.m)
29A-25
DRIVESHAFTS
ND4
Note:
be fitted.
a Refit:
N.m).
a Refit the brake hose and wheel speed sensor wiring
support.
a Torque tighten the bolt of the wheel speed sensor
wiring support (8 N.m).
a Clip:
- the brake hose,

21A-2) .
a Refit:
29A-26
DRIVESHAFTS
JH3 or JR5
page 21A-2) .

CONCERNED
1420, Tav.1050-04 , Tar.
1454, Tar. 1850.

without ram).
Tightening torquesm

bolts
hub nut 280 N.m
brake hose retaining N.m

bracket bolt8
134506
a Unclip the wiring from the wheel speed sensor at (1)
.
WARNING
a Remove the bolt (2) from the brake hose retaining
In order to prevent irreversible damage to the front bracket.
hub bearing: a Move aside the brake hose retaining bracket.
removed.
REMOVAL

a Remove:

29A-27
DRIVESHAFTS
JH3 or JR5
134505 134504
a Push back the front right-hand driveshaft (7) from
a Remove:
the stub axle carrier (8) using the assembled tools
(Tav. 1420-01) and (Tav. 1050-04).
- the hub nut (3) by immobilising the hub using the
tool (Rou. 604-01), a Remove:
- the front right-hand driveshaft from the gearbox,
- the track rod end nut (4) .
- the front right-hand driveshaft.
a Detach the track rod end using the (Tav. 476).
a Remove the shocker absorber base bolts (5) .
REFITTING

(13,02,03,20).
a parts always to be replaced: relay bearing brac-
ket bolt (13,01,01,11).
a Clean and grease the relay bearing hole on the front
right-hand driveshaft into which the bearing is inser-
ted with BR2 + GREASE (see Vehicle: Parts and
ingredients for the repairwork) (04B, Consuma-
bles - Products).
134682
a Remove the bolt (6) from the front right-hand drives-

haft relay bearing.
29A-28
DRIVESHAFTS
JH3 or JR5
II - REFITTING OPERATION FOR PART - the engine undertray.
CONCERNED
a Refit a new right-hand differential output seal (see
Note:
a Position and fit the front right-hand driveshaft into

the gearbox.
a Refit the front right-hand driveshaft in the relay bea-
ring equipped with a new bolt.
a Insert the front right-hand driveshaft into the stub
axle carrier.
Note:
be fitted.

(180 N.m).
a Fit the retaining bracket of the brake hose.
a Refit the brake hose retaining bracket.
a Torque tighten the brake hose retaining bracket
bolt8 (N.m).
a Clip on the wheel speed sensor wiring harness.

page 21A-2) .
a Refit:
29A-29
DRIVESHAFTS
FK0
a Fit a oil recovery container.
Rou. 604-01 Hub locking tool. II - OPERATION FOR REMOVAL OF PART

CONCERNED

1420, Tav.1050-04 , Tar.
1454, Tar. 1850.

without ram).
Essential equipment
Tightening torquesm

nuts
track rod end nut 37 N.m 134506

a Unclip:
hub nut 280 N.m
- the wheel speed sensor wiring (1) ,
wiring support a Remove:
sor wiring support,
WARNING support,
In order to prevent irreversible damage to the front the (Rou. 604-01),
hub bearing:
- the track rod end nut (5) ,
the wheels are on the ground. - the track rod end from the stub axle carrier using
the (Tav. 476),
ground when the driveshaft has been loosened or - the bolts and the nuts (6) of the shock absorber ba-
removed. se.

a Remove:

29A-30
DRIVESHAFTS
FK0
REFITTING
a Always replace:
- the universal joint nut,
- the relay bearing bracket bolt,
- the differential output seal (see 23A, Automatic

fitting, page 23A-64) .
Note:
Always replace the self-tapping bolt on the relay
bearing with a standard ogival ended bolt or a
cylindrical pilot point bolt whenever the right-
hand driveshaft is removed (except for a com-
plete replacement of the relay bearing as it is
134504 supplied with a self-tapping bolt).
a Push back the driveshaft from the stub-axle carrier
using the assembled tools (Tav. 1420-01) and (Tav. a Clean the bore of the driveshaft relay bearing into
1050-04). which the bearing will be fitted using SURFACE
ducts).

into which the bearing is fitted using BR2+ GREASE

CONCERNED
Note:
sal joint and universal joint nut when refitting.
134503 (see Vehicle: Parts and ingredients for the
repairwork) (04B, Consumables - Products).
a Remove:
- the driveshaft relay bearing bolt (7) , a Fit the driveshaft into the gearbox as horizontally as
- the front right-hand driveshaft. possible.
a Refit:
- the driveshaft into the relay bearing,
- the new bearing bolt.
29A-31
DRIVESHAFTS
FK0
a Insert the driveshaft in the stub-axle carrier.
Note:
be fitted.
a Refit:
N.m).
a Refit:
support,
wiring support.
a Clip:
- the brake hose,

a Refit the front right-hand wheel (see Wheel: Remo-
val - Refitting) (35A, Wheels and tyres).
a Fill up the manual gearbox (see 23A, Automatic
ling, page 23A-17) . (Put back the quantity equiva-
lent to the quantity recovered)
29A-32
DRIVESHAFTS
AJ0

1420, Tav.1050-04 , Tar.
1454, Tar. 1850.

without ram).
Tightening torquesm

bolts

134506
hub nut 280 N.m
a Unclip:
and wheel speed sensor - the wheel speed sensor wiring (1) ,
wiring support - the brake hose (2) .
WARNING

hub bearing:
removed.
REMOVAL

134505
a Remove: a Remove:
- the front right-hand wheel (see Wheel: Removal - - the bolt (3) of the brake hose and wheel speed sen-
Refitting) (35A, Wheels and tyres), sor wiring support,
- the engine undertray. support,
29A-33
DRIVESHAFTS
AJ0
- the nut (4) from the hub, immobilising the hub using REFITTING
the (Rou. 604-01),
- the track rod end nut (5) , I - REFITTING PREPARATION OPERATION
- the track rod end from the hub carrier using the tool a parts always to be replaced: Front wheel hub nut
(Tav. 476), (13,02,03,20)
- the shock absorber base studs (6) . a parts always to be replaced: relay bearing brac-
ket bolt (13,01,01,11)
Note:
Always replace the relay bearing self-threading
bolt with a classic tapered-end bolt or a cylindri-
cal-pilot bolt every time the right-hand driveshaft
replaced, in which case it is supplied with a self-
threading bolt).
a Clean the bore of the driveshaft relay bearing into

which the bearing will be fitted using SURFACE
ducts).
into which the bearing is fitted using BR2+ GREASE
134503
a Remove the driveshaft relay bearing bolt (7) . II - REFITTING OPERATION FOR PART
CONCERNED
possible.
a Refit:
ring,
rier.
Note:
ted.

134504
a Push back the driveshaft from the hub carrier using (180 N.m).
the assembled tools (Tav. 1420-01) and (Tav. 1050-
04). a Position the track rod.
a Remove the front right-hand driveshaft. a Torque tighten the track rod end nut (37 N.m).
29A-34
DRIVESHAFTS
AJ0
a Refit:
support,
wiring support.
a Clip:
- the brake hose,

a Refit:
29A-35
DRIVESHAFTS
Relay shaft bearing: Removal - Refitting 29A
JH3 or JR5
REMOVAL REFITTING
I - REMOVAL PREPARATION OPERATION I - REFITTING PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle: a parts always to be replaced: Relay shaft bearing
Towing and lifting) (02A, Lifting equipment). (13,01,01,07).
a parts always to be replaced: relay bearing rub-
a Remove:
ber ring (13,01,01,10).
- the engine undertray bolts, a Using SURFACE CLEANER (see Vehicle: Parts
mables - Products), clean and degrease the relay
a Drain the gearbox (see 21A, Manual gearbox, Ma- bearing bore.
nual gearbox oil: Draining - Refilling, page 21A-2) a Lubricate the relay shaft mating face into which the
. relay shaft bearing is inserted.
a Remove:
- the front right-hand wheel (see Wheel: Removal - CONCERNED
a Fit a new bearing on the relay shaft.
hafts, Front right-hand wheel driveshaft: Remo- a Fit the relay shaft bearing until it is fully inserted
val - Refitting, page 29A-18) , using a tube so that it rests on the relay shaft inner
bearing ring.
- the differential output seal (see 21A, Manual gear-
a Refit a new lock ring.
box, Differential output seal: Removal - Refit-
II - OPERATION FOR REMOVAL OF PART a Refit:

CONCERNED - the differential output seal (see 21A, Manual gear-
ting, page 21A-10) ,
a Fill the gearbox oil (see 21A, Manual gearbox, Ma-
.
100642
a Remove the lock ring (1) from the relay shaft bearing
(2) .
Note:
Do not scratch the contact surface of the lip seal
on the relay shaft (3) .
a Extract the relay shaft bearing (2) using a press and

an extractor.
29A-36
DRIVESHAFTS
Relay shaft bearing: Removal - Refitting 29A
ND4 or PK4 or TL4
REMOVAL REFITTING
I - REMOVAL PREPARATION OPERATION I - REFITTING PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle: a parts always to be replaced: Relay shaft bearing
Towing and lifting) (02A, Lifting equipment). (13,01,01,07).
parts always to be replaced: relay bearing rub-
a Remove:
ber ring (13,01,01,10).
- the engine undertray bolts, a Clean and degrease the bore of the relay bearing
with SURFACE CLEANER (see Vehicle: Parts
a Drain the gearbox (see 21A, Manual gearbox, Ma- mables - Products).
nual gearbox oil: Draining - Refilling, page 21A-2) a Lubricate the relay shaft mating face into which the
. bearing is inserted.
a Remove:
- the front right-hand wheel (see Wheel: Removal - CONCERNED
a Fit a new bearing on the relay shaft.
hafts, Front right-hand wheel driveshaft: Remo- a Fit the bearing to the end using a tube, so that it
val - Refitting, page 29A-18) , rests on the inner bearing race.
a Refit a new lock ring.
moval - Refitting, page 21A-10) . III - FINAL OPERATION
a Refit:
II - OPERATION FOR REMOVAL OF PART - a new right-hand differential output seal (see 21A,
CONCERNED Manual gearbox, Differential output seal: Re-
moval - Refitting, page 21A-10) ,
21A-2) .
100642
a Remove the lock ring (1) from the relay shaft bearing
(2) .
Note:
Do not scratch the contact surface of the lip seal
on the relay shaft (3) .
a Extract the relay shaft bearing (2) using a press and

an extractor.
29A-37
DRIVESHAFTS
Front driveshaft gaiter on wheel side: Removal - Refitting 29A
a Remove:
Tav. 1168 Thermoplastic driveshaft gai-
ter clip fitting tool.
Tav. 1784 Driveshaft gaiter clip tool. box, Manual gearbox oil: Draining - Refilling,
page 21A-2) .
Essential equipment a Remove:
steel inertia hammer - the wheel on the side concerned (see Wheel: Re-
roll pin punch
- the wheel driveshaft on the side concerned (see
parts washer 29A, Driveshafts, Front right-hand wheel dri-
veshaft: Removal - Refitting, page 29A-18) or
- the differential output seal on the side concerned
seal: Removal - Refitting, page 21A-10) .
109634
(1) Big securing clip

(2) Small securing clip
(3) Driveshaft gaiter
(4) Ball hub
(5) Stub axle bowl
(6) Ball race
(7) Driveshaft
(8) Balls
(9) Lock ring
IMPORTANT
tion.
REMOVAL

29A-38
DRIVESHAFTS
CONCERNED
128077
a Using a steel inertia hammer and a roll pin punch,

hit the ball hub (12) a few times to detach the stub
axle bowl (13) from the driveshaft.
93034
128411
a Remove the lock ring (14) .
REFITTING
128415
a Cut the big securing clip (10) and the small securing
clip (11) using cutting pliers or a metal saw, taking a parts always to be replaced: Front driveshaft
care not to damage the stub axle bowl and the dri- gaiter on wheel side (13,01,03,05).
veshaft. a parts always to be replaced: wheel side front dri-
veshaft seal locking ring (13,01,01,09).
a Push back the gaiter to release the stub axle bowl.
a Always replace:
a Cut off the driveshaft gaiter. - the small securing clip,
a Remove as much grease as possible. - the big securing clip.
29A-39
DRIVESHAFTS
a Using a parts washer, clean the driveshaft and the a Spread the quantity of grease around the gaiter and
stub axle bowl. the stub axle bowl.

CONCERNED
109768
a Refit the stub axle bowl (18) to the driveshaft by tap-
ping the stub axle bowl using a brass drift until the
128412
lock ring clicks into place behind the ball hub.
a Fit the small securing clip (15) onto the driveshaft. a Insert the gaiter lip into the groove of the stub axle
bowl.
a Lightly lubricate the driveshaft using the grease sup-
plied with the gaiter to facilitate its fitting.
Note:
Check that the gaiter lip is correctly positioned in
the groove of the driveshaft.
a Fit the small securing clip on the driveshaft gaiter.

a Refit the big securing clip on the driveshaft gaiter.
128416
a Refit the gaiter (16) onto the driveshaft.

a Insert the gaiter lip into the groove of the driveshaft.
a Refit the lock ring (17) .
29A-40
DRIVESHAFTS
Clic clip - the wheel driveshaft on the side concerned (see
29A, Driveshafts, Front right-hand wheel dri-
veshaft: Removal - Refitting, page 29A-18) or
- the wheel on the side concerned (see Wheel: Re-
page 21A-2) .
115197
Clip with profile end
115196
a Tighten the clips using the tool (Tav. 1168) (19) for
clic clips or the tool (Tav. 1784) (20) for profile end
clips.
a Refit:
- the differential output seal on the side concerned

seal: Removal - Refitting, page 21A-10) ,
29A-41
DRIVESHAFTS
Front right-hand driveshaft gaiter on gearbox side: Removal - Refitting 29A
Tav. 1168 Thermoplastic driveshaft gai- box, Manual gearbox oil: Draining - Refilling,
ter clip fitting tool. page 21A-2) .
Tav. 1784 Driveshaft gaiter clip tool. a Remove:

Essential equipment Refitting) (35A, Wheels and tyres),
parts washer
109767
(1) Deflector
(2) Driveshaft
(3) Ball bearing
(4) Driveshaft yoke sleeve
(5) Spider
(9) Lock ring
IMPORTANT
tion.
REMOVAL

a Remove
29A-42
DRIVESHAFTS
CONCERNED
128793
a Remove the driveshaft yoke sleeve (12) .
128487
Note:
- since the driveshaft yoke sleeve does not have
a stop tab, it can be removed without being for-
ced,
- do not remove the rollers from their respective
bushings as the rollers and needles are mat-
ched and should never be interchanged.
a Remove as much grease as possible from inside the

yoke sleeve.
Note:
Never use thinner to remove grease.
128486
clip (11) using cutting pliers or a metal saw, taking
care not to damage the yoke sleeve or the drives-
haft.
a Push back the driveshaft gaiter to release the drives-
haft yoke sleeve.
29A-43
DRIVESHAFTS
109409 127992
a Remove the lock ring (13) using circlip pliers. a
Note:
Note:
Mark the position of the spider before extracting
Mark the position of the spider before extracting it.
it.
a Remove the spider (14) using a press and a re-
leasing type extractor.
a Remove the driveshaft gaiter (15) from the drives-
haft.
REFITTING

a parts always to be replaced: Front right-hand
driveshaft gaiter on gearbox side (13,01,03,03).
a parts always to be replaced: gearbox side front
driveshaft seal locking ring (13,01,01,08).
a Always replace:
- the big securing clip,
- the small securing clip.
a Use a parts washer to clean the driveshaft, the spi-
der and the driveshaft yoke sleeve.
29A-44
DRIVESHAFTS
CONCERNED
127992
a Refit the spider (18) in the position marked during re-
128412 moval.
a Fit the small tightening clip (1 6) to the propeller
shaft.
109409
a Fit a new lock ring (19) using circlip pliers.
128409
29A-45
DRIVESHAFTS
Clic clip
128488 115197
a Divide the quantity of grease between the driveshaft
gaiter and the yoke sleeve.
a Engage the yoke sleeve (20) on the tripod (21) .
a Position the driveshaft gaiter lip into the groove of
the yoke sleeve.
Note:

115196
clips.
a Refit:
- a new differential output seal (see 21A, Manual

29A-46
DRIVESHAFTS
page 21A-2) .
29A-47
DRIVESHAFTS
Front left-hand driveshaft gaiter on gearbox side: Removal - Refitting 29A
REMOVAL
Tav. 1168 Thermoplastic driveshaft gai- I - REMOVAL PREPARATION OPERATION

ter clip fitting tool.
Tav. 1784 Driveshaft gaiter clip tool. Towing and lifting) (02A, Lifting equipment).
a Remove:
Essential equipment
parts washer - the engine undertray.
page 21A-2) .
a Remove:
109401

(4) Driveshaft yoke sleeve
(5) Lock ring
(6) Spider
(7) Cup
(8) Cup spring
(9) Deflector
(10) Driveshaft
a
IMPORTANT
tion.
29A-48
DRIVESHAFTS
CONCERNED
109408
a Remove the driveshaft yoke sleeve (13) .
128413
Note:
- since the driveshaft yoke sleeve does not have
a stop tab, it can be removed without being for-
ced,
- do not remove the rollers from their respective
bushings as the rollers and needles are mat-
ched and should never be interchanged.
a Remove as much grease as possible from inside the

driveshaft yoke sleeve.
Note:
Never use thinner to remove grease.
128414
clip (12) using cutting pliers or a metal saw, taking
care not to damage the yoke sleeve or the drives-
haft.
a Push back the driveshaft gaiter to release the drives-
haft yoke sleeve.
29A-49
DRIVESHAFTS
109409 127992
a Remove the lock ring (14) using circlip pliers. a
Note:
Note:
Mark the position of the spider before extracting
Mark the position of the spider before extracting it.
it.
a Remove the spider (15) using a press and a re-
leasing type extractor.
a Remove:
- the gaiter from the driveshaft,
- the cup equipped with the cup spring.
REFITTING
a parts always to be replaced: Front left-hand dri-

veshaft gaiter on gearbox side (13,01,03,04).
a parts always to be replaced: gearbox side front

driveshaft seal locking ring (13,01,01,08).
a Always replace:
- the cup,
- the cup spring,
- the big securing clip,
- the small securing clip.
a Use a parts washer to clean the driveshaft, the spi-

der and the driveshaft yoke sleeve.
29A-50
DRIVESHAFTS
CONCERNED
127992
a Refit the spider (18) in the position marked during re-
128412 moval.
a Fit the small securing clip (16) onto the driveshaft.
109409
a Refit a new lock ring (19) using circlip pliers.
128409
29A-51
DRIVESHAFTS
a Position the driveshaft gaiter lip into the groove of
the yoke sleeve.
Note:

128410
a Refit:
- the cup (20) onto the cup spring (21) ,
- the cup spring equipped with the cup into the dri-
veshaft yoke sleeve (22) .
109408
a Divide the quantity of grease between the driveshaft
gaiter and the yoke sleeve.
a Engage the yoke sleeve (23) on the tripod (24) .
29A-52
DRIVESHAFTS
Clic clip - the front left-hand driveshaft (see 29A, Drives-
page 21A-2) .
115197
115196
clips.
a Refit:
- a new differential output seal (see 21A, Manual

29A-53

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2 Transmission

21A MANUAL GEARBOX

23A AUTOMATIC GEARBOX

APRIL 2009 Edition Anglaise

© Renault s.a.s 2008

MEGANE III - Section 2

20A CLUTCH 23A AUTOMATIC GEARBOX

Clutch: Specifications 20A-1 Automatic gearbox:

Automatic gearbox oil:

Differential output seal:

23A AUTOMATIC GEARBOX

Speed sensor: Removal -

Oil pressure switch: Removal

Converter seal: Removal -

Driveshaft: Precautions for

Front left-hand wheel

Front right-hand wheel

Relay shaft bearing:

Front driveshaft gaiter on

Front right-hand driveshaft

Front left-hand driveshaft

K4M, and 858

Number of grooves: 24 Number of grooves: 24

K9K, and 830 or 834 K9K, and 832 or 836

Pressure plate Pressure plate

Drive plate Drive plate

Plate outer diameter: 216 mm Plate outer diameter: 225 mm

Plate thickness: 7.0 mm Plate thickness: 6.9 mm

Number of grooves: 24 Number of grooves: 24

F4R, and 870 F4R, and 874

Pressure plate Pressure plate

Drive plate Drive plate

Plate outer diameter: 239 mm Plate outer diameter: 239 mm

Plate thickness: 8.3 mm Plate thickness: 7.9 mm

Number of grooves: 24 Number of grooves: 24

Plate outer diameter: 239 mm

Plate thickness: 7.8 mm

a Drain the manual gearbox (see 21A, Manual gear-

If the old pressure plate is being refitted, apply the

a Unscrew and gradually remove by quarter turns the

I - REFITTING PREPARATION OPERATION

a Refit: - the battery tray (see Battery tray: Removal - Re-

- the front axle subframe (see Front axle sub-fra-

- the radiator mounting cross member (see Radiator

- the differential output seals (see 21A, Manual

- the front right-hand driveshaft (see 29A, Drives-

- the front left-hand driveshaft (see 29A, Drives-

- the starter (see Starter: Removal - Refitting)

- the front wheel arch liners (see Front wheel arch

- the front wheels (see Wheel: Removal - Refitting)

a Connect the clutch hydraulic pipe to the slave cylin-

a Bleed the clutch control (see Clutch circuit: Blee-

a Clip the control cables onto the gearbox (see Ma-

a Adjust the gearbox control cables (see Mechanical

a Disconnect the clutch hydraulic pipe from the slave

- the crankshaft position sensor (see Crankshaft

- the left-hand suspended engine mounting (see

II - OPERATION FOR REMOVAL OF PART

I - REFITTING PREPARATION OPERATION

a Centre the clutch plate using the (Emb. 1780) (7) .

a Torque tighten the clutch pressure plate bolts (15

a Remove the (Emb. 1780) and (Mot. 1677).

III - FINAL OPERATION