Figure : E5AM0L7D

Reference Description Reference

[2] Crossmember (-).0554
Figure : E5AM0LUD

Reference Description Reference

[3] Rear suspension positioning tool 4399-T

Figure : E5AM0LVD

Reference Description Reference

[4] Positioning pin (-).0629-C
[5] Positioning tool (-).0555-A
[6] Positioning tool (-).0555-B

2. Removing
Slacken the parking brake.
Untighten the rear wheel bolts.
Raise and support the vehicle on a 2 column lift.
Strap the vehicle on the 2 column lift.
Disconnect the battery.
Remove :
• The rear wheel bolts
• The rear wheels
• The centre console
Figure : C5FM0NSD

Place the handbrake lever at rest.

Press on the unlocking push (2) (in the direction of the arrow).
While maintaining the pressure on the unlocking push (2), move the integral play compensation activation lever by
a quarter turn (1) (in the direction of the arrow).
Release the unlocking push (2).

CAUTION : In order not to damage the spring of the integral play compensation system, do not action the parking
brake beyond the first notch of its total travel without the push (1) being in the position LOCKED.

Raise the parking brake lever to the first notch.

Move the integral play compensation activation lever by a quarter turn (1) (In the opposite direction).
Place the handbrake lever at rest.
Figure : B3DM068D

Remove :
• The screen (3)
• The rear suspension springs
• The rear dampers
Figure : B3DM069D

On both sides :
• Uncouple : The handbrake cable (4) (At " c ")
• Unfasten the parking brake cable (4) (At " b", "a ")
• Disengage the parking brake cable (4) from its guides
Figure : B3DM06AD

Place the pedal press on the brake pedal to prevent any flow of brake fluid when the brake hoses are uncoupled.
On both sides :
• Disconnect : The rear wheel sensor connector (5) (At " d ")
• Unclip the rear wheel sensor harness (5) (At " e", "f ")
• Uncouple the hydraulic pipe (6) (At " g ") (Prevent brake fluid from spilling)
• Blank the orifices on both sides
Figure : B3DM06BD

Remove the blocking plugs (At " h ").

On both sides :
• Position the tool [3] on the rear suspension yokes (At " h ")
• Support the tool [3] on the rear suspension (At " j ")
Figure : B3DM06CD

Position the crossmember [2] on the lifting table [1].

On each side of the crossmember [2] ; Put in place :
• The tools [5], [6] (At " k ")
• The positioning studs [4]
Figure : B3DM06DD

CAUTION : The following operation requires two operators.

CAUTION : Do not take weight under the rear axle crossmember with a component lifting ram or a jack.

On both sides :
• Place the positioning pins [4] ((take weight under the suspension spring cups at "l"))
• Place the blocks (at "m") between the tool [3] and tools [5] and [6]

Position the rear axle crossmember horizontally, with the aid of the assembly of lifting tools [1], [2], [3], [4], [5],
[6].
Figure : B3DM06ED

CAUTION : The following operation requires two operators.

Remove :
• The bolts (7)
• The rear suspension

3. Refitting
Figure : B3DM06FD

On both sides :
• Slacken bolt (8)
• Position the tool [3] on the rear suspension yokes (At " h ")
• Support the tool [3] on the rear suspension (At " j ")
• Position a block (at m) (so that the rear axle will be horizontal)
Figure : B3DM06GD

CAUTION : The following operation requires two operators.

Bring the rear suspension under the bodyshell in the same position as at removal.
Adjust the positioning of the rear axle in relation to the pegging holes (At " h ").
Reinstall screws (7).
Tighten :
• The bolts (7) to 11,5 ± 1,1 daNm
• The screws (8) to 11,5 ± 1,1 daNm

Remove the tools[1], [2], [3], [4], [5], [6].

On both sides :
• Refit the plugs (At " h ")
• Couple up : The hydraulic pipe (8) (At " f ") ; Tighten to 1,5 daNm ± 0,3 daNm
• Clip the rear wheel sensor harness (9) (At " e ")
• Connect : The rear wheel sensor connector (9) (At " d ")
• Engage the secondary handbrake cable (4) in its guides
• Secure the parking brake cable (4) (At " b", "a ")
• Couple the parking brake cable (4) (At " c ")

Refit :
• The rear dampers
• The rear suspension springs
• The screen (3)

Remove the pedal push .

N.B. : The parking brake lever is in the rest position.

Press on the unlocking push (2) (in the direction of the arrow).
While maintaining the pressure on the unlocking push (2), move the integral play compensation activation lever by
a quarter turn (1) (in the direction of the arrow).
Release the unlocking push (2).
Move the integral play compensation activation lever by a quarter turn (1) (In the opposite direction).
Connect the battery.
Fill and bleed the braking system .
Fit :
• The rear wheels
• The rear wheel bolts

Adjust the parking brake .

Fit :
• The centre console
• The vehicle to its wheels

Tighten : The rear wheel bolts :

• Alloy wheel : Tightening to 9 ± 0,9 daN.m
• Steel wheel : Tightening to 11 ± 1 daN.m

Set the vehicle to the reference height.

Tighten the lower damper screws to 19 ± 1,9 m.daN.

CAUTION : Perform the operations to be carried out following reconnection of the battery.
 REMOVING - REFITTING : FLEXIBLE MOUNTINGS (REAR
B3DG0112P0
SUSPENSION)

URGENT : Ensure that the precautions relating to safety and cleanliness are adhered to .

1. Recommended tools

Figure : E5AM0LSD

Reference Description Reference

[1] Cross piece (-).0549 A
[2] Shim for removing-refitting flexible joint (-).0549.B4
[3] Sleeve (-).0549.C4
[4] Counter-brace for removing-refitting flexible mounting (-).0549.D4
[5] Support for refitting flexible mounting (-).0549.E4
Figure : E5AM0LTD

[6] Set of supports (-).0005.

2. Removing
Remove the rear suspension .
Figure : B3DM060D

Immobilise the rear axle ; Using the tools [6a], [6b].

Figure : B3DM061D

Remove :
 • The bolt (1)
• The yoke (2)
• Washer (3)

2.1. "hydraulic" flexible mounting

Figure : B3DM062D

N.B. : Mark the direction of fitting of the washer (4) (Before refitting).

Remove : Washer (4).

Figure : B3DM063D

Mark the positioning of the flexible mounting (5) in relation to the suspension arm with a mark at "a" ; By means
of a mark (At "a").
2.2. "dual material" flexible mounting
Figure : B3DM064D

Mark the positioning of the flexible mounting (5) in relation to the suspension arm with a mark at "a".
Cut the tab (At "b").
2.3. Removing (continued)

Figure : B3DM065D

N.B. : Check that the bolt of the tool [1]is well greased.

Fit the tool [4]on the hub of the flexible mounting (5).
Fit the tools [1], [2]and [3]on the flexible mounting (5).
Extract the flexible mounting (5) by screwing in the screw of the tool [1].
Remove the tools[1], [2], [3], [4].

3. Refitting
Figure : B3DM066D

Fit the tools [4], [5] on the hub of the rear suspension flexible mounting [5].

Figure : B3DM067D
 CAUTION : Take care with the positioning of flexible mountings (5).

Position the flexible mounting (5) (New) (Respect the markings made at removal).

N.B. : For vehicles fitted with dual material flexible mountings, respect the position of the tab (at "b") of the flexible
mounting (5).

Fit :
• The flexible joint (5)
• The tools [1], [2], [3]

N.B. : Check that the bolt of the tool [1]is well greased.

Tighten the bolt of the tool [1] until the flexible mounting (5) is put in place.
Remove the tools[1], [2], [3], [4], [5].
3.1. "hydraulic" flexible mounting
Fit : Washer (4).
3.2. Refitting (continued)
Fit :
• Washer (3)
• The yoke (2)
• The bolt (1) (without tightening)
• The rear axle
 B3DG0113P0 REMOVING - REFITTING : REAR STUB AXLE

URGENT : Ensure that the precautions relating to safety and cleanliness are adhered to .

1. Removing
Slacken the rear wheel bolts .
Raise and support the vehicle, with the rear wheels hanging free.
Remove :
• The rear wheel bolts
• The rear wheel
• The rear brake hub disc

Figure : B3BM07ZD

Remove the bolt (1).

Pull away the wheel sensor (2).
Figure : B3BM080D

Remove :
• The screws (3)
• The rear wheel stub axle (4)
• The brake flange

2. Refitting
Fit :
• The brake flange
• The rear wheel stub axle (4)
• The bolts (3) coated with LOCTITE FRENETANCH

Tighten the bolts (3) to 11 ± 1,1 daNm.

Fit :
• The wheel sensor (2)
• The bolt (1)

Tighten the bolt (1) to 0,8 ± 0,1 daNm.

Fit :
• The rear brake hub disc
• The rear wheel
• The rear wheel bolts

Return the vehicle to its wheels.

Tighten : The rear wheel bolts :
• Alloy wheel : Tightening to 9 ± 0,9 daN.m
• Steel wheel : Tightening to 11 ± 1 daN.m
 B3EB010AP0 IDENTIFICATION - DATA : POWER ASSISTED STEERING

1. Power assisted steering

1.1. Power steering electropump assembly (DV6TED4 engine)

Figure : B3EM095D

(1) Power steering electropump assembly.

(2) Plug.
(3) Heat shield.
(4) Steering column.
(5) Steering mechanism with integral ram.
Regulating pressure : 100 ± 5 bars.
Capacity of power steering circuit : 1,8 litre.
Recommended power steering oil : TOTAL FLUIDE DA.
1.2. With pump driven by the accessories drive belt (Other DV6 engines)
Figure : B3EM096D

(6) Power steering fluid reservoir.

(7) Plug.
(8) Heat shield.
(9) Steering column.
(10) Steering mechanism with integral ram.
(11) Power-assisted steering pump.
(12) Power steering radiator pipe.
The power steering pump is fixed on the multifunction support and is driven by the accessories drive belt .
Adjustment pressure of power steering pump : 102,5 ± 3,5 bars.
Diameter of power steering pump pulley : 129 mm.
Capacity of power steering circuit : 1,8 litre.
Recommended power steering oil : TOTAL AT42.
1.3. With pump driven by the accessories drive belt (TU5JP4 engine)
Figure : B3EM0A0D

(13) Power steering fluid reservoir.

(14) Plug.
(15) Heat shield.
(16) Steering column.
(17) Steering mechanism with integral ram.
(18) Power-assisted steering pump.
(19) Pressure switch.
(20) Power steering radiator pipe.
The power steering pump is fixed on the multifunction support and is driven by the accessories drive belt .
Adjustment pressure of power steering pump : 102,5 ± 3,5 bars.
Diameter of power steering pump pulley : 140 mm.
Capacity of power steering circuit : 1,8 litre.
Recommended power steering oil : TOTAL AT42.

2. Steering mechanism
Power steering mechanism with integral ram.
The power steering mechanism is fixed on the front subframe by two studs.
Two non-slip shims are arranged between the steering mechanism and the front subframe.

Steering rack travel (in mm) 2 x 74

Gearbox ratio 1/51,27
Number of revolutions of the steering wheel 2,89
 B3EB0109P0 TIGHTENING TORQUES : POWER ASSISTED STEERING

1. Steering column

Figure : B3EM08XD

Reference Designation Tightening torque

(1) Steering wheel screw 3,3 ± 0,5 daNm
(2) Steering column screw on support 2 ± 0,5 daNm
(3) Steering column screw on support 0,5 ± 0,1 daNm
(4) Steering column screw on steering mechanism 2 ± 0,5 daNm

2. Steering mechanism
Figure : B3EM08YD

Reference Designation Tightening torque

(5) Steering ball-joint nut 4,5 ± 0,4 daNm
(6) Lock nut for adjusting the steering track rods 7,5 ± 0,7 daNm
(7) Steering rack ball-joint fixing 7 ± 0,7 daNm
(8) Hydraulic pipes clamp on steering assistance valve fixing 1,9 ± 0,2 daNm
(9) Hydraulic pipe fixing on ram 0,8 ± 0,1 daNm
Figure : B3EM09KD

Reference Designation Tightening torque

(10) Distributor valve fixing on steering mechanism 2 ± 0,2 daNm
(11) Clamp to valve fastener 1,9 ± 0,2 daNm
(12) Hydraulic tube connection 0,8 ± 0,1 daNm

3. Steering assistance
3.1. Power steering electropump assembly
Figure : B3EM08ZD

Reference Designation Tightening torque

(13) Pipe clamp on electropump assembly fixing bolt 1,9 ± 0,2 daNm
(14) Electropump fixing on chassis member 2 ± 0,5 daNm
(15) Fixing screw on support 2,3 ± 0,3 daNm

3.2. Power steering pump

Figure : B3EM09LD

Reference Designation Tightening torque

(16) Fastener fastening power steering pump to mounting 2,1 ± 0,3 daNm
(17) Fixing of union fastening the high pressure pipe on the power steering pump 2,1 ± 0,3 daNm

4. Power steering reservoir

Figure : B3EM09MD

Reference Designation Tightening torque

(18) Fastening screws 0,5 ± 0,1 daNm
 B3EG011RP0 REMOVING - REFITTING : POWER STEERING PUMP

URGENT : Ensure that the precautions relating to safety and cleanliness are adhered to .

CAUTION : Wait for the front exhaust heat shield to cool to avoid any risk of burns.

1. Recommended tools

Figure : E5AP2XND

Reference Designation Reference Reference

[1] set of two hose clamps 4153-T (-).1512
Figure : E5AP2Z7D

Reference Designation Reference

[2] pipe spanner (-).1603-G

2. Removing
Raise and support the vehicle.
Disconnect the battery.
Remove the ancillary drive belt .
Figure : B1BM16JD

N.B. : Protect the cooling radiator.

Remove :
• The air ducts (1) and (2)
• The screws (3)
• The heat shield (4)

CAUTION : Protect the alternator from discharges of fluid.

Figure : B3EM09FD

Clamp the power steering pump supply pipe (5) (at "a") ; Using the tool [1].
Slacken the power steering high pressure pipe (6) (at "b") ; Using the tool [2].
Remove the bolt (7).
Uncouple (Be prepared for the flow of power steering fluid) :
• The power steering high pressure pipe (6) (at "b")
• The power steering pump supply pipe (5) (at "c")

Plug the hydraulic unit unions ; Using cleanliness plugs.

Figure : B3EM09GD

Remove :
• The screws (8)
• The steering assistance pump (9)

3. Refitting
Figure : B1BM16KD

CAUTION : Before refitting the power steering pump, check that the ring (11) is present on the power steering
pump support (10).

Fit :
• The steering assistance pump (9)
• The screws (8) ; Tighten to 2,1 daNm ± 0,3 daNm

Couple up :
• The power steering pump supply pipe (5) (at "a")
• The power steering high pressure pipe (6) (at "b")

Refit the bolt (7) ; Tighten to 0,8 daNm ± 0,2 daNm.

Tighten the power steering high pressure pipe (6) (at "b") ; To 2 ± 0,3 daNm ; Using the tool [2].
Remove the tool [1].
Fit :
• The heat shield (4)
• The screws (3) ; Tighten to 0,4 daNm ± 0,1 daNm
• The air ducts (1) and (2)
• The ancillary drive belt

Connect the battery.

Fill and drain the power steering circuit .

CAUTION : Perform the operations that are necessary after a battery reconnection .
 B3EG011SP0 REMOVING - REFITTING : STEERING TRACK RODS

URGENT : Observe the safety and cleanliness instructions .

1. Recommended tools

Figure : E5AP3EWD

Reference Description Reference

[1] Steering rack locking tool (-).0721-B
Figure : E5AP3EXD

Reference Description Reference

[2] roller bearing spanner (-).0721-A
Figure : E5AP3EYD

Reference Description Reference Reference

[3] steering ball-joint extractor 1892-T (-).0709

Figure : E5AP3EZD

Reference Description Reference

[4] "CLIC" clip pliers (-).0172-Z

2. Removing
Raise and support the vehicle on a 2 column lift.
Remove :
• The front wheels
• The steering ball-joint nut

Uncouple the steering ball joint ; Using the tool [3].

Remove the steering ball-joint.
Figure : B3EM09TD

Uncouple the pipe (4) from the steering rack gaiter (2) (at "a").
Unclip the clip (3) ; Using a thin screwdriver.
Remove clip (1) ; Using universal pliers .
Remove the steering rack gaiter (2).
Full right hand lock and come back 1/4 turn (L.H.D.).
Full left hand lock and come back 1/4 turn (R.H.D.).
Figure : B3EM09UD

Position tool [1] on the steering rack gaiter so that its ball-joint supports are against the subframe.
Pre-tighten the 4 bolts (at "b").
Place the 2 supports "" in contact with the subframe (at "c").
Figure : B3EM09VD

Position the tool as close as possible to the steering ball-joint (in the direction of the arrow).
Tighten the bolts (at "b").

Figure : B3EM09WD

Remove the steering track rod ; Using the tool [2].

3. Refitting
Refit the steering track rod ; Using the tool [2].
Tighten the steering track rod to 7 ± 0,7 m.daN.
Remove the tool [1].
Smear the steering rack with TOTAL N3924/N3945 grease.
Fit a new steering rack gaiter (2).
Fit a new clip (3) ; Using the tool [4].
Couple the pipe (4) on the steering rack gaiter (2).
Fit :
• Clamping collar (1)
• The steering ball-joint ; Tighten to 4,5 ± 0,4 daNm

Fit the wheels.

Return the vehicle to its wheels.
Tighten the wheel screws :
• Alloy wheel : Tighten to 9 ± 0,9 daNm
• Steel wheel : Tighten to 11 ± 1 daNm

Check and adjust the wheel tracking.

4. Vehicle equipped with ESP

Calibrate the steering wheel angle sensor ; Using the diagnostic tool.
To perform this operation, select the menu "ABS (ABS/ESP)".
 B3EG011TP0 REMOVING - REFITTING : STEERING MECHANISM

URGENT : Ensure that the precautions relating to safety and cleanliness are adhered to .

1. Recommended tools

Figure : E5AP3F1D

Reference Description Reference Reference

[1] Steering ball joint extractor 1892-T (-).0709

2. Removing

CAUTION : Put the front wheels in the straight ahead position ; Lock the steering wheel in this position.

Disconnect the battery.

Release the front wheel bolts.
Lift and support the vehicle with front wheels suspended.
Remove :
• The front wheel bolts
• The front wheels
• The RH front splash shield

Drain the power steering hydraulic circuit .

Remove :
• The front subframe
 • The steering mechanism thermal protector

Attach the steering mechanism to the exhaust manifold .

Figure : B3EM0ACD

CAUTION : Handle the steering assistance valve delicately, using a clean tool, in order not to damage it.

"A" : L.H.D..
"B" : R.H.D..
Remove the bolt (1).
Uncouple the flange (2) of the steering assistance valve.

CAUTION : Proceed with care in order to avoid entry of pollutant particles.

Figure : B3EP1B7D

Remove the bolt (3).

Uncouple the steering column from the steering mechanism .

Figure : B3EM0ADD
Remove the nut (4) from the steering ball-joint (on each side).
Uncouple the steering ball-joint (5) ; Using the tool [1] (on each side).
Remove the steering mechanism.

3. Refitting

Figure : B3EP1B9D

Fit a new rubber seal (6).

Refit the steering mechanism ; Secure the steering system to the exhaust manifold.
Couple up the steering ball-joint (5) (on each side).
Refit the steering ball-joint nut (4); Tighten to 4,5 daNm ± 0,4 daNm (on each side).
Figure : B3EP1BAD

N.B. : On each removal : Systematically replace seals (7).

Couple the steering assistance valve flange (2).

Fit :
• The bolt (1) ; Tighten to 1,9 daNm ± 0,2 daNm
• The steering mechanism thermal protector

CAUTION : Do not forget the toothed washer between the front subframe and the steering mechanism.

Refit the front subframe .

Couple the steering column to the steering mechanism .
Fit :
• The bolt (3) ; Tighten to 2 daNm ± 0,2 daNm
• The RH front splash shield
• The front wheels
• The front wheel bolts

Return the vehicle to its wheels.

Tighten the wheel screws :
• Alloy wheel : Tightening to 9 ± 0,9 daN.m
• Steel wheel : Tightening to 11 ± 1 daN.m

Connect the battery.

CAUTION : Perform the operations that are necessary after a battery reconnection .

Fill and bleed the power steering hydraulic circuit .

Check and adjust the wheel tracking.
 B3EG0117P0 REMOVAL - REFITTING : STEERING WHEEL

URGENT : Ensure that the precautions relating to safety and cleanliness are adhered to .

CAUTION : Before taking any action : Place the road wheels in the straight ahead position.

CAUTION : For any work which includes uncoupling between the steering wheel and the wheels (steering wheel,
steering wheel controls module, column, rack...), ensure that the steering wheel controls module rotary switch is
immobilised.

CAUTION : The connectors must be disconnected without stressing the harnesses and connectors (No pulling
of the harnesses is permitted).

1. Removal

N.B. : The operation is carried out in the same way for right-hand or left-hand drive.

The following operations should be carried out :

• Switch off the ignition
• Wait 3 minutes before disconnecting the battery
• Disconnect the battery

Remove the driver's airbag .

Figure : B3EM06WD

Detach - Disconnect the connector (At "a").

Unscrew the bolt (2) by a few threads.
Release the steering wheel (1) from its splines by tapping the periphery with your hands.

CAUTION : When passing the horn and airbag connectors through the steering wheel opening (1) : No pulling
or other stressing of the harnesses and connectors is permitted.

Take down :
• The bolt (2)
• The steering wheel (1)

2. Refitting

CAUTION : Place the road wheels in the straight ahead position.

Refit the steering wheel (1).

CAUTION : Pass the horn and airbag connectors into the steering wheel opening ; Do not pull the connectors
excessively ; Do not fold the harnesses (curve to be observed).

Refit the bolt (2) ; Tighten to 3,3 ± 0,5 daNm.

Refit the driver's airbag .
Connect the battery.

CAUTION : Perform the operations to be carried out following reconnection of the battery.

Check the electrical operation of the equipment.

 REMOVAL - REFITTING : CONTROL UNDER THE STEERING
B3EG0119P0
WHEEL

URGENT : Ensure that the precautions relating to safety and cleanliness are adhered to .

CAUTION : Before taking any action : Place the road wheels in the straight ahead position.

CAUTION : For any work which includes uncoupling between the steering wheel and the wheels (steering wheel,
steering wheel controls module, column, rack...), ensure that the steering wheel controls module rotary switch is
immobilised.

CAUTION : When disconnecting, ensure that the connectors are released correctly ; When connecting, ensure
that the harnesses are correctly routed and clipped correctly.

CAUTION : The connectors must be disconnected without stressing the harnesses and connectors (No pulling
of the harnesses is permitted).

1. Recommended tools

Figure : E5AP30WD

[1] Trim removing tool (-).1350-ZZ.

2. Preliminary operations

N.B. : The operation is carried out in the same way for right-hand or left-hand drive.
Disconnect the battery.
Take down :
• The driver's airbag
• The steering wheel

3. Removal

Figure : C5FM0H7D

Unlock the steering column, pull it fully and lower it.

Take down :
• The bolts (2)
• The steering column lower half cowl (1)
Figure : C5FM0H8D

Unclip the steering column upper half cowl (3) (at "a") ; Using the tool [1].
Take down : The steering column upper half cowl (3).

Figure : C5FM0H9D
Disconnect the connectors (at "b").
Slacken bolt (4) (Maximum).

Figure : C5FM0HAD

CAUTION : No breaking of the steering wheel controls module locking clips is permitted.

Unclip the locking tabs of the controls under the steering wheel assembly (5) (at "c") ; Using the tool [1].
Remove the steering wheel controls assembly (5) (in the direction of the arrow).

4. Refitting

CAUTION : Adjust the rotary switch before refitting the steering wheel controls module .

4.1. Controls located under the steering wheel (new)

Figure : C5FM0HBD

The rotary switch of a new steering wheel controls module does not require adjustment.
The adjustment is guaranteed by alignment of the notch "d" and the index "e" (Supplier DELPHI).
4.2. Reused controls under the steering wheel
Figure : C5FM0HCD

Locate point 0 :
• Press the centre of the rotary switch (at "f")
• Turn clockwise to the stop
• Turn the rotary switch 2,5 turns anti-clockwise

N.B. : Do not force when the stop is reached.

Check the alignment of the notch "d" with the index "e".

CAUTION : Never turn anticlockwise before turning to the stop clockwise, this causes irrevocable damage to
the rotary switch ribbon.

5. Joint operations

CAUTION : Place the road wheels in the straight ahead position.

Make the following checks :

• The locking rods of the connectors must not be broken
• The harnesses of the steering wheel controls module must not be damaged

Position the controls under the steering wheel assembly (5) on the steering column, with the controls horizontal.
Clip in place : The controls under the steering wheel (5) (at "c").
Tighten the bolt (4) to 0,3 ± 0,07 daN.m.
The controls under the steering wheel (5) must be aligned on the steering column to avoid amplifying the noise.
Connect the connectors (at "b").

CAUTION : Do not pull the connectors excessively ; Do not fold the harnesses (curve to be observed) ; Take all
precautions required in order not to damage the harnesses (Do not twist the moulded harnesses).

Fit :
• The steering column upper half cowl (3)
• The steering column lower half cowl (1)
• The bolts (2)

6. Complementary operations
Fit :
• The steering wheel
• The driver's airbag

CAUTION : Perform the operations to be carried out following reconnection of the battery.

Connect the battery.

Check that the electrical equipment is working correctly.

7. Vehicles equipped with ESP (Electronic Stability Programme)

Calibrate the steering wheel angle sensor ; Using the diagnostic tool.
To perform this operation, select the menu "ABS (ABS/ESP)".
 B3EG0145P0 REMOVING - REFITTING : HANDS-FREE KIT UNIT

URGENT : Ensure that the precautions relating to safety and cleanliness are adhered to .

1. Removing
Disconnect the battery .
Remove the dashboard side trim (Passenger's side).
Detach : The front pillar lower trim (Passenger's side).

Figure : B3EG087D

Disconnect the connector (At "a").

Remove the bolt (3).
Detach : The hands-free kit unit (2) (In the direction of the arrow).
Remove :
• The hands-free kit unit (2)
• The front pillar lower trim (1)

2. Refitting
Proceed in the reverse order to removal.

CAUTION : Perform the operations that are necessary after a battery reconnection.

Reconnect the battery.

Check the operation of the equipment.
 DRAINAGE - REFILLING - BLEEDING : POWER STEERING
B3EI0109P0
CIRCUIT

URGENT : Ensure that the precautions relating to safety and cleanliness are adhered to .

1. Drainage
Open the cap of the power steering fluid tank.
Raise and support the vehicle with the wheels clear of the ground.

Figure : B3EP1B6D

Remove the steering mechanism heat shield .

Place a receptacle underneath the vehicle.
Remove the bolt (1).
Uncouple the flange (2) of the steering assistance valve.
Turn the steering in both directions, from lock to lock.

2. Refilling

CAUTION : Use new oil to fill and top up the circuit.

Figure : B3EM09HD

N.B. : On each removal ; Systematically replace seals (3).

Couple the steering assistance valve flange (2).

Refit the bolt (1) ; Tighten to 1,9 daNm ± 0,2 daNm.
Figure : B3EM09JD

Fill the power steering fluid reservoir to the maximum level "a".
Fit : The cap of the power steering fluid tank .

3. Bleeding
Turn the steering in both directions, from lock to lock.

Figure : B3EM09JD

Top up the power steering fluid to the maximum level "a".

Place the vehicle with the wheels on the ground.
Start the engine.
Turn the steering from lock to lock, until there are no points of resistance.
Top up the power steering fluid to the maximum level "a".
 B3FB010AP0 TIGHTENING TORQUES : BRAKING SYSTEM

1. Front brake

Figure : B3FM0DXD

Reference Description Tightening torque

(1) Screw - Front brake caliper support Pre-tighten to 3,3 da.Nm
(Fitting - Bolt(s) without washer) Angular tightening to 45 °
Screw - Front brake caliper support Pre-tighten to 9 da.Nm
(Fitting - Bolt with washer) Angular tightening to 45 °
(2) Union - Hose on caliper 1,8 daNm
(3) Bleed screw 1 daNm
(4) Screw - Front brake disc 1 daNm
(5) Screw - Front brake caliper 2,7 daNm
(6) Screw - Front wheel sensor 0,8 daNm

2. Master cylinder - Brake servo

Figure : B3FB06ED

Reference Description Tightening torque

(1) Nuts - Brake servo 2 daNm
(2) Hydraulic connectors (With ESP) 1,8 daNm
Hydraulic connectors (Without ESP) 1,5 daNm
(3) Nuts - Master cylinder on brake servo 2,3 daNm
(4) Brake fluid reservoir on master cylinder bolt 0,8 daNm

3. Hydraulic valve block

Figure : B3FB032D

Reference Description Tightening torque

(1) Hydraulic connectors 1,5 daNm
(2) Screw - Hydraulic valve block support 1,5 daNm
(3) Hydraulic connectors (With ESP) 1,8 daNm
Hydraulic connectors (Without ESP) 1,5 daNm
(4) Nuts - Hydraulic block on its support 0,7 daNm

4. Handbrake
Figure : B3FB06GD

Reference Description Tightening torque

(1) Nuts - Handbrake on body 1,5 daNm

5. Rear brake
Figure : B3FB06HD

Reference Description Tightening torque

(1) Bleed screw 1 daNm
(2) Screw - Rear brake calliper 3,5 daNm
(3) Screw - Rear brake caliper support Pre-tighten to 3 da.Nm
Angular tightening to 35 °
(4) Screw - Rear wheel sensor 0,8 daNm
(5) Hydraulic union 1,5 daNm

6. Gyrometer-accelerometer sensor
Figure : B3FB06ID

Reference Description Tightening torque

(1) Nuts - Gyrometer-accelerometer sensor 0,8 daNm

7. Vacuum pump (DV6 euro 4 engine)

Figure : B3FB036D

Reference Description Tightening method Tightening torques

(1) Screw - Vacuum pump Do up the screws by hand -
1st pre-tightening 0,3 daNm
2nd pre-tightening 0,5 daNm
Tightening 2 daNm

8. Vacuum pump (DV6 EURO5 engine)

Figure : B3FB03YD

Reference Description Tightening torque

(1) Screw - Vacuum pump 2 daNm
(2) Screw - Vacuum pump 1,8 daNm

9. Vacuum pump (EP6 engine)

Figure : B3FB040D

Reference Description Tightening torque

(1) Screw - Vacuum pump 0,9 daNm
 B3FB010BP0 IDENTIFICATION - DATA : BRAKING SYSTEM

1. Identification
Diagonally split system.
Disc brakes at the front : The front brake discs are ventilated.
Hub/disc brakes (at the rear) : The rear brake hubs/discs are solid.
Parking brake lever controlled by cables acting on the rear wheels.

2. Data

Figure : B3FM0E3D

2.1. Front brakes

Front brake discs

Type of disc Ventilated brake discs
Special feature ABS Or ABS / ESP
Nominal diameter (mm) 283
Nominal thickness (mm) 26
Minimum thickness (mm) 24
Maximum run-out (mm) 0,05

Front brake calipers

Supplier TEVES
Type FN3 - 60/26
Piston diameter (mm) 60
 Brake linings (Front)
Supplier GALFER
Material G 4032
Nominal thickness 12
Minimum thickness 2

2.2. Rear brakes

Rear brake discs

Type of disc Non-ventilated brake discs
Nominal diameter (mm) 268
Nominal thickness (mm) 12
Minimum thickness (mm) 10
Maximum run-out (mm) 0,05

Rear brake calipers

Supplier TRW
Type C1 38HR - PE
Piston diameter (mm) 38

Brake linings (Rear)

Supplier GALFER
Material G 6349
Nominal thickness 11
Minimum thickness 3

2.3. Brake servo

Brake servo
Supplier TRW TRW
Engine type Except "TU5" Type "TU5"
Diameter ( inch) 10 10,5

2.4. Master cylinder

Master cylinder
Supplier TRW
Diameter of the master cylinder (mm) 23,8

2.5. Hydraulic valve block

Hydraulic valve block

Supplier BOSCH
Type ABS 8.1
8.1 ESP

2.6. Brake fluid

- Type of brake fluid Quantity

Brake fluid DOT 4 1L

2.7. Handbrake

Figure : B3FM0E4D

Adjustment of the parking brake function is via the integral play compensation system located on the secondary
brake control.
The play compensation is done automatically when you operate the activation lever (1).
 CHECK : FRONT BRAKE DISC WEAR - REAR BRAKE DISC -
B3FD45K1
REAR BRAKE DRUM

1. Foreword
This document describes a brake wear checking method, it can be printed, as can the associated methods, at the
request of the customer.

2. Front brake disc check

Follow the operating procedure "removing the wheel", described in the handbook.
Chock the vehicle using an axle stand under the body as close as possible to the jack rest, before detaching the
wheel.

Figure : B3FP7NRD

Measure the thickness of the brake discs on the friction surfaces ; Using a micrometer (Capacity: 0 - 50 mm ).
See table below.

Front discs
Special Nominal diameter of a new disc (In Thickness of a new disc (In Minimum permitted thickness (In
feature mm ) mm ) mm )
Solid disc 247 10 8
Solid disc 247 13 11
Solid disc 247 20,4 18,4
Solid disc 257 20,4 18,4
Solid disc 266 13 11
Ventilated 257 20 18
disc
Ventilated 266 20,4 18,4
disc
 Front discs
Ventilated 266 22 20
disc
Ventilated 280 24 22
disc
Ventilated 280 28 26
disc
Ventilated 281 26 24
disc
Ventilated 283 26 24
disc
Ventilated 284 22 20,2
disc
Ventilated 285 28 26
disc
Ventilated 288 28 26
disc
Ventilated 294 24 22,4
disc
Ventilated 300 24 22
disc
Ventilated 300 32 28
disc
Ventilated 302 26 24
disc
Ventilated 304 28 26
disc
Ventilated 309 32 30
disc
Ventilated 310 32 30
disc
Ventilated 330 30 28
disc
Ventilated 340 30 28
disc

Follow the operating procedure "fitting the wheel" described in the handbook.
Disengage the axle stand before removing the jack.

3. Rear brake disc check

Follow the operating procedure "removing the wheel", described in the handbook.
Chock the vehicle using an axle stand under the body as close as possible to the jack rest, before detaching the
wheel.
Release the handbrake.
Figure : B3FP7NRD

Measure the thickness of the brake discs on the friction surfaces ; Using a micrometer (Capacity: 0 - 50 mm ).
See table below.

Rear discs
Special Nominal diameter of a new disc (In Thickness of a new disc (In Minimum permitted thickness (In
feature mm ) mm ) mm )
Solid disc 247 8 6
Solid disc 249 9 7
hub
Solid disc 268 12 10
hub
Solid disc 272 12 10
Solid disc 274 14 12
Solid disc 280 16 14
Solid disc 290 10 8
Solid disc 290 12 10
Solid disc 290 14 12
Solid disc 300 16 14
Solid disc 302 10 8,4
Ventilated 302 22 20
disc

Follow the operating procedure "fitting the wheel" described in the handbook.
Disengage the axle stand before removing the jack.

4. Rear brake drum check

Follow the operating procedure "removing the wheel", described in the handbook.
Chock the vehicle using an axle stand under the body as close as possible to the jack rest, before detaching the
wheel.
Release the handbrake.
Remove the brake drum (Refer to the corresponding annexed method ).

Figure : B3FP7NSD

Measure the internal diameter of the brake drums on the friction surface ; Using sliding calipers (Capacity: 250
mm ; Accuracy : 1/10).
See table below.

Rear brake drum

Drum Nominal diameter of a new drum (In mm ) Maximum permitted diameter (In mm )
7’’ 180 182
8’’ 203 204,4
9’’ 228,6 229,8
10’’ 254,15 256

Refit the brake drum (Refer to the corresponding annexed method ).

Follow the operating procedure "fitting the wheel" described in the handbook.
Disengage the axle stand before removing the jack.
 B3FD46P0 CHECKS : BRAKE FLUID

URGENT : Ensure that the precautions relating to safety and cleanliness are adhered
to .

CAUTION : Brake fluid is toxic. Avoid contact with the skin and the eyes. In the event of contact
with the eyes, rinse them immediately with copious amounts of water for several minutes.

CAUTION : Brake fluid is highly corrosive to paintwork. If any is projected onto the bodywork,
clean the surface immediately.

1. Tooling

Brake fluid tester (*)

Make Reference Type
SURETEST TLF Measures the boiling point of the brake fluid
DOW AUTOMOTIVE BETATEST
FACOM TOOLS DF.16
EBT 06.1 Measures the specific gravity of the brake fluid

(*) Non-exhaustive list, refer to the catalogue "Tools and Equipment".

2. Checks
Remove the brake fluid reservoir filter.

URGENT : Any contamination of the brake fluid is forbidden. The brake fluid should be clear
and free from sediments or floating substances.

Check the fluid, following the instructions provided by the equipment supplier.

Checking values
Brake fluid Boiling point (minimum humidity)
DOT 3 140 °C
DOT 4 155 °C
SUPER DOT 4 180 °C
DOT 5 180 °C

N.B. : If the value checked is lower than the value for the "minimum humidity" boiling point, or
within a tolerance of + 10 % of this value, replace the brake fluid (see the relevant operation).

URGENT : Use only approved and recommended hydraulic fluids.

 B3FF0105P0 ADJUSTMENT : HANDBRAKE

URGENT : Observe the safety and cleanliness instructions .

Raise and support the vehicle, with the rear wheels hanging free.
Before adjusting the parking brake :
• Check that all the parking brake cables are routed correctly
• Check that the cables are not constrained (incorrect hooking of inner or outer cables, incorrect adjustment)
• Check that all the parts making up the parking brake control slide correctly and have the correct travel

Remove the centre console.

Figure : C5FM0LLD

Position the parking brake lever in the released position.

Press on the unlocking push (2) (in the direction of the arrow).
While maintaining the pressure on the unlocking push (2), move the integral play compensation activation lever by
a quarter turn (1) (in the direction of the arrow).
Release the unlocking push (2).
Move the integral play compensation activation lever by a quarter turn (1) (In the opposite direction ).
Press several times on the brake pedal.
Pull the parking brake lever hard 10 or so times.
Press on the unlocking push (2) (in the direction of the arrow).
While maintaining the pressure on the unlocking push (2), move the integral play compensation activation lever by
a quarter turn (1) (in the direction of the arrow).
Release the unlocking push (2).
Move the integral play compensation activation lever by a quarter turn (1) (In the opposite direction ).
Check that the handbrake warning lamp comes on from the first notch of the total travel of the handbrake lever .
With the handbrake released, check that the wheels can be turned freely by hand.
Fit :
• The centre console
 • The vehicle to its wheels

Check the effectiveness of the handbrake.

 B3FG013CP0 REMOVAL - REFITTING : FRONT BRAKE DISC

URGENT : Observe the safety and cleanliness instructions .

1. Removal
Slacken the wheel bolts.
Lift and support the front of the vehicle.
Take down :
• The front wheel bolts
• The front wheels

The brake pads .

Figure : B3FP7QVD

Take down :
• The 2 bolts (1)
• The caliper bracket
Figure : B3FP7QWD

Take down :
• The 2 bolts (2)
• The brake disc

2. Cleaning

CAUTION : Do not use compressed air to clean the brakes.

2.1. 1st possibility

Clean the brake caliper disc using a recommended brake cleaning product .
Allow to dry and to drain.
Wipe with a paper cloth.
2.2. 2nd possibility
Use an approved appliance for removing dust (See the Workshop Equipment binder).

3. Refitting

N.B. : At each removal operation : Always replace the 2 bolts (1) ; Coat the 2 new bolts (1) with thread lock.

Fit :
• The brake disc
• The 2 bolts (2) ; Tighten to 1 daN.m
• The caliper bracket

Refit and tighten : The pre-coated new bolts (1).

Method for tightening the bolts (1) :
• Pre-tightening to 3,3 ± 0,3 daN.m
 • Angular tightening to 45 ± 3°

Fit :
• The brake pads
• The front wheels
• The front wheel bolts
• The vehicle on its wheels

Tighten the wheel screws :

• Alloy wheel : Tightening to 9 ± 0,9 daN.m
• Steel wheel : Tightening to 11 ± 1 daN.m

CAUTION : Press the brake pedal several times, smoothly and gradually, engine running, before driving the
vehicle .
 B3FG013DP0 REMOVING - REFITTING : FRONT BRAKE CALIPER

URGENT : Ensure that the precautions relating to safety and cleanliness are adhered to .

1. Removing
Untighten the wheel screws.
Lift and support the vehicle with front wheels suspended.
Remove the front wheels.

Figure : B3FP7QFD

Remove nut (1).

Disconnect the hose union (At " a ").
Plug the brake pipe.
Figure : B3FP7QGD

Disconnect the hose union (At " b ").

Plug the hydraulic unit unions.
Remove :
• The blanks (At " c ")
• The 2 bolts (2)
• The brake pads
• The brake caliper (3)
Figure : B3FP7QHD

Remove :
• The 2 bolts (4)
• The caliper (5) bracket

2. Cleaning

CAUTION : Do not use compressed air to clean the brakes.

2.1. 1st possibility

Clean the brake disc and the brake caliper, using an approved brake cleaning product.
Leave to drain and dry.
Wipe with a paper towel.
2.2. 2nd possibility
Use an approved dedusting instrument (refer to the Material and Equipment Catalogue).
Visually check :
• The seal around the piston
• That the protective gaiters are in good condition and correctly adjusted
• Wear of the brake discs

Replace any defective parts.

3. Refitting

CAUTION : At each removal, systematically replace the screws (2), (4).

Fit : The caliper (5) bracket.

Refit and tighten : The 2 new screws (4).
Bolt (4) tightening sequence :
• Tighten to 3,3 daNm ± 0,3 daNm
• Angular tighten to 45 ± 3 °

Fit :
• The brake pads
• The brake caliper (3)
• The screws pre-coated (2) (New bolts) ; Tighten to 2,7 daNm ± 0,2 daNm
• The blanks (At " c ")

Couple up :
• The brake hose (At " b ") ; Tighten to 1,5 daNm ± 0,3 daNm
• The brake hose (At " a ") ; Tighten to 1,5 daNm ± 0,3 daNm

Bleed the brake system.

Refit the front wheels.
Tighten the wheel screws :
• Alloy wheel : Tightening to 9 ± 0,9 daN.m
• Steel wheel : Tightening to 11 ± 1 daN.m

Check the operation of the brakes.

Check the brake fluid level and top up if necessary.
 B3FG0131P0 REMOVING - REFITTING : FRONT BRAKE PADS

URGENT : Ensure that the precautions relating to safety and cleanliness are adhered to .

1. Recommended tools

Figure : E5AP2X0D

[1] Pliers FACOM D.60A.

2. Removing
Untighten the wheel screws.
Lift and support the vehicle with front wheels suspended.
Remove the front wheels.
Figure : B3FP7QJD

Remove the spring (1).

Figure : B3FP7QKD

Remove :
 • The blanks (In "a")
• The screws (2)

Move aside and suspend the brake caliper (3).

Push the pistons back ; Using the tool [1] (insert a shim between tool [1] and the pad to push the pistons fully back
in their housings).
Check the brake fluid level.
Remove the brake pads.

3. Cleaning

CAUTION : Do not use compressed air to clean the brakes.

3.1. 1st possibility

Clean the brake disc and the brake caliper, using an approved brake cleaning product.
Leave to drain and dry.
Wipe with a paper towel.
3.2. 2nd possibility
Use an approved dedusting instrument (refer to the Material and Equipment Catalogue).

4. Refitting
Visually check :
• The seal around the piston
• That the protective gaiters are in good condition and correctly adjusted
• Wear of the brake discs

Replace any defective parts.

CAUTION : No trace of grease, oil or lubricant can be tolerated on the brake pads.

Fit :
• The new brake pads
• The brake caliper (3)

N.B. : At each removal, systematically replace the screws (2).

Fit :
• The screws pre-coated (2) (New bolts) ; Tighten to 2,7 daNm ± 0,2 daNm
• The blanks (In "a")
• The spring (1)

Check the brake fluid level and top up if necessary.

Fit :
• The front wheels
• The wheel bolts

Return the vehicle to its wheels.

Tighten the wheel screws :
• Alloy wheel : Tightening to 9 ± 0,9 daN.m
• Steel wheel : Tightening to 11 ± 1 daN.m

URGENT : Apply the brakes, with the engine running, several times before driving the vehicle.
 B3FG0134P0 REMOVING - REFITTING : MASTER CYLINDER

URGENT : Observe the safety and cleanliness instructions .

1. Removing

Figure : B1BM14WD

Disconnect the positive lead from the battery.

Unclip and move aside : The fuse box (2).
Remove the battery style cover (1).
Disconnect the battery negative cable.
Remove :
• The resonator (Depending on engine type)
• The battery
• The battery tray

Drain the braking circuit .

Figure : B3FM0DRD

N.B. : Protect the components under the master cylinder from brake fluid splashes.

Uncouple :
• The click-fit connection (at "c") (beware of escaping fluid)
• The hydraulic clutch circuit supply pipe (At "b") (beware of escaping fluid)
• The hydraulic unions (3) (beware of escaping fluid)

N.B. : Plug the openings using protective plugs.

Disconnect the brake fluid level sensor connector (At "a").

Remove :
• The nuts (4)
• The master cylinder and brake fluid reservoir assembly
Figure : B3FM0DSD

Remove :
• The bolt (6)
• The brake fluid reservoir (5)

2. Refitting

CAUTION : Observe the tightening torque values .

CAUTION : At each removal operation : Always replace the master cylinder seals.

Fit :
• The brake fluid reservoir (5) on the master cylinder
• The bolt (6)
• The master cylinder and brake fluid reservoir assembly
• The nuts (4)

Connect : The brake fluid level sensor connector (At "a").

Recouple :
• The hydraulic unions (3)
• The hydraulic clutch circuit supply pipe (At "b")
• The click-fit connection (at "c")

Fill and drain the clutch hydraulic circuit.

Fit :
• The battery tray
• The battery
• The resonator (Depending on engine type)
Reconnect : The battery negative cable.
Refit the battery style cover (1).
Clip : The fuse box (2).

CAUTION : Perform the operations to be carried out following reconnection of the battery.

Reconnect : The battery positive cable .

Fill and bleed the braking system .
 B3FG0135P0 REMOVING - REFITTING : REAR BRAKE PADS

URGENT : Observe the safety and cleanliness instructions .

1. Recommended tools

Figure : E5AP3RHD

[1] Piston and support nut (-).0805-J2.

[2] Thrust plate (-).0805-J6.
[3] (-).0805-J3 adaptor.

2. Removing
If the brake fluid reservoir is at maximum level, remove its filter and partially drain the reservoir with the aid of a
clean syringe in order to avoid it overflowing.
Untighten the rear wheel bolts.
Slacken the parking brake.
Raise and support the vehicle, with the rear wheels hanging free.
Remove :
• The rear wheel bolts
• The rear wheels
Figure : B3FM0DDD

Remove bolts (1).

Figure : B3FM0DED
 CAUTION : Take care not to damage the hydraulic pipe (2).

Move aside the brake caliper.

Remove :
• The brake pads (3)
• The sound-deadening pads (4)

3. Cleaning

URGENT : Do not use compressed air to clean the brakes.

3.1. 1st possibility

Clean the brake disc and the brake caliper, using an approved brake cleaning product.
Leave to drip dry.
Wipe with a paper towel :
• The brake disc
• The brake caliper

3.2. 2nd possibility

Use dedusting equipment approved by the manufacturer .

4. Refitting
Visually check :
• The sealing around the brake caliper piston
• The condition and perfect fitting of the piston sealing gaiters
• Wear of the brake discs

CAUTION : No trace of grease, oil or lubricant can be tolerated on the brake pads.

Replace any defective parts.

Figure : B3FM0DJD

Turn and push back : The brake caliper piston (Rear) (Clockwise) ; Using the tools [1], [2], [3].
Watch the level of the brake fluid.

CAUTION : The sound deadening pads (4) must be changed when replacing the brake pads (3).

Fit :
• The sound-deadening pads (4)
• The brake pads (3)

Position the brake caliper.

CAUTION : At each removal, systematically replace the screws (1).

Fit new screws (5) ; Tighten to 3,5 daNm ± 0,3 daNm.

Fit :
• The rear wheels
• The rear wheel bolts
• The vehicle to its wheels

Tighten the wheel bolts (Rear) :

• Alloy wheel : Tightening to 9 ± 0,9 daN.m
• Steel wheel : Tightening to 11 ± 1 daN.m

CAUTION : Apply the brakes several times, gently and progressively, with the engine running, before driving
the vehicle.

Check the brake fluid level and top up if necessary.

Check that the parking brake operates correctly.
 REMOVING - REFITTING : STOP LAMP SWITCH
B3FG0139P0
CONNECTION

URGENT : Ensure that the precautions relating to safety and cleanliness are adhered to .

1. Removing

Figure : C5FM0LKD

Remove the trim under the fascia (1).

Disconnect the connector (In "a").
Turn the brake light switch (2) anticlockwise to unlock it.
Remove : The stoplamp switch (2).

2. Refitting