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© Renault s.a.s. 2005 "The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed." All copyrights reserved by Renault. The reproduction or translation in part of whole of the present document, as well as the use of the spare parts reference numbering system, are prohibited without the prior written consent of Renault. 77 11 322 082 JUNE 2003 Edition Anglaise X84, and J84 6 Air conditioning 61A HEATING 62A AIR CONDITIONING 62B CLIMATE CONTROL 62C MANUAL AIR CONDITIONING

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Page 1: fgf gdf gf

© Renault s.a.s. 2005

"The repair methods given by the manufacturer in this document are based on the technicalspecifications current when it was prepared.

The methods may be modified as a result of changes introduced by the manufacturer in theproduction of the various component units and accessories from which his vehicles areconstructed."

All copyrights reserved by Renault.

The reproduction or translation in part of whole of the present document, as well as the useof the spare parts reference numbering system, are prohibited without the prior writtenconsent of Renault.

77 11 322 082 JUNE 2003 Edition Anglaise

X84, and J84

6 Air conditioning

61A HEATING

62A AIR CONDITIONING

62B CLIMATE CONTROL

62C MANUAL AIR CONDITIONING

Page 2: fgf gdf gf

Scénic II - Section 6

Contents

Page

Scénic II - Section 6ContentsPage

61A HEATING

General information 61A-1

Parts description 61A-2

Front air distribution duct: Removal - Refitting 61A-4

Central air distribution duct: Removal - Refitting 61A-6

Rear air distribution duct: Removal - Refitting 61A-7

Control panel: Removal - Refitting 61A-10

Control panel: Connection 61A-14

Recirculation control cable: Removal - Refitting 61A-15

Air distribution cable: Removal - Refitting 61A-19

Air mixing cable: Removal - Refitting 61A-23

Air distribution unit: Removal - Refitting 61A-24

Heater matrix: Removal - Refitting 61A-25

Fan assembly: Removal - Refitting 61A-29

Passenger compartment fan assembly control unit: Removal - Refitting 61A-30

Heating resistor unit: Removal - Refitting 61A-31

Heating resistor relays: Removal - Refitting 61A-35

62A AIR CONDITIONING

General information 62A-1

Maintenance 62A-2

Parts description 62A-4

Consumables 62A-6

Safety advice 62A-7

Air conditioning: Check 62A-8

Coolant circuit check 62A-10

Cabin filter: Removal - Refitting 62A-12

Condenser: Removal - Refitting 62A-13

Dehydration canister: Removal - Refitting 62A-15

Compressor: Removal - Refitting 62A-16

Calibrated opening: Removal - Refitting 62A-18

Connection bracket 62A-19

Evaporator: Removal - Refitting 62A-22

Condenser - compressor connecting pipe: Removal - Refitting 62A-24

Condenser - evaporator connecting pipe: Removal - Refitting 62A-25

Dehydration canister - evaporator connecting pipe: Removal - Refitting 62A-28

Page 3: fgf gdf gf

Contents

Dehydration canister - compressor connecting pipe: Removal - Refitting 62A-30

Pressure sensor: Removal - Refitting 62A-32

62B CLIMATE CONTROL

Operating principle 62B-1

Parts description 62B-3

Control panel: Removal - Refitting 62B-4

Control panel: Connection 62B-8

Power module: Removal - Refitting 62B-10

Recirculation motor: Removal - Refitting 62B-12

Mixer motor: Removal - Refitting 62B-13

Distribution motor: Removal - Refitting 62B-15

Passenger compartment temperature sensor: Removal - Refitting 62B-17

External temperature sensor: Removal - Refitting 62B-19

Insolation sensor: Removal - Refitting 62B-21

62C MANUAL AIR CONDITIONING

Parts description 62C-1

Control panel: Removal - Refitting 62C-2

Control panel: Connection 62C-6

62A AIR CONDITIONING

Page 4: fgf gdf gf

61A-1

HEATINGGeneral information 61A

Rear seat footwell heater vent104758

1 12

33

4 55 2

(1) Side vents

(2) Side window demisting vents

(3) Windscreen demister outlets

(4) Central air vents

(5) Footwell heater outlet

104148

Page 5: fgf gdf gf

61A-2

HEATINGParts description 61A

Air distribution ducts

Heating unit

102222

12

3 4

5

6

(1) Right rear footwell air duct

(2) Right intermediate duct

(3) Right front footwell air duct

(4) Left front footwell air duct

(5) Left intermediate duct

(6) Left rear footwell air duct

107379

7

8

9

10

11

12

13

(7) Passenger compartment filter

(8) Heating resistor unit

(9) Heater radiator

(10) Heater radiator pipe

(11) Power module

Page 6: fgf gdf gf

61A-3

HEATINGParts description 61A

(12) Distribution unit

(13) Engine cooling fan

Page 7: fgf gdf gf

61A-4

HEATINGFront air distribution duct: Removal - Refitting

DG

61AREMOVAL

Remove the lower trim (see 57A Interior equip-ment ).

Unclip at (1) .

Disconnect the air duct at (2) then (3) .

Remove the glovebox (see 57A Interior equipment).

Unclip at (4) .

Disconnect the air duct at (5) then (6) .

REFITTING

Proceed in the reverse order to removal.

104102

104103

3

2

1

54

6

Page 8: fgf gdf gf

61A-5

HEATINGFront air distribution duct: Removal - Refitting

DD

61AREMOVAL

Remove the lower trim (see 57A Interior equip-ment ).

Unclip at (1) .

Disconnect the air duct at (2) then (3) .

Remove the glovebox (see 57A Interior equipment).

Unclip at (4) .

Disconnect the air duct at (5) then (6) .

REFITTING

Proceed in the reverse order to removal.

104394

104393

3 21

654

Page 9: fgf gdf gf

61A-6

HEATINGCentral air distribution duct: Removal - Refitting 61A

Operations are symmetrical for both sides of the vehi-cle.

REMOVAL

Disconnect the battery, starting with the negativeterminal.

Remove the front seat ( (see 75A, Front seat fra-mes and runners) ).

Remove:

- the front air distribution duct (see 61A, Heating,Front air distribution duct: Removal - Refitting,page 61A-4) ,

- the carpet (partially).

Remove the protector (1) .

Extract the intermediate air distribution duct (2) fromthe rear air distribution duct (3) by tilting it towardsthe interior.

REFITTINGProceed in the reverse order to removal.

Equipment required

diagnostic tool

IMPORTANT

Before carrying out any wok on a safety systemcomponent, lock the air bag computer using the(diagnostic tool) (see 88C, Air bag and preten-sioner, Air bag computer locking procedure ).When this function is activated, all the triggerlines are inhibited and the air bag warning lighton the instrument panel lights up continuously(ignition on).

104219

1

104201

WARNING

Connect the battery, starting with the positive ter-minal; carry out the necessary programming (see80A Battery: removal - refitting ).

2

3

Page 10: fgf gdf gf

61A-7

HEATINGRear air distribution duct: Removal - Refitting 61A

REMOVAL

Disconnect the battery, starting with the negativeterminal.

Remove:

- the driver and front passenger seats ( (see 75A,Front seat frames and runners) ),

- the driver's and passenger front door sill lining(front section) ( (see 71A, Body interior trim) ),

- the driver's and passenger front door sill lining(centre section) ( (see 71A, Body interior trim) ),

- the driver's and passenger under-seat storagecompartments ( (see 71A, Body interior trim) ).

Unclip the retaining pin (1) (depending on the sidebeing removed).

Partially remove the front carpet.

Unclip the side trim (2) .

Equipment required

diagnostic tool

IMPORTANT

Before carrying out any work on a safety systemcomponent, lock the air bag computer using the(diagnostic tool) (see 88C, Air bag and preten-sioner, Air bag computer locking procedure ).When this function is activated, all the triggerlines are inhibited and the air bag warning lighton the instrument panel lights up continuously(ignition on).

104148

104217

104219

Note:

An aerial is clipped on the driver's side trim(depending on equipment level).

1

2

Page 11: fgf gdf gf

61A-8

HEATINGRear air distribution duct: Removal - Refitting 61A

Unclip the front half-floor (3) .

Unclip the seat connector from the clip.

Remove the mounting bolts (4) .

Remove the attachment (5) .

Lift the rear air distribution duct (6) .

Extract the rear air distribution duct (6) from the in-termediate air distribution duct (7) .

Remove the attachment (8) .

Lift the rear air distribution duct (9) .

Extract the rear air distribution duct (9) from the in-termediate air distribution duct (10) .

104209

104221

Note:

Depending on the equipment level, the ventila-tion ducts may mean the seat height adjuster hasto be removed.

3

44

104201

104200

7

65

10

9

8

Page 12: fgf gdf gf

61A-9

HEATINGRear air distribution duct: Removal - Refitting 61A

REFITTING

Proceed in the reverse order to removal.

WARNING

Connect the battery, starting with the positive ter-minal; carry out the necessary programming (see80A, Battery: removal - refitting ).

IMPORTANT

Unlock the air bag computer using the fault fin-ding tool (see 88C, Air bag and pretensioners,Air bag computer locking procedure ).

Page 13: fgf gdf gf

61A-10

HEATINGControl panel: Removal - Refitting 61A

REMOVAL

Disconnect the battery starting with the negative ter-minal.

Remove the gear lever knob.

Remove the spring (1) .

Unclip the gear lever gaiter.

Unclip the upper trim from the gear lever.

Disconnect the connector.

Special tooling required

Ms. 1639 Tool for removing radio- CD player

Ms. 1544 Tool for removing Car-minat Becker radio

Ms. 1373 Tool for removing radioor chronotachograph

104030

104031

104032

1

Page 14: fgf gdf gf

61A-11

HEATINGControl panel: Removal - Refitting 61A

Remove the clip using clip removal pliers (on both si-des).

Remove the three bolts.

Unclip the gear lever trim.

Remove (depending on the equipment level):

- the CD changer using tool (Ms. 1639) ,

- the radio-navigation unit using tool (Ms. 1544) ,

- the audio equipment using tool (Ms. 1373) .

Disconnect the various connectors.

Remove the two bolts (2) .

103603

104033

104034

2

Page 15: fgf gdf gf

61A-12

HEATINGControl panel: Removal - Refitting 61A

Carefully unclip the centre plate (the mounting clipsare shown in the diagram below).

Disconnect the various connectors.

Remove the two bolts (3) from the air conditioningcontrol panel.

Tilt the heating control panel.

Remove the control panel by tilting it.

Disconnect the connector (4) from the heating con-trol panel.

104035

103811

104036

104659

3

4

Page 16: fgf gdf gf

61A-13

HEATINGControl panel: Removal - Refitting 61A

Remove the heater control panel cables.

Disconnect at (5) .

Withdraw the bracket (6) .

Remove ball joint (7) .

REFITTING

To refit, proceed in the order of removal.

102011

WARNING

- Do not damage the control cables during theseoperations.

- Connect the battery; carry out the necessaryprogramming ( (see 80A, Battery) ).

Note:

- The recirculation control cable is black.

- The distribution control cable is white.

- The mixing control cable is grey.

- The heating control panel control cables do notneed to be adjusted.

5

6 7

Page 17: fgf gdf gf

61A-14

HEATINGControl panel: Connection 61A

102337

B9B1

A6A1

Control panel track Allocation Actuator sensor track

A1 Earth -

A2 Speed 1 control Resistor unit track 1 connector A

A3 Speed 2 control Resistor unit track 2 connector A

A4 Speed 3 control Resistor unit track 3 connector A

A5 Speed 4 control Resistor unit track 4 connector A

A6 Not used -

B1 Fan assembly speed signal 0 UCH

B2 + after ignition feed -

B3 Electric heated rear screen activa-tion request

UCH

B4 Electric heated rear screen war-ning light control

UCH

B5 Earth -

B6 - UCH

B7 - UCH

B8 + after ignition feed -

B9 + side lights feed Lighting dimmer

Page 18: fgf gdf gf

61A-15

HEATINGRecirculation control cable: Removal - Refitting

DG

61A

REMOVAL

Disconnect the battery, starting with the negativeterminal.

Extract the heater control panel (see 61A, Heating,Control panel: Removal - Refitting, page 61A-10).

Remove the lower trim ( (see 57A, Interior acces-sories) ).

Remove the air recirculation cable (black) from theheater control panel.

Disconnect at (1) .

Take out the bracket (2) .

Extract the ball joint (3) .

Unclip the electric wiring harness attached to the ca-sing reinforcement plate.

Remove the five casing reinforcement plate moun-ting bolts (4) .

Unclip at (5) .

Remove the air duct at (6) then at (7) .

Remove the brake pedal assembly (see 37A, Me-chanical component controls ).

Tightening torquesm

casing reinforcementplate mounting bolts

2.1 daNm

Note:

The air recirculation control cable is black.

102011

1

2 3

104118

104102

444

5

6

7

Page 19: fgf gdf gf

61A-16

HEATINGRecirculation control cable: Removal - Refitting

DG

61A

Remove:

- the two mounting bolts (8) ,

- the heater matrix pipes retaining bracket.

Unclip the sheath stop (11) then remove it.

Extract the ball joint (12) .

Remove the air recirculation control cable.

REFITTING

Proceed in the reverse order to removal.

Torque tighten the casing reinforcement platemounting bolts ( 2.1 daNm ) .

104660

Note:

The retaining bracket has a ball joint on its uppersection (9) : to remove it, pull at (1 0) , until itstops against the brake pedal mounting nut, thenpull sharply downwards.

8

9

10

104672

WARNING

Connect the battery, starting with the positive ter-minal; carry out the necessary programming (see80A, Battery, removal - refitting ).

Note:

The cable does not need adjustment.

1112

Page 20: fgf gdf gf

61A-17

HEATINGRecirculation control cable: Removal - Refitting

DD

61AREMOVAL

Disconnect the battery, starting with the negativeterminal.

Extract the heater control panel (see 61A, Heating,Control panel: Removal - Refitting, page 61A-10).

Remove the lower trim ( (see 57A, Interior acces-sories) ).

Remove the air recirculation cable (black) from theheater control panel.

Disconnect at (1) .

Take out the bracket (2) .

Extract the ball joint (3) .

Unclip at (4) .

Disconnect the air duct at (5) then (6) .

Remove the brake pedal assembly (see 37A, Me-chanical components control ).

Note:

The air recirculation control cable is black.

102011

32

1

104393

4 56

Page 21: fgf gdf gf

61A-18

HEATINGRecirculation control cable: Removal - Refitting

DD

61A

Remove:

- the two mounting bolts (7) ,

- the heater matrix pipes retaining bracket.

Unclip the sheath stop (11) then remove it.

Extract the ball joint (12) .

Remove the air recirculation control cable.

REFITTING

Proceed in the reverse order to removal.

104660

Note:

The retaining bracket has a ball joint on its uppersection (8) : to remove it, pull at (9) , until it stopsagainst the brake pedal mounting nut, then pullsharply downwards.

9

8

7

104672

WARNING

Connect the battery, starting with the positive ter-minal; carry out the necessary programming (see80A, Battery: removal - refitting ).

Note:

The cable does not need adjustment.

12

11

Page 22: fgf gdf gf

61A-19

HEATINGAir distribution cable: Removal - Refitting

DG

61A

REMOVAL

Disconnect the battery, starting with the negativeterminal.

Remove the heater control panel (see 61A, Hea-ting, Control panel: Removal - Refitting, page61A-10) .

Remove the lower trim ( (see 57A, Interior acces-sories) ).

Remove the air distribution cable (white) from theheater control panel.

Disconnect at (1) .

Take out the bracket (2) .

Extract the ball joint (3) .

Unclip the electric wiring harness attached to the ca-sing reinforcement plate.

Remove the five casing reinforcement plate moun-ting bolts (4) .

Unclip at (5) .

Disconnect the air duct at (6) then (7) .

Tightening torquesm

casing reinforcementplate mounting bolts

2.1 daNm

Note:

The air distribution control cable is white.

102011

32

1

104118

104102

444

5

7

6

Page 23: fgf gdf gf

61A-20

HEATINGAir distribution cable: Removal - Refitting

DG

61A

Unclip the sheath stop (8) , then extract it.

Extract the ball joint (9) .

Remove the air distribution control cable.

REFITTING

Proceed in the reverse order to removal.

Torque tighten the casing reinforcement platemounting bolts ( 2.1 daNm ) .

104673

WARNING

Connect the battery; carry out the necessary pro-gramming ( (see 80A, Battery) ).

Note:

The cable does not need adjustment.

8

9

Page 24: fgf gdf gf

61A-21

HEATINGAir distribution cable: Removal - Refitting

DD

61AREMOVAL

Disconnect the battery, starting with the negativeterminal.

Remove the heater control panel (see 61A, Hea-ting, Control panel: Removal - Refitting, page61A-10) .

Remove the lower trim ( (see 57A, Interior acces-sories) ).

Remove the air distribution cable (white) from theheater control panel.

Disconnect at (1) .

Take out the bracket (2) .

Extract the ball joint (3) .

Unclip at (4) .

Disconnect the air duct at (5) then (6) .

Unclip the sheath stop (7) , then remove it.

Extract the ball joint (8) .

Remove the distribution control cable.

Note:

The air distribution control cable is white.

102011

32

1

104393

104673

65

4

8

7

Page 25: fgf gdf gf

61A-22

HEATINGAir distribution cable: Removal - Refitting

DD

61AREFITTING

Proceed in the reverse order to removal.

WARNING

Connect the battery; carry out the necessary pro-gramming ( (see 80A, Battery) ).

Note:

The cable does not need adjustment.

Page 26: fgf gdf gf

61A-23

HEATINGAir mixing cable: Removal - Refitting 61A

REMOVAL

Extract the heater control panel (see 61A, Heating,Control panel: Removal - Refitting, page 61A-10).

Remove:

- the lower trim (left-hand drive) ( (see 57A, Interioraccessories) ),

- the glovebox (right-hand drive) ( (see 57A, Interioraccessories) ;).

Remove the (grey) cable from the heater control pa-nel.

Disconnect at (1) .

Take out the bracket (2) .

Extract the ball joint (3) .

Unclip the sheath stop (4) then rotate it to remove it.

Extract the ball joint (5) .

Remove the mixing control cable.

REFITTINGProceed in the reverse order to removal.

Note:

The air mixing control cable is grey.

102011

32

1104661

Note:

The cable does not need adjustment.

4

5

Page 27: fgf gdf gf

61A-24

HEATINGAir distribution unit: Removal - Refitting 61A

REMOVAL

Remove:

- the dashboard ( (see 57A, Interior accessories) ),

- the passenger compartment reinforcement crossmember ( (see 42A, Upper front structure) ),

- the air distribution unit.

REFITTING

To refit, proceed in the reverse order of removal.Equipment required

diagnostic tool

IMPORTANT

Before doing any work on safety system compo-nents, lock the airbag computer using the (dia-gnostic tool) ( (see 88C, Airbag andPretensioners) ). When this function is activated allthe trigger lines are inhibited and the airbag war-ning light on the instrument panel lights up conti-nuously (ignition on).

104115

IMPORTANT

Unlock the computer using the (diagnostic tool)( (see 88C, Airbag and Pretensioners) ).

WARNING

Connect the battery; carry out the necessary pro-gramming ( (see 80A, Battery) ).

Page 28: fgf gdf gf

61A-25

HEATINGHeater matrix: Removal - Refitting

DG

61A

REMOVAL

Fit a hose clamp on each water hose at the bulkheadin the engine compartment.

Remove the lower trim (1) ( (see 57A, Interior ac-cessories) ).

Unclip at (2) .

Disconnect the air duct at (3) then at (4) .

Remove:

- the five mounting bolts (5) ,

- the dashboard cross member reinforcement plate.

Special tooling required

Ms. 554-07 Cooling system testerkit (complete)

Tightening torquesm

dashboard cross mem-ber reinforcement platemounting bolts

2.1 daNm

104028

1

104102

104118

4

3

2

555

Page 29: fgf gdf gf

61A-26

HEATINGHeater matrix: Removal - Refitting

DG

61A

Remove:

- the heater radiator pipe clamp bolts (6) ,

- the heater radiator - air distribution unit mountingbolts (7) .

Put a protective cover on the carpet.

Remove the two heater radiator jubilee clip bolts (9) .

Put a container in place to collect the coolant.

Remove:

- the heater radiator and its pipes,

- the heater radiator jubilee clips.

Remove:

- the heater radiator pipes by pulling them towardsthe front of the vehicle,

- the heater radiator.

REFITTING

Be sure to replace the radiator seals.

Proceed in the reverse order to removal.

Torque tighten the dashboard cross member rein-forcement plate mounting bolts ( 2.1 daNm ) .

Perform the following operations:

- fill up,

- bleed the cooling circuit (see 19A, Cooling ).

Check the sealing using tool (Ms. 554-07) .

104110

Note:

Unlock the clamp (8) , then lift it to take it out ofthe heating unit.

6

7

8

104109

9

Page 30: fgf gdf gf

61A-27

HEATINGHeater matrix: Removal - Refitting

DD

61A

REMOVAL

Fit a hose clamp on each water hose at the bulkheadin the engine compartment.

Remove the glovebox ( (see 57A, Interior accesso-ries) ).

Unclip at (1) .

Disconnect the air duct at (2) then at (3) .

Remove:

- the five mounting bolts (4) ,

- the dashboard cross member reinforcement plate.

Special tooling required

Ms. 554-07 Cooling system testerkit (complete)

Tightening torquesm

dashboard cross mem-ber reinforcement platemounting bolts

2.1 daNm

104393

321

104118

444

Page 31: fgf gdf gf

61A-28

HEATINGHeater matrix: Removal - Refitting

DD

61A

Put a protective cover on the carpet.

Remove:

- the heater radiator pipe clamp bolts (5) ,

- the heater radiator - air conditioning unit mountingbolts (6) ,

- the two heater radiator jubilee clip bolts (7) .

Put a container in place to collect the coolant.

Remove:

- the heater radiator and its pipes,

- the heater radiator jubilee clips.

Remove:

- the heater radiator ducts by pulling them towardsthe front of the vehicle,

- the heater radiator.

REFITTING

Be sure to replace the radiator seals.

Proceed in the reverse order to removal.

Torque tighten the dashboard cross member rein-forcement plate mounting bolts ( 2.1 daNm ) .

Perform the following operations:

- fill up,

- bleed the cooling circuit (see 19A, Cooling ).

Check the sealing using tool (Ms. 554-07) .

104660

Note:

Unlock the clamp (8) , then lift it to take it out ofthe heating unit.

6

7

5

8

Page 32: fgf gdf gf

61A-29

HEATINGFan assembly: Removal - Refitting 61A

REMOVAL

Disconnect the battery starting with the negative ter-minal.

Remove the dashboard ( (see 57A, Interior acces-sories) ).

Remove:

- the two mounting bolts (1) ,

- the fan assembly connection (2) .

Pull the tab (3) .

Remove the fan assembly by lifting it.

REFITTINGTo refit, proceed in the reverse order of removal.

104114

WARNING

Connect the battery; carry out the necessary pro-gramming ( (see 80A, Battery) ).

1

23

Page 33: fgf gdf gf

61A-30

HEATINGPassenger compartment fan assembly control unit: Removal - Refitting 61A

REMOVAL

Disconnect the battery( (see Battery : Removal -Refitting) .

Remove the dashboard( (see Dashboard: Remo-val - Refitting) .

Remove the mounting bolt (1) .

Press on the bracket (2) .

Remove the air conditioning blower resistor unit (3)from its housing.

Move the wiring harness slightly to one side.

Remove:

- the connector on the blower unit,

- the passenger compartment blower resistor unit.

REFITTING

Refit:

- the passenger compartment blower resistor unit,

- the connector on the blower unit.

Refit the dashboard( (see Dashboard: Removal -Refitting) .

Connect the battery( (see Battery : Removal - Re-fitting) .

104671

Page 34: fgf gdf gf

61A-31

HEATINGHeating resistor unit: Removal - Refitting

DG

61A

REMOVAL

Disconnect the battery, starting with the negativeterminal.

Remove the lower trim (1) ( (see 57A, Interior ac-cessories) ).

Remove:

- the heating resistor unit connector (2) ,

- the two mounting bolts (3) .

Extract the heating resistor unit.

Tightening torquesm

heating resistor unitmounting bolts

0.2 daNm

104028

1

104662

102340

23

Page 35: fgf gdf gf

61A-32

HEATINGHeating resistor unit: Removal - Refitting

DG

61AREFITTING

Proceed in the reverse order to removal.

Torque tighten the heating resistor unit mountingbolts ( 0.2 daNm ) .

WARNING

Connect the battery; carry out the necessary pro-gramming ( (see 80A, Battery) ).

Page 36: fgf gdf gf

61A-33

HEATINGHeating resistor unit: Removal - Refitting

DD

61A

REMOVAL

Disconnect the battery starting with the negative ter-minal.

Remove the glove compartment (1) ( (see 57A, Inte-rior accessories) ).

Remove:

- the heating resistor unit connector (2)

- the two mounting bolts (3)

Remove the heating resistor unit.

Tightening torquesm

heating resistor unitmounting bolts to torque

0.2 daNm

104308

1

104662

102340

23

Page 37: fgf gdf gf

61A-34

HEATINGHeating resistor unit: Removal - Refitting

DD

61AREFITTING

To refit, proceed in the reverse order to removal.

Tighten the heating resistor unit mounting boltsto torque ( 0.2 daNm ) .

WARNING

Connect the battery; carry out the necessary pro-gramming ( (see 80A, Battery) ).

Page 38: fgf gdf gf

61A-35

HEATINGHeating resistor relays: Removal - Refitting

DG

61A

The heating resistors can be accessed from under-neath the dashboard.

REMOVALDisconnect the battery starting with the negative ter-minal.

Remove the gear lever knob.

Remove the spring (1) .

Unclip the gear lever gaiter.

Unclip the upper trim from the gear lever.

Disconnect the connector.

Special tooling required

Ms. 1639 Tool for removing radio- CD player

Ms. 1544 Tool for removing Car-minat Becker radio

Ms. 1373 Tool for removing radioor chronotachograph

104030

104031

104032

1

Page 39: fgf gdf gf

61A-36

HEATINGHeating resistor relays: Removal - Refitting

DG

61A

Remove the clip using clip removal pliers (on both si-des).

Remove the three bolts.

Unclip the gear lever trim.

Remove (depending on equipment level):

- the CD changer using tool (Ms. 1639) ,

- the radio-navigation unit using tool (Ms. 1544) ,

- the audio equipment using tool (Ms. 1373) .

Disconnect the various connectors.

Remove the two bolts (2) .

103603

104033

104034

2

Page 40: fgf gdf gf

61A-37

HEATINGHeating resistor relays: Removal - Refitting

DG

61A

Carefully unclip the centre panel (the fastening clipsare illustrated above).

Disconnect the various connectors.

Remove cover bolts (3) .

Unclip the door sill lining.

104035

103811

103853

104043

3

Page 41: fgf gdf gf

61A-38

HEATINGHeating resistor relays: Removal - Refitting

DG

61A

Unclip the side panel.

Remove the two bolts (4) .

Open the glove compartment beyond its point of re-sistance.

Remove the glove compartment.

Press from inside to unfasten the headlight adjust-ment control.

104044

104045

4

104046

104047

Page 42: fgf gdf gf

61A-39

HEATINGHeating resistor relays: Removal - Refitting

DG

61A

Remove (depending on equipment level):

- both parking brake lever bolts (5) ,

- the coin holder.

Disconnect the connectors.

Remove:

- the bolt (6) ,

- the lower trim under the steering wheel.

Remove fuse box (7) .

Remove the UCH.

104048

104049

5

6

103851

103852

7

Page 43: fgf gdf gf

61A-40

HEATINGHeating resistor relays: Removal - Refitting

DG

61A

Press lug (8) .

Remove the heating resistor relay located behindthe UCH.

REFITTING

To refit, proceed in the reverse order of removal.

104668

WARNING

Connect the battery; carry out the necessary pro-gramming ( (see 80A, Battery) ).

8

Page 44: fgf gdf gf

61A-41

HEATINGHeating resistor relays: Removal - Refitting

DD

61A

REMOVALDisconnect the battery starting with the negative ter-minal.

Remove the gear lever knob.

Remove the spring (1) .

Unclip the gear lever gaiter.

Unclip the upper trim from the gear lever.

Disconnect the connector.

Special tooling required

Ms. 1639 Tool for removing radio- CD player

Ms. 1544 Tool for removing Car-minat Becker radio

Ms. 1373 Tool for removing radioor chronotachograph

104030

104031

104032

1

Page 45: fgf gdf gf

61A-42

HEATINGHeating resistor relays: Removal - Refitting

DD

61A

Remove the clip using clip removal pliers (on both si-des).

Remove the three bolts.

Unclip the gear lever trim.

Remove (depending on equipment level):

- the CD changer using tool (Ms. 1639) ,

- the radio-navigation unit using tool (Ms. 1544) ,

- the audio equipment using tool (Ms. 1373) .

Disconnect the various connectors.

Remove the two bolts (2) .

103603

104033

104034

2

Page 46: fgf gdf gf

61A-43

HEATINGHeating resistor relays: Removal - Refitting

DD

61A

Carefully unclip the centre panel (the fastening clipsare illustrated above).

Disconnect the various connectors.

Remove the front door sill lining (front section).

Remove the side panel.

104035

103811

104308

104309

Page 47: fgf gdf gf

61A-44

HEATINGHeating resistor relays: Removal - Refitting

DD

61A

Remove the two bolts (3) .

Remove both glove compartment bolts (4) .

Remove the two bolts (5) .

Unclip the fuse box from the glove compartment.

104310

104312

3

4

104311

104095

5

Page 48: fgf gdf gf

61A-45

HEATINGHeating resistor relays: Removal - Refitting

DD

61A

Remove:

- the bolt (6) ,

- the UCH (7) .

Remove the heater relay resistor unit (8) by pressingat (9) .

REFITTING

To refit, proceed in the reverse order of removal.

104096

104665

7

6

8

9

WARNING

Connect the battery; carry out the necessary pro-gramming ( (see 80A, Battery) ).

Page 49: fgf gdf gf

62A-1

AIR CONDITIONINGGeneral information 62A

INFORMATION ON THE FLUID

A label in the engine compartment details the specifi-cations of the refrigerant fluid (refer to the « Air condi-tioning - new R134a refrigerant » booklet ).

For retrieval, vacuum extraction and refilling theR134A gas, use only the high-pressure hose from thefilling station.

104112

Note:

- Plugs must be fitted to the disconnected air condi-tioning hoses to prevent moisture from enteringthe system.

- Do not remove the plugs from the replacementparts until last.

- Check for leaks, with the engine running and theair conditioning and blower at their maximum set-tings, during the five minutes following refilling.

- The instructions for adding oil ( (see 62A, Air con-ditioning) ) must be strictly adhered to when workis being carried out on the components of the airconditioning circuit.

- When replacing valves, the tightening torque mustbe adhered to strictly 0.8 daNm .

Page 50: fgf gdf gf

62A-2

AIR CONDITIONINGMaintenance 62A

Recommended annual operations:

- clean and blast the engine cooling condenser and ra-diator,

- to ensure that the cold air blower unit's condensedwater outlet is not blocked.

To check that the refrigerant system has been filled re-gularly, refer to the Warranty and Servicing booklet.

I - AIR CONDITIONING CONTROL ANTI-BACTERIAL CLEANER

Spray the entire aerosol of cleaner, fitted with a no-zzle, through the passenger compartment filter duct.

Leave to work for 15 minutes .

Operate the ventilation fan very slowly for 5 minutes.

Equipment required

filling station

WARNING

It is mandatory to follow the safety instructionswhilst working on the cold circuit( (see Safety ins-tructions)

.

Note:

Treat the air conditioning system with a specialcleaner after each winter period or extendedperiod of non-usage to prevent odour when thesystem is in operation.

WARNING

Spraying the cleaning product through the airinlet is strictly forbidden as it could damage theair conditioning blower.

Page 51: fgf gdf gf

62A-3

AIR CONDITIONINGMaintenance 62A

II - RECOVERING REFRIGERANT FLUID

There are three possible scenarios to consider when recovering refrigerant or checking the refrigerant load:

- the engine and air conditioning work (Scenario A),

- the engine works but not the air conditioning (Sce-nario B),

- neither the engine nor the air conditioning work(Scenario C).

Scenario A:

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

- turn the engine off,

- drain for the first time (note down the original va-lue),

- wait 15 minutes ,

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

- start the draining cycles again if the relative pressu-re is above 0 bar ,

- add together the values of the various drainingoperations, the load is confirmed as being correct ifthe amount of refrigerant is the specified load + 35g or - 100 g .

Scenario B:

- run the engine until the cooling fan assembly is trig-gered twice,

- turn the engine off,

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

- wait 15 minutes ,

- run the engine until the cooling fan assembly is trig-gered twice,

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

- start the draining cycles again if the relative pressu-re is above 0 bar ,

- add together the values of the various drainingoperations, the load is confirmed as being correct ifthe amount of refrigerant is the specified load + 35g or - 100 g .

Scenario C:

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

- wait 2 hours ,

- start the draining cycles again if the relative pressu-re is above 0 bar ,

- add together the values of the various drainingoperations, the load is confirmed as being correct ifthe amount of refrigerant is the specified load + 35g or - 100 g .

III - CREATION OF A VACUUM

It is essential to create a sound vacuum before loa-ding, otherwise the air conditioning will be faulty.

There are two scenarios to consider:

- the vacuum should be created immediately afterdraining (scenario A ),

- the creation of a vacuum should be carried out aftera delay of several hours or days (scenario B).

Scenario A:

- the creation of a vacuum lasts 20 minutes .

Scenario B:

- creating the vacuum takes 45 minutes to removeany residual moisture.

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

IV - FILLING

Top up the oil with the recommended type and quan-tity of oil, depending on the work carried out.

Refill the system.

Empty the pipes on the (filling station) .

Check that the system is operating correctly.

Check for leaks.

Note:

- The air conditioning circuit is fitted with a singlerefill valve, some filling equipment requires onlythe use of the high pressure pipe ( refer to thefilling station instructions ).

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

IMPORTANT

These procedures must be followed in order to avoid:

- gas escaping when the circuit is opened,

- damaging the environment by releasing gas intothe atmosphere when the circuit is opened orduring creation of a vacuum.

Page 52: fgf gdf gf

62A-4

AIR CONDITIONINGParts description 62A

103112

19

1

1820

128

17

14

10

7

16

11

9

6

15

13

54

3

2

11

11

11

11

11

(1) Compressor

(2) Condenser

(3) Dehydration canister

(4) Pressure sensor

(5) Sized port pressure relief valve

(6) Evaporator

(7) Passenger compartment fan

(8) Engine cooling fan

(9) Engine radiator

(10) High-pressure fluid

(11) Low-pressure vapour

Page 53: fgf gdf gf

62A-5

AIR CONDITIONINGParts description 62A

(12) High-pressure vapour

(13) Filler valve

(14) Passenger compartment

(15) Engine compartment

(16) External air

(17) Towards air mixing unit

(18) Scuttle panel

(19) External or recirculated air

(20) Hose bracket on the scuttlepanel

Page 54: fgf gdf gf

62A-6

AIR CONDITIONINGConsumables 62A

Table of vehicle refrigerant capacities according to their engines and various specifications:

Engine Refrigerant capa-city (g)

Type of com-pressor

Type of oil Quantity of oil (inml)

K4J engine

550 g DELPHI 6 CVC135

PLANETELFPAG 488 orSANDEM SP10

150 ml

K4M engine

F4R engine

K9K engine

F9Q engine

Page 55: fgf gdf gf

62A-7

AIR CONDITIONINGSafety advice 62A

The specific gravity of refrigerant fluid is higher thanthat of air and it falls to the ground. This results in a riskof asphyxiation. Consequently, when working on thesystem ensure that there are no pits, wells, ventilationshafts, etc. any nearer than 5 m away, and start up thegas extraction equipment.

At temperatures above 100˚C , caused by a hot spotfor example, the refrigerant fluid decomposes and pro-duces a highly irritant gas.

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

The correct routing of the pipes must be observed.

Ensure that the refrigerant piping is correctly fitted sothat it will not come into contact with metal parts in theengine compartment.

IMPORTANT

The following must be worn when handling refrige-rant fluid:

• gloves,

• protective eyewear (with side shields where possi-ble).

- In the event of refrigerant fluid coming into contactwith the eyes, rinse thoroughly with clean water for15 minutes .

- Keep eyewash available if possible.

- If refrigerant gets into your eyes, consult a doctorimmediately. Inform the doctor that the burns werecaused by refrigerant R134A .

- If the fluid comes into contact with other unprotec-ted parts of the body (even though the safety ins-tructions were followed), rinse thoroughly withclean water for 15 minutes .

IMPORTANT

- Any work involving refrigerant fluid must be carriedout in a well-ventilated area.

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

- Refrigerant fluids are colourless and odourless.

IMPORTANT

It is forbidden to carry out welding or brazing on:

- components of the air conditioning system whenthese are in place,

- the vehicle, due to the risk of overheating a com-ponent of the air conditioning system.

IMPORTANT

- Repairing any faulty components of the air condi-tioning system is strictly prohibited.

- All faulty components must be replaced.

IMPORTANT

Smoking is strictly prohibited in the vicinity of arefrigerant fluid circuit.

Page 56: fgf gdf gf

62A-8

AIR CONDITIONINGAir conditioning: Check

CA or CAREG

62A

Fault finding

The fault finding table applies to all air conditioning sys-tems (automatic or not) and must be used as a referen-ce, since some listed components are not found on allversions in use (refer to specific workshop repair ma-nuals).

The numbers indicate the most common causes offaults (repeated where there is more than one cause):

PRELIMINARY CHECKCheck:

- the battery voltage ( (see 8, Electrical equipment)),

Equipment required

diagnostic tool

Components

Symptoms

No cold air Air too cold Inefficient

operation

Fuses 1 - -

Air distribution 1 1 -

Air flow 1 - 1

Recirculation flap - - 1

Passenger compartment fan - - 1

Lack of refrigerant 1 - 2

Compressor belt (condition or tension) 2 - 2

Wiring harness assembly 3 - 2

Sensor signal 4 2 3

Pressure sensor 4 3 4

Cooling fan - - 4

Compressor clutch relay 5 - -

Compressor clutch 5 - -

Compressor 5 - 5

Expansion valve 5 - 5

Dehydration canister - - 5

Control panel 6 4 6

IMPORTANT

Be sure to follow the safety instructions (see 62A,Air conditioning, Safety advice, page 62A-7) .

WARNING

Be sure to follow the cleanliness instructions( (seePrecautions) .

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62A-9

AIR CONDITIONINGAir conditioning: Check

CA or CAREG

62A- the cleanliness of the passenger compartment filter(see 62A, Air conditioning, Cabin filter: Remo-val - Refitting, page 62A-12) .

CHECK THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM

Start the engine.

Switch on the air conditioning control or activate thesupply to the compressor clutch directly.

Turn the cold air control to its maximum setting.

Switch the air distribution control to the centre andside vents, and activate air recirculation mode.

Close all the vents except one side air vent.

Activate the highest ventilation speed.

Check that the vent outlet temperature is below 10˚Cin approximately 1 min , at an ambient temperatureof 25˚C .

SYSTEM IDENTIFICATIONIdentify the vehicle's air conditioning system (readthe family, program number, etc.), using the (dia-gnostic tool) .

Consult the fault finding documents relevant to thesystem identified.

Page 58: fgf gdf gf

62A-10

AIR CONDITIONINGCoolant circuit check 62A

Leak screening table

There are two types of device for detecting leaks:

- electronic sensors,

- tracer detectors.

I - ELECTRONIC DETECTORS

This device is used to measure variations in thequantity of refrigerant in the air: it emits an audiblesignal depending on the extent of the variation.

The device must be initialised before the check is carried out. To do this:

- immobilise the device,

- calibrate the device at one point in the compart-ment.

This point then acts as a scale for detecting rates ofcontamination.

This device is highly sensitive: when a leak is detec-ted, only follow the line of the circuit as closely aspossible to limit variations due to other gases.

This device only detects relatively substantial leaks.

II - TRACER DETECTORS

Leak detection by tracer involves adding a dye to therefrigerant and locating the points where fluid isbeing lost using an ultraviolet light.

Component Detection area Part to be replaced

after first check

Part to be replaced after

filling and second check

Condenser Inlet or outlet Pipes Condenser

Evaporator Connection bracket Pipes Connection bracket and/or evaporator

Compressor Inlet or outlet Pipes Compressor

Dehydrationcanister

Inlet or outlet Pipes Dehydration canister

Note:

Use the electronic detector and then the tracerdetector to check for leaks.

WARNING

Always refer to user instructions for the devicebefore carrying out any work.

WARNING

Make sure that the sensor at the end of the rod iskept extremely clean and in good condition.

IMPORTANT

Safety instructions must be followed when wor-king on the air conditioning circuit (see 62A, Airconditioning, Safety advice, page 62A-7) .

WARNING

The procedure described must be followed.

Note:

This leak-detection procedure should only beused as a last resor t for « leaks that cannot befound » .

Page 59: fgf gdf gf

62A-11

AIR CONDITIONINGCoolant circuit check 62A

The refrigerant fluid leak-detection procedure isbased on the use of a dye available in the form of athrowaway capsule (1) : leak traces are revealedusing an ultraviolet light (2) .

The dye remains in the air conditioning system.

It is possible to check the condition of the cold loopusing an ultraviolet light without adding a new cap-sule.

If there is nothing to indicate that dye has been used previously (label, etc.):

- place a cloth,

- release a small jet of refrigerant through the twovalves,

- shine the ultraviolet light inside the valves,

- check for fluorescent traces.

Add a measure of detection dye if there are no fluo-rescent traces and a label.

Affix a label.

Record the date on which the dye was added.

1 - Adding dye to the circuit

Fit the system for adding the dye to the low-pressurevalve, and using union (3) for vehicles fitted with asingle valve.

Add the dye to the circuit.

Run the air conditioning for approximately 15 minu-tes .

2 - Leak-detection procedure

Carry out an initial check (with the engine stopped)by sweeping the circuit with an ultraviolet light.

Carefully clean the outside of the refrigerant circuit.

Run the air conditioning until the leak can be detec-ted (if no leak is detected, check the condition of theevaporator).

105944

WARNING

It is forbidden to introduce dye into the cold loopif fluorescent traces appear.

1

2

105944

Note:

Use an adjustable mirror wherever access is diffi-cult.

WARNING

After the dye has been used in the refrigerantfluid, it is essential that the reason for using thedye and the date of the operation are marked ona label (provided with the dye capsule). The labelmust be placed near the cold loop filling valves(shock absorber turret) where it is visible.

3

Page 60: fgf gdf gf

62A-12

AIR CONDITIONINGCabin filter: Removal - Refitting 62A

Located in front of the air intake, the cabin filter filtersand cleans the air before it is admitted into the passen-ger compartment.

REMOVAL

Remove the engine covers.

Remove:

- the cabin filter access flap (1) ,

- the passenger compartment filter.

Check for foreign bodies in the passenger compart-ment filter housing, and clean thoroughly if necessa-ry.

REFITTING

Refit:

- the passenger compartment filter,

- the cabin filter access flap.

Refit the engine covers.

106340

Note:

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

Note:

Break the rigid sections of the filter in order toremove it.

Note:

Be sure not to damage the filtering section.

1

Page 61: fgf gdf gf

62A-13

AIR CONDITIONINGCondenser: Removal - Refitting 62A

REMOVAL

Mount the vehicle on a two post lift.

Disconnect the battery, starting with the negativeterminal.

Drain the refrigerant circuit using the (filling station)tool.

Remove:

- the front bumper ( Workshop Repair Manual 371(see 5, Mechanisms and accessories) ),

- the frontal impact cross member ( Workshop Re-pair Manual 371 (see 4, Panelwork) ),

- the upper cross member ( Workshop Repair Ma-nual 371 (see 4, Panelwork) ).

Remove:

- the two air-air heat exchanger air hoses,

- the air-air heat exchanger.

Unscrew the condenser pipe unions (1) .

Disconnect the pipes.

Cap the apertures.

Remove the condenser by lifting its four retainingbrackets (2) .

REFITTINGProceed in the reverse order to removal.

Check that the condenser is properly secured.

Replace the seals.

Lubricate with air conditioning oil to make fittingeasier.

Torque tighten the pipe unions ( 0.8 daNm ) .

Equipment required

filling station

Tightening torquesm

pipe unions 0.8 daNm

F9Q or K9K

104107

Note:

When replacing a condenser, add 30 ml o fapproved oil to the quantity retrieved.

1

2

Page 62: fgf gdf gf

62A-14

AIR CONDITIONINGCondenser: Removal - Refitting 62A

Fill up the refrigerant circuit using the (filling sta-tion) tool.

WARNING

Connect the battery, starting with the positive ter-minal; carry out the necessary programming (seeWorkshop Repair Manual 370 (see 80A, Bat-tery) .

Note:

- Check that the air conditioning is working pro-perly (see Workshop Repair Manual 372,Fault finding ).

- Look for leaks (see 62A, Air conditioning,Coolant circuit check, page 62A-10) .

Page 63: fgf gdf gf

62A-15

AIR CONDITIONINGDehydration canister: Removal - Refitting 62A

REMOVAL

Mount the vehicle on a two post lift.

Disconnect the battery, starting with the negativeterminal.

Drain the refrigerant circuit using the (filling station)tool.

Remove:

- the front bumper ( Workshop Repair Manual 371(see 5, Mechanisms and accessories) ),

- the frontal impact cross member ( Workshop Re-pair Manual 371 (see 4, Panelwork) ),

- the upper cross member ( Workshop Repair Ma-nual 371 (see 4, Panelwork) ).

Unscrew the canister pipe unions (1) .

Disconnect the pipes.

Cap the apertures.

Lift the canister out.

REFITTING

Proceed in the reverse order to removal.

Replace the seals.

Lubricate with approved air conditioning oil to makefitting easier.

Torque tighten the pipe union mounting bolts ( 0.8daNm ) .

Fill up the refrigerant circuit using the (filling sta-tion) tool.

Equipment required

filling station

Tightening torquesm

pipe union mountingbolts

0.8 daNm

104107

11

Note:

When replacing a canister, add 15 ml of appro-ved oil to the quantity retrieved.

WARNING

Connect the battery, starting with the positive ter-minal; carry out the necessary programming (seeWorkshop Repair Manual 370 (see 80A, Bat-tery) ).

Note:

- Check that the air conditioning is working pro-perly (see Workshop Repair Manual 372,Fault finding ).

- Look for leaks (see 62A, Air conditioning,Coolant circuit check, page 62A-10) .

Page 64: fgf gdf gf

62A-16

AIR CONDITIONINGCompressor: Removal - Refitting 62A

REMOVAL

Mount the vehicle on a two post lift.

Disconnect the battery, starting with the negativeterminal.

Drain the refrigerant circuit using tool (filling sta-tion) .

Remove:

- the front bumper ( Workshop Repair Manual 371(see 5, Mechanisms and accessories) ),

- the frontal impact cross member ( Workshop Re-pair Manual 371 (see 4, Panelwork) ),

- the upper cross member ( Workshop Repair Ma-nual 371 (see 4, Panelwork) ).

Remove the reinforcement plate (1) .

Remove the accessories belt using the auto tensio-ner at (2) .

Unscrew the compressor pipe unions (3) .

Disconnect the pipes.

Cap the apertures.

Equipment required

filling station

Tightening torquesm

pipe union mountingbolts

0.8 daNm

compressor mountingbolts

2.5 daNm

reinforcement platemounting bolts

2.1 daNm

104119

1

104097

104111

2

3

Page 65: fgf gdf gf

62A-17

AIR CONDITIONINGCompressor: Removal - Refitting 62A

Disconnect the compressor connectors (4) and thepressure sensor connectors (5) .

Remove:

- the three compressor mounting bolts (6) ,

- the compressor.

REFITTING

Proceed in the reverse order to removal.

Replace the seals.

Lubricate with approved air conditioning oil to makefitting easier.

Torque tighten:

- the pipe union mounting bolts ( 0.8 daNm ) ,

- the compressor mounting bolts ( 2.5 daNm ) ,

- the reinforcement plate mounting bolts ( 2.1daNm ) .

Fill up the refrigerant circuit using the (filling sta-tion) tool.

104106

WARNING

Be sure to replace any belt removed (seeWorkshop Repair Manual 370 (see 1, Engineand peripherals) ).

When replacing the belt, be sure to replace thetension wheels and idler pulleys.

5

4

66

WARNING

Connect the battery, starting with the positive ter-minal; carry out the necessary programming (seeWorkshop Repair Manual 370 (see 80A, Bat-tery) ).

Note:

- When replacing the compressor, do not add anyoil.

- Check that the air conditioning is working pro-perly (see Workshop Repair Manual 372,Fault finding ).

- Look for leaks (see 62A, Air conditioning,Coolant circuit check, page 62A-10) .

Page 66: fgf gdf gf

62A-18

AIR CONDITIONINGCalibrated opening: Removal - Refitting 62A

Note:

- The calibrated choke (1) is designed as a part thatcannot be replaced.

- Replace the pipe connecting the condenser to theevaporator if the calibrated choke is faulty ( (see62A, Air conditioning) ).

102128

19330

1

Page 67: fgf gdf gf

62A-19

AIR CONDITIONINGConnection bracket 62A

REMOVAL

Disconnect the battery, starting with the negativeterminal.

Remove the engine covers.

Drain the refrigerant circuit using the (filling station)tool.

Remove:

- the cowl grille (see Workshop Repair Manual 370(see 85A, Wiping - Washing) ),

- the air filter access panel,

- the plenum chamber partition.

Remove the air inlet manifold (see Workshop Re-pair Manual 370, Fuel mixture, Air inlet ).

Unscrew the soundproofing screen mounting (1) .

Unscrew the pipe unions (2) .

Disconnect the pipes.

Cap the apertures.

Equipment required

filling station

Tightening torquesm

connecting flange 0.8 daNm

pipe union mountingbolts

0.8 daNm

F4R or K4J

104120

104105

1

2

Page 68: fgf gdf gf

62A-20

AIR CONDITIONINGConnection bracket 62A

Remove the two connecting flange mounting bolts(3) .

Refit one pipe union bolt to extract the connectingflange.

Remove the evaporator pipe O-rings.

102228

3

Page 69: fgf gdf gf

62A-21

AIR CONDITIONINGConnection bracket 62A

REFITTING

Refit the O-rings on the pipes (4) .

Proceed in the reverse order to removal.

Gradually retighten the two connecting flange moun-ting bolts so that the connecting flange is uniformlyfitted on the pipes.

Check that the contact faces of the seal on the con-necting flange are in good condition.

Replace the seals.

Lubricate with approved air conditioning oil to makefitting easier.

Torque tighten:

- the connecting flange ( 0.8 daNm ) ,

- the pipe union mounting bolts ( 0.8 daNm ) .

Fill up the refrigerant circuit using the (filling sta-tion) tool.

102227

Note:

When replacing a connecting flange, add 10 mlof recommended oil to the quantity of oil retrie-ved.

- Check that the air conditioning is working pro-perly (see Workshop Repair Manual 372,Fault finding ).

- Look for leaks (see 62A, Air conditioning,Coolant circuit check, page 62A-10) .

44

WARNING

Connect the battery, starting with the positive ter-minal; carry out the necessary programming (Workshop Repair Manual 370 (see 80A, Bat-tery) ).

Page 70: fgf gdf gf

62A-22

AIR CONDITIONINGEvaporator: Removal - Refitting 62A

REMOVAL

Disconnect the battery starting with the negative ter-minal.

Drain the refrigerant circuit using tool (filling sta-tion) .

Remove the connection flange ( (see 62A, Air con-ditioning) ).

Fit the plugs into the ports.

Attach hose clamps to the cooling circuit heater ma-trix pipes at the bulkhead.

Remove:

- the heater matrix pipes,

- the dashboard ( (see 57A, Interior accessories) ).

Remove:

- the bolts (1) ,

- the dashboard cross member ( (see 42A, Upperfront structure) ).

Remove:

- the two bolts (2) from the heater matrix pipe brac-ket,

- the bracket.

Put a container in place to collect the coolant.

Remove:

- both heater matrix pipe mounting clips (3) ,

- the pipes from their guides in the distributor hou-sing,

- the air conditioning unit,

- the condensation evacuation pipe,

Equipment required

diagnostic tool

filling station

Tightening torquesm

evaporator unit moun-ting bolts

0.65 daNm

pipe union mountingbolts

0.8 daNm

Note:

The evaporator is supplied mounted in its housing.

IMPORTANT

Lock the computer using (diagnostic tool) ( (see8 , Electrical equipment) ) before carrying outany interventions to the airbag system.

104100

104110

11

2

3

Page 71: fgf gdf gf

62A-23

AIR CONDITIONINGEvaporator: Removal - Refitting 62A

- the cabin filter,

- the control cables (if the vehicle has them),

- the mixing motor (if the vehicle has one),

- the timing motor (if the vehicle has one),

- the recycling motor (if the vehicle has one),

- the fan assembly,

- the heater radiator,

- the electrical resistors or the power module,

- the heating resistor unit and electrical harness.

REFITTINGTo refit, proceed in the reverse order of removal.

Oil the pipe seals with the approved oil.

Tighten to torque:

- the evaporator unit mounting bolts ( 0.65 daNm) ,

- the pipe union mounting bolts ( 0.8 daNm ) ,

Fill the refrigerant circuit using the tool (filling sta-tion) .

Note:

It is essential to refit the electrical harness cor-rectly to avoid any possible damage.

WARNING

Connect the battery; carry out the necessary pro-gramming ( (see 80A, Battery) ).

Note:

- When replacing the evaporator, add 30 ml ofapproved oil to the quantity recovered.

- Check that the air conditioning system is opera-ting correctly (see 62A, Air conditioning, Airconditioning: Check, page 62A-8) .

- Check for leaks (see 62A, Air conditioning,Coolant circuit check, page 62A-10) .

Page 72: fgf gdf gf

62A-24

AIR CONDITIONINGCondenser - compressor connecting pipe: Removal - Refitting 62A

REMOVAL

Mount the vehicle on a two post lift.

Disconnect the battery, starting with the negativeterminal.

Drain the refrigerant circuit using the (filling station)tool.

Remove:

- the front bumper ( Workshop Repair Manual 371(see 5, Mechanisms and accessories) ),

- the frontal impact cross member ( Workshop Re-pair Manual 371 (see 4, Panelwork) ),

- the up per cross member ( Workshop Repair Ma-nual 371 (see 4, Panelwork) ).

Unscrew the condenser pipe union (1) .

Disconnect the pipe.

Cap the condenser aperture.

Unscrew the compressor pipe union (2) .

Disconnect the pipe.

Cap the condenser aperture.

Remove the compressor - condenser connecting pi-pe.

REFITTING

Proceed in the reverse order to removal.

Replace the seals.

Lubricate with approved air conditioning oil to makefitting easier.

Torque tighten the pipe union mounting bolts ( 0.8daNm ) .

Equipment required

filling station

Tightening torquesm

pipe union mountingbolts

0.8 daNm

104107

1

104111

WARNING

Connect the battery, starting with the positive ter-minal; carry out the necessary programming (Workshop Repair Manual 370 (see 80A, Bat-tery) ).

Note:

- When replacing a pipe, add 10 ml of the recom-mended oil to the amount of oil retrieved.

- Check that the air conditioning is working pro-perly ( Workshop Repair Manual 372, Faultfinding ).

- Look for leaks ( (see 62A, Air conditioning) ).

2

Page 73: fgf gdf gf

62A-25

AIR CONDITIONINGCondenser - evaporator connecting pipe: Removal - Refitting 62A

REMOVAL

Mount the vehicle on a two post lift.

Disconnect the battery, starting with the negativeterminal.

Drain the refrigerant circuit using the (filling station)tool.

Remove:

- the front bumper ( Workshop Repair Manual 371(see 5, Mechanisms and accessories) ),

- the cowl grille ( Workshop Repair Manual 370(see 8, Electrical equipment) ),

- the air filter access panel,

- the plenum chamber partition.

Remove the air inlet manifold ( Workshop RepairManual 370 (see 1, Engine and peripherals) ).

Remove the reinforcement plate (1) .

Disconnect the pressostat (2) .

Remove the pressostat.

Equipment required

filling station

Tightening torquesm

pipe union mountingbolts

0.8 daNm

reinforcement platemounting bolts

2.1 daNm

F4R or K4J

104119

104106

1

2

Page 74: fgf gdf gf

62A-26

AIR CONDITIONINGCondenser - evaporator connecting pipe: Removal - Refitting 62A

Unscrew the condenser pipe union (3) .

Disconnect the pipe.

Cap the condenser aperture.

Remove the pipe from the retaining bracket (4) .

Unclip the pipe from the retaining brackets (5) .

Unscrew the bulkhead soundproofing mounting (6) .

Unscrew the pipe union (7) from the connecting flan-ge.

Disconnect the pipe.

Cap the connecting flange aperture.

Remove the condenser - evaporator connecting pi-pe.

104107

104104

34

5

104120

104105

6

7

Page 75: fgf gdf gf

62A-27

AIR CONDITIONINGCondenser - evaporator connecting pipe: Removal - Refitting 62A

REFITTING

Proceed in the reverse order to removal.

Replace the seals.

Lubricate with approved air conditioning oil to makefitting easier.

Torque tighten:

- the pipe union mounting bolts ( 0.8 daNm ) ,

- the reinforcement plate mounting bolts ( 2.1daNm ) .

Fill up the refrigerant circuit using the (filling sta-tion) tool.

Note:

When replacing a pipe, add 10 ml of the recom-mended oil to the amount of oil retrieved.

WARNING

Connect the battery, starting with the positive ter-minal; carry out the necessary programming (seeWorkshop Repair Manual 370 (see 80A, Bat-tery) ).

Note:

- Check that the air conditioning is working pro-perly (see Workshop Repair Manual 372,Fault finding ).

- Look for leaks ( (see 62A, Air conditioning) ).

Page 76: fgf gdf gf

62A-28

AIR CONDITIONINGDehydration canister - evaporator connecting pipe: Removal - Refitting 62A

REMOVAL

Disconnect the battery, starting with the negativeterminal.

Drain the refrigerant circuit using the (filling station)tool.

Remove:

- the cowl grille ( Workshop Repair Manual 370(see 8, Electrical equipment) ),

- the air filter access panel,

- the plenum chamber partition.

Remove the air inlet manifold( (see Air inlet) .

Unscrew the dehydration canister pipe union (1) .

Disconnect the pipe.

Cap the dehydration canister aperture.

Unclip the bulkhead soundproofing (2) .

Unscrew the pipe union (3) .

Disconnect the pipe.

Cap the connecting flange aperture.

Remove the evaporator - dehydration canister con-necting pipe.

REFITTING

Proceed in the reverse order to removal.

Replace the seals.

Equipment required

filling station

Tightening torquesm

pipe union mountingbolts

0.8 daNm

F4R or K4J

104107

1

104120

104105

2

3

Page 77: fgf gdf gf

62A-29

AIR CONDITIONINGDehydration canister - evaporator connecting pipe: Removal - Refitting 62ALubricate with approved air conditioning oil to makefitting easier.

Torque tighten the pipe union mounting bolts ( 0.8daNm ) .

Fill up the refrigerant circuit using the (filling sta-tion) tool.

Note:

When replacing a pipe, add 10 ml of recommen-ded oil to the quantity of oil retrieved.

WARNING

Connect the battery, starting with the positive ter-minal; carry out the necessary programming (seeWorkshop Repair Manual 370 (see 80A, Bat-tery) ).

Note:

- Check that the air conditioning is working pro-perly (see Workshop Repair Manual 372,Fault finding ),

- Look for leaks (see 62A, Air conditioning,Coolant circuit check, page 62A-10) .

Page 78: fgf gdf gf

62A-30

AIR CONDITIONINGDehydration canister - compressor connecting pipe: Removal - Refitting 62A

REMOVAL

Mount the vehicle on a two post lift.

Disconnect the battery, starting with the negativeterminal.

Drain the refrigerant circuit using the (filling station)tool.

Remove the front bumper ( Workshop Repair Ma-nual 371 (see 5, Mechanisms and accessories) ).

Unscrew the canister pipe union (1) .

Disconnect the pipe.

Cap the dehydration canister aperture.

Unscrew the compressor pipe union (2) .

Disconnect the pipe.

Cap the compressor aperture.

Remove the compressor - dehydration canister con-necting pipe.

REFITTINGProceed in the reverse order to removal.

Replace the seals.

Lubricate with the recommended oil to aid fitting.

Torque tighten the pipe union mounting bolts ( 0.8daNm ) .

Equipment required

filling station

Tightening torquesm

pipe union mountingbolts

0.8 daNm

104107

1

104111

Note:

When replacing a pipe, add 10 ml of the recom-mended oil to the amount of oil retrieved.

2

Page 79: fgf gdf gf

62A-31

AIR CONDITIONINGDehydration canister - compressor connecting pipe: Removal - Refitting 62A

Fill up the refrigerant circuit using the (filling sta-tion) tool.

WARNING

Connect the battery, starting with the positive ter-minal; carry out the necessary programming (seeWorkshop Repair Manual 370 (see 80A, Bat-tery) ).

Note:

- Check that the air conditioning is working pro-perly (see Workshop Repair Manual 372,Fault finding ).

- Look for leaks (see 62A, Air conditioning,Coolant circuit check, page 62A-10) .

Page 80: fgf gdf gf

62A-32

AIR CONDITIONINGPressure sensor: Removal - Refitting 62A

REMOVAL

Mount the vehicle on a two post lift.

Disconnect the battery, starting with the negativeterminal.

Remove the front bumper ( Workshop Repair Ma-nual 371 (see 8, Electrical equipment) ).

Disconnect the pressure sensor (1) .

Remove the pressure sensor.

The pressure sensor fitted at the condenser outlet protects the refrigerant circuit.

- low pressure cut off: 2 bar ,

- high pressure cut-off: 27 bar .

The pressure sensor informs the engine injectioncomputer of the refrigerant circuit pressure.

The engine injection computer controls the enginecooling fans according to the refrigerant circuit highpressure and the vehicle speed.

REFITTINGProceed in the reverse order to removal.

Replace the seals.

Torque tighten the pressure sensor ( 0.9 daNm ) .

Tightening torquesm

pressure sensor 0.9 daNm

valve 0.8 daNm

Note:

An automatic closure valve isolates the circuitfrom the atmosphere during removal; do notdrain the refrigerant circuit.

104106

1

82822

WARNING

Connect the battery; carry out the necessary pro-gramming (see Workshop Repair Manual 370(see 80A, Battery) ).

Note:

- Check that the air conditioning is working pro-perly (see Workshop Repair Manual 372,Fault finding ).

- If there is no cold air, look for leaks. (see 62A,Air conditioning, Coolant circuit check, page62A-10) .

- When replacing the valve, torque tighten thevalve ( 0.8 daNm ) .

Page 81: fgf gdf gf

62B-1

CLIMATE CONTROLOperating principle 62B

Only special features of climate control are describedin this section .

For sections not dealt with ( (see 62A, Air conditio-ning) ) and ( (see 62C, Manual air conditioning) ).

I - POWER MODULE

In automatic climate control, there are eight ventilationspeeds.

The fan assembly power module is controlled by a vol-tage modulated by the air conditioning computer.

This control voltage is always 12 V , it is the control si-gnal (square signal) which varies:

- the amplitude and frequency do not change,

- but the cyclic ratio changes.

II - FLAP CONTROL MOTORS

These motors are located in the climate control unit and act on different flaps to direct the flow according to certain criteria:

- the mixer motor (1) is used for mixing the hot and coldair,

- the distribution motor (2) directs the air flow into thepassenger compartment via the vents,

- the recirculation motor (3) allows the air in the pas-senger compartment to be reused by isolating it fromthe external air.

102237

104115

104114

1

2

3

Page 82: fgf gdf gf

62B-2

CLIMATE CONTROLOperating principle 62B

III - PASSENGER COMPARTMENT TEMPERATURE SENSOR

This sensor supplies information on the interior tempe-rature.

It is a negative temperature coefficient thermistor loca-ted behind the rear-view mirror.

IV - EXTERNAL TEMPERATURE SENSOR

It is a negative temperature thermistor located in the ri-ght-hand rear-view mirror.

V - INSOLATION SENSOR

This sensor informs the computer of the intensity of su-nlight to correct the air flow to the air vents.

It is located in the centre of the dashboard.

101716

19398

101624

104069

Page 83: fgf gdf gf

62B-3

CLIMATE CONTROLParts description 62B

AUTOMATIC AIR CONDITIONING CONTROL UNIT

107379

1

2

3

4

5

6

7

(1) Passenger compartment filter

(2) Heating resistor unit

(3) Heater radiator

(4) Heater radiator pipes

(5) Power module

(6) Distribution unit

(7) Engine cooling fan

Page 84: fgf gdf gf

62B-4

CLIMATE CONTROLControl panel: Removal - Refitting 62B

REMOVAL

Disconnect the battery starting with the negative ter-minal.

Remove the gear lever knob.

Remove the spring (1) .

Unclip the gear lever gaiter.

Unclip the upper trim from the gear lever.

Disconnect the connector.

Special tooling required

Ms. 1639 Tool for removing radio- CD player

Ms. 1544 Tool for removing Car-minat Becker radio

Ms. 1373 Tool for removing radioor chronotachograph

Tightening torquesm

climate control panelmounting bolt to torque

0.2 daNm

104030

104031

104032

1

Page 85: fgf gdf gf

62B-5

CLIMATE CONTROLControl panel: Removal - Refitting 62B

Remove the side clip using an unclipping tool Carryout this operation on both sides.

Remove the three bolts.

Unclip the lower trim from the gear lever.

Remove (depending on equipment level):

- the CD changer with tool (Ms. 1639) ,

- the radio-navigation unit using tool (Ms. 1544) ,

- the audio equipment using tool (Ms. 1373) .

Disconnect the various connectors.

Remove the two bolts (2) .

103603

104033

104034

2

Page 86: fgf gdf gf

62B-6

CLIMATE CONTROLControl panel: Removal - Refitting 62B

Carefully unclip the centre plate (the mounting clipsare shown in the diagram below).

Disconnect the various connectors.

Remove both screws (3) from the heater control.

Remove the control panel.

Disconnect the heater control panel connector.

104035

103811

104036

104116

3

Page 87: fgf gdf gf

62B-7

CLIMATE CONTROLControl panel: Removal - Refitting 62B

REFITTING

To refit, proceed in the reverse order of removal.

Tighten the climate control panel mounting boltto torque ( 0.2 daNm ) .

WARNING

Connect the battery; carry out the necessary pro-gramming ( (see 80A, Battery) ).

Note:

- The recirculation control cable is black.

- The distribution control cable is white.

- The mixer cable is grey.

- The cables require no adjustment.

Page 88: fgf gdf gf

62B-8

CLIMATE CONTROLControl panel: Connection 62B

Control panel

101618

21

12-track Blue connector trackA

Allocation Sensor or actuator track

A1 CAN L -

A2 Not used -

A3 Spare -

A4 Insolation sensor supply Track 2 of the insolation sen-sor

A5 Interior temperature sensor supply Track 4 of the interior tempera-ture sensor

A6 Computer earth -

A7 CAN H -

A8 Not used -

A9 + 12 V side lights Protection and switch Unit LHside lights fuse ( 7.5 A )

A10 + 12 V accessories Passenger compartment fuse( 15 A )

A11 + 12 V before ignition Passenger compartment fuse( 20 A )

A12 0 V sensor supply (insolation andinterior temperature)

Track 1 of the insolation sen-sor and track 5 of the interiortemperature sensor

Page 89: fgf gdf gf

62B-9

CLIMATE CONTROLControl panel: Connection 62B

Automatic control panel

Black 18 track connectortrack B

Allocation Sensor or actuator track

B1 Recirculation motor control Track 5 of the recirculationmotor

B2 Not used -

B3 Spare -

B4 Spare -

B5 Spare -

B6 Spare -

B7 Fan assembly module control Track 6 of the passenger com-partment fan assembly module6-track connector

B8 Mixer and distribution motors supply12 V

Track 2 of the mixer and distri-bution motors

B9 Mixer and distribution engine earth -

B10 Recirculation engine earth -

B11 Distribution motor control track 1 of the distribution motor(winding B2)

B12 Distribution motor control Track 6 of the distributionmotor (winding A2)

B13 Distribution motor control Track 3 of the distributionmotor (winding B1)

B14 Distribution motor control Track 4 of the distributionmotor (winding A1)

B15 Mixer motor control Track 1 of the mixer motor(winding B2)

16 B Mixer motor control Track 6 of the mixer motor(winding A2)

B17 Mixer motor control Track 3 of the mixer motor(winding B1)

B18 Mixer motor control Track 4 of the mixer motor(winding A1)

Page 90: fgf gdf gf

62B-10

CLIMATE CONTROLPower module: Removal - Refitting

DG

62BThe power module controls the speed of the blower de-pending on the requirements determined by the auto-matic control.

It can be accessed from underneath the instrument pa-nel.

REMOVAL

Disconnect the battery starting with the negative ter-minal.

Remove the glovebox ( (see 57A, Interior accesso-ries) ) (1) .

Remove the bolt (2) .

Press bracket (3) .

Remove the power module (4) .

REFITTING

To refit, proceed in the reverse order to removal.

104063

1

104117

WARNING

Connect the battery; carry out the necessary pro-gramming ( (see 8, Electrical equipment) ).

2

3

4

Page 91: fgf gdf gf

62B-11

CLIMATE CONTROLPower module: Removal - Refitting

DD

62BREMOVAL

Disconnect the battery starting with the negative ter-minal.

Remove:

- the lower housing ( (see 5, Mechanisms and ac-cessories) ),

- the front air distribution duct (1) ,

- the steering column ( (see 3, Chassis) ).

Disconnect the two connectors.

Remove the bolt (2) .

Press the bracket (3) .

Remove the power module (4) .

REFITTING

To refit, proceed in the reverse order to removal.

104394

1104117

WARNING

Connect the battery; carry out the necessary pro-gramming ( (see 8, Electrical equipment) ).

2

3

4

Page 92: fgf gdf gf

62B-12

CLIMATE CONTROLRecirculation motor: Removal - Refitting 62B

REMOVAL

Disconnect the battery, starting with the negativeterminal.

Remove the dashboard ( Workshop Repair Ma-nual 371 (see 5, Mechanisms and accessories) ).

Remove:

- the connector, (1)

- the two mounting bolts (2) ,

- the mixer motor. (3)

REFITTINGProceed in the reverse order to removal.

104114

WARNING

Connect the battery, starting with the positive ter-minal; carry out the necessary programming (Workshop Repair Manual 370 , see 80A, Bat-tery, Battery: Remove and Refit).

1

2

3

Page 93: fgf gdf gf

62B-13

CLIMATE CONTROLMixer motor: Removal - Refitting

DG

62BREMOVAL

Disconnect the battery, starting with the negativeterminal.

Remove the glovebox ( Workshop Repair Manual371 (see 5, Mechanisms and accessories) ).

Remove:

- the connector, (1)

- the two mounting bolts (2) ,

- the mixer motor. (3)

REFITTING

Proceed in the reverse order to removal.

104113

WARNING

Connect the battery; carry out the necessary pro-gramming ( Workshop Repair Manual 370 (see8, Electrical equipment) ).

1

23

Page 94: fgf gdf gf

62B-14

CLIMATE CONTROLMixer motor: Removal - Refitting

DD

62BREMOVAL

Disconnect the battery, starting with the negativeterminal.

Remove the lower trim ( Workshop Repair Manual371 (see 5, Mechanisms and accessories) ).

Remove:

- the connector (1) ,

- the two mounting bolts (2) ,

- the mixer motor. (3)

REFITTING

Proceed in the reverse order to removal.

104391

WARNING

Connect the battery; carry out the necessary pro-gramming ( Workshop Repair Manual 370 (see8, Electrical equipment) ).

3

1

2

Page 95: fgf gdf gf

62B-15

CLIMATE CONTROLDistribution motor: Removal - Refitting

DG

62BREMOVAL

Disconnect the battery, starting with the negativeterminal.

Remove the glovebox ( Workshop Repair Manual371 (see 5, Mechanisms and accessories) ).

Remove:

- the connector, (1)

- the two mounting bolts (2) ,

- the distribution motor. (3)

REFITTING

Proceed in the reverse order to removal.

104113

WARNING

Connect the battery; carry out the necessary pro-gramming ( Workshop Repair Manual 370 (see8, Electrical equipment) ).

1

2

3

Page 96: fgf gdf gf

62B-16

CLIMATE CONTROLDistribution motor: Removal - Refitting

DD

62BREMOVAL

Disconnect the battery, starting with the negativeterminal.

Remove:

- the lower trim ( Workshop Repair Manual 371(see 5, Mechanisms and accessories) ).

- the front air distribution duct,

- the steering column ( Workshop Repair Manual370 (see 3, Chassis) ).

Remove:

- the connector (1) ,

- the two mounting bolts (2) ,

- the distribution motor. (3)

REFITTING

Proceed in the reverse order to removal.

104113

WARNING

Connect the battery; carry out the necessary pro-gramming ( Workshop Repair Manual 370 (see8, Electrical equipment) ).

3

1

2

Page 97: fgf gdf gf

62B-17

CLIMATE CONTROLPassenger compartment temperature sensor: Removal - Refitting 62B

Location

REMOVAL

Disconnect the battery, starting with the negativeterminal.

Unclip the upper shell.

Unclip the lower shell of the interior rear-view mirror.

Disconnect the passenger compartment temperatu-re sensor connector (1) .

Remove the passenger compartment temperaturesensor.

19398

Note:

The passenger compartment temperature sensor islocated in the lower shell of the interior rear-viewmirror.

101715

101716

101717

Page 98: fgf gdf gf

62B-18

CLIMATE CONTROLPassenger compartment temperature sensor: Removal - Refitting 62B

REFITTING

Proceed in the reverse order to removal.

WARNING

Connect the battery; carry out the necessary pro-gramming ( Workshop Repair Manual 370 (see8, Electrical equipment) ).

Page 99: fgf gdf gf

62B-19

CLIMATE CONTROLExternal temperature sensor: Removal - Refitting 62B

The exterior temperature sensor is located in the doormirror on the right-hand side.

Check the resistance of the temperature sensor

REMOVAL

Remove the reflective glass using tool (Car. 1363) .

Remove the door mirror shell by pressing the lugs(1) .

Unclip the sensor from its mounting.

Cut the wires.

REFITTING

Solder both temperature sensor wires and insulatethem with heat shrink sleeves.

Refit the shell and reflector.

Special tooling required

Car. 1363 Trim removal lever

Approximate tempera-ture (˚C)

Sensor resistance (Ω)

Between 0 and 5 Between 5400 and 6200

Between 6 and 10 Between 4400 and 5400

Between 11 and 15 Between 3700 and 4400

Between 16 and 20 Between 3000 and 3700

Between 21 and 25 Between 2500 and 3000

Between 26 and 30 Between 2100 and 2500

Between 31 and 35 Between 1700 and 2100

Between 36 and 40 Between 1450 and 1700

101622

101623

101624

11

Page 100: fgf gdf gf

62B-20

CLIMATE CONTROLExternal temperature sensor: Removal - Refitting 62B

Page 101: fgf gdf gf

62B-21

CLIMATE CONTROLInsolation sensor: Removal - Refitting 62B

REMOVAL

Disconnect the battery, starting with the negativeterminal.

Remove the insolation sensor from above.

Disconnect the insolation sensor.

REFITTINGProceed in the reverse order to removal.

104069

WARNING

Connect the battery; carry out the necessary pro-gramming ( Workshop Repair Manual 370 (see8, Electrical equipment) ).

Page 102: fgf gdf gf

62C-1

MANUAL AIR CONDITIONINGParts description 62C

Manual climate control unit

107379

9

8

7

3

6

2

5

1

4

(1) Passenger compartment filter

(2) Distribution unit

(3) Heating resistor unit

(4) Heater radiator

(5) Heater radiator pipes

(6) Power module

(7) Passenger compartment fan

(8) Evaporator

(9) Evaporator flange

Page 103: fgf gdf gf

62C-2

MANUAL AIR CONDITIONINGControl panel: Removal - Refitting 62C

REMOVAL

Disconnect the battery starting with the negative ter-minal.

Remove the gear lever knob.

Remove the spring (1) .

Unclip the gear lever gaiter.

Unclip the upper trim from the gear lever.

Disconnect the connector.

Special tooling required

Ms. 1639 Tool for removing radio- CD player

Ms. 1544 Tool for removing Car-minat Becker radio

Ms. 1373 Tool for removing radioor chronotachograph

Tightening torquesm

climate control panelmounting bolt to torque

0.2 daNm

104030

104031

104032

1

Page 104: fgf gdf gf

62C-3

MANUAL AIR CONDITIONINGControl panel: Removal - Refitting 62C

Remove the side clip using clip removal pliers (onboth sides).

Remove the three bolts (2) .

Unclip the gear lever trim.

Remove (depending on the equipment level):

- the CD changer with tool (Ms. 1639) ,

- the radio-navigation unit using tool (Ms. 1544) ,

- the audio equipment using tool (Ms. 1373) .

Disconnect the various connectors.

Remove the two bolts (3) .

103603

104033

2

104034

3

Page 105: fgf gdf gf

62C-4

MANUAL AIR CONDITIONINGControl panel: Removal - Refitting 62C

Carefully unclip the centre panel (the fastening clipsare displayed in the diagram).

Disconnect the various connectors.

Remove both bolts from the heating control panel (4).

Remove the control panel.

Disconnect the heater control panel connector.

104035

103811

104036

104659

4

Page 106: fgf gdf gf

62C-5

MANUAL AIR CONDITIONINGControl panel: Removal - Refitting 62C

Unclip at (5) .

Remove the bracket (6) .

Remove ball joint (7) .

Remove the heater control panel cables.

REFITTING

To refit, proceed in the reverse order of removal.

Tighten the climate control panel mounting boltto torque ( 0.2 daNm ) .

102011

Note:

- The recirculation control cable is black.

- The distribution control cable is white.

- The mixer cable is grey.

- The cables require no adjustment.

WARNING

Connect the battery; carry out the necessary pro-gramming ( (see 80A, Battery) ).

7

6

5

Page 107: fgf gdf gf

62C-6

MANUAL AIR CONDITIONINGControl panel: Connection 62C

CONTROL PANEL

102337

B9

A6

B1

A1

Control panel track Allocation Sensor or actuator track

A1 Earth -

A2 Speed 1 control Resistor unit track 1 connector A

A3 Speed 2 control Resistor unit track 2 connector A

A4 Speed 3 control Resistor unit track 3 connector A

A5 Speed 4 control Resistor unit track 4 connector A

A6 Not used -

B1 Fan assembly speed signal 0 UCH

B2 + after ignition feed -

B3 Request for operation of therear screen de-icer

UCH

B4 Rear screen de-icer opera-tion indicator light control

UCH

B5 Earth -

B6 Air conditioning indicator lightreturn

UCH

B7 Air conditioning request UCH

B8 + before ignition Relay/fuse box

B9 Not used -