Page 101 of 241
86A-4
RADIO
Radio: Removal - Refitting
RADIO NO. 01 or RADIO NO. 03
86A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aSwitch off the ignition.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the radio using two (Ms. 1373) (1) .
aMark the routing of the wiring behind the radio.
aDisconnect the audio equipment connectors.
aMark the routing of the aerial cable behind the radio.
aDisconnect the aerial cable from the radio.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aConnect the aerial cable to the radio.
aClip the aerial cable into the position marked during
removal.
aConnect the radio connectors.
aFit the wiring in the position marked during removal.aRefit the radio.
II - FINAL OPERATION.
aCarry out the necessary operations (see Fault fin-
ding - Replacement of components) (MR 413,
86A, Radio). Special tooling required
Ms. 1373Tool for removing radios or
chronotachographs.
120073
Page 115 of 241

87B-1
PASSENGER COMPARTMENT CONNECTION UNIT
UCH: Removal - Refitting
87B
REMOVAL
I - OPERATION FOR REMOVAL OF PART
CONCERNED
aWhen replacing, carry out the necessary operations
using the Diagnostic tool (see Fault finding - Re-
placement of components) (MR 413, 87B, Pas-
senger compartment connection unit).
a
aLock the airbag computer using the Diagnostic tool
(see Fault finding - Replacement of compo-
nents)(MR 413, 88C, Airbags and seat belt preten-
sioners).
aSwitch off the ignition.
aDisconnect the battery (see 80A, Battery, Battery:
Removal - Refitting, page 80A-2) .aUnclip the dashboard lower trim (1)
aDisconnect the different connectors (2) from the
dashboard lower trim. Equipment required
Diagnostic tool
RIGHT-HAND DRIVE
IMPORTANT
To avoid any risk of triggering when working on
or near a pyrotechnic component (airbags or pre-
tensioners), lock the airbag computer using the
diagnostic tool.
When this function is activated, all the trigger
lines are inhibited and the airbag warning light on
the instrument panel lights up continuously (igni-
tion on).
IMPORTANT
Never handle the pyrotechnic systems (preten-
sioners or airbags) near to a source of heat or
naked flame - they may be triggered.
LEFT-HAND DRIVE
120278
119711
Page 139 of 241

88A-3
WIRING HARNESS
Front left-hand wiring: Removal - Refitting
LEFT-HAND DRIVE
88A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aSwitch off the ignition.
aRemove:
-the battery (see 80A, Battery, Battery: Removal -
Refitting, page 80A-2) ,
-the battery tray (see 80A, Battery, Battery tray:
Removal - Refitting, page 80A-6) ,
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (MR 412, 55A, Exterior
protection),
-the front bumper (see Front bumper: Removal -
Refitting) (MR 412, 55A, Exterior protection),
-the side indicators (see 80B, Headlights, Side in-
dicator: Removal - Refitting, page 80B-13) ,
-the master cylinder (see Master cylinder: Remo-
val - Refitting) (MR 411, 37A, Mechanical compo-
nent controls),
-the brake servo (see Brake servo: Removal - Re-
fitting) (MR 411, 37A, Mechanical component con-
trols),
-the left-hand suspended engine mounting (see
Left-hand suspended engine mounting: Remo-
val - Refitting) (MR 411, 19D, Engine mounting).aUnclip the glovebox.
aRemove the dashboard lower trim.
aDisconnect the cruise control switch connector (1) .
aRemove:
-the bolts (2) IMPORTANT
Consult the safety and cleanliness advice and ope-
ration recommendations before carrying out any
repair (see 88A, Wiring harness, Wiring: Precau-
tions for the repair, page 88A-2) .
Note:
The dashboard does not need to be removed in
order to access the pedal wiring.
119506
CRUISE CONTROL
121212
Page 149 of 241
88A-13
WIRING HARNESS
Engine wiring: Connector access
88A
aR 22 connector (engine harness/automatic trans-
mission connection).
II - ACCESSING THE CONNECTORS
a
aSwitch off the ignition.
aDisconnect the battery (see 80A, Battery, Battery:
Removal - Refitting, page 80A-2) Accessing the R 67 connector
aRemove:
-the engine compartment connection unit cover
bolts (1) ,
-the engine compartment connection unit cover (2) .
aDisconnect the R 67 connector. JH1
122154
IMPORTANT
Consult the safety and cleanliness advice and
operation recommendations before carrying out
any repair (see 88A, Wiring harness, Wiring:
Precautions for the repair, page 88A-2) .
WARNING
To prevent damaging the connectors, consult the
disconnection procedure (see Connector: Dis-
connection and reconnection) (Technical Note
6015A, 88A, Wiring).
121212
121213
Page 152 of 241

88A-16
WIRING HARNESS
Engine wiring: Removal - Refitting
K9K
88A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aSwitch off the ignition.
aRemove:
-the engine cover,
-the battery (see 80A, Battery, Battery: Removal -
Refitting, page 80A-2) ,
-the air filter unit (see Air filter unit: Removal - Re-
fitting) (MR 411, 12A, Fuel mixture),
-the battery tray (see 80A, Battery, Battery tray:
Removal - Refitting, page 80A-6) ,
aRemove:
-the bolts (1) ,
-the cover to the engine compartment connection
unit.II - REMOVAL OPERATION FOR PART
CONCERNED
a IMPORTANT
Consult the safety and cleanliness advice and ope-
ration recommendations before carrying out any
repair (see 88A, Wiring harness, Wiring: Precau-
tions for the repair, page 88A-2) .
121212
WARNING
To prevent any risk of noise, premature wear,
shor t circuits, etc. after the refitting operation,
mark the wiring routing and how to connect the
connectors.
Page 157 of 241

88A-21
WIRING HARNESS
Engine wiring: Removal - Refitting
D4F, and 780
88A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aSwitch off the ignition.
aRemove:
-the engine cover,
-the battery (see 80A, Battery, Battery: Removal -
Refitting, page 80A-2) ,
-the air filter unit (see Air filter unit: Removal - Re-
fitting) (MR 411, 12A, Fuel mixture),
-the battery tray (see 80A, Battery, Battery tray:
Removal - Refitting, page 80A-6) .
aRemove:
-the bolts (1) ,
-the cover to the engine compartment connection
unit.II - REMOVAL OPERATION FOR PART
CONCERNED
a IMPORTANT
Consult the safety and cleanliness advice and ope-
ration recommendations before carrying out any
repair (see 88A, Wiring harness, Wiring: Precau-
tions for the repair, page 88A-2) .
121212
WARNING
To prevent any risk of noise, premature wear,
shor t circuits, etc. after the refitting operation,
mark the wiring routing and how to connect the
connectors.
Page 159 of 241

88A-23
WIRING HARNESS
Engine wiring: Removal - Refitting
D4F, and 780
88A
-the oil vapour recirculation hose reheater connec-
tor (5) ,
-the engine harness/injection wiring connector (6) ,
-the coolant temperature sensor connector (7) ,
-the crankshaft position sensor connector (8) ,
-the oil pressure sensor connector (9) ,
-the alternator connector (10) ,
-the pinking sensor connector (11) ,
-the air temperature sensor connector (12) ,
-the turbocharger pressure sensor connector (13) ,
-the motorised throttle valve connector (14) ,
-the ignition coil connector (15) ,
-the turbocharger solenoid valve connector (16) ,
-the downstream oxygen sensor connector (17) ,
-the reversing lights switch connector (18) ,
-the petrol injection computer connectors (19) ,
-the engine harness/front of engine wiring connec-
tor (20) .
aDisconnect the cooling fan assembly connector (21)
.aDisconnect:
-the engine cooling fan assembly connector (22) ,
-the engine cooling fan assembly resistor connector
(23) .
-the refrigerant fluid pressure sensor connector (24)
,
-the air conditioning compressor connector (25) ,
aRemove:
-the alternator earth wiring nut (26) ,
-the nuts from the starter supply and earth terminals
(27) ,
-the earth wiring nuts on the engine (28) ,
-the earth wiring nut on the front left-hand side
member (29) ,
-the positive battery terminal wiring nut (30) ,
-the negative battery terminal wiring nuts (31) ,
-the wiring mounting nut on the battery protection
fuse board (33) ,
-the engine compartment connection unit supply
terminal nut (32) .
aUnclip:
-the section of wiring on the cylinder head, STANDARD HEATING
122359
AIR CONDITIONING
125249
Page 160 of 241

88A-24
WIRING HARNESS
Engine wiring: Removal - Refitting
D4F, and 780
88A
-the section of wiring on the cylinder block and sub-
frame,
-the section of wiring on the engine cooling fan as-
sembly.
aRemove the engine harness.
REFITTING
I - REFITTING PREPARATION OPERATION
aIf replacing with a complete wiring harness, lock the
unused connectors (see Connectors: Sealing and
locking) (Technical Note 6015A, 88A, Wiring).
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit the engine harness.
aConnect the engine cooling fan assembly connector.
aConnect:
-the air conditioning compressor connector,
-the refrigerant fluid pressure sensor connector,
-the engine cooling fan assembly connector,
-the engine cooling fan assembly resistor connec-
tor.
aConnect:
-the engine harness/front of engine wiring connec-
tor,
-the connectors to the petrol injection computer,
-the reversing lights switch connector,
-the downstream oxygen sensor connector,
-the turbocharger solenoid valve connector,-the ignition coil connector,
-the motorised throttle valve connector,
-the turbocharger pressure sensor connector,
-the air temperature sensor connector,
-the pinking sensor connector,
-the alternator connector,
-the oil pressure sensor connector,
-the crankshaft position sensor connector,
-the coolant temperature sensor connector,
-the engine harness/injection wiring connector,
-the oil vapour recirculation hose reheater connec-
tor,
-the air inlet pressure sensor connector,
-upstream oxygen sensor connector,
-the fuel vapour absorber connector.
aRefit:
-the engine compartment connection unit supply
terminal nut,
-the wiring mounting nut on the battery protection
fuse board,
-the negative battery terminal wiring nuts,
-the positive battery terminal wiring nut,
-the earth wiring nut on the front left-hand side
member,
-the earth wiring nuts on the engine,
-the starter wiring nuts,
-the alternator earth wiring nut.
aClip:
-the section of wiring on the cylinder head,
-the section of wiring on the cylinder block and sub-
frame,
-the section of wiring on the engine cooling fan as-
sembly.
III - FINAL OPERATION.
aRefit:
-the battery tray (see 80A, Battery, Battery tray:
Removal - Refitting, page 80A-6) ,
-the air filter unit (see Air filter unit: Removal - Re-
fitting) (MR 411, 12A, Fuel mixture),
-the battery (see 80A, Battery, Battery: Removal -
Refitting, page 80A-2) , WARNING
To prevent any damage during the removal ope-
ration, check that the wiring is free from its moun-
tings (retaining clip, plastic clip, adhesive tape,
connector, etc.).
STANDARD HEATING
AIR CONDITIONING