CONTENTS

VEHICLE / GENERAL

DATA - IDENTIFICATION

GENERAL REPAIR TIME SCHEDULE PRESENTATION

IDENTIFICATION VEHICLES

MODEL CODE 307

MODIFICATION BODY COLOURS

NUMBERING OF THE REPAIR TIME SCHEDULE GROUPS AND SUB-GROUPS

PAINT REPAIR TIME SCHEDULE PRESENTATION

VEHICLE / GENERAL

PRECAUTIONS TO BE TAKEN

LIFTING

PREPARATION NEW VEHICLE

VEHICLE / GENERAL

OPERATING INSTRUCTIONS

CATALOGUE OF THE SERVICES DOCUMENTATION - INFO FLASHES

CATALOGUE OF THE SERVICES DOCUMENTATION

MECHANICAL / ENGINE / GENERAL

DATA - IDENTIFICATION

ENGINE INTRODUCTION - TU5JP4 ENGINE

IDENTIFICATION ENGINE - DW10TD ENGINE - DW10ATED ENGINE

MECHANICAL / ENGINE / GENERAL

SPECIAL TOOLS USED FOR REPAIRS

PRESENTATION TOOLING ENGINE - DW10TD ENGINE - DW10ATED ENGINE

MECHANICAL / ENGINE / ENGINE ASSEMBLY

REMOVAL-FITTING

REASSEMBLY ENGINE (CYLINDER BLOCK) - DW10TD ENGINE - DW10ATED ENGINE

REMOVAL - REFITTING POWER UNIT - DW10TD ENGINE

REMOVAL - REFITTING POWER UNIT - TU3JP ENGINE - TU5JP4 ENGINE

MECHANICAL / ENGINE / ENGINE ASSEMBLY

MODIFICATIONS

MODIFICATION OIL SUMP FIXING - TU3JP ENGINE - TU5JP4 ENGINE

MECHANICAL / ENGINE / ENGINE BLOCK

DATA - IDENTIFICATION

IDENTIFICATION - DATA CYLINDER BLOCK - DW10TD ENGINE

MECHANICAL / ENGINE / ENGINE BLOCK

REMOVAL-FITTING

REMOVAL - REFITTING {{N11571}} BAGUES D'ÉTANCHÉITÉ : ENGINE - DV4TD ENGINE

MECHANICAL / ENGINE / CRANKSHAFT

DATA - IDENTIFICATION

DATA CRANKSHAFT - DW10TD ENGINE - DW10ATED ENGINE

DATA PISTONS PISTON RINGS - DW10ATED ENGINE - DW10TD ENGINE

IDENTIFICATION CENTERING OF THE GEARBOX INPUT SHAFT IN THE CRANKSHAFT - MA GEARBOX

MECHANICAL / ENGINE / CRANKSHAFT

REMOVAL-FITTING

REMOVAL - REFITTING ANCILLARY DRIVE BELT - TU3JP ENGINE

REMOVAL - REFITTING ANCILLARY DRIVE BELT - TU5JP4 ENGINE

REMOVAL - REFITTING {{N11571}} BAGUES D'ÉTANCHÉITÉ : ENGINE - DV4TD ENGINE

MECHANICAL / ENGINE / CYLINDER HEAD

DATA - IDENTIFICATION

DATA VALVE SEATS - DW10TD ENGINE - DW10ATED ENGINE

IDENTIFICATION - DATA CYLINDER HEAD GASKET - DW10TD ENGINE

IDENTIFICATION, DATA, TIGHTENING TORQUE(S) CYLINDER HEAD - DV4TD ENGINE

MECHANICAL / ENGINE / CYLINDER HEAD

REMOVAL-FITTING

REASSEMBLY ENGINE (CYLINDER HEAD) - DW10TD ENGINE - DW10ATED ENGINE

REMOVAL - REFITTING CYLINDER HEAD - DW10TD ENGINE

REMOVAL - REFITTING CYLINDER HEAD - EW10J4 ENGINE

REMOVAL - REFITTING CYLINDER HEAD - TU3JP ENGINE

REMOVAL - REFITTING CYLINDER HEAD - TU5JP4 ENGINE

MECHANICAL / ENGINE / TIMING

DATA - IDENTIFICATION

DATA CAMSHAFTS - DW10TD ENGINE - DW10ATED ENGINE

MECHANICAL / ENGINE / TIMING

ADJUSTMENTS CHECK

CHECK VALVE TIMING - TU3JP ENGINE

MECHANICAL / ENGINE / TIMING

REMOVAL-FITTING

REMOVAL - REFITTING CAMSHAFT HOUSING - DV4TD ENGINE

REMOVAL - REFITTING CAMSHAFT - EW10J4 ENGINE

REMOVAL - REFITTING CAMSHAFT - TU3JP ENGINE

REMOVAL - REFITTING CAMSHAFT - TU5JP4 ENGINE

REMOVAL - REFITTING TIMING BELT - DW10TD ENGINE

REMOVAL - REFITTING TIMING BELT - EW10J4 ENGINE

REMOVAL - REFITTING TIMING BELT - TU3JP ENGINE

REMOVAL - REFITTING TIMING BELT - TU5JP4 ENGINE

REMOVAL - REFITTING {{N11571}} BAGUES D'ÉTANCHÉITÉ : ENGINE - DV4TD ENGINE

MECHANICAL / ENGINE / LUBRICATION

DATA - IDENTIFICATION

DATA ENGINE LUBRICATION

DATA TIGHTENING TORQUE(S) LUBRICATION - DV4TD ENGINE

DATA - TIGHTENING TORQUES - LUBRICATION - TU3JP ENGINE - TU5JP4 ENGINE

MECHANICAL / ENGINE / LUBRICATION

CHECKS

CHECK OIL PRESSURE - TU3JP ENGINE - TU5JP4 ENGINE

MECHANICAL / ENGINE / LUBRICATION

REMOVAL-FITTING

REMOVAL - REFITTING OIL FILTER - TU3JP ENGINE

MECHANICAL / ENGINE / COOLING SYSTEM

REMOVAL-FITTING

REMOVAL - REFITTING COOLANT PUMP - DV4TD ENGINE

REMOVAL - REFITTING COOLANT PUMP - DW10TD ENGINE - DW10ATED ENGINE

REMOVAL - REFITTING COOLANT PUMP - TU5JP4 ENGINE

MECHANICAL / ENGINE / COOLING SYSTEM

DRAINING - FILLING - BLEEDING

DRAINING - FILLING - BLEEDING COOLING SYSTEM - EW10J4 ENGINE

DRAINING - FILLING - BLEEDING COOLING SYSTEM - TU3JP ENGINE - TU5JP4 ENGINE

MECHANICAL / ENGINE / SUPPLY

DATA - IDENTIFICATION

DATA INJECTOR FIXING FORK SUPPORT PIN - DW10TD ENGINE - DW10ATED ENGINE

MECHANICAL / ENGINE / SUPPLY

REMOVAL-FITTING

REMOVAL - REFITTING FUEL CAP COVER

REMOVAL - REFITTING FUEL FILTER - DW10TD ENGINE

REMOVAL - REFITTING FUEL PUMP GAUGE MODULE

REMOVAL - REFITTING HIGH PRESSURE FUEL INJECTION COMMON RAIL - DW10TD ENGINE

REMOVAL - REFITTING HIGH PRESSURE FUEL PUMP (SIEMENS) - DW10TD ENGINE

REMOVAL - REFITTING INJECTOR - DW10TD ENGINE

MECHANICAL / ENGINE / SUPPLY

DRAINING - FILLING - BLEEDING

DRAINING FUEL TANK - DW10ATED ENGINE

MECHANICAL / ENGINE / SUPPLY

OVERHAUL

CLEANING UNIONS ON THE HIGH PRESSURE FUEL DIRECT INJECTION RAIL - DV4TD ENGINE

REPAIR PROCEDURE FUEL UNIONS ON THE HIGH PRESSURE DIRECT INJECTION RAIL (INJECTION SYSTEM SIEMENS) - DW10TD ENGINE

MECHANICAL / ENGINE / SUPPLY

PRECAUTIONS TO BE TAKEN

CONDITIONS FOR WORKING ON THE DIESEL CIRCUIT (SIEMENS) - DW10TD ENGINE

MECHANICAL / TRANSMISSION / CLUTCH

DATA - IDENTIFICATION

IDENTIFICATION - BLEEDING OF THE HYDRAULIC CLUTCH CABLE - BE4R GEARBOX

IDENTIFICATION - BLEEDING OF THE HYDRAULIC CLUTCH CABLE - MA GEARBOX

IDENTIFICATION, DATA, TIGHTENING TORQUE(S) ; CLUTCH

PRESENTATION TOOLING CLUTCH - DW10TD ENGINE - DW10ATED ENGINE

REMOVAL - REFITTING HYDRAULIC CLUTCH CONTROL - MA GEARBOX

MECHANICAL / TRANSMISSION / CLUTCH

REMOVAL-FITTING

REMOVAL - REFITTING CLUTCH - BE4R GEARBOX

REMOVAL - REFITTING CLUTCH - MA GEARBOX

MECHANICAL / TRANSMISSION / GEARBOX

PRINCIPLES OF OPERATION

FUNCTION : OIL WEAR COUNTER (AL4) AUTOADAPTIVE AUTOMATIC GEARBOX - AL4 AUTOMATIC GEARBOX

MECHANICAL / TRANSMISSION / GEARBOX

DATA - IDENTIFICATION

DIAGNOSIS OIL LEAK - AL4 AUTOMATIC GEARBOX

GENERAL (AUTOMATIC GEARBOX) - AL4 AUTOMATIC GEARBOX

IDENTIFICATION AUTOMATIC GEARBOX - AL4 AUTOMATIC GEARBOX

IDENTIFICATION CENTERING OF THE GEARBOX INPUT SHAFT IN THE CRANKSHAFT - MA GEARBOX

IDENTIFICATION, DATA, TIGHTENING TORQUE(S) GEARBOX - BE4R GEARBOX

PRESENTATION OF GEARBOX SPECIAL TOOLS MA - MA GEARBOX

PRESENTATION TOOLING GEARBOX - BE4R GEARBOX

REMOVAL - REFITTING GEARBOX CONTROLS - MA GEARBOX - BE4R GEARBOX

MECHANICAL / TRANSMISSION / GEARBOX

CHECKS

MECHANICAL ACTION FUNCTION : SHIFT-LOCK - AL4 AUTOMATIC GEARBOX

MECHANICAL / TRANSMISSION / GEARBOX

ADJUSTMENTS CHECK

CHECK - ADJUSTMENT INPUT SHAFT BEARINGS - BE4R GEARBOX

MECHANICAL / TRANSMISSION / GEARBOX

ADJUSTMENTS

GEARBOX CONTROLS ADJUSTMENT - AL4 AUTOMATIC GEARBOX

MECHANICAL / TRANSMISSION / GEARBOX

REMOVAL-FITTING

DISMANTLING - ASSEMBLY CLUTCH HOUSING - BE4R GEARBOX

DISMANTLING - ASSEMBLY INPUT SHAFT - BE4R GEARBOX

DISMANTLING - ASSEMBLY OUTPUT SHAFT - BE4R GEARBOX

DISMANTLING/ASSEMBLY DIFFERENTIAL BOX - BE4R GEARBOX

REMOVAL - REFITTING AUTOMATIC GEARBOX FLUID TEMPERATURE SENSOR AUTOADAPTIVE (AL4) - AL4 AUTOMATIC GEARBOX

REMOVAL - REFITTING AUTOMATIC GEARBOX INPUT SPEED SENSOR (AL4) - AL4 AUTOMATIC GEARBOX

REMOVAL - REFITTING AUTOMATIC GEARBOX OIL PRESSURE SENSOR - AL4 AUTOMATIC GEARBOX

REMOVAL - REFITTING DIFFERENTIAL BOX - BE4R GEARBOX

REMOVAL - REFITTING GEARBOX CASING - BE4R GEARBOX

REMOVAL - REFITTING GEARBOX CONTROLS - AL4 AUTOMATIC GEARBOX

REMOVAL - REFITTING GEARBOX OUTPUT SPEED SENSOR - AL4 AUTOMATIC GEARBOX

REMOVAL - REFITTING GEARBOX - AL4 AUTOMATIC GEARBOX

REMOVAL - REFITTING GEARBOX - BE4R GEARBOX

REMOVAL - REFITTING HEAT EXCHANGER FLOW CONTROL SOLENOID - AL4 AUTOMATIC GEARBOX

REMOVAL - REFITTING INPUT AND OUTPUT SHAFTS - BE4R GEARBOX

REMOVAL - REFITTING MA GEARBOX - MA GEARBOX

REMOVAL - REFITTING POWER UNIT - DW10TD ENGINE

REMOVAL - REFITTING POWER UNIT - TU3JP ENGINE - TU5JP4 ENGINE

REMOVAL - REFITTING VEHICLE SPEED SENSOR AUTOADAPTIVE AUTOMATIC GEARBOX (AL4) - AL4 AUTOMATIC GEARBOX

MECHANICAL / TRANSMISSION / GEARBOX

REPLACEMENT

DISMANTLING / ASSEMBLY GEARBOX - BE4R GEARBOX

REMOVAL - REFITTING GEAR CHANGE SHAFT SEAL - AL4 AUTOMATIC GEARBOX

MECHANICAL / TRANSMISSION / GEARBOX

DRAINING - FILLING - BLEEDING

DRAINING - FILLING - LEVEL GEARBOX - MA GEARBOX

DRAINING/REFILLING/CHECK OF LEVEL OIL - AL4 AUTOMATIC GEARBOX

MECHANICAL / TRANSMISSION / GEARBOX

PRECAUTIONS TO BE TAKEN

CLEANING AND REFITTING CONDITIONS GEARBOX - BE4R GEARBOX

MECHANICAL / TRANSMISSION / GEARBOX

SPECIAL TOOLS USED FOR REPAIRS

PRESENTATION TOOLING DRIVE SHAFTS - AL4 AUTOMATIC GEARBOX

MECHANICAL / TRANSMISSION / DRIVE SHAFTS

REMOVAL-FITTING

REMOVAL - REFITTING DRIVE SHAFTS - AL4 AUTOMATIC GEARBOX

MECHANICAL / TRANSMISSION / WHEELS

DATA - IDENTIFICATION

IDENTIFICATION - DATA - TIGHTENING TORQUES WHEELS

MECHANICAL / SUSPENSION / GENERAL

ADJUSTMENTS

SETTING THE REFERENCE HEIGHT (H1) - (H2)

MECHANICAL / SUSPENSION / FRONT ANTI -ROLL BAR

REMOVAL-FITTING

REMOVAL - REFITTING FRONT ANTI -ROLL BAR

MECHANICAL / SUSPENSION / FRONT SHOCK ABSORBER

REMOVAL-FITTING

REMOVAL - REFITTING FRONT SHOCK ABSORBER

REMOVAL - REFITTING FRONT STRUT

MECHANICAL / SUSPENSION / REAR DAMPER

REMOVAL-FITTING

REMOVAL - REFITTING REAR DAMPER

MECHANICAL / FRONT AXLE / GENERAL

DATA - IDENTIFICATION

DATA ; TIGHTENING TORQUES FRONT SUSPENSION

MECHANICAL / FRONT AXLE / FRONT PIVOT

REMOVAL-FITTING

REMOVAL - REFITTING FRONT PIVOT BALL JOINT

REMOVAL - REFITTING FRONT PIVOT

REMOVAL - REFITTING FRONT WISHBONE

MECHANICAL / FRONT AXLE / FRONT PIVOT

OVERHAUL

OVERHAUL FRONT PIVOT

MECHANICAL / REAR AXLE / GENERAL

DATA - IDENTIFICATION

TIGHTENING DATA AND TORQUES REAR SUSPENSION

MECHANICAL / REAR AXLE / REAR HUB

REMOVAL-FITTING

REMOVAL - REFITTING STUB AXLE THRUST PLATE AND REAR BEARING HUB ASSEMBLY

MECHANICAL / REAR AXLE / REAR HUB

OVERHAUL

REMOVAL - REFITTING REAR HUB

MECHANICAL / REAR AXLE / REAR PIVOT

REMOVAL-FITTING

REMOVAL - REFITTING REAR SUSPENSION

MECHANICAL / STEERING / GENERAL

DATA - IDENTIFICATION

IDENTIFICATION - DATA - TIGHTENING TORQUES STEERING

MECHANICAL / STEERING / GENERAL

ADJUSTMENTS

ADJUSTMENT STEERING MECHANISM DAMPER

MECHANICAL / STEERING / GENERAL

REMOVAL-FITTING

REMOVAL - REFITTING STEERING MECHANISM - EW10J4 ENGINE - DW10TD ENGINE - TU5JP4 ENGINE - DW10ATED ENGINE

MECHANICAL / STEERING / GENERAL

PRECAUTIONS TO BE TAKEN

GENERAL PRECAUTIONS POWER STEERING WITH INTEGRAL RAM

MECHANICAL / STEERING / STEERING WHEEL

REMOVAL-FITTING

REMOVAL - REFITTING ASSEMBLY COM 2000

REMOVAL - REFITTING DRIVER'S AIR BAG

REMOVAL - REFITTING STEERING COLUMN COWLINGS

MECHANICAL / STEERING / STEERING COLUMN

REMOVAL-FITTING

REMOVAL - REFITTING ASSEMBLY COM 2000

REMOVAL - REFITTING STEERING COLUMN COWLINGS

REMOVAL - REFITTING STEERING COLUMN

MECHANICAL / STEERING / STEERING LOCK

REMOVAL-FITTING

REMOVAL - REFITTING STEERING LOCK

MECHANICAL / STEERING / STEERING RACK

REMOVAL-FITTING

REMOVAL - REFITTING RACK GAITER

REMOVAL - REFITTING STEERING ASSEMBLY TRACK RODS

REMOVAL - REFITTING STEERING MECHANISM DAMPER

REMOVAL - REFITTING STEERING MECHANISM - EW10J4 ENGINE - DW10TD ENGINE - TU5JP4 ENGINE - DW10ATED ENGINE

MECHANICAL / POWER STEERING / GENERAL

DATA - IDENTIFICATION

RECOMMENDATIONS POWER STEERING FLUID (SERVICE)

MECHANICAL / POWER STEERING / GENERAL

CHECKS

CHECK {{N11348}} PRESSSION D'ASSISTANCE DE DIRECTION

MECHANICAL / POWER STEERING / GENERAL

REMOVAL-FITTING

REMOVAL - REFITTING DISTRIBUTION VALVE

MECHANICAL / POWER STEERING / GENERAL

DRAINING - FILLING - BLEEDING

DRAINING - FILLING - BLEEDING HYDRAULIC CIRCUIT - TU5JP4 ENGINE - DW10TD ENGINE - DW10ATED ENGINE - EW10J4 ENGINE

MECHANICAL / BRAKES / GENERAL

DATA - IDENTIFICATION

IDENTIFICATION - DATA - TIGHTENING TORQUES BRAKES

MECHANICAL / BRAKES / GENERAL

CHECKS

EMERGENCY BRAKING ASSISTANCE CHECK, SYSTEM EVA BOSCH

MECHANICAL / BRAKES / GENERAL

DRAINING - FILLING - BLEEDING

DRAINING - FILLING - BLEEDING BRAKE SYSTEM

MECHANICAL / BRAKES / FRONT DISC BRAKES

REMOVAL-FITTING

REMOVAL - REFITTING FRONT BRAKE CALIPERS (BOSCH CALIPER SERIES 5)

REMOVAL - REFITTING FRONT BRAKE DISC

REMOVAL - REFITTING FRONT BRAKE PADS (BOSCH CALIPER)

MECHANICAL / BRAKES / REAR DISC BRAKES

REMOVAL-FITTING

REMOVAL - REFITTING REAR BRAKE CALIPERS (CALIPER LUCAS)

REMOVAL - REFITTING REAR BRAKE DISCS (CALIPER LUCAS)

REMOVAL - REFITTING REAR BRAKE PADS (CALIPER LUCAS)

MECHANICAL / BRAKES / BRAKE SERVO

CHECKS

CHECK VACUUM CIRCUIT

MECHANICAL / BRAKES / BRAKE SERVO

REMOVAL-FITTING

REMOVAL - REFITTING BRAKE SERVO

MECHANICAL / BRAKES / MASTER CYLINDER

REMOVAL-FITTING

REMOVAL - REFITTING MASTER CYLINDER

MECHANICAL / BRAKES / HANDBRAKE

ADJUSTMENTS CHECK

CHECK HANDBRAKE ADJUSTMENT

MECHANICAL / BRAKES / PEDAL BRACKET

DATA - IDENTIFICATION

DATA PEDAL BRACKET

MECHANICAL / BRAKES / PEDAL BRACKET

REMOVAL-FITTING

REMOVAL - REFITTING STOP LAMP SWITCH

MECHANICAL / BRAKES /

DRAINING - FILLING - BLEEDING

DRAINING - FILLING - BLEEDING BRAKE SYSTEM

MECHANICAL / ABS/TRACTION CONTROL / GENERAL

CHECKS

EMERGENCY BRAKING ASSISTANCE CHECK, SYSTEM EVA BOSCH

MECHANICAL / ABS/TRACTION CONTROL /

DRAINING - FILLING - BLEEDING

DRAINING - FILLING - BLEEDING BRAKE SYSTEM

BODYWORK / GENERAL

DATA - IDENTIFICATION