Renault Master/Mascott/Movano/NV400/Interstar Repair Service Manual 1997-2016
Complete service repair manual with Electrical Wiring Diagrams for Renault Master/Mascott/Movano/NV400/Interstar, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Renault Master/Mascott/Movano/NV400/Interstar workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 13,211 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
MR-225-MASTER-4...3
40-GENERAL...3
Vehicle dimensions...3
Vehicle identification...4
Lifting the vehicle...7
Towing the vehicle...8
Names of parts...9
Gaps and clearances...12
Procedure for replacing a welded component...14
General repair instructions...15
Adjusting welding equipment...21
Evaluating accident damage...23
Lower structure - Front wheel drive...29
Lower structure - rear wheel drive...30
The body jig bench...31
Body jig bench...34
41-LOWER STRUCTURE...40
Front cross member and side member end...40
Front croos member and side member end...41
Front side member...42
Side member outer panel...45
Rear side member crosspiece...47
Rear side member and rear spring shackle support...49
Rear cross member...52
Part of a rear cross member...54
42-UPPER FRONT STRUCTURE...57
Front wing...57
Complete front end panel...58
Replacing part of a front end panel...61
Cowl side panel...63
Front wheel arch...65
43-UPPER SIDE STRUCTURE...68
Front door pillar...68
Cab side...71
Lower body section...73
Extension panel...74
44-UPPER REAR STRUCTURE...77
Part of a rear wing panel...77
Part of a rear wing...79
Wing panel...80
Rear light support panel...83
45-UPPER BODY SECTION...85
Scuttle cross panel with the joint lines on the windscreen frame...85
47-SIDE DOORS AND LIDS...87
Front doors...87
Sliding side door...88
48-NON-SIDE DOORS AND LIDS...89
Bonnet...89
Rear loading door...91
Tailgate...92
MR-225-MASTER-5...94
51-SIDE DOOR AND LID MECHANISMS...94
Front door lock...94
Front door lock barrel...95
Window and window winder...96
Removing - refitting a lock...98
Sliding side door striker plate...99
Removing and refitting a wiper strip...100
52-NON SIDE DOOR AND LID MECHANISMS...101
Rear loading door lock...101
Tailgate lock...102
Tailgate gas strut...103
Bonnet lock...104
Bonnet lock (broken latch cable)...107
55-EXTERNAL PROTECTION...108
Front bumper...108
56-EXTERNAL ACCESSORIES...109
Radiator grill...109
57-LOWER BODY INTERIOR ACCESSORIES...110
Fascia panel...110
59-INTERIOR SAFETY EQUIPMENT...112
Seatbelt...112
MR-225-MASTER-6...113
60-GENERAL...113
Weatherproofing...113
Hollow section protection...114
Consumables...119
Equipment...121
MR-225-MASTER-7...122
71-BODY INTERIOR TRIM...122
Head lining...122
72-SIDE DOOR TRIM...123
Front door trim...123
77-FRONT SEAT FITTINGS...124
Front seat...124
MR225MASTER4...125
40-GENERAL...125
Vehicle dimensions...125
Vehicle identification...126
Lifting the vehicle...129
Towing the vehicle...130
Names of parts...131
Gaps and clearances...134
Procedure for replacing a welded component...136
General repair instructions...137
Adjusting welding equipment...143
Evaluating accident damage...145
Lower structure - Front wheel drive...151
Lower structure - rear wheel drive...152
The body jig bench...153
Body jig bench...156
41-LOWER STRUCTURE...162
Front cross member and side member end...162
Front croos member and side member end...163
Front side member...164
Side member outer panel...167
Rear side member crosspiece...169
Rear side member and rear spring shackle support...171
Rear cross member...174
Part of a rear cross member...176
42-UPPER FRONT STRUCTURE...179
Front wing...179
Complete front end panel...180
Replacing part of a front end panel...183
Cowl side panel...185
Front wheel arch...187
43-UPPER SIDE STRUCTURE...190
Front door pillar...190
Cab side...193
Lower body section...195
Extension panel...196
44-UPPER REAR STRUCTURE...199
Part of a rear wing panel...199
Part of a rear wing...201
Wing panel...202
Rear light support panel...205
45-UPPER BODY SECTION...207
Scuttle cross panel with the joint lines on the windscreen frame...207
47-SIDE DOORS AND LIDS...209
Front doors...209
Sliding side door...210
48-NON-SIDE DOORS AND LIDS...211
Bonnet...211
Rear loading door...213
Tailgate...214
MR225MASTER5...216
51-SIDE DOOR AND LID MECHANISMS...216
Front door lock...216
Front door lock barrel...217
Window and window winder...218
Removing - refitting a lock...220
Sliding side door striker plate...221
Removing and refitting a wiper strip...222
52-NON SIDE DOOR AND LID MECHANISMS...223
Rear loading door lock...223
Tailgate lock...224
Tailgate gas strut...225
Bonnet lock...226
Bonnet lock (broken latch cable)...229
55-EXTERNAL PROTECTION...230
Front bumper...230
56-EXTERNAL ACCESSORIES...231
Radiator grill...231
57-LOWER BODY INTERIOR ACCESSORIES...232
Fascia panel...232
59-INTERIOR SAFETY EQUIPMENT...234
Seatbelt...234
MR225MASTER6...235
60-GENERAL...235
Weatherproofing...235
Hollow section protection...236
Consumables...241
Equipment...243
MR225MASTER7...244
71-BODY INTERIOR TRIM...244
Head lining...244
72-SIDE DOOR TRIM...245
Front door trim...245
77-FRONT SEAT FITTINGS...246
Front seat...246
MR311...247
MR-311-MASTER-0...248
01-SPECIFICATIONS...248
Dimensions...248
Engine...249
Vehicle identification...250
Engine identification...253
02-MEANS OF LIFTING...256
Trolley jack - axle stands...256
03-TOWING...257
All types...257
04-LUBRICANTS - CONSUMABLES...258
Capacities - Grades...258
Packaging...261
05-DRAINING - FILLING...264
Engine...264
Gearbox...266
Final drive...267
Power assisted steerring...268
06-TOOLING...269
Special tooling...269
MR-311-MASTER-1...286
10-ENGINE AND PERIPHERALS...286
Consumables...286
Identification...287
Oil consumption...288
Oil pressure...289
Identification...290
Engine - Gearbox...291
Sump...298
Flywheel...299
11-TOP AND FRONT OF ENGINE...300
Cylinder head gasket...300
Timing belt...303
Accessories belt...313
12-FUEL MIXTURE...314
General...314
Carburettor...319
Throttle body...320
Turbo charger...322
Torque limiting device...327
13-FUEL SUPPLY...331
Fuel pressure...331
Auxiliary fuel tank pump...332
Supply circuit...333
13-PUMPS...335
Diesel equipment...335
Injection pump (LUCAS)...343
Injection pump (BOSCH)...344
Adjustments...350
Cold start solenoid (KSB)...353
13-PRE-HEATING...354
Heating the inlet air...354
Pre-post-heating unit...361
14-ANTI-POLLUTION...365
Oil vapour rebreating...365
Fuel vapour recirculation...369
Catalytic converter - oxygen sensor...375
Test for the presence of lead...376
Exhaust gas recycling...377
16-STARTING - CHARGING...389
Alternator...389
Starter...392
17-IGNITION...394
Conventional ignition...394
Integral electronic ignition...396
Power module...403
Plugs...404
17-INJECTION...405
Location of components...405
Fault finding...411
Fault finding with the XR25...419
19-EXHAUST...433
Exhaust assembly...433
Catalytic converter...434
19-FUEL TANK...435
Filler neck...435
MR-311-MASTER-2...436
20-CLUTCH...436
Identification...436
Section views...439
Exploded views...442
Consumables...443
Mechanism - Plate...444
Flywheel...445
Clutch shaft bearing...447
Clutch shaft lip seal...448
Thrust pad...449
Clutch clearance...450
21-MANUAL GEARBOX...451
Identification...451
Section view and tightening torques (in daN.m)...454
Ratios...457
Lubricants...459
Consumables...460
Parts to be systematically replaced...461
Gearbox (Removal - Refitting)...462
Rear output flange seal...471
5th gear on the vehicle...472
Speedometer shaft...476
Differential output seal...477
Gear mounting pads...480
Power take-off (Identification)...481
Power take-off (Cross member)...482
Power take-off (Control)...483
Power take-off...484
Removal - Refitting...485
Tooling...506
26-FINAL DRIVE...509
Identification...509
Section view and tightening torques (in daN.m)...510
Ratios...511
Exploded view...512
Special notes...513
Final drive assembly...514
Tooling...523
29-DRIVESHAFTS...525
Front driveshafts...525
Gaiter on gearbox end...527
Gaiter on wheel end...529
Prop shaft...531
Prop shaft spider...534
Prop shaft lubrication...535
MR-311-MASTER-3...536
30-GENERAL...536
Dimensions of main braking components...536
Tightening torques (in daN.m)...538
Axle assembly and suspension...543
Values for checking front axle geometry...544
Values for checking rear axle geometry...546
Measuring points...547
Parts to be renewed when they are removed / brake fluid...548
Influence of angles...549
Principle for checking angles...550
Checking - adjusting the castor angle...551
Checking - adjusting parallelism...552
Adjusting the steering...553
Bleeding the brake...555
Bleeding the brake circuit...556
31-FRONT AXLE ELEMENTS...557
Lower arm...557
Upper arm...559
Brake pads...561
Brake caliper...563
Brake disc...565
Stub axle carrier bearing...568
Stub axle carrier bearing / Stub axle carrier...571
Spring and shock absorber...572
Tooling...574
33-REAR AXLE ELEMENTS...577
Brake drum...577
Slave cylinder...580
Brake linings...581
Bearing...584
Half shaft...587
Half shaft (seal)...589
Bearing...590
Shock absorber...593
Leaf spring...594
Tooling...596
35-WHEELS AND TYRES...597
Specifications...597
36-STEERING ASSEMBLY...600
Steering rack...600
Steering column bush...602
37-MECHANICAL ELEMENT CONTROLS...603
Brake servo...603
Brake servo air filter / Replacing the non-return valve...605
Mechanisms and primary cable...606
Secondary cable...607
Braking compensator...608
Tooling...610
External gear control...611
MR-311-MASTER-6...613
61-HEATING...613
Operation...613
Heating assembly...614
Control panel...616
Water control valve cable...618
Water control valve...619
Heating radiator...620
Resistance unit...621
Fan motor...622
MR-311-MASTER-8...623
80-BATTERY...623
Special notes...623
80-HEADLIGHTS...624
Light units...624
80-FRONT HEADLIGHTS...625
Direction indicators...625
81-REAR LIGHTING...627
Rear lights...627
81-REAR AND INTERIOR LIGHTING...629
Fuses...629
83-INSTRUMENT PANEL...631
Dashboard...631
Instrument panel...635
Fuel tank sender unit...639
Oil level gauge...641
84-CONTROLS - SIGNALS...642
Wiper stalk...642
Lights stalk...644
Ignition switch...647
85-WIPERS...648
Windscreen wipers...648
87-ELECTRICAL ASSISTANCE EQUIPMENT...649
Wiper timer...649
Passenger compartment connection unit...650
Relay board...652
Dim dip headlights...653
89-WIRING DIAGRAMS...655
Identification of wires...655
Front wheel drive petrol engine van...656
Front wheel drive diesel engine van...660
Rear wheel drive petrol engine van...664
Platform drop side van and cab chassis, diesel engine...668
Identification...672
Tooling...673
Functions shown...674
Component key...675
1 - Main beam headlights...677
2 - Side lights/dipped beam headlights...678
3 - Side lights/dipped beam headlights...679
4 - Side lights/dipped beam headlights...680
5 - Side lights/dipped beam headlights/side markers...681
6 - Side lights/Side-mounted/Dipped headlights...682
7 - Side lights/Dipped headlights...683
8 - Direction indicator lights/Hasard warming lights...684
9 - Direction indicator lights/Hasard warming lights...685
10 - Direction indicator lights/Hasard warming lights...686
11 - Direction indicator lights/Hasard warming lights...687
12 - Heating All types (except Sweden Norway) / 13 - Heating/heated seat (Sweden - Norway)...688
14 - Horn - Left hand drive / 15 - Horn - Right and drive...689
16 - Windscreen wiper/washer...690
17 - Windscreen wiper/washer...691
18 - Headlight wiper/washer...692
19 - Headlight wiper/washer...693
20 - Headlight wiper/washer...694
21 - Tachograph/Cigar lighter/Radio feed / 22 - Tachograph/Cigar lighter/Radio feed...695
23 - Panel lighting, heating control, tachograph, cigar lighter...696
Heating control lighting, Cigar lighter, Tachograph, Instrument panel...697
Courtesy light 26 - Long chassis / 27 - Short chassis / 28 - Cab chassis...699
29 - Brake lights - Right and left hand drive / 30 - Brake lights, Right and left hand drive...700
31 - Reversing lights / 32 - Reversing lights...701
33 - Handbrake, brake pad wear, nivocode...702
34 - Fuel gauge...703
35 - Ignition, idle speed cut-out, rev counter / 36 - Cooling fan...704
37 / 38 - Thermistor, oil pressure switch, charging, starting...705
39 - Cooling fan / 40 - Pre-heating, electric stop...706
41 - Thermistor, oil switch, charging, rev counter, starting / 42 - Pre-heating, lectric stop...707
43 - Fan...708
44 - Rear fog lights - Left hand drive / 45 - Platform - Rear fog lights...709
46 - Rear fog lights - Right hand drive...710
47 - Rear fog lights - Right hand drive...711
Models 1988 - 1989 - 1990 - 1991 - 1992 - 1993 - 1994 - 1995...712
MR311MASTER0...713
01-SPECIFICATIONS...713
Dimensions...713
Engine...714
Vehicle identification...715
Engine identification...718
02-MEANS OF LIFTING...721
Trolley jack - axle stands...721
03-TOWING...722
All types...722
04-LUBRICANTS - CONSUMABLES...723
Capacities - Grades...723
Packaging...726
05-DRAINING - FILLING...729
Engine...729
Gearbox...731
Final drive...732
Power assisted steerring...733
06-TOOLING...734
Special tooling...734
MR311MASTER1...751
10-ENGINE AND PERIPHERALS...751
Consumables...751
Identification...752
Oil consumption...753
Oil pressure...754
Identification...755
Engine - Gearbox...756
Sump...763
Flywheel...764
11-TOP AND FRONT OF ENGINE...765
Cylinder head gasket...765
Timing belt...768
Accessories belt...778
12-FUEL MIXTURE...779
General...779
Carburettor...784
Throttle body...785
Turbo charger...787
Torque limiting device...792
13-FUEL SUPPLY...796
Fuel pressure...796
Auxiliary fuel tank pump...797
Supply circuit...798
13-PUMPS...800
Diesel equipment...800
Injection pump (LUCAS)...808
Injection pump (BOSCH)...809
Adjustments...815
Cold start solenoid (KSB)...818
13-PRE-HEATING...819
Heating the inlet air...819
Pre-post-heating unit...826
14-ANTI-POLLUTION...830
Oil vapour rebreating...830
Fuel vapour recirculation...834
Catalytic converter - oxygen sensor...840
Test for the presence of lead...841
Exhaust gas recycling...842
16-STARTING - CHARGING...854
Alternator...854
Starter...857
17-IGNITION...859
Conventional ignition...859
Integral electronic ignition...861
Power module...868
Plugs...869
17-INJECTION...870
Location of components...870
Fault finding...876
Fault finding with the XR25...884
19-EXHAUST...898
Exhaust assembly...898
Catalytic converter...899
19-FUEL TANK...900
Filler neck...900
MR311MASTER2...901
20-CLUTCH...901
Identification...901
Section views...904
Exploded views...907
Consumables...908
Mechanism - Plate...909
Flywheel...910
Clutch shaft bearing...912
Clutch shaft lip seal...913
Thrust pad...914
Clutch clearance...915
21-MANUAL GEARBOX...916
Identification...916
Section view and tightening torques (in daN.m)...919
Ratios...922
Lubricants...924
Consumables...925
Parts to be systematically replaced...926
Gearbox (Removal - Refitting)...927
Rear output flange seal...936
5th gear on the vehicle...937
Speedometer shaft...941
Differential output seal...942
Gear mounting pads...945
Power take-off (Identification)...946
Power take-off (Cross member)...947
Power take-off (Control)...948
Power take-off...949
Removal - Refitting...950
Tooling...971
26-FINAL DRIVE...974
Identification...974
Section view and tightening torques (in daN.m)...975
Ratios...976
Exploded view...977
Special notes...978
Final drive assembly...979
Tooling...988
29-DRIVESHAFTS...990
Front driveshafts...990
Gaiter on gearbox end...992
Gaiter on wheel end...994
Prop shaft...996
Prop shaft spider...999
Prop shaft lubrication...1000
MR311MASTER3...1001
30-GENERAL...1001
Dimensions of main braking components...1001
Tightening torques (in daN.m)...1003
Axle assembly and suspension...1008
Values for checking front axle geometry...1009
Values for checking rear axle geometry...1011
Measuring points...1012
Parts to be renewed when they are removed / brake fluid...1013
Influence of angles...1014
Principle for checking angles...1015
Checking - adjusting the castor angle...1016
Checking - adjusting parallelism...1017
Adjusting the steering...1018
Bleeding the brake...1020
Bleeding the brake circuit...1021
31-FRONT AXLE ELEMENTS...1022
Lower arm...1022
Upper arm...1024
Brake pads...1026
Brake caliper...1028
Brake disc...1030
Stub axle carrier bearing...1033
Stub axle carrier bearing / Stub axle carrier...1036
Spring and shock absorber...1037
Tooling...1039
33-REAR AXLE ELEMENTS...1042
Brake drum...1042
Slave cylinder...1045
Brake linings...1046
Bearing...1049
Half shaft...1052
Half shaft (seal)...1054
Bearing...1055
Shock absorber...1058
Leaf spring...1059
Tooling...1061
35-WHEELS AND TYRES...1062
Specifications...1062
36-STEERING ASSEMBLY...1065
Steering rack...1065
Steering column bush...1067
37-MECHANICAL ELEMENT CONTROLS...1068
Brake servo...1068
Brake servo air filter / Replacing the non-return valve...1070
Mechanisms and primary cable...1071
Secondary cable...1072
Braking compensator...1073
Tooling...1075
External gear control...1076
MR311MASTER6...1078
61-HEATING...1078
Operation...1078
Heating assembly...1079
Control panel...1081
Water control valve cable...1083
Water control valve...1084
Heating radiator...1085
Resistance unit...1086
Fan motor...1087
MR311MASTER8...1088
80-BATTERY...1088
Special notes...1088
80-HEADLIGHTS...1089
Light units...1089
80-FRONT HEADLIGHTS...1090
Direction indicators...1090
81-REAR LIGHTING...1092
Rear lights...1092
81-REAR AND INTERIOR LIGHTING...1094
Fuses...1094
83-INSTRUMENT PANEL...1096
Dashboard...1096
Instrument panel...1100
Fuel tank sender unit...1104
Oil level gauge...1106
84-CONTROLS - SIGNALS...1107
Wiper stalk...1107
Lights stalk...1109
Ignition switch...1112
85-WIPERS...1113
Windscreen wipers...1113
87-ELECTRICAL ASSISTANCE EQUIPMENT...1114
Wiper timer...1114
Passenger compartment connection unit...1115
Relay board...1117
Dim dip headlights...1118
89-WIRING DIAGRAMS...1120
Identification of wires...1120
Front wheel drive petrol engine van...1121
Front wheel drive diesel engine van...1125
Rear wheel drive petrol engine van...1129
Platform drop side van and cab chassis, diesel engine...1133
Identification...1137
Tooling...1138
Functions shown...1139
Component key...1140
1 - Main beam headlights...1142
2 - Side lights/dipped beam headlights...1143
3 - Side lights/dipped beam headlights...1144
4 - Side lights/dipped beam headlights...1145
5 - Side lights/dipped beam headlights/side markers...1146
6 - Side lights/Side-mounted/Dipped headlights...1147
7 - Side lights/Dipped headlights...1148
8 - Direction indicator lights/Hasard warming lights...1149
9 - Direction indicator lights/Hasard warming lights...1150
10 - Direction indicator lights/Hasard warming lights...1151
11 - Direction indicator lights/Hasard warming lights...1152
12 - Heating All types (except Sweden Norway) / 13 - Heating/heated seat (Sweden - Norway)...1153
14 - Horn - Left hand drive / 15 - Horn - Right and drive...1154
16 - Windscreen wiper/washer...1155
17 - Windscreen wiper/washer...1156
18 - Headlight wiper/washer...1157
19 - Headlight wiper/washer...1158
20 - Headlight wiper/washer...1159
21 - Tachograph/Cigar lighter/Radio feed / 22 - Tachograph/Cigar lighter/Radio feed...1160
23 - Panel lighting, heating control, tachograph, cigar lighter...1161
Heating control lighting, Cigar lighter, Tachograph, Instrument panel...1162
Courtesy light 26 - Long chassis / 27 - Short chassis / 28 - Cab chassis...1164
29 - Brake lights - Right and left hand drive / 30 - Brake lights, Right and left hand drive...1165
31 - Reversing lights / 32 - Reversing lights...1166
33 - Handbrake, brake pad wear, nivocode...1167
34 - Fuel gauge...1168
35 - Ignition, idle speed cut-out, rev counter / 36 - Cooling fan...1169
37 / 38 - Thermistor, oil pressure switch, charging, starting...1170
39 - Cooling fan / 40 - Pre-heating, electric stop...1171
41 - Thermistor, oil switch, charging, rev counter, starting / 42 - Pre-heating, lectric stop...1172
43 - Fan...1173
44 - Rear fog lights - Left hand drive / 45 - Platform - Rear fog lights...1174
46 - Rear fog lights - Right hand drive...1175
47 - Rear fog lights - Right hand drive...1176
Models 1988 - 1989 - 1990 - 1991 - 1992 - 1993 - 1994 - 1995...1177
MR323...1178
MR-323-MASTER-0...1179
01-SPECIFICATIONS...1183
Engine - Clutch - Gearbox...1183
Vehicle identification...1184
02-LIFTING EQUIPMENT...1185
Trolley jack - Axle stands...1185
03-TOWING...1187
All types...1187
04-LUBRICANTS - CONSUMABLES...1188
Packaging...1188
05-DRAINING - REFILLING...1191
Engine...1191
Gearbox...1192
Power assisted steering...1193
07-VALUES AND SETTINGS...1194
Dimensions...1194
Capacities - Grades...1195
Belt tension...1197
Accessories drive belt tension...1199
Cylinder head tightening...1201
Tyres - wheels...1202
Brakes...1203
Brake compensator...1204
Front axle checking values...1205
Rear axle checking values...1206
MR-323-MASTER-1...1207
10-ENGINE AND PERIPHERALS...1210
Oil pressure...1210
Engine - Gearbox...1211
11-TOP AND FRONT OF ENGINE...1214
Accessories belt...1214
Timing belt...1215
Cylinder head gasket...1218
12-TURBOCHARGING...1221
Turbocharger...1221
Wastegate...1223
Air - air exchanger...1225
Exhaust manifold...1226
Inlet manifold...1228
13-DIESEL EQUIPMENT...1230
Fuel cut-off on impact...1230
Specifications...1231
BOSCH coded solenoid valve...1233
Cold start device (KSB)...1236
Heating the inlet air...1241
Heating the inlet air / Fault finding...1245
Pre-postheating unit...1247
Pre-postheating unit / Diagnostic...1251
Correcting the idling speed...1253
Microswitch...1254
Fuel filter...1255
Pump...1257
Pump timing...1258
Adjustments...1261
16-STARTING - CHARGING...1271
Alternator...1271
Starter motor...1273
19-COOLING...1274
Specifications...1274
Filling - bleeding...1275
Checking...1276
Diagram...1277
Radiator temperature switch...1279
Radiator...1280
Cooling system...1281
Metal coolant pipe...1282
Water pump...1284
19-EXHAUST...1286
General...1286
Exhaust assembly...1287
19-FUEL TANK...1289
General...1289
Fuel tank...1290
Filler neck...1293
Pump and sender unit...1294
Gauge...1296
19-ENGINE MOUNTING...1297
Suspended engine mounting...1297
MR-323-MASTER-2...1298
20-CLUTCH...1301
Mechanism - Clutch plate...1301
21-MANUAL GEARBOX...1303
General...1303
Gearbox (Removal -Refitting)...1304
29-DRIVESHAFTS...1306
General...1306
Front driveshaft...1307
MR-323-MASTER-3...1315
30-GENERAL...1318
General braking circuits diagram...1318
Brake unions and pipes...1320
Composition, dimensions of main braking components...1321
Tightening torques (in daN.m)...1322
Specifications of the front anti-roll bars...1327
Bleeding the braking circuit (except ABS)...1328
Bleeding the braking circuit...1329
31-FRONT AXLE...1330
Lower wishbone...1330
Upper wishbone...1333
Lower wishbone ball joint...1335
Upper wishbone ball joint...1337
Lower wishbone rubber bushes...1339
Brake pads...1341
Brake caliper...1343
Brake disc...1344
Hub studs...1346
Stub axle carrier bearing...1347
Shock absorber / Spring...1348
Spring thrust ball joint...1349
Anti-roll bar...1350
Sub-frame...1351
33-REAR AXLE...1353
Leaf spring...1353
Brake drum...1355
Brake shoes (drum)...1356
35-WHEELS AND TYRES...1357
Specifications...1357
Wheel balancing...1360
36-STEERING ASSEMBLY...1361
Steering rack...1361
Steering column...1362
Retractable shaft...1364
Axial ball joint...1365
Steering pushrod...1367
37-MECHANICAL ELEMENT CONTROLS...1368
Master cylinder...1368
Brake servo...1369
Brake servo air filter - non-return valve...1370
Vacuum pump...1371
Handbrake control lever...1372
Handbrake cables...1373
Handbrake adjustment...1376
Brake hoses...1378
Braking compensator...1379
Clutch release control...1395
External gear control...1396
38-ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM...1397
TEVES ABS...1397
MR-323-MASTER-6...1442
61-HEATING...1445
Control panel...1445
Control cables...1446
Fan...1447
Air recirculation motor...1448
Radiator...1449
Distribution unit...1450
Resistor unit...1452
62-AIR CONDITIONING...1453
General...1453
Fault finding - Customer complaints...1455
Fault finding charts...1456
Wiring diagram...1489
Evaporator...1491
Blower unit...1493
Compressor...1494
Condenser...1495
Pressure relief valve...1496
Dehydration canister...1497
Connecting pipes...1498
Electrical control...1501
MR-323-MASTER-8...1504
80-BATTERY...1508
Special notes...1508
80-HEADLIGHTS...1510
Lens units and indicators...1510
Remote adjustment...1511
81-REAR AND INTERIOR LIGHTING...1512
Fuses...1512
82-IMMOBILISER...1515
Coded key immobiliser system...1515
83-INSTRUMENT PANEL...1557
Dashboard...1557
Instrument panel...1562
Instrument panel with tachograph...1567
Removal - refitting of fuel gauge...1568
Fuel level sensor...1569
84-CONTROLS - SIGNALS...1570
Windscreen wiper stalk...1570
Lights stalk...1571
Stalk mounting...1572
Rotary switch under steering wheel...1573
Ignition switch...1575
85-WIPERS...1576
Front windscreen wiper...1576
Electric washer pump...1578
87-ELECTRICAL ASSISTANCE EQUIPMENT...1579
Relay plate...1579
88-WIRING...1583
Heated rear screen...1583
Remote control for door locking...1585
Airbags and seat belt pretensioners...1607
MR323MASTER0...1643
01-SPECIFICATIONS...1647
Engine - Clutch - Gearbox...1647
Vehicle identification...1648
02-LIFTING EQUIPMENT...1649
Trolley jack - Axle stands...1649
03-TOWING...1651
All types...1651
04-LUBRICANTS - CONSUMABLES...1652
Packaging...1652
05-DRAINING - REFILLING...1655
Engine...1655
Gearbox...1656
Power assisted steering...1657
07-VALUES AND SETTINGS...1658
Dimensions...1658
Capacities - Grades...1659
Belt tension...1661
Accessories drive belt tension...1663
Cylinder head tightening...1665
Tyres - wheels...1666
Brakes...1667
Brake compensator...1668
Front axle checking values...1669
Rear axle checking values...1670
MR323MASTER1...1671
10-ENGINE AND PERIPHERALS...1674
Oil pressure...1674
Engine - Gearbox...1675
11-TOP AND FRONT OF ENGINE...1678
Accessories belt...1678
Timing belt...1679
Cylinder head gasket...1682
12-TURBOCHARGING...1685
Turbocharger...1685
Wastegate...1687
Air - air exchanger...1689
Exhaust manifold...1690
Inlet manifold...1692
13-DIESEL EQUIPMENT...1694
Fuel cut-off on impact...1694
Specifications...1695
BOSCH coded solenoid valve...1697
Cold start device (KSB)...1700
Heating the inlet air...1705
Heating the inlet air / Fault finding...1709
Pre-postheating unit...1711
Pre-postheating unit / Diagnostic...1715
Correcting the idling speed...1717
Microswitch...1718
Fuel filter...1719
Pump...1721
Pump timing...1722
Adjustments...1725
16-STARTING - CHARGING...1735
Alternator...1735
Starter motor...1737
19-COOLING...1738
Specifications...1738
Filling - bleeding...1739
Checking...1740
Diagram...1741
Radiator temperature switch...1743
Radiator...1744
Cooling system...1745
Metal coolant pipe...1746
Water pump...1748
19-EXHAUST...1750
General...1750
Exhaust assembly...1751
19-FUEL TANK...1753
General...1753
Fuel tank...1754
Filler neck...1757
Pump and sender unit...1758
Gauge...1760
19-ENGINE MOUNTING...1761
Suspended engine mounting...1761
MR323MASTER2...1762
20-CLUTCH...1765
Mechanism - Clutch plate...1765
21-MANUAL GEARBOX...1767
General...1767
Gearbox (Removal -Refitting)...1768
29-DRIVESHAFTS...1770
General...1770
Front driveshaft...1771
MR323MASTER3...1779
30-GENERAL...1782
General braking circuits diagram...1782
Brake unions and pipes...1784
Composition, dimensions of main braking components...1785
Tightening torques (in daN.m)...1786
Specifications of the front anti-roll bars...1791
Bleeding the braking circuit (except ABS)...1792
Bleeding the braking circuit...1793
31-FRONT AXLE...1794
Lower wishbone...1794
Upper wishbone...1797
Lower wishbone ball joint...1799
Upper wishbone ball joint...1801
Lower wishbone rubber bushes...1803
Brake pads...1805
Brake caliper...1807
Brake disc...1808
Hub studs...1810
Stub axle carrier bearing...1811
Shock absorber / Spring...1812
Spring thrust ball joint...1813
Anti-roll bar...1814
Sub-frame...1815
33-REAR AXLE...1817
Leaf spring...1817
Brake drum...1819
Brake shoes (drum)...1820
35-WHEELS AND TYRES...1821
Specifications...1821
Wheel balancing...1824
36-STEERING ASSEMBLY...1825
Steering rack...1825
Steering column...1826
Retractable shaft...1828
Axial ball joint...1829
Steering pushrod...1831
37-MECHANICAL ELEMENT CONTROLS...1832
Master cylinder...1832
Brake servo...1833
Brake servo air filter - non-return valve...1834
Vacuum pump...1835
Handbrake control lever...1836
Handbrake cables...1837
Handbrake adjustment...1840
Brake hoses...1842
Braking compensator...1843
Clutch release control...1859
External gear control...1860
38-ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM...1861
TEVES ABS...1861
MR323MASTER6...1906
61-HEATING...1909
Control panel...1909
Control cables...1910
Fan...1911
Air recirculation motor...1912
Radiator...1913
Distribution unit...1914
Resistor unit...1916
62-AIR CONDITIONING...1917
General...1917
Fault finding - Customer complaints...1919
Fault finding charts...1920
Wiring diagram...1953
Evaporator...1955
Blower unit...1957
Compressor...1958
Condenser...1959
Pressure relief valve...1960
Dehydration canister...1961
Connecting pipes...1962
Electrical control...1965
MR323MASTER8...1968
80-BATTERY...1972
Special notes...1972
80-HEADLIGHTS...1974
Lens units and indicators...1974
Remote adjustment...1975
81-REAR AND INTERIOR LIGHTING...1976
Fuses...1976
82-IMMOBILISER...1979
Coded key immobiliser system...1979
83-INSTRUMENT PANEL...2021
Dashboard...2021
Instrument panel...2026
Instrument panel with tachograph...2031
Removal - refitting of fuel gauge...2032
Fuel level sensor...2033
84-CONTROLS - SIGNALS...2034
Windscreen wiper stalk...2034
Lights stalk...2035
Stalk mounting...2036
Rotary switch under steering wheel...2037
Ignition switch...2039
85-WIPERS...2040
Front windscreen wiper...2040
Electric washer pump...2042
87-ELECTRICAL ASSISTANCE EQUIPMENT...2043
Relay plate...2043
88-WIRING...2047
Heated rear screen...2047
Remote control for door locking...2049
Airbags and seat belt pretensioners...2071
MR324...2107
MR-324-MASTER BUS 9-4...2108
40-GENERAL...2111
Information...2111
Key to parts in exploded view...2112
41-LOWER STRUCTURE...2114
Load floor...2114
43-UPPER SIDE STRUCTURE...2129
Cab rear pillar inner panel...2129
Side panel lower inner panel...2130
44-UPPER REAR STRUCTURE...2131
Rear wheel arch...2131
Spare wheel support...2132
Rear pillar lower inner panel...2133
45-TOP OF BODY...2134
Central roof crossmember...2134
Rear roof crossmember...2136
MR-324-MASTER BUS-4...2137
40-GENERAL...2140
Information...2140
Description of parts, exploded views...2141
41-LOWER STRUCTURE...2145
Load floor...2145
43-UPPER SIDE STRUCTURE...2157
Cab rear pillar lining...2157
44-UPPER REAR STRUCTURE...2158
Intermediate centre pillar lining...2158
Load area centre pillar lining...2160
Spare wheel support...2162
45-TOP OF BODY...2163
Roof crossmember bracket...2163
Load area roof centre crossmember...2167
Load area rear drip moulding lining...2168
MR-324-MASTER BUS-5...2169
54-WINDOWS...2172
Front and rear aperture windows...2172
Intermediate aperture window...2173
Sliding side door window...2174
57-LOWER INTERIOR ACCESSORIES...2175
Side door rail...2175
58-UPPER INTERIOR ACCESSORIES...2176
Side door handle...2176
Right rear door handle...2177
Left rear door handle...2178
59-INTERIOR SAFETY COMPONENTS...2180
Passenger seat belts...2180
MR-324-MASTER BUS-7...2182
71-INTERIOR BODY TRIM...2185
Sliding door upper and lower sills...2185
71-BODY INTERIOR TRIM...2186
Right rear door sill...2186
Right-hand floor...2187
Left-hand floor...2189
Centre floor...2191
Cab inner sill left-hand trim...2192
Cab inner sill right-hand trim...2193
Side door rail cover...2194
Cab luggage compartment upper trim...2195
Wheel arch interior trim...2197
Rear aperture trim...2198
Rear lower trim...2200
Intermediate aperture trim...2201
Intermediate lower trim...2203
Front left aperture trim...2204
Front left lower trim...2206
Front headlining...2207
Rear headlining...2208
Centre headlining...2209
Side aluminium extrusions...2210
76-REAR SEAT FRAMES AND SLIDES...2211
Single and double complete seats...2211
Seat height adjuster...2212
78-REAR SEAT TRIM...2214
Seat backrest trim...2214
Seat cushion trim...2216
MR-324-MASTER DCAB-4...2217
40-GENERAL...2220
Using symbols...2220
Key to symbols...2222
Description of parts (exploded view)...2223
Special tooling...2226
Opening clearances...2227
41-LOWER STRUCTURE...2229
Rear end cross member closure panel...2229
Rear end cross member...2231
Rear side member closure panel, part section...2233
Rear leaf spring mounting unit...2236
Central centre cross member...2239
Centre side member...2241
Front leaf spring mounting unit...2244
Front centre cross member...2249
Rear centre cross member...2251
Assembled cab rear step...2253
Cab rear pillar cross member...2258
Double cab rear floor part section...2260
Tunnel support...2264
43-UPPER SIDE STRUCTURE...2265
Double cab rear pillar...2265
Double cab stretcher...2271
Double cab stretcher lining...2276
Side panel...2277
Side door sill panel...2279
Cab rear pillar sill panel...2284
Rear pillar sill panel closure panel...2286
Cab side sill panel...2288
Cab rear pillar closure...2289
Partition cross members...2293
Partition pillar...2295
45-TOP OF BODY...2297
Roof...2297
Courtesy light mounting...2300
MR-324-MASTER-4...2301
40-GENERAL...2305
Dimensions...2305
Engine and equipment...2306
Identification...2307
Lifting equipment...2310
Towing...2312
Procedure symbols...2313
Key to symbols...2315
Description of parts (exploded views)...2316
Opening clearances...2320
Collision damage assessment...2327
Sub-frame dimensions...2330
Body jig bench...2332
41-LOWER STRUCTURE...2343
Lower front cross member...2343
Part front side member...2346
Front half unit...2349
Cab inner sill panel...2352
Cab front pillar bracket (jacking point)...2354
Cab side sill...2357
Cab rear pillar bracket...2360
Tunnel...2364
Cab floor...2366
Cab floor front cross member...2371
Cross members under front seat...2373
Load floor front cross member...2376
Front load floor...2380
Centre load floor...2386
Rear load floor (part)...2389
Centre side member...2394
Centre inner sill panel (side door)...2397
Sliding door runner bracket...2401
Centre inner sill panel...2405
Centre pillar cross member under floor...2409
Rear inner sill panel...2412
Load floor stiffener cross member...2415
Runner housing side stiffener...2417
Load floor centre cross member...2419
Load floor stiffener...2421
Leaf spring front mounting side cross member...2423
Leaf spring rear mounting centre cross member...2425
Leaf spring rear mounting side cross member...2427
Rear side member...2429
Rear side member side bracket...2430
Shock absorber stiffener bracket...2431
Rear side member extender...2432
Extreme rear cross member...2433
42-UPPER FRONT STRUCTURE...2436
Front wing...2436
Headlight carrier panel...2438
Cowl side panel...2441
Front wheel arch...2444
Tunnel stiffener...2449
Bulkhead...2451
Windscreen aperture lower cross member...2456
Windscreen aperture lower cross member closure panel...2459
43-UPPER SIDE STRUCTURE...2461
Cab front pillar...2461
Cab sill panel...2467
Outer front wheel arch...2470
Cab rear pillar...2472
Cab front pillar lining...2477
43-UPPER FRONT STRUCTURE...2479
Cab front pillar lining...2479
43-UPPER SIDE STRUCTURE...2480
Cab rear pillar lining...2480
Windscreen pillar lining...2482
44-UPPER REAR SIDE STRUCTURE...2485
Side panel extender...2485
Front side panel...2487
Centre side panel...2493
Rear side panel...2497
Rear corner panel...2507
Centre sill panel (side door)...2510
Centre sill panel...2514
Rear inner sill panel front section...2518
Rear sill panel rear section...2521
Centre pillar lower section...2524
Load area centre pillar upper section...2527
Load area centre pillar lining lower section...2529
Load area centre pillar lining upper section...2532
Extreme rear pillar lower section...2535
Extreme rear pillar upper section...2539
Side panel upper vertical stiffener...2542
Side panel front lower vertical stiffener...2544
Side panel rear lower vertical stiffener...2546
Side panel rear upper horizontal stiffener...2548
Side panel lower horizontal stiffener...2550
Outer rear wheel arch...2554
44-UPPER REAR STRUCTURE...2556
Outer rear wheel arch...2556
44-UPPER REAR SIDE STRUCTURE...2557
Outer rear wheel arch...2557
Inner rear wheel arch...2558
Rear lights support...2560
44-UPPER REAR STRUCTURE...2563
End panel...2563
45-BODY TOP...2567
Cab roof...2567
Load area roof...2570
Load area rear roof...2573
Cab roof front cross member...2576
Cab roof rear cross member...2578
Roof cross member bracket...2580
Load area roof centre cross member...2582
Roof longitudinal bracing rib...2584
Roof rear cross member...2586
Roof rear cross member lining...2589
Cab roof side extender...2591
Cab roof drip moulding lining...2595
Load area front roof drip moulding...2599
Load area rear roof drip moulding...2605
Load area rear drip moulding...2606
Load area rear roof drip moulding...2607
Load area front roof drip moulding lining...2608
Load area rear roof drip moulding lining...2611
47-SIDE OPENINGS...2613
Front door...2613
Sliding side door...2615
Sliding door panel...2620
48-OTHER OPENINGS...2623
Bonnet...2623
Hinged doors...2624
Hinged door panel...2626
MR-324-MASTER-5...2631
50-GENERAL...2634
Safety...2634
Tooling...2635
51-SIDE OPENING ELEMENT MECHANISMS...2637
Front door, outside handle...2637
Outside handle for sliding door...2640
Front door lock barrel...2641
Sliding door lock barrel...2644
Front door lock...2645
Locks and mechanisms for sliding door...2649
Front door window raiser...2661
Front door window riser...2662
52-NON-SIDE OPENING ELEMENT MECHANISMS...2665
Exterior catch for swing-out door...2665
Lock cylinder for swing-out door...2667
Locks and striker plates for swing-out doors...2669
54-WINDOWS...2674
Sliding window in door...2674
Fixed window in door...2678
Windscreen...2680
55-EXTERIOR PROTECTION...2683
Front bumper...2683
Rear bumper...2684
Radiator grille...2685
Cowl vent grille...2687
Side protective moulding...2689
Side protective mouldings...2690
Protective strip at base of swing-out doors...2694
56-EXTERIOR ACCESSORIES...2695
Exterior rear view mirror...2695
Large part of rear view mirror...2697
Plastic rear view mirror casing and small part of mirror...2698
Panel holding rear number plate lights...2699
Badge...2700
57-LOWER INTERIOR ACCESSORIES...2701
Dashboard...2701
Console...2706
Glove box door...2707
Notepad support...2708
Net retainer for storage compartment...2709
Central storage compartment...2710
59-INTERIOR SAFETY ACCESSORIES...2711
Front seat belts...2711
MR-324-MASTER-6...2715
66-WINDOW SEALING...2718
Sliding window surround...2718
MR-324-MASTER-7...2720
71-BODY INTERNAL TRIM...2723
Windscreen pillar trim...2723
Cabin pillar upper trim...2724
Cabin pillar centre trim...2725
Cabin pillar lower trim...2726
Door inner sill upper trim...2727
Door inner sill lower trim...2728
Headlining...2729
Cabin luggage compartment...2731
Cabin carpet...2732
72-TRIM FOR SIDE OPENINGS...2735
Front door trim...2735
73-TRIM FOR OPENINGS (OTHER THAN SIDE)...2738
Bonnet trim...2738
Swing door trims...2739
75-FRONT SEAT FRAMES AND RUNNERS...2741
Complete seat...2741
Seat height adjuster and runners...2742
Complete cabin bench seat...2743
77-FRONT SEAT TRIM...2744
Backrest trim...2744
Bench seat backrest trim...2746
Seat cushion trim...2750
Bench seat cushion trim...2752
MR324MASTER4...2754
40-GENERAL...2758
Dimensions...2758
Engine and equipment...2759
Identification...2760
Lifting equipment...2763
Towing...2765
Procedure symbols...2766
Key to symbols...2768
Description of parts (exploded views)...2769
Opening clearances...2773
Collision damage assessment...2780
Sub-frame dimensions...2783
Body jig bench...2785
41-LOWER STRUCTURE...2796
Lower front cross member...2796
Part front side member...2799
Front half unit...2802
Cab inner sill panel...2805
Cab front pillar bracket (jacking point)...2807
Cab side sill...2810
Cab rear pillar bracket...2813
Tunnel...2817
Cab floor...2819
Cab floor front cross member...2824
Cross members under front seat...2826
Load floor front cross member...2829
Front load floor...2833
Centre load floor...2839
Rear load floor (part)...2842
Centre side member...2847
Centre inner sill panel (side door)...2850
Sliding door runner bracket...2854
Centre inner sill panel...2858
Centre pillar cross member under floor...2862
Rear inner sill panel...2865
Load floor stiffener cross member...2868
Runner housing side stiffener...2870
Load floor centre cross member...2872
Load floor stiffener...2874
Leaf spring front mounting side cross member...2876
Leaf spring rear mounting centre cross member...2878
Leaf spring rear mounting side cross member...2880
Rear side member...2882
Rear side member side bracket...2883
Shock absorber stiffener bracket...2884
Rear side member extender...2885
Extreme rear cross member...2886
42-UPPER FRONT STRUCTURE...2889
Front wing...2889
Headlight carrier panel...2891
Cowl side panel...2894
Front wheel arch...2897
Tunnel stiffener...2902
Bulkhead...2904
Windscreen aperture lower cross member...2909
Windscreen aperture lower cross member closure panel...2912
43-UPPER SIDE STRUCTURE...2914
Cab front pillar...2914
Cab sill panel...2920
Outer front wheel arch...2923
Cab rear pillar...2925
Cab front pillar lining...2930
43-UPPER FRONT STRUCTURE...2932
Cab front pillar lining...2932
43-UPPER SIDE STRUCTURE...2933
Cab rear pillar lining...2933
Windscreen pillar lining...2935
44-UPPER REAR SIDE STRUCTURE...2938
Side panel extender...2938
Front side panel...2940
Centre side panel...2946
Rear side panel...2950
Rear corner panel...2960
Centre sill panel (side door)...2963
Centre sill panel...2967
Rear inner sill panel front section...2971
Rear sill panel rear section...2974
Centre pillar lower section...2977
Load area centre pillar upper section...2980
Load area centre pillar lining lower section...2982
Load area centre pillar lining upper section...2985
Extreme rear pillar lower section...2988
Extreme rear pillar upper section...2992
Side panel upper vertical stiffener...2995
Side panel front lower vertical stiffener...2997
Side panel rear lower vertical stiffener...2999
Side panel rear upper horizontal stiffener...3001
Side panel lower horizontal stiffener...3003
Outer rear wheel arch...3007
44-UPPER REAR STRUCTURE...3009
Outer rear wheel arch...3009
44-UPPER REAR SIDE STRUCTURE...3010
Outer rear wheel arch...3010
Inner rear wheel arch...3011
Rear lights support...3013
44-UPPER REAR STRUCTURE...3016
End panel...3016
45-BODY TOP...3020
Cab roof...3020
Load area roof...3023
Load area rear roof...3026
Cab roof front cross member...3029
Cab roof rear cross member...3031
Roof cross member bracket...3033
Load area roof centre cross member...3035
Roof longitudinal bracing rib...3037
Roof rear cross member...3039
Roof rear cross member lining...3042
Cab roof side extender...3044
Cab roof drip moulding lining...3048
Load area front roof drip moulding...3052
Load area rear roof drip moulding...3058
Load area rear drip moulding...3059
Load area rear roof drip moulding...3060
Load area front roof drip moulding lining...3061
Load area rear roof drip moulding lining...3064
47-SIDE OPENINGS...3066
Front door...3066
Sliding side door...3068
Sliding door panel...3073
48-OTHER OPENINGS...3076
Bonnet...3076
Hinged doors...3077
Hinged door panel...3079
MR324MASTER5...3084
50-GENERAL...3087
Safety...3087
Tooling...3088
51-SIDE OPENING ELEMENT MECHANISMS...3090
Front door, outside handle...3090
Outside handle for sliding door...3093
Front door lock barrel...3094
Sliding door lock barrel...3097
Front door lock...3098
Locks and mechanisms for sliding door...3102
Front door window raiser...3114
Front door window riser...3115
52-NON-SIDE OPENING ELEMENT MECHANISMS...3118
Exterior catch for swing-out door...3118
Lock cylinder for swing-out door...3120
Locks and striker plates for swing-out doors...3122
54-WINDOWS...3127
Sliding window in door...3127
Fixed window in door...3131
Windscreen...3133
55-EXTERIOR PROTECTION...3136
Front bumper...3136
Rear bumper...3137
Radiator grille...3138
Cowl vent grille...3140
Side protective moulding...3142
Side protective mouldings...3143
Protective strip at base of swing-out doors...3147
56-EXTERIOR ACCESSORIES...3148
Exterior rear view mirror...3148
Large part of rear view mirror...3150
Plastic rear view mirror casing and small part of mirror...3151
Panel holding rear number plate lights...3152
Badge...3153
57-LOWER INTERIOR ACCESSORIES...3154
Dashboard...3154
Console...3159
Glove box door...3160
Notepad support...3161
Net retainer for storage compartment...3162
Central storage compartment...3163
59-INTERIOR SAFETY ACCESSORIES...3164
Front seat belts...3164
MR324MASTER6...3168
66-WINDOW SEALING...3171
Sliding window surround...3171
MR324MASTER7...3173
71-BODY INTERNAL TRIM...3176
Windscreen pillar trim...3176
Cabin pillar upper trim...3177
Cabin pillar centre trim...3178
Cabin pillar lower trim...3179
Door inner sill upper trim...3180
Door inner sill lower trim...3181
Headlining...3182
Cabin luggage compartment...3184
Cabin carpet...3185
72-TRIM FOR SIDE OPENINGS...3188
Front door trim...3188
73-TRIM FOR OPENINGS (OTHER THAN SIDE)...3191
Bonnet trim...3191
Swing door trims...3192
75-FRONT SEAT FRAMES AND RUNNERS...3194
Complete seat...3194
Seat height adjuster and runners...3195
Complete cabin bench seat...3196
77-FRONT SEAT TRIM...3197
Backrest trim...3197
Bench seat backrest trim...3199
Seat cushion trim...3203
Bench seat cushion trim...3205
MR324MASTERBUS4...3207
40-GENERAL...3210
Information...3210
Description of parts, exploded views...3211
41-LOWER STRUCTURE...3215
Load floor...3215
43-UPPER SIDE STRUCTURE...3227
Cab rear pillar lining...3227
44-UPPER REAR STRUCTURE...3228
Intermediate centre pillar lining...3228
Load area centre pillar lining...3230
Spare wheel support...3232
45-TOP OF BODY...3233
Roof crossmember bracket...3233
Load area roof centre crossmember...3237
Load area rear drip moulding lining...3238
MR324MASTERBUS5...3239
54-WINDOWS...3242
Front and rear aperture windows...3242
Intermediate aperture window...3243
Sliding side door window...3244
57-LOWER INTERIOR ACCESSORIES...3245
Side door rail...3245
58-UPPER INTERIOR ACCESSORIES...3246
Side door handle...3246
Right rear door handle...3247
Left rear door handle...3248
59-INTERIOR SAFETY COMPONENTS...3250
Passenger seat belts...3250
MR324MASTERBUS7...3252
71-INTERIOR BODY TRIM...3255
Sliding door upper and lower sills...3255
71-BODY INTERIOR TRIM...3256
Right rear door sill...3256
Right-hand floor...3257
Left-hand floor...3259
Centre floor...3261
Cab inner sill left-hand trim...3262
Cab inner sill right-hand trim...3263
Side door rail cover...3264
Cab luggage compartment upper trim...3265
Wheel arch interior trim...3267
Rear aperture trim...3268
Rear lower trim...3270
Intermediate aperture trim...3271
Intermediate lower trim...3273
Front left aperture trim...3274
Front left lower trim...3276
Front headlining...3277
Rear headlining...3278
Centre headlining...3279
Side aluminium extrusions...3280
76-REAR SEAT FRAMES AND SLIDES...3281
Single and double complete seats...3281
Seat height adjuster...3282
78-REAR SEAT TRIM...3284
Seat backrest trim...3284
Seat cushion trim...3286
MR324MASTERBUS94...3287
40-GENERAL...3290
Information...3290
Key to parts in exploded view...3291
41-LOWER STRUCTURE...3293
Load floor...3293
43-UPPER SIDE STRUCTURE...3308
Cab rear pillar inner panel...3308
Side panel lower inner panel...3309
44-UPPER REAR STRUCTURE...3310
Rear wheel arch...3310
Spare wheel support...3311
Rear pillar lower inner panel...3312
45-TOP OF BODY...3313
Central roof crossmember...3313
Rear roof crossmember...3315
MR324MASTERDCAB4...3316
40-GENERAL...3319
Using symbols...3319
Key to symbols...3321
Description of parts (exploded view)...3322
Special tooling...3325
Opening clearances...3326
41-LOWER STRUCTURE...3328
Rear end cross member closure panel...3328
Rear end cross member...3330
Rear side member closure panel, part section...3332
Rear leaf spring mounting unit...3335
Central centre cross member...3338
Centre side member...3340
Front leaf spring mounting unit...3343
Front centre cross member...3348
Rear centre cross member...3350
Assembled cab rear step...3352
Cab rear pillar cross member...3357
Double cab rear floor part section...3359
Tunnel support...3363
43-UPPER SIDE STRUCTURE...3364
Double cab rear pillar...3364
Double cab stretcher...3370
Double cab stretcher lining...3375
Side panel...3376
Side door sill panel...3378
Cab rear pillar sill panel...3383
Rear pillar sill panel closure panel...3385
Cab side sill panel...3387
Cab rear pillar closure...3388
Partition cross members...3392
Partition pillar...3394
45-TOP OF BODY...3396
Roof...3396
Courtesy light mounting...3399
MR356...3400
MR-356-MASTER PRO-0...3401
General Information...3402
Contents...3402
01A-SPECIFICATIONS...3403
Engine- Clutch - Gearbox...3403
03A-TOWING - LASHING...3405
All types...3405
05A-FLUID CHANGE AND REFILLING...3406
Engine...3406
Gearbox...3407
Power assisted steering...3408
07A-ENGINE AND GEARBOX ASSEMBLY VALUES AND ADJUSTMENT...3409
Dimensions...3409
Capacities - grades...3412
Alternator belt tension...3414
Tightening the cylinder head...3415
07B-VALUES AND SETTINGS OF AXLE ASSEMBLIES...3416
Tyres and wheels...3416
Brakes...3417
Front axle checking values...3418
MR-356-MASTER PRO-1...3419
Engine and peripherals...3420
Contents...3420
10A-ENGINE ASSEMBLY AND PERIPHERALS...3421
Identification...3421
Oil consumption...3422
Oil pressure...3423
Engine and gearbox...3424
11A-TOP AND FRONT OF ENGINE...3429
Timing belt...3429
Cylinder head gasket...3434
13B-DIESEL INJECTION...3437
Specifications...3437
Special notes...3439
Location of components...3441
Cleanliness...3444
13A-FUEL SUPPLY...3445
Diesel pre-filter...3445
13B-DIESEL INJECTION...3446
High-pressure pump...3446
Injector...3448
Injector rail...3451
Pressure sensor...3454
Diesel fuel temperature sensor...3455
Clogging gauge sensor...3456
Accelerator potentiometer...3457
Computer...3458
Injection warning light...3459
Allocation of computer tracks...3460
16A-STARTING - CHARGING...3461
Alternator...3461
Starter...3462
19A-COOLING SYSTEM...3463
Specifications...3463
Filling - Bleeding...3464
Checking...3465
Diagram...3466
Radiator...3467
Cooling system...3468
Coolant pump...3470
19C-TANK...3471
General information...3471
Fuel tank...3472
Filler neck...3473
Fuel gauge...3474
19D-ENGINE MOUNTING...3477
Suspended engine mounting...3477
MR-356-MASTER PRO-2...3478
Transmission...3479
Contents...3479
20A-CLUTCH...3480
Identification...3480
Exploded view...3481
Mechanism / Plate...3482
Thrust bearing...3484
Thrust bearing guide...3485
Flywheel...3486
21A-GEARBOX...3487
Ratios...3487
21A-MANUAL GEARBOX...3488
Lubricants...3488
Gearbox...3489
26A-FINAL DRIVE...3491
Identification...3491
Consumables...3492
Final drive...3493
29A-TRANSMISSION...3496
Longitudinal driveshaft...3496
MR-356-MASTER PRO-3...3498
Chassis...3499
Contents...3499
30A-GENERAL INFORMATION...3500
Diagram of braking circuits...3500
Brake circuit connection and piping...3501
Brake fluid...3502
Dimensions and structure of main braking components...3503
Tightening torques (in daNm)...3504
Bleeding the brake circuit...3508
31A-FRONT AXLE...3510
Brake pads...3510
Brake calliper...3512
Hubs...3514
Brake discs...3515
33A-REAR AXLE COMPONENTS...3516
Brake pads...3516
Parking brake...3517
Parking brake pads...3519
35A-WHEELS AND TYRES...3520
Specifications...3520
Wheel balancing...3523
36B-POWER ASSISTED STEERING...3524
Steering rack...3524
37A-MECHANICAL COMPONENT CONTROLS...3526
Master cylinder...3526
Brake servo...3527
Clutch release control...3528
External gear control...3529
Parking brake adjustment...3530
Brake compensator...3531
38C-ANTI-LOCK BRAKING SYSTEM...3533
Location of components...3533
Allocation of computer tracks...3534
Hydraulic module track allocation...3535
Hydraulic unit...3536
Computer...3537
Bleeding the brake circuit...3538
MR-356-MASTER PRO-6...3539
Air conditioning...3540
Contents...3540
61A-HEATING...3541
Control panel...3541
Control cables...3542
Fan assembly...3543
Air recirculation motor...3544
Radiator...3545
Air distribution unit...3546
Resistor unit...3551
62A-AIR CONDITIONING...3552
General information...3552
Evaporator...3554
Compressor...3556
Condenser...3557
Dehydration canister...3558
Tri-function pressure switch...3559
Pressure relief valve...3560
Connecting pipes...3561
Evaporator sensor...3563
AC thermal cut-off switch...3564
MR-356-MASTER PRO-8...3565
Electrical equipment...3566
Contents...3566
80A-BATTERY...3567
Special notes...3567
Safety...3568
Checking...3569
80B-FRONT HEADLIGHTS...3571
Headlight and indicator...3571
Beam adjustment...3572
81C-FUSES...3573
Fuses and relays...3573
Relay and fuse box...3574
Engine interconnection unit...3576
82A-IMMOBILISER...3577
Coded key immobiliser system...3577
Decoder unit...3581
83A-INSTRUMENT PANEL...3587
Dashboard...3587
Instrument panel...3592
Fuel level sensor...3596
84A-CONTROLS - SIGNALS...3598
Windscreen wiper stalk...3598
Lights stalk...3599
Stalk mounting...3600
Rotary switch under steering wheel...3601
Ignition switch...3603
85A-WIPERS...3604
Windscreen wiper...3604
Electric screen washer pump...3606
87C-Door and boot management...3607
Remote control door locking...3607
88C-AIRBAGS AND PRETENSIONERS...3610
General information...3610
Airbag computer...3611
Computer...3612
Pretensioner...3613
88C-WIRING...3614
Airbags and seat belt pretensioners...3614
88C-AIRBAGS AND PRETENSIONERS...3616
Destruction procedure...3616
MR356MASTERPRO0...3618
General Information...3619
Contents...3619
01A-SPECIFICATIONS...3620
Engine- Clutch - Gearbox...3620
03A-TOWING - LASHING...3622
All types...3622
05A-FLUID CHANGE AND REFILLING...3623
Engine...3623
Gearbox...3624
Power assisted steering...3625
07A-ENGINE AND GEARBOX ASSEMBLY VALUES AND ADJUSTMENT...3626
Dimensions...3626
Capacities - grades...3629
Alternator belt tension...3631
Tightening the cylinder head...3632
07B-VALUES AND SETTINGS OF AXLE ASSEMBLIES...3633
Tyres and wheels...3633
Brakes...3634
Front axle checking values...3635
MR356MASTERPRO1...3636
Engine and peripherals...3637
Contents...3637
10A-ENGINE ASSEMBLY AND PERIPHERALS...3638
Identification...3638
Oil consumption...3639
Oil pressure...3640
Engine and gearbox...3641
11A-TOP AND FRONT OF ENGINE...3646
Timing belt...3646
Cylinder head gasket...3651
13B-DIESEL INJECTION...3654
Specifications...3654
Special notes...3656
Location of components...3658
Cleanliness...3661
13A-FUEL SUPPLY...3662
Diesel pre-filter...3662
13B-DIESEL INJECTION...3663
High-pressure pump...3663
Injector...3665
Injector rail...3668
Pressure sensor...3671
Diesel fuel temperature sensor...3672
Clogging gauge sensor...3673
Accelerator potentiometer...3674
Computer...3675
Injection warning light...3676
Allocation of computer tracks...3677
16A-STARTING - CHARGING...3678
Alternator...3678
Starter...3679
19A-COOLING SYSTEM...3680
Specifications...3680
Filling - Bleeding...3681
Checking...3682
Diagram...3683
Radiator...3684
Cooling system...3685
Coolant pump...3687
19C-TANK...3688
General information...3688
Fuel tank...3689
Filler neck...3690
Fuel gauge...3691
19D-ENGINE MOUNTING...3694
Suspended engine mounting...3694
MR356MASTERPRO2...3695
Transmission...3696
Contents...3696
20A-CLUTCH...3697
Identification...3697
Exploded view...3698
Mechanism / Plate...3699
Thrust bearing...3701
Thrust bearing guide...3702
Flywheel...3703
21A-GEARBOX...3704
Ratios...3704
21A-MANUAL GEARBOX...3705
Lubricants...3705
Gearbox...3706
26A-FINAL DRIVE...3708
Identification...3708
Consumables...3709
Final drive...3710
29A-TRANSMISSION...3713
Longitudinal driveshaft...3713
MR356MASTERPRO3...3715
38C-ANTI-LOCK BRAKING SYSTEM...5351
ABS without ESP: Operating diagram...5351
Hydraulic assembly without ESP: Removal - Refitting...5353
ABS with ESP: Operating diagram...5356
Wheel speed sensor: Removal - Refitting...5358
Hydraulic assembly with ESP: Removal - Refitting...5360
Yaw speed and transversal acceleration sensor: Removal - Refitting...5363
Steering wheel angle sensor: Removal - Refitting...5364
Braking computer: Removal - Refitting...5366
38F-PNEUMATIC SUSPENSION...5368
Air suspension: Precautions for repair...5368
Air suspension: List and location of components...5369
Air suspension...5370
Air cushion: Removal - Refitting...5375
Air tank: Removal - Refitting...5377
Compressor unit...5378
Compressor unit: Removal - Refitting...5379
Air intake unit: Removal - Refitting...5381
Rear height sensor: Removal - Refitting...5382
Air suspension Programming:...5383
MR377MASTER6...5385
61A-HEATING...5388
Heating: List and location of components...5388
Front air distribution duct: Removal - Refitting...5390
Air distribution cable: Removal - Refitting...5392
Air mixing cable: Removal - Refitting...5393
Air distribution unit: Removal - Refitting...5394
Heater matrix: Removal - Refitting...5396
Fan assembly: Removal - Refitting...5400
Rear motor-driven fan assembly: Removal - Refitting...5402
Heating resistor relays: Removal - Refitting...5405
Heating resistor unit: Removal - Refitting...5406
Passenger compartment fan assembly control unit: Removal - Refitting...5410
Control panel: Removal - Refitting...5412
Recirculation motor: Removal - Refitting...5413
61B-SELF-CONTAINED HEATER...5414
Heater unit: Removal - Refitting...5414
Additional heater plug: Removal - Refitting...5418
Heating duct: Removal - Refitting...5420
Dosing pump: Removal - Refitting...5422
Fuel supply hoses: Removal - Refitting...5423
Self-contained heater control panel Removal - Refitting...5425
62A-AIR CONDITIONING...5426
Air conditioning: Operating diagram...5426
Air conditioning: Check...5428
Consumables...5431
Air conditioning cleaner...5432
Coolant circuit check...5433
Coolant circuit Draining - Refilling...5434
Safety advice...5437
Condenser: Removal - Refitting...5438
Rear condenser: Removal - Refitting...5439
Dehydration canister: Removal - Refitting...5443
Compressor: Removal - Refitting...5444
Expansion valve: Removal - Refitting...5450
Rear expansion valve: Removal - Refitting...5458
Rear evaporator: Removal - Refitting...5462
Evaporator: Cleaning...5467
Evaporator: Removal - Refitting...5468
Rear condenser/front condenser connecting pipe: Removal - Refitting...5474
Rear condenser/compressor connecting pipe: Removal - Refitting...5479
Dehydrator reservoir/rear expansion valve connecting pipe: Removal - Refitting...5483
Dehydration canister - pressure relief valve connecting pipe: Removal - Refitting...5491
Dehydrator reservoir/condenser connecting pipe: Removal - Refitting...5496
Pressure relief valve - compressor connecting pipe: Removal - Refitting...5498
Expansion valve/rear expansion valve connecting pipe: Removal - Refitting...5500
Rear expansion valve/compressor connecting pipe: Removal - Refitting...5508
Pressure sensor: Removal - Refitting...5516
Exterior air temperature sensor: Removal - Refitting...5517
Condenser - compressor connecting pipe: Removal - Refitting...5518
MR377MASTER8...5520
80A-BATTERY...5526
Battery: Precautions for repair...5526
Battery : Removal - Refitting...5527
Battery tray: Removal - Refitting...5531
80B-HEADLIGHTS...5535
Halogen bulb: Removal - Refitting...5535
Halogen headlight: Removal - Refitting...5537
Halogen headlight: Adjustment...5539
Side indicator: Removal - Refitting...5540
Remote headlight adjustment control: Removal - Refitting...5541
81A-REAR LIGHTING...5542
Rear light on wing: Removal - Refitting...5542
Rear light bulb: Removal - Refitting...5543
Third brake light: Removal - Refitting...5544
Number plate light: Removal - Refitting...5545
81B-INTERIOR LIGHTING...5546
Interior lights: List and location of components...5546
Headlining light: Removal - Refitting...5547
Courtesy light...5549
81C-FUSES...5551
Fuses: List and location of components...5551
82A-ENGINE IMMOBILISER...5553
Immobiliser system: List and location of components...5553
General engine immobiliser system information...5555
Ignition switch: Removal - Refitting...5556
Transponder ring: Removal - Refitting...5557
82B-HORN...5559
Horn: Removal - Refitting...5559
82C-ALARM...5560
Alarm: List and location of components...5560
Alarm siren: Removal - Refitting...5562
Bonnet switch: Removal - Refitting...5563
Ultrasound sensor...5564
83A-INSTRUMENT PANEL...5565
Instrument panel: Removal - Refitting...5565
Tachograph: Removal - Refitting...5566
Tachograph: Repair...5569
83C-ON-BOARD TELEMATICS SYSTEM...5570
Navigation: List and location of components...5570
Radio navigation system: Removal - Refitting...5573
Navigation computer: Removal - Refitting...5575
Navigation interface unit: Removal - Refitting...5576
Central control: Removal - Refitting...5577
Navigation screen: Removal - Refitting...5578
Navigation aerial: Removal - Refitting...5580
83D-CRUISE CONTROL...5581
Cruise control and speed limiter: General information...5581
Cruise control / speed limiter: List and location of components...5583
Switch: Removal - Refitting...5584
84A-CONTROL - SIGNALS...5585
Rotary switch: Removal - Refitting...5585
Steering wheel controls assembly: Removal - Refitting...5587
Wiper switch: Removal - Refitting...5589
Indicator lighting switch: Removal - Refitting...5590
Hazard warning lights switch and central locking: Removal - Refitting...5591
Door mirror control switch: Removal - Refitting...5592
Heated rear screen: Repair...5593
Heated rear screen switch: Removal - Refitting...5595
85A-WIPING - WASHING...5596
Windscreen wiper blade: Removal - Refitting...5596
Windscreen wiper arm: Removal - Refitting...5597
Windscreen wiper mechanism: Removal - Refitting...5599
Windscreen wiper motor: Removal - Refitting...5602
Rain and light sensor: Removal - Refitting...5604
Windscreen washer pump: Removal - Refitting...5605
86A-RADIO...5606
Audio equipment: List and location of components...5606
Car radio: Removal - Refitting...5608
Radio aerial: Removal - Refitting...5609
Front speakers: Removal - Refitting...5610
Rear speakers: Removal - Refitting...5611
Display: Removal - Refitting...5612
Radio control satellite: Removal - Refitting...5613
86B-CAR PHONE...5614
Mobile phone: List and location of components...5614
Computer: Removal - Refitting...5616
Hands-free microphone: Removal - Refitting...5617
87B-PASSENGER COMPARTMENT CONNECTION UNIT...5619
UCH: Removal - Refitting...5619
87D-ELECTRIC WINDOWS - SUNROOF...5623
Electric window: List and location of components...5623
Front driver's door electric window switch...5625
Front electric window switch on the passenger door...5626
One-touch unit: Removal - Refitting...5627
87F-PARKING DISTANCE CONTROL...5628
Parking proximity sensor: List and location of components...5628
Parking proximity sensor buzzer: Removal - Refitting...5629
Proximity radar Removal - Refitting...5630
Parking proximity sensor computer: Removal - Refitting...5632
87G-ENGINE INTERCONNECTION UNIT...5633
Engine compartment connection unit: List and location of components...5633
88A-WIRING HARNESS...5634
Computers List and location of components...5634
Diagnostic socket: List and location of components...5637
88C-AIR BAG AND PRETENSIONERS...5638
Airbag and Pretensioners: List and location of components...5638
MR391X2488B000...9828
88B-MULTIPLEX...9829
Fault finding - Introduction...9829
88B-MULTIPLEX...9839
Fault finding - Allocation of computer tracks...9839
Fault finding - Configurations and programming...9840
Fault finding - Interpretation of faults...9841
MR391X2488B050...9844
88B-MULTIPLEXING...9845
Fault finding - Introduction...9845
Fault finding - List and location of components...9850
Fault finding - Function...9851
Fault finding - Defect and safe modes...9853
Fault finding - Configurations...9854
Fault finding - Fault Finding Chart...9861
MR391X2488C000...9866
88C-AIR BAG AND PRETENSIONERS...9867
Fault finding - Introduction...9867
88C-AIR BAG AND PRETENSIONERS...9876
Fault finding - System operation...9876
Fault finding - Allocation of computer tracks...9877
Fault finding - Component replacement...9878
Fault finding - Configurations / Programming...9879
Fault finding - Fault summary table...9880
Fault finding - Interpretation of faults...9881
Fault finding - Conformity check...9897
Fault finding - Summary table of system states and parameters...9898
Fault finding - Dealing with computer states and parameters...9899
Fault finding - Dealing with command modes...9900
Fault finding - Fault finding chart...9901
MR391X2488C050...9902
88C-AIRBAGS AND PRETENSIONERS...9903
Fault finding - Introduction...9903
ABG_V08_PRELI...9903
MR398...9904
MR398MASTERPRO0...9905
01A-MECHANICAL SPECIFICATIONS FOR THE VEHICLE...9907
Vehicle: Specifications...9907
Vehicle: Identification...9919
01D-MECHANICAL INTRODUCTION...9920
Vehicle: Precautions for repair...9920
02A-LIFTING EQUIPMENT...9922
Vehicle: Towing and lifting...9922
04A-LUBRICANTS...9924
Diesel engine oils: Specifications...9924
Manual gearbox oil: Specifications...9925
04B-CONSUMABLES - PRODUCTS...9926
Vehicle: Parts and ingredients for the repairwork...9926
MR398MASTERPRO1...9929
10A-ENGINE AND LOWER ENGINE ASSEMBLY...9934
Engine oil: Draining - Refilling...9934
Oil filter: Removal - Refitting...9936
Exchanger: Removal - Refitting...9937
Oil pressure sensor: Removal - Refitting...9941
Oil level sensor: Removal - Refitting...9942
Sump: Removal - Refitting...9943
Oil pump: Removal - Refitting...9946
Multifunction support: Removal - Refitting...9950
Engine/gearbox assembly: Removal - Refitting...9958
Oil pressure: Check...9975
11A-TOP AND FRONT OF ENGINE...9977
Final compression pressure: Check...9977
Accessories belt: Removal - Refitting...9979
Crankshaft accessories pulley: Removal - Refitting...9983
Timing chain: Removal - Refitting...9987
Rocker cover: Removal - Refitting...10002
Camshaft: Removal - Refitting...10009
Cylinder head: Removal - Refitting...10021
Lifting eyes: Removal - Refitting...10041
12A-FUEL MIXTURE...10042
Air intake: Description...10042
Air filter: Removal - Refitting...10043
Air filter unit: Removal - Refitting...10044
Air flowmeter: Removal - Refitting...10045
Air inlet flap: Removal - Refitting...10046
Inlet manifold: Removal - Refitting...10048
Exhaust manifold: Removal - Refitting...10053
12B-TURBOCHARGING...10059
Turbocharger: Removal - Refitting...10059
Turbocharger oil pipe: Removal - Refitting...10068
Pressure regulator: Checking...10071
Intercooler: Removal - Refitting...10072
13A-FUEL SUPPLY...10077
Diesel supply system: Operating diagram...10077
Diesel filter: Removal - Refitting...10078
13B-DIESEL INJECTION...10079
Diesel injection: Precautions for repair...10079
Diesel injection: List and location of components...10082
Diesel injection computer: Removal - Refitting...10087
Camshaft position sensor: Removal - Refitting...10089
Crankshaft position sensor: Removal - Refitting...10090
High pressure pump: Removal - Refitting...10091
Fuel pressure regulator: Removal - Refitting...10103
Diesel injector fuel return rail: Removal - Refitting...10106
High-pressure pipe between the pump and rail: Removal - Refitting...10113
High-pressure pipe between the rail and injector: Removal - Refitting...10120
Injector rail: Removal - Refitting...10128
Diesel injector: Removal - Refitting...10134
13C-PREHEATING...10143
Pre/postheating unit: Removal - Refitting...10143
Heater plugs Removal - Refitting...10144
14A-ANTIPOLLUTION...10148
Exhaust gas recirculation: Operating diagram...10148
Exhaust gas recirculation solenoid valve: Removal - Refitting...10150
Intercooler: Removal - Refitting...10157
Exhaust gas recirculation rigid pipe: Removal - Refitting...10160
16A-STARTING - LOAD...10165
Charging circuit: Specifications...10165
Starting system: Identification...10166
Alternator: Removal - Refitting...10167
Starter: Removal - Refitting...10169
19A-COOLING SYSTEM...10171
Engine cooling: Parts and consumables for the repair work...10171
Engine cooling: Precautions for repair...10172
Engine cooling circuit: Operating diagram...10173
Engine cooling circuit: Specifications...10174
Engine cooling circuit: check...10175
Cooling circuit: Draining - Refilling...10177
Cooling radiator: Removal - Refitting...10180
Water pump: Removal - Refitting...10186
Thermostat: Removal - Refitting...10190
Engine cooling fan assembly: Removal - Refitting...10194
Expansion bottle: Removal - Refitting...10196
Coolant temperature sensor: Removal - Refitting...10198
19B-EXHAUST...10200
Exhaust: Parts and consumables for the repair work...10200
Exhaust: Precautions for repair...10202
Catalytic pre-converter: Removal - Refitting...10203
Catalytic converter: Removal - Refitting...10205
Silencer: Removal - Refitting...10206
Connecting hose: Removal - Refitting...10207
19C-FUEL TANK...10210
Fuel tank: Draining...10210
Fuel tank: Removal - Refitting...10212
Filler neck: Removal - Refitting...10217
Sender unit: Removal - Refitting...10220
19D-ENGINE MOUNTING...10223
Suspended engine mounting: Tightening torque...10223
Left-hand suspended engine mounting: Removal - Refitting...10224
Right-hand suspended engine mounting: Removal - Refitting...10226
MR398MASTERPRO2...10228
20A-CLUTCH...10230
Clutch: Specifications...10230
Mechanism / Disk: Removal - Refitting...10232
Clutch thrust bearing: Removal - Refitting...10234
Flywheel: Removal - Refitting...10236
21A-MANUAL GEARBOX...10238
Manual gearbox oil: Specifications...10238
Manual gearbox oil: Draining - Refilling...10239
Manual gearbox: Parts and consumables for the repair work...10240
Manual gearbox: Identification...10241
Manual gearbox: Specifications...10242
Manual gearbox: Removal - Refitting...10243
Input shaft lip seal: Removal - Refitting...10247
26A-REAR AXLE...10249
Rear axle assembly: Identification...10249
Rear axle assembly: Specifications...10250
Rear axle assembly: Removing - Refitting...10251
Rear axle oil: Specifications...10259
Rear axle oil: Draining - Refilling...10261
29A-DRIVESHAFTS...10264
Propshaft: Removal - Refitting...10264
MR398MASTERPRO3...10266
30A-GENERAL INFORMATION...10270
Brake circuit Operating diagram...10270
Brake circuit Precautions for repair...10271
Brake circuit Bleeding...10272
Brake circuit Tightening torque...10273
Brake: Specifications...10283
Steering: Tightening torque...10285
Underbody height: Adjustment values...10289
Front axle: Tightening torque...10291
Front axle: Adjustment values...10295
Front axle: Adjusting...10299
Rear axle: Tightening torque...10301
Front anti-roll bars: Specifications...10305
31A-FRONT AXLE ASSEMBLIES...10306
Front brake pads: Removal - Refitting...10306
Front brake hose: Removal - Refitting...10308
Front brake calliper: Removal - Refitting...10310
Front brake calliper: Repair...10312
Front brake calliper support: Removal - Refitting...10315
Front brake disc: Removal - Refitting...10316
Front brake disc: Description...10318
Hydraulic unit - master cylinder brake pipe: Removal - Refitting...10319
Hydraulic unit - underbody union brake pipe: Removal - Refitting...10322
Hydraulic unit - front left-hand calliper brake pipe: Removal - Refitting...10325
Hydraulic unit - front right-hand calliper brake pipe: Removal - Refitting...10329
Front driveshaft hub carrier: Removal - Refitting...10332
Front hub carrier bearing: Removal - Refitting...10335
Spring and front shock absorber: Removal - Refitting...10337
33A-REAR AXLE ASSEMBLIES...10339
Rear brake pads: Removal - Refitting...10339
Rear brake hose: Removal - Refitting...10341
Rear brake caliper: Removal - Refitting...10343
Rear brake calliper mounting: Removal - Refitting...10345
Rear brake disc: Removal - Refitting...10346
Brake pipe: Removal - Refitting...10352
Shock absorber: Removal - Refitting...10354
Rear suspension spring: Removal - Refitting...10355
Rear disc brake bearing: Removal - Refitting...10356
Leaf spring bearing: Removal - Refitting...10365
35A-WHEELS AND TYRES...10366
Wheel: Removal - Refitting...10366
Wheel: Balancing...10369
Tyres: Removal - Refitting...10372
Tyre inflation pressure: Identification...10374
Tyres: Identification...10376
Wheel rim: Identification...10377
36A-STEERING ASSEMBLY...10378
Track rod: Removal - Refitting...10378
36B-POWER ASSISTED STEERING...10379
Power assisted steering rack: List and location of components...10379
Power assisted steering rack: Removal - Refitting...10381
Intermediate shaft: Removal - Refitting...10385
Steering column: Removal - Refitting...10387
Steering column: List and location of components...10389
Steering wheel: Removal - Refitting...10390
Power assisted steering pump: Checking...10392
Power assisted steering pipes: Removal - Refitting...10395
37A-MECHANICAL COMPONENT CONTROLS...10399
Master cylinder: Removal - Refitting...10399
Brake servo non-return valve: Removal - Refitting...10401
Brake servo: Removal - Refitting...10403
Vacuum pump: Removal - Refitting...10406
Accelerator pedal: Removal - Refitting...10407
Brake pedal: Removal - Refitting...10408
Brake light switch: Removal - Refitting...10410
Parking brake lever: Removal - Refitting...10412
Parking brake lever: Adjusting...10413
Braking assistance circuit: Check...10416
Clutch control: List and location of components...10417
Clutch pedal: Removal - Refitting...10418
Clutch pedal position sensor: Removal - Refitting...10419
Clutch master cylinder: Removal - Refitting...10421
Hydraulic clutch slave cylinder: Removal - Refitting...10424
Clutch control pipes: Removal - Refitting...10425
Manual gearbox selector cable: Removal - Refitting...10426
Gear control unit: Removal - Refitting...10429
Gear control unit: Adjusting...10431
Parking brake cables: Removal - Refitting...10434
38C-ANTI-LOCK BRAKING SYSTEM...10436
ABS without ESP: Operating diagram...10436
Hydraulic assembly without ESP: Removal - Refitting...10438
MR398MASTERPRO6...10440
61A-HEATING...10442
Heating: List and location of components...10442
Air distribution cable: Removal - Refitting...10444
Air mixing cable: Removal - Refitting...10445
Air distribution unit: Removal - Refitting...10446
Heater matrix: Removal - Refitting...10448
Fan assembly: Removal - Refitting...10450
Heating resistor relays: Removal - Refitting...10451
Heating resistor unit: Removal - Refitting...10452
Passenger compartment fan assembly control unit: Removal - Refitting...10454
Control panel: Removal - Refitting...10456
A-pillar air distribution duct: Removal - Refitting...10457
62A-AIR CONDITIONING...10459
Air conditioning: Parts and consumables for the repair work...10459
Condenser: Removal - Refitting...10460
Dehydration canister: Removal - Refitting...10463
Compressor: Removal - Refitting...10465
Expansion valve: Removal - Refitting...10467
Dehydration canister - pressure relief valve connecting pipe: Removal - Refitting...10469
Dehydrator reservoir/condenser connecting pipe: Removal - Refitting...10471
Pressure relief valve - compressor connecting pipe: Removal - Refitting...10473
Evaporator sensor: Removal - Refitting...10475
Condenser - compressor connecting pipe: Removal - Refitting...10476
MR398MASTERPRO8...10478
80A-BATTERY...10483
Battery: Precautions for repair...10483
Battery : Removal - Refitting...10484
80B-HEADLIGHTS...10490
Remote headlight adjustment motor: Removal - Refitting...10490
Front headlight: Adjusting...10491
Halogen headlight: Removal - Refitting...10492
Side indicator: Removal - Refitting...10493
81A-REAR LIGHTING...10494
Rear light bulb: Removal - Refitting...10494
Number plate light: Removal - Refitting...10495
Rear light: Removal - Refitting...10496
81B-INTERIOR LIGHTING...10497
Headlining light: Removal - Refitting...10497
81C-FUSES...10498
Fuses: List and location of components...10498
82A-ENGINE IMMOBILISER...10500
Immobiliser system: List and location of components...10500
Ignition switch: Removal - Refitting...10502
Transponder ring: Removal - Refitting...10503
Decoder unit: Removal - Refitting...10505
Remote door locking control battery: Removal - Refitting...10506
82B-HORN...10507
Horn: Removal - Refitting...10507
82C-ALARM...10508
Alarm: List and location of components...10508
Alarm siren: Removal - Refitting...10510
Bonnet switch: Removal - Refitting...10511
Ultrasound sensor: Removal - Refitting...10512
83A-INSTRUMENT PANEL...10513
MR414X7038F000...12057
MR414X7062A000...12114
62A-AIR CONDITIONING...12115
Fault finding - Introduction...12115
Fault finding - System operation...12116
Fault finding - Customer complaints...12119
Fault finding - Fault Finding Chart...12121
MR414X7080A000...12150
80A-BATTERY...12151
Battery – Initialisation...12151
Battery – Specifications...12152
Battery – Advice...12153
Battery – Check...12154
Battery – Test...12156
MR414X7080D000...12159
80D-INTERIOR LIGHTING...12160
Fault finding - Customer complaints...12160
Fault finding - Fault Finding Chart...12161
Fault finding - Customer complaints...12169
Fault finding - Fault Finding Chart...12170
Fault finding - Customer complaints...12175
Fault finding - Fault Finding Chart...12176
Fault finding - Customer complaints...12187
Fault finding - Fault Finding Chart...12188
Fault finding - Customer complaints...12193
Fault finding - Fault Finding Chart...12194
Fault finding - Customer complaints...12198
Fault finding - Fault Finding Chart...12199
Fault finding - Customer complaints...12204
Fault finding - Fault Finding Chart...12205
80D-EXTERIOR LIGHTS...12210
Fault finding - Customer complaints...12210
Fault finding - Fault Finding Chart...12211
MR414X7081C000...12222
81C-Fuses...12223
Passenger compartment fuse box - Customer complaints...12223
Passenger compartment fuse box - Fault finding chart...12225
Engine compartment relay/fuse box - Customer complaints...12241
Engine compartment relay/fuse box - Fault finding chart...12243
MR414X7082A000...12268
MR414X7083A000...12305
83A-INSTRUMENT PANEL...12306
Fault finding - Introduction...12306
Instrument panel - Configuration...12309
Instrument panel - Customer complaints...12310
Instrument panel - Fault Finding Chart...12312
Tachograph - List and location of components...12348
Tachograph - Function...12349
Tachograph - Role of components...12350
Tachograph - Customer complaints...12351
Tachograph - Fault finding chart...12352
Instrument panel: Customer complaints...12355
Gauging system fault finding...12356
MR414X7084A000...12360
84A-CONTROL - SIGNALS...12361
Radio control satellite: Connection...12361
Radio control satellite: Check...12362
MR414X7085A000...12363
85A-WIPERS - WASHERS...12364
Rain and light sensor: Role of components...12364
Rain and light sensor: Customer complaints...12365
Rain and light sensor: Fault finding chart...12366
Windscreen washer pump: Role of components...12376
Windscreen washer pump: Customer complaints...12377
Windscreen washer pump: Fault finding chart...12378
MR414X7086A000...12381
86A-RADIO...12382
List and location of components...12382
General Information...12384
Security code recovery procedure...12387
Anti-theft code...12389
Configuration - Settings...12393
Connections...12394
Self-test procedure...12395
Radio fault finding: Customer complaints...12396
Fault finding chart...12397
MR414X7088B000...12922
88B-MULTIPLEXING...12923
Fault finding - Introduction...12923
Fault finding - List and location of components...12928
Fault finding - Function...12929
Fault finding - Defect and safe modes...12931
Fault finding - Configurations...12932
Fault finding - Fault Finding Chart...12939
MR414X7088C000...12942
88C-AIRBAGS AND PRETENSIONERS...12943
Fault finding - Introduction...12943
ABG_V08_PRELI...12943
Fault finding - System operation...12948
Fault finding - Replacement of components...12951
Diagnostics - Configuration and Programming...12952
Fault finding - Fault summary table...12954
Fault finding - Interpretation of faults...12955
Fault finding - Dealing with commands...12986
Fault finding - Customer complaints...12987
Fault finding - Fault Finding Chart...12988
ABG_V08_ALP1...12988
Renault Master/Mascott/Movano/NV400/Interstar Repair Service Manual 1997-2016
