Cab + Air Bag Removal / Fitting: Renault V.I

RENAULT V.I.
60 027 - GB - 06/2004
CAB + AIR BAG REMOVAL / FITTING
RANGE FAMILY VARIANT

MASCOTT DXi - -
The above information may change in the course of time. Only the "Consult" section of the workshop manuals
repertory in standard N° 10320 serves as reference.
60 027
60.0
60.0 . . . .
60.0 . . . .
50 21 014 915
60 027 1
CONTENTS
Generalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 → 5
Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 → 1

— Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-3 → 6
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 → 6
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 → 1
— Removal/Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1-3 → 12
Airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 → 7
— Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1-4 → 5
— Fuse(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2-1 → 1
— Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3-1 → 3
— Layout of appliances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E4-1 → 2
— Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E5-1 → 1
— Removal/Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E6-1 → 9
— Destruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E7-1 → 3
© RENAULT V.I. 06/2004 - Imprimé en France - le 07/2004 50 21 014 915

60 027 A-1
GENERALITIES
RENAULT V.I. 06/2004

A-2 60 027
APPLICABILITY
Applicability date Page

Range Family Title Variant Updating
Start End N°
Conventional
MASCOTT DXi 23/05/2002 A-3
symbols
MASCOTT DXi Warnings 31/03/2003 A-5

60 027 A-3
Conventional symbols
Fitting
Tighten to torque (Nm) (left-hand thread) Tighten by indicated value
Tighten to torque (Nm) (right-hand thread) Loosen by indicated value
Tightening torque with lubricated threaded

hardware
Dimensioning
Tightening ... Greater than or equal to ...
Equal to Wear limit
... Less than ... Machining limit or dimension
... Greater than ... Maximum out-of-true
... Less than or equal to ... Maximum parallelism error
Repair
Force to be exerted in the direction shown

Smear or coat (see "Consumables" table)
(hammer - press)
Heat or cool: Temperature in degrees Fill to level (see "Technical Data" and
Celsius (e.g. + 80 °C) "Consumables" table)
Weld bead Grease or oil (see "Consumables" table)
Repair time - Heating time Mark - Assemble according to marking

A-4 60 027
Adjustment
Rotating friction torque Turn anti-clockwise
Turn anti-clockwise
Turn in alternate directions
(the figure shows the number of turns)
Turn clockwise
Turn clockwise
(the figure shows the number of turns)
Place in contact Move in the direction shown
Dimension to be assured (mm)
Various information
Exhaust - Outlet Operation with a sequence
Intake - Inlet Involves
Return to numbered operation -

Weight in kg (example: 275 kg)
Connected with numbered operation
Depending on versions or options Withdraw - Delete
Direction of disassembly
Wrong
(the arrow shows the direction)
Direction of assembly
Correct
(the arrow shows the direction)
Injection ... to ...
Repair dimension Inspect - Check condition of part
Part to be replaced Danger for persons, vehicle or equipment

60 027 A-5
Warnings
In this document, safety instructions are symbolized as follows:
DANGER! NON-OBSERVANCE OF THE PROCEDURE DESCRIBED OR LACK OF CARE OR ATTENTION, RISK CAUSING
SERIOUS INJURY OR EVEN DEATH.
WARNING! Any different or inappropriate working method risks causing damage to the product.
NOTE! Draws attention to particular or important points of the method.
Comply without fail with the regulations in force relative to the recovery and treatment of used parts and
waste.

A-6 60 027

60 027 B1-1
TECHNICAL DATA

B1-2 60 027
APPLICABILITY
Tightening torques

Start End N°
MASCOTT DXi Definitions 27/02/2003 B1-3
Standard nut and

MASCOTT DXi bolt tightening 06/06/2003 B1-4
torques table
Specific cab
MASCOTT DXi tightening torques 28/01/2004 B1-5
(in Nm)
Specific air bag

MASCOTT DXi device tightening 08202/03 12/02/2004 B1-6
torques (in Nm)

60 027 B1-3
Tightening torques
Definitions
There are several types of tightening:
– Tightening to torque (in Nm)
– Tightening to angle (in °)
– Tightening to torque-angle (en Nm + °)
Torques given in Nm are nominal torques (average value calculated on the basis of the minimum torque and the
maximum torque).
The tightening precision class defines the tolerance of this torque in percent as a function of the nominal torque
applied.
Tightening precision classes:

– Class I: Special threaded hardware (tolerances ± 10% of the final torque).
– Class II: Reserved for precise tightening (tolerance ± 10% of the nominal torque).
– Class III: Reserved for normal standard tightening (tolerance ± 20% of the nominal torque)
For standard threaded hardware indicated in the table below, use tightening class III.
For other torques, see the following page(s).
"FIH" type (Nylstop) locknuts must be replaced whenever removed. "DRH" type (oval) locknuts can be
re-used. If locknuts (DRH, FIH or other) are re-used, make absolutely certain that the screw-thread of the bolt
protrudes least two threads above the top edge of the nut.

B1-4 60 027
Standard nut and bolt tightening torques table
The tightening torque values given in the table are based on standard 01.50.4002 and apply to new nuts and bolts
fitted dry and re-used nuts and bolts with oil applied to the screw-threads. If any nuts and bolts are replaced, it is
absolutely essential to use nuts and bolts recommended by the RENAULT TRUCKS Spare Parts Department
(coefficient of friction in compliance with standard 01.50.4002).
Tightening torque values in Nm for conventional "metric system" threaded hardware based
on standard 01.50.4002 (H: normal and HE: with flange)
Quality class III
dia. and pitch of nuts and bolts
Quality class 8.8 Quality class 10.9
6 x 1.00 7.5 ± 1.5 11 ± 2.2

7 x 1.00 15 ± 3 20 ± 4
8 x 1.00 20 ± 4 30 ± 6
8 x 1.25 20 ± 4 27 ± 5.4
10 x 1.00 40 ± 8 60 ± 12
10 x 1.25 40 ± 8 60 ± 12
10 x 1.50 40 ± 8 50 ± 10
12 x 1.25 70 ± 14 100 ± 20
12 x 1.50 65 ± 13 95 ± 19
12 x 1.75 60 ±12 90 ± 18
14 x 1.50 105 ± 21 155 ± 31
14 x 2.00 100 ± 20 145 ± 29
16 x 1.50 160 ± 32 220 ± 44
16 x 2.00 150 ± 30 220 ± 44
18 x 1.50 240 ± 48 340 ± 68
18 x 2.50 210 ± 42 310 ± 62
20 x 1.50 330 ± 66 480 ± 96
20 x 2.50 300 ± 60 435 ± 87
22 x 1.50 450 ± 90 650 ± 130
22 x 2.50 410 ± 82 595 ± 119
24 x 2.00 560 ± 112 820 ± 164
24 x 3.00 510 ± 102 750 ± 150

60 027 B1-5
Specific cab tightening torques (in Nm)
Front grille to bumper securing bolts 3 ± 0.3 Nm

B1-6 60 027
Specific air bag device tightening torques (in Nm)

60 027 C-1
TOOLS

C-2 60 027
APPLICABILITY

Start End N°
MASCOTT DXi Generalities 12/12/2001 C-3

60 027 C-3
Generalities
RENAULT TRUCKS divide tools into three categories:
– General-purpose tools: proprietary tools.

• 50 00 26 .... reference number (possibility of purchasing through the RENAULT TRUCKS Spare Parts
department).
• 4-figure reference number (tools classified by RENAULT TRUCKS but available from the supplier).
– Special tools: specifically created tools distributed by the RENAULT TRUCKS Spare Parts Department.
– Locally manufactured tools: these tools are classified differently according to their degree of
sophistication:
• 4-figure reference number (represented by a drawing): tools that are simple to make without need for
special qualification.
• 50 00 26 .... reference number (possibility of purchasing through the RENAULT TRUCKS Spare Parts
department): a certain amount of skill is needed to make these tools.
Three levels (or echelons) determine their assignment:

– Level 1: tools for servicing, maintenance and minor tasks.
– Level 2: tools for major repairs.
– Level 3: tools for refurbishment.
Proprietary tools mentioned in this manual do not appear in the tools list.
These tools are identified in the standard tools manual (MO) by a 4-figure number.

C-4 60 027
TOOLS
Special Tools
Manufac- Manufac-
RENAULT
Illustration Designation turer turer Level Qty
TRUCKS Ref.
reference Code
5000262466 STRAP 1 1
BLANKING
5000262359 1 1
PLUG
5000262370 LIFTING BEAM 1 1
5010262623 INERT SQUIB 1 1

60 027 C-5
Locally manufactured tools
Manufac- Manufac-
RENAULT
Illustration Designation turer Ref- turer Level Qty
TRUCKS Ref.
erence Code
AIRBAG
2887 DESTRUCTION 1 1
DEVICE
AIRBAG
2886 DESTRUCTION 1 1
DEVICE

C-6 60 027

60 027 D1-1
CAB

D1-2 60 027
APPLICABILITY
Removal/Fitting

Start End N°
MASCOTT DXi Preparation 28/01/2004 D1-3
MASCOTT DXi Front end 28/01/2004 D1-3
Cab equipped with

MASCOTT DXi 62606 29/01/2004 D1-5
air conditioning
MASCOTT DXi Cooling circuit 29/01/2004 D1-6
MASCOTT DXi Clutch control 28/01/2004 D1-6
MASCOTT DXi Braking circuit 29/01/2004 D1-7
MASCOTT DXi Wiring harness 29/01/2004 D1-9
MASCOTT DXi Steering column 29/01/2004 D1-10
MASCOTT DXi Various 30/01/2004 D1-11
MASCOTT DXi Cab 30/01/2004 D1-12

60 027 D1-3
Removal/Fitting
Preparation
Chock the vehicle's rear wheels.
Disconnect the batteries, starting with the negative terminal.
Drain the cooling system.
With the front wheels parallel and in the straight ahead position and the steering wheel spokes in a horizontal
position, withdraw the ignition key and lock the steering column.
Remove the air filter.
The removal of hydraulic components does not require the circuits to be drained.
Place removed components in the vicinity of the engine.
Front end
Removal
Remove flashing lamps (1).

Remove front grille (2).
Remove front headlamps (3).

Remove the grille (4).
Unclip cable (5) from the lock securing the bonnet.
Remove switch (6).
Disengage the wiring harness from the fastening clips.

D1-4 60 027
POSITION BONNET RETAINING STRUT (7) AS SHOWN IN THE

DRAWING BEFORE REMOVING TECHNICAL FRONT END (8).
Remove technical front end (8).
Remove front bumper (1).
Double cab or van:

Remove cross-member (2).
Single cab:
Cross-member (2) must remain on the cab in order to fasten the
lifting straps 2466.
Fitting
To fit, proceed in the reverse sequence to removal.
Watch that the cable is correctly positioned on the bonnet securing lock. Check for correct operation before closing
the bonnet.
Tighten to torque.
See page(s) B-1-3.

60 027 D1-5
Cab equipped with air conditioning
Removal
Drain the air conditioning system.
Remove bolt (1) from the pressure reducer retaining flange.
Blank off the pressure reducer ports with tool 2359.

Blank off the high and low pressure pipes.
Fitting
Recharge the air conditioning system.

D1-6 60 027
Cooling circuit
Removal
Remove the expansion bottle and fasten it to the engine surrounds.
Disconnect heating hoses (1).
Fitting
Fill the cooling system (see "Driving and Servicing" handbook).
Clutch control
Removal
Remove ball-joint (1).
Unclip fluid reservoir (2).

Without disconnecting the flexible hydraulic pipe, turn clutch master
cylinder (3) through 1/4 of a turn to remove.
Unclip flexible pipe (4) on the cab.
Fitting

60 027 D1-7
Braking circuit
Removal
Two possible solutions: with or without draining of the system.
Without draining of the system
Unplug connector (1).

Remove master cylinder (2).
Remove bolt (3) from the windscreen wiper motor bracket.

Remove nut (4) from the left-hand windscreen wiper bracket.
Disengage brake pipes (5) from the windscreen wiper motor
bracket.
Unclip the brake pipes on the cab.

Disconnect earths (7).
Remove steering hydraulic fluid reservoir (8).
Remove bolts (9) securing the "ABS" unit bracket.

D1-8 60 027
Remove guard screen (10).
Remove bolts (11).
To free up space in the engine surrounds, remove the air and cooling
circuit hoses on the right-hand side of the engine, then disengage
the "ABS" unit and the steering hydraulic fluid reservoir from the cab.
Handle the brake pipes with precautions when placing

the different elements in the engine surrounds.
Disconnect union (12) from the braking assistance flexible pipe.

With draining of the system
It is absolutely essential to use this method for vehicles

of 5.5 tonnes and upwards as it is forbidden to separate
the master cylinder from the master servo (mastervac),
since there may still be residual pressure after
reassembly.

Disconnect flexible pipes (13).
Disconnect union (12) from the braking assistance flexible pipe.
Fitting
Tighten to torque.
See page(s) B-1-3.
Bleed the system, if necessary.
Bleed the braking system before reconnecting the battery so as not

to activate the "ABS" unit (risk of ingress of air into the piloting
solenoid valves).

60 027 D1-9
Wiring harness
Removal
Remove fuel-injection ECU complete with bracket (1).

Disconnect earths (2).
Disconnect the horn.
Remove covers (3) from the electrical box.
Unplug connectors.
Unclip fuse-holder (4) from the electrical box.
Mark and remove fuses (5), remove fuse-holder (4).
Fitting
Check the efficiency of the electrical functions.

D1-10 60 027
Steering column
Removal
Remove bolt (2).
Disconnect steering column (3).
Fitting
To reconnect the steering column, refer to the relative workshop
manual section.

60 027 D1-11
Various
Removal
Parking brake
With the parking brake released, remove pin (1).
Disengage hand brake cable sheath (2) from the sheath stop.
Gearshift control
Uncouple the ball-joints.
Pull rings (3) so as to withdraw the gearbox end cable stops.
Fuel tank
Remove hose (4).
Remove hose (5).
Depending on the assembly.

Diff. lock
Mark and disconnect diff. lock pipes (1) .
Fitting
Check the efficiency of the controls
(accelerator cable, connectors, etc...).

D1-12 60 027
Cab
Removal
Remove bolts (1 - 2).
Short cab
Close the bonnet.
Protect the radiator with a guard (1).
Use tool 2370 + 2466
Long cab
Use tool 2370.
Remove the cab.
Fitting
Tighten to torque.
See page(s) B-1-5.

60 027 E1-1
AIRBAG

E1-2 60 027
APPLICABILITY
Operation

Start End N°
MASCOTT DXi Operating principle 08202/03 05/02/2004 E1-4
Fuse(s)

Start End N°
MASCOTT DXi Airbag fuse 08202/03 05/02/2004 E2-1
Warnings

Start End N°
General
MASCOTT DXi 08202/03 05/02/2004 E3-1
instructions
Layout of appliances

Start End N°
Layout of
MASCOTT DXi 08202/03 12/02/2004 E4-1
appliances in cab
Diagnostics

Start End N°
Aid-to-trouble-
MASCOTT DXi 08202/03 12/02/2004 E5-1
shooting

60 027 E1-3
Removal/Fitting

Start End N°
MASCOTT DXi Airbag ECU 08202/03 13/02/2004 E6-1
Driver's airbag
MASCOTT DXi 08202/03 16/02/2004 E6-2
module
MASCOTT DXi Rotary switch 08202/03 17/02/2004 E6-4
Passenger's airbag
MASCOTT DXi 08203 16/02/2004 E6-7
module
MASCOTT DXi Pretensioner(s) 08202/03 17/02/2004 E6-9
Destruction

Start End N°
Airbag module
MASCOTT DXi destruction 08202/03 18/02/2004 E7-1
procedure
Pretensioner
MASCOTT DXi destruction 08202/03 18/02/2004 E7-3
procedure

E1-4 60 027
Operation
Operating principle
Airbag + pretensioner
The system consists of:
– an inflatable "bag" and its gas generator mounted under
steering wheel protective cover (1) and under dashboard (2) if
the vehicle is equipped with a passenger's airbag,
– seat belt pretensioners,
– an electronic box located under the driver's seat,
– an AIRBAG "Information" and fault test warning pictogram
(G23).
An "Airbag" marking on the protective cover(s) (1 - 2) and a self-
adhesive sticker on the windscreen as reminder of the presence of
this equipment.
Airbag
The airbag system uses a pyrotechnic principle, which explains why,
upon deployment, it produces heat, gives off smoke (which is not the
sign of an outbreak of fire) and generates a detonating noise.
Deployment of the airbag, which must be immediate, may cause
minor, reversible injuries to the surface of the skin.
Seat belt pretensioner

The pretensioner system uses a piston (1) which instantaneously
retracts the seat belt buckle, flattening it against the body and thus
increasing its effectiveness.
Electronic box
The box is an electronic control unit (ECU) which is provided with an
independent accelerations acquisition system allowing it to trigger
off detonation of the system igniter squibs.

60 027 E1-5
Warning pictogram
When the ignition is switched on, warning pictogram (G23) is
illuminated for 10 seconds and is then extinguished. The system is
henceforth operational. An illumination fault or permanent
illumination of the warning pictogram (G23) means system trouble
or locking (airbag inactive).
Operation
In the event of head-on, these systems combined with the seat belt
are designed to protect the occupants according to the violence of
the impact. There are two possible cases:
1° Only the seat belt provides protection.
2° The pretensioner is triggered to further tauten the seat belt and
the airbag inflates, thus deadening the impact suffered by the
driver against the steering wheel and by the passenger(s)
against the dashboard, then deflates.

E1-6 60 027

60 027 E2-1
Fuse(s)
Airbag fuse
Description Fuse N° Amperage
"AIRBAG" ECU F4 15

E2-2 60 027

60 027 E3-1
Warnings
General instructions
ANY WORK ON THE AIRBAG SYSTEM SHOULD BE CARRIED OUT BY QUALIFIED PERSONNEL WHO HAVE UNDERGONE
SUITABLE TRAINING.
Identification of a vehicle fitted with an airbag

A vehicle equipped with a driver's airbag can be identified by:
– the inscription "Airbag" in the middle of the steering wheel,
– a sticker affixed to the lower corner of the windscreen on the driver's side (if the windscreen is replaced,
place the sticker in the same corner of the new windscreen).
A vehicle equipped with a passenger's airbag can be identified by:
– the inscription "Airbag" on the dashboard,
– a sticker affixed to the lower corner of the windscreen on the passenger's side
(if the windscreen is replaced, place the sticker in the same corner of the new windscreen).
Work on the airbag
The RENAULT TRUCKS diagnostics tool serves to check out:
– the ECU,
– the wiring harness,
– the connecting arrangement.
BEFORE WORKING ON THE AIRBAG SYSTEM, LOCK THE ECU USING THE RENAULT TRUCKS DIAGNOSTICS TOOL,
DISCONNECT THE BATTERIES AND WAIT FOR 5 MINUTES.
Wiring harness
In the event of discrepancy on the wiring or a connector, it is essential to replace the wiring harness
(do not repair it).
ECU
The airbag ECU should not suffer any knocks or distortion and should not be subjected to splashing water.
Protect the electrical connections from dust. The mounting surface of the ECU should be clean and free from
any foreign matter.
Subsequent to the triggering at least one item in the system, the ECU locks up and illuminates the airbag
pictogram. From that time onwards, the ECU cannot be unlocked and must be replaced.
Airbag module and pretensioner

It is forbidden to fit any component that has suffered knocks, distortion or scratching. Take the component out
of its packaging at the very last moment before fitting it.
During fitting of the component, do not forget to remove any foreign bodies (screws, clips...) and ensure the
connector is properly engaged.
The components of an airbag module or a pretensioner cannot be separated.
DO NOT TAKE ANY READINGS ON THESE SYSTEMS USING A MULTI-METER OR ANY ELECTRICAL MEASURING
APPARATUS WHATSOEVER.
DO NOT HANDLE THE PYROTECHNIC DEVICES NEAR A NAKED FLAME OR ANY OTHER HEAT SOURCE.

E3-2 60 027
Points to be checked subsequent to an impact
Whatever the violence of the impact (even if the airbags have not been activated), certain sensitive points on
the vehicle are to be checked out paying special attention.
It is vital to check and replace or repair, if necessary:
– front spring hanger securing bolts (significant risk of shearing),
– engine / gearbox unit brackets,
– body bracket securing bolts (significant risk of shearing),
– cab structure for signs of distortion.
Instructions to be observed after triggering of airbags and/or pretensioners
It is essential to replace:
– pretensioners,
– airbag modules,
– rotary switch,
– airbag ECU,
– seat belts if attached when the pretensioners were triggered,
– frames of seats occupied at the time of deployment,
– dashboard and dash cowl cross-member if the passenger's airbag was deployed (do not forget to
affix the label on the side of a new dashboard forbidding a child's seat to be installed with back to
the road on the passenger's seat).
It is essential to inspect and replace, if necessary:
– steering wheel,
– steering column,
– pedal gear.
It is vital to keep the airbag ECU and the list of faults recorded on the airbag system after the accident.
Instructions to be followed after an incident involving an airbag system
When returning an airbag electronic box that has been involved in an incident for expert appraisal, it must be
accompanied by at least the following information:
– chassis number of vehicle on which the box was fitted,
– state of the connecting arrangement (connector locked or not),
– state of the fastening (tightness of securing bolts),
– context of the incident (place, date, vehicle moving or not),
– state of the warning pictogram prior to the incident,
– names and addresses of the persons to contact.
In the special case where expert appraisal by a supplier is necessary, it is vital to not dismount or unplug the
box, to not remove the wiring harness and to not detonate live initiator squibs by hand.
Scrapping a vehicle
Before scrapping a vehicle in which the airbag or the pretensioners have not been triggered, it is essential to
proceed with their destruction by following the recommended method (see page(s) E-7-1 / E-7-3).
The destruction and scrapping of airbags and pretensioners are subject to the laws in force in the country in which
this is carried out.
Work on the vehicle (excluding work on airbag) implying precautions to be taken to avoid inadvertent
deployment of the airbag
During repair or adaptation work, the vehicle is not to undergo significant knocks (hammer blows...) nor is
welding work to be undertaken without previously locking the electronic box using the RENAULT TRUCKS
diagnostics tool, disconnecting the batteries and waiting for at least 5 minutes.
No aftermarket electrical accessory should be installed within the close surrounds of an airbag electronic box.
(A loudspeaker or any other appliance generating a magnetic field might cause deployment of the airbag).
Before removing the steering wheel, it is essential to unplug the airbag module connector so as to avoid any
damage.
In the event of any work requiring uncoupling of the steering box universal joint, the roadwheels must be in the
straight-ahead position and the steering wheel must be immobilized, in order to keep to the mid-point of the
rotary switch.
No other electrical consumer should use the airbag electronic box fastening points as earth points.

60 027 E3-3
Non-observance of these instructions might cause malfunction or even inadvertent deployment of the
airbag.
– If the driver's seat or passenger's bench seat designed for the airbag system has to be
changed, they must be replaced by seats identical to the ones originally fitted.
– The protective covers must be free from any article (ledge, clock, various accessories...).
– There should be no objects within the airbag deployment area (dia. 80 cm for the driver's
airbag and dia. 100 cm for the passenger's airbag).
– Check out the airbag system in the case of accident or if there has been attempted theft of or
from the vehicle and at the time of second-hand resale of the vehicle.
– For safety reasons, replace the airbag and the pretensioner every 10 years.
– If water is splashed onto or gets into the electronic box, replace it.
– Any significant modification to the suspension or the front end of the vehicle or any
overloading of the vehicle may lead to inadvertent deployment of the airbag.
– Do not drive a vehicle in which the airbag system has been activated and whose bag is still
left on the steering wheel. Get the vehicle towed.
– It is forbidden to fit a bull-bar or a forward winch on a vehicle equipped with an airbag system.

E3-4 60 027

60 027 E4-1
Layout of appliances
Layout of appliances in cab
1249AA - Driver's airbag module + rotary switch.

861AA - Passenger's airbag module.
225AA - Diagnostic socket.
756AA - Airbag ECU.
G23 - Airbag test and fault warning pictogram.
757AA - Driver's seat belt pretensioner.
758BA - Passenger's seat belt pretensioner(s).

E4-2 60 027

60 027 E5-1
Diagnostics
Aid-to-troubleshooting
Faults can be visualized using the RENAULT TRUCKS diagnostics tool plugged into the vehicle diagnostic
socket.
DO NOT MAKE READINGS ON THESE SYSTEMS USING A MULTI-METER OR ANY ELECTRICAL MEASURING
INSTRUMENT WHATSOEVER AS THERE IS A RISK OF TRIGGERING INADVERTENT DEPLOYMENT OF THE AIRBAG DUE
TO THE OPERATING CURRENT OF SUCH INSTRUMENTS.
BEFORE WORKING ON THE AIRBAG SYSTEM, LOCK THE ECU USING THE RENAULT TRUCKS DIAGNOSTICS TOOL
(WARNING PICTOGRAM G23 SHOULD BE ILLUMINATED), DISCONNECT THE BATTERIES AND WAIT FOR 5 MINUTES.
IF CONNECTION PROVES TO BE IMPOSSIBLE, REMOVE FUSE F4, DISCONNECT THE BATTERIES AND WAIT FOR 5
MINUTES.
ENSURE THAT THE VOLTAGE DOES NOT DROP BELOW 10 VOLTS WHEN RUNNING THE DIAGNOSTICS CHECK.
To obtain more accurate diagnostics, use an inert igniter squib.

Tool 2623
To be able to connect tool 2623 to the module end wiring harness, it

is necessary to cut off one of the tool locking catches.
Lock the ECU using the RENAULT TRUCKS diagnostics tool.

Connect the inert igniter squib to the airbag wiring harness in the
place of the module or pretensioner of the line concerned.
Unlock the ECU.
If the fault is still present, it originates from the line.
If the fault is no longer present, it originates from the module or the
pretensioner.
Testing the wiring harness
The wiring harness and the rotary switch can be tested using a multi-meter if they are completely disconnected
from the other components including the rotary switch and the pretensioners wiring harness.
The pretensioners wiring harness and the rotary switch cannot be checked out directly as they contain a
capacitive component.
If the fault does not originate from the airbag module or the pretensioner and the continuity of the main wiring
harness and the seat wiring harnesses are in order, it may be deduced that the fault originates from the rotary
switch or the pretensioner wiring harness.
Some connectors short-circuit when they are unplugged in order to avoid any risk of inadvertent deployment of the
airbag.
After the work, erase the fault codes using the RENAULT TRUCKS diagnostics tool.

E5-2 60 027

60 027 E6-1
Removal/Fitting
Airbag ECU
BEFORE WORKING ON THE AIRBAG SYSTEM, LOCK THE ECU USING

THE RENAULT TRUCKS DIAGNOSTICS TOOL, DISCONNECT THE
BATTERIES AND WAIT FOR 5 MINUTES.
Removal
Remove the driver's seat.
Unplug the seat wiring harness connector.
Remove protective cover (1) from the airbag ECU.

Remove bolts (3).
Remove airbag ECU (4).
New ECUs are supplied locked and without their parameters

programmed.
It is necessary to switch on the ignition again after the parameters
have been programmed so that they are taken into account.
Fitting
Tighten to torque.
See page(s) B-1-6.
Check that the ECU connector is locked is locked.
Testing:
Turn the ignition key to the 'ignition' position.
Get out of the cab and make arrangements to forbid access.
Reconnect the batteries and switch the ignition back on.
Unlock the ECU.
Switch off the ignition.
After 10 seconds, airbag warning pictogram (G23) should be extinguished.
IT IS ESSENTIAL TO SECURE THE ECU TO THE VEHICLE BEFORE PLUGGING IN THE CONNECTOR.
IF THE AIRBAG(S) HAS(HAVE) BEEN DEPLOYED AND THE PRETENSIONER(S) TRIGGERED, IT IS VITAL TO REPLACE THE
AIRBAG ECU SINCE IT LOCKS AUTOMATICALLY AND CANNOT BE UNLOCKED (SOME COMPONENTS LOSE THEIR
RATED CHARACTERISTICS AFTER THE FIRING ENERGY HAS PASSED THROUGH THEM).

E6-2 60 027
Driver's airbag module
MOVE THE ROADWHEELS TO THE STRAIGHT-AHEAD POSITION.
THE COMPONENTS OF AN AIRBAG MODULE OR PRETENSIONER CANNOT BE SEPARATED.
DO NOT HANDLE THE PYROTECHNIC DEVICES CLOSE TO A NAKED FLAME OR ANY SOURCE OF HEAT AS THERE IS A
RISK OF TRIGGERING OFF THE AIRBAG DEPLOYMENT SYSTEM.
Removal
Move the roadwheels to the straight-ahead position.
Turn the steering wheel slightly.
Unclip airbag module (3) using a flat-bladed screwdriver inserted

into openings (1).
Move the roadwheels back to the straight-ahead position.
Unplug connector (2):

– A - unlock the connector.
– B - disconnect the connector.
Remove the airbag module (3).

60 027 E6-3
Fitting
Plug in and lock connector (2).
Clip on airbag module (3).
Testing:
Unlock the ECU.
After 10 seconds, airbag warning pictogram should be extinguished.

E6-4 60 027
Rotary switch
MOVE THE ROADWHEELS TO THE STRAIGHT AHEAD POSITION.
Removal
Remove the airbag module.
See page(s) E-6-2.
Do not bend or damage connector (1).
Remove bolt (2).
Mark the steering wheel.
Remove flywheel.
Ensure that rotary switch (3) does not move, with connector (1) in a
vertical position and facing upwards.
Retain rotary switch (3) against motion with a piece of adhesive
tape.
Remove covers (4).
Lock the rotary switch:

– A - lift up lock (8),
– B - unscrew screw (9) until flush with lock (8) in order to keep it
locked.

60 027 E6-5
Spread open clips (5) using a flat-bladed screwdriver.

Lift up the rotary switch.
Unplug connectors (6).

Remove rotary switch (3).
Remove controls (7).

E6-6 60 027
Finding the mid-point
IF YOU HAVE ANY DOUBT ON THE POSITIONING OF THE ROTARY SWITCH, IT IS VITAL TO CHECK ITS MID-POINT IN THE
FOLLOWING WAY.
Turn the rotary switch clockwise until it reaches abutment, without forcing.
Then turn back anti-clockwise through 3 turns.
Still turning anti-clockwise, bring connector (1) into a vertical position and facing upwards.
Ensure that rotary switch (3) does not move, with connector (1) in a vertical position and facing upwards.
Retain rotary switch (3) against motion with a piece of adhesive tape.
Lock the rotary switch:
– A - lift up lock (8),
– B - unscrew screw (9) until flush with lock (8) in order to keep it locked.
Fitting
Upon reassembly, take off the adhesive tape at the very last moment before refitting the steering wheel. Once the
adhesive tape is removed, ensure that the rotary switch does not move.
Align and fit the steering wheel.
Do not bend or damage connector (1).

Replace screw (2) without fail.
Tighten to torque.
See page(s) B-1-6.
Fit the driver's airbag module.
See page(s) E-6-2.
Testing:
Unlock the ECU.

60 027 E6-7
Passenger's airbag module
Removal
Press on both sides of glove box (A).
Tilt glove box (B) forwards.
Remove the glove box.
Remove bolts (1).

Unclip the airbag module from the dashboard.
Unplug connector (3); it unplugs in two stages.

Pull the connector:
1° unlock lock (2).
2° disconnect connector (3).

E6-8 60 027
Fitting
Plug in and lock connector (3).
Clip the passenger's airbag module to the dashboard.
Fit bolts (1).
Tighten to torque.
See page(s) B-1-6.
Fit the glove box.
Testing:
Unlock the ECU.

60 027 E6-9
Pretensioner(s)
AV BEFORE WORKING ON THE AIRBAG SYSTEM, LOCK THE ECU USING THE RENAULT TRUCKS DIAGNOSTICS TOOL,
Removal
Remove the cover.
Withdraw clip (1).
Remove bolt (3).
Fitting
Replace screw (3) without fail.
Tighten to torque.
See page(s) B-1-6.
Testing:
Unlock the ECU.
AFTER A PRETENSIONER IS TRIGGERED, THE STRAIN EXERTED ON THE BUCKLE IS PASSED ON TO THE INERTIA REEL
AND RISKS DAMAGING THE MECHANISM, SO THE SEAT BELT MUST BE REPLACED IF IT WAS ATTACHED AT THE TIME
OF TRIGGERING OR IF ANY DOUBT REMAINS ON THE FACTS OF THE MATTER.

E6-10 60 027

60 027 E7-1
Destruction
Airbag module destruction procedure
This procedure complies with French regulations.

For other countries, refer to the national regulations in force.
This operation must be performed outside the workshop.

To avoid any risk of accident, the pyrotechnic igniter squibs must be detonated before the vehicle or the single
component is scrapped.

E7-2 60 027
Method:
1° Connect tool 2887 to the module.
2° Place the module on two wooden blocks, with the conductor wires directed downwards to prevent them
from getting damaged.
3° Cover the unit over with a stack of four used tyres.
4° Unwind two wires over a distance of about 10 metres so as to be well away from the detonation zone.
5° Ensure there is nobody nearby.
6° Proceed with destruction of the airbag by connecting the two conductor wires to a 4.5 Volt battery (there is
no polarity to be observed).
DO NOT TOUCH THE METAL PART AROUND THE CONNECTOR AFTER DESTRUCTION: RISK OF SERIOUS BURNS.
DISCONNECT TOOL 2887 IMMEDIATELY AFTER DESTRUCTION TO PREVENT IT FROM MELTING.
Do not detonate modules and pretensioners that have to be returned under the warranty, as this would make analysis
impossible.
It is essential to return the defective part in the original packing for the new part.

60 027 E7-3
Pretensioner destruction procedure
This procedure complies with French regulations.

For other countries, refer to the national regulations in force.
This operation must be performed in the vehicle outside the workshop.
Unplug the connector of the pretensioner to be destroyed.
Method:
1° Connect tool 2886 to the pretensioner.
2° Unwind two wires over a distance of about 10 metres so as to be well away from the detonation zone.
3° Ensure there is nobody nearby.
4° Proceed with destruction of the pretensioner by connecting the two conductor wires to a 4.5 Volt battery
(there is no polarity to be observed).
DO NOT TOUCH THE METAL PART AROUND THE CONNECTOR AFTER DESTRUCTION: RISK OF SERIOUS BURNS.
DISCONNECT TOOL 2886 IMMEDIATELY AFTER DESTRUCTION TO PREVENT IT FROM MELTING.
Do not detonate modules and pretensioners that have to be returned under the warranty, as this would make analysis
impossible.
It is essential to return the defective part in the original packing for the new part.

E7-4 60 027

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RENAULT V.I.

RANGE FAMILY VARIANT

Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 → 1

© RENAULT V.I. 06/2004 - Imprimé en France - le 07/2004 50 21 014 915

RENAULT V.I. 06/2004

Applicability date Page

MASCOTT DXi Warnings 31/03/2003 A-5

RENAULT V.I. 06/2004

Tighten to torque (Nm) (left-hand thread) Tighten by indicated value

Tighten to torque (Nm) (right-hand thread) Loosen by indicated value

Tightening torque with lubricated threaded

Tightening ... Greater than or equal to ...

Equal to Wear limit

... Less than ... Machining limit or dimension

... Greater than ... Maximum out-of-true

... Less than or equal to ... Maximum parallelism error

Force to be exerted in the direction shown

Weld bead Grease or oil (see "Consumables" table)

Repair time - Heating time Mark - Assemble according to marking

RENAULT V.I. 06/2004

Rotating friction torque Turn anti-clockwise

Place in contact Move in the direction shown

Dimension to be assured (mm)

Exhaust - Outlet Operation with a sequence

Intake - Inlet Involves

Return to numbered operation -

Depending on versions or options Withdraw - Delete

Injection ... to ...

Repair dimension Inspect - Check condition of part

Part to be replaced Danger for persons, vehicle or equipment

RENAULT V.I. 06/2004

NOTE! Draws attention to particular or important points of the method.

RENAULT V.I. 06/2004

RENAULT V.I. 06/2004

RENAULT V.I. 06/2004

Applicability date Page

MASCOTT DXi Definitions 27/02/2003 B1-3

Standard nut and

Specific air bag

RENAULT V.I. 06/2004

Tightening precision classes:

RENAULT V.I. 06/2004

Standard nut and bolt tightening torques table

6 x 1.00 7.5 ± 1.5 11 ± 2.2

RENAULT V.I. 06/2004

Specific cab tightening torques (in Nm)

Front grille to bumper securing bolts 3 ± 0.3 Nm

RENAULT V.I. 06/2004

Specific air bag device tightening torques (in Nm)

RENAULT V.I. 06/2004

RENAULT V.I. 06/2004

Applicability date Page

MASCOTT DXi Generalities 12/12/2001 C-3

RENAULT V.I. 06/2004

– General-purpose tools: proprietary tools.

Three levels (or echelons) determine their assignment:

– Level 2: tools for major repairs.

– Level 3: tools for refurbishment.

RENAULT V.I. 06/2004