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PRIVATE CARS 

C2-C3-C3 PLURIEL-XSARA
XSARA PICASSO-BERLINGO

PRIV

A

TE CARS

CAR 050014
Volume 1

2004

AC/QCAV/MTD
Méthodes techniques documentation

«The intellectual property rights relating to the technical information contained in this document

belong exclusively to the manufacturer. Reproduction, translation or distribution in whole or in part
without prior written authorisation from the manufacturer is forbidden».

«The technical information contained in this document is intended for the exclusive use of the trained
personnel of the motor vehicle repair trade. In some instances, this information could concern the security and
safety of the vehicle. The information is to be used by the professional vehicle repairers for whom it is
intended and they alone would assume full responsibility to the exclusion of that of the manufacturer».
«The technical information appearing in this brochure is subject to updating as the characteristics of
each model in the range evolve. Motor vehicle repairers are invited to contact the CITROËN network
periodically for further information and to obtain any possible updates».

2004

 

 

 

 

     

Summary of Contents for 2004 C3 Pluriel

Page 1: ...and safety of the vehicle The information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full responsibility to the exclusion of that of the ma...

Page 2: ...UTCH GEARBOX DRIVESHAFTS AXLES SUSPENSION STEERING BRAKES ELECTRICAL AIR CONDITIONING In each section the vehicles are dealt with in the following order C2 C3 C3 PLURIEL XSARA XSARA PICASSO BERLINGO 1...

Page 3: ...invite you to send us your suggestions which we will take into account when preparing future publications For example INSUFFICIENT INFORMATION SUPERFLUOUS INFORMATION NEED FOR MORE DETAILS Please send...

Page 4: ...ARNING If the battery has been disconnected after reconnecting it is ESSENTIAL to wait 1 minute before switching on the ignition otherwise the engine ECU will lock up If the ECU has locked up Switch o...

Page 5: ...dywork B Manufacturer s name plate On the LH centre pillar C AS RP No and RP paint code On the LH centre pillar D Tyre pressures and tyre type On the LH centre pillar E Serial number on bodywork F Gea...

Page 6: ...CF 16 20 CN 48 20 CN 50 Gearbox ident plate RPO 9688 9784 RPO 9688 9784 1 m 4 2 m 4 mp 3 mp 3 20 CP 20 RPO 9919 20 CP 21 RPO 9786 5 6 7 8 C2 IDENTIFICATION OF VEHICLES 1 1i 1 4i 1 6i 16V Pack Pack amb...

Page 7: ...1 20 CN 33 2 20 CN 51 1 20 CN 33 2 20 CN 49 Gearbox ident plate m 4 m 4 m 4 m 4 mp 3 5 6 5 6 7 C2 IDENTIFICATION OF VEHICLES 1 4 HDi Pack Pack ambiance Exclusive 1 Europe IF 3 mp Piloted manual gearb...

Page 8: ...verspeed values have to be re initialised The button on the wiper stalk multifunction display B or C or the button on the dashboard multifunction display A or clock operates the following functions Ac...

Page 9: ...oof opening sequence Multifunction screen It is necessary to adjust the date time and ortside temperature Adjust the display language of the multifunction screen if necessary NOTE The default display...

Page 10: ...me plate On the LH centre pillar C AS RP No and RP paint code label affixed to the front pillar on driver s side D Tyre pressures and tyre type label affixed to the front pillar on driver s side E Ser...

Page 11: ...B T FR HFXB FC HFXC IF FN HFXC IF Engine type HFX Cubic capacity cc 1124 Fiscal rating hp 4 Gearbox type MA 5N Gearbox ident plate 20 CP 14 m 1 C3 IDENTIFICATION OF VEHICLES Petrol 1 1i Pack Pack ambi...

Page 12: ...KFVB KFVC IF KFVC IF KFVE D KFVE KFVE KFVF IF KFVF IF Engine type KFV Cubic capacity cc 1360 Fiscal rating hp 5 Gearbox type MA 5L MA 5N AL4 Gearbox ident plate 20 CP 15 m 1 20 TP 75 IDENTIFICATION O...

Page 13: ...1 4i 16V Emission standard L5 L4 IF L5 Type code FC KFUC P FC KFUN P FN NFUB FC NFUB FC NFUC IF FC NFUC PIF Engine type KFU NFU Cubic capacity cc 1360 1587 Fiscal rating hp 6 Gearbox type MA 5S Gearb...

Page 14: ...and 20 CP 72 m 1 Diesel 1 4 HDi Pack Entreprise Entreprise club Entreprise Pack Emission standard L4 Type code FC 8HXB T FN 8HXB FC 8HXB FC 8HXB MOD FC 8HXK FR 8HXB FN 8HWB FC 8HWB Engine type 8HX 8H...

Page 15: ...k clim Exclusive C3 Pack clim Pack Pack ambiance Pack clim Exclusive Emission standard L4 Type code FC 8HVB FN 8HVB FC 8HYB FC 8HYB T FC 8HYB MOD FC 8HYK FN 8HYB FR 8HYB Engine type 8HV 8HY Cubic capa...

Page 16: ...e plate On the LH centre pillar C AS RP No and RP paint code label affixed to the front pillar on driver s side D Tyre pressures and tyre type label affixed to the front pillar on driver s side E Seri...

Page 17: ...e type KFV NFU 8HX Cubic capacity cc 1360 1587 1398 Fiscal rating hp 5 6 4 Gearbox type MA 5N MA 5S MA 50 Gearbox ident plate 20 CP 60 m 1 20 CP 63 mp 2 20 CP 71 m 1 C3 PLURIEL IDENTIFICATION OF VEHIC...

Page 18: ...p cold stamp C Manufacturer s name plate Saloon D Label label affixed to the front pillar on driver s side Tyre pressures RP organisation no Paint code E Serial number visible throrgh the windscreen F...

Page 19: ...type KFW NFU Cubic capacity cc 1360 1581 Fiscal rating hp 5 7 Gearbox type MA 5 MA 5 AL4 MA 5 AL4 Gearbox ident plate 20 CP 13 20 CP 51 20 TP 49 20 CP 51 20 TP 49 XSARA II IDENTIFICATION OF VEHICLES S...

Page 20: ...N3 IF NO RFSB Engine type RFN RFS Cubic capacity cc 1998 Fiscal rating hp 8 9 11 Gearbox type BE4 5 AL4 BE3 5 Gearbox ident plate 20 DL 40 20 DM 03 1 20 TP 47 20 TE 47 IDENTIFICATION OF VEHICLES Saloo...

Page 21: ...97 Fiscal rating hp 4 5 6 Gearbox type BE4 5 AL4 Gearbox ident plate 20 DM 54 20 DL 41 20 DL 42 20 DM 10 20 TP 48 20 DM 05 1 20 DM 07 1 20 DM 11 1 IDENTIFICATION OF VEHICLES Saloon diesel 3 door 1 4 H...

Page 22: ...KFW NFU Cubic capacity cc 1360 1587 Fiscal rating hp 5 7 8 Gearbox type MA 5 MA 5 AL4 MA 5 AL4 Gearbox ident plate 20 CP 13 20 CP 51 20 TP 49 20 CP 51 20 TP 49 XSARA II IDENTIFICATION OF VEHICLES NFU...

Page 23: ...e RFN Cubic capacity cc 1998 Fiscal rating hp 8 9 Gearbox type BE4 5 AL4 Gearbox ident plate 20 DL 40 20 TP 47 20 DM 03 2 IDENTIFICATION OF VEHICLES Saloon petrol 5 door 2 0i 16V Exclusive AUTO XSARA...

Page 24: ...l rating hp 4 5 6 Gearbox type BE4 5 AL4 Gearbox ident plate 20 DM 54 20 DL 41 20 DL 42 20 DM 10 20 TP 48 20 DM 05 1 20 DM 07 1 20 DM 11 1 XSARA II IDENTIFICATION OF VEHICLES 1 Right hand drive Hydrau...

Page 25: ...Type code N2 KFWB N2 KFW1 IF N2 NFUB N2 NFU1 IF N2 NFUN N2 NFU3 IF Engine type KFW NFU Cubic capacity cc 1360 1581 Fiscal rating hp 5 7 Gearbox type MA 5 MA 5 AL4 Gearbox ident plate 20 CP 44 20 CP 51...

Page 26: ...ting hp 8 9 4 5 6 Gearbox type BE4 5 AL4 BE4 5 AL4 Gearbox ident plate 20 DL 40 20 TP 47 20 DM 54 20 DL 41 20 DL 42 20 DM10 20 DM 03 1 20 DM 05 20 DM 07 20 DM 11 20 TP 48 1 1 1 IDENTIFICATION OF VEHIC...

Page 27: ...f windscreen right hand side C Manufacturer s data plate Located at bottom of RH central pillar D Label Tyre pressures Tyre identification Spare wheel identification Located on front LH door inner pan...

Page 28: ...N Cubic capacity cc 1587 1749 1998 Fiscal rating hp 6 7 9 Gearbox type BE4 5 J BE4 5 V AL4 Gearbox ident plate 20 DL 67 20 DL 69 20 TS 02 IDENTIFICATION OF VEHICLES Petrol 2 0i 16V 1 8i 16V 1 6i Oc an...

Page 29: ...9HZ 9HY RHY Cubic capacity cc 1560 1997 Fiscal rating hp 6 5 Gearbox type BE4 5L BE4 5L Gearbox ident plate 20 DM 62 20 DL 65 IDENTIFICATION OF VEHICLES Diesel 2 0 HDi Oc anic Leader Pack Exclusive 1...

Page 30: ...IFICATION OF VEHICLES E1AP0AMD A Chassis stamp cold stamp B Manufacturer s vehicle plate C Label RPO No Paint colorr code Tyre pressures D Gearbox ident reference Factory serial no E Engine legislatio...

Page 31: ...ode GJ HFXB GJ KFWB GJ KFWC IF Engine type HFX KFW Cubic capacity cc 1124 1360 Fiscal rating hp 5 6 Gearbox type MA 5S MA 5L Gearbox ident plate 20 CD 43 20 CN 13 IDENTIFICATION OF VEHICLES Berlingo p...

Page 32: ...city cc 1360 1587 Fiscal rating hp 5 7 Gearbox type MA 5 BE4 5 Gearbox ident plate 20 CN 13 20 DM 46 IDENTIFICATION OF VEHICLES Berlingo petrol 5 seater 1 6i 16V Multispace X SX Multispace 1 4i BERLIN...

Page 33: ...Type code GJ WJYB GJ WJYB PMF 1 GJ RHYB Engine type WJY RHY Cubic capacity cc 1868 1997 Fiscal rating hp 5 6 Gearbox type BE4 5 BE4 5 Gearbox ident plate 20 DM 48 20 DM 50 Berlingo diesel 5 seater 2 0...

Page 34: ...equipped with hydropneumatic suspension 2 Engine warm oil temperature 80 C 3 Draining of the oil sump removal of the cartridge duration of draining dripping 15 min 4 Refit plug cartridge 5 Engine fill...

Page 35: ...ums 0 8 Litre version with front calipers 54 rear discs 7 5 6 40 45 Diesel Petrol C2 1 1i 1 4i 1 6i 16V 1 4 HDi ESSENTIAL Systematically check the oil level using the oil dipstick Engine type Drain by...

Page 36: ...FU 8HX 8HW 8HX 8HW 8HV 8HY 8HV 8HY 3 3 75 3 25 3 75 1 5 1 2 1 5 1 8 1 5 1 8 1 5 3 1 3 1 1 5 1 2 2 1 9 0 7 Litre version with front calipers 48 rear drums 0 8 Litre version with front calipers 54 rear...

Page 37: ...Litre version with front calipers 48 rear drums 0 8 Litre version with front calipers 54 rear discs Cooling system 7 5 7 Fuel tank capacity 45 ESSENTIAL systematically check the oil level using the oi...

Page 38: ...nage Hydraulic or brake circuit Cooling system Fuel tank capacity KFW NFU RFN RFS 3 3 25 4 25 1 5 1 5 1 7 1 2 1 9 1 9 6 6 3 3 With ABS 0 50 Without ABS 0 55 7 6 5 1 54 XSARA II CAPACITIES in litres Pe...

Page 39: ...ooling system Fuel tank capacity 8HZ WJY RHY RHZ 3 75 4 75 1 4 5 2 4 5 1 8 1 5 1 6 1 1 2 2 1 4 2 1 8 8 3 5 3 With ABS 0 50 Without ABS 0 55 5 7 9 8 5 54 Diesel XSARA II 1 RPO 9337 Manual dipstick with...

Page 40: ...9HY RHY 3 4 25 3 75 4 5 1 5 1 7 1 55 3 1 4 1 8 1 8 6 3 0 58 litres 5 8 1 and 2 6 5 1 and 2 11 11 1 and 2 55 60 XSARA PICASSO CAPACITIES in litres Diesel Petrol XSARA PICASSO 1 6i 1 8i 16 V 2 0i 16V 1...

Page 41: ...rbox Hydraulic or brake circuit Cooling system Fuel tank capacity HFX KFW NFU WJY RHY 3 3 25 4 5 1 5 1 2 1 4 2 1 8 1 8 With ABS 0 45 Without ABS 0 36 8 9 55 60 BERLINGO II CAPACITIES in litres Diesel...

Page 42: ...SJ CF Failing this it is essential to adhere to the maintenance programmes covering severe operating conditions Use of oil grade 10W 40 It is possible to use semi synthandic oil 7000 10W40 on PETROL...

Page 43: ...oil norms Current norms The classification of these engine oils is established by the following recognised organisations S A E Sociandy of Automotive Engineers API American Petroleum Institute ACEA A...

Page 44: ...gh performance oils permitting lower fuel consumption Example ACEA A3 high performance oils specifically for petrol and dual fuel petrol LPG engines ACEA A B blended oils giving very high performance...

Page 45: ...allows improved fuel economies approx 2 5 The oil 5W30 is used only for the following engines Year 2003 XU10 J4RS XSARA VTS 2 0i 16V 3 door SOFIM RELAY 2 8 TDi and 2 8 HDi HDi With particle filter FAP...

Page 46: ...A 9000 TOTAL QUARTZ 9000 5W40 A3 B3 SL CF SJ CF A5 B5 A3 B3 5W30 10W40 S A E norms Blended oils for all engines petrol diesel and dual fuel petrol LPG engines ACEA norms API norms It is essential not...

Page 47: ...L ACTIVA 7000 TOTAL QUARTZ 7000 10W40 A3 SJ 0W40 15W50 S A E norms Oils specifically for petrol and dual fuel petrol LPG engines ACEA norms API norms TOTAL ACTIVA DIESEL 7000 TOTAL ACTIVA DIESEL 7000...

Page 48: ...hot countries Engine types XU10 J4RS Xsara VTS 2 0i 16V X X X EW 12 J4 C8 2 2i 16V Other petrol engines HDi engines with FAP Other HDi engines SOFIM 2 8 TDi and 2 8 HDi RELAY DV4 TED4 C3 1 4 16V HDi...

Page 49: ...45 GENERAL LUBRICANTS TOTAL recommended oils ALL TYPES Selection of TOTAL engine oils to be used according to the climatic conditions in the country where the vehicle is marketed E4AP006D...

Page 50: ...OTAL recommended oils Blended oils for all engines supplied in bulk ENGINE OILS TOTAL ACTIVRAC S A E norms 10W40 TOTAL ACTIVA Blended oils for all engines 9000 5W40 9000 5W30 7000 10 W40 7000 10 W40 9...

Page 51: ...ia Belgium Bosnia Bulgaria Cyprus Croatia LUBRICANTS TOTAL recommended oils ENGINE OILS TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual fuel petrol LPG engines Oils spe...

Page 52: ...stonia Finland Great Britain Greece Holland LUBRICANTS TOTAL recommended oils ENGINE OILS TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual fuel petrol LPG engines Oils s...

Page 53: ...uania Macedonia LUBRICANTS TOTAL recommended oils ENGINE OILS TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual fuel petrol LPG engines Oils specifically for diesel engin...

Page 54: ...ugal Slovakia Czech Republic LUBRICANTS TOTAL recommended oils ENGINE OILS TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual fuel petrol LPG engines Oils specifically for...

Page 55: ...a Sweden Switzerland Turkey LUBRICANTS TOTAL recommended oils ENGINE OILS TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual fuel petrol LPG engines Oils specifically for...

Page 56: ...ded oils ENGINE OILS TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual fuel petrol LPG engines Oils specifically for diesel engines TOTAL ACTIVA DIESEL ALL TYPES 9000 5W4...

Page 57: ...S TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual fuel petrol LPG engines Oils specifically for diesel engines TOTAL ACTIVA DIESEL ALL TYPES 9000 5W40 FUTURE 9000 5W30...

Page 58: ...raguay Uruguay LUBRICANTS TOTAL recommended oils 7000 10W50 7000 15W50 ENGINE OILS TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual fuel petrol LPG engines Oils specific...

Page 59: ...000 15W50 7000 10W40 7000 15W50 7000 15W50 ENGINE OILS TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual fuel petrol LPG engines Oils specifically for diesel engines TOTA...

Page 60: ...OTAL recommended oils 7000 15W50 7000 10W40 7000 15W50 7000 15W50 ENGINE OILS TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual fuel petrol LPG engines Oils specifically...

Page 61: ...Emirates Iran Israel Jordan Kuwait Lebanon Oman Qatar Syria Yemen LUBRICANTS TOTAL recommended oils ENGINE OILS TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual fuel pe...

Page 62: ...0 A2 TOTAL FLUIDE ATX TOTAL FLUIDE AT 42 Special oil distributed by CITRO N Part No 9730 A3 Special oil distributed by CITRO N Part No 9736 22 TOTAL TRANSMISSION X4 Part No 9730 A4 Manual gearbox and...

Page 63: ...TOTAL FLUIDE DAS Special oil distributed by CITRO N Part No 9730 A1 Power steering All countries Very cold countries All countries CITRO N fluid Protection 35C 2 Litres 5 Litres 20 Litres 210 Litres...

Page 64: ...G CITRO N C5 Use exclusively TOTAL FLUIDE LDS suspension fluid All countries TOTAL HYDRAURINCAGE All countries CITRO N fluid 0 5 Litre 1 Litre 5 Litres 9979 05 9979 06 9979 07 Pack CITRO N Part No ALL...

Page 65: ...ady for use 9980 33 9980 06 9980 05 ZC 9875 953U ZC 9875 784U ZC 9885 077U 9980 56 ZC 9875 279U Pack CITRO N Part No LUBRICANTS TOTAL recommended oils ALL TYPES 1 Litre 5 Litres Norms NLGI 2 TOTAL MUL...

Page 66: ...ine III MAXIMUM PERMISSIBLE oil consumption for a RUN IN engine 0 5 litres per 600 miles 1 000 km for a PETROL engine 1 litre per 600 miles 1 000 km for a DIESEL engine DO NOT INTERVENE BELOW THESE VA...

Page 67: ...sion ratio Power ISO or EEC KW rpm Power DIN HP rpm Torque ISO or EEC m daN rpm C2 C3 BERLINGO II C2 C3 C3 Pluriel Xsara II Berlingo II C3 L4 IFL5 L4 W4 L4 IFL5 INF K L4 W4 IFL5 IFL5 L4 HFX KFV KFW KF...

Page 68: ...C KW rpm Power DIN HP rpm Torque ISO or EEC m daN rpm Xsara Picasso C2 C3 Xsara Xsara Picasso Xsara II Xsara II C3 Pluriel Xsara Picasso Berlingo II L4 L4 IFL5 IFL5 IFL4 IFL5 L4 NFV NFU 6FZ RFN RFS 15...

Page 69: ...ssion standard Engine type Cubic capacity cc Bore Stroke Compression ratio Power ISO or EEC KW rpm Power DIN HP rpm Torque ISO or EEC m daN rpm C2 C3 C3 Pluriel C3 Xsara C3 L4 IFL5 L4 8HX 8HW 8HZ 8HV...

Page 70: ...Stroke Compression ratio Power ISO or EEC KW rpm Power DIN HP rpm Torque ISO or EEC m daN rpm Xsara II Xsara Picasso Xsara II Berlingo II Xsara Picasso Xsara II Berlingo II L4 9HZ 9HY WJY RHY RHZ 1560...

Page 71: ...S TIGHTENING TORQUES m daN A KFV B NFU RH engine support 1 6 0 4 2 6 0 6 3 4 5 0 4 Torque reaction rod 4 6 0 6 5 6 0 6 6 8 5 0 2 7 6 0 6 LH engine support on gearbox 8 3 0 3 9 6 0 6 10 5 5 0 5 B1BP2Y3...

Page 72: ...Tightening 4 0 4 Angular tightening 45 4 Cylinder block Sump 0 8 0 2 Timing belt tensioner roller 2 1 0 2 Accessories belt guide roller 2 5 0 2 Alternator support 2 5 0 2 Alternator TU1JP TU3JP Pre ti...

Page 73: ...0 8 0 2 Camshaft bearing caps TU1JP TU3JP Tightening 2 0 2 Angular tightening 44 4 Camshaft bearing caps TU5JP4 Tightening 2 0 2 Angular tightening 50 5 Inlet manifold 0 8 0 2 Exhaust manifold 1 8 0...

Page 74: ...TENING TORQUES m daN Engines HFX KFV NFU Flywheel clutch Engine flywheel 6 7 1 LOCTITE FRENETANCH Oil pressure mechanism 2 0 2 Lubrication Circuit Oil pressure switch 3 5 0 5 Oil pump 0 9 0 1 Cooling...

Page 75: ...71 ENGINE SPECIAL FEATURES TIGHTENING TORQUES m daN Engine 8HX 1 6 0 6 2 6 0 6 3 6 0 6 4 6 0 6 5 3 0 3 6 6 0 6 7 5 5 0 5 8 5 7 0 9 B1BP2Y1P C2...

Page 76: ...e tightening 1 0 2 Slackening 180 Tightening 3 0 3 Angular tightening 140 Con rod screws Tightening 1 0 1 Angular tightening 100 5 Accessories drive pulley Pre tightening 3 0 3 Angular tightening 180...

Page 77: ...Pre tightening 0 3 0 1 Tightening 1 0 1 Fixing of camshaft sub assemblies on cylinder head Pre tightening 0 3 0 1 Tightening 1 0 1 Exhaust manifold 3 0 3 Camshaft pulley Pre tightening 0 3 0 1 Tighten...

Page 78: ...ion fixing fork 2 5 0 2 Fuel high pressure common injection rail on engine block 2 2 0 2 Unions on fuel high pressure common injection rail 2 5 0 2 Diesel injection pump on support 2 2 0 2 Union on di...

Page 79: ...support 1 6 0 4 2 6 0 6 3 4 5 0 4 Torque reaction rod 4 6 0 6 5 6 0 6 LH engine support on gearbox 6 3 0 3 7 6 0 6 8 5 5 0 5 B1BP2NEP C3 C3 PLURIEL C3 A HFX KFV B NFU RH engine support 1 4 5 0 4 2 6 1...

Page 80: ...r roller 2 0 2 2 2 0 2 Accessories belt tensioner roller 2 0 2 2 5 0 2 Alternator support fixing 1 7 0 3 Alternator fixing on support 3 7 0 3 Cylinder head Coolant outlet housing 0 8 0 2 Camshaft bear...

Page 81: ...RQUES m daN Flywheel Clutch Engines HFX KFV NFU Flywheel 6 7 0 6 LOCTITE FRENETANCH Clutch mechanism 2 0 2 Lubrication circuit Oil pressure switch 2 0 2 Oil pump 0 9 0 1 Cooling circuit Coolant pump 1...

Page 82: ...78 ENGINE TIGHTENING TORQUES POWER UNIT SUSPENSION Engine KFU RH engine support 1 6 0 6 2 6 0 6 Torque reaction rod 3 6 0 6 4 6 0 6 LH engine support on gearbox 5 3 0 3 6 6 0 6 7 5 5 0 5 B1BP2ZBP C3...

Page 83: ...ock Sump 0 8 0 2 Accessories belt guide roller 4 0 4 Timing belt tensioner roller 2 1 0 2 Accessories belt tensioner roller 2 5 0 2 Alternator support 2 5 0 3 Crankshaft bearing caps Tightening 2 0 3...

Page 84: ...lve 0 8 0 2 VVT inlet camshaft pulley screw Pre tightening 2 0 2 Tightening 6 1 0 6 Exhaust camshaft pulley screw 4 5 0 4 Flywheel Clutch Engine flywheel 6 7 0 6 coat the screws with LOCTITE FRENETANC...

Page 85: ...NGINE SPECIAL FEATURES TIGHTENING TORQUES m daN Engines 8HX 8HW RH engine support 1 4 5 0 4 2 3 0 3 Torque reaction rod 3 6 0 6 4 6 0 6 LH engine support on gearbox 5 5 4 0 5 6 6 0 6 7 5 5 0 5 B1BP2LJ...

Page 86: ...aN Engine 8HZ RH engine support 1 2 0 2 9 2 5 0 2 10 4 5 0 5 11 4 5 0 5 12 6 0 6 RH lower engine support 8 5 7 0 9 Torque reaction rod 2 4 5 0 5 3 4 5 0 5 4 4 5 0 5 LH engine support 5 6 5 0 6 LH lowe...

Page 87: ...ning YES Tightening 3 Angular tightening 140 Con rod nuts Pre tightening 1 Slackening YES Tightening 1 5 0 1 Angular tightening 100 5 Accessories drive pulley Pre tightening 3 0 4 Angular tightening 1...

Page 88: ...haft sub assemblies on cylinder head Pre tightening 0 5 Tightening 1 Exhaust manifold 2 5 0 2 Valve cover 2 5 0 2 Camshaft pulley 4 3 0 4 Flywheel Flywheel Pre tightening 1 7 1 7 Tightening 70 5 75 5...

Page 89: ...block 2 0 2 Unions on fuel high pressure common injection rail Pre tightening 1 7 0 2 Tightening 2 25 0 2 Diesel injection pump on support Union on diesel injection 2 25 0 2 Diesel injection pump pul...

Page 90: ...gines 8HV 8HY RH engine support Screw 1 6 0 6 Screw 2 6 0 6 RH lower engine support Screw 3 5 7 0 5 LH upper engine support Screw 7 6 0 6 Screw 8 5 5 0 5 LH lower engine support Screw 6 5 4 0 5 Torque...

Page 91: ...hub Tightening 3 0 3 Angular tightening 180 5 Cylinder block Oil sump 1 0 1 Timing belt tensioner roller 4 0 4 Timing belt guide roller 2 5 0 2 Timing belt guide roller support Cylinder head Camshaft...

Page 92: ...olant heat exchanger 1 0 1 Turbocharger lubrication pipe 2 2 0 2 Injection circuit Injector fixing flange nut Tightening 0 4 0 1 Angular tightening 65 5 Unions on fuel high pressure common injection r...

Page 93: ...G TORQUES m daN Crankshaft bearing Pre tightening 2 0 2 2 0 2 screws Angular tighten 45 50 5 Connecting rod screws Tightening 3 8 0 4 Flywheel screw Tightening 6 5 0 7 Crankshaft pinion screw Pre tigh...

Page 94: ...ORQUES m daN Pre tightening 1 11 1 0 1 2 0 1 2 5 0 3 2 6 1 0 1 Slackening 11 only Tightening 11 to 1 0 1 8 5 0 8 7 0 7 Crankshaft then to 2 0 1 bearing screws Tightening Angular 11 at 70 5 60 6 60 6 T...

Page 95: ...HY Torque reaction rod 1 5 4 0 8 2 5 4 0 8 13 6 0 9 LH upper engine support 3 2 1 0 2 4 5 0 5 LH lower engine support 5 2 1 0 2 6 5 7 0 8 RH lower engine support 7 5 5 0 5 RH engine support 8 4 5 0 4...

Page 96: ...htening 1 0 2 Slackening 180 Tightening 3 0 3 Angular tightening 140 Con rod screws Tightening 1 0 1 Angular tightening 100 5 Accessories drive pulley Pre tightening 3 5 0 4 Angular tightening 190 5 C...

Page 97: ...ening 0 5 0 1 Tightening 1 0 1 Exhaust manifold 3 0 3 Camshaft pulley Pre tightening 2 0 2 Angular tightening 50 5 Cylinder head Pre tightening 2 0 2 Tightening 4 0 5 Angular tightening 260 5 EGR valv...

Page 98: ...ubrication pipe 3 0 5 Diesel injection circuit Injector fixing flange nut Pre tightening 4 0 1 Angular tightening 65 5 Fuel high pressure common injection rail on engine block 2 2 0 2 Union on fuel hi...

Page 99: ...HZ 9HY Diesel injection circuit Diesel injection pump pulley 5 0 5 Union on fuel high pressure pump Pre tightening 2 0 5 Tightening 2 5 0 3 Cooling circuit Coolant pump Pre tightening 0 3 0 1 Tighteni...

Page 100: ...der head gasket Engine types HFX KFV NFU Thicknesses Standard 1 2 0 1 0 66 0 04 Thicknesses repair 1 4 0 1 Thickness references 2 1 4 Identification marks 1 2 3 4 Type of engine A B D Suppliers C Gask...

Page 101: ...1 5 0 2 Tightening 2 5 0 2 Angular tightening 200 5 In the order 1 to 10 B1BP1DVC KFU HFX KFV HFX KFV 175 5 0 5 122 0 3 NFU B1BP10KC NOTE Retightening of the cylinder head after a completed repair is...

Page 102: ...Engine type KFW NFV NFU Identification marks Notch on cylinder head gasket 1 1 1 1 2 0 0 1 Thickness 3 0 0 1 4 0 1 1 A 0 CURTY B 0 D 0 A 1 Suppliers MEILLOR B 1 D 0 A ELRING B D A 1 REINZ B 0 D 0 Mate...

Page 103: ...bolts X MAX re usable length Pre tightening 2 Angular tightening 240 5 Pre tightening 2 Angular tightening 260 5 B1DP059C NFU KFW NFV KFW NFV X 175 5 0 5 mm X 122 6 mm NFU B1BP10LC XSARA XSARA PICASSO...

Page 104: ...sket B1DP183D Nominal dimension Repair dimension 2 4 5 4 5 R1 R2 R3 1 1 1 0 8 Gasket thickness mm Supplier MEILLOR Marking zone e Identification zone d 1 3 100 Identification marks d Identification zo...

Page 105: ...e oil or Molykote G Rapid Plus Pre tightening 1 5 0 2 Tightening 5 0 2 Destightening 360 1 turn Tightening 2 0 2 Angular tightening 285 5 B1DP16FC B1DP05BC 6FZ 6FZ X 147 mm Cylinder head tightening m...

Page 106: ...YLINDER HEAD Engine RFN Identification of cylinder head gasket B1DP183D Nominal dimension Repair dimension 2 4 5 4 5 R1 R2 1 1 0 8 Gasket thickness mm Supplier MEILLOR Marking zone e Identification zo...

Page 107: ...e oil or Molykote G Rapid Plus Pre tightening 1 5 0 2 Tightening 5 0 2 Destightening 360 1 turn Tightening 2 0 2 Angular tightening 285 5 B1DP16FC B1DP05BC RFN RFN X 147 mm Cylinder head tightening m...

Page 108: ...CYLINDER HEAD Engine RFS Identification of cylinder head gasket Engine type Identification marks Notch on cylinder head gasket RFS A B C D E MEILLOR Suppliers 0 Without notch 1 One notch B1BP004C 1 0...

Page 109: ...NOTE Oil the threads and under the heads of the bolts use engine oil or Molykote G Rapid Plus Pre tightening 3 5 Slackening NO Tightening 7 Angular tightening 160 B1DP13PC B1DP05BC RFS RFS 112 mm Cyl...

Page 110: ...Thicknesss mm No of notches at d No of notches at e 0 771 to 0 820 1 35 1 0 611 to 0 720 1 25 2 8HY 8HV ELRING 0 721 to 0 770 1 30 3 1 0 821 to 0 870 1 40 4 0 871 to 0 977 1 45 5 B1DP1CMD Engines 8HX...

Page 111: ...andproud mm Thicknesss mm No of notches at d No of notches at e 0 771 to 0 820 1 35 1 0 611 to 0 720 1 25 2 8HY 8HV ELRING 0 721 to 0 770 1 30 3 2 0 821 to 0 870 1 40 4 0 871 to 0 977 1 45 5 B1DP1CKD...

Page 112: ...0 NOTE The bolts should have been tho roughly cleaned and dried with a dry metal brush Oil the threads and under the heads of the bolts use engine oil or Molykote G Rapid Plus Pass a tap into the hole...

Page 113: ...mm Thicknesss mm No of notches at d No of notches at e 0 685 to 0 734 1 35 1 0 533 to 0 634 1 25 2 9HZ 9HY FEDERAL 0 635 to 0 684 1 30 3 3 MOGUL 0 735 to 0 784 1 40 4 0 785 to 0 886 1 45 5 B1DP1HOD En...

Page 114: ...leaned and dried with a dry metal brush Oil the threads and under the heads of the bolts use engine oil or Molykote G Rapid Plus Pass a tap into the holes in the cylinder block B1DP1DBC B1DP1CLC 9HZ 9...

Page 115: ...at B Number of holes at A Thickness mm 0 04 Plaque Engine Piston standproud mm 0 51 to 0 55 1 26 1 0 55 to 0 59 1 30 2 0 59 to 0 63 1 34 3 0 63 to 0 67 1 38 4 0 67 to 0 71 1 42 5 WJY A Rep re engine B...

Page 116: ...n of cylinder head gasket No of notches at A Thickness mm Plaque Engine Piston standproud mm 0 47 to 0 605 1 30 0 06 1 0 605 to 0 655 1 35 0 06 2 0 655 to 0 705 1 40 0 06 3 0 705 to 0 755 1 45 0 06 4...

Page 117: ...ads and under the heads of the bolts use engine oil or Molykote G Rapid Plus Pre tightening 2 Tightening 6 Angular tightening 220 Pre tightening 2 Tightening 6 Angular tightening 180 B1DP15EC B1DP13PC...

Page 118: ...114 ENGINE Tools ALL TYPES BELT TENSION SEEM UNITS CORRESPONDENCE TABLE 4099 T C TRONIC 105 4122 T C TRONIC 105 5...

Page 119: ...ee pages See pages See pages HFX KFV KFW KFU NFV NFU 6FZ RFN RFS 1 1i 1 4i 1 6i 16V 118 to 119 118 to 119 1 1i 1 4i 1 4i 16V 1 6i 16V 118 to 119 123 to 124 118 to 119 1 4i 1 6i 16V 118 to 119 118 to 1...

Page 120: ...pages See pages See pages See pages 8HX 8HW 8HZ 8HV 8HY 9HZ 9HY WJY RHY RHZ 1 4 HDi 135 to 136 1 4 HDi 1 4 HDi 1 4 HDi 16V 1 4 HDi 16V 135 to 136 139 1 4 HDi 135 to 136 1 4 HDi 1 9 D 2 0 HDi 2 0 HDi...

Page 121: ...ring instrument 4122 T C TRONIC 105 5 WARNING If using tool 4099 T C TRONIC 105 refer to the correspondence table on page 96 Essential Before refitting the auxiliary equipment drive belt check that 1...

Page 122: ...hout air conditioning Refit Refit the belt Respect the following sequence Crankshaft pinion Alternator pulley Place tool 2 on the belt Tighten screw 1 to achieve a tension of 55 3 SEEM units Tighten S...

Page 123: ...ting on the tensioner roller Remove the accessories drive belt Refit Respect the following sequence Crankshaft pinion Aircon compressor pulley Guide roller Alternator pulley Tensioner roller Place too...

Page 124: ...ORX spanner Remove Release the central screw 1 tool 3 Detension the tensioner roller 2 flat spanner 27 on flat Remove the belt Refit Position the belt Hold the belt in position using the tensioner rol...

Page 125: ...2 Belt tension measuring instrument 4122 T 3 10 mm square drain spanner 4 TORX spanner Remove Detension the automatic tensioner tool 3 Place a 6 mm peg at a to immobilise the automatic tensioner Remov...

Page 126: ...e used belt AUXILIARY EQUIPMENT DRIVE BELT 2002 Alternator Power assisted steering Power steering and air con With air conditioning 1 Belt tension measuring instrument 4122 T Tension the belt using th...

Page 127: ...sing tool 1 Vehicle without air conditioning Removing Slacken the tension screw 2 screw 3 and screw 1 Push back the alternator towards the engine Remove the auxiliary equipment drive belt Refitting Re...

Page 128: ...r Remove the auxiliary equipment drive belt Refitting Refit the auxiliary equipment drive belt Respect the following sequence Crankshaft pinion aircon compressor pulley alternator pulley guide roller...

Page 129: ...its Reused belt 86 5 3 5 SEEM units 3 Tensioner roller fixing screw 4 Tensioning screw New belt 120 SEEM units Reused belt 86 5 3 5 SEEM units NOTE Removal of the tensioner roller makes it necessary t...

Page 130: ...ioner roller 1 Tighten the screws 3 to 2 m daN Move the tensioner roller 1 using the tool 9 52 mm square drive 3 8 at 2 in order to remove the tool or locking peg 4 mm at 4 Slowly release the tensione...

Page 131: ...y tighten the screws 2 Place the tool 1 on the belt Tension the belt using the screw 1 Reused belt 90 SEEM units New belt 120 SEEM units Tighten the screws 2 to 2 m daN Remove the tool 1 Rotate the cr...

Page 132: ...ove the belt Detension the belt 3 by turning the screw 2 of the tensioner roller 1 anti clockwise The screw 2 WARNING not left hand screw Remove the belt 3 while keeping the tensioner roller 1 tight R...

Page 133: ...ng instrument 4122 T Removal Loosen the screws 2 Tighten the screw 1 until it is against its stop Remove the belt Refitting Refit the belt Fit the tool 1 on the belt at d Tighten the screw 1 to obtain...

Page 134: ...1 Belt tension measuring instrument 4122 T Removal Loosen the screws 1 Tighten the screw 2 until it is against its stop Remove the belt Refitting Refit the belt Fit the tool 1 at e Tighten the screw...

Page 135: ...g without air conditioning Tools 1 Belt tension measuring instrument 4122 T Removal WARNING If the belt is to be reused measure the tension before removal Loosen the screw 1 the nut 2 NOTE The tension...

Page 136: ...b downwards Tighten the nut 2 to obtain a value of Reused belt Keep the value taken at removal New belt Tension should be 110 SEEM units Tighten the screw 1 to 9 5 m daN Check belt tension using tool...

Page 137: ...roller 3 backwards Remove the belt NOTE If it can not be pegged at a Loosen the screw 2 of the roller 3 Using a 7 mm square drive turn the roller 3 at b Peg the tensioner 1 at a using tool 1 NOTE If t...

Page 138: ...2002 Power assisted steering with air conditioning continued Refitting Refit the belt Using a 7 mm square drive at b turn the roller 3 until the tool 1 located at a becomes free Tighten the screw 2 Re...

Page 139: ...egative cable Raise and support the vehicle wheels hanging Remove the front RH wheel Move aside the splash shield using tool 1 IMPERATIVE In the case of belt re use mark the direction of rotation of t...

Page 140: ...sioner roller moves freely no tight spot If this is not the case replace the tensioner roller Respect the direction of fitting of the drive belt Complete the setting of the belt of both sides by means...

Page 141: ...gines HDi Remove The front RH wheel The under engine sounddeadening The splash shield WARNING Mark the direction of fitting of the accessories drive belt if it is to be re used Compress the tensioner...

Page 142: ...of fitting of the belt Refit the accessories drive belt Compress the tensioner roller 1 by acting at a clockwise using tool 1 Remove tool 2 IMPERATIVE Make sure the belt is correctly positioned in th...

Page 143: ...oner roller support 1 clockwise using tools 1a and 1b at a Remove the belt Immobilise the support 1 of the tensioner roller using tool 2 Remove the auxiliary drive belt 2 IMPERATIVE Ensure that the te...

Page 144: ...d Compress the tensioner roller 1 by acting at a clockwise using tool 1 Peg at b using tool 2 Remove the accessories drive belt IMPERATIVE Check that the rollers 1 and 2 can turn freely without play a...

Page 145: ...Removal Re use of belt WARNING Mark the direction the belt was fiited in case of re use of the same belt Compress the tensioner roller 2 by action at a in anti clockwise direction tool 4 Keep the tens...

Page 146: ...the belt WARNING Respect the belt fitting direction Remove the tool 4 New belt Refit the belt Turn the eccentric roller 3 tool 1 clockwise to free the tool 2 from its pegging at b Hold the eccentric r...

Page 147: ...lt WARNING Mark the direction the belt was fitted in case of re use of the same belt Compress the tensioner roller 7 by moving it at c in anti clockwise direction tool 4 Hold the tensioner roller 7 co...

Page 148: ...he belt WARNING Respect the direction belt was fitted Remove the tool 4 New belt Refit the belt Turn the eccentric roller 5 tool 1 clockwise to free the tool 2 from its pegging at d Hold the eccentric...

Page 149: ...es See pages HFX KFV KFW KFU NFV NFU 6FZ RFN RFS 1 1i 1 4i 1 6i 16V 148 to 157 148 to 157 1 1i 1 4i 1 4i 16V 1 6i 16V 148 to 157 165 to 170 148 to 157 1 4i 1 6i 16V 148 to 157 148 to 157 1 4i 1 6i 16V...

Page 150: ...ges See pages See pages See pages 8HX 8HW 8HZ 8HV 8HY 9HZ 9HY WJY RHY RHZ 1 4 HDi 184 to 191 1 4 HDi 1 4 HDi 1 4 HDi 16V 1 4 HDi 16V 184 to 191 192 to 200 1 4 HDi 184 to 191 1 4 HDi 1 9 D 2 0 HDi 2 0...

Page 151: ...OMMENDATIONS TIMING BELT ALL TYPES Petrol Engine Recommendations IMPERATIVE After any repair involving removal of the timing belt systematically replace The timing belt The tensioner roller fixing nut...

Page 152: ...roller pin 4200 T H 5 Belt retaining pin 4533 T AD 6 Pliers for removing plastic pins 7504 T Checking the valve timing Engines HFX KFV NFU Raise and support the front RH side of the vehicle Disconnec...

Page 153: ...e The engine support 4 complete The timing casing 3 The sparking plugs eases engine rotation Turn the wheel to rotate the engine normal direction of rotation Position the pegs 3a and 3b Peg the flywhe...

Page 154: ...The splash shield using tool 6 The accessories belt See corresponding operation The crankshaft pulley The oil filter Place a jack under the engine peg the engine Removing Engines HFX KFV Turn the eng...

Page 155: ...nes HFX KFV Slacken the screws 4 without removing them Remove the bottom engine support assembly 5 and the fixing screws 4 Slacken the nut 6 Completely detension the belt by acting on the tensioner ro...

Page 156: ...G Engine NFU B1BP2MBC Engine NFU Setting the timing continued Remove The bottom plastic casing The engine support 9 The middle support The timing cover 8 Peg the flywheel using tool 1 Position the too...

Page 157: ...ith the aid of an Allen key placed at a Turn the tensioner roller towards the right to bring it to the index c in position b Peg the tensioner roller in this position in order to slacken the timing be...

Page 158: ...ect the direction of fitting of the belt the arrows d indicate the direction of rotation of the crankshaft Refit the timing belt Position the timing belt belt e well tensioned in the following order C...

Page 159: ...he crankshaft Refit the timing belt Position the timing belt belt e well tensioned in the following order Crankshaft pinion hold the belt using tool 5 Camshaft pulley Coolant pump pulley Tensioner rol...

Page 160: ...tion f to tension the belt to the maximum of the interval indicated Hold the tensioner roller 7 using tool 4 Tighten the fixing nut of the tensioner roller tightening to 1 0 1 m daN Turn the crankshaf...

Page 161: ...The index c should not go beyond the notch g WARNING The index c must not go beyond the notch g If it should do this restart the timing belt tensioning operation Hold the tensioner roller 7 in this p...

Page 162: ...using tool 2 Setting the timing NOTE Remove the sparking plugs to ease rotation of the crankshaft Rotate the engine by means of the crankshaft screw 1 Peg the camshaft pinion Peg the flywheel Slacken...

Page 163: ...ley tensioner roller Tool 5 respect the direction of fitting relative to the valve timing Put the tensioner roller in contact with the belt Tighten the nut 2 Pre tensioning the belt Place tool 4 on th...

Page 164: ...tension Place tool 4 on the tensioned part of the belt Slacken the nut 2 Detension the belt but too much Tension the timing belt to obtain a value of 31 2 SEEM units Tighten the nut 2 to 2 m daN Remov...

Page 165: ...ting peg exhaust 4533 T A C2 Tool kit 4507 T 4 Camshaft pulley locating peg inlet 4533 T A C1 5 Tensioning tool 4707 T J Checking the valve timing Peg the flywheel using the tool 2 Peg the exhaust cam...

Page 166: ...between the screws and the pinions Check that the rollers 2 and 3 rotate freely NOTE The belt bears three identification marks a b and c facing its own teeth 1 52 and 72 respectively Identification ma...

Page 167: ...old the belt in this position and engage it over the water pump pinion and the tensioner roller Fit the tool 1 on the belt at e Rotate the roller 2 using tool 5 in an anti clockwise direction to obtai...

Page 168: ...re is still a slight amount of friction with the pulley Peg the camshaft hubs using pegs 3 and 4 WARNING In certain cases it may be necessary to slightly turn the camshaft using the hub fixing screw F...

Page 169: ...ankshaft setting peg 0194 A Checks Raise and support the vehicle front wheels hanging Disconnect the battery Remove The oil filter The engine cover The upper timing cover 1 The sparking plugs to ease...

Page 170: ...the flywheel using tool 1 NOTE If the setting is not correct recommence the operation Remove the pegs 2 and 3 Refit The oil filter The timing cover 1 The engine cover Reconnect the battery Lower the v...

Page 171: ...194 A 4 Camshaft peg 4533 TA C1 5 Belt retaining pin 4533 T AD Removing Raise and support the vehicle front wheels hanging Disconnect the battery Remove The front RH wheel The front RH splash shield T...

Page 172: ...e the engine by means of the crankshaft pinion screw 2 clockwise to bring it to the pegging position Peg the flywheel using tool 1 Position the tools 3 and 4 Position the tool 2 Support the engine Rem...

Page 173: ...Slacken the nut 7 Remove the timing belt IMPERATIVE Check that the tensioner roller turns freely no tight spot Refitting Fit the new timing belt in the following sequence Inlet camshaft pulley Exhaus...

Page 174: ...ure the timing setting is correct by refitting the pegs 1 3 and 4 Remove the pegs 1 3 and 4 Adjusting the tension of the belt Slacken the nut holding the position of the tensioner roller by means of a...

Page 175: ...Pegging on manual gearbox B Pegging on automatic gearbox The pegging of the crankshaft is done on the flywheel or on the converter drive plate automatic gearbox The pegging hole on the cylinder block...

Page 176: ...or angular tightening 4069 T 5 Tool for moving and locking the tensioner roller 0189 S 5a 0189 S1 5b 0189 S2 Pliers for removing plastic pins 7504 T Checking the setting of the timing Removing Disconn...

Page 177: ...t pinion screw to bring it to the pegging position Peg the crankshaft using tool 2 Peg the camshaft pulleys using tool 3 NOTE The pegs 3 should go in without effort WARNING If the pegs go in only with...

Page 178: ...the vehicle front wheels hanging Remove The front RH wheel The plastic pins 1 The splash shield 2 The accessories drive belt see corresponding operation Unclip and move aside the fuel delivery hose f...

Page 179: ...ew 3 of the crankshaft pulley 2 The lower timing cover 4 by moving the engine IMPERATIVE Never remove the crankshaft pulley 2 without pegging the crankshaft and the camshafts Slacken the screw 9 of th...

Page 180: ...ace respecting the following order Guide roller 10 Inlet camshaft pulley 6 Exhaust camshaft pulley 5 Coolant pump 11 Tensioner roller 8 NOTE Make so that the belt 7 is as flush as possible with the ex...

Page 181: ...ing position g by turning the tensioner roller in the direction of the arrow e WARNING the index a should not pass the slot g Otherwise repeat the operation to tension the timing belt IMPERATIVE The t...

Page 182: ...haft pulley using tool 1 Checks Tension of the timing belt ESSENTIAL Check the position of the index a which should be opposite the slot g If the position of the index a is not correct repeat the oper...

Page 183: ...d sector for locking the flywheel 9044 T Checking the setting Turn the engine by the crankshaft screw 1 Peg the crankshaft using the tool 3 ESSENTIAL Check that the crankshaft DAMPERS pulley is in goo...

Page 184: ...r 6 Remove The tool 6 The studs 8 Fit the tool 4 Loosen the screws 10 Remove the tool 4 Slacken the tensioner roller 7 Remove the belt 9 Peg the crankshaft using tool 3 Peg the camshaft pulleys using...

Page 185: ...faces of the pulleys and hubs Turn the camshaft pulleys in a clockwise direction to bring them to the end of the slots Fit the belt 9 Fit the tool 1 Turn the roller 7 using the tool 5 Pre tension to P...

Page 186: ...the camshaft pulleys using the tool 2 NOTE If it is not easy to peg the camshaft hubs loosen the tensioner roller 7 and turn the camshafts using the screw 10 Fit the tool 4 Loosen the screws 10 Remove...

Page 187: ...to 2 m daN Fit the tool 4 Tighten the screws 10 to 7 5 m daN Remove the tools Rotate the crankshaft by two turns normal direction of rotation Check the pegging of the crankshaft camshaft using tools 2...

Page 188: ...s Remove The front RH wheel The front RH splash shield using tool 1 The clips of the electrical harness on the upper timing cover The accessories belt using tool 2 see corresponding operation Check in...

Page 189: ...otate the engine by means of the crankshaft pinion screw 2 clock wise to bring it to the pegging position Position the tool 4 Peg the crankshaft pinion 1 using tool 5 Peg the high pressure pump pinion...

Page 190: ...from the manifold IMPERATIVE Uncouple the exhaust line in order to avoid damaging the front flexible pipe Twisting pulling and bending the front flexible pipe reduces its life Remove The engine speed...

Page 191: ...lock wise to bring it to the pegging position Peg the camshaft pulley using tool 4 Peg The crankshaft pinion 6 using tool 5 The high pressure pump pinion using tool 5 Support the engine with the aid o...

Page 192: ...the case replace the rollers Fitting of the pulleys Camshaft pulley Tighten to 4 3 0 4 m daN Fuel high pressure pump pulley Tighten to 5 0 5 m daN The crankshaft pinion is located without a screw at...

Page 193: ...inued NOTE Screw 9 slackened Position the timing belt 10 observing the following sequence Crankshaft pinion 4 Guide roller 12 Camshaft pulley 11 check that the belt is held correctly against the rolle...

Page 194: ...0 3 m daN Remove the tools 4 and 5 Rotate the engine ten times check that the timing pinion is correctly up against the crankshaft Check The pegging of the camshaft The crankshaft pinion The fuel hig...

Page 195: ...n the screws 17 to 4 5 0 4 m daN The bottom timing cover 3 Immobilise the engine flywheel using tool 3 Remove the screw 2 Refit the accessories drive pulley and tighten to Pre tighten to 3 0 3 m daN A...

Page 196: ...0194 A Preliminary operations Remove The front RH wheel The front RH splash shield The accessories belt see corresponding operation Uncouple The supply unions 1 The air air heat exchanger inlet outlet...

Page 197: ...1C B1BP2N2C Checks Rotate the engine to engage it normal direction of rotation Immobilise the engine flywheel at a using tool 1 Move aside the harness 6 Remove The engine support 7 The screw 8 The pul...

Page 198: ...igh pressure pump pulley 14 using tool 3 at c WARNING The magnetic track should show no signs of damage and should not be approached by any source of magnetism Peg the crankshaft at b using tool 3 IMP...

Page 199: ...e correct positioning of the index e If it is not correct repeat the operation to tension the timing belt see corresponding operation Refitting Refit the tool 1 at a Remove the screw 8 Refit The upper...

Page 200: ...ne support 5 tighten to 6 0 6 m daN The electrical harness 6 Couple The exhaust line tighten the collar to 2 5 0 3 m daN The fuel supply unions 1 The air air heat exchanger inlet outlet pipes 3 Connec...

Page 201: ...e camshaft using tool 2 oil the pegs WARNING Do not press or damage the track which is the target for the engine speed sensor 14 Peg the crankshaft at b using tool 3 Remove The timing protector 13 The...

Page 202: ...no play and no tight spot there are no traces of oil from the crankshaft and camshaft sealing rings there is no leak of coolant fluid from the coolant pump the target track of the engine speed sensor...

Page 203: ...eter peg at d Adjusting the fitting tension of the belt Action the tensioner roller 19 to align the marks f and g avoiding detensioning the timing belt with the aid of a male hexagonal spanner at c If...

Page 204: ...Check the position of the tensioner roller the alignment of the marks f and g should be correct If this is not the case repeat the operation to tension the belt Peg the camshaft pulley using tool 2 I...

Page 205: ...terminals of the battery Remove The front RH wheel The front RH splash shield The accessories drive belt see corresponding operation Uncouple The fuel supply unions 1 The air air heat exchanger inlet...

Page 206: ...te the engine to drive it in its normal direction of rotation Peg the flywheel using tool 1 at b Move aside the harness 7 Remove The engine support 8 The screw 10 The accessories drive pulley 9 The lo...

Page 207: ...t at d using tool 3 ESSENTIAL Should it not be possible to peg the camshaft check that the offset bet ween the camshaft pinion hole and the pegging hole is not more than 1 mm If it is more repeat the...

Page 208: ...support 5 tighten to 2 5 0 2 m daN The electrical harness 7 The power steering fluid reservoir 6 XSARA PICASSO Couple The tube 2 The exhaust line tighten the clip to 2 5 0 3 m daN The fuel unions 1 Th...

Page 209: ...terminals of the battery Remove The front RH wheel The front RH splash shield The accessories drive belt see corresponding operation Uncouple The fuel supply unions 1 The air air heat exchanger inlet...

Page 210: ...te the engine to drive it in its normal direction of rotation Peg the flywheel at b using tool 1 Move aside the harness 7 Remove The engine support 8 The screw 10 The accessories drive pulley 9 The lo...

Page 211: ...nd keep it slackened using an allen spanner at d Detension the timing belt by pivoting the tensioner roller clockwise Remove the timing belt starting with the coolant pump pinion Checks ESSENTIAL Just...

Page 212: ...ion Position the belt on the guide roller belt well tensioned Refit The timing belt protector 13 The engine speed sensor 14 Reposition the timing belt strip f well tensioned in the following sequence...

Page 213: ...e correct Remove tools 2 and 3 Rotate the crankshaft six times clockwise IMPERATIVE Never rotate the engine backwards WARNING Do not touch or damage the track of the target of the engine speed sensor...

Page 214: ...n to 2 5 0 2 m daN The electrical harness 7 The power steering fluid reservoir 6 XSARA PICASSO Disengage the jack from under the engine Couple The tube 2 The exhaust line tighten the clip to 2 5 0 3 m...

Page 215: ...4 Screw H M8 0188 E 5 Belt retaining pin 0188 K 6 Square for adjusting belt tension 0188 J1 7 Belt tension measuring instrument with digital display SEEM CTG 105 5M Checking the timing Peg the flywhee...

Page 216: ...workshop hoist Remove the RH engine support Engage 5th gear to permit rotation of the engine Remove the upper cover 1 Remove the intermediate cover 2 Remove the lower cover 3 WARNING Refit the screw 4...

Page 217: ...oner roller 8 Remove the timing belt Refitting Retighten screws 5 and 6 by hand Turn the pinions 10 and 7 clockwise in order to place them at end of slots Fit the timing belt on the crankshaft Hold th...

Page 218: ...ions can turn freely Position the belt tension instrument 7 on the belt at b Using tool 6 act at a in the direction opposite to that of engine rotation to obtain a tension value of 106 2 SEEM units Ti...

Page 219: ...IAL Visually check that the offsets between the holes of the camshaft and injection pump hubs and the corresponding pegging holes are not more than 1 mm If necessary recommence the procedure for fitti...

Page 220: ...S RHZ requires the following components Idler crankshaft pinion Fixed camshaft pulley 5 Fixed camshaft pulley pulley with integral cylinder reference sensor target 6 Idler crankshaft pinion with incre...

Page 221: ...ore ever removing the accessories drive pulley the pegging prevents any offsetting of the camshaft If necessary apply a paint spot to mark the accessories drive pulley being replaced Replacement parts...

Page 222: ...plugs 0188 T 8 Pulley extractor 0188 P 9 2 mm dia peg 0188 Q2 Removing IMPERATIVE Respect the safety and cleanliness requirements that are specific to high pressure diesel injection HDi engines Undo t...

Page 223: ...h a spacer 17 mm thick tighten the screw 7 to 1 5 0 1 m daN NOTE The screw 7 is one of the screws securing the coolant pump and is there for its sealing Put the gear lever in 5th gear Turn the road wh...

Page 224: ...t the screw 8 without its thrust washer Remove The accessories pulley 9 using tool 8 Tool 6 The lower torque reaction rod Support the engine by means of a workshop hoist Remove The bearing shell fitti...

Page 225: ...ollers 18 and 15 turn freely without play and without any tight spot The coolant pump pulley 16 turns freely without play and without any tight spot There are no traces of oil leaks from the crankshaf...

Page 226: ...lt at a Remove tools 4 and 9 Turn the tensioner roller 18 anti clockwise using tool 2 to attain an overtension of 98 2 SEEM units Tighten screw 17 of the tensioner roller to 2 5 0 2 m da N Lock the fl...

Page 227: ...sion of 54 2 SEEM units Tighten screw 17 of the tensioner roller 18 to 2 5 0 2 m daN Remove tool 1 Fit tool 1 The tension value should be 54 3 SEEM units ESSENTIAL If the value is incorrect recommence...

Page 228: ...ell 10 Take away the workshop hoist Clip the fuel delivery and return pipes Remove the tool 7 Couple The fuel delivery pipe 12 The fuel return pipe 1 Coat the screw 8 with loctite FRENETANCH Refit the...

Page 229: ...ENGINE 225 RFS SPECIAL FEATURES OF THE TIMING B1EP122C Camshaft hub identification Engine RFS Inlet Exhaust Hubs a Engraving B b Paint marking BLUE...

Page 230: ...HDi 1 4 HDi 16V 2 0 HDi 0 20 mm 0 05 Exhaust 0 40 mm 0 05 Hydraulic adjustment 1 mm 0 05 1 mm 0 05 Rocking Adjust 1 1 3 3 4 4 2 2 4 4 2 2 1 1 3 3 Inlet Adjust Rocking Valves fully open Adjust 1 3 4 2...

Page 231: ...4103 T 2279 T Bis X X X X 4103 T B X X X X 7001 T X X X 1503 J X C3 C3 Pluriel Plaque engine HFX KFV KFU NFU 8HX 8HW 8HV 8HY Temperature C 90 C Pressure Bars 3 4 1 3 3 5 Rpm 2000 4000 1000 4000 Tools...

Page 232: ...C 80 C 90 C Pressure Bars 3 4 1 5 5 1 2 5 5 1 3 3 5 1 8 4 5 2 4 Rpm 2000 4000 1000 4000 1000 4000 1000 4000 1000 4000 1000 4000 Tools Kit 4103 T 2279 T Bis X X X X X X X X 4103 T B X X X X X X X X 70...

Page 233: ...9HY RHY Temperature C 90 C 80 C 90 C Pressure Bars 3 4 3 3 6 3 1 5 5 1 3 3 5 2 4 Rpm 2000 4000 1000 4000 1000 3000 1000 4000 1000 4000 Tools Kit 4103 T 2279 T Bis X X X X X X 4103 T B X X X X X X 700...

Page 234: ...R7 Xsara 1109 R7 1109 T1 1109 N3 Xsara Picasso 1109 T1 1109 T1 DV4TD DV4TED4 DV6TED4 DW8 DW10 1 4 HDi 1 4 HDi 16V 1 6 HDi 16V 1 9 D 2 0 HDi 8HX 8HW 8HZ 8HV 8HY 9HZ 9HY WJY RHY RHZ C2 1109 S5 C3 1109...

Page 235: ...r adaptor 2 4222 T Picasso C2 C3 and the filling cylinder 1 4520 T all types Use the coolant to ensure protection between 15 C and 37 C Slowly fill the system NOTE Keep the cylinder filled up visible...

Page 236: ...7 4 4 1 4i KFW L4 IFL5 SAGEM S2000 850 1 6i NFU L4 BOSCH M 7 4 4 2 0i RFN L4 MAGNETTI MARELLI MM 48P2 2 0i 16V RFS L3 M MARELLI 1AP10 1 6i NFV L4 BOSCH M7 4 4 1 8i 6FZ L4 SAGEM S2000 700 2 0i 16V RFN...

Page 237: ...ssure bars Overspeed cut off rpm Injector resistive value ohms Engine coolant temperature sensor resistive value ohms Idling actuator or stepper motor resistive value ohms HFX KFV NFU L4 IFL5 L4 IFL5...

Page 238: ...t off rpm Injector resistive value ohms Engine coolant temperature sensor resistive value ohms Idling actuator or stepper motor resistive value ohms HFX K L4INF L4 IFL5 L5 K L4INF L4 IFL5 L4 L4 IFL5 I...

Page 239: ...verspeed cut off rpm Injector resistive value ohms Engine coolant temperature sensor resistive value ohms Idling actuator or stepper motor resistive value ohms KFW L4 IFL5 L5 L4 IFL5 L4 IFL5 L4 IFL5 L...

Page 240: ...s registered before 10 86 Less than 3 5 for vehicles registered after 10 86 With catalytic converter Greater than 2 0i 89 M Y All Types 93 M Y CO less than 0 5 at idle speed CO less than 0 3 at fast i...

Page 241: ...Petrol Diesel K K 15 04 15 04 With oxygen sensor without catalytic converter Utility vehicles All Types Private vehicles 2 litres new models existing models 10 89 imminent 01 10 88 01 10 89 Utility v...

Page 242: ...etrol Diesel Private vehicles certain non EEC European countries certain Export countries Private vehicles certain non EEC European countries certain Export coun tries Private vehicles certain Export...

Page 243: ...iesel Private vehicles certain non EEC European countries certain Export coun tries Private vehicles certain non EEC European countries certain Export coun tries Private vehicles certain non EEC Europ...

Page 244: ...HARACTERISTICS Petrol Diesel Petrol Diesel Gas Brussels Directive 94 12 EURO 93 standard made stricter Brussels Directive 96 69 3 classes depending on vehicle weight Class 1 1250 kg Class 2 1250 1700...

Page 245: ...esel Gas Petrol Brussels Directive 98 69 EURO 2 standard L3 made stricter Fiscal incentives 3 classes depending on vehicle weight Class 1 1305 kg Class 2 1305 1760 kg Class 3 1760 kg Brussels Directiv...

Page 246: ...ol Diesel Gas Petrol Gas Brussels Directive 2001 1 EURO 3 standard L4 made stricter Fiscal incentives Brussels Directives 99 102 et 2001 1 Gas EURO 3 standard L4 made stricter Fiscal incentives 3 clas...

Page 247: ...E Take into account the very high pressures in the high pressure fuel circuit 1350 bars and respect the requirements below No smoking in proximity to the high pressure circuit when work is being carri...

Page 248: ...res of the following sensitive components refer to corresponding procedures Fuel filter High pressure fuel pump High pressure fuel injection common rail High pressure fuel pipes Diesel injector carrie...

Page 249: ...ctric circuit Swapping injection ECUs between two vehicles will render it impossible to start either vehicle It is forbidden to supply a diesel injector with 12 volts High pressure fuel pump Do not se...

Page 250: ...separate the following components from the diesel injector carrier 2 Diesel injector f no replacement parts Electromagnetic element c no replacement parts Do not alter the position of the nut d malfu...

Page 251: ...lectric circuit Swapping injection ECUs between two vehicles will render it impossible to start either vehicle It is forbidden to supply a diesel injector with 12 volts High pressure fuel pump Do not...

Page 252: ...gulator c from the injection common rail 2 Risk of malfunction Diesel injectors WARNING Diesel and ultrasonic cleaners are prohibited Do not separate the following components from the diesel injector...

Page 253: ...tween two vehicles will render it impossible to start either vehicle It is forbidden to supply a diesel injector with 12 volts High pressure fuel pump Do not separate the following components from the...

Page 254: ...10 malfunction Do not separate the connector 12 from a diesel injector It is forbidden to clean the carbon deposits from the diesel injector nozzle Identification Injector carrier There are two types...

Page 255: ...251 INJECTION SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP PUMP TYPE REFERENCE D pollution Equipment L3 Transponder XSARA XSARA 8B DW WJY DWLP 12 R8448 B 371 B...

Page 256: ...ic timing checking at idle Reference Injector Injector holder injector Code colour Injector needle lift pressure Bar Adjustments rpm Max speed Fast idling Anti stall Idling Unladen rpm Laden rpm WJY D...

Page 257: ...proceed in the following manner Remove The screws 6 7 9 10 and 12 The upper casing 8 The intermediate casing 11 WARNING Refit the screw 6 equipped with a washer Thickness 5 mm Turn the front RH wheel...

Page 258: ...shaft but not the injection pump Carry out the following operations Loosen the screws of the injection pump hub Turn the injection pump hub Insert the peg 3 into the setting hole Tighten the screws of...

Page 259: ...s in tension Checking the thermostatic sensor There should be a minimum 6 mm cable travel between a cold and a hot engine Adjusting the accelerator control Prior conditions Engine hot cooling fan is e...

Page 260: ...just the speed using the idle adjustment screw 11 Idling speed 825 25 rpm Checking the engine deceleration Move the throttle lever 6 to obtain an engine speed of 3000 rpm Release the throttle lever 6...

Page 261: ...are to be replaced each time they are removed NOTE Fitting parts of diffe rent makes is PROHIBITED WARNING Ensure that the fire seal washer 3 is fitted the right way round Tighten the injector holder...

Page 262: ...es Injection system ECU High pressure pump Injectors BOSCH BOSCH EDC 15C2 SIEMENS ECUSID801 BOSCH EDC 15C2 BOSCH CP1 5WS 40001 BOSCH CP1 9625542580 5WS40000 9625542580 SIEMENS except PICASSO BOSCH DW...

Page 263: ...specific to high pressure diesel injection engines Link tools 1 and 2 in series between the fuel high pressure pump and the fuel filter ESSENTIAL Check that the tool 2 is clean Check the negative pres...

Page 264: ...tool 1 in series downstream of the injectors between the fuel high pressure pump and the fuel filter at a and b WARNING Any checking of pressure downstream of the fuel filter is prohibited Switch on...

Page 265: ...filter white mark at a on the fuel supply pipe Connect the tool 2 downstream of the diesel injectors between the high pressure fuel pump and the fuel filter green mark at b on the fuel return pipe WAR...

Page 266: ...tribution valve locked shut Check diesel injector return flow Table below Uncouple the diesel injector return pipe Fuel supply pressure Fuel return pressure Checks Between 3 and 3 5 Bar 0 7 0 2 Bar Ch...

Page 267: ...on Remove the clips 1 Fit the tool 2 in the place of the duct 2 Couple the sleeve 2 on the pressure gauge 1 using the tube a Mode of operation Position tool 1 in the vehicle Start the engine Engage fi...

Page 268: ...Fit the tool 2 in the place of the duct 2 Couple the sleeve 2 on the pressure gauge 1 using the tube a Mode of operation Position tool 1 in the vehicle Start the engine Engage first gear start the veh...

Page 269: ...ngine under full load Connect the diagnostic tool to the vehicle s diagnostic socket carry out parameter measures Mode of operation Start the engine Engage first gear start the vehicle Engage the gear...

Page 270: ...collar fixing 3 Insert the tool 2 connected with tool 3 between the pipe 1 and the duct 2 Position tool 1 in the vehicle Connect the sleeve 2 to the tool 1 with its tube a Procedure Start the engine...

Page 271: ...n Remove the collar 3 and the sleeve Insert the tool 2 between the pipe 1 and the duct 2 Position tool 1 in the vehicle Connect the pressure gauge 1 to the tool 2 with its tube a long enough for the g...

Page 272: ...PPLY CIRCUIT Tools 1 Manual pressure vacuum pump FACOM DA 16 Vacuum pump Connect the tool 1 onto the vacuum pump 1 Start the engine Wait 30 seconds The vacuum value should be 0 9 0 1 bar at idle B1HP1...

Page 273: ...rt the engine Pressure should be 0 8 bar at 780 rpm Boost pressure regulator electrovalve Connect the tool 1 between the electrovalve 2 and the valve 3 of the boost pressure regulator Compare readings...

Page 274: ...ve should click and lock itself back on its seating Regulation electrovalve EGR Engine 8HX 8HW Check to be performed between the electrovalve 1 and the EGR valve 2 Link the tool 1 in series between th...

Page 275: ...owing operations with the diagnostic tool INJECTION menu Actuator tests EGE electrovalve Check that you can hear the click from the EGR regulation electrovalve Double butterfly housing vehicle with pa...

Page 276: ...eral times in succession a vacuum of approx 0 6 bar to activate the rod a In abrupt reaction to the vacuum the valve should close on its seating with a clicking noise Exhaust gas reycling EGR electrov...

Page 277: ...re circuit After the engine has stopped wait 30 seconds before starting any operation NOTE The waiting time is necessary to allow the fuel high pressure circuit to return to atmospheric pressure Safet...

Page 278: ...ter Dispose of materials and solid residues in an authorised recovery point IMPERATIVE The filling kit should be recycled following a repair All Eolys additive containers that have been opened should...

Page 279: ...e vehicle in the high position WARNING Check that the fuel level is sufficient at least 20 litres Start the engine and allow it to warm up 60 C minimum Connect the diagnostic tool to the vehicle s cen...

Page 280: ...Disconnect the battery negative terminal Unclip the the factory filler connector 1 Couple the container of additive to the tube 2 using the adaptor and the tube with tap from the filling kit Screw the...

Page 281: ...ar protective goggles and gloves that are resistant to hydrocarbons Place the vehicle on a lift Raise the vehicle To test the flow of the additive pump Uncouple the tube 1 Couple tool 2 on the outlet...

Page 282: ...pressure should not fall rapidly NOTE Replace the fuel tank if the injector is defective Couple the tube 1 Operate the actuator test Filling the tube additive pump additive injector with the aid of L...

Page 283: ...N 58 HZ 0 9 0 05 0 9 0 05 2 5 0 2 1 4i KFW FR7 DE 0 9 0 1 RFN 58 LZ RC 8 YLC mda N XSARA 1 6i 16V NFU FR7 ME RFN 58 HZ 2 0i 16V RFN FR8 ME RFN 52 HZ REC 9 YCL RFS FR6 DE RFN 62 LZ 1 6i 90 hp NFV RFN 5...

Page 284: ...e For an actual speed of 100 Kph the speed displayed by the speedometer may be between 100 and 114 Kph The speed indicated by the speedometer may be influenced by The speedometer The tyres fitted to t...

Page 285: ...BVM BVM BVMP BVM BVMP BVM BVMP MA 5 S MA 5 N L MA 5 S L MA 5 0 Mechanism type VALEO LUK Engine type 180 CP0 3400 200 P 3900 Bearing supplier height SKF 17 mm Clutch disc 11 R 10 of lining Ext Int 180...

Page 286: ...V KFU NFU 8HX 8HW 8HV 8HY Gearbox type Supplier MA 5 BE4 5 Mechanism type VALEO LUK Engine type 180 CPO 3400 200 MF 200 P 3900 230 P 4700 3850 Clutch disc 11 R 10 X 200 VTB Garniture Ext Int 180 127 2...

Page 287: ...Gearbox type Supplier MA 5 MA 5 BE4 5 Mechanism type VALEO Engine type 180CPO 3400 200 CPR 3800 230 DNG 4700 215 DT 5250 Clutch disc 180 XJF 73 C 200X D95 11A12X 230 DNG 4700 215 FD 95 Garniture Ext I...

Page 288: ...e type 8HZ WJY RHY RHZ Gearbox type Supplier BE4 5 Mechanism type LUK Engine type 200 P 4200 200 P 3700 230 P 4700 235 T 5700 Clutch disc 215 F D 93 22 BX 228 228D Garniture Ext Int 200 134 200 134 23...

Page 289: ...e Supplier BE4 5 Mechanism type VALEO LUK Engine type 200 DNG 3800 230 DNG 4700 215 DT 5250 225 DNG 5100 230 P 4700 Clutch disc 200X D95 230 DNG 4700 215 FD 95 228 11A12X Garniture Ext Int 200 137 228...

Page 290: ...nt is screwed into the clutch casing 2 Declutch fork 3 Clutch casing 4 Bearing 5 Clutch plate The clutch control slave cylinder 7 is fixed by two screws 6 onto the exterior of the clutch casing Tighte...

Page 291: ...screwed into the clutch casing 2 Declutch fork 3 Clutch casing 4 Bearing 5 Clutch plate The clutch control slave cylinder 7 is fixed by two screws 6 onto the exterior of the clutch casing Tightening t...

Page 292: ...Y RHY RHZ Clutch cable Removing Uncouple the cable from the lever 1 Unclip the cable from the gearbox by actioning the side tabs 2 Detach the cable from the bulkhead Remove the clip 3 Uncouple the cab...

Page 293: ...in place Check that the end piece 4 is correctly lodged on the bulkhead Check the operation of the automatic adjusting system After fitting the cable pull the clutch lever in the inverse direction dir...

Page 294: ...clutch cable sleeve can move freely At rest the clutch cable sleeve should be free and able to lengthen and shorten Clutch pedal travel The automatic clutch wear adjustment system has no manual adjus...

Page 295: ...ATIVE Do not use automatic bleeding equipment risk of the brake fluid emulsifying in the hydraulic circuit Couple a transparent tube 5 on the bleed screw at c Submerge the end of the tube 5 in the rec...

Page 296: ...ction the clutch pedal manually through its entire travel 7 times rapidly down and up The last time keep the clutch pedal fully down Reclose the bleed screw at c If necessary repeat the operation Top...

Page 297: ...e 1 804 m 1 804 m 1 781 m 1 804 m 1 781 m Gearbox type MA 5 S MA 5 N MA 5 L MA 5 0 Gearbox ident plate 20 CP 20 20 CP 21 20 CP 16 20 CP 55 20 CP 67 PRO 9919 PRO 9919 PRO 9919 PRO 9919 PRO 9919 Reducti...

Page 298: ...1 804 m 1 781 m 1 781 m 1 772 m 1 804 m 1 804 m Gearbox type MA 5 N MA 5 S MA 5 L MA 5 0 Gearbox ident plate 20 CP 21 20 CP 64 20 CP 66 20 CP 65 PRO 9786 PRO 9786 PRO 9786 PRO 9786 Reduction box torq...

Page 299: ...arbox ident plate Reduction box torque GEARBOX AND TYRE SPECIFICATIONS 1 6i 16V AUTOMATIC 1 4i 1 1i Petrol HFX X SX Exclusive Exclusive Exclusive X SX Exclusive X SX X SX NFU KFV Diesel 165 70 R 14 1...

Page 300: ...level Engine type KFU NFU 8HX Tyres rolling 185 60 R15 165 70 R14 Circumference 1 828 m 1 804 m Gearbox type MA 5 Gearbox ident plate 20 CP 56 20 CP 65 Reduction box torque 17x64 16x63 Speedometer rat...

Page 301: ...ypes KFV NFU 8HX Tyres rolling Circumference Gearbox type MA 5N MA 5S MA 50 Gearbox ident plate 20 CP 60 m 1 20 CP 63 mp 2 20 CP 71 m 1 Reduction box torque 13x59 16x65 14x60 Speedometer ratio 21x18 1...

Page 302: ...KFW NFU RFN RFS 195 55 R15 1 815 m MA 5 AL4 BE4 5 AL4 BE3 5 20 CP 13 1 20 CP 51 2 20 TP 49 20 DL 40 20 TP 47 20 TE 47 16x65 21x73 19x72 23x73 14x62 21x18 24x21 22x19 24x21 22x19 Diesel 1 9 D 1 4 HDi 2...

Page 303: ...20 DL 69 20 TS 02 Reduction box torque 15x64 19x77 21x73 Speedometer ratio 22x18 24x20 Diesel 1 6 16V HDi 2 0 HDi Engine type 9HZ 9HY RHY Tyres rolling 185 65 R15 Circumference 1 895 m Gearbox type BE...

Page 304: ...300 CLUTCH GEARBOX TRANSMISSION MA 5 GEARBOX Engines HFX KFV NFU 8HX 8HW a Identification label b Location for engraving of serial and gearbox nos B2CP3SQC C2 C3 C3 PLURIEL...

Page 305: ...ng fixing screw 8 Clutch bearing guide screw 9 Clutch housing 10 Bearing guide 11 Primary shaft 12 Differential housing 13 Speedometer screw 14 Counter drive 15 Planet pinions 16 Satellite pinions 17...

Page 306: ...th gear 25 5th gear synchroniser Tightening torques m daN 4 Bearing retaining clip screw x4 1 8 0 2 6 Intermediate plate 11 fixing screws 5 0 5 7 Gearbox casing 15 fixing screws 1 9 0 2 16 fixing scre...

Page 307: ...continued from RPO 9919 Features This gearbox has no adjustment has a reverse gear braking device 5th gear synchroniser has a device for prohibiting a change from 5th gear into reverse gear The clutch...

Page 308: ...304 CLUTCH GEARBOX TRANSMISSION MA 5 GEARBOX Engines KFW NFU a Identification label b Location for engraving of serial and gearbox nos B2CP3HTC XSARA...

Page 309: ...8 Secondary shaft 9 5th gear synchroniser 10 Driven pinion 5th gear 11 Driven pinion 4th gear 12 3rd 4th gear synchroniser 13 Driven pinion 3rd gear 14 Driven pinion 2nd gear 15 1st 2nd gear synchroni...

Page 310: ...m daN 23 Clutch bearing guide 3 fixing screws 0 6 0 15 24 Intermediate plate 11 fixing screws 5 0 5 25 Rear cover 3 fixing screws 2 2 0 2 26 Bearing retaining clip 4 fixing screws 1 8 0 2 27 Secondary...

Page 311: ...77 mm strengthened bearings strengthened intermediate plate NOTE All vehicles are equipped with clutch control by cable Features This gearbox has no adjustment has a reverse gear braking device 5th g...

Page 312: ...vement of the clutch fork and of the gear engagement lever must always be kept free during the actuator operating phases CLUTCH GEARBOX TRANSMISSION IMPERATIVE When initialising the clutch actuator an...

Page 313: ...TIVE Never move the vehicle with the ignition switched off Never push the vehicle to attempt to start it impossible with a piloted manual gearbox Towing Conditions for towing It is necessary to lift t...

Page 314: ...type piloted manual gearbox Actuator test Gearbox actuator test Gear engagement test N neutral NOTE The letter N should appear on the instrument panel If not see the following solution Engaging of N w...

Page 315: ...tinued Preliminary operation Disconnect the battery negative terminal Remove the air filter Use a 22 mm spanner Use the spanner to lift the gear engagement lever the maximum possible until the axis A...

Page 316: ...312 CLUTCH GEARBOX TRANSMISSION MA 5 PILOTED MANUAL GEARBOX Engines KFV 8HX a Identification label b Location for engraving of serial and gearbox nos B2CP3STC C2...

Page 317: ...fixing screw 8 Clutch bearing guide screw 9 Clutch housing 10 Bearing guide 11 Primary shaft 12 Differential housing 13 Speedometer screw 14 Counter drive 15 Planet pinions 16 Satellite pinions 17 Di...

Page 318: ...iven pinion 5th gear 25 5th gear synchroniser Tightening torques m daN 4 Bearing stop screw x4 1 8 0 2 6 Intermediate plate 11 fixing screws 5 0 5 7 Gearbox casing 15 fixing screws 1 9 0 2 16 fixing s...

Page 319: ...EARBOX Engines KFV 8HX Tightening torques m daN 26 5th gear cover fixing screw 3 screws 2 2 0 2 27 Gearbox input speed sensor 1 screw 0 8 0 2 28 Reverse gear switch 1 screw 2 5 0 5 29 Drain plug 1 scr...

Page 320: ...supplier SIEMENS A gearbox actuator with two electric motors supplier SACHS A clutch actuator with one electric motor supplier SACHS A gearbox input speed sensor The piloted manual gearbox has no gear...

Page 321: ...UTCH GEARBOX TRANSMISSION BE4 5 GEARBOX Engines NFV 6FZ RFN RFS 8HV 8HY 9HZ 9HY WJY RHY RHZ B2CP3BNC B2CP3BPD a Marking zone sequence and serial no b Location of identification label C3 XSARA XSARA PI...

Page 322: ...Y 9HZ 9HY WJY RHY RHZ 1 Drain plug 2 Filling and top up plug 3 Air vent NOTE The air vent aperture can be used for filling Quality of oil Refer to the manufacturer s instructions Quantity of oil Gearb...

Page 323: ...Drive gear 5th gear 10 5th gear synchroniser 11 Driven gear 5th gear 12 Driven gear 2nd 4th gear 13 Driven gear 2nd gear 14 1st 2nd gear synchroniser 15 Driven gear 1st gear 16 Secondary shaft 17 Dif...

Page 324: ...w 7 25 0 5 26 Secondary shaft nut 1 screw 6 5 0 5 27 Yoke retaining screw 2 screws 1 5 0 2 28 Differential gearwheel screw 2 screws 6 5 0 5 Reverse gear switch 1 screw 2 5 0 3 29 Differential housing...

Page 325: ...BOX TRANSMISSION MA 5 GEARBOX CONTROLS Engines HFX KFV KFU NFU 8HX 8HW 1 Gear control lever 2 Gear engagement control cable 3 Gear selection control cable The two cables cannot be separated B2CP3HXD C...

Page 326: ...W 4 Gear engagement ball joint 10 mm 5 Gear selection ball joint 10 mm C2 C3 Length D Length C Length D Length C Gear engagement 1040 mm 815 mm 1015 mm 790 mm control cable 2 Length A Length B Length...

Page 327: ...ool to detach the ball joints The gear selection control and gear engagement control cables cannot be adjusted To unlock the ball joint press at a then pull the ball joint upwards To release the sleev...

Page 328: ...on rod 6 Gear engagement ball joint 7 Fixed point on gearbox Adjustment The gear control assembly is not adjustable The rods do not have threaded ends Features Grease the gear engagement ball joint WA...

Page 329: ...5 CLUTCH GEARBOX TRANSMISSION BE4 5 GEARBOX CONTROLS Engines 8HV 8HY 1 Gear control lever 2 Gear engagement control cable 3 Gear selection control cable These two cables cannot be separated B2CP3J3D C...

Page 330: ...STMENTS BE4 5 GEARBOX CONTROLS Engines 8HV 8HY 4 Gear engagement ball joint 10 mm 5 Gear selection ball joint 10 mm Length A Length B Gear selection 907 mm 645 mm cable 5 Length D Length C Gear engage...

Page 331: ...V 8HY Adjustment The gear selection control and gear engagement control cables cannot be adjusted To release the ball joint press at d then pull the ball joint upwards To release sleeve stops Press on...

Page 332: ...9HZ 9HY RHY RHZ 1 Gear control lever 2 Gear engagement control cable 3 Gear selection control cable 4 Gear selection ball joint 10 mm 5 Gear engagement ball joint 10 mm 6 Flexible insulating grommet...

Page 333: ...earbox in neutral Couple the cables on the lever Fit the ball joints on the gearbox lever Lock the cable lengths with the ball joint locking keys WARNING Do not use any tool to unclip the ball joints...

Page 334: ...nnet Remove the air filter assembly Unlock the ball joint keys at a Place the gear selection and control levers on neutral Lock the cable lengths with the ball joint locking keys Checks Remove the too...

Page 335: ...become contaminated with impurities the oil is said to be burnt This is characterised by a black colour and the presence of an unpleasant smell ESSENTIAL The gearbox must be replaced Oil level see cor...

Page 336: ...d off Never push the vehicle to try to start it impossible with an automatic gearbox NOTE The automatic gearbox is only lubricated when the engine is running Repairs on electrical components Do not di...

Page 337: ...when handling the gearbox It is imperative to use the centring peg and the converter retaining bracket to couple the gearbox on the engine After coupling the gearbox on the engine remove the centring...

Page 338: ...l usage counter present in the automatic gearbox ECU After the downloading operation carry out the following A clearing of faults A pedal initialisation A re initialisation of the auto adaptives A pro...

Page 339: ...ow the diagnostic tool procedure A new ECU or downloaded update is always configured with the following options SHIFT LOCK gear selection lever position Without OBD outlet depollution L4 If the ECU is...

Page 340: ...RFN RHZ B2CP3ECD Identification a Component reference WARNING This gearbox benefits from a special CITROEN semi synthetic oil which cannot be mixed with any other oil The gearbox is lubricated for li...

Page 341: ...ation electrovalve fixing 1 0 2 2 Heat exchanger fixing 5 1 3 Output speed sensor fixing 1 0 2 4 Output speed sensor fixing 1 0 2 5 Oil overflow and drain fixing 4 0 2 6 Oil level plug 2 4 0 4 7 Oil p...

Page 342: ...Engines KFV NFU RFN RHZ B2CP3EED Tightening torques m daN 8 Fixing of converter on diaphragm Pre tightening 1 0 1 Tightening 3 0 3 9 Plug fixing 0 8 0 2 10 Gearbox fixing on engine 5 2 1 AL4 AUTOMATIC...

Page 343: ...ighten respect the order indicated 0 75 NOTE The screw 11 is shouldered B DW10 engine Hydraulic block fixing Centre the hydraulic block using screws 11 and 12 Pre tighten no strict order 0 9 Slacken A...

Page 344: ...f the 4 gears in their autoadaptive automatic function Position M Manual this position lets the driver select his own gears in sequential mode by pulling the gear selector to M or pushing it to M NOTE...

Page 345: ...ctor lever from position P Two switches placed on the gear control gate permit the driver to choose one of the following three driving programmes Normal programme Operates as the default programme eco...

Page 346: ...able c or d Push button 1 Control lever with ball joint 2 Automatic adjustment pull out the button to adjust the control push it in to lock the adjustment of the control 3 Sleeve stop 4 Selection cont...

Page 347: ...d press the brake pedal to unlock the selector lever from position P P Park system locked R Reverse gear N Neutral D Automatic 1st to 4th gear 3 Automatic 1st to 3rd gear 2 Automatic 1st to 2nd gear A...

Page 348: ...344 CLUTCH GEARBOX TRANSMISSION AL4 AUTOMATIC GEARBOX Gearbox end 1 Control lever 2 Automatic adjustment 3 Sleeve stop The automatic gearbox is controlled by a cable Engines NFU RFN RHZ XSARA XSARA...

Page 349: ...e SHIFT LOCK with an operating fault NOTE It is impossible to unlock the shift lock with the Normal operation method The fault may originate from one of the following components Shift lock Gear lever...

Page 350: ...ed Move the gear selection lever out of position P Unlocking the SHIFT LOCK with an operating fault NOTE It is impossible to unlock the shift lock with the Normal operation method The fault may origin...

Page 351: ...f position P Unlocking the SHIFT LOCK with an operating fault NOTE It is impossible to unlock the shift lock with the Normal operation method The fault may originate from one of the following componen...

Page 352: ...the ball joint 3 Push in the component a without bending the cable Check all the gear selection control positions Re used gear selection control Release the component a Couple the ball joint 3 Push i...

Page 353: ...oceed in the opposite order to removal IMPERATIVE To adjust the gear selection control place the gear selection lever in the park position Press on the component 25 without bending the cable then rele...

Page 354: ...t 6 WARNING Do not deform the selection lever on the automatic gearbox Push in the component a without bending the cable Check all the gear selection control positions Re used gear selection control R...

Page 355: ...Approx 3 litres of oil should flow out Filling Refit the drain plug 1 equipped with a new seal tighten to 2 4 0 2 m daN Remove the oil filler cap 2 Use tool 1 Oil capacity for dry gearbox EW engine 5...

Page 356: ...5 litres extra oil into the gearbox Foot on the brake change through all the gears Selection lever in position P Engine running at idle Oil temperature 60 C 8 C 2 C Remove the oil level plug 3 C3 TU3...

Page 357: ...e level is correct at the moment the thread of oil becomes drip drip Refit the oil level plug 3 equipped with a new seal tighten to 2 4 0 2 m daN Checking the oil level continued Refit the oil filler...

Page 358: ...0338 J3 0338 H1 0338 H2 0338 J1 0338 J2 0338 H1 0338 H2 0338 7114 T X 7116 T Driveshaft nut HFX KFV KFU 8HX 8HW NFU KFW NFU NFV RFS RFN 6FZ WJY 8HZ 9HZ 9HY RHY RHZ 8HV 8HY NFU RFN RHZ KFV MA 5 XSARA...

Page 359: ...Front height Rear height L1 L2 H1 R1 L1 H2 R2 L2 H1 Measurement between the measuring zone underneath the front H2 Measurement between the measuring zone underneath the rear subframe and the ground s...

Page 360: ...the radius of the front wheel R1 Calculate dimension H1 R1 L1 Measure the radius of the rear wheel R2 Calculate dimension H2 R2 L2 Value at reference Except CRD Value at reference Except CRD height HF...

Page 361: ...RH wheel the total tracking value All types except CRD NFU Vehicle Tracking Castor Camber Pivot angle 0 18 0 30 0 30 ADJUSTABLE Non adjustable 2 1 0 18 0 09 3 58 0 31 11 26 NFU Vehicle Tracking Casto...

Page 362: ...Wheel bolt 9 1 9 Subframe to bodyshell fixing screw 10 1 10 Anti roll bar 11 Pivot lower ball joint fixing on lower arm 5 5 0 5 12 Pivot lower ball joint fixing 4 0 4 13 Lower arm front and rear mount...

Page 363: ...xing screw 7 0 5 31 Rear suspension arm 32 Stub axle bearing nut 20 2 33 Damper 34 Damper upper fixing 4 5 0 4 35 Damper lower fixing 9 3 0 9 36 Suspension springs 37 Travel stop 38 Secondary brake ca...

Page 364: ...ON FRONT AXLE 1 Nut fixing suspension leg on body 6 5 0 6 2 Damper 16 Cup 17 Damper nut 6 5 0 6 18 Damper cup 19 Ball bearing 20 Spring thrust cup 21 Travel stop cup 22 Suspension spring 23 Damper rod...

Page 365: ...8HX Steering column Tightening torques m daN 1 Steering wheel fixing 2 0 3 2 Steering column fixing on support 2 2 0 5 3 Steering cardan fixing 2 2 0 2 Identification Identified by the colour of the...

Page 366: ...ck nut 5 0 5 8 Threaded washer 9 Stud 0 8 0 1 10 Flat washers 11 Fixing of mechanism on subframe 8 0 8 Connectors 6 Supply of electric assistance motor 7 Torque sensor signals HFX KFV 8HX NFU Electric...

Page 367: ...he assistance motor 12 depends on Speed of the vehicle Torque applied on the steering wheel Only one ECU version whatever the engine type The electric power steering ECU is linked to the following con...

Page 368: ...o column lift Remove on the RH side of the steering rack Clip 1 Clip 2 Release the steering rack rpotection gaiter Setting Move the steering to full left hand lock Measure the dimension X Move the ste...

Page 369: ...sponding operation H1 R1 L1 H1 Measurement between the measuring zone underneath the front subframe and the ground R1 Front wheel radius under load L1 Distance between the wheel axis and the measuring...

Page 370: ...lculate dimension H2 R2 L2 Value at reference All types Except CRD Vehicle CRD Value at reference All types Except CRD Vehicle CRD height Raised suspension Raised suspension height Raised suspension R...

Page 371: ...al tracking value All types except CRD Raised suspension Sports Vehicle CRD Raised suspension Sports Vehicle Tracking Castor Camber Pivot angle 0 18 0 30 0 30 Adjustable Non adjustable 2 1 0 19 0 10 3...

Page 372: ...operation H1 R1 L1 H1 Measurement between the measuring zone underneath the front subframe and the ground R1 Front wheel radius under load L1 Distance between the wheel axis and the measuring zone un...

Page 373: ...Calculate dimension H1 R1 L1 Measure the radius of the rear wheel R2 Calculate dimension H2 R2 L2 Value at reference All Types Value at reference All Types height height 6 8 mm L1 132 5 mm 10 6 mm L2...

Page 374: ...t 0 18 Dissymmetry of lower castor at 0 30 Dissymmetry of lower camber at 0 18 Distribute symmetrically LH RH wheel the total tracking value All types Vehicle Tracking Castor Camber Pivot angle 0 18 0...

Page 375: ...bearing fixing on subframe 8 0 8 7 Hub nut 24 5 0 5 8 Wheel bolt 9 1 9 Subframe to bodyshell fixing screw 10 1 10 Anti roll bar 11 Pivot lower ball joint fixing on lower arm 5 5 0 5 12 Pivot lower ba...

Page 376: ...rubber mounting 6 Yoke suspension arm fixing screw 7 6 0 5 7 Rear suspension arm 8 Stub axle bearing nut 20 2 greased 9 Damper 10 Damper upper fixing 4 5 0 4 11 Damper lower fixing 9 3 1 12 Suspension...

Page 377: ...b nut 24 5 0 5 8 Wheel bolt 9 1 9 Subframe to bodyshell fixing screw 10 1 10 Anti roll bar 11 Pivot lower ball joint fixing on lower arm 5 5 0 5 12 Pivot lower ball joint fixing 4 0 4 13 Lower arm fro...

Page 378: ...ont axle 1 Nut fixing suspension leg on body 6 5 0 6 2 Damper 16 Cup 17 Damper nut 6 5 0 6 18 Damper cup 19 Ball bearing 20 Spring thrust cup 21 Travel stop cup 22 Suspension spring 23 Damper rod rpot...

Page 379: ...on arm silentblock 30 Suspension arm fixing screw on yoke 7 6 0 5 31 Rear suspension arm 32 Stub axle bearing nut 20 2 greased 33 Damper 34 Damper upper fixing screw 4 5 0 4 35 Damper lower fixing scr...

Page 380: ...8HV 8HY Steering column Tightening torques m daN 1 Steering wheel fixing 2 0 3 2 Steering column fixing on support 2 2 0 5 3 Steering cardan fixing 2 2 0 2 Identification Identified by the colour of t...

Page 381: ...0 5 8 Threaded washer 9 Stud 0 8 0 1 10 Flat washers 11 Fixing of mechanism on subframe 8 0 8 Connectors 6 Supply of electric assistance motor 7 Torque sensor signals HFX KFV 8HX 8HW KFV BVA NFU 8HY...

Page 382: ...tor 12 depends on Speed of the vehicle Torque applied on the steering wheel Electric power assisted steering ECU Only one ECU version whatever the engine type The electric power steering ECU is linked...

Page 383: ...two column lift Remove on the RH side of the steering rack Clip 1 Clip 2 Release the steering rack rpotection gaiter Setting Move the steering to full left hand lock Measure the dimension X Move the s...

Page 384: ...pension arm mounting and the ground H2 Dimension between the contact face of the rear mounting and the ground R1 Front wheel radius under load R2 Rear wheel radius under load L1 Distance between the c...

Page 385: ...lculate the dim H1 R1 L1 Measure the dimension R2 Calculate the dim H2 R2 L2 Compress the suspension until the values H1 and H2 are obtained NOTE The difference in height between the two sides should...

Page 386: ...E GEOMETRY Values of the front and rear suspensions at reference height Tools Compress the suspension to obtain the values at reference height 1 Set of two suspension compressors 9511 T A 2 Set of fou...

Page 387: ...0 26 0 12 0 07 0 07 10 40 0 Saloon or entreprise KFW Saloon all engine typesexcept KFW Estate all engine types except CRD Rear axle NO YES Saloon CRD KFW 2 0i 16V RFS Saloon CRD all engine types excep...

Page 388: ...384 AXLES SUSPENSION STEERING XSARA AXLE GEOMETRY a Angle which defines the tracking between the front and rear axles Its value must not exceed 12 B3CP04UC...

Page 389: ...5 5 0 5 6 Anti roll bars 7 Anti roll bar link rod lower ball joint 3 7 0 3 8 Pivot lower ball joint 4 0 4 9 Driveshaft nut 32 5 2 5 10 Wheel bolt 9 1 11 Lower arm front mounting 7 6 0 7 12 Lower arm...

Page 390: ...Suspension arm ball joint Pivot Old fitting A 16 mm New fitting A 18 mm Repair requirements ESSENTIAL Swapping of old and new components is forbidden It is permitted to fit a new pivot ball joint asse...

Page 391: ...LES SUSPENSION STEERING FRONT AXLE Anti roll bar Diameter Engine versions 1 6i 1 6i 16V 1 9 D 2 0i 16V RFV 1 4 HDi 2 0 HDi 19 Blue 20 21 Yellow White 2 0i 16V RFS colour reference XSARA Saloon Estate...

Page 392: ...388 AXLES SUSPENSION STEERING FRONT AXLE XSARA Pivot ball joint Manual steering groove at b Power steering groove at b Tongue a towards the front B3CP049C B3CP043D...

Page 393: ...ar 3 Transversal torsion bars 4 Rear crossmember flanges 8 3 0 8 5 Front silentblocks 5 5 0 5 6 Rear silentblocks 4 5 0 4 7 Anti vibration clamp 8 Damper pin 9 6 0 9 9 Stub axle nuts lubricated 18 5 1...

Page 394: ...olet 19 Orange 3 and 5 door TT exc Entreprise Estates All types 18 7 20 Grey 20 Green 3 and 5 door TT 19 3 Violet 19 Orange Estates All types 20 Grey 20 Green 3 door VTS 3 and 5 door TT Estates All ty...

Page 395: ...re two suppliers for the silentblocks RBT identified by a Green or Yellow painted dot on the side of the mounting PAULSTRA identified by a Black painted dot on the side of the mounting It is FORBIDDEN...

Page 396: ...mmy damper Lengths of the rear dummy damper mm Grand export 346 339 346 342 Normal driving 339 318 336 XSARA REAR DAMPER E5AP14WC Engines 1 9 D 1 6i 16V 3 door 1 6i 16V 5 door 2 0i 16V RFN 1 4 HDi 2 0...

Page 397: ...ted with AIRBAG according to equipment 4 Steering column adjustment lever Tightening torques m daN 2 AIRBAG to steering wheel fixing 0 8 3 Steering wheel fixing 3 3 5 Steering column to support fixing...

Page 398: ...ERING XSARA MANUAL STEERING SPECIFICATIONS Manual steering Tightening torques m daN 7 Pivot ball joint nut 4 8 Link rod lock nut 4 5 9 Ball joint on steering rack 6 10 Fixing on cradle 5 11 Plunger fl...

Page 399: ...rack travel mm 73 5 6 teeth RH helix 29 13 Yellow thickness mm 4 3 Left hand drive Steering rack Steering stop colour code Number of steering wheel turns Length of the steering track rods Pre adjustm...

Page 400: ...g wheel fitted with AIRBAG according to equipment 4 Steering column adjustment lever Tightening torques m daN 2 AIRBAG to steering wheel fixing 0 8 3 Steering wheel fixing 3 3 5 Steering column to sup...

Page 401: ...ues m daN 7 Pivot ball joint nut 4 8 Link rod lock nut 4 5 9 Ball joint on steering rack 6 10 Fixing on subframe 5 11 Hydraulic pipe connection 2 5 12 Valve to housing fixing 1 2 13 Plunger flange scr...

Page 402: ...tor colour Vehicles BLACK All Types except 1 6i 16V 1 9 TD 7 Steering valve Number of teeth 3 3 LHD Steering rack Number of steering wheel turns Length of the steering link rods Pre adjustment 371 mm...

Page 403: ...e union 2 5 16 Upper front fixing E3 2 5 17 Upper rear fixing E3 2 2 18 Fixing E3 2 2 Tightening sequence Tighten screws 16 and 18 Lightly tighten screw 17 then fully tighten Pressure switch on the pr...

Page 404: ...2 Radius of the rear wheel when laden L2 From the centre of the wheel to the rear axle silentblock face AXLE GEOMETRY Checks at reference height NOTE To make the setting of reference height easier it...

Page 405: ...e the radius of the front wheel R1 Calculate dimension H1 or H1 Checks at reference height the reference height of the vehicle is set as per the table below B3CP05BC B3CP05AC XSARA PICASSO Front axles...

Page 406: ...ence height the reference height of the vehicle is set as per the table below NO CRD Vehicle CRD Difficult road conditions Front axle Rear axle Vehicle Tracking Castor Pivot angle Camber Tracking Camb...

Page 407: ...r wheel R2 Calculate dimension H2 Measure the radius of the front wheel R1 Calculate dimension H1 or H1 Checks at reference height the reference height of the vehicle is set as per the table below B3C...

Page 408: ...the reference height of the vehicle is set as per the table below CRD Vehicle CRD Difficult road conditions Front axle Rear axle Vehicle Tracking Castor Pivot angle Camber Tracking Camber Adjustable...

Page 409: ...eased 32 5 2 10 Wheel bolt face and threads not greased 9 1 11 Lower arm front pivot 7 6 0 7 12 Lower arm rear pivot and anti roll bar bearing 6 8 0 6 13 Screw under rear pivot 3 5 0 3 Lower arm in fo...

Page 410: ...r arm 21 Wheel bolt face and threads not lubricated 9 1 22 Damper 23 Rear silentblock on subframe 5 4 0 5 24 Damper pin nut 11 1 25 Stub axle nuts lubricated 25 2 26 Rear silentblock on bodyshell 6 5...

Page 411: ...rking Right hand drive White marking 1 Steering wheel 4 Steering column adjustment Tightening torques m daN 2 Airbag to steering wheel fixing 0 8 0 1 3 Steering wheel fixing 3 3 0 6 5 Steering column...

Page 412: ...9 Ball joint on steering rack 6 0 6 10 Fixing steering on subframe 8 0 8 11 Hydraulic pipe connection 2 4 0 2 12 Power steering valve 1 2 0 2 13 Plunger flange screws 1 2 0 2 14 Steering ram screw on...

Page 413: ...Left hand drive 71 7 x 2 LH helix 28 Teeth 3 22 12 m 11 48 m Right hand drive RH helix Engines Steering valve NFV 6FZ RFN RHY number of teeth 7 Length of the steering link rods pre adjustment Between...

Page 414: ...the threads with product E3 A pressure switch is implanted in the hydraulic piping between the high pressure pump and the power steering valve Opening pressure 30 35 Bars Closing pressure 25 Bars min...

Page 415: ...T ABS Master cylinder Master vac mm Caliper piston makes Disc Plain FT Disc thickness minimum thickness Maximum run out mm Difference in max thickness on same circumference mm Supplier Brake pad grade...

Page 416: ...n Disc thickness minimum thickness RR Supplier Brake pad grade mm Original drum maximum Width Supplier Lining grade With emergency braking assistance AFU 1 1i HFX KFV NFU 8HX 1 4i 1 6i 16V 1 4 HDi C2...

Page 417: ...fications Braking circuit at X Front brakes with ventilated discs Rear brakes with eitther drums or discs Handbrake lever controlling cables acting on the rear wheels The compensator and main brake li...

Page 418: ...414 BRAKES BRAKE SPECIFICATIONS Braking circuit with ABS REF drum brakes at the rear B3FP7BTD C2...

Page 419: ...415 BRAKES BRAKE SPECIFICATIONS Braking circuit with ABS REF disc brakes at the rear B3FP7BUD C2...

Page 420: ...er in tandem 2 Braking servo 3 Brake caliper or drum at the rear 4 Hub equipped with a bearing with an integral magnetic wheel 48 pairs of poles 5 Wheel sensor 6 Brake fluid level sensor 7 Hydraulic b...

Page 421: ...al to the hydraulic block 2 way blue connector The sensors are inductive type Front wheel sensor TEVES Mounted on the pivot Non adjustable airgap 0 16 to 1 6 mm 5 96 387 201 80 Tightening torque 0 8 0...

Page 422: ...r brakes 16 Servo fixing 2 2 0 3 17 Fixing on master cylinder 2 0 5 12 Yoke fixing on caliper 10 5 1 13 Yoke fixing on caliper 3 0 3 14 Rear caliper fixing on arm 5 3 0 5 15 Yoke fixing on caliper 3 8...

Page 423: ...3 The screws 1 Disconnect the connectors of the following components The cigar lighter 2 The electric window buttons 4 Remove the central console 7 WARNING Check that the brake cables are correctly r...

Page 424: ...er from its stop Adjust the nut 10 to obtain a travel of less than or equal to 1 mm at a Refit the brake drums without tightening them according to version Action the handbrake lever 8 times with an e...

Page 425: ...eservoir 1 Empty the brake fluid reservoir 1 Clean the brake fluid reservoir 1 Refit The brake fluid reservoir 1 The shaft 3 Couple the pipe 2 Reconnect the connector 4 Filling the braking system WARN...

Page 426: ...mary braking circuit WARNING The ABS should not be active during the bleeding operation Front brake caliper Bleed screw 5 A Rear brake caliper B Rear brake drum Bleed screw 6 Bleed each wheel cylinder...

Page 427: ...ld be between MINI level and MAXI level Fill if necessary with the approved and recommended synthetic brake fluid Without the bleeding apparatus NOTE Two operators are necessary For each circuit Apply...

Page 428: ...tilated 266 Disc thickness minimum thickness 22 20 Brake pad grade TEXTRR T 4144 Drum Max thickness mm Width 203 205 38 RR Make DON Brake lining grade 8259 Braking compensator Vehicle without ABS CICR...

Page 429: ...thickness minimum thickness 22 20 22 20 Brake pad grade TEXTRR T 4144 Cylinder or caliper LUCAS C38 HR 9 13 mm Disc Plain 247 247 RR Disc thickness minimum thickness 9 7 9 7 Drum Max thickness mm Wid...

Page 430: ...hickness 9 7 Drum Max thickness mm Width 203 205 38 203 205 38 Make DON GALFER DON Brake lining grade 8259 1 G 4554 8259 1 With emergency braking system CICR Compensator integral to the wheel cylinder...

Page 431: ...ons Braking circuit at X Front brakes with ventilated discs Rear brakes with eitther drums or discs Handbrake lever controlling cables acting on the rear wheels The compensator and main brake limiter...

Page 432: ...428 BRAKES BRAKE SPECIFICATIONS Braking circuit with ABS REF drum brakes at the rear B3FP162D C3 C3 PLURIEL...

Page 433: ...429 BRAKES BRAKE SPECIFICATIONS Braking circuit with ABS REF disc brakes at the rear B3FP163D C3 C3 PLURIEL...

Page 434: ...tandem 2 Braking servo 3 Brake caliper or drum at the rear 4 Hub equipped with a bearing with an integral magnetic wheel 48 pairs of poles 5 Wheel sensor 6 Brake fluid level sensor 7 Hydraulic block p...

Page 435: ...2 80 Installed on the front LH chassis member 4 adjustment channels ABS hydraulic block TEVES Installed on the front LH chassis member 4 adjustment channels Components Supplier Part no Observations Co...

Page 436: ...rakes 16 Servo fixing 2 2 0 3 17 Fixing on master cylinder 2 0 5 12 Yoke fixing on caliper 10 5 1 13 Yoke fixing on caliper 3 0 3 14 Rear caliper fixing on arm 5 3 0 5 15 Yoke fixing on caliper 2 7 0...

Page 437: ...d of 35 bars Assembly 1 Rear wheel cylinder Repair IMPERATIVE The mixing of the old and new components is STRICTLY FORBIDDEN WARNING Identify the type of assembly prior to starting a repair ESSENTIAL...

Page 438: ...e screws 1 Disconnect the connectors of the following components The cigar lighter 2 The electric window buttons 4 Remove the central console 7 WARNING Check that the brake cables are correctly routed...

Page 439: ...ust the nut 10 to obtain a travel of less than or equal to 1 mm at a Refit the brake drums without tightening them accor ding to version Action the handbrake lever 8 times with an effort of 40 m daN W...

Page 440: ...ir 1 Empty the brake fluid reservoir 1 Clean the brake fluid reservoir 1 Refit The brake fluid reservoir 1 The shaft 3 Couple the pipe 2 Reconnect the connector 4 Filling the braking system WARNING Us...

Page 441: ...raking circuit WARNING The ABS should not be active during the bleeding operation Front brake caliper Bleed screw 5 A Rear brake caliper B Rear brake drum Bleed screw 6 Bleed each wheel cylinder proce...

Page 442: ...between MINI level and MAXI level Fill if necessary with the approved and recommended synthetic brake fluid Without the bleeding apparatus NOTE Two operators are necessary For each circuit Apply the...

Page 443: ...Load sensitive compensator 32 0 3 White BRAKE SPECIFICATIONS Saloons XSARA 1 4i 1 6i 16V 2 0i 16V KFW NFU RFN RFS WJY 8HZ RHY RHZ 1 9 D 1 4 HDi 2 0 HDi FT mm Master cylinder Master vac Caliper piston...

Page 444: ...pensator 32 0 3 White BRAKE SPECIFICATIONS Estates 1 4i 1 6i 16V 2 0i 16V 1 9 D 1 4 HDi 2 0 HDi Engine type KFW NFU RFN WJY 8HZ RHY RHZ FT mm Master cylinder Master vac Caliper piston makes Disc Disc...

Page 445: ...441 BRAKES BRAKE SPECIFICATIONS XSARA Tighten the nuts 1 to 2 3 m daN The clevis pin 2 is held in place by a plastic clip B3FP10YD...

Page 446: ...rding to model Rear drum brakes with automatic adjustment Cable operated handbrake acting on the rear wheels 1 Hydraulic valve block ABS Bosch 5 3 or 1 Hydraulic valve block ABS Bosch 5 3 REF or 1 Hyd...

Page 447: ...443 BRAKES Braking system without ABS rear drum brakes Up to OPR 8687 Braking system without ABS rear disc brakes BRAKE SPECIFICATIONS XSARA B3FP14GD B3FP14FD...

Page 448: ...444 BRAKES Braking system with ABS rear drum brakes BRAKE SPECIFICATIONS B3FP14HD XSARA...

Page 449: ...445 BRAKES Braking system with ABS REF rear disc brakes Braking system with ABS REF rear drum brakes BRAKE SPECIFICATIONS B3FP14JD B3FP14KD XSARA...

Page 450: ...446 BRAKES Braking system with ABS REF rear drum brakes BRAKE SPECIFICATIONS B3FP14LD XSARA...

Page 451: ...r in tandem 2 Braking servo 3 Brake caliper or drum at the rear 4 Toothed wheel 5 Wheel sensor 6 Brake fluid level sensor 7 Hydraulic block plus ECU 8 Stoplamp switch 9 Instrument panel 10 Diagnostic...

Page 452: ...are inductive type Mounted on the suspension arm Non adjustable airgap 0 3 to 1 2 mm Tightening torque 0 8 0 2 m daN Incorporated in the COM 2000 6 way blue connector Located on the central console 6...

Page 453: ...ed on the front LH wheelarch 4 adjustment channels IMPERATIVE Respect the direction of fitting of the gyrometer accelero meter sensor connector towards the rear of the vehicle WARNING The gyrometer ac...

Page 454: ...under the vehicle Apply and release the handbrake ten times Set the handbrake to the 3rd notch Tighten the nut 1 until the rear brakes are applied Pull the handbrake lever vigorously 4 to 5 times Set...

Page 455: ...her using brake bleeding equipment in which case the pressure of the equipment should be set to 2 Bars or in the conventional way IMPERATIVE order of bleeding Wheels Rear Right Front Left Rear Left Fr...

Page 456: ...nder travel 254 34 FT mm Caliper LUCAS BOSCH piston makes C54 54 ZOH54 54 Disc Ventilated 266 Disc thickness min thickness 20 4 18 4 22 20 Makes Brake pad grade JURID 3724 FERODO 769 37 Rear brake pla...

Page 457: ...ss minimum thickness 26 24 Makes Brake pad grade FERODO 769 37 Rear brake caliper Supplier Type TRW C38 mm Disc plain 247 RR Disc thickness minimum thickness 9 7 Make GALFER Brake lining grade G 4554...

Page 458: ...454 BRAKES B3FP7B9D BRAKING SYSTEM SPECIFICATIONS Without ABS XSARA PICASSO...

Page 459: ...455 BRAKES B3FP7B9D B3FP7BRD BRAKING SYSTEM SPECIFICATIONS With EPS Electronic Stability Program With ABS XSARA PICASSO...

Page 460: ...es ventilated Rear drum brakes with automatic adjustment Cable operated handbrake acting on the rear wheels Load sensitive braking compensator non ABS versions 1 Hydraulic valve block ABS Bosch 5 3 or...

Page 461: ...cables under the vehicle Apply and release the handbrake 4 times Set the handbrake to the 5th notch Tighten the nut 3 until the rear brakes are applied Pull the handbrake lever vigorously 4 to 5 time...

Page 462: ...Finish emptying the reservoir of brake fluid Clean the brake fluid reservoir Refit the brake fluid reservoir Reconnect the brake fluid warning lamp connector Filling Refill the reservoir with brake fl...

Page 463: ...C Hot Starting possible as low as 18 C T Temperate Starting possible as low as 18 C F Cold Starting possible as low as 25 C GF Very cold Starting possible as low as 30 C Meaning of abbreviations BV Ge...

Page 464: ...RS CLASS CLASS 2 CLASS 3 CLASS 4 CLASS 5 CLASS 6 Torque C 5 5 Nm 6 Nm 10 Nm 11 5 Nm 11 5 Nm Maximum power for a speed of 1200 rpm I 275 A I 300 A I 430 A I 470 A I 500 A ALL TYPES 460 ELECTRICAL SYSTE...

Page 465: ...461 ELECTRICAL SYSTEM Vehicles models Gearboxes Class Climate C 1 1i 1 T F M 3 GF 1 C T 1 1i R fri 3 F C2 GF 1 C T 1 4i 2 F 3 GF M MAP 1 C T 1 4i R fri 3 F GF STARTER MOTORS C2...

Page 466: ...462 ELECTRICAL SYSTEM Vehicles models Gearboxes Class Climate C 1 6i 16V M MAP A 3 T F C2 GF 4 C T 1 4 HDi M MAP 5 F GF STARTER MOTORS C2...

Page 467: ...463 ELECTRICAL SYSTEM Vehicles models Gearboxes Class Climate C 1 1i 1 T F 3 GF M 1 C 1 1i R fri T 3 F GF C3 1 C M MP T 2 F 1 4i 3 GF C A 3 T F GF 1 C T 1 4i R fri M MP 3 F GF STARTER MOTORS C3...

Page 468: ...ELECTRICAL SYSTEM 464 Vehicles models Gearboxes Class Climate 1 C 1 4i 16V T 3 F GF C 1 6i 16V M MAP 3 T F GF C3 4 C 1 4 HDi T 5 F GF 4 C 1 4 HDi 16V M T 5 F GF STARTER MOTORS C3...

Page 469: ...465 ELECTRICAL SYSTEM Vehicles models Gearboxes Class Climate 1 C 1 4i T 2 F M MAP 3 GF 1 C 1 4i R fri T 3 F C3 Pluriel GF C 1 6i 16V M MAP A 3 T F GF 4 C 1 4 HDi M T 5 F GF STARTER MOTORS C3 PLURIEL...

Page 470: ...466 ELECTRICAL SYSTEM Vehicles models Gearboxes Class Climate 1 C 1 4i T 2 F 3 GF 1 C XSARA 1 4i R fri M T 3 F GF 2 C 1 4i R fri DA T 3 F GF STARTER MOTORS XSARA...

Page 471: ...467 ELECTRICAL SYSTEM Vehicles models Gearboxes Class Climate C M T F 1 6i 16V 3 GF C A T F XSARA GF 3 C M T 4 F 2 0i 16V GF 3 C A T 4 F GF STARTER MOTORS XSARA...

Page 472: ...468 ELECTRICAL SYSTEM Vehicles models Gearboxes Class Climate 3 C 2 0i 16V T 4 F GF 4 C XSARA 1 9 D M T 5 F 6 GF 4 C 2 0 HDi T 6 F GF STARTER MOTORS XSARA...

Page 473: ...469 ELECTRICAL SYSTEM Vehicles models Gearboxes Class Climate 5 C 2 0 HDi M T 6 F GF 6 C XSARA A T 6 F GF 4 C 1 4 HDi M T 5 F GF STARTER MOTORS XSARA...

Page 474: ...470 ELECTRICAL SYSTEM Vehicles models Gearboxes Class Climate 1 C T 2 F 3 GF 1 C 1 6i T 3 F XSARA PICASSO M GF 2 C T 3 F GF C 1 8i 16V 3 T F 4 GF STARTER MOTORS XSARA PICASSO...

Page 475: ...471 ELECTRICAL SYSTEM Vehicles models Gearboxes Class Climate 3 C 2 0i 16V M A T 4 F GF 5 C XSARA PICASSO 1 6 HDi 16V T 6 F M GF 4 C 2 0 HDi T 6 F GF STARTER MOTORS XSARA PICASSO...

Page 476: ...ations BV Gearbox BVM Manual gearbox BVA Automatic gearbox BVMP Piloted manual gearbox NON REFRI Without air conditioning REFRI With air conditioning DA Power assisted steering GEP Electro pump motor...

Page 477: ...Without cold pack With cold pack Without cold pack With cold pack RT3 RT3 RT3 RT3 RT3 RT3 RT3 RT3 Engine Gearbox Climate Base N1 or N3 Base N1 or N3 Base N1 or N3 Base N1 or N3 N2 N2 N2 N2 C 8 8 8 8...

Page 478: ...ircon Without cold pack With cold pack Without cold pack With cold pack RT3 RT3 RT3 RT3 RT3 RT3 RT3 RT3 Engine Gearbox Climate Base N1 or N3 Base N1 or N3 Base N1 or N3 Base N1 or N3 N2 N2 N2 N2 C 8 1...

Page 479: ...ithout aircon With aircon Without cold pack With cold pack Without cold pack With cold pack RT3 RT3 RT3 RT3 RT3 RT3 RT3 RT3 Engine Gearbox Climate Base N1 or N3 Base N1 or N3 Base N1 or N3 Base N1 or...

Page 480: ...bbreviations see page 472 Without aircon With aircon Without cold pack With cold pack Without cold pack With cold pack Engine Gearbox Climate Base RT2 Base RT2 Base RT2 Base RT2 1 4i C 9 1 6i 16V T 8...

Page 481: ...ning of abbreviations see page 472 Without aircon With aircon Without cold pack With cold pack Without cold pack With cold pack Engine Gearbox Climate Base RT2 Base RT2 Base RT2 Base RT2 C 12 2 0i 16V...

Page 482: ...es XSARA Meaning of abbreviations see page 472 Without aircon With aircon Without cold pack With cold pack Without cold pack With cold pack Engine Gearbox Climate Base RT2 Base RT2 Base RT2 Base RT2 C...

Page 483: ...O Meaning of abbreviations see page 472 Without aircon With aircon Heated Nav Heated Nav Engine Gearbox Climate Base seat Nav Heated seat Base seat Nav Heated seat C 1 6i T 7 8 BVM F 8 GF C 12 1 8i 16...

Page 484: ...ed on It should go out when the engine has started accelerate slightly Checking the voltage regulator Set the rheostat to zero and disconnect all the electrical consumers Display 3000 alternator rpm I...

Page 485: ...5 65 75 92 110 145 176 6000 rpm 15 61 69 78 5 96 120 151 183 8000 rpm 16 63 70 80 97 123 157 188 15000 rpm 17 64 73 82 97 124 157 188 Min output Class 6 7 8 9 12 15 18 Alternator speed 1800 rpm 49 50...

Page 486: ...NGK YE04 NGK YE04 NGK YE04 BERU 0 100 226 371 CHAMPION CH 185 NGK YE04 CHAMPION CH170 CHAMPION CH 170 CHAMPION CH 170 PRE HEATING AND STARTING SYSTEMS TOUS TYPES Vehicles models Pre heater plugs Pre...

Page 487: ...IR CONDITIONING R 134 a HFC Vehicle Engines Date Refrigerant refill Compressor Variable Capacity Oil quantity cc Oil reference AIRCON C2 SD 6 V 12 SD 7 V 16 SD 6 V 12 SD 7 V 16 135 SP 10 12 1999 03 20...

Page 488: ...uminium Steel Pipes 1 7 0 3 1 3 0 3 M 06 3 8 0 3 2 0 2 M 08 4 0 3 2 5 0 3 M 10 NOTE Tighten the union to the recommended torque using a retaining spanner whenever possible NOTE For operations concerni...

Page 489: ...s XSARA Compressor and condenser end 08 2000 XSARA PICASSO Compressor end 11 2002 Engine versions NFV 10 12 2001 6FZ 01 04 2002 RHY 04 11 2002 Aircon compressor XSARA PICASSO engine versions 6FZ and R...

Page 490: ...mpressor oil SP10 The condenser 5 has a cylinder 6 incorporating the function of aircon fluid reservoir and with integral filtering cartridge The inlet 7 and the outlet 8 of the condenser 5 are equipp...

Page 491: ...filter Vehicle Equipment RPO No Presence of filter Observations SAXO C2 C3 ALL TYPES NO YES YES Behr YES Larger YES Val o NO Val o YES Val o Without aircon Base aircon Regulated aircon Without aircon...

Page 492: ...134 a Pollen filter Note The pollen filter is located in the engine compartment on the RH side Removing To remove Pull on the tab of the plastic cover 1 at a Tilt the flap 2 Remove the pollen filter 3...

Page 493: ...4 a Pollen filter Note The pollen filter is located in the engine compartment on the RH side Removing Remove The three screws 1 The plastic cover 2 Tilt the flap 3 Remove the pollen filter 4 Refitting...

Page 494: ...aircon circuit using tool 1 Remove the grille At a remove the pin and the plastic cover Unclip the condenser at b and c using a screwdriver Tilt the condenser towards the front Lift and release the co...

Page 495: ...p 4 using tool 6 Make sure that the circlip 4 is correctly positioned in its location WARNING Not more than 5 minutes should elapse between the removal of the cartridge 6 from its packaging and its be...

Page 496: ...lter 3 Concerns vehicles equipped with aircon without temperature regulation Fitting of a new pollen filter necessitates the following operations Engage the pollen filter upwards following arrow c Sli...

Page 497: ...493 AIRCON SPECIAL FEATURES AIR CONDITIONING SYSTEM R 134 a Pollen filter Remove The three screws 1 The cover 2 Remove the pollen filter XSARA PICASSO B1BP23ED...

Page 498: ...kshop equipment 2 TORX adaptor TORX 70 FACOM Removing Depressurise the aircon circuit using tool 1 Uncouple the hose 2 Remove The air filter assembly 3 The nuts 1 Protect the radiator harness with str...

Page 499: ...filtering drying cartridge 7 Clean the threads of the plug 6 It is essntial to change the O ring seals 8 Lubricate the O ring seals 8 with aircon compressor oil Refit The plug 6 using tool 2 tighten...

Page 500: ...lose any oil No more oil should be added when filling the system with R 134 a fluid b Using draining filling equipment fitted with an oil decanter Drain the R 134 a fluid from the system in accordance...

Page 501: ...dure should be followed as if there was no leak at all 3 Fast leak This type of leak causes both oil loss as well as allowing air to enter the system It is therefore necessary to Replace the dehydrato...

Page 502: ...m Once it is sufficiently hot in the engine compartment return the engine to idle and commence the test Switch on the air conditioning and adjust the engine speed to 2500 rpm In an ambient temperature...

Page 503: ...perature in C Temperature at the central air vents in C Engines Vehicle C3 C3 Pluriel KFV 22 2 17 6 2 14 4 2 11 5 2 7 6 2 7 2 2 NFU 18 5 2 15 2 12 5 2 10 2 8 5 2 6 5 2 8HX 8HW 22 2 17 6 2 14 4 2 11 5...

Page 504: ...filled see table After the air conditioning has been on for three minutes record the following parameters The temperature of the air coming from the central vents see table The High Pressure The Low P...

Page 505: ...ions vehicle equipment and checks have been fulfilled see table After the air conditioning has been on for three minutes record the following parameters The temperature of the air coming from the cent...

Page 506: ...502 AIRCON AIRCON 1 High pressure valve 2 Low pressure valve 3 Pressostat 4 Filter Tightening torques m daN a 0 6 b 0 6 c 0 6 d 0 6 e 0 6 f 0 7 C5HP19UP C2 AIR CONDITIONING SYSTEM R 134 a...

Page 507: ...503 AIRCON AIR CONDITIONING SYSTEM R 134 a 1 High pressure valve 2 Low pressure valve 3 Filter 4 Pressostat Tightening torques m daN a 0 6 b 0 6 c 0 6 d 0 6 e 0 6 f 0 6 C5HP17SP C3 C3 PLURIEL...

Page 508: ...cuit C5HP1A5D Key T P Average temperature C at the air vents high pressure Bars P Low pressure Bars Te Exterior temperature C HP Pressure at compressor outlet Bars BP Pressure at compressor inlet Bars...

Page 509: ...uit C5HP18GD Key T P Average temperature C at the air vents high pressure Bars P Low pressure Bars TE Exterior temperature C HP Pressure at compressor outlet Bars BP Pressure at compressor inlet Bars...

Page 510: ...C5HP1A8D Key T P Average temperature C at the air vents high pressure Bars P Low pressure Bars TE Exterior temperature C HP Pressure at compressor outlet Bars BP Pressure at compressor inlet Bars TA...

Page 511: ...ith NON EUROCLIM compressor O ring seals 2 EATON with EUROCLIM compressor quadrilobe seals 1 High pressure valve 2 Low pressure valve 3 Pressostat 4 Dryer Tightening torques m daN a 0 8 b 4 0 4 c 0 8...

Page 512: ...with EUROCLIM compressor and buffer capacity quadrilobe seals 1 High pressure valve 2 Low pressure valve 3 Buffer capacity Tightening torques m daN a 0 8 b 4 0 4 c 0 8 A Right hand drive XSARA RFN AI...

Page 513: ...th NON EUROCLIM compressor O ring seals 2 EATON with EUROCLIM compressor quadrilobe seals 1 High pressure valve 2 Low pressure valve 3 Pressostat 4 Dryer Tightening torques m daN a 0 8 b 4 0 4 c 0 8 A...

Page 514: ...OCLIM compressor O ring seals 2 EATON with EUROCLIM compressor quadrilobe seals 1 High pressure valve 2 Low pressure valve 3 Pressostat 4 Dryer Tightening torques m daN a 0 8 b 4 0 4 c 0 8 A Right han...

Page 515: ...TON with EUROCLIM compressor and buffer capacity quadrilobe seals 3 EATON with NON EUROCLIM compressor and buffer capacity O ring seals 1 High pressure valve 2 Low pressure valve 3 Buffer capacity Tig...

Page 516: ...LIM compressor O ring seals 2 EATON with EUROCLIM compressor quadrilobe seals 1 High pressure valve 2 Low pressure valve 3 Pressostat 4 Dryer Tightening torques m daN a 0 8 b 4 0 4 c 0 8 A Right hand...

Page 517: ...EATON with EUROCLIM compressor and buffer capacity quadrilobe seals 3 EATON with NON EUROCLIM compressor and buffer capacity O ring seals 1 High pressure valve 2 Low pressure valve 3 Buffer capacity T...

Page 518: ...I with NON EUROCLIM compressor O ring seals 2 EATON with EUROCLIM compressor quadrilobe seals 1 High pressure valve 2 Low pressure valve 3 Pressostat 4 Dryer Tightening torques m daN a 0 8 b 4 0 4 c 0...

Page 519: ...ssure clickfit union tool 8005 T C 4 Low pressure clickfit union tool 8005 T A 5 Pressostat 1 8 0 6 m daN 6 Filtering drying cartridge plug Tightening torques m daN a 0 8 0 1 b 0 5 0 1 c 1 4 0 2 d 2 5...

Page 520: ...fit union tool 8005 T C 4 Low pressure clickfit union tool 8005 T A 5 Pressostat 1 8 0 6 m daN 6 Filtering drying cartridge plug Tightening torques m daN a 0 8 0 1 b 0 5 0 1 c 1 4 0 2 HP LP compressor...

Page 521: ...conditioning circuit C5HP150D Key T P Scale of Temperature C average of air from the central vents Pressure High Bars Pressure Low Bars Te Exterior temperature C HP Pressure at compressor outlet Bars...

Page 522: ...t union tool 8005 T C 4 Low pressure clickfit union tool 8005 T A 5 Pressostat 1 8 0 6 m daN 6 Filtering drying cartridge plug Tightening torques m daN a 0 8 0 1 b 0 5 0 1 c 1 4 0 2 HP LP compressor f...

Page 523: ...conditioning circuit Key T P Scale of Temperature C average of air from the central vents Pressure High Bars Pressure Low Bars Te Exterior temperature C HP Pressure at compressor outlet Bars Ta Tempe...

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