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FR-C1-Index-2005 9/01/06 8:43 Page II

Summary of Contents for 2005 C1

Page 1: ... As the booklet is constantly re edited this one only covers vehicles for this particular model year It is therefore necessary to order a new booklet each year and RETAIN THE OLD ONES COUV C1 2005 9 01 06 8 41 Page 1 ...

Page 2: ...sive 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 sub...

Page 3: ...ts checks and special features concerning CITROËN C1 The handbook is divided into groups representing the main functions GENERAL ENGINE INJECTION IGNITION CLUTCH GEARBOX DRIVESHAFTS AXLES SUSPENSION STEERING BRAKES AIR CONDITIONING FR C1 Index 2005 9 01 06 8 43 Page I ...

Page 4: ... 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 your comments and suggestions to CITROEN U K Ltd 221 Bath Road SLOUGH SL1 4BA U K FR C1 Index 2005 9 01 06 8 43 Page II ...

Page 5: ...9 130 Specifications MT TOYOTA manual gearbox 131 132 Tightening torques MT TOYOTA manual gearbox 133 136 Recommendations precautions MMT piloted manual gearbox 137 140 Specifications MMT piloted manual gearbox 141 144 Tightening torques MMT piloted manual gearbox 145 147 Driveshafts 148 CONTENTS Exhaust specifications 78 82 Cooling system specifications 83 86 Checking the oil pressure 87 Valve cl...

Page 6: ...ack mid point 165 BRAKES Brake specifications 166 168 Tightening torques brakes 169 171 Checking the brake pedal 172 174 Checking the braking amplifier 175 176 CONTENTS Checking the vacuum pump 177 178 Adjusting the handbrake 179 Draining filling bleeding the braking 180 183 AIR CONDITIONING R134 a capacity 184 Air conditioning circuit 185 186 Pollen filter 187 Filtering cartridge 188 189 Aircon c...

Page 7: ...r 3 door version On the rear door aperture 5 door version A AS RP No and RP paint code B Chassis stamp Cold stamp on the crossmember under the front RH seat C Tyre pressures and tyre type Label on the front pillar on driver s side GENERAL FR C1 page001 21 2005 9 01 06 8 46 Page 1 ...

Page 8: ... Engine 3 C E4 C Version 4 Variants 5 T Variant 5 IF Fiscal incentives Family 1 T Entreprise van convertible P C1 P Piloted manual gearbox Body shape 2 M 3 door saloon 4 seats N 5 door saloon 4 seats Engine 3 CFA 1 0i 384F E4 8HT 1 4 HDi DV4TD E4 IDENTIFICATION OF VEHICLES Type approval FR C1 page001 21 2005 9 01 06 8 46 Page 2 ...

Page 9: ...de PN CFAC PN 8HTC Engine type CFA 8HT Cubic capacity cc 1 0i 1 4 HDi Fiscal rating hp 4 3 Gearbox type MT MMT MMT Gearbox ident plate C 551 m C 551A mp C 552 m Manual gearbox Piloted manual gearbox IDENTIFICATION OF VEHICLES FR C1 page001 21 2005 9 01 06 8 46 Page 3 ...

Page 10: ...g information a Type approval number b Type serial number VIN c Gross vehicle weight d Gross vehicle weight e Maximum weight on front axle f Maximum weight on rear axle g Manufacturer identification according to marketing country Manufacturer s plate FR C1 page001 21 2005 9 01 06 8 46 Page 4 ...

Page 11: ...5 GENERAL GENERAL SPECIFICATION DIMENSIONS E1A2001D Exterior dimensions mm FR C1 page001 21 2005 9 01 06 8 46 Page 5 ...

Page 12: ... at ground level E 1410 Front track at ground level F 1420 Width overall G 1630 Height overall H 1460 Height with longitudinal roof bars Interior dimensions and volumes mm 3 door version 5 door version Elbow width front 1379 1377 Elbow width rear 1336 1358 Boot Height of boot below shelf between boot carpet and parcel shelf 436 Minimum floor width 510 Volume of boot below parcel shelf dm3 199 FR C...

Page 13: ...370 355 355 Weight empty in running order 790 825 880 800 835 890 Gross Vehicle weight 1160 1180 1235 1170 1190 1245 Gross Train weight 1160 1180 1235 1170 1190 1245 Max trailer weight with brakes 8 incline Max trailer weight with brakes 10 incline Max trailer weight with brakes 12 incline Max trailer weight without brakes Maximum nose weight Maximum weight on roof bars kg 50 FR C1 page001 21 2005...

Page 14: ...ED OUT FOLLOWING A RECONNECTION OF THE BATTERY Radio Before disconnecting the battery make a note of the customer s rado stations After reconnecting the battery reprogramme the radio stations FR C1 page001 21 2005 9 01 06 8 46 Page 8 ...

Page 15: ... the engine is not running steering and braking are no longer power assisted The towing eye 1 is to be found in the vehicle toolkit NOTE The vehicle toolkit is stowed in the boot E2A200DD E2A200CD Vehicle towing Towing eye FR C1 page001 21 2005 9 01 06 8 46 Page 9 ...

Page 16: ...malfunction or fault the vehicle may remain immobilised depending on the seriousness of the fault If a gear is engaged the conditions for immobilisation of the vehicle may be engine stopped no starting clutch open clutched IMPERATIVE If a gear is engaged and it is impossible to disengage it it is compulsory to tow the vehicle with the front wheels lifted If it not possible to lift the front of the...

Page 17: ...tuator tests Gearbox actuator test Engaging Neutral NOTE The letter N should appear in the instrument panel If not see the following solution engage N without the help of a diagnostic tool Engaging N without the aid of a diagnostic tool In this configuration the gearbox actuator is jammed gear engaged IMPERATIVE This emergency solution is to be used only where the above solutions for setting the g...

Page 18: ...verse gear Using a large screwdriver move the screw 3 to bring the gearbox actuator to the neutral position When this position is reached N is engaged Driving IMPERATIVE Never drive with the ignition switched off Never push the vehicle to attempt to start it impossible with a piloted manual gearbox B2C201TD FR C1 page001 21 2005 9 01 06 8 46 Page 12 ...

Page 19: ...lifting points on the vehicle Do not use the jack without axle stands To raise the front wheels release the parking brake and place blocks at the rear of the rear wheels only To raise the rear wheels place blocks at the front of the front wheels only To raise the front wheels only or the rear wheels only place blocks on either side of the wheels that are in contact with the ground To relower a veh...

Page 20: ...e of it as far as possible with the centre of gravity of vehicle Present the vehicle as far as possible in the axis of the moving arms Adjust the moving arms to the vehicle s jacking points WARNING Do not raise the vehicle too high to avoid all risk of instability Lock the moving arms while the repairs are being carried out Raise the vehicle just off the ground and check that it is stable Example ...

Page 21: ...g 200 mm h 100 mm Use the following table in order to position the vehicle correctly Right left adjustment Place the vehicle in the middle of the lift Align the bottom of the blocks on the extreme edges of the platform rubber Front rear adjustment i and j Align the top of the blocks on one of the blocks k on the front jacking point lug Raise the vehicle just off the ground and check that it is sta...

Page 22: ... filter cartridge Stop the engine allow to stabilise for 5 minutes Draining of the engine lubrication system by SUCTION Place the vehicle on horizontal ground in the high position if hydro pneumatic suspension The engine should be hot oil temperature 80 C Remove the oil by suction through the dipstick tube Remove the oil filter cartridge Maintain the suction of oil in the sump 15 minutes approx Re...

Page 23: ...4 35 ESSENTIAL Systematically check the oil level using the oil dipstick Engine plate Draining by gravity engine with filter change Between min and max MT 5 speed gearbox MMT piloted 5 speed gearbox Braking circuit Cooling system Fuel tank capacity FR C1 page001 21 2005 9 01 06 8 46 Page 17 ...

Page 24: ...em The lubrication circuit is fully pressurised and all of the oil passes through the oil filter The rotary oil pump 30 is driven directly by the crankshaft Oil capacity in litres With oil filter 3 1 Without oil filter 2 9 B1B202CD FR C1 page001 21 2005 9 01 06 8 46 Page 18 ...

Page 25: ...il this to enhance starting from cold Oil filter specific to C1 petrol with a U S fixing step For more information refer to the lubricants bulletin for the model year in Laser under PDI MAINTENANCE NOTE For C1 petrol use of TOTAL 15 W 40 ACTIVA 5000 norm API SL CF or ACEA A2 B2 is recommended WARNING For vehicles with a maintenance interval of 30 000 km 20 000 miles use exclusively TOTAL ACTIVA QU...

Page 26: ...979 71 9979 76 9979 77 9979 72 9979 73 9979 74 9979 75 Packs CITROËN Part No REVKOGEL 2000 GLYSANTIN G33 All countries All Types of gearbox ExxonMobil LV 75 W GL 4 ENGINE COOLANT PETROL ENGINE All countries S LLC pink fluid 1 Litre 5 Litres 9735 Y5 9735 Y6 Packs Part No WARNING Never use PSA coolant G33 on C1 petrol engines FR C1 page001 21 2005 9 01 06 8 46 Page 20 ...

Page 27: ...s CITROËN Part No LIQUIDE LAVE VITRES GRAISSAGE Utilisation générale All countries Concentrate 250 ml Fluid ready to use 9980 33 9980 06 9980 05 ZC 9875 953U ZC 9875 784U ZC 9885 077U 9980 56 ZC 9875 279U Packs CITROËN Part No 1 Litre 5 Litres Norms NLGI 2 TOTAL MULTIS 2 TOTAL PETITES MECANISMES All countries FR C1 page001 21 2005 9 01 06 8 46 Page 21 ...

Page 28: ...Compression ratio Power ISO or EEC KW rpm Maximum power DIN hp rpm Torque ISO or EEC m daN rpm Petrol Diesel 1 0i 1 4 HDi CFA 8HT 998 1398 71 84 73 7 85 10 5 1 18 1 50 6000 40 3000 68 6000 54 3000 9 3 3600 13 3000 22 ENGINE FR C1 page022 92 2005 9 01 06 8 48 Page 22 ...

Page 29: ... engine with 3 cylinders in line with 12 overhead valves This engine is light and compact giving good fuel economy It uses DIS Direct Ignition System and VVT i Variable Valve Timing intelligent The search for high performance silence in operation reduced fuel consumption and low emissions were all decisive in its design FR C1 page022 92 2005 9 01 06 8 48 Page 23 ...

Page 30: ...mshaft driven by chain with VVT i Combustion chamber Wedge shaped Manifolds Cross flow Fuel delivery system Electronic injection Ignition system DIS Cylindrical capacity cc 998 Bore Travel mm 71 x 84 Compression ratio 10 5 1 Maximum power SAE NET 50 kW at 6000 rpm Maximum torque SAE NET 93 Nm at 3600 rpm FR C1 page022 92 2005 9 01 06 8 48 Page 24 ...

Page 31: ...fter BDC 55 after BDC Adjustment of exhaust valves opening 40 before BDC Adjustment of exhaust valves closing 2 after TDC Ignition sequence 1 2 3 Fuel Unleaded petrol Octane 95 or above Oil quality API SJ SL EC or ILSAC Emission standard EURO 4 Weight empty in running order kg 75 kg approx weight full of oil and coolant FR C1 page022 92 2005 9 01 06 8 48 Page 25 ...

Page 32: ...DC D BDC a operating range of VVT i b 0 c 2 d 5 e 40 f 10 Engine block Valve cover The valve cover 1 is made of plastic and incorporates the air filter housing so reducing weight The valve cover gasket 2 is made of acrylic rubber This material is known for its resistance to heat as well as for long life B1B201YD FR C1 page022 92 2005 9 01 06 8 48 Page 26 ...

Page 33: ...placed at the centre of the combustion chambers so as to make the engine less subject to knock The angle formed between the inlet valves and the exhaust valves is more closed It has been fixed at 33 5 h to permit a cylinder head of a more compact construction The combustion chambers are double wedge shaped k The shape of the inlet ducts has been optimised for improved combustion The cylinder head ...

Page 34: ...bore the engine block given the type of channels 7 The channels 7 present an exterior fin like structure which allows a larger surface of contact with the aluminium block by dint of the numerous irregularities l This solution enhances heat dissipation thus reducing overall temperature and deformation of the bores Pistons m resin coating 8 compression ring N 1 9 compression ring N 2 10 scraper ring...

Page 35: ...ducing vibrations Crankshaft and crankshaft bearings r hole for the oil 13 upper bearing shells 14 lower bearing shells The crankshaft possesses 4 journals and 6 counterweights All the journal contact surfaces are roll finished s in order to maintain the appropriate rigidity The crankshaft bearing shells are in aluminium alloy The surfaces of the crankshaft bearing shells have micro grooves q for ...

Page 36: ...he performance of the inlet and exhaust circuits is increased by the greater width of the ports Opening and closing of the valves is controlled directly by 2 camshafts The engine has 12 valves and 2 overhead camshafts driven by chain one for inlet and the other for exhaust The VVT i system 21 serves to reduce fuel consumption increase performance and also to reduce pollutant emissions Fuller infor...

Page 37: ...amshaft The valve stems are of reduced diameter to reduce resistance to the inlet mixture and to the exhaust gases The inlet valves 26 and the exhaust valves 26 use identical springs These are variable rate springs to make the valves operate correctly The cam followers 25 are not adjusted using shims this to reduce weight NOTE Adjustment of valve clearances is done by replacing the existing cam fo...

Page 38: ...ompact The chain tensioner 20 uses a spring and hydraulic pressure system to retain the correct tension at all times The chain tensioner 20 suppresses the noise generated by the chain An oil jet x lubricates the chain as well as the timing pinion on the crankshaft Timing cover The cover 29 of the oil pump 30 is incorporated in the timing cover made of aluminium on which the water pump 31 is mounte...

Page 39: ...UES ENGINE SUSPENSION 1 5 2 0 5 2 2 4 0 2 4 5 2 0 5 5 12 1 2 B1B201QD Engine gearbox suspension Engine CFA RH engine support LH engine support B1B201SD B1B201RD 3 5 2 0 5 A Screw on box B Screw on body FR C1 page022 92 2005 9 01 06 8 48 Page 33 ...

Page 40: ... screw 17 1 7 4 Seal carrier plate screw 1 0 1 Engine CFA B1B201DD B1B201ED Cylinder head bolts 5 Tightening 3 2 0 3 Angular tightening 180 5 6 Camshaft bearing cap cover screws assembly 1 5 0 1 7 Camshaft bearing cap cover screws 1 3 0 1 8 Exhaust manifold screws 2 4 0 2 9 Valve cover screws 0 8 0 1 10 Camshaft pulley screws 4 7 0 4 FR C1 page022 92 2005 9 01 06 8 48 Page 34 ...

Page 41: ...NE Crankshaft RH engine support 11 Tightening of screws on block 2 4 0 2 Tightening of screws on body 5 2 0 5 12 Timing chain cover screw 2 4 0 2 13 Timing chain cover screw 4 0 4 Engine CFA B1B201FD FR C1 page022 92 2005 9 01 06 8 48 Page 35 ...

Page 42: ...ETROL ENGINE Lubrication Oil pump 0 9 0 1 14 Sump screws 1 0 1 15 Sump screws 2 4 0 2 Flywheel clutch 16 Flywheel screws 7 8 0 8 17 Clutch plate screws 1 9 0 2 Engine CFA B1B201GD B1B2015D FR C1 page022 92 2005 9 01 06 8 48 Page 36 ...

Page 43: ...on block 2 7 0 3 Cooling circuit 19 Coolant pump screws 2 8 0 3 20 Coolant inlet housing screws 0 7 0 1 Accessories 21 Alternator screw 4 9 0 5 22 Tensioner screw 3 4 0 4 23 Aircon compressor screw 2 4 0 2 Engine CFA B1B201HD B1B201XD D1A2004D FR C1 page022 92 2005 9 01 06 8 48 Page 37 ...

Page 44: ...RQUES ENGINE SUSPENSION 1 5 2 0 5 2 5 2 0 5 3 5 2 0 5 5 5 2 0 5 6 12 1 2 7 B1B201AD Engine gearbox assembly suspension Engine 8HT RH engine support Lower RH engine support B1B201BD 4 5 7 0 6 8 5 2 0 5 9 5 2 0 5 10 5 2 0 5 B1B201CD FR C1 page022 92 2005 9 01 06 8 48 Page 38 ...

Page 45: ...ing 180 5 Tightening 3 0 3 Angular tightening 140 5 Con rod screws Tightening 1 0 1 Angular tightening 100 5 Accessories drive pulley Tightening 3 0 3 Angular tightening 180 5 Cylinder block Oil sump 1 3 0 1 Timing belt guide roller 3 7 0 3 Timing belt tensioner roller 2 3 0 2 FR C1 page022 92 2005 9 01 06 8 48 Page 39 ...

Page 46: ...lies on cylinder head Pre tightening 0 3 0 1 Tightening 1 0 1 Exhaust manifold 3 Camshaft pulleys Pre tightening 2 0 2 Angular tightening 50 5 Cylinder head Pre tightening 2 0 2 Tightening 4 0 4 Angular tightening 230 5 EGR valve 1 0 1 Flywheel Flywheel Pre tightening 1 7 0 2 Angular tightening 70 5 Clutch mechanism 2 0 2 FR C1 page022 92 2005 9 01 06 8 48 Page 40 ...

Page 47: ...ion rail on engine block 2 2 0 2 Unions on fuel high pressure common injection rail Pre tightening 1 7 0 1 Tightening 2 2 0 2 Diesel injection pump on support 2 2 0 2 Union on diesel injector Pre tightening 1 7 0 1 Tightening 2 2 0 2 Diesel injection pump pulley 5 0 5 Union on diesel high pressure pump Pre tightening 1 7 0 1 Tightening 2 2 0 2 Cooling circuit Coolant pump Pre tightening 0 3 0 1 Ti...

Page 48: ...how any traces of impacts or scratches Pass a tap into the threads in the cylinder block that receive the cylinder head bolts Brush the threads of the cylinder head bolts Coat the threads and under the heads with MOLYKOTE G RAPIDE PLUS Engines Tightening Cylinder head bolts Max re usable length i n mm Tightening 3 2 0 3 CFA Angular tightening 180 5 123 5 Pre tightening 2 0 2 8HT Tightening 4 0 4 1...

Page 49: ...43 ENGINE Tools BELT TENSION SEEM UNITS CORRESPONDENCE TABLE 4099 T C TRONIC 105 4122 T C TRONIC 105 5 FR C1 page022 92 2005 9 01 06 8 49 Page 43 ...

Page 50: ...44 ENGINE AUXILIARY EQUIPMENT DRIVE BELT Engine plate C1 See pages Petrol Diesel 1 0i 1 4 HDi CFA 8HT X X 46 to 47 48 to 49 FR C1 page022 92 2005 9 01 06 8 49 Page 44 ...

Page 51: ...ment 4122 T C TRONIC 105 5 WARNING If using tool 4099 T C TRONIC 105 ESSENTIAL Before refitting the auxiliary equipment drive belt check that 1 The roller s rotate freely no play or stiffness 2 The belt is correctly engaged in the grooves of the various pulleys FR C1 page022 92 2005 9 01 06 8 49 Page 45 ...

Page 52: ...ompressor pulley d Crankshaft pulley B With aircon C Without aircon Slacken the screw 1 Slacken the screw 2 Do up the screw 2 without tightening it until there is no more play A Slacken the screw 3 Remove the trapezoidal belt from the ventilator and from the alternator FR C1 page022 92 2005 9 01 06 8 49 Page 46 ...

Page 53: ... it until there is no more play A Tighten the screw 3 to tension the trapezoidal belt on the ventilator and on the alternator Check the trapezoidal belt on the ventilator and on the alternator Tighten the screw 2 Tightening torque 3 4 0 3 m daN Tighten the screw 1 Tightening torque between 4 3 and 5 5 m daN Visually check the cabling of the alternator and listen for any abnormal noise Check the ci...

Page 54: ...rt the vehicle wheels hanging Lock the front wheels on full RH lock Move aside the splash shield IMPERATIVE In the case of belt re use mark the direction of rotation of the belt If the index on the tensioner roller is outside the marks change the auxiliary equipment drive belt A Vehicle with air conditioning B Vehicle without air conditioning 1 and 4 Alternator pulley 3 and 6 Auxiliary drive belt ...

Page 55: ...sioner roller Respect the direction of fitting of the drive belt Position the auxiliary drive belt Move the tool 2 on the tensioner roller to remove the peg 3 Make sure that the drive belt is correctly positioned in the V grooves of the various pulleys Refit the splash shield Reconnect the battery negative cable IMPERATIVE Carry out the operations that are necessary following a reconnection of the...

Page 56: ...50 ENGINE Tools BELT TENSION SEEM UNITS CORRESPONDENCE TABLE 4099 T C TRONIC 105 4122 T C TRONIC 105 5 FR C1 page022 92 2005 9 01 06 8 49 Page 50 ...

Page 57: ...51 ENGINE 51 CHECKING AND SETTING THE VALVE TIMING Engine plate C1 See pages Petrol Diesel 1 0i 1 4 HDi CFA 8HT X X 53 to 69 70 to 77 FR C1 page022 92 2005 9 01 06 8 49 Page 51 ...

Page 58: ...S TIMING BELT Engines All Types Recommendations IMPERATIVE After any repair involving removal of the timing belt systematically replace The timing belt The tensioner roller fixing nut FR C1 page022 92 2005 9 01 06 8 49 Page 52 ...

Page 59: ...g operation Drain the cooling circuit see corresponding operation Remove the auxiliary drive belt see corresponding operation Remove the sump Remove the driveshafts see corresponding operation Remove the engine gearbox assembly see corresponding operation Move aside the elastic clip on the coolant pump Remove the alternator see corresponding operation Remove the screw and the guide tube of the oil...

Page 60: ...the camshaft position sensor Remove the screw and the crankshaft position sensor Remove the 13 screws and the 2 nuts in the sequence indicated Remove the valve cover with its gasket Remove the valve cover gasket B1D201QD B1D201RD FR C1 page022 92 2005 9 01 06 8 49 Page 54 ...

Page 61: ...NG AND SETTING THE VALVE TIMING Engine CFA Remove the 3 screws the support for the oil filter and its seal Remove the 5 screws the coolant pump and its seal B1D201SD B1D201TD FR C1 page022 92 2005 9 01 06 8 49 Page 55 ...

Page 62: ...h those on the timing cover Make sure that the setting mark a on the camshaft pulley is on top as indicated NOTE Failing this turn the crankshaft pulley by one full turn 360 degrees to bring the setting mark to the top Lock the crankshaft pulley using tool 1 and remove it 1 C 0132 AA Remove the timing cover B1D201UD B1D201VD FR C1 page022 92 2005 9 01 06 8 49 Page 56 ...

Page 63: ... compress the piston Insert peg into the hole in the stop plate so as to lock the tensioner with the thrust piston in the compressed position Remove the 2 screws and the chain tensioner Remove the screw the chain tensioner guide and the timing chain B1D201WD B1D201XD FR C1 page022 92 2005 9 01 06 8 49 Page 57 ...

Page 64: ... ENGINE CHECKING AND SETTING THE VALVE TIMING Engine CFA Remove the 2 screws the chain guide and the crankshaft toothed wheel Remove the keyway B1D201YD B1D201ZD FR C1 page022 92 2005 9 01 06 8 49 Page 58 ...

Page 65: ...ay in the groove of the crankshaft Align the groove of the crankshaft pinion with the keyway of the crankshaft and refit the crankshaft pinion Refit the chain guide with the 2 screws Tightening torque 0 9 0 1 m daN B1D201ZD B1D202HD FR C1 page022 92 2005 9 01 06 8 49 Page 59 ...

Page 66: ...ing mark b on the crankshaft pinion as indicated To complete the refitting of the timing chain align the 2 links d orange in colour with the setting marks a on the camshaft pulleys as indicated Refit the chain tensioner guide with the screw Tightening torque 1 9 0 2 m daN B1D202JD B1D202KD FR C1 page022 92 2005 9 01 06 8 49 Page 60 ...

Page 67: ...haft anti clockwise in order to detension the timing towards the tensioner Refit the tensioner with the 2 screws Tightening torque between 0 8 and 1 3 m daN Remove the peg rotate the crankshaft by 2 full turns and unlock the chain tensioner B1D202LD B1D202MD FR C1 page022 92 2005 9 01 06 8 49 Page 61 ...

Page 68: ...VE TIMING Engine CFA Check that the setting mark a on the camshaft pulley is on top with the chain in tension Refit the timing cover Coat the lip of a new lip seal with engine oil B1D202ND B1D202PD FR C1 page022 92 2005 9 01 06 8 49 Page 62 ...

Page 69: ...es Dimensions mm B 3 G 3 to 3 5 C 3 H 3 5 D 3 5 to 4 5 I 3 to 3 5 E 4 5 to 5 5 J 3 5 to 4 5 F 4 5 to 5 5 Apply a strip of seal paste on the cylinder block at g and on the timing cover at h as indicated and refit the timing cover h Seal paste AUTOJOINT OR WARNING Refit the timing cover within 3 minutes following the application of the strips of seal paste B1E200HD B1D202RD FR C1 page022 92 2005 9 0...

Page 70: ...ws in the sequence indicated Tightening torque for screws 1 2 4 0 2m daN Tightening torque for screws 2 4 0 4 m daN Remove the excess seal paste Fit a new coolant pump seal on the timing cover and refit the coolant pump B1D202SD B1D201TD FR C1 page022 92 2005 9 01 06 8 49 Page 64 ...

Page 71: ...ine CFA Tighten the 5 screws in the sequence indicated Tightening torque 2 8 0 3 m daN Lock the crankshaft pulley using tool 1 and tighten the screw 1 C 0132 AA Tightening torque 17 1 7 m daN B1D202TD B1D202UD FR C1 page022 92 2005 9 01 06 8 49 Page 65 ...

Page 72: ...ING Engine CFA Refit the oil filter seal on the timing cover and refit the oil filter support Tighten the 3 screws in the sequence indicated Tightening torque between 1 9 and 2 9 m daN B1D201SD B1D202VD FR C1 page022 92 2005 9 01 06 8 49 Page 66 ...

Page 73: ...he gasket which must be well seated around the bases of the bosses k 3 to 4 mm Apply a strip of seal paste j on the sealing faces of the cylinder head and of the timing cover Seal paste AUTOJOINT OR WARNING Refit the valve cover within 3 minutes and tighten the screws and nuts within 15 minutes following application of the strip of seal paste j B1D202WD B1D200VD FR C1 page022 92 2005 9 01 06 8 49 ...

Page 74: ... to the correct torque Refit the crankshaft position sensor WARNING Do not use any component that has been dropped or knocked WARNING Check the condition of the O ring seal before refitting it Coat the O ring seal with a thin layer of engine oil Refit the crankshaft position sensor with the screw Tightening torque 0 8 m daN Connect the connector of the crankshaft position sensor B1D202XD B1D201QD ...

Page 75: ... on the surround of the sump Refit the engine gearbox assembly see corresponding operation Refit the driveshafts see corresponding operation Refit the sump Refit the auxiliary drive belt see corresponding operation Fill and top up the engine and the gearbox see corresponding operation Fill and bleed the engine cooling circuit see corresponding operation Check all the levels Reconnect the battery n...

Page 76: ...moving exhaust clips C 193 A 6 Hose clamp 0188 AD Removing Preliminary operations Disconnect the battery negative terminal Place the vehicle on a 2 column lift Remove the screws 1 Move aside the bumper at a Remove the plastic rivet 4 Apply a force upwards at f Detach in the sequence b c d e Move aside the bumper 3 Remove the headlamp 2 C4A2003D C4A2004D FR C1 page022 92 2005 9 01 06 8 49 Page 70 ...

Page 77: ...cessories drive belt see corresponding operation Under the vehicle Remove the exhaust clip 10 using tool 5 Uncouple the exhaust line NOTE Removing the exhaust clip prevents the front flexible pipe from being damaged Twisting pulling and bending reduces the life of the front flexible exhaust pipe Rotae the engine by means of the crankshaft pulley screw to bring it to the flywheel locking posi tion ...

Page 78: ...onnect the connector at h Slacken the screws 13 Remove the lower timing cover 11 IMPERATIVE The magnetic track j of the crankshaft pinion should show no signs of damage and should not be approached by any other source of magnetism Remove the engine speed sensor 16 the belt retaining stop 15 B1E2000D B1E2004D FR C1 page022 92 2005 9 01 06 8 49 Page 72 ...

Page 79: ... support of the expansion chamber 20 the engine support 19 the intermediate engine support 18 Lower the engine by 3 cm WARNING Operate the jack with care Do not leave the engine without support Take care with the routing of the header tank hose Check for any interference between the lower crossmember and the heat shield of the catalytic converter B1E2005D B1B200GD FR C1 page022 92 2005 9 01 06 8 4...

Page 80: ...w 12 clockwise to bring it to the pegging position Position the camshaft pinion using the peg 2 the fuel high pressure pump using the peg 3 the crankshaft pinion using the peg 3 Hold the tensioner roller in place by means of a hexagonal spanner at k Slacken the screw 21 Detension the timing belt by pivoting the tensioner roller clockwise at k Remove the timing belt B1E2006D FR C1 page022 92 2005 9...

Page 81: ...t pinion screw 12 with new at each removal Do not twist or bend the belt NOTE Pegging the high pressure pump serves to increase the life of the timing belt NOTE Use of the tool 6 on the camshaft pinion 23 makes the operation to fit the timing belt easier WARNING The setting pegs have to be in place on the engine NOTE If the belt sections l m and n are not kept taut during the tensioning of the bel...

Page 82: ...e camshaft the pegging of the crankshaft pinion the pegging of the fuel high pressure pump and the correct positioning of the index on the dynamic ten sioner see diagram use a mirror If these are not correct restart the operation to position the timing belt In the engine compartment Raise the engine back to its initial position Refit the intermediate engine support 18 tighten the screws to 5 7 0 5...

Page 83: ...the screw of the accessories drive pulley 12 Pre tightening 3 0 3 m daN Angular tightening 180 5 Remove tool 1 Refit the exhaust clip using tool 5 In the engine compartment Refit the upper timing cover 5 the expansion chamber 8 the accessories drive belt see corresponding operation Proceed in the reverse order to the removal operations Reconnect the battery negative terminal IMPERATIVE Perform the...

Page 84: ...6 made of plastic to reduce weight The butterfly body 40 is of plastic The valve cover 1 is of plastic It incorporates the air filter housing 38 The exhaust manifold 39 and piping are of stainless steel These reduce weight and have better resistance to corrosion B1B202FD FR C1 page022 92 2005 9 01 06 8 49 Page 78 ...

Page 85: ...rfly body 40 Inlet manifold The inlet manifold 43 is of plastic to reduce weight and the quantity of the heat transmitted by the cylinder head This solution reduces the temperature of the inlet air and increases the inlet perfor mance by volume The inlet manifold comprises a depressiometer 44 for measurement of inlet vacuum and a sensor for measurement of inlet air temperature B1B202GD B1B202HD FR...

Page 86: ...alytic converter serves to reduce pollutant emissions Exhaust pipe ac from the exhaust manifold 47 tightening clip 48 front pipe 49 rear pipe 50 gasket The silencer 37 has been optimised with the aim of making it both compact and light The junction between the front and rear parts H of the exhaust pipe is by means of the insertion E making a gasket no longer necessary The junction of the exhaust p...

Page 87: ... 2 3 4 5 6 7 Exhaust Upstream Clip Rear silencer Downstream Screws Catalytic manifold oxygen sensor oxygen sensor converter Tightening m daN 2 4 0 2 4 4 0 4 3 2 0 3 4 4 0 4 4 5 0 4 Engine CFA B1J2000D FR C1 page022 92 2005 9 01 06 8 49 Page 81 ...

Page 88: ...IONS 1 2 3 4 5 6 7 Rubber Silencer Rubber Clip Catalytic Intermediate Clip suspension suspension converter pipe Tightening m daN 2 5 0 2 2 0 2 3 2 0 3 Reference TR PSA K278 Engine 8HT B1J2001D FR C1 page022 92 2005 9 01 06 8 49 Page 82 ...

Page 89: ...n Aircon cut off Alert Post cooling Coolant temperature sensor and alert located on the coolant outlet housing Engine coolant level sensor 1 0i 1 4 HDi CFA 8HT 4 4 4 12 2 dm2 1 4 bars 82 C 93 C 97 C 1 x 100 Watt 1 x 300 Watt 115 C 118 C 105 C for 6 minutes Green connector On the expansion chamber Temperature sensor tightening torque 2 0 2 m daN FR C1 page022 92 2005 9 01 06 8 49 Page 83 ...

Page 90: ... C Coolant fluid Type Coolant with very long life for petrol or equivalent engine Capacity litres 4 System diagram 35 heater unit Specifications of coolant fluid Type Coolant with very long life for petrol or equivalent engine Colour Pink 1st replacement of fluid 150 000 km 100 000 miles Subsequent replacements Every 60 000 km 40 000 miles WARNING The coolant is already a blended product 50 coolan...

Page 91: ... ENGINE COOLING SYSTEM SPECIFICATIONS Engine CFA 1 Coolant pump 2 Thermostat 3 Heater matrix 4 Cylinder block drain screw 5 Cooling radiator 6 Top hose B1G200YD FR C1 page022 92 2005 9 01 06 8 49 Page 85 ...

Page 92: ...86 ENGINE COOLING SYSTEM SPECIFICATIONS Engine 8HT 1 Bleed screw 2 Exhaust gas recycling EGR heat exchange EURO 4 version B1H200ZD FR C1 page022 92 2005 9 01 06 8 49 Page 86 ...

Page 93: ...rs 1 3 Rpm 1000 Pressure Bars 3 7 Rpm 2000 Pressure Bars Rpm Pressure Bars 5 3 5 Rpm 4000 4000 Tools 4386 T X 4601 T X 1503 L X 2279 T Bis X 4103 T X 1503 J X NOTE The oil pressure should be checked with the engine hot after the oil level has been checked FR C1 page022 92 2005 9 01 06 8 49 Page 87 ...

Page 94: ...88 ENGINE VALVE CLEARANCES CFA petrol engine Adjust by change of cam followers See presentation of 384F engine 8HT diesel engine Hydraulic compensator FR C1 page022 92 2005 9 01 06 8 49 Page 88 ...

Page 95: ...Couple the radiator outlet hose on the engine side Refit the drain screw 1 Tightening torque 2 0 2 m daN Fill the radiator with engine coolant fluid until it overflows Capacity 4 Litres WARNING Do not replace coolant fluid with water NOTE Use of coolant fluid that is inappropriate may damage the cooling system NOTE Use only Toyota Super Long Life Coolant engine coolant fluid or any other similar h...

Page 96: ... OFF button turned towards hot air air conditioning control in position OFF Maintain the engine speed between 2000 and 2500 rpm until the cooling fan triggers Press several times on the radiator inlet and outlet hoses several times during the rise in engine temperature Stop the engine and wait for the coolant temperature to come down If the coolant level is below the maximum mark repeat the 10 pre...

Page 97: ...the negative terminal of the battery Remove the header tank cap with care Place a draining tray under the cooling radiator Drain the radiator by uncoupling the bottom hose Place a draining tray under the engine Drain the engine by removing the plug 1 accessible from above the engine Refit the drain plug 1 with a new O ring seal and clip Engine 8HT B1G200TD FR C1 page022 92 2005 9 01 06 8 49 Page 9...

Page 98: ...s Reconnect the negative terminal of the battery Start the engine Maintain an engine speed of 1500 rpm up to the first cooling cycle starting and stopping of the cooling fan Plug the filling cylinder 1 with the plug 3 Remove the filling cylinder 1 plug 3 and adaptor 2 assembly Stop the engine and wait for it to cool down If necessary top up the level to the maximum mark with the engine cold Refit ...

Page 99: ...This ECU is of the Engine speed pressure type This injection system controls the engine injection and ignition thanks notably to the information on inlet air pressure and engine speed Multipoint injection 3 electromechanical injectors Sequential injection Integral electronic ignition Depollution L5 European norm EURO4 Marketing of vehicles respecting the depollution norm IFL5 according to country ...

Page 100: ...onverter Deterioration of the oxygen sensors EOBD requires the installing of an oxygen sensor downstream of the catalytic converter Features Features of the injection system Engine phase detector camshaft position sensor Camshaft dephaser VVT Sequential injection Air temperature sensor incorporated in the air pressure sensor in the inlet manifold Engine cooling function integral to the injection E...

Page 101: ...INJECTION 95 GENERAL SYNOPSIS BOSCH ME 7 9 5 INJECTION SYSTEM Engine CFA D4E2002D FR C1 page93 125 2005 9 01 06 8 51 Page 95 ...

Page 102: ...der 3 1333 Injector cylinder N 3 1215 Canister purge electrovalve 1350 Downstream oxygen sensor 1220 Engine coolant temperature sensor 1351 Upstream oxygen sensor 1240 Inlet air temperature sensor 1510 Cooling fan 1261 Accelerator pedal position sensor MMT piloted manual gearbox 2120 Brake dual function switch 1262 Motorised butterfly housing 8009 Linear pressure sensor for the coolant fluid with ...

Page 103: ...manual gearbox Open cycle ratio 4 Information on the position of the accelerator 14 Control of the variable valve OCR pedal timing electrovalve 5 Information on the inlet air pressure 15 Control of the cooling fan 6 Information on engine speed Open cycle 16 Supply of the ignition coils ratio OCR All or nothing 7 Information on the oxygen content of the exhaust gases after the cat converter Analogu...

Page 104: ... of fuel injected is proportional to the time of opening of the injectors which is determined as a function of 3 main parameters Engine load Speed of rotation of the engine TDC sensor The information from the oxygen sensor Numerous other corrections are also applied during operation in order to take account of the variations In the heat status of the engine coolant temperature sensor In the operat...

Page 105: ...mmands the following components Priming pump low pressure cut off after 3 seconds provided the starter motor has not operated The electrical supply of the oxygen sensors Functioning of the transitory engine speeds Command of the injectors is corrected as a function of the following variations Butterfly position Pressure in the inlet manifold The detection of these engine speeds accelerations decel...

Page 106: ...s Start of injection Time of injection The injection ECU draws on the specific strategies for starting and stopping of the engine Determination of the quantity of fuel to be injected The quantity of fuel to be injected is calculated from the demand coming from the driver provided by the position of the accelerator pedal To determine the quantity of fuel to be injected the injection ECU takes accou...

Page 107: ...e speed Engine load Engine temperature This correction stabilises the engine by varying the advance from one TDC to the next positively or negatively relative to the mapping value Corrections in injection advance are also applied during the transitory phases Synchronisation of ignition is achieved by the cylinder reference sensor N 1 Petrol vapour recycling canister function Engine stopped the ele...

Page 108: ...n good condition L Catalytic converter in poor condition a Upstream oxygen sensor b Downstream oxygen sensor The efficiency of the catalytic converter is determined by comparing the signals coming from the ups tream and downstream oxygen sensors The detection is performed 6 minutes after the starting of the engine Conditions of detection Engine operating for at least 6 minutes No fault in the oxyg...

Page 109: ...tion misfiring for a given cylinder 1 2 3 Knock sensor signal Engine speed sensor signal Camshaft sensor Ageing of the catalytic converter Vehcle speed sensor signal Idle stepper motor signal Supply of sensors Battery voltage too low Battery voltage too high Brake switch signal MMT gearbox Inlet manifold pressure sensor Signal internal to the ECU Control of the motorised butterfly MMT gearbox Jamm...

Page 110: ... The engine diagnosis warning lamp is not used for any other purpose except if there a risk of destruction of the engine or a risk for the safety of the vehicle occupants Access to the EOBD fault codes Access to the memorised fault codes is open to any trained person equipped with a normalised diagnostic tool known as SCANTOOL with which the ECU permits dialogue Access to the diagnostic codes is a...

Page 111: ...from the injection ECU Engine load as a function of the position of the accelerator pedal Engine speed Engine temperature The piloted manual gearbox ECU sends the following information from the injection ECU Information on request for torque reduction Information on request for compensation of idling speed Gear changing quality is enhanced by an order to reduce engine torque given by the gearbox E...

Page 112: ...SPECIFICATION Air filter 45 air filter cartridge 46 air filter cover The valve cover 1 incorporating the air filter housing 38 is made of plastic to reduce weight B1B202JD Engine CFA FR C1 page93 125 2005 9 01 06 8 51 Page 106 ...

Page 113: ...e fuel pump module 53 is compact and light comprising the fuel gauge which incorporates a car bon fuel vapour absorber The fuel supply rail 51 is made of plastic Fuel tank af HDPE high density polyethylene The fuel tank 52 is made of plastic The interior ag and exterior ad surfaces are coated with a layer of flourate polyethylene ae to prevent any penetration of fuel B1B202MD B1B202ND Engine CFA F...

Page 114: ...52 During dismantling destruction of the vehicle drill a hole at the spot indicated ah in order to drain the fuel Fuel filler piping The fuel filler piping 55 includes the tank breather pipe for greater compactness and saving of actual space B1B202PD B1B202QD Engine CFA FR C1 page93 125 2005 9 01 06 8 51 Page 108 ...

Page 115: ...ter 61 pressure regulator 62 cut off valve 63 foam filter for venting the canister The fuel pump module includes the carbon fuel vapour absorber 57 for saving of actual space Fuel supply rail The fuel supply rail 51 is made of plastic to reduce weight B1B202RD B1B202SD Engine CFA FR C1 page93 125 2005 9 01 06 8 51 Page 109 ...

Page 116: ...y system reduces emissions by evaporation The diagram shows that by integration of the fuel filter 60 the pressure regulator 61 and the fuel gauge with the fuel pump 53 there is no return of fuel from the engine and an increase of temperature inside the fuel tank is avoided B1B202TD Engine CFA FR C1 page93 125 2005 9 01 06 8 51 Page 110 ...

Page 117: ... to the elimination of the distributor The direct ignition system DIS on this engine is an independent ignition system with an ignition coil for each cylinder Ignition coil 66 secondary coil 67 primary coil 69 iron core The DIS system has 3 ignition coils one for each cylinder The caps 68 which establish contact with the sparking plugs are integral to the coils With a view to simplification of the...

Page 118: ...quirements below No smoking in proximity to the high pressure circuit when work is being carried out Do not work close to flame or sparks Always stay clear of the trajectory of any possible jet of fuel which could cause serious injuries Do not place your hand close to any leak in the high pressure fuel circuit After the engine has stopped wait 30 seconds before any intervention NOTE This waiting t...

Page 119: ...ng procedures Low pressure circuit Fuel filter Fuel gauge Unions on fuel pipes High pressure circuit Fuel high pressure pump Fuel high pressure injection common rail Fuel high pressure pipes Diesel injector carriers IMPERATIVE After dismantling immediately block the apertures of sensitive components with plugs to avoid the entry of impurities Work area The work area must be clean and free of clutt...

Page 120: ...pping injection ECUs between two vehicles will render it impossible to start either vehicle It is forbidden to supply a diesel injector with 12 volts Fuel high pressure pump Do not separate the fuel high pressure pump 1 from the following components Sealing ring a no replacement parts High pressure outlet connector b will cause a malfunction B1H200ZD FR C1 page93 125 2005 9 01 06 8 51 Page 114 ...

Page 121: ...replacement parts Electromagnetic component c no replacement parts Do not move the nut d will cause a malfunction Do not separate the union e from a diesel injector It is forbidden to clean the carbon deposits from the diesel injector nozzle Fuel high pressure common injection rail Do not separate the pressure regulator g from the common injection rail 3 will cause a mal function B1H2011D B1H2010D...

Page 122: ...nit is piloted by the engine ECU Pre postheating control unit Supplier Reference NAGARES 96 456 686 80 CARTIER 96 456 692 80 Pre heater plugs a Marking zone Supplier Reference NGK YE04 BERU 0 100 276 004 Tightening torques m daN Plugs on cylinder head tighten to 0 85 0 08 m daN Bar on plugs tighten to 0 12 0 03 m daN B1H200YD FR C1 page93 125 2005 9 01 06 8 51 Page 116 ...

Page 123: ...emove the engine cover IMPERATIVE Clean the unons before uncoupling them if necessary see corresponding operation Detach the pipe at a Move aside the diesel fuel filter top cover 1 Checks Uncouple the clickfit union at b ESSENTIAL Make sure that the tool 2 is clean Link tools 1 and 2 in series between the fuel high pressure pump and the fuel filter Prime the circuit using the manual priming pump s...

Page 124: ...ceed in the reverse order to removal Action the manual priming pump for 120 seconds in order to prime the fuel circuit Checking the sealing Reconnect the negative terminal of the battery Start the engine Let the engine run at idle for 2 minutes Check that there is no leak Check that there are no air bubbles in the return circuit IMPERATIVE Perform the operations that are required following a batte...

Page 125: ...Engine at operating temperature vehicle in running order engine under full load Preparation Remove the engine cover IMPERATIVE Do not disconnect the air temperature sensor 3 If the warning lamp in the instrument panel should come on delete the faults using the diagnostic tool Remove the clips 1 Move aside the duct 2 without disconnecting the air temperature sensor 3 Fit the tool 2 in the place of ...

Page 126: ...0 rpm Accelerate freely change from fourth gear to third gear Check the pressure 0 9 0 05 bar between 2500 and 3500 rpm Remove tools 1 2 Reposition the tube 2 Tighten the clips 1 NOTE Confirm the measurement with the aid of the diagnostic tool parameter measures Parameter measures diagnostic tool Checks on the inlet manifold pressure sensor Remove the engine cover 4 inlet manifold pressure sensor ...

Page 127: ...he diagnostic tool Checks IMPERATIVE Respect the following test conditions Engine at operating temperature vehicle in running order engine under full load NOTE Carry out the checks either during a road test or on a roller test bed Perform the checking with the aide of a diagnostic tool Start the engine Stage A Engage first gear start the vehicle Engage the gears up to third gear Decelerate to an e...

Page 128: ...ntegrated air inlet manifold The lower integrated air inlet system is composed of the following components 8 EGR upper pipe 9 Inlet distributor 10 Diesel fuel filter with heater and water detector according to country 11 Diesel fuel filter support 12 Oil separator 13 Oil filler cap 14 Air meter housing EURO 4 Features WARNING At each removal it is essential to replace the seals on the components t...

Page 129: ...to 10 1 0 1 Diesel fuel filter support fixing screw 11 0 5 Integrated air inlet distributor screw 12 to 13 1 0 1 Upper integrated air inlet manifold Ref Description Tightening 15 Air filter housing fixing screw 16 Air filter cover fixing screw 0 5 17 Air inlet neck fixing screw 18 Screw fixing the resonator on the turbocharger 0 75 19 Screw fixing the resonator on the oil separator B1H201MD B1H201...

Page 130: ...it 30 seconds The vacuum value should be 0 9 0 1 bar at idling speed NOTE The exhaust gas recycling valve is not linked to the air supply circuit The exhaust gas recycling electrovalve is controlled by the engine ECU Turbocharging pressure regulation valve Connect the tool 1 on the valve 2 tube identified by the colour grey Appy a vacuum of approx 0 8 bar Rod a should move 12 2 mm B1H201HD B1H201G...

Page 131: ...6 PEUGEOT DENSO 596085 Electrode gap 1 1 Charging system The charging system uses an alternator that is compact and light but of conventional type Specifications Type A115I Supplier DMIT Nominal voltage 12V Nominal output voltage 70 A 80 A Initial output starting speed 1300 rpm maximum Starting system The starter motor used is of the controlled pinion type Specifications Type D7E R70M Supplier VAL...

Page 132: ...h 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 the vehicle The final drive ratio The speedometer drive ratio Any of these components can be checked without removing them from the vehicle See information note N 78 85 TT of 19 October 1978 NOTE Before replacing the speedometer che...

Page 133: ... Engine type CFA 8HT Gearbox type MT MMT MT Gearbox make LUK ASIN LUCK Mechanism Type 200 CPXV Ext Int lining Ø 181 133 190 133 200 134 Disc lining type 1 0i 1 4 HDi MT Manual gearbox MMT Piloted manual gearbox FR C1 page126 148 2005 9 01 06 8 53 Page 127 ...

Page 134: ...Number of screws Tightening Align the reference b Screws for clutch Position the mechanism using 1 mechanism on flywheel the top screw a Tightening 1 9 0 1 2 Screws for flywheel 7 8 0 7 B2B2017D CLUTCH TIGHTENING TORQUES B2B2016D FR C1 page126 148 2005 9 01 06 8 53 Page 128 ...

Page 135: ...lation to the floor between 135 and 145 mm Adjust the height A of the pedal Slacken the locking nut and turn the stop screw until you obtain the correct height Tighten the locking nut Tightening torque 2 5 0 2 m daN Press on the pedal until you feel the start of resistance Play B in the pedal 18 to 28 mm B2B2000D B2B2001D FR C1 page126 148 2005 9 01 06 8 53 Page 129 ...

Page 136: ...reverse gear until the gearing meets a resistance from the clutch Progressively press on the clutch pedal and measure the travel from the point where the gear noise disappears point of release c to the position of maximum travel d 25 mm or more from the position of maximum travel d to the point of release c If the travel is not correct proceed to the following operations Check the height A of the ...

Page 137: ...NS OF MT TOYOTA MANUAL GEARBOX Vehicle Engine Gearbox type Gearbox Torque ratio Drive ratio identification CFA MT C 551 C1 MMT C 551 A 20 x 71 8HT MT C 551 MT Manual gearbox MMT Piloted manual gearbox FR C1 page126 148 2005 9 01 06 8 53 Page 131 ...

Page 138: ...d 4th gear synchroniser 3 Gearbox casing 4 Reverse gear motor pinion 5 Clutch housing 6 Primary shaft 7 Secondary shaft 8 Planet pinions 9 Satellite pinions 10 Differential gearwheels 11 1st gear driven pinion 12 1st 2nd gear synchroniser 13 Reverse gear driven pinion 14 2nd gear driven pinion 15 3rd gear driven pinion 16 4th gear driven pinion 17 5th gear driven pinion B2C2011D B2C202CD FR C1 pag...

Page 139: ... 1 Closing plate fixing 4 0 4 2 Fixing of gearbox on engine 6 4 0 6 3 Fixing of gearbox support on body 5 2 0 5 4 Fixing of clutch fork support 3 3 0 3 5 Fixing of gear controls plate 1 1 0 1 B2C201ED TIGHTENING TORQUES FOR MT TOYOTA MANUAL GEARBOX B2C201DD FR C1 page126 148 2005 9 01 06 8 53 Page 133 ...

Page 140: ...htening 6 Fixing of gear controls plate 1 8 0 2 7 Reverse gear switch 4 0 4 8 Drain plug 2 9 0 3 9 Filler plug 3 9 0 4 10 Locking finger 3 7 0 4 11 Fixing of engagement finger 1 6 0 2 B2C201GD TIGHTENING TORQUES FOR MT TOYOTA MANUAL GEARBOX B2C201FD FR C1 page126 148 2005 9 01 06 8 53 Page 134 ...

Page 141: ...N Tightening torques m daN Ref Description Number of screws Tightening 12 Fixings of gearbox casing and clutch housing 12 2 9 0 3 B2C201HD TIGHTENING TORQUES FOR MT TOYOTA MANUAL GEARBOX FR C1 page126 148 2005 9 01 06 8 53 Page 135 ...

Page 142: ... AND FILLING MT TOYOTA MANUAL GEARBOX Presentation 1 gearbox drain plug 2 filler and level plug Oil quality Refer to the manufacturer s instructions Oil quantity After draining 1 7 litres B2C2000D FR C1 page126 148 2005 9 01 06 8 53 Page 136 ...

Page 143: ...pushed in IMPERATIVE After Sales checks done with the engine running must be performed with Neutral engaged and the handbrake on unless there is a clear mention otherwise in the repair procedures IMPERATIVE The area of movement of the clutch fork must always be kept free during the actuator operating phases IMPERATIVE When initialising the clutch actuator and or gearbox actuator do not allow any p...

Page 144: ... The clutch and gearbox actuators with the ignition switched on When carrying out electrical checks The battery must be correctly charged Never use a voltage source higher than 16V Never use a warning lamp Never supply an actuator directly Before reconnecting a connector check The condition of the various contacts for deformation corrosion etc The presence and the status of the mechanical unlockin...

Page 145: ... the conditions for immobilisation of the vehicle are Engine stopped the engine should not be started The clutch is open clutched If these conditions are met you can lift the front of the vehicle to tow it If it should not be possibe to lift the front of the vehicle there are ways to unblock it Engage N using a diagnostic tool Engage N without using a diagnostic tool Engaging of N using a diagnost...

Page 146: ...iagnostic tool In this configuration the gearbox actuator is blocked gear engaged NOTE This recovery solution is to be used solely in a case where the attempt to make the gearbox actuator engage b via the diagnostic tool has failed Preliminary operation Disconnect the battery negative terminal Remove the plug on the gearbox actuator a neutral b 1st 3rd 5th c 2nd 4th reverse gear Using a large scre...

Page 147: ...arbox casing 4 Reverse gear motor pinion 5 Clutch housing 6 Primary shaft 7 Secondary shaft 8 Speedometer 9 Planet pinions 10 Satellite pinions 11 Differential gearwheels 12 1st gear driven pinion 13 1st 2nd gear synchroniser 14 Reverse gear driven pinion 15 2nd gear driven pinion 16 3rd gear driven pinion 17 4th gear driven pinion 18 5th gear driven pinion B2C201JD B2C2012D FR C1 page126 148 2005...

Page 148: ...ng lamps sensor 20 Gear engaged sensor 21 Gearbox input speed sensor 22 Gearbox actuator 23 Electric motor for clutch actuator 24 Clutch actuator 25 Electric motor for gearbox actuator selection 26 Electric motor for gearbox actuator engagement B2C201KD B2C201LD FR C1 page126 148 2005 9 01 06 8 53 Page 142 ...

Page 149: ...of the gearbox actuator use a diagnostic tool to perform an initialisation see corresponding operation IMPERATIVE At each refitting of the clutch actuator perform a position adjustment pre loading see corresponding operation Gearbox actuator Description 32 Electric motor for gearbox actuator selection 33 Electric motor for gearbox actuator engagement 34 Gearbox actuator body 35 Engagement angular ...

Page 150: ...refitting see corresponding operation 37 Gear engagement screw d Neutral e 1st 3rd 5th f 2nd 4th Reverse IMPERATIVE Before refitting a gearbox actuator check that it is in neutral position Piloted manual gearbox ECU The gearbox ECU decides on the changing of gear It is located in the vehicle dashboard on the front LH side B2C201PD B2C201QD FR C1 page126 148 2005 9 01 06 8 53 Page 144 ...

Page 151: ... daN Ref Description Number of screws Tightening 1 Clutch actuator fixing screws 3 1 7 0 1 2 Gearbox actuator fixing screws 6 1 8 0 1 B2C202LD TIGHTENING TORQUES FOR MMT TOYOTA PILOTED MANUAL GEARBOX B2C202KD FR C1 page126 148 2005 9 01 06 8 53 Page 145 ...

Page 152: ...ar engaged sensor 5 Fixing screw for gearbox input speed 1 sensor 0 8 0 1 6 Drain plug 2 9 0 3 7 Oil level plug 3 9 0 4 8 Angular sensor fixing screw 6 0 2 9 Fixing screw for clutch housing on gearbox casing 13 2 9 0 3 B2C202ND TIGHTENING TORQUES FOR MMT TOYOTA PILOTED MANUAL GEARBOX B2C202MD FR C1 page126 148 2005 9 01 06 8 53 Page 146 ...

Page 153: ... fixing screws 6 12 4 1 2 11 Fork fixing screws 2 1 6 0 2 12 Fixing screw for reverse gear shaft plate 1 7 0 2 13 Closing panel fixing screw 3 4 0 4 14 Fixing screw for coupling of engine on gearbox 4 6 4 0 6 B2C202QD TIGHTENING TORQUES FOR MMT TOYOTA PILOTED MANUAL GEARBOX B2C202PD FR C1 page126 148 2005 9 01 06 8 53 Page 147 ...

Page 154: ... torques m daN Gearbox oil seal mandrels Vehicles Driveshaft Driveshaft Gearbox Engines bearing nut RH side LH side Toolkit MT CFA C1 MMT 21 6 0 5 0345 A 0345 B MT 8HT Tightening torque m daN for wheel bolts C1 10 m daN FR C1 page126 148 2005 9 01 06 8 53 Page 148 ...

Page 155: ...teel 4 1 2 J14 H2 1 699 m Steel 4 1 2 J14 H2 Inflation pressures Normal operating pressure Pressure under load maximum Pressure Bars Pressure Bars Tyre dimensions Front Rear Spare Tyre dimensions Front Rear Spare wheel wheel 155 65 R14 75T 2 2 2 2 2 6 155 65 R14 75T 2 3 2 3 2 6 Tightening torques Tighten the wheel bolts to 10 m daN FR C1 page149 165 2005 9 01 06 8 56 Page 149 ...

Page 156: ...H1 R1 L1 H1 Measurement between the measuring zone underneath the front sub frame and the ground R1 Front wheel radius under load L1 Distance between the wheel axis and the measuring zone underneath the front subframe H2 R2 L2 H2 Measurement between the measuring zone underneath the rear sill and the ground R2 Rear wheel radius under load L2 Distance between the wheel axis and the measuring zone u...

Page 157: ...measuring the wheel radius 4 bolts tool 4801 T Value at reference Value at reference height L1 88 mm height L2 22 mm 6 8 mm 10 6 mm Compress the suspension to obtain the calculated values The height difference between the two axle dimensions should be less than 10 mm FR C1 page149 165 2005 9 01 06 8 56 Page 151 ...

Page 158: ... of lower camber at 0 30 Dissymmetry of lower camber at 0 30 All Types CFA 8HT CFA 8HT Tyres 155 65 R 14 Castor Camber Pivot Vehicule Tracking 0 18 0 30 angle Tracking Camber 0 30 Adjustable Non adjustable Non adjustable All mm 0 2 3 6 2 2 types 0 0 0 12 2 47 0 47 9 33 0 24 0 15 0 53 Angle of steering full 38 55 2 lock B3C200SD FR C1 page149 165 2005 9 01 06 8 56 Page 152 ...

Page 159: ...ibute the total tracking value symme trically between the LH wheel and the RH wheel Remove the clip 1 Slacken the nut 3 Adjust the rod 2 Tighten the nut 3 4 7 0 4 m daN Refit the clip 1 B3B200FD SPECIAL FEATURES FRONT AXLE FR C1 page149 165 2005 9 01 06 8 56 Page 153 ...

Page 160: ...r fixing points for the subframe under the floorpan are via two link brackets LH RH welded on the subframe Pivot Pivot type pinched Pivot bearing diameter 69 mm Bearing with double row of balls with integral magnetic wheel Suspension leg Front suspension with independent wheels type pseudo Mac Pherson Travel stop height A96 mm Anti roll bar All engine types Ø 22 mm B3C200UD B3C200VD SPECIFICATIONS...

Page 161: ...er ball joint nut 9 8 1 6 Hub nut 21 6 2 7 Steering ball joint on pivot 3 3 0 3 8 Suspension leg fixing on pivot 4 8 0 5 9 Suspension lower arm screw 11 1 1 10 Suspension lower arm screw 12 8 1 2 11 Screw fixing of subframe on body 8 5 0 8 12 Screw torque reaction rod on body 5 2 0 5 13 Screw fixing of subframe on body 12 8 1 2 14 Screw fixing of subframe on body 4 8 0 5 B3C2010D FR C1 page149 165...

Page 162: ...deformable axle crossmember Engines all types Thickness of crossmember panel 5 5 mm Rear hub 2 Rear hub Union on rear axle fixing 4 screws 4 Vehicle geometry NOTE The geometry specifications are given with the values for checking and adjusting the axle geometries B3D200DD B3D200ED SPECIFICATIONS REAR AXLE FR C1 page149 165 2005 9 01 06 8 56 Page 156 ...

Page 163: ...AR AXLE Tightening torques m daN Ref Description Tightening 1 Damper upper fixing 2 5 0 2 2 Damper lower fixing 4 8 0 4 3 Fixing of yoke on rear axle 12 3 1 2 4 Fixing of rear hub on rear axle 6 0 6 B3D200FD FR C1 page149 165 2005 9 01 06 8 56 Page 157 ...

Page 164: ...pension spring IMPERATIVE Check the presence and condition of the rubber protections on the fixed and sliding cups of the spring compressor IMPERATIVE Do not put a suspension spring in direct contact with a metallic object or tool IMPERATIVE Check the condition of the suspension springs absence of signs of impacts scratches or rust spots The paint coating on the suspension springs should not be da...

Page 165: ... nut 21 6 2 1 5 Steering ball joint on pivot 3 3 0 3 6 Suspension leg fixing on pivot 4 8 0 4 7 Screw fixing subframe on body 8 5 0 8 8 Screw fixing subframe on body 12 8 1 2 9 Screw fixing subframe on body 4 8 0 4 10 Anti roll bar bearing fixing on subframe 1 8 0 1 11 Screws steering mechanism on subframe 8 7 0 8 12 Indexed nuts steering mechanism on subframe B3B200ND B3B200MD FR C1 page149 165 2...

Page 166: ...ORQUES Tightening torques m daN Ref Description Tightening 13 Damper upper fixing 2 5 0 2 14 Damper lower fixing 4 8 0 4 15 Fixing of rear axle on body 12 3 1 2 16 Fixing of rear hub on rear axle 6 0 6 B3D200GD FR C1 page149 165 2005 9 01 06 8 56 Page 160 ...

Page 167: ...eering cardan 8 fixing of lower steering cardan Steering mechanism Number of turns of the steering wheel 3 27 Steering rack travel mm 2 x 70 2 Steering ratio 1 43 Inside angle of full lock 36 55 to 40 55 Outside angle of full lock 32 23 B3E2006D B3E200WD MANUAL STEERING SPECIFICATIONS FR C1 page149 165 2005 9 01 06 8 56 Page 161 ...

Page 168: ... 4 controls under steering wheel Steering column Electric power steering 5 steering wheel fixing 6 fixing of steering column on support 7 fixing of upper steering cardan 8 fixing of lower steering cardan B3E2004D B3E2005D POWER STEERING SPECIFICATIONS FR C1 page149 165 2005 9 01 06 8 56 Page 162 ...

Page 169: ...ectric power steering ECU Only one ECU version whatever the engine type The electric power steering ECU 10 is linked to the following connectors Electric assistance motor supply Electric power steering ECU supply Signals from the torque sensor Information on engine speed and vehicle speed NOTE After changing the electric power steering ECU it is necessary to perform a configu ration see correspond...

Page 170: ...ing column on support 2 5 0 2 3 Fixing of upper steering cardan 3 5 0 3 4 Fixing of lower steering cardan 3 5 0 3 5 Fixing of ball joint on pivot 3 3 0 3 6 Locking nut for adjusting the steering track rods 4 7 0 4 7 Fixing of mechanism on subframe 8 9 0 8 8 Fixing of mechanism on subframe indexed nut B3E2003D B3E2002D FR C1 page149 165 2005 9 01 06 8 56 Page 164 ...

Page 171: ...e the dimension Y Calculate the dimension L Y X 2 Position the steering rack to the dimension L steering rack mid point Additional operation Refit the protection gaiter In order to be able to fit the clip 1 remove The steering ball joint gudgeon pin The steering ball joint nut Uncouple the steering ball joint from the pivot Fit a new clip 1 Refit The clip 2 The new clip 1 The steering ball joint T...

Page 172: ...SPECIFICATIONS Master Cylinder Ø Master vac mm Caliper make piston Disc Plain Ventilated FT Disc thickness minimum thickness Brake pad supplier grade Ø Drum mm Original maximum width Lining supplier grade 1 0i 1 4 HDi CFA 8HT Engine type FR C1 PAGE166 183 2005 9 01 06 8 58 Page 166 ...

Page 173: ... front drum brakes at the rear NOTE The front brake pads have no wear warning lamp Handbrake lever controlled by cables acting on the rear wheels The compensator and main brake limiter functions are assured by the ABS REF systems NOTE REF Electronic Brakeforce Distribution EBD FR C1 PAGE166 183 2005 9 01 06 8 58 Page 167 ...

Page 174: ...168 BRAKES B3F2020D BRAKE SPECIFICATIONS Hydraulic valve block Make BOSCH Type ABS REF 8 0 Installed on the master cylinder FR C1 PAGE166 183 2005 9 01 06 8 58 Page 168 ...

Page 175: ...ption Tightening 1 Front brake disc 0 5 2 Yoke on brake caliper 3 0 3 3 Brake pipe unions 3 0 3 4 Front brake caliper 8 9 0 9 5 ABS hydraulic valve block support 1 9 0 2 6 Front wheel sensor 0 8 0 1 B3F201VD B3F201TD Front brakes FR C1 PAGE166 183 2005 9 01 06 8 58 Page 169 ...

Page 176: ...RQUES BRAKES Tightening torques m daN Ref Description Tightening 7 Master cylinder 2 0 2 8 Braking amplifier 2 0 2 9 Handbrake lever 2 2 0 2 B3F201YD B3F201XD Front brakes Handbrake FR C1 PAGE166 183 2005 9 01 06 8 58 Page 170 ...

Page 177: ...torques m daN Ref Description Tightening 10 Rear brake drum 0 5 11 Rear hub support 5 5 0 5 12 Brake pipe unions 1 5 0 1 13 Wheel cylinder 0 8 0 1 14 Rear wheel sensor 0 8 0 1 B3F201WD B3F201UD Rear brakes FR C1 PAGE166 183 2005 9 01 06 8 58 Page 171 ...

Page 178: ...131 6 mm for right hand drive models If the pedal height is not correct adjust it Disconnect the connector of the stoplamps switch 1 Unscrew the stoplamps switch 1 Remove the stoplamps switch 1 Slacken the push rod locking nut 2 Adjust the height relative to the floor A of the brake pedal by rotating the push rod 2 Tighten the push rod locking nut 2 Tightening torque 2 2 0 2 m daN FR C1 PAGE166 18...

Page 179: ...pedal a shaft Make a quarter turn to secure the stoplamps switch 1 in place IMPORTANT Do not press on the brake pedal NOTE Rotational torque for refitting the stoplamps switch 1 0 15 m daN maximum Check the gap of the stoplamps switch B 1 5 to 2 5 mm Connect the connector of the stoplamps switch 1 B3F2011D B3F2012D FR C1 PAGE166 183 2005 9 01 06 8 58 Page 173 ...

Page 180: ...engine running press on the brake pedal Measure the reserve travel D of the pedal as indicated in the diagram Reserve travel D of the brake pedal relative to the floor more than 48 mm at 490 N If it is not in conformity check the braking circuit Slacken the handbrake With the engine running press on the brake pedal Measure the reserve travel D of the pedal as indicated in the diagram Reserve trave...

Page 181: ...edal Keep the pedal pressed down and stop the engine NOTE If the reserve travel does not change after 30 seconds of keeping the pedal pressed down the braking amplifier is air tight Check the operation of the brakes Ignition switched off press several times on the brake pedal Check the reserve travel of the brake pedal Press on the brake pedal and start the engine NOTE If the pedal goes down a few...

Page 182: ...ES CHECKING THE BRAKING AMPLIFIER C circulation of air D absence of circulation of air In the event of a fault replace the vacuum hose Refit the vacuum hose B3F201AD FR C1 PAGE166 183 2005 9 01 06 8 58 Page 176 ...

Page 183: ...per arm mounting cap The windscreen wiper arm The upper seal between bonnet and scuttle panel The top scuttle panel ventilation grilles The wiper motor The scuttle panel Locate the vacuum pipe 1 between the vacuum pump and the braking amplifier Remove the screw 2 Uncouple the vacuum pipe at a B3F202ED FR C1 PAGE166 183 2005 9 01 06 8 58 Page 177 ...

Page 184: ...les The upper seal between bonnet and scuttle panel The windscreen wiper arm The windscreen wiper arm mounting cap Values to check NOTE The vacuum value should be higher than or equal to 0 850 bar Engine oil temperature Minimum Maximum time in seconds vacuuml to attain the minimum vacuum 80 C 5 C 500 mbar 4 5 800 mbar 18 If the value is outside the tolerance Check the vacuum pump directly Check th...

Page 185: ...96 N Remove the central console Turn the adjustment nut until the handbrake lever travel corresponds to the value indicated Travel of the handbrake lever 5 to 8 clicks at 196 N Action the handbrake lever 3 to 4 times and check its travel Check that the handbrake is not rubbing when it is in the released position Check that the handbrake warning lamp lights up when the handbrake is applied Standard...

Page 186: ... of a diagnostic tool Draining Disconnect the negative terminal of the battery Remove The windscreen wiper arm mounting cap The windscreen wiper arm The upper seal between bonnet and scuttle panel The top scuttle panel ventilation grilles The wiper motor The scuttle panel Drain the brake fluid reservoir 1 to the maximum if necessary use a clean syringe Disconnect the connector at a B3F202AD FR C1 ...

Page 187: ...t the negative terminal of the battery IMPERATIVE Carry out the operations that are necessary following a reconnection of the battery see corresponding operation Filling the braking circuit WARNING Use only the approved and recommended hydraulic fluids IMPERATIVE Only use new brake fluid that has not emulsified avoid any introduction of impurities into the hydraulic circuit Fill the brake fluid re...

Page 188: ...he brake fluid reservoir 1 Adjust the apparatus pressure to 2 bars For each brake circuit Couple a transparent tube on the bleed screw Submerge the other end of the tube in a clean container Open the bleed screw Wait until the brake fluid flows out without air bubbles Close the bleed screw Remove the bleed apparatus 1 Check the level of the brake fluid between the MINI level and the MAXI level Fil...

Page 189: ...he brake fluid between the MINI level and the MAXI level Fill if necessary with the the approved and recommended synthetic brake fluid Bleeding the secondary braking circuit WARNING During the bleed operations take care to maintain the level of the brake fluid in the reservoir keep it topped up NOTE The bleed apparatus 1 is still connected on the brake fluid reservoir 1 Use a diagnostic tool Selec...

Page 190: ... HFC Vehicule 384 F 450 C1 06 05 VALEO ZEXEL 80 VALEO ZEXEL DV4TD 500 DKV 06R ZXL 200PG Engines Date Refrigerant refill 30 gr Compressor Fixed Oil quantity cc Oil reference 184 AIR CONDITIONING FR C1 page184 191 2005 9 01 06 9 00 Page 184 ...

Page 191: ...ser 1 Air conditioning compressor drive plate 2 Connector 3 Seals 3 Seals 4 Condenser 5 Filtering cartridge 6 Condenser inlet 7 Condenser outlet SPECIFICATIONS OF AIR CONDITIONING CIRCUIT R 134 a C5H2021D FR C1 page184 191 2005 9 01 06 9 00 Page 185 ...

Page 192: ...heck the level of oil in the compressor when you fill the air conditioning circuit NOTE The oil level must be checked in cases of leaks in the air conditioning circuit see corresponding operation Pressostat Linear pressure sensor Filler valves Type of valves clickfit with protection cap NOTE The high pressure and low pressure valves have different diameters to avoid any error in fitting Seal O rin...

Page 193: ... located in the passenger compartment under the dashboard on RH side Remove the pollen filter 1 Refitting Clean the pollen filter housing Fit a new pollen filter Check the flow of air through the air blower operating it at its different speeds C5H202HD C5H202JD FR C1 page184 191 2005 9 01 06 9 00 Page 187 ...

Page 194: ...ltering drying cartridge Removing Remove the condenser see corresponding operation Remove the screw and the support Remove the screw and the filtering drying cartridge Remove the 4 O ring seals from the condenser C5H2006D C5H2007D FR C1 page184 191 2005 9 01 06 9 00 Page 188 ...

Page 195: ...face of the filtering drying cartridge using compressor oil Compressor oil ZXL 200PG or equivalent Fit the 4 O ring seals on the condenser Refit the filtering drying cartridge with the screw Tightening torque 1 3 0 1m daN Refit the support with the screw Refit the condenser see corresponding operation C5H2008D C5H2009D FR C1 page184 191 2005 9 01 06 9 00 Page 189 ...

Page 196: ...sure valve 11 High pressure valve 12 Pressostat a Pressure reducer outlet 1 0 1 b Pressure reducer inlet 1 0 1 c Condenser outlet 1 0 1 d Aircon compressor inlet 1 0 1 e Aircon compressor outlet 1 0 1 f Condenser inlet 1 0 1 C5H2024D FR C1 page184 191 2005 9 01 06 9 00 Page 190 ...

Page 197: ...ssure valve 11 High pressure valve 12 Pressostat a Pressure reducer outlet 1 0 1 b Pressure reducer inlet 1 0 1 c Condenser outlet 1 0 1 d Aircon compressor inlet 1 0 1 e Aircon compressor outlet 1 0 1 f Condenser inlet 1 0 1 C5H2025D FR C1 page184 191 2005 9 01 06 9 00 Page 191 ...

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CITROEN 2005 C1, User Manual

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