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CITROEN Berlingo 2003, Handbook

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CITROEN Berlingo 2003 Handbook Download Page 223

219

INJECTION

STANDARD

Private vehicles : 
< 6 seats and 
< 2.5 tonnes 
• new models 
• existing models 

Utility vehicles : 
< 3.5 tonnes 
Class 1 : 
• new models 
• existing models 
Class 2/3 : 
• new models 
• existing models 

ALL TYPES

EMISSION STANDARDS

PSA

A/S RP

Engines

Applicable

Vehicles

EURO 2

(EURO

96)

L3 

EURO 2

(EURO

96)

W3 

E.E.C. 

APPLICATIONS

NOTES

CHARACTERISTICS

Petrol 

Diesel 

Petrol 

Diesel 

Gaz

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 kg 
Class 3 : 1700 kg

With oxygen sensor and
reinforced catalytic
converter for petrol
vehicles. 
With catalytic converter
and EGR for diesel
vehicles.

With oxygen sensor and
reinforced catalytic
converter for petrol
vehicles. 
With catalytic converter
and EGR for diesel
vehicles.

01/96 

➞

01/97 

➞

01/97 

➞

10/97 

➞

01/98 

➞

10/98 

➞

CEE

95 

CEE

95 

Summary of Contents for Berlingo 2003

Page 1: ...afety 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 manufac...

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

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: ...TENTION 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...

Page 5: ...IFICATION OF VEHICLES E1AP07CD 1 Engine legislation type 2 RP organisation no 3 Chassis stamp 4 Manufacturer s name plate 5 01 02 99 Label Tyre pressures RP organisation no Paint code 6 Paint code 7 G...

Page 6: ...FX Cubic capacity cc 1124 1360 1587 Fiscal rating hp 4 6 5 5 8 Gearbox type MA 5 MB3 MA 5 MA 5 Gearbox ident plate 20 CF 03 312 20 CF 12 20 CF 11 20 CN 05 20 CN 03 SAXO All Types IDENTIFICATION OF VEH...

Page 7: ...Engine type HFX KFW Cubic capacity cc 1124 1360 Fiscal rating hp 4 6 5 Gearbox type MA 5 MB3 MA 5 Gearbox ident plate 20 CF 03 312 20 CF 12 SAXO All Types IDENTIFICATION OF VEHICLES Saxo petrol 5 door...

Page 8: ...ng hp 4 6 6 Gearbox type MA 5 MA 5 MA 5 Gearbox ident plate 20 CF 02 20 CF 03 20 CF 02 SAXO All Types IDENTIFICATION OF VEHICLES Diesel Entreprise 1 5 D 5 door 3 door Diesel 3 door Petrol 3 door 1 5 D...

Page 9: ...ate 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 Serial n...

Page 10: ...pe code FC HFXB T FR HFXB FN HFXB FC HFXB FN HFXC FC HFXC FC HFXB FC HFX5 IF IF D Engine type HFX Cubic capacity cc 1124 Fiscal rating hp 4 Gearbox type MA 5N Gearbox ident plate 20 CF 14 IDENTIFICATI...

Page 11: ...ndard L4 IFL5 Type code FC KFVE FN KFVB FN KFVE FC KFVC IF FC KFVF IF FN KFVC IF Engine type KFV Cubic capacity cc 1360 Fiscal rating hp 5 Gearbox type AL4 MA 5N AL4 MA 5N AL4 MA 5N Gearbox ident plat...

Page 12: ...xclusive Auto Emission standard IFL5 L4 L4 INF L4 Type code FN KFVF IF FC KFVB FC KFVB D FC KFVE D FN NFUB FC NFUB Engine type KFV NFU Cubic capacity cc 1360 1587 Fiscal rating hp 5 6 Gearbox type AL4...

Page 13: ...CLES DIESEL 1 4 HDi X SX Emission standard L4 Type code FC 8HBXB T FN 8HXB FC 8HXB FC 8HXB MOD FC 8HXK FR 8HXB Engine type 8HX Cubic capacity cc 1398 Fiscal rating hp 4 Gearbox type MA 5O Gearbox iden...

Page 14: ...WB FN 8HVB FC 8HVB Engine type 8HW 8HV Cubic capacity cc 1398 Fiscal rating hp 4 5 Gearbox type MA 50 BE4 5 Gearbox ident plate 20 CN 33 20 CN 36 20 DM 25 20 DM 26 IDENTIFICATION OF VEHICLES DIESEL S...

Page 15: ...xclusive SX SX Exclusive 1 4 HDi 16V Emission standard L4 Type code FN 8HYB FC 8HYC FC 8HYB MOD FC 8HYB T FC 8HYK FR 8HYB Engine type 8HY Cubic capacity cc 1398 Fiscal rating hp 5 Gearbox type BE4 5 G...

Page 16: ...old 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 through the windscreen F En...

Page 17: ...IF Engine 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 CF 13 20 CN 28 20 TP 49 20 CN 28 20 TP 49 XSARA All Types IDENTIFICAT...

Page 18: ...ating hp 8 11 5 6 Gearbox type BE4 5 AL4 BE3 5 BE4 5 AL4 Gearbox ident plate 20 DL 40 20 DL 41 20 DL 42 20 DM 10 20 TP 48 20 DM 03 1 20 TP 47 20 TE 47 20 DM 05 1 20 DM 07 1 20 DM 11 1 IDENTIFICATION O...

Page 19: ...ndard L4 Type code N0 8HZB N0 8HZB T N3 8HZB Engine type 8HZ Cubic capacity cc 1398 Fiscal rating hp 4 Gearbox type MA 5 Gearbox ident plate IDENTIFICATION OF VEHICLES Saloon diesel 3 door 1 4 HDi Ent...

Page 20: ...Y RHY Cubic capacity cc 1360 1868 1997 Fiscal rating hp 8 7 6 Gearbox type MA 5 BE4 5 Gearbox ident plate 20 CF 13 20 DL 41 20 DL 42 IDENTIFICATION OF VEHICLES 1 T The vehicle cannot be converted back...

Page 21: ...N1 NFUU N1 NFUB Engine type KFW NFU Cubic capacity cc 1360 1587 Fiscal rating hp 5 7 Gearbox type MA 5 MA 5 AL4 MA 5 Gearbox ident plate 20 CN 30 20 CF 13 20 CN 29 20 TP 49 20 CN 28 IDENTIFICATION OF...

Page 22: ...cc 1587 1998 Fiscal rating hp 7 11 Gearbox type AL4 MA 5 AL4 BE4 5 AL4 Gearbox ident plate 20 TP 49 20 CN 28 20 TP 49 20 DL 40 20 DM 03 1 20 TP 47 XSARA All Types IDENTIFICATION OF VEHICLES 1 Right ha...

Page 23: ...68 1997 Fiscal rating hp 5 5 6 Gearbox type BE4 5 BE4 5 AL4 Gearbox ident plate 20 DL 41 20 DM 05 1 20 DL 42 20 DM 07 1 20DM 10 20 DM 11 1 20 TP 48 XSARA All Types IDENTIFICATION OF VEHICLES Saloons d...

Page 24: ...standard L4 Type code N1 8HZB N1 8HZB T Engine type 8HZ Cubic capacity cc 1398 Fiscal rating hp 4 Gearbox type MA 5 Gearbox ident plate IDENTIFICATION OF VEHICLES Saloons diesel 5 door 1 4 HDi Entrepr...

Page 25: ...type WJY RHY Cubic capacity cc 1868 1997 Fiscal rating hp 7 5 Gearbox type BE4 5 BE4 5 Gearbox ident plate 20 DL 41 20 DL 42 IDENTIFICATION OF VEHICLES 1 T The vehicle cannot be converted back into a...

Page 26: ...ngine type KFW NFU Cubic capacity cc 1360 1587 Fiscal rating hp 5 7 Gearbox type MA 5 MA 5 AL4 MA 5 AL4 Gearbox ident plate 20 CN 21 20 CN 29 20 CN 28 20 TP 49 20 CN 28 20 TP 49 IDENTIFICATION OF VEHI...

Page 27: ...apacity cc 1998 1868 Fiscal rating hp 11 5 Gearbox type BE4 5 AL4 BE4 5 Gearbox ident plate 20 DL 40 20 DM 03 1 20 DL 41 20 DM 05 1 IDENTIFICATION OF VEHICLES Diesel estate Petrol estate 1 9 D 2 0i 16...

Page 28: ...RHY RHZ Cubic capacity cc 1997 Fiscal rating hp 5 6 Gearbox type BE4 5 AL4 Gearbox ident plate 20 DL 42 20 DM 07 1 20 DM 10 20 DM 11 1 20 TP 48 IDENTIFICATION OF VEHICLES Diesel estate 2 0 HDi X SX E...

Page 29: ...ard L4 Type code N2 8HZB N2 8HZB T N4 8HZB Engine type 8HZ Cubic capacity cc 1398 Fiscal rating hp 4 Gearbox type MA 5 Gearbox ident plate IDENTIFICATION OF VEHICLES Diesel saloon and estate 1 4 HDi E...

Page 30: ...bic capacity cc 1360 1868 1997 Fiscal rating hp 8 7 6 Gearbox type MA 5 BE4 5 BE4 5 Gearbox ident plate 20 CN 21 20 DL 41 20 DL 42 IDENTIFICATION OF VEHICLES 1 T The vehicle cannot be converted back i...

Page 31: ...tom of 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 inne...

Page 32: ...Cubic capacity cc 1587 1749 1998 1997 Fiscal rating hp 6 7 8 5 Gearbox type BE4 5 J BE4 5 V AL4 BE4 5 L Gearbox ident plate 20 DL 66 20 DL 68 20 TS 02 20 DL 65 IDENTIFICATION OF VEHICLES Diesel Petro...

Page 33: ...LES BERLINGO All Types E1AP0AMD 11 2002 A Chassis stamp cold stamp B Manufacturer s vehicle plate C Label RPO No Paint colour code Tyre pressures D Gearbox ident reference Factory serial no E Engine l...

Page 34: ...GJ K6D5G GJ KFWB GJ KFWC IF Engine type HFX KFW Cubic capacity cc 1124 1360 Fiscal rating hp 5 6 Gearbox type MA 5S MA 5 Gearbox ident plate 20 CD 43 20 CN 13 BERLINGO All Types IDENTIFICATION OF VEHI...

Page 35: ...c 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 11 2002 1 6i 16v Multispace X SX Multispace 1 4i BERL...

Page 36: ...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 IDENTIFICATION OF VEHICLES Berlingo diesel 5 seater 11 2002 2 0 HDi...

Page 37: ...pped 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 filling...

Page 38: ...tic gearbox after drainage Hydraulic or brake circuit Cooling system Fuel tank capacity HFX KFW NFX NFT VJX 3 3 5 4 5 1 5 1 5 2 2 2 4 5 2 With ABS 0 45 Without ABS 0 36 6 1 45 SAXO All Types CAPACITIE...

Page 39: ...box 2 2 1 9 Automatic gearbox 1 After oil change Braking circuit 0 7 Litre version with front calipers 48 rear drums 0 8 Litre version with front calipers 54 rear discs Cooling system 7 5 7 5 6 Fuel t...

Page 40: ...5 1 7 1 1 1 6 1 4 2 1 9 1 9 2 1 8 6 6 8 3 3 3 5 3 With ABS 0 50 Without ABS 0 55 7 8 5 6 5 1 5 7 9 11 1 54 XSARA All Types CAPACITIES in litres Ecological oil filter capacity 0 15 litre Petrol Diesel...

Page 41: ...ke circuit Cooling system Fuel tank capacity NFV 6FZ RFN RHY 3 4 25 4 5 1 5 1 7 1 4 1 8 1 8 6 3 0 58 litres 5 8 1 et 2 6 5 1 et 2 11 1 et 2 55 60 XSARA PICASSO All Types CAPACITIES in litres Diesel Pe...

Page 42: ...x 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 2 All Types CAPACITIES in litres D...

Page 43: ...g 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 synthetic oil 7000 10W40 on HDi and HDi FAP vehic...

Page 44: ...oil norms Current norms The classification of these engine oils is established by the following recognised organisations S A E Society of Automotive Engineers API American Petroleum Institute ACEA As...

Page 45: ...er 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 for all engines also permitting be...

Page 46: ...ox 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 DV4 TED4 CITRO N C3 1 4 HDi 16V EW...

Page 47: ...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 to...

Page 48: ...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 49: ...50 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 HDi 16...

Page 50: ...46 GENERAL ALL TYPES LUBRICANTS TOTAL recommended oils Selection of TOTAL engine oils to be used according to the climatic conditions in the country where the vehicle is marketed E4AP006D...

Page 51: ...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 900 5W 40 9000 5W 30 7000 10 W 40 7000 10 W 4...

Page 52: ...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 53: ...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 54: ...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 55: ...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 56: ...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 57: ...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 58: ...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 59: ...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 60: ...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 61: ...ls 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 for diesel engines...

Page 62: ...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 63: ...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 64: ...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 65: ...ARNING 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 N...

Page 66: ...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 67: ...ngine 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 WORK BELOW THESE VALUE...

Page 68: ...ity cc Bore Stroke Compression ratio Power ISO or EEC KW rpm Power DIN HP rpm Torque ISO or EEC m daN rpm Saxo C3 Saxo Xsara Saxo Picasso L4 IFL5 L4INF K L4 K L4 IFL5 L4 HFX KFW NFT NFV 1124 1360 1587...

Page 69: ...pression ratio Power ISO or EEC KW rpm Power DIN HP rpm Torque ISO or EEC m daN rpm Saxo C3 Xsara Picasso Xsara Picasso Xsara L4 K L4 IFL5 L4 IFL5 L4 IFL5 IFL5 L4 NFX NFU 6FZ RFN RFS 1587 1749 1197 19...

Page 70: ...re Stroke Compression ratio Power ISO or EEC KW rpm Power DIN HP rpm Torque ISO or EEC m daN rpm Saxo C3 Xsara Xsara Picasso Xsara L4 L4 IFL5 VJX 8HX 8HW 8HV 8HY 8HZ RHY RHZ 1527 1398 1997 77 82 73 5...

Page 71: ...cting rod screws Flywheel screw Crankshaft pinion screw Camshaft pulley screw Camshaft hubs Camshaft hub screw CYLINDER HEAD mm TIGHTENING TORQUES m daN ALL TYPES Pre tightening Angular tightening Tig...

Page 72: ...ws Connecting rod screws CYLINDER HEAD mm TIGHTENING TORQUES m daN ALL TYPES Pre tightening Slackening Tightening Angular tightening Tightening Pre tightening Slackening Tightening Angular tightening...

Page 73: ...SPECIAL FEATURES TIGHTENING TORQUES m daN A HFX KFV B NFU RH engine support 1 4 5 0 4 2 6 1 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 B1...

Page 74: ...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 75: ...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 76: ...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 77: ...ning 1 Slackening 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...

Page 78: ...ngs of camshaft 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 Tightening 70...

Page 79: ...mon injection rail on engine block 2 0 2 Unions on fuel high pressure common injection rail Diesel injection pump on support 2 25 0 2 Union on diesel injection Diesel injection pump pulley 5 0 5 Union...

Page 80: ...gines 8HY 8HV 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 81: ...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 bea...

Page 82: ...nt 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 rail...

Page 83: ...79 ENGINE SPECIAL FEATURES TIGHTENING TORQUES m daN Engines RFS VJX SAXO VJX Pre tighten 0 4 Tighten to 0 7 XSARA RFS Pre tighten 0 5 Tighten to 1 TUD XU B1DP03BC B1DP01YD...

Page 84: ...entification marks Notch on cylinder head gasket HFX KFW NFT NFV NFX NFU VJX 1 2 3 4 A B D A B D A B D A B D C R 0 Standard gasket 1 Repair gasket 0 With asbestos 1 Without asbestos 0 0 1 1 0 1 0 1 1...

Page 85: ...reads and under the heads of the cylinder head bolts Use engine oil or Molykote G Rapid Plus Pre tightening 2 Angular tightening 260 5 Pre tightening 2 Angular tightening 240 5 Pre tightening 4 Angula...

Page 86: ...NFU Identification of the cylinder head gasket Engines HFX KFV NFU Thicknesses Standard 1 2 0 1 0 66 0 04 Thickness repair 1 4 0 1 Thickness ref 2 1 4 References 1 2 3 4 Type of engine A B D Suppliers...

Page 87: ...r tightening 240 5 in the order 1 to 10 Tighten to 2 0 2 Angular tightening 260 5 in the order 1 to 10 NOTE Oil the threads and under the heads of the cylinder head bolts Use engine oil or Molykote G...

Page 88: ...tandproud mm Thicknesses mm No of notches at d No of notches at e 0 675 to 0 725 1 25 1 0 726 to 0 775 1 30 2 8HY 8HV ELRING 0 776 to 0 825 1 35 3 2 0 826 to 0 875 1 40 4 0 876 to 0 983 1 45 5 B1DP1CM...

Page 89: ...tandproud mm Thicknesses 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 00 821 to 0 870 1 40 4 0 871 to 0 977 1 45 5 B1DP1C...

Page 90: ...to 10 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...

Page 91: ...entification of the cylinder head gasket 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 Marking zone d 1 3 Marking d Marki...

Page 92: ...the cylinder head bolts Use engine oil or Molykote G Rapid Plus Pre tightening 1 5 0 2 Tightening 5 0 2 Loosening 360 1 turn Tightening 2 0 2 Angular tightening 285 5 B1DP16FC B1DP05BC 6FZ 6FZ X 147...

Page 93: ...EAD continued Engine RFN Identification of the 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 Marking zone...

Page 94: ...the cylinder head bolts Use engine oil or Molykote G Rapid Plus Pre tightening 1 5 0 2 Tightening 5 0 2 Loosening 360 1 turn Tightening 2 0 2 Angular tightening 285 5 B1DP16FC B1DP05BC RFN RFN X 147...

Page 95: ...INDER HEAD XSARA Engine RFS Identification of the 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 B1BP00...

Page 96: ...h Note Oil the threads and under the heads of the cylinder head bolts Use engine oil or Molykote G Rapid Plus Pre tightening 3 5 Slackening NON Tightening 7 Angular tightening 160 B1DP13PC B1DP05BC RF...

Page 97: ...mber of holes at A Thickness mm 0 04 Engine type Piston stand proud 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 Engine identification B...

Page 98: ...the cylinder head gasket Number of notches at A Thickness mm Engine type Piston stand proud 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...

Page 99: ...and under the heads of the cylinder head 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 B1DP15E...

Page 100: ...96 ENGINE Tools ALL TYPES BELT TENSION SEEM UNITS CORRESPONDENCE TABLE 4099 T C TRONIC 105 4122 T C TRONIC 105 5...

Page 101: ...X X 101 to 102 101 to 102 101 to 102 X X X X 105 106 110 108 to 109 X X X 103 to 104 110 97 ENGINE 97 ALL TYPES AUXILIARY EQUIPMENT DRIVE BELT TU 3 JP 5 J4 JP4 J4 J4RS 7 10 1 XU EW Engine type SAXO C...

Page 102: ...E BELT TU 5 B 4 TED4 TD 8 B 10 ATED TD DV DW Engine type SAXO C3 XSARA XSARA PICASSO See pages See pages See pages See pages VJX 8HX 8HW 8HZ 8HV 8HY WJY RHY RHZ X 107 X X X X 117 to 118 119 X X X X 11...

Page 103: ...instrument 4122 T C TRONIC 105 5 WARNING If using tool 4099 T C TRONIC 105 refer to the correspondence table on page 90 ESSENTIAL Before refitting the auxiliary equipment drive belt check that 1 The...

Page 104: ...tool 4122 T Tighten the tensioning screw 3 to obtain 55 3 SEEM units ighten the screws 2 and 1 Remove the tool 4122 T Fit the tool 4122 T Tighten the tensioning screw 5 to obtain 120 3 SEEM units Tigh...

Page 105: ...le without 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 unit s SEEM Ti...

Page 106: ...t by acting 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 Pl...

Page 107: ...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 108: ...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 109: ...d belt 75 SEEM units AUXILIARY EQUIPMENT DRIVE BELT Alternator Power assisted steering Power steering and air con With air conditioning 1 Belt tension measuring instru ment 4122 T Tension the belt usi...

Page 110: ...Reused belt 86 5 3 5 SEEM units 3 Tensioner roller fixing screw 4 Tensioning screw CNew belt 120 SEEM units Reused belt 86 5 3 5 SEEM units NOTE Removal of the tensioner roller makes it necessary to...

Page 111: ...Tighten the screws 6 to 2 5 m daN Run the engine for 10 min Check the tension 3 Roller support fixing screw 5 Tensioning screw Pre tension the belt 4 to 120 SEEM units Rotate the crankshaft by 3 turns...

Page 112: ...er 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 tensioner r...

Page 113: ...ighten 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 crank...

Page 114: ...e 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 Ref...

Page 115: ...g 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 116: ...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 2...

Page 117: ...ithout 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 tensioner...

Page 118: ...knob 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 tool 1 T...

Page 119: ...oller 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 th...

Page 120: ...LT 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 Remo...

Page 121: ...y negative 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 o...

Page 122: ...the tensioner 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 b...

Page 123: ...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 124: ...MOVAL 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 tensio...

Page 125: ...e 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 rol...

Page 126: ...t 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 com...

Page 127: ...elt 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 rol...

Page 128: ...TTING THE VALVE TIMING TU 3 JP 5 J4 JP4 J4 J4RS 7 10 1 XU EW HFX KFW KFV NFT NFV NFX NFU 6FZ RFN RFS X X X X 126 to 128 126 to 128 139 to 142 X X X 129 to 138 129 to 138 129 to 138 X X X X 1 2003 126...

Page 129: ...KING AND SETTING THE VALVE TIMING TUD 5 B 4 TED4 TD 8 B 10 ATED TD DV DW ALL TYPES VJX 8HX 8HW 8HZ 8HV 8HY WJY RHY RHZ X 143 to 145 X X X X 146 to 153 154 to 162 X X X X 1 N RPO 9127 192 to 196 146 to...

Page 130: ...he tool 2 SETTING THE VALVE TIMING NOTE Remove the spark plugs to allow the crankshaft to rotate more freely Rotate the engine by the crankshaft screw 1 Peg the camshaft gearwheel Peg the flywheel Loo...

Page 131: ...pulley water pump pulley tensioner roller The tool 5 Ensure it is fitted in the right direction in relation to the timing Bring the tensioner roller into contact with the belt Tighten the nut 2 PRE TE...

Page 132: ...amshaft pulley water pump pulley tensioner roller The tool 5 Ensure it is fitted in the right direction in relation to the timing Bring the tensioner roller into contact with the belt Tighten the nut...

Page 133: ...nsioner 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 Di...

Page 134: ...e Remove 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...

Page 135: ...H wheel 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 Engine HFX KFV Turn t...

Page 136: ...ed Engine 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 tensio...

Page 137: ...E TIMING 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...

Page 138: ...ol 4 with 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 tim...

Page 139: ...NG Respect 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...

Page 140: ...on of the 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 Tensio...

Page 141: ...to position f to tension the belt to the maximum of the inter val 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 c...

Page 142: ...ition a 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...

Page 143: ...ating 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 ca...

Page 144: ...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 145: ...d the belt in this position and engage it over the water pump pinion and the tensioner roller Fit the tool 1 on the belt strip e Rotate the roller 2 using tool 5 in an anti clockwise direction to obta...

Page 146: ...ere 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...

Page 147: ...6 T CHECKING THE VALVE TIMING Peg the flywheel the injection pump pulley the camshaft pulley SETTING THE VALVE TIMING Peg the flywheel the injection pump pulley the camshaft pulley Loosen the tensione...

Page 148: ...p and camshaft pulleys they should be turned in the opposite direction of rotation so as to engage the nearest tooth Pre tension belt strip slightly tightened NOTE Check that the pulley fixings are no...

Page 149: ...and 3 by 360 gently tighten the screws 1 and 3 by hand Set a final tension of 55 5 SEEM units Tighten the tensioner roller and the screws 1 and 3 to 2 3 m daN lock the pulleys using tool 6016 T Remov...

Page 150: ...screws 1 and 3 by 360 gently tighten the screws 1 and 3 by hand Set a final tension of 55 5 SEEM units Tighten the tensioner roller and the screws 1 and 3 to 2 3 m daN lock the pulleys using tool 6016...

Page 151: ...tool 3 Rotate the engine by means of the crankshaft pinion screw 2 clockwise to bring it to the pegging position Position the tool 4 Peg the crankshaft pinion 1 using tool 5 Peg the high pressure pum...

Page 152: ...st line 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 engin...

Page 153: ...crew 2 clockwise 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 th...

Page 154: ...s is not 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 s...

Page 155: ...ing continued 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 t...

Page 156: ...ten to 3 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...

Page 157: ...t tighten 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...

Page 158: ...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 159: ...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 160: ...h 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 IMPER...

Page 161: ...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 162: ...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 163: ...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 164: ...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 165: ...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 166: ...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 167: ...the camshaft pulleys using tools 1 NOTE The pegs 1 must go in without effort WARNING If the pegs do not engage without effort restart the fitting and tensioning of the timing belt see below Setting th...

Page 168: ...key at a Position the index c in its maximum setting at d IMPERATIVE The index c must stand proud of the notch f by an angular value of 10 If it does not replace the tensioner roller 6 or the timing...

Page 169: ...otation IMPERATIVE No pressure or outside action must be brought to bear on the timing belt Peg the inlet camshaft pulley using the tool 1 Checks Timing belt tension IMPERATIVE Check the position of t...

Page 170: ...ol 5 Tighten screw 13 to 4 0 4 m daN then angular tighten 53 4 fitting with steel washer gold colour 40 4 fitting with sintered washer metallic colour using tool 4 Remove tools 1 2 and 5 Refit The low...

Page 171: ...Removing Disconnect the battery Remove The under engine shield The accessories drive belt See corresponding operation Move aside The fuel delivery pipe The canister purge electrovalve The expansion c...

Page 172: ...ed Peg The camshafts using tool 2 The crankshaft using tool 1 Slacken screw 7 holding tool 4 Using the hexagonal key C turn the eccentric hub 8 of the tensioner roller 9 clockwise to detension the bel...

Page 173: ...olant pump 12 turn freely no tight spot If replacing the roller 11 tighten the fixing to 3 5 0 3 m daN Engage the belt on the crankshaft pinion 13 respecting its direction of fitting Immobilise the be...

Page 174: ...n if the tool 4 is in position NOTE This operation enables you to place the index 10 in the nominal position E Tighten the screw 7 to 2 0 2 m daN holding the roller with the aid of the hexagonal key C...

Page 175: ...ble reposition the flange 17 IMPERATIVE This operation guarantees the setting of the timing for subsequent operations Slacken the screw 16 so as to free the pinion 17 of the crankshaft Bring the flang...

Page 176: ...The accessories drive pulley Screws 4 tighten to 2 1 0 2 m daN The timing cover 5 The torque reaction rod 3 Screws 1 and 2 tighten to 4 5 0 4 m daN Refit the accessories drive belt See corresponding...

Page 177: ...ew fixing the flange 2 on the crankshaft a Integral keyway b Keyway slot The timing belt drive pinion 1 is separate from the flange 2 With the fixing screw 5 of the flange 2 not slackened the pinion 1...

Page 178: ...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 auto matic gearbox The pegging hole on the cylinder bloc...

Page 179: ...069 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 Disconnect the battery negativ...

Page 180: ...inion screw to bring it to the pegging position Peg the crankshaft using tool 2 Peg the camshaft pulleys using tool 3 WARNING If the pegs go in only with difficulty repeat the operation for fitting an...

Page 181: ...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 182: ...and 6 using tool 1 Remove The screw 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 ca...

Page 183: ...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 184: ...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 185: ...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 186: ...6 Toothed 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...

Page 187: ...he 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 tool 2 Lock the flywhee...

Page 188: ...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 189: ...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 190: ...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 and...

Page 191: ...the flywheel 0 188 F 5 Belt retaining clip 0 188 K 6 Square drive for adjusting the tension 0 188 J 7 Belt tension measuring instrument 4122 T 8 Toothed sector for locking the flywheel 6016 T Checkin...

Page 192: ...t tightening it Coat the threads with E6 Tighten the screw 3 to 4 m daN and finish by carrying out an angular tightening of 60 Remove the tool 4 Retighten screws 4 and 5 by hand Turn the pinions 6 and...

Page 193: ...in relation to the pinions must not exceed half a tooth Fit the tool 7 to the belt strap at a Turn the roller 9 anti clockwise using tool 6 to obtain 106 2 SEEM units Check that pinions 6 and 2 are n...

Page 194: ...irection of rotation Peg The hub 1 using tool 1 The pinion 2 using tool 2 The flywheel using the tool 3 Loosen The screws 4 and 5 The roller 9 Retighten screws 4 and 5 by hand Fit the tool 7 to the be...

Page 195: ...daN Remove the tool 7 Fit the tool 7 to the belt strap at a The tensioning value should be between 42 4 SEEM units ESSENTIAL If the value obtained is outside the set limits repeat the tensioning oper...

Page 196: ...om below the vehicle The camshaft tool 5 WARNING On removing the screws 6 7 9 and 5 from the timing cover refit screw 5 equipped with a spacer thickness 17 mm Tighten to 1 5 0 1m daN Screw 5 is one of...

Page 197: ...Checks IMPERATIVE Just before refitting carry out the checks below Check that the rollers 20 23 and the coolant pump turn freely without play or tightness there are no traces of oil on camshaft or cr...

Page 198: ...bottom of the buttonhole Refit the belt on the crankshaft 25 in the following order using the tool 4 to keep the belt tight at a Guide roller 23 Fuel high pressure pump pinion 26 Camshaft pinion 24 C...

Page 199: ...ion 24 to check that the screws are not against the end of the buttonhole Tighten the screws 21 to 2 m daN Remove tools 1 2 3 and 5 Rotate the crankshaft 8 times normal direction of rotation Fit the t...

Page 200: ...ls 1 3 and 5 Rotate the crankshaft 2 times normal direction of rotation Fit the tool 3 WARNING Should it be impossible to peg the camshaft check that the offset between the camshaft pinion hole and th...

Page 201: ...quires 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 increased wid...

Page 202: ...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 The Rep...

Page 203: ...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 the front RH wheel bolts Raise an...

Page 204: ...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 205: ...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 206: ...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 207: ...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 208: ...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 209: ...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 210: ...206 ENGINE RFS SPECIAL FEATURES OF THE TIMING B1EP122C Camshaft hub identification Engine RFS Inlet Exhaust Hubs a engraving B b paint marking BLUE XSARA...

Page 211: ...4 16V HDi 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 Exhaust Rocking Valves fully open Adjust 1 3 4 2 3 4 4...

Page 212: ...4 90 3 4000 4000 DV4TD DV4TED4 DW8 DW10TD TUD all Types 1 5 D 1 4 HDi RHZ RHY WJY 8HY 8HV 8HW 8HX VJX 90 80 4 5 1 3 1000 4000 4 4000 1 4 16V HDi 1 9 D 4 5 5 90 80 1 1 i 1 4 i 1 6 i 1 6 i 16V 2 0 i 16...

Page 213: ...S 1 1 i 1 4 i 1 6 i 1 6i 16V 1 8i 2 0i 16V TUD5 DV4TD DV4TED4 DW8 DW10 VJX 8HX 8HW 8HZ 8HV 8HY WJY RHY RHZ 1 5 D 1 4 HDi 1 4 16V HDi 1 9D 2 0 HDi Specification Diameter mm Height mm LS 923 1109 T1 76...

Page 214: ...r adaptor 2 4222 T Picasso and 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 215: ...NFU L4 BOSCH M 7 4 4 1 4 i KFW IFL5 L4 SAGEM S2000 850 1 6i NFU L4 BOSCH M 7 4 4 2 0 i RFN L4 MAGNETTI MARELLI MM 48 P2 2 0 i 16V RFS L3 M MARELLI 1AP10 1 6i NFV L4 BOSCH M7 4 4 850 1 8i 6FZ L4 SAGEM...

Page 216: ...ssure bars 3 Overspeed cut off rpm Injector resistive value ohms Engine coolant temperature sensor resistive value ohms Idling actuator or stepper motor resistive value ohms HFX IFL5 L4 L4 L4 L4 1 1 i...

Page 217: ...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 KFW NFU L4 IFL5 L4 L4 1...

Page 218: ...erspeed cut off rpm Injector resistive value ohms Engine coolant temperature sensor resistive value ohms Idling actuator or stepper motor resistive value ohms KFW IFL5 L4 IFL5 L4 IFL5 L4 K L4 L3 IFL5...

Page 219: ...5 for vehicles 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...

Page 220: ...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 89 216 INJECTION Utility vehic...

Page 221: ...Diesel Private vehicles certain non EEC European countries certain Export countries Private vehicles certain non EEC European countries certain Export countries Private vehicles certain Export countri...

Page 222: ...sel Private vehicles certain non EEC European countries certain Export countries Private vehicles certain non EEC European countries certain Export countries Private vehicles certain non EEC European...

Page 223: ...ARACTERISTICS Petrol Diesel Petrol Diesel Gaz 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 k...

Page 224: ...trol 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 Directive 99 102 EU...

Page 225: ...Diesel Gaz Petrol Gaz 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 classes...

Page 226: ...e 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 carried ou...

Page 227: ...lean the apertures 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...

Page 228: ...224 INJECTION BOSCH INJECTION PUMP SPECIFICATIONS PUMP TYPE REFERENCE Emission standards Equipement L3 L4 Transponder SAXO SAXO 5B TUD VJX 539 The fuel high pressure pump is driven by the timing belt...

Page 229: ...n Time cylinder N 4 Dynamic timing checking at idle Reference Injector Injector holder injector Colour code Injector needle lift pressure Bar Adjustments rpm Max speed Fast idling Anti stall Idling Un...

Page 230: ...7 T Camshaft peg 4527 T S2 Checks Peg the flywheel Visually check the pegging of the camshaft and injection pump pulleys or check using the tools 4527 T S1 and 4527 T S2 Setting the injection pump Peg...

Page 231: ...hat the lever 3 is up against the screw stop 2 If not slightly tension the cable 4 using the cable clamp 1 Finish tensioning with the sheath tensioner 5 Engine hot Ensure that the cable 4 is slack Che...

Page 232: ...stop screw 6 If not modify the position of the spring clip 7 Check that at idle the lever 10 is against its stop 9 Preliminary conditions Engine hot The cooling fan is engaged twice Fast idle control...

Page 233: ...tput adjustment screw 9 Turn the residual output adjustment screw 9 to obtain an engine speed of 835 40 rpm Remove the shim 1 CHECKING THE ENGINE DECELERATION Move the throttle lever 10 to obtain an e...

Page 234: ...ch time they are removed NOTE Fitting parts of diffe rent makes is PROHIBITED WARNING Ensure that the fire seal washer 2 is fitted the right way round Tightening of the injector holder on the cylinder...

Page 235: ...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 236: ...not 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 ma...

Page 237: ...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 238: ...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 239: ...s 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 pr...

Page 240: ...ink 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...

Page 241: ...pper integrated air inlet distributor The upper integrated air inlet system is composed of the following elements 1 Air filter cover 2 Air filter chamber 3 Flowmeter 4 Turbocharger inlet 5 Resonator 6...

Page 242: ...ributor The lower integrated air inlet system is composed of the following elements 7 Top EGR pipe 8 Inlet manifold 9 Diesel fuel filter with reheater and water detector according to country 10 Diesel...

Page 243: ...IL TRAP FIXING SCREW Diesel fuel filter support fixing screw Diesel fuel filter support fixing screw Integrated air distributor fixing screw 1 8 9 10 11 12 13 1 0 1 1 0 1 0 5 1 0 1 13 14 15 16 17 0 5...

Page 244: ...CUIT SPECIFICATION 1 Air filter assembly 2 Oil trap 3 Turbocharger resonance attenuator 4 Turbocharger 5 Air air exchanger 6 Air distributor Air filter Ref MARK 4 Turbocharger Ref RHF 3V Supplier IHI...

Page 245: ...SPECIFICATION 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 B1H...

Page 246: ...lve 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 t...

Page 247: ...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 vehicl...

Page 248: ...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 vehicl...

Page 249: ...245 INJECTION SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP PUMP TYPE REFERENCE Emission standards Equipment L3 XSARA 8B DW WJY DWLP 12 R8448 B 371 B Transponder XSARA...

Page 250: ...ic timing checking at idle Reference Injector Injector holder injector Colour code Injector needle lift pressure Bar Adjustments rpm Max speed Fast idling Anti stall Idling Unladen rpm Laden rpm WJY D...

Page 251: ...injection pump with hole for checking the setting The setting of the diesel injection pump is done with the aid of the following tools A peg placed at a A peg and a dial gauge placed in the checking h...

Page 252: ...eed 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 to t...

Page 253: ...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 254: ...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 255: ...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 256: ...are to be replaced each time they are removed NOTE Fitting parts of different makes is PROHIBITED WARNING Ensure that the fire seal washer 3 is fitted the right way round Tighten the injector holder o...

Page 257: ...SCH and SIEMENS Engines 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 exc...

Page 258: ...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 259: ...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 260: ...el 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...

Page 261: ...distribution valve locked shut Check diesel injector return flow Table Uncouple the diesel injector return pipe Fuel supply pressure Fuel return pressure Checks Between 3 and 3 5 Bar 0 7 0 2 Bar Check...

Page 262: ...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 w...

Page 263: ...e the 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 en...

Page 264: ...tion 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 th...

Page 265: ...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 266: ...KFW 1 6i 16v NFU 2 0i 16v RFN 2 0i 16v RFS 16i NFV 1 8i 16v 6FZ 2 0i 16V RFN 262 SPARKING PLUGS ALL TYPES Vehicles Models BOSCH Engine type CHAMPION SAGEM Electrode gap setting Tightening torque SAXO...

Page 267: ...ST SD 1 10 ST 4 Kph Example 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 speedo...

Page 268: ...Engine type Gearbox Make Mechanism Type Clutch disc Ext Int lining Disc lining type 1 1i 1 4i 1 6i 16V 1 4 HDi 1 4 HDi 16V HFX KFV NFU 8HX 8HW 8HV 8HY MA 5 BE4 5 VALEO LUK 180 CP0 3400 200 P 3900 230...

Page 269: ...joint 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 Tig...

Page 270: ...DRIVESHAFTS CLUTCH SPECIFICATIONS 1 4i 1 6i 1 6i 16V 1 8i 16V 2 0i 16V 1 9 D 1 4 HDi 2 0 HDi 180CPO 3400 180 XJF 73 C 200X D95 11A12X 230 DNG 4700 215 FD 95 215 F D 93 22 BX 228 228D 200 CPR 3800 230...

Page 271: ...NGO Engine type HFX KFW NFU WJY RHY Gearbox MA 5 BE4 5 Make VALEO LUK M canisme Type 200 CPX 3850 200 P 4700 235 T 5700 Clutch disc 200 XS L73C 11RX 200 XSL 73 200 228 Ext Int lining 200 137 228 155 D...

Page 272: ...ustable steering wheels should be put into the low position Record the measurement X between positions L1 pedal at rest and L2 pedal fully depressed Measurement X should be Pedal travel Adjustments If...

Page 273: ...3 to the pedal Fit the end piece 4 to the bulkhead G6 grease Clip the end piece 5 to the gearbox Refit the cable to the lever 1 Depress the clutch cable several times to set the assembly in place Chec...

Page 274: ...clip 3 to the pedal Fit the end piece 4 to the bulkhead G6 Grease Clip the end piece 5 to the gearbox Refit the cable to the lever 1 Depress the clutch cable several times to set the assembly in plac...

Page 275: ...t until there is a free play of 2 1 mm Tighten the screw 7 and the nut 6 Check that the outer cable slides freely at rest the pedal is against its upper stop A the outer cable length should be variabl...

Page 276: ...sion of the outer cable DESCRIPTION 1 Metallic cable crimped on both ends 5 Tensioning spring ensuring the maximum length of the cable sleeve 2 Outer cable or telescopic duct 6 Wear take up device 3 O...

Page 277: ...d the attaching end piece 4 leaves the sleeve 1 which moves back The rollers pushed by spring 5 jam the system The cable behaves like a conventional cable The pedal returns to rest on its upper stop A...

Page 278: ...9x17 GEARBOX AND TYRE SPECIFICATIONS Engine type Tyres Rolling circumference Speedometer ratio Gearbox type Gearbox ident plate Reduction box torque Auto 1 1i 1 4i 1 6i 1 6i 16V Petrol HFX KFW NFT NFX...

Page 279: ...ND TYRE SPECIFICATIONS 1 6i 16V Auto 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 1 804 m 185 60 R15 1 828 m 165 70 R 14 1 804 m 185 60 R...

Page 280: ...03 WJZ WJY 20 DM 05 8HZ 20 DM 53 RHY 20 DM 07 RHZ 20 DM 11 Gearbox type Gearbox ident plate Reduction box torque 1 4i 1 6i 16V Auto Auto 2 0i 16V KFW NFU RFN RFS 195 55 R15 1 815 m MA 5 AL4 BE4 5 AL4...

Page 281: ...7 21x73 19x72 22x18 24x20 22x18 GEARBOX AND TYRE SPECIFICATIONS Engine type Tyres Rolling circumference Speedometer ratio Gearbox type Gearbox ident plate Reduction box torque 1 6i 1 8i 16 V 2 0i 16V...

Page 282: ...278 CLUTCH GEARBOX DRIVESHAFTS GEARBOX MA 5 Engines HFX KFW NFT NFX NFU VJX 8HX 8HW B2CP34HP B2CP20FC B2CP20GC SAXO XSARA Filler screw Drain screw Vent plug...

Page 283: ...ROLS MA 5 Engines HFX KFW NFT NFX NFU VJX 8HX 8HW 1 Gear lever 2 Gear control rod 3 Gear control rod 4 Gear selection rod 5 Gear selection rod 6 Knuckle joint 7 Fixed point on the gearbox A 11 5 mm B...

Page 284: ...280 CLUTCH GEARBOX DRIVESHAFTS GEARBOX MA 5 Engines HFX KFV NFU 8HX 8HW a Identification label b Location for engraving of serial and gearbox nos B2CP3HTC C3...

Page 285: ...8HX 8HW Draining filling level 1 Gearbox drain plug 2 Filling and level cap Oil quality Refer to the manufacturer s instructions Oil quantity After draining 2 Litres Draining intervals Lubricated for...

Page 286: ...h gear 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 3nd gear 14 Driven pinion 2nd gear 15 1st 2nd gear sy...

Page 287: ...xing 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 shaft nut 1 nut 14 1 28 Gearbox c...

Page 288: ...UTCH GEARBOX DRIVESHAFTS GEARBOX CONTROLS MA 5 Engines HFX KFV NFU 8HX 8HW 1 Gear control lever 2 Gear engagement control cable 3 Gear selection control cable The two cables cannot be separated B2CP3H...

Page 289: ...5 Engines HFX KFV NFU 8HX 8HW 4 Gear engagement ball joint 10 mm 5 Gear selection ball joint 10 mm Length D Length C Gear engagement control 1015 mm 790 mm cable 2 Length A Length B Gear selection co...

Page 290: ...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 sleeve stops...

Page 291: ...CLUTCH GEARBOX DRIVESHAFTS GEARBOX BE4 5 Engines NFV 6FZ 8HV 8HY 8HZ RFN RFS WJY RHY RHZ B2CP3BNC B2CP3BPD a Marking zone Sequence and serial no b Location of identification label C3 XSARA XSARA PICA...

Page 292: ...8HZ RFN RFS 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 Gea...

Page 293: ...ive gear 5th gear 10 5th gear synchroniser 11 Driven gear 5th gear 12 Driven gear 3rd 4th gear 13 Driven gear 2nd gear 14 1st 2nd gear synchroniser 15 Driven gear 1st gear 16 Secondary shaft 17 Differ...

Page 294: ...5 26 Secondary shaft nut 1 screw 6 5 0 5 27 Vis de maintien du jonc 2 vis 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 4 screws...

Page 295: ...3 Primary shaft nut 1 7 2 0 7 4 Secondary shaft nut 1 6 5 0 7 5 Yoke holding screw 2 1 5 0 1 6 Differential gearwheel screw 2 6 5 0 7 Reverse gear contact 1 2 5 0 3 7 Differential housing 4 5 0 5 8 B...

Page 296: ...92 CLUTCH GEARBOX DRIVESHAFTS GEARBOX CONTROLS BE4 5 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 297: ...BOX CONTROLS BE4 5 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 engagement 965 mm...

Page 298: ...ment 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 the tabs of...

Page 299: ...8HZ 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 throu...

Page 300: ...position using tool 9607 T Place the gearbox 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...

Page 301: ...nnet Remove the air filter assembly Unlock the ball joint keys at a Place the gear selection and control levers neutral Lock the cable lengths with the ball joint locking keys CHECKS Remove the tool 1...

Page 302: ...engine fixing 3 5 Converter to engine fixing 2 5 Converter closing plate fixing M8 1 6 M10 2 6 Electrical bracket fixing 6 5 Flexible mounting to gearbox fixing 8 5 Speedometer drive 1 Heat exchanger...

Page 303: ...bricated when the engine is running Wait until the vehicle is completely stationary before engaging the gear lever in position P REMOVING REFITTING Automatic gearbox WARNING Never place the gearbox on...

Page 304: ...s 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 prior conditions Oil hot 80 C min Foot on the brake...

Page 305: ...tment of the gear selection control The adjustment of the accelerator cable Carry out the necessary operations Reading the fault codes Read the fault codes Absence of fault codes Measure the parameter...

Page 306: ...7 Refit the strainer without tightening the screws Observe the following tightening sequence Screws 1 2 3 4 and 5 to 0 9 m daN ESSENTIAL Respect the position of the magnets in the lower casing Clean t...

Page 307: ...303 CLUTCH GEARBOX DRIVESHAFTS MB3 AUTOMATIC GEARBOX CONTROLS Engine KFW B2CP352D SAXO...

Page 308: ...SSENTIAL Check the passage of all the gears otherwise adjust the selection control WARNING No part must be forced while performing these operations careful removal Removing the gear lever knob Remove...

Page 309: ...TIC GEARBOX AL4 WARNING This gearbox benefits from a special CITROEN semi synthetic oil which cannot be mixed with any other oil The gearbox is lubricated for life a Part reference Engines KFV NFU RFN...

Page 310: ...gearbox Lubrication The automatic gearbox is only lubricated when the engine is running REMOVING REFITTING Automatic gearbox WARNING Never place the gearbox on its lower casing risk of deforming the t...

Page 311: ...il Quality If the gearbox has suffered a serious fault resulting in a malfunction or the destruction of a clutch the oil will overheat and become contaminated with impurities the oil is said to be bur...

Page 312: ...n position P Engine running at idle Oil temperature 60 C 8 C 2 C measured with the aid of a diagnostic tool Remove the oil level plug 3 Thread of oil then drip drip refit plug 3 Tighten 2 4 m daN Drip...

Page 313: ...ort gear selection quality loss of functions Access to emergency programme only 3rd gear and reverse are available Reading the fault codes Read the fault codes Absence of fault codes Carry out a measu...

Page 314: ...on An initialisation of the auto adaptives A recording of the value of the oil usage counter previously read A road test ESSENTIAL Every update of the automatic gearbox ECU should be accompanied by an...

Page 315: ...f the option s concerned Pedal initialisation A pedal initialisation must be carried out in the following cases Replacement of the automatic gearbox ECU Replacement of the automatic gearbox Downloadin...

Page 316: ...r 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 originate from one of the following c...

Page 317: ...on the ignition Press and hold down the brake pedal Using the selection lever disengage from position P Unlocking the SHIFT LOCK In the event of a malfunction Remove the cover 1 Unlock the shift lock...

Page 318: ...r RH LH 0338 C 0338 J1 0338 J2 0338 H1 0338 H2 0338 J1 0338 J2 0338 H1 0338 H2 0338 7114 T X 7116 T Driveshaft nut HFX KFW NFT NFX VJX HFX KFV 8HX 8HW NFU KFW NFU NFV RFS RFN 6FZ WJY 8HZ RHY RHZ 8HV 8...

Page 319: ...ounting face of the rear cross member R2 Distance between the centre of the rear wheel and the ground L2 Distance between the centre of the rear wheel and the rear crossmember C4CP0N2C H1 R1 L1 H2 R2...

Page 320: ...Reminder Measuring the front height H1 Distance between the ground and the mounting face of the fixings The front heights H1 are measured between the ground and the moun ting face of the arm fixings 1...

Page 321: ...39 1 to 3 1 to 3 1 49 to 6 39 Camber 0 9 30 0 40 30 1 35 30 0 9 30 0 40 30 1 35 30 Castor 2 13 30 3 14 30 2 13 30 3 3 14 30 Pivot angle 12 41 40 12 42 40 12 41 40 12 42 40 HFX KFW NFT NFX VJX All Typ...

Page 322: ...0 2 4 Anti roll bar bearing fixing on the lower arm 2 2 0 2 5 Suspension leg upper fixing 2 1 0 2 6 Lower ball joint fixing screw 3 8 0 4 7 Anti roll bar link rod fixing 7 0 6 8 Suspension arm rear f...

Page 323: ...Damper 5 Rear suspension arm 7 Rear brake drum 9 Torsion bar The antiroll bar is located inside the tube of the rear axle Tightening torques m daN 3 Damper upper fixing screw 10 1 4 Damper lower fixi...

Page 324: ...LH 2 rings Torsion bar RH 1 ring 1 Entreprise 2 VTS trim level 3 With raised suspension Raised suspension 17 9 18 3 Black White Green HFX KFW NFX VJX HFX VJX 3 HFX Anti roll bar mm None 18 22 18 15 HF...

Page 325: ...65 65 R14 7 28 68 Pinion no of teeth Rack no of teeth Rack travel Stop colour NOTA The steering assembly is secured to the bulkhead Length of the steering track rods between the centre lines of the ba...

Page 326: ...3 Steering wheel fixing 3 4 Steering column fixing 2 3 5 Steering cardan joint fixing 2 3 6 Fixing to bulkhead 2 2 7 Pivot ball joint nut 3 5 8 Lock nut M14 4 5 8 Lock nut M16 5 9 Track rod articulat...

Page 327: ...fixing 2 3 5 Steering cardan joint fixing 2 3 6 Fixing to bulkhead 2 2 7 Pivot ball joint nut 3 5 8 Track rod lock nut M14 4 5 8 Track rod lock nut M16 5 9 Track rod articulation 2 1 10 Splined coupli...

Page 328: ...5 High pressure pipe 6 Upper reservoir 7 Power steering electro pump unit and built in lower reservoir 8 Flexible mounting 9 Electro pump unit bracket Tightening torque m daN Pump support fixing 2 Pum...

Page 329: ...on vehicles without aircon is supplied by a mechanical pump driven by the accessories drive belt 6 Power steering mechanism 7 Upper reservoir 8 Lower reservoir 9 Radiator 10 Power steering pump 11 Th...

Page 330: ...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 331: ...the radius of the rear wheel R2 Calculate dimension H2 R2 L2 CRD Difficult road conditions Definition for a type of vehicle whose axles and suspensions are adapted for driving on rough roads Compress...

Page 332: ...lly LH RH wheel the total tracking value All types except CRD CRD vehicles Vehicle Tracking Castor Camber Pivot angle 0 18 0 30 0 30 Adjustable Non adjustable 2 1 0 19 0 10 3 57 0 28 11 24 Vehicle Tra...

Page 333: ...2 0 3 6 Anti roll bar 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...

Page 334: ...r 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 spri...

Page 335: ...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 ball joint fixing 4 0 4 13 Lower arm...

Page 336: ...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 337: ...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 2 0 4 35 Damper lower fixing screw 10 6 1 36 Suspension spring 3...

Page 338: ...8HW 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...

Page 339: ...nut 5 0 5 8 Threaded washer 9 Stud 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 Auto NFU 8HY 8H...

Page 340: ...motor 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 link...

Page 341: ...a two column lift Remove on the RH side of the steering rack Clip 1 Clip 2 Release the steering rack protection gaiter Setting Move the steering to full left hand lock Measure the dimension X Move the...

Page 342: ...e of the front suspension 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 Dist...

Page 343: ...Calculate 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 shou...

Page 344: ...AXLE GEOMETRY Values of the front and rear suspensions at reference height Tools used Compress the suspension to obtain the values at reference height 1 Set of two suspension compressors 9511 T A 2 Se...

Page 345: ...10 26 0 12 0 07 0 07 10 40 0 Saloon or entreprise KFW Saloon all engine types except KFW Estate all engine types except CRD Rear axle YES NO Saloon CRD KFW 2 0i 16V RFS Saloon CRD all engine types exc...

Page 346: ...342 AXLES SUSPENSION STEERING XSARA All Types AXLE GEOMETRY a Angle which defines the tracking between the front and rear axles Its value must not exceed 12 B3CP04UC...

Page 347: ...ll bar link rod lower ball joint 8 Pivot lower ball joint 9 Driveshaft nut 10 Wheel bolt 11 Lower arm front mounting 12 Lower arm rear mounting and anti roll bar bearing 13 Screw under rear mounting 1...

Page 348: ...ents 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...

Page 349: ...ES SUSPENSION STEERING FRONT AXLE Anti roll bars Diameter Engines 1 6i 1 6i 16V 1 9D 2 0i 16V RFV 1 4 HDi 2 0 HDi 19 Blue 20 21 Yellow White 2 0i 16V RFS Colour reference XSARA All Types Saloon Estate...

Page 350: ...ges to 3 except for LPG vehicles CRD vehicles and Estates All Types CRD Difficult Road Conditions this type of vehicle has axles and suspensions designed for driving on rough road surfaces Pivot ball...

Page 351: ...oll bar 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 1...

Page 352: ...9 3 Violet 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...

Page 353: ...ten to 27 5 2 7 m daN New fitting B 3 Rear hub nut ESSENTIAL Tighten to 25 2 5 m daN greased NOTE It is possible to have both types of fitting on the same axle The old nut 1 requires the fitting of th...

Page 354: ...ere are 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 FORB...

Page 355: ...amper Lengths of the rear dummy damper mm Grand export 346 339 346 342 Normal driving 339 318 336 XSARA All Types REAR DAMPER E5AP14WC Engines 1 9 D 1 6i 16V 3 door 1 6i 16V 5 door 2 0i 16V RFN 1 4 HD...

Page 356: ...eel 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 support...

Page 357: ...XSARA All Types 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 Plung...

Page 358: ...n Steering rack travel mm 73 5 6 teeth RH helix 29 13 Yellow thickness mm 4 3 L H D Steering rack Steering stop colour code Number of steering wheel turns Length of the steering track rods Pre adjustm...

Page 359: ...Steering 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...

Page 360: ...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 subframe 5 11 Hydraulic pipe connection 2 5 12 Valve to housing fixing 1 2 13 Plunger flang...

Page 361: ...otector colour Vehicles BLACK All types except 1 8i 16V 1 9TD 7 Steering valve Number of teeth 3 3 L H D Steering rack Number of steering wheel turns Length of the steering link rods Pre adjustment 37...

Page 362: ...valve 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 t...

Page 363: ...when laden H2 R2 L2 H2 From the rear axle silentblock face to the ground R2 Radius of the rear wheel when laden L2 From the centre of the wheel to the rear axle silentblock face AXLE GEOMETRY Measurem...

Page 364: ...eel R2 Calculate dimension H2 Measure the radius of the front wheel R1 Calculate dimension H1 or H1 Measurements at reference height continued The reference height of the vehicle is set as per the tab...

Page 365: ...ing Camber Adjustable Yes No All Types 0 1mm 4 8 mm 1mm 0 09 0 09 3 18 10 43 30 0 30 0 43 0 09 1 13 18 Vehicle All Types CRD Condition de route difficile Front axle Rear axle Vehicle Tracking Castor P...

Page 366: ...ll joint 4 0 4 8 Lower swivel ball joint 4 0 4 9 Hub nut 32 5 2 greased 10 Wheel bolts 9 1 Face and threads not greased 11 Lower arm front pivot 8 0 8 12 Lower arm rear pivot and anti roll bar bearing...

Page 367: ...rm 21 Wheel bolt 9 1 Face and threads not lubricated 22 Damper 23 Rear silentblock on subframe 5 5 0 5 24 Damper pin nut 11 1 25 Stub axle nuts lubricated 25 2 26 Rear silentblock on bodyshell 5 5 0 5...

Page 368: ...hten to 25 2 5 m daN NOTE It is possible to have both types of fitting on the same axle The old nut 1 requires the fitting of the thrust washer 2 WARNING do not fit a thrust washer 2 with a new nut 3...

Page 369: ...e height when in running order is set according to the measurements shown in the table below Checking conditions Vehicle empty All reservoirs full Tyre pressures correct Steering rack locked straight...

Page 370: ...CRD Front axle Adjustable NFV 6FZ RHY Adjustable NFV 6FZ RHY Tracking Yes 2 1 mm 1 7 1 mm 1 2 1 mm 0 18 0 09 0 15 0 09 Tracking 0 11 0 09 Castor 2 54 20 Camber No 1 15 20 Pivot angle No 10 6 30 10 12...

Page 371: ...g 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 to s...

Page 372: ...oint 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 housing...

Page 373: ...ft hand drive 71 7x2 LH helix 28 teeth 3 22 12 m 11 48 m Right hand drive RH helix Motorisation Steering valve NFV 6FZ RFN RHY Number of teeth 7 Length of the steering link rods pre adjustment Between...

Page 374: ...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 minimum...

Page 375: ...Rr Disc thickness min thickness Make Brake lining grade Compensator 1 Compensator integral with the wheel cylinder 2 Load sensitive compensator 1 1 i 1 4 i 1 5 D Power assisted steering without ABS 1...

Page 376: ...CIFICATIONS continued Master cylinder Master vac Caliper piston makes Fr mm Disc Non ventilated Ventilated Disc thickness min thickness Brake pad grade Cylinder or caliper mm Drum max Disc Non ventila...

Page 377: ...sting the brake limiter Apply the brake pedal to close the limiter Adjust using the screw 2 to obtain a clearance J of 0 5 to 2 mm NOTE Do not touch 3 which has been adjusted at the factory Adjusting...

Page 378: ...pes Auto 1 1 i 1 4 i 1 6 i Tightening torques m daN Removing the caliper 1 1i Manual steering Screw M8 3 2 0 3 Screw M12 12 1 2 1 1 i 1 4 i Except 1 6 i 2 Screws M12 12 1 2 1 6 i 2 Screws M12 10 5 1 N...

Page 379: ...for better centring of the fixing screws NOTE The fixing screws are matched to the stop plates IMPERATIVE Respect the tightening torques Old fitting tighten to 12 m daN 1 2 up to RPO 8972 NEW FITTING...

Page 380: ...langes for better centring of the fixing screws NOTE The fixing screws are matched to the stop plates IMPERATIVE Respect the tightening torques Old fitting tighten to 11 m daN 1 up to RPO 8972 NEW FIT...

Page 381: ...ctly Bleed the main circuit Adjustment Set the brake to the 4th notch Tighten the nut 3 until the rear brakes are applied Check that there is a total travel of between 4 and 7 notches the two secondar...

Page 382: ...e bleeding equipment in which case the pressure of the equipment should be set to a maximum of 2 Bars Top up to level using the brake fluid sold by the CITROEN Replacement Parts Division IMPERATIVE or...

Page 383: ...03 205 DON 8259 BRAKE SPECIFICATIONS WITHOUT ABS Master cylinder Master vac Caliper piston makes Fr mm Disc Plain Ventilated Disc thickness min thickness Brake pad grade Drum Max thickness Make Brake...

Page 384: ...G 4554 BRAKE SPECIFICATIONS WITH ABS Master cylinder Master vac Caliper piston makes Fr mm Disc Plain Ventilated Disc thickness min thickness Brake pad grade Cylinder or caliper Disc Ventilated Rr Di...

Page 385: ...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 386: ...382 BRAKES BRAKE SPECIFICATIONS Braking circuit with ABS REF drum brakes at the rear B3FP162D C3...

Page 387: ...383 BRAKES BRAKE SPECIFICATIONS Braking circuit with ABS REF Disc brakes at the rear B3FP163D C3...

Page 388: ...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 389: ...raulic block Components Supplier Vehicle equipped with ABS and ESP systems Part No Observations ABS hydraulic block TEVES ABS MK 60 96 394 937 80 Installed on the front LH chassis member 4 adjustment...

Page 390: ...Rear brake 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...

Page 391: ...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 392: ...op 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 effort of 40 m...

Page 393: ...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 394: ...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 395: ...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 396: ...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 Fr mm Master cylinder Master vac Caliper piston makes...

Page 397: ...ive compensator 32 0 3 White BRAKE SPECIFICATIONS Estates 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 Fr mm Master cylinder Master vac Caliper piston makes Disc Disc t...

Page 398: ...394 BRAKES BRAKE SPECIFICATIONS XSARA All Types Tighten the nuts 1 to 2 3 m daN The clevis pin 2 is held in place by a plastic clip B3FP10YD...

Page 399: ...according 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...

Page 400: ...396 BRAKES Braking system without ABS rear drum brakes Up to RPO 8687 Braking system without ABS rear disc brakes BRAKE SPECIFICATIONS XSARA All Types B3FP14GD B3FP14FD...

Page 401: ...397 BRAKES Braking system with ABS rear drum brakes BRAKE SPECIFICATIONS B3FP14HD XSARA All Types...

Page 402: ...398 BRAKES Braking system with ABS REF rear disc brakes Braking system with ABS REF rear drum brakes BRAKE SPECIFICATIONS B3FP14JD B3FP14KD XSARA All Types...

Page 403: ...399 BRAKES Braking system with ABS REF rear drum brakes BRAKE SPECIFICATIONS B3FP14LD XSARA All Types...

Page 404: ...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 socke...

Page 405: ...ductive 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 way co...

Page 406: ...Located on the front LH wheelarch 4 adjustment channels IMPERATIVE Respect the direction of fitting of the gyrometer accele rometer sensor connector towards the rear of the vehicle WARNING The gyrome...

Page 407: ...Double shouldered washer ref 5 NOTE The new assembly is identified by a figure from 1 to 6 cold stamped on the head of the wheel stub at a 1 Washer exterior diameter 38 mm 2 Stop ring 3 Circlip NOTE...

Page 408: ...head of the wheel stub at c Sealing of the brake disc hub New components Sealed bearing incorporated at b ref 6 Spacer without seal face ref 5 Cap ref 8 Fixing of the brake disc hub New components Rea...

Page 409: ...E WEIGHT remove all objects from the vehicle totalling more than 10 kg in weight 5 Select the adjustment graph that corresponds to the vehicle model Refer to table N 4 6 Check the brake pressure 7 Adj...

Page 410: ...ued Weights in kg Trim level X SX Exclusive VTS Type of fuel 5 litres 4 9 18 27 36 4 10 20 30 40 1 4 1 2 3 4 Plein Petrol Diesel Engine 1 4 i 392 405 412 423 424 428 431 432 447 450 422 424 425 405 44...

Page 411: ...407 BRAKES GRAPH N 2 CHECKS AND ADJUSTMENTS BRAKE COMPENSATOR continued GRAPH N 1 B3FP09YD B3FP09XD XSARA All Types...

Page 412: ...408 BRAKES CHECKS AND ADJUSTMENTS BRAKE COMPENSATOR continued XSARA All Types B3FP09ZD GRAPH N 3...

Page 413: ...e preceding pages CHECKS Perform the checks between the wheels as follows front left and rear right front right and rear left With the engine running increase the pressure at the rear to obtain a fron...

Page 414: ...2 and use a spanner to hold the lock nut 4 in place thus restraining the spring Loosen the nut 2 while ensuring the lock nut 4 is held firmly in place Adjust the length of the spring 3 Reduce the spr...

Page 415: ...bles 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...

Page 416: ...bled either using brake bleeding equipment in which case the pressure of the equipment should be set to 2 Bars or in the usual way IMPERATIVE order of bleeding Wheels Rear Right Front Left Rear Left F...

Page 417: ...n makes Fr mm Disc Non ventilated Ventilated Disc thickness min thickness Brake pad grade Cylinder or caliper mm Drum max Disc non ventilated Rr Disc thickness min thickness Make Brake lining grade Co...

Page 418: ...king compensator non ABS models 1 Hydraulic valve block ABS Bosch 5 3 or 1 Hydraulic valve block ECU 2 Load sensitive rear braking compensator X braking circuit Front disc brakes ventilated Rear drum...

Page 419: ...415 BRAKES B3FP11WD B3FP7B9D BRAKING SYSTEM SPECIFICATIONS With ABS Without ABS XSARA PICASSO All Types...

Page 420: ...416 BRAKES B3FP7BRD B3FP11XD BRAKING SYSTEM SPECIFICATIONS Handbrake With ESP Electronic Stability Programme XSARA PICASSO All Types...

Page 421: ...vehicle type Consult the correspondence table Weight of fuel in the fuel tank Note the level of fuel in the vehicle and from this deduce the weight according to the table Determining the rear weight o...

Page 422: ...cle 542 22 10 574 Kg Weight of the options on the vehicle Note the options on the vehicle and deduce the weight according to this table 1 CRD OPR 8885 2 CRD 3 OPR 8886 4 OPR 8886 CRD Difficult road co...

Page 423: ...KING AND ADJUSTING THE LOAD SENSITIVE BRAKE COMPENSATOR GRAPH N 2 GRAPH N 1 B3FP13RD B3FP13SD Key P Rear pressure in Bars a Front pressure 60 3 Bars M Weight in Kg b Front pressure 100 3 Bars XSARA PI...

Page 424: ...KING AND ADJUSTING THE LOAD SENSITIVE BRAKE COMPENSATOR GRAPH N 4 GRAPH N 3 XSARA PICASSO All Types Key P Rear pressure in Bars a Front pressure 60 3 Bars M Weight in Kg b Front pressure 100 3 Bars B3...

Page 425: ...KING AND ADJUSTING THE LOAD SENSITIVE BRAKE COMPENSATOR GRAPH N 6 GRAPH N 5 B3FP14ND B3FP14PD Key P Rear pressure in Bars a Front pressure 60 3 Bars M Weight in Kg b Front pressure 100 3 Bars XSARA PI...

Page 426: ...cle engine running note the rear pressure when the front pressure is 60 3 Bars ESSENTIAL The control pressure should be obtained by progressively increasing the pressure without ever releasing the pre...

Page 427: ...spring rod Decrease the length of the spring to increase the pressure Increase the length of the spring to decrease the pressure Tighten the screw 1 to 1 2 0 25 m daN Check the brake pressure After t...

Page 428: ...rake 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...

Page 429: ...ards 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 bra...

Page 430: ...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 Gearbox...

Page 431: ...motors Vehicles models Manufacturer and Ref Class Climate STARTER MOTORS 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...

Page 432: ...001 183 027F MELCO M002T13081 VALEO D7E23 BOSCH E OAL 101 390 VALEO D6RA572 VALEO D6 RA 572 VALEO D6RA100 VALEO D7R151 STARTER MOTORS SAXO Class Climate Vehicles models Manufacturer and Ref SAXO CLIM...

Page 433: ...LCO M002T 13081 VALEO D7E23 BOSCH E OAL 101 390 VALEO D6RA572 VALEO D6RA572 VALEO D6RA110 VALEO D7GP09 1 H T C 3 VC 1 H T 3 C VC 1 H T 2 C 3 VC 3 H T C VC 4 H T 5 C VC STARTER MOTORS Class Climate Veh...

Page 434: ...6 i 1 6i Automatic 2 0i 16 v 2 0i 16 v Automatic EW10J4 2 0i 16v XU10J4RS 1 H T 2 H T 3 C VC C VC H T F T 3 C VC C VC 4 3 4 430 VALEO D7E16 BOSCH A 001183 027 F MELCO M002T13081 VALEO D6 RA 572 VALEO...

Page 435: ...LEO D7 R 27 VALEO D7 R 26 MELCO M 001 T 80481 VALEO D7 R 27 VALEO D7 R 27 MELCO A 001 236 000 VALEO D6RA110 VALEO D7GP09 STARTER MOTORS XSARA Class Climate Vehicles models Manufacturer and Ref XSARA C...

Page 436: ...6i Power steering and aircon 1 8i 16v 2 0i 16v Automatic 2 0 HDi 1 H T 2 3 C VC 3 C VC H T C 4 6 VALEO D7E16 BOSCH A 001 183 027F MELCO M002T13081 VALEO D6RA572 VALEO D7E23 BOSCH E OAL 101 390 VALEO D...

Page 437: ...aning of abbreviations BV Gearbox BVM Manual gearbox BVA Automatic gearbox BVMP Piloted manual gearbox Whitout aircon Without air conditioning Whit aircon With air conditioning DA Power assisted steer...

Page 438: ...aircon Without aircon DA by GEP Non DA or SAGINAW DA DA by GEP Non DA or SAGINAW DA SAXO Meaning of abbreviations see page 433 Climate H T C VC H T C VC H T C VC H T C VC Engine gearbox TU1JP BVM TU3J...

Page 439: ...5 ELECTRICAL SYSTEM Meaning of abbreviations see page 433 ALTERNATORS Refer to the correspondance table for petrol or diesel engine ALL APPLICATIONS SAXO Climate T Engine gearbox TU All Types TUD5 BVM...

Page 440: ...or petrol or diesel engine Whitout aircon C3 Meaning of abbreviations see page 433 Climate Engine gearbox TU1JP BVM TU3JP BVM TU3JP Automatic TU5JP4 BVM TU5JP4 BVMP DV4TD DV4TED4 BVM 7 Base RT3 N 1 or...

Page 441: ...or petrol or diesel engine With aircon C3 Meaning of abbreviations see page 433 Climate Engine gb TU1JP BVM TU3JP BVM TU3JP Automatic TU5JP4 BVM TU5JP4 BVMP DV4TD DV4TED4 BVM Base RT3 N 1 or 2 RT3 N 3...

Page 442: ...esel engine Whit aircon Whitout aircon XSARA Climate Engine gb TU3JP BVM TU5JP4 BVM TU5JP4 Automatic EW10J4 BVM EW10J4 Automatic XU10J4RS BVM Base RT2 Base RT2 Base RT2 NAV Base RT2 NAV 7 Without Cold...

Page 443: ...Automatic DV4TD BVM Cold Pack Without Cold Pack 8 8 12 8 15 15 RT2 Base Cold Pack Without Cold Pack RT2 Base RT2 NAV Base RT2 NAV Base 8 9 8 9 9 9 9 8 9 8 15 9 15 12 15 9 15 12 9 8 9 8 12 8 9 8 12 8 8...

Page 444: ...petrol or diesel engine Whit aircon Whitout aircon Nav Radio telephone Base Nav Radio telephone Base Climate H T C VC H T C VC H T C VC Engine gb TU5JP4 L3 et L4 BVM EW7J4 L4 BVM DW10TD BVM 7 XSARA PI...

Page 445: ...l engine Whit aircon Whitout aircon Climate Engine gb TU5JP L4 BVM DW10TD BVM DW10ATED BVM DW10ATED Automatic DV4TD BVM NC 7 8 Heated seat Base Nav Si ge chauffant Navigation Heated seat Base Nav Heat...

Page 446: ...itched 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 r...

Page 447: ...14 55 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 4...

Page 448: ...HAMPION CH 185 NGK YE04 CHAMPION CH170 CHAMPION CH 170 CHAMPION CH 170 PRE HEATING AND STARTING SYSTEMS ALL TYPES Vehicles models Pre heater plugs Pre heater control unit Pre Post heating pre heating...

Page 449: ...0 50 gr 675 gr 50 gr 775 gr 25 gr AIR CONDITIONING R 134 a HFC Vehicle Engines Date Refrigerant refill Compressor Variable Capacity Oil quantity cc Oil reference AIR CONDITIONING SAXO SD 6 V 12 SD 7 V...

Page 450: ...s 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 concerning draining drying...

Page 451: ...ARA PICASSO engine versions NFV 10 12 2001 6FZ 01 04 2002 RHY 04 11 2002 Aircon compressor XSARA PICASSO engine versions 6FZ and RHY Discontinuation of compressor SD 6 V 12 Replaced by compressor SD 7...

Page 452: ...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 equipped with new seals 3 MA...

Page 453: ...filter Vehicle Equipment RPO No Presence of filter Observations SAXO C3 All Types NO YES YES Larger YES Plus grand YES Valeo NO Valeo YES Valeo Without aircon Base aircon Regulated aircon Without airc...

Page 454: ...SYSTEM R 134 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...

Page 455: ...rise the 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 relea...

Page 456: ...fit the safety circlip 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...

Page 457: ...ipped with aircon without temperature regulation Fitting of a new pollen filter necessitates the following operations Engage the pollen filter upwards following arrow c Slide the pollen filter towards...

Page 458: ...the air conditioning loop has been open for more than 5 minutes the filter dryer cartridge assembly should be replaced no set interval After undoing the cap TORX 70 the cold loop must be depressurised...

Page 459: ...455 AIR CONDITIONING SPECIAL FEATURES AIR CONDITIONING SYSTEM R 134 a BEHR plate evaporator Pollen filter XSARA PICASSO Remove The three screws 1 The cover 2 Remove the pollen filter C5HP062C B1BP23ED...

Page 460: ...n 5 minutes the filter dryer cartridge assembly should be replaced no set interval Instruction for replacing the filter dryer cartridge After undoing the cap TORX 70 the cold loop must be depressurise...

Page 461: ...ny 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 with...

Page 462: ...same procedure 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...

Page 463: ...2000 rpm 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 tem...

Page 464: ...bient temperature in C Temperature at the central air vents in C Engine types Vehicle SAXO C3 All Types 17 3 13 3 11 3 9 3 8 3 All Types 18 5 2 15 2 12 5 2 10 2 8 5 2 6 5 2 TU 18 2 17 2 14 5 2 11 2 8...

Page 465: ...ditioning has been on for three minutes record the following parameters CHECK The temperature of the air coming from the central vents see table The High Pressure The Low Pressure Compare the values r...

Page 466: ...alve 3 Click fit union 4 Pressostat 1 seal 10 82 5 Dryer 2 seals 7 65 6 Relief valve tighten to 0 43 m daN 0 1 1 seal 7 65 1seal 16 5 7 Compressor fixing flange 3 0 8 m daN 2 seals 20 8 O ring seal 7...

Page 467: ...nditioning circuit SAXO All Types C5HP067D Key T Scale of Temperature C and of High Pressure Bars P Scale of Low pressure Bars Te Exterior temperature C HP Pressure at compressor outlet Bars Ta Temper...

Page 468: ...464 AIR CONDITIONING AIR CONDITIONING SYSTEM R 134 a 1 Low pressure valve 2 High pressure valve 3 Filter 4 Pressostat Tightening torque m daN a 0 6 b 0 6 c 0 6 d 0 6 e 0 6 f 0 6 C5HP17SP C3...

Page 469: ...5HP18GD Keys 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 A...

Page 470: ...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 dri...

Page 471: ...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 All Types A...

Page 472: ...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 dri...

Page 473: ...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 dri...

Page 474: ...CLIM 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 Tightening torqu...

Page 475: ...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 dri...

Page 476: ...CLIM 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 Tightening torqu...

Page 477: ...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 dri...

Page 478: ...it 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 0 25 XSARA...

Page 479: ...005 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 flange fixing 2...

Page 480: ...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 Ta Temperatu...

Page 481: ...005 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 flange fixing 2...

Page 482: ...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 Temperature C of ai...

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