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CITROEN C3 2002, User Manual, Page: 161 / 228

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CITROEN C3 2002 User Manual Download Page 161

RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX)

Engine : KFV

Gearbox only

PROCEDURE BEFORE REPAIRS

Oil level  AL 4 (prior conditions).
- Vehicle in horizontal position.
- Check gearbox is not in back-up mode.
- Remove the oil filler plug (3).
- Add 0.5 litres extra oil into the gearbox.
- Foot on the brake, change through all the gears.
- Selection lever in position "P".
- Engine running, at idle.
- Oil temperature : 60°C (+8°C; -2°C), 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-drip" or nothing : refit the plug (3).
- Stop the engine.
- Add 0.5 litres extra oil into the gearbox.
- Repeat the oil level procedure.
NOTE : The level is correct at the moment the thread of oil becomes drip-drip.
- Refit the oil filler plug (3). Tighten to 2.4 m.daN.
Initialise the oil usage counter (open the diagnostic tool procedure).
NOTE : The dimension X : TU engines = 81 mm

B2CP31FD

159

CLUTCH

GEARBOX

DRIVESHAFTS

Summary of Contents for C3 2002

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

Page 2: ...ts checks and special features of the CITROEN C3 The handbook is divided into the following sections representing the main functions GENERAL ENGINE INJECTION IGNITION CLUTCH GEARBOX DRIVESHAFTS AXLES...

Page 3: ...plate on the LH centre pillar C A S RP No and RP paint code label on front pillar close to driver s door D Inflation pressures and tyre references label on front pillar close to driver s door E Seria...

Page 4: ...Type 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 IDENTIFIC...

Page 5: ...mission standard 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...

Page 6: ...4i SX Exclusive 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 t...

Page 7: ...EHICLES DIESEL DV 4 TD 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 G...

Page 8: ...B 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 DV...

Page 9: ...4 TED4 1 4 HDi 16V SX Exclusive SX SX Exclusive 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 t...

Page 10: ...e manufacturer s plate carries the following information a Type approval number b Type serial number c Gross vehicle weight d Gross vehicle weight e Maximum weight on front axle f Maximum weight on re...

Page 11: ...r saloon Van not suitable for conversion C N R Version Gearbox and emission standard Ref Gearbox Manual 5 gears Automatic 4 gears Gear ratios and or gearbox different from base version Emissions L4 If...

Page 12: ...10 GENERAL GENERAL SPECIFICATION DIMENSIONS E1AP09KD...

Page 13: ...round E 1435 Front track on the ground F 1438 Width overall G 1667 Height overall H 1521 ODM Vehicle in running order vehicle empty levels topped up Boot floor with adjustable configuration Elbow widt...

Page 14: ...1080 1133 1114 1097 1147 running order With all options 1138 1147 1200 1182 1177 1214 Gross vehicle weight 1463 1470 1525 1507 1501 1539 Gross train weight 2113 2370 2425 2407 2401 2439 Maximum trail...

Page 15: ...of the tailgate Overspeed check The vehicle s overspeed values have to be re initialised The button on the wiper stalk operates the following functions Activation of the vehicle s overspeed function P...

Page 16: ...h within 5 seconds Keep the sun roof switch pressed until the end of the sun roof opening sequence Multifunction screen It is necessary to adjust the date time and outside temperature Adjust the displ...

Page 17: ...HICLE Front towing Rear towing WARNING When the engine is not running steering and braking are no longer power assisted Towing eye 1 Towing eye The towing eye is stowed in the jack pro tection box ins...

Page 18: ...heels hanging towing by the wheels AL4 autoactive gearbox Towing In the event of impossibility to raise the front of the vehicle It is ESSENTIAL to place the selection lever in position N Do not add o...

Page 19: ...ts at a using a crossbeam equipped with blocks For front lifting from the side take weight at the lifting point at a ESSENTIAL Never attempt to lift by the front panel mounting Side lifting ESSENTIAL...

Page 20: ...ued Lifting with the handle jack at the front Lifting with the handle jack at the rear Lifting on a two column lift using the jack supports Lift accessory with blocks on the jack supports E2AP01PC E2A...

Page 21: ...pension 2 Engine warm oil temperature 80 C 3 Drain oil sump remove filter cartidge time for draining to last drops 15 minutes 4 Refit drain plug filter cartridge 5 Refill the engine 6 Start the engine...

Page 22: ...d gearbox 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...

Page 23: ...21 GENERAL LUBRICANTS TOTAL recommended oils S A E Norm Table for selection of engine oil grade E4AP006D...

Page 24: ...ve this requirement NOTE Only PORTUGAL and GREECE may use 10W40 semi synthetic oil ESSENTIAL For all vehicles with a 30 000 km 20 000 miles maintenance interval use exclusively TOTAL ACTIVA QUARTZ 700...

Page 25: ...norms Example ACEA A1 98 B1 98 Blended oils for all engines permitting fuel economy complying with ACEA 98 norms API Norms The first letter corresponds to the type of fuel used by the engine S petrol...

Page 26: ...OTAL ACTIVA France only TOTAL QUARTZ Outside France Summary Engine oil norms to be respected in 2001 model year It is essential not to use engine oils respecting these norms for the following engine t...

Page 27: ...40 SJ CF A3 98 B3 98 Blended oils for all engines permitting fuel economy Oils specifically for petrol and dual fuel petrol LPG engines TOTAL ACTIVA 7000 TOTAL QUARTZ 7000 10W 40 TOTAL QUARTZ 9000 0W...

Page 28: ...LUBRICANTS TOTAL RECOMMENDED OILS Blended oils for all engines supplied in bulk TOTAL ACTIVRAC S A E 10W 40 Norms TOTAL ACTIVA 9000 5W 40 9000 5W 30 7000 10 W 40 7000 10W 40 9000 5W 40 TOTAL ACTIVA DI...

Page 29: ...for all engines Oils specifically for petrol and dual fuel petrol LPG engines Oils specifically for diesel engines 9000 5W 40 9000 5W 30 Blended oils for all engines permitting fuel economy 7000 10W...

Page 30: ...TOTAL RECOMMENDED OILS TOTAL QUARTZ TOTAL QUARTZ DIESEL Blended oils for all engines Oils specifically for petrol and dual fuel petrol LPG engines Blended oils for all engines permitting fuel economy...

Page 31: ...7000 10W 40 7000 10W 40 Turkey 7000 15W 50 9000 0W 40 Ukraine 7000 10W 40 9000 0W 40 Yugoslavia 7000 10W 40 LUBRICANTS TOTAL RECOMMENDED OILS Oils specifically for diesel engines TOTAL QUARTZ TOTAL QU...

Page 32: ...Senegal Tunisia Argentina Brazil Chile Cuba Mexico Paraguay Uruguay LUBRICANTS TOTAL RECOMMENDED OILS TOTAL QUARTZ TOTAL QUARTZ DIESEL Blended oils for all engines Oils specifically for petrol and dua...

Page 33: ...OMMENDED OILS TOTAL QUARTZ TOTAL QUARTZ DIESEL Blended oils for all engines Oils specifically for petrol and dual fuel petrol LPG engines SOUTH EAST ASIA 9000 5W 40 9000 5W 40 9000 5W 30 9000 5W 40 70...

Page 34: ...OILS TOTAL QUARTZ TOTAL QUARTZ DIESEL Blended oils for all engines Oils specifically for petrol and dual fuel petrol LPG engines MIDDLE EAST 9000 5W 40 7000 15W 50 7000 10W 50 Saudi Arabia Bahrain Du...

Page 35: ...ecial oils distributed by CITRO N Part No 9730 A3 4 HP 20 and AL4 automatic gearboxes Special oil distributed by CITRO N Part No 9736 22 Transfer box and rear axle TOTAL TRANSMISSION X 4 All countries...

Page 36: ...OEN reference All countries CITROEN Fluid 0 5 litre 9979 05 1 litre 9979 06 5 litres 9979 07 CITROEN hydraulic circuit fluid Norm Pack CITROEN reference TOTAL LHM PLUS ISO 7308 7309 ZCP 830 095 Green...

Page 37: ...e 1 litre 9980 06 ZC 9875 784 U Liquid ready to use 5 litres 9980 05 ZC 9885 077 U ZC 9875 279 U Grease Norms NLGI 1 TOTAL MULTIS EP2 2 All countries TOTAL MULTIS COMPLEX EP2 2 TOTAL MULTIS N4128 1 TO...

Page 38: ...ne 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 VALUES I...

Page 39: ...pm Power DIN HP rpm Torque ISO or EEC m daN rpm Torque DIN mkg rpm Max speed rpm HFX KFV NFU 8HX 8HW 8HY 8HV 1124 1360 1587 1398 72 69 75 77 78 82 73 82 10 5 1 11 1 17 9 1 18 25 1 44 5500 54 5400 80 5...

Page 40: ...IFICATIONS Engines HFX KFV NFU Engine identification B1BP10JC B1BP2GKC A Engines HFX KFV B Engine NFU Compulsory engine identification in zone a Component reference Engine legislation type Factory ser...

Page 41: ...ler 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 bearing c...

Page 42: ...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 4 0 1...

Page 43: ...fication of cylinder head gasket Engine types HFX KFV NFU Thicknesses Standard 1 2 0 1 0 66 0 04 Thicknesses repair 1 4 0 1 Thickness references 2 1 4 ENGINE References 1 2 3 4 Type of engine A B D Su...

Page 44: ...ngular tightening 240 5 In the order 1 to 10 Tightening 2 0 2 Angular tightening 260 5 In the order 1 to 10 NOTE Oil the threads and under the heads of the bolts Use engine oil or Molykote G Rapid Plu...

Page 45: ...43 ENGINE ENGINE SPECIFICATIONS Engines 8HX 8HW Engine identification a Engine legislation type b Component reference c Factory serial no B1CP0BKD...

Page 46: ...e order 1 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...

Page 47: ...45 ENGINE SPECIFICATIONS Engines 8HY 8HV Engine identification a Engine legislation type b Component reference c Factory serial no B1CP0BKD ENGINE...

Page 48: ...ightening 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 beari...

Page 49: ...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 2...

Page 50: ...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 B1DP1CK...

Page 51: ...to 10 NOTE The bolts should have been thoroughly 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 52: ...50 CAMSHAFT Engines 8HY 8HV Camshaft identification 1 Inlet camshaft 2 Exhaust camshaft f Marking zone B1EP18AD ENGINE...

Page 53: ...51 ENGINE Tools BELT TENSION SEEM UNITS CORRESPONDENCE TABLE 4099 T C TRONIC 105 4122 T C TRONIC 105 5 B1EP135D...

Page 54: ...52 Petrol Diesel TU DV 1 3 5 4 JP JP4 TD TED4 Engine type HFX KFV NFU 8HX 8HW 8HV 8HYX C3 X X X X X X X See pages 53 to 54 55 to 56 57 AUXILIARY EQUIPMENT DRIVE BELT ENGINE...

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

Page 56: ...cting on the tensioner roller Remove the accessories drive belt Refit Respect the following sequence Crankshaft pinion Aircon compressor pulley Guide roller Alternator pulley Tensioner roller Place to...

Page 57: ...tive 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 direc tion of rotation of the...

Page 58: ...nsioner roller moves freely no tight spot If this is not the case replace the tensioner roller Respect the direction of fitting of the drive belt Complete the setting of the belt of both sides by mean...

Page 59: ...er 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 tensioner r...

Page 60: ...58 Petrol Diesel TU DV 1 3 5 4 JP JP4 TD TED4 Engine type HFX KFV NFU 8HX 8HW 8HV 8HY C3 X X X X X X X See pages 59 to 68 69 to76 77 to 85 CHECKING AND SETTING THE VALVE TIMING ENGINE...

Page 61: ...r 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 Disconne...

Page 62: ...ve 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 flywh...

Page 63: ...l 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 HFX KFV engine Turn the eng...

Page 64: ...KFV engines Slacken the screws 4 without removing them Remove the bottom engine support assembly 5 and the fixing screws 4 Slacken the nut 6 Completely detension the belt by acting on the tensioner r...

Page 65: ...NG Engine NFU B1BP2MBC NFU engine Setting the timing continued Remove The bottom plastic casing The engine support 9 The middle support The timing cover 8 Peg the flywheel using tool 1 Position the to...

Page 66: ...ith the aid of an Allen key placed at a Turn the tensioner roller towards the right to bring it to the index c in position b Peg the tensioner roller in this position in order to slacken the timing be...

Page 67: ...pect the direction of fitting of the belt the arrows d indicate the direction of rotation of the crankshaft Refit the timing belt Position the timing belt belt e well tensioned in the following order...

Page 68: ...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 Tensioner ro...

Page 69: ...ition f to tension the belt to the maximum of the interval indicated Hold the tensioner roller 7 using tool 4 Tighten the fixing nut of the tensioner roller tightening to 1 0 1 m daN Turn the cranksha...

Page 70: ...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 this...

Page 71: ...ons Remove The front RH wheel The front RH splash shield using tool 1 The clips of the electrical harness on the upper timing cover The accessories belt using tool 2 see corresponding operation Check...

Page 72: ...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 pump pini...

Page 73: ...e from the manifold IMPERATIVE Uncouple the exhaust line in order to avoid damaging the front flexible pipe Twisting pulling and bending the front flexible pipe reduces its life Remove The engine spee...

Page 74: ...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 the aid...

Page 75: ...ot the case replace the rollers Fitting of the pulleys Camshaft pulley Tighten to 4 3 0 4 m daN Fuel high pressure pump pulley Tighten to 5 0 5 m daN The crankshaft pinion is located without a screw a...

Page 76: ...ntinued NOTE Screw 9 slackened Position the timing belt 10 observing the following sequence Crankshaft pinion 4 Guide roller 12 Camshaft pulley 11 check that the belt is held correctly against the rol...

Page 77: ...hten 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 78: ...ten the screws 17 to 4 5 0 4 m daN The bottom timing cover 3 Immobilise the engine flywheel using tool 3 Remove the screw 2 Refit the accessories drive pulley and tighten to Pre tighten to 3 0 3 m daN...

Page 79: ...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 pipes...

Page 80: ...P2N2C 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 pulley 9...

Page 81: ...essure 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 IMPERATIV...

Page 82: ...ect 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 timin...

Page 83: ...ort 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 Connect the c...

Page 84: ...haft 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 engin...

Page 85: ...ay 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 14 is...

Page 86: ...eg 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 this...

Page 87: ...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 IMPERATI...

Page 88: ...URES POWER UNIT SUSPENSION Engines HFX KFV NFU Tightening torques m daN 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 6 3 0 3 7 6 0 6 8 5 5 0 5...

Page 89: ...AL FEATURES POWER UNIT SUSPENSION Engines 8HX 8HW Tightening torques m daN 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 5 5 4 0 5 6 6 0 6 7 5 5 0 5 ENGINE...

Page 90: ...orques m daN Upper RH engine support 1 Screws 6 0 6 2 Screws 6 0 6 Lower RH engine support 3 Screws 5 7 0 9 Torque reaction rod 4 Screws 6 0 6 5 Screws 6 0 6 Lower LH engine support 6 Screws 5 4 0 5 U...

Page 91: ...179 PSA 4173 KFV 4 7 0 5 TR PSA K208 4 7 0 5 PSA 4175 PSA 4174 NFU TR PSA K181 PSA 4176 Engine types 1 Upstream oxygen sensor Tighten to m daN 2 Catalytic converter 3 Downstream oxygen sensor Tighten...

Page 92: ...nto contact with corrosi ve products Do not distort the flexible pipe by more than 20 angular X 20 mm axial 25 mm shear Y flexible pipe not fitted Do not distort the flexible pipe by more than 3 angul...

Page 93: ...xible pipe by more than 3 angular X 0 mm axial 3 mm shear Y flexible pipe in place WARNING Non respect for these precautions will result in a reduction in the lifetime of the flexible pipe It is thus...

Page 94: ...aircon 300W with aircon 118 C Managed by the ECU COOLING SYSTEM SPECIFICATIONS Engines HFX KFV NFU Engine type Capacity Radiator surface Pressurisation Opening of thermostatic regulator Cooling fan 1s...

Page 95: ...enting chamber 2 Water pump 3 Heater matrix 4 Bleed screw heater matrix 5 Coolant outlet housing 6 Bleed screw coolant outlet housing 7 Calorstat 8 Cooling radiator Thermostat Colour of connector Blue...

Page 96: ...ater pump 3 Heater matrix 4 Bleed screw heater matrix 5 Coolant outlet housing 6 Bleed screw coolant outlet housing 7 Calorstat 8 Cooling radiator 9 Heat exchanger for automatic gearbox Thermostat Col...

Page 97: ...nutes COOLING SYSTEM SPECIFICATIONS Engines 8HX 8HW 8HY 8HV Engine type Capacity Radiator surface Pressurisation Opening of thermostatic regulator Cooling fan 1st speed 2nd speed Air conditioning cut...

Page 98: ...96 COOLING SYSTEM SPECIFICATIONS Engines 8HX 8HW 1 Bleed screw with or without aircon B1GP09MP ENGINE...

Page 99: ...97 COOLING SYSTEM SPECIFICATIONS Engines 8HY 8HV 1 Venting chamber 2 Bleed screw 3 Thermostat B1GP09QP ENGINE...

Page 100: ...Petrol Diesel 98 OIL FILTERS ENGINE TU 1 JP 1 1i HFX KFV NFU X FILTRAUTO X X 1 4i 1 6i 16V 3 5 JP4 DV TD 1 4 HDi 8HX 8HW 8HV 8HY X MALHEX X X X 1 4 HDi 16V 4 TED4...

Page 101: ...90 C 1 3 1000 8HV 8HY Petrol engines Temperature C Pressure Bars Rpm Tools Pressure gauge 2279 T Bis Toolkit 4103 T Flexible pipe Engine oil pressure take off union TU engine 7001 T Toolkit 4103 T Oi...

Page 102: ...0 40 mm 0 05 1 mm 0 05 Hydraulic adjustment 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 2 2 1 1 3 Fully open Exhaust POSSIBLE...

Page 103: ...g Fit the cylinder adaptor 2 4222 T and the filling cylinder 1 4520 T Use the coolant to ensure protection between 15 C and 37 C Slowly fill the system NOTE Keep the cylinder filled up visible level C...

Page 104: ...mission standard L4 MAGNETTI MARELLI 48P SAGEM S2000 BOSCH M 7 4 4 850 0 5 9 HFX KFW NFU 1 1 i 1 4 i 1 6 i 16V IF L5 L4 IF L5 L4 Make Injection type Content CO CO2 Idling speed 50 rpm Manual gearbox A...

Page 105: ...cut off rpm Injection cut in during deceleration rpm Injector resistive value ohms Engine coolant temperature sensor resistive value ohms Idling actuator or stepper motor resistive value ohms HFX KFW...

Page 106: ...25 Utility vehicles 10 89 For private vehicles All Types imminent and utility vehicles in major export Private vehicles Brussels directive 88 76 2 litres 01 10 88 Luxembourg Accords new models 01 10 8...

Page 107: ...r certain non EEC Current Adoption of U S standard and catalytic converter European countries for petrol vehicles certain Export countries EMISSION STANDARDS PSA A S RP Engines Applicable Vehicles ECE...

Page 108: ...standard certain non EEC Current for light utility vehicles European countries certain Export countries Private vehicles Adoption of the U S standard certain non EEC Current for light utility vehicles...

Page 109: ...from 1992 to 1994 Private vehicles All Types new models EU Brussels Directive 93 59 existing models 91 441 new models existing models EMISSION STANDARDS PSA A S RP Engines Applicable Vehicles US 90 LD...

Page 110: ...2 EURO 96 L3 CEE 95 E E C APPLICATION NOTES CHARACTERISTICS Petrol Diesel Petrol Diesel With oxygen sensor and catalytic converter for petrol vehicles Brussels Directive 93 59 3 classes depending on...

Page 111: ...3 classes depending on vehicle weight Class 1 1250 kg Class 2 1250 1700 kg Class 3 1700 kg Brussels Directive 98 69 EURO 2 standard L3 made stricter Fiscal incentives With oxygen sensor and reinforced...

Page 112: ...OTES CHARACTERISTICS Petrol Diesel Gas Petrol Brussels Directive 98 69 EURO 2 standard L3 made stricter Fiscal incentives 3 classes depending on vehicle weight Class 1 1305 kg Class 2 1305 1760 kg Cla...

Page 113: ...ls 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 depending on vehicle weight...

Page 114: ...Electric 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 no...

Page 115: ...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 m...

Page 116: ...Electric 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 117: ...egulator 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 118: ...VE Take into account the very high pressures in the high pressure fuel circuit 1350 bars and respect the requirements below No smoking in proximity to the high pressure circuit when work is being carr...

Page 119: ...sensitive components refer to corresponding procedures Fuel filter High pressure fuel pump Third piston deactivator High pressure regulator High pressure sensor High pressure fuel injection common rai...

Page 120: ...eanliness 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 neg...

Page 121: ...Link 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 122: ...Upper 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...

Page 123: ...tributor 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 Diese...

Page 124: ...Oil 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 125: ...IRCUIT 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 IH...

Page 126: ...PPLY CIRCUIT Tools 1 Manual pressure vacuum pump FACOM DA 16 Vacuum pump Connect the tool 1 onto the vacuum pump 1 Start the engine Wait 30 seconds The vacuum value should be 0 9 0 1 bar at idle B1HP1...

Page 127: ...valve 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...

Page 128: ...Fit the tool 2 in the place of the duct 2 Couple the sleeve 2 on the pressure gauge 1 using the tube a Mode of operation Position tool 1 in the vehicle Start the engine Engage first gear start the ve...

Page 129: ...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 vehicle Eng...

Page 130: ...ovalve 6 Canister reservoir 7 Fuel pump fuel filter gauge pressure regulator 8 Injectors 9 Ignition coil 10 Thermoswitch engine coolant thermostat 11 Engine coolant temperature sensor 12 Accelerator p...

Page 131: ...er assembly BOSCH MAGNETTI MARELLI SAGEM MAGNETTI MARELLI BOSCH EATON SAGEM PLASTIC OMNIUM COUTIER BOSCH KFV 1 4i HFX 1 1i NFU 1 6i 16V Unleaded 95 RON or 98 RON Pressure 3 5 Bars Fixing Integrated in...

Page 132: ...LLI SOLEX 1 1i 1 4i 96 393 814 80 1 6i 16V 0261 230 043 1 1i 1 4i 96 407 962 80 1 6i 16V 0 289 000 259 96 458 515 80 4 way black connector fixed on the air inlet manifold 4 way black connector fixed o...

Page 133: ...LECTRIFIL EATON 1 1i MM 48 P2 1 4i S2000 PM 1 1 6i 16V M7 4 4 261 204 707 Flash type Eprom reprogrammable Eprom On the cylinder head closing temperature 118 C 2 way black connector fixed on the rear p...

Page 134: ...stream oxygen sensor SAGEM BOSCH CHAMPION SAGEM ELECTRIFIL RFN 58 LZ FR 7 DE RC 8 YCL BBC 2 2 NDT 2 526 208 BBC 2 2 NDT C15 43 02 Electrode gap 0 9 mm Tighten to 3 m daN 4 way grey connector 4 way gre...

Page 135: ...133 INJECTION FEATURES OF SIEMENS HDI DIRECT INJECTION SYSTEM Summary B1HP1JFP...

Page 136: ...ket Electronic immobiliser Consumption information Rev counter Preheating warning lamp Pre postheating unit Preheater plugs Accelerator pedal sensor SIEMENS ELECTRIFIL ELTH SIEMENS SIEMENS F217718001...

Page 137: ...pressure regulator Fuel cooler Fuel heater Fuel high pressure pump Fuel high pressure common injection rail Diesel injector Fuel high pressure regulator SIEMENS Diesel fuel On fuel filter Capacity 45...

Page 138: ...Reference Observations 29 30 31 32 33 34 35 Air flowmeter Air filter Turbocharger Exhaust gas recycling EGR valve EGR recycling regulation electrovalve Exhaust line Vacuum pump MECAPLAST KKK SAGEM In...

Page 139: ...137 INJECTION FEATURES OF DELPHI C6 HDI DIRECT INJECTION SYSTEM Summary B1HP1JRP...

Page 140: ...mp Fuel pressure sensor Fuel high pressure supply common rail Diesel injectors Vehicle speed sensor Air flowmeter Engine coolant temperature sensor Air temperature sensor Inlet air pressure sensor Acc...

Page 141: ...ensor Diagnostic socket Preheater indicator Diagnostic warning lamp Accelerator pedal potentiometer Aircon compressor Rev counter Cooling fan unit Battery ELECTRICFIL BITRON ELTH SIEMENS BOSCH DELPHI...

Page 142: ...O RRT 2051 238 342 9307Z502A R6356010 2690362 783DCC20 LUCAS DELPHI ELTH DELPHI DELPHI BOSCH Volume 14 cc Pressure 1350 bars 3 way black connector on the fuel high pressure rail 2 way black connector...

Page 143: ...141 ALLUMAGE 1 1i HFX FR7DE RC8YCL 1 4i KFV RFN58LZ 0 9 mm 2 5 mda N 1 6i 16v NFU FR7ME SPARKING PLUGS Vehicles Models BOSCH Enginre type CHAMPION SAGEM Electrode gap Tightening torque C3...

Page 144: ...pe Clutch disc Identification of springs No of splines of lining Ext Int Quality of lining Diesel Petrol 1 1i 1 4i 1 6i 16V 1 4 HDi 1 4 HDi 16V HFX KFV NFU 8HX 8HW 8HV 8HY MA 5N MA 5S MA 50 BE4 5 VALE...

Page 145: ...unted on a ball joint 1 The ball 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...

Page 146: ...16 20 TP 75 20 CN 40 14x60 16x63 ou 14x60 21x73 17x64 21x18 52 67 GEARBOX AND TYRE SPECIFICATIONS Trim level Engine type Tyres Rolling circumference Gearbox type Gearbox ident plate Differential ratio...

Page 147: ...17x61 16x65 19x72 19x77 21x18 22x19 GEARBOX AND TYRE SPECIFICATIONS Trim level Engine type Tyres Rolling circumference Gearbox type Gearbox ident plate Differential ratio Speedo drive ratio 1 4 HDi 16...

Page 148: ...146 CLUTCH GEARBOX DRIVESHAFTS MA 5 GEARBOX Engines HFX KFV NFU 8HX 8HW a Identification label b Location of engraving of serial and gearbox nos B2CP3HTC...

Page 149: ...l 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 life Check the oil level Ever...

Page 150: ...5th 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 3rd gear 14 Driven pinion 2nd gear 15 1st 2nd gear...

Page 151: ...mediate 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 casing 15 fixing screws 1 8 0...

Page 152: ...150 CLUTCH GEARBOX DRIVESHAFTS BE4 5 GEARBOX Engines 8HV 8HY B2CP3BNC B2CP3BPD a Engraving zone sequence and serial no b Location of identification label...

Page 153: ...ain 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 Gearbox empty 1 9 Litres After...

Page 154: ...gear 9 Drive 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...

Page 155: ...rew 6 5 0 5 27 Yoke retaining screw 2 screws 1 5 0 2 28 Differential gearwheel screw 2 screws 6 5 0 5 Reverse gear switch 1 screw 2 5 0 3 29 Differential housing 4 screws 5 0 5 30 Breather pipe 1 7 0...

Page 156: ...DRIVESHAFTS AL 4 AUTOMATIC GEARBOX Engine KFV 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...

Page 157: ...ion of flow of oil into the exchange EPDE 1 0 2 2 Fixing of oil heat exchanger 5 1 3 Fixing of gearbox input speed sensor 1 0 2 4 Fixing of oil overflow and drainage X 81 mm 4 0 2 5 Oil top up plug 2...

Page 158: ...ening torques m daN 7 Fixing of plug 0 8 0 2 8 Fixing of converter on the engine diaphragm Pre tightening 1 0 1 Tightening 3 0 3 9 Fixing of gearbox on the engine 5 2 1 12 Fixing of the selection leve...

Page 159: ...block by means of screws 10 and 11 Pre tightening 0 9 Slacken the screws 9 Tightening 0 75 respect the order indicated NOTE The screw 11 est collared WARNING Do not slacken the TORX screw 14 risk of...

Page 160: ...earbox 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 tr...

Page 161: ...t 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 drip or nothing refit the pl...

Page 162: ...s 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 measure of parameters Presence of a...

Page 163: ...gearbox ECU by downloading Follow the procedure using the diagnostic tool The downloading operation enables the automatic gearbox to be updated or adapted to an evolution of the engine ECU Before com...

Page 164: ...l initialisation must be carried out in the following cases Replacement of the automatic gearbox ECU Replacement of the automatic gearbox Downloading of the ECU configuration Adjustment or replacement...

Page 165: ...king the shift lock with a fault NOTE It is impossible to unlock the shift lock with the normal operation method The causes of the fault may arise from the following components Shift lock Gear lever p...

Page 166: ...CLUTCH GEARBOX DRIVESHAFTS MA 5 GEARBOX CONTROLS 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 B2CP...

Page 167: ...W 4 Gear engagement ball joint 10 mm 5 Gear selection ball joint 10 mm Length D Length C Gear engagement control cable 2 1015 mm 790 mm Length A Length B Gear selection control cable 3 1093 mm 775 mm...

Page 168: ...o 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 sto...

Page 169: ...BE4 5 GEARBOX CONTROLS Engines 8HV 8HY 1 Gear control lever 2 Gear engagement control cable 3 Gear selection control cable These two cables cannot be separated B2CP3J3D 167 CLUTCH GEARBOX DRIVESHAFTS...

Page 170: ...4 5 GEARBOX CONTROLS Engines 8HV 8HY 4 Gear engagement ball joint 10 mm 5 Gear selection ball joint 10 mm Length A Length B Gear selection 907 mm 645 mm cable 5 Length D Length C Gear selection 965 mm...

Page 171: ...ol 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 the clip 6 at a Disengage th...

Page 172: ...170 CLUTCH GEARBOX DRIVESHAFTS AL4 GEARBOX CONTROLS Engine KFV B2CP3H7D...

Page 173: ...e sensor cells is achieved by a magnet located on the lever opposite the cells this causing the change of status The information is transmitted to the gearbox ECU NOTE On a vehicle equipped with the s...

Page 174: ...he automatic gearbox is by a cable c Push button 1 Control lever with ball joint 2 Automatic adjustment Pull out the button to permit adjustment of the control Press in the button to lock the adjustme...

Page 175: ...t 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 compo...

Page 176: ...wheels designed for the ABS system Features The driveshafts no longer have gearwheels for the ABS system This function is performed by the wheel bearings The driveshaft gaiters are secured by rings S...

Page 177: ...L4 Engine types Gearbox Type Differential diameter Wheel end Gearbox end References Housing diameter mm Wheel end 1 1i HFX 75 72 22 8 79 75 26 7 75 72 22 8 79 75 26 7 31 36 TP 1 C C 2 KFV NFU 8HX 8HW...

Page 178: ...arbox RH side LH side Tool kit Gearbox oil seal mandrels 24 5 0 5 32 5 1 5 7114 T W 7114 T X 0338 J1 0338 J3 7114 T W 7114 T X 7116 T 0338 7116 T Driveshaft nut HFX KFV 8HX 8HW NFU KFV 8HV 8HY MA 5 AL...

Page 179: ...5 5 J14 CH 4 24 Tiger 6J 15 CH 4 27 Lynx 2 1 2 1 165 70 R14 81T XT1 1 804 m 165 70 R14 81T XT1 1 804 m 185 60 R15 84H XH1 1 828 m 165 70 R14 81T XT1 1 804 m 185 60 R15 84H XH1 1 828 m 5 5J 14 H2 4 24...

Page 180: ...R15 84H XH1 1 828 m 185 60 R15 84H XH1 1 828 m 185 60 R15 84H XH1 1 828 m S O T A 1 S O T T 6J 15 H2 4 27 Eagle trims 6J 15 CH 4 27 Lynx 5 5J 14 CH 4 24 Tiger 2 1 2 1 185 60 R15 84H XH1 1 828 m 185 6...

Page 181: ...S O T T 5 5 J14 H2 4 24 Milan trims 5 5 J14 H2 4 24 Tiger 6J 15 H2 4 27 Coyote 6J 15 H2 4 27 Eagle trims 6J 15 H2 4 27 Lynx 2 1 2 1 165 70 R14 84H XH1 1 804 m 165 70 R14 84H XH1 1 804 m 185 60 R15 84...

Page 182: ...tion pressures The label indicating recommended tyre pressures is affixed to the inner panel of one of the front doors a Recommended tyre inflation pressures vehicle empty and vehicle under load b Typ...

Page 183: ...ith conical contact surface Light alloy wheel Mixed fixing wheel bolts permitting the securing of the following wheel types Light alloy wheel fixing with flat contact surface Steel spare wheel fixing...

Page 184: ...rresponding 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 measur...

Page 185: ...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 the suspension to obtain the...

Page 186: ...symmetrically LH RH wheel the total tracking value All types except CRD CRD vehicle Vehicle Tracking Castor Camber King pin inclination Adjustable Non adjustable 2 1 0 19 0 10 3 57 0 28 11 24 Vehicle...

Page 187: ...ar bearing fixing 8 0 8 7 Hub nut 24 5 0 5 8 Wheel bolt 9 1 9 Subframe to bodyshell fixing screw 9 2 0 9 10 Anti roll bar 11 Pivot lower ball joint fixing 14 1 4 12 Ball joint fixing on lower arm 4 0...

Page 188: ...arm mounting 7 6 0 5 6 Yoke suspension arm fixing screw 7 Rear suspension arm 8 Stub axle bearing nut 20 2 9 Damper 10 Damper upper fixing 4 2 0 4 11 Damper lower fixing 10 6 1 12 Suspension spring 1...

Page 189: ...rame on bodyshell fixing screw 9 2 0 9 10 Anti roll bar 11 Pivot lower ball joint fixing on lower arm 4 0 4 12 Pivot lower ball joint fixing 6 6 0 7 13 Lower arm front and rear mounting fixing 14 1 4...

Page 190: ...SION 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 r...

Page 191: ...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 37 Travel stop 38 Secondary...

Page 192: ...HX 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 o...

Page 193: ...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 8HV Electric motor 60 A 65 A Steering r...

Page 194: ...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 lin...

Page 195: ...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 steering to full right hand lock Measure...

Page 196: ...203 205 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 197: ...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 Dis...

Page 198: ...ifications 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 l...

Page 199: ...BRAKE SPECIFICATIONS Braking circuit with ABS REF drum brakes at the rear B3FP162D BRAKE 197...

Page 200: ...BRAKE 198 BRAKE SPECIFICATIONS Braking circuit with ABS REF disc brakes at the rear B3FP163D...

Page 201: ...dem 2 Braking servo 3 Brake caliper or drum at the rear 4 Hub equipped with a bearing with an integral magnetic wheel 48 pairs of poles 5 Wheel sensor 6 Brake fluid level sensor 7 Hydraulic block plus...

Page 202: ...way connector Alone on the hydraulic block Changing only the ECU is prohibited 2 way blue connector The sensors are inductive type Mounted on the pivot Non adjustable airgap 0 16 to 1 6 mm Tightening...

Page 203: ...e 16 Servo fixing 2 2 0 3 17 Fixing on master cylinder 2 0 5 12 Yoke fixing on caliper 10 5 1 13 Yoke fixing on caliper 3 0 3 14 Rear caliper fixing on arm 5 3 0 5 15 Yoke fixing on caliper 3 8 0 3 Ti...

Page 204: ...r 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...

Page 205: ...ts stop Adjust the nut 10 to obtain a travel of less than or equal to 1 mm at a Refit the brake drums without tightening them according to version Action the handbrake lever 8 times with an effort of...

Page 206: ...reservoir 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 WAR...

Page 207: ...g the primary 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...

Page 208: ...between MINI level and MAXI level Fill if necessary with the approved and recommended synthetic brake fluid Without the bleeding apparatus Without the bleeding apparatus NOTE Two operators are necess...

Page 209: ...MELCO 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...

Page 210: ...O SG7 S016 VALEO A13 VI 282 VALEO SG8 B022 1 1i 1 4i 1 4i VALEO A11 VI 109 VALEO SG7 S016 VALEO A13 VI 282 VALEO SG8 B022 VALEO A11 VI 109 VALEO SG7 S016 VALEO A13 VI 282 VALEO SG8 B022 VALEO A13 VI 2...

Page 211: ...VALEO SG8 B022 VALEO A13 VI 282 VALEO SG8 B022 DENSO SC2 VALEO A13 VI 282 VALEO SG8 B022 DENSO SC2 1 6i 16 v 1 4 HDi 1 4 HDi 16v VALEO A13 VI 282 VALEO SG8 B022 VALEOA13 VI 282 VALEO SG8 B022 DENSO S...

Page 212: ...AGARES 960411 P NAGARES 960411 P NAGARES 960411 P NGK YE04 NGK YE04 NGK YE04 PRE HEATING AND STARTING CIRCUITS Vehicles models Pre heater plugs Pre heater control unit Pre post heating Pre heating tim...

Page 213: ...when the ignition is switched 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 Di...

Page 214: ...11 2001 625 0 50 gr SD 6 V 12 135 SP 10 AIR CONDITIONING R 134 a HFC Vehicle Engine Date Refrigerant refill Compressor Variable Capacity Oil quantity cc Oil reference Cooling fan FAURE ECIA 250 Watts...

Page 215: ...outlet 8 of the condenser 5 are equipped with new seals 3 MANULLI Condenser MODINE 16 dm3 The drive plate 1 is held on the aircon compressor shaft by ribs New wiring 2 New seals 3 MANULLI Identificat...

Page 216: ...fusebox but also the fuse referred to above After 04 2002 the fuse should be incorporated in the blower itself SPECIAL FEATURES AIR CONDITIONING SYSTEM R 134 a Seals Pressure reducer Special feature...

Page 217: ...ter Note The pollen filter is located in the engine compartment on the RH side Removing Remove The three screws 1 The plastic cover 2 Tilt the flap 3 Remove the pollen filter 4 Refitting Proceed in re...

Page 218: ...urise 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 rele...

Page 219: ...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 packag...

Page 220: ...ose any oil No more oil should be added when filling the system with R 134 a fluid b Using draining filling equipment fitted with an oil decanter Drain the R 134 a fluid from the system in accordance...

Page 221: ...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 dryer Drain as much oil...

Page 222: ...conditions are met take the following action Start the engine with the air conditioning off and wait for the cooling fan first speed to cut in Operate the air conditioning and set the engine speed to...

Page 223: ...TEMPERATURES continued Vehicle using R134 a fluid Compressor with variable capacity Ambient temperature in C Air temperature from the central vents in C Engine types Vehicle All types C3 18 5 2 15 2...

Page 224: ...The High Pressure The Low Pressure Compare the values recorded with the table below or the graphs Ambient temperature in C 40 35 30 25 20 15 Vehicle Engine types C3 All types High pressure Bars Low p...

Page 225: ...Faulty pressure control valve System blocked Water in the system Presence of solid matter in the system Dirty condenser Excessive fluid charge Dirty condenser Faulty pressure control valve Cooling fan...

Page 226: ...224 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 AIR CONDITIONING...

Page 227: ...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 temp...

Page 228: ...AIR CONDITIONING C5HP18GD Key T P Average temperature C at the air vents high pressure Bars P Low pressure Bars Te Exterior temperature C HP Pressure at compressor outlet Bars BP Pressure at compresso...

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