background image

2000

2000

CAR 050007

AC/QCAV/MTD
Méthodes Techniques Documentation

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

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

PRIV

A

TE CARS

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

Summary of Contents for C5 2000

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 C5 The handbook is divided into the following sections representing the main functions GENERAL ENGINE INJECTION IGNITION CLUTCH GEARBOX DRIVESHAFTS AXLES...

Page 3: ...ing braking system 230 233 HYDRAULICS Specifications 234 237 Suspension spheres 238 240 ELECTRICAL Starter motors 241 Alternators 242 Charging circuit 243 AIR CONDITIONING Quantities in R 134a aircon...

Page 4: ...plate under the rear bench seat 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 Seri...

Page 5: ...6FZ RFN RLZ XFX Cubic capacity cc 1749 1997 2946 Fiscal rating hp 7 8 9 14 Gearbox type BE4 5 AL4 BE4 5 AL4 BE4 5 ML5 5 4 HP 20 Gearbox ident plate 20 DL 29 20 TP 44 20 DL 30 20 TP 42 20 DL 31 20 LE 9...

Page 6: ...RHY RHZ 4HX Cubic capacity cc 1997 2178 Fiscal rating hp 5 6 7 8 9 Gearbox type BE4 5 ML 5 AL4 ML 5 4 HP 20 Gearbox ident plate 20 DL 32 20 LE 94 20 TP 43 20 LE 96 20 HZ 20 IDENTIFICATION OF VEHICLES...

Page 7: ...ox Emission standard B Manual L4 C 5 gears L5 E Automatic L4 F 4 gears L5 4 IDENTIFICATION OF VEHICLES Manufacturer s plate Factory code Structure The factory code is composed of 6 figures or letters...

Page 8: ...GENERAL 5 GENERAL SPECIFICATION DIMENSIONS E1AP08TD...

Page 9: ...ear track on the ground C 1509 1495 1493 Front track on the ground D 1544 1530 1528 Width overall E 1770 Height overall F 1476 Front overhang G 971 Rear overhang H 897 Vehicle in running order vehicle...

Page 10: ...810 1845 1845 2010 1835 1845 2020 Gross train weight 3310 3345 3345 3610 3335 3345 3420 Maximum trailer weight without brakes 660 695 700 750 695 700 750 Maximum trailer weight with brakes Incline 12...

Page 11: ...e weight 1880 1905 1985 1910 2020 Gross train weight 3380 3405 3485 3410 3120 Maximum trailer weight without brakes 715 730 750 740 750 Maximum trailer weight with brakes Incline 12 1500 1500 1500 150...

Page 12: ...s not running steering and braking are no longer power assisted Towing eye 1 Towing eye The towing eye is stowed in the jack protection box inside the spare wheel Vehicle with either manual or automat...

Page 13: ...o not exceed a speed of 30 mph over a distance of 30 miles Moving the vehicle Never be towed with the ignition switched off Never attempt to push start the vehicle Impossible with an automatic gearbox...

Page 14: ...he jack to support the centre of the front subframe crossmember ESSENTIAL Never attempt to lift by the front panel mounting or front panel crossmember Place axle stands under the front subframe E2AP01...

Page 15: ...g ESSENTIAL Always ensure the jack is correctly positioned at the lifting points ESSENTIAL Do not place the axle stands under the jack contact lugs Position of the axle stand E2AP017C E2AP018C E2AP019...

Page 16: ...not lift under the rear subframe crossmember Lift under the strengthened rim of the spare wheel pan Positioning of the axle stand Lifting using the handle jack Front lifting Rear lifting NOTE The han...

Page 17: ...GENERAL 14 Lifting and supporting the vehicle continued Lifting on a platform Two column lift Auxiliary lift with blocks E2AP01EC E2AP01FC GENERAL SPECIFICATION LIFTING AND SUPPORTING THE VEHICLE...

Page 18: ...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 19: ...cuit Cooling system Fuel tank capacity 6FZ RFN RLZ RHY RHZ 4 25 4 75 1 7 1 5 1 8 1 8 1 8 1 8 6 6 8 3 3 3 5 3 4 3 8 8 9 3 8 8 10 7 66 68 16 CAPACITIES in litres 1 8i 16V 2 0i 16V 2 0 HPi 2 0 HDi Petrol...

Page 20: ...t Hydraulic circuit Cooling system Fuel tank capacity CAPACITIES in litres Petrol Vehicle with air conditioning With automatic gearbox ESSENTIAL Systematically check the oil level using the oil dipsti...

Page 21: ...hange Braking circuit Hydraulic circuit Cooling system Fuel tank capacity CAPACITIES in litres Diesel Vehicle with air conditioning ESSENTIAL Systematically check the oil level using the oil dipstick...

Page 22: ...OTAL oil of grade S A E 5W 30 allows improved fuel economies approx 2 5 This oil is not used in the following engines XU10 4 RS XSARA VTS 2 0i 16V 3 door SOFIM RELAY 2 8 D and 2 8 TD Engine oil norms...

Page 23: ...0 all engine oils must comply with ACEA 98 norms Example ACEA A1 98 B1 98 Blended oils for all engines permetting fuel economy complying with ACEA 98 norms API Norms The first letter corresponds to th...

Page 24: ...ine oils respecting these norms for the following engine types XU10J4RS 1580 SPI SOFIM 2 8 D and SOFIM 2 8 TD IMPERATIVE From 1999 model year to preserve engine performance all engines fitted in CITRO...

Page 25: ...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 40 SJ A3...

Page 26: ...Mayotte LUBRICANTS TOTAL RECOMMENDED OILS Blended oils for all engines TOTAL ACTIVRAC Norms S A E 10W 40 TOTAL ACTIVA 9000 5W 40 9000 5W 30 7000 10 W 40 7000 10W 40 9000 5W 40 TOTAL ACTIVA DIESEL Blen...

Page 27: ...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 40 9000 0W 40 7000 10W 40 7000 10W...

Page 28: ...uania 9000 5W 40 9000 0W 40 Macedonia 9000 5W 30 7000 10W 40 Malta 7000 10W 40 7000 10W 40 7000 15W 40 7000 15W 40 Norway 7000 10W 40 9000 0W 40 Poland 7000 10W 40 Portugal 7000 10W 40 Slovak Republic...

Page 29: ...9000 5W 30 7000 10W 40 9000 0W 40 Switzerland 7000 10W 40 Turkey 7000 10W 40 7000 10W 40 7000 15W 40 7000 15W 40 9000 0W 40 Ukraine 7000 10W 40 7000 10W 40 9000 0W 40 LUBRICANTS TOTAL recommended oils...

Page 30: ...tina Brazil Chile Colombia Cuba Guatemala Paraguay Peru El Salvador Uruguay LUBRICANTS TOTAL recommended oils TOTAL QUARTZ TOTAL QUARTZ DIESEL Blended oils for all engines Oils specifically for petrol...

Page 31: ...ded oils Oils specifically for diesel engines TOTAL QUARTZ TOTAL QUARTZ DIESEL Blended oils for all engines Oils specifically for petrol and dual fuel petrol LPG engines 7000 10W 40 7000 15W 50 7000 1...

Page 32: ...bai United Arab Emirates Israel MIDDLE 9000 5W 40 7000 15W 50 7000 15W 50 Jordan EAST Kuwa t Lebanon Qatar Yemen LUBRICANTS TOTAL recommended oils TOTAL QUARTZ TOTAL QUARTZ DIESEL Blended oils for all...

Page 33: ...Automatic gearbox 4 HP 14 et 4 HP 18 All countries Special oil distributed by CITROEN Part No 9730 94 Automatic gearbox 4 HP 20 et AL4 Special oil distributed by CITROEN Part No 9736 22 Transfer box a...

Page 34: ...3 20 litres 9979 76 9979 74 210 litres 9979 77 9979 75 Synthetic brake fluid Packs CITROEN reference All countries CITROEN Fluid 0 5 litre 9979 05 1 litre 9979 06 5 litres 9979 07 CITROEN hydraulic ci...

Page 35: ...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 All countries TOTAL MULTIS EP2 2 TOTAL MULTIS COMPLEX EP2 2 TOTAL MULTIS N4128 1 TOTAL...

Page 36: ...SEL engine 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...

Page 37: ...daN rpm Torque DIN mkg rpm Max speed rpm Petrol Engines 6FZ RFN LZ XFX All Types 1 8i 16V 2 0i 16V 2 0i Hpi 3 0i V6 6FZ RFN RLZ XFX 1749 1997 1998 2946 82 7 81 4 85 88 85 88 87 82 6 10 8 1 10 8 1 11 4...

Page 38: ...EEC KW rpm Power DIN HP rpm Torque ISO or EEC m daN rpm Torque DIN mkg rpm Max speed rpm Diesel Engines RHY RHZ 4HX All Types 2 0 HDi 2 2 HDi RHY RHZ 4HX 1997 2179 85 88 85 96 17 6 1 18 1 66 4000 80 4...

Page 39: ...ENGINE 36 ENGINE SPECIFICATIONS Engines 6FZ RFN RLZ Compulsory engine plate a Engine legislation type b Component reference c Factory serial no B1BPWMD...

Page 40: ...head gasket identification Nominal dimension Repair dimension 6FZ RFN RLZ Marking zone d 4 5 1 4 2 4 5 Marking zone e R1 R2 Gasket thickness 1 1 mm 1 4 mm Supplier MEILLOR Multilayer metallic cylinde...

Page 41: ...ing 1 5 0 1 Tightening 5 0 1 Untightening 360 2 Tightening 2 0 2 Angular tightening 285 5 in the order 1 to 10 NOTE Oil the threads and under the heads of the cylinder head bolts Use engine oil or Mol...

Page 42: ...tion end 1 Inlet camshaft 2 Exhaust camshaft j Camshaft position sensor target h Paint rings repair reference Valve clearances when cold Hydraulic followers with clearance B1EP15YD Inlet camshaft Exha...

Page 43: ...ightening 60 6 60 Con rod cap screws Tightening 1 Untightening 180 Tightening 2 3 0 2 2 3 0 1 Angular tightening 46 2 4 46 5 Con rod nuts Pre tightening 2 0 2 Angular tightening 70 Accessories drive p...

Page 44: ...4 3 0 4 Timing guide roller Pre tightening 1 5 Tightening 2 5 0 2 4 3 0 4 Timing belt tensioner roller 2 1 0 2 2 5 0 2 RH engine mounting Pre tightening 1 4 screws Tightening 2 0 2 8 Tightening 6 1 0...

Page 45: ...3 0 3 Valve cover Pre tightening 0 5 0 5 0 15 Tightening 1 1 0 1 0 9 0 1 0 8 0 1 0 9 0 1 Camshaft pulley hub 7 5 0 7 4 3 0 5 Hub pulley 2 0 2 Flywheel Clutch Flywheel Pre tightening 2 0 2 1 5 Tighteni...

Page 46: ...Angular tightening 45 5 Union on injection rail 2 0 2 Injection pump 0 5 0 1 2 25 0 3 Union on injector 2 0 2 Common rail fixing screw 0 9 0 1 0 8 0 1 Injection pump pulley 5 0 5 Union on injection p...

Page 47: ...ENGINE 44 ENGINE SPECIFICATIONS Engine XFX B1BP27CD Compusory engine plate 1 Identification plate a Engine legislation type b Component reference c Factory serial no...

Page 48: ...1 Pencil type ignition coil 0 8 0 3 2 Valve cover Pre tightening 0 5 0 1 Tightening 1 0 1 3 Camshaft bearing cap cover Pre tightening 0 2 0 1 Tightening 1 0 1 4 Cylinder head Pre tightening 2 0 2 Unti...

Page 49: ...FEATURES TIGHTENING TORQUES m daN 5 Exhaust manifold Equipped with a new seal Pre tightening 1 0 1 Tightening 3 0 3 6 Con rod caps Tightening 2 0 2 Angular tightening 74 7 Flywheel Tightening 2 0 2 An...

Page 50: ...centring pins are in place Tightening Pre tightening M11 to 3 0 3 Order from 1 to 8 Pre tightening M8 to 1 0 1 Orer from A to H Tightening M6 to 1 0 1 Order from a to m Untightening M11 to M8 Proceed...

Page 51: ...htening 0 5 0 1 Tightening 0 8 0 1 10 Crankshaft hub Tightening 4 0 4 Angular tightening 80 11 Crankshaft pulley 2 5 0 6 12 Inlet distibutor Equipped with a new seal Pre tightening 0 4 0 1 Tightening...

Page 52: ...daN 14 Camshaft hubs 1st method Advised method Tightening 2 0 2 Angular tightening 57 2nd method Tightening 8 0 8 15 Guide roller 16 Timing belt tensioner roller 8 1 2 17 Camshaft pulley 8 1 2 18 Wat...

Page 53: ...ENGINE 50 Engine XFX SPECIAL FEATURES TIGHTENING TORQUES m daN In the order indicated 19 Oil pump Pre tightening 0 5 0 1 Tightening 0 8 0 1 B1FP04KC...

Page 54: ...e XFX Cylinder head gasket identification Supplier ERLING Thickness Standard mm 0 75 Thickness reference Central lug Exhaust end Multilayer metallic cylinder head seal 1 LH cylinder head gasket 2 RH c...

Page 55: ...m daN Cylinder head bolts NOTE Oil the threads and under the heads of the bolts Use engine oil or Molykote G Rapid Plus In the order indicated Pre tightening 2 0 2 Untightening YES Pre tightening 1 5...

Page 56: ...at d 6 Exhaust camshaft front cylinder head A 389 7 Inlet camshaft front cylinder head A 423 8 Inlet camshaft rear cylinder head E 422 9 Exhaust camshaft rear cylinder head E 388 Valve clearances when...

Page 57: ...ENGINE SPECIFICATION Engines RHY RHZ 4HX Engine identification Engine 4HX Engines RHY RHZ References Compulsory engine plate a Engine legislative type b Component reference c Factory serial no B1CP046...

Page 58: ...1 35 0 06 2 0 655 to 0 705 1 40 0 06 3 0 705 to 0 755 1 45 0 06 4 0 755 to 0 83 1 50 0 06 5 RHZ RHY B1DP15AD Cylinder head New cylinder head height 133 mm Maximum permitted deformation 0 03 mm Cylinde...

Page 59: ...e threads and under the heads using engine oil or Molykote G plus ESSENTIAL Tighten screw by screw in the order indicated Pre tightening 2 0 2 Tightening 6 0 6 Angular tightening 220 5 Order from 1 to...

Page 60: ...1 0 61 to 0 65 1 30 0 04 1 2 0 66 to 0 70 1 35 0 04 3 0 71 to 0 75 1 40 0 04 4 4HX Cylinder head New cylinder head height 133 mm Maximum permitted deformation 0 03 mm Cylinder head gasket Multilayer c...

Page 61: ...L Tighten screw by screw and in the order indicated Pre tightening 2 0 2 Order 1 to 10 Tightening 6 0 6 Order 1 to 10 Untightening 360 Order 10 to 1 Pre tightening 2 0 2 Order 1 to 10 Tightening 6 0 6...

Page 62: ...ENGINE 59 Tooling BELT TENSION SEEM UNITS CORRESPONDENCE TABLE 4099 T C TRONIC 105 4122 T C TRONIC 105 5 B1EP135D...

Page 63: ...trument 4122 T C TRONIC 105 5 WARNING If using tool 4099 T C TRONIC 105 refer to the correspondence table on page 59 ESSENTIAL Before refitting the auxiliary equipment drive belt check that 1 The roll...

Page 64: ...turning the tensioner roller 1 by the screw 2 anti clockwise WARNING the screw 2 has a left hand thread Remove the belt 3 while keeping the tensioner roller 1 tensioned Refit the belt Compress the te...

Page 65: ...move the auxiliary equipment drive belt ESSENTIAL Check that the guide rollers are turning freely No play and no tightness Refit Refit the auxiliary equipment drive belt Respect the following order of...

Page 66: ...belt WARNING Mark the direction the belt was fitted 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 tensioner roller 2 com...

Page 67: ...rection in which the belt is fitted 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 roller 3 tool 1 a...

Page 68: ...rk 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 compressed and...

Page 69: ...direction in which the belt is 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 roller 5 tool 1...

Page 70: ...g 0188 Q1 Remove WARNING mark the direction of fitting in case the belt is to be reused Compress the tensioner roller 1 by action at a anti clockwise using tool 1 Peg at b using tool 2 Remove the auxi...

Page 71: ...0188 Q1 Remove WARNING mark the direction of fitting in case the belt is to be reused Compress the tensioner roller 4 by action at c anti clockwise using tool 1 Peg at d using tool 2 Remove the auxili...

Page 72: ...DW 7 10 9 10 12 J4 J4D J4 TD ATED TED4 1 8i 16V 2 0i 16V 3 0i V6 2 0 HDi 2 2 HDi Engine plate 6FZ RFN RLZ XFX RHY RHZ 4HX CITRO N C5 X X X X X X X See pages 70 to 73 74 to 79 80 to 84 85 to 90 CHECKIN...

Page 73: ...engage without effort WARNING If the pegs do not engage without effort restart the fitting and tensioning of the timing belt see below Setting the valve timing Remove Remove the screws 2 the pulley 1...

Page 74: ...ng an Allen 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...

Page 75: ...ction of rotation 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 pos...

Page 76: ...sing tool 5 Tighten screw 13 to 4 0 4 m daN then angular tighten to 53 4 Assembly with steel washer gold in colour 40 4 Assembly with sintered washer metallic in colour using the tool 4 Remove tools 1...

Page 77: ...aining pin 0187 J 5 Exhaust camshaft hubs immobilising tool 0187 F 6 Inlet camshaft hubs immobilising tool 0187 F Remove the auxiliaries drive belt See corresponding operation Checking the valve timin...

Page 78: ...tool 2 engages without effort in the cylinder heads at the camshaft pulleys Remove the tools 1 and 2 Refit The lower timing cover 13 The upper timing covers 9 and 10 The crankshaft pulley 12 The rolle...

Page 79: ...ey screws 15 and 17 NOTE Damp the rotation of the camshafts 14 and 18 using tool 5 Untighten the camshaft pulley screws 14 and 18 NOTE Lubricate the tools 1 with grease G6 TOTAL MULTIS Peg the camshaf...

Page 80: ...nscriptions on the belt should be readable the correct way up Fit the timing belt on the crankshaft pinion Position the tool 6 Position the timing belt in the following sequence Belt well tensioned Th...

Page 81: ...ghten the nut 23 of the tensioner roller 24 tighten to 1 0 1 m daN Check that the camshaft pinion screws are not at the end of slots By loosening one screw Otherwise restart the operation of positioni...

Page 82: ...the crankshaft using tool 2 Check the roller position 24 the alignment of the marks c and d should be correct Peg the camshaft pinions using tool 1 If the peg 1 goes in loosen the camshaft pulley scre...

Page 83: ...sing tool 3 From under the vehicle The camshaft using tool 5 WARNING On removing screws 6 7 9 and 5 of the timing cover refit the screw 5 equipped with a spacer thickness 17 mm Tighten to 1 5 0 1m daN...

Page 84: ...timing belt 22 Checks IMPERATIVE Just before refitting carry out the checks below Check that The rollers 20 23 and the water pump turn freely without play or tightness There are no traces of oil on ca...

Page 85: ...nhole Refit the belt on the crankshaft 25 Hold the belt using tool 4 Reposition the timing belt keeping the belt tight at a in the following order Guide roller 23 Fuel high pressure pump pinion 26 Cam...

Page 86: ...21 from the pinion 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 rot...

Page 87: ...t the operation Remove tools 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 c...

Page 88: ...plugs 0188 T IMPERATIVE Respect the safety and cleanliness recommendations specific to high pressure diesel injection HDi engines Checking the setting of the valve timing Turn the crankshaft normal d...

Page 89: ...re coinciding continue the checking operations Peg The crankshaft using tool 3 The camshaft pinion using tool 5 IMPERATIVE Should it be impossible to peg the camshaft check that the offset between the...

Page 90: ...ove the timing belt 26 Checks IMPERATIVE just prior to refitting carry out the checks below Check That the rollers 24 and 27 and the water pump 22 are turning freely Without play and without tightness...

Page 91: ...nhole Refit the belt on the crankshaft 28 Hold the belt using tool 4 Reposition the timing belt keeping the belt tight at a in the following order Guide roller 27 Fuel high pressure pump pinion 30 Cam...

Page 92: ...not against the end of the buttonhole Tighten the screws 25 to 2 m daN Remove tools 1 2 3 and 5 Rotate the crankshaft 8 times normal direction of rotation Fit the tool 3 Loosen screws 25 Fit tool 5 Lo...

Page 93: ...Rotate the crankshaft 2 times normal direction of rotation Fit the tool 3 IMPERATIVE Should it be impossible to peg the camshaft check that the offset between the camshaft pinion hole and the pegging...

Page 94: ...INE 91 SPECIAL FEATURES POWER UNIT SUSPENSION Engines 6FZ RFN RLZ Tightening torques m daN 1 4 5 0 5 2 6 1 0 6 3 5 0 5 4 5 0 5 5 5 0 5 6 5 0 5 7 4 5 0 5 8 6 5 0 6 9 2 7 0 3 10 4 5 0 5 11 4 5 0 5 B1BP2...

Page 95: ...5 3 Bolt 3 0 3 4 Nut 6 5 0 6 B Automatic gearbox 5 Bolt 6 0 6 6 Bolt 5 5 0 5 7 Pin 0 8 0 1 8 Bolt 2 7 0 3 9 Nut 2 8 0 1 Upper RH engine mounting 10 Bolt 6 1 0 6 11 Bolt 6 1 0 6 12 Bolt 4 5 0 5 13 Nut...

Page 96: ...NE 93 SPECIAL FEATURES POWER UNIT SUSPENSION Engine RHY Tightening torques m daN 1 4 5 0 5 2 5 0 5 3 5 0 5 4 2 7 0 3 5 6 5 0 6 6 4 5 0 5 7 2 1 0 2 8 4 5 0 5 9 6 1 0 6 10 4 5 0 5 11 5 0 5 12 5 0 5 B1BP...

Page 97: ...INE 94 SPECIAL FEATURES POWER UNIT SUSPENSION Engine RHZ Tightening torques m daN 13 4 5 0 5 14 5 0 5 15 5 0 5 16 2 7 0 3 17 4 5 0 5 18 2 1 0 2 19 4 5 0 5 20 61 0 6 21 4 5 0 5 22 5 0 5 23 5 0 5 B1BP27...

Page 98: ...ENGINE 95 SPECIAL FEATURES POWER UNIT SUSPENSION Engine 4HX Tightening torques m daN 1 4 5 0 5 2 5 0 5 3 5 0 5 4 2 7 0 3 5 4 5 0 5 6 2 1 0 2 7 4 5 0 5 8 6 1 0 6 9 4 5 0 5 10 5 0 5 11 5 0 5 B1BP284P...

Page 99: ...CIFICATIONS Engines 6FZ RFN Tightening torques m daN 3 Collars 2 5 0 3 6FZ RLZ 4 Oxygen sensor 4 5 0 5 5 1 5 Oxygen sensor 4 5 0 5 5 1 Engines Catalytic converter 1 Rear silencer 2 6FZ RFN TR PSA K183...

Page 100: ...mm axial 25 mm shear Y flexible pipe not fitted Do not distort the flexible 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...

Page 101: ...ngular 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 essential to disconnect or...

Page 102: ...m axial 25 mm shear Y flexible pipe not fitted Do not distort the flexible 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 r...

Page 103: ...axial 25 mm shear Y flexible pipe not fitted Do not distort the flexible 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 res...

Page 104: ...05 C 118 C 6 mn Max With automatic gearbox COOLING SYSTEM SPECIFICATIONS Engines 6FZ RFN RLZ RHY RHZ Vehicle without air conditioning Engine plate Capacity Radiator surface Pressurisation Opening of t...

Page 105: ...118 C 6 minutes Max ENGINE 102 COOLING SYSTEM SPECIFICATIONS Engines 6FZ RFN RLZ XFX RHY RHZ 4HX Vehicle with air conditioning Engine plate Capacity Radiator surface Pressurisation Opening of thermost...

Page 106: ...amber 2 Water pump 3 Heater matrix 4 Bleed screw heater matrix 5 Drain screw cylinder cover 6 Water outlet housing 7 Bleed screw water outlet housing 8 Drain screw cooling radiator 9 Plug cooling radi...

Page 107: ...Heater matrix 4 Bleed screw heater matrix 5 Drain screw cylinder block 6 Coolant outlet housing 7 Bleed screw coolant outlet housing 8 Bleed screw top hose 9 Cooling radiator 10 Drain screw cooling r...

Page 108: ...nting chamber 3 Thermostat 4 Coolant outlet housing 5 Coolant inlet housing 6 Engine cooling radiator 7 Venting chamber 8 Bleed screw 9 Water oil exchanger 10 Thermostat 11 Thermostat Coolant outlet h...

Page 109: ...enting chamber 2 Heater matrix 3 Coolant inlet housing 4 Exhaust gas coolant heat exchanger 5 Bleed screw 6 Cylinder block drain plug 7 Coolant outlet housing 8 Additional heating Option or according...

Page 110: ...er matrix 2 Coolant inlet housing 3 Exhaust gas coolant heat exchanger 4 Bleed screw 5 Coolant outlet housing 6 Additional heating Option or according to version 7 Radiator 8 Air coolant heat exchange...

Page 111: ...re Bars Rpm 6FZ RFN RLZ XFX 90 C 1 5 5 1 5 5 1 5 5 7 8 1000 3000 1000 3000 1000 3000 900 3000 Diesel engines 1 8i 16V 2 0 HDi 2 2 HDi 2 0i 16V 2 0 HPi 3 0i V6 Petrol engines Tools Tool kit 4103 T RHY...

Page 112: ...NE 109 To be read together with the Petrol and Diesel correspondence tables OIL FILTERS PURFLUX LS 304 LS 880 Specifications Dia mm Height mm LS 880 LS 304 76 89 6FZ RFN RLZ XFX RHY RHZ 4HX X X X X X...

Page 113: ...t 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 Close...

Page 114: ...L5 MAGNETTI MARELLI 900 0 5 9 48P 2 0 i 16V RLZ L4 SIEMENS 900 SIRIUS 81 3 0 i V6 XFZ IF L5 BOSCH 650 600 ME 7 4 6 IDLING ANTI POLLUTION Vehicles Engine type Emission standard Make Injection type Cont...

Page 115: ...esistive value ohms Engine coolant temperature sensor resistive value ohms Idling actuator or stepper motor resistive value ohms 1 8i 16V 2 0i 16V 3 0i V6 6FZ RFN RLZ XFX L4 IF L5 IF L5 L4 IF L5 SAGEM...

Page 116: ...10 89 Brussels directive 83 351 except special derogations for certain private vehicles cyl 2 litres Utility vehicle limits private vehicle limits increased by 25 For private vehicles and utility veh...

Page 117: ...esel certain non EEC European countries certain Export countries EMISSION STANDARDS PSA A S RP Engines Applicable Vehicles ECE R 15 05 US 83 E E C APPLICATION NOTES CHARACTERISTICS With oxygen sensor...

Page 118: ...tries X1 US 84 Petrol Utility vehicles Current Adoption of U S standard Diesel certain non EEC standard for light utility European countries vehicles certain Export countries X2 US 87 Petrol Utility v...

Page 119: ...le alternative to existing models 31 12 94 emission standard L from 1992 to 1994 L CEE Petrol Private vehicles EU Brussels Directive 19 5 Diesel All Types 93 59 91 441 new models 07 92 existing models...

Page 120: ...8 existing models 10 98 L3 CEE Petrol Private vehicles Brussels Directive 94 12 95 Diesel 6 seats and 2 5 tonnes EURO 93 standard made new models 01 96 stricter existing models 01 97 All Types EMISSIO...

Page 121: ...tive 98 69 2000 Diesel All Types EURO 2 standard L3 Gaz new models 01 2000 made stricter existing models 01 2001 Fiscal incentives EMISSION STANDARDS PSA A S RP Engines Applicable Vehicles EURO 2 EURO...

Page 122: ...3 1760 kg IF L5 Petrol Private vehicles Brussels Directive 98 69 All Types EURO 3 standard L4 new models 01 2001 made stricter existing models 01 2003 Fiscal incentives EMISSION STANDARDS PSA A S RP E...

Page 123: ...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 124: ...Do not separate the following components from the diesel injector carrier 2 Diesel injector e no replacement parts Electromagnetic element c no replacement parts Do not alter the position of the nut...

Page 125: ...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 carrie...

Page 126: ...nents refer to corresponding procedures Fuel filter High pressure fuel pump Third piston deactivator High pressure regulator High pressure sensor High pressure fuel injection common rail High pressure...

Page 127: ...ply 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 WARNING Any check of pressure downstream...

Page 128: ...ution valve locked shut Check diesel injector return flow Table below Uncouple the diesel injector return pipe Fuel supply pressure Fuel return pressure Checks Between 3 3 et 4 Bars 0 8 0 4 Bar Check...

Page 129: ...SUPPLY CIRCUIT SPECIFICATION Engine RHY 1 Air filter PSA 7899 2 Flowmeter SIEMENS 3 Water recycled gas exchanger VALEO 4 E G R valve PURFLUX 5 Turbocharger KKK K03 6 Air butterfly MAGNETI MARELLI 48W7...

Page 130: ...exchanger VALEO 8 Turbocharger KKK K03 9 EGR valve PURFLUX 10 Air butterfly MAGNETI MARELLI 48W7 Ref 648 11 Air filter PSA 7899 12 Turbocharging pressure sensor NIPPON DENSO AIR SUPPLY CIRCUIT SPECIF...

Page 131: ...IRCUIT SPECIFICATION Engine 4HX 1 Air air exchanger 2 Air water exchanger 3 Warm air metering device BOSCH 4 Cold air metering device BOSCH 5 Turbocharger ALLIEDSIGNAL GT1549P 6 Flowmeter SIEMENS 7 Ai...

Page 132: ...gine 4HX ESSENTIAL Respect the safety and cleanliness recommendations Tool 1 Manual vacuum pump FACOMM DA 16 Checks ESSENTIAL Respect the safety and cleanliness recommendations that are specific to hi...

Page 133: ...n the valve 1 Grey marking on pipe Appy a vacuum of 0 8 bar The rod a should move 12 2 mm Rod a should be moved 12 mm Swirl control electrovalve Connect the tool 1 as an adaptor between the electroval...

Page 134: ...HDi engines EGR electrovalve Check not under load between the electrovalve 4 and the EGR valve 2 Connect the tool 1 between the electrovalve 3 and the butterfly housing 1 Compare readings with the va...

Page 135: ...In abruptly suppressing the vacuum the valve should click and lock itself back on its seating Repeat the operation several times Butterfly housing Remove the air duct between the air air exchanger and...

Page 136: ...with blue marking Connect the tool 1 between the electrovalve 3 and the EGR valve 2 Compare readings with the values in the table below Butterfly housing electrovalve Check not under load between the...

Page 137: ...cuum the valve should click and lock itself back on its seating Repeat the operation several times Butterfly housing Remove the air duct between the air air exchanger and the butterfly housing 1 Disco...

Page 138: ...ween the tube 1 and the duct 2 Position the tool 1 in the vehicle Connect the pressure gauge 1 to the tool 2 with its tube a long enough for the gauge to be positioned inside the vehicle Checks Prepar...

Page 139: ...at running temperature Vehicle in running order Engine at full load Start the engine Engage first gear and start the vehicle Engage the gears up to third gear Decelerate to 2000 rpm Gradually accelera...

Page 140: ...h pressure diesel injection HDi engines Preliminary operations Carry out the following operations Remove the screw 1 Disconnect the tube 2 Move aside the pressure sensor 3 Preparation of tools in posi...

Page 141: ...tension 2 on the hose b and tool 5 ESSENTIAL Observe the following checking requirements Start the engine Engage first gear and start the vehicle Engage the gears up to third gear Decelerate to 1500 r...

Page 142: ...nder 13 Diagnostic connector 14 Ignition injection test warning lamp 15 Battery 16 Immobiliser unit 17 Air conditioning 18 Instrument panel 19 Fuel tank 20 Fuel pump gauge and filter assembly 21 Canis...

Page 143: ...H MGI MAGNETI MARELLI 1 MGI MAGNETI MARELLI 280520274 IAT S04 0261230034 B13 1 Unleaded 95 RON or 98 RON 2 way black connector Resistance 12 2 ohms 2 way brown connector Installation between the engin...

Page 144: ...2 526 118 ELECTRIFIL SIEMENS SAGEM 1 ELECTRIFIL DAV ELECTRIFIL BITRON 1 Engine RFN Ignition circuit SAGEM BOSCH SAGEM Flash eprom reprogrammable eprom sequential injection 112 way connector 3 way grey...

Page 145: ...ump Air inlet valve DELPHI NGK BOSCH 1 NGK BOSCH 1 SAGEM SAGEM 97097 A OZA 495 PG2 OZA 341 PG7 2 590 004 2 580 034 5 way black connector installed on the cylinder head 4 way blue connector length of w...

Page 146: ...nd tank assembly 16 Fuel tank 17 Inlet air temperature sensor 18 Inlet air pressure sensor 19 Engine coolant temperature sensor 20 Sparking plug 21 Ignition coil block 22 High pressure injector 23 Eng...

Page 147: ...ated on the petrol injection common rail 2 way orange connector resistance 1 88 ohms 3 way black connector located on the petrol injection common rail 2 way brown connector Capacity 66 Litres Installe...

Page 148: ...ay grey connector fixed on the cylinder head 2 way black connector fixed on the front part of the engine block ESSENTIAL Respect the tightening torque 2 5 0 5 m daN 2 way green connector fixed on the...

Page 149: ...onal oxygen sensor 2 Catalytic converter downstream oxygen sensor Electrode gap 1 mm Tighten to 2 5 0 2 m daN 6 way black connector 6 way grey connector installed on the cylinder head 2 way brown conn...

Page 150: ...ery 11 Pressostat 12 Engine speed sensor 13 Camshaft position sensors x2 14 Motorised butterfly housing 15 Canister purge electrovalve 16 Cooling fan unit 17 Pencil type ignition coils x2 18 Petrol in...

Page 151: ...148 INJECTION FEATURES OF BOSCH ME 7 4 6 MULTIPOINT INJECTION SYSTEM Summary 31 Pulse damper 32 Sparking plugs x6 33 Fuel tank 34 Canister reservoir 35 Discharge valve 36 Exhaust line B1HP1B3D...

Page 152: ...ectric pump immersed in the tank voltage 12 V Bars Flow 115 at 120 l h regulation pressure 3 5 Bars Located under front LH wing Electrovalve normally closed 2 way brown connector located under the fro...

Page 153: ...6 way black connector Installed in the ECU compartment 2 way blue connector switch opens at 20 Bars for ECU information steering wheel on full lock Ring seal marked violet fixed on the power steering...

Page 154: ...pstream oxygen sensors 21 Downstream oxygen sensors Electrode gap 1 mm Tightening torque 2 5 0 1 m daN 4 way black connector Static type ignition 4 way green connector Front fixing On the exhaust mani...

Page 155: ...152 INJECTION FEATURES OF BOSCH HDi DIRECT INJECTION SYSTEM Summary B1HP1BTP...

Page 156: ...ehicle speed sensor 9 EATON On the gearbox Brake pedal switch 10a Open at rest 10b Closed at rest Clutch pedal switch 11 Atmospheric pressure sensor 12 BOSCH Integrated in the injection ECU Battery 13...

Page 157: ...unter 35 Incorporated in the dashboard instrument panel Preheater warning lamp 36 Incorporated in the dashboard instrument panel Pre postheating unit 37 NAGARES 960411P CARTIER 735068 Preheater plugs...

Page 158: ...s Composition Polyethylene Fuel pump 16 VDO Electric pump immersed in the tank Voltage 12V Pressure 7 Bars Fuel filter 17 BOSCH 0450907 Fixing on the engine Low pressure regulator Adjustment 2 5 bars...

Page 159: ...sure pump Fuel high pressure pump 3rd piston deactivator 28 BOSCH Fixed on the fuel high pressure pump Air circuit Component diagr Supplier Reference Observations Air flowmeter 4 SIEMENS Air filter 23...

Page 160: ...157 INJECTION FEATURES OF BOSCH HDi DIRECT INJECTION SYSTEM Summary B1HP1BUP...

Page 161: ...RON 240 109 15 way black connector Installed in the ECU compartment Battery 14 VARTA L2 12 volts 400 amps Engine compartment Atmospheric pressure sensor 13 BOSCH Incorporated in the injection ECU Cent...

Page 162: ...ON CH170 BOSCH 0250202032 Coolant temperature sensor 8 ELECTRIFIL Fixed on the coolant outlet housing Electronic immobiliser 37 Accelerator pedal sensor 9 PHILIPS Brake pedal switch 11 a Open at rest...

Page 163: ...BEL PLASTIQUE Fixed under the bodyshell Fuel high pressure pump 21 BOSCH CP1 The high pressure pump is driven by the timing belt Diesel injectors 23 BOSCH 9625542580 Fuel high pressure regulator 31 BO...

Page 164: ...cycling valve 27 PIERBORG Shim reference violet Turbo valve adjustment control capsule 28 Integral with the turbocompressor EGR recycling regulation electrovalve 29 BOSCH Turbo pressure regulation ele...

Page 165: ...162 INJECTION FEATURES OF BOSCH HDi DIRECT INJECTION SYSTEM Summary B1HP1BXP...

Page 166: ...pressure sensor 18 BOSCH Incorporated in the injection ECU Central diagnostic socket 50 In the passenger compartment Diagnostic warning lamp 27 Incorporated in the dashboard instrument panel Vehicle...

Page 167: ...or pedal sensor 54 Brake pedal switch 36 PHILIPS 56 Clutch pedal switch 55 Additional heating control relay 1 Additional heating 2 a Open at rest Boiler elements 2 b Closed at rest Air conditioning co...

Page 168: ...DIRECT INJECTION SYSTEM Fuel circuit Component diagr Supplier Reference Observations Recommended fuel Diesel Fuel temperature sensor 65 MAGNETI MARELLI On the injection rail Fuel high pressure sensor...

Page 169: ...pressure common injection rail 63 BOSCH On the engine 18 cc Reference 1 on injector carrier Class 1 injector Reference 2 on injector carrier Class 2 injector Diesel injector 69 BOSCH 963727798 Refere...

Page 170: ...m reference violet Turbo valve adjustment control capsule 13 Integral with the turbocompressor EGR recycling regulation electrovalve 12 BOSCH Turbo pressure regulation electrovalve 11 BOSCH Catalytic...

Page 171: ...e filter 7 TR PSA F002 Catalyser downstream temperature sensor 8 Differential pressure sensor 9 KAVLICO Catalyser upstream temperature sensor 10 Additive ECU 38 MARWAL Additive reservoir 39 Additive m...

Page 172: ...9 IGNITION 1 8i 16v 6FZ FR8ME RFN52HZ 2 0i 16v RFN FR8ME RFN52HZ 1 mm 2 5 m daN 2 0i HPi RLZ ZR8TPP15 SPARKING PLUGS Vehicles Models BOSCH Engine type CHAMPION EYQUEM Electrode gap Tightening torque C...

Page 173: ...L 1 10 VR 4 Km h 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 speedomete...

Page 174: ...ication of springs No of splines of lining Ext Int Quality of lining Petrol 1 8i 16V 2 0i 16V 2 0 HPi 3 0i V6 6FZ RFN RLZ RHY BE4 5 ML 5 VALEO 230 DNG 4700 230 DNG 4700 R 242 T 6500 11 R 10X 12 R 14X...

Page 175: ...Clutch disc Identification of springs No of splines of lining Ext Int Quality of lining Diesel 2 0 HDi 2 2 HDi RHY RHZ 4HX BE4 5 ML 5 LUK 230 P 4700 225 T 5700 242 T 6500 Damping performed by engine...

Page 176: ...rence Speedometer ratio Gearbox type Gearbox ident plate Reduction box torque Petrol Petrol 18i 16V 2 0i 16V 2 0 HPi Automatic Automatic 6FZ RFN RLZ 195 65 R15 1 93 m 195 65 R15 1 93 m BE4 5 AL4 BE4 5...

Page 177: ...ence Speedometer ratio Gearbox type Gearbox ident plate Reduction box torque Diesel 2 0 HDi 2 2 HDi Automatic Automatic RHY RHZ 4HX 195 65 R15 1 93 m 215 65 R16 1 96 m BE4 5 ML 5 AL4 ML 5 4 HP 20 20 D...

Page 178: ...5 BE4 5 GEARBOX SPECIFICATION Engines 6FZ RFN RLZ RHY Identification CLUTCH GEARBOX DRIVESHAFTS Identification a Marking zone Sequence and serial no b Location of identification label B2CP3BNC B2CP3BP...

Page 179: ...gear 3rd 4th gear 13 Driven gear 2nd gear 14 1st 2nd gear synchroniser 15 Driven gear 1st gear 16 Secondary shaft 17 Differential gear 18 Satellite gears 19 Planet gears 20 Differential housing 21 Spe...

Page 180: ...RHY Identification continued CLUTCH GEARBOX DRIVESHAFTS B2CP3BRD Tightening torques m daN 29 Differential housing 5 30 Breather pipe 1 7 31 Rear housing cover screws 1 25 32 Top up plug 2 2 33 Differ...

Page 181: ...Z RFN RLZ RHY Recommendations Precautions B2CP3BLD 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 See chapter on lubrication page 1...

Page 182: ...nes 6FZ RFN RLZ RHY B2CP3CJD Gear controls 1 Gear lever positioning tool 8605 T 1 Gear engagement ball joint 10 mm 2 Gear control lever 3 Gear engagement control cable 4 Gear selection control cable 5...

Page 183: ...6FZ RFN RLZ RHY Gear selection control cable Gear engagement control cable B2CP3CKD B2CP3CLD Left hand drive Right hand drive Left hand drive Right hand drive Length A 730 3 mm Length G 700 3 mm Lengt...

Page 184: ...ted each time the gearbox is removed or cables changed WARNING Do not use oil to detach the ball joints To release the ball joint press at the centre a then pull the ball joint upwards Ball joints alo...

Page 185: ...power unit are removed Adjustment principles Lock the gear lever in neutral position using tool 1 Position the gearbox in neutral Anchor the ball joints on the gearbox levers Lock the cable lengths w...

Page 186: ...ble ball joint c Make sure the gear levers engagement and selection are in neutral position Lock the cable lengths with the ball joint locking keys Remove the tool 1 Checks Remove the tool 1 Check tha...

Page 187: ...184 CLUTCH GEARBOX DRIVESHAFTS ML 5 GEARBOX SPECIFICATION Engines XFX RHZ 4HX Identification Identification a Marking zone Sequence and serial no b Location of identification label B2CP3CMC...

Page 188: ...gears 11 Speedometer screw 12 Speedometer drive 13 Planet gears 14 Differential housing 15 Differential gearwheel 16 Differential bearing stop plate 17 1st 2nd gear synchroniser and reverse gear driv...

Page 189: ...8 Reverse lamp switch 2 5 0 2 29 Gearbox casing clutch housing fixing screws 2 0 2 30 Differential bearing stop plate screws 2 0 2 31 Gearbox rear casing screws 2 0 2 32 Drain plug 3 0 3 33 Filling to...

Page 190: ...DRIVESHAFTS ML 5 GEARBOX SPECIFICATION Engines XFX RHZ 4HX Recommendations Precautions B2CP3CUC 1 Drain plug 2 Filler and top up plug Oil quality See chapter on lubricants page 19 Oil quantity After d...

Page 191: ...ARBOX SPECIFICATION Engines XFX RHZ 4HX B2CP3CQD 1 Gear lever positioning tool 8605 T 1 Gear engagement ball joint 10 mm 2 Gear control lever 3 Gear engagement control cable 4 Gear selection control c...

Page 192: ...s XFX RHZ 4HX Gear selection control cable Gear engagement control cable B2CP3CRD B2CP3CSD Left hand drive Right hand drive Left hand drive Right hand drive Length A 750 3 mm Length C 771 3 mm Length...

Page 193: ...l cables should be adjusted each time the gearbox is removed or cables changed WARNING Do not use oil to detach the ball joints To release the ball joint press at the centre a then pull the ball joint...

Page 194: ...wer unit are removed Adjustment principles Lock the gear lever in neutral position using tool 1 Position the gearbox in neutral Anchor the ball joints on the gearbox levers Lock the cable lengths with...

Page 195: ...b Make sure the gear levers engagement and selection are in neutral position Lock the cable lengths with the ball joint locking keys Remove the tool 1 Checks Remove the tool 1 Check that all the gear...

Page 196: ...RBOX SPECIFICATION Engines XFX 4HX B2CP3CYD Identification 1 Identification plate riveted on the casing a Serial no b ZF number last digits taken into account c Type of automatic gearbox d Component r...

Page 197: ...ometer take off aperture plug 1 0 1 5 Steel casing fixing 0 6 0 1 6 Converter fixing on engine 6 1 7 Interior fixing of converter cover on clutch housing 2 3 0 5 8 Torx fixing of converter cover on cl...

Page 198: ...HP 20 AUTOACTIVE GEARBOX SPECIFICATION Engines XFX 4HX Tightening torques m daN Gearbox interior 9 Input speed sensor fixing 0 8 0 1 10 Hydraulic block fixing Large head 0 8 0 1 11 Output speed senso...

Page 199: ...start it impossible with an automatic gearbox Lubrication The automatic gearbox is only lubricated when the engine is running Removing refitting Automatic gearbox WARNING Never place the gearbox on it...

Page 200: ...ulting in a malfunction or the destruction of a clutch the oil will overheat and become contaminated with impurities the oil is said to be burnt This is characterised by a black colour and the presenc...

Page 201: ...comfort gear selection quality loss of functions Access to emergency programme only 3rd ratio and reverse are available NOTE 4 HP 20 A snatching may be felt when changing P R N R N D Reading the fault...

Page 202: ...or to adapt it to evolutions of the engine ECU After downloading carry out the following Note down the value in the oil usage counter present in the automatic gearbox ECU Delete the fault codes Again...

Page 203: ...e options Carry out a configuration which inhibits the diagnosis of the option s concerned Pedal initialisation AL 4 only A pedal initialisation must be carried out in the following cases Replacement...

Page 204: ...selection lever disengage from position P Unlocking 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...

Page 205: ...unlock the selection lever from the park position Selection P Park locking and immobilisation of the vehicle Selection R Reverse gear Selection N Neutral Selection D Drive Use of the four gears in th...

Page 206: ...lowing three driving programmes Normal The normal programme operates in the absence of the other two Eco law autoadaptative mode Sport Permits a more dynamic sporty performance Snow Facilitates starti...

Page 207: ...kit Gearbox oil seal mandrels 32 5 1 5 7114 T X 9017 T C 0338 J1 0338 J3 8010 T D 8010 T K1 7114 T W 5701 T A 0338 H1 0338 H2 8010 T J 8010 T K2 7116 T 9017 T 0338 8010 T Driveshaft nut 6FZ RFN RLZ R...

Page 208: ...2 3 2 7 Tyre S 195 65 R15 HX1 ENERGY 1 920 m Spare Circumference O 195 65 R15 HX1 ENERGY 1 920 m Wheel T 6 JX 15 H2 4 18 wheel T 6 JX 15 H2 4 18 Pressure Bars 2 7 Electronic under inflation detection...

Page 209: ...7 2 5 2 7 Tyre S 195 65 R15 XH1 ENERGY 1 920 m 215 55 R16W PILOT PRIMACY 1 953 m Spare Circumference O 195 65 R15 XH1 ENERGY 1 920 m Wheel T 6 JX 15 H2 4 18 A 6 5 JX 16 4 26 MONZA wheel T 6 JX 15 H2 4...

Page 210: ...2 3 Bars Front Rear 2 2 3 2 3 Tyre S 195 65 R15H XH1 ENERGY 1 920 m Spare circumference O 195 65 R15H XH1 ENERGY 1 920 m Wheel T 6 JX 15 H2 4 18 wheel T 6 JX 15 H2 4 18 Pressure Bars 2 7 Electronic un...

Page 211: ...Tyre S 205 65 R15H XH1 ENERGY 1 959m 215 55 R16W PILOT PRIMACY 1 953m Spare circumference O 215 55 R16W PILOT PRIMACY 1 953m 205 65 R15H XH1 ENERGY 1 959m Wheel T 6 5 JX 15 CH 4 25 IMOLA 6 5 JX 16 4...

Page 212: ...door pillar a Type of tyre b Tyre specifications c Recommended tyre inflation pressures unladen and laden d Recommended tyre inflation pressures for the spare wheel 1 Wheel bolt For all rim types 2 W...

Page 213: ...red rim on which is affixed a label indicating a speed limit of 80 km h 50 mph A MICHELIN 125 90 R15 TEX tyre pressure 3 5 0 5 Bars NOTE These wheels are available only to replace the 195 65 R15 H tyr...

Page 214: ...transmitter modules 4 incorporated in the wheels in place of the valves each including a lithium battery with 10 years guaranteed life A HF receiver incorporated in the communication module under the...

Page 215: ...the vehicle body and before each mea surement Move the vehicle slightly forwards and backwards by turning the road wheel by hand Check the tyre pressures Release the handbrake Place the manual height...

Page 216: ...the measuring zone on the front subframe to the rear of the front yokes fixing the suspension arm L1 mm Theoretical dimension between the level of the front subframe and the wheel axis 140 L1 mm Theo...

Page 217: ...B Negative figure TOE OUT A B Positive figure TOE IN NOTE Vehicle All types Tracking Adjustable 0 to 3 mm 0 to 0 27 3 03 30 0 30 12 56 30 5 4 1 3 mm 0 49 0 12 1 20 Non adjustable Adjustable Non adjus...

Page 218: ...0 4 6 Ball joint fixing on pivot 25 2 5 7 Suspension leg upper fixing on pivot 5 4 0 5 8 Hub nut 32 5 2 6 9 Wheel fixing 9 1 10 Arm front fixing 13 1 3 11 Arm rear fixing 8 0 8 12 Anti roll bar beari...

Page 219: ...5 1 1 4 Front subframe fixing on bodyshell 11 5 1 1 5 Suspension shaft fixing 14 9 1 3 6 Hub nut 25 2 5 7 Wheel fixing 9 1 NOTE 3 and 4 Face and threads not greased Anti roll bar Engines Diameter mm...

Page 220: ...xing 13 1 3 11 Arm rear fixing 8 0 8 12 Anti roll bar bearing fixing on subframe 4 2 0 6 Hydractive 3 hydraulic suspension Power steering Suspension piston diameter 35 mm Anti roll bar diameter 23 5 m...

Page 221: ...fixing 13 1 1 4 16 Front fixing of subframe on bodyshell 11 5 1 1 NOTE 13 and 16 Face and threads greased 17 Arm shaft fixing 14 9 1 3 18 Hub nut 25 2 5 19 Wheel fixing 9 1 Hydractive 3 hydraulic sus...

Page 222: ...219 AXLES SUSPENSION STEERING SUSPENSION Height control Tightening torques m daN 20 Collars 0 6 B3CP06TD...

Page 223: ...Vehicle All types Tracking Adjustable 0 to 3 mm 0 to 0 27 3 03 30 0 30 12 56 30 4 1 5 mm 0 41 0 13 1 20 Non adjustable Adjustable Non adjustable Castor Camber King pin inclination Tracking Camber B3CP...

Page 224: ...olumn fixing on mounting 2 3 0 4 3 Column fixing on mounting 2 3 0 2 4 Cardan fixing 2 3 0 3 5 Ball joint fixing on pivot 3 5 0 6 6 Link rod lock nut 6 0 4 7 Valve fixing on cover 2 3 0 1 8 Piping fix...

Page 225: ...Z RFR RJX RHY RHZ 2x83 XFX 4HX 2x74 3 34 29 31 58 50 4 1 39 74 35 65 9 33 3 3 Tightening torques m daN Engines EW DW ES9J4 12 Vis 13 Vis 14 Vis 2 2 0 3 2 5 0 6 Engine XFX A converter integral with the...

Page 226: ...ston 276 14 12 ABEX or TEXTAR 949 1 or T 4110 BRAKE SPECIFICATIONS Master cylinder Master vac Caliper piston makes FR mm Brake disc Non ventilated Ventilated Disc thickness min thickness Brake pad gra...

Page 227: ...EXTAR or ABEX T 4110 or 949 1 BRAKE SPECIFICATIONS Master cylinder Master vac Caliper piston makes FR mm Brake disc Non ventilated Ventilated Disc thickness min thickness Brake pad grade Cylinder or c...

Page 228: ...d discs Rear brakes with non ventilated discs Handbrake lever controlling cables acting on the front wheels The compensator and main brake limiter functions are assured by the ABS EBD system fitted as...

Page 229: ...in tandem 2 Braking servo 3 Brake caliper 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 ECU 8 Stopla...

Page 230: ...0 2 1 5 mm Tightening torque 0 8 0 2 m daN 2 way black connector Rear wheel The sensors are inductive type sensor 96 332 954 80 Mounted on the brake caliper support Non adjustable airgap 0 15 1 6 mm T...

Page 231: ...age Front brake Rear brake 15 Fixing on bodyshell 1 8 0 25 16 Servo fixing 2 1 0 1 12 Caliper fixing on pivot 12 1 8 13 Yoke fixing on caliper 3 1 0 1 14 Rear caliper fixing on suspension arm 7 0 7 Ti...

Page 232: ...he brake cables under the vehicle Apply and release the handbrake 10 times Set the handbrake to the 5th notch Tighten the nut 1 until the front brakes are applied Pull the handbrake lever vigorously 4...

Page 233: ...brake fluid reservoir Drain the brake fluid reservoir 1 to the maximum if necessary use a clean syringe Disconnect the connector 3 Uncouple the pipe 2 Remove the reservoir 1 by separating the lugs a f...

Page 234: ...NG During the bleeding operation take care to maintain the level of brake fluid in the reser voir and to top it up using only brake fluid that is clean and clear Bleeding the primary circuit WARNING T...

Page 235: ...vel Should be between DANGER 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 cir...

Page 236: ...e reservoir Use LEXIA or PROXIA diagnostic tools Select the menu corresponding to the vehicle ABS menu ESP menu Follow the instructions on the diagnostic tool At the end of the bleeding process check...

Page 237: ...Hydro electronic Interface BHI 22 Front slimline sphere 23 Front suspension cylinder 24 Rear slimline sphere 25 Rear suspension cylinder 26 Front hydractive 3 regulator accumulator 27 Front hydractive...

Page 238: ...Reference Function Component d Induction Built in Hydro electronic Interface BHI Power steering pump e Built in Hydro electronic Interface BHI f Return Power steering pump c Suspension cylinders Synt...

Page 239: ...with 5 axial pistons Throughput 0 7 l min at 2300 rpm 35 Anti pulse hydropneumatic Diameters of the pistons 6 35 mm accumulator Safety valve rating 180 Bars A safety valve 34 Electronic control unit...

Page 240: ...D HYDRAULIC SPECIFICATIONS Hydractive 3 regulator 40 Slimline sphere 39 Hydractive regulator 38 Electrovalve 41 Depressurisation screw Hydraulic unions Reference Tube diameter Tightening torque mm m d...

Page 241: ...re number marked on the suspension sphere indicates the initial inflation pressure value Example The pressure value of this type of suspension sphere is given merely as a guide When checking the value...

Page 242: ...IC SYSTEM 239 B4BP01DD SPECIFICATION IDENTIFICATION SUSPENSION SPHERES 1 Front suspension sphere 2 Rear suspension sphere 3 Front hydractive 3 regulator accumulator 4 Rear hydractive 3 regulator accum...

Page 243: ...r of damper hole mm 6FZ 96 420 906 80 385 57 1 9 1 3 RHY RHZ 96 420 907 80 1 75 1 3 Rear suspension sphere 2 All Types 96 420 905 80 385 25 0 7 0 48 Hydractive 3 suspension Front suspension sphere 1 R...

Page 244: ...0i 16v MELCO M002T13081 2 0i HPi MELCO 9625169680 4 VC 3 0i V6 MELCO 9625169680 4 H T C VC VALEO D7R26 5 H T 2 0 HDi MELCO M001T80481 BOSCH 1236080 6 C VC VALEO D7R27 2 2 HDi BOSCH 1236080 6 H T C VC...

Page 245: ...M 12 MELCO A003TA6491 T MELCO A003TA0891 1 8i 16v 9 VALEO A13 VI 204 C VC 2 0i 16v MELCO A002TB2291 2 0i 16v HPi 9 VALEO A13 VI 204 H T BOSCH A12051611 Level 1 MELCO A002TB2291 C 15 VALEO A14 VI 27 H...

Page 246: ...OSCH 0250202032 CARTIER 960411 P Managed by the 2 2 HDi CHAMPION CH170 NAGARES 735068 diesel injection ECU BERU 0100226344 CARTIER 960411 P PRE HEATING AND STARTING CIRCUITS Vehicles models Pre heater...

Page 247: ...10 CITRO N XFX 11 2000 650 6 C5 4HX 0 50 gr RHY DELPHI V5 265 15 PLANETELF RHZ 1 488 AIR CONDITIONING R 134 a HFC Vehicle Engines Date Refrigerant refill Compressor Variable capacity Number of valves...

Page 248: ...inium Steel Pipes 1 7 3 1 3 3 M 06 3 8 3 2 2 M 08 4 3 2 5 3 M 10 NOTE For operations concerning draining drying empty checking and refilling of a system refer to BRE 0290 WARNING For R 134 a quantitie...

Page 249: ...IR CONDITIONING SPECIAL FEATURES AIR CONDITIONING SYSTEM R 134 a Pollen filter Remove The trim 1 under the dashboard driver s side The cover 2 Unclip at a and pull out the pollen filter 3 Remove the p...

Page 250: ...he condenser proceed to clean the area of the skirt 8 of the reservoir 6 using a cloth then replace the dryer reservoir 6 Removing the plastic bracket holding the reservoir 6 Remove the screw 3 Torx 2...

Page 251: ...n in and around the base 8 with a paper cloth Preparing the new dryer reservoir Remove the black plastic protection cap from the reservoir neck 6 leaving in place the green protec tion at the other en...

Page 252: ...otherwise there is a risk of damaging the air conditioning circuit Screwing the reservoir 6 into the base 8 Screw the reservoir 6 manually until the neck of the reservoir 6 is in contact with the bott...

Page 253: ...ve so as not to lose any oil No more oil should be added when filling the system with R 134 a fluid b Using draining filling equipment fitted with an oil decanter Drain the R 134 a fluid from the syst...

Page 254: ...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 255: ...em 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 speed unsuitable High pressure to...

Page 256: ...pressure valve 2 Low pressure valve 3 Pressostat 4 Capacity a Condenser bracket Tighten to 0 8 m daN b Pressure control valve Tighten to 0 8 m daN c Compressor bracket Tighten to 2 5 0 1 m daN d Cond...

Page 257: ...ngine XFX 1 High pressure valve 2 Low pressure valve 3 Pressostat 4 Capacity a Condenser bracket Tighten to 0 8 m daN b Pressure control valve Tighten to 0 8 m daN c Compressor bracket Tighten to 2 5...

Page 258: ...ressure valve 2 Low pressure valve 3 Pressostat 4 Capacity a Condenser bracket Tighten to 0 8 m daN b Pressure control valve Tighten to 0 8 m daN c Compressor bracket Tighten to 2 5 0 1 m daN d Conden...

Page 259: ...ngine 4HX 1 High pressure valve 2 Low pressure valve 3 Pressostat 4 Capacity a Condenser bracket Tighten to 0 8 m daN b Pressure control valve Tighten to 0 8 m daN c Compressor bracket Tighten to 2 5...

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