CITROEN C8 2002 Handbook Download Page 86

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CLUTCH

GEARBOX

DRIVESHAFTS

BE4/5 GEARBOX SPECIFICATION

Engine : RFN

Tightening torques m.daN.

(1) Gearbox rear casing

: 1.5 ± 0.1

(2) Gearbox casing / clutch casing fixings

: 1.5 ± 0.1

(3) Reverse gear rocker shaft fixing nut

: 4.5 ± 0.4

(4) Breather pipe

: 1.5 ± 0.1

(5) Reverse gear switch

: 2.5 ± 0.2

(6) Drain plug

: 3.5 ± 0.2

(7) Top-up plug

: 2 ± 0.2

(8) Speedo drive support

: 1.5 ± 0.1

(9) Differential housing fixings (M7)

: 1.5 ± 0.1

(10) Differential housing fixings (M10)

: 5 ± 0.5

(11) Clutch bearing guide fixing screw

: 1.5 ± 0.1

(12) Differential extension fixing

: 1.5 ± 0.1

B2CKUB0D

Summary of Contents for C8 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 C8 The handbook is divided into the following sections representing the main functions GENERAL ENGINE INJECTION IGNITION CLUTCH GEARBOX DRIVESHAFTS AXLES...

Page 3: ...p on bodywork B Manufacturer s data plate under RH centre pillar C A S RP No and RP paint code label on front pillar D Inflation pressures and tyre references label on front pillar E Gearbox reference...

Page 4: ...capacity cc 1998 2230 Fiscal rating hp 9 11 Gearbox type BE4 5 AL4 ML5C Gearbox ident plate 20 DL 27 1 20 DL 26 2 20 TP 74 20 LM 09 IDENTIFICATION OF VEHICLES Petrol 2 0i 16V 2 2i 16V X SX Exclusive...

Page 5: ...ndard IFL5 Type code SEB XFWF IF EA XFWF IF Engine type XFW Cubic capacity cc 2946 Fiscal rating hp 14 Gearbox type 4 HP 20 Gearbox ident plate 20 HZ 27 IDENTIFICATION OF VEHICLES Petrol 3 0i V6 S24 E...

Page 6: ...capacity cc 1997 Fiscal rating hp 7 Gearbox type ML5C AL4 ML5C AL4 Gearbox ident plate 20 LM 05 20 TS 04 20 LM 05 20 TS 04 IDENTIFICATION OF VEHICLES Diesel 2 0 HDi 2 0 HDi X SX Exclusive SX Captain C...

Page 7: ...n standard L4 Type code EB 4HWB EA 4HWB Engine type 4HW Cubic capacity cc 2179 Fiscal rating hp 8 Gearbox type ML5C Gearbox ident plate 20 LM 01 IDENTIFICATION OF VEHICLES Diesel 2 2 HDi SX Captain Ch...

Page 8: ...ide lifting At the front and at the rear Take the weight at the sill by means of the crossbeam 1 as close as possible to the jacking point Position a stand at the jacking point provided for the purpos...

Page 9: ...vehicle toppling it is prohibited to remove mechanical components With body clamps WARNING These clamps are fitted only on FOG lifts Position the clamps at the sill in the jacking points provided scre...

Page 10: ...tween Min and Max 1 7 2 1 9 1 5 5 speed gearbox 1 8 2 2 2 Automatic gearbox 6 8 3 6 After oil change 3 5 3 3 Hydraulic or brake circuit 0 66 0 66 Cooling system 7 7 2 10 5 10 10 2 11 3 Fuel tank capac...

Page 11: ...c Bore Stroke Compression ratio Power ISO or EEC KW rpm Power DIN HP rpm Torque ISO or EEC m daN rpm RFN 3FZ XFW RHT RHW 4HW 1997 2230 2946 1997 2179 85 88 86 96 87 82 6 85 88 85 96 10 8 1 10 9 1 17 3...

Page 12: ...10 ENGINE SPECIFICATIONS Engines RFN 3FZ 1 Compulsory engine plate A Engine legislation type B Component reference C Factory serial no B1BB010D ENGINE...

Page 13: ...Description M11 M6 Pre tightening 1 0 1 0 5 Slackening Yes No Re tightening 1 0 1 puis 2 0 2 1 0 1 Angular tightening 70 5 B1BK1X8D Description 16 Con rod caps 17 Flywheel crankshaft fixing Pre tight...

Page 14: ...t on cylinder head Engine RFN Engine 3FZ 12 B1BK1X9D B1BK1XAD Description 18 Camshaft bearing cap covers 19 Valve covers 0 5 0 5 1 0 1 1 5 0 1 20 Inlet manifold 21 Exhaust manifold 1 0 1 3 5 0 3 Pre t...

Page 15: ...xing screw Upper support body fixing screw Upper support flexible support fixing nut Support LH flexible support LH engine support fixing nut LH flexible support body fixing screw Intermediate engine...

Page 16: ...ne support Engines RFN 3FZ Description RFN 3FZ Gearbox type 12 13 14 Lower RH rod subframe fixing screw Lower RH engine support cylinder block fixing screw Lower rod lower RH engine support fixing scr...

Page 17: ...Angular tightening Tightening Slackening Pre tightening 285 2 360 2 5 1 1 5 3FZ RFN RFN Tighten in the order indicated X MAXI re usable 270 1C Repair dimension E F H 0 99 E F G sans E H 0 8 E G 0 8 R...

Page 18: ...end of shaft 5 Target for camshaft position sensor Marking position 1 Paint ring Repair reference 2 Green paint ring Factory reference 3 Inlet D1309 Exhaust D1348 4 Inlet 96 332 713 99 Exhaust 96 342...

Page 19: ...17 ENGINE SPECIFICATIONS Engine XFW A Component reference B Engine legislation type C Factory serial no B1BK1JWD ENGINE...

Page 20: ...pport flexible mounting 6 0 6 5 Fixing of RH engine support on flexible mounting 4 5 0 4 6 Fixing of flexible mounting 3 0 3 7 Fixing of RH intermediate engine support on cylinder block 6 0 6 8 Fixing...

Page 21: ...Fixing of torque reaction flexible mounting 4 5 0 4 16 Fixing of heat shield on torque reaction flexible mounting 1 0 1 17 Bearing cap Tightening 2 0 2 Angular tightening 74 7 18 Timing pinion Tighte...

Page 22: ...bearings cap covers or bearings caps 21 Fixings of bearings cap covers or bearings caps Slacken to zero torque 21 Fixings of bearing cap cover or bearing caps Tighten bolt by bolt Tightening Angular t...

Page 23: ...exchanger 0 5 Oil filter 0 2 Stage 1 Do up bolts 13 15 and 17 Stage 2 Tighten bolts 13 15 and 17 to 0 2 Stage 3 Do up the 17 remaining bolts Stage 4 Tighten the remaining bolts to 0 5 Stage 5 Tighten...

Page 24: ...4 Repeat the tightening a few times in the same order to obtain a tightening torque of 0 8 m daN on all the screws Stage 1 Position the screws and do them up by hand Stage 2 Pre tighten the screws 0 5...

Page 25: ...23 SPECIAL FEATURES TIGHTENING TORQUES m daN Engine XFW Cylinder head equipment Lubrication circuit Coolant manifold 27 Screws 2 5 0 2 28 Screws 0 8 29 Screws 0 8 B1BK24YD B1BK24ZD ENGINE...

Page 26: ...head equipment Camshaft bearing cap cover left hand side Camshaft bearing cap cover right hand side 30 Camshaft bearing cap cover or camshaft bearing Pre tighten to 0 2 Tighten to 1 B1EK0GCC B1BK3B8D...

Page 27: ...UES m daN Engine XFW Cylinder head equipment Valve covers left hand side Valve covers right hand side 31 Valve cover Pre tighten to 0 5 Tighten to 0 8 B1EK0GEC B1EK0GFC Respect the sequence of stages...

Page 28: ...FEATURES TIGHTENING TORQUES m daN Engine XFW Cylinder head equipment Inlet manifold 32 Inlet manifold Pre tighten to 0 4 Tighten to 0 8 B1BK251D Respect the sequence of stages and the order of tighten...

Page 29: ...daN Engine XFW Cylinder head equipment Exhaust manifold left hand side Exhaust manifold right hand side 33 Exhaust manifold Pre tighten to 1 Tighten to 3 0 3 B1JK03ND B1JK03LD Respect the sequence of...

Page 30: ...TURES TIGHTENING TORQUES m daN Engine XFW Cylinder head equipment Inlet distributor 34 Inlet distributor Pre tighten to 0 4 Tighten to 0 8 B1BK252D Respect the sequence of stages and the order of tigh...

Page 31: ...inder head gasket thicknesses 1A Engine ref G H 1B Nominal dimension Without marking 0 75 mm 1C CRepair dimension E 1st repair dimension R1 0 95 mm 1C Repair dimension E F 2nd repair dimension R2 1 15...

Page 32: ...head tightening m daN Cylinder head bolts X MAX re usable Pre tightening 2 Slackening YES Tightening 1 5 Angular tightening 225 NOTE Grease the bolts on the threads and under the heads using engine oi...

Page 33: ...The camshafts are identified by the following references 1 Exhaust camshaft E389 Front 2 Inlet camshaft A423 Front 3 Inlet camshaft A422 Rear 4 AExhaust camshaft E388 Rear A Inlet camshaft E Exhaust...

Page 34: ...ackening 360 Tightening 1 2 2 6 Angular tightening 220 B1DK1M6D RHT RHW 4HW 134 mm 134 5 mm B1DK00SC B1DK0Q6C ENGINE NOTE Grease the bolts on the threads and under the heads using engine oil or Molyko...

Page 35: ...y actioning the screw 1 Peg the dynamic tensioner roller 2 using tool 1 Remove the auxiliary drive belt ESSENTIAL Check that the rollers 3 and 4 turn freely no tight spot Refitting Refit the auxiliary...

Page 36: ...2 Remove the auxiliary drive belt IMPERATIVE Check the operation of the rollers no play no tight spot Refitting Position the auxiliary drive belt Commence with the crankshaft pulley 2 Finish with the...

Page 37: ...le B Belt wear check mark fixed on engine C Zero wear mark D Maximum wear mark This marking system permits checking of the belt wear if the marks D and B coincide it implies that the belt requires rep...

Page 38: ...using the belt refit it respecting the direction of rotation marked on removal Refit the belt finishing with the tensioner roller 4 Action the roller 3 using tool 1 clockwise to free the tool 2 Tight...

Page 39: ...wear mark D Maximum wear mark This marking system permits checking of the belt wear if the marks D and B coincide it implies that the belt requires replacing Tighten the screw 1 to 4 5 0 4 m daN Remo...

Page 40: ...k that the rollers 3 and 4 turn freely no play no tight spot Refitting IMPERATIVE If re using the belt refit it respecting the direction of rotation marked on removal Refit the belt finishing with the...

Page 41: ...39 ENGINE Tools BELT TENSION SEEM UNITS CORRESPONDENCE TABLE 4099 T C TRONIC 105 4122 T C TRONIC 105 5 B1EP135D...

Page 42: ...4122 T C TRONIC 105 5 WARNING If using tool 4099 T C TRONIC 105 refer to the correspondence table on page 39 ESSENTIAL Before refitting the auxiliary equipment drive belt check that 1 The roller s ro...

Page 43: ...hub 6310 T Removing Disconnect the battery Remove The under engine shield The auxiliary drive belt see corresponding operation Move aside The fuel delivery pipe The canister purge electrovalve The ex...

Page 44: ...fts using tool 2 The crankshaft using tool 1 Slacken the screw 7 while holding tool 4 Using the hexagonal recess C turn the eccentric hub 8 of the tensioner roller 9 clockwise to detension the belt Th...

Page 45: ...ant pump 12 turn freely no tight spot When replacing the belt 11 tighten the fixing to 3 5 0 3 m daN Position the belt on the crankshaft pinion 13 respecting its direction of fitting Immobilise the be...

Page 46: ...sition NOTE This operation places the index 10 in the nominal position E Tighten the screw 7 to 2 0 2 m daN while holding the roller by means of the hexagonal recess C Remove the pegs 1 2 and 4 Checks...

Page 47: ...ition the flange 17 IMPERATIVE This operation guarantees the setting of the timing for subsequent operations Slacken the screw 16 so as to free the crankshaft pinion 17 Bring the flange 17 to the pegg...

Page 48: ...he auxiliary drive pulley The screws 4 tighten to 2 1 0 2 m daN The timing cover 5 The torque reaction rod 3 The screws 1 and 2 tighten to 4 5 0 4 m daN Refit the auxiliary drive belt see correspondin...

Page 49: ...obilising hub 6310 T 6 Belt retaining pin 0189 K 7 Engine support crossmember 4090 T Removing Disconnect the battery Remove The under engine shield The auxiliary drive belt see corresponding operation...

Page 50: ...rews 5 The RH engine support 6 The screws 7 plus the auxiliary drive pulley The timing covers 8 and 9 WARNING Do not slacken the fixing screws A IMPERATIVE Do not slacken the fixing screws B Peg The e...

Page 51: ...ting Systematically replace the timing belt IMPERATIVE Check that the rollers 12 and 14 as well as the coolant pump 15 turn freely No play no tight spot When replacing the belt 14 tighten the fixing t...

Page 52: ...OTE This operation places the index 13 in the nominal position F Tighten the screw 10 to 2 0 2 m daN while holding the roller by means of the hexagonal recess D Remove the tools 1 2 3 and 4 Checks Mak...

Page 53: ...s is not possible reposition the flange 20 IMPERATIVE This operation guarantees the setting of the timing for subsequent operations Immobilise the crankshaft using tool 5 Slacken the screw 19 so as to...

Page 54: ...ary drive pulley The screws 7 tighten to 2 1 0 2 m daN The timing cover 8 The RH engine support 6 The torque reaction rod 3 Tighten Screws 5 to 6 0 6 m daN Nut 4 to 4 5 0 4 m daN Screws 1 and 2 to 4 5...

Page 55: ...inlet camshaft hubs 0187 C 6 Tool for immobilising exhaust camshaft hubs 0187 F 7 Instrument for measuring belt tension 0192 Removing Remove The front RH wheel The RH wheelarch The front RH tie bar Th...

Page 56: ...covers 5 The cover 6 The fixing screws of the power steering pump then suspend the latter The support 7 NOTE The camshaft pegging operation can be performed without slackening the pinion screws or ro...

Page 57: ...p Refitting Make sure that the camshafts as well as the crankshaft are correctly pegged Check that the rollers 13 and 14 as well as the coolant pump 15 turn freely no tight spots If replacing the belt...

Page 58: ...rection to the rotation of the engine in order to engage the belt on the pinion Engage the belt on the LH exhaust camshaft pinion 17 IMPERATIVE The angular displacement value of the pinion relative to...

Page 59: ...e to be able to engage the screw 8 Tighten screws 8 9 and 10 to 2 5 0 2 m daN Pivot the tensoner roller to tension the belt to the maximum anti clockwise using tool FACOM R 161 at B SEEM CTI 901 1 440...

Page 60: ...ine backwards Peg the crankshaft using tool 2 Slacken the nut 11 a 1 4 turn Align the marks D and E of the tensioner roller using tool FACOM R 161 Tighten the nut 11 to 2 5 0 2 m daN without altering...

Page 61: ...b until the peg will go in ESSENTIAL Check that the camshaft pinions are not at end of slots by removing a screw If they are repeat the operation to refit the belt Tighten the pinions in the sequence...

Page 62: ...d Refit The power steering pump The support 7 The tensioner roller assembly 1 Tighten Screw 22 to 2 5 m daN LOCTITE FRNETANCH Screw 23 to 4 0 m daN LOCTITE FRNETANCH Screw 24 to 2 5 m daN LOCTITE FRNE...

Page 63: ...pin 0188 K 5 Engine flywheel stop 0188 F 7 Tensioning lever 0188 J2 8 Pulley extractor 0188 P 9 Crankshaft setting peg engine DW10ATED4 0188 Y 10 Crossmember 4090 T 11 Tie bar support 4176 T 12 Retai...

Page 64: ...ing block the engine flywheel tool 5 The auxiliary drive pulley screw Refit the screw without the washer Remove The auxiliary drive pulley using tool 8 The tool 5 Turn the crankshaft Peg The engine fl...

Page 65: ...rod 1 The fuel unions 2 IMPERATIVE Plug the apertures using tool 13 Protect the radiator harness with strong cardboard cut out to the dimensions of the radiator Remove The RH engine support 4 The tim...

Page 66: ...ts Refit the timing belt well tensioned in the following order Crankshaft immobilise the belt using tool 4 Guide roller 6 Engage the timing belt on the pulley 10 Carefully turn the camshaft pinion in...

Page 67: ...1 to 2 3 0 2 m daN without modifying the position of the roller Remove the tool 1 IMPERATIVE By removing one of the screws 8 on the pulley 9 make sure that these screws 8 are not at end of slots If th...

Page 68: ...t A Turn the roller anti clockwise using tool 7 to obtain a tension of 51 2 SEEM units Tighten screw 11 to 2 3 0 2 m daN without modifying the position of the roller Tighten the screws 8 to 2 0 2 m da...

Page 69: ...lly that the offset between the hole in the camshaft hubs and the corresponding pegging hole is not more than 1 mm Remove the peg 2 Refit The lower timing cover The elements 3 of the timing cover The...

Page 70: ...dans le vilebrequin Taraud M16x150 Brosser le filetage de la screws Tightening torque for the screw Tighten to 7 0 7 m daN LOCTITE FRENETANCH Angular tighten 60 6 Outil FACOM D360 Check the tightenin...

Page 71: ...in aircon in aircon circuit circuit circuit 105 C or 22 Bars in aircon circuit 115 C 112 C 115 C 118 C No COOLING SYSTEM SPECIFICATIONS Vehicle with air conditioning Engines RFN 3FZ XFW RHT 4HW Engin...

Page 72: ...flexible pipe by more than 20 angular X 20mm 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 WARN...

Page 73: ...N 1 Bicone collar 74 5 mm Fixing of catalytic converter manifold pipework 2 5 0 4 2 Flexible metallic pipe 3 Lambda probes take off 4 7 0 7 4 Catalytic converter 5 Intermediate silencer 6 Rear silence...

Page 74: ...ne collar 66 mm front rear precatalyser assembly 2 5 0 4 4 Rear precatalyser 5 Flexible metallic pipe 6 Catalytic converters 7 Intermediate silencer 8 Rear silencer 9 Upstream lambda probe take off 4...

Page 75: ...ghtening torques m daN 1 Ball joint front fixing bracket 4 5 0 7 2 Precatalyser 3 Catalytic converter 4 Particle filter 5 Bicone collar 74 5 mm 2 5 0 4 6 Rear silencer 7 Catalytic converter bracket P...

Page 76: ...t particle filter B1JK061D Tightening torques m daN 1 Ball joint front fixing bracket 4 5 0 7 2 Precatalyser 3 Catalytic converter 4 Intermediate silencer 5 Rear silencer A and A After sales cutting z...

Page 77: ...3000 2 2i 16V 3 0i 24V 2 0 HDi 2 2 HDi RHT RHW 80 C 4HW Petrol engines Temperature C Pressure Bars Rpm Tools Toolkit 4103 T 1 Pressure gauge 2 Flexible pipe 3 Union 4202 T ESSENTIAL Respect the safet...

Page 78: ...GINE OIL FILTERS PURFLUX LS 880 LS 923 Specifications mm Height mm LS 923 LS 880 140 86 X 2 0i 16V 2 2i 16V 3 0i 24V 2 0 HDi 2 2 HDi X X To be read together with the Petrol and Diesel correspondence t...

Page 79: ...type RFN 3FZ RHT RHW 4HW Gearbox type BE4 5 ML5C Feature Push clutch Pull clutch Supplier VALEO LUK Mechanism type 230 DNG 4700 230 DNG 5100 225 T 5700 242 T 6500 Clutch disc 11 R 14 X Clutch with do...

Page 80: ...78 CLUTCH GEARBOX DRIVESHAFTS CLUTCH SPECIFICATION Engines RFN 3FZ RHT RHW 4HW Push clutch Pull clutch Push clutch and Pull clutch 1 Clutch disc 2 Clutch plate 3 Clutch bearing B2BK22WD B2BB000D...

Page 81: ...on or inside the clutch housing depending on gearbox type Bleed IMPERATIVE Use only new clear brake fluid avoid entry of any foreign bodies or impurities into the hydraulic circuit Use only hydraulic...

Page 82: ...ave cylinder 2 Create a syphon at A above the clutch slave cylinder using the transparent pipe Open the bleed screw 1 Action the clutch pedal 3 manually through all its travel with seven rapid down up...

Page 83: ...brake fluid level to the MAXIMUM of the brake fluid reservoir capacity Declutch and clutch rapidly 40 times Start the engine Apply the handbrake Engage a gear Check that the clutch starts to engage a...

Page 84: ...2 2 HDi Auto RHT RHW RHT 4HW 215 65 R 15 2 016 M ML5C AL4 ML5C 20 LM 05 20 TP 74 20 LM 01 15x67 21 x 73 16x69 27x21 20 x 16 27x21 GEARBOX AND TYRE SPECIFICATIONS Engine type Tyres Rolling circumferen...

Page 85: ...83 BE4 5 GEARBOX SPECIFICATION CLUTCH GEARBOX DRIVESHAFTS Engine RFN A Marking zone including Component reference Factory serial no B2CKU3PD...

Page 86: ...s 1 5 0 1 3 Reverse gear rocker shaft fixing nut 4 5 0 4 4 Breather pipe 1 5 0 1 5 Reverse gear switch 2 5 0 2 6 Drain plug 3 5 0 2 7 Top up plug 2 0 2 8 Speedo drive support 1 5 0 1 9 Differential ho...

Page 87: ...EARBOX SPECIFICATION Engine RFN Tightening torques m daN 13 Primary shaft nut 7 5 0 7 14 Secondary shaft nut 6 5 0 6 15 Bearing retaining screw 1 5 0 1 16 Differential gearwheel screw 6 0 6 17 Gear co...

Page 88: ...86 CLUTCH GEARBOX DRIVESHAFTS ML5C GEARBOX SPECIFICATION Engines 3FZ RHT RHW 4HW A Label B Gearbox reference C Sequence no D Bar code E Marking zone Gearbox reference Sequence no B2CKUC2D B2CKUCAD...

Page 89: ...arbox is via the venting hole Tightening torques m daN 1 Differential housing fixing M8 L45 1 8 0 1 2 Differential housing fixing M8 L70 1 8 0 1 3 Differential housing fixing M10 L70 4 0 4 4 Different...

Page 90: ...SPECIFICATION Engines 3FZ RHT RHW 4HW Tightening torques m daN 8 Fixing of gearbox cover on gearbox casing 2 0 2 9 Bearing stop plate 2 0 2 10 Vent hole 11 Reverse gear switch 2 5 0 2 12 Fixing of gea...

Page 91: ...L5C GEARBOX SPECIFICATION Engines 3FZ RHT RHW 4HW Tightening torques m daN 13 Flange fixing screws 2 0 2 14 Secondary shaft nut 17 1 7 15 Gear control support screw 1 5 0 1 16 Differential gearwheel s...

Page 92: ...GEARBOX DRIVESHAFTS AL4 AUTOMATIC GEARBOX SPECIFICATION Engines RFN RHT The automatic gearbox is identified by a self adhesive label A or failing that by a marking B 1 Component reference 2 Serial no...

Page 93: ...Tightening 3 0 3 2 Fixing of gearbox on cylinder block 5 2 0 5 3 Speedometer drive 0 8 4 Electrovalve and or regulators on hydraulic block 0 9 5 Hydraulic block 0 8 6 Hydraulic block casing 0 8 7 Aut...

Page 94: ...N 10 Electrovalve controlling flow into the exchanger 1 0 1 11 Multifunction switch 1 5 0 1 12 Sleeve stop 1 5 0 1 13 Automatic gearbox heat exchanger 5 0 5 14 Filler cap 2 4 0 2 15 Top up plug 2 4 0...

Page 95: ...c tool Select the parameter measures function Make starting this operation make sure that the oil temperature is well below 55 C if it is not allow the oil to cool Press the brake pedal Start the engi...

Page 96: ...60 1 C 1st possibility Oil flows out the level is correct Refit the top up plug 3 tighten to 2 5 0 2 m daN 2nd possibility Oil does not flow out Refit the top up plug 3 Add 0 5 litres of oil Refer to...

Page 97: ...SSO LT 71141 Place the vehicle on a lift Move aside the air filter assembly ESSENTIAL Leave the air temperature sensor connected Remove the air vent assembly 2 Raise the vehicle Remove the top up plug...

Page 98: ...eft Tool kit Gearbox oil seal mandrels 10 60 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 RFN 3FZ...

Page 99: ...eNIG Ref 9410 26 Vehicles equipped with the under inflation detection system are identifiable by the presence of aluminium valves The under inflation detection option can only be fitted on vehicles eq...

Page 100: ...giving the recommended inflation pressures is affixed to one of the front door pillars a Type of tyre b Tyre specifications c Recommended tyre inflation pressures unladen and laden d Recommended tyre...

Page 101: ...oor of the boot The cable cannot be accessed from under the vehicle 1 Bolt for steel wheel 2 Bolt for light alloy wheel 3 Anti theft bolt for light alloy wheel 4 Anti theft socket Post equipment for a...

Page 102: ...of the valves each including a lithium battery A HF receiver incorporated in the switching module under the steering wheel The tightening torque for the nut 9 is 0 6 0 1 m daN WARNING Each time a tyre...

Page 103: ...ive figure TOE OUT A B Positive figure TOE IN NOTE E1AP0A5D Front axle Engines RFN 3FZ RHT RHW 4HW XFW 205 65 R15 215 65 R15 215 60 R16 170 174 178 2 1 0 18 0 9 0 30 3 30 30 12 24 40 Specification H1...

Page 104: ...102 AXLES SUSPENSION STEERING AXLE GEOMETRY Front axle Engines RFN 3FZ RHT RHW 4HW XFW 205 65 R15 215 65 R15 215 60 R16 390 394 398 5 1 0 46 0 8 1 30 Specification H1 Wheel tracking Camber mm...

Page 105: ...To check all the angles it is necessary to set the vehicle at reference height Castor camber tracking Setting at reference height Requirements prior to setting at reference height WARNING The checks...

Page 106: ...aration A most suited to pull the straps as far upwards as possible Compress the suspension so as to obtain on the RH and LH sides the bodyshell height H1 reference height to be measured between the l...

Page 107: ...suited to pull the straps as far upwards as possible Compress the suspension so as to obtain on the RH and LH sides the bodyshell height H2 reference height to be measured between the lowermost edge C...

Page 108: ...RY SETTING AT REFERENCE HEIGHT Adjusting the rolling axles NOTE Only the tracking is adjustable at the front If the value is incorrect adjust the track rods 1 One turn of the rod 2 mm approx Tighten t...

Page 109: ...S SUSPENSION STEERING FRONT AXLE Identification 1 Crossmember 2 Tie rods 3 Springs 4 Front suspension leg 5 Anti roll bar 6 Subframe B3CK09JD Anti roll bar Diameter mm Engines RFN 3FZ RHT RHW 4HW 21 5...

Page 110: ...pivot 9 0 9 Fixing of damper rod on upper cup 9 0 9 Fixing of upper cup on body 3 5 0 3 Fixing of anti roll bar on subframe 10 5 1 Driveshaft nut 10 1 Fixing of wishbone on subframe 7 0 7 Fixing of ba...

Page 111: ...109 AXLES SUSPENSION STEERING REAR AXLE Identification 1 Damper 2 Spring 3 Stabiliser bar B2CP3J3D...

Page 112: ...htening torques m daN 5 Fixing of rear axle on body 8 0 8 6 Fixing of stabiliser bar on rear axle 8 0 8 7 Fixing of stabiliser bar on body 6 0 6 8 Hub nut 38 3 8 9 Fixing of damper on body 9 0 9 10 Fi...

Page 113: ...RHT RHW 4HW Identification X Pre adjustment 1 Steering mechanism 2 Distributor valve 3 Power steering reservoir 4 Power steering pump 5 High pressure union 6 Low pressure union 7 Steering oil radiato...

Page 114: ...W 4HW Features Power steering with integral ram Travel mm 166 156 162 Angle of lock for inside wheel 40 48 37 18 39 24 Angle of lock for outside wheel 34 36 32 24 33 42 Type of pump Falling flow Pump...

Page 115: ...steering column to support 2 0 2 10 Fixing of upper and lower shafts to steering column 2 5 0 2 11 Fixing of ram valve supply unions 1 0 1 12 Fixing of steering mechanism 14 5 1 4 13 Fixing of pump v...

Page 116: ...2 LUCAS C38HR 38 272 12 10 TEXTAR T 4131 BRAKE SPECIFICATIONS Master cylinder Master vac Caliper piston makes FT Disc Ventilated Disc thickness min thickness Brake pad grade Caliper piston makes Disc...

Page 117: ...rake caliper on support 3 5 0 3 Fixing of front brake caliper support on pivot 16 1 6 Fixing of brake pipe unions 1 5 0 1 Fixing of rear brake caliper on support 3 5 0 3 Fixing of rear brake caliper s...

Page 118: ...116 BRAKES ADJUSTING THE HANDBRAKE Identification A Zone for fixing on floor B Clips for retaining on bodyshell B3FK263D...

Page 119: ...sion Pull the handbrake lever about ten times in a normal fashion Engage the handbrake lever at the 2nd notch of its travel relative to its position of rest Turn the nut 1 until the brake pads start t...

Page 120: ...r Drain the brake fluid reservoir with the aid of a clean syringe Refit the filter in the brake fluid reservoir Filling IMPERATIVE Use only new clear brake fluid avoiding any ingress of impurities int...

Page 121: ...c tool See Tools following the instruc tions given by the diagnostic tool Use of the diagnostic tool will be necessary in cases where the following conditions all come together simultaneously Air in t...

Page 122: ...XFW 13 06 02 1 750 SD 7 V 16 135 15 SP10 RHT RHW 4HW AIR CONDITIONING SYSTEM R 134A HFC Vehicle Engines Date Refrigerant refill 25 gr Compressor Variable capacity Quantity of oil cc Quality of oil AI...

Page 123: ...2 2 2 5 3 Steel Steel 1 7 3 3 8 3 4 3 Pipe diameters M 06 M 08 M 10 NOTE Tighten the unions to the recommended torques using a retaining spanner whenever possible NOTE For operations concerning drain...

Page 124: ...s located under the bonnet on the LH side Removing Remove the handle 1 Uncouple the evacuation pipe 2 Release at 3 on the RH and LH sides Slacken the screws 4 on the RH and LH sides by a quarter turn...

Page 125: ...emoving Depressurise the air conditioning circuit Remove the hose 1 Disconnect the connector 2 Remove the air filter 3 Turn the plastic pins 4 by a quarter turn Move aside the condenser 5 Clean the ar...

Page 126: ...screw the reservoir 7 Adaptor TORX 70 FACOM Unscrew the reservoir 7 and the protection skirt 6 WARNING This operation should remain clean before the fitting of the new reservoir Cap the base 10 WARNIN...

Page 127: ...ing seals 7 sachet of oil in the kit Remove The protection cap fitted at the time of removal from the base 10 The protection at the other end of the reservoir 7 Engage the reservoir 7 equipped with it...

Page 128: ...lve so as not to lose any oil No more oil should be added when filling the system with R 134A fluid b Using draining filling equipment fitted with an oil decanter Drain the R 134A fluid from the syste...

Page 129: ...me procedure should be followed as if there was no leak at all 3 Fast leak This type of leak causes both oil loss as well as allowing air to enter the system It is therefore necessary to Replace the d...

Page 130: ...speed unsuitable 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...

Page 131: ...129 AIR CONDITIONING AIR CONDITIONING SYSTEM R 134A Engines RFN 3FZ 1 Drying cartridge 2 Clickfit union 3 Buffer capacity 4 Clickfit union 5 High pressure valve 6 Low pressure valve C5HP17TP...

Page 132: ...AIR CONDITIONING SYSTEM R 134A Engine XFW 1 High pressure valve 2 Low pressure valve 3 Buffer capacity 4 Drying cartridge 5 Pressostat 6 Clickfit union Tool 8005 T C Tightening torques m daN a 0 8 b 1...

Page 133: ...ONDITIONING AIR CONDITIONING SYSTEM R 134A Engines RHT 4HW 1 Drying cartridge 2 Clickfit union 3 Buffer capacity 4 Clickfit union 5 High pressure valve Tool 8005 T C 6 Low pressure valve Tool 8005 T A...

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