CITROEN C2 2004 User Manual
  1. Manuals
  2. Brands
  3. CITROEN Manuals
  4. Automobile
  5. C2 2004
  6. User manual

CITROEN C2 2004 User Manual

Specifications, adjustments, checks and special features of citroen private vehicles
Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
Table of Contents

Advertisement

Quick Links

PRIVATE CARS
C2-C3-C3 PLURIEL-XSARA
Xsara Picasso-BERLINGO
«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».
CAR 050014
Volume 1
2004

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the C2 2004 and is the answer not in the manual?

Questions and answers

Related Manuals for CITROEN C2 2004

Summary of Contents for CITROEN C2 2004

  • Page 1 PRIVATE CARS 2004 C2-C3-C3 PLURIEL-XSARA XSARA PICASSO-BERLINGO «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.
  • Page 2 PRESENTATION THIS HANDBOOK summarises the specifications, adjustments, checks and special features of CITROEN private vehicles, not including UTILITY vehicles for which there exists a separate handbook. The handbook is divided into nine groups representing the main functions : GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - ELECTRICAL - AIR CONDITIONING.
  • Page 3 If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into account when preparing future publications. For example : - INSUFFICIENT INFORMATION - SUPERFLUOUS INFORMATION - NEED FOR MORE DETAILS Please send your comments and suggestions to : CITROEN U.K. Ltd. 221, Bath Road, SLOUGH, SL1 4BA. U.K.

  • Page 4: Reconnect Battery After Vehicle Repair

    XSARA 2, all types Operation to reconnect the battery after a vehicle repair WARNING If the battery has been disconnected, after reconnecting it is ESSENTIAL to wait 1 minute before switching on the ignition, otherwise the engine ECU will lock up. If the ECU has locked up : - Switch off the ignition.

  • Page 5: Identification Of Vehicles

    IDENTIFICATION OF VEHICLES A - Cold stamp (Cold stamp engraved on the bodywork) B - Manufacturer’s name plate (On the LH centre pillar) C - AS/RP No. and RP paint code (On the LH centre pillar) D - Tyre pressures and tyre type (On the LH centre pillar) E - Serial number on bodywork F - Gearbox ident.
  • Page 6 IDENTIFICATION OF VEHICLES 1.1i 1.4i 1.6i 16V Pack - Pack ambiance Pack ambiance - VTR - Exclusive IFL5 IFL5 Emission standard JM HFXB JM HFXC/IF (*) JM KFVB/P JM KFVC/PIF (**) JM KFVC/IF (*) JM NFUC/PIF (*) Type code Engine type Cubic capacity (cc) 1124 1360...
  • Page 7 IDENTIFICATION OF VEHICLES 1.4 HDi Pack - Pack ambiance - Exclusive IFL5 Emission standard JM 8HXB JM 8HXC/IF (*) JM 8HXC/PIF (**) Type code Engine type 1398 Cubic capacity (cc) Fiscal rating (hp) MA/50 Gearbox type 20 CN 51 (1) 20 CN 33 (2) 20 CN 51 (1) 20 CN 33 (2)
  • Page 8 C2 - C3 OPERATIONS TO BE CARRIED ORT AFTER A REPAIR IMPERATIVE: All these operations are to be performed following a reconnection of the battery. Antiscanning function. It is necessary to wait 1 minute after the battery has been disconnected in order to be able to start the vehicle. Tailgate.
  • Page 9 OPERATIONS TO BE CARRIED ORT AFTER A REPAIR Sun roof. The anti-pinch function has to be re-initialised. Place the sun roof switch in the maximum tilt position. Keep the sun roof switch pressed until the sun roof ceases its movement. Release the sun roof switch within 5 seconds.
  • Page 10 IDENTIFICATION OF VEHICLES A - Cold stamp (Cold stamp engraved on the bodywork). B - Manufacturer’s name plate (On the LH centre pillar) C - AS/RP No. and RP paint code. (label affixed to the front pillar on driver’s side) D - Tyre pressures and tyre type.
  • Page 11 IDENTIFICATION OF VEHICLES Petrol 1.1i Entreprise Pack - Pack ambiance Pack - Pack ambiance Pack K’ L4/INF IFL5 Emission standard FC HFX5 FC HFXB/D FC HFXB FN HFXB FC HFXB/T FR HFXB FC HFXC/IF FN HFXC/IF Type code Engine type Cubic capacity (cc) 1124 Fiscal rating (hp)
  • Page 12 IDENTIFICATION OF VEHICLES PETROL 1.4i AUTO. Pack - Pack ambiance - Pack clim - Exclusive L4/INF IFL5 L4/INF IFL5 Emission standard Type code KFVB/D KFVB KFVB KFVC/IF KFVC/IF KFVE/D KFVE KFVE KFVF/IF KFVF/IF Engine type 1360 Cubic capacity (cc) Fiscal rating (hp) MA/5L MA/5N Gearbox type...
  • Page 13 IDENTIFICATION OF VEHICLES PETROL 1.4i 16V 1.6i 16V SensoDrive Pack ambiance - Pack clim - Exclusive IF/L5 Emission standard FC KFUC/P FC KFUN/P FN NFUB FC NFUB FC NFUC/IF FC NFUC/PIF Type code Engine type 1360 1587 Cubic capacity (cc) Fiscal rating (hp) MA/5S Gearbox type...
  • Page 14 IDENTIFICATION OF VEHICLES Diesel 1.4 HDi Entreprise Entreprise club Entreprise Pack Pack Emission standard FC 8HXB/T FN 8HXB FC 8HXB FC 8HXB/MOD FC 8HXK FR 8HXB FN 8HWB FC 8HWB Type code Engine type 1398 Cubic capacity (cc) Fiscal rating (hp) Gearbox type MA/50 20 CP 54 (m) (1) (*)
  • Page 15 IDENTIFICATION OF VEHICLES Diesel 1.4 HDi 16V Pack - Pack ambiance - Pack clim Pack - Pack ambiance - Pack clim Pack clim Exclusive Exclusive Emission standard FC 8HVB FN 8HVB FC 8HYB FC 8HYB/T FC 8HYB/MOD FC 8HYK FN 8HYB FR 8HYB Type code Engine type...
  • Page 16 C3 PLURIEL IDENTIFICATION OF VEHICLES A - Cold stamp (Cold stamp engraved on the bodywork). B - Manufacturer’s name plate (On the LH centre pillar) C - AS/RP No. and RP paint code. (label affixed to the front pillar on driver’s side) D - Tyre pressures and tyre type.
  • Page 17 IDENTIFICATION OF VEHICLES C3 PLURIEL Petrol Diesel 1.4i 1.6i 16V 1.4 HDi SensoDrive IF/L5 IF/L5 Emission standard HB KFVB HB KFVC/IF HB NFUC/IF HB 8HXB Type code Engine type 1360 1587 1398 Cubic capacity (cc) Fiscal rating (hp) MA/5N MA/5S MA/50 Gearbox type 20 CP 60 (m) (1)
  • Page 18 XSARA II IDENTIFICATION OF VEHICLES A - Manufacturer’s name plate (Estate). B - Chassis stamp, cold stamp. C - Manufacturer’s name plate (Saloon). D - Label : (label affixed to the front pillar on driver’s side) - Tyre pressures. - RP organisation no. - Paint code.
  • Page 19 IDENTIFICATION OF VEHICLES XSARA II Saloon petrol 3-door 1.6i 16V 1.4i AUTO. AUTO. Océanic Pack VTR - VTS Pack X - VTR VTR - VTS L5/IF L5/IF Emission standard NO KFWB NO KFW1/IF NO NFUB NO NFUN NO NFU1/IF NO NFU3/IF Type code Engine type 1360...
  • Page 20 IDENTIFICATION OF VEHICLES XSARA II Saloon petrol 3-door 2.0i 16V AUTO. L5/IF L4/IF L5/IF Emission standard NO RFN1/IF NO RFNN/IF NO RFN3/IF NO RFSB Type code Engine type 1998 Cubic capacity (cc) Fiscal rating (hp) BE4/5 BE3/5 Gearbox type 20 DL 40 20 TP 47 20 TE 47 Gearbox ident.
  • Page 21 IDENTIFICATION OF VEHICLES XSARA II Saloon diesel 3-door 1.4 HDi 1.9 D 2.0 HDi AUTO. Océanic Océanic - Pack Pack Pack club VTR - VTS Emission standard N0 8HZB N0 WJYB N0 RHYB N0 RHZB N0 RHZN Type code Engine type 1398 1868 1997...
  • Page 22 XSARA II IDENTIFICATION OF VEHICLES Saloon petrol 5-door 1.4i 1.6i 16V AUTO. AUTO. Océanic - Pack X - SX Pack Exclusive Exclusive Exclusive L5/IF Emission standard N1 KFW1/IF N1 KFW1/IF N1 NFUB N1 NFUN N1 NFU1/IF N1 NFU3/IF Type code Engine type Cubic capacity (cc) 1360...
  • Page 23 IDENTIFICATION OF VEHICLES XSARA II Saloon petrol 5-door 2.0i 16V AUTO. Exclusive L5/IF L5/IF Emission standard N1 RFN1/IF N1 RFNN RFN3/IF Type code Engine type 1998 Cubic capacity (cc) Fiscal rating (hp) BE4/5 Gearbox type Gearbox ident. plate 20 DL 40 20 TP 47 20 DM 03 (2) (1) = Right hand drive : Hydraulic clutch control.
  • Page 24 XSARA II IDENTIFICATION OF VEHICLES Saloon diesel 5-door 1.4 HDi 16V 1.9 D 2 HDi AUTO. Pack - Leader Océanic - Pack Océanic - Leader - Leader Pack - Exclusive Emission standard N1 8HZB N1 WJYB N1 RHYB N1 RHZB N1 RHZN Type code Engine type...
  • Page 25 IDENTIFICATION OF VEHICLES XSARA II Estate petrol 1.4i 1.6i 16V AUTO. Océanic - Pack X - Pack Exclusive Exclusive L5/IF L5/IF Emission standard N2 KFWB N2 KFW1/IF N2 NFUB N2 NFU1/IF N2 NFUN N2 NFU3/IF Type code Engine type 1360 1581 Cubic capacity (cc) Fiscal rating (hp)
  • Page 26 XSARA II IDENTIFICATION OF VEHICLES Estate petrol Estate diesel 2.0i 16V 1.4 HDi 1.9 D 2.0 HDi AUTO. AUTO. Océanic Exclusive X - Pack Pack Océanic - Pack - Exclusive L5/IF Emission standard N2 RFN1/IF N2 RFNN N2 RFN3/IF N2 8HZB N2 WJYB N2 RHYB N2 RHZB...
  • Page 27 XSARA PICASSO IDENTIFICATION OF VEHICLES A - Chassis stamp (Cold stamp on bodywork) B - Chassis no. reminder (Label located at bottom of windscreen right hand side) C - Manufacturer’s data plate. (Located at bottom of RH central pillar) D - Label : - Tyre pressures.
  • Page 28 XSARA PICASSO IDENTIFICATION OF VEHICLES Petrol 1.6i 1.8i 16V 2.0i 16V AUTO. Océanic - Pack Océanic - Pack - Exclusive Exclusive IFL5 Emission standard CH NFVB CH 6FZB CH 6FZC/IF CH RFNF/IF Type code Engine type 1587 1749 1998 Cubic capacity (cc) Fiscal rating (hp) BE4/5/ J (*) BE4/5 V (*)
  • Page 29 XSARA PICASSO IDENTIFICATION OF VEHICLES Diesel 1.6 HDi 16V 2.0 HDi Océanic - Leader - Pack - Exclusive Emission standard CH 9HZC CH 9HYB CH RHYB Type code 9HZ (*) 9HY (**) Engine type 1560 1997 Cubic capacity (cc) Fiscal rating (hp) Gearbox type BE4/5L BE4/5L...
  • Page 30 BERLINGO IDENTIFICATION OF VEHICLES A - Chassis stamp, cold stamp B - Manufacturer’s vehicle plate C - Label - RPO No. - Paint colorr code - Tyre pressures D - Gearbox ident. reference - Factory serial no. E - Engine legislation type - Factory serial no. E1AP0AMD...
  • Page 31 IDENTIFICATION OF VEHICLES BERLINGO Berlingo petrol 5-seater 1.1i 1.4i X - SX - Multispace L4/W4 L4/W4 IFL5 Emission standard GJ HFXB GJ KFWB GJ KFWC/IF Type code Engine type 1124 1360 Cubic capacity (cc) Fiscal rating (hp) MA/5S MA/5L Gearbox type 20 CD 43 20 CN 13 Gearbox ident.
  • Page 32 BERLINGO IDENTIFICATION OF VEHICLES Berlingo petrol 5-seater 1.4i 1.6i 16V Dual fuel Multispace X - SX - Multispace IFL5 Emission standard GJ KFWB/GL (1) GJ KFWB/GN (2) GJ NFUB GJ NFUC/IF Type code Engine type 1360 1587 Cubic capacity (cc) Fiscal rating (hp) Gearbox type MA/5...
  • Page 33 IDENTIFICATION OF VEHICLES BERLINGO Berlingo diesel 5-seater 1.9 D 2.0 HDi X - SX - Multispace X - SX - Multispace Emission standard GJ WJYB GJ WJYB/PMF (1) GJ RHYB Type code Engine type Cubic capacity (cc) 1868 1997 Fiscal rating (hp) BE4/5 BE4/5 Gearbox type...
  • Page 34 CAPACITIES (in litres) Draining mandhod. The oil capacities are defined according to the following mandhods. 1/ Vehicle on level surface (in high position, if equipped with hydropneumatic suspension). 2/ Engine warm (oil temperature 80°C). 3/ Draining of the oil sump + removal of the cartridge (duration of draining + dripping = 15 min). 4/ Refit plug + cartridge.
  • Page 35 CAPACITIES (in litres) Petrol Diesel 1.1i 1.4i 1.6i 16V 1.4 HDi Engine type 8HX   RPO 9884 8HX RPO 9885   Drain by gravity : engine 3,25 3,75 with filter change Bandween min. and max. MA5 5-speed gearbox MA5 piloted 5-speed gearbox 2 ±...
  • Page 36 CAPACITIES (in litres) Petrol Diesel 1.1i 1.4i 1.4i 1.6i 1.4 HDi 1.4 HDI 16V AUTO.   RPO 9884 RPO 9885     RPO 9884 RPO 9885   Engine type Drain by gravity : engine 3,75 3,25 3,75 with filter change Bandween min.
  • Page 37 CAPACITIES (in litres) C3 PLURIEL C3 Pluriel Petrol Diesel 1.4i 1.6i 16V 1.4 HDi Engine type Drain by gravity: engine with filter change 3,25 3,75 Bandween min. and max. 5-speed gearbox 0,7 Litre version with front calipers Ø 48 / rear drums Braking circuit 0,8 Litre version with front calipers Ø...
  • Page 38 XSARA II CAPACITIES (in litres) XSARA II Petrol 1.4i 1.6i 16V 2.0i 16V AUTO. AUTO. Engine type 3,25 4,25 Engine with filter element Bandween min. and max. 5-speed gearbox Automatic gearbox After drainage With ABS = 0,50 - Without ABS = 0,55 Hydraulic or brake circuit Cooling system 6,5 (1)
  • Page 39 IDENTIFICATION OF VEHICLES XSARA II XSARA II Diesel 1.4 HDi 1.9 D 2.0 HDi AUTO.   RPO 9884 RPO 9885   Engine type 3,75 4,75 (1) 4,5 (2) Engine with filter element 1,6 (1) 1,2 (2) Bandween min. and max. 5-speed gearbox Automatic gearbox After drainage...
  • Page 40 XSARA PICASSO CAPACITIES (in litres) XSARA PICASSO Petrol Diesel 1.6i 1.8i 16 V 2.0i 16V 1.6 16V HDi 2.0 HDi AUTO. Engine type Engine with filter element 4,25 3,75 1,55 (3) Bandween min. and max. 5-speed gearbox Automatic gearbox After drainage Hydraulic or brake circuit 0,58 litres Cooling system...
  • Page 41 CAPACITIES (in litres) BERLINGO II Berlingo 2 Petrol Diesel Ecological oil filter capacity 0.15 litre. 1.1i 1.4i 1.6i 16V 1.9 D 2.0 HDi Engine type Moteur avec cartorche 3,25 Bandween min. and max. 5-speed gearbox Hydraulic or brake circuit With ABS = 0,45 - Without ABS = 0,36 Cooling system Fuel tank capacity ESSENTIAL: Systematically check the oil level using the oil dipstick.
  • Page 42 LUBRICANTS - TOTAL recommended oils ALL TYPES Evolutions (year 2004). Use of oil grade 10W 40. It is possible to use semi-synthandic oil 7000 10W40 on PETROL and CITROËN C2, C3 PLURIEL, DISPATCH and DV6 engines. DIESEL vehicles. Only petrol versions are available. WARNING: To avoid problems with starting from cold, use this oil as allowed by the climatic conditions in the corntry concerned (see table).
  • Page 43 LUBRICANTS - TOTAL recommended oils ALL TYPES Engine oil norms. Current norms. The classification of these engine oils is established by the following recognised organisations: - S.A.E : Sociandy of Automotive Engineers. - API : American Petroleum Institute. - ACEA : Association des Constructeurs Européens d’Automobiles E4AP006D...
  • Page 44 ALL TYPES LUBRICANTS - TOTAL recommended oils S.A.E. Norms - Table for selection of engine oil grade Selection of engine oil grades recommended for climatic conditions in corntries of distribution. Evolution of the norms as at 01/01/2003 API norms ACEA 2003 norms The meaning of the first landter has not changed, it still corresponds The meaning of the first landter has not changed, it still corresponds to to the type of engine:...
  • Page 45 LUBRICANTS - TOTAL recommended oils ALL TYPES Recommendations. ESSENTIAL: To preserve engine performances, all engines fitted in CITROEN vehicles must be lubricated with high quality oils (synthan- dic or semi-synthandic). CITROËN engines are lubricated at the factory with TOTAL oil of grade S.A.E.5W-30.
  • Page 46 ALL TYPES LUBRICANTS - TOTAL recommended oils Récapitulation Norms to be observed for engine oils (year 2003) Year Types of engine concerned ACEA norms API norms Petrol and A3 or A5 5 (*) SJ or SL dual fuel petrol / LPG engines Year 2003 B3 or B5 (*) Diesel engines...
  • Page 47 ALL TYPES LUBRICANTS - TOTAL recommended oils Oils specifically for petrol and dual fuel petrol / LPG engines S.A.E. norms ACEA norms API norms TOTAL ACTIVA 7000 10W40 TOTAL QUARTZ 7000 TOTAL QUARTZ 9000 0W40 TOTAL ACTIVA 7000 15W50 TOTAL QUARTZ 7000 Oils specifically for diesel engines S.A.E.
  • Page 48 ALL TYPES LUBRICANTS - TOTAL recommended oils Oil usage table TOTAL ACTIVA QUARTZ Engine types Synthetic 9000 Semi-synthetic 7000 15W50 0W40 5W30 5W40 10W40 cold countries contries XU10 J4RS (Xsara VTS 2.0i 16V) Petrol engines EW 12 J4 (C8 2.2i 16V) Other petrol engines HDi engines with FAP (*) Other HDi engines...
  • Page 49 LUBRICANTS - TOTAL recommended oils ALL TYPES Selection of TOTAL engine oils, to be used according to the climatic conditions in the country where the vehicle is marketed. E4AP006D...
  • Page 50 ALL TYPES LUBRICANTS - TOTAL recommended oils ENGINE OILS FRANCE Blended oils for all engines, supplied in bulk Metropolitan FRANCE TOTAL ACTIVRAC S.A.E. norms : 10W40 TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines...
  • Page 51 LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 7000 10W40 Germany 9000 0W40 Austria 7000 10W40 7000 10W40...
  • Page 52 LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 7000 10W40 Denmark 9000 0W40 7000 10W40 Spain 7000 15W40...
  • Page 53 LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 7000 10W40 Hungary 9000 0W40 Italy Ireland 7000 10W40...
  • Page 54 LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 7000 10W40 Malta 7000 15W50 Moldavia 7000 10W40 7000 10W40...
  • Page 55 LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 7000 10W40 7000 15W50 Romania 9000 0W40 Russia 7000 10W40...
  • Page 56 LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines Ukraine 9000 5W40 7000 10W40 7000 10W40 FUTURE 9000 5W30 (*) 9000 0W40...
  • Page 57 LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS OCEANIA TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines Australia 9000 5W40 7000 10W40 7000 10W40 FUTURE 9000 5W30 New Zealand...
  • Page 58 LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS CENTRAL AND SOUTH AMERICA TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines Argentina Brazil Chile 7000 10W50 7000 15W50...
  • Page 59 LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS SOUTH-EAST ASIA TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 7000 10W50 China 7000 15W50 9000 5W40 South Korea 7000 10W40...
  • Page 60 LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS SOUTH-EAST ASIA TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines Philippines 7000 15W50 Singapore 7000 10W40 9000 5W40 Taiwan...
  • Page 61 LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS MIDDLE EAST TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines Saudi Arabia - Bahrain Dubai 7000 15W50 United Arab Emirates...
  • Page 62 LUBRICANTS - TOTAL recommended oils ALL TYPES GEARBOX OILS TOTAL TRANSMISSION BV norms S.A.E.: 75W80 Manual gearbox and SensoDrive Part No.: 9730 A2. TOTAL FLUIDE ATX TOTAL FLUIDE AT 42 MB3 automatic gearbox Special oil distributed by All countries CITROËN Part No.: 9730 A3 Special oil distributed by 4HP20 and AL4 autoactive...
  • Page 63 LUBRICANTS - TOTAL recommended oils ALL TYPES POWER STEERING OILS TOTAL FLUIDE ATX All countries TOTAL FLUIDE DAS Power steering Special oil distributed by Very cold countries CITROËN Part No.: 9730 A1 ENGINE COOLANT FLUID CITROËN Part No. Pack GLYSANTIN G33 REVKOGEL 2000 2 Litres 9979 70...
  • Page 64 LUBRICANTS - TOTAL recommended oils ALL TYPES BRAKE FLUIDS Synthetic brake fluid Pack CITROËN Part No. 9979 05 0,5 Litre CITROËN fluid All countries 1 Litre 9979 06 5 Litres 9979 07 HYDRAULIC CIRCUIT Pack CITROËN Part No. All countries Norm TOTAL FLUIDE LDS Orange...
  • Page 65 LUBRICANTS - TOTAL recommended oils ALL TYPES SCREEN WASH FLUID Pack CITROËN Part No. Concentrated: 250 ml 9980 33 9980 56 ZC 9875 953U 9980 06 1 Litre ZC 9875 784U All countries Fluid ready for use 5 Litres 9980 05 ZC 9885 077U ZC 9875 279U GREASE...
  • Page 66 ENGINE OIL CONSUMPTION ALL TYPES I - Oil consumption depends on: - the engine type. - how run-in or worn it is. - the type of oil used. - the driving conditions. II - An engine can be considered RUN-IN after: - 3,000 miles (5,000 km) for a PETROL engine.
  • Page 67 ENGINE SPECIFICATIONS Engines: HFX - KFV - KFW - KFU Petrol All types 1.1i 1.4i 16V 1.4i Vehicle C2/C3 BERLINGO II C2/C3/C3 Pluriel Xsara II/Berlingo II Emission standard L4/IFL5 L4/W4 L4/IFL5/INF K’/L4/W4/IFL5 IFL5/L4 Engine type Cubic capacity (cc) 1124 1360 Bore / Stroke 72/69 75/77...
  • Page 68 ENGINE SPECIFICATIONS Engines: NFV - NFU - 6FZ - RFN - RFS Petrol All types 1.6i 1.6i 16V 1.8i 16V 2.0i 16V Xsara Picasso C2/C3 Xsara Xsara Picasso Xsara II Xsara II C3 Pluriel Xsara Picasso Vehicle Berlingo II Emission standard L4/IFL5 IFL5 IFL4/IFL5...
  • Page 69 ENGINE SPECIFICATIONS Engines: 8HX - 8HW - 8HZ - 8HV - 8HY Diesel All types 1.4 HDi 1.4 HDi 16V Vehicle C2/C3/C3 Pluriel Xsara Emission standard L4/IFL5 Engine type Cubic capacity (cc) 1398 Bore / Stroke 73/82 73,5/82 73/82 Compression ratio 17,9/1 18,25/1 Power ISO or EEC KW - rpm...
  • Page 70 ENGINE SPECIFICATIONS Engines: 9HZ - 9HY - WJY - RHU - RHZ Diesel All types 1.6 HDi 16V 1.9 D 2.0 HDi Xsara II Xsara Picasso Xsara II Berlingo II Xsara Picasso Xsara II Vehicle Berlingo II Emission standard Engine type Cubic capacity (cc) 1560 1868...
  • Page 71 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines: HFX - KFV - NFU A = KFV B = NFU RH engine support : 6 ± 0,4 : 6 ± 0,6 : 4,5 ± 0,4 Torque reaction rod : 6 ± 0,6 : 6 ±...
  • Page 72 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines HFX - KFV - NFU Crankshaft Accessories drive pulley 2,5 ± 0,2 Pinion fixing on crankshaft 4 ± 0,4 - Tightening - Angular tightening 45° ± 4° Cylinder block Sump 0,8 ± 0,2 2,1 ±...
  • Page 73 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines HFX - KFV - NFU Cylinder head Coolant outlet housing - in plastic 0,8 ± 0,2 - in aluminium 0,8 ± 0,2 Camshaft bearing caps (TU1JP-TU3JP) - Tightening 2 ± 0,2 - Angular tightening 44 °±...
  • Page 74 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines HFX - KFV - NFU Flywheel - clutch 6,7 ± 1 (LOCTITE FRENETANCH) Engine flywheel 2 ± 0,2 Oil pressure mechanism Lubrication Circuit 3,5 ± 0,5 Oil pressure switch 0,9 ± 0,1 Oil pump Cooling circuit Coolant pump...
  • Page 75 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engine: 8HX : 6 ± 0,6 : 6 ± 0,6 : 6 ± 0,6 : 6 ± 0,6 : 3 ± 0,3 : 6 ± 0,6 : 5,5± 0,5 : 5,7 ± 0,9 B1BP2Y1P...
  • Page 76 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engine Crankshaft Bearing cap fixing screws Pre-tightening 1 ± 0,2 Slackening 180° 3 ± 0,3 Tightening Angular tightening 140° Con rod screws Tightening 1 ± 0,1 100° ± 5° Angular tightening Accessories drive pulley Pre-tightening 3 ±...
  • Page 77 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engine Cylinder head Camshaft bearing covers 0,3 ± 0,1 Pre-tightening Tightening 1 ± 0,1 Fixing of camshaft sub-assemblies on cylinder head 0,3 ± 0,1 Pre-tightening Tightening 1 ± 0,1 Exhaust manifold 3 ± 0,3 Camshaft pulley Pre-tightening 0,3 ±...
  • Page 78 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engine Lubrication circuit Oil pump assembly 0,5 ± 0,1 Pre-tightening 0,9 ± 0,1 Tightening Coolant/oil heat exchanger 1 ± 0,1 Diesel injection circuit Spherical-base screws for diesel injection fixing fork 2,5 ± 0,2 Fuel high pressure common injection rail on engine block 2,2 ±...
  • Page 79 C3 - C3 PLURIEL SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines: HFX - KFV - NFU C3 Pluriel A = HFX - KFV A = KFV B = NFU B = NFU RH engine support RH engine support : 4,5 ± 0,4 : 6 ±...
  • Page 80 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Crankshaft Engine types Accessories drive pulley 0,8 ± 0,2 10 ± 1 2,5 ± 0,2 Pinion fixing on crankshaft Cylinder block 0,8 ± 0,2 Sump 2 ± 0,2 2,2 ± 0,2 Timing belt tensioner roller 2 ±...
  • Page 81 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Flywheel - Clutch Engines Flywheel 6,7 ± 0,6 + LOCTITE FRENETANCH 2 ± 0,2 Clutch mechanism Lubrication circuit Oil pressure switch 2 ± 0,2 0,9 ± 0,1 Oil pump Cooling circuit Coolant pump 1,4 ±...
  • Page 82 TIGHTENING TORQUES: POWER UNIT SUSPENSION Engine: KFU RH engine support : 6 ± 0,6 : 6 ± 0,6 Torque reaction rod : 6 ± 0,6 : 6 ± 0,6 LH engine support on gearbox : 3 ± 0,3 : 6 ± 0,6 : 5,5 ±...
  • Page 83 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engine Crankshaft 0,8 ± 0,2 Accessories drive pulley Pinion fixing on crankshaft - Pre-tightening 4 ± 0,4 45 ± 4° - Angular tightening Cylinder block Sump 0,8 ± 0,2 Accessories belt guide roller 4 ±...
  • Page 84 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Cylinder head Exhaust manifold 1,8 ± 0,2 2,2 ± 0,2 Sparking plugs 4 ± 0,4 VVT pulley cap VVT control electrovalve 0,8 ± 0,2 VVT inlet camshaft pulley screw 2 ± 0,2 - Pre-tightening - Tightening 6,1 ±...
  • Page 85 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines: 8HX - 8HW RH engine support : 4,5 ± 0,4 : 3 ± 0,3 Torque reaction rod : 6 ± 0,6 : 6 ± 0,6 LH engine support on gearbox : 5,4 ± 0,5 : 6 ±...
  • Page 86 XSARA SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engine: 8HZ RH engine support : 2 ± 0,2 : 2,5 ± 0,2 (10) : 4,5 ± 0,5 (11) : 4,5 ± 0,5 (12) : 6 ± 0,6 RH lower engine support : 5,7 ±...
  • Page 87 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) C3 - C3 PLURIEL - XSARA Engines Crankshaft Bearing cap fixing screw Pre-tightening Slackening Tightening Angular tightening 140° Con rod nuts Pre-tightening Slackening 1,5 ± 0,1 Tightening Angular tightening 100° ± 5° Accessories drive pulley Pre-tightening 3 ±...
  • Page 88 C3 - C3 PLURIEL - XSARA SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines Cylinder head Camshaft bearing covers 0,5 ± Pre-tightening Tightening 1 ± Fixings of camshaft sub-assemblies on cylinder head Pre-tightening Tightening Exhaust manifold 2,5 ± 0,2 Valve cover 2,5 ±...
  • Page 89 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) C3 - C3 PLURIEL - XSARA Engines 8HX - 8HW - 8HZ Diesel injection circuit Spherical-base screws for diesel injection fixing fork 0,3 ± 0,1 Fuel high pressure common injection rail on engine block 2 ±...
  • Page 90 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines: 8HV - 8HY RH engine support Screw (1) : 6 ± 0,6 Screw (2) : 6 ± 0,6 RH lower engine support Screw (3) : 5,7 ± 0,5 LH upper engine support Screw (7) : 6 ±...
  • Page 91 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines 8HV - 8HY Crankshaft Bearing cap fixing screw 3 ± 0,3 Tightening 140° ± 1°,4’ Angular tightening Crankshaft pullet hub 3 ± 0,3 Tightening 180° ± 5° Angular tightening Cylinder block Oil sump 1 ±...
  • Page 92 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines 8HV - 8HY Flywheel - Clutch Flywheel 1,7 ± 0,2 Clutch mechanism 2 ± 0,2 Lubrication circuit Oil pump assembly 0,9 ± 0,1 Oil/coolant heat exchanger 1 ± 0,1 Turbocharger lubrication pipe 2,2 ±...
  • Page 93 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) XSARA - XSARA PICASSO CYLINDER HEAD (mm) Engine types Maximum permissible bow 0,05 Gasket surface regrinding - 0,20 TIGHTENING TORQUES (m.daN) Crankshaft bearing Pre-tightening 2 ± 0,2 2 ± 0,2 screws Angular tighten 45°...
  • Page 94 XSARA - XSARA PICASSO SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) CYLINDER HEAD (mm) Engine types Maximum permissible bow 0,05 0,03 Gasket surface regrinding - 0,30 - 0,20 - 0,40 TIGHTENING TORQUES ( m.daN) Pre-tightening (1) Ø 11 : 1 ± 0,1 2 ±...
  • Page 95 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) XSARA PICASSO Engines: 9HZ - 9HY Torque reaction rod : 5,4 ± 0,8 : 5,4 ± 0,8 : 6 ± 0,9 LH upper engine support : 2,1 ± 0,2 : 5 ± 0,5 LH lower engine support : 2,1 ±...
  • Page 96 XSARA PICASSO SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines 9HZ - 9HY Crankshaft Bearing cap fixing screw Pre-tightening 1 ± 0,2 180° Slackening 3 ± 0,3 Tightening Angular tightening 140° Con rod screws Tightening 1 ± 0,1 100 ± 5° Angular tightening Accessories drive pulley 3,5 ±...
  • Page 97 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) XSARA PICASSO Engines 9HZ - 9HY Cylinder head Camshaft bearing covers Pre-tightening 0,5 ± 0,1 1 ± 0,1 Tightening Exhaust manifold 3 ± 0,3 Camshaft pulley Pre-tightening 2 ± 0,2 Angular tightening 50 ± 5° Cylinder head Pre-tightening 2 ±...
  • Page 98 XSARA PICASSO SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines 9HZ - 9HY Lubrication circuit Oil pump assembly 0,5 ± 0,1 Pre-tightening 0,9 ± 0,1 Tightening Oil/coolant heat exchanger 1 ± 0,2 Turbocharger lubrication pipe 3 ± 0,5 Diesel injection circuit Injector fixing flange nut 4 ±...
  • Page 99 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) XSARA PICASSO Engines 9HZ - 9HY Diesel injection circuit Diesel injection pump pulley 5 ± 0,5 Union on fuel high pressure pump Pre-tightening 2 ± 0,5 Tightening 2,5 ± 0,3 Cooling circuit Coolant pump 0,3 ±...
  • Page 100 C2 - C3 - C3 PLURIEL CYLINDER HEAD Engines: HFX - KFV - NFU Identification of cylinder head gasket Engine types Thicknesses (repair) Thickness references Thicknesses (Standard) 1,4 ± 0,1 1,2 ± 0,1 0,66 ± 0,04 1,2 ± 0,1 1,5 ± 0,1 Identification marks 1,2,3,4 = Type of engine A,B,D...
  • Page 101 CYLINDER HEAD C2 - C3 - C3 PLURIEL Engines: HFX - KFV - NFU Cylinder head tightening (m.daN) Cylinder head bolts HFX - KFV Tightening : 2 ± 0,2 Angular tightening : 240° ± 5° (In the order 1 to 10) Pre-tightening : 1,5 ±...
  • Page 102 XSARA - XSARA PICASSO CYLINDER HEAD Engines: KFW - NFV - NFU Identification of cylinder head gasket Engine type Identification marks (Notch on cylinder head gasket) * Thickness CURTY Suppliers MEILLOR ELRING REINZ 0 = Without notch Material 0 (With asbestos) – 1 (Without asbestos) 1 = One notch Repair 0 (Standard gasket) –...
  • Page 103 CYLINDER HEAD (Continued) XSARA - XSARA PICASSO Engines: KFW - NFV - NFU Cylinder head tightening (m.daN) One Cylinder head bolts KFW - NFV Pre-tightening Angular tightening : 240 ± 5° B1BP10LC Pre-tightening NOTE: Oil the threads and under the heads of the bolts (use Angular tightening : 260 ±...
  • Page 104 XSARA - XSARA PICASSO CYLINDER HEAD Engine: 6FZ Identification of cylinder head gasket Nominal Repair dimension dimension Identification zone 4 – 5 2 – 4 – 5 "d" Marking zone "e" Gasket thickness (mm) Supplier MEILLOR Identification marks “d” = Identification zone. “e”...
  • Page 105 XSARA - XSARA PICASSO CYLINDER HEAD Engine: 6FZ Cylinder head tightening (m.daN) One Cylinder head bolts : 1,5 ± 0,2 Pre-tightening Tightening : 5 ± 0,2 Destightening : 360 ° (1 turn) Tightening : 2 ± 0,2 Angular tightening : 285° ± 5° B1DP16FC A = Washer thickness: 4 ±...
  • Page 106 XSARA - XSARA PICASSO CYLINDER HEAD Engine: RFN Identification of cylinder head gasket Nominal Repair dimension dimension Identification zone 4 – 5 2 – 4 – 5 "d" Marking zone "e" Gasket thickness (mm) Supplier MEILLOR Multilayer metallic gasket B1DP183D...
  • Page 107 XSARA - XSARA PICASSO CYLINDER HEAD Engine: RFN Cylinder head tightening (m.daN) One Cylinder head bolts : 1,5 ± 0,2 Pre-tightening Tightening : 5 ± 0,2 Destightening : 360 ° (1 turn) Tightening : 2 ± 0,2 Angular tightening : 285° ± 5° B1DP16FC A = Washer thickness: 4 ±...
  • Page 108 CYLINDER HEAD XSARA Engine: RFS Identification of cylinder head gasket Engine type Identification marks (Notch on cylinder head gasket) Suppliers MEILLOR 0 = Without notch 1 = One notch B1BP004C...
  • Page 109 CYLINDER HEAD XSARA Engine: RFS Cylinder head tightening (m.daN) One Cylinder head bolts : 3,5 Pre-tightening : NO Slackening Tightening Angular tightening : 160° NOTE: Oil the threads and under the heads of the bolts B1DP13PC (use engine oil or Molykote G X =MAX.
  • Page 110 C2 - C3 - C3 PLURIEL - XSARA CYLINDER HEAD Engines: 8HX - 8HW - 8HZ Identification of cylinder head gasket Piston Thicknesss No. of notches at No. of notches at Engine types Supplier standproud (mm) “d “ “e” (mm) Type of gasket: Metallic multilayer 0,771 to 0,820...
  • Page 111 CYLINDER HEAD Engines: 8HY - 8HV Identification of cylinder head gasket Piston Thicknesss No. of notches at No. of notches at Engine types Supplier standproud (mm) “d” “e” (mm) Type of gasket: Metallic multilayer 0,771 to 0,820 1,35 0,611 to 0,720 1,25 «d»...
  • Page 112 C2 - C3 - C3 PLURIEL CYLINDER HEAD Engines: 8HX - 8HW - 8HZ - 8HV - 8HY Cylinder head tightening (m.daN) One Cylinder head bolts 8HX - 8HW - 8HZ - 8HV - 8HY Pre-tightening : 2 ± 0,2 m.daN Tightening : 4 ±...
  • Page 113 CYLINDER HEAD XSARA PICASSO Engines: 9HZ - 9HY Identification of cylinder head gasket Piston Thicknesss No. of notches at No. of notches at Engine types Supplier standproud (mm) “d” “e” (mm) Type of gasket: Metallic multilayer 0,685 to 0,734 1,35 0,533 to 0,634 1,25 «d»...
  • Page 114 XSARA PICASSO CYLINDER HEAD Engines: 9HZ - 9HY Cylinder head tightening (m.daN) One Cylinder head bolts 9HZ - 9HY : 2 ± 0,2 m.daN Pre-tightening : 4 ± 0,4 m.daN Tightening Angular tightening : 260° ± 5° (In the order 1 to 10) NOTE: - The bolts should have been tho- roughly cleaned and dried with a...
  • Page 115 XSARA CYLINDER HEAD Engine: WJY Identification of cylinder head gasket Piston Thickness Number Number Plaque standproud (mm) of holes of holes Engine (mm)-( ± 0,04 at A at B 0,51 to 0,55 1,26 0,55 to 0,59 1,30 0,59 to 0,63 1,34 0,63 to 0,67 1,38...
  • Page 116 XSARA - XSARA PICASSO CYLINDER HEAD Engines: RHY - RHZ Identification of cylinder head gasket Piston Plaque Thickness standproud No. of notches at A Engine (mm) (mm) 0,47 to 0,605 1,30 ± 0,06 0,605 to 0,655 1,35 ± 0,06 0,655 to 0,705 1,40 ±...
  • Page 117 CYLINDER HEAD (Continued) XSARA - XSARA PICASSO Engines: WJY - RHY - RHZ Cylinder head tightening (m.daN) One Cylinder head bolts RHY - RHZ Pre-tightening Tightening Angular tightening : 180° RHY - RHZ Pre-tightening Tightening NOTE: Oil the threads and under the heads B1DP15EC B1DP13PC : 220°...
  • Page 118 ALL TYPES BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE Tools 4099-T (C.TRONIC.105) 4122-T (C.TRONIC.105.5)
  • Page 119 AUXILIARY EQUIPMENT DRIVE BELT PETROL JP + J4RS Engine type 1.1i 1.4i 1.6i 16V See pages: 118 to 119 118 to 119 1.1i 1.4i 1.4i 16V 1.6i 16V See pages: 118 to 119 123 to 124 118 to 119 1.4i 1.6i 16V C3 Pluriel See pages:...
  • Page 120 DIESEL AUXILIARY EQUIPMENT DRIVE BELT TED4 ATED Engine type 1.4 HDi See pages: 135 to 136 1.4 HDi 1.4 HDi 1.4 HDi 16V 1.4 HDi 16V See pages: 135 to 136 1.4 HDi C3 Pluriel See pages: 135 to 136 XSARA 1.4 HDi 1.9 D...
  • Page 121 AUXILIARY EQUIPMENT DRIVE BELT 2002 ALL TYPES Engines: All Types Petrol and Diesel Tools. - Belt tension measuring instrument : 4122 - T. (C.TRONIC 105.5) WARNING: If using tool 4099-T (C.TRONIC 105), refer to the correspondence table on page 96. Essential.
  • Page 122 C2 - C3 - C3 PLURIEL AUXILIARY EQUIPMENT DRIVE BELT Engines: HFX - KFV - NFU Tools. [1] Pliers for removing plastic pegs : 7504 –T [2] Belt tension measuring instrument : 4122-T Vehicle without air conditioning. Remove. Refit. Refit the belt. Slacken: Respect the following sequence: - Crankshaft pinion.
  • Page 123 AUXILIARY EQUIPMENT DRIVE BELT C2 - C3 - C3 PLURIEL Engines: HFX - KFV - NFU Vehicle with air conditioning. Remove Slacken: - Screws (6), (4) and (5). - Fully detension the belt by acting on the tensioner roller. - Remove the accessories drive belt. Refit.
  • Page 124 XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT Engine: NFV Without air conditioning. Tools. [1] Pliers for removing plastic pegs : 7504 –T [2] Belt tension measuring instrument : 4122 –T [3] TORX spanner Remove. - Release the central screw (1), tool [3] - Detension the tensioner roller (2), (flat spanner 27 on flat).
  • Page 125 AUXILIARY EQUIPMENT DRIVE BELT XSARA PICASSO Engine: NFV With air conditioning. Tools. [1] Pliers for removing plastic pegs : 7504 –T [2] Belt tension measuring instrument : 4122 –T [3] 10 mm square (drain spanner) [4] TORX spanner Remove. - Detension the automatic tensioner, tool [3]. - Place a Ø...
  • Page 126 AUXILIARY EQUIPMENT DRIVE BELT 2002 XSARA Engine: KFW Alternator With air conditioning [1] Belt tension measuring instrument: [1] Belt tension measuring instrument: 4122-T 4122-T - Tension the belt using the screw (2). - Tension the belt using the screw (4). - Tension should be: - Tension should be: 102 ±...
  • Page 127 AUXILIARY EQUIPMENT DRIVE BELT Engine: KFU Tools. [1] Plyers for removing plastic pegs : 7504 –T [2] Belt tension measuring instrument (SEEM) : 4122 –T Removing. Raise and support the vehicle, front wheels hanging. Disconnect the battery. Remove the front RH wheel and the front RH splash-shield, using tool [1]. Vehicle without air conditioning.
  • Page 128 AUXILIARY EQUIPMENT DRIVE BELT Engine: KFU Vehicle With air conditioning. Removing. Slacken the tension, screw (6), screw (4) and screw (5). Completely detension the belt by acting on the tensioner roller. Remove the auxiliary equipment drive belt. Refitting. Refit the auxiliary equipment drive belt. Respect the following sequence : - Crankshaft pinion, aircon compressor pulley, alternator pulley guide roller and guide roller.
  • Page 129 AUXILIARY EQUIPMENT DRIVE BELT 2002 XSARA Engine: NFU Without air conditioning (1) Tensioner roller fixing screw (2) Tensioning screw - New belt: 120 SEEM units. - Reused belt: 86.5 ± 3.5 SEEM units. B1BP1AMC With air conditioning (3) Tensioner roller fixing screw (4) Tensioning screw - New belt: 120 SEEM units.
  • Page 130 XSARA AUXILIARY EQUIPMENT DRIVE BELT 2002 Engine: RFS With air conditioning. - Fit the drive belt. - The tensioner roller (1). - Tighten the screws (3) to 2 m.daN. - Move the tensioner roller (1) using the tool (9.52 mm square drive (3/8)) at (2), in order to remove the tool or locking peg (Ø...
  • Page 131 XSARA AUXILIARY EQUIPMENT DRIVE BELT 2002 Engine: RFS Without air conditioning. Tools. [1] Belt tension measuring instrument : 4122-T - (1) Tensioning screw. - (2) Roller support fixing screw (3). - Lightly tighten the screws (2). - Place the tool [1] on the belt. - Tension the belt using the screw (1).
  • Page 132 AUXILIARY EQUIPMENT DRIVE BELT 2002 XSARA - XSARA PICASSO Without air conditioning. Engines: 6FZ - RFN With air conditioning. Tools. [1] Pliers for removing plastic pegs : 7504-T Remove the belt. - Detension the belt (3) by turning the screw (2) of the tensioner roller (1) (anti-clockwise).
  • Page 133 AUXILIARY EQUIPMENT DRIVE BELT 2002 XSARA Engine: WJY Sans Power-assisted steering. Tools. [1] Belt tension measuring instrument : 4122-T Removal. - Loosen the screws (2). - Tighten the screw (1) until it is against its stop. - Remove the belt. Refitting.
  • Page 134 XSARA AUXILIARY EQUIPMENT DRIVE BELT 2002 Engine: WJY Sans Power-assisted steering With air conditioning. Tools. [1] Belt tension measuring instrument : 4122-T Removal. - Loosen the screws (1). - Tighten the screw (2) until it is against its stop. - Remove the belt. Refitting.
  • Page 135 XSARA AUXILIARY EQUIPMENT DRIVE BELT 2002 Engine: WJY Power-assisted steering without air conditioning. Tools. [1] Belt tension measuring instrument : 4122-T Removal. WARNING: If the belt is to be reused, measure the tension before removal. Loosen: - the screw (1). - the nut (2).
  • Page 136 XSARA AUXILIARY EQUIPMENT DRIVE BELT Engine: WJY Power-assisted steering without air conditioning (continued). Refitting. - Refit the belt. - Place the tool [1] on belt at "f". WARNING: Position tool [1], with the knob downwards. - Tighten the nut (2) to obtain a value of : Reused belt: Keep the value taken at removal.
  • Page 137 XSARA AUXILIARY EQUIPMENT DRIVE BELT 2002 Engine: WJY Power-assisted steering with air conditioning. Tools. [1] Dynamic tensioner peg : (-) 0188 H [2] Belt tension measuring instrument : 4122-T Removal. - Peg the dynamic tensioner (1) at "a", using tool [1]. - Loosen the screw (2) of the roller (3).
  • Page 138 XSARA AUXILIARY EQUIPMENT DRIVE BELT 2002 Engine: WJY Power-assisted steering with air conditioning (continued). Refitting. - Refit the belt. - Using a 7 mm square drive at "b", turn the roller (3), until the tool [1] located at "a" becomes free.
  • Page 139 AUXILIARY EQUIPMENT DRIVE BELT C2 - C3 - C3 PLURIEL With compressor and alternator. Engines: 8HX - 8HW Tools. [1] Pliers for removing plastic pegs : 7504-T [2] Tensioner roller compression lever : (-).0194.E [3] Tensioner roller setting peg Ø4 mm : (-).0194.F Removing.
  • Page 140 C2 - C3 - C3 PLURIEL AUXILIARY EQUIPMENT DRIVE BELT Engines: 8HX - 8HW Markings on the dynamic tensioner roller. «a» Position of «maximum wear» of the auxiliary drive belt. «b» Normal position. Refitting. NOTE: Check that the tensioner roller moves freely (no tight spot). If this is not the case, replace the tensioner roller.
  • Page 141 XSARA AUXILIARY EQUIPMENT DRIVE BELT 2002 Engine: 8HZ Tools. [1] Dynamic tensioner compression lever : (-).0188.Z [2] Peg for dynamic tensioner roller : (-).0194.F Removing. IMPERATIVE: Respect the safety and cleanliness requirements specific to high pressure diesel injection engines (HDi). Remove: - The front RH wheel.
  • Page 142 XSARA AUXILIARY EQUIPMENT DRIVE BELT 2002 Engine: 8HZ Refitting. WARNING: Belt to be re-used, mark the direction of fitting of the belt. Refit the accessories drive belt. Compress the tensioner roller (1) by acting at «a» (clockwise), using tool [1]. Remove tool [2].
  • Page 143 AUXILIARY EQUIPMENT DRIVE BELT Engines: 8HY - 8HV Tools. [1a] Dynamic tensioner roller lever : (-).0194-E1 [1b] Lever extension : (-).0194-E2 [2] Accessories belt roller locking peg Ø 4 mm : (-).0194-F Removing. Pivot the tensioner roller support (1) (clockwise), using tools [1a] and [1b] at «a». Remove the belt.
  • Page 144 XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT Engines: 9HZ - 9HY Tools. [1] Dynamic tensioner compression lever : (-).0188.Z [2] Peg for dynamic tensioner roller : (-).0194.F Removing. Remove the front RH wheel, the under-engine sounddeadening and the splash-shield. Vehicle with air conditioning. WARNING: Mark the direction of fitting of the accessories drive belt, if it is to be re-used.
  • Page 145 AUXILIARY EQUIPMENT DRIVE BELT 2002 XSARA - XSARA PICASSO Engines: RHY - RHZ Without air conditioning. Tools. [1] Belt tension adjusting square : (-).0188 J2 [2] Ø 4 mm peg : (-).0188.Q1 [3] Ø 2 mm peg : (-).0188.Q2 [4] Dynamic tensioner compression lever : (-).0188.Z Removal.
  • Page 146 XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT 2002 Engines: RHY - RHZ Without air conditioning (continued). Refitting. Re-used belt. - Compress the tensioner roller (2) by action at «a» (in anti-clockwise direction), tool [4]. - Refit the belt. WARNING: Respect the belt-fitting direction. Remove the tool [4].
  • Page 147 XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT 2002 Engines: RHY - RHZ With air conditioning. Tools. [1] Belt tension adjusting square : (-).0188 J2 [2] Ø 4 mm peg : (-).0188.Q1 [3] Ø 2 mm peg : (-).0188.Q2 [4] Dynamic tensioner compression lever : (-).0188.Z Removal.
  • Page 148 XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT 2002 Engines: RHY - RHZ With air conditioning (continued). Refitting. Re-used belt. - Compress the tensioner roller (7) by action at «c» (in anti-clockwise direction), tool [4]. - Refit the belt. WARNING: Respect the direction belt was fitted. Remove the tool [4].
  • Page 149 CHECKING AND SETTING THE VALVE TIMING PETROL JP + J4RS Engine type 1.1i 1.4i 1.6i 16V See pages: 148 to 157 148 to 157 1.1i 1.4i 1.4i 16V 1.6i 16V See pages: 148 to 157 165 to 170 148 to 157 1.4i 1.6i 16V C3 Pluriel...
  • Page 150 DIESEL CHECKING AND SETTING THE VALVE TIMING TED4 ATED Engine type 1.4 HDi See pages: 184 to 191 1.4 HDi 1.4 HDi 1.4 HDi 16V 1.4 HDi 16V See pages: 184 to 191 192 to 200 1.4 HDi C3 Pluriel See pages: 184 to 191 XSARA...
  • Page 151 RECOMMENDATIONS: TIMING BELT ALL TYPES Diesel Engine Petrol Engine Recommendations. IMPERATIVE: After any repair involving removal of the timing belt, systematically replace: The timing belt, The tensioner roller fixing nut.
  • Page 152 C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engines: HFX - KFV - NFU Tools. [1] Engine flywheel peg : 4507-T.A [2] Camshaft pulley peg : 4507-T.B [3a] Camshaft peg : 4533-TA.C1 [3b] Camshaft peg : 4533-TA.C2 [4] Dynamic tensioner roller pin : 4200-T.H [5] Belt retaining pin...
  • Page 153 CHECKING AND SETTING THE VALVE TIMING C2 - C3 - C3 PLURIEL Engine: NFU Checking the timing (continued). Engine: NFU. Place a jack under the engine, peg the engine. Remove: - The engine support (4) complete. - The timing casing (3). - The sparking plugs (eases engine rotation).
  • Page 154 C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engines: HFX - KFV Setting the timing. Preliminary operation. Lift and support the vehicle, wheels hanging. Disconnect the battery. Remove: - The front RH wheel. - The splash-shield, using tool [6]. - The accessories belt (See corresponding operation).
  • Page 155 CHECKING AND SETTING THE VALVE TIMING C2 - C3 - C3 PLURIEL Engines: HFX - KFV Setting the timing (continued). Engines: HFX – KFV. Slacken the screws (4) without removing them. Remove the bottom engine support assembly (5), and the fixing screws (4). Slacken the nut (6).
  • Page 156 C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engine: NFU Engine: NFU. Setting the timing (continued). Remove: - The bottom plastic casing. - The engine support (9). - The middle support. - The timing cover (8). - Peg the flywheel, using tool [1].
  • Page 157 C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engine: NFU Setting the timing (continued). Engine: NFU. Slacken the tensioner roller. Turn the tensioner roller so as to be able to position the tool [4], with the aid of an Allen key placed at «a». Turn the tensioner roller towards the right to bring it to the index «c»...
  • Page 158 C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engines: HFX - KFV Setting the timing (continued). Engines: HFX-KFV. Refit. WARNING: Respect the direction of fitting of the belt (the arrows «d» indicate the direction of rotation of the crankshaft).
  • Page 159 CHECKING AND SETTING THE VALVE TIMING C2 - C3 - C3 PLURIEL Engines: KFX - KFV - NFU Setting the timing (continued). Engines: HFX-KFV. Refitting. NOTE: Check that the pegs [1] and [2] are in place. WARNING: Respect the direction of fitting of the timing belt, the arrows «d» indicate the direction of rotation of the crankshaft.
  • Page 160 C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engine: NFU Timing belt overtensioned. A: Engine: HFX – KFV. B: Engine: NFU. Turn the tensioner roller (7) with the aid of a hexagonal spanner at «a». Bring the index «c» to position «f», to tension the belt to the maximum of the interval indicated.
  • Page 161 CHECKING AND SETTING THE VALVE TIMING C2 - C3 - C3 PLURIEL Engines: HFX - KFV - NFU Adjusting the fitting tension of the timing belt. A: Engine: HFX – KFV. B: Engine: NFU. Slacken the nut while maintaining the position of the tensioner roller, with the aid of a hexagonal spanner at «a».
  • Page 162 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines: KFW - NFV Tools. à [1] Flywheel peg : 4507-T.A [2] Camshaft pulley peg : 4507-T.B Tool kit 4507-T [3] Square : 4507-T.J [4] Belt tension measuring instrument : 4122-T [5] Valve rocker thrust plate : 4533-T.Z Checking the timing.
  • Page 163 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines: KFW - NFV Refitting the timing belt. NOTE: Check that the pegs [1] and [2] are in place. WARNING: Respect the direction of fitting of the belt: The arrows "a" indicate the direction of rotation of the crankshaft.
  • Page 164 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines: KFW - NFV Pre-tensioning the timing belt (continued). - Make sure of the timing setting by refitting the pegs [1] and [2]. - Remove the valve cover. - Position the tool [5] (respect the direction of fitting relative to the valve timing). Adjusting the belt tension.
  • Page 165 XSARA CHECKING AND SETTING THE VALVE TIMING Engine: NFU Tools. [1] Belt tension measuring instrument : 4122 - T. à [2] Flywheel locating peg : 4507 - T.A [3] Camshaft pulley locating peg, exhaust : 4533 - T.A C2 Tool kit 4507 - T [4] Camshaft pulley locating peg, inlet : 4533 - T.A C1 [5] Tensioning tool...
  • Page 166 XSARA CHECKING AND SETTING THE VALVE TIMING Engine: NFU Setting the valve timing. - Loosen the screw (2), remove the belt. - Loosen the six pulley screws (1) on the hubs (there should be a slight amount of friction between the screws and the pinions). - Check that the rollers (2) and (3) rotate freely.
  • Page 167 CHECKING AND SETTING THE VALVE TIMING XSARA Engine: NFU Setting the valve timing. - Turn the two pulleys (1) clockwise to the end of the slots. - With the belt strip (e) fully tensioned, place the belt over the pulley, first exhaust side, then inlet side, while ensuring that marks (b) and (c) on the belt are aligned with marks (f) on the pulleys.
  • Page 168 XSARA CHECKING AND SETTING THE VALVE TIMING Engine: NFU Setting the valve timing. - Remove the tools [1], [2], [3] and [4]. - Rotate the engine by 4 turns in the normal direction (do not turn backwards). - Peg the flywheel [2]. - Loosen the six screws (5), while ensuring there is still a slight amount of friction with the pulley.
  • Page 169 CHECKING AND SETTING THE VALVE TIMING Engine: KFU Tools. [1] Flywheel peg : 4507-T [2] Camshaft peg : 4533-TA.C1 [3] Crankshaft setting peg : (-).0194.A Checks. Raise and support the vehicle, front wheels hanging. Disconnect the battery. Remove: - The oil filter. - The engine cover.
  • Page 170 CHECKING AND SETTING THE VALVE TIMING Engine: KFU Position the tools [3] and [2]. Peg the flywheel, using tool [1]. NOTE: If the setting is not correct, recommence the operation. Remove the pegs [2] and [3]. Refit : - The oil filter. - The timing cover (1).
  • Page 171 CHECKING AND SETTING THE VALVE TIMING Engine: KFU Tools. [1] Flywheel setting peg : 4507-T [2] Engine support crossmember [3] Crankshaft setting peg : (-).0194.A [4] Camshaft peg : 4533-TA.C1 [5] Belt retaining pin : 4533-T.AD Removing. Raise and support the vehicle, front wheels hanging. Disconnect the battery.
  • Page 172 CHECKING AND SETTING THE VALVE TIMING Engine: KFU Rotate the engine by means of the crankshaft pinion screw (2) (clockwise), to bring it to the pegging position. Peg the flywheel, using tool [1]. Position the tools [3] and [4]. Position the tool [2]. Support the engine.
  • Page 173 CHECKING AND SETTING THE VALVE TIMING Engine: KFU Remove: - The lower engine support assembly (5) and the fixing screw (4). - Remove the lower timing cover (6). - Slacken the nut (7). - Remove the timing belt. IMPERATIVE: Check that the tensioner roller turns freely (no tight spot). Refitting.
  • Page 174 CHECKING AND SETTING THE VALVE TIMING Engine: KFU Overtensioning the belt. Position «a» Tensioner roller in slackened position. Position «b» Tensioner roller in normal position. Position «c» Tensioner roller in overtensioned position. Turn the tensioner roller (8) using an allen spanner at «e». Position the index «d»...
  • Page 175 CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO 2003 # 2003 # NEW ASSEMBLY Engines: 6FZ - RFN (6) Crankshaft pinion (7) Accessories drive pulley (8) Washer (9) Screw The pinion (6) is fitted as an idler on the crankshaft. The accessories drive pulley (7) is immobilised on the crankshaft by a half-moon keyway and by the tightening of washer (8) and screw (9).
  • Page 176 CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO NOTE: Checking and setting the timing # 2003: See Mechanic’s Handbook 2003: pages 163 to 173. 2003 # Engines: 6FZ - RFN Tools. [1] Camshaft setting peg : (-) 0189.A [2] Crankshaft setting peg : (-).0189.R [3] Timing belt retaining pin...
  • Page 177 CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO 2003 # Engines: 6FZ - RFN Checking the setting of the timing (continued). A: Pegging on the manual gearbox. B: Pegging on the automatic gearbox. Turn the engine by means of the crankshaft pinion screw, to bring it to the pegging position. Peg the crankshaft, using tool [2].
  • Page 178 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines: 6FZ - RFN 2003 # Setting the timing. Removing. Disconnect the battery negative terminal (see corresponding operation). Raise and support the vehicle, front wheels hanging. Remove: - The front RH wheel. - The plastic pins (1).
  • Page 179 CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO 2003 # Engines: 6FZ - RFN Setting the timing (continued). A: Pegging on the manual gearbox. B: Pegging on the automatic gearbox. Peg: - The crankshaft, using tool [2]. - The camshaft pulleys (5) and (6), using tool [1]. Remove: - The screw (3) of the crankshaft pulley (2).
  • Page 180 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 2003 # Engines: 6FZ - RFN Setting the timing (continued). Turn the tensioner roller (8), using tool [5a] to go beyond slot «b». Position the tool [5b] to lock the index «a» and remove the tool [5a]. Reposition the timing belt (7) on the crankshaft pulley.
  • Page 181 CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines: 6FZ - RFN 2003 # Tensioning the timing belt. Turn the tensioner roller (8) in the direction of the arrow «c», by means of a hexagonal spanner at «d». Positionner l’index «a»...
  • Page 182 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines: 6FZ - RFN 2003 # Refitting (continued). Remove the tools [1] and [2]. Rotate the crankshaft ten times (normal direction of rotation). IMPERATIVE: No pressure or outside force should be brought to bear on the timing belt. Peg the inlet camshaft pulley, using tool [1].
  • Page 183 XSARA CHECKING AND SETTING THE VALVE TIMING Engine: RFS Tools. [1] Belt tension measuring instrument : 4122-T à [2] Camshaft pulley locating peg : 9041-T.Z Tool kit 7004-T [3] Crankshaft locating peg : 7014-T.N [4] Camshaft pulley locking peg : 4200-T.G [5] Tensioner spanner : 7017-T.W [6] Toothed sector for locking the flywheel...
  • Page 184 XSARA CHECKING AND SETTING THE VALVE TIMING Engine: RFS Setting the valve timing. - Peg the crankshaft using tool [3]. Remove: - Peg the camshaft pulleys using tool [2]. - The peg [3]. - Lock the flywheel using the tool [6]. - The screw (4) (brush the screw thread).
  • Page 185 CHECKING AND SETTING THE VALVE TIMING XSARA Engine: RFS Pretensioning the timing belt. - Peg the crankshaft using the tool [3]. - Peg the camshaft pulleys using the tool [2]. NOTE: Ensure that the camshaft pulleys rotate freely on the hubs. Clean the contact faces of the pulleys and hubs.
  • Page 186 XSARA CHECKING AND SETTING THE VALVE TIMING Engine: RFS Tensioning the timing belt. - Peg the crankshaft using the tool [3]. - Peg the camshaft pulleys using the tool [2]. NOTE: If it is not easy to peg the camshaft hubs, loosen the tensioner roller (7), and turn the camshafts using the screw (10).
  • Page 187 CHECKING AND SETTING THE VALVE TIMING XSARA Engine: RFS - Tension to: (Pulleys slackened). Engine New belt 35 SEEM units - Tighten the screw of the roller (7) to 2 m.daN. - Fit the tool [4]. - Tighten the screws (10) to 7.5 m.daN. - Remove the tools.
  • Page 188 CHECKING AND SETTING THE VALVE TIMING C2 - C3 - C3 PLURIEL - XSARA Engines: 8HX - 8HW - 8HZ Tools. [1] Pliers for removing plastic pegs : 7504-T [2] Lever for detensioning the dynamic tensioner roller : (-).0194.E [3] Engine flywheel setting peg : (-).0194.C [4] Camshaft setting peg : (-).0194.B...
  • Page 189 CHECKING AND SETTING THE VALVE TIMING C2 - C3 - C3 PLURIEL - XSARA Engines: 8HX - 8HW - 8HZ Checking the setting (continued). Remove: - the accessories drive belt. - the accessories drive pulley. - the lower timing cover (3). IMPERATIVE: The magnetic track should show no signs of damage and should not be approached by any other source of magnetism.
  • Page 190 C2 - C3 - C3 PLURIEL - XSARA CHECKING AND SETTING THE VALVE TIMING Engines: 8HX - 8HW - 8HZ Setting the timing. Remove the upper timing cover (1). Rotate the engine by means of the crankshaft screw (2). NOTE: The pegging hole is located under the crankshaft bearing cap cover. Peg the engine flywheel, using tool [3].
  • Page 191 CHECKING AND SETTING THE VALVE TIMING C2 - C3 - C3 PLURIEL - XSARA Engines: 8HX - 8HW - 8HZ Setting the timing (continued). Remove the tool [3]. Rotate the engine by means of the crankshaft pinion screw (2) (clock- wise), to bring it to the pegging position.
  • Page 192 C2 - C3 - C3 PLURIEL - XSARA CHECKING AND SETTING THE VALVE TIMING Engines: 8HX - 8HW - 8HZ Setting the timing (continued). Hold the tensioner roller, using a hexagonal spanner at «b». Slacken the screw (9). Remove the timing belt (10). Refitting.
  • Page 193 CHECKING AND SETTING THE VALVE TIMING C2 - C3 - C3 PLURIEL - XSARA Engines: 8HX - 8HW - 8HZ Setting the timing (continued). NOTE: Screw (9) slackened. Position the timing belt (10) observing the following sequence: - Crankshaft pinion (4). - Guide roller (12).
  • Page 194 C2 - C3 - C3 PLURIEL - XSARA CHECKING AND SETTING THE VALVE TIMING Engines: 8HX - 8HW - 8HZ Setting the timing (continued). Turn the tensioner roller to the right to bring the index «c» to position «d», using a hexagonal spanner.
  • Page 195 CHECKING AND SETTING THE VALVE TIMING C2 - C3 - C3 PLURIEL - XSARA Engines: 8HX - 8HW - 8HZ Setting the timing (continued). Refit: - The intermediate RH engine support, tighten the screws (16) to 5,5 ± 0,5 m.daN. - The RH engine support, tighten the screws (17) to 4,5 ±...
  • Page 196 CHECKING AND SETTING THE VALVE TIMING Engines: 8HY - 8HV Tools. [1] Engine flywheel peg Ø 12 mm : (-).0194-C [2] Camshaft pulley peg Ø 8 mm : (-).0194-B [3] Crankshaft pulley peg Ø 5 mm : (-).0194-A Preliminary operations. Remove: - The front RH wheel.
  • Page 197 CHECKING AND SETTING THE VALVE TIMING Engines: 8HY - 8HV 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).
  • Page 198 CHECKING AND SETTING THE VALVE TIMING Engines: 8HY - 8HV Checks (continued). Refit the screw (8). Rotate the crankshaft six times (clockwise). IMPERATIVE: Never rotate the engine backwards. Peg: - The camshaft, using tool [2] (oil the pegs). - The fuel high pressure pump pulley (14), using tool [3] at «c». WARNING: The magnetic track should show no signs of damage and should not be approached by any source of magnetism.
  • Page 199 CHECKING AND SETTING THE VALVE TIMING Engines: 8HY - 8HV Checks (continued). NOTE: The index «e» of the dynamic tensioner roller should be centred within the area «d». Check the correct positioning of the index «e». If it is not correct, repeat the operation to tension the timing belt (see corresponding operation). Refitting.
  • Page 200 CHECKING AND SETTING THE VALVE TIMING Engines: 8HY - 8HV Checks (continued). Refit: - The engine support (7), tighten to 1,5 ± 0,4 m.daN. - The engine support (4), tighten to 6,1 ± 0,6 m.daN. - The engine support (5), tighten to 6 ± 0,6 m.daN. - The electrical harness (6).
  • Page 201 CHECKING AND SETTING THE VALVE TIMING Engines: 8HY - 8HV Setting the timing. Perform the preliminary operations for checking the timing up to removing tool [1] at «a» for immobiling the engine flywheel. Refit screw (8). Rotate the crankshaft to bring the camshaft towards its pegging point. Peg the camshaft, using tool [2] (oil the pegs).
  • Page 202 CHECKING AND SETTING THE VALVE TIMING Engines: 8HY - 8HV Setting the timing (continued). Checking the setting. IMPERATIVE: Just prior to refitting, carry out the following tests. Check that: - the rollers and the coolant pump operate freely (no play and no tight spot). - there are no traces of oil (from the crankshaft and camshaft sealing rings).
  • Page 203 CHECKING AND SETTING THE VALVE TIMING Engines: 8HY - 8HV Setting the timing (continued). Checks (continued). Reposition the timing belt, belt at «e» well tensioned, in the following order: - Guide roller (17). - Camshaft pulley (16). - Fuel high pressure pump pulley (15). - Coolant pump pinion (18).
  • Page 204 CHECKING AND SETTING THE VALVE TIMING Engines: 8HY - 8HV Adjusting the timing belt tension (continued). IMPERATIVE: Never rotate the engine backwards. WARNING: Do not touch or damage the track of the target of the engine speed sensor (14). Peg the crankshaft, using tool [3]. Check the position of the tensioner roller (the alignment of the marks «f»...
  • Page 205 CHECKING AND SETTING THE VALVE TIMING XSARA PICASSO Engines: 9HZ - 9HY Tools. [1] Flywheel setting peg : (-).0194.C [2] Camshaft setting peg : (-).0194.B [3] Crankshaft setting peg : (-).0194.A Checking and setting the timing. Removing. Raise and support the vehicle, wheels hanging. Disconnect the positive and negative terminals of the battery.
  • Page 206 XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines: 9HZ - 9HY Rotate the engine to drive it in its normal direction of rotation. Peg the flywheel, using tool [1] at «b». Move aside the harness (7). Remove: - The engine support (8). - The screw (10).
  • Page 207 CHECKING AND SETTING THE VALVE TIMING XSARA PICASSO Engines: 9HZ - 9HY Refit the screw (10). Rotate the crankshaft six times (clockwise). IMPERATIVE: Never turn it backwards. Peg the camshaft at «c», using tool [2] (oil the peg). WARNING: The magnetic track should not show any sign of damage and should not be approached by any other magnetic source.
  • Page 208 CHECKING AND SETTING THE VALVE TIMING XSARA PICASSO Engines: 9HZ - 9HY Couple: Refitting. - The tube (2). - The exhaust line, tighten the clip to 2,5 ± 0,3 m.daN. Refit tool [1] at «b». - The fuel unions (1). Remove the screw (10).
  • Page 209 CHECKING AND SETTING THE VALVE TIMING XSARA PICASSO Engines: 9HZ - 9HY Tools. [1] Flywheel setting peg : (-).0194.C [2] Camshaft setting peg : (-).0194.B [3] Crankshaft setting peg : (-).0194.A Checking and setting the timing. Removing. Raise and support the vehicle, wheels hanging. Disconnect the positive and negative terminals of the battery.
  • Page 210 CHECKING AND SETTING THE VALVE TIMING XSARA PICASSO Engines: 9HZ - 9HY Rotate the engine to drive it in its normal direction of rotation. Peg the flywheel at «b». using tool [1]. Move aside the harness (7). Remove: - The engine support (8). - The screw (10).
  • Page 211 CHECKING AND SETTING THE VALVE TIMING XSARA PICASSO Engines: 9HZ - 9HY Refit the screw (10). Turn the crankshaft to bring the camshaft towards its pegging point. Peg the camshaft at «c», using tool [2] (oil the pegs). WARNING: Do not press or damage the track of the engine speed sensor target (13).
  • Page 212 XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines: 9HZ - 9HY Refitting. Fit the timing belt on the crankshaft pinion. Position the belt on the guide roller, belt well tensioned. Refit: - The timing belt protector (13). - The engine speed sensor (14). Reposition the timing belt, strip «f»...
  • Page 213 CHECKING AND SETTING THE VALVE TIMING XSARA PICASSO Engines: 9HZ - 9HY Adjusting the timing belt tension. Act on the tensioner roller (18) to align the marks «g» and «h», avoiding detensioning the timing belt, using an allen spanner at «d». Should this fail, repeat the operation to tension the timing belt.
  • Page 214 CHECKING AND SETTING THE VALVE TIMING XSARA PICASSO Engines: 9HZ - 9HY Disengage the jack from under the engine. Refitting (continued). Couple: - The tube (2). Refit tool [1] at «b». - The exhaust line, tighten the clip to 2,5 ± 0,3 m.daN. Remove the screw (10).
  • Page 215 CHECKING AND SETTING THE VALVE TIMING XSARA Engine: WJY Tools. [1] Pliers for remving plastic pins : 7504-T or (-).1311 [2] Flywheel peg : 7014-T.J or (-).0188 Y [3] Injection pump setting peg Ø 6 mm : (-).0188 H [4] Screw H M8 : (-).0188 E [5] Belt retaining pin : (-).0188 K...
  • Page 216 XSARA CHECKING AND SETTING THE VALVE TIMING Engine: WJY Setting the timing. Removing. - Disconnect the battery. - Remove the front RH lower splash-shield, using tool [1]. - Remove the accessories drive belt (see corresponding operation). - Uncouple and plug the diesel fuel delivery and return hoses. - Support the engine, using a workshop hoist.
  • Page 217 CHECKING AND SETTING THE VALVE TIMING XSARA Engine: WJY Setting the timing (continued). - Peg the camshaft hub, using tool [4]. - Peg the injection pump hub, using tool [3]. - Slacken screws (5) and (6). - Slacken screw (9) of the tensioner roller (8). - Remove the timing belt.
  • Page 218 CHECKING AND SETTING THE VALVE TIMING XSARA Engine: WJY Setting the timing (continued). NOTE: If necessary, you can slightly rotate the pinions (10) and (7) anti-clockwise in order to engage the belt. The angular displacement value of the belt in relation to the pinions should not be more than half a tooth. - Remove tool [5].
  • Page 219 CHECKING AND SETTING THE VALVE TIMING XSARA Engine: WJY Setting the timing (continued). Setting the timing (continued). - Remove the peg [2]. Tighten: - Screw (9) to 2.1 ± 0.2 m.daN. - Remove the screw (4) and the washer. - Screws (5) to 2,3 ± 0.2 m.daN. - Refit the lower cover (3).
  • Page 220 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines: RHY - RHZ N° RPO 9128 # OLD FITTING: # N° RPO 9127 NEW FITTING N° RPO 9128 # The new timing on 8 valve engines DW10TD (RHY) and DW10 (1) «Idler»...
  • Page 221 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines: RHY - RHZ N° RPO 9128 # NEW FITTING N° RPO 9128 # (Continued) The new fitting discontinues the following components: - Camshaft hub. - Cylinder reference sensor target. Repair –...
  • Page 222 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING NOTE: Checking and setting the valve timing on engines: RHY-RHZ N° ⁄ RPO 9127 See Mechanic’s Handbook 2003: pages 193 to196 Engines: RHY - RHZ N° RPO 9128 # Removing. Tools.
  • Page 223 CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines: RHY - RHZ N° RPO 9128 # Uncouple, plug and move aside, using tool [7], the fuel delivery pipe (2) and return pipe (1). Remove: - Screws (3), (4) and (6). - Screw (7).
  • Page 224 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING N° RPO 9128 # Engines: RHY - RHZ Remove: - The fixings of the pipe linking the power steering pump with the rotary valve. - The clutch lower closing plate. Lock the engine flywheel, using tool [6].
  • Page 225 CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO N° RPO 9128 # Engines: RHY - RHZ Slacken the screw (17) of the tensioner roller (18). Remove the timing belt (14). Checks. IMPERATIVE: Just before refitting, carry out the checks below. Check that: - The rollers (18) and (15) turn freely (without play and without any tight spot).
  • Page 226 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING N° RPO 9128 # Engines: RHY - RHZ Reposition the timimg belt, belt at «a» well tensioned, in the following order: - Fuel high pressure pump pulley (21). - Guide roller (15). - Crankshaft pinion (19).
  • Page 227 CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines: RHY - RHZ N° RPO 9128 # Lock the engine flywheel, using tool [6]. Slacken: - The accessories drive pulley (8). - The screw (17) of the tensioner roller (18). Fit the tool [1].
  • Page 228 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING N° RPO 9128 # Engines: RHY - RHZ Remove: - Tools [3] and [5]. - Screw (7) and the spacer. Refit: - The lower, intermediate and upper covers (5). - Screw (7), tighten to 1,5 ± 0,1 m.daN. - Screws (3), (4) and (6).
  • Page 229 SPECIAL FEATURES OF THE TIMING Camshaft hub identification ‘‘a’’ Engraving Engine Hubs ‘‘b’’ Paint marking Inlet BLUE Exhaust B1EP122C...

  • Page 230: Valve Clearance Settings

    VALVE CLEARANCE SETTINGS POSSIBLE PROCEDURES The valve clearances must be checked with the engine cold For engines with 4 cylinders in a line (1-3-4-2 ) Rocking Fully open (Exhaust) Exhaust G Inlet Rocking Adjust Adjust Valves fully Petrol all types open 0,20 mm ±...
  • Page 231 CHECKING THE OIL PRESSURE C2 - C3 - C3 PLURIEL To be read with the Petrol and Diesel correspondence tables Plaque engine Temperature (°C) 90°C Pressure (Bars) NOTE: The oil pressure 2000 4000 1000 4000 should be checked with the Tools (Kit 4103-T) engine hot, after the oil level 2279-T.Bis...
  • Page 232 XSARA CHECKING THE OIL PRESSURE To be read with the Petrol and Diesel correspondence tables XSARA Plaque engine Temperature (°C) 90°C 80°C 90°C Pressure (Bars) 1,5 - 5,1 2 - 5,5 1,3 - 3,5 1,8 - 4,5 2000 4000 1000 - 4000 1000 - 4000 1000 - 4000 1000 - 4000...
  • Page 233 CHECKING THE OIL PRESSURE XSARA PICASSO To be read with the Petrol and Diesel correspondence tables XSARA PICASSO Plaque engine Temperature (°C) 90°C 80°C 90°C Pressure (Bars) 3 - 4 3,3 - 6,3 1,5 - 5 2 - 4 2000 - 4000 1000 - 4000 1000 - 3000 1000...
  • Page 234 OIL FILTERS TU all types ET3J4 TU all types 1.1i 1.4i 1.4i 16V 1.6i 1.6i 16V 1.8i 16V 2.0i 16V NFV (1) 1109 R7 1109 X4 1109 R7 C3 Pluriel 1109 R7 Xsara 1109 R7 1109 T1 1109 N3 Xsara Picasso 1109 T1 1109 T1 DV4TD...
  • Page 235 FILLING AND BLEEDING THE COOLING CIRCUIT ALL TYPES Tools. [1] Filling cylinder : 4520-T [2] Adaptor for filling cylinder : 4222-T IMPERATIVE: Respect the safety and cleanliness requirements. - The draining and refilling operations can be carried out using WINN’S or similar coolant fluid replacement equipment;...
  • Page 236 IDLING - DEPOLLUTION C2 - C3 - C3 PLURIEL - XSARA PICASSO Idling speed % Content (± 50 rpm) Emission Vehicles Engine type Make - Injection type standard Man. Auto. gbox : N gbox gear engaged 1.1i L4/IFL5 MAGNETTI MARELLI 48P KFW - KFV L4/IFL5 1.4i...

  • Page 237: Petrol Injection

    PETROL INJECTION 1.1i 1.4i 1.6i 16V Engine type Emission standard L4/IFL5 L4/IFL5 IFL5 Injection make M. MARELLI 48P2 SAGEM S2000 BOSCH M.7.4.4. and type Fuel pressure (bars) Overspeed cut-off (rpm) 5500 5500 6600 Injector resistive value (ohms) 14,5 12,2 14,5 Engine coolant temperature 3 800 at 10°C 2500 at 20°...
  • Page 238 PETROL INJECTION C3 - C3 PLURIEL C3 PLURIEL 1.1i 1.4i 1.4i 16V 1.6i 16V 1.4i 1.6i 16V Engine type IFL5 Emission standard K’-L4INF-L4/IFL5 K’-L4INF-L4/IFL5 L4/IFL5 Injection make M. MARELLI SAGEM M. MARELLI BOSCH BOSCH SAGEM and type 48P2 S2000 M.7.4.4. M.7.4.4.
  • Page 239 PETROL INJECTION XSARA - XSARA PICASSO XSARA 2 XSARA PICASSO 1.4i 1.6i 16V 2.0i 16V 1.6i 1.8i 16V 2.0i 16V Engine type L4/IFL5 Emission standard L4/IFL5/L5 L4/IFL5 L4/IFL5 IFL5 Injection make SAGEM BOSCH M. MARELLI M. MARELLI BOSCH SAGEM and type S2000 M.7.4.4.
  • Page 240 DEPOLLUTION TECHNICAL CHECKS (FRANCE) ALL TYPES All Types Petrol CO Corrected (In %) All Types Diesel (m Conditions: At idle, engine warm. 01/96 01/96 Atmospheric engine. Less than 4.5 % for vehicles registered before 10/86. Less than 3.5 % for vehicles registered after 10/86. Less than 2.5 m With catalytic converter Turbocharged engine.
  • Page 241 EMISSION STANDARDS ALL TYPES STANDARD APPLICATIONS OBSERVATIONS CHARACTERISTICS E.E.C. Engines Vehicles Applicable © Utility vehicle limits = private vehicle limits © 10/89 increased by 25 %. Utility vehicles: Petrol 15.04 All Types R 15.04 K’ 15.04 Diesel © For private vehicles and utility vehicles imminent in major export...
  • Page 242 ALL TYPES EMISSION STANDARDS STANDARD APPLICATIONS OBSERVATIONS CHARACTERISTICS E.E.C. Engines Vehicles Applicable Private vehicles: • certain non-EEC With oxygen sensor and Petrol © Adoption of U.S. standard Current European countries catalytic converter for US 83 US 83 Diesel • certain Export countries petrol vehicles Private vehicles: •...
  • Page 243 ALL TYPES EMISSION STANDARDS STANDARD APPLICATIONS OBSERVATIONS CHARACTERISTICS E.E.C. Engines Vehicles Applicable Private vehicles: © • certain non-EEC Adoption of the U.S. Petrol US 84 Current standard for light utility European countries US 84 Diesel vehicles • certain Export coun- tries Private vehicles: ©...
  • Page 244 ALL TYPES EMISSION STANDARDS STANDARD APPLICATIONS OBSERVATIONS CHARACTERISTICS E.E.C. Engines Vehicles Applicable With oxygen sensor and Private vehicles: reinforced catalytic conver- Brussels Directive 94/12 EURO 2 < 6 seats and ter for petrol vehicles. Petrol E.E.C. < 2.5 tonnes Diesel ©...
  • Page 245 EMISSION STANDARDS ALL TYPES STANDARD APPLICATIONS OBSERVATIONS CHARACTERISTICS E.E.C. Engines Vehicles Applicable Brussels Directive 98/69 With 2 oxygen sensors Utility vehicles: © and catalytic converter for EURO 2 standard (L3) < 3.5 tonnes petrol vehicles. made stricter With catalytic converter EURO 3 Class 1: ©...
  • Page 246 ALL TYPES EMISSION STANDARDS STANDARD APPLICATIONS OBSERVATIONS CHARACTERISTICS E.E.C. Engines Vehicles Applicable With 2 oxygen sensors Brussels Directive: 2001/1 Private vehicles: and catalytic converter for © EURO 3 standard (L4) made Petrol All types petrol vehicles. stricter Diesel EURO 4 IF/L5 •...
  • Page 247 SAFETY REQUIREMENTS: HDi DIRECT INJECTION SYSTEM Engines: HDi ALL TYPES SAFETY REQUIREMENTS. Preamble. All interventions on the injection system must be carried out to conform with the following requirements and regulations: - Competent health authorities. - Accident prevention. - Environmental protection. WARNING: Repairs must be carried out by specialised personnel informed of the safety requirements and of the precautions to be taken.
  • Page 248 SAFETY REQUIREMENTS: HDi DIRECT INJECTION SYSTEM Engines: HDi ALL TYPES CLEANLINESS REQUIREMENTS. Preliminary operations. IMPERATIVE: The technician should wear clean overalls. Before working on the injection system, it may be necessary to clean the apertures of the following sensitive components: (refer to corresponding procedures) - Fuel filter.
  • Page 249 PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM C2 - C3 -XSARA Engines: 8HX - 8HW - 8HZ Cleaning. - The use of high pressure cleaners is prohibited. - Do not use compressed air. Fuel supply circuit. - Required fuel: diesel. Electric circuit.
  • Page 250 C2 - C3 -XSARA PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM Engines: 8HX - 8HW - 8HZ Diesel injectors. WARNING: Diesel and ultrasonic cleaners are prohibited. Do not separate the following components from the diesel injector carrier (2): - Diesel injector (f) (no replacement parts). - Electromagnetic element (c) (no replacement parts).
  • Page 251 PROHIBITED OPERATIONS: DELPHI HDI DIRECT INJECTION SYSTEM Engines: 8HY - 8HV Cleaning. - The use of high pressure cleaners is prohibited. - Do not use compressed air. Fuel supply circuit. - Required fuel: diesel. 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.
  • Page 252 PROHIBITED OPERATIONS: DELPHI HDI DIRECT INJECTION SYSTEM Engines: 8HY - 8HV Fuel high pressure injection common rail. Do not separate the pressure regulator «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 carrier (3): - Diesel injector (e) (no replacement parts).
  • Page 253 PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM XSARA PICASSO Engines: RHY - RHZ Cleaning. - The use of high pressure cleaners is prohibited. - Do not use compressed air. Fuel supply circuit. - Required fuel: diesel. WARNING: Do not use other fuels. Electric circuit.
  • Page 254 XSARA PICASSO PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM Engines: RHY - RHZ High pressure fuel injection common rail. - Do not separate the connectors (7) from the common injection rail (6) (malfunction). Diesel injectors. WARNING: Diesel and ultrasonic cleaners are prohibited. Do not separate the following components from the diesel injector carrier (9): - Diesel injector (8) (no replacement parts).
  • Page 255 SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP XSARA PUMP -TYPE - REFERENCE Dépollution Equipment Transponder DWLP 12 XSARA R8448 B 371 B...
  • Page 256 XSARA SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP Static timing Reference Code Injector Adjustments (rpm) Max. speed Dynamic Pump Injector Type Engine Initial advance needle lift timing holder Fast Unladen Laden Reference type Compression colour pressure checking Injector Anti-stall Idling + injector idling Time...
  • Page 257 CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP XSARA Engine: WJY Tools. [1] Flywheel locating peg : 7014-T.J [2] H M8 screw : (-).0188.E Tool kit C.0188 [3] Injection pump setting peg Ø 6 mm : (-).0188.H After carrying out the necessary dismantling operations on the vehicle, proceed in the following manner: Remove: - The screws (6), (7), (9), (10) and (12).
  • Page 258 CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP XSARA Engine: WJY (continued) Peg: - The camshaft hub, using tool [2]. - The injection pump hub, using tool [3]. Impossible to peg the camshaft. Reset the valve timing (See page 245). Possible to peg the camshaft, but not the injection pump.
  • Page 259 ADJUSTING THE MECHANICAL CONTROLS OF THE DELPHI INJECTION PUMP XSARA Engine: WJY Adjusting the fast idle. Engine cold. - Ensure that the lever (2) is up against its stop to the right. - If not, adjust the tension of the cable (3) using the cable clamp (1). - Finish tensioning using the sleeve tensioner (4).
  • Page 260 ADJUSTING THE MECHANICAL CONTROLS OF THE DELPHI INJECTION PUMP XSARA Engine: WJY (continued) Adjusting the anti-stall (residual output). - Insert a 3 mm thick shim (10) between the throttle lever (6) and the anti-stall screw (7). - Push the stop lever (8). - Insert a 3 mm diameter peg (9) in the lever (2).
  • Page 261 FITTING DELPHI DIESEL INJECTORS XSARA Engine: WJY [1] Tool to remove/refit injectors : 7007-T Fitting an injector. : 7008-T.A Tool kit 4123-T - The copper seal (1) and the fire seal washer (3) are to be replaced each time they are removed.
  • Page 262 XSARA PICASSO INJECTION PUMP SPECIFICATIONS (BOSCH and SIEMENS) Engines Injection system High pressure pump Injectors BOSCH CP 3.2 BOSCH EDC 16C3 760680 BOSCH BOSCH EDC 15C2 BOSCH CP1 9625542580 SIEMENS ECUSID801 5WS 40001 5WS40000 SIEMENS (except PICASSO) BOSCH EDC 15C2 BOSCH CP1 9625542580 ATED...
  • Page 263 CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT C2 - C3 Engines: 8HX - 8HW Tools. [1] Ø 10 mm low pressure connector : 4215-T. [2] Pressure gauge for testing boost pressure : 4073-T.A Tool kit 4073-T IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines.
  • Page 264 C3 - XSARA PICASSO CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT Engines: 8HV - 8HY - 9HZ - 9HY Tools. [1] Ø 10 mm low pressure connector : 4215-T. [2] Pressure gauge for testing boost pressure : 4073-T.A Tool kit 4073-T IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines.
  • Page 265 CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT XSARA PICASSO Engines: RHY - RHZ Tools. [1] Ø 10 mm low pressure connector : 4215-T. [2] Ø 8 mm low pressure connector : 4218 -T. [3] Pressure gauge for testing boost pressure : 4073 -T Kit 4073 -T Connect the tool [1] between the booster pump and the fuel filter (white mark at "a"...
  • Page 266 XSARA PICASSO CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT Engines: RHY - RHZ (continued) Checks on pressure: dynamic. Engine running, at idle (normal functioning): - Fuel supply pressure shown by the pressure gauge [3] = 2 ± 0.4 Bar. - Fuel return pressure shown by the pressure gauge [3] = 0.7 ± 0.4 Bar. Abnormal functioning Fuel supply pressure Fuel return pressure...
  • Page 267 CHECKS: TURBO PRESSURE C2 - C3 Engines: 8HX - 8HW Tools. [1] Pressure gauge for checking boost pressure : 4073-T.A [2] Sleeve for checking boost pressure : (-).0171.F Checks. IMPERATIVE: Respect the following test conditions: - Engine at operating temperature. - Vehicle in running order.
  • Page 268 CHECKS: TURBO PRESSURE Engines: 8HV - 8HY Tools. [1] Pressure gauge for checking boost pressure : 4073-T.A [2] Sleeve for checking boost pressure : (-).0171.F Checks. IMPERATIVE: Respect the following test conditions: - Engine at operating temperature. - Vehicle in running order. - Engine under full load.
  • Page 269 CHECKS: TURBO PRESSURE XSARA PICASSO Engines: 9HZ - 9HY IMPERATIVE: Respect the safety and cleanliness requirements. Preparation. IMPERATIVE: Respect the following test conditions: - Engine at operating temperature. - Vehicle in running order. - Engine under full load. Connect the diagnostic tool to the vehicle’s diagnostic socket, carry out parameter measures. Mode of operation.
  • Page 270 XSARA PICASSO CHECKS: TURBO PRESSURE Engine: RHZ Tools. [1] Pressure gauge for checking boost pressure : 4073-T.A Kit 4073-T [2] Sleeve for checking boost pressure : 4185-T [3] Adaptor sleeve : 4229-T Checks. IMPERATIVE: respect the following checking requirements: Engine at running temperature.
  • Page 271 CHECKS: TURBO PRESSURE XSARA PICASSO Engine: RHY Tools. [1] Pressure gauge for checking boost pressure : 4073-T.A Kit 4073-T [2] Sleeve for checking boost pressure : 4185-T Checks. IMPERATIVE: respect the following checking requirements: Engine at running temperature. Vehicle running at full load. Preparation.
  • Page 272 CHECKING THE AIR SUPPLY CIRCUIT C2 - C3 Engines: 8HX - 8HW - 8HY - 8HV 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.
  • Page 273 CHECKING THE AIR SUPPLY CIRCUIT XSARA PICASSO Engines: RHY - RHZ Tools. [1] Manual vacuum pump : FACOM DA 16 IMPERATIVE: Respect the safety and cleanliness requirements. Vacuum pump. - Connect the tool [1] on the vacuum pump (1). - Start the engine. - Pressure should be 0.8 bar at 780 rpm.
  • Page 274 C2 - C3 CHECKS: EXHAUST GASES RECYCLING CIRCUIT Engines: 8HX - 8HW Tools. [1] Manual pressure-vacuum pump : FACOM DA 16 IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection (HDi) engines. EGR valve. Connect tool [1] on the capsule take-off (2). Apply a vacuum of approx.
  • Page 275 CHECKS: EXHAUST GASES RECYCLING CIRCUIT XSARA PICASSO Engines: 9HZ - 9HY Exhaust gas recycling (EGR) valve. (1) Exhaust gas recycling (EGR) electrovalve NOTE: The engine ECU pilots the EGR valve. Perform the check with the aid of a diagnostic tool. Carry out the following operations with the diagnostic tool: - «INJECTION»...
  • Page 276 XSARA PICASSO CHECKS: EXHAUST GASES RECYCLING CIRCUIT Engines: RHY - RHZ Tools. [1] Manual vacuum pump : FACOM DA 16 IMPERATIVE: Respect the safety and cleanliness requirements. EGR valve. - Connect the tool [1] to the capsule union (1). - Apply several times in succession a vacuum of approx. 0.6 bar to activate the rod "a". - In abrupt reaction to the vacuum, the valve should close on its seating with a clicking noise.
  • Page 277 PARTICLE FILTER SAFETY AND CLEANLINESS REQUIREMENTS ALL TYPES General. ESSENTIAL: Given the very high pressures prevailing in the fuel high pressure circuit (1600 Bars), respect the following regulations. - It is forbidden to smoke in the immediate proximity of the high pressure circuit during a repair. - Avoid working close to flames or sparks.
  • Page 278 ALL TYPES PARTICLE FILTER SAFETY AND CLEANLINESS REQUIREMENTS Operations on the fuel additive circuit. IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves that are resistant to hydrocarbons. The work area must be ventilated. In the event of any significant dispersion of additive: - Wear a breathing mask for filtering the particles.
  • Page 279 SPECIAL FEATURES: FORCED REGENERATION OF THE PARTICLE FILTER ALL TYPES Tools. Diagnostic stations : LEXIA or PROXIA Imperative: Respect the safety and cleanliness requirements. Forced regeneration of the particle filter. IMPERATIVE: Respect the safety and cleanliness requirements specific to HDi engines. ESSENTIAL: Connect the vehicle to a gas extractor approved for this type of operation.
  • Page 280 XSARA PICASSO SPECIAL FEATURES: PARTICLE FILTER / FILLING OF THE ADDITIVE RESERVOIR Imperative: Respect the safety and cleanliness requirements. Tools. Filling kit comprising the following items: 1 Container of Eolys 2 Filters 2 Tubes 1 Empty container 2 Hooks 1 Adaptor Filling.
  • Page 281 SPECIAL FEATURES: PARTICLE FILTER / CHECKING THE ADDITIVE PUMP XSARA PICASSO Engine: 9 HZ IMPERATIVE: Respect the safety and cleanliness requirements. Tools. [1] Manual pressure/vacuum pump : FACOM DA 16 [2] Additive container : (-).1613.G Kit 1613 Checks. IMPERATIVE: Respect the safety and cleanliness requirements specific to HDi engines. IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves that are resistant to hydrocarbons.
  • Page 282 XSARA PICASSO SPECIAL FEATURES: PARTICLE FILTER / CHECKING THE ADDITIVE PUMP Sealing of the additive injector. Couple tool [1] to the tube (1). Action the manual pump [1]. WARNING: The additive injector should open at a pressure of 100 ± 20 Bars. Action the manual pump in vacuum [1] at 800 m.bars.
  • Page 283 SPARKING PLUGS ALL TYPES Engine Electrode Electrode Electrode Tightening Vehicles BOSCH EYQUEM CHAMPION type gap setting gap setting gap setting torque 1.1i FR7 DE RFN 58 LZ RC 8 YLC 1.4i 1.6i 16V FR7 ME 0,9 ± 0,1 RFN 58 HZ 1.1i FR7 DE RFN 58 LZ...
  • Page 284 ALL TYPES SPEEDOMETER An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled. This decree stipulates: - The speed indicated by a speedometer must never be lower than the actual vehicle speed. - Between the speed displayed «SD»...
  • Page 285 CLUTCH SPECIFICATIONS 1.1i 1.4i 1.6i 16V 1.4 HDi Engine type Gearbox type Supplier BVM/BVMP (*) BVM/BVMP (*) BVM/BVMP (*) MA 5/S MA 5 N/L MA 5 S/L MA 5/0 Mechanism / type VALEO Engine type 180 CP0 3400 200 P 3900 Bearing supplier / height SKF 17 mm Clutch disc...
  • Page 286 C3 - C3 PLURIEL CLUTCH SPECIFICATIONS 1.1i 1.4i 1.4i 16V 1.6i 16V 1.4 HDi 1.4 HDi 16V Engine type Gearbox type Supplier MA/5 BE4/5 Mechanism / type VALEO 200 MF Engine type 180 CPO 3400 200 P 3900 230 P 4700 3850 Clutch disc 11 R 10 X...
  • Page 287 CLUTCH SPECIFICATIONS XSARA 1.4i 1.6i 16V 2.0i 16V Engine type Gearbox type Supplier MA/5 MA/5 BE4/5 Mechanism / type VALEO Engine type 180CPO 3400 200 CPR 3800 230 DNG 4700 215 DT 5250 Clutch disc 180 XJF 73 C 200X(D95) 11A12X 230 DNG 4700 215 FD 95 Ø...
  • Page 288 XSARA CLUTCH SPECIFICATIONS 1.4 HDi 1.9 D 2.0 HDi Engine type Gearbox type Supplier BE4/5 Mechanism / type Engine type 200 P 4200 200 P 3700 230 P 4700 235 T 5700 Clutch disc 215 F (D 93) 22 BX 228D Ø...
  • Page 289 CLUTCH SPECIFICATIONS XSARA PICASSO 1.6i 1.8i 16V 2.0i 16V 1.4 HDi 16V 2.0 HDi Engine type Gearbox type Supplier BE4/5 Mechanism / type VALEO Engine type 200 DNG 3800 230 DNG 4700 215 DT 5250 225 DNG 5100 230 P 4700 Clutch disc 200X(D95) 230 DNG 4700...
  • Page 290 C2 - C3 - C3 PLURIEL CLUTCH SPECIFICATIONS Engines: HFX – KFV – KFU – NFU – 8HX – 8HW – 8HV – 8HY NOTE: All the clutches are «push» type with hydraulic control. Description. The declutch control has a declutch fork mounted on a ball-joint. (1) The ball-joint is screwed into the clutch casing.
  • Page 291 CLUTCH SPECIFICATIONS XSARA - XSARA PICASSO Engines: KFW - NFU - NFV - 6FZ - RFN - RFS - 8HZ - 9HZ - 9HY - WJY - RHY - RHZ NOTE: All the clutches are «push» type with hydraulic control. Description.
  • Page 292 XSARA - XSARA PICASSO CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS Engines: KFW - NFU - 6FZ - RFN - RFS - 8HX - 9HZ - 9HY - WJY - RHY - RHZ «PUSH» clutch Clutch cable. Removing. Uncouple the cable from the lever (1). B2BP002C Unclip the cable from the gearbox by actioning B2BP001C...
  • Page 293 CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS XSARA - XSARA PICASSO Engines: KFW - NFU - 6FZ - RFN - RFS - 8HX - 9HZ - 9HY - WJY - RHY - RHZ «PUSH» clutch Refitting. Place the pedal in the high position (contact at “a”). Attach the cable yoke on the hook of the clutch pedal.
  • Page 294 XSARA - XSARA PICASSO CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS Engines: KFW - NFU - 6FZ - RFN - RFS - 8HX - 9HZ - 9HY - WJY - RHY - RHZ Adjusting the pedal height. Loosen the nut (6) and the screw (7). Using a lever, raise the stop support (8) to its highest position.
  • Page 295 CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS HYDRAULIQUE C3 PLURIEL- XSARA C2-C3-XSARA PICASSO Bleeding the hydraulic clutch control IMPERATIVE: Use only new brake brake fluid that is not emulsified, avoid any ingress of impurities into the hydraulic circuit. IMPERATIVE: Do not use automatic bleeding equipment (risk of the brake fluid emulsifying in the hydraulic circuit).
  • Page 296 C2 - C3 - C3 PLURIEL CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS HYDRAULIQUE XSARA PICASSO Bleeding the hydraulic clutch control Action the clutch pedal manually through its full travel: 7 times rapidly down and up. Allow the clutch pedal to come back up to its high position. Fill the brake fluid reservoir to the maximum of its capacity.
  • Page 297 GEARBOX AND TYRE SPECIFICATIONS Manual gearbox Petrol Diesel 1.1i 1.4i 1.4 HDi Engine types Tyres-rolling 165/70 R14 165/70 R14 185/55 R14 165/70 R14 185/55 R15 Circumference 1,804 m 1,804 m 1,781 m 1,804 m 1,781 m Gearbox type MA 5/S MA 5/N MA 5/L MA 5/0...
  • Page 298 GEARBOX AND TYRE SPECIFICATIONS Piloted manual gearbox Petrol Diesel 1.4i 1.6i 16V 1.4 HDi Engine types Tyres-rolling 165/70 R14 185/55 R15 185/55 R14 195/45 R16 185/70 R15 165/70 R14 Circumference 1,804 m 1,781 m 1,781 m 1,772 m 1,804 m 1,804 m Gearbox type MA 5/N...
  • Page 299 GEARBOX AND TYRE SPECIFICATIONS Manual gearbox Petrol 1.1i 1.4i 1.6i 16V AUTOMATIC X - SX - Exclusive X - SX Exclusive X - SX Exclusive Trim level X - SX Exclusive Engine type Tyres-rolling - Circumference 165/70 R 14 1,804 m 185/60 R15 1,828 m 165/70 R 14 1,804 m 185/60 R15 1,828 m Gearbox type...
  • Page 300 GEARBOX AND TYRE SPECIFICATIONS Piloted manual gearbox Petrol Diesel 1.4i 16V 1.6i 16V 1.4 HDi Trim level Engine type Tyres-rolling 185/60 R15 165/70 R14 Circumference 1,828 m 1,804 m Gearbox type MA/5 Gearbox ident. plate 20 CP 56 20 CP 65 Reduction box torque 17x64 16x63...
  • Page 301 GEARBOX AND TYRE SPECIFICATIONS C3 PLURIEL Petrol Diesel 1.4i 1.4 HDi 1.6i 16V Engine types Tyres-rolling Circumference Gearbox type MA/5N MA/5S MA/50 Gearbox ident. plate 20 CP 60 (m) (1) 20 CP 63 (mp) (2) 20 CP 71 (m) (1) Reduction box torque 13x59 16x65...
  • Page 302 XSARA GEARBOX AND TYRE SPECIFICATIONS Petrol 1.6i 16V 2.0i 16V 1.4i AUTOMATIC AUTOMATIC Engine type Tyres-rolling - Circumference 195/55 R15 - 1,815 m Gearbox type MA/5 BE4/5 BE3/5 Gearbox ident. plate 20 CP 13 (1) 20 CP 51 (2) 20 TP 49 20 DL 40 20 TE 47 20 TP 47...
  • Page 303 GEARBOX AND TYRE SPECIFICATIONS XSARA PICASSO Petrol 2.0i 16V 1.6i 1.8i 16V AUTOMATIC Engine type Tyres-rolling 185/65 R15 Circumference 1,895 m Gearbox type BE4/5 Gearbox ident. plate 20 DL 67 20 DL 69 20 TS 02 Reduction box torque 15x64 19x77 21x73 Speedometer ratio...
  • Page 304 C2 - C3 - C3 PLURIEL MA/5 GEARBOX Engines: HFX - KFV - NFU - 8HX - 8HW «a» Identification label. «b» Location for engraving of serial and gearbox nos. B2CP3SQC...
  • Page 305 C2 - C3 - C3 PLURIEL MA/5 GEARBOX Engines: HFX - KFV - NFU - 8HX - 8HW (1) Retaining clip. (2) Secondary shaft. (3) Drive pinion (5th gear). (4) Bearing retaining clip screw. (5) Gearbox casing. (6) Intermediate plate. (7) Gearbox casing fixing screw.
  • Page 306 C2 - C3 - C3 PLURIEL MA/5 GEARBOX Engines: HFX - KFV - NFU - 8HX - 8HW (23) Driven pinion (4th gear). (24) Driven pinion (5th gear). (25) 5th gear synchroniser. Tightening torques (m.daN). (4) Bearing retaining clip screw (x4) : 1,8 ±...
  • Page 307 C2 - C3 - C3 PLURIEL MA/5 GEARBOX Engines: HFX - KFV - NFU - 8HX - 8HW Tightening torques (m.daN). (26) 5th gear cover fixing screw (3 screws) : 2,2 ± 0,2 (27) Reverse gear switch : 2,5 ± 0,5 (1 screw) (28) Drain plug (1 screw)
  • Page 308 XSARA MA/5 GEARBOX Engines: KFW - NFU «a» Identification label. «b» Location for engraving of serial and gearbox nos. B2CP3HTC...
  • Page 309 XSARA MA/5 GEARBOX Engines: KFW - NFU (1) Primary shaft. (2) Clutch bearing guide. (3) Clutch housing. (4) Gearbox casing. (5) Intermediate plate. (6) Bearing retaining clip. (7) Drive pinion (5th gear). (8) Secondary shaft. (9) 5th gear synchroniser. (10) Driven pinion (5th gear). (11) Driven pinion (4th gear).
  • Page 310 XSARA MA/5 GEARBOX Engines: KFW - NFU Tightening torques (m.daN). (23) Clutch bearing guide (3 fixing screws) : 0,6 ± 0,15. (24) Intermediate plate (11 fixing screws) : 5 ± 0,5. (25) Rear cover (3 fixing screws) : 2,2 ± 0,2. (26) Bearing retaining clip (4 fixing screws) : 1,8 ±...
  • Page 311 XSARA MA/5 GEARBOX Engines: KFW - NFU (29) Top-up plug (x1) : 2,5 ± 0,5. (30) Drain plug (x1) : 2,5 ± 0,5. (31) Reverse gear switch (x1) : 2,5 ± 0,5. Strengthened MA gearboxes are marked with the letter «B» or «C»: «B»...
  • Page 312 RECOMMENDATIONS - PRECAUTIONS: MA PILOTED MANUAL GEARBOX Engines: HFX - KFV - NFU - 8HX Safety requirements. ESSENTIAL: Given the special features of the MA type piloted IMPERATIVE: When initialising the clutch actuator and/or gearbox manual gearbox, observe the requirements detailed below. actuator, do not allow any person to walk or stand in front of the vehicle.
  • Page 313 RECOMMENDATIONS - PRECAUTIONS: MA PILOTED MANUAL GEARBOX Engines: HFX - KFV - NFU - 8HX Operations on electrical components. Towing. Do not disconnect: - The battery when the engine is running. Conditions for towing. - The ECU with the ignition switched on. - The clutch and gearbox actuators with the ignition switched on.
  • Page 314 RECOMMENDATIONS - PRECAUTIONS: MA PILOTED MANUAL GEARBOX Engines: HFX - KFV - NFU - 8HX Engaging of «N», without using a diagnostic tool. Engaging of «N», using a diagnostic tool. In this configuration, the gearbox actuator is blocked, gear engaged. Preliminary operations: - Battery voltage higher than 12.5 volts.
  • Page 315 RECOMMENDATIONS - PRECAUTIONS: MA PILOTED MANUAL GEARBOX Engines: HFX - KFV - NFU - 8HX Engaging of «N», without using a diagnostic tool (continued). Preliminary operation: - Disconnect the battery negative terminal. - Remove the air filter. - Use a 22 mm spanner. Use the spanner to lift the gear engagement lever the maximum possible until the axis «A»...
  • Page 316 MA/5 PILOTED MANUAL GEARBOX Engines: KFV - 8HX «a» Identification label. «b» Location for engraving of serial and gearbox nos. B2CP3STC...
  • Page 317 MA/5 PILOTED MANUAL GEARBOX Engines: KFV - 8HX (1) Circlip. (2) Secondary shaft. (3) Drive pinion (5th gear). (4) Bearing stop screw. (5) Gearbox casing. (6) Intermediate plate. (7) Gearbox casing fixing screw. (8) Clutch bearing guide screw. (9) Clutch housing. (10) Bearing guide.
  • Page 318 MA/5 PILOTED MANUAL GEARBOX Engines: KFV - 8HX (23) Driven pinion (4th gear). (24) Driven pinion (5th gear). (25) 5th gear synchroniser. Tightening torques (m.daN). (4) Bearing stop screw (x4) : 1,8 ± 0,2 (6) Intermediate plate : 5 ± 0,5 (11 fixing screws) (7) Gearbox casing (15 fixing screws)
  • Page 319 MA/5 PILOTED MANUAL GEARBOX Engines: KFV - 8HX Tightening torques (m.daN). (26) 5th gear cover fixing screw (3 screws) : 2,2 ± 0,2 (27) Gearbox input speed sensor : 0,8 ± 0,2 (1 screw) (28) Reverse gear switch (1 screw) : 2,5 ±...
  • Page 320 MA/5 PILOTED MANUAL GEARBOX Engines: KFV - 8HX Features. The piloted gearbox is a modern manual gearbox with technology that offers enhancements in every driving situation. The piloted manual gearbox has two operating programmes: - «Sequential» programme. - «Automatic» programme. The piloted manual gearbox has: - A gearbox ECU (supplier: SIEMENS).
  • Page 321 BE4/5 GEARBOX C3 - XSARA - XSARA PICASSO Engines: NFV - 6FZ - RFN - RFS - 8HV - 8HY - 9HZ - 9HY - WJY - RHY - RHZ B2CP3BNC B2CP3BPD (a) Marking zone (sequence and serial no.). (b) Location of identification label.
  • Page 322 BE4/5 GEARBOX C3 - XSARA - XSARA PICASSO Engines: NFV - 6FZ - RFN - RFS - 8HV - 8HY - 9HZ - 9HY - WJY - RHY - RHZ (1) Drain plug. (2) Filling and top-up plug. (3) Air vent. NOTE: The air vent aperture can be used for filling.
  • Page 323 BE4/5 GEARBOX C3 - XSARA - XSARA PICASSO Engines: NFV - 6FZ - RFN - RFS - 8HV - 8HY - 9HZ - 9HY - WJY - RHY - RHZ Description (1) Primary shaft. (14) 1st / 2nd gear synchroniser. (2) Clutch bearing guide.
  • Page 324 C3 - XSARA - XSARA PICASSO BE4/5 GEARBOX Engines: 6FZ - RFN - RFS - WJY - 8HV - 8HY - 8HZ - 9HZ - 9HY - RHY - RHZ Tightening torques (m.daN). (23) Clutch bearing guide (3 screws) : 1,25 ± 0,2 (24) Clutch housing (13 screws) : 1,3 ±...
  • Page 325 C2 - C3 - C3 PLURIEL MA/5 GEARBOX CONTROLS Engines: HFX - KFV - KFU - NFU - 8HX - 8HW (1) Gear control lever. (2) Gear engagement control cable. (*) (3) Gear selection control cable. (*) (*) The two cables cannot be separated. B2CP3HXD...
  • Page 326 C2 - C3 - C3 PLURIEL CHECKS AND ADJUSTMENTS: MA/5 GEARBOX CONTROLS Engines: HFX - KFV - KFU - NFU - 8HX - 8HW (4) Gear engagement ball-joint Ø 10 mm. (5) Gear selection ball-joint Ø 10 mm. B2CP3HYC Length D Length C Length D Length C...
  • Page 327 C2 - C3 - C3 PLURIEL CHECKS AND ADJUSTMENTS: MA/5 GEARBOX CONTROLS Engines: HFX - KFV - KFU - NFU - 8HX - 8HW Adjustment. WARNING: Do not use any tool to detach the ball-joints. The gear selection control and gear engagement control cables cannot be adjusted.
  • Page 328 XSARA CHECKS AND ADJUSTMENTS: MA/5 GEARBOX CONTROLS Engines: KFW NFU 8HZ 1 - Gear lever. 2 - Gear control bar. 3 - Engagement rod. 4 - Gear selection rod. 5 - Torque reaction rod. 6 - Gear engagement ball-joint. 7 - Fixed point on gearbox. Adjustment.
  • Page 329 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...
  • Page 330 CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS Engines: 8HV - 8HY (4) Gear engagement ball-joint Ø 10 mm. (5) Gear selection ball-joint Ø 10 mm. B2CP3J4C Length A Length B Gear selection 907 mm 645 mm cable (5) Length D Length C Gear 965 mm 610 mm...
  • Page 331 CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS Engines: 8HV - 8HY Adjustment. The gear selection control and gear engagement control cables cannot be adjusted. To release the ball-joint, press at «d» then pull the ball-joint upwards. To release sleeve stops: - Press on the tabs of the clip (6) at «a». - Disengage the sleeve stops from their supports.
  • Page 332 BE4/5 GEARBOX CONTROLS XSARA - XSARA PICASSO Engines: NFV - 6FZ - RFN - RFS - WJY - 8HZ - 9HZ - 9HY - RHY - RHZ (1) Gear control lever. (2) Gear engagement control cable. (*) (3) Gear selection control cable. (*) (4) Gear selection ball-joint Ø...
  • Page 333 CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS XSARA - XSARA PICASSO Engines: NFV - 6FZ - RFN - RFS - WJY - 8HZ - 9HZ - 9HY - RHY - RHZ Principles of adjusting the gear controls. WARNING: Cables should be adjusted each time the gearbox, gear controls or power unit are removed.
  • Page 334 XSARA - XSARA PICASSO CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS Engines: NFV - 6FZ - RFN - RFS - WJY - 8HZ - 9HZ - 9HY - RHY - RHZ Adjusting the gear controls Tools. [1] Tool for positioning the gear lever : 9607-T.
  • Page 335 XSARA - XSARA PICASSO RECOMMENDATIONS - PRECAUTIONS: AL4 AUTOMATIC GEARBOX Engines: KFV - NFU - RFN - RHZ Procedure to be followed prior to carrying out repairs on AL4 autoactive gearbox If a gearbox malfunction occurs, there are two possible Oil level (see corresponding operation).
  • Page 336 C3 - XSARA - XSARA PICASSO RECOMMENDATIONS - PRECAUTIONS: AL4 AUTOMATIC GEARBOX Engines: KFV - NFU - RFN - RHZ Precautions to be taken. Towing. Repairs on electrical components. The front of the vehicle must be raised in order to be towed. Do not disconnect: If the front of the vehicle cannot be raised: - The battery when the engine is running.
  • Page 337 C3 - XSARA - XSARA PICASSO RECOMMENDATIONS - PRECAUTIONS: AL4 AUTOMATIC GEARBOX Engines: KFV - NFU - RFN - RHZ Precautions to be taken. Repairs on mechanical components. Modification of the oil usage counter value. Exchanging the gearbox ECU: Never place the gearbox on the ground without protection. In order to avoid breaking the input shaft ring, it is imperative that - Note down the gearbox counter value.
  • Page 338 C3 - XSARA - XSARA PICASSO RECOMMENDATIONS - PRECAUTIONS: AL4 AUTOMATIC GEARBOX Engines: KFV - NFU - RFN - RHZ Procedure for initialising the automatic gearbox ECU Downloading. Updating the 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.
  • Page 339 C3 - XSARA - XSARA PICASSO RECOMMENDATIONS - PRECAUTIONS: AL4 AUTOMATIC GEARBOX Engines: KFV - NFU - RFN - RHZ Procedure for initialising the automatic gearbox ECU Updating the value of the oil usage counter. Downloading. Using PROXIA. ECU downloading procedure: Access to reading and recording of the oil counter is via the menu: - Follow the diagnostic tool procedure.
  • Page 340 AL4 AUTOMATIC GEARBOX Engines: KFV - NFU - RFN - RHZ Identification. «a» Component reference. 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. B2CP3ECD...
  • Page 341 AL4 AUTOMATIC GEARBOX C3 - XSARA - XSARA PICASSO Engines: KFV - NFU - RFN - RHZ Tightening torques (m.daN). (1) Oil flow modulation electrovalve fixing : 1 ± 0,2 (2) Heat exchanger fixing : 5 ± 1 (3) Output speed sensor fixing : 1 ±...
  • Page 342 C3 - XSARA - XSARA PICASSO AL4 AUTOMATIC GEARBOX Engines: KFV - NFU - RFN - RHZ Tightening torques (m.daN). (8) Fixing of converter on diaphragm Pre-tightening : 1 ± 0,1 Tightening : 3 ± 0,3 (9) Plug fixing : 0,8 ± 0,2 (10) Gearbox fixing on engine : 5,2 ±...
  • Page 343 AL4 AUTOMATIC GEARBOX C3 - XSARA - XSARA PICASSO Engines: KFV - NFU - RFN - RHZ Tightening torques (m.daN). A: EW7 and EW10 engines Hydraulic block fixing. Centre the hydraulic block, using screws (11) and (12) . Pre-tighten (no strict order) : 0,9 Slacken : All 7 screws...
  • Page 344 C3 - XSARA PICASSO AL4 AUTOMATIC GEARBOX Engines: KFV - RFN In passenger compartment. The gear selector is guided by the shape of the stepped gate and by a retaining spring which pulls it to the left hand side. The gear selector control has 5 positions: - Position «P»: Park (locking and immobilisation of the vehicle).
  • Page 345 AL4 AUTOMATIC GEARBOX Engine: KFV In passenger compartment (continued). The information is transmitted to the gearbox ECU. NOTE: The vehicle is equipped with the «shift lock»: you have to switch on the ignition and press the brake pedal to unlock the selector lever from position «P». Two switches placed on the gear control gate permit the driver to choose one of the following three driving programmes: - Normal programme: Operates as the default programme (eco law, autoadaptive mode).
  • Page 346 C3 - XSARA PICASSO AL4 AUTOMATIC GEARBOX Engines: KFV - RFN Gearbox end. The automatic gearbox is controlled by a cable. «c» or «d» Push-button. (1) Control lever with ball-joint. XSARA PICASSO (2) Automatic adjustment (pull out the button to adjust the control, push it in to lock the adjustment of the control).
  • Page 347 AL4 AUTOMATIC GEARBOX XSARA XSARA Engines: NFU - RFN - RHZ In passenger compartment. The selector control has 6 positions: - The gear selector is guided by the shape of the stepped gate and by a retaining spring which pulls it to the left hand side. - Push the lever to the right to exit from position «P».
  • Page 348 XSARA AL4 AUTOMATIC GEARBOX XSARA Engines: NFU - RFN - RHZ Gearbox end. (1) Control lever. (2) Automatic adjustment. (3) Sleeve stop. The automatic gearbox is controlled by a cable.
  • Page 349 AL4 AUTOMATIC GEARBOX Engine: KFV NOTE: The «shift lock» is a system that locks the gear selection lever in position «P». Unlocking the «SHIFT LOCK» (normal operation). - Switch on the ignition. - Press the brake pedal and keep it pressed. - Move the gear selection lever out of position «P».
  • Page 350 AL4 AUTOMATIC GEARBOX XSARA Engines: NFU - RFN - RHZ SHIFT LOCK. NOTE: The «shift lock» is a system that locks the gear selection lever in position «P». Unlocking the «SHIFT LOCK» (normal operation). - Switch on the ignition. - Press the brake pedal and keep it pressed. - Move the gear selection lever out of position «P».
  • Page 351 AL4 AUTOMATIC GEARBOX XSARA PICASSO Engine: RFN SHIFT LOCK. NOTE: The «shift lock» is a system that locks the gear selection lever in position «P». Unlocking the «SHIFT LOCK» (normal operation). - Switch on the ignition. - Press the brake pedal and keep it pressed. - Move the gear selection lever out of position «P».
  • Page 352 AL4 AUTOMATIC GEARBOX Engine: KFV Refitting the gearbox control. New gear selection control Couple the ball-joint (3). Push in the component (a) without bending the cable. Check all the gear selection control positions. Re-used gear selection control. Release the component (a). Couple the ball-joint (3).
  • Page 353 AL4 AUTOMATIC GEARBOX XSARA Engines: NFU - RFN - RHZ Refitting the gearbox control. Proceed in the opposite order to removal. IMPERATIVE: To adjust the gear selection control, place the gear selection lever in the park position. Press on the component (25) without bending the cable, then release. IMPERATIVE: Check that all the gears can engage.
  • Page 354 XSARA PICASSO AL4 AUTOMATIC GEARBOX Engine: RFN Refitting. Proceed in the opposite order to removal. Lubricate the support (13). New gear selection control. Couple the ball-joint (6). WARNING: Do not deform the selection lever on the automatic gearbox. Push in the component (a) without bending the cable. Check all the gear selection control positions.
  • Page 355 DRAINING / FILLING / TOP-UP: AL4 GEARBOX C3 - XSARA - XSARA PICASSO Engines: KFV - NFU - RFN - RHZ Tools. [1] Filling cylinder : (-).0341 Draining. IMPERATIVE: The gearbox should be drained when the oil is warm (at least 60°C), to eliminate the impurities in suspension in the oil.
  • Page 356 C3 - XSARA - XSARA PICASSO DRAINING / FILLING / TOP-UP: AL4 GEARBOX Engines: KFV - NFU - RFN - RHZ Checking the oil level. Prior conditions: - Vehicle in horizontal position. - Check gearbox is not in back-up mode. - Remove the oil filler cap (2).
  • Page 357 DRAINING / FILLING / TOP-UP: AL4 GEARBOX C3 - XSARA - XSARA PICASSO Engines: KFV - NFU - RFN - RHZ Thread of oil then "drip-drip". Refit the plug (3), Tighten to 2,4± 0,2 m.daN. "Drip-drip" or nothing. Refit the oil level plug (3). Stop the engine.
  • Page 358 C2 - C3 - C3 PLURIEL - XSARA - XSARA PICASSO DRIVESHAFTS - GEARBOX Gearbox oil seal mandrels Tightening torques (m.daN) Driveshaft Driveshaft RH side LH side Tool kit Vehicles Gearbox Engines bearing HFX - KFV - KFU C2 C3 C3 Pluriel 24,5 ±...
  • Page 359 AXLE GEOMETRY Conditions for checking and adjusting Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point (see corresponding operation). Vehicle heights at reference height E1APOBZD Front height Rear height H1 = R1 – L1 H2 = R2 + L2 H1 = Measurement between the measuring zone underneath the front H2 = Measurement between the measuring zone underneath the rear...

  • Page 360: Axle Geometry

    AXLE GEOMETRY B3CP07SD Measuring front height Measuring rear height [1] Gauge for measuring the wheel radius, 4 bolts, tool 8006-T Z1 = Measuring zone underneath the front subframe. Z2 = Measuring zone underneath the rear sill. Measure the radius of the front wheel R1 - Calculate dimension H1 = R1 – L1 Measure the radius of the rear wheel R2 - Calculate dimension H2 = R2 + L2 Except CRD (*) Except CRD (*)
  • Page 361 AXLE GEOMETRY Front axle Rear axle Dissymmetry of lower castor at 0° 30’. DISSYMMETRY OF LOWER CAMBER 0° 18’. Distribute symmetrically, LH / RH wheel, the total tracking value. Dissymmetry of lower camb8er 0° 18. All types (except CRD) HFX - KFV - 8HX HFX - KFV - 8HX Castor Camber...

  • Page 362: Front Axle

    FRONT AXLE Tightening torques (m.daN). (1) Nut fixing suspension leg on body : 6,5 ± 0,6 (2) Damper (3) Anti-roll bar link rod upper ball-joint : 3,2 ± 0,3 (4) Suspension leg pivot : 5,4 ± 0,5 (5) Anti-roll bar link rod lower ball-joint : 3,2 ±...

  • Page 363: Rear Axle

    REAR AXLE Tightening torques (m.daN). (25) Rear axle fixing screw : 10 ± 1 (26) Anti-roll bar (27) Rear axle crossmember (28) Rear suspension arm silentblock yoke (29) Rear suspension arm silentblock (30) Yoke / suspension arm fixing screw : 7 ± 0,5 (31) Rear suspension arm (32) Stub axle bearing nut : 20 ±...
  • Page 364 SUSPENSION FRONT AXLE (1) Nut fixing suspension leg on body : 6,5 ± 0,6 (2) Damper (16) Cup (17) Damper nut : 6,5 ± 0,6 (18) Damper cup (19) Ball bearing (20) Spring thrust cup (21) Travel stop cup (22) Suspension spring (23) Damper rod rpotector (24) Travel stop B3BP180D...
  • Page 365 FEATURES OF ELECTRIC POWER STEERING Engines: HFX - KFV - NFU - 8HX Steering column B3EP13GD B3EP13HC Tightening torques (m.daN.). Identification. (1) Steering wheel fixing : 2 ± 0,3 Identified by the colour of the ring at «a». (2) Steering column fixing on support : 2,2 ±...
  • Page 366 FEATURES OF ELECTRIC POWER STEERING Engines: HFX - KFV - NFU - 8HX Steering mechanism Tightening torques (m.daN.). (4) Ball-joint fixing on pivot : 3,5 ± 0,3 (5) Steering rod lock-nut : 5 ± 0,5 (8) Threaded washer (9) Stud : 0,8 ±...
  • Page 367 FEATURES OF ELECTRIC POWER STEERING Engines: HFX - KFV - NFU - 8HX Steering assistance Electric power steering ECU B3EP13KC B3EP13LC Supplier: KOYO. Only one ECU version, whatever the engine-type. The steering assistance is rpovided by the assistance motor (12), The electric power steering ECU is linked to the following connectors: controlled by the ECU.
  • Page 368 SPECIAL FEATURES: STEERING Engines: HFX - KFV - NFU - 8HX Centring the steering rack Preliminary operation. Raise and support the vehicle on a two-column lift. Remove, on the RH side of the steering rack: - Clip (1). - Clip (2). Release the steering rack rpotection gaiter.
  • Page 369 AXLE GEOMETRY Conditions for checking and adjusting Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point (see corresponding operation). Vehicle heights at reference height E1AP09MD Front height Rear height H1 = R1 - L1 H2 = R2 + L2 H1 = Measurement between the measuring zone underneath the front H2 = Measurement between the measuring zone underneath the rear...
  • Page 370 AXLE GEOMETRY Checks at reference height B3CP07SD Measuring front height Measuring rear height [1] Gauge for measuring the wheel radius, 4 bolts, tool 4003-T or 8006-T (according to version). Z1 = Measuring zone underneath the front subframe. Z2 = Measuring zone underneath the rear sill. Measure the radius of the front wheel R1 - Calculate dimension H1 = R1 –...
  • Page 371 AXLE GEOMETRY Front axle Rear axle Dissymmetry of lower castor at 0° 30’. Dissymmetry of lower camber at 0° 18’. Dissymmetry of lower camber at 0° 18’. Distribute symmetrically, LH / RH wheel, the total tracking value. All types (except CRD) Raised suspension - Sports Castor Camber Pivot angle...
  • Page 372 C3 PLURIEL AXLE GEOMETRY Conditions for checking and adjusting Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point (see corresponding operation). Vehicle heights at reference height C3 Pluriel E1AP0AUD Front height Rear height H1 = R1 - L1 H2 = R2 + L2 H1 = Measurement between the measuring zone underneath the front H2 = Measurement between the measuring zone underneath the rear...
  • Page 373 AXLE GEOMETRY C3 PLURIEL Checks at reference height B3CP07SD Measuring front height Measuring rear height [1] Gauge for measuring the wheel radius, 4 bolts, tool 4003-T Z1 = Measuring zone underneath the front subframe. Z2 = Measuring zone underneath the rear sill. Measure the radius of the front wheel R1 - Calculate dimension H1 = R1 –...
  • Page 374 C3 PLURIEL AXLE GEOMETRY Front axle Rear axle Dissymmetry of lower castor at 0° 30’. Dissymmetry of lower camber at 0° 18’. Dissymmetry of lower camber at 0° 18’. Distribute symmetrically, LH / RH wheel, the total tracking value. All types Castor Camber Pivot angle...
  • Page 375 FRONT AXLE C3 - C3 PLURIEL Tightening torques (m.daN). (1) Nut fixing suspension leg on body : 6,5 ± 0,6 (2) Suspension leg (3) Anti-roll bar link rod upper ball-joint : 3,2 ± 0,3 (4) Suspension leg pivot : 5,4 ± 0,5 (5) Anti-roll bar link rod lower ball-joint : 3,2 ±...
  • Page 376 C3 - C3 PLURIEL REAR AXLE Tightening torques (m.daN). (1) Rear axle fixing screw : 10 ± 1 (2) Anti-roll bar (3) Rear axle crossmember (4) Rear suspension arm rubber mounting yoke (5) Rear suspension arm rubber mounting (6) Yoke / suspension arm fixing screw : 7,6 ±...
  • Page 377 C3 - C3 PLURIEL SUSPENSION Front axle (1) Nut fixing suspension leg on body : 6,5 ± 0,6 (2) Damper (3) Anti-roll bar link rod upper ball-joint : 3,2 ± 0,3 (4) Suspension leg pivot : 5,4 ± 0,5 (5) Anti-roll bar link rod lower ball-joint : 3,2 ±...
  • Page 378 C3 - C3 PLURIEL SUSPENSION Front axle (1) Nut fixing suspension leg on body : 6,5 ± 0,6 (2) Damper (16) Cup (17) Damper nut. : 6,5 ± 0,6 (18) Damper cup (19) Ball bearing (20) Spring thrust cup (21) Travel stop cup (22) Suspension spring (23) Damper rod rpotector (24) Travel stop...
  • Page 379 C3 - C3 PLURIEL SUSPENSION Rear axle (25) Rear axle fixing screw : 10 ± 1 (26) Anti-roll bar (27) Rear axle crossmember (28) Rear suspension arm silentblock mounting yoke (29) Rear suspension arm silentblock (30) Suspension arm fixing screw on yoke : 7,6 ±...
  • Page 380 FEATURES OF ELECTRIC POWER STEERING C3 - C3 PLURIEL Engines: HFX - KFV - KFU - NFU - 8HX - 8HW - 8HV - 8HY Steering column B3EP13GD B3EP13HC Tightening torques m.daN. Identification. (1) Steering wheel fixing : 2 ± 0,3 Identified by the colour of the ring at «a».
  • Page 381 C3 - C3 PLURIEL FEATURES OF ELECTRIC POWER STEERING Engines: HFX - KFV - KFU - NFU - 8HX - 8HW - 8HV - 8HY Steering mechanism Tightening torques m.daN. (4) Ball-joint fixing on pivot : 3,5 ± 0,3 (5) Steering rod lock-nut : 5 ±...
  • Page 382 C3 - C3 PLURIEL FEATURES OF ELECTRIC POWER STEERING Engines: HFX - KFV - KFU - NFU - 8HX - 8HW - 8HV - 8HY Steering assistance B3EP13KC B3EP13LC Supplier: KOYO. Electric power-assisted steering ECU. Only one ECU version, whatever the engine-type. The steering assistance is rpovided by the assistance motor (12), controlled The electric power steering ECU is linked to the following connectors: by the ECU.
  • Page 383 C3 - C3 PLURIEL SPECIAL FEATURES: STEERING Engines: HFX - KFV - KFU - NFU - 8HX - 8HW - 8HV - 8HY Centring the steering rack Preliminary operation. Raise and support the vehicle on a two-column lift. Remove, on the RH side of the steering rack: - Clip (1).
  • Page 384 XSARA AXLE GEOMETRY Front and rear measuring points XSARA ALL TYPES N°RPO 8667 # Front height Rear height B3CP06ZD H1 = Dimension between the centre of the front suspension arm mounting and the ground. H2 = Dimension between the contact face of the rear mounting and the ground. R1 = Front wheel radius under load.
  • Page 385 AXLE GEOMETRY XSARA Reference heights Tools. [1] Gauge for measuring the radius of wheels with 4 bolts N°RPO 9429 # : 4300-T Setting the reference height. Front Front Measure the dimension «R1». Measure the dimension «R2». Calculate the dim. H1 = R1 - L1. Calculate the dim.
  • Page 386 XSARA AXLE GEOMETRY Values of the front and rear suspensions, at reference height ESSENTIAL: When checking the suspensions, the vehicle should be at reference height. Tools. Compress the suspension, to obtain the values at reference height. [1] Set of two suspension compressors : 9511-T.A [2] Set of four straps : 9511-T.B...
  • Page 387 XSARA AXLE GEOMETRY Values of the front and rear suspensions, at reference height Front axle Saloon all engine Saloon CRD (*) typesexcept KFW all engine types Saloon CRD (*) Saloon or Tolerances Adjustable Estate 2.0i 16V (RFS) except KFW entreprise KFW all engine types Estate CRD (*) all engine types...
  • Page 388 XSARA AXLE GEOMETRY a = Angle which defines the tracking between the front and rear axles. Its value must not exceed 12'. B3CP04UC...
  • Page 389 FRONT AXLE XSARA Tightening torques (m.daN). (1) Damper nut : 4,5 ± 0,4 (2) Cup screw : 2,5 ± 0,3 (3) Suspension leg (4) Anti-roll bar link rod upper ball-joint : 3,7 ± 0,3 (5) Suspension leg pivot (hollow pivot) : 4,5 ±...
  • Page 390 FRONT AXLE XSARA Evolution: Suspension arm ball-joint Application from RPO: 7968. New components: - Suspension arm ball-joint. - Pivot. Old fitting ØA = 16 mm. ØA = 18 mm. New fitting Repair requirements. ESSENTIAL: Swapping of old and new components is forbidden. It is permitted to fit a new pivot/ball-joint assembly on one side of an old vehicle.
  • Page 391 XSARA FRONT AXLE Anti-roll bar Engine versions Diameter colour reference Saloon Blue 1.6i - 1.6i 16V - 1.9 D 2.0i 16V (RFV) - 1.4 HDi - 2.0 HDi Estate Yellow Saloon 2.0i 16V (RFS) White...
  • Page 392 XSARA FRONT AXLE Pivot ball-joint: - Manual steering, groove at «b». - Power steering, groove at «b». B3CP043D Tongue «a» towards the front. B3CP049C...
  • Page 393 REAR AXLE XSARA Tightening torques (m.daN). (1) Anti-roll bar lever : 3,2 ± 0,3 (2) Anti-roll bar (3) Transversal torsion bars (4) Rear crossmember flanges : 8,3 ± 0,8 (5) Front silentblocks : 5,5 ± 0,5 (6) Rear silentblocks : 4,5 ± 0,4 (7) Anti-vibration clamp (8) Damper pin : 9,6 ±...
  • Page 394 XSARA REAR AXLE Vehicles Torsion bars (mm) Anti-roll bar (mm) Engines Diameter colour reference Diameter colour reference 3-door Entreprise 19,3 Violet Orange 3- and 5-door TT 1.9 D 18,7 yellow Blue exc. Entreprise Estates All types Grey Green 19,3 Orange 3- and 5-door TT Violet 1.6i 16V - 2.i 16V...
  • Page 395 REAR AXLE XSARA B3DP04UD B3DP04TC - The front silentblocks are aligned at an angle of 45° in relation to the vehicle’s axis. Operating clearance - X = 1 to 1.4 mm. - The rear silentblocks are in parallel with the vehicle’s axis. NOTE: The RH torsion bar can be identified by 1 NOTE: There are two suppliers for the silentblocks: paint line.
  • Page 396 XSARA REAR DAMPER Adjusting the rear dummy damper Lengths of the rear dummy damper (mm) Engines Normal driving Grand export 1.9 D 1.6i 16V 3-door 1.6i 16V 5-door 2.0i 16V (RFN) - 1.4 HDi 2.0 HDi 2.0i 16V (RFS) Estates and Entreprise all types E5AP14WC...
  • Page 397 XSARA MANUAL STEERING SPECIFICATIONS Steering wheel - Manual steering - (a) : LHD/RHD = White. - (L) : Shaft length = 311 ± 1.5 mm. - (1) Steering wheel fitted with AIRBAG (according to equipment). - (4) Steering column adjustment lever. Tightening torques (m.daN).
  • Page 398 XSARA MANUAL STEERING SPECIFICATIONS Manual steering Tightening torques (m.daN). (7) Pivot ball-joint nut (8) Link rod lock nut : 4.5 (9) Ball-joint on steering rack (10) Fixing on cradle (11) Plunger flange screw : 1.2 B3EP042D...
  • Page 399 XSARA MANUAL STEERING SPECIFICATIONS Manual steering (continued) Number of teeth Number Steering rack Steering ratio Steering stop of steering travel wheel turns colour code (mm) Pinion Steering rack 6 teeth (13) Left hand drive 73,5 22/1 (RH helix) Yellow thickness mm - Length of the steering track rods (Pre-adjustment) = 371 mm (Between ball-joint centres) or 391 mm (Between the centre of the pivot ball-joint and the contact face of the steering rack ball-joint).
  • Page 400 XSARA POWER-ASSISTED STEERING SPECIFICATIONS Steering wheel - Power-assisted steering - (a) : LHD = Blue. : RHD = White. - (L): Shaft length = 311 ± 1.5 mm. - (1) Steering wheel fitted with AIRBAG (according to equipment). - (4) Steering column adjustment lever. Tightening torques (m.daN).
  • Page 401 POWER-ASSISTED STEERING SPECIFICATIONS XSARA Power-assisted steering Tightening torques (m.daN). (7) Pivot ball-joint nut (8) Link rod lock nut : 4.5 (9) Ball-joint on steering rack (10) Fixing on subframe (11) Hydraulic pipe connection : 2.5 (12) Valve to housing fixing : 1.2 (13) Plunger flange screw : 1.2...
  • Page 402 POWER-ASSISTED STEERING SPECIFICATIONS XSARA Power-assisted steering (Continued) Number of teeth Steering rack Steering Number of travel ratio steering wheel (mm) Pignon Steering rack turns 71,7 18,8/1 (RH helix) Steering valve Number of teeth (*) Vehicles Protector colour All Types (except 1.6i 16V - 1.9 TD) BLACK 1.6i 16V - 1.9 TD ORANGE...
  • Page 403 POWER-ASSISTED STEERING SPECIFICATIONS XSARA Power-assisted steering assembly Tightening torques (m.daN). High pressure tube (Rubber seal pump side) - Power-assisted valve and pump union : 2.5 Return pipe. - Power-assisted valve union : 2.5 - (16) Upper front fixing (E3) : 2.5 - (17) Upper rear fixing (E3) : 2.2 - (18) Fixing (E3)

  • Page 404: Xsara Picasso

    XSARA PICASSO AXLE GEOMETRY Checks at reference height WARNING: The values shown should only be used as guides. In case of doubt, check the settings at reference height Conditions for checking and adjusting: Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point (see corresponding operation).
  • Page 405 AXLE GEOMETRY XSARA PICASSO Checks at reference height (the reference height of the vehicle is set as per the table below). Front axles Rear axle B3CP05BC B3CP05AC B3DP079C NO - CRD Vehicle (CRD = Difficult road conditions) Engines: NFV - 6FZ - RFN - 9HZ - 9HY - RHY Front axles Rear axle H2 = R2 + L2...
  • Page 406 XSARA PICASSO AXLE GEOMETRY Checks at reference height (the reference height of the vehicle is set as per the table below). NO - CRD Vehicle (CRD = Difficult road conditions) Front axle Rear axle Vehicle Tracking Castor Pivot angle Camber Tracking Camber Adjustable...
  • Page 407 AXLE GEOMETRY XSARA PICASSO Checks at reference height (the reference height of the vehicle is set as per the table below). Front axle Rear axle B3CP05BC B3CP05AC B3DP079C NO - CRD Vehicle (CRD = Difficult road conditions) Engines: NFV - RFN - RHY Front axle Rear axle H2 = R2 + L2...
  • Page 408 XSARA PICASSO AXLE GEOMETRY Checks at reference height (the reference height of the vehicle is set as per the table below). CRD Vehicle (CRD = Difficult road conditions) Engines: NFV - RFN - RHY Front axle Rear axle Vehicle Tracking Castor Pivot angle Camber...
  • Page 409 FRONT AXLE XSARA PICASSO Tightening torques m.daN. (1) Damper nut : 4.5 ± 0.4 (2) Cup screw : 2.5 ± 0.2 (3) Suspension leg (4) Anti-roll bar link rod ball-joint : 3.7 ± 0.3 (5) Suspension leg swivel : 4.5 ± 0.4 (6) Anti-roll bar (7) Anti-roll bar link rod ball-joint : 3.7 ±...
  • Page 410 XSARA PICASSO REAR AXLE Tightening torques m.daN. (14) Front silentblock on subframe : 9.4 ± 0.9 (15) Anti-roll bar bolt : 5.5 ± 0.5 (16) Rear torsion bar (17)Anti-roll bar (18) Tubular axle (19) Front silentblock on bodyshell : 4 ± 0.4 (20) Rear upper arm.
  • Page 411 STEERING COLUMN SPECIFICATIONS XSARA PICASSO Left hand drive = Green marking. Right hand drive = White marking. (1) Steering wheel (4) Steering column adjustment Tightening torques m.daN. (2) Airbag to steering wheel fixing : 0.8 ± 0.1 (3) Steering wheel fixing : 3.3 ±...
  • Page 412 XSARA PICASSO STEERING COLUMN SPECIFICATIONS Tightening torques (m.daN). (7) Pivot ball-joint nut : 4 ± 0.4 (8) Steering rod adjusting lock nut : 4.5 ± 0.4 (9) Ball-joint on steering rack : 6 ± 0.6 (10) Fixing steering on subframe : 8 ±...
  • Page 413 STEERING COLUMN SPECIFICATIONS XSARA PICASSO Steering Rack pinion Number of teeth Number of steering Turning circle Turning circle rack travel in rack wheel turns between walls between kerbs Left hand drive LH helix 71,7 x 2 28 Teeth 3,22 12 m 11,48 m Right hand drive RH helix...
  • Page 414 XSARA PICASSO POWER-ASSISTED STEERING SPECIFICATIONS Tightening torques (m.daN). Unions between pump unions and power steering valve : 2 ± 0.3 (16) Fixing screw : 2.2 ± 0.3 (17) Fixing screw : 2.2 ± 0.3 (18) Fixing screw : 2.2 ± 0.3 NOTE: Coat the threads with product «E3».
  • Page 415 BRAKE SPECIFICATIONS (WITHOUT ABS) 1.4 HDi 1.1i 1.4i Engine type Master cylinder 20,6 Master vac 203,2 Ø mm Caliper/piston makes LUCAS.TRW-/-C 48/13-/-48 Disc Plain Disc thickness/minimum thickness 13/11 Maximum run-out (mm) 0,05 Difference in max. thickness 0,01 on same circumference (mm) Supplier / Brake pad grade TEXTRR-/-T 4144 Original thickness/minimum thickness...
  • Page 416 BRAKE SPECIFICATIONS (WITH ABS) 1.6i 16V 1.4 HDi 1.1i 1.4i Engine type Master cylinder 22,2 (*) Master vac 228,6 LUCAS.TRW LUCAS.TRW-/-C Caliper/piston makes LUCAS.TRW-/-C 48/13-/-48 Ø C 54/22-/-54 48/13-/-48 Plain Disc Ventilated Disc thickness/minimum thickness 13/11 22/20 13/11 Supplier / Brake pad grade TEXTRR-/-T 4144 Ø...
  • Page 417 BRAKE SPECIFICATIONS Braking circuit without ABS - REF (drum brakes at the rear) Braking system specifications - 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.
  • Page 418 BRAKE SPECIFICATIONS Braking circuit with ABS - REF (drum brakes at the rear) B3FP7BTD...
  • Page 419 BRAKE SPECIFICATIONS Braking circuit with ABS - REF (disc brakes at the rear) B3FP7BUD...
  • Page 420 BRAKE SPECIFICATIONS Braking circuit with ABS - REF (a) Hydraulic circuit (b) Electrical circuit (1) Master cylinder in tandem (2) Braking servo (3) Brake caliper (or drum at the rear) (4) Hub equipped with a bearing with an integral magnetic wheel (48 pairs of poles) (5) Wheel sensor (6) Brake fluid level sensor...
  • Page 421 BRAKE SPECIFICATIONS (7) Hydraulic block Ref. Components Supplier Part no. Observations ABS MK 70 Mounted on the front LH chassis Hydraulic block 96 514 120 80 member. ESP -ABS MK.60 4 adjustment channels. 96 490 288 80 ABS MK.70 ESP -ABS 26-way connector.

  • Page 422: Brake Specifications

    BRAKE SPECIFICATIONS Brake pedal Front brakes Rear brakes B3FP166D B3FP164C B3FP165C Tightening torques (m.daN). (14) Rear caliper fixing on arm : 5,3 ± 0,5 (16) Servo fixing : 2,2 ± 0,3 (12) Yoke fixing on caliper : 10,5 ± 1 (15) Yoke fixing on caliper : 3,8 ±...
  • Page 423 HANDBRAKE (Adjustment) Adjustment. Lift and chock the vehicle. Remove: - The rear cover (8). - The nut (9). - The handbrake trim (6). - The gear lever gaiter (5). - The front cover (3). - The screws (1). Disconnect the connectors of the following components: - The cigar lighter (2).
  • Page 424 HANDBRAKE (Adjustment) Adjustment (continued). A: Drum brakes. B: Disc brakes. (10) Nut for adjusting cable tensions. Remove: - The rear wheels. - The drums (according to version). Release the handbrake. Use a gauge set to measure at «a» the travel of the lever from its stop.
  • Page 425 BLEEDING AND FILLING THE BRAKING SYSTEM Tools. [1] Generic bleeding apparatus : «LURO» or similar. Bleeding, refilling. Draining. Drain the brake fluid reservoir (1) to the maximum (if necessary, use a clean syringe). Disconnect the connector (4). Uncouple the pipe (2). Unscrew the shaft (3).
  • Page 426 BLEEDING AND FILLING THE BRAKING SYSTEM (Continued) Bleeding 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 cylinder, proceeding in the following order: Front LH wheel.
  • Page 427 BLEEDING AND FILLING THE BRAKING SYSTEM (Continued) With the bleeding apparatus. - Connect the bleeding apparatus [1] on the brake fluid reservoir (1). - Adjust the apparatus pressure to 2 Bars. For each circuit: - Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container. - Open the bleed screw, wait until the fluid is flowing out without air bubbles.
  • Page 428 BRAKE SPECIFICATIONS (WHITHOUT ABS REF) 1.4i 16V 1.4 HDi 1.1i 1.4i Engine type Master cylinder 20,6 Ø Master vac 203,2 Caliper/piston makes LUCAS/TRW C48/13 Disc Plain Disc thickness/minimum thickness 13/11 13/11 Ø Disc Ventilated Disc thickness/minimum thickness 22/20 Brake pad grade TEXTRR T 4144 Ø...
  • Page 429 BRAKE SPECIFICATIONS (WITH ABS REF) 1.1i 1.4i 1.4i 16V 1.6i 16V 1.4 HDi 1.4 HDi 16V Engine type Master cylinder 22,2 (*) Ø Master vac 228,6 Caliper /piston LUCAS/TRW LUCAS/TRW LUCAS/TRW LUCAS/TRW makes C 48/13 48 C 54/22 54 C 48/13 48 C 54/22 54 Disc Plain...
  • Page 430 C3 PLURIEL BRAKE SPECIFICATIONS (WITH & WITHOUT ABS REF) Sans ABS REF Ftec ABS REF 1.4i 1.4 HDi 1.4i 1.6i 16V 1.4 HDi Engine type Master cylinder 20,6 22,2 (*) Ø Master vac 203,2 228,6 FT mm Makes /piston makes LUCAS/TRW C38 HR 9/13 Disc Ventilated...
  • Page 431 BRAKE SPECIFICATIONS C3 - C3 PLURIEL Braking circuit without ABS - REF (drum brakes at the rear) Braking system specifications - 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.
  • Page 432 C3 - C3 PLURIEL BRAKE SPECIFICATIONS Braking circuit with ABS - REF (drum brakes at the rear) B3FP162D...
  • Page 433 BRAKE SPECIFICATIONS C3 - C3 PLURIEL Braking circuit with ABS - REF (disc brakes at the rear) B3FP163D...
  • Page 434 C3 - C3 PLURIEL BRAKE SPECIFICATIONS Braking circuit with ABS - REF (a) Hydraulic circuit (b) Electrical circuit (1) Master cylinder in tandem (2) Braking servo (3) Brake caliper (or drum at the rear) (4) Hub equipped with a bearing with an integral magnetic wheel (48 pairs of poles) (5) Wheel sensor (6) Brake fluid level sensor...
  • Page 435 BRAKE SPECIFICATIONS C3 - C3 PLURIEL C3 Pluriel ABS hydraulic block: # N°RPO 9423 ABS hydraulic block: N°RPO 9424 # B3FP12XC B3FP7BVC Components Supplier Part no. Observations Components Supplier Part no. Observations ABS MK 60 : ABS MK 70 : Installed on the front LH Installed on the front LH 96 394 937 80...
  • Page 436 C3 - C3 PLURIEL BRAKE SPECIFICATIONS Brake pedal gear Front brakes Rear brakes B3FP166D B3FP164C B3FP165C Tightening torques (m.daN). (14) Rear caliper fixing on arm : 5,3 ± 0,5 (16) Servo fixing : 2,2 ± 0,3 (12) Yoke fixing on caliper : 10,5 ±...
  • Page 437 C3 - C3 PLURIEL BRAKE SPECIFICATIONS Evolution: rear wheel cylinder (applies from RPO 9667) C3 - C3 Pluriel Evolution. New wheel cylinders at the rear, with cut-off pressure 27 bars instead of 35 bars. Assembly. (1) Rear wheel cylinder. Repair. IMPERATIVE: The mixing of the old and new components is STRICTLY FORBIDDEN.
  • Page 438 C3 - C3 PLURIEL HANDBRAKE (Adjustment) Adjustment. Lift and chock the vehicle. Remove: - The rear cover (8). - The nut (9). - The handbrake trim (6). - The gear lever gaiter (5). - The front cover (3). - The screws (1). Disconnect the connectors of the following components: - The cigar lighter (2).
  • Page 439 HANDBRAKE (Adjustment) C3 - C3 PLURIEL Adjustment (continued). (10) Nut for adjusting cable tensions Remove: - The rear wheels. - The drums (according to version). Release the handbrake. Use a gauge set to measure at «a» the travel of the lever from its stop.
  • Page 440 C3 - C3 PLURIEL BLEEDING AND FILLING THE BRAKING SYSTEM Tools. [1] Generic bleeding apparatus : «LURO» or similar. Bleeding, refilling. Draining. Drain the brake fluid reservoir (1) to the maximum (if necessary, use a clean syringe). Disconnect the connector (4). Uncouple the pipe (2).
  • Page 441 BLEEDING AND FILLING THE BRAKING SYSTEM (Continued) C3 - C3 PLURIEL Bleeding 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).
  • Page 442 C3 - C3 PLURIEL BLEEDING AND FILLING THE BRAKING SYSTEM (Continued) With the bleeding apparatus. - Connect the bleeding apparatus [1] on the brake fluid reservoir (1). - Adjust the apparatus pressure to 2 Bars. For each circuit: - Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container. - Open the bleed screw, wait until the fluid is flowing out without air bubbles.
  • Page 443 BRAKE SPECIFICATIONS XSARA Saloons 2.0 HDi 1.4i 1.6i 16V 2.0i 16V 1.9 D 1.4 HDi Engine type Master cylinder Without ABS 23,8 (expansion holes) Ftec ABS 23,8 (valve) Ø Master vac 228,6 Caliper/piston makes BOSCH 54 LUCAS 57 BOSCH 54 Disc Ventilated Disc thickness/min.
  • Page 444 XSARA BRAKE SPECIFICATIONS Estates 1.4i 1.6i 16V 2.0i 16V 1.9 D 1.4 HDi 2.0 HDi Engine type Master cylinder Without ABS 23,8 (expansion holes) Ftec ABS 23,8 (valve) Ø Master vac 228,6 Caliper/piston makes BOSCH 54 LUCAS 57 BOSCH 54 Disc Ventilated Disc thickness/min.
  • Page 445 BRAKE SPECIFICATIONS XSARA - Tighten the nuts (1) to 2.3 m.daN. - The clevis pin (2) is held in place by a plastic clip. B3FP10YD...
  • Page 446 XSARA BRAKE SPECIFICATIONS Braking system specifications - “X” braking circuit. - Front: disc brakes, ventilated (according to model). - Rear: drum brakes with automatic adjustment. - Cable operated handbrake acting on the rear wheels. (1) Hydraulic valve block «ABS Bosch 5.3» (1) Hydraulic valve block «ABS Bosch 5.3 REF»...
  • Page 447 BRAKE SPECIFICATIONS XSARA Braking system without ABS (rear drum brakes) Braking system without ABS (rear disc brakes) Up to # OPR 8687 B3FP14FD B3FP14GD...
  • Page 448 BRAKE SPECIFICATIONS XSARA Braking system with ABS (rear drum brakes) B3FP14HD...
  • Page 449 BRAKE SPECIFICATIONS XSARA Braking system with ABS REF (rear disc brakes) Braking system with ABS REF (rear drum brakes) B3FP14JD B3FP14KD...
  • Page 450 XSARA BRAKE SPECIFICATIONS Braking system with ABS REF (rear drum brakes) B3FP14LD...
  • Page 451 BRAKE SPECIFICATIONS XSARA Braking circuit with ESP (BOSCH 5.7) (A) Hydraulic circuit (B) Electrical circuit (1) Master cylinder in tandem (2) Braking servo (3) Brake caliper (or drum at the rear) (4) Toothed wheel (5) Wheel sensor (6) Brake fluid level sensor (7) Hydraulic block plus ECU (8) Stoplamp switch (9) Instrument panel...
  • Page 452 XSARA BRAKE SPECIFICATIONS Electrical circuit Components Ref. Supplier Part no. Observations 42-way connector. Electronic 5.7 ESP Integral to the hydraulic block.. Changing only the ECU is prohibited. 2-way grey connector. 0 265 006 389 The sensors are inductive-type. Front wheel sensor Tightening torque: 0,8 ±...
  • Page 453 BRAKE SPECIFICATIONS XSARA (7) Hydraulic block Gyrometer sensor B3HP002C C4AP17YC Components Supplier Part no. Observations IMPERATIVE: Respect the direction of fitting of the gyrometer/accelero- meter sensor (connector towards the rear of the vehicle). Located on the front LH WARNING: The gyrometer/accelerometer sensor should not be sub- wheelarch: jected to any impact.
  • Page 454 HANDBRAKE XSARA Checking and adjusting the handbrake. - Remove the handbrake console. - Jack up and chock the vehicle with the rear wheels hanging free. - Check the correct routing of the brake cables under the vehicle. - Apply and release the handbrake ten times. - Set the handbrake to the 3rd notch.
  • Page 455 - using brake bleeding equipment, in which case the pressure of the equipment should be set to 2 Bars. - or in the conventional way. IMPERATIVE order of bleeding Wheels: - Rear Right. - Front Left. - Rear Left. - Front Right. Top up using brake fluid supplied by CITROEN Replacement Parts.
  • Page 456 XSARA PICASSO BRAKE SPECIFICATIONS Mercosur Europe Without ESP (*) 2.0i 16V 2.0 HDi 1.6i 1.8i 16V 2.0i 16V 2.0 HDi Engine type Master cylinder 23,8 Master vac Ø Master cylinder travel 254/34 FT mm Caliper LUCAS BOSCH piston makes C54/54 ZOH54/54 Disc Ventilated...
  • Page 457 BRAKE SPECIFICATIONS XSARA PICASSO All types Ftec ESP (*) 1.8i 16V 2.0i 16V 1.4 HDi 2.0 HDi Engine type Master cylinder 23,8 Ø Master vac mm Master cylinder travel 254/35 Piston Makes/Caliper BOSCH ZOH54/54 Disc Ventilated Disc thickness/minimum thickness 26/24 Makes/Brake pad grade FERODO/769 (37) Rear brake caliper...
  • Page 458 BRAKING SYSTEM SPECIFICATIONS XSARA PICASSO Without ABS B3FP7B9D...
  • Page 459 BRAKING SYSTEM SPECIFICATIONS XSARA PICASSO With ABS With EPS (Electronic Stability Program) B3FP7B9D B3FP7BRD...
  • Page 460 XSARA PICASSO BRAKE SPECIFICATIONS Braking system specifications - “X” braking circuit. - Front: disc brakes, ventilated. - Rear: drum brakes with automatic adjustment. - Cable operated handbrake acting on the rear wheels. - Load sensitive braking compensator (non ABS versions). (1) Hydraulic valve block «ABS Bosch 5.3»...
  • Page 461 HANDBRAKE (Adjustment) XSARA PICASSO Adjustment. Remove the handbrake trim (1). Unclip the sound-deadening (2). Raise and support the vehicle with the rear wheels hanging free. Check the correct routing of the brake cables under the vehicle. Apply and release the handbrake 4 times. Set the handbrake to the 5th notch.
  • Page 462 BLEEDING THE BRAKES XSARA PICASSO Tools. Bleeding equipment of type «LURO» or similar. IMPERATIVE: For bleeding the secondary circuit, use ELIT, LEXIA or PROXIA diagnostic tools. Draining. Drain the brake fluid reservoir as empty as possible using a syringe. Disconnect the brake fluid warning lamp connector. Retrieve the brake fluid reservoir from its supply pipes by pulling upwards.
  • Page 463 STARTER MOTORS ALL TYPES Abbreviations and definitions Coding of climates is as follows: Meaning of abbreviations: CLIMATES: : Starting possible as low as -18°C. : Gearbox. Temperate : Starting possible as low as -18°C. : Manual gearbox. Cold : Starting possible as low as -25°C. : Automatic gearbox.
  • Page 464 ALL TYPES STARTER MOTORS Vehicles/models Starter type Class Climate Table of class of starter motors CLASS CLASS 2 CLASS 3 CLASS 4 CLASS 5 CLASS 6 Torque C 5.5 Nm 6 Nm 10 Nm 11.5 Nm 11.5 Nm Maximum power for I ≤...
  • Page 465 STARTER MOTORS Vehicles/models Gearboxes Class Climate 1.1i 1.1i Réfri 1.4i M-MAP 1.4i Réfri...
  • Page 466 STARTER MOTORS Vehicles/models Gearboxes Class Climate 1.6i 16V M-MAP-A 1.4 HDi M-MAP...
  • Page 467 STARTER MOTORS Vehicles/models Gearboxes Class Climate 1.1i 1.1i Réfri M-MP 1.4i 1.4i Réfri M-MP...
  • Page 468 STARTER MOTORS Vehicles/models Gearboxes Class Climate 1.4i 16V 1.6i 16V M-MAP 1.4 HDi 1.4 HDi 16V...
  • Page 469 STARTER MOTORS C3 PLURIEL Vehicles/models Gearboxes Class Climate 1.4i M-MAP 1.4i Réfri C3 Pluriel 1.6i 16V M-MAP-A 1.4 HDi...
  • Page 470 STARTER MOTORS XSARA Vehicles/models Gearboxes Class Climate 1.4i XSARA 1.4i Réfri 1.4i Réfri + DA...
  • Page 471 STARTER MOTORS XSARA Vehicles/models Gearboxes Class Climate 1.6i 16V XSARA 2.0i 16V...
  • Page 472 STARTER MOTORS XSARA Vehicles/models Gearboxes Class Climate 2.0i 16V XSARA 1.9 D 2.0 HDi...
  • Page 473 STARTER MOTORS XSARA Vehicles/models Gearboxes Class Climate 2.0 HDi XSARA 1.4 HDi...
  • Page 474 STARTER MOTORS XSARA PICASSO Vehicles/models Gearboxes Class Climate 1.6i XSARA PICASSO 1.8i 16V...
  • Page 475 STARTER MOTORS XSARA PICASSO Vehicles/models Gearboxes Class Climate 2.0i 16V XSARA PICASSO 1.6 HDi 16V 2.0 HDi...
  • Page 476 ALL TYPES ALTERNATORS Abbreviations and definitions Coding of climates is as follows: Meaning of abbreviations: : Gearbox. CLIMATES: : Manual gearbox. : Automatic gearbox. : Hot (45°C/37°C). BVMP : Piloted manual gearbox. NON REFRI : Without air conditioning. : Temperate (37°C/17°C). REFRI : With air conditioning.
  • Page 477 ALTERNATORS Allocation of alternator classes Without aircon With aircon Without cold pack With cold pack Without cold pack With cold pack Engine Gearbox Climate Base N1 or Base N1 or Base N1 or Base N1 or 1.1i 1.4i BVMP 1.6i 16V 1.4 HDi Meaning of abbreviations, see page: 472.
  • Page 478 C3 - C3 PLURIEL ALTERNATORS Allocation of alternator classes Without aircon With aircon Without cold pack With cold pack Without cold pack With cold pack Engine Gearbox Climate Base N1 or Base N1 or Base N1 or Base N1 or 1.1i 1.4i 1.4i...
  • Page 479 C3 - C3 PLURIEL ALTERNATORS Allocation of alternator classes Without aircon With aircon Without cold pack With cold pack Without cold pack With cold pack Engine Gearbox Climate Base N1 or Base N1 or Base N1 or Base N1 or 1.6i 16V 1.6i 16V BVMP...
  • Page 480 XSARA ALTERNATORS Allocation of alternator classes Without aircon With aircon Without cold pack With cold pack Without cold pack With cold pack Engine Gearbox Climate Base Base Base Base 1.4i 1.6i 16V 1.6i 16V 2.0i 16V Meaning of abbreviations, see page: 472.
  • Page 481 XSARA ALTERNATORS Allocation of alternator classes Without aircon With aircon Without cold pack With cold pack Without cold pack With cold pack Engine Gearbox Climate Base Base Base Base 2.0i 16V 2.0i 16V 1.9 D Meaning of abbreviations, see page: 472.
  • Page 482 XSARA ALTERNATORS Allocation of alternator classes Without aircon With aircon Without cold pack With cold pack Without cold pack With cold pack Engine Gearbox Climate Base Base Base Base 1.4 HDi 2.0 HDi 2.0 HDi Meaning of abbreviations, see page: 472.
  • Page 483 XSARA PICASSO ALTERNATORS Allocation of alternator classes Without aircon With aircon Heated Nav. + Heated Nav. + Engine Gearbox Climate Base seat Nav. Heated seat Base seat Nav. Heated seat 1.6i 1.8i 16V 2.0i 16V 1.6 HDi 16V 2.0 HDi Meaning of abbreviations, see page: 472.
  • Page 484 CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR Checking the alternator output. Connect as shown in the diagram opposite, using an ammeter (A), a voltmeter (V), and a rheostat (R) or a Volt/Ammeter/Rheostat combination. Referring to the vehicle’s equipment specification (see table opposite), adjust the engine speed and rheostat charge to obtain U = 13.5 V.
  • Page 485 CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR MINIMUM OUTPUTS (in A) Class Alternator Min. output speed 1800 rpm 2000 rpm 3000 rpm 68.5 4000 rpm 6000 rpm 78.5 8000 rpm 15000 rpm MINIMUM YIELDS (in %) Class Alternator speed 1800 rpm 2000 rpm 3000 rpm 4000 rpm...
  • Page 486 TOUS TYPES PRE-HEATING AND STARTING SYSTEMS Pre/Post heating Vehicles - models Pre-heater plugs Pre-heater control unit (pre-heating duration at 20°C) NAGARES 960411-P 1.4 HDi NGK YE04 CARTIER 735068 NGK YE04 NAGARES 960411-P 1.4 HDi Controlled by the diesel injection ECU. CARTIER 735068 NGK YE04 NAGARES 960411-P...
  • Page 487 AIR CONDITIONING R 134 a (HFC) Compressor Refrigerant Vehicle Engines Date Variable refill Oil quantity cc Oil reference Capacity 05/2003 # ALL TYPES 600 + 0 - 50 gr SD 6 V 12 11/2001 # ALL TYPES 625 + 0 - 50 gr C3 Pluriel TU EW SP 10...
  • Page 488 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Click-fit connector removing/fitting tool Vehicle Ø Inch Ring colour Tool kit 4164-T XSARA Black 8005-T.A XSARA PICASSO 8005-T.C C5HP073C Tightening torques (m.daN). Unions Aircon compressor fixings. Ø Pipes Steel/Steel Aluminium/Steel ESSENTIAL: Tighten the front part of the compressor 1,7 ±...
  • Page 489 C2 - C3 - XSARA PICASSO SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) «EUROCLIM» Compressor (MANULLI seal) Tools. : FACOM (-).1702 Tool for removing-refitting air conditioning seals IMPERATIVE: Removing-refitting the MANULLI seal (see corresponding operation). MANULLI seal. C2 C3 : All engine-versions XSARA : 08/2000 # (Compressor and condenser end)
  • Page 490 C2 - C3 - XSARA PICASSO SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Condenser (MANULLI seal) Seals (MANULLI seal) C5HP18XD C5HP18VD The condenser (5) has a cylinder (6) incorporating the function of aircon MANULLI calibrated seal (3). fluid reservoir and with integral filtering cartridge. Direction of fitting of the seal (3).
  • Page 491 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Presence of pollen filter Vehicle Equipment RPO No. Presence of filter Observations SAXO ALL TYPES C2 - C3 YES (Behr) Without aircon Except driving school XSARA Base aircon YES (Larger) XSARA PICASSO Regulated aircon YES (Valéo) NO (Valéo) Without aircon...
  • Page 492 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Pollen filter Note: The pollen filter is located in the engine compartment on the RH side. Removing. To remove: - Pull on the tab of the plastic cover (1), at «a». - Tilt the flap (2). - Remove the pollen filter (3).
  • Page 493 C3 - C3 PLURIEL SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Pollen filter Note: The pollen filter is located in the engine compartment on the RH side. Removing. Remove: - The three screws (1). - The plastic cover (2). Tilt the flap (3). Remove the pollen filter (4).
  • Page 494 C2 - C3 - C3 PLURIEL SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Changing the filtering/drying cartridge Tools. [1] Charge station : (according to workshop equipment) [2] TORX adaptor : TORX 70 FACOM [3] Inertia extractor :1671-T Tool kit 4114-T [4] Endpiece Ø...
  • Page 495 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) C2 - C3 - C3 PLURIEL Changing the filtering/drying cartridge Refitting. Remove the new cartridge from its packaging. Do not expose the cartridge, the filter and seals to pollutants. Lightly oil the seals (compressor oil). Remove tool [5] from the reservoir (6).
  • Page 496 XSARA SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Pollen filter Removing-refitting. Remove: - The interior trim (1). - The cover (4). - The pollen filter (3). Concerns vehicles equipped with aircon without temperature regulation. C5HP07JC Fitting of a new pollen filter necessitates the following operations: - Engage the pollen filter upwards (following arrow «c»).
  • Page 497 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) XSARA PICASSO Pollen filter Remove: - The three screws (1). - The cover (2). Remove the pollen filter. B1BP23ED...
  • Page 498 XSARA PICASSO SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Changing the filtering/drying cartridge Tools. [1] Charge station : (according to workshop equipment) [2] TORX adaptor : TORX 70 FACOM Removing. Depressurise the aircon circuit, using tool [1]. Uncouple the hose (2). Remove: - The air filter assembly (3).
  • Page 499 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) XSARA PICASSO Changing the filtering/drying cartridge Move aside the radiator/condenser assembly. Remove the plug (6), using tool [2]. Support the radiator/condenser assembly thus moved aside. Remove the filtering/drying cartridge (7), using pliers. Refitting. Refit the filtering/drying cartridge (7).
  • Page 500 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Compressor lubricant ESSENTIAL: The compressor lubricant is extremely hygroscopic; always use FRESH oil. Checking the compressor oil level There are three specific cases: 1/ Repairs to a system without leaks. 2/ Slow leak. 3/ Fast leak.
  • Page 501 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Checking the compressor oil level (Continued) 2/ Slow leak. - Slow leaks do not lead to oil loss, therefore the same procedure should be followed as if there was no leak at all. 3/ Fast leak.
  • Page 502 ALL TYPES AIR CONDITIONING SYSTEM R 134.a Testing procedure Conditions inside the vehicle. Switch on the air conditioning and adjust the engine speed to 2500 rpm. Positions of the air conditioning controls: In an ambient temperature of 40°C, the engine speed will be brought Maximum cold.
  • Page 503 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM C3 - C3 PLURIEL KFV CHECKING TEMPERATURES (Continued) Vehicle using R134.a fluid (Compressor with variable capacity) Ambient temperature in °C Vehicle Engines 22 ± 2 17,6 ± 2 14,4 ± 2 11,5 ± 2 7,6 ±...
  • Page 504 C3 - C3 PLURIEL - XSARA - XSARA PICASSO KFV CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Checking pressures Tools. - 1 charging station. - 2 thermometers. - The temperature of the air coming from the central vents (see table). Once the preliminary conditions, vehicle equipment and checks have - The High Pressure.
  • Page 505 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM XSARA - XSARA PICASSO Checking pressures Tools. - 1 charging station. - 2 thermometers. - The temperature of the air coming from the central vents (see table). Once the preliminary conditions, vehicle equipment and checks have - The High Pressure.
  • Page 506 AIR CONDITIONING SYSTEM R 134.a (1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Filter. Tightening torques (m.daN). : 0,6 : 0,6 : 0,6 : 0,6 : 0,6 : 0,7 C5HP19UP...
  • Page 507 AIR CONDITIONING SYSTEM R 134.a C3 - C3 PLURIEL (1) High pressure valve. (2) Low pressure valve. (3) Filter. (4) Pressostat. Tightening torques (m.daN). : 0,6 : 0,6 : 0,6 : 0,6 : 0,6 : 0,6 C5HP17SP...
  • Page 508 C3 - C3 PLURIEL BVA - KFV AIR CONDITIONING SYSTEM R 134.a Checks on the air conditioning circuit 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).
  • Page 509 C3 - C3 PLURIEL NFV AIR CONDITIONING SYSTEM R 134.a Checks on the air conditioning circuit 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).
  • Page 510 C3 - C3 PLURIEL BV MECANIQUE 8HX - 8HW AIR CONDITIONING SYSTEM R 134.a Checks on the air conditioning circuit 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).
  • Page 511 AIR CONDITIONING SYSTEM R 134.a XSARA KFW - NFU - TU - TT Plan of air conditioning system. Two solutions: 1/ «MANULLI», with «NON EUROCLIM» compressor (O-ring seals). 2/ «EATON», with «EUROCLIM» compressor (quadrilobe seals). (1) High pressure valve. (2) Low pressure valve. (3) Pressostat.
  • Page 512 XSARA RFN AIR CONDITIONING SYSTEM R 134.a Plan of air conditioning system. Solution: «EATON», with «EUROCLIM» compressor and buffer capacity (quadrilobe seals). (1) High pressure valve. (2) Low pressure valve. (3) Buffer capacity. Tightening torques (m.daN). : 0,8 : 4 ± 0,4 : 0,8 A Right hand drive.
  • Page 513 AIR CONDITIONING SYSTEM R 134.aw XSARA RFN Plan of air conditioning system. Two solutions : 1/ «MANULLI», with «NON EUROCLIM» compressor (O-ring seals). 2/ «EATON», with «EUROCLIM» compressor (quadrilobe seals). (1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Dryer.
  • Page 514 XSARA RFS AIR CONDITIONING SYSTEM R 134.a Plan of air conditioning system. Two solutions: 1/ «MANULLI», with «NON EUROCLIM» compressor (O-ring seals). 2/ «EATON», with «EUROCLIM» compressor (quadrilobe seals). (1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Dryer. Tightening torques (m.daN).
  • Page 515 AIR CONDITIONING SYSTEM R 134.a XSARA WJY - RHY Plan of air conditioning system. Three solutions: 1) «MANULLI», with «NON EUROCLIM» compressor (O-ring seals). 2) «EATON», with «EUROCLIM» compressor and buffer capacity (quadrilobe seals). 3) «EATON», with «NON EUROCLIM» compressor and buffer capacity (O-ring seals). (1) High pressure valve.
  • Page 516 XSARA WJY - RHY AIR CONDITIONING SYSTEM R 134.a Plan of air conditioning system. Two solutions: 1/ «MANULLI», with «NON EUROCLIM» compressor (O-ring seals). 2/ «EATON», with «EUROCLIM» compressor (quadrilobe seals). (1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Dryer.
  • Page 517 AIR CONDITIONING SYSTEM R 134.a XSARA RHZ Plan of air conditioning system. Three solutions : 1) «MANULLI», with «NON EUROCLIM» compressor (O-ring seals). 2) «EATON», with «EUROCLIM» compressor and buffer capacity (quadrilobe seals). 3) «EATON», with «NON EUROCLIM» compressor and buffer capacity (O-ring seals). (1) High pressure valve (2) Low pressure valve (3) Buffer capacity.
  • Page 518 XSARA RHZ AIR CONDITIONING SYSTEM R 134.a Plan of air conditioning system. Two solutions: 1/ «MANULLI», with «NON EUROCLIM» compressor (O-ring seals). 2/ «EATON», with «EUROCLIM» compressor (quadrilobe seals). (1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Dryer. Tightening torques (m.daN).
  • Page 519 AIR CONDITIONING SYSTEM R 134.a XSARA PICASSO NFV (1) High pressure valve (2) Low pressure valve (3) High pressure clickfit union (tool 8005-T.C) (4) Low pressure clickfit union (tool 8005-T.A) (5) Pressostat. : 1,8 ± 0,6 m.daN (6) Filtering/drying cartridge plug Tightening torques (m.daN).
  • Page 520 XSARA PICASSO 6FZ AIR CONDITIONING SYSTEM R 134.a (1) High pressure valve (2) Low pressure valve (3) High pressure clickfit union (tool 8005-T.C) (4) Low pressure clickfit union (tool 8005-T.A) (5) Pressostat : 1,8 ± 0,6 m.daN (6) Filtering/drying cartridge plug Tightening torques (m.daN).
  • Page 521 AIR CONDITIONING SYSTEM R 134.a XSARA PICASSO NFV - 6FZ Checks on the air conditioning circuit Key. T/P = Scale of: - Temperature (°C ), average of air from the central vents. - Pressure High (Bars). - Pressure Low (Bars). Te = Exterior temperature (°C).
  • Page 522 XSARA PICASSO RHY - RHZ AIR CONDITIONING SYSTEM R 134.a (1) High pressure valve (2) Low pressure valve (3) High pressure clickfit union (tool 8005-T.C) (4) Low pressure clickfit union (tool 8005-T.A) (5) Pressostat : 1,8 ± 0,6 m.daN (6) Filtering/drying cartridge plug Tightening torques (m.daN).
  • Page 523 AIR CONDITIONING SYSTEM R 134.a XSARA PICASSO RHY - RHZ Checks on the air conditioning circuit Key. T/P = Scale of: - Temperature (°C ), average of air from the central vents. - Pressure High (Bars). - Pressure Low (Bars). Te = Exterior temperature (°C).

This manual is also suitable for:

2004 c3 plurielC3 pluriel 20042004 berlingoXsara picasso 20042004 xsara picasso

Table of Contents

Save PDF