CITROEN 2005 C4-XSARA-XSARA PICASSO BERLINGO Owner's Manual
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CITROEN 2005 C4-XSARA-XSARA PICASSO BERLINGO Owner's Manual

CITROEN 2005 C4-XSARA-XSARA PICASSO BERLINGO Owner's Manual

2005 c4-xsara-xsara picasso berlingo
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Table of Contents

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CORRESPONDENCE TABLE FOR PETROL ENGINES
TU
ET
TU
1
3
5
Engine
JP
J4
JP +
families
1.1i
1.4i
1.4i 16V
1.6i
HFX
KFW
KFU
NFV
Engine types
C4
X
XSARA
X
XSARA
X
PICASSO
BERLINGO
X
X
VERY IMPORTANT
As the booklet is constantly re-edited, this one only covers vehicles for this
particular model year.
It is therefore necessary to order a new booklet each year and RETAIN THE
OLD ONES.
EW
7
10
JP4
J4
A
J4
J4S
1.6i 16V
1.8i 16V
2.0i
2.0i 16V
NFU
6FZ
RFJ
RFN
RFK
X
X
X
X
X
X
X
X
X
CORRESPONDENCE TABLE FOR DIESEL ENGINES
DV
4
6
Engine
TD
TED4
families
1.4 HDi
1.6 16V HDi
8HX
8HZ
9HY
9HZ
Engine types
C4
X
X
XSARA
X
X
XSARA
X
X
PICASSO
BERLINGO
DW
8
10
ATED4
B
TD
ATED
BTED4
2.0 16V
1.9D
2.0 HDi
HDi
9HX
WJY
RHY
RHZ
RHR
X
X
X
X
X
X
X
X
X

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Summary of Contents for CITROEN 2005 C4-XSARA-XSARA PICASSO BERLINGO

  • Page 1 CORRESPONDENCE TABLE FOR PETROL ENGINES CORRESPONDENCE TABLE FOR DIESEL ENGINES Engine Engine JP + TED4 ATED4 ATED BTED4 families families 2.0 16V 1.1i 1.4i 1.4i 16V 1.6i 1.6i 16V 1.8i 16V 2.0i 2.0i 16V 1.4 HDi 1.6 16V HDi 1.9D 2.0 HDi Engine types Engine types...

  • Page 2: C4 Xsara Xsara Picasso Berlingo

    PRIVATE CARS 2005 C4-XSARA-XSARA PICASSO BERLINGO «The technical information contained in this document is intended for the exclusive use of the trained person- nel of the motor vehicle repair trade. In some instances, this information could concern the security and safe- ty of the vehicle.
  • Page 3 PRESENTATION THIS HANDBOOK summarises the specifications, adjustments, checks and special features of CITROËN private vehicles, not including UTILITY vehicles for which there exists a separate handbook. The handbook is divided into groups representing the main functions: GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - AIR CONDITIONING. In each section, the vehicles are dealt with in the following order: C4 - XSARA - XSARA PICASSO - BERLINGO and all models where applicable.
  • Page 4 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 5: Table Of Contents

    CONTENTS Checking the turbo pressure: GENERAL INJECTION Xsara picasso (DW10ATED) 1 - 2 Checking the low pressure fuel supply Checking the air supply circuit: Xsara (DV4TD) circuit: Xsara (DV4TD) Vehicle XSARA 3 - 4 Checking the air supply circuit: C4 (DV6ATED4) identification Checking the low pressure fuel supply XSARA PICASSO...
  • Page 6 CONTENTS CLUTCH - GEARBOX - TRANSMISSION (continued) Adjusting the handbrake Tightening torques: front axle Filling, bleeding the brakes Gearbox specifications 312 - 314 Tightening torques: rear axle Clutch specifications 315 - 316 Tightening torques: steering 383 - 384 AIR CONDITIONING Checking and adjusting the hydraulic Tightening torques: power steering 385 - 387...
  • Page 7 IDENTIFICATION OF THE VEHICLE A - Manufacturer's name plate A1 - Front RH chassis member = All versions except CITROËN C4 Coupé EW10J4S (right hand drive). A2 - LH centre pillar = CITROËN C4 coupé EW10J4S (right hand drive). B - Cold stamp (cold stamp engraved on the bodywork).
  • Page 8 IDENTIFICATION OF THE VEHICLE Type approval Structure Version (4) Family (1) Depollution levels Bodywork (2) Others Alcohol LA KFUC Engine (3) 83/87 L3/L4 Version (4) Manual 5-speed gearbox Variant (5) Manual 4-speed gearbox Family (1) Manual 6-speed gearbox Automatic 6-speed gearbox Body shape (2) Axle and/or gearbox gears 3-door saloon...
  • Page 9 XSARA IDENTIFICATION OF THE VEHICLE 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 10 XSARA IDENTIFICATION OF THE VEHICLE Type approval Structure Version (4) Family (1) Depollution levels Bodywork (2) 15.04 Spécif US 93/59 96/69 98/69A 98/69B Alcohol Engine (3) ≠ CEE L/W2 L3/W3 L3/L4 N2 RFN1/IF Version (4) Manual 4-speed gearbox Variant (5) Manual 5-speed gearbox Family (1) Manual 6-speed gearbox...
  • Page 11 IDENTIFICATION OF THE VEHICLE XSARA PICASSO 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: (located on front LH door inner panel) - Tyre pressures.

  • Page 12: Xsara

    XSARA PICASSO IDENTIFICATION OF THE VEHICLE Type approval Structure Version (4) Family (1) Depollution levels Bodywork (2) Others Alcohol CH 6FZC/IF 6FZ Engine (3) 83/87 L3/L4 Version (4) Manual 5-speed gearbox Variant (5) Manual 4-speed gearbox Family (1) Manual 6-speed gearbox XSARA PICASSO Automatic 6-speed gearbox Body shape (2)
  • Page 13 IDENTIFICATION OF THE VEHICLE BERLINGO A - Chassis stamp, cold stamp. B - Manufacturer's vehicle plate. C - Label - RPO No. - Paint colour code. - Tyre pressures. D - Gearbox ident. reference - Factory serial no. E - Engine legislation type - Factory serial no. E1AP0AMD...

  • Page 14: Berlingo

    BERLINGO IDENTIFICATION OF THE VEHICLE Type approval Structure Version (4) Family (1) Depollution levels Bodywork (2) Others Alcohol Euro IV GJ NFUC/IF NFU Engine (3) 83/87 L3/L4 Euro IV Version (4) Manual 5-speed gearbox Variant (5) Manual 4-speed gearbox Family (1) Manual 6-speed gearbox Automatic 6-speed gearbox Body shape (2)
  • Page 15 OPERATIONS TO BE CARRIED OUT 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. Electric windows.
  • Page 16 CAPACITIES (in litres) Draining methods Oil capacities are defined according to the following methods Draining of the engine lubrication system by GRAVITY Draining of the engine lubrication system by SUCTION Place the vehicle on horizontal ground (in the high position if Place the vehicle on horizontal ground (in the high position if hydropneumatic suspension).
  • Page 17 CAPACITIES (in litres) Petrol 1.4i 16V 1.6i 16V 2.0i 16V 2.0i 2.0i 16V AUTO. AUTO. Engine type Oil capacity with change 3,75 3,25 4,25 of cartridge Between Min. and Max. 2 ± 0,15 Manual gearbox Automatic gearbox After draining With ESP = 0,85 Without ESP = 0,75 Braking circuit Cooling circuit...
  • Page 18 CAPACITIES (in litres) Diesel 1.6 HDi 16V 2.0 HDi 16V Engine type Oil capacity with change 3,75 5,25 of cartridge Between Min. and Max. 1,55 Manual gearbox With ESP = 0,85 Without ESP = 0,75 Braking circuit Cooling circuit Additive reservoir Steering electro-pump 0,85 reservoir...
  • Page 19 CAPACITIES (in litres) XSARA Petrol 1.4i 1.6i 16V 2.0i 16V AUTO. AUTO. Engine type 3,25 4,25 Engine with filter element Between Min. and Max. 5-speed gearbox Automatic gearbox After draining Hydraulic or brake circuit With ABS = 0,50 Without ABS = 0,55 Cooling circuit 6,5 (1) Fuel tank...
  • Page 20 XSARA CAPACITIES (in litres) Diesel 1.4 HDi 1.4 16V HDi 1.9D 2.0 HDi AUTO. 9884 9885 9884 9885 8HX 8HZ 8HX 8HZ Engine type 3,75 3,75 Engine with filter element Between Min. and Max. 5-speed gearbox Automatic gearbox After draining Hydraulic or brake circuit With ABS = 0,50 Without ABS = 0,55...
  • Page 21 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 4,25 3,75 Engine with filter element filtrante Between Min. and Max. 1,55 (3) 5-speed gearbox Automatic gearbox After draining 0,58 litres Hydraulic or brake circuit 5,8 (1) and (2)

  • Page 22: Engine

    BERLINGO CAPACITIES (in litres) Petrol Diesel 1.1i 1.4i 1.6i 16V 1.4i 16V HDi 2.0 HDi 1.9 D Engine type 3,25 3,75 Engine with filter element 1,55 Between Min. and Max. 5-speed gearbox With ABS = 0,45 - Without ABS = 0,36 Hydraulic or brake circuit Cooling circuit Fuel tank capacity...

  • Page 23: Engine

    LUBRICANTS - TOTAL recommended oils EVOLUTIONS (YEAR 2004). New Look CITROËN C5 CITROËN C4 Petrol engine versions: Normal maintenance interval: 30 000 km (20 000 miles) . Petrol engine versions except 2.0 i 16V 180 hp (132 kW) : Severe maintenance interval: 20 000 km (12 000 miles) . Normal maintenance interval: 30 000 km (20 000 miles) .

  • Page 24: Engine

    LUBRICANTS - TOTAL recommended oils Use of oil grade 10W40. S.A.E. Norms - Table for selection of engine oil grade. It is possible to use the semi-synthetic oil 7000 10W40 on HDi and HDi Selection of engine oil grades recommended for climatic conditions in FAP vehicles.

  • Page 25: Lubricants

    LUBRICANTS - TOTAL recommended oils API Norms: WARNING: CITROËN engines prior to model year 2000 do not have The meaning of the first letter has not changed, it still corresponds to the to be lubricated with oils adhering to the norms: type of engine: - ACEA AI-98 and API SJ/CF EC or current norms ACEA A5/B5.

  • Page 26: Engine

    LUBRICANTS - TOTAL recommended oils Classes and grades of TOTAL recommended engine oils. The oils distributed in each country are suited to the local climatic conditions. Blended oils for all engines (petrol, diesel and dual fuel Oils specifically for diesel engines: petrol/LPG) : S.A.E.

  • Page 27: Engine

    LUBRICANTS - TOTAL recommended oils Oil usage table TOTAL ACTIVA QUARTZ Synthetic 9000 Semi-synthetic 7000 Engine types 0W40 5W30 5W40 10W40 15W50 Hot countries Temperate countries Cold countries EW10J4S (CITROËN C4) EW12J4 (CITROËN C8 2.2i 16V) Petrol engines EW10A (CITROËN C4 and C5) Others petrol engines X (*) HDi engines with FAP (*)
  • Page 28 LUBRICANTS - TOTAL recommended oils E4AP006D...

  • Page 29: Engine

    LUBRICANTS - TOTAL recommended oils ENGINE OILS FRANCE Blended oils for all engines, supplied in bulk Metropolitan FRANCE TOTAL ACTIVRAC Norms S.A.E: 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 7000 10W40...

  • Page 30: Engine

    LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ 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 Belgium 9000 0W40...

  • Page 31: Engine

    LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ 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 Estonia...

  • Page 32: Engine

    LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ 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 9000 5W40 Iceland...

  • Page 33: Engine

    LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ 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 Norway 9000 0W40...

  • Page 34: Engine

    LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ 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 Slovenia...

  • Page 35: Engine

    LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ 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 FUTUR 9000 5W30 (*) 9000 0W40 Serbia-Montenegro...

  • Page 36: Engine

    LUBRICANTS - TOTAL recommended oils ENGINE OILS OCEANIA TOTAL QUARTZ TOTAL QUARTZ 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 New Zealand FUTUR 9000 5W30 (*) AFRICA...

  • Page 37: Engine

    LUBRICANTS - TOTAL recommended oils ENGINE OILS CENTRAL AND SOUTH AMERICA TOTAL QUARTZ TOTAL QUARTZ 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 10W40 7000 15W50 7000 10W40 Cuba...

  • Page 38: Engine

    LUBRICANTS - TOTAL recommended oils ENGINE OILS SOUTH-EAST ASIA TOTAL QUARTZ TOTAL QUARTZ 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 FUTUR 9000 5W30 (*)

  • Page 39: Engine

    LUBRICANTS - TOTAL recommended oils ENGINE OILS SOUTH-EAST ASIA TOTAL QUARTZ TOTAL QUARTZ 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 7000 10W40...

  • Page 40: Engine

    LUBRICANTS - TOTAL recommended oils ENGINE OILS MIDDLE EAST TOTAL QUARTZ TOTAL QUARTZ 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 9000 5W40 7000 10W40...
  • Page 41 LUBRICANTS - TOTAL recommended oils GEARBOX OILS TOTAL TRANSMISSION BV Manual and piloted manual Norms S.A.E: 75W80 gearboxes Part No.: 9730 A2 TOTAL FLUIDE ATX TOTAL FLUIDE AT 42 Special oil distributed by MB3 automatic gearbox CITROËN Part No.: 9730 A6 All countries Special oil distributed by 4HP20 and AL4 autoactive...

  • Page 42: Engine

    LUBRICANTS - TOTAL recommended oils POWER STEERING OILS Power steering all vehicles TOTAL FLUIDE ATX (except CITROËN C4 and C5) All countries TOTAL FLUIDE LDS Power steering Special oil distributed by CITROËN C4 and C5 Part No.: 9979 A3 TOTAL FLUIDE DA Very cold countries Power steering Special oil distributed by CITROËN...
  • Page 43 LUBRICANTS - TOTAL recommended oils BRAKE FLUID Synthetic brake fluid CITROËN Part No. Packs 9979 05 0,5 Litre CITROËN fluid All countries 1 Litre 9979 06 5 Litres 9979 07 HYDRAULIC SYSTEM CITROËN Part No. Packs All countries Norm TOTAL FLUIDE LDS Orange 9979 A3 TOTAL LHM PLUS...
  • Page 44 LUBRICANTS - TOTAL recommended oils SCREEN WASH FLUID Packs CITROËN Part No. Concentrated: 250 ml 9980 33 9980 56 ZC 9875 953U 9980 06 1 Litre ZC 9875 784U All countries Fluid ready to use 5 Litres 9980 05 ZC 9885 077U ZC 9875 279U GREASING General use...

  • Page 45: Engine

    ENGINE OIL CONSUMPTION 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. - 6,000 miles (10,000 km) for a DIESEL engine.

  • Page 46: Engine Specifications

    ENGINE SPECIFICATIONS Petrol engines All Types TU1JP TU3JP ET3J4 TU5JP+ TU5JP4 EW7J4 EW10A EW10J4 EW10J4S Engine type Cubic capacity (cc) 1124 1360 1587 1749 1997 Bore/stroke 72/69 75/77 78,5/82 82,7/81,4 85/88 Compression ratio 10,5/1 11/1 10,5/1 11/1 10,8/1 11/1 10,8/1 11/1 Power ISO or EEC (KW - rpm) 44,1-5500...
  • Page 47 ENGINE SPECIFICATIONS Diesel engines All Types DW10AT DW10 DV4TD DV6TED4 DW8B DW10TD ATED4 BTED4 Engine type 1398 1560 1868 1997 Cubic capacity (cc) 73,7/82 75/88,3 82,2/88 85/88 Bore/stroke 17,9/1 18/1 23/1 17,6/1 18/1 Compression ratio 50-4000 80-4000 66,2-4000 51-4600 66-4000 80-4000 100-4000 Power ISO or EEC (KW - rpm)

  • Page 48: Engine

    XSARA SPECIAL FEATURES - TIGHTENINGING TORQUES (m.daN) Engine: KFW Power unit 5 ± 0,5 6 ± 0,6 2,5 ± 0,2 6,5 ± 0,6 2,5 ± 0,2 4,5 ± 0,4 4,5 ± 0,4 B1BP1EYD...

  • Page 49: Engine

    XSARA PICASSO SPECIAL FEATURES - TIGHTENINGINGING TORQUES (m.daN) Engine: NFV Power unit 5,5 ± 0,5 5,5 ± 0,5 6,5 ± 0,6 6,5 ± 0,6 2,2 ± 0,2 3,3 ± 0,3 2,7 ± 0,2 4,6 ± 0,4 4,5 ± 0,4 4,5 ± 0,4, B1BP21HP...

  • Page 50: Engine

    XSARA SPECIAL FEATURES - TIGHTENINGING TORQUES (m.daN) Engine: NFU Power unit 4,5 ± 0,4 6 ± 0,6 4,5 ± 0,4 4 ± 0,4 6 ± 0,6 5,4 ± 0,8 6,5 ± 0,6 3 ± 0,3 4,5 ± 0,6 B1BP2GGP...

  • Page 51: Engine

    XSARA - XSARA PICASSO SPECIAL FEATURES - TIGHTENINGING TORQUES (m.daN) Tighteninging torques (m.daN) Engine type Crankshaft Pre-tightening 2 ± 0,2 2 ± 0,2 bearing screws Angular tightening 45° 50° ± 5° Connecting rod Tightening 3,8 ± 0,4 screws Flywheel screw Tightening 6,5 ±...

  • Page 52: Engine

    SPECIAL FEATURES - TIGHTENINGING TORQUES (m.daN) Suspensions for engine/gearbox assembly Engine: KFU Gearbox on RH side Gearbox on LH side 6 ± 0,6 1 ± 0,2 6 ± 0,1 1,8 ± 0,2 4,5 ± 0,4 2 ± 0,2 3 ± 0,3 1,9 ±...

  • Page 53: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: KFU Cylinder head Inlet air pressure sensor 0,8 ± 0,1 Motorised butterfly housing fixing screws 0,8 ± 0,2 Coolant outlet housing screw 0,8 ± 0,2 Oxygen sensor 4,7 ± 0,7 Catalytic converter fixing nuts (*) Pre-tightening 2 ±...

  • Page 54: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: KFU Cylinder head IMPERATIVE: Respect the tightening sequence. (8) Cylinder head bolts (10) Valve cover screws (5) Catalytic converter fixing nuts (11) Camshaft bearing cap screws B1JP063C B1DP05BC...

  • Page 55: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: KFU Cylinder block Crankshaft bearing cap sealing screw (*) 0,8 ± 0,1 Knock sensor 2 ± 0,4 Coolant pump stud screw 1,6 ± 0,2 Coolant pump cover screw 0,6 ± 0,1 Screw of coolant pump body on cylinder block 6,5 ±...

  • Page 56: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: KFU Cylinder block IMPERATIVE: Respect the tightening sequence. (14) Crankshaft bearing cap sealing screw (25) Crankshaft bearing cap cover screw (21) Flywheel screw B1CP0GYC B1DP05BC...

  • Page 57: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: KFU Lubrication Oil gauge screw 0,7 ± 0,1 Electric oil gauge fixng screw 3,2 ± 0,5 Oil filter support screw 1 ± 0,1 Strainer fixing screw 1 ± 0,1 Oil pressure switch 2 ± 0,2 Oil sump screw 0,8 ±...

  • Page 58: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: KFU Timing Inlet camshaft dephaser plug (VVT) 3,2 ± 0,2 Inlet camshaft dephaser screw (VVT) Pre-tightening 2 ± 0,2 Tightening 6 ± 0,6 Guide roller screw 2,1 ± 0,2 Exhaust camshaft pulley screw 4,5 ±...

  • Page 59: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: KFU Accessories Alternator support fixing screw 2,5 ± 0,3 Alternator power circuit fixing nut 1,4 ± 0,2 Alternator fixing screw 4 ± 0,4 Aircon compressor fixing screw 2,4 ± 0,1 Aircon compressor support fixing screw 2,5 ±...

  • Page 60: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Suspensions for engine/gearbox assembly Engine: NFU Gearbox on RH side Gearbox on LH side 6 ± 0,6 1,8 ± 0,2 6 ± 0,6 2 ± 0,2 4,5 ± 0,4 6,5 ± 0,6 1,9 ± 0,1 4 ±...

  • Page 61: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: NFU Cylinder head Inlet air pressure sensor 0,8 ± 0,1 Motorised butterfly housing fixing screws 0,7 ± 0,1 Inlet manifold nuts 0,8 ± 0,2 Valve cover screws (*) 0,9 ± 0,1 Coolant outlet housing screw 0,8 ±...

  • Page 62: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: NFU Cylinder block Coolant pump screw 2 ± 0,1 Oil plug 2,5 ± 0,5 Con rod cap bolt 3,8 ± 0,2 Seal plate screw, flywheel end 1 ± 0,1 Flywheel screw (*) 7 ± 0,7 Seal plate screw, timing end 1 ±...

  • Page 63: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: NFU IMPERATIVE: Respect the tightening sequence. Sequence of tightening the nuts (8) (Catalytic converter) (22) Sequence of tightening the flywheel screws B1CP0GCC B1JP063C...

  • Page 64: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: NFU Lubrication Strainer fixing 0,8 ± 0,2 Oil gauge screw 0,8 ± 0,1 Piston skirt spray jet 1,5 ± 0,2 Drain plug 3 ± 0,5 Oil sump screw 0,8 ± 0,1 Oil pressure switch 2 ±...

  • Page 65: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: NFU Timing Camshaft pulley screw 4,5 ± 0,5 Guide roller screw 2 ± 0,2 Tensioner roller screw 2,1 ± 0,4 B1BP1GMP...

  • Page 66: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: NFU Accessories Alternator support fixing screw 2,5 ± 0,6 Alternator power circuit fixing nut 1,4 ± 0,2 Alternator fixing screw 4 ± 0,4 Aircon compressor fixing screw 2,5 ± 0,2 Tensioner roller support fixing screw 2,5 ±...

  • Page 67: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Suspensions for engine/gearbox assembly Engine: RFJ RH side Torque reaction rod 6 ± 0,6 4,5 ± 0,4 6 ± 0,6 3,9 ± 0,4 4,5 ± 0,4 5,4 ± 0,6 B1BP35TD B1BP35UD 1 ± 0,1 5 ±...

  • Page 68: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFJ Cylinder head Valve cover screws (*) Pre-tightening Tightening 1,1 ± 0,1 Oxygen sensor 4,7 ± 0,5 Exhaust manifold nuts 3,5 ± 0,3 Coolant outlet housing fixing nuts 1 ± 0,1 Coolant outlet housing bolts Motorised butterfly housing fixing screws 0,8 ±...

  • Page 69: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFJ Cylinder head Camshaft bearing cap screws (*) Pre-tightening Tightening 1 ± 0,1 Exhaust manifold fixing stud 0,8 ± 0,2 Coolant outlet housing fixing stud 0,8 ± 0,2 Engine coolant temperature sensor 1,7 ± 0,1 Inner timing cover screw 0,8 ±...

  • Page 70: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFJ Cylinder head IMPERATIVE: Respect the tightening sequence. (1) Valve cover screws (9) Cylinder head bolts (11) Camshaft bearing cap screws B1DP03XD B1DP05BC...

  • Page 71: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFJ Cylinder block Oil circuit plugs 3 ± 0,3 Coolant pump screw (*) Pre-tightening Tightening 1,4 ± 0,1 Cooling circuit plug 3 ± 0,3 Accessories drive belt pulley screw Tightening 4 ± 0,4 Angular tightening 40°...

  • Page 72: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFJ Cylinder block Crankshaft bearing cap cover screw (*) Pre-tightening Tightening 2 ± 0,2 Angular tightening 72° ± 5° Crankshaft bearing cap sealing screw Con rod cap screw (*) Pre-tightening Tightening 2,3 ± 0,2 Angular tightening 46°...

  • Page 73: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFJ Cylinder head IMPERATIVE: Respect the tightening sequence. (22) Crankshaft bearing cap screws (24) Con rod cap screws (21) Flywheel screw (18) Coolant pump screw B1CP0GCC B1GP08WC B1DP05BC...

  • Page 74: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFJ Lubrication Oil gauge screw 1 ± 0,2 Oil filter support screw 0,8 ± 0,1 Anti-emulsion plate fixing screw 1,9 ± 0,3 Oil level sensor fixing screw 1 ± 0,2 Drain plug 3,4 ± 0,3 Oil sump screw 0,8 ±...

  • Page 75: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFJ Timing Exhaust camshaft pulley screw Pre-tightening 3 ± 0,5 Tightening 8,5 ± 0,5 1,1 ± 0,1 Inlet camshaft pulley screw Pre-tightening 2 ± 0,2 Tightening 11 ± 1 Tensioner roller screw 2,1 ± 0,2 Guide roller screw Pre-tightening 1,5 ±...

  • Page 76: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFJ Accessories Accessories support fixing stud 0,8 ± 0,1 Accessories support fixings Pre-tightening 1 ± 0,1 Tightening 1,9 ± 0,2 Alternator top fixing screw 4,1 ± 0,5 Alternator power circuit fixing nut 1,7 ± 0,2 Aircon compressor fixing screw 2,3 ±...

  • Page 77: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) XSARA - XSARA PICASSO Engines: 6FZ - RFN Power unit 2 ± 0,2 4,5 ± 0,4 6 ± 0,6 5,4 ± 0,5 5,4 ± 0,5 4,5 ± 0,5 2,1 ± 0,2 6,5 ± 0,6 2,2 ±...

  • Page 78: Engine

    XSARA - XSARA PICASSO SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFN Crankshaft Bearing cap fixing screws Pre-tightening 2 ± 0,2 Angular tightening 60° ± 5° Bearing cap screws Pre-tightening 2,3 ± 0,2 Angular tightening 46° ± 3° Accessories belt automatic tensioner roller 2 ±...

  • Page 79: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) XSARA - XSARA PICASSO Engine: RFN Cylinder head Camshaft bearing cover 0,9 ± 0,1 Exhaust manifold 3,5 ± 0,3 Valve cover 1,1 ± 0,1 Camshaft pulley Pre-tightening 3 ± 0,3 Tightening 7,5 ± 0,7 Pulley on hub 2,1 ±...

  • Page 80: Engine

    XSARA - XSARA PICASSO SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFN Lubrication circuit Oil pump closing plate 0,8 ± 0,1 Oil pump Pre-tightening 0,7 ± 0,1 Tightening 0,9 ± 0,1 Injection circuit Common injection rail fixing screws 0,9 ± 0,1 Cooling circuit Coolant pump Pre-tightening...

  • Page 81: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Suspensions for engine/gearbox assembly Engine: RFN Gearbox on RH side Gearbox at torque reaction rod 6 ± 0,6 4,5 ± 0,4 6 ± 0,6 3,9 ± 0,4 4,5 ± 0,4 5,4 ± 0,6 B1BP35TD B1BP35UD Gearbox on LH side 1 ±...

  • Page 82: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFN Cylinder head Valve cover screws (*) Pre-tightening Tightening 1,1 ± 0,1 Exhaust manifold stud 0,7 ± 0,1 Exhaust manifold nuts Tightening on heat shield 2,5 ± 0,2 Tightening apart from on heat shield 3,5 ±...

  • Page 83: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFN Cylinder head Cylinder head bolts (*) 1st pre-tightening 1,5 ± 0,1 2nd pre-tightening 5 ± 0,5 Angular slackening 360° Tightening 2 ± 0,2 Angular tightening 285° ± 5° Camshaft bearing cap cover screws (*) Pre-tightening Tightening 1 ±...

  • Page 84: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFN Cylinder head IMPERATIVE: Respect the tightening sequence. (1) Valve cover screws (11) Cylinder head bolts (12) Camshaft bearing cap screws B1DP03XD B1DP05BC...

  • Page 85: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFN Cylinder block Oil circuit plugs 3 ± 0,3 Coolant pump screw (*) Pre-tightening Tightening 1,4 ± 1 Cooling circuit plug 3 ± 0,7 Flywheel screw (*) Pre-tightening 0,8 ± 0,1 Tightening 2 ± 0,2 Angular tightening 23°...

  • Page 86: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFN Cylinder block Crankshaft bearing cap sealing screw 1 ± 0,1 Con rod cap bolt (*) Pre-tightening Tightening 2,3 ± 0,1 Angular tightening 46° ± 3° Knock sensor 2 ± 0,5 Accessories drive belt pulley screw Tightening 4 ±...

  • Page 87: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFN Cylinder head IMPERATIVE: Respect the tightening sequence. (22) Crankshaft bearing cap screws (24) Con rod cap screws (21) Flywheel screws (19) Coolant pump screws B1CP0GCC B1GP08WC B1DP05BC...

  • Page 88: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFN Lubrication Oil gauge screw 1 ± 0,2 Oil level sensor fixing screw 1 ± 0,2 Drain plug 3,4 ± 0,3 Oil sump screw 0,8 ± 0,1 Oil pressure switch 2 ± 0,2 Oil strainer fixing nuts 1,1 ±...

  • Page 89: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFN Timing Camshaft pulley screw 7,5 ± 0,5 Tensioner roller screw 2 ± 0,3 Guide roller screw 3,5 ± 0,5 B1EP1G6P...

  • Page 90: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFN Accessories Accessories support fixing stud 0,8 ± 0,1 Accessories support fixings Pre-tightening 1 ± 0,1 Tightening 1,9 ± 0,2 Alternator top fixing screw 4,1 ± 0,5 Alternator power circuit fixing nut 1,7 ± 0,2 Aircon compressor fixing screw 2,3 ±...

  • Page 91: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Suspensions for engine/gearbox assembly Engine: RFK Gearbox on RH side Gearbox at torque reaction rod 6 ± 0,6 4,5 ± 0,4 6 ± 0,6 3,9 ± 0,4 4,5 ± 0,4 5,4 ± 0,6 B1BP35TD B1BP35UD Gearbox on LH side 1 ±...

  • Page 92: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFK Cylinder head Exhaust manifold stud 0,7 ± 0,1 Exhaust manifold nuts Tightening on heat shield 2,5 ± 0,2 Tightening apart from on heat shield 3,5 ± 0,3 Oxygen sensor 4,7 ± 0,5 Coolant outlet housing fixing Tightening of the nuts 1 ±...

  • Page 93: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFK Cylinder head Cylinder head bolts (*) 1st pre-tightening 1,5 ± 0,1 2nd pre-tightening 5 ± 0,5 Angular slackening 360° Tightening 2 ± 0,2 Angular tightening 285° ± 5° Valve cover screws (*) Pre-tightening Tightening 1,1 ±...

  • Page 94: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFK Cylinder head IMPERATIVE: Respect the tightening sequence. (12) Valve cover screws (13) Cylinder head bolts (15) Camshaft bearing cap screws B1DP03XD B1DP05BC...

  • Page 95: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFK Cylinder block Oil circuit plugs 3 ± 0,3 Coolant pump screw (*) Pre-tightening Tightening 1,4 ± 1 Cooling circuit plug 3 ± 0,7 Flywheel screw (*) Pre-tightening 0,8 ± 0,1 Tightening 2 ± 0,2 Angular tightening 23°...

  • Page 96: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFK Cylinder block Crankshaft bearing cap sealing screw 1 ± 0,1 Con rod cap bolt (*) Pre-tightening Tightening 2,3 ± 0,1 Angular tightening 46° ± 3° Knock sensor 2 ± 0,5 Accessories drive belt pulley screw Tightening 4 ±...

  • Page 97: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFK Cylinder head IMPERATIVE: Respect the tightening sequence. (21) Crankshaft bearing cap screws (23) Con rod cap screws (20) Flywheel screws (18) Coolant pump screws B1CP0GCC B1GP08WC B1DP05BC...

  • Page 98: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFK Lubrication Oil gauge screw 1 ± 0,2 Oil level sensor fixing screw 1 ± 0,2 Drain plug 3,4 ± 0,3 Oil sump screw 0,8 ± 0,1 Oil pressure switch 2 ± 0,2 Oil strainer stud 0,6 ±...

  • Page 99: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFK Timing Camshaft pulley screw 7,5 ± 0,5 Camshaft dephaser cap (VVT) 3,2 ± 0,3 Inlet camshaft pulley screw Pre-tightening 2 ± 0,2 Tightening 11 ± 1 Tensioner roller screw 2,1 ± 0,2 Guide roller screw 3,5 ±...

  • Page 100: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RFK Accessories Accessories support fixing stud 0,8 ± 0,1 Accessories support fixings Pre-tightening 1 ± 0,1 Tightening 1,9 ± 0,2 Alternator top fixing screw 4,1 ± 0,5 Alternator power circuit fixing nut 1,6 ± 0,2 Aircon compressor fixing screw 2,4 ±...

  • Page 101: Engine

    XSARA SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines: 8HX - 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 102: Engine

    XSARA SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines Crankshaft Bearing cap fixing screws Pre-tightening Slackening Tightening Angular tightening 140° Con rod nuts Pre-tightening Slackening Tightening 1,5 ± 0,1 Angular tightening 100° ± 5° Accessories drive pulley Pre-tightening 3 ± 0,4 Angular tightening 180°...

  • Page 103: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) XSARA Engines Cylinder head Camshaft bearing covers Pre-tightening Tightening Fixing of camshaft sub-assemblies on cylinder head Pre-tightening Tightening Exhaust manifold 2,5 ± 0,2 Valve cover 2,5 ± 0,2 Camshaft pulley 4,3 ± 0,4 Flywheel Flywheel Pre-tightening Angular tightening...

  • Page 104: Engine

    XSARA SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines 8HX - 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 ± 0,2 Unions on fuel high pressure common injection rail Pre-tightening 1,7±...

  • Page 105: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Suspensions for engine/gearbox assembly Engines: 9HX - 9HY - 9HZ RH engine support Torque reaction rod 6 ± 0,6 6 ± 0,6 5,5 ± 0,5 3,9 ± 0,4 6 ± 0,6 5,4 ± 0,8 B1BP38CC B1BP38DC Impact absorber...

  • Page 106: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HY Cylinder head Air inlet manifold 1 ± 0,1 Oil trap 1 ± 0,1 Camshaft bearing covers Pre-tightening 0,5 ± 0,1 Tightening 1 ± 0,1 (3) Camshaft bearing cover screws (4) Camshaft bearing cover studs B1BP39YP B1DP1D7D...

  • Page 107: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Cylinder head Camshaft bearing cover studs Pre-tightening 0,5 ± 0,1 Tightening 1 ± 0,1 Exhaust gas recycling electrovalve (EGR) 1 ± 0,1 Cylinder head Pre-tightening 2 ± 0,2 Tightening 4 ± 0,5 Angular tightening 260°...

  • Page 108: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Cylinder head Exhaust manifold 2,5 ± 0,2 Exhaust manifold stud 1 ± 0,2 Turbocompressor nuts 2,6 ± 0,6 Catalytic converter nuts 2 ± 0,1 Air flowmeter Pre-tightening Tightening 0,9 ± 0,2 B1BP39YP...

  • Page 109: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Cylinder block Coolant pump Pre-tightening 0,3 ± 0,1 Tightening 0,9 ± 0,1 Con rod screws Pre-tightening 1 ± 0,1 Angular tightening 100° ± 5° Flywheel (according to equipment) Pre-tightening 1,7 ± 0,2 Angular tightening 75°...

  • Page 110: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Cylinder block Bearing cap fixing screws Pre-tightening 1 ± 0,2 Slackening 180° Tightening 3 ± 0,3 Angular tightening 140° ± 5° Crankshaft bearing cap cover screws 0,8 ± 0,3 Crankshaft bearing cap cover screws Pre-tightening 0,6 ±...

  • Page 111: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Cylinder block Crankshaft bearing cap cover Tightening method: Pre-tighten the 10 screws (17) (from 1 to 10) to Pre-tighten the 14 screws (19) (from 11 to 24) to Tighten the 2 screws (18) (inside the flywheel bell housing) to Slacken the screws (17) by 180°...

  • Page 112: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Lubrication 3 ± 0,5 Turbocharger lubrication pipe 2,1 ± 0,3 Oil pressure switch 2 ± 0,2 Oil gauge 0,8 ± 0,2 Electric oil gauge 2,7 ± 0,5 Piston skirt spray jets 2 ± 0,5 Oil filter cover 2,5 ±...

  • Page 113: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Timing Camshaft bearing caps 1 ± 0,1 Camshaft pulleys Pre-tightening 2 ± 0,2 Angular tightening 50° ± 5° Timing belt guide roller 3,7 ± 0,3 Timing belt tensioner roller 2,7 ± 0,2 Timing chain tensioner 1 ±...

  • Page 114: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Injection circuit Union on injector Pre-tightening 2 ± 0,5 Tightening 2,5 ± 0,3 Injector fixing flange but Pre-tightening 0,5 ± 0,5 Angular tightening 65° ± 5° Diesel injection pump on support 2,2 ± 0,3 Diesel injection pump pulley 5 ±...

  • Page 115: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Injection circuit Diesel fuel high pressure pump rear support 2 ± 0,5 Union on diesel fuel high pressure pump Pre-tightening 2 ± 0,5 Tightening 2,5 ± 0,3 Fuel high pressure common injection rail on engine block 2,2 ±...

  • Page 116: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Accessories Version without particle filter Multifunction support 2 ± 0,4 Alternator fixing screw 4,9 ± 1,2 Alternator power circuit fixing nut 1,4 ± 0,2 Accessories tensioner roller 2,1 ± 0,2 D1AP02NC...

  • Page 117: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Accessories Version without air conditioning Accessories support 2 ± 0,5 Guide roller 4,5 ± 0,5 D1AP02PC Accessories Version with air conditioning Aircon compressor support 2 ± 0,5 Aircon compressor screw 2,4 ± 0,5 D1AP02QD...

  • Page 118: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines: 9HY - 9HZ Cylinder head Air inlet manifold 1 ± 0,1 Oil trap 1 ± 0,1 Camshaft bearing cover screws Pre-tightening 0,5 ± 0,1 Tightening 1 ± 0,1 (3) Sequence for tightening the camshaft bearing cover screws B1BP39XP B1DP1D7D...

  • Page 119: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines: 9HY - 9HZ Cylinder head Camshaft bearing cover studs Pre-tightening 0,5 ± 0,1 Tightening 1 ± 0,1 Exhaust gas recycling electrovalve (EGR) 1 ± 0,1 Cylinder head Pre-tightening 2 ± 0,2 Tightening 4 ± 0,5 Angular tightening 260°...

  • Page 120: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines: 9HY - 9HZ Cylinder head Exhaust manifold 5 ± 0,2 Exhaust manifold stud 1 ± 0,2 Turbocompressor nuts 2,6 ± 0,6 Catalytic converter nuts 2 ± 0,1 Double butterfly housing (according to equipment) Pre-tightening Tightening 0,9 ±...

  • Page 121: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines: 9HY - 9HZ Cylinder block Coolant pump Pre-tightening 0,3 ± 0,1 Tightening 0,9 ± 0,1 Con rod screws Pre-tightening 1 ± 0,1 Angular tightening 100° ± 5° Damping flywheel (according to equipment) Pre-tightening 3 ±...

  • Page 122: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines: 9HY - 9HZ Cylinder block Bearing cap fixing screws Pre-tightening 1 ± 0,2 Slackening 180° Tightening 3 ± 0,3 Angular tightening 140° ± 5° Crankshaft bearing cap cover screws 0,8 ± 0,3 Crankshaft bearing cap cover screws Pre-tightening 0,6 ±...

  • Page 123: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines: 9HY - 9HZ Cylinder block Crankshaft bearing cap cover. Tightening method: Pre-tighten the 10 screws (17) (from 1 to 10) to Pre-tighten the 14 screws (19) (from 11 to 24) to Tighten the 2 screws (18) (inside the flywheel bell housing) to Slacken the screws (17) by 180°...

  • Page 124: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines: 9HY - 9HZ Lubrication 3 ± 0,5 Turbocharger lubrication pipe 2,1 ± 0,3 Oil pressure switch 2 ± 0,2 Oil gauge 0,8 ± 0,2 Oil level sensor 2,7 ± 0,5 Piston skirt spray jets 2 ±...

  • Page 125: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines: 9HY - 9HZ Timing Camshaft bearing caps 1 ± 0,1 Camshaft pulleys Pre-tightening 2 ± 0,2 Angular tightening 50° ± 5° Timing belt guide roller 3,7 ± 0,3 Timing belt tensioner roller 2,7 ± 0,2 Timing chain tensioner 1 ±...

  • Page 126: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines: 9HY - 9HZ Injection circuit Union on injector Pre-tightening 2 ± 0,5 Tightening 2,5 ± 0,3 Injector fixing flange but Pre-tightening 0,5 ± 0,5 Angular tightening 65° ± 5° Diesel injection pump on support 2,2 ±...

  • Page 127: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines: 9HY - 9HZ Injection circuit Diesel fuel high pressure pump rear support 2 ± 0,5 Union on diesel fuel high pressure pump Pre-tightening 2 ± 0,5 Tightening 2,5 ± 0,3 Fuel high pressure common injection rail on engine block 2,2 ±...

  • Page 128: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines: 9HY - 9HZ Accessories Version without particle filter Multifunction support 2 ± 0,4 Alternator fixing screw 4,9 ± 1,2 Alternator power circuit fixing nuts 1,4 ± 0,2 Accessories tensioner roller 2,1 ± 0,2 D1AP02NC...

  • Page 129: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines: 9HY - 9HZ Accessories Version without air conditioning Accessories support 2 ± 0,5 Guide roller 4,5 ± 0,5 D1AP02PC Accessories Version with air conditioning Aircon compressor support 2 ± 0,5 Aircon compressor screw 2,4 ±...

  • Page 130: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines: 9HY - 9HZ Accessories Version with particle filter Multifunction support 3,2 ± 0,2 D1AP02RC...

  • Page 131: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) XSARA PICASSO Engines: 9HZ - 9HY Torque reaction rod : 5,4 ± 0,8 : 5,4 ± 0,8 (13) : 6 ± 0,9 LH upper engine support : 2,1 ± 0,2 : 5 ± 0,5 Lower LH engine support : 2,1 ±...

  • Page 132: Engine

    XSARA PICASSO SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines 9HZ - 9HY Crankshaft Bearing cap fixing screws Pre-tightening 1 ± 0,2 Slackening 180° ± 5° Tightening 3 ± 0,3 Angular tightening 140° ± 5° Con rod screws Tightening 1 ± 0,1 Angular tightening 100°...

  • Page 133: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) XSARA PICASSO Engines 9HZ - 9HY Cylinder head Camshaft bearing covers Pre-tightening 0,5 ± 0,1 Tightening 1 ± 0,1 Exhaust manifold 3 ± 0,3 Camshaft pulley Pre-tightening 2 ± 0,2 Angular tightening 50° ± 5° Cylinder head Pre-tightening 2 ±...

  • Page 134: Engine

    XSARA PICASSO SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines 9HZ - 9HY Lubrication circuit Oil pump assembly Pre-tightening 0,5 ± 0,1 Tightening 0,9 ± 0,1 Oil/coolant heat exchanger 1 ± 0,2 Turbocharger lubrication pipe 3 ± 0,5 Diesel injection circuit Injector fixing flange nut Pre-tightening 4 ±...

  • Page 135: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) XSARA PICASSO Engines 9HZ - 9HY Diesel injection circuit (continued) 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 Pre-tightening 0,3 ±...

  • Page 136: Engine

    XSARA SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: WJY Engine suspension 4,5 ± 0,4 2,2 ± 0,2 2,2 ± 0,2 4,5 ± 0,4 5 ± 0,5 5 ± 0,5 4,5 ± 0,4 6,5 ± 0,6 2,2 ± 0,2 5 ± 0,5 2,2 ±...

  • Page 137: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) XSARA Engine: WJY Crankshaft Bearing cap fixing screws 7 ± 0,7 Con rod nuts Pre-tightening 2 ± 0,2 Angular tightening 70° ± 5° Accessories drive pulley hub Pre-tightening 4 ± 0,2 Angular tightening 55° ± 5° Accessories drive pulley 1 ±...

  • Page 138: Engine

    XSARA SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: WJY Crankshaft Bearing cap fixing screws 7 ± 0,7 Con rod nuts Pre-tightening 2 ± 0,2 Angular tightening 70° ± 5° Accessories drive pulley hub Pre-tightening 4 ± 0,2 Angular tightening 55° ± 5° Accessories drive pulley 1 ±...

  • Page 139: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) XSARA Engine: WJY Flywheel Flywheel 4,8 ± 0,4 Clutch mechanism 2 ± 0,2 Lubrication circuit Oil pump 2,3 ± 0,2 Coolant/oil heat exchanger 7 ± 0,7 Injection circuit Injector on cylinder head 9 ± 0,9 Diesel fuel heater 1,5 ±...

  • Page 140: Engine

    XSARA SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines: RHY - RHZ Engine suspension 4,5 ± 0,4 2,2 ± 0,2 2,2 ± 0,2 6,1 ± 0,6 4,5 ± 0,5 4,5 ± 0,5 4,5 ± 0,4 6,5 ± 0,6 2,2 ± 0,2 5 ±...

  • Page 141: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) XSARA Engines: RHY - RHZ Crankshaft Bearing cap fixing screws Pre-tightening 2,5 ± 0,2 Angular tightening 60° ± 5° Con rod nuts Pre-tightening 2 ± 0,2 Angular tightening 70° ± 5° Accessories drive pulley hub Pre-tightening 4 ±...

  • Page 142: Engine

    XSARA SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines: RHY - RHZ Flywheel Flywheel 4,8 ± 0,4 Clutch mechanism 2 ± 0,2 Lubrication circuit Oil pump 1,6 ± 0,2 Coolant oil heat exchanger 7 ± 0,7 Turbocharger lubrication pipe Engine end 4,8 ±...

  • Page 143: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Suspensions for engine/gearbox assembly Engine: RHR RH engine support LH engine support 5,5 ± 0,5 3 ± 0,3 6 ± 0,5 6,5 ± 0,6 2 ± 0,2 5,5 ± 0,5 4,5 ± 0,4 3 ± 0,3 5,5 ±...

  • Page 144: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RHR Cylinder head Exhaust manifold Pre-tightening Tightening 3 ± 0,3 Turbocompressor 2,5 ± 0,2 Exhaust clip 2,5 ± 0,5 Cylinder head bolts (*) Pre-tightening 2,2 ± 0,2 Tightening 6 ± 0,5 Slackening 1 Turn Tightening 6 ±...

  • Page 145: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RHR Cylinder head Camshaft bearing cap cover screws (*) 1 ± 0,1 Coolant outlet housing fixing 2 ± 0,2 Camshaft bearing cap cover studs (*) Pre-tightening (the 26 screws Ø 6) Tightening (the 26 screws Ø 6) 1 ±...

  • Page 146: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RHR Cylinder head (*) Bolts (5) and (7) Sequence of tightening (*) Bolts (8) Sequence of tightening (5) Camshaft bearing cap cover screws (7) Camshaft bearing cap cover studs (8) Inlet valve cover screws B1BP38ZD B1DP1LED...

  • Page 147: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RHR Cylinder block Oil circuit plug 3 ± 0,3 Coolant pump screw 1,6 ± 0,3 Crankshaft bearing cap screws (*) Pre-tightening 2,5 ± 0,2 Angular tightening 60° ± 5° Con rod cap nuts Tightening Slackening 180°...

  • Page 148: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RHR Cylinder block Front closing plate screw Flywheel screws Pre-tightening Tightening 4,7 ± 0,4 Accessories drive pulley screw Pre-tightening 7 ± 0,25 Angular tightening 60° ± 5° B1CP0GNP...

  • Page 149: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RHR Lubrication Oil pump screw 1,6 ± 0,1 Piston skirt spray jet screw 1 ± 0,1 Drain plug 3,4 ± 0,4 Oil sump (length 40 mm ) Pre-tightening Tightening 1,6 ± 0,3 Oil sump (length 21 mm) Pre-tightening Tightening 1,6 ±...

  • Page 150: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RHR Lubrication Oil pressure switch 2 ± 0,2 Oil filter support (*) Tightening 1 ± 0,1 Tightening 2 ± 0,2 Oil filter cover 2,5 ± 0,5 (*) (23) Sequence of tightening B1CP0GPP B1FP062C...

  • Page 151: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RHR Timing Camshaft drive pulley screw Tightening 7 ± 0,7 Angular tightening 60° ± 5° Guide roller screw Pre-tightening Tightening 4,3 ± 0,4 Tensioner roller screw 2,1 ± 0,2 B1EP1HPD...

  • Page 152: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RHR Injection circuit High pressure pipe union on injector 2,5 ± 0,2 Diesel injector nuts Do up both nuts by hand Tightening 0,4 ± 0,3 Angular tightening 45° ± 5° Fuel high pressure pump screw 2,25 ±...

  • Page 153: Engine

    SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: RHR Accessories Alternator support 2 ± 0,2 Alternator 4,9 ± 0,4 Aircon compressor 2,5 ± 0,2 Accessories belt tensioner roller 4,3 ± 0,4 B1BP390D...

  • Page 154: Engine

    SPECIAL FEATURES - CYLINDER HEAD TIGHTENING Engines all types Cleaning to be carried out just prior to refitting the cylinder head. WARNING: Clean the contact faces with the approved CITROËN cleaning product. Do not use abrasives or cutting tools on the contact faces. The contact faces must not bear any traces of impact or scratching.

  • Page 155: Engine

    SPECIAL FEATURES - CYLINDER HEAD TIGHTENING Engines all types Cleaning to be carried out just prior to refitting the cylinder head. WARNING: Clean the contact faces with the approved CITROËN cleaning product. Do not use abrasives or cutting tools on the contact faces. The contact faces must not bear any traces of impact or scratching.

  • Page 156: Engine

    SPECIAL FEATURES - CYLINDER HEAD TIGHTENING Engines all types Cleaning to be carried out just prior to refitting the cylinder head. WARNING: Clean the contact faces with the approved CITROËN cleaning product. Do not use abrasives or cutting tools on the contact faces. The contact faces must not bear any traces of impact or scratching.
  • Page 157 BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE Tools 4122-T (C.TRONIC.105.5) 4099-T (C.TRONIC.105)

  • Page 158: Engine

    AUXILIARY EQUIPMENT DRIVE BELT Engine type XSARA XSARA PICASSO See pages: 156 to 157 156 to 157...

  • Page 159: Engine

    AUXILIARY EQUIPMENT DRIVE BELT TED4 ATED4 ATED BTED4 Engine type XSARA XSARA PICASSO See pages: 165 to 166 167 to 168 167 to 168 170 to 175 176 to 179...

  • Page 160: Engine

    AUXILIARY EQUIPMENT DRIVE BELT 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). Essential. - Before refitting the auxiliary equipment drive belt, check that: - 1 / The roller(s) rotate freely (no play or stiffness). - 2 / The belt is correctly engaged in the grooves of the various pulleys.

  • Page 161: Engine

    AUXILIARY EQUIPMENT DRIVE BELT 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 162: Engine

    AUXILIARY EQUIPMENT DRIVE BELT Engines: KFU - NFU Tools. [1] Pliers for removing plastic pegs : 7504 -T [2] Belt tension measuring instrument (SEEM) : 4122 -T [3] Compression lever for dynamic tensioner : (-).0194.D [4] Peg for dynamic tensioner roller of Ø 4 mm : (-) 0194.F WARNING: (With or without air conditioning) The auxiliaries drive belt cannot be re-used with a manual tensioner roller.

  • Page 163: Engine

    AUXILIARY EQUIPMENT DRIVE BELT Engine: KFU Véhicule with air conditioning. Removing. Place tool [4] at «a». Compress the dynamic tensioner roller. Place tool [3] at «b». Remove the auxiliary equipment drive belt. IMPERATIVE: Check that the dynamic tensioner roller turns freely (without play and without tight spots) .

  • Page 164: Engine

    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 165: Engine

    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 166: Engine

    XSARA AUXILIARY EQUIPMENT DRIVE BELT 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 167: Engine

    AUXILIARY EQUIPMENT DRIVE BELT Engine: RFJ Tool. [1] «Junior» T extension : (-).1608.E Removing. Engage tool [1] in the notch «a». Exert on the roller (1) an effort upwards to hold it at maximum. Remove the auxiliaries drive belt. Carefully release the tensioner roller (1) to reach its minimum. Remove tool [1].

  • Page 168: Engine

    AUXILIARY EQUIPMENT DRIVE BELT XSARA - XSARA PICASSO Without air conditioning Engines: 6FZ - RFN With air conditioning Tool. [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) . The screw (2) (WARNING: not left hand screw) .

  • Page 169: Engine

    AUXILIARY EQUIPMENT DRIVE BELT Engine: RFN Without air conditioning Removing. Raise and support the vehicle, wheels hanging. Remove the front RH wheel, the plastic pins and the splash-shield. Detension the belt (3) by turning the tensioner roller (1) by means of the screw (2) (clockwise) .

  • Page 170: Engine

    AUXILIARY EQUIPMENT DRIVE BELT Engine: RFK Tools. [1] Detensioning lever for auxiliaries drive belt tensioner roller Dynamic spanner extension : FACOM SJ.214 Adaptor for socket 9x12 : FACOM J.274 Polygon socket 9x12 : 016 Removing. Raise and support the vehicle, wheels hanging. Remove the front RH wheel, the plastic pins and the splash-shield.

  • Page 171: Engine

    XSARA AUXILIARY EQUIPMENT DRIVE BELT Engines: 8HX - 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 (HDi) engine versions. Remove: - the front RH wheel.

  • Page 172: Engine

    XSARA AUXILIARY EQUIPMENT DRIVE BELT Engines: 8HX - 8HZ Refitting. WARNING: If the accessories belt is being re-used, respect the direction of fitting of the belt. Refit the accessories belt. Compress the tensioner roller (1) by acting at «a» (clockwise) , using tool [1]. Remove tool [2].

  • Page 173: Engine

    AUXILIARY EQUIPMENT DRIVE BELT Engines: 9HX - 9HY - 9HZ Tools. [1] Dynamic tensioner roller lever (DV6 TED4 engine) : (-).0194-E3 [1a] Dynamic tensioner roller lever (DV6 ATED4 engine) : (-).0194-E1 [1b] Lever extension (DV6 ATED4 engine) : (-).0194-E2 [2] Dynamic tensioner roller locking peg : (-).0194-F IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions.

  • Page 174: Engine

    AUXILIARY EQUIPMENT DRIVE BELT Engines: 9HX - 9HY - 9HZ Refitting. WARNING: Belt to be re-used, mark the direction of fitting of the belt. Refit the auxiliaries drive belt. Compress the tensioner roller (1) by acting at «c» (clockwise) , using tool [1]. Remove tool [2].

  • Page 175: Engine

    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 176: Engine

    XSARA AUXILIARY EQUIPMENT DRIVE BELT Engine: WJY Without power-assisted steering Tool. [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. Refit the belt. Fit the tool [1] on the belt at "d".

  • Page 177: Engine

    AUXILIARY EQUIPMENT DRIVE BELT XSARA Engine: WJY Without power-assisted steering, with air conditioning Tool. [1] Belt tension measuring instrument : 4122-T Removal. Loosen the screws (1). Tighten the screw (2) until it is against its stop. Remove the belt. Refitting. Refit the belt.

  • Page 178: Engine

    XSARA AUXILIARY EQUIPMENT DRIVE BELT Engine: WJY Power-assisted steering, without air conditioning Tool. [1] Belt tension measuring instrument : 4122-T Removal. WARNING: If the belt is to be reused, measure the tension before removal. Loosen: - the screw (1). - the nut (2). NOTE: The tensioner arm (3) must be against the alternator.

  • Page 179: Engine

    AUXILIARY EQUIPMENT DRIVE BELT XSARA 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 180: Engine

    XSARA AUXILIARY EQUIPMENT DRIVE BELT 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). Turn the roller (3) backwards.

  • Page 181: Engine

    AUXILIARY EQUIPMENT DRIVE BELT XSARA 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. Tighten the screw (2). Remove the tool [1].

  • Page 182: Engine

    XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT 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 Removing.

  • Page 183: Engine

    AUXILIARY EQUIPMENT DRIVE BELT XSARA - XSARA PICASSO 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 184: Engine

    XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT 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 185: Engine

    AUXILIARY EQUIPMENT DRIVE BELT XSARA - XSARA PICASSO 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 186: Engine

    JUMPER AUXILIARY EQUIPMENT DRIVE BELT Engines: RHV - 4HY Without air conditioning Tools. [1] Dynamic tensioner compression lever : (-).0188.Z. [2] Dynamic tensioner roller retaining peg Ø 4 mm : (-).0188.Q1 Removing. Remove the splash-shield, under-engine sound-deadening, front RH wheel. WARNING: Mark the direction of fitting of the auxiliaries drive belt in the case of re-use of the belt.

  • Page 187: Checking And Setting The Valve Timing

    CHECKING AND SETTING THE VALVE TIMING Engine type XSARA XSARA PICASSO See pages: 185 to 187 188 to 192 185 to 187 197 to 202 193 to 196 217 to 223 103 to 209 210 to 216 217 to 223 224 to 231...

  • Page 188: Engine

    CHECKING AND SETTING THE VALVE TIMING TED4 ATED4 ATED BTED4 Engine type XSARA XSARA PICASSO See pages: 232 to 239 240 to 248 249 to 258 240 to 248 259 to 263 264 to 270 271 to 278...
  • Page 189 BELT TENSION CORRESPONDANCE TABLE / SEEM UNITS 4099-T (C.TRONIC.105) Tools 4122-T (C.TRONIC.105.5)
  • Page 190 RECOMMENDATIONS: TIMING BELT Recommendations. IMPERATIVE: After any repair involving removal of the timing belt, systematically replace: - The timing belt. - The tensioner roller fixing nut.

  • Page 191: Xsara Picasso

    CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines: KFW - NFV Tools. [1] Flywheel peg : 4507-T.A [2] Camshaft pulley peg : 4507-T.B Toolkit 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 192: Circuit: Xsara Picasso (Dv6Ted4)

    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 193: Engine

    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 194: Engine

    CHECKING THE VALVE TIMING Engine: KFU Tools. [1] Flywheel setting peg : 4507-TA. Toolkit 4507-T [2] Camshaft setting peg : 4533-TA.C1 [3] Camshaft setting peg : (-).0194.A IMPERATIVE: Respect the safety and cleanliness requirements. Checking. Deconnect the battery. B1BP37JC Remove: - The engine cover.

  • Page 195: Engine

    CHECKING THE VALVE TIMING Engine: KFU Checking (continued). Position the tools [3] and [2]. Peg the flywheel, using tool [1]. NOTE: If the setting is not correct, recommence the operation. B1BP2ZMC Remove the tools. Complete the refitting. B1BP2MBC...

  • Page 196: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: KFU Tools. [1] Flywheel setting peg : 4507-T.A [2] Camshaft setting peg : 4533-T.AC1 [3] Camshaft setting peg : (-).0194.A [4] Belt retaining pin : 4533-TA.D IMPERATIVE: Respect the safety and cleanliness requirements. Setting the timing.

  • Page 197: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: KFU Setting the timing (continued). Rotate the engine by means of the crankshaft screw (clockwise) , to bring it to the pegging position. Peg the flywheel, using tool [1]. Position the tools [2] and [3]. Remove the engine support assembly (9), the fixing screw (8) and the lower cover (7).

  • Page 198: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: KFU Overtension on the belt. Position «a»: Tensioner roller in detensioned position. Position «b»: Tensioner roller in normal position. Position «c»: Tensioner roller in overtension position. Turn the tensioner roller (10), using an allen spanner at «e». Place the index «d»...

  • Page 199: Engine

    XSARA CHECKING AND SETTING THE VALVE TIMING Engine: NFU Tools. [1] Belt tension measuring instrument : 4122-T [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 : 4707-T.J...

  • Page 200: Engine

    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) .

  • Page 201: Engine

    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 202: Engine

    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 four 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 203: Engine

    CHECKING THE VALVE TIMING Engine: NFU Tools. [1] Flywheel setting peg : 4507-T.A Toolkit 4507-T [2a] Camshaft setting peg : 4533-TA.C1 [3b] Camshaft setting peg : 4533-TA.C2 IMPERATIVE: Respect the safety and cleanliness requirements. Checking. Disconnect the negative terminal of the battery. B1BP2M7C Remove: - The oil filter (1).

  • Page 204: Engine

    CHECKING THE VALVE TIMING Engine: NFU Remove the sparking plugs, to facilitate rotation of the crankshaft. Rotate the engine by means of the crankshaft pinion screw (clockwise) to bring it to the pegging position. Fit the tools [2a] and [2b]. Peg the flywheel, using tool [1].

  • Page 205: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: NFU Tools. [1] Flywheel setting peg : 4507-T.A Toolkit 4507-T [2a] Camshaft setting peg : 4533-TA.C1 [2b] Camshaft setting peg : 4533-TA.C2 [3] Belt retaining pin : 4533-T.AD [4] Dynamic tensioner roller pin : 4200-T.H IMPERATIVE: Respect the safety and cleanliness requirements.

  • Page 206: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: NFU Peg the flywheel, using tool [1]. Position the tools [2a] and [2b]. Slacken the tensioner roller. Turn the dynamic tensioner roller so as to be able to position the tool [4], with the aid of an Allen key placed at «a».

  • Page 207: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: NFU Refitting. Fit the (new) timing belt in position, in the following order: - Inlet camshaft pulley, exhaust camshaft pulley, guide roller, crankshaft pulley, position tool [5], coolant pump pulley, dynamic tensioner roller. Remove tools [1], [2a], [2b] and [4].

  • Page 208: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: NFU Adjusting the fitting tension of the timing belt. Slacken the nut while maintaining the position of the tensioner roller, with the aid of a hexagonal spanner at «a». Next bring the index «c» to its adjusting position «e». WARNING: The index «c»...

  • Page 209: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RFJ Tools. [1] Camshaft pinion peg : (-).0194.A [2] Crankshaft setting peg : (-).0189.R IMPERATIVE: Respect the safety and cleanliness requirements. Disconnect the battery. Raise and support the vehicle, front wheels hanging. Remove the front RH wheel, the plastic pins holding the splash-shield, the splash-shield itself. B1BP2V3D A: Pegging on the manual gearbox.

  • Page 210: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RFJ Peg the crankshaft, using tool [2]. Suspend the engine, using a workshop hoist. Remove the RH engine support, the upper timing cover. Peg the camshaft pulleys, using tool [1]. NOTE: The pegs [1] should go in without forcing. WARNING: If the pegs go in only with difficulty, repeat the operation for fitting and tensioning B1BP2V3D the timing belt (see corresponding operation) .
  • Page 211 CHECKING AND SETTING THE VALVE TIMING Engine: RFJ Tools. [1] Camshaft setting peg : (-).0194.B [2] Crankshaft setting peg : (-).0189.R [3] Timing belt retaining pin : (-) 0189.K [4] Adaptor for angular tightening : 4069-T [5] Hub immobilising tool : (-).0189.S [5a] : (-).0189.S1...

  • Page 212: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RFJ Checking and setting the timing (continued). A: Pegging on the manual gearbox. B: Pegging on the automatic gearbox. Peg the crankshaft, using tool [2]. Remove the fixing bracket screw (4). Move aside the power steering pipes. Peg the camshaft pulleys (6) and (7), using tool [1].

  • Page 213: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RFJ Checking and setting the timing (continued). Refitting. Turn the tensioner roller (9), using tool [5a] to go past the notch «b». Position the tool [5b] to lock the index «a» and remove the tool [5a]. NOTE: Check the presence of the crankshaft pinion keyway (12) before positioning the timing belt.

  • Page 214: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RFJ Tensioning the timing belt. Refitting (continued). Turn the tensioner roller (9) anti-clockwise, using a hexagonal spanner at «c». Place the index «a» in position «e». IMPERATIVE: The index «a» should go past the slot «f» by an angular value of 10°. If it does not, replace the tensioner roller or the tensioner roller and timing belt assembly.

  • Page 215: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RFJ Tensioning the timing belt. Refitting (continued). Remove the tools [1] and [2]. Rotate the crankshaft ten times (normal direction of rotation). IMPERATIVE: No exterior pressure or action should be applied on the timing belt. Peg the inlet camshaft pulley, using tool [1].

  • Page 216: Engine

    CHECKING THE VALVE TIMING Engine: RFN Tools. [1] Camshaft setting peg : (-).0189.A [2] Crankshaft setting peg : (-).0189.R IMPERATIVE: Respect the safety and cleanliness requirements. Checking the timing. Removing. Disconnect the battery negative terminal. Raise and support the vehicle, front wheels hanging. Remove the front RH wheel, the splash-shield and the upper timing cover.

  • Page 217: Engine

    CHECKING THE VALVE TIMING Engine: RFN Checking the timing (continued). Suspend the engine, using a workshop hoist. Remove the engine support (2) and the timing cover (1). Peg the camshaft pulleys, using tool [1]. NOTE: The pegs [1] should go in without forcing. B1EP1GTC WARNING: If the pegs go in only with difficulty, repeat the operation for fitting and tensioning the timing belt (see corresponding operation) .

  • Page 218: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RFN Tools. [1] Camshaft setting peg : (-).0189.A [2] Crankshaft setting peg : (-).0189.R [3] Timing belt retaining pin : (-) 0189.K [4] Adaptor for angular tightening : 4069-T [5] Hub immobilising tool : (-).0189.S [5a] : (-).0189.S1...

  • Page 219: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RFN Checking and setting the timing (continued). A: Pegging on the manual gearbox. B: Pegging on the automatic gearbox. Peg the crankshaft, using tool [2]. Remove the fixing bracket screw (4). Move aside the power steering pipes. Peg the camshaft pulleys (6) and (7), using tool [1].

  • Page 220: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RFN Checking and setting the timing (continued). Refitting. Turn the tensioner roller (9), using tool [5a] to go past the notch «b». Position the tool [5b] to lock the index «a» and remove the tool [5a]. Reposition the timing belt (10) on the crankshaft pinion (1).

  • Page 221: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RFN Tensioning the timing belt. Refitting (continued). Turn the tensioner roller (9) in the direction of the arrow «c», using a hexagonal spanner at «d». Place the index «a» in position «f». IMPERATIVE: The index «a» should go past the slot «g» by an angular value of 10°. If it does not, replace the tensioner roller or the tensioner roller and timing belt assembly.

  • Page 222: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RFN Tensioning the timing belt. Refitting (continued). Remove the tools [1] and [2]. Rotate the crankshaft ten times (normal direction of rotation). IMPERATIVE: No exterior pressure or action should be applied on the timing belt. Peg the inlet camshaft pulley, using tool [1].

  • Page 223: Engine

    CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines: 6FZ - RFN Tools. [1] Camshaft setting peg : (-) 0189.A [2] Crankshaft setting peg : (-).0189.R [3] Timing belt retaining pin : (-).0189.K [4] Adaptor for angular tightening : 4069-T [5] Tool for moving and locking the tensioner roller : (-).0189.S...

  • Page 224: Engine

    XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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 225: Engine

    CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines: 6FZ - RFN 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 226: Engine

    XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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 227: Engine

    CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO 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 228: Engine

    XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines: 6FZ - RFN Tensioning the timing belt. Turn the tensioner roller (8) in the direction of the arrow «c», by means of a hexagonal spanner at «d». IMPERATVE: The index «a» should go past the slot «g» by an angular value of 10°. If it does not, replace the tensioner roller or the timing belt and tensioner roller assembly.

  • Page 229: Engine

    XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines: 6FZ - RFN 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 230: Engine

    CHECKING THE VALVE TIMING Engine: RFK Tools. [1] Camshaft setting peg : (-).0194.B [2] Crankshaft setting peg : (-).0189.R IMPERATIVE: Respect the safety and cleanliness requirements. Checking the timing. Removing. Disconnect the battery negative terminal. Raise and support the vehicle, front wheels hanging. Remove the front RH wheel and the splash-shield.

  • Page 231: Engine

    CHECKING THE VALVE TIMING Engine: RFK Checking the timing (continued). Suspend the engine, using a workshop hoist. Remove: - The RH engine support. - The upper timing cover. Peg the camshaft pulleys, using tool [1]. NOTE: The pegs [1] should go in without forcing. WARNING: If the pegs go in only with difficulty, repeat the operation for fitting and tensioning the timing belt (see corresponding operation) .

  • Page 232: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RFK Tools. [1] Camshaft setting peg : (-).0189.A [2] Crankshaft setting peg : (-).0189.R [3] Timing belt retaining pin : (-) 0189.K [4] Adaptor for angular tightening : 4069-T [5] Hub immobilising tool : (-).0189.S [5a] : (-).0189.S1...

  • Page 233: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RFK Checking and setting the timing (continued). Peg the crankshaft using tool [2]. Suspend the engine, using a workshop hoist. B1BP36YC Remove: - The upper RH engine support. - The upper timing cover (2). B1BP2V5D...

  • Page 234: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RFK Checking and setting the timing (continued). Peg the camshaft pulleys (6) and (7), using tool [1]. Remove: - The screw (4). - The crankshaft pulley (3). - The lower timing cover (5). IMPERATIVE: Never remove the crankshaft pulley (3), without pegging the crankshaft and the camshafts.

  • Page 235: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RFK Checking and setting the timing (continued). Refitting. Turn the tensioner roller (9), using tool [5a] to go past the notch «b». Position the tool [5b] to lock the index «a» and remove the tool [5a]. Reposition the timing belt (8) on the crankshaft pinion (3).

  • Page 236: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RFK Tensioning the timing belt. Turn the tensioner roller (9) anti-clockwise, using a hexagonal spanner at «c». Place the index «a» in position «e». IMPERATIVE: The index «a» should go past the slot «f» by an angular value of 10°. If it does not, replace the tensioner roller or the tensioner roller and timing belt assembly.

  • Page 237: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RFK Checking and setting the timing (continued). Refitting (continued). Remove the tools [1] and [2]. Refit the upper RH engine support. Remove the workshop hoist. Rotate the crankshaft ten times (normal direction of rotation) . IMPERATIVE: No exterior pressure or action should be applied on the timing belt.

  • Page 238: Engine

    CHECKING AND SETTING THE VALVE TIMING XSARA Engines: 8HX - 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 [5] Crankshaft and high pressure pump setting peg : (-).0194.A...

  • Page 239: Engine

    XSARA CHECKING AND SETTING THE VALVE TIMING Engines: 8HX - 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 240: Engine

    XSARA CHECKING AND SETTING THE VALVE TIMING Engines: 8HX - 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 241: Engine

    XSARA CHECKING AND SETTING THE VALVE TIMING Engines: 8HX - 8HZ Setting the timing (continued). Remove the tool [3]. Rotate the engine by means of the crankshaft pinion screw (2) (clockwise) , to bring it to the pegging position. Peg the camshaft pulley, using tool [4]. Peg: - The crankshaft pinion (6), using tool [5].

  • Page 242: Engine

    XSARA CHECKING AND SETTING THE VALVE TIMING Engines: 8HX - 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. IMPERATIVE: Check that both the tensioner roller and the fixed roller turn freely (no tight spots) .

  • Page 243: Engine

    XSARA CHECKING AND SETTING THE VALVE TIMING Engines: 8HX - 8HZ Setting the timing (continued). NOTE: Screw (9) slackened. Position the timing belt (10) observing the following sequence: - Crankshaft pinion (4). - Guide roller (12). - Camshaft pulley (11) (check that the belt is held correctly against the roller) . - Coolant pump pinion (13).

  • Page 244: Engine

    XSARA CHECKING AND SETTING THE VALVE TIMING Engines: 8HX - 8HZ Setting the timing (continued). Turn the tensioner roller to the right to bring the index «c» to position «d», using a hexagonal spanner. Tighten the screw (9) of the tensioner roller, tighten to 3 ± 0,3 m.daN. Remove the tools [4] and [5].

  • Page 245: Engine

    CHECKING AND SETTING THE VALVE TIMING XSARA Engines: 8HX - 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 ± 0,4 m.daN. - The bottom timing cover (3).

  • Page 246: Engine

    CHECKING THE VALVE TIMING Engines: 9HX - 9HY - 9HZ Tools. [1] Flywheel setting peg : (-).0194.C [2] Camshaft setting peg : (-).0194.B [3] Crankshaft setting peg : (-).0194.A IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions.

  • Page 247: Engine

    CHECKING THE VALVE TIMING Engines: 9HX - 9HY - 9HZ Turn the engine in the normal direction of rotation until the peg [1] engages in the setting hole. Peg the flywheel at «b», using tool [1]. Move aside the electrical harness (6). Remove: - The engine support (7).

  • Page 248: Engine

    CHECKING THE VALVE TIMING Engines: 9HX - 9HY - 9HZ Checking the timing (continued). Peg the camshaft at «c», using tool [2] (oil the pegs) . WARNING: The magnetic track should not show any sign of damage and should not be approached by any other magnetic source.

  • Page 249: Engine

    CHECKING AND SETTING THE VALVE TIMING Engines: 9HX - 9HY - 9HZ Tools. [1] Flywheel setting peg : (-).0194.C [2] Camshaft setting peg : (-).0194.B [3] Crankshaft setting peg : (-).0194.A IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions.

  • Page 250: Engine

    CHECKING AND SETTING THE VALVE TIMING Engines: 9HX - 9HY - 9HZ Checking and setting the timing (continued). Turn the engine in the normal direction of rotation until the peg [1] engages in the setting hole. Peg the flywheel at «b», using tool [1]. Move aside the electrical harness (6).

  • Page 251: Engine

    CHECKING AND SETTING THE VALVE TIMING Engines: 9HX - 9HY - 9HZ Checking and setting the timing (continued). Peg the crankshaft at «e», using tool [3]. Remove: - The timing belt protector (13). - The engine speed sensor (14). Slacken the screw (12) of the tensioner roller and keep it slackened using an allen spanner at «d». Detension the timing belt by pivoting the tensioner roller (clockwise) .

  • Page 252: Engine

    CHECKING AND SETTING THE VALVE TIMING Engines: 9HX - 9HY - 9HZ Checking and setting the timing (continued). 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).

  • Page 253: Engine

    CHECKING AND SETTING THE VALVE TIMING Engines: 9HX - 9HY - 9HZ Adjusting the timing belt tension. Act on the tensioner roller (18) to align the marks «j» 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 254: Engine

    CHECKING AND SETTING THE VALVE TIMING Engines: 9HX - 9HY - 9HZ IMPERATIVE: Should it be impossible to peg the camshaft, check that the offset between the camshaft hole and the pegging hole is not more than 1 mm. If the offset is too great, repeat the operation to position the timing belt (see corresponding operation) . Remove the tools [2] and [3].

  • Page 255: Engine

    XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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 256: Engine

    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, using tool [1] at «b». Move aside the harness (7). Remove: - The engine support (8). B1BP305C - The screw (10).

  • Page 257: Xsara Picasso (Dw10Ated)

    XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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 258: Engine

    CHECKING AND SETTING THE VALVE TIMING XSARA PICASSO Engines: 9HZ - 9HY Refitting. 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). - The fuel unions (1). - The air/air heat exchanger inlet and outlet pipes (3).

  • Page 259: Engine

    XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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 260: Engine

    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 261: Engine

    XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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). Peg the crankshaft at «e», using tool [3].

  • Page 262: Engine

    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 263: Engine

    XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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 264: Engine

    CHECKING AND SETTING THE VALVE TIMING XSARA PICASSO Engines: 9HZ - 9HY Refitting (continued). Disengage the jack from under the engine. Couple: Refit tool [1] at «b». - The tube (2). Remove the screw (10). - The exhaust line, tighten the clip to 2,5 ± 0,3 m.daN. - The fuel unions (1).

  • Page 265: Engine

    XSARA CHECKING AND SETTING THE VALVE TIMING 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 266: Engine

    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 267: Engine

    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 268: Engine

    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 269: Engine

    CHECKING AND SETTING THE VALVE TIMING XSARA Engine: WJY Setting the timing (continued). Setting the timing (continued). Tighten: Remove the peg [2]. - 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 270: Engine

    XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines: RHY - RHZ Tools. Removing. [1] Belt tension measuring equipment : 4122-T IMPERATIVE: Respect the safety and cleanliness requirements that are specific to high pressure diesel injection (HDi) engines. [2] Tension lever : (-).0188.J2 Undo the front RH wheel bolts.

  • Page 271: Engine

    CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines: RHY - RHZ 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). - The upper timing cover (5).

  • Page 272: Engine

    XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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]. Remove the screw (8).

  • Page 273: Engine

    CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO 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. B1EP1A8D Check that: - The rollers (18) and (15) turn freely (without play and without any tight spot) .

  • Page 274: Engine

    XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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). - Coolant pump pinion (16).

  • Page 275: Engine

    CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines: RHY - RHZ 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]. Turn the tensioner roller, using tool [2], to attain a tension of: 54 ± 2 SEEM units. Tighten screw (17) of the tensioner roller (18) to 2,5 ±...

  • Page 276: Engine

    XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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 277: Engine

    CHECKING THE VALVE TIMING Engine: RHR Tools. [1] Kit of plugs : (-).0188.T [2] Double flywheel setting peg : (-).0188.X Toolkit 0188-T [3] Camshaft setting peg : (-).0188.M IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions.

  • Page 278: Engine

    CHECKING THE VALVE TIMING Engine: RHR Checks. Turn the crankshaft in the normal direction of rotation. Line up the black markings «b» and «c» on the chain with the teeth «a» and «d» of the camshaft drive pinions (40 turns of the camshafts maximum) . IMPERATIVE: If it is impossible to line up the markings on the chain with the camshaft drive pinions, repeat the setting of the camshafts (see operation: removing-refitting camshafts) .

  • Page 279: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RHR Tools. [1] Kit of plugs : (-).0188.T [2] Double flywheel setting peg : (-).0188.X [3] Camshaft setting peg : (-).0188.M [4] Belt clamp : (-).0188.AD [5] Pinion centrer : (-).0188.AH [6] Flywheel lock : (-).0188.F [7] Pulley (-).0188.P...

  • Page 280: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RHR Uncouple, plug and move aside, using tool [7], the fuel delivery pipe (1) and the fuel return pipe (2). Suspend the engine, using a workshop hoist. Remove the bracket (3) and the RH engine support (4).

  • Page 281: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RHR Remove: - The screw (8). - The auxiliaries drive pulley (7). - The crankshaft position sensor (11). - The lower timing cover (9). - The target of the crankshaft position sensor (10), using tool [7]. - The lower torque reaction rod.

  • Page 282: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RHR Refitting. Centre the crankshaft pinion (15), using tool [5]. Reposition the timimg belt on the pulley (18). Put the tool [4] in place (tighten moderately) . Reposition the timimg belt, strip «a» well tensioned in the following order: - Guide roller (14).

  • Page 283: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RHR Refitting. Rotate the crankshaft ten times (in the direction of rotation of the engine) . Peg the crankshaft, using tool [2] and the camshaft drive pinion, using tool [3]. Lock the flywheel, using tool [6]. Slacken the screw (8) of the auxiliaries drive pulley (7) and the screw (12) of the tensioner roller (17).

  • Page 284: Engine

    CHECKING AND SETTING THE VALVE TIMING Engine: RHR Refitting. IMPERATIVE: If the position of the index «d» is not correct, restart the operations to tension the timing belt (for this, slightly slacken the screw (12) of the tensioner roller) . Refit tool [6].

  • Page 285: Engine

    CHECKING THE OIL PRESSURE Petrol Diesel Engine type Temperature (°C) 90° 80° Pressure (bars) 1000 Pressure (bars) 2000 2000 2000 Pressure (bars) 3000 3000 Pressure (bars) 4000 4000 Tools (Toolkit 4103) 2279-T.Bis 4103-T (-).0710.F1 (-).0710.B1 (-).1503.J 4103-T.B 7001-T 4202-T NOTE: The oil pressure should be checked with the engine hot, after the oil level has been checked.
  • Page 286 XSARA CHECKING THE OIL PRESSURE To be read with the Petrol and Diesel correspondence tables XSARA Engine type Temperature (°C) 90°C Pressure (bars) 1000 1000 Pressure (bars) 2000 Pressure (bars) 3000 Pressure (bars) 4000 Tools (Toolkit 4103-T) 2279-T.Bis 4103-T 4202-T 1503-J 3099-T 7017-T.X23...
  • Page 287 CHECKING THE OIL PRESSURE XSARA PICASSO To be read with the Petrol and Diesel correspondence tables XSARA PICASSO Engine type Temperature (°C) 90°C 80°C 90°C Pressure (bars) 1000 Pressure (bars) 2000 Pressure (bars) 3000 Pressure (bars) 4000 4000 Tools (Toolkit 4103-T) 2279-T.Bis 4103-T 7001-T...
  • Page 288 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 Inlet Valves Adjust Rocking Adjust fully TU1JP - TU3JP open 0,20 mm ±...
  • Page 289 CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT XSARA Engines: 8HX - 8HZ Tools. [1] Ø 10 mm low pressure connector : 4215-T [2] Pressure gauge for testing boost pressure : 4073-T.A Toolkit 4073-T IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines.
  • Page 290 CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT Engines: 9HX - 9HY - 9HZ Tools. [1] Ø 10 mm low pressure connector : 4215-T [2] Pressure gauge for testing boost pressure : 4073-T.A Toolkit 4073-T IMPERATIV: Respect the safety and cleanliness specific to high pressure diesel injection engines.
  • Page 291 CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT XSARA PICASSO Engines: 9HZ - 9HY Tools. [1] Ø 10 mm low pressure connector : 4215-T [2] Pressure gauge for testing boost pressure : 4073-T.A Toolkit 4073-T IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines.
  • Page 292 CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT Engine: RHR Tools. [1] Ø 10 mm low pressure connector : 4215-T [2] Pressure gauge for testing boost pressure : 4073-T.A Toolkit 4073-T IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines.
  • Page 293 CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT XSARA Engine: RHY Tools. [1] Ø 10 mm low pressure connector : 4215-T [2] Pressure gauge for testing boost pressure : 4073-T.A Toolkit 4073-T Checks. IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines.
  • Page 294 XSARA PICASSO CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT 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 295 CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT XSARA PICASSO 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 296 CHECKS: TURBO PRESSURE XSARA Engines: 8HX - 8HZ 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 297 CHECKS: TURBO PRESSURE Engines: 9HX - 9HY - 9HZ 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 298 XSARA PICASSO CHECKS: TURBO PRESSURE 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 299 CHECKS: TURBO PRESSURE Engine: RHR Tools. [1] Pressure gauge for checking the turbo pressure : 4073-T Toolkit 4073-T [2] Pressure take-off extension : 8607-T.A [3] Pressure take-off union and hose : 8607-T.B [4] Sleeve for checking the turbo pressure : 4185-T [5] Adaptor sleeve : 4219-T IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection...
  • Page 300 XSARA PICASSO CHECKS: TURBO PRESSURE 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 301 CHECKS: TURBO PRESSURE XSARA PICASSO 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. Vehicle in running order at full load.

  • Page 302: Checking The Air Supply Circuit

    XSARA CHECKING THE AIR SUPPLY CIRCUIT Engines: 8HX - 8HZ Tool. [1] Manual pressure-vacuum pump : FACOM DA 16 Vacuum pump: - Connect the tool [1] onto the vacuum pump (1). - Start the engine. - Wait 30 seconds. The vacuum value should be 0.9 ± 0.1 bar at idle. B1HP1K8D...
  • Page 303 CHECKING THE AIR SUPPLY CIRCUIT Engine: 9HX Tool. [1] Manual pressure-vacuum pump : FACOM DA 16 Checks. Vacuum pump. Connect the tool [1] into the vacuum pump (1). Start the engine. B1HP1UGC The vacuum value should be 0.9 ± 0.1 bar at idle (after 30 seconds of operation) . NOTE: The exhaust gas recycling valve is not linked to the air supply circuit.
  • Page 304 CHECKING THE AIR SUPPLY CIRCUIT Engines: 9HY - 9HZ Tool. [1] Manual pressure-vacuum pump : FACOM DA 16 Checks. Vacuum pump. Connect the tool [1] into the vacuum pump (1). Start the engine. B1HP1UGC Wait 30 seconds. The vacuum value should be 0.9 ± 0.1 bar at idle. NOTE: The exhaust gas recycling valve is not linked to the air supply circuit.
  • Page 305 CHECKING THE AIR SUPPLY CIRCUIT Engine: RHR Tool. [1] Manual pressure-vacuum pump : FACOM DA 16 IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines. WARNING: After switching off the ignition, wait 15 minutes before disconnecting the battery (to guarantee memorisation of the initialisations of the different ECUS) .
  • Page 306 CHECKING THE AIR SUPPLY CIRCUIT Engine: RHR Checking the warm air opening. Remove: - The air duct (4). - The air duct (5). - The air duct (6). Connect the tool [1] on the warm air butterfly control diaphragm at «e». Apply a vacuum of 0,7 ±...

  • Page 307: Xsara Picasso (Dw10Td/Ated)

    CHECKING THE AIR SUPPLY CIRCUIT XSARA PICASSO Engines: RHY - RHZ Tool. [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 308 XSARA CHECKS: EXHAUST GASES RECYCLING CIRCUIT Engines: 8HX - 8HZ Tool. [1] Manual pressure-vacuum pump : FACOM DA 16 IMPERATIVE: Respect the safety and cleanliness requirements. EGR valve. Connect tool [1] on the capsule take-off (2). Apply a vacuum of approx. 0,6 bar several times to activate the rod «a». In abruptly suppressing the vacuum, the valve should click and lock itself back on its seating.
  • Page 309 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 310 XSARA PICASSO CHECKS: EXHAUST GASES RECYCLING CIRCUIT Engines: RHY - RHZ Tool. [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 311: Sparking Plugs

    SPARKING PLUGS Engine Electrode gap Tightening Vehicles BOSCH EYQUEM CHAMPION SAGEM type setting torque 1.4i 16V VR8SE 2,25 ± 0,2 1.6i 16V 3 ± 0,3 2.0i 16V RFN52HZ3A 2.0i REC9MCLX 2,7 ± 0,2 2.0i 16V FR 7 ME 1.4i FR 7 DE RFN 58 LZ RC 8 YLC 0,9 ±...
  • Page 312 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 313: Clutch Specifications

    CLUTCH SPECIFICATIONS Petrol ET3J4 TU5JP EW10J4 EW10J4S Engine type Gearbox type MA5/L MA5/N BE4/5N BE4R/5S Supplier SACHS VALEO VALEO VALEO Mechanism/type 200 MF 3850 200 CPX 3850 230 DNG 5100 230 DNG 5100 Hub disc SAE 24/48-18Z 11 RX 11 R 14X 11 R 14X Ø...
  • Page 314 CLUTCH SPECIFICATIONS Diesel DV6TED4 DV6ATED4 DW10BTED4 Engine type 9HY (*) 9HZ (*) RHR (**) Gearbox type BE4/5L ML6C Supplier Mechanism/type 235 P 4800 235 P 7400 Hub disc Ø of lining. ext/int 234/165 235/150 Quality of lining 810 DS NOTE: (*) DVAR: Equipped with a Double Damping Flywheel with springs in the radial position in relation to the axis of the crankshaft. NOTE: (**) DVA: Equipped with a Double Damping Flywheel with springs arranged concentrically.
  • Page 315 CLUTCH SPECIFICATIONS XSARA TU3JP TU5JP4 EW10J4 Engine type Gearbox type MA/5 MA/5 BE4/5 Supplier VALEO Mechanism/type 180CPO 3400 200 CPR 3800 230 DNG 4700 Hub disc 180 XJF 73 C 200X(D95) 11A12X 230 DNG 4700 Ø of lining. ext/int 180/127 200/137 228/155 Quality of lining...
  • Page 316 XSARA CLUTCH SPECIFICATIONS DV4TD DW8B DW10TD DW10ATED Engine type Gearbox type BE4/5 Supplier Mechanism/type 200 P 4200 200 P 3700 230 P 4700 235 T 5700 Hub disc 215 F (D 93) 22 BX 228D Ø of lining. ext/int 200/134 200/134 230/155 235/155...
  • Page 317 CLUTCH SPECIFICATIONS XSARA PICASSO TU5JP+ EW7J4 EW10J4 DV6TED4 DW10TD Engine type Gearbox type BE4/5 Supplier VALEO Mechanism/type 200 DNG 3800 230 DNG 4700 215 DT 5250 225 DNG 5100 230 P 4700 200X(D95) Hub disc 230 DNG 4700 215 FD 95 11A12X Ø...
  • Page 318 MA MANUAL GEARBOX SPECIFICATIONS Vehicle Engine Gearbox type Sequence Torque ratio Drive ratio ET3J4 MA/5L 20 CQ 15 13x59 21x18 TU5JP4 MA/5N 20 CQ 16 13x61 None 20 CP 44 16x65 TU3JP MA/5L 20 CP 52 14x60 XSARA 21x18 MA/5N 20 CP 51 16x65 TU5JP4...

  • Page 319: Be4/5 Manual Gearbox Specifications

    BE4/5 MANUAL GEARBOX SPECIFICATIONS Vehicle Engine Gearbox type Sequence Torque ratio Drive ratio TU5JP4 20 DM 81 15x74 21x18 BE4/5N 20 DM 71 17x81 EW10A/J4 BE4R/5S 20 DM 74 19x77 EW10J4S BE4/5L 20 DM 68 17x73 None DV6TED4 BE4R/5L 20 DM 69 19x72 DV6ATED4 MA/5L...
  • Page 320 ML6/AL4 GEARBOX SPECIFICATIONS Vehicle Engine Gearbox type Sequence Torque ratio Drive ratio Type ML6 DW10BTED4 ML6C 20 MB 01 17x67 None Type AL4 TU5JP4 20 TS 12 20x73 EW10A 20 TS 11 21x73 TU5JP4 20 TP 97 21x73 XSARA EW10J4 20 TP 89 23x73 None...
  • Page 321 CLUTCH SPECIFICATIONS Engines: KFU - NFU - RFN - RFJ - RFK - 9HX - 9HY - 9HZ - RHR NOTE: All the clutches are «push» type with hydraulic control. NOTE: The DV6TED4 and DW10BTED4 engines are equipped with a double damping flywheel (DVA). Description.
  • Page 322 XSARA - XSARA PICASSO CLUTCH SPECIFICATIONS Engines: KFW - NFU - NFV - 6FZ - RFN - 8HX - 8HZ - 9HY - 9HZ - WJY - RHY - RHZ NOTE: All the clutches are «push» type with hydraulic control. Description.
  • Page 323 HYDRAULIC CLUTCH CONTROL: CHECKS AND ADJUSTMENTS 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 324 XSARA PICASSO HYDRAULIC CLUTCH CONTROL: CHECKS AND ADJUSTMENTS 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 325 TIGHTENING TORQUES: MA/5 GEARBOX Engines: KFU - NFU Tightening torques (m.daN). (1) Gearbox fixings on engine : 4,5 ± 0,5 (2) Reverse gear switch : 2,5 ± 0,2 (3) Drain plug : 3,3 ± 0,3 (4) 5th gear housing fixing : 2,2 ±...
  • Page 326 TIGHTENING TORQUES: MA/5 GEARBOX Engines: KFU - NFU Tightening torques (m.daN). (6) Clutch bearing guide screw : 1 ± 0,1 (7) Bearing retaining clip screw : 1,8 ± 0,2 Intermediate plate fixing : 5 ± 0,5 Hydraulic clutch slave cylinder fixing : 3 ±...
  • Page 327 TIGHTENING TORQUES: MA/5 GEARBOX Engines: KFU - NFU Tightening torques (m.daN). (8) Gearbox support shaft nut : 6,5 ± 0,6 (9) Screws fixing gearbox support on body : 1,9 ± 0,1 (10) Gearbox support plate nut : 2,5 ± 0,2 (11) Nut fixing gearbox support on body : 1,9 ±...
  • Page 328 XSARA MA/5 GEARBOX SPECIFICATIONS 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 329 XSARA MA/5 GEARBOX SPECIFICATIONS Engines: KFW - NFU Tightening torques (m.daN). (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 B2CP169D...
  • Page 330 TIGHTENING TORQUES: BE4/5 GEARBOX Engines: RFN - RFK - 9HX - 9HY - 9HZ Tightening torques (m.daN). (1) Air vent hole : 1,5 ± 0,2 (2) Reverse gear rocker switch shaft fixing nut : 4,5 ± 0,2 (3) Differential housing fixing nut : 1,5 ±...
  • Page 331 TIGHTENING TORQUES: BE4/5 GEARBOX Engines: RFN - RFK - 9HX - 9HY - 9HZ Tightening torques (m.daN). (12) Fork shaft stop screw : 1,5 ± 0,2 (13) Differential gearwheel fixing screw : 6 ± 0,5 (14) Bearing stop screw : 1,5 ± 0,2 (15) Secondary shaft nut : 6,5 ±...
  • Page 332 TIGHTENING TORQUES: BE4/5 GEARBOX Engines: RFN - RFK - 9HX - 9HY - 9HZ Tightening torques (m.daN). (18) Stop guide screw : 1,25 ± 0,2 (19) Speedometer fixing screw : 1,5 ± 0,2 (20) Gearbox support shaft nut : 6,5 ± 0,6 (21) Nuts fixing rubber support : 3 ±...
  • Page 333 XSARA - XSARA PICASSO TIGHTENING TORQUES: BE4/5 GEARBOX Engines: 6FZ - RFN - WJY - 8HX - 8HZ - 9HY - 9HZ - RHY - RHZ Tightening torques (m.daN). (23) Clutch bearing guide (3 screws) : 1,25 ± 0,2 (24) Clutch housing (13 screws) : 1,3 ±...
  • Page 334 TIGHTENING TORQUES: ML6 GEARBOX Engine: RHR Tightening torques (m.daN). (1) Primary shaft screw : 10 ± 1 (2) Bearing guide screw : 2 ± 0,2 (3) Differential gearwheel screw : 7,7 ± 0,3 (4) Secondary shaft screw : 13 ± 1,3 B2CP3ZLD...
  • Page 335 TIGHTENING TORQUES: ML6 GEARBOX Engine: RHR Tightening torques (m.daN). (5) Reverse gear switch : 2,5 ± 0,5 (6) Level plug : 3 ± 0,2 (7) Drain plug : 3 ± 0,3 (8) Differential bearing stop plate screw : 3 ± 0,3 (9) Screw fixing gearbox housing / clutch housing : 3 ±...
  • Page 336 TIGHTENING TORQUES: ML6 GEARBOX Engine: RHR Tightening torques (m.daN). (13) Screws/nuts fixing the gearbox support : 4,5 ± 0,4 (14) Screw fixing the rubber bush : 3 ± 0,3 (15) Nut fixing the gearbox casing : 6,5 ± 0,6 B2CP3ZNC...
  • Page 337 MA/5 GEARBOX CONTROLS Engines: KFU - NFU Gear controls The gear selection and engagement cables have no adjustment. NOTE: The two gear control cables cannot be separated. (1) Gear engagement ball-joint : Ø 10 mm (2) Gear engagement control cable (3) Gear control lever (4) Gear selection control cable (5) Gear selection ball-joint...
  • Page 338 MA/5 GEARBOX CONTROLS Engines: KFU - NFU Gear engagement and selection control cables Length A (mm) Gear engagement control cable 791,2 ± 2 Length B (mm) Gear selection control cable 791,2 ± 2 B2CP3ZDD NOTE: The gear engagement cable has a black colour identification on the sleeve stop at «a».
  • Page 339 MA/5 GEARBOX CONTROLS Engines: KFU - NFU Features. Unlocking a sleeve stop: - Press on the tabs of the clip (6) at «b», using a flat screwdriver. - Disengage the sleeve stops from their supports by pulling upwards. B2CP3ZFD...
  • Page 340 XSARA CHECKS AND ADJUSTMENTS: MA/5 GEARBOX CONTROLS Engines: KFW - NFU - 8HX - 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 341 BE4/5 GEARBOX CONTROLS Engines: NFU - RFN - RFK - 9HX - 9HY - 9HZ The gear selection and engagement cables have no adjustment. Gear controls. (1) Gear engagement ball-joint : Ø 10 mm (2) Gear engagement control cable (3) Gear control lever (4) Gear selection control cable (5) Gear selection ball-joint : Ø...
  • Page 342 BE4/5 GEARBOX CONTROLS Engines: NFU - RFN - RFK - 9HX - 9HY - 9HZ Length A (mm) Gear engagement control cable 643 ± 2 Length B (mm) Gear selection control cable 670 ± 2 NOTE: The gear engagement cable has a black colour identification on the sleeve stop at «a».
  • Page 343 BE4/5 GEARBOX CONTROLS Engines: NFU - RFN - RFK - 9HX - 9HY - 9HZ Features. Unlocking a sleeve stop: - Press on the tabs of the clip (6) at «b», using a flat screwdriver. - Disengage the sleeve stops from their supports by pulling upwards. B2CP3Z3D...
  • Page 344 BE4/5 GEARBOX CONTROLS XSARA - XSARA PICASSO Engines: NFV - 6FZ - RFN - WJY - 8HX - 8HZ - 9HY - 9HZ - RHY - RHZ (1) Gear control lever (2) Gear engagement control cable (*) (3) Gear selection control cable (*) (4) Gear selection ball-joint Ø...
  • Page 345 CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS XSARA - XSARA PICASSO Engines: NFV - 6FZ - RFN - WJY - 8HX - 8HZ - 9HY - 9HZ - 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 346 XSARA - XSARA PICASSO CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS Engines: NFV - 6FZ - RFN - WJY - 8HX - 8HZ - 9HZ - 9HY - RHY - RHZ Adjusting the gear controls Tools. [1] Tool for positioning the gear lever : 9607-T Adjustments.
  • Page 347 ML6 GEARBOX CONTROLS Engine: RHR Gear controls. (1) Gear engagement ball-joint Ø 10 mm (2) Gear selection ball-joint Ø 10 mm (3) Gear engagement control cable (4) Gear control lever (5) Gear selection control cable (6) Reverse gear unlocking cable (7) O-ring seal (8) Reverse gear unlocking device B2CP3ZPD...
  • Page 348 CHECKS AND ADJUSTMENTS: ML6 GEARBOX CONTROLS Engine: RHR Adjustment of the gear selection control cable Adjustment NO Length A (mm) Gear engagement control cable 723 ± 2 Adjustment YES at «b» Length B (mm) Gear selection control cable 674 ± 2 NOTE: In order to differentiate the two gear control cables when they have been removed, the gear engagement cable has a black colour identification on the sleeve stop at «a».
  • Page 349 CHECKS AND ADJUSTMENTS: ML6 GEARBOX CONTROLS Engine: RHR Adjustment of the gear selection control cable Peform the following operations simultaneously: - Move the cylinder «f» in the direction of the arrow «e». - Pull the locking key «c» in the direction of the arrow «d». Check that the gear lever (18) is in the mid position on the control housing (17).
  • Page 350 RECOMMENDATIONS/PRECAUTIONS : AL4 AUTOMATIC GEARBOX Precautions to be taken Repairs on mechanical components. Modification of the oil usage counter value. Never place the gearbox on the ground without protection. Exchanging the gearbox ECU: - Note down the gearbox counter value. In order to avoid breaking the input shaft ring, it is imperative that the - Transfer the value read into the the new gearbox ECU.
  • Page 351 RECOMMENDATIONS/PRECAUTIONS : AL4 AUTOMATIC GEARBOX Procedure to be followed prior to carrying out repairs on AL4 autoactive gearbox If a gearbox malfunction occurs, there are two possible configurations Oil level (see corresponding operation) . depending on the seriousness of the fault: - Gearbox in back-up mode with a replacement programme of (the fault An excessive oil level can result in the following consequences: values are taken in substitution) .
  • Page 352 RECOMMENDATIONS/PRECAUTIONS : AL4 AUTOMATIC GEARBOX Procedure for initialising the automatic gearbox ECU Downloading. Updating the value of the oil usage counter. Updating the gearbox ECU by downloading: - Follow the procedure using the diagnostic tool. Using PROXIA. Access to reading and recording of the oil counter is via the menu: - «Configuration (integrated circuit button) /Oil counter».
  • Page 353 C4 - XSARA - XSARA PICASSO TIGHTENING TORQUES: AL4 AUTOMATIC GEARBOX Engines: NFU - RFJ Tightening torques (m.daN). (1) Fixing of the electrovalve for modulation of the flow of oil into the exchanger (EPDE) : 1 ± 0,2 (2) Heat exchanger fixing : 5 ±...
  • Page 354 TIGHTENING TORQUES: AL4 AUTOMATIC GEARBOX C4 - XSARA - XSARA PICASSO Engines: NFU - RFJ 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 B2CP3EED (10) Gearbox fixing on engine : 5,2 ±...
  • Page 355 C4 - XSARA - XSARA PICASSO TIGHTENING TORQUES: AL4 AUTOMATIC GEARBOX Engines: NFU - RFJ (13) Fixing of selector lever position switch : 1,5 ± 0,2 (14) Oil filler plug : 2,4 ± 0,4 B2CP3EGC...
  • Page 356 AL4 GEARBOX CONTROLS Engines: NFU - RFJ Gearbox end. The automatic gearbox is controlled by a cable. «c» Push-button (1) Control lever with ball-joint (2) Automatic adjustment Pull out the button to adjust the control. Push it in to lock the adjustment of the control. (3) Sleeve stop (4) Selection control locking clip (5) on the sleeve stop (3) B2CP3H8C...

  • Page 357: Automatic Gearbox

    RECOMMENDATIONS/PRECAUTIONS: AL4 AUTOMATIC GEARBOX (SHIFT LOCK) Engines: NFU - RFJ SHIFT LOCK. 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 358 XSARA PICASSO AL4 GEARBOX CONTROLS 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 359 AL4 GEARBOX CONTROLS C4 - XSARA - XSARA PICASSO Engines: KFV - RFN Gearbox end. The automatic gearbox is controlled by a cable. «c» or «d» Push-button. (1) Control lever with ball-joint (2) Automatic adjustment (pull out the button to adjust the control, push it in to lock the adjustment of the control) (3) Sleeve stop (4) Selection control locking clip (5) on the sleeve stop (3)
  • Page 360 XSARA AL4 GEARBOX CONTROLS 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 361 AL4 GEARBOX CONTROLS XSARA Engines: NFU - RFN - RHZ Gearbox end. (1) Control lever (2) Automatic adjustment (3) Sleeve stop The automatic gearbox is controlled by a cable. B2CP3AEC...
  • Page 362 XSARA AL4 GEARBOX CONTROLS 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 363 RECOMMENDATIONS/PRECAUTIONS: AL4 AUTOMATIC GEARBOX (SHIFT LOCK) 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.
  • Page 364 XSARA PICASSO RECOMMENDATIONS/PRECAUTIONS: AL4 AUTOMATIC GEARBOX (SHIFT LOCK) 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.
  • Page 365 AL4 GEARBOX CONTROLS XSARA PICASSO 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 366: Driveshafts

    DRIVESHAFTS - GEARBOX Tightening torques (m.daN) Gearbox oil seal mandrels Driveshaft Driveshaft Vehicles Gearbox Engines RH side LH side Toolkit bearing ET3J4 TU5JP4 MA/5 XSARA TU3JP TU5JP4 EW10/DV6 7114-T.W 7114-T.X 7116-T All types BE4/5 XSARA EW7/10J4B DW8 XSARA PICASSO DV6/DW10 DW10BTED4 9017-T.C 5701-T.A...

  • Page 367: Axle Geometry: C4

    AXLE GEOMETRY Conditions for checking and adjusting Tools : [1] Gauge for measuring the the wheel radius, 4 bolts : 4300-T. Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point (see corresponding operation) . Vehicle heights at reference height E1AP0F3D Front height...
  • Page 368 AXLE GEOMETRY B3CP097D Measuring front height Measuring rear height [1] Gauge for measuring the the wheel radius, 4 bolts : 4300-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+ 2 Value at reference All types...
  • Page 369 AXLE GEOMETRY Front axle Dissymmetry of lower castor 0° 30'. Dissymmetry of lower camber 0° 30'. Distribute symmetrically, LH / RH wheel, the total tracking value. ET3J4 - TU5JP EW10 EW10DV6 Engines DW10BTED4 DW10BTED4 Tyres 195/65 R 15 205/55 R 16 205/50 R 17 Camber 0°...
  • Page 370 AXLE GEOMETRY Rear axle Dissymmetry of lower camber 0° 30'. ET3J4 - TU5JP EW10DV6 EW10DV6 Engines DW10BTED4 DW10BTED4 Tyres 195/65 R 15 205/55 R 16 205/50 R 17 Camber No adjustable 1° 45’ (± 0° 30’) Push angle 0° (± 0° 06’) 6,5 ±...

  • Page 371: Tightening Torques: Front Axle

    TIGHTENING TORQUES: FRONT AXLE Tightening torques (m.daN). (1) Nut fixing suspension leg on body : 6,9 ± 0,6 (2) Nut fixing upper damper cup : 6,9 ± 0,6 (3) Upper fixing of anti-roll bar rod : 3,6 ± 0,3 (4) Lower fixing of anti-roll bar rod : 3,6 ±...

  • Page 372: Tightening Torques: Front Axle

    TIGHTENING TORQUES: FRONT AXLE Tightening torques (m.daN). (10) Fixing of subframe extension on body : 5,1 ± 1,2 (11) Fixing of tie-rod on body : 1,8 ± 0,4 (12) Tie-rod screw on front subframe : 9,8 ± 0,9 (13) Fixing of anti-roll bar bearing on subframe : 10,4 ±...

  • Page 373: Tightening Torques: Rear Axle

    TIGHTENING TORQUES: REAR AXLE Tightening torques (m.daN). (17) Damper upper fixing : 5,8 ± 0,5 (18) Fixing of yoke on rear axle : 7,6 ± 0,7 (19) Fixing of rear axle yoke on body : 6,2 ± 0,6 (20) Stub axle bearing nut - Pre-tightening : 9 ±...

  • Page 374: Tightening Torques: Power Steering

    TIGHTENING TORQUES: POWER-ASSISTED STEERING Steering column Ref. Description Tightening Fixed central controls steering wheel screw 2,2 ± 0,2 Steering column interface nuts 2,2 ± 0,2 Upper nuts Lower nuts Fixing of steering cardan on valve stem B3EP176D Steering mechanism with integral ram Ref.
  • Page 375 TIGHTENING TORQUES: POWER-ASSISTED STEERING Steering assistance electrovalve Ref. Description Tightening Fixing of electrovalve on chassis member 2,3 ± 0,2 Screw fixing bracket on electrovalve 2 ± 0,2 Fixing of electrovalve on chassis member 2,2 ± 0,2 B3EP178D...
  • Page 376 SPECIAL FEATURES: STEERING Engines: KFU - NFU - RFN - RFJ - RFK - 9HX - 9HY - 9HZ - RHR Setting the steering rack mid-point Preliminary operation. Raise and support the vehicle on a two-column lift. Remove (on RH side) : - The clip (1).
  • Page 377 CHECKING THE POWER STEERING ASSISTANCE PRESSURE Tools. [1] Pressure gauge : (-).0710.AZ [2] Checking tube: pressure gauge to tap : (-).0710.B1 [3] Checking tube: high pressure pipe to tap : (-).0710.B2 [4] Checking tube: high pressure pump to tap : (-).0710.B3 [5] 3-way tap : (-).0710.C [6] Union...
  • Page 378 CHECKING THE POWER STEERING ASSISTANCE PRESSURE Preliminary operation. Move aside the high pressure pipe (1). Do up: - The union [6] on the power steering electropump. - The union [7] on the high pressure pipe (1). - Tighten all the unions. Fill the power steering reservoir 10 mm above the max.
  • Page 379 CHECKING THE POWER STEERING ASSISTANCE PRESSURE Checking the valve sealing. Remove the under-engine shield. Move aside the heat shield from the steering mechanism. Slacken the unions (2) on the power steering ram. Uncouple the two supply pipes (3) from the distributor valve and move them aside. Fit on the distributor valve the two plugs [8], tighten to 0,8 m.daN.
  • Page 380 CHECKING THE POWER STEERING ASSISTANCE PRESSURE Fill the power steering reservoir to the max. mark «a» on the cap (4). Engine stopped, move the steering slowly from lock to lock, in both directions approx. ten times. Top up the fluid to the max. mark «a» on the cap (4). Run the engine at idle for 3 minutes, without any action on the steering wheel.
  • Page 381 AXLE GEOMETRY XSARA Front and rear measuring points - RPO 8667 # XSARA ALL TYPES Front height Rear height B3CP06ZD H2 = Dimension between the contact face of the rear mounting and H1 = Dimension between the centre of the front suspension arm the ground.
  • Page 382 XSARA AXLE GEOMETRY Reference heights - RPO 8667 # Tools [1] Gauge for measuring the radius of wheels with 4 bolts : 4300-T0 B3CP04AD Setting at reference height Front axle Rear axle Measure the dimension «R1». Calculate the dimension H1 = R1 - L1. Measure the dimension «R2».
  • Page 383 XSARA AXLE GEOMETRY Values of the front and rear suspensions, at reference height - RPO 8667 # ESSENTIAL: When checking the suspensions, the vehicle should be at reference height. Tools used. Compress the suspension, to obtain the values at reference height. [1] Set of two suspension compressors : 9511-T.A [2] Set of four straps...
  • Page 384 XSARA AXLE GEOMETRY Values of the front and rear suspensions, at reference height RPO 8667 # Front axle Saloon / Estate Saloon / Estate CRD Saloon or Entreprise Saloon TU3JP Tolerances Adjustable All engines (except All engines All TU3JP engines CRD (*) TU3JP/CRD) (except TU3JP)
  • Page 385 AXLE GEOMETRY XSARA a = Angle which defines the tracking between the front and rear axles. Its value must not exceed 12'. Anti-roll bars Engine versions Diameter Colour ref. Saloon Blue ALL TYPES Estate Yellow B3CP04UC...

  • Page 386: Tightening Torques: Front Axle

    XSARA TIGHTENING TORQUES: FRONT AXLE 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 387 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 NOTE: There are two suppliers for the silentblocks: by 1 paint line.

  • Page 388: Tightening Torques: Rear Axle

    XSARA TIGHTENING TORQUES: REAR AXLE 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 ±...
  • Page 389 XSARA TIGHTENING TORQUES: MANUAL STEERING Steering wheel - Manual steering Tightening torques (m.daN). (2) AIRBAG to steering wheel fixing : 0.8 (3) Steering wheel fixing : 3.3 (5) Steering column to support fixing : 2.3 (6) Steering cardan joint fixing : 2.3 B3EP08PD...
  • Page 390 XSARA TIGHTENING TORQUES: MANUAL STEERING 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 screws : 1.2 B3EP042D...

  • Page 391: Tightening Torques: Power Steering

    TIGHTENING TORQUES: POWER-ASSISTED STEERING XSARA Steering wheel - Power steering Tightening torques (m.daN). (2) AIRBAG to steering wheel fixing : 0.8 (3) Steering wheel fixing : 3.3 (5) Steering column to support fixing : 2.3 (6) Steering cardan joint fixing : 2.3 B3EP08QD...
  • Page 392 XSARA TIGHTENING TORQUES: POWER-ASSISTED STEERING Power 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 393 TIGHTENING TORQUES: POWER-ASSISTED STEERING 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) : 2.2...
  • Page 394 XSARA PICASSO AXLE GEOMETRY Measurements 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 395 AXLE GEOMETRY XSARA PICASSO Measurements at reference height (the reference height of the vehicle is set as per the table below). Front axle Rear axle B3CP05BC B3CP05AC B3DP079C Vehicles all engine versions (except CRD (*)) Front axle Rear axle H1 = R1 – L1 H1’...
  • Page 396 XSARA PICASSO AXLE GEOMETRY Measurements at reference height (compress the suspension to obtain the calculated values). Vehicles all engine versions (except CRD (*)) Front axle Rear axle Vehicle Tracking Castor Pivot angle Camber Tracking Camber Adjustable 0 ± 1 mm 4,8 ±...
  • Page 397 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 CRD vehicle versions (*) Front axle Rear axle H1 = R1 – L1 H1’...
  • Page 398 XSARA PICASSO AXLE GEOMETRY Measurements at reference height (compress the suspension to obtain the calculated values). Vehicles all engine versions (except CRD (*)) Front axle Rear axle Vehicle Tracking Castor Pivot angle Camber Tracking Camber Adjustable - 1 ± 1 mm 3,7 ±...
  • Page 399 TIGHTENING TORQUES: 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 ±...
  • Page 400 XSARA PICASSO TIGHTENING TORQUES: 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 ±...
  • Page 401 TIGHTENING TORQUES: POWER-ASSISTED STEERING XSARA PICASSO Tightening torques (m.daN). (2) Airbag to steering wheel fixing : 0.8 ± 0.1 (3) Steering wheel fixing : 3.3 ± 0.6 (5) Steering column to support fixing : 4 ± 0.1 (6) Steering cardan joint fixing : 2.3 ±...
  • Page 402 XSARA PICASSO TIGHTENING TORQUES: POWER-ASSISTED STEERING 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 403 TIGHTENING TORQUES: POWER-ASSISTED STEERING XSARA PICASSO 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 404: Brake Specifications

    BRAKE SPECIFICATIONS With ABS ET3J4 TU5JP4 TU5JP4 Manual Auto. Master cylinder 22,2 (in valve) (1) Amplifier 22,86/BOSCH/EVA2 (2) 25,4/ BOSCH/MCT8 (2) Ø mm Supplier/pistons BOSCH/ZOH 54/22 BOSCH/ZOH 54/26 Disc Ventilated Disc thickness 22/20 26/24 Brake pad grade FEDERAL MODUL/F769 GALFER/G4554 Cylinder or caliper BOSCH/TRW C38 Ø...

  • Page 405: Brake Specifications

    BRAKE SPECIFICATIONS With ESP DW10 ET3J4 TU5JP4 EW10A/J4 EW10J4S DV6TED4/ATED4 BTED4 Manual/Automatic Master cylinder 23,8 (in click) (1) Amplifier 25,4/ BOSCH/MCT8 (2) Ø mm Supplier TEVES/F TEVES/F BOSCH/ZOH 54/26 BOSCH/ZOH 54/26 pistons N3 57/26 N3 57/26 Disc Ventilated Disc thickness 26/24 Brake pad grade GALFER/G4554...
  • Page 406 BRAKE SPECIFICATIONS Braking system. Braking circuit in the form of an X. Disc brakes at the front and at the rear (vehicles all types) : - The front brake discs are ventilated. - The rear brake discs are plain. NOTE: The front brake pads have no wear warning lamp.
  • Page 407 TIGHTENING TORQUES: BRAKING SYSTEM Front brakes Front brake disc 1 ± 0,1 Yoke on caliper 3 ± 0,3 Unions on brake piping 1,5 ± 0,1 Caliper on pivot 10,5 ± 1 B3FP7DVD ABS/ESP hydraulic block support on the chassis member 0,2 ±...
  • Page 408 TIGHTENING TORQUES: BRAKING SYSTEM Front brakes Braking amplifier 2,2 ± 0,3 Master cylinder on braking amplifier 2 ± 0,5 B3FP7DXD Parking brake Parking brake lever 1,5 ± 0,2 B3FP7DYC...
  • Page 409 TIGHTENING TORQUES: BRAKING SYSTEM Rear brakes Unions on brake piping 1,5 ± 0,1 Rear brake caliper support 5,3 ± 0,5 Rear brake caliper 3 ± 0,3 Wheel sensor 0,8 ± 0,1 B3FP7DZC B3FP7EOC...
  • Page 410 ABS/ESP HYDRAULIC BLOCK Components Supplier Type Observations ABS REF 8.0 Installed under the front LH Hydraulic block BOSCH chassis member. 4 regulation channels. ESP 8.0 B3FP7E3C The emergency braking control is incorporated in the primary piston at «a». B3FP7E2D...
  • Page 411 PARKING BRAKE ADJUSTMENT Adjustment. IMPERATIVE: Respect the safety and cleanliness requirements. Raise and support the vehicle. Remove the central console. WARNING: Check the routing of the brake cables under the vehicle. Release the handbrake lever. Press gently on the brake pedal (then repeat the operation 3 times) . B3FP7F1C Action the handbrake lever with a force of 40 daN.
  • Page 412 BLEEDING AND FILLING THE BRAKING SYSTEM Tools. [1] Bleeding apparatus : «LURO» or similar [2] LEXIA diagnostic tool : 4171-T [3] PROXIA diagnostic tool : 4165-T NOTE: Bleeding of the secondary braking circuit is done with the aid of diagnostic tools [2] and [3]. Draining of the brake fluid reservoir.
  • Page 413 BLEEDING AND FILLING THE BRAKING SYSTEM Disconnect the connector «b». Uncouple the pipe (5). Remove the reservoir (6), moving aside the tabs «c» of the pins (7). Clean the brake fluid reservoir (4) and the brake fluid reservoir (6). Refit the brake fluid reservoir (6). Couple the pipe (5).
  • Page 414 BLEEDING AND FILLING THE BRAKING SYSTEM Filling the braking circuit. WARNING: Use only the approved and recommended hydraulic fluids. IMPERATIVE: Only use new brake fluid that has not emulsified; avoid any introduction of impurities into the hydraulic circuit. Fill the brake fluid reservoir (4). Bleeding the primary braking circuit.
  • Page 415 BLEEDING AND FILLING THE BRAKING SYSTEM Bleeding the braking circuit with the bleed apparatus. Connect the bleed apparatus [1] on the brake fluid reservoir (4). Adjust the apparatus pressure to 2 bars. For each brake circuit: - Couple a transparent tube on the bleed screw. - Submerge the other end of the tube in a clean container.
  • Page 416 BLEEDING AND FILLING THE BRAKING SYSTEM Bleeding the braking circuit without the bleed apparatus. Bleeding the secondary braking circuit. NOTE: Two operators are necessary. WARNING: During the bleed operations: take care to maintain the level of the brake fluid in the reservoir, keep it topped up. For each brake circuit: NOTE: The bleed apparatus [1] is still connected on the brake fluid - Apply the brake pedal to place the circuit under pressure.
  • Page 417 BRAKE SPECIFICATIONS XSARA Estates DW10 TU3JP TU5JP4 EW10J4 DV4TD DW10TD ATED Master cylinder Without ABS 23,8 (expansion holes) With ABS 23,8 (valve) Ø Amplifier 228,6 BOSCH 54 LUCAS 57 BOSCH 54 Caliper makes/pistons Disc Ventilated Disc thickness/min. thickness 22 / 20 Brake pad grade FERF 769 ASFM 380...
  • Page 418 XSARA ABS/ESP HYDRAULIC BLOCK 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. B3FP09HC (1) Hydraulic valve block «ABS Bosch 5.3» (1) Hydraulic valve block «ABS Bosch 5.3 REF»...
  • Page 419 BRAKE SPECIFICATIONS XSARA (7) Hydraulic block Gyrometer sensor B3HP002C C4AP17YC Components Supplier Part no. Observations IMPERATIVE: Respect the direction of fitting of the gyrometer/ accelerometer sensor (connector towards the rear of the vehicle). Located on the front WARNING: The gyrometer/accelerometer sensor should not be ESP hydraulic LH wheelarch: subjected to any impact.
  • Page 420 TIGHTENING TORQUES: BRAKING SYSTEM XSARA Tighten the nuts (1) to 2.3 m.daN. The shaft (2) is held in place by a plastic clip. B3FP10YD...
  • Page 421 XSARA BRAKE SPECIFICATIONS Braking system without ABS (rear drum brakes) Braking system without ABS (rear disc brakes) B3FP14FD B3FP14GD...
  • Page 422 BRAKE SPECIFICATIONS XSARA Braking system with ABS (rear drum brakes) B3FP14HD...
  • Page 423 BRAKE SPECIFICATIONS XSARA Braking system with ABS REF (rear disc brakes) Braking system with ABS REF (rear drum brakes) B3FP14JD B3FP14KD...
  • Page 424 XSARA BRAKE SPECIFICATIONS Braking system with ABS REF (rear drum brakes) B3FP14LD...

  • Page 425: Parking Brake

    PARKING BRAKE 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 426 XSARA BLEEDING THE BRAKING SYSTEM Bleeding: The brakes can be bled either: - 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.
  • Page 427 BRAKE SPECIFICATIONS XSARA PICASSO Mercosur Europe Without ESP (*) EW10J4 DW10TD TU5JP+ EW4J4 EW10J4 DW10TD Master cylinder 23,8 Master-vac/ 254/34 Master cylinder travel Ø FT mm Caliper makes LUCAS BOSCH Piston C54/54 ZOH54/54 Disc Ventilated Disc thickness/min. thickness 20,4/18,4 22/20 Makes/brake pad grade JURID/3724 FERODO/769 (37)
  • Page 428 XSARA PICASSO BRAKE SPECIFICATIONS All Types With ESP (*) EW4J4 EW10J4 DW10TD Master cylinder 23,8 Ø Master-vac/ 254/35 mm Master cylinder travel Caliper makes/pistons BOSCH ZOH54/54 Disc Ventilated Disc thickness/min. thickness 26/24 Brake pad supplier/grade FERODO/769 (37) Rear brake caliper TRW C38 Ø...
  • Page 429 BRAKING SYSTEM SPECIFICATIONS XSARA PICASSO Without ABS B3FP11WD...
  • Page 430 XSARA PICASSO BRAKING SYSTEM SPECIFICATIONS With ABS With EPS (Electronic Stability Program) B3FP7B9D B3FP7BRD...
  • Page 431 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. B3FP09HC - Load sensitive braking compensator (non ABS versions). (1) Hydraulic valve block «ABS Bosch 5.3»...
  • Page 432 PARKING BRAKE 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 433 BLEEDING THE BRAKING SYSTEM 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.

  • Page 434: Air Conditioning

    AIR CONDITIONING R 134.a (HFC) Compressor Refrigerant Vehicle Engines Date Variable Oil quantity refill (gr) Oil reference Capacity All types SD 7C 12 (except DW10BTED4) 09/04 450 ± 25 DW10BTED4 SD 6 C 12 XSARA All types 10/00 565 ± 25 SP 10 TU5JP + EW7 12/02...
  • Page 435 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 436 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. This type of leak causes both oil loss as well as allowing air to enter the system.
  • Page 437 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: C5HP1C5C C5HP1C7C - The plastic pins (1). - The plastic cover (2). - The flap (3). - The pollen filter (4).
  • Page 438 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 439 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 440 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Changing the filtering/drying cartridge The condenser (4) has a cylinder acting as a fluid reservoir with a filtering cartridge incorporated in it. a: Inlet union b: Outlet union NOTE: The filtering cartridge cannot be swapped. C5HP1CKC...
  • Page 441 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) XSARA PICASSO 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 442 XSARA PICASSO SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) 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 443 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Outillage EXXOTest Outillage (flash équipement & matériel). Procédure de l’essai. Exxoclim : 2.4.2-1 Mode d’emploi : Voir notice constructeur Contrôle. Mettre en place l'outillage (selon notice du constructeur). Opérations préliminaires. Fermer tous les aérateurs frontaux. Démarrer le moteur.
  • Page 444 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Tools. [1] Clim test 2 VALEO : 4372-T Checks. Position the tool [1] (depending on manufacturer's instructions). E5AP2ECC...
  • Page 445 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Checking. Position the tool CLIM TEST II (according to the manufacturer's instructions). Preliminary operations. Close all the front air vents. Start the engine. Open the front LH air vent. Position the air distribution control to «frontal flow». Activate the «air recirculation»...
  • Page 446 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Interpretation of the measurements. «m»: High pressure. «s»: Over-heating (SC). «n»: High temperature. «t»: Ambient air temperature. «p»: Under-cooling (SR). «u»: Blown air temperature. «q»: Low pressure. «v»: Humidity. «r»: Low temperature. «w»: Temperature T3.
  • Page 447 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Interpretation of the measurements. «m»: High pressure. «s»: Over-heating (SC). «n»: High temperature. «t»: Ambient air temperature. «p»: Under-cooling (SR). «u»: Blown air temperature. «q»: Low pressure. «v»: Humidity. «r»: Low temperature. «w»: Temperature T3.
  • Page 448 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Interpretation of the diagnosis E5AP2FCD «x» Check satisfactory «y» Lack of aircon fluid in the aircon circuit «z» Excess aircon fluid in the aircon circuit «aa» Filtering and drying cartridge clogged «ab» Other problems (see table on previous page)

  • Page 449: Filtering And Drying Cartridge

    CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table Principal problem Symptom Possible causes Aircon compressor clutch Lack of aircon fluid in the aircon circuit The clutch of the aircon compressor does not Aircon pressostat engage, or disengages suddenly Aircon evaporator sensor Electrical circuit (wiring, fuses, etc.) The aircon compressor does not turn...
  • Page 450 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table Principal problem Symptom Possible causes Incorrect adjustment of the aircon compressor clutch The clutch of the aircon compressor Aircon fluid quantity remains engaged Aircon compressor defective The aircon compressor makes an abnormal Lack of aircon fluid in the aircon circuit noise Aircon compressor valves defective...
  • Page 451 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table Principal problem Symptom Possible causes Aircon pressure reducer defective Low pressure and high pressure too high Duct clogged Low pressure too high and high pressure too low Aircon compressor seal defective Aircon evaporator sensor defective Low pressure too low and high pressure too high Aircon pressure reducer jammed...
  • Page 452 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table Principal problem Symptom Possible causes Low pressure normal and high pressure too high Presence of air in the aircon circuit Aircon pressostat defective Low pressure normal and high pressure too low Evaporator sensor defective Abnormal levels of pressure Low pressure too high and high pressure normal...
  • Page 453 AIR CONDITIONING SYSTEM (R 134.a) Engines: ET3J4 - TU5JP4 (1) High pressure valve (2) Low pressure valve (3) Pressostat (tighten to 0,6 m.daN) (4) Aircon pressure reducer (5) Filtering and drying cartridge (6) Buffer capacity «a» Outlet and inlet of the aircon pressure reducer, tighten to 0,8 m.daN «b»...
  • Page 454 AIR CONDITIONING SYSTEM (R 134.a) Engine: EW10J4 (1) High pressure valve (2) Low pressure valve (3) Pressostat (tighten to 0,6 m.daN) (4) Aircon pressure reducer (5) Filtering and drying cartridge (6) Buffer capacity «a» Outlet and inlet of the aircon pressure reducer, tighten to 0,8 m.daN «b»...
  • Page 455 AIR CONDITIONING SYSTEM (R 134.a) Engines: EW10A - EW10J4S (1) High pressure valve (2) Low pressure valve (3) Pressostat (tighten to 0,6 m.daN) (4) Aircon pressure reducer (5) Filtering and drying cartridge (6) Buffer capacity «a» Outlet and inlet of the aircon pressure reducer, tighten to 0,8 m.daN «b»...
  • Page 456 AIR CONDITIONING SYSTEM (R 134.a) Engine: DV6 (1) High pressure valve (2) Low pressure valve (3) Pressostat (tighten to 0,6 m.daN) (4) Aircon pressure reducer (5) Filtering and drying cartridge (6) Buffer capacity «a» Outlet and inlet of the aircon pressure reducer, tighten to 0,8 m.daN «b»...
  • Page 457 AIR CONDITIONING SYSTEM (R 134.a) Engine: DW10BTED4 (1) High pressure valve (2) Low pressure valve (3) Pressostat (tighten to 0,6 m.daN) (4) Aircon pressure reducer (5) Filtering and drying cartridge (6) Buffer capacity «a» Outlet and inlet of the aircon pressure reducer, tighten to 0,8 m.daN «b»...
  • Page 458 XSARA AIR CONDITIONING SYSTEM (R 134.a) Engines: TU3JP - TU5JP4 - EW10J4 - DV4TD - DW8B - DW10TD - DW10ATED (1) High pressure valve (2) Low pressure valve (3) Pressostat (4) Dryer NOTE: The method of connecting the High Pressure and Low Pressure compressor pipes may vary according to engine type.

  • Page 459: Xsara Picasso

    AIR CONDITIONING SYSTEM (R 134.a) XSARA PICASSO Engine: TU5JP+ (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 460 XSARA PICASSO AIR CONDITIONING SYSTEM (R 134.a) Engine: EW7J4 (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 461 AIR CONDITIONING SYSTEM (R 134.a) XSARA PICASSO Engine: DV6TED4 (1) High pressure valve (2) Low pressure valve (3) Dryer NOTE: The filtering and drying cartridge is removed from under the condenser. (4) Pressostat Tightening torques (m.daN). «a» Outlet and inlet of the aircon pressure reducer, tighten to 0,8 m.daN «b»...
  • Page 462 XSARA PICASSO AIR CONDITIONING SYSTEM (R 134.a) Engine: DW10 (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).

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