CITROEN C5 Handbook
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CITROEN C5 Handbook

Private cars 2003
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PRIVATE CARS
C5 - C8
«The technical information contained in this document is intended for the exclusive use of the trained personnel of the
motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The
information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full
responsibility to the exclusion of that of the manufacturer».
«The technical information appearing in this brochure is subject to updating as the characteristics of each model in the
range evolve. Motor vehicle repairers are invited to contact the CITROËN network periodically for further information and
to obtain any possible updates».
CAR 050014
Volume 2
2003

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  • Page 1 PRIVATE CARS 2003 C5 - C8 «The technical information contained in this document is intended for the exclusive use of the trained personnel of the motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full responsibility to the exclusion of that of the manufacturer».
  • Page 2 GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - ELECTRICAL - AIR CONDITIONING. In each section, the vehicles are dealt with in the following order : C5 and C8, or all models where applicable. The information given in this handbook is based on vehicles marketed in EUROPE.
  • Page 3 If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into account when preparing future publications. For example : – INSUFFICIENT INFORMATION – ISUPERFLUOUS INFORMATION – INEED FOR MORE DETAILS Please send your comments and suggestions to : CITROEN U.K. Ltd. 221, Bath Road, SLOUGH, SL1 4BA. U.K.

  • Page 4: Identification Of Vehicles

    IDENTIFICATION OF VEHICLES (A) Chassis stamp (cold stamp on bodywork). (B) Manufacturer’s data plate. (under the rear bench seat) (C) A-S / RP No. and RP paint code (label on front pillar close to driver’s door). (D) Inflation pressures and tyre references. (label on front pillar close to driver’s door) (E) Serial no.
  • Page 5 IDENTIFICATION OF VEHICLES Petrol saloons 1.8i 16V 2.0i 16V Auto. Auto. X-SX-Exclusive X-SX Emission standard Type code DC 6FZB DC 6FZC/IF DC 6FZE DC RFNC/IF DC RFNB DC RFNE Engine type Cubic capacity (cc) 1749 1997 Fiscal rating (hp) Gearbox type BE4/5 BE4/5 20 DL 29...
  • Page 6 IDENTIFICATION OF VEHICLES Petrol saloons 2.0 HPi 30.i 24S V6 Auto. Exclusive Emission standard Type code DC RLZB DC XFXC/IF DC XFXF/IF Engine type Cubic capacity (cc) 1997 2946 Fiscal rating (hp) BE4/5 ML/5C ML/5T 4 HP 20 Gearbox type Gearbox ident.
  • Page 7 IDENTIFICATION OF VEHICLES Diesel saloons 2.0 HDi Auto. Auto. X-Exclusive Emission standard Type code DC RHYB DC RHSB DC RHSE DC RHZB DC RHZE Engine type Cubic capacity (cc) 1997 Fiscal rating (hp) Gearbox type BE4/5 ML/5C ML/5T (*) ML/5C ML/5T Gearbox ident.
  • Page 8 IDENTIFICATION OF VEHICLES Diesel saloons 2.2 HDi Auto. SX-Exclusive Emission standard Type code DC 4HXB DC 4HXE Engine type Cubic capacity (cc) 2179 Fiscal rating (hp) Gearbox type ML/5C ML/5T 4 HP 20 Gearbox ident. plate 20 LM 17 20 LE 96 20 HZ 20...
  • Page 9 IDENTIFICATION OF VEHICLES Petrol estates 1.8i 16V 2.0i 16V 2.0 HPi 3.0i 24S V6 Auto. Auto. Exclusive Exclusive X-SX Emission standard Type code DE 6FZC/IF DE 6FZB DE RFNC/IF DE RFNE DE RLZB DE XFX/IF DE XFXF/IF Engine type Cubic capacity (cc) 1749 1997 2946...
  • Page 10 IDENTIFICATION OF VEHICLES Diesel estates 2.0 HDi Auto. Auto. X-Exclusive Emission standard Type code DE RHYB DE RHSB DE RHSE DE RHZB DE RHZE Engine type Cubic capacity (cc) 1997 Fiscal rating (hp) Gearbox type BE4/5 ML/5C ML/5T ML/5C ML/5T Gearbox ident.
  • Page 11 IDENTIFICATION OF VEHICLES Diesel estates 2.2 HDi Auto. SX-Exclusive Emission standard Type code DE 4HXB DE 4HXE Engine type Cubic capacity (cc) 2179 Fiscal rating (hp) Gearbox type ML/5C ML/5T 4 HP 20 Gearbox ident. plate 20 LM 17 20 LE 96 20 HZ 20...
  • Page 12 IDENTIFICATION OF VEHICLES (A) Chassis stamp (cold stamp on bodywork). (B) Manufacturer’s data plate (under RH centre pillar). (C) A-S / RP No. and RP paint code (label on front pillar). (D) Inflation pressures and tyre references. (label on front pillar) (E) Gearbox reference –...
  • Page 13 IDENTIFICATION OF VEHICLES Petrol 2.2i 16V 2.0i 16V Manual Automatic Manual X – SX Captain Chair X - SX Captain Chair Exclusive Exclusive Captain Chair Emission standard IFL5 Type code EB RFNC/IF EB RFNF/IF EA RFNF/IF EB 3FZC/IF EA 3FZC/IF Engine type Cubic capacity (cc) 1998...
  • Page 14 IDENTIFICATION OF VEHICLES Petrol 3.0i V6 S24 Automatic Exclusive Exclusive Captain Chair Emission standard IFL5 Type code SEB XFWF/IF EA XFWF/IF Engine type Cubic capacity (cc) 2946 Fiscal rating (hp) Gearbox type 4 HP 20 Gearbox ident. plate 20 HZ 27...
  • Page 15 IDENTIFICATION OF VEHICLES Diesel 2.0 HDi (**) 2.0 HDi (*) Manual Automatic Manual Automatic X – SX – Exclusive X – SX – Exclusive Captain Chair Captain Chair Emission standard Type code EB RHTB EB RHTE EA RHTE EB RHWB EB RHWE EA RHWE Engine type...
  • Page 16 IDENTIFICATION OF VEHICLES Diesel 2.2 HDi (*) Manual Captain Chair Captain Chair Exclusive Captain Chair Emission standard Type code EB 4HWB EA 4HWB Engine type Cubic capacity (cc) 2179 Fiscal rating (hp) Gearbox type ML5C Gearbox ident. plate 20 LM 01 (*) = FAP (Particle filter).
  • Page 17 ALL TYPES CAPACITIES (in litres) Draining method. The oil capacities are defined according to the following methods. 1) - Vehicle on level surface (in high position, if equipped with hydropneumatic suspension). 2) - Engine warm (oil temperature 80°C). 3) - Draining of the oil sump + removal of the cartridge (duration of draining + dripping = 15 min). 4) - Refit plug + cartridge.
  • Page 18 CAPACITIES (in litres) Petrol 1.8i 16V 2.0i 16V 2.0 HPi 3.0i V6 Auto. Auto. Auto. Engine type Engine with filter change 4.25 5.25 Between Min. and Max. 5-speed gearbox Automatic gearbox After oil change Braking circuit Hydraulic circuit 8.8 – 9.3 (*) Cooling system Fuel tank capacity (*) = With automatic gearbox...
  • Page 19 CAPACITIES (in litres) Diesel 2.0 HDi 2.2 HDi Auto. Auto. Auto. Engine type Engine with filter change 4.75 Between Min. and Max. 5-speed gearbox Automatic gearbox 8.3 - 6 (1) 8.3 - 6 (1) After oil change 5.3 – 3 (1) 5.3 –...
  • Page 20 CAPACITIES (in litres) Petrol Diesel 2.0i 16V 2.2i 16V 3.0i 24S 2.0 HDi 2.2 HDi Auto. Auto. Auto. Engine type RHT - RHW Engine angle Engine with filter change 4.25 5.25 4.75 Between Min. and Max. 5-speed gearbox Automatic gearbox After oil change Hydraulic or brake circuit 0.66...

  • Page 21: Total Activa

    ALL TYPES LUBRICANTS - TOTAL recommended oils Evolutions (year 2003). Use of oil grade 10W 40. It is possible to use semi-synthetic oil 7000 10W40 on HDi and HDi CITROËN C3 PLURIEL. FAP vehicles. Only petrol versions are available. WARNING : To avoid problems with starting from cold, use this oil as allowed by the climatic conditions in the country concerned (see Normal maintenance interval : 30 000 km (20 000 miles) table).
  • Page 22 ALL TYPES LUBRICANTS - TOTAL recommended oils Engine oil norms. Current norms. The classification of these engine oils is established by the following recognised organisations : : Society of Automotive Engineers. - S.A.E - API : American Petroleum Institute. - ACEA : Association des Constructeurs Européens d’Automobiles E4AP006D...
  • Page 23 ALL TYPES LUBRICANTS - TOTAL recommended oils S.A.E. Norms - Table for selection of engine oil grade Selection of engine oil grades recommended for climatic conditions in countries of distribution Evolution of the norms as at 01/01/2003 ACEA 2003 norms API norms The meaning of the first letter has not changed, it still corresponds to the type of engine :...

  • Page 24: Total Quartz

    LUBRIFIANTS - PRECONISATIONS DE LA GAMME TOTAL Recommendations. ESSENTIAL : To preserve engine performances, all engines fitted in CITROEN vehicles must be lubricated with high quality oils (synthetic or semi-synthetic). CITROËN engines are lubricated at the factory with TOTAL oil of grade S.A.E.5W-30.
  • Page 25 ALL TYPES LUBRICANTS - TOTAL recommended oils Recapitulation Norms to be observed for engine oils (year 2003) Year Types of engine concerned ACEA norms API norms Petrol and dual fuel petrol / A3 or A5 5 (*) SJ or SL LPG engines 2003 Diesel engines...

  • Page 26: Table Of Contents

    LUBRICANTS - TOTAL recommended oils ALL TYPES S.A.E. norms ACEA norms API norms Oils specifically for petrol and dual fuel petrol / LPG engines TOTAL ACTIVA 7000 10W-40 TOTAL QUARTZ 7000 TOTAL QUARTZ 9000 0W-40 TOTAL ACTIVA 7000 15W-50 TOTAL QUARTZ 7000 Oils specifically for diesel engines TOTAL ACTIVA DIESEL 7000 10W-40...
  • Page 27 ALL TYPES LUBRICANTS - TOTAL recommended oils Oil usage table TOTAL ACTIVA QUARTZ Engine types Synthetic 9000 Semi-synthetic 7000 0W40 15W50 5W30 5W40 10W40 cold countries hot countries XU10 J4RS (Xsara VTS 2.0i 16V) Petrol engines EW 12 J4 (C8 2.2i 16V) Other petrol engines HDi engines with FAP (*) Other HDi engines...
  • Page 28 LUBRICANTS - TOTAL recommended oils ALL TYPES Selection of TOTAL engine oils, to be used according to the climatic conditions in the country where the vehicle is marketed. E4AP006D...

  • Page 29: Total Activa Diesel

    ALL TYPES LUBRICANTS - TOTAL recommended oils ENGINE OILS FRANCE Blended oils for all engines, supplied in bulk Metropolitan FRANCE TOTAL ACTIVRAC S.A.E. norms : 10W40 TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines...
  • Page 30 LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 7000 10W40 Germany 9000 0W40 Austria 7000 10W40 7000 10W40...
  • Page 31 ALL TYPES LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 7000 10W40 Denmark 9000 0W40 7000 10W40 Spain 7000 15W40...
  • Page 32 LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 7000 10W40 Hungary 9000 0W40 Italy Ireland 7000 10W40...
  • Page 33 ALL TYPES LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 7000 10W40 Malta 7000 15W50 Moldavia 7000 10W40 7000 10W40...
  • Page 34 LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 7000 10W40 Romania 7000 15W50 9000 0W40 Russia 7000 10W40...
  • Page 35 ALL TYPES LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for petrol and Oils specifically for diesel Blended oils for all engines dual-fuel petrol / LPG engines engines Ukraine 9000 5W40 7000 10W-40 7000 10W-40 FUTURE 9000 5W30 (*) 9000 0W-40...
  • Page 36 LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS OCEANIA TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for petrol and Oils specifically for diesel Blended oils for all engines dual-fuel petrol / LPG engines engines 9000 5W40 Australia 7000 10W-40 7000 10W-40 FUTURE 9000 5W30 (*) New Zealand...
  • Page 37 ALL TYPES LUBRICANTS - TOTAL recommended oils ENGINE OILS CENTRAL AND SOUTH AMERICA TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for petrol and Oils specifically for diesel Blended oils for all engines dual-fuel petrol / LPG engines engines Argentina Brazil Chile 7000 10W-40 9000 5W40...
  • Page 38 LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS SOUTH-EAST ASIA TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 7000 10W50 China 7000 15W50 9000 5W40 South Korea 7000 10W40...
  • Page 39 ALL TYPES LUBRICANTS - TOTAL recommended oils ENGINE OILS SOUTH-EAST ASIA TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for petrol and Oils specifically for diesel Blended oils for all engines dual-fuel petrol / LPG engines engines Philippines 7000 15W-50 Singapore 7000 10W-40 7000 10W-40 9000 5W40...
  • Page 40 LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS MIDDLE EAST TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for petrol and Oils specifically for diesel Blended oils for all engines dual-fuel petrol / LPG engines engines Saudi Arabia – Bahrain 7000 15W-50 Dubai United Arab Emirates...
  • Page 41 ALL TYPES LUBRICANTS - TOTAL recommended oils GEARBOX OILS TOTAL TRANSMISSION BV Manual gearbox and SensoDrive Norms S.A.E. : 75W80 Part No. : 9730 A2. TOTAL FLUIDE ATX TOTAL FLUIDE AT 42 MB3 automatic gearbox Special oil distributed by All countries CITROËN Part No.
  • Page 42 LUBRICANTS - TOTAL recommended oils ALL TYPES POWER STEERING OILS TOTAL FLUIDE ATX All countries TOTAL FLUIDE DAS Power steering Special oil distributed by Very cold countries CITROËN Part No. : 9730 A1 ENGINE COOLANT FLUID CITROËN Part No. Pack GLYSANTIN G33 REVKOGEL 2000 2 Litres...
  • Page 43 1 Litre Green TOTAL LHM PLUS 9979 20 Very cold countries WARNING : TOTAL FLUIDE LDS fluid cannot be blended with TOTAL LHM LDS WARNING : CITROËN C5 : Use exclusively TOTAL FLUIDE LDS suspension fluid. All countries TOTAL HYDRAURINCAGE...
  • Page 44 LUBRICANTS - TOTAL recommended oils ALL TYPES SCREEN WASH FLUID Pack CITROËN Part No. Concentrated : 250 ml 9980 33 9980 56 ZC 9875 953U 9980 06 1 Litre ZC 9875 784U All countries Fluid ready for use 5 Litres 9980 05 ZC 9885 077U ZC 9875 279U...
  • Page 45 ALL TYPES 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.
  • Page 46 ENGINE SPECIFICATIONS C5 - C8 Engines : 6FZ - RFN - RLZ - 3FZ - XFX - XFW Petrol 1.8i 16V 2.0i 16V 2.0 Hpi 2.2i 16V 3.0i 24S Engine type Cubic capacity (cc) 1749 1997 2230 2946 Bore / Stroke 82.7/81.4...
  • Page 47 C5 - C8 ENGINE SPECIFICATIONS Engines : RHS - RHZ - RHT - RHW - RHY - RHW - 4HX - 4HW Diesel 2.0 HDi 2.0 HDi 16V 2.2 HDi Engine type 1997 2179 Cubic capacity (cc) Bore / Stroke...
  • Page 48 COMPRESSION RATIO - DIESEL ENGINES COMPRESSION MAX. DIFFERENCE ENGINE RATIO BETWEEN CYLINDERS In bars 30 ± 5 DW10 20 ± 5 DW12...

  • Page 49: Pre-Tightening

    SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engines : 6FZ - RFN - RLZ - RHY - RHS - RHZ - 4HX Crankshaft Petrol Diesel Bearing cap screws. - Pre-tightening 2 ± 0.1 2.5 ± 0.2 - Angular tightening 60° ± 6° 60°...

  • Page 50: Tighten

    SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engines : 6FZ - RFN - RLZ - RHY - RHS - RHZ - 4HX Cylinder block Petrol Diesel Piston skirt spray jet 1 ± 0.1 Sump - Pre-tightening - Tightening 0.8 ± 0.2 1.6 ±...
  • Page 51 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engines : 6FZ - RFN - RLZ - RHY - RHS - RHZ - 4HX Cylinder head Petrol Diesel Camshaft bearing cover - Tightening 1 ± 0.1 - Pre-tightening 0.5 ± 0.1 0.5 (Ø6) - Tightening 0.9 ±...
  • Page 52 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engines : 6FZ - RFN - RLZ - RHY - RHS - RHZ - 4HX Lubrication circuit Petrol Diesel Oil pump - Pre-tightening - Tightening 0.9 ± 0.1 1.3 ± 0.1 0.9 ± 0.1 Coolant / oil heat exhanger 5.8 ±...
  • Page 53 CYLINDER HEAD Engines : 6FZ - RFN - RLZ Cylinder head gasket identification Nominal dimension Repair dimension RFN - RLZ Marking zone 4 - 5 2-4-5 "d" Marking zone "e" Gasket thickness (mm) Supplier MEILLOR (d) Marking zone. (e) Marking zone. Multilayer metallic cylinder head gasket.
  • Page 54 CYLINDER HEAD Engines : 6FZ - RFN - RLZ Cylinder head tightening (m.daN) Cylinder head bolts 6FZ - RFN - RLZ Pre-tightening 1.5 ± 0.1 Tightening 5 ± 0.1 Slackening 360°± 2° Tightening 2 ± 0.2 Angular tightening 285° ± 5° (in the order 1 to 10) B1DP16FC A = Washer thickness : 4 ±...
  • Page 55 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engines : RFN - 3FZ Crankshaft bearing cap cover (15) Description Pre-tightening 1 ± 0.1 Slackening Re-tightening 1 ± 0.1 puis 2 ± 0.2 1 ± 0.1 Angular tightening 70° ± 5° Crankshaft (17) Flywheel/ Description (16) Con-rod caps crankshaft fixing...
  • Page 56 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Equipment on cylinder head Engine : RFN Engine : 3FZ B1BK1X9D B1BK1XAD Description (18) Camshaft bearing cap covers (19) Valve covers Pre-tightening Tightening 1 ± 0.1 1.5 ± 0.1 Description (20) Inlet manifold (21) Exhaust manifold Tightening 1 ±...
  • Page 57 SPECIAL FEATURES: POWER UNIT SUSPENSION Upper RH engine support Engines : RFN – 3FZ Description Ref. Gearbox type BE4/5 ML5C Rod/body fixing screw. 5 ± 0.5 Engine support/torque reaction rod 4.5 ± 0.4 flexible stop pin Upper support/intermediate support 6.5 ± 0.6 fixing screw.
  • Page 58 SPECIAL FEATURES: POWER UNIT SUSPENSION Intermediate engine support Engines : RFN – 3FZ Description Ref. Gearbox type BE4/5 ML5C (12) 9 ± 0.9 Lower RH rod/subframe fixing screw. Lower RH engine support/cylinder (13) 4.5 ± 0.4 block fixing screw. Lower rod/lower RH engine support (14) 6.5 ±...
  • Page 59 CYLINDER HEAD Engines : RFN - 3FZ Cylinder head gasket identification Multi-layer metallic gasket. Cylinder head gasket thickness (mm) Ref. E – H = 0.8 E – G = 0.8 (1B) : Nominal dimension E – F – H = 0.99 E –...
  • Page 60 CYLINDER HEAD Engines : RFN - 3FZ Cylinder head tightening (m.daN) Cylinder head bolts B1DK001C B1DB002C Tighten in the order indicated X = MAX. re-usable length 1/ : 1.5 Pre-tightening 2/ : 5 144.5 mm 127.5 mm Slackening 360° Tightening Angular 285°...
  • Page 61 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFZ (1) Compact coil unit 1 ± 0.1 (9) Flywheel - Tightening - Angular tightening 60°± 6° (11) Connecting rod caps - Tightening 2 ± - Angular tightening 74° ± 7 (12) Crankshaft hub - Tightening 4 ±...
  • Page 62 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFZ - 2 Cylinder head cover (A) Front cyl. head - (B) Rear cyl. head - 3 Bearing caps housing (A) Front cyl. head - (B) Rear cyl. head B1DP08UD B1DP08TD WARNING : Tighten screw by screw in the order shown. - Pre-tighten - Pre-tighten - Tighten...
  • Page 63 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFZ - 5 Air inlet manifold - 6 Lower manifold (A) Front cyl. head - (B) Rear cyl. head B1HPOLJC B1DP097C WARNING : Tighten screw by screw in the order shown. - Pre-tighten 1 ±...
  • Page 64 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFZ -7 Exhaust manifold (NEW gasket) -10 Oil sump B1BP1GXD B1BP1GZD WARNING : Tighten screw by screw in the order shown. - Pre-tighten 1 ± 0.1 - Pre-tighten 0.5 ± - Tighten 3 ±...
  • Page 65 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFZ - 8 Crankshaft bearing - Clean the threads of the screws with a brush. - Refit the screws with a coating of grease ( MOLYKOTE G RAPID PLUS ). - Check that the 8 centring pins are in place Maximum length under the heads of the screws : - M11 = 131.5 mm.
  • Page 66 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFZ (14) Coolant pump - Pre-tighten - Tighten (15) Oil pump - Pre-tighten - Tighten (16) Guide roller 8 ± 0.8 (17) Tensioner roller 8 ± 0.8 (18) Camshaft hubs - Pre-tighten 2 ±...
  • Page 67 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFZ - 20 Oil vapour recovery housing. WARNING : Tighten screw by screw in the order shown - Pre-tighten 0.5 ± - Tighten 1 ± 0.1 B1BP1H1D...
  • Page 68 CYLINDER HEAD Engine : XFZ Cylinder head gasket identification Thickness Supplier Thickness reference (Standard) (mm) Central lug ERLING 0.75 Exhaust end (1) LH cylinder head gasket. Multilayer metallic cylinder head seal. (2) RH cylinder head gasket. B1DP18YD...

  • Page 69: Pre-Tightening 2 ± 0.2

    CYLINDER HEAD Engine : XFX Cylinder head tightening (m.daN) Cylinder head bolts In the order indicated. - Pre-tightening 2 ± 0.2 - Slackening - Pre-tightening 1.5 ± 0.2 - Angular tightening 225° Note : Oil the threads and under the heads of the bolts.
  • Page 70 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFW Power unit suspension RH engine support (Suspension) Gearbox suspension B1BK24RD B1BK24SD (2) Link rod fixing : 5 ± 0.5 (8) Fixing of gearbox support on LH flexible mounting : 6.5 ± 0.6 (3) Link rod fixing : 4.5 ±...
  • Page 71 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFW Power unit suspension – Engine support (Lower) Crankshaft B1BK24TD B1BK24UD (17) Bearing cap Tightening : 2 ± 0.2 (13) Torque reaction link rod fixing : 9 ± 0.9 + Angular tightening : 74°...
  • Page 72 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFW Cylinder block Bearing cap cover Respect the sequence of stages and the order of tightening Reference/description Bolts from 1 Bolts from 9 to 8 to 16 (21) Fixings of bearings/cap covers or Stage 1 Stage 2 Stage 3...
  • Page 73 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFW Lubrication circuit. Lubrication circuit. Oil sump B1BK24WD B1BK24XD Respect the sequence of stages and the order of tightening (22) Oil separator : 0.8 Stage 1 : Do up bolts 13,15 and 17. (23) Strainer : 0.8 Stage 2 : Tighten bolts 13,15 and 17 to...
  • Page 74 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFW Lubrication circuit Cooling circuit Oil pump Coolant pump B1BK3B6D B1BK3B7D Respect the sequence of stages and the order of tightening Stage 1 : Position the screws and do them up by hand. Stage 1 : Position the screws and do them up by hand.
  • Page 75 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFW Lubrication circuit Cylinder head equipment Coolant manifold B1BK24YD (27) Screws : 2.5 ± 0.2 (28) Screws : 0.8 (29) Screws : 0.8 B1BK24ZD...
  • Page 76 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFW Cylinder head equipment Camshaft bearing cap cover (right hand side) Camshaft bearing cap cover (left hand side) B1EK0GCC B1BK3B8D Respect the sequence of stages and the order of tightening (30) Camshaft bearing cap cover or camshaft bearing: Pre-tighten to : 0.2 Tighten to...
  • Page 77 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFW Cylinder head equipment Valve covers (right hand side) Valve covers (left hand side) B1EK0GEC B1EK0GFC Respect the sequence of stages and the order of tightening (31) Valve cover : Pre-tighten to : 0.5 Tighten to : 0.8...
  • Page 78 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFW Cylinder head equipment Inlet manifold B1BK251D Respect the sequence of stages and the order of tightening (32) Inlet manifold: Pre-tighten to : 0.4 Tighten to : 0.8...
  • Page 79 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFW Cylinder head equipment Exhaust manifold (right hand side) Exhaust manifold (left hand side) B1JK03ND B1JK03LD Respect the sequence of stages and the order of tightening (33) Exhaust manifold: Pre-tighten to Tighten to : 3 ±...
  • Page 80 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFW Cylinder head equipment Inlet distributor B1BK252D Respect the sequence of stages and the order of tightening (34) Inlet distributor: Pre-tighten to : 0.4 Tighten to : 0.8...
  • Page 81 CYLINDER HEAD Engine : XFW Cylinder head gasket identification The RH and LH cylinder head gaskets are specific, of multilayer metallic type. B1DK0QKD B1DK0QLD Cylinder head gasket thicknesses (1A) : Engine ref : G-H (a) : RH cylinder head gasket. (1B) : Nominal dimension : Without marking = 0.75 mm (b) : LH cylinder head gasket.
  • Page 82 CYLINDER HEAD Engine : XFW Cylinder head tightening (m.daN) Cylinder head bolts Pre-tightening Slackening : YES Tightening : 1.5 Angular tightening : 225° NOTE : Grease the bolts on the threads and under the heads, using engine oil or Molykote G plus).
  • Page 83 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFZ - 7 Exhaust manifold (NEW gasket) - 10 Oil sump B1BP1GXD B1BP1GZD WARNING : Tighten screw by screw in the order indicated. - Pre-tighten 1 ± 0.1 - Pre-tighten 0.5 ± - Tighten 3 ±...
  • Page 84 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : RHY Tightening torques 4.5 ± 0.5 5 ± 0.5 5 ± 0.5 2.7 ± 0.3 6.5 ± 0.6 4.5 ± 0.5 2.1 ± 0.2 4.5 ± 0.5 6.1 ± 0.6 (10) 4.5 ± 0.5 (11) 5 ±...
  • Page 85 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engines : RHS - RHZ Tightening torques (13) 4.5 ± 0.5 (14) 5 ± 0.5 (15) 5 ± 0.5 (16) 2.7 ± 0.3 (17) 4.5 ± 0.5 (18) 2.1 ± 0.2 (19) 4.5 ± 0.5 (20) 6.1 ±...
  • Page 86 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engines : RHS - RHZ Crankshaft Flywheel – Clutch Bearing cap fixing screws Flywheel 4,8 ± 0,5 Pre-tightening 2,5 ± 0,2 Clutch plate 2 ± 0,2 Angular tightening 60° Lubrication circuit Con rod nuts Oil pump 1,3 ±...
  • Page 87 CYLINDER HEAD Engines : RHY - RHS - RHZ Cylinder head gasket identification Piston Engine Thickness Number stand-proud plate (mm) of notches at A (mm) 0.47 to 0.605 1.30 ± 0.06 0.605 to 0.655 1.35 ± 0.06 0.655 to 0.705 1.40 ±...
  • Page 88 CYLINDER HEAD Engines : RHY - RHS - RHZ Cylinder head gasket identification Cylinder head tightening (m.daN) Cylinder head bolts RHY - RHS - RHZ RHY - RHS - RHZ - Pre-tightening 2 ± 0.2 - Tightening 6 ± 0.6 - Angular tightening 220°±...
  • Page 89 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : 4HX Tightening torques 4.5 ± 0.5 5 ± 0.5 5 ± 0.5 2.7 ± 0.3 4.5 ± 0.5 2.1 ± 0.2 4.5 ± 0.5 6.1 ± 0.6 4.5 ± 0.5 (10) 5 ± 0.5 (11) 5 ±...
  • Page 90 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : 4HX Crankshaft Cylinder block (continued) Bearing cap fixing screws RH engine support Pre-tighten 2,5 ± 0,2 Pre-tighten (the four screws to) Angular-tighten 60° Tighten (the screws Ø 8 to) 2 ± 0,2 Rod cap screws Tighten (the screws Ø...
  • Page 91 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : 4HX Flywheel – Clutch Diesel.injection.circuit Flywheel Diesel injector (do up by hand) Pre-tighten Tighten 0,4 ± 0,04 Tighten 4,7 ± 0,4 Angular-tighten 45° ± 5° Clutch plate 2 ± 0,2 Union on injection rail 2 ±...
  • Page 92 CYLINDER HEAD Engine : 4HX Cylinder head gasket identification Number of notches Piston Engine Thickness stand-proud plate (mm) (mm) 0.55 to 0.60 1.25 ± 0.04 0.61 to 0.65 1.30 ± 0.04 0.66 to 0.70 1.35 ± 0.04 0.71 to 0.75 1.40 ±...

  • Page 93: Pre-Tighten 2 ±

    CYLINDER HEAD (Continued) Engine : 4HX Cylinder head tightening (m.daN) Cylinder head bolts ESSENTIAL : Proceed screw by screw in the order indicated. - Pre-tighten 2 ± 0.2 (Order 1 to 10). - Tighten 6 ± 0.6 (Order 1 to 10). - Destighten 360°...
  • Page 94 CYLINDER HEAD Engines : RHT - RHW - 4HW Cylinder head gasket identification Piston Hole at F Thickness Hole at stand-proud (mm) (mm) 0.55 to 0.60 1.25 ± 0.04 0.61 to 0.65 1.30 ± 0.04 0.66 to 0.70 1.35 ± 0.04 0.71 to 0.75 1.40 ±...
  • Page 95 CYLINDER HEAD Engines : RHT - RHW - 4HW Tighten cylinder head (m.daN) Cylinder head bolts Tighten in the order indicated Pre-tighten : Slacken : 360° Tighten : Angular-tighten : 220° NOTE : Oil the threads and under the heads of the bolts.
  • Page 96 BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE C5 - C8 Tools 4099-T (C.TRONIC.105) 4122-T (C.TRONIC.105.5) B1EP135D...
  • Page 97 C5 - C8 AUXILIARY EQUIPMENT DRIVE BELT ATED ATED4 TED4 Engine type 106 to See pages : 100 to 103 108 to See pages : 104 to 105...
  • Page 98 AUXILIARY EQUIPMENT DRIVE BELT C5 - C8 Engines: all types Petrol and Diesel TOOLS - Belt tension measuring instrument : 4122 - T. (C.TRONIC 105.5) WARNING : If using tool 4099-T (C.TRONIC 105), refer to the correspondence table on page 93.
  • Page 99 AUXILIARY EQUIPMENT DRIVE BELT Engines : 6FZ - RFN - RLZ Without aircon With aircon Tools [1] Pliers for removing plastic pegs 7504-T Remove the belt. - Detension the belt (3) by turning the tensioner roller (1), by the screw (2) (anti-clockwise).
  • Page 100 AUXILIARY EQUIPMENT DRIVE BELT Engines : RFN-3FZ Tools [1] Peg for dynamic tensioner roller (-).0189-E Removing. Remove: The front RH wheel. The front RH splash-shield. BXXK08DD Detension the auxiliary drive belt by actioning the screw (1). Peg the dynamic tensioner roller (2), using tool [1]. Remove the auxiliary drive belt.
  • Page 101 AUXILIARY EQUIPMENT DRIVE BELT Engine : XFX Tools [1] Ratchet spanner S.171 FACOM (1/2 square) S 171. [2] Reduction box S.230 FACOM (1/2-3/8) S 230. Remove. Remove the engine cover. Pivot the tensioner roller bracket (1) clockwise, until it locks, using tools [1] and [2] at «a».
  • Page 102 AUXILIARY EQUIPMENT DRIVE BELT Engine : XFW Tools [1] Ratchet spanner FACOM (1/2" square). [2] Reduction box FACOM S.230 (1/2" - 3/8" square). Removing. Move aside the power steering oil low pressure pipe flange. Pivot the support (1) of the tensioner roller clockwise, as far as it will go, using tools [1] and [2]. B1EK0VAD Remove the auxiliary drive belt.
  • Page 103 AUXILIARY EQUIPMENT DRIVE BELT Engines : RHY - RHS - 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 Remove Re-use of belt...
  • Page 104 AUXILIARY EQUIPMENT DRIVE BELT Engines : RHY - RHS - RHZ Without air conditioning (continued) Refit. Re-used belt. - Compress the tensioner roller (2) by action at « a » (anti-clockwise), tool [4]. - Refit the belt. WARNING : Respect the direction in which the belt is fitted. Remove the tool [4].
  • Page 105 AUXILIARY EQUIPMENT DRIVE BELT Engines : RHY - RHS - RHZ With air conditioning Outillages [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 Remove Re-use of belt...
  • Page 106 AUXILIARY EQUIPMENT DRIVE BELT Engines : RHY - RHS - RHZ With air conditioning (continued) Refit. 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 in which the belt is fitted. Remove the tool [4].
  • Page 107 AUXILIARY EQUIPMENT DRIVE BELT Engines : RHT - RHW Tools. [1] Tensioning lever : (-).0188-J2. [2] Peg for dynamic roller Ø 4 mm : (-) 0188-Q1. [3] Peg for dynamic roller Ø 2 mm : (-).0188-Q2. [4] Dynamic roller compression lever : (-).1888-Z.
  • Page 108 AUXILIARY EQUIPMENT DRIVE BELT Engine : RHT - RHW Removing (continued). Slacken the fixing (2). Action the roller (3), using tool [1], until the tool [2] is positioned in the pegging hole (A). Bring the roller (3) back towards the rear. Gently tighten the screw (2).
  • Page 109 AUXILIARY EQUIPMENT DRIVE BELT Engine : 4HX Without air conditioning Tools [1] Dynamic tensioner compression lever : (-).0188.Z [2] Peg Ø 4 mm : (-).0188.Q1 Remove. WARNING : mark the direction of fitting in case the belt is to be reused - Compress the tensioner roller (1) by action at «a»...
  • Page 110 AUXILIARY EQUIPMENT DRIVE BELT Engine : 4HX With air conditioning Tools [1] Dynamic tensioner compression lever : (-).0188.Z [2] Peg Ø 4 mm : (-).0188.Q1 Remove. WARNING : mark the direction of fitting in case the belt is to be reused. - Compress the tensioner roller (4) by action at «c»...
  • Page 111 AUXILIARY EQUIPMENT DRIVE BELT Engine : 4HW Tools. [1] Peg for dynamic roller : (-) 0188-Q1 [2] Dynamic roller compression lever : (-).1888-Z. (A) Pegging hole. (B) Belt wear check mark (fixed on engine). (C) Zero wear mark. (D) Maximum wear mark. E5AK0EDC B3EK09PC This marking system permits checking of the belt wear;...
  • Page 112 AUXILIARY EQUIPMENT DRIVE BELT Engine : 4HW Removing (continued). Action the roller (3), using tool [2], until the tool [1] is positioned in the pegging hole (A). Remove the belt. ESSENTIAL : Check that the rollers (3) and (4) turn freely (no play, no tight spot). Refitting.
  • Page 113 C5 - C8 CHECKING AND SETTING THE VALVE TIMING ATED ATED4 TED4 Engine type 2003 N° RPO 9128 111 to 114 136 to 141 150 to 154 164 to 169 See pages : 2003 N° RPO 9128 129 to 135...
  • Page 114 CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN - RLZ 2003 Tools [1] Camshaft setting pegs : (-).0189.A [2] Crankshaft setting peg : (-).0189.B Toolkit C.0189. [3] Belt retaining pin : (-).0189.K [4] Adaptor for angular tightening : 4069-T [5] Hub immobilising tool : 6310-T...
  • Page 115 CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN - RLZ 2003 Refit - Refit the belt (10) on the pinion (12). - Hold the belt (10) with tool [3]. - Position the belt (10) in the following order : - The guide roller (11), the inlet camshaft pinion (9), the exhaust camshaft pinion (8), the water pump (5), the ten- sioner roller (6).
  • Page 116 CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN - RLZ 2003 Adjusting the tension (continued). -Tighten the screw (7) of the the tensioner roller (6) to 2.1 ± 0.2 m.daN. IMPERATIVE : The hexagonal drive of the tensioner roller (6) must be at 15° below the level of the cylinder head gasket «g».
  • Page 117 CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN - RLZ 2003 Checks (continued) Repositioning the flange. - Immobilise the crankshaft using tool [5]. - Loosen the screw (13). - Release the pinion (12) of the crankshaft. - Bring the flange (14) to the pegging position; using tool [5]. - Fit the tool [2].
  • Page 118 CHECKING AND SETTING THE VALVE TIMING Engine : RFN 2003 Tools. [1] Crankshaft setting peg : (-).0189-B [2] Camshaft hub setting pegs : (-).0189-AZ [3] Belt retaining pin : (-).0189-K [4] Positioning peg : (-).0189-J [5] Tool for immobilising hub : (-).6310-T Removing.
  • Page 119 CHECKING AND SETTING THE VALVE TIMING Engine : RFN 2003 Removing (continued). Peg : - The camshafts, using tool [2]. - The crankshaft, using tool [1]. Slacken the screw (7) while holding tool [4]. Using the hexagonal recess (C), turn the eccentric hub (8) of the tensioner roller (9) (clockwise), to detension the belt.
  • Page 120 CHECKING AND SETTING THE VALVE TIMING Engine : RFN 2003 Refitting. Systematically replace the timing belt. IMPERATIVE : Check that the rollers (9) and (11), as well as the coolant pump (12) turn freely (no tight spot). When replacing the belt (11), tighten the fixing to 3,5 ± 0,3 m.daN. Position the belt on the crankshaft pinion (13), respecting its direction of fitting.
  • Page 121 CHECKING AND SETTING THE VALVE TIMING Engine : RFN 2003 Tensioning the timing belt. Remove tool [3]. (D) : Max. position. (E) : Nominal tension position. Using the hexagonal recess (C), turn the roller hub (anti-clockwise), to bring the index (10) to position (D) to tension the belt to the maximum.
  • Page 122 CHECKING AND SETTING THE VALVE TIMING Engine : RFN 2003 Positioning the crankshaft. NOTE : This operation positions all the pegs in their respective pegging points. Peg: - The camshaft pulleys, using tool [2]. - The crankshaft, using tool [1]. If this is not possible, reposition the flange (17).
  • Page 123 CHECKING AND SETTING THE VALVE TIMING Engine : RFN 2003 Refitting (continued). Refit: - The timing cover (6). - The auxiliary drive pulley. - The screws (4), tighten to 2,1 ± 0,2 m.daN. B1EK0V7D - The timing cover (5). - The torque reaction rod (3). - The screws (1) and (2), tighten to 4,5 ±...
  • Page 124 CHECKING AND SETTING THE VALVE TIMING Engine : 3FZ 2003 Tools. [1] Crankshaft setting peg : (-).0189-B [2] Exhaust camshaft setting peg : (-).0189-AZ [3] Inlet camshaft setting peg : (-).0189-L [4] Positioning peg : (-).0189-J B1EK0V1D [5] Tool for immobilising hub : 6310-T [6] Belt retaining pin : (-).0189.K...
  • Page 125 CHECKING AND SETTING THE VALVE TIMING Engine : 3FZ 2003 Remove: - The screws (1) and (2). - The torque reaction rod (3). - The nut (4). - The 3 screws (5). - The RH engine support (6). - The screws (7), plus the auxiliary drive pulley. - The timing covers (8) and (9).
  • Page 126 CHECKING AND SETTING THE VALVE TIMING Engine : 3FZ 2003 Position tool [4]. Slacken the screw (10) while holding tool [4]. Using the hexagonal recess (D), turn the eccentric hub (11) of the tensioner roller (12) (clockwise), to detension the belt.
  • Page 127 CHECKING AND SETTING THE VALVE TIMING Engine : 3FZ 2003 Tensioning the timing belt. Remove tool [6]. (E) : Max. position. (F) : Nominal tension position. Using the hexagonal recess (D), turn the roller hub (anti-clockwise), to bring the index (13) to position (E) to tension the belt to the maximum.
  • Page 128 CHECKING AND SETTING THE VALVE TIMING Engine : 3FZ 2003 Positioning the crankshaft. NOTE : This operation positions all the pegs in their respective pegging points. Peg: - The inlet camshaft pulley, using tool [3]. - The crankshaft, using tool [1]. If this is not possible, reposition the flange (20).
  • Page 129 CHECKING AND SETTING THE VALVE TIMING Engine : 3FZ 2003 Refitting (continued). Refit: - The timing cover (9). - The auxiliary drive pulley. - The screws (7), tighten to 2,1 ± 0,2 m.daN. - The timing cover (8). B1EK1STD - The RH engine support (6). - The torque reaction rod (3).
  • Page 130 ALL TYPES CHECKING AND SETTING THE VALVE TIMING OLD FITTING 2003 Engine : 6FZ - RFN - RLZ - 3FZ 2003 (1) Crankshaft pinion. (2) Flange. (3) Accessories drive pulley. (4) Screw for fixing accessories drive pulley on the flange (2). (5) Screw for fixing the flange (2) on the crankshaft.
  • Page 131 ALL TYPES CHECKING AND SETTING THE VALVE TIMING NEW FITTING 2003 Engine : 6FZ - RFN - RLZ - 3FZ 2003 (6) Crankshaft pinion. (7) Accessories drive pulley. (8) Washer. (9) Screw. The pinion (6) is fitted as an idler on the crankshaft. The accessories drive pulley (7) is immobilised on the crankshaft by a half-moon keyway and by the tightening of the shouldering of the washer (8) with the screw (9).
  • Page 132 ALL TYPES CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN - RLZ - 3FZ 2003 Tools. [1] Camshaft setting peg : (-).0189.A [2] Crankshaft setting peg : (-).0189.R [3] Belt retaining pin : (-).0189.K [4] Adaptor for angular tightening : 4069-T [5] Tool for manœuvring and locking the tensioner roller : (-).0189.S...
  • Page 133 ALL TYPES CHECKING AND SETTING THE VALVE TIMING Engine : 6FZ - RFN - RLZ - 3FZ 2003 Checking the setting of the timing (continued). Rotate the engine using the crankshaft pinion screw to bring it to the pegging position.. Peg the crankshaft, using tool [2].
  • Page 134 ALL TYPES CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN - RLZ - 3FZ 2003 Setting the timing. Removing. Disconnect the battery negative terminal (See corresponding operation). Raise and support the vehicle, front wheels hanging. Remove: The front RH wheel. The plastic pins (1) The splash-shield (2) The accessories drive belt (See corresponding operation).
  • Page 135 ALL TYPES CHECKING AND SETTING THE VALVE TIMING Engine : 6FZ - RFN - RLZ - 3FZ 2003 Setting the timing (continued) Peg: The crankshaft, using tool [2] The camshaft pulleys (5) and (6), using tool [1] Remove: B1EP1B9D The screw (3) of the crankshaft pulley (2). The lower timing cover (4) (by moving the engine).
  • Page 136 ALL TYPES CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN - RLZ - 3FZ 2003 Setting the timing (continued) Turn the tensioner roller (8), using tool [5a] to go past the notch (b). Position tool [5b] to lock the index (a) and remove tool [5a]. Reposition the timing belt (7) on the crankshaft pulley.
  • Page 137 ALL TYPES CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN - RLZ - 3FZ 2003 Tensioning the timing belt. Turn the tensioner roller (8) in the direction of the arrow « c », by means of a hexagonal spanner at « d ». Positionner l’index «...
  • Page 138 ALL TYPES CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN - RLZ - 3FZ 2003 Refitting (continued) Remove the tools [1] and [2]. Rotate the crankshaft ten times (normal direction of rotation). IMPERATIVE : No pressure or outside force should be brought to bear on the timing belt. Peg the inlet camshaft pulley, using tool [1].
  • Page 139 CHECKING AND SETTING THE VALVE TIMING Engine : XFX OUTILLAGES [1] Camshaft setting pegs (-).0187.B [2] Crankshaft setting peg (-).0187.A. [3] Fuel pressure take-off union 4192-T [4] Belt retaining pin (-).0187.J [5] Exhaust camshaft hubs immobilising tool (-).0187.F. [6] Inlet camshaft hubs immobilising tool (-).0187.F Remove the auxiliaries drive belt (See corresponding operation).
  • Page 140 CHECKING AND SETTING THE VALVE TIMING Engine : XFX Checking the valve timing setting (continued). - Peg the crankshaft, using tool [1]. - Check that the tool [2] engages without effort in the cylinder heads at the camshaft pulleys. - Remove the tools [1] and [2]. Refit : - The lower timing cover (13).
  • Page 141 CHECKING AND SETTING THE VALVE TIMING Engine : XFX Setting the valve timing - Remove the components as necessary for the operation. - Remove the screws (19) and the plate (20). - Peg the crankshaft, using tool [2]. NOTE : Damp the rotation of the camshafts (15) and (17), using tool [6]. - Untighten the camshaft pulley screws (15) and (17).
  • Page 142 CHECKING AND SETTING THE VALVE TIMING Engine : XFX Setting the valve timing (continued) Refit. - Check that the camshafts and the crankshaft are correctly pegged. - Check that the rollers and the water pump pulley are turning freely. (No tightness) - Loosen the camshaft pulley screws by a 1/4 turn.
  • Page 143 CHECKING AND SETTING THE VALVE TIMING Engine : XFX Setting the valve timing (continued) Adjusting the timing belt tension. - Pivot the plate (25) of the tensioner roller (24), using a spanner. (type FACOM S.161). - Engage the screw (21) on the plate (25). - Tighten the screws (21) and (22), tighten to 2,5 ±...
  • Page 144 CHECKING AND SETTING THE VALVE TIMING Engine : XFX Setting the valve timing (continued) - Align the marks "c" and "d", without detensioning the timing belt. (Failing this, restart the operation of adjusting the belt tension). - Hold the tensioner roller (24). - Tighten the nut (23), tighten to 1 ±...
  • Page 145 CHECKING AND SETTING THE VALVE TIMING Engine : XFW Tools. [1] Camshaft setting pegs : (-).0187-B [2] Crankshaft setting peg : (-).0187-A [3] Belt retaining pin : (-).0187-J [4] Peg for checking camshaft settings : (-).0187-CZ [5] Tool for immobilising inlet camshaft hubs : (-).0187-C [6] Tool for immobilising exhaust camshaft hubs : (-).0187-F...
  • Page 146 CHECKING AND SETTING THE VALVE TIMING Engine : XFW Removing (continued). Remove: The twelve screws (3) (6mm external hexagonal adaptor). The seven screws (4) (7mm external hexagonal adaptor). The two covers (5). The cover (6). B1EK005D B1EK007D The fixing screws of the power steering pump, then suspend the latter. The support (7).
  • Page 147 CHECKING AND SETTING THE VALVE TIMING Engine : XFW Removing (continued). Remove screw (8). Slacken screws (9) and (10) and nut (11). Pivot the tensioner roller eccentric (clockwise), using tool FACOM R 161 at "B". Remove the guide roller (12). Remove the timing belt, commencing with the tensioner roller and the coolant pump.
  • Page 148 CHECKING AND SETTING THE VALVE TIMING Engine : XFW Refitting (continued). Position the belt on the guide roller (13), belt at (C) well tensioned. NOTE : Carefully turn the camshaft pinion in the opposite direction to the rotation of the engine in order to engage the belt on the pinion.
  • Page 149 CHECKING AND SETTING THE VALVE TIMING Engine : XFW Refitting (continued). Engage the belt on: The roller (13). The camshaft pinions, inlet (19) then RH exhaust (20), as before for the camshafts. Simultaneously engage the belt on: The roller (21). The pump (15).
  • Page 150 CHECKING AND SETTING THE VALVE TIMING Engine : XFW Refitting (continued). Tighten at least two screws (16) per hub to 1 ± 0,1 m.daN, in the order indicated (17), (18), (19) and (20). Remove tools [4], [7], [1] and [2]. Effect two rotations of the crankshaft (direction of rotation of the engine).
  • Page 151 CHECKING AND SETTING THE VALVE TIMING Engine : XFW Refitting (continued). Peg the camshaft hubs, starting with LH exhaust (17) then (18), (19) and (20), using tool [1], proceeding in the following way: - The peg goes in: slacken by 45° the fixing screws of the pinion on the camshaft hub, - The peg does not go in: slacken by 45°...
  • Page 152 CHECKING AND SETTING THE VALVE TIMING Engine : XFW Checking the setting of the timing (continued). Should this not be the case, repeat the operation to refit the belt. Remove the crankshaft peg [2]. Refitting (continued). Refit: The power steering pump. The support (7).
  • Page 153 CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHS - RHZ N° RPO 9127 Tools [1] Belt tension measuring instrument : 4122-T [2] Tension lever : (-).188.J2 [3] Engine flywheel peg : (-).188.X [4] Belt retaining pin : (-).0188.K [5] Camshaft pinion peg : (-).0188.M [6] Engine flywheel lock...
  • Page 154 CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHS - RHZ N° RPO 9127 Setting the valve timing. Peg : The engine flywheel, tool [3]. (From under the vehicle) The camshaft, tool [5]. Slacken : The three screws (9). The screw (7) of the tensioner roller (6).
  • Page 155 CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHS - RHZ N° RPO 9127 Setting the valve timing (continued). - Retighten the screws (21) by hand. - Turn the pinion (24) (clockwise) to the bottom of the buttonhole. - Refit the belt on the crankshaft (25) - Hold the belt, using tool [4].
  • Page 156 CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHS - RHZ N° RPO 9127 Setting the valve timing (continued). Position tool [1] on the belt at "b". Turn the roller (20) (anti-clockwise) using tool [2] to attain a tension of : 98 ±...
  • Page 157 CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHS - RHZ N° RPO 9127 Setting the valve timing (continued). Tighten : The screw of the roller (19) to 2.5 ± 0.2 m.daN. The screws (21) to 2 ± 0.2 m.daN Remove the tool [1].
  • Page 158 SPECIAL FEATURES : CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHS - RHZ N° RPO 9128 OLD FITTING : RPO 9127 NEW FITTING : RPO 9128 B1EP176D B1EP177D The new timing on 8 valve engines DW10TD (RHY) and DW 10ATED (1) "Idler"...
  • Page 159 SPECIAL FEATURES : CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHS - RHZ N° RPO 9128 NEW FITTING : RPO 9128 (Continued) The new fitting discontinues the following components : - Camshaft hub. - Cylinder reference sensor target. Repair - Accessories drive pulley Remove - Refit WARNING : Peg the camshaft and the crankshaft before ever removing the...
  • Page 160 CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHS - RHZ N° RPO 9128 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) [2] Tension lever : (-).0188.J2.
  • Page 161 CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHS - RHZ N° RPO 9128 Uncouple, plug and move aside, using tool [7], the fuel delivery pipe (2) and return pipe (1). Remove : Screws (3), (4) and (6). Screw (7).
  • Page 162 CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHS - RHZ N° RPO 9128 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 163 CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHS - RHZ N° RPO 9128 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 164 CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHS - RHZ N° RPO 9128 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 165 CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHS - RHZ N° RPO 9128 Lock the engine flywheel, using tool [6]. Slacken : The accessories drive pulley (8). The screw (17) of the tensioner roller (18). Fit the tool [1]. Turn the tensioner roller, using tool [2], to attain a tension of : 54 ±...
  • Page 166 CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHS - RHZ N° RPO 9128 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 167 CHECKING AND SETTING THE VALVE TIMING Engine : 4HX Tools [1] Belt tension measuring instrument : 4122-T [2] Engine flywheel peg : (-).0188.X. [3] Tension lever : (-).0188.Y. [4] Belt compression spring : (-).0188.K. [5] Camshaft pinion peg : (-).0188.M. [6] Engine flywheel lock : (-).0188.F.
  • Page 168 CHECKING AND SETTING THE VALVE TIMING Engine : 4HX Checking the setting of the valve timing (continued). IMPERATIVE : If it is impossible to line up the marks on the chain and on the camshaft drive pinions, restart the camshaft setting. (See operation for removing and refitting camshafts).
  • Page 169 CHECKING AND SETTING THE VALVE TIMING Engine : 4HX Setting the valve timing. - Turn the crankshaft to bring camshaft to its pegging point. - Peg the crankshaft, using tool [2]. - Peg the camshaft, using tool [5]. Untighten : - The three screws (25).
  • Page 170 CHECKING AND SETTING THE VALVE TIMING Engine : 4HX Setting the valve timing (continued). Refit - Retighten the screws (25) by hand. - Turn the pinion (29) (clockwise) to the bottom of the buttonhole. - Refit the belt on the crankshaft (28) - Hold the belt, using tool [4].
  • Page 171 CHECKING AND SETTING THE VALVE TIMING Engine : 4HX Setting the valve timing (continued) Position tool [1] on the belt at "b". Turn the tensioner roller (24) (anti-clockwise) using tool [2] to attain a tension of : 106 ± 2 SEEM units. Tighten screw (23) of the tensioner roller, tighten to 2.5 m.daN.
  • Page 172 CHECKING AND SETTING THE VALVE TIMING Engine : 4HX Setting the valve timing (continued) Remove the tool [1]. Refit the tool [1]. Tension value should be : 51 ± 3 SEEM units. IMPERATIVE : If value is incorrect, restart the operation. Remove tools [1], [2] and [5].
  • Page 173 CHECKING AND SETTING THE VALVE TIMING Engines : RHT - RHW - 4HW TOOLS : [1] Instrument for measuring belt tension SEEM C.TRONIC : (-).0192 [2] Crankshaft setting peg (engine DW12TED4) : (-).0188-X [3] Camshaft peg : (-).0188-M [4] Belt retaining pin : (-).0188-K [5] Engine flywheel stop : (-).0188-F...
  • Page 174 CHECKING AND SETTING THE VALVE TIMING Engines : RHT - RHW - 4HW Removing. Remove: - The closing panel of the clutch casing (block the engine flywheel, tool [5]). - The auxiliary drive pulley screw. Refit the screw without the washer. Remove: B1EK0TVC B1EK0TUC...
  • Page 175 CHECKING AND SETTING THE VALVE TIMING Engines : RHT - RHW - 4HW Removing (continued). Disconnect the battery. Move aside the header tank. Position the tools for supporting the engine [10], [11], [12] and [13]. Remove: - The scuttle panel grille. - The torque reaction rod (1).
  • Page 176 CHECKING AND SETTING THE VALVE TIMING Engines : RHT - RHW - 4HW Refitting. IMPERATIVE : Check that the rollers (5) and (6) as well as the coolant pump (7) turn freely (no play, no tight spot), check also that these rollers are not noisy and/or that they are not throwing out grease. In the event of replacement, tighten the roller (6) to 4,3 ±...
  • Page 177 CHECKING AND SETTING THE VALVE TIMING Engines : RHT - RHW - 4HW Pre-tensioning the timing belt. Position the tool [1]. NOTE : Check that the tool is not in contact with anything else around it. Turn the roller (5) (anti-clockwise), using tool [7] to obtain a tension of: 98 ±...
  • Page 178 CHECKING AND SETTING THE VALVE TIMING Engines : RHT - RHW - 4HW Tensioning the timing belt. Refit the pegs [2] and [3]. Slacken the screws (8). Tighten the screws (8), by hand. Slacken the screws (8) by a 1/6 turn. Slacken screw (11).
  • Page 179 CHECKING AND SETTING THE VALVE TIMING Engines : RHT - RHW - 4HW Checking the timing setting. Effect two turns of the engine in the normal direction of rotation, without turning the engine backwards. Refit the peg [2]. IMPERATIVE : Check visually that the offset between the hole in the camshaft hubs and the corresponding pegging hole is not more than 1 mm.
  • Page 180 CHECKING AND SETTING THE VALVE TIMING Engines : RHT - RHW - 4HW Refit: - The tool [5]. - The auxiliary drive pulley Clean the threads of the pulley screw going into the crankshaft, (Tap M16x150). Brush the screw threads. Tightening torque for the screw: Tighten to : 7 ±...
  • Page 181 ALL TYPES VALVE CLEARANCES 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) G Inlet Exhaust Valves Adjust Rocking Adjust fully open Inlet ALL TYPES Hydraulic adjustment Exhaust...
  • Page 182 CHECKING THE OIL PRESSURE Petrol engines Tools Toolkit 4103 -T 1.8i 16V 3.0i V6 2.0 HPi 2.0i 16V Engine type Temperature (°C) 90°C Pressure (Bars) 1000 3000 1000 3000 1000 3000 3000 Diesel engines 2.0 HDi 2.2 HDi RHY - RHS - RHZ Engine type 90°...
  • Page 183 CHECKING THE OIL PRESSURE Petrol engines 2.0i 16V 2.2i 16V 3.0i 24S Engine type Temperature (°C) 80°C Pressure (Bars) 3000 1000 2000 4000 3000 1000 Diesel engines 2.0 HDi 2.2 HDi RHT- RHW Engine type Temperature (°C) 80°C Pressure (Bars) 1000 2000 1000...
  • Page 184 FILTRES A HUILE To be read together with the petrol and diesel correspondence tables LS 923 PURFLUX LS 880 A Ø (mm) Height (mm) LS 923 Specifications LS 880 A...
  • Page 185 CHECKING THE OIL PRESSURE To be read together with the petrol and diesel correspondence tables RFN - 3FZ RHW - RHT - 4HW LS 923 PURFLUX LS 880 A Ø (mm) Height (mm) LS 880 A Specifications LS 923...
  • Page 186 FILLING AND BLEEDING THE COOLING CIRCUIT TOOLS [1] Filling cylinder : 4520-T [2] Adaptor for filling cylinder : 4222-T. ESSENTIAL : Respect the safety and cleanliness recommendations. - The draining and refilling operations can be carried out by means of a WINN’S coolant replacement apparatus or similar;...
  • Page 187 C5 - C8 IDLING - DEPOLLUTION Idling speed % Content (± 50 rpm) Emission Vehicles Engine type Make - Injection type standard Manual Auto. gearbox: N engaged gearbox 1.8i 16V SAGEM IF/L5 EW7J4 S2000 2.0i 16V M. MARELLI IF/L5 EW10J4 48P2 <...
  • Page 188 C5 - C8 PETROL INJECTION 1.8i 16V 2.0i 16V 2.0i 16V HPi 3.0i V6 2.0i 16 V 2.2i 16 V 3.0i V6 EW7J4 EW10J4 EW10D ES9J4S EW10J4 EW12J4 ES9J4S Engine type Emission standard L4 - IF/L5 IF L5 IF/L5 IF L5...
  • Page 189 ALL TYPES DEPOLLUTION TECHNICAL CHECKS (FRANCE) All Types Petrol CO Corrected (In %) All Types Diesel (m Conditions : At idle, engine warm. 01/96 Less than 4.5 % for vehicles registered before 10/86. 01/96 Less than 3.5 % for vehicles registered after 10/86. Atmospheric engine.
  • Page 190 EMISSION STANDARDS ALL TYPES APPLICATIONS STANDARD NOTES CHARACTERISTICS E.E.C. Engines Vehicles Applicable © Utility vehicle limits © = private vehicle limits 10/89 With oxygen sensor, increased by 25 % Petrol without catalytic 15.04 Utility vehicles : R 15.04 K’ 15.04 Diesel converter All Types...
  • Page 191 EMISSION STANDARDS ALL TYPES APPLICATIONS STANDARD NOTES CHARACTERISTICS E.E.C. Engines Vehicles Applicable Private vehicles : With oxygen sensor and Petrol • certain non-EEC © Adoption of U.S. standard Current catalytic converter for US 83 US 83 Diesel European countries petrol vehicles •...
  • Page 192 ALL TYPES EMISSION STANDARDS APPLICATIONS STANDARD NOTES CHARACTERISTICS E.E.C. Engines Vehicles Applicable Private vehicles : © Petrol • certain non-EEC Adoption of U.S. standard US 84 Current US 84 Diesel European countries Utility vehicles légers • certain Export countries Private vehicles : ©...
  • Page 193 ALL TYPES EMISSION STANDARDS APPLICATIONS STANDARD NOTES CHARACTERISTICS E.E.C. Engines Vehicles Applicable With oxygen sensor and reinforced catalytic Private vehicles : Brussels Directive 94/12 EURO 2 converter for petrol < 6 seats and Petrol vehicles. < 2.5 tonnes © Diesel EURO 93 standard made (EURO ©...
  • Page 194 ALL TYPES EMISSION STANDARDS APPLICATIONS STANDARD NOTES CHARACTERISTICS E.E.C. Engines Vehicles Applicable Brussels Directive 98/69 Utility vehicles : With 2 oxygen sensors © and catalytic converter for < 3.5 tonnes EURO 2 standard (L3) petrol vehicles. made stricter EURO 3 Petrol ©...
  • Page 195 ALL TYPES EMISSION STANDARDS APPLICATIONS STANDARD NOTES CHARACTERISTICS E.E.C. Engines Vehicles Applicable Brussels Directive: 2001/1 With 2 oxygen sensors Private vehicles : and catalytic converter for All Types Petrol © petrol vehicles. EURO 3 standard (L4) made Diesel EURO 4 IF / L5 ©...
  • Page 196 C5 - C8 PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM Engines : RHY - RHS - RHZ - 4HX - RHW - RHT - 4HW Cleaning. - The use of high pressure cleaners is prohibited. - Do not use compressed air.
  • Page 197 C5 - C8 PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM Engines : RHY - RHS - RHZ -4HX Engines : RHY - RHS - RHZ - 4HX - RHW - RHT - 4HW Engines : RHW - RHT - 4HW Diesel injectors.
  • Page 198 SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM C5 - C8 Engines : RHY - RHS - RHZ - 4 HX SAFETY REQUIREMENTS Preamble. All interventions on the injection system must be carried out to conform with the following requirements and regulations : - Competent health authorities.
  • Page 199 C5 - C8 SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM Engines: RHY - RHS - RHZ - 4HX CLEANLINESS REQUIREMENTS. Preliminary operations IMPERATIVE : The technician should wear clean overalls. Before working on the injection system, it may be necessary to clean the apertures of the following sensitive components : (refer to corresponding procedures).
  • Page 200 CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engines : RHY - RHS - RHZ - 4HX Engines : RHY - RHS - RHZ TOOLS [1] Ø 10 mm low pressure connector : 4215-T. [2] Ø 8 mm low pressure connector : 4218 -T.
  • Page 201 CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engines : RHY - RHS - RHZ - 4HX (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] = 0.8 ±...
  • Page 202 AIR SUPPLY CIRCUIT SPECIFICATION Engine : RHY (1) Air filter PSA 7899. (2) Flowmeter SIEMENS. (3) Water / recycled gas exchanger VALEO. (4) EGR valve PURFLUX. (5) Turbocharger KKK K03. (6) Air butterfly MAGNETI MARELLI 48W7 Ref. 648 B1HP1A6D...
  • Page 203 AIR SUPPLY CIRCUIT SPECIFICATION Engines : RHS - RHZ (7) Air / air heat exchanger VALEO. (8) Turbocharger KKK K03. (9) EGR valve PURFLUX. (10) Air butterfly MAGNETI MARELLI 48W7 Ref. 648. (11) Air filter PSA 7899. (12) Turbocharging pressure sensor NIPPON DENSO.
  • Page 204 AIR SUPPLY CIRCUIT SPECIFICATION Engine : 4HX (1) Air / air exchanger (2) Air / water exchanger (3) Warm air metering device BOSCH. (4) Cold air metering device BOSCH. (5) Turbocharger ALLIEDSIGNAL GT1549P. (6) Flowmeter SIEMENS. (7) Air filter PSA 7885. B1HP1BYP...
  • Page 205 AIR SUPPLY CIRCUIT SPECIFICATION Engine : 4HX ESSENTIAL : Respect the safety and cleanliness recommendations. Tool. [1] Manual vacuum pump: FACOM DA 16. Checks. ESSENTIAL : Respect the safety and cleanliness recommendations that are specific to high pressure diesel injection (HDi) engines. B1HP1ARP...
  • Page 206 CHECKS : AIR SUPPLY CIRCUIT Engine : 4HX Vacuum pump. - Connect the tool [1] on the vacuum pump (3). - Start the engine. - The vacuum should be 0.8 bar at 750 rpm. Boost vacuum regulation electrovalve. - Connect the tool [1] between the electrovalve (2) and the valve (1). Compare readings with the values in the table below Engine speed (rpm) Vacuum (Bar)
  • Page 207 CHECKS : EXHAUST GAS RECYCLING CIRCUIT Engines : RHY - RHS - RHZ (1) Butterfly housin (3) Electrovalve (black connector) (2) EGR valve (tube with blue marking) (4) Electrovalve (blue connector) Tools [1] Manual vacuum pump : FACOM DA 16. ESSENTIAL : Respect the safety and cleanliness requirements specific to high pressure diesel injection (HDi) engines.
  • Page 208 CHECKS : EXHAUST GAS RECYCLING CIRCUIT Engines : RHY - RHS - RHZ EGR valve - Connect tool [1] on the EGR valve capsule take-off (2). - Apply a vacuum of approx. 0.6 bar to activate the EGR valve. - In abruptly suppressing the vacuum, the valve should click and lock itself back on its seating. - Repeat the operation several times.
  • Page 209 CHECKS : EXHAUST GAS RECYCLING CIRCUIT Engine : 4HX TOOLS [1] Manual vacuum pump : FACOM DA 16. ESSENTIAL : Respect the safety and cleanliness requirements specific to high pressure diesel injection (HDi) engines. Electrovalve (EGR). - Check, not under load, between the electrovalve (3) (blue connector) and the EGR valve (2). (tube with blue marking).
  • Page 210 CHECKS : EXHAUST GAS RECYCLING CIRCUIT Engine : 4HX EGR valve - Connect tool [1] on the take-off (a) of the EGR valve capsule (2). - Apply a vacuum of approx. 0.6 bar to activate the EGR valve. - In abruptly suppressing the vacuum, the valve should click and lock itself back on its seating. - Repeat the operation several times.
  • Page 211 CHECKS : TURBO PRESSURE Engine : RHY Engines : RHY - RHS - 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 : 4219-T Checks. Preparation for RHY engine Remove : - The collars (3).
  • Page 212 CHECKS : TURBO PRESSURE Engines : RHY - RHS - RHZ Procedure. ESSENTIAL : Observe the following checking requirements : - Engine at running temperature. - Vehicle in running order. - Engine at full load. - Start the engine. - Engage first gear and start the vehicle. - Engage the gears up to third gear.
  • Page 213 CHECKS : TURBO PRESSURE Engine : 4HX Tools [1] Pressure gauge for checking pressure 7073-T.A. [2] Extension cable for taking pressure 8607-T.A [3] Union and hose for taking pressure 8607-T.B. [4] Adaptor for taking pressure 8607-T.C. [5] Unions and hoses for taking pressure 4088-T Checks.
  • Page 214 CHECKS : TURBO PRESSURE Engine : 4HX Preparation of tools : in position on the vehicle (continued). Screw the tool [3] on the take-off of the turbo air radiator at «c». Place the pressure gauge on the cup holder at «d.». Connect the extension [2] on the hose «b»...
  • Page 215 INJECTION PUMP SPECIFICATIONS (BOSCH and SIEMENS). Engines Injection system High pressure pump Injectors BOSCH BOSCH EDC 15C2 BOSCH CP1 9625542580 SIEMENS ECUSID801 5WS 40001 5WS40000 SIEMENS (except PICASSO) ATED 9625542580 BOSCH EDC 15C2 BOSCH CP1 BOSCH TED4 96372277980...
  • Page 216 SPARKING PLUGS C5 - C8 Tightening torque Vehicles - Models EYQUEM BOSCH Engine type Electrode gap (m.daN) 1.8I 16V 2.75 ± 0.2 RFN 52 HZ 0.9 ± 0.05 2.0i 16V 2.0i 16V HPi ZR8PTT15 2.25 ± 0.2 (1) 1 ± 0.1 FGR8MQPE 3.0i 24S...
  • Page 217 ALL TYPES SPEEDOMETER An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled. This decree stipulates : - The speed indicated by a speedometer must never be lower than the actual vehicle speed. - Between the speed displayed «SD»...
  • Page 218 CLUTCH SPECIFICATIONS Petrol 1.8i 16V 2.0i 16V 2.0 HPi 3.0i V6 Engine type Gearbox type BE4/5 ML/5 Marque VALEO Mécanisme / Type 230 DNG 4700 230 DING 4700 230 DNG 4700 R 242 T 6500 228 D 73 Clutch disc 11 R 10X 12 R 14X 11 R 14X...
  • Page 219 CLUTCH SPECIFICATIONS Diesel 2.0 HDi 2.2 HDi Engine type Gearbox type BE4/5 ML/5 Supplier Mechanism / type 230 P 4700 225 T 5700 242 T 6500 Clutch disc Damping performed by engine flywheel Ø of lining. Ext/Int 228/155 225/150 242/162 Quality of lining F 408 F 808...
  • Page 220 CLUTCH SPECIFICATIONS Petrol Diesel 2.0i 16V 2.2i 16V 2.0 HDi 2.2 HDi Engine type RHT - RHW Gearbox type BE4/5 ML5C Feature «Push» clutch «Pull» clutch Supplier VALEO Mechanism / type 230 DNG 4700 230 DNG 5100 225 T 5700 242 T 6500 Clutch disc 11 R 14 X...
  • Page 221 BE4/5 GEARBOX CONTROL SPECIFICATIONS Engines : 6FZ - RFN - RLZ - RHY Gear controls [1] Gear lever positioning tool 8605-T. (1) Gear engagement ball-joint Ø 10 mm. (2) Gear control lever (3) Gear engagement control cable. (4) Gear selection control cable. (5) Cable selection locking ley.
  • Page 222 BE4/5 GEARBOX CONTROL SPECIFICATIONS Engines : 6FZ - RFN - RLZ - RHY Gear selection control cable. Gear engagement control cable B2CP3CKD B2CP3CLD Left hand drive Right hand drive Left hand drive Right hand drive Lenght A 730 ± 3mm Lenght G 700 ±...
  • Page 223 CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS Engines : 6FZ - RFN - RLZ - RHY Adjustments. WARNING : Control cables should be adjusted each time the gearbox is removed or cables changed. WARNING : Do not use oil to detach the ball-joints. To release the ball-joint, press at the centre «a»...
  • Page 224 CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS Engines : 6FZ - RFN - RLZ - RHY Tools. [1] Tool for positioning the gearbox control lever 8605-T Toolkit 9040-T Adjustments. Cables should be adjusted each time the gearbox, gear controls or power unit are removed Adjustment principles : - Lock the gear lever in neutral position, using tool [1].
  • Page 225 CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS Engines : 6FZ - RFN - RLZ - RHY Adjustments (continued) Under the bonnet. - Remove the air filter assembly. - Unlock the gear engagement cable ball-joint (b). - Unlock the gear selection cable ball-joint (c). - Make sure the gear levers (engagement and selection) are in neutral position.
  • Page 226 ML/5 GEARBOX CONTROL SPECIFICATIONS Engines : XFX - RHZ - RHS - 4HX [1] Gear lever positioning tool 8605-T. (1) Gear engagement ball-joint Ø 10 mm. (2) Gear control lever (3) Gear engagement control cable. (4) Gear selection control cable. (5) Gear selection ball-joint Ø...
  • Page 227 ML/5 GEARBOX CONTROL SPECIFICATIONS Engines : XFX - RHZ - RHS - 4HX Gear selection control cable. Gear engagement control cable. B2CP3CRD B2CP3CSD Left hand drive Right hand drive Left hand drive Right hand drive Lenght A 750 ± 3mm Lenght C 771 ±...
  • Page 228 CHECKS AND ADJUSTMENTS : ML/5 GEARBOX CONTROLS Engines : XFX - RHZ - RHS - 4HX Adjustments. WARNING : Control cables should be adjusted each time the gearbox is removed or cables changed. WARNING : Do not use oil to detach the ball-joints. To release the ball-joint, press at the centre «a»...
  • Page 229 CHECKS AND ADJUSTMENTS : ML/5 GEARBOX CONTROLS Engines : XFX - RHZ - RHS - 4HX Tools [1] Tool for positioning the gearbox control lever 8605-T Toolkit 9040-T Adjustments. Cables should be adjusted each time the gearbox, gear controls or power unit are removed. Adjustment principles : - Lock the gear lever in neutral position, using tool [1].
  • Page 230 CHECKS AND ADJUSTMENTS : ML/5 GEARBOX CONTROLS Engines : XFX - RHZ - RHS - 4HX Adjustments (continued) Under the bonnet. - Remove the air filter assembly. - Unlock the gear engagement and selection cable ball-joint (b) - Make sure the gear levers (engagement and selection) are in neutral position. - Lock the cable lengths with the ball-joint locking keys.
  • Page 231 CLUTCH SPECIFICATIONS Engines: RFN - 3FZ - RHT - RHW - 4HW «Push» clutch «Push» clutch and «Pull» clutch (1) Clutch disc. B2BB000D «Pull» clutch (2) Clutch plate. (3) Clutch bearing. B2BK22WD...
  • Page 232 HYDRAULIC CLUTCH CONTROL SPECIFICATION Engines : RFN - 3FZ - RHT - RHW - 4HW Bleeding the hydraulic clutch control. Composition of the hydraulic circuit. - Brake fluid reservoir located on the master cylinder. - Hydraulic control sender located in the passenger compartment and fixed on the pedal gear. - Clutch pedal.
  • Page 233 HYDRAULIC CLUTCH CONTROL SPECIFICATION Engines : RFN-3FZ-RHT-RHW-4HW Bleeding the hydraulic clutch control (continued). Couple a transparent pipe onto the bleed screw (1). Submerge the end of the pipe in a receptacle containing brake fluid, situated lower than the clutch slave cylinder (2). Create a syphon at «A»...
  • Page 234 HYDRAULIC CLUTCH CONTROL SPECIFICATION Engines : RFN - 3FZ - RHT - RHW - 4HW Bleeding the hydraulic clutch control (continued). Top up the brake fluid level to the MAXIMUM of the brake fluid reservoir capacity. Declutch and clutch rapidly 40 times. Start the engine.
  • Page 235 GEARBOX AND TYRE SPECIFICATIONS Petrol 18i 16V 2.0i 16V 2.0 HPi Automatic Automatic Engine type Tyres-Rolling circumference 195/65 R15 – 1.93 m 195/65 R15 – 1.93 m Gearbox type BE4/5 BE4/5 BE4/5 Gearbox ident. plate 20 DL 29 20 TP 44 20 DL 30 20 TP 42 20 DL 31...
  • Page 236 GEARBOX AND TYRE SPECIFICATIONS Diesel 2.0 HDi 2.2 HDi Automatic RHS - RHZ Engine type Tyres-Rolling circumference 195/65 R15 – 1.93 m 215/65 R16-1.96 m Gearbox type BE4/5 ML/5C ML/5T ML/5C Gearbox ident. plate 20 DL 32 20 LM 18 20 LE 94 20 TP 43 20 LM 17...
  • Page 237 BE4/5 GEARBOX ENGINE : RFN (a) = Marking zone (sequence and serial no.). (b) = Location of identification label. B2CP3BNC B2CP3BPD...
  • Page 238 BE4/5 GEARBOX Engine : RFN Description (1) Primary shaft. (14) 1 gear synchroniser (2) Clutch bearing guide. (15) Driven gear (1 gear). (3) Gearbox casing. (16) Secondary shaft. (4) Clutch housing. (17) Differential gear. (5) Reverse idle. (18) Satellite gears. (6) Drive gear (3 gear).
  • Page 239 BE4/5 GEARBOX Engine : RFN Tightening torques Ref. Description Number of screws m.daN End guide 1.2 ± 0.1 Clutch housing 1.3 ± 0.1 Primary shaft nut 7.2 ± 0.7 Secondary shaft nut 6.5 ± 0.7 Yoke holding screw 1.5 ± 0.1 Differential gearwheel screw 6.5 ±...
  • Page 240 ML/5 GEARBOX SPECIFICATION Engines : XFX - RHZ - RHS - 4HX Identification Identification. (a) Marking zone (Sequence and serial no.). (b) Location of identification label. B2CP3CMC...
  • Page 241 ML/5 GEARBOX SPECIFICATION Engines : XFX - RHZ - RHS - 4HX Identification (continued) (1) Primary shaft. (18) Driven gear (2 (19) Driven gears (3 (2) Clutch bearing guide. (20) 3rd/4th gear synchroniser. (3) Clutch housing (21) Driven gears (4 (4) Gearbox casing.
  • Page 242 ML/5 GEARBOX SPECIFICATION Engines : XFX - RHZ - RHS - 4HX Identification (continued) Tightening torques m.daN. (28) Reverse lamp switch 2,5 ± 0,2 (29) Gearbox casing /clutch housing fixing screws 2 ± 0,2 (30) Differential bearing stop plate screws 2 ±...
  • Page 243 ML/5 GEARBOX SPECIFICATION Engines : XFX - RHZ - RHS - 4HX Recommendations - Precautions (1) Drain plug. (2) Filler and top-up plug. Oil quality. - See chapter on lubricants: page 23. Oil quantity. - After draining = 1.8 litres B2CP3CUC...
  • Page 244 4 HP 20 AUTOACTIVE GEARBOX SPECIFICATION Engines : XFX - 4HX Identification. (1) Identification plate (riveted on the casing). (a) Serial no.. (b) ZF number. (last digits taken into account) (c) Type of automatic gearbox. (d) Component reference Oil quality and quantity (See chapter, page 23).
  • Page 245 4 HP 20 AUTOACTIVE GEARBOX SPECIFICATION Engines : XFX - 4HX Tightening torques m.daN. Gearbox exterior. (2) Oil channel union fixing 2,5 ± 0,5 (3) Exterior fixing of converter cover on clutch housing 2,3 ± 0,5 (4) Speedometer take-off aperture plug 1 ±...
  • Page 246 4 HP 20 AUTOACTIVE GEARBOX SPECIFICATION Engines : XFX - 4HX Tightening torques m.daN. Gearbox interior. (9) Input speed sensor fixing 0,8 ± 0,1 (10) Hydraulic block fixing (Large head) 0,8 ± 0,1 (11) Output speed sensor fixing 1 ± 0,2 B2CP24DC B2CP24EC...
  • Page 247 RECOMMENDATIONS - PRECAUTIONS (AL 4 and 4 HP 20 AUTOMATIC GEARBOXES) Engines : 6FZ - RFN - RHZ - XFX - 4HX Precautions to be taken Towing. REMOVING - REFITTING. (Automatic gearbox). The front of the vehicle must be raised in order to be towed. If the front of the vehicle cannot be raised : WARNING : Never place the gearbox on its lower casing IMPERATIVE : - Put gear lever in position «N».
  • Page 248 RECOMMENDATIONS - PRECAUTIONS (AL 4 and 4 HP 20 AUTOMATIC GEARBOXES) Engines : 6FZ - RFN - RHZ 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.
  • Page 249 RECOMMENDATIONS - PRECAUTIONS (AL 4 and 4 HP 20 AUTOMATIC GEARBOXES) Engines : 6FZ - RFN - RHZ - XFX - 4HX Procedure prior to carrying out repairs (continued) When the ECU detects an erroneous or non-existent value Reading the fault codes. on input or output : Read the fault codes.
  • Page 250 RECOMMENDATIONS - PRECAUTIONS (AL 4 and 4 HP 20 AUTOMATIC GEARBOXES) Engines : 6FZ - RFN - RHZ - XFX - 4HX ECU : Downloading, Configuration, Initialisation (Pedal). Downloading. ( AL 4 and 4 HP 20 ) Updating the gearbox ECU by downloading : - Follow the procedure using the diagnostic equipment.
  • Page 251 RECOMMENDATIONS - PRECAUTIONS (AL 4 and 4 HP 20 AUTOMATIC GEARBOXES) Engines : 6FZ - RFN - RHZ ECU : Downloading, Configuration, Initialisation (Pedal) (continued) Downloading (AL 4 only). Pedal initialisation. (AL 4 only). ECU downloading procedure : A pedal initialisation must be carried out in the following cases : - Follow the diagnostic tooling procedure.
  • Page 252 RECOMMENDATIONS - PRECAUTIONS (4 HP 20 AUTOMATIC GEARBOX) Engines : XFX - 4HX SHIFT LOCK The shift lock is a system which locks the gear selection lever in the park position «P». Unlocking the «shift lock» (normal operation). Switch on the ignition. Apply the brake pedal and keep it pressed.
  • Page 253 4 HP 20 GEARBOX CONTROLS Engines : XFX - 4HX Selection control. The gear selection control has 5 positions. The selection lever is guided by the shape of the stepped gate and by a retaining spring which holds it towards the left. The gear selection control is equipped with the «shift lock», so you have to switch on the ignition and apply the brake pedal to unlock the selection lever from the park position.
  • Page 254 4 HP 20 GEARBOX CONTROLS Engines : XFX - 4HX Selection control (continued). In position M, selection is by an electronic sensor located close to the gear lever. The variation of flux necessary to the movement of the sensor cells is obtained by a magnet located on the lever itself.
  • Page 255 GEARBOX AND TYRE SPECIFICATIONS Petrol 2.0i 16V 2.2i 16V 3.0i 24S Automatic Automatic Engine type Tyres-Rolling circumference 205/65 R 15 – 1.973 m 215/65 R15-2.016 m 215/60 R16-2.025 m Gearbox type BE4/5 ML5C 4 HP 20 Gearbox ident. plate 20 DL 26 (*) 20 DL 27 (**) 20 TP 74 20 LM 09...
  • Page 256 BE4/5 GEARBOX SPECIFICATION Engine : RFN (A) Marking zone including: - Component reference. - Factory serial no. B2CKU3PD...
  • Page 257 BE4/5 GEARBOX TIGHTENING TORQUES (m.daN) Engine : RFN Tightening torques m.daN. (1) Gearbox rear casing : 1,5 ± 0,1 (2) Gearbox casing / clutch casing fixings : 1,5 ± 0,1 (3) Reverse gear rocker shaft fixing nut : 4,5 ± 0,4 (4) Breather pipe : 1,5 ±...
  • Page 258 BE4/5 GEARBOX TIGHTENING TORQUES (m.daN) Engine : RFN Tightening torques m.daN. (13) Primary shaft nut : 7,5 ± 0,7 (14) Secondary shaft nut : 6,5 ± 0,6 (15) Bearing retaining screw : 1,5 ± 0,1 (16) Differential gearwheel screw : 6 ± 0,6 (17) Gear control support screw : 1,5 ±...
  • Page 259 ML5C GEARBOX SPECIFICATION Engines : 3FZ - RHT - RHW - 4HW (A) Label. (B) Gearbox reference. (C) Sequence no. B2CKUC2D (D) Bar code. (E) Marking zone: Gearbox reference. Sequence no. B2CKUCAD...
  • Page 260 ML5C GEARBOX SPECIFICATION Engines : 3FZ - RHT - RHW - 4HW Gearbox lubrication. Oil type: ESSO 75W80 EZL 848 or TOTAL 75W 80W H 6965 Oil capacity: 2.1 litres. Lubricated for life. NOTE : If the gearbox is drained, refilling of the gearbox is via the venting hole. Tightening torques m.daN.
  • Page 261 ML5C GEARBOX SPECIFICATION Engines : 3FZ – RHT – RHW – 4HW Tightening torques (m.daN). (8) Fixing of gearbox cover on gearbox casing : 2 ± 0,2 (9) Bearing stop plate : 2 ± 0,2 (10) Vent hole. (11) Reverse gear switch : 2,5 ±...
  • Page 262 ML5C GEARBOX SPECIFICATION Engines : 3FZ - RHT - RHW - 4HW Tightening torques (m.daN). (13) Flange fixing screws : 2 ± 0,2 B2CKUC5D (14) Secondary shaft nut : 17 ± 1,7 (15) Gear control support screw : 1,5 ± 0,1 (16) Differential gearwheel screw : 7,7 ±...
  • Page 263 AL4 AUTOMATIC GEARBOX SPECIFICATION Engines : RFN - RHT The automatic gearbox is identified by a self-adhesive label (A) or, failing that, by a marking (B). (1) Component reference. (2) Serial no. B2CA085D...
  • Page 264 AL4 AUTOMATIC GEARBOX SPECIFICATION Engines : RFN - RHT Tightening torques m.daN. (1) Converter: Pre-tightening : 1 ± 0,1 Tightening : 3 ± 0,3 B2CKU7AD (2) Fixing of gearbox on cylinder block : 5,2 ± 0,5 (3) Speedometer drive : 0,8 (4) Electrovalve and/or regulators on hydraulic block : 0,9 (5) Hydraulic block...
  • Page 265 AL4 AUTOMATIC GEARBOX SPECIFICATION Engines : RFN - RHT Tightening torques m.daN. (10) Electrovalve controlling flow into the exchanger : 1 ± 0,1 (11) Multifunction switch : 1,5 ± 0,1 (12) Sleeve stop : 1,5 ± 0,1 (13) Automatic gearbox heat exchanger : 5 ±...
  • Page 266 DRAIN / REFILL / TOP-UP : 4 HP 20 GEARBOX Engine : XFW Preliminary conditions: Tools. Checks there are no faults , using the diagnostic tool. [1] Filling kit : (-).0341 Place the vehicle on a lift, keep vehicle horizontal. [1a] Filling cylinder : (-).0341-A Gear lever in position «P», without applying the handbrake.
  • Page 267 DRAIN / REFILL / TOP-UP : 4 HP 20 GEARBOX Engine : XFW Checks (continued) With the engine running at the temperature 55° ± 1°C, open the top-up plug (3). Wait for the temperature to reach 60° ± 1°C. 1st possibility : - Oil flows out, the level is correct.
  • Page 268 DRAIN / REFILL / TOP-UP : 4 HP 20 GEARBOX Engine : XFW Draining. Preliminary conditions: - Draining should be carried out with the engine hot, to eliminate impurities in suspension in the oil. The draining is partial since the converter cannot be totally emptied. In draining, approx.
  • Page 269 C5 - C8 DRIVESHAFTS - GEARBOX Tightening torques (m.daN) Gearbox oil seal mandrels Driveshaft Driveshaft Right Left Tool kit Vehicles Gearbox Engines bearing 6FZ - RFN - RLZ BE4/5 7114-T.W 7114-T.X 7116-T XFX - RHZ - 4HX 2 ± 0.2 32.5 ±...
  • Page 270 AXLE GEOMETRY Measuring front height Measuring rear height The measurement of the front dimension «H1» is between ground level and the measuring zone on the front subframe (to the rear of the front yokes fixing the suspension arm). B3BP166D B3BP168D L1 (mm) L2 (mm) Theoretical dimension between the level of the front subframe and...
  • Page 271 AXLE GEOMETRY Front axle Rear axle King pin Vehicle Tracking Castor Camber Tracking Camber inclination Adjustable Non adjustable Adjustable Non adjustable 0 à - 3 mm 5.4 ± 1.3 mm All Types 3° 03' ± 30' 0° ± 30' 12° 56' ± 30' - 1°...
  • Page 272 FRONT AXLE Tightening torques m.daN. (1) Suspension leg upper fixing 7 ± 0,7 (2) Suspension leg fixing on bodyshell 4,3 ± 0,6 (3) Anti-roll bar link rod upper fixing 6,4 ± 0,6 (4) Anti-roll bar link rod upper fixing 6,4 ± 0,6 (5) Ball-joint fixing 4,5±...
  • Page 273 REAR AXLE Tightening torques m.daN. (1) Anti-roll bar fixing 13,1± 1,4 (2) Rear rubber mounting fixing on bodyshell 8 ± 1,2 (3) Rear subframe fixing 11,5± 1,1 (4) Front subframe fixing on bodyshell 11,5± 1,1 (5) Suspension shaft fixing 14,9± 1,3 (6) Hub nut 25±...
  • Page 274 SUSPENSION Front suspension Tightening torques m.daN. (10) Arm front fixing 13 ± 1,3 (11) Arm rear fixing 8 ± 0,8 (12) Anti-roll bar bearing fixing on subframe 4,2 ± 0,6 Hydractive 3+ hydraulic suspension (power steering) Suspension piston diameter = 35 mm. Anti-roll bar diameter = 23,5 mm.
  • Page 275 SUSPENSION Rear suspension Tightening torques m.daN. (13) Subframe rear fixing 11,5 ± 1,1 (14) Rear rubber mounting fixing on bodyshell 8 ± 1,2 (15) Anti-roll bar fixing 13,1 ± 1,4 (16) Front fixing of subframe on bodyshell 11,5 ± 1,1 NOTE : (13) and (16) Face and threads greased.
  • Page 276 SUSPENSION Height control Tightening torques m.daN. (20) Clips B3CP06TD...
  • Page 277 SUSPENSION Front axle Rear axle King pin Vehicle Tracking Castor Camber Tracking Camber inclination Adjustable Non adjustable Adjustable Non adjustable 0 à - 3 mm 5.4 ± 1.3 mm Tous types 3° 03' ± 30' 0° ± 30' 12° 56' ± 30' - 1°...
  • Page 278 SPECIFICATIONS OF POWER-ASSISTED STEERING Engines : 6FZ - RFN - RLZ - XFX - RHY - RHS - RHZ - 4HX Tightening torques m.daN. (1) Steering wheel fixing 2 ± 0,3 (2) Column fixing on mounting 2,3 ± 0,4 (3) Column fixing on mounting 2,3 ±...
  • Page 279 SPECIFICATIONS OF POWER-ASSISTED STEERING Engines : 6FZ - RFN - RLZ - XFX - RHY - RHS - RHZ - 4HX Number of teeth Number of Angle of lock Steering rack Steering Engines turns of the travel (mm) ratio Inner Outer Pinion Rack...
  • Page 280 AXLE GEOMETRY (SETTING AT REFERENCE HEIGHT) Setting at reference height Requirements prior to setting at reference height WARNING : The checks of the front and rear axle geometry values, as well as the adjusting of the front suspension should be carried out at precise positions of suspension compression (reference height) on a suspension test bed Check the pressures in the tyres.
  • Page 281 AXLE GEOMETRY Setting at reference height (continued) Measuring front height (H1) Measuring rear height (H2) C4AP1AUC E1AP0AYD B3BP18GC Front height Rear height H1 = R1 - L1 H2 = R2 + L2 H1 = Measurement between the bottom of the subframe (b) at the front H2 = Measurement between bottom of longeron (c) and the ground.
  • Page 282 AXLE GEOMETRY Setting at reference height (continued) Height of the vehicle at the front at reference height (H1 = R1 - L1) Engage the straps [3] with their shackles [2] on the subframe. Position the suspension compressor[1], selecting the separation (a) most suited to pull the straps as far upwards as possible.
  • Page 283 AXLE GEOMETRY Setting at reference height (continued) Height of the vehicle at the rear at reference height (H2 = R2 + L2) Engage the slings [4] on the rear longerons. Position the suspension compressor [1] selecting the separation (a) most suited to pull the straps as far upwards as possible.
  • Page 284 AXLE GEOMETRY Values for front suspension angles Values for rear suspension angles 3FZ-RHT 3FZ-RHT Engines Engines RHW-4HW RHW-4HW Tyres 205x65 R15 215x65 R15 215x60 R16 Tyres 205x65 R15 215x65 R15 215x60 R16 L1 (mm) L1 (mm) L2 (mm) L2 (mm) Adjustable Non Adjustable Tracking (mm)
  • Page 285 AXLE GEOMETRY Réglage des trains roulants NOTE : Only the tracking is adjustable (at the front). If the value is incorrect, adjust the track rods (1). One turn of the rod = 2 mm approx. Tighten the nuts (2), tighten to 4 ± 0,4 m.daN. B3BKAELD...
  • Page 286 FRONT AXLE Identification (1) Crossmember (2) Tie-rods (3) Springs (4) Front suspension leg (5) Anti-roll bar (6) Subframe Anti-roll bar Engines Diameter (mm) RFN-3FZ-RHT-RHW-4HW 21.5 B3CK09JD...
  • Page 287 FRONT AXLE Tightening torques (m.daN) Fixing of subframe on body : 10,7 ± 1 Fixing on tie-rod on body : 6,3 ± 0,6 Fixing of crossmember on body : 8 ± 0,8 Fixing of tie-rod on front subframe : 6,3 ± 0,6 Fixing of damper on pivot : 9 ±...
  • Page 288 REAR AXLE Identification (1) Damper. (2) Spring. (3) Stabiliser bar. B3DK0AFD...
  • Page 289 REAR AXLE Tightening torques (m.daN) (5) Fixing of rear axle on body : 8 ± 0,8 (6) Fixing of stabiliser bar on rear axle : 8 ± 0,8 (7) Fixing of stabiliser bar on body : 6 ± 0,6 (8) Hub nut : 38 ±...
  • Page 290 SPECIFICATIONS OF POWER-ASSISTED STEERING Engines : RFN - 3FZ - XFW - RHT - RHW - 4HW Identification (X) Pre-adjustment. (1) Steering mechanism. (2) Distributor valve. (3) Power steering reservoir. (4) Power steering pump. (5) High pressure union. (6) Low pressure union. (7) Steering oil radiator fitted on the front panel.
  • Page 291 SPECIFICATIONS OF POWER-ASSISTED STEERING Engines : RFN – 3FZ – XFW – RHT – RHW – 4HW Engine Type RHT - RHW Features Power steering with integral ram Travel (mm Angle of lock for inside wheel 40°48’ 37°18’ 39°24’ Angle of lock for outside wheel 34°36’...
  • Page 292 SPECIFICATIONS OF POWER-ASSISTED STEERING Engines : RFN - 3FZ - XFW - RHT - RHW - 4HW Tightening torques (m.daN) (8) Steering wheel fixing nut : 2 ± 0,2 (9) Fixing of steering column to support : 2 ± 0,2 (10) Fixing of upper and lower shafts to steering column : 2,5 ±...
  • Page 293 BRAKE SPECIFICATIONS 1.8i 16V 2.0i 16V 2.0 HPi 3.0i V6 Engine type Master cylinder 22.2 (valve type) Master-vac Caliper/piston BOSCH ZO 54/55 BOSCH ZO 57/56 BOSCH ZO Ø makes BIR 54 BIR 57 57/28BIR 57 Non-ventilated Brake disc Ventilated Disc thickness/min. thickness 22/20 26/24 28/26...
  • Page 294 BRAKE SPECIFICATIONS 2.0 HDi 2.2 HDi Engine type Master cylinder 22.2 (valve type) Master-vac Caliper/piston BOSCH ZO 57/26 Ø BOSCH ZO 57/28 BIR 57 makes BIR 57 Non-ventilated Brake disc Ventilated Disc thickness/min. thickness 26/24 28/26 TEXTAR T 4110 Brake pad grade Cylinder or caliper PSA - 32 (double piston) Ø...
  • Page 295 BRAKE SPECIFICATIONS Braking circuit Braking system specifications - Braking circuit at «X». - Front brakes with ventilated discs. - Rear brakes with non-ventilated discs. - Handbrake lever controlling cables acting on the front wheels. - The compensator and main brake limiter functions are assured by the ABS EBD system fitted as stan- dard at the factory on all versions.
  • Page 296 BRAKE SPECIFICATIONS Braking circuit diagram (a) Hydraulic circuit. (b) Electrical circuit. (1) Master cylinder in tandem. (2) Braking servo. (3) Brake caliper. (4) Hub equipped with a bearing with an integral magnetic wheel (48 pairs of poles). (5) Wheel sensor. (6) Brake fluid level sensor.
  • Page 297 BRAKE SPECIFICATIONS (7) Hydraulic block Part No. Elements Ref. Supplier Observations ABS MK.60 Electronic 47 way connector. ITT - A ECU. Alone on the hydraulic block. BASR MK.60 2 way black connector. The sensors are inductive-type. Front wheel ITT - A 96 332 952 80 Mounted on the pivot.
  • Page 298 BRAKE SPECIFICATIONS Brake pedal carriage Front brake Rear brake B3FP130C B3FP12YC B3FP12ZC Couple de serrage (m.daN). (15) Fixing on bodyshell 1.8 ± 0.25. (12) Caliper fixing on pivot 12± 1.8 (14) Rear caliper fixing on suspension arm 7 ± 0.7 (16) Servo fixing 2.1 ±...
  • Page 299 HANDBRAKE (Adjustment) Adjustment - Remove the rear ashtray from the handbrake console. - (1) Nut for adjusting the tension of the handbrake cables. - Raise and support the vehicle with the front wheels hanging free. - Check the correct routing of the brake cables under the vehicle.
  • Page 300 BLEEDING AND FILLING THE BRAKING SYSTEM Tools. [1] Generic bleeding apparatus : "LURO" or similar. [2] PROXIA station : 4165-T. [3] LEXIA station : 4171-T. Bleeding, filling. Draining the brake fluid reservoir. - Drain the brake fluid reservoir (1) to the maximum (if necessary, use a clean syringe). - Disconnect the connector (3).
  • Page 301 BLEEDING AND FILLING THE BRAKING SYSTEM Bleeding, filling (continued). Filling the braking system. WARNING : Use only those hydraulic fluids that are approved and recommended. - Fill the brake fluid reservoir (1). Bleeding the braking system. WARNING: During the bleeding operation, take care to maintain the level of brake fluid in the reservoir and to top it up, using only brake fluid that is clean and clear.
  • Page 302 BLEEDING AND FILLING THE BRAKING SYSTEM Bleeding, filling (continued). With the bleeding apparatus - Connect the bleeding apparatus [1] on the brake fluid reservoir (1). - Adjust the apparatus pressure to 2 Bars. For each circuit : - Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container. - Open the bleed screw, wait until the fluid is flowing out without air bubbles.
  • Page 303 BLEEDING AND FILLING THE BRAKING SYSTEM Bleeding, filling (continued). Bleeding the secondary circuit. NOTE : The bleeding apparatus is connected on the brake reservoir. - Use LEXIA or PROXIA diagnostic tools. Select the menu corresponding to the vehicle : - ABS menu. - ESP menu.
  • Page 304 BRAKE SPECIFICATIONS 2.0i 16V 2.2i 16V 3.0i 24S 2.0 HDi 2.2 HDi RHT - RHW Engine type Master cylinder 22.2 (valve type)) 23.8 (valve type)) 22.2 (valve type)) Master-vac 203.2 + 228.6 Ø LUCAS BREMBO LUCAS Caliper/piston makes 40 + 44 Disc Ventilated 28/26...
  • Page 305 BRAKE TIGHTENING TORQUES (m.daN) Engines : RFN - 3FZ - XFW - RHT - RHW - 4HW Tightening torques (m.daN) Fixing of disc on hub : 1,5 ± 0,1 Fixing of front brake caliper on support : 3,5 ± 0,3 Fixing of front brake caliper support on pivot : 16 ±...
  • Page 306 ADJUSTING THE HANDBRAKE Identification (A) Zone for fixing on floor. (B) Clips for retaining on bodyshell. B3FK263D...
  • Page 307 ADJUSTING THE HANDBRAKE Adjustment Raise and support the vehicle, wheels hanging. WARNING : Bleed the braking circuit. Detension the secondary brake cables by slackening the nut (1). With the engine running and the handbrake released, press 40 times on the brake pedal.
  • Page 308 DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM Tools. [1] Generic bleeding apparatus : «LURO» or similar [2] Filler plug : (-).0810 [3] PROXIA diagnostic tool : 4165-T. [4] LEXIA diagnostic tool : 4171-T Draining. Remove the pollen filter (See corresponding operation). Take out the filter from the brake fluid reservoir.
  • Page 309 DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM Pre-conditions for bleeding a braking circuit: Use of the diagnostic tool will be necessary in cases where the following After a repair on the master cylinder or ABS block, bleed in the following conditions all come together simultaneously: order: - Air in the circuit.
  • Page 310 HYDRAULIC SPECIFICATIONS Location of components (A) High pressure hydraulic circuit. (B) Low pressure hydraulic circuit. (C) Electric circuit. (21) Built-in Hydro-electronic Interface (BHI). (22) Front slimline sphere. (23) Front suspension cylinder. (24) Rear slimline sphere. (25) Rear suspension cylinder. (26) Front hydractive 3+ regulator accumulator. (27) Front hydractive 3+ regulator.
  • Page 311 HYDRAULIC SPECIFICATIONS Reservoir Reference Function Component (BHI) Built-in Hydro-electronic "d" Induction InterfacePower steering pump "e" (BHI) Built-in Hydro-electronic Interface "f" Return Power steering pump "c" Suspension cylinders Synthetic fluid TOTAL FLUIDE LDS. Capacity of the circuit 4.3 litres. B4BP01BC...
  • Page 312 HYDRAULIC SPECIFICATIONS Built-in Hydro-electronic Interface (BHI). Ref. Component Specifications (36) Electric motor 2350 ± 150 tr/min Hydraulic unit comprising : Pump with 5 axial pistons Throughput = 0,7 l/min at 2300 rpm (35) - Anti-pulse hydropneumatic Diameters of the pistons = 6,35 mm accumulator Safety valve rating = 180 Bars A safety valve...
  • Page 313 HYDRAULIC SPECIFICATIONS Hydractive 3+ regulator Hydraulic unions B4DP003D B4BP01CD Tube diameter Tightening torque Reference (40) Slimline sphere. (mm) m.daN (39) Hydractive regulator. (38) Electrovalve. 1.5 ± 0.3 (41) Depressurisation screw. 6.35 2.5 ± 0.5...
  • Page 314 SPECIFICATION - IDENTIFICATION : SUSPENSION SPHERES Special features Identification - Fitting of new slimline spheres with multilayer membrane and earth grey colour. - It is prohibited either to recharge or repair this type of sphere. - The number marked on the suspension sphere is the reference number for the component, not the Replacement Parts No. - The 2-digit number on the suspension sphere indicates the value of the initial inflation pressure.
  • Page 315 SPECIFICATION - IDENTIFICATION : SUSPENSION SPHERES (1) Front suspension sphere. (2) Rear suspension sphere. (3) Front hydractive 3+ regulator accumulator. (4) Rear hydractive 3+ regulator accumulator. B4BP01DD...
  • Page 316 CARACTERISTIQUES-IDENTIFICATIONS : BLOCS PNEUMATIQUES Special features Identification The « slimline » spheres are grey in colour, with multilayer membranes. IMPERATIVE : It is impossible to recharge or overhaul the « slimline » spheres with nitrogen. The two-figure number marked on the suspension sphere indicates the initial pressure rating value. Example Suspension Day in year of...
  • Page 317 SPECIFICATION - IDENTIFICATION : SUSPENSION SPHERES Hydractive 3 hydraulic suspension (1) Front suspension spheres Engines Suspension sphere marking Volume (cc) Pressure rating (Bars) Type RHY-RHS-RHZ (2) Rear suspension spheres Engines Suspension sphere marking Volume (cc) Pressure rating (Bars) Saloon RHY-RHS-RHZ Estate...
  • Page 318 SPECIFICATION - IDENTIFICATION : SUSPENSION SPHERES Hydractive 3+ hydraulic suspension (1) Front suspension spheres Engines Suspension sphere marking Volume (cc) Pressure rating (Bars) Types XFX-4HX (2) Rear suspension spheres Engines Suspension sphere marking Volume (cc) Pressure rating (Bars) Saloon RFN-XFX-4HX Estate...
  • Page 319 SPECIFICATION - IDENTIFICATION : SUSPENSION SPHERES Hydractive 3+ hydraulic suspension (3) Front hydractive regulator accumulator Engines Suspension sphere marking Volume (cc) Pressure rating (Bars) RFN-4HX Types (4) Rear hydractive regulator accumulator Engines Suspension sphere marking Volume (cc) Pressure rating (Bars) RFN-4HX Types NOTE : The dampers are integral to the hudractive regulators, depending on the versions of hydractive accumulator.
  • Page 320 STARTER MOTORS C5 - C8 Abbreviations and definitions Coding of climates is as follows : Meaning of abbreviations : CLIMATES : : Starting possible as low as -18°C : Gearbox Temperate : Starting possible as low as -18°C MANUEL : Manual gearbox Cold : Starting possible as low as -25°C...
  • Page 321 STARTER MOTORS Petrol engines Engine Gearbox Reference Class Climate C.T.F 1.8i 16 V F.GF 2.0 16V HPi F.GF F.GF 2.0 16V F.GF C.T.F.GF 2.0i 24 S C.T.F.GF...
  • Page 322 STARTER MOTORS Diesel engines Engines Gearbox Reference Class Climate F.GF 2.0 HDi F.GF F.GF F.GF 2.2 HDi F.GF...
  • Page 323 STARTER MOTORS Petrol engines Engines Gearbox Reference Class Climate 1.8i 16 V F.GF 2.2 16 V HPi F.GF 3.0i 24 S C.T.F.GF Diesel engines 2.0 16 V HDi F.GF 2.2 HDi F.GF...
  • Page 324 ALTERNATORS C5 - C8 Abbreviations and definitions Meaning of abbreviations : Coding of climates is as follows : : Gearbox MANUEL : Manual gearbox CLIMATES : AUTOMATIC : Automatic gearbox MANUELP : Piloted manual gearbox : Hot NON REFRI : Without air conditioning...
  • Page 325 ALTERNATORS Without hi-fi pack With hi-fi pack Without heated seat With heated seat Without heated seat With heated seat Engine/ Climate Gearbox Mono Colour Mono Colour Mono Colour Mono Colour Base Base Base Base Navig. Navig. Navig. Navig. Navig. Navig. Navig.
  • Page 326 ALTERNATORS With hi-fi pack Without hi-fi pack Without heated seat With heated seat Without heated seat With heated seat Engine Climat Mono Colour Mono Colour Mono Colour Mono Colour Boîte Base Base Base Base Navig. Navig. Navig. Navig. Navig. Navig. Navig.
  • Page 327 ALTERNATORS AIRCON Engine/ Without heated seats With heated seats Climate gearbox Base Base 2.0i 16 V 2.2 16 V HPi MANUEL 2.0i 16 V AUTOMATIC 3.0i 24 S 2.016 V HDi AUTOMATIC 2.0 HDi MANUEL...
  • Page 328 CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR ALL TYPES Checking the alternator output Connect as shown in the diagram opposite, using an ammeter (A), a voltmeter (V), and a rheostat (R) or a Volt/Ammeter/Rheostat combination. Referring to the vehicle’s equipment specification (see table opposite), adjust the engine speed and rheostat charge to obtain U=13.5V.
  • Page 329 ALL TYPES CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR MINIMUM OUTPUTS (in A) Class Alternator Min. output speed 1800 rpm 2000 rpm 3000 rpm 68.5 4000 rpm 6000 rpm 78.5 8000 rpm 15000 rpm MINIMUM YIELDS (in %) Class Alternator speed 1800 rpm 2000 rpm 3000 rpm...
  • Page 330 PRE-HEATING AND STARTING CIRCUITS ALL TYPES Pre-post-heating Vehicles Pre-heater plugs Pre-heater control unit Engine (Pre-heating time at 20°C) CARTIER 51299011A 2.0 HDI CHAMPION CH 170 NAGARES 960411-P 2.0 16V HDI Piloted by the diesel injection ECU CARTIER 51299011A 2.2 HDI BERU A0100 226 344 NAGARES 960411-P ≤...
  • Page 331 C5 - C8 AIR CONDITIONING R 134 a (HFC) Compressor Refrigerant Vehicle Engine version Date refill Oil quantity cc Variable capacity Oil reference (± 25 gr) 1.8i 16V - 2.0i 16V 2.0 HPi SD 7 V16 SD 7 V16 SP 10 3.0i 24S 16V...
  • Page 332 C5 - C8 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Summary table for presence of pollen filter Vehicle Equipment RPO no. Presence of filter Observations Located under the dashboard. Aircon all types Located in the engine compartment.
  • Page 333 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Pollen filter Remove : - The trim (1) under the dashboard (driver’s side). - The cover (2). Unclip at « a » and pull out the pollen filter (3). Remove the pollen filter (3). C5FP0C5C C5FP0C6D...
  • Page 334 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Drying cartridge Tools [1] Filling and recycling station MULLER - ECOTECHNICS [2] TORX adaptor 70 FACOM [3] After Sales kit (Bottle /skirt / bottle nozzle /grease / compressor oil) Reminder : All repairs on an aircon circuit require the aircon circuit to be drained. After carrying out the dismantling operations necessary to gain access to the condenser, proceed to clean the area of the skirt (8) of the reservoir (6) using a cloth, then replace the dryer reservoir (6).
  • Page 335 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Condenser with integral reservoir (continued) Removing the reservoir (6) from the base (8). WARNING : This operation requires the greatest care, the base (8) should be kept clean prior to fitting the new reservoir. - Remove the reservoir (6) and the protection skirt (7), avoiding WITHOUT FAIL any contact or collision with other items under the bonnet (Risk of impurities entering the base (8)).
  • Page 336 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Condenser with integral reservoir (continued) WARNING : The reservoir (6) contains a drying agent. As soon as the black protection is removed, the reser- voir must be mounted in the base (8), otherwise there is a risk of damaging the air conditioning circuit. Screwing the reservoir (6) into the base (8).
  • Page 337 ALL TYPES 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.
  • Page 338 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) ALL TYPES Checking the compressor oil level (continued) 2/ Slow leak. - Slow leaks do not lead to oil loss, therefore the same procedure should be followed as if there was no leak at all. 3/ Fast leak.
  • Page 339 ALL TYPES CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM CHECKING TEMPERATURES. TOOLS CHECKS. Two thermometers. If all these conditions are met, take the following action : Preliminary conditions. - Start the engine, with the air conditioning off, and wait for the cooling fan first speed to cut in.
  • Page 340 AIR CONDITIONING SYSTEM R 134.a Engines : 6FZ - RFN - RLZ (1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Capacity. (a) Condenser bracket Tighten to 0,8 m.daN (b) Pressure control valve Tighten to 0,8 m.daN (c) Compressor bracket Tighten to 2,5 ±...
  • Page 341 AIR CONDITIONING SYSTEM R 134.a Engine : XFX (1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Capacity. (a) Condenser bracket Tighten to 0,8 m.daN (b) Pressure control valve Tighten to 0,8 m.daN (c) Compressor bracket Tighten to 2,5 ± 0,1 m.daN (d) Condenser dryer reservoir Tighten to 1,4 ±...
  • Page 342 AIR CONDITIONING SYSTEM R 134.a Engines : RHY - RHZ (1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Capacity. (a) Condenser bracket Tighten to 0,8 m.daN (b) Pressure control valve Tighten to 0,8 m.daN (c) Compressor bracket Tighten to 2,5 ±...
  • Page 343 AIR CONDITIONING SYSTEM R 134.a Engine : 4HX (1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Capacity. (a) Condenser bracket Tighten to 0,8 m.daN (b) Pressure control valve Tighten to 0,8 m.daN (c) Compressor bracket Tighten to 2,5 ± 0,1 m.daN (d) Condenser dryer reservoir Tighten to 1,4 ±...
  • Page 344 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Pollen filter C5HP183C NOTE : The pollen filter is located under the bonnet on the LH side. Removing. Remove the handle (1). Uncouple the evacuation pipe (2). Release at (3), on the RH and LH sides. Slacken the screws (4) on the RH and LH sides by a quarter turn.
  • Page 345 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Removing-refitting the drying cartridge Removing. Depressurise the air conditioning circuit. Remove the hose (1). Disconnect the connector (2). Remove the air filter (3). Turn the plastic pins (4) by a quarter turn. Move aside the condenser (5).
  • Page 346 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Removing-refitting the drying cartridge (continued) Unscrew the reservoir (7) (Adaptor: TORX 70 FACOM) Unscrew the reservoir (7), and the protection skirt (6). WARNING : This operation should remain clean before the fitting of the new reservoir. Cap the base (10).
  • Page 347 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Removing-refitting the drying cartridge (continued) Refitting. Note: Check, before you refit the reservoir (7), that the base (10) is clean. (If it is not, clean in and around the base with a paper towel (10)). Preparing the new drying reservoir Remove the protection cap from the neck of the reservoir (7).
  • Page 348 AIR CONDITIONING SYSTEM R 134.a Engines : RFN - 3FZ 1 - Drying cartridge. 2 - Clickfit union. (Tool 8005-T.C) 3 - Buffer capacity. 4 - Clickfit union. (Tool 8005-T.A) 5 - High pressure valve. 6 - Low pressure valve. C5HP17TP...
  • Page 349 AIR CONDITIONING SYSTEM R 134.a Engine : XFW 1 -High pressure valve 2 -Low pressure valve 3 -Buffer capacity. 4 -Drying cartridge. 5 -Pressostat 6 -Clickfit union. (Tool 8005-T.C) Tightening torques (m.daN) C5HP18TP...
  • Page 350 AIR CONDITIONING SYSTEM R 134.a Engines : RHT - 4HW 1 - Drying cartridge. 2 - Clickfit union. (Tool 8005-T.C) 3 - Buffer capacity. 4 - Clickfit union. (Tool 8005-T.A) 5 - High pressure valve. 6 - Low pressure valve. C5HP17UP...

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