CITROEN Saxo 2003 Handbook
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CITROEN Saxo 2003 Handbook

CITROEN Saxo 2003 Handbook

Private cars
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Table of Contents

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PRIVATE CARS
SAXO-C3-XSARA
XSARA PICASSO-BERLINGO
«The technical information contained in this document is intended for the exclusive use of the trained personnel of the
motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The
information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full
responsibility to the exclusion of that of the manufacturer».
«The technical information appearing in this brochure is subject to updating as the characteristics of each model in the
range evolve. Motor vehicle repairers are invited to contact the CITROËN network periodically for further information and
to obtain any possible updates».
CAR 050014
Volume 1
2003

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  • Page 1 PRIVATE CARS 2003 SAXO-C3-XSARA XSARA PICASSO-BERLINGO «The technical information contained in this document is intended for the exclusive use of the trained personnel of the motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full responsibility to the exclusion of that of the manufacturer».
  • Page 2 PRESENTATION THIS HANDBOOK summarises the specifications, adjustments, checks and special features of CITROEN private vehicles, not including UTILITY vehicles for which there exists a separate handbook. The handbook is divided into nine groups representing the main functions : GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - ELECTRICAL - AIR CONDITIONING.
  • Page 3 IMPORTANT If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into account when preparing future publications. For example : – INSUFFICIENT INFORMATION – SUPERFLUOUS INFORMATION –...
  • Page 4 XSARA 2, all types Operation to reconnect the battery after a vehicle repair ATTENTION If the battery has been disconnected, after reconnecting it is ESSENTIAL to wait 1 minute before switching on the ignition, otherwise the engine ECU will lock up. If the ECU has locked up : - Switch off the ignition.
  • Page 5 IDENTIFICATION OF VEHICLES SAXO - All Types Engine legislation type RP organisation no. Chassis stamp Manufacturer’s name plate 01/02/99 # Label : - Tyre pressures. - RP organisation no. - Paint code. Paint code. Gearbox ident. reference E1AP07CD...
  • Page 6 SAXO - All Types IDENTIFICATION OF VEHICLES Saxo petrol 3-door 1.1 i 1.4 i 1.6 i 1.6i 16V Auto. A-X-SX Administration Exclusive X-SX Exclusive Exclusive IFL5 Emission standard SO HFX1 SO HFXB SO KFWL S6 KFWB SO KFWB S6 NFTB N6 NFXB Type code Engine type...
  • Page 7 IDENTIFICATION OF VEHICLES SAXO - All Types Saxo petrol 5-door 1.1i 1.4i A-Administration Auto. Driving school -x-SX X-SX SX-Exclusive Exclusive IFL5 Emission standard S1 HFX1 S1 HFXB S1 KFWL S1 KFWB Type code Engine type 1124 1360 Cubic capacity (cc) Fiscal rating (hp) MA/5 MA/5...
  • Page 8 SAXO - All Types IDENTIFICATION OF VEHICLES Diesel Entreprise 3-door 5-door Petrol 3-door Diesel 3-door 1.5 D 1.1i 1.5 D A-Administration Driving school A- Administration Administration Administration X-SX-VTS -Exclusive X-SX-Exclusive Poste-X-SX Poste-X-SX Emission standard SO VJXB S1 VJXB S3 HFXB S3 VJXB Type code Engine type...
  • Page 9 IDENTIFICATION OF VEHICLES C3 - All Types A : Cold stamp (Cold stamp engraved on the bodywork). B : Manufacturer’s name plate (On the LH centre pillar) C : AS/RP No. and RP paint code. (label affixed to the front pillar on driver’s side) D : Tyre pressures and tyre type.
  • Page 10 C3 - All Types IDENTIFICATION OF VEHICLES PETROL 1.1i X-SX IFL5 L4/INF K’ Emission standard FN HFXC FC HFXC FC HFXB FC HFXB/T FR HFXB FN HFXB FC HFXB FC HFX5 Type code Engine type 1124 Cubic capacity (cc) Fiscal rating (hp) MA/5N Gearbox type 20 CF 14...
  • Page 11 IDENTIFICATION OF VEHICLES C3 - All Types PETROL 1.4i Auto. Auto. Auto. SX – Exclusive IFL5 Emission standard FC KFVE FN KFVB FN KFVE FC KFVC/IF FC KFVF/IF FN KFVC/IF Type code Engine type 1360 Cubic capacity (cc) Fiscal rating (hp) MA/5N MA/5N MA/5N...
  • Page 12 C3 - All Types IDENTIFICATION OF VEHICLES PETROL 1.4i 1.6i 16V Auto. SX – Exclusive SX – Exclusive IFL5 L4/INF Emission standard FN KFVF/IF FC KFVB FC KFVB/D FC KFVE/D FN NFUB FC NFUB Type code Engine type 1360 1587 Cubic capacity (cc) Fiscal rating (hp) MA/5N...
  • Page 13 IDENTIFICATION OF VEHICLES C3 - All Types DIESEL 1.4 HDi X - SX Emission standard FC 8HBXB/T FN 8HXB FC 8HXB FC 8HXB/MOD FC 8HXK FR 8HXB Type code Engine type 1398 Cubic capacity (cc) Fiscal rating (hp) MA/5O Gearbox type 20 CN 33 20 CN 36 (*) Gearbox ident.
  • Page 14 C3 - All Types IDENTIFICATION OF VEHICLES DIESEL 1.4 HDi 1.4 HDi 16V S - SX SX - Exclusive Emission standard FN 8HWK FC 8HWB FN 8HVB FC 8HVB Type code Engine type 1398 Cubic capacity (cc) Fiscal rating (hp) MA/50 BE4/5 Gearbox type...
  • Page 15 IDENTIFICATION OF VEHICLES C3 - All Types DIESEL 1.4 HDi 16V SX - Exclusive SX - Exclusive Emission standard FN 8HYB FC 8HYC FC 8HYB/MOD FC 8HYB/T FC 8HYK FR 8HYB Type code Engine type 1398 Cubic capacity (cc) Fiscal rating (hp) BE4/5 Gearbox type 20 DM 25...
  • Page 16 XSARA - All Types IDENTIFICATION OF VEHICLES A - Manufacturer’s name plate (Estate). B - Chassis stamp, cold stamp. C - Manufacturer’s name plate (Saloon). D - Label : (label affixed to the front pillar on driver’s side) - Tyre pressures. - RP organisation no.
  • Page 17 IDENTIFICATION OF VEHICLES XSARA - All Types Saloon petrol 3-door 1.6i 16V 1.4 i Auto. Auto. X-SX X-SX-VTR X-VTR SX-VTR VTR-VTS IFL5 IFL5 Emission standard NO KFWB NO KFW1/IF NO NFUB NO NFUN NO NFU1/IF NO NFU3/IF Type code Engine type 1360 1581 Cubic capacity (cc)
  • Page 18 XSARA - All Types IDENTIFICATION OF VEHICLES Saloon petrol 3-door Saloon diesel 3-door 20i.16V 1.9 D 2.0 HDi Auto. Auto. X-SX X-SX-VTR SX-VTR IFL5 Emission standard NO RFN1/IF NO RFNN/IF NO RFSB NO WJYB NO RHYB NO RHZB NO RHZN Type code Engine type 1998...
  • Page 19 IDENTIFICATION OF VEHICLES XSARA - All Types Saloon diesel 3 door 1.4 HDi Entreprise Emission standard N0 8HZB N0 8HZB/T N3 8HZB Type code Engine type 1398 Cubic capacity (cc) Fiscal rating (hp) MA/5 Gearbox type Gearbox ident. plate...
  • Page 20 XSARA - All Types IDENTIFICATION OF VEHICLES Saloon 3-door versions Petrol Diesel 1.4i 1.9 D 2.0 HDi Emission standard NO KFWB/T (1) NO WJYB/T (1) NO RHYB/T (1) Type code Engine type 1360 1868 1997 Cubic capacity (cc) Fiscal rating (hp) MA/5 BE4/5 Gearbox type...
  • Page 21 IDENTIFICATION OF VEHICLES XSARA - All Types Saloon petrol 5-door. 1.6i 16V 1.4i Auto. X-SX X-SX Exclusive K’ IFL5 K’ Emission standard N1 KFWG N1 KFWB N1 KFW1/IF N1 NFUG N1 NFUU N1 NFUB Type code Engine type 1360 1587 Cubic capacity (cc) Fiscal rating (hp) MA/5...
  • Page 22 XSARA - All Types IDENTIFICATION OF VEHICLES Saloons petrol 5-door 2.0i 16V 16i 16V Auto. Auto. Auto. X-SX Exclusive Exclusive Exclusive Exclusive IFL5 IFL5 Emission standard N1 NFUN N1 NFU1/IF N1 NFU3/IF N1 RFN1/IF N1 RFNN Type code Engine type 1587 1998 Cubic capacity (cc)
  • Page 23 IDENTIFICATION OF VEHICLES XSARA - All Types Saloons diesel 5-door 1.9 D 2.0 HDi Auto. X-SX X-SX-Exclusive SX-Exclusive Exclusive Emission standard N1 WJYB N1 RHYB N1 RHZB N1 RHZN Type code Engine type 1868 1997 Cubic capacity (cc) Fiscal rating (hp) BE4/5 BE4/5 Gearbox type...
  • Page 24 XSARA - All Types IDENTIFICATION OF VEHICLES Saloons diesel 5-door 1.4 HDi Entreprise Emission standard N1 8HZB N1 8HZB/T Type code Engine type 1398 Cubic capacity (cc) Fiscal rating (hp) MA/5 Gearbox type Gearbox ident. plate...
  • Page 25 IDENTIFICATION OF VEHICLES XSARA - All Types Saloons diesel entreprise 5-door 1.9 D 2.0 HDi Emission standard N1 WJYB/T (1) N RHYB N1 RHYB/T (1) Type code Engine type 1868 1997 Cubic capacity (cc) Fiscal rating (hp) BE4/5 BE4/5 Gearbox type 20 DL 41 20 DL 42 Gearbox ident.
  • Page 26 XSARA - All Types IDENTIFICATION OF VEHICLES Petrol estate 1.4i 16. 16V Auto. Auto. X-SX X-SX X-SX Eclusive Exclusive Exclusive Exclusive IFL5 K’ IFL5 Emission standard N2 KFWB KFW1/IF N2 NFUG N2 NFUB N2 NFUN N2 NFU1/IF N2 NFU3/IF Type code Engine type 1360 1587...
  • Page 27 IDENTIFICATION OF VEHICLES XSARA - All Types Petrol estate Diesel estate 2.0i 16V 1.9 D Auto. Exclusive X - SX IFL5 Emission standard N2 RFN1/IF N2 RFNN N2 WJYB Type code Engine type 1998 1868 Cubic capacity (cc) Fiscal rating (hp) BE4/5 BE4/5 Gearbox type...
  • Page 28 IDENTIFICATION OF VEHICLES XSARA - All Types Diesel estate 2.0 HDi Auto. X-SX-Eclusive Exclusive IFL5 Emission standard N2 RHYB N2 RHYB/IF N2 RHZN Type code Engine type 1997 Cubic capacity (cc) Fiscal rating (hp) BE4/5 Gearbox type 20 DL 42 20 DM 07 (1) 20 DM 10 20 DM 11 (1)
  • Page 29 XSARA - All Types IDENTIFICATION OF VEHICLES Diesel saloon and estate 1.4 HDi Entreprise Emission standard N2 8HZB N2 8HZB/T N4 8HZB Type code Engine type 1398 Cubic capacity (cc) Fiscal rating (hp) MA/5 Gearbox type Gearbox ident. plate...
  • Page 30 XSARA - All Types IDENTIFICATION OF VEHICLES Estate petrol versions Estate diesel versions 1.4i 1.9 D 2.0 HDi Emission standard N2 KFWB/T (1) N2 WJYB/T (1) N2 RHYB/T (1) Type code Engine type 1360 1868 1997 Cubic capacity (cc) Fiscal rating (hp) MA/5 BE4/5 BE4/5...
  • Page 31 IDENTIFICATION OF VEHICLES XSARA PICASSO - All Types A - Chassis stamp (Cold stamp on bodywork) B : Chassis no. reminder (Label located at bottom of windscreen right hand side) C : Manufacturer’s data plate. (Located at bottom of RH central pillar) D : Label : Tyre pressures.
  • Page 32 XSARA PICASSO - All Types IDENTIFICATION OF VEHICLES Petrol Diesel 1.6i 1.8i 16 V 2.0i 16 V 2.0 HDi Auto. SX-Exclusive IFL5 Emission standard CH NFVB CH 6FZB CH 6FZC/IF CH RFNF/IF CH RHYB Type code Engine type 1587 1749 1998 1997 Cubic capacity (cc)
  • Page 33 IDENTIFICATION OF VEHICLES BERLINGO - All Types 11/2002 # A Chassis stamp, cold stamp B Manufacturer’s vehicle plate C Label RPO No. Paint colour code Tyre pressures D Gearbox ident. reference – Factory serial no. E Engine legislation type – Factory serial no. E1AP0AMD...
  • Page 34 BERLINGO - All Types IDENTIFICATION OF VEHICLES Berlingo petrol 5-seater 11/2002 # 1.1i 1.4i X-SX- Multispace L4/W4 K’ L4/W4 IFL5 Emission standard GB VHFXB GJ K6D5G GJ KFWB GJ KFWC/IF Type code Engine type 1124 1360 Cubic capacity (cc) Fiscal rating (hp) MA/5S MA/5 Gearbox type...
  • Page 35 BERLINGO - All Types IDENTIFICATION OF VEHICLES Berlingo petrol 5-seater 11/2002 # 1.4i 1.6i 16v Dual fuel Multispace X-SX- Multispace L4/W4 IFL5 Emission standard GJ KFWB/GL (1) GJ KFWB/GN (2) GJ NFUB GJ NFUC/IF Type code Engine type 1360 1587 Cubic capacity (cc) Fiscal rating (hp) MA/5...
  • Page 36 BERLINGO - All Types IDENTIFICATION OF VEHICLES Berlingo diesel 5-seater 11/2002 # 1.9 D 2.0 HDi X-SX-Multispace X-SX-Multispace L4/W4 L4/W4 Emission standard GJ WJYB GJ WJYB/PMF (1) MF RHYF Type code Engine type 1868 1997 Cubic capacity (cc) Fiscal rating (hp) BE4/5 BE4/5 Gearbox type...
  • Page 37 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 38 SAXO - All Types CAPACITIES (in litres) SAXO Petrol Diesel Ecological oil filter capacity 0.15 litre. 1.1i 1.4i 1.6i 16V 1.6i 1.5D Auto. Engine type Engine with filter change Between Min. and Max. 5-speed gearbox Automatic gearbox after drainage With ABS = 0.45 - Without ABS = 0.36 Hydraulic or brake circuit Cooling system Fuel tank capacity...
  • Page 39 C3 - All Types CAPACITIES (in litres) Petrol Diesel 1.1i 1.4i 1.6i 16V 1.4 HDi 1.4 HDi 16V Auto. Engine type Drain by gravity : engine with filter change 3.75 Between min. And max. Drain by suction : engine with filter change Between Min.
  • Page 40 XSARA - All Types CAPACITIES (in litres) XSARA Petrol Diesel Ecological oil filter capacity 0.15 litre. 1.4 HDi 1.4i 1.6i 16V 2.0i 16V 1.9D 2.0 HDi Auto. Auto. Auto. Engine type 3.25 4.25 4 (*) 4.75 4.5-4.25 (1) Engine with filter element 1 (*) Between Min.
  • Page 41 CAPACITIES (in litres) XSARA PICASSO - All Types XSARA PICASSO Petrol Diesel Ecological oil filter capacity 0.15 litre 1.6i 1.8i 16 V 2.0i 16 V 2.0 HDi Auto. Engine type 4.25 Engine with filter change Between Min. and Max. 5-speed gearbox Automatic gearbox - after drainage 0.58 litres...
  • Page 42 BERLINGO 2 - All Types CAPACITIES (in litres) BERLINGO 2 Petrol Diesel Ecological oil filter capacity 0.15 litre 1.1i 1.4i 1.6i 16V 1.9 D 2.0 HDi Engine type Engine with filter change 3.25 Between Min. and Max. 5-speed gearbox With ABS = 0.45 - Without ABS = 0.36 Hydraulic or brake circuit Cooling system Fuel tank capacity...
  • Page 43 LUBRICANTS - TOTAL recommended oils ALL TYPES Evolutions (year 2003). Use of oil grade 10W 40. It is possible to use semi-synthetic oil 7000 10W40 on HDi and HDi FAP CITROËN C3 PLURIEL. vehicles. Only petrol versions are available. WARNING : To avoid problems with starting from cold, use this oil as allo- wed by the climatic conditions in the country concerned (see table).
  • Page 44 ALL TYPES LUBRICANTS - TOTAL recommended oils Engine oil norms. Current norms. The classification of these engine oils is established by the following recognised organisations : - S.A.E : Society of Automotive Engineers. - API : American Petroleum Institute. - ACEA : Association des Constructeurs Européens d’Automobiles E4AP006D...
  • Page 45 LUBRICANTS - TOTAL recommended oils ALL TYPES 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 46 ALL TYPES LUBRICANTS - TOTAL recommended oils 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. TOTAL oil of grade S.A.E.5W-30 allows improved fuel economies (approx 2.5%).
  • Page 47 LUBRICANTS - TOTAL recommended oils ALL TYPES Recapitulation Norms to be observed for engine oils (year 2003) Year Types of engine concerned ACEA norms API norms Petrol and dual fuel A3 or A5 5 (*) SJ or SL petrol / LPG engines 2003 Diesel engines B3 or B5 (*)
  • Page 48 ALL TYPES LUBRICANTS - TOTAL recommended oils Oils specifically for petrol and dual fuel petrol / LPG engines S.A.E. norms ACEA norms API norms TOTAL ACTIVA 7000 10W40 TOTAL QUARTZ 7000 TOTAL QUARTZ 9000 0W40 TOTAL ACTIVA 7000 15W50 TOTAL QUARTZ 7000 Oils specifically for diesel engines S.A.E.
  • Page 49 LUBRICANTS - TOTAL recommended oils ALL TYPES Oil usage table TOTAL ACTIVA QUARTZ Engine types Synthetic 9000 Semi-synthetic 7000 0W40 cold 15W50 hot 5W30 5W40 10W40 countries countries XU10 J4RS (Xsara VTS 2.0i 16V) Petrol EW 12 J4 (C8 2.2i 16V) engines Other petrol engines HDi engines with FAP (*)
  • Page 50 ALL TYPES LUBRICANTS - TOTAL recommended oils Selection of TOTAL engine oils, to be used according to the climatic conditions in the country where the vehicle is marketed. E4AP006D...
  • Page 51 LUBRICANTS - TOTAL recommended oils ALL TYPES 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 petrol and Oils specifically for diesel Blended oils for all engines dual-fuel petrol / LPG engines engines...
  • Page 52 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 7000 10W40 Germany 9000 0W40 Austria 7000 10W40 7000 10W40...
  • Page 53 LUBRICANTS - TOTAL recommended oils ALL TYPES 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 7000 10W40 Denmark 9000 0W40 7000 10W40 Spain 7000 15W40...
  • Page 54 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 7000 10W40 Hungary 9000 0W40 Italy Ireland 7000 10W40...
  • Page 55 LUBRICANTS - TOTAL recommended oils ALL TYPES 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 7000 10W40 Malta 7000 15W50 Moldavia 7000 10W40 7000 10W40...
  • Page 56 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 7000 10W40 Romania 7000 15W50 9000 0W40 Russia 7000 10W40...
  • Page 57 LUBRICANTS - TOTAL recommended oils ALL TYPES 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 10W40 7000 10W40 FUTURE 9000 5W30 (*) 9000 0W40...
  • Page 58 ALL TYPES LUBRICANTS - TOTAL recommended oils ENGINE OILS OCEANIA TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines Australia 9000 5W40 7000 10W40 7000 10W40 FUTURE 9000 5W30 New Zealand...
  • Page 59 LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS CENTRAL AND SOUTH AMERICA TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines Argentina Brazil Chile 7000 10W50 7000 15W50...
  • Page 60 ALL TYPES LUBRICANTS - TOTAL recommended oils 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 61 LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS SOUTH-EAST ASIA TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines Philippines 7000 15W50 Singapore 7000 10W40 9000 5W40 Taiwan...
  • Page 62 ALL TYPES LUBRICANTS - TOTAL recommended oils 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 Dubai 7000 15W50 United Arab Emirates...
  • Page 63 LUBRICANTS - TOTAL recommended oils ALL TYPES 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 64 ALL TYPES LUBRICANTS - TOTAL recommended oils 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 65 LUBRICANTS - TOTAL recommended oils ALL TYPES BRAKE FLUID Synthetic brake fluid CITROËN Part No. Pack 9979 05 0.5 Litre CITROËN fluid All countries 1 Litre 9979 06 5 Litres 9979 07 HYDRAULIC CIRCUIT Pack CITROËN Part No. All countries Norm TOTAL FLUIDE LDS Orange...
  • Page 66 ALL TYPES LUBRICANTS - TOTAL recommended oils SCREEN WASH FLUID Pack CITROËN Part No. Concentrated : 250 ml 9980 33 ZC 9875 953U 9980 56 9980 06 1 Litre ZC 9875 784U All countries Fluid ready for use 5 Litres 9980 05 ZC 9885 077U ZC 9875 279U...
  • Page 67 ENGINE OIL CONSUMPTION ALL TYPES I - Oil consumption depends on : - the engine type. - how run-in or worn it is. - the type of oil used. - the driving conditions. II - An engine can be considered RUN-IN after: - 3,000 miles (5,000 km) for a PETROL engine.
  • Page 68 ALL TYPES ENGINE SPECIFICATIONS Engines : HFX - KFW - NFT - NFV Petrol All Types 1.1i 1.6i 1.4i Vehicle Saxo Saxo Xsara Saxo Picasso Emission standard L4/IFL5/L4INF K’ K’/L4/IFL5 Engine type Cubic capacity (cc) 1124 1360 1587 Bore / Stroke 72/69 75/77 78.5/82...
  • Page 69 ENGINE SPECIFICATIONS ALL TYPES Engines : NFX - NFU - 6FZ - RFN - RFS Petrol All Types 1.6i 16V 1.8i 16V 2.0i 16V Vehicle Saxo C3/Xsara Picasso Xsara Picasso Xsara Emission standard K’/L4/IFL5 L4/IFL5 L4/IFL5 IFL5 Engine type Cubic capacity (cc) 1587 1749 1197...
  • Page 70 ALL TYPES ENGINE SPECIFICATIONS Engines : VJX - 8HX - 8HW - 8HV - 8HY - 8HZ Diesel All Types 1.5D 1.4 HDi 2.0 HDi 1.4 16V HDi 1.4 HDi Vehicle Saxo Xsara Xsara-Picasso Xsara Emission standard L4/IFL5 Engine type 8HX-8HW 8HV-8HY Cubic capacity (cc)
  • Page 71 SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) ALL TYPES CYLINDER HEAD (mm) Engine type 0.05 Maximum permissible bow - 0.20 Gasket surface regrinding TIGHTENING TORQUES ( m.daN) Crankshaft Pre-tightening 2 ± 0.2 2 ± 0.2 bearing screws Angular tightening 45°...

  • Page 72: All Types

    ALL TYPES SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) CYLINDER HEAD (mm) Engine type Maximum permissible bow 0.05 0.03 Gasket surface regrinding - 0.30 - 0.20 - 0.40 TIGHTENING TORQUES ( m.daN) (1) Ø 11 : 1 ± 0.1 2 ±...
  • Page 73 SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) A = HFX- KFV B = NFU RH engine support 4.5 ± 0.4 6.1 ± 0.6 4.5 ± 0.4 Torque reaction rod 6 ± 0.6 6 ± 0.6 LH engine support on gearbox 3 ±...
  • Page 74 SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) Crankshaft Engine types Accessories drive pulley 0.8 ± 0.2 Pinion fixing on crankshaft 10 ± 1 2.5 ± 0.2 Cylinder block Sump 0.8 ± 0.2 Timing belt tensioner roller 2 ± 0.2 2.2 ±...
  • Page 75 SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) Flywheel -Clutch Engines Flywheel 6.7 ± 0.6 + LOCTITE FRENETANCH Clutch mechanism 2 ± 0.2 Lubrication circuit Oil pressure switch 2 ± 0.2 Oil pump 0.9 ± 0.1 Cooling circuit Coolant pump 1.4 ±...
  • Page 76 SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) Engines : 8HX - 8HW RH engine support 4.5 ± 0.4 3 ± 0.3 Torque reaction rod 6 ± 0.6 6 ± 0.6 LH engine support on gearbox 5.4 ± 0.5 6 ± 0.6 5.5 ±...
  • Page 77 SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) Engines 8HW - 8HX Crankshaft Bearing cap fixing screw Pre-tightening Slackening Tightening Angular tightening 140° Con rod nuts Pre-tightening Slackening Tightening 1.5 ± 0.1 Angular tightening 100° ± 5° Accessories drive pulley Pre-tightening 3 ±...
  • Page 78 SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) Engines 8HW - 8HX Cylinder head Camshaft bearing covers Pre-tightening 0.5 ± Tightening 1 ± Fixings of camshaft sub-assemblies on cylinder head Pre-tightening Tightening Exhaust manifold 2.5 ± 0.2 Valve cover 2.5 ± 0.2 Camshaft pulley 4.3 ±...
  • Page 79 SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) Engines 8HW - 8HX Diesel injection circuit Spherical-base screws for diesel injection fixing fork 0.3 ± 0.1 Fuel high pressure common injection rail on engine block 2 ± 0.2 Unions on fuel high pressure common injection rail Diesel injection pump on support 2.25 ±...
  • Page 80 SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) Engines : 8HY - 8HV RH engine support Screw (1) 6 ± 0.6 Screw (2) 6 ± 0.6 RH lower engine support Screw (3) 5.7 ± 0.5 LH upper engine support Screw (7) 6 ±...
  • Page 81 C3 - XSARA SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) Engines 8HY - 8HV Crankshaft Bearing cap fixing screw Tightening 3 ± 0.3 Angular tightening 140° ± 1°.4’ Crankshaft pullet hub Tightening 3 ± 0.3 Angular tightening 180° ± 5° Cylinder block Oil sump 1 ±...
  • Page 82 C3 - XSARA SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) Engines 8HY - 8HV Flywheel -Clutch Flywheel 1.7 ± 0.2 Clutch mechanism 2 ± 0.2 Lubrication circuit Oil pump assembly 0.9 ± 0.1 Oil/coolant heat exchanger 1 ± 0.1 Turbocharger lubrication pipe 2.2 ±...
  • Page 83 TUD - XU SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) Engines : RFS - VJX SAXO XSARA - Pre-tighten 0.5 - Pre-tighten 0.4 - Tighten to - Tighten to B1DP03BC B1DP01YD...
  • Page 84 SAXO - XSARA PICASSO CYLINDER HEAD Engines : HDZ - HFX - KFW - KFV - NFT - NFV - NFX - NFU - VJX Identification of the cylinder head gasket NFT - NFV NFX - NFU Engine type Identification marks (Notch on cylinder head gasket) Thickness CURTY...
  • Page 85 CYLINDER HEAD (continued) SAXO - XSARA - PICASSO Engines : HDZ – HFX – KFW - NFT – NFV - NFX – NFU – VJX Cylinder head tightening (m.daN) Cylinder head bolts HDZ-HFX-KFW-NFV-NFT - Pre-tightening - Angular tightening 240° ± 5° Note : Oil the threads and under the heads of the cylinder head bolts.
  • Page 86 CYLINDER HEAD Engines : HFX - KFV - NFU Identification of the cylinder head gasket Engines Thickness (repair) Thickness ref. Thicknesses (Standard) 1.4 ± 0.1 1.2 ± 0.1 0.66 ± 0.04 References 1.2.3.4 = Type of engine. A.B.D = Suppliers = Gasket material.
  • Page 87 CYLINDER HEAD Engines : HFX - KFV - NFU Cylinder head tightening (m.daN) Cylinder head bolts HFX - KFV Tighten to 2 ± 0.2 Angular tightening 240° ± 5° (in the order 1 to 10) Tighten to 2 ± 0.2 Angular tightening 260°...
  • Page 88 CYLINDER HEAD Engines : 8HY - 8HV Identification of the cylinder head gasket Piston Thicknesses No. of notches No. of notches Engine types Supplier standproud (mm) at d at e (mm) Type of gasket : Metallic multilayer 0.675 to 0.725 1.25 0.726 to 0.775 1.30...
  • Page 89 CYLINDER HEAD Engines : 8HY - 8HV Identification of the cylinder head gasket Piston Thicknesses No. of notches No. of notches Engine types Supplier standproud (mm) at d at e (mm) Type of gasket Metallic multilayer 0.771 to 0.820 1.35 0.611 to 0.720 1.25 "d"...
  • Page 90 XSARA - C3 CYLINDER HEAD Engines : 8HX - 8HW - 8HY - 8HV Cylinder head tightening (m.daN) Cylinder head bolts 8HX - 8HW - 8HY - 8HV Pre-tightening 2 ± 0.2 m.daN Tightening 4 ± 0.4 m.daN Angular tightening 230° ± 5° (In the order 1 to 10) NOTE : - The bolts should have been tho-...
  • Page 91 CYLINDER HEAD XSARA PICASSO Engine : 6FZ Identification of the cylinder head gasket Nominal Repair dimension dimension Marking zone 4 – 5 2 – 4 – 5 «d» Marking zone «e» Gasket thickness (mm) Supplier MEILLOR Marking « d » Marking zone «...
  • Page 92 XSARA PICASSO CYLINDER HEAD (continued) Engine : 6FZ Cylinder head tightening (m.daN) Cylinder head bolts Pre-tightening 1.5 ± 0.2 Tightening 5 ± 0.2 Loosening 360 ° (1 turn) Tightening 2 ± 0.2 Angular tightening 285° ± 5° B1DP16FC A = Washer thickness: 4 ± 0.2 mm. X = Length under heads of new bolts = 144.5 ±...
  • Page 93 CYLINDER HEAD (continued) XSARA PICASSO Engine : RFN Identification of the cylinder head gasket Nominal Repair dimension dimension Marking zone 4 – 5 2 – 4 – 5 «d» Marking zone «e» Gasket thickness (mm) Supplier MEILLOR Multilayer metallic gasket B1DP183D...
  • Page 94 XSARA PICASSO CYLINDER HEAD (continued) Engine : RFN Cylinder head tightening (m.daN) Cylinder head bolts Pre-tightening 1.5 ± 0.2 Tightening 5 ± 0.2 Loosening 360 ° (1 turn) Tightening 2 ± 0.2 Angular tightening 285° ± 5° B1DP16FC A = Washer thickness: 4 ± 0.2 mm. X = Length under heads of new bolts = 144.5 ±...
  • Page 95 CYLINDER HEAD XSARA Engine : RFS Identification of the cylinder head gasket Engine type Identification marks (Notch on cylinder head gasket) Suppliers MEILLOR 0 = Without notch 1 = One notch B1BP004C...
  • Page 96 CYLINDER HEAD (continued) XSARA Engine : RFS Cylinder head tightening (m.daN) Cylinder head bolts - Pre-tightening - Slackening - Tightening - Angular tightening 160° Note : Oil the threads and under the heads of the cylinder B1DP13PC head bolts. X = MAXIMUM re-usable length (Use engine oil or Molykote G Rapid Plus).
  • Page 97 CYLINDER HEAD XSARA Engine : WJY Identification of the cylinder head gasket Piston Thickness Number Number Engine stand-proud (mm) of holes of holes type (mm)* ± 0.04 at A at B 0.51 to 0.55 1.26 0.55 to 0.59 1.30 0.59 to 0.63 1.34 0.63 to 0.67 1.38...
  • Page 98 XSARA - XSARA PICASSO CYLINDER HEAD Engines : RHY - RHZ Identification of the cylinder head gasket Piston Engine Thickness Number of notches stand-proud type (mm) 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 99 CYLINDER HEAD (continued) XSARA - XSARA PICASSO Engines : WJY - RHY - RHZ Cylinder head tightening (m.daN) Cylinder head bolts RHY - RHZ - Pre-tightening - Tightening - Angular tightening 180° RHY - RHY - Pre-tightening - Tightening - Angular tightening 220°...
  • Page 100 ALL TYPES BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE Tools 4122-T (C.TRONIC.105.5) 4099-T (C.TRONIC.105)
  • Page 101 AUXILIARY EQUIPMENT DRIVE BELT ALL TYPES J4RS Engine type : SAXO See pages : See pages : 101 to 102 101 to 102 101 to 102 XSARA 108 to 109 See pages : XSARA PICASSO See pages : 103 to 104...
  • Page 102 ALL TYPES AUXILIARY EQUIPMENT DRIVE BELT TED4 ATED Engine type SAXO See pages : See pages : 117 to 118 XSARA See pages : 117 to 118 111 to 116 120 to 123 XSARA PICASSO See pages : 120 to 123...
  • Page 103 AUXILIARY EQUIPMENT DRIVE BELT ALL TYPES Engines : All Types Petrol et 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 90. ESSENTIAL - Before refitting the auxiliary equipment drive belt, check that: 1) The roller(s) rotate freely (no play or stiffness).
  • Page 104 SAXO AUXILIARY EQUIPMENT DRIVE BELT Engines : HFX - KFW - NFT Without air conditioning With air conditioning - Fit the tool 4122 - T. - Fit the tool 4122-T. - Tighten the tensioning screw (3) - Tighten the tensioning screw (5) to obtain : to obtain : 55 ±...
  • Page 105 AUXILIARY EQUIPMENT DRIVE BELT Engines : HFX - KFV - NFU Tools [1] Pliers for removing plastic pegs : 7504-T. [2] Belt tension measuring instrument : 4122-T. Vehicle without air conditioning. Remove. Refit. Slacken: Refit the belt. Respect the following sequence: - Screw (2).
  • Page 106 AUXILIARY EQUIPMENT DRIVE BELT Engines : HFX - KFV - NFU Vehicle with air conditioning. Remove Slacken: - Screws (6), (4) and (5). - Fully detension the belt by acting on the tensioner roller. - Remove the accessories drive belt. Refit.
  • Page 107 AUXILIARY EQUIPMENT DRIVE BELT XSARA PICASSO Engine : NFV Without air conditioning. Tools. [1] Pliers for removing plastic pegs : 7504 –T. [2] Belt tension measuring instrument : 4122 –T. [3] TORX spanner. Remove. - Release the central screw (1) tool [3]. - Detension the tensioner roller (2), (flat spanner 27 on flat).
  • Page 108 XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT Engine : NFV With air conditioning. Tools. [1] Plyers for removing plastic pegs : 7504 –T. [2] Belt tension measuring instrument : 4122 –T. [3] 10 mm square(drain spanner). [4] TORX spanner. Remove. - Detension the automatic tensioner, tool [3]. - Place a Ø...
  • Page 109 AUXILIARY EQUIPMENT DRIVE BELT XSARA Engine : KFW Alternator With air conditioning [1] Belt tension measuring instru- [1] Belt tension measuring instru- ment : 4122-T ment : 4122-T - Tension the belt using the screw (2). - Tension the belt using the screw (4).
  • Page 110 SAXO - XSARA AUXILIARY EQUIPMENT DRIVE BELT Engines :NFX - NFU Without air conditioning (1) Tensioner roller fixing screw (2) Tensioning screw - New belt : 120 SEEM units. - Reused belt : 86.5 ± 3.5 SEEM units. B1BP1AMC With air conditioning (3) Tensioner roller fixing screw (4) Tensioning screw - CNew belt : 120 SEEM units.
  • Page 111 AUXILIARY EQUIPMENT DRIVE BELT SAXO- XSARA Engine : VJX Without air conditioning - (6) Roller support fixing screw. - (7) Tensioning screw - Pre-tension the belt (8) to : 120 SEEM units. - Rotate the crankshaft by 3 turns (Direction of rotation). - Adjust the belt (8) tension to : 120 SEEM units.
  • Page 112 XSARA AUXILIARY EQUIPMENT DRIVE BELT Engine : RFS With air conditioning - Fit the drive belt. - The tensioner roller (1). - Tighten the screws (3) to 2 m.daN. - Move the tensioner roller (1) using the tool (9.52 mm square drive (3/8)) at (2), in order to remove the tool or locking peg (Ø...
  • Page 113 AUXILIARY EQUIPMENT DRIVE BELT XSARA Engine : RFS Without air conditioning TOOLS [1] Belt tension measuring instrument 4122-T - (1) Tensioning screw. - (2) Roller support fixing screw (3). - Lightly tighten the screws (2). - Place the tool [1] on the belt. - Tension the belt using the screw (1).
  • Page 114 XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT Engines : 6FZ - RFN Without air conditioning With air conditioning Tools [1] Pliers for removing plastic pegs 7504-T Remove the belt. - Detension the belt (3) by turning the screw (2) of the tensioner roller (1) (anti-clockwise).
  • Page 115 AUXILIARY EQUIPMENT DRIVE BELT XSARA Engine : WJY Without power-assisted steering Tools : [1] Belt tension measuring instrument : 4122-T. Removal. - Loosen the screws (2). - Tighten the screw (1) until it is against its stop. - Remove the belt. Refitting.
  • Page 116 XSARA AUXILIARY EQUIPMENT DRIVE BELT Engine : WJY Without power-assisted steering, with air conditioning Tools : [1] Belt tension measuring instrument : 4122-T. Removal. - Loosen the screws (1). - Tighten the screw (2) until it is against its stop. - Remove the belt.
  • Page 117 AUXILIARY EQUIPMENT DRIVE BELT XSARA Engine : WJY Power-assisted steering, without air conditioning Tools : [1] Belt tension measuring instrument : 4122-T. Removal. WARNING : If the belt is to be reused, measure the tension before removal. - Loosen : - the screw (1).
  • Page 118 XSARA AUXILIARY EQUIPMENT DRIVE BELT Engine : WJY Power-assisted steering, without air conditioning (continued) Refitting. - Refit the belt. - Place the tool [1] on belt at "f". WARNING : Position tool [1], with the knob downwards. - tighten the nut (2) to obtain a value of : Reused belt: Keep the value taken at removal.
  • Page 119 AUXILIARY EQUIPMENT DRIVE BELT XSARA Engine : WJY Power-assisted steering, with air conditioning Outillage : [1] Dynamic tensioner peg : (-) 0188 H. [2] Belt tension measuring instrument : 4122-T. Removal. - Peg the dynamic tensioner (1) at "a", using tool [1]. - Loosen the screw (2) of the roller (3).
  • Page 120 XSARA AUXILIARY EQUIPMENT DRIVE BELT Engine : WJY Power-assisted steering with air conditioning (continued) Refitting. - Refit the belt. - Using a 7 mm square drive at "b", turn the roller (3), until the tool [1] located at "a" becomes free. - Tighten the screw (2).
  • Page 121 AUXILIARY EQUIPMENT DRIVE BELT With compressor and alternator Engines : 8HX - 8HW Tools [1] Pliers for removing plastic pegs : 7504-T. [2] Tensioner roller compression lever : (-).0194.E. [3] Tensioner roller setting peg Ø4 mm : (-).0194.F. Removing. Disconnect the battery negative cable. Raise and support the vehicle, wheels hanging.
  • Page 122 AUXILIARY EQUIPMENT DRIVE BELT Engines : 8HX - 8HW Markings on the dynamic tensioner roller. "a" Position of «maximum wear» of the auxiliary drive belt. "b" Normal position. Refitting NOTE : Check that the tensioner roller moves freely (no tight spot). If this is not the case, replace the tensioner roller.
  • Page 123 AUXILIARY EQUIPMENT DRIVE BELT Engines : 8HY - 8HV Tools. [1a] Dynamic tensioner roller lever : (-).0194-E1. [1b] Lever extension : (-).0194-E2. [2] Accessories belt roller locking peg Ø 4 mm : (-).0194-F Removing Pivot the tensioner roller support (1) (clockwise), using tools [1a] and [1b] at «a». Remove the belt.
  • Page 124 XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT Engines : RHY - RHZ Without air conditioning Tools [1] Belt tension adjusting square : (-).0188 J2 [2] Ø 4 mm peg : (-).0188.Q1 [3] Ø 2 mm peg : (-).0188.Q2 [4] Dynamic tensioner compression lever : (-).0188.Z REMOVAL Re-use of belt...
  • Page 125 AUXILIARY EQUIPMENT DRIVE BELT XSARA - XSARA PICASSO Engines : RHY - RHZ Without air conditioning (continued) REFITTING. Re-used belt - Compress the tensioner roller (2) by action at « a » (in anti-clockwise direction), tool [4]. - Refit the belt. WARNING : Respect the belt-fitting direction.
  • Page 126 XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT Engines : RHY - RHZ With air conditioning Tools [1] Belt tension adjusting square : (-).0188 J2 [2] Pige Ø 4 mm : (-).0188.Q1 [3] Pige Ø 2 mm : (-).0188.Q2 [4] Dynamic tensioner compression lever : (-).0188.Z REMOVAL Re-use of belt...
  • Page 127 AUXILIARY EQUIPMENT DRIVE BELT XSARA - XSARA PICASSO Engines : RHY - RHZ With air conditioning (continued) REFITTING. Re-used belt - Compress the tensioner roller (7) by action at « c » (in anti-clockwise direction), tool [4]. - Refit the belt. WARNING : Respect the direction belt was fitted.
  • Page 128 ALL TYPES CHECKING AND SETTING THE VALVE TIMING J4RS Engine type SAXO See pages : 126 to 128 126 to 128 139 to 142 See pages : 129 to 138 129 to 138 129 to 138 XSARA 2003 163 to 173 126 to 128 139 to 142 182 to 186...
  • Page 129 CHECKING AND SETTING THE VALVE TIMING ALL TYPES TED4 ATED Engine type SAXO See pages : 143 to 145 See pages : 146 to 153 154 to 162 XSARA N° RPO 9127 192 to 196 See pages : 146 to 153 187 to 191 N°...
  • Page 130 SAXO - XSARA CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFW - NFT - NFV TOOLS à - [1] Flywheel locating peg : 4507-T.A - [2] Camshaft pulley locating peg : 4507-T.B Tool kit 4507-T - [3] Square drive : 4507-T.J - [4] Belt tension measuring instrument : 4122-T...
  • Page 131 SAXO - XSARA CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFW - NFT - NFV REFITTING THE TIMING BELT. NOTE : Check that the pegs [1] and [2] are in place. WARNING : Ensure the belt is fitted in the right direction : The arrows «a» signify the crankshaft direc- tion of rotation.
  • Page 132 SAXO - XSARA CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFW - NFT - NFV REFITTING THE TIMING BELT NOTE : Check that the pegs [1] and [2] are in place. WARNING : Ensure the belt is fitted in the right direction : The arrows «a» signify the crankshaft direction of rotation. Fit : - The timing belt, with the belt strip "b"...
  • Page 133 CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFV - NFU Tools. [1] Engine flywheel peg : 4507-T.A [2] Camshaft pulley peg : 4507-T.B [3a] Camshaft peg : 4533-TA.C1 [3b] Camshaft peg : 4533-TA.C2 [4] Dynamic tensioner roller pin : 4200-T.H [5] Belt retaining pin : 4533-T.AD...
  • Page 134 CHECKING AND SETTING THE VALVE TIMING Engine : NFU Checking the timing (continued) Engine : NFU Place a jack under the engine, peg the engine. Remove: - The engine support (4) complete. - The timing casing (3). - The sparking plugs (eases engine rotation). Turn the wheel to rotate the engine (normal direction of rotation).
  • Page 135 CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFV Setting the timing Preliminary operation. Lift and support the vehicle, wheels hanging. Disconnect the battery. Remove: - The front RH wheel. - The splash-shield, using tool [6] - The accessories belt (See corresponding operation). - The crankshaft pulley.
  • Page 136 CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFV Setting the timing (continued) Engine HFX - KFV Slacken the screws (4) without removing them. Remove the bottom engine support assembly (5), and the fixing screws (4). Slacken the nut (6). Completely detension the belt by acting on the tensioner roller (7).
  • Page 137 CHECKING AND SETTING THE VALVE TIMING Engine : NFU Engine NFU. Setting the timing (continued) Remove: The bottom plastic casing. The engine support (9). The middle support. The timing cover (8). Peg the flywheel, using tool [1]. Position the tools [3a] and [3b]. B1BP2MFC B1BP2MBC B1EP18MC...
  • Page 138 CHECKING AND SETTING THE VALVE TIMING Engine : NFU Setting the timing (continued) Engine: NFU Slacken the tensioer roller. Turn the tensioner roller so as to be able to position the tool [4], with the aid of an Allen key placed at «a». Turn the tensioner roller towards the right to bring it to the index «c»...
  • Page 139 CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFV Setting the timing (continued) Engines: HFX-KFV Refit. WARNING: Respect the direction of fitting of the belt: (the arrows «d» indicate the direction of rotation of the crankshaft). Refit the timing belt. Position the timing belt, belt «e»...
  • Page 140 CHECKING AND SETTING THE VALVE TIMING Engines : KFX - KFV - NFU Setting the timing (continued) Engines: HFX-KFV Refitting. NOTE : Check that the pegs [1] and [2] are in place. WARNING: Respect the direction of fitting of the timing belt, the arrows «d» indicate the direction of rotation of the crankshaft.
  • Page 141 CHECKING AND SETTING THE VALVE TIMING Engine : NFU Timing belt overtensioned: A : Engines: HFX – KFV. B : Engine: NFU Turn the tensioner roller (7) with the aid of a hexagonal spanner at «a». Bring the index «c» to position «f», to tension the belt to the maximum of the inter- val indicated.
  • Page 142 CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFV - NFU Adjusting the fitting tension of the timing belt A : Engine : HFX – KFV. B : Engine: NFU. Slacken the nut while maintaining the position of the tensioner roller, with the aid of a hexagonal spanner at «a».
  • Page 143 SAXO - XSARA CHECKING AND SETTING THE VALVE TIMING Engines : NFX - NFU TOOLS - [1] Belt tension measuring instrument : 4122-T à - [2] Flywheel locating peg : 4507-T.A. - [3] Camshaft pulley locating peg, exhaust : 4533-T.A. C2 Tool kit 4507-T - [4] Camshaft pulley locating peg, inlet : 4533-T.A.
  • Page 144 SAXO - XSARA CHECKING AND SETTING THE VALVE TIMING Engines : NFX - NFU SETTING THE VALVE TIMING - Loosen the screw (2), remove the belt. - Loosen the six pulley screws (1) on the hubs. (There should be a slight amount of friction between the screws and the pinions). - Check that the rollers (2) and (3) rotate freely.
  • Page 145 CHECKING AND SETTING THE VALVE TIMING SAXO - XSARA Engines : NFX – NFU SETTING THE VALVE TIMING Turn the two pulleys (1) clockwise to the end of the slots. - With the belt strip (e) fully tensioned, place the belt over the pulley, first exhaust side, then inlet side, while ensuring that marks (b) and (c) on the belt are aligned with marks (f) on the pulleys.
  • Page 146 SAXO - XSARA CHECKING AND SETTING THE VALVE TIMING Engines : NFX – NFU SETTING THE VALVE TIMING - Remove the tools [1], [2], [3] and [4]. - Rotate the engine by four turns in the normal direction. (do not turn backwards). - Peg the flywheel [2].
  • Page 147 SAXO CHECKING AND SETTING THE VALVE TIMING Engine : VJX TOOLS à - Belt tension measuring instrument : 4099-T or 4122-T - Flywheel locating peg : 4507-T.A. - Injection pump pulley locating peg : 4527-T. S1 Tool kit 4507-T - Camshaft pulley locating peg : 4527-T.
  • Page 148 SAXO CHECKING AND SETTING THE VALVE TIMING Engine : VJX SETTING THE VALVE TIMING - Fit the belt in the following order : The crankshaft pinion, the injection pump pulley, the camshaft pulley, the water pump pinion. WARNING : When positioning the belt on the injection pump and camshaft pulleys, they should be turned in the opposite direction of rotation so as to engage the nearest tooth.
  • Page 149 CHECKING AND SETTING THE VALVE TIMING SAXO Engine : VJX SETTING THE VALVE TIMING - Tighten the screws (1) and (3) to 2.3 m.daN (lock the pulleys using tool 6016 - T). - Remove the tools. - Rotate the engine by 10 turns. - Peg : The flywheel, the pulleys (2) and (4).
  • Page 150 CHECKING AND SETTING THE VALVE TIMING Engines : 8HX - 8HW SETTING THE VALVE TIMING - Tighten the screws (1) and (3) to 2.3 m.daN (lock the pulleys using tool 6016 - T). - Remove the tools. - Rotate the engine by 10 turns. - Peg : The flywheel, the pulleys (2) and (4).
  • Page 151 CHECKING AND SETTING THE VALVE TIMING Engines : 8HX - 8HW Check ing the setting (continued) Remove: - the accessories drive belt. - the accessories drive pulley. - the lower timing cover (3). IMPERATIVE : The magnetic track should show no signs of damage and should not be approached by any other source of magnetism.
  • Page 152 CHECKING AND SETTING THE VALVE TIMING Engines : 8HX - 8HW Setting the timing. Remove the upper timing cover (1). Rotate the engine by means of the crankshaft screw (2). NOTE : The pegging hole is located under the crankshaft bearing cap cover. Peg the engine flywheel, using tool [3].
  • Page 153 CHECKING AND SETTING THE VALVE TIMING Engines : 8HX - 8HW Setting the timing (continued). Remove the tool [3]. Rotate the engine by means of the crankshaft pinion screw (2) (clockwise), to bring it to the pegging position. Peg the camshaft pulley, using tool [4]. Peg : - The crankshaft pinion (6), using tool [5].
  • Page 154 CHECKING AND SETTING THE VALVE TIMING Engines : 8HX - 8HW Setting the timing (continued). Hold the tensioner roller, using a hexagonal spanner at «b». Slacken the screw (9). Remove the timing belt (10). Refitting. IMPERATIVE : Check that both the tensioner roller and the fixed roller turn freely (no tight spots).
  • Page 155 CHECKING AND SETTING THE VALVE TIMING Engines : 8HX - 8HW Setting the timing (continued). NOTE : Screw (9) slackened. Position the timing belt (10) observing the following sequence: Crankshaft pinion (4). Guide roller (12). Camshaft pulley (11), (check that the belt is held correctly against the roller). Coolant pump pinion (13).
  • Page 156 CHECKING AND SETTING THE VALVE TIMING Engines : 8HX - 8HW Setting the timing (continued). Turn the tensioner roller to the right to bring the index «c» to position «d», using a hexagonal spanner. Tighten the screw (9) of the tensioner roller, tighten to 3 ± 0,3 m.daN. Remove the tools [4] and [5].
  • Page 157 CHECKING AND SETTING THE VALVE TIMING Engines : 8HX - 8HW Setting the timing (continued). Refit: The intermediate RH engine support, tighten the screws (16) to 5,5 ± 0,5 m.daN. The RH engine support, tighten the screws (17) to 4,5 ± 0,4 m.daN. The bottom timing cover (3).
  • Page 158 CHECKING AND SETTING THE VALVE TIMING Engines : 8HY - 8HV Tools. [1] Engine flywheel peg Ø 12 mm : (-).0194-C. [2] Camshaft pulley peg Ø 8 mm : (-).0194-B. [3] Crankshaft pulley peg Ø 5 mm : (-).0194-A. Preliminary operations. Remove: - The front RH wheel.
  • Page 159 CHECKING AND SETTING THE VALVE TIMING Engines : 8HY - 8HV Checks. Rotate the engine to engage it (normal direction of rotation). Immobilise the engine flywheel at «a», using tool [1]. Move aside the harness (6). Remove: - The engine support (7). - The screw (8).
  • Page 160 CHECKING AND SETTING THE VALVE TIMING Engines : 8HY - 8HV Checks (continued). Refit the screw (8). Rotate the crankshaft six times (clockwise). IMPERATIVE : Never rotate the engine backwards. Peg : - The camshaft, using tool [2]. (Oil the pegs.) - The fuel high pressure pump pulley (14), using tool [3] at «c».
  • Page 161 CHECKING AND SETTING THE VALVE TIMING Engines : 8HY - 8HV Checks (continued). NOTE : The index «e» of the dynamic tensioner roller should be centred within the area «d». Check the correct positioning of the index «e». If it is not correct, repeat the operation to tension the timing belt (see corresponding operation). Refitting.
  • Page 162 CHECKING AND SETTING THE VALVE TIMING Engines : 8HY - 8HV Checks (continued). Refit : - The engine support (7), tighten to 1,5 ± 0,4 m.daN. - The engine support (4), tighten to 6,1 ± 0,6 m.daN. - The engine support (5), tighten to 6 ± 0,6 m.daN. - The electrical harness (6).
  • Page 163 CHECKING AND SETTING THE VALVE TIMING Engines : 8HY - 8HV Setting the timing. Perform the preliminary operations for checking the timing up to removing tool [1] at «a» for immobiling the engine flywheel. Refit screw (8). Rotate the crankshaft to bring the camshaft towards its pegging point. Peg the camshaft, using tool [2].
  • Page 164 CHECKING AND SETTING THE VALVE TIMING Engines : 8HY - 8HV Setting the timing (continued). Checking the setting. IMPERATIVE : Just prior to refitting, carry out the following tests: Check that: - the rollers and the coolant pump operate freely (no play and no tight spot).
  • Page 165 CHECKING AND SETTING THE VALVE TIMING Engines : 8HY - 8HV Setting the timing (continued). Checks (continued). Reposition the timing belt, belt at «e» well tensioned, in the following order: - Guide roller (17). - Camshaft pulley (16). - Fuel high pressure pump pulley (15). - Coolant pump pinion (18).
  • Page 166 CHECKING AND SETTING THE VALVE TIMING Engines : 8HY - 8HV Adjusting the timing belt tension (continued). IMPERATIVE : Never rotate the engine backwards. WARNING : Do not touch or damage the track of the target of the engine speed sensor (14). Peg the crankshaft, using tool [3].
  • Page 167 CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines : 6FZ - RFN # 2003 TOOLS [1] Camshaft setting pegs : (-).0189.A [2] Crankshaft setting peg : (-).0189.B Tool kit C.0189. [3] Belt locking pin : (-).0189.K [4] Angular tightening adaptor : 4069-T.
  • Page 168 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN # 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 tensioner roller (6).
  • Page 169 CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines : 6FZ - RFN # 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 170 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN # 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;...
  • Page 171 CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engine : RFN # 2003 Tools. [1] Crankshaft setting peg : (-).0189-B [2] Camshaft hub setting pegs : (-).0189-AZ [3] Belt locking pin : (-).0189-K [4] Positioning peg : (-).0189-J [5] Hub immobilising tool : (-).6310-T Removing.
  • Page 172 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engine : RFN # 2003 Removing (continued). Peg : - The camshafts, using tool [2]. - The crankshaft, using tool [1]. Slacken screw (7), holding tool [4]. Using the hexagonal key (C), turn the eccentric hub (8) of the tensioner roller (9) (clockwise), to detension the belt.
  • Page 173 CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO 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). If replacing the roller (11), tighten the fixing to 3,5 ±...
  • Page 174 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engine : RFN # 2003 Fitting tension of the timing belt. Remove the tool [3]. (D) : Maximum position. (E) : Nominal tension position. Using the hexagonal key (C), turn the hub of the roller (anti-clockwise), to bring the index (10) to position (D) so as to tension the belt to the maximum.
  • Page 175 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engine : RFN # 2003 Position of the crankshaft. NOTE : This operation enables you to position all the pegs in their respective pegging points. Peg : - The camshaft pulleys, using tool [2]. - The crankshaft, using tool [1].
  • Page 176 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engine : RFN # 2003 Refitting (continued). Refit : - The timing cover (6). - The accessories drive pulley. B1EK0V7D - Screws (4), tighten to 2,1 ± 0,2 m.daN. - The timing cover (5). - The torque reaction rod (3).
  • Page 177 CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO OLD FITTING # 2003 Engines : 6FZ - RFN # 2003 (1) Crankshaft pinion. (2) Flange. (3) Accessories drive pulley. (4) Screw fixing accessories drive pulley on flange (2). (5) Screw fixing the flange (2) on the crankshaft. «a»...
  • Page 178 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING NEW FITTING 2003 # Engines : 6FZ - RFN 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 washer (8) and screw (9).
  • Page 179 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN 2003 # Tools. [1] Camshaft setting peg : (-) 0189.A [2] Crankshaft setting peg : (-).0189.R [3] Timing belt retaining pin : (-).0189.K [4] Adaptor for angular tightening : 4069-T [5] Tool for moving and locking the tensioner roller : (-).0189.S...
  • Page 180 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING NEW FITTING # 2003 Engines : 6FZ - RFN 2003 # Checking the setting of the timing (continued). Turn the engine by means of the crankshaft pinion screw, to bring it to the pegging position. Peg the crankshaft, using tool [2].
  • Page 181 CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines : 6FZ - RFN 2003 # Setting the timing. Removing. Disconnect the battery negative terminal (See corresponding operation). Raise and support the vehicle, front wheels hanging. Remove: The front RH wheel. The plastic pins (1).
  • Page 182 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN 2003 # Setting the timing (continued) Peg: The crankshaft, using tool [2]. The camshaft pulleys (5) and (6), using tool [1]. Remove: The screw (3) of the crankshaft pulley (2). The lower timing cover (4) (by moving the engine).
  • Page 183 CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines : 6FZ - RFN 2003 # Setting the timing (continued) Turn the tensioner roller (8), using tool [5a] to go beyond slot (b). Position the tool [5b] to lock the index (a) and remove the tool [5a]. Reposition the timing belt (7) on the crankshaft pulley.
  • Page 184 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ-RFN 2003 # Tensioning the timing belt. Turn the tensioner roller (8) in the direction of the arrow « c », by means of a hexagonal spanner at « d ». Positionner l’index «...
  • Page 185 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN 2003 # Refitting (continued) Remove the tools [1] and [2]. Rotate the crankshaft ten times (normal direction of rotation). IMPERATIVE : No pressure or outside force should be brought to bear on the timing belt. Peg the inlet camshaft pulley, using tool [1].
  • Page 186 XSARA CHECKING AND SETTING THE VALVE TIMING Engine : RFS TOOLS [1] Belt tension measuring instrument : 4122-T à [2] Camshaft pulley locating peg : 9041-T.Z Tool kit 7004-T [3] Crankshaft locating peg : 7014-T.N [4] Camshaft pulley locking peg : 4200-T.G [5] Tensioner spanner : 7017-T.W...
  • Page 187 XSARA CHECKING AND SETTING THE VALVE TIMING Engine : RFS Setting the valve timing. Peg the crankshaft using tool [3]. Refit : - Peg the camshaft pulleys using tool [2]. - Lock the flywheel using the tool [6]. - The pulley (5). - The screw (4) (Tighten moderately).
  • Page 188 CHECKING AND SETTING THE VALVE TIMING XSARA Engine : RFS Pretensioning the timing belt. - Peg the crankshaft using the tool [3]. - Peg the camshaft pulleys using the tool [2]. NOTE : Ensure that the camshaft pulleys rotate freely on the hubs. Clean the contact faces of the pulleys and hubs.
  • Page 189 CHECKING AND SETTING THE VALVE TIMING XSARA Engine : RFS Tensioning the timing belt. - Peg the crankshaft using the tool [3]. - Peg the camshaft pulleys using the tool [2]. NOTE : If it is not easy to peg the camshaft hubs, loosen the tensioner roller (7), and turn the camshafts using the screw (10).
  • Page 190 CHECKING AND SETTING THE VALVE TIMING XSARA Engine : RFS - Tension to : (Pulleys slackened). Engine Engine : RFS New belt 35 SEEM units - Tighten the screw of the roller (7) to 2 m.daN. Fit the tool [4]. - Tighten the screws (10) to 7.5 m.daN.
  • Page 191 CHECKING AND SETTING THE VALVE TIMING XSARA Engine : WJY TOOLS - [1] HM screw : (-) 0 188 E - [2] Locating peg Ø 6 mm : (-) 0 188 H - [3] Flywheel locating peg : (-) 0 188 D ( or 7014-T.J) Tool kit (-) 0 188.
  • Page 192 XSARA CHECKING AND SETTING THE VALVE TIMING Engine : WJY Setting the valve timing Peg : - The camshaft hub (1), using tool [1]. - The injection pump pinion (2), using tool [2]. - The flywheel, using tool [3]. - Lock the flywheel, using tool [4]. - Refit the screw (3) (without tightening it).
  • Page 193 CHECKING AND SETTING THE VALVE TIMING XSARA Engine : WJY Setting the valve timing (continued) NOTE : If necessary, slightly turn pinions (6) and (2) in an anti-clockwise direction in order to fit the belt. The angular movement of the belt in relation to the pinions must not exceed half a tooth.
  • Page 194 CHECKING AND SETTING THE VALVE TIMING XSARA Engine : WJY Setting the valve timing (continued) Rotate the crankshaft by 8 turns (direction of rotation). Peg : - The hub (1), using tool [1]. - The pinion (2), using tool [2]. - The flywheel, using the tool [3].
  • Page 195 CHECKING AND SETTING THE VALVE TIMING XSARA Engine : WJY Setting the valve timing (continued) Tighten : - The roller (9) to 2.1 m.daN. - The screws (4) and (5) to 2.3 m.daN. - Remove the tool [7]. - Fit the tool [7] to the belt strap at "a". - The tensioning value should be between 42 ±...
  • Page 196 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines : RHY-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...
  • Page 197 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines : RHY-RHZ # N° RPO 9127 Setting the valve timing. Peg : The engine flywheel, tool [3] (from below the vehicle). The camshaft, tool [5]. Slacken : The three screws (21). The screw (19) of the tensioner roller (20).
  • Page 198 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHZ # N° RPO 9127 Setting the valve timing (continued) - Setting the valve timing (continued) - Retighten screws (21) by hand. - Turn the pinion (24) (clockwise) to the bottom of the buttonhole. - Refit the belt on the crankshaft (25), in the following order, using the tool [4] to keep the belt tight at «...
  • Page 199 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines : RHY - 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 200 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHZ # N° RPO 9127 Setting the valve timing (continued) Tighten : The screw of the roller (19) to 2.5 ± 0.2 m.daN. The screw (21) to 2 ± 0.2 m.daN. Remove the tool [1].
  • Page 201 XSARA - XSARA PICASSO SPECIAL FEATURES: CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHZ N° RPO 9128 # OLD FITTING # N° RPO 9127 NEW FITTING N° RPO 9128 # The new timing on 8 valve engines DW10TD (RHY) and DW10 ATED (1) ) «Idler»...
  • Page 202 XSARA - XSARA PICASSO SPECIAL FEATURES: CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHZ N° RPO 9128 # NEW FITTING : RPO 9128 # (continued) The new fitting discontinues the following components : Camshaft hub. Cylinder reference sensor target. Repair –...
  • Page 203 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHZ N° RPO 9128 # Tools. Removing [1] Belt tension measuring equipment : 4122-T IMPERATIVE : Respect the safety and cleanliness requirements [2] Tension lever : (-).0188.J2. that are specific to high pressure diesel injection (HDi) engines.
  • Page 204 CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines : RHY - RHZ N° RPO 9128 # Uncouple, plug and move aside, using tool [7], the fuel delivery pipe (2) and return pipe (1). Remove : Screws (3), (4) and (6). Screw (7).
  • Page 205 CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines : RHY - 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].
  • Page 206 XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines : RHY - 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 : Check that : The rollers (18) and (15) turn freely (without play and without any tight spot).
  • Page 207 CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines : RHY - 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).
  • Page 208 CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines : RHY - RHZ N° RPO 9128 # Lock the engine flywheel, using tool [6]. Slacken : The accessories drive pulley (8). The screw (17) of the tensioner roller (18). Fit the tool [1].
  • Page 209 CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines : RHY - 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 210 SPECIAL FEATURES OF THE TIMING XSARA Camshaft hub identification Engine ‘‘a’’ engraving Hubs ‘‘b’’ paint marking Inlet BLUE Exhaust B1EP122C...
  • Page 211 VALVE CLEARANCE SETTINGS ALL TYPES 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 fully Rocking Adjust Adjust open Petrol All Types 0.20 mm ±...
  • Page 212 CHECKING THE OIL PRESSURE ALL TYPES To be read with the Petrol and Diesel correspondence tables Tools Tool kit 4103 -T TU all Types XU all Types 1.1 i 1.4 i 1.6 i 1.6 i 16V 1.8 i 16V 2.0 i 16V Vehicle Engine type 90°...
  • Page 213 ALL TYPES OIL FILTERS TU All Types 1.1 i 1.4 i 1.6 i 1.6i 16V 1.8i 2.0i 16V FILTRAUTO 1109 R7 1109 N3 LS 867 B PURFLUX 1109 T1 LS 923 TUD5 DV4TD DV4TED4 DW10 1.4 16V HDi 1.9D 2.0 HDi 1.5 D 1.4 HDi 1109 T3...
  • Page 214 ALL TYPES FILLING AND BLEEDING THE COOLING CIRCUIT TOOLS [1] Filling cylinder : 4520-T [2] Adaptor for filling cylinder : 4222-T. IMPERATIVE : Respect the safety and cleanliness requirements. - The draining and refilling operations can be carried out using WINN’S or similar coolant fluid replacement equipment;...
  • Page 215 IDLING - DEPOLLUTION SAXO - C3 - XSARA PICASSO Idling speed % Content (± 50 rpm) Emission Vehicles Engine type Make - Injection type standard Man. Auto. gbox : N gbox gear engaged 1.1 i BOSCH M7.4.4. 1.4 i SAGEM 2000 SAXO 1.6 i BOSCH M7.4.4.
  • Page 216 SAXO PETROL INJECTION SAXO 1.6 i 1.6 i 16 V 1.1 i 1.4 i Engine type Emission standard IFL5 / L4 BOSCH SAGEM BOSCH M. MARELLI Injection make and type M.7.4.4. 48P2 S2000 M.7.4.4. Fuel pressure (bars) 5500 5500 5700 6600 Overspeed cut-off (rpm) 14.5...

  • Page 217: Petrol Injection

    PETROL INJECTION 1.1i 1.4i 1.6i 16 V Engine type Emission standard L4 / IFL5 Injection make M. MARELLI 48P2 SAGEM S2000 BOSCH M.7.4.4. and type Fuel pressure (bars) 5500 5500 5800 Overspeed cut-off (rpm) Injector resistive value (ohms) 14.5 14.5 14.5 Engine coolant temperature 3 800 at 10°C...
  • Page 218 XSARA - XSARA PICASSO PETROL INJECTION XSARA XSARA PICASSO 1.4 i 1.6 i 16 V 2.0 i 16 V 2.0 i 16 V 1.6 i 1.8 i 16 V Engine type IFL5 / L4 Emission standard IFL5 / L4 IFL5 / L4 / K’ IFL5 / L4 SAGEM BOSCH...
  • Page 219 DEPOLLUTION TECHNICAL CHECKS (FRANCE) ALL TYPES 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 220 ALL TYPES EMISSION STANDARDS APPLICATIONS STANDARD NOTES CHARACTERISTICS E.E.C. Engines Vehicles Applicable © Utility vehicle limits © = private vehicle limits 10/89 increased by 25 % With oxygen sensor, Petrol 15.04 Utility vehicles : without catalytic R 15.04 K’ 15.04 Diesel All Types ©...
  • Page 221 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 the U.S Current catalytic converter for US 83 US 83 Diesel European countries standard petrol vehicles •...
  • Page 222 ALL TYPES EMISSION STANDARDS APPLICATIONS STANDARD NOTES CHARACTERISTICS E.E.C. Engines Vehicles Applicable Private vehicles : © Adoption of the U.S. Petrol • certain non-EEC US 84 Current standard for light utility US 84 Diesel European countries vehicles • certain Export countries Private vehicles : ©...
  • Page 223 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 224 ALL TYPES EMISSION STANDARDS APPLICATIONS STANDARD NOTES CHARACTERISTICS E.E.C. Engines Vehicles Applicable Brussels Directive 98/69 Utility vehicles : © With 2 oxygen sensors EURO 2 standard (L3) and catalytic converter for < 3.5 tonnes made stricter petrol vehicles. © EURO 3 Fiscal incentives Petrol With catalytic converter...
  • Page 225 ALL TYPES EMISSION STANDARDS APPLICATIONS STANDARD NOTES CHARACTERISTICS E.E.C. Engines Vehicles Applicable With 2 oxygen sensors Private vehicles : Brussels Directive: 2001/1 © and catalytic converter for All Types EURO 3 standard (L4) made Petrol petrol vehicles. stricter Diesel EURO 4 IF / L5 ©...
  • Page 226 SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM XSARA - XSARA PICASSO Engines : RHY - RHZ - 8HX - 8HW - 8HY - 8HV 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 227 SAFETY REQUIREMENTS : HDI DIRECT INJECTION SYSTEM XSARA - XSARA PICASSO Engines : RHY - RHZ - 8HX - 8HW - 8HY - 8HV 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 228 SAXO BOSCH INJECTION PUMP SPECIFICATIONS PUMP -TYPE - REFERENCE Emission standards L3/L4 Equipement Transponder SAXO (*) = The fuel high pressure pump is driven by the timing belt.
  • Page 229 BOSCH INJECTION PUMP SPECIFICATION SAXO Dynamic Static timing Reference Adjustments (rpm) Max. speed Injector Pump Engine timing Initial advance Colour Injector Type needle lift Fast Anti- Unladen Laden type checking Compression code Injector holder Idling Reference pressure idling stall (at idle) Time + injector (Bar)
  • Page 230 SAXO CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP Engine : VJX Tools à - Flywheel locating peg : 4507-T.A - Mounting plate locating peg : 4527-T.S1 Tool kit 4507-T - Camshaft peg : 4527-T.S2 Checks - Peg the flywheel. - Visually check the pegging of the camshaft and injection pump pulleys, or check using the tools 4527-T.S1 and 4527-T.S2.
  • Page 231 ADJUSTING THE MECHANICAL CONTROLS OF THE BOSCH INJECTION PUMP SAXO Engine : VJX ADJUSTING THE FAST IDLE SPEED. - Bring the lever (3) into contact with the screw (2). - Use the screw (2) to obtain the fast idle speed : 1100 ± 100 rpm. Engine cold.
  • Page 232 SAXO ADJUSTING THE MECHANICAL CONTROLS OF THE BOSCH INJECTION PUMP Engine : VJX (continued) ADJUSTING THE ACCELERATOR CONTROL. - Fully depress the accelerator pedal. - Check that the lever (10) is against the stop screw (6). If not, modify the position of the spring clip (7). - Check that, at idle, the lever (10) is against its stop (9).
  • Page 233 ADJUSTING THE MECHANICAL CONTROLS OF THE BOSCH INJECTION PUMP SAXO Engine : VJX (continued) ANTI-STALL ADJUSTMENT. - Insert a 1 mm shim [1] between the throttle lever (10) and the residual output adjustment screw (9). - Turn the residual output adjustment screw (9) to obtain an engine speed of: 835 ±...
  • Page 234 SAXO FITTING BOSCH INJECTORS Engine :VJX [1] Tool to remove/refit injectors 7007-T Fitting an injector 7008-T Tool kit 4123-T The copper seal (1) and the fire seal washer (2) are to be replaced each time they are removed. NOTE : Fitting parts of diffe- rent makes is PROHIBITED.
  • Page 235 PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM Engines : 8HX - 8HW Cleaning. - The use of high pressure cleaners is prohibited. - Do not use compressed air. Fuel supply circuit. - Required fuel : diesel. Electric circuit. - Swapping injection ECUs between two vehicles will render it impossible to start either vehicle. - It is forbidden to supply a diesel injector with 12 volts.
  • Page 236 PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM Engines : 8HX - 8HW Diesel injectors. WARNING: Diesel and ultrasonic cleaners are prohibited. Do not separate the following components from the diesel injector carrier (2) : - Diesel injector (f) (no replacement parts). - Electromagnetic element (c) (no replacement parts).
  • Page 237 PROHIBITED OPERATIONS: DELPHI HDI DIRECT INJECTION SYSTEM Engines : 8HY - 8HV Cleaning. - The use of high pressure cleaners is prohibited. - Do not use compressed air. Fuel supply circuit. - Required fuel : diesel. Electric circuit. - Swapping injection ECUs between two vehicles will render it impossible to start either vehicle. - It is forbidden to supply a diesel injector with 12 volts.
  • Page 238 PROHIBITED OPERATIONS: DELPHI HDI DIRECT INJECTION SYSTEM Engines : 8HY - 8HV Fuel high pressure injection common rail. Do not separate the pressure regulator «c» from the injection common rail (2) (Risk of malfunction). Diesel injectors. WARNING: Diesel and ultrasonic cleaners are prohibited.
  • Page 239 CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engines : 8HX - 8HW TOOLS [1] Ø 10 mm low pressure connector : 4215-T. [2] Pressure gauge for testing boost pressure : 4073-T.A Tool kit 4073-T IMPERATIVE : Respect the safety and cleanliness specific to high pressure diesel injection engines.
  • Page 240 CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engines : 8HV-8HY TOOLS [1] Ø 10 mm low pressure connector : 4215-T. [2] Pressure gauge for testing boost pressure : 4073-T.A Tool kit 4073-T IMPERATIVE : Respect the safety and cleanliness specific to high pressure diesel injection engines.
  • Page 241 AIR SUPPLY CIRCUIT SPECIFICATION Engines : 8HX - 8HW Upper integrated air inlet distributor. The upper integrated air inlet system is composed of the following elements: (1) Air filter cover. (2) Air filter chamber. (3) Flowmeter (4) Turbocharger inlet. (5) Resonator. (6) Turbocharger outlet.
  • Page 242 AIR SUPPLY CIRCUIT SPECIFICATION Engines : 8HX - 8HW Lower integrated air inlet distributor. The lower integrated air inlet system is composed of the following elements: (7) Top EGR pipe. (8) Inlet manifold. (9) Diesel fuel filter with reheater and water detector (according to country). (10) Diesel fuel filter support.
  • Page 243 AIR SUPPLY CIRCUIT SPECIFICATION Engines : 8HX - 8HW Lower integrated air inlet distributor. Upper integrated air inlet distributor. B1HP1JPD B1HP1JQD WARNING: After each removal, replace the seals of components that have been removed, lubricating the new seals when refitting. Tighten in Tighten in m.daN.
  • Page 244 AIR SUPPLY CIRCUIT SPECIFICATION Engines : 8HY - 8HV (1) Air filter assembly. (2) Oil trap. (3) Turbocharger resonance attenuator. (4) Turbocharger. (5) Air/air exchanger. (6) Air distributor. Air filter : Ref : MARK 4. Turbocharger : Ref : RHF 3V. (Supplier: «IHI») B1HP1JGP...
  • Page 245 AIR SUPPLY CIRCUIT SPECIFICATION Engines : 8HX - 8HW - 8HY - 8HV Tools. [1] Manual pressure-vacuum pump FACOM DA 16. Vacuum pump : Connect the tool [1] onto the vacuum pump (1). Start the engine. Wait 30 seconds. The vacuum value should be 0.9 ± 0.1 bar at idle. B1HP1K8D...
  • Page 246 CHECKS : EXHAUST GASES RECYCLING CIRCUIT Engines : 8HX - 8HW TOOLS [1] Manual pressure-vacuum pump : FACOM DA 16. IMPERATIVE : Respect the safety and cleanliness specific to high pressure diesel injection (HDi) engines. EGR valve Connect tool [1] on the capsule take-off (2). Apply a vacuum of approx.
  • Page 247 CHECKS : TURBO PRESSURE Engines : 8HX - 8HW 1] Pressure gauge for checking boost pressure : 4073-T.A [2] Sleeve for checking boost pressure : (-).0171.F CHECKS IMPERATIVE : Respect the following test conditions: - Engine at operating temperature. - Vehicle in running order. - Engine under full load.
  • Page 248 CHECKS : TURBO PRESSURE Engines : 8HV - 8HY [1] Pressure gauge for checking boost pressure : 4073-T.A [2] Sleeve for checking boost pressure : (-).0171.F CHECKS IMPERATIVE : Respect the following test conditions: - Engine at operating temperature. - Vehicle in running order. - Engine under full load.
  • Page 249 XSARA SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP PUMP - TYPE - REFERENCE Emission standards Equipment Transponder DWLP 12 XSARA R8448 B 371 B...
  • Page 250 XSARA SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP Dynamic Static timing Reference Adjustments (rpm) Max. speed Injector Pump Engine timing needle lift Initial advance Colour Injector Type Fast Anti- Unladen Laden type checking pressure Compression code Injector holder Idling Reference idling stall (at idle)
  • Page 251 CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP XSARA Engine : WJY Evolution of the checking of the setting of the LUCAS diesel injection pump Old assembly. NEW ASSEMBLY : RPO 7910 # Diesel injection pump without a hole for Diesel injection pump with hole for checking the setting checking the setting...
  • Page 252 XSARA CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP Engine : WJY (continued) Tools. [1] Flywheel locating peg 7014-T.J. [2] H M8 screw (-).0188.E. Tool kit C.0188 [3] Injection pump setting peg Ø 6 mm (-).0188.H After carrying out the necessary dismantling operations on the vehicle, proceed in the following manner : Remove : - The screws (6), (7), (9), (10) and (12).
  • Page 253 CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP XSARA Engine : WJY (continued) Peg : - The camshaft hub, using tool [2]. - The injection pump hub, using tool [3]. Impossible to peg the camshaft. Reset the valve timing (See page 245). Possible to peg the camshaft, but not the injection pump.
  • Page 254 XSARA ADJUSTING THE MECHANICAL CONTROLS OF THE DELPHI INJECTION PUMP Engine : WJY Adjusting the fast idle. Engine cold. - Ensure that the lever (2) is up against its stop to the right. - If not, adjust the tension of the cable (3) using the cable clamp (1). - Finish tensioning using the sleeve tensioner (4).
  • Page 255 XSARA ADJUSTING THE MECHANICAL CONTROLS OF THE DELPHI INJECTION PUMP Engine : WJY (continued) Adjusting the anti-stall (residual output). - Insert a 3 mm thick shim (10) between the throttle lever (6) and the anti-stall screw (7). - Push the stop lever (8). - Insert a 3 mm diameter peg (9) in the lever (2).
  • Page 256 XSARA FITTING DELPHI DIESEL INJECTORS Engine : WJY [1] Tool to remove/refit injectors (2) 7007-T Fitting an injector 7008-T.A Tool kit 4123-T The copper seal (1) and the fire seal washer (3) are to be replaced each time they are removed. NOTE : Fitting parts of different makes is PROHIBITED.
  • Page 257 XSARA PICASSO INJECTION PUMP SPECIFICATIONS (BOSCH and SIEMENS). Engines Injection system High pressure pump Injectors BOSCH BOSCH EDC 15C2 BOSCH CP1 9625542580 SIEMENS (except PICASSO SIEMENS ECUSID801 5WS 40001 5WS40000 BOSCH CP1 9625542580 ATED BOSCH BOSCH EDC 15C2...
  • Page 258 PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM XSARA PICASSO Engines : RHY - RHZ Cleaning. - The use of high pressure cleaners is prohibited. - Do not use compressed air. Fuel supply circuit. - Required fuel : diesel. WARNING : Do not use other fuels. Electric circuit.
  • Page 259 PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM XSARA PICASSO Engines: RHY - RHZ High pressure fuel injection common rail. - Do not separate the connectors (7) from the common injection rail (6) - (malfunction). Diesel injectors. WARNING: Diesel and ultrasonic cleaners are prohibited. Do not separate the following components from the diesel injector carrier (9) : - Diesel injector (8) (no replacement parts).
  • Page 260 XSARA PICASSO CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engines : RHY - RHZ TOOLS [1] Ø 10 mm low pressure connector : 4215-T [2] Ø 8 mm low pressure connector : 4218-T [3] Pressure gauge for testing boost pressure : 4073-T Tool kit 4073-T Connect the tool [1] between the booster pump and the fuel filter (white mark at "a"...
  • Page 261 CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT XSARA PICASSO Engines : RHY - RHZ (continued) Checks on pressure : dynamic. Engine running, at idle (normal functioning): - Fuel supply pressure shown by the pressure gauge [3] = 2 ± 0.4 Bar. - Fuel return pressure shown by the pressure gauge [3] = 0.7 ±...
  • Page 262 XSARA PICASSO CHECKS : AIR SUPPLY CIRCUIT Engines: RHY - RHZ TOOLS [1] Manual vacuum pump : FACOMM DA 16. IMPERATIVE : Respect the safety and cleanliness requirements. Vacuum pump. - Connect the tool [1] on the vacuum pump (1). - Start the engine.
  • Page 263 CHECKS : TURBO PRESSURE XSARA PICASSO Engine : RHZ Outillages. [1] Pressure gauge for checking boost pressure : 4073-T.A Tool kit 4073-T [2] Sleeve for checking boost pressure : 4185-T [3] Adaptor sleeve : 4229-T Checks. IMPERATIVE : respect the following checking requirements : Engine at running temperature.
  • Page 264 XSARA PICASSO CHECKS : TURBO PRESSURE Engine : RHY TOOLS. [1] Pressure gauge for checking boost pressure : 4073-T.A Tool kit 4073-T [2] Sleeve for checking boost pressure : 4185-T Checks. IMPERATIVE : respect the following checking requirements : Engine at running tempe- rature.
  • Page 265 CHECKS : EXHAUST GASES RECYCLING CIRCUIT XSARA PICASSO Engines : RHY - RHZ TOOLS [1] Manual vacuum pump : FACOMM DA 16. IMPERATIVE : Respect the safety and cleanliness requirements. EGR valve - Connect the tool [1] to the capsule union (1). - Apply, several times in succession, a vacuum of approx.
  • Page 266 ALL TYPES SPARKING PLUGS Engine Electrode Tightening Vehicles – Models BOSCH CHAMPION SAGEM type gap setting torque 1.1i 1.4i SAXO 1.6i 1.6i 16v RC8YCL 1.1i 1.4i 1.6i 16v RFN58LZ 0.9 mm 2.5 ± 0.2 mda N FR7DE 1.4i 1.6i 16v XSARA 2.0i 16v 2.0i 16v...
  • Page 267 SPEEDOMETER ALL TYPES 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 268 CLUTCH SPECIFICATIONS C3 - SAXO 1.1i 1.4i 1.6i 16V 1.4 HDi 1.4 HDi 16V Engine type 8HX - 8HW 8HV - 8HY Gearbox MA/5 BE4/5 Make VALEO Mechanism/Type 180 CP0 3400 200 P 3900 230 P 4700 Clutch disc 11 R 10X Ext./Int.
  • Page 269 CLUTCH SPECIFICATIONS Engines : HFX – KFV – NFU - 8HX – 8HW – 8HV – 8HY NOTE : All the clutches are «push» type with hydraulic control. Description. The declutch control has a declutch fork mounted on a ball-joint. - The ball-joint is screwed into the clutch casing.
  • Page 270 XSARA - XSARA PICASSO CLUTCH SPECIFICATIONS 1.4i 1.6i 1.6i 16V 1.8i 16V 2.0i 16V 1.9 D 1.4 HDi 2.0 HDi Engine type Gearbox MA/5 BE4/5 MA/5 BE4/5 Make VALEO 180CPO 215 DT 200 P 200 P 230 P 235 T 200 CPR 3800 230 DNG 4700 Mechanism/Type...
  • Page 271 CLUTCH SPECIFICATIONS BERLINGO 1.1i 1.4i 1.6i 16V 1.9 D 2.0 HDi Engine type Gearbox MA/5 BE4/5 Make VALEO Mécanisme/Type 200 CPX 3850 200 P 4700 235 T 5700 Clutch disc 200 XS L73C 11RX 200 XSL 73 Ext./Int. lining Ø 200/137 228/155 Disc lining type...
  • Page 272 SAXO - XSARA LUTCH : CHECKS AND ADJUSTMENTS Mechanically operated push-action clutch SAXO Adjustable HFX-KFW-NFT-NFX-VJX Engines MA/5 Gearbox XSARA Non-adjustable KFW-NFU ESSENTIAL : If the clutch control is new, squeeze the cable sheath before adjusting by declutching successively a minimum of 20 times. Checks NOTE : Adjustable steering wheels should be put into the low position - Record the measurement «X»...
  • Page 273 CLUTCH : CHECKS AND ADJUSTMENTS XSARA Push-action clutch with automatic adjustment (non-adjustable) BE4/5 Engines Gearbox Refitting the clutch cable. - Set the pedal to the high position (contact at A). - Attach the cable end-piece to the pedal. - Refit a new clip (3) to the pedal. - Fit the end-piece (4) to the bulkhead (G6 grease).
  • Page 274 XSARA CLUTCH : CHECKS AND ADJUSTMENTS Pull-action clutch with automatic adjustment (non-adjustable) BE4/5 Engines RFS - RFN - RHY - RHZ Gearbox Refitting the clutch cable. - Set the pedal to the high position (contact at A). - Attach the cable end-piece to the pedal. - Refit a new clip (3) to the pedal.
  • Page 275 CLUTCH : CHECKS AND ADJUSTMENTS XSARA Adjustment of push and pull action clutch with automatic compensation (adjustment of compensation system) Engines : RFN - RFS - WJY - RHY - RHZ WARNING : If a system blockage is detected when checking, or if the pedal has been removed, the pedal position must be adjusted.
  • Page 276 CLUTCH : CHECKS AND ADJUSTMENTS XSARA Engines : RFN - RFS – WJY – RHY - RHZ B2BP02SC NOTE : This cable has an automatic adjusting device which takes up the clutch disc wear and makes up for the compression of the outer cable. DESCRIPTION 1 - Metallic cable, crimped on both ends.
  • Page 277 XSARA - XSARA PICASSO CLUTCH : CHECKS AND ADJUSTMENTS Engines : RFN - RFS - WJY - RHY - RHZ B2BP03QD Operation Clutch disengagement phase Engagement / adjustment phase For the adjusting device to operate correctly, it As soon as the pedal is applied, the attaching The pedal returns to rest on its upper stop.
  • Page 278 SAXO GEARBOX AND TYRE SPECIFICATIONS Petrol 1.4i 1.1i 1.6i 1.6i 16V Auto. Engine type Tyres-Rolling circumference 155/70 R 13 – 1.67 m 165/65 R14 1.725m 185/55 R14 1.7 m Gearbox type MA/5 MA/5 Gearbox ident. plate 20 CF 03 20 CF 12 20 CN 03 –...
  • Page 279 GEARBOX AND TYRE SPECIFICATIONS C3 - All Types Petrol 1.1i 1.4i 1.6i 16V Auto.. X - SX Exclusive X - SX Exclusive X - SX Exclusive Trim level X - SX Exclusive Engine type Tyres-Rolling circumference 165/70 R 14 1.804 m 185/60 R15 1.828 m 165/70 R 14 1.804 m 185/60 R15 1.828 m Gearbox type...
  • Page 280 XSARA GEARBOX AND TYRE SPECIFICATIONS Petrol 1.6i 16V 2.0i 16V 1.4i Auto. Auto. Engine type 195/55 R15 - 1.815 m Tyres-Rolling circumference MA/5 BE4/5 BE3/5 Gearbox type Gearbox ident. plate 20 CF 13 20 TP 49 20 DL 40 20 TE 47 20 CN 28 20 TP 47 Reduction box torque...
  • Page 281 GEARBOX AND TYRE SPECIFICATIONS XSARA PICASSO Petrol Diesel 1.6i 1.8i 16 V 2.0 Hdi 2.0i 16V Auto. Engine type Tyres-Rolling circumference 185/65 R15 – 1.895 m Gearbox type BE4/5 BE4/5 Gearbox ident. plate 20 DL 66 20 DL 68 20 TS 02 20 DL 64 Reduction box torque 15x64...
  • Page 282 SAXO - XSARA GEARBOX - MA/5 Engines : HFX - KFW - NFT - NFX - NFU - VJX - 8HX - 8HW Vent plug Filler screw Drain screw B2CP34HP B2CP20FC B2CP20GC...
  • Page 283 GEARBOX CONTROLS - MA/5 SAXO - XSARA Engines : HFX - KFW - NFT - NFX – NFU - VJX– 8HX- 8HW 1 - Gear lever. 2 - Gear control rod. 3 - Gear control rod. A = 11.5 mm. 4 - Gear selection rod.
  • Page 284 GEARBOX - MA/5 Engines : HFX - KFV - NFU - 8HX - 8HW «a» Identification label. «b» Location for engraving of serial and gearbox nos.. B2CP3HTC...
  • Page 285 GEARBOX - MA/5 Engines : HFX - KFV - NFU - 8HX - 8HW Draining – filling – level (1) Gearbox drain plug. (2) Filling and level cap. Oil quality. Refer to the manufacturer’s instructions. Oil quantity. After draining: 2 Litres. Draining intervals.
  • Page 286 GEARBOX - MA/5 Engines : HFX - KFV - NFU - 8HX - 8HW (1) Primary shaft. (2) Clutch bearing guide. (3) Clutch housing. (4) Gearbox casing. (5) Intermediate plate. (6) Bearing retaining clip. (7) Drive pinion (5 gear). (8) Secondary shaft. (9) 5 gear synchroniser.
  • Page 287 GEARBOX - MA/5 Engines : HFX - KFV - NFU - 8HX - 8HW Tightening torques: m.daN. (23) Clutch bearing guide (3 fixing screws) : 0.6 ± 0.15. (24) Intermediate plate (11 fixing screws) : 5 ± 0.5. (25) Rear cover (3 fixing screws) : 2.2 ±...
  • Page 288 GEARBOX CONTROLS - MA/5 Engines : HFX - KFV - NFU - 8HX - 8HW (1) Gear control lever. (2) Gear engagement control cable (*) (3) Gear selection control cable (*) (*) The two cables cannot be separated. B2CP3HXD...
  • Page 289 GEARBOX CONTROLS - MA/5 Engines : HFX - KFV - NFU - 8HX - 8HW (4) Gear engagement ball-joint Ø 10 mm. (5) Gear selection ball-joint Ø 10 mm. B2CP3HYC Length D Length C Gear engagement control 1015 mm 790 mm cable (2) Length A Length B...
  • Page 290 GEARBOX CONTROLS - MA/5 Engines : HFX - KFV - NFU - 8HX - 8HW Adjustment. WARNING: Do not use any tool to detach the ball- joints. The gear selection control and gear engagement control B2CP3J0D cables cannot be adjusted. To unlock the ball-joint, press at «a»...
  • Page 291 GEARBOX – BE4/5 C3 - XSARA - XSARA PICASSO Engines : NFV - 6FZ – 8HV – 8HY - 8HZ - RFN - RFS - WJY – RHY - RHZ B2CP3BNC B2CP3BPD (a) Marking zone. (Sequence and serial no.). (b) = Location of identification label.
  • Page 292 C3 - XSARA - XSARA PICASSO GEARBOX CONTROLS - BE4/5 Engines : NFV - 6FZ – 8HV – 8HY- 8HZ - RFN - RFS - WJY – RHY - RHZ (1) Drain plug. (2) Filling and top-up plug. (3) Air vent. NOTE : The air vent aperture can be used for filling.
  • Page 293 GEARBOX – BE4/5 C3 - XSARA - XSARA PICASSO Engines : NFV - 6FZ – 8HV – 8HY - 8HZ - RFN - RFS - WJY – RHY - RHZ Description (1) Primary shaft. (14) 1 gear synchroniser (2) Clutch bearing guide. (15) Driven gear (1 gear).
  • Page 294 GEARBOX - BE4/5 Engines : 8HV - 8HY Tightening torques (m.daN). (23) Clutch bearing guide (3 screws) : 1.25 ± 0.2 (24) Clutch housing (13 screws) : 1.3 ± 0.2 (25) Primary shaft nut (1 screw) : 7.25 ± 0.5 (26) Secondary shaft nut (1 screw) : 6.5 ±...
  • Page 295 GEARBOX – BE4/5 XSARA - XSARA PICASSO Engines : NFV - 6FZ - RFN - RFS - WJY - 8HZ - RHY - RHZ 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 ±...
  • Page 296 GEARBOX CONTROLS - BE4/5 Engines : 8HV - 8HY (1) Gear control lever (2) Gear engagement control cable (*) (3) Gear selection control cable (*) (*) These two cables cannot be separated. B2CP3J3D...
  • Page 297 GEARBOX CONTROLS - BE4/5 Engines : 8HV - 8HY (4) Gear engagement ball-joint Ø 10 mm. (5) Gear selection ball-joint Ø 10 mm. B2CP3J4C Length A Length B Gear selection 907 mm 645 mm cable (5) Length D Length C Gear engagement 965 mm...
  • Page 298 GEARBOX CONTROLS - BE4/5 Engines : 8HV - 8HY Adjustment. The gear selection control and gear engagement control cables cannot be adjusted. To release the ball-joint, press at «d» then pull the ball-joint upwards. To release sleeve stops: - Press on the tabs of the clip (6) at «a». - Disengage the sleeve stops from their supports.
  • Page 299 GEARBOX CONTROLS - BE4/5 XSARA - XSARA PICASSO Engines : NFV - 6FZ - RFN - RFS - WJY - 8HZ – RHY - RHZ (1) Gear control lever (2) Gear engagement control cable (*) (3) Gear selection control cable (*) (4) Gear selection ball-joint Ø...
  • Page 300 XSARA - XSARA PICASSO BE4/5 GEARBOX - CHECKS AND ADJUSTMENTS Engines : NFV - 6FZ - RFN - RFS - WJY - 8HZ – RHY - RHZ Principles of adjusting the gear controls. WARNING : Cables should be adjusted each time the gearbox, gear controls or power unit are removed.
  • Page 301 XSARA - XSARA PICASSO BE4/5 GEARBOX - CHECKS AND ADJUSTMENTS Engines : NFV - 6FZ - RFN - RFS - WJY - 8HZ – RHY - RHZ Adjusting the gear controls. TOOLS. [1] Tool for positioning the gear lever : 9607-T. ADJUSTMENTS.
  • Page 302 SAXO AUTOMATIC GEARBOX - MB3 Engine : KFW Tightening torques m.daN. - Gearbox to engine fixing - Converter to engine fixing - Converter closing plate fixing - Electrical bracket fixing - Flexible mounting to gearbox fixing - Speedometer drive - Heat exchanger fixing NOTE : When fitting a new automatic gearbox, it is ESSENTIAL that the heat exchanger and the oil be replaced.
  • Page 303 RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - MB3) SAXO Engine : KFW PRECAUTIONS TO BE TAKEN Towing REMOVING - REFITTING. (Automatic gearbox). The front of the vehicle must be raised in order to be towed. WARNING : Never place the gearbox on its lower casing If the front of the vehicle cannot be raised : (risk of deforming the tray and damaging the hydraulic valve block).
  • Page 304 SAXO RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - MB3) Engine : KFW PRE-REPAIR PROCEDURE Oil quality If the gearbox has suffered a serious fault resulting in a malfunction or the destruction of a clutch, the oil will overheat and become contaminated with impurities : the oil is said to be «burnt».
  • Page 305 RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - MB3) SAXO Engine : KFW PRE-REPAIR PROCEDURE (continued) Negative pressure circuit. Absence of fault codes - Check the negative pressure circuit. Measure the parameters. - Carry out the necessary repairs. Anomalies present: - YES : Carry out the necessary repairs. Checks using the diagnostic tool.
  • Page 306 SAXO SPECIAL FEATURES: AUTOMATIC GEARBOX - MB3 Engine : KFW Hydraulic valve block. Refitting. WARNING : On refitting the strainer, ensure that the bracket (6) runs under the washer of the screw (7). - Refit the strainer without tightening the screws. - Observe the following tightening sequence : - Screws 1,2,3,4 and 5 to 0.9 m.daN.
  • Page 307 MB3 AUTOMATIC GEARBOX CONTROLS SAXO Engine : KFW B2CP352D...
  • Page 308 MB3 AUTOMATIC GEARBOX CONTROLS - CHECKS AND ADJUSTMENTS SAXO Selection control Adjusting the selection control WARNING: No part must be forced ESSENTIAL : Put the gearbox side while performing these operations control in the 1st imposed position; (careful removal). the 2 markings «a» must be aligned. Removing the gear lever knob.
  • Page 309 AUTOMATIC GEARBOX - AL4 C3 - XSARA - XSARA PICASSO Engines : KFV - NFU - RFN - RHZ WARNING : This gearbox benefits from a special CITROEN semi-synthetic oil which cannot be mixed with any other oil. The gearbox is lubricated for life. (a) Part reference.
  • Page 310 C3 - XSARA - XSARA PICASSO RECOMMANDATIONS - PRECAUTIONS (BOITE DE VITESSES AUTOMATIQUE AL 4) Engines : KFV - NFU – RFN - RHZ 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 (risk of deforming the tray and damaging the hydraulic valve block).
  • Page 311 C3 - XSARA - XSARA PICASSO RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 ) Engines : KFV - NFU - RFN - RHZ PROCEDURE BEFORE REPAIRS AL4 gearbox Oil Quality If the gearbox has suffered a serious fault resulting in a malfunction or the destruction of a clutch, the oil will overheat and become contaminated with impurities : the oil is said to be «burnt».
  • Page 312 C3 - XSARA - XSARA PICASSO RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 ) AL4 gearbox only Engines : KFV - NFU - RFN - RHZ PROCEDURE BEFORE REPAIRS Oil level AL 4 (prior conditions). - Vehicle in horizontal position. - Check gearbox is not in back-up mode.
  • Page 313 RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 ) C3 - XSARA - XSARA PICASSO Engines : KFV - NFU - RFN - RHZ PROCEDURE BEFORE REPAIRS (continued) When the ECU detects an erroneous or absent value Reading the fault codes. on input or output : Read the fault codes.
  • Page 314 C3 - XSARA - XSARA PICASSO RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 ) Engines : KFV - NFU - RFN - RHZ ECU : Downloading Updating the gearbox ECU by downloading : - Follow the procedure using the diagnostic tool. The downloading operation enables the automatic gearbox to be updated, or adapted to an evolution of the engine ECU.
  • Page 315 RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 ) C3 - XSARA - XSARA PICASSO Engines : KFV - NFU - RFN - RHZ ECU : Configuration, Initialisation (pedal) (continued) Downloading. Pedal initialisation. ECU downloading procedure : - Follow the diagnostic tooling procedure. A pedal initialisation must be carried out in the following cases : - Replacement of the automatic gearbox ECU.
  • Page 316 RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 ) Engine : KFV SHIFT LOCK - The «shift lock» is a system that locks the gear selection lever in position «P». Unlocking the «SHIFT LOCK». (Normal operation). - Switch on the ignition. - Press the brake pedal and keep it pressed.
  • Page 317 RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 ) XSARA - XSARA PICASSO Engines : NFU - RFN - RHZ SHIFT LOCK - The shift lock is a system which locks the selection lever in the park position «P». Unlocking the SHIFT LOCK (In normal operation) - Switch on the ignition.
  • Page 318 SAXO - C3 - XSARA - XSARA PICASSO DRIVESHAFTS - GEARBOX Gearbox oil seal mandrels Tightening torques (m.daN) Gearbox Driveshaft Driveshaft RH side LH side Tool kit Vehicles Engines bearing HFX-KFW-NFT-NFX-VJX SAXO NONE 24.5 ± 0.5 HFX-KFV-8HX-8HW MA/5 2 ± 0.2 7114-T.W 7114-T.X 7116-T...
  • Page 319 AXLE GEOMETRY SAXO - All Types Geometry of the axles at reference height. Front height Rear height H1 = R1 – L1 H2 = R2 + L2 H1 = Distance between the ground and H2 = Distance between the ground and the mounting face of the fixings.
  • Page 320 SAXO - All Types AXLE GEOMETRY Geometry of the axles at reference height. Front height Rear height Reminder : Measuring the front height Reminder : Measuring the rear height H1 = Distance between the ground and the mounting face of the fixings H2 = Distance between the ground and the rear crossmember B3BP07UC B3BP07VD...

  • Page 321: Axle Geometry

    AXLE GEOMETRY SAXO - All Types Geometry of the axles at reference height. Normal suspension Raised suspension Front Rear Front Rear HFX (**) HFX (**) All Types Engines All Types KFW - NFT KFW - NFT NFX - VJX NFX - VJX Steering Manual Manual...

  • Page 322: Front Axle

    SAXO - All Types FRONT AXLE Anti-roll bar Ø 18 and 22 mm Anti-roll bar Ø 19 and 21 mm (1) Suspension leg. (3) Front anti-roll bar. (9) Lower arm. Tightening torques m.daN (2) Anti-roll bar bearing fixing on the bodyshell 5.5 ±...
  • Page 323 REAR AXLE SAXO - All Types (1) Rear axle. (2) Damper. (5) Rear suspension arm. (7) Rear brake drum. (9) Torsion bar. The antiroll bar is located inside the tube of the rear axle. Tightening torques m.daN. (3) Damper upper fixing screw 10 ±...
  • Page 324 SAXO - All Types REAR AXLE - SUSPENSION Torsion bar HFX (1) (2) – KFW (2) HFX - KFW HFX-VJX (3) NFX - VJX (1) NFX - VJX Torsion bar Ø (mm) 17.9 18.3 Black White Green Colour reference LH : 2 rings Torsion bar RH : 1 ring (1) = Entreprise.
  • Page 325 STEERING SPECIFICATIONS SAXO - All Types Manual steering Tyres 155/70 R13 165/70 R13 165/65 R14 Pinion (no. of teeth) Rack (no. of teeth) NOTA : The steering assembly is secured to the bulkhead. Length of the steering track rods Rack travel (between the centre lines of the ball-joints).

  • Page 326: Manual Steering

    MANUAL STEERING SAXO - All Types Tightening torques (m.daN) 1 - Airbag 7 - Pivot ball-joint nut 2 - Airbag fixing to steering wheel 8 - Lock nut M14 3 - Steering wheel fixing 8 - Lock nut M16 4 - Steering column fixing 9 - Track rod articulation 5 - Steering cardan joint fixing 10 - Splined coupling fixing to steering rack...
  • Page 327 POWER-ASSISTED STEERING SAXO - All Types Tightening torques (m.daN) 1 - Airbag 8 - Track rod lock nut M16 2 - Airbag fixing to steering wheel 9 - Track rod articulation 3 - Steering wheel fixing 10 - Splined coupling fixing to steering rack 4 - Steering column fixing 11 - Steering ram to splined coupling 5 - Steering cardan joint fixing...
  • Page 328 SAXO - All Types POWER-ASSISTED STEERING (continued) Power steering system WARNING : Saxo all types except diesel without aircon 1 - Power steering 2 - Oil dispensing valve 3 - Power-assisted steering ram 4 - Low pressure pipe 5 - High pressure pipe 6 - Upper reservoir 7 - Power steering electro-pump unit and built-in lower reservoir...
  • Page 329 POWER-ASSISTED STEERING (continued) SAXO - All Types Power steering system WARNING : Saxo diesel with aircon Description. Note : The power steering system on vehicles without aircon is supplied by a mechanical pump driven by the accessories drive belt. (6) Power steering mechanism. (7) Upper reservoir.
  • Page 330 AXLE GEOMETRY Conditions for checking and adjusting Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point (See corresponding operation). Vehicle heights at reference height E1AP09MD Front height Rear height H1 = R1 - L1 H2 = R2 + L2 H1 = Measurement between the measuring zone underneath the front H2 = Measurement between the measuring zone underneath the rear sill...
  • Page 331 AXLE GEOMETRY B3CP07SD Measuring front height Measuring rear height [1] Gauge for measuring the wheel radius, 4 bolts, tool 8006-T Z2 = Measuring zone underneath the rear sill. Z1 =Measuring zone underneath the front subframe. Measure the radius of the front wheel R1 - Calculate dimension H1 = R1 – L1 Measure the radius of the rear wheel R2 - Calculate dimension H2 = R2 + L2 All Types All Types...
  • Page 332 AXLE GEOMETRY Front axle Rear axle Dissymmetry of lower castor at 0° 30’. Dissymmetry of lower camber at 0° 18’. Dissymmetry of lower camber at 0° 18. Distribute symmetrically, LH / RH wheel, the total tracking value. All types (except CRD) Castor Camber Pivot angle...
  • Page 333 FRONT AXLE Tightening torques (m.daN) (1) Nut fixing suspension leg on body : 6,5 ± 0,6 (2) Damper (3) Anti-roll bar link rod upper ball-joint : 3,2 ± 0,3 (4) Suspension leg pivot : 5,4 ± 0,5 (5) Anti-roll bar link rod lower ball-joint : 3,2 ±...

  • Page 334: Rear Axle

    REAR AXLE Tightening torques (m.daN) (1) Rear axle fixing screw : 10 ± 1 (2) Anti-roll bar (3) Rear axle crossmember (4) Rear suspension arm rubber mounting yoke (5) Rear suspension arm rubber mounting (6) Yoke / suspension arm fixing screw : 7,6 ±...
  • Page 335 SUSPENSION Front axle (1) Nut fixing suspension leg on body : 6,5 ± 0,6 (2) Damper (3) Anti-roll bar link rod upper ball-joint : 3,2 ± 0,3 (4) Suspension leg pivot : 5,4 ± 0,5 (5) Anti-roll bar link rod lower ball-joint : 3,2 ±...
  • Page 336 SUSPENSION Front axle (1) Nut fixing suspension leg on body : 6,5 ± 0,6 (2) Damper. (16) Cup. (17) Damper nut. : 6,5 ± 0,6 (18) Damper cup. (19) Ball bearing (20) Spring thrust cup. (21) Travel stop cup. (22) Suspension spring. (23) Damper rod protector.
  • Page 337 SUSPENSION Rear axle (25) Rear axle fixing screw : 10 ± 1 (26) Anti-roll bar (27) Rear axle crossmember (28) Rear suspension arm silentblock mounting yoke (29) Rear suspension arm silentblock (30) Suspension arm fixing screw on yoke : 7,6 ± 0,5 (31) Rear suspension arm (32) Stub axle bearing nut : 20±2 (greased).
  • Page 338 FEATURES OF ELECTRIC POWER STEERING Engines : HFX - KFV - NFU - 8HX - 8HW - 8HY Steering column B3EP13GD B3EP13HC Tightening torques m.daN. Identification (1) Steering wheel fixing : 2 ± 0.3 Identified by the colour of the ring at "a". (2) Steering column fixing on support : 2.2 ±...
  • Page 339 FEATURES OF ELECTRIC POWER STEERING Engines : HFX - KFV - NFU - 8HX - 8HW - 8HY Steering mechanism Tightening torques m.daN (4) Ball-joint fixing on pivot : 3,5 ± 0,3 (5) Steering rod lock-nut : 5 ± 0,5 (8) Threaded washer (9) Stud (10) Flat washers...
  • Page 340 FEATURES OF ELECTRIC POWER STEERING Engines : HFX - KFV - NFU - 8HX - 8HW - 8HY Steering assistance B3EP13KC B3EP13LC Supplier: KOYO. Electric power-assisted steering ECU. Only one ECU version, whatever the engine-type. The steering assistance is provided by the assistance motor (12), control- The electric power steering ECU is linked to the following connectors: led by the ECU.
  • Page 341 SPECIAL FEATURES : STEERING Engines : HFX - KFV - NFU - 8HX - 8HW - 8HY Centring the steering rack Preliminary operation. Raise and support the vehicle on a two-column lift. Remove, on the RH side of the steering rack: - Clip (1).
  • Page 342 AXLE GEOMETRY Front and rear measuring points XSARA ALL TYPES # RPO 8666 XSARA ALL TYPES RPO 8667 # Front height Rear height Front height Rear height B3CP046D B3CP06ZD H1 = Dimension between the centre of the front suspension arm mounting and the ground. H2 = Dimension between the contact face of the rear mounting and the ground.
  • Page 343 AXLE GEOMETRY XSARA - All Types Reference heights : 8006-T # N°RPO 9428 Tools [1] Gauge for measuring the radius of wheels with 4 bolts : 4300-T N°RPO 9429 # Setting the reference height. Front Rear Measure the dimension «R1». Measure the dimension «R2».
  • Page 344 XSARA - All Types AXLE GEOMETRY Values of the front and rear suspensions, at reference height ESSENTIAL : When checking the suspensions, the vehicle should be at reference height. Tools used : Compress the suspension, to obtain the values at reference height. [1] Set of two suspension compressors : 9511-T.A [2] Set of four straps...
  • Page 345 AXLE GEOMETRY XSARA Values of the front and rear suspensions, at reference height Front axle Saloon CRD (*) Saloon all engine all engine types types except KFW Saloon CRD (*) Saloon or Tolerances Adjustable Estate all engine 2.0i 16V (RFS) except KFW entreprise KFW types except...
  • Page 346 XSARA - All Types AXLE GEOMETRY a = Angle which defines the tracking between the front and rear axles. Its value must not exceed 12'. B3CP04UC...
  • Page 347 FRONT AXLE XSARA - All Types Tightening torques (m.daN). (1) Damper nut 4.5 ± 0.4 (2) Cup screw 2.5 ± 0.3 (3) Suspension leg (4) Anti-roll bar link rod upper ball-joint 3.7 ± 0.3 (5) Suspension leg pivot (hollow pivot) 4.5 ±...
  • Page 348 XSARA - All Types FRONT AXLE Evolution : Suspension arm ball-joint Application from RPO : 7968. New components : - Suspension arm ball-joint. - Pivot. Old fitting ØA = 16 mm. New fitting ØA = 18 mm. Repair requirements. ESSENTIAL : Swapping of old and new components is forbidden. It is permitted to fit a new pivot/ball-joint assembly on one side of an old vehicle.
  • Page 349 FRONT AXLE XSARA - All Types Anti-roll bars Engines Diameter Colour reference Saloon Blue 1.6i-1.6i 16V-1.9D 2.0i 16V (RFV)-1.4 HDi -2.0 HDi Estate Yellow 2.0i 16V (RFS) Saloon White...
  • Page 350 XSARA - All Types FRONT AXLE XSARA # 07/1999 XSARA 07/1999 # 09/2000 XSARA 07/1999 # 09/2000 The angle of castor changes to 3° except for LPG vehicles, CRD vehicles, and Estates All Types. CRD = Difficult Road Conditions : this type of vehicle has axles and suspensions designed for driving on rough road surfaces.
  • Page 351 REAR AXLE XSARA - All Types Tightening torques (m.daN)* (1) Anti-roll bar lever 3.2 ± 0.3 (2) Anti-roll bar (3) Transversal torsion bars (4) Rear crossmember flanges 8.3 ± 0.8 (5) Front silentblocks 5.5 ± 0.5 (6) Rear silentblocks 4.5 ± 0.4 (7) Anti-vibration clamp.
  • Page 352 XSARA - All Types REAR AXLE Vehicles Torsion bars (mm) Anti-roll bars (mm) Engines Diameter Colour reference Diameter Colour reference 3-door Entreprise 19.3 Violet Orange 3- and 5-door TT exc. 19.D 18.7 Yellow Blue Entreprise Grey Green Estates All types 19.3 Orange 3- and 5-door TT...
  • Page 353 REAR AXLE XSARA Evolution : Rear hub nut Old # 15/12/1999 New 15/12/1999 # Evolution -New rear hub nut (3). - Washer discontinued (2). Old fitting (A) (1) Rear hub nut. (2) Thrust washer. ESSENTIAL : Tighten to : 27,5 ± 2,7 m.daN New fitting (B) (3) Rear hub nut.
  • Page 354 XSARA - All Types REAR AXLE - The front silentblocks are aligned at an angle of 45° in relation to the vehicle’s axis. Operating clearance - X = 1 to 1.4 mm. - The rear silentblocks are in parallel with the vehicle’s axis. NOTE : There are two suppliers for the silentblocks: NOTE : The RH torsion bar can be identified by - RBT, identified by a Green or Yellow painted dot on the side of the mounting.
  • Page 355 REAR DAMPER XSARA - All Types Adjusting the rear dummy damper Lengths of the rear dummy damper (mm) Engines Normal driving Grand export 1.9 D 1.6i 16V 3-door 1.6i 16V 5-door 2.0i 16V (RFN) 1.4 HDi -2.0 HDi 2.0i 16V (RFS) Estates and Entreprise all types E5AP14WC...
  • Page 356 XSARA - All Types MANUAL STEERING SPECIFICATIONS Steering wheel - Manual steering - (a) : L.H.D./R.H.D. = White. - (L) : Shaft length = 311 ± 1.5 mm. - (1) Steering wheel fitted with AIRBAG. (according to equipment). - (4) Steering column adjustment lever. Tightening torques (m.daN).
  • Page 357 MANUAL STEERING SPECIFICATIONS XSARA - All Types Manual steering Tightening torques (m.daN) (7) Pivot ball-joint nut (8) Link rod lock nut : 4.5 (9) Ball-joint on steering rack (10) Fixing on cradle (11) Plunger flange screw : 1.2 B3EP042D...
  • Page 358 XSARA - All Types MANUAL STEERING SPECIFICATIONS Manual steering (continued) Number of teeth Steering rack Number of Steering stop travel Steering ratio steering wheel colour code (mm) turns Pinion Steering rack 6 teeth (13) 22/1 L.H.D. 73.5 (RH helix) Yellow thickness mm - Length of the steering track rods (Pre-adjustment) = 371 mm (Between ball-joint centres) or 391 mm (Between the centre of the pivot ball-joint and the contact face of the steering rack ball-joint).
  • Page 359 POWER-ASSISTED STEERING SPECIFICATIONS XSARA - All Types Steering wheel - Power-assisted steering - (a) : L.H.D. = Blue. : R.H.D. = White. - (L) : Shaft length = 311 ± 1.5 mm. - (1) Steering wheel fitted with AIRBAG. (according to equipment). - (4) Steering column adjustment lever.
  • Page 360 XSARA - All Types POWER-ASSISTED STEERING SPECIFICATIONS Power-assisted steering Tightening torques (m.daN) (7) Pivot ball-joint nut (8) Link rod lock nut : 4.5 (9) Ball-joint on steering rack (10) Fixing on subframe (11) Hydraulic pipe connection : 2.5 (12) Valve to housing fixing : 1.2 (13) Plunger flange screw : 1.2...
  • Page 361 POWER-ASSISTED STEERING SPECIFICATIONS XSARA - All Types Power-assisted steering (continued) Number of teeth Steering rack Number of travel steering wheel Steering ratio (mm) turns Pinion Steering rack L.H.D. 71.7 18.8/1 (RH helix) Steering valve Vehicles Number of teeth ( Protector colour All types (except 1.8i 16V - 1.9TD) BLACK 1.8 i 16V - 1.9 TD...
  • Page 362 POWER-ASSISTED STEERING SPECIFICATIONS XSARA - All Types Power-assisted steering assembly Tightening torques (m.daN). High pressure tube (Rubber seal pump side) - Power-assisted valve and pump union : 2.5 Return pipe. - Power-assisted valve union : 2.5 - (16) Upper front fixing (E3) : 2.5 - (17) Upper rear fixing (E3) : 2.2...
  • Page 363 AXLE GEOMETRY XSARA PICASSO - All Types Measurements at reference height NOTE : To make the setting of reference height easier, it is acceptable to take the measurement from the flange of the jacking point. WARNING : The values shown should only be used as guides. In case of doubt, check the settings at reference height Front height Rear height B3CP05BC...
  • Page 364 AXLE GEOMETRY XSARA PICASSO - All Types Measurements at reference height (continued). (The reference height of the vehicle is set as per the table below). Front axle Rear axle B3CP05BC B3CP05AC B3DP079C H1 = R1 – L1 H1’ = R1 – L1’ H2 = R2 + L2 Front axle Rear axle...
  • Page 365 XSARA PICASSO - All Types AXLE GEOMETRY Measurements at reference height (continued). Compress the suspension to obtain the calculated values. Vehicle All Types Front axle Rear axle Vehicle Tracking Castor Pivot angle Camber Tracking Camber Adjustable 0 ± 1mm 4.8 mm ± 1mm 3°...
  • Page 366 XSARA PICASSO - All Types FRONT AXLE Tightening torques m.daN. (1) Damper nut : 4.5 ± 0.4. (2) Cup screw : 2.5 ± 0.2. (3) Suspension arm. (4) Anti-roll bar link rod ball-joint : 4 ± 0.4. (5) Suspension arm swivel : 4.5 ±...
  • Page 367 XSARA PICASSO - All Types REAR AXLE Tightening torques m.daN. (14) Front silentblock on subframe : 9.5 ± 0.9. (15) Anti-roll bar bolt : 5.5 ± 0.5. (16) Rear torsion bar (17) Anti-roll bar (18) Tubular axle (19) Front silentblock on bodyshell : 4 ±...
  • Page 368 XSARA PICASSO - All Types REAR AXLE Evolution : Rear hub nut Old # 15/12/1999. New 15/12/1999 # Evolution : - New rear hub nut (3). - Washer discontinued (2). Old fitting (A) (1) Rear hub nut. (2) Thrust washer. ESSENTIAL : Tighten to : 27,5 ±...
  • Page 369 SUSPENSION XSARA PICASSO - All Height of the vehicle in running order (The vehicle height, when in running order, is set according to the measurements shown in the table below). Checking conditions : - Vehicle empty. - All reservoirs full. - Tyre pressures correct.
  • Page 370 XSARA PICASSO - All Types SUSPENSION Measurements at the front and rear axles, vehicle in running order Vehicles all types (except CRD) Front axle Rear axle Adjustable NFV – 6FZ Adjustable NFV – 6FZ - RHY 2 ± 1 mm 1.7 ±...
  • Page 371 STEERING COLUMN SPECIFICATIONS XSARA PICASSO - All Types Left hand drive = Green marking. Right hand drive = White marking. (1) Steering wheel. (4) Steering column adjustment. Tightening torques m.daN. - (2) Airbag to steering wheel fixing : 0.8 ± 0.1 - (3) Steering wheel fixing : 3.3 ±...
  • Page 372 XSARA PICASSO - All Types STEERING SPECIFICATIONS Tightening torques (m.daN) (7) Pivot ball-joint nut : 4 ± 0.4 (8) Steering rod adjusting lock nut : 4.5 ± 0.4 (9) Ball-joint on steering rack : 6 ± 0.6 (10) Fixing steering on subframe : 8 ±...
  • Page 373 STEERING SPECIFICATIONS XSARA PICASSO - All Types Steering rack Number of teeth Number of steering Turning circle Turning circle Rack pinion travel in rack wheel turns between walls between kerbs Left hand drive LH helix 71.7x2 28 teeth 3.22 12 m 11.48 m Right hand drive RH helix...
  • Page 374 XSARA PICASSO - All Types POWER-ASSISTED STEERING SPECIFICATIONS Tightening torques (m.daN). Unions between pump unions and power steering valve 2 ± 0.3 (16) Fixing screw 2.2 ± 0.3 (17) Fixing screw 2.2 ± 0.3 (18) Fixing screw 2.2 ± 0.3 NOTE : Coat the threads with product ‘‘E3’’.
  • Page 375 BRAKE SPECIFICATIONS SAXO - All Types 1.1 i - 1.4 i 1.6 i (1) Compensator integral with the wheel cylinder. 1.6 i 1.5 D 1.6 i 16V (2) Load sensitive compensator. Power-assisted steering without ABS Master cylinder 20.6 22.2 Master-vac 177.8 203.2 228.6...
  • Page 376 SAXO - All Types BRAKE SPECIFICATIONS (continued) 1.6 i Entreprise 1.1 i - 1.4 i (1) Compensator integral with the wheel cylinder. 1.6 i 1.6 i 16V 1.5 D 1.1i-1.5D (2) Load sensitive compensator. Power-assisted steering with ABS Manual steering Master cylinder 20.6 Master-vac...
  • Page 377 BRAKES SAXO - All Types B3FP06GC Conditions - Vehicle in running order - 5 litres of fuel. - A driver (75 Kg). Adjusting the brake limiter. - Apply the brake pedal to close the limiter. Adjusting the stop lamp switch. - Adjust using the screw (2) to obtain a clearance J of 0.5 to 2 mm.
  • Page 378 BRAKES (continued) SAXO - All Types Tightening torques (m.daN) Auto. - 1.1 i - 1.4 i - 1.6 i Removing the caliper - 1.1i Manual steering - Screw M8 3.2 ± 0.3 - Screw M12 12 ± 1.2 - 1.1 i - 1.4 i (Except 1.6 i) - 2 Screws M12 12 ±...
  • Page 379 BRAKES (Continued) SAXO - All Types EVOLUTION : Fixing screws for FRONT brake calipers: Type BENDIX STANDARD 4. Application from RPO 8973. Repair. Vehicles concerned. Vehicles equipped with non-ventilated brake discs. (Except VTS trim Removing-refitting the front brake caliper (old and new fitting) level).
  • Page 380 SAXO - All Types BRAKES (Continued) EVOLUTION : Fixing screws for REAR brake calipers: Type BENDIX STANDARD 4. Application from RPO 8973. Repair. Vehicles concerned. Vehicles equipped with non-ventilated brake discs. (Except VTS trim Removing-refitting the rear brake caliper (old and new fitting) level).
  • Page 381 HANDBRAKE (Adjustment) SAXO - All Types Prior to adjustment. - Release the handbrake. - Drums rotating freely. - No tight spot (If there is one, check if the primary or secondary cables are correctly routed). - Check that all the parts slide and move correctly. - Bleed the main circuit.
  • Page 382 SAXO BLEEDING THE BRAKES The brakes are bled : - Using brake bleeding equipment, in which case the pressure of the equipment should be set to a maximum of 2 Bars. IMPERATIVE order of bleeding Wheel : - Rear left. - Front right.
  • Page 383 BRAKE SPECIFICATIONS (WITHOUT ABS) 1.1i 1.4i 1.4 HDi Engine type Master cylinder 20.6 Master vac 203.2 Caliper/piston Ø LUCAS/TRW C48/13 48 makes Plain Disc Ventilated Disc thickness/min. thickness 13/11 TEXTAR T 4144 Brake pad grade Drum Ø Max. thickness Make 8259 Brake lining grade...
  • Page 384 BRAKE SPECIFICATIONS (WITH ABS) 1.6i 16V 1.4 HDi 16V Engine type Master cylinder 22.2 Master vac 228.6 Caliper/piston Ø LUCAS/TRW C54/22 54 makes Plain Disc Ventilated Disc thickness/min. thickness 22/20 Brake pad grade TEXTAR T 4144 Cylinder or caliper LUCAS C38 HR 9/13 Ø...
  • Page 385 BRAKE SPECIFICATIONS Braking system specifications Braking circuit without ABS - REF (drum brakes at the rear) Braking circuit at «X». - Front brakes with ventilated discs (*). - Rear brakes with eitther drums or discs (*). - Handbrake lever controlling cables acting on the rear wheels.
  • Page 386 BRAKE SPECIFICATIONS Braking circuit with ABS - REF (drum brakes at the rear) B3FP162D...
  • Page 387 BRAKE SPECIFICATIONS Braking circuit with ABS - REF (Disc brakes at the rear) B3FP163D...
  • Page 388 BRAKE SPECIFICATIONS Braking circuit with ABS - REF (a) Hydraulic circuit. (b) Electrical circuit. (1) Master cylinder in tandem. (2) Braking servo. (3) Brake caliper (or drum at the rear). (4) Hub equipped with a bearing with an integral magnetic wheel (48 pairs of poles).
  • Page 389 BRAKE SPECIFICATIONS ABS hydraulic block # N°OPR 9423 ABS hydraulic block: RPO 9424 # B3GP03DC B3GP03EC Components Supplier Part No. Observations Components Supplier Part No. Observations Installed on the front LH Installed on the front LH ABS MK 60 : chassis member : ABS MK 70 : chassis member :...

  • Page 390: Brake Specifications

    BRAKE SPECIFICATIONS Brake pedal gear Front brake Rear brake B3FP166D B3FP164C B3FP165C Tightening torques (m.daN). (16) Servo fixing 2.2 ± 0.3 (12) Yoke fixing on caliper 10.5± 1 (14) Rear caliper fixing on arm 5.3±0.5 (17) Fixing on master cylinder 2 ±...
  • Page 391 HANDBRAKE (Adjustment) Adjustment Lift and chock the vehicle. Remove: - The rear cover (8) - The nut (9). - The handbrake trim (6). - The gear lever gaiter (5). - The front cover (3). - The screws (1). Disconnect the connectors of the following components: - The cigar lighter (2).
  • Page 392 HANDBRAKE (Adjustment) Adjustment (continued) (10) Nut for adjusting cable tensions. Remove: - The rear wheels. - The drums (according to version). Release the handbrake. Use a gauge set to measure at «a» the travel of the lever from its stop. Adjust the nut (10) to obtain a travel of less than or equal to 1 mm at «a».
  • Page 393 BLEEDING AND FILLING THE BRAKING SYSTEM Tools. [1] Generic bleeding apparatus : ‘‘LURO’’ or similar. Bleeding, refilling. Draining. Drain the brake fluid reservoir (1) to the maximum (if necessary, use a clean syringe). Disconnect the connector (4). Uncouple the pipe (2). Unscrew the shaft (3).
  • Page 394 BLEEDING AND FILLING THE BRAKING SYSTEM (CONTINUED) Bleeding the primary braking circuit. WARNING: The ABS should not be active during the bleeding operation. Front brake caliper: Bleed screw (5). A : Rear brake caliper B : Rear brake drum Bleed screw (6). Bleed each wheel cylinder, proceeding in the following order : Front LH wheel.
  • Page 395 BLEEDING AND FILLING THE BRAKING SYSTEM (CONTINUED) With the bleeding apparatus - Connect the bleeding apparatus [1] on the brake fluid reservoir (1). - Adjust the apparatus pressure to 2 Bars. For each circuit : - Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container. - Open the bleed screw, wait until the fluid is flowing out without air bubbles.
  • Page 396 XSARA BRAKE SPECIFICATIONS Saloons 1.6i 16V 2.0 HDi 1.4i 2.0i 16V 1.9 D 1.4 HDi Master cylinder Without ABS 23,8 (expansion holes) With ABS 23,8 (valve) Ø Master-vac 228.6 BOSCH 54 LUCAS 57 BOSCH 54 Caliper/piston makes Disc Ventilated 22 /20 Disc thickness/min.
  • Page 397 BRAKE SPECIFICATIONS XSARA Estates 1.6i 16V 2.0 HDi 1.4i 2.0i 16V 1.9 D 1.4 HDi Master cylinder Without ABS 23,8 (expansion holes) With ABS 23,8 (valve) Ø Master-vac 228.6 BOSCH 54 LUCAS 57 BOSCH 54 Caliper/piston makes Disc Ventilated 22 /20 Disc thickness/min.
  • Page 398 BRAKE SPECIFICATIONS XSARA - All Types Tighten the nuts (1) to 2.3 m.daN. - The clevis pin (2) is held in place by a plastic clip. B3FP10YD...
  • Page 399 BRAKE SPECIFICATIONS XSARA - All Types Braking system specifications - ‘X’ braking circuit. - Front : disc brakes, ventilated (according to model). - Rear : drum brakes with automatic adjustment. - Cable operated handbrake acting on the rear wheels. (1) Hydraulic valve block « ABS Bosch 5.3 » (1) Hydraulic valve block «...
  • Page 400 XSARA - All Types BRAKE SPECIFICATIONS Braking system without ABS (rear drum brakes) Braking system without ABS (rear disc brakes) Up to RPO 8687 B3FP14FD B3FP14GD...
  • Page 401 BRAKE SPECIFICATIONS XSARA - All Types Braking system with ABS (rear drum brakes) B3FP14HD...
  • Page 402 BRAKE SPECIFICATIONS XSARA - All Types Braking system with ABS REF (rear disc brakes) Braking system with ABS REF (rear drum brakes) B3FP14JD B3FP14KD...
  • Page 403 BRAKE SPECIFICATIONS XSARA - All Types Braking system with ABS REF (rear drum brakes) B3FP14LD...
  • Page 404 BRAKE SPECIFICATIONS XSARA - All Types Braking circuit with ESP (BOSCH 5.7) (A) Hydraulic circuit. (B) Electrical circuit. (1) Master cylinder in tandem. (2) Braking servo. (3) Brake caliper (or drum at the rear). (4) Toothed wheel. (5) Wheel sensor. (6) Brake fluid level sensor.
  • Page 405 XSARA - All Types BRAKE SPECIFICATIONS Electrical circuit Components Ref. Supplier Part No. Observations 42-way connector. Electronic ECU 5.7 ESP Alone on the hydraulic block. Changing only the ECU is prohibited. 2-way grey connector. 0 265 006 389 The sensors are inductive-type. Front wheel sensor Tightening torque: 0,8 ±...
  • Page 406 BRAKE SPECIFICATIONS XSARA - All Types (7) Hydraulic block Gyrometer sensor B3HP002C C4AP17YC Components Supplier Part No. Observations IMPERATIVE : Respect the direction of fitting of the gyrometer/accele- rometer sensor (connector towards the rear of the vehicle). WARNING : The gyrometer/accelerometer sensor should not be Located on the front LH ESP hydraulic subjected to any impact.
  • Page 407 REAR BRAKE SPECIFICATIONS XSARA - All Types Evolution : Rear brake drum hub 01/1999 # Old assembly New assembly B3FP119D B3FP11AD Evolutions. New components : Rear wheel stub. - Stop ring (ref. (4)). - Double shouldered washer (ref. (5)) NOTE : The new assembly is identified by a figure from 1 to 6 cold-stamped on the head of the wheel stub at «a». (1) Washer exterior diameter = 38 mm.
  • Page 408 XSARA - All Types REAR BRAKE SPECIFICATIONS Evolution : Rear brake disc hub 01/99 # Old assembly New assembly B3FP11BD B3FP11CD Evolutions Fixing of the brake disc hub. Sealing of the brake disc hub. New components: New components: - Rear wheel stub. - Sealed bearing incorporated at «b»...
  • Page 409 CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR XSARA - All Types To perform any checks, it is necessary to calculate the weight on the rear axle in order to refer to the adjustment graphs. Preliminary pre-check operations. Calculate : 1) The rear weight of the vehicle (empty tank + 1 person) # Note the vehicle type Refer to table N°...
  • Page 410 CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued) XSARA - All Types (Weights in kg) TABLE N° 1 (Rear weight of the vehicle (Empty tank + 1 person)). TABLE N° 2 (Weight of fuel in the fuel tank). Type of fuel Diesel Trim level Petrol...
  • Page 411 CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued) XSARA - All Types GRAPH N° 1 GRAPH N° 2 B3FP09YD B3FP09XD...
  • Page 412 CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued) XSARA - All Types GRAPH N° 3 B3FP09ZD...
  • Page 413 CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued) XSARA - All Types TOOLS - Braking pressure checking tool : 4140-T. CHECKING THE BRAKE PRESSURE WARNING : Do not touch the plastic nut (1). PRELIMINARY OPERATIONS - Place the vehicle on a 4-column lift if possible. - Fit tool 4140-T.
  • Page 414 XSARA - All Types CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued) ADJUSTING THE COMPENSATOR WARNING : Do not touch the plastic nut (1). IMPORTANT : When loosening the nut (2), the spring (3) may suddenly force off the nut (2) and lock nut (4) assembly.
  • Page 415 HANDBRAKE XSARA - All Types CHECKING AND ADJUSTING THE HANDBRAKE - Remove the handbrake console. - Jack up and chock the vehicle with the rear wheels hanging free. - Check the correct routing of the brake cables under the vehicle. - Apply and release the handbrake ten times.
  • Page 416 SAXO - All Types BLEEDING THE BRAKES Bleeding : The brakes can be bled either : - using brake bleeding equipment, in which case the pressure of the equipment should be set to 2 Bars. - or in the usual way. IMPERATIVE order of bleeding Wheels : - Rear Right.
  • Page 417 BRAKE SPECIFICATIONS XSARA PICASSO - All Types 1.6i - 1.8i 16V - 2.0i 16V - 2.0 HDi 1.8i 16V - 2.0i 16V - 2.0 HDi NOTE : On models equipped with ABS, there is no load-sensitive braking compensator. Without ESP (*) With ESP (*) (*) ESP = Electronic Stability Programme Master cylinder...
  • Page 418 XSARA PICASSO - All Types BRAKE SPECIFICATIONS Braking system specifications ‘X’ braking circuit. - Front : disc brakes, ventilated. - Rear : drum brakes with automatic wear adjustment. - Cable operated handbrake acting on the rear wheels. Rear : load-sensitive braking compensator (non-ABS models). - (1) Hydraulic valve block «...
  • Page 419 BRAKING SYSTEM SPECIFICATIONS XSARA PICASSO - All Types Without ABS With ABS B3FP11WD B3FP7B9D...
  • Page 420 XSARA PICASSO - All Types BRAKING SYSTEM SPECIFICATIONS With ESP (Electronic Stability Programme) Handbrake B3FP7BRD B3FP11XD...
  • Page 421 XSARA PICASSO - All Types CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR Tools [1] Brake pressure checking tool : 4140-T Checking procedure Determining the rear weight of the vehicle Determine the weight on the rear axle and then refer to the adjustment Refer to the tables of different weights.
  • Page 422 XSARA PICASSO - All Types CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR Tools [1] Brake pressure checking tool : 4140-T Example. Type of vehicle = TU5JP+ Rear weight (tank empty + 1 person). = 542 Kg Fuel tank half full : = 22 Kg Sun roof = 10 Kg...
  • Page 423 CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR XSARA PICASSO - All Types GRAPH N° 1 GRAPH N° 2 B3FP13RD B3FP13SD Key : P = Rear pressure (in Bars). a = Front pressure 60 ± 3 Bars. M = Weight (in Kg). b = Front pressure 100 ±...
  • Page 424 XSARA PICASSO - All Types CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR GRAPH N° 3 GRAPH N° 4 B3FP14MD B3FP13UD Key : P = Rear pressure (in Bars). a = Front pressure 60 ± 3 Bars. M = Weight (in Kg). b = Front pressure 100 ±...
  • Page 425 CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR XSARA PICASSO - All Types GRAPH N° 5 GRAPH N°6 B3FP14ND B3FP14PD Key : P = Rear pressure (in Bars). a = Front pressure 60 ± 3 Bars. M = Weight (in Kg).) b = Front pressure 100 ±...
  • Page 426 XSARA PICASSO - All Types CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR Checking the braking pressure Preliminary operations : The vehicle should be placed on all 4 wheels, preferably on a lift. - The tool [1] (in good working order) in place. - Compare the value noted with the graph.
  • Page 427 XSARA PICASSO - All Types CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR Adjusting the load-sensitive brake compensator - Untighten the screw (1). - Move the spring rod. - Decrease the length of the spring to increase the pressure. - Increase the length of the spring to decrease the pressure. - Tighten the screw (1) to 1,2 ±...
  • Page 428 HANDBRAKE (Adjustment) XSARA PICASSO - All Tpes Adjustment : Remove the handbrake trim (1). Unclip the sound-deadening (2). Raise and support the vehicle with the rear wheels hanging free. Check the correct routing of the brake cables under the vehicle. Apply and release the handbrake 4 times.
  • Page 429 BLEEDING THE BRAKES XSARA PICASSO - Alll Types Tools Bleeding equipment of type «LURO» or similar. IMPERATIVE : For bleeding the secondary circuit, use ELIT, LEXIA or PROXIA diagnostic tools. Draining. Drain the brake fluid reservoir as empty as possible using a syringe. Disconnect the brake fluid warning lamp connector.
  • Page 430 ALL TYPES STARTER MOTORS Abbreviations and definitions Coding of climates is as follows : Meaning of abbreviations : CLIMATES : : Starting possible as low as -18°C : Gearbox Temperate : Starting possible as low as -18°C : Manual gearbox Cold : Starting possible as low as -25°C : Automatic gearbox...
  • Page 431 STARTER MOTORS ALL TYPES Vehicles / models Manufacturer and Ref. Class Climate Table of classes of starter motors CLASS CLASS 2 CLASS 3 CLASS 4 CLASS 5 CLASS 6 Torque C 5.5 Nm 6 Nm 10 Nm 11.5 Nm 11.5 Nm Maximum power for I ≤...
  • Page 432 SAXO STARTER MOTORS Manufacturer and Ref. Vehicles / models Class Climate VALEO D7E16 H, T, C BOSCH A 001183 027 F 1.1i MELCO M002T13081 VALEO D6 RA 572 VALEO D7E16 C, T BOSCH A 001183 027 F 1.4i (Aircon) 1.6i (Aircon) MELCO M002T13081 C, VC VALEO D6 RA 572...
  • Page 433 STARTER MOTORS Manufacturer and Ref. Vehicles / models Class Climate VALEO D7E16 H, T, C BOSCH A001 183 027F 1.1i MELCO M002T 13081 VALEO D6RA572 VALEO D7E16 1.1 i Aircon H, T BOSCH A001 183 027F 1.4 i Aircon MELCO M002T 13081 1.6i 16v Aircon C, VC VALEO D6RA572...
  • Page 434 XSARA STARTER MOTORS Manufacturer and Ref. Vehicles / models Class Climate VALEO D7E16 1.4i BOSCH A 001183 027 F H, T 1.6i (Power steering MELCO M002T13081 or aircon) VALEO D6 RA 572 C, VC VALEO D7E23 1.4i H, T (Power steering BOSCH E OAL 101 390 and aircon) VALEO D6RA572...
  • Page 435 STARTER MOTORS XSARA Manufacturer and Ref. Vehicles / models Class Climate VALEO D6 RA 109 H, T BOSCH A 001 111 562F MELCO M 001 T 80381 1.9D VALEO D7 R 26 MELCO M 001 T 80481 VALEO D7 R 27 VALEO D6 RA 109 2.0 HDi H, T...
  • Page 436 XSARA PICASSO STARTER MOTORS Manufacturer and Ref. Class Climate Vehicles / models VALEO D7E16 H, T BOSCH A 001 183 027F 1.6i (Power steering or aircon) MELCO M002T13081 C, VC VALEO D6RA572 VALEO D7E23 1.6i (Power steering H, T BOSCH E OAL 101 390 and aircon) VALEO D6RA572 C, VC...
  • Page 437 ALL TYPES ALTERNATORS Abbreviations and definitions Meaning of abbreviations : Coding of climates is as follows : : Gearbox CLIMATES : : Manual gearbox : Automatic gearbox : Hot (45°C/37°C) BVMP : Piloted manual gearbox : Temperate (37°C/17°C) Whitout aircon : Without air conditioning Whit aircon : With air conditioning : Cold (17°C/-25°C)
  • Page 438 SAXO ALTERNATORS Refer to the correspondance table for petrol or diesel engine Without aircon With aircon Climate Engine/gearbox DA by GEP DA by GEP Non DA or SAGINAW DA Non DA or SAGINAW DA TU1JP TU3JP/TU5JP/ TU5JP4 TU3JP Automatic TUD5 Meaning of abbreviations, see page : 433...
  • Page 439 SAXO ALTERNATORS Refer to the correspondance table for petrol or diesel engine Climate Engine/gearbox ALL APPLICATIONS TU All Types TUD5 Meaning of abbreviations, see page : 433...
  • Page 440 ALTERNATORS Refer to the correspondance table for petrol or diesel engine Whitout aircon Climate Engine/gearbox Base RT3 N 1 or 2 RT3 N 3 Cold Pack Cold Pack + RT3 N 1 or 2 Cold Pack + RT3 N 3 TU1JP TU3JP TU3JP...
  • Page 441 ALTERNATORS Refer to the correspondance table for petrol or diesel engine With aircon Climate Engine/gb Base RT3 N 1 or 2 RT3 N 3 Cold Pack Cold Pack + RT3 N 1 or 2 Cold Pack + RT3 N 3 TU1JP TU3JP TU3JP...
  • Page 442 XSARA ALTERNATORS Refer to the correspondance table for petrol or diesel engine Whitout aircon Whit aircon Engine/gb Climate Without Cold Pack Cold Pack Without Cold Pack Cold Pack Base Base Base Base RT2+NAV RT2+NAV TU3JP TU5JP4 TU5JP4 Automatic EW10J4 EW10J4 Automatic XU10J4RS...
  • Page 443 ALTERNATORS XSARA Refer to the correspondance table for petrol or diesel engine Whitout aircon Whit aircon Climate Engine/gb Without Cold Pack Cold Pack Without Cold Pack Cold Pack Base Base Base RT2+NAV Base RT2+NAV DW8B 8(8) 9(8) 8(8) 9(8) 9(8) 12(8) 9(8) 12(8)
  • Page 444 XSARA PICASSO ALTERNATORS Refer to the correspondance table for petrol or diesel engine Whitout aircon Whit aircon Climate Engine/gb Nav. + Radio-telephone Nav. + Radio-telephone Base Base TU5JP4 L3 et L4 EW7J4/L4 DW10TD Meaning of abbreviations, see page : 433...
  • Page 445 ALTERNATORS XSARA PICASSO Refer to the correspondance table for petrol or diesel engine Whitout aircon Whit aircon Climate Engine/gb Nav.+ Siège Heated Nav.+ Heated Base Base Navigation Navigation chauffant Heated seat seat seat TU5JP/L4 DW10TD DW10ATED DW10ATED Automatic DV4TD Meaning of abbreviations, see page : 433...
  • Page 446 ALL TYPES CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR Checking the alternator output Connect as shown in the diagram opposite, using an ammeter (A), a voltmeter (V), and a rheostat (R) or a Volt/Ammeter/Rheostat combination. Referring to the vehicle’s equipment specification (see table opposite), adjust the engine speed and rheostat charge to obtain U=13.5V.
  • Page 447 CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR ALL TYPES 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 448 ALL TYPES PRE-HEATING AND STARTING SYSTEMS Pre / Post heating Vehicles / models Pre-heater plugs Pre-heater control unit (pre-heating duration at 20°C) BERU 0 100 226 371 NAGARES 960411-P SAXO 1.5D 10s / 150s CHAMPION CH 185 CARTIER 735068 NGK YE04 NAGARES 960411-P 1.4 HDI CARTIER 735068...
  • Page 449 AIR CONDITIONING R 134 a (HFC) ALL TYPES Compressor Refrigerant Vehicle Engines Date Variable refill Oil reference Oil quantity cc Capacity TU - TUD All types 850 gr +0 - 50 gr AM 2000 # SAXO TU All types 825 gr ± 25 gr AM 2001 # TUD All types 795 gr ±...
  • Page 450 ALL TYPES SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Click-fit connector removing/fitting tool Vehicles Circuit Ø Inch Ring colour Tool kit 4164-T SAXO All Types XSARA Black 8005-T.A. XSARA PICASSO 8005-T.C C5HP073C Unions Aircon compressor fixings Ø Pipes Steel/Steel Aluminium/Steel ESSENTIAL : Tighten the front part of the compressor 1.7 ±...
  • Page 451 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) C3 - XSARA PICASSO «EUROCLIM» Compressor (MANULLI seal) Tools. Tool for removing-refitting air conditioning seals : K.1702 MANULLI seal C3 engine versions : All types XSARA PICASSO engine versions : : 10/12/2001 # : 01/04/2002 # : 04/11/2002 # Aircon compressor.
  • Page 452 C3 - XSARA PICASSO SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Condenser (MANULLI seal) Seals (MANULLI seal) C5HP18XD C5HP18VD The condenser (5) has a cylinder (6) incorporating the function of aircon MANULLI calibrated seal (3). fluid reservoir and with integral filtering cartridge. Direction of fitting of the seal (3).
  • Page 453 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) ALL TYPES Presence of pollen filter Vehicle Equipment RPO No. Presence of filter Observations SAXO All Types Without aircon YES (Larger) Except driving school XSARA Base aircon YES (Plus grand) XSARA PICASSO Regulated aircon YES (Valeo) Without aircon...
  • Page 454 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Pollen filter Note: The pollen filter is located in the engine compartment on the RH side. Removing Remove: - The three screws (1). - The plastic cover (2). Tilt the flap (3). Remove the pollen filter (4) Refitting Proceed in reverse order.
  • Page 455 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Changing the filtering/drying cartridge Tools. [1] Charge station : (according to workshop equipment) [2] TORX adaptor : TORX 70 FACOM. [3] Inertia extractor : 1671-T. Tool kit 4114-T [4] Endpiece Ø 20 : 1671-T.D20.
  • Page 456 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Changing the filtering/drying cartridge Refitting Remove the new cartridge from its packaging. Do not expose the cartridge, the filter and seals to pollutants. Lightly oil the seals (compressor oil). Remove tool [5] from the reservoir (6). Insert the new cartridge (5) into the reservoir (6).
  • Page 457 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) XSARA - All Types BEHR plate evaporator Pollen filter C5HP07JC C5FP075D Remove-refit. Remove : - The interior trim (1). - The cover (4). - The pollen filter (3). Concerns vehicles equipped with aircon without temperature regulation. Fitting of a new pollen filter necessitates the following operations: - Engage the pollen filter upwards (following arrow «c») - Slide the pollen filter towards the rear (following arrow «d»)
  • Page 458 XSARA - All Types SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) BEHR condenser with integral reservoir (16 Ti) The condenser is equpped with a cylinder (1) that acts as the fluid reservoir Petrol engine versions which in turn incorporates a filter cartridge. NOTE : As soon as the air conditioning loop has been open for more than 5 minutes, the filter/dryer cartridge assembly should be replaced (no set interval).
  • Page 459 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) XSARA PICASSO BEHR plate evaporator Pollen filter Remove: - The three screws (1). - The cover (2). - Remove the pollen filter. C5HP062C B1BP23ED...
  • Page 460 XSARA PICASSO SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) BEHR condenser with integral reservoir (16 Ti) The condenser is equpped with a cylinder (1) that acts as the fluid reservoir which in turn incorporates a filter cartridge. NOTE : As soon as the air conditioning loop has been open for more than 5 minutes, the filter/dryer cartridge assembly should be replaced (no set interval).
  • Page 461 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 462 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 463 ALL TYPES AIR CONDITIONING SYSTEM R 134.a Testing procedure Conditions inside the vehicle Switch on the air conditioning and adjust the engine speed to 2500 rpm. Positions of the air conditioning controls : In an ambient temperature of 40°C, the engine speed will be brought Maximum cold.
  • Page 464 ALL TYPES CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM CHECKING TEMPERATURES (continued) Vehicle using R134.a fluid (Compressor with variable capacity) Ambient temperature in °C Vehicle Engine types SAXO All Types 17 ± 3 13 ± 3 11 ± 3 9 ±...
  • Page 465 ALL TYPES CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM CHECKING PRESSURES TOOLS - 1 charging station. - 2 thermometers. CHECK - The temperature of the air coming from the central vents (see table). Once the preliminary conditions, vehicle equipment and checks - The High Pressure.
  • Page 466 SAXO - All Types AIR CONDITIONING SYSTEM R 134.a Click-fit union. C5HP12EC Tightening torques (m.daN). (1) High pressure valve (2) Low pressure valve (3) Click-fit union (4) Pressostat (1 seal Ø 10,82) (5) Dryer (2 seals Ø 7,65) (6) Relief valve, tighten to 0,43 m.daN ± 0,1 (1 seal Ø...
  • Page 467 SAXO - All Types AIR CONDITIONING SYSTEM R 134.a Checks on the air conditioning circuit Key. T = Scale of Temperature (°C ), and of High Pressure (Bars). P = Scale of Low pressure (Bars). Te = Exterior temperature (°C). HP = Pressure at compressor outlet (Bars).
  • Page 468 AIR CONDITIONING SYSTEM R 134.a (1) Low pressure valve. (2) High pressure valve. (3) Filter. (4) Pressostat Tightening torque m.daN : 0.6 : 0.6 : 0.6 : 0.6 : 0.6 : 0.6 C5HP17SP...
  • Page 469 AIR CONDITIONING SYSTEM R 134.a Checks on the air conditioning circuit Keys. T/P = Average temperature (°C ) at the air vents / high pressure (Bars). P = Low pressure (Bars). TE = Exterior temperature (C°). HP = Pressure at compressor outlet (Bars). BP = Pressure at compressor inlet (Bars).
  • Page 470 XSARA - All Types AIR CONDITIONING SYSTEM R 134.a Plan of air conditioning system Two solutions : 1 « MANULLI », with « NON EUROCLIM » compressor (O-ring seals). 2 « EATON », with « EUROCLIM » compressor (quadrilobe seals). (1) - High pressure valve (2) - Low pressure valve (3) - Pressostat...
  • Page 471 AIR CONDITIONING SYSTEM R 134.a XSARA - All Types Plan of air conditioning system Solution : 1 « EATON », with « EUROCLIM » compressor and buffer capacity (quadrilobe seals). (1) - High pressure valve (2) - Low pressure valve (3) - Buffer capacity Tightening torques m.daN.
  • Page 472 XSARA - All Types AIR CONDITIONING SYSTEM R 134.a Plan of air conditioning system Two solutions : 1 « MANULLI », with « NON EUROCLIM » compressor (O-ring seals). 2 « EATON », with « EUROCLIM » compressor (quadrilobe seals). (1) - High pressure valve (2) - Low pressure valve (3) - Pressostat...
  • Page 473 AIR CONDITIONING SYSTEM R 134.a XSARA - All Types Plan of air conditioning system Two solutions : 1 « MANULLI », with « NON EUROCLIM » compressor (O-ring seals). 2 « EATON », with « EUROCLIM » compressor (quadrilobe seals). (1) - High pressure valve (2) - Low pressure valve (3) - Pressostat...
  • Page 474 XSARA - All Types AIR CONDITIONING SYSTEM R 134.a Plan of air conditioning system Three solutions : 1) « MANULLI », with « NON EUROCLIM » compressor (O-ring seals). 2) « EATON », with « EUROCLIM » compressor and buffer capacity (quadrilobe seals). 3) «...
  • Page 475 AIR CONDITIONING SYSTEM R 134.a XSARA - All Types Plan of air conditioning system Two solutions : 1 « MANULLI », with « NON EUROCLIM » compressor (O-ring seals). 2 « EATON », with « EUROCLIM » compressor (quadrilobe seals). (1) - High pressure valve (2) - Low pressure valve (3) - Pressostat...
  • Page 476 XSARA - All Types AIR CONDITIONING SYSTEM R 134.a Plan of air conditioning system. Three solutions : 1) « MANULLI », with « NON EUROCLIM » compressor (O-ring seals). 2) « EATON », with « EUROCLIM » compressor and buffer capacity (quadrilobe seals). 3) «...
  • Page 477 AIR CONDITIONING SYSTEM R 134.a XSARA - All Types Plan of air conditioning system Two solutions : 1 « MANULLI », with « NON EUROCLIM » compressor (O-ring seals). 2 « EATON », with « EUROCLIM » compressor (quadrilobe seals). (1) - High pressure valve (2) - Low pressure valve (3) - Pressostat...
  • Page 478 AIR CONDITIONING SYSTEM R 134.a XSARA PICASSO TU (1) High pressure valve. (2) Low pressure valve. (3) High pressure clickfit union (tool 8005-T.C). (4) Low pressure clickfit union (tool 8005-T.A). (5) Pressostat. 1,8 ± 0,6 m.daN (6) Filtering / drying cartridge plug. Tightening torques m.daN.
  • Page 479 AIR CONDITIONING SYSTEM R 134.a XSARA PICASSO EW7 (1) High pressure valve. (2) Low pressure valve. (3) High pressure clickfit union (tool 8005-T.C). (4) Low pressure clickfit union (tool 8005-T.A). (5) Pressostat. 1,8 ± 0,6 m.daN (6) Filtering / drying cartridge plug. Tightening torques m.daN.
  • Page 480 AIR CONDITIONING SYSTEM R 134.a XSARA PICASSO TU - EW7 Checks on the air conditioning circuit Key. T/P = Scale of: - Temperature (°C), average of air from the central vents. - Pressure, High (Bars). - Pressure, Low (Bars). Te = Exterior temperature (°C). HP = Pressure at compressor outlet (Bars).
  • Page 481 XSARA PICASSO DW10 AIR CONDITIONING SYSTEM R 134.a (1) High pressure valve. (2) Low pressure valve. (3) High pressure clickfit union (tool 8005-T.C). (4) Low pressure clickfit union (tool 8005-T.A). (5) Pressostat. 1,8 ± 0,6 m.daN (6) Filtering / drying cartridge plug. Tightening torques m.daN.
  • Page 482 XSARA PICASSO DW10 AIR CONDITIONING SYSTEM R 134.a Checks on the air conditioning circuit Key. T/P = Scale of: - Temperature (°C), average of air from the central vents. - Pressure, High (Bars). - Pressure, Low (Bars). Te = Exterior temperature (°C). HP = Pressure at compressor outlet (Bars).

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