en_us_t1_2003

PRIVATE CARS

SAXO-C3-XSARAXSARA PICASSO-BERLINGO

PR

IVA

TE

CA

RS

CAR 050014Volume 1

2003AC.QCAV/MTD

Méthodes Techniques Documentation

� ’’The intellectual property rights relating to the technical information contained in this document belongexclusively to the manufacturer. Reproduction, translation or distribution in whole or in part withoutprior written authorisation from the manufacturer is forbidden.‘‘

«The technical information contained in this document is intended for the exclusive use of the trained personnel of themotor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. Theinformation is to be used by the professional vehicle repairers for whom it is intended and they alone would assume fullresponsibility 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 therange evolve. Motor vehicle repairers are invited to contact the CITROËN network periodically for further information andto obtain any possible updates».

2003

PRESENTATION

THIS HANDBOOK summarises the specifications, adjustments, checks and special features of CITROEN private vehicles, not including UTILITYvehicles 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.

In each section, the vehicles are dealt with in the following order : SAXO - C3 - XSARA - XSARA PICASSO - BERLINGO (1) and all models whereapplicable.

The information given in this handbook is based on vehicles marketed in EUROPE.

(1) NOTE : The BERLINGO familiale appears only in : - The correspondance tables for petrol and diesel engines.- The general chapter.

For all the other chapters, see the Mechanics’ Handbook for UTILITY vehicles.

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 accountwhen preparing future publications. For example :

– INSUFFICIENT INFORMATION– SUPERFLUOUS INFORMATION– NEED FOR MORE DETAILS

Please send your comments and suggestions to :

CITROEN U.K. Ltd.221, Bath Road,SLOUGH,SL1 4BA. U.K.

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.- Wait 1 minute.- Switch the ignition back on, the ECU is unlocked.

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1

SAXO - All TypesIDENTIFICATION OF VEHICLES

E1AP07CD

1 Engine legislation type

2 RP organisation no.

3 Chassis stamp

4 Manufacturer’s name plate

5 01/02/99 # Label :- Tyre pressures.- RP organisation no.- Paint code.

6 Paint code.

7 Gearbox ident. reference

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2

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Emission standard IFL5 L4 L4 L4 L4

Type code SO HFX1 SO HFXB SO KFWL S6 KFWB SO KFWB S6 NFTB N6 NFXB

Engine type HFX KFW NFT NFX

Cubic capacity (cc) 1124 1360 1587

Fiscal rating (hp) 4 6 5 5 8

Gearbox type MA/5 MB3 MA/5 MA/5

Gearbox ident. plate 20 CF 03 312 20 CF 12 20 CF 11 20 CN 05 20 CN 03

SAXO - All Types IDENTIFICATION OF VEHICLES

Saxo petrol 3-door

1.1 i 1.4 i 1.6 i 1.6i 16V

X-SX

A-X-SXAdministration

ExclusiveSX

Exclusive VTS

SXExclusive

VTS VTS VTS

Auto.

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Emission standard IFL5 L4 L4

Type code S1 HFX1 S1 HFXB S1 KFWL S1 KFWB

Engine type HFX KFW

Cubic capacity (cc) 1124 1360

Fiscal rating (hp) 4 6 5

Gearbox type MA/5 MB3 MA/5

Gearbox ident. plate 20 CF 03 312 20 CF 12

SAXO - All TypesIDENTIFICATION OF VEHICLES

Saxo petrol 5-door

1.1i 1.4i

A-AdministrationDriving school -x-SX

Exclusive SX-ExclusiveX-SX

Auto.

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Emission standard L4 L4

Type code SO VJXB S1 VJXB S3 HFXB S3 VJXB

Engine type VJX HFX VJX



Gearbox type MA/5 MA/5 MA/5

Gearbox ident. plate 20 CF 02 20 CF 03 20 CF 02

SAXO - All Types IDENTIFICATION OF VEHICLES

Diesel Entreprise

1.5 D

5-door3-door Diesel 3-doorPetrol 3-door

1.5 D1.1i

A-AdministrationDriving schoolX-SX-Exclusive

AAdministration

Poste-X-SX

AAdministration

Poste-X-SXA- Administration

X-SX-VTS -Exclusive

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E1AP09HD

IDENTIFICATION OF VEHICLES

A : Cold stamp (Cold stamp engraved on the bodywork).

B : Manufacturer’s name plate(On the LH centre pillar)

C : AS/RP No. and RP paint code.(label affixed to the front pillar on driver’s side)

D : Tyre pressures and tyre type.(label affixed to the front pillar on driver’s side)

E : Serial number on bodywork.

F : Gearbox ident. reference – Factory serial no.

G : Engine legislation type– Factory serial no.

C3 - All Types

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Emission standard L4 IFL5 L4/INF K’

Type code FC HFXB/T FR HFXB FN HFXB FC HFXB FN HFXC FC HFXC FC HFXB FC HFX5/IF /IF /D

Engine type HFX

Cubic capacity (cc) 1124

Fiscal rating (hp) 4

Gearbox type MA/5N

Gearbox ident. plate 20 CF 14


PETROL

1.1i

X-SX X

C3 - All Types

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(*) = Export.

PETROL

SX – Exclusive

1.4i

Auto.Auto. Auto.

Emission standard L4 IFL5

Type code FC KFVE FN KFVB FN KFVE FC KFVC/IF FC KFVF/IF FN KFVC/IF

Engine type KFV



Gearbox type AL4 MA/5N AL4 MA/5N AL4 MA/5N

Gearbox ident. plate 20 TP 7520 CF 15

20 TP 7520 CF 15

20 TP 7520 CF 15

20 CF 16 (*) 20 CF 16 (*) 20 CF 16 (*)

C3 - All Types

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(*) = Export.

PETROL

1.6i 16V1.4i

SX – ExclusiveSX – Exclusive

Auto.

Emission standard IFL5 L4 L4/INF L4

Type code FN KFVF/IF FC KFVB FC KFVB/D FC KFVE/D FN NFUB FC NFUB

Engine type KFV NFU


Fiscal rating (hp) 5 6

Gearbox type AL4 MA/5N MA/5S

Gearbox ident. plate 20 TP 75 20 CF 15 20 CF 16 (*) 20 CN 40

C3 - All Types

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(*) = Export.


DIESEL

1.4 HDi

X - SX

Emission standard L4

Type code FC 8HBXB/T FN 8HXB FC 8HXB FC 8HXB/MOD FC 8HXK FR 8HXB

Engine type 8HX



Gearbox type MA/5O

Gearbox ident. plate 20 CN 33 20 CN 36 (*)

C3 - All Types

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Type code FN 8HWK FC 8HWB FN 8HVB FC 8HVB

Engine type 8HW 8HV



Gearbox type MA/50 BE4/5

Gearbox ident. plate 20 CN 33 20 CN 36 (*) 20 DM 25 20 DM 26


DIESEL

S - SX SX - Exclusive

1.4 HDi 1.4 HDi 16V

(*) = Export.

C3 - All Types

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DIESEL

SX - Exclusive SX SX - Exclusive

1.4 HDi 16V


Type code FN 8HYB FC 8HYC FC 8HYB/MOD FC 8HYB/T FC 8HYK FR 8HYB

Engine type 8HY



Gearbox type BE4/5

Gearbox ident. plate 20 DM 25 20 DM 26

C3 - All Types

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E1AP08WD

A - Manufacturer’s name plate (Estate).

B - Chassis stamp, cold stamp.

C - Manufacturer’s name plate (Saloon).

D - Label : (label affixed to the front pillar on driver’s side)

- Tyre pressures.- RP organisation no.- Paint code.

E - Serial number. (visible through the windscreen)

F - Engine legislation type.Factory serial no.

G - Gearbox ident. reference. Factory serial no.

XSARA - All Types

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LEmission standard L4 IFL5 L4 IFL5

Type code NO KFWB NO KFW1/IF NO NFUB NO NFUN NO NFU1/IF NO NFU3/IF

Engine type KFW NFU



Gearbox type MA/5 MA/5 AL4 MA/5 AL4

Gearbox ident. plate 20 CF 13 20 CN 28 20 TP 49 20 CN 28 20 TP 49

XSARA - All TypesIDENTIFICATION OF VEHICLES

Saloon petrol 3-door

1.4 i 1.6i 16V

X-VTRX-SX-VTR

VTS VTR-VTSSX-VTR VTR

Auto. Auto.

X-SXVTR

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Type code NO RFN1/IF NO RFNN/IF NO RFSB NO WJYB NO RHYB NO RHZB NO RHZN

Engine type RFN RFS WJY RHY RHZ


Fiscal rating (hp) 8 11 5 6

Gearbox type BE4/5 AL4 BE3/5 BE4/5 AL4

Gearbox ident. plate20 DL 40 20 DL 41 20 DL 42 20 DM 10

20 TP 4820 DM 03 (1)20 TP 47 20 TE 47

20 DM 05 (1) 20 DM 07 (1) 20 DM 11 (1)


Saloon diesel 3-doorSaloon petrol 3-door

20i.16V 1.9 D 2.0 HDi

VTSX-SXVTR

X-SX-VTRVTS

SX-VTRVTS SX

Auto. Auto.

(1) = Right hand drive : Hydraulic clutch control.

XSARA - All Types

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Type code N0 8HZB N0 8HZB/T N3 8HZB

Engine type 8HZ



Gearbox type MA/5

Gearbox ident. plate


Saloon diesel 3 door

1.4 HDi

Entreprise

XSARA - All Types

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Type code NO KFWB/T (1) NO WJYB/T (1) NO RHYB/T (1)

Engine type KFW WJY RHY




Gearbox ident. plate 20 CF 13 20 DL 41 20 DL 42


(1) /T = The vehicle cannot be converted back into a private vehicle.

Saloon 3-door versions

DieselPetrol

1.4i 1.9 D 2.0 HDi

XX

XSARA - All Types

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Emission standard K’ L4 IFL5 K’ L4

Type code N1 KFWG N1 KFWB N1 KFW1/IF N1 NFUG N1 NFUU N1 NFUB

Engine type KFW NFU



Gearbox type MA/5 MA/5 AL4 MA/5

Gearbox ident. plate 20 CN 30 20 CF 13 20 CN 29 20 TP 49 20 CN 28


Saloon petrol 5-door.

1.4i 1.6i 16V

X-SX SXX-SX

Exclusive

Auto.

XSARA - All Types

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Emission standard L4 IFL5 IFL5 L4

Type code N1 NFUN N1 NFU1/IF N1 NFU3/IF N1 RFN1/IF N1 RFNN

Engine type NFU RFN



Gearbox type AL4 MA/5 AL4 BE4/5 AL4

Gearbox ident. plate 20 TP 49 20 CN 28 20 TP 49 20 DL 40 20 DM 03 (1) 20 TP 47

XSARA - All Types IDENTIFICATION OF VEHICLES


Saloons petrol 5-door

16i 16V 2.0i 16V

X-SXExclusive

SXExclusive Exclusive

Auto. Auto. Auto.

SXExclusive

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Type code N1 WJYB N1 RHYB N1 RHZB N1 RHZN

Engine type WJY RHY RHZ



Gearbox type BE4/5 BE4/5 AL4

Gearbox ident. plate 20 DL 41 20 DM 05 (1) 20 DL 42 20 DM 07 (1) 20DM 10 20 DM 11 (1) 20 TP 48

XSARA - All TypesIDENTIFICATION OF VEHICLES

Saloons diesel 5-door

1.9 D 2.0 HDi

X-SX X-SX-Exclusive SX-ExclusiveSX

Exclusive

Auto.


20

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Type code N1 8HZB N1 8HZB/T

Engine type 8HZ



Gearbox type MA/5


IDENTIFICATION OF VEHICLESSaloons diesel 5-door

1.4 HDi

Entreprise

XSARA - All Types

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Type code N1 WJYB/T (1) N RHYB N1 RHYB/T (1)

Engine type WJY RHY



Gearbox type BE4/5 BE4/5

Gearbox ident. plate 20 DL 41 20 DL 42



Saloons diesel entreprise 5-door

2.0 HDi1.9 D

XX

XSARA - All Types

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Emission standard L4 IFL5 K’ L4 IFL5

Type code N2 KFWB KFW1/IF N2 NFUG N2 NFUB N2 NFUN N2 NFU1/IF N2 NFU3/IF

Engine type KFW NFU



Gearbox type MA/5 MA/5 AL4 MA/5 AL4

Gearbox ident. plate 20 CN 21 20 CN 29 20 CN 28 20 TP 49 20 CN 28 20 TP 49


Petrol estate

1.4i 16. 16V

X-SXX-SX

EclusiveSXX-SX

ExclusiveSX

ExclusiveSX

Exclusive

Auto.Auto.

XSARA - All Types


Type code N2 RFN1/IF N2 RFNN N2 WJYB

Engine type RFN WJY



Gearbox type BE4/5 AL4 BE4/5

Gearbox ident. plate 20 DL 40 20 DM 03 (1) 20 DL 41 20 DM 05 (1)


Diesel estatePetrol estate

1.9 D2.0i 16V

Exclusive X - SX


Auto.

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XSARA - All Types

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Emission standard L4 IFL5

Type code N2 RHYB N2 RHYB/IF N2 RHZN

Engine type RHY RHZ



Gearbox type BE4/5 AL4

Gearbox ident. plate 20 DL 42 20 DM 07 (1) 20 DM 10 20 DM 11 (1) 20 TP 48


Diesel estate

2.0 HDi

X-SX-EclusiveSX

Exclusive


Auto.

XSARA - All Types

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25


Type code N2 8HZB N2 8HZB/T N4 8HZB

Engine type 8HZ



Gearbox type MA/5


IDENTIFICATION OF VEHICLESDiesel saloon and estate

1.4 HDi

EntrepriseX

XSARA - All Types

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Type code N2 KFWB/T (1) N2 WJYB/T (1) N2 RHYB/T (1)

Engine type KFW WJY RHY



Gearbox type MA/5 BE4/5 BE4/5

Gearbox ident. plate 20 CN 21 20 DL 41 20 DL 42



Estate diesel versionsEstate petrol versions

2.0 HDi1.9 D1.4i

XX

XSARA - All Types

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IDENTIFICATION OF VEHICLES XSARA PICASSO - All Types

E1AP088D

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.Tyre identification.Spare wheel identification.

(Located on front LH door inner panel).

E : Label : Factory code.A-S / RP N°Paint code.

(Located on fuse box cover)

F : Gearbox identification ref.

G : Engine legislation type.Factory serial number.

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Emission standard L4 IFL5 L4

Type code CH NFVB CH 6FZB CH 6FZC/IF CH RFNF/IF CH RHYB

Engine type NFV 6FZ RFN RHY

Cubic capacity (cc) 1587 1749 1998 1997

Fiscal rating (hp) 6 7 8 5

Gearbox type BE4/5/ J (*) BE4/5 V (*) AL4 BE4/5 L (*)

Gearbox ident. plate 20 DL 66 20 DL 68 20 TS 02 20 DL 65


DieselPetrol

2.0 HDi2.0i 16 V1.8i 16 V1.6i

SX-Exclusive

(*) L,J V = Corresponds to the stepping of the gears.

Auto.

XSARA PICASSO - All Types

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IDENTIFICATION OF VEHICLES BERLINGO - All Types

E1AP0AMD

11/2002 #

A Chassis stamp, cold stamp

B Manufacturer’s vehicle plate

C LabelRPO No.Paint colour codeTyre pressures

D Gearbox ident. reference – Factory serial no.

E Engine legislation type – Factory serial no.

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Emission standard L4/W4 K’ L4/W4 IFL5

Type code GB VHFXB GJ K6D5G GJ KFWB GJ KFWC/IF

Engine type HFX KFW



Gearbox type MA/5S MA/5

Gearbox ident. plate 20 CD 43 20 CN 13

BERLINGO - All Types IDENTIFICATION OF VEHICLES

Berlingo petrol 5-seater 11/2002 #

1.4i

X X X-SX- Multispace

1.1i

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Emission standard L4/W4 L4 IFL5

Type code GJ KFWB/GL (1) GJ KFWB/GN (2) GJ NFUB GJ NFUC/IF

Engine type KFW NFU




Gearbox ident. plate 20 CN 13 20 DM 46


Berlingo petrol 5-seater 11/2002 #

1.6i 16v

Multispace X-SX- Multispace

1.4i

BERLINGO - All Types

Dual fuel

(1) GL = LPG = Liquefied Petroleum Gas, with ring-shaped tank.(2) GN = CNG = Compressed Natural Gas, with cylindrical tank.

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Emission standard L4/W4 L4/W4

Type code GJ WJYB GJ WJYB/PMF (1) MF RHYF

Engine type WJY RHY



Gearbox type BE4/5 BE4/5

Gearbox ident. plate 20 DM 48 20 DM 50


Berlingo diesel 5-seater 11/2002 #

2.0 HDi

X-SX-Multispace X-SX-Multispace

1.9 D

BERLINGO - All Types

(1) /PMF = Multifunction roof.

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CAPACITIES (in litres)ALL TYPES

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.

5/ Engine filling.

6/ Engine starting (allowing the cartridge to be filled).

7/ Engine stopped (stationary for 5 min).

ESSENTIAL : Systematically check the oil level using the oil dipstick.

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Ecological oil filter capacity 0.15 litre.

Engine type

Engine with filter change

Between Min. and Max.

5-speed gearbox

Automatic gearbox

after drainage

Hydraulic or brake circuit

Cooling system

Fuel tank capacity

HFX KFW NFX NFT VJX

3 3.5 4.5

1.5 1.5 2

2 2

4.5

2

With ABS = 0.45 - Without ABS = 0.36

6.1

45

SAXO - All Types CAPACITIES (in litres)

DieselPetrol

SAXO

1.1i 1.4i 1.6i 16V 1.5D1.6i

ESSENTIAL : systematically check the oil level using the oil dipstick.

Auto.

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1.1i 1.4i 1.6i 16V 1.4 HDi 1.4 HDi 16V

Engine type HFX KFV NFU 8HX 8HW 8HV 8HYDrain by gravity : engine with filter change 2.9 3.75Between min. And max. 1.5 1 2

Drain by suction : engine with filter change

3.1

Between Min. and Max. 1.5 15-speed gearbox 2 2 1.9Automatic gearbox (1)

After oil change

Braking circuit0,7 Litre version with front calipers Ø 48 / rear drums 0,8 Litre version with front calipers Ø 54 / rear discs

Cooling system 7 5.7 5.6Fuel tank capacity 45

ESSENTIAL : systematically check the oil level using the oil dipstick.(1) = The gearbox is lubricated for life. (For your information, the TOTAL capacity is 5,85 litres, after draining: 3 litres).

CAPACITIES (in litres)

Petrol

C3

Diesel

Auto.

C3 - All Types

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Engine type

Engine with filter element


5-speed gearbox

Automatic gearbox

after drainage


Cooling system

Fuel tank capacity

KFW NFU RFN RFS 8HZ WJZ RHY RHZ

3 3.25 4.25 4 (*) 4.75 4.5-4.25 (1)

1.4 1.5 1.7 1 1 (*) 1.6 1.4

2 1.9 1.9 2 1.8

6 6 8.3

3 3 5.3


7 8.56.5 (1) 5.7 9 11 (1)

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XSARA - All Types CAPACITIES (in litres)

Ecological oil filter capacity 0.15 litre.

Petrol Diesel

XSARA

(*) = 01/12/03 # from 11/02 to 01/12/03 # Engine with filter element = 3,75 and Between min. and max. = 1,8(1) = With air conditioning ESSENTIAL : systematically check the oil level using the oil dipstick.

1.4i 1.6i 16V 2.0i 16V 1.9D1.4 HDi 2.0 HDi

Auto. Auto. Auto.

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Ecological oil filter capacity 0.15 litre

Engine type



5-speed gearbox

Automatic gearbox

- after drainage


Cooling system

Fuel tank capacity

NFV 6FZ RFN RHY

3 4.25 4.5

1.5 1.7 1.4

1.8 1.8

6

3

0.58 litres

5.8 (1) et (2) 6.5 (1) et (2) 11 (1) et (2)

55 60

XSARA PICASSO - All TypesCAPACITIES (in litres)

DieselPetrol

XSARA PICASSO

1.6i 1.8i 16 V 2.0i 16 V 2.0 HDi

(1) = With air conditioning(2) = Without air conditioning ESSENTIAL : systematically check the oil level using the oil dipstick.

Auto.

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Ecological oil filter capacity 0.15 litre

Engine type



5-speed gearbox


Cooling system

Fuel tank capacity

HFX KFW NFU WJY RHY

3 3.25 4.5

1.5 1.2 1.4

2 1.8 1.8


8 9

55 60

BERLINGO 2 - All Types CAPACITIES (in litres)

DieselPetrol

BERLINGO 2

1.1i 1.4i 1.6i 16V 2.0 HDi1.9 D

ESSENTIAL : systematically check the oil level using the oil dipstick.

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ALL TYPESLUBRICANTS - TOTAL recommended oils

Evolutions (year 2003).

CITROËN C3 PLURIEL.

Only petrol versions are available.

Normal maintenance interval : 30 000 km (20 000 miles)Severe maintenance interval : 20 000 km (12 000 miles)

ESSENTIAL : For all vehicles with a 30 000 km (20 000 miles) main-tenance interval, use exclusively TOTAL ACTIVA/QUARTZ 7000 or9000 or any other oils offering identical specifications to these.These oils offer specifications that are superior to those definedby norms ACEA A3 OR API SJ/CF.Failing this, it is essential to adhere to the maintenance programmescovering severe operating conditions.

Use of oil grade 10W 40.It is possible to use semi-synthetic oil 7000 10W40 on HDi and HDi FAPvehicles.

WARNING : To avoid problems with starting from cold, use this oil as allo-wed by the climatic conditions in the country concerned (see table).

For more details see the oil usage table.

New commercial designation for energy economy oil.The oil TOTAL ACTIVA/QUARTZ 9000 5W30 becomesTOTAL ACTIVA FUTUR 9000 (for France),QUARTZ FUTURE 9000 5W30 (outside France).The usage exclusions for this oil are the same as before :

- XSARA VTS 2.0i 16V (XU10J4RS).- RELAY 2.8 TDi; 2.8 HDi (SOFIM engine).- HDi FAP vehicles.- C3 1.6i 16V (DV4TED4).- C8 2.2i (EW12J4)

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ALL TYPES LUBRICANTS - TOTAL recommended oils

Engine oil norms.

Current norms.

The classification of these engine oils is established bythe following recognised organisations :

- S.A.E : Society of Automotive Engineers.

- API : American Petroleum Institute.

- ACEA : Association des Constructeurs Européensd’Automobiles

E4AP006D

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ALL TYPES

S.A.E. Norms - Table for selection of engine oil gradeSelection of engine oil grades recommended for climatic conditions in countries of distribution

Evolution of the norms as at 01/01/2003

ACEA 2003 normsThe meaning of the first letter has not changed, it still corresponds tothe type of engine :

A : petrol and dual fuel petrol / LPG engines.B : diesel engines.

The figure following the first letter corresponds to the type of oil: .3 : high performance oils.4 : oils specifically for direct injection diesel engines.5 : very high performance oils permitting lower fuel consumption Example : ACEA A3 : high performance oils specifically for petrol and dual fuelpetrol / LPG engines ACEA A/B : blended oils giving very high performance for all engines,also permitting better fuel economy, specifically for direct injection die-sel engines NOTE : From 01/01/2003 there is no longer any reference to the yearof creation of the norm, (Example : ACEA A3/B3 98 becomes ACEAA3/B3.

API norms

The meaning of the first letter has not changed, it still corresponds to thetype of engine :

S : petrol and dual fuel petrol / LPG engines.C : diesel engines.

The second letter corresponds to the degree of evolution of the oil(ascending order).

Example : Norm SL is more severe than norm SJ, corresponding to ahigher level of performance.

LUBRICANTS - TOTAL recommended oils

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ALL TYPES

Recommendations.

ESSENTIAL : To preserve engine performances, all engines fitted in CITROEN vehicles must be lubricated with high quality oils (syntheticor 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%).

The oil 5W30 is used only for the following engines (Year 2003) :

- XU10 J4RS : XSARA VTS 2.0i 16V (3-door)- SOFIM : RELAY 2.8 TDi and 2.8 HDi.- HDi : With particle filter (FAP).- DV4 TED4 : CITROËN C3 1.4 HDi 16V- EW 12J4 : CITROËN C8 2.2i.

WARNING : CITROËN engines prior to model year 2000 do not have to be lubricated with oils adhering to the norms :ACEA AI-98 and API SJ/CF EC or current norms ACEA A5/B5

Denomination of TOTAL oils according to country of marketing : TOTAL ACTIVA (France only).TOTAL QUARTZ (outside France).


LUBRICANTS - TOTAL recommended oils ALL TYPES

Year

2003Petrol and dual fuelpetrol / LPG engines

A3 or A5 5 (*) SJ or SL

CFB3 or B5 (*)Diesel engines

Types of engine concerned

Norms to be observed for engine oils (year 2003)

ACEA norms API norms

Recapitulation

43

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TOTAL ACTIVATRAC

TOTAL QUARTZ FUTUR 9000 (*)

TOTAL ACTIVA FUTUR 9000 (*)

TOTAL ACTIVA 9000TOTAL QUARTZ 9000 5W40 A3 / B3

SL / CF

SJ / CF

A5 / B5

A3 / B3

5W30

10W40

S.A.E. norms

Blended oils for all engines (petrol, diesel and dual fuel petrol / LPG engines).


(*) It is essential not to use engine oils respecting these norms for the following engine-types : XU10 J4RS , SOFIM 2.8 TDiand SOFIM 2.8 HDi , HDi with particle filter (FAP), EW 12 J4, DV4 TED4.

Classes and grades of TOTAL recommended engine oils.Oils marketed in each country are adapted to the local climatic conditions.

(*) Blended oils for all engines, permitting fuel economy.

44

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LUBRICANTS - TOTAL recommended oilsALL TYPES

TOTAL ACTIVA 7000TOTAL QUARTZ 7000

TOTAL QUARTZ 9000

TOTAL ACTIVA 7000TOTAL QUARTZ 7000 10W40

A3 SJ0W40

15W50

S.A.E. norms

Oils specifically for petrol and dual fuel petrol / LPG engines


TOTAL ACTIVA DIESEL 7000

TOTAL ACTIVA DIESEL 7000TOTAL QUARTZ DIESEL 7000 10W40

B3 CF

15W50

S.A.E. norms

Oils specifically for diesel engines


45

GE

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LUBRICANTS - TOTAL recommended oils ALL TYPES

TOTAL ACTIVA QUARTZ

Semi-synthetic 7000Synthetic 9000

0W40 coldcountries 5W30 5W40 10W40 15W50 hot

countries

Engine types

XU10 J4RS (Xsara VTS 2.0i 16V) X

X

X

EW 12 J4 (C8 2.2i 16V)

Other petrol engines

HDi engines with FAP (*)

Other HDi engines

SOFIM 2.8 TDi and 2.8 HDi (RELAY)

DV4 TED4 (C3 1.4 HDi 16V)

Indirect injection diesel engines

Petrolengines

Dieselengines

Oil usage table

X

X

X

X X X

X X X

X X X

X X

X X X

X X X

X X X

X X X

(*) = Particle filter

46

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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

47

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FRANCE

Metropolitan FRANCE

Metropolitan FRANCE

New CaledoniaGuadeloupeSaint-martinReunion

9000 5W-40 7000 15W-50 7000 15W-50MartiniqueGuyanaTahitiMauritiusMayotte


Blended oils for all engines, supplied in bulk

ENGINE OILS

TOTAL ACTIVRAC S.A.E. norms : 10W40

TOTAL ACTIVA

Blended oils for all engines

900 5W-409000 5W-30 (*)

7000 10 W-407000 10 W-409000 5W-40

Oils specifically for petrol anddual-fuel petrol / LPG engines

Oils specifically for dieselengines

TOTAL ACTIVA DIESEL

(*) = Blended oils for all engines, permitting fuel economy

ALL TYPES

48

GE

NE

RA

L

EUROPE

7000 10W409000 0W40

7000 10W40

7000 10W409000 0W40

7000 10W409000 0W40

7000 10W40

7000 10W409000 15W40

7000 10W40

Germany

Austria

Belgium

Bosnia

Bulgaria

Cyprus

Croatia


ENGINE OILS

TOTAL ACTIVA

Blended oils for all engines Oils specifically for petrol anddual-fuel petrol / LPG engines


TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40FUTURE 9000 5W30 (*) 7000 10W40


49

GE

NE

RA

L

EUROPE

7000 10W409000 0W407000 10W407000 15W40

7000 10W409000 0W40

7000 10W40

7000 10W407000 15W40

7000 10W409000 0W40

Denmark

Spain

Estonia

Finland

Great Britain

Greece

Holland


ENGINE OILS

TOTAL ACTIVA



TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40FUTURE 9000 5W30 (*) 7000 10W40


50

GE

NE

RA

L

EUROPE

7000 10W409000 0W40

7000 10W40

7000 10W409000 0W40

7000 10W40

Hungary

Italy

Ireland

Iceland

Latvia

Lithuania

Macedonia


ENGINE OILS

TOTAL ACTIVA



TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40FUTURE 9000 5W30 (*) 7000 10W40


51

GE

NE

RA

L

EUROPE

7000 10W407000 15W50

7000 10W40

7000 10W409000 0W40

7000 10W40

7000 10W409000 0W40

Malta

Moldavia

Norway

Poland

Portugal

Slovakia

Czech Republic


ENGINE OILS

TOTAL ACTIVA



TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40FUTURE 9000 5W30 (*) 7000 10W40


52

GE

NE

RA

L

EUROPE

7000 10W407000 15W509000 0W40

7000 10W409000 0W40

7000 10W40

7000 10W409000 15W509000 0W40

Romania

Russia

Slovenia

Sweden

Switzerland

Turkey


ENGINE OILS

TOTAL ACTIVA



TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40FUTURE 9000 5W30 (*) 7000 10W40


53

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NE

RA

L

EUROPE

7000 10W409000 0W40

Ukraine

Yugoslavia


ENGINE OILS

TOTAL ACTIVA



TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40FUTURE 9000 5W30 (*) 7000 10W40


54

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OCEANIA

AFRICA

7000 10W40Australia

New Zealand

Algeria, South Africa,

Ivory Coast, Egypt,

Gabon, Ghana, Kenya,

Madagascar, Morocco,

Nigeria, Senegal, Tunisia


ENGINE OILS

TOTAL ACTIVA



TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40FUTURE 9000 5W30 7000 10W40

7000 15W50

TOTAL ACTIVA



TOTAL ACTIVA DIESEL

9000 5W40 7000 10W40

55

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NE

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CENTRAL AND SOUTH AMERICA

Argentina

Brazil

Chile

Cuba

Mexico

Paraguay

Uruguay


7000 10W507000 15W50

ENGINE OILS

TOTAL ACTIVA



TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40 7000 10W40

56

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SOUTH-EAST ASIA

China

South Korea

Hong Kong

India – Indonesia

Japan

Malaysia

Pakistan


7000 10W507000 15W50

7000 10W40

7000 15W50

7000 10W407000 15W50

7000 15W50

ENGINE OILS

TOTAL ACTIVA



TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40FUTURE 9000 5W30

9000 5W40

9000 5W40FUTURE 9000 5W30 (*)

9000 5W40

7000 10W40


57

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SOUTH-EAST ASIA

Philippines

Singapore

Taiwan

Thailand

Vietnam


7000 15W50

7000 10W407000 15W50

7000 15W50

ENGINE OILS

TOTAL ACTIVA



TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40 7000 10W40


58

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MIDDLE EAST

7000 15W50

7000 10W407000 15W50

7000 15W50

Saudi Arabia – Bahrain

Dubai

United Arab Emirates

Iran

Israel – Jordan – Kuwait – Lebanon

Oman – Qatar – Syria – Yemen


ENGINE OILS

TOTAL ACTIVA



TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40 7000 10W40

59

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GEARBOX OILS

ALL TYPES

TOTAL TRANSMISSION BVNorms S.A.E. : 75W80

Part No. : 9730 A2

TOTAL FLUIDE ATX

TOTAL FLUIDE AT 42Special oil distributed by

CITROËNPart No. : 9730 A3

Special oil distributed byCITROËN

Part No. : 9736 22

TOTAL TRANSMISSION X4Part No. : 9730 A4

Manual gearbox and SensoDrive

MB3 automatic gearbox

4HP20 and AL4 autoactiveautomatic gearboxes

Transfer box and rear axle

All countries

60

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POWER STEERING OILS

ENGINE COOLANT FLUID

ALL TYPES

TOTAL FLUIDE ATX

TOTAL FLUIDE DAsSpecial oil distributed by

CITROËNPart No. : 9730 A1

Power steering

All countries

Very cold countries

All countriesCITROËN fluid

Protection : - 35C°

2 Litres

5 Litres

20 Litres

210 Litres

9979 70

9979 71

9979 76

9979 77

9979 72

9979 73

9979 74

9979 75

PackCITROËN Part No.

REVKOGEL 2000GLYSANTIN G33

61

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BRAKE FLUIDSynthetic brake fluid

HYDRAULIC CIRCUIT

WARNING : TOTAL FLUIDE LDS fluid cannot be blended with TOTAL LHM LDS

WARNING : CITROËN C5 : Use exclusively TOTAL FLUIDE LDS suspension fluid.

All countries TOTAL HYDRAURINCAGE

All countries CITROËN fluid

0.5 Litre

1 Litre

5 Litres

9979 05

9979 06

9979 07

Pack CITROËN Part No.

ALL TYPES

Pack CITROËN Part No.Norm

Colour

All countries

TOTAL FLUIDE LDS

TOTAL LHM PLUS

TOTAL LHM PLUSGrand Froid

Orange 9979 69

ZCP 830095

9979 20Green

1 Litre

62

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SCREEN WASH FLUID

GREASEGeneral use

All countries

Concentrated : 250 ml

Fluid readyfor use

9980 33

9980 06

9980 05

ZC 9875 953U

ZC 9875 784U

ZC 9885 077U

9980 56

ZC 9875 279U

Pack CITROËN Part No.

LUBRICANTS - TOTAL recommended oilsALL TYPES

1 Litre

5 Litres

Norms NLGI

2TOTAL MULTIS 2

TOTAL SMALL MECHANISMSAll countries

Note : NLGI = National Lubricating Grease Institute.

63

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ENGINE OIL CONSUMPTION

I - Oil consumption depends on :- the engine type.- how run-in or worn it is.- the type of oil used.- the driving conditions.

II - An engine can be considered RUN-IN after:

- 3,000 miles (5,000 km) for a PETROL engine.- 6,000 miles (10,000 km) for a DIESEL engine.

III - MAXIMUM PERMISSIBLE oil consumption for a RUN-IN engine.- 0.5 litres per 600 miles (1,000 km) for a PETROL engine.- 1 litre per 600 miles (1,000 km) for a DIESEL engine.

DO NOT WORK BELOW THESE VALUES.

IV - OIL LEVEL : The level should NEVER be above the MAX. mark on the dipstick after changing or topping up the oil.

- This excess oil will be used up rapidly.- It will reduce the engine output and adversely affect the operation of the air circuits and gas recycling.

ALL TYPES

64

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ENGINE SPECIFICATIONSALL TYPES

Engines : HFX - KFW - NFT - NFV

Petrol

All Types

1.1i 1.4i 1.6i

Vehicle

Emission standard

Engine type

Cubic capacity (cc)

Bore / Stroke

Compression ratio

Power ISO or EEC - KW - rpm

Power DIN (HP - rpm)

Torque ISO or EEC (m.daN - rpm)

Saxo C3 Saxo Xsara Saxo Picasso

L4/IFL5/L4INF K’ L4 K’/L4/IFL5 L4

HFX KFW NFT NFV

1124 1360 1587

72/69 75/77 78.5/82

10.5/1

44.1-5500 55-5500 72-5700 70-5700

60-5500 75-5500 98-5700 95-5700

9.4-3500 9.4-3300 12-3400 12-2800 13.5-3500 13.5-3000

65

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EENGINE SPECIFICATIONS ALL TYPESEngines : NFX - NFU - 6FZ - RFN - RFS

Petrol

All Types

1.6i 16V 2.0i 16V1.8i 16V

Vehicle

Emission standard

Engine type

Cubic capacity (cc)

Bore / Stroke

Compression ratio




Saxo C3/Xsara Picasso Xsara Picasso Xsara

L4 K’/L4/IFL5 L4/IFL5 L4/IFL5 IFL5 L4

NFX NFU 6FZ RFN RFS

1587 1749 1197 1998

78.5/82 82.7/81.4 85/88 86/86

10.8/1 11/1 10.8/1

87-6600 80-5800 85-5500 100-6000 120-6000

118-6600 109-5800 115-5500 136-6000 163-6000

14.5-5200 14.7-4000 16-4000 19-4100 19.3-5000

66

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ENGINE SPECIFICATIONSALL TYPES

Engines : VJX - 8HX - 8HW - 8HV - 8HY - 8HZ

Diesel

All Types

1.4 HDi1.5D 1.4 HDi1.4 16V HDi 2.0 HDi

Vehicle

Emission standard

Engine type

Cubic capacity (cc)

Bore / Stroke

Compression ratio




Saxo C3 Xsara Xsara-Picasso Xsara

L4 L4/IFL5

VJX 8HX-8HW 8HV-8HY 8HZ RHY RHZ

1527 1398 1997

77/82 73.5/82 85/88

23/1 17.9/1 18.4/1 17.9/1 17.6/1

42-5000 50-4000 66-4000 50-4000 66-4000 80-4000

57-5000 70-4000 90-4000 70-4000 90-4000 109-4000

9.5-2250 15-1750 20-1750 16-2000 20.5-1900 25-1750

67

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ESPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

Engine type HFX KFW KFV NFT NFV NFX NFU VJX

Maximum permissible bow 0.05

Gasket surface regrinding - 0.20

Crankshaftbearing screws

Connecting rod screws

Flywheelscrew

Crankshaft pinion screw

Camshaft pulley screw

Camshaft hubs

Camshaft hub screw

CYLINDER HEAD (mm)

TIGHTENING TORQUES ( m.daN)

ALL TYPES

Pre-tighteningAngular tightening

Tightening

Tightening



Tightening

2 ± 0.2 2 ± 0.245° 50° ± 5°

3.8 ± 0.4

6.5 ± 0.7

10 ± 17 ± 0.745° ± 4°

8 ± 0.84 ± 0.420° ± 2°

8 ± 0.8

1 ± 0.1 2.5 ± 0.2

68

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SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

Engine type 6FZ RFN RFS WJZ WJY RHY RHZ

Maximum permissible bow 0.05 0.03

Gasket surface regrinding - 0.30 - 0.20 - 0.40

Crankshaft bearing screws

Connectingrod screws

CYLINDER HEAD (mm)

TIGHTENING TORQUES ( m.daN)

ALL TYPES

Pre-tightening

Slackening

Tightening Angular tighteningTightening

Pre-tighteningSlackeningTightening Angular tightening

1 ± 0.1180° (1/2 turn)

2.3 ± 0.246° ± 5°

(1) Ø 11 : 1 ± 0.1(2) Ø 6 : 1 ± 0.1

Ø 11 (only)

Ø 11 to 1 ± 0.1 thento 2 ± 0.1

Ø 11 to 70° ± 5°Ø 6 to 1 ± 0.1

2.3 ± 0.246° ±4.6°

2 ± 0.1

60° ± 6°

4 ± 0.4

2± 0.270° ± 7°

8.5 ± 0.8 7 ± 0.7

2.5 ± 0.3

60° ± 6°

2 ± 0.2

70° ± 7°

69

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ESPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

A = HFX- KFVB = NFU

RH engine support

(1) 4.5 ± 0.4(2) 6.1 ± 0.6(3) 4.5 ± 0.4

Torque reaction rod

(4) 6 ± 0.6(5) 6 ± 0.6

LH engine support on gearbox

(6) 3 ± 0.3(7) 6 ± 0.6(8) 5.5 ± 0.5

B1BP2NEP

C3

70

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SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )Crankshaft

Engine types HFX KFV NFUAccessories drive pulley 0.8 ± 0.2Pinion fixing on crankshaft 10 ± 1 2.5 ± 0.2

Cylinder blockSump 0.8 ± 0.2Timing belt tensioner roller 2 ± 0.2 2.2 ± 0.2Accessories belt tensioner roller 2 ± 0.2 2.5 ± 0.2Alternator support fixing 1.7 ± 0.3Alternator fixing on support 3.7 ± 0.3

Cylinder headCoolant outlet housing 0.8 ± 0.2Camshaft bearing cap

Tightening 2 ± 0.2 2 ± 0.2Angular tightening 44° ± 4° 50° ± 5°Inlet manifold 0.8 ± 0.2Exhaust manifold 1.7 ± 0.3 2 ± 0.2Valve rockers adjusting screw 1.75 ± 0.25Sparking plugs 2.75 ± 0.25Camshaft pulley screw 8 ± 0.8

C3

71

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ESPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )Flywheel -Clutch

Engines HFX KFV NFU

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 ± 0.1

Coolant outlet housing 0.8 ± 0.1

C3

72

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SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )Engines : 8HX - 8HW

RH engine support

(1) 4.5 ± 0.4(2) 3 ± 0.3

Torque reaction rod

(3) 6 ± 0.6(4) 6 ± 0.6

LH engine support on gearbox

(5) 5.4 ± 0.5(6) 6 ± 0.6(7) 5.5 ± 0.5

B1BP2LJP

C3

73

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ESPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )Engines 8HW - 8HX

Crankshaft

Bearing cap fixing screwPre-tightening 1Slackening YESTightening 3Angular tightening 140°

Con rod nutsPre-tightening 1Slackening YESTightening 1.5 ± 0.1Angular tightening 100° ± 5°

Accessories drive pulleyPre-tightening 3 ± 0.4Angular tightening 180° ± 5°

Cylinder block

Sump 1 ± 0.1

Timing belt guide roller 4.5 ± 0.4

Timing belt tensioner roller 3 ± 0.3

C3

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SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )Engines 8HW - 8HX

Cylinder head

Camshaft bearing coversPre-tightening 0.5 ±Tightening 1 ±

Fixings of camshaft sub-assemblies on cylinder headPre-tightening 0.5Tightening 1Exhaust manifold 2.5 ± 0.2Valve cover 2.5 ± 0.2Camshaft pulley 4.3 ± 0.4

FlywheelFlywheelPre-tightening 1.7Tightening 70° ± 5°

Clutch mechanism 2 ± 0.2Lubrication circuit

Oil pump assemblyPre-tightening 0.5 ± 0.06Tightening 0.9 ± 0.1

Coolant/oil heat exchanger 1 ± 0.1

C3

75

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ESPECIAL 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 ± 0.2

Union on diesel injection

Diesel injection pump pulley 5 ± 0.5

Union on diesel high pressure pump 2.25 ± 0.2

Cooling circuit

Coolant pump

Pre-tightening 0.3 ± 0.06

Tightening 1 ± 0.1

Coolant outlet housing

Pre-tightening 0.3 ± 0.06

Tightening 0.7 ± 0.08

C3

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SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )Engines : 8HY - 8HV

RH engine support

Screw (1) 6 ± 0.6Screw (2) 6 ± 0.6

RH lower engine support

Screw (3) 5.7 ± 0.5

LH upper engine support

Screw (7) 6 ± 0.6Screw (8) 5.5 ± 0.5

LH lower engine support

Screw (6) 5.4 ± 0.5

Torque reaction rod

Screw (4) 6 ± 0.6Screw (5) 6 ± 0.6

B1BP2MNP

C3

77

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ESPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )Engines 8HY - 8HV

Crankshaft

Bearing cap fixing screwTightening 3 ± 0.3Angular tightening 140° ± 1°.4’Crankshaft pullet hubTightening 3 ± 0.3Angular tightening 180° ± 5°

Cylinder blockOil sump 1 ± 0.1Timing belt tensioner roller 4 ± 0.4Timing belt guide roller

2.5 ± 0.2Timing belt guide roller support

Cylinder headCamshaft bearing cap cover

1 ± 0.1Inlet manifoldExhaust manifold 2.5 ± 0.2Cylinder head cover Screws (M6) to 1 ± 0.2Camshaft pinion 4.3 ± 0.4Fuel high pressure pump pinion 5 ± 0.5

C3 - XSARA

78

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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 ± 0.2

Injection circuit

Injector fixing flange nut

Tightening 0.4 ± 0.1

Angular tightening 65° ± 5°

Unions on fuel high pressure common injection rail

Fuel high pressure pump 2.3 ± 0.2

Union on diesel injector

Fuel high pressure pump pinion 5 ± 0.5

Union on fuel high pressure pump 2.3 ± 0.2

Cooling circuit

Coolant pump 1 ± 0.2±

C3 - XSARA

79

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ESPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )Engines : RFS - VJX

SAXO

VJX

- Pre-tighten 0.4

- Tighten to 0.7

XSARA

RFS

- Pre-tighten 0.5

- Tighten to 1

TUD - XU

B1DP03BC B1DP01YD

80

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CYLINDER HEADSAXO - XSARA PICASSOEngines : HDZ - HFX - KFW - KFV - NFT - NFV - NFX - NFU - VJX

Identification of the cylinder head gasket

Engine type

Identification marks (Notch on cylinder head gasket)*HFX KFW NFT - NFV NFX - NFU VJX

1234ABDABDABDABDC

R 0 (Standard gasket) - 1 (Repair gasket)

0 (With asbestos) - 1 (Without asbestos)001

101

011000

1 1 1 10 0 1 10 0 1 10 1 1 0

110

CURTY

MEILLOR

ELRING

REINZ

Material

Repairs

Suppliers

Thickness

* 0 = Without notch

1 = One notchB1BP10KC

81

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ECYLINDER HEAD (continued)Engines : HDZ – HFX – KFW - NFT – NFV - NFX – NFU – VJX

Cylinder head tightening (m.daN) Cylinder head bolts

X = MAXIMUM reusable length

Note : Oil the threads and under theheads of the cylinder head bolts.(Use engine oil or Molykote G Rapid Plus).

- Pre-tightening 2

- Angular tightening 260° ± 5°

- Pre-tightening 2


- Pre-tightening 4


B1DP059C

B1BP10LC

NFU - NFX

VJX

HDZ-HFX-KFW-NFV-NFT

HDZ-HFX-KFW-NFV-NFT

X= 175.5 ± 0.5 mm X = 197.1 mm X = 122.6 mm

VJX NFU-NFX

B1DP13NC

SAXO - XSARA - PICASSO

82

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CYLINDER HEADEngines : HFX - KFV - NFU


Engines

HFX

KFV

NFU

Thicknesses (Standard)

1.2 ± 0.1

0.66 ± 0.04

Thickness (repair)

1.4 ± 0.1

Thickness ref.

2

1

4

References

1.2.3.4 = Type of engine.

A.B.D = Suppliers

C = Gasket material.

R = Repair.

B1BP10KC

C3

83

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ECYLINDER HEADEngines : HFX - KFV - NFU


X = MAX. re-usable length

Tighten to 2 ± 0.2


(in the order 1 to 10)

Tighten to 2 ± 0.2Angular tightening 260° ± 5°

(in the order 1 to 10)

NOTE : Oil the threads andunder the heads of the cylinderhead bolts.(Use engine oil or Molykote GRapid Plus).

B1BP1DVC

NFU

HFX - KFV

HFX - KFV

175.5 ± 0.5 122 ± 0.3

NFU

B1DP05BC

NOTE : Retightening of the cylinderhead after a repair is forbidden.

C3

84

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CYLINDER HEAD


Engine types SupplierPiston

standproud(mm)

Thicknesses(mm)

No. of notchesat d

No. of notchesat e

0.675 to 0.725 1.25 1

0.726 to 0.775 1.30 2

8HY - 8HV ELRING 0.776 to 0.825 1.35 3 2

0.826 to 0.875 1.40 4

0.876 to 0.983 1.45 5

B1DP1CMD

Engines : 8HY - 8HV

Type of gasket :Metallic multilayer

"d" Thickness reference.

"e" Engine reference.

C3

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Engine types SupplierPiston

standproud(mm)

Thicknesses(mm)

No. of notchesat d

No. of notchesat e

0.771 to 0.820 1.35 1

0.611 to 0.720 1.25 2

8HY - 8HV ELRING 0.721 to 0.770 1.30 3 2

00.821 to 0.870 1.40 4

0.871 to 0.977 1.45 5

B1DP1CKD

Engines : 8HY - 8HV

Type of gasket Metallic multilayer

"d" Thickness reference.

"e" Engine reference.

C3

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CYLINDER HEADEngines : 8HX - 8HW - 8HY - 8HV


X = MAX. re-usable length

Pre-tightening 2 ± 0.2 m.daN

Tightening 4 ± 0.4 m.daN


(In the order 1 to 10)

NOTE :

- The bolts should have been tho-roughly cleaned and dried with adry metal brush.

- Oil the threads and under theheads of the bolts. (Use engineoil or Molykote G Rapid Plus).

- Pass a tap into the holes in thecylinder block.

8HX - 8HW - 8HY - 8HV

8HX - 8HW - 8HY - 8HV

X = 149 mm B1DP1CLC

B1DP1DBC

NOTE : Retightening of the cylinder headafter a completed repair is prohibited.

The cylinder head gasket is dry-fitted.

XSARA - C3

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EXSARA PICASSOCYLINDER HEADEngine : 6FZ


B1DP183D

Nominaldimension Repair dimension

2 – 4 – 54 – 5

R1 R2 R3

1 1.10.8Gasket thickness(mm)

Supplier MEILLOR

Marking zone«e»

Marking zone«d»

1.3

Marking

« d » Marking zone

« e » Marking zone

NOTE : 3 layer metallic gasket.

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XSARA PICASSO CYLINDER HEAD (continued)Engine : 6FZ

X = MAXIMUM reusable lengthNOTE : Oil the threads andunder the heads of the cylinderhead bolts.(Use engine oil or Molykote GRapid Plus).

Pre-tightening 1.5 ± 0.2Tightening 5 ± 0.2Loosening 360 ° (1 turn)Tightening 2 ± 0.2Angular tightening 285° ± 5°

B1DP16FC

B1DP05BC

6FZ

6FZ

X= 147 mm


A = Washer thickness: 4 ± 0.2 mm.X = Length under heads of new bolts = 144.5 ± 0.5 mm.

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EXSARA PICASSOCYLINDER HEAD (continued)Engine : RFN


B1DP183D

Nominaldimension Repair dimension

2 – 4 – 54 – 5

R1 R2

1.10.8Gasket thickness(mm)

Supplier MEILLOR

Marking zone «e»

Marking zone«d»

1.4

Multilayer metallic gasket

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XSARA PICASSO CYLINDER HEAD (continued)Engine : RFN

X = MAXIMUM reusable lengthNOTE : Oil the threads andunder the heads of the cylinderhead bolts.(Use engine oil or Molykote GRapid Plus).

Pre-tightening 1.5 ± 0.2Tightening 5 ± 0.2Loosening 360 ° (1 turn)Tightening 2 ± 0.2Angular tightening 285° ± 5°

B1DP16FC

B1DP05BC

RFN

RFN

X= 147 mm


A = Washer thickness: 4 ± 0.2 mm.X = Length under heads of new bolts = 144.5 ± 0.5 mm.

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Engine : RFS


Engine type

Identification marks (Notch on cylinder head gasket) *RFS

A

B

C

D

E

MEILLORSuppliers

* 0 = Without notch

1 = One notchB1BP004C

1

0

1

0

0

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CYLINDER HEAD (continued)Engine : RFS

X = MAXIMUM re-usable length

Note : Oil the threads andunder the heads of the cylinderhead bolts.(Use engine oil or Molykote GRapid Plus).

- Pre-tightening 3.5- Slackening NON- Tightening 7- Angular tightening 160°

B1DP13PC

B1DP05BC

RFS

RFS

112 mm


XSARA

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EXSARACYLINDER HEAD


Numberof holes

at B

Numberof holes

at A

Thickness(mm)

± 0.04

Enginetype

Pistonstand-proud

(mm)*

0.51 to 0.55 1.26 1

0.55 to 0.59 1.30 2

0.59 to 0.63 1.34 3

0.63 to 0.67 1.38 4

0.67 to 0.71 1.42 5

WJY

(A) = Engine identification.

(B) = Thickness identification.

(*) = Take the highest piston as a reference point.

B1DP14QD

Engine : WJY

WJY

2

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XSARA - XSARA PICASSO CYLINDER HEAD


Number of notchesat A

Thickness(mm)

Enginetype

Pistonstand-proud

(mm)

0.47 to 0.605 1.30 ± 0.06 1

0.605 to 0.655 1.35 ± 0.06 2

0.655 to 0.705 1.40 ± 0.06 3

0.705 to 0.755 1.45 ± 0.06 4

0.755 to 0.83 1.50 ± 0.06 5

RHYRHZ

B1DP15AD

Engines : RHY - RHZ

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XSARA - XSARA PICASSOCYLINDER HEAD (continued)Engines : WJY - RHY - RHZ

X = MAXIMUM re-usable lengthNote : Oil the threads and under theheads of the cylinder head bolts.(Use engine oil or Molykote G Rapid Plus).

- Pre-tightening 2

- Tightening 6

- Angular tightening 220°

- Pre-tightening 2

- Tightening 6

- Angular tightening 180°

B1DP15ECB1DP13PC

RHY - RHY

WJY

WJY RHY - RHY

125.5 mm 133.3 mm


WJY RHY - RHZ

B1DP05BC

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ALL TYPES BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE

! 4099-T (C.TRONIC.105) 4122-T (C.TRONIC.105.5) !

!

!

HFX KFW KFV NFT NFV NFX NFU 6FZ RFN RFS

X X X X

100 100 106

X X X

101 to 102 101 to 102 101 to 102

X X X X

105 106 110 108 to 109

X X X

103 to 104 110

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ALL TYPESAUXILIARY EQUIPMENT DRIVE BELTTU

3

JP

5

J4 JP4 J4 J4RS

7 101

XUEW

Engine type :

SAXO

C3

XSARA

XSARAPICASSO

See pages :

See pages :

See pages :

See pages :

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ALL TYPES AUXILIARY EQUIPMENT DRIVE BELTTU

5

B

4

TED4TD

8

B

10

ATEDTD

DV DW

Engine type

SAXO

C3

XSARA

XSARAPICASSO

See pages :

See pages :

See pages :

See pages :

VJX 8HX 8HW 8HZ 8HV 8HY WJY RHY RHZ

X

107

X X X X

117 to 118 119

X X X X

117 to 118 111 to 116 120 to 123

X

120 to 123

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EAUXILIARY 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).

2) The belt is correctly engaged in the grooves of the various pulleys.

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SAXO AUXILIARY EQUIPMENT DRIVE BELT

Without air conditioning With air conditioning

- Fit the tool 4122 - T.

- Tighten the tensioning screw (3)

to obtain :

55 ± 3 SEEM units.

- ighten the screws (2) and (1).

- Remove the tool 4122-T.

- Fit the tool 4122-T.

- Tighten the tensioning screw (5)

to obtain :

120 ± 3 SEEM units.

- Tighten the screws (6) and (4).

- Remove the tool 4122-T.

B1BP10VC B1BP10XCB1BP10UC B1BP10WC

Engines : HFX - KFW - NFT

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B1BP2LSC B1BP2LTC

AUXILIARY EQUIPMENT DRIVE BELTEngines : HFX - KFV - NFU

Tools

[1] Pliers for removing plastic pegs : 7504-T.[2] Belt tension measuring instrument : 4122-T.

Vehicle without air conditioning.

Refit.

Refit the belt.Respect the following sequence: - Crankshaft pinion.- Alternator pulley.Place tool [2] on the belt.Tighten screw (1) to achieve a tension of:

55 ± 3 unités SEEM.Tighten:- Screw (3).- Screw (2)Remove tool [2] and complete the refitting.

Remove.

Slacken:

- Screw (2).- Screw (3).- Tensioning screw (1).

Push the alternator back towards the engine.Remove the belt.

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AUXILIARY EQUIPMENT DRIVE BELTEngines : HFX - KFV - NFU

B1BP10XC

Vehicle with air conditioning.

RemoveSlacken:- Screws (6), (4) and (5).- Fully detension the belt by acting on the tensioner roller.- Remove the accessories drive belt.

Refit.Respect the following sequence: - Crankshaft pinion.- Aircon compressor pulley.- Guide roller.- Alternator pulley.- Tensioner roller.Place tool [2] on the belt.- Tighten screw (5) to achieve a belt tension of:

120 ± 3 SEEM units.- Tighten screws (4) and (6).- Remove tool [2].- Complete the refitting.

B1BP10VC

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B1BP234C

XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELTEngine : 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).- Remove the belt.

Refit.- Position the belt.- Hold the belt in position using the tensioner roller (2).- Pre-tension the belt 120 SEEM units, tool [2].- Lock the central screw (1) tool [3].- Remove the tool [2].- Rotate the crankshaft 2 to 4 times.- Check the tension, 120 SEEM units.- If not, restart the operation.

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AUXILIARY EQUIPMENT DRIVE BELT

Engine : NFV

With air conditioning.

XSARA PICASSO

B1BP235C

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 6 mm peg at (a) to immobilise the automatic tensioner.- Remove the belt.

Refit.- Position the belt- Detension the automatic tensioner, tool [3].- Remove the Ø 6 mm peg.- Release the automatic tensioner.- Remove the tool [3].

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[1] Belt tension measuring instru-ment : 4122-T

- Tension the belt using the screw (2).

- Tension should be :102 ± 7 SEEM units.

- Tighten the screws (1).

- New belt100 SEEM units.

- Reused belt75 SEEM units.


Alternator

Power-assisted steering Power steering and air con.

With air conditioning

[1] Belt tension measuring instru-ment : 4122-T

- Tension the belt using the screw(4).

- Tension should be:102 ± 7 unites SEEM.

- Tighten the screws (3).

- New belt100 SEEM units.

- Reused belt 75 SEEM units.

B1BP1B3C B1BP124CB1BP1B2C B1BP122C

Engine : KFW

XSARA

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AUXILIARY EQUIPMENT DRIVE BELTSAXO - XSARA

(1) Tensioner roller fixing screw

(2) Tensioning screw

- New belt : 120 SEEM units.

- Reused belt : 86.5 ± 3.5 SEEM units.

(3) Tensioner roller fixing screw

(4) Tensioning screw

- CNew belt : 120 SEEM units.

- Reused belt : 86.5 ± 3.5 SEEM units.

NOTE : Removal of the tensioner roller makes it necessary to remove the plate with the upper fixing screw (5).

Without air conditioning


B1BP1ANC

B1BP1AMC

Engines :NFX - NFU

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EAUXILIARY EQUIPMENT DRIVE BELT

- (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.- Tighten the screws (6) to : 2.5 m.daN.- Run the engine for 10 min.- Check the tension.

- (3) Roller support fixing screw - (5) Tensioning screw- Pre-tension the belt (4) to : 120 SEEM units.- Rotate the crankshaft by 3 turns (Direction of rotation).- Adjust the belt (4) tension to : 120 SEEM units.- Tighten the screws (3) to : 2.5 m.daN.- Run the engine for 10 min.- Check the tension.



B1BP11DC

B1BP11EC

Engine : VJX

SAXO- XSARA

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B1BP1HJC

XSARA AUXILIARY EQUIPMENT DRIVE BELT

- 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 4 mm) at (4).

- Slowly release the tensioner roller (1) so that the roller (5) presses against the belt.


Engine : RFS

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EAUXILIARY EQUIPMENT DRIVE BELT XSARA

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).

• Reused belt 90 SEEM units.• New belt 120 SEEM units.

- Tighten the screws (2) to 2 m.daN.- Remove the tool [1].- Rotate the crankshaft by 3 turns (direction of rotation).- Check the belt tension using the tool [1], and adjust (if necessary).


B1EP12YCB1EP12XC

Engine : RFS

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AUXILIARY EQUIPMENT DRIVE BELTEngines : 6FZ - RFNWithout 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).

- The screw (2) (WARNING : not left hand screw).- Remove the belt (3), while keeping the tensioner roller (1) tight.

Refit the belt.- Refit the belt (3), while keeping the tensioner roller (1) tight.- Release the tensioner roller (1).

B1BP23PC B1BP23QC B1BP23PC B1BP23RC

XSARA - XSARA PICASSO

111

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EAUXILIARY EQUIPMENT DRIVE BELT

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.- Refit the belt.- Fit the tool [1] on the belt at "d".- Tighten the screw (1) to obtain : 106 ± 10 SEEM units.- Tighten the screws (2) to 2 m.daN.- Remove the tool [1].

B1BP1SECB1BP1SDC

Engine : WJY

XSARA

112

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XSARA AUXILIARY EQUIPMENT DRIVE BELT

Without power-assisted steering, with air conditioning

Tools :


Removal.- Loosen the screws (1).- Tighten the screw (2) until it is against its stop.- Remove the belt.

Refitting.- Refit the belt.- Fit the tool [1] at "e".- Tighten the screw (2) to obtain : 106 ± 10 SEEM units.- Tighten the screws (1) to 2 m.daN.- Remove the tool [1].

B1BP1SGCB1BP1SFC

Engine : WJY

113

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EXSARAAUXILIARY EQUIPMENT DRIVE BELT

Power-assisted steering, without air conditioning

Tools :


Removal.

WARNING : If the belt is to be reused, measure the tension before removal.- Loosen :- the screw (1).- the nut (2).

NOTE : The tensioner arm (3) must be against the alternator.

- Remove the belt.

B1BP1SHD

Engine : WJY

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AUXILIARY EQUIPMENT DRIVE BELTEngine : WJY

Power-assisted steering, without air conditioning (continued)

XSARA

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.New belt:Tension should be 110 SEEM units.- Tighten the screw (1) to 9.5 m.daN.- Check belt tension (tool [1].Tension should be 144 ± 3 SEEM units.- Remove the tool [1].- Start the engine and run it for 10 seconds.- Stop the engine.- Place the tool [1] on the belt at "f".- Tension should be 130 ± 4 SEEM units.- Remove the tool [1].

B1BP1SJD

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EXSARAAUXILIARY EQUIPMENT DRIVE BELT

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).- Turn the roller (3) backwards.- Remove the belt.NOTE : If it can not be pegged at "a" :- Loosen the screw (2) of the roller (3).- Using a 7 mm square drive, turn the roller (3) at "b".- Peg the tensioner (1) at "a", using tool [1].NOTE : If the belt is broken :- Support the engine using a jack (insert a wooden block between the housing and the jack).- Remove the right engine support.- Using a square drive at (b) turn the tool (3) in the direction of the arrow "a", so that it can bepegged at "a" using the tool [1].

B1BP1SKC

Engine : WJY

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Power-assisted steering with air conditioning (continued)

Refitting.

- Refit the belt.

- Using a 7 mm square drive at "b", turn the roller (3), until the tool [1] located at "a" becomes free.

- Tighten the screw (2).

- Remove the tool [1].

B1BP1SLC

Engine : WJY

XSARA

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EAUXILIARY EQUIPMENT DRIVE BELTEngines : 8HX - 8HWWith compressor and alternator

B1BP2MKCB1BP2MJD

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.Remove the front RH wheel.Move aside the splash-shield, using tool [1].

IMPERATIVE : In the case of belt re-use, mark the directionof rotation of the belt. If the index on the tensioner rolleris outside the marks, change the auxiliary equipmentdrive belt.

Remove :The alternator (1).The aircon compressor (2).Detension the auxiliary belt tensioner roller, using tool [2].Position the peg [3]. Remove the auxiliary drive belt.

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AUXILIARY EQUIPMENT DRIVE BELTEngines : 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 thecase, replace the tensioner roller.

Respect the direction of fitting of the drive belt.

Complete the setting of the belt, of both sides, by means of the tensioner roller.Make sure that the drive belt is correctly positioned in the «V» grooves of the variouspulleys.

Move the tool [2] on the tensioner roller to remove the peg [3].

B1EP18UD

C3

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EAUXILIARY EQUIPMENT DRIVE BELTEngines : 8HY - 8HV

B1BP2MYD B1BP2MZC

Tools.

[1a] Dynamic tensioner roller lever : (-).0194-E1.[1b] Lever extension : (-).0194-E2.[2] Accessories belt roller locking peg Ø 4 mm : (-).0194-F

RemovingPivot the tensioner roller support (1) (clockwise), using tools [1a] and [1b] at «a».Remove the belt.Immobilise the support (1) of the tensioner roller, using tool [2].Remove the auxiliary drive belt (2).

IMPERATIVE : Ensure that the tensioner rollers turn freely (no play, no tight spot).

RefittingRefit the belt.Move the tool [1] on the tensioner roller to remove the peg [2].ESSENTIAL: Make sure that the belt is correctly positioned in the various pulleygrooves.

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XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELTEngines : RHY - RHZ


B1BP1YKD

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

REMOVALRe-use of belt

WARNING : Mark the direction the belt was fiited in case of re-use of the same belt.- Compress the tensioner roller (2) by action at « a » (in anti-clockwise direction), tool [4].- Keep the tensioner roller (2) compressed and remove the belt.

No re-use of belt- Compress the tensioner roller (2) by action at « a » (in anti-clockwise direction), tool [4].- Peg using tool [2], at « b ».- Keep the tensioner roller (2) compressed and remove the belt.- Loosen the screw (1).

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EXSARA - XSARA PICASSOAUXILIARY EQUIPMENT DRIVE BELTEngines : RHY - RHZ

Without air conditioning (continued)

REFITTING.Re-used belt

- Compress the tensioner roller (2) by action at « a » (in anti-clockwise direction), tool [4].- Refit the belt.

WARNING : Respect the belt-fitting direction.

Remove the tool [4].

New beltRefit the belt.- Turn the eccentric roller (3), tool [1] (clockwise) to free the tool [2] from its pegging

at « b ».- Hold the eccentric roller (3), tool [1], and tighten the screw (1) to 4.3 m.daN.

Remove the tool [2].- Rotate the crankshaft 4 times in the direction of rotation.- Check that it is possible to peg at « b », tool [3].- If not possible to peg, restart the adjustment.

B1BP1YMD

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XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELTEngines : RHY - RHZ


B1BP1YLD

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 beltWARNING : Mark the direction the belt was fitted in case of re-use of the same belt.- Compress the tensioner roller (7) by moving it at « c » (in anti-clockwise direction),tool [4].- Hold the tensioner roller (7) compressed and remove the belt.No re-use of belt- Compress the tensioner roller (7) by moving it at « c » (in anti-clockwise direction), tool [4].- Peg using tool [2], at « d ».- Loosen the screw (6).- Bring the eccentric roller (5) towards the rear.- Tighten the screw (6) by hand.- Remove the belt.

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EXSARA - XSARA PICASSOAUXILIARY EQUIPMENT DRIVE BELTEngines : RHY - RHZ

With air conditioning (continued)

REFITTING.

Re-used belt- Compress the tensioner roller (7) by action at « c » (in anti-clockwise direction), tool [4].- Refit the belt.

WARNING : Respect the direction belt was fitted.Remove the tool [4].

New beltRefit the belt.- Turn the eccentric roller (5), tool [1] (clockwise) to free the tool [2] from its pegging

at « d ».- Hold the eccentric roller (5), tool [1], and tighten the screw (6) to 4.3 m.daN.

Remove the tool [2].- Rotate the crankshaft 4 times in the direction of rotation.- Check that it is possible to peg at « d », tool [3].- If not possible to peg, restart the adjustment.

B1BP1YND

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Engine type

SAXO

C3

XSARA

PICASSO

See pages :

See pages :

See pages :

See pages :

ALL TYPES CHECKING AND SETTING THE VALVE TIMINGTU

3

JP

5

J4 JP4 J4 J4RS

7 101

XUEW


X X X X

126 to 128 126 to 128 139 to 142

X X X

129 to 138 129 to 138 129 to 138

X X X X

1 2003

126 to 128 139 to 142163 to 173

182 to 1862003 1

174 to 181

X X X

1 2003

126 to 128163 to 173

2003 1174 to 181

125

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Engine type

SAXO

C3

XSARA

PICASSO

See pages :

See pages :

See pages :

See pages :

CHECKING AND SETTING THE VALVE TIMINGTUD

5

B

4

TED4TD

8

B

10

ATEDTD

DV DW

ALL TYPES


X

143 to 145

X X X X

146 to 153 154 to 162

X X X X

1 N° RPO 9127

192 to 196146 to 153 187 to 191

N° RPO 9128 1197 to 205

X

1 N° RPO 9127

192 to 196

N° RPO 9128 1197 to 205

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TOOLS- [1] Flywheel locating peg : 4507-T.A- [2] Camshaft pulley locating peg : 4507-T.B- [3] Square drive : 4507-T.J- [4] Belt tension measuring instrument : 4122-T- [5] Rocker plate : 4533-T.Z

CHECKING THE VALVE TIMING- Peg the flywheel using the tool [1].- Peg the camshaft pulley using the tool [2].

SETTING THE VALVE TIMINGNOTE : Remove the spark plugs, to allow the crankshaft to rotate more freely.- Rotate the engine by the crankshaft screw (1).- Peg the camshaft gearwheel.- Peg the flywheel.- Loosen the nut (2).- Totally slacken the belt by moving the tensioner roller.- Remove the belt.

ESSENTIAL : Check that the tensioner roller rotates freely (no stiffness).

CHECKING AND SETTING THE VALVE TIMINGEngines : HFX - KFW - NFT - NFV

� Tool kit 4507-T

B1EP067C B1EP066C B1EP0668C

SAXO - XSARA

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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.Fit :- The timing belt, with the belt strip "b" well tightened, in the following order:

Crankshaft pinion, camshaft pulley, water pump pulley, tensioner roller.- The tool [5] (Ensure it is fitted in the right direction in relation to the timing).- Bring the tensioner roller into contact with the belt.- Tighten the nut (2).

PRE-TENSIONING THE TIMING BELT.- Fit the tool [4] on the tightened belt strip "b".- Loosen the nut (2).- Turn the roller (3) in an anti-clockwise direction using a square drive to obtain :

44 SEEM units.- Tighten the nut (2) to 2 m.daN.- Remove the tools [1] [2] and [4].- Rotate the crankshaft by 4 turns in the normal direction.ESSENTIAL : Never turn the crankshaft backwards.

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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" well tightened, in the following order:Crankshaft pinion, camshaft pulley, water pump pulley, tensioner roller.

- The tool [5] (Ensure it is fitted in the right direction in relation to the timing).- Bring the tensioner roller into contact with the belt.- Tighten the nut (2).

PRE-TENSIONING THE TIMING BELT.- Fit the tool [4] on the tightened belt strip "b".- Loosen the nut (2).- Turn the roller (3) in an anti-clockwise direction using a square drive to obtain :

44 SEEM units.- Tighten the nut (2) to 2 m.daN.- Remove the tools [1] [2] and [4].- Rotate the crankshaft by 4 turns in the normal direction.ESSENTIAL : Never turn the crankshaft backwards.

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CHECKING AND SETTING THE VALVE TIMINGEngines : HFX - KFV - NFU

B1BP2M7C B1BP2M9CB1BP2M8C

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[6] Pliers for removing plastic pins : 7504-T.

Checking the valve timing

Engines HFX - KFV - NFURaise and support the front RH side of the vehicle.Disconnect the battery positive terminal.Engage 5th gear.Remove the oil filter (1).

Engine HFX - KFVRemove : The timing top casing (2).Turn the wheel to rotate the engine (normal direction of rotation).Peg the camshaft pulley, using tool [2].

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CHECKING AND SETTING THE VALVE TIMINGEngine : NFU

B1BP2MAC

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).Position the pegs [3a] and [3b].Peg the flywheel, using tool [1].If the setting is not correct, recommence the operation.Remove the tools [1], [2], [3a] and [3b].Complete the refitting.

B1BP2MBCB1EP18MC

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CHECKING AND SETTING THE VALVE TIMINGEngines : HFX - KFV

B1BP2MBCB1BP2M9C B1BP2MDC

Setting the timingPreliminary 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.- The oil filter.Place a jack under the engine, peg the engine.

Removing.Engine HFX - KFV

Turn the engine by means of screw (1). (normal direction of rotation).Remove the timing casings.Peg the camshaft pinion, using tool [2].Peg the flywheel, using tool [1].Remove:- The fixing screws (2).- The upper engine support (3).

B1BP2MCC

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B1BP2MEC B1EP18NC

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).

Remove the timing belt.

IMPERATIVE : Check that the tensioner roller turns freely (no tight spot).

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B1BP2MBC

Engine NFU.


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 B1EP18MC

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B1EP18PC


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» in position «b».

Peg the tensioner roller in this position in order to slacken the timing belt to the maximum.

IMPERATIVE : Never make the dynamic tensioner roller turn by a complete rotation.

Remove the timing belt (8)

Check that the rollers (9) and (10) turn freely (no tight spot).

B1EP18QC

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B1EP18QC


Engines: HFX-KFV

Refit.

WARNING: Respect the direction of fitting of the belt: (the arrows «d» indicate the direction of rotation ofthe crankshaft).

Refit the timing belt.

Position the timing belt, belt «e» well tensioned, in the following order:Crankshaft pinion, hold the belt using tool [5].Camshaft pulley.Coolant pump pulley.Tensioner roller.Remove the pegs [1] and [2].

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CHECKING AND SETTING THE VALVE TIMINGEngines : KFX - KFV - NFU

Setting the timing (continued)Engines: HFX-KFVRefitting.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 rotationof the crankshaft.Refit the timing belt.Position the timing belt, belt «e» well tensioned, in the following order:Crankshaft pinion, hold the belt using tool [5].- Camshaft pulley.- Coolant pump pulley.- Tensioner roller.Remove the tools [1], [2]Engine: NFUFit the timing belt in position in the following order: - Inlet camshaft pulley.- Exhaust camshaft pulley.- Guide roller.- Crankshaft pulley.Position tool [5].- Coolant pump pulley.- Dynamic tensioner roller.Remove the tools [1], [3] and [5].B1EP18RC

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B1EP18SD

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.Hold the tensioner roller (7), using tool [4].

Tighten the fixing nut of the tensioner roller, tightening to 1 ± 0,1 m.daN.

Turn the crankshaft by 4 rotations (normal direction of rotation).

IMPERATIVE : Never make the crankshaft rotate backwards.Make sure that the timing is correctly set by refitting the tools [1], [2] and [3].Remove the tools [1], [2] and [3].

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CHECKING AND SETTING THE VALVE TIMINGEngines : HFX - KFV - NFU

B1EP18TD

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 ofa hexagonal spanner at «a».Next bring the index «c» to its adjusting position «a».The index «c» should not go beyond the notch «g».

WARNING: The index «c» must not go beyond the notch «g». If it should do this,restart the timing belt tensioning operation.

Hold the tensioner roller (7) in this position, with the aid of a hexagonal spanner.Tighten the tensioner roller fixing nut to :

2 ± 0.2 m.daN. (HFX – KFV engines )2.2 ± 0.2 m.daN. (NFU engine )

IMPERATIVE : The tensioner roller must not rotate during the tightening of itsfixing. If it does, restart the timing belt tensioning operation.Complete the refitting.

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CHECKING AND SETTING THE VALVE TIMINGEngines : NFX - NFU

TOOLS

- [1] Belt tension measuring instrument : 4122-T- [2] Flywheel locating peg : 4507-T.A.- [3] Camshaft pulley locating peg, exhaust : 4533-T.A. C2

Tool kit 4507-T- [4] Camshaft pulley locating peg, inlet : 4533-T.A. C1- [5] Tensioning tool : 4707-T.J.

CHECKING THE VALVE TIMING

- Peg the flywheel using the tool [2].- Peg the exhaust camshaft pulley [3].- Peg the inlet camshaft pulley [4].

SETTING THE VALVE TIMING.

- Peg the flywheel using the tool [2].- Peg the camshaft pulleys [3] and [4].

�

B1EP11CCB1EP11BC

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CHECKING AND SETTING THE VALVE TIMINGEngines : 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.

NOTE : The belt bears three identification marks * (a), (b) and (c), facing its own teeth (1), (52) and (72)respectively.

* (Identification marks = white paint lines on the back of the belt facing the corresponding teeth).

- Refit the belt.- Line up mark (A) on the belt with groove (D) of the pinion (4).- Hold the belt against the pinion (4).

B1EP11ECB1EP11DC

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CHECKING AND SETTING THE VALVE TIMINGEngines : NFX – NFU


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, whileensuring that marks (b) and (c) on the belt are aligned with marks (f) on the pulleys.- Hold the belt in this position, and engage it over the water pump pinion and the tensioner roller.

- Fit the tool [1] on the belt strip (e).- Rotate the roller (2) (using tool [5] ) in an anti-clockwise direction, to obtain: 63 SEEM units.- Tighten the roller (2) to 2 m.daN.- Tighten the six screws (5) to 1 m.daN.

ESSENTIAL : Check that : - The camshaft pulleys (1) are not at the end of the slots (by removing a screw).- The markings on the belt are aligned with the markings on the crankshaft and camshaft pulleys.If not, repeat the setting procedure.

B1EP11GCB1EP11FC

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CHECKING AND SETTING THE VALVE TIMINGEngines : NFX – NFU


- Remove the tools [1], [2], [3] and [4].- Rotate the engine by four turns in the normal direction. (do not turn backwards).- Peg the flywheel [2].- Loosen the six screws (5), while ensuring there is still a slight amount of friction with the pulley.- Peg the camshaft hubs using pegs [3] and [4] .

WARNING : In certain cases, it may be necessary to slightly turn the camshaft using the hub fixing screw.

- Fit the tool [1].- Loosen the tensioner roller screw (2).- Rotate the roller (2) (using tool [5]) in an anti-clockwise direction to obtain : 37 SEEM units.- Tighten the tensioner roller screw (2) to 2 m.daN.- Tighten the six pulley screws (1) to 1m.daN.- Remove the tools.

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CHECKING AND SETTING THE VALVE TIMINGEngine : VJX

TOOLS

- 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. S2- Tensioning lever. : 4507-T.J.- Pinion locking tool : 6016-T.

CHECKING THE VALVE TIMING

- Peg : the flywheel, the injection pump pulley, the camshaft pulley.


- Peg : the flywheel, the injection pump pulley, the camshaft pulley.- Loosen the tensioner roller, and remove the belt.ESSENTIAL: Check that the tensioner and guide rollers rotate freely (no stiffness). If not, replace the roller(s).- Loosen the screws (1) and (3) (lock the pulley with tool 6016 - T).- Position pulleys (2) and (4) to the end of the slots (without tightening the screws (1) and (3)).

�

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- 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 shouldbe turned in the opposite direction of rotation so as to engage the nearest tooth.

- Pre-tension (belt strip slightly tightened).

NOTE : Check that the pulley fixings are not at the end of the slots(adjust by one tooth if necessary).

- Tighten the screws (1) and (3 ) to 0.5 m.daN, loosen by 180°.(Gently tighten the screws (1) and (3) by hand).

- Loosen the tensioner roller.- Tension to 100 SEEM units.- Tighten the tensioner roller to 2.3 m.daN.

B1EP07QC

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- 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).

NOTE : If necessary, lightly slacken the belt (with the tensioner roller).- Loosen the screws (1) and (3) by 360° (gently tighten the screws (1) and (3) by hand).- Set a final tension of 55 ± 5 SEEM units.- Tighten the tensioner roller, and the screws (1) and (3) to 2.3 m.daN (lock the pulleys using tool 6016-T).- Remove the tools.- Rotate the engine by two turns.

NOTE : If the belt is not correctly located on the pinions and pulleys, rotate it by an additional two turns.- Peg the flywheel.- Check that the camshaft and injection pump pulleys are correctly pegged.

WARNING : If the visual check is not correct, repeat the setting operation.- Remove the tools.

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CHECKING AND SETTING THE VALVE TIMINGEngines : 8HX - 8HW

B1BP2LXC


- 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).

NOTE : If necessary, lightly slacken the belt (with the tensioner roller).- Loosen the screws (1) and (3) by 360° (gently tighten the screws (1) and (3) by hand).- Set a final tension of 55 ± 5 SEEM units.- Tighten the tensioner roller, and the screws (1) and (3) to 2.3 m.daN (lock thepulleys using tool 6016-T).- Remove the tools.- Rotate the engine by two turns.

NOTE : If the belt is not correctly located on the pinions and pulleys, rotate it by anadditional two turns.- Peg the flywheel.- Check that the camshaft and injection pump pulleys are correctly pegged.

WARNING : If the visual check is not correct, repeat the setting operation.- Remove the tools.

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B1EP18EC

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 damageand should not be approached by any other source of magnetism.Reposition the screw (2).Remove tool [3].Rotate the engine by means of the crankshaft pinion screw (2)(clockwise), to bring it to the pegging position.Position the tool [4].Peg the crankshaft pinion (1), using tool [5].Peg the high pressure pump pinion, using tool [5].NOTE: Index «a» of the roller tensioner must be centred within thearea «b».Check the correct positioning of index «a».Remove tools [4] and [5].Rotate the engine ten times.Fit the tools [4] and [5].If pegging is not possible, carry out the operation to remove/refit thetiming belt. (See corresponding operation).

B1JP03SC B1EP18DC B1EP18FC

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B1EP18GC

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].Remove the lower timing cover (3).Uncouple the exhaust line from the manifold.

IMPERATIVE : Uncouple the exhaust line in order to avoid damaging the front flexible pipe. Twisting,pulling and bending the front flexible pipe reduces its life.Remove: - The engine speed sensor (6).- The belt retaining stop (5).- The screw (2).- The crankshaft pinion (4) (with its magnetic track «a»).

IMPERATIVE : The magnetic track should show no signs of damage and should not be approachedby any other source of magnetism. Should this not be adhered to, it is essential to replace thecrankshaft pinion.Refit the screw (2).

B1BP2LXC

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Setting the timing (continued).


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].- The high pressure pump pinion, using tool [5].Support the engine with the aid of a roller jack equipped with a chock.

Remove: - The RH engine support (7).- The intermediate engine support (right hand side) (8).

B1JP03SC B1EP18DC B1EP195C B1BP2LYC

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B1EP18HC


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). If this is not the case, replace the rollers.

Fitting of the pulleys.

- Camshaft pulley Tighten to 4.3 ± 0.4 m.daN.- Fuel high pressure pump pulley Tighten to 5 ± 0.5 m.daN.The crankshaft pinion is located without a screw at the end of the crankshaft.

Fitting of the rollers.

IMPERATIVE : Check that the tensioner roller turns freely (no tight spot). Otherwise,replace the rollers.

- Guide roller Tighten to 4.5 ± 0.4 m.daN- Tensioner roller Pre-tighten to 0.1 m.daN

Check the condition of the seals at the camshaft and at the crankshaft pinion.

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B1EP18JD


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).

Fuel high pressure pump pulley (15).

Tensioner roller (14).

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B1EP18KC


Turn the tensioner roller to the right to bring the index «c» to position «d», using ahexagonal spanner.Tighten the screw (9) of the tensioner roller, tighten to 3 ± 0,3 m.daN.Remove the tools [4] and [5].

Rotate the engine ten times (check that the timing pinion is correctly up against thecrankshaft).

Check: The pegging of the camshaft.The crankshaft pinion.The fuel high pressure pump pinion (15).The correct positioning of the index of the dynamic tensioner.

If these are not correct, repeat the operation to position the timing belt.

Refit: The engine speed sensor (6).The belt retaining stop (5), tighten to 0,7 m.daN.

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B1EP18LC B1BP2LZC


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).

Immobilise the engine flywheel, using tool [3].Remove the screw (2).Refit the accessories drive pulley and tighten to:

Pre-tighten to : 3 ± 0,3 m.daN.Angular tighten to : 180° ± 1,8°

Remove tool [3]Refit:The top cover (1).The accessories belt (see corresponding operation).The exhaust line (see corresponding operation).The front RH splash-shield.The front RH wheel.

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CHECKING AND SETTING THE VALVE TIMINGEngines : 8HY - 8HV

B1BP2N0C

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.- The front RH splash-shield.- The accessories belt (see corresponding operation). Uncouple: - The supply unions (1).- The air/air heat exchanger inlet/outlet pipes (3).- The exhaust line (at the flexible pipe).Disconnect the connector (2).Support the engine by means of a roller jack equipped with a chock.Remove the engine supports (4) and (5).

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B1BP2N1C B1BP2N2C

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).

- The pulley (9).

- The lower timing cover (10).

- The upper timing cover (11).

- The tool [1].

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B1EP18YD

Checks (continued).

Refit the screw (8).Rotate the crankshaft six times (clockwise).

IMPERATIVE : Never rotate the engine backwards.

Peg : - The camshaft, using tool [2]. (Oil the pegs.)- The fuel high pressure pump pulley (14), using tool [3] at «c».

WARNING: The magnetic track should show no signs of damage and should notbe approached by any source of magnetism.

Peg the crankshaft at «b», using tool [3].

IMPERATIVE: Should it be impossible to peg the camshaft, check that the off-set between the hole in the camshaft pinion and the pegging hole is not grea-ter than 1 mm.Otherwise repeat the operation to position the timing belt. (See correspon-ding operation).

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B1EP18ZC

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.Refit the tool [1] at «a».Remove the screw (8).Refit: - The upper timing cover (11).- The lower timing cover (10).- The accessories drive pulley (9).- The screw (8).

Tightening torque: - Screw (8) :

Pre-tighten to : 3 ± 0.3 m.daN.Angular tightening : 180° ± 5°.


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B1BP2N0C

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).

Couple: - The exhaust line, tighten the collar to : 2.5 ± 0.3 m daN- The fuel supply unions (1).- The air/air heat exchanger inlet/outlet pipes (3).Connect the connector (2).

Refit : - The accessories belt (see corresponding operation).- The front RH splash-shield (see corresponding operation).- The front RH road wheel, tighten to 9 ± 1 m.daN.Reconnect the battery.

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B1EP18VD

Setting the timing.

Perform the preliminary operations for checking the timing up to removing tool [1] at «a» for immobilingthe engine flywheel.Refit screw (8).Rotate the crankshaft to bring the camshaft towards its pegging point.Peg the camshaft, using tool [2]. (Oil the pegs).

WARNING: Do not press or damage the track which is the target for the engine speed sensor (14).

Peg the crankshaft at «b», using tool [3].Remove: - The timing protector (13).- The engine speed sensor (14).Slacken the screw (12) of the tensioner roller, keeping it slack with the aid of a hexagonal spanner at «c».Detension the belt by pivoting the tensioner roller (clockwise).Remove the timing belt, commencing with the coolant pump pinion.Peg the pulley (15), using a 5 mm diameter peg at «d».

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B1EP18WD


Checking the setting.

IMPERATIVE : Just prior to refitting, carry out the following tests:

Check that:- the rollers and the coolant pump operate freely(no play and no tight spot).- there are no traces of oil (from the crankshaft and camshaft sealing rings).- there is no leak of coolant fluid (from the coolant pump).- the target track of the engine speed sensor (14) is not damaged or scratched.(If necessary replace the defective components).

RefittingFit the timing belt on the crankshaft pinion.Position the belt on the guide roller, with the belt well tensioned.Refit: - The timing protector (13).- The sensor (14).

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B1EP18XC


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).- Tensioner roller (19).Remove the 5 mm diameter peg at «d».Adjusting the fitting tension of the belt.Action the tensioner roller (19) to align the marks «f» and «g», avoiding detensioning the timing belt,with the aid of a male hexagonal spanner, at «c».If this is not successful, repeat the operation to tension the belt.Hold the tensioner roller in position (19).Tighten the tensioner roller, tightening to 3,7 ± 0,3 m.daN.Check the position of the tensioner roller (the alignment of the marks «f» and «g» should be correct).Remove tools [2] and [3].Turn the crankshaft six rotations (clockwise).

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B1EP18XC

Adjusting the timing belt tension (continued).

IMPERATIVE : Never rotate the engine backwards.

WARNING : Do not touch or damage the track of the target of the engine speed sensor (14).

Peg the crankshaft, using tool [3].Check the position of the tensioner roller (the alignment of the marks «f» and «g» should be correct).If this is not the case, repeat the operation to tension the belt.Peg the camshaft pulley, using tool [2].

IMPERATIVE : Should it be impossible to peg the camshaft, check that the offset between thecamshaft hole and the pegging hole is not more than 1 mm. If the offset is too great, repeat theoperation.

Remove the pegs [2] and [3].Refit tool [1] at «a».Remove the screw (8).

Complete the refitting.

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CHECKING AND SETTING THE VALVE TIMINGEngines : 6FZ - RFN # 2003

B1BP23XC

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.[5] Hub immobilising tool : 6310-TChecking the valve timing-Turn the engine by the crankshaft pinion screw (3) to bring it to pegging position.-Peg the crankshaft, using tool [2].-Peg the camshaft pulleys, using tools [1].NOTE : The pegs [1] must go in without effort.WARNING : If the pegs do not engage without effort, restart the fitting andtensioning of the timing belt (see below).Setting the valve timingRemove- Remove the screws (2), the pulley (1), upper valve cover (4), lower valve cover (3).- Turn the engine by the screw (13) of the pinion (12) to bring it to pegging position.- Peg the pulleys (8) and (9) using tools [1].- Peg the pinion (12) using tool [2].- Loosen the screw (7) of the tensioner roller (6).- Turn the tensioner roller (6) (clockwise).- Remove the timing belt (10).

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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), thetensioner roller (6).NOTE : Make sure that the belt (10) is as flush as possilble with the outer face of the various pinions and rollers.- Remove the tools [3] and [1].

Timing belt tension

Adjusting the tension- Turn the roller (6) in the direction of the arrow «b»; using an Allen key at «a».- Position the index «c» in its maximum setting at «d».IMPERATIVE : The index «c» must stand proud of the notch «f» by an angular value of 10°. If it does not,replace the tensioner roller (6) or the timing belt and the tensioner roller (6).Bring the index «c» to its adjusting position «f» by turning the tensioner roller (6) in the direction of the arrow «e»WARNING: The index «c» must not stand proud of the notch «f» : if it does, restart the timing belt tensioningoperation.IMPERATIVE : The tensioner roller (6) must not turn while its fixing is being tightened up. If it does,recommence the adjusting operation.


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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 cylinderhead gasket «g». If not, replace the tensioner roller (6) or the timing belt and the tensioner roller (6).

Refit (continued).- Remove the tools [1] et [2].- Turn the crankshaft 10 times in the normal direction of rotation.

IMPERATIVE : No pressure or outside action must be brought to bear on the timing belt.- Peg the inlet camshaft pulley, using the tool [1].Checks.Timing belt tension.IMPERATIVE : Check the position of the index «c», it should be facing the notch «f». If the position of index«c» is not correct, restart the adjustment of its position.Positioning of the crankshaft.- Fit tool [2].- As long as it is possible to fit tool [2], continue with the refit operations.IMPERATIVE : If it is not possible to fit tool [2], reposition the flange (14).


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Checks (continued)

Repositioning the flange- Immobilise the crankshaft using tool [5].- Loosen the screw (13).- Release the pinion (12) of the crankshaft.- Bring the flange (14) to the pegging position; using tool [5].- Fit the tool [2].- Immobilise the crankshaft using tool [5].- Tighten screw (13) to 4 ± 0.4 m.daN, then angular tighten :

53° ± 4° (fitting with steel washer, gold colour)40° ± 4° (fitting with sintered washer, metallic colour)

using tool [4].- Remove tools [1], [2] and [5].Refit :- The lower valve cover (3).- The upper valve cover (4).- The crankshaft pulley (1).- The screws (2).- Pretighten the screws (2) to 1.5 m.daN.- Tighten the screws (2) to 2.1 ± 0.5 m.daN.


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CHECKING AND SETTING THE VALVE TIMINGEngine : 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-TRemoving.Disconnect the battery.Remove: - The under-engine shield.- The accessories drive belt (See corresponding operation).Move aside : - The fuel delivery pipe.- The canister purge electrovalve.- The expansion chamberRemove : -The screws (1) and (2).- The torque reaction rod (3).- The screws (4), plus the accessories drive pulley.- The timing cover (5) and (6).WARNING : Do not slacken the fixing screws (A).


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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 tensionerroller (9) (clockwise), to detension the belt. The cursor (10) presses onthe tool [4].

Remove the timing belt.

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Refitting.

Systematically replace the timing belt.

IMPERATIVE : Check that the rollers (9) and (11), as well as the coolant pump (12), turnfreely (no tight spot).

If replacing the roller (11), tighten the fixing to 3,5 ± 0,3 m.daN.

Engage the belt on the crankshaft pinion (13), respecting its direction of fitting.

Immobilise the belt, using tool [3].

Refit the timing belt, well tensioned, in the following order : - Guide roller (11).- Pinions (14) and (15).- Coolant pump (12).- Tensioner roller (9).


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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 asto tension the belt to the maximum.Turn the eccentric hub (8) of the roller (9) (clockwise), until the cursor (10) just comes into contact with the peg [4].IMPERATIVE : Never turn the eccentric hub (8) by a complete rotation if the tool [4] is in position.NOTE : This operation enables you to place the index (10) in the nominal position (E).Tighten the screw (7) to 2 ± 0,2 m.daN holding the roller with the aid of the hexagonal key (C).Remove pegs [1], [2] and [4].Checks.Turn the crankshaft by two rotations (direction of engine rotation).IMPERATIVE : Never rotate the crankshaft backwards.Make sure that the timing is correctly set by refitting the pegs [1] and [2].Remove pegs [1] and [2].Rotate the crankshaft ten times (direction of engine rotation).Check the position of the index (10).If the tensioner index is not at its adjusting position (E), recommence the operation to tension the timing belt.

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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].If this should not be possible, reposition the flange (17).

IMPERATIVE : This operation guarantees the setting of the timing for subsequent operations.

Slacken the screw (16) so as to free the pinion (17) of the crankshaft.Bring the flange (17) to the pegging point, using tool [5].Position the tool [1].Tighten the screw (16) to : (Tool FACOM D360).

Tighten to : 4 ± 0,4 m.daNAngular tighten : 53° ± 5°

Remove tools [1], [2] and [5].

ESSENTIAL : When tightening screw (16), hold the pulley (17) by means of tool [5].

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Refitting (continued).

Refit :

- The timing cover (6).

- The accessories drive pulley.

- Screws (4), tighten to 2,1 ± 0,2 m.daN.

- The timing cover (5).

- The torque reaction rod (3).

- Screws (1) and (2), tighten to 4,5 ± 0,4 m.daN.

Refit the accessories drive belt (See corresponding operation).

Continue the refitting operations in reverse order to removal.

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CHECKING AND SETTING THE VALVE TIMINGEngines : 6FZ - RFN # 2003OLD FITTING # 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» Integral keyway.

«b» Keyway slot.

The timing belt drive pinion (1) is separate from the flange (2).With the fixing screw (5) of the flange (2) not slackened, the pinion (1) floats within the limitof travel of the integral keyway «a» in the keyway slot «b».

NOTE : The flange is immobilised on the crankshaft by a half-moon keyway and by the screw (5).


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CHECKING AND SETTING THE VALVE TIMINGEngines : 6FZ - RFN 2003 # NEW FITTING 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 andby the tightening of washer (8) and screw (9).A : Pegging on manual gearbox.B : Pegging on automatic gearbox.

The pegging of the crankshaft is done on the flywheel, or on the converter drive plate (auto-matic gearbox).The pegging hole on the cylinder block (exhaust end) is calibrated and reinforced.

IMPERATIVE : Never turn the crankshaft with the accessories drive pulley slackened.

IMPERATIVE : Never remove the accessories drive pulley without pegging thecrankshaft and the camshafts.

IMPERATIVE : Always turn the crankshaft in the direction of engine rotation.

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CHECKING AND SETTING THE VALVE TIMINGEngines : 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[5a] : (-).0189.S1[5b] : (-).0189 S2Pliers for removing plastic pins : 7504-T

Checking the setting of the timing

Removing.Disconnect the battery negative terminal (See corresponding operation).Raise and support the vehicle, front wheels hanging.Remove : The front RH wheel.The plastic pins (1).The splash-shield (2).The upper timing cover.

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CHECKING AND SETTING THE VALVE TIMINGEngines : 6FZ - RFN 2003 # NEW FITTING # 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].

Peg the camshaft pulleys, using tool [3].

WARNING : If the pegs go in only with difficulty, repeat the operation for fitting and tensioningthe timing belt (See corresponding operation).

Refitting.

Remove tools [2] and [3].

Complete the refitting in reverse order to removal.

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Setting the timing.

Removing.Disconnect the battery negative terminal (See corresponding operation).Raise and support the vehicle, front wheels hanging.Remove: The front RH wheel.The plastic pins (1).The splash-shield (2).The accessories drive belt (See corresponding operation).

Unclip and move aside the fuel delivery hose from the timing cover.

Remove the upper timing cover (1).

Turn the engine by means of the screw (3) of the crankshaft pulley (2) to bring it to the pegging position.

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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).

IMPERATIVE : Never remove the crankshaft pulley (2) without pegging the crankshaftand the camshafts.

Slacken the screw (9) of the tensioner roller (8).Turn the tensioner roller (8) (clockwise).Remove the timing belt (7).

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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.Hold the timing belt (7) in place using tool [3].Fit the timing belt (7) in place, respecting the following order : - Guide roller (10).- Inlet camshaft pulley (6).- Exhaust camshaft pulley (5).- Coolant pump (11).-Tensioner roller (8).NOTE : Make so that the belt (7) is as flush as possible with the exterior face of the variouspinions and rollers.Remove : Tool [3].Tool [1] from the exhaust camshaft pulley.Tool [5b] from the tensioner roller (8).Refit : The lower timing cover (4) (by moving the engine)The crankshaft pulley (2).Screw (3) of the crankshaft pulleyTighten screw (3) to 4 ± 0,4 m.daN, then angular tighten to 53° ± 4°, tool [4].

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CHECKING AND SETTING THE VALVE TIMINGEngines : 6FZ-RFN 2003 #

Tensioning the timing belt.Turn the tensioner roller (8) in the direction of the arrow « c », by means of a hexagonal spanner at « d ».Positionner l’index « a » en poition « f ».

IMPERATVE : The index «a» should go past the slot « g » by an angular value of 10°.If it does not, replace the tensioner roller or the timing belt and tensioner roller assembly.Next bring the index « a » to its adjusting position « g », by turning the tensioner roller in the direction of the arrow « e ».

WARNING : the index « a » should not pass the slot « g ».Otherwise, repeat the operation to tension the timing belt.

IMPERATIVE : The tensioner roller should not turn during the tightening of its fixing.If it does, repeat the operation to tension the timing belt.

Tighten the screw (9) of the tensioner roller (8) to 2,1 ± 0,2 m.daN.

IMPERATIVE : The hexagonal tensioner roller drive should be approx. 15° below the level of the cylinderhead gasket « h ».If it is not, replace the tensioner roller or the timing belt and tensioner roller assembly.

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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].

Checks.

Tension of the timing belt.

ESSENTIAL : Check the position of the index « a », which should be opposite the slot « g ».If the position of the index « a » is not correct, repeat the operations to tension the timing belt.

Refit the upper timing cover (1).Clip the fuel delivery hose on the timing cover.Refit the accessories drive belt (See corresponding operation).Lower the vehicle.Reconnect the battery (See corresponding operation).

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CHECKING AND SETTING THE VALVE TIMINGEngine : RFS

TOOLS

[1] Belt tension measuring instrument : 4122-T[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 Tool kit 7004-T[6] Toothed sector for locking the flywheel : 9044-T

CHECKING THE SETTING- Turn the engine by the crankshaft screw (1).- Peg the crankshaft using the tool [3].

ESSENTIAL : Check that the crankshaft DAMPERS pulley is in good condition. If the hub/pulley mar-kings do not line up, the crankshaft pulley must be replaced.

- Peg the camshaft using the tool [2].(The locating pegs [2] should slide in easily).

- If this is not the case, set the timing.

NOTE : Camshaft hubs (See pages 138 and 139).

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XSARACHECKING AND SETTING THE VALVE TIMINGEngine : RFS

Refit :

- The pulley (5).- The screw (4) (Tighten moderately).- The peg [3].

Remove :

- The tool [6].- The studs (8).- Fit the tool [4].- Loosen the screws (10).- Remove the tool [4].- Slacken the tensioner roller (7).- Remove the belt (9).

Peg the crankshaft using tool [3].- Peg the camshaft pulleys using tool [2].- Lock the flywheel using the tool [6].

Remove :

- The peg [3].- The screw (4) (Brush the screw thread).- The pulley (5).- The lower cover (6).

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Setting the valve timing.

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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 andhubs.- Turn the camshaft pulleys in a clockwise direction to bring them to the end of the slots. - Fit the belt (9).- Fit the tool [1].Turn the roller (7) using the tool [5].- Pre-tension to : (Pulleys slackened).

- Tighten the screws of the roller (7) to 2 m.daN.- Fit the tool [4].- Tighten the screws (10) to 4 m.daN.- Remove the tools.- Rotate the crankshaft by six turns (Normal direction of rotation).

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RFS

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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 usingthe screw (10).

- Fit the tool [4].- Loosen the screws (10).- Remove the tool [4].- Loosen the tensioner roller (7).- Fit the tool [1] to the belt.- Turn the roller (7) using the tool [5].

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- Tension to : (Pulleys slackened).

- Tighten the screw of the roller (7) to 2 m.daN.

Fit the tool [4].- Tighten the screws (10) to 7.5 m.daN.- Remove the tools.- Rotate the crankshaft by two turns (Normal direction of rotation).- Check the pegging of the crankshaft/camshaft using tools [2] and [3].

NOTE : Tools [2] and [3] should slide in easily.

- Remove the tools.

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Engine : RFS

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CHECKING AND SETTING THE VALVE TIMINGEngine : 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.- [4] Toothed sector for locking the flywheel : (-) 0 188 F- [5] Belt retaining clip : (-) 0 188 K- [6] Square drive for adjusting the tension : (-) 0 188 J- [7] Belt tension measuring instrument : 4122-T- [8] Toothed sector for locking the flywheel : 6016-T

Checking the valve timing

- Peg the flywheel using tool [3].- Visually check that the offset between the camshaft and injection pump hub holes, and the correspondingpegging holes do not exceed 1 mm.

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XSARA CHECKING AND SETTING THE VALVE TIMINGEngine : 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). (Coat the threads with E6).

- Tighten the screw (3) to 4 m.daN and finish by carrying out an angular tighteningof 60°.- Remove the tool [4].- Retighten screws (4) and (5) by hand.- Turn the pinions (6) and (2) so that they are at the end of their stops. (Clockwisedirection).- Place the belt on the crankshaft and hold in place using tool [5].- Fit the belt in the following order:

Roller (7), pinion (2), pinion (6), pump (8) and roller (9).

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Setting the valve timing (continued)

NOTE : If necessary, slightly turn pinions (6) and (2) in an anti-clockwise direction inorder to fit the belt.The angular movement of the belt in relation to the pinions must not exceed half atooth.

- Fit the tool [7] to the belt strap at "a".-Turn the roller (9) (anti-clockwise) using tool [6], to obtain:106 ± 2 SEEM units.

- Check that pinions (6) and (2) are not at the end of their stops.Otherwise, repeat the belt fitting procedure from the beginning.

Tighten:- The roller (9) to 4.5 m.daN.- The screws (4) and (5) to 2.5 m.daN.- Remove the tools [7], [5], [1], [2] and [3].

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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].

Loosen :- The screws (4) and (5).- The roller (9).- Retighten screws (4) and (5) by hand.- Fit the tool [7] to the belt strap at "a".- Turn the roller (9) (anti-clockwise direction) using tool [6], to obtain :

42 ± 2 SEEM units.

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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 ± 4 SEEM units.

ESSENTIAL : If the value obtained is outside the set limits, repeat thetensioning operation.

- Remove the tools [7], [5], [1], [2] and [3].- Rotate the crankshaft by 2 turns (direction of rotation).

- Check the valve timing.

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CHECKING AND SETTING THE VALVE TIMINGEngines : 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[6] Engine flywheel lock : (-).0188.F[7] Set of blocking plugs : (-).0188.T[8] Crankshaft pulley extractor : (-).0188.P

Checking the setting of the valve timing.Peg : The engine flywheel, tool [3] (from below the vehicle).The camshaft, tool [5].WARNING : On removing the screws (6), (7), (9), and (5) from the timing cover,refit screw (5) equipped with a spacer (thickness 17 mm)Tighten to 1,5 ± 0,1m.daN.(Screw (5) is one of the fixing screws for the coolant pump and is used for its sealing).WARNING : Should it be impossible to peg the camshaft, check that theoffset between the camshaft pinion hole and the pegging hole is not morethan 1 mm, with the help of a mirror « a » and a Ø 7 mm screw.

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IMPERATIVE : If pegging is impossible, restart the adjusting.(See corresponding operation).


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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).Remove the timing belt (22).

Checks.

IMPERATIVE : Just before refitting, carry out the checks below :

Check that : - the rollers (20), (23) and the coolant pump turn freely (without play or tightness).- there are no traces of oil (on camshaft or crankshaft)- there are no leaks of engine coolant (coolant pump).Replace defective components if necessary.

CHECKING AND SETTING THE VALVE TIMINGEngines : RHY-RHZ # N° RPO 9127

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CHECKING AND SETTING THE VALVE TIMINGEngines : RHY - RHZ # N° RPO 9127


- 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 « a ».- Guide roller (23).- Fuel high pressure pump pinion (26).- Camshaft pinion (24).- Coolant pump pinion (18).- Tensioner roller (20).

NOTE : If needed, slightly turn the pinion (24) anti-clockwise (theoffset should not be more than one tooth).

- Remove the tool [4].

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Position tool [1] on the belt at « b ».Turn the roller (20) (anti-clockwise) using tool [2] to attain a tension of :

98 ± 2 SEEM units

Tighten the screw of the roller (19), tighten to 2.5 m.daN.Remove one screw (21) from the pinion (24).(to check that the screws are not against the end of the buttonhole).Tighten the screws (21) to 2 m daN.Remove tools [1], [2], [3] and [5].Rotate the crankshaft 8 times (normal direction of rotation).Fit the tool [3].Loosen screws (21).Fit tool [5].Loosen screw (19) (to free the roller).Fit tool [1].Turn the roller (20) (anti-clockwise), tool [2], to attain a tension of :

54 ± 2 SEEM units.


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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].Refit the tool [1].Tension value should be : 54 ± 3 SEEM units.

IMPERATIVE : If value is incorrect, restart the operation.

- Remove tools [1], [3] and [5].- Rotate the crankshaft 2 times (normal direction of rotation).- Fit the tool [3].

WARNING : Should it be impossible to peg the camshaft, checkthat the offset between the camshaft pinion hole and the pegginghole is not more than 1 mm..In the case of an incorrect value, recommence the operation.

- Remove the tool [3].- Complete the refitting of components.


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(1) ) «Idler» camshaft pulley(2) Target for cylinder reference sensor.(3) Camshaft hub.(4) «Fixed» crankshaft pinion.The determining of the tension of the timing belt is done on the cam-shaft pulley (1).

The new timing on 8 valve engines DW10TD (RHY) and DW10 ATED(RHS-RHZ) requires the following components :

«Idler» crankshaft pinion«Fixed» camshaft pulley.

(5) «Fixed» camshaft pulley (pulley with integral cylinder referencesensor target).(6) «Idler» crankshaft pinion (with increased width keyway groove).The determining of the tension of the timing belt is done on the crank-shaft pinion (6).

SPECIAL FEATURES: CHECKING AND SETTING THE VALVE TIMINGEngines : RHY - RHZ N° RPO 9128 #

OLD FITTING # N° RPO 9127 NEW FITTING N° RPO 9128 #

B1EP176D B1EP177D


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The new fitting discontinues the following components : Camshaft hub.Cylinder reference sensor target.

Repair – Accessories drive pulley

Remove – Refit

WARNING : Peg the camshaft and the crankshaft before ever removing theaccessories drive pulley (the pegging prevents any offsetting of the camshaft).

If necessary, apply a paint spot to mark the accessories drive pulley beingreplaced.

Replacement parts.

The Replacement Parts service markets the old as well as the new components.

SPECIAL FEATURES: CHECKING AND SETTING THE VALVE TIMINGEngines : RHY - RHZ N° RPO 9128 #

NEW FITTING : RPO 9128 # (continued)

B1EP177D


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CHECKING AND SETTING THE VALVE TIMINGEngines : RHY - RHZ N° RPO 9128 #

Tools.

[1] Belt tension measuring equipment : 4122-T

[2] Tension lever : (-).0188.J2.

[3] Engine flywheel peg : (-).0188.Y.

[4] Belt clamp : (-).0188.AD

[5] Camshaft pulley peg : (-).0188.M

[6] Engine flywheel lock : (-).0188.F.

[7] Set of blocking plugs : (-).0188.T.

[8] Pulley extractor : (-).0188.P.

[9] 2 mm dia.peg : (-).0188.Q2

Removing

IMPERATIVE : Respect the safety and cleanliness requirementsthat are specific to high pressure diesel injection (HDi) engines.

Undo the front RH wheel bolts.Raise and support the vehicle on the front RH side.Disconnect the battery negative terminal.Remove : The under-engine sound-deadening.The front RH wheel.The front RH splash-shield.The engine cover.Unclip and move aside the cooling hose.Remove the accessories drive belt.(See corresponding operation).


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CHECKING AND SETTING THE VALVE TIMING

Engines : RHY - RHZ N° RPO 9128 #

Uncouple, plug and move aside, using tool [7], the fuel delivery pipe (2) andreturn pipe (1).Remove : Screws (3), (4) and (6).Screw (7).The upper timing cover (5).

WARNING : Refit screw (7) equipped with a spacer (17 mm thick), tightenthe screw (7) to 1,5 ± 0,1 m. daN.

NOTE : The screw (7) is one of the screws securing the coolant pump andis there for its sealing.Put the gear lever in 5th gear.Turn the road wheel to turn the engine in its direction of rotation.Orient the camshaft pulley in the pegging position, use a mirror if necessary.

Peg the camshaft, using tool [5].

Peg the engine flywheel, using tool [3].

B1EP1A7C B1BP2H3CB1BP2H2CB1BP2R2C


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Remove : The fixings of the pipe linking the power steering pump with the rotary valve.The clutch lower closing plate.Lock the engine flywheel, using tool [6].Remove the screw (8).Refit the screw (8) without its thrust washer.Remove : The accessories pulley (9), using tool [8].Tool [6].The lower torque reaction rod.Support the engine by means of a workshop hoist.Remove : The bearing shell fitting (10).The nut (12).Screws (11).The bracket (13).NOTE : Lift then lower the engine with the workshop hoist, to have access tothe timing cover fixing screws.Remove : The intermediate timing cover.The lower timing cover.

B1CP04BC B1BP2R3C B1BP2R4C


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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).The coolant pump pulley (16) turns freely (without play and without any tight spot).There are no traces of oil leaks from the crankshaft and camshaft seals, etc.The crankshaft pinion travels freely on the keyway.

Replace defective components if necessary.

Peg the crankshaft pinion (19) by inserting tool [9] on the LH side of the keyway.

B1EP1A8D B1EP1A9C


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Reposition the timimg belt, belt at «a» well tensioned, in the following order : Fuel high pressure pump pulley (21).Guide roller (15).Crankshaft pinion (19).Coolant pump pinion (16).Tensioner roller (18).Position tool [1] on the belt at «a».Remove tools [4] and [9].Turn the tensioner roller (18) anti-clockwise, using tool [2], to attain an overtension of :

98 ± 2 SEEM units.Tighten screw (17) of the tensioner roller to 2,5 ± 0,2 m.da N.Lock the flywheel by means of tool [6].Tighten the accessories drive pulley screw (8) to 7 ± 0,7 m.da N.Remove tools [1], [3], [5] and [6].Rotate the crankshaft eight times in the normal direction of rotation.Peg : The crankshaft, using tool [3].The camshaft drive pulley, using tool [5].

B1EP1ABD B1EP1ACC


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Lock the engine flywheel, using tool [6].Slacken : The accessories drive pulley (8).The screw (17) of the tensioner roller (18).Fit the tool [1].Turn the tensioner roller, using tool [2], to attain a tension of :

54 ± 2 SEEM units.Tighten screw (17) of the tensioner roller (18) to 2,5 ± 0,2 m.daN.Remove tool [1].Fit tool [1].The tension value should be :

54 ± 3 SEEM units.ESSENTIAL : If the value is incorrect, recommence the operation.

Remove tools [1], [3], [5] and [6].Rotate the crankshaft two times in the normal direction of rotation.Peg : The crankshaft, using tool [3].The camshaft drive pulley.

IMPERATIVE : If the pegging is not possible, recommence the operation.

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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).The bracket (13).Screws (11), tighten to 6,1 ± 0,5 m.daN.The nut (12), tighten to 4,5 ± 0,5 m.daN.Fit the bearing shell (10).Take away the workshop hoist.Clip the fuel delivery and return pipes.Remove the tool [7].Couple : The fuel delivery pipe (12).The fuel return pipe (1).Coat the screw (8) with loctite FRENETANCH.Refit the tool [6] and the screw (8) with the washer (22),Tighten to 7 ± 0,2 m.daN and angular tighten to A = 60° ± 5°Refit the torque reaction rod on the lower engine support.Remove the tool [6].Reposition and reclip the cooling hose.Complete the refitting of components in reverse order to removal.

B1EP1A7C B1BP2R4C B1EP1ADC


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SPECIAL FEATURES OF THE TIMING

B1EP122C

Camshaft hub identification

Engine

RFSInlet

Exhaust

Hubs ‘‘a’’ engraving

B

‘‘b’’ paint marking

BLUE

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ALL TYPESVALVE CLEARANCE SETTINGS

The valve clearances must be checked with the engine cold

� Inlet

Petrol All Types(except 16V - NFU)

NFU

Petrol - 16V1.4 HDi

1.4 16V HDi2.0 HDi

Diesel All Types(except: 1.4 HDi

1.4 16V HDi2.0 HDi)

0.20 mm ± 0.05

Exhaust

0.40 mm ± 0.05

Hydraulic adjustment

1 mm ± 0.05 1 mm ± 0.05

Rocking Adjust

1 � 1

3 � 3

4 � 4

2 � 2

4 � 4

2 � 2

1 � 1

3 � 3

Inlet

�

Exhaust

Rocking

Valves fully open Adjust

1

3

4

2

3 � 4

4 � 2

2 � 1

1 � 3

Fully open (Exhaust)

POSSIBLE PROCEDURESFor engines with 4 cylinders in a line (1-3-4-2 )

Engines without hydraulicadjustment : the clearance (J)should be checked oppositethe cam.

B1DP13QC

0.15 mm ± 0.08 0.30 mm ± 0.08

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2.0 HDi

CHECKING THE OIL PRESSURE

Engine type

Vehicle

Temperature (°C)

Pressure (Bars)

Rpm

Engine type

Temperature (°C)

Pressure (Bars)

Rpm

HFX

TT C3

NFV NFT NFX NFU 6FZ RFN RFS

43434

90°

3

4000 4000

DV4TD DV4TED4 DW8 DW10TDTUD all Types

1.5 D 1.4 HDi

RHZRHYWJY8HY8HV8HW8HXVJX

90° 80°

4.5> 1.3

1000 4000

4

4000

1.4 16V HDi 1.9 D

4 5.5

90° 80°

1.1 i 1.4 i 1.6 i 1.6 i 16V 2.0 i 16V1.8 i 16V

TU all Types XU all TypesEW

To be read with the Petrol and Diesel correspondence tablesToolsTool kit 4103 -T

ALL TYPES

TT C3 TT TT C3 TT

KFVKFW

2000 2000400020004000

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LS 867 B 1109 N3

ALL TYPESOIL FILTERS

1109 R7

1109 N3

1109 T1

FILTRAUTO

PURFLUXLS 867 B

LS 923

PURFLUXLS 923

LS 867 B

TU All Types XUEW


1.1 i 1.4 i 1.6 i 1.6i 16V 1.8i 2.0i 16V

TUD5 DV4TD DV4TED4 DW8 DW10


1.5 D 1.4 HDi 1.4 16V HDi 1.9D 2.0 HDi

Specification

Diameter (mm) Height (mm)

LS 923 1109 T176 89

1109 N3

TU engine (except L4) : The PURFLUX LS 867 filter is still available.EW and DW engines : The PURFLUX LS 304 filter has been replaced by the PURFLUX LS 923 filter.

1109 T1

MALHE 1109 T3

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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 replacementequipment; it is essential to follow the instructions as stated for that equipment.

Filling and bleeding- Fit the cylinder adaptor [2] 4222-T (Picasso and C3) and the filling cylinder [1] 4520-T (all types).- Use the coolant to ensure protection between - 15°C and - 37°C.- Slowly fill the system.

NOTE : Keep the cylinder filled up (visible level).

- Close each bleed screw as soon as the coolant flows without air bubbles.- Start the engine : Engine speed 1500 rpm.- Maintain this speed until the first cooling cycle (cooling fans cut in and cut out).- Stop the engine and allow it to cool down.- Remove the filling cylinder [1] 4520-T (all types) and the cylinder adaptor [2] 4222-T.- Top up the system to the max. mark, with the engine cold.- Refit the filler cap. E5AP1GNCB1GP00AC

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ION1.1 i HFX L4 BOSCH M7.4.4.

1.4 i KFW L4 SAGEM 2000 850

1.6 i NFT L4 BOSCH M7.4.4.

1.6 i 16V NFX L4 M. MARELLI 48P2 800

1.1 i HFX L4 -IF/L5 MAGNETTI MARELLI 48P

1.4 i KFW L4 - IF/L5 SAGEM S2000 850

1.6 i 16V NFU L4 BOSCH M 7.4.4.

1.4 i KFW IFL5/L4 SAGEM S2000

8501.6i NFU L4 BOSCH M.7.4.4.

2.0 i RFN L4 MAGNETTI MARELLI MM 48.P2

2.0 i 16V RFS L3 M. MARELLI 1AP10

1.6i NFV L4 BOSCH M7.4.4. 850

1.8i 6FZ L4 SAGEM - S2000 700

SAXO - C3 - XSARA PICASSOIDLING - DEPOLLUTION

Vehicles Engine typeEmissionstandard Make - Injection type

% Content

CO CO2

Idling speed (± 50 rpm)

Man.gbox

Auto. gbox : Ngear engaged

SAXO

C3

C3

XSARAPICASSO

< 0.5 > 9

< 0.5 > 9

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Emission standard

Engine type

Injection make and type

PETROL INJECTIONSAXO

Air temperature sensorresistive value (ohms)

SAXO

BOSCHM.7.4.4.

SAGEMS2000

BOSCHM.7.4.4.

M. MARELLI48P2

Fuel pressure (bars) 3

Overspeed cut-off (rpm)

Injector resistive value (ohms)

Engine coolant temperaturesensor resistive value (ohms)

Idling actuator or steppermotor resistive value (ohms)

HFX

IFL5 / L4 L4 L4L4

1.1 i 1.4 i 1.6 i 16 V1.6 i

KFW NFX NFT

3 3 3.5

14.5 14.5 14.5 14.5

5500 5500 5700 6600

Idle actuator : 11

3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C

3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C

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Emission standard

Engine type


PETROL INJECTION


C3

M. MARELLI 48P2 SAGEM S2000 BOSCH M.7.4.4.

Fuel pressure (bars)





HFX KFW NFU

L4 / IFL5 L4 L4

1.1i 1.4i 1.6i 16 V

3.5 3.5 3.5

5500 5500 5800

14.5 14.5 14.5

Idle actuator : 53

3 800 at 10°C 2500 at 20° C 800 at 50°C 230 at 90° C

3 800 at 10°C 2500 at 20° C 800 at 50°C 230 at 90° C

C3

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Emission standard

Engine type


PETROL INJECTIONXSARA - XSARA PICASSO


XSARA PICASSOXSARA

SAGEMS2000

M. MARELLI48P2

BOSCHM.7.4.4.

M. MARELLI1AP10

BOSCHM.7.4.4.

SAGEMS2000

Fuel pressure (bars)





KFW

IFL5 / L4 IFL5 / L4IFL5 / L4 / K’ L4 L3 IFL5 / L4

1.4 i 1.6 i 16 V 2.0 i 16 V 2.0 i 16 V 1.8 i 16 V1.6 i

RFNNFU RFS NFV 6FZ

3.5 333 3.5 3.5

14.5 12.2 1614.5 14.5 12.2

57006500600058005500 5500

Stepper motor: 53

3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C

3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C

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DEPOLLUTION TECHNICAL CHECKS (FRANCE) ALL TYPESAll Types Petrol CO Corrected (In %) All Types Diesel (m-1)

Conditions : At idle, engine warm.# 01/96

Less than 4.5 % for vehicles registered before 10/86.Less than 3.5 % for vehicles registered after 10/86.

With catalytic converter Greater than 2.0i 89 M.Y.All Types 93 M.Y.CO less than 0.5 % at idle speed.CO less than 0.3 % at fast idle speed between 2500 and 3000 rpm(*)

Lambda Probe value 0,97 to 1,03.

01/96 #

Atmospheric engine.

Less than 2.5 m -1

Turbocharged engine.

Less than 3.0 m -1

STANDARD

ALL TYPES EMISSION STANDARDS

PSA

A/S RPEngines ApplicableVehicles

ECE R 15.04

ECE R 15.05 W vp 15.05 Petrol

E.E.C.

APPLICATIONS

NOTES CHARACTERISTICS

PetrolDiesel

K K’

15.0415.04

With oxygen sensor,without catalyticconverter

Utility vehicles : All Types

Private vehicles : > 2 litres • new models • existing models

� 10/89

imminent

01/10/88 �01/10/89 �

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� Utility vehicle limits = private vehicle limitsincreased by 25 %

� For private vehicles and utility vehicles in major export

Brussels directive 88/76 « Luxembourg Accords » � Replaced by 89/458 + 91/441

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STANDARD

ALL TYPESEMISSION STANDARDS

PSA


US 83 Z US 83

US 87

US 93

E.E.C.

APPLICATIONS


Y US 87

Y2 US 93PetrolDiesel

PetrolDiesel

PetrolDiesel

Private vehicles : • certain non-EEC

European countries • certain Export countries



Private vehicles : • certain Export countries

Current� Adoption of the U.Sstandard

� Adoption of the U.Sstandard

� Adoption of the U.Sstandard

Current

Current

With oxygen sensor andcatalytic converter forpetrol vehicles

With catalytic converterand EGR

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STANDARD


PSA


US 84 LDT

X1 US 84

US 87 LDT

US 90 LDT

E.E.C.

APPLICATIONS


X2 US 87

X3 US 90PetrolDiesel

PetrolDiesel

PetrolDiesel







Current� Adoption of the U.S.standard for light utilityvehicles

� Adoption of the U.S.standard for light utilityvehicles

� Adoption of the U.S.standard for light utilityvehicles

Current

Current

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STANDARD

Private vehicles : < 6 seats and < 2.5 tonnes • new models • existing models

Utility vehicles : < 3.5 tonnes Class 1 : • new models • existing models Class 2/3 : • new models • existing models


PSA


EURO 2

(EURO96)

L3

EURO 2

(EURO96)

W3

E.E.C.

APPLICATIONS


Petrol Diesel

Petrol Diesel Gaz

Brussels Directive 94/12

� EURO 93 standard madestricter


� 3 classes depending onvehicle weight : Class 1 < 1250 kg Class 2 : 1250/1700 kg Class 3 : 1700 kg

With oxygen sensor andreinforced catalyticconverter for petrolvehicles. With catalytic converterand EGR for dieselvehicles.

With oxygen sensor andreinforced catalyticconverter for petrolvehicles. With catalytic converterand EGR for dieselvehicles.

01/96 �

01/97 �

01/97 �10/97 �

01/98 �10/98 �

CEE95

CEE95

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STANDARD

Utility vehicles :

< 3.5 tonnes

Class 1 : • new models • existing models Class 2/3 : • new models • existing models

Private vehicles : All Types

• new models • existing models


PSA


EURO 3

(EURO2000)

W3

EURO 4 IF / L5

E.E.C.

APPLICATIONS


Petrol Diesel Gaz

Petrol


� EURO 2 standard (L3)

made stricter

� Fiscal incentives

� 3 classes depending on

vehicle weight :

Class 1 < 1305 kg

Class 2 : 1305/1760 kg

Class 3 : 1760 kg


� EURO 3 standard (L4) made

stricter

� Fiscal incentives

With 2 oxygen sensorsand catalytic converter forpetrol vehicles.

With EOBD on-boarddiagnosis.

With 2 oxygen sensorsand catalytic converter forpetrol vehicles. With catalytic converterand EGR for dieselvehicles.


� 01/2000� 01/2001

� 01/2001� 01/2002

� 01/2005� 01/2006

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STANDARD

Private vehicles : All Types

• new models • existing models

Utility vehicles :

< 3.5 tonnes

Class 1 : • new models • existing models Class 2/3 : • new models • existing models


PSA


EURO 4 IF / L5

EURO 4 IF / L5

E.E.C.

APPLICATIONS


Petrol DieselGaz

PetrolGaz

Brussels Directive: 2001/1� EURO 3 standard (L4) madestricter� Fiscal incentives

Brussels Directives: 99/102 et2001/1 (Gas)� EURO 3 standard (L4) madestricter� Fiscal incentives� 3 classes depending onvehicle weight : Class 1 < 1305 kg Class 2 : 1305/1760 kg Class 3 : 1760 kg





� 01/2005� 01/2006

� 01/2005� 01/2006

� 01/2006� 01/2007

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SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM

Engines : RHY - RHZ - 8HX - 8HW - 8HY - 8HV

SAFETY REQUIREMENTSPreamble.All interventions on the injection system must be carried out to conform with the following requirements and regulations :- Competent health authorities.- Accident prevention.- Environmental protection.WARNING : Repairs must be carried out by specialised personnel informed of the safety requirements and of the precautions to be taken.

Safety requirements.IMPERATIVE : Take into account the very high pressures in the high pressure fuel circuit (1350 bars), and respect the requirements below :- No smoking in proximity to the high pressure circuit when work is being carried out.- Avoid working close to flame or sparks.Engine running : - Do not work on the high pressure fuel circuit.- Always stay clear of the trajectory of any possible jet of fuel, which could cause serious injuries.- Do not place your hand close to any leak in the high pressure fuel circuit.After the engine has stopped, wait 30 seconds before any intervention.NOTE : This waiting time is necessary in order to allow the high pressure fuel circuit to return to atmospheric pressure.


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SAFETY REQUIREMENTS : HDI DIRECT INJECTION SYSTEMEngines : 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).- Fuel filter.- High pressure fuel pump.- High pressure fuel injection common rail.- High pressure fuel pipes - Diesel injector carriers.

IMPERATIVE : After dismantling, immediately block the apertures of the sensitive components with plugs, to avoid the entry of impurities.Work area.- The work area must be clean and free of clutter.- Components being worked on must be protected from dust contamination.

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BOSCH INJECTION PUMP SPECIFICATIONS

PUMP -TYPE - REFERENCE

Emission standards

Equipement

L3/L4

Transponder

SAXO

SAXO 5BTUD VJX 539

(*) = The fuel high pressure pump is driven by the timing belt.

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BOSCH INJECTION PUMP SPECIFICATION SAXO

Enginetype

PumpType

Reference

Static timing

Initial advanceCompression

Time(cylinder N° 4)

Dynamic

timingchecking(at idle)

Reference

InjectorInjectorholder

+ injector

Colourcode

Injector

needle liftpressure

(Bar)

Adjustments (rpm) Max. speed

Fastidling

Anti-stall

IdlingUnladen

rpmLadenrpm

VJX 539 299KCA

20S106120± 5

No800

± 1005450± 160

5000± 160

Pump0,60 ± 0,1 mm

After BDC

(1) = Engine : TDC peg hole

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�

CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMPEngine : VJX

B1HP0YAC

Tools

- 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 checkusing the tools 4527-T.S1 and 4527-T.S2.

Setting the injection pump.- Peg :

• The flywheel.• The camshaft pulley.

- Fit the pump and tighten to 2 m.daN.- Peg the pump mounting plate.- Fit the pump drive pinion together with the timing belt. Tighten to 2 m.daN.

SAXO

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SAXOADJUSTING THE MECHANICAL CONTROLS OF THE BOSCH INJECTION PUMP

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.

- Ensure that the lever (3) is up against the screw stop (2).- If not, slightly tension the cable (4) using the cable clamp (1).- Finish tensioning with the sheath tensioner (5).

Engine hot.

- Ensure that the cable (4) is slack.- Check the operation of the thermostatic sensor on the coolant outlet housing : there should be a minimum

6 mm cable travel between a cold and a hot engine.- If not, replace the thermostatic sensor. Tighten to 2.5 m.daN.

B1HP0HQC

Engine : VJX

B1HP0HUC

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ADJUSTING THE MECHANICAL CONTROLS OF THE BOSCH INJECTION PUMP

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).

Preliminary conditions.

- Engine hot (The cooling fan is engaged twice).- Fast idle control released.

ADJUSTING THE IDLE SPEED.

- Slacken the screw (9) by a few turns until it no longer touches the lever (10).- Adjust the idling speed using the screw (8).

B1HP0HSD

Engine : VJX (continued)

SAXO

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ADJUSTING THE MECHANICAL CONTROLS OF THE BOSCH INJECTION PUMPEngine : 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 speedof: 835 ± 40 rpm.

- Remove the shim [1].

CHECKING THE ENGINE DECELERATION.

- Move the throttle lever (10) to obtain an engine speed of 3000 rpm.- Release the throttle lever (10). - The deceleration should be between 2 and 3 seconds.

ESSENTIAL : Check the operation of the manually-operated «STOP»control (11).

B1HP0HRD

SAXO

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FITTING BOSCH INJECTORSEngine :VJX

B1HP0YNC B1HP0YPC B1HP0YGC

Fitting an injectorThe copper seal (1) and thefire seal washer (2) are to bereplaced each time they areremoved.

NOTE : Fitting parts of diffe-rent makes is PROHIBITED.

WARNING : Ensure that thefire seal washer (2) is fittedthe right way round.

Tightening of the injectorholder on the cylinder head:

[1] Tool to remove/refit injectors 7007-T

[2] 7008-T Tool kit 4123-T

(3) Tighten lightly to avoid distortion. Tighten to 7 m.daN.

VJZ

7 m.daN

All Types

9 m.daN

SAXO

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PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEMEngines : 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.

High pressure fuel pump.Do not separate the following components from the high pressure fuel pump (5) :- Sealing ring (a) (no replacement parts).- High pressure outlet connector (b) (will cause a malfunction).

PS : HDi = High pressure Diesel injection

B1HP1K9C

C3

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PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEMEngines : 8HX - 8HW

Diesel injectors.

WARNING: Diesel and ultrasonic cleaners are prohibited.

Do not separate the following components from the diesel injectorcarrier (2) :- Diesel injector (f) (no replacement parts).- Electromagnetic element (c) (no replacement parts).

Do not alter the position of the nut (d) (malfunction).

Do not separate the connector (e) from a diesel injector.

It is forbidden to clean the carbon deposits from the diesel injectornozzle.

B1HP1KAC B1HP1KBC

C3

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PROHIBITED OPERATIONS: DELPHI HDI DIRECT INJECTION SYSTEMEngines : 8HY - 8HV


Fuel supply circuit.- Required fuel : diesel.


High pressure fuel pump.Do not separate the following components from the high pressure fuel pump (5) :- Sealing ring (a) (no replacement parts).- High pressure outlet connector (b) (will cause a malfunction).

PS : HDI = HIGH PRESSURE DIESEL INJECTION

B1HP1J6C

C3

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PROHIBITED OPERATIONS: DELPHI HDI DIRECT INJECTION SYSTEMEngines : 8HY - 8HV

B1HP1J7CB1HP1J8C

Fuel high pressure injection common rail.

Do not separate the pressure regulator «c» from the injectioncommon rail (2) (Risk of malfunction).

Diesel injectors.

WARNING: Diesel and ultrasonic cleaners areprohibited.

Do not separate the following components from the dieselinjector carrier (3) :- Diesel injector (e) (no replacement parts).- Electromagnetic component «d» (no replacement parts).

It is forbidden to clean the carbon deposits from the dieselinjector nozzle..

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CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUITEngines : 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 dieselinjection engines.

Link tools [1] and [2] in series between the fuel high pressure pump and the fuel filter.

ESSENTIAL : Check that the tool [2] is clean.

Check the negative pressure according to the table below:

Vacuum Observations

10 ±5 cmHg Engine driven by the starter motor

20 ±5 cmHg

60 ±5 cmHg

Engine running under full load

Supply circuit obstructed (full tankstrainer, piping, fuel filter).

B1BP2NWC

C3

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CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUITEngines : 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 dieselinjection engines.

Remove the air filter duct.Link tool [1] in series, downstream of the injectors, between the fuel high pressure pumpand the fuel filter at «a» and «b».

WARNING: Any checking of pressure downstream of the fuel filter is prohibited.Switch on the ignition.

ESSENTIAL : Check that the tool [2] is clean.

Check the negative pressure according to the table below:

Vacuum Observations

10 ± 05 cmhg Engine driven by the starter motor

20 ± 20 cmhg

60 ± 05 cmhg

Engine running under full load

Supply circuit obstructed (full tankstrainer, piping, fuel filter).

B1BP2PHC

C3

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AIR SUPPLY CIRCUIT SPECIFICATION

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.

B1HP1JMP

Engines : 8HX - 8HW

C3

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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.

(11) Oil trap.

(12) Oil filler cap.

B1HP1JND

Engines : 8HX - 8HW

C3

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AIR SUPPLY CIRCUIT SPECIFICATIONEngines : 8HX - 8HW

WARNING: After each removal, replace the seals of components that have been removed, lubricating the new seals when refitting.

Lower integrated air inlet distributor. Upper integrated air inlet distributor.

OIL TRAP FIXING SCREW.Diesel fuel filter support fixing screw.Diesel fuel filter support fixing screw.Integrated air distributor fixing screw.

1 à 89 à 10

1112 à 13

1 ± 0.11 ± 0.1

0.51 ± 0.1

1314151617

0.5

0.75

DescriptionTighten insequence

m.daN.

Air filter housing fixing screw.Air filter cover fixing screw.Air inlet duct fixing screw.Resonator on turbocharger fixing screw.Resonator on oil trap fixing screw.

DescriptionTighten insequence

m.daN.

B1HP1JPD B1HP1JQD

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(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

Engines : 8HY - 8HV

C3

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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

Engines : 8HX - 8HW - 8HY - 8HV

C3

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CHECKS : EXHAUST GASES RECYCLING CIRCUITEngines : 8HX - 8HW

Engines : 8HV - 8HY

TOOLS[1] Manual pressure-vacuum pump : FACOM DA 16.

IMPERATIVE : Respect the safety and cleanliness specific to high pressure dieselinjection (HDi) engines.

EGR valveConnect tool [1] on the capsule take-off (2).Apply a vacuum of approx. 0,6 bar several times to activate the rod «a».In abruptly suppressing the vacuum, the valve should click and lock itself back on its seating.

Regulation electrovalve (EGR). (Engine: 8HX-8HW).Check to be performed between the electrovalve (1) and the EGR valve (2).Link the tool [1] in series, between the electrovalve (1) and the capsule (2).Compare the values noted with those in the table below.

Regulation electrovalve (EGR). (Engine: 8HV-8HY).Check to be performed between the electrovalve (2) and the EGR valve (1).Link the tool [1] in series, between the electrovalve (2) and the capsule (1).Compare the values noted with those in the table below.

Engine speed (rpm) Vacuum value

780 0.5

2500 0

B1HP15GD

B1HP1K6D

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CHECKS : TURBO PRESSUREEngines : 8HX - 8HW

1] Pressure gauge for checking boost pressure : 4073-T.A[2] Sleeve for checking boost pressure : (-).0171.FCHECKSIMPERATIVE : Respect the following test conditions: - Engine at operating temperature.- Vehicle in running order.- Engine under full load.Preparation.Remove the clips (1).Fit the tool [2] in the place of the duct (2).Couple the sleeve [2] on the pressure gauge [1] using the tube «a».Mode of operation.Position tool [1] in the vehicle.Start the engine.Engage first gear, start the vehicle.Engage the gears up to third gear.Decelerate to an engine speed of 1000 rpm.Check the pressure : 0,6 ± 0,05 bar (1500 rpm).Accelerate freely (change from fourth gear to third gear)Check the pressure: 0,9 ± 0,05 bar (between 2500 and 3500 rpm).Remove tools [1], [2] at «a».Reposition the tube (2) and tighten the clip (1).

B1BP2NXD

C5FP0F5C

C3

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CHECKS : TURBO PRESSUREEngines : 8HV - 8HY

[1] Pressure gauge for checking boost pressure : 4073-T.A[2] Sleeve for checking boost pressure : (-).0171.FCHECKSIMPERATIVE : Respect the following test conditions: - Engine at operating temperature.- Vehicle in running order.- Engine under full load.Preparation.Remove the clips (1).Fit the tool [2] in the place of the duct (2).Couple the sleeve [2] on the pressure gauge [1] using the tube «a».Mode of operation.Position tool [1] in the vehicle.Start the engine.Engage first gear, start the vehicle.Engage the gears up to third gear.Decelerate to an engine speed of 1000 rpm.Check the pressure : 0,6 ± 0,05 bar (1500 rpm).Accelerate freely (change from fourth gear to third gear)Check the pressure: 0,9 ± 0,05 bar (between 2500 and 3500 rpm).Remove tools [1], [2] at «a».Reposition the tube (2) and tighten the clip (1).

C5FP0EJC

B1BP2NBD

C3

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SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP

PUMP - TYPE - REFERENCE

Emission standards

Equipment

L3

XSARA 8BDW WJYDWLP 12R8448 B

371 B

Transponder

XSARA

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SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMPXSARA

Enginetype

PumpType

Reference

Static timing

Initial advanceCompression

Time(cylinder N° 4)

Dynamic

timingchecking(at idle)

Reference

InjectorInjectorholder

+ injector

Colourcode

Injectorneedle liftpressure

(Bar)

Adjustments (rpm) Max. speed

Fastidling

Anti-stall

IdlingUnladen

rpmLadenrpm

WJYDWLP 12

R 8448 B/ *

RDNOSDC6903

LDCR0260IAA

135.5± 5

950± 25

1500+ 3mmshim

875± 25

875± 25

5350± 125

EngineTDC

Pegging hole. Value «X»

engraved on thepump.

(*) = See table, page : 245.

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CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMPEngine : WJY

Evolution of the checking of the setting of the LUCAS diesel injection pump

NEW ASSEMBLY : RPO 7910 #Old assembly.

Diesel injection pump with hole forchecking the setting

The setting of the diesel injection pump isdone with the aid of the following tools :

- A peg placed at «a».

- A peg and a dial gauge placed in thechecking hole at «b»

Diesel injection pump without a hole forchecking the setting

The setting of the diesel injection pumpis done with the aid of a peg at «c».

See method on following pages.

B1HP1A4C B1HP1A5C

XSARA

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XSARA CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP

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).- The upper casing (8).- The intermediate casing (11).

WARNING : Refit the screw (6) equipped with a washer. (Thickness 5 mm).

- Turn the front RH wheel to turn the engine. (Normal direction of rotation).- Bring the camshaft and injection pump pulleys to their setting point.- Position the flywheel peg, using tool [1]. (From below the vehicle).- Turn the engine until the peg [1] engages in the flywheel.

B1BP1S9CB1EP12NC

Engine : WJY (continued)

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CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMPEngine : 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.Carry out the following operations: - Loosen the screws of the injection pump hub.- Turn the injection pump hub.- Insert the peg [3] into the setting hole.- Tighten the screws of the injection pump hub. Tighten to 2,3 ± 0,2 m.daN.

ESSENTIAL : If setting the diesel injection pump proves impossible, reset the valvetiming. (See page 245).

Remove:- The tools [1], [2] and [3].- The screw (6) and the washer.Reassemble the components.

B1EP12WD B1BP1S9C

XSARA

250

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ADJUSTING THE MECHANICAL CONTROLS OF THE DELPHI INJECTION PUMPEngine : 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).

Engine hot.- Check that the cable (3) is in tension.

Checking the thermostatic sensor.- There should be a minimum 6 mm cable travel between a cold and a hot engine.

Adjusting the accelerator control.Prior conditions.- Engine hot (cooling fan is engaged twice).

Checking the accelerator cable tension.- Fully depress the accelerator pedal.- Check that the lever (6) is against its stop (5) otherwise, alter the position of the pin.- If not, adjust the position of the accelerator cable tensioning retaining pin. - Ensure that in the idle position the lever (6) is against the stop (7).

B1HP0K9C

XSARA

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ADJUSTING THE MECHANICAL CONTROLS OF THE DELPHI INJECTION PUMPEngine : 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).- Adjust the engine speed to 1500 rpm ± 100 using the stop screw (7).- Remove the shim (10) and the peg (9).

Adjusting the idle speed.- Adjust the speed using the idle adjustment screw (11).- Idling speed : 825 ± 25 rpm.

Checking the engine deceleration.- Move the throttle lever (6) ) to obtain an engine speed of 3000 rpm.- Release the throttle lever (6).- The deceleration should be between 2.5 and 3.5 seconds.- The drop should be approximately 50 rpm in relation to the idle speed.- Deceleration too fast, (the engine has a tendency to stall) slacken the screw (7) by a quarter turn.- Deceleration too slow, (engine speed is greater than the idle speed) tighten screw (7) by a quarter turn.NOTE : In each case, check the idle speed for any necessary adjustments.

B1HP0K9C B1HP0KAC

XSARA

252

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FITTING DELPHI DIESEL INJECTORSEngine : WJY

B1DP158C B1HP12VC B1HP0YGC

Fitting an injector

The copper seal (1) and the fireseal washer (3) are to be replacedeach time they are removed.

NOTE : Fitting parts of differentmakes is PROHIBITED.

WARNING : Ensure that thefire seal washer (3) is fitted theright way round.Tighten the injector holderon the cylinder head to :

9 m.daN

[1] Tool to remove/refit injectors (2) 7007-T

[2] 7008-T.A Tool kit 4123-T

(3) Tighten lightly to prevent any distortion.

XSARA

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INJECTION PUMP SPECIFICATIONS (BOSCH and SIEMENS).

Engines Injection system ECU High pressure pump Injectors

BOSCH BOSCH EDC 15C2

SIEMENS ECUSID801

BOSCH EDC 15C2

BOSCH CP1

5WS 40001

BOSCH CP1

9625542580

5WS40000

9625542580

SIEMENS (except PICASSO

BOSCH

DW 10TD

ATED

XSARA PICASSO

254

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PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM

Engines : RHY - RHZ

XSARA PICASSO


Fuel supply circuit.- Required fuel : diesel.WARNING : Do not use other fuels.


High pressure fuel pump.Do not separate the following components from the high pressure fuel pump (5) :- High pressure fuel pump third piston deactivator (3) (no replacement parts).- High pressure fuel regulator (4) (no replacement parts).- Sealing ring (1) (no replacement parts).- High pressure outlet connector (3) (will cause a malfunction).PS: HDi = High pressure Diesel injection

B1HP12CC

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PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEMEngines: RHY - RHZ

XSARA PICASSO

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).- Electromagnetic element (11) (destruction).- Do not alter the position of the nut (10) (malfunction).- Do not separate the connector (12) from a diesel injector.- It is forbidden to clean the carbon deposits from the diesel injector nozzle.- Identification : Injector carrier- There are two types of diesel injector carrier classed according to fuel flow.Identification by engraving or paint mark

B1HP12EC

B1HP12DC

B1HP16PC

IMPERATIVE: When replacing a dieselinjector carrier, order a componentof the same class.(See repair manual).

Identification markings:-« a » : Supplier identification.-« b » : PSA identification number.-« c » : Class identification.

Injector carrier

Class 1

Class 2

Engraving

1

2

Paint mark

Blue

Green

Location

On the upper part of thecoil near to the fuel returnaperture

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XSARA PICASSO CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUITEngines : 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"on the fuel supply pipe).Connect the tool [2] downstream of the diesel injectors, between the high pressurefuel pump and the fuel filter (green mark at "b" on the fuel return pipe.

WARNING : Any check of pressure downstream of the fuel filter is PROHIBITED.

Checks on pressure : static.

- Switch on ignitionFor 3 seconds (normal functioning):- Fuel supply pressure shown by the pressure gauge [3] = 1.8 ± 0.4 Bar.- Fuel return pressure shown by the pressure gauge [3] = 0.5 ± 0.4 Bar.

B1BP1TWD

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XSARA PICASSOCHECKS : LOW PRESSURE FUEL SUPPLY CIRCUITEngines : RHY - RHZ (continued)

Checks on pressure : dynamic.Engine running, at idle (normal functioning):- Fuel supply pressure shown by the pressure gauge [3] = 2 ± 0.4 Bar.- Fuel return pressure shown by the pressure gauge [3] = 0.7 ± 0.4 Bar.Abnormal functioning

Impossible to start the engine :Fuel supply pressure less than 0.8 Bar :- Check the low pressure regulator incorporated in the filter (locked open)- Check the high pressure pump distribution valve (locked shut)

Check : diesel injector return flow. (Table)

Uncouple the diesel injector return pipe.

Fuel supply pressure Fuel return pressure Checks

Between 3 and 3.5 Bar 0.7 ± 0.2 Bar Check the condition of the diesel filter

More than 3.5 Bar

More than 3.5 Bar

Less than 0.7 Bar

More than 0.7 Bar

Check the low pressure regulator incorporated inthe filter (locked shut) : replace.

Check the fuel return circuit(pipe pinched or trapped.......).

Between 0.8 and 1.5 Bar Less than 0.7 Bar Check the fuel suppy circuit :- Booster pump (low pressure), piping.

Check : Observe :

The flow should be drop by drop Diesel injector functioning correctly

Excessive fuel return Diesel injector locked shut.

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CHECKS : AIR SUPPLY CIRCUITEngines: RHY - RHZ

XSARA PICASSO

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.- Pressure should be 0.8 bar at 780 rpm.Boost pressure regulator electrovalve.- Connect the tool [1] between the electrovalve (2) and the valve (3) of the boost pressureregulator.Compare readings with the values in the table below.

Pressure regulator valve.- Connect the tool [1] on the valve (3).- Appy a pressure of 0.5 bar to activate the rod "a" : - Rod "a" should be moved 12 mm.

Engine speed (rpm) Pressure (Bar)

780 0.6

4000 0.25

B1HP12FD

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CHECKS : TURBO PRESSUREEngine : RHZ

XSARA PICASSO

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-TChecks.IMPERATIVE : respect the following checking requirements : Engine at runningtemperature. Vehicle in running order at full load.Preparation.- Remove the collar fixing (3).- Insert the tool [2] connected with tool [3], between the pipe (1) and the duct (2). - Position tool [1] in the vehicle.- Connect the sleeve [2] to the tool [1] with its tube « a ».Procedure.- Start the engine.- Engage first gear and start the engine.- Engage the gears up to third gear.- Decelerate to 1000 rpm.- Accelerate hard, and check the pressure : 0.6 ± 0.05 Bar (1500 rpm).- Accelerate freely in kick-down, (changing from fourth to third gear). - Check the pressure : 0.95 ± 0.05 Bar (between 2500 and 3500 rpm). - Remove the tools, reposition the pipe (1) and refit the collar (3).

B1HP12JD

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CHECKS : TURBO PRESSUREEngine : 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. Vehicle running at full load.

Preparation.- Remove the collar (3) and the sleeve.- Insert the tool [2] between the pipe (1) and the duct (2).- Position tool [1] in the vehicle.- Connect the pressure gauge [1] to the tool [2] with its tube « a » long enough for the gaugeto be positioned inside the vehicle.Procedure.- Start the engine.- Engage first gear and start the engine.- Engage the gears up to third gear.- Decelerate to 2000 rpm.- Gradually accelerate.- Check the pressure : 0.95 ± 0.05 Bar. - Remove the tools, refit the collars (3) and the sleeve.

B1BP1ZXD

XSARA PICASSO

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CHECKS : EXHAUST GASES RECYCLING CIRCUITEngines : RHY - RHZ

XSARA PICASSO

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. 0.6 bar to activate the rod "a".- In abrupt reaction to the vacuum, the valve should close on its seating with a clicking noise.

Exhaust gas reycling (EGR) electrovalve.- Check, not under load, between the electrovalve (2) and the EGR valve (1).- Connect the tool [1] between the electrovalve (2) and the capsule (1).- Compare readings with the values in the table below.

Engine speed (rpm) Pressure (Bar)

780 0.5

2500 0

B1HP12GD

1.1i HFX

1.4i KFW

1.6i NFT

1.6i 16v NFX

1.1i HFX

1.4i KFV

1.6i 16v NFU

1.4i KFW

1.6i 16v NFU

2.0i 16v RFN

2.0i 16v RFS

16i NFV

1.8i 16v 6FZ

2.0i 16V RFN

262

SPARKING PLUGSALL TYPES

Vehicles – Models BOSCHEnginetype

CHAMPION SAGEMElectrode

gap settingTightening

torque

SAXO

C3

XSARA

XSARA PICASSO

IGN

ITIO

N

FR7DE

RC8YCL

RFN58LZ 0.9 mm 2.5 ± 0.2 mda N

CL

UT

CH

GE

AR

BO

XD

RIV

ES

HA

FT

S

263

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» and the speed travelled «ST», there must always be the following relationship :

ST < SD < 1.10 ST + 4 Kph

Example : For an actual speed of 100 Kph the speed displayed by the speedometer may be between 100 and 114 Kph.The speed indicated by the speedometer may be influenced by :

- The speedometer.- The tyres fitted to the vehicle.- The final drive ratio.- The speedometer drive ratio.Any of these components can be checked without removing them from the vehicle. (See information note N° 78-85 TT of 19 October 1978.NOTE : Before replacing the speedometer, check the conformity of the following points :- The tyres fitted to the vehicle.- The gearbox final drive ratio.- The speedometer drive ratio.

264

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CLUTCH SPECIFICATIONS

Engine type

Gearbox

Make

Mechanism/Type

Clutch disc

Ext./Int. lining Ø

Disc lining type

1.1i 1.4i 1.6i 16V 1.4 HDi 1.4 HDi 16V

HFX KFV NFU 8HX - 8HW 8HV - 8HY

MA/5 BE4/5

VALEO LUK

180 CP0 3400 200 P 3900 230 P 4700

11 R 10X

180/127 200/134 228/155

F408

C3 - SAXO

265

CL

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GE

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S

CLUTCH SPECIFICATIONSEngines : 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.(2) Declutch fork.(3) Clutch casing.(4) Bearing.(5) Clutch plate.

The clutch control slave cylinder (7) is fixed by two screws (6) onto the exterior of the clutch casing.

Tightening torques (m.daN).

- Fixing of clutch plate / engine flywheel : 2 ± 0.2- Fixing of clutch control slave cylinder / clutch housing : 2 ± 0. 25- Fixing of engine flywheel / crankshaft

Pre-tightening : 1.7 ± 0.1Angular tightening : 70° ± 5°

B2BP047C B2BP04QC

C3

Engine type KFW NFV NFU 6FZ RFN RFS WJY 8HZ RHY RHZ

Gearbox MA/5 BE4/5 MA/5 BE4/5

Make VALEO LUK

Mechanism/Type

Clutch disc

Ext./Int. lining Ø

Disc lining type

266

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GE

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BO

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ES

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FT

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CLUTCH SPECIFICATIONS

1.4i 1.6i 1.6i 16V 1.8i 16V 2.0i 16V 1.9 D 1.4 HDi 2.0 HDi

180CPO3400

180 XJF73 C

200X(D95) 11A12X 230 DNG 4700 215 FD 95215 F (D

93) 22 BX228 228D

200 CPR 3800 230 DNG 4700215 DT5250

200 P3700

200 P4200

230 P4700

235 T5700

180/127 200/137 228/155 215/147 200/134 200/134 230/155 235/155

F 408 F410 F 808 F408 F202


267

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CLUTCH SPECIFICATIONS BERLINGO

Engine type HFX KFW NFU WJY RHY

Gearbox MA/5 BE4/5

Make VALEO LUK

Mécanisme/Type 200 CPX 3850 200 P 4700 235 T 5700

Clutch disc 200 XS L73C 11RX 200 XSL 73 200 228

Ext./Int. lining Ø 200/137 228/155

Disc lining type F808 F408

1.1i 1.4i 1.6i 16V 1.9 D 2.0 HDi

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LUTCH : CHECKS AND ADJUSTMENTSMechanically operated push-action clutch

HFX-KFW-NFT-NFX-VJX

KFW-NFUGearboxEngines

SAXO Adjustable

Non-adjustableXSARAMA/5

ESSENTIAL : If the clutch control is new, squeeze the cable sheath before adjusting by declutchingsuccessively a minimum of 20 times.

ChecksNOTE : Adjustable steering wheels should be put into the low position- Record the measurement «X» between positions L1, pedal at rest, and L2, pedal fully depressed.- Measurement «X» should be : (Pedal travel).

Adjustments.

- If the measurement is incorrect, adjust the clutch pedal travel «X».- Loosen the lock nuts (1).- To adjust the travel to conform with the measurements indicated above, either loosen or tighten the nut (2).

(Tighten the nut to increase the travel, and loosen it to decrease the travel.)- Tighten the lock nut (1).

SAXO

135 ± 5 mm

B2BP00GCB2BP023C

SAXO - XSARA

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CLUTCH : CHECKS AND ADJUSTMENTS

B2BP03CD

Push-action clutch with automatic adjustment (non-adjustable)

WJY GearboxEngines BE4/5

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).- Clip the end-piece (5) to the gearbox.- Refit the cable to the lever (1).- Depress the clutch cable several times to set theassembly in place.- Check that the end-piece (4) is properly fitted to thebulkhead.- Check the operation of the automatic adjusting device.1) Pull the lever (in direction F), the lever must move whenpulled by hand.2) Press the clutch pedal very lightly and repeat the sameoperation. The lever should not move back.

XSARA

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CLUTCH : CHECKS AND ADJUSTMENTSPull-action clutch with automatic adjustment (non-adjustable)

RFS - RFN - RHY - RHZ GearboxEngines BE4/5

B2BP03DD

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).- Clip the end-piece (5) to the gearbox.- Refit the cable to the lever (1).- Depress the clutch cable several times to set theassembly in place.- Check that the end-piece (4) is properly fitted to thebulkhead.- Check the operation of the automatic adjusting device.1) Pull the lever (in direction F), the lever must move whenpulled by hand.2) Press the clutch pedal very lightly and repeat the sameoperation. The lever should not move back.

XSARA

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WARNING : If a system blockage is detected when checking, or if the pedal has been removed, thepedal position must be adjusted. This position is obtained by the angular displacement of the stopsupports "a" and "b".

Procedure.

- Loosen the nut (6) and the screw (7).- Using a lever, raise the stop support (8) to its highest position.- In this position, there must be a substantial free play in the pedal.- Lower the support until there is a free play of 2 ± 1 mm.- Tighten the screw (7) and the nut (6).- Check that the outer cable slides freely (at rest, the pedal is against its upper stop «A», the outer cablelength should be variable).

Characteristics

- The automatic adjusting device requires no manual adjustment.- Pedal travel remains constant for all models 145 ± 5 mm.- Automatic adjustment is achieved by modifying the curvature of the outer cable.- Take extra care with the routing of the outer cable, and do not add any supplementary fixing points.

Engines : RFN - RFS - WJY - RHY - RHZ

B2BP03EC

Adjustment of push and pull action clutch with automatic compensation (adjustment of compensation system)

XSARA

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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.

DESCRIPTION1 - Metallic cable, crimped on both ends. 5 - Tensioning spring ensuring the maximum length of the cable sleeve.2 - Outer cable or telescopic duct. 6 - Wear take-up device.3 - Outer cable stop, bulkhead side (fixed point on the bodyshell). 7 - Hooking yoke.4 - Outer cable stop, gearbox side (fixed point on the gearbox).

Engines : RFN - RFS – WJY – RHY - RHZ

B2BP02SC

XSARA

273

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B2BP03QD

For the adjusting device to operate correctly, itis necessary that :The pedal is at rest (against its upper stop)The locking sleeve (1) is slightly compressed,the rollers (2) are free, the outer cable (3) lengthmay vary.

Engines : RFN - RFS - WJY - RHY - RHZ

As soon as the pedal is applied, the attachingend-piece (4) leaves the sleeve (1) whichmoves back. The rollers, pushed by spring (5)jam the system. The cable behaves like aconventional cable.

The pedal returns to rest on its upper stop.Attaching end-piece (4) pushes sleeve (1)which frees the rollers. The outer cable (3),kept extended by the spring (6) becomes :-Shorter if the clutch disc is worn.-Longer if the outer cable has beencompressed.

Operation Clutch disengagement phase Engagement / adjustment phase

NOTE : The pedal gear has a non-adjustable assisting device.


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155/70 R 13 – 1.67 m 165/65 R14 1.725m 185/55 R14 1.7 m

MA/5 MB3 MA/5

20 CF 03 20 CF 12 312 20 CN 03 – 20 CN 05

14x60 17x64 17x56 17x61 16x63

19x17 19x17 21x19 19x17

GEARBOX AND TYRE SPECIFICATIONS

Engine type

Tyres-Rolling circumference

Speedometer ratio

Gearbox type


Reduction box torque

Auto.1.1i

1.4i1.6i 1.6i 16V

Petrol

HFX KFW NFT NFX

Engine type


Speedometer ratio

Gearbox type



1.5D

Diesel

VJX

165/65 R14 – 1.725 m

MA/5

20 CF 0229/08/200 �

17x64

19x17

SAXO

275

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Engine typeTrim level


Speedometer ratio

Gearbox typeGearbox ident. plateReduction box torque

Engine typeTrim level


Speedometer ratioNOTE : (*) = Export

Gearbox typeGearbox ident. plate



1.6i 16V

Auto..

1.4i1.1i

Petrol

HFX

X - SX ExclusiveExclusiveExclusiveX - SX Exclusive X - SXX - SX

NFUKFV

Diesel

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

MA/5 AL4 MA/520 CN 14 20 CF 15 ou 20 CF 16 (*) 20 TP 75 20 CN 40

14x60 16x63 ou 14x60 (*) 21x73 17x6421x18

1.4 HDi

X – SX - Exclsive

8HX 8HW 8HV 8HY165/70 R14 1.804 185/60 R15 1.828 m

MA/5 BE4/520 CN 33 ou 20 CN 36(*) 20 DM 25 20 DM26

17x61 ou 16x65 (*) 19x72 19x7721x18 22x19

1.4 HDi 16V

C3 - All Types

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GEARBOX AND TYRE SPECIFICATIONSPetrol

XSARA

Engine type


Speedometer ratio

Gearbox typeGearbox ident. plate


Engine type


Speedometer ratio

Right hand drive : 6FZ-RFN - 20 DM 03 WJZ-WJY - 20 DM 05 8HZ - 20 DM 53 RHY - 20 DM 07 RHZ - 20 DM 11

Gearbox type

Gearbox ident. plateReduction box torque

1.4i1.6i 16V

Auto.Auto.

2.0i 16V

KFW NFU RFN RFS

195/55 R15 - 1.815 mMA/5 AL4 BE4/5 AL4 BE3/5

20 CF 13 20 CN 28 20 TP 49 20 DL 40 20 TP 47 20 TE 47

16x65 21x73 19x72 23x73 14x6221x18 24x21 22x19 24x21 22x19

Diesel

1.9D 1.4HDi2.0 Hdi

WJY 8HZ RHY RHZ

Auto.

195/55 R15 – 1.815 mBE4/5 AL4

20 DL 4119x75

22x19

20 DM 54 20 DL 4219x70

20 DM 1017x61

20 TP 4814x62

22x19

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185/65 R15 – 1.895 m

BE4/5 AL4 BE4/5

20 DL 66 20 DL 68 20 TS 02 20 DL 64

15x64 19x77 21x73 19x72

22x18 24x20 22x18


Engine type


Speedometer ratio

Gearbox type



1.6i 1.8i 16 V 2.0i 16V

Auto.

2.0 Hdi

Petrol Diesel

NFV 6FZ RFN RHY

XSARA PICASSO

Right hand drive : NFV = 20 DL 67 6FZ = 20 DL 69 RHY = 20 DL 65.

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GEARBOX - MA/5Engines : HFX - KFW - NFT - NFX - NFU - VJX - 8HX - 8HW

B2CP34HP B2CP20FC B2CP20GC

SAXO - XSARA

Filler screw Drain screw

Vent plug

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GEARBOX CONTROLS - MA/5Engines : HFX - KFW - NFT - NFX – NFU - VJX– 8HX- 8HW

1 - Gear lever.

2 - Gear control rod.

3 - Gear control rod.

4 - Gear selection rod.

5 - Gear selection rod.

6 - Knuckle joint.

7 - Fixed point on the gearbox

A = 11.5 mm.

B = 9.5 mm.

C = 3 mm.

B2CP16SP B2CP16TC

SAXO - XSARA

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GEARBOX - MA/5Engines : HFX - KFV - NFU - 8HX - 8HW

«a» Identification label.

«b» Location for engraving of serial and gearbox nos..

B2CP3HTC

C3

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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.

«Lubricated for life »Check the oil level: Every 37 500/40 000 miles.

B2CP3HWC

C3

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(1) Primary shaft.(2) Clutch bearing guide.(3) Clutch housing.(4) Gearbox casing.(5) Intermediate plate.(6) Bearing retaining clip.(7) Drive pinion (5th gear).(8) Secondary shaft.(9) 5th gear synchroniser.(10) Driven pinion (5th gear).(11) Driven pinion (4th gear).(12) 3rd / 4th gear synchroniser.(13) Driven pinion (3nd gear).(14) Driven pinion (2nd gear).(15) 1st / 2nd gear synchroniser and reverse gear driven pinion.(16) Driven pinions (1st gear).(17) Differential gearwheel.(18) Satellite pinions.(19) Planet pinions.(20) Counter drive.(21) Speedometer screw.(22) Differential housing.B2CP167P

C3

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Tightening torques: m.daN.

(23) Clutch bearing guide (3 fixing screws) : 0.6 ± 0.15.

(24) Intermediate plate (11 fixing screws) : 5 ± 0.5.

(25) Rear cover (3 fixing screws) : 2.2 ± 0.2.

(26) Bearing retaining clip (4 fixing screws) : 1.8 ± 0.2.

(27) Secondary shaft nut (1 nut) : 14 ± 1.

(28) Gearbox casing (15 fixing screws) : 1.8 ± 0.2.

(29) Top-up plug (1) : 2.5 ± 0.5.

(30) Drain plug (1) : 2.5 ± 0.5.

(31) Reverse gear switch (1) : 2.5 ± 0.5.

B2CP3HUD

C3

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GEARBOX CONTROLS - MA/5Engines : 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

C3

285

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(4) Gear engagement ball-joint Ø 10 mm.

(5) Gear selection ball-joint Ø 10 mm.

Length D Length C

Gear engagement control 1015 mm 790 mmcable (2)

Length A Length B

Gear selection control 1093 mm 775 mmcable (3)B2CP3HZD

B2CP3HYC

C3

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Adjustment.

WARNING: Do not use any tool to detach the ball-joints.

The gear selection control and gear engagement controlcables cannot be adjusted.

To unlock the ball-joint, press at «a» then pull the ball-jointupwards.

To release the sleeve stops, pull the needles «b», in thedirection of the arrow, then disengage the sleeve stopsfrom their supports.

B2CP3J1D

B2CP3J0D

C3

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GEARBOX – BE4/5Engines : NFV - 6FZ – 8HV – 8HY - 8HZ - RFN - RFS - WJY – RHY - RHZ

B2CP3BNC B2CP3BPD

(a) Marking zone. (Sequence and serial no.).(b) = Location of identification label.

C3 - XSARA - XSARA PICASSO

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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.

Quality of oilRefer to the manufacturer’s instructions.

Quantity of oilGearbox empty : 1,9 Litres.After draining : 2 Litres.

B2CP3BLD


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GEARBOX – BE4/5Engines : NFV - 6FZ – 8HV – 8HY - 8HZ - RFN - RFS - WJY – RHY - RHZ

Description

(1) Primary shaft.

(2) Clutch bearing guide.

(3) Gearbox casing.

(4) Clutch housing.

(5) Reverse idle.

(6) Drive gear (3rd gear).

(7) 3rd /4th gear synchroniser

(8) Drive gear (4th gear).

(9) Drive gear (5th gear).

(10) 5th gear synchroniser.

(11) Driven gear (5th gear).

(12) Driven gear (3rd / 4th gear )

(13) Driven gear (2nd gear).

(14) 1st / 2nd gear synchroniser

(15) Driven gear (1st gear).

(16) Secondary shaft.

(17) Differential gear.

(18) Satellite gears.

(19) Planet gears.

(20) Differential housing.

(21) Speedometer drive.

(22) Extension.

« d » Adjusting shims : 0.7 to 2.4 mm

( 0.10 mm and increasing by 0.10 mm).

« c » Adjusting shims: 1.4 to 1.6 mm

( 0.10 mm and increasing by 0.10 mm).

B2CP3BQP


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GEARBOX - BE4/5Engines : 8HV - 8HY


(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 ± 0.5(27) Vis de maintien du jonc (2 vis) : 1.5 ± 0.2(28) Differential gearwheel screw (2 screws) : 6.5 ± 0.5

Reverse gear switch (1 screw) : 2.5 ± 0.3(29) Differential housing (4 screws) : 5 ± 0.5(30) Breather pipe : 1.7 ± 0.2(31) Rear housing cover screws (7 screws) : 1.25 ± 0.2(32) Top-up plug (1 screw) : 2.2 ± 0.2(33) Differential housing screws (4 screws) : 1.25 ± 0.2(34) Drain plug (1 screw) : 3.5 ± 0.3

B2CP3BRD

C3

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GEARBOX – BE4/5Engines : NFV - 6FZ - RFN - RFS - WJY - 8HZ - RHY - RHZ

Tightening torques

Ref. Description Number of screws m.daN

1 End guide 3 1.2 ± 0.1

2 Clutch housing 13 1.3 ± 0.1

3 Primary shaft nut 1 7.2 ± 0.7

4 Secondary shaft nut 1 6.5 ± 0.7

5 Yoke holding screw 2 1.5 ± 0.1

6 Differential gearwheel screw 2 6.5 ± 0.7

Reverse gear contact 1 2.5 ± 0.3

7 Differential housing 4 5 ± 0.5

8 Breather pipe 1 1.7 ± 0.2

9 Rear housing cover screw 7 1.2 ± 0.1

10 Top-up plug 1 2.2 ± 0.2

11 Differential housing screw 4 1.2 ± 0.1

12 Drain plug screw 1 3.5 ± 0.4


B2CP3BSP

B2CP3BTD

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GEARBOX CONTROLS - BE4/5Engines : 8HV - 8HY

(1) Gear control lever



(*) These two cables cannot be separated.

B2CP3J3D

C3

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Length A Length B

Gear selection 907 mm 645 mmcable (5)

Length D Length C

Gear engagement 965 mm 610 mmcable (4)B2CP3J5D

B2CP3J4C

C3

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Adjustment.

The gear selection control and gear engagementcontrol cables cannot be adjusted.

To release the ball-joint, press at «d» then pull theball-joint upwards.

To release sleeve stops:

- Press on the tabs of the clip (6) at «a».- Disengage the sleeve stops from their supports.

B2CP3J6D

C3

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GEARBOX CONTROLS - BE4/5

Engines : NFV - 6FZ - RFN - RFS - WJY - 8HZ – RHY - RHZ

(1) Gear control lever





(6) Flexible insulating grommet through thebulkhead.

(*) = These two cables cannot be separated.

B2CP3BWD


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BE4/5 GEARBOX - CHECKS AND ADJUSTMENTSEngines : 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.

Principles.

Lock the gear lever in neutral position,using tool: 9607-T.

Place the gearbox in neutral.

Couple the cables on the lever.

Fit the ball-joints on the gearbox lever.

Lock the cable lengths with the ball-joint lockingkeys.

WARNING : Do not use any tool to unclip the ball-joints.

To unlock the ball-joint, press at the centre «a»,then pull the ball-joint upwards.

NOTE : Changing an individual ball-joint is possibleas long as the locking key is removed.

Unclip at «b», using two small screwdrivers.


B2CP3BXC B2CP3BYC

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BE4/5 GEARBOX - CHECKS AND ADJUSTMENTS

TOOLS.[1] Tool for positioning the gear lever : 9607-T.

ADJUSTMENTS.

WARNING : Cables should be adjusted each timethe gearbox, gear controls or power unit areremoved.

Inside the vehicle.- Remove the trim under the gear lever.- Lock the gear lever in neutral position, using tool [1].

Under the bonnet.- Remove the air filter assembly.- Unlock the ball-joint keys at «a».- Place the gear selection and control levers neutral.Lock the cable lengths with the ball-joint locking keys.

CHECKS.

- Remove the tool [1].- Check that all the gears engage without « tightness ».- Check that the gear lever moves identicallyforwards and backwards and to right and left. If itdoes not, repeat the adjustment.

- Refit the trim under the gear lever.- Refit the air filter assembly.

Adjusting the gear controls.

Engines : NFV - 6FZ - RFN - RFS - WJY - 8HZ – RHY - RHZ


B2CP3C6C B2CP3C0C

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AUTOMATIC GEARBOX - MB3Engine : KFW

SAXO

B2CP14ZP

Tightening torques m.daN.

- Gearbox to engine fixing 3.5- Converter to engine fixing 2.5- Converter closing plate fixing

M8 1.6M10 2.6

- Electrical bracket fixing 6.5- Flexible mounting to gearbox fixing 8.5- Speedometer drive 1- Heat exchanger fixing 5

NOTE : When fitting a new automatic gearbox, it isESSENTIAL that the heat exchanger and the oil bereplaced.

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RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - MB3)Engine : KFW

TowingThe front of the vehicle must be raised in order to be towed.If the front of the vehicle cannot be raised :- Add an extra 2 litres of oil to the automatic gearbox.- Do not exceed 30 kph over a distance of 50 km.- Gear lever in position «N».WARNING : Do not forget to remove the extra oil.

Driving.Never drive with the ignition switched off.Never push the vehicle to try to start it(impossible with an automatic gearbox).NOTE : The automatic gearbox is only lubricated when the engineis running.Wait until the vehicle is completely stationary before engaging thegear lever in position «P».

REMOVING - REFITTING. (Automatic gearbox).WARNING : Never place the gearbox on its lower casing(risk of deforming the tray and damaging the hydraulic valve block).

Driveshafts.ESSENTIAL : When moving the left driveshaft, ensure it remainshorizontal (risk of losing the tri-axe joint needles).

Initialising procedure.The gearbox should be initialised in the following cases :- Replacement of the ECU.- Clearing of faults.- Replacement of the potentiometer.- Replacement or adjustment of the accelerator cable.- Incorrect initialisation.NOTE : The initialisation procedure should be checked using adiagnostic tool.

PRECAUTIONS TO BE TAKEN

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PRE-REPAIR PROCEDUREOil qualityIf the gearbox has suffered a serious fault resulting in a malfunction or the destruction of a clutch, theoil will overheat and become contaminated with impurities :the oil is said to be «burnt».This is characterised by a black colour and the presence of an unpleasant smell.ESSENTIAL : The gearbox must be replaced.

Oil level (prior conditions)- Oil hot (80°C min.).- Foot on the brake, change through all the gears.- Vehicle on a level surface.- Selection lever in position «P».- Engine running.The level should be between the min. markings «A» and «B» on the dipstick.

ESSENTIAL : In no case should the oil level exceed the marking «B».Top up the automatic gearbox oil level (if necessary).

B2CP16WC

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PRE-REPAIR PROCEDURE (continued)

Negative pressure circuit.

- Check the negative pressure circuit.- Carry out the necessary repairs.

Checks using the diagnostic tool.

Preliminary checks :- The adjustment of the gear selection control.- The adjustment of the accelerator cable.Carry out the necessary operations

Reading the fault codesRead the fault codes.

Absence of fault codes

Measure the parameters.Anomalies present:- YES : Carry out the necessary repairs.- NO : Check (adjust the negative pressure capsule).

ESSENTIAL : Initialise the ECUPerform a road test.

Fault codes presentCarry out the necessary repairs.Clear the fault codes.

ESSENTIAL : Initialise the ECUPerform a road test.

SAXO

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SPECIAL FEATURES: AUTOMATIC GEARBOX - MB3

Engine : KFW

B2CP13TC B2CP34QCB2CP34PC

Hydraulic valve block.

Refitting.WARNING : On refitting the strainer, ensure that the bracket (6) runs under thewasher 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.

ESSENTIAL : Respect the position of the magnets in the lower casing. Cleanthe casing before placing the smooth side of the magnet against the sheetmetal.

Fitting the casing.WARNING : The fixing brackets (8) of the lower casing have a fitting direction(small side = lower casing side).

Tightening torque 0.6 m.daN.

SAXO

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MB3 AUTOMATIC GEARBOX CONTROLSEngine : KFW

B2CP352D

SAXO

304

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MB3 AUTOMATIC GEARBOX CONTROLS - CHECKS AND ADJUSTMENTS

Selection control Adjusting the selection control

- Turn forwards by 1/4 turn, remove the gear lever knob (2).Refitting the gear lever knob.- Press and hold down the locking button (3).- Fit the knob (2) on the lever until it touches its stop

(in the direction shown in the diagram).- Release the locking button (3).- Turn forwards by 1/4 turn.- Refit the screws (1).ESSENTIAL : Check the passage of all the gears, otherwise adjustthe selection control.

WARNING: No part must be forcedwhile performing these operations(careful removal).Removing the gear lever knob.- Remove the screws (1).- Lift the lever knob (2) by about 10mm.- Turn backwards by 1/4 turn, andraise by approximately 7mm.- Press and hold down the lockingbutton (3)

ESSENTIAL : Put the gearbox sidecontrol in the 1st imposed position;the 2 markings «a» must be aligned.

- Fit the ball joint (1).- Fit the lug (2).

- Lock the outer cable stop by 1/4 turn (in the direction of the arrow).- Check that the painted markings «b»are aligned.

B2CP18YC B2CP18WC B2CP18XC

SAXO

305

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AUTOMATIC GEARBOX - AL4

WARNING : This gearbox benefits from a special CITROEN semi-synthetic oilwhich cannot be mixed with any other oil.

The gearbox is lubricated for life.

(a) Part reference.

Engines : KFV - NFU - RFN - RHZ

B2CP30ZD


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RECOMMANDATIONS - PRECAUTIONS (BOITE DE VITESSES AUTOMATIQUE AL 4)Engines : KFV - NFU – RFN - RHZ

TowingThe front of the vehicle must be raised in order to be towed.If the front of the vehicle cannot be raised :

IMPERATIVE : - Put gear lever in position «N»..- Do not add any oil.- Do not exceed 50 kph over a distance of 50 km.

Driving.Never drive with the ignition switched off.Never push the vehicle to try to start it;(impossible with an automatic gearbox).

LubricationThe automatic gearbox is only lubricated when the engine is running.

REMOVING - REFITTING. (Automatic gearbox).

WARNING : Never place the gearbox on its lower casing(risk of deforming the tray and damaging the hydraulic valve block).Never use the connections as handles for raising, turning, holding orpushing the gearbox.

ESSENTIAL : - Fit the converter retaining peg while the gearbox is removed.- Fit the centring peg to locate the gearbox on the engine:(remove the converter retaining peg just before locating)

WARNING : With the safety programme selected, a snatching can befelt when changing from ‘‘P’’ � ‘‘R’’ or ‘‘N’’ � ‘‘R’’.

PRECAUTIONS TO BE TAKEN


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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 contaminatedwith impurities :the oil is said to be «burnt».This is characterised by a black colour and the presence of an unpleasant smell.

ESSENTIAL : The gearbox must be replaced.


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RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 )Engines : KFV - NFU - RFN - RHZAL4 gearbox only

AL4

B2CP31FD

PROCEDURE BEFORE REPAIRSOil level AL 4 (prior conditions).- Vehicle in horizontal position.- Check gearbox is not in back-up mode.- Remove the oil filler plug (3).- Add 0.5 litres extra oil into the gearbox.- Foot on the brake, change through all the gears.- Selection lever in position "P".- Engine running, at idle.- Oil temperature : 60°C (+8°C; -2°C), measured with the aid of a diagnostic tool.- Remove the oil level plug (3).- Thread of oil then "drip-drip": refit plug (3). Tighten 2.4 m.daN.- "Drip-drip" or nothing : refit the plug (3).- Stop the engine.- Add 0.5 litres extra oil into the gearbox.- Repeat the oil level procedure.NOTE : The level is correct at the moment the thread of oil becomes drip-drip.- Refit the oil filler plug (3). Tighten to 2.4 m.daN.- Initialise the oil usage counter (open the diagnostic tool procedure).NOTE : Dimension X : TU and EW engines = 81 mm DW engines = 77 mm.


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PROCEDURE BEFORE REPAIRS (continued)

When the ECU detects an erroneous or absent valueon input or output :

- It writes the fault in memory.- For each associated context, it writes the context of the oldest fault

in memory.- It initiates a back-up mode strategy.

There are two types of back-up modes :

- The ECU makes replacement values available (relating to comfort,gear selection quality, loss of functions).

- Access to emergency programme (only 3rd gear and reverse areavailable)

Reading the fault codes.Read the fault codes.

Absence of fault codes:Carry out a measure of parameters.

Presence of anomalies:

• YES : Carry out the necessary repairs

• NO : Read the fault codes – engine ECU

- Carry out a road test.

Following an initialisation of the ECU, for a certain period of timethere may be an inconsistent gear selection quality (while ECUparameters are adapting to the gearbox.To achieve a consistent standard, it will be necessary to carry out aroad test taking in frequent gear changes (auto-adaptive laws).


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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.Before commencing the downloading, take the value of the oil usage counter present in the automatic gearbox ECU.

After the downloading operation, carry out the following: A clearing of faults.A pedal initialisation.An initialisation of the auto-adaptives.A recording of the value of the oil usage counter previously read.A road test.

ESSENTIAL : Every update of the automatic gearbox ECU should be accompanied by an update of the engine ECU.

Updating the value of the oil usage counter.

Using LEXIA or ELIT.Access to reading and recording of the oil counter is via the menu :«Oil counter ».Adjustment of the oil counter value is done by entering directly the5 figures of the oil counter.

Using PROXIAAccess to reading and recording of the oil counter is via the menu :«Configuration (integrated circuit button) / Oil counter ».Adjustment of the oil counter value is done in incremental steps of2750 units.

ECU : Downloading


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Engines : KFV - NFU - RFN - RHZ

ECU : Configuration, Initialisation (pedal) (continued)Downloading.

ECU downloading procedure :- Follow the diagnostic tooling procedure.

A new ECU or downloaded update is always configured with the following options :- SHIFT LOCK gear selection lever position.- OBD outlet (emission standard L4).

If the ECU is to be fitted to a vehicle without one or bothof these options:- Carry out a configuration which inhibits the diagnosis of the option(s) concerned.

Pedal initialisation.

A pedal initialisation must be carried out in the following cases :

- Replacement of the automatic gearbox ECU.

- Replacement of the automatic gearbox.

- Downloading of the ECU configuration.

- Adjustment or replacement of the accelerator cable.

- Replacement of the throttle potentiometer.

RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 )

IMPERATIVE : For a certain period of time, while the ECU parameters are adapted to the gearbox, there may be an inconsistentgear selection quality. To achieve a consistent standard, it will be necessary to carry out a road test taking in frequent gear changes(auto-adaptive laws).


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C3 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.- Move the gear selection lever out of position «P».Unlocking the «SHIFT LOCK». (With an operating fault).NOTE : It is impossible to unlock the «shift lock» with the «Normal operation» method.The fault may originate from one of the following components: - «Shift lock».- Gear lever position switch.- Automatic gearbox ECU.- Electrical harness.- Battery voltage.Remove: - The gear lever knob (1) (Pull upwards).- The cover (2) (Unclip).- The top of the central console (3).- Unlock the «shift lock» (4) with the aid of a screwdriver.- Move the gear selection lever out of position «P».

B2CP3GZC

C5FP0ETC

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RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 )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.- Press and hold down the brake pedal.- Using the selection lever, disengage from position «P».

Unlocking the SHIFT LOCK (In the event of a malfunction)

- Remove the cover (1).- Unlock the shift lock (2) using a screwdriver.

NOTE : It is IMPERATIVE to disengage the gear selection lever from position "P" the minuteyou start applying the brake pedal. Otherwise, release pressure on the brake pedal and then try again.

B2CP268C B2CP269C


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DRIVESHAFTS - GEARBOXTightening torques (m.daN)

Driveshaftbearing

EnginesVehicles Gearbox RH side LH side Tool kit

Gearbox oil seal mandrels

24.5 ± 0.5

32 ± 1.5

24.5 ± 0.5

32.5 ± 2.5

7114-T.W

4101-T.E1 +4601-T.E2

Seal extractorRH / LH

(-) 0338 C(-) 0338 J1

+ (-) 0338 J2(-) 0338 H1

+(-) 0338 H2

(-) 0338 J1+ (-) 0338 J2

(-) 0338 H1+(-) 0338 H2

(-) 0338

7114-T.X 7116-T

Driveshaftnut

HFX-KFW-NFT-NFX-VJX

HFX-KFV-8HX-8HW

NFU

KFW-NFU

NFV-RFS-RFN-6FZ-WJY-8HZ -RHY-RHZ

8HV-8HY

KFW

NFU-RFN-RHZ

KFV

MA/5

XSARAXSARA PICASSO

SAXO

C3

XSARA

NONE

2 ± 0.2

1.8 ± 0.1

2 ± 0.2

1.8 ± 0.1

1 ± 0.1

NONE 4601-T

C3

SAXO

XSARAXSARA PICASSO

C3

Tightening torque (m.da.N) for wheel bolts : SAXO – XSARA = 8.5 C3= 9

BE4/5

MB3

AL 4

SAXO - C3 - XSARA - XSARA PICASSO

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315

SAXO - All TypesAXLE GEOMETRY

The values L1 and L2 are given in the table below.

Geometry of the axles at reference height.

Rear heightFront height

H1 = Distance between the ground andthe mounting face of the fixings.R1 = Distance between the centre ofthe front wheel and the ground.L1 = Distance between the centre of thefront wheel and the mounting face ofthe fixings.

H2 = Distance between the ground andthe mounting face of the rear cross-member.R2 = Distance between the centre ofthe rear wheel and the ground.L2 = Distance between the centre of therear wheel and the rear crossmember.

C4CP0N2C

H1 = R1 – L1 H2 = R2 + L2

Normal suspension Raised suspension

Rear axle Front axle Rear axleFront axle

L1Dimension L2 L1 L271 ± 10 mmValue (mm) 53 ± 6 mm 36 ± 10 mm 82 ± 6 mm

Measure the dimension R1. Calculate the dimension H1 = R1 – L1.Measure the dimension R2. Calculate the dimension H2 = R2 + L2.Compress the suspension until the calculated values «H1» and «H2» are obtained.NOTE : The difference in height between the two sides at the rear should be less than 7.5 mm.

C4CP0N3C

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316

SAXO - All Types AXLE GEOMETRYGeometry of the axles at reference height.


Reminder : Measuring the rear heightH2 = Distance between the ground and the rear crossmember

Reminder : Measuring the front heightH1 = Distance between the ground and the mounting face of the fixings

The front heights H1 are measured between the ground and the moun-ting face of the arm fixings (1) at the point «a».

The rear heights H2 are measured between the ground and the mountingface of the rear crossmember (2) at «b» and «c».

A > B = Negative figure: – = TOE-OUTA < B = Positive figure : + = TOE-IN

WARNING

B3BP07UC B3BP07VD

B3CP02UC

Rear Rear

317

SAXO - All TypesAXLE GEOMETRYGeometry of the axles at reference height.

Normal suspension

Front Front

HFX(*)

Steering Manual Manual Assisted Manual Manual Assisted

Tracking O° -0°10’to 0°31’ -0°10’to 0°31’ -0°16’to -1°6’ -0°10’to 0°31’ -0°10’to 0°31’ -0°16’to -1°6’Toe-in mm -1 to -3 +1 to +3 +1.49 to +6.39 -1 to -3 +1 to +3 +1.49 to +6.39

Camber - 0°9’ ± 30’ - 0°40’ ± 30’ - 1°35 ’± 30’ - 0°9’ ± 30’ - 0°40’ ± 30’ - 1°35 ’± 30

Castor 2°13’± 30’ 3°14’± 30’ 2°13’± 30’3° 3°14’± 30’

Pivot angle 12°± 41’± 40’ 12°42’± 40’ 12°± 41’± 40’ 12°42’± 40’

HFX (**)KFW - NFTNFX - VJX

All TypesHFX(*)

HFX (**)KFW - NFTNFX - VJX

All Types

Raised suspension

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(*) = Without assisted steering option and ABS. (**) = With assisted steering and ABS options.

WARNING : For the vehicle to be at reference height, compress the suspension untilthe calculated values «H1» and «H2» are obtained.

Engines

318

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Suspension – Front anti-roll bar

FRONT AXLEAnti-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 ± 0.2(4) Anti-roll bar bearing fixing on the lower arm 2.2 ± 0.2(5) Suspension leg upper fixing 2.1 ± 0.2(6) Lower ball-joint fixing screw 3.8 ± 0.4(7) Anti-roll bar link rod fixing 7 ± 0.6(8) Suspension arm rear fixing nut 4.2 ± 0.4(9) Suspension arm front fixing 8.5 ± 0.8

Ø Anti-roll bar None 21 19 18 22 21 19

HFX (1)KFW VJX NFT

Raised suspensionHFX

HFX (3)KFW (3)NFX (3)

FranceAdministration

ExportHFX (2)

(1) = With airbag. (2) = Without option. (3) = VTS level.

B3CP02SD

SAXO - All Types

319

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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.


(3) Damper upper fixing screw 10 ± 1(4) Damper lower fixing screw 10 ± 1(6) Stub nut 20 ± 1(8) Rear axle fixing bolt 8.7 ± 1

B3DP02ND

320

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Antiroll bar

Torsion bar

REAR AXLE - SUSPENSION

HFX (1) (2) – KFW (2)NFX - VJX (1)

19Torsion bar Ø (mm)

Colour reference LH : 2 rings

Torsion bar RH : 1 ring

(1) = Entreprise. (2) = VTS trim level (3) = With raised suspension

Raised suspension

17.9 18.3

Black White Green

HFX - KFWNFX - VJX

HFX-VJX (3)

HFX

Ø Anti-roll bar(mm)

None 18 22 18 15

HFX (2)-KFW

NFX-VJXHFX (3)-KFW (3)

NFX (3) France Export

(1) = With airbag. (2) = With airbag or assisted steering or ABS. (3) = VTS trim level.

SAXO - All Types

321

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STEERING SPECIFICATIONSManual steering

Power-assisted steering

Tyres 155/70 R13

6

28

7280

WhiteBlack

165/70 R13 165/65 R14

7

28

68

Pinion (no. of teeth)

Rack (no. of teeth)

Rack travel

Stop (colour)

NOTA : The steering assembly is secured to the bulkhead.

Length of the steering track rods(between the centre lines of the ball-joints).Pre-adjustment = 520 mm.

Tyres 165/70 R13 165/70 R14 185/55 R14

Pinion (no. of teeth)

Rack (no. of teeth)

Rack travel

Stop (colour)

SAXO - All Types

322

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MANUAL STEERINGSAXO - All Types

1 - Airbag2 - Airbag fixing to steering wheel 0.83 - Steering wheel fixing 34 - Steering column fixing 2.35 - Steering cardan joint fixing 2.36 - Fixing to bulkhead 2.2

7 - Pivot ball-joint nut 3.58 - Lock nut M14 4.58 - Lock nut M16 59 - Track rod articulation 2.110 - Splined coupling fixing to steering rack 2.4

Tightening torques (m.daN)

B3EP09TD

B3EP02UD

B3EP09SC

323

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SAXO - All TypesPOWER-ASSISTED STEERING


1 - Airbag2 - Airbag fixing to steering wheel 0.83 - Steering wheel fixing 34 - Steering column fixing 2.35 - Steering cardan joint fixing 2.36 - Fixing to bulkhead 2.27 - Pivot ball-joint nut 3.58 - Track rod lock nut M14 4.5

8 - Track rod lock nut M16 59 - Track rod articulation 2.110 - Splined coupling fixing to steering rack 2.411 - Steering ram to splined coupling 812 - Steering ram to casing 813 - Nut fixing the pinion to the bearing 1.514 - Valve/casing fixing 0.7

B3EP02WDB3EP02TD

324

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WARNING : Saxo all types except diesel without aircon

POWER-ASSISTED STEERING (continued)SAXO - All Types

Power steering system

1 - Power steering2 - Oil dispensing valve3 - Power-assisted steering ram4 - Low pressure pipe5 - High pressure pipe6 - Upper reservoir7 - Power steering electro-pump unit and built-in

lower reservoir8 - Flexible mounting9 - Electro-pump unit bracket

Tightening torque (m.daN).

Pump support fixing 2Pump fixing to support 2High pressure pumpElectro-pump connection 2Power steering valve connection 2,5Low pressure pumpElectro-pump connection 2,5Power steering valve connection 2,5

B3EP09UDNote : Fluid type TOTAL Fluide ATX capacity : 0.950 L.

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POWER-ASSISTED STEERING (continued)Power steering system

WARNING : Saxo diesel with aircon

SAXO - All Types

Description.

Note : The power steering system on vehicles without aircon is suppliedby a mechanical pump driven by the accessories drive belt.

(6) Power steering mechanism.(7) Upper reservoir.(8) Lower reservoir.(9) Radiator.(10) Power steering pump.(11) The grooves on the connector (6) indicate that the pump (5) isconstant flow.

Max. pressure : 80 Bars.Pulley diameter : 112 mm.Fluid quality : TOTAL Fluide ATXCapacity : 1.55 litres.

B3EP12XD

326

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AXLE GEOMETRYConditions for checking and adjusting

Vehicle heights at reference height


L2L1

Tyres inflated to correct pressures.Vehicle at reference height.Steering rack locked at mid point (See corresponding operation).

H1 = R1 - L1

H1 = Measurement between the measuring zone underneath the frontsubframe and the ground.R1 = Front wheel radius under load.L1 = Distance between the wheel axis and the measuring zone under-neath the front subframe.

H2 = R2 + L2

H2 = Measurement between the measuring zone underneath the rear silland the ground.R2 =Rear wheel radius under load.L2 = Distance between the wheel axis and the measuring zone under-neath the rear sill.

E1AP09MD

C3

327

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AXLE GEOMETRY

Measure the radius of the front wheel R1 - Calculate dimension H1 = R1 – L1

Z1 =Measuring zone underneath the front subframe.

[1] Gauge for measuring the wheel radius, 4 bolts, tool 8006-TMeasuring rear heightMeasuring front height

Z2 = Measuring zone underneath the rear sill.

Measure the radius of the rear wheel R2 - Calculate dimension H2 = R2 + L2

(*) = CRD : Difficult road conditions.Definition for a type of vehicle whose axles and suspensions are adapted for driving on rough roads.Compress the suspension to obtain the calculated values.The height difference between the two axle dimensions should be less than 10 mm.

Value at referenceheight

(+ 6 - 8 mm)

All Types(except CRD) (*)

CRD vehicles (*) All Types(except CRD) (*)

CRD vehicles (*)

L1 = 142.5 mm L1 = 132.5 mm

Value at referenceheight

(+ 10 - 6 mm)L2= 52 mm L2= 62 mm

B3CP07SD

C3

328

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A < B = Positive figure: + = TOE-IN

A > B = Negative figure: - = TOE-OUT

NOTE

AXLE GEOMETRYRear axleFront axle

Dissymmetry of lower camber at 0° 18.Dissymmetry of lower castor at 0° 30’.Dissymmetry of lower camber at 0° 18’.Distribute symmetrically, LH / RH wheel, the total tracking value.

All types (except CRD)

CRD vehicles

Vehicle TrackingCastor Camber Pivot angle

(± 0°18’) (± 0°30’) (± 0°30’)

Adjustable Non adjustable

- 2 ± 1- 0° 19’±0°10’ 3°57’ - 0°28’ 11°24’

Vehicle Tracking Castor Camber Pivot angle (± 0°30’)

Adjustable Non adjustable

- 2 ± 1- 0° 19’±0°10’ 3°53’ - 0°26’ 11°14’

Tracking Camber (± 0°30’)

Non adjustable

+ 5.5 ± 1+ 0°50’ ± 0°10’ - 1°30’

Tracking Camber

Non adjustable

+ 5.2 ± 1+ 0°47’ ± 0°10’ -1°28’

AllTypes

mm

0°

AllTypes

mm

0°

B3CP02UC

C3

(±0°18’) (±0°30’)

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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 ± 0,3(6) Anti-roll bar bearing fixing on subframe : 8 ± 0,8(7) Hub nut : 24,5 ± 0,5(8) Wheel bolt : 9 ± 1(9) Subframe to bodyshell fixing screw : 10 ± 1(10) Anti-roll bar(11) Pivot lower ball-joint fixing on lower arm : 5,5 ± 0,5(12) Pivot lower ball-joint fixing : 4 ± 0,4(13) Lower arm front and rear mounting fixing : 14 ± 0,4(14) Stabiliser bar screw : 6,6 ± 0,7 (15) Steering ball-joint fixing : 3,5 ± 0,3

Anti-roll bar

Diameter (mm) Colour

B3CP07HP

HFX- KFV- NFU8HX-8HW8HV-8HY

19 Blue

C3

330

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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 ± 0,5(7) Rear suspension arm : (8) Stub axle bearing nut : 20 ± 2 greased(9) Damper : (10) Damper upper fixing : 4,5 ± 0,4(11) Damper lower fixing : 9,3 ± 1(12) Suspension spring : (13) Suspension arm fixing on rear axle crossmembe : 13 ± 1,3(14) Secondary brake cable guide and support assembly : (15) Travel stop :

Anti-roll bar

Diameter (mm)

B3DP09GP

HFX- KFV- NFU8HX-8HW8HV-8HY

25.5 (tubular)

C3

331

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SUSPENSIONFront 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 ± 0,3(6) Anti-roll bar bearing fixing on subframe : 8 ± 0,8(7) Hub nut : 24,5 ± 0,5(8) Wheel bolt : 9 ± 1(9) Subframe to bodyshell fixing screw : 10 ± 1(10) Anti-roll bar : (11) Pivot lower ball-joint fixing on lower arm : 5,5 ± 0,5(12) Pivot lower ball-joint fixing : 4 ± 0,4(13) Lower arm front and rear mounting fixing : 14 ± 0,4(14) Stabiliser bar screw : 6,6 ± 0,7(15) Steering ball-joint fixing : 3,5 ± 0,3

Anti-roll barEngines Diameter (mm) ColourAll Types 19 Bue

PivotEngines Diameter of bearing TypeAll Types 72 U (Cast-iron)

DamperEngines Damping lawAll Types R 59 MB3CP07RP

C3

332

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SUSPENSIONFront 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.

(24) Travel stop.

B3BP180D

C3

333

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SUSPENSIONRear 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).(33) Damper : (34) Damper upper fixing screw : 4,2 ± 0,4(35) Damper lower fixing screw : 10,6 ± 1(36) Suspension spring : (37) Travel stop : (38) Secondary brake cable guide support :

Anti-roll barEngines Diameter (mm)All Types 25.5 (Tubular)

DamperEngines

1.4i (Auto.) - 1.6i 16V1.4 HDi 16V

F168K

1.1i-1.4i (BVM)-1.4 HDi F77DF77B (*)

(*) = For CRD vehicleB3DP09UP

C3

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FEATURES OF ELECTRIC POWER STEERINGEngines : HFX - KFV - NFU - 8HX - 8HW - 8HY

Steering column


(1) Steering wheel fixing : 2 ± 0.3

(2) Steering column fixing on support : 2.2 ± 0.5

(3) Steering cardan fixing : 2.2 ± 0.2

Identification

Identified by the colour of the ring at "a".

Left hand drive : BLUE ring

Right hand drive : WHITE ring.

B3EP13GD B3EP13HC

C3

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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(11) Fixing of mechanism on subframe : 8 ± 0,8

Connectors.

(6) Supply of electric assistance motor.

(7) Torque sensor signals..

HFX - KFV - 8HX - 8HWKFV (Auto.)

NFU - 8HY - 8HV

Electric motor 60 A 65 ASteering rack travel 2x72 2x64Steering ratio 45.6/1

Number of rotations ofsteering wheel

3.2 2.8

Inner angle of lock 38° 32°30’Outer angle of lock 32°24’ 28°42’

B3EP13JD

C3

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Steering assistance

Supplier: KOYO.

The steering assistance is provided by the assistance motor (12), control-led by the ECU.

Power delivered to the assistance motor (12) depends on:

- Speed of the vehicle.

- Torque applied on the steering wheel.

Electric power-assisted steering ECU.

Only one ECU version, whatever the engine-type.The electric power steering ECU is linked to the following connectors: - (6) Assistance motor supply.- (13) Electric power steering ECU supply.- (14) Control signals.After changing the electric power steering ECU, it is necessary toperform a configuration. (See corresponding operation).

B3EP13KC B3EP13LC

C3

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SPECIAL FEATURES : STEERINGEngines : 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).- Clip (2).

Release the steering rack protection gaiter.

SettingMove the steering to full left hand lock.Measure the dimension X.Move the steering to full right hand lock.Measure the dimension Y.

Calculate the dimension: L = (Y – X) : 2.

Refit: - The steering rack protection gaiter- New clips (1) and (2).

B3EP13UC

B3EP13VD

C3

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C3 AXLE GEOMETRYFront and rear measuring points

XSARA ALL TYPES RPO 8667 #XSARA ALL TYPES # RPO 8666

Rear heightFront height Rear heightFront height

H1 = Dimension between the centre of the front suspension arm mounting and the ground.H2 = Dimension between the contact face of the rear mounting and the ground.R1 = Front wheel radius under load.R2 = Rear wheel radius under load.L1 = Distance between the centre of the wheel and the centre of the front suspension arm mounting.L2 = Distance between the centre of the wheel and the contact face of the rear mounting on the bodyshell.

B3CP046D B3CP06ZD

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Front axle Rear axle

AXLE GEOMETRYReference heights

: 8006-T # N°RPO 9428

: 4300-T N°RPO 9429 # Tools [1] Gauge for measuring the radius of wheels with 4 bolts

Setting the reference height.

RearFront

Measure the dimension «R1».

Calculate the dim. H1 = R1 - L1.

Measure the dimension «R2».

Calculate the dim. H2 = R2 + L2.

Compress the suspension until the values (H1) and (H2) are obtained.NOTE : The difference in height between the two sides should be less than10 mm.

XSARA - All Types

Reference heights(in mm)

115.5 90.5 75.5 73 83 88 103

Engines2.0i 16V(RFS)

All engines(except 2.0i 16V

and CRD)

All CRDengines

2.0i 16V(RFS)

All saloons(except 2.0i 16V

and CRD)Estate All CRD

engines

B3CP04AD

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ESSENTIAL : When checking the suspensions, the vehicle should be at reference height.

XSARA - All Types AXLE GEOMETRYValues of the front and rear suspensions, 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 : 9511-T.B[3] Set of four shackles : 9511T.C

A > B = Negative figure: – = TOE-OUTA < B = Positive figure: + = TOE-IN

WARNING

B3CP04LC

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AXLE GEOMETRY XSARAValues of the front and rear suspensions, at reference height

Front axle

Adjustable

YES

NOPivot angleCamber

Castor

Tracking

Camber

(*) CRD = Difficult road conditions.

Tracking

Tolerances

± 30’± 30’± 18’

± 1 mm - 1.5 ± 1 mm

- 0°15’ ± 10’ (ouverture)

3° 2°55’ 3° ± 07’ 2°55’10°22’ 11° ± 07’ 10°26’0°12’ - 0° ± 07’ 0°07’

10°40’0°

Saloon orentreprise KFW

Saloon all enginetypes except KFWEstate all engine

types exceptCRD (*)

Rear axle

YES

NO

Saloon CRD (*)KFW 2.0i 16V (RFS)

Saloon CRD (*) all engine types

except KFWEstate CRD (*)

all engine types

AdjustableTolerancesSaloon all engine

typesSaloon entreprise

2.0i 16V (RFS) Estate all engine types

Saloon CRD (*) all engine types Estate CRD (*)

all engine types

10°44’

± 1.3 mm

± 15’

4.54 ± 1.3 mm 5.1 ± 1.3 mm 4.27 ± 1.3 mm 3.45 ± 1.3 mm0° 41’ ± 11’ 0° 46’ ± 11’ 0° 39’ ± 11’ 0° 31’ ± 10’

- 0°57’ - 0°58’ - 0°59’

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XSARA - All Types AXLE GEOMETRY

a = Angle which defines the tracking between the front and rear axles.

Its value must not exceed 12'.

B3CP04UC

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XSARA - All TypesFRONT AXLE


(1) Damper nut(2) Cup screw (3) Suspension leg(4) Anti-roll bar link rod upper ball-joint(5) Suspension leg pivot (hollow pivot)(5) Suspension leg pivot (pivot «H»)(6) Anti-roll bars(7) Anti-roll bar link rod lower ball-joint(8) Pivot lower ball-joint(9) Driveshaft nut(10) Wheel bolt(11) Lower arm front mounting(12) Lower arm rear mounting and anti-roll

bar bearing(13) Screw under rear mounting(14) Ball-joint fixing on lower armSubframe to bodyshell fixing screw

4.5 ± 0.42.5 ± 0.3

3.7 ± 0.34.5 ± 0.55.5 ± 0.5

3.7 ± 0.34 ± 0.432.5 ±2.59 ± 17.6 ± 0.76.8 ± 0.6

3.1 ± 0.35± 0.58.5 ± 0.8

B3CP040P B3CP041D

Vehicles RPO 8667 # are all equipped

as standard with ventilated discs.

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FRONT AXLEEvolution : Suspension arm ball-joint

XSARA - All Types

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 oldvehicle.

Replacement Parts.The old components are still available from Replacement Parts.

B3CP054D

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FRONT AXLE

Anti-roll bars

DiameterEngines

1.6i-1.6i 16V-1.9D2.0i 16V (RFV)-1.4 HDi -2.0 HDi

19 Blue

20

21

Yellow

White2.0i 16V (RFS)

Colour reference

XSARA - All Types

Saloon

Estate

Saloon

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FRONT AXLEXSARA - All Types

B3CP042D

Lug "a" to the rear. Lug "a" to the front.

XSARA # 07/1999 XSARA 07/1999 # 09/2000 XSARA 07/1999 # 09/2000

The angle of castor changes to 3° exceptfor LPG vehicles, CRD vehicles, and EstatesAll Types.CRD = Difficult Road Conditions : this type ofvehicle has axles and suspensions designed fordriving on rough road surfaces.

Pivot ball-jointManual steering, groove at "b".Power-assisted steering, groove at "b".

NOTE : Vehicles after 09/2000 # are all equipped as standard with ball-joints without the grooveat "b".

B3CP049C B3CP043D

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XSARA - All TypesREAR AXLE

Tightening torques (m.daN)*

(1) Anti-roll bar lever 3.2 ± 0.3

(2) Anti-roll bar

(3) Transversal torsion bars

(4) Rear crossmember flanges 8.3 ± 0.8

(5) Front silentblocks 5.5 ± 0.5

(6) Rear silentblocks 4.5 ± 0.4

(7) Anti-vibration clamp.

(8) Damper pin 9.6 ± 0.9

(9) Stub axle nuts (lubricated) 18.5 ± 1

Note

- The RH torsion bar is identified by 1 paint line.

- The LH torsion bar is identified by 2 paint lines.

B3DP04SP

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REAR AXLEXSARA - All Types

Vehicles

Engines Diameter Colour reference Diameter Colour reference

Torsion bars (mm) Anti-roll bars (mm)

3-door Entreprise 19.3 Violet 19 Orange

3- and 5-door TT exc.Entreprise

Estates All types

18.7

20 Grey 20 Green

3- and 5-door TT 19.3 Violet 19 Orange

Estates All types 20 Grey 20 Green

3-door VTS

3- and 5-door TT

Estates All types

21 Light green 23

19.3 Violet 19

20 Grey 20

Without colour,or white sticker

Yellow 18 Blue19.D

1.6i 16V-2.i 16V1.4 Hdi-2.0 HDi

2.0i 16V

Grand Export«GRD»

Orange

Green

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XSARAEvolution : Rear hub nut

Old # 15/12/1999 New 15/12/1999 #

REAR AXLE

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.ESSENTIAL : Tighten to : 25 ± 2,5 m.daN (greased)

NOTE : It is possible to have both types of fitting on the same axle.The old nut (1) requires the fitting of the thrust washer (2).WARNING : do not fit a thrust washer (2) with a new nut (3).ESSENTIAL: Respect the tightening torque to be appliedwhen fitting.WARNING: Identify the type of fitting, before starting a repair.

B3DP08AD

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XSARA - All Types REAR AXLE

- The front silentblocks are aligned at an angle of 45° in relation to the vehicle’s axis.- The rear silentblocks are in parallel with the vehicle’s axis.NOTE : There are two suppliers for the silentblocks: - RBT, identified by a Green or Yellow painted dot on the side of the mounting.- PAULSTRA, identified by a Black painted dot on the side of the mounting.It is FORBIDDEN to swap components of different suppliers.

Operating clearance - X = 1 to 1.4 mm.

NOTE : The RH torsion bar can be identified by1 paint line.The LH torsion bar can be identified by 2 paintlines

B3DP04UDB3DP04TC

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Adjusting the rear dummy damper

Lengths of the rear dummy damper (mm)

Grand export

346

339

346

342

Normal driving

339

318

336

XSARA - All TypesREAR DAMPER

E5AP14WC

Engines

1.9 D

1.6i 16V 3-door

1.6i 16V 5-door2.0i 16V (RFN)

1.4 HDi -2.0 HDi

2.0i 16V (RFS)

Estates andEntreprise all types

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XSARA - All Types

Steering wheel - Manual steering

MANUAL STEERING SPECIFICATIONS

- (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.


- (2) AIRBAG to steering wheel fixing : 0.8- (3) Steering wheel fixing : 3.3- (5) Steering column to support fixing : 2.3- (6) Steering cardan joint fixing : 2.3

- (b) = Locating bush.

The locating bush must be centred in the reference windowbefore tightening the cardan bolts (6).

B3EP08PD

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XSARA - All TypesMANUAL STEERING SPECIFICATIONS

Manual steering


(7) Pivot ball-joint nut : 4

(8) Link rod lock nut : 4.5

(9) Ball-joint on steering rack : 6

(10) Fixing on cradle : 5

(11) Plunger flange screw : 1.2

B3EP042D

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22/1

Steering ratio

MANUAL STEERING SPECIFICATIONSXSARA - All Types

Manual steering (continued)

Number of teeth

Pinion

Steering racktravel(mm)

73.56 teeth

(RH helix)29

(13)

Yellow thickness mm4.3L.H.D.

Steering rack

Steering stopcolour code

Number ofsteering wheel

turns

- Length of the steering track rods (Pre-adjustment) = 371 mm (Between ball-joint centres) or391 mm (Between the centre of the pivot ball-joint and the contact face of the steering rack ball-joint).

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XSARA - All TypesPOWER-ASSISTED STEERING SPECIFICATIONSSteering 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.


- (2) AIRBAG to steering wheel fixing : 0.8- (3) Steering wheel fixing : 3.3- (5) Steering column to support fixing : 2.3- (6) Steering cardan joint fixing : 2.3

- (b) = Locating bush.

The locating bush must be centred in the reference window before tightening the cardan bolts (6).

B3EP08QD

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POWER-ASSISTED STEERING SPECIFICATIONSPower-assisted steering

XSARA - All Types


(7) Pivot ball-joint nut : 4

(8) Link rod lock nut : 4.5

(9) Ball-joint on steering rack : 6

(10) Fixing on subframe : 5

(11) Hydraulic pipe connection : 2.5

(12) Valve to housing fixing : 1.2

(13) Plunger flange screw : 1.2

(14) Screw fixing the steering ram to the housing : 5.5

(15) Nut fixing the steering ram to the yoke : 5.5

B3EP08RD

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POWER-ASSISTED STEERING SPECIFICATIONS XSARA - All TypesPower-assisted steering (continued)

Number of teeth

Pinion

Steering racktravel(mm)

71.7(*)

(RH helix)

28

Protector colourVehicles

BLACKAll types (except 1.8i 16V - 1.9TD) 7

Steering valve

Number of teeth (*)

3.3L.H.D.

Steering rack

Number ofsteering wheel

turns

- Length of the steering link rods (Pre-adjustment) = 371 mm (Between ball-joint centres) or391 mm (Between the centre of the pivot ball-joint and the contact face of the steering rack ball-joint).

1.8 i 16V - 1.9 TD ORANGE 8

18.8/1

Steering ratio

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POWER-ASSISTED STEERING SPECIFICATIONSXSARA - All TypesPower-assisted steering assembly


High pressure tube (Rubber seal pump side)- Power-assisted valve and pump union : 2.5

Return pipe.- Power-assisted valve union : 2.5- (16) Upper front fixing (E3) : 2.5- (17) Upper rear fixing (E3) : 2.2- (18) Fixing (E3) : 2.2

Tightening sequence.

-Tighten screws (16) and (18).-Lightly tighten screw (17), then fully tighten.

Pressure switch on the pressure circuit.

- Switch opens 30 to 35 Bars.- Switch closes 25 Bars.- Tighten to : 2 m.daN.

Power-assisted steering system capacity = 1 litre.Oil type: TOTAL FLUIDE ATX.SAGINAW Pump adjustment = 100 Bars ± 5.Pump shaft threading 3/8 - 16 threads per inch.

B3EP045D

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H1 = R1 – L1 H1’ = R1 – L1’

H1 = From the front suspension arm linkage bolt axis to the ground.R1 =Radius of the front wheel when laden.L1 = From the centre of the wheel to the front suspension arm linkagebolt axis.H1’ = From the front jacking point to the ground.L1’ = From the front jacking point to the radius of the front wheel when laden.

H2 = R2 - L2

H2 = From the rear axle silentblock face to the ground.R2 = Radius of the rear wheel when laden.L2 = From the centre of the wheel to the rear axle silentblock face.

AXLE GEOMETRYMeasurements 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


B3CP05BC B3CP058D B3DP079C


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CRD vehicles (Difficult Road Conditions)

AXLE GEOMETRY

Compress the suspension to obtain the calculated values. The difference in height between the two sides should be less than 10 mm.

Measure the radius of the rear wheel: R2.Calculate dimension H2.

Measure the radius of the front wheel : R1.Calculate dimension H1 or H1’.

Measurements at reference height (continued). (The reference height of the vehicle is set as per the table below).

B3CP05BC B3CP05AC



Front axle

H1 = R1 – L1 ou H1’ = R1 – L1’

Rear axle

H2 = R2 + L2

6FZ - RHZ

H1 = R1 – L1 or H1’ = R1 – L1’

Vehicles all typesL1 = 90.5mm L1’ = 124 mm H2 = R2 + 8.5 mm

H2 = R2 + L2

10975.5L1’L1

23.5

L2

B3DP079C

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A > B = Negative figure: – = TOE-OUT


WARNING

AXLE GEOMETRYMeasurements at reference height (continued). Compress the suspension to obtain the calculated values.

Vehicle All Types


Vehicle Tracking Castor Pivot angle Camber Tracking Camber

Adjustable Yes No

All Types0 ± 1mm 4.8 mm ± 1mm

- 0°09’ à +0°09’3° ± 18’ 10° 43’ ± 30’’ 0° ± 30’

- 0° 43’ ± 0° 09’- 1°13’ ± 18’

Vehicle All Types CRD (Condition de route difficile)


Vehicle Tracking Castor Pivot angle Camber Tracking Camber

Adjustable Yes No

All Types- 1 ± 1mm 3.8 mm ± 1mm

- 0°18’ à 0°0’2°56’ ± 18’ 10°25’ ± 30’ 0°07’ ± 30’

- 0°34’ ± 0° 09’- 1°14’ ± 18’

NOTE : When checking axles, the vehicle should be at reference height.(*) = Fuel tank full.


All Types

Unladen (*) 150 mm (Minimum value)

Ground clearance

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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 ± 0.4.(6) Anti-roll bar.(7) Anti-roll bar link rod ball-joint : 4 ± 0.4.(8) Lower swivel ball-joint : 4 ± 0.4.(9) Hub nut : 32.5 ± 2 (greased).(10) Wheel bolts : 9 ± 1

(Face and threads not greased).(11) Lower arm front pivot : 8 ± 0.8.(12) Lower arm rear pivot and

anti-roll bar bearing : 6.5 ± 0.6.(13) Screw under rear pivot : 3.5 ± 0.3.Fixing bolt : subframe on bodyshell: 8.5 ± 0.8.

Anti-roll bar

Engine

NFV-6FZRFN-RHY

Diameter

21

Colour ref.

WHITEDamper upper bracket :Lug «a» to the front.B3CP056P B3CP057D B3CP043D


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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 ± 0.4.(20) Rear upper arm.(21) Wheel bolt : 9 ± 1.(Face and threads not lubricated) (22) Damper(23) Rear silentblock on subframe : 5.5 ± 0.5.(24) Damper pin nut : 11 ± 1.(25) Stub axle nuts (lubricated) : 25 ± 2.(26) Rear silentblock on bodyshell : 5.5 ± 0.5.

Anti-roll barTorsion bar

Engine

NFV-6FZRFN-RHY

19.6 PINK

Ø (mm) Colourmark

Ø (mm)

21

Colourmark

ORANGE

B3DP078D

NOTE : - The RH torsion bar can be identified by 1 paint line.- The LH torsion bar can be identified by 2 paint lines.


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REAR AXLE

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.

ESSENTIAL : Tighten to : 25 ± 2,5 m.daN.

NOTE : It is possible to have both types of fitting on the same axle.

The old nut (1) requires the fitting of the thrust washer (2).

WARNING : do not fit a thrust washer (2) with a new nut (3).

ESSENTIAL: Respect the tightening torque to be applied when fitting.

WARNING : Identify the type of fitting, before starting a repair.B3DP08AD

Evolution : Rear hub nut

Old # 15/12/1999. New 15/12/1999 #


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GEngine NFV - 6FZ - RHYL2 51 mm

Vehicles all types (except CRD)

Front

SUSPENSIONHeight 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.- Steering rack locked straight ahead : point zero (see corresponding

operation).

Rear

H1 = R1 – L1 ou H1’ = R1 – L1’

Engine NFV - 6FZ RHYL1 62.5 66.5 mmL1’ 96 100 mm

H2 = R2 – L2

B3CP058D

XSARA PICASSO - All

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SUSPENSIONMeasurements at the front and rear axles, vehicle in running order

Vehicles all types (except CRD)

Front axle

Adjustable NFV – 6FZ RHY Adjustable NFV – 6FZ - RHY

Tracking Yes2 ± 1 mm 1.7 ± 1 mm 1.2 ± 1 mm

0° 18’ ± 0° 09’ 0° 15’ ± 0° 09’Tracking

0° 11’ ± 0° 09’

Castor 2° 54’ ± 20’ Camber

No

1° 15’ ± 20’

Pivot angle

No 10° 6’ ± 30’ 10° 12’ ± 30’

Camber 0° 20’ ± 30’ 0° 15’ ± 30’

Rear axle

A > B = Negative figure: – = TOE-OUT


WARNING

B3CP02UC


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STEERING COLUMN SPECIFICATIONS

Left hand drive = Green marking.Right hand drive = White marking.

(1) Steering wheel.(4) Steering column adjustment.


- (2) Airbag to steering wheel fixing : 0.8 ± 0.1- (3) Steering wheel fixing : 3.3 ± 0.6- (5) Steering column to support fixing : 4 ± 1- (6) Steering cardan joint fixing : 2.3 ± 0.2

B3EP116D


368

AX

LE

SS

US

PE

NS

ION

ST

EE

RIN

G

STEERING SPECIFICATIONS


(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 ± 0.8

(11) Hydraulic pipe connection : 2.4 ± 0.2

(12) Power steering valve : 1.2 ± 0.2

(13) Plunger flange screws : 1.2 ± 0.2

(14) Steering ram screw on housing : 9 ± 1

(15) Steering ram screw on yoke : 9 ± 1

NOTE : When removing the steering, it is imperative to replace screws

(14) and (15) (new screws).

B3EP117D


369

AX

LE

SS

US

PE

NS

ION

ST

EE

RIN

G

Steering rack Rack pinion Number of teeth Number of steering Turning circle Turning circle travel in rack wheel turns between walls between kerbs

Left hand drive71.7x2

LH helix28 teeth 3.22 12 m 11.48 m

Right hand drive RH helix

Motorisation Steering valve

NFV - 6FZ - RFN - RHY Number of teeth : 7

Length of the steering link rods (pre-adjustment): - Between ball-joint centres = 392 mm - Between the centre of the pivot ball-joint and the contact face of the steering rack ball-joint = 412 mm.

STEERING SPECIFICATIONS XSARA PICASSO - All Types

370

AX

LE

SS

US

PE

NS

ION

ST

EE

RIN

G

POWER-ASSISTED STEERING SPECIFICATIONS


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’’.

A pressure switch is implanted in the hydraulic piping between the highpressure pump and the power steering valve.- Opening pressure = 30 / 35 Bars.- Closing pressure = 25 Bars minimum.Tightening torque = 2 ± 0.2

Capacity of power steering circuit = 1 Litre.Oil quality = TOTAL FLUIDE ATX.Power steering pump : Supplier SAGINAW.Pump adjustment = 100 ± 5 Bars.Pump shaft threading 3/8 - 16 threads per inch

B3EP118D


371

BR

AK

ESSAXO - All TypesBRAKE SPECIFICATIONS

Master cylinder

Master-vac

Ø Caliper/pistonmakes

Frmm

DiscNon-ventilated

Ventilated

Disc thickness/min. thickness

Brake pad grade

ØCylinder or caliper

mmDrum / Ø max.

Disc Non-ventilated

Rr Disc thickness/min. thickness

Make

Brake lining grade

Compensator

(1) Compensator integral with the wheel cylinder.

(2) Load sensitive compensator.

1.1 i - 1.4 i1.5 D

Power-assisted steering without ABS

1.6 i1.6 i

1.6 i 16V

19 20.6 22.2

177.8 203.2 228.6

BENDIX Standard 4/48 TEVES FN48/48

247

247

10/8 20.4/18.4

GALFER 3726

TEXTART 4009TEXTART 4900 AS – FM 380

19 30

180/182

247

8/6

BENDIX RAD BENDIX S4

DON 8259 AS FM 380

(1) 20 (2) 13

372

BR

AK

ES

20.6

203.2

BENDIX Standard TEVES FN BENDIX Standard4/48 48/48 4/48

247 247

247

10/8 20.4/18.4 10/8

JURID 519 AS FM 380 GALFER 3726TEXTART 4009

20.6 30 19

203/205 180/182

247

8/6

LUCAS RAI BENDIX S4 BENDIX RAD

JURID E 558 AS FM 380 DON 8259

(2) 13 (1) 20

BRAKE SPECIFICATIONS (continued)

Master cylinder

Master-vac

Ø Caliper/piston makes

Frmm

DiscNon-ventilated

Ventilated


Brake pad grade


mmDrum / Ø max.

Disc Non-ventilated


Make

Brake lining grade

Compensator

(1) Compensator integral with the wheel cylinder.(2) Load sensitive compensator.

1.1 i - 1.4 i1.5 D

Power-assisted steering with ABS Manual steering

1.6 i 1.6 i1.6 i 16V

Entreprise1.1i-1.5D

SAXO - All Types

373

BR

AK

ES

B3FP06FC

B3FP06GC

BRAKES

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.- Adjust using the screw (2) to obtain a clearance J of 0.5 to 2 mm.

NOTE : Do not touch (3) which has been adjusted at the factory.

Adjusting the stop lamp switch.Clearance J = 2 to 3 mm.After adjustment, tighten the lock nut (1) to 1 m.daN.

SAXO - All Types

374

BR

AK

ES

B3FP10ND

BRAKES (continued)SAXO - All TypesAuto. - 1.1 i - 1.4 i - 1.6 i Tightening torques (m.daN)

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 ± 1.2

- 1.6 i- 2 Screws M12 10.5 ± 1

NOTE : See evolution on following pages 254 to 256.

375

SAXO - All TypesBRAKES (Continued)EVOLUTION : Fixing screws for FRONT brake calipers: Type BENDIX STANDARD 4.

BR

AK

ES

Application from RPO 8973.

Vehicles concerned.Vehicles equipped with non-ventilated brake discs. (Except VTS trimlevel).Vehicles equipped with the following engines: TUD5 – TU1JP – TU3JPTU1M+ (Entreprise) and TU9M (Entreprise).Evolutions.Evolutions of the following components: Front brake caliper fixing screws.Stop plates for front brake caliper fixing screws.Evolutions of the fixing screws: Coating on the threads of the fixing screws.Flanges for better centring of the fixing screws.NOTE : The fixing screws are matched to the stop plates.

IMPERATIVE : Respect the tightening torques.

Old fitting: tighten to 12 m.daN.± 1.2 (up to RPO 8972).

NEW FITTING (from RPO 8973).Tightening : 3.5 m.daN ± 0.3Angular tightening : 87° ± 3°

Repair.

Removing-refitting the front brake caliper (old and new fitting)

Clean the threads of the fixing screws and coat them with a brake productof type «E3».

Tightening : 3.5 m.daN ± 0.3Angular tightening : 87° ± 3°

InterchangeabilityThe new fixing screws matched to the new stop plates can be fitted on theold front brake calipers.

IMPERATIVE : Respect the matching of the stop plates and fixingscrews.

Replacement parts.The Replacement Parts service markets both the old and the newcomponents.

376

BR

AK

ES

SAXO - All Types BRAKES (Continued)EVOLUTION : Fixing screws for REAR brake calipers: Type BENDIX STANDARD 4.

Application from RPO 8973.

Vehicles concerned.Vehicles equipped with non-ventilated brake discs. (Except VTS trimlevel).Vehicles equipped with the following engines:TU5J4 and TU5JP.Evolutions.Evolutions of the following components: Rear brake caliper fixing screws.Stop plates for rear brake caliper fixing screws.Evolutions of the fixing screws: Coating on the threads of the fixing screws.Flanges for better centring of the fixing screws.NOTE : The fixing screws are matched to the stop plates.

IMPERATIVE : Respect the tightening torques.

Old fitting: tighten to 11 m.daN ± 1 (up to RPO 8972).

NEW FITTING (from RPO 8973).Tightening : 7.5 m.daN ± 0.7

Repair.

Removing-refitting the rear brake caliper (old and new fitting)

Clean the threads of the fixing screws and coat them with a brake productof type «E3».

Tightening : 7.5 m.daN ± 0.7

InterchangeabilityThe new fixing screws matched to the new stop plates can be fitted on theold rear brake calipers.

IMPERATIVE : Respect the matching of the stop plates and fixingscrews.

Replacement parts.The Replacement Parts service markets both the old and the new com-ponents.

377

BR

AK

ESHANDBRAKE (Adjustment)

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.

Adjustment.

- Set the brake to the 4th notch.- Tighten the nut (3) until the rear brakes are applied.- Check that:- there is a total travel of between 4 and 7 notches.- the two secondary cables (1) on the balance lever (2) move together.- the wheels rotate freely when the brake is released.- Check that the brake warning lamp comes on from the 4th notch.

NOTE : The handbrake operates on the rear wheels.

B3FP106JC

SAXO - All Types

378

BR

AK

ES

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.

Top up to level using the brake fluid sold by the CITROEN Replacement Parts Division.

IMPERATIVE order of bleeding

Wheel :- Rear left.- Front right.- Rear right.- Front left.

379

BR

AK

ES

20.6

203.2

LUCAS/TRW C48/13 48

266

13/11

TEXTAR T 4144

203

205

DON

8259

BRAKE SPECIFICATIONS (WITHOUT ABS)

Master cylinder

Master vac


Frmm

DiscPlain

Ventilated


Brake pad grade

Drum

Max. thickness

Make

Brake lining grade

1.1i 1.4i 1.4 HDi

HFX KFV 8HX 8HWEngine type

Rr

Ømm

C3

380

BR

AK

ES

22.2

228.6

LUCAS/TRW C54/22 54

266

22/20

TEXTAR T 4144

LUCAS C38 HR 9/13

247

9/7

GALFER

G 4554

BRAKE SPECIFICATIONS (WITH ABS)

Master cylinder

Master vac


Frmm

DiscPlain

Ventilated


Brake pad grade

Cylinder or caliper

Disc Ventilated


Make

Brake pad grade

1.6i 16V 1.4 HDi 16V

NFU 8HV 8HYEngine type

Ømm

C3

381

BR

AK

ES

B3FP161D

BRAKE SPECIFICATIONSBraking circuit without ABS - REF (drum brakes at the rear) Braking system specifications

Braking circuit at «X».

- Front brakes with ventilated discs (*).

- Rear brakes with eitther drums or discs (*).

- Handbrake lever controlling cables acting on therear wheels.

The compensator and main brake limiter functions areassured by the ABS EBD system.

NOTE : REF = Electronic Brakeforce Distribution

(*) = according to version

C3

382

BR

AK

ES

BRAKE SPECIFICATIONSBraking circuit with ABS - REF (drum brakes at the rear)

B3FP162D

C3

383

BR

AK

ESBRAKE SPECIFICATIONS

Braking circuit with ABS - REF (Disc brakes at the rear)

B3FP163D

C3

384

BR

AK

ES

BRAKE SPECIFICATIONS

Braking circuit with ABS - REF

(a) Hydraulic circuit.(b) Electrical circuit.

(1) Master cylinder in tandem.(2) Braking servo.(3) Brake caliper (or drum at the rear).(4) Hub equipped with a bearing with an integral magnetic wheel(48 pairs of poles).(5) Wheel sensor.(6) Brake fluid level sensor.(7) Hydraulic block plus ECU.(8) Stoplamp switch.(9) Instrument panel.(10) Diagnostic socket.(11) Built-in systems interface (BSI).

B3GP02RP

C3

385

C3BRAKE SPECIFICATIONSABS hydraulic block: RPO 9424 #ABS hydraulic block # N°OPR 9423

BR

AK

ES

NOTE : ESP = Electronic Stability Programme

TEVESESP -ABS

MK 60 : 96 418 772 80

Installed on the front LH chassismember : 4 adjustment channels

47-way connector.ABS hydraulic block

Components Supplier

Vehicle equipped with ABS and ESP systems

Part No. Observations

ABShydraulic

blockTEVES

ABS MK 60 :96 394 937 80

Installed on the front LHchassis member :

4 adjustment channels47-way connector.

ABShydraulic

blockTEVES

ABS MK 70 :96 419 653 80

Installed on the front LHchassis member :

4 adjustment channels26-way connector.

Components Supplier Part No. Observations Components Supplier Part No. Observations

B3GP03DC B3GP03EC

386

BR

AK

ES


Brake pedal gear Front brake Rear brake

(16) Servo fixing 2.2 ± 0.3

(17) Fixing on master cylinder 2 ± 0.5(12) Yoke fixing on caliper 10.5± 1

(13) Yoke fixing on caliper 3± 0.3

(14) Rear caliper fixing on arm 5.3±0.5

(15) Yoke fixing on caliper 3.8±0.3


B3FP166D B3FP164C B3FP165C

C3

387

BR

AK

ES

C5FP0ELD

HANDBRAKE (Adjustment)

AdjustmentLift 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).- The electric window buttons (4).Remove the central console (7).

WARNING: Check that the brake cables are correctlyrouted under the vehicle.

Slacken the handbrake lever.Press gently on the brake pedal (Then repeat the ope-ration 3 times).Pull vigorously on the handbrake lever 4 or 5 times.

C3

388

BR

AK

ES

B3FP16ED

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 leverfrom its stop.Adjust the nut (10) to obtain a travel of less than or equal to1 mm at «a».Refit the brake drums without tightening them (according toversion).Action the handbrake lever 8 times with an effort of 40 m.daN.With the handbrake released, check the travel of the leverat «a», using a gauge set.NOTE : The travel should be less than 1 mm and more than0,05 mm.Refit: - The brake drums.- The wheels.- The central console.Check the operation of the handbrake.

C3

389

BR

AK

ES

B3FP15XC

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).Remove the reservoir (1).- Empty the brake fluid reservoir (1).- Clean the brake fluid reservoir (1).Refit: The brake fluid reservoir (1).The shaft (3).Couple the pipe (2).Reconnect the connector (4).Filling the braking system.WARNING : Use only those hydraulic fluids that are approved and recommended.- Fill the brake fluid reservoir (1).Bleeding the braking system.WARNING: During the bleeding operation, take care to maintain the level of brake fluid in thereservoir and to top it up, using only brake fluid that is clean and clear.

C3

390

BR

AK

ES

B3FP15YC B3FP15ZD

BLEEDING AND FILLING THE BRAKING SYSTEM (CONTINUED)

Bleeding the primary braking circuit.

WARNING: The ABS should not be active during thebleeding operation.

Front brake caliper: Bleed screw (5).A : Rear brake caliperB : Rear brake drum

Bleed screw (6).

Bleed each wheel cylinder, proceeding in the followingorder :

Front LH wheel.Front RH wheel.Rear LH wheel.Rear RH wheel

C3

391

BR

AK

ES

B3FP160C

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.- Close the bleed screw.- Remove the bleeding apparatus [1].- Check the brake fluid level (Should be between «MINI» level and «MAXI» level).- Fill if necessary with the approved and recommended synthetic brake fluid.Without the bleeding apparatus.NOTE : Two operators are necessary.For each circuit :- Apply the brake pedal to place the circuit under pressure.- 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.- Close the bleed screw.- Remove the tool [1].NOTE : Recommence the process a second time if that is necessary.- Check the brake fluid level, (Should be between «MINI» level and «MAXI» level).- Fill if necessary with the approved and recommended synthetic brake fluid.

C3

Without ABS 23,8 (expansion holes) With ABS 23,8 (valve)

228.6

BOSCH 54 LUCAS 57 BOSCH 54

266 283 266

22 /20

FERF 769 ASFM 380 FERF 769

13 / 2

203/205 203/205

247 247

8/6 8/6

BENDIX JURID TEXTAR BENDIX JURID

D 8259 519 428 D 8259 E 558 519

BOSCH / Load-sensitive compensator32

0.3 - White

BRAKE SPECIFICATIONSSaloons

XSARA

1.4i 1.6i 16V 2.0i 16V

KFW NFU RFN RFS WJY 8HZ RHY RHZ

1.9 D 1.4 HDi 2.0 HDi

Fr

Ømm

Master cylinder

Master-vac

Caliper/piston makes

Disc


Ventilated

Brake pad grade

Thickness/min. thickness

Rr

Ømm

Drum - Ø min./max.

Disc non-ventilated

Make

Brake lining grade

Make/Type

Cut-off pressure in BarsRamp/Paint reference


392

BR

AK

ES

393

BR

AK

ES

Without ABS 23,8 (expansion holes) With ABS 23,8 (valve)

228.6

BOSCH 54 LUCAS 57 BOSCH 54

266 283 266

22 /20

FERF 769 ASFM 380 FERF 769

13 / 2

228/230 228 / 230

247 247

8/6 8/6

JURID

E 558 519 E 558 519

BOSCH / Load-sensitive compensator32

0.3 - White

BRAKE SPECIFICATIONSEstates

1.4i 1.6i 16V 2.0i 16V

KFW NFU RFN RFS WJY 8HZ RHY RHZ

1.9 D 1.4 HDi 2.0 HDi

Fr

Ømm

Master cylinder

Master-vac

Caliper/piston makes

Disc


Ventilated

Brake pad grade

Thickness/min. thickness

Rr

Ømm

Drum - Ø min./max.

Disc non-ventilated

MakeBrake lining grade

Make

Cut-off pressure in BarsRamp/Paint reference


XSARA

394

BR

AK

ES

BRAKE SPECIFICATIONSXSARA - All Types

Tighten the nuts (1) to 2.3 m.daN.

- The clevis pin (2) is held in place by a plastic clip.

B3FP10YD

395

BR

AK

ES

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 » or(1) Hydraulic valve block « ABS Bosch 5.3 REF » or(1) Hydraulic valve block « ABS with ESP Bosch 5.7 ».

- (2) Load sensitive braking compensator (according to model).

B3FP09HC B3FP09JC

2

1

396

BR

AK

ES Braking system without ABS (rear drum brakes)

Up to RPO 8687Braking system without ABS (rear disc brakes)

BRAKE SPECIFICATIONSXSARA - All Types

B3FP14GDB3FP14FD

397

BR

AK

ES

Braking system with ABS (rear drum brakes)


B3FP14HD

XSARA - All Types

398

BR

AK

ES Braking system with ABS REF (rear disc brakes) Braking system with ABS REF (rear drum brakes)


B3FP14JD B3FP14KD

XSARA - All Types

399

BR

AK

ES

Braking system with ABS REF (rear drum brakes)


B3FP14LD

XSARA - All Types

400

BR

AK

ES


Braking circuit with ESP (BOSCH 5.7)

(A) Hydraulic circuit.(B) Electrical circuit.

(1) Master cylinder in tandem.(2) Braking servo.(3) Brake caliper (or drum at the rear).(4) Toothed wheel.(5) Wheel sensor.(6) Brake fluid level sensor.(7) Hydraulic block plus ECU.(8) Stoplamp switch.(9) Instrument panel.(10) Diagnostic socket.(11) Built-in systems interface (BSI). (12) Steering angle sensor.(13) Gyrometer/accelerometer sensor.(14) Switch.

B3HP004P

XSARA - All Types

401

BR

AK

ESBRAKE SPECIFICATIONSElectrical circuit

Components Ref. Supplier Part No. Observations42-way connector.Alone on the hydraulic block.Changing only the ECU is prohibited.2-way grey connector.The sensors are inductive-type.Tightening torque: 0,8 ± 0,2 m.daN2-way grey connector.The sensors are inductive-type.Mounted on the brake caliper support.Non-adjustable airgap: 0,3 to 1,2 mm.Tightening torque: 0.8 ± 0.2 m.daN2-way grey connector.The sensors are inductive-type.Mounted on the suspension arm.Non-adjustable airgap: 0,3 to 1,2 mm.Tightening torque: 0,8 ± 0,2 m.daN.Incorporated in the COM 2000.6-way blue connector.Located on the central console.6-way connector.Toothed wheel: 48 teeth.Integral with the driveshaft stub housing forthe front wheels, joined to the hub bearing forthe rear wheels.

XSARA - All Types

5.7 ESP

0 265 006 389

0 265 006 202

0 265 006 203

0 265 006 441

BOSCH

VALEO

BOSCH

GKN

Electronic ECU

Front wheel sensor

Rear wheel sensor(disc brakes)

Rear wheel sensor(Saloon : drum brakes)

Rear wheel sensor(Estate : drum brakes)

Steering angle sensor

Gyrometer/accelerometer sensor

Toothed wheel

7

5

12

13

4

402

BR

AK

ES


Gyrometer sensor(7) Hydraulic block

C4AP17YCB3HP002C

ObservationsPart No.SupplierComponents

XSARA - All Types

ESP hydraulicblock

BOSCH 5.7 ESPLocated on the front LH

wheelarch :4 adjustment channels.

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 besubjected to any impact. Any gyrometer/accelerometer sensorhaving suffered an impact must be replaced.Tightening torque (15) : 0,6 ± 0,1 m.daN.

403

BR

AK

ESXSARA - All TypesREAR BRAKE SPECIFICATIONS

Evolution : Rear brake drum hub 01/1999 #

New assemblyOld assembly

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.(2) Stop ring(3) Circlip.NOTE : This assembly is equipped with either part (2) or part (3).

Ref. «a»: Figure from 1 to 6 cold-stamped.(4) Stop ring.(5) Double shouldered washer, exterior diameter = 48 mm.

B3FP11ADB3FP119D

404

BR

AK

ES

XSARA - All Types REAR BRAKE SPECIFICATIONSEvolution : Rear brake disc hub 01/99 #

New assemblyOld assembly

Evolutions

New assembly

NOTE : The new assembly is identified by a figure from 1 to 6 cold-stamped on the head of the wheel stub at «c».

Sealing of the brake disc hub.New components: - Sealed bearing incorporated at «b» (ref. (6)).- Spacer without seal face (ref. (5)).- Cap (ref. (8) ).

Fixing of the brake disc hub.New components: - Rear wheel stub.- Double shouldered washer (ref. (7)).

Ref. «c» : Figure from 1 to 6 cold-stamped.(5) Spacer without seal face.(6) Sealed bearing incorporated at «b».

(7) Double shouldered washer, exterior diameter = 48 mm.(8) Cap.

B3FP11BD B3FP11CD

405

BR

AK

ES

CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR

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.

Example

Calculate :

1) The rear weight of the vehicle (empty tank + 1 person)

2) The weight of fuel in the fuel tank

3) The weight of options fitted to the vehicle

4) Add these three weights together to obtain the TOTAL REAR VEHICLE WEIGHT; remove all objects from the vehicle totalling more than10 kg in weight.

5) Select the adjustment graph that corresponds to the vehicle model. ( Refer to table N° 4).

6) Check the brake pressure.

7) Adjust the load sensitive brake compensator if necessary.

- The rear weight of the vehicle (empty tank + 1 person) = 412 kg- The weight of fuel in the fuel tank (tank 1/2 full) = 18 kg- The weight of options fitted to the vehicle (sun roof) = 8 kg- Total rear vehicle weight = 438 kg- Corresponding graph (Graph N° 1).

# Note the vehicle type Refer to table N° 1

# Note the fuel level Refer to table N° 2

# Note the vehicle options Refer to table N° 3

XSARA - All Types

406

BR

AK

ES

TABLE N° 1 (Rear weight of the vehicle (Empty tank + 1 person)). TABLE N° 2 (Weight of fuel in the fuel tank).

TABLE N° 3 (Weight of options fitted to the vehicle). TABLE N° 4 (Graph selection).

CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued)(Weights in kg)

Trim levelX SX Exclusive VTS

Type of fuel

5 litres 4

9

18

27

36

4

10

20

30

40

1/4

1/2

3/4

Plein

Petrol Diesel

Engine

1.4 i 392 405

412 423

424

428 431

432

447 450

422

424

425405

449436

416

1.6 i

1.8 i

1.8 i 16 V

1.9 D

1.9 TD

(Weights in Kg)

XSARA - All Types

Options Vehicle Model

1.4 i - 1.6 i - 1.8 i - 1.8 i (BVA) 1.9 D

1.8 i 16 V

1.9 TD

Electric sun roof 8 1

Graph

2

3

5

20

Protective grille

Towing equipment (All models)

407

BR

AK

ES

GRAPH N° 2

CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued)

GRAPH N° 1

B3FP09YDB3FP09XD

XSARA - All Types

408

BR

AK

ES

CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued)XSARA - All Types

B3FP09ZD

GRAPH N° 3

409

BR

AK

ES

CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued) XSARA - All Types

B3FP101C

TOOLS- Braking pressure checking tool : 4140-T.

CHECKING THE BRAKE PRESSUREWARNING : Do not touch the plastic nut (1).

PRELIMINARY OPERATIONS- Place the vehicle on a 4-column lift if possible.- Fit tool 4140-T.- Calculate the rear vehicle weight (see tables on preceding pages). - Check that no hydraulic fluid is leaking andthat the pipes are not obstructed.- Refer to the graph which corresponds to the vehicle type (see preceding pages).

CHECKS- Perform the checks between the wheels as follows : front left and rear right - front right and rear left.- With the engine running, increase the pressure at the rear to obtain a front pressure of 60 Bars.ESSENTIAL : The checking pressure must be obtained by progressively increasing the pressure (neverreduce the pressure to adjust it).- Check the increased measurement against the graph. (If the measurement is not within the limits, adjust thecompensator) (see following page).- To check that the compensator works correctly, increase the rear pressure to 100 bars. (If the measurement is notwithin the limits, replace the compensator).- Bleed the brake system and carry out a road test.

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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. Calculate the spring length (3) before loosening the nut (2), and use a spanner to hold thelock-nut (4) in place, thus restraining the spring.

- Loosen the nut (2) while ensuring the lock-nut (4) is held firmly in place.

- Adjust the length of the spring (3) :- Reduce the spring length (3) to increase brake pressure.- Increase the spring length (3) to reduce brake pressure.

- Tighten the nut (2) to 1.5 m.daN.- Check the brake pressure.

CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued)XSARA - All Types

B3FP102CB3FP101C

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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.- Set the handbrake to the 3rd notch.- Tighten the nut (1) until the rear brakes are applied.- Pull the handbrake lever vigorously 4 to 5 times.- Set the handbrake to the 3rd notch.- Check that the rear brakes are applied.

- Check that the wheels can be turned freely by hand with thehandbrake released.- Lower the vehicle.- Refit the handbrake console.

B3FP095D

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BLEEDING THE BRAKESSAXO - All Types

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.- Front Left.- Rear Left.- Front Right.

Top up using brake fluid supplied by CITROEN Replacement Parts.

413

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23.8

254

BOSCH ZOH 54

266 283

22/20 26/24

FERODO 769(37)

22.2

228.6/230

247/-

9/7

LUCAS TRW

ABEX 4930/2 GALFER G4554

20/61.6

BRAKE SPECIFICATIONS XSARA PICASSO - All Types

Master cylinder

Master-vac


Frmm

DiscNon-ventilated

Ventilated


Brake pad grade


mmDrum / Ø max.

Disc non-ventilated


Make

Brake lining grade

Compensator – cut-off in Bars

NOTE : On models equipped with ABS, there isno load-sensitive braking compensator.(*) ESP = Electronic Stability Programme

1.6i - 1.8i 16V - 2.0i 16V - 2.0 HDi 1.8i 16V - 2.0i 16V - 2.0 HDi

Without ESP (*) With ESP (*)

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BRAKE SPECIFICATIONSBraking system specifications


Rear : load-sensitive braking compensator (non-ABS models).

- (1) Hydraulic valve block « ABS Bosch 5.3 » or

- (1) Hydraulic valve block + ECU.

- (2) Load sensitive rear braking compensator.

‘X’ braking circuit.

- Front : disc brakes, ventilated.

- Rear : drum brakes with automatic wear adjustment.

- Cable operated handbrake acting on the rear wheels.

B3FP11VD B3FP08ND

1

415

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B3FP11WD B3FP7B9D

BRAKING SYSTEM SPECIFICATIONSWith ABSWithout ABS


416

BR

AK

ES

B3FP7BRD B3FP11XD

BRAKING SYSTEM SPECIFICATIONSHandbrakeWith ESP (Electronic Stability Programme)


417

BR

AK

ESXSARA PICASSO - All Types CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR

Tools [1] Brake pressure checking tool : 4140-T

Checking procedure Determine the weight on the rear axle and then refer to the adjustmentgraphs.The allocation table enables you to choose which graph to use foreach type of vehicle.Connect the tool [1] in order to check the rear pressure values relati-ve to the front pressures (60 and 100 bars).

Rear weight of the vehicle (tank empty + 1 person)Note the vehicle type.Consult the correspondence table.

Weight of fuel in the fuel tankNote the level of fuel in the vehicle and from this deduce the weightaccording to the table.

Determining the rear weight of the vehicleRefer to the tables of different weights.To obtain the rear weight of the vehicle, add the following weights :

- Rear weight of the vehicle (tank empty + 1 person).- Weight of fuel in the fuel tank.- Weight of the options on the vehicle.

Remove from the vehicle any object weighing more than 1 Kg.

Engine type

NFZ6FZRFNRHY

Rear weight (tank empty + 1 person)

542531532540

Level of fuel(Litres)

51/41/23/4Full

Weight of fuel in the fuel tank (Kg)DieselPetrol

4 412243648

11223344

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XSARA PICASSO - All Types CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATORTools [1] Brake pressure checking tool : 4140-T

Example.Type of vehicle = TU5JP+Rear weight (tank empty + 1 person). = 542 KgFuel tank half full : = 22 KgSun roof = 10 KgRear weight of the vehicle = 542 + 22 + 10 = 574 Kg.

Weight of the options on the vehicle

Note the options on the vehicle and deduce the weight according tothis table

(1) CRD # OPR 8885(2) CRD(3) OPR 8886 #(4) OPR 8886 #CRD = Difficult road conditions.

Options

Electric sun roof 10Bicycle carrier 5

Roof bars 4Refrigeration/heating module 10

Under-engine shield 9Towbar all versions 19

Weight (Kg)

Vehicle engine version

Table of allocation of graphs

NFV – RHY 16FZ 2

NFV – RHY (1) 36FZ – RFN (2) 4

RFN (3) 5RHY (4) 6

Graph N°

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ESCHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR

GRAPH N° 2GRAPH N° 1

B3FP13RD B3FP13SD

Key :P = Rear pressure (in Bars). a = Front pressure 60 ± 3 Bars.M = Weight (in Kg). b = Front pressure 100 ± 3 Bars


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CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATORGRAPH N° 4GRAPH N° 3


Key :P = Rear pressure (in Bars). a = Front pressure 60 ± 3 Bars.M = Weight (in Kg). b = Front pressure 100 ± 3 Bars

B3FP14MD B3FP13UD

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ESCHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR

GRAPH N°6GRAPH N° 5

B3FP14ND B3FP14PD

Key :P = Rear pressure (in Bars). a = Front pressure 60 ± 3 Bars.M = Weight (in Kg).) b = Front pressure 100 ± 3 Bars


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E5-P01IC

CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATORChecking 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.- Rear weight of the vehicle determined.- Check there are no hydraulic leaks.- Check the absence of pinching on the pipes.- Refer to the graph corresponding to the vehicleengine version.- Checks are done between the following compo-nents :

Front LH wheel and rear RH wheel.Front RH wheel and rear LH wheel.

- On the vehicle, engine running, note the rearpressure when the front pressure is 60 ± 3 Bars.

ESSENTIAL : The control pressure should beobtained by progressively increasing the pressure(without ever releasing the pressure to adjust it).

- Compare the value noted with the graph.- If the value is outside the tolerance, adjust thecompensator.- In order to check that the compensator is workingproperly, note the rear pressure when the frontpressure is 100 ± 3 Bars.- If the value is outside the tolerance, replace thecompensator.NOTE : Any large discrepancy between the two cir-cuits will mean that the braking compensatorshould be replaced.- After completing these operations, bleed the bra-king circuit (see corresponding operation).- Carry out a road test.


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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 ± 0,25 m.daN.- Check the brake pressure.

After the operation :

- Remove the checking tool [1].- Bleed the braking circuit (see corresponding operation).- Carry out a road test.


B3FP13VC

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B3FP11YD

HANDBRAKE (Adjustment)XSARA PICASSO - All Tpes

Adjustment :

Remove the handbrake trim (1).Unclip the sound-deadening (2).Raise and support the vehicle with the rearwheels hanging free.Check the correct routing of the brake cables underthe vehicle.Apply and release the handbrake 4 times.Set the handbrake to the 5th notch.Tighten the nut (3) until the rear brakes are applied.Pull the handbrake lever vigorously 4 to 5 times.Set the handbrake to the 5th notch.Check that the rear brakes are applied.With the handbrake released, check that the wheelscan be turned freely by hand.Lower the vehicle.Refit the sound-deadening (2) and the handbraketrim (1).

425

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ESBLEEDING 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.Retrieve the brake fluid reservoir from its supply pipes by pulling upwards.Finish emptying the reservoir of brake fluid.Clean the brake fluid reservoir.Refit the brake fluid reservoir.Reconnect the brake fluid warning lamp connector.

FillingRefill the reservoir with brake fluid.WARNING : Use only the recommended hydraulic fluids.

Bleeding.NOTE : Two technicians are required.

IMPERATIVE: During bleed operations, ensure that the level of brake fluid is maintained inthe reservoir and top it up, use only new brake fluid.

Bleed each wheel cylinder, proceeding in the following order : Rear right hand wheel.Front left hand wheel.Rear left hand wheel.Front right hand wheel.

STARTER MOTORSAbbreviations and definitions

ALL TYPES

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Coding of climates is as follows :

CLIMATES :

C Hot : Starting possible as low as -18°CT Temperate : Starting possible as low as -18°CF Cold : Starting possible as low as -25°CGF Very cold : Starting possible as low as -30°C

Meaning of abbreviations :

BV : Gearbox

BVM : Manual gearbox

BVA : Automatic gearbox

BVMP : Piloted manual gearbox

DA : Power-assisted steering

WHIT AIRCON : Air conditioning

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Table of classes of starter motors

Vehicles / models Manufacturer and Ref. Class Climate

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

a speed of 1200 rpmI ≤ 275 A I ≤ 300 A I ≤ 430 A I ≤ 470 A I ≤ 500 A

ALL TYPES

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VALEO D7E16BOSCH A 001183 027 F

MELCO M002T13081VALEO D6 RA 572

VALEO D7E16BOSCH A 001183 027 F

MELCO M002T13081VALEO D6 RA 572

VALEO D7E16BOSCH A 001 183 027F

MELCO M002T13081VALEO D7E23

BOSCH E OAL 101 390VALEO D6RA572

VALEO D6 RA 572

VALEO D6RA100VALEO D7R151

STARTER MOTORSSAXO

Class ClimateVehicles / models Manufacturer and Ref.

SAXO

CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)

1.1i

1.4i (Aircon)1.6i (Aircon)

1.4i1.6i

1.6i 16v1.4i Automatic

1.5D

1 H, T, C

1 C, T

3 C, VC

1 H.T

2 C

3 VC

VC3

H, T, C, VC

4 H, T, C5 VC

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VALEO D7E16

BOSCH A001 183 027F

MELCO M002T 13081

VALEO D6RA572

VALEO D7E16

BOSCH A001 183 027F

MELCO M002T 13081

VALEO D6RA572

VALEO D7E16

BOSCH A001 183 027F

MELCO M002T 13081

VALEO D7E23

BOSCH E OAL 101 390

VALEO D6RA572

VALEO D6RA572

VALEO D6RA110

VALEO D7GP09

1 H, T, C

3 VC

1 H, T

3 C, VC

1 H, T

2 C

3 VC

3 H, T, C, VC

4 H, T

5 C, VC

STARTER MOTORS



1.1i

1.1 i Aircon1.4 i Aircon

1.6i 16v Aircon

1.4 i1.6 i 16v

1.4I Automatic

1.4 HDi1.4 HDi 16v

C3

C3

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STARTER MOTORS


XSARA


1.4i1.6i

(Power steeringor aircon)

1.4i(Power steering

and aircon)

1.6 i1.6i Automatic

2.0i 16 v2.0i 16 v Automatic

EW10J4

2.0i 16vXU10J4RS

1 H, T

2 H, T

3

C, VC

C, VC, H, T

F, T

3 C, VC

C, VC4

3

4

430

VALEO D7E16

BOSCH A 001183 027 F

MELCO M002T13081

VALEO D6 RA 572

VALEO D7E23

BOSCH E OAL 101 390

VALEO D6RA572

VALEO D6 RA 572

VALEO D6 RA 72

MELCO M000T82081

BOSCH E OAL 098 390

MELCO M 000 T 85 381

VALEO D6 RA 661

BOSCH A 001 110 140 F

BOSCH A 001 111 473

XSARA

H, T

C, VC

431

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EC

TR

ICIT

E

VALEO D6 RA 109

BOSCH A 001 111 562F

MELCO M 001 T 80381

VALEO D7 R 26

MELCO M 001 T 80481

VALEO D7 R 27

VALEO D6 RA 109

BOSCH A 001 111 562F

MELCO M 001 T 80381

VALEO D7 R 27

VALEO D7 R 26

MELCO M 001 T 80481

VALEO D7 R 27

VALEO D7 R 27

MELCO A 001 236 000

VALEO D6RA110

VALEO D7GP09

STARTER MOTORS XSARA


XSARA


1.9D

2.0 HDi90 CV

2.0 HDi110 CV

2.0 HDI Automatic110 CV

1.4 HDi

4 H, T

C

VC

H, T

C, VC

H, T

5

6

4

6

5

6

66+4

5

C, VCC, VC

C, VC

H, T

C, VC

432

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STARTER MOTORS


XSARA PICASSO


1.6i (Power steeringor aircon)

1.6i (Power steeringand aircon)

1.8i 16v2.0i 16v Automatic

2.0 HDi

1 H, T

2

3

C, VC

3 C, VC

H, T, C

4

6

VALEO D7E16

BOSCH A 001 183 027F

MELCO M002T13081

VALEO D6RA572

VALEO D7E23

BOSCH E OAL 101 390

VALEO D6RA572

VALEO D6 RA 72

MELCO M000T82081

BOSCH E OAL 098 390

MELCO M 000 T 85 381

VALEO D6 RA 109

BOSCH A 001 111 562F

MELCO M 001 T 80381

VALEO D7 R 27

XSARA PICASSO

H, T

C, VC

H, T

VC

433

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ALTERNATORSAbbreviations and definitions

ALL TYPES

Coding of climates is as follows :

CLIMATES :

C : Hot (45°C/37°C)

T : Temperate (37°C/17°C)

F : Cold (17°C/-25°C)

GF : Very cold (<-25°C)

Meaning of abbreviations :

BV : GearboxBVM : Manual gearboxBVA : Automatic gearboxBVMP : Piloted manual gearboxWhitout aircon : Without air conditioning Whit aircon : With air conditioning DA : Power-assisted steeringGEP : Electro-pump motorDP : Double lug3 Pts : 3-PointNC : Not marketedTT : All TypesN : LevelSOP : Without OptionTOP : All OptionsL.C. : Heated rear screenDAG : Left hand driveDAD : Right hand drive

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ALTERNATORSRefer to the correspondance table for petrol or diesel engine

With airconWithout aircon

DA by GEPNon DA or SAGINAW DA DA by GEP Non DA or SAGINAW DA

SAXO

Meaning of abbreviations, see page : 433

Climate

HTC

VCHTC

VCHTC

VCHTC

VC

Engine/gearbox

TU1JPBVM

TU3JP/TU5JP/TU5JP4

BVM

TU3JPAutomatic

TUD5BVM

7

7

8

7

7

7 8 9

87 8

7 8

8

8

9

7

8

9

8

9

9

8

9

8

7

8

8

7

435

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ALL APPLICATIONS

SAXO

Climate

T

Engine/gearbox

TU All TypesTUD5BVM

9

HTC

VCHTC

VCHTC

VCHTC

VCHTC

VCH,T,C,VC

436

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Whitout aircon

C3


ClimateEngine/gearbox

TU1JPBVM

TU3JPBVM

TU3JPAutomatic

TU5JP4BVM

TU5JP4BVMP

DV4TD - DV4TED4 - BVM

7

Base RT3 N 1 or 2 RT3 N 3 Cold Pack Cold Pack + RT3 N 1 or 2 Cold Pack + RT3 N 36

76

78

6

78

7

7

8

6

77

8

7

8

6

7

7

67

88

15

67 7

89

437

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EC

TR

ICA

LS

YS

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HTC

VCHTC

VCHTC

VCHTC

VCHTC

VCH,T,C,VC


With aircon

C3


ClimateEngine/gb

TU1JPBVM

TU3JPBVM

TU3JPAutomatic

TU5JP4BVM

TU5JP4BVMP

DV4TD - DV4TED4 - BVM

Base RT3 N 1 or 2 RT3 N 3 Cold Pack Cold Pack + RT3 N 1 or 2 Cold Pack + RT3 N 3

7

15

8

7 78

88

7

8

77

9878

8

8 9

8

778

9878

9

8 88

9 9

98

438

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LS

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HTC

VCHTC

VCHTC

VCHTC

VCHTC

VCHTC

VC


Whit airconWhitout aircon

XSARA

ClimateEngine/gb

TU3JPBVM

TU5JP4BVM

TU5JP4Automatic

EW10J4BVM

EW10J4Automatic

XU10J4RSBVM

Base RT2 Base RT2 Base RT2+NAVBase RT2+NAV

7

Without Cold Pack Cold Pack Without Cold Pack Cold Pack

7

8

7

8

7

9

88

NC

NC

NC

87

8

98

98

7

7 78

129

129

99

8

999 988

878

129

89

8

9

439

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EC

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HTC

VCHTC

VCHTC

VCHTC

VCHTC

VC



XSARA

ClimateEngine/gb

DW8BBVM

DW10TDBVM

DW10ATEDBVM

DW10ATEDAutomatic

DV4TDBVM

Cold PackWithout Cold Pack

8(8)

12(8) 15 15

RT2BaseCold PackWithout Cold Pack

RT2Base RT2+NAVBase RT2+NAVBase

8

9

8

9 9

99

8

9(8)15(9)15(12)

15(9)15(12)

9(8) 9(8) 12(8) 9(8) 12(8)8(8)

15(9) 15(12) 15(9) 15(12)

12(8) 12(8)

15(9) 15(9)15(12)

15(12)

12(8) 12(8)

9(8) 9(8) 12(8)9(8)12(8)

15(9) 15(12)15(9)15(12)

15(12)

9(8) 15

15(15)

15 15

15(15) 15(15)

NC NC

NOTE : ( ) Allocation of climates for alternators on vehicles with additional heating.

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Nav. + Radio-telephoneBase Nav. + Radio-telephone BaseClimate

HTC

VCHTC

VCHTC

VC

Engine/gb

TU5JP4L3 et L4

BVM

EW7J4/L4BVM

DW10TDBVM

7

XSARA PICASSO

87

8

NC 9

79

88

9 9

15 15


441

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HTC

VCHTC

VCHTC

VCHTC

VCHTC

VC


Whit airconWhitout airconClimateEngine/gb

TU5JP/L4BVM

DW10TDBVM

DW10ATEDBVM

DW10ATEDAutomatic

DV4TDBVM

NC7

8

HeatedseatBase Nav.+ Siège

chauffantNavigation HeatedseatBase Nav.+

Heated seatNavigation


XSARA PICASSO

NC7

8

NC

8

8 8

9 988

NC

1515

15

NC

9

8

9

8

129

898

15

442

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CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATORALL TYPES

Checking the alternator outputConnect 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 theengine speed and rheostat charge to obtain U=13.5V.Reminder : The excitation energising current will flow through the warning lamp;check that the warning lamp comes on when the ignition is switched on. It shouldgo out when the engine has started (accelerate slightly).

Checking the voltage regulatorSet the rheostat to zero and disconnect all the electrical consumers.Display 3000 alternator rpm. If U alternator is > 14.7 V, the regulator is faulty.Note: These tests should be performed with the engine hot and the battery fullycharged.

Method of reading the alternator speedFit a reflecting shim on the pulley of the alternator.Adjust a stroboscope to the frequency equivalent to the control speed. (e.g. 2000 rpm = 2000/60 = 83 Hz)Adjust the engine speed so that the shim appears fixed.

D1AP025C

A : AmmeterB : BatteryG : GeneratorL : Warning lampK1 and K2 : SwitchR : Electric chargeS : Shunt 200mV/200AV : Voltmeter1 : Alternator.

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CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATORMINIMUM OUTPUTS (in A)

ALL TYPES

Alternatorspeed

1800 rpm 11 27 39 46 61 73 89 1082000 rpm 12 34 46 54 68 80 105 1233000 rpm 13 47 60 68.5 84 100 139 1644000 rpm 14 55 65 75 92 110 145 1766000 rpm 15 61 69 78.5 96 120 151 1838000 rpm 16 63 70 80 97 123 157 18815000 rpm 17 64 73 82 97 124 157 188

Min. outputClass

6 7 8 9 12 15 18

Alternator speed

1800 rpm 49 50 52 57 58 60 612000 rpm 48 49 51 54 55 57 603000 rpm 45 46 48 51 52 54 564000 rpm 43 44 46 48 50 52 536000 rpm 39 40 42 43 48 50 508000 rpm 26 37 39 40 45 48 4815000 rpm 24 25 27 29 34 38 38

Class

6 7 8 9 12 15 18

MINIMUM YIELDS (in %)

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NAGARES 960411-P

CARTIER 735068

NAGARES 960411-P

CARTIER 735068

NAGARES 960411-P

NAGARES 960411-P

CARTIER 735068

NAGARES 960411-P

NAGARES 960411-P

CARTIER 735068

CARTIER 735068

NAGARES 960411-P

CARTIER 735068

NAGARES 960411-P

CARTIER 735068

NAGARES 960411-P

BERU 0 100 226 371

CHAMPION CH 185

NGK YE04

NGK YE04

BERU 0 100 226 371

CHAMPION CH 185

NGK YE04

CHAMPION CH170

CHAMPION CH 170

CHAMPION CH 170

PRE-HEATING AND STARTING SYSTEMSALL TYPES

Vehicles / models Pre-heater plugs Pre-heater control unitPre / Post heating

(pre-heating duration at 20°C)

SAXO

C3

XSARA

PICASSO

1.5D

1.4 HDI

1.4 HDI 16v

1.9D

1.4 HDI

2.0 HDI

2.0 HDI

2.0 HDI

VJX

8HW8HX

8HV8HY

WJY

8HZ

RHY

RHZ

RHY

10s / 150s

Controlled by the diesel injection ECU.

10s / 150s





AM 2001 #

445

850 gr +0 - 50 gr

TU All types

TUD All types

TU EW

DW

XU10

TU

EW7-DW10

BRESIL All types

825 gr ± 25 gr

795 gr ± 25 gr

590 gr +0 –50 gr

725 gr +0 –50 gr

675 gr ± 50 gr

775 gr ± 25 gr

AIR CONDITIONING R 134 a (HFC)

Vehicle Engines DateRefrigerant

refill

Compressor

Variable

CapacityOil quantity cc Oil reference

AIR

CO

ND

ITIO

NIN

G

SAXO

SD 6 V 12

SD 7 V 16

SD 6 V 12

SD 7 V 16

135 SP 10

12/1999 #

03/2001 #

ALL TYPES

XSARA

XSARAPICASSO

TU - TUD All types AM 2000 #

09/2000 #

C3 All types 11/2001 # 625 + 0 - 50 gr

446

ALL TYPES

C5HP073C

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)Click-fit connector removing/fitting tool

Ø InchCircuitVehicles

SAXOXSARA

XSARAPICASSO

All Types

BP

HP

5/8 Black 8005-T.A.

3/8 Red 8005-T.C

Ring colour Tool kit 4164-T

Unions

Steel/Steel Aluminium/SteelØ Pipes

1.7 ± 0.3 1.3 ± 0.3M 06

3.8 ± 0.3 2 ± 0.2M 08

4 ± 0.3 2.5 ± 0.3M 10

NOTE : Tighten the union to the recommended torque using a retaining spanner whenever possible.

NOTE : For operations concerning draining, drying (empty), checking and recharging of a system: refer to BRE 0290.WARNING : For R 134.a quantities (See table on preceding page).

Aircon compressor fixings

ESSENTIAL : Tighten the front part of the compressor(timing belt end), before the rear part of the compressor.

ALT

ER

NA

TOR

SA

IRC

ON

DIT

ION

ING

447

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)

Compressor (MANULLI seal)«EUROCLIM»

Tools.

Tool for removing-refitting air conditioning seals : K.1702

MANULLI seal

C3 engine versions : All typesXSARA PICASSO engine versions :NFV : 10/12/2001 #6FZ : 01/04/2002 #RHY : 04/11/2002 #

Aircon compressor.

XSARA PICASSO engine versions : 6FZ and RHYDiscontinuation of compressor SD 6 V 12Replaced by compressor SD 7 V 16 : 04/11/2002 #

C3 - XSARA PICASSO

The drive plate (1) is held on the aircon compressor shaft by ribs.New wiring (2).New seals (3) (MANULLI).Identification label (4) for aircon compressor.

AIR

CO

ND

ITIO

NIN

G

448

MANULLI calibrated seal (3).Direction of fitting of the seal (3).Before fitting the seal, amply lubricate the seal with air conditioningcompressor oil (SP10).

The condenser (5) has a cylinder (6) incorporating the function of airconfluid reservoir and with integral filtering cartridge.The inlet (7) and the outlet (8) of the condenser (5) are equipped withnew seals (3) (MANULLI).

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)Seals (MANULLI seal)Condenser (MANULLI seal)

C5HP18VD C5HP18XD

C3 - XSARA PICASSO

ALT

ER

NA

TOR

SA

IRC

ON

DIT

ION

ING

449

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) ALL TYPESPresence of pollen filter

Vehicle Equipment RPO No. Presence of filter Observations

SAXO

C3All Types

NO

YES

YES (Larger)

YES (Plus grand)

YES (Valeo)

NO (Valeo)

YES (Valeo)

Without aircon

Base aircon

Regulated aircon

Without aircon

Base aircon

XSARAXSARA PICASSO

BERLINGO

Except driving school

AIR

CO

ND

ITIO

NIN

G

450

ALT

ER

NA

TOR

SA

IRC

ON

DIT

ION

ING

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)Pollen filter

Note: The pollen filter is located in the engine compartment on the RHside.

RemovingRemove:

- The three screws (1).- The plastic cover (2).

Tilt the flap (3).

Remove the pollen filter (4)

RefittingProceed in reverse order.

C4AP169C C4AP16AC C4AP16BC

C3

451

AIR

CO

ND

ITIO

NIN

G

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.[5] Set of plugs : (-).0188.T.[6] Circlip pliers : FACOM.

RemovingDepressurise the aircon circuit, using tool [1].Remove the grille.At «a», remove the pin and the plastic cover.Unclip the condenser at «b» and «c», using a screwdriver.Tilt the condenser towards the front.Lift and release the condenser.Clean the area around the cap (3).Remove the plastic cap (3), using tool [2].Remove the safety circlip (4), using tool [6].Position the tool [3] and [4] in the aperture of the cartridge (5).Extract the cartridge from the reservoir (6), using tool [3] and [4].Block the reservoir (6), using tool [5].

C4AP163C C4AP164C C4AP166CC4AP165C

C3

452

AIR

CO

ND

ITIO

NIN

GA

IRC

ON

DIT

ION

ING

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)Changing the filtering/drying cartridge

RefittingRemove 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).Refit the safety circlip (4), using tool [6].Make sure that the circlip (4) is correctly positioned in its location.

WARNING : Not more than 5 minutes should elapse between the removalof the cartridge (6) from its packaging and its being fitted.

Refit: - The plastic cap (3), using tool [5] - Tighten to 1,2 ± 0,1 m.daN.- The condenser (reclip, pushing at «b» and «c»).- The plastic cover and the pins at «a».- The grille (2).- The screws (1).Proceed to: - Recharge the circuit (see corresponding operation).- Check the operation of the air conditioning (see corresponding operation).

C4AP167C C4AP165C C4AP164CC4AP163C

C3

453

AIR

CO

ND

ITIO

NIN

G

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)Pollen filter

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»)- Position the index (4) on the cover forward of the pollen filter.((4) Index on the cover).

BEHR plate evaporator

XSARA - All Types

C5HP062C

C5HP07JC C5FP075D

454

AIR

CO

ND

ITIO

NIN

GA

IRC

ON

DIT

ION

ING

Instruction for replacing the filter/dryer cartridge.

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)BEHR condenser with integral reservoir (16 Ti)

XSARA - All Types

The condenser is equpped with a cylinder (1) that acts as the fluid reservoirwhich in turn incorporates a filter cartridge.

NOTE : As soon as the air conditioning loop has been open for more than5 minutes, the filter/dryer cartridge assembly should be replaced (no setinterval).

-After undoing the cap (TORX 70), the cold loop must be depressurised.-Unscrew the cap and clean the cap’s thread.-Take out the filter/dryer cartridge.-Clean the threaded zone of the condenser reservoir.-Fit the new filter/dryer cartridge.-Lubricate the cap’s O-ring seals with compresser oil.(New seals).-Screw the cap back on, tighten to 1,4 ± 0,2 m.daN.

C5HP07BC

C5HP060C

Petrol engine versions

Diesel engine versions

455

AIR

CO

ND

ITIO

NIN

G

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)BEHR plate evaporator Pollen filter

XSARA PICASSO

Remove: - The three screws (1).- The cover (2).- Remove the pollen filter.C5HP062C B1BP23ED

456

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)BEHR condenser with integral reservoir (16 Ti)

XSARA PICASSO

The condenser is equpped with a cylinder (1) that acts as the fluid reservoir whichin turn incorporates a filter cartridge.

NOTE : As soon as the air conditioning loop has been open for more than5 minutes, the filter/dryer cartridge assembly should be replaced (no set interval).

Instruction for replacing the filter/dryer cartridge.

-After undoing the cap (TORX 70), the cold loop must be depressurised.-Unscrew the cap and clean the cap’s thread.-Take out the filter/dryer cartridge.-Clean the threaded zone of the condenser reservoir.-Fit the new filter/dryer cartridge.-Lubricate the cap’s O-ring seals with compresser oil.(New seals).-Screw the cap back on, tighten to 1,4 ± 0,2 m.daN.

C5HP07BC

AIR

CO

ND

ITIO

NIN

G

457

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)Compressor lubricant.

ESSENTIAL: The compressor lubricant is extremely hygroscopic; always use FRESH oil.

Checking the compressor oil level.

There are three specific cases :- 1/ Repairs to a system without leaks.- 2/ Slow leak.- 3/ Fast leak.

1/ Repairing a system without leaks.

a) - Using draining/recovery equipment not fitted with an oil decanter.- Drain the system as slowly as possible via the LOW PRESSURE valve, so as not to lose any oil.- No more oil should be added when filling the system with R 134.a fluid.b) - Using draining/filling equipment fitted with an oil decanter.- Drain the R 134.a fluid from the system in accordance with the instructions in the equipment handbook.- Measure the amount of oil recovered.- Add the same amount of NEW oil when filling the system with R 134.a fluid.c) - Replacing a compressor.- Remove the old compressor, drain it and measure the oil quantity.- Drain the new compressor (supplied full), so that the same amount of NEW oil is left in the compressor as was in the old compressor.- No more oil should be added when filling the system with R 134.a fluid.

ALL TYPES

AIR

CO

ND

ITIO

NIN

G

458

AIR

CO

ND

ITIO

NIN

G

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.

This type of leak causes both oil loss as well as allowing air to enter the system.

It is therefore necessary to :

- Replace the dehydrator.- Drain as much oil as possible (when replacing the faulty component).

Either before or during filling of the system with R 134.a fluid, introduce 80 cc of NEW oil into the system.

459

AIR

CO

ND

ITIO

NIN

G

AIR CONDITIONING SYSTEM R 134.a

Testing procedure

Conditions inside the vehiclePositions of the air conditioning controls :

Maximum cold.Maximum blower power.Air distribution on «ventilation» with the air vents open.Position the air inlet flap to outside air.

WARNING: For RFTA (1), disconnect the air inlet motor connector, firstensuring that it is in the outside air position.(1) RFTA = Fully automatic air conditioning.

Test procedure.When all these conditions are met, proceed in the following order: Measure the temperature in the workshop approx. one metre in front ofthe vehicle’s air inlet grille.Start the engine (without the air conditioning, or the blower, operating)and wait for the cooling fan slow speed to trigger (should the engine tem-perature not rise sufficiently, it is permissable to increase the enginespeed to 2000 rpm).Once it is sufficiently hot in the engine compartment, return the engine toidle and commence the test.

Switch on the air conditioning and adjust the engine speed to 2500 rpm.In an ambient temperature of 40°C, the engine speed will be broughtdown to 2000 rpm, in order for the pressure safety threshold to cut offthe compressor.

For further temperatures/pressures: see Tables and Graphs on followingpages.

After 3 minutes of operation, note down the following 3 parameters: - The temperature of the blown air coming out of the 2 central air vents(take the average).- The high pressure, via the intermediary of the clickfit union (at the pres-sure reducer inlet).- The low pressure, via the intermediary of the clickfit union (at the pres-sure reducer outlet).NOTE: The low and high pressures are absolute pressures.When measuring the blown air temperatures, avoid any contact betweenthe thermocouple and the air vents.

At the conclusion of the test involving vehicles with «RFTA», do notforget to reconnect the air inlet motor connector.

ALL TYPES

460

CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEMALL TYPESCHECKING TEMPERATURES (continued)

Vehicle using R134.a fluid (Compressor with variable capacity)

Ambient temperature in °C

Temperature at the central

air ventsin °C

Engine typesVehicle

SAXO

C3

All Types 17 ± 3 13 ± 3 11 ± 3 9 ± 3 8 ± 3

All Types 18.5 ± 2 15 ± 2 12.5 ± 2 10 ± 2 8.5 ± 2 6.5 ± 2

TU 18 ± 2 17 ± 2 14.5 ± 2 11 ± 2 8.5 ± 28 ± 2

EW 19 ± 2 18 ± 2 15 ± 2 12 ± 2 10 ± 2

DW 15 ± 2 15.5 ± 2 11 ± 2 9 ± 2 7 ± 2 5 ± 2

All Types 22 ± 3 16 ± 3 12.5 ± 3 10 ± 3 8 ± 3 6.5 ± 3

XSARA

XSARAPICASSO

40 35 30 25 20 15

AIR

CO

ND

ITIO

NIN

G

461

AIR

CO

ND

ITIO

NIN

G

20 ± 3 18 ± 3 16 ± 3 13 ± 3 11 ± 3 9 ± 33 ± 0.3

14.5 ± 2 17.6 ± 2 20 ± 2 21.4 ± 2 23.6 ± 2 25.2 ± 22.4 ± 0.2 2.5 ± 0.2 2.8 ± 0.2 3 ± .02 3.5 ± .02

23 ± 2 22.5 ± 2 20 ± 2 17 ± 2 15.5 ± 2 14.5 ± 23.8 ± 0.2 3.6 ± 0.2 3.5 ± 0.2 3.1 ± 0.2 3 ± 0.2 2.9 ± 0.2

24.5 ± 2 21.5 ± 2 18.5 ± 2 17 ± 2 15.5 ± 24± 0.2 3.8 ± 0.2 3.5 ± 0.2 3.2 ± 0.2 3 ± 0.2

21.5 ± 2 22.5 ± 2 20 ± 2 18 ± 2 16.5 ± 2 15.6 ± 23.2 ± 0.2 3.3 ± 0.2 3 ± 0.2 2.8 ± 0.2 2.6 ± 0.2

CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM ALL TYPESCHECKING PRESSURES

TOOLS - 1 charging station. - 2 thermometers.Once the preliminary conditions, vehicle equipment and checkshave been fulfilled (see table) : After the air conditioning has beenon for three minutes, record the following parameters :

CHECK - The temperature of the air coming from the central vents (see table).- The High Pressure. - The Low Pressure.Compare the values recorded with the table below, or the graphs.

Ambient temperature in °C 40 35 30 25 20 15

Vehicles Engines

SAXO

C3

All types

All types

High pressure (Bars)Low pressure (Bars)

Low pressure (Bars)High pressure (Bars)Low pressure (Bars)High pressure (Bars)Low pressure (Bars)High pressure (Bars)Low pressure (Bars)High pressure (Bars)Low pressure (Bars)High pressure (Bars)Low pressure (Bars)

TU

XSARA EW

DW

Vehicle using R134.a fluid (Compressor with variable capacity)

25.5 ± 3 20.5 ± 3 18 ± 3 20 ± 3 13.5 ± 3 11 ± 34 ± 0.3 3.5 ± 0.3 3 ± 0.325 ± 3 22.5 ± 3 20 ± 3 17 ± 3 15 ± 34 ± 0.3 3.5 ± 0.3 3 ± 0.3

TUEW

DW

XSARAPICASSO

High pressure (Bars)

462

AIR

CO

ND

ITIO

NIN

G

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 7,65 – 1seal Ø 16,5)(7) Compressor fixing flange 3 ± 0,8 m.daN (2 seals Ø 20)(8) (O-ring seal Ø 7,65).

SAXO - All Types AIR CONDITIONING SYSTEM R 134.a

C5HP15UP

C5HP12EC

Click-fit union.

463

AIR

CO

ND

ITIO

NIN

G

AIR CONDITIONING SYSTEM R 134.aChecks on the air conditioning circuit

SAXO - All Types

C5HP067D

Key.

T = Scale of Temperature (°C ), and of HighPressure (Bars).P = Scale of Low pressure (Bars).

Te = Exterior temperature (°C).

HP = Pressure at compressor outlet (Bars).

Ta = Temperature (°C) of air blown from the vents.

BP = Pressure at compressor inlet (Bars).

464

AIR

CO

ND

ITIO

NIN

G


(1) Low pressure valve.

(2) High pressure valve.

(3) Filter.

(4) Pressostat

Tightening torque m.daN

(a) : 0.6(b) : 0.6(c) : 0.6(d) : 0.6(e) : 0.6(f) : 0.6

C5HP17SP

C3

465

AIR CONDITIONING SYSTEM R 134.aChecks on the air conditioning circuit

C5HP18GD

Keys.

T/P = Average temperature (°C ) at the air vents /high pressure (Bars).

P = Low pressure (Bars).

TE = Exterior temperature (C°).



TA = Average temperature (°C) of air blown from thecentral vents.

C3

AIR

CO

ND

ITIO

NIN

G

466

Plan of air conditioning system

Two solutions :

1 « MANULLI », with « NON EUROCLIM » compressor (O-ring seals).

2 « EATON », with « EUROCLIM » compressor (quadrilobe seals).

(1) - High pressure valve (2) - Low pressure valve(3) - Pressostat(4) - Dryer

Tightening torques m.daN.(a) 0,8(b) 4 ± 0,4(c) 0,8

A Right hand drive.

XSARA - All Types AIR CONDITIONING SYSTEM R 134.a

C5HP16RP

AIR

CO

ND

ITIO

NIN

G

467


Solution :

1 « EATON », with « EUROCLIM » compressor and buffer capacity (quadrilobe seals).

(1) - High pressure valve(2) - Low pressure valve(3) - Buffer capacity


A Right hand drive.

XSARA - All TypesAIR CONDITIONING SYSTEM R 134.a

C5HP17WP

AIR

CO

ND

ITIO

NIN

G

468


Two solutions :





A Right hand drive.


C5HP16SP

AIR

CO

ND

ITIO

NIN

G

469


Two solutions :





A Right hand drive.


C5HP16VP

AIR

CO

ND

ITIO

NIN

G

470


Three solutions :

1) « MANULLI », with « NON EUROCLIM » compressor (O-ring seals).

2) « EATON », with « EUROCLIM » compressor and buffer capacity (quadrilobe seals).

3) « EATON », with « NON EUROCLIM » compressor and buffer capacity (O-ring seals).

(1) - High pressure valve(2) - Low pressure valve(3) - Buffer capacity


A Right hand drive.


C5HP17XP

AIR

CO

ND

ITIO

NIN

G

471


Two solutions :





A Right hand drive.


C5HP16TP

AIR

CO

ND

ITIO

NIN

G

472

Plan of air conditioning system.

Three solutions :

1) « MANULLI », with « NON EUROCLIM » compressor (O-ring seals).

2) « EATON », with « EUROCLIM » compressor and buffer capacity (quadrilobe seals).

3) « EATON », with « NON EUROCLIM » compressor and buffer capacity (O-ring seals).

(1) - High pressure valve(2) - Low pressure valve(3) - Buffer capacity.


A Right hand drive.


C5HP17YP

AIR

CO

ND

ITIO

NIN

G

473


Two solutions :





A Right hand drive.


C5HP16UP

XSARA - All Types

AIR

CO

ND

ITIO

NIN

G

474

(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.


- a 0,8.± 0,1- b 0,5.± 0,1- c 1,4 ± 0,2.- d 2,5 ± 0,25.

XSARA PICASSO TUAIR CONDITIONING SYSTEM R 134.a

C5HP13PP

AIR

CO

ND

ITIO

NIN

G

475



- a 0,8.± 0,1- b 0,5.± 0,1- c 1,4 ± 0,2.

HP/LP compressor flange fixing 2,5 ± 0,25.

XSARA PICASSO EW7AIR CONDITIONING SYSTEM R 134.a

C5HP13QP

AIR

CO

ND

ITIO

NIN

G

476

XSARA PICASSO TU - EW7 AIR CONDITIONING SYSTEM R 134.a

Checks on the air conditioning circuit

C5HP150D

Key.

T/P = Scale of: - Temperature (°C), average of air from the centralvents. - Pressure, High (Bars).- Pressure, Low (Bars).





AIR

CO

ND

ITIO

NIN

G

477



- a 0,8.± 0,1- b 0,5.± 0,1- c 1,4 ± 0,2.

HP/LP compressor flange fixing 2,5 ± 0,25.

XSARA PICASSO DW10AIR CONDITIONING SYSTEM R 134.a

C5HP13RP

AIR

CO

ND

ITIO

NIN

G

478

XSARA PICASSO DW10 AIR CONDITIONING SYSTEM R 134.aChecks 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).





C5HP14ZD

AIR

CO

ND

ITIO

NIN

G

en_us_t1_2003

Documents

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