User's Manual

ManualsBrandsCITROEN ManualsAutomobileCITROEN C2 2004

PRIVATE CARS

C2-C3-C3 PLURIEL-XSARA

XSARA PICASSO-BERLINGO

PRIVATE CARS

CAR 050014

Volume 1

2004

AC/QCAV/MTD

Méthodes techniques documentation

«The intellectual property rights relating to the technical information contained in this document

belong exclusively to the manufacturer. Reproduction, translation or distribution in whole or in part

without prior 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 the motor vehicle repair trade. In some instances, this information could concern the security and

safety of the vehicle. The information is to be used by the professional vehicle repairers for whom it is

intended and they alone would assume full responsibility to the exclusion of that of the manufacturer».

«The technical information appearing in this brochure is subject to updating as the characteristics of

each model in the range evolve. Motor vehicle repairers are invited to contact the CITROËN network

periodically for further information and to obtain any possible updates».

2004

Summary of content (523 pages)

PAGE 1
PRIVATE CARS C2-C3-C3 PLURIEL-XSARA XSARA PICASSO-BERLINGO «The technical information contained in this document is intended for the exclusive use of the trained personnel of the motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full responsibility to the exclusion of that of the manufacturer».
PAGE 2
PRESENTATION THIS HANDBOOK summarises the specifications, adjustments, checks and special features of CITROEN private vehicles, not including UTILITY vehicles for which there exists a separate handbook. The handbook is divided into nine groups representing the main functions : GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - ELECTRICAL - AIR CONDITIONING.
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IMPORTANT If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into account when preparing future publications. For example : - INSUFFICIENT INFORMATION - SUPERFLUOUS INFORMATION - NEED FOR MORE DETAILS Please send your comments and suggestions to : CITROEN U.K. Ltd. 221, Bath Road, SLOUGH, SL1 4BA. U.K.
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XSARA 2, all types Operation to reconnect the battery after a vehicle repair WARNING If the battery has been disconnected, after reconnecting it is ESSENTIAL to wait 1 minute before switching on the ignition, otherwise the engine ECU will lock up. If the ECU has locked up : - Switch off the ignition. - Wait 1 minute. - Switch the ignition back on, the ECU is unlocked.
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IDENTIFICATION OF VEHICLES C2 A - Cold stamp (Cold stamp engraved on the bodywork) C - AS/RP No. and RP paint code (On the LH centre pillar) D - Tyre pressures and tyre type (On the LH centre pillar) E - Serial number on bodywork F - Gearbox ident. reference – Factory serial no. G - Engine legislation type– Factory serial no.
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C2 Emission standard Type code IDENTIFICATION OF VEHICLES 1.1i 1.4i 1.
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IDENTIFICATION OF VEHICLES C2 1.4 HDi Pack - Pack ambiance - Exclusive L4 IFL5 JM 8HXB Type code JM 8HXC/IF (*) Engine type 8HX Cubic capacity (cc) 1398 4 Fiscal rating (hp) MA/50 Gearbox type Gearbox ident. plate (1) = Europe. (2) = DAIC. JM 8HXC/PIF (**) GENERAL Emission standard 20 CN 51 (1) (m) (4) (5) (*) = IF. (**) = PIF.
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C2 - C3 OPERATIONS TO BE CARRIED ORT AFTER A REPAIR IMPERATIVE: All these operations are to be performed following a reconnection of the battery. Antiscanning function. It is necessary to wait 1 minute after the battery has been disconnected in order to be able to start the vehicle. Tailgate. The opening of the tailgate is deactivated on reconnection of the battery. Perform locking/unlocking to activate the opening of the tailgate. GENERAL Overspeed check.
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OPERATIONS TO BE CARRIED ORT AFTER A REPAIR C2 Multifunction screen. It is necessary to adjust the date, time and ortside temperature. Adjust the display language of the multifunction screen if necessary. NOTE: The default display language of the multifunction screen is French. Navigation. Warning, the vehicle has to be in the open air (on switching on the ignition, the ECU searches for satellites). Vehicle location is only effective after some ten minutes. Reprogramme the customer paramanders. Radio.
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C3 IDENTIFICATION OF VEHICLES A - Cold stamp (Cold stamp engraved on the bodywork). B - Manufacturer’s name plate (On the LH centre pillar) GENERAL 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.
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IDENTIFICATION OF VEHICLES C3 Petrol 1.1i Emission standard Type code K’ L4/INF FC HFX5 FC HFXB/D Pack - Pack ambiance L4 FC HFXB FN HFXB IFL5 FC HFXB/T Engine type HFX Cubic capacity (cc) 1124 4 Fiscal rating (hp) MA/5N Gearbox type 20 CP 14 (m) (1) (*) Gearbox ident. plate (1) m = Manual gearbox (*) EXPORT and DAIC = 20 CP 17 (14x60) (21x18).
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IDENTIFICATION OF VEHICLES C3 PETROL 1.4i AUTO. Pack - Pack ambiance - Pack clim - Exclusive GENERAL Emission standard Type code L4/INF FC KFVB/D L4 FC KFVB IFL5 FN KFVB FC KFVC/IF Engine type L4 FN KFVE IFL5 FC KFVE 1360 Cubic capacity (cc) 5 Fiscal rating (hp) Gearbox type L4/INF FN FC KFVC/IF KFVE/D KFV MA/5L Gearbox ident. plate MA/5N AL4 20 CP 15 (m) (1) (*) 20 TP 75 (1) m = Manual gearbox (*) EXPORT = 20 CP 16 (m) (1).
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C3 IDENTIFICATION OF VEHICLES 1.4i 16V 1.6i 16V SensoDrive Pack ambiance - Pack clim - Exclusive L5 Emission standard Type code FC KFUC/P L4 FC KFUN/P Engine type KFU Cubic capacity (cc) 1360 FN NFUB FC NFUB FC NFUC/IF NFU 1587 6 Fiscal rating (hp) MA/5S Gearbox type Gearbox ident.
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C3 IDENTIFICATION OF VEHICLES Diesel 1.4 HDi GENERAL Entreprise Entreprise club Entreprise Pack Pack L4 Emission standard Type code FC 8HXB/T FN 8HXB FC 8HXB FC 8HXB/MOD FR 8HXB 4 MA/50 Fiscal rating (hp) Gearbox type 20 CP 54 (m) (1) (*) (1) m = Manual gearbox (2) mp = Piloted manual gearbox (*) EXPORT and DAIC = 20 CP 55 (m) (1) and 20 CP 72 (m) (1). 10 FN 8HWB FC 8HWB 8HW 1398 Cubic capacity (cc) Gearbox ident.
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C3 IDENTIFICATION OF VEHICLES Diesel 1.4 HDi 16V L4 Emission standard Type code Engine type FC 8HVB FN 8HVB FC 8HYB FC 8HYB/T FC 8HYB/MOD 8HV FC 8HYK 8HY 1398 Cubic capacity (cc) 5 BE4/5L Fiscal rating (hp) Gearbox type Gearbox ident.
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C3 PLURIEL IDENTIFICATION OF VEHICLES A - Cold stamp (Cold stamp engraved on the bodywork). B - Manufacturer’s name plate (On the LH centre pillar) GENERAL 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.
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IDENTIFICATION OF VEHICLES C3 PLURIEL Diesel Petrol 1.4i 1.6i 16V 1.4 HDi Emission standard Type code L4 IF/L5 IF/L5 HB KFVB HB KFVC/IF HB NFUC/IF HB 8HXB Engine type KFV NFU 8HX Cubic capacity (cc) 1360 1587 1398 Fiscal rating (hp) Gearbox type Gearbox ident.
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XSARA II IDENTIFICATION OF VEHICLES A - Manufacturer’s name plate (Estate). B - Chassis stamp, cold stamp. C - Manufacturer’s name plate (Saloon). GENERAL D - Label : (label affixed to the front pillar on driver’s side) - Tyre pressures. - RP organisation no. - Paint code. E - Serial number. (visible throrgh the windscreen) F - Engine legislation type. Factory serial no. G - Gearbox ident. reference. Factory serial no.
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IDENTIFICATION OF VEHICLES XSARA II Saloon petrol 3-door 1.6i 16V AUTO. Océanic Pack Emission standard Type code X - VTR L4 L5/IF NO KFWB NO KFW1/IF Pack VTR - VTS AUTO. SX VTR - VTS L4 NO NFUB L5/IF NO NFUN Engine type KFW NFU Cubic capacity (cc) 1360 1581 5 Fiscal rating (hp) Gearbox type Gearbox ident. plate VTR NO NFU1/IF NO NFU3/IF 7 MA/5 MA/5 AL4 MA/5 AL4 20 CP 13 20 CP 51 (*) 20 TP 49 20 CP 51 (*) 20 TP 49 (*) NFU DAIC = 20 CP 52 (14x60) (21x18). 15 GENERAL 1.
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IDENTIFICATION OF VEHICLES XSARA II Saloon petrol 3-door 2.0i 16V AUTO. VTS Emission standard GENERAL Type code L5/IF L4/IF L5/IF L4 NO RFN1/IF NO RFNN/IF NO RFN3/IF NO RFSB RFN Engine type 1998 Cubic capacity (cc) Fiscal rating (hp) Gearbox type Gearbox ident. plate RFS 8 9 11 BE4/5 AL4 BE3/5 20 DL 40 20 DM 03 (1) 20 TP 47 20 TE 47 (1) = Right hand drive : Hydraulic clutch control.
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XSARA II IDENTIFICATION OF VEHICLES Saloon diesel 3-door 1.4 HDi 1.9 D 2.0 HDi AUTO. Pack Océanic Pack club Océanic - Pack VTR - VTS N0 8HZB N0 WJYB N0 RHYB Engine type 8HZ WJY RHY Cubic capacity (cc) 1398 1868 Fiscal rating (hp) 4 RHZ 6 BE4/5 20 DM 54 N0 RHZN 1997 5 Gearbox type Gearbox ident. plate N0 RHZB 20 DL 41 20 DM 05 (1) AL4 20 DL 42 20 DM 07 (1) (*) (1) = Right hand drive : Hydraulic clutch control. (*) DAIC DAD = 20 DM 08.
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XSARA II IDENTIFICATION OF VEHICLES Saloon petrol 5-door 1.4i 1.6i 16V AUTO. Océanic - Pack Exclusive Pack GENERAL Emission standard Type code L4 L5 N1 KFW1/IF N1 KFW1/IF AUTO. X - SX Exclusive Exclusive L4 N1 NFUB L5/IF N1 NFUN N1 NFU1/IF Engine type KFW NFU Cubic capacity (cc) 1360 1587 5 Fiscal rating (hp) 8 MA/5 MA/5 AL4 MA/5 AL4 20 CP 13 20 CP 51 (*) 20 TP 49 20 CP 51 (*) 20 TP 49 Gearbox type Gearbox ident.
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IDENTIFICATION OF VEHICLES XSARA II Saloon petrol 5-door 2.0i 16V AUTO. Emission standard Type code L5/IF L4 N1 RFN1/IF N1 RFNN 1998 Cubic capacity (cc) Gearbox type Gearbox ident. plate RFN3/IF RFN Engine type Fiscal rating (hp) L5/IF 8 9 BE4/5 AL4 20 DL 40 20 DM 03 (2) 20 TP 47 (1) = Right hand drive : Hydraulic clutch control. (2) = Right hand drive : Hydraulic clutch control.
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XSARA II IDENTIFICATION OF VEHICLES Saloon diesel 5-door 1.4 HDi 16V 1.9 D 2 HDi AUTO. Pack - Leader Océanic - Pack Océanic - Leader - Leader Pack - Exclusive GENERAL L4 Emission standard N1 8HZB N1 WJYB N1 RHYB Engine type 8HZ WJY RHY Cubic capacity (cc) 1398 1868 Type code Fiscal rating (hp) 4 1997 6 BE4/5 20 DM 54 N1 RHZN RHZ 5 Gearbox type Gearbox ident. plate N1 RHZB 20 DL 41 20 DM 05 (1) AL4 20 DL 42 20 DM 07 (1) (*) (1) = Right hand drive : Hydraulic clutch control.
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IDENTIFICATION OF VEHICLES XSARA II Estate petrol 1.6i 16V 1.4i X - Pack Emission standard Type code L4 Océanic - Pack Exclusive Exclusive L4 L5/IF L5/IF N2 KFWB N2 KFW1/IF N2 NFUB N2 NFU1/IF N2 NFUN Engine type KFW NFU Cubic capacity (cc) 1360 1581 Fiscal rating (hp) Gearbox type Gearbox ident. plate 5 N2 NFU3/IF 7 MA/5 MA/5 AL4 20 CP 44 20 CP 51 (*) 20 TP 49 21 GENERAL AUTO.
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XSARA II IDENTIFICATION OF VEHICLES Estate diesel Estate petrol 2.0i 16V 1.4 HDi 1.9 D X - Pack Océanic Pack 2.0 HDi AUTO. AUTO. Exclusive Emission standard GENERAL Type code L5/IF L4 N2 RFN1/IF N2 RFNN Gearbox ident.
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XSARA PICASSO IDENTIFICATION OF VEHICLES A - Chassis stamp (Cold stamp on bodywork) B - Chassis no. reminder (Label located at bottom of windscreen right hand side) 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. E1AP088D 23 GENERAL C - Manufacturer’s data plate.
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XSARA PICASSO IDENTIFICATION OF VEHICLES Petrol 1.6i 1.8i 16V 2.0i 16V AUTO. Océanic - Pack Emission standard GENERAL Type code Océanic - Pack - Exclusive L4 CH NFVB Exclusive IFL5 CH 6FZB CH 6FZC/IF CH RFNF/IF Engine type NFV 6FZ RFN Cubic capacity (cc) 1587 1749 1998 Fiscal rating (hp) Gearbox type Gearbox ident. plate 6 7 9 BE4/5/ J (*) BE4/5 V (*) AL4 20 DL 67 20 DL 69 20 TS 02 (*) L,J V = Corresponds to the stepping of the gears.
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XSARA PICASSO IDENTIFICATION OF VEHICLES Diesel 1.6 HDi 16V 2.0 HDi Océanic - Leader - Pack - Exclusive Type code Engine type Cubic capacity (cc) CH 9HZC CH 9HYB CH RHYB 9HZ (*) 9HY (**) RHY 1560 1997 6 Fiscal rating (hp) Gearbox type Gearbox ident. plate 5 BE4/5L BE4/5L 20 DM 62 20 DL 65 (*) = With particle filter (FAP). (**) = Withort particle filter (FAP).
PAGE 30
BERLINGO IDENTIFICATION OF VEHICLES A - Chassis stamp, cold stamp B - Manufacturer’s vehicle plate C - Label GENERAL - RPO No. - Paint colorr code - Tyre pressures D - Gearbox ident. reference - Factory serial no. E - Engine legislation type - Factory serial no.
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BERLINGO IDENTIFICATION OF VEHICLES Berlingo petrol 5-seater Type code 1.4i X X - SX - Multispace L4/W4 L4/W4 GJ HFXB GJ KFWB IFL5 GJ KFWC/IF Engine type HFX KFW Cubic capacity (cc) 1124 1360 5 6 MA/5S MA/5L 20 CD 43 20 CN 13 Fiscal rating (hp) Gearbox type Gearbox ident. plate 27 GENERAL Emission standard 1.
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BERLINGO IDENTIFICATION OF VEHICLES Berlingo petrol 5-seater 1.4i 1.6i 16V Dual fuel Multispace L4 Emission standard GENERAL Type code X - SX - Multispace GJ KFWB/GL (1) IFL5 GJ KFWB/GN (2) GJ NFUB GJ NFUC/IF Engine type KFW NFU Cubic capacity (cc) 1360 1587 5 7 MA/5 BE4/5 20 CN 13 20 DM 46 Fiscal rating (hp) Gearbox type Gearbox ident. plate (1) GL = LPG = Liquefied Petroleum Gas, with ring-shaped tank. (2) GN = CNG = Compressed Natural Gas, with cylindrical tank.
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IDENTIFICATION OF VEHICLES BERLINGO Berlingo diesel 5-seater 1.9 D 2.0 HDi X - SX - Multispace X - SX - Multispace Type code GJ WJYB GJ WJYB/PMF (1) GJ RHYB Engine type WJY RHY Cubic capacity (cc) 1868 1997 5 6 BE4/5 BE4/5 20 DM 48 20 DM 50 Fiscal rating (hp) Gearbox type Gearbox ident. plate (1) /PMF = Multifunction roof.
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CAPACITIES (in litres) Draining mandhod. The oil capacities are defined according to the following mandhods. 1/ Vehicle on level surface (in high position, if equipped with hydropneumatic suspension). 2/ Engine warm (oil temperature 80°C). GENERAL 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).
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CAPACITIES (in litres) C2 C2 Petrol Drain by gravity : engine with filter change Bandween min. and max. 1.1i 1.4i 1.6i 16V HFX KFV NFU 3 8HX ➔ RPO 9884 3,25 1,5 8HX RPO 9885 ➔ 3,75 1,8 1,5 2 MA5 5-speed gearbox 2 ± 0,15 MA5 piloted 5-speed gearbox Braking circuit 1.
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C3 CAPACITIES (in litres) C3 Petrol 1.1i 1.4i 1.6i 16V KFV KFU NFU 3 3,75 3,25 1,5 1,2 1,5 AUTO. Engine type HFX GENERAL Drain by gravity : engine with filter change Bandween min. and max. Drain by suction : engine with filter change Bandween min. and max. 5-speed gearbox Automatic gearbox After oil change 3,1 1.4 HDI 16V 1.
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C3 PLURIEL CAPACITIES (in litres) C3 Pluriel Engine type Drain by gravity: engine with filter change Bandween min. and max. 1.4i 1.6i 16V 1.4 HDi KFV 3 1,5 NFU 3,25 1,5 8HX 3,75 1,5 5-speed gearbox Braking circuit Cooling system Fuel tank capacity Diesel 2 0,7 Litre version with front calipers Ø 48 / rear drums 0,8 Litre version with front calipers Ø 54 / rear discs 7 45 ESSENTIAL: systematically check the oil level using the oil dipstick. (1) = The gearbox is lubricated for life.
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XSARA II CAPACITIES (in litres) XSARA II Petrol 1.4i 1.6i 16V 2.0i 16V AUTO. GENERAL Engine type Engine with filter element Bandween min. and max. KFW NFU 3 3,25 1,5 1,5 RFN 4,25 1 1,9 Automatic gearbox 6 3 After drainage 7 6,5 (1) Fuel tank capacity 54 ESSENTIAL: Systematically check the oil level using the oil dipstick. 34 1,9 6 3 With ABS = 0,50 - Without ABS = 0,55 Hydraulic or brake circuit RFS 1,7 2 5-speed gearbox Cooling system AUTO.
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IDENTIFICATION OF VEHICLES XSARA II XSARA II Diesel 1.4 HDi 1.9 D 2.0 HDi AUTO. RPO 9885 ➔ 8HZ Engine type 3,75 Engine with filter element Bandween min. and max.
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XSARA PICASSO CAPACITIES (in litres) XSARA PICASSO Petrol Diesel 1.8i 16 V 1.6i 2.0i 16V 1.6 16V HDi 2.0 HDi AUTO. NFV Engine type GENERAL Engine with filter element Bandween min. and max.
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CAPACITIES (in litres) BERLINGO II Berlingo 2 Petrol Diesel Engine type Moteur avec cartorche Bandween min. and max. 5-speed gearbox Hydraulic or brake circuit Cooling system Fuel tank capacity 1.1i 1.4i 1.6i 16V 1.9 D 2.0 HDi HFX KFW NFU WJY RHY 3 3,25 1,5 4,5 1,2 2 1,8 1,4 1,8 With ABS = 0,45 - Without ABS = 0,36 8 9 55 60 ESSENTIAL: Systematically check the oil level using the oil dipstick. 37 GENERAL Ecological oil filter capacity 0.15 litre.
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ALL TYPES LUBRICANTS - TOTAL recommended oils Evolutions (year 2004). Use of oil grade 10W 40. It is possible to use semi-synthandic oil 7000 10W40 on PETROL and DIESEL vehicles. CITROËN C2, C3 PLURIEL, DISPATCH and DV6 engines. WARNING: To avoid problems with starting from cold, use this oil as allowed by the climatic conditions in the corntry concerned (see table). Only petrol versions are available. GENERAL Normal maintenance interval: 30 000 km (20 000 miles).
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LUBRICANTS - TOTAL recommended oils ALL TYPES Engine oil norms. The classification of these engine oils is established by the following recognised organisations: - S.A.E : Sociandy of Automotive Engineers. - API : American Petroleum Institute. - ACEA : Association des Constructeurs Européens d’Automobiles E4AP006D 39 GENERAL Current norms.
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ALL TYPES LUBRICANTS - TOTAL recommended oils S.A.E. Norms - Table for selection of engine oil grade Selection of engine oil grades recommended for climatic conditions in corntries of distribution. Evolution of the norms as at 01/01/2003 API norms GENERAL ACEA 2003 norms The meaning of the first landter has not changed, it still corresponds to the type of engine: A: petrol and dual fuel petrol / LPG engines. B: diesel engines.
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LUBRICANTS - TOTAL recommended oils ALL TYPES Recommendations. ESSENTIAL: To preserve engine performances, all engines fitted in CITROEN vehicles must be lubricated with high quality oils (synthandic or semi-synthandic). GENERAL 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%).
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ALL TYPES LUBRICANTS - TOTAL recommended oils Récapitulation Norms to be observed for engine oils (year 2003) Year Types of engine concerned ACEA norms API norms Year 2003 Petrol and dual fuel petrol / LPG engines A3 or A5 5 (*) SJ or SL Diesel engines B3 or B5 (*) CF GENERAL (*) It is essential not to use engine oils respecting these norms for the following engine-types: XU10 J4RS , SOFIM 2.8 TDi and SOFIM 2.8 HDi , HDi with particle filter (FAP), EW 12 J4, DV4 TED4.
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ALL TYPES LUBRICANTS - TOTAL recommended oils Oils specifically for petrol and dual fuel petrol / LPG engines TOTAL ACTIVA 7000 TOTAL QUARTZ 7000 10W40 TOTAL QUARTZ 9000 0W40 TOTAL ACTIVA 7000 TOTAL QUARTZ 7000 15W50 ACEA norms API norms A3 SJ GENERAL S.A.E. norms Oils specifically for diesel engines S.A.E.
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ALL TYPES LUBRICANTS - TOTAL recommended oils Oil usage table TOTAL ACTIVA QUARTZ Engine types Synthetic 9000 10W40 15W50 hot countries X X X X X X X X X X X X X X X SOFIM 2.8 TDi and 2.8 HDi (RELAY) X X X DV4 TED4 (C3 1.4 16V HDi) X X X X X X XU10 J4RS (Xsara VTS 2.0i 16V) GENERAL Petrol engines EW 12 J4 (C8 2.
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LUBRICANTS - TOTAL recommended oils ALL TYPES GENERAL Selection of TOTAL engine oils, to be used according to the climatic conditions in the country where the vehicle is marketed.
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ALL TYPES LUBRICANTS - TOTAL recommended oils ENGINE OILS FRANCE Metropolitan FRANCE Blended oils for all engines, supplied in bulk TOTAL ACTIVRAC S.A.E.
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LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS TOTAL ACTIVA Blended oils for all engines TOTAL ACTIVA DIESEL Oils specifically for petrol and dual-fuel petrol / LPG engines Germany 7000 10W40 9000 0W40 Austria 7000 10W40 Belgium 7000 10W40 9000 0W40 Bosnia 9000 5W40 FUTURE 9000 5W30 (*) 7000 10W40 9000 0W40 Bulgaria 7000 10W40 Cyprus 7000 10W40 9000 15W40 Croatia 7000 10W40 (*) Blended oils for all engines, permitting fuel economy 47 Oils specifically for diesel engines GENE
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ALL TYPES LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines Oils specifically for diesel engines 7000 10W40 9000 0W40 7000 10W40 7000 15W40 Denmark GENERAL Spain Estonia Finland TOTAL ACTIVA DIESEL 7000 10W40 9000 0W40 9000 5W40 FUTURE 9000 5W30 (*) 7000 10W40 Great Britain 7000 10W40 Greece 7000 10W40 7000 15W40 Holland 7000 10W40 9000 0W40 (*) Blended oils for all engines, perm
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LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS EUROPE TOTAL ACTIVA Blended oils for all engines TOTAL ACTIVA DIESEL Oils specifically for petrol and dual-fuel petrol / LPG engines Oils specifically for diesel engines GENERAL 7000 10W40 9000 0W40 Hungary Italy Ireland Iceland 7000 10W40 9000 5W40 FUTURE 9000 5W30 (*) 7000 10W40 Latvia Lithuania 7000 10W40 9000 0W40 Macedonia 7000 10W40 (*) Blended oils for all engines, permitting fuel economy 49
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ALL TYPES LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL ACTIVA Blended oils for all engines TOTAL ACTIVA DIESEL Oils specifically for petrol and dual-fuel petrol / LPG engines GENERAL Malta 7000 10W40 7000 15W50 Moldavia 7000 10W40 Norway 7000 10W40 9000 0W40 Poland 9000 5W40 FUTURE 9000 5W30 (*) Oils specifically for diesel engines 7000 10W40 Portugal 7000 10W40 Slovakia 7000 10W40 9000 0W40 Czech Republic (*) Blended oils for all engines, permitting fuel economy 50
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LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS EUROPE TOTAL ACTIVA Blended oils for all engines TOTAL ACTIVA DIESEL Oils specifically for petrol and dual-fuel petrol / LPG engines Oils specifically for diesel engines GENERAL 7000 10W40 7000 15W50 9000 0W40 Romania Russia Slovenia 7000 10W40 9000 0W40 9000 5W40 FUTURE 9000 5W30 (*) 7000 10W40 Sweden Switzerland 7000 10W40 Turkey 7000 10W40 9000 15W50 9000 0W40 (*) Blended oils for all engines, permitting fuel economy 51
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ALL TYPES LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE Ukraine TOTAL ACTIVA TOTAL ACTIVA DIESEL GENERAL Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines Oils specifically for diesel engines 9000 5W40 FUTURE 9000 5W30 (*) 7000 10W40 9000 0W40 7000 10W40 Yugoslavia (*) Blended oils for all engines, permitting fuel economy 52
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LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS Australia New Zealand TOTAL ACTIVA TOTAL ACTIVA DIESEL Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines Oils specifically for diesel engines 9000 5W40 FUTURE 9000 5W30 7000 10W40 7000 10W40 AFRICA TOTAL ACTIVA TOTAL ACTIVA DIESEL Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines Oils specifically for diesel engines 9000 5W40 7000 15W50 7000 10W4
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ALL TYPES LUBRICANTS - TOTAL recommended oils ENGINE OILS CENTRAL AND SOUTH AMERICA TOTAL ACTIVA Blended oils for all engines TOTAL ACTIVA DIESEL Oils specifically for petrol and dual-fuel petrol / LPG engines Oils specifically for diesel engines 7000 10W50 7000 15W50 7000 10W40 Argentina GENERAL Brazil Chile Cuba 9000 5W40 Mexico Paraguay Uruguay 54
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LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS SOUTH-EAST ASIA TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines Oils specifically for diesel engines 9000 5W40 FUTURE 9000 5W30 GENERAL 7000 10W50 7000 15W50 China South Korea TOTAL ACTIVA DIESEL 7000 10W40 Hong Kong 7000 15W50 India - Indonesia Japan 7000 10W40 9000 5W40 9000 5W40 FUTURE 9000 5W30 (*) 7000 10W40 7000 15W50 9000 5W40 7000 15W50 Malaysia Pakistan (*) Blended o
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ALL TYPES LUBRICANTS - TOTAL recommended oils ENGINE OILS SOUTH-EAST ASIA TOTAL ACTIVA Blended oils for all engines TOTAL ACTIVA DIESEL Oils specifically for petrol and dual-fuel petrol / LPG engines Oils specifically for diesel engines Philippines GENERAL 7000 15W50 Singapore Taiwan 7000 10W40 7000 15W50 9000 5W40 Thailand 7000 15W50 Vietnam 56 7000 10W40
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LUBRICANTS - TOTAL recommended oils ALL TYPES ENGINE OILS MIDDLE EAST TOTAL ACTIVA Blended oils for all engines TOTAL ACTIVA DIESEL Oils specifically for petrol and dual-fuel petrol / LPG engines Oils specifically for diesel engines Dubai 7000 15W50 United Arab Emirates Iran 9000 5W40 7000 10W40 7000 15W50 Israel - Jordan - Kuwait 7000 15W50 Lebanon - Oman - Qatar - Syria - Yemen 57 7000 10W40 GENERAL Saudi Arabia - Bahrain
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ALL TYPES LUBRICANTS - TOTAL recommended oils GEARBOX OILS TOTAL TRANSMISSION BV norms S.A.E.: 75W80 Part No.: 9730 A2. Manual gearbox and SensoDrive TOTAL FLUIDE ATX GENERAL MB3 automatic gearbox All countries TOTAL FLUIDE AT 42 Special oil distributed by CITROËN Part No.: 9730 A3 4HP20 and AL4 autoactive automatic gearboxes Special oil distributed by CITROËN Part No.: 9736 22 Transfer box and rear axle TOTAL TRANSMISSION X4 Part No.
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LUBRICANTS - TOTAL recommended oils ALL TYPES All countries TOTAL FLUIDE ATX Very cold countries TOTAL FLUIDE DAS Special oil distributed by CITROËN Part No.: 9730 A1 Power steering ENGINE COOLANT FLUID Pack All countries CITROËN fluid Protection: - 35C° CITROËN Part No.
PAGE 64
LUBRICANTS - TOTAL recommended oils ALL TYPES BRAKE FLUIDS Synthetic brake fluid All countries CITROËN fluid Pack CITROËN Part No. 0,5 Litre 9979 05 1 Litre 9979 06 5 Litres 9979 07 GENERAL HYDRAULIC CIRCUIT All countries TOTAL FLUIDE LDS TOTAL LHM PLUS TOTAL LHM PLUS Very cold countries Pack Norm Orange Colour CITROËN Part No. 9979 69 1 Litre Green ZCP 830095 9979 20 WARNING: TOTAL FLUIDE LDS fluid cannot be blended with TOTAL LHM.
PAGE 65
LUBRICANTS - TOTAL recommended oils ALL TYPES SCREEN WASH FLUID Pack CITROËN Part No. All countries Fluid ready for use 9980 33 ZC 9875 953U 1 Litre 9980 06 ZC 9875 784U 5 Litres 9980 05 ZC 9885 077U GREASE General use All countries TOTAL MULTIS 2 TOTAL SMALL MECHANISMS Note: NLGI = National Lubricating Grease Institute.
PAGE 66
ENGINE OIL CONSUMPTION ALL TYPES I - Oil consumption depends on: - the engine type. how run-in or worn it is. the type of oil used. the driving conditions. GENERAL 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.
PAGE 67
ENGINE ENGINE SPECIFICATIONS Engines: HFX - KFV - KFW - KFU Petrol All types 1.1i Vehicle Emission standard 1.4i 16V 1.
PAGE 68
ENGINE ENGINE SPECIFICATIONS Engines: NFV - NFU - 6FZ - RFN - RFS Petrol All types 1.6i 1.6i 16V 1.8i 16V Xsara Picasso C2/C3 Xsara C3 Pluriel Berlingo II Xsara Picasso Xsara II Xsara Picasso Xsara II L4 L4/IFL5 IFL5 IFL4/IFL5 L4 NFV NFU 6FZ RFN RFS Vehicle Emission standard Engine type Cubic capacity (cc) 1587 2.
PAGE 69
ENGINE ENGINE SPECIFICATIONS Engines: 8HX - 8HW - 8HZ - 8HV - 8HY Diesel All types 1.4 HDi Vehicle Emission standard Engine type C2/C3/C3 Pluriel C3 L4/IFL5 L4 8HX 8HW 1.4 HDi 16V Xsara 8HZ Cubic capacity (cc) Bore / Stroke C3 8HV 8HY 1398 73/82 Compression ratio Power ISO or EEC KW - rpm 73,5/82 73/82 17,9/1 18,25/1 50-4000 66-4000 Power DIN (HP - rpm) 70-4000 69-4000 92-4000 Torque ISO or EEC (m.
PAGE 70
ENGINE ENGINE SPECIFICATIONS Engines: 9HZ - 9HY - WJY - RHU - RHZ Diesel All types 1.6 HDi 16V Vehicle 1.9 D Xsara Picasso Xsara II Berlingo II Emission standard Engine type Cubic capacity (cc) 2.0 HDi Xsara II Xsara Picasso Berlingo II Xsara II RHY RHZ L4 9HZ 9HY WJY 1560 1868 88,3/75 82,2/88 85/88 18/1 23/1 17,6/1 Power ISO or EEC KW - rpm 80-4000 51-4600 66-4000 80-4000 Power DIN (HP - rpm) 110-4000 71-4600 90-4000 109-4000 Torque ISO or EEC (m.
PAGE 71
Engines: HFX - KFV - NFU A = KFV B = NFU RH engine support (1) : 6 ± 0,4 (2) : 6 ± 0,6 (3) : 4,5 ± 0,4 Torque reaction rod (4) : 6 ± 0,6 (5) : 6 ± 0,6 (6) : 8,5 ± 0,2 (7) : 6 ± 0,6 LH engine support on gearbox (8) : 3 ± 0,3 (9) : 6 ± 0,6 (10) : 5,5 ± 0,5 B1BP2Y3P 67 C2 ENGINE SPECIAL FEATURES - TIGHTENING TORQUES (m.
PAGE 72
ENGINE C2 SPECIAL FEATURES - TIGHTENING TORQUES (m.
PAGE 73
HFX - KFV - NFU Cylinder head Coolant outlet housing - in plastic 0,8 ± 0,2 - in aluminium 0,8 ± 0,2 Camshaft bearing caps (TU1JP-TU3JP) - Tightening 2 ± 0,2 - Angular tightening 44 °± 4° Camshaft bearing caps (TU5JP4) - Tightening 2 ± 0,2 - Angular tightening 50° ± 5° Inlet manifold 0,8 ± 0,2 Exhaust manifold 1,8 ± 0,4 1,75 ± 0,25 Valve rockers adjusting screw 3 Sparking plugs Camshaft pulley screw (TU1JP-TU3JP) 3,7 ± 0,2 Camshaft pulley screw (TU5JP4) 4,5 ± 0,5 69 C2 ENGINE SPECI
PAGE 74
ENGINE C2 SPECIAL FEATURES - TIGHTENING TORQUES (m.
PAGE 75
Engine: 8HX B1BP2Y1P 71 (1) : 6 ± 0,6 (2) : 6 ± 0,6 (3) : 6 ± 0,6 (4) : 6 ± 0,6 (5) : 3 ± 0,3 (6) : 6 ± 0,6 (7) : 5,5± 0,5 (8) : 5,7 ± 0,9 C2 ENGINE SPECIAL FEATURES - TIGHTENING TORQUES (m.
PAGE 76
ENGINE C2 SPECIAL FEATURES - TIGHTENING TORQUES (m.
PAGE 77
Engine 8HX Cylinder head Camshaft bearing covers 0,3 ± 0,1 Pre-tightening 1 ± 0,1 Tightening Fixing of camshaft sub-assemblies on cylinder head 0,3 ± 0,1 Pre-tightening Tightening 1 ± 0,1 Exhaust manifold 3 ± 0,3 Camshaft pulley 0,3 ± 0,1 Pre-tightening 4,3 ± 0,4 Tightening Engine flywheel Flywheel Pre-tightening 1,7 ± 0,2 Tightening 70° ± 5° Clutch mechanism 2 ± 0,2 73 ENGINE C2 SPECIAL FEATURES - TIGHTENING TORQUES (m.
PAGE 78
ENGINE C2 SPECIAL FEATURES - TIGHTENING TORQUES (m.
PAGE 79
Engines: HFX - KFV - NFU C3 C3 Pluriel A = HFX - KFV B = NFU A = KFV B = NFU RH engine support (1) : 4,5 ± 0,4 (2) : 6,1 ± 0,6 (3) : 4,5 ± 0,4 RH engine support (1) : 6 ± 0,4 (2) : 6 ± 0,6 (3) : 4,5 ± 0,4 Torque reaction rod (4) : 6 ± 0,6 (5) : 6 ± 0,6 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 LH engine support on gearbox (6) : 3 ± 0,3 (7) : 6 ± 0,6 (8) : 5,5 ± 0,5 B1BP2NEP 75 ENGINE C3 - C3 PLURIEL SPECIAL FEATURE
PAGE 80
ENGINE C3 Engine types Accessories drive pulley Pinion fixing on crankshaft SPECIAL FEATURES - TIGHTENING TORQUES (m.
PAGE 81
Flywheel - Clutch Engines HFX KFV 6,7 ± 0,6 + LOCTITE FRENETANCH Flywheel 2 ± 0,2 Clutch mechanism Lubrication circuit 2 ± 0,2 Oil pressure switch 0,9 ± 0,1 Oil pump Cooling circuit Coolant pump 1,4 ± 0,1 Coolant outlet housing 0,8 ± 0,1 77 NFU ENGINE C3 SPECIAL FEATURES - TIGHTENING TORQUES (m.
PAGE 82
ENGINE C3 TIGHTENING TORQUES: POWER UNIT SUSPENSION Engine: KFU RH engine support (1) (2) : 6 ± 0,6 : 6 ± 0,6 Torque reaction rod (3) (4) : 6 ± 0,6 : 6 ± 0,6 LH engine support on gearbox (5) (6) (7) B1BP2ZBP 78 : 3 ± 0,3 : 6 ± 0,6 : 5,5 ± 0,5
PAGE 83
KFU Crankshaft 0,8 ± 0,2 Accessories drive pulley Pinion fixing on crankshaft - Pre-tightening - Angular tightening 4 ± 0,4 45 ± 4° Cylinder block 0,8 ± 0,2 4 ± 0,4 2,1 ± 0,2 2,5 ± 0,2 2,5 ± 0,3 Sump Accessories belt guide roller Timing belt tensioner roller Accessories belt tensioner roller Alternator support Crankshaft bearing caps - Tightening - Angular tightening 2 ± 0,3 44° (re-used screws cleaned and greased) Cylinder head 0,8 ± 0,2 1 ± 0,2 0,9 ± 0,1 0,8 ± 0,2 Coolant outlet housing Camshaft bear
PAGE 84
ENGINE C3 SPECIAL FEATURES - TIGHTENING TORQUES (m.
PAGE 85
Engines: 8HX - 8HW RH engine support (1) (2) : 4,5 ± 0,4 : 3 ± 0,3 Torque reaction rod (3) (4) : 6 ± 0,6 : 6 ± 0,6 LH engine support on gearbox (5) (6) (7) B1BP2LJP 81 : 5,4 ± 0,5 : 6 ± 0,6 : 5,5 ± 0,5 C3 ENGINE SPECIAL FEATURES - TIGHTENING TORQUES (m.
PAGE 86
ENGINE XSARA SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engine: 8HZ RH engine support (1) : 2 ± 0,2 (9) : 2,5 ± 0,2 (10) : 4,5 ± 0,5 (11) : 4,5 ± 0,5 (12) : 6 ± 0,6 RH lower engine support (8) : 5,7 ± 0,9 Torque reaction rod.
PAGE 87
Engines 8HX 8HW 8HZ Crankshaft Bearing cap fixing screw Pre-tightening Slackening Tightening Angular tightening Con rod nuts Pre-tightening Slackening Tightening Angular tightening Accessories drive pulley Pre-tightening Angular tightening 1 YES 3 140° 1 YES 1,5 ± 0,1 100° ± 5° 3 ± 0,4 180° ± 5° Cylinder block 1 ± 0,1 Sump Timing belt guide roller Timing belt tensioner roller 4,5 ± 0,4 3 ± 0,3 83 3,7 ± 0,4 2,3 ± 0,3 ENGINE C3 - C3 PLURIEL - XSARA SPECIAL FEATURES - TIGHTENING TORQUES (m.
PAGE 88
ENGINE C3 - C3 PLURIEL - XSARA SPECIAL FEATURES - TIGHTENING TORQUES (m.
PAGE 89
C3 - C3 PLURIEL - XSARA 8HX - 8HW - 8HZ Diesel injection circuit Spherical-base screws for diesel injection fixing fork 0,3 ± 0,1 Fuel high pressure common injection rail on engine block 2 ± 0,2 Unions on fuel high pressure common injection rail 1,7± 0,2 Pre-tightening 2,25 ± 0,2 Tightening Diesel injection pump on support Union on diesel injection 2,25 ± 0,2 Diesel injection pump pulley 5 ± 0,5 Union on diesel high pressure pump 2,25 ± 0,2 Cooling circuit Coolant pump 0,3 ± 0,06 Pre-tighteni
PAGE 90
ENGINE C3 SPECIAL FEATURES - TIGHTENING TORQUES (m.
PAGE 91
Engines 8HV - 8HY Crankshaft Bearing cap fixing screw Tightening Angular tightening Crankshaft pullet hub Tightening Angular tightening 3 ± 0,3 140° ± 1°,4’ 3 ± 0,3 180° ± 5° Cylinder block 1 ± 0,1 4 ± 0,4 Oil sump Timing belt tensioner roller Timing belt guide roller Timing belt guide roller support 2,5 ± 0,2 Cylinder head Camshaft bearing cap cover Inlet manifold Exhaust manifold Cylinder head cover Camshaft pinion Fuel high pressure pump pinion 1 ± 0,1 2,5 ± 0,2 Screws (M6) to 1 ± 0,2 4,3 ± 0,4 5
PAGE 92
ENGINE C3 SPECIAL FEATURES - TIGHTENING TORQUES (m.
PAGE 93
CYLINDER HEAD (mm) Engine types KFW NFV Maximum permissible bow 0,05 Gasket surface regrinding - 0,20 NFU TIGHTENING TORQUES (m.
PAGE 94
ENGINE XSARA - XSARA PICASSO SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) CYLINDER HEAD (mm) Engine types 6FZ RFN Maximum permissible bow RFS WJY 0,05 Gasket surface regrinding - 0,30 RHY RHZ 0,03 - 0,20 - 0,40 TIGHTENING TORQUES ( m.
PAGE 95
Engines: 9HZ - 9HY Torque reaction rod 1 : 5,4 ± 0,8 2 : 5,4 ± 0,8 13 : 6 ± 0,9 LH upper engine support 3 : 2,1 ± 0,2 4 : 5 ± 0,5 LH lower engine support 5 : 2,1 ± 0,2 6 : 5,7 ± 0,8 RH lower engine support 7 : 5,5 ± 0,5 RH engine support 8 : 4,5 ± 0,4 9 : 4,5 ± 0,6 10 : 2,5 ± 0,6 11 : 2,1 ± 0,2 12 : 6,1 ± 0,6 B1BP2Z4P 91 ENGINE XSARA PICASSO SPECIAL FEATURES - TIGHTENING TORQUES (m.
PAGE 96
ENGINE XSARA PICASSO SPECIAL FEATURES - TIGHTENING TORQUES (m.
PAGE 97
Engines 9HZ - 9HY Cylinder head Camshaft bearing covers 0,5 ± 0,1 Pre-tightening Tightening 1 ± 0,1 Exhaust manifold 3 ± 0,3 Camshaft pulley Pre-tightening 2 ± 0,2 Angular tightening 50 ± 5° Cylinder head Pre-tightening 2 ± 0,2 Tightening 4 ± 0,5 260 ± 5° Angular tightening EGR valve 1 ± 0,1 Flywheel - Clutch Flywheel Pre-tightening 3 ± 0,3 Angular tightening 90 ± 5° Clutch mechanism 2 ± 0,2 93 ENGINE XSARA PICASSO SPECIAL FEATURES - TIGHTENING TORQUES (m.
PAGE 98
ENGINE XSARA PICASSO SPECIAL FEATURES - TIGHTENING TORQUES (m.
PAGE 99
Engines XSARA PICASSO 9HZ - 9HY Diesel injection circuit Diesel injection pump pulley 5 ± 0,5 Union on fuel high pressure pump 2 ± 0,5 Pre-tightening 2,5 ± 0,3 Tightening Cooling circuit Coolant pump Pre-tightening 0,3 ± 0,1 Tightening 0,9 ± 0,1 Coolant outlet housing Pre-tightening 0,3 ± 0,1 Tightening 0,7 ± 0,1 95 ENGINE SPECIAL FEATURES - TIGHTENING TORQUES (m.
PAGE 100
ENGINE C2 - C3 - C3 PLURIEL CYLINDER HEAD Engines: HFX - KFV - NFU Identification of cylinder head gasket Engine types Thicknesses (Standard) Thicknesses (repair) 1,2 ± 0,1 1,4 ± 0,1 HFX KFV NFU 0,66 ± 0,04 KFU 1,2 ± 0,1 Thickness references 2 1 4 1,5 ± 0,1 Identification marks 1,2,3,4 = Type of engine A,B,D =Suppliers. C = Gasket material. R = Repair.
PAGE 101
Engines: HFX - KFV - NFU Cylinder head tightening (m.daN) Cylinder head bolts HFX - KFV Tightening Angular tightening : 2 ± 0,2 : 240° ± 5° (In the order 1 to 10) KFU Pre-tightening Tightening Angular tightening : 1,5 ± 0,2 : 2,5 ± 0,2 : 200 ± 5° (In the order 1 to 10) NFU NOTE: Retightening of the cylinder head after a completed repair is prohibited.
PAGE 102
ENGINE XSARA - XSARA PICASSO CYLINDER HEAD Engines: KFW - NFV - NFU Identification of cylinder head gasket Engine type Identification marks KFW Material 1 2 3 4 A B D A B D A B D A B D C Repair R Thickness CURTY Suppliers MEILLOR ELRING REINZ 1 0 0 0 0 0 0 1 1 0 NFV (Notch on cylinder head gasket) * 1 0 0 1 NFU 1 1 1 1 1 0 0 0 (With asbestos) – 1 (Without asbestos) 0 (Standard gasket) – 1 (Repair gasket) 98 0 = Without notch 1 = One notch B1BP10KC
PAGE 103
Engines: KFW - NFV - NFU Cylinder head tightening (m.daN) One Cylinder head bolts KFW - NFV Pre-tightening Angular tightening :2 : 240 ± 5° B1BP10LC NFU Pre-tightening Angular tightening :2 NOTE: Oil the threads and under the heads of the bolts (use : 260 ± 5° engine oil or Molykote G Rapid Plus). B1DP059C X =MAX.
PAGE 104
ENGINE XSARA - XSARA PICASSO CYLINDER HEAD Engine: 6FZ Identification of cylinder head gasket Identification zone "d" Marking zone "e" Gasket thickness (mm) Nominal dimension Repair dimension 4–5 2–4–5 0,8 Supplier R1 R2 R3 1 1,1 1,3 MEILLOR Identification marks “d” “e” = Identification zone. = Marking zone.
PAGE 105
Engine: 6FZ Cylinder head tightening (m.daN) One Cylinder head bolts 6FZ Pre-tightening Tightening Destightening Tightening Angular tightening : 1,5 ± 0,2 : 5 ± 0,2 : 360 ° (1 turn) : 2 ± 0,2 : 285° ± 5° B1DP16FC NOTE: Oil the threads and under the heads of the bolts (use engine oil or Molykote G Rapid Plus). A = Washer thickness: 4 ± 0,2 mm. X = Length under heads of new bolts = 144,5 ± 0,5 mm. X =MAX.
PAGE 106
ENGINE XSARA - XSARA PICASSO CYLINDER HEAD Engine: RFN Identification of cylinder head gasket Nominal dimension Repair dimension 4–5 2–4–5 Identification zone "d" Marking zone "e" Gasket thickness (mm) Supplier 0,8 R1 R2 1,1 1,4 MEILLOR Multilayer metallic gasket B1DP183D 102
PAGE 107
Engine: RFN Cylinder head tightening (m.daN) One Cylinder head bolts RFN Pre-tightening Tightening Destightening Tightening Angular tightening : 1,5 ± 0,2 : 5 ± 0,2 : 360 ° (1 turn) : 2 ± 0,2 : 285° ± 5° B1DP16FC NOTE: Oil the threads and under the heads of the bolts (use engine oil or Molykote G Rapid Plus). A = Washer thickness: 4 ± 0,2 mm. X = Length under heads of new bolts = 144,5 ± 0,5 mm. X =MAX.
PAGE 108
ENGINE CYLINDER HEAD XSARA Engine: RFS Identification of cylinder head gasket Engine type RFS Identification marks Suppliers MEILLOR (Notch on cylinder head gasket) A 1 B 0 C 1 D 0 E 0 * * B1BP004C 104 0 = Without notch 1 = One notch
PAGE 109
Engine: RFS Cylinder head tightening (m.daN) One Cylinder head bolts RFS Pre-tightening Slackening Tightening Angular tightening : 3,5 : NO :7 : 160° NOTE: Oil the threads and under the heads of the bolts (use engine oil or Molykote G Rapid Plus). B1DP13PC X =MAX.
PAGE 110
ENGINE C2 - C3 - C3 PLURIEL - XSARA CYLINDER HEAD Engines: 8HX - 8HW - 8HZ Identification of cylinder head gasket Engine types 8HY - 8HV Supplier ELRING Piston standproud (mm) Thicknesss (mm) 0,771 to 0,820 1,35 1 0,611 to 0,720 1,25 2 0,721 to 0,770 1,30 3 0,821 to 0,870 1,40 4 0,871 to 0,977 1,45 5 No. of notches at No. of notches at “d “ “e” Type of gasket: Metallic multilayer «d» Thickness reference. 1 «e» Engine reference.
PAGE 111
Engines: 8HY - 8HV Identification of cylinder head gasket Engine types 8HY - 8HV Supplier ELRING Piston standproud (mm) Thicknesss (mm) 0,771 to 0,820 1,35 1 0,611 to 0,720 1,25 2 0,721 to 0,770 1,30 3 0,821 to 0,870 1,40 4 0,871 to 0,977 1,45 5 No. of notches at No. of notches at “d” “e” Type of gasket: Metallic multilayer «d» Thickness reference. 2 «e» Engine reference.
PAGE 112
ENGINE C2 - C3 - C3 PLURIEL CYLINDER HEAD Engines: 8HX - 8HW - 8HZ - 8HV - 8HY Cylinder head tightening (m.daN) One Cylinder head bolts 8HX - 8HW - 8HZ - 8HV - 8HY Pre-tightening : 2 ± 0,2 m.daN Tightening : 4 ± 0,4 m.daN Angular tightening : 230° ± 5° (In the order 1 to 10) NOTE: - The bolts should have been thoroughly cleaned and dried with a dry metal brush. - Oil the threads and under the heads of the bolts (use engine oil or Molykote G Rapid Plus). The cylinder head gasket is dry-fitted.
PAGE 113
Engines: 9HZ - 9HY Identification of cylinder head gasket Engine types 9HZ - 9HY Supplier Piston standproud (mm) Thicknesss (mm) 0,685 to 0,734 1,35 1 No. of notches at No. of notches at “d” “e” 0,533 to 0,634 1,25 2 FEDERAL 0,635 to 0,684 1,30 3 MOGUL 0,735 to 0,784 1,40 4 0,785 to 0,886 1,45 5 Type of gasket: Metallic multilayer «d» Thickness reference. 3 «e» Engine reference.
PAGE 114
ENGINE XSARA PICASSO CYLINDER HEAD Engines: 9HZ - 9HY Cylinder head tightening (m.daN) One Cylinder head bolts 9HZ - 9HY Pre-tightening : 2 ± 0,2 m.daN Tightening : 4 ± 0,4 m.daN Angular tightening : 260° ± 5° (In the order 1 to 10) The cylinder head gasket is dry-fitted. NOTE: Retightening of the cylinder head after a completed repair is prohibited. NOTE: - The bolts should have been thoroughly cleaned and dried with a dry metal brush.
PAGE 115
Engine: WJY Identification of cylinder head gasket Plaque Engine WJY Piston standproud (mm)-(*) Thickness (mm) ± 0,04 0,51 to 0,55 1,26 0,55 to 0,59 1,30 0,59 to 0,63 1,34 0,63 to 0,67 1,38 4 0,67 to 0,71 1,42 5 Number of holes at A WJY Number of holes at B 1 2 2 3 (A) = Repère engine. (B) = Thickness references. (*) = Take the highest piston as a reference.
PAGE 116
ENGINE CYLINDER HEAD XSARA - XSARA PICASSO Engines: RHY - RHZ Identification of cylinder head gasket Plaque Engine RHY RHZ Piston standproud (mm) Thickness (mm) No.
PAGE 117
XSARA - XSARA PICASSO Engines: WJY - RHY - RHZ Cylinder head tightening (m.daN) One Cylinder head bolts WJY WJY Pre-tightening :2 Tightening :6 Angular tightening : 180° RHY - RHZ RHY - RHZ Pre-tightening NOTE: Oil the threads and under the heads of the bolts (use engine oil or Molykote G Rapid Plus). Tightening Angular tightening :2 :6 : 220° B1DP15EC B1DP13PC X =MAX.
PAGE 118
4099-T (C.TRONIC.105) Tools 114 ! ! ! ENGINE BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE ALL TYPES 4122-T (C.TRONIC.105.
PAGE 119
TU 3 1 JP Engine type HFX KFV C2 1.1i 1.4i See pages: C3 See pages: KFW ET TU 3 5 J4 JP + KFU NFV EW XU 7 J4 JP4 NFU 10 6FZ J4RS RFN RFS 1.6i 16V 118 to 119 1.1i PETROL 118 to 119 1.4i 118 to 119 1.4i 16V 1.6i 16V 123 to 124 118 to 119 C3 Pluriel 1.4i 1.6i 16V See pages: 118 to 119 118 to 119 XSARA 1.4i 1.6i 16V 2.0i 16V 2.0i 16V See pages: 122 125 128 126 to 127 XSARA Picasso 1.6i See pages: 120 to 121 115 1.8i 16V 2.
PAGE 120
ENGINE DIESEL AUXILIARY EQUIPMENT DRIVE BELT DV DW 4 TED4 TD Engine type 8HX C2 1.4 HDi See pages: 135 to 136 C3 1.4 HDi See pages: 8HW 8HZ 1.4 HDi 1.4 HDi See pages: 135 to 136 8HV 8HY 9HZ 9HY 10 B TD ATED WJY RHY RHZ 2.0 HDi 2.0 HDi 1.4 HDi 16V 1.4 HDi 16V 135 to 136 C3 Pluriel 8 6 139 XSARA 1.4 HDi 1.9 D See pages: 137 to 138 129 to 134 141 to 144 XSARA Picasso 1.6 HDi 16V 1.6 HDi 16V 2.
PAGE 121
Engines: All Types Petrol and Diesel Tools. - Belt tension measuring instrument : 4122 - T. (C.TRONIC 105.5) WARNING: If using tool 4099-T (C.TRONIC 105), refer to the correspondence table on page 96. Essential. - Before refitting the auxiliary equipment drive belt, check that: - 1 / The roller(s) rotate freely (no play or stiffness). - 2 / The belt is correctly engaged in the grooves of the various pulleys.
PAGE 122
ENGINE C2 - C3 - C3 PLURIEL AUXILIARY EQUIPMENT DRIVE BELT Engines: HFX - KFV - NFU Tools. [1] Pliers for removing plastic pegs [2] Belt tension measuring instrument : 7504 –T : 4122-T Vehicle without air conditioning. Refit. Remove. Slacken: - Screw (2). - Screw (3). - Tensioning screw (1). Push the alternator back towards the engine. Remove the belt. B1BP2LSC B1BP2LTC 118 Refit the belt. Respect the following sequence: - Crankshaft pinion. - Alternator pulley. Place tool [2] on the belt.
PAGE 123
C2 - C3 - C3 PLURIEL Engines: HFX - KFV - NFU Vehicle with air conditioning. Remove Slacken: - Screws (6), (4) and (5). - Fully detension the belt by acting on the tensioner roller. - Remove the accessories drive belt. Refit. 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].
PAGE 124
ENGINE XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT Engine: NFV Without air conditioning. Tools. [1] Pliers for removing plastic pegs [2] Belt tension measuring instrument [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].
PAGE 125
XSARA PICASSO Engine: NFV With air conditioning. Tools. [1] [2] [3] [4] Pliers for removing plastic pegs Belt tension measuring instrument 10 mm square (drain spanner) TORX spanner : 7504 –T : 4122 –T 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].
PAGE 126
ENGINE AUXILIARY EQUIPMENT DRIVE BELT 2002 XSARA Engine: KFW Alternator With air conditioning [1] Belt tension measuring instrument: 4122-T [1] Belt tension measuring instrument: 4122-T - Tension the belt using the screw (2). - Tension the belt using the screw (4). - Tension should be: 102 ± 7 SEEM units. - Tension should be: 102 ± 7 SEEM units. - Tighten the screws (1). - Tighten the screws (3). Power-assisted steering Power steering and air con. - New belt 100 SEEM units.
PAGE 127
C3 Engine: KFU Tools. [1] Plyers for removing plastic pegs : 7504 –T [2] Belt tension measuring instrument (SEEM) : 4122 –T Removing. Raise and support the vehicle, front wheels hanging. Disconnect the battery. Remove the front RH wheel and the front RH splash-shield, using tool [1]. Vehicle without air conditioning. Removing. Slacken the tension, screw (2), screw (3) and screw (1). Push back the alternator towards the engine. Remove the auxiliary equipment drive belt. Refitting.
PAGE 128
ENGINE AUXILIARY EQUIPMENT DRIVE BELT C3 Engine: KFU Vehicle With air conditioning. Removing. Slacken the tension, screw (6), screw (4) and screw (5). Completely detension the belt by acting on the tensioner roller. Remove the auxiliary equipment drive belt. Refitting. Refit the auxiliary equipment drive belt. Respect the following sequence : - Crankshaft pinion, aircon compressor pulley, alternator pulley guide roller and guide roller. - Position tool [2] on the belt.
PAGE 129
XSARA Engine: NFU Without air conditioning (1) Tensioner roller fixing screw (2) Tensioning screw - New belt: 120 SEEM units. - Reused belt: 86.5 ± 3.5 SEEM units. B1BP1AMC With air conditioning (3) Tensioner roller fixing screw (4) Tensioning screw - New belt: 120 SEEM units. - 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).
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ENGINE XSARA AUXILIARY EQUIPMENT DRIVE BELT 2002 Engine: RFS With air conditioning. - Fit the drive belt. - The tensioner roller (1). - Tighten the screws (3) to 2 m.daN. - Move the tensioner roller (1) using the tool (9.52 mm square drive (3/8)) at (2), in order to remove the tool or locking peg (Ø 4 mm) at (4). - Slowly release the tensioner roller (1) so that the roller (5) presses against the belt.
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Engine: RFS Without air conditioning. Tools. [1] Belt tension measuring instrument : 4122-T - (1) Tensioning screw. - (2) Roller support fixing screw (3). - Lightly tighten the screws (2). - Place the tool [1] on the belt. - Tension the belt using the screw (1). • 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).
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ENGINE AUXILIARY EQUIPMENT DRIVE BELT 2002 XSARA - XSARA PICASSO Engines: 6FZ - RFN Without air conditioning. With air conditioning. Tools. [1] Pliers for removing plastic pegs : 7504-T Remove the belt. - Detension the belt (3) by turning the screw (2) of the tensioner roller (1) (anti-clockwise). - 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.
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XSARA Engine: WJY Sans Power-assisted steering. Tools. [1] Belt tension measuring instrument : 4122-T Removal. - Loosen the screws (2). - Tighten the screw (1) until it is against its stop. - Remove the belt. Refitting. - 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].
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ENGINE XSARA AUXILIARY EQUIPMENT DRIVE BELT 2002 Engine: WJY Sans Power-assisted steering With air conditioning. Tools. [1] Belt tension measuring instrument : 4122-T Removal. - Loosen the screws (1). - Tighten the screw (2) until it is against its stop. - Remove the belt. Refitting. - 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].
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Engine: WJY Power-assisted steering without air conditioning. Tools. [1] Belt tension measuring instrument : 4122-T Removal. WARNING: If the belt is to be reused, measure the tension before removal. Loosen: - the screw (1). - the nut (2). NOTE: The tensioner arm (3) must be against the alternator. - Remove the belt.
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ENGINE XSARA AUXILIARY EQUIPMENT DRIVE BELT Engine: WJY Power-assisted steering without air conditioning (continued). Refitting. - Refit the belt. - Place the tool [1] on belt at "f". WARNING: Position tool [1], with the knob downwards. - Tighten the nut (2) to obtain a value of : Reused belt: Keep the value taken at removal. New belt: Tension should be 110 SEEM units. - Tighten the screw (1) to 9.5 m.daN. - Check belt tension, using tool [1]. Tension should be 144 ± 3 SEEM units. - Remove the tool [1].
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Engine: WJY Power-assisted steering with air conditioning. Tools. [1] Dynamic tensioner peg [2] Belt tension measuring instrument : (-) 0188 H : 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].
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ENGINE XSARA AUXILIARY EQUIPMENT DRIVE BELT 2002 Engine: WJY Power-assisted steering with air conditioning (continued). Refitting. - Refit the belt. - Using a 7 mm square drive at "b", turn the roller (3), until the tool [1] located at "a" becomes free. - Tighten the screw (2). - Remove the tool [1].
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Engines: 8HX - 8HW Tools. [1] Pliers for removing plastic pegs [2] Tensioner roller compression lever [3] Tensioner roller setting peg Ø4 mm : 7504-T : (-).0194.E : (-).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 direction of rotation of the belt.
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ENGINE C2 - C3 - C3 PLURIEL AUXILIARY EQUIPMENT DRIVE BELT Engines: 8HX - 8HW Markings on the dynamic tensioner roller. «a» Position of «maximum wear» of the auxiliary drive belt. «b» Normal position. Refitting. NOTE: Check that the tensioner roller moves freely (no tight spot). If this is not the case, replace the tensioner roller. Respect the direction of fitting of the drive belt. Complete the setting of the belt, of both sides, by means of the tensioner roller.
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Engine: 8HZ Tools. [1] Dynamic tensioner compression lever [2] Peg for dynamic tensioner roller : (-).0188.Z : (-).0194.F Removing. IMPERATIVE: Respect the safety and cleanliness requirements specific to high pressure diesel injection engines (HDi). Remove: - The front RH wheel. - The under-engine sounddeadening. - The splash-shield. WARNING: Mark the direction of fitting of the accessories drive belt, if it is to be re-used. Compress the tensioner roller (1) by acting at «a» (clockwise), using tool [1].
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ENGINE XSARA AUXILIARY EQUIPMENT DRIVE BELT 2002 Engine: 8HZ Refitting. WARNING: Belt to be re-used, mark the direction of fitting of the belt. Refit the accessories drive belt. Compress the tensioner roller (1) by acting at «a» (clockwise), using tool [1]. Remove tool [2]. IMPERATIVE: Make sure the belt is correctly positioned in the grooves of the various pulleys. Complete the refitting in the opposite order to removal.
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Engines: 8HY - 8HV Tools. [1a] Dynamic tensioner roller lever [1b] Lever extension [2] Accessories belt roller locking peg Ø 4 mm : (-).0194-E1 : (-).0194-E2 : (-).0194-F Removing. Pivot 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). Refitting. Refit the belt.
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ENGINE XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT Engines: 9HZ - 9HY Tools. [1] Dynamic tensioner compression lever [2] Peg for dynamic tensioner roller : (-).0188.Z : (-).0194.F Removing. Remove the front RH wheel, the under-engine sounddeadening and the splash-shield. Vehicle with air conditioning. WARNING: Mark the direction of fitting of the accessories drive belt, if it is to be re-used. Compress the tensioner roller (1) by acting at «a» (clockwise), using tool [1]. Peg at «b», using tool [2].
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XSARA - XSARA PICASSO Engines: RHY - RHZ Without air conditioning. [1] [2] [3] [4] Tools. Belt tension adjusting square Ø 4 mm peg Ø 2 mm peg Dynamic tensioner compression lever : (-).0188 J2 : (-).0188.Q1 : (-).0188.Q2 : (-).0188.Z Removal. Re-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.
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ENGINE XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT 2002 Engines: RHY - RHZ Without air conditioning (continued). Refitting. Re-used belt. - Compress the tensioner roller (2) by action at «a» (in anti-clockwise direction), tool [4]. - Refit the belt. WARNING: Respect the belt-fitting direction. Remove the tool [4]. New belt. - Refit the belt. - Turn the eccentric roller (3), tool [1] (clockwise) to free the tool [2] from its pegging at «b».
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Engines: RHY - RHZ With air conditioning. Tools. [1] [2] [3] [4] Belt tension adjusting square Ø 4 mm peg Ø 2 mm peg Dynamic tensioner compression lever : (-).0188 J2 : (-).0188.Q1 : (-).0188.Q2 : (-).0188.Z Removal. Re-use of belt. WARNING: 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.
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ENGINE XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT 2002 Engines: RHY - RHZ With air conditioning (continued). Refitting. Re-used belt. - Compress the tensioner roller (7) by action at «c» (in anti-clockwise direction), tool [4]. - Refit the belt. WARNING: Respect the direction belt was fitted. Remove the tool [4]. New belt. - Refit the belt. - Turn the eccentric roller (5), tool [1] (clockwise) to free the tool [2] from its pegging at «d».
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TU 3 1 JP Engine type HFX KFV C2 1.1i 1.4i See pages: C3 See pages: KFW ET TU 3 5 J4 JP + KFU NFV EW XU 7 10 J4 JP4 NFU 6FZ J4RS RFN RFS 1.6i 16V 148 to 157 1.1i PETROL 148 to 157 1.4i 148 to 157 1.4i 16V 1.6i 16V 165 to 170 148 to 157 C3 Pluriel 1.4i 1.6i 16V See pages: 148 to 157 148 to 157 XSARA 1.4i 1.6i 16V 2.0i 16V 2.0i 16V See pages: 148 to 157 161 to 164 171 to 178 179 to 183 XSARA Picasso 1.6i See pages: 158 to 160 145 1.8i 16V 2.
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ENGINE DIESEL CHECKING AND SETTING THE VALVE TIMING DV DW 4 TED4 TD Engine type 8HX C2 1.4 HDi See pages: 184 to 191 C3 1.4 HDi See pages: 8HW 8HZ 1.4 HDi 1.4 HDi See pages: 184 to 191 8HV 8HY 9HZ 9HY 10 B TD ATED WJY RHY RHZ 2.0 HDi 2.0 HDi 1.4 HDi 16V 1.4 HDi 16V 184 to 191 C3 Pluriel 8 6 192 to 200 XSARA 1.4 HDi 1.9 D See pages: 184 to 191 211 to 215 216 to 224 XSARA Picasso 1.6 HDi 16V 1.6 HDi 16V 2.
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ALL TYPES Diesel Engine Petrol Engine Recommendations. IMPERATIVE: After any repair involving removal of the timing belt, systematically replace: The timing belt, The tensioner roller fixing nut.
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ENGINE C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engines: HFX - KFV - NFU Tools. [1] Engine flywheel peg [2] Camshaft pulley peg [3a] Camshaft peg [3b] Camshaft peg [4] Dynamic tensioner roller pin [5] Belt retaining pin [6] Pliers for removing plastic pins : 4507-T.A : 4507-T.B : 4533-TA.C1 : 4533-TA.C2 : 4200-T.H : 4533-T.AD : 7504-T Checking the valve timing. Engines: HFX – KFV – NFU. Raise and support the front RH side of the vehicle. Disconnect the battery positive terminal.
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Engine: NFU Checking the timing (continued). Engine: NFU. Place a jack under the engine, peg the engine. Remove: - The engine support (4) complete. - The timing casing (3). - The sparking plugs (eases engine rotation). Turn the wheel to rotate the engine (normal direction of rotation). 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.
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ENGINE C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engines: HFX - KFV Setting the timing. Preliminary operation. Lift and support the vehicle, wheels hanging. Disconnect the battery. Remove: - The front RH wheel. - The splash-shield, using tool [6]. - The accessories belt (See corresponding operation). - The crankshaft pulley. - The oil filter. Place a jack under the engine, peg the engine. Removing. Engines: HFX – KFV. Turn the engine by means of screw (1) (normal direction of rotation).
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Engines: HFX - KFV Setting the timing (continued). Engines: HFX – KFV. Slacken the screws (4) without removing them. Remove the bottom engine support assembly (5), and the fixing screws (4). Slacken the nut (6). 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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ENGINE C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engine: NFU Engine: NFU. Setting the timing (continued). Remove: - The bottom plastic casing. - The engine support (9). - The middle support. - The timing cover (8). - Peg the flywheel, using tool [1]. - Position the tools [3a] and [3b].
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C2 - C3 - C3 PLURIEL Engine: NFU Setting the timing (continued). Engine: NFU. Slacken the tensioner roller. Turn the tensioner roller so as to be able to position the tool [4], with the aid of an Allen key placed at «a». Turn the tensioner roller towards the right to bring it to the index «c» 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.
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ENGINE C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engines: HFX - KFV Setting the timing (continued). Engines: HFX-KFV. Refit. WARNING: Respect the direction of fitting of the belt (the arrows «d» indicate the direction of rotation of the crankshaft). 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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C2 - C3 - C3 PLURIEL Engines: KFX - KFV - NFU Setting the timing (continued). B1EP18RC Engines: HFX-KFV. Refitting. NOTE: Check that the pegs [1] and [2] are in place. WARNING: Respect the direction of fitting of the timing belt, the arrows «d» indicate the direction of rotation of the crankshaft. 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.
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ENGINE C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engine: NFU Timing belt overtensioned. A: Engine: HFX – KFV. B: Engine: NFU. Turn the tensioner roller (7) with the aid of a hexagonal spanner at «a». Bring the index «c» to position «f», to tension the belt to the maximum of the interval indicated. 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).
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Engines: HFX - KFV - NFU Adjusting the fitting tension of the timing belt. A: Engine: HFX – KFV. B: Engine: NFU. Slacken the nut while maintaining the position of the tensioner roller, with the aid of a hexagonal spanner at «a». 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.
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ENGINE CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines: KFW - NFV Tools. [1] Flywheel peg [2] Camshaft pulley peg [3] Square [4] Belt tension measuring instrument [5] Valve rocker thrust plate : 4507-T.A : 4507-T.B : 4507-T.J : 4122-T : 4533-T.Z J Tool kit 4507-T Checking the timing. - Peg the flywheel, using tool [1]. - Peg the camshaft pulley, using tool [2]. Setting the timing. NOTE: Remove the sparking plugs, to ease rotation of the crankshaft.
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XSARA - XSARA PICASSO Engines: KFW - NFV Refitting the timing belt. NOTE: Check that the pegs [1] and [2] are in place. WARNING: Respect the direction of fitting of the belt: The arrows "a" indicate the direction of rotation of the crankshaft. Position: -The timing belt, belt "b" well-tensioned, in the following order: Crankshaft pinion, camshaft pulley, coolant pump pulley, tensioner roller. - Tool [5] (respect the direction of fitting relative to the valve timing).
PAGE 164
ENGINE XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines: KFW - NFV Pre-tensioning the timing belt (continued). - Make sure of the timing setting by refitting the pegs [1] and [2]. - Remove the valve cover. - Position the tool [5] (respect the direction of fitting relative to the valve timing). Adjusting the belt tension. - Place tool [4] on the tensioned part of the belt. - Slacken the nut (2). - Detension the belt, but too much.
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Engine: NFU Tools. [1] Belt tension measuring instrument [2] Flywheel locating peg [3] Camshaft pulley locating peg, exhaust [4] Camshaft pulley locating peg, inlet [5] Tensioning tool : 4122 : 4507 : 4533 : 4533 : 4707 - T. - T.A - T.A C2 - T.A C1 - T.J J Tool kit 4507 - T 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].
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ENGINE XSARA CHECKING AND SETTING THE VALVE TIMING Engine: NFU Setting the valve timing. - Loosen the screw (2), remove the belt. - Loosen the six pulley screws (1) on the hubs (there should be a slight amount of friction between the screws and the pinions). - 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.
PAGE 167
XSARA Engine: NFU Setting the valve timing. - Turn the two pulleys (1) clockwise to the end of the slots. - With the belt strip (e) fully tensioned, place the belt over the pulley, first exhaust side, then inlet side, while ensuring that marks (b) and (c) on the belt are aligned with marks (f) on the pulleys. - 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 at (e).
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ENGINE XSARA CHECKING AND SETTING THE VALVE TIMING Engine: NFU Setting the valve timing. - Remove the tools [1], [2], [3] and [4]. Rotate the engine by 4 turns in the normal direction (do not turn backwards). Peg the flywheel [2]. Loosen the six screws (5), while ensuring there is still a slight amount of friction with the pulley. 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].
PAGE 169
Engine: KFU Tools. [1] Flywheel peg [2] Camshaft peg [3] Crankshaft setting peg : 4507-T : 4533-TA.C1 : (-).0194.A Checks. Raise and support the vehicle, front wheels hanging. Disconnect the battery. Remove: - The oil filter. - The engine cover. - The upper timing cover (1). - The sparking plugs, to ease rotation of the engine. Rotate the engine by means of the crankshaft screw (never turn the engine backwards).
PAGE 170
ENGINE C3 CHECKING AND SETTING THE VALVE TIMING Engine: KFU Position the tools [3] and [2]. Peg the flywheel, using tool [1]. NOTE: If the setting is not correct, recommence the operation. Remove the pegs [2] and [3]. Refit : - The oil filter. - The timing cover (1). - The engine cover. Reconnect the battery. Lower the vehicle. Perform the operations that are necessary following a reconnection of the battery.
PAGE 171
Engine: KFU Tools. [1] [2] [3] [4] [5] Flywheel setting peg Engine support crossmember Crankshaft setting peg Camshaft peg Belt retaining pin : 4507-T : : (-).0194.A : 4533-TA.C1 : 4533-T.AD Removing. Raise and support the vehicle, front wheels hanging. Disconnect the battery. Remove: - The front RH wheel. - The front RH splash-shield. - The engine cover. - The accessories drive belt (see corresponding operation). - The crankshaft pulley. - The oil filter. Remove the upper timing cover (1).
PAGE 172
ENGINE C3 CHECKING AND SETTING THE VALVE TIMING Engine: KFU Rotate the engine by means of the crankshaft pinion screw (2) (clockwise), to bring it to the pegging position. Peg the flywheel, using tool [1]. Position the tools [3] and [4]. Position the tool [2]. Support the engine. Remove the screws (3). The upper RH engine support.
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C3 Engine: KFU Remove: - The lower engine support assembly (5) and the fixing screw (4). - Remove the lower timing cover (6). - Slacken the nut (7). - Remove the timing belt. IMPERATIVE: Check that the tensioner roller turns freely (no tight spot). Refitting. Fit the (new) timing belt, in the following sequence: - Inlet camshaft pulley. - Exhaust camshaft pulley. - Guide roller. - Crankshaft pulley. Position the tool [5]. Coolant pump pulley. Dynamic tensioner roller. Remove tools [3], [4] and [5].
PAGE 174
ENGINE C3 CHECKING AND SETTING THE VALVE TIMING Engine: KFU Overtensioning the belt. Position «a» Tensioner roller in slackened position. Position «b» Tensioner roller in normal position. Position «c» Tensioner roller in overtensioned position. Turn the tensioner roller (8) using an allen spanner at «e». Position the index «d» in position «c», tension the belt to the maximum indicated. Tighten the fixing nut of the tensioner roller to 2,1 ± 0,2 m.daN.
PAGE 175
NEW ASSEMBLY 2003 # Engines: 6FZ - RFN 2003 # (6) Crankshaft pinion (7) Accessories drive pulley (8) Washer (9) Screw The pinion (6) is fitted as an idler on the crankshaft. The accessories drive pulley (7) is immobilised on the crankshaft by a half-moon keyway and by the tightening of washer (8) and screw (9). A: Pegging on manual gearbox. B: Pegging on automatic gearbox. B1EP1B9D The pegging of the crankshaft is done on the flywheel, or on the converter drive plate (automatic gearbox).
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ENGINE XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING NOTE: Checking and setting the timing # 2003: See Mechanic’s Handbook 2003: pages 163 to 173. Engines: 6FZ - RFN 2003 # Tools. [1] Camshaft setting peg [2] Crankshaft setting peg [3] Timing belt retaining pin [4] Adaptor for angular tightening [5] Tool for moving and locking the tensioner roller [5a] [5b] Pliers for removing plastic pins : (-) 0189.A : (-).0189.R : (-).0189.K : 4069-T : (-).0189.S : (-).0189.S1 : (-).
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Engines: 6FZ - RFN 2003 # Checking the setting of the timing (continued). A: Pegging on the manual gearbox. B: Pegging on the automatic gearbox. Turn the engine by means of the crankshaft pinion screw, to bring it to the pegging position. Peg the crankshaft, using tool [2]. Peg the camshaft pulleys, using tool [3]. B1BP2V3D NOTE: The pegs [3] should go in without effort.
PAGE 178
ENGINE XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines: 6FZ - RFN 2003 # Setting the timing. Removing. Disconnect the battery negative terminal (see corresponding operation). Raise and support the vehicle, front wheels hanging. Remove: - The front RH wheel. - The plastic pins (1). - 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).
PAGE 179
Engines: 6FZ - RFN 2003 # Setting the timing (continued). A: Pegging on the manual gearbox. B: Pegging on the automatic gearbox. Peg: - The crankshaft, using tool [2]. - The camshaft pulleys (5) and (6), using tool [1]. Remove: - The screw (3) of the crankshaft pulley (2). - The lower timing cover (4) (by moving the engine). IMPERATIVE: Never remove the crankshaft pulley (2) without pegging the crankshaft and the camshafts. Slacken the screw (9) of the tensioner roller (8).
PAGE 180
ENGINE CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines: 6FZ - RFN 2003 # Setting the timing (continued). Turn the tensioner roller (8), using tool [5a] to go beyond slot «b». Position the tool [5b] to lock the index «a» and remove the tool [5a]. Reposition the timing belt (7) on the crankshaft pulley. 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).
PAGE 181
Engines: 6FZ - RFN 2003 # Tensioning the timing belt. Turn the tensioner roller (8) in the direction of the arrow «c», by means of a hexagonal spanner at «d». Positionner l’index «a» en position «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».
PAGE 182
ENGINE XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines: 6FZ - RFN 2003 # Refitting (continued). Remove the tools [1] and [2]. Rotate the crankshaft ten times (normal direction of rotation). IMPERATIVE: No pressure or outside force should be brought to bear on the timing belt. Peg the inlet camshaft pulley, using tool [1]. Checks. B1EP1BEC Tension of the timing belt. ESSENTIAL: Check the position of the index «a», which should be opposite the slot «g».
PAGE 183
Engine: RFS Tools. [1] Belt tension measuring instrument [2] Camshaft pulley locating peg [3] Crankshaft locating peg [4] Camshaft pulley locking peg [5] Tensioner spanner [6] Toothed sector for locking the flywheel : 4122-T : 9041-T.Z : 7014-T.N : 4200-T.G : 7017-T.W : 9044-T J Tool kit 7004-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.
PAGE 184
ENGINE XSARA CHECKING AND SETTING THE VALVE TIMING Engine: RFS Setting the valve timing. - Peg the crankshaft using tool [3]. - Peg the camshaft pulleys using tool [2]. - Lock the flywheel using the tool [6]. Refit: - The pulley (5). - The screw (4) (tighten moderately). - The peg [3]. B1EP120C B1EP11ZC 180 Remove: - The - The - The - The peg [3]. screw (4) (brush the screw thread). pulley (5). lower cover (6). Remove: - The tool [6]. - The studs (8). - Fit the tool [4]. - Loosen the screws (10).
PAGE 185
XSARA Engine: RFS Pretensioning the timing belt. - Peg the crankshaft using the tool [3]. - Peg the camshaft pulleys using the tool [2]. NOTE: Ensure that the camshaft pulleys rotate freely on the hubs. Clean the contact faces of the pulleys and hubs. - 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).
PAGE 186
ENGINE CHECKING AND SETTING THE VALVE TIMING XSARA Engine: RFS Tensioning the timing belt. - Peg the crankshaft using the tool [3]. - Peg the camshaft pulleys using the tool [2]. NOTE: If it is not easy to peg the camshaft hubs, loosen the tensioner roller (7), and turn the camshafts using the screw (10). - 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].
PAGE 187
XSARA Engine: RFS - Tension to: (Pulleys slackened). Engine RFS New belt 35 SEEM units - Tighten the screw of the roller (7) to 2 m.daN. - Fit the tool [4]. - Tighten the screws (10) to 7.5 m.daN. - 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.
PAGE 188
ENGINE CHECKING AND SETTING THE VALVE TIMING C2 - C3 - C3 PLURIEL - XSARA Engines: 8HX - 8HW - 8HZ Tools. [1] [2] [3] [4] [5] Pliers for removing plastic pegs Lever for detensioning the dynamic tensioner roller Engine flywheel setting peg Camshaft setting peg Crankshaft and high pressure pump setting peg : 7504-T : (-).0194.E : (-).0194.C : (-).0194.B : (-).0194.A Preliminary operations. Remove: - The front RH wheel. - The front RH splash-shield, using tool [1].
PAGE 189
Engines: 8HX - 8HW - 8HZ Checking the setting (continued). Remove: - the accessories drive belt. - the accessories drive pulley. - the lower timing cover (3). IMPERATIVE: The magnetic track should show no signs of damage and should not be approached by any other source of magnetism. 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].
PAGE 190
ENGINE C2 - C3 - C3 PLURIEL - XSARA CHECKING AND SETTING THE VALVE TIMING Engines: 8HX - 8HW - 8HZ Setting the timing. Remove the upper timing cover (1). Rotate the engine by means of the crankshaft screw (2). NOTE: The pegging hole is located under the crankshaft bearing cap cover. Peg the engine flywheel, using tool [3]. 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.
PAGE 191
Engines: 8HX - 8HW - 8HZ Setting the timing (continued). Remove the tool [3]. Rotate the engine by means of the crankshaft pinion screw (2) (clockwise), to bring it to the pegging position. Peg the camshaft pulley, using tool [4]. Peg: - The crankshaft pinion (6), using tool [5]. - 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).
PAGE 192
ENGINE C2 - C3 - C3 PLURIEL - XSARA CHECKING AND SETTING THE VALVE TIMING Engines: 8HX - 8HW - 8HZ Setting the timing (continued). Hold the tensioner roller, using a hexagonal spanner at «b». Slacken the screw (9). Remove the timing belt (10). Refitting. 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.
PAGE 193
Engines: 8HX - 8HW - 8HZ Setting the timing (continued). NOTE: Screw (9) slackened. Position the timing belt (10) observing the following sequence: - Crankshaft pinion (4). - Guide roller (12). 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).
PAGE 194
ENGINE C2 - C3 - C3 PLURIEL - XSARA CHECKING AND SETTING THE VALVE TIMING Engines: 8HX - 8HW - 8HZ Setting the timing (continued). Turn the tensioner roller to the right to bring the index «c» to position «d», using a hexagonal spanner. 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 the crankshaft). Check: - The - The - The - The pegging of the camshaft.
PAGE 195
Engines: 8HX - 8HW - 8HZ Setting the timing (continued). Refit: - The intermediate RH engine support, tighten the screws (16) to 5,5 ± 0,5 m.daN. - The RH engine support, tighten the screws (17) to 4,5 ± 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 - Angular tighten to : 3 ± 0,3 m.daN. : 180° ± 1,8°. Remove tool [3]. Refit: - The top cover (1).
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ENGINE C3 CHECKING AND SETTING THE VALVE TIMING Engines: 8HY - 8HV Tools. [1] Engine flywheel peg Ø 12 mm [2] Camshaft pulley peg Ø 8 mm [3] Crankshaft pulley peg Ø 5 mm : (-).0194-C : (-).0194-B : (-).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).
PAGE 197
Engines: 8HY - 8HV Checks. Rotate the engine to engage it (normal direction of rotation). Immobilise the engine flywheel at «a», using tool [1]. Move aside the harness (6). Remove: - The - The - The - The - The - The engine support (7). screw (8). pulley (9). lower timing cover (10). upper timing cover (11). tool [1].
PAGE 198
ENGINE C3 CHECKING AND SETTING THE VALVE TIMING Engines: 8HY - 8HV Checks (continued). Refit the screw (8). Rotate the crankshaft six times (clockwise). IMPERATIVE: Never rotate the engine backwards. Peg: - The camshaft, using tool [2] (oil the pegs). - The fuel high pressure pump pulley (14), using tool [3] at «c». WARNING: The magnetic track should show no signs of damage and should not be approached by any source of magnetism. Peg the crankshaft at «b», using tool [3].
PAGE 199
C3 Engines: 8HY - 8HV Checks (continued). NOTE: The index «e» of the dynamic tensioner roller should be centred within the area «d». Check the correct positioning of the index «e». If it is not correct, repeat the operation to tension the timing belt (see corresponding operation). Refitting. 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.
PAGE 200
ENGINE C3 CHECKING AND SETTING THE VALVE TIMING Engines: 8HY - 8HV Checks (continued). Refit: - The engine support (7), tighten to 1,5 ± 0,4 m.daN. - The engine support (4), tighten to 6,1 ± 0,6 m.daN. - The engine support (5), tighten to 6 ± 0,6 m.daN. - The electrical harness (6). 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).
PAGE 201
C3 Engines: 8HY - 8HV Setting the timing. Perform the preliminary operations for checking the timing up to removing tool [1] at «a» for immobiling the engine flywheel. Refit screw (8). Rotate the crankshaft to bring the camshaft towards its pegging point. Peg the camshaft, using tool [2] (oil the pegs). 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).
PAGE 202
ENGINE C3 CHECKING AND SETTING THE VALVE TIMING Engines: 8HY - 8HV Setting the timing (continued). Checking the setting. IMPERATIVE: Just prior to refitting, carry out the following tests. Check that: - the rollers and the coolant pump operate freely (no play and no tight spot). - there are no traces of oil (from the crankshaft and camshaft sealing rings). - there is no leak of coolant fluid (from the coolant pump).
PAGE 203
C3 Engines: 8HY - 8HV Setting the timing (continued). Checks (continued). Reposition the timing belt, belt at «e» well tensioned, in the following order: - Guide roller (17). - Camshaft pulley (16). - Fuel high pressure pump pulley (15). - Coolant pump pinion (18). - Tensioner roller (19). Remove the 5 mm diameter peg at «d». Adjusting the fitting tension of the belt.
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ENGINE C3 CHECKING AND SETTING THE VALVE TIMING Engines: 8HY - 8HV Adjusting the timing belt tension (continued). IMPERATIVE: Never rotate the engine backwards. WARNING: Do not touch or damage the track of the target of the engine speed sensor (14). Peg the crankshaft, using tool [3]. Check the position of the tensioner roller (the alignment of the marks «f» 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].
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Engines: 9HZ - 9HY B1BP304D Tools. [1] Flywheel setting peg : (-).0194.C [2] Camshaft setting peg : (-).0194.B [3] Crankshaft setting peg : (-).0194.A Checking and setting the timing. Removing. Raise and support the vehicle, wheels hanging. Disconnect the positive and negative terminals of the battery. Remove: - The front RH wheel. - The front RH splash-shield. - The accessories drive belt (see corresponding operation). Uncouple: - The fuel supply unions (1).
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ENGINE CHECKING AND SETTING THE VALVE TIMING XSARA PICASSO Engines: 9HZ - 9HY Rotate the engine to drive it in its normal direction of rotation. Peg the flywheel, using tool [1] at «b». Move aside the harness (7). Remove: - The engine support (8). - The screw (10). - The accessories drive pulley (9). - The lower timing cover (11). - The upper timing cov (12). - The tool [1].
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Engines: 9HZ - 9HY Refit the screw (10). Rotate the crankshaft six times (clockwise). IMPERATIVE: Never turn it backwards. Peg the camshaft at «c», using tool [2] (oil the peg). WARNING: The magnetic track should not show any sign of damage and should not be approached by any other magnetic source. Peg the crankshaft at «d», using tool [3]. ESSENTIAL: Should it not be possible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm.
PAGE 208
ENGINE XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines: 9HZ - 9HY Couple: - The tube (2). - The exhaust line, tighten the clip to 2,5 ± 0,3 m.daN. - The fuel unions (1). - The air/air heat exchanger inlet and outlet pipes (3). Connect the connector at «a». Refitting. Refit tool [1] at «b». Remove the screw (10). Refit: - The upper timing cover (12). - The lower timing cover (11). - The accessories drive pulley (9). - The screw (10). Tightening torque Screw (10) Pre-tighten to : 3 ± 0,3 m.daN.
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Engines: 9HZ - 9HY B1BP304D Tools. [1] Flywheel setting peg : (-).0194.C [2] Camshaft setting peg : (-).0194.B [3] Crankshaft setting peg : (-).0194.A Checking and setting the timing. Removing. Raise and support the vehicle, wheels hanging. Disconnect the positive and negative terminals of the battery. Remove: - The front RH wheel. - The front RH splash-shield. - The accessories drive belt (see corresponding operation). Uncouple: - The fuel supply unions (1).
PAGE 210
ENGINE CHECKING AND SETTING THE VALVE TIMING XSARA PICASSO Engines: 9HZ - 9HY Rotate the engine to drive it in its normal direction of rotation. Peg the flywheel at «b». using tool [1]. Move aside the harness (7). Remove: - The engine support (8). - The screw (10). - The accessories drive pulley (9). - The lower timing cover (11). - The upper timing cov (12). - The tool [1].
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Engines: 9HZ - 9HY Refit the screw (10). Turn the crankshaft to bring the camshaft towards its pegging point. Peg the camshaft at «c», using tool [2] (oil the pegs). WARNING: Do not press or damage the track of the engine speed sensor target (13). Peg the crankshaft at «e», using tool [3]. Remove: - The timing belt protector (13). - The engine speed sensor (14). Slacken the screw (15) of the tensioner roller, and keep it slackened using an allen spanner at «d».
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ENGINE XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines: 9HZ - 9HY Refitting. Fit the timing belt on the crankshaft pinion. Position the belt on the guide roller, belt well tensioned. Refit: - The timing belt protector (13). - The engine speed sensor (14). Reposition the timing belt, strip «f» well tensioned, in the following sequence: - Guide roller (16). - Camshaft pulley (20). - Fuel high pressure pump pulley (19). - Coolant pump pulley (17). - Tensioner roller (18).
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Engines: 9HZ - 9HY Adjusting the timing belt tension. Act on the tensioner roller (18) to align the marks «g» and «h», avoiding detensioning the timing belt, using an allen spanner at «d». Should this fail, repeat the operation to tension the timing belt. Hold the tensioner roller (18). Tighten the tensioner roller fixing nut to 3,7 ± 0,3 m.daN. Check the position of the tensioner roller (the alignment of the marks «g» and «h» should be correct). Remove tools [2] and [3].
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ENGINE XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING Engines: 9HZ - 9HY Disengage the jack from under the engine. Couple: - The tube (2). - The exhaust line, tighten the clip to 2,5 ± 0,3 m.daN. - The fuel unions (1). - The air/air heat exchanger inlet and outlet pipes (3). Connect the connector at «a». Refitting (continued). Refit tool [1] at «b». Remove the screw (10). Refit: - The upper timing cover (12). - The lower timing cover (11). - The accessories drive pulley (9). - The screw (10).
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Engine: WJY Tools. [1] [2] [3] [4] [5] [6] [7] Pliers for remving plastic pins Flywheel peg Injection pump setting peg Ø 6 mm Screw H M8 Belt retaining pin Square for adjusting belt tension Belt tension measuring instrument, with digital display : 7504-T or (-).1311 : 7014-T.J or (-).0188 Y : (-).0188 H : (-).0188 E : (-).0188 K : (-).0188 J1 : SEEM CTG 105.5M Checking the timing. - Peg the flywheel, using tool [2]. - Peg the camshaft hub, using tool [4]. - Peg the injection pump hub, using tool [3].
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ENGINE XSARA CHECKING AND SETTING THE VALVE TIMING Engine: WJY Setting the timing. Removing. - Disconnect the battery. - Remove the front RH lower splash-shield, using tool [1]. - Remove the accessories drive belt (see corresponding operation). - Uncouple and plug the diesel fuel delivery and return hoses. - Support the engine, using a workshop hoist. - Remove the RH engine support. - Engage 5th gear to permit rotation of the engine. - Remove the upper cover (1). - Remove the intermediate cover (2).
PAGE 217
XSARA Engine: WJY Setting the timing (continued). - Peg the camshaft hub, using tool [4]. Peg the injection pump hub, using tool [3]. Slacken screws (5) and (6). Slacken screw (9) of the tensioner roller (8). Remove the timing belt. Refitting. - Retighten screws (5) and (6) by hand. - Turn the pinions (10) and (7) clockwise in order to place them at end of slots. - Fit the timing belt on the crankshaft. - Hold the belt, using tool [5].
PAGE 218
ENGINE CHECKING AND SETTING THE VALVE TIMING XSARA Engine: WJY Setting the timing (continued). NOTE: If necessary, you can slightly rotate the pinions (10) and (7) anti-clockwise in order to engage the belt. The angular displacement value of the belt in relation to the pinions should not be more than half a tooth. - Remove tool [5]. - Act on the tensioner roller (8) by its square «a», using tool [6] to check that the camshaft and injection pump pinions can turn freely.
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XSARA Engine: WJY Setting the timing (continued). Setting the timing (continued). - Remove the peg [2]. - Remove the screw (4) and the washer. - Refit the lower cover (3). - Refit the intermediate cover (2). - Refit the upper cover (1). - Remove the RH engine support. - Take away the workshop hoist. - Remove the plugs and recouple the diesel fuel delivery and return hoses. - Refit the accessories drive belt (see corresponding operation). - Refit the RH lower splash-shield. - Disengage 5th gear.
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ENGINE XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING N° RPO 9128 # Engines: RHY - RHZ OLD FITTING: # N° RPO 9127 NEW FITTING N° RPO 9128 # (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 camshaft pulley (1).
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Engines: RHY - RHZ N° RPO 9128 # NEW FITTING N° RPO 9128 # (Continued) The new fitting discontinues the following components: - Camshaft hub. - Cylinder reference sensor target. Repair – Accessories drive pulley Remove – Refit WARNING: Peg the camshaft and the crankshaft before ever removing the accessories drive pulley (the pegging prevents any offsetting of the camshaft). If necessary, apply a paint spot to mark the accessories drive pulley being replaced. Replacement parts.
PAGE 222
ENGINE XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING NOTE: Checking and setting the valve timing on engines: RHY-RHZ N° ⁄ RPO 9127 See Mechanic’s Handbook 2003: pages 193 to196 N° RPO 9128 # Engines: RHY - RHZ Removing. 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 : (-).
PAGE 223
XSARA - XSARA PICASSO N° RPO 9128 # Engines: RHY - RHZ Uncouple, plug and move aside, using tool [7], the fuel delivery pipe (2) and return pipe (1). Remove: - Screws (3), (4) and (6). - Screw (7). - The upper timing cover (5). WARNING: Refit screw (7) equipped with a spacer (17 mm thick), tighten the screw (7) to 1,5 ± 0,1 m. daN. NOTE: The screw (7) is one of the screws securing the coolant pump and is there for its sealing. Put the gear lever in 5th gear.
PAGE 224
ENGINE CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines: RHY - RHZ N° RPO 9128 # Remove: - The fixings of the pipe linking the power steering pump with the rotary valve. - The clutch lower closing plate. Lock the engine flywheel, using tool [6]. 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.
PAGE 225
Engines: RHY - RHZ N° RPO 9128 # Slacken the screw (17) of the tensioner roller (18). Remove the timing belt (14). Checks. IMPERATIVE: Just before refitting, carry out the checks below. Check that: - The rollers (18) and (15) turn freely (without play and without any tight spot). - 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.
PAGE 226
ENGINE CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines: RHY - RHZ N° RPO 9128 # Reposition the timimg belt, belt at «a» well tensioned, in the following order: - Fuel high pressure pump pulley (21). - Guide roller (15). - Crankshaft pinion (19). - 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.
PAGE 227
Engines: RHY - RHZ XSARA - XSARA PICASSO N° RPO 9128 # Lock the engine flywheel, using tool [6]. Slacken: - The accessories drive pulley (8). - The screw (17) of the tensioner roller (18). Fit the tool [1]. Turn the tensioner roller, using tool [2], to attain a tension of: 54 ± 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.
PAGE 228
ENGINE CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO Engines: RHY - RHZ N° RPO 9128 # Remove: - Tools [3] and [5]. - Screw (7) and the spacer. Refit: - The lower, intermediate and upper covers (5). - Screw (7), tighten to 1,5 ± 0,1 m.daN. - Screws (3), (4) and (6). - 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].
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RFS Camshaft hub identification Engine RFS Hubs ‘‘a’’ Engraving ‘‘b’’ Paint marking B BLUE Inlet Exhaust B1EP122C 225 ENGINE SPECIAL FEATURES OF THE TIMING
PAGE 230
ENGINE VALVE CLEARANCE SETTINGS POSSIBLE PROCEDURES For engines with 4 cylinders in a line (1-3-4-2 ) The valve clearances must be checked with the engine cold ● Inlet Rocking Petrol all types (Except16V-NFU) 0,20 mm ± 0,05 NFU 1 mm ± 0,05 Petrol - 16V all types 1.4 HDi 1.4 HDi 16V Diesel 2.0 HDi Diesel all types (Except Diesel 1.4 HDi 1.4 HDi 16V 2.
PAGE 231
C2 - C3 - C3 PLURIEL To be read with the Petrol and Diesel correspondence tables Plaque engine Temperature (°C) Pressure (Bars) Rpm 2279-T.Bis 4103-T.B 7001-T 1503.J Plaque engine Temperature (°C) Pressure (Bars) Rpm 2279-T.Bis 4103-T.B 7001-T 1503.
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ENGINE CHECKING THE OIL PRESSURE XSARA To be read with the Petrol and Diesel correspondence tables Plaque engine Temperature (°C) Pressure (Bars) Rpm 2279-T.Bis 4103-T.B 7001-T 4202-T 5709-T.B2 1503-J 4156-T 7017-T.
PAGE 233
XSARA PICASSO To be read with the Petrol and Diesel correspondence tables Plaque engine Temperature (°C) Pressure (Bars) Rpm 2279-T.Bis 4103-T.B 7001-T 4202-T 1503-J NFV 6FZ 90°C 3-4 2000 - 4000 3,3 - 6,3 1000 - 4000 X X X X X X XSARA PICASSO RFN 9HZ 80°C 1,5 - 5 1,3 1000 - 3000 1000 Tools (Kit 4103-T) X X X X X X 9HY 90°C 3,5 4000 2-4 1000 - 4000 X X X X X X NOTE: The oil pressure should be checked with the engine hot, after the oil level has been checked.
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ENGINE OIL FILTERS TU all types 1.1i HFX C2 C3 C3 Pluriel Xsara Xsara Picasso ET3J4 1.4i KFV KFW 1109 R7 PURFLUX MAHLE FILTRAUTO 1.6i NFV (1) 1109 X4 1.6i 16V NFU EW 1.8i 16V 6FZ XU 2.0i 16V RFN RFS 1109 T1 1109 N3 1109 R7 1109 R7 1109 R7 1109 T1 DV4TD 1.4 HDi 8HW C2 C3 C3 Pluriel Xsara Xsara Picasso 1.4i 16V KFU TU all types 8HX 1109 S5 1109 S5 1109 S5 8HZ DV4TED4 1.4 HDi 16V 8HV 8HY 1109 T1 DV6TED4 1.6 HDi 16V 9HZ 9HY DW8 1.9 D WJY DW10 2.
PAGE 235
Tools. [1] Filling cylinder [2] Adaptor for filling cylinder : 4520-T : 4222-T IMPERATIVE: Respect the safety and cleanliness requirements. - The draining and refilling operations can be carried out using WINN’S or similar coolant fluid replacement equipment; it is essential to follow the instructions as stated for that equipment. Filling and bleeding. - Fit the cylinder adaptor [2] 4222-T (Picasso, C2, C3) and the filling cylinder [1] 4520-T (all types).
PAGE 236
IDLING - DEPOLLUTION Vehicles INJECTION C2 C3 PLURIEL C3 XSARA XSARA PICASSO Engine type Emission standard 1.1i HFX L4/IFL5 C2 - C3 - C3 PLURIEL - XSARA PICASSO Idling speed (± 50 rpm) Make - Injection type Man. gbox Auto. gbox : N gear engaged % Content CO CO2 < 0,5 >9 MAGNETTI MARELLI 48P 1.4i KFW - KFV L4/IFL5 SAGEM S2000 1.6i 16V NFU L4 BOSCH M 7.4.4. 1.1i HFX L4/IFL5 MAGNETTI MARELLI 48P 1.4i KFW L4/IFL5 SAGEM S2000 1.4i 16V KFU L5 MAGNETTI MARELLI 6LP 1.
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C2 PETROL INJECTION Engine type Emission standard Injection make and type Fuel pressure (bars) 1.1i 1.4i 1.6i 16V HFX KFV NFU L4/IFL5 L4/IFL5 IFL5 M. MARELLI 48P2 SAGEM S2000 BOSCH M.7.4.4.
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PETROL INJECTION C3 - C3 PLURIEL C3 INJECTION Engine type Emission standard Injection make and type C3 PLURIEL 1.1i 1.4i 1.4i 16V 1.6i 16V HFX KFV KFU NFU KFV NFU L5 L4 L4/IFL5 IFL5 M. MARELLI 6LP BOSCH M.7.4.4. SAGEM S2000 BOSCH M.7.4.4. K’-L4INF-L4/IFL5 K’-L4INF-L4/IFL5 M. MARELLI 48P2 SAGEM S2000 1.4i 1.
PAGE 239
PETROL INJECTION XSARA - XSARA PICASSO 1.4i Engine type Emission standard Injection make and type 1.6i 16V XSARA PICASSO 2.0i 16V 1.6i 1.8i 16V 2.0i 16V KFW NFU RFN NFV 6FZ RFN L4/IFL5/L5 L4/IFL5 L4/IFL5 L4 IFL5 L4/IFL5 SAGEM S2000 BOSCH M.7.4.4. M. MARELLI 6LP BOSCH M.7.4.4. SAGEM S2000 M.
PAGE 240
DEPOLLUTION TECHNICAL CHECKS (FRANCE) ALL TYPES All Types Petrol CO Corrected (In %) All Types Diesel (m-1) INJECTION Conditions: At idle, engine warm. # 01/96 01/96 # Atmospheric engine. Less than 4.5 % for vehicles registered before 10/86. Less than 3.5 % for vehicles registered after 10/86. Less than 2.5 m-1 With catalytic converter Greater than 2.0i All Types CO less than 0.5 % CO less than 0.3 % Turbocharged engine. 89 M.Y. 93 M.Y. at idle speed.
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ALL TYPES EMISSION STANDARDS APPLICATIONS E.E.C. PSA A/S PR Engines Vehicles Applicable ➞ 10/89 ECE R 15.04 K K’ 15.04 15.04 Petrol Diesel Utility vehicles: All Types imminent OBSERVATIONS CHARACTERISTICS INJECTION STANDARD ➞ Utility vehicle limits = private vehicle limits increased by 25 %. ➞ For private vehicles and utility vehicles in major export With oxygen sensor, without catalytic converter ECE R 15.05 W vp 15.
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ALL TYPES EMISSION STANDARDS APPLICATIONS STANDARD E.E.C. INJECTION US 83 PSA A/S Z PR US 83 Engines Petrol Diesel US 87 Y US 87 Diesel US 93 Y2 US 93 Petrol Diesel Vehicles Private vehicles: • certain non-EEC European countries • certain Export countries Private vehicles: • certain non-EEC European countries • certain Export countries Private vehicles: • certain Export countries Applicable OBSERVATIONS CHARACTERISTICS Current ➞ Adoption of U.S.
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ALL TYPES EMISSION STANDARDS APPLICATIONS E.E.C. US 84 LDT US 87 LDT US 90 LDT PSA A/S X1 X2 X3 PR US 84 US 87 US 90 Engines Vehicles Applicable OBSERVATIONS Petrol Diesel Private vehicles: • certain non-EEC European countries • certain Export countries Current ➞ Adoption of the U.S. standard for light utility vehicles Petrol Diesel Private vehicles: • certain non-EEC European countries • certain Export countries Current ➞ Adoption of the U.S.
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ALL TYPES EMISSION STANDARDS APPLICATIONS STANDARD E.E.C. PSA A/S PR Engines INJECTION EURO 2 (EURO 96) L3 E.E.C. 95 EURO 2 (EURO 96) W3 E.E.C. 95 Petrol Diesel Petrol Diesel Gas Vehicles Private vehicles: < 6 seats and < 2.5 tonnes • new models • existing models Utility vehicles: < 3.
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EMISSION STANDARDS PSA A/S PR Engines Vehicles Applicable Utility vehicles: < 3.
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ALL TYPES EMISSION STANDARDS APPLICATIONS STANDARD E.E.C.
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SAFETY REQUIREMENTS: HDi DIRECT INJECTION SYSTEM Engines: HDi ALL TYPES Preamble. All interventions on the injection system must be carried out to conform with the following requirements and regulations: - Competent health authorities. - Accident prevention. - Environmental protection. WARNING: Repairs must be carried out by specialised personnel informed of the safety requirements and of the precautions to be taken. Safety requirements.
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SAFETY REQUIREMENTS: HDi DIRECT INJECTION SYSTEM Engines: HDi ALL TYPES CLEANLINESS REQUIREMENTS. Preliminary operations. INJECTION 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.
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PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM C2 - C3 -XSARA Engines: 8HX - 8HW - 8HZ - 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.
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C2 - C3 -XSARA PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM Engines: 8HX - 8HW - 8HZ Diesel injectors. WARNING: Diesel and ultrasonic cleaners are prohibited. INJECTION Do not separate the following components from the diesel injector carrier (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.
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PROHIBITED OPERATIONS: DELPHI HDI DIRECT INJECTION SYSTEM C3 Engines: 8HY - 8HV - 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.
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C3 PROHIBITED OPERATIONS: DELPHI HDI DIRECT INJECTION SYSTEM Engines: 8HY - 8HV Fuel high pressure injection common rail. INJECTION Do not separate the pressure regulator «c» from the injection common rail (2) (Risk of malfunction). Diesel injectors. WARNING: Diesel and ultrasonic cleaners are prohibited. Do not separate the following components from the diesel injector carrier (3): - Diesel injector (e) (no replacement parts). - Electromagnetic component «d» (no replacement parts).
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PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM XSARA PICASSO Engines: RHY - RHZ - The use of high pressure cleaners is prohibited. - Do not use compressed air. Fuel supply circuit. - Required fuel: diesel. WARNING: Do not use other fuels. Electric circuit. - 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.
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XSARA PICASSO PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM Engines: RHY - RHZ INJECTION B1HP12DC B1HP12EC 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).
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SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP XSARA L3 Equipment Transponder XSARA DW 8B DWLP 12 R8448 B 371 B WJY 251 INJECTION PUMP -TYPE - REFERENCE Dépollution
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XSARA Engine type INJECTION WJY SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP Pump Type Reference DWLP 12 R 8448 B/* Static timing Dynamic Initial advance Compression Time (cylinder N° 4) timing checking (at idle) Engine TDC Pegging hole. Value «X» engraved on the pump. Reference Injector RDNO SDC 6903 Injector holder + injector LDCR 0260 IAA (*) = See table page: 251.
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CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP XSARA Engine: WJY : 7014-T.J : (-).0188.E : (-).0188.H Tool kit C.0188 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.
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XSARA CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP Engine: WJY (continued) Peg: - The camshaft hub, using tool [2]. - The injection pump hub, using tool [3]. INJECTION 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.
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ADJUSTING THE MECHANICAL CONTROLS OF THE DELPHI INJECTION PUMP XSARA 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.
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XSARA ADJUSTING THE MECHANICAL CONTROLS OF THE DELPHI INJECTION PUMP Engine: WJY (continued) Adjusting the anti-stall (residual output). INJECTION - 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).
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FITTING DELPHI DIESEL INJECTORS XSARA Engine: WJY [1] Tool to remove/refit injectors : 7007-T [2] : 7008-T.A Tool kit 4123-T INJECTION Fitting an injector. - The copper seal (1) and the fire seal washer (3) are to be replaced each time they are removed. NOTE: Fitting parts of different makes is PROHIBITED. WARNING: Ensure that the fire seal washer (3) is fitted the right way round. Tighten the injector holder on the cylinder head to: 9 m.daN (3) Tighten lightly to prevent any distortion.
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XSARA PICASSO Engines DV 6 Injection system TE TD INJECTION DW INJECTION PUMP SPECIFICATIONS (BOSCH and SIEMENS) 10 ATED ECU High pressure pump BOSCH EDC 16C3 BOSCH CP 3.
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CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT C2 - C3 Engines: 8HX - 8HW : 4215-T. : 4073-T.A Tool kit 4073-T IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection 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.
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C3 - XSARA PICASSO CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT Engines: 8HV - 8HY - 9HZ - 9HY Tools. [1] Ø 10 mm low pressure connector : 4215-T. [2] Pressure gauge for testing boost pressure : 4073-T.A Tool kit 4073-T INJECTION IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines. Remove the air filter duct. Link tool [1] in series, downstream of the injectors, between the fuel high pressure pump and the fuel filter at «a» and «b».
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XSARA PICASSO CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT Engines: RHY - RHZ [1] Ø 10 mm low pressure connector [2] Ø 8 mm low pressure connector [3] Pressure gauge for testing boost pressure : 4215-T. : 4218 -T. : 4073 -T 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 pressure fuel pump and the fuel filter (green mark at "b" on the fuel return pipe).
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XSARA PICASSO CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT Engines: RHY - RHZ (continued) INJECTION Checks on pressure: dynamic. Engine running, at idle (normal functioning): - Fuel supply pressure shown by the pressure gauge [3] = 2 ± 0.4 Bar. - Fuel return pressure shown by the pressure gauge [3] = 0.7 ± 0.4 Bar. Abnormal functioning Fuel supply pressure Fuel return pressure Between 3 and 3.5 Bar 0,7 ± 0,2 Bar Check the condition of the diesel filter More than 3.5 Bar Less than 0.
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CHECKS: TURBO PRESSURE C2 - C3 B1BP2NXD C5FP0F5C Tools. [1] Pressure gauge for checking boost pressure : 4073-T.A [2] Sleeve for checking boost pressure : (-).0171.F Checks. IMPERATIVE: Respect the following test conditions: - Engine at operating temperature. - Vehicle in running order. - Engine under full load. 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.
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C3 CHECKS: TURBO PRESSURE Engines: 8HV - 8HY INJECTION C5FP0EJC B1BP2NBD Tools. [1] Pressure gauge for checking boost pressure : 4073-T.A [2] Sleeve for checking boost pressure : (-).0171.F Checks. IMPERATIVE: Respect the following test conditions: - Engine at operating temperature. - Vehicle in running order. - Engine under full load. 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.
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CHECKS: TURBO PRESSURE XSARA PICASSO Engines: 9HZ - 9HY IMPERATIVE: Respect the safety and cleanliness requirements. INJECTION Preparation. IMPERATIVE: Respect the following test conditions: - Engine at operating temperature. - Vehicle in running order. - Engine under full load. Connect the diagnostic tool to the vehicle’s diagnostic socket, carry out parameter measures. Mode of operation. Start the engine. Engage first gear, start the vehicle. Engage the gears up to third gear.
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XSARA PICASSO CHECKS: TURBO PRESSURE Engine: RHZ Tools. INJECTION [1] Pressure gauge for checking boost pressure [2] Sleeve for checking boost pressure [3] Adaptor sleeve B1HP12JD : 4073-T.A Kit 4073-T : 4185-T : 4229-T Checks. IMPERATIVE: respect the following checking requirements: Engine at running temperature. 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).
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XSARA PICASSO CHECKS: TURBO PRESSURE Engine: RHY : 4073-T.A Kit 4073-T : 4185-T Checks. IMPERATIVE: respect the following checking requirements: Engine at running temperature. 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 gauge to be positioned inside the vehicle. Procedure.
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C2 - C3 CHECKING THE AIR SUPPLY CIRCUIT Engines: 8HX - 8HW - 8HY - 8HV INJECTION 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.
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CHECKING THE AIR SUPPLY CIRCUIT XSARA PICASSO Tools. [1] Manual vacuum pump : FACOM DA 16 IMPERATIVE: Respect the safety and cleanliness requirements. Vacuum pump. - Connect the tool [1] on the vacuum pump (1). - Start the engine. - Pressure should be 0.8 bar at 780 rpm. Boost pressure regulator electrovalve. - Connect the tool [1] between the electrovalve (2) and the valve (3) of the boost pressure regulator. Compare readings with the values in the table below.
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C2 - C3 CHECKS: EXHAUST GASES RECYCLING CIRCUIT Engines: 8HX - 8HW Tools. [1] Manual pressure-vacuum pump : FACOM DA 16 IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection (HDi) engines. INJECTION EGR valve. Connect tool [1] on the capsule take-off (2). Apply a vacuum of approx. 0,6 bar several times to activate the rod «a». In abruptly suppressing the vacuum, the valve should click and lock itself back on its seating.
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CHECKS: EXHAUST GASES RECYCLING CIRCUIT XSARA PICASSO Engines: 9HZ - 9HY Exhaust gas recycling (EGR) valve. NOTE: The engine ECU pilots the EGR valve. B1HP1UPC Perform the check with the aid of a diagnostic tool. Carry out the following operations with the diagnostic tool: - «INJECTION» menu. - Actuator tests. - EGE electrovalve. Check that you can hear the click from the EGR regulation electrovalve. Double butterfly housing (vehicle with particle filter). (2) Double butterfly housing.
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XSARA PICASSO CHECKS: EXHAUST GASES RECYCLING CIRCUIT Engines: RHY - RHZ Tools. [1] Manual vacuum pump : FACOM DA 16 INJECTION 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.
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PARTICLE FILTER SAFETY AND CLEANLINESS REQUIREMENTS ALL TYPES General. - It is forbidden to smoke in the immediate proximity of the high pressure circuit during a repair. - Avoid working close to flames or sparks. When the engine is running: - Do touch the fuel high pressure circuit. - Always keep out of range of possible projections of fuel, which could cause serious injuries. - Do not place your hand near to any leak on the fuel high pressure circuit.
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ALL TYPES PARTICLE FILTER SAFETY AND CLEANLINESS REQUIREMENTS INJECTION Operations on the fuel additive circuit. IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves that are resistant to hydrocarbons. The work area must be ventilated. In the event of any significant dispersion of additive: - Wear a breathing mask for filtering the particles. - Recover as much of the product as possible. - Place the product thus recovered in an appropriately labelled container.
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SPECIAL FEATURES: FORCED REGENERATION OF THE PARTICLE FILTER ALL TYPES Tools. Forced regeneration of the particle filter. IMPERATIVE: Respect the safety and cleanliness requirements specific to HDi engines. ESSENTIAL: Connect the vehicle to a gas extractor approved for this type of operation. In the absence of the required installations, carry out the forced regeneration of the particle filter outside the workshop, in a concreted area well away from any inflammable materials.
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XSARA PICASSO SPECIAL FEATURES: PARTICLE FILTER / FILLING OF THE ADDITIVE RESERVOIR INJECTION B1HP1UVC Imperative: Respect the safety and cleanliness requirements. Tools. Filling kit comprising the following items: 1 Container of Eolys 2 Filters 2 Tubes 1 Empty container 2 Hooks 1 Adaptor Filling. IMPERATIVE: Respect the safety and cleanliness requirements specific to HDi engines.
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SPECIAL FEATURES: PARTICLE FILTER / CHECKING THE ADDITIVE PUMP XSARA PICASSO Engine: 9 HZ IMPERATIVE: Respect the safety and cleanliness requirements. [1] Manual pressure/vacuum pump [2] Additive container : FACOM DA 16 : (-).1613.G Kit 1613 Checks. IMPERATIVE: Respect the safety and cleanliness requirements specific to HDi engines. IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves that are resistant to hydrocarbons. Place the vehicle on a lift.
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XSARA PICASSO SPECIAL FEATURES: PARTICLE FILTER / CHECKING THE ADDITIVE PUMP Sealing of the additive injector. Couple tool [1] to the tube (1). Action the manual pump [1]. INJECTION WARNING: The additive injector should open at a pressure of 100 ± 20 Bars. Action the manual pump in vacuum [1] at 800 m.bars. WARNING: The downstream pressure should not fall rapidly. B1HP1UUC NOTE: Replace the fuel tank if the injector is defective. Couple the tube (1).
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SPARKING PLUGS Engine type Vehicles C2 C3 PLURIEL XSARA 1.6i XSARA PICASSO 16V 16V 16V 16V 16V 16V 90 hp 100 hp 1.8i 16V 2.0i 16V HFX KFV NFU HFX KFV KFU NFU KFV NFU KFW NFU RFN RFS NFV 6FZ RFN Electrode gap setting FR7 DE FR7 ME 0,9 ± 0,1 CHAMPION Electrode gap setting Tightening torque 0,9 ± 0,05 2.5 ± 0,2 mda.
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ALL TYPES SPEEDOMETER An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled. This decree stipulates: - The speed indicated by a speedometer must never be lower than the actual vehicle speed. - Between the speed displayed «SD» and the speed travelled «ST», there must always be the following relationship: ST < SD < 1.
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CLUTCH SPECIFICATIONS 1.1i C2 1.4i 1.6i 16V 1.4 HDi Engine type HFX KFV NFU 8HX Gearbox type Supplier BVM BVM/BVMP (*) BVM/BVMP (*) BVM/BVMP (*) MA 5 N/L MA 5 S/L MA 5/S Engine type VALEO 180 CP0 3400 200 P 3900 Bearing supplier / height SKF 17 mm Clutch disc 11 R 10 Ø of lining. Ext/Int 180/127 ? ? 200/134 Quality of lining (*) MA 5/0 LUK 408 : BVM = Manual gearbox. : BVMP = Piloted manual gearbox.
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C3 - C3 PLURIEL Engine type CLUTCH SPECIFICATIONS 1.1i 1.4i 1.4i 16V HFX KFV KFU Gearbox type Supplier Mechanism / type 1.4 HDi NFU 8HX 1.4 HDi 16V 8HW MA/5 CLUTCH GEARBOX TRANSMISSION VALEO ? Engine type 180 CPO 3400 200 MF 3850 Clutch disc 11 R 10 X 200 VTB 180/127 ? Ø Garniture.Ext/Int 1.
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CLUTCH SPECIFICATIONS 1.4i XSARA 1.6i 16V 2.0i 16V Engine type KFW NFU Gearbox type Supplier MA/5 MA/5 Engine type 180CPO 3400 200 CPR 3800 230 DNG 4700 215 DT 5250 Clutch disc 180 XJF 73 C 200X(D95) 11A12X 230 DNG 4700 215 FD 95 180/127 200/137 228/155 215/147 Mechanism / type Quality of lining RFS BE4/5 VALEO F 408 F 808 283 CLUTCH GEARBOX TRANSMISSION Ø Garniture.
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XSARA Engine type CLUTCH SPECIFICATIONS 1.4 HDi 1.9 D 8HZ WJY Gearbox type Supplier CLUTCH GEARBOX TRANSMISSION Quality of lining RHZ 230 P 4700 235 T 5700 LUK 200 P 4200 Clutch disc Ø Garniture.Ext/Int RHY BE4/5 Mechanism / type Engine type 2.
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CLUTCH SPECIFICATIONS 1.8i 16V 2.0i 16V NFV 6FZ RFN Gearbox type Supplier 9HY VALEO Engine type 200 DNG 3800 230 DNG 4700 215 DT 5250 Clutch disc 200X(D95) 11A12X 230 DNG 4700 215 FD 95 200/137 228/155 215/147 Quality of lining 9HZ 2.0 HDi RHY BE4/5 Mechanism / type Ø Garniture.Ext/Int 1.4 HDi 16V F410 F 808 285 LUK 225 DNG 5100 230 P 4700 228 225/150 230/155 F 810 DS F408 CLUTCH GEARBOX TRANSMISSION Engine type 1.
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C2 - C3 - C3 PLURIEL CLUTCH SPECIFICATIONS Engines: HFX – KFV – KFU – NFU – 8HX – 8HW – 8HV – 8HY NOTE: All the clutches are «push» type with hydraulic control. Description. The declutch control has a declutch fork mounted on a ball-joint. (1) The ball-joint is screwed into the clutch casing. (2) Declutch fork. (3) Clutch casing. (4) Bearing. (5) Clutch plate. CLUTCH GEARBOX TRANSMISSION The clutch control slave cylinder (7) is fixed by two screws (6) onto the exterior of the clutch casing.
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CLUTCH SPECIFICATIONS XSARA - XSARA PICASSO Engines: KFW - NFU - NFV - 6FZ - RFN - RFS - 8HZ - 9HZ - 9HY - WJY - RHY - RHZ NOTE: All the clutches are «push» type with hydraulic control. The clutch control slave cylinder (7) is fixed by two screws (6) onto the exterior of the clutch casing. Tightening torques (m.daN).
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XSARA - XSARA PICASSO CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS Engines: KFW - NFU - 6FZ - RFN - RFS - 8HX - 9HZ - 9HY - WJY - RHY - RHZ «PUSH» clutch Clutch cable. Removing. Uncouple the cable from the lever (1). B2BP001C B2BP002C CLUTCH GEARBOX TRANSMISSION «PULL» clutch Unclip the cable from the gearbox by actioning the side tabs (2). B2BP02VC Detach the cable from the bulkhead. Remove the clip (3). Uncouple the cable from the clutch pedal.
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CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS XSARA - XSARA PICASSO Engines: KFW - NFU - 6FZ - RFN - RFS - 8HX - 9HZ - 9HY - WJY - RHY - RHZ «PUSH» clutch B2BP03CD «PULL» clutch Place the pedal in the high position (contact at “a”). Attach the cable yoke on the hook of the clutch pedal. Fit a new clip (3). Fit the end-piece (4) to the bulkhead (fit with G6 grease). Clip the end-piece (5) on the gearbox. Couple the cable to the lever (1).
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XSARA - XSARA PICASSO CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS Engines: KFW - NFU - 6FZ - RFN - RFS - 8HX - 9HZ - 9HY - WJY - RHY - RHZ Adjusting the pedal height. Loosen the nut (6) and the screw (7). Using a lever, raise the stop support (8) to its highest position. In this position, there should be a substantial free play in the pedal. Lower the support until there is a free play of 2 ± 1 mm. Tighten the nut (6) and the screw (7). Check that the clutch cable sleeve can move freely.
PAGE 295
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS HYDRAULIQUE Bleeding the hydraulic clutch control C3 PLURIEL- XSARA C2-C3-XSARA PICASSO IMPERATIVE: Use only new brake brake fluid that is not emulsified, avoid any ingress of impurities into the hydraulic circuit. Couple a transparent tube (5) on the bleed screw, at «c». Submerge the end of the tube (5) in the recipient containing the brake fluid, located below the level of the clutch slave cylinder.
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C2 - C3 - C3 PLURIEL XSARA PICASSO CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS HYDRAULIQUE Bleeding the hydraulic clutch control CLUTCH GEARBOX TRANSMISSION Action the clutch pedal manually through its full travel: 7 times rapidly down and up. Allow the clutch pedal to come back up to its high position. Fill the brake fluid reservoir to the maximum of its capacity. Open the bleed screw, at «c». Action the clutch pedal manually through its entire travel: 7 times rapidly down and up.
PAGE 297
GEARBOX AND TYRE SPECIFICATIONS C2 Manual gearbox Petrol Diesel 1.1i 1.4i 1.4 HDi Engine types HFX KFV 8HX Tyres-rolling 165/70 R14 165/70 R14 185/55 R14 165/70 R14 Circumference 1,804 m 1,804 m 1,781 m 1,804 m Gearbox type MA 5/S MA 5/N MA 5/L 20 CP 20 PRO 9919 ➞ 20 CP 21 PRO 9919 ➞ 20 CP 16 PRO 9919 ➞ Reduction box torque 16x65 14X60 Speedometer ratio 21x18 293 1,781 m MA 5/0 20 CP 55 PRO 9919 ➞ 20 CP 67 PRO 9919 ➞ 17X61 CLUTCH GEARBOX TRANSMISSION Gearbox ident.
PAGE 298
C2 GEARBOX AND TYRE SPECIFICATIONS Piloted manual gearbox Petrol Diesel 1.4i Engine types Tyres-rolling Circumference Gearbox type Gearbox ident. plate 1.4 HDi 1.
PAGE 299
GEARBOX AND TYRE SPECIFICATIONS Manual gearbox C3 Petrol 1.1i 1.4i 1.6i 16V AUTOMATIC X - SX - Exclusive X - SX HFX 165/70 R 14 1,804 m Gearbox type Gearbox ident. plate Reduction box torque Speedometer ratio 20 CP 14 14x60 Exclusive KFV 185/60 R15 1,828 m 165/70 R 14 1,804 m MA/5 20 CP 15 ou (*) 16x63 21x18 u X - SX Exclusive NFU 185/60 R15 1,828 m AL4 20 TP 75 21x73 MA/5 20 CP 58 17x64 Diesel 1.4 HDi Trim level Engine type Tyres-rolling - Circumference Gearbox type Gearbox ident.
PAGE 300
C3 GEARBOX AND TYRE SPECIFICATIONS Piloted manual gearbox Petrol Diesel 1.4i 16V 1.6i 16V 1.4 HDi NFU 8HX Trim level Engine type Tyres-rolling Circumference KFU 185/60 R15 1,828 m Gearbox type CLUTCH GEARBOX TRANSMISSION Gearbox ident.
PAGE 301
GEARBOX AND TYRE SPECIFICATIONS Petrol Diesel 1.4i Engine types C3 PLURIEL KFV 1.6i 16V 1.4 HDi NFU 8HX Tyres-rolling Gearbox type MA/5N MA/5S MA/50 20 CP 60 (m) (1) 20 CP 63 (mp) (2) 20 CP 71 (m) (1) Reduction box torque 13x59 16x65 14x60 Speedometer ratio 21x18 Gearbox ident. plate (1) m = Manual geearbox. (2) mp = Piloted manual gearbox.
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GEARBOX AND TYRE SPECIFICATIONS XSARA Petrol 1.6i 16V 1.4i Engine type KFW 20 CP 51 (2) 16x65 21x18 Speedometer ratio RFN RFS 195/55 R15 - 1,815 m AL4 BE4/5 MA/5 20 CP 13 (1) Reduction box torque AUTOMATIC NFU Tyres-rolling - Circumference Gearbox type Gearbox ident. plate 2.0i 16V AUTOMATIC AL4 BE3/5 20 TP 49 20 DL 40 20 TP 47 20 TE 47 21x73 24x21 19x72 22x19 23x73 24x21 14x62 22x19 CLUTCH GEARBOX TRANSMISSION Diesel Engine type 1.9 D 1.
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Petrol 1.8i 16V 1.6i Engine type Tyres-rolling Circumference Gearbox type Gearbox ident. plate Reduction box torque Speedometer ratio NFV 6FZ 185/65 R15 1,895 m BE4/5 20 DL 67 15x64 22x18 20 DL 69 19x77 XSARA PICASSO 2.0i 16V AUTOMATIC RFN AL4 20 TS 02 21x73 24x20 Diesel 1.6 16V HDi Engine type Tyres-rolling Circumference Gearbox type Gearbox ident.
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C2 - C3 - C3 PLURIEL MA/5 GEARBOX Engines: HFX - KFV - NFU - 8HX - 8HW «a» Identification label. CLUTCH GEARBOX TRANSMISSION «b» Location for engraving of serial and gearbox nos.
PAGE 305
C2 - C3 - C3 PLURIEL MA/5 GEARBOX B2CP3SRP (1) Retaining clip. (2) Secondary shaft. (3) Drive pinion (5th gear). (4) Bearing retaining clip screw. (5) Gearbox casing. (6) Intermediate plate. (7) Gearbox casing fixing screw. (8) Clutch bearing guide screw. (9) Clutch housing. (10) Bearing guide. (11) Primary shaft. (12) Differential housing. (13) Speedometer screw. (14) Counter drive. (15) Planet pinions. (16) Satellite pinions. (17) Differential gearwheel. (18) Driven pinion (1st gear).
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C2 - C3 - C3 PLURIEL MA/5 GEARBOX Engines: HFX - KFV - NFU - 8HX - 8HW (23) Driven pinion (4th gear). (24) Driven pinion (5th gear). (25) 5th gear synchroniser. CLUTCH GEARBOX TRANSMISSION Tightening torques (m.daN).
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C2 - C3 - C3 PLURIEL MA/5 GEARBOX Engines: HFX - KFV - NFU - 8HX - 8HW Tightening torques (m.daN). (26) (27) (28) (29) 5th gear cover fixing screw Reverse gear switch Drain plug Top-up plug (3 (1 (1 (1 screws) screw) screw) screw) : 2,2 : 2,5 : 3,3 : 3,3 ± ± ± ± 0,2 0,5 0,3 0,3 (*) Features. This gearbox: - has no adjustment. - has a reverse gear braking device (5th gear synchroniser). - has a device for prohibiting a change from 5th gear into reverse gear.
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XSARA MA/5 GEARBOX Engines: KFW - NFU «a» Identification label. CLUTCH GEARBOX TRANSMISSION «b» Location for engraving of serial and gearbox nos.
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XSARA MA/5 GEARBOX B2CP167P (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 (3rd gear). (14) Driven pinion (2nd gear). (15) 1st / 2nd gear synchroniser and reverse gear driven pinion. (16) Driven pinions (1st gear).
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XSARA MA/5 GEARBOX Engines: KFW - NFU Tightening torques (m.daN). CLUTCH GEARBOX TRANSMISSION (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.
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XSARA MA/5 GEARBOX Engines: KFW - NFU (29) Top-up plug (x1) (30) Drain plug (x1) (31) Reverse gear switch (x1) : 2,5 ± 0,5. : 2,5 ± 0,5. : 2,5 ± 0,5. Strengthened MA gearboxes are marked with the letter «B» or «C»: «B» = Differential diameter 77 mm + strengthened bearings. «C» = Differential diameter 77 mm + strengthened bearings + strengthened intermediate plate. NOTE: All vehicles are equipped with clutch control by cable. This gearbox: - has no adjustment.
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C2 RECOMMENDATIONS - PRECAUTIONS: MA PILOTED MANUAL GEARBOX Engines: HFX - KFV - NFU - 8HX Safety requirements. ESSENTIAL: Given the special features of the MA type piloted manual gearbox, observe the requirements detailed below. IMPERATIVE: When initialising the clutch actuator and/or gearbox actuator, do not allow any person to walk or stand in front of the vehicle. IMPERATIVE: Always disconnect the battery negative terminal before operating on the actuators.
PAGE 313
RECOMMENDATIONS - PRECAUTIONS: MA PILOTED MANUAL GEARBOX C2 Engines: HFX - KFV - NFU - 8HX Operations on electrical components. Do not disconnect: - The battery when the engine is running. - The ECU with the ignition switched on. - The clutch and gearbox actuators with the ignition switched on. Towing. Conditions for towing. When carrying out electrical checks: - The battery must be correctly charged. - Never use a voltage source higher than 16V. - Never use a lamp to supply an actuator directly.
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C2 RECOMMENDATIONS - PRECAUTIONS: MA PILOTED MANUAL GEARBOX Engines: HFX - KFV - NFU - 8HX Engaging of «N», without using a diagnostic tool. Engaging of «N», using a diagnostic tool. In this configuration, the gearbox actuator is blocked, gear engaged. Preliminary operations: - Battery voltage higher than 12.5 volts. - Ignition switched on. - Connect the diagnostic tool to the vehicle’s diagnostic socket.
PAGE 315
RECOMMENDATIONS - PRECAUTIONS: MA PILOTED MANUAL GEARBOX C2 Engines: HFX - KFV - NFU - 8HX Engaging of «N», without using a diagnostic tool (continued). Preliminary operation: - Disconnect the battery negative terminal. - Use a 22 mm spanner. Use the spanner to lift the gear engagement lever the maximum possible until the axis «A» of the engagement lever is perpendicular to the axis «B» (mid point of the gear engagement lever). When this position is attained, position «N» is engaged.
PAGE 316
C2 MA/5 PILOTED MANUAL GEARBOX Engines: KFV - 8HX «a» Identification label. CLUTCH GEARBOX TRANSMISSION «b» Location for engraving of serial and gearbox nos.
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MA/5 PILOTED MANUAL GEARBOX C2 B2CP3SRP (1) Circlip. (2) Secondary shaft. (3) Drive pinion (5th gear). (4) Bearing stop screw. (5) Gearbox casing. (6) Intermediate plate. (7) Gearbox casing fixing screw. (8) Clutch bearing guide screw. (9) Clutch housing. (10) Bearing guide. (11) Primary shaft. (12) Differential housing. (13) Speedometer screw. (14) Counter drive. (15) Planet pinions. (16) Satellite pinions. (17) Differential gearwheel. (18) Driven pinion (1st gear).
PAGE 318
C2 MA/5 PILOTED MANUAL GEARBOX Engines: KFV - 8HX (23) Driven pinion (4th gear). (24) Driven pinion (5th gear). (25) 5th gear synchroniser. CLUTCH GEARBOX TRANSMISSION Tightening torques (m.daN).
PAGE 319
C2 MA/5 PILOTED MANUAL GEARBOX Engines: KFV - 8HX (26) 5th gear cover fixing screw (3 screws) : 2,2 ± 0,2 (27) Gearbox input speed sensor (1 screw) : 0,8 ± 0,2 (28) Reverse gear switch (1 screw) : 2,5 ± 0,5 (29) Drain plug (1 screw) : 3,3 ± 0,3 (30) Level plug (1 screw) : 3,3 ± 0,3 B2CP3SUD 315 CLUTCH GEARBOX TRANSMISSION Tightening torques (m.daN).
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C2 MA/5 PILOTED MANUAL GEARBOX Engines: KFV - 8HX Features. CLUTCH GEARBOX TRANSMISSION The piloted gearbox is a modern manual gearbox with technology that offers enhancements in every driving situation. The piloted manual gearbox has two operating programmes: - «Sequential» programme. - «Automatic» programme. The piloted manual gearbox has: - A gearbox ECU (supplier: SIEMENS). - A gearbox actuator with two electric motors (supplier: SACHS). A clutch actuator with one electric motor (supplier: SACHS).
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BE4/5 GEARBOX C3 - XSARA - XSARA PICASSO CLUTCH GEARBOX TRANSMISSION Engines: NFV - 6FZ - RFN - RFS - 8HV - 8HY - 9HZ - 9HY - WJY - RHY - RHZ B2CP3BNC B2CP3BPD (a) Marking zone (sequence and serial no.). (b) Location of identification label.
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BE4/5 GEARBOX C3 - XSARA - XSARA PICASSO Engines: NFV - 6FZ - RFN - RFS - 8HV - 8HY - 9HZ - 9HY - WJY - RHY - RHZ (1) Drain plug. (2) Filling and top-up plug. (3) Air vent. CLUTCH GEARBOX TRANSMISSION NOTE: The air vent aperture can be used for filling. Quality of oil. Refer to the manufacturer’s instructions. Quantity of oil. Gearbox empty: 1,9 Litres. After draining: 2 Litres.
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BE4/5 GEARBOX C3 - XSARA - XSARA PICASSO Engines: NFV - 6FZ - RFN - RFS - 8HV - 8HY - 9HZ - 9HY - WJY - RHY - RHZ (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 (2nd / 4th gear). (13) Driven gear (2nd gear).
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C3 - XSARA - XSARA PICASSO BE4/5 GEARBOX Engines: 6FZ - RFN - RFS - WJY - 8HV - 8HY - 8HZ - 9HZ - 9HY - RHY - RHZ Tightening torques (m.daN).
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C2 - C3 - C3 PLURIEL MA/5 GEARBOX CONTROLS Engines: HFX - KFV - KFU - NFU - 8HX - 8HW (1) Gear control lever. (3) Gear selection control cable. (*) (*) The two cables cannot be separated. B2CP3HXD 321 CLUTCH GEARBOX TRANSMISSION (2) Gear engagement control cable.
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C2 - C3 - C3 PLURIEL CHECKS AND ADJUSTMENTS: MA/5 GEARBOX CONTROLS Engines: HFX - KFV - KFU - NFU - 8HX - 8HW (4) Gear engagement ball-joint Ø 10 mm. (5) Gear selection ball-joint Ø 10 mm.
PAGE 327
CHECKS AND ADJUSTMENTS: MA/5 GEARBOX CONTROLS C2 - C3 - C3 PLURIEL Engines: HFX - KFV - KFU - NFU - 8HX - 8HW Adjustment. The gear selection control and gear engagement control cables cannot be adjusted. B2CP3J0D To unlock the ball-joint, press at «a» then pull the ball-joint upwards. To release the sleeve stops, pull the needles «b», in the direction of the arrow, then disengage the sleeve stops from their supports.
PAGE 328
XSARA CHECKS AND ADJUSTMENTS: MA/5 GEARBOX CONTROLS Engines: KFW NFU 8HZ 1 2 3 4 5 6 7 - Gear lever. - Gear control bar. - Engagement rod. - Gear selection rod. - Torque reaction rod. - Gear engagement ball-joint. - Fixed point on gearbox. CLUTCH GEARBOX TRANSMISSION Adjustment. The gear control assembly is not adjustable. The rods do not have threaded ends. Features. Grease the gear engagement ball-joint. WARNING: To secure the ball-joints, set the gearbox control to neutral.
PAGE 329
C3 BE4/5 GEARBOX CONTROLS Engines: 8HV - 8HY (1) Gear control lever. (3) Gear selection control cable. (*) (*) These two cables cannot be separated. B2CP3J3D 325 CLUTCH GEARBOX TRANSMISSION (2) Gear engagement control cable.
PAGE 330
C3 CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS Engines: 8HV - 8HY (4) Gear engagement ball-joint Ø 10 mm. (5) Gear selection ball-joint Ø 10 mm.
PAGE 331
C3 CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS Engines: 8HV - 8HY Adjustment. To release the ball-joint, press at «d» then pull the ball-joint upwards. To release sleeve stops: - Press on the tabs of the clip (6) at «a». - Disengage the sleeve stops from their supports. B2CP3J6D 327 CLUTCH GEARBOX TRANSMISSION The gear selection control and gear engagement control cables cannot be adjusted.
PAGE 332
BE4/5 GEARBOX CONTROLS XSARA - XSARA PICASSO Engines: NFV - 6FZ - RFN - RFS - WJY - 8HZ - 9HZ - 9HY - RHY - RHZ (1) Gear control lever. (2) Gear engagement control cable. (*) (3) Gear selection control cable. (*) (4) Gear selection ball-joint Ø 10 mm. CLUTCH GEARBOX TRANSMISSION (5) Gear engagement ball-joint Ø 10 mm. (6) Flexible insulating grommet through the bulkhead. (*) = These two cables cannot be separated.
PAGE 333
CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS XSARA - XSARA PICASSO Engines: NFV - 6FZ - RFN - RFS - WJY - 8HZ - 9HZ - 9HY - RHY - RHZ Principles of adjusting the gear controls. WARNING: Cables should be adjusted each time the gearbox, gear controls or power unit are removed. CLUTCH GEARBOX TRANSMISSION 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.
PAGE 334
XSARA - XSARA PICASSO CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS Engines: NFV - 6FZ - RFN - RFS - WJY - 8HZ - 9HZ - 9HY - RHY - RHZ Adjusting the gear controls Tools. [1] Tool for positioning the gear lever Adjustements. WARNING: Cables should be adjusted each time the gearbox, gear controls or power unit are removed. CLUTCH GEARBOX TRANSMISSION Inside the vehicle: - Remove the trim under the gear lever. - Lock the gear lever in neutral position, using tool [1].
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RECOMMENDATIONS - PRECAUTIONS: AL4 AUTOMATIC GEARBOX XSARA - XSARA PICASSO Engines: KFV - NFU - RFN - RHZ Procedure to be followed prior to carrying out repairs on AL4 autoactive gearbox An excessive oil level can result in the following consequences: - Excessive heating of the oil. - Oil leaks. An insufficent level causes the destruction of the gearbox. Top up the level of oil in the gearbox (if necessary). Check using a diagnostic tool. Read the fault codes (engine and gearbox). Réception client.
PAGE 336
C3 - XSARA - XSARA PICASSO RECOMMENDATIONS - PRECAUTIONS: AL4 AUTOMATIC GEARBOX Engines: KFV - NFU - RFN - RHZ Precautions to be taken. Towing. Repairs on electrical components. The front of the vehicle must be raised in order to be towed. If the front of the vehicle cannot be raised: Do not disconnect: - The battery when the engine is running. - The ECU when the ignition is switched on. CLUTCH GEARBOX TRANSMISSION IMPERATIVE: - Put gear lever in position «N». - Do not add any oil.
PAGE 337
RECOMMENDATIONS - PRECAUTIONS: AL4 AUTOMATIC GEARBOX C3 - XSARA - XSARA PICASSO Engines: KFV - NFU - RFN - RHZ Repairs on mechanical components. Modification of the oil usage counter value. Never place the gearbox on the ground without protection. Exchanging the gearbox ECU: In order to avoid breaking the input shaft ring, it is imperative that the converter retaining bracket should be in place when handling the gearbox. - Note down the gearbox counter value.
PAGE 338
C3 - XSARA - XSARA PICASSO RECOMMENDATIONS - PRECAUTIONS: AL4 AUTOMATIC GEARBOX Engines: KFV - NFU - RFN - RHZ Procedure for initialising the automatic gearbox ECU Downloading. Updating the gearbox ECU by downloading: - Follow the procedure using the diagnostic tool. The downloading operation enables the automatic gearbox to be updated, or adapted to an evolution of the engine ECU. Before commencing the downloading, take the value of the oil usage counter present in the automatic gearbox ECU.
PAGE 339
RECOMMENDATIONS - PRECAUTIONS: AL4 AUTOMATIC GEARBOX C3 - XSARA - XSARA PICASSO Engines: KFV - NFU - RFN - RHZ Procedure for initialising the automatic gearbox ECU Updating the value of the oil usage counter. Downloading. Using PROXIA. Access to reading and recording of the oil counter is via the menu: ECU downloading procedure: - Follow the diagnostic tool procedure. Adjustment of the oil counter value is done in incremental steps of 2750 units.
PAGE 340
C3 - XSARA - XSARA PICASSO AL4 AUTOMATIC GEARBOX Engines: KFV - NFU - RFN - RHZ Identification. «a» Component reference. CLUTCH GEARBOX TRANSMISSION WARNING: This gearbox benefits from a special CITROEN semi-synthetic oil, which cannot be mixed with any other oil. The gearbox is lubricated for life.
PAGE 341
C3 - XSARA - XSARA PICASSO AL4 AUTOMATIC GEARBOX Engines: KFV - NFU - RFN - RHZ (1) Oil flow modulation electrovalve fixing : 1 ± 0,2 (2) Heat exchanger fixing :5±1 (3) Output speed sensor fixing : 1 ± 0,2 (4) Output speed sensor fixing : 1 ± 0,2 (5) Oil overflow and drain fixing : 4 ± 0,2 (6) Oil level plug : 2,4 ± 0,4 (7) Oil pressure sensor fixing : 0,8 ± 0,1 CLUTCH GEARBOX TRANSMISSION Tightening torques (m.daN).
PAGE 342
C3 - XSARA - XSARA PICASSO AL4 AUTOMATIC GEARBOX Engines: KFV - NFU - RFN - RHZ Tightening torques (m.daN).
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C3 - XSARA - XSARA PICASSO AL4 AUTOMATIC GEARBOX Engines: KFV - NFU - RFN - RHZ Tightening torques (m.daN). A: EW7 and EW10 engines Hydraulic block fixing. Centre the hydraulic block, using screws (11) and (12) . Pre-tighten (no strict order) : 0,9 Slacken : All 7 screws Tighten (respect the order indicated) : 0,75 CLUTCH GEARBOX TRANSMISSION NOTE: The screw (11) is shouldered. B: DW10 engine. Hydraulic block fixing. Centre the hydraulic block, using screws (11) and (12).
PAGE 344
C3 - XSARA PICASSO AL4 AUTOMATIC GEARBOX Engines: KFV - RFN C3 In passenger compartment. The gear selector is guided by the shape of the stepped gate and by a retaining spring which pulls it to the left hand side. The gear selector control has 5 positions: CLUTCH GEARBOX TRANSMISSION XSARA PICASSO - Position «P»: Park (locking and immobilisation of the vehicle). - Position «R»: Reverse gear. - Position «N»: Neutral. - Position «D»: Drive (use of the 4 gears in their autoadaptive automatic function).
PAGE 345
C3 AL4 AUTOMATIC GEARBOX Engine: KFV In passenger compartment (continued). The information is transmitted to the gearbox ECU. NOTE: The vehicle is equipped with the «shift lock»: you have to switch on the ignition and press the brake pedal to unlock the selector lever from position «P». - Normal programme: Operates as the default programme (eco law, autoadaptive mode). - Sport programme (a): Permits a more dynamic, sporty performance.
PAGE 346
C3 - XSARA PICASSO AL4 AUTOMATIC GEARBOX Engines: KFV - RFN C3 Gearbox end. The automatic gearbox is controlled by a cable. «c» or «d» Push-button. (1) Control lever with ball-joint. CLUTCH GEARBOX TRANSMISSION XSARA PICASSO (2) Automatic adjustment (pull out the button to adjust the control, push it in to lock the adjustment of the control). (3) Sleeve stop. (4) Selection control locking clip (5) on the sleeve stop (3).
PAGE 347
XSARA AL4 AUTOMATIC GEARBOX XSARA Engines: NFU - RFN - RHZ In passenger compartment. The selector control has 6 positions: - The gear selector is guided by the shape of the stepped gate and by a retaining spring which pulls it to the left hand side. - Push the lever to the right to exit from position «P». P: Park (system locked). R: Reverse gear. N: Neutral. D: Automatic (1st to 4th gear). 3: Automatic (1st to 3rd gear). 2: Automatic (1st to 2nd gear).
PAGE 348
XSARA AL4 AUTOMATIC GEARBOX XSARA Engines: NFU - RFN - RHZ Gearbox end. (1) Control lever. CLUTCH GEARBOX TRANSMISSION (2) Automatic adjustment. (3) Sleeve stop. The automatic gearbox is controlled by a cable.
PAGE 349
C3 AL4 AUTOMATIC GEARBOX Engine: KFV NOTE: The «shift lock» is a system that locks the gear selection lever in position «P». Unlocking the «SHIFT LOCK» (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 harnesses. - Battery voltage. Remove: - The gear lever knob (1) (pull upwards).
PAGE 350
XSARA AL4 AUTOMATIC GEARBOX Engines: NFU - RFN - RHZ SHIFT LOCK. NOTE: The «shift lock» is a system that locks the gear selection lever in position «P». Unlocking the «SHIFT LOCK» (normal operation). - Switch on the ignition. - Press the brake pedal and keep it pressed. - Move the gear selection lever out of position «P». C5FP06YC CLUTCH GEARBOX TRANSMISSION Unlocking the «SHIFT LOCK» (with an operating fault). NOTE: It is impossible to unlock the «shift lock» with the «Normal operation» method.
PAGE 351
XSARA PICASSO AL4 AUTOMATIC GEARBOX Engine: RFN SHIFT LOCK. NOTE: The «shift lock» is a system that locks the gear selection lever in position «P». Unlocking the «SHIFT LOCK» (normal operation). - Switch on the ignition. - Press the brake pedal and keep it pressed. - Move the gear selection lever out of position «P». Unlocking the «SHIFT LOCK» (with an operating fault). The fault may originate from one of the following components: - «Shift lock». Gear lever position switch. Automatic gearbox ECU.
PAGE 352
C3 AL4 AUTOMATIC GEARBOX Engine: KFV C3 Refitting the gearbox control. New gear selection control Couple the ball-joint (3). Push in the component (a) without bending the cable. Check all the gear selection control positions. CLUTCH GEARBOX TRANSMISSION Re-used gear selection control. Release the component (a). Couple the ball-joint (3). Push in the component (a) without bending the cable. Check all the gear selection control positions.
PAGE 353
XSARA AL4 AUTOMATIC GEARBOX Engines: NFU - RFN - RHZ Refitting the gearbox control. Proceed in the opposite order to removal. IMPERATIVE: Check that all the gears can engage. B2CP3AXC 349 CLUTCH GEARBOX TRANSMISSION IMPERATIVE: To adjust the gear selection control, place the gear selection lever in the park position. Press on the component (25) without bending the cable, then release.
PAGE 354
XSARA PICASSO AL4 AUTOMATIC GEARBOX Engine: RFN Refitting. Proceed in the opposite order to removal. Lubricate the support (13). New gear selection control. Couple the ball-joint (6). WARNING: Do not deform the selection lever on the automatic gearbox. CLUTCH GEARBOX TRANSMISSION Push in the component (a) without bending the cable. Check all the gear selection control positions. Re-used gear selection control. Release the component (a). Couple the ball-joint (6).
PAGE 355
C3 - XSARA - XSARA PICASSO DRAINING / FILLING / TOP-UP: AL4 GEARBOX Engines: KFV - NFU - RFN - RHZ Tools. [1] Filling cylinder : (-).0341 Draining. IMPERATIVE: The gearbox should be drained when the oil is warm (at least 60°C), to eliminate the impurities in suspension in the oil. NOTE: Draining is partial, the converter cannot be completely emptied. Remove the drain plug (1). NOTE: Approx. 3 litres of oil should flow out. Filling.
PAGE 356
C3 - XSARA - XSARA PICASSO DRAINING / FILLING / TOP-UP: AL4 GEARBOX Engines: KFV - NFU - RFN - RHZ Checking the oil level. Prior conditions: CLUTCH GEARBOX TRANSMISSION - Vehicle in horizontal position. - Check gearbox is not in back-up mode. - Remove the oil filler cap (2). - 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). - Remove the oil level plug (3).
PAGE 357
C3 - XSARA - XSARA PICASSO DRAINING / FILLING / TOP-UP: AL4 GEARBOX Engines: KFV - NFU - RFN - RHZ Thread of oil then "drip-drip". Refit the plug (3), Tighten to 2,4± 0,2 m.daN. "Drip-drip" or nothing. Refit the oil level plug (3). Stop the engine. Add 0.5 litres extra oil into the gearbox. Repeat the oil level procedure. Checking the oil level (continued). Refit the oil filler plug (3) (equipped with a new seal), tighten to 2,4± 0,2 m.daN.
PAGE 358
C2 - C3 - C3 PLURIEL - XSARA - XSARA PICASSO DRIVESHAFTS - GEARBOX Gearbox oil seal mandrels Tightening torques (m.daN) Vehicles Gearbox Engines Driveshaft bearing NO MA/5 HFX - KFV - KFU 8HX - 8HW NFU C2 C3 C3 Pluriel CLUTCH GEARBOX TRANSMISSION XSARA XSARA PICASSO NFV - RFS - RFN - 6FZ - WJY 8HZ - 9HZ - 9HY - RHY- RHZ 1,8 ± 0,1 8HV - 8HY 2 ± 0,2 C3 XSARA PICASSO AL 4 NFU - RFN - RHZ KFV Tool kit 7114-T.W 7114-T.
PAGE 359
AXLE GEOMETRY C2 Conditions for checking and adjusting Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point (see corresponding operation). Vehicle heights at reference height E1APOBZD Front height Rear height L1 L2 H2 = R2 + L2 H2 = Measurement between the measuring zone underneath the rear sill and the ground. R2 = Rear wheel radius under load. L2 = Distance between the wheel axis and the measuring zone underneath the rear sill.
PAGE 360
C2 AXLE GEOMETRY B3CP07SD Measuring front height Measuring rear height [1] Gauge for measuring the wheel radius, 4 bolts, tool 8006-T AXLES SUSPENSION STEERING Z1 = Measuring zone underneath the front subframe. Z2 = Measuring zone underneath the rear sill.
PAGE 361
AXLE GEOMETRY C2 Front axle Rear axle Dissymmetry of lower castor at 0° 30’. DISSYMMETRY OF LOWER CAMBER 0° 18’. Dissymmetry of lower camb8er 0° 18. Distribute symmetrically, LH / RH wheel, the total tracking value.
PAGE 362
C2 FRONT AXLE Tightening torques (m.daN).
PAGE 363
C2 REAR AXLE Tightening torques (m.daN).
PAGE 364
C2 SUSPENSION FRONT AXLE (1) Nut fixing suspension leg on body : 6,5 ± 0,6 (2) Damper (16) Cup (17) Damper nut (18) Damper cup (19) Ball bearing (20) Spring thrust cup (21) Travel stop cup (22) Suspension spring (23) Damper rod rpotector AXLES SUSPENSION STEERING (24) Travel stop B3BP180D 360 : 6,5 ± 0,6
PAGE 365
FEATURES OF ELECTRIC POWER STEERING C2 Engines: HFX - KFV - NFU - 8HX Steering column B3EP13HC B3EP13GD Identification. (1) Steering wheel fixing : 2 ± 0,3 Identified by the colour of the ring at «a». (2) Steering column fixing on support : 2,2 ± 0,5 Left hand drive : BLUE ring. (3) Steering cardan fixing : 2,2 ± 0,2 Right hand drive : WHITE ring. 361 AXLES SUSPENSION STEERING Tightening torques (m.daN.).
PAGE 366
C2 FEATURES OF ELECTRIC POWER STEERING Engines: HFX - KFV - NFU - 8HX Steering mechanism Tightening torques (m.daN.).
PAGE 367
FEATURES OF ELECTRIC POWER STEERING C2 Engines: HFX - KFV - NFU - 8HX Electric power steering ECU Steering assistance B3EP13LC Supplier: KOYO. Only one ECU version, whatever the engine-type. The steering assistance is rpovided by the assistance motor (12), controlled by the ECU. The electric power steering ECU is linked to the following connectors: - (6) Assistance motor supply. - (13) Electric power steering ECU supply. - (14) Control signals.
PAGE 368
C2 SPECIAL FEATURES: STEERING Engines: HFX - KFV - NFU - 8HX Centring the steering rack Preliminary operation. Raise and support the vehicle on a two-column lift. Remove, on the RH side of the steering rack: - Clip (1). - Clip (2). Release the steering rack rpotection gaiter. Setting. Move the steering to full left hand lock. Measure the dimension X. Move the steering to full right hand lock. Measure the dimension Y. B3EP13UC Calculate the dimension: L = (Y – X) : 2.
PAGE 369
AXLE GEOMETRY C3 Conditions for checking and adjusting Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point (see corresponding operation). Vehicle heights at reference height C3 E1AP09MD Rear height L1 H1 = R1 - L1 H1 = Measurement between the measuring zone underneath the front subframe and the ground. R1 = Front wheel radius under load. L1 = Distance between the wheel axis and the measuring zone underneath the front subframe.
PAGE 370
C3 AXLE GEOMETRY Checks at reference height B3CP07SD Measuring front height Measuring rear height [1] Gauge for measuring the wheel radius, 4 bolts, tool 4003-T or 8006-T (according to version). Z1 = Measuring zone underneath the front subframe. Z2 = Measuring zone underneath the rear sill.
PAGE 371
C3 AXLE GEOMETRY Front axle Rear axle Dissymmetry of lower castor at 0° 30’. Dissymmetry of lower camber at 0° 18’. Distribute symmetrically, LH / RH wheel, the total tracking value. Dissymmetry of lower camber at 0° 18’.
PAGE 372
C3 PLURIEL AXLE GEOMETRY Conditions for checking and adjusting Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point (see corresponding operation). Vehicle heights at reference height C3 Pluriel E1AP0AUD Front height Rear height AXLES SUSPENSION STEERING L1 H1 = R1 - L1 H1 = Measurement between the measuring zone underneath the front subframe and the ground. R1 = Front wheel radius under load.
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AXLE GEOMETRY C3 PLURIEL Checks at reference height B3CP07SD Measuring front height Measuring rear height [1] Gauge for measuring the wheel radius, 4 bolts, tool 4003-T Z1 = Measuring zone underneath the front subframe. Z2 = Measuring zone underneath the rear sill.
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C3 PLURIEL AXLE GEOMETRY Front axle Rear axle Dissymmetry of lower castor at 0° 30’. Dissymmetry of lower camber at 0° 18’. Distribute symmetrically, LH / RH wheel, the total tracking value. Dissymmetry of lower camber at 0° 18’.
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C3 - C3 PLURIEL FRONT AXLE Tightening torques (m.daN).
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C3 - C3 PLURIEL REAR AXLE Tightening torques (m.daN).
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C3 - C3 PLURIEL SUSPENSION Front axle C3 C3 Pluriel B3CP07RP C3 C3 Pluriel 373 : 6,5 ± 0,6 : : 3,2 ± 0,3 : 5,4 ± 0,5 : 3,2 ± 0,3 : 8 ± 0,8 : 24,5 ± 0,5 :9±1 : 10 ± 1 : : 5,5 ± 0,5 : 4 ± 0,4 : 14 ± 0,4 : 6,6 ± 0,7 : 3,5 ± 0,3 Anti-roll bar Engines Diameter (mm) 19 AllTypes 20 Pivot Colour Blue Green Engines Diameter of bearing Type AllTypes 72 In U (cast iron) AXLES SUSPENSION STEERING (1) Nut fixing suspension leg on body (2) Damper (3) Anti-roll bar link rod upper ball-joint (4) Suspension l
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C3 - C3 PLURIEL SUSPENSION Front axle (1) Nut fixing suspension leg on body : 6,5 ± 0,6 (2) Damper (16) Cup (17) Damper nut.
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C3 - C3 PLURIEL SUSPENSION Rear axle Rear axle fixing screw Anti-roll bar Rear axle crossmember Rear suspension arm silentblock mounting yoke Rear suspension arm silentblock Suspension arm fixing screw on yoke Rear suspension arm Stub axle bearing nut Damper Damper upper fixing screw Damper lower fixing screw Suspension spring Travel stop Secondary brake cable guide support Anti-roll bar Engines C3 AllTypes C3 Pluriel B3CP09UP 375 : 10 ± 1 : : : : : 7,6 ± 0,5 : : 20 ± 2 greased : : 4,5 ± 0,4 : 9,3 ± 0,
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FEATURES OF ELECTRIC POWER STEERING C3 - C3 PLURIEL Engines: HFX - KFV - KFU - NFU - 8HX - 8HW - 8HV - 8HY Steering column B3EP13HC B3EP13GD Tightening torques m.daN. Identification. AXLES SUSPENSION STEERING (1) Steering wheel fixing : 2 ± 0,3 Identified by the colour of the ring at «a». (2) Steering column fixing on support : 2,2 ± 0,5 Left hand drive : BLUE ring. (3) Steering cardan fixing : 2,2 ± 0,2 Right hand drive : WHITE ring.
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C3 - C3 PLURIEL FEATURES OF ELECTRIC POWER STEERING Engines: HFX - KFV - KFU - NFU - 8HX - 8HW - 8HV - 8HY Steering mechanism Tightening torques m.daN. (4) Ball-joint fixing on pivot (5) Steering rod lock-nut (8) Threaded washer (9) Stud (10) Flat washers (11) Fixing of mechanism on subframe : 3,5 ± 0,3 : 5 ± 0,5 : 0,8 ± 0,1 : 8 ± 0,8 B3EP13JD KFV (BVA) NFU - 8HY - 8HV 60 A 2x72 65 A 2x64 45,6/1 Connectors.
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C3 - C3 PLURIEL FEATURES OF ELECTRIC POWER STEERING Engines: HFX - KFV - KFU - NFU - 8HX - 8HW - 8HV - 8HY Steering assistance B3EP13KC B3EP13LC Electric power-assisted steering ECU. Supplier: KOYO. The steering assistance is rpovided by the assistance motor (12), controlled by the ECU. AXLES SUSPENSION STEERING Power delivered to the assistance motor (12) depends on: - Speed of the vehicle. - Torque applied on the steering wheel. Only one ECU version, whatever the engine-type.
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C3 - C3 PLURIEL SPECIAL FEATURES: STEERING Engines: HFX - KFV - KFU - NFU - 8HX - 8HW - 8HV - 8HY Centring the steering rack Preliminary operation. Raise and support the vehicle on a two-column lift. Remove, on the RH side of the steering rack: - Clip (1). - Clip (2). Release the steering rack rpotection gaiter. Setting. Move the steering to full left hand lock. Measure the dimension X. Move the steering to full right hand lock. Measure the dimension Y.
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XSARA AXLE GEOMETRY Front and rear measuring points XSARA ALL TYPES N°RPO 8667 # Rear height Front height B3CP06ZD AXLES SUSPENSION STEERING 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.
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AXLE GEOMETRY XSARA Reference heights Tools. [1] Gauge for measuring the radius of wheels with 4 bolts : 4300-T N°RPO 9429 # Setting the reference height. Front Front Measure the dimension «R1». Measure the dimension «R2». Calculate the dim. H1 = R1 - L1. 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 than 10 mm. B3CP04AD Rear axle Engines 2.
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XSARA AXLE GEOMETRY Values of the front and rear suspensions, at reference height ESSENTIAL: When checking the suspensions, the vehicle should be at reference height. Tools. Compress the suspension, to obtain the values at reference height. [1] Set of two suspension compressors [2] Set of four straps [3] Set of four shackles : 9511-T.A : 9511-T.B : 9511T.
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XSARA AXLE GEOMETRY Values of the front and rear suspensions, at reference height Front axle Tolerances Adjustable Tracking Castor Pivot angle Camber ± 1 mm ± 18’ ± 30’ ± 30’ Saloon all engine typesexcept KFW Estate all engine types except CRD (*) Saloon or entreprise KFW Saloon CRD (*) KFW 3° ± 07’ 11° ± 07’ - 0° ± 07’ 2°55’ 10°26’ 0°07’ - 1,5 ± 1 mm YES - 0°15’ ± 10’ (toe-out) 3° NO 2.
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XSARA AXLE GEOMETRY a = Angle which defines the tracking between the front and rear axles. Its value must not exceed 12'.
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FRONT AXLE XSARA Tightening torques (m.daN). Vehicles RPO 8667 # are all equipped as standard with ventilated discs.
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FRONT AXLE XSARA Evolution: Suspension arm ball-joint Application from RPO: 7968. New components: - Suspension arm ball-joint. - Pivot. Old fitting New fitting ØA = 16 mm. ØA = 18 mm. Repair requirements. ESSENTIAL: Swapping of old and new components is forbidden. It is permitted to fit a new pivot/ball-joint assembly on one side of an old vehicle. Replacement Parts. The old components are still available from Replacement Parts.
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XSARA FRONT AXLE Engine versions Diameter colour reference 1.6i - 1.6i 16V - 1.9 D 2.0i 16V (RFV) - 1.4 HDi - 2.0 HDi Saloon 19 Blue Estate 20 Yellow 2.
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XSARA FRONT AXLE Pivot ball-joint: - Manual steering, groove at «b». - Power steering, groove at «b». B3CP043D Tongue «a» towards the front.
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REAR AXLE XSARA Tightening torques (m.daN). (1) Anti-roll bar lever (2) Anti-roll bar (3) Transversal torsion bars (4) Rear crossmember flanges (5) Front silentblocks (6) Rear silentblocks (7) Anti-vibration clamp (8) Damper pin (9) Stub axle nuts (lubricated) : 3,2 ± 0,3 : 8,3 ± 0,8 : 5,5 ± 0,5 : 4,5 ± 0,4 : 9,6 ± 0,9 : 18,5 ± 1 NOTE: - The RH torsion bar is identified by 1 paint line. B3DP04SP 389 AXLES SUSPENSION STEERING - The LH torsion bar is identified by 2 paint lines.
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XSARA REAR AXLE Vehicles Engines 1.9 D 1.6i 16V - 2.i 16V 1.4 HDi - 2.0 HDi Torsion bars (mm) Anti-roll bar (mm) Diameter colour reference Diameter colour reference 3-door Entreprise 19,3 Violet 19 Orange 3- and 5-door TT exc. Entreprise 18,7 yellow 18 Blue Estates All types 20 Grey 20 Green 3- and 5-door TT 19,3 Violet 19 Orange Estates All types 20 Grey 20 Green Without colour, or white sticker 2.
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REAR AXLE Operating clearance - X = 1 to 1.4 mm. NOTE: The RH torsion bar can be identified by 1 paint line. The LH torsion bar can be identified by 2 paint lines. B3DP04UD - 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.
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XSARA REAR DAMPER Adjusting the rear dummy damper Engines Lengths of the rear dummy damper (mm) Normal driving 346 1.9 D 1.6i 16V 3-door 1.6i 16V 5-door 2.0i 16V (RFN) - 1.4 HDi 2.0 HDi 339 339 346 2.
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XSARA MANUAL STEERING SPECIFICATIONS Steering wheel - Manual steering - (a) : LHD/RHD = White. - (L) : Shaft length = 311 ± 1.5 mm. - (1) Steering wheel fitted with AIRBAG (according to equipment). - (4) Steering column adjustment lever. Tightening torques (m.daN). - (2) (3) (5) (6) AIRBAG to steering wheel fixing Steering wheel fixing Steering column to support fixing Steering cardan joint fixing : 0.8 : 3.3 : 2.3 : 2.3 - (b) = Locating bush.
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MANUAL STEERING SPECIFICATIONS XSARA Manual steering Tightening torques (m.daN). AXLES SUSPENSION STEERING B3EP042D 394 (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.
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XSARA MANUAL STEERING SPECIFICATIONS Manual steering (continued) Steering rack travel (mm) Left hand drive 73,5 Number of teeth Pinion Steering rack 6 teeth (RH helix) 29 Steering stop colour code Number of steering wheel turns Steering ratio 4,3 22/1 (13) Yellow thickness mm 395 AXLES SUSPENSION STEERING - Length of the steering track rods (Pre-adjustment) = 371 mm (Between ball-joint centres) or 391 mm (Between the centre of the pivot ball-joint and the contact face of the steering rack b
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XSARA POWER-ASSISTED STEERING SPECIFICATIONS Steering wheel - Power-assisted steering - (a) : LHD = Blue. : RHD = White. - (L): Shaft length = 311 ± 1.5 mm. - (1) Steering wheel fitted with AIRBAG (according to equipment). - (4) Steering column adjustment lever. Tightening torques (m.daN). - (2) (3) (5) (6) AIRBAG to steering wheel fixing Steering wheel fixing Steering column to support fixing Steering cardan joint fixing : 0.8 : 3.3 : 2.3 : 2.3 - (b) = Locating bush.
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POWER-ASSISTED STEERING SPECIFICATIONS XSARA Power-assisted steering B3EP08RD 397 (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 AXLES SUSPENSION STEERING Tightening torques (m.daN).
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POWER-ASSISTED STEERING SPECIFICATIONS XSARA Power-assisted steering (Continued) Steering rack travel (mm) LHD 71,7 Number of teeth Pignon Number of Steering Steering rack steering wheel turns ratio 28 3,3 18,8/1 (*) (RH helix) Steering valve Vehicles All Types (except 1.6i 16V - 1.9 TD) AXLES SUSPENSION STEERING 1.6i 16V - 1.
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POWER-ASSISTED STEERING SPECIFICATIONS XSARA Power-assisted steering assembly Tightening torques (m.daN). High pressure tube (Rubber seal pump side) - Power-assisted valve and pump union : 2.5 Return pipe. - Power-assisted valve union - (16) Upper front fixing (E3) - (17) Upper rear fixing (E3) - (18) Fixing (E3) : 2.5 : 2.5 : 2.2 : 2.2 Tightening sequence. -Tighten screws (16) and (18). -Lightly tighten screw (17), then fully tighten. - Switch opens 30 to 35 Bars. - Switch closes 25 Bars.
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XSARA PICASSO AXLE GEOMETRY Checks at reference height WARNING: The values shown should only be used as guides. In case of doubt, check the settings at reference height Conditions for checking and adjusting: Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point (see corresponding operation). NOTE: To make the setting of reference height easier, it is acceptable to take the measurement from the flange of the jacking point.
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AXLE GEOMETRY Checks at reference height XSARA PICASSO (the reference height of the vehicle is set as per the table below).
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XSARA PICASSO AXLE GEOMETRY Checks at reference height (the reference height of the vehicle is set as per the table below).
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AXLE GEOMETRY Checks at reference height XSARA PICASSO (the reference height of the vehicle is set as per the table below). Front axle Rear axle B3CP05AC B3CP05BC B3DP079C NO - CRD Vehicle (CRD = Difficult road conditions) Engines: NFV - RFN - RHY Front axle or Rear axle H2 = R2 + L2 L2 = 23,5 mm H1’ = R1 – L1’ L1’ = 109 mm Measure the radius of the front wheel: R1. Calculate dimension H1 or H1’. Measure the radius of the rear wheel: R2. Calculate dimension H2.
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XSARA PICASSO AXLE GEOMETRY Checks at reference height (the reference height of the vehicle is set as per the table below).
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FRONT AXLE XSARA PICASSO B3CP057D Anti-roll bar B3CP056P B3CP043D Suspension leg angle : Tab «a» towards the front. 405 Engine Diameter colour reference All Types 21 WHITE AXLES SUSPENSION STEERING Tightening torques m.daN. (1) Damper nut : 4.5 ± 0.4 (2) Cup screw : 2.5 ± 0.2 (3) Suspension leg (4) Anti-roll bar link rod ball-joint : 3.7 ± 0.3 (5) Suspension leg swivel : 4.5 ± 0.4 (6) Anti-roll bar (7) Anti-roll bar link rod ball-joint : 3.7 ± 0.3 (8) Lower swivel ball-joint : 4 ± 0.4.
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XSARA PICASSO REAR AXLE Tightening torques m.daN. (14) Front silentblock on subframe : 9.4 ± 0.9 (15) Anti-roll bar bolt : 5.5 ± 0.5 (16) Rear torsion bar (17)Anti-roll bar (18) Tubular axle (19) Front silentblock on bodyshell : 4 ± 0.4 (20) Rear upper arm. (21) Wheel bolt (face and threads not lubricated) : 9 ± 1 (22) Damper (23) Rear silentblock on subframe : 5.4 ± 0.5 (24) Damper pin nut : 11 ± 1 (25) Stub axle nuts (lubricated) : 25 ± 2 (26) Rear silentblock on bodyshell : 6.5 ± 0.
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STEERING COLUMN SPECIFICATIONS XSARA PICASSO Left hand drive = Green marking. Right hand drive = White marking. (1) Steering wheel (4) Steering column adjustment Tightening torques m.daN. B3EP116D 407 Airbag to steering wheel fixing Steering wheel fixing Steering column to support fixing Steering cardan joint fixing : 0.8 ± 0.1 : 3.3 ± 0.6 : 4 ± 0.1 : 2.3 ± 0.
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XSARA PICASSO STEERING COLUMN SPECIFICATIONS Tightening torques (m.daN). (7) Pivot ball-joint nut : 4 ± 0.4 (8) Steering rod adjusting lock nut : 4.5 ± 0.4 (9) Ball-joint on steering rack : 6 ± 0.6 (10) Fixing steering on subframe : 8 ± 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.
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STEERING COLUMN SPECIFICATIONS Steering rack travel Left hand drive Right hand drive 71,7 x 2 Rack pinion LH helix RH helix XSARA PICASSO Number of teeth in rack Number of steering wheel turns Turning circle between walls Turning circle between kerbs 28 Teeth 3,22 12 m 11,48 m Engines Steering valve NFV - 6FZ - RFN - RHY number of teeth : 7 409 AXLES SUSPENSION STEERING Length of the steering link rods (pre-adjustment): - Between ball-joint centres = 392 mm.
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XSARA PICASSO POWER-ASSISTED STEERING SPECIFICATIONS Tightening torques (m.daN). Unions between pump unions and power steering valve (16) Fixing screw (17) Fixing screw (18) Fixing screw : 2 ± 0.3 : 2.2 ± 0.3 : 2.2 ± 0.3 : 2.2 ± 0.3 NOTE: Coat the threads with product «E3». A pressure switch is implanted in the hydraulic piping between the high pressure pump and the power steering valve. - Opening pressure = 30 / 35 Bars. - Closing pressure = 25 Bars minimum. Tightening torque = 2 ± 0.2.
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Engine type 1.1i 1.4i 1.4 HDi HFX KFV 8HX Master cylinder 20,6 Master vac Ø mm Caliper/piston makes LUCAS.TRW-/-C 48/13-/-48 Disc FT C2 203,2 Plain 266 Disc thickness/minimum thickness 13/11 Maximum run-out (mm) 0,05 Difference in max.
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BRAKES BRAKE SPECIFICATIONS (WITH ABS) C2 Engine type 1.1i 1.4i HFX KFV Master cylinder Ø mm Plain LUCAS.TRW-/-C 48/13-/-48 266 Plain Original drum/ maximum/Width Supplier / Lining grade 22/20 13/11 TEXTRR-/-T 4144 247 9/7 Supplier / Brake pad grade Ø mm LUCAS.TRW-/-C 48/13-/-48 13/11 Disc thickness/minimum thickness RR LUCAS.TRW C 54/22-/-54 266 Supplier / Brake pad grade Disc 8HX Ventilated Disc thickness/minimum thickness Ø mm NFU 228,6 Caliper/piston makes Disc 1.
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Braking circuit without ABS - REF (drum brakes at the rear) Braking system specifications - Braking circuit at «X». - Front brakes with ventilated discs (*). - Rear brakes with eitther drums or discs (*). - Handbrake lever controlling cables acting on the rear wheels. - The compensator and main brake limiter functions are assured by the ABS EBD system. NOTE: REF = Electronic Brakeforce Distribution. (*) = according to version.
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BRAKES C2 BRAKE SPECIFICATIONS Braking circuit with ABS - REF (drum brakes at the rear) B3FP7BTD 414
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Braking circuit with ABS - REF (disc brakes at the rear) B3FP7BUD 415 C2 BRAKES BRAKE SPECIFICATIONS
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BRAKES C2 BRAKE SPECIFICATIONS Braking circuit with ABS - REF (a) Hydraulic circuit (b) Electrical circuit (1) (2) (3) (4) Master cylinder in tandem Braking servo Brake caliper (or drum at the rear) 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 416
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Ref. Components Supplier 7 ABS MK.70 ESP -ABS MK 60 ECU Front wheel sensor TEVES 5 96 387 201 80 B3FP7BVC 417 26-way connector. Integral to the hydraulic block. 2-way blue connector. The sensors are inductive-type. Mounted on the pivot Non-adjustable airgap: 0.16 to 1.6 mm. Tightening torque: 0.8 ± 0.2 m.daN. 2-way blue connector. The sensors are inductive-type Mounted on the suspension arm. Non-adjustable airgap: 0,35 à 1,6 mm. Tightening torque: 0,8 ± 0,2 m.daN.
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BRAKES BRAKE SPECIFICATIONS C2 Brake pedal Front brakes B3FP166D Rear brakes B3FP164C B3FP165C Tightening torques (m.daN).
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C2 Adjustment. Lift and chock the vehicle. Remove: - The rear cover (8). - The nut (9). - The handbrake trim (6). - The gear lever gaiter (5). - The front cover (3). - The screws (1). Disconnect the connectors of the following components: - The cigar lighter (2). - The electric window buttons (4). Remove the central console (7). WARNING: Check that the brake cables are correctly routed under the vehicle. Slacken the handbrake lever. Press gently on the brake pedal (Then repeat the operation 3 times).
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BRAKES C2 HANDBRAKE (Adjustment) Adjustment (continued). A: Drum brakes. B: Disc brakes. (10) Nut for adjusting cable tensions. Remove: - The rear wheels. - The drums (according to version). Release the handbrake. Use a gauge set to measure at «a» the travel of the lever from its stop. Adjust the nut (10) to obtain a travel of less than or equal to 1 mm at «a». Refit the brake drums without tightening them (according to version). Action the handbrake lever 8 times with an effort of 40 m.daN.
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C2 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.
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BRAKES C2 BLEEDING AND FILLING THE BRAKING SYSTEM (Continued) Bleeding the primary braking circuit. WARNING: The ABS should not be active during the bleeding operation. Front brake caliper, Bleed screw (5). A: Rear brake caliper B: Rear brake drum Bleed screw (6). Bleed each wheel cylinder, proceeding in the following order: Front LH wheel. Front RH wheel. Rear LH wheel. Rear RH wheel.
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B3FP160C C2 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).
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BRAKES BRAKE SPECIFICATIONS (WHITHOUT ABS REF) C3 Engine type 1.1i 1.4i 1.4i 16V HFX KFV KFU Master cylinder Ø Master vac mm Caliper/piston makes FT Disc Disc 8HW 203,2 LUCAS/TRW C48/13 Plain 48 266 266 13/11 13/11 Ventilated Disc thickness/minimum thickness 266 22/20 Brake pad grade Ø mm 8HX 20,6 Disc thickness/minimum thickness Ø mm 1.4 HDi TEXTRR T 4144 Drum / Max.
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1.1i 1.4i 1.4i 16V 1.6i 16V C3 1.4 HDi 1.
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BRAKES C3 PLURIEL BRAKE SPECIFICATIONS (WITH & WITHOUT ABS REF) 1.4i Engine type Master cylinder Ø Master vac FT mm Makes /piston makes Disc Ventilated Disc thickness/minimum thickness Brake pad grade Ø Cylinder or caliper mm Disc Plain RR Disc thickness/minimum thickness Ø Drum / Max. thickness / mm Width Make Brake lining grade Sans ABS REF 1.4 HDi KFV 8HX 20,6 1.4i Ftec ABS REF 1.6i 16V KFV NFU 1.
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Braking circuit without ABS - REF (drum brakes at the rear) C3 - C3 PLURIEL Braking system specifications - Braking circuit at «X». - Front brakes with ventilated discs (*). - Rear brakes with eitther drums or discs (*). - Handbrake lever controlling cables acting on the rear wheels. The compensator and main brake limiter functions are assured by the ABS EBD system. NOTE: REF = Electronic Brakeforce Distribution. (*) = according to version.
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BRAKES C3 - C3 PLURIEL BRAKE SPECIFICATIONS Braking circuit with ABS - REF (drum brakes at the rear) B3FP162D 428
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Braking circuit with ABS - REF (disc brakes at the rear) B3FP163D 429 C3 - C3 PLURIEL BRAKES BRAKE SPECIFICATIONS
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BRAKES C3 - C3 PLURIEL BRAKE SPECIFICATIONS Braking circuit with ABS - REF (a) Hydraulic circuit (b) Electrical circuit (1) Master cylinder in tandem (2) Braking servo (3) Brake caliper (or drum at the rear) (4) Hub equipped with a bearing with an integral magnetic wheel (48 pairs of poles) (5) Wheel sensor (6) Brake fluid level sensor (7) Hydraulic block plus ECU (8) Stoplamp switch (9) Instrument panel (10) Diagnostic socket (11) Built-in systems interface (BSI) B3GP02RP 430
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C3 - C3 PLURIEL C3 Pluriel ABS hydraulic block: # N°RPO 9423 ABS hydraulic block: N°RPO 9424 # B3FP12XC Components ABS hydraulic block Supplier TEVES Part no. ABS MK 60 : 96 394 937 80 ESP - ABS MK 60 : 96 418 772 80 B3FP7BVC Observations Components Installed on the front LH chassis member: 4 adjustment channels ABS hydraulic block NOTA : ESP = Electronic Stability Program 431 Supplier Part no.
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BRAKES BRAKE SPECIFICATIONS C3 - C3 PLURIEL Brake pedal gear Front brakes B3FP166D Rear brakes B3FP164C B3FP165C Tightening torques (m.daN).
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Evolution: rear wheel cylinder (applies from RPO 9667) C3 - C3 Pluriel Evolution. New wheel cylinders at the rear, with cut-off pressure 27 bars instead of 35 bars. Assembly. (1) Rear wheel cylinder. Repair. IMPERATIVE: The mixing of the old and new components is STRICTLY FORBIDDEN. WARNING: Identify the type of assembly prior to starting a repair. ESSENTIAL: Systematically replace the wheel cylinders on both sides on the same axle. Replacement parts.
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BRAKES C3 - C3 PLURIEL HANDBRAKE (Adjustment) Adjustment. Lift and chock the vehicle. Remove: - The rear cover (8). - The nut (9). - The handbrake trim (6). - The gear lever gaiter (5). - The front cover (3). - The screws (1). Disconnect the connectors of the following components: - The cigar lighter (2). - The electric window buttons (4). Remove the central console (7). WARNING: Check that the brake cables are correctly routed under the vehicle. Slacken the handbrake lever.
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C3 - C3 PLURIEL Adjustment (continued). (10) Nut for adjusting cable tensions Remove: - The rear wheels. - The drums (according to version). Release the handbrake. Use a gauge set to measure at «a» the travel of the lever from its stop. Adjust the nut (10) to obtain a travel of less than or equal to 1 mm at «a». Refit the brake drums without tightening them (according to version). Action the handbrake lever 8 times with an effort of 40 m.daN.
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BRAKES C3 - C3 PLURIEL BLEEDING AND FILLING THE BRAKING SYSTEM Tools. [1] Generic bleeding apparatus : «LURO» or similar. Bleeding, refilling. Draining. Drain the brake fluid reservoir (1) to the maximum (if necessary, use a clean syringe). Disconnect the connector (4). Uncouple the pipe (2). 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).
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Bleeding the primary braking circuit. WARNING: The ABS should not be active during the bleeding operation. Front brake caliper, Bleed screw (5). A: Rear brake caliper B: Rear brake drum Bleed screw (6). Bleed each wheel cylinder, proceeding in the following order: Front LH wheel. Front RH wheel. Rear LH wheel.
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BRAKES C3 - C3 PLURIEL BLEEDING AND FILLING THE BRAKING SYSTEM (Continued) With the bleeding apparatus. - Connect the bleeding apparatus [1] on the brake fluid reservoir (1). - Adjust the apparatus pressure to 2 Bars. For each circuit: - Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container. - Open the bleed screw, wait until the fluid is flowing out without air bubbles. - Close the bleed screw. - Remove the bleeding apparatus [1].
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XSARA Saloons 1.6i 16V 1.4i Engine type KFW Master cylinder Ø mm FT 2.0i 16V NFU RFN RFS Without ABS 23,8 (expansion holes) Master vac 1.4 HDi WJY 8HZ 2.0 HDi RHY 228,6 BOSCH 54 LUCAS 57 BOSCH 54 Disc Ventilated Disc thickness/min. thickness 266 283 266 FERF 769 ASFM 380 22 /20 Thickness/min. thickness Ø Drum - Ø min./max. mm Disc non-ventilated RHZ Ftec ABS 23,8 (valve) Caliper/piston makes Brake pad grade FERF 769 13 / 2 203/205 203/205 Disc thickness/min. thickness RR 1.
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BRAKES XSARA BRAKE SPECIFICATIONS Estates Engine type Master cylinder Ø mm FT 1.4i 1.6i 16V 2.0i 16V 1.9 D 1.4 HDi KFW NFU RFN WJY 8HZ RHY Without ABS 23,8 (expansion holes) Master vac 228,6 BOSCH 54 LUCAS 57 BOSCH 54 Disc Ventilated Disc thickness/min. thickness 266 283 266 FERF 769 ASFM 380 22 / 20 thickness/min. thickness Ø Drum - Ø min./max. mm Disc non-ventilated FERF 769 13 / 2 228 / 230 Disc thickness/min.
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XSARA - Tighten the nuts (1) to 2.3 m.daN. - The clevis pin (2) is held in place by a plastic clip.
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BRAKES XSARA BRAKE SPECIFICATIONS Braking system specifications 1 - “X” braking circuit. - Front: disc brakes, ventilated (according to model). - Rear: drum brakes with automatic adjustment. - Cable operated handbrake acting on the rear wheels. 2 (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).
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Braking system without ABS (rear drum brakes) Up to # OPR 8687 B3FP14FD XSARA Braking system without ABS (rear disc brakes) B3FP14GD 443 BRAKES BRAKE SPECIFICATIONS
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BRAKES XSARA BRAKE SPECIFICATIONS Braking system with ABS (rear drum brakes) B3FP14HD 444
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Braking system with ABS REF (rear disc brakes) XSARA Braking system with ABS REF (rear drum brakes) B3FP14JD B3FP14KD 445 BRAKES BRAKE SPECIFICATIONS
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BRAKES XSARA BRAKE SPECIFICATIONS Braking system with ABS REF (rear drum brakes) B3FP14LD 446
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XSARA Braking circuit with ESP (BOSCH 5.
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BRAKES XSARA BRAKE SPECIFICATIONS Components Ref. Electronic ECU 7 Electrical circuit Part no. Supplier 5.7 ESP 0 265 006 389 Front wheel sensor Rear wheel sensor (disc brakes) BOSCH 0 265 006 202 5 Rear wheel sensor (Saloon: drum brakes) 0 265 006 203 Rear wheel sensor (Estate: drum brakes) 0 265 006 441 Steering angle sensor 12 VALEO Gyrometer/accelerometer sensor 13 BOSCH Toothed wheel 4 GKN Observations 42-way connector. Integral to the hydraulic block..
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(7) Hydraulic block Gyrometer sensor B3HP002C Components ESP hydraulic block Supplier BOSCH Part no. 5.7 ESP XSARA Observations Located on the front LH wheelarch: 4 adjustment channels. 449 C4AP17YC IMPERATIVE: Respect the direction of fitting of the gyrometer/accelerometer sensor (connector towards the rear of the vehicle). WARNING: The gyrometer/accelerometer sensor should not be subjected to any impact. Any gyrometer/accelerometer sensor having suffered an impact must be replaced.
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BRAKES HANDBRAKE XSARA Checking and adjusting the handbrake. - Remove the handbrake console. - Jack up and chock the vehicle with the rear wheels hanging free. - Check the correct routing of the brake cables under the vehicle. - Apply and release the handbrake ten times. - Set the handbrake to the 3rd notch. - 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.
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Bleeding: The brakes can be bled either: - using brake bleeding equipment, in which case the pressure of the equipment should be set to 2 Bars. - or in the conventional way. IMPERATIVE order of bleeding Wheels: - Rear Right. Front Left. Rear Left. Front Right. Top up using brake fluid supplied by CITROEN Replacement Parts.
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BRAKES BRAKE SPECIFICATIONS XSARA PICASSO Mercosur Engine type Master cylinder Master vac Ø Master cylinder travel FT mm Caliper piston makes Disc Ventilated Disc thickness/min. thickness Makes/Brake pad grade Rear brake plates Supplier/Type Ø Cylinder or caliper mm Drum/Ø maxi RR Make Brake lining grade Compensator/Supplier/Type Cut-off pressure in Bars Europe 2.0i 16V 2.0 HDi RFN RHY Without ESP (*) 1.6i 1.8i 16V NFV 2.0i 16V 2.
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XSARA PICASSO All types Ftec ESP (*) Engine type Master cylinder Ø Master vac mm Master cylinder travel FT Piston Makes/Caliper Disc Ventilated Disc thickness/minimum thickness Makes/Brake pad grade Rear brake caliper Ø Supplier/Type mm Disc plain RR Disc thickness/minimum thickness Make Brake lining grade Compensator – cut-off in Bars 1.8i 16V 2.0i 16V 6FZ RFN 1.4 HDi 9HZ 23,8 2.
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BRAKES XSARA PICASSO BRAKING SYSTEM SPECIFICATIONS Without ABS B3FP7B9D 454
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With ABS XSARA PICASSO With EPS (Electronic Stability Program) B3FP7B9D B3FP7BRD 455 BRAKES BRAKING SYSTEM SPECIFICATIONS
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BRAKES XSARA PICASSO BRAKE SPECIFICATIONS Braking system specifications 1 - “X” braking circuit. - Front: disc brakes, ventilated. - Rear: drum brakes with automatic adjustment. - Cable operated handbrake acting on the rear wheels. - Load sensitive braking compensator (non ABS versions). 2 (1) Hydraulic valve block «ABS Bosch 5.3» or (1) Hydraulic valve block + ECU. (2) Load sensitive braking compensator (according to version).
PAGE 461
XSARA PICASSO Adjustment. Remove the handbrake trim (1). Unclip the sound-deadening (2). Raise and support the vehicle with the rear wheels hanging free. Check the correct routing of the brake cables under the vehicle. Apply and release the handbrake 4 times. Set the handbrake to the 5th notch. 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.
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BRAKES XSARA PICASSO BLEEDING THE BRAKES 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.
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STARTER MOTORS ALL TYPES Abbreviations and definitions Meaning of abbreviations: CLIMATES: C T F GF Hot Temperate Cold Very cold : Starting possible as low as -18°C. BV : Gearbox. : Starting possible as low as -18°C. : Starting possible as low as -25°C. : Starting possible as low as -30°C. M A MAP : Manual gearbox. : Automatic gearbox. : Piloted manual gearbox. DA REFRI : Power-assisted steering. : Air conditioning.
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ALL TYPES STARTER MOTORS Vehicles/models Starter type Class Climate Table of class of starter motors ELECTRICAL SYSTEM CLASS CLASS 2 CLASS 3 CLASS 4 CLASS 5 CLASS 6 Torque C 5.5 Nm 6 Nm 10 Nm 11.5 Nm 11.
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STARTER MOTORS Vehicles/models C2 Gearboxes Class Climate C 1 T F M 3 1 GF C T 1.1i Réfri 3 C2 F GF 1 1.4i M-MAP C-T 2 F 3 GF 1 C T 1.4i Réfri 3 F GF 461 ELECTRICAL SYSTEM 1.
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STARTER MOTORS C2 Vehicles/models Gearboxes Class Climate C 1.6i 16V M-MAP-A 3 T ELECTRICAL SYSTEM F C2 GF 4 C T 1.
PAGE 467
STARTER MOTORS Gearboxes 1.1i Class 1 3 M 1.1i Réfri 1 3 C3 M-MP 1 2 3 1.4i A 3 1 1.
PAGE 468
STARTER MOTORS C3 Vehicles/models Gearboxes Class 1 1.4i 16V Climate C T ELECTRICAL SYSTEM 3 F GF C 1.6i 16V M-MAP 3 T F GF C3 4 1.4 HDi C T 5 F GF 4 1.
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STARTER MOTORS C3 PLURIEL Vehicles/models Gearboxes Class 1 C T M-MAP 2 F 3 GF 1 1.4i Réfri C T 3 C3 Pluriel F GF C 1.6i 16V M-MAP-A 3 T F GF 4 1.4 HDi M C T 5 F GF 465 ELECTRICAL SYSTEM 1.
PAGE 470
STARTER MOTORS XSARA Vehicles/models Gearboxes Class 1 1.4i C T ELECTRICAL SYSTEM 2 F 3 GF 1 XSARA Climate 1.4i Réfri M C T 3 F GF 2 1.
PAGE 471
STARTER MOTORS Vehicles/models XSARA Gearboxes Class Climate C T F 1.6i 16V 3 GF C A T F XSARA GF 3 M C T 4 2.
PAGE 472
STARTER MOTORS XSARA Vehicles/models Gearboxes Class 3 2.0i 16V Climate C T ELECTRICAL SYSTEM 4 F GF 4 XSARA 1.9 D M C T 5 F 6 GF 4 2.
PAGE 473
STARTER MOTORS Gearboxes Class 5 2.0 HDi M Climate C T 6 F GF 6 XSARA A C T 6+ F GF 4 1.
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STARTER MOTORS XSARA PICASSO Vehicles/models Gearboxes Class 1 Climate C T ELECTRICAL SYSTEM 2 F 3 GF 1 1.6i C T 3 XSARA PICASSO M F GF 2 C T 3 F GF C 1.
PAGE 475
STARTER MOTORS Gearboxes Class 3 2.0i 16V M-A Climate C T 4 F GF 5 XSARA PICASSO 1.6 HDi 16V C T 6 M F GF 4 2.
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ALL TYPES ALTERNATORS ELECTRICAL SYSTEM Abbreviations and definitions Coding of climates is as follows: Meaning of abbreviations: CLIMATES: BV BVM BVA BVMP NON REFRI REFRI DA GEP DP 3 Pts NC TT N SOP TOP L.C. DAG DAD C : Hot (45°C/37°C). T F GF : Temperate (37°C/17°C). : Cold (17°C/-25°C). : Very cold (<-25°C). 472 : Gearbox. : Manual gearbox. : Automatic gearbox. : Piloted manual gearbox. : Without air conditioning. : With air conditioning. : Power-assisted steering. : Electro-pump motor.
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C2 ALTERNATORS Engine Gearbox 1.1i BVM 1.4i BVMP 1.6i 16V BVM 1.4 HDi BVM Climate Without aircon With cold pack Without cold pack RT3 RT3 RT3 RT3 Base N1 or Base N1 or N3 N3 N2 N2 C T F GF C T F GF C T F GF C T F GF With aircon Without cold pack With cold pack RT3 RT3 RT3 RT3 Base N1 or Base N1 or N3 N3 N2 N2 8 8 8 8 7 7 7 7 8 8 7 7 8 8 8 473 7 8 7 8 9 8 7 15 Meaning of abbreviations, see page: 472.
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C3 - C3 PLURIEL ALTERNATORS Allocation of alternator classes ELECTRICAL SYSTEM Engine Gearbox 1.1i BVM 1.4i BVM 1.4i BVA 1.4i 16V BVMP Climate Without aircon With cold pack Without cold pack RT3 RT3 RT3 RT3 Base N1 or Base N1 or N3 N3 N2 N2 With aircon Without cold pack With cold pack RT3 RT3 RT3 RT3 Base N1 or Base N1 or N3 N3 N2 N2 7 8 C T F GF C T F GF C T F GF C T F GF 7 8 9 8 9 8 7 7 8 7 7 7 8 7 7 9 8 8 8 8 7 9 8 7 7 8 9 Meaning of abbreviations, see page: 472.
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Engine Gearbox 1.6i 16V BVM 1.6i 16V BVMP 1.4 HDi 1.4 HDi 16V Climate Allocation of alternator classes Without aircon Without cold pack With cold pack RT3 RT3 RT3 RT3 Base N1 or Base N1 or N3 N3 N2 N2 C T F GF C T F GF C T F GF With aircon Without cold pack With cold pack RT3 RT3 RT3 RT3 Base N1 or Base N1 or N3 N3 N2 N2 8 7 7 8 9 8 9 8 7 7 8 9 8 15 Meaning of abbreviations, see page: 472.
PAGE 480
XSARA ALTERNATORS Allocation of alternator classes Without aircon With cold pack Without cold pack ELECTRICAL SYSTEM Engine Gearbox Climate 1.4i 1.6i 16V BVM C T F GF C T F GF C T F GF 1.6i 16V BVA 2.0i 16V BVM Base RT2 Base RT2 With aircon Without cold pack Base With cold pack RT2 Base RT2 9 8 8 9 8 8 8 9 12 8 Meaning of abbreviations, see page: 472.
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XSARA ALTERNATORS Engine Gearbox 2.0i 16V BVA 2.0i 16V BVM 1.9 D BVM Climate Base C T F GF C T F GF C T F GF RT2 Base RT2 With aircon Without cold pack Base With cold pack RT2 Base RT2 12 8 12 8 8 9 Meaning of abbreviations, see page: 472.
PAGE 482
XSARA ALTERNATORS Allocation of alternator classes Without aircon With cold pack Without cold pack ELECTRICAL SYSTEM Engine Gearbox 1.4 HDi BVM 2.0 HDi BVM 2.0 HDi BVA Climate Base RT2 Base C T F GF C T F GF C T F GF With aircon Without cold pack RT2 Base 15 Meaning of abbreviations, see page: 472.
PAGE 483
XSARA PICASSO ALTERNATORS Allocation of alternator classes Engine Gearbox 1.6i BVM 1.8i 16V BVM 2.0i 16V BVA 1.6 HDi 16V 2.0 HDi Climate Base C T F GF C T F GF C T F GF C T F GF Heated seat Nav. With aircon Nav. + Heated seat Base 7 Heated seat Nav. 8+ 8+ 12 8+ 12 8+ 8+ 15 15 Meaning of abbreviations, see page: 472. 479 Nav.
PAGE 484
CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR Checking the alternator output. ELECTRICAL SYSTEM Connect as shown in the diagram opposite, using an ammeter (A), a voltmeter (V), and a rheostat (R) or a Volt/Ammeter/Rheostat combination. Referring to the vehicle’s equipment specification (see table opposite), adjust the engine speed and rheostat charge to obtain U = 13.5 V.
PAGE 485
CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR MINIMUM OUTPUTS (in A) Min. output 1800 rpm 2000 rpm 3000 rpm 4000 rpm 6000 rpm 8000 rpm 15000 rpm 11 12 13 14 15 16 17 Class 6 27 34 47 55 61 63 64 7 39 46 60 65 69 70 73 8 46 54 68.5 75 78.
PAGE 486
TOUS TYPES PRE-HEATING AND STARTING SYSTEMS Vehicles - models ELECTRICAL SYSTEM C2 1.4 HDi Pre-heater plugs 8HX NGK YE04 1.4 HDi 8HW 8HX NGK YE04 1.4 HDi 16V 8HV 8HY NGK YE04 C3 1.9 D WJY 1.4 HDi 8HZ XSARA PICASSO 2.0 HDi RHY 2.0 HDi RHZ 2.0 HDi RHY Pre-heater control unit Pre/Post heating (pre-heating duration at 20°C) NAGARES 960411-P CARTIER 735068 NAGARES 960411-P Controlled by the diesel injection ECU.
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AIR CONDITIONING R 134 a (HFC) Compressor Vehicle Engines Date Refrigerant refill C2 ALL TYPES 05/2003 # 600 + 0 - 50 gr Variable Capacity Oil quantity cc Oil reference 135 SP 10 SD 6 V 12 ALL TYPES 11/2001 # TU EW XSARA DW 09/2000 # TU EW7 - DW10 BRESIL ALL TYPES 590 gr + 0 - 50 gr 725 gr + 0 - 50 gr XU10 XSARA PICASSO 625 + 0 - 50 gr 12/1999 # 675 gr ± 50 gr 03/2001 # 775 gr ± 25 gr SD 7 V 16 SD 6 V 12 SD 7 V 16 483 AIRCON C3 C3 Pluriel
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SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Click-fit connector removing/fitting tool Vehicle ELECTRICAL SYSTEM C5HP073C XSARA TT XSARA PICASSO BP HP Ø Inch Ring colour Tool kit 4164-T 5/8 Black 8005-T.A 3/8 Red 8005-T.C Tightening torques (m.daN). Unions Aircon compressor fixings. ESSENTIAL: Tighten the front part of the compressor (timing belt end), before the rear part of the compressor.
PAGE 489
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Tools. Tool for removing-refitting air conditioning seals : FACOM (-).1702 IMPERATIVE: Removing-refitting the MANULLI seal (see corresponding operation). MANULLI seal. C2 C3 : All engine-versions XSARA (Compressor and condenser end) : 08/2000 # XSARA PICASSO (Compressor end) : 11/2002 # Engine-versions: - NFV : 10/12/2001 # - 6FZ : 01/04/2002 # - RHY : 04/11/2002 # Aircon compressor.
PAGE 490
C2 - C3 - XSARA PICASSO SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Condenser (MANULLI seal) Seals (MANULLI seal) ELECTRICAL SYSTEM C5HP18XD C5HP18VD The condenser (5) has a cylinder (6) incorporating the function of aircon fluid reservoir and with integral filtering cartridge. The inlet (7) and the outlet (8) of the condenser (5) are equipped with new seals (3) (MANULLI). MANULLI calibrated seal (3). Direction of fitting of the seal (3).
PAGE 491
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Presence of pollen filter Vehicle SAXO Equipment RPO No.
PAGE 492
C2 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Pollen filter Note: The pollen filter is located in the engine compartment on the RH side. ELECTRICAL SYSTEM Removing. To remove: - Pull on the tab of the plastic cover (1), at «a». - Tilt the flap (2). - Remove the pollen filter (3). Refitting. Proceed in reverse order.
PAGE 493
C3 - C3 PLURIEL SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Pollen filter ELECTRICAL SYSTEM Note: The pollen filter is located in the engine compartment on the RH side. Removing. Remove: - The three screws (1). - The plastic cover (2). Tilt the flap (3). Remove the pollen filter (4). Refitting. Proceed in reverse order.
PAGE 494
C2 - C3 - C3 PLURIEL SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Changing the filtering/drying cartridge Tools. [1] Charge station [2] TORX adaptor [3] Inertia extractor [4] Endpiece Ø 20 [5] Set of plugs [6] Circlip pliers : (according to workshop equipment) : TORX 70 FACOM :1671-T Tool kit 4114-T : 1671-T.D20 : (-).0188.T : FACOM AIRCON Removing. Depressurise the aircon circuit, using tool [1]. Remove the grille. At «a», remove the pin and the plastic cover.
PAGE 495
C2 - C3 - C3 PLURIEL SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Changing the filtering/drying cartridge Refitting. Remove the new cartridge from its packaging. Do not expose the cartridge, the filter and seals to pollutants. Lightly oil the seals (compressor oil). Remove tool [5] from the reservoir (6). Insert the new cartridge (5) into the reservoir (6). Refit the safety circlip (4), using tool [6]. Make sure that the circlip (4) is correctly positioned in its location.
PAGE 496
XSARA SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Pollen filter Removing-refitting. Remove: - The interior trim (1). - The cover (4). - The pollen filter (3). C5HP07JC Concerns vehicles equipped with aircon without temperature regulation. AIRCON 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»).
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SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) XSARA PICASSO Pollen filter Remove: - The three screws (1). - The cover (2). AIRCON Remove the pollen filter.
PAGE 498
XSARA PICASSO SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Changing the filtering/drying cartridge Tools. [1] Charge station [2] TORX adaptor : (according to workshop equipment) : TORX 70 FACOM Removing. Depressurise the aircon circuit, using tool [1]. Uncouple the hose (2). AIRCON Remove: - The air filter assembly (3). - The nuts (1). Protect the radiator harness with strong cardboard cut to the dimensions of the radiator. Move aside the cooling fan. Remove: - The screws (4).
PAGE 499
XSARA PICASSO SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Changing the filtering/drying cartridge Move aside the radiator/condenser assembly. Remove the plug (6), using tool [2]. Support the radiator/condenser assembly thus moved aside. Remove the filtering/drying cartridge (7), using pliers. Refitting. Refit the filtering/drying cartridge (7). Clean the threads of the plug (6). It is essntial to change the O-ring seals (8). Lubricate the O-ring seals (8) with aircon compressor oil.
PAGE 500
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Compressor lubricant ESSENTIAL: The compressor lubricant is extremely hygroscopic; always use FRESH oil. Checking the compressor oil level There are three specific cases: 1/ Repairs to a system without leaks. 2/ Slow leak. 3/ Fast leak. 1/ Repairing a system without leaks. AIRCON 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.
PAGE 501
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Checking the compressor oil level (Continued) 2/ Slow leak. - Slow leaks do not lead to oil loss, therefore the same procedure should be followed as if there was no leak at all. 3/ Fast leak. AIRCON 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).
PAGE 502
ALL TYPES AIR CONDITIONING SYSTEM R 134.a Testing procedure Conditions inside the vehicle. Positions 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, first ensuring that it is in the outside air position. (1) RFTA = Fully automatic air conditioning. AIRCON Test procedure.
PAGE 503
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM C3 - C3 PLURIEL KFV CHECKING TEMPERATURES (Continued) 40 35 KFV 22 ± 2 NFU 18,5 ± 2 8HX - 8HW 22 ± 2 TU 18 ± 2 EW 30 25 20 15 17,6 ± 2 14,4 ± 2 11,5 ± 2 7,6 ± 2 7,2 ± 2 15 ± 2 12,5 ± 2 10 ± 2 8,5 ± 2 6,5 ± 2 17,6 ± 2 14,4 ± 2 11,5 ± 2 7,6 ± 2 7,2 ± 2 17 ± 2 14,5 ± 2 11 ± 2 8,5 ± 2 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
PAGE 504
C3 - C3 PLURIEL - XSARA - XSARA PICASSO KFV CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM AIRCON Checking pressures Tools. - 1 charging station. - 2 thermometers. - The temperature of the air coming from the central vents (see table). Once the preliminary conditions, vehicle equipment and checks have - The High Pressure. - The Low Pressure. been fulfilled (see table). After the air conditioning has been on for Compare the values recorded with the table below, or the graphs.
PAGE 505
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM XSARA - XSARA PICASSO Checking pressures Tools. - 1 charging station. - 2 thermometers. - The temperature of the air coming from the central vents (see table). Once the preliminary conditions, vehicle equipment and checks have - The High Pressure. - The Low Pressure. been fulfilled (see table). After the air conditioning has been on for Compare the values recorded with the table below, or the graphs.
PAGE 506
C2 AIR CONDITIONING SYSTEM R 134.a (1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Filter. Tightening torques (m.daN).
PAGE 507
AIR CONDITIONING SYSTEM R 134.a C3 - C3 PLURIEL (1) High pressure valve. (2) Low pressure valve. (3) Filter. (4) Pressostat. (a) (b) (c) (d) (e) (f) C5HP17SP 503 : 0,6 : 0,6 : 0,6 : 0,6 : 0,6 : 0,6 AIRCON Tightening torques (m.daN).
PAGE 508
C3 - C3 PLURIEL BVA - KFV AIR CONDITIONING SYSTEM R 134.a Checks on the air conditioning circuit Key. T/P = Average temperature (°C) at the air vents/ high pressure (Bars). P = Low pressure (Bars). AIRCON Te = Exterior temperature (C°). HP = Pressure at compressor outlet (Bars). BP = Pressure at compressor inlet (Bars). TA = Average temperature (°C) of air blown from the central vents.
PAGE 509
AIR CONDITIONING SYSTEM R 134.a C3 - C3 PLURIEL NFV Checks on the air conditioning circuit Key. T/P = Average temperature (°C ) at the air vents/ high pressure (Bars). TE = Exterior temperature (C°). HP = Pressure at compressor outlet (Bars). BP = Pressure at compressor inlet (Bars). TA = Average temperature (°C) of air blown from the central vents. C5HP18GD 505 AIRCON P = Low pressure (Bars).
PAGE 510
C3 - C3 PLURIEL BV MECANIQUE 8HX - 8HW AIR CONDITIONING SYSTEM R 134.a Checks on the air conditioning circuit ELECTRICAL SYSTEM Key. T/P = Average temperature (°C ) at the air vents/ high pressure (Bars). P = Low pressure (Bars). TE = Exterior temperature (C°). HP = Pressure at compressor outlet (Bars). BP = Pressure at compressor inlet (Bars). TA = Average temperature (°C) of air blown from the central vents.
PAGE 511
AIR CONDITIONING SYSTEM R 134.a XSARA KFW - NFU - TU - TT Plan of air conditioning system. Two solutions: 2/ «EATON», with «EUROCLIM» compressor (quadrilobe seals). (1) (2) (3) (4) High pressure valve. Low pressure valve. Pressostat. Dryer. Tightening torques (m.daN). : 0,8 : 4 ± 0,4 : 0,8 (a) (b) (c) A Right hand drive. C5HP16RP 507 ELECTRICAL SYSTEM 1/ «MANULLI», with «NON EUROCLIM» compressor (O-ring seals).
PAGE 512
XSARA RFN AIR CONDITIONING SYSTEM R 134.a Plan of air conditioning system. Solution: 1/ «EATON», with «EUROCLIM» compressor and buffer capacity (quadrilobe seals). (1) High pressure valve. (2) Low pressure valve. (3) Buffer capacity. AIRCON Tightening torques (m.daN). (a) (b) (c) : 0,8 : 4 ± 0,4 : 0,8 A Right hand drive.
PAGE 513
XSARA RFN AIR CONDITIONING SYSTEM R 134.aw Plan of air conditioning system. Two solutions : 1/ «MANULLI», with «NON EUROCLIM» compressor (O-ring seals). 2/ «EATON», with «EUROCLIM» compressor (quadrilobe seals). Tightening torques (m.daN). (a) (b) (c) : 0,8 : 4 ± 0,4 : 0,8 A Right hand drive. C5HP16SP 509 AIRCON (1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Dryer.
PAGE 514
XSARA RFS AIR CONDITIONING SYSTEM R 134.a Plan of air conditioning system. Two solutions: 1/ «MANULLI», with «NON EUROCLIM» compressor (O-ring seals). 2/ «EATON», with «EUROCLIM» compressor (quadrilobe seals). AIRCON (1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Dryer. Tightening torques (m.daN). : 0,8 : 4 ± 0,4 : 0,8 (a) (b) (c) A Right hand drive.
PAGE 515
XSARA WJY - RHY AIR CONDITIONING SYSTEM R 134.a Plan of air conditioning system. Three solutions: 1) «MANULLI», with «NON EUROCLIM» compressor (O-ring seals). 2) «EATON», with «EUROCLIM» compressor and buffer capacity (quadrilobe seals). 3) «EATON», with «NON EUROCLIM» compressor and buffer capacity (O-ring seals). Tightening torques (m.daN). : 0,8 : 4 ± 0,4 : 0,8 (a) (b) (c) A Right hand drive. C5HP17XP 511 AIRCON (1) High pressure valve. (2) Low pressure valve. (3) Buffer capacity.
PAGE 516
XSARA WJY - RHY AIR CONDITIONING SYSTEM R 134.a Plan of air conditioning system. Two solutions: 1/ «MANULLI», with «NON EUROCLIM» compressor (O-ring seals). 2/ «EATON», with «EUROCLIM» compressor (quadrilobe seals). (1) (2) (3) (4) High pressure valve. Low pressure valve. Pressostat. Dryer. AIRCON Tightening torques (m.daN). : 0,8 : 4 ± 0,4 : 0,8 (a) (b) (c) A Right hand drive.
PAGE 517
XSARA RHZ AIR CONDITIONING SYSTEM R 134.a Plan of air conditioning system. Three solutions : 1) «MANULLI», with «NON EUROCLIM» compressor (O-ring seals). 2) «EATON», with «EUROCLIM» compressor and buffer capacity (quadrilobe seals). 3) «EATON», with «NON EUROCLIM» compressor and buffer capacity (O-ring seals). Tightening torques (m.daN). : 0,8 : 4 ± 0,4 : 0,8 (a) (b) (c) A Right hand drive. C5HP17YP 513 AIRCON (1) High pressure valve (2) Low pressure valve (3) Buffer capacity.
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XSARA RHZ AIR CONDITIONING SYSTEM R 134.a Plan of air conditioning system. Two solutions: 1/ «MANULLI», with «NON EUROCLIM» compressor (O-ring seals). 2/ «EATON», with «EUROCLIM» compressor (quadrilobe seals). (1) (2) (3) (4) High pressure valve. Low pressure valve. Pressostat. Dryer. AIRCON Tightening torques (m.daN). : 0,8 : 4 ± 0,4 : 0,8 (a) (b) (c) A Right hand drive.
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AIR CONDITIONING SYSTEM R 134.a XSARA PICASSO NFV (1) (2) (3) (4) (5) (6) High pressure valve Low pressure valve High pressure clickfit union (tool 8005-T.C) Low pressure clickfit union (tool 8005-T.A) Pressostat. : 1,8 ± 0,6 m.daN Filtering/drying cartridge plug (a) (b) (c) (d) C5HP13PP 515 : 0,8.± 0,1 : 0,5.± 0,1 : 1,4 ± 0,2 : 2,5 ± 0,25 AIRCON Tightening torques (m.daN).
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XSARA PICASSO 6FZ AIR CONDITIONING SYSTEM R 134.a (1) (2) (3) (4) (5) (6) High pressure valve Low pressure valve High pressure clickfit union (tool 8005-T.C) Low pressure clickfit union (tool 8005-T.A) Pressostat : 1,8 ± 0,6 m.daN Filtering/drying cartridge plug Tightening torques (m.daN). AIRCON C5HP13QP 516 (a) (b) (c) : 0,8.± 0,1 : 0,5.
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AIR CONDITIONING SYSTEM R 134.a XSARA PICASSO NFV - 6FZ Checks on the air conditioning circuit Key. T/P = Scale of: - Temperature (°C ), average of air from the central vents. - Pressure High (Bars). - Pressure Low (Bars). HP = Pressure at compressor outlet (Bars). Ta = Temperature (°C) of air blown from the vents. BP = Pressure at compressor inlet (Bars). C5HP150D 517 AIRCON Te = Exterior temperature (°C).
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XSARA PICASSO RHY - RHZ AIR CONDITIONING SYSTEM R 134.a (1) (2) (3) (4) (5) (6) High pressure valve Low pressure valve High pressure clickfit union (tool 8005-T.C) Low pressure clickfit union (tool 8005-T.A) Pressostat : 1,8 ± 0,6 m.daN Filtering/drying cartridge plug Tightening torques (m.daN). AIRCON C5HP13RP 518 (a) (b) (c) : 0,8.± 0,1 : 0,5.
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XSARA PICASSO RHY - RHZ AIR CONDITIONING SYSTEM R 134.a Checks on the air conditioning circuit Key. T/P = Scale of: - Temperature (°C ), average of air from the central vents. - Pressure High (Bars). - Pressure Low (Bars). Te = Exterior temperature (°C). Ta = Temperature (°C) of air blown from the vents. BP = Pressure at compressor inlet (Bars). C5HP14ZD 519 AIRCON HP = Pressure at compressor outlet (Bars).