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2014-12-12
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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». «The technical information appearing in this brochure is subject to updating as the characteristics of each model in the range evolve. Motor vehicle repairers are invited to contact the CITROËN network periodically for further information and to obtain any possible updates». CAR 050014 Volume 1 2004 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. In each section, the vehicles are dealt with in the following order: C2-C3-C3 PLURIEL XSARA -XSARA PICASSO - BERLINGO (1) and all models where applicable. The information given in this handbook is based on vehicles marketed in EUROPE. (1) NOTE : The BERLINGO familiale appears only in : - The correspondance tables for petrol and diesel engines. - The general chapter. For all the other chapters, see the Mechanics’ Handbook for UTILITY vehicles. IMPORTANT If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into 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. 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. 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. E1AP0C3D 1 GENERAL B - Manufacturer’s name plate (On the LH centre pillar) C2 Emission standard Type code IDENTIFICATION OF VEHICLES 1.1i 1.4i 1.6i 16V Pack - Pack ambiance Pack ambiance - VTR - Exclusive VTR L4 JM HFXB IFL5 L4 IFL5 JM HFXC/IF (*) JM KFVB/P JM KFVC/PIF (**) JM KFVC/IF (*) JM NFUC/PIF (*) GENERAL Engine type HFX KFV NFU Cubic capacity (cc) 1124 1360 1585 4 5 6 Fiscal rating (hp) MA/5S MA/5N MA/5L MA/5S MA/5L 20 CF 20 (m) (4) RPO 9688 ➔ 9784 20 CP 20 RPO 9919 ➔ 20 CF 21 (mp) (3) RPO 9688 ➔ 9784 20 CP 21 RPO 9786 ➔ 20 CF 25 20 CF 16 (1) (m) (4) (2) (m) (4) (5) (6) 20 CN 48 (mp) (3) (7) 20 CN 50 (mp) (3) (8) Gearbox type Gearbox ident. plate (1) = Europe. (2) = DAIC. (5) (6) (7) (8) = = = = 20 20 20 20 (3) mp = Piloted manual gearbox (4) m = Manual gearbox (*) = IF. (**) = PIF. CF 25 RPO 9919 ➔ 9784 CF 16 RPO 9688 ➔ 9784 CN 48 RPO 9688 ➔ 9784 CN 50 RPO 9688 ➔ 9784 20 20 20 20 CP CP CP CP 24 16 64 66 RPO RPO RPO RPO 9919 9919 9786 9786 ➔ ➔ ➔ ➔ 2 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. (5) = 20 CN 51 RPO 9688 ➔ 9784 (6) = 20 CN 33 RPO 9688 ➔ 9784 (7) = 20 CN 49 RPO 9688 ➔ 9784 20 CN 33 (2) (m) (4) (6) 20 CN 51 (1) (m) (4) (5) (3) mp = Piloted manual gearbox (4) m = Manual gearbox 20 CP 67 RPO 9919 ➔ 20 CP 54 RPO 9919 ➔ 20 CP 65 RPO 9786 ➔ 3 20 CN 33 (2) (m) (4) (6) 20 CN 49 (mp) (3) (7) 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. The vehicle’s overspeed values have to be re-initialised. The button on the wiper stalk (multifunction display B or C) or the button on the dashboard (multifunction display A or clock) operates the following functions: - Activation of the vehicle’s overspeed function. - Programming of the overspeed alert. Electric windows. It may be necessary to re-initialise the sequential and anti-pinch functions. NOTE: If the window is open at the time the battery is reconnected, action the window switch several times to close it, then re-initialise. Open the window fully. Action and release the window switch until the window is complandely closed. This operation has to be carried ort on each electric window. 4 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. Reprogramme the radio stations. Radiotelephone RT3. Reprogramme the radio stations. 5 GENERAL Sun roof. The anti-pinch function has to be re-initialised. Place the sun roof switch in the maximum tilt position. Keep the sun roof switch pressed until the sun roof ceases its movement. Release the sun roof switch within 5 seconds. Keep the sun roof switch pressed until the end of the sun roof opening sequence. 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. E1AP09HD 6 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). 7 FR HFXB FC HFXC/IF FN HFXC/IF GENERAL Entreprise Pack Pack - Pack ambiance 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). 8 FC KFVF/IF FN KFVF/IF 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. plate IF/L5 20 CP 56 (mp) (2) 20 CP 58 (m) (1) 20 CP 56 (mp) (2) (1) m = Manual gearbox (2) mp = Piloted manual gearbox 9 FC NFUC/PIF GENERAL PETROL 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. plate FC 8HXK 8HX Engine type 20 CP 65 (mp) (2) 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. plate Pack - Pack ambiance - Pack clim Exclusive Pack clim 20 DM 25 (m) (1) 20 DM 26 (m) (1) (1) m = Manual gearbox 11 FN 8HYB FR 8HYB GENERAL Pack - Pack ambiance - Pack clim Exclusive 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. E1AP0B2D 12 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. plate 5 6 4 MA/5N MA/5S MA/50 20 CP 60 (m) (1) 20 CP 63 (mp) (2) 20 CP 71 (m) (1) (1) m = Manual gearbox (2) mp = Piloted manual gearbox 13 GENERAL SensoDrive 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. E1AP08WD 14 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 1.4i 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. 16 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. 17 20 DM 10 20 DM 11 (1) 20 TP 48 GENERAL L4 Emission standard Type code SX 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. plate 7 N1 NFU3/IF (*) NFU DAIC = 20 CP 52 (14x60) (21x18). 18 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. 19 GENERAL Exclusive 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. (*) DAIC DAD = 20 DM 08. 20 20 DM 10 20 DM 11 (1) 20 TP 48 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. 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. plate N2 8HZB N2 WJYB N2 RHYB 8HZ WJY RHY 1398 1868 1998 Cubic capacity (cc) Gearbox type N2 RFN3/IF RFN Engine type Fiscal rating (hp) Océanic - Pack - Exclusive 8 9 BE4/5 AL4 20 DL 40 20 DM 03 (1) 20 TP 47 N2 RHZB 1997 4 5 6 BE4/5 20 DM 54 (1) = Right hand drive : Hydraulic clutch control. (*) DAIC DAD = 20 DM 08. 22 N2 RHZN RHZ 20 DL 41 20 DM 05 (1) 20 DL 42 20 DM 07 (1) (*) AL4 20 DM10 20 DM 11 (1) 20 TP 48 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. (Located at bottom of RH central pillar) 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. 24 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). 25 GENERAL L4 Emission standard 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. E1AP0AMD 26 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 1.1i 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. 28 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. 29 GENERAL L4 Emission standard 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). ESSENTIAL: Systematically check the oil level using the oil dipstick. 30 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 1.4 HDi 0,7 Litre version with front calipers Ø 48 / rear drums 0,8 Litre version with front calipers Ø 54 / rear discs Cooling system Fuel tank capacity 7 5,6 40 45 ESSENTIAL: Systematically check the oil level using the oil dipstick. 31 GENERAL Engine type Diesel 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 1.4 HDi ➔ RPO 9884 RPO 9885 ➔ ➔ RPO 9884 RPO 9885 ➔ 8HX 8HX 8HV 8HV 8HW 8HW 8HY 1,8 1,5 1,8 1,5 2 1,9 (1) 7 8HY 3,75 3,1 1 1,5 2 Braking circuit Cooling system Fuel tank capacity Diesel 1.4i 16V 0,7 Litre version with front calipers Ø 48 / rear drums 0,8 Litre version with front calipers Ø 54 / rear discs 7 5,7 45 ESSENTIAL: systematically check the oil level using the oil dipstick. (1) = The gearbox is lubricated for life. (For yorr information, the TOTAL capacity is 5,85 litres, after draining: 3 litres). 32 5,6 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. (For yorr information, the TOTAL capacity is 5,85 litres, after draining : 3 litres) 33 5,7 GENERAL Petrol 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. 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. 5-speed gearbox 1,8 1,5 2 WJY RHY RHZ 4,75 (1) 4,5 (2) 4,5 1,6 (1) 1,2 (2) 1,4 1,8 Automatic gearbox 8,3 5,3 After drainage With ABS = 0,50 - Without ABS = 0,55 Hydraulic or brake circuit Cooling system GENERAL ➔ RPO 9884 5,7 9 Fuel tank capacity 8,5 54 (1) = ➔ RPO 9337 (Manual dipstick with two twists) (2) = RPO 9338 ➔ (Manual dipstick withort twists but with a sphere) ESSENTIAL: Systematically check the oil level using the oil dipstick. 35 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. 6FZ 3 1,5 RFN 9HY RHY 4,25 3,75 4,5 1,7 1,55 (3) 1,4 1,8 5-speed gearbox 1,8 6 Automatic gearbox After drainage 3 Hydraulic or brake circuit Cooling system 9HZ 0,58 litres 5,8 (1) and (2) 6,5 (1) and (2) Fuel tank capacity (1) = With air conditioning (2) = Withort air conditioning (3) = RPO 9884 ➔ = Restyled XSARA PICASSO. 11 55 11 (1) and (2) 60 ESSENTIAL: Systematically check the oil level using the oil dipstick. 36 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. 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). Severe maintenance interval: 20 000 km (12 000 miles). For more dandails see the oil usage table. New commercial designation for energy economy oil. The oil TOTAL ACTIVA/QUARTZ 9000 5W30 becomes TOTAL ACTIVA FUTUR 9000 (for France), QUARTZ FUTURE 9000 5W30 (outside France). The usage exclusions for this oil are the same as before: ESSENTIAL: For all vehicles with a 30 000 km (20 000 miles) maintenance interval, use exclusively TOTAL ACTIVA/QUARTZ 7000 or 9000 or any other oils offering identical specifications to these. These oils offer specifications that are superior to those defined by norms ACEA A3 OR API SJ/CF. Failing this, it is essential to adhere to the maintenance programmes covering severe operating conditions. - 38 XSARA VTS 2.0i 16V (XU10J4RS) RELAY 2.8 TDi ; 2.8 HDi (SOFIM engine) HDi FAP vehicles C3 1.6i 16V (DV4TED4) C8 2.2i (EW12J4) 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. 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. The figure following the first landter corresponds to the type of oil: 3: high performance oils. 4: oils specifically for direct injection diesel engines. 5: very high performance oils permitting lower fuel consumption. Example: ACEA A3: high performance oils specifically for petrol and dual fuel petrol / LPG engines. ACEA A/B: blended oils giving very high performance for all engines, also permitting bandter fuel economy, specifically for direct injection diesel engines NOTE: From 01/01/2003 there is no longer any reference to the year of creation of the norm (example: ACEA A3/B3 98 becomes ACEA A3/B3). The meaning of the first landter has not changed, it still corresponds to the type of engine: S: petrol and dual fuel petrol / LPG engines. C: diesel engines. The second landter corresponds to the degree of evolution of the oil (ascending order). Example: Norm SL is more severe than norm SJ, corresponding to a higher level of performance. 40 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%). The oil 5W30 is used only for the following engines (Year 2003): - XU10 J4RS SOFIM HDi DV4 TED4 EW 12J4 : XSARA VTS 2.0i 16V (3-door) : RELAY 2.8 TDi and 2.8 HDi. : With particle filter (FAP). : CITROËN C3 1.4 HDi 16V : CITROËN C8 2.2i. WARNING: CITROËN engines prior to model year 2000 do not have to be lubricated with oils adhering to the norms ACEA AI-98 and API SJ/CF EC or current norms ACEA A5/B5 Denomination of TOTAL oils according to corntry of markanding: TOTAL ACTIVA (France only). TOTAL QUARTZ (outside France). 41 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. Classes and grades of TOTAL recommended engine oils. Oils markanded in each country are adapted to the local climatic conditions. Blended oils for all engines (petrol, diesel and dual fuel petrol / LPG engines). TOTAL ACTIVA 9000 TOTAL QUARTZ 9000 TOTAL ACTIVA FUTUR 9000 (*) TOTAL QUARTZ FUTUR 9000 (*) TOTAL ACTIVATRAC S.A.E. norms ACEA norms 5W40 A3 / B3 5W30 A5 / B5 10W40 A3 / B3 API norms SL / CF (*) Blended oils for all engines, permitting fuel economy. 42 SJ / CF 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. norms TOTAL ACTIVA DIESEL 7000 TOTAL QUARTZ DIESEL 7000 10W40 TOTAL ACTIVA DIESEL 7000 15W50 43 ACEA norms API norms B3 CF 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 2.2i 16V) X Other petrol engines X 5W30 X HDi engines with FAP (*) Other HDi engines Diesel engines Semi-synthetic 7000 5W40 0W40 cold contries X X X Indirect injection diesel engines (*) = Particle filter 44 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. E4AP006D 45 ALL TYPES LUBRICANTS - TOTAL recommended oils ENGINE OILS FRANCE Metropolitan FRANCE Blended oils for all engines, supplied in bulk TOTAL ACTIVRAC S.A.E. norms : 10W40 TOTAL ACTIVA DIESEL TOTAL ACTIVA GENERAL Metropolitan FRANCE New Caledonia Guadeloupe Saint martin Réunion Martinique Guyana Tahiti Mauritius Mayotte Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines Oils specifically for diesel engines 9000 5W40 9000 5W30 (*) 7000 10 W40 7000 10 W40 9000 5W40 9000 5W40 7000 15W50 (*) Blended oils for all engines, permitting fuel economy 46 7000 15W50 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 GENERAL EUROPE 7000 10W40 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, permitting fuel economy 48 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 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 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 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 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 10W40 Algeria, South Africa, Ivory Coast, Egypt, Gabon, Ghana, Kenya, Madagascar, Morocco, Nigeria, Senegal, Tunisia 53 GENERAL OCEANIA 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 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 oils for all engines, permitting fuel economy 55 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 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 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.: 9730 A4 58 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. GLYSANTIN G33 REVKOGEL 2000 2 Litres 9979 70 9979 72 5 Litres 9979 71 9979 73 20 Litres 9979 76 9979 74 210 Litres 9979 77 9979 75 59 GENERAL POWER STEERING OILS 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. WARNING: CITROËN C5: Use exclusively TOTAL FLUIDE LDS suspension fluid. TOTAL HYDRAURINCAGE All countries 60 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. 61 9980 56 ZC 9875 279U Norms NLGI 2 GENERAL Concentrated: 250 ml 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. DO NOT INTERVENE BELOW THESE VALUES. IV - OIL LEVEL: The level should NEVER be above the MAX. mark on the dipstick after changing or topping up the oil. - This excess oil will be used up rapidly. - It will reduce the engine output and adversely affect the operation of the air circuits and gas recycling 62 ENGINE ENGINE SPECIFICATIONS Engines: HFX - KFV - KFW - KFU Petrol All types 1.1i Vehicle Emission standard 1.4i 16V 1.4i C2/C3 BERLINGO II L4/IFL5 L4/W4 C2/C3/C3 Pluriel Xsara II/Berlingo II K’/L4/W4/IFL5 IFL5/L4 KFV KFW KFU Engine type HFX Cubic capacity (cc) 1124 1360 Bore / Stroke 72/69 75/77 Compression ratio C3 L4/IFL5/INF 10,5/1 11/1 Power ISO or EEC KW - rpm 44-5500 44,1-5500 54-5400 55-5500 65-5250 Power DIN (HP - rpm) 61-5500 60-5500 75-5400 75-5500 90-5250 Torque ISO or EEC (m.daN - rpm) 94-3400 94-3300 94-3500 12-3400 12-2800 13,3-3250 63 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 2.0i 16V 1749 1998 Bore / Stroke 78,5/82 78/82 82,7/81,4 85/86 Compression ratio 10,5/1 11/1 10,8/1 10,8/1 Power ISO or EEC KW - rpm 70-5700 80-5800 85-5500 100-6000 120-6000 Power DIN (HP - rpm) 95-5700 110-5800 115-5500 136-6000 163-6000 13,5-3000 14,7-4000 16-4000 19-4100 19,3-5000 Torque ISO or EEC (m.daN - rpm) 64 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.daN - rpm) 15-2000 16-2000 20-2000 65 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.daN - rpm) 24,5-2000 20,5-1900 25-1750 Bore / Stroke Compression ratio 12,5-2500 66 1997 10,5-2500 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.daN ) ENGINE C2 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines HFX - KFV - NFU Crankshaft 2,5 ± 0,2 Accessories drive pulley Pinion fixing on crankshaft - Tightening - Angular tightening 4 ± 0,4 45° ± 4° Cylinder block 0,8 ± 0,2 2,1 ± 0,2 2,5 ± 0,2 2,5 ± 0,2 Sump Timing belt tensioner roller Accessories belt guide roller Alternator support Alternator TU1JP-TU3JP - Pre-tightening - Tightening Alternator TU5JP4 - Pre-tightening - Tightening Aircon compressor support Aircon compressor 1± 3,7 ± 0,3 1± 4 ± ,04 2,2 ± 0,2 2,3 ± 0,2 68 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 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines ENGINE C2 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines HFX - KFV - NFU Flywheel - clutch 6,7 ± 1 (LOCTITE FRENETANCH) Engine flywheel 2 ± 0,2 Oil pressure mechanism Lubrication Circuit 3,5 ± 0,5 Oil pressure switch 0,9 ± 0,1 Oil pump Cooling circuit 1,6 ± 0,2 Coolant pump 70 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.daN ) ENGINE C2 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engine 8HX Crankshaft Bearing cap fixing screws 1 ± 0,2 Pre-tightening Slackening 180° Tightening 3 ± 0,3 140° Angular tightening Con rod screws 1 ± 0,1 Tightening 100° ± 5° Angular tightening Accessories drive pulley 3 ± 0,3 Pre-tightening 180° ± 5° Angular tightening Cylinder block Sump 1,3 ± 0,1 Timing belt guide roller 2,3 ± 0,2 Timing belt tensioner roller 3,7 ± 0,3 72 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.daN ) ENGINE C2 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engine 8HX Lubrication circuit Oil pump assembly Pre-tightening Tightening Coolant/oil heat exchanger 0,5 ± 0,1 0,9 ± 0,1 1 ± 0,1 Diesel injection circuit 2,5 ± 0,2 2,2 ± 0,2 2,5 ± 0,2 2,2 ± 0,2 2,5 ± 0,2 5 ± 0,5 2,5 ± 0,2 Cooling circuit Spherical-base screws for diesel injection fixing fork Fuel high pressure common injection rail on engine block Unions on fuel high pressure common injection rail Diesel injection pump on support Union on diesel injection Diesel injection pump pulley Union on diesel high pressure pump Coolant pump Pre-tightening Tightening Coolant outlet housing Pre-tightening Tightening 0,3 ± 0,1 0,9 ± 0,1 0,3 ± 0,1 0,7 ± 0,1 74 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 FEATURES - TIGHTENING TORQUES (m.daN ) ENGINE C3 Engine types Accessories drive pulley Pinion fixing on crankshaft SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Crankshaft KFV 0,8 ± 0,2 HFX 10 ± 1 NFU 2,5 ± 0,2 Cylinder block 0,8 ± 0,2 Sump Timing belt tensioner roller Accessories belt tensioner roller Alternator support fixing Alternator fixing on support 2 ± 0,2 2 ± 0,2 2,2 ± 0,2 2,5 ± 0,2 1,7 ± 0,3 3,7 ± 0,3 Cylinder head 0,8 ± 0,2 Coolant outlet housing Camshaft bearing cap Tightening Angular tightening Inlet manifold Exhaust manifold Valve rockers adjusting screw Sparking plugs Camshaft pulley screw 2 ± 0,2 44° ± 4° 2 ± 0,2 50° ± 5° 0,8 ± 0,2 1,7 ± 0,3 2 ± 0,2 1,75 ± 0,25 2,75 ± 0,25 8 ± 0,8 76 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.daN ) 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 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 bearing caps Camshaft bearing cap covers Inlet manifold 79 C3 ENGINE SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engine ENGINE C3 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Cylinder head Exhaust manifold 1,8 ± 0,2 Sparking plugs 2,2 ± 0,2 4 ± 0,4 VVT pulley cap 0,8 ± 0,2 VVT control electrovalve VVT inlet camshaft pulley screw 2 ± 0,2 - Pre-tightening 6,1 ± 0,6 - Tightening 4,5 ± 0,4 Exhaust camshaft pulley screw Flywheel / Clutch 6,7 ± 0,6 (coat the screws with LOCTITE FRENETANCH) Engine flywheel 2 ± 0,2 Clutch mechanism Lubrication circuit 2 ± 0,2 Oil pressure switch 0,9 ± 0,1 Oil pump Cooling circuit 1 ± 0,1 Coolant pump 0,8 ± 0,1 Coolant outlet housing 80 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.daN ) 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. (2) : 4,5 ± 0,5 (3) : 4,5 ± 0,5 (4) : 4,5 ± 0,5 LH engine support (5) : 6,5 ± 0,6 LH lower engine support (6) : 2,2 ± 0,2 (7) : 2 ± 0,2 B1BP2WLP 82 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.daN ) ENGINE C3 - C3 PLURIEL - XSARA SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines 8HX 8HW 8HZ Cylinder head Camshaft bearing covers Pre-tightening Tightening Fixings of camshaft sub-assemblies on cylinder head Pre-tightening Tightening Exhaust manifold Valve cover Camshaft pulley 0,5 ± 1± 0,5 1 2,5 ± 0,2 2,5 ± 0,2 4,3 ± 0,4 Flywheel Flywheel Pre-tightening Tightening Clutch mechanism 1,7 70° ± 5° 1,7 75° ± 5° 2 ± 0,2 Lubrication circuit Oil pump assembly Pre-tightening Tightening Coolant/oil heat exchanger 0,5 ± 0,06 0,9 ± 0,1 1 ± 0,1 84 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-tightening 1 ± 0,1 Tightening Coolant outlet housing Pre-tightening 0,3 ± 0,06 Tightening 0,7 ± 0,08 85 ENGINE SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines ENGINE C3 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines: 8HV - 8HY RH engine support Screw (1) Screw (2) : 6 ± 0,6 : 6 ± 0,6 RH lower engine support Screw (3) : 5,7 ± 0,5 LH upper engine support Screw (7) Screw (8) : 6 ± 0,6 : 5,5 ± 0,5 LH lower engine support Screw (6) : 5,4 ± 0,5 Torque reaction rod Screw (4) Screw (5) B1BP2MNP 86 : 6 ± 0,6 : 6 ± 0,6 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 ± 0,5 87 C3 ENGINE SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) ENGINE C3 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines 8HV - 8HY Flywheel - Clutch Flywheel 1,7 ± 0,2 Clutch mechanism 2 ± 0,2 Lubrication circuit Oil pump assembly 0,9 ± 0,1 Oil/coolant heat exchanger 1 ± 0,1 Turbocharger lubrication pipe 2,2 ± 0,2 Injection circuit Injector fixing flange nut 0,4 ± 0,1 Tightening Angular tightening 65° ± 5° Unions on fuel high pressure common injection rail 2,3 ± 0,2 Fuel high pressure pump Union on diesel injector Fuel high pressure pump pinion 5 ± 0,5 Union on fuel high pressure pump 2,3 ± 0,2 Cooling circuit Coolant pump 1 ± 0,2± 88 CYLINDER HEAD (mm) Engine types KFW NFV Maximum permissible bow 0,05 Gasket surface regrinding - 0,20 NFU TIGHTENING TORQUES (m.daN) Crankshaft bearing Pre-tightening 2 ± 0,2 2 ± 0,2 screws Angular tighten Connecting rod screws Tightening 3,8 ± 0,4 Flywheel screw Tightening 6,5 ± 0,7 Crankshaft pinion screw Pre-tightening Angular tighten Camshaft pulley screw 45° 10 ± 1 Pre-tightening Angular tighten 8 ± 0,8 Camshaft hubs Camshaft hub screw 50° ± 5° 8 ± 0,8 Tightening 1 ± 0,1 89 ENGINE XSARA - XSARA PICASSO SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) 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.daN) Pre-tightening (1) Ø 11 : 1 ± 0,1 2 ± 0,1 2,5 ± 0,3 (2) Ø 6 : 1 ± 0,1 Slackening Ø 11 (only) Tightening Ø 11 to 1 ± 0,1 Tightening Angular Ø 11 at 70° ± 5° Crankshaft bearing screws 8,5 ± 0,8 7 ± 0,7 then to 2 ± 0,1 Tightening Pre-tightening 60° ± 6° 60° ± 6° Ø 6 to 1 ± 0,1 1 ± 0,1 4 ± 0,4 Connecting Slackening 180° (1/2 turn) rod screws Tightening 2,3 ± 0,2 2,3 ± 0,2 2± 0,2 Angular tightening 46° ± 5° 46° ±4,6° 70° ± 7° 90 2 ± 0,2 70° ± 7° 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.daN ) ENGINE XSARA PICASSO SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines 9HZ - 9HY Crankshaft Bearing cap fixing screw 1 ± 0,2 Pre-tightening Slackening 180° Tightening 3 ± 0,3 140° Angular tightening Con rod screws 1 ± 0,1 Tightening 100 ± 5° Angular tightening Accessories drive pulley 3,5 ± 0,4 Pre-tightening 190 ± 5° Angular tightening Cylinder block Sump 1,3 ± 0,1 Timing belt guide roller 3,7 ± 0,3 Timing belt tensioner roller 2,7 ± 0,2 92 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.daN ) ENGINE XSARA PICASSO SPECIAL FEATURES - TIGHTENING TORQUES (m.daN ) Engines 9HZ - 9HY Lubrication circuit Oil pump assembly Pre-tightening 0,5 ± 0,1 Tightening 0,9 ± 0,1 1 ± 0,2 Oil/coolant heat exchanger Turbocharger lubrication pipe 3 ± 0,5 Diesel injection circuit Injector fixing flange nut Pre-tightening 4 ± 0,1 Angular tightening 65° ± 5° Fuel high pressure common injection rail on engine block 2,2 ± 0,2 Union on fuel high pressure common injection rail Pre-tightening 1,7 ± 0,2 Tightening 2,2 ± 0,2 Diesel injection pump on support 2,2 ± 0,2 Union on diesel injector 2 ± 0,5 Pre-tightening 2,5 ± 0,3 Tightening 94 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.daN ) 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. B1BP10KC 96 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. Tightening Angular tightening : 2 ± 0,2 : 260° ± 5° (In the order 1 to 10) B1BP10KC 97 NOTE: Oil the threads and under the heads of the bolts (use engine oil or Molykote G Rapid Plus). B1BP1DVC X =MAX. re-usable length HFX - KFV KFV NFU 175,5 ± 0,5 119 122 ± 0,3 ENGINE C2 - C3 - C3 PLURIEL CYLINDER HEAD 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 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. re-usable length B1DP13NC 99 KFW - NFV NFU X = 175,5 ± 0,5 mm X = 122,6 mm ENGINE XSARA - XSARA PICASSO CYLINDER HEAD (Continued) 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. NOTE: 3 layer metallic gasket B1DP183D 100 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. re-usable length 6FZ X = 147 mm B1DP05BC 101 ENGINE XSARA - XSARA PICASSO CYLINDER HEAD 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 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. re-usable length RFN X = 147 mm B1DP05BC 103 ENGINE XSARA - XSARA PICASSO CYLINDER HEAD 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 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. re-usable length RFS 112 mm B1DP05BC 105 ENGINE XSARA CYLINDER HEAD 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. B1DP1CMD 106 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. B1DP1CKD 107 ENGINE C3 CYLINDER HEAD 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. NOTE: Retightening of the cylinder head after a completed repair is prohibited. - Pass a tap into the holes in the cylinder block. B1DP1DBC X =MAX. re-usable length 8HX - 8HW - 8HZ - 8HV - 8HY X = 149 mm B1DP1CLC 108 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. B1DP1HOD 109 ENGINE XSARA PICASSO CYLINDER HEAD 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. - Oil the threads and under the heads of the bolts (use engine oil or Molykote G Rapid Plus). - Pass a tap into the holes in the cylinder block. B1DP1CLC 110 B1DP1DBC X =MAX. re-usable length 9HZ - 9HY X = 147 mm 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. B1DP14QD 111 ENGINE XSARA CYLINDER HEAD ENGINE CYLINDER HEAD XSARA - XSARA PICASSO Engines: RHY - RHZ Identification of cylinder head gasket Plaque Engine RHY RHZ Piston standproud (mm) Thickness (mm) No. of notches at A 0,47 to 0,605 1,30 ± 0,06 1 0,605 to 0,655 1,35 ± 0,06 2 0,655 to 0,705 1,40 ± 0,06 3 0,705 to 0,755 1,45 ± 0,06 4 0,755 to 0,83 1,50 ± 0,06 5 B1DP15AD 112 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. re-usable length B1DP05BC 113 WJY RHY - RHZ 125,5 mm 133,3 mm ENGINE CYLINDER HEAD (Continued) 4099-T (C.TRONIC.105) Tools 114 ! ! ! ENGINE BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE ALL TYPES 4122-T (C.TRONIC.105.5) ! 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 2.0i 16V 128 ENGINE AUXILIARY EQUIPMENT DRIVE BELT 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 2.0 HDi See pages: 140 141 to 144 116 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. 117 ALL TYPES ENGINE AUXILIARY EQUIPMENT DRIVE BELT 2002 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. Tighten screw (1) to achieve a tension of: 55 ± 3 SEEM units. Tighten: - Screw (3). - Screw (2). Remove tool [2] and complete the refitting. 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]. - Complete the refitting. B1BP10VC B1BP10XC 119 ENGINE AUXILIARY EQUIPMENT DRIVE BELT 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]. - Remove the tool [2]. - Rotate the crankshaft 2 to 4 times. - Check the tension, 120 SEEM units. - If not, restart the operation. B1BP234C 120 : 7504 –T : 4122 –T 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]. B1BP235C 121 ENGINE AUXILIARY EQUIPMENT DRIVE BELT 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. - New belt 100 SEEM units. - Re-used belt - Re-used belt 75 SEEM units. B1BP1B2C B1BP122C B1BP1B3C B1BP124C 122 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. Refit the auxiliary equipment drive belt. Respect the following sequence : - Crankshaft pinion, alternator pulley. - Position tool [2] on the belt. Tighten the screw (1) to tension the belt to 55 ± 3 SEEM units. - Tighten screw (3), screw (2). - Remove tool [2]. - Complete the refitting in the opposite order to removal. B1BP2LSC B1BP2LTC 123 ENGINE AUXILIARY EQUIPMENT DRIVE BELT 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. Tighten the screw (5) to tension the belt to 120 ± 3 SEEM units. Tighten screw (4), screw (6). Remove tool [2]. Complete the refitting in the opposite order to removal. B1BP10VC B1BP10XC 124 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). B1BP1ANC 125 ENGINE AUXILIARY EQUIPMENT DRIVE BELT 2002 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. B1BP1HJC 126 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). B1EP12XC B1EP12YC 127 ENGINE XSARA AUXILIARY EQUIPMENT DRIVE BELT 2002 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. - Release the tensioner roller (1). B1BP23PC B1BP23QC B1BP23PC 128 B1BP23RC 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]. B1BP1SDC B1BP1SEC 129 ENGINE AUXILIARY EQUIPMENT DRIVE BELT 2002 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]. B1BP1SFC B1BP1SGC 130 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. B1BP1SHD 131 ENGINE XSARA AUXILIARY EQUIPMENT DRIVE BELT 2002 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]. - Start the engine and run it for 10 seconds. - Stop the engine. - Place the tool [1] on the belt at "f". - Tension should be 130 ± 4 SEEM units. - Remove the tool [1]. B1BP1SJD 132 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]. NOTE: If the belt is broken: - Support the engine using a jack (insert a wooden block between the housing and the jack). - Remove the right engine support. - Using a square drive at (b) turn the tool (3) in the direction of the arrow "a", so that it can be pegged at "a" using the tool [1]. B1BP1SKC 133 ENGINE XSARA AUXILIARY EQUIPMENT DRIVE BELT 2002 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]. B1BP1SLC 134 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. If the index on the tensioner roller is outside the marks, change the auxiliary equipment drive belt. The alternator (1). The aircon compressor (2). Detension the auxiliary belt tensioner roller, using tool [2]. Position the peg [3]. Remove the auxiliary drive belt. B1BP2MJD B1BP2MKC 135 ENGINE C2 - C3 - C3 PLURIEL AUXILIARY EQUIPMENT DRIVE BELT With compressor and alternator. 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. Make sure that the drive belt is correctly positioned in the «V» grooves of the various pulleys. Move the tool [2] on the tensioner roller to remove the peg [3]. B1EP18UD 136 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]. Peg at «b», using tool [2]. Keeping the tensioner roller (1) compressed, remove the accessories drive belt. IMPERATIVE: Check that the rollers (1) and (2) can turn freely (without play and without tight spots). B1BP2VZD 137 ENGINE XSARA AUXILIARY EQUIPMENT DRIVE BELT 2002 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. B1BP2VZD 138 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. Move the tool [1] on the tensioner roller to remove the peg [2]. ESSENTIAL: Make sure that the belt is correctly positioned in the various pulley grooves. B1BP2MYD B1BP2MZC 139 ENGINE C3 AUXILIARY EQUIPMENT DRIVE BELT 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]. Remove the accessories drive belt. IMPERATIVE: Check that the rollers (1) and (2) can turn freely (without play and without tight spots). 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. B1BP2Z6D B1BP2ZCD 140 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. No re-use of belt. - Compress the tensioner roller (2) by action at «a» (in anti-clockwise direction), tool [4]. - Peg using tool [2], at «b». - Keep the tensioner roller (2) compressed and remove the belt. - Loosen the screw (1). B1BP1YKD 141 ENGINE AUXILIARY EQUIPMENT DRIVE BELT 2002 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». - Hold the eccentric roller (3), tool [1], and tighten the screw (1) to 4.3 m.daN. - Remove the tool [2]. - Rotate the crankshaft 4 times in the direction of rotation. - Check that it is possible to peg at «b», tool [3]. - If not possible to peg, restart the adjustment. B1BP1YMD 142 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. - Compress the tensioner roller (7) by moving it at «c» (in anti-clockwise direction), tool [4]. - Peg using tool [2], at «d». - Loosen the screw (6). - Bring the eccentric roller (5) towards the rear. - Tighten the screw (6) by hand. - Remove the belt. B1BP1YLD 143 ENGINE XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT 2002 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». - Hold the eccentric roller (5), tool [1], and tighten the screw (6) to 4.3 m.daN. - Remove the tool [2]. - Rotate the crankshaft 4 times in the direction of rotation. - Check that it is possible to peg at «d», tool [3]. - If not possible to peg, restart the adjustment. B1BP1YND 144 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 2.0i 16V 171 to 178 ENGINE CHECKING AND SETTING THE VALVE TIMING 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 2.0 HDi See pages: 201 to 210 216 to 224 146 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. 147 ENGINE RECOMMENDATIONS: TIMING BELT 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. Engage 5th gear. Remove the oil filter (1). Engines: HFX – KFV. Remove: - The timing top casing (2). - Turn the wheel to rotate the engine (normal direction of rotation). - Peg the camshaft pulley, using tool [2]. B1BP2M7C B1BP2M9C B1BP2M8C 148 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. B1BP2MAC B1EP18MC B1BP2MBC 149 ENGINE C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING 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). Remove the timing casings. Peg the camshaft pinion, using tool [2]. Peg the flywheel, using tool [1]. Remove: - The fixing screws (2). - The upper engine support (3). B1BP2MCC B1BP2M9C B1BP2MBC B1BP2MDC 150 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). B1BP2MEC B1EP18NC 151 C2 - C3 - C3 PLURIEL ENGINE CHECKING AND SETTING THE VALVE TIMING 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]. B1BP2MFC B1BP2MBC B1EP18MC 152 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. Remove the timing belt (8). Check that the rollers (9) and (10) turn freely (no tight spot). B1EP18PC B1EP18QC 153 ENGINE CHECKING AND SETTING THE VALVE TIMING 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]. B1EP18QC 154 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. Remove the tools [1], [2]. Engine: NFU. Fit the timing belt in position in the following order: - Inlet camshaft pulley. - Exhaust camshaft pulley. - Guide roller. - Crankshaft pulley. Position tool [5]. - Coolant pump pulley. - Dynamic tensioner roller. Remove the tools [1], [3] and [5]. 155 ENGINE CHECKING AND SETTING THE VALVE TIMING 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). IMPERATIVE: Never make the crankshaft rotate backwards. Make sure that the timing is correctly set by refitting the tools [1], [2] and [3]. Remove the tools [1], [2] and [3]. B1EP18SD 156 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. Hold the tensioner roller (7) in this position, with the aid of a hexagonal spanner. Tighten the tensioner roller fixing nut to : 2 ± 0.2 m.daN. (HFX - KFV engines) 2.2 ± 0.2 m.daN. (NFU engine) B1EP18TD IMPERATIVE: The tensioner roller must not rotate during the tightening of its fixing. If it does, restart the timing belt tensioning operation. Complete the refitting. 157 ENGINE C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING 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. - Rotate the engine by means of the crankshaft screw (1). - Peg the camshaft pinion. - Peg the flywheel - Slacken the nut (2). - Fullt detension the belt by acting on the tensioner roller. - Remove the belt. IMPERATIVE: Check that the tensioner roller turns freely (no tight spot). B1EP067C B1EP066C B1EP068C 158 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). - Put the tensioner roller in contact with the belt. - Tighten the nut (2). Pre-tensioning the belt. - Place tool [4] on the tensioned part "b" of the belt. - Slacken the screw (2). - Turn the roller (3) in the anti-clockwise direction using the drive square, to obtain a value of: 44 SEEM units. - Tighten the nut (2) to 2 m.daN. - Remove tools [1], [2] and [4]. - Rotate the crankshaft 4 turns in the normal direction of rotation. IMPERATIVE: Never turn the crankshaft backwards. B1EP069C 159 B1EP06AC ENGINE CHECKING AND SETTING THE VALVE TIMING 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. - Tension the timing belt to obtain a value of: 31 ± 2 SEEM units. - Tighten the nut (2) to 2 m.daN. - Remove tools [1], [2], [4] and [5]. Checking the belt tension. - Rotate the crankshaft 2 turns in the normal direction of rotation. Check that it is still possible to peg the following components. Flywheel. Camshaft. IMPERATIVE: Repeat the belt tensioning operation if the pegging is not possible. 160 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]. - Peg the camshaft pulleys [3] and [4]. B1EP11BC B1EP11CC 161 ENGINE XSARA CHECKING AND SETTING THE VALVE TIMING 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. * (Identification marks = white paint lines on the back of the belt facing the corresponding teeth). - Refit the belt. - Line up mark (A) on the belt with groove (D) of the pinion (4). - Hold the belt against the pinion (4). B1EP11DC 162 B1EP11EC 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). - Rotate the roller (2) (using tool [5]) in an anti-clockwise direction, to obtain: 63 SEEM units. - Tighten the roller (2) to 2 m.daN. - Tighten the six screws (5) to 1m.daN. ESSENTIAL: Check that: - The camshaft pulleys (1) are not at the end of the slots (by removing a screw). - The markings on the belt are aligned with the markings on the crankshaft and camshaft pulleys. If not, repeat the setting procedure. B1EP11FC 163 B1EP11GC ENGINE CHECKING AND SETTING THE VALVE TIMING 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]. - Loosen the tensioner roller screw (2). - Rotate the roller (2) (using tool [5]) in an anti-clockwise direction to obtain: 37 SEEM units. - Tighten the tensioner roller screw (2) to 2 m.daN. - Tighten the six pulley screws (1) to 1m.daN. - Remove the tools. 164 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). B1BP2ZJD 165 ENGINE C3 CHECKING AND SETTING THE VALVE TIMING 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. B1BP2ZTC B1BP2MBC 166 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). B1BP2ZJD 167 ENGINE C3 CHECKING AND SETTING THE VALVE TIMING 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. B1BP2MCC B1BP2MBC B1BP2ZTC 168 B1BP2ZUC 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]. B1CP0F1D 169 B1CP0F2D ENGINE CHECKING AND SETTING THE VALVE TIMING 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. Rotate the crankshaft by 4 turns (normal direction of rotation). IMPERATIVE: Never turn the crankshaft backwards. Make sure the timing setting is correct by refitting the pegs [1], [3] and [4]. Remove the pegs [1], [3] and [4]. Adjusting the tension of the belt. Slacken the nut, holding the position of the tensioner roller, by means of an allen spanner at «e». Then bring the index «d» to its adjustment position «b». WARNING: The index «d» should not go past the notch «b». If it should do so, repeat the operation to tension the timing belt. Maintain the tensioner roller (8) in this position, using the allen spanner. Tighten the fixing nut of the tensioner roller to 2,1 ± 0,2 m.daN. IMPERATIVE: The tensioner roller should not turn during the tightening of its fixing. If it should do so, repeat the operation to tension the timing belt. Refitting. Complete the refitting in the opposite order to removal. B1EP1DTC B1EP1DUC 170 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). The pegging hole on the cylinder block (exhaust end) is calibrated and reinforced. IMPERATIVE: Never turn the crankshaft with the accessories drive pulley slackened. IMPERATIVE: Never remove the accessories drive pulley without pegging the crankshaft and the camshafts. IMPERATIVE: Always turn the crankshaft in the direction of engine rotation. B1BP2V2D 171 ENGINE XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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 : (-).0189 S2 : 7504-T Checking the setting of the timing. Removing. Disconnect the battery negative terminal (see corresponding operation). Raise and support the vehicle, front wheels hanging. Remove: - The front RH wheel. - The plastic pins (1). - The splash-shield (2). - The upper timing cover. C4AP12TC 172 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. WARNING: If the pegs go in only with difficulty, repeat the operation for fitting and tensioning the timing belt (see corresponding operation). Refitting. Remove tools [2] and [3]. Complete the refitting in reverse order to removal. B1EP1BAC 173 ENGINE XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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). Turn the engine by means of the screw (3) of the crankshaft pulley (2) to bring it to the pegging position. B1BP2V4C 174 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). Turn the tensioner roller (8) (clockwise). Remove the timing belt (7). IMPERATIVE: Systematically replace the following components: timing belt, exhaust manifold fixing nuts, timing belt tensioner roller nut. B1BP2V3D B1EP1BBD 175 ENGINE XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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). - Exhaust camshaft pulley (5). - Coolant pump (11). - Tensioner roller (8). NOTE: Make so that the belt (7) is as flush as possible with the exterior face of the various pinions and rollers. Remove: - Tool [3]. - Tool [1] from the exhaust camshaft pulley. - Tool [5b] from the tensioner roller (8). Refit: - The lower timing cover (4) (by moving the engine). - The crankshaft pulley (2). Screw (3) of the crankshaft pulley Tighten screw (3) to 4 ± 0,4 m.daN, then angular tighten to 53° ± 4°, tool [4]. B1EP1BCD B1EP1BDC 176 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». B1EP1BEC WARNING: the index «a» should not pass the slot «g». Otherwise, repeat the operation to tension the timing belt. IMPERATIVE: The tensioner roller should not turn during the tightening of its fixing. If it does, repeat the operation to tension the timing belt. Tighten the screw (9) of the tensioner roller (8) to 2,1 ± 0,2 m.daN. IMPERATIVE: The hexagonal tensioner roller drive should be approx. 15° below the level of the cylinder head gasket «h». If it is not, replace the tensioner roller or the timing belt and tensioner roller assembly. B1EP1BFC 177 ENGINE XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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». If the position of the index «a» is not correct, repeat the operations to tension the timing belt. Refit the upper timing cover (1). Clip the fuel delivery hose on the timing cover. Refit the accessories drive belt (see corresponding operation). Lower the vehicle. Reconnect the battery (see corresponding operation). B1EP1BFC 178 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. If the hub/pulley markings do not line up, the crankshaft pulley must be replaced. - Peg the camshaft using the tool [2] (the locating pegs [2] should slide in easily). - If this is not the case, set the timing. NOTE: Camshaft hubs (see pages 138 and 139). B1EP12FC 179 B1EP12GC ENGINE XSARA CHECKING AND SETTING THE VALVE TIMING 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). - Remove the tool [4]. - Slacken the tensioner roller (7). - Remove the belt (9). 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). Engine RFS New belt 55 SEEM units - Tighten the screws of the roller (7) to 2 m.daN. - Fit the tool [4]. - Tighten the screws (10) to 4 m.daN. - Remove the tools. - Rotate the crankshaft by six turns (normal direction of rotation). B1EP12OC B1EP121C 181 ENGINE CHECKING AND SETTING THE VALVE TIMING 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]. B1EP120C B1EP121C 182 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. B1EP120C B1EP121C 183 ENGINE CHECKING AND SETTING THE VALVE TIMING 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]. - The clips of the electrical harness on the upper timing cover. - The accessories belt, using tool [2] (see corresponding operation). Check ing the setting. Disconnect the battery negative cable. Remove the upper timing cover (1). Rotate the engine using the screw (2) of the crankshaft pulley. B1BP2LXC NOTE: The locking hole is located under the crankshaft bearing cap cover. Undo the screw (2). Detension the auxiliary drive belt dynamic tensioner roller, using tool [2]. 184 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]. Peg the high pressure pump pinion, using tool [5]. NOTE: Index «a» of the roller tensioner must be centred within the area «b». Check the correct positioning of index «a». Remove tools [4] and [5]. Rotate the engine ten times. Fit the tools [4] and [5]. If pegging is not possible, carry out the operation to remove/refit the timing belt (see corresponding operation). B1JP03SC B1EP18EC B1EP18DC 185 B1EP18FC ENGINE C2 - C3 - C3 PLURIEL - XSARA CHECKING AND SETTING THE VALVE TIMING 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. Twisting, pulling and bending the front flexible pipe reduces its life. Remove: - The engine speed sensor (6). - The belt retaining stop (5). - The screw (2). - The crankshaft pinion (4) (with its magnetic track «a»). IMPERATIVE: The magnetic track should show no signs of damage and should not be approached by any other source of magnetism. Should this not be adhered to, it is essential to replace the crankshaft pinion. Refit the screw (2). B1BP2LXC B1EP18GC 186 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). B1JP03SC B1EP18DC B1EP195C 187 B1BP2LYC ENGINE C2 - C3 - C3 PLURIEL - XSARA CHECKING AND SETTING THE VALVE TIMING 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. - Fuel high pressure pump pulley : Tighten to 5 ± 0,5 m.daN. The crankshaft pinion is located without a screw at the end of the crankshaft. Fitting of the rollers. IMPERATIVE: Check that the tensioner roller turns freely (no tight spot). Otherwise, replace the rollers. - Guide roller - Tensioner roller : Tighten to 4,5 ± 0,4 m.daN. : Pre-tighten to 0,1 m.daN. Check the condition of the seals at the camshaft and at the crankshaft pinion. B1EP18HC 188 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). B1EP18JD 189 ENGINE C2 - C3 - C3 PLURIEL - XSARA CHECKING AND SETTING THE VALVE TIMING 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. crankshaft pinion. fuel high pressure pump pinion (15). correct positioning of the index of the dynamic tensioner. If these are not correct, repeat the operation to position the timing belt. Refit: - The engine speed sensor (6). - The belt retaining stop (5), tighten to 0,7 m.daN. B1EP18KC 190 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). - The accessories belt (see corresponding operation). - The exhaust line (see corresponding operation). - The front RH splash-shield. - The front RH wheel. B1EP18LC B1BP2LZC 191 ENGINE C2 - C3 - C3 PLURIEL - XSARA CHECKING AND SETTING THE VALVE TIMING 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). Support the engine by means of a roller jack equipped with a chock. Remove the engine supports (4) and (5). B1BP2N0C 192 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]. B1BP2N1C B1BP2N2C 193 C3 ENGINE CHECKING AND SETTING THE VALVE TIMING 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]. IMPERATIVE: Should it be impossible to peg the camshaft, check that the offset between the hole in the camshaft pinion and the pegging hole is not greater than 1 mm. Otherwise repeat the operation to position the timing belt (see corresponding operation). B1EP18YD 194 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. - Screw (8): - Pre-tighten to - Angular tightening : 3 ± 0,3 m.daN. : 180° ± 5°. Remove the tool [1]. B1EP18ZC 195 ENGINE CHECKING AND SETTING THE VALVE TIMING 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). Refit: - The accessories belt (see corresponding operation). - The front RH splash-shield (see corresponding operation). - The front RH road wheel, tighten to 9 ± 1 m.daN. Reconnect the battery. B1BP2N0C 196 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). - The engine speed sensor (14). Slacken the screw (12) of the tensioner roller, keeping it slack with the aid of a hexagonal spanner at «c». Detension the belt by pivoting the tensioner roller (clockwise). Remove the timing belt, commencing with the coolant pump pinion. Peg the pulley (15), using a 5 mm diameter peg at «d». B1EP18VD 197 ENGINE CHECKING AND SETTING THE VALVE TIMING 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). - the target track of the engine speed sensor (14) is not damaged or scratched (if necessary replace the defective components). Refitting. Fit the timing belt on the crankshaft pinion. Position the belt on the guide roller, with the belt well tensioned. Refit: - The timing protector (13). - The sensor (14). B1EP18WD 198 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. Action the tensioner roller (19) to align the marks «f» and «g», avoiding detensioning the timing belt, with the aid of a male hexagonal spanner, at «c». If this is not successful, repeat the operation to tension the belt. Hold the tensioner roller in position (19). Tighten the tensioner roller, tightening to 3,7 ± 0,3 m.daN. Check the position of the tensioner roller (the alignment of the marks «f» and «g» should be correct). Remove tools [2] and [3]. Turn the crankshaft six rotations (clockwise). B1EP18XC 199 ENGINE CHECKING AND SETTING THE VALVE TIMING 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]. IMPERATIVE: Should it be impossible to peg the camshaft, check that the offset between the camshaft hole and the pegging hole is not more than 1 mm. If the offset is too great, repeat the operation. Remove the pegs [2] and [3]. Refit tool [1] at «a». Remove the screw (8). Complete the refitting. B1EP18XC 200 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). - The air/air heat exchanger inlet and outlet pipes (3). - The exhaust line (at the flexible pipe). Disconnect the connecter at «a». Remove and move aside the power steering fluid reservoir (6). Uncouple, plug and move aside the tube (2). Support the engine with a roller jack equipped with a block. Remove the engine supports (4) and (5). 201 ENGINE XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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]. B1BP305C B1EP1E3D 202 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. If it is more, repeat the operation to position the timing belt (see corresponding operation). Note: The index «e» of the dynamic tensioner roller should be centred in the interval «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). Remove tools [2] and [3]. B1EP1E4D B1EP1E5C 203 ENGINE XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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. Angular tighten : 180° ± 5°. Remove tool [1]. Refit: - The engine support (8), tighten to 5,5 ± 0,4 m.daN. - The engine support (4), tighten to 6,1 ± 0,6 m.daN. - The engine support (5), tighten to 2,5 ± 0,2 m.daN. - The electrical harness (7). - The power steering fluid reservoir (6). Refit: - The accessories drive belt (see corresponding operation). The front RH splash-shield (see corresponding operation). The front RH wheel, tighten to 9 ± 1 m.daN. Reconnect the positive and negative terminals of the battery. IMPERATIVE: Perform the operations that are necessary following a reconnection of the battery (see corresponding operation). 204 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). - The air/air heat exchanger inlet and outlet pipes (3). - The exhaust line (at the flexible pipe). Disconnect the connecter at «a». Remove and move aside the power steering fluid reservoir (6). Uncouple, plug and move aside the tube (2). Support the engine with a roller jack equipped with a block. Remove the engine supports (4) and (5). 205 ENGINE XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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]. B1BP305C B1EP1E3D 206 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». Detension the timing belt by pivoting the tensioner roller (clockwise). Remove the timing belt, starting with the coolant pump pinion. Checks. ESSENTIAL: Just prior to refitting, proceed to the checks as below. Check: - That the rollers and the coolant pump pulley turn freely (without play and without tight spot). - That there are no signs of oil leaks (at the crankshaft and camshaft seals). - That there are no leaks of coolant fluid (at the coolant pump). - That the track of the engine speed sensor target (15) is not damaged or scratched. Replace any components that are defective (if necessary). B1EP1E6D 207 ENGINE XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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). B1EP1E7D 208 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]. Rotate the crankshaft six times (clockwise). 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 «g» and «h» should be correct). If this is not the case, repeat the operation to tension the timing belt. Peg the camshaft pulley, using tool [2]. IMPERATIVE: Should it be impossible to peg the camshaft, check that the offset between the camshaft hole and the pegging hole is not more than 1 mm. If the offset is too great, repeat the operation. Remove tools [2] and [3]. B1EP1E8C 209 ENGINE XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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). Tightening torque Screw (10) Pre-tighten to : 3 ± 0,3 m.daN. Angular tighten : 180° ± 5°. Remove tool [1]. Refit: - The engine support (8), tighten to 5,5 ± 0,4 m.daN. - The engine support (4), tighten to 6,1 ± 0,6 m.daN. - The engine support (5), tighten to 2,5 ± 0,2 m.daN. - The electrical harness (7). - The power steering fluid reservoir (6). Refit: - The accessories drive belt (see corresponding operation). - The front RH splash-shield (see corresponding operation). - The front RH wheel, tighten to 9 ± 1 m.daN. Reconnect the positive and negative terminals of the battery. IMPERATIVE: Perform the operations that are necessary following a reconnection of the battery (see corresponding operation). 210 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]. IMPERATIVE: If the pegging proves impossible, repeat the setting of the timing. B1BP2FTC B1EP16PD 211 ENGINE XSARA CHECKING AND SETTING THE VALVE TIMING 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). - Remove the lower cover (3). WARNING: Refit the screw (4) equipped with a washer (5 mm thick). - Rotate the front RH wheel to drive the engine in its normal direction of rotation. - Bring the camshaft drive and injection pump pinions to their setting points. - Position the peg [2] (from underneath the vehicle). - Continue turning the engine until the peg [2] engages in the flywheel. B1BP30BC B1BP2FTC 212 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]. Position the timing belt in the following sequence: - Guide roller (11). - Injection pump pinion (7). - Camshaft pinion (10). - Coolant pump pinion (12). - Tensioner roller (8). B1EP16PD B1EP132C B1EP1EDC 213 B1EP1EEC ENGINE CHECKING AND SETTING THE VALVE TIMING 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. - Position the belt tension instrument [7] on the belt at «b». - Using tool [6], act at «a» in the direction opposite to that of engine rotation, to obtain a tension value of 106 ± 2 SEEM units. - Tighten screws (9), (5) and (6). - Remove tools [7], [2], [3] and [4]. - Rotate the crankshaft 8 times in the normal direction of rotation. - Peg the flywheel, using tool [2]. - Peg the camshaft hub, using tool [4]. - Peg the injection pump hub, using tool [3]. - Slacken screws (9), (5) and (6). - Position the belt tension instrument [7] on the belt at «b». - Using tool [6], act at «a» in the direction opposite to that of engine rotation, to obtain a tension value of 42 ± 2 SEEM units. B1EP1EFC B1EP1EDC 214 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. - Connect the battery. Tighten: - Screw (9) to 2.1 ± 0.2 m.daN. - Screws (5) to 2,3 ± 0.2 m.daN. - Screws (6) to 2,3 ± 0.2 m.daN. - Remove and refit tool [7]. - The tension value should be between 38 and 46 SEEM units. - Remove tools [7], [2], [3] and [4]. - Turn the crankshaft 2 times in the normal direction of rotation. - Peg the flywheel, using the peg [2]. - Visually check the peggings of the camshaft and injection pump. ESSENTIAL: Visually check that the offsets between the holes of the camshaft and injection pump hubs and the corresponding pegging holes are not more than 1 mm. If necessary, recommence the procedure for fitting the timing belt. 215 ENGINE CHECKING AND SETTING THE VALVE TIMING 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). The new timing on 8 valve engines DW10TD (RHY) and DW10 ATED (RHS-RHZ) requires the following components: «Idler» crankshaft pinion «Fixed» camshaft pulley. (5) «Fixed» camshaft pulley (pulley with integral cylinder reference sensor target). (6) «Idler» crankshaft pinion (with increased width keyway groove). The determining of the tension of the timing belt is done on the crankshaft pinion (6). B1EP176D B1EP177D 216 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. The Replacement Parts service markets the old as well as the new components. B1EP177D 217 ENGINE XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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 : (-).0188.T [8] Pulley extractor : (-).0188.P [9] 2 mm dia.peg : (-).0188.Q2 IMPERATIVE: Respect the safety and cleanliness requirements that are specific to high pressure diesel injection (HDi) engines. Undo the front RH wheel bolts. Raise and support the vehicle on the front RH side. Disconnect the battery negative terminal. Remove: - The under-engine sound-deadening. - The front RH wheel. - The front RH splash-shield. - The engine cover. Unclip and move aside the cooling hose. Remove the accessories drive belt (see corresponding operation). 218 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. Turn the road wheel to turn the engine in its direction of rotation. Orient the camshaft pulley in the pegging position, use a mirror if necessary. Peg the camshaft, using tool [5]. Peg the engine flywheel, using tool [3]. B1BP2H2C B1BP2H3C B1BP2R2C B1EP1A7C 219 ENGINE CHECKING AND SETTING THE VALVE TIMING 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. Remove: - The bearing shell fitting (10). - The nut (12). - Screws (11). - The bracket (13). NOTE: Lift then lower the engine with the workshop hoist, to have access to the timing cover fixing screws. Remove: - The intermediate timing cover. - The lower timing cover. B1CP04BC B1BP2R4C B1BP2R3C 220 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. Replace defective components if necessary. Peg the crankshaft pinion (19) by inserting tool [9] on the LH side of the keyway. B1EP1A8D B1EP1A9C 221 ENGINE XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING 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. Tighten screw (17) of the tensioner roller to 2,5 ± 0,2 m.da N. Lock the flywheel by means of tool [6]. Tighten the accessories drive pulley screw (8) to 7 ± 0,7 m.da N. Remove tools [1], [3], [5] and [6]. Rotate the crankshaft eight times in the normal direction of rotation. Peg: - The crankshaft, using tool [3]. - The camshaft drive pulley, using tool [5]. B1EP1ABD B1EP1ACC 222 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. Remove tools [1], [3], [5] and [6]. Rotate the crankshaft two times in the normal direction of rotation. Peg: - The crankshaft, using tool [3]. - The camshaft drive pulley. IMPERATIVE: If the pegging is not possible, recommence the operation. B1EP1ACC 223 ENGINE CHECKING AND SETTING THE VALVE TIMING 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]. Couple: - The fuel delivery pipe (12). - The fuel return pipe (1). Coat the screw (8) with loctite FRENETANCH. Refit the tool [6] and the screw (8) with the washer (22), Tighten to 7 ± 0,2 m.daN and angular tighten to A = 60° ± 5°. Refit the torque reaction rod on the lower engine support. Remove the tool [6]. Reposition and reclip the cooling hose. Complete the refitting of components in reverse order to removal. B1EP1A7C B1EP1ADC B1BP2R4C 224 RFS Camshaft hub identification Engine RFS Hubs ‘‘a’’ Engraving ‘‘b’’ Paint marking B BLUE Inlet Exhaust B1EP122C 225 ENGINE SPECIAL FEATURES OF THE TIMING 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 2.0 HDi) Fully open (Exhaust) Rocking Exhaust Valves fully open Adjust 0,40 mm ± 0,05 1 mm ± 0,05 1● 1 4● 4 3● 3 2● 2 4● 4 1● 1 2● 2 3● 3 Inlet ● Adjust Hydraulic adjustment 0,15 mm ± 0,08 0,30 mm ± 0,08 Engines without hydraulic adjustment: the clearance (J) should be checked opposite the cam. B1DP13QC 226 Adjust 1 3 ● 4 3 4 ● 2 4 2 ● 1 2 1 ● 3 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.J XFX KFV 3 2000 X X X X X X HFX KFV NFU 90°C 4 1,3 4000 1000 Tools (Kit 4103-T) X X X KFU 3 2000 X X X X X X X X X 8HX 3,5 4000 X X X C3 - C3 Pluriel NFU 8HX 90°C 4 4000 Tools (Kit 4103-T) X X X 227 8HW NOTE: The oil pressure should be checked with the engine hot, after the oil level has been checked. 8HV 1,3 1000 8HY 3,5 4000 X X X X X X X X X X X X ENGINE CHECKING THE OIL PRESSURE 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.X23 KFW 3 2000 NFU 90°C 4 4000 X X X X XSARA RFS 8HZ 80°C 1,5 - 5,1 2 - 5,5 1,3 - 3,5 1000 - 4000 1000 - 4000 1000 - 4000 Tools (Kit 4103-T) X X X X X X X X X X RFN WJY 1,8 - 4,5 1000 - 4000 RHY 90°C 2 1000 4 4000 X X X X X X X X X X NOTE: The oil pressure should be checked with the engine hot, after the oil level has been checked. 228 RHZ 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. 229 RHY ENGINE CHECKING THE OIL PRESSURE 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 2.0 HDi RHY RHZ 1109 S5 1109 S5 1109 S5 1109 S5 = 1109 R7 – 1109 N3 – 1109 T1 = 1109 S5 = 1109 X4 1109 T1 1109 T1 (1) = NFV (90 hp = 1109 T1) et NFV (100 hp = 1109 R7) 230 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). - Use the coolant to ensure protection between - 15°C and - 37°C. - Slowly fill the system. NOTE: Keep the cylinder filled up (visible level). - Close each bleed screw as soon as the coolant flows without air bubbles. - Start the engine : Engine speed 1500 rpm. - Maintain this speed until the first cooling cycle (cooling fans cut in and cut out). - Stop the engine and allow it to cool down. - Remove the filling cylinder [1] 4520-T (all types) and the cylinder adaptor [2] 4222-T. - Top up the system to the max. mark, with the engine cold. - Refit the filler cap. B1GP00AC E5AP1GNC 231 ALL TYPES ENGINE FILLING AND BLEEDING THE COOLING CIRCUIT 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 1.6i 16V NFU L4 BOSCH M 7.4.4. 1.4i KFW L4/IFL5 SAGEM S2000 1.6i NFU L4 BOSCH M.7.4.4. 2.0i RFN L4 MAGNETTI MARELLI MM 48P2 2.0i 16V RFS L3 M. MARELLI 1AP10 1.6i NFV L4 BOSCH M7.4.4. 850 850 1.8i 6FZ L4 SAGEM S2000 700 2.0i 16V RFN L4/IFL5 M. MARELLI 6LP 850 232 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. 3 3 3 Overspeed cut-off (rpm) 5500 5500 6600 Injector resistive value (ohms) 14,5 12,2 14,5 Engine coolant temperature sensor resistive value (ohms) 3 800 at 10°C 2500 at 20° C Idling actuator or stepper motor resistive value (ohms) Air temperature sensor resistive value (ohms) 800 at 50°C 230 at 90° C Stepper motor: 53 3 800 at 10°C 2500 at 20° C 233 800 at 50°C 230 at 90° C INJECTION C2 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 1.6i 16V 3,5 3,5 3,5 3,5 3,5 3,5 Overspeed cut-off (rpm) 5500 5500 5500 5800 5500 5800 Injector resistive value (ohms) 14,5 12,2 14,5 14,5 14,5 14,5 Fuel pressure (bars) Engine coolant temperature sensor resistive value (ohms) 3800 at 10° C 2 500 at 20° C Idling actuator or stepper motor resistive value (ohms) Air temperature sensor resistive value (ohms) 800 at 50° C 230 at 90° C 800 at 50° C 230 at 90° C Stepper motor: 53 3800 at 10° C 2 500 at 20° C 234 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. MARELLI 6LP 3 3 3,5 3,5 3,5 3,5 Overspeed cut-off (rpm) 5500 5800 6000 5700 5500 6000 Injector resistive value (ohms) 14,5 14,5 14,5 14,5 12,2 14,5 Fuel pressure (bars) Engine coolant temperature sensor resistive value (ohms) 3800 at 10° C 2 500 at 20° C Idling actuator or stepper motor resistive value (ohms) Air temperature sensor resistive value (ohms) 800 at 50° C 230 at 90° C 800 at 50° C 230 at 90° C Stepper motor: 53 3800 at 10° C 2 500 at 20° C 235 INJECTION XSARA 2 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. at fast idle speed between 2500 and 3000 rpm (*) Less than 3.0 m-1 Lambda Probe value 0,97 to 1,03. 236 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 15.05 Petrol Private vehicles: > 2 litres • new models • existing models 01/10/88 ➞ 01/10/89 ➞ 237 Brussels directive 88/76 «Luxembourg Accords» ➞ Replaced by 89/458 + 91/441 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. standard With oxygen sensor and catalytic converter for petrol vehicles Current ➞ Adoption of U.S. standard With catalytic converter and EGR Current ➞ Adoption of U.S. standard 238 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. standard for light utility vehicles Petrol Diesel Private vehicles: • certain non-EEC European countries • certain Export countries Current ➞ Adoption of the U.S. standard for light utility vehicles 239 CHARACTERISTICS INJECTION STANDARD 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: < 3.5 tonnes Class 1: • new models • existing models Class 2/3: • new models • existing models OBSERVATIONS Applicable Brussels Directive 94/12 01/96 ➞ 01/97 ➞ ➞ EURO 93 standard made stricter With oxygen sensor and reinforced catalytic converter for petrol vehicles. With catalytic converter and EGR for diesel vehicles. Brussels Directive 96/69 01/97 ➞ 10/97 ➞ ➞ 3 classes depending on vehicle weight: Class 1 < 1250 kg 01/98 ➞ 10/98 ➞ Class 2: 1250/1700 kg Class 3: 1700 kg 240 CHARACTERISTICS With oxygen sensor and reinforced catalytic converter for petrol vehicles. With catalytic converter and EGR for diesel vehicles. EMISSION STANDARDS PSA A/S PR Engines Vehicles Applicable Utility vehicles: < 3.5 tonnes EURO 3 (EURO 2000) EURO 4 W3 IF/L5 Petrol Diesel Gas Petrol Class 1: • new models • existing models Class 2/3: • new models • existing models ➞ 01/2000 ➞ 01/2001 ➞ 01/2001 ➞ 01/2002 OBSERVATIONS Brussels Directive 98/69 ➞EURO 2 standard (L3) made stricter ➞ Fiscal incentives ➞ 3 classes depending on vehicle weight: Class 1 < 1305 kg Class 2: 1305/1760 kg Class 3: 1760 kg Brussels Directive 99/102 ➞ EURO 3 standard (L4) made stricter ➞ Fiscal incentives Private vehicles: All Types • new models • existing models 241 CHARACTERISTICS With 2 oxygen sensors and catalytic converter for petrol vehicles. With catalytic converter and EGR for diesel vehicles. With EOBD on-board diagnosis. With 2 oxygen sensors and catalytic converter for petrol vehicles. With EOBD on-board diagnosis. INJECTION STANDARD E.E.C. ALL TYPES APPLICATIONS ALL TYPES EMISSION STANDARDS APPLICATIONS STANDARD E.E.C. INJECTION EURO 4 PSA A/S IF/L5 PR Engines Petrol Diesel Gas Vehicles Private vehicles: All types • new models • existing models Applicable Brussels Directive: 2001/1 ➞ EURO 3 standard (L4) made ➞ 01/2005 ➞ 01/2006 Utility vehicles: < 3,5 tonnes EURO 4 IF/L5 Petrol Gas Class 1: • new models • existing models Class 2/3: • new models • existing models OBSERVATIONS ➞ 01/2005 ➞ 01/2006 ➞ 01/2006 ➞ 01/2007 242 stricter ➞ Fiscal incentives Brussels Directives: 99/102 et 2001/1 (Gas) ➞ EURO 3 standard (L4) made stricter ➞ Fiscal incentives ➞ 3 classes depending on vehicle weight: Class 1 < 1305 kg Class 2: 1305/1760 kg Class 3: 1760 kg CHARACTERISTICS With 2 oxygen sensors and catalytic converter for petrol vehicles. With EOBD on-board diagnosis. With 2 oxygen sensors and catalytic converter for petrol vehicles. With EOBD on-board diagnosis. 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. IMPERATIVE: Take into account the very high pressures in the high pressure fuel circuit (1350 bars), and respect the requirements below: - No smoking in proximity to the high pressure circuit when work is being carried out. - Avoid working close to flame or sparks. Engine running: - Do not work on the high pressure fuel circuit. - Always stay clear of the trajectory of any possible jet of fuel, which could cause serious injuries. - Do not place your hand close to any leak in the high pressure fuel circuit. After the engine has stopped, wait 30 seconds before any intervention. NOTE: This waiting time is necessary in order to allow the high pressure fuel circuit to return to atmospheric pressure. 243 INJECTION SAFETY REQUIREMENTS. 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. IMPERATIVE: After dismantling, immediately block the apertures of the sensitive components with plugs, to avoid the entry of impurities. Work area. - The work area must be clean and free of clutter. - Components being worked on must be protected from dust contamination. 244 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. Do not separate the following components from the high pressure fuel pump (5): - Sealing ring (a) (no replacement parts). - High pressure outlet connector (b) (will cause a malfunction). PS: HDi = High pressure Diesel injection B1HP1K9C 245 INJECTION Cleaning. 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. It is forbidden to clean the carbon deposits from the diesel injector nozzle. B1HP1KBC B1HP1KAC 246 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. Do not separate the following components from the high pressure fuel pump (5): - Sealing ring (a) (no replacement parts). - High pressure outlet connector (b) (will cause a malfunction). PS: HDi = High pressure Diesel injection B1HP1J6C 247 INJECTION Cleaning. 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). It is forbidden to clean the carbon deposits from the diesel injector nozzle.. B1HP1J8C B1HP1J7C 248 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. Do not separate the following components from the high pressure fuel pump (5): - High pressure fuel pump third piston deactivator (3) (no replacement parts). - High pressure fuel regulator (4) (no replacement parts). - Sealing ring (1) (no replacement parts). - High pressure outlet connector (3) (will cause a malfunction). PS: HDi = High pressure Diesel injection B1HP12CC 249 INJECTION Cleaning. 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). - Do not alter the position of the nut (10) (malfunction). - Do not separate the connector (12) from a diesel injector. - It is forbidden to clean the carbon deposits from the diesel injector nozzle. - Identification: Injector carrier - There are two types of diesel injector carrier classed according to fuel flow. Identification by engraving or paint mark Injector carrier Engraving Class 1 Class 2 Paint mark Location 1 Blue 2 Green On the upper part of the coil near to the fuel return aperture Identification markings: -«a»: Supplier identification. -«b»: PSA identification number. -«c»: Class identification. IMPERATIVE: When replacing a diesel injector carrier, order a component of the same class. (See repair manual) 250 B1HP16PC 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 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. 252 Code Injector colour needle lift pressure (Bar) Fast idling Anti-stall Idling Unladen rpm Laden rpm 135,5 ±5 950 ± 25 1500 +3 mm shim 875 ± 25 875 ± 25 5350 ± 125 Adjustments (rpm) Max. speed 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. (Normal direction of rotation) - Bring the camshaft and injection pump pulleys to their setting point. - Position the flywheel peg, using tool [1]. (From below the vehicle) - Turn the engine until the peg [1] engages in the flywheel. B1EP12NC B1BP1S9C 253 INJECTION Tools. [1] Flywheel locating peg [2] H M8 screw [3] Injection pump setting peg Ø 6 mm 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. - Tighten the screws of the injection pump hub. Tighten to 2,3 ± 0,2 m.daN. ESSENTIAL: If setting the diesel injection pump proves impossible, reset the valve timing. (See page 251) Remove: - The tools [1], [2] and [3]. - The screw (6) and the washer. Reassemble the components. B1EP12WD B1BP1S9C 254 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. Prior conditions. - Engine hot (cooling fan is engaged twice). Checking the accelerator cable tension. - Fully depress the accelerator pedal. - Check that the lever (6) is against its stop (5) otherwise, alter the position of the pin. - If not, adjust the position of the accelerator cable tensioning retaining pin. - Ensure that in the idle position the lever (6) is against the stop (7). B1HP0K9C 255 INJECTION Engine: WJY 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). - Idling speed: 825 ± 25 rpm. Checking the engine deceleration. - Move the throttle lever (6) to obtain an engine speed of 3000 rpm. - Release the throttle lever (6). - The deceleration should be between 2.5 and 3.5 seconds. - The drop should be approximately 50 rpm in relation to the idle speed. - Deceleration too fast, (the engine has a tendency to stall) slacken the screw (7) by a quarter turn. - Deceleration too slow, (engine speed is greater than the idle speed) tighten screw (7) by a quarter turn. NOTE: In each case, check the idle speed for any necessary adjustments. B1HP0K9C B1HP0KAC 256 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. B1DP158C B1HP0YGC B1HP12VC 257 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 3.2 760680 BOSCH EDC 15C2 BOSCH CP1 9625542580 SIEMENS (except PICASSO) SIEMENS ECUSID801 5WS 40001 5WS40000 BOSCH BOSCH EDC 15C2 BOSCH CP1 9625542580 BOSCH 258 Injectors 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. Check the negative pressure according to the table below: Vacuum B1BP2NWC 259 Observations 10 ±5 cmHg Engine driven by the starter motor 20 ±5 cmHg Engine running under full load 60 ±5 cmHg Supply circuit obstructed (full tank strainer, piping, fuel filter). INJECTION Tools. [1] Ø 10 mm low pressure connector [2] Pressure gauge for testing boost pressure 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». WARNING: Any checking of pressure downstream of the fuel filter is prohibited. Switch on the ignition. ESSENTIAL: Check that the tool [2] is clean. Check the negative pressure according to the table below: Vacuum Observations 10 ± 05 cmhg Engine driven by the starter motor 20 ± 20 cmhg Engine running under full load 60 ± 05 cmhg Supply circuit obstructed (full tank strainer, piping, fuel filter). B1BP2PHC 260 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). WARNING: Any check of pressure downstream of the fuel filter is PROHIBITED. Checks on pressure: static. - Switch on ignition For 3 seconds (normal functioning): - Fuel supply pressure shown by the pressure gauge [3] = 1.8 ± 0.4 Bar. - Fuel return pressure shown by the pressure gauge [3] = 0.5 ± 0.4 Bar. B1BP1TWD 261 INJECTION Tools. 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 0.7 Bar Check the low pressure regulator incorporated in the filter (locked shut): replace. More than 3.5 Bar More than 0.7 Bar Check the fuel return circuit (pipe pinched or trapped…) Between 0.8 and 1.5 Bar Less than 0.7 Bar Check the fuel suppy circuit: - Booster pump (low pressure), piping. Impossible to start the engine: Fuel supply pressure less than 0.8 Bar: - Check the low pressure regulator incorporated in the filter (locked open). - Check the high pressure pump distribution valve (locked shut). Checks Check: diesel injector return flow. (Table below) Uncouple the diesel injector return pipe. Check: Observe: The flow should be drop by drop. Diesel injector functioning correctly. Excessive fuel return. Diesel injector locked shut. 262 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. Position tool [1] in the vehicle. Start the engine. Engage first gear, start the vehicle. Engage the gears up to third gear. Decelerate to an engine speed of 1000 rpm. Check the pressure: 0,6 ± 0,05 bar (1500 rpm). Accelerate freely (change from fourth gear to third gear). Check the pressure: 0,9 ± 0,05 bar (between 2500 and 3500 rpm). Remove tools [1], [2] at «a». Reposition the tube (2) and tighten the clips (1). 263 INJECTION Engines: 8HX - 8HW 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. Position tool [1] in the vehicle. Start the engine. Engage first gear, start the vehicle. Engage the gears up to third gear. Decelerate to an engine speed of 1000 rpm. Check the pressure: 0,6 ± 0,05 bar (1500 rpm). Accelerate freely (change from fourth gear to third gear) Check the pressure: 0,9 ± 0,05 bar (between 2500 and 3500 rpm). Remove tools [1], [2] at «a». Reposition the tube (2) and tighten the clip (1). 264 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. Decelerate to an engine speed of 1000 rpm. Check the pressure: 0,6 ± 0,05 bar (1500 rpm). Accelerate freely (change from fourth gear to third gear). Check the pressure: 0,9 ± 0,05 bar (between 2500 and 3500 rpm). 265 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). - Position tool [1] in the vehicle. - Connect the sleeve [2] to the tool [1] with its tube «a». Procedure. - Start the engine. - Engage first gear and start the engine. - Engage the gears up to third gear. - Decelerate to 1000 rpm. - Accelerate hard, and check the pressure: 0.6 ± 0.05 Bar (1500 rpm). - Accelerate freely in kick-down (changing from fourth to third gear). - Check the pressure: 0.95 ± 0.05 Bar (between 2500 and 3500 rpm). - Remove the tools, reposition the pipe (1) and refit the collar (3). 266 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. - Start the engine. - Engage first gear and start the engine. - Engage the gears up to third gear. - Decelerate to 2000 rpm. - Gradually accelerate. - Check the pressure: 0.95 ± 0.05 Bar - Remove the tools, refit the collars (3) and the sleeve. B1BP1ZXD 267 INJECTION Tools. [1] Pressure gauge for checking boost pressure [2] Sleeve for checking boost pressure 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. B1HP1K8D 268 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. Engine speed (rpm) 780 0,6 4000 0,25 Pressure regulator valve. - Connect the tool [1] on the valve (3). - Appy a pressure of 0.5 bar to activate the rod "a": - Rod "a" should be moved 12 mm. B1HP12FD 269 Pressure (Bar) INJECTION Engines: RHY - RHZ 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. B1HP15GD Engines: 8HV - 8HY Regulation electrovalve (EGR). (Engine: 8HX-8HW). Check to be performed between the electrovalve (1) and the EGR valve (2). Link the tool [1] in series, between the electrovalve (1) and the capsule (2). Compare the values noted with those in the table below. Regulation electrovalve (EGR). (Engine: 8HV-8HY). Check to be performed between the electrovalve (2) and the EGR valve (1). Link the tool [1] in series, between the electrovalve (2) and the capsule (1). Compare the values noted with those in the table below. Engine speed (rpm) Vacuum value 780 0,5 2500 0 B1HP1K6D 270 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. Perform the check with the aid of a diagnostic tool. Carry out the following operations with the diagnostic tool: - «INJECTION» menu. - Actuator tests. - Butterfly. - EGR exchanger butterfly. Check that you can hear the click from the double butterfly housing. B1HP1UQC 271 INJECTION (1) Exhaust gas recycling (EGR) electrovalve 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. - Check, not under load, between the electrovalve (2) and the EGR valve (1). - Connect the tool [1] between the electrovalve (2) and the capsule (1). - Compare readings with the values in the table below. Engine speed (rpm) Vacuum value 780 0,5 2500 0 B1HP12GD 272 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. - After the engine has stopped, wait 30 seconds before starting any operation. NOTE: The waiting time is necessary to allow the fuel high pressure circuit to return to atmospheric pressure. Safety rules. IMPERATIVE: Wait at least an hour before starting any repair on the exhaust line. Forced regeneration of the particle filter: - Check that there are no aerosols or inflammable products inside the vehicle’s boot. - Wear high temperature gloves. - Connect the vehicle to a gas extractor approved for this type of operation. IMPERATIVE: 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. Place the vehicle in the high position. 273 INJECTION ESSENTIAL: Given the very high pressures prevailing in the fuel high pressure circuit (1600 Bars), respect the following regulations. 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. - Wash the soiled area with copious amounts of water. - Dispose of materials and solid residues in an authorised recovery point. IMPERATIVE: The filling kit should be recycled following a repair. All «Eolys» additive containers that have been opened should be disposed of. Cleanliness rules. ESSENTIAL: The operator should wear clean overalls. Before working on the injection circuit, it may be necessary to clean the unions of the following sensitive components (see corresponding operations). - Fuel filter. - Fuel high pressure pump. - Fuel high pressure regulator. - Fuel high pressure common injection rail. - Fuel high pressure piping. - Diesel injector carriers. IMPERATIVE: After dismantling, immediately blank the unions of the sensitive components with plugs, to prevent any ingress of impurities. 274 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. Place the vehicle in the high position. WARNING: Check that the fuel level is sufficient (at least 20 litres). Start the engine and allow it to warm up (60°C minimum). Connect the diagnostic tool to the vehicle’s central socket. Trigger the regeneration cycle, with the diagnostic tool. Automatic running of the regeneration cycle of the particle filter: - Autocheck by the engine ECU. - Stabilisation of engine speed at 4000 rpm, operating with post injection. - Change to idling speed (for 30 seconds). - Stabilisation of engine speed at 3000 rpm, checking of the efficiency of the regeneration of the particle filter. - Change to idling speed. NOTE: Let the engine run at idling speed for the benefit of cooling. Stop the engine. IMPERATIVE: Wait for at least an hour before any operation on the exhaust line. 275 INJECTION Diagnostic stations : LEXIA or PROXIA Imperative: Respect the safety and cleanliness requirements. 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. IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves that are resistant to hydrocarbons. Place the vehicle on a lift. Disconnect the battery negative terminal. Unclip the the factory filler connector (1). Couple the container of additive to the tube (2) using the adaptor and the tube (with tap) from the filling kit. Screw the filler connector on the additive container (3) at «b». Place the additive container (3) on the component lift. Open the tap located on the filler connector at «a». Tilt the additive container (3) (to facilitate the end of filling). Close the tap at «a». Remove the filler connector and the tube (4). Couple the tube (2). Reconnect the battery negative terminal. IMPERATIVE: The filling kit should be recycled after this operation. Any «Eolys» additive containers that have been opened should not be kept. C4BP1EGC 276 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. Raise the vehicle To test the flow of the additive pump : Uncouple the tube (1). Couple tool [2] on the outlet «a» of the additive reservoir. Operate for 50 seconds the actuator test «Additive pump» with the aid of LEXIA or PROXIA. IMPERATIVE: The volume collected by the tool [2] should be 20 ± 5 ml. NOTE: Replace the additive pump if it is defective. Couple the tube (1). Operate the actuator test «Filling the tube: additive pump – additive injector», with the aid of LEXIA or PROXIA. B1HP1UTC 277 INJECTION Tools. 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). Operate the actuator test «Filling the tube: additive pump – additive injector», with the aid of LEXIA or PROXIA. Check the additive level. The checking of the additive level is done with reference to the gradations «a» marked on the additive reservoir. The top graduation indicates maximum filling (3 Litres). The difference between the two gradations equates to 0,25 Litres. B1KP019C 278 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.N RC 8 YLC RFN 58 HZ RFN 58 LZ RC 8 YLC 0,9 ± 0,05 RFN 58 HZ RFN 58 LZ RFN 58 HZ RFN 58 LZ RFN 58 HZ RFN 52 HZ RFN 62 LZ 0,9 ± 0,1 RFN 58 LZ FR7 DE FR8 ME Electrode gap setting RFN 58 LZ FR7 DE VR8 SE FR7 ME FR7 DE FR7 ME FR7 DE FR7 ME FR8 ME FR6 DE EYQUEM IGNITION C3 1.1i 1.4i 1.6i 1.1i 1.4i 1.4i 1.6i 1.4i 1.6i 1.4i 1.6i 2.0i BOSCH ALL TYPES 0,9 ± 0,1 RFN 52 HZ 279 RC 8 YLC 0,9 ± 0,05 RC 8 YLC REC 9 YCL RC 8 YLC REC 9 YCL 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 < 1.10 ST + 4 Kph CLUTCH GEARBOX TRANSMISSION Example: For an actual speed of 100 Kph the speed displayed by the speedometer may be between 100 and 114 Kph. The speed indicated by the speedometer may be influenced by: - The speedometer. - The tyres fitted to the vehicle. - The final drive ratio. - The speedometer drive ratio. Any of these components can be checked without removing them from the vehicle (see information note N° 78-85 TT of 19 October 1978). NOTE: Before replacing the speedometer, check the conformity of the following points: - The tyres fitted to the vehicle. - The gearbox final drive ratio. - The speedometer drive ratio. 280 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. 281 CLUTCH GEARBOX TRANSMISSION Mechanism / type 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 1.6i 16V 8HV 8HY BE4/5 LUK Quality of lining 200 P 3900 230 P 4700 200/134 228/155 F408 282 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.Ext/Int RFN 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 2.0 HDi 200/134 200 P 3700 215 F (D 93) 22 BX 228 228D 200/134 230/155 235/155 F 408 284 F202 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 1.6i XSARA PICASSO 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. Tightening torques (m.daN). - Fixing of clutch plate / engine flywheel - Fixing of clutch control slave cylinder / clutch housing - Fixing of engine flywheel / crankshaft Pre-tightening Angular tightening B2BP047C B2BP04QC 286 : 2 ± 0,2 : 2 ± 0,25 : 1,7 ± 0,1 : 70° ± 5° 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). - Fixing of clutch plate / engine flywheel - Fixing of clutch control slave cylinder / clutch housing - Fixing of engine flywheel / crankshaft Pre-tightening Angular tightening Checking torque B2BP047C B2BP05SC 287 : 2 ± 0,2 : 2 ± 0,25 : 1,75 ± 0,1 : 75° ± 5° : 6,3 ± 2,2 CLUTCH GEARBOX TRANSMISSION 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. 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. B2BP002C B2BP03BC B2BP02WC 288 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). Depress the clutch cable several times to lodge the cable in place. Check that the end-piece (4) is correctly lodged on the bulkhead. Check the operation of the automatic adjusting system. After fitting the cable, pull the clutch lever in the inverse direction (direction F), the lever should move back when pulled by hand. Press the clutch pedal very lightly and repeat the same operation. The lever should not move back. WARNING: If a system blockage is detected when checking, or if the pedal has been removed, the pedal position must be adjusted. The correct positioning of the pedal is obtained by the angular displacement of the stop supports "a" and "b". B2BP03DD 289 CLUTCH GEARBOX TRANSMISSION Refitting. 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. At rest, the clutch cable sleeve should be free and able to lengthen and shorten. CLUTCH GEARBOX TRANSMISSION Clutch pedal travel. The automatic clutch wear adjustment system has no manual adjustment. Pedal travel is identical on all models: 154 ± 5 mm. The adjustment is achieved by reducing the length of the cable sleeve. WARNING: Automatic adjustment of the pedal travel is accompanied by a modification of the curvature of the cable sleeve. Do not add any supplementary fixing points or alter the routing in any way. «c» Routing of new cable. «b» Routing after adjustment of play. «x» Clutch wear. B2BP03EC B2BP03FD 290 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. Use the transparent tube (5) to act as a siphon, at «b». WARNING: the end of the tube (5) must be submerged in the brake fluid. Open the bleed screw, at «c». B2BP04XC 291 CLUTCH GEARBOX TRANSMISSION IMPERATIVE: Do not use automatic bleeding equipment (risk of the brake fluid emulsifying in the hydraulic circuit). 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. The last time, keep the clutch pedal fully down. Reclose the bleed screw, at «c». If necessary, repeat the operation. Top up the brake fluid to the MAX. level of the brake fluid reservoir. Work the clutch vigorously 40 times. Start the engine. Apply the handbrake. Engage a gear. Check that the clutch starts to engage at a dimension (X) greater than or equal to 45 mm (the dimension (X) is given as a guide). Repeat the bleed operations if necessary. C5FP0FQC B2BP04YC 292 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. plate 185/55 R15 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 1.6i 16V KFV NFU 8HX 165/70 R14 185/55 R15 185/55 R14 195/45 R16 185/70 R15 165/70 R14 1,804 m 1,781 m 1,781 m 1,772 m 1,804 m 1,804 m MA 5/L MA 5/0 MA 5/N MA 5/S CLUTCH GEARBOX TRANSMISSION 20 CP 21 20 CP 64 20 CP 66 20 CP 65 PRO 9786 ➞ PRO 9786 ➞ PRO 9786 ➞ PRO 9786 ➞ Reduction box torque 16x65 16x63 14x60 16X63 Speedometer ratio 21x18 21x18 294 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. plate Exclusive X - SX 1.4 HDi 16V X - SX - Exclusive 8HX 8HW 8HV 8HY 165/70 R14 1,804 185/60 R15 1,828 m MA/5 BE4/5 20 CP 54 (2) 20 DM 25 20 DM 26 Reduction box torque 19x72 19x77 17x61 Speedometer ratio 21x18 22x19 (1) Export et DAIC = 20 CP 16 (14X60) (21X18) - (2) EXPORT et DAIC = 20 CP 55 - 20 CP 72 (16X65) (21X18). 295 CLUTCH GEARBOX TRANSMISSION Trim level Engine type Tyres-rolling - Circumference 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. plate Reduction box torque 165/70 R14 1,804 m MA/5 20 CP 56 17x64 20 CP 65 16x63 Speedometer ratio 21x18 296 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. 297 CLUTCH GEARBOX TRANSMISSION Circumference 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 1.4 HDi WJY 8HZ RHY (3) Tyres-rolling - Circumference 20 DM 54 20 DL 41 20 DL 42 19x70 19x75 Speedometer ratio 22x19 AUTOMATIC RHZ 195/55 R15 – 1,815 m BE4/5 Gearbox type Gearbox ident. plate Reduction box torque 2.0 Hdi AL4 20 DM 10 17x61 20 TP 48 14x62 22x19 NOTE: (RHY engine - BE4/5 gearbox) - (1) Estate = 20 CP 44 (16x65) (21x18) - (2) DAIC = 20 CP 52 (14x60) (21x18) - (3) XSARA DAIC RHD = 20 DM 08 Right hand drive: 6FZ-RFN = 20 DM 03 - WJY = 20 DM 05 - 8HZ = 20 DM 53 - RHY = 20 DM 07 - RHZ = 20 DM 11 298 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. plate Reduction box torque Speedometer ratio Right hand drive: 9HZ 9HY 185/65 R15 1,895 m BE4/5 20 DM 62 19x70 22x18 NFV = 20 DL 67 20 DL 65 19x72 22x18 6FZ = 20 DL 69 299 2.0 HDi RHY RHY = 20 DL 65. CLUTCH GEARBOX TRANSMISSION GEARBOX AND TYRE SPECIFICATIONS 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. B2CP3SQC 300 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). (19) 1st / 2nd gear synchroniser and reverse gear driven pinion. (20) Driven pinion (2nd gear). (21) Driven pinion (3rd gear). (22) 3rd / 4th gear synchroniser. 301 CLUTCH GEARBOX TRANSMISSION Engines: HFX - KFV - NFU - 8HX - 8HW 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). (4) Bearing retaining clip screw (x4) : 1,8 ± 0,2 (6) Intermediate plate (11 fixing screws) : 5 ± 0,5 (7) Gearbox casing 16 fixing screws ➞ RPO 9784 17 fixing screws RPO 9786 ➞ (15 fixing screws) : 1,9 ± 0,2 (8) Clutch bearing guide screw (3 fixing screws) : 0,6 ± 0,15 B2CP3SRP 302 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. The clutch control has a ball-joint mounted declutch fork. Oil capacity Checking the oil level Lubrication interval B2CP3SSD Lubrication. : 2 ± 0,15 Litres. : No oil level check (*) : Lubricated «for life». NOTE: There should be a visual check on the sealing at each engine oil change. 303 CLUTCH GEARBOX TRANSMISSION (*) = The oil top-up plug is discontinued from RPO 9919 ➞ XSARA MA/5 GEARBOX Engines: KFW - NFU «a» Identification label. CLUTCH GEARBOX TRANSMISSION «b» Location for engraving of serial and gearbox nos. B2CP3HTC 304 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). (17) Differential gearwheel. (18) Satellite pinions. (19) Planet pinions. (20) Counter drive. (21) Speedometer screw. (22) Differential housing. 305 CLUTCH GEARBOX TRANSMISSION Engines: KFW - NFU 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. B2CP167P 306 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. - has a reverse gear braking device (5th gear synchroniser). - has a device for prohibiting a change from 5th gear into reverse gear. The clutch control has a ball-joint mounted declutch fork. Lubrication. Oil capacity Checking the oil level Lubrication interval B2CP169D 307 : 2 ± 0,15 Litres. : Every 37,500 miles. : Lubricated «for life». CLUTCH GEARBOX TRANSMISSION Features. 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. WARNING: When the engine is running, it is forbidden to perform repairs on the clutch and gearbox actuators on the vehicle (whether manually or using a diagnostic tool). CLUTCH GEARBOX TRANSMISSION NOTE: After disconnecting the battery, never try to remove the clutch actuator on the vehicle before having checked that it is in the closed position (rod pushed in). WARNING: Each time the driver’s door is opened and each time the igntion is switched on, the gearbox ECU prompts the initialising of the clutch and gearbox actuators (there is movement of the clutch fork and of the gear lever). IMPERATIVE: After Sales checks done with the engine running must be performed with «Neutral» engaged and the handbrake on (unless there is a clear mention otherwise in the repair procedures). WARNING: Whether the ignition is switched on or not, an action on the gear selector causes the clutch fork and the gear engagement lever to move on the gearbox. IMPERATIVE: The areas of movement of the clutch fork and of the gear engagement lever must always be kept free during the actuator operating phases. 308 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. If a gear is engaged, the conditions for immobilisation of the vehicle are: Combustion engine stopped (the engine should not be started). The clutch is open (clutched). Before disconnecting connector, check: - The condition of the various contacts (for deformation, corrosion, etc). - The presence and the status of the mechanical unlocking. In these conditions are met, you can lift the front of the vehicle to tow it. Driving the vehicle. IMPERATIVE: Never move the vehicle with the ignition switched off. If it should not be possibe to lift the front of the vehicle, there are ways to unblock it: Never push the vehicle to attempt to start it (impossible with a piloted manual gearbox). - Engage «N», using a diagnostic tool. - Engage «N», without using a diagnostic tool. 309 CLUTCH GEARBOX TRANSMISSION It is necessary to lift the front of the vehicle to tow it, after having positioned the gear lever in neutral. If there is a gearbox fault or malfunction, the vehicle can remain immobilised depending on the seriousness of the fault. 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. NOTE: This recovery solution is to be used solely in a case where the attempt to make the gearbox actuator engage b via the diagnostic tool has failed. From the diagnostic tool menus, select: CLUTCH GEARBOX TRANSMISSION «DIAGNOSIS» MA type piloted manual gearbox. Actuator test. Gearbox actuator test. Gear engagement test. N (neutral). NOTE: The letter «N» should appear on the instrument panel. If not, see the following solution: Engaging of «N», without using a diagnostic tool. 310 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. B2CP3L8D 311 CLUTCH GEARBOX TRANSMISSION - Remove the air filter. C2 MA/5 PILOTED MANUAL GEARBOX Engines: KFV - 8HX «a» Identification label. CLUTCH GEARBOX TRANSMISSION «b» Location for engraving of serial and gearbox nos. B2CP3STC 312 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). (19) 1st / 2nd gear synchroniser and reverse gear driven pinion. (20) Driven pinion (2nd gear). (21) Driven pinion (3rd gear). (22) 3rd and 4th gear synchroniser. 313 CLUTCH GEARBOX TRANSMISSION Engines: KFV - 8HX 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). (4) Bearing stop screw (x4) : 1,8 ± 0,2 (6) Intermediate plate (11 fixing screws) : 5 ± 0,5 (7) Gearbox casing 16 fixing screws ➞ RPO 9784 17 fixing screws RPO 9786 ➞ (15 fixing screws) : 1,9 ± 0,2 (8) Clutch bearing guide screw (3 fixing screws) : 0,6 ± 0,15 B2CP3SRP 314 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). 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). A gearbox input speed sensor. The piloted manual gearbox has no gear control cable and no clutch cable. Changes of gear and clutching/declutching are activated by the gearbox actuator and the clutch actuator. Lubrication. Oil capacity Checking of oil level Lubrication intervals : 2 ± 0,15 litres. : No oil level check. (*) : Lubricated «for life». (*) = Only a visual check of the sealing at each engine oil change interval. B2CP3SUD 316 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. 317 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. B2CP3BLD 318 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). (14) (15) (16) (17) (18) (19) (20) (21) (22) 1st / 2nd gear synchroniser. Driven gear (1st gear). Secondary shaft. Differential gear. Satellite gears. Planet gears. Differential housing. Speedometer drive. Extension. «d» Adjusting shims: 0.7 to 2.4 mm (0.10 mm and increasing by 0.10 mm). «c» Adjusting shims: 1.4 to 1.6 mm (0.10 mm and increasing by 0.10 mm). B2CP3BQP 319 CLUTCH GEARBOX TRANSMISSION Description C3 - XSARA - XSARA PICASSO BE4/5 GEARBOX Engines: 6FZ - RFN - RFS - WJY - 8HV - 8HY - 8HZ - 9HZ - 9HY - RHY - RHZ Tightening torques (m.daN). (23) (24) (25) (26) (27) (28) CLUTCH GEARBOX TRANSMISSION Clutch bearing guide (3 screws) Clutch housing (13 screws) Primary shaft nut (1 screw) Secondary shaft nut (1 screw) Yoke retaining screw (2 screws) Differential gearwheel screw (2 screws) Reverse gear switch (1 screw) (29) Differential housing (4 screws) (30) Breather pipe (31) Rear housing cover screws (7 screws) (32) Top-up plug (1 screw) (33) Differential housing screws (4 screws) (34) Drain plug (1 screw) B2CP3BRD 320 : 1,25 ± 0,2 : 1,3 ± 0,2 : 7,25 ± 0,5 : 6,5 ± 0,5 : 1,5 ± 0,2 : 6,5 ± 0,5 : 2,5 ± 0,3 : 5 ± 0,5 : 1,7 ± 0,2 : 1,25 ± 0,2 : 2,2 ± 0,2 : 1,25 ± 0,2 : 3,5 ± 0,3 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. (*) 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. CLUTCH GEARBOX TRANSMISSION B2CP3HYC C2 Gear engagement control cable (2) B2CP3HZD Gear selection control cable (3) 322 C3 Length D Length C Length D Length C 1040 mm 815 mm 1015 mm 790 mm Length A Length B Length A Length B 1149 mm 800 mm 1093 mm 775 mm 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. B2CP3J1D 323 CLUTCH GEARBOX TRANSMISSION WARNING: Do not use any tool to detach the ball-joints. 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. After fitting the gear control assembly, check that all the gears will engage without any ”tight spot”. B2CP27WD 324 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. (*) 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. CLUTCH GEARBOX TRANSMISSION B2CP3J4C Gear selection cable (5) Gear engagement cable (4) B2CP3J5D 326 Length A Length B 907 mm 645 mm Length D Length C 965 mm 610 mm 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. 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. B2CP3BWD 328 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. Lock the cable lengths with the ball-joint locking keys. WARNING: Do not use any tool to unclip the ball-joints. To unlock the ball-joint, press at the centre «a», then pull the ball-joint upwards. NOTE: Changing an individual ball-joint is possible as long as the locking key is removed. Unclip at «b», using two small screwdrivers. B2CP3BXC 329 B2CP3BYC 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]. Under the bonnet: - Remove the air filter assembly. - Unlock the ball-joint keys at «a». - Place the gear selection and control levers on neutral. - Lock the cable lengths with the ball-joint locking keys. : 9607-T. Checks. - Remove the tool [1]. - Check that all the gears engage without «tightness ». - Check that the gear lever moves identically forwards and backwards and to right and left. If it does not, repeat the adjustment. - Refit the trim under the gear lever. - Refit the air filter assembly. B2CP3C6C 330 B2CP3C0C 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. Discuss with the customer, to find out all the malfunction symptoms. Oil quality - Oil level. Oil quality. If the gearbox has suffered a serious fault resulting in a malfunction or the destruction of a clutch, the oil will overheat and become contaminated with impurities: the oil is said to be «burnt». This is characterised by a black colour and the presence of an unpleasant smell. Absence of fault codes. Carry out parameter measures, actuator tests and a road test. Presence of fault codes. Carry out the necessary repairs. Delete the fault codes. Carry out a road test to check the repair and, if need be, modify the gearbox ECU parameters (this is essential after an initialisation of the ECU). ESSENTIAL: The gearbox must be replaced. 331 CLUTCH GEARBOX TRANSMISSION Oil level (see corresponding operation). If a gearbox malfunction occurs, there are two possible configurations depending on the seriousness of the fault: - Gearbox in back-up mode with a replacement programme of (the fault values are taken in substitution). - Gearbox in back-up mode with an emergency programme (3rd hydraulic). WARNING: In the emergency programme, an impact is felt when changing P/R, N/R and N/D. 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. - Do not exceed 30 mph over a distance of 30 miles of maximum. Before reconnecting a switch, check: - The condition of the various contacts (for deformation, corrosion etc). - The presence and condition of the mechanical locking. Driving. When performing electrical checks: - The battery should be correctly charged. - Never use a voltage source higher than 16V. - Never use a test lamp. Never drive with the ignition switched off. Never push the vehicle to try to start it (impossible with an automatic gearbox). NOTE: The automatic gearbox is only lubricated when the engine is running. 332 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. - Transfer the value read into the the new gearbox ECU. Exchanging the gearbox -: It is imperative to use the centring peg and the converter retaining bracket to couple the gearbox on the engine. - Initialise the oil usage counter to 0. After coupling the gearbox on the engine, remove the centring peg. Draining the gearbox: - Initialise the oil usage counter (follow the diagnostic tool procedure). 333 CLUTCH GEARBOX TRANSMISSION Precautions to be taken. 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. CLUTCH GEARBOX TRANSMISSION After the downloading operation, carry out the following: - A clearing of faults. - A pedal initialisation. - A re-initialisation of the auto-adaptives. - A programming (if necessary). - A writing of the value of the oil usage counter previously read. - A road test. ESSENTIAL: Every update of the automatic gearbox ECU should be accompanied by an update of the engine ECU. 334 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. If the ECU is to be fitted to a vehicle with depollution L4 or not equipped with gear lever locking safety: - Perform a configuration operation. Using LEXIA or ELIT. Access to reading and recording of the oil counter is via the menu: Pedal initialisation. - «Oil counter». A pedal initialisation must be carried out in the following cases: - Replacement of the automatic gearbox ECU. - Replacement of the automatic gearbox. - Downloading of the ECU configuration. - Adjustment or replacement of the accelerator cable. - Replacement of the butterfly potentiometer. Adjustment of the oil counter value is done by entering directly the 5 figures of the oil counter. 335 CLUTCH GEARBOX TRANSMISSION A new ECU or downloaded update is always configured with the following options: - SHIFT LOCK gear selection lever position. - Without OBD outlet (depollution L4). - «Configuration (integrated circuit button) / Oil counter». 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. B2CP3ECD 336 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). B2CP3EDD 337 B2CP311D C3 - XSARA - XSARA PICASSO AL4 AUTOMATIC GEARBOX Engines: KFV - NFU - RFN - RHZ Tightening torques (m.daN). (8) Fixing of converter on diaphragm Pre-tightening Tightening : 1 ± 0,1 : 3 ± 0,3 CLUTCH GEARBOX TRANSMISSION (9) Plug fixing : 0,8 ± 0,2 (10) Gearbox fixing on engine : 5,2 ± 1 B2CP3EED 338 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). Pre-tighten (no strict order) : 0,9 Slacken : All 7 screws Tighten (respect the order indicated) : 0,75 NOTE: The screw (11) is shouldered. (13) Fixing of selector lever position switch (14) Oil filler plug : 1,5 ± 0,2 : 2,4 ± 0,4 B2CP3EFD 339 B2CP3EGC 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). - Position «M»: Manual (this position lets the driver select his own gears in sequential mode by pulling the gear selector to «M-» or pushing it to «M+»). NOTE: Only the positions «P» or «N» authorise the starting of the engine. In position «M», selection is by an electronic sensor located close to the gear lever. The variation of flux necessary to the movement of the sensor cells is obtained by a magnet located on the lever itself. This enables the change of status. B2CP3H7D 340 B2CP3MUD 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. - Snow programme (b): Facilitates starting and adhesion on slippery surfaces. To return to the normal programme, press a second time on the sport switch or snow switch. B2CP3DKD 341 CLUTCH GEARBOX TRANSMISSION Two switches placed on the gear control gate permit the driver to choose one of the following three driving programmes: 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). B2CP3H8C 342 B2CP3N7C 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). A switch located to the left of the gear control allows the driver to choose from these programmes: Normal: Conventional use of the automatic gearbox. Sport: This programme favours performance. Snow: In position «D», starting is in 2nd gear for diesel and in 3rd gear for petrol. NOTE: Only the positions «P» or «N» authorise the starting of the engine. B2CP3ADC 343 CLUTCH GEARBOX TRANSMISSION 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». 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. 344 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). - The cover (2) (Unclip). - The top of the central console (3). - Unlock the «shift lock» (4) with the aid of a screwdriver. - Move the gear selection lever out of position «P». C5FP0ETC 345 B2CP3GZC CLUTCH GEARBOX TRANSMISSION 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». 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. 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 cover (1). - Unlock the «shift lock» (2) with the aid of a screwdriver. - Move the gear selection lever out of position «P». C5FP06ZC 346 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. Electrical harnesses. Battery voltage. Remove: - Unlock the «shift lock» by pressing at «a» with a screwdriver placed in the gear selection control gate. - Move the gear selection lever out of position «P». B2CP3N8C 347 CLUTCH GEARBOX TRANSMISSION NOTE: It is impossible to unlock the «shift lock» with the «Normal operation» method. 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. B2CP3GYD 348 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. 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). Push in the component (a) without bending the cable. Check all the gear selection control positions. B2CP3GYD 350 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. Refit the drain plug (1) (equipped with a new seal), tighten to 2,4 ± 0,2 m.daN. Remove the oil filler cap (2). Use tool [1]. Oil capacity for dry gearbox: - EW engine: 5,85 litres. - DW engine: 5,40 litres. B2CP31GC Oil remaining after draining: 3 litres (approx.). Quantity of oil to be put in : 3 litres (approx.). Refit the oil filler cap (2) (equipped with a new seal), tighten to 2,4± 0,2 m.daN. Initialise the oil wear counter (follow the diagnostic tool procedure). 351 CLUTCH GEARBOX TRANSMISSION B2CP3AYD 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). C3 TU3 engines Dimension «X» = 81 mm XSARA TU5 and EW10 engines Dimension «X» = 81 mm XSARA DW10 engines Dimension «X» = 77 mm XSARA PICASSO EW10 engines Dimension «X» = 81 mm B2CP3AZD 352 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. An excessive level of oil can lead to the following consequences: - Oil heating up abnormally, - Oil leaks. A level that is too low will result in the destruction of the gearbox. B2CP3AZD 353 CLUTCH GEARBOX TRANSMISSION NOTE: The level is correct at the moment the thread of oil becomes “drip-drip”. Refit the oil level plug (3) (equipped with a new seal), tighten to 2,4± 0,2 m.daN. 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.X 7116-T 32 ± 1,5 Seal extractor RH / LH (-) 0338 C 1,8 ± 0,1 32,5 ± 2,5 XSARA LH side 24,5 ± 0,5 KFW - NFU C3 RH side 2 ± 0,2 XSARA BE4/5 Driveshaft nut 1 ± 0,1 Tightening torque (m.daN) for wheel bolts: XSARA = 8,5 ± 0,8 (-) 0338 J1 + (-) 0338 J3 (-) 0338 H1 + (-) 0338 H2 (-) 0338 J1 + (-) 0338 J2 (-) 0338 H1 + (-) 0338 H2 XSARA PICASSO = 10 ± 1 354 (-) 0338 C2 C3 C3 PLURIEL = 9 ± 1 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. 355 AXLES SUSPENSION STEERING 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. 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. Measure the radius of the front wheel R1 - Calculate dimension H1 = R1 – L1 Value at reference Except CRD (*) height HFX - KFV - 8HX NFU (+ 6 - 8 mm) L1 = 142,5 mm L1 = 152,5 mm Measure the radius of the rear wheel R2 - Calculate dimension H2 = R2 + L2 Value at reference Except CRD (*) height HFX - KFV - 8HX NFU (+ 10 - 6 mm) L2 = 52 mm L2 = 42 mm Compress the suspension to obtain the calculated values. The height difference between the two axle dimensions should be less than 10 mm. (*) = CRD: Difficult road conditions. 356 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. All types (except CRD) HFX - KFV - 8HX HFX - KFV - 8HX Tracking Castor (± 0°18’) ADJUSTABLE All Types mm 0° 2±1 0°18’ ± 0°09’ Camber (± 0°30’) Non adjustable Pivot angle ± 0°30’ - 0°31’ 11°26’ 3°58’ Tracking Non adjustable 5,5 ± 1 0°53’ ± 0°09’ All Types mm 0° Tracking ADJUSTABLE 2±1 0°18’± 0°09’ Castor ± 0°18’ Camber ± 0°30’ Pivot angle ± 0°30’ Tracking 11°35’ 5,8 ± 1 0°49’ ± 0°09’ - 0°32’ Camber Non adjustable Non adjustable 4° - 1°30’ NFU NFU Vehicle Camber -1°31’ WARNING B3CP02UC 357 A < B = Positive figure: += A > B = Negative figure: -= TOE-IN TOE-OUT AXLES SUSPENSION STEERING Vehicle C2 FRONT AXLE Tightening torques (m.daN). (1) Nut fixing suspension leg on body (2) Damper (3) Anti-roll bar link rod upper ball-joint (4) Suspension leg pivot (5) Anti-roll bar link rod lower ball-joint (6) Anti-roll bar bearing fixing on subframe (7) Hub nut (8) Wheel bolt (9) Subframe to bodyshell fixing screw (10) Anti-roll bar (11) Pivot lower ball-joint fixing on lower arm (12) Pivot lower ball-joint fixing (13) Lower arm front and rear mounting fixing (14) Stabiliser bar screw (15) Steering ball-joint fixing AXLES SUSPENSION STEERING B3CP07RP Private vehicles Europe HFX - KFV NFU 8HX Entreprise vehicles HFX - 8HX CRD vehicles KFV - 8HX NFU 358 : 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 Diameter (mm) 18 20 19 Diameter (mm) 18 Diameter (mm) 18 20 Colour Violet Green Blue Colour Violet Colour Violet Green C2 REAR AXLE Tightening torques (m.daN). Private vehicles Europe B3DP09UP HFX - KFV 8HX NFU Vehicle entreprise 8HX CRD vehicles 8HX NFU 359 : 10 ± 1 : : : : : 7 ± 0,5 : : 20 ± 2 : : 4,5 ± 0,4 : 9,3 ± 0,9 : : : Anti-roll bar Diameter (mm) 20,5 (tubular) 23,5 (tubular) 25 (solid) Diameter (mm) 20,5 (tubular) Diameter (mm) 20,5 (tubular) 25,5 (tubular) AXLES SUSPENSION STEERING (25) Rear axle fixing screw (26) Anti-roll bar (27) Rear axle crossmember (28) Rear suspension arm silentblock yoke (29) Rear suspension arm silentblock (30) Yoke / suspension arm fixing screw (31) Rear suspension arm (32) Stub axle bearing nut (33) Damper (34) Damper upper fixing (35) Damper lower fixing (36) Suspension springs (37) Travel stop (38) Secondary brake cable guide support 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 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.). C2 FEATURES OF ELECTRIC POWER STEERING Engines: HFX - KFV - NFU - 8HX Steering mechanism Tightening torques (m.daN.). (4) Ball-joint fixing on pivot : 3,5 ± 0,3 (5) Steering rod lock-nut : 5 ± 0,5 (8) Threaded washer (9) Stud : 0,8 ± 0,1 (10) Flat washers (11) Fixing of mechanism on subframe B3EP13JD Electric motor Steering rack travel Steering ratio AXLES SUSPENSION STEERING Number of rotations of steering wheel Inner angle of lock Outer angle of lock HFX - KFV - 8HX NFU 60 A 2x72 65 A 2x64 45,6/1 3,2 2,8 38° 32°24’ 32°30’ 28°42’ 362 Connectors. (6) Supply of electric assistance motor (7) Torque sensor signals : 8 ± 0,8 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. Power delivered to the assistance motor (12) depends on: - Speed of the vehicle. After changing the electric power steering ECU, it is necessary to perform a configuration. - Torque applied on the steering wheel. 363 AXLES SUSPENSION STEERING B3EP13KC 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. AXLES SUSPENSION STEERING Refit: - The steering rack rpotection gaiter. - New clips (1) and (2). B3EP13VD 364 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. 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. 365 AXLES SUSPENSION STEERING Front height 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. Measure the radius of the front wheel R1 - Calculate dimension H1 = R1 – L1 Measure the radius of the rear wheel R2 - Calculate dimension H2 = R2 + L2 AXLES SUSPENSION STEERING Value at reference All types Except CRD (*) Vehicle CRD (*) Value at reference All types Except CRD (*) Vehicle CRD (*) height Raised suspension Raised suspension height Raised suspension Raised suspension Sports Sports Sports Sports (+ 6 - 8 mm) (+ 10 - 6 mm) L1 = 142,5 mm L1 = 132,5 mm L2 = 52 mm L2 = 62 mm (*) = CRD : Difficult road conditions. Definition for a type of vehicle whose axles and suspensions are adapted for driving on rough roads. Compress the suspension to obtain the calculated values. The height difference between the two axle dimensions should be less than 10 mm. 366 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’. All types (except CRD) Raised suspension - Sports Tracking Adjustable All Types mm 0° Vehicle All Types mm 0° -2±1 - 0°19’ ± 0°10’ Tracking Adjustable -2±1 - 0°19’± 0°10’ 3°57’ Castor (± 0°18’) Camber (± 0°30’) Non adjustable Pivot angle (± 0°30’) Tracking Non adjustable 5,5 ± 1 0°50’ ± 0°10’ - 0°28’ 11°26’ Vehicle CRD Raised suspension - Sports Camber (± 0°30’) Pivot angle (± 0°30’) Tracking 11°14’ 5,2 ± 1 0°47’ ± 0°10’ - 0°26’ - 1°30’ Camber Non adjustable Non adjustable 3°53’ Camber (± 0°18’) -1°28’ WARNING B3CP02UC 367 A < B = Positive figure: += A > B = Negative figure: -= TOE-IN TOE-OUT AXLES SUSPENSION STEERING Vehicle Castor (± 0°18’) 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. L1 = Distance between the wheel axis and the measuring zone underneath the front subframe. 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. 368 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. Value at reference height (+ 6 - 8 mm) Measure the radius of the rear wheel R2 - Calculate dimension H2 = R2 + L2 Value at reference height (+ 10 - 6 mm) All Types L1 = 132,5 mm All Types L2 = 47 mm (*) = CRD : Difficult road conditions. Definition for a type of vehicle whose axles and suspensions are adapted for driving on rough roads. Compress the suspension to obtain the calculated values. The height difference between the two axle dimensions should be less than 10 mm. 369 AXLES SUSPENSION STEERING Measure the radius of the front wheel R1 - Calculate dimension H1 = R1 – L1 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’. All types Vehicle Tracking Castor (± 0°18’) Adjustable All Types mm 0° -2±1 - 0°18’ ± 0°09’ 3°53’ Camber (± 0°30’) Non adjustable - 0°26’ Pivot angle (± 0°30’) Tracking Camber (± 0°18’) Non adjustable 5,7 ± 1 0°51’ ± 0°09’ 11°14’ - 1°30’ AXLES SUSPENSION STEERING WARNING B3CP02UC 370 A < B = Positive figure: += TOE-IN A > B = Negative figure: -= TOE-OUT C3 - C3 PLURIEL FRONT AXLE Tightening torques (m.daN). (1) Nut fixing suspension leg on body (2) Suspension leg (3) Anti-roll bar link rod upper ball-joint (4) Suspension leg pivot (5) Anti-roll bar link rod lower ball-joint (6) Anti-roll bar bearing fixing on subframe (7) Hub nut (8) Wheel bolt (9) Subframe to bodyshell fixing screw (10) Anti-roll bar (11) Pivot lower ball-joint fixing on lower arm (12) Pivot lower ball-joint fixing (13) Lower arm front and rear mounting fixing (14) Stabiliser bar screw (15) Steering ball-joint fixing : 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 Colour C3 HFX - KFV KFU - NFU - 8HX 8HW - 8HV - 8HY 19 Blue C3 Pluriel KFV - NFU - 8HX 20 Green B3CP07RP 371 AXLES SUSPENSION STEERING Anti-roll bar Diameter (mm) C3 - C3 PLURIEL REAR AXLE Tightening torques (m.daN). (1) Rear axle fixing screw (2) Anti-roll bar (3) Rear axle crossmember (4) Rear suspension arm rubber mounting yoke (5) Rear suspension arm rubber mounting (6) Yoke / suspension arm fixing screw (7) Rear suspension arm (8) Stub axle bearing nut (9) Damper (10) Damper upper fixing (11) Damper lower fixing (12) Suspension spring (13) Travel stop (14) Secondary brake cable guide and its support : 10 ± 1 : : : : : 7,6 ± 0,5 : : 20 ± 2 greased : : 4,5 ± 0,4 : 9,3 ± 1 : : : Anti-roll bar Diameter (mm) C3 AXLES SUSPENSION STEERING C3 Pluriel B3CP0AFP 372 HFX - KFV KFU - NFU - 8HX 8HW - 8HV - 8HY 25,5 (tubular) KFV - NFU - 8HX 26 (tubular) 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 leg pivot (5) Anti-roll bar link rod lower ball-joint (6) Anti-roll bar bearing fixing on subframe (7) Hub nut (8) Wheel bolt (9) Subframe to bodyshell fixing screw (10) Anti-roll bar (11) Pivot lower ball-joint fixing on lower arm (12) Pivot lower ball-joint fixing (13) Lower arm front and rear mounting fixing (14) Stabiliser bar screw (15) Steering ball-joint fixing C3 - C3 PLURIEL 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 374 : 6,5 ± 0,6 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 ± 0,9 : : : Diameter (mm) 25,5 (tubular) 26 (tubular) AXLES SUSPENSION STEERING (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38) 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. 376 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. (6) Supply of electric assistance motor (7) Torque sensor signals 3,2 2,8 38° 32°24’ 32°30’ 28°42’ 377 AXLES SUSPENSION STEERING Electric motor Steering rack travel Steering ratio Number of rotations of steering wheel Inner angle of lock Outer angle of lock HFX - KFV - 8HX - 8HW 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. The electric power steering ECU is linked to the following connectors: - (6) Assistance motor supply. - (13) Electric power steering ECU supply. - (14) Control signals. After changing the electric power steering ECU, it is necessary to perform a configuration (see corresponding operation). 378 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. B3EP13UC Refit: - The steering rack rpotection gaiter - New clips (1) and (2). B3EP13VD 379 AXLES SUSPENSION STEERING Calculate the dimension: L = (Y – X): 2. 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. L2 = Distance between the centre of the wheel and the contact face of the rear mounting on the bodyshell. 380 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 2.0i 16V (RFS) All engines (except 2.0 i 16V and CRD) All CRD engines 2.0i 16V (RFS) All Saloon (except 2.0i 16V and CRD) Estate All CRD engines Reference heights (in mm) 115,5 90,5 75,5 73 83 88 103 381 AXLES SUSPENSION STEERING Front axle 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.C AXLES SUSPENSION STEERING WARNING B3CP04LC A < B = Positive figure: A > B = Negative figure: += –= 382 TOE-IN TOE-OUT 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 2.0i 16V (RFS) Saloon CRD (*) all engine types except KFW Estate CRD (*) all engine types 10°40’ 10°44’ 0° 2°55’ 10°22’ 0°12’ Tolerances Adjustable ± 1,3 mm Tracking Camber ± 15’ YES NO Saloon all engine types Saloon entreprise 2.0i 16V (RFS) Estate all engine types Saloon CRD (*) all engine types Estate CRD (*) all engine types 4,54 ± 1,3 mm 0°41’ ± 11’ 5,1 ± 1,3 mm 0°46’ ± 11’ 4,27 ± 1,3 mm 0°39’ ± 11’ 3,45 ± 1,3 mm 0°31’ ± 10’ - 0°58’ - 0°59’ - 0°57’ (*) CRD = Difficult road conditions. 383 AXLES SUSPENSION STEERING Rear axle XSARA AXLE GEOMETRY a = Angle which defines the tracking between the front and rear axles. Its value must not exceed 12'. AXLES SUSPENSION STEERING B3CP04UC 384 FRONT AXLE XSARA Tightening torques (m.daN). Vehicles RPO 8667 # are all equipped as standard with ventilated discs. B3CP040P B3CP041D 385 : 4,5 ± 0,4 : 2,5 ± 0,3 : 3,7 ± 0,3 : 4,5 ± 0,5 : 5,5 ± 0,5 : 3,7 ± 0,3 : 4 ± 0,4 : 32,5 ± 2,5 :9±1 : 7,6 ± 0,7 : 6,8 ± 0,6 : 3,1 ± 0,3 : 5 ± 0,5 : 8,5 ± 0,8 AXLES SUSPENSION STEERING (1) Damper nut (2) Cup screw (3) Suspension leg (4) Anti-roll bar link rod upper ball-joint (5) Suspension leg pivot (hollow pivot) (5) Suspension leg pivot (pivot «H») (6) Anti-roll bars (7) Anti-roll bar link rod lower ball-joint (8) Pivot lower ball-joint (9) Driveshaft nut (10) Wheel bolt (11) Lower arm front mounting (12) Lower arm rear mounting and anti-roll bar bearing (13) Screw under rear mounting (14) Ball-joint fixing on lower arm Subframe to bodyshell fixing screw 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. AXLES SUSPENSION STEERING B3CP054D 386 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 2.0i 16V (RFS) Saloon 21 White 387 AXLES SUSPENSION STEERING Anti-roll bar XSARA FRONT AXLE Pivot ball-joint: - Manual steering, groove at «b». - Power steering, groove at «b». B3CP043D Tongue «a» towards the front. AXLES SUSPENSION STEERING B3CP049C 388 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. 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 2.0i 16V 3-door VTS 21 Light green 23 Grand Export «CRD» 3- and 5-door TT 19,3 Violet 19 Orange Estates All types 20 Grey 20 Green AXLES SUSPENSION STEERING 390 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. - PAULSTRA, identified by a Black painted dot on the side of the mounting. It is FORBIDDEN to swap components of different suppliers. 391 AXLES SUSPENSION STEERING B3DP04TC XSARA 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 2.0i 16V (RFS) 318 Estates and Entreprise all types 336 AXLES SUSPENSION STEERING E5AP14WC 392 Grand export 342 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. B3EP08PD 393 AXLES SUSPENSION STEERING The locating bush must be centred in the reference window before tightening the cardan bolts (6). 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 : 1.2 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 ball-joint). 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. AXLES SUSPENSION STEERING The locating bush must be centred in the reference window before tightening the cardan bolts (6). B3EP08QD 396 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). 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 - 1.9 TD Protector colour Number of teeth (*) BLACK 7 ORANGE 8 - Length of the steering link rods (Pre-adjustment) = 371 mm (Between ball-joint centres) or 391 mm (Between the centre of the pivot ball-joint and the contact face of the steering rack ball-joint). 398 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. - Tighten to : 2 m.daN. B3EP045D 399 AXLES SUSPENSION STEERING Pressure switch on the pressure circuit. Power-assisted steering system capacity = 1 litre. Oil type: TOTAL FLUIDE ATX. SAGINAW Pump adjustment = 100 Bars ± 5. Pump shaft threading 3/8 - 16 threads per inch. 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. Front height Rear height B3CP05BC B3DP079C B3CP058D H1 = R1 – L1 H1’ = R1 – L1’ H2 = R2 - L2 AXLES SUSPENSION STEERING H1 = From the front suspension arm linkage bolt axis to the ground. R1 = Radius of the front wheel when laden. L1 = From the centre of the wheel to the front suspension arm linkage bolt axis. H1’ = From the front jacking point to the ground. L1’ = From the front jacking point to the radius of the front wheel when laden. H2 = From the rear axle silentblock face to the ground. R2 = Radius of the rear wheel when laden. L2 = From the centre of the wheel to the rear axle silentblock face. 400 AXLE GEOMETRY Checks at reference height XSARA PICASSO (the reference height of the vehicle is set as per the table below). Front axles Rear axle B3CP05AC B3CP05BC B3DP079C NO - CRD Vehicle (CRD = Difficult road conditions) Engines: NFV - 6FZ - RFN - 9HZ - 9HY - RHY Front axles Rear axle H1 = R1 – L1 ou H1’ = R1 – L1’ L1’ = 124 mm L1 = 90,5 mm Value at reference height (-8/+3 mm) H2 = R2 + L2 L2 = 8,5 mm Value at reference height (+10/-3 mm) Compress the suspension to obtain the calculated values. NOTE: The difference in height between the two sides should be less than 10 mm. 401 AXLES SUSPENSION STEERING Measure the radius of the rear wheel: R2. Calculate dimension H2. Measure the radius of the front wheel: R1. Calculate dimension H1 or H1’. XSARA PICASSO AXLE GEOMETRY Checks at reference height (the reference height of the vehicle is set as per the table below). NO - CRD Vehicle (CRD = Difficult road conditions) Front axle Vehicle Tracking Adjustable Yes All types 0 ± 1 mm - 0°09’ at + 0°09’ Castor Rear axle Pivot angle Camber Tracking Camber 4,8 ± 1,3 mm - 0°43’ ± 0°12’ - 1°13’ ± 18’ No 3° ± 18’ 10°43’ ± 30’ 0° ± 30’ AXLES SUSPENSION STEERING WARNING B3CP02UC 402 A < B = Positive figure: += TOE-IN A > B = Negative figure: –= TOE-OUT 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. Compress the suspension to obtain the calculated values. NOTE: The difference in height between the two sides should be less than 10 mm. 403 AXLES SUSPENSION STEERING H1 = R1 – L1 L1 = 75,5 mm XSARA PICASSO AXLE GEOMETRY Checks at reference height (the reference height of the vehicle is set as per the table below). CRD Vehicle (CRD = Difficult road conditions) Engines: NFV - RFN - RHY Front axle Vehicle Tracking Adjustable Yes All types - 1 ± 1 mm - 0°18’ at 0°0’ Castor Rear axle Pivot angle Camber Tracking Camber 3,7 ± 1,3 mm - 0°33’ ± 0°12’ - 1°14’ ± 18’ No 2°56’ ± 18’ 10°25’ ± 30’ 0°07’ ± 30’ AXLES SUSPENSION STEERING WARNING B3CP02UC 404 A < B = Positive figure: += TOE-IN A > B = Negative figure: –= TOE-OUT 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. (9) Hub nut (greased) : 32.5 ± 2 (10) Wheel bolt (face and threads not greased) :9±1 (11) Lower arm front pivot : 7.6 ± 0.7 (12) Lower arm rear pivot and anti-roll bar bearing : 6.8 ± 0.6 (13) Screw under rear pivot : 3.5 ± 0.3 - Lower arm in forged steel : 3.7 ± 0,3 - Lower arm in plate steel : 3.1 ± 0,3 Screw fixing subframe on bodyshell : 8.5 ± 0,8 Screw fixing ball-joint on lower arm (plate steel) : 4.5 ± 0,4 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 ± 0.6 Engine AXLES SUSPENSION STEERING All Types Torsion bar Colour Ø (mm) reference 19,6 PINK Anti-roll bar Ø (mm) Colour reference 21 ORANGE NOTE: The RH torsion bar can be identified by 1 paint line. The LH torsion bar can be identified by 2 paint lines. B3DP078D 406 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 ± 0.2 AXLES SUSPENSION STEERING (2) (3) (5) (6) 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 ± 0.2 (14) Steering ram screw on housing :9±1 (15) Steering ram screw on yoke :9±1 NOTE: When removing the steering, it is imperative to replace screws (14) and (15) (new screws). AXLES SUSPENSION STEERING B3EP117D 408 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. - Between the centre of the pivot ball-joint and the contact face of the steering rack ball-joint = 412 mm. 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. AXLES SUSPENSION STEERING Capacity of power steering circuit = 1 Litre. Oil quality = TOTAL FLUIDE ATX. Power steering pump: Supplier SAGINAW. Pump adjustment = 100 ± 5 Bars. Pump shaft threading 3/8 - 16 threads per inch. B3EP118D 410 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. thickness on same circumference (mm) 0,01 Supplier / Brake pad grade TEXTRR-/-T 4144 Original thickness/minimum thickness 13/3 Original drum/maximum Ø RR mm Width 203/205 38 Supplier / grade DON-/-8259/1 411 BRAKES BRAKE SPECIFICATIONS (WITHOUT ABS) 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 1.4 HDi 22,2 (*) Master vac FT 1.6i 16V LUCAS.TRW C 38 HR 9/13 203/205-/-38 DON 8259/1 (*) = With emergency braking assistance (AFU). 412 203/205-/-38 GALFER G 4554 DON 8259/1 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. B3FP7BSD 413 BRAKES C2 BRAKE SPECIFICATIONS BRAKES C2 BRAKE SPECIFICATIONS Braking circuit with ABS - REF (drum brakes at the rear) B3FP7BTD 414 Braking circuit with ABS - REF (disc brakes at the rear) B3FP7BUD 415 C2 BRAKES BRAKE SPECIFICATIONS 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 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. Rear wheel sensor Hub bearing Observations ABS MK 70 Mounted on the front LH chassis 96 514 120 80 member. ESP -ABS MK.60 4 adjustment channels. 96 490 288 80 Hydraulic block 4 C2 Part no. SNR Hub equipped with a bearing with an integral magnetic wheel (48 pairs of poles). BRAKES BRAKE SPECIFICATIONS (7) Hydraulic block BRAKES BRAKE SPECIFICATIONS C2 Brake pedal Front brakes B3FP166D Rear brakes B3FP164C B3FP165C Tightening torques (m.daN). (16) Servo fixing (17) Fixing on master cylinder : 2,2 ± 0,3 : 2 ± 0,5 (12) Yoke fixing on caliper (13) Yoke fixing on caliper 418 : 10,5 ± 1 : 3 ± 0,3 (14) Rear caliper fixing on arm (15) Yoke fixing on caliper : 5,3 ± 0,5 : 3,8 ± 0,3 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). Pull vigorously on the handbrake lever 4 or 5 times. C5FP0ELD 419 BRAKES HANDBRAKE (Adjustment) 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. With the handbrake released, check the travel of the lever at «a», using a gauge set. NOTE: The travel should be less than 1 mm and more than 0,05 mm. Refit: - The brake drums. - The wheels. - The central console. Check the operation of the handbrake. B3FP16ED 420 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. WARNING: Use only those hydraulic fluids that are approved and recommended. - Fill the brake fluid reservoir (1). B3FP15XC Bleeding the braking system. WARNING: During the bleeding operation, take care to maintain the level of brake fluid in the reservoir and to top it up, using only brake fluid that is clean and clear. 421 BRAKES BLEEDING AND FILLING THE BRAKING SYSTEM 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. B3FP15YC B3FP15ZD 422 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). - Fill if necessary with the approved and recommended synthetic brake fluid. Without the bleeding apparatus. NOTE: Two operators are necessary. For each circuit: - Apply the brake pedal to place the circuit under pressure. - Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container. - Open the bleed screw, wait until the fluid is flowing out without air bubbles. - Close the bleed screw. - Remove the tool [1]. NOTE: Recommence the process a second time if that is necessary. - Check the brake fluid level (should be between «MINI» level and «MAXI» level). - Fill if necessary with the approved and recommended synthetic brake fluid. 423 BRAKES BLEEDING AND FILLING THE BRAKING SYSTEM (Continued) 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. thickness Width 203/205/38 RR Make DON Brake lining grade 8259 Braking compensator (Vehicle without ABS) - (CICR = Compensator integral to the wheel cylinder). - REF = Electronic brakeforce distribution. Supplier/Type/Cut-off pressure (Bar) ➝ RPO 9666 LUCAS LUCAS/CICR/35 Supplier/Type/Cut-off pressure (Bar) RPO 9667 LUCAS ➝ LUCAS/CICR/27 424 1.1i 1.4i 1.4i 16V 1.6i 16V C3 1.4 HDi 1.4 HDi 16V Engine type HFX KFV KFU NFU 8HX 8HW 8HV 8HY Master cylinder 22,2 (*) Ø Master vac 228,6 mm Caliper /piston LUCAS/TRW LUCAS/TRW LUCAS/TRW LUCAS/TRW makes C 48/13 48 C 54/22 54 C 48/13 48 C 54/22 54 Disc Plain 266 266 FT Disc thickness/minimum thickness 13/11 13/11 Ø mm Disc Ventilated 266 266 Disc thickness/minimum thickness 22/20 22/20 Brake pad grade TEXTRR T 4144 Ø Cylinder or caliper LUCAS C38 HR 9/13 mm Disc Plain 247 247 RR Disc thickness/minimum thickness 9/7 9/7 Ø Drum / Max. thickness / mm Width 203/205/38 203/205/38 Make DON GALFER DON GALFER Brake lining grade 8259 G 4554 8259 G 4554 (*) = With emergency braking system. REF = Electronic brakeforce distribution. NOTE: Braking compensators = The compensator and limiter functions for the main brakes are assured by the ABS REF system. 425 BRAKES BRAKE SPECIFICATIONS (WITH ABS REF) 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 1.4 HDi 8HX 22,2 (*) 203,2 228,6 LUCAS/TRW C38 HR 9/13 266 22/20 TEXTRR T 4144 LUCAS/TRW C 38/13 38 247 9/7 203/205/38 DON 8259/1 GALFER G 4554 (*) = With emergency braking system. (CICR = Compensator integral to the wheel cylinder) Braking compensator (Vehicle without ABS) REF = Electronic brakeforce distribution. : LUCAS/CICR/27 Supplier/Type/Cut-off pressure (Bar) Braking compensator (Vehicle with ABS) NOTE: Braking compensators = The compensator and limiter functions for the main brakes are assured by the ABS REF system. 426 203/205/38 DON 8259/1 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. B3FP161D 427 BRAKES BRAKE SPECIFICATIONS BRAKES C3 - C3 PLURIEL BRAKE SPECIFICATIONS Braking circuit with ABS - REF (drum brakes at the rear) B3FP162D 428 Braking circuit with ABS - REF (disc brakes at the rear) B3FP163D 429 C3 - C3 PLURIEL BRAKES BRAKE SPECIFICATIONS 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 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. ABS MK 70 : 96 419 653 80 TEVES ESP - ABS MK 60 : 96 418 772 80 Observations Installed on the front LH chassis member: 4 adjustment channels BRAKES BRAKE SPECIFICATIONS C3 BRAKES BRAKE SPECIFICATIONS C3 - C3 PLURIEL Brake pedal gear Front brakes B3FP166D Rear brakes B3FP164C B3FP165C Tightening torques (m.daN). (16) Servo fixing (17) Fixing on master cylinder : 2,2 ± 0,3 : 2 ± 0,5 (12) Yoke fixing on caliper (13) Yoke fixing on caliper 432 : 10,5 ± 1 : 3 ± 0,3 (14) Rear caliper fixing on arm (15) Yoke fixing on caliper : 5,3 ± 0,5 : 2,7 ± 0,5 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. Replacement Parts will market only the components for the new assembly. 433 C3 - C3 PLURIEL BRAKES BRAKE SPECIFICATIONS 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. Press gently on the brake pedal (Then repeat the operation 3 times). Pull vigorously on the handbrake lever 4 or 5 times. C5FP0ELD 434 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. With the handbrake released, check the travel of the lever at «a», using a gauge set. NOTE: The travel should be less than 1 mm and more than 0,05 mm. Refit: - The brake drums. - The wheels. - The central console. Check the operation of the handbrake. B3FP16ED 435 BRAKES HANDBRAKE (Adjustment) 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). Reconnect the connector (4). Filling the braking system. WARNING: Use only those hydraulic fluids that are approved and recommended. - Fill the brake fluid reservoir (1). Bleeding the braking system. WARNING: During the bleeding operation, take care to maintain the level of brake fluid in the reservoir and to top it up, using only brake fluid that is clean and clear. B3FP15XC 436 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 B3FP15YC B3FP15ZD 437 C3 - C3 PLURIEL BRAKES BLEEDING AND FILLING THE BRAKING SYSTEM (Continued) 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]. - Check the brake fluid level (should be between «MINI» level and «MAXI» level). - Fill if necessary with the approved and recommended synthetic brake fluid. Without the bleeding apparatus. NOTE: Two operators are necessary. For each circuit: B3FP160C - Apply the brake pedal to place the circuit under pressure. - Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container. - Open the bleed screw, wait until the fluid is flowing out without air bubbles. - Close the bleed screw. - Remove the tool [1]. NOTE: Recommence the process a second time if that is necessary. - Check the brake fluid level (should be between «MINI» level and «MAXI» level). - Fill if necessary with the approved and recommended synthetic brake fluid. 438 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 1.9 D 247 247 8/6 8/6 Make BENDIX JURID TEXTRR BENDIX Brake lining grade D 8259 519 428 D 8259 JURID E 558 BOSCH/Load-sensitive compensator 32 0,3 - White Make/Type Cut-off pressure in Bars Ramp/Paint reference 439 519 BRAKES BRAKE SPECIFICATIONS 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. thickness 228 / 230 247 247 8/6 8/6 JURID Make Brake lining grade RHZ Ftec ABS 23,8 (valve) Caliper/piston makes Brake pad grade RR 2.0 HDi E 558 519 E 558 BOSCH/Load-sensitive compensator Make/Type 32 Cut-off pressure in Bars Ramp/Paint reference 0,3 - White 440 519 XSARA - Tighten the nuts (1) to 2.3 m.daN. - The clevis pin (2) is held in place by a plastic clip. B3FP10YD 441 BRAKES BRAKE SPECIFICATIONS 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). B3FP09HC B3FP09JC 442 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 BRAKES XSARA BRAKE SPECIFICATIONS Braking system with ABS (rear drum brakes) B3FP14HD 444 Braking system with ABS REF (rear disc brakes) XSARA Braking system with ABS REF (rear drum brakes) B3FP14JD B3FP14KD 445 BRAKES BRAKE SPECIFICATIONS BRAKES XSARA BRAKE SPECIFICATIONS Braking system with ABS REF (rear drum brakes) B3FP14LD 446 XSARA Braking circuit with ESP (BOSCH 5.7) (A) Hydraulic circuit (B) Electrical circuit (1) Master cylinder in tandem (2) Braking servo (3) Brake caliper (or drum at the rear) (4) Toothed wheel (5) Wheel sensor (6) Brake fluid level sensor (7) Hydraulic block plus ECU (8) Stoplamp switch (9) Instrument panel (10) Diagnostic socket (11) Built-in systems interface (BSI) (12) Steering angle sensor (13) Gyrometer/accelerometer sensor (14) Switch B3HP004P 447 BRAKES BRAKE SPECIFICATIONS 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.. Changing only the ECU is prohibited. 2-way grey connector. The sensors are inductive-type. Tightening torque: 0,8 ± 0,2 m.daN. 2-way grey connector. The sensors are inductive-type. Mounted on the brake caliper support. Non-adjustable airgap: 0,3 to 1,2 mm. Tightening torque: 0,8 ± 0,2 m.daN. 2-way grey connector. The sensors are inductive-type. Mounted on the suspension arm. Non-adjustable airgap: 0,3 to 1,2 mm. Tightening torque: 0,8 ± 0,2 m.daN. Incorporated in the COM 2000. 6-way blue connector. Located on the central console. 6-way connector. Toothed wheel: 48 teeth. Integral with the driveshaft stub housing for the front wheels, joined to the hub bearing for the rear wheels. 448 (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. Tightening torque (15) : 0,6 ± 0,1 m.daN. BRAKES BRAKE SPECIFICATIONS 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. - Check that the wheels can be turned freely by hand with the handbrake released. - Lower the vehicle. - Refit the handbrake console. B3FP095D 450 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. 451 XSARA BRAKES BLEEDING THE BRAKES 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 2.0 HDi RFN RHY 6FZ 23,8 254/34 LUCAS C54/54 BOSCH ZOH54/54 266 20,4/18,4 JURID/3724 22/20 FERODO/769 (37) LUCAS/ENERGIT/C52980 22,2 228,6/230 ABEX 4930/2 TEVESITTA (load-sensitive rear braking compensator) 20/61,6 (*) ESP + Electronic Stability Program 452 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 2.0 HDi 9HY 254/35 BOSCH ZOH54/54 283 26/24 FERODO/769 (37) TRW C38 247 9/7 GALFER G 4554 On versions with ABS, there is no load-sensitive rear braking compensator. (*) ESP = Electronic Stability Program. 453 RHY BRAKES BRAKE SPECIFICATIONS BRAKES XSARA PICASSO BRAKING SYSTEM SPECIFICATIONS Without ABS B3FP7B9D 454 With ABS XSARA PICASSO With EPS (Electronic Stability Program) B3FP7B9D B3FP7BRD 455 BRAKES BRAKING SYSTEM SPECIFICATIONS 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). B3FP09HC B3FP08ND 456 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. With the handbrake released, check that the wheels can be turned freely by hand. Lower the vehicle. Refit the sound-deadening (2) and the handbrake trim (1). B3FP11XD 457 BRAKES HANDBRAKE (Adjustment) 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. Reconnect the brake fluid warning lamp connector. Filling. Refill the reservoir with brake fluid. WARNING: Use only the recommended hydraulic fluids. Bleeding. NOTE: Two technicians are required. IMPERATIVE: During bleed operations, ensure that the level of brake fluid is maintained in the reservoir and top it up, use only new brake fluid. Bleed each wheel cylinder, proceeding in the following order: Rear right hand wheel. Front left hand wheel. Rear left hand wheel. Front right hand wheel. 458 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. 459 ELECTRICAL SYSTEM Coding of climates is as follows: 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 11.5 Nm I ≤ 275 A I ≤ 300 A I ≤ 430 A I ≤ 470 A I ≤ 500 A Maximum power for a speed of 1200 rpm 460 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 1.1i 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 1.4 HDi M-MAP 5 F GF 462 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 1.4i Réfri M-MP 463 3 Climate C T F GF C T F GF C T F GF C T F GF C T F GF ELECTRICAL SYSTEM Vehicles/models C3 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 1.4 HDi 16V M C T 5 F GF 464 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 1.4i Climate 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 1.4i Réfri + DA C T 3 F GF 466 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 2.0i 16V F GF 3 A C T 4 F GF 467 ELECTRICAL SYSTEM M 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 2.0 HDi C T 6 F GF 468 STARTER MOTORS Gearboxes Class 5 2.0 HDi M Climate C T 6 F GF 6 XSARA A C T 6+ F GF 4 1.4 HDi M C T 5 F GF 469 ELECTRICAL SYSTEM Vehicles/models XSARA 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 1.8i 16V 3 T 4 GF F 470 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 2.0 HDi C T 6 F GF 471 ELECTRICAL SYSTEM Vehicles/models XSARA PICASSO 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. : Double lug. : 3-Point. : Not marketed. : All Types. : Level. : Without Option. : All Options. : Heated rear screen. : Left hand drive. : Right hand drive. 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. 7 9 7 7 7 7 7 8 8 ELECTRICAL SYSTEM Allocation of alternator classes 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. 474 8 9 9 8 8 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. 475 9 ELECTRICAL SYSTEM C3 - C3 PLURIEL ALTERNATORS 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. 476 12 8 12 8 12 8 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. 477 8 9 9 8 9 9 ELECTRICAL SYSTEM Allocation of alternator classes Without aircon With cold pack Without cold pack 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. 478 RT2 With cold pack Base RT2 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. + Heated seat ELECTRICAL SYSTEM Without aircon 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. Reminder: The excitation energising current will flow through the warning lamp; check that the warning lamp comes on when the ignition is switched on. It should go out when the engine has started (accelerate slightly). Checking the voltage regulator. D1AP025C A : Ammeter. B : Battery. G : Generator. L : Warning lamp. K1 and K2 : Switch. R : Electric charge. S : Shunt 200mV/200A. V : Voltmeter. 1 : Alternator. Set the rheostat to zero and disconnect all the electrical consumers. Display 3000 alternator rpm. If U alternator is > 14.7 V, the regulator is faulty. Note: These tests should be performed with the engine hot and the battery fully charged. Method of reading the alternator speed. Fit a reflecting shim on the pulley of the alternator. Adjust a stroboscope to the frequency equivalent to the control speed. (e.g. 2000 rpm = 2000/60 = 83 Hz). Adjust the engine speed so that the shim appears fixed. 480 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 78.5 80 82 9 61 68 84 92 96 97 97 12 73 80 100 110 120 123 124 15 89 105 139 145 151 157 157 18 108 123 164 176 183 188 188 12 58 55 52 50 48 45 34 15 60 57 54 52 50 48 38 18 61 60 56 53 50 48 38 MINIMUM YIELDS (in %) Alternator speed 1800 rpm 2000 rpm 3000 rpm 4000 rpm 6000 rpm 8000 rpm 15000 rpm Class 6 49 48 45 43 39 26 24 7 50 49 46 44 40 37 25 8 52 51 48 46 42 39 27 481 9 57 54 51 48 43 40 29 ELECTRICAL SYSTEM Alternator speed 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. CARTIER 735068 NAGARES 960411-P NAGARES 960411-P BERU 0 100 226 371 CARTIER 735068 CHAMPION CH 185 NAGARES 960411-P NGK YE04 NAGARES 960411-P 10s / 150s CARTIER 735068 CARTIER 735068 CHAMPION CH170 NAGARES 960411-P CARTIER 735068 CHAMPION CH 170 NAGARES 960411-P CHAMPION CH 170 CARTIER 735068 NAGARES 960411-P 482 Controlled by the diesel injection ECU. 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 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. Ø Pipes Steel/Steel Aluminium/Steel M 06 1,7 ± 0,3 1,3 ± 0,3 M 08 3,8 ± 0,3 2 ± 0,2 M 10 4 ± 0,3 NOTE: Tighten the union to the recommended torque using a retaining spanner whenever possible. NOTE: For operations concerning draining, drying (empty), checking and recharging of a system: refer to BRE 0290. WARNING: For R 134.a quantities (see table on preceding page: 483). 484 2,5 ± 0,3 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. XSARA PICASSO engine versions : 6FZ and RHY Discontinuation of compressor SD 6 V 12 Replaced by compressor SD 7 V 16 : 04/11/2002 # Compressor (MANULLI seal) AIRCON «EUROCLIM» C2 - C3 - XSARA PICASSO C5HP18UD The drive plate (1) is held on the aircon compressor shaft by ribs. New wiring (2). New seals (3) (MANULLI). Identification label (4) for aircon compressor. 485 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). Before fitting the seal, amply lubricate the seal with air conditioning compressor oil (SP10). 486 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Presence of pollen filter Vehicle SAXO Equipment RPO No. YES YES (Behr) Without aircon Base aircon YES (Larger) Regulated aircon YES (Valéo) Without aircon NO (Valéo) Base aircon YES (Valéo) Except driving school AIRCON BERLINGO Observations NO ALL TYPES C2 - C3 XSARA XSARA PICASSO Presence of filter 487 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. C4AP1BRC C4AP1BSC C4AP1BTC 488 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. C4AP169C C4AP16AC C4AP16BC 489 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. Unclip the condenser at «b» and «c», using a screwdriver. Tilt the condenser towards the front. Lift and release the condenser. Clean the area around the cap (3). Remove the plastic cap (3), using tool [2]. Remove the safety circlip (4), using tool [6]. Position the tool [3] and [4] in the aperture of the cartridge (5). Extract the cartridge from the reservoir (6), using tool [3] and [4]. Block the reservoir (6), using tool [5]. C4AP163C C4AP165C C4AP164C 490 C4AP166C 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. WARNING: Not more than 5 minutes should elapse between the removal of the cartridge (6) from its packaging and its being fitted. AIRCON Refit: - The plastic cap (3), using tool [5] - Tighten to 1,2 ± 0,1 m.daN. - The condenser (reclip, pushing at «b» and «c»). - The plastic cover and the pins at «a». - The grille (2). - The screws (1). Proceed to: - Recharge the circuit (see corresponding operation). - Check the operation of the air conditioning (see corresponding operation). C4AP167C C4AP165C C4AP163C 491 C4AP164C 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»). - Position the index (4) on the cover forward of the pollen filter ((4) Index on the cover). C5FP075D 492 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. B1BP23ED 493 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). - The brackets (5). B1BP23FC B1BP23GC 494 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. C5HP14NC C5HP14PC AIRCON Refit: - The plug (6), using tool [2], tighten to 1,4 ± 0,2 m.daN. - The brackets (5). - The screws (4). - The cardboard from the radiator harness. - The nuts (1). - The air filter assembly (3). Couple the hose (2). Recharge the circuit (R134.a) (according to equipment) (see corresponding operation). Check the operation of the air conditioning. C5HP14QC 495 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. - No more oil should be added when filling the system with R 134.a fluid. b) Using draining/filling equipment fitted with an oil decanter. - Drain the R 134.a fluid from the system in accordance with the instructions in the equipment handbook. - Measure the amount of oil recovered. - Add the same amount of NEW oil when filling the system with R 134.a fluid. c) Replacing a compressor. - Remove the old compressor, drain it and measure the oil quantity. - Drain the new compressor (supplied full), so that the same amount of NEW oil is left in the compressor as was in the old compressor. - No more oil should be added when filling the system with R 134.a fluid. 496 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). Either before or during filling of the system with R 134.a fluid, introduce 80 cc of NEW oil into the system. 497 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. When all these conditions are met, proceed in the following order: - Measure the temperature in the workshop approx. one metre in front of the vehicle’s air inlet grille. - Start the engine (without the air conditioning, or the blower, operating) and wait for the cooling fan slow speed to trigger (should the engine temperature not rise sufficiently, it is permissable to increase the engine speed to 2000 rpm). - Once it is sufficiently hot in the engine compartment, return the engine to idle and commence the test. 498 Switch on the air conditioning and adjust the engine speed to 2500 rpm. In an ambient temperature of 40°C, the engine speed will be brought down to 2000 rpm, in order for the pressure safety threshold to cut off the compressor. For further temperatures/pressures: see Tables and Graphs on following pages 221, 222 and 226. After 3 minutes of operation, note down the following 3 parameters: - The temperature of the blown air coming out of the 2 central air vents (take the average). - The high pressure, via the intermediary of the clickfit union (at the pressure reducer inlet). - The low pressure, via the intermediary of the clickfit union (at the pressure reducer outlet). NOTE: The low and high pressures are absolute pressures. When measuring the blown air temperatures, avoid any contact between the thermocouple and the air vents. At the conclusion of the test involving vehicles with «RFTA», do not forget to reconnect the air inlet motor connector. 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 ± 3 Ambient temperature in °C Temperature at the central air vents in °C Vehicle Engines C3 C3 Pluriel XSARA XSARA PICASSO 499 8±2 AIRCON Vehicle using R134.a fluid (Compressor with variable capacity) 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. three minutes, record the following parameters: Vehicle using R134.a fluid (Compressor with variable capacity) 40 35 30 25 20 15 Ambient temperature in °C Engines Vehicles High pressure (Bars) 26 ± 2 23,2 ± 2 21 ± 2 19,2 ± 2 15,3 ± 2 15 ± 2 KFV C3 4,3 ± 2 3,4 ± 2 3,1 ± 2 2,8 ± 2 2,7 ± 2 Low pressure (Bars) 25,2 ± 2 23,6 ± 2 21,4 ± 2 20 ± 2 17,6 ± 2 14,5 ± 2 High pressure (Bars) NFU 3,5 ± 2 3±2 2,8 ± 2 2,5 ± 2 2,4 ± 2 Low pressure (Bars) C3 26,2 ± 2 23,2 ± 2 21 ± 2 19,2 ± 2 15,3 ± 2 15 ± 2 High pressure (Bars) C3 Pluriel 8HX - 8HW 4,3 ± 2 3,4 ± 2 3,1 ± 2 2,8 ± 2 2,7 ± 2 Low pressure (Bars) 500 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. three minutes, record the following parameters: Vehicle using R134.a fluid (Compressor with variable capacity) 40 Ambient temperature in °C High pressure (Bars) Low pressure (Bars) High pressure (Bars) Low pressure (Bars) High pressure (Bars) Low pressure (Bars) High pressure (Bars) Low pressure (Bars) High pressure (Bars) Low pressure (Bars) TU XSARA EW DW XSARA PICASSO 35 30 25 20 15 Engines TU EW DW 23 ± 2 22,5 ± 2 3,8 ± 0,2 3,6 ± 0,2 24,5 ± 2 4 ± 0,2 3,8 ± 0,2 21,5 ± 2 22,5 ± 2 3,2 ± 0,2 3,3 ± 0,2 25,5 ± 3 20,5 ± 3 4 ± 0,3 3,5 ± 0,3 25 ± 3 22,5 ± 3 4 ± 0,3 3,5 ± 0,3 501 20 ± 2 3,5 ± 0,2 21,5 ± 2 3,5 ± 0,2 20 ± 2 3 ± 0,2 18 ± 3 17 ± 2 15,5 ± 2 14,5 ± 2 3,1 ± 0,2 3 ± 0,2 2,9 ± 0,2 18,5 ± 2 17 ± 2 15,5 ± 2 3,2 ± 0,2 3 ± 0,2 18 ± 2 16,5 ± 2 15,6 ± 2 2,8 ± 0,2 2,6 ± 0,2 20 ± 3 13,5 ± 3 11 ± 3 3 ± 0,3 20 ± 3 17 ± 3 15 ± 3 3 ± 0,3 AIRCON Vehicles C2 AIR CONDITIONING SYSTEM R 134.a (1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Filter. Tightening torques (m.daN). AIRCON (a) (b) (c) (d) (e) (f) C5HP19UP 502 : 0,6 : 0,6 : 0,6 : 0,6 : 0,6 : 0,7 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). 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. C5HP1A5D 504 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). 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. C5HP1A8D 506 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). 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. C5HP17WP 508 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. 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. C5HP16VP 510 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. 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. C5HP16TP 512 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. 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. C5HP16UP 514 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). 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.± 0,1 : 1,4 ± 0,2 HP/LP compressor flange fixing : 2,5 ± 0,25 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). 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.± 0,1 : 1,4 ± 0,2 HP/LP compressor flange fixing : 4,2 ± 0,15 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).
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