Transcript
PRIVATE CARS
PRIVATE CARS
AC.QCAV/MTD Méthodes Techniques Documentation
’’The intellectual property rights relating to the technical information contained in this document belong exclusively to the manufacturer. Reproduction, translation or distribution in whole or in part without prior written authorisation from the manufacturer is forbidden.‘‘
2001
SAXO-XSARA-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 050008 Book 1
2001
PRESENTATION THIS HANDBOOK summarises the characteristics, adjustments, checks and special features of CITROEN vehicles, not including COMMERCIAL 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 : SAXO - XSARA – XSARA PICASSO - BERLINGO and all models where applicable. The information given in this handbook is based on vehicles marketed in EUROPE.
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.
INDEX GENERAL Identification of vehicles
Capacities
Saxo Xsara 9/2000 Xsara 09/2000 Xsara Picasso Berlingo Saxo Xsara 9/2000 Xsara 09/2000 Xsara Picasso Berlingo
Lubricants ENGINE Specifications Cylinder head marking, tightening Auxiliary drive belt Checking, setting valve timing Valve clearances Checking oil pressure Oil filter INJECTION Idling, anti-pollution Petrol injection
1-8 9 - 24 25 - 31 32 - 33 34 - 37 39 40 41 42 43 44 - 58 59 - 62 66 - 77 78 - 102 103 - 104 140 141 144 146 - 149 150 - 157
LPG safety requirements HDi safety requirements Checking the HDi fuel circuit Checking the HDi air circuit Checking turbo pressure Checking the HDi recycling circuit Checking, setting DELPHI injection Checking, setting BOSCH injection
166 - 170 171 - 174 175 - 176 177 178 - 179 180 181 - 195 196 - 205
IGNITION Sparking plugs
206
CLUTCH-GEARBOX-TRANSMISSION Speedometer 207 Checking, adjusting the clutch 211 - 216 Driveshafts 250 AXLES-SUSPENSION-STEERING Saxo Axle geometry Xsara TT Xsara Picasso
251 - 258 263 - 267 292 - 293
BRAKES Brake specifications
Saxo Xsara Xsara Picasso
298 - 299 304 - 306 321
Saxo Xsara Xsara Picasso
Handbrake Bleed brakes Handbrake Bleed brakes Handbrake Bleed brakes
302 303 319 302 330 331
ELECTRICAL Starters Alternators Charging circuit Preheater plugs
332 - 340 341 - 354 355 356 - 357
AIR CONDITIONING Quantity in R 134.a Special features Checking temperatures Checking pressures Saxo Air conditioning Xsara 09/2000 Xsara 09/2000 circuit Xsara Picasso
359 367 369 371 375 382 386
-
358 366 368 370 374 381 385 390
E1AP07CD
1
SAXO - All Types
1
Engine legislation type
2
RP organisation no.
3
Chassis stamp
4
Manufacturer's name plate
5
01/02/99 # Label : - Tyre pressures. - RP organisation no. - Paint code.
6
Paint code.
7
Gearbox ident. reference
GENERAL
IDENTIFICATION OF VEHICLES
SAXO - All Types
IDENTIFICATION OF VEHICLES 3-DOOR PETROL SALOONS 1.0 i
1.4 i
1.1 i AUTO.
A-X Administration GENERAL
SO CDZF
IF/L4
SO HDZF/GL (1)
SO KFXD
S6 KFXB/IF
Engine type
CDZ
HDZ
KFX
Cubic capacity (cc)
954
1124
1360
Fiscal rating (hp) Gearbox type Gearbox ident. plate
SX VTS
VTS
L3
Emission standard Type code
SX Exclusive
A-X
SO KFXB/IF
4
6
5
MA/5
MB3
MA/5
20 CE 81 (2) 20 CF 03 (3)
312
(1) = LPG. (2) = # 28/08/2000. (3) = 29/08/2000 #
2
20 CE 95 (2) 20 CF 12 (3)
20 CE73 (2) 20 CF 02 (3)
IDENTIFICATION OF VEHICLES
SAXO - All Types
3-DOOR PETROL SALOONS 1.6 i
3-DOOR DIESEL SALOONS
1.6 i 16 V
VTS
VTS
S6 NFZF
S6 NFXF
SO VJZF
SO VJYF
NFZ
NFX
VJZ (1)
VJY (2)
1587
Cubic capacity (cc) Fiscal rating (hp)
6
1527 8
4 MA/5
Gearbox type Gearbox ident. plate
S - SX
20 CD 60 (3) 20 CN 05 (4)
20 CD 46 (3) 20 CN 03 (4)
(1) = With EGR (2) = Catalytic converter with EGR (3) = # 28/08/2000. (4) = 29/08/2000 # NOTE : EGR = Exhaust Gas Recycling device. 3
20 CE 73 (3) 20 CF 02 (4)
GENERAL
Engine type
A-X-SX Exclusive Administration L3
Emission standard Type code
1.5 D
SAXO - All Types
IDENTIFICATION OF VEHICLES 5-DOOR PETROL SALOONS 1.0 i (1) A-X Administration
(2) A-SX Driving School
AUTO. SX
SX - Exclusive
L3
Emission standard
GENERAL
Type code
1.4 i
1.1 i
S1 CDZF
S1 HDZF/GL (3)
IF/L4 S1 KFXD
S1 KFXB/IF
Engine type
CDZ
HDZ
KFX
Cubic capacity (cc)
954
1124
1360
Fiscal rating (hp) Gearbox type Gearbox ident. plate
(1) (2) (3) (4) (5)
= = = = =
4
6
5
MA/5
MB3
MA/5
20 CE 81 (4) 20 CF 03 (5)
312
20 CE 73 (4) 20 CF 02 (5)
Cylindrical tank Ring-shaped tank. LPG. # 28/08/2000 29/08/2000 # 4
IDENTIFICATION OF VEHICLES
SAXO - All Types
5-DOOR DIESEL SALOONS 1.5 D
A-X-SX-Exclusive
Driving School
S1 VJZF (1)
Engine type
S1 VJZF/MOD (2) VJZ
VJY 1527
Cubic capacity (cc)
4
Fiscal rating (hp)
MA/5
Gearbox type Gearbox ident. plate
S1 VJYF (3)
20 CE 73 (a)
(1) = With EGR (2) MOD = Modifiable. (3) = Catalytic converter (a) = # 28/08/2000. (b) =.29/08/2000 # NOTE : EGR = Exhaust Gas Recycling device. 5
20 CF 02 (b)
GENERAL
L3
Emission standard Type code
A-X-SX-Exclusive Administration
SAXO - All Types
IDENTIFICATION OF VEHICLES Commercial version Entreprise 3 door Petrol
Diesel
1.0 i
1.1 i
1.5D
A-X-Poste Administration
A
A-X-Poste Administration
L3
Emission standard
GENERAL
Type code
SO CDZF/T (1)
SO HDZF /T.MOD.GL (3)
S3 CDZF (2)
SO VJZF/T (1)
S3 VJZF (2)
Engine type
CDZ
HDZ
VJZ
Cubic capacity (cc)
954
1124
1527
5
6
6
Fiscal rating (hp)
MA/5
Gearbox type Gearbox ident. plate
(1) (2) (3) (4) (5)
20 CE 81 (4) 20 CF 03 (5)
20 CE 73 (4) 20 CF 02 (5)
= Can be converted. = Non-convertible van. /T.MOD.GL = Convertible to LPG. = # 28/08/2000. = 29/08/2000 # 6
IDENTIFICATION OF VEHICLES
SAXO - All Types
3-DOOR SALOONS Petrol 1.1i A-X-SX Exclusive Administration
1.4i
1.6i SX – Exclusive VTS
VTS
S6 KFWB
SO KFWB
HFX
KFW
Cubic capacity (cc)
1124
1360
VTS
VTS
S6 NFTB
S6 NFXB
SO VJXB
4
5
NFT
NFX 1587
6
VJX 1527
8
4
MA/5
Gearbox type Gearbox ident. plate
1.5 D A-X-SX Exclusive Administration
20 CF 03 (1) 20 CF 02 (2)
20 CE 95 (1) 20 CF 12 (2)
20 CF 03
(1) = # 02/05/2000 (2) = 03/05/2000 #
7
20 CD 46 (1) 20 CN 03 (2)
20 CE 73 (1) 20 CF 02 (2)
GENERAL
SO HFXB
Engine type
Fiscal rating (hp)
1.6i 16V
L4
Emission standard Type code
Diesel
SAXO - All Types
IDENTIFICATION OF VEHICLES COMMERCIAL VERSION ENTREPRISE 3 DOOR
GENERAL
Emission standard Type code
Petrol
Diesel
1.1i (1) A-S-SX Poste Administration
1.5 D (1) A-S-SX Poste Administration
L4
L4
S3 HFXB
S3 VJXB
Engine type
HFX
VJX
Cubic capacity (cc)
1124
1527
Fiscal rating (hp) Gearbox type Gearbox ident. plate
6
6
MA/5
MA/5
20 CE 81 (1) 20 CF 03 (2)
20 CE 73 (1) 20 CF 02 (2)
(1) = Non-convertible van (2) = # 28/08/2000 (3) = 29/08/2000 # 8
IDENTIFICATION OF VEHICLES
XSARA - All Types # 09/2000
1 Manufacturer’s name plate (Estate).
3 Manufacturer’s name plate (Saloon).. 4 01/02/1999 # Label : - Tyre pressures. - RP organisation no. - Paint code. 5 Gearbox ident. reference
6 Engine legislation type
E1AP08MD
9
GENERAL
2 Chassis stamp
IDENTIFICATION OF VEHICLES
XSARA - All Types # 09/2000
3-DOOR PETROL SALOONS 1.4i
1.6i AUTO.
Dual fuel
Emission standard
GENERAL
Type code
X - X Pack
A - X - X Pack SX - VTR
X - X Pack SX
K'
L3
IF L4
NO KFXG
NO KFXF
NO KFXB
X - SX
X - X Pack SX - VTR
X - X Pack SX - Exclusive
L3 NO KXF/GL (1)
NO NFZF
NO NFZM
Engine type
KFX
NFZ
Cubic capacity (cc)
1360
1587
Fiscal rating (hp) Gearbox type Gearbox ident. plate
5
6
MA/5
MA/5
AL4
20 CE 42 (*)
20 CD 29
20 TP 22
(*) = Differential diameter 68 mm. (1) GL = LPG (Liquid Petroleum Gas) with ring-shaped tank.
10
IDENTIFICATION OF VEHICLES
XSARA - All Types # 09/2000 3-DOOR PETROL SALOONS
1.8i
X - X Pack SX - VTR
1.8i 16V
X Pack - SX Exclusive
VTR - VTS
Emission standard
Engine type
NO LFXF
NO LFYF
LFX
N6 LFYF
N6 RFSF
LFY
N6 RFSY RFS
1761 6
1998 7
11 BE3/5
Gearbox type Gearbox ident. plate
Brazil
L3
Cubic capacity (cc) Fiscal rating (hp)
VTS
20 TB 91
20 TB 62
11
20 TB 92
20 TB 93
GENERAL
Type code
2.0i 16V
XSARA - All Types # 09/2000
IDENTIFICATION OF VEHICLES 3-DOOR DIESEL SALOONS
1.9 D
X - X Pack VTR
1.9 TD
X - X Pack SX - VTR Exclusive
X - X Pack SX
VTS
X - X Pack SX
VTR - VTS
GENERAL
L3
Emission standard Type code
2.0 HDi (1)
NO WJZF
NO DHYF
L4
N6 DHYF
NO RHYF
N6 RHYF
NO RHYB
Engine type
WJZ
DHY
RHY
Cubic capacity (cc)
1868
1905
1997
5
6
5
20 TB 38
20 TB 59
Fiscal rating (hp)
BE3/5
Gearbox type Gearbox ident. plate
VTR - VTS
20 TB 51
(1) = High pressure Diesel injection
12
N6 RHYB
IDENTIFICATION OF VEHICLES
XSARA - All Types # 09/2000
3-DOOR SALOON VERSIONS - ALL TYPES Petrol
Diesel
1.4i
1.9 D Dual fuel X Entreprise SX L3
Emission standard Type code
NO KFXF/T (1)
NO KFXF/T MOD GL (2)
Engine type
KFX
Cubic capacity (cc)
1360
NO WJZF/T (1)
N3 WJZF WJZ 1868
5
Fiscal rating (hp)
MA/5
Gearbox type Gearbox ident. plate
X Entreprise
20 CE 42
20 TB 38
(1) /T = The vehicle can be converted back into a private vehicle. (2) /T MOD GL : /T = The vehicle can be converted back into a private vehicle. MOD = Modifiable. GL = LPG (Liquid Petroleum Gas) with ring-shaped tank. 13
GENERAL
X Entreprise
IDENTIFICATION OF VEHICLES
XSARA - All Types # 09/2000
5-DOOR PETROL SALOONS 1.6i
1.4 i Dual fuel A-X X Pack
X - X Pack SX
X-SX
X Pack
K'
L3
L4
L3
K'
N1 KFXG
N1 KFXF
N1 KFXB
N1 KFXF/GL (1)
Emission standard
GENERAL
Type code
AUTO.
A-X X Pack - SX Exclusive
N1 NFZG
N1 NFZU
Engine type
KFX
NFZ
Cubic capacity (cc)
1360
1587
Fiscal rating (hp) Gearbox type Gearbox ident. plate
5
6
MA/5
MA/5
AL4
20 CE 42 (1)
20 CE 29
20 TP 22
(1) = Differential diameter 68 mm.
14
IDENTIFICATION OF VEHICLES
XSARA - All Types # 09/2000
5-DOOR PETROL SALOONS 1.6i
1.8i 16V
1.8i AUTO.
X - X Pack - SX Exclusive
X - X Pack - SX Exclusive
Emission standard
L3 N1 NFZF
N1 NFZM
Engine type
NFZ
Cubic capacity (cc)
1587
Gearbox ident. plate
N1 LFXF
N1 LFYF
LFX
N7 LFYF LFY
1761 6
Fiscal rating (hp) Gearbox type
VTS
MA/5
AL4
20 CD 29
20 TP 22
7 BE3/5 20 TB 91
15
20 TB 84
GENERAL
Type code
X - X pack - SX Exclusive
IDENTIFICATION OF VEHICLES
XSARA - All Types # 09/2000
5-DOOR PETROL SALOONS 1.8i 16V
2.0i 16V Dual fuel
Brazil
AUTO. X - X Pack Exclusive
X - SX L3
Emission standard
GENERAL
Type code
N1 LFYY
N1 LFYF/GL (1)
Engine type
LFY
Cubic capacity (cc)
1761
N1 RFVF
9
BE3/5 20 TD 05
N1 RFVY
1998 7
Gearbox type
N1 RFVB RFV
Fiscal rating (hp)
Gearbox ident. plate
Brazil
20 TB 84
(1) GL = LPG (Liquid Petroleum Gas) with ring-shaped tank.
16
BE3/5
4HP20
BE3/5
20 TB 39
20 GZ 9F
20 TB 39
IDENTIFICATION OF VEHICLES
XSARA - All Types # 09/2000 5-DOOR DIESEL SALOONS
SX
2.0 HDi
X - X Pack - SX Exclusive
X - X Pack SX L3
Emission standard Type code
1.9D
N1 VJZF
L4
N1 WJZF
N1 RHYF
N1 RHYB
Engine type
VJZ
WJZ
RHY
Cubic capacity (cc)
1527
1868
1997
4
5
5
Fiscal rating (hp) Gearbox type Gearbox ident. plate
MA/5 20 CE 46 (*)
BE3/5 20 TB 38
(*) = Differential diameter 68 mm.
17
20 TB 51
GENERAL
1.5 D
XSARA - All Types # 09/2000
IDENTIFICATION OF VEHICLES 5-DOOR SALOON VERSIONS – ALL TYPES Petrol 1.4i
X Police Unmarked X Police Marked
Diesel 1.8i X Police Marked X Gendarmerie
X Police Marked
X Administration
L3
Emission standard
GENERAL
Type code
1.9 D
N1 KFXF
N1 LFXF
N1 WJZF
N1 WJZC
Engine type
KFX
LFX
WJZ
Cubic capacity (cc)
1360
1761
1868
5
6
5
Fiscal rating (hp) Gearbox type Gearbox ident. plate
MA/5
BE3/5
BE3/5
20 CE 42
20 TB 22
20 TB 38
(1) /T = The vehicle can be converted back into a private vehicle. (2) /T MOD GL : /T = The vehicle can be converted back into a private vehicle MOD = Modifiable. GL = LPG (Liquid Petroleum Gas) with ring-shaped tank. 18
IDENTIFICATION OF VEHICLES
XSARA - All Types # 09/2000
5-DOOR SALOON VERSIONS Diesel 1.9 TD
X Driving School
X Entreprise
Emission standard Type code
X Entreprise
2.0 HDi
X Police Spain
X Entreprise
L3 N1 WJZF/MOD (1)
N1 WJZF/T (2)
W3 N1 DHYF
N1 RHYF
N1 RHYF/T (2)
Engine type
WJZ
DHY
RHY
Cubic capacity (cc)
1868
1905
1997
5
6
Fiscal rating (hp)
BE3/5
Gearbox type Gearbox ident. plate
5
20 TB 38
20 TB 59
(1) /T = The vehicle can be converted back into a private vehicle. (2) MOD = Modifiable.
19
20 TB 51
20 TB 38
GENERAL
1.9 D
XSARA - All Types # 09/2000
IDENTIFICATION OF VEHICLES PETROL ESTATES 1.4i
1.6i Dual fuel
X - X Pack - SX GENERAL
Emission standard Type code
L3
L4
N2 KFXF
N2 KFXB
AUTO.
(1) X - SX
AUTO.
X Pack
X - X - Pack SX - Exclusive L3
N2 KFXF/GL
N2 NFZU
N2 NFZG
N2 NFZF
Engine type
KFX
NFZ
Cubic capacity (cc)
1360
1587
5
6
Fiscal rating (hp) Gearbox type Gearbox ident. plate
N2 NFZM
MA/5
AL4
MA/5
AL4
20 CD 28 (*)
20 TP 22
20 CD 30
20 TP 22
(1) /GL = LPG (Liquid Petroleum Gas). (*) = Differential diameter 77 mm.
20
IDENTIFICATION OF VEHICLES
XSARA - All Types # 09/2000 PETROL ESTATES
1.8i
1.8i 16V
2.0i 16V
Dual fuel X – X Pack – SX Exclusive
X – X Pack – SX Exclusive
(1) X – SX
Brazil
X – X Pack – SX – Exclusive
N2 LFXF
N2 LFYF
N2 LFYF/GL
N2 LFYY
N2 RFVF
N2 RFVM
Engine type
LFX
LFY
RFV
Cubic capacity (cc)
1761
1761
1998
Fiscal rating (hp) Gearbox type Gearbox ident. plate
6
7
BE3/5
BE3/5
20 TB 22
20 TB 62
9
20 TD 05
(1) GL = LPG (Liquid Petroleum Gas).
21
BE3/5
4HP14
20 TB 39
20 GZ 9F
GENERAL
L3
Emission standard Type code
AUTO.
IDENTIFICATION OF VEHICLES
XSARA - All Types # 09/2000
DIESEL ESTATES 1.5 D
1.9 D
1.9 TD
2.0 HDi
SX
X – X Pack SX
X – X Pack SX Exclusive
X – X Pack – SX - Exclusive
L3
Emission standard
GENERAL
Type code
N2 VJZF
N2 WJZF
L4 N2 DHYF
N2 RHYF
N2 RHYM
Engine type
VJZ
WJZ
DHY
RHY
Cubic capacity (cc)
1527
1868
1905
1997
4
5
Fiscal rating (hp)
MA/5
Gearbox type Gearbox ident. plate
20 CD 33 (*)
6 BE3/5
20 TB 38
20 TB 59
(*) = Differential diameter 68 mm.
22
5 BE3/5 20 TP22
IDENTIFICATION OF VEHICLES
XSARA - All Types # 09/2000 ESTATE VERSIONS Petrol
1.4i
1.6i Dual fuel
X Entreprise
X Police Unmarked
L3
Emission standard Type code
X – SX Entreprise
N2 KFXF
N2 KFXF/T (1)
N2 KFXF/T MOD GL (2)
N2 LFXF
Engine type
KFX
LFX
Cubic capacity (cc)
1360
1761
Fiscal rating (hp) Gearbox type Gearbox ident. plate
6
5
6
MA/5
BE3/5
20 CD 28
20 TB 22
(1) /T = The vehicle can be converted back into a private vehicle. (2) /T MOD GL : /T = The vehicle can be converted back into a private vehicle MOD = Modifiable. GL = LPG (Liquid Petroleum Gas) with ring-shaped tank. 23
GENERAL
X Police Unmarked X Police Marked
IDENTIFICATION OF VEHICLES
XSARA - All Types # 09/2000
ESTATE VERSIONS Diesel 1.9 D X Police Unmarked X Police Marked
X Entreprise L3
Emission standard
GENERAL
Type code
N2 WJZF
WJZF/T (1)
Engine type
WJZ
Cubic capacity (cc)
1868 5
Fiscal rating (hp)
BE3/5
Gearbox type
20 TP 38
Gearbox ident. plate
(1) = Can be converted.
24
N2 WJZF
IDENTIFICATION OF VEHICLES 09/2000 #
XSARA - All Types # 09/2000 A - Manufacturer’s name plate (Estate). B - Chassis stamp, cold stamp.
D - Label : (affixed on windscreen pillar on driver’s side) - Tyre pressures. - RP organisation no. - Paint code. E - Serial No. (visible through the windscreen) F - Engine legislation type. Factory Serial No. G - Gearbox ident. reference. Factory Serial No
E1AP08WD
25
GENERAL
C - Manufacturer’s name plate (Saloon).
IDENTIFICATION OF VEHICLES
XSARA - All Types 09/2000 #
3-DOOR PETROL SALOONS 1.4 i
2.0i 16V
1.6i 16V AUTO. X-SX-VTR VTS
X-SX VTR
SX-VTR
GENERAL
L4
Emission standard Type code
NO KFWB
NO NFUB
NO NFUN
Engine type
KFW
NFU
Cubic capacity (cc)
1360
1587
5
7
Fiscal rating (hp)
20 CF 13 (1)
20 CN 28 (2)
VTS
VTS
IFL5
L4
NO RFN1/IF
NO RFN3/IF RFN
NO RFSB RFS
1998 8
MA/5
Gearbox type Gearbox ident. plate
AUTO.
11
AL4
AL4
BE4/5
BE4/5
20 TP 49
20TP47
20 TE 40 (3)
20 TE 47
(1) = Grand Export 20 CN 30 (2) = Grand Export 20 CN 29 (3) = Right Hand Drive 20 DM 03
26
IDENTIFICATION OF VEHICLES
XSARA - All Types 09/2000 #
3-DOOR PETROL SALOONS 1.9 D
2.0 HDi
X-SX VTR
X-SX-VTR VTS
Type code
1.4i
1.9 D
2.0 HDi
Entreprise
L4
L4
NO WJZB
NO RHYB
NO KFWB/T (1)
NO WJZB/T (1)
NO RHYB/T (1)
Engine type
WJZ
RHY
KFW
WJZ
RHY
Cubic capacity (cc)
1868
1997
1360
1868
1997
5
Fiscal rating (hp)
BE4/5
Gearbox type Gearbox ident. plate
(1) (2) (3) (4) (5) (6)
5
20 DL (2)-(3)
MA/5 20 DL (4)-(5)
20 CF 13 (6)
/T = The vehicle can be converted back into a private vehicle = Left Hand Drive version 20 DL 41 = Right Hand Drive version 20 DM 05 = Left Hand Drive version 20 DL 42 = Right Hand Drive version 20 DM 07 = Grand Export 20 CN 30 27
BE4/5 20 DL (2)-(3)
20 DL (4)-(5)
GENERAL
Emission standard
PETROL / DIESEL VERSIONS
IDENTIFICATION OF VEHICLES
XSARA - All Types 09/2000 #
5-DOOR PETROL SALOONS 1.6i 16V
1.4 i
AUTO.
AUTO.
GENERAL
Emission standard Type code
X
X-SX
SX
K’
L4
K’
N1 KFWG
N1 KFWB
N1 NFUG
X-SX Exclusive L4 N1 NFUU
N1 NFUB
N1 NFUN
AL4
MA/5
AL4
20 TP 49
20 CN 28 (1)
20 TP 49
Engine type
KFW
NFU
Cubic capacity (cc)
1360
1587
5
7
Fiscal rating (hp)
MA/5
Gearbox type Gearbox ident. plate
20 CF 21
20 CN 28 (1)
(1) = Grand Export 20 CN 29
28
SX Exclusive
IDENTIFICATION OF VEHICLES
XSARA - All Types 09/2000 #
5-DOOR PETROL SALOONS
5-DOOR DIESEL SALOONS
2.0i 16V
1.9 D
2.0 HDi
Emission standard Type code
Exclusive
X-SX
IFL5
L4
N1 RFN1/IF
N1 RFN3/IF
N1 WJZB
N1 RHYB
Engine type
RFN
WJZ
RHY
Cubic capacity (cc)
1998
1868
1997
11
Fiscal rating (hp) Gearbox type Gearbox ident. plate
(1) (2) (3) (4)
= = = =
5
BE4/5
AL4
20 DL (1) (2)
20 TP 47
Left Hand Drive version 20 DL 40 Right Hand Drive version 20 DM 03 Left Hand Drive version 20 DL 41 Right Hand Drive version 20 DM 05
(5) = Left Hand Drive version 20 DL 42 (6) = Right Hand Drive version 20 DM 07
29
BE4/5 20 DL (3)-(4)
20 DL (5)-(6)
GENERAL
AUTO.
IDENTIFICATION OF VEHICLES
XSARA - All Types 09/2000 #
PETROL SALOONS / ESTATES 1.6i 16V
1.4 i
2.0i 16V AUTO.
GENERAL
Emission standard Type code
X-SX
SX
L4
K'
N2 KFWB
N2 NFUG
Engine type
KFW
Cubic capacity (cc)
1360
Fiscal rating (hp)
Gearbox ident. plate
Exclusive
L4 N2 NFUB
IFL5 N2 NFUN
N2 RFN1/IF
20 CN 29 (1)
1998 11
20 CN 28
(1) = Grand Export 20 CN 29 (2) = Left Hand Drive version 20 DL 40 (3) = Right Hand Drive version 20 DM 03 30
N2 RFN3/IF RFN
1587 7 MA/5
20 CN 21
SX Exclusive
X-SX
NFU
5
Gearbox type
AUTO.
11
AL4
BE4/5
AL4
20 TP 47
20 DL (2)-(3)
20 TP 47
IDENTIFICATION OF VEHICLES
XSARA - All Types 09/2000 #
DIESEL ESTATES
PETROL / DIESEL ESTATE VERSIONS
1.9 D
2.0 HDi
1.4i
X-SX
X-SX Exclusive
Entreprise
Emission standard
2.0 HDi
Entreprise
L4 N2 WJZB
N2 RHYB
N2 KFWB/T (1)
N2 WJZB/T (1)
N2 RHYB/T (1)
Engine type
WJZ
RHY
KFW
WJZ
RHY
Cubic capacity (cc)
1868
1997
1360
1868
1997
5
Fiscal rating (hp)
BE4/5
Gearbox type Gearbox ident. plate
(1) (2) (3) (4) (5) (6)
5
20 DL (2)-(3)
MA/5 20 DL (4)-(5)
20 CN 21 (6)
/T = The vehicle can be converted back into a private vehicle = Left Hand Drive version 20 DL 41 = Right Hand Drive version 20 DM 05 = Left Hand Drive version 20 DL 42 = Right Hand Drive version 20 DM 07 = Grand Export 20 CN 30 31
BE4/5 20 DL (2)-(3)
20 DL (4)-(5)
GENERAL
Type code
1.9 D
XSARA PICASSO - All Types
IDENTIFICATION OF VEHICLES A - Chassis stamp (Cold stamp on bodywork) B - Chassis no. reminder (Label located at bottom of windscreen right hand side) C - Manufacturer’s data plate. (Located at bottom of RH central pillar).
GENERAL
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
32
IDENTIFICATION OF VEHICLES
XSARA PICASSO - All Types
Petrol
Diesel
1.6i
1.8i 16 V
L3 ou L4
CH NFZ
CH 6FZ
CH RHY
Engine type
NFZ
6FZ
RHY
Cubic capacity (cc)
587
1749
1997
6
7
5
BE4/5/ J (*)
BE4/5 V (*)
BE4/5 L (*)
20 DL 66
20 DL 68
20 DL64
Type code
Fiscal rating (hp) Gearbox type Gearbox ident. plate
(*) L,J, V = Corresponds to the stepping of the gears.
33
GENERAL
L3
Emission standard
2.0 HDi
BERLINGO - All Types
IDENTIFICATION OF VEHICLES
GENERAL E1AP07AD
34
1
Chassis stamp
2
Manufacturer’s name plate
3
Supplementary plate
4
Weights label
5
01/02/99 # Label : - Tyre pressures. - RP organisation no. - Paint code.
6
Paint code
7
RP organisation no.
8
Gearbox ident. reference
9
Engine legislation type
IDENTIFICATION OF VEHICLES
BERLINGO - All Types PETROL 1.4i
X Emission standard Type code Engine type Cubic capacity (cc) Fiscal rating (hp)
L3/W3
L4/W4
K'
MF HDZF
MF HFXB
MF KFXG
HDZ
Multispace L3/W3
MF KFXF
HFX
X-SX L4/W4
MF KFXF/A
KFX
1124
MF KFWB KFW
1360
5
6 MA/5
Gearbox type Gearbox ident. plate
X-SX
X
20 CN 43 # 09/200 20 CN 02 09/2000 #
20 CN 12
35
20 CN 13
20 CN 12
GENERAL
1.1i
BERLINGO - All Types
IDENTIFICATION OF VEHICLES PETROL 1.8i
1.4i Dual fuel Multispace Emission standard
GENERAL
Type code Engine type
L4/W4 MF KFWB/A
SX
L3 MF KFXF /MOD GL
KFW
Fiscal rating (hp) Gearbox type
20 CN 13
Multispace L3/W3
MF KFXF /MOD GL
MF LFXF
KFX
MF LFXF/A LFX
1360
Cubic capacity (cc)
Gearbox ident. plate
Multispace
X
1761
6
7
MA/5
BE3/5
20 CN 12
20 CN 13
36
20 TE 25
20 TE 26
IDENTIFICATION OF VEHICLES
BERLINGO - All Types DIESEL
X-SX Emission standard Type code
2.0 HDi
Multispace L3/W3
L4/W4
MF WJZF /A
MF WJZF
Multispace
X-SX
WJZ
Engine type
MF RHYF /A
WJY
MF RHYB
MF RHYB /A
RHY 1997
5
Fiscal rating (hp)
6 BE3/5
Gearbox type Gearbox ident. plate
MF RHYF
L4/W4
1868
Cubic capacity (cc)
Multispace
L3/W3
MF WJYB /A
MF WJYB
Multispace
20 TE 22
20 TE 24
20 TE 49
20 TE 24
37
20 TE 28
20 TE 29
20 TE 28
20 TE 29
GENERAL
1.9 D
ALL TYPES
CAPACITIES (in litres) Draining method. The oil capacities are defined according to the following methods.
1/ Vehicle on level surface (in high position, if equipped with hydropneumatic suspension). 2/ Engine warm (oil temperature 80°C). 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.
38
CAPACITIES (in litres)
SAXO - All Types SAXO
Petrol
Diesel Ecological oil filter capacity 0.15 litre.
1.0I
1.1I
1.4I
1.6I
1.1I
KFX 3 1.4
KFW
NFZ
1.4I
1.6I
1.6I
1.6I 16V
1.6I
KFW 3 1.5 2
NFZ
NFX
NFT 3.5 1.5
1.5D
CDZ
Engine type
HDZ
Engine with filter change Between Min. and Max. 5-speed gearbox Automatic gearbox after drainage Hydraulic or brake circuit Cooling system Fuel tank capacity
NFX
2
KFX
4.5 2 With ABS : 0.45 - Without ABS : 0.36 6.1 45
ESSENTIAL : Engine : systematically check the oil level using the oil dipstick. 39
VJZ
VJY 4.5 2
VJX
GENERAL
AUTO.
CAPACITIES (in litres)
XSARA - All Types # 09/2000
XSARA # 09/2000 Petrol 1.4i
1.6i
Diesel 2.0i 16 V
1.8i 16V
1.8i
AUTO. KFX
Engine type
NFZ
GENERAL
Automatic gearbox after drainage
RFS
4.25 1
1.8
2.0HDi
VJZ
WJZ
DHY
RHY
4.5
4.75 4.5 (1)
4 4.25 (1)
4.5 4.25 (1)
2
1.9
1.9
6
6
3
3
7 - 6.5 (1)
7
9
1.5
2
8.8 54
Fuel tank capacity
(1) With aircon
1.9TD
1.8
With ABS = 0.50 - Without ABS = 0.55
Hydraulic or brake circuit Cooling system
RFV
1.3
2
5-speed gearbox
LFY
4.75 4.25 (1)
1.4
Between Min. and Max.
1.9D
AUTO. LFX
3
Engine with filter change
1.5D
- ESSENTIAL : Engine : systematically check the oil level using the oil dipstick. 40
9
9 - 9.5 (1) 8.5 - 11 (1)
CAPACITIES (in litres)
XSARA - All Types 09/2000 # XSARA 09/2000 # Petrol
Diesel
Ecological oil filter capacity 0,15 litre. 1.6 i 16V AUTO. Engine type Engine with filter change Between Min. and Max.
KFW
NFU
3
3.25
1.5
1.5
Automatic gearbox after drainage
RFN
RFS 4.25
1.7
1
1.9
WJZ
RHY
4.75
4.5
1.6
1.4
1.9
6
6
3
3
1.8
With ABS = 0.50 - Without ABS = 0.55
Hydraulic or brake circuit Cooling system
2.0 HDi
AUTO.
2
5-speed gearbox
1.9D
2.0i 16V
7 - 6.5 (1)
9 54
Fuel tank capacity
(1) = With aircon - ESSENTIAL : Engine : systematically check the oil level using the oil dipstick. 41
8.5 - 11 (1)
GENERAL
1.4 i
XSARA PICASSO - All Types
CAPACITIES (in litres) XSARA PICASSO Petrol
Diesel
Cartouche écologique capacité 0.15 Litre.
Engine type
GENERAL
Engine with filter change Between Min. and Max.
1.6I
1.8I 16 V
2.0 HDI
NFZ
6FZ
RHY
3
4.25
4.5
1.5
1.7
1.4
1.8
5-speed gearbox Automatic gearbox after drainage
0.58 litres
Hydraulic or brake circuit Cooling system Fuel tank capacity
5.8 (1) and (2)
6.5 (1) and (2) 55
11 (1) and (2) 60
(1) = With aircon (2) = Without aircon ESSENTIAL : Engine : systematically check the oil level using the oil dipstick. 42
CAPACITIES (in litres)
BERLINGO - All Types BERLINGO Petrol
Diesel
1.1I
HDZ
Engine type
1.4I
HFX
KFX
KFW
1.8I
1.1I
LFX
HFX
1.4I
KFX
Engine with filter change
3.5
4.75 4.5 (1)
3
Between Min. and Max.
1.5 2
1.3 1.8
1.5 2
5-speed gearbox
KFW
1.9D
2.0 HDI
WJZ
RHY
4.75 4.5 (1)
4.5 4.25 (1)
1.5 1.8
Automatic gearbox after drainage
With ABS = 0.62 - Without ABS = 0.525
Hydraulic or brake circuit Cooling system Fuel tank capacity
6.5
6.5-7 (1)
8
6.5
55
(1) = With aircon - ESSENTIAL : Engine : systematically check the oil level using the oil dipstick. 43
6.5-7 (1)
With ABS = 0.62 Without ABS = 0.525 10.5 60
GENERAL
Ecological oil filter capacity 0,15 litre.
ALL TYPES
LUBRICANTS - TOTAL recommended oils
S.A.E. Norm - Table for selection of engine oil grade
Factory evolutions in 2000 model year 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%).
GENERAL
This oil is not used in the following engines : - XU10 4 RS - XSARA VTS 2.0i 16V (3-door) - SOFIM - RELAY 2.8 D and 2.8 TD. Engine oil norms These engine oils have been classified by the following recognised organisations: SAE : Society of Automotive Engineers. API : American Petroleum Institute. ACEA : Association des Constructeurs Européens d'Automobiles. E4AP006D
44
LUBRICANTS - TOTAL recommended oils
ALL TYPES
Selection of engine oil grades recommended for climatic conditions in countries of distribution
API Norms
ACEA Norms
The figure following the first letter corresponds to the type of oil. 1 : highly fluid oils, for reducing friction and lowering fuel consumption. 3 : high performance oils. The number after that (96 or 98) corresponds to the year of creation of the norm. NOTE : From 01/03/2000, all engine oils must comply with ACEA-98 norms.
The first letter corresponds to the type of fuel used by the engine : S : petrol and dual fuel petrol / LPG engines. C : diesel engines. The second letter corresponds to the degree of evolution, in ascending order. Example : The norm SJ is more severe than the norm SH and corresponds to a higher level of performance. The adding of the letters EC indicates that the engine oil concerned is an oil which permits fuel economy. EC : Energy Conserving, reduction in fuel consumption. Examples : API SJ / CF : Blended oils for diesel and dual fuel petrol / LPG engines API CF / EC : Oils specifically for diesel engines, permitting fuel economy. API SJ / CF / EC : Blended oils for all engines, permetting fuel economy.
Example : ACEA A1-98 / B1-98 : Blended oils for all engines, permetting fuel economy (complying with ACEA 98 norms).
45
GENERAL
The first letter corresponds to the type of engine concerned : A : petrol and dual fuel petrol / LPG engines.. B : diesel engines.
ALL TYPES
LUBRICANTS - TOTAL recommended oils
Recommendations. Denominations of TOTAL oils, according to country of marketing : TOTAL ACTIVA (France only). TOTAL QUARTZ (outside France). IMPERATIVE : From 1999 model year, to preserve engine performance, all engines fitted in CITROEN vehicles must be lubricated with high quality oils (synthetic or semi-synthetic)
GENERAL
These oils must comply with the following norms : Petrol and dual fuel petrol / LPG engines: ACEA A3-98 and API SJ. Diesel engines: ACEA B3-98 and API CF. ATTENTION : Engines fitted in CITROEN vehicles prior to 2000 model year must not be lubricated with oil complying with standards ACEA A1-98 / B1-98 and API SJ/CF EC. Summary Engine oil norms to be respected in 2001 model year. Model year 2001 model year
Types of engine
ACEA norms
API norms
Petrol and dual fuel petrol / LPG engines
A3-98 or A1-98 (*)
SJ or SJ / EC (*)
Diesel engines
B3-98 or B1-98 (*)
CF or CF / EC (*)
(*) = It is essential not to use engine oils respecting these norms for the following engine-types : XU10J4RS, 1580 SPI, SOFIM 2.8 D and SOFIM 2.8 TD. 46
LUBRICANTS - TOTAL recommended oils S.A.E. grades
ALL TYPES SPI norms
ACEA norms
Blended oils for all engines (petrol, dual-fuel petrol / LPG and diesel) 5W-40
SJ / CF
A3-98 / B3-98
5W-30
SJ / CF EC
A1-98 / B1-98
10W-40
SJ / CF
A3-98 / B3-98
SJ
A3-98
CF
B3-98
GENERAL
TOTAL ACTIVA 9000 TOTAL QUARTZ 9000 TOTAL ACTIVA 9000 (*) TOTAL QUARTZ 9000 (*) TOTAL ACTIVRAC (*) = Blended oils for all engines, permitting fuel economy.
Oils specifically for petrol and dual-fuel petrol / LPG engines TOTAL ACTIVA 7000 TOTAL QUARTZ 7000 TOTAL QUARTZ 9000 TOTAL ACTIVA 7000 TOTAL QUARTZ 7000
10W-40 0W-40 15W-50 Oils specifically for diesel engines
TOTAL ACTIVA DIESEL 7000 TOTAL QUARTZ DIESEL 7000 TOTAL ACTIVA DIESEL 7000 TOTAL QUARTZ DIESEL 7000 TOTAL ACTIVA 9000
10W-40 15W-50 5W-40 47
ALL TYPES
LUBRICANTS - TOTAL recommended oils FRANCE Blended oils for all engines TOTAL ACTIVRAC
Metropolitan FRANCE
S.A.E : 10W-40 Norms TOTAL ACTIVA DIESEL
TOTAL ACTIVA GENERAL
Metropolitan FRANCE New Caledonia Guadeloupe Saint-martin La 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
900 5W-40 9000 5W-30 (*)
7000 10 W-40
7000 10 W-40 9000 5W-40
9000 5W-40
7000 15W-50
7000 15W-50
(*) = Blended oils for all engines, permitting fuel economy. 48
LUBRICANTS - TOTAL recommended oils
ALL TYPES
EUROPE
(*) = Blended oils for all engines, permitting fuel economy.
Blended oils for all engines
Austria Belgium Bulgaria Cyprus Croatia
Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 9000 7000 7000 9000 7000
Germany
9000 5W-40 9000 5W-30 (*)
Spain Finland Great Britain 49
Oils specifically for diesel engines
10W-40 0W-40 10W-40 10W-40 0W-40 10W-40
7000 10W-40
7000 15W-50
7000 10W-40 7000 15W-50
7000 7000 9000 7000 7000 7000 9000 7000
Denmark
TOTAL QUARTZ DIESEL
10W-40 10W-40 0W-40 10W-40 15W-50 10W-40 0W-40 10W-40
7000 10W-40 7000 10W-40 7000 15W-50 7000 10W-40
GENERAL
TOTAL QUARTZ
ALL TYPES
LUBRICANTS - TOTAL recommended oils EUROPE (continued) TOTAL QUARTZ
(*) = Blended oils for all engines, permitting fuel economy.
TOTAL QUARTZ DIESEL
GENERAL
Oils specifically for petrol and dual-fuel petrol / LPG engines
Oils specifically for diesel engines
Greece
7000 10W-40 7000 15W-50
7000 10W-40 7000 15W-50
Holland
7000 10W-40
Blended oils for all engines
Hungary
9000 0W-40
Italy
7000 10W-40
Latvia
7000 10W-40
Lithuania Macedonia
9000 5W-40 9000 5W-30 (*)
7000 10W-40
9000 0W-40 7000 10W-40
Malta
7000 10W-40 7000 15W-50
Norway
7000 10W-40 9000 0W-40
Poland
7000 10W-40 7000 15W-50
7000 10W-40
Portugal
7000 10W-40
Slovak Republic 50
LUBRICANTS - TOTAL recommended oils
ALL TYPES
EUROPE (continued)
(*) = Blended oils for all engines, permitting fuel economy.
Blended oils for all engines
TOTAL QUARTZ DIESEL
Oils specifically for petrol and dual-fuel petrol / LPG engines
Czech Republic
7000 10W-40 9000 0W-40
Romania
7000 10W-40 7000 15W-50
Russia
7000 10W-40 9000 0W-40
Slovenia Sweden
7000 10W-40
9000 5W-40 9000 5W-30 (*)
7000 10W-40 9000 0W-40 7000 10W-40
Switzerland
Oils specifically for diesel engines 7000 10W-40 7000 10W-40 7000 15W-50
7000 10W-40
Turkey
7000 10W-40 7000 15W-50 9000 0W-40
7000 10W-40 7000 15W-50
Ukraine
7000 10W-40 9000 0W-40
7000 10W-40
51
GENERAL
TOTAL QUARTZ
ALL TYPES
LUBRICANTS - TOTAL recommended oils TOTAL QUARTZ
Australia New Zealand
TOTAL QUARTZ DIESEL
GENERAL
Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol / LPG engines
Oils specifically for diesel engines
OCEANIA
9000 5W-40
7000 10W-40
7000 10W-40
AFRICA
9000 5W-40
7000 15W-50
7000 15W-50
9000 5W-40
7000 15W-50
7000 15W-50
Angola - Ivory Coast Egypt- Ecuador - Gabon Madagascar - Morocco Dominican Republic Senegal - Tunisia Argentina - Brazil - Chile Colombia - Cuba Guatemala - Paraguay
SOUTH AMERICA
Peru - El Salvador Uruguay 52
TOTAL QUARTZ Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol / LPG engines
China
7000 10W-40 7000 15W-50
South Korea
7000 10W-40
Hong Kong - India Indonesia
7000 15W-50
Japan Malaysia
TOTAL QUARTZ DIESEL Oils specifically for diesel engines
7000 10W-40 7000 15W-50
SOUTH & EAST ASIA
ALL TYPES
GENERAL
LUBRICANTS - TOTAL recommended oils
7000 15W-50
9000 5W-40 7000 15W-50
Singapore Taiwan
7000 10W-40 7000 15W-50
Thaïland
7000 15W-50
Vietnam 53
ALL TYPES
LUBRICANTS - TOTAL recommended oils TOTAL QUARTZ
TOTAL QUARTZ DIESEL
Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol / LPG engines
Oils specifically for diesel engines
9000 5W-40
7000 15W-50
7000 15W-50
Saudi Arabia GENERAL
Bahrain Dubaï United Arab Emirates Israel Jordan
MIDDLE EAST
Kuwaït Lebanon Qatar Yemen 54
LUBRICANTS - TOTAL recommended oils
ALL TYPES
Gearbox oils Europe Overseas France Asia
TOTAL FLUIDE ATX ou TOTAL FLUIDE AT 42. Special oil distributed by CITROEN (Part No. : 9730 94).
Automatic gearbox MB3
Automatic gearbox 4 HP 14 et 4 HP 18
TOTAL TRANSMISSION (new formula) Norms S.A.E 75W-80
All countries
TOTAL FLUIDE AT 42 ou Special oil distributed by CITROEN (Part No. : 9730 94). Special oil distributed by CITROEN (Part No. : 9736 22).
Automatic gearbox 4 HP 20 et AL4 Transfer box and differential
TOTAL TRANSMISSION X 4
C MATIC gearbox
TOTAL FLUIDE T Oils for power-assisted steering
Power-assisted steering
All countries 55
TOTAL FLUIDE ATX
GENERAL
Manual gearbox
LUBRICANTS - TOTAL recommended oils
ALL TYPES
Engine coolant CITROEN reference
Packs All countries
GENERAL
GLYSANTIN G 33
REVCOGEL 2000
CITROEN Fluid
2 litres
9979 70
9979 72
Protection : - 35°C
5 litres
9979 71
9979 73
20 litres 210 litres
9979 76 9979 77
9979 74 9979 75
Synthetic brake fluid
All countries
CITROEN Fluid
Packs
CITROEN reference
0.5 litre
9979 05
1 litre
9979 06
5litres
9979 07
CITROEN hydraulic circuit fluid Mineral fluid for hydraulic circuit - green colour TOTAL LHM PLUS All countries
Packs
Norms ISO 7308-7309
1 litre Hydraulic circuit rinsing fluid - green colour TOTAL HYDRAURINCAGE 56
CITROEN reference ZCP 830 095
ALL TYPES
LUBRICANTS - TOTAL recommended oils Wash / wipe fluid CITROEN reference
All countries
Concentrate : 250 ml
9980 33
ZC 9875 953 U
Liquid ready to use : 1 litre
9980 06
ZC 9875 784 U
Liquid ready to use : 5 litres
9980 05
ZC 9885 077 U
9980 56
ZC 9875 279 U
Norms : NLGI (1) All countries
TOTAL MULTIS EP2 TOTAL MULTIS COMPLEX EP2 TOTAL MULTIS N4128
2 2 1
TOTAL SMALL MECHANISMS
(1) NLGI = National Lubricating Grease Institute.
57
GENERAL
Grease
ALL TYPES
ENGINE OIL CONSUMPTION
I - Oil consumption depends on : -
the engine type. how run-in or worn it is. the type of oil used. the driving conditions.
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 WORK BELOW THESE VALUES. IV - OIL LEVEL : The level should NEVER be above the MAX. mark on the dipstick after changing or topping up the oil. - This excess oil will be used up rapidly. - It will reduce the engine output and adversely affect the operation of the air circuits and gas recycling.
58
Engines : CDZ - HDZ - HDZ/GPL - HFX - KFX - KFX/GPL - KFW Petrol All Types 1.0i
1.1i
1.4i
Engine type
CDZ
Cubic capacity (cc)
954
1124
1360
Bore / Stroke
70/62
72/79
75/77
Compression ratio
9.4/1
HDZ
HDZ/GPL
9.7/1
HFX
KFX
KFX/GPL
10.5/1
10.2/1
Power ISO or EEC KW-rpm
37-6000
44.1-6200
43.2-6200
44.1-5500
55-5500
Power DIN (HP-rpm)
50-6000
60-6200
58.8-6200
60-5500
75-5500
7.35-3700
8.75-3800
8.31-3800
9.4-3500
11.1-3400
7.5-3700
9.1-3800
8.65-3800
-3500
11.5-3400
Torque ISO or EEC (m.daN-rpm) Torque DIN (mkg-rpm) Max. speed (rpm)
6400
6500
6500 59
KFW
ENGINE
ALL TYPES
ENGINE SPECIFICATIONS
ENGINE
ALL TYPES
ENGINE SPECIFICATIONS Engines : NFZ – NFT – NFU – NFX - LFX Petrol All Types 1.6 i SAXO
Engine type
1.6 i 16 V
PICASSO NFZ
NFT
Cubic capacity (cc) Bore / Stroke Compression ratio
1.8 i
9.6/1
NFU
NFX
LFX
1587
1761
78.5/82
83/81.5
10.5/1
11/1
10.8/1
9.5/1
Power ISO or EEC KW-rpm
65-5600
70-5700
72-5700
80-5800
8.7-6600
66-5000
Power DIN (HP-rpm)
90-5600
95-5700
98-5700
11-5800
120-6600
90-5000
13.5-3500
14.7-4000
14.5-5200
14.7-2600
?-3500
15.6-4000
15-5200
15.2-2600
13.5-3000
Torque ISO or EEC (m.daN-rpm) Torque DIN (mkg-rpm) Max. speed (rpm)
14-3000
13.8-3000 6100
6300 60
ALL TYPES
Engines : LFY - LFY/GPL - 6FZ - RFN - RFS - RFV Petrol All Types
2.0i 16V
1.8i 16V
Engine type
LFY
LFY/GPL
Cubic capacity (cc) Bore / Stroke
6FZ
RFN
1761
1749
1997
1998
83/81.4
82.7/81.4
85/88
86/86
10.4/1
Compression ratio
RFS
RFV
10.8/1
10.4/1
Power ISO or EEC KW-rpm
81-5500
72-5500
85-5500
99-6000
12-6500
97.4-5500
Power DIN (HP-rpm)
112-5500
109-5500
115-5500
136-6000
167-6500
135-5500
Torque ISO or EEC (m.daN-rpm)
15.5-4250
16.3-4000
19-4100
19.3-5500
18-4200
Torque DIN (mkg-rpm)
16.1-4250
16.6-4000
19.8-4100
20-5500
18.7-4200
6400
6500
Max. speed (rpm)
61
6800
ENGINE
ENGINE SPECIFICATIONS
ENGINE
ALL TYPES
ENGINE SPECIFICATIONS Engines :VJZ - VJX - VJY - WJZ - DHV - RHY Diesel All Types
1.9 D
1.9TD
DHY
WJZ
DHY
RHY
1.5 D
Engine type
VJZ
VJX
2.0 HDi
Cubic capacity (cc)
1527
1527
1868
1905
1997
Bore / Stroke
77/82
77/82
82.2/88
83/88
85/88
23/1
23/1
23/1
21.8/1
17.6/1
Power ISO or EEC KW-rpm
42-5000
40-5000
51-4600
66-4000
Power DIN (HP-rpm)
58-5000
55-5000
70-4600
90-4000
Compression ratio
Torque ISO or EEC (m.daN-rpm) Torque DIN (mkg-rpm) Max. speed (rpm)
9.5-2250
12.5-2500
19.6-2250
20.5-1900
9.68-2250
14-2500
20.5-2250
21.4-1900
5450
5350
4600
5300
62
ALL TYPES
CYLINDER HEAD (mm) Engine type
CDZ
HDZ-HFX
KFX-KFW
NFZ
NFU-NFX
VJZ-VJY-VJX
0.05 - 0.20
Maximum permissible bow Gasket surface regrinding
TIGHTENING TORQUES ( m.daN) Crankshaft bearing screws
Connecting rod screws
Flywheel screw
Pre-tightening Loosening Tightening Angular tightening Tightening Pre-tightening Loosening Tightening Angular tightening Pre-tightening Tightening Angular tightening Tightening Angular tightening Pre-tightening Tightening Pre-tightening Angular tightening
Crankshaft pinion screw Crankshaft pulley screw Camshaft pulley screw Camshaft hubs Camshaft end pulley screw Camshaft hub Pre-tightening screw Tightening
2 ± 0.2
2 ± 0.2
45°
50° ± 5°
3.8 ± 0.4
6.5 ± 0.7
7 ± 0.7 45° ± 4° 4 ± 0.4 20° ± 2°
10 ± 1 8 ± 0.8 8 ± 0.8 1 ± 0.1
63
2.5 ± 0.2
ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )
ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )
ALL TYPES
CYLINDER HEAD (mm) Engine type
LFX
LFY
6FZ
Maximum permissible bow Gasket surface regrinding
RFN
RFV
RFS
WJZ
0.05 - 0.20
RHY 0.03
- 0.30
- 0.20
- 0.40
TIGHTENING TORQUES ( m.daN) Pre-tightening Loosening Crankshaft bearing screws
Tightening
Angular tightening Tightening Pre-tightening Connecting rod Loosening Tightening screws Angular tightening Pre-tightening Flywheel screw Tightening Angular tightening Crankshaft Tightening pinion screw Angular tightening Crankshaft Pre-tightening pulley screw Tightening Camshaft pulley Pre-tightening screw Angular tightening Camshaft end pulley screws Camshaft hub Pre-tightening screw Tightening
5.5 ± 0.5
4 ± 0.4 2 ± 0.2 70° ± 7° 5 ± 0.5
12 ± 1.2
(1) Ø 11 : 1 ± 0.1 (2) Ø 6 : 1 ± 0.1 (only) Ø 11 to 1 ± 0.1 then to 2 ± 0.1 Ø 11 to 70° ± 5° Ø 6 to 1 ± 0.1 1 ± 0.1 180° (1/2 turn) 2.3 ± 0.2 46° ± 5° 0.8 ± 0.1 2 ± 0.2 26 ° ± 3° 4 ± 0.4 53 ° ± 4° 1.5 ± 0.2 2.1 ± 0.2
2 ± 0.1
2.5 ± 0.3
7 ± 0.7
8.5 ± 0.8
7 ± 0.7 60° ± 6°
60° ± 6° 4 ± 0.4
2 ± 0.2
2.3 ± 0.2 46° ± 4.6°
2± 0.2 70° ± 7°
70° ± 7°
2 ± 0.2 21° ± 3°
5 ±0.5
5 ± 0.5
12 ± 1.2
4± 60° ± 4 ± 0.4 51° ±5°
5.5 ± 0.5
5.5 ± 0.5 3 ± 0.3 7.5 ± 0.7
64
4.5 ± 0.5
TUD - XU
Engines : LFY -RFV - RFS - VJZ - VJY - VJX SAXO
XSARA
VJZ-VJY-VJX
LFY-RFV-RFS
- Pre-tighten 0.4
- Pre-tighten 0.5
- Tighten
- Tighten
0.7
B1DP03BC
1
B1DP01YD
65
ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )
ENGINE ENGINE
CYLINDER HEAD
TU - TUD - All Types
Engines : CDZ – HDZ – HFX – KFX - KFW – NFZ – NFT – NFU - NFX – VJZ – VJY – VJX IDENTIFICATION OF THE CYLINDER HEAD GASKET Engine type
CDZ
HDZ - KFX HFX - KFW NFZ - NFT NFU - NFX
Identification marks
Thickness
CURTY
MEILLOR Suppliers ELRING
REINZ Material Repairs
(Notch on cylinder head gasket) 1 2 3 4 A B D A B D A B D A B D C R
0 0 0 0
1 0 0 0
1 0 0 1
1 1 1 1
*
0 0 0 1 1 0
VJZ- VJY - VJX 1 1 1 0
1 1 0
1 0 1 1 0 0 0 (With asbestos) - 1 (Without asbestos) 0 (Standard gasket) - 1 (Repair gasket) 66
*
0 = Without notch 1 = One notch B1BP10KC
TU - TUD - All Types
Cylinder head tightening (m.daN)
Cylinder head bolts
CDZ - HDZ - HFX - KFX KFW - NFZ - NFT - Pre-tightening - Angular tightening
2 240° ± 5°
VJZ - VJY - VJX
B1BP10LC
- Pre-tightening - Angular tightening
4 300° ± 5°
Note : Oil the threads and under the heads of the cylinder head bolts. (Use engine oil or Molykote G Rapid Plus).
NFU - NFX - Pre-tightening - Angular tightening
2 B1DP059C
260° ± 5° X = MAXIMUM reusable length
B1DP13NC
67
CDZ - HDZ - HFX - KFX KFW - NFZ - NFT
VJX - VJY - VJX
NFU - NFX
X = 175.5 ± 0.5 mm
X = 197.1 mm
X = 122.6 mm
ENGINE
CYLINDER HEAD (continued) Engines : CDZ - HDZ - HFX - KFX - KFW - NFZ - NFT - NFU - NFX - VJX - VJY - VJX
ENGINE
XU - All Types
CYLINDER HEAD Engine : 6FZ Identification of the cylinder head gasket
Marking zone "d" Marking zone "e" Gasket thickness (mm)
Nominal dimension
Repair dimension
4–5
2–4–5
0.8
R1
R2
R3
1
1.1
1.3
Supplier
MEILLOR Marking " d " Marking zone " e " Marking zone
NOTE : 3 layer metallic gasket. B1DP183D
68
EW 10 - All Types
Engine : 6FZ Cylinder head tightening (m.daN)
Cylinder head bolts 6FZ
Pre-tightening
1.5 ± 0.2
Tightening Loosening Tightening Angular tightening
5 ± 0.2 360 ° (1 turn) 2 ± 0.2 285° ± 5°
B1DP16FC
NOTE : Oil the threads and under the heads of the cylinder head 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 = MAXIMUM reusable length 6FZ X= 147 mm
B1DP05BC
69
ENGINE
CYLINDER HEAD (continued)
ENGINE
EW 10 - All Types
CYLINDER HEAD (continued) Engine : RFN Identification of the cylinder head gasket
Nominal dimension
Repair dimension
4–5
2–4–5
Marking zone "d" Marking zone "e" Gasket thickness (mm) Supplier
0.8
R1
R2
1.1
1.4
MEILLOR
Multilayer metallic gasket
B1DP183D
70
EW 10 - All Types
Engine : RFN Cylinder head tightening (m.daN)
Cylinder head bolts RFN
Pre-tightening
1.5 ± 0.1
Tightening Loosening Tightening Angular tightening
5 ± 0.1 360°± 2° 2 ± 0.75 285° ± 5°
B1DP16FC
NOTE : Oil the threads and under the heads of the cylinder head 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 = MAXIMUM reusable length RFN X= 147 mm
B1DP05BC
71
ENGINE
CYLINDER HEAD (continued)
ENGINE
CYLINDER HEAD
XU - All Types
Engines : LFX - LFY - RFV - RFS IDENTIFICATION OF THE CYLINDER HEAD GASKET Engine type
LFY
LFX
Identification marks
CURTY
Suppliers
MEILLOR
RFV
(Notch on cylinder head gasket) A
1
B
0
C
0
D
0
RFS
*
E
0
A
0
B
1
0
0
C
0
1
1
0
1
D
0
0
0
E
0
0
0
*
0 = Without notch
1 = One notch
B1BP004C
72
XU - All Types
Engines : LFX - LFY - RFV - RFS Cylinder head tightening (m.daN)
Cylinder head bolts LFX - LFY
- Pre-tightening - Loosening - Tightening - Angular tightening
6 YES 2 300° Note : Oil the threads and under the heads of the cylinder head bolts. (Use engine oil or Molykote G Rapid Plus). B1DP13PC
X = MAXIMUM reusable length
RFV - RFS - Pre-tightening - Loosening - Tightening - Angular tightening
3.5 NO 7 160°
B1DP05BC
73
LFX
LFY
RFV - RFS
171.5 mm
160.5 mm
112 mm
ENGINE
CYLINDER HEAD (continued)
ENGINE
CYLINDER HEAD
DW8 - All Types
Engine : WJZ Identification of the cylinder head gasket Engine type
WJZ
Piston stand-proud (mm) (*)
Thickness (mm) ± 0.04
0.51 to 0.55
1.26
1
0.55 to 0.59
1.30
2
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
2
WJZ
Number of holes at B
3
(A) = Engine identification. (B) = Thickness identification. (*) = Take the highest piston as a reference point.
B1DP14QD
74
XUD - All Types
Engine : DHY Identification of the cylinder head gasket Engine type
DHY
Piston stand-proud (mm)
Thickness (mm) ± 0.06
0.56 to 0.67
1.36
0.68 to 0.71
1.40
0.72 to 0.75
1.44
0.76 to 0.79
1.48
0.80 to 0.83
1.52
Marking (B)
(A) = Engine identification. (B) = Thickness identification.
B1BP10TC
75
Engine
Ident. (A)
Ident. (B)
DHY
3 notches
1 to 5 notches
ENGINE
CYLINDER HEAD
ENGINE
CYLINDER HEAD
DW10 - All Types
Engine : RHY Identification of the cylinder head gasket Engine type
RHY
Piston stand-proud (mm)
Thickness (mm)
Number 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
76
XUD - DW8 - DW10 - All Types
Engines : WJZ – DHY - RHY Cylinder head tightening (m.daN)
Cylinder head bolts WJZ
WJZ - Pre-tightening - Tightening - Angular tightening
DHY
RHY
2 6 180°
DHY-RHY - Pre-tightening
2
- Tightening
6
- Angular tightening
220°
Note : Oil the threads and under the heads of the cylinder head bolts. (Use engine oil or Molykote G Rapid Plus). B1DP05BC
X = MAXIMUM reusable length
B1DP13PC
B1DP14NC B1DP15EC
77
WJZ
DHY
RHY
125.5 mm
150.2 mm
133.3 mm
ENGINE
CYLINDER HEAD (continued)
4099-T (C.TRONIC.105)
Tools
78
!
!
!
ENGINE
BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE
ALL TYPES
4122-T (C.TRONIC.105.5)
!
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 57.
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.
79
ALL TYPES
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
ENGINE
SAXO
AUXILIARY EQUIPMENT DRIVE BELT Engines : CDZ – HDZ – HFX – (KFX – KFW) Saxo – (NFZ) Saxo - NFT Without air conditioning
With air conditioning.
- Fit the tool 4122-T.
- Fit the tool 4122-T.
- Tighten the tensioning screw (3) to obtain :
- Tighten the tensioning screw (5) to obtain :
55 ± 3 SEEM units.
120 ± 3 SEEM units.
- Tighten the screws (2) and (1).
- Tighten the screws (6) and (4).
- Remove the tool 4122-T.
- Remove the tool 4122-T.
B1BP10UC B1BP10WC
B1BP10VC B1BP10XC
80
XSARA PICASSO
Engine : NFZ (Xsara Picasso) Without air conditioning Tools. [1] Plyers for removing plastic pegs [2] Belt tension measuring instrument [3] TORX spanner
: 7504 –T. : 4122 –T.
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
81
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
ENGINE
XSARA PICASSO
AUXILIARY EQUIPMENT DRIVE BELT Engine : NFZ (Xsara Picasso) With air conditioning. Tools. [1] Plyers for removing plastic pegs [2] Belt tension measuring instrument [3] 10 mm square (drain spanner). [4] 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
82
XSARA
Engine : KFX - KFW (Xsara) 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.
- Reused belt 75 SEEM units.
- Reused belt 75 SEEM units.
B1BP1B2C B1BP122C
B1BP1B3C B1BP124C
83
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
SAXO - XSARA
Engines : NFX - NFU Without air conditioning (1) Tensioner roller fixing screw. (2) Tensioning screw. - New belt : 120 SEEM units. - Reused belt : 86.5 ± 3.5 SEEM units.
B1BP1AMC
With air conditioning. (3) Tensioner roller fixing screw. (4) Tensioning screw. - 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
84
SAXO- XSARA
Engine : VJZ - VJY - VJX Without air conditioning - (6) Roller support fixing screw. - (7) Tensioning screw. - Pre-tension the belt (8) to : 120 SEEM units. - Rotate the crankshaft by 3 turns (Direction of rotation). - Adjust the belt (8) tension to : 120 SEEM units. - Tighten the screws (6) to : 2.5 m.daN. - Run the engine for 10 mm. - Check the tension.
B1BP11EC
With air conditioning. - (3) Roller support fixing screw - (5) Tensioning screw. - Pre-tension the belt (4) to : 120 SEEM units. - Rotate the crankshaft by 3 turns (Direction of rotation). - Adjust the belt (4) tension to : 120 SEEM units. - Tighten the screws (3) to : 2.5 m.daN. - Run the engine for 0 mm. - Check the tension. 85
B1BP11DC
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
ENGINE
XSARA
AUXILIARY EQUIPMENT DRIVE BELT Engines : LFX - LFY - RFV Without air conditioning - (3) and (5) Roller support fixing screws. - (6) Tensioning screw. - Tighten the belt, by loosening the screw (6) to : In SEEM units. LFX
LFY
RFV
100 ± 10
120 ± 10
100 ± 10
- Tighten the screws (3) and (5). - Rotate the crankshaft by 4 turns (Direction of rotation). - Loosen the screws (3) and (5). - Tighten the belt, by loosening the screw (6) to : In SEEM units. LFX
LFY
RFV
115 ± 5
120 ± 10
105 ± 10
- Tighten the screws (3) and (5) to 2 m.daN. B1BP00HC
86
B1BP00IC
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
87
XSARA
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
ENGINE
XSARA
AUXILIARY EQUIPMENT DRIVE BELT Engines : LFX - LFY - RFV - RFS With air conditioning.
- Fit the drive belt. - The tensioner roller (1). - Tightening des vis (3) à 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
88
Engine : RFV With air conditioning. - Loosen : - The screws (4) of the tensioner roller (13 mm angle spanner). - The screw (3). - Tendre la courroie en agissant sur la vis (3) pour obtenir une valeur de : - New belt : 120 SEEM units. - Reused belt : 90 SEEM units. - Tighten the screws (4) to 2 m.daN. - Rotate the crankshaft by 4 turns (direction of rotation). - Adjust the belt tension (if necessary ).
B1EP05FC
89
XSARA
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
XSARA - XSARA PICASSO
Engines : 6FZ - RFN
Without air conditioning
With air conditioning.
Tools [1] Plyers 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
90
B1BP23RC
Engines : WJZ Without power-assisted steering Tools :
[1] Belt tension measuring instrument :
4122-T.
Removal. - Loosen the screws (2). - Tighten the screw (1) until it is against its stop. - Remove the belt. Refitting. - Refit the belt. - Fit the tool [1] on the belt at "d". - Tighten the screw (1) to obtain : 106 ± 10 SEEM units. - Tighten the screws (2) to 2 m.daN. - Remove the tool [1].
B1BP1SDC
B1BP1SEC
91
ENGINE
XSARA
AUXILIARY EQUIPMENT DRIVE BELT
ENGINE
XSARA
AUXILIARY EQUIPMENT DRIVE BELT Engine : WJZ Without power-assisted steering With air conditioning. Tools :
[1] Belt tension measuring instrument :
4122-T.
Removal. - Loosen the screws (1). - Tighten the screw (2) until it is against its stop. - Remove the belt. 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
92
Engine : WJZ 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
93
ENGINE
XSARA
AUXILIARY EQUIPMENT DRIVE BELT
ENGINE
XSARA
AUXILIARY EQUIPMENT DRIVE BELT Engine : WJZ 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 (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
94
Engine : WJZ 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
95
ENGINE
XSARA
AUXILIARY EQUIPMENT DRIVE BELT
ENGINE
XSARA
AUXILIARY EQUIPMENT DRIVE BELT Engine : WJZ 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
96
Engine : DHY Without air conditioning
[2] Belt tension measuring instrument
: 4122-T
- Tension the belt by loosening the screw (4) to obtain : 115 ± 10 SEEM units - Tighten the screws (1) and (3). - Rotate the crankshaft by 4 turns (direction of rotation). - Loosen the screws (1) and (3). - Tension the belt to : 115 ± 10 SEEM units (if necessary).. - Tighten the screws (1) and (3) to 2 m.daN.
B1BP10GC B1BP10HC
97
ENGINE
XSARA
AUXILIARY EQUIPMENT DRIVE BELT
ENGINE
XSARA
AUXILIARY EQUIPMENT DRIVE BELT Engine : DHY With air conditioning
Tools (1) Peg
: 7019-T.
.- Loosen the screws (1). - Tighten or loosen the screw (2) until holes "a" and "b" are superimposed. - Place the peg [1] : (in the hole "a"). - Tighten the screw (2) until it is against its stop. - Loosen the screw (2), in order to remove the peg [1]. - Tighten the screws (1) to 2 m.daN.
B1BP1HHC
98
XSARA - XSARA PICASSO
Engine : RHY Without 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-used 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
99
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
ENGINE
XSARA - XSARA PICASSO
AUXILIARY EQUIPMENT DRIVE BELT Engine : RHY 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
100
XSARA - XSARA PICASSO
Engine : RHY With 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-used 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
101
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
ENGINE
XSARA - XSARA PICASSO
AUXILIARY EQUIPMENT DRIVE BELT Engine : RHY 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
102
ALL TYPES
TU 1
9
XU
3
M
M+
CDZ
HDZ
HFX
KFX
X
X
X
X
JP+
14
KFW
NFZ
NFT
X
X
X
K 09/2000 XSARA
X
X
XSARA 09/2000 K
X
Engine type SAXO
XSARA PICASSO See pages :
EW
XU
7
5
JP
JP4
NFU
NFX
JB
JP4
LFX
LFY
X
X
10 J4
6FZ
RFN
J4R
J4RS
RFV
RFS
X
X
X
X
X
X
X
X 108 to 111
105 to 107
103
ENGINE
CHECKING AND SETTING THE VALVE TIMING
115 to 116
122 to 126
117 to 121
122 to 126
ENGINE
CHECKING AND SETTING THE VALVE TIMING (continued)
TUD - XUD
Engine type
TUD
XUD
5
9 B
TD DHY
VJZ
VJY
VJX
SAXO
X
X
X
K 09/2000 XSARA
X
X
DW 8 B WJZ
TD RHY
X
X
XSARA 09/2000 K
X
XSARA PICASSO See pages :
10
X X
112 to 114
132
104
127 to 131
133 to 137
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engines : CDZ - HDZ - HFX - KFX - KFW - NFZ - NFT TOOLS - [1] Flywheel locating peg - [2] Camshaft pulley locating peg - [3] Square drive - [4] Belt tension measuring instrument - [5] Rocker plate
: : : : :
4507-T.A 4507-T.B 4507-T.J 4122-T 4533-T.Z
Tool kit 4507-T
CHECKING THE VALVE TIMING. - Peg the flywheel using the tool [1]. - Peg the camshaft pulley using the tool [2]. SETTING THE VALVE TIMING. NOTE : Remove the spark plugs, to allow the crankshaft to rotate more freely. - Rotate the engine by the crankshaft screw (1). - Peg the camshaft gearwheel. - Peg the flywheel. - Loosen the nut (2). - Totally slacken the belt by moving the tensioner roller. - Remove the belt. ESSENTIAL : Check that the tensioner roller rotates freely (no stiffness). B1EP067C
B1EP066C
B1EP0668C
105
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engines : CDZ - HDZ - HFX - KFX - KFW - NFZ - NFT (Continued).
REFITTING THE TIMING BELT. NOTE : Check that the pegs [1] and [2] are in place. WARNING : Ensure the belt is fitted in the right direction : The arrows "a" signify the crankshaft direction of rotation. Fit : - The timing belt, with the belt strip "b" well tightened, in the following order: Crankshaft pinion, camshaft pulley, water pump pulley, tensioner roller. -The tool [5] (Ensure it is fitted in the right direction in relation to the timing). - Bring the tensioner roller into contact with the belt. -Tighten the nut (2). PRE-TENSIONING THE TIMING BELT. - Fit the tool [4] on the tightened belt strip "b". - Loosen the nut (2). -Turn the roller (3) in an anti-clockwise direction using a square drive to obtain : 44 SEEM units - Tighten the nut (2) to 2 m.daN. - Remove the tools [1] [2] and [4]. - Rotate the crankshaft by 4 turns in the normal direction. ESSENTIAL : Never turn the crankshaft backwards. B1EP069C
106
B1EP06AC
Engines : CDZ - HDZ - HFX - KFX - KFW - NFZ - NFT (Continued). PRE-TENSIONING THE TIMING BELT (Cont.). - Ensure the timing is correctly set by refitting the pegs [1] and [2]. - Remove the cylinder head cover. - Fit the tool [5] (Ensure it is fitted in the right direction in relation to the timing). ADJUSTING THE BELT FITTING TENSION. - Fit the tool [4] to the tightened belt strip. - Loosen the nut (2). - Slacken the belt (not excessively). - Tighten the timing belt to obtain : 31 ± 2 SEEM units. - Tighten the nut (2) to 2.2 m.daN. - Remove the tools [1] [2] [4] and [5]. CHECKING THE BELT TENSION. -
Rotate the crankshaft by 2 turns in the normal direction of rotation. Check that the following components can still be pegged : Flywheel. Camshaft.
ESSENTIAL : If the components cannot be pegged, repeat the belt tensioning procedure.
107
ENGINE
CHECKING AND SETTING THE VALVE TIMING
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engines : NFX - NFU
TOOLS -
[1] [2] [3] [4] [5]
Belt tension measuring instrument Flywheel locating peg Camshaft pulley locating peg, exhaust Camshaft pulley locating peg, inlet Tensioning tool
: : : : :
4122-T 4507-T.A. 4533-T.A. C2 4533-T.A. C1 4707-T.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
108
B1EP11CC
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engine : NFX - NFU (continued)
SETTING THE VALVE TIMING - Remove the tools [1], [2], [3] and [4]. - 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. the back of the belt facing the corresponding teeth).
* (Identification marks = white paint lines on
- 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
109
B1EP11EC
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engine : NFX - NFU (continued)
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 strip (e). - Rotate the roller (2) (using tool [5]) in an anti-clockwise direction, to obtain: 63 SEEM units. - Tighten the roller (2) to 2 m.daN. - Tighten the six screws (5) to 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
110
B1EP11GC
Engines : NFX - NFU (Continued)
SETTING THE VALVE TIMING -
Remove the tools [1] , [2] , [3] and [4]. Rotate the engine by four turns in the normal direction. (do not turn backwards). Peg the flywheel [2]. 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.
111
ENGINE
CHECKING AND SETTING THE VALVE TIMING
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engines : VJZ - VJY - VJX TOOLS - Belt tension measuring instrument - Flywheel locating peg - Injection pump pulley locating peg - Camshaft pulley locating peg - Tensioning lever. - Pinion locking tool
: 4099-T or 4122-T : 4507-T.A. : 4527-T. S1 Tool kit 4507-T : 4527-T. S2 : 4507-T.J. : 6016-T.
CHECKING THE VALVE TIMING - Peg : the flywheel, the injection pump pulley, the camshaft pulley. SETTING THE VALVE TIMING - Peg : the flywheel, the injection pump pulley, the camshaft pulley. - Loosen the tensioner roller, and remove the belt. ESSENTIAL: Check that the tensioner and guide rollers rotate freely (no stiffness). If not, replace the roller(s). - Loosen the screws (1) and (3) (lock the pulley with tool 6016 - T). - Position pulleys (2) and (4) to the end of the slots (without tightening the screws (1) and (3)). B1EP07PC
112
Engines : VJZ - VJY - VJX (Continued)
SETTING THE VALVE TIMING - Fit the belt in the following order : The crankshaft pinion, the injection pump pulley, the camshaft pulley, the water pump pinion. WARNING : When positioning the belt on the injection pump and camshaft pulleys, they should be turned in the opposite direction of rotation so as to engage the nearest tooth. - Pre-tension (belt strip slightly tightened). NOTE : Check that the pulley fixings are not at the end of the slots (adjust by one tooth if necessary). - Tighten the screws (1) and (3) to 0.5 m.daN, loosen by 180°. (Gently tighten the screws (1) and (3) by hand). - Loosen the tensioner roller. - Tension to 100 SEEM units. - Tighten the tensioner roller to 2.3 m.daN.
B1EP07QC
113
ENGINE
CHECKING AND SETTING THE VALVE TIMING
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engines : VJZ - VJY - VJX (Continued) SETTING THE VALVE TIMING - Tighten the screws (1) and (3) to 2.3 m.daN (lock the pulleys using tool 6016-T). - Remove the tools. - Rotate the engine by 10 turns. - Peg : The flywheel, the pulleys (2) and (4). NOTE : If necessary, lightly slacken the belt (with the tensioner roller). - Loosen the screws (1) and (3) by 360° (gently tighten the screws (1) and (3) by hand). - Set a final tension of 55 ± 5 SEEM units. - Tighten the tensioner roller, and the screws (1) and (3) to 2.3 m.daN (lock the pulleys using tool 6016-T). - Remove the tools. - Rotate the engine by two turns. NOTE : If the belt is not correctly located on the pinions and pulleys, rotate it by an additional two turns. - Peg the flywheel. - Check that the camshaft and injection pump pulleys are correctly pegged. WARNING : If the visual check is not correct, repeat the setting operation. - Remove the tools.
114
Engine : LFX
TOOLS -
Belt tension measuring instrument Camshaft pulley locating peg Crankshaft locating peg Square drive
: : : :
4099-T or 4122-T 7004-T.G. 7014-T.N. Tool kit 7004-T 7017-T.W.
CHECKING THE VALVE TIMING - Remove the protective covers. - Peg the camshaft pulley at "a" using the tool 7004-T.G. - Peg the crankshaft at "b" using the tool 7014 - T.N. SETTING THE VALVE TIMING - Check that the pegs can be engaged correctly at "a" and "b". - Fit the belt in the following order : camshaft pulley, crankshaft pinion, water pump pinion, tensioner roller. - Peg the camshaft pulley at "a" and the crankshaft pinion at "b" . - Remove the peg at "b" only. - Bring the tensioner roller (2) into contact with the belt.
B1EP07SC
115
ENGINE
CHECKING AND SETTING THE VALVE TIMING
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engine : LFX (Continued) SETTING THE VALVE TIMING - Fit the tension measuring tool to the middle of the belt strip "c". - Turn the tensioner roller (2) (anti-clockwise direction) using the tool 7017-T.W to obtain the following measurement : 30 ± 2 SEEM units. - Tighten the screw (1) to 2 m.daN. - Remove the tools. - Rotate the crankshaft by two turns (do not turn backwards). - Check the setting by positioning the pegs at "a" and "b". - Remove the pegs. CHECKING THE TENSION - Rotate the crankshaft by two turns (do not turn backwards). - Peg the camshaft pulley at "a". - Fit the tension measuring tool on the belt strip at "c". - The tension measurement should be 44 ± 2 SEEM units. (If the measurement is not correct, repeat the tensioning procedure). - Remove the tools.
B1EP07RC
116
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engine : 6FZ - RFN TOOLS [1] Camshaft setting pegs [2] Crankshaft setting peg [3] Belt locking pin [4] Angular tightening adaptor [5] Hub immobilising tool
: : : : :
(-).0189.A (-).0189.B (-).0189.K 4069-T 6310-T
Tool kit C.0189.
CHECKING THE VALVE TIMING.. - Turn the engine by the crankshaft pinion screw (3) to bring it to pegging position. - Peg the crankshaft, using tool [2]. - Peg the camshaft pulleys, using tools [1]. NOTE : The pegs [1] must go in without effort.
B1BP22SC B1BP25PC
117
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engine : 6FZ - RFN CHECKING THE VALVE TIMING. (continued). WARNING : If the pegs do not engage without effort, restart the fitting and tensioning of the timing belt (see below). SETTING THE VALVE TIMING Remove - Remove the screws (2), the pulley (1), upper valve cover (4), lower valve cover (3). - Turn the engine by the screw (13) of the pinion (12) to bring it to pegging position. - Peg the pulleys (8) and (9) using tools [1]. - Peg the pinion (12) using tool [2]. - Loosen the screw (7) of the tensioner roller (6). - Turn the tensioner roller (6) (clockwise). - Remove the timing belt (10).
B1BP23XC B1EP14JD
118
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN Refit (continued) - Refit the belt (10) on the pinion (12). - Hold the belt (10) with tool [3]. - Position the belt (10) in the following order : - The guide roller (11), the inlet camshaft pinion (9), the exhaust camshaft pinion (8), the water pump (5), the tensioner roller (6). NOTE : Make sure that the belt (10) is as flush as possilble with the outer face of the various pinions and rollers. -Remove the tools [3] and [1]. Timing belt tension Adjusting the tension - Turn the roller (6) in the direction of the arrow "b"; using an Allen key at "a". -Position the index "c" in its maximum setting at "d". IMPERATIVE : The index "c" must stand proud of the notch "f" by an angular value of 10°. If it does not, replace the tensioner roller (6) or the timing belt and the tensioner roller (6). - Bring the index "c" to its adjusting position "f" by turning the tensioner roller (6) in the direction of the arrow "e"; WARNING: The index "c" must not stand proud of the notch "f" : if it does, restart the timing belt tensioning operation; IMPERATIVE : The tensioner roller (6) must not turn while its fixing is being tightened up. If it does, recommence the adjusting operation. B1EP14JD
119
B1EP14KC
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN Adjusting the tension (continued). - Tighten the screw (7) of the the tensioner roller (6) to 2.1 ± 0.2 m.daN. IMPERATIVE : The hexagonal drive of the tensioner roller (6) must be at 15° below the level of the cylinder head gasket "g". If not, replace the tensioner roller (6) or the timing belt and the tensioner roller (6). Refit (continued). - Remove the tools [1] and [2]. - Turn the crankshaft 10 times in the normal direction of rotation. IMPERATIVE : No pressure or outside action must be brought to bear on the timing belt. - Peg the inlet camshaft pulley, using the tool [1]. Checks. Timing belt tension MPERATIVE : Check the position of the index "c", it should be facing the notch "f". If the position of index "c" is not correct, restart the adjustment of its position. Positioning of the crankshaft. - Fit tool [2]. - As long as it is possible to fit tool [2], continue with the refit operations. IMPERATIVE : If it is not possible to fit tool [2], reposition the flange (14). B1EP14LC B1EP14NC
120
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ – RFN
Checks (continued) Repositioning the flange. - Immobilise the crankshaft using tool [5]. - Loosen the screw (13). - Release the pinion (12) of the crankshaft. - Bring the flange (14) to the pegging position; using tool [5]. - Fit the tool [2]. - Immobilise the crankshaft using tool [5]. - Tighten screw (13) to 4 ± 0.4 m.daN, then angular tighten 53° ± 4° with tool [4]. - Remove tools [1], [2] and [5]. Refit : - The lower valve cover (3). - The upper valve cover (4). - The crankshaft pulley (1). - The screws (2). - Pretighten the screws (2) to 1.5 m.daN. - Tighten the screws (2) to 2.1 ± 0.5 m.daN. B1EP14PC
121
B1BP23XC
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engines : LFY - RFV - RFS TOOLS [1] [2] [3] [4] [5] [6]
Belt tension measuring instrument Camshaft pulley locating peg Crankshaft locating peg Camshaft pulley locking peg Tensioner spanner Toothed sector for locking the flywheel
: : : : : :
4122-T 9041-T.Z 7014-T.N 4200-T.G 7017-T.W 9044-T
Tool kit 7004-T 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
122
B1EP12GC
Engines : LFY - RFV - RFS
RFV - 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]. Remove :
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).
- The peg [3]. - The screw (4) (Brush the screw thread). - The pulley (5). - LThe lower cover (6).
B1EP11XC
B1EP11ZC
B1EP12OC
123
ENGINE
CHECKING AND SETTING THE VALVE TIMING LFY
ENGINE
CHECKING AND SETTING THE VALVE TIMING LFY
Engines : LFY - RFV - RFS
RFV - 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
LFY - RFV - 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).
B1EP11YC
B1EP121C
B1EP12OC
124
Engines : LFY - RFV - RFS
RFV - 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].
B1EP11YC
B1EP121C
B1EP12OC
125
ENGINE
CHECKING AND SETTING THE VALVE TIMING LFY
ENGINE
CHECKING AND SETTING THE VALVE TIMING LFY
Engines : LFY - RFV - RFS
RFV - RFS
- Tension to : (Pulleys slackened). Engine New belt
LFY - RFV - RFS 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.
B1EP11YC
B1EP121C
B1EP12OC
126
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engine : WJZ TOOLS
-
[1] HM screw [2] Locating peg Ø 6 mm [3] Flywheel locating peg [4] Toothed sector for locking the flywheel [5] Belt retaining clip [6] Square drive for adjusting the tension [7] Belt tension measuring instrument [8] Toothed sector for locking the flywheel
: : : : : : : :
(-) 0 188 (-) 0 188 (-) 0 188 (-) 0 188 (-) 0 188 (-) 0 188 4122-T 6016-T
E H D ( ou 7014-T.J) F K J
Tool kit (-) 0 188.
Checking the valve timing - Peg the flywheel using tool [3]. - Visually check that the offset between the camshaft and injection pump hub holes, and the corresponding pegging holes do not exceed 1 mm.
B1CP045C
127
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engine : WJZ SETTING THE VALVE TIMING Peg : - The camshaft hub (1), using tool [1]. - The injection pump pinion (2), using tool [2]. - The flywheel, using tool [3]. - Lock the flywheel, using tool [4]. - Refit the screw (3) (without tightening it). (Coat the threads with E6). - Tighten the screw (3) to 4 m.daN and finish by carrying out an angular tightening of 60°. - Remove the tool [4]. - Retighten screws (4) and (5) by hand. - Turn the pinions (6) and (2) so that they are at the end of their stops. (Clockwise direction). - Place the belt on the crankshaft and hold in place using tool [5]. - Fit the belt in the following order: - Roller (7), pinion (2), pinion (6), pump (8) and roller (9). B1EP130C
B1CP045C
B1EP131C
128
B1EP132C
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engine : WJZ SETTING THE VALVE TIMING (Continued) NOTE : If necessary, slightly turn pinions (6) and (2) in an anti-clockwise direction in order to fit the belt. The angular movement of the belt in relation to the pinions must not exceed 1/2 tooth. - Fit the tool [7] to the belt strap at "a". - Turn the roller (9) (anti-clockwise) using tool [6], to obtain: 106 ± 2 SEEM units. - Check that pinions (6) and (2) are not at the end of their stops. Otherwise, repeat the belt fitting procedure from the beginning. Tighten: - The roller (9) to 4.5 m.daN. - The screws (4) and (5) to 2.5 m.daN. - Remove the tools [7]. [5]. [1]. [2] and [3].
B1EP133C
B1CP045C
B1EP134C
129
B1EP132C
ENGINE ENGINE
CHECKING AND SETTING THE VALVE TIMING Engine : WJZ SETTING THE VALVE TIMING (Continued).
Rotate the crankshaft by 8 turns (direction of rotation). Peg : - The hub (1), using tool [1]. - The pinion (2), using tool [2]. - The flywheel, using the tool [3]. Loosen : - The screws (4) and (5). - The roller (9). - Retighten screws (4) and (5) by hand. - Fit the tool [7] to the belt strap at "a". - Turn the roller (9) (anti-clockwise direction) using tool [6], to obtain : 42 ± 2 SEEM units.
B1EP133C
B1CP045C
B1EP134C
130
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engine : WJZ SETTING THE VALVE TIMING (Continued)
Tighten : - The roller (9) to 4.5 m.daN. - The screws (4) and (5) to 2.5 m.daN. - Remove the tool [7]. - Fit the tool [7] to the belt strap at "a". - The tensioning value should be between 42 ± 2 SEEM units. ESSENTIAL : If the value obtained is outside the set limits, repeat the tensioning operation. - Remove the tools [7]. [5]. [1]. [2] and [3]. - Rotate the crankshaft by 2 turns (direction of rotation). - Check the valve timing.
B1EP133C
B1CP045C
B1EP134C
131
B1EP132C
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engine : DHY TOOLS - Crankshaft locating peg - Camshaft and injection pump locating peg
: 7014 - T.J or 7014 - T.R : 7004 - T.G Tool kit 7004-T. CHECKS
- Peg the crankshaft. - Peg the pulleys (1) and (2) at "a" and «b». SETTING THE VALVE TIMING. - Peg the crankshaft. - Peg the pulleys (1) at "a" and (2) at «b». - Fit the belt in the following order : Crankshaft pinion, guide roller (3), injection pump pulley (2), camshaft pulley (1), tensioner roller (5), water pump (4). - Remove the pegs. - Free the tensioner roller (5) (nut (6) and screw (7)), retighten the screw (7). - Rotate the crankshaft by 2 turns. Do not turn backwards. - Loosen the tensioner roller (5), allow the tensioner to operate. - Retighten the screw (7) and the nut (6). Tighten to 1.8 m.daN. - Check the setting. NOTE : The injection pump is removed without changing the valve timing. (immobilise the injection pump pulley using the screws (8x125) at «b»). B1EP09KC
B1EP080C
132
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engine : RHY Tools [1] Belt tension measuring instrument [2] Tension lever [3] Engine flywheel peg [4] Belt compression spring [5] Camshaft pinion peg [6] Engine flywheel lock [7] Set of blocking plugs [8] Crankshaft pulley extractor
: : : : : : : :
4122-T (-).188.J2 (-).0288.D (-).0188.K (-).0188.M (-).0188.F (-).0188.T (-).0188.P
Checking the setting of the valve timing. Peg : - The engine flywheel, tool [3]. - The camshaft, tool [5]. WARNING : Should it be impossible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm, with the help of a mirror " a " and a Ø 7 mm screw. IMPERATIVE : If pegging is impossible, restart the adjusting. (See corresponding operation). B1BP1TTC
B1CP04CC B1BP1TSC
133
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engine : RHY SETTING THE VALVE TIMING. Peg : - The engine flywheel, tool [3]. -The camshaft, tool [5]. Loosen : - The three screws (9). - The screw (7) of the tensioner roller (6). Remove the timing belt. Checks. IMPERATIVE : Just before refitting, carry out the checks below : Check that : - The rollers (6), (11) and the water pump (10) turn freely (without play or tightness). - There are no traces of oil (on camshaft or crankshaft).
B1EP13DD
134
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engine : RHY SETTING THE VALVE TIMING (continued). - Retighten screws (9) by hand. - Turn the pinion (12) (clockwise) to the bottom of the buttonhole. - Refit the belt on the crankshaft, in the following order, using the tool [4] to keep the belt tight at "a". - Guide roller (11). - Fuel high pressure pump pinion (13). - Camshaft pinion (12). - Water pump pinion (10). - Tensioner roller (6). NOTE : If needed, slightly turn the pinion (12) anticlockwise (offset should not be more than one tooth). - Remove the tool [4].
B1EP13ED
B1EP13FC
B1EP13GD
135
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engine : RHY SETTING THE VALVE TIMING (continued). - Position tool [1] on the belt at "b". - Turn the roller (6) (anti-clockwise) using tool [2] to attain a tension of : 98 ± 2 SEEM units. - Tighten screw (7) of the roller (6), tighten to 2.5 m.daN. - Remove one screw (9) from the pinion (12). (to check that the screws are not against the end of the buttonhole). - Tighten the screws (9) to 2.m daN. - Remove tools [1].[2].[3] and [5]. - Rotate the crankshaft 8 times (normal direction of rotation). - Fit the tool [3]. - Loosen screws (9). - Fit tool [5]. - Loosen screw (7) (to free the roller (6)). - Fit tool [1]. - Turn the roller (6) (anti-clockwise), tool [2], to attain a tension of : 54 ± 2 SEEM units.
B1EP13HD
136
ENGINE
CHECKING AND SETTING THE VALVE TIMING Engine : RHY SETTING THE VALVE TIMING (continued). Tighten : - The screw (7) of the roller (6) to 2.5 m.daN. - The screw (9) to 2.m.daN. - Remove the tool [1]. - Refit the tool [1]. - Tension value should be : 54 ± 3 SEEM units. IMPERATIVE : If value is incorrect, restart the operation - Remove tools [1].[3] and [5]. - Rotate the crankshaft 2 times (normal direction of rotation). - Fit the tool [3]. WARNING : Should it be impossible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm. In the case of an incorrect value, recommence the operation. - Remove the tool [3]. B1EP13HD
137
ENGINE
XSARA
SPECIAL FEATURES OF THE TIMING Camshaft hub marking
11/97
LFY
Identification marks a - b Inlet camshaft
«a»
Exhaust camshaft
«b» Number in mark c
Inlet camshaft
N° 1
Exhaust camshaft
N° 2
Note : The identification marks are visible next to the pegging slot. Mark "c", bearing the number, is engraved on the rear side of the hub (1).
B1EP11LC
B1EP11MC
138
Camshaft hub marking
Engines LFY
RFV
RFS
LFY - RFV - RFS
Hubs
‘‘a’’ marking
‘‘b’’ paint marking
Inlet
C
BLUE
Exhaust
D
BROWN
Inlet
A
GREEN
Exhaust
B
BLUE
B
BLUE
Inlet Exhaust
B1EP122C
139
ENGINE
XSARA
SPECIAL FEATURES OF THE TIMING
ENGINE
VALVE CLEARANCE SETTINGS
ALL TYPES
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 (except 16V)
Petrol - 16V Diesel 2.0 HDi
Diesel All Types except 2.0 HDi
0.20 mm ± 0.05
0.40 mm ± 0.05
Hydraulic adjustment
0.15 mm ± 0.08
0.30 mm ± 0.08
Fully open (Exhaust)
Rocking
Exhaust
Valves fully open
Adjust
1●
1 4●
4
3●
3 2●
2
4●
4 1●
1
2●
2 3●
3
Exhaust ● Inlet
Engines without hydraulic adjustment : the clearance (J) should be checked opposite the cam.
B1DP13QC
140
Adjust
1
3 ●
4
3
4 ●
2
4
2 ●
1
2
1 ●
3
To be read with the Petrol and Diesel correspondence tables
Tools Tool kit 4103-T
TU all types 1.0 i
Engine type
CDZ
1.1 i HDZ
HFX
XU all types
1.4 i KFX
1.6i
KFW
NFZ
NFT
1.6i 16 V
1.8 i
NFU
NFX
5.3
TUD all types 1.5 D
Pressure (Bars)
XU all types
LFY
2.0 i 16 V 6FZ
RFN
RFS
90° 6
4
RFV 80°
5.5
4 000
Rpm
Temperature (°C)
LFX 80°
4
Pressure (Bars)
EW
1.8 i 16 V
90°
Temperature (°C)
Engine type
ALL TYPES
VJZ
VJY
VJX
DW8
DW10TD
1.8 D
2.0 HDi
WJZ
RHY 80°
90° 4
4.5
Rpm
4 000
141
4
6.4
ENGINE
CHECKING THE OIL PRESSURE
ENGINE ENGINE
ALL TYPES
ENGINE OIL PRESSURE SWITCH
Engine type 1.0 i 1.1 i TU all types
1.4 i
1.6 i 16v
Tightening torque (m.daN)
Above the oil filter
2.8
Warning lamp goes out at : (Bars)
CDZ HDZ HFX KFX KFW NFZ
1.6 i
Location
NFT 0.5
NFX NFU
XU all types
1.8 i
LFX LFY
1.8 i 16v EW
6FZ RFN
XU all types
2.0 i 16v
RFS
Close to the oil filter
3
RFV
D6AP01MB D6AP01ND
142
Engine type
Location
Tightening torque (m.daN)
Above the oil filter
3.4
Warning lamp goes out at : (Bars)
VJZ TUD
1.5 D
VJY VJX
DW8
1.9 D
WJZ
DW10
2.0 HDi
RHY
0.5 2.8
Close to the oil filter
D6AP01MB D6AP01ND
143
ENGINE
ALL TYPES
ENGINE OIL PRESSURE SWITCH
ENGINE ENGINE
ALL TYPES
OIL FILTERS To be read with the Petrol and Diesel correspondence tables TU all types 1.0 i CDZ
PURFLUX
PURFLUX
1.4 i
1.1 i HDZ
XU all types
HFX
KFX
1.6 16 V
1.6 i
KFW
NFZ
NFT
NFU
LFX
XU all types
1.8 i 16 V
1.8 i
NFX
EW
LFY
6FZ
2.0 i 16 V RFN
RFS
RFV
LS 867
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
LS 304
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
TUD all types
DW8
DW10
1.5 D
1.8 D
2.0 HDi
VJX
WJZ
RHY
●
●
●
VJZ
VJY
LS 867
●
●
LS 304
●
●
Specifications
LS 867 LS 304 144
Ø (mm)
Height (mm)
76
89
ALL TYPES
Filling and bleeding
- Fit the cylinder adaptor [2] 4222-T (Picasso) 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 third 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 (Picasso). - Top up the system to the max. mark, with the engine cold. - Refit the filler cap
B1GP00AC E5AP1GNC
145
ENGINE
FILLING AND BLEEDING THE COOLING CIRCUIT
SAXO - All Types Vehicle
IDLING - ANTI-POLLUTION Engine type
INJECTION
1.0 i
Emission standard
BOSCH MA3.1 BOSCH MA3.1 L3
1.1 i Dual fuel 1.1 i
HFX
KFX
L4
BOSCH M7.4.4.
CO2
< 0.5
>9
850
SAGEM 2000 L3
M. MARELLI 1AP81
IF L4
BOSCH MP7.3 BOSCH MP5.2
NFZ
L3
1.6 i (100 hp)
NFT
L4
BOSCH M7.4.4.
L3
M. MARELLI 1AP41
L4
M. MARELLI 48P2
NFX
CO
BOSCH MA3.1
1.6 i (90 hp)
1.6 i 16V
Auto. gbox : N gear engaged
% Content
BOSCH MA3.1(Petrol)/ BRC ECOGAS (LPG)
KFW 1.4 i
Man. gbox
CDZ
HDZ
SAXO
Make - Injection type
CDY 1.1 i
Idling speed (± 50 rpm)
146
850
800
IDLING - ANTI-POLLUTION Engine type
1.4 i 1.4 i Dual fuel
KFX
1.4 i XSARA
1.6 i
NFZ
1.8 i
LFX
Make - Injection type
K'/L3
M. MARELLI 1AP40
L3
SAGEM SL96 (Petrol)/ BRC FLYING INJECTION (LPG)
1.8 i 16V Dual fuel
Man. gbox
IF L4
BOSCH MP7.3
K'/L3
BOSCH MP5.2 M. MARELLI 1AP20
1.8 i 16V
Idling speed (± 50 rpm)
L3
SAGEM SL 96 (Petrol)/ NECAM KOLTEC (LPG)
RFV
BOSCH MP5.2
RFS
M. MARELLI 1AP10
2.0 i 16V 147
CO
CO2
< 0.5
>9
850
800 800
SAGEM SL96 LFY
Auto. gbox : N gear engaged
% Content
INJECTION
Vehicle
Emission standard
XSARA - All Types
850
XSARA PICASSO - All Types Vehicle
INJECTION
XSARA PICASSO
Engine type
IDLING - ANTI-POLLUTION Emission standard
Make - Injection type
Idling speed (± 50 rpm) Man. gbox
1.6i (90 hp)
NFZ
L3
BOSCH - MP7.2
850
1.8i
6FZ
L4
SAGEM - S2000
700
148
Auto. gbox : N gear engaged
% Content CO
CO2
< 0.5
> 0.9
IDLING - ANTI-POLLUTION Make - Injection type
HDZ
L3 / W3
BOSCH MA3.1
HFX
L4 / W4
BOSCH M 7.4.4.
Engine type
1.1 i
Idling speed (± 50 rpm) Man. gbox
Auto. gbox : N gear engaged
% Content CO
CO2
< 0.5
>9
INJECTION
Vehicle
Emission standard
BERLINGO - All Types
K'/L3 BERLINGO
1.4 i KFX 1.4 i Dual fuel
W3
M. MARELLI 1AP40
L3
SAGEM SL96 / BRC FLYING INJECTION
1.4 i
KFW
L4 / W4
SAGEM 2000
1.8 i
LFX
L3 / W3
M. MARELLI 1AP20
149
850
800
SAXO - All Types
PETROL INJECTION SAXO
Engine type
1.0 i
1.0 i
CDZ
CDY
INJECTION
Emission standard Injection make and type
1.1 i Dual fuel
1.1 i
HDZ
HFX
L3 BOSCH MA3.1
BOSCH MA3.1
Fuel pressure (bars)
BOSCH MA3.1 (Petrol)
BRC ECOGAS (LPG)
6 420
6 420
6 510
6 000
Injection cut-in during deceleration (rpm)
1500
1500
1500 except 1st
/
2 500 at 20° C
Idling actuator or stepper motor resistive value (ohms) Air temperature sensor resistive value (ohms)
SAGEM S2000
/
7 3800 at 10° C
M. MARELLI M7.4.4
/
Overspeed cut-off (rpm)
Engine coolant temperature sensor resistive value (ohms)
KFW L4
1
Injector resistive value (ohms)
1.1 i
800 at 50° C
230 at 90° C
800 at 50° C
230 at 90° C
Idling actuator: 11 3800 at 10° C
2 500 at 20° C 150
SAXO - All Types
PETROL INJECTION SAXO 1.4 i
1.6 i
Engine type
NFZ
NFT
NFX
NFX
L3
IFL4
L3
L4
L3
L4
M. MARELLI 1AP81
BOSCH MP7.3
BOSCH MP5.2
BOSCH M.7.4.4
M. MARELLI 1AP41
M. MARELLI 48P2
3.5
3.5
2.5
2.5
6 400
6 440
6 314
7 300
exc. aircon: 1 426 stationary: 4 550≈
1 500
1 300 at 2 500 except 1st
1 300 at 2 400 (no cut-off with no throttle)
3.5
14.5
14.5
Overspeed cut-off (rpm)
Injector resistive value (ohms) Engine coolant temperature sensor resistive value (ohms)
16
14.5
3800 at 10° C
2 500 at 20° C
Idling actuator or stepper motor resistive value (ohms) Air temperature sensor resistive value (ohms)
16 V
KFX
Fuel pressure (bars)
Injection cut-in during deceleration (rpm)
(100 hp)
KFX
Emission standard Injection make and type
(90 hp)
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 151
INJECTION
AUTO.
PETROL INJECTION
XSARA - All Types
XSARA 1.4 i Dual fuel
1.6 i
KFX
NFZ
Engine type
INJECTION
Emission standard Injection make and type Fuel pressure (bars) Overspeed cut-off (rpm) Injection cut-in during deceleration (rpm) Injector resistive value (ohms) Engine coolant temperature sensor resistive value (ohms)
K'/L3 M. MARELLI 1AP40
L3 SAGEM SL96 (petrol)
K'/L3
BOSCH MP7.3
BOSCH MP5.2
/
3.5
2.5
3 6 500
6 400
6 000
6 440
6 314
Depending on gear ratio
1 500 at 1 800
/
1 500
1 300 at 2 500 except 1st
14.5
16
/
12
14.5
3800 at 10° C
2 500 at 20° C
Idling actuator or stepper motor resistive value (ohms) Air temperature sensor resistive value (ohms)
IFL4 BRC FLYING INJECTION (LPG)
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 152
PETROL INJECTION
XSARA
1.6i 16V
2.0I 16V
NFU
RFN
L3
L4
BOSCH M7.4.4.
M. MARELLI MM 48.P2
Engine type Emission standard Injection make and type Fuel pressure (bars)
3
1
3
Overspeed cut-off (rpm)
6 530
7 300
Injection cut-in during deceleration (rpm)
1 200
1 350
Injector resistive value (ohms)
14.5
16
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)
INJECTION
XSARA
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 153
PETROL INJECTION
XSARA - All Types
XSARA 1.8 i Engine type
INJECTION
Emission standard
16 V
1.8 i 16 V Dual fuel
LFX
LFY
LFY
L3
L3
L3 NECAM KOLTEC (LPG)
M. MARELLI 1AP20
SAGEM SL96
SAGEM SL96 (petrol)
3
3
3
/
Overspeed cut-off (rpm)
6 400
6 500
6 500
6 300
Injection cut-in during deceleration (rpm)
1 400
1 500
1 500
1 300 at 1 500
Injector resistive value (ohms)
14.5
16
16
/
Engine coolant temperature sensor resistive value (ohms)
3800 at 10° C
Injection make and type Fuel pressure (bars)
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 154
PETROL INJECTION
XSARA - BERLINGO - All Types BERLINGO
2.0 i 16 V Engine type
1.1 i HDZ
1.4 i HFX
KFX
RFV
RFS
L3
L3
BOSCH MP5.2
M. MARELLI 1AP10
BOSCH MA3.1
BOSCH M7.4.4
M. MARELLI 1AP40
3
3
1
/
3
Overspeed cut-off (rpm)
6 530
7 300
6 510
6 000
6 500
Injection cut-in during deceleration (rpm)
1 200
1 350
1 500 except 1st
/
Depending on gear ratio
Injector resistive value (ohms)
14.5
16
7
/
12
Emission standard Injection make and type Fuel pressure (bars)
Engine coolant temperature sensor resistive value (ohms) Idling actuator or stepper motor resistive value (ohms) Air temperature sensor resistive value (ohms)
3800 at 10° C
L3
2 500 at 20° C
K'/L3
800 at 50° C
Stepper motor: 53 3800 at 10° C
230 at 90° C Stepper motor: 53
2 500 at 20° C 155
800 at 50° C
230 at 90° C
INJECTION
XSARA
BERLINGO - All Types
PETROL INJECTION BERLINGO 1.4 i (Dual fuel )
1.4 i Engine type
INJECTION
Emission standard Injection make and type Fuel pressure (bars) Overspeed cut-off (rpm)
KFX
KFW
KFX
LFX
W3
L4 /W4
L3
K'/L3
M. MARELLI 1AP40
SAGEM S2000
SAGEM SL96
BRC FLYING INJECTION
M. MARELLI 1AP20
3
3.5
3.5
/
3
6 500
6 440
6 440
6 000
6400
1 500
1 500 at 1800
/
1 400
12
12
/
14.5
Injection cut-in during deceleration (rpm) Injector resistive value (ohms) Engine coolant temperature sensor resistive value (ohms)
12 3800 at 10° C
2 500 at 20° C
Idling actuator or stepper motor resistive value (ohms) Air temperature sensor resistive value (ohms)
1.8 i
800 at 50° C
230 at 90° C
Stepper motor: 53 3800 at 10° C
2 500 at 20° C 156
800 at 50° C
230 at 90° C
PETROL INJECTION
XSARA PICASSO - All Types
1.6 i
1.8i 16 V
NFZ
6FZ
L3
L4
BOSCH MP7.2
SAGEM S2000
Engine type Emission standard Injection make and type Fuel pressure (bars)
3.5
1
3.5
Overspeed cut-off (rpm)
6 300
6 500
Injection cut-in during deceleration (rpm)
1 150
1 300
Injector resistive value (ohms)
14.5
12.2
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)
INJECTION
XSARA PICASSO
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 157
EMISSION STANDARDS
ALL TYPES
APPLICATIONS
STANDARD E.E.C
PSA A-S
RP
Engines
Vehicle
INJECTION
Private vehicles: > 2 litres • new cyl. < 2 litres • existing cyl. < 2 litres ECE R 15.04
ECE R 15.05
K K’
W vp
15.04 15.04
15.05
Petrol Diesel
Petrol
Utility vehicles: All Types
Private vehicles: > 2 litres • new models • existing models
NOTES
CHARACTERISTICS
Applicable
➞ 06/89 ➞ 06/92 ➞ 12/92
Brussels directive 83/351 ➞ except special derogations for certain private vehicles cyl. > 2 litres
➞ 10/89
➞ Utility vehicle limits
imminent
= private vehicle limits increased by 25 % ➞ For private vehicles and utility vehicles in major export
01/10/88 ➞ 01/10/89 ➞ 158
Brussels directive 88/76 " Luxembourg Accords " ➞ Replaced by 89/458 + 91/441
With oxygen sensor, without catalytic converter
EMISSION STANDARDS
A-S
RP
Engines
Vehicle
Brussels directives 88/76
All Types
W vu
15.05
and 88/436
• new models
01/10/88 ➞
• existing models
01/10/89 ➞
Petrol Diesel
CHARACTERISTICS
Applicable
Utility vehicles:
ECE R 15.05
NOTES
INJECTION
E.E.C
PSA
ALL TYPES
APPLICATIONS
STANDARD
➞ 10/94
➞ Utility vehicle limits = private vehicle limits of Brussels directive 88/436 7 classes of limits byvehicle weight
Private vehicles: US 83
Z
US 83
Petrol Diesel
Current
➞ Adoption of U.S. standard
With oxygen sensor
• certain non-EEC
and catalytic converter
European countries
for petrol vehicles
• certain Export countries 159
ALL TYPES
EMISSION STANDARDS APPLICATIONS
STANDARD E.E.C
PSA A-S
RP
NOTES
Engines
Vehicle
Current
➞ Adoption of U.S. standard
Applicable
INJECTION
US 87
Y
US 87
Diesel
Private vehicles: • certain non-EEC European countries • certain Export countries
US 93
Y2
US 93
Petrol Diesel
Private vehicles: • certain Export countries
Current
➞ Adoption of U.S. standard
US 84
Utility vehicles: • certain non-EEC European countries • certain Export countries
Current
Petrol Diesel
➞ Adoption of U.S. standard standard for light utility vehicles
US 87
Utility vehicles: • certain non-EEC European countries • certain Export countries
Current
Petrol Diesel
➞ Adoption of U.S. standard standard for light utility vehicles
US 84 LDT
US 87 LDT
X1
X2
CHARACTERISTICS
160
With catalytic converter and EGR
ALL TYPES
EMISSION STANDARDS APPLICATIONS
E.E.C
US 90 LDT
PSA A-S
X3
RP
US 90
Engines
Vehicle
Petrol Diesel
Private vehicles: • certain non-EEC European countries • certain Export countries
EURO 1 (EURO 93)
L1
CEE 19.5
Petrol Diesel
EURO 1 (EURO 93)
L
CEE 19.5
Petrol Diesel
Private vehicles: < 1.4 litres • new models • existing models
Private vehicles: All Types • new models • existing models • new models • existing models
NOTES
CHARACTERISTICS
Applicable Current
➞ Adoption of U.S. standard standard for light utility vehicles
INJECTION
STANDARD
Brussels directive 89/458 07/92 ➞ ➞ 01/07/93 ➞ 31/12/94
07/92 ➞ 01/93 ➞ ➞ 01/96 ➞ 01/97 161
➞ Possible alternative to emission standard L from 1992 to 1994
EU Brussels Directive 93/59 (91/441)
With oxygen sensor and catalytic converter for petrol vehicles. With catalytic converter and EGR for diesel vehicles.
ALL TYPES
EMISSION STANDARDS APPLICATIONS
STANDARD E.E.C
PSA A-S
RP
Engines
INJECTION
EURO 1 (EURO 93)
W2
CEE W2
Petrol Diesel
EURO 2 (EURO 96)
L3
CEE 95
Petrol Diesel
Vehicle Utility vehicles: < 3.5 tonnes • new models • existing models Class 1 : • new models • existing models Class 2/3 : • new models • existing models
Private vehicles: < 6 seats and < 2.5 tonnes • new models • existing models
NOTES
CHARACTERISTICS
Applicable
01/10/93 ➞ 01/10/9 ➞
➞ 01/97 ➞ 10/97 ➞ 01/98 ➞ 10/98
Brussels Directive 93/59
➞ 3 classes depending on vehicle weight : Class 1 < 1250 kg Class 2 : 1250/1700 kg Class 3 > 1700 kg
Brussels Directive 94/12 01/96 ➞ 01/97 ➞ 162
➞ EURO 93 standard made stricter
With oxygen sensor and catalytic converter for petrol vehicles
With oxygen sensor and reinforced catalytic converter for petrol vehicles. With catalytic converter and EGR for diesel vehicles.
EMISSION STANDARDS APPLICATIONS
E.E.C
PSA A-S
RP
EURO 2 (EURO 96)
W3
CEE 95
EURO 3 (EURO 2000)
L4
CEE 2000
Engines
Petrol Diesel Gas
Petrol Diesel Gas
Vehicle Utility vehicles: < 3.5 tonnes Class 1 : • new models • existing models Class 2/3 : • new models • existing models Private vehicles: All Types • new models • existing models
ALL TYPES NOTES
CHARACTERISTICS
Applicable
Brussels Directive 96/69 01/97 ➞ 10/97 ➞ 01/98 ➞ 10/98 ➞
01/2000 ➞ 01/2001 ➞
163
➞ 3 classes depending on vehicle weight : Class 1 < 1250 kg Class 2 : 1250/1700 kg Class 3 : 1700 kg
Brussels Directive 98/69
➞ EURO 2 standard (L3) made stricter ➞ Fiscal incentives
With oxygen sensor and reinforced catalytic converter for petrol vehicles. With catalytic converter and EGR for diesel vehicles.
With 2 oxygen sensors and catalytic converter for petrol vehicles. With catalytic converter and EGR for diesel vehicles.With EOBD on-board diagnosis.
INJECTION
STANDARD
ALL TYPES
EMISSION STANDARDS APPLICATIONS
STANDARD E.E.C
PSA A-S
RP
Engines
Vehicle
INJECTION
(EURO 2000)
W3
Petrol Diesel Gas
Brussels Directive 98/69
< 3.5 tonnes
➞ EURO 2 standard (L3)
• existing models
made stricter ➞ Fiscal incentives ➞ 3 classes depending on vehicle weight : Class 1 < 1305 kg Class 2 : 1305/1760 kg Class 3 : 1760 kg
Private vehicles:
Brussels Directive 98/69
• new models
➞ 01/2000 ➞ 01/2001
• existing models Class 2/3 : • nouveaux modèles
➞ 01/2001 ➞ 01/2002
All Types EURO 4
IF / L5
Petrol
CHARACTERISTICS
Applicable
Utility vehicles: Class 1 : EURO 3
NOTES
• new models
01/96 ➞
• existing models
01/97 ➞
164
➞ EURO 3 standard (L4) made stricter ➞ Fiscal incentives
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.
ANTI-POLLUTION TECHNICAL CHECKS (FRANCE)
ALL TYPES All Types Diesel (m -1)
All Types Petrol CO Corrected (In %) Conditions : At idle, engine warm.
# 01/96
Xantia, MMDCM injection on 1.6i (BFZ) engine, 1.8i (LFZ) engine and 2.0i (RFX) engine.Should the check reveal excessive CO, make sure that the ECU channel 25 is not connected to earth in error.
With catalytic converter Greater than 2.0i 89 M.Y. All Types 93 M.Y. CO less than 0.5 % at idle speed.
(See Info-rapid N° 77)
CO less than 0.3 % at fast idle speed between 2500 and 3000 rpm (*).
01/96 #
(*) Except : TU5 JP : 2200 rpm ± 100. XU5JP : 1500 rpm or 3100 rpm (± 100). XU7JP : 1500 rpm or 3100 rpm (± 100).
Atmospheric engine.
NOTE : On XU5JP and XU7JP engines at 1500 rpm, the check should be carried out with main beams, rear heated screen and cabin ventilation switched on and with the front wheels on maximum lock (if the vhicle has power-assisted steering).
Turbocharged engine.
Less than 2.5 m-1
Less than 3.0 m-1
Lambda Probe value 0.97 at 1.03. 165
INJECTION
Features :
Less than 4.5 % for vehicles registered before 10/86. Less than 3.5 % for vehicles registered after 10/86.
ALL TYPES
SAFETY REQUIREMENTS : PETROL/LPG DUAL FUEL SYSTEM
ESSENTIAL : Special precautions should be taken when dealing with gas powered systems INJECTION
SAFETY REQUIREMENTS. Only personnel who have been specially trained to work with petrol/LPG DUAL FUEL vehicles are authorised to carry out repairs to the DUAL FUEL system - Ensure that these qualified personnel are provided with acrylic-free overalls (risk of static electricity) In the event of a major gas leak - Isolate the vehicle in the open air, away from any buildings - Call the emergency services (police and fire brigade) should the situation get out of hand
166
SAFETY REQUIREMENTS : PETROL/LPG DUAL FUEL SYSTEM
ALL TYPES
Any work on a gas powered vehicle must be carried out in a ventilated area. Disconnect the battery negative terminal. Ensure the vehicle is connected to earth.
Before removing the fuel tank or working on the gas circuit located downstream of the safety electrovalve (on the gauge valve), perform the following operations : - Close the safety electrovalve. - Switch the engine to use gas. - Wait for the engine to stop due to lack of fuel.
Ensure the vehicle is kept away from the following hazards : - Sparks. - Flames. - Slow combustion (lit cigarette).
After each operation, check that the circuit is sealed using one of the following systems :
Drain the fuel tank using "flare" type material (following the instructions for this material) before performing one of the following operations : - Remove the gauge valve. - Working on the fuel tank.
Electronic detector . - Soapy water. - Any other leak detection product. Remove the fuel tank when the vehicle is to be subject to high temperatures (above 50oC) (spray booth). Do not clean the engine compartment with a high pressure device and do not use detergents .
167
INJECTION
PRECAUTIONS TO BE TAKEN BEFORE CARRYING OUT ANY REPAIR WORK
ALL TYPES
SPECIFICATIONS : PETROL/LPG DUAL FUEL SYSTEM
INJECTION B1HP0Q4P
B1CV0Q5P
168
ALL TYPES
(1) Fuel tank. - Capacity : 70 litres. - Max. pressure : during tests / in operation : 30 bars / 20 bars. - Max. operating temperature : 50°C. - Location : in the boot.
(6) Injectors and valves. - location : in the engine compartment, under the air manifold.
(2) Fuel gauge - supply voltage : 12 volts. - resistance : 0 to 15 ohms empty, 280 to 315 ohms full. - location : on the gauge valve;
(8) Temperature sensor 15°C. - location : on the control valve reheating circuit.
(7) Pressure sensor. - supply voltage : 5 volts. - location : on the evaporator control valve support.
(3) LPG gauge valve. - location : on the fuel tank.
(9) LPG filter. - Type : paper. - replacement intervals: every 60,000 Km. - location : on the evaporator control valve inlet union.
(4) Safety electrovalve. - supply voltage : 12 volts. - power : 8W .- resistance : 18 ohms. - location : on the gauge valve
(10) Supply electrovalve. - supply voltage : 12 volts. - power : 8W. - resistance : 18 ohms. - location : on the evaporator control valve inlet union.
(5) Filler orifice with safety valve. - location : on the rear right wing.
169
INJECTION
SPECIFICATIONS : PETROL/LPG DUAL FUEL SYSTEM
ALL TYPES
SPECIFICATIONS : PETROL/LPG DUAL FUEL SYSTEM
(11) Evaporator control valve. - make : NECAM. - type : MEGA.
Setting pressure - 2nd stage.
INJECTION
- Setting pressure for a new evaporator control valve : • - 970 ± 10 mb.
ESSENTIAL :
- Setting pressure for a used evaporator control valve : • - 960 ± 10 mb.
Before checking and setting the pressure, it is essential that you read through and follow closely BROCHURE REF : 0332.
(12) Stepper motor. - location : on the distributor.
Setting pressure - 1st stage. - Setting pressure for a new evaporator control valve : • 1450 ± 50 mb.
(13) Distributor. - location : on the evaporator control valve support.
- Setting pressure for a used evaporator control valve : • 1400 ± 50 mb.
(14) Distributor electrovalve. - supply voltage : 12 volts. - resistance : 25 ohms.
170
PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM
XSARA - XSARA PICASSO
Engine : RHY
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 regulateur (4) (no replacement parts). - Sealing ring (1) (no replacement parts). - High pressure outlet connector (3) (will cause a malfunction).
B1HP12CC
171
INJECTION
Cleaning. - The use of high pressure cleaners is prohibited .- Do not use compressed air.
PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM
XSARA - XSARA PICASSO
Engine : RHY
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
Paint mark
Location
Class 1
1
Blue
Class 2
2
Green
Sur la partie supérieure du Bobinage vers l'orifice de retour de carburant
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). 172
B1HP16PC
SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM
XSARA - XSARA PICASSO
SAFETY REQUIREMENTS 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.
173
INJECTION
Engine : RHY
XSARA - XSARA PICASSO
SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM Engine : RHY
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.
174
XSARA - XSARA PICASSO
CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engine : RHY
[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
Tool kit 4073-T
Connect the tool [1] between the booster pump and the fuel filter (white mark at "a" on the fuel supply pipe). Connect the tool [2] downstream of the diesel injectors, between the high 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
175
INJECTION
TOOLS
XSARA - XSARA PICASSO
CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engine : RHY (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. 176
CHECKS : AIR SUPPLY CIRCUIT
XSARA - XSARA PICASSO
TOOLS [1] Manual vacuum pump : FACOMM DA 16. IMPERATIVE : Respect the safety and cleanliness requirements. Vacuum pump. - Connect the tool [1] on the vacuum pump (1). - Start the engine. - Pressure should be 0.8 bar at 780 rpm. Boost pressure regulator electrovalve. - Connect the tool [1] between the electrovalve (2) and the valve (3) of the boost pressure regulator. Compare readings with the values in the table below. Engine speed (rpm)
Pressure (Bar)
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
177
INJECTION
Engine : RHY
XSARA - XSARA PICASSO
CHECKS : TURBO PRESSURE Engine : RHZ
INJECTION
Tools. [1] Pressure gauge for checking boost pressure : 4073-T.A Tool kit 4073-T [2] Sleeve for checking boost pressure : 4185-T [3] Adaptor sleeve : 4229-T Checks. IMPERATIVE : respect the following checking requirements : Engine at running temperature. 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 1000rpm. - Accelerate hard, and check the pressure : 0.6 ± 0.05 Bar (1500 rpm). - Accelerate freely in kick-down, (changing from fourth to third gear). - Check the pressure : 0.95 ± 0.05 Bar (between 2500 and 3500 rpm). - Remove the tools, reposition the pipe (1) and refit the collar (3). B1HP12JD
178
CHECKS : TURBO PRESSURE
XSARA - XSARA PICASSO Engines : RHY : 4073-T.A Tool 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
179
INJECTION
TOOLS. [1] Pressure gauge for checking boost pressure [2] Sleeve for checking boost pressure
XSARA - XSARA PICASSO
CHECKS : EXHAUST GASES RECYCLING CIRCUIT Engine : RHY TOOLS [1] Manual vacuum pump
: FACOMM 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)
Pressure (Bar)
780
0.5
2500
0
B1HP12GD
180
SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP
SAXO - XSARA
L3
Equipment
Transponder
SAXO XSARA
TUD
5
VJZ
DPC R 8444 B/ 662 C
DW
8
WJZ
DWLP 12 R8448 B 371 B
XUD
9TD
DHY
XUD 110 R8445B/ 081 A
XSARA
181
INJECTION
PUMP -TYPE - REFERENCE Emission standards
SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP
SAXO - XSARA Engine type
INJECTION
VJZ VJY VJX
Pump Type Reference
DPC R 8444 B/
*
Static timing
Dynamic
Initial advance Compression Time (cylinder N° 4)
timing checking (at idle)
14 ° before TDC (Not adjustable)
DWLP 12 WJZ
R 8448 B/
*
XUD 110 DHY
R 8445 B/
*
Crankshaft TDC hole. Value «X» engraved on the pump.
Reference
Injector
Injector holder + injector
RDN 12SDC 6849
LDC 010R01B
RDNO SDC 6903
LCR 6736001
6872D
6734 303D
( ) See table on page : 181
*
182
Injector Colour needle lift code pressure (Bar)
PINK
WHITE + GREEN
Adjustments (rpm)
Max. speed
Fast idling
Antistall
Idling
Unladen rpm
135 +5 - 0
1000 ± 100
1600 + 15 mm shim
800 ± 25
5450 ± 125
135.5 ±5
950 ± 25
1500 +3 mm shim
875 ± 25
875 ± 25
5350 ± 125
144.5 ± 2.5
950 ± 50
1500 + 4 mm shim
800 +0 -50 (1)
5150 ± 125
4600 ± 80
Laden rpm
SAXO - XSARA
CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP Engine : VJZ - VJY - VJX
- Flywheel locating peg - Mounting plate locating peg - Camshaft peg
: 4507-T.A : 4527-T.S1 : 4527-T.S2
Tool kit 4507-T
Checks - Peg the flywheel. - Visually check the pegging of the camshaft and pump pulleys, or check using the tools 4527-T.S1 and 4527-T.S2. Setting the injection pump - Peg : - The flywheel. - The camshaft pulley. - Fit the pump and tighten to 2.5 m.daN. - Peg the pump mounting plate. - Fit the pump drive pinion together with the timing belt. Tighten to 2.5 m.daN.
B1HP0YAC
183
INJECTION
Tools
CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP
XSARA
Engine : WJZ Evolution of the checking of the setting of the LUCAS diesel injection pump Old assembly.
NEW ASSEMBLY : RPO 7910 #
INJECTION
Diesel injection pump with hole for checking the setting
Diesel injection pump without a hole for checking the setting.
The setting of the diesel injection pump is done with the aid of the following tools :
The setting of the diesel injection pump is done with the aid of a peg at "c".
- A peg placed at "a". - A peg and a dial gauge placed in the checking hole at "b".
See method on following pages. B1HP1A4C
B1HP1A5C
184
CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP
XSARA
Engine : WJZ
[1] Flywheel locating peg [2] H M8 screw [3] Injection pump setting peg Ø 6 mm
: 7014-T.J. : (-).0188.E. Tool kit C.0188 : (-).0188.H
After carrying out the necessary dismantling operations on the vehicle, proceed in the following manner : Remove : - The screws (6), (7), (9), (10) and (12). - The upper casing (8). - The intermediate casing (11). WARNING : Refit the screw (6) equipped with a washer. (Thickness 5 mm). - Turn the front RH wheel to turn the engine. (Normal direction of rotation). - Bring the camshaft and injection pump pulleys to their setting point. - Position the flywheel peg, using tool [1]. (From above the vehicle). - Turn the engine until the peg [1] engages in the flywheel.
B1EP12NC
185
B1BP1S9C
INJECTION
Tools.
XSARA
CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP Engine : WJZ (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 pages 127 to 131). 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 pages 127 to 131). Remove: - The tools [1]. [2] and [3]. - The screw (6) and the washer. Reassemble the components. B1EP12WD B1BP1S9C
186
CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP
XSARA
Engines : DHY
1 2 3 4 5
TOOLS
4093-T Peg Bracket Dial gauge Flat end Relay lever
- Flywheel locating peg : 7014-T.J.Tool kit 7004-T - Bracket and peg : 4093-T Tool kit 4123-T
CHECKING THE PUMP - Peg engaged: The dial gauge should read "X" ± 0.03 engraved on the pump. - If not, check the timing again. SETTING THE PUMP - Insert the peg (1) into the pump - The peg must be against the guide tube "a". (If not, turn the engine backwards). - Fit the tool 4093-T. - Set the dial gauge to "0". - When the dial gauge starts to move, it signifies that the piston is nearing TDC. - Peg the flywheel. - Slowly turn the pump toward the engine until measurement "X" can be seen. B1HPOL6C B1HPON9C
("X" = Value engraved on each pump). 187
INJECTION
Rep :
SAXO - XSARA
ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS Engines : VJZ - VJY - VJX
ADJUSTING THE FAST IDLE INJECTION
Engine cold. - Ensure that the lever (1) is up against its stop to the right. - If not, adjust the tension of the cable (3) using the cable clamp (2). (Tighten to 0.5 m.daN). - Finish tensioning using the sleeve tensioner (4). - Tighten the lock nuts to 1.7 m.daN. Engine hot. - Ensure that the cable (3) is slack. - Check the operation of the thermostatic sensor on the coolant outlet housing. - There should be a minimum 6 mm cable travel between "engine cold" and "engine hot". - If this is not the case, replace the thermostatic sensor. Tighten to 2.5 m.daN.
B1HP08YD B1HP0HUC
188
ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS
SAXO - XSARA
Engines : VJZ - VJY - VJX (continued)
Engine stopped. - Fully depress the accelerator pedal. - Check that the lever (5) is against its stop (6), otherwise, alter the position of the clip (7) (Accelerator cable tension). - Ensure that in the idle position the lever (5) is against the stop (8). Adjusting the anti-stall (Residual output). - Insert a 1.5 mm thick shim between the lever (5) and the residual output adjustment screw (8). - Adjust the residual output adjustment screw (8) to obtain an engine speed of 1600 ± 100 rpm - Remove the 1.5 mm thick shim. Idling speed. Adjust the idle speed adjustment screw (9) to obtain a speed of 800 ± 25 rpm.
B1HP090D
189
INJECTION
ADJUSTING THE ACCELERATOR CONTROL.
SAXO - XSARA
ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS Engines : VJZ - VJY - VJX (continued) Checking the engine deceleration.
INJECTION
- Move the throttle lever (5) to obtain an engine speed of 3000 rpm. - Release the throttle lever (5). - The deceleration should be between 2 and 3 seconds. Deceleration too fast
Deceleration too slow
Problem encountered
Engine has a tendency to stall
Engine speed is greater than the idle speed
Step to be taken
Tighten the screw (8) by a quarter turn
Slacken the screw (8) by a quarter turn
NOTE : In each case, check the idle speed for any necessary adjustments. ESSENTIAL : Check the operation of the manually-operated "STOP" control (10).
B1HP090D
190
ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS
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
191
INJECTION
Engine : WJZ
XSARA
ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS Engine : WJZ (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
192
ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS
XSARA
Engine cold : - Check the fast idle speed. - Ensure that the lever (9) is against its stop by pushing it in the direction of the arrow (‘). If not, adjust with the cable clamp (8), and then the sleeve tensioner (4). Fast idle : - Refer to the specifications on page : 182 Engine hot : - Ensure that cable (7) is slack. Engine stopped: - Fully depress the accelerator pedal, check that the lever (5) is against its stop (3). Residual output (Anti-stall)) - Insert a 4 mm thick shim at (a) between the lever (5) and the screw (6). - Set the engine speed to 1500 ± 100 rpm using the stop screw (6). Idling speed : - 800 +0 rpm using the screw (2) (Air conditioning + 50 rpm). -50
Engine deceleration : from 3000 rpm to ‘‘0’’. - Deceleration too fast (tendency to stall) : Loosen (6) by a 1/4 turn. - Deceleration too slow : tighten (6) by a 1/4 turn. B1HPOYDD
193
INJECTION
Engine : RHY
FITTING DELPHI DIESEL INJECTORS
SAXO - XSARA
Engines : VJZ - VJY – VJX - DHY Fitting an injector
INJECTION
The copper seal (1) and the fire seal washer (3) are to be replaced each time they are removed.
[1] Tool to remove/refit injectors 7007-T [2] 7008-T.A Tool kit 4123-T
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 : VJZ 7 m.daN All Types 9 m.daN B1HPOYEC
B1HPOYFC
(3) Tighten lightly to prevent any distortion. Tighten to 1 m.daN + 20° or 6 m.daN. B1HPOYGC
194
FITTING DELPHI DIESEL INJECTORS
XSARA
Engine : WJZ [1] Tool to remove/refit injectors (2) Fitting an injector
[2]
7007-T
7008-T.A Tool kit 4123-T INJECTION
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
195
SAXO - XSARA - XSARA PICASSO
BOSCH INJECTION PUMP SPECIFICATIONS PUMP -TYPE - REFERENCE
Emission standards
L3/L4 Transponder
Equipment INJECTION
SAXO XSARA
VJZ TUD
VE 8 F 25000 R 611/5
VJY
5
SAXO
VJX
539
XUD
9TD
DHY
XUD 213 R 445/3
DW
10
RHY
CP1 (*)
XSARA
(*) = The fuel high pressure pump is driven by the timing belt. 196
SAXO - XSARA - XSARA PICASSO
Engine type
VJZ VJY
Pump Type Reference
VE 8F 2500 /
*
Static timing
Dynamic
(1) Initial advance Compression Time (cylinder N° 4)
timing checking (at idle)
539
Pump 0,60 ± 0,1 mm after BDC
DHY
XUD 213 VE R 445 / *
Pump 0,66 mm after BDC
RHY
CP1
Non-adjustable
DNOSD 3026
11°± 1°
Injector Colour
Injector
DNOSD 299 A
Setting by pegging
VJX
Reference Injector holder + injector
KCE 30S8
code
needle lift pressure (Bar)
GREEN
Adjustments (rpm) Fast idling
Antistall
Idling
Unladen rpm
1000 ± 100
835 ± 40 + 1 mm shim
800 ± 25
5450 ± 125
800 ± 100
5450 ± 160
5000 ± 160
875 ± 25
5350 ± 125
4500 ± 80
120 ±5
299
KCA 20S106
299
KCA 17S42 (218)
No
BLUE
175 +5 -0
± 50 (2)
+ 3 mm shim
96255 42580
(1) = Engine : TDC peg hole - (2) = Auto gearbox or air con. + 50 rpm - Auto gearbox and air con. + 100 rpm (*) = See table page : 196 197
Max. speed
Laden rpm
INJECTION
BOSCH INJECTION PUMP SPECIFICATIONS
SAXO - XSARA
CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP Engine : VJZ -VJY - VJX TOOLS
INJECTION
- Flywheel locating peg - Mounting plate locating peg - Camshaft peg
: 4507-T.A : 4507-T.S1 Tool kit 4507-T : 4507-T.S2 CHECKS
- Peg the flywheel. - Visually check the pegging of the camshaft and injection pump pulleys, or check using the tools 4527-T.S1 and 4527-T.S2. SETTING THE INJECTION PUMP. - Peg : • The flywheel. • The camshaft pulley. - Fit the pump and tighten to 2 m.daN. - Peg the pump mounting plate. - Fit the pump drive pinion together with the timing belt. Tighten to 2 m.daN. B1HP0YAC
198
CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP
XSARA
Engine : DHY TOOLS : 7017-T.R. : 4132-T. : 11 X 13 : 3089-T.H. : 7010.T. : 5003-T.D.
Tool kit 7004-T
Tool kit 4123-T.
SETTING THE INJECTION PUMP. - Tilt the pump in the retarded direction (away from the engine). - Fit the timing tool. - Turn the engine (direction of engine rotation) until the peg engages in the flywheel. - Ensure that the pump pinion can be pegged (if not, rotate the crankshaft by 1 turn). - Remove the tool 7017-T.R - Find the BDC position of the pump (by turning the crankshaft backwards) and set the dial gauge to ‘‘0’’. - Turn the crankshaft (direction of engine rotation) until the locating peg 7017-T.R engages. - Turn the pump, in the advance direction (towards the engine) until the dial gauge shows (See the table on pages : 197). NOTE : The dial gauge needle must not move when tightening. B1HP0YKD
199
INJECTION
- Flywheel locating peg - Ring spanner - Crescent spanner FACOM 57 - Dial gauge - Dial gauge bracket - 31 mm lever
XSARA
CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP Engine : DHY
TOOLS INJECTION
Flywheel setting peg
: 7017-T.R
Tool kit 7004-T
Checking the injection pump. - Remove the tool 7017-T.R. - Rotate the crankshaft (direction of rotation). - Peg the flywheel. - In this position, the dial gauge should show the value ‘‘X’’ (See the table on page : 197). - The value ‘‘X’’ corresponds to the travel of the pump piston in relation to the BDC. - Remove the tool.
B1HP0NQC
200
B1HP0NPC
CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP
SAXO - XSARA
Engine : VJZ - VJY - VJX ADJUSTING THE FAST IDLE SPEED. INJECTION
- Bring the lever (3) into contact with the screw (2). - Use the screw (2) to obtain the fast idle speed : 1100 ± 100 rpm. Engine cold : - Ensure that the lever (3) is up against the screw stop (2). - If not, slightly tension the cable (4) using the cable clamp (1). - Finish tensioning with the sheath tensioner (5). Engine hot : - Ensure that the cable (4) is slack. - Check the operation of the thermostatic sensor on the coolant outlet housing : there should be a minimum 6 mm cable travel between a cold and a hot engine. - If not, replace the thermostatic sensor. Tighten to 2.5 m.daN.
B1HP0HQC
201
B1HP0HUC
SAXO - XSARA
CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP Engine : VJZ - VJY - VJX (continued) ADJUSTING THE ACCELERATOR CONTROL. - Fully depress the accelerator pedal.
INJECTION
- Check that the lever (10) is against the stop screw (6). If not, modify the position of the spring clip (7). - Check that, at idle, the lever (10) is against its stop (9). Preliminary conditions : - Engine hot (The cooling fan is engaged twice). - Fast idle control released.
ADJUSTING THE IDLE SPEED. - Slacken the screw (9) by a few turns until it no longer touches the lever (10). - Adjust the idling speed using the screw (8).
B1HP0HSD
202
CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP
SAXO - XSARA
Engine : VJZ - VJY - VJX (continued)
output adjustment screw (9). - Turn the residual output adjustment screw (9) to obtain an engine speed of : 835 ± 40 rpm. - Remove the shim [1].
CHECKING THE ENGINE DECELERATION.E - Move the throttle lever (10) to obtain an engine speed of 3000 rpm. - Release the throttle lever (10). - The deceleration should be between 2 and 3 seconds.
ESSENTIAL : Check the operation of the manually-operated ‘‘STOP’’ control (11). B1HP0HRD
203
INJECTION
ANTI-STALL ADJUSTMENT - Insert a 1 mm shim [1] between the throttle lever (10) and the residual
FITTING BOSCH INJECTORS
SAXO - XSARA
Engines : VJZ - VJY - VJX - DHY [1] Tool to remove/refit injectors (2) Fitting an injector
[2]
7007-T
7008-T Tool kit 4123-T
INJECTION
The copper seal (1) and the fire seal washer (2) are to be replaced each time they are removed. NOTE : Fitting parts of different makes is PROHIBITED. WARNING : Ensure that the fire seal washer (2) is fitted the right way round. Tighten the injector holder on the cylinder head to : VJZ 7 m.daN All Types (3) Tighten lightly to avoid distortion. Tighten to 7 m.daN.
9 m.daN B1HP0YNC
B1HP0YPC
B1HP0YGC
204
PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM
XSARA - XSARA PICASSO
Engine : RHY Evolution : Classification of diesel injector carriers Reminder : RHY and RHZ are equipped with 4 diesel injector carriers marked according to their injection duct diameters (flow of diesel fuel). Identification. The injector carriers have an engraving or paint mark on the upper part of the coil, close to the diesel fuel return aperture : Mark 1 = BLUE paint mark = Injector class 1. Mark 2 = GREEN paint mark = Injector class 2. Identification marking: a : Supplier identification. b : PSA identification no. c : Identification of class. After Sales operations. ESSENTIAL : When changing a diesel injector carrier, order a component of the same class. # 15/11/98 (RPO No.) (injector carrier without marking), always order a class 2 injector carrier. B1HP16PC
205
INJECTION
16/11/98 #
ALL TYPES
SPARKING PLUGS
Vehicles – Models
IGNITION
SAXO
XSARA
BERLINGO
Engine type
1.0i
CDZ
1.1i
HDZ
1.4i
KFX
1.6i
NFZ
1.6i 16v
NFX
1.4i
KFX
1.6i
NFZ
1.8i
LFX
1.8i 16v
LFY
2.0i 16v
RFS
2.0i 16v
RFV
1.1i
HDZ
1.4i
KFX
1.8i
LFX
BOSCH
CHAMPION
EYQUEM
Electrode gap setting
FR7DE
RC8YCL
RFC58 LZ
0.9 mm
FR7DE
RC8YCL
RFC58 LZ
2.5 mdaN 0.9 mm
RFN 52 LZ FR7DE
RC8YCL
RFC58 LZ
FR7DE
RC8YCL
RFC58 LZ
206
Tightening torque
0.9 mm
SPEEDOMETER
ALL TYPES
An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled. This decree stipulates : -The speed indicated by a speedometer must never be lower than the actual vehicle speed. - Between the speed displayed «SD» and the speed travelled «ST», there must always be the following relationship :
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.
207
CLUTCH GEARBOX DRIVESHAFTS
VR < VL < 1.10 VR + 4 Km/h
CLUTCH SPECIFICATIONS
ALL TYPES
1.1 i
1.0 i Engine type
CDZ
HDZ
HFX
Gearbox
KFX
NFZ
180CPO 3400
200 CPR 3800
VALEO
Mechanism/Type
180 CP 3400 181 XJ (E73) 11 R 10 X
CLUTCH GEARBOX DRIVESHAFTS
Ext./Int. lining Ø Disc lining type
KFW
MA/4 - MA/5
Make
Clutch disc
1.6 i
1.4 i
180 XJF 73 C
180/127 F 408
11A12X 200/137
F 408
208
200X(D95)
F 808
ALL TYPES
CLUTCH SPECIFICATIONS 1.6i 16V
1.6i NFT
NFX
NFU
Gearbox
Clutch disc
VALEO 200 CPR 3800 200 X (D 95) 11 AX 12 X
Ext./Int. lining Ø Disc lining type
VJY
VJX
MA/5
Make Mechanism/Type
VJZ
LUK 200 CPX 3850
180 P 3000
200 XSL 73
180 D
200/137
180/135
F 410
F 808
209
F 410
CLUTCH GEARBOX DRIVESHAFTS
Engine type
1.5 D
CLUTCH SPECIFICATIONS
ALL TYPES 1.8i 16V
1.8i Engine type
LFX
LFY
2.0i 16V 6FZ
RFN
RFS
Gearbox
Clutch disc
1.9TD
2.0 HDi
WJZ
DHY
RHY
LUK
VALEO
LUK
200 P 3700
215 DT 5250
230 P 4700
BE4/5
Make Mechanism/Type
RFV
1.9D
VALEO 200 CP 4250
230 DNG 4700
200 B (D73) 33AX
230 DNG 4700
CLUTCH GEARBOX DRIVESHAFTS
Ext./Int. lining Ø
200/137
Disc lining type
F 408
215 DT 5250 215 F D95
228/155
215 F (D 93) 22 BX
215/147 F 808
210
200
215 FM (95) 11 AX
228
200/134
215/147
228
F408
F 202
F 408
SAXO - XSARA
CLUTCH : CHECKS AND ADJUSTMENTS Mechanically operated push-action clutch (adjustable) Engines
SAXO XSARA
Adjustable
CDZ-HDZ-HFX-KFX-KFW-NFZ-NFT-NFX-VJZ-VJY-VJX MA/5
Gearbox
Non-adjustable*
VJZ-KFX-NFZ
(*) See page 214)
Checks NOTE : Adjustable steering wheels should be put into the low position - Record the measurement ‘‘X’’ between positions L1, pedal at rest, and L2, pedal fully depressed. - Measurement ‘‘X’’ should be : (Pedal travel). SAXO 135 ± 5 mm Adjustments. - If the measurement is incorrect, adjust the clutch pedal travel "X". - Loosen the lock nuts (1). - To adjust the travel to conform with the measurements indicated above, either loosen or tighten the nut (2) (Tighten the nut to increase the travel, and loosen it to decrease the travel.) - Tighten the lock nut (1). B2BP023C
211
B2BP00GC
CLUTCH GEARBOX DRIVESHAFTS
ESSENTIAL : If the clutch control is new, squeeze the cable sheath before adjusting by declutching successively a minimum of 20 times.
CLUTCH : CHECKS AND ADJUSTMENTS
XSARA
Push-action clutch with automatic adjustment (non-adjustable) (*) Engines
Gearboxes
LFX - LFY - WJZ
BE3/5 – BE4/5 Refitting the clutch cable.
CLUTCH GEARBOX DRIVESHAFTS
- Set the pedal to the high position (contact at A). - Attach the cable end-piece to the pedal. - Refit a new clip (3) to the pedal. - Fit the end-piece (4) to the bulkhead (G6 grease). - Clip the end-piece (5) to the gearbox. - Refit the cable to the lever (1). - Depress the clutch cable several times to set the assembly in place. - Check that the end-piece (4) is properly fitted to the bulkhead. - Check the operation of the automatic adjusting device. 1) - Pull the lever (in direction F), the lever must move when pulled by hand. 2) - Press the clutch pedal very lightly and repeat the same operation. The lever should not move back. (*) See pages 215-216).
B2BP03CD
212
XSARA - XSARA PICASSO
CLUTCH : CHECKS AND ADJUSTMENTS Pull-action clutch with automatic adjustment (non-adjustable) (*) RFS - RFV - RHY
Gearbox
BE3/5
Refitting the clutch cable. - Set the pedal to the high position (contact at A). - Attach the cable end-piece to the pedal. - Refit a new clip (3) to the pedal. - Fit the end-piece (4) to the bulkhead (G6 grease). - Clip the end-piece (5) to the gearbox. - Refit the cable to the lever (1). - Depress the clutch cable several times to set the assembly in place. - Check that the end-piece (4) is properly fitted to the bulkhead. - Check the operation of the automatic adjusting device. 1) - Pull the lever (in direction F), the lever must move when pulled by hand. 2) - Press the clutch pedal very lightly and repeat the same operation. The lever should not move back. (*) See pages 215-216). B2BP03DD
213
CLUTCH GEARBOX DRIVESHAFTS
Engines
XSARA - XSARA PICASSO
CLUTCH : CHECKS AND ADJUSTMENTS
Adjustment of push and pull action clutch with automatic compensation (adjustment of compensation system) Engines : LFX - LFY - RFS - RFV - WJZ - DHY - RHY WARNING : If a system blockage is detected when checking, or if the pedal has been removed, the pedal position must be adjusted. This position is obtained by the angular displacement of the stop supports "a" and "b". Procedure
CLUTCH GEARBOX DRIVESHAFTS
- Loosen the nut (6) and the screw (7). - Using a lever, raise the stop support (8) to its highest position. - In this position, there must be a substantial free play in the pedal. - Lower the support until there is a free play of 2 ± 1 mm. - Tighten the screw (7) and the nut (6). - Check that the outer cable slides freely (at rest, the pedal is against its upper stop "A", the outer cable length should be variable). Characteristics - The automatic adjusting device requires no manual adjustment. - Pedal travel remains constant for all models 145 ± 5 mm. - Automatic adjustment is achieved by modifying the curvature of the outer cable. - Take extra care with the routing of the outer cable, and do not add any supplementary fixing points. B2BP03EC
214
CLUTCH : CHECKS AND ADJUSTMENTS
XSARA - XSARA PICASSO
B2BP02SC
NOTE : This cable has an automatic adjusting device which takes up the clutch disc wear and makes up for the compression of the outer cable.
1 2 3 4
-
Metallic cable, crimped on both ends. Outer cable or telescopic duct. Outer cable stop, bulkhead side (fixed point on the bodyshell). Outer cable stop, gearbox side (fixed point on the gearbox).
DESCRIPTION 5 - Tensioning spring ensuring the maximum length of the cable sleeve. 6 - Wear take-up device. 7 - Hooking yoke.
215
CLUTCH GEARBOX DRIVESHAFTS
Engines : LFX - LFY - RFS - RFV - WJZ - RHY
XSARA - XSARA PICASSO
CLUTCH : CHECKS AND ADJUSTMENTS Engines : LFX - LFY - RFS - RFV - WJZ - RHY (continued)
CLUTCH GEARBOX DRIVESHAFTS
B2BP03QD
Operation
Clutch disengagement phase
Engagement / adjustment phase
For the adjusting device to operate correctly, it is necessary that : The pedal is at rest (against its upper stop) The locking sleeve (1) is slightly compressed, the rollers (2) are free, the outer cable (3) length may vary.
As soon as the pedal is applied, the attaching end-piece (4) leaves the sleeve (1) which moves back. The rollers, pushed by spring (5) jam the system. The cable behaves like a conventional cable.
The pedal returns to rest on its upper stop.Attaching end-piece (4) pushes sleeve (1) which frees the rollers. Outer cable (3), kept extended by the spring (6) becomes : - Shorter if the clutch disc is worn. - Longer if the outer cable has been compressed.
NOTE : The pedal gear has a non-adjustable assisting device. 216
GEARBOX AND TYRE SPECIFICATIONS
SAXO - All Types Petrol
1.0i CDZ
HDZ
HFX
KFX
MA/4 – MA/5 20 CF 03 29/08/200 ➞
Gearbox ident. plate Reduction box torque
20 CF 02 03/05/200 ➞ 14X60
20 CF 12 20 CF 02 29/08/200 ➞ 17x64
19x17
Speedometer ratio Petrol
Tyres-Rolling circumference
NFZ
Gearbox ident. plate Reduction box torque Speedometer ratio
1.6i 16V
20 CD 05 29/08/200 ➞ 17x64
NFX
NFT
165/65 R14 – 1.725m
Gearbox type
MB3
MA/4 – MA/5
312
20 CF 12 03/05/200 ➞
17x56 21x19
17x64 19x17
Diesel
1.6i Engine type
KFW
155/70 R 13 – 1.67 m
Tyres-Rolling circumference Gearbox type
185/55 R14 1.7 m
MA/5 20 CN 03 03/05/200 ➞ 17x61 19x17
20 CN 03 29/08/20 ➞ 16x63
217
1.5D VJZ
VJY 165/65 R14 – 1.725 m MA/5 20 CF 02 29/08/200 ➞ 17x64 19x17
VJX
CLUTCH GEARBOX DRIVESHAFTS
Engine type
1.4i Automatic
1.1i
GEARBOX AND TYRE SPECIFICATIONS
XSARA # 09/2000
Petrol 1.4i
1.6i
1.8i
1.8i 16V
LFX
LFY
Automatic Engine type
KFX
KFW
Tyres-Rolling circumference Gearbox type Gearbox ident. plate
20 CE 42
Reduction box torque CLUTCH GEARBOX DRIVESHAFTS
Engine type Tyres-Rolling circumference Gearbox type Gearbox ident. plate Reduction box torque Speedometer ratio
MA/5 20 CE 42 03/05/2000 ➞
14x60 22x17 Petrol 2.0i 16V Automatic RFV
Speedometer ratio
BE3/5 20 TB 39 19x72
NFZ 185/65 R14 – 1.815 m AL4
BE3/5
20 CD 29
20 TP 22
20 TB 91
16x65 21x18
21x73 24x21
19x70
20 TB 62 19x75 22x19
Diesel
RFS
195/55 R15 – 1.815 m 4 HP 20 BE3/5 20 TB 92 20 GZ 9F 20 TB 93 17x65 19x72 22x19 218
1.5D
1.9D
1.9TD
2.0 HDi
VJZ
WJZ
DHY
RHY
MA/5
185/65 R14 – 1.820 m BE3/5
20 CE 46
20 TB 38
20 TB 59
14x60 21x18
19x75
19x77 22x19
20 TB 51 1.815 m 19x70
GEARBOX AND TYRE SPECIFICATIONS
XSARA 09/2000 # Petrol
1.6i 16V
2.0i 16V
Automatic Engine type
KFW
NFU
Tyres-Rolling circumference Gearbox type Gearbox ident. plate Reduction box torque Speedometer ratio
Automatic
MA/5 20 CF 13 (1)
RFN 195/55 R15 – 1.815 m AL4 BE4/5
20 CN 28 (2)
16 x 65 21 x 18
RFS AL4
BE4/5
20 TP 49
20 DL 40
20 TP 47
20 TE 47
21 x 73 24 x 21
19 x 72 22 x 19
23 x 73 24 x 21
14 x 62 22 x 19
Diesel 1.9D Engine type
2.0 HDi
WJZ
RHY
Tyres-Rolling circumference
195/55 R15 – 1.815 m BE4/5
Gearbox type Gearbox ident. plate Reduction box torque
20 DL 41
20 DL 42
19x75
19x70
Speedometer ratio
22x19 219
CLUTCH GEARBOX DRIVESHAFTS
1.4i
GEARBOX AND TYRE SPECIFICATIONS
XSARA PICASSO
Petrol 1.6i Engine type
NFZ
Tyres-Rolling circumference
Reduction box torque
1.8i 16 V
2.0 HDi
6FZ
RHY
185/65 R15 – 1.895 m
Gearbox type Gearbox ident. plate
Diesel
BE4/5 20 DL 68 19x77
20 DL 66 15x64
Speedometer ratio
22x18
CLUTCH GEARBOX DRIVESHAFTS 220
20 DL 64 19x72
MA/5 GEARBOX
SAXO - XSARA
Engines : CDZ - HDZ - HFX - KFW - KFX - NFZ - NFT - NFU - NFX - VJZ - VJY - VJX
CLUTCH GEARBOX DRIVESHAFTS
Vent hole
Filler screw
B2CP34HP
Drain screw
B2CP20FC
221
B2CP20GC
SAXO - XSARA
MA/5 GEARBOX CONTROLS Engines : CDZ - HDZ - HFX - KFW - KFX - NFZ - NFT - NFU - NFX - VJZ - VJY - VJX
1 - Gear lever. 2 - Gear control rod. 3 - Gear control rod.
A = 11.5 mm.
CLUTCH GEARBOX DRIVESHAFTS
4 - Gear selection rod.
B = 9.5 mm.
5 - Gear selection rod.
C = 3 mm.
6 - Knuckle joint 7 - Fixed point on the gearbox.
B2CP16SP
B2CP16TC
222
XSARA - XSARA PICASSO
BE3/5 GEARBOX
CLUTCH GEARBOX DRIVESHAFTS
Engines : LFX - LFY - RFS - RFV - WJZ - DHY - RHY
Filler screw
Drain screw
Vent hole
B2CP20HC
B2CP34JP
223
B2CP20JC
XSARA - XSARA PICASSO
BE3/5 GEARBOX CONTROLS Engines : LFX - LFY - RFS - RFV - WJZ - DHY - RHY
(1) - Gear lever. (2) - Gear control rod. (3) - Gear engagement rod. (4) - Gear selection rod. CLUTCH GEARBOX DRIVESHAFTS
(5) - Torque rod. (6) - Gear engagement ball-joint. (7) - Fixed point on the gearbox.
NOTE : The gear change mechanism is not adjustable.
B2CP197D
224
BE4/5 GEARBOX SPECIFICATIONS
XSARA - XSARA PICASSO
CLUTCH GEARBOX DRIVESHAFTS
ENGINES : NFZ - 6FZ - RFN - RFS - WJZ - RHY
(a) = Marking zone (Sequence and serial no.). (b) = Location of identification label. B2CP3BNC
B2CP3BPD
225
XSARA - XSARA PICASSO
BE4/5 GEARBOX SPECIFICATIONS Engines : NFZ - 6FZ - RFN - RFS - WJZ - RHY Description
CLUTCH GEARBOX DRIVESHAFTS
(1) (2) (3) (4) (5) (6) (7) (8)
Primary shaft. Clutch bearing guide. Gearbox casing. Clutch housing. Reverse idle. Drive gear (3rd gear). 3rd /4th gear synchroniser Drive gear (4th gear).
(9) Drive gear (5th gear). (10) 5th gear synchroniser. (11) Driven gear (5th gear). (12) Driven gear (3rd / 4th gear ) (13) Driven gear (2nd gear).
(14) (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
226
BE4/5 GEARBOX
SAXO - XSARA - XSARA PICASSO Engines : NFZ - 6FZ - RFN - RFS - WJZ - RHY
Ref.
Number of screws
m.daN
1
End guide
3
1,2 ± 0,1
2
Clutch housing
13
1,3 ± 0,1
3
Primary shaft nut
1
7,2 ± 0,7
4
Secondary shaft nut
1
6,5 ± 0,7
5
Yoke holding screw
2
1,5 ± 0,1
6
Differential gearwheel screw
2
6,5 ± 0,7
Reverse gear contact
1
2,5 ± 0,3
B2CP3BSP
B2CP3BTD
Description
7
Differential housing
4
5 ± 0,5
8
Breather pipe
1
1,7 ± 0,2
9
Rear housing cover screw
7
1,2 ± 0,1
10
Top-up plug
1
2,2 ± 0,2
11
Differential housing screw
4
1,2 ± 0,1
12
Drain plug screw.
1
3,5 ± 0,4
227
CLUTCH GEARBOX DRIVESHAFTS
Tightening torques
SAXO - XSARA - XSARA PICASSO
BE4/5 GEARBOX CONTROLS
Engines : NFZ - 6FZ - RFN - RFS - WJZ - RHY
(1) Gear control lever. (2) Gear engagement control cable (*). (3) Gear selection control cable (*). (4) Gear selection ball-joint Ø 10 mm. CLUTCH GEARBOX DRIVESHAFTS
(5) Gear engagement ball-joint Ø 10 mm. (6) Flexible insulating grommet through the bulkhead.
(*) = These two cables cannot be separated.
B2CP3BWD
228
SAXO - XSARA - XSARA PICASSO
BE4/5 GEARBOX - CHECKS AND ADJUSTMENTS Engines : NFZ - 6FZ - RFN - RFS - WJZ - RHY Principles of adjusting the gear controls. WARNING : Cables should be adjusted each time the gearbox, gear controls or power unit are removed. Principles.
Place the gearbox in neutral. Couple the cables on the lever.
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.
Fit the ball-joints on the gearbox lever. Unclip at "b", using two small screwdrivers. Lock the cable lengths with the ball-joint locking keys.
B2CP3BXC
229
B2CP3BYC
CLUTCH GEARBOX DRIVESHAFTS
Lock the gear lever in neutral position,using tool: 9607-T.
SAXO - XSARA - XSARA PICASSO
BE4/5 GEARBOX - CHECKS AND ADJUSTMENTS Engines : NFZ - 6FZ - RFN - RFS - WJZ - RHY Adjusting the gear controls. TOOLS.
[1] ] Tool for positioning the gear lever ADJUSTMENTS. WARNING : Cables should be adjusted each time the gearbox, gear controls or power unit are removed. CLUTCH GEARBOX DRIVESHAFTS
Inside the vehicle. - Remove the trim under the gear lever. - Lock the gear lever in neutral position,using tool [1]. Under the bonnet. - Remove the air filter assembly. - Unlock the ball-joint keys at "a". - Place the gear selection and control levers neutral. - Lock the cable lengths with the ball-joint locking keys
: 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
230
B2CP3C0C
MB3 AUTOMATIC GEARBOX
SAXO
Engine : KFX
Tightening torques m.daN. 3.5 2.5 1.6 2.6 6.5 8.5 1 5
NOTE : When fitting a new automatic gearbox, it is ESSENTIAL that the heat exchanger and the oil be replaced.
B2CP14ZP
231
CLUTCH GEARBOX DRIVESHAFTS
- Gearbox to engine fixing - Converter to engine fixing - Converter closing plate fixing M8 M10 - Electrical bracket fixing - Flexible mounting to gearbox fixing - Speedometer drive - Heat exchanger fixing
SAXO
RECOMMENDATIONS - PRECAUTIONS (MB3 AUTOMATIC GEARBOX) Engine : KFX PRECAUTIONS TO BE TAKEN
Towing The front of the vehicle must be raised in order to be towed.If the front of the vehicle cannot be raised : - Add an extra 2 litres of oil to the automatic gearbox. - Do not exceed 30 kph over a distance of 50 km. - Gear lever in position "N". WARNING : Do not forget to remove the extra oil.
REMOVING - REFITTING. (Automatic gearbox). WARNING : Never place the gearbox on its lower casing (risk of deforming the tray and damaging the hydraulic valve block). Driveshafts. ESSENTIAL : When moving the left driveshaft, ensure it remains horizontal (risk of losing the tri-axe joint needles).
CLUTCH GEARBOX DRIVESHAFTS
Initialising procedure. The gearbox should be initialised in the following cases : - Replacement of the ECU. - Clearing of faults. - Replacement of the potentiometer. - Replacement or adjustment of the accelerator cable. - Incorrect initialisation. NOTE : The initialisation procedure should be checked using a diagnostic tool.
Driving. Never drive with the ignition switched off. Never push the vehicle to try to start it (impossible with an automatic gearbox). NOTE : The automatic gearbox is only lubricated when the engine is running. Wait until the vehicle is completely stationary before engaging the gear lever in position "P".
232
RECOMMENDATIONS - PRECAUTIONS (MB3 AUTOMATIC GEARBOX)
SAXO
Engine : KFX PRE-REPAIR PROCEDURE Oil quality
Oil level (prior conditions) - Oil hot (80°C min.). - Foot on the brake, change through all the gears. - Vehicle on a level surface. - Selection lever in position "P". - Engine running. The level should be between the min. markings "A" and "B" on the dipstick. ESSENTIAL : In no case should the oil level exceed the marking "B". Top up the automatic gearbox oil level (if necessary).
B2CP16WC
233
CLUTCH GEARBOX DRIVESHAFTS
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. ESSENTIAL : The gearbox must be replaced.
SAXO
RECOMMENDATIONS - PRECAUTIONS (MB3 AUTOMATIC GEARBOX) Engine : KFX PRE-REPAIR PROCEDURE (continued)
Negative pressure circuit.
Absence of fault codes
- Check the negative pressure circuit. - Carry out the necessary repairs.
Measure the parameters. Anomalies present: - YES : Carry out the necessary repairs. - NO : Check (adjust the negative pressure capsule).
Checks using the diagnostic tool. CLUTCH GEARBOX DRIVESHAFTS
ESSENTIAL : Initialise the ECU Perform a road tes
Preliminary checks : - The adjustment of the gear selection control. - The adjustment of the accelerator cable. Carry out the necessary operations
Fault codes present Carry out the necessary repairs. Clear the fault codes.
Reading the fault codes
ESSENTIAL : Initialise the ECU Perform a road test.
Read the fault codes.
234
SPECIAL FEATURES : MB3 AUTOMATIC GEARBOX
SAXO
Engine : KFX
Hydraulic valve block. Refitting. WARNING : On refitting the strainer, ensure that the bracket (6) runs under the washer of the screw (7).
CLUTCH GEARBOX DRIVESHAFTS
- Refit the strainer without tightening the screws. - Observe the following tightening sequence : - Screws 1,2,3,4 and 5 to 0.9 m.daN. ESSENTIAL : Respect the position of the magnets in the lower casing. Clean the casing before placing the smooth side of the magnet against the sheet metal. Fitting the casing. WARNING : The fixing brackets (8) of the lower casing have a fitting direction (small side = lower casing side). Tightening torque 0.6 m.daN. B2CP34PC
B2CP13TC
B2CP34QC
235
SAXO
MB3 AUTOMATIC GEARBOX CONTROLS Engine : KFX
CLUTCH GEARBOX DRIVESHAFTS B2CP352D
236
SAXO
MB3 AUTOMATIC GEARBOX CONTROLS - CHECKS AND ADJUSTMENTS Selection control
Adjusting the selection control
WARNING: No part must be forced while performing these operations (careful removal). Removing the gear lever knob. - Remove the screws (1). - Lift the lever knob (2) by about 10 mm. - Turn backwards by 1/4 turn, and raise by approximately 7 mm. - Press and hold down the locking button (3).
ESSENTIAL : Put the gearbox side control in the 1st imposed position; the 2 markings "a" must be aligned.
- Lock the outer cable stop by 1/4 turn (in the direction of the arrow). - Check that the painted markings "b" are aligned.
- Turn forwards by 1/4 turn, remove the gear lever knob (2). Refitting the gear lever knob - Press and hold down the locking button (3). - Fit the knob (2) on the lever until it touches its stop (in the direction shown in the diagram). - Release the locking button (3). - Turn forwards by 1/4 turn. - Refit the screws (1). ESSENTIAL : Check the passage of all the gears, otherwise adjust the selection control.
B2CP18YC
237
B2CP18WC
B2CP18XC
CLUTCH GEARBOX DRIVESHAFTS
- Fit the ball joint (1). - Fit the lug (2).
XSARA
AL 4 AUTOMATIC GEARBOX Engines : NFZ - NFU - RFN
WARNING : This gearbox benefits from a special CITROEN semi-synthetic oil which cannot be mixed with any other oil. The gearbox is lubricated for life. (a) Part reference. CLUTCH GEARBOX DRIVESHAFTS B2CP30ZD
238
RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX
XSARA
Engines : NFZ - NFU - RFN PRECAUTIONS TO BE TAKEN REMOVING - REFITTING. (Automatic gearbox).
Towing The front of the vehicle must be raised in order to be towed.If the front of the vehicle cannot be raised :
WARNING : Never place the gearbox on its lower casing (risk of deforming the tray and damaging the hydraulic valve block).
IMPERATIVE : - Put gear lever in position "N". - Do not add any oil. - Do not exceed 50 kph over a distance of 50 km. Driving. Never drive with the ignition switched off. Never push the vehicle to try to start it; (impossible with an automatic gearbox).
ESSENTIAL : - Fit the converter retaining peg while the gearbox is removed. - Fit the centring peg to locate the gearbox on the engine : (remove the converter retaining peg just before locating)
Lubrication The automatic gearbox is only lubricated when the engine is running
WARNING : With the safety programme selected, a snatching can be felt when changing from ‘‘P’’ ‘‘R’’ or ‘‘N’’ ‘‘R’’.
239
CLUTCH GEARBOX DRIVESHAFTS
Never use the connections as handles for raising, turning, holding or pushing the gearbox
XSARA
RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX Engines : NFZ - NFU - RFN PROCEDURE BEFORE REPAIRS
AL 4 gearbox
Oil Quality
CLUTCH GEARBOX DRIVESHAFTS
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. ESSENTIAL : The gearbox must be replaced.
240
RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX
XSARA
Engines : NFZ - NFU - RFN AL 4 gearbox only
Oil level AL 4 (prior conditions). - Vehicle in horizontal position. - Check gearbox is not in back-up mode. - Remove the oil filler plug (3). - Add 0.5 litres extra oil into the gearbox. - Foot on the brake, change through all the gears. - Selection lever in position "P". - Engine running, at idle. - Oil temperature : 60°C (+8°C; -2°C), measured with the aid of a diagnostic tool. - Remove the oil level plug (3). - Thread of oil then "drip-drip" : refit plug (3). Tighten 2.4 m.daN. - "Drip-drip" or nothing : refit the plug (3). - Stop the engine. - Add 0.5 litres extra oil into the gearbox. - Repeat the oil level procedure. NOTE : The level is correct at the moment the thread of oil becomes drip-drip. - Refit the oil filler plug (3). Tighten to 2.4 m.daN. - Initialise the oil usage counter (open the diagnostic tool procedure). B2CP31FD
241
CLUTCH GEARBOX DRIVESHAFTS
PROCEDURE BEFORE REPAIRS
XSARA
RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX Engines : NFZ - NFU - RFN PROCEDURE BEFORE REPAIRS (continued)
When the ECU detects an erroneous or absent valueon input or output :
Reading the fault codes. Read the fault codes. - Absence of fault codes: - Carry out a measure of parameters.
- It writes the fault in memory. - For each associated context, it writes the context of the oldest fault in memory. - It initiates a back-up mode strategy.
Presence of anomalies:
CLUTCH GEARBOX DRIVESHAFTS
There are two types of back-up modes :
- YES : Carry out the necessary repairs. - NO : Read the fault codes - engine ECU - Carry out a road test.
- The ECU makes replacement values available (relating to comfort, gear selection quality, loss of functions).
Following an initialisation of the ECU, for a certain period of time there may be an inconsistent gear selection quality (while ECU parameters are adapting to the gearbox). To achieve a consistent standard, it will be necessary to carry out a road test taking in frequent gear changes (auto-adaptive laws).
- Access to emergency programme (only 3rd gear and reverse are available)
242
RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX
XSARA
Engines : NFZ - NFU - RFN ECU : Downloading
After the downloading operation, carry out the following: A clearing of faults. A pedal initialisation. An initialisation of the auto-adaptives. A recording of the value of the oil usage counter previously read. A road test. ESSENTIAL : Every update of the automatic gearbox ECU should be accompanied by an update of the engine ECU. Updating the value of the oil usage counter. Using LEXIA or ELIT. Access to reading and recording of the oil counter is via the menu : "Oil counter ". Adjustment of the oil counter value is done by entering directly the 5 figures of the oil counter.
Using PROXIA Access to reading and recording of the oil counter is via the menu : "Configuration (integrated circuit button) / Oil counter ". Adjustment of the oil counter value is done in incremental steps of 2750 units. 243
CLUTCH GEARBOX DRIVESHAFTS
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.
XSARA
RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX Engines : NFZ - NFU - RFN ECU : Downloading, Configuration, Initialisation (pedal) (continued)
Downloading.
Pedal initialisation.
ECU downloading procedure : - Follow the diagnostic tooling procedure.
A pedal initialisation must be carried out in the following cases : - Replacement of the automatic gearbox ECU.
CLUTCH GEARBOX DRIVESHAFTS
A new ECU or downloaded update is always configured with the following options : - SHIFT LOCK gear selection lever position. - OBD outlet (emission standard L4). If the ECU is to be fitted to a vehicle without one or bothof these options: - Carry out a configuration which inhibits the diagnosis of the option(s) concerned.
- Replacement of the automatic gearbox. - Downloading of the ECU configuration. - Adjustment or replacement of the accelerator cable. - Replacement of the throttle potentiometer.
IMPERATIVE : For a certain period of time, while the ECU parameters are adapted to the gearbox, there may be an inconsistentgear selection quality. To achieve a consistent standard, it will be necessary to carry out a road test taking in frequent gear changes (autoadaptive laws).
244
RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX
XSARA
Engines : NFZ - NFU - RFN SHIFT LOCK - The shift lock is a system which locks the selection lever in the park position "P". Unlocking the SHIFT LOCK (In normal operation)
NOTE : It is IMPERATIVE to disengage the gear selection lever from position "P" the minute you start applying the brake pedal. Otherwise, release pressure on the brake pedal and then try again. Unlocking the SHIFT LOCK (In the event of a malfunction) - Remove the cover (1). - Unlock the shift lock (2) using a screwdriver. - Using the selection lever, disengage from position "P".
B2CP268C
B2CP269C
245
CLUTCH GEARBOX DRIVESHAFTS
- Switch on the ignition. - Press and hold down the brake pedal. - Using the selection lever, disengage from position P.
XSARA
4 HP 14 AUTOMATIC GEARBOX Engine : RFV
CLUTCH GEARBOX DRIVESHAFTS B2CP34RD
B2CP34SC
B2CP34TC
Ref. letter
X (mm)
Y (mm)
Torque m.daN
A B C D E
80 80 75 65 60
12 10 12 10 10
0.8 0.6 0.8 0.6 0.6
Tightening torques m.daN (1) (2) (3) (4)
Gearbox casing screw Oil dipstick tube nut Strainer cover Hydraulic valve block
1 4.5 0.8
Note : If replacing an automatic gearbox, it is ESSENTIAL also to replace the heat exchanger, as well as the oil. 246
4 HP 14 AUTOMATIC GEARBOX CONTROLS
XSARA
Engine : RFV
Tightening torques m.daN.
(1) - Fixing to the body. (2) - Gearbox bracket fixing.
(4) - Gearbox selector fixing.
NOTE : Ball-joint lubrication ESSO NORVA 275 (G9).
B2CP287D
247
CLUTCH GEARBOX DRIVESHAFTS
(3) - Adjusting nuts.
XSARA
4 HP 14 AUTOMATIC GEARBOX - CHECKS AND ADJUSTMENTS Engine : RFV Adjusting the gear selector Tools [1] Ball-joint extractor
9040-T.G2
Tool kit 9040-T
- Uncouple the ball-joint housing (1) from the selector lever using tool [1].
CLUTCH GEARBOX DRIVESHAFTS
CAUTION : Do not twist the rod (2) of the selector cable when uncoupling. - Gear lever in position N (Normal). - Selector lever (5) in position N. - Loosen the nuts (3). - Position the ball-joint housing (1) opposite the ball-joint (4). - Fit the ball-joint housing (1) to the selector lever (5) ball-joint (4). - Tighten the nut (3). Check that : - The gear selector works correctly in all the positions. - The "starter" function only works in positions P and N.
B2CP010C
B2CP27YC
B2CP27XC
248
4 HP 14 AUTOMATIC GEARBOX - CHECKS AND ADJUSTMENTS
XSARA
Engine : RFV Checks - Adjustments : Kick down cable Preliminary conditions : - Engine hot. - Idling speed correct. - Automatic cold start device out of action (according to equipment).
Kick down cable adjustment: - Pull the cable until the point of resistance. (Start of kick down command A = 39 mm). - The lug (4) must be positioned and crimped on the cable. - Refit the kick down cable (1) on the throttle quadrant. - Adjust the clearance (B) from 0.5 mm to 1 mm max. by tightening the nuts (5). B2CP35GC
B2CP35JC
B2CP35HC
249
B2CP35KC
CLUTCH GEARBOX DRIVESHAFTS
Accelerator cable adjustment : - Remove the kick down cable (1) from the throttle quadrant. - Pull out the sheath stop (2) and fit the spring clip (3) so as to obtain a small clearance. - Press the accelerator pedal fully down. - Ensure that the throttle is fully open.
ALL TYPES
DRIVESHAFTS - GEARBOXES Tightening torques (m.daN)
Gearbox
Engines
Driveshaft bearing
Driveshaft nut
MA/5
CDZ-HDZ-HFX-KFX-KFW-NFZ NFT-NFX-NFU-VJZ-VJY-VJX
NONE
24.5
1.8
32
CLUTCH GEARBOX DRIVESHAFTS
MA/5 XSARA
KFX
BE4/5
NFZ - 6FZ - RFN - RHY
BE3/5
LFX - LFY - RFS - RFV WJZ - DHY - RHY
32.5
MB3
KFX
24.5
4 HP 14
Right
Left
Tool kit
7114-T.W
7114-T.X
7116-T
4101-T.E1 +4601-T.E2
NONE
4601-T
Seal extractor RH / LH (-) 0338 C
1 AL 4
Gearbox oil seal mandrels
(-) 0338
32.5
KFX - NFU - RFN
32.5
RFV
Tightening torque for wheel bolts : SAXO - XSARA = 8.5 m.daN 250
(-) 0338 J1 + (-) 0338 J2
(-) 0338 H1 +(-) 0338 H2
9017-T.B
9017-T.C
9017-T
AXLE GEOMETRY
SAXO - All Types
Geometry of the axles at reference height. Front height
Rear height H1 = R1 – L1
H2 = R2 + L2
H1 = Distance between the ground and the mounting face of the fixings. R1 = Distance between the centre of the front wheel and the ground. L1 = Distance between the centre of the front wheel and the mounting face of the fixings.
H2 = Distance between the ground and the mounting face of the rear crossmember. R2 = Distance between the centre of the rear wheel and the ground. L2 = Distance between the centre of the rear wheel and the rear crossmember.
The values L1 and L2 are given in the table below. Normal suspension Dimension Value (mm)
Raised suspension
Front axle
Rear axle
Front axle
Rear axle
L1 71 ± 10 mm
L2 53 ± 6 mm
L1 36 ± 10 mm
L2 82 ± 6 mm
Measure the dimension R1. Calculate the dimension H1 = R1 - L1. Measure the dimension R2. Calculate the dimension H2 = R2 + L2 Compress the suspension until the calculated values «H1» and «H2» are obtained. NOTE : The difference in height between the two sides at the rear should be less than 7.5 mm. 251
C4CP0N3C
AXLES SUSPENSION STEERING
C4CP0N2C
SAXO - All Types
AXLE GEOMETRY Geometry of the axles at reference height. Front height
Rear height
Reminder : Measuring the front height H1 = Distance between the ground and the mounting face of the fixings
Reminder : Measuring the rear height H2 = Distance between the ground and the rear crossmember
B3BP07UC
The front heights H1 are measured between the ground and the mounting face of the arm fixings (1) at the point «a».
B3BP07VD
The rear heights H2 are measured between the ground and the mounting face of the rear crossmember (2) at «b» and «c».
AXLES SUSPENSION STEERING
B3CP02UC
252
A < B = Positive figure:
+=
A > B = Negative figure:
–=
WARNING TOE-IN TOE-OUT
AXLE GEOMETRY
SAXO - All Types
Geometry of the axles at reference height. Raised suspension Rear
Front Engines
TU9M TU1M+ (*)
Steering
Manual
Tracking Toe-in
0° mm
Camber Castor King pin inclination
TU1M+ (**) TU3JP – TU5JP TU5J4 – TUD5 Manual
-0°10’ to 0°31’ -1 to -3 - 0°9’ ± 30’
All types
Assisted
- 0°40’ ± 30’
TU9M TU1M+ (*) Manual
-0°10’ to 0°31’ -0°16’ to -1°6’ +1 to +3 +1.49 to +6.39 - 1°35 ’± 30’
Rear
Front TU1M+ (**) TU3JP – TU5JP TU5J4 – TUD5 Manual
-0°10’ to 0°31’ -1 to -3 - 0°9’ ± 30’
Assisted -0°10’ to 0°31’ +1 to +3
- 0°40’ ± 30’
2°13’± 30’
3°14’± 30’
2°13’± 30’3°
3°14’± 30’
12°± 41’± 40’
12°42’± 40’
12°± 41’± 40’
12°42’± 40’
(*) = Without assisted steering option and ABS.
(**) = With assisted steering and ABS options.
WARNING : For the vehicle to be at reference height, compress the suspension until the calculated values «H1» and «H2» are obtained. 253
All types
-0°16’ to -1°6’ +1.49 to +6.39 - 1°35 ’± 30
AXLES SUSPENSION STEERING
Normal suspension
SAXO - All Types
SPECIAL FEATURES : SUSPENSION - STEERING EVOLUTIONS : Damper springs – Driveshafts – Wheel hubs. Date of application : 01/1999 - RPO : 06/01/1999
Front suspension springs. Vehicles concerned : Saxo all types. Modification : 5 1/2 spirals instead of 6. Driveshafts. Vehicles concerned : Saxo all types, with or without ABS, except versions with 3 wheel bolts. RH / LH transversal transmission. - Tapered stem instead of cylindrical stem. - Helicoidal instead of straight splines. - Increased thread length. Modification of the grease used. Front wheel hubs. - Helicoidal instead of straight splines. Bearing assembly. - Increased height of driveshaft nut. - New bearing. AXLES SUSPENSION STEERING
The driveshaft nut becomes common for wheels with both 3 and 4 bolts. Replacement parts. WARNING : These new components cannot be fitted on vehicles prior to RPO 8094 (06/01/1999). 254
FRONT AXLE Anti-roll bar Ø 18 and 22 mm
SAXO - All Types
Anti-roll bar Ø 19 and 21 mm
(1) Suspension leg. (3) Front anti-roll bar. (9) Lower arm. Tightening torques m.daN (2) Anti-roll bar bearing fixing on the bodyshell (4) Anti-roll bar bearing fixing on the lower arm (5) Suspension leg upper fixing (6) Lower ball-joint fixing screw (7) Anti-roll bar link rod fixing (8) Suspension arm rear fixing nut (9) Suspension arm front fixing
5.5 ± 0.2 2.2 ± 0.2 2.1 ± 0.2 3.8 ± 0.4 7 ± 0.6 4.2 ± 0.4 8.5 ± 0.8
B3CP02SD
Suspension – Front anti-roll bar
(1) =With airbag.
TU9M (2)
TU9M
TU1M+ (2)
TU1M+ (1) TU3JP TUD5
TU1M+
None
21
19
(2) = Without option.
TU5JP
TU1M+ (3)
18
(3) = VTS level. 255
Raised suspension
TU3JP (3) TU5JP(3) - TU5J4
France Administration
Export
22
21
19
LPG Cylindrical Ring-shaped 21
19
AXLES SUSPENSION STEERING
Ø Anti-roll bar
TU9M (2)
SAXO - All Types
REAR AXLE (1) Rear axle. (2) Damper. (5) Rear suspension arm. (7) Rear brake drum. (9) Torsion bar.
The Anti-roll bar is located inside the tube of the rear axle.
Tightening torques m.daN. (3) (4) (6) (8) AXLES SUSPENSION STEERING
B3DP02ND
256
Damper upper fixing screw Damper lower fixing screw Stub nut Rear axle fixing bolt
10 ± 1 10 ± 1 20 ± 1 8.7 ± 1
REAR AXLE - SUSPENSION
SAXO - All Types Torsion bar
TU9M (1)-TUD5 (1) TU1M+ (1) (2) – TU3JP (2) TU5J4
TU9M - TU1M+ - TU3JP TU5JP – TUD5
TU1M+ LPG TUD5 (3)
19
17.9
18.3
Black
White
Green
Torsion bar Ø (mm) Colour reference
LH : 2 rings
Torsion bar
RH : 1 ring
(1) = Entreprise.
(2) = VTS trim level
(3) = With raised suspension Anti-roll bar
Anti-roll bar Ø (mm) (1) =With airbag.
None
TU1M+ (3) TU3JP (3) TU5JP (3) TU5J4
TU1M+ LPG
18
22
15
(2) = With airbag or assisted steering or ABS.
257
(3) = VTS trim level.
France
Export
18
15
AXLES SUSPENSION STEERING
TU9M - TU1M+
Raised suspension
TU9M (1) TU1M+(2) TU3JP TU5JP TUD5
SAXO - All Types
STEERING SPECIFICATIONS Manual steering
Tyres
155/70 R13
Pinion (no. of teeth)
6
Rack (no. of teeth)
28
Rack travel Stop (colour)
165/65 R14
165/70 R13
Length of the steering track rods (Between the centre lines of the ball-joints).
80
72
Black
White
Pre-adjustment = 520 mm.
Power-assisted steering Tyres Pinion (no. of teeth)
165/70 R13
165/70 R14
185/55 R14
7
Rack (no. of teeth)
28
Rack travel
68
NOTE : The steering assembly is secured to the bulkhead..
Stop (colour) AXLES SUSPENSION STEERING
258
MANUAL STEERING
SAXO - All Types
B3EP02UD
1 2 3 4 5 6
- Airbag - Airbag fixing to steering wheel - Steering wheel fixing - Steering column fixing - Steering cardan joint fixing - Fixing to bulkhead
7 - Pivot ball-joint nut 8 - Lock nut M14 8 - Lock nut M16 9 - Track rod articulation 10 - Splined coupling fixing to steering rack
0.8 3 2.3 2.3 2.2
B3EP09SC
3.5 4.5 5 2.1 2.4 B3EP09TD
259
AXLES SUSPENSION STEERING
Tightening torques (m.daN)
SAXO - All Types
POWER-ASSISTED STEERING
Tightening torques (m.daN)
AXLES SUSPENSION STEERING
1 2 3 4 5 6 7 8
- Airbag - Airbag fixing to steering wheel - Steering wheel fixing - Steering column fixing - Steering cardan joint fixing - Fixing to bulkhead - Pivot ball-joint nut - Track rod lock nut M14
8 - Track rod lock nut M16 9 - Track rod articulation 10 - Splined coupling fixing to steering rack 11 - Steering ram to splined coupling 12 - Steering ram to casing 13 - Nut fixing the pinion to the bearing 14 - Valve/casing fixing
0.8 3 2.3 2.3 2.2 3.5 4.5
B3EP02TD
5 2.1 2.4 8 8 1.5 0.7 B3EP02WD
260
POWER STEERING (continued)
SAXO - All Types
Power steering system WARNING : Saxo all types except diesel without aircon
1 2 3 4 5 6 7
-
Power steering Oil dispensing valve Power-assisted steering ram Low pressure pipe High pressure pipe Upper reservoir Power steering electro-pump unit and built-in lower reservoir 8 - Flexible mounting 9 - Electro-pump unit bracket Tightening torques (m.daN)
B3EP09UD
NOTE : Fluid type TOTAL Fluide ATX capacity : 0.950 L. 261
2 2
High pressure pump Electro-pump connection Power steering valve connection
2 2.5
Low pressure pump Electro-pump connection Power steering valve connection
2.5 2.5
AXLES SUSPENSION STEERING
Pump support fixing Pump fixing to support
SAXO - All Types
POWER STEERING (continued) POWER STEERING SYSTEM
WARNING : Saxo diesel with aircon Description. NOTE : The power steering system on vehicles without aircon is supplied by a mechanical pump driven by the accessories drive belt. (6) Power steering mechanism. (7) Upper reservoir. (8) Lower reservoir. (9) Radiator. (10) Power steering pump. (11) The grooves on the connector (6) indicate that the pump (5) is constant flow.
AXLES SUSPENSION STEERING
Max. pressure : 80 Bars. Pulley diameter : 112 mm. Fluid quality : TOTAL Fluide ATX Capacity : 1.55 litres.
B3EP12XD
262
XSARA - All Types
AXLE GEOMETRY Front and rear measuring points XSARA # 09/2000 Front height
XSARA 09/2000 # Rear height
Front height
Rear height
H1 = Dimension between the centre of the front suspension arm mounting and the ground. H2 = Dimension between the contact face of the rear mounting and the ground. R1 = Front wheel radius under load. R2 = Rear wheel radius under load. L1 = Distance between the centre of the wheel and the centre of the front suspension arm mounting. L2 = Distance between the centre of the wheel and the contact face of the rear mounting on the bodyshell.
263
AXLES SUSPENSION STEERING
B3CP046D
XSARA - All Types
AXLE GEOMETRY Reference heights
Tools
[1] Gauge for measuring the radius of wheels with 4 bolts
: 8006-T
Setting the reference height. Front
Rear
Measure the dimension «R1». Calculate the dim. H1 = R1 - L1.
Measure the dimension «R2». Calculate the dim. H2 = R2 + L2.
Compress the suspension until the values (H1) and (H2) are obtained. NOTE : The difference in height between the two sides should be less than 10 mm.
B3CP04AD
XSARA # 09/2000 Front axle
Rear axle
Height
H1 =R1 – L1
H2 = R2 + L2
All types
H1 = R1 – 85.5 mm
H2 = R2 + 83 mm
XSARA 09/2000 # AXLES SUSPENSION STEERING
Front axle
Rear axle
Engines
2.0i 16V (RFS)
All Types (except 2.0i 16V and CRD)
All Types CRD
2.0i 16V (RFS)
Saloons All Types (except 2.0i 16V and CRD)
Estates
All Types CRD
Reference heights
115.5
90.5
75.5
73
83
88
103
264
AXLE GEOMETRY
XSARA - All Types
Values of the front and rear suspensions, at reference height ESSENTIAL : When checking the suspensions, the vehicle should be at reference height.
Tools used : Compress the suspension, to obtain the values at reference height. : 9511-T.A : 9511-T.B : 9511T.C
WARNING B3CP04LC
A < B = Positive figure:
+=
TOE-IN
A > B = Negative figure:
–=
TOE-OUT
265
AXLES SUSPENSION STEERING
[1] Set of two suspension compressors [2] Set of four straps [3] Set of four shackles
XSARA - All Types
AXLE GEOMETRY Values of the front and rear suspensions, at reference height XSARA # 09/2000 Front axle Adjustable
Tracking
mm
YES
Steering All Types - 1.5 ± 1
Rear axle Adjustable
(Toe-out)
- 0°15' ±10'
0° Castor
Tracking
King pin inclination
NO
Camber
mm 0°
1° 30 ± 40’
4.5 ± 1 mm NO
Camber
10° 50’ ± 1°
0°45' ± 10'
(Toe-in)
- 1° 20' ± 40’
0° ± 1° XSARA 07/1999 # 09/2000 Front axle Adjustable
Tracking
mm
YES
AXLES SUSPENSION STEERING
Castor
Camber
- 1.5 ± 1
Adjustable (Toe-out)
- 0°15’ ± 10’
0°
King pin inclination
Rear axle
Steering All Types
Tracking
0°
3° ± 40’ (*) NO
Camber
10° 50’ ± 1° 0° ± 1°
mm
4.5 ± 1 mm NO
0°45' ± 10'
(Toe-in)
- 1° 20' ± 40’
(*) = Estates, LPG, DRC (difficult road conditions) Castor remains at 1°30’ ± 40’ 266
XSARA
AXLE GEOMETRY Values of the front and rear suspensions, at reference height XSARA 09/2000 # Front axle Adjustable Tracking
mm
All types (except 2.0i 16V)
2.0i 16V
All Types CRD
- 1.5 ± 1
YES
- 0°15' ±10'
0° Castor
3° ± 40’ NO
King pin inclination
11° ± 1°
10° 40’ ± 1°
Camber
10° 40’ ± 1°
0° ± 1° Rear axle
Tracking
mm 0°
NO
All types (except 2.0i 16V)
All Types CRD
2.0i 16V
Estates
4.6 ± 1
5.2 ± 1
4.4 ± 1
3.5 ± 1
0° 41’ ± 10’
0° 47’ ± 10’
0° 40’ ± 10’
0° 32’ ± 10’
- 1° 30’ ± 1°
Camber 267
AXLES SUSPENSION STEERING
Adjustable
XSARA - All Types
AXLE GEOMETRY
a = Angle which defines the tracking between the front and rear axles. Its value must not exceed 12'
AXLES SUSPENSION STEERING
B3CP04UC
268
FRONT AXLE
XSARA - All Types
Vehicles 09/2000 # are all equipped as standard with ventilated discs. B3CP040P
B3CP041D
269
(1) Damper nut 4.5 ± 0.4 (2) Cup screw 2.5 ± 0.3 (3) Suspension leg (4) Anti-roll bar link rod upper ball-joint 3.7 ± 0.3 (5) Suspension leg pivot (hollow pivot) 4.5 ± 0.5 (5) Suspension leg pivot (pivot «H») 5.5 ± 0.5 (6) Anti-roll bars (7) Anti-roll bar link rod lower ball-joint 3.7 ± 0.3 (8) Pivot lower ball-joint 4 ± 0.4 (9) Driveshaft nut 32.5 ±2.5 (10) Wheel bolt 9±1 (11) Lower arm front mounting 7.6 ± 0.7 (12) Lower arm rear mounting and anti-roll bar bearing 6.8 ± 0.6 (13) Screw under rear mounting (14) Ball-joint fixing on lower arm 3.1 ± 0.3 Subframe to bodyshell fixing screw 5± 0.5 8.5 ± 0.8
AXLES SUSPENSION STEERING
Tightening torques (m.daN).
XSARA - All Types
FRONT AXLE XSARA # 09/2000
Anti-roll bars Engines
Diameter
Colour reference
1.4i - 1.5 D - 1.9 TD
18
Violet
1.6i - 1.8i - 1.8i 16V - 1.9 TE
19
Blue
XSARA 09/2000 #
Anti-roll bars
AXLES SUSPENSION STEERING
Engines
Diameter
Colour reference
1.4i et 1.9D Saloons All Types
19
Blue
1.6i-2.0i 16V (RFV) - 2.0 HDi All Types except Saloons 1.4i et 1.9 D
20
Yellow
2.0i 16V (RFS)
21
White
270
FRONT AXLE
XSARA - All Types
Evolution : Suspension arm ball-joint 09/98 #
Evolution : Application from RPO : 7968. New components : - Suspension arm ball-joint. - Pivot. Old fitting ØA = 16 mm. New fitting ØA = 18 mm. Repair requirements. ESSENTIAL : Swapping of old and new components is forbidden.
Replacement Parts. The old components are still available from Replacement Parts. B3CP054D
271
AXLES SUSPENSION STEERING
It is permitted to fit a new pivot/ball-joint assembly on one side of an old vehicle.
XSARA - All Types XSARA # 07/1999
FRONT AXLE XSARA 07/1999 # 09/2000
XSARA 07/1999 # 09/2000
The angle of castor changes to 3° except for LPG vehicles, DRC vehicles, and Estates All Types. DRC = Difficult Road Conditions : this type of vehicle has axles and suspensions designed for driving on rough road surfaces. Lug "a" to the rear.
Lug "a" to the front.
Pivot ball joint Manual steering, groove at "b". Power-assisted steering, groove at "b". AXLES SUSPENSION STEERING
NOTE : Vehicles after 09/2000 # are all equipped as standard with ball-joints without the groove at «b». B3CP042D
B3CP049C
B3CP043D
272
REAR AXLE
XSARA - All Types Tightening torques (m.daN)* (1) Anti-roll bar lever
3.2 ± 0.3
(2) Anti-roll bar (3) Transversal torsion bars (4) Rear crossmember flanges
8.3 ± 0.8
(5) Front mountings
5.5 ± 0.5
(6) Rear mountings
4.5 ± 0.4
(7) Anti-vibration clamp. (8) Damper pin
9.6 ± 0.9
(9) Stub axle nuts (lubricated)
18.5 ± 1
- The RH torsion bar can be identified by 1 paint line. - The LH torsion bar can be identified by 2 paint lines. B3DP04SP
273
AXLES SUSPENSION STEERING
NOTE
XSARA - All Types
REAR AXLE XSARA # 09/2000 Torsion bars (mm)
Vehicles
Diameter
Colour reference
All Types except VTS
18.7
Yellow
VTS
19.3
Violet
Torsion bars (mm)
Torsion bars (mm)
Diameter
Colour reference
20
XSARA 09/2000 # Vehicles Engines
1.4i - 19.D
1.6i 16V-2.i 16V 2.0 HDi AXLES SUSPENSION STEERING
2.0i 16V Grand Export «DRC»
Torsion bars (mm)
Anti-roll bars (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
3-door VTS
21
Green clair
23
3- and 5-door TT
19.3
Violet
19
Orange
Estates All types
20
Grey
20
Green
274
REAR AXLE
XSARA - All Types
Evolution : Rear hub nut Old # 15/12/1999.
New 15/12/1999 #
Evolution : - New rear hub nut (3). - Washer discontinued (2). Old fitting (A) (1) Rear hub nut. (2) Thrust washer. ESSENTIAL : Tighten to : 27.5 ± 2.7 m.daN New fitting (B) (3) Rear hub nut. ESSENTIAL : Tighten to : 25 ± 2.5 m.daN. NOTE : It is possible to have both types of fitting on the same axle. The old nut (1) requires the fitting of the thrust washer (2). WARNING : do not fit a thrust washer (2) with a new nut (3).
WARNING: Identify the type of fitting, before starting a repair.
B3DP08AD
275
AXLES SUSPENSION STEERING
ESSENTIAL: Respect the tightening torque to be applied when fitting.
REAR AXLE
XSARA - All Types
Operating clearance - X = 1 to 1.4 mm.
AXLES SUSPENSION STEERING
NOTE : The RH torsion bar can be identified by 1 paint line. The LH torsion bar can be identified by 2 paint lines.
- The front mountings are aligned at an angle of 45° in relation to the vehicle’s axis. - The rear mountings are in parallel with the vehicle’s axis. NOTE : There are two suppliers for the mountings: - 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 ABSOLUTELY FORBIDDEN to swap components of different suppliers.
B3DP04TC
B3DP04UD
276
REAR DAMPER
XSARA - All Types XSARA # 09/2000 Adjusting the rear dummy damper All types
Adjustment of X = 288 mm. XSARA 09/2000 #
Adjusting the rear dummy damper Lengths of the rear dummy damper (mm) Normal driving 1.4i Saloons All Types
346
1.9 D 1.6i 16V 3-door
339
1.6i 16 V 5-door 2.0i 16V (RFN)-2.0 HDi 318
Estates and Entreprise all types
336
277
346 339 346
2.0i 16V (RFS)
E5AP14WC
Grand export
342
AXLES SUSPENSION STEERING
Engines
XSARA - All Types
MANUAL STEERING SPECIFICATIONS
Steering wheel - Manual steering
- (a) : L.H.D./R.H.D = White. - (L) : Shaft length = 311 ± 1.5 mm. - (1) Steering wheel fitted with AIRBAG. (according to equipment). - (4) Steering column adjustment lever. Tightening torques (m.daN). -
(2) AIRBAG to steering wheel fixing (3) Steering wheel fixing (5) Steering column to support fixing (6) 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). B3EP08PD
278
MANUAL STEERING SPECIFICATIONS
XSARA - All Types
Manual steering
B3EP042D
279
(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
AXLES SUSPENSION STEERING
Tightening torques (m.daN)
MANUAL STEERING SPECIFICATIONS
XSARA - All Types
Manual steering (continued) Number of teeth Steering rack travel (mm)
Pinion
Steering rack
73.5
Number of steering wheel turns
Steering ratio
4.3
22/1
(13)
6 teeth L.H.D.
Steering stop colour code
29 Yellow thickness 14 mm
(RH helix)
- 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). AXLES SUSPENSION STEERING
280
POWER-ASSISTED STEERING SPECIFICATIONS
XSARA - All Types
Steering wheel - Power-assisted steering - (a) : L.H.D. = Blue. : R.H.D. = White. - (L) : Shaft length = 311 ± 1.5 mm. - (1) Steering wheel fitted with AIRBAG. (according to equipment). - (4) Steering column adjustment lever. 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.
B3EP08QD
281
AXLES SUSPENSION STEERING
The locating bush must be centred in the reference window before tightening the cardan bolts (6).
XSARA - All Types
POWER-ASSISTED STEERING SPECIFICATIONS Power-assisted steering Tightening torques (m.daN)
(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 AXLES SUSPENSION STEERING
B3EP08RD
282
: 5.5
POWER-ASSISTED STEERING SPECIFICATIONS
XSARA - All Types
Power-assisted steering (continued) Steering rack travel (mm)
71.7
L.H.D.
Number of teeth
Pinion
Steering rack
(*) (RH helix)
28
Number of steering wheel turns
Steering ratio
3.3
18.8/1
Steering valve
All types (except 1.8i 16V - 1.9TD) 1.8 i 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). 283
AXLES SUSPENSION STEERING
Vehicles
XSARA - All Types
POWER-ASSISTED STEERING SPECIFICATIONS 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)
: : : :
Tightening sequence. - Tighten screws (16) and (18) - Lightly tighten screw (17), then fully tighten.
AXLES SUSPENSION STEERING
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.
Pressure switch on the pressure circuit. - Switch opens 30 to 35 Bars. - Switch closes 25 bars. - Tighten to : 2 m.daN.
B3EP045D
284
2.5 2.5 2.2 2.2
AXLE GEOMETRY
XSARA PICASSO - All Types
Front height
Rear height
H1 = R1 - L1
H2 = R2 - L2
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
H2 = From the rear axle flexible mounting face to the ground. R2 = Radius of the rear wheel when laden.. L2 = From the centre of the wheel to the rear axle flexible mounting face
B3CP05BC
B3CP058D
285
B3DP079C
AXLES SUSPENSION STEERING
Measurements at reference height.
XSARA PICASSO - All Types
AXLE GEOMETRY Measurements at reference height (continued). (The ref. height of the vehicle is set as per the table below
Front axle
Rear axle
Front axle
Rear axle
H1 = R1 – 90.5 mm
H2 = R2 + 7 mm
AXLES SUSPENSION STEERING
Measure the radius of the front wheel : R1. Calculate dimension H1.
Measure the radius of the rear wheel: R2. Calculate dimension H2.
Compress the suspension to obtain the calculated values. The difference in height between the two sides should be less than 10 mm. B3CP05BC
B3CP05AC
B3DP079C
286
AXLE GEOMETRY
XSARA PICASSO - All Types
Measurements at reference height (continued) NOTE : To make the setting of reference height easier, it is acceptable to take the measurement from the flange of the jacking point. WARNING : The values shown should only be used as guides. In case of doubt, check the settings at reference height (See page 286)
B3CP05BC
Rear height
H1’ = Measurement from the jacking point. L1’ = R1 – H1’ L2 = R2 – H2 Compress the suspension to obtain the calculated values.
B3CP058D
B3DP079C
Engines
1.6i – 1.8i 16 V – 2.0 HDi
L1
90.5 mm
L1’
124 mm 287
AXLES SUSPENSION STEERING
Front height
XSARA PICASSO - All Types
AXLE GEOMETRY Measurements at reference height (continued).
Compress the suspension to obtain the calculated values (see page : 287) Front axle Vehicles
Tracking
Castor
Adjustable All types
0 mm ± 1mm - 0°09’à + 0°09’
Rear axle King pin inclination
Camber
Tracking
( Non-adjustable ) 3° ± 20’
10° 45’ ± 30’
Camber Adjustable
4.8 mm ± 1mm 0° 43’ ± 0° 09’
0° ± 30’
1°20’ ± 20’
NOTE : When checking axles, the vehicle should be at reference height. WARNING
AXLES SUSPENSION STEERING
(*) = Fuel tank full.
B3CP02UC
288
A < B = Positive figure:
+=
TOE-IN
A > B = Negative figure:
–=
TOE-OUT
All types
Ground clearance
No load
150 mm (Minimum value)
XSARA PICASSO - All Types
FRONT AXLE
Tightening torques m.daN. : 4.5 ± 0.4. : 2.5 ± 0.3. : 3.7 ± 0.3. : 4.5 ± 0.4. : : : :
3.7 ± 0.3. 4 ± 0.4. 32.5 ± 2. 9 ± 1.
: 7.6 ± 0.7. : 6.8 ± 0.6. : 3.7 ± 0.3. : 8.5 ± 0.8.
Anti-roll bar
B3CP056P
B3CP057D
B3CP043D
Damper upper bracket : Lug «a» to the front. 289
Engines
Diameter
Colour mark
NFZ-6FZ RHY
21
WHITE
AXLES SUSPENSION STEERING
(1) Damper nut (2) Cup screw (3) Suspension arm. (4) Anti-roll bar link rod ball-joint (5) Suspension arm swivel (6) Anti-roll bar (7) Anti-roll bar link rod ball-joint (8) Lower swivel ball-joint (9) Hub nut (10) Wheel bolt (Face and threads not lubricated). (11) Lower arm front pivot (12) Lower arm rear pivot and anti-roll bar bearing (13) Screw under rear pivot Fixing bolt : subframe on bodyshell
XSARA PICASSO - All Types
REAR AXLE Tightening torques m.daN. (14) Front flexible mounting on subframe (15) Anti-roll bar bolt (16) Rear torsion bar (17) Anti-roll bar (18) Tubular axle (19) Front flexible mounting on bodyshell (20) Rear upper arm. (21) Wheel bolt (Face and threads not lubricated) (22) Damper (23) Rear flexible mounting on subframe (24) Damper pin nut (25) Stub axle nuts (lubricated) (26) Rear flexible mounting on bodyshell
Engine AXLES SUSPENSION STEERING
NFZ-6FZRHY
Torsion bar Colour Ø (mm) mark 19.6
Pink
: 9.5 ± 0.9. : 5.5 ± 0.5.
: 4 ± 0.4. : 9 ± 0.9.
: 5.5 ± 0.5. : 11 ± 0.1. : 25 ± 0.2. : 5.5 ± 0.5. Anti-roll bar
Ø (mm)
Colour mark
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
290
REAR AXLE
XSARA PICASSO - All Types Evolution : Rear hub nut
Old # 15/12/1999.
New 15/12/1999 #
Evolution : - New rear hub nut (3). - Washer discontinued (2). Old fitting (A) (1) Rear hub nut. (2) Thrust washer. ESSENTIAL : Tighten to : 27.5 ± 2.7 m.daN New fitting (B) (3) Rear hub nut. ESSENTIAL : Tighten to : 25 ± 2.5 m.daN. NOTE : It is possible to have both types of fitting on the same axle. The old nut (1) requires the fitting of the thrust washer (2). WARNING : do not fit a thrust washer (2) with a new nut (3).
WARNING : Identify the type of fitting, before starting a repair.
B3DP08AD
291
AXLES SUSPENSION STEERING
ESSENTIAL: Respect the tightening torque to be applied when fitting.
XSARA PICASSO - All Types
SUSPENSION
Height of the vehicle in running order (The vehicle height, when in running order, is set according to the measurements shown in the table below).
The vehicle is said to be in running order when it is empty, with all reservoirs full, including the fuel tank.
B3CP058D
AXLES SUSPENSION STEERING
Engines L1 L1’
Front
Rear
H1 = R1 – L1
H2 = R2 – L2
1.6i - 1.8 i 16 V 62.5 96
Engine L2
2.0 HDi 66.5 mm 100 mm 292
1.6i - 1.8 i 16 V - 2.0 HDi 51 mm
XSARA PICASSO - All Types
SUSPENSION Checking the front and rear axles, vehicle in running order Front axle Adjustable
1.6i - 1.8i 16 V
2.0 HDi
YES
2 mm ± 1 mm 0° 18’ ± 0° 09’
1.7 mm ± 1 mm 0° 15’ ± 0° 09’
Castor King pin inclination Camber
2° 54’ ± 20’ NO
10° 6’ ± 30’
10° 12’ ± 30’
0° 20’ ± 30’
0° 15’ ± 30’
Adjustable
1.6i - 1.8i 16 V 2.0 HDi
Tracking
YES
1.2 mm ± 1 mm 0° 11’ ± 0° 09’
Camber
NO
1° 15’ ± 20’
WARNING A < B = Positive figure:
+=
TOE-IN
A > B = Negative figure:
–=
TOE-OUT
B3CP02UC
293
AXLES SUSPENSION STEERING
Tracking
Rear axle
XSARA PICASSO - All Types
STEERING COLUMN SPECIFICATIONS
Left hand drive = Green marking. Right hand drive = White marking.
(1) Steering wheel. (4) Steering column adjustment.
Tightening torques m.daN. (2) (3) (5) (6) AXLES SUSPENSION STEERING
B3EP116D
294
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±1 2.3 ± 0.2
XSARA PICASSO - All Types
STEERING SPECIFICATIONS
Tightening torques (m.daN)
B3EP117D
295
AXLES SUSPENSION STEERING
(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).
STEERING SPECIFICATIONS
XSARA PICASSO - All Types
Steeringl rack trave Left hand drive Right hand drive
71.7x2
Rack pinion Hélice à gauche
Number of teeth in rack
Number of steering wheel turns
Turning circle between walls
Turning circle entre trottoirs
28 Dents
3.22
12 m
11.48 m
Hélice à droite
Engines
Steering valve
1.6i - 1.8i 16 V - 2.0 HDi No. of teeth : 7 Length of the steering link rods (pre-adjustment): (Between ball-joint centres) = 392 mm (Between the centre of the pivot ball-joint and the contact face of the steering rack ball-joint). = 412 mm. AXLES SUSPENSION STEERING
296
POWER-ASSISTED STEERING SPECIFICATIONS
XSARA PICASSO - All Types
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’’.
Capacity of power steering circuit = 1 Litre. Oil quality = TOTAL FLUIDE ATX. Power steering pump : Supplier SAGINAW. Pump adjustment = 100 ± 5 Bars.
B3EP118D
297
AXLES SUSPENSION STEERING
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
BRAKES
SAXO - All types
BRAKE SPECIFICATIONS
(1) Compensator integral with the wheel cylinder. (2) Load sensitive compensator. Master cylinder Master-vac Ø mm Ft
Caliper/piston makes Disc
Non-ventilated
Brake pad grade
mm Rr
Manual steering
Power-assisted steering without ABS
20.6
19
20.6 203.2
203.2
177.8
TEVES FR 12/45
BENDIX Standard 4/48
238
247
8/6
10/8
VALEO F 714 ABEX 966
GALFER 3726 TEXTART 4009
22.2 228.6 TEVES FN 48/48 247
Cylinder or caliper Drum / Ø max. Disc
1.6 i 1.6 i 16V
1.6 i
Ventilated
Disc thickness/min. thickness
Ø
1.1 i - 1.4 i 1.5 D
1.0 i
20.4/18.4 TEXTART 4900
19 165/167
AS - FM 380 30
180/182
Non-ventilated
247
Disc thickness/min. thickness
8/6
Make Brake lining grade Compensator 298
BENDIX RAD
BENDIX S4
DON 8259
AS FM 380
(1) 20
(2) 13
(1) Compensator integral with the wheel cylinder. (2) Load sensitive compensator.
1.1 i - 1.4 i 1.5 D
SAXO - All types 1.6 i 1.6 i 16V
1.6 i Power-assisted steering with ABS
Master cylinder
Ft
203.2
Caliper/piston makes Disc
BENDIX Standard 4/48 Non-ventilated
Brake pad grade
mm Rr
Cylinder or caliper Drum / Ø max. Disc
TEVES FN 48/48
BENDIX Standard 4/48
247
247
Ventilated
Disc thickness/min. thickness
Ø
Manual steering
20.6
Master-vac Ø mm
Entreprise 1.0i-1.1i-1.5D
247 10/8
20.4/18.4
10/8
JURID 519
AS FM 380
GALFER 3726 TEXTART 4009
20.6
30
203/205
19 180/182
Non-ventilated
247
Disc thickness/min. thickness
8/6
Make
LUCAS RAI
BENDIX S4
BENDIX RAD
Brake lining grade
JURID E 558
AS FM 380
DON 8259
Compensator
(2) 13 299
(1) 20
BRAKES
BRAKE SPECIFICATIONS (continued)
BRAKES
BRAKES
SAXO - All types
B3FP06GC
Conditions - Vehicle in running order - 5 litres of fuel. - A driver (75 Kg). Adjusting the brake limiter. - Apply the brake pedal to close the limiter. - Adjust using the screw (2) to obtain a clearance J of 0.5 to 2 mm.
Adjusting the stop lamp switch. Clearance J = 2 to 3 mm. After adjustment, tighten the lock nut (1) to 1 m.daN.
NOTE : Do not touch (3) which has been adjusted at the factory. B3FP06FC
300
SAXO - All types Tightening torques (m.daN)
ABS - 1.1 i - 1.4 i - 1.6 i
Removing the caliper
B3FP10ND
301
- 1.0 i and 1.1 i Manual steering (except 1.0i Entreprise) - Screw M8 - Screw M12
3.2 ± 0.3 12 ± 1.2
- 1.0i Enterprise - 1.1 i - 1.4 i except 1.6 i) - 2 Screw M12
12 ± 1.2
- 1.6 i - 2 Screw M12
10.5 ± 1
BRAKES
BRAKES (continued)
BRAKES
SAXO - All types
HANDBRAKE (Adjustment) Prior to adjustment. - Release the handbrake. - Drums rotating freely. - No tight spot (If there is one, check if the primary or secondary cables are correctly routed). - Check that all the parts slide and move correctly. - Bleed the main circuit. Adjustment. - Set the brake to the 4th notch. - Tighten the nut (3) until the rear brakes are applied. - Check that: - there is a total travel of between 4 and 7 notches. - the two secondary cables (1) on the balance lever (2) move together. - the wheels rotate freely when the brake is released. - Check that the brake warning lamp comes on from the 4th notch. NOTE : The handbrake operates on the rear wheels.
B3FP106JC
302
The brakes are bled : - Using brake bleeding equipment, in which case the pressure of the equipment should be set to a maximum of 2 Bars.
IMPERATIVE order of bleeding
Wheel : -
Rear left. Front right. Rear right. Front left.
Top up to level using the brake fluid sold by the CITROEN Replacement Parts Division.
303
BRAKES
SAXO - All types
PURGE DES BRAKES
BRAKES
XSARA
#
09/2000
BRAKE SPECIFICATIONS
Without ABS
1.6 i 1.8 i
1.4 i
Master cylinder
1.8 i 16 V
22.2
Disc
Non-ventilated
BENDIX Série VZO 48
TEVES FN 48
22.2
Brake pad grade Cylinder or caliper Ø Drum / Ø max. mm Disc - ventilated
LUCAS C542013 - 20
247
266
247
20.4/18.4
20/18
20.4/18.4
ASFM 197
ASFM 380
ASFM 197
20.6
32
20.6
13/11
180/182
180/182
203/205
247
Disc thickness/min. thickness
8/6
Make
DON
TEXTAR
Brake lining grade
8259
T 428
20
32
Compensator cut-off in Bars
TEVES FN 48
247
Ventilated
Disc thickness/min. thickness
Rr
1.9 TD
228.6
Caliper/piston makes
Ft
1.9 D
23.8
Master-vac Ø mm
1.5 D
304
DON 8259 20
32
With ABS
Master cylinder Ø Ft
mm
1.8 i 16 V
22.2
2.0 i 16 V 23.8
Master-vac
#
09/2000
1.8 D 1.9 D
1.9 TD 22.2
228.6
Caliper/piston makes Disc
TEVES FN 48
LUCAS C542013 - 54
LUCAS C572213N57
TEVES FN 48
Non-ventilated Ventilated
247
266
283
247
Disc thickness/min. thickness
20.4/18.4
20/18
22/20
20.4/18.4
Brake pad grade
ASFM 197
ASFM 380
ASFM 197
20.6
32
20.6
Cylinder or caliper Ø Drum / Ø max. mm Disc - ventilated Rr
1.6 i 1.8 i
1.4 i
XSARA
203/205
203/205 247 8/6
Disc thickness/min. thickness
Make
DON
Brake lining grade
8259
Compensator cut-off in Bars
TEXTAR
DON
T 428 32
8259 25
305
32
BRAKES
BRAKE SPECIFICATIONS
BRAKES
XSARA
#
09/2000
BRAKE SPECIFICATIONS Without ABS 1.4i-1.9D Saloon
Ø mm
Estate
2.0i 16V
Master cylinder
23.8
23.8
Master-vac
228.6
228.6
BOSCH ZOH 54/2 54
LUCAS C57 22 13N/57
Caliper/piston makes
Ft Disc
Non-ventilated Ventilated
Disc thickness/min. thickness Brake pad grade Cylinder or caliper Ø Drum / Ø max. mm Disc - ventilated Rr
With ABS 1.4i-1.6i 16V-1.9D 2.0 HDi
266
283
22/20
22/20
FERF 769
ASFM 380
20.6
22
203/205
228/230
BENDIX Standard IV G - 32
247
Disc thickness/min. thickness
8/6
Make Brake lining grade
JURID D 8259
E 558
Compensator cut-off in Bars
JURID 519
T 428 32
306
XSARA - All Types
- Tighten the nuts (1) to 2.3 m.daN. - The clevis pin (2) is held in place by a plastic clip.
B3FP10YD
307
BRAKES
BRAKE SPECIFICATIONS
BRAKES
XSARA - All Types
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. (1) Hydraulic valve block «ABS Bosch 5.3».
2
(2) Load sensitive braking compensator (according to model).
B3FP09HC
B3FP09JC
308
Braking system without ABS (rear drum brakes)
B3FP09ED
XSARA - All Types Braking system without ABS (rear disc brakes)
B3FP09FD
309
BRAKES
BRAKE SPECIFICATIONS
BRAKES
XSARA - All Types
BRAKE SPECIFICATIONS
Braking system with ABS (rear drum brakes)
Braking system with ABS (rear disc brakes)
B3FP09GD
B3FP09KD
310
XSARA - All Types
Evolution : Rear brake drum hub 01/1999 # Old assembly
B3FP119D
New assembly
B3FP11AD
Evolutions. New components : - Rear wheel stub. - Stop ring (ref. (4)). - Double shouldered washer (ref. (5)) NOTE : The new assembly is identified by a figure from 1 to 6 cold-stamped on the head of the wheel stub at "a". (1) Washer exterior diameter = 38 mm. (2) Stop ring (3) Circlip. NOTE : This assembly is equipped with either part (2) or part (3).
Ref. "a": Figure from 1 to 6 cold-stamped. (4) Stop ring. (5) Double shouldered washer, exterior diameter = 48 mm. 311
BRAKES
REAR BRAKE SPECIFICATIONS
BRAKES
REAR BRAKE SPECIFICATIONS
XSARA - All Types
Evolution : Rear brake disc hub 01/99 # Old assembly
B3FP11BD
New assembly
B3FP11CD
Evolutions Fixing of the brake disc hub. Sealing of the brake disc hub. New components: New components: - Rear wheel stub. - Sealed bearing incorporated at "c" (ref. (6)). - Double shouldered washer (ref. (7)). - Spacer without seal face (ref. (5)). - Cap (ref. (8)). NOTE : The new assembly is identified by a figure from 1 to 6 cold-stamped on the head of the wheel stub at "c". Ref. "c". : Figure from 1 to 6 cold-stamped. (5) Spacer without seal face. (6) Sealed bearing incorporated at "b".
New assembly (7) Double shouldered washer, exterior diameter = 48 mm.) (8) Cap. 312
XSARA - All Types
To perform any checks, it is necessary to calculate the weight on the rear axle in order to refer to the adjustment graphs. Preliminary pre-check operations. Calculate : 1) The rear weight of the vehicle (empty tank + 1 person)
# Note the vehicle type
2) The weight of fuel in the fuel tank
# Note the fuel level
Refer to table N° 2
3) The weight of options fitted to the vehicle
# Note the vehicle options
Refer to table N° 3
Refer to table N° 1
4) Add these three weights together to obtain the TOTAL REAR VEHICLE WEIGHT; remove all objects from the vehicle totalling more than 10 kg in weight. 5) Select the adjustment graph that corresponds to the vehicle model. (Refer to tableN° 4). 6) Check the brake pressure. 7) Adjust the load sensitive brake compensator if necessary. Example - The rear weight of the vehicle (empty tank + 1 person) - The weight of fuel in the fuel tank (tank 1/2 full) - The weight of options fitted to the vehicle (sun roof) - Total rear vehicle weight - Corresponding graph (Graph N° 1)
= = = =
412 kg 18 kg 8 kg 438 kg
313
BRAKES
CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR
BRAKES
CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued)
XSARA - All Types
(Weights in kg) TABLE N° 2 (Weight of fuel in the fuel tank).
TABLE N° 1 (Rear weight of the vehicle (Empty tank + 1 person)). Trim level
Type of fuel
Petrol
5 litres
4
4
1/4
9
10
423
1/2
18
20
3/4
27
30
Non-ventilated
36
40
X
SX
Exclusive
392
405
416
412
VTS
Engine 1.4 i 1.6 i 1.8 i
422
424
1.8 i 16 V
424
428
1.9 D
405
425
432
1.9 TD
436
449
447
431
Diesel
450 (Weights in kg)
TABLE N° 3 (Weight of options fitted to the vehicle).
TABLE N° 4 (Graph selection).
Option Electric sun roof
Vehicle Model
Graph
8
1.4i - 1.6i - 1.8i - 1.8i (Automatic) - 1.9 D
1
Protective grille
5
1.8 i 16 V
2
Towing equipment (All models)
20
1.9 TD
3
314
XSARA - All Types
GRAPH N°2
GRAPH N°1
B3FP09YD
B3FP09XD
315
BRAKES
CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued)
BRAKES
XSARA - All Types
CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued) GRAPH N°3
B3FP09ZD
316
XSARA - All Types
TOOLS : 4140-T
- Braking pressure checking tool
CHECKING THE BRAKE PRESSURE WARNING : Do not touch the plastic nut (1). PRELIMINARY OPERATIONS - Place the vehicle on a 4-column lift if possible. - Fit tool 4140-T. - Calculate the rear vehicle weight. (See pages : 313-314). - Check that no hydraulic fluid is leaking and that the pipes are not being obstructed. - Refer to the graph which corresponds to the vehicle type. ( See page: 315-316). CHECKS - Perform the checks between the wheels as follows : front left and rear right - front right and rear left. - With the engine running, increase the pressure at the rear to obtain a front pressure of 60 bars. ESSENTIAL : The checking pressure must be obtained by progressively increasing the pressure (never reduce the pressure to adjust it). - Check the increased measurement against the graph. (If the measurement is not within the limits, adjust the compensator). (See page 318). - To check that the compensator works correctly, increase the rear pressure to 100 bars. (If the measurement is not within the limits, replace the compensator). - Bleed the brake system and carry out a road test. B3FP101C
317
BRAKES
CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued)
BRAKES
XSARA - All Types
CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued)
ADJUSTING THE COMPENSATOR WARNING : Do not touch the plastic nut (1). IMPORTANT : When loosening the nut (2), the spring (3) may suddenly force off the nut (2) and lock nut (4) assembly. Calculate the spring length (3) before loosening the nut (2), and use a spanner to hold the lock-nut (4) in place, thus restraining the spring. - Loosen the nut (2) while ensuring the lock-nut (4) is held firmly in place. - Adjust the length of the spring (3) : - Reduce the spring length (3) to increase brake pressure. - Increase the spring length (3) to reduce brake pressure.
- Tighten the nut (2) to 1.5 m.daN. - Check the brake pressure.
B3FP101C
318
B3FP102C
XSARA - All Types
CHECKING AND ADJUSTING THE HANDBRAKE
- Remove the handbrake console. - Jack up and chock the vehicle with the rear wheels hanging free. - Check the correct routing of the brake cables under the vehicle. - Apply and release the handbrake ten times. - Set the handbrake to the 3rd notch. - Tighten the nut (1) until the rear brakes are applied. - Pull the handbrake lever vigorously 4 to 5 times. - Set the handbrake to the 3rd notch. - Check that the rear brakes are applied. - Check that the wheels can be turned freely by hand with the handbrake released. - Lower the vehicle. - Refit the handbrake console.
B3FP095D
319
BRAKES
HANDBRAKE
BRAKES
XSARA - All Types
BLEEDING THE BRAKES
Bleeding : The brakes can be bled either : - using brake bleeding equipment, in which case the pressure of the equipment should be set to 2 Bars. - or in the usual way.
IMPERATIVE order of bleeding
Wheels : - Rear Right. - Rear Left. - Front Right. - Front Left
Top up using brake fluid supplied by CITROEN Replacement Parts 320
NOTE : On models equipped with ABS, there is no load-sensitive braking compensator.
Ø mm Fr
1.6 i
1.8 i 16 V
Master cylinder
23.8
Master-vac
254
Caliper/piston makes Brake disc
LUCAS C 54 Non-ventilated Ventilated
266
Disc thickness/min. thickness
20.4 / 18.4
Brake pad grade
AS-FM 380
Ø mm Rr
XSARA PICASSO - All Types
Cylinder or caliper
22.2
Drum / Ø max.
228/230
Non-ventilated disc
Disc thickness/min. thickness Make
LUCAS
Brake lining grade
ABEX 4930/2
Compensator
35/75 321
2.0 HDi
BRAKES
BRAKE SPECIFICATIONS
BRAKES
XSARA PICASSO - All Types
BRAKE SPECIFICATIONS Braking system specifications
- ‘‘X’’ braking circuit. - Front : disc brakes, ventilated - Rear : drum brakes with automatic wear adjustment. - Cable operated handbrake acting on the rear wheels. - Rear: load-sensitive braking compensator (non-ABS models)
- (1) Hydraulic valve block ‘‘ABS Bosch 5.3’’. - (2) Load sensitive rear braking compensator.
B3FP11VD
B3FP08ND
322
Without ABS
XSARA PICASSO - All Types With ABS
B3FP11WD
B3FP11UD
323
BRAKES
BRAKING SYSTEM SPECIFICATIONS
BRAKES
XSARA PICASSO - All Types Tools
CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR [1] Brake pressure checking tool
Checking procedure Determine the weight on the rear axle and then refer to the adjustment graphs. The allocation table enables you to choose which graph to use for each type of vehicle. Connect the tool [1] in order to check the rear pressure values relative to the front pressures (60 and 100 bars).
Determining the rear weight of the vehicle Refer to the tables of different weights. To obtain the rear weight of the vehicle, add the following weights : - Rear weight of the vehicle (tank empty + 1 person). - Weight of fuel in the fuel tank. - Weight of the options on the vehicle. Remove from the vehicle any object that could weigh more than 1 Kg.
Rear weight of the vehicle (tank empty + 1 person) Note the vehicle type. Consult the correspondence table. Engine type
Rear weight (tank empty + 1 person)
NFZ 6FZ RFN RHY
542 531 532 540
: 4140-T
Masse carburant dans le réservoir. Relever le niveau du carburant du véhicule et en déduire la masse d’après le tableau. Level of fuel (Litres) 5 1/4 1/2 3/4 Full 324
Weight of fuel in the fuel tank (Kg) Petrol Diesel 4 4 11 12 22 24 33 36 44 48
Tools
[1] Brake pressure checking tool
Example. Type of vehicle Rear weight (tank empty + 1 person). Fuel tank half full Sun roof
XSARA PICASSO - All Types : 4140-T
= TU5JP+ = 542 Kg. = 22 Kg = 10 Kg
Rear weight of the vehicle = 542 + 22 + 10 = 574 Kg.
Weight of the options on the vehicle Note the options on the vehicle and deduce the weight according to this table Options Electric sun roof Bicycle carrier Roof bars Refrigeration/heating module Under-engine shield Towbar all versions
Table of allocation of graphs
Weight (Kg)
Vehicle engine version
10 5 4 10 9 19
NFZ – RHY 6FZ NFZ – RHY (CRD) 6FZ – RFN (CRD) 325
Graph N° 1 2 3 4
BRAKES
CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR
BRAKES
XSARA PICASSO - All Types
CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR
GRAPH N°1
B3FP09XD
GRAPH N°2
B3FP09YD
Key : P = Rear pressure (in Bars). M = Weight (in Kg).
a = Front pressure 60 ± 3 Bars. b = Front pressure 100 ± 3 Bars. 326
GRAPH N°3
B3FP09ZD
XSARA PICASSO - All Types GRAPH N°4
B3FP100D
Key : P = Rear pressure (in Bars). M = Weight (in Kg)
a = Front pressure 60 ± 3 Bars. b = Front pressure 100 ± 3 Bars. 327
BRAKES
CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR
BRAKES
XSARA PICASSO - All Types
CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR CHECKING THE BRAKING PRESSURE
Preliminary operations : - The vehicle should be placed on all 4 wheels, preferably on a lift. - The tool [1] (in good working order) in place. - Rear weight of the vehicle determined. - Check there are no hydraulic leaks. - Check the absence of pinching on the pipes. - Refer to the graph corresponding to the vehicle engine version. - Checks are done between the following components : Front LH wheel and rear RH wheel. Front RH wheel and rear LH wheel.. - On the vehicle, engine running, note the rear pressure when the front pressure is 60 ± 3 Bars. - The control pressure should be obtained by progressively increasing the pressure (without ever releasing the pressure to adjust it).
E5-P01IC
328
- Compare the value noted with the graph. - If the value is outside the tolerance, adjust the compensator. - In order to check that the compensator is working properly, note the rear pressure when the front pressure is 100 ± 3 Bars. - If the value is outside the tolerance, replace the compensator. - Any large discrepancy between the two circuits will mean that the braking compensator should be replaced. - After completing these operations, bleed the braking circuit.(See corresponding operation). - Carry out a road test.
XSARA PICASSO - All Types
Adjusting the load-sensitive brake compensator - Untighten the screw (1). - Move the spring rod. - Decrease the length of the spring to increase the pressure. - Increase the length of the spring to decrease the pressure. - Tighten the screw (1) to 1,2 ± 0,25 m.daN. - Check the brake pressure. After the operation : - Remove the checking tool [1]. - Bleed the braking circuit (See corresponding operation). - Carry out a road test.
B3FP13VC
329
BRAKES
CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR
BRAKES
XSARA PICASSO - All Types
HANDBRAKE (Adjustment) 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).
B3FP11YD
330
XSARA PICASSO - All Types
Tools Bleeding equipment of type «LURO» or similar. IMPERATIVE : For bleeding the secondary circuit, use ELIT, LEXIA or PROXIA diagnostic tools. Draining. Drain the brake fluid reservoir as empty as possible using a syringe. Disconnect the brake fluid warning lamp connector. Retrieve the brake fluid reservoir from its supply pipes by pulling upwards. Finish emptying the reservoir of brake fluid. Clean the brake fluid reservoir. Refit the brake fluid reservoir. Reconnect the brake fluid warning lamp connector. 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. 331
BRAKES
BLEEDING THE BRAKES
ELECTRICAL SYSTEM
STARTER MOTORS
SAXO
Manufacturer and Ref.
Vehicles / models
Class
Climat
1
H,T,C
3
VC
1
H,T
2
C
3
VC
VALEO D7E7
1.0i 1.1i 1.4i (AIRCON) 1.6i ( AIRCON)
BOSCH 1116003 MELCO M002T13081 VALEO D6 RA 571 VALEO D7E7
SAXO
BOSCH 1116003 MELCO M002T13081
1.4i 1.6i
VALEO D7E5 BOSCH 1112041 VALEO D6 RA 571
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold) 332
Vehicles / models
Manufacturer and Ref.
Class
Climat
VALEO D6 RA 571
3
H,T,C,VC
4
H,T,C
5
VC
1
H,T
2
C
3
VC
1
H,T
3
C,VC
1.4i (Auto.) 1.6i (Auto./ 1.6i 16v SAXO
VALEO D7R11 1.5D
BOSCH 1108162 VALEO D7R15 VALEO D7E7 BOSCH 1116003 MELCO M002T13081
1.4i 1.6i
VALEO D7E5 BOSCH 1112041
XSARA
VALEO D6 RA 571 VALEO D7E7 BOSCH 1116003
1.4i (Power-st. or aircon) 1.6i (Power-st. or aircon)
MELCO M002T13081 VALEO D6 RA 571
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold) 333
ELECTRICAL SYSTEM
SAXO - XSARA
STARTER MOTORS
XSARA
STARTER MOTORS Manufacturer and Ref.
Vehicles / models
VALEO D7E5
1.4i (Power-st. + aircon) 1.6i (Power-st. + aircon)
BOSCH 1112041
Class 2
ELECTRICAL SYSTEM
VALEO D6 RA 571 1.6i (Auto.) XSARA
VALEO D6 RA 571 VALEO D6RA661
1.8i 1.8i 16v
BOSCH 1108085 2.0i 16v
BOSCH 1107019 BOSCH 1108085
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
334
H,T C,VC
3
H,T,C,VC H,T,C
BOSCH 1107019 VALEO D6RA661
Climate
4
VC
3
H,T
4
C,VC
STARTER MOTORS Manufacturer and Ref.
Vehicles / models
VALEO D7R11 1.5D
BOSCH 1108162 VALEO D7R15
Class
Climate
4
H,T,C
5
VC
4
H,T
VALEO D6RA109 XSARA
BOSCH 1.9D
MELCO M001T80381
2.0 HDi
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold) 335
VALEO D7R26
5
C
VALEO D7R27
6
VC
VALEO D7R26
5
H,T
VALEO D7R27
6
C,VC
ELECTRICAL SYSTEM
XSARA
BERLINGO
STARTER MOTORS Manufacturer and Ref.
Vehicles / models
Class
Climate
VALEO D7E7 BOSCH 1116003
1.1i ELECTRICAL SYSTEM
1
H,T,C
3
VC
1
H,T
2
C
3
VC
2
H,T
3
C,VC
MELCO M002T13081 VALEO D6 RA 571 VALEO D7E7 BOSCH 1116003
BERLINGO
MELCO M002T13081
1.4i
VALEO D7E5 BOSCH 1112041 VALEO D6 RA 571 VALEO D7E5 1.4i (Power-st. + aircon)
BOSCH 1112041 VALEO D6 RA 571
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
336
Manufacturer and Ref.
Vehicles / models
VALEO D6RA661 1.8i
BOSCH 1107019 BOSCH 1108085
Class
Climate
3
H,T,C
4
VC
4
H,T
5
C
6
VC
5
H,T
6
C,VC
VALEO BOSCH BERLINGO
MELCO
1.9D
VALEO D7R26 MELCO VALEO D7R27 VALEO D7R26 2.0 HDi
MELCO VALEO D7R27
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
337
ELECTRICAL SYSTEM
BERLINGO
STARTER MOTORS
XSARA PICASSO
STARTER MOTORS Manufacturer and Ref.
Vehicles / models
Class
Climate
VALEO D7E7 BOSCH 1116003 ELECTRICAL SYSTEM
1
H,T
2
C
3
VC
2
H,T
3
C,VC
1
H,T
3
C,VC
MELCO M002T13081
1.6i
VALEO D7E5 BOSCH 1112041 VALEO D6 RA 571 XSARA PICASSO
VALEO D7E5 BOSCH 1112041
1.6i (Power-st. + aircon)
VALEO D6 RA 571 VALEO D7E7 BOSCH 1116003
1.6i (Power-st. or aircon)
MELCO M002T13081 VALEO D6 RA 571
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
338
XSARA PICASSO Manufacturer and Ref.
Vehicles / models
VALEO D6RA661 1.8i 16v
BOSCH 1107019
XSARA PICASSO 2.0HDi
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
339
Class 3
Climate H,T,C
BOSCH 1108085
4
VC
VALEO D7R26
5
H,T
VALEO D7R27
6
C,VC
ELECTRICAL SYSTEM
STARTER MOTORS
ALL TYPES
STARTER MOTORS Table of classes 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
Maximum power for a speed of 1200 rpm
I ≤ 275 A
I ≤ 300 A
I ≤ 430 A
I ≤ 470 A
I ≤ 500 A
340
ALTERNATORS Gbox.
1.0i/L3 1.4i/L3
M
1.1i/L3
M
Classes and types Without aircon. 7
7
7 A
1.5D /L4
M M
H,T,C VC
VALEO A11 VI 55
H,T,C
With aircon. 7 8 7
VALEO A13 VI 96
VC
VALEO A11 VI 55
H,T
BOSCH A120310028 8
1.5D /L3
VALEO A11 VI 55 BOSCH A120310028
BOSCH A120310028 8
1.4i/L3
Climate
Climate
VALEO A11 VI 55
H,T,C
BOSCH A120310028
VC
VALEO A13 VI 96
H
VALEO A11 VI 55
T,C
BOSCH A120310028 8 7
VALEO A13 VI 96 VALEO A11 VI 55
H,T,VC C
VALEO A13 VI 96
C,VC
7
VALEO A11 VI 45
H,T,C
7
VALEO A11 VI 45
H,T,C
8
VALEO A13 VI 84
VC
8
VALEO A13 VI 84
VC
7
VALEO A11 VI 45
H,T,C,VC
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
341
BOSCH A120310028
ELECTRICAL SYSTEM
Engine
SAXO Without power-steering
ALTERNATORS
SAXO With power-steering Engine
Classes and types
Gbox. Without aircon. 7
Climate
VALEO A11 VI 55
H
ELECTRICAL SYSTEM
BOSCH A120310028 1.1i
1.4i 1.6i
1.4i
1.5D
1.6i 16v
M
8
VALEO A13 VI 96
T
9
VALEO A13 VI 141+
C,VC
7 M
A
M
M
VALEO A11 VI 55
H,T
BOSCH A120310028
With aircon.
Climate
9
VALEO A13 VI 141+
H,T
8
VALEO A13 VI 96
C
9
VALEO A13 VI 141+
H
8
VALEO A13 VI 96
T,C
8
VALEO A13 VI 96
C,VC
9
VALEO A13 VI 141+
H,T,C,VC
8
VALEO A13 VI 96
H
9
VALEO A13 VI 141+
H,T,C,VC
9
VALEO A13 VI 141+
T,C,VC
7
VALEO A11 VI 45
H
8
VALEO A13 VI 84
T,C
8
VALEO A13 VI 84
T,C
9
VALEO A13 VI 142+
H,VC
9
VALEO A13 VI 142+
VC
8
VALEO A13 VI 96
H,T,C
9
VALEO A13 VI 141+
H,T
8
VALEO A13 VI 96
C
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold) 342
ALTERNATORS Classes and types
Gbox. Without aircon. 7
1.1i
M
1.6i
M
1.6i 16v
7 8
1.4i
A
1.5D
M
VALEO A11 VI 55
H,T
BOSCH A120310028 8
1.4i
Climate
VALEO A13 VI 96
With aircon.
Climate
9
VALEO A13 VI 141+
H
8
VALEO A13 VI 96
T,C,VC
9
VALEO A13 VI 141+
H,T
8
VALEO A13 VI 96
C,VC
9
VALEO A13 VI 141+
H,T,C,VC
C,VC
VALEO A11 VI 55
H,T
BOSCH A120310028 VALEO A13 VI 96
C,VC
8
VALEO A13 VI 96
H
9
VALEO A13 VI 141+
T,C,VC
7
VALEO A11 VI 45
H
8
VALEO A13 VI 84
C
8
VALEO A13 VI 84
T,C
9
VALEO A13 VI 142+
H,T,VC
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
343
ELECTRICAL SYSTEM
Engine
SAXO With power-steering
ALTERNATORS
SAXO Police Engine
Classes and types
Gbox. Without aircon.
Climate SAXO POLICE
ELECTRICAL SYSTEM
1.1i/1.4i
M
9
VALEO A13 VI 141+
T
1.5D
M
9
VALEO A13 VI 142+
T
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
344
With aircon.
Climate
XSARA Without power-steering
ALTERNATORS Classes and types
Gbox. Without aircon.
1.4i /L3 1.6i /L3 1.5D
VALEO A11 VI 55
H,T
BOSCH A120310028
C,VC
8
VALEO A13 VI 96
C,VC
8
VALEO A13 VI 84
T
7 M
M
Climate
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
345
With aircon. 8 7
VALEO A13 VI 96 VALEO A11 VI 55 BOSCH A120310028
Climate H,C,VC T
ELECTRICAL SYSTEM
Engine
ALTERNATORS
XSARA With power-steering
Classes and types Engine
Gbox.
1.4i /L3
M
Without aircon. 7
ELECTRICAL SYSTEM
7 M
8 M
H
With aircon. 8 7
VALEO A13 VI 96
T,C,VC
VALEO A11 VI 57
H
VALEO A13 VI 96 VALEO A11 VI 57
Climate C,VC T
BOSCH A12220310104 8
VALEO A13 VI 96
H,T,C,VC
BOSCH A12220310104 8
1.6i /L4
VALEO A11 VI 57 BOSCH A12220310104
8
1.6i /L3
Climate
9
VALEO A13 VI 96
T,C,VC
VALEO A13 VI 96
H
VALEO A13 VI 101+
9
T,C,VC
VALEO A13 VI 101+
T,C,VC
MELCO A002TA2091
H
VALEO A13 VI 101+
T,C,VC
MELCO A002TA2091
H
MELCO A002TA2091 H 1.6i
A
9
VALEO A13 VI 101+
T,C,VC
MELCO A002TA2091 CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
346
9
XSARA With power-steering
ALTERNATORS Classes and types
Gbox. Without aircon. 7
Climate
BOSCH A120411525
C
BOSCH A120411523 8 1.8i 16v /L3
M
With aircon. BOSCH A120411523 8
MELCO A002TA1991
T,C
MELCO A002TA1991
Climate C,VC H,T
VALEO A13 VI 102
VALEO A13 VI 102 9
VALEO A13 VI 101+
VC
MELCO A002TA2091 7
BOSCH A120411525
C
BOSCH A120411523 1.8i /L3
M
8
2.0i 16 v /L3
MELCO A002TA1991
T
VALEO A13 VI 102 9
BOSCH A120411523 8
VALEO A13 VI 101+ C,VC
MELCO A002TA2091 CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
347
MELCO A002TA1991 VALEO A13 VI 102
C,VC H,T
ELECTRICAL SYSTEM
Engine
ALTERNATORS
XSARA With power-steering
Classes and types Engine
Gbox.
Without aircon.
Climate
BOSCH A120411523 ELECTRICAL SYSTEM
8 2.0i 16v
M
M
1.5D (poulie 66.6)
1.9D /L3
M
H
9
VALEO A13 VI 102
9 1.5D (poulie 59.4)
12
MELCO A002TA1991
8
With aircon.
Climate
VALEO A14 VI 14
H
VALEO A13 VI 101+
T,C,VC
MELCO A002TA2091
VALEO A13 VI 101+
T
MELCO A002TA2091
C,VC
VALEO A13 VI 273+
T
9
VALEO A13 VI 273+
T
VALEO A13 VI 142+
T
9
VALEO A13 VI 142+
T
VALEO A13 VI 203
H,T
VALEO A13 VI 203
H
8
MELCO A002TB2191
MELCO A002TB2191
C,VC
MELCO A002TB4791
MELCO A002TB4791 7
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
348
VALEO A11 VI 91
C,VC T
XSARA With power-steering
ALTERNATORS Classes and types
Gbox. Without aircon. 9
Climate
VALEO A13 VI 94+
H
With aircon. 12
MELCO A002TA2094
M
8
H
MELCO A002TA5591
BOSCH A120411513 1.9TD
VALEO A14 VI 13
Climate
9
VALEO A13 VI 95
T,C,VC
VALEO A13 VI 94+
T
MELCO A002TA2094
MELCO A002TA1994
BOSCH A120411513 8
VALEO A13 VI 95
C,VC
MELCO A002TA1994 7
VALEO A11 VI 91
H
VALEO A13 VI 204+ 9
MELCO A002TB2291
H
MELCO A002TB4891 2.0 HDi
M
VALEO A14 VI 27+ 15
VALEO A14 VI 27+
BOSCH A1222051611
T,C,VC
MELCO A004TF0091
15
BOSCH A1222051611 MELCO A004TF0091
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold) 349
T,C,VC
ELECTRICAL SYSTEM
Engine
ALTERNATORS
XSARA With power-steering - XSARA Police
Classes and types Engine
Gbox.
Without aircon.
Climate
With aircon.
VALEO A13 VI 203 ELECTRICAL SYSTEM
8 2.0 Hdi
A 15
Climate
VALEO A13 VI 204+
MELCO A002TB2191
H
9
MELCO A002TB2291
MELCO A002TB4791
MELCO A002TB4891
VALEO A14 VI 27+
VALEO A14 VI 27+
BOSCH A1222051611
T,C,VC
15
MELCO A004TF0091
BOSCH A1222051611
H
T,C,VC
MELCO A004TF0091
XASARA POLICE 1.4i 1.9D
M
9
VALEO A13 VI 141+
H,T,C,VC
VALEO A13 VI 94+
H,T
MELCO A002TA2094
C,VC
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
350
9 12
VALEO A13 VI 141+
H,T,C,VC
VALEO A14 VI 13
H,T
MELCO A002TA5591
C,VC
XSARA PICASSO
ALTERNATORS Classes and types
Gbox. Without aircon. 7
1.6i
M
Climate
VALEO A11 VI 91
H,T
BOSCH A120316004
C,VC
With aircon. 9 8
8 1.8i 16v
M 7 15 (*)
2.0 Hdi
M
MELCO A002TB4791
T
VALEO A13 VI 203
C,VC
VALEO A11 VI 91
H
BOSCH A120316004 VALEO A13 VI 27+
T,C,VC
BOSCH A120516111 MELCO A004TF0091 VALEO A13 VI 204+
9
H,T
MELCO A002TB4891
C,VC
(*) = With cabin heating CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold) 351
9 8 15 (*) 12 9
VALEO A13 VI 204+ MELCO A002TB4891
Climate H
MELCO A002TB4791
T,C,
VALEO A13 VI 203
VC
VALEO A13 VI 204+ MELCO A002TB4891 MELCO A002TB4791 VALEO A13 VI 203
H,T C,VC
VALEO A13 VI 27+ BOSCH A120516111
T,C,VC
MELCO A004TF0091 MELCO A003TA0891 VALEO A13 VI 204+ MELCO A002TB4891
H T,C,VC
ELECTRICAL SYSTEM
Engine
ALTERNATORS
BERLINGO Without power-steering
Classes and types Engine
Gbox.
1.1i /L3
Without aircon. 8
Climate
VALEO A13 VI 96
ELECTRICAL SYSTEM
VALEO A11 VI 55
1.4i /K 7 1.4i /L3 8 M
7
1.9D L4/W4
7
VALEO A11 VI 55
H,T,C
VALEO A13 VI 203
H
MELCO A002TB2191
C,VC
VALEO A11 VI 91
H
VALEO A13 VI 203 8
MELCO A002TB2191 VALEO A13 VI 203 MELCO A002TB2191
2.0 HDi
VALEO A11 VI 55
H
BOSCH A120310028 BOSCH A120310028
1.9D L3/W3
With aircon.
BOSCH A120310028 VALEO A11 VI 55 BOSCH A120310028
8 7
T,C,VC
8
H
9
VALEO A14 VI 27+ 15
Climate
T
VALEO A13 VI 203 MELCO A002TB2191 VALEO A11 VI 91 VALEO A13 VI 203 MELCO A002TB2191 VALEO A13 VI 204+ MELCO A002TB2291
H H,T,C VC T H,C,VC H
VALEO A14 VI 27+
MELCO A004TF0091
T,C,VC
BOSCH A122051611
15
MELCO A004TF0091 BOSCH A122051611
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold) 352
T,C,VC
BERLINGO With power-steering
ALTERNATORS
Classes and types
Gbox. Without aircon. 7
1.1i /L3
1.4i /L3
M
M
Climate
VALEO A11 VI 55 VALEO A13 VI 96
T
9
VALEO A13 VI 141+
C,VC
8
VALEO A13 VI 96
C
8
VALEO A11 VI 55
M
BOSCH A120411523 8
MELCO A002TA1991 VALEO A13 VI 102
VALEO A13 VI 101+
VC
MELCO A002TA2091 7
VALEO A11 VI 55 BOSCH A120310028 BOSCH A120411523
T,C
VALEO A13 VI 102 9
7
H,T
BOSCH A120310028 MELCO A002TA1991
1.8i
Climate
H
BOSCH A120310028
8
7
With aircon.
BOSCH A120411525
H
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold) 353
H,T,C
H,T C,VC
ELECTRICAL SYSTEM
Engine
ALTERNATORS
BERLINGO With power-steering
Classes and types Engine
Gbox.
Without aircon. 8
Climate
VALEO A13 VI 203
H
With aircon. 8
ELECTRICAL SYSTEM
MELCO A002TB2191 1.9D /L3 9
T,C
9
MELCO A002TB2291 7 1.9D /L4
8
VALEO A11 VI 91
H T,C,VC
7 8
MELCO A002TB2191 VALEO A13 VI 203
H
9
T H,C,VC
VALEO A13 VI 204+
H
MELCO A002TB2291
VALEO A14 VI 27+ 15
VALEO A11 VI 91 VALEO A13 VI 203 MELCO A002TB2191
MELCO A002TB2191 2.0 HDi
H,T,C
VALEO A13 VI 204+ MELCO A002TB2291
VALEO A13 VI 203
M
VALEO A13 VI 203 MELCO A002TB2191
VALEO A13 VI 204+
Climate
VALEO A14 VI 27+
MELCO A004TF0091
T,C,VC
BOSCH A122051611
15
MELCO A004TF0091 BOSCH A122051611
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
354
T,C,VC
ALL TYPES
CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR
Connect as shown in the diagram opposite, using an ammeter (A), a voltmeter (V), and a rheostat (R) or a Volt/Ammeter/Rheostat combination. Adjust the engine speed (table opposite) and rheostat charge according to the vehicle's equipment specification in order 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 must go out when the engine has started (accelerate slightly).
Output under 13.5 V Intensity (A) / Alternator speed Speed
2000 tr/min
3000 tr/min
4000 tr/min
5
29 A
39 A
43 A
7
42 A
54 A
59 A
8
49 A
62 A
68 A
9
62 A
76 A
83 A
12
72 A
90 A
100 A
15
99 A
128 A
140 A
Class
CHECKING THE VOLTAGE REGULATOR the rheostat to zero and disconnect all the electrical consumers. Display 5000 alternator rpm. If U alternator is > 14.7 V, the regulator is faulty.Set Note : These tests should be performed with the engine hot and the battery fully charged. D1AP01SC
355
ELECTRICAL SYSTEM
CHECKING THE ALTERNATOR OUTPUT
SAXO - XSARA - XSARA PICASSO Vehicles / models
PRE-HEATING AND STARTING SYSTEMS
ELECTRICAL SYSTEM
Pre-heater plugs
Pre-heater control unit
BERU 0 100 226 188
LUCAS R0490001B
CHAMPION CH 168
BOSCH A 281 023 045
BERU 0 100 226 188
LUCAS R0490001B
CHAMPION CH 168
BOSCH A 281 023 045
BERU 0 100 226 186
BOSCH 0 281 003 005
BOSCH 0 250 201 039
VALEO 73507212
CHAMPION CH185
LUCAS R0490001B
BERU 0 100 226 371
BOSCH A 281 023 045
CHAMPION CH170
NAGARES 735068
BOSCH 0250202032
CARTIER 960411-P
SAXO
Pre / Post heating (pre-heating duration at 20°C)
10s / 150s 1.5D 10s / 150s
1.9TD
6s / 180s
XSARA 1.9D
10s / 150s
2.0 Hdi
356
Controlled by the diesel injection ECU.
Vehicles / models
1.9D BERLINGO 2.0 HDi
Pre-heater plugs
Pre-heater control unit
CHAMPION CH185
LUCAS R0490001B
BERU 0 100 226 371
BOSCH A 281 023 045
CHAMPION CH170
NAGARES 735068
BOSCH 0250202032
CARTIER 960411-P
357
BERLINGO Pre / Post heating (pre-heating duration at 20°C)
10s / 150s Controlled by the diesel injection ECU.
ELECTRICAL SYSTEM
PRE-HEATING AND STARTING SYSTEMS
ALL TYPES
AIR CONDITIONING R 134 a (HFC) Compressor
Vehicle
Engine
Date
Refrigerant refill
Variable Capacity
AIR CONDITIONING
TU - TUD-TT SAXO
TU TT
MY 2000 #
825 gr ± 25 gr
135
SP 10
SD 6 V 12
795 gr ± 25 gr
TU XU (1)
975 gr ± 25 gr
SD 7 V 12
875 gr ± 25 gr)
SD 7 V 16
725 gr ± 25 gr
SD 7 V 12
700 gr ± 25 gr
SD 7 V 16
09/97 # XUD - DW (1) TU-XU (2) MY 2000 # XUD - DW (3)
Oil reference
850 gr +0 - 50 gr
TUD TT
XSARA # 09/2000
Oil quantity cc
(1) = With VALEO air conditioning, XSARA loop. (2) = With BEHR RF air conditioning and TGK 2.0/2.5 pressure valve, 306 loop. (3) = With VALEO air conditioning, 306 loop. 358
ALL TYPES
AIR CONDITIONING R 134 a (HFC) Compressor Engine
Date
Refrigerant refill
Variable Capacity
TU-TT
DW (2) and (3)
SP 10
SD SD 7 7V V 16 16 Gbox.
09/2000 #
590 gr +0 -50 gr
Gbox.
500 gr +0 -50 gr 590 gr +0 -50 gr
Auto.
500 gr +0 -50 gr
Auto.
XU 10
EW7-DW10
SD 6 V 12
SD 7 V 16
725 gr +0 -50 gr
TU XSARA PICASSO
135
570 gr +0 -50 gr
DW (1) EW (2) and (3)
Oil reference
SD 6 V 12 SD 6 V 12
EW (1) XSARA 09/2000 #
Oil quantity cc
SD 6 V 12 12/1999 #
675 gr ± 50 gr
03/2001 #
800 gr ± 25 gr
SD 7 V 16 BRASIL All Types
(1) = Circuit with damper capacity. (4) RFTD = With automatic air conditioning. (5) RF = With manual air conditioning. 359
AIR CONDITIONING
Vehicle
ALL TYPES
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Click-fit connector removing/fitting tool Vehicle SAXO XSARA
C5HP073C
Ø Inch
Ring colour
Tool kit 4164-T
5/8
Black
8005-T.A.
3/8
Red
8005-T.C
TT BP
XSARA PICASSO
HP
Tightening torques (m.daN). AIR CONDITIONING
Unions 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
2.5 ± 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 page: 358). 360
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
ALL TYPES
Presence of pollen filter
XSARA XSARA PICASSO XANTIA I and II XM I and II
Equipment
RPO No.
All Types Without aircon Base aircon Regulated aircon Without aircon Regulated aircon All Types Without aircon Base aircon # 8148 8148 # 8421
EVASION Automatic aircon
8421 # BERLINGO DISPATCH RELAY
Without aircon Base aircon All Types Base aircon Without aircon Base or double aircon 361
Presence of filter NO YES (Behr) YES (Larger) YES (Valeo) NO YES NO NO NO Do not fit YES (Behr) YES if Exclusive NO if X and SX NO (Valeo) YES (Vaeo) NO NO NO YES
Observations Exc. driving school
Except Brazil
Ingress of water Body modification 2 blowers 1 blower
AIR CONDITIONING
Vehicle AX-SAXO-ZX-BX-C15
XSARA - All Types
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
BEHR plate evaporator
Pollen filter
AIR CONDITIONING
C5HP07JC
C5HP062C
C5FP075D
Remove-refit. Remove : - The interior trim (1). - The cover (4). - The pollen filter (3). Concerns vehicles equipped with aircon without temperature regulation. Fitting of a new pollen filter necessistates 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). 362
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
XSARA - All Types
BEHR condenser with integral reservoir (16 Ti) Petrol engine The condenser is equpped with a cylinder (1) that acts as the fluid reservoir which in turn incorporates a filter cartridge.
C5HP07BC
Instruction for replacing the filter/dryer cartridge.
Engine Diesel
- After undoing the cap (TORX 70), the cold loop must be depressurised. - Unscrew the cap and clean the cap's thread. - Take out the filter/dryer cartridge. - Clean the threaded zone of the condenser reservoir - Fit the new filter/dryer cartridge. - Lubricate the cap's O-ring seals with compresser oil. (New seals). - Screw the cap back on, tighten to 1.4 ± 0.2 m.daN. C5HP060C
363
AIR CONDITIONING
NOTE : As soon as the air conditioning loop has been open for more than 5 minutes, the filter/dryer cartridge assembly should be replaced (no set interval).
XSARA PICASSO
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
BEHR plate evaporator
Pollen filter
AIR CONDITIONING C5HP062C
B1BP23ED
Remove: - The three screws (1). - The cover (2). - Remove the pollen filter. 364
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
XSARA PICASSO
BEHR condenser with integral reservoir (16 Ti)
The condenser is equpped with a cylinder (1) that acts as the fluid reservoir which in turn incorporates a filter cartridge.
Instruction for replacing the filter/dryer cartridge. - After undoing the cap (TORX 70), the cold loop must be depressurised. - Unscrew the cap and clean the cap's thread. - Take out the filter/dryer cartridge. - Clean the threaded zone of the condenser reservoir. - Fit the new filter/dryer cartridge. - Lubricate the cap's O-ring seals with compresser oil.(New seals). - Screw the cap back on, tighten to 1.4 ± 0.2 m.daN.
C5HP07BC
365
AIR CONDITIONING
NOTE : As soon as the air conditioning loop has been open for more than 5 minutes, the filter/dryer cartridge assembly should be replaced (no set interval).
ALL TYPES
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Compressor lubricant. ESSENTIAL: The compressor lubricant is extremely hygroscopic; always use FRESH oil. Checking the compressor oil level.
There are three specific cases : 1) Repairs to a system without leaks. 2) Slow leak. 3) Fast leak. 1) Repairing a system without leaks. AIR CONDITIONING
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. 366
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
ALL TYPES
Checking the compressor oil level (continued)
2) Slow leak. - Slow leaks do not lead to oil loss, therefore the same procedure should be followed as if there was no leak at all.
- 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.
367
AIR CONDITIONING
3) Fast leak.
ALL TYPES
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM CHECKING TEMPERATURES TOOLS
Checks
AIR CONDITIONING
Two thermometers
If all these conditions are met, take the following action :
Preliminary conditions.
- Start the engine, with the air conditioning off, and wait for the cooling fan first speed to cut in. - Operate the air conditioning and set the engine speed to 2500 rpm.
Position of the air conditioning controls : - Maximum cold air. - Air blower in maximum position. - Air distributor in "ventilation" position, with the dashboard vents open. - Air intake flap in "exterior air" position.
NOTE : If the ambient temperature reaches 40 °C, the engine speed will return to 2000 rpm in order to prevent the compressor from being cut off by the High Pressure safety device (Pressostat). After the air conditioning has been on for three minutes, measure : - the ambient temperature in the workshop, - the temperature of the air coming from the central vents.
Conditions and vehicle equipment. - Boot closed.Doors and windows shut. - Ensure the vehicle is in a sheltered area (away from wind, sun, etc..).
Compare the two values using the table overleaf.
368
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
ALL TYPES
CHECKING TEMPERATURES (continued)
Vehicle using R134.a fluid (Compressor with variable capacity) 40
35
30
25
SAXO
17 ± 3
13 ± 3
11 ± 3
9±3
8±3
XSARA
21 ± 3
17 ± 3
15 ± 3
12 ± 3
10 ± 3
XSARA PICASSO
22 ± 3
16 ± 3
12.5 ± 3
10 ± 3
Ambient temperature in °C
20
15
Air temperature from the central ventsin °C
8±3
NOTE : In general, the temperature of the air being blown from the central vents should be around 5°C to 8°C.
369
6.5 ± 3
AIR CONDITIONING
Vehicles
ALL TYPES
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM CHECKING PRESSURES
TOOLS
- 1 Charging station. - 2 Thermometers. Once the preliminary conditions, vehicle equipment and checks have been fulfilled (see table) : After the air conditioning has been on for three minutes, record the following parameters : 40
Ambient temperature in °C
AIR CONDITIONING
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) High pressure (Bars) Low pressure (Bars)
Vehicles
Engines
SAXO
All Types TU-TUD
XSARA
XU XUD
XSARA PICASSO
TU EW DW
CHECK - The temperature of the air coming from the central vents (see table) - The High Pressure. - The Low Pressure. Compare the values recorded with the table below, or the graphs.
Vehicle using R134.a fluid (Compressor with variable capacity) 35 30 25 20 15
20 ± 3
18 ± 3
16 ± 3
13 ± 3
11 ± 3
9±3
3 ± 0.3 22 ± 3 20 ± 3 3 ± 0.3 27 ± 3 24 ± 3 3 ± 0.3 23 ± 3 3 ± 0.3 25.5 ± 3 20.5 ± 3 4 ± 0.3 3.5 ± 0.3 25 ± 3 22.5 ± 3 4 ± 0.3 3.5 ± 0.3 370
17 ± 3 16 ± 3 15 ± 3 11 ± 3 2.4 ± 0.3 2 ± 0.3 22 ± 3 18 ± 3 17 ± 3 14 ± 3 2 ± 0.3 16 ± 3 14 ± 3 2 ± 0.3 18 ± 3 20 ± 3 13.5 ± 3 11 ± 3 3 ± 0.3 20 ± 3 17 ± 3 15 ± 3 3 ± 0.3
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
ALL TYPES
CHECKING PRESSURES (continued)
High pressure too low
- Insufficient fluid charge. - Constriction of the HP system. - Dirty pressure control valve.
High pressure normal
- Faulty compressor. - Dirty evaporator.
High pressure too high
- Faulty pressure control valve. - System blocked. - Water in the system.
Low pressure normal - Cooling fan speed unsuitable. - Faulty compressor. - Circuit normal
Low pressure too high - Faulty pressure control valve. - Faulty compressor.
- Cooling fan speed unsuitable.
- Excessive fluid charge. - Presence of solid matter in the system. - Dirty condenser. - Dirty condenser. - Faulty pressure control valve. - Cooling fan speed unsuitable.
Checking the pressure at temperatures between 15°C and 35°C for information only. In general, the pressure should be approximately : - for R134.a fluid, less than 2 Bars (Low pressure), and between 13 and 24 Bars (High pressure).
371
AIR CONDITIONING
Low pressure too low
AIR CONDITIONING SYSTEM R 134.a
SAXO # 09/1999
(3) Click-fit union.
# 09/1999
AIR CONDITIONING
C5HP12EC
Tightening torques (m.daN). a- 1 b- 3 c- 2 d - 1.3 e - 1.3
(1) Click-fit union.. (2) Low pressure valve. (3)Pressostat (4) High pressure valve.
NOTE : (b) = flange coupling. C5HP12DD
372
AIR CONDITIONING SYSTEM R 134.a
SAXO # 09/1999
C5HP12EC
Tightening torques (m.daN). (1) High pressure valve (2) Low pressure valve. (3) Click-fit union (4) Pressostat (1 seal Ø 10,82) (5) Dryer (2 seals Ø 7,65) (6) Relief valve, tighten to 0,43 m.daN ± 0,1 (1 seal Ø 7,65 - 1seal Ø 16,5) (7) Compressor fixing flange 3 ± 0,8 m.daN (2 seals Ø 20) (8) (O-ring seal Ø 7,65) C5HP15UP
373
AIR CONDITIONING
(3) Click-fit union.
# 09/1999
AIR CONDITIONING SYSTEM R 134.a
SAXO 09/1999 #
Click-fit union.
09/1999 #
AIR CONDITIONING
C5HP12EC
Tightening torques m.daN. (1) High pressure valve (2) Low pressure valve (3) Click-fit union. (4) Pressostat (1 Joint Ø 10.82) (5) Dryer (2 Joints Ø 7.65) (6) Détendeur serrage 0.43 m.daN ± 0.1 (1 Joint Ø 7.65-1Joint Ø 16.5) (7) Compressor fixation bride 3 ± 0.8 m.daN (2 Joints Ø 20) (8) (Joint torique Ø 7.65) C5HP15AP
374
AIR CONDITIONING SYSTEM R 134.a
SAXO - All Types
Checking the air conditioning system
T/P = Scale of: - Temperature (°C), average of air from the central vents. - Pressure, High (Bars). - Pressure, Low (Bars). Te = Exterior temperature (°C). HP = Pressure at compressor outlet (Bars). Ta = Temperature (°C) of air blown from the vents. BP = Pressure at compressor inlet (Bars).
C5HP067D
375
AIR CONDITIONING
Key
XSARA TU # 09/2000
AIR CONDITIONING SYSTEM R 134.a
(1) (2) (3) (4)
-
High pressure valve Low pressure valve Pressostat Dryer
Tightening torques m.daN. AIR CONDITIONING
(a) 0.8 (b) 4 ± 0.4 (c) 0.8
A Right hand drive.
C5HP15VP
376
AIR CONDITIONING SYSTEM R 134.a
XSARA TUD # 09/2000
C5HP12EC
(1) (2) (3) (4) (5)
-
High pressure valve Low pressure valve Pressostat Dryer Click-fit union Tightening torques m.daN.
(a) 0.8 (b) 4 ± 0.4 (c) 0.8
C5HP15YP
377
AIR CONDITIONING
(5) Click-fit union.
XSARA TU - TUD # 09/2000
AIR CONDITIONING SYSTEM R 134.a Checking the air conditioning system
Key
T/P = Scale of: - Temperature (°C), average of air from the central vents. - Pressure, High (Bars). - Pressure, Low (Bars). AIR CONDITIONING
Te = Exterior temperature (°C). HP = Pressure at compressor outlet (Bars). T CX = Temperature (°C) of air blown from the vents. BP = Pressure at compressor inlet (Bars).
C5HP076D
378
AIR CONDITIONING SYSTEM R 134.a
XSARA XU # 09/2000
(1) (2) (3) (4)
-
High pressure valve Low pressure valve Pressostat Dryer
(a) 0.8 (b) 4 ± 0.4 (c) 0.8
A Right hand drive.
C5HP15WP
379
AIR CONDITIONING
Tightening torques m.daN.
XSARA XU # 09/2000
AIR CONDITIONING SYSTEM R 134.a Checking the air conditioning system
Key
T = Temperature (C°) and High Pressure (Bars). P = Low pressure (Bars). AIR CONDITIONING
Te = Exterior temperature (C°). HP = Pressure at compressor outlet (Bars). T Cx = Temperature of air blown from the central air vents (C°). BP = Pressure at compressor inlet (Bars).
C5HP077D
380
XSARA XUD # 09/2000
AIR CONDITIONING SYSTEM R 134.a
(1) (2) (3) (4)
-
High pressure valve Low pressure valve Pressostat Dryer
(a) 0.8 (b) 4 ± 0.4 (c) 0.8
A Right hand drive.
C5HP15XP
381
AIR CONDITIONING
Tightening torques m.daN.
XSARA XUD # 09/2000
AIR CONDITIONING SYSTEM R 134.a Checking the air conditioning system
Key
T/P = Scale of: - Temperature (°C), average of air from the central vents. - Pressure, High (Bars). - Pressure, Low (Bars). AIR CONDITIONING
Te = Exterior temperature (°C). HP = Pressure at compressor outlet (Bars). T CX = Temperature (°C) of air blown from the vents. BP = Pressure at compressor inlet (Bars).
C5HP078D
382
XSARA TU 09/2000 #
AIR CONDITIONING SYSTEM R 134.a
(1) (2) (3) (4)
-
High pressure valve Low pressure valve Pressostat Dryer
(a) 0.8 (b) 4 ± 0.4 (c) 0.8
A Right hand drive.
C5HP16RP
383
AIR CONDITIONING
Tightening torques m.daN.
XSARA EW 09/2000 #
AIR CONDITIONING SYSTEM R 134.a
(1) (2) (3) (4)
-
High pressure valve Low pressure valve Pressostat Dryer
Tightening torques m.daN. AIR CONDITIONING
(a) 0.8 (b) 4 ± 0.4 (c) 0.8
A Right hand drive.
C5HP16SP
384
XSARA DW 09/2000 #
AIR CONDITIONING SYSTEM R 134.a
(1) (2) (3) (4)
-
High pressure valve Low pressure valve Pressostat Dryer
(a) 0.8 (b) 4 ± 0.4 (c) 0.8
A Right hand drive.
C5HP16VP
385
AIR CONDITIONING
Tightening torques m.daN.
XSARA XU10J4RS 09/2000 #
AIR CONDITIONING SYSTEM R 134.a
(1) (2) (3) (4)
-
High pressure valve Low pressure valve Pressostat Dryer Tightening torques m.daN.
AIR CONDITIONING
(a) 0.8 (b) 4 ± 0.4 (c) 0.8
A Right hand drive.
C5HP16TP
386
AIR CONDITIONING SYSTEM R 134.a
XSARA PICASSO TU
High pressure valve . Low pressure valve. High pressure click-fit union (tool 8005-T.C). Low pressure click-fit union (tool 8005-T.A). Pressostat. 1.8 ± 0.6 m.daN Filter/dryer cartridge cap.
Tightening torques m.daN. -
C5HP13PP
387
a b c d
0.8.± 0.1 0.5.± 0.1 1.4 ± 0.2. 2.5 ± 0.25.
AIR CONDITIONING
(1) (2) (3) (4) (5) (6)
XSARA PICASSO EW7
AIR CONDITIONING SYSTEM R 134.a
(1) (2) (3) (4) (5) (6)
High pressure valve . Low pressure valve. High pressure click-fit union (tool 8005-T.C). Low pressure click-fit union (tool 8005-T.A). Pressostat. 1.8 ± 0.6 m.daN Filter/dryer cartridge cap.
AIR CONDITIONING
Tightening torques m.daN. -a -b -c
0.8.± 0.1 0.5.± 0.1 1.4 ± 0.2.
HP BP compressor fixing flange
C5HP13QP
388
2.5 ± 0.25.
AIR CONDITIONING SYSTEM R 134.a
XSARA PICASSO TU - EW7
Checking the air conditioning system
Key
Te = Exterior temperature (°C). HP = Pressure at compressor outlet (Bars). Ta = Temperature (°C) of air blown from the vents. BP = Pressure at compressor inlet (Bars).
C5HP150D
389
AIR CONDITIONING
T/P = Scale of: - Temperature (°C), average of air from the central vents. - Pressure, High (Bars). - Pressure, Low (Bars).
XSARA PICASSO DW10
AIR CONDITIONING SYSTEM R 134.a
(1) (2) (3) (4) (5) (6)
High pressure valve . Low pressure valve. High pressure click-fit union (tool 8005-T.C). Low pressure click-fit union (tool 8005-T.A). Pressostat. 1.8 ± 0.6 m.daN Filter/dryer cartridge cap
AIR CONDITIONING
Tightening torques m.daN. -a -b -c
0.8.± 0.1 0.5.± 0.1 1.4 ± 0.2.
HP BP compressor fixing flange
C5HP13RP
390
2.5 ± 0.25.
AIR CONDITIONING SYSTEM R 134.a
XSARA PICASSO DW10
Checking the air conditioning system
Key
Te = Exterior temperature (°C). HP = Pressure at compressor outlet (Bars). Ta = Temperature (°C) of air blown from the vents. BP = Pressure at compressor inlet (Bars).
C5HP14ZD
391
AIR CONDITIONING
T/P = Scale of: - Temperature (°C ), average of air from the central vents. - Pressure, High (Bars). - Pressure, Low (Bars).
