En Us t1 2003

PRIVATE CARS
SAXO-C3-XSARA XSARA PICASSO-BERLINGO

The technical information contained in this document is intended for the exclusive use of the trained personnel of the motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full responsibility to the exclusion of that of the manufacturer. The technical information appearing in this brochure is subject to updating as the characteristics of each model in the range evolve. Motor vehicle repairers are invited to contact the CITRON network periodically for further information and to obtain any possible updates.
2003
CAR 050014 Volume 1
PRESENTATION
THIS HANDBOOK summarises the specifications, adjustments, checks and special features of CITROEN private vehicles, not including UTILITY vehicles for which there exists a separate handbook. The handbook is divided into nine groups representing the main functions : GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - ELECTRICAL AIR CONDITIONING. In each section, the vehicles are dealt with in the following order : SAXO - C3 - XSARA - XSARA PICASSO - BERLINGO (1) and all models where applicable. The information given in this handbook is based on vehicles marketed in EUROPE.
(1)
NOTE : The BERLINGO familiale appears only in : - The correspondance tables for petrol and diesel engines. - The general chapter. For all the other chapters, see the Mechanics Handbook for UTILITY vehicles.
IMPORTANT
If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into account when preparing future publications. For example : INSUFFICIENT INFORMATION SUPERFLUOUS INFORMATION NEED FOR MORE DETAILS
Please send your comments and suggestions to : CITROEN U.K. Ltd. 221, Bath Road, SLOUGH, SL1 4BA. U.K.
XSARA 2, all types

Operation to reconnect the battery after a vehicle repair
ATTENTION
If the battery has been disconnected, after reconnecting it is ESSENTIAL to wait 1 minute before switching on the ignition, otherwise the engine ECU will lock up. If the ECU has locked up : - Switch off the ignition. - Wait 1 minute. - Switch the ignition back on, the ECU is unlocked.
IDENTIFICATION OF VEHICLES
SAXO - All Types
1 2 3 4 5
Engine legislation type RP organisation no. GENERAL Chassis stamp Manufacturers name plate 01/02/99 # Label : - Tyre pressures. - RP organisation no. - Paint code. Paint code. Gearbox ident. reference
6 7
E1AP07CD
SAXO - All Types

1.1 i
Saxo petrol 3-door 1.4 i Auto. A-X-SX Administration Exclusive L4 SO HFXB HFX 1124 4 MA/5 20 CF 03 6 MB3 312 20 CF 12 SO KFWL SX Exclusive SX Exclusive VTS 1.6 i 1.6i 16V
X-SX
Emission standard
VTS L4 S6 KFWB KFW 1360 5 MA/5
VTS L4
VTS L4 N6 NFXB NFX 1587 8 MA/5 20 CN 03
IFL5 SO HFX1
GENERAL
Type code Engine type Cubic capacity (cc) Fiscal rating (hp) Gearbox type Gearbox ident. plate
SO KFWB
S6 NFTB NFT 5
20 CF 11
20 CN 05
Saxo petrol 5-door 1.1i A-Administration Driving school -x-SX Exclusive L4 S1 HFXB HFX 1124 4 MA/5 20 CF 03 6 MB3 312 S1 KFWL KFW 1360 Auto. 1.4i
SAXO - All Types
X-SX
Emission standard Type code Engine type Cubic capacity (cc) Fiscal rating (hp) Gearbox type Gearbox ident. plate
SX-Exclusive L4 S1 KFWB GENERAL
IFL5 S1 HFX1
5 MA/5 20 CF 12
SAXO - All Types

Diesel 3-door 1.5 D
Entreprise 5-door Petrol 3-door 1.1i A-Administration Driving school X-SX-Exclusive L4 SO VJXB VJX 1527 4 MA/5 20 CF 02 S1 VJXB S3 HFXB HFX 1124 6 MA/5 20 CF 03 A Administration Poste-X-SX L4 S3 VJXB VJX 1527 6 MA/5 20 CF 02 Diesel 3-door 1.5 D A Administration Poste-X-SX
A- Administration X-SX-VTS -Exclusive GENERAL

C3 - All Types
A : Cold stamp (Cold stamp engraved on the bodywork). B : Manufacturers name plate (On the LH centre pillar) GENERAL C : AS/RP No. and RP paint code. (label affixed to the front pillar on drivers side) D : Tyre pressures and tyre type. (label affixed to the front pillar on drivers side) E : Serial number on bodywork. F : Gearbox ident. reference Factory serial no. G : Engine legislation type Factory serial no.
E1AP09HD
C3 - All Types
PETROL
1.1i
X-SX GENERAL
X IFL5 L4/INF FC HFXB /D K FC HFX5
L4 FC HFXB/T FR HFXB FN HFXB FC HFXB HFX 1124 4 MA/5N 20 CF 14 FN HFXC /IF
FC HFXC /IF
PETROL
C3 - All Types
1.4i
Auto.
Auto. SX Exclusive
Auto. GENERAL
L4 FC KFVE FN KFVB FN KFVE KFV 1360 5 AL4 20 TP 75 MA/5N 20 CF 15 20 CF 16 (*) AL4 20 TP 75 MA/5N 20 CF 15 20 CF 16 (*) FC KFVC/IF
IFL5 FC KFVF/IF FN KFVC/IF
AL4 20 TP 75
MA/5N 20 CF 15 20 CF 16 (*)
(*) = Export. 7
C3 - All Types
PETROL
1.4i
1.6i 16V
Auto. GENERAL SX Exclusive

SX Exclusive L4/INF L4 FC KFVE/D FN NFUB NFU 1587 6 FC NFUB
IFL5 FN KFVF/IF
L4 FC KFVB KFV 1360 5 FC KFVB/D
AL4 20 TP 75 20 CF 15
MA/5N 20 CF 16 (*)
MA/5S 20 CN 40
(*) = Export. 8
DIESEL
C3 - All Types
1.4 HDi
X - SX
L4 FC 8HBXB/T FN 8HXB FC 8HXB 8HX 1398 4 MA/5O 20 CN 33 20 CN 36 (*) FC 8HXB/MOD FC 8HXK FR 8HXB
(*) = Export. 9
GENERAL
C3 - All Types
DIESEL
1.4 HDi
1.4 HDi 16V
S - SX GENERAL
SX - Exclusive L4
FN 8HWK 8HW
FC 8HWB
FN 8HVB 8HV 1398
FC 8HVB
4 MA/50 20 CN 33 20 CN 36 (*)
5 BE4/5 20 DM 25 20 DM 26
(*) = Export. 10
DIESEL
C3 - All Types
1.4 HDi 16V
SX - Exclusive
SX L4
SX - Exclusive GENERAL
FN 8HYB
FC 8HYC
FC 8HYB/MOD 8HY 1398 5 BE4/5 20 DM 25
FC 8HYB/T
FC 8HYK
FR 8HYB
20 DM 26
11
XSARA - All Types
A - Manufacturers name plate (Estate). B - Chassis stamp, cold stamp. C - Manufacturers name plate (Saloon). GENERAL
E1AP08WD
D - Label : (label affixed to the front pillar on drivers side) - Tyre pressures. - RP organisation no. - Paint code. E - Serial number. (visible through the windscreen) F - Engine legislation type. Factory serial no. G - Gearbox ident. reference. Factory serial no.
12
Saloon petrol 3-door 1.4 i Auto. X-SX VTR
XSARA - All Types

1.6i 16V Auto.
X-VTR IFL5 NO KFW1/IF KFW 1360 5 MA/5 20 CF 13
X-SX-VTR VTS L4 NO NFUB
SX-VTR
VTR-VTS IFL5
VTR GENERAL
L4 NO KFWB
NO NFUN NFU 1581 7
NO NFU1/IF
NO NFU3/IF
MA/5 20 CN 28
AL4 20 TP 49
MA/5 20 CN 28
AL4 20 TP 49
13
XSARA - All Types

Saloon petrol 3-door 20i.16V Auto.
Saloon diesel 3-door 1.9 D 2.0 HDi Auto. X-SX VTR L4 NO RFNN/IF RFN 1998 8 BE4/5 20 DL 40 20 DM 03 (1) AL4 20 TP 47 11 BE3/5 20 TE 47 20 DL 41 20 DM 05 (1) NO RFSB RFS NO WJYB WJY 1868 5 BE4/5 20 DL 42 20 DM 07 (1) 20 DM 10 20 DM 11 (1) NO RHYB RHY 1997 6 AL4 20 TP 48 X-SX-VTR VTS L4 NO RHZB RHZ NO RHZN SX-VTR VTS
VTS
Emission standard
SX
IFL5 NO RFN1/IF
GENERAL
(1) = Right hand drive : Hydraulic clutch control.
14
Saloon diesel 3 door 1.4 HDi
XSARA - All Types
Entreprise
L4 N0 8HZB N0 8HZB/T 8HZ 1398 4 MA/5 N3 8HZB GENERAL
15
XSARA - All Types

Petrol 1.4i
Saloon 3-door versions Diesel 1.9 D 2.0 HDi
X
Emission standard
X L4 NO WJYB/T (1) WJY 1868 7 BE4/5 20 DL 41 20 DL 42 NO RHYB/T (1) RHY 1997 6
L4 NO KFWB/T (1) KFW 1360 8 MA/5 20 CF 13
GENERAL
(1) /T = The vehicle cannot be converted back into a private vehicle.
16
Saloon petrol 5-door. 1.4i
XSARA - All Types

1.6i 16V Auto.
X-SX
SX IFL5 N1 KFW1/IF N1 NFUG K N1 NFUU NFU 1587 7 MA/5 20 CF 13 20 CN 29 AL4 20 TP 49
X-SX Exclusive L4 N1 NFUB GENERAL
K N1 KFWG
L4 N1 KFWB KFW 1360 5 MA/5
MA/5 20 CN 28
20 CN 30
17
XSARA - All Types

16i 16V Auto. X-SX Exclusive
Saloons petrol 5-door 2.0i 16V Auto. Auto.
SX Exclusive GENERAL
SX Exclusive IFL5 IFL5 N1 NFU3/IF N1 RFN1/IF
Exclusive L4 N1 RFNN RFN 1998 11
L4 N1 NFUN N1 NFU1/IF NFU 1587 7 AL4 20 TP 49 MA/5 20 CN 28
AL4 20 TP 49 20 DL 40
BE4/5 20 DM 03 (1)
AL4 20 TP 47
(1) = Right hand drive : Hydraulic clutch control. 18
Saloons diesel 5-door 1.9 D 2.0 HDi
XSARA - All Types
Auto. SX Exclusive GENERAL
X-SX
X-SX-Exclusive L4 N1 RHYB RHY
SX-Exclusive
L4 N1 WJYB WJY 1868 5 BE4/5 20 DL 41 20 DM 05 (1) 20 DL 42 5 BE4/5 20 DM 07 (1)
N1 RHZB RHZ 1997 6
N1 RHZN
AL4 20DM 10 20 DM 11 (1) 20 TP 48
(1) = Right hand drive : Hydraulic clutch control.
19
XSARA - All Types
Saloons diesel 5-door 1.4 HDi
Entreprise
Emission standard
L4 N1 8HZB 8HZ 1398 4 MA/5 N1 8HZB/T
GENERAL
20
Saloons diesel entreprise 5-door 1.9 D 2.0 HDi
XSARA - All Types
X
X L4 N RHYB RHY 1997 5 BE4/5 20 DL 42 N1 RHYB/T (1) GENERAL
L4 N1 WJYB/T (1) WJY 1868 7 BE4/5 20 DL 41
(1) /T = The vehicle cannot be converted back into a private vehicle.
21
XSARA - All Types

1.4i
Petrol estate 16. 16V
Auto.
Auto. X-SX Exclusive IFL5 SX Exclusive
X-SX
Emission standard
SX IFL5 KFW1/IF K N2 NFUG
X-SX Eclusive L4 N2 NFUB
SX Exclusive
L4 N2 KFWB KFW 1360 5 MA/5 20 CN 21
GENERAL
N2 NFUN NFU 1587 7
N2 NFU1/IF
N2 NFU3/IF
MA/5 20 CN 29 20 CN 28
AL4 20 TP 49
MA/5 20 CN 28
AL4 20 TP 49
22
Petrol estate 2.0i 16V Auto. Exclusive
XSARA - All Types

Diesel estate 1.9 D
X - SX L4 N2 RFNN L4 N2 WJYB WJY 1868 5 AL4 20 DM 03 (1) 20 DL 41 BE4/5 20 DM 05 (1) GENERAL
IFL5 N2 RFN1/IF RFN 1998 11 BE4/5 20 DL 40
XSARA - All Types
Diesel estate 2.0 HDi Auto. X-SX-Eclusive SX Exclusive IFL5 N2 RHYB/IF RHY 1997 5 BE4/5 20 DL 42 20 DM 07 (1) 20 DM 10 20 DM 11 (1) 6 AL4 20 TP 48 N2 RHZN RHZ
Emission standard
L4 N2 RHYB
GENERAL
Diesel saloon and estate 1.4 HDi
XSARA - All Types
X
Entreprise L4 GENERAL
N2 8HZB
N2 8HZB/T 8HZ 1398 4 MA/5
N4 8HZB
25
XSARA - All Types

Estate petrol versions 1.4i
Estate diesel versions 1.9 D 2.0 HDi
X
Emission standard
X L4 N2 WJYB/T (1) WJY 1868 7 BE4/5 20 DL 41 N2 RHYB/T (1) RHY 1997 6 BE4/5 20 DL 42
L4 N2 KFWB/T (1) KFW 1360 8 MA/5 20 CN 21
GENERAL
(1) /T = The vehicle cannot be converted back into a private vehicle. 26
XSARA PICASSO - All Types

A - Chassis stamp (Cold stamp on bodywork) B : Chassis no. reminder (Label located at bottom of windscreen right hand side) C : Manufacturers data plate. (Located at bottom of RH central pillar) D : Label : Tyre pressures. Tyre identification. Spare wheel identification. (Located on front LH door inner panel). E : Label : Factory code. A-S / RP N Paint code. (Located on fuse box cover) F : Gearbox identification ref. G : Engine legislation type. Factory serial number. GENERAL
E1AP088D
27

1.6i
Petrol 1.8i 16 V 2.0i 16 V Auto. SX-Exclusive Diesel 2.0 HDi
Emission standard
L4 CH NFVB NFV 1587 6 BE4/5/ J (*) 20 DL 66 CH 6FZB 6FZ 1749 7 BE4/5 V (*) 20 DL 68 CH 6FZC/IF
IFL5 CH RFNF/IF RFN 1998 8 AL4 20 TS 02
L4 CH RHYB RHY 1997 5 BE4/5 L (*) 20 DL 65
GENERAL
(*) L,J V = Corresponds to the stepping of the gears. 28
BERLINGO - All Types
11/2002 # A Chassis stamp, cold stamp B Manufacturers vehicle plate GENERAL C Label RPO No. Paint colour code Tyre pressures D Gearbox ident. reference Factory serial no. E Engine legislation type Factory serial no.
E1AP0AMD
29
Berlingo petrol 5-seater 11/2002 # 1.1i 1.4i
X
Emission standard
X K GJ K6D5G L4/W4 GJ KFWB KFW 1360 6 MA/5 20 CN 13
X-SX- Multispace IFL5 GJ KFWC/IF
L4/W4 GB VHFXB HFX 1124 5 MA/5S 20 CD 43
GENERAL
30
Berlingo petrol 5-seater 11/2002 # 1.4i Dual fuel Multispace
1.6i 16v
X-SX- Multispace L4 IFL5 GJ NFUC/IF NFU 1587 7 BE4/5 20 DM 46 GENERAL
L4/W4 GJ KFWB/GL (1) KFW 1360 5 MA/5 20 CN 13 GJ KFWB/GN (2)
GJ NFUB
(1) GL = LPG = Liquefied Petroleum Gas, with ring-shaped tank. (2) GN = CNG = Compressed Natural Gas, with cylindrical tank.
31
Berlingo diesel 5-seater 11/2002 # 1.9 D 2.0 HDi
X-SX-Multispace
Emission standard
X-SX-Multispace L4/W4
L4/W4 GJ WJYB WJY 1868 5 BE4/5 20 DM 48 GJ WJYB/PMF (1)
GENERAL
MF RHYF RHY 1997 6 BE4/5 20 DM 50
(1) /PMF = Multifunction roof.
32
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 80C). 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). GENERAL ESSENTIAL : Systematically check the oil level using the oil dipstick. 33
SAXO - All Types

SAXO Petrol Ecological oil filter capacity 0.15 litre. 1.1i 1.4i Auto. 1.6i 16V 1.6i 1.5D Diesel
GENERAL
Engine type Engine with filter change Between Min. and Max. 5-speed gearbox Automatic gearbox after drainage Hydraulic or brake circuit Cooling system Fuel tank capacity
HFX
KFW 3 1.5 2 4.5 2
NFX
NFT 3.5 1.5 2
VJX 4.5 2
With ABS = 0.45 - Without ABS = 0.36 6.1 45
ESSENTIAL : systematically check the oil level using the oil dipstick.
34

C3 Petrol 1.1i 1.4i Auto. Engine type Drain by gravity : engine with filter change Between min. And max. Drain by suction : engine with filter change Between Min. and Max. 5-speed gearbox Automatic gearbox After oil change Braking circuit Cooling system Fuel tank capacity 1.5 2 (1) 0,7 Litre version with front calipers 48 / rear drums 0,8 Litre version with front calipers 54 / rear discs 7 45 5.7 HFX 1.5 3.1 1 2 KFV 2.9 NFU 1 8HX 8HW 3.75 2 1.6i 16V 1.4 HDi
C3 - All Types
Diesel 1.4 HDi 16V
8HV
8HY
1.9
5.6
ESSENTIAL : systematically check the oil level using the oil dipstick. (1) = The gearbox is lubricated for life. (For your information, the TOTAL capacity is 5,85 litres, after draining: 3 litres). 35
GENERAL
XSARA - All Types

Petrol Ecological oil filter capacity 0.15 litre. 1.4i 1.6i 16V Auto.
Engine type Engine with filter element Between Min. and Max. 5-speed gearbox Automatic gearbox after drainage Hydraulic or brake circuit Cooling system Fuel tank capacity

XSARA Diesel
2.0i 16V Auto. RFN 4.25 1.7 1.9 6 3 1 1.9 RFS
1.4 HDi
1.9D
2.0 HDi Auto.
KFW 3 1.4 2
NFU 3.25 1.5
8HZ 4 (*) 1 (*) 2
WJZ 4.75 1.6
RHY
RHZ 4.5-4.25 (1) 1.4 1.8 8.3 5.3 8.5 11 (1)
GENERAL
6 3 With ABS = 0.50 - Without ABS = 0.55 5.7 54 9
7 6.5 (1)
(*) = 01/12/03 # (1) = With air conditioning
from 11/02 to 01/12/03 # Engine with filter element = 3,75 and Between min. and max. = 1,8 ESSENTIAL : systematically check the oil level using the oil dipstick. 36

XSARA PICASSO Petrol Ecological oil filter capacity 0.15 litre 1.6i 1.8i 16 V 2.0i 16 V Auto. RFN 4.25 1.7 1.8 6 3 0.58 litres 5.8 (1) et (2) 6.5 (1) et (2) 55

Diesel
2.0 HDi
Engine with filter change Between Min. and Max. 5-speed gearbox Automatic gearbox - after drainage Hydraulic or brake circuit Cooling system Fuel tank capacity
3 1.5
4.5 1.4 1.8
11 (1) et (2) 60
(1) = With air conditioning (2) = Without air conditioning
ESSENTIAL : systematically check the oil level using the oil dipstick. 37
GENERAL
Engine type
NFV
6FZ
RHY
BERLINGO 2 - All Types

Petrol Ecological oil filter capacity 0.15 litre

BERLINGO 2 Diesel
1.1i GENERAL
1.4i
1.6i 16V
1.9 D
2.0 HDi
Engine type Engine with filter change Between Min. and Max. 5-speed gearbox Hydraulic or brake circuit Cooling system Fuel tank capacity
HFX 3
KFW
NFU 3.25
WJY 4.5 1.2
RHY
1.5 2 1.8
1.4 1.8
With ABS = 0.45 - Without ABS = 0.36 8 55 9 60
ESSENTIAL : systematically check the oil level using the oil dipstick. 38
LUBRICANTS - TOTAL recommended oils

Evolutions (year 2003). CITRON C3 PLURIEL. Only petrol versions are available. Normal maintenance interval : 30 000 km (20 000 miles) Severe maintenance interval : 20 000 km (12 000 miles) ESSENTIAL : For all vehicles with a 30 000 km (20 000 miles) maintenance interval, use exclusively TOTAL ACTIVA/QUARTZ 7000 or 9000 or any other oils offering identical specifications to these. These oils offer specifications that are superior to those defined by norms ACEA A3 OR API SJ/CF. Failing this, it is essential to adhere to the maintenance programmes covering severe operating conditions.
ALL TYPES
Use of oil grade 10W 40. It is possible to use semi-synthetic oil 7000 10W40 on HDi and HDi FAP vehicles. WARNING : To avoid problems with starting from cold, use this oil as allowed by the climatic conditions in the country concerned (see table). For more details see the oil usage table. New commercial designation for energy economy oil. The oil TOTAL ACTIVA/QUARTZ 9000 5W30 becomes TOTAL ACTIVA FUTUR 9000 (for France), QUARTZ FUTURE 9000 5W30 (outside France). The usage exclusions for this oil are the same as before : - XSARA VTS 2.0i 16V (XU10J4RS). - RELAY 2.8 TDi; 2.8 HDi (SOFIM engine). - HDi FAP vehicles. - C3 1.6i 16V (DV4TED4). - C8 2.2i (EW12J4) 39
GENERAL
ALL TYPES
Engine oil norms.
Current norms. GENERAL

E4AP006D
The classification of these engine oils is established by the following recognised organisations : - S.A.E - API - ACEA : Society of Automotive Engineers. : American Petroleum Institute. : Association des Constructeurs Europens dAutomobiles
40

S.A.E. Norms - Table for selection of engine oil grade Selection of engine oil grades recommended for climatic conditions in countries of distribution Evolution of the norms as at 01/01/2003 ACEA 2003 norms The meaning of the first letter has not changed, it still corresponds to the type of engine : A : petrol and dual fuel petrol / LPG engines. B : diesel engines. The figure following the first letter corresponds to the type of oil: . 3 : high performance oils. 4 : oils specifically for direct injection diesel engines. 5 : very high performance oils permitting lower fuel consumption Example : ACEA A3 : high performance oils specifically for petrol and dual fuel petrol / LPG engines ACEA A/B : blended oils giving very high performance for all engines, also permitting better fuel economy, specifically for direct injection diesel engines NOTE : From 01/01/2003 there is no longer any reference to the year of creation of the norm, (Example : ACEA A3/B3 98 becomes ACEA A3/B3. API norms
ALL TYPES
The meaning of the first letter has not changed, it still corresponds to the type of engine : S : petrol and dual fuel petrol / LPG engines. C : diesel engines. The second letter corresponds to the degree of evolution of the oil (ascending order). Example : Norm SL is more severe than norm SJ, corresponding to a higher level of performance. GENERAL
41
ALL TYPES
Recommendations.
ESSENTIAL : To preserve engine performances, all engines fitted in CITROEN vehicles must be lubricated with high quality oils (synthetic or semi-synthetic). CITRON engines are lubricated at the factory with TOTAL oil of grade S.A.E.5W-30. TOTAL oil of grade S.A.E.5W-30 allows improved fuel economies (approx 2.5%). The oil 5W30 is used only for the following engines (Year 2003) : XU10 J4RS SOFIM HDi DV4 TED4 EW 12J4 : : : : : XSARA VTS 2.0i 16V (3-door) RELAY 2.8 TDi and 2.8 HDi. With particle filter (FAP). CITRON C3 1.4 HDi 16V CITRON C8 2.2i. GENERAL
WARNING : CITRON engines prior to model year 2000 do not have to be lubricated with oils adhering to the norms : ACEA AI-98 and API SJ/CF EC or current norms ACEA A5/B5 Denomination of TOTAL oils according to country of marketing : TOTAL ACTIVA (France only). TOTAL QUARTZ (outside France).
42

Recapitulation Norms to be observed for engine oils (year 2003) Year 2003 Types of engine concerned Petrol and dual fuel petrol / LPG engines Diesel engines ACEA norms A3 or A5 5 (*) B3 or B5 (*)
ALL TYPES
API norms SJ or SL CF GENERAL
(*) It is essential not to use engine oils respecting these norms for the following engine-types : XU10 J4RS , SOFIM 2.8 TDi and SOFIM 2.8 HDi , HDi with particle filter (FAP), EW 12 J4, DV4 TED4. Classes and grades of TOTAL recommended engine oils. Oils marketed in each country are adapted to the local climatic conditions. Blended oils for all engines (petrol, diesel and dual fuel petrol / LPG engines). S.A.E. norms TOTAL ACTIVA 9000 TOTAL QUARTZ 9000 TOTAL ACTIVA FUTUR 9000 (*) TOTAL QUARTZ FUTUR 9000 (*) TOTAL ACTIVATRAC 5W40 5W30 10W40 ACEA norms A3 / B3 SL / CF A5 / B5 A3 / B3 SJ / CF API norms
(*) Blended oils for all engines, permitting fuel economy. 43
ALL TYPES
Oils specifically for petrol and dual fuel petrol / LPG engines S.A.E. norms TOTAL ACTIVA 7000 TOTAL QUARTZ 7000 TOTAL QUARTZ 9000 GENERAL TOTAL ACTIVA 7000 TOTAL QUARTZ 7000 10W40 0W40 15W50 A3 SJ ACEA norms API norms
Oils specifically for diesel engines S.A.E. norms TOTAL ACTIVA DIESEL 7000 TOTAL QUARTZ DIESEL 7000 TOTAL ACTIVA DIESEL 7000 10W40 15W50 ACEA norms B3 API norms CF
44

Oil usage table Engine types 0W40 cold countries XU10 J4RS (Xsara VTS 2.0i 16V) Petrol engines EW 12 J4 (C8 2.2i 16V) Other petrol engines HDi engines with FAP (*) Diesel engines Other HDi engines SOFIM 2.8 TDi and 2.8 HDi (RELAY) DV4 TED4 (C3 1.4 HDi 16V) Indirect injection diesel engines X X X X X X TOTAL ACTIVA QUARTZ Synthetic 9000 5W30 5W40 X X X X X X X X
ALL TYPES
Semi-synthetic 7000 10W40 X X X X X X X X X X X X 15W50 hot countries X X X GENERAL
(*) = Particle filter 45
ALL TYPES
Selection of TOTAL engine oils, to be used according to the climatic conditions in the country where the vehicle is marketed.
GENERAL
E4AP006D
46

ENGINE OILS FRANCE Metropolitan FRANCE Blended oils for all engines, supplied in bulk TOTAL ACTIVRAC TOTAL ACTIVA Blended oils for all engines 900 5W-40 9000 5W-30 (*) Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10 W-40
ALL TYPES
S.A.E. norms : 10W40 TOTAL ACTIVA DIESEL Oils specifically for diesel engines 7000 10 W-40 9000 5W-40
Metropolitan FRANCE New Caledonia Guadeloupe Saint-martin Reunion Martinique Guyana Tahiti Mauritius Mayotte
9000 5W-40
7000 15W-50
7000 15W-50
(*) = Blended oils for all engines, permitting fuel economy 47
GENERAL
ALL TYPES
EUROPE

ENGINE OILS TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10W40 9000 0W40 7000 10W40 7000 10W40 9000 0W40 9000 5W40 FUTURE 9000 5W30 (*) 7000 10W40 9000 0W40 7000 10W40 7000 10W40 9000 15W40 7000 10W40 7000 10W40 TOTAL ACTIVA DIESEL Oils specifically for diesel engines
Germany GENERAL Austria Belgium Bosnia Bulgaria Cyprus Croatia (*) = Blended oils for all engines, permitting fuel economy 48

ENGINE OILS EUROPE TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10W40 9000 0W40 7000 10W40 7000 15W40 7000 10W40 9000 0W40
ALL TYPES
TOTAL ACTIVA DIESEL Oils specifically for diesel engines
Denmark Spain Estonia Finland Great Britain Greece Holland (*) = Blended oils for all engines, permitting fuel economy 49 9000 5W40 FUTURE 9000 5W30 (*)
7000 10W40 7000 10W40 7000 10W40 7000 15W40 7000 10W40 9000 0W40
GENERAL
ALL TYPES
EUROPE

ENGINE OILS TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10W40 9000 0W40 TOTAL ACTIVA DIESEL Oils specifically for diesel engines
Hungary GENERAL Italy Ireland Iceland Latvia Lithuania Macedonia (*) = Blended oils for all engines, permitting fuel economy 50 9000 5W40 FUTURE 9000 5W30 (*)
7000 10W40 7000 10W40 7000 10W40 9000 0W40
7000 10W40

ENGINE OILS EUROPE TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10W40 7000 15W50 7000 10W40 7000 10W40 9000 0W40 9000 5W40 FUTURE 9000 5W30 (*) 7000 10W40
ALL TYPES
Malta Moldavia Norway Poland Portugal Slovakia Czech Republic (*) = Blended oils for all engines, permitting fuel economy 51
7000 10W40
7000 10W40 9000 0W40
GENERAL
ALL TYPES
EUROPE

ENGINE OILS TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10W40 7000 15W50 9000 0W40 TOTAL ACTIVA DIESEL Oils specifically for diesel engines
Romania GENERAL Russia
Slovenia 9000 5W40 FUTURE 9000 5W30 (*) Sweden Switzerland Turkey (*) = Blended oils for all engines, permitting fuel economy 52
7000 10W40 9000 0W40 7000 10W40
7000 10W40 7000 10W40 9000 15W50 9000 0W40

ENGINE OILS EUROPE TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines
ALL TYPES
Ukraine Yugoslavia
GENERAL
9000 5W40 FUTURE 9000 5W30 (*)
7000 10W40 9000 0W40
7000 10W40
ALL TYPES
OCEANIA

ENGINE OILS TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10W40 TOTAL ACTIVA DIESEL Oils specifically for diesel engines
Australia New Zealand AFRICA GENERAL
9000 5W40 FUTURE 9000 5W30
7000 10W40
TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines
Algeria, South Africa, Ivory Coast, Egypt, Gabon, Ghana, Kenya, Madagascar, Morocco, Nigeria, Senegal, Tunisia 54 9000 5W40 7000 15W50 7000 10W40

ENGINE OILS CENTRAL AND SOUTH AMERICA TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines
ALL TYPES
Argentina Brazil Chile Cuba Mexico Paraguay Uruguay 55 9000 5W40 7000 10W50 7000 15W50 7000 10W40 GENERAL
ALL TYPES
SOUTH-EAST ASIA

ENGINE OILS TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10W50 7000 15W50 9000 5W40 FUTURE 9000 5W30 7000 10W40 TOTAL ACTIVA DIESEL Oils specifically for diesel engines
China GENERAL South Korea Hong Kong
7000 15W50 India Indonesia Japan Malaysia 9000 5W40 Pakistan (*) = Blended oils for all engines, permitting fuel economy 56 7000 15W50 9000 5W40 9000 5W40 FUTURE 9000 5W30 (*) 7000 10W40 7000 15W50 7000 10W40

ENGINE OILS SOUTH-EAST ASIA TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines
ALL TYPES
Philippines Singapore Taiwan Thailand 7000 15W50 Vietnam 9000 5W40 7000 10W40 7000 15W50 7000 10W40 GENERAL 7000 15W50
ALL TYPES
MIDDLE EAST

ENGINE OILS TOTAL ACTIVA Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines TOTAL ACTIVA DIESEL Oils specifically for diesel engines
Saudi Arabia Bahrain Dubai United Arab Emirates Iran Israel Jordan Kuwait Lebanon Oman Qatar Syria Yemen 9000 5W40 7000 10W40 7000 15W50 7000 15W50 7000 10W40 7000 15W50 GENERAL
58

GEARBOX OILS TOTAL TRANSMISSION BV Norms S.A.E. : 75W80 Part No. : 9730 A2 TOTAL FLUIDE ATX
ALL TYPES
Manual gearbox and SensoDrive
All countries
4HP20 and AL4 autoactive automatic gearboxes Transfer box and rear axle
Special oil distributed by CITRON Part No. : 9736 22 TOTAL TRANSMISSION X4 Part No. : 9730 A4
59
GENERAL
MB3 automatic gearbox
TOTAL FLUIDE AT 42 Special oil distributed by CITRON Part No. : 9730 A3
ALL TYPES

POWER STEERING OILS All countries Power steering Very cold countries TOTAL FLUIDE ATX TOTAL FLUIDE DAs Special oil distributed by CITRON Part No. : 9730 A1
GENERAL All countries CITRON fluid Protection : - 35C
ENGINE COOLANT FLUID CITRON Part No. GLYSANTIN G33 2 Litres 5 Litres 20 Litres 210 Litres 9979 70 9979 71 9979 76 9979 77 REVKOGEL 2000 9979 72 9979 73 9979 74 9979 75
Pack
60

BRAKE FLUID Synthetic brake fluid Pack 0.5 Litre All countries CITRON fluid 1 Litre 5 Litres HYDRAULIC CIRCUIT All countries TOTAL FLUIDE LDS TOTAL LHM PLUS TOTAL LHM PLUS Grand Froid Colour Norm Orange Green 1 Litre Pack
ALL TYPES
CITRON Part No. 9979 05 9979 06 9979 07 GENERAL
CITRON Part No. 9979 69 ZCP 830095 9979 20
WARNING : TOTAL FLUIDE LDS fluid cannot be blended with TOTAL LHM LDS WARNING : CITRON C5 : Use exclusively TOTAL FLUIDE LDS suspension fluid. All countries 61 TOTAL HYDRAURINCAGE
ALL TYPES

SCREEN WASH FLUID
Pack Concentrated : 250 ml All countries GENERAL Fluid ready for use 1 Litre 5 Litres 9980 33 9980 06 9980 05
CITRON Part No. ZC 9875 953U ZC 9875 784U ZC 9885 077U ZC 9875 279U 9980 56
GREASE General use TOTAL MULTIS 2 TOTAL SMALL MECHANISMS
Norms NLGI 2
All countries
Note : NLGI = National Lubricating Grease Institute.
62
ENGINE OIL CONSUMPTION

I - Oil consumption depends on : - the engine type. - how run-in or worn it is. - the type of oil used. - the driving conditions. II - An engine can be considered RUN-IN after: - 3,000 miles (5,000 km) for a PETROL engine. - 6,000 miles (10,000 km) for a DIESEL engine. III - MAXIMUM PERMISSIBLE oil consumption for a RUN-IN engine. - 0.5 litres per 600 miles (1,000 km) for a PETROL engine. - 1 litre per 600 miles (1,000 km) for a DIESEL engine. DO NOT WORK BELOW THESE VALUES.
ALL TYPES
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.
63
GENERAL
ENGINE
ALL TYPES
ENGINE SPECIFICATIONS
Engines : HFX - KFW - NFT - NFV Petrol All Types
1.1i
1.4i
1.6i
Vehicle Emission standard Engine type Cubic capacity (cc) Bore / Stroke Compression ratio Power ISO or EEC - KW - rpm Power DIN (HP - rpm) Torque ISO or EEC (m.daN - rpm)
Saxo L4/IFL5/L4INF HFX 1124 72/69
C3 K
Saxo L4 KFW 1360 75/77 10.5/1
Xsara K/L4/IFL5
Saxo L4 NFT 1587 78.5/82
Picasso
NFV
44.1-5500 60-5500 9.4-3500 9.4-3300 64 12-3400
55-5500 75-5500 12-2800
72-5700 98-5700 13.5-3500
70-5700 95-5700 13.5-3000
Engines : NFX - NFU - 6FZ - RFN - RFS Petrol All Types
ALL TYPES
1.6i 16V
1.8i 16V
2.0i 16V
Saxo L4 NFX 1587 78.5/82 10.8/1 87-6600 118-6600 14.5-5200
C3/Xsara K/L4/IFL5 NFU
Picasso L4/IFL5 6FZ 1749 82.7/81.4
Xsara L4/IFL5 RFN 1197 85/88 10.8/1
Picasso IFL5
Xsara L4 RFS 1998 86/86
11/1 80-5800 109-5800 14.7-4000 65 85-5500 115-5500 16-4000
100-6000 136-6000 19-4100
120-6000 163-6000 19.3-5000
ENGINE
ENGINE
ALL TYPES
Engines : VJX - 8HX - 8HW - 8HV - 8HY - 8HZ Diesel All Types
1.5D
1.4 HDi
1.4 16V HDi
1.4 HDi
2.0 HDi
Saxo
C3 L4
Xsara
Xsara-Picasso L4/IFL5
Xsara
VJX 1527 77/82 23/1 42-5000 57-5000 9.5-2250
8HX-8HW
8HV-8HY 1398 73.5/82
8HZ
RHY 1997 85/88
RHZ
17.9/1 50-4000 70-4000 15-1750 66
18.4/1 66-4000 90-4000 20-1750
17.9/1 50-4000 70-4000 16-2000 66-4000 90-4000 20.5-1900
17.6/1 80-4000 109-4000 25-1750
SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

CYLINDER HEAD (mm)
Engine type Maximum permissible bow Gasket surface regrinding HFX KFW KFV NFT NFV NFX
ALL TYPES
NFU VJX
0.05 - 0.20
TIGHTENING TORQUES ( m.daN) 2 0.2 45 3.8 0.4 6.5 0.7 10 1 8 0.8 8 0.8 7 0.7 45 4 4 0.4 20 2 2 0.2 50 5
Crankshaft bearing screws Connecting rod screws Flywheel screw Crankshaft pinion screw Camshaft pulley screw Camshaft hubs Camshaft hub screw
Pre-tightening Angular tightening Tightening Tightening Pre-tightening Angular tightening Pre-tightening Angular tightening
Tightening
1 0.1
2.5 0.2
67
ENGINE
ENGINE
ALL TYPES
Engine type Maximum permissible bow Gasket surface regrinding

CYLINDER HEAD (mm)
6FZ 0.05 - 0.30 - 0.20 TIGHTENING TORQUES ( m.daN) Pre-tightening Slackening (1) 11 : 1 0.1 (2) 6 : 1 0.1 11 (only) 11 to 1 0.1 then to 2 0.1 11 to 70 5 6 to 1 0.1 1 0.1 180 (1/2 turn) 2.3 0.2 46 5 2 0.1 2.5 0.3 RFN RFS WJZ WJY 0.03 - 0.40 RHY RHZ
Crankshaft bearing screws
Tightening Angular tightening Tightening Pre-tightening Slackening Tightening Angular tightening
8.5 0.8 60 6 4 0.4 2.3 0.2 46 4.6 2 0.2 70 7
7 0.7 60 6 2 0.2
Connecting rod screws
70 7
68

A = HFX- KFV B = NFU RH engine support (1) (2) (3) 4.5 0.4 6.1 0.6 4.5 0.4
C3
Torque reaction rod (4) (5) 6 0.6 6 0.6
LH engine support on gearbox (6) (7) (8) 3 0.3 6 0.6 5.5 0.5
B1BP2NEP
69
ENGINE
ENGINE
C3
Engine types Accessories drive pulley Pinion fixing on crankshaft Sump Timing belt tensioner roller Accessories belt tensioner roller Alternator support fixing Alternator fixing on support Coolant outlet housing Camshaft bearing cap Tightening Angular tightening Inlet manifold Exhaust manifold Valve rockers adjusting screw Sparking plugs Camshaft pulley screw

Crankshaft HFX 10 1 Cylinder block 0.8 0.2 2 0.2 2 0.2 1.7 0.3 3.7 0.3 Cylinder head 0.8 0.2 2 0.2 44 4 0.8 0.2 1.7 0.3 1.75 0.25 2.75 0.25 8 0.8 70 2 0.2 2 0.2 50 5 2.2 0.2 2.5 0.2 KFV 0.8 0.2 NFU 2.5 0.2

Flywheel -Clutch Engines Flywheel Clutch mechanism Oil pressure switch Oil pump Coolant pump Coolant outlet housing HFX KFV 6.7 0.6 + LOCTITE FRENETANCH 2 0.2 Lubrication circuit 2 0.2 0.9 0.1 Cooling circuit 1.4 0.1 0.8 0.1 NFU
C3
71
ENGINE
ENGINE
C3

Engines : 8HX - 8HW
RH engine support (1) (2) 4.5 0.4 3 0.3
Torque reaction rod (3) (4) 6 0.6 6 0.6
LH engine support on gearbox (5) (6) (7) 5.4 0.5 6 0.6 5.5 0.5
B1BP2LJP
72

Engines Bearing cap fixing screw Pre-tightening Slackening Tightening Angular tightening Con rod nuts Pre-tightening Slackening Tightening Angular tightening Accessories drive pulley Pre-tightening Angular tightening Sump Timing belt guide roller Timing belt tensioner roller 73 8HW - 8HX Crankshaft 1 YES 3 140 1 YES 1.5 0.1 100 5 3 0.4 180 5 Cylinder block 1 0.1 4.5 0.4 3 0.3
C3
ENGINE
ENGINE
C3
Engines

8HW - 8HX Cylinder head
Camshaft bearing covers Pre-tightening Tightening Fixings of camshaft sub-assemblies on cylinder head Pre-tightening Tightening Exhaust manifold Valve cover Camshaft pulley Flywheel Pre-tightening Tightening Clutch mechanism Oil pump assembly Pre-tightening Tightening Coolant/oil heat exchanger 74
0.5 1 0.5 1 2.5 0.2 2.5 0.2 4.3 0.4 Flywheel 1.7 70 5 2 0.2 Lubrication circuit 0.5 0.06 0.9 0.1 1 0.1

Engines 8HW - 8HX Diesel injection circuit Spherical-base screws for diesel injection fixing fork Fuel high pressure common injection rail on engine block Unions on fuel high pressure common injection rail Diesel injection pump on support Union on diesel injection Diesel injection pump pulley Union on diesel high pressure pump 5 0.5 2.25 0.2 Cooling circuit Coolant pump Pre-tightening Tightening Coolant outlet housing Pre-tightening Tightening 75 0.3 0.06 0.7 0.08 0.3 0.06 1 0.1 2.25 0.2 0.3 0.1 2 0.2
C3
ENGINE
ENGINE
C3

Engines : 8HY - 8HV RH engine support Screw (1) Screw (2) 6 0.6 6 0.6
RH lower engine support Screw (3) 5.7 0.5
LH upper engine support Screw (7) Screw (8) 6 0.6 5.5 0.5
LH lower engine support Screw (6) 5.4 0.5
Torque reaction rod Screw (4) Screw (5) 6 0.6 6 0.6
B1BP2MNP
76

Engines 8HY - 8HV Crankshaft Bearing cap fixing screw Tightening Angular tightening Crankshaft pullet hub Tightening Angular tightening Oil sump Timing belt tensioner roller Timing belt guide roller Timing belt guide roller support Camshaft bearing cap cover Inlet manifold Exhaust manifold Cylinder head cover Camshaft pinion Fuel high pressure pump pinion 77 3 0.3 140 1.4 3 0.3 180 5 Cylinder block 1 0.1 4 0.4 2.5 0.2 Cylinder head 1 0.1 2.5 0.2 Screws (M6) to 1 0.2 4.3 0.4 5 0.5
C3 - XSARA
ENGINE
ENGINE
C3 - XSARA
Engines Flywheel Clutch mechanism Oil pump assembly Oil/coolant heat exchanger Turbocharger lubrication pipe Injector fixing flange nut Tightening Angular tightening

8HY - 8HV Flywheel -Clutch 1.7 0.2 2 0.2 Lubrication circuit 0.9 0.1 1 0.1 2.2 0.2 Injection circuit 0.4 0.1 65 5 2.3 0.2 5 0.5 2.3 0.2 Cooling circuit 1 0.2 78
Unions on fuel high pressure common injection rail Fuel high pressure pump Union on diesel injector Fuel high pressure pump pinion Union on fuel high pressure pump Coolant pump

Engines : RFS - VJX SAXO VJX - Pre-tighten 0.4 - Tighten to 0.7 XSARA RFS - Pre-tighten 0.5 - Tighten to 1
TUD - XU
B1DP03BC
B1DP01YD
79
ENGINE
ENGINE
SAXO - XSARA PICASSO
CYLINDER HEAD
Engines : HDZ - HFX - KFW - KFV - NFT - NFV - NFX - NFU - VJX Identification of the cylinder head gasket
Engine type Identification marks 1 2 3 4 A B D A B D A B D A B D C R
HFX 1 0 0 0 0 0 0 1 1 0 1 0 1
KFW
NFT - NFV 1 0 0 1
NFX - NFU 1 1 1 1
VJX 1 1 1 0
(Notch on cylinder head gasket)*
Thickness
CURTY
MEILLOR Suppliers ELRING
1 1 0
REINZ Material Repairs
1 0 0 0 (With asbestos) - 1 (Without asbestos) 0 (Standard gasket) - 1 (Repair gasket) 80
0 = Without notch 1 = One notch

B1BP10KC
CYLINDER HEAD (continued)

Engines : HDZ HFX KFW - NFT NFV - NFX NFU VJX Cylinder head tightening (m.daN) HDZ-HFX-KFW-NFV-NFT - Pre-tightening - Angular tightening VJX - Pre-tightening - Angular tightening NFU - NFX - Pre-tightening - Angular tightening 2 260 5 4 300 5 2 240 5
SAXO - XSARA - PICASSO

Cylinder head bolts
Note : Oil the threads and under the heads of the cylinder head bolts. (Use engine oil or Molykote G Rapid Plus).
B1BP10LC
B1DP059C
X = MAXIMUM reusable length HDZ-HFX-KFW-NFV-NFT

B1DP13NC
VJX X = 197.1 mm
NFU-NFX X = 122.6 mm
X= 175.5 0.5 mm 81
ENGINE
ENGINE
C3
CYLINDER HEAD
Engines : HFX - KFV - NFU Identification of the cylinder head gasket
Engines HFX KFV NFU
Thicknesses (Standard) 1.2 0.1 0.66 0.04
Thickness (repair) 1.4 0.1
Thickness ref. 2 1 4
References 1.2.3.4 = Type of engine. A.B.D C R = Suppliers = Gasket material. = Repair.
B1BP10KC
82
CYLINDER HEAD
Engines : HFX - KFV - NFU Cylinder head tightening (m.daN) HFX - KFV Tighten to Angular tightening 2 0.2 240 5 Cylinder head bolts
C3
(in the order 1 to 10) NFU Tighten to Angular tightening 2 0.2 260 5
(in the order 1 to 10) NOTE : Oil the threads and under the heads of the cylinder head bolts. (Use engine oil or Molykote G Rapid Plus).
B1DP05BC
B1BP1DVC
X = MAX. re-usable length HFX - KFV 175.5 0.5 NFU 122 0.3
NOTE : Retightening of the cylinder head after a repair is forbidden.
83
ENGINE
ENGINE
C3
CYLINDER HEAD
Engines : 8HY - 8HV Identification of the cylinder head gasket
Engine types
Supplier
Piston standproud (mm) 0.675 to 0.725 0.726 to 0.775
Thicknesses (mm) 1.25 1.30 1.35 1.40 1.45
No. of notches at d 1 2 3 4 5
No. of notches at e Type of gasket : Metallic multilayer "d" Thickness reference. 2 "e" Engine reference.
8HY - 8HV
ELRING
0.776 to 0.825 0.826 to 0.875 0.876 to 0.983
B1DP1CMD
84
CYLINDER HEAD
Engines : 8HY - 8HV Identification of the cylinder head gasket Engine types Supplier Piston standproud (mm) 0.771 to 0.820 0.611 to 0.720 8HY - 8HV ELRING 0.721 to 0.770 00.821 to 0.870 0.871 to 0.977 Thicknesses (mm) 1.35 1.25 1.30 1.40 1.45 No. of notches at d 1 2 3 4 5 2 No. of notches at e Type of gasket Metallic multilayer
C3
"d" Thickness reference. "e" Engine reference.
B1DP1CKD
85
ENGINE
ENGINE
XSARA - C3
Cylinder head tightening (m.daN)
CYLINDER HEAD
Engines : 8HX - 8HW - 8HY - 8HV Cylinder head bolts
8HX - 8HW - 8HY - 8HV Pre-tightening Tightening 2 0.2 m.daN 4 0.4 m.daN
Angular tightening 230 5 (In the order 1 to 10) NOTE : - The bolts should have been thoroughly cleaned and dried with a dry metal brush. - Oil the threads and under the heads of the bolts. (Use engine oil or Molykote G Rapid Plus). The cylinder head gasket is dry-fitted. NOTE : Retightening of the cylinder head after a completed repair is prohibited. - Pass a tap into the holes in the cylinder block. X = MAX. re-usable length 8HX - 8HW - 8HY - 8HV
B1DP1CLC
B1DP1DBC
X = 149 mm 86
CYLINDER HEAD
Engine : 6FZ Identification of the cylinder head gasket Nominal dimension Marking zone d Marking zone e Gasket thickness (mm) Supplier 45 R1 0.8 1 MEILLOR Repair dimension 245 R2 1.1 R3 1.3
XSARA PICASSO
Marking d Marking zone e Marking zone NOTE : 3 layer metallic gasket.
B1DP183D
87
ENGINE
ENGINE
XSARA PICASSO
Cylinder head tightening (m.daN) 6FZ Pre-tightening Tightening Loosening Tightening Angular tightening

Engine : 6FZ Cylinder head bolts
1.5 0.2 5 0.2 360 (1 turn) 2 0.2 285 5
B1DP16FC
B1DP05BC
NOTE : Oil the threads and under the heads of the cylinder head bolts. (Use engine oil or Molykote G Rapid Plus). 88
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

Engine : RFN Identification of the cylinder head gasket Nominal dimension Marking zone d Marking zone e Gasket thickness (mm) Supplier 0.8 45 R1 1.1 MEILLOR Repair dimension 245 R2 1.4
XSARA PICASSO
Multilayer metallic gasket
B1DP183D
89
ENGINE
ENGINE
XSARA PICASSO
Cylinder head tightening (m.daN) RFN Pre-tightening Tightening Loosening Tightening Angular tightening

Engine : RFN Cylinder head bolts
1.5 0.2 5 0.2 360 (1 turn) 2 0.2 285 5
B1DP16FC
B1DP05BC
NOTE : Oil the threads and under the heads of the cylinder head bolts. (Use engine oil or Molykote G Rapid Plus). 90
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
CYLINDER HEAD
Engine : RFS Identification of the cylinder head gasket Engine type Identification marks A B Suppliers MEILLOR C D E RFS (Notch on cylinder head gasket) 1 0 1 0 0
XSARA
*
B1BP004C
0 = Without notch 1 = One notch
91
ENGINE
ENGINE
XSARA
Cylinder head tightening (m.daN)

Engine : RFS Cylinder head bolts RFS - Pre-tightening - Slackening - Tightening - Angular tightening 3.5 NON 7 160
Note : Oil the threads and under the heads of the cylinder head bolts. (Use engine oil or Molykote G Rapid Plus).
B1DP05BC
B1DP13PC
X = MAXIMUM re-usable length RFS 112 mm
92
CYLINDER HEAD
Engine : WJY Identification of the cylinder head gasket Engine type Piston stand-proud (mm)* 0.51 to 0.55 0.55 to 0.59 WJY 0.59 to 0.63 0.63 to 0.67 0.67 to 0.71 Thickness (mm) 0.04 1.26 1.30 1.34 1.38 1.42
2
XSARA
Number of holes at A
Number of holes at B 1 2 3 4 5
WJY
(A) = Engine identification. (B) = Thickness identification. (*) = Take the highest piston as a reference point.
B1DP14QD
93
ENGINE
ENGINE
XSARA - XSARA PICASSO
CYLINDER HEAD
Engines : RHY - RHZ Identification of the cylinder head gasket
Engine type
Piston stand-proud (mm) 0.47 to 0.605 0.605 to 0.655
Thickness (mm) 1.30 0.06 1.35 0.06 1.40 0.06 1.45 0.06 1.50 0.06
Number of notches at A 1 2 3 4 5
RHY RHZ
0.655 to 0.705 0.705 to 0.755 0.755 to 0.83
B1DP15AD
94

Engines : WJY - RHY - RHZ Cylinder head tightening (m.daN) WJY - Pre-tightening - Tightening - Angular tightening 2 6 180 WJY

Cylinder head bolts RHY - RHZ
RHY - RHY - Pre-tightening - Tightening - Angular tightening Note : Oil the threads and under the heads of the cylinder head bolts. (Use engine oil or Molykote G Rapid Plus).
B1DP05BC B1DP13PC B1DP15EC
2 6 220
X = MAXIMUM re-usable length WJY 125.5 mm 95 RHY - RHY 133.3 mm
ENGINE
ENGINE
ALL TYPES ! !
4099-T (C.TRONIC.105)
BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE !

Tools 4122-T (C.TRONIC.105.5)
96
AUXILIARY EQUIPMENT DRIVE BELT

TU 1 3 JP Engine type : HFX KFW KFV NFT NFV 5 J4 NFX JP4 NFU 6FZ 7 J4 EW
ALL TYPES
XU 10 J4RS RFN RFS
SAXO See pages : C3 See pages : XSARA See pages : XSARA PICASSO See pages :
X 100 X 101 to 102
X 100 X 101 to 102
X 106 X 101 to 102 X 106 X 103 to 104 97 X 110 X 110 X X 108 to 109
X 105
ENGINE
ENGINE
ALL TYPES
TU 5 B Engine type VJX 8HX TD 8HW

DV 4 TED4 8HZ 8HV 8HY 8 B WJY TD RHY DW 10 ATED RHZ
SAXO See pages : C3 See pages : XSARA See pages : XSARA PICASSO See pages :
X 107 X 117 to 118 X 117 to 118 X X 119 X 111 to 116 X 120 to 123 98 X 120 to 123 X X

Engines : All Types Petrol et Diesel
ALL TYPES
TOOLS - Belt tension measuring instrument : 4122 -T. (C.TRONIC 105.5) - WARNING : If using tool 4099-T (C.TRONIC 105), refer to the correspondence table on page 90.
ESSENTIAL - Before refitting the auxiliary equipment drive belt, check that: 1) The roller(s) rotate freely (no play or stiffness). 2) The belt is correctly engaged in the grooves of the various pulleys.
99
ENGINE
ENGINE
SAXO

Engines : HFX - KFW - NFT Without air conditioning - Fit the tool 4122 - T. - Tighten the tensioning screw (3) to obtain : 55 3 SEEM units. With air conditioning - Fit the tool 4122-T. - Tighten the tensioning screw (5) to obtain : 120 3 SEEM units.
- ighten the screws (2) and (1). - Remove the tool 4122-T.
- Tighten the screws (6) and (4). - Remove the tool 4122-T.
B1BP10UC B1BP10WC
B1BP10VC B1BP10XC
100

Engines : HFX - KFV - NFU
C3
Tools [1] Pliers for removing plastic pegs [2] Belt tension measuring instrument Vehicle without air conditioning. Remove. Slacken: - Screw (2). - Screw (3). - Tensioning screw (1). Push the alternator back towards the engine. Remove the belt. Refit. Refit the belt. Respect the following sequence: - Crankshaft pinion. - Alternator pulley. Place tool [2] on the belt. Tighten screw (1) to achieve a tension of: 55 3 units SEEM. Tighten: - Screw (3). - Screw (2) Remove tool [2] and complete the refitting. : 7504-T. : 4122-T.
B1BP2LSC
B1BP2LTC
101
ENGINE
ENGINE
C3

Engines : HFX - KFV - NFU Vehicle with air conditioning. Remove Slacken: - Screws (6), (4) and (5). - Fully detension the belt by acting on the tensioner roller. - Remove the accessories drive belt. Refit. Respect the following sequence: - Crankshaft pinion. - Aircon compressor pulley. - Guide roller. - Alternator pulley. - Tensioner roller. Place tool [2] on the belt. - Tighten screw (5) to achieve a belt tension of: 120 3 SEEM units. - Tighten screws (4) and (6). - Remove tool [2]. - Complete the refitting.
B1BP10VC B1BP10XC
102

Engine : NFV Without air conditioning. Tools. [1] Pliers for removing plastic pegs [2] Belt tension measuring instrument [3] TORX spanner. : 7504 T. : 4122 T.
XSARA PICASSO
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
103
ENGINE
ENGINE
XSARA PICASSO

Engine : NFV 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 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 6 mm peg. Release the automatic tensioner. Remove the tool [3].
B1BP235C
104

Engine : KFW Alternator [1] Belt tension measuring instrument : 4122-T - Tension the belt using the screw (2). - Tension should be : 102 7 SEEM units. - Tighten the screws (1).
XSARA
With air conditioning [1] Belt tension measuring instrument : 4122-T - Tension the belt using the screw (4). - Tension should be: 102 7 unites SEEM. - Tighten the screws (3).
Power-assisted steering - New belt 100 SEEM units. - Reused belt 75 SEEM units.
Power steering and air con. - New belt 100 SEEM units. - Reused belt 75 SEEM units.
B1BP1B2C B1BP122C
B1BP1B3C B1BP124C
105
ENGINE
ENGINE
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 - CNew belt : 120 SEEM units. - Reused belt : 86.5 3.5 SEEM units. NOTE : Removal of the tensioner roller makes it necessary to remove the plate with the upper fixing screw (5).
B1BP1ANC
106

Engine : VJX Without air conditioning - (6) Roller support fixing screw. - (7) Tensioning screw - Pre-tension the belt (8) to : 120 SEEM units. - Rotate the crankshaft by 3 turns (Direction of rotation). - Adjust the belt (8) tension to : 120 SEEM units. - Tighten the screws (6) to : 2.5 m.daN. - Run the engine for 10 min. - Check the tension. 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 10 min. - Check the tension. 107
SAXO- XSARA
B1BP11EC
B1BP11DC
ENGINE
ENGINE
XSARA

Engine : RFS With air conditioning
- Fit the drive belt. - The tensioner roller (1). - Tighten the screws (3) to 2 m.daN. - Move the tensioner roller (1) using the tool (9.52 mm square drive (3/8)) at (2), in order to remove the tool or locking peg ( 4 mm) at (4). - Slowly release the tensioner roller (1) so that the roller (5) presses against the belt.
B1BP1HJC
108

Engine : RFS Without air conditioning TOOLS [1] Belt tension measuring instrument - (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). 4122-T
XSARA
B1EP12XC
B1EP12YC
109
ENGINE
ENGINE

Without air conditioning

Engines : 6FZ - RFN Tools With air conditioning
[1] Pliers for removing plastic pegs
7504-T
Remove the belt. - Detension the belt (3) by turning the screw (2) of the tensioner roller (1) (anti-clockwise).
- The screw (2) (WARNING : not left hand screw). - Remove the belt (3), while keeping the tensioner roller (1) tight.
Refit the belt. - Refit the belt (3), while keeping the tensioner roller (1) tight. - Release the tensioner roller (1).
B1BP23PC
B1BP23QC
B1BP23PC
B1BP23RC
110

Engine : WJY Without power-assisted steering Tools :
XSARA
[1] Belt tension measuring instrument : 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].
4122-T.
B1BP1SDC
B1BP1SEC
111
ENGINE
ENGINE
XSARA

Engine : WJY Without power-assisted steering, with air conditioning Tools :
[1] Belt tension measuring instrument : Removal. - Loosen the screws (1). - Tighten the screw (2) until it is against its stop. - Remove the belt.
4122-T.
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
112

Engine : WJY Power-assisted steering, without air conditioning
XSARA
Tools : [1] Belt tension measuring instrument : 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. 4122-T.
B1BP1SHD
113
ENGINE
ENGINE
XSARA

Engine : WJY Power-assisted steering, without air conditioning (continued) Refitting. - Refit the belt. - Place the tool [1] on belt at "f". WARNING : Position tool [1], with the knob downwards. - tighten the nut (2) to obtain a value of : Reused belt: Keep the value taken at removal. New belt: Tension should be 110 SEEM units. - Tighten the screw (1) to 9.5 m.daN. - Check belt tension (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
114

Engine : WJY Power-assisted steering, with air conditioning Outillage : [1] Dynamic tensioner peg [2] Belt tension measuring instrument : (-) 0188 H. : 4122-T.
XSARA
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
115
ENGINE
ENGINE
XSARA

Engine : WJY Power-assisted steering with air conditioning (continued)
Refitting. - Refit the belt. - Using a 7 mm square drive at "b", turn the roller (3), until the tool [1] located at "a" becomes free. - Tighten the screw (2). - Remove the tool [1].
B1BP1SLC
116

With compressor and alternator Engines : 8HX - 8HW Tools [1] Pliers for removing plastic pegs [2] Tensioner roller compression lever [3] Tensioner roller setting peg 4 mm : 7504-T. : (-).0194.E. : (-).0194.F.
C3
Removing. Disconnect the battery negative cable. Raise and support the vehicle, wheels hanging. Remove the front RH wheel. Move aside the splash-shield, using tool [1]. IMPERATIVE : In the case of belt re-use, mark the direction of rotation of the belt. If the index on the tensioner roller is outside the marks, change the auxiliary equipment drive belt. Remove : The alternator (1). The aircon compressor (2). Detension the auxiliary belt tensioner roller, using tool [2]. Position the peg [3]. Remove the auxiliary drive belt.
B1BP2MJD B1BP2MKC
117
ENGINE
ENGINE
C3

Engines : 8HX - 8HW Markings on the dynamic tensioner roller. "a" Position of maximum wear of the auxiliary drive belt. "b" Normal position.
Refitting NOTE : Check that the tensioner roller moves freely (no tight spot). If this is not the case, replace the tensioner roller. Respect the direction of fitting of the drive belt. Complete the setting of the belt, of both sides, by means of the tensioner roller. Make sure that the drive belt is correctly positioned in the V grooves of the various pulleys. Move the tool [2] on the tensioner roller to remove the peg [3].
B1EP18UD
118

Engines : 8HY - 8HV Tools. [1a] Dynamic tensioner roller lever [1b] Lever extension [2] Accessories belt roller locking peg 4 mm : (-).0194-E1. : (-).0194-E2. : (-).0194-F
C3
Removing Pivot the tensioner roller support (1) (clockwise), using tools [1a] and [1b] at a. Remove the belt. Immobilise the support (1) of the tensioner roller, using tool [2]. Remove the auxiliary drive belt (2). IMPERATIVE : Ensure that the tensioner rollers turn freely (no play, no tight spot). Refitting Refit the belt. Move the tool [1] on the tensioner roller to remove the peg [2]. ESSENTIAL: Make sure that the belt is correctly positioned in the various pulley grooves.
B1BP2MYD B1BP2MZC
119
ENGINE
ENGINE

Engines : RHY - RHZ Without air conditioning Tools [1] [2] [3] [4] Belt tension adjusting square 4 mm peg 2 mm peg Dynamic tensioner compression lever : (-).0188 J2 : (-).0188.Q1 : (-).0188.Q2 : (-).0188.Z
REMOVAL Re-use of belt WARNING : Mark the direction the belt was fiited in case of re-use of the same belt. - Compress the tensioner roller (2) by action at a (in anti-clockwise direction), tool [4]. - Keep the tensioner roller (2) compressed and remove the belt. No re-use of belt - Compress the tensioner roller (2) by action at a (in anti-clockwise direction), tool [4]. - Peg using tool [2], at b . - Keep the tensioner roller (2) compressed and remove the belt. - Loosen the screw (1).
B1BP1YKD
120

Engines : RHY - RHZ

Without air conditioning (continued)
REFITTING. Re-used belt - Compress the tensioner roller (2) by action at a (in anti-clockwise direction), tool [4]. - Refit the belt. WARNING : Respect the belt-fitting direction. Remove the tool [4]. New belt Refit the belt. - Turn the eccentric roller (3), tool [1] (clockwise) to free the tool [2] from its pegging at b . - Hold the eccentric roller (3), tool [1], and tighten the screw (1) to 4.3 m.daN. Remove the tool [2]. - Rotate the crankshaft 4 times in the direction of rotation. - Check that it is possible to peg at b , tool [3]. - If not possible to peg, restart the adjustment.
B1BP1YMD
121
ENGINE
ENGINE

Engines : RHY - RHZ With air conditioning [1] [2] [3] [4] Tools Belt tension adjusting square Pige 4 mm Pige 2 mm Dynamic tensioner compression lever : : : : (-).0188 J2 (-).0188.Q1 (-).0188.Q2 (-).0188.Z
REMOVAL Re-use of belt WARNING : Mark the direction the belt was fitted in case of re-use of the same belt. - Compress the tensioner roller (7) by moving it at c (in anti-clockwise direction), tool [4]. - Hold the tensioner roller (7) compressed and remove the belt. No re-use of belt - Compress the tensioner roller (7) by moving it at c (in anti-clockwise direction), tool [4]. - Peg using tool [2], at d . - Loosen the screw (6). - Bring the eccentric roller (5) towards the rear. - Tighten the screw (6) by hand. - Remove the belt.
B1BP1YLD
122

Engines : RHY - RHZ

With air conditioning (continued)
REFITTING. Re-used belt - Compress the tensioner roller (7) by action at c (in anti-clockwise direction), tool [4]. - Refit the belt. WARNING : Respect the direction belt was fitted. Remove the tool [4]. New belt Refit the belt. - Turn the eccentric roller (5), tool [1] (clockwise) to free the tool [2] from its pegging at d . - Hold the eccentric roller (5), tool [1], and tighten the screw (6) to 4.3 m.daN. Remove the tool [2]. - Rotate the crankshaft 4 times in the direction of rotation. - Check that it is possible to peg at d , tool [3]. - If not possible to peg, restart the adjustment.
B1BP1YND
123
ENGINE
ENGINE
ALL TYPES
1 3 JP Engine type SAXO See pages : C3 See pages : XSARA HFX X X 129 to 138 X KFW X KFV
CHECKING AND SETTING THE VALVE TIMING

TU 5 J4 NFT X 126 to 128 X 129 to 138 NFV NFX X 139 to 142 X 129 to 138 X X X JP4 NFU 6FZ 7 J4 RFN EW 10 J4RS RFS XU
126 to 128
1 2003
See pages : 126 to 128 139 to 142 163 to 173 2003 X X
182 to 186
174 to 181 PICASSO X
1 2003
See pages : 126 to 128 163 to 173 2003
174 to 181 124

TUD 5 B Engine type SAXO See pages : C3 See pages : XSARA VJX X 143 to 145 X 146 to 153 X X X 154 to 162 X X X 8HX TD 8HW 8HZ 8HV DV 4 TED4 8HY 8 B WJY TD
ALL TYPES
DW 10 ATED RHZ
RHY
X 192 to 196
1 N RPO 9127
See pages : 146 to 153 187 to 191 N RPO 9128 197 to 205 PICASSO X
1 N RPO 9127
See pages : 192 to 196 N RPO 9128
197 to 205 125
ENGINE
ENGINE
SAXO - XSARA

Engines : HFX - KFW - NFT - NFV 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
126

Engines : HFX - KFW - NFT - NFV
SAXO - XSARA
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 B1EP06AC
127
ENGINE
ENGINE
SAXO - XSARA

Engines : HFX - KFW - NFT - NFV REFITTING THE TIMING BELT
NOTE : Check that the pegs [1] and [2] are in place. WARNING : Ensure the belt is fitted in the right direction : The arrows a signify the crankshaft direction of rotation. Fit : - The timing belt, with the belt strip "b" 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.
128

Engines : HFX - KFV - NFU Tools. [1] Engine flywheel peg [2] Camshaft pulley peg [3a] Camshaft peg [3b] Camshaft peg [4] Dynamic tensioner roller pin [5] Belt retaining pin [6] Pliers for removing plastic pins Checking the valve timing Engines HFX - KFV - NFU Raise and support the front RH side of the vehicle. Disconnect the battery positive terminal. Engage 5th gear. Remove the oil filter (1). Engine HFX - KFV Remove : The timing top casing (2). Turn the wheel to rotate the engine (normal direction of rotation). Peg the camshaft pulley, using tool [2].
B1BP2M7C B1BP2M8C B1BP2M9C
C3
: 4507-T.A : 4507-T.B : 4533-TA.C1 : 4533-TA.C2 : 4200-T.H : 4533-T.AD : 7504-T.
129
ENGINE
ENGINE
C3

Engine : NFU Checking the timing (continued) Engine : NFU Place a jack under the engine, peg the engine. Remove: - The engine support (4) complete. - The timing casing (3). - The sparking plugs (eases engine rotation). Turn the wheel to rotate the engine (normal direction of rotation). Position the pegs [3a] and [3b]. Peg the flywheel, using tool [1]. If the setting is not correct, recommence the operation. Remove the tools [1], [2], [3a] and [3b]. Complete the refitting.
B1BP2MAC
B1EP18MC
B1BP2MBC
130

Engines : HFX - KFV Setting the timing Preliminary operation. Lift and support the vehicle, wheels hanging. Disconnect the battery. Remove: - The front RH wheel. - The splash-shield, using tool [6] - The accessories belt (See corresponding operation). - The crankshaft pulley. - The oil filter. Place a jack under the engine, peg the engine. Removing. Engine HFX - KFV Turn the engine by means of screw (1). (normal direction of rotation). Remove the timing casings. Peg the camshaft pinion, using tool [2]. Peg the flywheel, using tool [1]. Remove: - The fixing screws (2). - The upper engine support (3).
B1BP2MCC B1BP2M9C B1BP2MBC B1BP2MDC
C3
131
ENGINE
ENGINE
C3

Engines : HFX - KFV Setting the timing (continued)
Engine HFX - KFV Slacken the screws (4) without removing them. Remove the bottom engine support assembly (5), and the fixing screws (4). Slacken the nut (6). Completely detension the belt by acting on the tensioner roller (7). Remove the timing belt. IMPERATIVE : Check that the tensioner roller turns freely (no tight spot).
B1BP2MEC
B1EP18NC
132

Engine : NFU Engine NFU. Setting the timing (continued) Remove: The bottom plastic casing. The engine support (9). The middle support. The timing cover (8). Peg the flywheel, using tool [1]. Position the tools [3a] and [3b].
C3
B1BP2MFC
B1BP2MBC
B1EP18MC
133
ENGINE
ENGINE
C3

Engine : NFU Setting the timing (continued) Engine: NFU Slacken the tensioer roller. Turn the tensioner roller so as to be able to position the tool [4], with the aid of an Allen key placed at a. Turn the tensioner roller towards the right to bring it to the index c in position b. Peg the tensioner roller in this position in order to slacken the timing belt to the maximum. IMPERATIVE : Never make the dynamic tensioner roller turn by a complete rotation. Remove the timing belt (8) Check that the rollers (9) and (10) turn freely (no tight spot).
B1EP18PC
B1EP18QC
134

Engines : HFX - KFV
C3
Setting the timing (continued) Engines: HFX-KFV Refit. WARNING: Respect the direction of fitting of the belt: (the arrows d indicate the direction of rotation of the crankshaft). Refit the timing belt. Position the timing belt, belt e well tensioned, in the following order: Crankshaft pinion, hold the belt using tool [5]. Camshaft pulley. Coolant pump pulley. Tensioner roller. Remove the pegs [1] and [2].
B1EP18QC
135
ENGINE
ENGINE
C3

Engines : KFX - KFV - NFU Setting the timing (continued) Engines: HFX-KFV Refitting. NOTE : Check that the pegs [1] and [2] are in place. WARNING: Respect the direction of fitting of the timing belt, the arrows d indicate the direction of rotation of the crankshaft. Refit the timing belt. Position the timing belt, belt e well tensioned, in the following order: Crankshaft pinion, hold the belt using tool [5]. - Camshaft pulley. - Coolant pump pulley. - Tensioner roller. Remove the tools [1], [2] Engine: NFU Fit the timing belt in position in the following order: - Inlet camshaft pulley. - Exhaust camshaft pulley. - Guide roller. - Crankshaft pulley. Position tool [5]. - Coolant pump pulley. - Dynamic tensioner roller. Remove the tools [1], [3] and [5]. 136
B1EP18RC

Engine : NFU Timing belt overtensioned: A : Engines: HFX KFV. B : Engine: NFU Turn the tensioner roller (7) with the aid of a hexagonal spanner at a.
C3
Bring the index c to position f, to tension the belt to the maximum of the interval indicated. Hold the tensioner roller (7), using tool [4]. Tighten the fixing nut of the tensioner roller, tightening to 1 0,1 m.daN. Turn the crankshaft by 4 rotations (normal direction of rotation). IMPERATIVE : Never make the crankshaft rotate backwards. Make sure that the timing is correctly set by refitting the tools [1], [2] and [3]. Remove the tools [1], [2] and [3].
B1EP18SD
137
ENGINE
ENGINE
C3

Engines : HFX - KFV - NFU Adjusting the fitting tension of the timing belt A : Engine : HFX KFV. B : Engine: NFU. Slacken the nut while maintaining the position of the tensioner roller, with the aid of a hexagonal spanner at a. Next bring the index c to its adjusting position a. The index c should not go beyond the notch g. WARNING: The index c must not go beyond the notch g. If it should do this, restart the timing belt tensioning operation. Hold the tensioner roller (7) in this position, with the aid of a hexagonal spanner. Tighten the tensioner roller fixing nut to : 2 0.2 m.daN. (HFX KFV engines ) 2.2 0.2 m.daN. (NFU engine ) IMPERATIVE : The tensioner roller must not rotate during the tightening of its fixing. If it does, restart the timing belt tensioning operation. Complete the refitting.
B1EP18TD
138

Engines : NFX - NFU
SAXO - XSARA
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
B1EP11CC
139
ENGINE
ENGINE
SAXO - XSARA

Engines : NFX - NFU
SETTING THE VALVE TIMING - Loosen the screw (2), remove the belt. - Loosen the six pulley screws (1) on the hubs. (There should be a slight amount of friction between the screws and the pinions). - Check that the rollers (2) and (3) rotate freely. NOTE : The belt bears three identification marks respectively.
* (a), (b) and (c), facing its own teeth (1), (52) and (72)
* (Identification marks = white paint lines on
the back of the belt facing the corresponding teeth).
- Refit the belt. - Line up mark (A) on the belt with groove (D) of the pinion (4). - Hold the belt against the pinion (4).
B1EP11DC
B1EP11EC
140

Engines : NFX NFU
SAXO - XSARA
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 1 m.daN. ESSENTIAL : Check that : - The camshaft pulleys (1) are not at the end of the slots (by removing a screw). - The markings on the belt are aligned with the markings on the crankshaft and camshaft pulleys. If not, repeat the setting procedure.
B1EP11FC
B1EP11GC
141
ENGINE
ENGINE
SAXO - XSARA

Engines : NFX NFU
SETTING THE VALVE TIMING Remove the tools [1], [2], [3] and [4]. Rotate the engine by four turns in the normal direction. (do not turn backwards). Peg the flywheel [2]. 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.
142

Engine : 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.
SAXO
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
143
ENGINE
ENGINE
SAXO

Engine : VJX
SETTING THE VALVE TIMING - Fit the belt in the following order : The crankshaft pinion, the injection pump pulley, the camshaft pulley, the water pump pinion. WARNING : When positioning the belt on the injection pump and camshaft pulleys, they should be turned in the opposite direction of rotation so as to engage the nearest tooth. - 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
144

Engine : VJX SETTING THE VALVE TIMING - Tighten the screws (1) and (3) to 2.3 m.daN (lock the pulleys using tool 6016 - T). - Remove the tools. - Rotate the engine by 10 turns. - Peg : The flywheel, the pulleys (2) and (4). 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. 145
SAXO
ENGINE
ENGINE
C3

Engines : 8HX - 8HW SETTING THE VALVE TIMING - Tighten the screws (1) and (3) to 2.3 m.daN (lock the pulleys using tool 6016 - T). - Remove the tools. - Rotate the engine by 10 turns. - Peg : The flywheel, the pulleys (2) and (4). 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. 146
B1BP2LXC

Engines : 8HX - 8HW Check ing the setting (continued) Remove: - the accessories drive belt. - the accessories drive pulley. - the lower timing cover (3). IMPERATIVE : The magnetic track should show no signs of damage and should not be approached by any other source of magnetism. Reposition the screw (2). Remove tool [3]. Rotate the engine by means of the crankshaft pinion screw (2) (clockwise), to bring it to the pegging position. Position the tool [4]. Peg the crankshaft pinion (1), using tool [5]. Peg the high pressure pump pinion, using tool [5]. NOTE: Index a of the roller tensioner must be centred within the area b. Check the correct positioning of index a. Remove tools [4] and [5]. Rotate the engine ten times. Fit the tools [4] and [5]. If pegging is not possible, carry out the operation to remove/refit the timing belt. (See corresponding operation).
B1JP03SC B1EP18DC B1EP18EC B1EP18FC
C3
147
ENGINE
ENGINE
C3

Engines : 8HX - 8HW Setting the timing. Remove the upper timing cover (1). Rotate the engine by means of the crankshaft screw (2). NOTE : The pegging hole is located under the crankshaft bearing cap cover. Peg the engine flywheel, using tool [3]. Remove the lower timing cover (3). Uncouple the exhaust line from the manifold. IMPERATIVE : Uncouple the exhaust line in order to avoid damaging the front flexible pipe. Twisting, pulling and bending the front flexible pipe reduces its life. Remove: - The engine speed sensor (6). - The belt retaining stop (5). - The screw (2). - The crankshaft pinion (4) (with its magnetic track a). IMPERATIVE : The magnetic track should show no signs of damage and should not be approached by any other source of magnetism. Should this not be adhered to, it is essential to replace the crankshaft pinion. Refit the screw (2).
B1BP2LXC B1EP18GC
148

Engines : 8HX - 8HW
C3
Setting the timing (continued). Remove the tool [3]. Rotate the engine by means of the crankshaft pinion screw (2) (clockwise), to bring it to the pegging position. Peg the camshaft pulley, using tool [4]. Peg : - The crankshaft pinion (6), using tool [5]. - The high pressure pump pinion, using tool [5]. Support the engine with the aid of a roller jack equipped with a chock. Remove: - The RH engine support (7). - The intermediate engine support (right hand side) (8).
B1JP03SC
B1EP18DC
B1EP195C
B1BP2LYC
149
ENGINE
ENGINE
C3

Engines : 8HX - 8HW Setting the timing (continued). Hold the tensioner roller, using a hexagonal spanner at b . Slacken the screw (9) . Remove the timing belt (10) . Refitting. IMPERATIVE : Check that both the tensioner roller and the fixed roller turn freely (no tight spots). If this is not the case, replace the rollers. Fitting of the pulleys. - Camshaft pulley Tighten to 4.3 0.4 m.daN. - Fuel high pressure pump pulley Tighten to 5 0.5 m.daN. The crankshaft pinion is located without a screw at the end of the crankshaft. Fitting of the rollers. IMPERATIVE : Check that the tensioner roller turns freely (no tight spot). Otherwise, replace the rollers. - Guide roller - Tensioner roller Tighten to 4.5 0.4 m.daN Pre-tighten to 0.1 m.daN
Check the condition of the seals at the camshaft and at the crankshaft pinion.
B1EP18HC
150

Engines : 8HX - 8HW Setting the timing (continued).
C3
NOTE : Screw (9) slackened. Position the timing belt (10) observing the following sequence: Crankshaft pinion (4). Guide roller (12). Camshaft pulley (11), (check that the belt is held correctly against the roller). Coolant pump pinion (13). Fuel high pressure pump pulley (15). Tensioner roller (14).
B1EP18JD
151
ENGINE
ENGINE
C3

Engines : 8HX - 8HW Setting the timing (continued). Turn the tensioner roller to the right to bring the index c to position d, using a hexagonal spanner. Tighten the screw (9) of the tensioner roller, tighten to 3 0,3 m.daN. Remove the tools [4] and [5]. Rotate the engine ten times (check that the timing pinion is correctly up against the crankshaft). Check: The pegging of the camshaft. The crankshaft pinion. The fuel high pressure pump pinion (15). The correct positioning of the index of the dynamic tensioner. If these are not correct, repeat the operation to position the timing belt. Refit: The engine speed sensor (6). The belt retaining stop (5), tighten to 0,7 m.daN.
B1EP18KC
152

Engines : 8HX - 8HW Setting the timing (continued). Refit: The intermediate RH engine support, tighten the screws (16) to 5,5 0,5 m.daN. The RH engine support, tighten the screws (17) to 4,5 0,4 m.daN. The bottom timing cover (3). Immobilise the engine flywheel, using tool [3]. Remove the screw (2). Refit the accessories drive pulley and tighten to: Pre-tighten to : 3 0,3 m.daN. Angular tighten to : 180 1,8 Remove tool [3] Refit: The top cover (1). The accessories belt (see corresponding operation). The exhaust line (see corresponding operation). The front RH splash-shield. The front RH wheel.
B1EP18LC B1BP2LZC
C3
153
ENGINE
ENGINE
C3

Engines : 8HY - 8HV Tools. [1] Engine flywheel peg 12 mm [2] Camshaft pulley peg 8 mm [3] Crankshaft pulley peg 5 mm : (-).0194-C. : (-).0194-B. : (-).0194-A.
Preliminary operations. Remove: - The front RH wheel. - The front RH splash-shield. - The accessories belt (see corresponding operation). Uncouple: - The supply unions (1). - The air/air heat exchanger inlet/outlet pipes (3). - The exhaust line (at the flexible pipe). Disconnect the connector (2). Support the engine by means of a roller jack equipped with a chock. Remove the engine supports (4) and (5).
B1BP2N0C
154

Engines : 8HY - 8HV Checks. Rotate the engine to engage it (normal direction of rotation). Immobilise the engine flywheel at a, using tool [1]. Move aside the harness (6). Remove: - The engine support (7). - The screw (8). - The pulley (9). - The lower timing cover (10). - The upper timing cover (11). - The tool [1].
C3
B1BP2N1C
B1BP2N2C
155
ENGINE
ENGINE
C3

Engines : 8HY - 8HV Checks (continued). Refit the screw (8). Rotate the crankshaft six times (clockwise). IMPERATIVE : Never rotate the engine backwards. Peg : - The camshaft, using tool [2]. (Oil the pegs.) - The fuel high pressure pump pulley (14), using tool [3] at c. WARNING: The magnetic track should show no signs of damage and should not be approached by any source of magnetism. Peg the crankshaft at b, using tool [3]. IMPERATIVE: Should it be impossible to peg the camshaft, check that the offset between the hole in the camshaft pinion and the pegging hole is not greater than 1 mm. Otherwise repeat the operation to position the timing belt. (See corresponding operation).
B1EP18YD
156

Engines : 8HY - 8HV Checks (continued). NOTE : The index e of the dynamic tensioner roller should be centred within the area d. Check the correct positioning of the index e.
C3
If it is not correct, repeat the operation to tension the timing belt (see corresponding operation). Refitting. Refit the tool [1] at a. Remove the screw (8). Refit: - The upper timing cover (11). - The lower timing cover (10). - The accessories drive pulley (9). - The screw (8). Tightening torque: - Screw (8) : Pre-tighten to Angular tightening Remove the tool [1].
B1EP18ZC
: 3 0.3 m.daN. : 180 5.
157
ENGINE
ENGINE
C3

Engines : 8HY - 8HV Checks (continued). Refit : - The engine support (7), tighten to 1,5 0,4 m.daN. - The engine support (4), tighten to 6,1 0,6 m.daN. - The engine support (5), tighten to 6 0,6 m.daN. - The electrical harness (6). Couple: - The exhaust line, tighten the collar to : 2.5 0.3 m daN - The fuel supply unions (1). - The air/air heat exchanger inlet/outlet pipes (3). Connect the connector (2). Refit : - The accessories belt (see corresponding operation). - The front RH splash-shield (see corresponding operation). - The front RH road wheel, tighten to 9 1 m.daN. Reconnect the battery.
B1BP2N0C
158

Engines : 8HY - 8HV Setting the timing.
C3
Perform the preliminary operations for checking the timing up to removing tool [1] at a for immobiling the engine flywheel. Refit screw (8). Rotate the crankshaft to bring the camshaft towards its pegging point. Peg the camshaft, using tool [2]. (Oil the pegs). WARNING: Do not press or damage the track which is the target for the engine speed sensor (14). Peg the crankshaft at b, using tool [3]. Remove: - The timing protector (13). - The engine speed sensor (14). Slacken the screw (12) of the tensioner roller, keeping it slack with the aid of a hexagonal spanner at c. Detension the belt by pivoting the tensioner roller (clockwise). Remove the timing belt, commencing with the coolant pump pinion. Peg the pulley (15), using a 5 mm diameter peg at d.
B1EP18VD
159
ENGINE
ENGINE
C3

Engines : 8HY - 8HV Setting the timing (continued). Checking the setting. IMPERATIVE : Just prior to refitting, carry out the following tests: Check that: - the rollers and the coolant pump operate freely (no play and no tight spot). - there are no traces of oil (from the crankshaft and camshaft sealing rings). - there is no leak of coolant fluid (from the coolant pump). - the target track of the engine speed sensor (14) is not damaged or scratched. (If necessary replace the defective components). Refitting Fit the timing belt on the crankshaft pinion. Position the belt on the guide roller, with the belt well tensioned. Refit: - The timing protector (13). - The sensor (14). 160
B1EP18WD

Engines : 8HY - 8HV Setting the timing (continued). Checks (continued).
C3
Reposition the timing belt, belt at e well tensioned, in the following order: - Guide roller (17). - Camshaft pulley (16). - Fuel high pressure pump pulley (15). - Coolant pump pinion (18). - Tensioner roller (19). Remove the 5 mm diameter peg at d. Adjusting the fitting tension of the belt. Action the tensioner roller (19) to align the marks f and g, avoiding detensioning the timing belt, with the aid of a male hexagonal spanner, at c. If this is not successful, repeat the operation to tension the belt. Hold the tensioner roller in position (19). Tighten the tensioner roller, tightening to 3,7 0,3 m.daN. Check the position of the tensioner roller (the alignment of the marks f and g should be correct). Remove tools [2] and [3]. Turn the crankshaft six rotations (clockwise).
B1EP18XC
161
ENGINE
ENGINE
C3

Engines : 8HY - 8HV Adjusting the timing belt tension (continued). IMPERATIVE : Never rotate the engine backwards. WARNING : Do not touch or damage the track of the target of the engine speed sensor (14). Peg the crankshaft, using tool [3]. Check the position of the tensioner roller (the alignment of the marks f and g should be correct). If this is not the case, repeat the operation to tension the belt. Peg the camshaft pulley, using tool [2]. IMPERATIVE : Should it be impossible to peg the camshaft, check that the offset between the camshaft hole and the pegging hole is not more than 1 mm. If the offset is too great, repeat the operation. Remove the pegs [2] and [3]. Refit tool [1] at a. Remove the screw (8). Complete the refitting.
B1EP18XC
162

Engines : 6FZ - RFN # 2003
TOOLS [1] Camshaft setting pegs : (-).0189.A [2] Crankshaft setting peg : (-).0189.B Tool kit C.0189. [3] Belt locking pin : (-).0189.K [4] Angular tightening adaptor : 4069-T. [5] Hub immobilising tool : 6310-T 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. 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).
B1BP27JC B1BP25PC B1BP23XC B1EP14JD
163
ENGINE
ENGINE

Refit - Refit the belt (10) on the pinion (12). - Hold the belt (10) with tool [3]. - Position the belt (10) in the following order : - The guide roller (11), the inlet camshaft pinion (9), the exhaust camshaft pinion (8), the water pump (5), the tensioner roller (6). 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 B1EP14KC
164

Engines : 6FZ - RFN # 2003 Adjusting the tension (continued). - Tighten the screw (7) of the the tensioner roller (6) to 2.1 0.2 m.daN.
IMPERATIVE : The hexagonal drive of the tensioner roller (6) must be at 15 below the level of the cylinder head gasket g. If not, replace the tensioner roller (6) or the timing belt and the tensioner roller (6). Refit (continued). - Remove the tools [1] et [2]. - Turn the crankshaft 10 times in the normal direction of rotation. IMPERATIVE : No pressure or outside action must be brought to bear on the timing belt. - Peg the inlet camshaft pulley, using the tool [1]. Checks. Timing belt tension. IMPERATIVE : Check the position of the index c, it should be facing the notch f. If the position of index c is not correct, restart the adjustment of its position. Positioning of the crankshaft. - Fit tool [2]. - As long as it is possible to fit tool [2], continue with the refit operations. IMPERATIVE : If it is not possible to fit tool [2], reposition the flange (14).
B1EP14MC B1EP14VC
165
ENGINE
ENGINE

Checks (continued) Repositioning the flange - Immobilise the crankshaft using tool [5]. - Loosen the screw (13). - Release the pinion (12) of the crankshaft. - Bring the flange (14) to the pegging position; using tool [5]. - Fit the tool [2]. - Immobilise the crankshaft using tool [5]. - Tighten screw (13) to 4 0.4 m.daN, then angular tighten : 53 4 (fitting with steel washer, gold colour) 40 4 (fitting with sintered washer, metallic colour) using tool [4]. - Remove tools [1], [2] and [5]. Refit : - The lower valve cover (3). - The upper valve cover (4). - The crankshaft pulley (1). - The screws (2). - Pretighten the screws (2) to 1.5 m.daN. - Tighten the screws (2) to 2.1 0.5 m.daN. 166
B1EP14PC
B1EP14JD
B1BP23XC

Engine : RFN # 2003 Tools. [1] Crankshaft setting peg : (-).0189-B [2] Camshaft hub setting pegs : (-).0189-AZ [3] Belt locking pin : (-).0189-K [4] Positioning peg : (-).0189-J [5] Hub immobilising tool : (-).6310-T Removing. Disconnect the battery. Remove: - The under-engine shield. - The accessories drive belt (See corresponding operation). Move aside : - The fuel delivery pipe. - The canister purge electrovalve. - The expansion chamber Remove : -The screws (1) and (2). - The torque reaction rod (3). - The screws (4), plus the accessories drive pulley. - The timing cover (5) and (6). WARNING : Do not slacken the fixing screws (A). 167
B1EK1UDD B1EK1T7D
B1EK0V7D
ENGINE
ENGINE

Engine : RFN # 2003
Removing (continued). Peg : - The camshafts, using tool [2]. - The crankshaft, using tool [1]. Slacken screw (7), holding tool [4]. Using the hexagonal key (C), turn the eccentric hub (8) of the tensioner roller (9) (clockwise), to detension the belt. The cursor (10) presses on the tool [4]. Remove the timing belt.
B1EK1UED
B1EK1UFD
168

Engine : RFN Refitting. Systematically replace the timing belt.

# 2003
IMPERATIVE : Check that the rollers (9) and (11), as well as the coolant pump (12), turn freely (no tight spot). If replacing the roller (11), tighten the fixing to 3,5 0,3 m.daN. Engage the belt on the crankshaft pinion (13), respecting its direction of fitting. Immobilise the belt, using tool [3]. Refit the timing belt, well tensioned, in the following order : - Guide roller (11). - Pinions (14) and (15). - Coolant pump (12). - Tensioner roller (9).
B1EK1T8D
169
ENGINE
ENGINE

Engine : RFN # 2003
B1EK1T9D
Fitting tension of the timing belt. Remove the tool [3]. (D) : Maximum position. (E) : Nominal tension position. Using the hexagonal key (C), turn the hub of the roller (anti-clockwise), to bring the index (10) to position (D) so as to tension the belt to the maximum. Turn the eccentric hub (8) of the roller (9) (clockwise), until the cursor (10) just comes into contact with the peg [4]. IMPERATIVE : Never turn the eccentric hub (8) by a complete rotation if the tool [4] is in position. NOTE : This operation enables you to place the index (10) in the nominal position (E). Tighten the screw (7) to 2 0,2 m.daN holding the roller with the aid of the hexagonal key (C). Remove pegs [1], [2] and [4]. Checks. Turn the crankshaft by two rotations (direction of engine rotation). IMPERATIVE : Never rotate the crankshaft backwards. Make sure that the timing is correctly set by refitting the pegs [1] and [2]. Remove pegs [1] and [2]. Rotate the crankshaft ten times (direction of engine rotation). Check the position of the index (10). If the tensioner index is not at its adjusting position (E), recommence the operation to tension the timing belt.
B1EK1TAD
170

Engine : RFN Position of the crankshaft. # 2003
NOTE : This operation enables you to position all the pegs in their respective pegging points. Peg : - The camshaft pulleys, using tool [2]. - The crankshaft, using tool [1]. If this should not be possible, reposition the flange (17).
B1EK1TBD
IMPERATIVE : This operation guarantees the setting of the timing for subsequent operations. Slacken the screw (16) so as to free the pinion (17) of the crankshaft. Bring the flange (17) to the pegging point, using tool [5]. Position the tool [1]. Tighten the screw (16) to : (Tool FACOM D360). Tighten to : 4 0,4 m.daN Angular tighten : 53 5 Remove tools [1], [2] and [5]. ESSENTIAL : When tightening screw (16), hold the pulley (17) by means of tool [5].
B1EK1TCD
171
ENGINE
ENGINE

Engine : RFN # 2003
Refitting (continued). Refit : - The timing cover (6). - The accessories drive pulley.
B1EK0V7D
- Screws (4), tighten to 2,1 0,2 m.daN. - The timing cover (5). - The torque reaction rod (3). - Screws (1) and (2), tighten to 4,5 0,4 m.daN. Refit the accessories drive belt (See corresponding operation). Continue the refitting operations in reverse order to removal.
B1EK1T7D
172

OLD FITTING # 2003 (1) Crankshaft pinion. (2) Flange. (3) Accessories drive pulley. (4) Screw fixing accessories drive pulley on flange (2). (5) Screw fixing the flange (2) on the crankshaft. a Integral keyway. b Keyway slot. Engines : 6FZ - RFN

# 2003
The timing belt drive pinion (1) is separate from the flange (2). With the fixing screw (5) of the flange (2) not slackened, the pinion (1) floats within the limit of travel of the integral keyway a in the keyway slot b. NOTE : The flange is immobilised on the crankshaft by a half-moon keyway and by the screw (5).
B1EP1B8D
173
ENGINE
ENGINE

NEW FITTING 2003 #

Engines : 6FZ - RFN 2003 # (6) Crankshaft pinion. (7) Accessories drive pulley. (8) Washer. (9) Screw. The pinion (6) is fitted as an idler on the crankshaft. The accessories drive pulley (7) is immobilised on the crankshaft by a half-moon keyway and by the tightening of washer (8) and screw (9). A : Pegging on manual gearbox. B : Pegging on automatic gearbox.
B1EP1B9D
The pegging of the crankshaft is done on the flywheel, or on the converter drive plate (automatic gearbox). The pegging hole on the cylinder block (exhaust end) is calibrated and reinforced. IMPERATIVE : Never turn the crankshaft with the accessories drive pulley slackened. IMPERATIVE : Never remove the accessories drive pulley without pegging the crankshaft and the camshafts. IMPERATIVE : Always turn the crankshaft in the direction of engine rotation.
B1BP2V2D
174

Engines : 6FZ - RFN Tools. [1] Camshaft setting peg [2] Crankshaft setting peg [3] Timing belt retaining pin [4] Adaptor for angular tightening [5] Tool for moving and locking the tensioner roller [5a] [5b] Pliers for removing plastic pins Checking the setting of the timing Removing. Disconnect the battery negative terminal (See corresponding operation). Raise and support the vehicle, front wheels hanging. Remove : The front RH wheel. The plastic pins (1). The splash-shield (2). The upper timing cover.
C4AP12TC

2003 #
: : : : : : : :
(-) 0189.A (-).0189.R (-).0189.K 4069-T (-).0189.S (-).0189.S1 (-).0189 S2 7504-T
175
ENGINE
ENGINE

NEW FITTING # 2003

Engines : 6FZ - RFN Checking the setting of the timing (continued). Turn the engine by means of the crankshaft pinion screw, to bring it to the pegging position. Peg the crankshaft, using tool [2]. Peg the camshaft pulleys, using tool [3].
B1BP2V5D
2003 #
WARNING : If the pegs go in only with difficulty, repeat the operation for fitting and tensioning the timing belt (See corresponding operation). Refitting. Remove tools [2] and [3]. Complete the refitting in reverse order to removal.
B1EP1BAC
176

Engines : 6FZ - RFN Setting the timing. 2003 #
Removing. Disconnect the battery negative terminal (See corresponding operation). Raise and support the vehicle, front wheels hanging. Remove: The front RH wheel. The plastic pins (1). The splash-shield (2). The accessories drive belt (See corresponding operation). Unclip and move aside the fuel delivery hose from the timing cover. Remove the upper timing cover (1). Turn the engine by means of the screw (3) of the crankshaft pulley (2) to bring it to the pegging position.
B1BP2V4C
177
ENGINE
ENGINE

Engines : 6FZ - RFN Setting the timing (continued) Peg: The crankshaft, using tool [2]. The camshaft pulleys (5) and (6), using tool [1]. Remove: The screw (3) of the crankshaft pulley (2). The lower timing cover (4) (by moving the engine). IMPERATIVE : Never remove the crankshaft pulley (2) without pegging the crankshaft and the camshafts. Slacken the screw (9) of the tensioner roller (8). Turn the tensioner roller (8) (clockwise). Remove the timing belt (7). 2003 #
B1BP2V5D
B1EP1BBD
178

Engines : 6FZ - RFN

2003 #
Setting the timing (continued) Turn the tensioner roller (8), using tool [5a] to go beyond slot (b). Position the tool [5b] to lock the index (a) and remove the tool [5a]. Reposition the timing belt (7) on the crankshaft pulley. Hold the timing belt (7) in place using tool [3]. Fit the timing belt (7) in place, respecting the following order : - Guide roller (10). - Inlet camshaft pulley (6). - Exhaust camshaft pulley (5). - Coolant pump (11). -Tensioner roller (8). NOTE : Make so that the belt (7) is as flush as possible with the exterior face of the various pinions and rollers. Remove : Tool [3]. Tool [1] from the exhaust camshaft pulley. Tool [5b] from the tensioner roller (8). Refit : The lower timing cover (4) (by moving the engine) The crankshaft pulley (2). Screw (3) of the crankshaft pulley Tighten screw (3) to 4 0,4 m.daN, then angular tighten to 53 4, tool [4].
B1EP1BCD B1EP1BDC
179
ENGINE
ENGINE

Engines : 6FZ-RFN 2003 #
Tensioning the timing belt. Turn the tensioner roller (8) in the direction of the arrow c , by means of a hexagonal spanner at d . Positionner lindex a en poition f . IMPERATVE : The index a should go past the slot g by an angular value of 10. If it does not, replace the tensioner roller or the timing belt and tensioner roller assembly. Next bring the index a to its adjusting position g , by turning the tensioner roller in the direction of the arrow e . WARNING : the index a should not pass the slot g . Otherwise, repeat the operation to tension the timing belt. IMPERATIVE : The tensioner roller should not turn during the tightening of its fixing. If it does, repeat the operation to tension the timing belt. Tighten the screw (9) of the tensioner roller (8) to 2,1 0,2 m.daN. IMPERATIVE : The hexagonal tensioner roller drive should be approx. 15 below the level of the cylinder head gasket h . If it is not, replace the tensioner roller or the timing belt and tensioner roller assembly.
B1EP1BEC
B1EP1BFC
180

Engines : 6FZ - RFN Refitting (continued) Remove the tools [1] and [2]. Rotate the crankshaft ten times (normal direction of rotation). 2003 #
IMPERATIVE : No pressure or outside force should be brought to bear on the timing belt. Peg the inlet camshaft pulley, using tool [1].
B1EP1BEC
Checks. Tension of the timing belt. ESSENTIAL : Check the position of the index a , which should be opposite the slot g . If the position of the index a is not correct, repeat the operations to tension the timing belt. Refit the upper timing cover (1). Clip the fuel delivery hose on the timing cover. Refit the accessories drive belt (See corresponding operation). Lower the vehicle. Reconnect the battery (See corresponding operation).
B1EP1BFC
181
ENGINE
ENGINE
XSARA

Engine : 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 B1EP12GC
182

Engine : RFS Setting the valve timing.
XSARA
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 : - The - The - The - The peg [3]. screw (4) (Brush the screw thread). pulley (5). lower cover (6).
Remove : - The tool [6]. - The studs (8). - Fit the tool [4]. - Loosen the screws (10). - Remove the tool [4]. - Slacken the tensioner roller (7). - Remove the belt (9).
B1EP120C
B1EP11ZC
183
ENGINE
ENGINE
XSARA

Engine : RFS Pretensioning the timing belt. - Peg the crankshaft using the tool [3]. - Peg the camshaft pulleys using the tool [2]. NOTE : Ensure that the camshaft pulleys rotate freely on the hubs. Clean the contact faces of the pulleys and hubs. - Turn the camshaft pulleys in a clockwise direction to bring them to the end of the slots. - Fit the belt (9). - Fit the tool [1]. Turn the roller (7) using the tool [5]. - Pre-tension to : (Pulleys slackened). Engine New belt RFS 55 SEEM units
- Tighten the screws of the roller (7) to 2 m.daN. - Fit the tool [4]. - Tighten the screws (10) to 4 m.daN. - Remove the tools. - Rotate the crankshaft by six turns (Normal direction of rotation).
B1EP12OC B1EP121C
184

Engine : RFS
XSARA
Tensioning the timing belt. - Peg the crankshaft using the tool [3]. - Peg the camshaft pulleys using the tool [2]. NOTE : If it is not easy to peg the camshaft hubs, loosen the tensioner roller (7), and turn the camshafts using the screw (10). - Fit the tool [4]. - Loosen the screws (10). - Remove the tool [4]. - Loosen the tensioner roller (7). - Fit the tool [1] to the belt. - Turn the roller (7) using the tool [5].
B1EP120C
B1EP121C
185
ENGINE
ENGINE
XSARA

Engine : RFS
- Tension to : (Pulleys slackened). Engine New belt Engine : 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.
B1EP120C B1EP121C
186

Engine : WJY TOOLS
XSARA
[1] HM screw [2] Locating peg 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 ( or 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
187
ENGINE
ENGINE
XSARA

Engine : WJY Setting the valve timing Peg : - The camshaft hub (1), using tool [1]. - The injection pump pinion (2), using tool [2]. - The flywheel, using tool [3]. - Lock the flywheel, using tool [4]. - Refit the screw (3) (without tightening it). (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 B1EP131C B1CP045C B1EP132C
188

Engine : WJY Setting the valve timing (continued) NOTE : If necessary, slightly turn pinions (6) and (2) in an anti-clockwise direction in order to fit the belt. The angular movement of the belt in relation to the pinions must not exceed half a tooth. - 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.
XSARA
- 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 B1EP134C B1CP045C B1EP132C
189
ENGINE
ENGINE
XSARA

Engine : WJY
Setting the valve timing (continued) Rotate the crankshaft by 8 turns (direction of rotation). Peg : - The hub (1), using tool [1]. - The pinion (2), using tool [2]. - The flywheel, using the tool [3].
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
B1EP134C
B1CP045C
190

Engine : WJY Setting the valve timing (continued) Tighten : - The roller (9) to 2.1 m.daN. - The screws (4) and (5) to 2.3 m.daN. - Remove the tool [7]. - Fit the tool [7] to the belt strap at "a". - The tensioning value should be between 42 4 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.
XSARA
B1EP133C
B1EP134C
B1CP045C
B1EP132C
191
ENGINE
ENGINE

Engines : RHY-RHZ # N RPO 9127
Tools Belt tension measuring instrument : 4122-T Tension lever : (-).188.J2 Engine flywheel peg : (-).188.X Belt retaining pin : (-).0188.K Camshaft pinion peg : (-).0188.M Engine flywheel lock : (-).0188.F Set of blocking plugs : (-).0188.T Crankshaft pulley extractor : (-).0188.P Checking the setting of the valve timing. Peg : The engine flywheel, tool [3] (from below the vehicle). The camshaft, tool [5]. WARNING : On removing the screws (6), (7), (9), and (5) from the timing cover, refit screw (5) equipped with a spacer (thickness 17 mm) Tighten to 1,5 0,1m.daN. (Screw (5) is one of the fixing screws for the coolant pump and is used for its sealing). WARNING : Should it be impossible to peg the camshaft, check that 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 7 mm screw. [1] [2] [3] [4] [5] [6] [7] [8] IMPERATIVE : If pegging is impossible, restart the adjusting. (See corresponding operation).
B1EP14AC B1BP282C B1EP152D B1BP1YSC
192

Engines : RHY-RHZ

# N RPO 9127
Setting the valve timing. Peg : The engine flywheel, tool [3] (from below the vehicle). The camshaft, tool [5]. Slacken : The three screws (21). The screw (19) of the tensioner roller (20). Remove the timing belt (22). Checks. IMPERATIVE : Just before refitting, carry out the checks below : Check that : - the rollers (20), (23) and the coolant pump turn freely (without play or tightness). - there are no traces of oil (on camshaft or crankshaft) - there are no leaks of engine coolant (coolant pump). Replace defective components if necessary.
B1BP282C B1EP152D
193
ENGINE
ENGINE

Engines : RHY - RHZ # N RPO 9127
Setting the valve timing (continued) - Setting the valve timing (continued) - Retighten screws (21) by hand. - Turn the pinion (24) (clockwise) to the bottom of the buttonhole. - Refit the belt on the crankshaft (25), in the following order, using the tool [4] to keep the belt tight at a . - Guide roller (23). - Fuel high pressure pump pinion (26). - Camshaft pinion (24). - Coolant pump pinion (18). - Tensioner roller (20). NOTE : If needed, slightly turn the pinion (24) anti-clockwise (the offset should not be more than one tooth). - Remove the tool [4].
B1EP153D
B1EP154C
B1EP155D
194

Engines : RHY - RHZ

# N RPO 9127
Setting the valve timing (continued) Position tool [1] on the belt at b . Turn the roller (20) (anti-clockwise) using tool [2] to attain a tension of : 98 2 SEEM units Tighten the screw of the roller (19), tighten to 2.5 m.daN. Remove one screw (21) from the pinion (24). (to check that the screws are not against the end of the buttonhole). Tighten the screws (21) to 2 m daN. Remove tools [1], [2], [3] and [5]. Rotate the crankshaft 8 times (normal direction of rotation). Fit the tool [3]. Loosen screws (21). Fit tool [5]. Loosen screw (19) (to free the roller). Fit tool [1]. Turn the roller (20) (anti-clockwise), tool [2], to attain a tension of : 54 2 SEEM units.
B1EP156D
195
ENGINE
ENGINE

Engines : RHY - RHZ # N RPO 9127
Setting the valve timing (continued) Tighten : The screw of the roller (19) to 2.5 0.2 m.daN. The screw (21) to 2 0.2 m.daN. Remove the tool [1]. 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]. - Complete the refitting of components. 196
B1EP156D
SPECIAL FEATURES: CHECKING AND SETTING THE VALVE TIMING

Engines : RHY - RHZ OLD FITTING # N RPO 9127 N RPO 9128 #
NEW FITTING N RPO 9128 #
(1) ) Idler camshaft pulley (2) Target for cylinder reference sensor. (3) Camshaft hub. (4) Fixed crankshaft pinion. The determining of the tension of the timing belt is done on the camshaft pulley (1).
The new timing on 8 valve engines DW10TD (RHY) and DW10 ATED (RHS-RHZ) requires the following components : Idler crankshaft pinion Fixed camshaft pulley. (5) Fixed camshaft pulley (pulley with integral cylinder reference sensor target). (6) Idler crankshaft pinion (with increased width keyway groove). The determining of the tension of the timing belt is done on the crankshaft pinion (6). 197
B1EP176D
B1EP177D
ENGINE
ENGINE
SPECIAL FEATURES: CHECKING AND SETTING THE VALVE TIMING

Engines : RHY - RHZ N RPO 9128 # NEW FITTING : RPO 9128 # (continued) The new fitting discontinues the following components : Camshaft hub. Cylinder reference sensor target. Repair Accessories drive pulley Remove Refit WARNING : Peg the camshaft and the crankshaft before ever removing the accessories drive pulley (the pegging prevents any offsetting of the camshaft). If necessary, apply a paint spot to mark the accessories drive pulley being replaced. Replacement parts. The Replacement Parts service markets the old as well as the new components.
B1EP177D
198

Engines : RHY - RHZ Tools. [1] Belt tension measuring equipment [2] Tension lever [3] Engine flywheel peg [4] Belt clamp [5] Camshaft pulley peg [6] Engine flywheel lock [7] Set of blocking plugs [8] Pulley extractor [9] 2 mm dia.peg : 4122-T : (-).0188.J2. : (-).0188.Y. : (-).0188.AD : (-).0188.M : (-).0188.F. : (-).0188.T. : (-).0188.P. : (-).0188.Q2 N RPO 9128 #
Removing IMPERATIVE : Respect the safety and cleanliness requirements that are specific to high pressure diesel injection (HDi) engines. Undo the front RH wheel bolts. Raise and support the vehicle on the front RH side. Disconnect the battery negative terminal. Remove : The under-engine sound-deadening. The front RH wheel. The front RH splash-shield. The engine cover. Unclip and move aside the cooling hose. Remove the accessories drive belt. (See corresponding operation).
199
ENGINE
ENGINE

Engines : RHY - RHZ N RPO 9128 #
Uncouple, plug and move aside, using tool [7] , the fuel delivery pipe (2) and return pipe (1) . Remove : Screws (3), (4 ) and (6) . Screw (7) . The upper timing cover (5). WARNING : Refit screw (7) equipped with a spacer ( 17 mm thick), tighten the screw (7) to 1,5 0,1 m. daN. NOTE : The screw (7) is one of the screws securing the coolant pump and is there for its sealing. Put the gear lever in 5th gear. Turn the road wheel to turn the engine in its direction of rotation. Orient the camshaft pulley in the pegging position, use a mirror if necessary. Peg the camshaft, using tool [5] . Peg the engine flywheel, using tool [3] .
B1BP2R2C B1EP1A7C
B1BP2H2C B1BP2H3C
200

Engines : RHY - RHZ N RPO 9128 #
Remove : The fixings of the pipe linking the power steering pump with the rotary valve. The clutch lower closing plate. Lock the engine flywheel, using tool [6]. Remove the screw (8). Refit the screw (8) without its thrust washer. Remove : The accessories pulley (9), using tool [8]. Tool [6]. The lower torque reaction rod. Support the engine by means of a workshop hoist. Remove : The bearing shell fitting (10). The nut (12). Screws (11). The bracket (13). NOTE : Lift then lower the engine with the workshop hoist, to have access to the timing cover fixing screws. Remove : The intermediate timing cover. The lower timing cover.
B1CP04BC B1BP2R3C B1BP2R4C
201
ENGINE
ENGINE

Engines : RHY - RHZ Slacken the screw (17) of the tensioner roller (18). Remove the timing belt (14). Checks. IMPERATIVE : Just before refitting, carry out the checks below : Check that : The rollers (18) and (15) turn freely (without play and without any tight spot). The coolant pump pulley (16) turns freely (without play and without any tight spot). There are no traces of oil leaks from the crankshaft and camshaft seals, etc. The crankshaft pinion travels freely on the keyway. Replace defective components if necessary. Peg the crankshaft pinion (19) by inserting tool [9] on the LH side of the keyway. N RPO 9128 #
B1EP1A8D
B1EP1A9C
202

Engines : RHY - RHZ

N RPO 9128 #
Reposition the timimg belt, belt at a well tensioned, in the following order : Fuel high pressure pump pulley (21). Guide roller (15). Crankshaft pinion (19). Coolant pump pinion (16). Tensioner roller (18). Position tool [1] on the belt at a. Remove tools [4] and [9]. Turn the tensioner roller (18) anti-clockwise, using tool [2], to attain an overtension of : 98 2 SEEM units. Tighten screw (17) of the tensioner roller to 2,5 0,2 m.da N. Lock the flywheel by means of tool [6]. Tighten the accessories drive pulley screw (8) to 7 0,7 m.da N. Remove tools [1], [3], [5] and [6]. Rotate the crankshaft eight times in the normal direction of rotation. Peg : The crankshaft, using tool [3]. The camshaft drive pulley, using tool [5].
B1EP1ABD
B1EP1ACC
203
ENGINE
ENGINE

Engines : RHY - RHZ N RPO 9128 # Lock the engine flywheel, using tool [6] . Slacken : The accessories drive pulley (8) . The screw (17) of the tensioner roller (18) . Fit the tool [1] . Turn the tensioner roller, using tool [2 ], to attain a tension of : 54 2 SEEM units . Tighten screw (17) of the tensioner roller (18) to 2,5 0,2 m.daN . Remove tool [1] . Fit tool [1] . The tension value should be : 54 3 SEEM units . ESSENTIAL : If the value is incorrect, recommence the operation. Remove tools [1], [3], [5] and [6] . Rotate the crankshaft two times in the normal direction of rotation. Peg : The crankshaft, using tool [3] . The camshaft drive pulley. IMPERATIVE : If the pegging is not possible, recommence the operation.
B1EP1ACC
204

Engines : RHY - RHZ N RPO 9128 # Remove : Tools [3] and [5] . Screw (7) and the spacer. Refit : The lower, intermediate and upper covers (5) . Screw (7), tighten to 1,5 0,1 m.daN. Screws (3) , (4) and (6) . The bracket (13) . Screws (11), tighten to 6,1 0,5 m.daN. The nut (12), tighten to 4,5 0,5 m.daN. Fit the bearing shell (10) . Take away the workshop hoist. Clip the fuel delivery and return pipes. Remove the tool [7] . Couple : The fuel delivery pipe (12) . The fuel return pipe (1) . Coat the screw (8) with loctite FRENETANCH . Refit the tool [6] and the screw (8) with the washer (22) , Tighten to 7 0,2 m.daN and angular tighten to A = 60 5 Refit the torque reaction rod on the lower engine support. Remove the tool [6] . Reposition and reclip the cooling hose. Complete the refitting of components in reverse order to removal.
B1EP1A7C B1BP2R4C
B1EP1ADC
205
ENGINE
ENGINE
XSARA
SPECIAL FEATURES OF THE TIMING

Camshaft hub identification RFS
Engine RFS
Hubs Inlet Exhaust
a engraving B
b paint marking BLUE
B1EP122C
206
VALVE CLEARANCE SETTINGS

The valve clearances must be checked with the engine cold G Inlet Petrol All Types (except 16V - NFU) NFU Petrol - 16V 1.4 HDi 1.4 16V HDi 2.0 HDi Diesel All Types (except: 1.4 HDi 1.4 16V HDi 2.0 HDi) 0.20 mm 0.05 Exhaust 0.40 mm 0.05 1G 1 mm 0.05 1 mm 0.05 3G 4G 2G Hydraulic adjustment Engines without hydraulic adjustment : the clearance (J) should be checked opposite the cam. 1 4G 3 2G 4 1G 2 3G 4 2 1 3 G Exhaust
ALL TYPES
POSSIBLE PROCEDURES For engines with 4 cylinders in a line (1-3-4-2 ) Rocking Fully open (Exhaust)
Valves fully open
Rocking
Adjust Inlet
Adjust
3 G 4 G 2 G 1 G 4 2 1 3
1 3 4 2
0.15 mm 0.08
0.30 mm 0.08
B1DP13QC
207
ENGINE
ENGINE
ALL TYPES
Tools Tool kit 4103 -T 1.1 i Vehicle Engine type Temperature (C) Pressure (Bars) Rpm 4 4000 3 2000 4 4000 3 2000 TT HFX C3 TT KFW
CHECKING THE OIL PRESSURE

To be read with the Petrol and Diesel correspondence tables TU all Types 1.4 i C3 KFV NFV 90 4 4000 DV4TED4 1.4 16V HDi 8HW 90 4 4000 > 1.3 1000 4.5 4000 8HV 8HY 3 2000 DW8 1.9 D WJY RHY 80 4 1.6 i TT NFT NFX 1.6 i 16V TT NFU C3 6FZ 90 4 4000 DW10TD 2.0 HDi RHZ EW 1.8 i 16V XU all Types 2.0 i 16V TT RFN RFS 80 5.5
TUD all Types 1.5 D Engine type Temperature (C) Pressure (Bars) Rpm VJX 8HX
DV4TD 1.4 HDi
208
OIL FILTERS
TU All Types 1.1 i HFX FILTRAUTO PURFLUX LS 867 B LS 923 TUD5 1.5 D VJX MALHE PURFLUX LS 923 LS 867 B 1109 N3 Diameter (mm) Specification LS 923 LS 867 B 1109 T1 1109 N3 76 Height (mm) 89 8HX DV4TD 1.4 HDi 8HW 8HZ 1109 T3 DV4TED4 1.4 16V HDi 8HV 8HY DW8 1.9D WJY KFW 1.4 i KFV NFT 1109 R7 1.6 i NFV 1.6i 16V NFX NFU 1.8i 6FZ EW
ALL TYPES
XU 2.0i 16V RFN RFS
1109 N3 1109 T1 DW10 2.0 HDi RHY RHZ
1109 T1
TU engine (except L4) : The PURFLUX LS 867 filter is still available. EW and DW engines : The PURFLUX LS 304 filter has been replaced by the PURFLUX LS 923 filter. 209
ENGINE
ENGINE
ALL TYPES
[1] Filling cylinder [2] Adaptor for filling cylinder
FILLING AND BLEEDING THE COOLING CIRCUIT

TOOLS : 4520-T : 4222-T.
IMPERATIVE : Respect the safety and cleanliness requirements. - The draining and refilling operations can be carried out using WINNS or similar coolant fluid replacement equipment; it is essential to follow the instructions as stated for that equipment. Filling and bleeding - Fit the cylinder adaptor [2] 4222-T (Picasso and C3) and the filling cylinder [1] 4520-T (all types). - Use the coolant to ensure protection between - 15C and - 37C. - Slowly fill the system. NOTE : Keep the cylinder filled up (visible level). - Close each bleed screw as soon as the coolant flows without air bubbles. - Start the engine : Engine speed 1500 rpm . - Maintain this speed until the first cooling cycle (cooling fans cut in and cut out). - Stop the engine and allow it to cool down. - Remove the filling cylinder [1] 4520-T (all types) and the cylinder adaptor [2] 4222-T . - Top up the system to the max . mark, with the engine cold. - Refit the filler cap. 210
B1GP00AC E5AP1GNC
IDLING - DEPOLLUTION
Vehicles Engine type Emission standard L4 L4 L4 L4 L4 -IF/L5 L4 - IF/L5 L4 IFL5/L4 L4 L4 L3 L4 L4 Make - Injection type Man. gbox BOSCH M7.4.4. SAGEM 2000 BOSCH M7.4.4. M. MARELLI 48P2 MAGNETTI MARELLI 48P SAGEM S2000 BOSCH M 7.4.4. SAGEM S2000 BOSCH M.7.4.4. MAGNETTI MARELLI MM 48.P2 M. MARELLI 1AP10 BOSCH M7.4.4. SAGEM - S2000 211 850 700 850 850 800 850
SAXO - C3 - XSARA PICASSO

Idling speed ( 50 rpm) Auto. gbox : N gear engaged % Content CO CO2 INJECTION < 0.5 >9 < 0.5 >9
1.1 i SAXO 1.4 i 1.6 i 1.6 i 16V 1.1 i C3 1.4 i 1.6 i 16V 1.4 i C3 1.6i 2.0 i 2.0 i 16V XSARA PICASSO 1.6i 1.8i
HFX KFW NFT NFX HFX KFW NFU KFW NFU RFN RFS NFV 6FZ
SAXO
PETROL INJECTION
SAXO 1.1 i 1.4 i KFW L4 SAGEM S2000 3 5500 14.5 2 500 at 20 C 1.6 i NFT L4 BOSCH M.7.4.4. 3.5 5700 14.5 800 at 50 C 1.6 i 16 V NFX L4 M. MARELLI 48P2 3 6600 14.5 230 at 90 C
INJECTION
Engine type Emission standard Injection make and type Fuel pressure (bars) Overspeed cut-off (rpm) Injector resistive value (ohms) Engine coolant temperature sensor resistive value (ohms) Idling actuator or stepper motor resistive value (ohms) Air temperature sensor resistive value (ohms)
HFX IFL5 / L4 BOSCH M.7.4.4. 3 5500 14.5 3800 at 10 C
Idle actuator : 11 3800 at 10 C 2 500 at 20 C 212 800 at 50 C 230 at 90 C
PETROL INJECTION
C3 1.1i 1.4i 1.6i 16 V
C3
HFX L4 / IFL5 M. MARELLI 48P2 3.5 5500 14.5 3 800 at 10C 2500 at 20 C
KFW L4 SAGEM S2000 3.5 5500 14.5 800 at 50C
NFU L4 BOSCH M.7.4.4. 3.5 5800 14.5 230 at 90 C
Idle actuator : 53
3 800 at 10C
2500 at 20 C 213
800 at 50C
230 at 90 C
INJECTION

XSARA 1.4 i INJECTION
PETROL INJECTION
XSARA PICASSO 2.0 i 16 V RFS L4 M. MARELLI 1AP10 3 6500 16 800 at 50 C 1.6 i NFV L3 BOSCH M.7.4.4. 3.5 5700 14.5 1.8 i 16 V 6FZ IFL5 / L4 SAGEM S2000 3.5 5500 12.2 230 at 90 C
1.6 i 16 V NFU IFL5 / L4 / K BOSCH M.7.4.4. 3 5800 14.5 3800 at 10 C
2.0 i 16 V RFN IFL5 / L4 M. MARELLI 48P2 3.5 6000 12.2 2 500 at 20 C
KFW IFL5 / L4 SAGEM S2000 3 5500 14.5
Stepper motor: 53
3800 at 10 C
2 500 at 20 C 214
800 at 50 C
230 at 90 C
DEPOLLUTION TECHNICAL CHECKS (FRANCE)

All Types Petrol CO Corrected (In %) All Types Diesel (m-1)
ALL TYPES
01/96 #
Atmospheric engine.
With catalytic converter Greater than 2.0i 89 M.Y. All Types 93 M.Y. CO less than 0.5 % at idle speed. CO less than 0.3 % at fast idle speed between 2500 and 3000 rpm(*)
Less than 2.5 m -1 Turbocharged engine. Less than 3.0 m -1
Lambda Probe value 0,97 to 1,03.
215
INJECTION
Conditions : At idle, engine warm. # 01/96 Less than 4.5 % for vehicles registered before 10/86. Less than 3.5 % for vehicles registered after 10/86.
ALL TYPES
STANDARD E.E.C. PSA A/S RP Engines
EMISSION STANDARDS
APPLICATIONS Vehicles Applicable NOTES CHARACTERISTICS
INJECTION
10/89
ECE R 15.04 K K 15.04 15.04 Petrol Diesel Utility vehicles : All Types imminent
Utility vehicle limits = private vehicle limits increased by 25 % For private vehicles and utility vehicles in major export
With oxygen sensor, without catalytic converter
ECE R 15.05
W vp
15.05
Petrol
Private vehicles : > 2 litres new models existing models
01/10/88 01/10/89
Brussels directive 88/76 Luxembourg Accords Replaced by 89/458 + 91/441
216
EMISSION STANDARDS
STANDARD E.E.C. PSA A/S RP Engines APPLICATIONS Vehicles Applicable NOTES
ALL TYPES
CHARACTERISTICS
US 83
US 83
Petrol Diesel
Private vehicles : certain non-EEC European countries certain Export countries
Current
Adoption of the U.S

standard
With oxygen sensor and catalytic converter for petrol vehicles
US 87
US 87
Petrol Diesel
Current
Adoption of the U.S standard
With catalytic converter and EGR
US 93
Y2
US 93
Petrol Diesel
Private vehicles : certain Export countries
Current
Adoption of the U.S standard
217
INJECTION
ALL TYPES
STANDARD E.E.C. PSA A/S RP Engines
EMISSION STANDARDS
APPLICATIONS Vehicles Applicable NOTES CHARACTERISTICS
US 84 LDT
X1
US 84
Petrol Diesel
INJECTION
Current
Adoption of the U.S. standard for light utility vehicles
US 87 LDT
X2
US 87
Petrol Diesel
Current
US 90 LDT
X3
US 90
Petrol Diesel
Current
218
EMISSION STANDARDS
ALL TYPES
CHARACTERISTICS
EURO 2 (EURO 96) L3 CEE 95 Petrol Diesel
Private vehicles : < 6 seats and < 2.5 tonnes new models existing models
Brussels Directive 94/12 01/96 01/97
EURO 93 standard made stricter
With oxygen sensor and reinforced catalytic converter for petrol vehicles. With catalytic converter and EGR for diesel vehicles.
EURO 2 (EURO 96) W3 CEE 95
Petrol Diesel Gaz
Utility vehicles : < 3.5 tonnes Class 1 : new models existing models Class 2/3 : new models existing models
Brussels Directive 96/69 01/97 10/97 01/98 10/98 219
3 classes depending on
vehicle weight : Class 1 < 1250 kg Class 2 : 1250/1700 kg Class 3 : 1700 kg
With oxygen sensor and reinforced catalytic converter for petrol vehicles. With catalytic converter and EGR for diesel vehicles.
INJECTION
ALL TYPES
STANDARD E.E.C. PSA A/S RP Engines Vehicles Utility vehicles : INJECTION < 3.5 tonnes EURO 3 (EURO 2000) W3 Petrol Diesel Gaz Class 1 : new models existing models Class 2/3 : new models existing models
EMISSION STANDARDS
APPLICATIONS Applicable NOTES CHARACTERISTICS
01/2000 01/2001 01/2001 01/2002
Brussels Directive 98/69 EURO 2 standard (L3) made stricter Fiscal incentives 3 classes depending on vehicle weight : Class 1 < 1305 kg Class 2 : 1305/1760 kg Class 3 : 1760 kg
With 2 oxygen sensors and catalytic converter for petrol vehicles. With catalytic converter and EGR for diesel vehicles. With EOBD on-board diagnosis.
Private vehicles : All Types EURO 4 IF / L5 Petrol new models existing models
01/2005 01/2006
With 2 oxygen sensors Brussels Directive 99/102 and catalytic converter for EURO 3 standard (L4) made petrol vehicles. stricter With EOBD on-board Fiscal incentives diagnosis.
220
EMISSION STANDARDS
ALL TYPES
CHARACTERISTICS
EURO 4 IF / L5
Petrol Diesel Gaz
Private vehicles : All Types new models existing models
01/2005 01/2006
Brussels Directive: 2001/1 EURO 3 standard (L4) made stricter Fiscal incentives
With 2 oxygen sensors and catalytic converter for petrol vehicles. With EOBD on-board diagnosis.
Utility vehicles : < 3.5 tonnes EURO 4 IF / L5 Petrol Gaz Class 1 : new models existing models Class 2/3 : new models existing models
01/2005 01/2006 01/2006 01/2007

221
Brussels Directives: 99/102 et 2001/1 (Gas) EURO 3 standard (L4) made stricter Fiscal incentives 3 classes depending on vehicle weight : Class 1 < 1305 kg Class 2 : 1305/1760 kg Class 3 : 1760 kg
With 2 oxygen sensors and catalytic converter for petrol vehicles. With EOBD on-board diagnosis.
INJECTION
SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM

Engines : RHY - RHZ - 8HX - 8HW - 8HY - 8HV
SAFETY REQUIREMENTS Preamble. All interventions on the injection system must be carried out to conform with the following requirements and regulations : - Competent health authorities. - 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.
INJECTION
222
SAFETY REQUIREMENTS : HDI DIRECT INJECTION SYSTEM

Engines : RHY - RHZ - 8HX - 8HW - 8HY - 8HV CLEANLINESS REQUIREMENTS. Preliminary operations IMPERATIVE : The technician should wear clean overalls.
Before working on the injection system, it may be necessary to clean the apertures of the following sensitive components : (refer to corresponding procedures). - 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.
223
INJECTION
SAXO
Emission standards Equipement INJECTION SAXO TUD 5B VJX
BOSCH INJECTION PUMP SPECIFICATIONS

PUMP -TYPE - REFERENCE L3/L4 Transponder 539
(*) = The fuel high pressure pump is driven by the timing belt.
224
BOSCH INJECTION PUMP SPECIFICATION

Static timing Engine type Pump Type Reference Initial advance Compression Time (cylinder N 4) Dynamic timing checking (at idle) Reference Injector holder + injector Colour code Injector needle lift pressure (Bar) Adjustments (rpm) Fast idling Antistall
SAXO
Max. speed Unladen rpm Laden rpm
Injector
Idling
VJX
539
Pump 0,60 0,1 mm After BDC
299
KCA 20S106
120 5
No
800 100
5450 160
5000 160
(1) = Engine : TDC peg hole
225
INJECTION
SAXO
CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP

Engine : VJX Tools - Flywheel locating peg - Mounting plate locating peg - Camshaft peg : 4507-T.A : 4527-T.S1 : 4527-T.S2
INJECTION
B1HP0YAC
Tool kit 4507-T
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.
226
ADJUSTING THE MECHANICAL CONTROLS OF THE BOSCH INJECTION PUMP

Engine : VJX
SAXO
ADJUSTING THE FAST IDLE SPEED. - Bring the lever (3) into contact with the screw (2). - Use the screw (2) to obtain the fast idle speed : 1100 100 rpm. Engine cold. - Ensure that the lever (3) is up against the screw stop (2). - If not, slightly tension the cable (4) using the cable clamp (1). - Finish tensioning with the sheath tensioner (5). Engine hot. - Ensure that the cable (4) is slack. - Check the operation of the thermostatic sensor on the coolant outlet housing : there should be a minimum 6 mm cable travel between a cold and a hot engine. - If not, replace the thermostatic sensor. Tighten to 2.5 m.daN. INJECTION
B1HP0HQC B1HP0HUC
227
SAXO

Engine : VJX (continued) ADJUSTING THE ACCELERATOR CONTROL. - Fully depress the accelerator pedal. - Check that the lever (10) is against the stop screw (6). If not, modify the position of the spring clip (7). - Check that, at idle, the lever (10) is against its stop (9).
INJECTION
B1HP0HSD
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).
228

Engine : VJX (continued)
SAXO
ANTI-STALL ADJUSTMENT. - Insert a 1 mm shim [1] between the throttle lever (10) and the residual output adjustment screw (9). - Turn the residual output adjustment screw (9) to obtain an engine speed of: 835 40 rpm. - Remove the shim [1]. CHECKING THE ENGINE DECELERATION. - Move the throttle lever (10) to obtain an engine speed of 3000 rpm. - Release the throttle lever (10). - The deceleration should be between 2 and 3 seconds. ESSENTIAL : Check the operation of the manually-operated STOP control (11). INJECTION
B1HP0HRD
229
SAXO
FITTING BOSCH INJECTORS

Engine :VJX [1] Tool to remove/refit injectors Fitting an injector 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. Tightening of the injector holder on the cylinder head: VJZ 7 m.daN All Types 9 m.daN (3) Tighten lightly to avoid distortion. Tighten to 7 m.daN.
B1HP0YGC
7007-T
[2]
7008-T Tool kit 4123-T
INJECTION
B1HP0YNC B1HP0YPC
230
PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM

Engines : 8HX - 8HW Cleaning. - The use of high pressure cleaners is prohibited. - Do not use compressed air. Fuel supply circuit. - Required fuel : diesel.
C3
Electric circuit. - Swapping injection ECUs between two vehicles will render it impossible to start either vehicle. - It is forbidden to supply a diesel injector with 12 volts. High pressure fuel pump. Do not separate the following components from the high pressure fuel pump (5) : - Sealing ring (a) (no replacement parts). - High pressure outlet connector (b) (will cause a malfunction). PS : HDi = High pressure Diesel injection
B1HP1K9C
231
INJECTION
C3
PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM

Engines : 8HX - 8HW Diesel injectors. WARNING: Diesel and ultrasonic cleaners are prohibited.
INJECTION
B1HP1KAC
Do not separate the following components from the diesel injector carrier (2) : - Diesel injector (f) (no replacement parts). - Electromagnetic element (c) (no replacement parts).
Do not alter the position of the nut (d) (malfunction). Do not separate the connector (e) from a diesel injector. It is forbidden to clean the carbon deposits from the diesel injector nozzle.
B1HP1KBC
232
PROHIBITED OPERATIONS: DELPHI HDI DIRECT INJECTION SYSTEM

Engines : 8HY - 8HV Cleaning. - The use of high pressure cleaners is prohibited. - Do not use compressed air. Fuel supply circuit. - Required fuel : diesel.
C3
Electric circuit. - Swapping injection ECUs between two vehicles will render it impossible to start either vehicle. - It is forbidden to supply a diesel injector with 12 volts. High pressure fuel pump. Do not separate the following components from the high pressure fuel pump (5) : - Sealing ring (a) (no replacement parts). - High pressure outlet connector (b) (will cause a malfunction). PS : HDI = HIGH PRESSURE DIESEL INJECTION
B1HP1J6C
233
INJECTION
C3
PROHIBITED OPERATIONS: DELPHI HDI DIRECT INJECTION SYSTEM

Engines : 8HY - 8HV Fuel high pressure injection common rail. Do not separate the pressure regulator c from the injection common rail (2) (Risk of malfunction). Diesel injectors. WARNING: Diesel and ultrasonic cleaners are prohibited. Do not separate the following components from the diesel injector carrier (3) : - Diesel injector (e) (no replacement parts). - Electromagnetic component d (no replacement parts). It is forbidden to clean the carbon deposits from the diesel injector nozzle..
INJECTION
B1HP1J8C
B1HP1J7C
234
CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT

Engines : 8HX - 8HW TOOLS [1] 10 mm low pressure connector [2] Pressure gauge for testing boost pressure
C3
: 4215-T. : 4073-T.A
Tool kit 4073-T INJECTION
IMPERATIVE : Respect the safety and cleanliness specific to high pressure diesel injection engines. Link tools [1] and [2] in series between the fuel high pressure pump and the fuel filter. ESSENTIAL : Check that the tool [2] is clean. Check the negative pressure according to the table below:
Vacuum 10 5 cmHg 20 5 cmHg 60 5 cmHg

B1BP2NWC
Observations Engine driven by the starter motor Engine running under full load Supply circuit obstructed (full tank strainer, piping, fuel filter).
235
C3

Engines : 8HV-8HY TOOLS [1] 10 mm low pressure connector [2] Pressure gauge for testing boost pressure : 4215-T. : 4073-T.A Tool kit 4073-T
INJECTION
B1BP2PHC
IMPERATIVE : Respect the safety and cleanliness specific to high pressure diesel injection engines. Remove the air filter duct. Link tool [1] in series, downstream of the injectors, between the fuel high pressure pump and the fuel filter at a and b. WARNING: Any checking of pressure downstream of the fuel filter is prohibited. Switch on the ignition. ESSENTIAL : Check that the tool [2] is clean. Check the negative pressure according to the table below: Vacuum 10 05 cmhg 20 20 cmhg 60 05 cmhg Observations Engine driven by the starter motor Engine running under full load Supply circuit obstructed (full tank strainer, piping, fuel filter).
236
AIR SUPPLY CIRCUIT SPECIFICATION

Engines : 8HX - 8HW
C3
The upper integrated air inlet system is composed of the following elements: (1) Air filter cover. (2) Air filter chamber. (3) Flowmeter (4) Turbocharger inlet. (5) Resonator. (6) Turbocharger outlet.
B1HP1JMP
237
INJECTION
Upper integrated air inlet distributor.
C3

Engines : 8HX - 8HW
Lower integrated air inlet distributor.
INJECTION
B1HP1JND
The lower integrated air inlet system is composed of the following elements: (7) Top EGR pipe. (8) Inlet manifold. (9) Diesel fuel filter with reheater and water detector (according to country). (10) Diesel fuel filter support. (11) Oil trap. (12) Oil filler cap.
238

Engines : 8HX - 8HW Lower integrated air inlet distributor. Upper integrated air inlet distributor.
C3
B1HP1JPD
B1HP1JQD
WARNING: After each removal, replace the seals of components that have been removed, lubricating the new seals when refitting. Description OIL TRAP FIXING SCREW. Diesel fuel filter support fixing screw. Diesel fuel filter support fixing screw. Integrated air distributor fixing screw. Tighten in sequence 18 9 10 11 12 13 m.daN. 1 0.1 1 0.1 0.5 1 0.1 Description Air filter housing fixing screw. Air filter cover fixing screw. Air inlet duct fixing screw. Resonator on turbocharger fixing screw. Resonator on oil trap fixing screw. 239 Tighten in sequence 13 14 15 16 17 m.daN. 0.5 0.75
INJECTION
C3

Engines : 8HY - 8HV
(1) Air filter assembly. (2) Oil trap. (3) Turbocharger resonance attenuator. (4) Turbocharger. (5) Air/air exchanger. (6) Air distributor.
INJECTION
B1HP1JGP
Air filter Turbocharger (Supplier: IHI)
: Ref : MARK 4. : Ref : RHF 3V.
240

Engines : 8HX - 8HW - 8HY - 8HV
C3
[1] Manual pressure-vacuum pump Vacuum pump :
FACOM DA 16.
Connect the tool [1] onto the vacuum pump (1). Start the engine. Wait 30 seconds. The vacuum value should be 0.9 0.1 bar at idle.
B1HP1K8D
241
INJECTION
Tools.
C3
Engines : 8HX - 8HW
CHECKS : EXHAUST GASES RECYCLING CIRCUIT

[1] Manual pressure-vacuum pump TOOLS : FACOM DA 16.
IMPERATIVE : Respect the safety and cleanliness specific to high pressure diesel injection (HDi) engines. EGR valve Connect tool [1] on the capsule take-off (2). Apply a vacuum of approx. 0,6 bar several times to activate the rod a. In abruptly suppressing the vacuum, the valve should click and lock itself back on its seating.
B1HP15GD
INJECTION Engines : 8HV - 8HY

B1HP1K6D
Regulation electrovalve (EGR). (Engine: 8HX-8HW). Check to be performed between the electrovalve (1) and the EGR valve (2). Link the tool [1] in series, between the electrovalve (1) and the capsule (2). Compare the values noted with those in the table below. Regulation electrovalve (EGR). (Engine: 8HV-8HY). Check to be performed between the electrovalve (2) and the EGR valve (1). Link the tool [1] in series, between the electrovalve (2) and the capsule (1). Compare the values noted with those in the table below.
Engine speed (rpm) 780 2500 242
Vacuum value 0.5 0
CHECKS : TURBO PRESSURE

Engines : 8HX - 8HW
C3
B1BP2NXD
C5FP0F5C
1] Pressure gauge for checking boost pressure : 4073-T.A [2] Sleeve for checking boost pressure : (-).0171.F CHECKS IMPERATIVE : Respect the following test conditions: - Engine at operating temperature. - Vehicle in running order. - Engine under full load. Preparation. Remove the clips (1). Fit the tool [2] in the place of the duct (2). Couple the sleeve [2] on the pressure gauge [1] using the tube a. Mode of operation. Position tool [1] in the vehicle. Start the engine. Engage first gear, start the vehicle. Engage the gears up to third gear. Decelerate to an engine speed of 1000 rpm. Check the pressure : 0,6 0,05 bar (1500 rpm). Accelerate freely (change from fourth gear to third gear) Check the pressure: 0,9 0,05 bar (between 2500 and 3500 rpm). Remove tools [1], [2] at a. Reposition the tube (2) and tighten the clip (1). 243
INJECTION
C3

Engines : 8HV - 8HY [1] Pressure gauge for checking boost pressure : 4073-T.A [2] Sleeve for checking boost pressure : (-).0171.F CHECKS IMPERATIVE : Respect the following test conditions: - Engine at operating temperature. - Vehicle in running order. - Engine under full load. Preparation. Remove the clips (1). Fit the tool [2] in the place of the duct (2). Couple the sleeve [2] on the pressure gauge [1] using the tube a. Mode of operation. Position tool [1] in the vehicle. Start the engine. Engage first gear, start the vehicle. Engage the gears up to third gear. Decelerate to an engine speed of 1000 rpm. Check the pressure : 0,6 0,05 bar (1500 rpm). Accelerate freely (change from fourth gear to third gear) Check the pressure: 0,9 0,05 bar (between 2500 and 3500 rpm). Remove tools [1], [2] at a. Reposition the tube (2) and tighten the clip (1). 244
INJECTION
C5FP0EJC B1BP2NBD
SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP

PUMP - TYPE - REFERENCE Emission standards Equipment XSARA DW 8B WJY L3 Transponder
XSARA
245
INJECTION
DWLP 12 R8448 B 371 B
XSARA
Engine type Pump Type Reference
SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP

Static timing Initial advance Compression Time (cylinder N 4) Dynamic timing checking (at idle) Reference Injector holder + injector Colour code Injector needle lift pressure (Bar) Adjustments (rpm) Fast idling Antistall Max. speed Unladen rpm Laden rpm
Injector
Idling
INJECTION
WJY
DWLP 12 R 8448 B/ *
Engine TDC Pegging hole. Value X engraved on the pump.
RDNO SDC 6903
LDCR 0260 IAA
135.5 5
950 25
1500 + 3mm shim
875 25
875 25
5350 125
(*) = See table, page : 245. 246
CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP

Engine : WJY Evolution of the checking of the setting of the LUCAS diesel injection pump Old assembly. Diesel injection pump with hole for checking the setting The setting of the diesel injection pump is done with the aid of the following tools : - A peg placed at a. - A peg and a dial gauge placed in the checking hole at b NEW ASSEMBLY : RPO 7910 #
XSARA
Diesel injection pump without a hole for checking the setting
The setting of the diesel injection pump is done with the aid of a peg at c.
See method on following pages.
B1HP1A4C
B1HP1A5C
247
INJECTION
XSARA

Engine : WJY (continued) Tools. [1] Flywheel locating peg [2] H M8 screw [3] Injection pump setting peg 6 mm 7014-T.J. (-).0188.E. (-).0188.H
Tool kit C.0188
INJECTION
After carrying out the necessary dismantling operations on the vehicle, proceed in the following manner : Remove : - The screws (6), (7), (9), (10) and (12). - The upper casing (8). - The intermediate casing (11). WARNING : Refit the screw (6) equipped with a washer. (Thickness 5 mm). - Turn the front RH wheel to turn the engine. (Normal direction of rotation). - Bring the camshaft and injection pump pulleys to their setting point. - Position the flywheel peg, using tool [1]. (From below the vehicle). - Turn the engine until the peg [1] engages in the flywheel.
B1EP12NC
B1BP1S9C
248

Engine : WJY (continued) Peg : - The camshaft hub, using tool [2]. - The injection pump hub, using tool [3]. Impossible to peg the camshaft. Reset the valve timing (See page 245). Possible to peg the camshaft, but not the injection pump. 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.
XSARA
ESSENTIAL : If setting the diesel injection pump proves impossible, reset the valve timing. (See page 245). Remove: - The tools [1], [2] and [3]. - The screw (6) and the washer. Reassemble the components.
B1EP12WD B1BP1S9C
249
INJECTION
XSARA
ADJUSTING THE MECHANICAL CONTROLS OF THE DELPHI INJECTION PUMP

Engine : WJY Adjusting the fast idle. Engine cold. - Ensure that the lever (2) is up against its stop to the right. - If not, adjust the tension of the cable (3) using the cable clamp (1). - Finish tensioning using the sleeve tensioner (4). 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).
INJECTION
B1HP0K9C
250
ADJUSTING THE MECHANICAL CONTROLS OF THE DELPHI INJECTION PUMP

Engine : WJY (continued) Adjusting the anti-stall (residual output). - Insert a 3 mm thick shim (10) between the throttle lever (6) and the anti-stall screw (7). - Push the stop lever (8). - Insert a 3 mm diameter peg (9) in the lever (2). - 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.
XSARA
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
251
INJECTION
XSARA
FITTING DELPHI DIESEL INJECTORS

Engine : WJY [1] Tool to remove/refit injectors (2) Fitting an injector The copper seal (1) and the fire seal washer (3) are to be replaced each time they are removed. [2] 7007-T
7008-T.A Tool kit 4123-T
INJECTION
B1DP158C B1HP12VC
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.

B1HP0YGC
252
INJECTION PUMP SPECIFICATIONS (BOSCH and SIEMENS).

Engines TD DW 10 ATED Injection system BOSCH SIEMENS (except PICASSO BOSCH ECU BOSCH EDC 15C2 SIEMENS ECUSID801 BOSCH EDC 15C2 High pressure pump BOSCH CP1 5WS 40001 BOSCH CP1
XSARA PICASSO
Injectors 9625542580 5WS40000 INJECTION 9625542580
253
XSARA PICASSO
PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM

Engines : RHY - RHZ Cleaning. - The use of high pressure cleaners is prohibited. - Do not use compressed air.
INJECTION
B1HP12CC
Fuel supply circuit. - Required fuel : diesel. WARNING : Do not use other fuels. Electric circuit. - Swapping injection ECUs between two vehicles will render it impossible to start either vehicle. - It is forbidden to supply a diesel injector with 12 volts. High pressure fuel pump. Do not separate the following components from the high pressure fuel pump (5) : - High pressure fuel pump third piston deactivator (3) (no replacement parts). - High pressure fuel regulator (4) (no replacement parts). - Sealing ring (1) (no replacement parts). - High pressure outlet connector (3) (will cause a malfunction). PS: HDi = High pressure Diesel injection
254
PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM

Engines: RHY - RHZ High pressure fuel injection common rail. - Do not separate the connectors (7) from the common injection rail (6) - (malfunction). Diesel injectors. WARNING: Diesel and ultrasonic cleaners are prohibited. Do not separate the following components from the diesel injector carrier (9) : - Diesel injector (8) (no replacement parts). - 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 Class 1 Class 2 Engraving 1 2 Paint mark Blue Green Location On the upper part of the coil near to the fuel return aperture
XSARA PICASSO
B1HP12DC
B1HP12EC
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). 255
B1HP16PC
INJECTION
XSARA PICASSO

Engines : RHY - RHZ TOOLS [1] 10 mm low pressure connector [2] 8 mm low pressure connector [3] Pressure gauge for testing boost pressure : 4215-T : 4218-T : 4073-T
INJECTION
B1BP1TWD
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.
256

Engines : RHY - RHZ (continued) Checks on pressure : dynamic. Engine running, at idle (normal functioning): - Fuel supply pressure shown by the pressure gauge [3] = 2 0.4 Bar. - Fuel return pressure shown by the pressure gauge [3] = 0.7 0.4 Bar. Abnormal functioning Fuel supply pressure Between 3 and 3.5 Bar More than 3.5 Bar More than 3.5 Bar Between 0.8 and 1.5 Bar Fuel return pressure 0.7 0.2 Bar Less than 0.7 Bar More than 0.7 Bar Less than 0.7 Bar
XSARA PICASSO
Checks Check the condition of the diesel filter Check the low pressure regulator incorporated in the filter (locked shut) : replace. Check the fuel return circuit (pipe pinched or trapped.......). 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) Check : The flow should be drop by drop Excessive fuel return
Check : diesel injector return flow. (Table) Uncouple the diesel injector return pipe. Observe : Diesel injector functioning correctly Diesel injector locked shut.
257
INJECTION
XSARA PICASSO
CHECKS : AIR SUPPLY CIRCUIT

Engines: RHY - RHZ TOOLS [1] Manual vacuum pump : FACOMM DA 16. IMPERATIVE : Respect the safety and cleanliness requirements. Vacuum pump. - Connect the tool [1] on the vacuum pump (1). - Start the engine. - Pressure should be 0.8 bar at 780 rpm. Boost pressure regulator electrovalve. - Connect the tool [1] between the electrovalve (2) and the valve (3) of the boost pressure regulator. Compare readings with the values in the table below. Engine speed (rpm) 780 4000 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. Pressure (Bar) 0.6 0.25
INJECTION
B1HP12FD
258

Engine : RHZ
XSARA PICASSO
Outillages. [1] Pressure gauge for checking boost pressure : 4073-T.A Tool kit 4073-T [2] Sleeve for checking boost pressure : 4185-T [3] Adaptor sleeve : 4229-T Checks. IMPERATIVE : respect the following checking requirements : Engine at running temperature. Vehicle in running order at full load. Preparation. - Remove the collar fixing (3). - Insert the tool [2] connected with tool [3], between the pipe (1) and the duct (2). - Position tool [1] in the vehicle. - Connect the sleeve [2] to the tool [1] with its tube a . Procedure. - Start the engine. - Engage first gear and start the engine. - Engage the gears up to third gear. - Decelerate to 1000 rpm. - Accelerate hard, and check the pressure : 0.6 0.05 Bar (1500 rpm). - Accelerate freely in kick-down, (changing from fourth to third gear). - Check the pressure : 0.95 0.05 Bar (between 2500 and 3500 rpm). - Remove the tools, reposition the pipe (1) and refit the collar (3).
B1HP12JD
259
INJECTION
XSARA PICASSO

Engine : RHY TOOLS. [1] Pressure gauge for checking boost pressure [2] Sleeve for checking boost pressure : 4073-T.A Tool kit 4073-T : 4185-T
INJECTION
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. 260
B1BP1ZXD
CHECKS : EXHAUST GASES RECYCLING CIRCUIT

Engines : RHY - RHZ TOOLS [1] Manual vacuum pump
XSARA PICASSO
: 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) 780 2500

B1HP12GD
Pressure (Bar) 0.5 0
261
ALL TYPES
Vehicles Models 1.1i SAXO 1.4i 1.6i 1.6i 16v 1.1i C3 1.4i 1.6i 16v 1.4i XSARA 1.6i 16v 2.0i 16v 2.0i 16v 16i XSARA PICASSO 1.8i 16v 2.0i 16V IGNITION Engine type HFX KFW NFT NFX HFX KFV NFU KFW NFU RFN RFS NFV 6FZ RFN FR7DE BOSCH
SPARKING PLUGS
CHAMPION SAGEM Electrode gap setting Tightening torque
RC8YCL
RFN58LZ
0.9 mm
2.5 0.2 mda N
262
SPEEDOMETER
ALL TYPES
An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled. This decree stipulates : - The speed indicated by a speedometer must never be lower than the actual vehicle speed. - Between the speed displayed SD and the speed travelled ST, there must always be the following relationship :
ST < SD < 1.10 ST + 4 Kph

CLUTCH GEARBOX DRIVESHAFTS 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. 263
C3 - SAXO
1.1i Engine type Gearbox Make Mechanism/Type Clutch disc Ext./Int. lining Disc lining type CLUTCH GEARBOX DRIVESHAFTS VALEO 180 CP0 3400 11 R 10X 180/127 HFX 1.4i KFV
CLUTCH SPECIFICATIONS
1.6i 16V NFU MA/5 LUK 200 P 3900 230 P 4700 1.4 HDi 8HX - 8HW 1.4 HDi 16V 8HV - 8HY BE4/5
200/134 F408
228/155
264
Engines : HFX KFV NFU - 8HX 8HW 8HV 8HY NOTE : All the clutches are push type with hydraulic control. Description. The declutch control has a declutch fork mounted on a ball-joint. - The ball-joint is screwed into the clutch casing. (2) Declutch fork. (3) Clutch casing. (4) Bearing. (5) Clutch plate. The clutch control slave cylinder (7) is fixed by two screws (6) onto the exterior of the clutch casing. Tightening torques (m.daN). - Fixing of clutch plate / engine flywheel - Fixing of clutch control slave cylinder / clutch housing - Fixing of engine flywheel / crankshaft Pre-tightening Angular tightening : 2 0.2 : 2 0. 25 : 1.7 0.1 : 70 5
C3
B2BP047C
B2BP04QC
265
CLUTCH GEARBOX DRIVESHAFTS

1.4i Engine type Gearbox Make Mechanism/Type Clutch disc CLUTCH GEARBOX DRIVESHAFTS Ext./Int. lining Disc lining type 180CPO 3400 180 XJF 73 C 180/127 F 408 200 CPR 3800 200X(D95) 11A12X 200/137 F410 KFW MA/5 1.6i NFV BE4/5 1.6i 16V NFU MA/5 VALEO 1.8i 16V 6FZ
2.0i 16V RFN RFS 1.9 D WJY BE4/5 LUK 230 DNG 4700 230 DNG 4700 228/155 F 808 215 DT 5250 215 FD 95 215/147 200 P 3700 215 F (D 93) 22 BX 200/134 200/134 F408 200 P 4200 230 P 4700 228 230/155 235 T 5700 228D 235/155 F202 1.4 HDi 8HZ RHY 2.0 HDi RHZ
266
1.1i Engine type Gearbox Make Mcanisme/Type Clutch disc Ext./Int. lining Disc lining type F808 HFX MA/5 VALEO 200 CPX 3850 200 XS L73C 11RX 200/137 F408 200 XSL 73 200 P 4700 200 1.4i KFW 1.6i 16V NFU 1.9 D WJY BE4/5 LUK
BERLINGO
2.0 HDi RHY
235 T 5700 228 228/155 CLUTCH GEARBOX DRIVESHAFTS
267
SAXO - XSARA
SAXO XSARA
LUTCH : CHECKS AND ADJUSTMENTS

Mechanically operated push-action clutch Engines Adjustable Non-adjustable HFX-KFW-NFT-NFX-VJX Gearbox KFW-NFU MA/5
ESSENTIAL : If the clutch control is new, squeeze the cable sheath before adjusting by declutching successively a minimum of 20 times. Checks NOTE : Adjustable steering wheels should be put into the low position - Record the measurement X 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 B2BP00GC
268
CLUTCH : CHECKS AND ADJUSTMENTS

Push-action clutch with automatic adjustment (non-adjustable) Engines WJY Gearbox BE4/5 Refitting the clutch cable.
XSARA
- 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.
B2BP03CD
269
XSARA
Engines RFS - RFN - RHY - RHZ

Pull-action clutch with automatic adjustment (non-adjustable) Gearbox BE4/5 Refitting the clutch cable. - Set the pedal to the high position (contact at A). - Attach the cable end-piece to the pedal. - Refit a new clip (3) to the pedal. - Fit the end-piece (4) to the bulkhead (G6 Grease). - Clip the end-piece (5) to the gearbox. - Refit the cable to the lever (1). - Depress the clutch cable several times to set 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.
B2BP03DD
CLUTCH GEARBOX DRIVESHAFTS 270

Adjustment of push and pull action clutch with automatic compensation (adjustment of compensation system) Engines : RFN - RFS - WJY - RHY - RHZ
XSARA
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. - 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
271
XSARA

Engines : RFN - RFS WJY RHY - RHZ
B2BP02SC
NOTE : This cable has an automatic adjusting device which takes up the clutch disc wear and makes up for the compression of the outer cable. DESCRIPTION 5 - Tensioning spring ensuring the maximum length of the cable sleeve. 6 - Wear take-up device. 7 - Hooking yoke.
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).
272

Engines : RFN - RFS - WJY - RHY - RHZ
B2BP03QD
Operation 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.
Clutch disengagement phase 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.
Engagement / adjustment phase The pedal returns to rest on its upper stop. Attaching end-piece (4) pushes sleeve (1) which frees the rollers. The outer cable (3), kept extended by the spring (6) becomes : -Shorter if the clutch disc is worn. -Longer if the outer cable has been compressed.
NOTE : The pedal gear has a non-adjustable assisting device. 273
SAXO
GEARBOX AND TYRE SPECIFICATIONS

Petrol 1.1i 1.4i Auto. 1.6i NFT 165/65 R14 1.725m MB3 20 CF 12 17x64 19x17 Diesel 1.5D VJX 165/65 R14 1.725 m MA/5 20 CF 02 29/08/200 17x64 19x17 274 312 17x56 21x19 1.6i 16V NFX 185/55 R14 1.7 m
Engine type Tyres-Rolling circumference Gearbox type Gearbox ident. plate Reduction box torque Speedometer ratio CLUTCH GEARBOX DRIVESHAFTS
HFX
KFW 155/70 R 13 1.67 m MA/5
MA/5 20 CN 03 20 CN 05 17x61 19x17 16x63
20 CF 03 14x60 19x17
Engine type Tyres-Rolling circumference Gearbox type Gearbox ident. plate Reduction box torque Speedometer ratio

Petrol 1.1i Trim level Engine type Tyres-Rolling circumference Gearbox type Gearbox ident. plate Reduction box torque Speedometer ratio X - SX Exclusive X - SX Exclusive 1.4i Auto.. X - SX Exclusive
C3 - All Types
1.6i 16V X - SX Exclusive
HFX 165/70 R 14 1.804 m 20 CN 14 14x60
1.4 HDi Trim level Engine type Tyres-Rolling circumference Gearbox type Gearbox ident. plate Reduction box torque Speedometer ratio NOTE : (*) = Export X SX - Exclsive 8HX 8HW 165/70 R14 1.804 MA/5 20 CN 33 ou 20 CN 36(*) 17x61 ou 16x65 (*) 21x18 275 8HV
1.4 HDi 16V 8HY 185/60 R15 1.828 m BE4/5 20 DM 25 20 DM26 19x72 19x77 22x19
KFV 185/60 R15 1.828 m 165/70 R 14 1.804 m MA/5 AL4 20 CF 15 ou 20 CF 16 (*) 20 TP 75 16x63 ou 14x60 (*) 21x73 21x18 Diesel
NFU 185/60 R15 1.828 m MA/5 20 CN 40 17x64
XSARA
1.4i Engine type Tyres-Rolling circumference Gearbox type Gearbox ident. plate Reduction box torque Speedometer ratio CLUTCH GEARBOX DRIVESHAFTS MA/5 20 CF 13 KFW

Petrol 1.6i 16V Auto. NFU 195/55 R15 - 1.815 m AL4 BE4/5 20 CN 28 16x65 21x18 20 TP 49 21x73 24x21 Diesel 1.9D 1.4HDi 8HZ RHY 195/55 R15 1.815 m BE4/5 20 DL 41 19x75 22x19 6FZ-RFN - 20 DM 03 WJZ-WJY - 20 DM 05 276 8HZ - 20 DM 53 RHY - 20 DM 07 20 DM 54 20 DL 42 19x70 20 DM 10 17x61 2.0 Hdi Auto. RHZ AL4 20 TP 48 14x62 22x19 RHZ - 20 DM 11 20 DL 40 19x72 22x19 RFN AL4 20 TP 47 23x73 24x21 2.0i 16V
Auto.
RFS BE3/5 20 TE 47 14x62 22x19
Engine type Tyres-Rolling circumference Gearbox type Gearbox ident. plate Reduction box torque Speedometer ratio Right hand drive :
WJY

Petrol
1.6i
XSARA PICASSO
Diesel 2.0i 16V Auto. 2.0 Hdi
1.8i 16 V
Engine type Tyres-Rolling circumference Gearbox type Gearbox ident. plate Reduction box torque Speedometer ratio
NFV
6FZ
RFN 185/65 R15 1.895 m
RHY
BE4/5 20 DL 66 15x64 22x18 20 DL 68 19x77
AL4 20 TS 02 21x73 24x20
BE4/5 20 DL 64 19x72 CLUTCH GEARBOX DRIVESHAFTS 22x18
Right hand drive :
NFV = 20 DL 67
6FZ = 20 DL 69
RHY = 20 DL 65.
277
SAXO - XSARA
GEARBOX - MA/5
Engines : HFX - KFW - NFT - NFX - NFU - VJX - 8HX - 8HW
Vent plug
CLUTCH GEARBOX DRIVESHAFTS Filler screw Drain screw

B2CP34HP B2CP20FC B2CP20GC
278
GEARBOX CONTROLS - MA/5

Engines : HFX - KFW - NFT - NFX NFU - VJX 8HX- 8HW
SAXO - XSARA
1 - Gear lever. 2 - Gear control rod. 3 - Gear control rod. 4 - Gear selection rod. 5 - Gear selection rod. 6 - Knuckle joint. 7 - Fixed point on the gearbox A = 11.5 mm. B = 9.5 mm. C = 3 mm. CLUTCH GEARBOX DRIVESHAFTS
B2CP16SP
B2CP16TC
279
C3
GEARBOX - MA/5
Engines : HFX - KFV - NFU - 8HX - 8HW
a Identification label. CLUTCH GEARBOX DRIVESHAFTS

B2CP3HTC
b Location for engraving of serial and gearbox nos..
280
GEARBOX - MA/5
C3
Draining filling level (1) Gearbox drain plug. (2) Filling and level cap.
Oil quality. Refer to the manufacturers instructions. Oil quantity. After draining: 2 Litres. Draining intervals. Lubricated for life Check the oil level: Every 37 500/40 000 miles. CLUTCH GEARBOX DRIVESHAFTS
B2CP3HWC
281
C3
GEARBOX - MA/5
Engines : HFX - KFV - NFU - 8HX - 8HW (1) Primary shaft. (2) Clutch bearing guide. (3) Clutch housing. (4) Gearbox casing. (5) Intermediate plate. (6) Bearing retaining clip. (7) Drive pinion (5th gear). (8) Secondary shaft. (9) 5th gear synchroniser. (10) Driven pinion (5th gear). (11) Driven pinion (4th gear). (12) 3rd / 4th gear synchroniser. (13) Driven pinion (3nd gear). (14) Driven pinion (2nd gear). (15) 1st / 2nd gear synchroniser and reverse gear driven pinion. (16) Driven pinions (1st gear). (17) Differential gearwheel. (18) Satellite pinions. (19) Planet pinions. (20) Counter drive. (21) Speedometer screw. (22) Differential housing. 282

B2CP167P
GEARBOX - MA/5
Engines : HFX - KFV - NFU - 8HX - 8HW Tightening torques: m.daN. (23) Clutch bearing guide (3 fixing screws) (24) Intermediate plate (11 fixing screws) (25) Rear cover (3 fixing screws) (26) Bearing retaining clip (4 fixing screws) (27) Secondary shaft nut (1 nut) (28) Gearbox casing (15 fixing screws) (29) Top-up plug (1) (30) Drain plug (1) (31) Reverse gear switch (1)
B2CP3HUD
C3
: 0.6 0.15. : 5 0.5. : 2.2 0.2. : 1.8 0.2. : 14 1. : 1.8 0.2. : 2.5 0.5. : 2.5 0.5. : 2.5 0.5. CLUTCH GEARBOX DRIVESHAFTS
283
C3

(1) Gear control lever.
(2) Gear engagement control cable (*)
(3) Gear selection control cable (*)

B2CP3HXD
(*) The two cables cannot be separated.
284

C3
(4) Gear engagement ball-joint 10 mm.
(5) Gear selection ball-joint 10 mm.
Length D Gear engagement control cable (2) 1015 mm Length A Gear selection control cable (3) 285 1093 mm
Length C 790 mm Length B 775 mm
B2CP3HZD
B2CP3HYC
C3

Adjustment.
WARNING: Do not use any tool to detach the balljoints. The gear selection control and gear engagement control cables cannot be adjusted. To unlock the ball-joint, press at a then pull the ball-joint upwards. To release the sleeve stops, pull the needles b, in the direction of the arrow, then disengage the sleeve stops from their supports.
B2CP3J0D
B2CP3J1D
286
GEARBOX BE4/5
C3 - XSARA - XSARA PICASSO
Engines : NFV - 6FZ 8HV 8HY - 8HZ - RFN - RFS - WJY RHY - RHZ
B2CP3BNC
B2CP3BPD
(a) Marking zone. (Sequence and serial no.). (b) = Location of identification label. 287
GEARBOX CONTROLS - BE4/5
Engines : NFV - 6FZ 8HV 8HY- 8HZ - RFN - RFS - WJY RHY - RHZ
(1) Drain plug. (2) Filling and top-up plug. (3) Air vent.
NOTE : The air vent aperture can be used for filling. CLUTCH GEARBOX DRIVESHAFTS
B2CP3BLD
Quality of oil Refer to the manufacturers instructions. Quantity of oil Gearbox empty : 1,9 Litres. After draining : 2 Litres.
288
GEARBOX BE4/5

Description
Engines : NFV - 6FZ 8HV 8HY - 8HZ - RFN - RFS - WJY RHY - RHZ
(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).
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
289
(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).
(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.
C3
GEARBOX - BE4/5
Engines : 8HV - 8HY
Tightening torques (m.daN). (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) Clutch bearing guide (3 screws) Clutch housing (13 screws) Primary shaft nut (1 screw) Secondary shaft nut (1 screw) Vis de maintien du jonc (2 vis) Differential gearwheel screw (2 screws) Reverse gear switch (1 screw) Differential housing (4 screws) Breather pipe Rear housing cover screws (7 screws) Top-up plug (1 screw) Differential housing screws (4 screws) Drain plug (1 screw) : : : : : : : : : : : : : 1.25 0.2 1.3 0.2 7.25 0.5 6.5 0.5 1.5 0.2 6.5 0.5 2.5 0.3 5 0.5 1.7 0.2 1.25 0.2 2.2 0.2 1.25 0.2 3.5 0.3

B2CP3BRD
290
GEARBOX BE4/5

Engines : NFV - 6FZ - RFN - RFS - WJY - 8HZ - RHY - RHZ Tightening torques
Ref. 1 2 3 4 5 6
B2CP3BSP
Description End guide Clutch housing Primary shaft nut Secondary shaft nut Yoke holding screw Differential gearwheel screw Reverse gear contact
Number of screws 3 13 1 1 2 2 1 4 1 7 1 4 1
m.daN 1.2 0.1 1.3 0.1 7.2 0.7 6.5 0.7 1.5 0.1 6.5 0.7 2.5 0.3 5 0.5 1.7 0.2 1.2 0.1 2.2 0.2 1.2 0.1 3.5 0.4 CLUTCH GEARBOX DRIVESHAFTS
7 8 9 10 11
B2CP3BTD
Differential housing Breather pipe Rear housing cover screw Top-up plug Differential housing screw Drain plug screw 291
12
C3

Engines : 8HV - 8HY
(1) Gear control lever (2) Gear engagement control cable (*) (3) Gear selection control cable (*) CLUTCH GEARBOX DRIVESHAFTS
B2CP3J3D
(*) These two cables cannot be separated.
292

Engines : 8HV - 8HY
C3
(4) Gear engagement ball-joint 10 mm.
(5) Gear selection ball-joint 10 mm.
Length A Gear selection cable (5) 907 mm Length D Gear engagement cable (4) 293 965 mm
Length B 645 mm Length C 610 mm
B2CP3J5D
B2CP3J4C
C3

Engines : 8HV - 8HY
Adjustment. The gear selection control and gear engagement control cables cannot be adjusted.

B2CP3J6D
To release the ball-joint, press at d then pull the ball-joint upwards. To release sleeve stops: - Press on the tabs of the clip (6) at a. - Disengage the sleeve stops from their supports.
294

Engines : NFV - 6FZ - RFN - RFS - WJY - 8HZ RHY - RHZ
(1) Gear control lever (2) Gear engagement control cable (*) (3) Gear selection control cable (*) (4) Gear selection ball-joint 10 mm. (5) Gear engagement ball-joint 10 mm. (6) Flexible insulating grommet through the bulkhead. CLUTCH GEARBOX DRIVESHAFTS
(*) = These two cables cannot be separated.
B2CP3BWD
295
BE4/5 GEARBOX - CHECKS AND ADJUSTMENTS

Principles of adjusting the gear controls. WARNING : Cables should be adjusted each time the gearbox, gear controls or power unit are removed.
Principles. Lock the gear lever in neutral position, using tool: 9607-T. CLUTCH GEARBOX DRIVESHAFTS Place the gearbox in neutral. Couple the cables on the lever. Fit the ball-joints on the gearbox lever. Lock the cable lengths with the ball-joint locking keys.
WARNING : Do not use any tool to unclip the ball-joints. To unlock the ball-joint, press at the centre a, then pull the ball-joint upwards.
NOTE : Changing an individual ball-joint is possible as long as the locking key is removed. Unclip at b, using two small screwdrivers.
B2CP3BXC
B2CP3BYC
296
BE4/5 GEARBOX - CHECKS AND ADJUSTMENTS

Adjusting the gear controls. TOOLS. [1] Tool for positioning the gear lever
: 9607-T.
ADJUSTMENTS. WARNING : Cables should be adjusted each time the gearbox, gear controls or power unit are removed. Inside the vehicle. - Remove the trim under the gear lever. - Lock the gear lever in neutral position, using tool [1]. Under the bonnet. - Remove the air filter assembly. - Unlock the ball-joint keys at a. - Place the gear selection and control levers neutral. Lock the cable lengths with the ball-joint locking keys.
CHECKS. - Remove the tool [1]. - Check that all the gears engage without tightness . - Check that the gear lever moves 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
B2CP3C0C
297
SAXO
AUTOMATIC GEARBOX - MB3

Engine : KFW
Tightening torques m.daN. - 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 3.5 2.5 1.6 2.6 6.5 8.5 1 5
CLUTCH GEARBOX DRIVESHAFTS 298
NOTE : When fitting a new automatic gearbox, it is ESSENTIAL that the heat exchanger and the oil be replaced.
B2CP14ZP
RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - MB3)

Engine : KFW PRECAUTIONS TO BE TAKEN
SAXO
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). 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. CLUTCH GEARBOX DRIVESHAFTS
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.
299
SAXO

Engine : KFW
PRE-REPAIR PROCEDURE Oil quality If the gearbox has suffered a serious fault resulting in a malfunction or the destruction of a clutch, the oil will overheat and become contaminated with impurities : the oil is said to be burnt. This is characterised by a black colour and the presence of an unpleasant smell. ESSENTIAL : The gearbox must be replaced. Oil level (prior conditions) - Oil hot (80C 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). CLUTCH GEARBOX DRIVESHAFTS
B2CP16WC
300

Engine : KFW PRE-REPAIR PROCEDURE (continued) Negative pressure circuit. - Check the negative pressure circuit. - Carry out the necessary repairs. Checks using the diagnostic tool. Preliminary checks : - The adjustment of the gear selection control. - The adjustment of the accelerator cable. Carry out the necessary operations Reading the fault codes Read the fault codes. Absence of fault codes Measure the parameters. Anomalies present: - YES : Carry out the necessary repairs. - NO : Check (adjust the negative pressure capsule).
SAXO
Fault codes present Carry out the necessary repairs. Clear the fault codes. ESSENTIAL : Initialise the ECU Perform a road test.
301
ESSENTIAL : Initialise the ECU Perform a road test.
SAXO
SPECIAL FEATURES: AUTOMATIC GEARBOX - MB3

Engine : KFW Hydraulic valve block. Refitting. WARNING : On refitting the strainer, ensure that the bracket (6) runs under the washer of the screw (7). - Refit the strainer without tightening the screws. - Observe the following tightening sequence : - Screws 1,2,3,4 and 5 to 0.9 m.daN.
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
302
MB3 AUTOMATIC GEARBOX CONTROLS

Engine : KFW
SAXO
B2CP352D
303
SAXO
MB3 AUTOMATIC GEARBOX CONTROLS - CHECKS AND ADJUSTMENTS

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 10mm. - Turn backwards by 1/4 turn, and raise by approximately 7mm. - Press and hold down the locking button (3) Adjusting the selection control ESSENTIAL : Put the gearbox side control in the 1st imposed position; the 2 markings a must be aligned. - Fit the ball joint (1). - Fit the lug (2). - Lock the outer cable stop by 1/4 turn (in the direction of the arrow). - Check that the painted markings b are aligned.
- 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
B2CP18WC
B2CP18XC
304
AUTOMATIC GEARBOX - AL4

Engines : KFV - NFU - RFN - RHZ
WARNING : This gearbox benefits from a special CITROEN semi-synthetic oil which cannot be mixed with any other oil. The gearbox is lubricated for life.
(a) Part reference. CLUTCH GEARBOX DRIVESHAFTS

B2CP30ZD
305
RECOMMANDATIONS - PRECAUTIONS (BOITE DE VITESSES AUTOMATIQUE AL 4)

Engines : KFV - NFU RFN - RHZ 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 : 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). Lubrication The automatic gearbox is only lubricated when the engine is running. CLUTCH GEARBOX DRIVESHAFTS
REMOVING - REFITTING. (Automatic gearbox). WARNING : Never place the gearbox on its lower casing (risk of deforming the tray and damaging the hydraulic valve block). Never use the connections as handles for raising, turning, holding or pushing the gearbox. ESSENTIAL : - Fit the converter retaining peg while the gearbox is removed. - Fit the centring peg to locate the gearbox on the engine: (remove the converter retaining peg just before locating) WARNING : With the safety programme selected, a snatching can be felt when changing from P R or N R.
306
RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 )

Engines : KFV - NFU - RFN - RHZ PROCEDURE BEFORE REPAIRS AL4 gearbox Oil Quality
ESSENTIAL : The gearbox must be replaced.
307
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.

AL4 gearbox only AL4

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

B2CP31FD
308

Engines : KFV - NFU - RFN - RHZ PROCEDURE BEFORE REPAIRS (continued) When the ECU detects an erroneous or absent value on input or output : - It writes the fault in memory. - For each associated context, it writes the context of the oldest fault in memory. - It initiates a back-up mode strategy. There are two types of back-up modes : - The ECU makes replacement values available (relating to comfort, gear selection quality, loss of functions). - Access to emergency programme (only 3rd gear and reverse are available) Reading the fault codes. Read the fault codes.
Absence of fault codes: Carry out a measure of parameters. Presence of anomalies: CLUTCH GEARBOX DRIVESHAFTS
YES : Carry out the necessary repairs NO : Read the fault codes engine ECU
- Carry out a road test. Following an initialisation of the ECU, for a certain period of 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).
309

Engines : KFV - NFU - RFN - RHZ ECU : Downloading
Updating the gearbox ECU by downloading : - Follow the procedure using the diagnostic tool. The downloading operation enables the automatic gearbox to be updated, or adapted to an evolution of the engine ECU. Before commencing the downloading, take the value of the oil usage counter present in the automatic gearbox ECU. After the downloading operation, carry out the following: A clearing of faults. A pedal initialisation. An initialisation of the auto-adaptives. A recording of the value of the oil usage counter previously read. A road test. ESSENTIAL : Every update of the automatic gearbox ECU should be accompanied by an update of the engine ECU. Updating the value of the oil usage counter. Using 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. 310 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.

Engines : KFV - NFU - RFN - RHZ ECU : Configuration, Initialisation (pedal) (continued) Pedal initialisation. ECU downloading procedure : - Follow the diagnostic tooling procedure. A new ECU or downloaded update is always configured with the following options : - SHIFT LOCK gear selection lever position. - OBD outlet (emission standard L4). If the ECU is to be fitted to a vehicle without one or both of these options: - Carry out a configuration which inhibits the diagnosis of the option(s) concerned.
Downloading.
A pedal initialisation must be carried out in the following cases : - Replacement of the automatic gearbox ECU. - Replacement of the automatic gearbox. - Downloading of the ECU configuration. - Adjustment or replacement of the accelerator cable. - Replacement of the throttle potentiometer. CLUTCH GEARBOX DRIVESHAFTS
IMPERATIVE : For a certain period of time, while the ECU parameters are adapted to the gearbox, there may be an inconsistent gear selection quality. To achieve a consistent standard, it will be necessary to carry out a road test taking in frequent gear changes (auto-adaptive laws).
311
C3

Engine : KFV SHIFT LOCK - The shift lock is a system that locks the gear selection lever in position P. Unlocking the SHIFT LOCK. (Normal operation). - Switch on the ignition. - Press the brake pedal and keep it pressed. - Move the gear selection lever out of position P. Unlocking the SHIFT LOCK. (With an operating fault). NOTE : It is impossible to unlock the shift lock with the Normal operation method. The fault may originate from one of the following components: - Shift lock. - Gear lever position switch. - Automatic gearbox ECU. - Electrical harness. - Battery voltage. Remove: - The gear lever knob (1) (Pull upwards). - The cover (2) (Unclip). - The top of the central console (3). - Unlock the shift lock (4) with the aid of a screwdriver. - Move the gear selection lever out of position P.
C5FP0ETC

B2CP3GZC
312

Engines : NFU - RFN - RHZ SHIFT LOCK
- The shift lock is a system which locks the selection lever in the park position P. Unlocking the SHIFT LOCK (In normal operation) - Switch on the ignition. - Press and hold down the brake pedal. - Using the selection lever, disengage from position P. 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. CLUTCH GEARBOX DRIVESHAFTS
B2CP268C
B2CP269C
313
SAXO - C3 - XSARA - XSARA PICASSO

Vehicles SAXO C3 XSARA XSARA XSARA PICASSO CLUTCH GEARBOX DRIVESHAFTS C3 SAXO MB3 BE4/5 MA/5 Gearbox Engines HFX-KFW-NFT-NFX-VJX HFX-KFV-8HX-8HW NFU KFW-NFU NFV-RFS-RFN-6FZ-WJY8HZ -RHY-RHZ 8HV-8HY KFW 1.8 0.1 NFU-RFN-RHZ AL 4 KFV 1 0.1 : SAXO XSARA = 8.5 314 1.8 0.1 Driveshaft bearing NONE 2 0.2
DRIVESHAFTS - GEARBOX
Tightening torques (m.daN) Driveshaft nut 24.5 0.5 7114-T.W 32 1.5 2 0.2 24.5 0.5 4101-T.E1 + 4601-T.E2 NONE 4601-T 7114-T.X 7116-T Gearbox oil seal mandrels RH side LH side Tool kit
XSARA XSARA PICASSO
32.5 2.5
Seal extractor RH / LH (-) 0338 C (-) 0338 J1 (-) 0338 H1 + (-) 0338 J2 +(-) 0338 H2 (-) 0338 J1 + (-) 0338 J2 (-) 0338 H1 +(-) 0338 H2
(-) 0338
C3 Tightening torque (m.da.N) for wheel bolts
C3= 9
AXLE GEOMETRY
Geometry of the axles at reference height. Front height H1 = R1 L1 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 = R2 + L2 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. Rear height
SAXO - All Types
The values L1 and L2 are given in the table below.

C4CP0N2C
Normal suspension Front axle Dimension Value (mm) L1 71 10 mm Rear axle L2 53 6 mm
Raised suspension Front axle L1 36 10 mm Rear axle L2 82 6 mm
C4CP0N3C
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. 315
AXLES SUSPENSION STEERING
SAXO - All Types

Front height Reminder : Measuring the front height H1 = Distance between the ground and the mounting face of the fixings
AXLE GEOMETRY
Geometry of the axles at reference height. Rear height Reminder : Measuring the rear height H2 = Distance between the ground and the rear crossmember
B3BP07UC
B3BP07VD
The front heights H1 are measured between the ground and the mounting face of the arm fixings (1) at the point a. AXLES SUSPENSION STEERING
The rear heights H2 are measured between the ground and the mounting face of the rear crossmember (2) at b and c.
WARNING
B3CP02UC
A B = Negative figure: 316
+= =
TOE-IN TOE-OUT
AXLE GEOMETRY
Geometry of the axles at reference height. Normal suspension Front Engines HFX (*) Manual O mm HFX (**) KFW - NFT NFX - VJX Manual Assisted -010to 031 -016to -16 +1 to +3 +1.49 to +6.39 - 040 30 314 30 1242 40 - 135 30 Rear All Types HFX (*) Manual
SAXO - All Types

Raised suspension Front HFX (**) KFW - NFT NFX - VJX Manual Assisted -010to 031 +1 to +3 - 040 30 314 30 1242 40 AXLES SUSPENSION STEERING -016to -16 +1.49 to +6.39 - 135 30 Rear All Types
Steering Tracking Toe-in Camber Castor Pivot angle
-010to 031 -1 to -3 - 09 30 213 30 12 41 40
-010to 031 -1 to -3 - 09 30 213 303 12 41 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. 317
SAXO - All Types

Anti-roll bar 18 and 22 mm Anti-roll bar 19 and 21 mm
FRONT AXLE
(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 HFX (2) AXLES SUSPENSION STEERING HFX (1) KFW VJX 21 HFX 19 NFT 18 HFX (3) KFW (3) NFX (3) 22 Raised suspension France Administration 21 Export 19
Anti-roll bar
None
(1) = With airbag. (2) = Without option. (3) = VTS level. 318
REAR AXLE
SAXO - All Types
(1) (2) (5) (7) (9)
Rear axle. Damper. Rear suspension arm. Rear brake drum. Torsion bar.
The antiroll bar is located inside the tube of the rear axle.
Tightening torques m.daN. (3) (4) (6) (8) Damper upper fixing screw Damper lower fixing screw Stub nut Rear axle fixing bolt 10 1 10 1 20 1 8.7 1 AXLES SUSPENSION STEERING
B3DP02ND
319
SAXO - All Types
REAR AXLE - SUSPENSION

Torsion bar HFX (1) (2) KFW (2) NFX - VJX (1) HFX - KFW NFX - VJX 17.9 White HFX-VJX (3) 18.3 Green
Torsion bar (mm) Colour reference Torsion bar (1) = Entreprise. LH : 2 rings RH : 1 ring (2) = VTS trim level
19 Black
(3) = With raised suspension Antiroll bar Raised suspension HFX (2)-KFW NFX-VJX HFX (3)-KFW (3) NFX (3)
HFX
France
Export
Anti-roll bar (mm) AXLES SUSPENSION STEERING (1) = With airbag.
None
18
22 (3) = VTS trim level.
18
15
(2) = With airbag or assisted steering or ABS.
320
STEERING SPECIFICATIONS
Manual steering Tyres Pinion (no. of teeth) Rack (no. of teeth) Rack travel Stop (colour) 80 Black 155/70 R13 165/70 R13 6 28 72 White Power-assisted steering Tyres Pinion (no. of teeth) Rack (no. of teeth) Rack travel Stop (colour) 165/70 R13 7 28 68 165/70 R14 185/55 R14 165/65 R14
SAXO - All Types
NOTA : The steering assembly is secured to the bulkhead. Length of the steering track rods (between the centre lines of the ball-joints). Pre-adjustment = 520 mm.
321
SAXO - All Types
MANUAL STEERING
Tightening torques (m.daN) 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 0.8 3 2.3 2.3 2.2 322 7 - Pivot ball-joint nut 8 - Lock nut M14 8 - Lock nut M16 9 - Track rod articulation 10 - Splined coupling fixing to steering rack 3.5 4.5 5 2.1 2.4
B3EP09TD
B3EP02UD B3EP09SC
POWER-ASSISTED STEERING
SAXO - All Types
Tightening torques (m.daN) 1 2 3 4 5 6 7 8

B3EP02TD
B3EP02WD
323
- 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
0.8 3 2.3 2.3 2.2 3.5 4.5
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
5 2.1 2.4 8 8 1.5 0.7
SAXO - All Types
POWER-ASSISTED STEERING (continued)

Power steering system
WARNING : Saxo all types except diesel without aircon
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 torque (m.daN). Pump support fixing Pump fixing to support High pressure pump Electro-pump connection Power steering valve connection Low pressure pump Electro-pump connection Power steering valve connection 2 2 2 2,5 2,5 2,5
1 2 3 4 5 6 7
B3EP09UD
Note : Fluid type TOTAL Fluide ATX capacity : 0.950 L. 324
POWER-ASSISTED STEERING (continued)

Power steering system WARNING : Saxo diesel with aircon Description.
SAXO - All Types
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.
B3EP12XD
325
Max. pressure : 80 Bars. Pulley diameter : 112 mm. Fluid quality : TOTAL Fluide ATX Capacity : 1.55 litres.
C3
Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point (See corresponding operation).
AXLE GEOMETRY
Conditions for checking and adjusting
Vehicle heights at reference height
E1AP09MD
Front height L1 H1 = R1 - L1 AXLES SUSPENSION STEERING H1 = Measurement between the measuring zone underneath the front subframe and the ground. R1 = Front wheel radius under load. L1 = Distance between the wheel axis and the measuring zone underneath the front subframe. 326
Rear height L2 H2 = R2 + L2 H2 = Measurement between the measuring zone underneath the rear sill and the ground. R2 =Rear wheel radius under load. L2 = Distance between the wheel axis and the measuring zone underneath the rear sill.
AXLE GEOMETRY
C3
B3CP07SD
Measuring front height Measuring rear height [1] Gauge for measuring the wheel radius, 4 bolts, tool 8006-T Z1 =Measuring zone underneath the front subframe. Measure the radius of the front wheel R1 - Calculate dimension H1 = R1 L1 Value at reference height (+ 6 - 8 mm) All Types (except CRD) (*) L1 = 142.5 mm CRD vehicles (*) L1 = 132.5 mm Z2 = Measuring zone underneath the rear sill. Measure the radius of the rear wheel R2 - Calculate dimension H2 = R2 + L2 Value at reference height (+ 10 - 6 mm) All Types (except CRD) (*) L2= 52 mm CRD vehicles (*) AXLES SUSPENSION STEERING L2= 62 mm
(*) = CRD : Difficult road conditions.

Definition for a type of vehicle whose axles and suspensions are adapted for driving on rough roads. Compress the suspension to obtain the calculated values. The height difference between the two axle dimensions should be less than 10 mm. 327
C3
Front axle Dissymmetry of lower castor at 0 30. Dissymmetry of lower camber at 0 18. Distribute symmetrically, LH / RH wheel, the total tracking value.
AXLE GEOMETRY
Rear axle Dissymmetry of lower camber at 0 18.
All types (except CRD) Vehicle Tracking Adjustable All Types mm 0 -21 - 0 19010 357 Castor (018) Castor ( 018) Camber ( 030) Non adjustable - 028 Camber (030) Non adjustable 353 - 026 1114 + 5.2 1 + 047 010 1124 CRD vehicles Pivot angle ( 030) + 5.5 1 + 050 010 Pivot angle ( 030) Tracking Non adjustable - 130 Camber ( 030)
Vehicle
Tracking Adjustable
Tracking Non adjustable
Camber
All Types AXLES SUSPENSION STEERING
mm 0
-21 - 0 19010
-128 NOTE
A B = Negative figure: 328
FRONT AXLE
Tightening torques (m.daN) (1) Nut fixing suspension leg on body (2) Damper (3) Anti-roll bar link rod upper ball-joint (4) Suspension leg pivot (5) Anti-roll bar link rod lower ball-joint (6) Anti-roll bar bearing fixing on subframe (7) Hub nut (8) Wheel bolt (9) Subframe to bodyshell fixing screw (10) Anti-roll bar (11) Pivot lower ball-joint fixing on lower arm (12) Pivot lower ball-joint fixing (13) Lower arm front and rear mounting fixing (14) Stabiliser bar screw (15) Steering ball-joint fixing Anti-roll bar Diameter (mm) HFX- KFV- NFU 8HX-8HW 8HV-8HY 329 19 : : : : : : : : : : : : : :
C3
6,5 0,6 3,2 0,3 5,4 0,5 3,2 0,3 8 0,8 24,5 0,5 91 10 1 5,5 0,5 4 0,4 14 0,4 6,6 0,7 3,5 0,3
Colour Blue
B3CP07HP
C3
REAR AXLE
Tightening torques (m.daN) (1) Rear axle fixing screw (2) Anti-roll bar (3) Rear axle crossmember (4) Rear suspension arm rubber mounting yoke (5) Rear suspension arm rubber mounting (6) Yoke / suspension arm fixing screw (7) Rear suspension arm (8) Stub axle bearing nut (9) Damper (10) Damper upper fixing (11) Damper lower fixing (12) Suspension spring (13) Suspension arm fixing on rear axle crossmembe (14) Secondary brake cable guide and support assembly (15) Travel stop : : : : : : : : : : : : : : : 10 1
7,6 0,5 20 2 greased 4,5 0,4 9,3 1 13 1,3
Anti-roll bar AXLES SUSPENSION STEERING Diameter (mm) HFX- KFV- NFU 8HX-8HW 8HV-8HY 330 25.5 (tubular)
B3DP09GP
SUSPENSION
C3
Front axle (1) Nut fixing suspension leg on body : 6,5 0,6 (2) Damper : (3) Anti-roll bar link rod upper ball-joint : 3,2 0,3 (4) Suspension leg pivot : 5,4 0,5 (5) Anti-roll bar link rod lower ball-joint : 3,2 0,3 (6) Anti-roll bar bearing fixing on subframe : 8 0,8 (7) Hub nut : 24,5 0,5 (8) Wheel bolt :91 (9) Subframe to bodyshell fixing screw : 10 1 (10) Anti-roll bar : (11) Pivot lower ball-joint fixing on lower arm : 5,5 0,5 (12) Pivot lower ball-joint fixing : 4 0,4 (13) Lower arm front and rear mounting fixing : 14 0,4 (14) Stabiliser bar screw : 6,6 0,7 (15) Steering ball-joint fixing : 3,5 0,3 Anti-roll bar Engines Diameter (mm) Colour All Types 19 Bue Pivot Engines Diameter of bearing Type All Types 72 U (Cast-iron) Damper Engines Damping law All Types R 59 M
B3CP07RP
331
C3
SUSPENSION
Front axle (1) Nut fixing suspension leg on body (2) Damper. (16) Cup. (17) Damper nut. (18) Damper cup. (19) Ball bearing (20) Spring thrust cup. (21) Travel stop cup. (22) Suspension spring. (23) Damper rod protector. (24) Travel stop. : 6,5 0,6 : 6,5 0,6
B3BP180D
332
SUSPENSION
Rear axle (25) Rear axle fixing screw (26) Anti-roll bar (27) Rear axle crossmember (28) Rear suspension arm silentblock mounting yoke (29) Rear suspension arm silentblock (30) Suspension arm fixing screw on yoke (31) Rear suspension arm (32) Stub axle bearing nut (33) Damper (34) Damper upper fixing screw (35) Damper lower fixing screw (36) Suspension spring (37) Travel stop (38) Secondary brake cable guide support Anti-roll bar Engines All Types Damper Engines 1.4i (Auto.) - 1.6i 16V 1.4 HDi 16V 1.1i-1.4i (BVM)-1.4 HDi
B3DP09UP
C3
: : : : : : : : : : : : : : 10 1
7,6 0,5 202 (greased). 4,2 0,4 10,6 1
Diameter (mm) 25.5 (Tubular)
F77D F77B (*)
(*) = For CRD vehicle 333
F168K
C3
FEATURES OF ELECTRIC POWER STEERING

Engines : HFX - KFV - NFU - 8HX - 8HW - 8HY Steering column
B3EP13GD
B3EP13HC
Tightening torques m.daN. (1) Steering wheel fixing (2) Steering column fixing on support (3) Steering cardan fixing 334 : 2 0.3 : 2.2 0.5 : 2.2 0.2 AXLES SUSPENSION STEERING
Identification Identified by the colour of the ring at "a". Left hand drive Right hand drive : BLUE ring : WHITE ring.

Engines : HFX - KFV - NFU - 8HX - 8HW - 8HY Steering mechanism Tightening torques m.daN (4) Ball-joint fixing on pivot (5) Steering rod lock-nut (8) Threaded washer (9) Stud (10) Flat washers (11) Fixing of mechanism on subframe
B3EP13JD
C3
: 3,5 0,3 : 5 0,5
: 8 0,8
HFX - KFV - 8HX - 8HW Electric motor Steering rack travel Steering ratio Number of rotations of steering wheel Inner angle of lock Outer angle of lock 60 A 2x72 45.6/1 3.2 38 3224
KFV (Auto.) NFU - 8HY - 8HV 65 A 2x64 Connectors. (6) Supply of electric assistance motor. (7) Torque sensor signals.. AXLES SUSPENSION STEERING
2.8 3230 2842 335
C3

Engines : HFX - KFV - NFU - 8HX - 8HW - 8HY Steering assistance
B3EP13KC
B3EP13LC
Supplier: KOYO. The steering assistance is provided by the assistance motor (12), controlled by the ECU. Power delivered to the assistance motor (12) depends on: - Speed of the vehicle. - Torque applied on the steering wheel. 336 AXLES SUSPENSION STEERING
Electric power-assisted steering ECU. Only one ECU version, whatever the engine-type. The electric power steering ECU is linked to the following connectors: - (6) Assistance motor supply. - (13) Electric power steering ECU supply. - (14) Control signals. After changing the electric power steering ECU, it is necessary to perform a configuration. (See corresponding operation).
SPECIAL FEATURES : STEERING

Engines : HFX - KFV - NFU - 8HX - 8HW - 8HY Centring the steering rack Preliminary operation.
C3
Raise and support the vehicle on a two-column lift. Remove, on the RH side of the steering rack: - Clip (1). - Clip (2). Release the steering rack protection gaiter. Setting Move the steering to full left hand lock. Measure the dimension X. Move the steering to full right hand lock. Measure the dimension Y. Calculate the dimension: L = (Y X) : 2. Refit: - The steering rack protection gaiter - New clips (1) and (2).
B3EP13VD
B3EP13UC
337
C3
XSARA ALL TYPES # RPO 8666 Front height Rear height
AXLE GEOMETRY
Front and rear measuring points XSARA ALL TYPES RPO 8667 # Front height Rear height
B3CP046D
B3CP06ZD
H1 = Dimension between the centre of the front suspension arm mounting and the ground. H2 = Dimension between the contact face of the rear mounting and the ground. 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.
338
AXLE GEOMETRY
Reference heights Tools [1] Gauge for measuring the radius of wheels with 4 bolts : 8006-T : 4300-T # NRPO 9428 NRPO 9429 #
XSARA - All Types
Setting the reference height. Front Measure the dimension R1. Calculate the dim. H1 = R1 - L1. Rear 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
Front axle Engines Reference heights (in mm) 2.0i 16V (RFS) 115.5 All engines (except 2.0i 16V and CRD) 90.5 All CRD engines 75.5 339 2.0i 16V (RFS) 73
Rear axle AXLES SUSPENSION STEERING All saloons (except 2.0i 16V and CRD) 83 Estate All CRD engines 103
88
XSARA - All Types
AXLE GEOMETRY
Values of the front and rear suspensions, at reference height
ESSENTIAL : When checking the suspensions, the vehicle should be at reference height.
Tools used : Compress the suspension, to obtain the values at reference height. [1] Set of two suspension compressors [2] Set of four straps [3] Set of four shackles : 9511-T.A : 9511-T.B : 9511T.C
WARNING
B3CP04LC
A B = Negative figure: 340
+= =
TOE-IN TOE-OUT
AXLE GEOMETRY
Values of the front and rear suspensions, at reference height Front axle Saloon or entreprise KFW Saloon all engine types except KFW Estate all engine types except CRD (*) Saloon CRD (*) KFW - 1.5 1 mm - 015 10 (ouverture) 3 NO 1040 0 Rear axle Tolerances Adjustable Saloon all engine types Saloon entreprise 4.54 1.3 mm 0 41 11 - 057 2.0i 16V (RFS) Estate all engine types 4.27 1.3 mm 0 39 11 - 058 1044 255 1022 012 3 07 11 07 - 0 07
XSARA
Tolerances Adjustable
2.0i 16V (RFS)
Saloon CRD (*) all engine types except KFW Estate CRD (*) all engine types
Tracking Castor Pivot angle Camber
1 mm 18 30 30
YES
255 1026 007 Saloon CRD (*) all engine types Estate CRD (*) all engine types AXLES SUSPENSION STEERING 3.45 1.3 mm 0 31 10 - 059
1.3 mm Tracking Camber 15
NO YES
5.1 1.3 mm 0 46 11
(*) CRD = Difficult road conditions. 341
XSARA - All Types
AXLE GEOMETRY
a = Angle which defines the tracking between the front and rear axles. Its value must not exceed 12'.
B3CP04UC
342
FRONT AXLE
XSARA - All Types

Tightening torques (m.daN). (1) Damper nut (2) Cup screw (3) Suspension leg (4) Anti-roll bar link rod upper ball-joint (5) Suspension leg pivot (hollow pivot) (5) Suspension leg pivot (pivot H) (6) Anti-roll bars (7) Anti-roll bar link rod lower ball-joint (8) Pivot lower ball-joint (9) Driveshaft nut (10) Wheel bolt (11) Lower arm front mounting (12) Lower arm rear mounting and anti-roll bar bearing (13) Screw under rear mounting (14) Ball-joint fixing on lower arm Subframe to bodyshell fixing screw 4.5 0.4 2.5 0.3 3.7 0.3 4.5 0.5 5.5 0.5 3.7 0.3 4 0.4 32.5 2.5 91 7.6 0.7 6.8 0.6 3.1 0.3 5 0.5 8.5 0.8
Vehicles RPO 8667 # are all equipped as standard with ventilated discs.
B3CP040P B3CP041D
343
XSARA - All Types
FRONT AXLE
Evolution : Suspension arm ball-joint Application from RPO : 7968. New components : - Suspension arm ball-joint. - Pivot. Old fitting A = 16 mm. New fitting A = 18 mm. Repair requirements. ESSENTIAL : Swapping of old and new components is forbidden. It is permitted to fit a new pivot/ball-joint assembly on one side of an old vehicle. Replacement Parts. The old components are still available from Replacement Parts.
B3CP054D
344
FRONT AXLE
Anti-roll bars Engines 1.6i-1.6i 16V-1.9D 2.0i 16V (RFV)-1.4 HDi -2.0 HDi 2.0i 16V (RFS) Saloon Estate Saloon Diameter 19 20 21
XSARA - All Types
Colour reference Blue Yellow White
345
XSARA - All Types

XSARA # 07/1999
FRONT AXLE
XSARA 07/1999 # 09/2000 The angle of castor changes to 3 except for LPG vehicles, CRD vehicles, and Estates All Types. CRD = Difficult Road Conditions : this type of vehicle has axles and suspensions designed for driving on rough road surfaces. XSARA 07/1999 # 09/2000
Lug "a" to the rear.
Lug "a" to the front.
Pivot ball-joint Manual steering, groove at "b". Power-assisted steering, groove at "b". NOTE : Vehicles after 09/2000 # are all equipped as standard with ball-joints without the groove at "b".
B3CP042D
B3CP049C
B3CP043D
346
REAR AXLE
XSARA - All Types

Tightening torques (m.daN)* (1) Anti-roll bar lever (2) Anti-roll bar (3) Transversal torsion bars (4) Rear crossmember flanges (5) Front silentblocks (6) Rear silentblocks (7) Anti-vibration clamp. (8) Damper pin (9) Stub axle nuts (lubricated) 9.6 0.9 18.5 1 8.3 0.8 5.5 0.5 4.5 0.4 3.2 0.3
Note AXLES SUSPENSION STEERING - The RH torsion bar is identified by 1 paint line. - The LH torsion bar is identified by 2 paint lines.
B3DP04SP
347
XSARA - All Types

Vehicles Engines 3-door Entreprise 19.D 3- and 5-door TT exc. Entreprise 19.3 18.7 20 19.3 20 21 19.3 20
REAR AXLE
Torsion bars (mm) Diameter Colour reference Violet Yellow Grey Violet Grey Light green Violet Grey 19 18 20 19 20 23 19 20 Anti-roll bars (mm) Diameter Colour reference Orange Blue Green Orange Green Without colour, or white sticker Orange Green
Estates All types

1.6i 16V-2.i 16V 1.4 Hdi-2.0 HDi 2.0i 16V Grand Export GRD 3- and 5-door TT
Estates All types

3-door VTS 3- and 5-door TT Estates All types
348
REAR AXLE
Evolution : Rear hub nut Old # 15/12/1999 New 15/12/1999 # -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 Evolution
XSARA
New fitting (B) (3) Rear hub nut. ESSENTIAL : Tighten to : 25 2,5 m.daN (greased) NOTE : It is possible to have both types of fitting on the same axle. The old nut (1) requires the fitting of the thrust washer (2). WARNING : do not fit a thrust washer (2) with a new nut (3). ESSENTIAL: Respect the tightening torque to be applied when fitting. WARNING: Identify the type of fitting, before starting a repair.
B3DP08AD
349
XSARA - All Types
REAR AXLE
Operating clearance - X = 1 to 1.4 mm. NOTE : The RH torsion bar can be identified by 1 paint line. The LH torsion bar can be identified by 2 paint lines
B3DP04TC
- The front silentblocks are aligned at an angle of 45 in relation to the vehicles axis. - The rear silentblocks are in parallel with the vehicles axis. NOTE : There are two suppliers for the silentblocks: - RBT, identified by a Green or Yellow painted dot on the side of the mounting. - PAULSTRA, identified by a Black painted dot on the side of the mounting. It is FORBIDDEN to swap components of different suppliers.
B3DP04UD
350
REAR DAMPER
Adjusting the rear dummy damper Engines 1.9 D 1.6i 16V 3-door 1.6i 16V 5-door 2.0i 16V (RFN) 1.4 HDi -2.0 HDi 2.0i 16V (RFS) Estates and Entreprise all types 339
XSARA - All Types

Lengths of the rear dummy damper (mm) Normal driving Grand export 346 339 346 318 336 342
E5AP14WC
351
XSARA - All Types

Steering wheel - Manual steering
MANUAL STEERING SPECIFICATIONS

- (a) : L.H.D./R.H.D. = White. - (L) : Shaft length = 311 1.5 mm. - (1) Steering wheel fitted with AIRBAG. (according to equipment). - (4) Steering column adjustment lever. 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. The locating bush must be centred in the reference window before tightening the cardan bolts (6). AXLES SUSPENSION STEERING
B3EP08PD
352

Manual steering
XSARA - All Types
Tightening torques (m.daN)
(7) Pivot ball-joint nut (8) Link rod lock nut (9) Ball-joint on steering rack (10) Fixing on cradle (11) Plunger flange screw
:4 : 4.5 :6 :5 : 1.2 AXLES SUSPENSION STEERING
B3EP042D
353
XSARA - All Types

Manual steering (continued) Steering rack travel (mm) Number of teeth Steering stop colour code Pinion Steering rack
Number of steering wheel turns
Steering ratio
6 teeth L.H.D. 73.5 (RH helix) 29
(13) 4.3 Yellow thickness mm 22/1
- Length of the steering track rods (Pre-adjustment) = 371 mm (Between ball-joint centres) or 391 mm (Between the centre of the pivot ball-joint and the contact face of the steering rack ball-joint). AXLES SUSPENSION STEERING
354
POWER-ASSISTED STEERING SPECIFICATIONS

Steering wheel - Power-assisted steering
XSARA - All Types
- (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) AIRBAG (3) Steering (5) Steering (6) Steering to steering wheel fixing wheel fixing column to support fixing cardan joint fixing : : : : 0.8 3.3 2.3 2.3
- (b) = Locating bush. The locating bush must be centred in the reference window before tightening the cardan bolts (6).
B3EP08QD
355
XSARA - All Types

Power-assisted steering
Tightening torques (m.daN)
(7) Pivot ball-joint nut (8) Link rod lock nut (9) Ball-joint on steering rack (10) Fixing on subframe (11) Hydraulic pipe connection (12) Valve to housing fixing (13) Plunger flange screw
:4 : 4.5 :6 :5 : 2.5 : 1.2 : 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 : 5.5
B3EP08RD
356

Power-assisted steering (continued) Steering rack travel (mm) Number of teeth Pinion Steering rack Number of steering wheel turns
XSARA - All Types
Steering ratio
L.H.D.
71.7
(*) (RH helix)
28
3.3
18.8/1
Steering valve Vehicles All types (except 1.8i 16V - 1.9TD) 1.8 i 16V - 1.9 TD Protector colour BLACK ORANGE Number of teeth (*) 7 AXLES SUSPENSION STEERING 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). 357
XSARA - All Types

Power-assisted steering assembly Tightening torques (m.daN). High pressure tube (Rubber seal pump side) - Power-assisted valve and pump union 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.
: 2.5
: : : :
2.5 2.5 2.2 2.2
Power-assisted steering system capacity = 1 litre. Oil type: TOTAL FLUIDE ATX. SAGINAW Pump adjustment = 100 Bars 5. Pump shaft threading 3/8 - 16 threads per inch.
B3EP045D
Pressure switch on the pressure circuit. - Switch opens 30 to 35 Bars. - Switch closes 25 Bars. - Tighten to : 2 m.daN.
358
AXLE GEOMETRY
Measurements at reference height
NOTE : To make the setting of reference height easier, it is acceptable to take the measurement from the flange of the jacking point. WARNING : The values shown should only be used as guides. In case of doubt, check the settings at reference height Front height Rear height
B3CP05BC
B3CP058D
B3DP079C
H1 = R1 L1
H1 = R1 L1
H2 = R2 - L2 H2 = From the rear axle silentblock face to the ground. R2 = Radius of the rear wheel when laden. L2 = From the centre of the wheel to the rear axle silentblock face.
359
H1 = From the front suspension arm linkage bolt axis to the ground. R1 =Radius of the front wheel when laden. L1 = From the centre of the wheel to the front suspension arm linkage bolt axis. H1 = From the front jacking point to the ground. L1 = From the front jacking point to the radius of the front wheel when laden.

Front axle
AXLE GEOMETRY
Rear axle
Measurements at reference height (continued). (The reference height of the vehicle is set as per the table below).
B3CP05BC
B3CP05AC
B3DP079C
H1 = R1 L1
ou Front axle
H1 = R1 L1 Vehicles all types
H2 = R2 + L2 Rear axle
L1 = 90.5mm H1 = R1 L1 L1 75.5 Measure the radius of the front wheel : R1. Calculate dimension H1 or H1. AXLES SUSPENSION STEERING or
L1 = 124 mm CRD vehicles (Difficult Road Conditions) H1 = R1 L1 6FZ - RHZ L1 109
H2 = R2 + 8.5 mm H2 = R2 + L2 L2 23.5
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. 360
AXLE GEOMETRY
Measurements at reference height (continued). Vehicle All Types Front axle Vehicle Adjustable All Types Tracking Yes 0 1mm - 009 +009 3 18 10 43 30 Castor Pivot angle No 0 30 Camber

Compress the suspension to obtain the calculated values.
Rear axle Tracking Camber
4.8 mm 1mm - 0 43 0 09
- 113 18
Vehicle All Types CRD (Condition de route difficile) Front axle Vehicle Adjustable All Types Tracking Yes - 1 1mm - 018 00 256 18 1025 30 Castor Pivot angle Camber No 007 30 3.8 mm 1mm - 034 0 09 - 114 18 Tracking Rear axle Camber
WARNING A B = Negative figure: += = TOE-IN TOE-OUT
All Types Unladen (*)
Ground clearance 150 mm (Minimum value) 361
NOTE : When checking axles, the vehicle should be at reference height. (*) = Fuel tank full.
FRONT AXLE
Tightening torques m.daN. (1) Damper nut : 4.5 0.4. (2) Cup screw : 2.5 0.2. (3) Suspension arm. (4) Anti-roll bar link rod ball-joint : 4 0.4. (5) Suspension arm swivel : 4.5 0.4. (6) Anti-roll bar. (7) Anti-roll bar link rod ball-joint : 4 0.4. (8) Lower swivel ball-joint : 4 0.4. (9) Hub nut : 32.5 2 (greased). (10) Wheel bolts :91 (Face and threads not greased). (11) Lower arm front pivot : 8 0.8. (12) Lower arm rear pivot and anti-roll bar bearing : 6.5 0.6. (13) Screw under rear pivot : 3.5 0.3. Fixing bolt : subframe on bodyshell: 8.5 0.8. Anti-roll bar Engine Diameter 21 Colour ref. WHITE Damper upper bracket : Lug a to the front. 362
B3CP056P
B3CP057D
B3CP043D
NFV-6FZ RFN-RHY
REAR AXLE

Tightening torques m.daN. (14) Front silentblock on subframe (15) Anti-roll bar bolt (16) Rear torsion bar (17) Anti-roll bar (18) Tubular axle (19) Front silentblock on bodyshell (20) Rear upper arm. (21) Wheel bolt (Face and threads not lubricated) (22) Damper (23) Rear silentblock on subframe (24) Damper pin nut (25) Stub axle nuts (lubricated) (26) Rear silentblock on bodyshell Torsion bar Colour (mm) mark 19.6 PINK : 9.5 0.9. : 5.5 0.5.
: 4 0.4. : 9 1.
: : : :
5.5 0.5. 11 1. 25 2. 5.5 0.5. Colour mark ORANGE AXLES SUSPENSION STEERING
Anti-roll bar (mm) 21
Engine NFV-6FZ RFN-RHY

B3DP078D
NOTE : - The RH torsion bar can be identified by 1 paint line. - The LH torsion bar can be identified by 2 paint lines. 363

Evolution : Rear hub nut Old # 15/12/1999. New 15/12/1999 #
REAR AXLE
Evolution : - New rear hub nut (3). - Washer discontinued (2). Old fitting (A) (1) Rear hub nut. (2) Thrust washer. ESSENTIAL : Tighten to : 27,5 2,7 m.daN New fitting (B) (3) Rear hub nut. ESSENTIAL : Tighten to : 25 2,5 m.daN. NOTE : It is possible to have both types of fitting on the same axle. The old nut (1) requires the fitting of the thrust washer (2). WARNING : do not fit a thrust washer (2) with a new nut (3).
ESSENTIAL: Respect the tightening torque to be applied when fitting.

B3DP08AD
WARNING : Identify the type of fitting, before starting a repair. 364
SUSPENSION
XSARA PICASSO - All
Height of the vehicle in running order (The vehicle height, when in running order, is set according to the measurements shown in the table below).
Checking conditions : - Vehicle empty. - All reservoirs full. - Tyre pressures correct. - Steering rack locked straight ahead : point zero (see corresponding operation).
B3CP058D
Vehicles all types (except CRD) Front H1 = R1 L1 Engine L1 L1 ou H1 = R1 L1 RHY 66.5 mm 100 mm 365 Engine L2 Rear H2 = R2 L2 NFV - 6FZ - RHY 51 mm AXLES SUSPENSION STEERING
NFV - 6FZ 62.5 96
SUSPENSION
Vehicles all types (except CRD)
Measurements at the front and rear axles, vehicle in running order
Front axle Adjustable Tracking Castor Pivot angle Camber No Yes NFV 6FZ 2 1 mm 0 18 0 09 RHY 1.7 1 mm 0 15 0 09 Tracking
Rear axle Adjustable NFV 6FZ - RHY 1.2 1 mm 0 11 0 09 1 15 20
No Camber
2 54 20 10 6 30 0 20 30 10 12 30 0 15 30
WARNING A B = Negative figure:

B3CP02UC
+= =
TOE-IN TOE-OUT
366
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) 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 AXLES SUSPENSION STEERING
B3EP116D
367
Tightening torques (m.daN) (7) Pivot ball-joint nut (8) Steering rod adjusting lock nut (9) Ball-joint on steering rack (10) Fixing steering on subframe (11) Hydraulic pipe connection (12) Power steering valve (13) Plunger flange screws (14) Steering ram screw on housing (15) Steering ram screw on yoke : : : : : : : : : 4 0.4 4.5 0.4 6 0.6 8 0.8 2.4 0.2 1.2 0.2 1.2 0.2 9 1 9 1
NOTE : When removing the steering, it is imperative to replace screws (14) and (15) (new screws).
B3EP117D
368
Steering rack travel Left hand drive Right hand drive 71.7x2
Rack pinion LH helix RH helix
Number of teeth in rack 28 teeth
Number of steering wheel turns 3.22
Turning circle between walls 12 m
Turning circle between kerbs 11.48 m
Motorisation NFV - 6FZ - RFN - RHY
Steering valve Number of teeth : 7
Length of the steering link rods (pre-adjustment): - Between ball-joint centres = 392 mm - Between the centre of the pivot ball-joint and the contact face of the steering rack ball-joint = 412 mm. AXLES SUSPENSION STEERING
369
Tightening torques (m.daN). Unions between pump unions and power steering valve (16) Fixing screw (17) Fixing screw (18) Fixing screw NOTE : Coat the threads with product E3. 2 0.3 2.2 0.3 2.2 0.3 2.2 0.3
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 Capacity of power steering circuit = 1 Litre. Oil quality = TOTAL FLUIDE ATX. Power steering pump : Supplier SAGINAW. Pump adjustment = 100 5 Bars. Pump shaft threading 3/8 - 16 threads per inch
B3EP118D
370
BRAKE SPECIFICATIONS
(1) Compensator integral with the wheel cylinder. (2) Load sensitive compensator. Master cylinder Master-vac mm Fr Caliper/piston makes Disc Non-ventilated Ventilated 10/8 GALFER 3726 TEXTART 4009 19 180/182 TEXTART 4900 1.1 i - 1.4 i 1.5 D 19 177.8 BENDIX Standard 4/48 247 247 20.4/18.4 1.6 i Power-assisted steering without ABS 20.6 203.2
SAXO - All Types

1.6 i 1.6 i 16V 22.2 228.6 TEVES FN48/48
Disc thickness/min. thickness Brake pad grade mm Rr Cylinder or caliper Drum / max. Disc Non-ventilated
AS FM 380 30 247 8/6
Disc thickness/min. thickness Make Brake lining grade Compensator 371 BENDIX RAD DON 8259 (1) 20
BENDIX S4 AS FM 380 (2) 13
BRAKES
BRAKES
SAXO - All Types

(1) Compensator integral with the wheel cylinder. (2) Load sensitive compensator. Master cylinder Master-vac mm Fr Caliper/piston makes Disc Non-ventilated Ventilated
BRAKE SPECIFICATIONS (continued)

1.1 i - 1.4 i 1.5 D 1.6 i Power-assisted steering with ABS 20.6 203.2 BENDIX Standard 4/48 247 247 10/8 JURID 519 20.6 203/205 247 8/6 LUCAS RAI JURID E 558 (2) 13 372 BENDIX S4 AS FM 380 BENDIX RAD DON 8259 (1) 20 20.4/18.4 AS FM 380 30 10/8 GALFER 3726 TEXTART 4009 19 180/182 TEVES FN 48/48 BENDIX Standard 4/48 247 1.6 i 1.6 i 16V Entreprise 1.1i-1.5D Manual steering
Disc thickness/min. thickness Brake pad grade mm Rr Cylinder or caliper Drum / max. Disc Non-ventilated
Disc thickness/min. thickness Make Brake lining grade Compensator
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. NOTE : Do not touch (3) which has been adjusted at the factory.
B3FP06FC
Adjusting the stop lamp switch. Clearance J = 2 to 3 mm. After adjustment, tighten the lock nut (1) to 1 m.daN. 373
BRAKES
BRAKES
SAXO - All Types

Auto. - 1.1 i - 1.4 i - 1.6 i
BRAKES (continued)
Tightening torques (m.daN) Removing the caliper
- 1.1i Manual steering - Screw M8 - Screw M12
3.2 0.3 12 1.2
- 1.1 i - 1.4 i (Except 1.6 i) - 2 Screws M12
12 1.2
- 1.6 i - 2 Screws M12
10.5 1
NOTE : See evolution on following pages 254 to 256.

B3FP10ND
374
BRAKES (Continued)
EVOLUTION : Fixing screws for FRONT brake calipers: Type BENDIX STANDARD 4. Application from RPO 8973. Vehicles concerned. Vehicles equipped with non-ventilated brake discs. (Except VTS trim level). Vehicles equipped with the following engines: TUD5 TU1JP TU3JP TU1M+ (Entreprise) and TU9M (Entreprise). Evolutions. Evolutions of the following components: Front brake caliper fixing screws. Stop plates for front brake caliper fixing screws. Evolutions of the fixing screws: Coating on the threads of the fixing screws. Flanges for better centring of the fixing screws. NOTE : The fixing screws are matched to the stop plates. IMPERATIVE : Respect the tightening torques. Old fitting: tighten to 12 m.daN. 1.2 (up to RPO 8972). NEW FITTING (from RPO 8973). Tightening : 3.5 m.daN 0.3 Angular tightening : 87 3 Repair.
SAXO - All Types
Removing-refitting the front brake caliper (old and new fitting) Clean the threads of the fixing screws and coat them with a brake product of type E3. Tightening Angular tightening : 3.5 m.daN 0.3 : 87 3
Interchangeability The new fixing screws matched to the new stop plates can be fitted on the old front brake calipers. IMPERATIVE : Respect the matching of the stop plates and fixing screws. Replacement parts. The Replacement Parts service markets both the old and the new components.
375
BRAKES
BRAKES
SAXO - All Types

Application from RPO 8973. Vehicles concerned. Vehicles equipped with non-ventilated brake discs. (Except VTS trim level). Vehicles equipped with the following engines: TU5J4 and TU5JP. Evolutions. Evolutions of the following components: Rear brake caliper fixing screws. Stop plates for rear brake caliper fixing screws. Evolutions of the fixing screws: Coating on the threads of the fixing screws. Flanges for better centring of the fixing screws. NOTE : The fixing screws are matched to the stop plates. IMPERATIVE : Respect the tightening torques. Old fitting: tighten to 11 m.daN 1 (up to RPO 8972). Tightening NEW FITTING (from RPO 8973). : 7.5 m.daN 0.7
BRAKES (Continued)
EVOLUTION : Fixing screws for REAR brake calipers: Type BENDIX STANDARD 4.
Repair. Removing-refitting the rear brake caliper (old and new fitting) Clean the threads of the fixing screws and coat them with a brake product of type E3. Tightening : 7.5 m.daN 0.7
Interchangeability The new fixing screws matched to the new stop plates can be fitted on the old rear brake calipers. IMPERATIVE : Respect the matching of the stop plates and fixing screws. Replacement parts. The Replacement Parts service markets both the old and the new components.
376
HANDBRAKE (Adjustment)
Prior to adjustment.
SAXO - All Types
- 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
377
BRAKES
BRAKES
SAXO
The brakes are bled :
BLEEDING THE BRAKES
- 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.
378
BRAKE SPECIFICATIONS (WITHOUT ABS)

1.1i Engine type Master cylinder Master vac mm Fr Caliper/piston makes Disc Plain Ventilated 13/11 TEXTAR T 4144 203 205 DON 8259 HFX 1.4i KFV 20.6 203.2 LUCAS/TRW 266 C48/13 48 8HX 1.4 HDi
C3
8HW
Disc thickness/min. thickness Brake pad grade mm Rr Make Brake lining grade Drum Max. thickness
379
BRAKES
BRAKES Fr Rr
C3
BRAKE SPECIFICATIONS (WITH ABS)

1.6i 16V 1.4 HDi 16V 8HV 22.2 228.6 LUCAS/TRW Plain Ventilated 266 22/20 TEXTAR T 4144 LUCAS C38 HR 9/13 247 9/7 GALFER G 4554 C54/22 54 8HY
Engine type Master cylinder Master vac mm Caliper/piston makes Disc
NFU
Disc thickness/min. thickness Brake pad grade mm Cylinder or caliper Disc Ventilated
Disc thickness/min. thickness Make Brake pad grade
380
Braking circuit without ABS - REF (drum brakes at the rear) Braking system specifications
C3
Braking circuit at X. - Front brakes with ventilated discs (*). - Rear brakes with eitther drums or discs (*). - Handbrake lever controlling cables acting on the rear wheels. The compensator and main brake limiter functions are assured by the ABS EBD system. NOTE : REF = Electronic Brakeforce Distribution
(*) = according to version
B3FP161D
381
BRAKES
BRAKES
C3
Braking circuit with ABS - REF (drum brakes at the rear)
B3FP162D
382
Braking circuit with ABS - REF (Disc brakes at the rear)
C3
B3FP163D
383
BRAKES
BRAKES
C3
Braking circuit with ABS - REF
(a) Hydraulic circuit. (b) Electrical circuit. (1) Master cylinder in tandem. (2) Braking servo. (3) Brake caliper (or drum at the rear). (4) Hub equipped with a bearing with an integral magnetic wheel (48 pairs of poles). (5) Wheel sensor. (6) Brake fluid level sensor. (7) Hydraulic block plus ECU. (8) Stoplamp switch. (9) Instrument panel. (10) Diagnostic socket. (11) Built-in systems interface (BSI).
B3GP02RP
384
ABS hydraulic block # NOPR 9423 ABS hydraulic block: RPO 9424 #
C3
B3GP03DC
B3GP03EC
Components ABS hydraulic block
Supplier TEVES
Part No. ABS MK 60 : 96 394 937 80
Observations Installed on the front LH chassis member : 4 adjustment channels 47-way connector. Supplier TEVES
Components ABS hydraulic block
Supplier TEVES
Part No. ABS MK 70 : 96 419 653 80
Observations Installed on the front LH chassis member : 4 adjustment channels 26-way connector. Observations
Vehicle equipped with ABS and ESP systems Components ABS hydraulic block NOTE : ESP = Electronic Stability Programme 385 Part No. ESP -ABS MK 60 : 96 418 772 80 Installed on the front LH chassis member : 4 adjustment channels 47-way connector.
BRAKES
BRAKES
C3
Brake pedal gear
Front brake Rear brake
B3FP166D
B3FP164C
B3FP165C
Tightening torques (m.daN). (16) Servo fixing (17) Fixing on master cylinder 2.2 0.3 2 0.5 (12) Yoke fixing on caliper (13) Yoke fixing on caliper 386 10.5 1 3 0.3 (14) Rear caliper fixing on arm (15) Yoke fixing on caliper 5.30.5 3.80.3
Adjustment Lift and chock the vehicle. Remove: - The rear cover (8) - The nut (9). - The handbrake trim (6). - The gear lever gaiter (5). - The front cover (3). - The screws (1).
C3
Disconnect the connectors of the following components: - The cigar lighter (2). - The electric window buttons (4). Remove the central console (7). WARNING: Check that the brake cables are correctly routed under the vehicle. Slacken the handbrake lever. Press gently on the brake pedal (Then repeat the operation 3 times). Pull vigorously on the handbrake lever 4 or 5 times. 387
C5FP0ELD
BRAKES
BRAKES
C3
Adjustment (continued) (10) Nut for adjusting cable tensions. Remove: - The rear wheels. - The drums (according to version). Release the handbrake. Use a gauge set to measure at a the travel of the lever from its stop. Adjust the nut (10) to obtain a travel of less than or equal to 1 mm at a. Refit the brake drums without tightening them (according to version). Action the handbrake lever 8 times with an effort of 40 m.daN. With the handbrake released, check the travel of the lever at a, using a gauge set. NOTE : The travel should be less than 1 mm and more than 0,05 mm. Refit: - The brake drums. - The wheels. - The central console. Check the operation of the handbrake. 388
B3FP16ED
BLEEDING AND FILLING THE BRAKING SYSTEM

Tools. [1] Generic bleeding apparatus : LURO or similar. Bleeding, refilling.
C3
B3FP15XC
Draining. Drain the brake fluid reservoir (1) to the maximum (if necessary, use a clean syringe). Disconnect the connector (4). Uncouple the pipe (2). Unscrew the shaft (3). Remove the reservoir (1). - Empty the brake fluid reservoir (1). - Clean the brake fluid reservoir (1). Refit: The brake fluid reservoir (1). The shaft (3). Couple the pipe (2). Reconnect the connector (4). Filling the braking system. WARNING : Use only those hydraulic fluids that are approved and recommended. - Fill the brake fluid reservoir (1). Bleeding the braking system. WARNING: During the bleeding operation, take care to maintain the level of brake fluid in the reservoir and to top it up, using only brake fluid that is clean and clear. 389
BRAKES
BRAKES
C3
BLEEDING AND FILLING THE BRAKING SYSTEM (CONTINUED)

Bleeding the primary braking circuit.
WARNING: The ABS should not be active during the bleeding operation. Front brake caliper: Bleed screw (5). A : Rear brake caliper B : Rear brake drum Bleed screw (6). Bleed each wheel cylinder, proceeding in the following order : Front LH wheel. Front RH wheel. Rear LH wheel. Rear RH wheel
B3FP15YC
B3FP15ZD
390
BLEEDING AND FILLING THE BRAKING SYSTEM (CONTINUED)
C3
With the bleeding apparatus - Connect the bleeding apparatus [1] on the brake fluid reservoir (1). - Adjust the apparatus pressure to 2 Bars. For each circuit : - Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container. - Open the bleed screw, wait until the fluid is flowing out without air bubbles. - Close the bleed screw. - Remove the bleeding apparatus [1]. - Check the brake fluid level (Should be between MINI level and MAXI level). - Fill if necessary with the approved and recommended synthetic brake fluid. Without the bleeding apparatus. NOTE : Two operators are necessary. For each circuit : - Apply the brake pedal to place the circuit under pressure. - Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container. - Open the bleed screw, wait until the fluid is flowing out without air bubbles. - Close the bleed screw. - Remove the tool [1]. NOTE : Recommence the process a second time if that is necessary. - Check the brake fluid level, (Should be between MINI level and MAXI level). - Fill if necessary with the approved and recommended synthetic brake fluid.
B3FP160C
391
BRAKES
BRAKES Fr Rr
XSARA
1.4i KFW Master cylinder mm Master-vac Caliper/piston makes Disc Ventilated BOSCH 54 266 FERF 769 203/205
Saloons 1.6i 16V NFU RFN 2.0i 16V RFS 1.9 D WJY 1.4 HDi 8HZ RHY 2.0 HDi RHZ
Without ABS 23,8 (expansion holes) 228.6 LUCAS 57 283 22 /20 ASFM 380 13 / 2
With ABS 23,8 (valve) BOSCH 54 266 FERF 769
Disc thickness/min. thickness Brake pad grade Thickness/min. thickness Drum - min./max. mm Disc non-ventilated Disc thickness/min. thickness Make Brake lining grade Make/Type Cut-off pressure in Bars Ramp/Paint reference
203/205 247 8/6 247 8/6 TEXTAR 428 BENDIX D 8259 E 558 JURID 519
BENDIX D 8259
JURID 519
BOSCH / Load-sensitive compensator 32 0.3 - White 392
Estates 1.4i KFW Master cylinder mm Fr Master-vac Caliper/piston makes Disc Ventilated BOSCH 54 266 FERF 769 228/230 247 8/6 JURID E 558 519 E 558 BOSCH / Load-sensitive compensator 32 0.3 - White 393 1.6i 16V NFU RFN 2.0i 16V RFS 1.9 D WJY 1.4 HDi 8HZ RHY
XSARA
2.0 HDi RHZ
Without ABS 23,8 (expansion holes) 228.6 LUCAS 57 283 22 /20 ASFM 380 13 / 2
With ABS 23,8 (valve) BOSCH 54 266 FERF 769 228 / 230 247 8/6 519
Disc thickness/min. thickness Brake pad grade Thickness/min. thickness Drum - min./max. mm Disc non-ventilated Disc thickness/min. thickness Rr Make Brake lining grade Make Cut-off pressure in Bars Ramp/Paint reference
BRAKES
BRAKES
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
394
XSARA - All Types

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 or (1) Hydraulic valve block ABS Bosch 5.3 REF or (1) Hydraulic valve block ABS with ESP Bosch 5.7 . - (2) Load sensitive braking compensator (according to model).
B3FP09HC
B3FP09JC
395
BRAKES
BRAKES
XSARA - All Types

Braking system without ABS (rear drum brakes) Up to RPO 8687
Braking system without ABS (rear disc brakes)
B3FP14FD
B3FP14GD
396
Braking system with ABS (rear drum brakes)
XSARA - All Types
B3FP14HD
397
BRAKES
BRAKES
XSARA - All Types

Braking system with ABS REF (rear disc brakes)
Braking system with ABS REF (rear drum brakes)
B3FP14JD
B3FP14KD
398
Braking system with ABS REF (rear drum brakes)
XSARA - All Types
B3FP14LD
399
BRAKES
BRAKES
XSARA - All Types
Braking circuit with ESP (BOSCH 5.7)
(A) Hydraulic circuit. (B) Electrical circuit. (1) Master cylinder in tandem. (2) Braking servo. (3) Brake caliper (or drum at the rear). (4) Toothed wheel. (5) Wheel sensor. (6) Brake fluid level sensor. (7) Hydraulic block plus ECU. (8) Stoplamp switch. (9) Instrument panel. (10) Diagnostic socket. (11) Built-in systems interface (BSI). (12) Steering angle sensor. (13) Gyrometer/accelerometer sensor. (14) Switch.
B3HP004P
400
Components Electronic ECU Ref. 7 Electrical circuit Part No. Supplier 5.7 ESP 0 265 006 389
XSARA - All Types

Observations 42-way connector. Alone on the hydraulic block. Changing only the ECU is prohibited. 2-way grey connector. The sensors are inductive-type. Tightening torque: 0,8 0,2 m.daN 2-way grey connector. The sensors are inductive-type. Mounted on the brake caliper support. Non-adjustable airgap: 0,3 to 1,2 mm. Tightening torque: 0.8 0.2 m.daN 2-way grey connector. The sensors are inductive-type. Mounted on the suspension arm. Non-adjustable airgap: 0,3 to 1,2 mm. Tightening torque: 0,8 0,2 m.daN. Incorporated in the COM 2000. 6-way blue connector. Located on the central console. 6-way connector. Toothed wheel: 48 teeth. Integral with the driveshaft stub housing for the front wheels, joined to the hub bearing for the rear wheels.
Front wheel sensor
Rear wheel sensor (disc brakes) Rear wheel sensor (Saloon : drum brakes) Rear wheel sensor (Estate : drum brakes) Steering angle sensor Gyrometer/accelerometer sensor
BOSCH 5
0 265 006 202
0 265 006 203 0 265 006 441 12 13 VALEO BOSCH GKN
Toothed wheel
401
BRAKES
BRAKES
XSARA - All Types

(7) Hydraulic block
Gyrometer sensor
B3HP002C
C4AP17YC
Components
Supplier
Part No.
Observations
ESP hydraulic block
BOSCH
5.7 ESP
Located on the front LH wheelarch : 4 adjustment channels.
IMPERATIVE : Respect the direction of fitting of the gyrometer/accelerometer sensor (connector towards the rear of the vehicle). WARNING : The gyrometer/accelerometer sensor should not be subjected to any impact. Any gyrometer/accelerometer sensor having suffered an impact must be replaced. Tightening torque (15) : 0,6 0,1 m.daN.
402
REAR BRAKE SPECIFICATIONS

Evolution : Rear brake drum hub 01/1999 # Old assembly New assembly
XSARA - All Types
B3FP119D
B3FP11AD
Evolutions. New components : Rear wheel stub. - Stop ring (ref. (4)). - Double shouldered washer (ref. (5)) NOTE : The new assembly is identified by a figure from 1 to 6 cold-stamped on the head of the wheel stub at a. (1) Washer exterior diameter = 38 mm. (2) Stop ring (3) Circlip. NOTE : This assembly is equipped with either part (2) or part (3). 403 Ref. a: Figure from 1 to 6 cold-stamped. (4) Stop ring. (5) Double shouldered washer, exterior diameter = 48 mm.
BRAKES
BRAKES
XSARA - All Types

Old assembly
REAR BRAKE SPECIFICATIONS

Evolution : Rear brake disc hub 01/99 # New assembly
B3FP11BD
B3FP11CD
Evolutions Sealing of the brake disc hub. Fixing of the brake disc hub. New components: New components: - Rear wheel stub. - Sealed bearing incorporated at b (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. 404
CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR

Preliminary pre-check operations. Calculate : 1) The rear weight of the vehicle (empty tank + 1 person) 2) The weight of fuel in the fuel tank 3) The weight of options fitted to the vehicle # Note the vehicle type # Note the fuel level # Note the vehicle options
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.
Refer to table N 1 Refer to table N 2 Refer to table N 3
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 table N 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
405
BRAKES
BRAKES
XSARA - All Types
CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued)

(Weights in kg) TABLE N 2 (Weight of fuel in the fuel tank). Type of fuel 5 litres Petrol 4 9 18 27 36 Diesel 4 10 20 30 40
TABLE N 1 (Rear weight of the vehicle (Empty tank + 1 person)). Trim level Engine 1.4 i 1.6 i 1.8 i 1.8 i 16 V 1.9 D 1.9 TD 405 436 392 405 412 422 424 425 449 416 423 424 428 432 447 450 (Weights in Kg) TABLE N 3 (Weight of options fitted to the vehicle). Options Electric sun roof Protective grille Towing equipment (All models) 8 5 20 406 431 X SX Exclusive VTS
1/4 1/2 3/4 Plein
TABLE N 4 (Graph selection). Vehicle Model 1.4 i - 1.6 i - 1.8 i - 1.8 i (BVA) 1.9 D 1.8 i 16 V 1.9 TD Graph 1 2 3

GRAPH N 1 GRAPH N 2
XSARA - All Types
B3FP09XD
B3FP09YD
407
BRAKES
BRAKES
XSARA - All Types

GRAPH N 3
B3FP09ZD
408

- Braking pressure checking tool TOOLS : 4140-T.
XSARA - All Types
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 tables on preceding pages). - Check that no hydraulic fluid is leaking and that the pipes are not obstructed. - Refer to the graph which corresponds to the vehicle type (see preceding pages). CHECKS - Perform the checks between the wheels as follows : front left and rear right - front right and rear left. - With the engine running, increase the pressure at the rear to obtain a front pressure of 60 Bars. ESSENTIAL : The checking pressure must be obtained by progressively increasing the pressure (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 following page). - 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
409
BRAKES
BRAKES
XSARA - All Types
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
B3FP102C
410
HANDBRAKE
XSARA - All Types
CHECKING AND ADJUSTING THE HANDBRAKE
- Remove the handbrake console. - Jack up and chock the vehicle with the rear wheels hanging free. - Check the correct routing of the brake cables under the vehicle. - Apply and release the handbrake ten times. - Set the handbrake to the 3rd notch. - Tighten the nut (1) until the rear brakes are applied. - Pull the handbrake lever vigorously 4 to 5 times. - Set the handbrake to the 3rd notch. - Check that the rear brakes are applied. - Check that the wheels can be turned freely by hand with the handbrake released. - Lower the vehicle. - Refit the handbrake console.
B3FP095D
411
BRAKES
BRAKES
SAXO - All Types
BLEEDING THE BRAKES
Bleeding : The brakes can be bled either : - using brake bleeding equipment, in which case the pressure of the equipment should be set to 2 Bars. - or in the usual way. IMPERATIVE order of bleeding
Wheels : Rear Right. Front Left. Rear Left. Front Right.
Top up using brake fluid supplied by CITROEN Replacement Parts.
412
NOTE : On models equipped with ABS, there is no load-sensitive braking compensator. (*) ESP = Electronic Stability Programme Master cylinder Master-vac mm Fr Caliper/piston makes Disc Non-ventilated Ventilated 266 22/20 1.6i - 1.8i 16V - 2.0i 16V - 2.0 HDi Without ESP (*) 23.8 254 BOSCH ZOH 54

1.8i 16V - 2.0i 16V - 2.0 HDi With ESP (*)
283 26/24 FERODO 769(37)
Disc thickness/min. thickness Brake pad grade mm Rr Cylinder or caliper Drum / max. Disc non-ventilated
22.2 228.6/230 247/9/7 LUCAS ABEX 4930/2 20/61.6 413 TRW GALFER G4554
Disc thickness/min. thickness Make Brake lining grade Compensator cut-off in Bars
BRAKES
BRAKES
Braking system specifications
1
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 or - (1) Hydraulic valve block + ECU. - (2) Load sensitive rear braking compensator.
B3FP11VD
B3FP08ND
414
BRAKING SYSTEM SPECIFICATIONS

Without ABS

With ABS
B3FP11WD
B3FP7B9D
415
BRAKES
BRAKES

With ESP (Electronic Stability Programme)
BRAKING SYSTEM SPECIFICATIONS

Handbrake
B3FP7BRD
B3FP11XD
416

Tools
CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR

[1] Brake pressure checking tool : 4140-T 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 weighing more than 1 Kg.
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).
Rear weight of the vehicle (tank empty + 1 person) Note the vehicle type. Consult the correspondence table. Engine type NFZ 6FZ RFN RHY Rear weight (tank empty + 1 person) 542 531 532 540
Weight of fuel in the fuel tank Note the level of fuel in the vehicle and from this deduce the weight according to the table. Level of fuel (Litres) 5 1/4 1/2 3/4 Full 417 Weight of fuel in the fuel tank (Kg) Petrol Diesel 4 4 11 12 22 24 33 36 44 48
BRAKES
BRAKES

Tools

[1] Brake pressure checking tool = TU5JP+ = 542 Kg = 22 Kg = 10 Kg : 4140-T
Example. Type of vehicle Rear weight (tank empty + 1 person). Fuel tank half full : Sun roof 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 Weight (Kg) 10 5 4 10 9 19
(1) CRD # OPR 8885 (2) CRD (3) OPR 8886 # (4) OPR 8886 # CRD = Difficult road conditions. Table of allocation of graphs Vehicle engine version NFV RHY 6FZ NFV RHY (1) 6FZ RFN (2) RFN (3) RHY (4) 418 Graph N 1 2 3 4 5 6

GRAPH N 1

GRAPH N 2
B3FP13RD
B3FP13SD
Key : P = Rear pressure (in Bars). M = Weight (in Kg). 419 a = Front pressure 60 3 Bars. b = Front pressure 100 3 Bars
BRAKES
BRAKES

GRAPH N 4
GRAPH N 3
B3FP14MD
B3FP13UD
Key : P = Rear pressure (in Bars). M = Weight (in Kg). 420 a = Front pressure 60 3 Bars. b = Front pressure 100 3 Bars

GRAPH N 5

GRAPH N6
B3FP14ND
B3FP14PD
Key : P = Rear pressure (in Bars). M = Weight (in Kg).) 421 a = Front pressure 60 3 Bars. b = Front pressure 100 3 Bars
BRAKES
BRAKES

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. ESSENTIAL : The control pressure should be obtained by progressively increasing the pressure (without ever releasing the pressure to adjust it).
- Compare the value noted with the graph. - If the value is outside the tolerance, adjust 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. NOTE : 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.
E5-P01IC
422
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
423
BRAKES
BRAKES
XSARA PICASSO - All Tpes
Adjustment : Remove the handbrake trim (1). Unclip the sound-deadening (2). Raise and support the vehicle with the rear wheels hanging free. Check the correct routing of the brake cables under the vehicle. Apply and release the handbrake 4 times. 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
424
BLEEDING THE BRAKES

Tools Bleeding equipment of type LURO or similar. IMPERATIVE : For bleeding the secondary circuit, use ELIT, LEXIA or PROXIA diagnostic tools. Draining. Drain the brake fluid reservoir as empty as possible using a syringe. Disconnect the brake fluid warning lamp connector. Retrieve the brake fluid reservoir from its supply pipes by pulling upwards. Finish emptying the reservoir of brake fluid. Clean the brake fluid reservoir. Refit the brake fluid reservoir. Reconnect the brake fluid warning lamp connector. Filling Refill the reservoir with brake fluid. WARNING : Use only the recommended hydraulic fluids. Bleeding. NOTE : Two technicians are required.
XSARA PICASSO - Alll Types
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. 425
BRAKES
ALL TYPES
STARTER MOTORS
Abbreviations and definitions Coding of climates is as follows :
Meaning of abbreviations :
ELECTRICAL SYSTEM
CLIMATES : C T F GF Hot Temperate Cold Very cold : Starting possible as low as -18C : Starting possible as low as -18C : Starting possible as low as -25C : Starting possible as low as -30C BV BVM BVA BVMP DA WHIT AIRCON : Gearbox : Manual gearbox : Automatic gearbox : Piloted manual gearbox : Power-assisted steering : Air conditioning
426
STARTER MOTORS
Vehicles / models Manufacturer and Ref. Table of classes of starter motors CLASS Torque C Maximum power for a speed of 1200 rpm CLASS 2 5.5 Nm I 275 A CLASS 3 6 Nm I 300 A CLASS 4 10 Nm I 430 A CLASS 5 11.5 Nm I 470 A Class
ALL TYPES
Climate
CLASS 6 11.5 Nm I 500 A ELECTRICAL SYSTEM
427
SAXO
Vehicles / models
STARTER MOTORS
Manufacturer and Ref. VALEO D7E16 BOSCH A 001183 027 F MELCO M002T13081 VALEO D6 RA 572 VALEO D7E16 BOSCH A 001183 027 F MELCO M002T13081 VALEO D6 RA 572 VALEO D7E16 BOSCH A 001 183 027F MELCO M002T13081 VALEO D7E23 BOSCH E OAL 101 390 VALEO D6RA572 VALEO D6 RA 572 VALEO D6RA100 VALEO D7R151 Class 1 3 1 3 1 Climate H, T, C VC C, T C, VC H.T C VC 3 4 5 H, T, C, VC H, T, C VC
1.1i ELECTRICAL SYSTEM SAXO 1.4i 1.6i
1.4i (Aircon) 1.6i (Aircon)
1.6i 16v 1.4i Automatic 1.5D CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold) 428
STARTER MOTORS
Vehicles / models Manufacturer and Ref. VALEO D7E16 1.1i BOSCH A001 183 027F MELCO M002T 13081 VALEO D6RA572 VALEO D7E16 1.1 i Aircon 1.4 i Aircon 1.6i 16v Aircon C3 1.4 i 1.6 i 16v BOSCH A001 183 027F MELCO M002T 13081 VALEO D6RA572 VALEO D7E16 BOSCH A001 183 027F MELCO M002T 13081 VALEO D7E23 BOSCH E OAL 101 390 VALEO D6RA572 1.4I Automatic 1.4 HDi 1.4 HDi 16v CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold) 429 VALEO D6RA572 VALEO D6RA110 VALEO D7GP09 3 3 4 5 2 1 3 1 3 1 Class
C3
Climate
H, T, C VC H, T C, VC H, T ELECTRICAL SYSTEM
C VC H, T, C, VC H, T C, VC
XSARA
Vehicles / models 1.4i 1.6i (Power steering or aircon) 1.4i (Power steering and aircon) XSARA 1.6 i 1.6i Automatic 2.0i 16 v 2.0i 16 v Automatic EW10J4
STARTER MOTORS
Manufacturer and Ref. VALEO D7E16 BOSCH A 001183 027 F MELCO M002T13081 VALEO D6 RA 572 VALEO D7E23 BOSCH E OAL 101 390 VALEO D6RA572 VALEO D6 RA 572 VALEO D6 RA 72 MELCO M000T82081 BOSCH E OAL 098 390 MELCO M 000 T 85 381 VALEO D6 RA 661 2.0i 16v XU10J4RS BOSCH A 001 110 140 F BOSCH A 001 111 473 4 3 4 C, VC H, T C, VC 3 F, T 3 2 C, VC H, T C, VC C, VC, H, T 1 H, T Class Climate
ELECTRICAL SYSTEM
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold) 430
STARTER MOTORS
Vehicles / models Manufacturer and Ref. VALEO D6 RA 109 BOSCH A 001 111 562F 1.9D MELCO M 001 T 80381 VALEO D7 R 26 MELCO M 001 T 80481 VALEO D7 R 27 2.0 HDi 90 CV VALEO D6 RA 109 BOSCH A 001 111 562F MELCO M 001 T 80381 VALEO D7 R 27 2.0 HDi 110 CV 2.0 HDI Automatic 110 CV 1.4 HDi CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold) 431 VALEO D7 R 26 MELCO M 001 T 80481 VALEO D7 R 27 VALEO D7 R 27 MELCO A 001 236 000 VALEO D6RA110 VALEO D7GP09 6 5 6 6 6+ 4 5 4 5 6 4 Class
XSARA
Climate H, T ELECTRICITE
C VC H, T C, VC H, T C, VC C, VC C, VC H, T C, VC
XSARA
XSARA PICASSO
Vehicles / models
STARTER MOTORS
Manufacturer and Ref. VALEO D7E16 1.6i (Power steering or aircon) BOSCH A 001 183 027F MELCO M002T13081 VALEO D6RA572 1.6i (Power steering and aircon) VALEO D7E23 BOSCH E OAL 101 390 VALEO D6RA572 3 2 C, VC H, T C, VC 3 H, T, C VC 4 H, T 1 H, T Class Climate
ELECTRICAL SYSTEM XSARA PICASSO
VALEO D6 RA 72 1.8i 16v 2.0i 16v Automatic MELCO M000T82081 BOSCH E OAL 098 390 MELCO M 000 T 85 381 VALEO D6 RA 109 2.0 HDi BOSCH A 001 111 562F MELCO M 001 T 80381 VALEO D7 R 27
C, VC
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold) 432
ALTERNATORS
Abbreviations and definitions Coding of climates is as follows : CLIMATES : C T F GF : Hot (45C/37C) : Temperate (37C/17C) : Cold (17C/-25C) : Very cold (<-25C) BV BVM BVA BVMP Whitout aircon Whit aircon DA GEP DP 3 Pts NC TT N SOP TOP L.C. DAG DAD Meaning of abbreviations : : Gearbox : Manual gearbox : Automatic gearbox : Piloted manual gearbox : Without air conditioning : With air conditioning : Power-assisted steering : Electro-pump motor : Double lug : 3-Point : Not marketed : All Types : Level : Without Option : All Options : Heated rear screen : Left hand drive : Right hand drive
ALL TYPES
433
ELECTRICAL SYSTEM
SAXO
ALTERNATORS
Refer to the correspondance table for petrol or diesel engine Without aircon With aircon DA by GEP 7 7 8 7 7 8 7 8 8 9 8 9 Non DA or SAGINAW DA 8 7 8 7 DA by GEP 9 8 9 8
Engine/gearbox ELECTRICAL SYSTEM
Climate H T C VC H T C VC H T C VC H T C VC
Non DA or SAGINAW DA
TU1JP BVM
TU3JP/TU5JP/ TU5JP4 BVM
TU3JP Automatic
8 7 7 8 7 8
TUD5 BVM
9 8 9
Meaning of abbreviations, see page : 433 434
ALTERNATORS
Refer to the correspondance table for petrol or diesel engine Engine/gearbox Climate ALL APPLICATIONS
SAXO
TU All Types TUD5 BVM
ELECTRICAL SYSTEM
C3
Engine/gearbox Climate
ALTERNATORS
Refer to the correspondance table for petrol or diesel engine Whitout aircon Base RT3 N 1 or 2 RT3 N 3 Cold Pack Cold Pack + RT3 N 1 or 2 6 7 7 8 6 7 7 8 6 7 7 8 15 436 7 8 6 7 8 7 8 9 7 8 7 8 6 7
H TU1JP T BVM C VC H TU3JP T BVM C VC H TU3JP T Automatic C VC H TU5JP4 T BVM C VC H 6 TU5JP4 T 7 BVMP C VC DV4TD - DV4TED4 - BVM H,T,C,VC Meaning of abbreviations, see page : 433
Cold Pack + RT3 N 3 6 7
ELECTRICAL SYSTEM
ALTERNATORS
Engine/gb Climate Refer to the correspondance table for petrol or diesel engine With aircon Base RT3 N 1 or 2 RT3 N 3 Cold Pack Cold Pack + RT3 N 1 or 2 8 7 8 7 7 8 9 8 7 8 8 8 8 7 8 9
8
C3
Cold Pack + RT3 N 3 ELECTRICAL SYSTEM 9 8
H TU1JP T BVM C VC H TU3JP T 7 BVM C VC H TU3JP T Automatic C VC H TU5JP4 T BVM C 7 VC H TU5JP4 T BVMP C VC DV4TD - DV4TED4 - BVM H,T,C,VC Meaning of abbreviations, see page : 433
7 8 8 7
9 8 8 15 437
9
8 9
7 8
XSARA
ALTERNATORS
Refer to the correspondance table for petrol or diesel engine Whitout aircon Whit aircon Without Cold Pack Cold Pack Without Cold Pack Cold Pack RT2 RT2 Base Base Base Base RT2+NAV RT2+NAV
7 7 8 7 8 7 8 7 8 8 8 9 9 7 12 9 8 9 8 9 7 8 9 12 9 8 9 9 8 9 9 9 8 7 9 8 7 8 12 9
Engine/gb ELECTRICAL SYSTEM
Climate
H T C VC H T C VC H T C VC H T C VC H T C VC H T C VC
TU3JP BVM TU5JP4 BVM TU5JP4 Automatic EW10J4 BVM EW10J4 Automatic XU10J4RS BVM
NC
NC
NC 438
ALTERNATORS
Climate H T C VC H T C VC H T C VC H T C VC H T C VC
XSARA
Engine/gb
Refer to the correspondance table for petrol or diesel engine Whitout aircon Whit aircon Without Cold Pack Cold Pack Without Cold Pack Cold Pack Base RT2 Base RT2 Base RT2+NAV Base RT2+NAV
8 9 9(8) 15(9) 15(12) 12(8) 9(8) 15(9) 15(12) 12(8) 9(8) 15(12) 12(8) NC 15(15) 15 15(12) 8 9 8(8) 9(8) 15(12) 9(8) 15(9) 9(8) 15(9) 12(8) 15(9) 15(12) 12(8) 15 15(15) 9 8 9 12(8) 15(9) 15(12) 12(8) 9(8) 9(8) 9 12(8) 15(12) 12(8) 15(12)
DW8B BVM DW10TD BVM DW10ATED BVM DW10ATED Automatic DV4TD BVM
8(8) 15(9)
15(9)
15
NC 15(15) 15
15 NOTE : ( ) Allocation of climates for alternators on vehicles with additional heating.
439
ELECTRICAL SYSTEM
XSARA PICASSO
Whitout aircon Engine/gb ELECTRICAL SYSTEM Climate H T C VC H T C VC H T C VC Base NC 7 7 8 9 15
ALTERNATORS
Refer to the correspondance table for petrol or diesel engine Whit aircon Base 9 7 8 9 8 9 15 8 Nav. + Radio-telephone
Nav. + Radio-telephone
TU5JP4 L3 et L4 BVM
EW7J4/L4 BVM
DW10TD BVM
ALTERNATORS
Climate Refer to the correspondance table for petrol or diesel engine Whitout aircon Nav.+ Sige Heated Base Base Navigation chauffant seat
NC 7 8 NC 7 8 NC 8 8 9 NC 15 NC 15 8 8 9 8 8
XSARA PICASSO
Whit aircon Nav.+ Heated Navigation Heated seat seat
9 8 9 8 12 9 8 9 15
Engine/gb
H T C VC H DW10TD T BVM C VC H DW10ATED T BVM C VC H DW10ATED T Automatic C VC H DV4TD T BVM C VC Meaning of abbreviations, see page : 433 TU5JP/L4 BVM
15
441
ELECTRICAL SYSTEM
ALL TYPES
CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR

Checking the alternator output Connect as shown in the diagram opposite, using an ammeter (A), a voltmeter (V), and a rheostat (R) or a Volt/Ammeter/Rheostat combination. Referring to the vehicles equipment specification (see table opposite), adjust the engine speed and rheostat charge to obtain U=13.5V. Reminder : The excitation energising current will flow through the warning lamp; check that the warning lamp comes on when the ignition is switched on. It should go out when the engine has started (accelerate slightly). Checking the voltage regulator Set the rheostat to zero and disconnect all the electrical consumers. Display 3000 alternator rpm. If U alternator is > 14.7 V, the regulator is faulty. Note: These tests should be performed with the engine hot and the battery fully charged. Method of reading the alternator speed Fit a reflecting shim on the pulley of the alternator. Adjust a stroboscope to the frequency equivalent to the control speed. (e.g. 2000 rpm = 2000/60 = 83 Hz) Adjust the engine speed so that the shim appears fixed.
ELECTRICAL SYSTEM A : Ammeter B : Battery G : Generator L : Warning lamp K1 and K2 : Switch R : Electric charge S : Shunt 200mV/200A V : Voltmeter 1 : Alternator.
D1AP025C
442
CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR

MINIMUM OUTPUTS (in A) Alternator speed 1800 rpm 2000 rpm 3000 rpm 4000 rpm 6000 rpm 8000 rpm 15000 rpm Min. output 11 12 13 14 15 16 17 Class 6 27 34 47 55 61 63 64 7 39 46 60 65 69 70 73 8 46 54 68.5 75 78.5 80 82 MINIMUM YIELDS (in %) Alternator speed 1800 rpm 2000 rpm 3000 rpm 4000 rpm 6000 rpm 8000 rpm 15000 rpm Class 6 49 48 45 43 39 26 24 7 50 49 46 44 40 37 25 8 52 51 48 46 42 39 27 443 9 57 54 51 48 43 40 29 12 58 55 52 50 48 45 34 15 60 57 54 52 50 48 38 9 61 68 84 92 96 97 97 12 73 80 100 110 120 123 124 15 89 105 139 145 151 157 157
ALL TYPES
18 108 123 164 176 183 188 188
18 61 60 56 53 50 48 38
ELECTRICAL SYSTEM
ALL TYPES
Vehicles / models
PRE-HEATING AND STARTING SYSTEMS

Pre-heater plugs Pre-heater control unit Pre / Post heating (pre-heating duration at 20C)
SAXO
1.5D 1.4 HDI
VJX 8HW 8HX 8HV 8HY WJY 8HZ RHY RHZ RHY
BERU 0 100 226 371 CHAMPION CH 185 NGK YE04 NGK YE04 BERU 0 100 226 371 CHAMPION CH 185 NGK YE04 CHAMPION CH170 CHAMPION CH 170 CHAMPION CH 170
NAGARES 960411-P CARTIER 735068 NAGARES 960411-P CARTIER 735068 NAGARES 960411-P NAGARES 960411-P CARTIER 735068 NAGARES 960411-P NAGARES 960411-P CARTIER 735068 CARTIER 735068 NAGARES 960411-P CARTIER 735068 NAGARES 960411-P CARTIER 735068 NAGARES 960411-P 444
10s / 150s
ELECTRICAL SYSTEM
C3 1.4 HDI 16v 1.9D 1.4 HDI XSARA 2.0 HDI 2.0 HDI PICASSO 2.0 HDI
Controlled by the diesel injection ECU.
10s / 150s Controlled by the diesel injection ECU. Controlled by the diesel injection ECU. Controlled by the diesel injection ECU. Controlled by the diesel injection ECU.
AIR CONDITIONING R 134 a (HFC)

Compressor Vehicle Engines Date Refrigerant refill 850 gr +0 - 50 gr 825 gr 25 gr 795 gr 25 gr 625 + 0 - 50 gr 135 SD 7 V 16 SD 6 V 12 SD 7 V 16 03/2001 # 775 gr 25 gr SD 6 V 12 Variable Capacity TU - TUD All types SAXO TU All types TUD All types C3 All types TU EW XSARA DW XU10 TU XSARA PICASSO EW7-DW10 BRESIL All types 12/1999 # 09/2000 # AM 2000 # AM 2001 # Oil quantity cc
ALL TYPES
Oil reference
11/2001 #
590 gr +0 50 gr 725 gr +0 50 gr 675 gr 50 gr
SP 10
445
AIR CONDITIONING
ALL TYPES
Vehicles SAXO XSARA XSARA PICASSO
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)

Click-fit connector removing/fitting tool Circuit All Types 5/8 BP HP 3/8 Red 8005-T.C Inch Ring colour Black Tool kit 4164-T 8005-T.A.
C5HP073C
Aircon compressor fixings Pipes ESSENTIAL : Tighten the front part of the compressor (timing belt end), before the rear part of the compressor. M 06 M 08 M 10 Steel/Steel 1.7 0.3 3.8 0.3 4 0.3
Unions Aluminium/Steel 1.3 0.3 2 0.2 2.5 0.3
AIR ALTERNATORS CONDITIONING
NOTE : Tighten the union to the recommended torque using a retaining spanner whenever possible. NOTE : For operations concerning draining, drying (empty), checking and recharging of a system: refer to BRE 0290. WARNING : For R 134.a quantities (See table on preceding page). 446

EUROCLIM Tools. Tool for removing-refitting air conditioning seals MANULLI seal C3 engine versions : All types XSARA PICASSO engine versions : NFV 6FZ RHY : K.1702
C3 - XSARA PICASSO
Compressor (MANULLI seal)
Aircon compressor. XSARA PICASSO engine versions : 6FZ and RHY Discontinuation of compressor SD 6 V 12 Replaced by compressor SD 7 V 16 : 04/11/2002 # The drive plate (1) is held on the aircon compressor shaft by ribs. New wiring (2). New seals (3) (MANULLI). Identification label (4) for aircon compressor.
447
AIR CONDITIONING
: 10/12/2001 # : 01/04/2002 # : 04/11/2002 #
C3 - XSARA PICASSO

Seals (MANULLI seal)
Condenser (MANULLI seal)
AIR ALTERNATORS CONDITIONING
C5HP18VD
C5HP18XD
The condenser (5) has a cylinder (6) incorporating the function of aircon fluid reservoir and with integral filtering cartridge. The inlet (7) and the outlet (8) of the condenser (5) are equipped with new seals (3) (MANULLI).
MANULLI calibrated seal (3). Direction of fitting of the seal (3). Before fitting the seal, amply lubricate the seal with air conditioning compressor oil (SP10).
448

Presence of pollen filter Vehicle SAXO C3 Without aircon XSARA XSARA PICASSO Base aircon Regulated aircon Without aircon BERLINGO Base aircon All Types Equipment RPO No. Presence of filter NO YES YES (Larger) YES (Plus grand) YES (Valeo) NO (Valeo) YES (Valeo)
ALL TYPES
Observations
Except driving school
449
AIR CONDITIONING
C3

Pollen filter
Note: The pollen filter is located in the engine compartment on the RH side.
Removing Remove: - The three screws (1). - The plastic cover (2). AIR ALTERNATORS CONDITIONING Tilt the flap (3). Remove the pollen filter (4)
Refitting Proceed in reverse order.
C4AP169C
C4AP16AC
C4AP16BC
450

Changing the filtering/drying cartridge Tools. [1] [2] [3] [4] [5] [6] Charge station TORX adaptor Inertia extractor Endpiece 20 Set of plugs Circlip pliers : (according to workshop equipment) : TORX 70 FACOM. : 1671-T. Tool kit 4114-T : 1671-T.D20. : (-).0188.T. : FACOM.
C3
Removing Depressurise the aircon circuit, using tool [1]. Remove the grille. At a, remove the pin and the plastic cover. Unclip the condenser at b and c, using a screwdriver. Tilt the condenser towards the front. Lift and release the condenser. Clean the area around the cap (3). Remove the plastic cap (3), using tool [2]. Remove the safety circlip (4), using tool [6]. Position the tool [3] and [4] in the aperture of the cartridge (5). Extract the cartridge from the reservoir (6), using tool [3] and [4]. Block the reservoir (6), using tool [5].
C4AP163C C4AP164C C4AP165C C4AP166C
451
AIR CONDITIONING
C3

Changing the filtering/drying cartridge Refitting Remove the new cartridge from its packaging. Do not expose the cartridge, the filter and seals to pollutants. Lightly oil the seals (compressor oil). Remove tool [5] from the reservoir (6). Insert the new cartridge (5) into the reservoir (6). Refit the safety circlip (4), using tool [6]. Make sure that the circlip (4) is correctly positioned in its location. WARNING : Not more than 5 minutes should elapse between the removal of the cartridge (6) from its packaging and its being fitted. Refit: - The plastic cap (3), using tool [5] - Tighten to 1,2 0,1 m.daN. - The condenser (reclip, pushing at b and c). - The plastic cover and the pins at a. - The grille (2). - The screws (1). Proceed to: - Recharge the circuit (see corresponding operation). - Check the operation of the air conditioning (see corresponding operation).
C4AP167C C4AP165C C4AP163C C4AP164C
AIR CONDITIONING
452

BEHR plate evaporator Pollen filter
XSARA - All Types
C5HP07JC
C5FP075D
C5HP062C
Remove-refit. Remove : - The interior trim (1). - The cover (4). - The pollen filter (3). Concerns vehicles equipped with aircon without temperature regulation. Fitting of a new pollen filter necessitates the following operations: - Engage the pollen filter upwards (following arrow c) - Slide the pollen filter towards the rear (following arrow d) - Position the index (4) on the cover forward of the pollen filter. ((4) Index on the cover). 453
AIR CONDITIONING
XSARA - All Types

Petrol engine versions

BEHR condenser with integral reservoir (16 Ti) The condenser is equpped with a cylinder (1) that acts as the fluid reservoir which in turn incorporates a filter cartridge. NOTE : As soon as the air conditioning loop has been open for more than 5 minutes, the filter/dryer cartridge assembly should be replaced (no set interval).
C5HP07BC
AIR CONDITIONING
Diesel engine versions
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 caps thread. -Take out the filter/dryer cartridge. -Clean the threaded zone of the condenser reservoir. -Fit the new filter/dryer cartridge. -Lubricate the caps O-ring seals with compresser oil. (New seals). -Screw the cap back on, tighten to 1,4 0,2 m.daN.
C5HP060C
454

BEHR plate evaporator Pollen filter
XSARA PICASSO
C5HP062C
B1BP23ED
Remove: - The three screws (1). - The cover (2). - Remove the pollen filter. 455
AIR CONDITIONING
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. 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). 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 caps thread. -Take out the filter/dryer cartridge. -Clean the threaded zone of the condenser reservoir. -Fit the new filter/dryer cartridge. -Lubricate the caps O-ring seals with compresser oil. (New seals). -Screw the cap back on, tighten to 1,4 0,2 m.daN.
AIR CONDITIONING
C5HP07BC
456

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.
ALL TYPES
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. 457
AIR CONDITIONING
ALL TYPES

Checking the compressor oil level (continued)
2) Slow leak. - Slow leaks do not lead to oil loss, therefore the same procedure should be followed as if there was no leak at all. 3) Fast leak. This type of leak causes both oil loss as well as allowing air to enter the system. AIR CONDITIONING 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.
458
AIR CONDITIONING SYSTEM R 134.a

Testing procedure Conditions inside the vehicle Positions of the air conditioning controls : Maximum cold. Maximum blower power. Air distribution on ventilation with the air vents open. Position the air inlet flap to outside air. WARNING: For RFTA (1), disconnect the air inlet motor connector, first ensuring that it is in the outside air position. (1) RFTA = Fully automatic air conditioning. Test procedure. When all these conditions are met, proceed in the following order: Measure the temperature in the workshop approx. one metre in front of the vehicles air inlet grille. Start the engine (without the air conditioning, or the blower, operating) and wait for the cooling fan slow speed to trigger (should the engine temperature not rise sufficiently, it is permissable to increase the engine speed to 2000 rpm). Once it is sufficiently hot in the engine compartment, return the engine to idle and commence the test.
ALL TYPES
Switch on the air conditioning and adjust the engine speed to 2500 rpm. In an ambient temperature of 40C, the engine speed will be brought down to 2000 rpm, in order for the pressure safety threshold to cut off the compressor. For further temperatures/pressures: see Tables and Graphs on following pages. After 3 minutes of operation, note down the following 3 parameters: - The temperature of the blown air coming out of the 2 central air vents (take the average). - The high pressure, via the intermediary of the clickfit union (at the pressure reducer inlet). - The low pressure, via the intermediary of the clickfit union (at the pressure reducer outlet). NOTE: The low and high pressures are absolute pressures. When measuring the blown air temperatures, avoid any contact between the thermocouple and the air vents. At the conclusion of the test involving vehicles with RFTA, do not forget to reconnect the air inlet motor connector.
459
AIR CONDITIONING
ALL TYPES
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM

CHECKING TEMPERATURES (continued)
Vehicle using R134.a fluid (Compressor with variable capacity) Ambient temperature in C Vehicle SAXO Temperature at the central air vents in C C3 Engine types All Types All Types TU XSARA EW DW XSARA PICASSO All Types 17 3 18.5 2 18 2 19 2 15 2 22 3 13 3 15 2 17 2 18 2 15.5 2 16 3 11 3 12.5 2 14.5 2 15 2 11 2 12.5 3 93 10 2 11 2 12 2 92 10 3 83 8.5 2 8.5 2 10 2 72 83 52 6.5 3 6.5 2 82 40 35 30 25 20 15
AIR CONDITIONING
460
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
ALL TYPES
CHECKING PRESSURES TOOLS - 1 charging station. - 2 thermometers. CHECK - The temperature of the air coming from the central vents (see table). Once the preliminary conditions, vehicle equipment and checks - The High Pressure. - The Low Pressure. have been fulfilled (see table) : After the air conditioning has been Compare the values recorded with the table below, or the graphs. on for three minutes, record the following parameters : Vehicle using R134.a fluid (Compressor with variable capacity) Ambient temperature in C Vehicles 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) High pressure (Bars) Low pressure (Bars) Engines 40 20 3 35 18 3 30 16 3 3 0.3 14.5 2 17.6 2 2.4 0.2 23 2 22.5 2 3.8 0.2 3.6 0.2 24.5 2 4 0.2 3.8 0.2 21.5 2 22.5 2 3.2 0.2 3.3 0.2 25.5 3 20.5 3 4 0.3 3.5 0.3 25 3 22.5 3 4 0.3 3.5 0.3 461 20 2 2.5 0.2 20 2 3.5 0.2 21.5 2 3.5 0.2 20 2 3 0.2 18 3 21.4 2 23.6 2 25.2 2 2.8 0.2 3 .02 3.5 .02 17 2 15.5 2 14.5 2 3.1 0.2 3 0.2 2.9 0.2 18.5 2 17 2 15.5 2 3.2 0.2 3 0.2 18 2 16.5 2 15.6 2 2.8 0.2 2.6 0.2 20 3 13.5 3 11 3 3 0.3 20 3 17 3 15 3 3 0.3 AIR CONDITIONING 25 13 3 20 11 3 15 93
SAXO C3
All types All types

TU
XSARA
EW DW TU EW DW
XSARA PICASSO
SAXO - All Types

Click-fit union.
AIR CONDITIONING
C5HP15UP
C5HP12EC
Tightening torques (m.daN). (1) High pressure valve (2) Low pressure valve (3) Click-fit union (4) Pressostat (1 seal 10,82) (5) Dryer (2 seals 7,65) (6) Relief valve, tighten to 0,43 m.daN 0,1 (1 seal 7,65 1seal 16,5) (7) Compressor fixing flange 3 0,8 m.daN (2 seals 20) (8) (O-ring seal 7,65). 462

Checks on the air conditioning circuit
SAXO - All Types
Key.
T = Scale of Temperature (C ), and of High Pressure (Bars). P = Scale of Low pressure (Bars). AIR CONDITIONING 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
463
C3
(1) Low pressure valve. (2) High pressure valve. (3) Filter. (4) Pressostat
AIR CONDITIONING
C5HP17SP
Tightening torque m.daN (a) (b) (c) (d) (e) (f) : : : : : : 0.6 0.6 0.6 0.6 0.6 0.6
464

C3
Keys.
T/P = Average temperature (C ) at the air vents / high pressure (Bars). P = Low pressure (Bars). TE = Exterior temperature (C). HP = Pressure at compressor outlet (Bars). BP = Pressure at compressor inlet (Bars). TA = Average temperature (C) of air blown from the central vents. AIR CONDITIONING
C5HP18GD
465
XSARA - All Types

Plan of air conditioning system Two solutions : 1 MANULLI , with NON EUROCLIM compressor (O-ring seals). 2 EATON , with EUROCLIM compressor (quadrilobe seals).
(1) (2) (3) (4)
High pressure valve Low pressure valve Pressostat Dryer Tightening torques m.daN.
AIR CONDITIONING
C5HP16RP
(a) 0,8 (b) 4 0,4 (c) 0,8 A Right hand drive. 466
XSARA - All Types

Plan of air conditioning system
Solution : 1 EATON , with EUROCLIM compressor and buffer capacity (quadrilobe seals).
(1) - High pressure valve (2) - Low pressure valve (3) - Buffer capacity AIR CONDITIONING
Tightening torques m.daN. (a) 0,8 (b) 4 0,4 (c) 0,8 A Right hand drive.
C5HP17WP
467
XSARA - All Types

Plan of air conditioning system Two solutions : 1 MANULLI , with NON EUROCLIM compressor (O-ring seals). 2 EATON , with EUROCLIM compressor (quadrilobe seals).
(1) (2) (3) (4)
High pressure valve Low pressure valve Pressostat Dryer Tightening torques m.daN.
AIR CONDITIONING
C5HP16SP
(a) 0,8 (b) 4 0,4 (c) 0,8 A Right hand drive.
468

Plan of air conditioning system Two solutions :
XSARA - All Types
1 MANULLI , with NON EUROCLIM compressor (O-ring seals). 2 EATON , with EUROCLIM compressor (quadrilobe seals).
C5HP16VP
469
AIR CONDITIONING
(1) (2) (3) (4)
High pressure valve Low pressure valve Pressostat Dryer
XSARA - All Types

Plan of air conditioning system Three solutions : 1) MANULLI , with NON EUROCLIM compressor (O-ring seals). 2) EATON , with EUROCLIM compressor and buffer capacity (quadrilobe seals). 3) EATON , with NON EUROCLIM compressor and buffer capacity (O-ring seals). (1) - High pressure valve (2) - Low pressure valve (3) - Buffer capacity Tightening torques m.daN. (a) 0,8 (b) 4 0,4 (c) 0,8 A Right hand drive.
AIR CONDITIONING
C5HP17XP
470
XSARA - All Types

Two solutions : 1 MANULLI , with NON EUROCLIM compressor (O-ring seals). 2 EATON , with EUROCLIM compressor (quadrilobe seals). (1) (2) (3) (4) High pressure valve Low pressure valve Pressostat Dryer Tightening torques m.daN. (a) 0,8 (b) 4 0,4 (c) 0,8 A Right hand drive.
C5HP16TP
471
AIR CONDITIONING
XSARA - All Types

Plan of air conditioning system. Three solutions : 1) MANULLI , with NON EUROCLIM compressor (O-ring seals). 2) EATON , with EUROCLIM compressor and buffer capacity (quadrilobe seals). 3) EATON , with NON EUROCLIM compressor and buffer capacity (O-ring seals).
AIR CONDITIONING
C5HP17YP
(1) - High pressure valve (2) - Low pressure valve (3) - Buffer capacity. Tightening torques m.daN. (a) 0,8 (b) 4 0,4 (c) 0,8 A Right hand drive. 472
XSARA - All Types

Two solutions : 1 MANULLI , with NON EUROCLIM compressor (O-ring seals). 2 EATON , with EUROCLIM compressor (quadrilobe seals).
C5HP16UP
473
AIR CONDITIONING
(1) (2) (3) (4)
High pressure valve Low pressure valve Pressostat Dryer
XSARA PICASSO TU
(1) (2) (3) (4) (5) (6)
High pressure valve. Low pressure valve. High pressure clickfit union (tool 8005-T.C). Low pressure clickfit union (tool 8005-T.A). Pressostat. 1,8 0,6 m.daN Filtering / drying cartridge plug.
AIR CONDITIONING
C5HP13PP
Tightening torques m.daN. a b c d 0,8. 0,1 0,5. 0,1 1,4 0,2. 2,5 0,25.
474
XSARA PICASSO EW7
(1) (2) (3) (4) (5) (6)
Tightening torques m.daN. -a -b -c 0,8. 0,1 0,5. 0,1 1,4 0,2.
HP/LP compressor flange fixing 2,5 0,25.
C5HP13QP
475
AIR CONDITIONING
XSARA PICASSO TU - EW7

Key.
T/P = Scale of: - Temperature (C), average of air from the central vents. - Pressure, High (Bars). - Pressure, Low (Bars). Te = Exterior temperature (C). HP = Pressure at compressor outlet (Bars). Ta = Temperature (C) of air blown from the vents. BP = Pressure at compressor inlet (Bars).
AIR CONDITIONING 476
C5HP150D
XSARA PICASSO DW10
(1) (2) (3) (4) (5) (6)
Tightening torques m.daN. -a -b -c 0,8. 0,1 0,5. 0,1 1,4 0,2.
HP/LP compressor flange fixing 2,5 0,25.
C5HP13RP
477
AIR CONDITIONING
XSARA PICASSO DW10

Checks on the air conditioning circuit Key.
T/P = Scale of: - Temperature (C), average of air from the central vents. - Pressure, High (Bars). - Pressure, Low (Bars). Te = Exterior temperature (C). AIR CONDITIONING 478 HP = Pressure at compressor outlet (Bars). Ta = Temperature (C) of air blown from the vents. BP = Pressure at compressor inlet (Bars).
C5HP14ZD

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PRIVATE CARS

SAXO-C3-XSARA XSARA PICASSO-BERLINGO

CAR 050014 Volume 1

XSARA 2, all types

SAXO - All Types

SAXO - All Types

VTS L4 S6 KFWB KFW 1360 5 MA/5

VTS L4 N6 NFXB NFX 1587 8 MA/5 20 CN 03

SAXO - All Types

SX-Exclusive L4 S1 KFWB GENERAL

SAXO - All Types

A- Administration X-SX-VTS -Exclusive GENERAL

X IFL5 L4/INF FC HFXB /D K FC HFX5

L4 FC HFXB/T FR HFXB FN HFXB FC HFXB HFX 1124 4 MA/5N 20 CF 14 FN HFXC /IF

IFL5 FC KFVF/IF FN KFVC/IF

Auto. GENERAL SX Exclusive

SX Exclusive L4/INF L4 FC KFVE/D FN NFUB NFU 1587 6 FC NFUB

L4 FC KFVB KFV 1360 5 FC KFVB/D

1.4 HDi 16V

FN 8HVB 8HV 1398

1.4 HDi 16V

FC 8HYB/MOD 8HY 1398 5 BE4/5 20 DM 25

XSARA - All Types

XSARA - All Types

X-VTR IFL5 NO KFW1/IF KFW 1360 5 MA/5 20 CF 13

X-SX-VTR VTS L4 NO NFUB

NO NFUN NFU 1581 7

XSARA - All Types

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

XSARA - All Types

L4 N0 8HZB N0 8HZB/T 8HZ 1398 4 MA/5 N3 8HZB GENERAL

XSARA - All Types

X L4 NO WJYB/T (1) WJY 1868 7 BE4/5 20 DL 41 20 DL 42 NO RHYB/T (1) RHY 1997 6

L4 NO KFWB/T (1) KFW 1360 8 MA/5 20 CF 13

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

XSARA - All Types

SX IFL5 N1 KFW1/IF N1 NFUG K N1 NFUU NFU 1587 7 MA/5 20 CF 13 20 CN 29 AL4 20 TP 49

X-SX Exclusive L4 N1 NFUB GENERAL

L4 N1 KFWB KFW 1360 5 MA/5

XSARA - All Types

SX Exclusive IFL5 IFL5 N1 NFU3/IF N1 RFN1/IF

Exclusive L4 N1 RFNN RFN 1998 11

L4 N1 NFUN N1 NFU1/IF NFU 1587 7 AL4 20 TP 49 MA/5 20 CN 28

(1) = Right hand drive : Hydraulic clutch control. 18

XSARA - All Types

Auto. SX Exclusive GENERAL

X-SX-Exclusive L4 N1 RHYB RHY

L4 N1 WJYB WJY 1868 5 BE4/5 20 DL 41 20 DM 05 (1) 20 DL 42 5 BE4/5 20 DM 07 (1)

N1 RHZB RHZ 1997 6

AL4 20DM 10 20 DM 11 (1) 20 TP 48

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

XSARA - All Types

L4 N1 8HZB 8HZ 1398 4 MA/5 N1 8HZB/T

XSARA - All Types

X L4 N RHYB RHY 1997 5 BE4/5 20 DL 42 N1 RHYB/T (1) GENERAL

L4 N1 WJYB/T (1) WJY 1868 7 BE4/5 20 DL 41

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

XSARA - All Types

Auto. X-SX Exclusive IFL5 SX Exclusive

SX IFL5 KFW1/IF K N2 NFUG

X-SX Eclusive L4 N2 NFUB

L4 N2 KFWB KFW 1360 5 MA/5 20 CN 21

8HZ 4 () 1 () 2