CITROEN C2 2003 Handbook
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CITROEN C2 2003 Handbook

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2003
«The technical information contained in this document is intended for the exclusive use of the trained personnel of the
motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The
information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full
responsibility to the exclusion of that of the manufacturer».
«The technical information appearing in this brochure is subject to updating as the characteristics of each model in the
range evolve. Motor vehicle repairers are invited to contact the CITROËN network periodically for further information and
to obtain any possible updates».
CAR 050016

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Summary of Contents for CITROEN C2 2003

  • Page 1 2003 «The technical information contained in this document is intended for the exclusive use of the trained personnel of the motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full responsibility to the exclusion of that of the manufacturer».
  • Page 2 PRESENTATION THIS HANDBOOK summarises the specifications, adjustments, checks and special features of the CITROEN C2. The handbook is divided into nine groups representing the main functions : GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - ELECTRICAL...
  • Page 3 IDENTIFICATION OF VEHICLES A : Cold stamp (Cold stamp engraved on the bodywork). B : Manufacturer’s name plate (On the LH centre pillar) C : AS/RP No. and RP paint code. (On the LH centre pillar) D : Tyre pressures and tyre type. (On the LH centre pillar) E : Serial number on bodywork.
  • Page 4 IDENTIFICATION OF VEHICLES Petrol 1.1i 1.4i 1.6i 16 V A - X - SX - SX Pack SX - SX Pack - VTR Emission standard IFL5 IFL5 Type code JM HFXB JM KFVC/IF (*) JM NFUC/IF (*) HFXC/IF (*) KFVC/P KFVC/PIF (**) Engine type Cubic capacity (cc)
  • Page 5 IDENTIFICATION OF VEHICLES Diesel 1.4 HDi X - SX – SX Pack - VTR Emission standard IFL5 Type code JM 8HXB JM 8HXC/IF (*) JM 8HXC/PIF (**) Engine type Cubic capacity (cc) 1398 Fiscal rating (hp) Gearbox type Gearbox ident. plate 20 CN 51 (1) (m) (4) 20 CN 33 (2) (m) (4) 20 CN 51 (1) (m) (4)
  • Page 6 IDENTIFICATION OF VEHICLES Manufacturer’s plate. The manufacturer’s plate carries the following information : (a) Type approval number (*). (b) Type serial number (VIN). (c) Gross vehicle weight (*). (d) Gross vehicle weight (*). (e) Maximum weight on front axle (*). (f) Maximum weight on rear axle (*).
  • Page 7 IDENTIFICATION OF VEHICLES Factory code. Structure The factory code is composed of 6 figures or letters. Example : JM HFXC J = Vehicle family. HFX = Engine. M = Body shape. C = Version. Family Body shape Ref. Family Ref. Body shape CITROËN C2 3-door saloon (4-seater)
  • Page 8 GENERAL SPECIFICATION : DIMENSIONS Exterior dimensions E1AP0C4D...
  • Page 9 GENERAL SPECIFICATION : DIMENSIONS Exterior dimensions (mm) Vehicles All types Wheelbase 2315 Length overall 3666 Front overhang Rear overhang Rear track * 1435 Front track * 1438 Width overall 1660 Height overall * 1462 (*) = Vehicle in running order (vehicle empty, levels topped up). Interior dimensions and volumes (mm) Elbow width, front 1406...
  • Page 10 GENERAL SPECIFICATION : WEIGHTS Petrol Diesel Versions 1.1i 1 4i 1.6i 16V 1.4 HDi Engine type Gearbox type Payload Weight empty Without options 1053 1080 1133 1097 in running order With all options 1138 1147 1200 1177 Gross vehicle weight 1463 1470 1525...
  • Page 11 OPERATIONS TO BE CARRIED OUT AFTER A REPAIR IMPERATIVE : All these operations are to be performed following a reconnection of the battery. Antiscanning function. It is necessary to wait 1 minute after the battery has been disconnected in order to be able to start the vehicle. Tailgate.
  • Page 12 OPERATIONS TO BE CARRIED OUT AFTER A REPAIR Sun roof. The anti-pinch function has to be re-initialised. Place the sun roof switch in the maximum tilt position. Keep the sun roof switch pressed until the sun roof ceases its movement. Release the sun roof switch within 5 seconds.
  • Page 13 GENERAL SPECIFICATION : TOWING THE VEHICLE Front towing WARNING : When the engine is not running, steering and braking are no longer power-assisted. Towing eye (1) Towing eye Rear towing The towing eye (1) is to be found in the vehicle toolkit located under one of the front seats.
  • Page 14 GENERAL SPECIFICATION : TOWING THE VEHICLE Vehicle towing : Precautions to be taken Manual gearbox Piloted manual gearbox IMPERATIVE : It is necessary to lift the front of the vehicle in order to tow it, after having positioned the gear lever in neutral. WARNING : Whether the ignition is switched on or not, an action on the gear selector will move the clutch fork and the gear engagement lever.
  • Page 15 GENERAL SPECIFICATION : TOWING THE VEHICLE Vehicle towing : Precautions to be taken Piloted manual gearbox Engagement of «N», using a diagnostic tool. Engagement of «N», without a diagnostic tool. Preliminary operation : In this configuration, the gearbox actuator is blocked, gear engaged. - Battery voltage higher than 12 Volts.
  • Page 16 GENERAL SPECIFICATION : TOWING THE VEHICLE Vehicle towing : Precautions to be taken Piloted manual gearbox Preliminary operations: - Disconnect the battery negative terminal. - Remove the air filter. - Position a 22 mm flat spanner. - Lift the gear engagement lever as far as possible (in the direction of the arrow);...
  • Page 17 GENERAL SPECIFICATION: LIFTING AND SUPPORTING THE VEHICLE Front lifting Lifting and supporting the vehicle Side lifting Front of the vehicle. The authorised lifting points at the front of the vehicle are on the rear fixing bolts of the subframe at «a». For front lifting, take weight at the two lifting points at «a», using a crossbeam equipped with blocks.
  • Page 18 GENERAL SPECIFICATION: LIFTING AND SUPPORTING THE VEHICLE Lifting and supporting the vehicle (continued) Lifting with the handle jack at the front Lifting on a two-column lift using the jack supports E2AP025C E2AP027D Lifting with the handle jack at the rear Lift accessory with blocks on the jack supports NOTE : The handle jack is specific to the vehicle, do not use it for any other purposes.
  • Page 19 CAPACITIES (in litres) Draining method. The oil capacities are defined according to the following methods. 1/ Vehicle on level surface (in high position, if equipped with hydropneumatic suspension). 2/ Engine warm (oil temperature 80°C). 3/ Draining of the oil sump + removal of the cartridge (duration of draining + dripping = 15 min). 4/ Refit plug + cartridge.
  • Page 20 CAPACITIES (in litres) Petrol Diesel 1.1i 1.4i 1.6i 16V 1.4 HDi Engine type Drain by gravity : engine with filter change 3.25 3.75 RPO 9844) Between Min. and Max. 1.5 (RPO 9845 MA5 5-speed gearbox MA5 piloted 5-speed gearbox 2 ± 0.15 0.7 Litre version with front calipers Ø...
  • Page 21 LUBRICANTS - TOTAL recommended oils S.A.E. Norm - Table for selection of engine oil grade E4AP006D...

  • Page 22: Total Quartz

    LUBRICANTS – TOTAL recommended oils Factory evolutions in 2001 model year ESSENTIAL : For all vehicles with a 30,000 km (20,000 miles) maintenance interval, use exclusively TOTAL ACTIVA/QUARTZ CITROËN engines are lubricated at the factory with TOTAL oil of 7000 or 9000 or any other oils offering identical specifications to grade S.A.E.5W-30.

  • Page 23: Blended Oils For All Engines, Permitting Fuel Economy

    LUBRICANTS – TOTAL recommended oils Selection of engine oil grades recommended for climatic conditions in countries of distribution ACEA Norms API Norms The first letter corresponds to the type of engine concerned : The first letter corresponds to the type of fuel used by the engine : A : petrol and dual fuel petrol / LPG engines.
  • Page 24 TOTAL ACTIVA (France only). TOTAL QUARTZ (Outside France). ESSENTIAL : To preserve engine performances, all engines fitted in CITROEN vehicles must be lubricated with high quality oils (synthetic or semi-synthetic) Summary Engine oil norms to be respected in 2001 model year...

  • Page 25: Table Of Contents

    LUBRICANTS – TOTAL recommended oils S.A.E. grades SPI norms ACEA norms Blended oils for all engines (petrol, dual-fuel petrol / LPG and diesel) TOTAL ACTIVA 9000 5W-40 SJ / CF A3-98 / B3-98 TOTAL QUARTZ 9000 TOTAL ACTIVA 9000. (*) 5W-30 SJ / CF EC A1-98 / B1-98...
  • Page 26 LUBRICANTS – TOTAL RECOMMENDED OILS FRANCE Blended oils for all engines, supplied in bulk TOTAL ACTIVRAC S.A.E : 10W-40 Norms Metropolitan FRANCE TOTAL ACTIVA DIESEL TOTAL ACTIVA Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 7000 10W-40...

  • Page 27: Table Of Contents

    LUBRICANTS – TOTAL RECOMMENDED OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ DIESEL (*) = Blended oils for all engines, Oils specifically for petrol and Oils specifically for diesel Blended oils for all engines permitting fuel economy engines dual-fuel petrol / LPG engines 7000 10W-40 Germany 9000 0W-40...

  • Page 28: Table Of Contents

    LUBRICANTS – TOTAL recommended oils EUROPE (continued) TOTAL QUARTZ TOTAL QUARTZ DIESEL (*) = Blended oils for all engines, Oils specifically for petrol and Oils specifically for diesel Blended oils for all engines permitting fuel economy dual-fuel petrol / LPG engines engines 7000 10W-40 Greece...

  • Page 29: Table Of Contents

    LUBRICANTS – TOTAL recommended oils EUROPE (continued) TOTAL QUARTZ TOTAL QUARTZ DIESEL (*) = Blended oils for all engines, per- Oils specifically for petrol and Oils specifically for diesel Blended oils for all engines mitting fuel economy dual-fuel petrol / LPG engines engines 7000 10W-40 Czech Republic...

  • Page 30: Total Quartz Diesel

    LUBRICANTS – TOTAL recommended oils TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for petrol and Blended oils for all Oils specifically for diesel dual-fuel petrol / LPG engines engines engines Australia OCEANIA 7000 10W-40 New-Zealand Ivory Coast Egypt Gabon Madagascar AFRICA Morocco 7000 10W-40...

  • Page 31: Oils Specifically For Petrol And Dual-Fuel Petrol / Lpg Engines

    LUBRICANTS – TOTAL recommended oils TOTAL QUARTZ TOTAL QUARTZ DIESEL (*) = Blended oils for all engines, Oils specifically for petrol and Blended oils for all Oils specifically for diesel permitting fuel economy dual-fuel petrol / LPG engines engines engines 7000 10W-40 China 7000 15W-50...
  • Page 32 LUBRICANTS – TOTAL recommended oils TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for petrol and Oils specifically for diesel Blended oils for all engines dual-fuel petrol / LPG engines engines Saudi Arabia Bahrain Dubai United Arab Emirates Iran Israel MIDDLE 9000 5W-40 7000 15W-50 7000 10W-50...
  • Page 33 LUBRICANTS – TOTAL recommended oils Gearbox oils TOTAL TRANSMISSION BV Norms S.A.E 75W-80 Manual gearbox Special oil distributed by CITROËN (Part No. 9730 A2) TOTAL FLUIDE ATX ou TOTAL FLUIDE AT 42. All countries MB3 automatic gearbox Special oils distributed by CITROËN (Part No.
  • Page 34 CITROEN reference 0.5 litre 9979 05 CITROEN Fluid All countries 1 litre 9979 06 5 litres 9979 07 CITROEN hydraulic circuit fluid Norme Packs CITROEN reference ISO 7308-7309 ZCP 830 095 TOTAL LHM PLUS Green in colour 1 litre 9979.20 (Scandinavia)
  • Page 35 LUBRICANTS – TOTAL recommended oils Wash/wipe fluid Packs CITROEN reference Concentrated : 250 ml 9980 33 ZC 9875 953 U 9980 56 All countries Liquid ready to use: 1 litre 9980 06 ZC 9875 784 U Liquid ready to use: 5 litres...
  • Page 36 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.
  • Page 37 ENGINE SPECIFICATIONS Petrol Diesel 1.1i 1.4i 1.6i 16V 1.4 HDi Engine type Cubic capacity (cc) 1124 1360 1587 1398 Bore / Stroke 72/69 75/77 78/82 73/82 Compression ratio 10.5/1 11/1 17.9/1 44-5500 54-5400 80-5800 50-4000 Power ISO or EEC KW - rpm Power DIN (HP - rpm) 61-5500 75-5400...
  • Page 38 ENGINE SPECIFICATIONS Engines : HFX - KFV - NFU Engine identification A = Engines : HFX - KFV B = Engine : Compulsory engine identification in zone « a »: - Component reference. - Engine legislation type. - Factory serial no. B1BP10JC B1BP2GKC...
  • Page 39 CYLINDER HEAD Engines : HFX - KFV - NFU Identification of cylinder head gasket Thicknesses Engine types Thicknesses (repair) Thickness references (Standard) 1.4 ± 0.1 1.2 ± 0.1 0.66 ± 0.04 References 1.2.3.4 = Type of engine. A,B,D = Suppliers. = Gasket material.
  • Page 40 CYLINDER HEAD Engines : HFX - KFV - NFU Cylinder head tightening (m.daN) Cylinder head bolts HFX - KFV Tightening 2 ± 0.2 Angular tightening 240° ± 5° (In the order 1 to 10) Tightening 2 ± 0.2 Angular tightening 260°...
  • Page 41 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Crankshaft Accessories drive pulley 2.5 ± 0.2 Pinion fixing on crankshaft - Tightening 4 ± 0.4 - Angular tightening 45° ± 4° Cylinder block Sump 0.8 ± 0.2 Timing belt tensioner roller 2.1 ± 0.2 Accessories belt tensioner roller 2.5 ±...
  • Page 42 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Cylinder head Coolant outlet housing - in plastic 0.8 ± 0.2 - in aluminium 0.8 ± 0.2 Camshaft bearing caps (TU1JP-TU3JP) - Tightening 2 ± 0,2 - Angular tightening 44 °± 4° Camshaft bearing caps (TU5JP4) - Tightening 2 ±...
  • Page 43 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Flywheel - Clutch Engine flywheel 6.7 ± 1 (LOCTITE FRENETANCH) Oil pressure mechanism 2 ± 0.2 Lubrication circuit Oil pressure switch 3.5 ± 0.5 Oil pump 0.9 ± 0.1 Cooling circuit Coolant pump 1.6 ± 0.2...
  • Page 44 TIGHTENING TORQUES : POWER UNIT SUSPENSION Engines : HFX - KFV - NFU : 6 ± 0.6 : 6 ± 0.6 : 4.5 ± 0.4 : 6 ± 0.6 : 6 ± 0.6 : 8.5 ± 0.8 : 6 ± 0.6 : 3 ±...
  • Page 45 ENGINE SPECIFICATIONS Engine : 8HX Engine identification "a" Engine legislation type. "b"Component reference. "c" Factory serial no. B1CP0BKD...
  • Page 46 CYLINDER HEAD Engine : 8HX Cylinder head tightening (m.daN) Cylinder head bolts Pre-tightening 2 ± 0.2 m.daN Tightening 4 ± 0.4 m.daN Angular tightening 230° ± 5° (In the order 1 to 10) NOTE : - The bolts should have been tho- roughly cleaned and dried with a dry metal brush.
  • Page 47 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Crankshaft mobile Bearing cap fixing screws Pre-tightening 1 ± 0.2 Slackening 180° Tightening 3 ± 0.3 Angular tightening 140° Con rod screws Tightening 1 ± 0.1 Angular tightening 100° ± 5° Accessories drive pulley Pre-tightening 3 ±...
  • Page 48 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Cylinder head Camshaft bearing covers Pre-tightening 0.3 ± 0.1 Tightening 1 ± 0.1 Fixing of camshaft sub-assemblies on cylinder head Pre-tightening 0.3 ± 0.1 Tightening 1 ± 0.1 Exhaust manifold 3 ± 0.3 Camshaft pulley Pre-tightening 0.3 ±...
  • Page 49 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Lubrication circuit Oil pump assembly Pre-tightening 0.5 ± 0.1 Tightening 0.9 ± 0.1 Coolant/oil heat exchanger 1 ± 0.1 Diesel injection circuit Spherical-base screws for diesel injection fixing fork 2.5 ± 0.2 Fuel high pressure common injection rail on engine block 2.2 ±...
  • Page 50 TIGHTENING TORQUES : POWER UNIT SUSPENSION Engine : 8HX : 6 ± 0.6 : 6 ± 0.6 : 6 ± 0.6 : 6 ± 0.6 : 3 ± 0.3 : 6 ± 0.6 : 5.5± 0.5 : 5.7 ± 0.9 B1BP2Y1P...
  • Page 51 BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE Tools 4122-T (C.TRONIC.105.5) 4099-T (C.TRONIC.105) B1EP135D...
  • Page 52 AUXILIARY EQUIPMENT DRIVE BELT Petrol Diesel Engine type See pages : 50 to 52 53 to 55...
  • Page 53 AUXILIARY EQUIPMENT DRIVE BELT Engines : HFX - KFV - NFU Tools. [1] Pliers for removing plastic pegs : 7504-T. [2] Belt tension measuring instrument : 4122-T. Vehicle without air conditioning. Remove. Refit. Refit the belt. Respect the following sequence: Slacken: - Crankshaft pinion.
  • Page 54 AUXILIARY EQUIPMENT DRIVE BELT 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.
  • Page 55 AUXILIARY EQUIPMENT DRIVE BELT With compressor and alternator Engine : 8HX Tools [1] Pliers for removing plastic pegs : 7504-T. [2] Tensioner roller compression lever : (-).0194.E. [3] Tensioner roller setting peg Ø4 mm : (-).0194.F. Removing. Disconnect the battery negative cable. Raise and support the vehicle, wheels hanging.
  • Page 56 AUXILIARY EQUIPMENT DRIVE BELT Engine : 8HX 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.
  • Page 57 AUXILIARY EQUIPMENT DRIVE BELT Engine : 8HY Tools. [1a] Dynamic tensioner roller lever : (-).0194-E1. [1b] Lever extension : (-).0194-E2. [2] Accessories belt roller locking peg Ø 4 mm : (-).0194-F Removing Pivot the tensioner roller support (1) (clockwise), using tools [1a] and [1b] at «a». Remove the belt.
  • Page 58 CHECKING AND SETTING THE VALVE TIMING Petrol Diesel Engine type See pages : 57 to 66 67 to 83...
  • Page 59 CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFV - NFU Tools. [1] Engine flywheel peg : 4507-T.A [2] Camshaft pulley peg : 4507-T.B [3a] Camshaft peg : 4533-TA.C1 [3b] Camshaft peg : 4533-TA.C2 [4] Dynamic tensioner roller pin : 4200-T.H [5] Belt retaining pin : 4533-T.AD...
  • Page 60 CHECKING AND SETTING THE VALVE TIMING 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).
  • Page 61 CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFV Setting the timing Preliminary operation. Lift and support the vehicle, wheels hanging. Disconnect the battery. Remove: - The front RH wheel. - The splash-shield, using tool [6] - The accessories belt (See corresponding operation). - The crankshaft pulley.
  • Page 62 CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFV Setting the timing (continued) HFX - KFV engines 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).
  • Page 63 CHECKING AND SETTING THE VALVE TIMING Engine : NFU NFU engine. Setting the timing (continued) Remove: The bottom plastic casing. The engine support (9). The middle support. The timing cover (8); Peg the flywheel, using tool [1]. Position the tools [3a] and [3b]. B1BP2MFC B1BP2MBC B1EP18MC...
  • Page 64 CHECKING AND SETTING THE VALVE TIMING Engine : NFU Setting the timing (continued) NFU engine. 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»...
  • Page 65 CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFV Setting the timing (continued) HFX - KFV engines 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.
  • Page 66 CHECKING AND SETTING THE VALVE TIMING Engines : KFX - KFV - NFU Setting the timing (continued) HFX - KFV engines 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.
  • Page 67 CHECKING AND SETTING THE VALVE TIMING Engines : KFX - KFV - NFU Timing belt overtensioned: A : Engine HFX - KFV. B : Engine NFU Turn the tensioner roller (7) with the aid of a hexagonal spanner at «a». Bring the index «c»...
  • Page 68 CHECKING AND SETTING THE VALVE TIMING 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».
  • Page 69 CHECKING AND SETTING THE VALVE TIMING Engine : 8HX Tools. [1] Pliers for removing plastic pegs : 7504-T. [2] Lever for detensioning the dynamic tensioner roller : (-).0194.E [3] Engine flywheel setting peg : (-).0194.C [4] Camshaft setting peg : (-).0194.B. [5] Crankshaft and high pressure pump setting peg : (-).0194.A.
  • Page 70 CHECKING AND SETTING THE VALVE TIMING Engine : 8HX Checking the setting (continued) Remove: - the accessories drive belt. - the accessories drive pulley. - the lower timing cover (3). IMPERATIVE : The magnetic track should show no signs of damage and should not be approached by any other source of magnetism.
  • Page 71 CHECKING AND SETTING THE VALVE TIMING Engine : 8HX 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].
  • Page 72 CHECKING AND SETTING THE VALVE TIMING Engine : 8HX 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].
  • Page 73 CHECKING AND SETTING THE VALVE TIMING Engine : 8HX 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).
  • Page 74 CHECKING AND SETTING THE VALVE TIMING Engine : 8HX Setting the timing (continued). NOTE : Screw (9) slackened. Position the timing belt (10) observing the following sequence: Crankshaft pinion (4). Guide roller (12). Camshaft pulley (11), (check that the belt is held correctly against the roller). Coolant pump pinion (13).
  • Page 75 CHECKING AND SETTING THE VALVE TIMING Engine : 8HX 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].
  • Page 76 CHECKING AND SETTING THE VALVE TIMING Engine : 8HX 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).
  • Page 77 CHECKING AND SETTING THE VALVE TIMING Engine : 8HY Tools. [1] Engine flywheel peg Ø 12 mm : (-).0194-C. [2] Camshaft pulley peg Ø 8 mm : (-).0194-B. [3] Crankshaft pulley peg Ø 5 mm : (-).0194-A. Preliminary operations. Remove: - The front RH wheel.
  • Page 78 CHECKING AND SETTING THE VALVE TIMING Engine : 8HY 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).
  • Page 79 CHECKING AND SETTING THE VALVE TIMING Engine : 8HY 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.
  • Page 80 CHECKING AND SETTING THE VALVE TIMING Engine : 8HY Checks (continued). NOTE : The index «e» of the dynamic tensioner roller should be centred within the area «d». Check the correct positioning of the index «e». If it is not correct, repeat the operation to tension the timing belt (see corresponding operation). Refitting.
  • Page 81 CHECKING AND SETTING THE VALVE TIMING Engine : 8HY 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).
  • Page 82 CHECKING AND SETTING THE VALVE TIMING Engine : 8HY Setting the timing. Perform the preliminary operations for checking the timing up to removing tool [1] at «a» for immobiling the engine flywheel. Refit screw (8). Rotate the crankshaft to bring the camshaft towards its pegging point. Peg the camshaft, using tool [2].
  • Page 83 CHECKING AND SETTING THE VALVE TIMING Engine : 8HY 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).
  • Page 84 CHECKING AND SETTING THE VALVE TIMING Engine : 8HY Setting the timing (continued). Checks (continued). Reposition the timing belt, belt at «e» well tensioned, in the following order: - Guide roller (17). - Camshaft pulley (16). - Fuel high pressure pump pulley (15). - Coolant pump pinion (18).
  • Page 85 CHECKING AND SETTING THE VALVE TIMING Engine : 8HY 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].
  • Page 86 EXHAUST SPECIFICATIONS Engines: HFX - KFV (Depollution L4) «a» Cutting zone B1JP03TD...
  • Page 87 EXHAUST SPECIFICATIONS Engines: HFX - KFV (Depollution IFL5) «a» Cutting zone B1JP04RD...
  • Page 88 EXHAUST SPECIFICATIONS Engine: NFU (Depollution IFL5) «a» Cutting zone B1JP04TD...
  • Page 89 EXHAUST SPECIFICATIONS Engine: HFX (Depollution L4 and IFL5) Upstream Catalytic Downstream Front silencer Rear silencer Air to exhaust injection valve oxygen sensor converter oxygen sensor Engine type Tightening (m.daN) Tightening (m.daN) Tightening (m.daN) 4.7 ± 0.5 TR PSA K179 4.7 ± 0.5 PSA 4173 PSA 96 362 494 80 0.8 ±...
  • Page 90 EXHAUST SPECIFICATIONS Engine : 8HX «a» Flexible pipe «b» Cutting zone (marked by burrs) «c» Silencer fixing strap B1JP03PD...
  • Page 91 EXHAUST SPECIFICATIONS Engine : 8HX Catalytic converter Intermediate pipe Rear silencer Engine types Strap TR PSA K278 PSA 4177 Tightening (m.daN) 2.5 ± 0.3 Tightening (m.daN) 2.5 ± 0.3 Tightening (m.daN) 2.5 ± 0.3...
  • Page 92 COOLING SYSTEM SPECIFICATIONS Engines : HFX - KFV - NFU - 8HX 1.1i 1.4i. 1.6i 16V 1.4 HDi Engine type Capacity 7 litres 5.7 Litres Radiator surface 16 dm 1.4 bar 1.4 bar Pressurisation Opening of thermostatic 89°C Start of opening 101°C Opening complete 83°...
  • Page 93 COOLING SYSTEM SPECIFICATIONS Engines : HFX - KFV - NFU Venting chamber (2) Coolant pump (3) Bleed screw of heater matrix B1GP0AXP...
  • Page 94 COOLING SYSTEM SPECIFICATIONS Engine : 8HX Bleed screw (with or without aircon) B1GP09MP...
  • Page 95 OIL FILTERS Petrol 1.1i 1.4i 1.6i 16V FILTRAUTO Diesel 1.4 HDi MALHEX...
  • Page 96 CHECKING THE OIL PRESSURE Petrol engines 1.1i 1.4i 1.6i 16V Engine type Temperature (°C) 90°C Pressure (Bars) 2000 Diesel engines 1.4 HDi Engine type 90°C Temperature (°C) Pressure (Bars) > 1.3 1000 Tools : Pressure gauge : 2279-T.Bis Toolkit 4103-T. Flexible pipe Engine oil pressure take-off union (TU engine) : 7001-T...
  • Page 97 VALVE CLEARANCES POSSIBLE METHODS The valve clearances should be checked with the engine cold. On engines: 4 cylinders in line (1-3-4-2 ) Rocking Fully open (Exhaust) G Inlet Exhaust Valves Rocking fully Adjust Adjust open 0.20 mm ± 0.05 HFX - KFV 0.40 mm ±...
  • Page 98 FILLING AND BLEEDING THE COOLING CIRCUIT HFX-KFV-NFU Tools [1] Filling cylinder : 4520-T [2] Adaptor for filling cylinder : 4222-T. [3] Pliers for removing-refitting elastic clips : 9029-T Draining. Perform the operation with the engine cold. Remove the air filter housing. Open the expansion chamber cap.
  • Page 99 FILLING AND BLEEDING THE COOLING CIRCUIT Filling and bleeding. Fit the filling cylinder [1], with the adaptor [2] on the filling aperture. Slowly fill the circuit with the coolant fluid. Reclose the bleed screws when the liquid starts to flow out continuously without air bubbles. NOTE : The filling cylinder [1] should be filled to the «1 Litre»...
  • Page 100 IDLING - DEPOLLUTION Idling speed % Content (± 50 rpm) Emission Vehicles Engine type Make - Injection type standard Auto. gearbox: N Manual gear engaged gearbox MAGNETTI MARELLI 1.1 i IF/L5 1.4 i SAGEM S2000 < 0.5 > 9 IF/L5 BOSCH 1.6 i 16V M 7.4.4.
  • Page 101 PETROL INJECTION 1.1i 1.4i 1.6i 16 V Engine type Emission standard L4 / IFL5 Make M. MARELLI 48P2 SAGEM S2000 BOSCH M.7.4.4. Injection type Fuel pressure (bars) Overspeed cut-off (rpm) 5500 5800 Injector resistive value (ohms) 14.5 Engine coolant temperature 3 800 at 10°C 2500 at 20°...
  • Page 102 EMISSION STANDARDS APPLICATIONS STANDARD NOTES CHARACTERISTICS E.E.C. Engines Vehicles Applicable © Utility vehicle limits © 10/89 = private vehicle limits increased by 25 % 15.04 Petrol Utility vehicles : 15.04 K’ R 15.04 Diesel All Types © For private vehicles and en cours utility vehicles in major export With oxygen sensor,...
  • Page 103 NORMES DE DEPOLLUTION APPLICATIONS STANDARD NOTES CHARACTERISTICS E.E.C. Engines Vehicles Applicable Private vehicles : With oxygen sensor and Petrol • certain non-EEC © US 83 US 83 Adoption of U.S. standard Current catalytic converter for Diesel European countries petrol vehicles •...
  • Page 104 NORMES DE DEPOLLUTION APPLICATIONS STANDARD NOTES CHARACTERISTICS E.E.C. Engines Vehicles Applicable Utility vehicles : © Adoption of the U.S. US 84 Petrol • certain non-EEC US 84 Current standard for light utility Diesel European countries vehicles • certain Export countries Utility vehicles : ©...
  • Page 105 NORMES DE DEPOLLUTION APPLICATIONS STANDARD NOTES CHARACTERISTICS E.E.C. Engines Vehicles Applicable With oxygen sensor and Private vehicles : reinforced catalytic Brussels Directive 94/12 EURO 2 < 6 seats and converter for petrol Petrol < 2.5 tonnes vehicles. © EURO 93 standard made Diesel (EURO ©...
  • Page 106 NORMES DE DEPOLLUTION APPLICATIONS STANDARD NOTES CHARACTERISTICS E.E.C. Engines Vehicles Applicable Utility vehicles : < 3.5 tonnes Brussels Directive 98/69 With 2 oxygen sensors © EURO 2 standard (L3) and catalytic converter for made stricter petrol vehicles. EURO 3 © Fiscal incentives With catalytic converter Petrol...
  • Page 107 NORMES DE DEPOLLUTION APPLICATIONS STANDARD NOTES CHARACTERISTICS E.E.C. Engines Vehicles Applicable Private vehicles : With 2 oxygen sensors All Types and catalytic converter for Brussels Directive: 2001/1 Petrol © petrol vehicles. EURO 3 standard (L4) made Diesel stricter EURO 4 IF / L5 ©...
  • Page 108 PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM Engine : 8HX Cleaning. - The use of high pressure cleaners is prohibited. - Do not use compressed air. Fuel supply circuit. - Required fuel : diesel. Electric circuit. - Swapping injection ECUs between two vehicles will render it impossible to start either vehicle. - It is forbidden to supply a diesel injector with 12 volts.
  • Page 109 PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM Engine : 8HX Diesel injectors. WARNING: Diesel and ultrasonic cleaners are prohibited. 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).
  • Page 110 SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM Engine : 8HX 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.
  • Page 111 SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM Engine : 8HX 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).
  • Page 112 CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engine : 8HX TOOLS [1] Ø 10 mm low pressure connector : 4215-T. [2] Pressure gauge for testing boost pressure : 4073-T.A Toolkit 4073-T IMPERATIVE : Respect the safety and cleanliness specific to high pressure diesel injection engines.
  • Page 113 AIR SUPPLY CIRCUIT SPECIFICATION Engine : 8HX Upper integrated air inlet distributor. The upper integrated air inlet system is composed of the following ele- ments: (1) Air filter cover. (2) Air filter chamber. (3) Flowmeter (4) Turbocharger inlet. (5) Resonator. (6) Turbocharger outlet.
  • Page 114 AIR SUPPLY CIRCUIT SPECIFICATION Engine : 8HX Lower integrated air inlet distributor. The lower integrated air inlet system is composed of the following ele- ments: (7) Top EGR pipe. (8) Inlet manifold. (9) Diesel fuel filter with reheater and water detector (according to country). (10) Diesel fuel filter support.
  • Page 115 AIR SUPPLY CIRCUIT SPECIFICATION Engine : 8HX Upper integrated air inlet distributor. Lower integrated air inlet distributor. B1HP1JPD B1HP1JQD WARNING: After each removal, replace the seals of components that have been removed, lubricating the new seals when refitting. Tightening Tightening m.daN.
  • Page 116 AIR SUPPLY CIRCUIT SPECIFICATION Engine : 8HX (1) Air filter assembly. (2) Oil trap. (3) Turbocharger resonance attenuator. (4) Turbocharger. (5) Air/air exchanger. (6) Air distributor. Air filter : Ref : MARK 4. Turbocharger : Ref : RHF 3V. (Supplier: «IHI») B1HP1JGP...
  • Page 117 CHECKS : AIR SUPPLY CIRCUIT Engine : 8HX Tools. [1] Manual pressure-vacuum pump FACOM DA 16. Vacuum pump : Connect the tool [1] onto the vacuum pump (1). Start the engine. Wait 30 seconds. The vacuum value should be 0.9 ± 0.1 bar at idle. NOTE : Depollution EURO 4 : The exhaust gas recycling valve is not linked to the air supply circuit.
  • Page 118 CHECKS : EXHAUST GAS RECYCLING CIRCUIT Engine : 8HX Tools : [1] Manual pressure-vacuum pump : FACOM DA 16. IMPERATIVE : Respect the safety and cleanliness requirements. Depollution EURO 3 EGR valve Connect tool [1] on the capsule take-off (2). Apply a vacuum of approx.
  • Page 119 CHECKS : TURBO PRESSURE Engine : 8HX Tools. [1] Pressure gauge for checking boost pressure : 4073-T.A [2] Sleeve for checking boost pressure : (-).0171.F Checks IMPERATIVE : Respect the following test conditions: - Engine at operating temperature. - Vehicle in running order. - Engine under full load.
  • Page 120 FEATURES OF MULTIPOINT INJECTION SYSTEM Summary (1) Vehicle speed sensor. (2) Catalytic converter. (3) Downstream oxygen sensor. (4) Upstream oxygen sensor. (5) Canister purge electrovalve. (6) Canister reservoir. (7) Fuel pump, fuel filter, gauge, pressure regulator. (8) Injectors. (9) Ignition coil. (10) Thermoswitch –...
  • Page 121 FEATURES OF MULTIPOINT INJECTION SYSTEM Fuel circuit (diagr.) Component Supplier Reference Observations Fuel Unleaded 95 RON or 98 RON 2-way brown connector – Location : under the front Electrovalve SAGEM RH wing. Capacity : 40 Litres. Fuel tank 2-way black connector – Location : on the side of the Canister reservoir MGI COUTIER fuel tank.
  • Page 122 FEATURES OF MULTIPOINT INJECTION SYSTEM Air inlet circuit (diagr.) Component Supplier Reference Observations Accelerator pedal position sensor 2-way connector. (HFX – NFU) 4-way black connector. MAGNETI Idle regulation stepper motor (KFX) Fixing : on the butterfly housing MARELLI SONCEBOZ The butterfly housing comprises : butterfly potentiometer, step- MAGNETI Butterfly housing (HFX) MARELLI...
  • Page 123 FEATURES OF MULTIPOINT INJECTION SYSTEM Ignition circuit (diagr.) Component Supplier Reference Observations 3-way white connector Vehicle speed sensor EATON Fixing : on the gearbox differential casing. Fixing : on the cylinder head, alert temperature : 118 °C Engine coolant thermoswitch Tighten to : 1.7 ±...
  • Page 124 FEATURES OF MULTIPOINT INJECTION SYSTEM Ignition circuit (diagr.) Component Supplier Reference Observations SAGEM Electrode gap : 0.9 mm BOSCH Sparking plugs Tighten to : 3 m.daN CHAMPION 4-way blue connector Downstream oxygen sensor Location : on the exhaust manifold Tighten to : 4.7 ± 0.7 m.daN 4-way green connector Upstream oxygen sensor Location : on the exhaust manifold...
  • Page 125 FEATURES OF SIEMENS HDI DIRECT INJECTION SYSTEM Summary B1HP1JFP...
  • Page 126 FEATURES OF SIEMENS HDI DIRECT INJECTION SYSTEM Electrical circuit (diagr.) Component Supplier Reference Observations Diesel injection ECU SID 802 SIEMENS 112-way grey connector : sequential injection 3-way black connector - Location : Close to crankshaft pulley. Engine speed sensor Tighten to 0.7 ± 0.2 m.daN ELECTRIFIL 3-way grey connector –...
  • Page 127 FEATURES OF SIEMENS HDI DIRECT INJECTION SYSTEM Ignition circuit (diagr.) Component Supplier Reference Observations CARTIER 5-way connector Pre-postheating unit NAGARES Preheater plugs YE04 Tighten to : 0.8 ± 0.1 m.daN.
  • Page 128 FEATURES OF SIEMENS HDI DIRECT INJECTION SYSTEM Fuel circuit (diagr.) Component Supplier Reference Observations Fuel Diesel fuel 5-way black connector Fuel high pressure sensor SIEMENS Fixed on the fuel high pressure pump Fuel tank Capacity = 45 litres – Composition = Polyethylene. Fuel filter Low pressure regulator Fixed on the fuel high pressure pumpt...
  • Page 129 FEATURES OF SIEMENS HDI DIRECT INJECTION SYSTEM Air circuit (diagr.) Component Supplier Reference Observations Air flowmeter SIEMENS 39071LS.F Air filter MECAPLAST 50557LLP.A Incorporated in the inlet manifold Type KP35 Turbocharger Type SAGEM Exhaust gas recycling (EGR) valve 2580132-A EGR recycling regulation PIEBURG electrovalve Exhaust line...
  • Page 130 SPARKING PLUGS Engine Electrode Tightening Vehicles – Models BOSCH CHAMPION SAGEM type torque 1.1i FR7DE RC8YCL 1.4i RFN58LZ 0.9 mm 2.5 mda.N 1.6i 16v FR7ME...
  • Page 131 CLUTCH SPECIFICATION 1.1i 1.4i 1.6i 16V 1.4 HDi Engine type BVM/BVMP (*) BVM/BVMP (*) BVM/BVMP (*) Gearbox type Supplier MA 5/S MA 5 N/L MA 5 S/L MA 5/0 Mechanism / type VALEO Engine type 180 CP0 3400 200 P 3900 Bearing supplier / height SKF 17 mm Clutch disc...
  • Page 132 CLUTCH SPECIFICATION NOTE : All the clutches are «push» type with hydraulic control. Description. The declutch control has a declutch fork mounted on a ball-joint. (1) The ball-joint is screwed into the clutch casing. (2) Declutch fork. (3) Clutch casing. (4) Bearing.
  • Page 133 GEARBOX AND TYRE SPECIFICATIONS MA5 gearbox Petrol Diesel 1.1i 1.4 HDi 1.4i Engine type 165/70 R14 165/70 R14 185/55 R14 165/70 R14 185/55 R15 Tyres-Rolling circumference 1.804 m 1.804 m 1.781 m 1.804 m 1.781 m MA 5/S MA 5/N MA 5/L MA 5/0 Gearbox type...
  • Page 134 MA/5 GEARBOX Engines : HFX - KFV - 8HX «a» Location of engraving of serial and gearbox nos. «b» Identification label. B2CP3SQC...
  • Page 135 MA/5 GEARBOX Engines : HFX - KFV - 8HX (1) Circlip (2).Secondary shaft (3) Drive pinion (5th gear) (4) Bearing stop screw (5) Gearbox casing (6) Intermediate plate (7) Gearbox casing fixing screw (8) Clutch bearing guide screw (9) Clutch housing (10) Bearing guide (11) Primary shaft (12) Differential housing...
  • Page 136 MA/5 GEARBOX Engines : HFX - KFV - 8HX (23) Driven pinion (4 gear). (24) Driven pinion (5 gear). (25) 5th gear synchroniser. Tightening torques (m.daN) (4) Bearing stop screw (x4) : 1,8 ± 0,2 (6) Intermediate plate (11 fixing screws) : 5 ±...
  • Page 137 MA/5 GEARBOX Engines : HFX - KFV - 8HX Tightening torques (m.daN) (26) 5th gear cover fixing screw (3 screws) : 2,2 ± 0,2 (27) Reverse gear switch (1 screw) : 2,5 ± 0,5 (28) Drain plug (1 screw) : 3,3 ± 0,3 (29) Level plug (1 screw) : 3,3 ±...
  • Page 138 GEARBOX AND TYRE SPECIFICATIONS MA5 piloted manual gearbox Petrol Diesel 1.4i 1.6i 16v 1.4 Hdi Engine type 165/70 R14 185/55 R15 185/55 R14 195/45 R16 185/70 R15 165/70 R14 Tyres-Rolling circumference 1.804 m 1.781 m 1.781 m 1.772 m 1.804 m 1.804 m Gearbox type MA 5/N...
  • Page 139 MA/5 PILOTED MANUAL GEARBOX Engines : KFV - 8HX «a» Identification label. «b» Location of engraving of serial and gearbox nos. B2CP3STC...
  • Page 140 MA/5 PILOTED MANUAL GEARBOX Engines : KFV - 8HX (1) Circlip (2) Secondary shaft (3) Drive pinion (5 gear) (4) Bearing stop screw (5) Gearbox casing (6) Intermediate plate (7) Gearbox casing fixing screw (8) Clutch bearing guide screw (9) Clutch housing (10) Bearing guide (11) Primary shaft (12) Differential housing...
  • Page 141 MA/5 PILOTED MANUAL GEARBOX Engines : KFV - 8HX (23) Driven pinion (4 gear). (24) Driven pinion (5 gear). (25) 5th gear synchroniser Tightening torques (m.daN) (4) Bearing stop screw (x4) : 1.8 ± 0.2 (6) Intermediate plate (11 fixing screws) : 5 ±...
  • Page 142 MA/5 PILOTED MANUAL GEARBOX Engines : KFV - 8HX Tightening torques (m.daN) (26) 5th gear cover fixing screw (3 screws) : 2,2 ± 0,2 (27) Gearbox input speed sensor (1 screw) : 0,8 ± 0,2 (28) Reverse gear switch (1 screw) : 2,5 ±...
  • Page 143 MA/5 PILOTED MANUAL GEARBOX Engines : KFV - 8HX Features. The piloted gearbox is a modern manual gearbox with technology that offers enhancements in every driving situation. The piloted manual gearbox has two operating programmes: « Sequential » programme « Automatic » programme The piloted manual gearbox has : A gearbox ECU (supplier: SIEMENS) A gearbox actuator with two electric motors (supplier: SACHS)
  • Page 144 RECOMMENDATIONS - PRECAUTIONS : MA TYPE PILOTED MANUAL GEARBOX Safety requirements IMPERATIVE : When initialising the clutch actuator and/or gearbox actuator, do not allow any person to walk or stand in front of the ESSENTIAL : Given the special features of the MA type piloted vehicle.
  • Page 145 RECOMMENDATIONS - PRECAUTIONS : MA TYPE PILOTED MANUAL GEARBOX Operations on electrical components : Towing. Do not disconnect : The battery when the engine is running. Conditions for towing. The ECU with the ignition switched on. The clutch and gearbox actuators with the ignition switched on. It is necessary to lift the front of the vehicle to tow it, after having positioned the gear lever in neutral.
  • Page 146 RECOMMENDATIONS - PRECAUTIONS : MA TYPE PILOTED MANUAL GEARBOX Engaging of «N», à using a diagnostic tool. Engaging of «N», without using a diagnostic tool. Preliminary operations: In this configuration, the gearbox actuator is blocked, gear engaged. Battery voltage higher than 12,5 volts. Ignition switched on.
  • Page 147 RECOMMENDATIONS - PRECAUTIONS : MA TYPE PILOTED MANUAL GEARBOX Engaging of «N», without using a diagnostic tool (continued). Preliminary operation: Disconnect the battery negative terminal. Remove the air filter. Use a 22 mm spanner. Use the spanner to lift the gear engagement lever the maximum possible until the axis «A»...
  • Page 148 MA/5 GEARBOX CONTROLS Engines : HFX - KFV - NFU - 8HX (1) Gear control lever. (2) Gear engagement control cable (*) (3) Gear selection control cable (*) (*) The two cables cannot be separated. B2CP3HXD...
  • Page 149 MA/5 GEARBOX CONTROLS Engines : HFX - KFV - NFU - 8HX (4) Gear engagement ball-joint Ø 10 mm. (5) Gear selection ball-joint Ø 10 mm. B2CP3HYC Length D Length C Gear engagement control 1040 mm 815 mm cable (2) Length A Length B Gear selection...
  • Page 150 MA/5 GEARBOX CONTROLS Engines : HFX - KFV - NFU - 8HX Adjustment. WARNING: Do not use any tool to detach the ball-joints. The gear selection control and gear engagement control B2CP3J0D cables cannot be adjusted. To unlock the ball-joint, press at «a» then pull the ball-joint upwards.
  • Page 151 DRIVESHAFTS - GEARBOX Gearbox oil seal mandrels Tightening torques (m.daN) Driveshaft Driveshaft RH side LH side Tool kit Vehicles Gearbox Engines bearing HFX - KFV NONE MA/5 7114-T.X 7116-T 24.5 ± 0.5 7114-T.W 2 ± 0.2 Tightening torques for wheel bolts (m.daN) Steel CITROËN C2 9 ±...
  • Page 152 WHEELS AND TYRES Standard fitting Spare wheel Tyres Wheels Engines Trim levels (Circumference) Trims Tyres Wheels 5.5J 14 H2 4.24 A - X MILAN 1.1i 5.5J 14 H2 4.24 SX - SX - Pack CONDOR 165/70 R14 81 T XT1 165/70 R14 81 T XT1 5.5J 14 H2 4.24 1.804 m...
  • Page 153 WHEELS AND TYRES Standard fitting Spare wheel Tyres Wheels Engines Trim levels (Circumference) Trims Tyres Wheels 5.5J 14 H2 4.24 A - X MILAN 165/70 R14 81 T XT1 165/70 R14 81 T XT1 5.5J 14 H2 4.24 1.804 m 5.5J 14 H2 4.24 SX - SX - Pack 1.4 HDi...
  • Page 154 WHEELS AND TYRES Optional fitting Spare wheel Wheels Engines Tyre Trims Tyres Wheels 1.1i 165/70R14 81 T XT1 5.5J 14 H2 4.24 5.5 J14 CH 4.24 TIGRE 165/70R14 81 T XT1 1.4i 6J 15CH 4.27 6J 15CH 4.27 LYNX 185/60 R15 84 H XH1 185/60 R15 84 H XH1 1.6i 16V 5.5J 14 H2 4.24...
  • Page 155 WHEELS AND TYRES Tyre pressures, vehicle empty Pressure (Bars) Tyre dimensions Front Rear Spare wheel 165/70 R14 (81T) XT1 185/55 R15 (84H) XH1 195/45 R16 (80V) Tyre pressures, vehicle under load Pressure (Bars) Tyre dimensions Front Rear Spare wheel 165/70 R14 (81T) XT1 185/55 R15 (84H) XH1 195/45 R16 (80V)
  • Page 156 WHEELS AND TYRES Identification of inflation pressures The label indicating recommended tyre pressures is affixed to the inner panel of one of the front doors. ‘‘a’’: Recommended tyre inflation pressures. (vehicle empty and vehicle under load). «b»: Type of tyre. «c»: Recommended inflation pressure for the spare tyre.
  • Page 157 WHEELS AND TYRES Identification of wheel bolts : Wheel bolt. : Light alloy wheel. : Spare wheel. Steel wheel. Bolt for wheel with conical contact surface. Light alloy wheel. Mixed fixing wheel bolts, permitting the securing of the following wheel types: Light alloy wheel (fixing with flat contact surface).
  • Page 158 AXLE GEOMETRY Conditions for checking and adjusting Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point (See corresponding operation). Vehicle heights at reference height E1AP0BZD Front height Rear height H1 = R1 - L1 H2 = R2 + L2 H2 = Measurement between the measuring zone underneath the rear sill H1 = Measurement between the measuring zone underneath the front...

  • Page 159: Axle Geometry

    AXLE GEOMETRY 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. Z2 = Measuring zone underneath the rear sill. Measure the radius of the rear wheel R2 - Calculate dimension H2 = R2 + L2 Measure the radius of the front wheel R1 - Calculate dimension H1 = R1 –...
  • Page 160 AXLE GEOMETRY Front axle Rear axle Dissymmetry of lower castor at 0° 30’. Dissymmetry of lower camber at 0° 18’ Dissymmetry of lower camber at 0° 18. Distribute symmetrically, LH / RH wheel, the total tracking value. All types (except CRD) HFX - KFV - 8HX HFX - KFV - 8HX Camber...

  • Page 161: Front Axle

    FRONT AXLE Tightening torques (m.daN) (1) Nut fixing suspension leg on body : 6,5 ± 0,6 (2) Damper (3) Anti-roll bar link rod upper ball-joint : 3,2 ± 0,3 (4) Suspension leg pivot : 5,4 ± 0,5 (5) Anti-roll bar link rod lower ball-joint : 3,2 ±...

  • Page 162: Rear Axle

    REAR AXLE Tightening torques (m.daN) (25) Rear axle fixing screw : 10 ± 1 (26) Anti-roll bar (27) Rear axle crossmember (28) Rear suspension arm silentblock yoke (29) Rear suspension arm silentblock (30) Yoke / suspension arm fixing screw : 7 ± 0,5 (31) Rear suspension arm (32) Stub axle bearing nut : 20 ±...
  • Page 163 SUSPENSION FRONT AXLE (1) Nut fixing suspension leg on body : 6,5 ± 0,6 (2) Damper. (16) Cup. (17) Damper nut. : 6,5 ± 0,6 (18) Damper cup. (19) Ball bearing (20) Spring thrust cup. (21) Travel stop cup. (22) Suspension spring. (23) Damper rod protector.
  • Page 164 FEATURES OF ELECTRIC POWER STEERING Engines : HFX - KFV - NFU - 8HX Steering column B3EP13GD B3EP13HC Tightening torques m.daN. Identification (1) Steering wheel fixing 2 ± 0,3 Identified by the colour of the ring at «a». (2) Steering column fixing on support 2,2 ±...
  • Page 165 FEATURES OF ELECTRIC POWER STEERING Engines : HFX - KFV - NFU - 8HX Steering mechanism Tightening torques m.daN (4) Ball-joint fixing on pivot : 3,5 ± 0,3 (5) Steering rod lock-nut : 5 ± 0,5 (8) Threaded washer (9) Stud : 0,8 ±...
  • Page 166 FEATURES OF ELECTRIC POWER STEERING Engines : HFX - KFV - NFU - 8HX Steering assistance Electric steering assistance ECU B3EP13KC B3EP13LC Only one ECU version, whatever the engine-type. Supplier: KOYO. The electric power steering ECU is linked to the following connec- The steering assistance is provided by the assistance motor (12), control- tors: led by the ECU.
  • Page 167 SPECIAL FEATURES : STEERING Engines : HFX - KFV - NFU - 8HX Centring the steering rack Preliminary operation. Raise and support the vehicle on a two-column lift. Remove, on the RH side of the steering rack: - Clip (1). - Clip (2).
  • Page 168 BRAKE SPECIFICATIONS (WITHOUT ABS) 1.1i 1.4i 1.4 HDi Engine type Master cylinder 20.6 Master vac 203.2 Ø Caliper/piston makes LUCAS .TRW-/-C 48/13-/-48 Disc Plain Disc thickness/minimum thickness 13/11 0.05 Maximum run-out (mm) Difference in max. thickness on same 0.01 circumference (mm) TEXTAR-/-T 4144 Supplier / Brake pad grade Original thickness/minimum thickness...
  • Page 169 BRAKE SPECIFICATIONS (WITH ABS) 1.1i 1.4i 1.4i 1.4 HDi Engine type Master cylinder 22.2 (*) 228.6 Master vac Ø Caliper/piston makes LUCAS .TRW-/-C 48/13-/-48 LUCAS .TRW C 54/22-/-54 LUCAS.TRW-/-C 48/13-/-48 Plain Disc Ventilated Disc thickness/minimum thickness 13/11 22/20 13/11 Supplier / Brake pad grade TEXTAR-/-T 4144 Ø...
  • Page 170 BRAKE SPECIFICATIONS Braking circuit without ABS - REF (drum brakes at the rear) Braking system specifications - Braking circuit at «X». - Front brakes with ventilated discs (*). - Rear brakes with eitther drums or discs (*). - Handbrake lever controlling cables acting on the rear wheels.
  • Page 171 BRAKE SPECIFICATIONS Braking circuit with ABS - REF (drum brakes at the rear) B3FP7BTD...
  • Page 172 BRAKE SPECIFICATIONS Braking circuit with ABS - REF (disc brakes at the rear) B3FP7BUD...

  • Page 173: Brake Specifications

    BRAKE SPECIFICATIONS Braking circuit with ABS - REF (a) Hydraulic circuit. (b) Electrical circuit. (1) Master cylinder in tandem. (2) Braking servo. (3) Brake caliper (or drum at the rear). (4) Hub equipped with a bearing with an integral magnetic wheel (48 pairs of poles).
  • Page 174 BRAKE SPECIFICATIONS Part No. (7) Hydraulic block Ref. Elements Supplier Observations ABS MK 70 Hydraulic 96 514 120 80 Mounted on the front LH chassis member. block 4 adjustment channels ESP -ABS MK.60 96 490 288 80 ABS MK.70 26-way connector. Integral to the hydraulic block ESP -ABS MK 60 2-way blue connector.
  • Page 175 BRAKE SPECIFICATIONS Brake pedal gear Front brake Rear brake B3FP166D B3FP164C B3FP165C Tightening torques (m.daN). (16) Servo fixing 2,2 ± 0,3. (12) Yoke fixing on caliper 10,5± 1 (14) Rear caliper fixing on arm 5,3±0,5 (17) Fixing on master cylinder 2 ±...
  • Page 176 HANDBRAKE (Adjustment) Adjustment Lift and chock the vehicle. Remove: - The rear cover (8) - The nut (9) - The handbrake trim (6). - The gear lever gaiter (5). - The front cover (3). - The screws (1). Disconnect the connectors of the following components: - The cigar lighter (2).
  • Page 177 HANDBRAKE (Adjustment) Adjustment (continued) A : Drum brakes B : Disc brakes (10) Nut for adjusting cable tensions. Remove: - The rear wheels. - The drums (according to version). Release the handbrake. Use a gauge set to measure at «a» the travel of the lever from its stop.
  • Page 178 BLEEDING AND FILLING THE BRAKING SYSTEM Tools. [1] Generic bleeding apparatus : «LURO» or similar. Bleeding, refilling. Draining. Drain the brake fluid reservoir (1) to the maximum (if necessary, use a clean syringe). Disconnect the connector (4). Uncouple the pipe (2). Unscrew the shaft (3).
  • Page 179 BLEEDING AND FILLING THE BRAKING SYSTEM Bleeding, filling (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).
  • Page 180 BLEEDING AND FILLING THE BRAKING SYSTEM Bleeding, filling (continued) With the bleeding apparatus - Connect the bleeding apparatus [1] on the brake fluid reservoir (1). - Adjust the apparatus pressure to 2 Bars. For each circuit : - Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container. - Open the bleed screw, wait until the fluid is flowing out without air bubbles.
  • Page 181 FEATURES OF THE PRE-POSTHEATING CIRCUIT ESSENTIAL : Respect the safety and cleanliness requirements. The pre-heating time varies according to the engine coolant temperature. The pre-post heating control unit is managed by the engine ECU. Pre-post heating control unit Supplier CARTIER NAGARES Reference 96 399 073 80...
  • Page 182 STARTER MOTORS Abbreviations and definitions Coding of climatees is as follows : Meaning of abbreviations : CLIMATEES : : Manual gearbox : Starting possible as low as -18°C Temperate : Starting possible as low as -18°C BVMP : Piloted manual gearbox Cold : Starting possible as low as -25°C REFRI...
  • Page 183 STARTER MOTORS Types of starter Class Climate Vehicles / models Gearbox VALEO D7E16 BOSCH A001183027F 1.1i MELCO M002T13081 VALEO D6RA572 VALEO D7E16 BOSCH A001183027F 1.1i REFRI MELCO M002T13081 VALEO D6RA572 VALEO D7E16 BOSCH A001183027F MELCO M002T13081 1.4i VALEO D7E23 BOSCH A0001180093F BVM - BVMP VALEO D6RA572 VALEO D7E16...
  • Page 184 STARTER MOTORS Vehicles / models Gearbox Types of starter Class Climate 1.6i 16V BVMP VALEO D6RA572 VALEO D6RA110 14.HD i VALEO D7GP09 DENSO 5S228000-001 Meanings of abbreviations : see page 180...
  • Page 185 ALTERNATORS Abbreviations and definitions Coding of climates is as follows : Meaning of abbreviations : CLIMATES : : Manual gearbox : Starting possible as low as -18°C Temperate : Starting possible as low as -18°C BVMP : Piloted manual gearbox Cold : Starting possible as low as -25°C NON REFRI...
  • Page 186 ALTERNATORS NON REFRI REFRI Without cold pack With cold pack Without cold pack With cold pack Gearbox Climate Base Base Base Base N1 or N2 N1 or N2 N1 or N2 N1 or N2 1.1i 1.4i BVMP 1.6i 16V 1.4 HDi 1.4 HDi BVMP Meanings of abbreviations : see page 183...
  • Page 187 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 vehicle’s equipment specification (see table opposite), adjust the engine speed and rheostat charge to obtain U=13.5V.
  • Page 188 CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR MINIMUM OUTPUTS (in A) Class Alternator Min. output speed 1800 rpm 2000 rpm 3000 rpm 68.5 4000 rpm 6000 rpm 78.5 8000 rpm 15000 rpm MINIMUM YIELDS (in %) Class Alternator speed 1800 rpm 2000 rpm 3000 rpm 4000 rpm...
  • Page 189 PRE-HEATING AND STARTING SYSTEMS Pre / Post heating Vehicles - models Pre-heater plugs Pre-heater control unit (pre-heating duration at 20°C) NAGARES 960411-P Controlled by the diesel injection NGK YE04 1.4 HDI CARTIER 735068...
  • Page 190 AIR CONDITIONING R 134 a (HFC) Compressor Refrigerant Vehicle Engine Date refill Variable Oil quantity Capacity reference All types 05/2003 # 600 + 0 - 50 gr SD 6 V 12 SP 10...
  • Page 191 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Compressor Condenser C5HP18UD C5HP18VD The condenser (5) has a cylinder (6) incorporating the function of aircon fluid reservoir and with integral filtering cartridge. The drive plate (1) is held on the aircon compressor shaft by ribs. New wiring (2).
  • Page 192 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Pressure reducer Seals C5HP18WC C5HP18XD The inlet (10) and the outlet (9) are equipped with new seals (3) MANULLI calibrated seal (3) (MANULLI). Direction of fitting of the seal (3). Before fitting the seal, amply lubricate the seal with air conditioning compressor oil (SP10).
  • Page 193 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Pollen filter Note: The pollen filter is located in the engine compartment on the RH side. Removing Pull on the tab of the plastic cover (1), at «a». Tilt the flap (2). Remove the pollen filter (3) Refitting Proceed in reverse order.
  • Page 194 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Changing the filtering/drying cartridge Tools. [1] Charge station : (according to workshop equipment) [2] TORX adaptor : TORX 70 FACOM. [3] Inertia extractor :1671-T. Toolkit 4114-T [4] Endpiece Ø 20 : 1671-T.D20. [5] Set of plugs : (-).0188.T.
  • Page 195 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Changing the filtering/drying cartridge Refitting Remove the new cartridge from its packaging. Do not expose the cartridge, the filter and seals to pollutants. Lightly oil the seals (compressor oil). Remove tool [5] from the reservoir (4). Insert the new cartridge (5) into the reservoir (4).
  • Page 196 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Compressor lubricant ESSENTIAL: The compressor lubricant is extremely hygroscopic; always use FRESH oil. Checking the compressor oil level. There are three specific cases : - 1/ Repairs to a system without leaks. - 2/ Slow leak.
  • Page 197 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Checking the compressor oil level (continued) 2/ Slow leak. - Slow leaks do not lead to oil loss, therefore the same procedure should be followed as if there was no leak at all. 3/ Fast leak.
  • Page 198 AIR CONDITIONING CIRCUIT R 134.a (1) High pressure valve. (2) Low pressure valve (3) Pressostat (4) Filter. Tightening torque m.daN : 0.6 : 0.6 : 0.6 : 0.6 : 0.6 : 0.7 C5HP19UP...

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