CITROEN C4 2004 Handbook
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CITROEN C4 2004 Handbook

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Table of Contents

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CITROËN C4
2004
«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».
Mechanics' handbook 050 0019

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Do you have a question about the C4 2004 and is the answer not in the manual?

Questions and answers

Pedro Henrique
May 29, 2025

Do we have the 2012 service manual for the Citroen C4 or does this 2004 cover it all? Reading it seems like it covers everything i need, but im having a hard time with such an old manual, and i feel i might be missing some information about the clutch specially, like, what is the name of this part? The Manual doesnt cover it.

User image 68383dbb5a813
0
2 comments:
Mr. Anderson
May 29, 2025

The name of the clutch part for the 2004 Citroen C4 is not specified in the provided context.

The 2004 service manual covers specifications, adjustments, checks, and special features for that model year only. It does not include information for later years like 2012. Therefore, it may not cover all necessary information compared to the 2012 version.

This answer is automatically generated

1
Pedro Henrique
May 29, 2025

@Mr. Anderson Do we have a service book that covers that?

0

Related Manuals for CITROEN C4 2004

Summary of Contents for CITROEN C4 2004

  • Page 1 CITROËN C4 2004 «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 VERY IMPORTANT As the booklet is constantly re-edited, this one only covers vehicles for this particular model year. It is therefore necessary to order a new booklet each year and RETAIN THE OLD ONES.
  • Page 3 PRESENTATION THIS HANDBOOK summarises the specifications, adjustments, checks and special features of the CITROEN C4. The handbook is divided into nine groups representing the main functions : GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES,...
  • Page 4 A: Manufacturer’s name plate A1: Front RH chassis member = All versions except CITROEN C4 Coupé EW10J4S (right hand drive) A2: LH centre pillar = CITROEN C4 coupé EW10J4S (right hand drive) B: Cold stamp (cold stamp engraved on the bodywork).
  • Page 5 IDENTIFICATION OF THE VEHICLE Trim level Version Level 1 Level 2 SX - VTR Level 3 VTR PACK - SX PACK Level 4 EXCLUSIVE - VTS...

  • Page 6: Level

    IDENTIFICATION OF THE VEHICLE C4 Coupé petrol 3-door 1.4i 16V 1.6i 16V 2.0i 16V AUTO. Level 1-2 Level 1-2-3 Level 3-4 Level 4 Euro 4 Emission standard LA KFUC LA NFUC LA NFUF LA RFNC LA RFKC Type code Engine type 1360 1587 1997...
  • Page 7 IDENTIFICATION OF THE VEHICLE C4 Coupé diesel 3-door ATED4 TED4 BTED4 1.6 16V HDi 2.0 16V HDi Level 1-2-3 Level 1-2-3-4 Level 3-4 Euro 4 Euro 3 Euro 4 Emission standard LA 9HXC LA 9HYB LA 9HZC LA RHRH Type code Engine type 1560 1997...
  • Page 8 IDENTIFICATION OF THE VEHICLE C4 petrol 5-door 1.4i 16V 1.6i 16V 2.0i 16V AUTO. AUTO. Level 1-2 Level 1-2-3-4 Level 2-3-4 Level 2-3-4 Euro 4 Emission standard LC KFUC LC NFUC LC NFUF LC RFNC LC RFJF Type code Engine type 1360 1587 1997...
  • Page 9 IDENTIFICATION OF THE VEHICLE C4 diesel 5-door ATED4 TED4 BTED4 1.6 16V HDi 2.0 16V HDi Euro 4 Euro 3 Euro 4 Emission standard LC 9HXC LC 9HYB LC 9HZC LC RHRH Type code Engine type 1560 1997 Cubic capacity (cc) Fiscal rating (hp) BE4/5R ML6C...
  • Page 10 IDENTIFICATION OF THE VEHICLE 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 (*) (g) Manufacturer identification (*) = according to marketing country.
  • Page 11 IDENTIFICATION OF THE VEHICLE Structure Family (1) CITROËN C4 3-door saloon Body shape (2) 5-door saloons 1360 ET3J4 1587 TU5JP4 EW10J4 1997 EW10A Engine (3) EW10J4S DV6ATED4 without FAP 1560 DV6TED4 without FAP DV6TED4 with FAP 1997 DW10BTED4 with FAP Fiscal incentives 5-speed Variants (5)
  • Page 12 GENERAL SPECIFICATION: DIMENSIONS E1AP0EXD...
  • Page 13 GENERAL SPECIFICATION: DIMENSIONS Exterior dimensions (mm) Vehicles 3-door saloons 5-door saloons Wheelbase 2608 Length overall 4273 4260 Front overhang Rear overhang Rear track at ground level 1510 Front track at ground level 1505 Width overall 1769 1773 Height overall * 1456 à...
  • Page 14 GENERAL SPECIFICATION: WEIGHTS Petrol 3-door Diesel 3-door 2.0 16V 1.4i 16V 1.6i 16V 2.0i 16V 1.6 16V HDi Engine type Gearbox type MA/5 BE4/5 ML6C Payload Weight empty in running order 1181 1200 1278 1279 1337 1255 1269 1279 1379 Gross Vehicle weight 1701 1720...
  • Page 15 GENERAL SPECIFICATION: WEIGHTS Petrol 5-door Diesel 5-door 2.0 16V 1.4i 16V 1.6i 16V 2.0i 16V 1.6 16V HDi Engine type Gearbox type MA/5 BE4/5 BE4/5 ML6C Payload Weight empty in running order 1182 1200 1274 1262 1292 1257 1270 1280 1381 Gross Vehicle weight 1702...
  • Page 16 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. Electric windows.
  • Page 17 GENERAL SPECIFICATION: TOWING THE VEHICLE Vehicle towing: Precautions to be taken Manual gearbox AL4 automatic gearbox ESSENTIAL: Never tow the vehicles with wheels hanging (towing by the wheels). AL4 autoactive gearbox. Towing. If it not possible to lift the front of the vehicle: - It is imperative to place the selection lever in position «N».
  • Page 18 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. The towing eye is stowed in the jack protection box in the spare wheel. Towing.
  • Page 19 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 20 GENERAL SPECIFICATION: LIFTING AND SUPPORTING THE VEHICLE Lifting and supporting the vehicle (continued) E2AP02HD Side lifting crossmember (-).0010 Positioning of the crossmember. Take weight on the sill rebate with the crossmember as close as possible to the mating edge. Position the axle stand at the point provided for lifting the vehicle with the jack. NOTE: To have 2 wheels hanging, repeat the operation on the other side.
  • Page 21 GENERAL SPECIFICATION: LIFTING AND SUPPORTING THE VEHICLE Lifting and supporting the vehicle (continued) Lifting with the jack at the front Raising the vehicle on a lift, supported from the jacking points Tooling [1] Safety straps E2AP02JC E2AP02FC E5AP2DNC Lifting from the rear. Lifting with the jack at the rear IMPERATIVE: Do not lift the vehicle by the rear.
  • Page 22 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 23 CAPACITIES (in litres) Petrol 1.4i 16V 1.6i 16V 2.0i 16V 2.0i 2.0i 16V AUTO. AUTO. Engine type Oil capacity with change 3,75 3,25 4,25 4,25 of cartridge Between min. and max. 2 ± 0,15 Manual gearbox Automatic gearbox After draining WITH ESP = 0,85 WITHOUT ESP = 0,75 Braking circuit...
  • Page 24 CAPACITIES (in litres) Diesel 1.6 HDi 16V 2.0 HDi 16V Engine type Oil capacity with change 3,75 5,25 of cartridge Between min. and max. Manual gearbox WITH ESP = 0,85 WITHOUT ESP = 0,75 Braking circuit Cooling circuit Additive reservoir Steering electro-pump 0,85 reservoir...

  • Page 25: Total Activa

    LUBRICANTS - TOTAL recommended oils Evolutions (year 2004). CITROËN C5 Restyled Petrol engine versions. CITROËN C4. Normal maintenance interval : 30 000 Km (20 000 miles). Severe maintenance interval : 20 000 Km (12 000 miles). Petrol engine versions. Diesel engine versions. Normal maintenance interval : 30 000 Km (20 000 miles).

  • Page 26: Total Quartz

    LUBRICANTS - TOTAL recommended oils Use of oil grade 10W40. Exclusions of use of this oil are: Possibility to use the semi-synthetic oil 7000 10W40 on vehicles HDi XSARA VTS 2.0i 16V (XU10J4RS). and HDi FAP. JUMPER/RELAY 2.8 TDi ; 2.8 HDi (SOFIM engine). WARNING: To avoid difficulties starting from cold (<20°C), Use oil 5W40.
  • Page 27 LUBRICANTS - TOTAL recommended oils Engine oil norms. Current norms. The classification of these engine oils is established by the following recognised organisations: - S.A.E : Society of Automotive Engineers. - API : American Petroleum Institute. - ACEA : Association des Constructeurs Européens d’Automobiles E4AP006D...
  • Page 28 LUBRICANTS - TOTAL recommended oils S.A.E. Norms - Table for selection of engine oil grade. Selection of engine oil grades recommended for climatic conditions in countries of distribution. Evolution of the norms as at 01/01/2003 ACEA 2003 norms API norms The meaning of the first letter has not changed, it still corresponds to The meaning of the first letter has not changed, it still corresponds to the the type of engine:...
  • Page 29 LUBRICANTS - TOTAL recommended oils Recommendations. ESSENTIAL: To preserve engine performances, all engines fitted in CITROËN vehicles must be lubricated with high quality oils (synthetic or semi-synthetic). CITROËN engines are lubricated at the factory with TOTAL oil of grade S.A.E 5W-30. TOTAL oil of grade S.A.E 5W-30 allows improved fuel economies (approx 2.5%).
  • Page 30 LUBRICANTS - TOTAL recommended oils Recapitulation Norms to be observed for engine oils (year 2003) Year Types of engine concerned ACEA norms API norms Petrol and dual fuel A3 or A5 (*) SJ or SL petrol/LPG engines 2003 Diesel engines B3, B4 or B5 (*) (*) 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), EW10A, EW 12 J4, DV4 TED4.

  • Page 31: Table Of Contents

    LUBRICANTS - TOTAL recommended oils Oils specifically for petrol and dual fuel petrol/LPG engines S.A.E norms ACEA norms API norms TOTAL ACTIVA 7000 10W40 TOTAL QUARTZ 7000 TOTAL QUARTZ 9000 0W40 TOTAL ACTIVA 7000 15W50 TOTAL QUARTZ 7000 Oils specifically for diesel engines S.A.E norms ACEA norms API norms...
  • Page 32 LUBRICANTS - TOTAL recommended oils Oil usage table Huile TOTAL ACTIVA QUARTZ Synthetic 9000 Semi-synthetic 7000 0W40 5W30 5W40 10W40 15W50 Engines versions cold countries temperate countries hot countries XU10 J4RS (C4) EW 12 J4 (C8 2.2i 16V) Petrol engines Other petrol engines HDi engines with FAP (*) Other HDi engines...
  • Page 33 LUBRICANTS - TOTAL recommended oils Selection of TOTAL engine oils, to be used according to the climatic conditions in the country where the vehicle is marketed. E4AP006D...

  • Page 34: Total Activa Diesel

    LUBRICANTS - TOTAL recommended oils ENGINE OILS FRANCE Blended oils for all engines, supplied in bulk Metropolitan FRANCE TOTAL ACTIVRAC S.A.E norms: 10W40 TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines 7000 10W40...
  • Page 35 LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines 7000 10W40 Germany 9000 0W40 Austria 7000 10W40 7000 10W40 Belgium 9000 0W40 9000 5W40...
  • Page 36 LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines 7000 10W40 Denmark 9000 0W40 7000 10W40 Spain 7000 15W40 Estonia 7000 10W40 9000 0W40...
  • Page 37 LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines 7000 10W40 Hungary 9000 0W40 Italy Ireland 7000 10W40 9000 5W40 Iceland FUTURE 9000 5W30 (*)
  • Page 38 LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines 7000 10W40 Malta 7000 15W50 Moldavia 7000 10W40 7000 10W40 Norway 9000 0W40 9000 5W40...
  • Page 39 LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines 7000 10W40 7000 15W50 Romania 9000 0W40 Russia 7000 10W40 Slovenia 9000 0W40 9000 5W40...
  • Page 40 LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines Ukraine 9000 5W40 7000 10W40 7000 10W40 FUTURE 9000 5W30 (*) 9000 0W40 Serbia-Montenegro (*) Blended oils for all engines, permitting fuel economy.
  • Page 41 LUBRICANTS - TOTAL recommended oils ENGINE OILS OCEANIA TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines Australia 9000 5W40 7000 10W40 7000 10W40 FUTURE 9000 5W30 New Zealand AFRICA...
  • Page 42 LUBRICANTS - TOTAL recommended oils ENGINE OILS CENTRAL AND SOUTH AMERICA TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines Argentina Brazil Chile 7000 10W50 7000 15W50 7000 10W40 Cuba 9000 5W40...
  • Page 43 LUBRICANTS - TOTAL recommended oils ENGINE OILS SOUTH-EAST ASIA TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines 7000 10W50 China 7000 15W50 9000 5W40 South Korea 7000 10W40 FUTURE 9000 5W30 Hong Kong...
  • Page 44 LUBRICANTS - TOTAL recommended oils ENGINE OILS SOUTH-EAST ASIA TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines Philippines 7000 15W50 Singapore 7000 10W40 9000 5W40 Taiwan 7000 10W40 7000 15W50...
  • Page 45 LUBRICANTS - TOTAL recommended oils ENGINE OILS MIDDLE EAST TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines Saudi Arabia - Bahrain Dubai 7000 15W50 United Arab Emirates 9000 5W40 7000 10W40 7000 10W40...
  • Page 46 LUBRICANTS - TOTAL recommended oils GEARBOX OILS TOTAL TRANSMISSION BV Manual gearbox and Norms S.A.E: 75W80 piloted manual gearbox Part No.: 9730 A2 TOTAL FLUIDE ATX TOTAL FLUIDE AT 42 Special oil distributed by MB3 automatic gearbox CITROËN Part No.: 9730 A3 All countries Special oil distributed by 4HP20 and AL4 autoactive...
  • Page 47 LUBRICANTS - TOTAL recommended oils POWER STEERING OILS Power steering TOTAL FLUIDE ATX All vehicles except CITROËN C4, C5 All countries TOTAL FLUIDE DA Power steering Special oil distributed by CITROËN CITROËN C4, C5 Part No.: 9979 69 TOTAL FLUIDE DA Very cold countries Power steering Special oil distributed by CITROËN...
  • Page 48 LUBRICANTS - TOTAL recommended oils BRAKE FLUID Synthetic brake fluid CITROËN Part No. Pack 9979 05 0,5 Litre CITROËN fluid All countries 1 Litre 9979 06 5 Litres 9979 07 HYDRAULIC CIRCUIT CITROËN Part No. Pack All countries Norm TOTAL FLUIDE LDS Orange 9979 69 TOTAL LHM PLUS...
  • Page 49 LUBRICANTS - TOTAL recommended oils SCREEN WASH FLUID Pack CITROËN Part No. Concentrated: 250 ml 9980 33 9980 56 ZC 9875 953U 9980 06 1 Litre ZC 9875 784U All countries Fluid ready for use 5 Litres 9980 05 ZC 9885 077U ZC 9875 279U GREASE General use...

  • Page 50: Engine Oil Consumption

    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.
  • Page 51 ENGINE SPECIFICATIONS Petrol 1.4i 16V 1.6i 16V 2.0i 2.0i 16V Emission standard EURO 4 IF EURO 4 Engine type Cubic capacity (cc) 1360 1587 1997 Bore / Stroke 75/77 78/82 85/88 Compression ratio 11/1 10,8/1 Power ISO or EEC (KW - rpm) 65-5250 80-5800 103-6000...
  • Page 52 ENGINE SPECIFICATIONS Diesel 1.6 16V HDi 2.0 16V HDi Emission standard EURO 4 EURO 3 (with or without FAP) EURO 4 Engine type Cubic capacity (cc) 1560 1997 Bore / Stroke 75/88,3 85/88 Compression ratio 18/1 18/1 Power ISO or EEC (KW - rpm) 66-4000 80-4000 100-4000...
  • Page 53 SPECIAL FEATURES: TIGHTENING TORQUES Suspensions for engine/gearbox assembly Engine: KFU Gearbox on RH side Gearbox on LH side 6 ± 0,6 1 ± 0,2 6 ± 0,1 1,8 ± 0,2 4,5 ± 0,4 2 ± 0,2 3 ± 0,3 1,9 ± 0,1 2,5 ±...
  • Page 54 SPECIAL FEATURES: TIGHTENING TORQUES Engine: KFU Cylinder head Inlet air pressure sensor 0,8 ± 0,1 Motorised butterfly housing fixing screws 0,8 ± 0,2 Coolant outlet husing screws 0,8 ± 0,2 Oxygen sensor 4,7 ± 0,7 Catalytic converter fixing nuts (*) Pre-tightening 2 ±...
  • Page 55 SPECIAL FEATURES: TIGHTENING TORQUES Engine: KFU Cylinder head IMPERATIVE: Respect the tightening sequence. (8) Cylinder head bolts (10) Valve cover screws (5) Catalytic converter fixing nuts (11) Camshaft bearing cap screws B1JP063C B1DP05BC...
  • Page 56 SPECIAL FEATURES: TIGHTENING TORQUES Engine: KFU Cylinder block Crankshaft bearing cap sealing screw (*) 0,8 ± 0,1 Knock sensor 2 ± 0,4 Coolant pump stud screw 1,6 ± 0,2 Coolant pump cover screw 0,6 ± 0,1 Screw of coolant pump body on cylinder block 6,5 ±...
  • Page 57 SPECIAL FEATURES: TIGHTENING TORQUES Engine: KFU Cylinder block IMPERATIVE: Respect the tightening sequence. (14) Crankshaft bearing cap sealing screw (25) Crankshaft bearing cap cover screw (21) Flywheel screw B1CP0GYC B1DP05BC...
  • Page 58 SPECIAL FEATURES: TIGHTENING TORQUES Engine: KFU Lubrication Oil gauge screw 0,7 ± 0,1 Electric oil gauge fixing screw 3,2 ± 0,5 Oil filter support screw 1 ± 0,1 Strainer fixing screw 1 ± 0,1 Oil pressure switch 2 ± 0,2 Oil sump screw 0,8 ±...
  • Page 59 SPECIAL FEATURES: TIGHTENING TORQUES Engine: KFU Timing Inlet camshaft dephaser plug (VVT) 3,2 ± 0,2 Inlet camshaft dephaser screw (VVT) Pre-tightening 2 ± 0,2 Tightening 6 ± 0,6 Guide roller screw 2,1 ± 0,2 Exhaust camshaft pulley screw 4,5 ± 0,4 Tensioner roller screw 2,1 ±...
  • Page 60 SPECIAL FEATURES: TIGHTENING TORQUES Engine: KFU Accessories Alternator support fixing screw 2,5 ± 0,3 Alternator power circuit fixing nut 1,4 ± 0,2 Alternator fixing screw 4 ± 0,4 Aircon compressor fixing screw 2,4 ± 0,1 Aircon compressor support fixing screw 2,5 ±...
  • Page 61 CYLINDER HEAD Engine: KFU Identification of cylinder head gasket Engine types Thicknesses (repair) Thickness references Thicknesses (Standard) 1,2 ± 0,1 1,5 ± 0,1 Engine type : 1 to 4 Supplier (MEILLOR) : A B D Cylinder head gasket without asbestos : Ref.
  • Page 62 CYLINDER HEAD Engine: KFU Cylinder head tightening (m.daN) Cylinder head bolts (Sequence from 1 to 10) Pre-tightening : 1,5 ± 0,2 Tightening : 2,5 ± 0,2 Angular tightening : 200° ± 5° NOTE: Oil the threads and under B1BP1DVC the heads of the bolts (use engine oil or Molykote G Rapid Plus).
  • Page 63 SPECIAL FEATURES: TIGHTENING TORQUES Suspensions for engine/gearbox assembly Engine: NFU Gearbox on RH side Gearbox on LH side 6 ± 0,6 1,8 ± 0,2 6 ± 0,6 2 ± 0,2 4,5 ± 0,4 6,5 ± 0,6 1,9 ± 0,1 4 ± 0,4 3 ±...
  • Page 64 SPECIAL FEATURES: TIGHTENING TORQUES Engine: NFU Cylinder head Inlet air pressure sensor 0,8 ± 0,1 Motorised butterfly housing fixing screws 0,7 ± 0,1 Inlet manifold nuts 0,8 ± 0,2 Valve cover screws (*) 0,9 ± 0,1 Coolant outlet husing screws 0,8 ±...
  • Page 65 SPECIAL FEATURES: TIGHTENING TORQUES Engine: NFU Cylinder block Coolant pump screw 2 ± 0,1 Oil plugs 2,5 ± 0,5 Con rod cap bolt 3,8 ± 0,2 Seal plate screw, flywheel end 1 ± 0,1 Flywheel screw (*) 7 ± 0,7 Seal plate screw, timing end 1 ±...
  • Page 66 SPECIAL FEATURES: TIGHTENING TORQUES Engine: NFU IMPERATIVE: Respect the tightening sequence. Sequence of tightening the nuts (8) (Catalytic converter) (22) Sequence of tightening the flywheel screws B1CP0GCC B1JP063C...
  • Page 67 SPECIAL FEATURES: TIGHTENING TORQUES Engine: NFU Lubrication Strainer fixing 0,8 ± 0,2 Oil gauge screw 0,8 ± 0,1 Piston skirt spray jet 1,5 ± 0,2 Drain plug 3 ± 0,5 Oil sump screw 0,8 ± 0,1 Oil pressure switch 2 ± 0,2 Oil circuit plugs 2,5 ±...
  • Page 68 SPECIAL FEATURES: TIGHTENING TORQUES Engine: NFU Timing Camshaft pulley screw 4,5 ± 0,5 Guide roller screw 2 ± 0,2 Tensioner roller screw 2,1 ± 0,4 B1BP1GMP...
  • Page 69 SPECIAL FEATURES: TIGHTENING TORQUES Engine: NFU Accessories Alternator support fixing screw 2,5 ± 0,6 Alternator power circuit fixing nut 1,4 ± 0,2 Alternator fixing screw 4 ± 0,4 Aircon compressor fixing screw 2,5 ± 0,2 Tensioner roller support fixing screw 2,5 ±...
  • Page 70 CYLINDER HEAD Engine: NFU Identification of cylinder head gasket Engine types Thicknesses (repair) Thickness references Thicknesses (Standard) 0,66 ± 0,04 Engine type : 1 à 4 Supplier (MEILLOR) : A B D Cylinder head gasket without asbestos : Ref. C Repair ref.
  • Page 71 CYLINDER HEAD Engine: NFU Cylinder head tightening (m.daN) Cylinder head bolts Pre-tightening : 2 ± 0,2 Angular tightening : 260° ± 5° NOTE: Oil the threads and under the heads of the bolts (use engine oil or Molykote G Rapid Plus). B1DP059C X = MAXIMUM reusable length Retightening of the cylinder head after a...
  • Page 72 SPECIAL FEATURES: TIGHTENING TORQUES Suspensions for engine/gearbox assembly Engine: RFJ RH side Torque reaction rod 6 ± 0,6 4,5 ± 0,4 6 ± 0,6 3,9 ± 0,4 4,5 ± 0,4 5,4 ± 0,6 B1BP35TD B1BP35UD 1 ± 0,1 5 ± 0,5 6,5 ±...
  • Page 73 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFJ Cylinder head Valve cover screws (*) Pre-tightening Tightening 1,1 ± 0,1 Oxygen sensor 4,7 ± 0,5 Exhaust manifold nuts 3,5 ± 0,3 Coolant outlet housing fixing nuts 1 ± 0,1 Coolant outlet housing bolts Motorised butterfly housing fixing screws 0,8 ±...
  • Page 74 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFJ Cylinder head Camshaft bearing cap screws (*) Pre-tightening Tightening 1 ± 0,1 Exhaust manifold fixing stud 0,8 ± 0,2 Coolant outlet housing fixing stud 0,8 ± 0,2 Engine coolant temperature sensor 1,7 ± 0,1 Inner timing cover screw 0,8 ±...
  • Page 75 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFJ Cylinder head IMPERATIVE: Respect the tightening sequence. (1) Valve cover screws (9) Cylinder head bolts (11) Camshaft bearing cap screws B1DP03XD B1DP05BC...
  • Page 76 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFJ Cylinder block Oil circuit plugs 3 ± 0,3 Coolant pump screw (*) Pre-tightening Tightening 1,4 ± 0,1 Cooling circuit plug 3 ± 0,3 Accessories drive belt pulley screw Tightening 4 ± 0,4 Angular tightening 40°...
  • Page 77 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFJ Cylinder block Crankshaft bearing cap cover screw (*) Pre-tightening Tightening 2 ± 0,2 Angular tightening 72° ± 5° Crankshaft bearing cap sealing screw Con rod cap bolt (*) Pre-tightening Tightening 2,3 ± 0,2 Angular tightening 46°...
  • Page 78 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFJ Cylinder head IMPERATIVE: Respect the tightening sequence. (22) Crankshaft bearing cap screws (24) Con rod cap bolt (21) Flywheel screw (18) Coolant pump screw B1CP0GCC B1GP08WC B1DP05BC...
  • Page 79 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFJ Lubrication Oil gauge screw 1 ± 0,2 Oil filter support screw 0,8 ± 0,1 Anti-emulsion plate fixing screw 1,9 ± 0,3 Oil level sensor fixing screw 1 ± 0,2 Drain plug 3,4 ± 0,3 Oil sump screw 0,8 ±...
  • Page 80 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFJ Timing Exhaust camshaft pulley screw Pre-tightening 3 ± 0,5 Tightening 8,5 ± 0,5 1,1 ± 0,1 Inlet camshaft pulley screw Pre-tightening 2 ± 0,2 Tightening 11 ± 1 Tensioner roller screw 2,1 ± 0,2 Guide roller screw Pre-tightening 1,5 ±...
  • Page 81 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFJ Accessories Accessories support fixing stud 0,8 ± 0,1 Accessories support fixings Pre-tightening 1 ± 0,1 Tightening 1,9 ± 0,2 Alternator top fixing screw 4,1 ± 0,5 Alternator power circuit fixing nut 1,7 ± 0,2 Aircon compressor fixing screw 2,3 ±...
  • Page 82 CYLINDER HEAD Engine: RFJ Identification of cylinder head gasket Supplier MEILLOR A : Timing end Thickness 0,67 ± 0,04 mm B : Clutch end C : Engraving zone D : Marking zone Multi-layer metallic cylinder head gasket B1DP1LPD...

  • Page 83: Cylinder Head

    CYLINDER HEAD Engine: RFJ Cylinder head tightening (m.daN) Cylinder head bolts Pre-tightening : 1,5 ± 0,1 Tightening : 5 ± 0,1 Angular tightening : 360° ± 2° Tightening : 2 ± 0,75 Angular tightening : 285° ± 5° (Sequence from 1 to 10) WARNING: Refit the cylinder head A = Thickness of the washer : 4 ±...
  • Page 84 SPECIAL FEATURES: TIGHTENING TORQUES Suspensions for engine/gearbox assembly Engine: RFN Gearbox on RH side Gearbox at torque reaction rod 6 ± 0,6 4,5 ± 0,4 6 ± 0,6 3,9 ± 0,4 4,5 ± 0,4 5,4 ± 0,6 B1BP35TD B1BP35UD Gearbox on LH side 1 ±...
  • Page 85 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFN Cylinder head Valve cover screws (*) Pre-tightening Tightening 1,1 ± 0,1 Exhaust manifold stud 0,7 ± 0,1 Exhaust manifold nuts Tightening on heat shield 2,5 ± 0,2 Tightening apart from on heat shield 3,5 ± 0,3 Oxygen sensor 4,7 ±...
  • Page 86 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFN Cylinder head Cylinder head bolts (*) 1st pre-tightening 1,5 ± 0,1 2nd pre-tightening 5 ± 0,5 Angular tightening 360° Tightening 2 ± 0,2 Angular tightening 285° ± 5° Camshaft bearing cap cover screws (*) Pre-tightening Tightening 1 ±...
  • Page 87 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFN Cylinder head IMPERATIVE: Respect the tightening sequence. (1) Valve cover screws (11) Cylinder head bolts (12) Camshaft bearing cap screws B1DP03XD B1DP05BC...
  • Page 88 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFN Cylinder block Oil circuit plug 3 ± 0,3 Coolant pump screw (*) Pre-tightening Tightening 1,4 ± 1 Cooling circuit plug 3 ± 0,7 Flywheel screw (*) Pre-tightening 0,8 ± 0,1 Tightening 2 ± 0,2 Angular tightening 23°...
  • Page 89 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFN Cylinder block Crankshaft bearing cap sealing screw 1 ± 0,1 Con rod cap screw (*) Pre-tightening Tightening 2,3 ± 0,1 Angular tightening 46° ± 3° Knock sensor 2 ± 0,5 Accessories drive belt pulley screw Tightening 4 ±...
  • Page 90 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFN Cylinder head IMPERATIVE: Respect the tightening sequence. (22) Crankshaft bearing cap screws (24) Con rod cap screws (21) Flywheel screws (19) Coolant pump screws B1CP0GCC B1GP08WC B1DP05BC...
  • Page 91 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFN Lubrication Oil gauge screw 1 ± 0,2 Oil level sensor fixing screw 1 ± 0,2 Drain plug 3,4 ± 0,3 Oil sump screw 0,8 ± 0,1 Oil pressure switch 2 ± 0,2 Oil strainer fixing nuts 1,1 ±...
  • Page 92 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFN Timing Camshaft pulley screw 7,5 ± 0,5 Tensioner roller screw 2 ± 0,3 Guide roller screw 3,5 ± 0,5 B1EP1G6P...
  • Page 93 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFN Accessories Accessories support fixing stud 0,8 ± 0,1 Accessories support fixings Pre-tightening 1 ± 0,1 Tightening 1,9 ± 0,2 Alternator top fixing screw 4,1 ± 0,5 Alternator power circuit fixing nuts 1,7 ± 0,2 Aircon compressor fixing screw 2,3 ±...
  • Page 94 CYLINDER HEAD Engine: RFN Identification of cylinder head gasket Nominal Repair dimension dimension Identification zone 2-4-5 "d" Marking zone "e" Gasket thickness (mm) Supplier MEILLOR NOTA : Multilayer metallic gasket. B1DP183D...
  • Page 95 CYLINDER HEAD (continued) Engine: RFN Cylinder head tightening (m.daN) Cylinder head bolts Pre-tightening : 1,5 ± 0,1 Tightening : 5 ± 0,1 Slackening : 360° ± 2° Tightening : 2 ± 0,75 Angular tightening : 285° ± 5° NOTA : Oil the threads and under the heads of the bolts (use engine oil or Molykote G Rapid Plus).
  • Page 96 SPECIAL FEATURES: TIGHTENING TORQUES Suspensions for engine/gearbox assembly Engine: RFK Gearbox on RH side Gearbox at torque reaction rod 6 ± 0,6 4,5 ± 0,4 6 ± 0,6 3,9 ± 0,4 4,5 ± 0,4 5,4 ± 0,6 B1BP35TD B1BP35UD Gearbox on LH side 1 ±...
  • Page 97 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFK Cylinder head Exhaust manifold stud 0,7 ± 0,1 Exhaust manifold nuts Tightening on heat shield 2,5 ± 0,2 Tightening apart from on heat shield 3,5 ± 0,3 Oxygen sensor 4,7 ± 0,5 Coolant outlet housing fixing Tightening of the nuts 1 ±...
  • Page 98 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFK Cylinder head Cylinder head bolts (*) Pre-tightening 1 1,5 ± 0,1 Pre-tightening 2 5 ± 0,5 Angular slackening 360° Tightening 2 ± 0,2 Angular tightening 285° ± 5° Valve cover screws (*) Pre-tightening Tightening 1,1 ±...
  • Page 99 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFK Cylinder head IMPERATIVE: Respect the tightening sequence. (12) Valve cover screws (13) Cylinder head bolts (15) Camshaft bearing cap screws B1DP03XD B1DP05BC...
  • Page 100 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFK Cylinder block Oil circuit plug 3 ± 0,3 Coolant pump screw (*) Pre-tightening Tightening 1,4 ± 1 Cooling circuit plug 3 ± 0,7 Flywheel screw (*) Pre-tightening 0,8 ± 0,1 Tightening 2 ± 0,2 Angular tightening 23°...
  • Page 101 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFK Cylinder block Crankshaft bearing cap sealing screw 1 ± 0,1 Con rod cap screw (*) Pre-tightening Tightening 2,3 ± 0,1 Angular tightening 46° ± 3° Knock sensor 2 ± 0,5 Accessories drive belt pulley screw Tightening 4 ±...
  • Page 102 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFK Cylinder head IMPERATIVE: Respect the tightening sequence. (21) Crankshaft bearing cap screws (23) Con rod cap screws (20) Flywheel screws (18) Coolant pump screws B1CP0GCC B1GP08WC B1DP05BC...
  • Page 103 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFK Lubrication Oil gauge screw 1 ± 0,2 Oil level sensor fixing screw 1 ± 0,2 Drain plug 3,4 ± 0,3 Oil sump screw 0,8 ± 0,1 Oil pressure switch 2 ± 0,2 Oil strainer stud 0,6 ±...
  • Page 104 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFK Timing Camshaft pulley screw 7,5 ± 0,5 Camshaft dephaser cap (VVT) 3,2 ± 0,3 Inlet camshaft pulley screw Pre-tightening 2 ± 0,2 Tightening 11 ± 1 Tensioner roller screw 2,1 ± 0,2 Guide roller screw 3,5 ±...
  • Page 105 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RFK Accessories Accessories support fixing stud 0,8 ± 0,1 Accessories support fixings Pre-tightening 1 ± 0,1 Tightening 1,9 ± 0,2 Alternator top fixing screw 4,1 ± 0,5 Alternator power circuit fixing nut 1,6 ± 0,2 Aircon compressor fixing screw 2,4 ±...
  • Page 106 CYLINDER HEAD Engine: RFK Identification of cylinder head gasket Supplier MEILLOR A : Timing end Thickness 0,80 ± 0,04 mm B : Clutch end C : Identification zone D : Marking zone Multi-layer metallic gasket B1DP1LQD...
  • Page 107 CYLINDER HEAD Engine: RFK Cylinder head tightening (m.daN) Cylinder head bolts Pre-tightening : 1,5 ± 0,1 Tightening : 5 ± 0,1 Slackening : 360° ± 2° Tightening : 2 ± 0,75 Angular tightening : 285° ± 5° (Sequence from 1 to 10) A = Washer thickness : 4 ±...
  • Page 108 SPECIAL FEATURES: TIGHTENING TORQUES Suspensions for engine/gearbox assembly Engines: 9HX - 9HY - 9HZ RH engine support Torque reaction rod 6 ± 0,6 6 ± 0,6 5,5 ± 0,5 3,9 ± 0,4 6 ± 0,6 5,4 ± 0,8 B1BP38CC B1BP38DC Impact absorber LH engine support on gearbox 2 ±...
  • Page 109 SPECIAL FEATURES: TIGHTENING TORQUES Engine: 9HX Cylinder head Air inlet manifold 1 ± 0,1 Oil trap 1 ± 0,1 Camshaft bearing covers Pre-tightening 0,5 ± 0,1 Tightening 1 ± 0,1 (3) Camshaft bearing cover screws (4) Camshaft bearing cover studs B1BP39YP B1DP1D7D...
  • Page 110 SPECIAL FEATURES: TIGHTENING TORQUES Engine: 9HX Cylinder head Camshaft bearing cover studs Pre-tightening 0,5 ± 0,1 Tightening 1 ± 0,1 Exhaust gas recycling electrovalve (EGR) 1 ± 0,1 Cylinder head Pre-tightening 2 ± 0,2 Tightening 4 ± 0,5 Angular tightening 260°...
  • Page 111 SPECIAL FEATURES: TIGHTENING TORQUES Engine: 9HX Cylinder head Exhaust manifold 2,5 ± 0,2 Exhaust manifold stud 1 ± 0,2 Turbocompressor nuts 2,6 ± 0,6 Catalytic converter nuts 2 ± 0,1 Air flowmeter Pre-tightening Tightening 0,9 ± 0,2 B1BP39YP...
  • Page 112 SPECIAL FEATURES: TIGHTENING TORQUES Engine: 9HX Cylinder block Coolant pump Pre-tightening 0,3 ± 0,1 Tightening 0,9 ± 0,1 Con rod screws Pre-tightening 1 ± 0,1 Angular tightening 100° ± 5° Flywheel (according to equipment) Pre-tightening 1,7 ± 0,2 Angular tightening 75°...
  • Page 113 SPECIAL FEATURES: TIGHTENING TORQUES Engine: 9HX Cylinder block Bearing cap fixing screws Pre-tightening 1 ± 0,2 Slackening 180° Tightening 3 ± 0,3 Angular tightening 140° ± 5° Crankshaft bearing cap cover screws 0,8 ± 0,3 Crankshaft bearing cap cover screws Pre-tightening 0,6 ±...
  • Page 114 SPECIAL FEATURES: TIGHTENING TORQUES Engine: 9HX Cylinder block Crankshaft bearing cap cover Tightening method Pre-tightening the 10 screws (17) (from 1 to 10) to Pre-tightening the 14 screws (19) (from 11 to 24) to Tightening the 2 screws (18) (inside the flywheel bell housing) to 180°...
  • Page 115 SPECIAL FEATURES: TIGHTENING TORQUES Engine: 9HX Lubrication 3 ± 0,5 Turbocharger lubrication tube 2,1 ± 0,3 Oil pressure switch 2 ± 0,2 Oil gauge 0,8 ± 0,2 Electric oil gauge 2,7 ± 0,5 Piston skirt spray jets 2 ± 0,5 Oil filter cover 2,5 ±...
  • Page 116 SPECIAL FEATURES: TIGHTENING TORQUES Engine: 9HX Timing Camshaft bearing caps 1 ± 0,1 Camshaft pulleys Pre-tightening 2 ± 0,2 Angular tightening 50° ± 5° Timing belt guide roller 3,7 ± 0,3 Timing belt tensioner roller 2,7 ± 0,2 Timing chain tensioner 1 ±...
  • Page 117 SPECIAL FEATURES: TIGHTENING TORQUES Engine: 9HX Injection circuit Union on injector Pre-tightening 2 ± 0,5 Tightening 2,5 ± 0,3 Injector fixing flange but Pre-tightening 0,5 ± 0,5 Angular tightening 65° ± 5° Diesel injection pump on support 2,2 ± 0,3 Diesel injection pump pulley 5 ±...
  • Page 118 SPECIAL FEATURES: TIGHTENING TORQUES Engine: 9HX Injection circuit Diesel fuel high pressure pump rear support 2 ± 0,5 Union on diesel fuel high pressure pump Pre-tightening 2 ± 0,5 Tightening 2,5 ± 0,3 Fuel high pressure common injection rail on engine block 2,2 ±...
  • Page 119 SPECIAL FEATURES: TIGHTENING TORQUES Engine: 9HX Accessories Version without particle filter Multifunction support 2 ± 0,4 Alternator fixing screw 4,9 ± 1,2 Alternator power circuit fixing nut 1,4 ± 0,2 Accessories tensioner roller 2,1 ± 0,2 D1AP02NC...
  • Page 120 SPECIAL FEATURES: TIGHTENING TORQUES Engine: 9HX Accessories Version without aircon Accessories support 2 ± 0,5 Guide roller 4,5 ± 0,5 D1AP02PC Accessories Version with aircon Aircon compressor support 2 ± 0,5 Aircon compressor screw 2,4 ± 0,5 D1AP02QD...
  • Page 121 SPECIAL FEATURES: TIGHTENING TORQUES Engines: 9HY - 9HZ Cylinder head Air inlet manifold 1 ± 0,1 Oil trap 1 ± 0,1 Camshaft bearing covers screws Pre-tightening 0,5 ± 0,1 Tightening 1 ± 0,1 (3) Sequence for tightening the camshaft bearing cover screws B1BP39XP B1DP1D7D...
  • Page 122 SPECIAL FEATURES: TIGHTENING TORQUES Engines: 9HY - 9HZ Cylinder head Camshaft bearing cover studs Pre-tightening 0,5 ± 0,1 Tightening 1 ± 0,1 Exhaust gas recycling electrovalve (EGR) 1 ± 0,1 Cylinder head Pre-tightening 2 ± 0,2 Tightening 4 ± 0,5 Angular tightening 260°...
  • Page 123 SPECIAL FEATURES: TIGHTENING TORQUES Engines: 9HY - 9HZ Cylinder head Exhaust manifold 2,5 ± 0,2 Exhaust manifold stud 1 ± 0,2 Turbocompressor nuts 2,6 ± 0,6 Catalytic converter nuts 2 ± 0,1 Double butterfly housing (according to equipment) Pre-tightening Tightening 0,9 ±...
  • Page 124 SPECIAL FEATURES: TIGHTENING TORQUES Engines: 9HY - 9HZ Cylinder block Coolant pump Pre-tightening 0,3 ± 0,1 Tightening 0,9 ± 0,1 Con rod screws Pre-tightening 1 ± 0,1 Angular tightening 100° ± 5° Damping flywheel (according to equipment) Pre-tightening 3 ± 0,3 Angular tightening 90°...
  • Page 125 SPECIAL FEATURES: TIGHTENING TORQUES Engines: 9HY - 9HZ Cylinder block Bearing cap fixing screws Pre-tightening 1 ± 0,2 Slackening 180° Tightening 3 ± 0,3 Angular tightening 140° ± 5° Crankshaft bearing cap cover screws 0,8 ± 0,3 Crankshaft bearing cap cover screws Pre-tightening 0,6 ±...
  • Page 126 SPECIAL FEATURES: TIGHTENING TORQUES Engines: 9HY - 9HZ Cylinder block Crankshaft bearing cap cover Tightening method Pre-tightening the 10 screws (17) (from 1 to 10) to Pre-tightening the 14 screws (19) (from 11 to 24) to Tightening the 2 screws (18) (inside the flywheel bell housing) to Slacken the screws (17) by 180°...
  • Page 127 SPECIAL FEATURES: TIGHTENING TORQUES Engines: 9HY - 9HZ Lubrication 3 ± 0,5 Turbocharger lubrication tube 2,1 ± 0,3 Oil pressure switch 2 ± 0,2 Oil gauge 0,8 ± 0,2 Oil level sensor 2,7 ± 0,5 Piston skirt spray jets 2 ± 0,5 Oil filter cover 2,5 ±...
  • Page 128 SPECIAL FEATURES: TIGHTENING TORQUES Engines: 9HY - 9HZ Timing Camshaft bearing caps 1 ± 0,1 Camshaft pulleys Pre-tightening 2 ± 0,2 Angular tightening 50° ± 5° Timing belt guide roller 3,7 ± 0,3 Timing belt tensioner roller 2,7 ± 0,2 Timing chain tensioner 1 ±...
  • Page 129 SPECIAL FEATURES: TIGHTENING TORQUES Engines: 9HY - 9HZ Injection circuit Union on injector Pre-tightening 2 ± 0,5 Tightening 2,5 ± 0,3 Injector fixing flange but Pre-tightening 0,5 ± 0,5 Angular tightening 65° ± 5° Diesel injection pump on support 2,2 ± 0,3 Diesel injection pump pulley 5 ±...
  • Page 130 SPECIAL FEATURES: TIGHTENING TORQUES Engines: 9HY - 9HZ Injection circuit Diesel fuel high pressure pump rear support 2 ± 0,5 Union on diesel fuel high pressure pump Pre-tightening 2 ± 0,5 Tightening 2,5 ± 0,3 Fuel high pressure common injection rail on engine block 2,2 ±...
  • Page 131 SPECIAL FEATURES: TIGHTENING TORQUES Engines: 9HY - 9HZ Accessories Version without particle filter Multifunction support 2 ± 0,4 Alternator fixing screw 4,9 ± 1,2 Alternator power circuit fixing nuts 1,4 ± 0,2 Accessories tensioner roller 2,1 ± 0,2 D1AP02NC...
  • Page 132 SPECIAL FEATURES: TIGHTENING TORQUES Engines: 9HY - 9HZ Accessories Version without aircon Accessories support 2 ± 0,5 Guide roller 4,5 ± 0,5 D1AP02PC Accessories Version with aircon Aircon compressor support 2 ± 0,5 Aircon compressor screw 2,4 ± 0,5 D1AP02QD...
  • Page 133 SPECIAL FEATURES: TIGHTENING TORQUES Engines: 9HY - 9HZ Accessories Version with particle filter Multifunction support 3,2 ± 0,2 D1AP02RC...
  • Page 134 CYLINDER HEAD Engines: 9HX - 9HY - 9HZ Identification of the cylinder head gasket Piston No. of No. of Type of gasket: Metallic multilayer Engine types Supplier standproud thicknesses notches notches (mm) (mm) at d at e «d» Thickness reference 0,685 to 0,734 1,35 «e»...
  • Page 135 CYLINDER HEAD Engines: 9HX - 9HY - 9HZ Cylinder head tightening (m.daN) Cylinder head bolts (Sequence from 1 to 10) Pre-tightening : 2 ± 0,2 Tightening : 4 ± 0,5 Angular tightening : 260° ± 5° NOTE: Oil the threads and under B1DP1DBC the heads of the bolts (use engine oil or Molykote G Rapid Plus).
  • Page 136 SPECIAL FEATURES: TIGHTENING TORQUES Suspensions for engine/gearbox assembly Engine: RHR RH engine support LH engine support 5,5 ± 0,5 3 ± 0,3 6 ± 0,5 6,5 ± 0,6 2 ± 0,2 5,5 ± 0,5 4,5 ± 0,4 3 ± 0,3 5,5 ±...
  • Page 137 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RHR Cylinder head Exhaust manifold Pre-tightening Tightening 3 ± 0,3 Turbocompressor 2,5 ± 0,2 Exhaust clip 2,5 ± 0,5 Cylinder head bolts (*) Pre-tightening 2,2 ± 0,2 Tightening 6 ± 0,5 Slackening 1 Turn Tightening 6 ±...
  • Page 138 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RHR Cylinder head Camshaft bearing cap cover screws (*) 1 ± 0,1 Coolant outlet housing fixing 2 ± 0,2 Camshaft bearing cap cover studs (*) Pre-tightening (the 26 screws Ø 6) Tightening (the 26 screws Ø 6) 1 ±...
  • Page 139 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RHR Cylinder head (*) Bolts (5) and (7) Sequence of tightening (*) Bolts (8) Sequence of tightening (5) Camshaft bearing cap cover screws (7) Camshaft bearing cap cover studs (8) Inlet valve cover screws B1BP38ZD B1DP1LED...
  • Page 140 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RHR Cylinder block Oil circuit plug 3 ± 0,3 Coolant pump screw 1,6 ± 0,3 Crankshaft bearing cap screws (*) Pre-tightening 2,5 ± 0,2 Angular tightening 60° ± 5° Con rod cap nuts Tightening Slackening 180°...
  • Page 141 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RHR Cylinder block Front closing plate screw Flywheel screws Pre-tightening Tightening 4,7 ± 0,4 Accessories drive pulley screw Pre-tightening 7 ± 0,25 Angular tightening 60° ± 5° B1CP0GNP...
  • Page 142 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RHR Lubrication Oil pump screw 1,6 ± 0,1 Piston skirt spray jet screw 1 ± 0,1 Drain plug 3,4 ± 0,4 Oil sump (length 40 mm ) Pre-tightening Tightening 1,6 ± 0,3 Oil sump (length 21 mm) Pre-tightening Tightening 1,6 ±...
  • Page 143 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RHR Lubrication Oil pressure switch 2 ± 0,2 Oil filter support (*) Tightening 1 ± 0,1 Tightening 2 ± 0,2 Oil filter cover 2,5 ± 0,5 (*) (23) Sequence of tightening B1CP0GPP B1FP062C...
  • Page 144 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RHR Timing Camshaft drive pulley screw Tightening 7 ± 0,7 Angular tightening 60° ± 5° Guide roller screw Pre-tightening Tightening 4,3 ± 0,4 Tensioner roller screw 2,1 ± 0,2 B1EP1HPD...
  • Page 145 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RHR Injection circuit High pressure pipe union on injector 2,5 ± 0,2 Diesel injector nuts Do up both nuts by hand Tightening 0,4 ± 0,3 Angular tightening 45° ± 5° Fuel high pressure pump screw 2,25 ±...
  • Page 146 SPECIAL FEATURES: TIGHTENING TORQUES Engine: RHR Accessories Alternator support 2 ± 0,2 Alternator 4,9 ± 0,4 Aircon compressor 2,5 ± 0,2 Accessories belt tensioner roller 4,3 ± 0,4 B1BP390D...
  • Page 147 CYLINDER HEAD Engine: RHR Identification of the cylinder head gasket Piston thicknesses of No. of No. of Type of gasket: Metallic multilayer Engine types standproud flattened gasket holes at holes at (mm) (mm) «d» Thickness reference 0,55 to 0,60 1,25 ± 0,04 «e»...
  • Page 148 CYLINDER HEAD Engine: RHR Cylinder head bolts Cylinder head tightening (m.daN) Pre-tightening : 2 ± 0,2 Tightening : 6 ± 0,6 Slackening : The bolts by 360° Pre-tightening : 2 ± 0,2 Tightening : 6 ± 0,6 Angular tightening : 220° ± 5° (in the sequence from 1 to 10) NOTE: - The bolts should have been carefully brushed with...
  • Page 149 AUXILIARY EQUIPMENT DRIVE BELT EW10 ATED BTED Engine types See pages: 147 to 148 152 to 153...
  • Page 150 AUXILIARY EQUIPMENT DRIVE BELT Engines: KFU - NFU Tools. [1] Pliers for removing plastic pegs : 7504-T [2] Belt tension measuring instrument (SEEM) : 4122-T [3] Compression lever for dynamic tensioner : (-).0194.D [4] Peg for dynamic tensioner roller of Ø 4 mm : (-) 0194.F WARNING: (with or without air conditioning).
  • Page 151 AUXILIARY EQUIPMENT DRIVE BELT Engine: KFU Vehicle with air conditioning. Removing. Place tool [4] at «a». Compress the dynamic tensioner roller. Place tool [3] at «b». Remove the auxiliary equipment drive belt. IMPERATIVE: Check that the dynamic tensioner roller turns freely (without play and without tight spots).
  • Page 152 AUXILIARY EQUIPMENT DRIVE BELT Engines: RFJ Tools. [1] «Junior» T extension : (-).1608.E Removing. Engage tool [1] in the notch «a». Exert on the roller (1) an effort upwards to hold it at maximum. Remove the auxiliaries drive belt. Carefully release the tensioner roller (1) to reach its minimum. Remove tool [1].
  • Page 153 AUXILIARY EQUIPMENT DRIVE BELT Engine: RFN Without air conditioning Removing. Raise and support the vehicle, wheels hanging. Remove the front RH wheel, the plastic pins and the splash-shield. Detension the belt (3) by turning the tensioner roller (1) by means of the screw (2) (clockwise).
  • Page 154 AUXILIARY EQUIPMENT DRIVE BELT Engine: RFK Tools. [1] Detensioning lever for auxiliaries drive belt tensioner roller Dynamic spanner extension : FACOM SJ.214 Adaptor for socket 9x12 : FACOM J.274 Polygon socket 9x12 : 016 Removing. Raise and support the vehicle, wheels hanging. Remove the front RH wheel, the plastic pins and the splash-shield.
  • Page 155 AUXILIARY EQUIPMENT DRIVE BELT Engines: 9HX - 9HY - 9HZ Tools. [1] Dynamic tensioner roller lever (DV6 TED4 engine) : (-).0194-E3 [1a] Dynamic tensioner roller lever (DV6 ATED4 engine) : (-).0194-E1 [1b] Lever extension (DV6 ATED4 engine) : (-).0194-E2 [2] Dynamic tensioner roller locking peg : (-).0194-F IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions.
  • Page 156 AUXILIARY EQUIPMENT DRIVE BELT Engines: 9HX - 9HY - 9HZ Refitting. WARNING: Belt to be re-used, mark the direction of fitting of the belt. Refit the auxiliaries drive belt. Compress the tensioner roller (1) by acting at «c» (clockwise), using tool [1]. Remove tool [2].
  • Page 157 AUXILIARY EQUIPMENT DRIVE BELT Engine: RHR Tools. [1] Dynamic tensioner compression lever : (-).0188.Z [2] Dynamic tensioner roller retaining peg Ø 4 mm : (-).0188.Q1 Removing. Remove the splash-shield, under-engine sound-deadening, front RH wheel. WARNING: Mark the direction of fitting of the auxiliaries drive belt in the case of re-use of the belt. Compress the dynamic tensioner roller (1) by acting at «b»...
  • Page 158 CHECKING AND SETTING THE VALVE TIMING EW10 ATED BTED Engine types See pages: 158 to 162 163 to 168 169 to 175 176 to 182 183 to 190 191 to 199 200 to 207...
  • Page 159 BELT TENSION CORRESPONDANCE TABLE / SEEM UNITS 4099-T (C.TRONIC.105) Tools 4122-T (C.TRONIC.105.5)
  • Page 160 RECOMMENDATIONS: TIMING BELT Diesel engine Petrol engine Recommendations IMPERATIVE: After any repair involving removal of the timing belt, systematically replace: The timing belt, The tensioner roller fixing nut.
  • Page 161 CHECKING THE VALVE TIMING Engine: KFU Tools. [1] Flywheel setting peg : 4507-TA Toolkit 4507-T [2] Camshaft setting peg : 4533-TA.C1 [3] Camshaft setting peg : (-).0194.A IMPERATIVE: Respect the safety and cleanliness requirements. Checking. Deconnect the battery. Remove: B1BP37JC - The engine cover.
  • Page 162 CHECKING THE VALVE TIMING Engine: KFU Checking (continued). Position the tools [3] and [2]. Peg the flywheel, using tool [1]. NOTE: If the setting is not correct, recommence the operation. Remove the tools. B1BP2ZMC Complete the refitting. B1BP2MBC...
  • Page 163 CHECKING AND SETTING THE VALVE TIMING Engine: KFU Tools. [1] Flywheel setting peg : 4507-T.A [2] Camshaft setting peg : 4533-T.AC1 [3] Camshaft setting peg : (-).0194.A [4] Belt retaining pin : 4533-TA.D IMPERATIVE: Respect the safety and cleanliness requirements. Setting the timing.
  • Page 164 CHECKING AND SETTING THE VALVE TIMING Engine: KFU Setting the timing (continued). Rotate the engine by means of the crankshaft screw (clockwise), to bring it to the pegging position. Peg the flywheel, using tool [1]. Position the tools [2] and [3]. Remove the engine support assembly (9), the fixiing screw (8) and the lower cover (7).
  • Page 165 CHECKING AND SETTING THE VALVE TIMING Engine: KFU Overtension on the belt. Position «a»: Tensioner roller in detensioned position. Position «b»: Tensioner roller in normal position. Position «c»: Tensioner roller in overtension position. Turn the tensioner roller (10), using an allen spanner at «e». Place the index «d»...
  • Page 166 CHECKING THE VALVE TIMING Engine: NFU Tools. [1] Flywheel setting peg : 4507-T.A Toolkit 4507-T [2a] Camshaft setting peg : 4533-TA.C1 [3b] Camshaft setting peg : 4533-TA.C2 IMPERATIVE: Respect the safety and cleanliness requirements. Checking. Disconnect the negative terminal of the battery. B1BP2M7C Remove: - The oil filter (1).
  • Page 167 CHECKING THE VALVE TIMING Engine: NFU Remove the sparking plugs, to facilitate rotation of the crankshaft. Rotate the engine by means of the crankshaft pinion screw (clockwise) to bring it to the pegging position. Fit the tools [2a] and [2b]. Peg the flywheel, using tool [1].
  • Page 168 CHECKING AND SETTING THE VALVE TIMING Engine: NFU Tools. [1] Flywheel setting peg : 4507-T.A Toolkit 4507-T [2a] Camshaft setting peg : 4533-TA.C1 [2b] Camshaft setting peg : 4533-TA.C2 [3] Belt retaining pin : 4533-T.AD [4] Dynamic tensioner roller pin : 4200-T.H IMPERATIVE: Respect the safety and cleanliness requirements.
  • Page 169 CHECKING AND SETTING THE VALVE TIMING Engine: NFU Peg the flywheel, using tool [1]. Position the tools [2a] and [2b]. Slacken the tensioner roller. Turn the dynamic tensioner roller so as to be able to position the tool [4], with the aid of an Allen key placed at «a».
  • Page 170 CHECKING AND SETTING THE VALVE TIMING Engine: NFU Refitting. Fit the (new) 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 tools [1], [2a], [2b] and [4]. Overtension on the belt.
  • Page 171 CHECKING AND SETTING THE VALVE TIMING Engine: NFU Adjusting the fitting tension of the timing belt. 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 «e». WARNING: The index «c»...
  • Page 172 CHECKING AND SETTING THE VALVE TIMING Engine: RFJ Tools. [1] Camshaft pinion peg : (-).0194.A [2] Crankshaft setting peg : (-).0189.R IMPERATIVE: Respect the safety and cleanliness requirements. Disconnect the battery. Raise and support the vehicle, front wheels hanging. Remove the front RH wheel, the plastic pins holding the splash-shield, the splash-shield itself. B1BP2V3D A: Pegging on the manual gearbox.
  • Page 173 CHECKING AND SETTING THE VALVE TIMING Engine: RFJ Peg the crankshaft, using tool [2]. Suspend the engine, using a workshop hoist. Remove the RH engine support, the upper timing cover. Peg the camshaft pulleys, using tool [1]. NOTE: The pegs [1] should go in without forcing. WARNING: If the pegs go in only with difficulty, repeat the operation for fitting and tensioning the B1BP2V3D timing belt (see corresponding operation).
  • Page 174 CHECKING AND SETTING THE VALVE TIMING Engine: RFJ Tools. [1] Camshaft setting peg : (-).0194.B [2] Crankshaft setting peg : (-).0189.R [3] Timing belt retaining pin : (-) 0189.K [4] Adaptor for angular tightening : 4069-T [5] Hub immobilising tool : (-).0189.S [5a] : (-).0189.S1...
  • Page 175 CHECKING AND SETTING THE VALVE TIMING Engine: RFJ Checking and setting the timing (continued). A: Pegging on the manual gearbox. B: Pegging on the automatic gearbox. Peg the crankshaft, using tool [2]. Remove the fixing bracket screw (4). Move aside the power steering pipes. Peg the camshaft pulleys (6) and (7), using tool [1].
  • Page 176 CHECKING AND SETTING THE VALVE TIMING Engine: RFJ Checking and setting the timing (continued). Refitting. Turn the tensioner roller (9), using tool [5a] to go past the notch «b». Position the tool [5b] to lock the index «a» and remove the tool [5a]. NOTE: Check the presence of the crankshaft pinion keyway (12) before positioning the timing belt.
  • Page 177 CHECKING AND SETTING THE VALVE TIMING Engine: RFJ Tensioning the timing belt. Refitting (continued). Turn the tensioner roller (9) anti-clockwise, using a hexagonal spanner at «c». Place the index «a» in position «e». IMPERATIVE: The index «a» should go past the slot «f» by an angular value of 10°. If it does not, replace the tensioner roller or the tensioner roller and timing belt assembly.
  • Page 178 CHECKING AND SETTING THE VALVE TIMING Engine: RFJ Tensioning the timing belt. Refitting (continued). Remove the tools [1] and [2]. Rotate the crankshaft ten times (normal direction of rotation). IMPERATIVE: No exterior pressure or action should be applied on the timing belt. Peg the inlet camshaft pulley, using tool [1].
  • Page 179 CHECKING THE VALVE TIMING Engine: RFN Tools. [1] Camshaft setting peg : (-).0189.A [2] Crankshaft setting peg : (-).0189.R IMPERATIVE: Respect the safety and cleanliness requirements. Checking the timing. Removing. Disconnect the battery negative terminal. Raise and support the vehicle, front wheels hanging. Remove the front RH wheel, the splash-shield and the upper timing cover.
  • Page 180 CHECKING THE VALVE TIMING Engine: RFN Checking the timing (continued). Suspend the engine, using a workshop hoist. Remove the engine support (2) and the timing cover (1). Peg the camshaft pulleys, using tool [1]. NOTE: The pegs [1] should go in without forcing. B1EP1GTC WARNING: If the pegs go in only with difficulty, repeat the operation for fitting and tensioning the timing belt (see corresponding operation).
  • Page 181 CHECKING AND SETTING THE VALVE TIMING Engine: RFN Tools. [1] Camshaft setting peg : (-).0189.A [2] Crankshaft setting peg : (-).0189.R [3] Timing belt retaining pin : (-) 0189.K [4] Adaptor for angular tightening : 4069-T [5] Hub immobilising tool : (-).0189.S [5a] : (-).0189.S1...
  • Page 182 CHECKING AND SETTING THE VALVE TIMING Engine: RFN Checking and setting the timing (continued). A: Pegging on the manual gearbox. B: Pegging on the automatic gearbox. Peg the crankshaft, using tool [2]. Remove the fixing bracket screw (4). Move aside the power steering pipes. Peg the camshaft pulleys (6) and (7), using tool [1].
  • Page 183 CHECKING AND SETTING THE VALVE TIMING Engine: RFN Checking and setting the timing (continued). Refitting. Turn the tensioner roller (9), using tool [5a] to go past the notch «b». Position the tool [5b] to lock the index «a» and remove the tool [5a]. Reposition the timing belt (10) on the crankshaft pinion (1).

  • Page 184: Checking And Setting The Valve Timing

    CHECKING AND SETTING THE VALVE TIMING Engine: RFN Tensioning the timing belt. Refitting (continued). Turn the tensioner roller (9) in the direction of the arrow «c», using a hexagonal spanner at «d». Place the index «a» in position «f» IMPERATIVE: 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 tensioner roller and timing belt assembly.
  • Page 185 CHECKING AND SETTING THE VALVE TIMING Engine: RFN Tensioning the timing belt. Refitting (continued). Remove the tools [1] and [2]. Rotate the crankshaft ten times (normal direction of rotation). IMPERATIVE: No exterior pressure or action should be applied on the timing belt. Peg the inlet camshaft pulley, using tool [1].
  • Page 186 CHECKING THE VALVE TIMING Engine: RFK Tools. [1] Camshaft setting peg : (-).0194.B [2] Crankshaft setting peg : (-).0189.R IMPERATIVE: Respect the safety and cleanliness requirements. Checking the timing. Removing. Disconnect the battery negative terminal. Raise and support the vehicle, front wheels hanging. Remove the front RH wheel and the splash-shield.
  • Page 187 CHECKING THE VALVE TIMING Engine: RFK Checking the timing (continued). Suspend the engine, using a workshop hoist. Remove: - The RH engine support. - The upper timing cover. Peg the camshaft pulleys, using tool [1]. NOTE: The pegs [1] should go in without forcing. WARNING: If the pegs go in only with difficulty, repeat the operation for fitting and tensioning the timing belt (see corresponding operation).
  • Page 188 CHECKING AND SETTING THE VALVE TIMING Engine: RFK Tools. [1] Camshaft setting peg : (-).0189.A [2] Crankshaft setting peg : (-).0189.R [3] Timing belt retaining pin : (-) 0189.K [4] Adaptor for angular tightening : 4069-T [5] Hub immobilising tool : (-).0189.S [5a] : (-).0189.S1...
  • Page 189 CHECKING AND SETTING THE VALVE TIMING Engine: RFK Checking and setting the timing (continued). Peg the crankshaft using tool [2]. Suspend the engine, using a workshop hoist. Remove: B1BP36YC - The upper RH engine support. - The upper timing cover (2). B1BP2V5D...
  • Page 190 CHECKING AND SETTING THE VALVE TIMING Engine: RFK Checking and setting the timing (continued). Peg the camshaft pulleys (6) and (7), using tool [1]. Remove: - The screw (4). - The crankshaft pulley (3). - The lower timing cover (5). IMPERATIVE: Never remove the crankshaft pulley (3), without pegging the crankshaft and the camshafts.
  • Page 191 CHECKING AND SETTING THE VALVE TIMING Engine: RFK Checking and setting the timing (continued). Refitting. Turn the tensioner roller (9), using tool [5a] to go past the notch «b». Position the tool [5b] to lock the index «a» and remove the tool [5a]. Reposition the timing belt (8) on the crankshaft pinion (3).
  • Page 192 CHECKING AND SETTING THE VALVE TIMING Engine: RFK Tensioning the timing belt. Turn the tensioner roller (9) anti-clockwise, using a hexagonal spanner at «c». Place the index «a» in position «e». IMPERATIVE: The index «a» should go past the slot «f» by an angular value of 10°. If it does not, replace the tensioner roller or the tensioner roller and timing belt assembly.
  • Page 193 CHECKING AND SETTING THE VALVE TIMING Engine: RFK Checking and setting the timing (continued). Refitting (continued). Remove the tools [1] and [2]. Refit the upper RH engine support. Remove the workshop hoist. Rotate the crankshaft ten times (normal direction of rotation). IMPERATIVE: No exterior pressure or action should be applied on the timing belt.
  • Page 194 CHECKING THE VALVE TIMING Engines: 9HX - 9HY - 9HZ Tools. [1] Flywheel setting peg : (-).0194.C [2] Camshaft setting peg : (-).0194.B [3] Crankshaft setting peg : (-).0194.A IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions.
  • Page 195 CHECKING THE VALVE TIMING Engines: 9HX - 9HY - 9HZ Turn the engine in the normal direction of rotation until the peg [1] engages in the setting hole. Peg the flywheel at «b», using tool [1]. Move aside the electrical harness (6). Remove: - The engine support (7).
  • Page 196 CHECKING THE VALVE TIMING Engines: 9HX - 9HY - 9HZ Checking the timing (continued). Peg the camshaft at «c», using tool [2] (oil the pegs). WARNING: The magnetic track should not show any sign of damage and should not be approached by any other magnetic source.
  • Page 197 CHECKING AND SETTING THE VALVE TIMING Engines: 9HX - 9HY - 9HZ Tools. [1] Flywheel setting peg : (-).0194.C [2] Camshaft setting peg : (-).0194.B [3] Crankshaft setting peg : (-).0194.A IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions.
  • Page 198 CHECKING AND SETTING THE VALVE TIMING Engines: 9HX - 9HY - 9HZ Checking and setting the timing (continued). Turn the engine in the normal direction of rotation until the peg [1] engages in the setting hole. Peg the flywheel at «b», using tool [1]. Move aside the electrical harness (6).
  • Page 199 CHECKING AND SETTING THE VALVE TIMING Engines: 9HX - 9HY - 9HZ Checking and setting the timing (continued). Peg the crankshaft at «e», using tool [3]. Remove: - The timing belt protector (13). - The engine speed sensor (14). Slacken the screw (12) of the tensioner roller, and keep it slackened using an allen spanner at «d». Detension the timing belt by pivoting the tensioner roller (clockwise).
  • Page 200 CHECKING AND SETTING THE VALVE TIMING Engines: 9HX - 9HY - 9HZ Checking and setting the timing (continued). Refitting. Fit the timing belt on the crankshaft pinion. Position the belt on the guide roller, belt well tensioned. Refit: - The timing belt protector (13). - The engine speed sensor (14).
  • Page 201 CHECKING AND SETTING THE VALVE TIMING Engines: 9HX - 9HY - 9HZ Adjusting the timing belt tension. Act on the tensioner roller (18) to align the marks «j» and «h», avoiding detensioning the timing belt, using an allen spanner at «d». Should this fail, repeat the operation to tension the timing belt.
  • Page 202 CHECKING AND SETTING THE VALVE TIMING Engines: 9HX - 9HY - 9HZ 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 to position the timing belt (see corresponding operation). Remove the tools [2] and [3].
  • Page 203 CHECKING THE VALVE TIMING Engine: RHR Tools. [1] Kit of plugs : (-).0188.T [2] Double flywheel setting peg : (-).0188.X Toolkit 0188-T [3] Camshaft setting peg : (-).0188.M IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions Remove the engine cover and the battery.
  • Page 204 CHECKING THE VALVE TIMING Engine: RHR Checks. Turn the crankshaft in the normal direction of rotation. Line up the black markings «b» and «c» on the chain with the teeth «a» and «d» of the camshaft drive pinions (40 turns of the camshafts maximum). IMPERATIVE: If it is impossible to line up the markings on the chain with the camshaft drive pinions, repeat the setting of the camshafts (see operation: removing-refitting camshafts).
  • Page 205 CHECKING AND SETTING THE VALVE TIMING Engine: RHR Tools. [1] Kit of plugs : (-).0188.T [2] Double flywheel setting peg : (-).0188.X [3] Camshaft setting peg : (-).0188.M [4] Belt clamp : (-).0188.AD [5] Pinion centrer : (-).0188.AH [6] Flywheel lock : (-).0188.F [7] Pulley : (-).0188.P...
  • Page 206 CHECKING AND SETTING THE VALVE TIMING Engine: RHR Uncouple, plug and move aside, using tool [7], the fuel delivery pipe (1) and the fuel return pipe (2). Suspend the engine, using a workshop hoist. Remove the bracket (3) and the RH engine support (4).
  • Page 207 CHECKING AND SETTING THE VALVE TIMING Engine: RHR Remove: - The screw (8). - The auxiliaries drive pulley (7). - The crankshaft position sensor (11). - The lower timing cover (9). - The target of the crankshaft position sensor (10), using tool [7]. - The lower torque reaction rod.
  • Page 208 CHECKING AND SETTING THE VALVE TIMING Engine: RHR Refitting. Centre the crankshaft pinion (15), using tool [5]. Reposition the timimg belt, belt at «a» well tensioned, in the following order: - Guide roller (14). - Crankshaft pinion (15). - Coolant pump pinion (16). - Tensioner roller (17).
  • Page 209 CHECKING AND SETTING THE VALVE TIMING Engine: RHR Refitting. Rotate the crankshaft ten times (in the direction of rotation of the engine). Peg the crankshaft, using tool [2] and the camshaft drive pinion, using tool [3]. Lock the flywheel, using tool [6]. Slacken the screw (8) of the auxiliaries drive pulley (7) and the screw (12) of the tensioner roller (17).
  • Page 210 CHECKING AND SETTING THE VALVE TIMING Engine: RHR Refitting. IMPERATIVE: If the position of the index «d» is not correct, restart the operations to tension the timing belt (for this, slightly slacken the screw (12) of the tensioner roller). Refit tool [6]. Remove the auxiliaries drive pulley (7).
  • Page 211 ADJUSTING THE CAMSHAFT POSITION SENSOR Engines: 9HX - 9HY - 9HZ NOTE: When removing a camshaft sensor, respect the airgap between the sensor and the target. Slacken the screw (14). Pusk back the camshaft position sensor (15) to the end of slots. Do up the screw (14) a few turns.
  • Page 212 CHECKING THE ENGINE COMPRESSION RATES Engines: 9HX - 9HY - 9HZ Tools. [1] Compression meter : MULLER 203102-100 [2] Dummy sparking plug : (-).0194.G Removing. IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions. Remove the engine cover and the battery.
  • Page 213 CHECKING THE ENGINE COMPRESSION RATES Engines: 9HX - 9HY - 9HZ Checks (continued). Remove tool [1] from tool [2]. Remove the tool [2] from cylinder N°1. Apply the same method to cylinders N°2, N°3 and N°4. NOTE: The difference between any two cylinders should not be greater than 5 Bars. Disconnect the battery.
  • Page 214 ADJUSTING THE CAMSHAFT POSITION SENSOR Engine: RHR Tools. [1] Setting peg for double flywheel : (-).0188.X Adjusting the camshaft position sensor. Peg the flywheel, using tool [1]. Sensor re-used. Position a drill bit Ø 8,5 mm, at «e» (between the inlet valve cover (2) and the camshaft position sensor (5)).
  • Page 215 CHECKING THE ENGINE COMPRESSION RATES Engine: RHR Tools. [1] Compression meter : MULLER 203102-100 [2] Dummy sparking plug : (-).0194.G Removing. IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions. WARNING: After switching off the ignition, wait 15 minutes before disconnecting the battery (to guarantee memorisation of the initialisations of the various ECUS).
  • Page 216 CHECKING THE ENGINE COMPRESSION RATES Engine: RHR NOTE: Use a mirror to carry out the operations described below. Remove the four nuts (5). Move aside the supply wires (6). Remove the preheater plugs (7). Fit the tool [2] on cylinder N°1, tighten to 1 m.daN. NOTE: Use a mirror “a”...
  • Page 217 TIGHTENING TORQUES - EXHAUST LINE Engine: KFU Catalytic converter fixing nuts Pre-tightening 2 ± 0,2 Tightening 4 ± 0,4 Checking the tightening 4 ± 0,4 Oxygen sensor 4,7 ± 0,7 Clip 2,5 ± 0,3 Clip 2,5 ± 0,3 Silencer 1,6 ± 0,2 Fixing nut on subframe 0,75 ±...
  • Page 218 TIGHTENING TORQUES - EXHAUST LINE Engine: NFU Exhaust manifold nuts 2,3 ± 0,4 Upstream oxygen sensor 4,7 ± 0,5 Nuts on front pipe / intermediate pipe 1 ± 0,2 Clips 2,5 ± 0,3 Screw on front pipe / clutch housing 3,5 ±...
  • Page 219 TIGHTENING TORQUES - EXHAUST LINE Engine: RFJ Clips 2,5 ± 0,3 Downstream oxygen sensor 4,7 ± 0,5 Upstream oxygen sensor 4,7 ± 0,5 Exhaust manifold nuts 3,5 ± 0,4 Heat shield nuts 1,2 ± 0,3 Additional fixings 1,5 ± 0,2 Flexible support nuts 1 ±...
  • Page 220 EXHAUST SPECIFICATIONS Engine: RFN B1JP065D Engine type Exhaust Upstream and Intermediate Catalytic converter manifold downstream oxygen exhaust pipe clips Rear silencer clip clip sensors Tightening torques (m.daN) 2,5 ± 0,2 (*) 4,7 ± 0,5 3,5 ± 0,5 3,5 ± 0,3 (**) (*) = Tightening on heat shield.
  • Page 221 EXHAUST SPECIFICATIONS Engine: RFK B1JP064D Engine type Exhaust manifold Upstream and downstream oxygen Clips sensors Tightening torques (m.daN) 2,5 ± 0,2 (*) 4,7 ± 0,5 2,5 ± 0,5 3,5 ± 0,3 (**) (*) = Tightening on heat shield. (**) = Tightening except on heat shield.
  • Page 222 EXHAUST SPECIFICATIONS Engine: 9HX «a» Clip (particle filter) «b» Flexible pipe «c» Silencer fixing strap B1JP076D Catalytic converter Clip Front Rear Rear silencer Particle filter Engine type intermediate intermediate pipe pipe (Version EURO 3) (Version EURO 4) (Version EURO 4) Tightening (m.daN) 2,5 ±...
  • Page 223 EXHAUST SPECIFICATIONS Engines: 9HY - 9HZ B1JP076D Catalytic converter Clip Front Rear Exhaust Particle filter Engine types intermediate intermediate silencer pipe pipe (Version EURO 3) (Version EURO 4) (Version EURO 4) Tightening (m.daN) 2,5 ± 0,3 9HY - 9HZ TR PSA K295 TR PSA K266 PSA 3051 TR PSA F007...
  • Page 224 EXHAUST SPECIFICATIONS Engine: RHR B1JP06KD Flexible pipe and Particle filter Tightening clip Rear silencer Engine type catalytic converter Tightening (m.daN) PSA K216 PSA F008 2,5 ± 0,3 PSA 3068...
  • Page 225 EXHAUST SPECIFICATIONS Engines: RFN - RFK - 9HX - 9HY - 9HZ - RHR Repair. Take all the precautions when working on a vehicle. The flexible pipe must not come into contact with corrosive products. Do not deform the flexible pipe more than 20°...
  • Page 226 COOLING SYSTEM SPECIFICATIONS Engines: KFU - NFU - RFJ - RFN - RFK 1.4i 16V 1.6i 16V 2.0i 2.0i 16V Engine type 6,6 (*) 6,2 (1) – 6,6 (2) Total capacity of the circuit (*) 6,8 (1) – 6,9 (2) Radiator surface (dm Pressurisation (Bars) Opening of thermostatic...
  • Page 227 COOLING SYSTEM SPECIFICATIONS Engines: 9HX - 9HY - 9HZ - RHR 1.6 16V HDi 2.0 16V HDi Engine plate Capacity Radiator surface (dm Pressurisation (Bars) Opening of thermostatic 83°C regulator 118°C Alert 105°C (for 6 minutes) 6 minutes Post cooling 1x130W 1x150W Cooling fan...
  • Page 228 COOLING SYSTEM SPECIFICATIONS Engine: KFU (1) Header tank (2) Coolant pump (3) Bleed screw of heater matrix (4) Heater matrix (5) Coolant outlet housing (6) Bleed screw of coolant outlet housing (7) Thermostat (8) Cooling radiator B1GP0BWP...
  • Page 229 COOLING SYSTEM SPECIFICATIONS Engine: NFU Manual gearbox (1) Header tank (2) Coolant pump (3) Bleed screw of heater matrix (4) Heater matrix (5) Coolant outlet housing (6) Bleed screw of coolant outlet housing (7) Calorstat (8) Cooling radiator B1GP0CBP...
  • Page 230 COOLING SYSTEM SPECIFICATIONS Engine: NFU Automatic gearbox (1) Header tank (2) Coolant pump (3) Bleed screw of heater matrix (4) Heater matrix (5) Coolant outlet housing (6) Bleed screw of coolant outlet housing (7) Calorstat (8) Cooling radiator (9) Heat exchanger (automatic gearbox) B1GP0CCP...
  • Page 231 COOLING SYSTEM SPECIFICATIONS Engine: RFJ (1) Heater matrix (2) Bleed screw (3) Cylinder block drain screw (4) Coolant outlet housing with piloted thermostatic regulator (5) Cooling radiator (6) Header tank (7) Coolant pump (8) Coolant/oil exchanger (engine) (9) Coolant/oil exchanger (automatic gearbox) B1GP0CAP...
  • Page 232 COOLING SYSTEM SPECIFICATIONS Engine: RFN (1) Header tank (2) Coolant pump (3) Heater matrix (4) Bleed screw of heater matrix (5) Cylinder block drain screw (6) Coolant outlet housing (7) Bleed screw of coolant outlet housing (8) Cooling radiator B1GP0BYP...
  • Page 233 COOLING SYSTEM SPECIFICATIONS Engine: RFK (1) Header tank (2) Coolant pump (3) Heater matrix (4) Bleed screw of heater matrix (5) Cylinder block drain screw (6) Coolant outlet housing (7) Bleed screw of coolant outlet housing (8) Cooling radiator (9) Coolant/oil exchanger B1GP0BUP...
  • Page 234 COOLING SYSTEM SPECIFICATIONS Engines: 9HX - 9HY - 9HZ (1) Cooling radiator (2) Header tank (3) Assembly with drain plug (all countries except very cold) (4) Bleed screw (5) Coolant outlet housing with thermostatic valve (according to equipment) (6) Exhaust gas recycling (EGR) heat exchanger B1GP0C9D...
  • Page 235 COOLING SYSTEM SPECIFICATIONS Engine: RHR (1) Header tank (2) Coolant inlet housing (3) Coolant / exhaust gas exchanger (4) Heater matrix (5) Bleed screw (6) Coolant outlet housing (7) Cooling radiator (8) Venting electrovalve (9) Coolant/oil heat exchanger B1GP0COP...
  • Page 236 OIL FILTERS Petrol engines MAHLE MAMELON MANN - HUMMEL MECAFILTER - MISFAT PURFLUX LS 923 Diesel engines MAHLE PURFLUX LS 923 Ø (mm) Height (mm) MAHLE MAMELON Specifications MANN - HUMMEL MECAFILTER - MISFAT PURFLUX...
  • Page 237 OIL PRESSURE CHECKS Petrol Diesel Engine type Temperature (°C) 90° 80° Pressure (Bars) 1000 Pressure (Bars) 2000 2000 2000 Pressure (Bars) 3000 3000 Pressure (Bars) 4000 4000 Tools (Toolkit 4103) 2279-T.Bis (-).0710.F1 (-).0710.B1 (-).1503.J 4103-T.B 7001-T 4202-T NOTE: The oil pressure must be checked with the engine cold, after checking the oil level. NOTE: The oil pressure warning lamp lights up at a threshold of 0.8 bar.
  • Page 238 VALVE CLEARANCE SETTINGS POSSIBLE PROCEDURES The valve clearances must be checked with the engine cold For engines with 4 cylinders in a line (1-3-4-2) Rocking Fully open (Exhaust) Inlet Exhaust Valves Adjust Rocking Adjust fully open Hydraulic adjustment Inlet 1 ± 0,05 mm 1 ±...
  • Page 239 FILLING AND BLEEDING THE COOLING CIRCUIT Engines: KFU - NFU - RFJ - RFN - RFK - RHR Tools. [1] Filling cylinder : 4520-T [2] Adaptor for filling cylinder : 4222-T [3] Control rod for filling cylinder : 4370-T IMPERATIVE: Respect the safety and cleanliness requirements. The draining and refilling operations can be carried out using coolant fluid replacement equipment.
  • Page 240 FILLING AND BLEEDING THE COOLING CIRCUIT Engines: KFU - NFU - RFJ - RFN - RFK - RHR Fit the filling cylinder [1] and adaptor [2] assembly on the filling orifice. Fill the cooling circuit. NOTE: Keep the filling cylinder full to the maximum. Start the engine.
  • Page 241 IDLING - DEPOLLUTION Idling speed % Content (± 50 rpm) Emission Vehicles Engine type Make - Injection type standard Manual Auto. gearbox: gearbox N gear engaged 1.4i 16V Euro 4 MAGNETTI - MARELLI 6LP 1.6i 16V Euro 4 BOSCH ME7.4.5 2.0i 16V IF Euro 4 <...

  • Page 242: Petrol Injection

    PETROL INJECTION 1.4i 16 V 1.6i 16 V 2.0i 16 V 2.0i 2.0i 16 V Engine type Euro 4 Euro 4 IF Euro 4 Euro 4 IF Euro 4 Emission standard MAGNETTI BOSCH ME7.4.5 MAGNETTI MAGNETTI MAGNETTI Make Injection type MARELLI 6LP MARELLI 6LP MARELLI 6LP...
  • Page 243 EMISSION STANDARDS STANDARD APPLICATIONS NOTES CHARACTERISTICS E.E.C. Engines Vehicles Applicable With 2 oxygen sensors and catalytic converter for Brussels Directive 98/69 petrol vehicles. Private vehicles: Petrol With catalytic converter All Types E.E.C. Diesel 01/2000 EURO 2 standard (L3) and EGR for diesel EURO 3 •...
  • Page 244 EMISSION STANDARDS STANDARD APPLICATIONS NOTES CHARACTERISTICS E.E.C. Engines Vehicles Applicable With 2 oxygen sensors Directives 2001/100B/CE: and catalytic converter Private vehicles: Petrol for petrol vehicles. All Types Diesel 01/2005 EURO 3 standard (L4) EURO 3 • new models made stricter 01/2006 With EOBD on-board •...
  • Page 245 EMISSION STANDARDS STANDARD APPLICATIONS NOTES CHARACTERISTICS E.E.C. Engines Vehicles Applicable With 2 oxygen sensors and catalytic converter Private vehicles: Directives 2001/100A/CE: for petrol vehicles. All Types 01/2005 IF/L5 Petrol • new models Fiscal incentives 01/2006 EURO 4 With EOBD on-board •...
  • Page 246 EMISSION STANDARDS STANDARD APPLICATIONS NOTES CHARACTERISTICS E.E.C. Engines Vehicles Applicable Utility vehicles: < 3.5 tonnes Directives 2001/100A/CE: With 2 oxygen sensors Class 1: and catalytic converter Fiscal incentives 01/2005 • new models for petrol vehicles. 3 classes depending on Petrol 01/2006 •...
  • Page 247 PROHIBITED OPERATIONS: BOSCH HDi DIRECT INJECTION SYSTEM Engines: 9HX - 9HY - 9HZ Cleaning. - The use of high pressure cleaners is prohibited. - Do not use compressed air. Fuel supply circuit. - Required fuel: diesel. Electrical 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 248 PROHIBITED OPERATIONS: BOSCH HDi DIRECT INJECTION SYSTEM Engines: 9HX - 9HY - 9HZ Fuel high pressure injection common rail. Do not separate the unions «c» from the injection common rail (2) (risk of malfunction). Diesel injectors. WARNING: Diesel and ultrasonic cleaners are prohibited. Do not separate the diesel injector carrier (3) from the following components: B1HP1TWC - Diesel injector (e) (no replacement parts).
  • Page 249 PROHIBITED OPERATIONS: BOSCH HDi DIRECT INJECTION SYSTEM Engines: 9HX - 9HY - 9HZ Identification: Injector carrier There are two types of diesel injector carrier classed according to fuel flow. Identification by engraving or paint mark Injector carrier Engraving Paint mark Location Class 1 Blue...
  • Page 250 PROHIBITED OPERATIONS: BOSCH HDi DIRECT INJECTION SYSTEM Engine: RHR Cleaning. - The use of high pressure cleaners is prohibited. - Do not use compressed air. Fuel supply circuit. - Required fuel: diesel. Electrical 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 251 PROHIBITED OPERATIONS: BOSCH HDi DIRECT INJECTION SYSTEM Engine: RHR Diesel injectors. WARNING: Diesel and ultrasonic cleaners are prohibited. Do not separate the diesel injector carrier (2) from the following components: - Diesel injector (f) (no replacement parts). - Electromagnetic component (c) (no replacement parts). Do not move the nut «d»...
  • Page 252 SAFETY REQUIREMENTS: HDi DIRECT INJECTION SYSTEM Engines: 9HX – 9HY – 9HZ – RHR 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.
  • Page 253 SAFETY REQUIREMENTS: HDi DIRECT INJECTION SYSTEM Engines: 9HX – 9HY – 9HZ – RHR 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.
  • Page 254 PARTICLE FILTER SAFETY AND CLEANLINESS REQUIREMENTS General. ESSENTIAL: Given the very high pressures prevailing in the fuel high pressure circuit (1600 Bars), respect the following regulations. - It is forbidden to smoke in the immediate proximity of the high pressure circuit during a repair. - Avoid working close to flames or sparks.
  • Page 255 PARTICLE FILTER SAFETY AND CLEANLINESS REQUIREMENTS Operations on the fuel additive circuit. IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves that are resistant to hydrocarbons. The work area must be ventilated. In the event of any significant dispersion of additive: - Wear a breathing mask for filtering the particles.
  • Page 256 SPECIAL FEATURES: FORCED REGENERATION OF THE PARTICLE FILTER Tools. Diagnostic stations : LEXIA or PROXIA. Imperative: Respect the safety and cleanliness requirements. Forced regeneration of the particle filter. IMPERATIVE: Respect the safety and cleanliness requirements specific to HDi engines. ESSENTIAL: Connect the vehicle to a gas extractor approved for this type of operation. In the absence of the required installations, carry out the forced regeneration of the particle filter outside the workshop, in a concreted area well away from any inflammable materials.
  • Page 257 SPECIAL FEATURES: ADDITIVE SYSTEM Filling the additive reservoir Imperative: Respect the safety and cleanliness requirements. Tools. Diagnostic stations : LEXIA or PROXIA Filling kit for 1 litre, comprising the following items: - 1 Container of Eolys - 2 Filters - 2 Tubes - 2 Hooks - 1 Adaptor B1HP20VC...
  • Page 258 SPECIAL FEATURES: ADDITIVE SYSTEM Filling the additive reservoir (continued) Open the tap located on the filler connector at «a». Tilt the additive container (3) (to facilitate the end of filling). Close the tap at «a». Remove: - The filler connector . - The tube (4).
  • Page 259 SPECIAL FEATURES: CHECKING THE ADDITIVE LEVEL IMPERATIVE: Respect the safety and cleanliness requirements. Preliminary operation. Place the vehicle on a 2-column lift. Raise and support the vehicle. Remove: - The heat shield from the additive reservoir. - The additive reservoir (see corresponding operation). Checks.
  • Page 260 SPECIAL FEATURES: ADDITIVE SYSTEM Checking the additive pump pressure and the sealing of the additive injector Tools. [1] Manual pressure/vacuum pump : FACOM DA 16 [2] Additive container : (-).1613.G Kit 1613 IMPERATIVE: Respect the safety and cleanliness requirements. Checks. IMPERATIVE: Respect the safety and cleanliness requirements specific to HDi engines.
  • Page 261 SPECIAL FEATURES: ADDITIVE SYSTEM Checking the additive pump pressure and the sealing of the additive injector Sealing of the additive injector. Couple tool [1] to the tube (1). Action the manual pump [1]. WARNING: The additive injector should open at a pressure of 100 ± 20 Bars. Action the manual pump in vacuum [1] at 800 m.bars.
  • Page 262 AIR SUPPLY CIRCUIT SPECIFICATION Engine: 9HX (1) Air filter assembly (2) Oil trap (3) Turbocharger resonance attenuator (4) Turbocharger (5) Air/air exchanger (6) Air metering device (7) Air distributor Air filter : MARK 4 Turbocharger : MHI TD025S2 B1HP22PD...
  • Page 263 AIR SUPPLY CIRCUIT SPECIFICATION Engines: 9HY - 9HZ (1) Air filter assembly (2) Oil trap (3) Turbocharger resonance attenuator (4) Turbocharger (5) Air/air exchanger (6) Double butterfly air metering device (EURO 4 version) (7) Air distributor Air filter : MARK 4 Turbocharger : GARRET GT 1544V B1HP22FD...
  • Page 264 CHECKING THE AIR SUPPLY CIRCUIT Engine: 9HX Tools. [1] Manual pressure-vacuum pump : FACOM DA 16 Checks. Vacuum pump. Connect the tool [1] onto the vacuum pump (1). Start the engine. The vacuum value should be 0.9 ± 0.1 bar at idle (after 30 seconds of operation). B1HP1UGC NOTE: The exhaust gas recycling valve is not linked to the air supply circuit.
  • Page 265 CHECKING THE AIR SUPPLY CIRCUIT Engines: 9HY - 9HZ Tools. [1] Manual pressure-vacuum pump : FACOM DA 16 Checks. Vacuum pump. Connect the tool [1] onto the vacuum pump (1). Start the engine. Wait 30 seconds. B1HP1UGC The vacuum value should be 0.9 ± 0.1 bar at idle. NOTE: The exhaust gas recycling valve is not linked to the air supply circuit.
  • Page 266 CHECKS: TURBO PRESSURE Engines: 9HX - 9HY - 9HZ IMPERATIVE: Respect the safety and cleanliness requirements. Preparation. IMPERATIVE: Respect the following test conditions: - Engine at operating temperature. - Vehicle in running order. - Engine under full load. Connect the diagnostic tool to the vehicle’s diagnostic socket, carry out parameter measures. Mode of operation.
  • Page 267 CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT Engines: 9HX - 9HY - 9HZ 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 268 CHECKING THE AIR SUPPLY CIRCUIT Engine: RHR Tools. [1] Manual pressure-vacuum pump : FACOM DA 16 IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines. WARNING: After switching off the ignition, wait 15 minutes before disconnecting the battery (to guarantee memorisation of the initialisations of the different ECUS).
  • Page 269 CHECKING THE AIR SUPPLY CIRCUIT Engine: RHR Checking the warm air opening. Remove: - The air duct (4). - The air duct (5). - The air duct (6). Connect the tool [1] on the warm air butterfly control diaphragm at «e». Apply a vacuum of 0,7 ±...
  • Page 270 CHECKS: TURBO PRESSURE Engine: RHR Tools. [1] Pressure gauge for checking the turbo pressure : 4073-T Toolkit 4073-T [2] Pressure take-off extension : 8607-T.A [3] Pressure take-off union and hose : 8607-T.B [4] Sleeve for checking the turbo pressure : 4185-T [5] Adaptor sleeve : 4219-T IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection...
  • Page 271 CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT Engine: RHR 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 272 SPECIFICATIONS OF THE DIESEL SYSTEM INJECTION PUMP BOSCH DIESEL SYSTEM equipment Engines Injection system High pressure pump Injectors BOSCH EDC 16C34 2.10 ATED4 BOSCH S71 DV63S BOSCH S74 BOSCH BOSCH S71 BOSCH S74 BOSCH CP1H TED4 BOSCH S80 DV6CS BOSCH EDC 16C34 2.10 SIEMENS DIESEL SYSTEM equipment BTED4 SIEMENS...
  • Page 273 SPARKING PLUGS Electrode gap Tightening Vehicles - Models Engine type BOSCH CHAMPION SAGEM setting (mm) torque (m.daN) 1.4i 16V VR8SE 2.25 ± 0.2 1.6i 16V 2.0i 16V RFN52HZ3A 0.9 ± 0.05 2.0i REC9MCLX 2.7 ± 0.2 2.0i 16V FR7ME...
  • Page 274 SPEEDOMETER An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled. This decree stipulates: - The speed indicated by a speedometer must never be lower than the actual vehicle speed. - Between the speed displayed «SD»...
  • Page 275 CLUTCH SPECIFICATIONS Petrol 1.4i 16V 1.6i 16V 2.0i 16V 2.0i 2.0i 16V Engine type Gearbox type MA5/L MA5/N BE4/5N BE4R/5S Supplier SACHS VALEO VALEO VALEO Mechanism / Type 200 MF 3850 200 CPX 3850 230 DNG 5100 230 DNG 5100 Clutch disc SAE 24/48-8Z 11 RX...
  • Page 276 CLUTCH SPECIFICATIONS Diesel 1.6 HDi 16V 2.0 HDi 16V Engine type 9HY* 9HZ* RHR** Gearbox type BE4/5L ML6C Supplier Mechanism / Type 235 P 4800 235 P 7400 Clutch disc Identification of the springs (White) Number of splines Ø of lining. Ext/Int 234/165 235/150 Quality of lining...

  • Page 277: Clutch Specifications

    CLUTCH SPECIFICATIONS Engines: KFU - NFU - RFN - RFJ - RFK - 9HX - 9HY - 9HZ - RHR NOTE: All the clutches are «push» type with hydraulic control. NOTE: The DV6TED4 and DW10BTED4 engines are equipped with a double damping flywheel (DVA). NOTE: All the clutches are «push»...
  • Page 278 CLUTCH SPECIFICATIONS Features. The LUK clutch discs have no damper hubs. The filtering of the noise generated by the gearbox is provided by the double damping flywheel (DVA) (*) and no longer by the clutch disc hub. The LUK clutch mechanism has an automatic compensation device, requiring special tooling when being refitted.
  • Page 279 GEARBOX AND TYRE SPECIFICATIONS Petrol 1.4i 16V 1.6i 16V 2.0i 16V Automatic Trim level Level 1 - Level 2 Level 1 - Level 4 Level 2 - Level 4 Level 2 - Level 4 Engine type 195/65 R15 1,934 m (*) 205/55 R16 205/55 R16 Tyres...
  • Page 280 GEARBOX AND TYRE SPECIFICATIONS Petrol 2.0i 2.0i 16V Automatic Trim level Level 3 – Level 4 Level 4 Engine type Tyres 205/50 R17 205/50 R17 Rolling circumference 1,941 m 1,941 m Gearbox type BE4/5T Gearbox ident. plate 20 TS 11 20 DM 68 Reduction box torque 21x73...
  • Page 281 GEARBOX AND TYRE SPECIFICATIONS Diesel 1.6 HDi 16V 2.0 HDi 16V Trim level Level 1 - Level 3 Level 2 - Level 4 Level 3 - Level 4 Engine type 195/65 R15 205/55 R16 205/55 R16 Tyres 1,934 m* 1,924 m 1,924 m Rolling circumference 205/55 R16...
  • Page 282 MA/5 GEARBOX Engines: KFU - NFU «a» Location for engraving of serial and gearbox nos «b» Identification label Features. This gearbox has no adjustment. Gearbox equipment: - Reverse gear braking device (5th gear synchroniser). - Device for prohibiting a change from 5th gear into reverse gear. - Hydraulic clutch control.
  • Page 283 MA/5 GEARBOX Engines: KFU - NFU Draining - Filling - Level. (1) Gearbox drain plug Oil quality. Refer to the manufacturer’s recommendations. Oil quantity. After draining: 2 ± 0,15 litres. Checking the oil level. No oil level checks *. Lubrication interval. Lubrication «for life».
  • Page 284 MA/5 GEARBOX Engines: KFU - NFU (1) Retaining clip (13) Speedometer screw (2) Secondary shaft (14) Counter drive (3) Drive pinion (5th gear) (15) Planet pinions (4) Bearing retaining clip screw (16) Satellite pinions (5) Gearbox casing (17) Differential gearwheel (6) Intermediate plate (18) Driven pinion (1st gear) (7) Gearbox casing fixing screw...
  • Page 285 TIGHTENING TORQUES: MA/5 GEARBOX Engines: KFU - NFU Tightening torques (m.daN). (1) Gearbox fixings on engine : 4,5 ± 0,5 (2) Reverse gear switch : 2,5 ± 0,2 (3) Drain plug : 3,3 ± 0,3 (4) 5th gear housing fixing : 2,2 ±...
  • Page 286 TIGHTENING TORQUES: MA/5 GEARBOX Engines: KFU - NFU Tightening torques (m.daN). (6) Clutch bearing guide screw : 1 ± 0,1 (7) Bearing retaining clip screw : 1,8 ± 0,2 Intermediate plate fixing : 5 ± 0,5 Hydraulic clutch slave cylinder fixing : 3 ±...
  • Page 287 TIGHTENING TORQUES: MA/5 GEARBOX Engines: KFU - NFU Tightening torques (m.daN). (8) Gearbox support shaft nut : 6,5 ± 0,6 (9) Screws fixing gearbox support on body : 1,9 ± 0,1 (10) Gearbox support plate nut : 2,5 ± 0,2 (11) Nut fixing gearbox support on body : 1,9 ±...
  • Page 288 MA/5 GEARBOX CONTROLS Engines: KFU - NFU Gear controls The gear selection and engagement cables have no adjustment. NOTE: The two cables cannot be separated. (1) Gear engagement ball-joint : Ø 10 mm (2) Gear engagement control cable (3) Gear control lever (4) Gear selection control cable (5) Gear selection ball-joint : Ø...
  • Page 289 MA/5 GEARBOX CONTROLS Engines: KFU - NFU Gear selection and engagement control cables Length A (mm) Gear engagement control cable 791,2 ± 2 Length B (mm) Gear selection control cable 791,2 ± 2 B2CP3ZDD NOTE: The gear engagement cable has a black colour identification on the sleeve stop at «a».
  • Page 290 MA/5 GEARBOX CONTROLS Engines: KFU - NFU Unlocking a sleeve stop. Press on the tabs of the clip (6) at «b», using a small flat screwdriver. Disengage the sleeve stops from their supports by pulling upwards. B2CP3ZFD...
  • Page 291 BE4/5 GEARBOX Engines: RFN - RFK - 9HX - 9HY - 9HZ B2CP3BNC B2CP3BPD (a) Engraving zone (serial nos.) (b) Location of the identification label...
  • Page 292 BE4/5 GEARBOX Engines: RFN - RFK - 9HX - 9HY - 9HZ Draining - Filling - Level. (1) Drain plug (2) Filling and level plug (3) Air vent NOTE: The air vent hole can be used for filling. Oil quality. Refer to the manufacturer’s recommendations.
  • Page 293 BE4/5 GEARBOX Engines: RFN - RFK - 9HX - 9HY - 9HZ (1) Primary shaft (2) Clutch bearing guide (3) Gearbox casing (4) Clutch housing (5) Reverse idle (6) Drive gear (3rd gear) (7) 3rd/4th gear synchroniser (8) Drive gear (4th gear) (9) Drive gear (5th gear) (10) 5th gear synchroniser (11) Driven gear (5th gear)
  • Page 294 TIGHTENING TORQUES: BE4/5 GEARBOX Engines: RFN - RFK - 9HX - 9HY - 9HZ Tightening torques (m.daN). (1) Air vent hole : 1,5 ± 0,2 (2) Reverse gear rocker switch shaft fixing nut : 4,5 ± 0,2 (3) Differential housing fixing nut : 1,5 ±...
  • Page 295 TIGHTENING TORQUES: BE4/5 GEARBOX Engines: RFN - RFK - 9HX - 9HY - 9HZ Tightening torques (m.daN). (12) Fork shaft stop screw : 1,5 ± 0,2 (13) Differential gearwheel fixing screw : 6 ± 0,5 (14) Bearing stop screw : 1,5 ± 0,2 (15) Secondary shaft nut : 6,5 ±...
  • Page 296 TIGHTENING TORQUES: BE4/5 GEARBOX Engines: RFN - RFK - 9HX - 9HY - 9HZ Tightening torques (m.daN). (18) Stop guide screw : 1,25 ± 0,2 (19) Speedometer fixing screw : 1,5 ± 0,2 (20) Gearbox support shaft nut : 6,5 ± 0,6 (21) Nuts fixing rubber support : 3 ±...
  • Page 297 BE4/5 GEARBOX CONTROLS Engines: NFU - RFN - RFK - 9HX - 9HY - 9HZ Gear controls. (1) Gear engagement ball-joint : Ø 10 mm (2) Gear engagement control cable (3) Gear control lever (4) Gear selection control cable (5) Gear selection ball-joint : Ø...
  • Page 298 BE4/5 GEARBOX CONTROLS Engines: NFU - RFN - RFK - 9HX - 9HY - 9HZ Length A (mm) Gear engagement control cable 643 ± 2 Length B (mm) Gear selection control cable 670 ± 2 NOTE: The gear engagement cable has a black colour identification on the sleeve stop at «a».
  • Page 299 BE4/5 GEARBOX CONTROLS Engines: NFU - RFN - RFK - 9HX - 9HY - 9HZ Features. Unlocking a sleeve stop: - Press on the tabs of the clip (6) at «b», using a flat screwdriver. - Disengage the sleeve stops from their supports by pulling upwards. B2CP3Z3D...
  • Page 300 ML6 GEARBOX Engine: RHR Features. Differential. - The differential has 4 satellites. - The adjustment of the meshing clearance between the planet and satellite pinions is by means of friction washers of different thicknesses: 1,66 mm 1,73 mm - 1,80 mm - 1,87 mm. Primary shaft.
  • Page 301 ML6 GEARBOX Engine: RHR Draining - Filling - Level. «c» Filling the gearbox with oil through the air vent hole Oil quantity (after draining). Minimum: 2,4 litres. Maximum: 2,7 litres. Oil quantity (after a repair in the gearbox). Minimum: 2,6 litres. Maximum: 2,9 litres.
  • Page 302 ML6 GEARBOX Engine: RHR (1) Shim for adjusting the play of the primary (16) Differential housing shat bearings (17) Planet adjustment shim (2) Drive pinion (6th gear) (18) Planet pinions (3) 5th/6th gear synchronisation (19) Satellite shaft (4) Drive pinion (5th gear) (20) Differential bearing stop plate (5) Gearbox housing (21) Reverse gear driven pinion...
  • Page 303 TIGHTENING TORQUES: ML6 GEARBOX Engine: RHR Tightening torques (m.daN). (1) Primary shaft screw : 10 ± 1 (2) Bearing guide screw : 2 ± 0,2 (3) Differential gearwheel screw : 7,7 ± 0,3 (4) Secondary shaft screw : 13 ± 1,3 B2CP3ZLD...
  • Page 304 TIGHTENING TORQUES: ML6 GEARBOX Engine: RHR Tightening torques (m.daN). (5) Reverse gear switch : 2,5 ± 0,5 (6) Level plug : 3 ± 0,2 (7) Drain plug : 3 ± 0,3 (8) Differential bearing stop plate screw : 3 ± 0,3 (9) Screw fixing gearbox housing/clutch housing : 3 ±...
  • Page 305 TIGHTENING TORQUES: ML6 GEARBOX Engine: RHR Tightening torques (m.daN). (13) Screws/nuts fixing the gearbox support : 4,5 ± 0,4 (14) Screw fixing the rubber bush : 3 ± 0,3 (15) Nut fixing the gearbox casing : 6,5 ± 0,6 B2CP3ZNC...
  • Page 306 ML6 GEARBOX CONTROLS Engine: RHR Gear controls. (1) Gear engagement ball-joint : Ø 10 mm (2) Gear selection ball-joint : Ø 10 mm (3) Gear engagement control cable (4) Gear control lever (5) Gear selection control cable (6) Reverse gear unlocking cable (7) O-ring seal (8) Reverse gear unlocking device B2CP3ZPD...
  • Page 307 ML6 GEARBOX CONTROLS Engine: RHR Adjustment of the gear selection control cable Adjustment NO Length A (mm) Gear engagement control cable 723 ± 2 Adjustment YES at «b» Length B (mm) Gear selection control cable 674 ± 2 NOTE: In order to differentiate the two gear control cables when they have been removed, the gear engagement cable has a black colour identification on the sleeve stop at «a».
  • Page 308 ML/6 GEARBOX CONTROLS Engine: RHR Adjustment of the gear selection control cable Peform the following operations simultaneously: - Move the cylinder «f» in the direction of the arrow «e». - Pull the locking key «c» in the direction of the arrow «d». Check that the gear lever (18) is in the mid position on the control housing (17).
  • Page 309 AL4 AUTOMATIC GEARBOX Engines: NFU - RFJ WARNING: This gearbox uses a special CITROEN semi-synthetic oil, which cannot be mixed with any other oil. The gearbox is lubricated for life. Total oil capacity : 5,85 Litres. Capacity after draining : 3 Litres.
  • Page 310 RECOMMENDATIONS - PRECAUTIONS (AL4 AUTOMATIC GEARBOX) Engines: NFU - RFJ PRECAUTIONS TO BE TAKEN Towing. Removing - Refitting (automatic gearbox). The front of the vehicle must be raised in order to be towed. If the front of the vehicle cannot be raised. WARNING: Never place the gearbox on its lower casing (risk of deformation of the tray and damage to the hydraulic block).
  • Page 311 RECOMMENDATIONS - PRECAUTIONS (AL4 AUTOMATIC GEARBOX) Engines: NFU - RFJ Draining - Filling. Tooling recommended. [1] Filling cylinder : (-).0341 Draining. IMPERATIVE: The gearbox should be drained when the oil is warm (at least 60°C), to eliminate the impurities in suspension in the oil. NOTE: Draining is partial, the converter cannot be completely emptied.
  • Page 312 RECOMMENDATIONS - PRECAUTIONS (AL4 AUTOMATIC GEARBOX) Engines: NFU - RFJ Checking the oil level (prior conditions). - Vehicle in horizontal position. - Check gearbox is not in back-up mode. - Remove the oil filler cap (3). - Add 0,5 litres extra oil into the gearbox. - Foot on the brake, change through all the gears.
  • Page 313 RECOMMENDATIONS - PRECAUTIONS (AL4 AUTOMATIC GEARBOX) Engines: NFU - RFJ PROCEDURE BEFORE A REPAIR Reading of fault codes. When the ECU detects a value that is incorrect or absent on one of its inputs or outputs: Carry out a reading of the fault codes. - Absence of fault codes.
  • Page 314 RECOMMENDATIONS - PRECAUTIONS (AL4 AUTOMATIC GEARBOX) Engines: NFU - RFJ ECU: Initialisation Updating the gearbox ECU by downloading. - Follow the procedure using the diagnostic tool. The downloading operation enables the automatic gearbox to be updated, or adapted to an evolution of the engine ECU. Before commencing the downloading, take the value of the oil usage counter present in the automatic gearbox ECU.
  • Page 315 TIGHTENING TORQUES: AUTOMATIQUE AL4 Engines: NFU - RFJ Tightening torques (m.daN). (1) Oil flow modulation electrovalve fixing in the exchanger (EPDE) : 1 ± 0,2 (2) Heat exchanger fixing : 5 ± 1 (3) Output speed sensor fixing : 1 ± 0,2 B2CP3EDD (4) Input speed sensor fixing : 1 ±...
  • Page 316 AL4 AUTOMATIC GEARBOX Engines: NFU - RFJ Tightening torques (m.daN). (8) Fixing of converter on diaphragm - Pre-tightening : 1 ± 0,1 - Tightening : 3 ± 0,3 (9) Plug fixing : 0,8 ± 0,2 (10) Gearbox fixing on engine : 5,2 ±...
  • Page 317 AL4 AUTOMATIC GEARBOX Engines: NFU - RFJ (13) Fixing of selector lever position switch : 1,5 ± 0,2 (14) Oil filler plug : 2,4 ± 0,4 B2CP3EGC...
  • Page 318 RECOMMANDATIONS - PRECAUTIONS ( AL4 AUTOMATIC GEARBOX ) Engines: NFU - RFJ 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.
  • Page 319 AL4 AUTOMATIC GEARBOX CONTROLS Engines: NFU - RFJ B2CP3H7D...
  • Page 320 AL4 AUTOMATIC GEARBOX CONTROLS Engines: NFU - RFJ The gear selection lever is guided by the shape of the step grille and by a recall spring which holds it to the left. The gear control has 5 positions: - «P» Parking (locking and immobilisation of the vehicle).w - «R»...
  • Page 321 AL4 AUTOMATIC GEARBOX CONTROLS Engines: NFU - RFJ Gearbox end. The automatic gearbox is controlled by a cable. «c» Push-button (1) Control lever with ball-joint (2) Automatic adjustment - Pull out the button to adjust the control. - Push it in to lock the adjustment of the control. (3) Sleeve stop (4) Selection control locking clip (5) on the sleeve stop (3) B2CP3H8C...
  • Page 322 DRIVESHAFT SPECIFICATIONS Engines: KFU – NFU – RFN – RFJ – RFK – 9HX – 9HY– 9HZ – RHR NOTE: The wheel hubs have a bearing with an integral magnetic wheel designed for the ABS system. Features. The driveshafts no longer have crownwheels for the ABS system. This function is assured by the wheel bearings.
  • Page 323 DRIVESHAFT SPECIFICATIONS Gearbox Identification Type Diameter of differential Wheel end Gearbox end 1.4i 16V MA/5L AC 2000i GI 2000i MA/5N 1.6i 16V 2.0i 16V BE4/5N - BE4R/5S 2.0i RZ17,5 JB2A 2.0i 16V BE4/5L BE4/5L 1.6 Hdi 16V 9HY - 9HZ BE4/5L 2.0 HDi 16V ML6C...
  • Page 324 DRIVESHAFT - GEARBOX Tightening torques (m.daN) Gearbox oil seal mandrels Driveshaft RH side LH side Tool kit Vehicle Engines Gearbox Driveshaft nut bearing KFU - NFU MA/5 7116-T 7114-T.W 7114-T.X RFN - RFK BE4/5 7116-T 7114-T.W 7114-T.X 9HX - 9HY - 9HZ 2 ±...
  • Page 325 WHEEL AND TYRES (1) = Normal operating pressure Petrol 3-door (max. 4 persons in the vehicle 1.4i 16V 2.0i 16V and 40 Kg in the boot). Level 1 - Level 2 Level 2 - Level 4 Level 4 Engine type Tyre 195/65 R15 91H - 1,934 m 205/55 R16 90V - 1,924 m...
  • Page 326 WHEEL AND TYRES (1) = Normal operating pressure Petrol 3-door (max. 4 persons in the vehicle 1.6i 16V - Manual and Auto. and 40 Kg in the boot). Level 1 - Level 4 Engine type Tyre 195/65 R15 91H - 1,934 m 205/55 R16 90V - 1,924 m 205/50 R17 89W - 1,941 m Circumference...
  • Page 327 WHEEL AND TYRES (1) = Normal operating pressure Diesel 3-door (max. 4 persons in the vehicle 1.6 HDi 16V and 40 Kg in the boot). Level 1 - Level 3 Engine type Tyre 205/55 R16 90V 205/50 R17 89W 205/50 R17 89W 205/55 R16 90V - 1,924 m Circumference 1,924 m...
  • Page 328 WHEEL AND TYRES (1) = Normal operating pressure Diesel 3-door (max. 4 persons in the vehicle 1.6 HDi 16V 2.0 HDi 16V and 40 Kg in the boot). Level 1 - Level 3 Level 3 - Level 4 Engine type Tyre 195/65 R15 91H 205/55 R16 90V...
  • Page 329 WHEEL AND TYRES (1) = Normal operating pressure Petrol 5-door (max. 4 persons in the vehicle 1.4i 16V 2.0i 16V 2.0i and 40 Kg in the boot). Level 1 - Level 2 Level 2 - Level 4 Level 3 - Level 4 Engine type Tyre 195/65 R15 91H - 1,934 m...
  • Page 330 WHEEL AND TYRES (1) = Normal operating pressure Petrol 5-door (max. 4 persons in the vehicle 1.6i 16V - BVM/BVA and 40 Kg in the boot). Level 1 - Level 4 / Level 2 - Level 4 Engine type Tyre 195/65 R15 91H - 1,934 m 205/55 R16 90V - 1,924 m 205/50 R17 89W - 1,941 m...
  • Page 331 WHEEL AND TYRES (1) = Normal operating pressure Diesel 5-door (max. 4 persons in the vehicle 1.6 HDi 16V and 40 Kg in the boot). Level 2 - Level 4 Engine type Tyre 205/50 R17 89W 205/55 R16 90V - 1,924 m 205/55 R16 90V - 1,924 m Circumference 1,941 m...
  • Page 332 WHEEL AND TYRES (1) = Normal operating pressure Diesel 5-door (max. 4 persons in the vehicle 1.6 HDi 16V and 40 Kg in the boot). Level 1 - Level 3 Engine type Tyre 195/65 R15 91H – 1,934 m 205/55 R16 90V – 1,924 m 205/50 R17 89W –...
  • Page 333 WHEEL AND TYRES (1) = Normal operating pressure Diesel 5-door (max. 4 persons in the vehicle 2.0 HDi 16V and 40 Kg in the boot). Level 3 - Level 4 Engine type Tyre 205/55 R16 90V - 1,924 m 205/50 R17 89W - 1,941 m Circumference Wheel 6 1/2J16 CH4-26...
  • Page 334 WHEEL AND TYRES Inflation pressures Normal operating pressure Pressure under load «Max.» Pressure (Bars) Tyre dimension Engine version Front Rear Spare wheel Front Rear Spare wheel 195/65 R15 91H KFU - NFU - 9HX NFU - RFN - 9HX 205/55 R16 90C 9HY - 9HZ - RHR NFU - RFN - RFJ 205/50 R17 89W...
  • Page 335 WHEEL AND TYRES Identification of inflation pressures NOTE: The label indicating the recommended tyre pressures is affixed, driver’s side, on the vehicle front pillar or on the front door edge. «a» Recommended tyre inflation pressures (empty and under load) «b» Tyre specifications «c»...
  • Page 336 WHEEL AND TYRES Identification of the wheel bolts : Wheel bolt (all rim types) : Light alloy wheel : Steel aluminium wheel Tightening torque for wheel bolts. 9 ± 1 m.daN. B2GP00JD...
  • Page 337 WHEEL AND TYRES Deflation detection system (according to trim level) (4) Valve (8) Seal (5) Antenna (9) Cap (6) HF transmitter unit (10) Nut (7) Washer Composition. A SIEMENS HF transmitter module (6) integral to each wheel in the place of the valve, each including a lithium battery.

  • Page 338: Axle Geometry

    AXLE GEOMETRY Conditions for checking and adjusting Tools : [1] Gauge for measuring the the wheel radius, 4 bolts : 4300-T. Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point (see corresponding operation). Vehicle heights at reference height E1AP0F3D Front height Rear height...
  • Page 339 AXLE GEOMETRY B3CP097D Measuring front height Measuring rear height Tools : [1] Gauge for measuring the the wheel radius, 4 bolts : 4300-T Z1 = Measuring zone underneath the front subframe Z2 = Measuring zone underneath the rear sill. Measure the radius of the front wheel R1/Calculate dimension H1 = R1 – L1 Measure the radius of the rear wheel R2/Calculate dimension H2 = R2 + L2 Value at reference All types Value at reference...
  • Page 340 AXLE GEOMETRY Front axle Dissymmetry of lower castor at 0° 30’. Dissymmetry of lower camber 0° 30’. Distribute symmetrically, LH / RH wheel, the total tracking value. KFU - NFU RFJ - RFN RFJ - RFN - RFK Engines 9HX - 9HY - 9HZ 9HX - 9HY - 9HZ 9HX - 9HY - 9HZ - RHR Tyres...
  • Page 341 AXLE GEOMETRY Rear axle Dissymmetry of lower camber 0° 30’. KFU - NFU RFJ - RFN - RHR RFJ - RFN - RFK Engines 9HX - 9HY - 9HZ 9HX - 9HY - 9HZ 9HX - 9HY - 9HZ - RHR Tyres 195/65 R 15 205/55 R 16...
  • Page 342 GENERAL SPECIFICATIONS: FRONT AXLE Subframe (1) Subframe extensions (2) Subframe Subframe extensions lodged on two pins Subframe machine-welded and painted. «a», subframe end. Subframe extensions screwed on the Subframe positioned by indexing lower crossmember and body at the front on the body. Pivot Pivot of «pinched»...
  • Page 343 TIGHTENING TORQUES: FRONT AXLE Tightening torques (m.daN). (1) Nut fixing suspension leg on body : 6,9 ± 0,6 (2) Nut fixing upper damper cup : 6,9 ± 0,6 (3) Upper fixing of anti-roll bar rod : 3,6 ± 0,3 (4) Lower fixing of anti-roll bar rod : 3,6 ±...
  • Page 344 TIGHTENING TORQUES: FRONT AXLE Tightening torques (m.daN). (10) Fixing of subframe extension on body : 5,1 ± 1,2 (11) Fixing of tie-rod on body : 1,8 ± 0,4 (12) Tie-rod screw on front subframe : 9,8 ± 0,9 (13) Fixing of anti-roll bar bearing on subframe : 10,4 ±...
  • Page 345 GENERAL SPECIFICATIONS: REAR AXLE Subframe (1) Rear axle crossmember (2) Yoke fixing rear axle crossmember on body Rear axle machine-welded, of trailing arm type with rear axle deformable. Stub axle (3) Stub axle Stub axle connected on the rear axle, fixed by 4 screws (4). Diameter of stub axle: 25 mm.
  • Page 346 TIGHTENING TORQUES: REAR AXLE Tightening torques (m.daN). (1) Damper upper fixing : 5,8 ± 0,5 (2) Fixing of yoke on rear axle : 7,6 ± 0,7 (3) Fixing of rear axle yoke on body : 6,2 ± 0,6 (4) Stub axle bearing nut Pre-tightening : 9 ±...
  • Page 347 GENERAL SPECIFICATIONS: SUSPENSION Suspension leg angle Front axle Position the bosses «a» of the damper support in the slots «b» in the wheelarch. Anti-roll bars Engines Diameter (mm) Colour KFU NFU RFJ RFN 21,5 Pink 9HX 9HY 9HZ RFK RHR White Rear axle The anti-roll bar is inside the rear axle crossmember.
  • Page 348 GENERAL SPECIFICATIONS: SUSPENSION Front suspension spring Colour reference at «f». Supplier: ARA : Blue. Supplier: KRUPP : Violet. Colour reference at «e»-«c», «d». Depending on vehicle trim levels (see corresponding operations). B3BP19SC Rear suspension spring (1) Suspension spring (2) Upper cup in elastomer (3) Lower cup in elastomer «g»...
  • Page 349 TIGHTENING TORQUES: SUSPENSION Suspension leg Tightening torques (m.daN). (1) Nut fixing suspension leg on body : 6,9 ± 0,6 (2) Nut fixing upper damper cup : 6,9 ± 0,6 (3) Upper fixing of anti-roll bar rod : 3,6 ± 0,3 (4) Lower fixing of anti-roll bar rod : 3,6 ±...
  • Page 350 TIGHTENING TORQUES: SUSPENSION Subframe Tightening torques (m.daN). (10) Fixing of subframe extension on body : 5,1 ± 1,2 (11) Fixing of tie-rod on body : 1,8 ± 0,4 (12) Tie-rod screw on front subframe : 9,8 ± 0,9 (13) Fixing of anti-roll bar bearing on subframe : 10,4 ±...
  • Page 351 TIGHTENING TORQUES: SUSPENSION Tightening torques (m.daN). (1) Damper upper fixing : 5,8 ± 0,5 (2) Fixing of yoke on rear axle : 7,6 ± 0,7 (3) Fixing of rear axle yoke on body : 6,2 ± 0,6 (4) Stub axle bearing nut Pre-tightening : 9 ±...
  • Page 352 GENERAL SPECIFICATIONS: POWER-ASSISTED STEERING STEERING Reference Description Driver’s airbag Controls on the steering wheel Fixed central controls steering wheel Steering wheel angle sensor Controls on the steering wheel Ignition / steering lock C5FP0QQD...
  • Page 353 GENERAL SPECIFICATIONS: POWER-ASSISTED STEERING Fixed central controls steering wheel [1] Tool for locking the fixed central controls steering wheel : 9702-T WARNING: The mechanism of the fixed central controls steering wheel cannot be dismantled. C5FP0QRC...
  • Page 354 GENERAL SPECIFICATIONS: POWER-ASSISTED STEERING Steering column Reference Description Fixing of the fixed central controls steering wheel on the steering column shaft Steering column interface Locking handle Fixing of the steering cardan on the distributor valve stem Steering column support The steering column is in aluminium. The adjustment of the steering column for height and reach is by means of the handle (9).
  • Page 355 GENERAL SPECIFICATIONS: POWER-ASSISTED STEERING Steering mechanism - Steering mechanism with integral ram, fixed on the subframe by means of two studs. - The distributor valve has groove technology. - The hydraulic supply and return pipes are fixed on the distributor valve by a flange. - The adjustment of the steering push-rod is via a screw plug «a», in plastic material.
  • Page 356 GENERAL SPECIFICATIONS: POWER-ASSISTED STEERING Steering assistance circuit The degree of steering assistance varies as a function of the following parameters: - The speed of the vehicle. - The speed of rotation of the steering wheel. Power steering oil : TOTAL FLUIDE LDS H 50126. Quantity of oil in the power steering circuit : 0,85 Litre.
  • Page 357 TIGHTENING TORQUES: POWER-ASSISTED STEERING Steering column Ref. Description Tightening Fixed central controls steering wheel screw 2,2 ± 0,2 Steering column interface nuts 2,2 ± 0,2 Upper nuts Lower nuts Fixing of steering cardan on valve stem B3EP176D Steering mechanism with integral ram Ref.
  • Page 358 TIGHTENING TORQUES: POWER-ASSISTED STEERING Steering assistance electrovalve Ref. Description Tightening Fixing of electrovalve on chassis member 2,3 ± 0,2 Screw fixing bracket on electrovalve 2 ± 0,2 Fixing of electrovalve on chassis member 2,2 ± 0,2 B3EP178D...
  • Page 359 SPECIAL FEATURES: STEERING Engines: KFU - NFU - RFN - RFJ - RFK - 9HX - 9HY - 9HZ - RHR Setting the steering rack mid-point Preliminary operation. Raise and support the vehicle on a two-column lift. Remove (on RH side): - The clip (1).
  • Page 360 CHECKING THE POWER STEERING ASSISTANCE PRESSURE Tools. [1] Pressure gauge : (-).0710.AZ [2] Checking tube: pressure gauge to tap : (-).0710.B1 [3] Checking tube: high pressure pipe to tap : (-).0710.B2 [4] Checking tube: high pressure pump to tap : (-).0710.B3 [5] 3-way tap : (-).0710.C [6] Union...
  • Page 361 CHECKING THE POWER STEERING ASSISTANCE PRESSURE Preliminary operations. Move aside the high pressure pipe (1). Do up: - The union [6] on the power steering electropump. - The union [7] on the high pressure pipe (1). - Tighten all the unions. - Fill the power steering reservoir 10 mm above the max.
  • Page 362 CHECKING THE POWER STEERING ASSISTANCE PRESSURE Checking the valve sealing. Remove the under-engine shield. Move aside the heat shield from the steering mechanism. Slacken the unions (2) on the power steering ram. Uncouple the two supply pipes (3) from the distributor valve, and move them aside. Fit on the distributor valve the two plugs [8], tighten to 0,8 m.daN.
  • Page 363 CHECKING THE POWER STEERING ASSISTANCE PRESSURE Fill the power steering reservoir to the max. mark «a» on the cap (4). Engine stopped, move the steering slowly from lock to lock, in both directions approx. ten times. Top up the fluid to the max. mark «a» on the cap (4). Run the engine at idle for 3 minutes, without any action on the steering wheel.
  • Page 364 BRAKE SPECIFICATIONS With ABS 1.4i 16V 1.6i 16V 1.6 16V HDi 1.6i 16V Manual Auto. Engine type Master cylinder 22,2 (in valve) (1) Amplifier 22,86/BOSCH/EVA2 (2) 25,4/ BOSCH/MCT8 (2) Ø mm Supplier /pistons BOSCH/ZOH 54/22 BOSCH/ZOH 54/26 Disc Ventilated Disc thickness/ min. 22/20 26/24 Brake pad grade...
  • Page 365 BRAKE SPECIFICATIONS With ESP 1.4i 16V 1.6i 16V 2.0i 2.0i 16V 1.6HDi 16V 2.0HDi 16V Manual - Auto. Engine type Master cylinder 23,8 (in click) (1) Amplifier 25,4/ BOSCH/MCT8 (2) Ø TEVES/F TEVES/F Supplier/pistons BOSCH/ZOH 54/26 BOSCH/ZOH 54/26 N3 57/26 N3 57/26 Disc Ventilated...
  • Page 366 BRAKE SPECIFICATIONS Braking system. Braking circuit in the form of an X. Disc brakes at the front and at the rear (vehicles all types): - The front brake discs are ventilated. - The rear brake discs are plain. NOTE: The front brake pads have no wear warning lamp.
  • Page 367 BRAKE SPECIFICATIONS ABS/ESP hydraulic block Components Supplier Type Observations ABS REF 8.0 Installed under the front LH chassis Hydraulic block BOSCH ESP 8.0 member. 4 regulation channels. B3FP7E3C The emergency braking control is incorporated in the primary piston at «a». B3FP7E2D...
  • Page 368 TIGHTENING TORQUES: BRAKING SYSTEM Front brakes Front brake disc 1 ± 0,1 Yoke on caliper 3 ± 0,3 Unions on brake piping 1,5 ± 0,1 Caliper on pivot 10,5 ± 1 B3FP7DVD ABS/ESP hydraulic block support on the chassis member 0,2 ±...
  • Page 369 TIGHTENING TORQUES: BRAKING SYSTEM Front brakes Braking amplifier 2,2 ± 0,3 Master cylinder on braking amplifier 2 ± 0,5 B3FP7DXD Handbrake Handbrake lever 1,5 ± 0,2 B3FP7DYC...
  • Page 370 TIGHTENING TORQUES: BRAKING SYSTEM Rear brakes Unions on brake piping 1,5 ± 0,1 Rear brake caliper support 5,3 ± 0,5 Rear brake caliper 3 ± 0,3 Wheel sensor 0,8 ± 0,1 B3FP7DZC B3FP7EOC...
  • Page 371 VALUES FOR CHECKING AND ADJUSTING THE BRAKING SYSTEM Front brake KFU - NFU Engines KFU - NFU (Manual) NFU (Auto.) (Manual - Auto.) RFJ - RFN 9HX - 9HY - 9HZ With ABS With ESP Diameter (mm) Thickness (mm) Front brake disc Minimum thickness (mm) Difference in maximum thickness on the same 0,01...
  • Page 372 VALUES FOR CHECKING AND ADJUSTING THE BRAKING SYSTEM Rear brake Engines KFU - NFU- RFJ - RFN - RFK - 9HX - 9HY - 9HZ - RHR Diameter (mm) Thickness (mm) Rear brake disc Minimum thickness (mm) Difference in maximum thickness on the same 0,01 circumference (mm)
  • Page 373 HANDBRAKE ADJUSTMENT Adjustment. IMPERATIVE: Respect the safety and cleanliness requirements. Raise and support the vehicle. Remove the central console. WARNING: Check the routing of the brake cables under the vehicle. Release the handbrake lever. Press gently on the brake pedal (then repeat the operation 3 times). Action the handbrake lever 8 times with a force of 40 daN.
  • Page 374 BLEEDING AND FILLING THE BRAKING SYSTEM Tools. [1] Bleeding apparatus : «LURO» or similar [2] LEXIA diagnostic tool : 4171-T [3] PROXIA diagnostic tool : 4165-T NOTE: Bleeding of the secondary braking circuit is done with the aid of diagnostic tools [2] and [3].
  • Page 375 BLEEDING AND FILLING THE BRAKING SYSTEM Disconnect the connector «b». Uncouple the pipe (5). Remove the reservoir (6), moving aside the tabs «c» of the pins (7). Clean the brake fluid reservoir (4) and the brake fluid reservoir (6). Refit the brake fluid reservoir (6). Couple the pipe (5).
  • Page 376 BLEEDING AND FILLING THE BRAKING SYSTEM Filling the braking circuit. WARNING: Use only the approved and recommended hydraulic fluids. IMPERATIVE: Only use new brake fluid that has not emulsified; avoid any introduction of impurities into the hydraulic circuit. Fill the brake fluid reservoir (4). Bleeding the primary braking circuit.
  • Page 377 BLEEDING AND FILLING THE BRAKING SYSTEM Bleeding the braking circuit with the bleed apparatus. Connect the bleed apparatus [1] on the brake fluid reservoir (4). Adjust the apparatus pressure to 2 Bars. For each brake circuit: - Couple a transparent tube on the bleed screw. - Submerge the other end of the tube in a clean container.
  • Page 378 BLEEDING AND FILLING THE BRAKING SYSTEM Bleeding the braking circuit without the bleed apparatus. Bleeding the secondary braking circuit. NOTE: Two operators are necessary. WARNING: During the bleed operations: take care to maintain the level of the brake fluid in the reservoir, keep it topped up. For each brake circuit: NOTE: The bleed apparatus [1] is still connected on the brake fluid - Apply the brake pedal to place the circuit under pressure.
  • Page 379 STARTER MOTORS Engine Gearbox Engine type Supplier Class Climate 1.4i 16V 1.6i 16V VALEO BOSCH 2.0i 16V MELCO VALEO BOSCH 2.0i MELCO VALEO BOSCH 2.0i 16V MELCO GEARBOX: BVM (Manual), BVA (Automatic). CLIMATE: T (Temperate), C (Hot), F (Cold), GF (Very cold).
  • Page 380 STARTER MOTORS Engine Gearbox Engine type Supplier Class Climate VALEO 1.6 HDi VALEO VALEO 2.0 HDi VALEO GEARBOX: BVM (Manual), BVA (Automatic). CLIMATE: T (Temperate), C (Hot), F (Cold), GF (Very cold).
  • Page 381 ALTERNATORS Without air conditioning Heated seat Engine Gearbox Engine type Base HiFi Heated seat Climate + HiFi 1.4i 16V 1.6 HDi GEARBOX: BVM (Manual), BVA (Automatic). CLIMATE: T (Temperate), C (Hot), F (Cold), GF (Very cold).
  • Page 382 ALTERNATORS Without air conditioning Heated seat Engine Gearbox Engine type Base HiFi Heated seat Climate + HiFi 2.0i 16V 2.0i 2.0i 16V GEARBOX: BVM (Manual), BVA (Automatic). CLIMATE: T (Temperate), C (Hot), F (Cold), GF (Very cold).
  • Page 383 ALTERNATORS With air conditioning Heated seat Engine Gearbox Engine type Base HiFi Heated seat Climate + HiFi 1.4i 16V 1.6i 16V GEARBOX: BVM (Manual), BVA (Automatic). CLIMATE: T (Temperate), C (Hot), F (Cold), GF (Very cold).
  • Page 384 ALTERNATORS With air conditioning Heated seat Engine Gearbox Engine type Base HiFi Heated seat Climate + HiFi 2.0i 16V 2.0i 2.0i 16V GEARBOX: BVM (Manual), BVA (Automatic). CLIMATE: T (Temperate), C (Hot), F (Cold), GF (Very cold).
  • Page 385 ALTERNATORS With or without air conditioning Heated seat Engine Gearbox Engine type Base HiFi Heated seat Climate + HiFi 1.6 HDi 2.0 HDi GEARBOX: BVM (Manual), BVA (Automatic). CLIMATE: T (Temperate), C (Hot), F (Cold), GF (Very cold).
  • Page 386 PRE-HEATING AND STARTING SYSTEM Pre-heater Pre / Post heating Tightening torque Tightening torque Vehicles - models Pre-heater plugs (m.daN) control unit (pre-heating duration at 20°C) (m.daN) NGK YE04 0,85 ± 0,08 0,25 ± 0,02 1.6 HDi BERU Controlled by the diesel NAGARES BDL/7-12 injection ECU CARTIER DV4HSS...
  • Page 387 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 = 13.5 V.
  • Page 388 AIR CONDITIONING R 134 a : CAPACITIES Compressor Refrigerant Vehicle Engines Date Variable Oil quantity refill Oil reference Capacity All types SD 7 C 12 (except RHR) 09/04 450 ± 25 SP 10 SD 6 C 12...
  • Page 389 SPECIAL FEATURES: AIR CONDITIONING SYSTEM Condenser Compressor The variable capacity air conditioning compressor has external control. The internal pneumatic valve is replaced by an external electrovalve. The condenser (4) has a cylinder incorporating the function of aircon fluid reservoir and with integral filtering cartridge. a: Inlet union b: Outlet union NOTE: The filtering cartridge is not interchangeable.
  • Page 390 SPECIAL FEATURES: AIR CONDITIONING SYSTEM Tightening Requirements for fitting the inlet and outlet brackets: - Aircon compressor. - Aircon condenser. - Aircon pressure reducer valve. IMPERATIVE: Assembly requirement: the bracket(s) «f» must be against their interface(s) before the nut(s) are tightened. IMPERATIVE: Respect the tightening torques.
  • Page 391 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. Remove: C5HP1C5C C5HP1C7C - The plastic pins (1). - The plastic cover (2). - The flap (3). - The pollen filter (4).
  • Page 392 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Compressor lubricant ESSENTIAL: The compressor lubricant is extremely hygroscopic; always use FRESH oil. Checking the compressor oil level There are three specific cases: - 1/ Repairs to a system without leaks. - 2/ Slow leak. - 3/ Fast leak.
  • Page 393 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 394 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Tools. [1] Clim test 2 VALEO : 4372-T Checks. Position the tool [1] (depending on manufacturer’s instructions). E5AP2ECC...
  • Page 395 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Management of the air conditioning compressor Air conditioning compressor safety. Cutting of the aircon compressor caused by the speed of the com- pressor. The management of the aircon compressor clutch is identical whether The aircon compressor is cut in the following cases: with basic air conditioning (RF) or with fully automatic air conditioning - If the aircon compressor speed reaches 8100 rpm ;...
  • Page 396 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Management of the air conditioning compressor Safety as a function of the outside temperature. The aircon compressor is cut if the outside temperature is lower than 3.5 °C. The aircon compressor is triggered when the outside temperature goes above 5°C. Safety as a function of electric diagnosis.
  • Page 397 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Manual air conditioning Checking. Position the tool [1] (depending on manufacturer’s instructions). Preliminary operations. Close all the front air vents. Start the engine. Open the front LH air vent (1). Position the air distribution control (6) to frontal flow at «b». Activate the air recirculation control by pressing on the switch (2) (lamp comes on).
  • Page 398 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Automatic bi-zone air conditioning Checking. Position the tool [1] (depending on manufacturer’s instructions). Preliminary operations. Close all the front air vents. Start the engine. Open the front LH air vent (1). Operating the air distribution function. Press on the switch (12).
  • Page 399 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Automatic bi-zone air conditioning Operating the air conditioning function. Press on the switch (13). The display at «d» appears on the screen (8). Operating the air flow function. Press on the switch (10) to increase the air flow to the maximum. The level of air flow is indicated on the display (8) at «c»...
  • Page 400 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Setting the checking tool [1] to measurement mode. Operate the checking tool, press on button "j". Select the type of aircon fluid: R134.a or R12: - Press on button "l", validate by pressing on button "k". Select the type of aircon fluid: with filtering and drying cartridge, or calibrated aperture: - Press on button "l", validate by pressing on button "k".
  • Page 401 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Interpretation of the measurements «m»: High pressure. «s»: Over-heating (SC). «n»: High temperature. «t»: Ambient air temperature. «p»: Under-cooling (SR). «u»: Blown air temperature. «q»: Low pressure. «v»: Humidity. «r»: Low temperature. «w»: Temperature T3.
  • Page 402 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Interpretation of the measurements. «m»: High pressure. «s»: Over-heating (SC). «n»: High temperature. «t»: Ambient air temperature. «p»: Under-cooling (SR). «u»: Blown air temperature. «q»: Low pressure. «v»: Humidity. «r»: Low temperature. «w»: Temperature T3.
  • Page 403 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Interpretation of the diagnosis E5AP2FCD «x» Check correct. «y» Lack of aircon fluid in the aircon circuit. «z» Excess aircon fluid in the aircon circuit. «aa» Filtering and drying cartridge clogged. «ab» Other problems (see table above).
  • Page 404 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table Principal problem Symptom Possible causes Aircon compressor clutch Lack of aircon fluid in the aircon circuit The clutch of the aircon compressor does not Aircon pressostat engage, or disengages suddenly Aircon evaporator sensor Electrical circuit (wiring, fuses, etc.) The aircon compressor does not turn, or...
  • Page 405 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table Principal problem Symptom Possible causes Incorrect adjustment of the aircon compressor clutch Aircon fluid quantity The clutch of the aircon compressor remains Aircon compressor defective engaged The aircon compressor makes Lack of aircon fluid in the aircon circuit an abnormal noise Aircon compressor valves defective...
  • Page 406 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table Principal problem Symptom Possible causes Aircon pressure reducer defective Low pressure and high pressure too high Duct clogged Low pressure too high and high pressure too low Aircon compressor seal defective Aircon evaporator sensor defective Aircon pressure reducer jammed Low pressure too low and high pressure too high...
  • Page 407 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table Principal problem Symptom Possible causes Presence of air in the aircon circuit Low pressure normal and high pressure too high Aircon pressostat defective Low pressure normal and high pression too low Evaporator sensor defective Abnormal levels of pressure Aircon pressure reducer jammed open...
  • Page 408 AIR CONDITIONING SYSTEM R 134.a Engines: KFU - NFU (1) High pressure valve (2) Low pressure valve (3) Pressostat (tighten to 0,6 m.daN) (4) Aircon pressure reducer (5) Filtering and drying cartridge (6) Buffer capacity «a» Outlet and inlet of the aircon pressure reducer, tighten to 0,8 m.daN «b»...
  • Page 409 AIR CONDITIONING SYSTEM R 134.a Engine: RFN (1) High pressure valve (2) Low pressure valve (3) Pressostat (tighten to 0,6 m.daN) (4) Aircon pressure reducer (5) Filtering and drying cartridge (6) Buffer capacity «a» Outlet and inlet of the aircon pressure reducer, tighten to 0,8 m.daN «b»...
  • Page 410 AIR CONDITIONING SYSTEM R 134.a Engines: RFJ - RFK (1) High pressure valve (2) Low pressure valve (3) Pressostat (tighten to 0,6 m.daN) (4) Aircon pressure reducer (5) Filtering and drying cartridge (6) Buffer capacity «a» Outlet and inlet of the aircon pressure reducer, tighten to 0,8 m.daN «b»...
  • Page 411 AIR CONDITIONING SYSTEM R 134.a Engines: 9HX - 9HY - 9HZ (1) High pressure valve (2) Low pressure valve (3) Pressostat (tighten to 0,6 m.daN) (4) Aircon pressure reducer (5) Filtering and drying cartridge (6) Buffer capacity «a» Outlet and inlet of the aircon pressure reducer, tighten to 0,8 m.daN «b»...
  • Page 412 AIR CONDITIONING SYSTEM R 134.a Engine: RHR (1) High pressure valve (2) Low pressure valve (3) Pressostat (tighten to 0,6 m.daN) (4) Aircon pressure reducer (5) Filtering and drying cartridge (6) Buffer capacity «a» Outlet and inlet of the aircon pressure reducer, tighten to 0,8 m.daN «b»...

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