CITROEN C1 User Manual
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CITROEN C1 User Manual

Citroen c1
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Enlarged version
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.

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Summary of Contents for CITROEN C1

  • Page 1 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 2 PRIVATE CARS 2005 CITROËN C1 «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.
  • Page 3 PRESENTATION THIS HANDBOOK summarises the specifications, adjustments, checks and special features concerning CITROËN C1. The handbook is divided into groups representing the main functions : GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - AIR CONDITIONING.
  • Page 4 If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into account when preparing future publications. For example : – INSUFFICIENT INFORMATION – SUPERFLUOUS INFORMATION – NEED FOR MORE DETAILS Please send your comments and suggestions to : CITROEN U.K. Ltd. 221, Bath Road, SLOUGH, SL1 4BA. U.K.

  • Page 5: Table Of Contents

    CONTENTS GENERAL Exhaust specifications 78 - 82 IGNITION Vehicle identification 1 - 4 Cooling system specifications 83 - 86 Sparking plugs Checking the oil pressure Specifications & dimensions 5 - 6 CLUTCH-GEARBOX-TRANSMISSION Valve clearances Weight specifications Clutch specifications Draining, filling and bleeding the Operations to be performed following 89 - 92 Tightening torques : clutch...
  • Page 6 CONTENTS Checking the vacuum pump 177 - 178 AXLES-SUSPENSION-STEERING Adjusting the handbrake Wheels and tyres Draining, filling, bleeding the braking 180 - 183 Axle geometry 150 - 152 Front axle 153 - 154 AIR CONDITIONING Tightening torques: front axle R134.a capacity Rear axle Air conditioning circuit 185 - 186...
  • Page 7 IDENTIFICATION OF VEHICLES A - Manufacturer’s plate (On the centre pillar : 3-door version) (On the rear door aperture : 5-door version) A - AS/RP No. and RP paint code. B - Chassis stamp (Cold stamp on the crossmember, under the front RH seat). C - Tyre pressures and tyre type (Label on the front pillar on driver’s side).
  • Page 8 IDENTIFICATION OF VEHICLES Type approval Structure Version (Depollution gearbox) (4) Family (1) Gearbox Depollution Bodywork (2) 5-speed gearbox PN CFAC/T Engine (3) Version (4) Variants (5) Variant (5) Fiscal incentives Family (1) Entreprise van-convertible Piloted manual gearbox Body shape (2) 3-door saloon (4 seats) 5-door saloon (4 seats) Engine (3)
  • Page 9 IDENTIFICATION OF VEHICLES Petrol Diesel 1.0i 1.4 HDi Emission standard Type code PN CFAC PN 8HTC Engine type Cubic capacity (cc) 1.0i 1.4 HDi Fiscal rating (hp) Gearbox type Gearbox ident. plate C 551 (m) (*) C 551A (mp) (**) C 552 (m) (*) (*) = Manual gearbox (**) = Piloted manual gearbox...
  • Page 10 IDENTIFICATION OF VEHICLES Manufacturer’s plate. The manufacturer’s plate carries the following information : (a) Type approval number (*). (b) Type serial number (VIN). (c) Gross vehicle weight (*). (d) Gross vehicle weight (*). (e) Maximum weight on front axle (*). (f) Maximum weight on rear axle (*).

  • Page 11: Specifications & Dimensions

    GENERAL SPECIFICATION : DIMENSIONS Exterior dimensions (mm) E1A2001D...

  • Page 12: Specifications & Dimensions

    GENERAL SPECIFICATION : DIMENSIONS Exterior dimensions (mm) Vehicles All types Wheelbase 2340 Length overall 3429 Front overhang Rear overhang Rear track at ground level 1410 Front track at ground level 1420 Width overall * 1630 Height overall * 1460 Height with longitudinal roof bars ODM = Vehicle in running order (vehicle empty, levels topped up) .
  • Page 13 GENERAL SPECIFICATION : WEIGHTS 3-door 5-door Petrol Diesel Petrol Diesel 1.0i 1.4 HDi 1.0i 1.4 HDi Engine type 384F E4 DV4TD E4 384F E4 DV4TD E4 Gearbox type C551 C551A C552 C551 C551A C552 Payload Weight empty in running order Gross Vehicle weight 1160 1180...
  • Page 14 OPERATION TO BE CARRIED OUT FOLLOWING A RECONNECTION OF THE BATTERY Radio Before disconnecting the battery, make a note of the customer’s rado stations. After reconnecting the battery, reprogramme the radio stations.
  • Page 15 GENERAL SPECIFICATION : TOWING THE VEHICLE Vehicle towing Towing eye WARNING : When the engine is not running, steering and braking are no longer power-assisted. The towing eye (1) is to be found in the vehicle toolkit. E2A200CD NOTE : The vehicle toolkit is stowed in the boot E2A200DD...
  • Page 16 GENERAL SPECIFICATION : TOWING THE VEHICLE Vehicle towing : Precautions to be taken Manual gearbox Piloted manual gearbox Vehicle equipped with a piloted manual gearbox IMPERATIVE : It is necessary to lift the front of the vehicle in order to tow it, having placed the gear selector in neutral.
  • Page 17 GENERAL SPECIFICATION : TOWING THE VEHICLE Vehicle towing : Precautions to be taken Piloted manual gearbox Engaging "N" with the aid of a diagnostic tool Preliminary operations : - Vehicle stationary, engine stopped Engaging "N" without the aid of a diagnostic tool - Battery voltage higher than 12.5 volts - Ignition switched on In this configuration, the gearbox actuator is jammed, gear engaged.
  • Page 18 GENERAL SPECIFICATION : TOWING THE VEHICLE Vehicle towing : Precautions to be taken Piloted manual gearbox "a" Neutral. "b" 1 "c" 2 , reverse gear. Using a large screwdriver, move the screw (3) to bring the gearbox actuator to the neutral position. When this position is reached, "N"...

  • Page 19: Lifting And Supporting The Vehicle

    GENERAL SPECIFICATION : LIFTING AND SUPPORTING THE VEHICLE Lifting and supporting the vehicle Note on status of the vehicle before lifting The vehicle should be unloaded before any lifting operation. Never place a loaded vehicle on a jack or on a lift. When you remove a heavy component, such as the engine or the gearbox, the vehicle’s centre of gravity moves.
  • Page 20 GENERAL SPECIFICATION : LIFTING AND SUPPORTING THE VEHICLE Lifting and supporting the vehicle Note on use of a 4-point lift with moving arms IMPERATIVE : Position the safety straps, if placing the vehicle on a lift supported from the jacking points (risk of the vehicle overbalancing when a heavy component is removed).

  • Page 21: Lifting And Supporting The Vehicle

    GENERAL SPECIFICATION : LIFTING AND SUPPORTING THE VEHICLE Lifting and supporting the vehicle Note on use of a platform lift Respect the safety requirements set out in the user instructions. Use blocks for a platform lift. B : lift with moving arms. C : platform lift.

  • Page 22: Capacities

    CAPACITIES (in litres) Draining methods. Oil capacities are defined according to the following methods. Draining of the engine lubrication system by GRAVITY Draining of the engine lubrication system by SUCTION. Place the vehicle on horizontal ground (in the high position if hydro- Place the vehicle on horizontal ground (in the high position if hydro- pneumatic suspension).

  • Page 23: Capacities

    CAPACITIES (in litres) Petrol Diesel 1.0i 1.4 HDi Engine plate 3,75 Draining by gravity : engine with filter change Between min. and max. MT 5-speed gearbox MMT piloted 5-speed gearbox Braking circuit Cooling system Fuel tank capacity ESSENTIAL : Systematically check the oil level using the oil dipstick.

  • Page 24: Lubrication System

    LUBRICATION CIRCUIT SPECIFICATIONS Engine : CFA Lubrication system The lubrication circuit is fully pressurised and all of the oil passes through the oil filter. The rotary oil pump (30) is driven directly by the crankshaft. Oil capacity (in litres) With oil filter : 3,1 Without oil filter : 2,9...

  • Page 25: Lubricants

    For more information, refer to the lubricants bulletin for the model year in Laser under PDI/MAINTENANCE. NOTE : For C1 petrol, use of TOTAL 15 W 40 ACTIVA 5000 : norm API SL/CF or ACEA A2/B2 is recommended. WARNING : For vehicles with a maintenance interval of 30 000 km (20 000 miles), use exclusively TOTAL ACTIVA/QUARTZ 7000 or TOTAL ACTIVA/QUARTZ FUTURE 9000 or any other oil with specifications equivalent to these.

  • Page 26: Engines

    Part No 9735 Y5 1 Litre All countries S-LLC pink fluid 5 Litres 9735 Y6 WARNING : Never use PSA coolant (G33) on C1 petrol engines. ENGINE COOLANT : DIESEL ENGINE CITROËN Part No. Packs GLYSANTIN G33 REVKOGEL 2000 2 Litres...

  • Page 27: Lubricants

    RECOMMENDED LUBRICANTS BRAKE FLUID Synthetic brake fluid CITROËN Part No. Packs 9979 05 0,5 Litre CITROËN fluid All countries 1 Litre 9979 06 5 Litres 9979 07 LIQUIDE LAVE-VITRES Packs CITROËN Part No. Concentrate : 250 ml 9980 33 9980 56 ZC 9875 953U Fluid 9980 06...

  • Page 28: Specifications

    ENGINE SPECIFICATIONS Petrol Diesel 1.0i 1.4 HDi Engine type Cubic capacity (cc) 1398 Bore / Stroke 71/84 73,7/85 Compression ratio 10,5/1 18/1 Power ISO or EEC KW - rpm 50-6000 40-3000 Maximum power DIN (hp-rpm) 68-6000 54-3000 Torque ISO or EEC (m.daN - rpm) 9,3-3600 13-3000...
  • Page 29 PRESENTATION OF ENGINE 384 F ( CFA) Engine : CFA Description. The petrol engine 384F used on the new vehicle has been developed recently. This is a 1.0 engine with 3 cylinders in line, with 12 overhead valves. This engine is light and compact, giving good fuel economy. It uses DIS (Direct Ignition System) and VVT-i (Variable Valve Timing-intelligent).
  • Page 30 PRESENTATION OF ENGINE 384 F ( CFA) Engine : CFA Number of cylinders and arrangement : 3 cylinders in line Timing : 12 valves, overhead camshaft driven by chain (with VVT-i) Combustion chamber : Wedge-shaped Manifolds : Cross flow Fuel delivery system : Electronic injection Ignition system : DIS...
  • Page 31 PRESENTATION OF ENGINE 384 F ( CFA) Engine : CFA Adjustment of inlet valves (opening) : 40° after TDC - 5° after TDC Adjustment of inlet valves (closing) : 10° after BDC - 55° after BDC Adjustment of exhaust valves (opening) : 40°...
  • Page 32 PRESENTATION OF ENGINE 384 F ( CFA) Engine : CFA Valve adjustments. A : angle of opening of inlet valve. B : angle of opening of exhaust valve C : TDC D : BDC. "a" operating range of VVT-i. "b" 0° "c"...
  • Page 33 PRESENTATION OF ENGINE 384 F ( CFA) Engine : CFA Cylinder head gasket : transversal section. : shim. The cylinder head gasket used is in laminated steel. The gasket surface is coated with NBR in order to make the cylinder head more air-tight. NOTE : NBR (Nitrile Butadiene Rubber) : rubber material known for its resistance to heat, oil and wear.
  • Page 34 PRESENTATION OF ENGINE 384 F ( CFA) Engine : CFA Engine block (5) oil separator cover An aluminium engine block (4) with a wall thickness of 7 mm between the cylinder bores produces an engine that is light and compact. An oil separator (6) incorporated in the engine block (4), where the exhaust gases pass, thus sepa- rates the engine oil from the gases passing from the combustion chambers to the sump so as to preserve the quality of the engine oil and to reduce oil consumption.
  • Page 35 PRESENTATION OF ENGINE 384 F ( CFA) Engine : CFA Con rods and big end bearing shells (12) gudgeon pin The forged steel con rods have increased rigidity and reduced weight. The con rod caps are fixed with extended tension screws (11). The glide surfaces of the big end bearing shells have micro-grooves "n"...
  • Page 36 PRESENTATION OF ENGINE 384 F ( CFA) Engine : CFA Oil sump (15) protection plate. (17) oil sump. The oil strainer (16) is made of plastic to reduce weight. Valve timing system General (18) timing chain. (19) chain guide. B1B2026D (20) chain tensioner.
  • Page 37 PRESENTATION OF ENGINE 384 F ( CFA) Engine : CFA Camshaft "t" oil channel (retard). "u" oil channel (advance). The end of the inlet camshaft (22) is provided with holes for suppling the VVT-i system with engine oil under pressure. The control for the VVT-i system (21) is fitted on the front end of the inlet camshaft (22), it modifies the adjustment of the inlet valves.
  • Page 38 PRESENTATION OF ENGINE 384 F ( CFA) Engine : CFA Timing chain and tensioner (19) chain guide. (27) chain damper. (28) timing pinion on crankshaft. A high-resistance roller chain (18) with a pitch of 8 mm gives reliability and makes the engine more compact.
  • Page 39 TIGHTENING TORQUES : ENGINE SUSPENSION Engine/gearbox suspension Engine : CFA RH engine support LH engine support 5,2 ± 0,5 5,2 ± 0,5 2,4 ± 0,2 A = Screw on box B = Screw on body B1B201QD B1B201RD Lower suspension 5,2 ± 0,5 12 ±...
  • Page 40 TIGHTENING TORQUES : PETROL ENGINE Engine : CFA Crankshaft Crankshaft bearing cap screws 5,9 ± 0,6 Con rod cap screws Tightening 1,5 ± 0,1 Angular tightening 90° ± 5° Crankshaft pulley screw 17 ± 1,7 Seal carrier plate screw 1 ± 0,1 B1B201DD Cylinder head bolts Tightening...
  • Page 41 TIGHTENING TORQUES : PETROL ENGINE Engine : CFA Crankshaft RH engine support Tightening of screws on block 2,4 ± 0,2 Tightening of screws on body 5,2 ± 0,5 Timing chain cover screw 2,4 ± 0,2 Timing chain cover screw 4 ± 0,4 B1B201FD...
  • Page 42 TIGHTENING TORQUES : PETROL ENGINE Engine : CFA Lubrication Oil pump 0,9 ± 0,1 Sump screws 1 ± 0,1 Sump screws 2,4 ± 0,2 Flywheel /clutch Flywheel screws 7,8 ± 0,8 Clutch plate screws 1,9 ± 0,2 B1B201GD B1B2015D...
  • Page 43 TIGHTENING TORQUES : PETROL ENGINE Engine : CFA Injection circuit Injection rail screw on block 2,7 ± 0,3 Cooling circuit Coolant pump screws 2,8 ± 0,3 Coolant inlet housing screws 0,7 ± 0,1 Accessories Alternator screw 4,9 ± 0,5 Tensioner screw 3,4 ±...
  • Page 44 TIGHTENING TORQUES : ENGINE SUSPENSION Engine/gearbox assembly suspension Engine : 8HT RH engine support Lower RH engine support 5,2 ± 0,5 5,7 ± 0,6 5,2 ± 0,5 5,2 ± 0,5 B1B201AD Torque reaction rod LH engine support on gearbox 5,2 ± 0,5 5,2 ±...
  • Page 45 TIGHTENING TORQUES : DIESEL ENGINE Engine Crankshaft Bearing cap fixing screws Pre-tightening 1 ± 0,1 Slackening 180° ± 5° Tightening 3 ± 0,3 Angular tightening 140° ± 5° Con rod screws Tightening 1 ± 0,1 Angular tightening 100° ± 5° Accessories drive pulley Tightening 3 ±...
  • Page 46 TIGHTENING TORQUES : DIESEL ENGINE Engine Cylinder head Camshaft bearing cap covers Pre-tightening 0,3 ± 0,1 Tightening 1 ± 0,1 Fixing of camshaft sub-assemblies on cylinder head Pre-tightening 0,3 ± 0,1 Tightening 1 ± 0,1 Exhaust manifold 3 ± Camshaft pulleys Pre-tightening 2 ±...
  • Page 47 TIGHTENING TORQUES : DIESEL ENGINE Engine Lubrication circuit Oil pump assembly Pre-tightening 0,5 ± 0,1 Tightening 0,9 ± 0,1 Oil/coolant heat exchanger 1 ± 0,1 Turbocharger lubrication pipe 3 ± 0,3 Diesel injection circuit Spherical base screw for diesel injection fixing fork 2,5 ±...
  • Page 48 TIGHTENING TORQUES : CYLINDER HEAD Petrol and Diesel engines Operation to be performed prior to refitting the cylinder head Clean the seal faces with the CITROËN-approved product. Do not use abrasives or cutting tools on the seal faces. The seal faces must not show any traces of impacts or scratches. Pass a tap into the threads in the cylinder block that receive the cylinder head bolts.
  • Page 49 BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE Tools 4122-T (C.TRONIC.105.5) 4099-T (C.TRONIC.105)
  • Page 50 AUXILIARY EQUIPMENT DRIVE BELT Petrol Diesel 1.0i 1.4 HDi Engine plate See pages : 46 to 47 48 to 49...
  • Page 51 AUXILIARY EQUIPMENT DRIVE BELT Engines : Petrol and Diesel TOOLS Belt tension measuring instrument : 4122 - T (C.TRONIC 105.5) WARNING : If using tool 4099-T (C.TRONIC 105) ESSENTIAL. Before refitting the auxiliary equipment drive belt, check that: 1) The roller(s) rotate freely (no play or stiffness) 2) The belt is correctly engaged in the grooves of the various pulleys.
  • Page 52 AUXILIARY EQUIPMENT DRIVE BELT Engine : CFA Removing "a" Tension pulley "b" Alternator pulley "c" Compressor pulley. "d" Crankshaft pulley. B : With aircon C : Without aircon. Slacken the screw (1). Slacken the screw (2). Do up the screw (2) without tightening it, until there is no more play A. Slacken the screw (3).
  • Page 53 AUXILIARY EQUIPMENT DRIVE BELT Engine : CFA Refitting Refit the trapezoidal belt on the ventilator and on the alternator. "a" Tension pulley "b" Alternator pulley. "c" Compressor pulley "d" Crankshaft pulley. B : With aircon C : Without aircon. Do up the screw (2) without tightening it, until there is no more play A. Tighten the screw (3) to tension the trapezoidal belt on the ventilator and on the alternator.

  • Page 54: Auxiliary Drive Belt

    AUXILIARY EQUIPMENT DRIVE BELT Engine : 8HT Tools. [1] Compression lever for dynamic tensioner : (-).0194.E3 [2] Peg for dynamic tensioner roller : (-).0194.F References on the dynamic tensioner roller "b" Nominal position. "a" Position for "maximum wear" of the auxiliary drive belt. Removing.
  • Page 55 AUXILIARY EQUIPMENT DRIVE BELT Engine : 8HT Compress the dynamic tensioner roller, using tool [1]. Position the peg [2]. Remove the auxiliary drive belt (7). Refitting NOTE : Check that the tensioner roller moves freely (no tight spot). If this is not the case, replace the tensioner roller.
  • Page 56 BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE Tools 4122-T (C.TRONIC.105.5) 4099-T (C.TRONIC.105)

  • Page 57: Checking And Setting The Valve Timing

    CHECKING AND SETTING THE VALVE TIMING Petrol Diesel 1.0i 1.4 HDi Engine plate See pages : 53 to 69 70 to 77...
  • Page 58 RECOMMENDATIONS : TIMING BELT Engines : All Types Recommendations IMPERATIVE : After any repair involving removal of the timing belt, systematically replace : The timing belt, The tensioner roller fixing nut.
  • Page 59 CHECKING AND SETTING THE VALVE TIMING Engine : CFA MPERATIVE : Respect the safety and cleanliness requirements. Removing. Raise and support the vehicle, wheels hanging. Disconnect the battery negative cable (see corresponding operation). Drain the engine oil (see corresponding operation). Drain the gearbox oil (see corresponding operation).
  • Page 60 CHECKING AND SETTING THE VALVE TIMING Engine : CFA Disconnect the camshaft position sensor. Remove the screw and the crankshaft position sensor Remove the 13 screws and the 2 nuts in the sequence indicated. B1D201QD Remove the valve cover with its gasket. Remove the valve cover gasket B1D201RD...
  • Page 61 CHECKING AND SETTING THE VALVE TIMING Engine : CFA Remove the 3 screws, the support for the oil filter and its seal Remove the 5 screws, the coolant pump and its seal. B1D201SD B1D201TD...
  • Page 62 CHECKING AND SETTING THE VALVE TIMING Engine : CFA Turn the crankshaft pulley clockwise in order to align the setting mark "a" on the toothed wheel (0 degrees) with those on the timing cover. Make sure that the setting mark "a" on the camshaft pulley is on top as indicated. NOTE : Failing this, turn the crankshaft pulley by one full turn (360 degrees) to bring the setting mark to the top.
  • Page 63 CHECKING AND SETTING THE VALVE TIMING Engine : CFA Turn the chain tensioner stop plate clockwise and compress the piston. Insert peg into the hole in the stop plate so as to lock the tensioner with the thrust piston in the compressed position.
  • Page 64 CHECKING AND SETTING THE VALVE TIMING Engine : CFA Remove the 2 screws, the chain guide and the crankshaft toothed wheel. Remove the keyway. B1D201YD B1D201ZD...
  • Page 65 CHECKING AND SETTING THE VALVE TIMING Engine : CFA Refit the keyway in the groove of the crankshaft. Align the groove of the crankshaft pinion with the keyway of the crankshaft and refit the crankshaft pinion. B1D201ZD Refit the chain guide with the 2 screws. Tightening torque : 0,9 ±...
  • Page 66 CHECKING AND SETTING THE VALVE TIMING Engine : CFA To refit the timing chain, align the link "c" (yellow in colour) with the setting mark "b" on the crankshaft pinion as indicated. To complete the refitting of the timing chain, align the 2 links "d" (orange in colour) with the setting B1D202JD marks "a"...
  • Page 67 CHECKING AND SETTING THE VALVE TIMING Engine : CFA Turn the hexagonal part of the inlet camshaft anti-clockwise in order to detension the timing towards the tensioner. Refit the tensioner with the 2 screws. B1D202LD Tightening torque between : 0,8 and 1,3 m.daN. Remove the peg, rotate the crankshaft by 2 full turns and unlock the chain tensioner..
  • Page 68 CHECKING AND SETTING THE VALVE TIMING Engine : CFA Check that the setting mark "a" on the camshaft pulley is on top with the chain in tension. Refit the timing cover. B1D202ND Coat the lip of a new lip seal with engine oil. B1D202PD...
  • Page 69 CHECKING AND SETTING THE VALVE TIMING Engine : CFA Fit the new crankshaft seal using tool [2]. : 0196.B Degrease the sealing faces of the cylinder block and of the timing cover. References Dimensions (mm) References Dimensions (mm) 3 to 3,5 B1E200HD 3,5 to 4,5 3 to 3,5...
  • Page 70 CHECKING AND SETTING THE VALVE TIMING Engine : CFA Tighten the 11 screws in the sequence indicated. Tightening torque for screws (1) : 2,4 ± 0,2m.daN. B1D202SD Tightening torque for screws (2) : 4 ± 0,4 m.daN. Remove the excess seal paste. Fit a new coolant pump seal on the timing cover and refit the coolant pump.
  • Page 71 CHECKING AND SETTING THE VALVE TIMING Engine : CFA Tighten the 5 screws in the sequence indicated. Tightening torque : 2,8 ± 0,3 m.daN. B1D202TD Lock the crankshaft pulley using tool [1] and tighten the screw. : C.0132.AA Tightening torque : 17 ±...
  • Page 72 CHECKING AND SETTING THE VALVE TIMING Engine : CFA Refit the oil filter seal on the timing cover and refit the oil filter support. Tighten the 3 screws in the sequence indicated. B1D201SD Tightening torque : between 1,9 and 2,9 m.daN. B1D202VD...
  • Page 73 CHECKING AND SETTING THE VALVE TIMING Engine : CFA Refit the valve cover gasket in the groove of the valve cover and on the centring bosses indicated by the arrows. WARNING: Check the positioning of the gasket, which must be well seated around the bases of the bosses.
  • Page 74 CHECKING AND SETTING THE VALVE TIMING Engine : CFA Tighten the 13 bolts and 2 nuts to the correct torque in the sequence indicated. Tightening torque : 0,8 m.daN. After tightening all the screws and nuts, check that "1" and "2" are tightened to the correct torque. Refit the crankshaft position sensor.
  • Page 75 CHECKING AND SETTING THE VALVE TIMING Engine : CFA Fit a new O-ring seal on the guide-tube of the oil level gauge. Coat the O-ring seal with a thin layer of engine oil. Refit the guide-tube of the oil level gauge with the screw. Tightening torque : 1 ±...
  • Page 76 CHECKING AND SETTING THE VALVE TIMING Engine : 8HT Tools. [1] Engine flywheel setting peg : (-).0194.C [2] Camshaft setting peg : (-).0194.B [3] Crankshaft setting peg : (-).0194.A [4] Movable mirror [5] Tool for removing exhaust clips : C.193.A [6] Hose clamp : (-).0188.AD Removing.
  • Page 77 CHECKING AND SETTING THE VALVE TIMING Engine : 8HT In the engine compartment Remove the screw (9). Disconnect the connector at "g". Move aside the header tank (8). Detach the harness (6) on the timing cover (5). Refit : - the screws (7) - the upper timing cover (5) Put the header tank (8) back in its initial position.
  • Page 78 CHECKING AND SETTING THE VALVE TIMING Engine : 8HT Remove : - the screw (12) - the accessories drive pulley (14) Refit the screw (12). Remove the peg [1]. Disconnect the connector at "h". Slacken the screws (13). Remove the lower timing cover (11). B1E2000D IMPERATIVE : The magnetic track "j"...
  • Page 79 CHECKING AND SETTING THE VALVE TIMING Engine : 8HT Remove the nut (17). In the engine compartment Move aside the header tank. Support the engine with a roller jack equipped with a block. B1E2005D Remove : - the bottom support of the expansion chamber (20) - the engine support (19) - the intermediate engine support (18) Lower the engine by 3 cm.
  • Page 80 CHECKING AND SETTING THE VALVE TIMING Engine : 8HT NOTE : The engine has to be lowered by 3 cm so that you can position the crankshaft by means of the peg. Rotate the engine by means of the crankshaft pinion screw (12) clockwise, to bring it to the pegging position.
  • Page 81 CHECKING AND SETTING THE VALVE TIMING Engine : 8HT Refitting Preliminary operations IMPERATIVE : Check the condition of the seals for the camshaft and the crankshaft pinion. If in doubt don’t hesitate to change the seals. Check that there are no leaks at the coolant pump. If in doubt don’t hesitate to change it. Check that both the tensioner roller and the guide roller can turn freely (no tight spots).
  • Page 82 CHECKING AND SETTING THE VALVE TIMING Engine : 8HT NOTE : The tensioning operation is made easier by use of a mirror. Move the tensioner roller at "k" anti-clockwise by means of a hexagonal spanner. Rotate the tensioner roller to bring the index "p" to position "q". -Tighten the screw (21) of the tensioner roller to : 3 ±...
  • Page 83 CHECKING AND SETTING THE VALVE TIMING Engine : 8HT Under the vehicle. Refit the nut (17), tighten to : 6 ± 0,6 m.daN. Refit : - the engine speed sensor (16) - the belt retaining stop (15), tighten to : 0,7 ± 0,1 m.daN. - the lower timing cover (11) Lock the engine flywheel, using tool [1].
  • Page 84 EXHAUST LINE SPECIFICATIONS Engine : CFA Inlet and exhaust system General (37) Silencer. An inlet manifold (36) made of plastic to reduce weight. The butterfly body (40) is of plastic. The valve cover (1) is of plastic. It incorporates the air filter housing (38). The exhaust manifold (39) and piping are of stainless steel.
  • Page 85 EXHAUST LINE SPECIFICATIONS Engine : CFA Butterfly body (manual gearbox) (42) : butterfly position sensor. The butterfly body (40) is of plastic to reduce weight. An idle control valve (41) of the stepper motor type is fitted inside the butterfly body (40). B1B202GD Inlet manifold The inlet manifold (43) is of plastic to reduce weight and the quantity of the heat transmitted by the...
  • Page 86 EXHAUST LINE SPECIFICATIONS Engine : CFA Exhaust manifold "aa" view from above. "ab" front view. The exhaust manifold (39) made of stainless steel is designed both to enhance the rise in temperature of the 3-way catalytic converter and to reduce weight. The catalytic converter uses ceramics with ultra-thin walls with high cell density.
  • Page 87 EXHAUST LINE SPECIFICATIONS Engine : CFA B1J2000D Exhaust Upstream Clip Rear silencer Downstream Screws Catalytic manifold oxygen sensor oxygen sensor converter Tightening (m.daN) 2,4 ± 0,2 4,4 ± 0,4 3,2 ± 0,3 4,4 ± 0,4 4,5 ± 0,4...
  • Page 88 EXHAUST LINE SPECIFICATIONS Engine : 8HT B1J2001D Rubber Silencer Rubber Clip Catalytic Intermediate Clip suspension suspension converter pipe Tightening (m.daN) 2,5 ± 0,2 2 ± 0,2 3,2 ± 0,3 Reference TR PSA K278...
  • Page 89 COOLING SYSTEM SPECIFICATIONS 1.0i 1.4 HDi Engine type Capacity Radiator surface 12,2 dm Pressurisation 1,4 bars Opening of thermostatic regulator 82°C Cooling fan (Triggering threshold) 93°C 97°C Without aircon 1 x 100 Watt With aircon 1 x 300 Watt Aircon cut-off 115°C Alert 118°C...
  • Page 90 COOLING SYSTEM SPECIFICATIONS Engine : CFA Cooling circuit "y" towards the heater unit. "z" from the heater unit. (32) bypass pipe. (34) radiator A thermostat (33) with bypass valve is fitted at the inlet end of the coolant pump (31) on the cooling circuit.
  • Page 91 COOLING SYSTEM SPECIFICATIONS Engine : CFA (1) Coolant pump. (2) Thermostat. (3) Heater matrix. (4) Cylinder block drain screw. (5) Cooling radiator. (6) Top hose B1G200YD...
  • Page 92 COOLING SYSTEM SPECIFICATIONS Engine : 8HT (1) Bleed screw. (2) Exhaust gas recycling (EGR) heat exchange (EURO 4 version). B1H200ZD...

  • Page 93: Checking The Oil Pressure

    CHECKING THE OIL PRESSURE Petrol Diesel Engines Temperature (°C) 90°C Pressure (Bars) 1000 Pressure (Bars) 2000 Pressure (Bars) Pressure (Bars) 4000 4000 Tools 4386-T 4601-T 1503-L 2279-T.Bis 4103-T (-).1503.J NOTE : The oil pressure should be checked with the engine hot, after the oil level has been checked.

  • Page 94: Valve Clearances

    VALVE CLEARANCES CFA petrol engine Adjust by change of cam followers (See presentation of 384F engine). 8HT diesel engine Hydraulic compensator...

  • Page 95: Cooling Circuit

    DRAINING, FILLING AND BLEEDING THE ENGINE COOLING CIRCUIT Engine : CFA IMPERATIVE : Respect the safety and cleanliness requirements. WARNING : To avoid all risk of burns, do not remove the radiator cap while the engine and the radiator are hot. Thermal expansion may cause coolant fluid and steam to escape from the radiator. Slacken the drain screw (1) and drain the coolant fluid.

  • Page 96: Draining, Filling And Bleeding The

    DRAINING, FILLING AND BLEEDING THE ENGINE COOLING CIRCUIT Engine : CFA Press the radiator inlet and outlet hoses several times to test the level of coolant in the radiator. If the level goes down, add more coolant fluid. Screw the radiator cap "a" back on securely. Slowly pour engine coolant into the expansion chamber up to the maximum mark.

  • Page 97: Draining, Filling And Bleeding The

    DRAINING, FILLING AND BLEEDING THE ENGINE COOLING CIRCUIT Engine : 8HT Tools. [1] Filling cylinder : 4520-T [2] Adaptor for filling cylinder : 4222-T [3] Control rod for filling cylinder : 4370-T Draining Disconnect the negative terminal of the battery. Remove the header tank cap with care.

  • Page 98: Cooling Circuit

    DRAINING, FILLING AND BLEEDING THE ENGINE COOLING CIRCUIT Engine : 8HT Filling and bleeding the circuit Fit the filling cylinder [1], plug [3] and adaptor [2] assembly on the filling aperture. Slowly fill the cooling circuit [1] with coolant fluid, up to the "1 litre" mark, to pressurise the circuit. Remove the clip (2) from the tube.

  • Page 99: Bosch Me 7.9.5 Injection

    BOSCH ME 7.9.5 INJECTION SPECIFICATIONS Engine : CFA Presentation : BOSCH ME 7.9.5 Injection Introduction Application. This principle of operation for injection – ignition applies to the 384F engine. the BOSCH injection system satisfies the following norms : Depollution norm L5 EOBD depollution NOTE : EOBD : European On Board Diagnosis, for diagnosis of depollution equipment.
  • Page 100 BOSCH ME 7.9.5 INJECTION SPECIFICATIONS Engine : CFA System of on-board diagnosis (EOBD) This diagnostic system informs the driver when the depollution equipment is no longer fulfilling its role. Faults in the system causing polluting emissions are memorised in the injection ECU. The "engine diagnosis"...
  • Page 101 GENERAL SYNOPSIS : BOSCH ME 7.9.5 INJECTION SYSTEM Engine : CFA D4E2002D...
  • Page 102 GENERAL SYNOPSIS : BOSCH ME 7.9.5 INJECTION SYSTEM Engine : CFA Components Components 1115 Cylinder reference sensor 1313 Engine speed sensor 1120 Knock sensor 1320 Engine ECU 1131 Ignition coil : cylinder 1 1331 Injector : cylinder N°1 1132 Ignition coil : cylinder 2 1332 Injector : cylinder N°2 1133...
  • Page 103 GENERAL SYNOPSIS : BOSCH ME 7.9.5 INJECTION SYSTEM Engine : CFA Nature of the Nature of the Link N° Signal Link N° Signal signal signal Open cycle Information on the cooling circuit Information on the position of the camshaft Analogue ratio (OCR) pressure Information on the noise of combustion...
  • Page 104 OPERATING PHASES : BOSCH ME 7.9.5 INJECTION SYSTEM Engine : CFA Engine management The engine ECU manages the injection on the basis of the information on engine torque : The engine ECU calculates the need for engine torque from the accelerator pedal sensor The engine torque requested takes account of various corrections The engine torque requested is obtained by acting on the following components : - Butterfly angle (motorised butterfly housing)
  • Page 105 OPERATING PHASES : BOSCH ME 7.9.5 INJECTION SYSTEM Engine : CFA Regulation of the idling speed The engine is equipped with an idle regulation stepper motor : Important variations in the engine idling speed due to the different accessories on the vehicles, depending on their operating status (aircon, alternator) Variations in engine idling speed due to the ageing of the engine This device enables a progressive return to idling speed.
  • Page 106 OPERATING PHASES : BOSCH ME 7.9.5 INJECTION SYSTEM Engine : CFA Air supply function Motorised butterfly housing for MMT piloted manual gearbox. The torque requested by the injection ECU determines an angle of opening of the butterfly: The angle of opening of the butterfly varies with the demand coming from the driver. Engine load is commanded by the butterfly housing.
  • Page 107 OPERATING PHASES : BOSCH ME 7.9.5 INJECTION SYSTEM Engine : CFA Correction by oxygen sensor At idling speed, engine hot, stable with partial load, the signal emitted by the sensor causes an adjustment of the flow from the injector, so as to remain on stoechiometric richness R = 1/15 or lambda = 1.
  • Page 108 OPERATING PHASES : BOSCH ME 7.9.5 INJECTION SYSTEM Engine : CFA EOBD diagnostic function EOBD : European On Board Diagnosis, for diagnosis of depollution equipment. This diagnosis informs the driver if the depollution equipment is no longer fulfilling its role. The on-board diagnosis system monitors : - Elements of the injection system (polluting emissions, destruction of the catalytic converter) - The efficiency of the catalytic converter...
  • Page 109 OPERATING PHASES : BOSCH ME 7.9.5 INJECTION SYSTEM Engine : CFA Display of faults The engine diagnosis warning lamp lights up if there is a fault on any of Ageing of the catalytic converter the following components or types of information : Vehcle speed sensor signal Idle stepper motor signal Control of the variable valve timing electrovalve...
  • Page 110 OPERATING PHASES : BOSCH ME 7.9.5 INJECTION SYSTEM Engine : CFA Driver’s information function Lighting of engine diagnosis (EOBD) warning lamp The engine diagnosis warning lamp indicates a failure of a component or of a system relating to emissions if it is causing an increase in emissions, to exceed the legal limits.

  • Page 111: Bosch Me 7.9.5 Injection

    OPERATING PHASES : BOSCH ME 7.9.5 INJECTION SYSTEM Engine : CFA MMT piloted manual gearbox The injection ECU dialogues with the automatic gearbox ECU in order to guarantee optimal functioning of the gearbox as well as of the engine. WARNING : Following any incident concerning the injection, it is essential to read the faults in the injection ECU and the piloted manual gearbox ECU. The piloted manual gearbox ECU receives the following information from the injection ECU: - Engine load (as a function of the position of the accelerator pedal) - Engine speed...
  • Page 112 AIR FILTER SPECIFICATION Engine : CFA Air filter (45) air filter cartridge. (46) air filter cover. The valve cover (1) incorporating the air filter housing (38) is made of plastic to reduce weight. B1B202JD...

  • Page 113: Fuel Supply System

    FUEL SUPPLY SYSTEM SPECIFICATIONS Engine : CFA General Injectors (54) with 4 holes are used in order to enhance the spraying of the fuel. The non-return fuel supply system reduces emissions by evaporation. The fuel tank (52) is made of plastic. The fuel pump module (53) is compact and light, comprising the fuel gauge which incorporates a car- bon fuel vapour absorber.
  • Page 114 FUEL SUPPLY SYSTEM SPECIFICATIONS Engine : CFA Fuel tank A marking indicates the lowest point of the fuel tank (52). During dismantling (destruction) of the vehicle, drill a hole at the spot indicated "ah" in order to drain the fuel. B1B202PD Fuel filler piping The fuel filler piping (55) includes the tank breather pipe for greater compactness and saving of actual...
  • Page 115 FUEL SUPPLY SYSTEM SPECIFICATIONS Engine : CFA Fuel pump module (56) : fuel pump stop ring. (58) : pump. (59) : reserve cup. (60) : fuel filter. (61) : pressure regulator. (62) : cut-off valve. (63) : foam filter for venting the canister. B1B202RD The fuel pump module includes the carbon fuel vapour absorber (57) for saving of actual space.

  • Page 116: Fuel Supply System

    FUEL SUPPLY SYSTEM SPECIFICATIONS Engine : CFA Non-return fuel supply system (64) pulse damper. (65) fuel pump module. This type of fuel supply system reduces emissions by evaporation. The diagram shows that by integration of the fuel filter (60), the pressure regulator (61) and the fuel gauge with the fuel pump (53), there is no return of fuel from the engine and an increase of temperature inside the fuel tank is avoided.

  • Page 117: Injectors

    INJECTOR SPECIFICATIONS Engine : CFA Injectors Injectors (54) with 4 holes are used in order to enhance the spraying of the fuel. Ignition system This is a Direct Ignition System (DIS). It enhances the precision of the point of ignition, reduces the loss of voltage and increases the general reliability of the ignition system thanks to the elimination of the distributor.

  • Page 118: Safety Requirements : Hdi Direct Injection

    SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM Engine : 8HT SAFETY REQUIREMENTS Preamble All interventions on the injection system must be carried out to conform with the following requirements and regulations : - Competent health authorities. - Accident prevention. - Environmental protection. WARNING : Repairs must be carried out by specialised personnel informed of the safety requirements and of the precautions to be taken Safety requirements IMPERATIVE : Take into account the very high pressures in the high pressure fuel circuit (1350 bars), and respect...

  • Page 119: Safety Requirements : Hdi Direct Injection

    SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM Engine : 8HT Cleanliness Requirements Preliminary operations IMPERATIVE : The technician should wear clean overalls. Before working on the injection system, it may be necessary to clean the apertures of the following sensitive components : (refer to corresponding procedures).

  • Page 120: Prohibited Operations : Hdi Direct Injection

    PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM Engine : 8HT Cleaning - The use of high pressure cleaners is prohibited. 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 121: Prohibited Operations : Hdi Direct Injection

    PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM Engine : 8HT 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). B1H2010D Do not move the nut «d»...
  • Page 122 SPECIFICATIONS : PRE-POSTHEATING CIRCUIT Engine : 8HT The pre-heating time varies as a function of the engine coolant temperature The pre-postheating control unit is piloted by the engine ECU. Pre-postheating control unit Supplier/Reference : NAGARES : 96 456 686 80. CARTIER : 96 456 692 80.

  • Page 123: Circuit

    CONTROLE : CIRCUIT D'ALIMENTATION CARBURANT BASSE PRESSION Engine : 8HT 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 124: Circuit

    CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engine : 8HT Normal vacuum values: Vacuum Observations 10 ± 05 cmhg Engine driven by the starter motor 20 ± 20 cmhg Engine running under full load Supply circuit obstructed 60 ± 05 cmhg (full tank strainer, piping, fuel filter).
  • Page 125 CHECKS : TURBO PRESSURE Engine : 8HT Tools. [1] Pressure gauge for checking boost pressure : 4073-T.A [2] Sleeve for checking boost pressure : (-).0171.F [3] Manual pressure/vacuum pump : FACOM DA 16 [4] Pliers for removing clic clips : (-).0172.Z IMPERATIVE : Respect the safety requirements.
  • Page 126 CHECKS : TURBO PRESSURE Engine : 8HT Mode of operation Position tool [1] in the vehicle. Start the engine. Engage first gear, start the vehicle. Engage the gears up to third gear. Decelerate to an engine speed of 1000 rpm. Check the pressure : 0,6 ±...
  • Page 127 CHECKS : TURBO PRESSURE Engine : 8HT NOTE : The engine has to be switched off. Uncouple the tube at "b" using tool [4]. Couple tool [3] on the tube at "b". Check the inlet manifold pressure sensor using the diagnostic tool. Make the following selections in the diagnostic tool : Menu : "PARAMETER MEASURES"...

  • Page 128: Air Supply Circuit

    AIR SUPPLY CIRCUIT SPECIFICATIONS Engine : 8HT Identification Upper integrated air inlet manifold The upper integrated air inlet system is composed of the following components : (1) Air filter cover (2) Air filter housing (3) Air duct (4) Flowmeter (5) Turbocharger inlet elbow (6) Resonator (7) Turbocharger outlet elbow B1H201JD...
  • Page 129 AIR SUPPLY CIRCUIT SPECIFICATIONS Engine : 8HT Tightening torques (m.daN) Lower integrated air inlet manifold Description Tightening sequence Tightening Oil separator fixing screw 1 to 8 1 ± 0,1 Diesel fuel filter support fixing screw 9 to 10 1 ± 0,1 Diesel fuel filter support fixing screw Integrated air inlet distributor screw 12 to 13...

  • Page 130: Air Supply Circuit

    CHECKING THE AIR SUPPLY CIRCUIT Engine : 8HT Tools [1] Manual pressure-vacuum pump : FACOM DA 16 IMPERATIVE : Respect the safety and cleanliness requirements. Checks Vacuum pump Connect the tool [1] onto the vacuum pump (1). B1H201GD Start the engine. Wait 30 seconds.

  • Page 131: Sparking Plugs

    SPARKING PLUGS Engine : CFA "ak" conventional type. The sparking plugs are of the long thread type"aj". This permits an increased thickness of the cylinder head in the zone where the sparking plugs are siuated. The coolant liners "j" can thus be extended around the combustion chambers to improve cooling.
  • Page 132 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 133: Clutch Specifications

    CLUTCH SPECIFICATIONS 1.0i 1.4 HDi Engine type Gearbox type MT (*) MMT (**) MT (*) Gearbox make ASIN LUCK Mechanism /Type 200 CPXV Ext./Int. lining Ø 181/133 190/133 200/134 Disc lining type (*) MT = Manual gearbox (**) MMT = Piloted manual gearbox...
  • Page 134 CLUTCH TIGHTENING TORQUES Tightening torques (m.daN) Ref. Description Number of screws Tightening Align the reference “b” Screws for clutch Position the mechanism using mechanism on flywheel the top screw “a” Tightening 1,9 ± 0,1 Screws for flywheel 7,8 ± 0,7 B2B2016D B2B2017D...

  • Page 135: Travel

    CHECKING AND ADJUSTING THE CLUTCH PEDAL TRAVEL Move aside the floor carpet. "a" : Pedal height adjustment point. Height A of the pedal in relation to the floor : between 135 and 145 mm. Adjust the height A of the pedal. Slacken the locking nut and turn the stop screw until you obtain the correct height.

  • Page 136: Travel

    CHECKING AND ADJUSTING THE CLUTCH PEDAL TRAVEL Turn the clutch adjustment nut "b" until you obtain the correct play B in the pedal. After adjusting the play B in the pedal, check the height A of the pedal. Tighten the parking brake lever and fit a wheel chock. Start the engine and let it run at idle.

  • Page 137: Mt (Toyota) Manual Gearbox

    SPECIFICATIONS OF MT (TOYOTA) MANUAL GEARBOX Gearbox Vehicle Engine Gearbox type Torque ratio Drive ratio identification MT (*) C 551 MMT (**) C 551.A 20 x 71 MT (*) C 551 (*) MT = Manual gearbox (**) MMT = Piloted manual gearbox...

  • Page 138: Mt (Toyota) Manual Gearbox

    SPECIFICATIONS OF MT (TOYOTA) MANUAL GEARBOX Identification "a" identification zone for gearbox no. Reference : C 551 : Petrol engine version C 552 : Diesel engine version Description (1) 5th gear synchroniser. (2) 3rd/4th gear synchroniser. (3) Gearbox casing. (4) Reverse gear motor pinion. B2C2011D (5) Clutch housing.

  • Page 139: Toyota) Manual Gearbox

    TIGHTENING TORQUES FOR MT (TOYOTA) MANUAL GEARBOX Tightening torques (m.daN) Ref. Description Number of screws Tightening Closing plate fixing 4 ± 0,4 Fixing of gearbox on engine 6,4 ± 0,6 Fixing of gearbox support on body 5,2 ± 0,5 Fixing of clutch fork support 3,3 ±...
  • Page 140 TIGHTENING TORQUES FOR MT (TOYOTA) MANUAL GEARBOX Tightening torques (m.daN) Ref. Description Number of screws Tightening Fixing of gear controls plate 1,8 ± 0,2 Reverse gear switch 4 ± 0,4 Drain plug 2,9 ± 0,3 Filler plug 3,9 ± 0,4 Locking finger 3,7 ±...
  • Page 141 TIGHTENING TORQUES FOR MT (TOYOTA) MANUAL GEARBOX Tightening torques (m.daN) Description Number of screws Tightening Fixings of gearbox casing and clutch 2,9 ± 0,3 housing B2C201HD...

  • Page 142: Toyota) Manual Gearbox

    DRAINING AND FILLING : MT (TOYOTA) MANUAL GEARBOX Presentation (1) gearbox drain plug. (2) filler and level plug. Oil quality Refer to the manufacturer’s instructions. Oil quantity After draining : 1.7 litres. B2C2000D...

  • Page 143: Mmt Piloted Manual Gearbox

    RECOMMENDATIONS / PRECAUTIONS : MMT PILOTED MANUAL GEARBOX Safety requirements ESSENTIAL : Given the special features of the MMT piloted manual gearbox, observe the requirements detailed below. IMPERATIVE : Always disconnect the battery negative terminal before operating on the actuators (*). NOTE : (*) After disconnecting the battery, never try to remove the clutch actuator on the vehicle before having checked that it is in the closed position (rod pushed in).
  • Page 144 RECOMMENDATIONS / PRECAUTIONS : MMT PILOTED MANUAL GEARBOX Repairs on the gearbox Gearbox removed : position a block (1) so as not to damage the gear sensor (2). Operations on electrical components : Do not disconnect : - The battery when the engine is running. - The ECU with the ignition switched on.
  • Page 145 RECOMMENDATIONS / PRECAUTIONS : MMT PILOTED MANUAL GEARBOX Driving Never push the vehicle to attempt to start it (impossible with a piloted manual gearbox. Towing Conditions for towing: It is necessary to lift the front of the vehicle to tow it, after having positioned the gear lever in neutral.

  • Page 146: Mmt Piloted Manual Gearbox

    RECOMMENDATIONS / PRECAUTIONS : MMT PILOTED MANUAL GEARBOX From the diagnostic tool menus, select : « DIAGNOSIS » MMT piloted manual gearbox. Actuator test. Gearbox actuator test. Engage N (neutral). NOTE : The letter «N» should appear on the instrument panel. If not, see the following solution: Engaging of «N», without using a diagnostic tool..

  • Page 147: Specifications

    SPECIFICATIONS OF MMT (TOYOTA) PILOTED MANUAL GEARBOX Identification "a" gearbox no. identification zone. Ref. C 551-A (piloted). Presentation (1) 5th gear synchroniser. (2) 3rd/4th gear synchroniser. (3) Gearbox casing. (4) Reverse gear motor pinion. (5) Clutch housing. (6) Primary shaft. B2C201JD (7) Secondary shaft.

  • Page 148: Specifications

    SPECIFICATIONS OF MMT (TOYOTA) PILOTED MANUAL GEARBOX Description (19) Reversing lamps sensor. (20) Gear engaged sensor. (21) Gearbox input speed sensor. (22) Gearbox actuator. B2C201KD (23) Electric motor for clutch actuator. (24) Clutch actuator. (25) Electric motor for gearbox actuator selection. (26) Electric motor for gearbox actuator engagement.

  • Page 149: Specifications

    SPECIFICATIONS OF MMT (TOYOTA) PILOTED MANUAL GEARBOX Clutch actuator Description (27) Declutch angular sensor. (28) Electric motor for clutch actuator. (29) Push rod. (30) Clutch actuator body. (31) Declutch fork. Features IMPERATIVE : Before each removal and after each refitting of the gearbox actuator, use a diagnostic tool B2C201MD to perform an initialisation (see corresponding operation).

  • Page 150: Specifications

    SPECIFICATIONS OF MMT (TOYOTA) PILOTED MANUAL GEARBOX "b" Selection. "c" Engagement. Features IMPERATIVE : Perform an initialisation of the gearbox actuator after refitting (see corresponding operation). (37) Gear engagement screw. "d" Neutral. B2C201PD "e" 1st, 3rd, 5th. "f" 2nd, 4th, Reverse. IMPERATIVE : Before refitting a gearbox actuator, check that it is in "neutral"...
  • Page 151 TIGHTENING TORQUES FOR MMT (TOYOTA) PILOTED MANUAL GEARBOX Tightening torques (m.daN) Ref. Description Number of screws Tightening Clutch actuator fixing screws 1,7 ± 0,1 Gearbox actuator fixing screws 1,8 ± 0,1 B2C202KD B2C202LD...
  • Page 152 TIGHTENING TORQUES FOR MMT (TOYOTA) PILOTED MANUAL GEARBOX Tightening torques (m.daN) Ref. Description Number of screws Tightening Reversing lamps sensor 4 ± 0,4 Gear engaged sensor Fixing screw for gearbox input speed 0,8 ± 0,1 sensor Drain plug 2,9 ± 0,3 Oil level plug 3,9 ±...
  • Page 153 TIGHTENING TORQUES FOR MMT (TOYOTA) PILOTED MANUAL GEARBOX Tightening torques (m.daN) Ref. Description Number of screws Tightening Differential gearwheel fixing screws 12,4 ± 1,2 Fork fixing screws 1,6 ± 0,2 Fixing screw for reverse gear shaft plate 1,7 ± 0,2 Closing panel fixing screw 4 ±...
  • Page 154 DRIVESHAFTS - GEARBOX Tightening torques (m.daN) Gearbox oil seal mandrels Driveshaft Driveshaft Gearbox Engines RH side LH side Toolkit Vehicles bearing 21,6 ± 0,5 (-).0345.A (-).0345.B Tightening torque (m.daN) for wheel bolts : C1 = 10 m.daN.

  • Page 155: Wheels And Tyres

    WHEELS AND TYRES Standard fit Spare wheel Tyres Rims Wheels Engines (Circumference) Tyre Wheel 155/65 R14 75T 155/65 R14 75T Steel 4 1/2 J14 H2 Steel 4 1/2 J14 H2 All types 1,699 m 1,699 m Inflation pressures Normal operating pressure Pressure under load (maximum) Pressure (Bars) Pressure (Bars)

  • Page 156: Axle Geometry

    AXLE GEOMETRY Conditions for checking and adjusting Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point (see corresponding operation). Vehicle heights at reference height B3B200ED Front height Rear height H1 = R1 - L1 H2 = R2 - L2 H1 = Measurement between the measuring zone underneath the front sub- H2 = Measurement between the measuring zone underneath the rear sill...
  • Page 157 AXLE GEOMETRY B3B200DD Measuring front height Measuring rear height [1] Gauge for measuring the wheel radius, 4 bolts, tool 4801-T Value at reference Value at reference height L1 = 88 mm height L2 = 22 mm (+ 6 - 8 mm) (+ 10 - 6 mm) Compress the suspension to obtain the calculated values.

  • Page 158: Front Axle

    AXLE GEOMETRY Front axle Rear axle Dissymmetry of lower castor at 0°30’. Dissymmetry of lower camber at 0°30’. Dissymmetry of lower camber at 0°30’. All Types CFA - 8HT CFA - 8HT Tyres 155/65 R 14 Pivot Castor Camber Vehicule Tracking angle Tracking...

  • Page 159: Front Axle

    SPECIAL FEATURES : FRONT AXLE Tracking adjustment IMPERATIVE : Distribute the total tracking value symme- trically between the LH wheel and the RH wheel. Remove the clip (1). Slacken the nut (3). Adjust the rod (2). Tighten the nut (3) : 4,7 ±...

  • Page 160: Front Axle

    SPECIFICATIONS : FRONT AXLE Subframe (1) subframe. (2) suspension arm. Subframe in two steel shells, fixed by means of six screws on the body, with a yoke for the lower engine suspension rod and lateral yokes (2 LH + 2 RH) for the suspension arm fixings. The two rear fixing points for the subframe, under the floorpan, are via two link brackets (LH/RH) welded on the subframe.
  • Page 161 TIGHTENING TORQUES : FRONT AXLE Tightening torques (m.daN) Ref. Description Tightening Damper upper cup fixing nut 5,5 ± 0,5 Damper Anti-roll bar bearing fixing 1,8 ± 0,2 Anti-roll bar Pivot lower ball-joint nut 9,8 ± 1 Hub nut 21,6 ± 2 Steering ball-joint on pivot 3,3 ±...
  • Page 162 SPECIFICATIONS : REAR AXLE Rear axle. (1) Rear axle crossmember. (2) Rear hub. (3) Rear axle rubber bush. Machine-welded rear axle, of trailing arm type with deformable axle crossmember. Engines all types B3D200DD Thickness of crossmember panel : 5,5 mm Rear hub (2) Rear hub.

  • Page 163: Tightening Torques : Rear Axle

    TIGHTENING TORQUES : REAR AXLE Tightening torques (m.daN) Ref. Description Tightening Damper upper fixing 2,5 ± 0,2 Damper lower fixing 4,8 ± 0,4 Fixing of yoke on rear axle 12,3 ± 1,2 Fixing of rear hub on rear axle 6 ± 0,6 B3D200FD...

  • Page 164: Suspension

    SUSPENSION SPECIFICATIONS Front axle Anti-roll bars Engines all types : 22 mm Travel stop Travel stop height A : 96 mm. Rear axle Rear axle crossmember Machine-welded rear axle, of trailing arm type with deformable axle crossmember. Engines all types : 5,5 mm Suspension spring During a repair on a suspension spring.

  • Page 165: Tightening Torques: Suspension

    SUSPENSION TIGHTENING TORQUES Tightening torques (m.daN) Ref. Description Tightening Damper upper cup fixing nut 5,5 ± 0,5 Anti-roll bar fixing 1,8 ± 0,2 Pivot lower ball-joint nut 9,8 ± 0,9 Hub nut 21,6 ± 2,1 Steering ball-joint on pivot 3,3 ± 0,3 Suspension leg fixing on pivot 4,8 ±...
  • Page 166 SUSPENSION TIGHTENING TORQUES Tightening torques (m.daN) Ref. Description Tightening Damper upper fixing 2,5 ± 0,2 Damper lower fixing 4,8 ± 0,4 Fixing of rear axle on body 12,3 ± 1,2 Fixing of rear hub on rear axle 6 ± 0,6 B3D200GD...

  • Page 167: Manual Steering

    MANUAL STEERING SPECIFICATIONS Manual steering (5) steering wheel fixing. (6) fixing of steering column on support. (7) fixing of upper steering cardan. (8) fixing of lower steering cardan. B3E2006D Steering mechanism Number of turns of the steering wheel : 3,27 Steering rack travel (mm) : 2 x 70,2 Steering ratio...

  • Page 168: Power Steering

    POWER STEERING SPECIFICATIONS Top of column (1) driver’s airbag. (2) steering wheel. (3) rotary switch. (4) controls under steering wheel. Steering column B3E2004D Electric power steering (5) steering wheel fixing. (6) fixing of steering column on support. (7) fixing of upper steering cardan. (8) fixing of lower steering cardan.

  • Page 169: Power Steering

    POWER STEERING SPECIFICATIONS Steering assistance Supplier : KOYO. Electric motor : 33 A. The steering assistance is provided by the electric assistance motor (9), controlled by an ECU. Power delivered to the electric assistance motor (9) depends on: - Vehicle speed. - Engine speed.
  • Page 170 POWER STEERING TIGHTENING TORQUES Tightening torques (m.daN) Ref. Description Tightening Steering wheel fixing 5 ± 0,5 Fixing of steering column on support 2,5 ± 0,2 Fixing of upper steering cardan 3,5 ± 0,3 Fixing of lower steering cardan 3,5 ± 0,3 Fixing of ball-joint on pivot 3,3 ±...

  • Page 171: Setting The Steering Rack Mid-Point

    SETTING THE STEERING RACK MID-POINT IMPERATIVE : Respect the precautions that must be taken prior to a repair. Preliminary operation Raise and support the vehicle on a 2-column lift. Remove the clips (1) and (2). Detach the steering rack protection gaiter. Setting Turn the steering wheel to full LH lock.

  • Page 172: Brake Specifications

    BRAKE SPECIFICATIONS 1.0i 1.4 HDi Engine type Master Cylinder 20,64 Master vac 228,6 Ø BOSCH 48 mm Caliper make / piston Plain Disc Ventilated Disc thickness/minimum thickness 20/18 Brake pad supplier / grade JURID 682 Drum Ø 200/201 mm Original/maximum/width Lining supplier / grade FERODO 3627 F...
  • Page 173 BRAKE SPECIFICATIONS Braking system Braking circuit in the form of an X. Ventilated disc brakes at the front, drum brakes at the rear. NOTE : The front brake pads have no wear warning lamp. Handbrake lever controlled by cables acting on the rear wheels.

  • Page 174: Brake Specifications

    BRAKE SPECIFICATIONS Hydraulic valve block Make : BOSCH. Type : ABS REF 8.0. Installed on the master cylinder B3F2020D...

  • Page 175: Tightening Torques: Brakes

    TIGHTENING TORQUES : BRAKES Front brakes Tightening torques (m.daN) Ref. Description Tightening Front brake disc Yoke on brake caliper 3 ± 0,3 Brake pipe unions 3 ± 0,3 Front brake caliper 8,9 ± 0,9 ABS hydraulic valve block support 1,9 ± 0,2 Front wheel sensor 0,8 ±...
  • Page 176 TIGHTENING TORQUES : BRAKES Front brakes Tightening torques (m.daN) Ref. Description Tightening Master-cylinder 2 ± 0,2 Braking amplifier 2 ± 0,2 Handbrake lever 2,2 ± 0,2 B3F201XD Handbrake B3F201YD...
  • Page 177 TIGHTENING TORQUES : BRAKES Rear brakes Tightening torques (m.daN) Ref. Description Tightening Rear brake drum Rear hub support 5,5 ± 0,5 Brake pipe unions 1,5 ± 0,1 Wheel cylinder 0,8 ± 0,1 Rear wheel sensor 0,8 ± 0,1 B3F201UD B3F201WD...

  • Page 178: Checking The Brake Pedal

    CHECKING THE BRAKE PEDAL IMPERATIVE : Respect the safety and cleanliness requirements. Height A of the brake pedal in relation to the floor (engine running) : 135,8 to 145,8 mm for left hand drive models 121,6 to 131,6 mm for right hand drive models If the pedal height is not correct, adjust it.
  • Page 179 CHECKING THE BRAKE PEDAL Do up the stoplamps switch (1) in its support (3) until it is flush with the brake pedal (4). IMPORTANT : Do not press on the brake pedal. "a" : shaft. Make a quarter turn to secure the stoplamps switch (1) in place. IMPORTANT : Do not press on the brake pedal.
  • Page 180 CHECKING THE BRAKE PEDAL Press several times on the brake pedal until any vacuum in the braking amplifier disappears totally (engine stopped). Press on the pedal until you feel the start of resistance. Measure the play as indicated in the dia- gram.

  • Page 181: Checking The Braking Amplifier

    CHECKING THE BRAKING AMPLIFIER IMPERATIVE : Respect the safety and cleanliness requirements. A : in conformity. B : not in conformity. Check the air-tightness. Start the engine. Stop the engine 1 or 2 minutes later. Press several times but slowly on the brake pedal.
  • Page 182 CHECKING THE BRAKING AMPLIFIER C : circulation of air. D : absence of circulation of air. In the event of a fault, replace the vacuum hose. Refit the vacuum hose. B3F201AD...

  • Page 183: Checking The Vacuum Pump

    CHECKING THE VACUUM PUMP Tools [1] Pressure tester : (-).1602.A Coffret S.1602 [2] Pressure take-off union : (-).1602.B Checks Remove : The windscreen wiper arm mounting cap The windscreen wiper arm The upper seal between bonnet and scuttle panel The top scuttle panel ventilation grilles The wiper motor The scuttle panel Locate the vacuum pipe (1) between the vacuum pump and the braking amplifier.
  • Page 184 CHECKING THE VACUUM PUMP Insert the union [2] between the vacuum pump and the braking amplifier. Connect the tool [1] on the union [2]. Run the engine at idling speed. Check the vacuum value. Remove the tools. Uncouple the vacuum pipe at "a". Refit : The screw (2) The scuttle panel...

  • Page 185: Adjusting The Handbrake

    ADJUSTING THE HANDBRAKE The handbrake adjustment is under the central console. IMPERATIVE : Respect the safety and cleanliness requirements. Adjust the handbrake shoe clearance. Check the travel of the handbrake lever. Slowly pull the handbrake lever to the maximum high position, counting the number of clicks. Travel of the handbrake lever : 5 to 8 clicks at 196 N.

  • Page 186: Draining, Filling, Bleeding The Braking

    DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM Tools [1] Generic bleeding apparatus «LURO» or similar IMPERATIVE : Respect the safety and cleanliness requirements. NOTE : Bleeding of the secondary braking circuit is done with the aid of a diagnostic tool.. Draining Disconnect the negative terminal of the battery.
  • Page 187 DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM Drain the brake fluid reservoir (1) to the maximum (if necessary, use a clean syringe). Disconnect the connector at "a". Remove the brake fluid reservoir (1), by moving aside the tabs at "b" of the pins (2). Clean the brake fluid reservoir (1).
  • Page 188 DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM Front brake caliper : Bleed screw (3). Rear brake caliper : Bleed screw (4). Bleed each brake cylinder, proceeding in the following sequence : Front LH wheel. Front RH wheel. Rear LH wheel. Rear RH wheel.
  • Page 189 DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM Bleeding the braking circuit without the bleed apparatus NOTE : Two operators are necessary. For each brake circuit: Apply the brake pedal to place the circuit under pressure. Couple a transparent tube on the bleed screw. Submerge the other end of the tube in a clean container.

  • Page 190: Air Conditioning

    AIR CONDITIONING R 134 a (HFC) Compressor Refrigerant Fixed Vehicule Engines Date refill (± 30 gr) Capacity (fan) quantity cc reference 384/F 06/05 ➔ ➔ VALEO/ZEXEL VALEO/ZEXEL DV4TD DKV-06R ZXL 200PG...

  • Page 191: Air Conditioning Circuit

    SPECIFICATIONS OF AIR CONDITIONING CIRCUIT (R 134.a) Compressor/condenser (1) Air conditioning compressor drive plate. (2) Connector. C5H2021D (3) Seals. (3) Seals. (4) Condenser. (5) Filtering cartridge. (6) Condenser inlet. (7) Condenser outlet. C5H2022D...

  • Page 192: Air Conditioning Circuit

    SPECIFICATIONS OF AIR CONDITIONING CIRCUIT (R 134.a) Pressure reducer (8) Pressure reducer inlet. (9) Pressure reducer outlet. (3) Seals. Lubricant WARNING : As these oils have a pronounced tendancy to absorb moisture, avoid stocking them in containers that have been opened. Type of oil used : ZXL 200PG.

  • Page 193: Pollen Filter

    SPECIAL FEATURES : AIR CONDITIONING CIRCUIT (R 134.a) Pollen filter The pollen filter is located in the passenger compartment under the dashboard (on RH side). Remove the pollen filter (1). C5H202HD Refitting Clean the pollen filter housing. Fit a new pollen filter. Check the flow of air through the air blower, operating it at its different speeds.

  • Page 194: Filtering Cartridge

    SPECIAL FEATURES : AIR CONDITIONING CIRCUIT (R 134.a) Filtering/drying cartridge Removing Remove the condenser (see corresponding operation). C5H2006D Remove the screw and the support. Remove the screw and the filtering/drying cartridge. Remove the 4 O-ring seals from the condenser. C5H2007D...
  • Page 195 SPECIAL FEATURES : AIR CONDITIONING CIRCUIT (R 134.a) Filtering/drying cartridge Refitting Lubricate 4 new O-ring seals, as well as the contact surface of the filtering/drying cartridge, using compressor oil. Compressor oil : ZXL 200PG or equivalent. C5H2008D Fit the 4 O-ring seals on the condenser. Refit the filtering/drying cartridge, with the screw.

  • Page 196: Aircon Circuit : Cfa Engine

    AIR CONDITIONING CIRCUIT R 134.a Engine : 384F (10) Low pressure valve. (11) High pressure valve. (12) Pressostat. a) Pressure reducer outlet : 1 ± 0,1 b) Pressure reducer inlet : 1 ± 0,1 c) Condenser outlet : 1 ± 0,1 d) Aircon compressor inlet : 1 ±...

  • Page 197: Aircon Circuit : 8Ht Engine

    AIR CONDITIONING CIRCUIT R 134.a Engine : DV4TD (10) Low pressure valve. (11) High pressure valve. (12) Pressostat “a” Pressure reducer outlet : 1 ± 0,1 “b” Pressure reducer inlet : 1 ± 0,1 “c” Condenser outlet : 1 ± 0,1 “d”...

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2005 c1

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