Page 1 2002 «The technical information contained in this document is intended for the exclusive use of the trained personnel of the motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full responsibility to the exclusion of that of the manufacturer».
Page 2 PRESENTATION THIS HANDBOOK summarises the specifications, adjustments, checks and special features of the CITROEN C3. The handbook is divided into the following sections representing the main functions : GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH - GEARBOX - DRIVESHAFTS - AXLES - SUSPENSION - STEERING - BRAKES -...
Page 3: Identification Of Vehicles
IDENTIFICATION OF VEHICLES A : Chassis stamp (cold stamp on bodywork). B : Manufacturer’s data plate. (on the LH centre pillar) C : A-S / RP No. and RP paint code (label on front pillar close to driver’s door). D : Inflation pressures and tyre references. (label on front pillar close to driver’s door) E : Serial no.
Page 4 IDENTIFICATION OF VEHICLES PETROL 1.1i X-SX IFL5 L4/INF K’ Emission standard FN HFXC FC HFXC FC HFXB FC HFXB/T FR HFXB FN HFXB FC HFXB FC HFX5 Type code Engine type 1124 Cubic capacity (cc) Fiscal rating (hp) MA/5N Gearbox type 20 CF 14 Gearbox ident.
Page 5 IDENTIFICATION OF VEHICLES PETROL 1.4i Auto. Auto. Auto. SX – Exclusive IFL5 Emission standard FC KFVE FN KFVB FN KFVE FC KFVC/IF FC KFVF/IF FN KFVC/IF Type code Engine type 1360 Cubic capacity (cc) Fiscal rating (hp) MA/5N MA/5N MA/5N Gearbox type 20 CF 15 20 CF 15...
Page 6 IDENTIFICATION OF VEHICLES PETROL 1.4i 1.6i 16V Auto. SX – Exclusive IFL5 L4/INF Emission standard FN KFVF/IF FC KFVB FC KFVB/D FC KFVE/D FN NFUB FC NFUB Type code Engine type 1360 1587 Cubic capacity (cc) Fiscal rating (hp) MA/5N MA/5S Gearbox type 20 TP 75...
Page 7 IDENTIFICATION OF VEHICLES DIESEL 1.4 HDi X - SX Emission standard FC 8HBXB/T FN 8HXB FC 8HXB FC 8HXB/MOD FC 8HXK FR 8HXB Type code Engine type 1398 Cubic capacity (cc) Fiscal rating (hp) MA/5O Gearbox type 20 CN 33 20 CN 36 (*) Gearbox ident.
Page 8 IDENTIFICATION OF VEHICLES DIESEL TED4 1.4 HDi 1.4 HDi 16V S - SX SX - Exclusive Emission standard FN 8HWK FC 8HWB FN 8HVB FC 8HVB Type code Engine type 1398 Cubic capacity (cc) Fiscal rating (hp) MA/50 BE4/5 Gearbox type 20 CN 33 20 CN 36 (*) 20 DM 25...
Page 9 IDENTIFICATION OF VEHICLES DIESEL TED4 1.4 HDi 16V SX - Exclusive SX - Exclusive Emission standard FN 8HYB FC 8HYC FC 8HYB/MOD FC 8HYB/T FC 8HYK FR 8HYB Type code Engine type 1398 Cubic capacity (cc) Fiscal rating (hp) BE4/5 Gearbox type 20 DM 25 20 DM 26...
Page 10 IDENTIFICATION OF VEHICLES Manufacturer’s plate. The manufacturer’s plate carries the following information : (a) Type approval number (*). (b) Type serial number. (c) Gross vehicle weight (*). (d) Gross vehicle weight (*). (e) Maximum weight on front axle (*). (f) Maximum weight on rear axle (*). (g) Manufacturer identification.
Page 11 IDENTIFICATION OF VEHICLES Factory code. Structure The factory code is composed of 6 figures or letters. F = Vehicle family. Example : F.C.8.H.Y.B : C = Body shape. 8.H.Y = Engine. B = Version. Body shape Family Ref. Family Ref. Body shape CITROËN C3 5 door saloon...
Page 12 GENERAL SPECIFICATION : DIMENSIONS E1AP09KD...
Page 13 GENERAL SPECIFICATION : DIMENSIONS Exterior dimensions (mm) Vehicles All types Wheelbase 2460 Length overall 3850 Front overhang Rear overhang Rear track on the ground 1435 Front track on the ground 1438 Width overall 1667 Height overall (*) 1521 ODM = Vehicle in running order (vehicle empty, levels topped up). Interior dimensions and volumes (mm) Elbow width, front 1406...
Page 14 GENERAL SPECIFICATION : WEIGHTS Petrol Diesel Manual Auto. Manual Versions 1.1i 1 4i 1.6i 1.4i 1.4 HDi 1.4 HDi 16V Engine type Gearbox type MA/5N MA/50 BE4/5 Payload Weight empty in Without options 1053 1080 1133 1114 1097 1147 running order With all options 1138 1147...
Page 15 OPERATIONS TO BE CARRIED OUT AFTER A REPAIR IMPERATIVE : All these operations are to be performed following a reconnection of the battery. Antiscanning function. It is necessary to wait 1 minute after the battery has been disconnected in order to be able to start the vehicle. Tailgate.
Page 16 OPERATIONS TO BE CARRIED OUT AFTER A REPAIR Sun roof. The anti-pinch function has to be re-initialised. Place the sun roof switch in the maximum tilt position. Keep the sun roof switch pressed until the sun roof ceases its movement. Release the sun roof switch within 5 seconds.
Page 17 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 pro- Rear towing tection box inside the spare wheel.
Page 18 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. In the event of impossibility to raise the front of the vehicle : ESSENTIAL : Never tow the vehicles with wheels hanging - It is ESSENTIAL to place the selection lever in position «N».
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) Lifting with the handle jack at the front Lifting on a two-column lift using the jack supports E2AP01NC E2AP01QD Lifting with the handle jack at the rear Lift accessory with blocks on the jack supports NOTE : The handle jack is specific to the vehicle, do not use it for any other purposes.
Page 21 CAPACITIES (in litres) Draining method. Oil capacities are defined as below. 1/ Vehicle on horizontal ground (in the high position, if hydropneumatic suspension). 2/ Engine warm (oil temperature 80°C). 3/ Drain oil sump + remove filter cartidge (time for draining to last drops = 15 minutes). 4/ Refit drain plug + filter cartridge.
Page 22 CAPACITIES (in litres) Petrol Diesel 1.1i 1.4i 1.6i 16V 1.4 HDi 1.4 HDi 16V Auto. Engine type Drain by gravity : engine with filter change Between Min. and Max. Drain by suction : engine with filter change Between Min. and Max. 5-speed gearbox Automatic gearbox After oil change...
Page 23 LUBRICANTS – TOTAL recommended oils S.A.E. Norm - Table for selection of engine oil grade E4AP006D...
Page 24: Total Quartz
LUBRICANTS – TOTAL recommended oils ESSENTIAL : For all vehicles with a 30.000 km (20.000 miles) Factory evolutions in 2001 model year maintenance interval, use exclusively TOTAL ACTIVA/QUARTZ 7000 or 9000 or any other oils offering identical specifications CITROËN engines are lubricated at the factory with TOTAL oil of to these.
Page 25: Blended Oils For All Engines, Permitting Fuel Economy
LUBRICANTS – TOTAL recommended oils Selection of engine oil grades recommended for climatic conditions in countries of distribution ACEA Norms API Norms The first letter corresponds to the type of engine concerned : The first letter corresponds to the type of fuel used by the engine : A : petrol and dual fuel petrol / LPG engines.
Page 26 TOTAL ACTIVA (France only). TOTAL QUARTZ (Outside France). ESSENTIAL : To preserve engine performances, all engines fitted in CITROEN vehicles must be lubricated with high quality oils (synthetic or semi-synthetic) Summary Engine oil norms to be respected in 2001 model year...
Page 27: Table Of Contents
LUBRICANTS – TOTAL RECOMMENDED OILS S.A.E. grades SPI norms ACEA norms Blended oils for all engines (petrol, dual-fuel petrol / LPG and diesel) TOTAL ACTIVA 9000 5W-40 SJ / CF A3-98 / B3-98 TOTAL QUARTZ 9000 TOTAL ACTIVA 9000. (*) 5W-30 SJ / CF EC A1-98 / B1-98...
Page 28 LUBRICANTS – TOTAL RECOMMENDED OILS FRANCE Blended oils for all engines, supplied in bulk Metropolitan FRANCE TOTAL ACTIVRAC S.A.E : 10W-40 Norms TOTAL ACTIVA DIESEL TOTAL ACTIVA Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 9000 5W-40...
Page 29: Table Of Contents
LUBRICANTS – TOTAL RECOMMENDED OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ DIESEL (*) = Blended oils for all engines, Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines permitting fuel economy engines dual-fuel petrol / LPG engines 7000 10W-40 Germany 9000 0W-40...
Page 30: Table Of Contents
LUBRICANTS – TOTAL RECOMMENDED OILS EUROPE (continued) TOTAL QUARTZ TOTAL QUARTZ DIESEL (*) = Blended oils for all engines, Oils specifically for petrol and Oils specifically for diesel Blended oils for all engines permitting fuel economy dual-fuel petrol / LPG engines engines 7000 10W-40 Greece...
Page 31: Table Of Contents
LUBRICANTS – TOTAL RECOMMENDED OILS EUROPE (continued) TOTAL QUARTZ TOTAL QUARTZ DIESEL (*) = Blended oils for all engines, per- Oils specifically for petrol and Oils specifically for diesel Blended oils for all engines mitting fuel economy dual-fuel petrol / LPG engines engines 7000 10W-40 Czech Republic...
Page 32: Total Quartz Diesel
LUBRICANTS – TOTAL RECOMMENDED OILS TOTAL QUARTZ DIESEL TOTAL QUARTZ Oils specifically for petrol and Oils specifically for diesel Blended oils for all engines dual-fuel petrol / LPG engines engines Australia OCEANIA 7000 10W-40 New-Zealand Ivory Coast Egypt Gabon Madagascar AFRICA Morocco 7000 10W-40...
Page 33 LUBRICANTS – TOTAL RECOMMENDED OILS TOTAL QUARTZ DIESEL TOTAL QUARTZ (*) = Blended oils for all engines, permitting Oils specifically for petrol and Oils specifically for diesel Blended oils for all fuel economy engines dual-fuel petrol / LPG engines engines 7000 10W-40 China 7000 15W-50...
Page 34 LUBRICANTS – TOTAL RECOMMENDED OILS TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for petrol and Oils specifically for diesel Blended oils for all engines dual-fuel petrol / LPG engines engines Saudi Arabia Bahrain Dubai United Arab Emirates Iran Israel MIDDLE 9000 5W-40 7000 15W-50 7000 10W-50...
Page 35 LUBRICANTS – TOTAL RECOMMENDED OILS Gearbox oils TOTAL TRANSMISSION BV Norms S.A.E 75W-80 Manual gearbox Special oil distributed by CITROËN (Part No. 9730 A2) TOTAL FLUIDE ATX or TOTAL FLUIDE AT 42. All countries MB3 automatic gearbox Special oils distributed by CITROËN (Part No.
Page 36 CITROEN reference 0.5 litre 9979 05 CITROEN Fluid All countries 1 litre 9979 06 5 litres 9979 07 CITROEN hydraulic circuit fluid Norm Pack CITROEN reference ISO 7308-7309 ZCP 830 095 TOTAL LHM PLUS Green in colour 1 litre 9979.20 (Scandinavia)
Page 37 LUBRICANTS – TOTAL RECOMMENDED OILS Wash/wipe fluid Packs CITROEN reference Concentrated : 250 ml 9980 33 ZC 9875 953 U 9980 56 All countries Liquid ready to use: 1 litre 9980 06 ZC 9875 784 U Liquid ready to use: 5 litres...
Page 38 ENGINE OIL CONSUMPTION I - Oil consumption depends on : - the engine type. - how run-in or worn it is. - the type of oil used. - the driving conditions. II - An engine can be considered RUN-IN after: - 3.000 miles (5.000 km) for a PETROL engine.
Page 39: Engine Specifications
ENGINE SPECIFICATIONS Petrol Diesel 1.1i 1.4i 1.6i 16V 1.4 HDi 1.4 HDi 16V Engine type 1124 1360 1587 1398 Cubic capacity (cc) 72/69 75/77 78/82 73/82 Bore / Stroke 10.5/1 11/1 17.9/1 18.25/1 Compression ratio 44-5500 54-5400 80-5800 50-4000 66-4000 Power ISO or EEC KW - rpm) 61-5500 75-5400...
Page 40 ENGINE SPECIFICATIONS Engines : HFX - KFV - NFU Engine identification A = Engines: HFX - KFV B = Engine: NFU. Compulsory engine identification in zone «a» : - Component reference. - Engine legislation type. - Factory serial no. B1BP10JC B1BP2GKC...
Page 41 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Crankshaft Engine types Accessories drive pulley 0.8 ± 0.2 Pinion fixing on crankshaft 10 ± 1 2.5 ± 0.2 Cylinder block Sump 0.8 ± 0.2 Timing belt tensioner roller 2 ± 0.2 2.2 ± 0.2 Accessories belt tensioner roller 2 ±...
Page 42 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Flywheel - Clutch Engines Flywheel 6.7 ± 0.6 + LOCTITE FRENETANCH Clutch mechanism 2 ± 0.2 Lubrication circuit Oil pressure switch 2 ± 0.2 Oil pump 0.9 ± 0.1 Cooling circuit Coolant pump 1.4 ± 0.1 Coolant outlet housing 0.8 ±...
Page 43 CYLINDER HEAD Engines : HFX - KFV - NFU Identification of cylinder head gasket Engine types Thicknesses (repair) Thickness references Thicknesses (Standard) 1.4 ± 0.1 1.2 ± 0.1 0.66 ± 0.04 References 1,2,3,4 = Type of engine. A,B,D = Suppliers. = Gasket material.
Page 44 CYLINDER HEAD Engines : HFX - KFV - NFU Cylinder head tightening (m.daN) Cylinder head bolts HFX - KFV Tightening 2 ± 0.2 Angular tightening 240° ± 5° (In the order 1 to 10) Tightening 2 ± 0.2 Angular tightening 260°...
Page 45 ENGINE SPECIFICATIONS Engines : 8HX - 8HW Engine identification "a" Engine legislation type. "b" Component reference. "c" Factory serial no. B1CP0BKD...
Page 46 CYLINDER HEAD Engines : 8HX - 8HW Cylinder head tightening (m.daN) Cylinder head bolts 8HX - 8HW Pre-tightening 2 ± 0.2 m.daN Tightening 4 ± 0.4 m.daN Angular tightening 230° ± 5° (In the order 1 to 10) NOTE : - The bolts should have been tho- roughly cleaned and dried with a dry metal brush.
Page 47 ENGINE SPECIFICATIONS Engines : 8HY - 8HV Engine identification "a" Engine legislation type. "b" Component reference. "c" Factory serial no. B1CP0BKD...
Page 48 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Crankshaft Engines 8HY-8HV Bearing cap fixing screw Tightening 3 ± 0.3 Angular tightening 140° ± 1°.4' Crankshaft pullet hub Tightening 3 ± 0.3 Angular tightening 180° ± 5° Cylinder block Oil sump 1 ± 0.1 Timing belt tensioner roller 4 ±...
Page 49 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Flywheel - Clutch Engines 8HY-8HV Flywheel 1.7 ± 0.2 Clutch mechanism 2 ± 0.2 Lubrication circuit Oil pump assembly 0.9 ± 0.1 Oil/coolant heat exchanger 1 ± 0.1 Turbocharger lubrication pipe 2.2 ± 0.2 Injection circuit Injector fixing flange nut Tightening...
Page 50 CYLINDER HEAD Engines : 8HY - 8HV Identification of cylinder head gasket Piston Thicknesses No. of notches No. of notches Engine types Supplier standproud (mm) at d at e (mm) Type of gasket : Metallic multilayer 0.675 to 0.725 1.25 0.726 to 0.775 1.30 "d"...
Page 51 CYLINDER HEAD Engines : 8HY - 8HV Cylinder head tightening (m.daN) Cylinder head bolts 8HY - 8HV Pre-tightening : 2 ± 0.2 Tightening : 4 ± 0.5 Angular tightening : 230 ° ± 5° (In the order 1 to 10) NOTE : - The bolts should have been thoroughly cleaned and dried...
Page 52 CAMSHAFT Engines : 8HY - 8HV Camshaft identification (1) - Inlet camshaft. (2) - Exhaust camshaft. "f" : Marking zone. B1EP18AD...
Page 53 BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE Tools 4122-T (C.TRONIC.105.5) 4099-T (C.TRONIC.105) B1EP135D...
Page 54 AUXILIARY EQUIPMENT DRIVE BELT Petrol Diesel TED4 Engine type 8HYX See pages : 53 to 54 55 to 56...
Page 55 AUXILIARY EQUIPMENT DRIVE BELT Engines : HFX - KFV - NFU Tools. [1] Pliers for removing plastic pegs : 7504-T. [2] Belt tension measuring instrument : 4122-T. Vehicle without air conditioning. Remove. Refit. Slacken: Refit the belt. Respect the following sequence: - Screw (2).
Page 56 AUXILIARY EQUIPMENT DRIVE BELT Engines : HFX - KFV - NFU Vehicle with air conditioning. Remove Slacken: - Screws (6), (4) and (5). - Fully detension the belt by acting on the tensioner roller. - Remove the accessories drive belt. Refit.
Page 57 AUXILIARY EQUIPMENT DRIVE BELT With compressor and alternator Engines : 8HX - 8HW Tools [1] Pliers for removing plastic pegs : 7504-T. [2] Tensioner roller compression lever : (-).0194.E. [3] Tensioner roller setting peg Ø4 mm : (-).0194.F. Removing. Disconnect the battery negative cable. Raise and support the vehicle, wheels hanging.
Page 58 AUXILIARY EQUIPMENT DRIVE BELT Engines : 8HX - 8HW Markings on the dynamic tensioner roller. "a" Position of «maximum wear» of the auxiliary drive belt. "b" Normal position. Refitting NOTE : Check that the tensioner roller moves freely (no tight spot). If this is not the case, replace the tensioner roller.
Page 59 AUXILIARY EQUIPMENT DRIVE BELT Engines : 8HY - 8HV Tools. [1a] Dynamic tensioner roller lever : (-).0194-E1. [1b] Lever extension : (-).0194-E2. [2] Accessories belt roller locking peg Ø 4 mm : (-).0194-F Removing Pivot the tensioner roller support (1) (clockwise), using tools [1a] and [1b] at «a». Remove the belt.
Page 60 CHECKING AND SETTING THE VALVE TIMING Petrol Diesel TED4 Engine type See pages : 59 to 68 69 to76 77 to 85...
Page 61 CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFV - NFU Tools. [1] Engine flywheel peg : 4507-T.A [2] Camshaft pulley peg : 4507-T.B [3a] Camshaft peg : 4533-TA.C1 [3b] Camshaft peg : 4533-TA.C2 [4] Dynamic tensioner roller pin : 4200-T.H [5] Belt retaining pin : 4533-T.AD...
Page 62 CHECKING AND SETTING THE VALVE TIMING Engine : NFU Checking the timing (continued) Engine: NFU Place a jack under the engine, peg the engine. Remove: - The engine support (4) complete. - The timing casing (3). - The sparking plugs (eases engine rotation). Turn the wheel to rotate the engine (normal direction of rotation).
Page 63 CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFV Setting the timing Preliminary operation. Lift and support the vehicle, wheels hanging. Disconnect the battery. Remove: - The front RH wheel. - The splash-shield, using tool [6] - The accessories belt (See corresponding operation). - The crankshaft pulley.
Page 64 CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFV Setting the timing (continued) HFX – KFV engines Slacken the screws (4) without removing them. Remove the bottom engine support assembly (5), and the fixing screws (4). Slacken the nut (6). Completely detension the belt by acting on the tensioner roller (7).
Page 65 CHECKING AND SETTING THE VALVE TIMING Engine : NFU NFU engine. Setting the timing (continued) Remove: The bottom plastic casing. The engine support (9). The middle support. The timing cover (8). Peg the flywheel, using tool [1]. Position the tools [3a] and [3b]. B1BP2MFC B1BP2MBC B1EP18MC...
Page 66 CHECKING AND SETTING THE VALVE TIMING Engine : NFU Setting the timing (continued) NFU Engine Slacken the tensioer roller. Turn the tensioner roller so as to be able to position the tool [4], with the aid of an Allen key placed at «a». Turn the tensioner roller towards the right to bring it to the index «c»...
Page 67 CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFV Setting the timing (continued) HFX-KFV Engines Refit. WARNING: Respect the direction of fitting of the belt: (the arrows «d» indicate the direction of rotation of the crankshaft). Refit the timing belt. Position the timing belt, belt «e»...
Page 68 CHECKING AND SETTING THE VALVE TIMING Engines : KFX - KFV - NFU Setting the timing (continued) HFX-KFV engines Refitting. NOTE : Check that the pegs [1] and [2] are in place. WARNING: Respect the direction of fitting of the timing belt, the arrows «d» indicate the direction of rotation of the crankshaft.
Page 69 CHECKING AND SETTING THE VALVE TIMING Engine : NFU Timing belt overtensioned: A : Engines HFX – KFV. B : Engine NFU Turn the tensioner roller (7) with the aid of a hexagonal spanner at «a». Bring the index «c» to position «f», to tension the belt to the maximum of the interval indicated.
Page 70 CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFV - NFU Adjusting the fitting tension of the timing belt A : Engines HFX – KFV. B : Engine NFU. Slacken the nut while maintaining the position of the tensioner roller, with the aid of a hexagonal spanner at «a».
Page 71 CHECKING AND SETTING THE VALVE TIMING Engines : 8HX - 8HW Tools. [1] Pliers for removing plastic pegs : 7504-T. [2] Lever for detensioning the dynamic tensioner roller : (-).0194.E [3] Engine flywheel setting peg :.(-).0194.C [4] Camshaft setting peg : (-).0194.B.
Page 72 CHECKING AND SETTING THE VALVE TIMING Engines : 8HX - 8HW Check ing the setting (continued) Remove: - the accessories drive belt. - the accessories drive pulley. - the lower timing cover (3). IMPERATIVE : The magnetic track should show no signs of damage and should not be approached by any other source of magnetism.
Page 73 CHECKING AND SETTING THE VALVE TIMING Engines : 8HX - 8HW Setting the timing. Remove the upper timing cover (1). Rotate the engine by means of the crankshaft screw (2). NOTE : The pegging hole is located under the crankshaft bearing cap cover. Peg the engine flywheel, using tool [3].
Page 74 CHECKING AND SETTING THE VALVE TIMING Engines : 8HX - 8HW Setting the timing (continued). Remove the tool [3]. Rotate the engine by means of the crankshaft pinion screw (2) (clockwise), to bring it to the pegging position. Peg the camshaft pulley, using tool [4]. Peg : - The crankshaft pinion (6), using tool [5].
Page 75 CHECKING AND SETTING THE VALVE TIMING Engines : 8HX - 8HW Setting the timing (continued). Hold the tensioner roller, using a hexagonal spanner at «b». Slacken the screw (9). Remove the timing belt (10). Refitting. IMPERATIVE : Check that both the tensioner roller and the fixed roller turn freely (no tight spots).
Page 76 CHECKING AND SETTING THE VALVE TIMING Engines : 8HX - 8HW Setting the timing (continued). NOTE : Screw (9) slackened. Position the timing belt (10) observing the following sequence: Crankshaft pinion (4). Guide roller (12). Camshaft pulley (11), (check that the belt is held correctly against the roller). Coolant pump pinion (13).
Page 77 CHECKING AND SETTING THE VALVE TIMING Engines : 8HX - 8HW Setting the timing (continued). Turn the tensioner roller to the right to bring the index «c» to position «d», using a hexagonal spanner. Tighten the screw (9) of the tensioner roller, tighten to 3 ± 0.3 m.daN. Remove the tools [4] and [5].
Page 78 CHECKING AND SETTING THE VALVE TIMING Engines : 8HX - 8HW Setting the timing (continued). Refit: The intermediate RH engine support, tighten the screws (16) to 5,5 ± 0,5 m.daN. The RH engine support, tighten the screws (17) to 4,5 ± 0,4 m.daN. The bottom timing cover (3).
Page 79 CHECKING AND SETTING THE VALVE TIMING Engines : 8HY - 8HV Tools. [1] Engine flywheel peg Ø 12 mm : (-).0194-C. [2] Camshaft pulley peg Ø 8 mm : (-).0194-B. [3] Crankshaft pulley peg Ø 5 mm : (-).0194-A. Preliminary operations. Remove: - The front RH wheel.
Page 80 CHECKING AND SETTING THE VALVE TIMING Engines : 8HY - 8HV Checks. Rotate the engine to engage it (normal direction of rotation). Immobilise the engine flywheel at «a», using tool [1]. Move aside the harness (6). Remove: - The engine support (7). - The screw (8).
Page 81 CHECKING AND SETTING THE VALVE TIMING Engines : 8HY - 8HV Checks (continued). Refit the screw (8). Rotate the crankshaft six times (clockwise). IMPERATIVE : Never rotate the engine backwards. Peg : - The camshaft, using tool [2]. (Oil the pegs.) - The fuel high pressure pump pulley (14), using tool [3] at «c».
Page 82 CHECKING AND SETTING THE VALVE TIMING Engines : 8HY - 8HV Checks (continued). NOTE : The index «e» of the dynamic tensioner roller should be centred within the area «d». Check the correct positioning of the index «e». If it is not correct, repeat the operation to tension the timing belt (see corresponding operation). Refitting.
Page 83 CHECKING AND SETTING THE VALVE TIMING Engines : 8HY - 8HV Checks (continued). Refit : - The engine support (7), tighten to 1,5 ± 0.4 m.daN. - The engine support (4), tighten to 6,1 ± 0,. m.daN. - The engine support (5), tighten to 6 ± 0.6 m.daN. - The electrical harness (6).
Page 84 CHECKING AND SETTING THE VALVE TIMING Engines : 8HY - 8HV Setting the timing. Perform the preliminary operations for checking the timing up to removing tool [1] at «a» for immobiling the engine flywheel. Refit screw (8). Rotate the crankshaft to bring the camshaft towards its pegging point. Peg the camshaft, using tool [2].
Page 85 CHECKING AND SETTING THE VALVE TIMING Engines : 8HY - 8HV Setting the timing (continued). Checking the setting. IMPERATIVE : Just prior to refitting, carry out the following tests: Check that: - the rollers and the coolant pump operate freely (no play and no tight spot).
Page 86 CHECKING AND SETTING THE VALVE TIMING Engines : 8HY - 8HV Setting the timing (continued). Checks (continued). Reposition the timing belt, belt at «e» well tensioned, in the following order: - Guide roller (17). - Camshaft pulley (16). - Fuel high pressure pump pulley (15). - Coolant pump pinion (18).
Page 87 CHECKING AND SETTING THE VALVE TIMING Engines : 8HY - 8HV Adjusting the timing belt tension (continued). IMPERATIVE : Never rotate the engine backwards. WARNING : Do not touch or damage the track of the target of the engine speed sensor (14). Peg the crankshaft, using tool [3].
Page 88 SPECIAL FEATURES : POWER UNIT SUSPENSION Engines : HFX - KFV - NFU Tightening torques (m.daN) RH engine support. (1) : 4.5 ± 0.4 (2) : 6.1 ± 0.6 (3) : 4.5 ± 0.4 Torque reaction rod. (4) : 6 ± 0.6 (5) : 6 ±...
Page 89 SPECIAL FEATURES : POWER UNIT SUSPENSION Engines : 8HX - 8HW Tightening torques (m.daN) RH engine support. (1) : 4,5 ± 0,4 (2) : 3 ± 0,3 Torque reaction rod. (3) : 6 ± 0.6 (4) : 6 ± 0.6 LH engine support.
Page 90 SPECIAL FEATURES : POWER UNIT SUSPENSION Engines : 8HY - 8HV Tightening torques m.daN. Upper RH engine support. (1) Screws : 6 ± 0.6 (2) Screws : 6 ± 0.6 Lower RH engine support. (3) Screws : 5.7 ± 0.9 Torque reaction rod.
Page 91 EXHAUST SPECIFICATIONS Engines : HFX - KFV - NFU B1JP03TD Downstream oxygen Upstream oxygen Engine types Catalytic converter Front silencer Rear silencer sensor sensor Tighten to (m.daN) Tighten to (m.daN) TR PSA K179 PSA 4173 4,7 ± 0.5 TR PSA K208 4.7 ±...
Page 92 EXHAUST SPECIFICATIONS Engines : 8HX - 8HW Repair Respect the precautions to be taken when operating on a vehicle. The flexible pipe must not come into contact with corrosi- ve products. Do not distort the flexible pipe by more than 20° angular (X), 20 mm axial, 25 mm shear (Y) (flexible pipe not fitted).
Page 93 EXHAUST SPECIFICATIONS Engines : 8HY – 8HV «a» : Cutting zone (Marked by burrs). Flexible pipe Respect the precautions to be taken when operating on a vehicle. The flexible pipe must not come into contact with corrosive products. Do not distort the flexible pipe by more than 20° angular (X), 20 mm axial, 25 mm shear (Y) (flexible pipe not fitted).
Page 94 COOLING SYSTEM SPECIFICATIONS Engines : HFX - KFV - NFU 1.1i 1.4i 1.6i 16V Engine type Capacity Radiator surface 12 and 16 dm Pressurisation 1,4 bars Opening of thermostatic 89°C/101°C regulator Cooling fan 100W (without aircon) 300W (with aircon) 1st speed 2nd speed Warning 118°C...
Page 95 COOLING SYSTEM SPECIFICATIONS Engines : HFX - KFV - NFU Manual gearbox. (1) Venting chamber. (2) Water pump. (3) Heater matrix. (4) Bleed screw, heater matrix (5) Coolant outlet housing (6) Bleed screw, coolant outlet housing. (7) Calorstat. (8) Cooling radiator. Thermostat.
Page 96 COOLING SYSTEM SPECIFICATIONS Engines : HFX – KFV – NFU Automatic gearbox (1) Venting chamber. (2) Water pump. (3) Heater matrix. (4) Bleed screw, heater matrix (5) Coolant outlet housing (6) Bleed screw, coolant outlet housing. (7) Calorstat. (8) Cooling radiator. (9) Heat exchanger (for automatic gearbox).
Page 97 COOLING SYSTEM SPECIFICATIONS Engines : 8HX - 8HW - 8HY - 8HV 1.4 HDi 1.4 HDi 16V Engine type Capacity 5.7 Litres 5.6 Litres Radiator surface 16 dm Pressurisation 1.4 bar Opening of thermostatic 83°C regulator 1x300W Cooling fan 1st speed 97°C 2nd speed 115°C...
Page 98 COOLING SYSTEM SPECIFICATIONS Engines : 8HX - 8HW (1) Bleed screw (with or without aircon) B1GP09MP...
Page 99 COOLING SYSTEM SPECIFICATIONS Engines : 8HY - 8HV (1) Venting chamber. (2) Bleed screw. (3) Thermostat. B1GP09QP...
Page 100 OIL FILTERS Petrol 1.1i 1.4i 1.6i 16V FILTRAUTO Diesel TED4 1.4 HDi 1.4 HDi 16V MALHEX...
Page 101 CHECKING THE OIL PRESSURE Petrol engines 1.1i 1.4i 1.6i 16V Engine type Temperature (°C) 90°C Pressure (Bars) 2000 Diesel engine 1.4 HDi 1.4 HDi 16V 8HX - 8HW 8HV - 8HY Engine type 90°C Temperature (°C) Pressure (Bars) > 1.3 1000 Tools : Pressure gauge...
Page 102 VALVE CLEARANCES POSSIBLE METHODS The valve clearances should be checked with the engine cold. On engines: 4 cylinders in line (1-3-4-2 ) Rocking Fully open (Exhaust) Exhaust Inlet Valves fully Rocking Adjust Adjust open HFX - KFV 0.20 mm ± 0.05 0.40 mm ±...
Page 103 FILLING AND BLEEDING THE COOLING CIRCUIT Engines : 8HX - 8HW Tools [1] Filling cylinder : 4520-T [2] Adaptor for filling cylinder : 4222-T. ESSENTIAL : Respect the safety and cleanliness recommendations. - The draining and refilling operations can be carried out by means of a WINN’S coolant replacement apparatus or similar;...
Page 104 IDLING - ANTI-POLLUTION Idling speed % Content (± 50 rpm) Emission Vehicles Engine type Make - Injection type standard Auto. gearbox: Manual N gear engaged gearbox MAGNETTI MARELLI 1.1 i IF/L5 1.4 i SAGEM S2000 < 0.5 > 9 IF/L5 BOSCH 1.6 i 16V M 7.4.4.
Page 105: Petrol Injection
PETROL INJECTION 1.1i 1.4i 1.6i 16 V Engine type Emission standard L4 / IFL5 Make M. MARELLI 48P2 SAGEM S2000 BOSCH M.7.4.4. Injection type Fuel pressure (bars) Overspeed cut-off (rpm) 5500 5500 5500 Injection cut-in during deceleration (rpm) 14.5 14.5 14.5 Injector resistive value (ohms) Engine coolant temperature sensor...
Page 106 EMISSION STANDARDS APPLICATION NOTES STANDARD CHARACTERISTICS E.E.C. Engines Vehicles Applicable Brussels directive 83/351 Private vehicles : except special > 2 litres 06/89 derogations for certain • new cyl. < 2 litres 06/92 private vehicles • existing cyl. < 2 litres 12/92 cyl.
Page 107 EMISSION STANDARDS APPLICATION NOTES STANDARD CHARACTERISTICS E.E.C. Engines Vehicles Applicable Brussels directives 88/76 and 88/436 Utility vehicle limits Utility vehicles : 01/10/88 All Types = private vehicle limits of Petrol 15.05 W vu 01/10/89 R 15.05 • new models Diesel Brussels directive 88/436 10/94 •...
Page 108 EMISSION STANDARDS APPLICATION NOTES STANDARD CHARACTERISTICS E.E.C. Engines Vehicles Applicable Private vehicles : • certain non-EEC With catalytic Diesel Current Adoption of the U.S. standard US 87 US 87 European countries converter and EGR • certain Export countries Petrol Private vehicles : US 93 US 93 Current...
Page 109 EMISSION STANDARDS APPLICATION NOTES STANDARD CHARACTERISTICS E.E.C. Engines Vehicles Applicable Private vehicles : • certain non-EEC Adoption of the U.S. standard US 90 Petrol Current US 90 Diesel European countries for light utility vehicles • certain Export countries Brussels directive 89/458 Private vehicles : EURO 1 07/92...
Page 110 EMISSION STANDARDS APPLICATION NOTES STANDARD CHARACTERISTICS E.E.C. Engines Vehicles Applicable Utility vehicles : < 3.5 tonnes 01/10/93 • new models Brussels Directive 93/59 • existing models 01/10/94 EURO 1 With oxygen sensor and 3 classes depending on Class 1 : 01/97 Petrol vehicle weight :...
Page 111 EMISSION STANDARDS APPLICATION NOTES STANDARD CHARACTERISTICS E.E.C. Engines Vehicles Applicable Utility vehicles : < 3.5 tonnes Brussels Directive 96/69 With oxygen sensor and 01/97 Class 1 : EURO 2 reinforced catalytic converter 3 classes depending on Petrol 10/97 • new models vehicle weight : for petrol vehicles.
Page 112 EMISSION STANDARDS APPLICATION NOTES STANDARD CHARACTERISTICS E.E.C. Engines Vehicles Applicable Brussels Directive 98/69 Utility vehicles : With 2 oxygen sensors < 3.5 tonnes and catalytic converter for EURO 2 standard (L3) Class 1 : 01/2000 made stricter petrol vehicles. EURO 3 Petrol •...
Page 113 EMISSION STANDARDS APPLICATION NOTES STANDARD CHARACTERISTICS E.E.C. Engines Vehicles Applicable With 2 oxygen sensors Brussels Directive: 2001/1 and catalytic converter for Private vehicles : Petrol EURO 3 standard (L4) made petrol vehicles. All Types 01/2005 EURO 4 Diesel IF/ L5 stricter •...
Page 114 PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM Engines : 8HX - 8HW Cleaning. - The use of high pressure cleaners is prohibited. - Do not use compressed air. Fuel supply circuit. - Required fuel : diesel. Electric circuit. - Swapping injection ECUs between two vehicles will render it impossible to start either vehicle. - It is forbidden to supply a diesel injector with 12 volts.
Page 115 PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM Engines : 8HX - 8HW Diesel injectors. WARNING: Diesel and ultrasonic cleaners are prohibited. Do not separate the following components from the diesel injector carrier (2) : - Diesel injector (f) (no replacement parts). - Electromagnetic element (c) (no replacement parts).
Page 116 PROHIBITED OPERATIONS: DELPHI HDI DIRECT INJECTION SYSTEM Engines : 8HY - 8HV Cleaning. - The use of high pressure cleaners is prohibited. - Do not use compressed air Fuel supply circuit. - Required fuel : diesel. Electric circuit. - Swapping injection ECUs between two vehicles will render it impossible to start either vehicle. - It is forbidden to supply a diesel injector with 12 volts.
Page 117 PROHIBITED OPERATIONS: DELPHI HDI DIRECT INJECTION SYSTEM Engines : 8HY - 8HV Fuel high pressure injection common rail. Do not separate the pressure regulator «c» from the injection common rail (2) (Risk of malfunction). Diesel injectors. WARNING: Diesel and ultrasonic cleaners are prohibited. Do not separate the following components from the diesel injector carrier (3) : - Diesel injector (e) (no replacement parts).
Page 118 SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM Engines : 8HX - 8HW - 8HY - 8HV SAFETY REQUIREMENTS Preamble. All interventions on the injection system must be carried out to conform with the following requirements and regulations : - Competent health authorities. - Accident prevention.
Page 119 SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM Engines : 8HX - 8HW - 8HY - 8HV CLEANLINESS REQUIREMENTS. Preliminary operations IMPERATIVE : The technician should wear clean overalls. Before working on the injection system, it may be necessary to clean the apertures of the following sensitive components : (refer to corresponding procedures).
Page 120 CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engines : 8HX-8HW 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 121 CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engines : 8HV-8HY 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 122 AIR SUPPLY CIRCUIT SPECIFICATION Engines : 8HX - 8HW Upper integrated air inlet distributor. The upper integrated air inlet system is composed of the following elements: (1) Air filter cover. (2) Air filter chamber. (3) Flowmeter (4) Turbocharger inlet. (5) Resonator. (6) Turbocharger outlet.
Page 123 AIR SUPPLY CIRCUIT SPECIFICATION Engines : 8HX - 8HW Lower integrated air inlet distributor. The lower integrated air inlet system is composed of the following elements: (7) Top EGR pipe. (8) Inlet manifold. (9) Diesel fuel filter with reheater and water detector (according to country). (10) Diesel fuel filter support.
Page 124 AIR SUPPLY CIRCUIT SPECIFICATION Engines : 8HX - 8HW Upper integrated air inlet distributor. Lower integrated air inlet distributor. B1HP1JPD B1HP1JQD WARNING: After each removal, replace the seals of components that have been removed, lubricating the new seals when refitting. Tighten in Tighten in m.daN.
Page 125 AIR SUPPLY CIRCUIT SPECIFICATION Engines : 8HY - 8HV (1) Air filter assembly. (2) Oil trap. (3) Turbocharger resonance attenuator. (4) Turbocharger. (5) Air/air exchanger. (6) Air distributor. Air filter : MARK 4. Turbocharger : RHF 3V. (Supplier: «IHI») B1HP1JGP...
Page 126 CHECKS : AIR SUPPLY CIRCUIT Engines : 8HX - 8HW - 8HY - 8HV Tools. [1] Manual pressure-vacuum pump FACOM DA 16. Vacuum pump : Connect the tool [1] onto the vacuum pump (1). Start the engine. Wait 30 seconds. The vacuum value should be 0.9 ±...
Page 127 CHECKS : EXHAUST GASES RECYCLING CIRCUIT Engines : 8HX-8HW Tools [1] Manual pressure-vacuum pump : FACOM DA 16. IMPERATIVE : Respect the safety and cleanliness specific to high pressure diesel injection (HDi) engines. EGR valve Connect tool [1] on the capsule take-off (2). Apply a vacuum of approx.
Page 128 CHECKS : TURBO PRESSURE Engines : 8HX - 8HW Tools. 1] Pressure gauge for checking boost pressure : 4073-T.A [2] Sleeve for checking boost pressure : (-).0171.F Checks IMPERATIVE : Respect the following test conditions: - Engine at operating temperature. - Vehicle in running order.
Page 129 CHECKS : TURBO PRESSURE Engines : 8HV - 8HY Tools. 1] Pressure gauge for checking boost pressure : 4073-T.A [2] Sleeve for checking boost pressure Checks Respect the following test conditions: - Engine at operating temperature. - Vehicle in running order. - Engine under full load.
Page 130 FEATURES OF MULTIPOINT INJECTION SYSTEM Summary (1) Vehicle speed sensor. (2) Catalytic converter. (3) Downstream oxygen sensor. (4) Upstream oxygen sensor. (5) Canister purge electrovalve. (6) Canister reservoir. (7) Fuel pump, fuel filter, gauge, pressure regulator. (8) Injectors. (9) Ignition coil. (10) Thermoswitch –...
Page 131 FEATURES OF MULTIPOINT INJECTION SYSTEM Fuel system (diagr.) Component Supplier Reference Observations Approved fuel Unleaded 95 RON or 98 RON. BOSCH Pressure: 3,5 Bars. Pressure regulator MAGNETTI Fixing : Integrated in the fuel pump and gauge assembly. MARELLI SAGEM (1.4i) MAGNETTI 2-way black connector.
Page 132 FEATURES OF MULTIPOINT INJECTION SYSTEM Air inlet system (diagr.) Component Supplier Reference Observations 1.1i-1.4i 96.393.814.80 Air inlet pressure sensor (16) BOSCH 4 way black connector, fixed on the air inlet manifold. 1.6i 16V 0261 230 043 MAGNETTI Idle regulation stepper motor 4 way black connector, fixed on the butterfly housing.
Page 133 FEATURES OF MULTIPOINT INJECTION SYSTEM Electrical system (diagr.) Component Supplier Reference Observations MAGNETTI 1.1i MARELLI MM 48.P2 1.4i SAGEM (18) Ignition injection ECU S2000 PM.1 ”Flash” type Eprom (reprogrammable Eprom). 1.6i 16V BOSCH M7.4.4 261 204 707 (10) Engine coolant thermoswitch On the cylinder head, closing temperature 118°C SIEMENS 2 way black connector, fixed on the rear part of the engine block.
Page 134 FEATURES OF MULTIPOINT INJECTION SYSTEM Ignition system (diagr.) Component Supplier Reference Observations SAGEM RFN 58 LZ Electrode gap : 0.9 mm. BOSCH Sparking plugs FR 7 DE Tighten to 3 m.daN RC 8 YCL CHAMPION BBC 2.2 SAGEM 2 526 208 Ignition coil 4 way grey connector.
Page 135 FEATURES OF SIEMENS HDI DIRECT INJECTION SYSTEM Summary B1HP1JFP...
Page 136 FEATURES OF SIEMENS HDI DIRECT INJECTION SYSTEM Electrical system (diagr.) Component Supplier Reference Observations Diesel injection ECU F217718001 SIEMENS Tightening torque between 5 min. and 10 max. m.daN – 3 way black Engine speed sensor ELECTRIFIL Airgap adjustment 1.2 mm – 3 way grey. Camshaft position sensor On coolant outlet housing.
Page 137 FEATURES OF SIEMENS HDI DIRECT INJECTION SYSTEM Fuel system (diagr.) Component Supplier Reference Observations Fuel Diesel fuel Fuel high pressure sensor On fuel filter Capacity 45 Litres - Composition = polyethylene Fuel tank Fuel filter Low pressure regulator Fuel cooler Fuel heater Incorporated in the diesel fuel filter The fuel high pressure pump is driven by...
Page 138 FEATURES OF SIEMENS HDI DIRECT INJECTION SYSTEM Air inlet system (diagr.) Component Supplier Reference Observations Air flowmeter 3907 LS.F In the Integrated Exhaust System MECAPLAST Air filter 50557 LP.A In the Integrated Inlet System Turbocharger TYPE KP35 Exhaust gas recycling (EGR) SAGEM 25801 32-A valve...
Page 139 FEATURES OF DELPHI C6 HDI DIRECT INJECTION SYSTEM Summary B1HP1JRP...
Page 140 FEATURES OF DELPHI C6 HDI DIRECT INJECTION SYSTEM (diagr.) Component Supplier Reference Observations Fuel high pressure pump. Fuel pressure sensor. Fuel high pressure supply common rail. Diesel injectors. Vehicle speed sensor. PIERBURG Air flowmeter. 238 342 Engine coolant temperature sensor. Air temperature sensor.
Page 141 FEATURES OF DELPHI C6 HDI DIRECT INJECTION SYSTEM Electrical system (diagr.) Component Supplier Reference Observations 112 way connector. Engine injection ECU DELPHI Sequential injection. 14.43.22 Camshaft phase sensor 3 way white connector, on the valve cover. ELECTRICFIL 14.43.34 Engine speed sensor 3 way black connector.
Page 142 FEATURES OF DELPHI C6 HDI DIRECT INJECTION SYSTEM Air system (diagr.) Component Supplier Reference Observations 5 way black connector. PIERBURG 238 342 Air flowmeter On the air filter inlet duct. 3 way grey connector. DENSO Inlet air pressure sensor On the inlet manifold. Fuel system Fuel high pressure supply LAJOUS...
Page 143 SPARKING PLUGS Enginre Electrode Tightening Vehicles – Models BOSCH CHAMPION SAGEM type torque 1.1i FR7DE RC8YCL 1.4i RFN58LZ 0.9 mm 2.5 mda.N 1.6i 16v FR7ME...
Page 144 CLUTCH SPECIFICATION Petrol Diesel 1.1i 1.4i 1.6i 16V 1.4 HDi 1.4 HDi 16V Engine type 8HX - 8HW 8HV - 8HY Gearbox type MA/5N MA/5S MA/50 BE4/5 Supplier VALEO Mechanism / type 180 CP0 3400 200 P 3900 230 P 4700 Clutch disc 11 R 10X Identification...
Page 145 CLUTCH SPECIFICATION Engines : HFX – KFV – NFU - 8HX – 8HW – 8HV – 8HY NOTE : All the clutches are «push» type with hydraulic control. Description. The declutch control has a declutch fork mounted on a ball-joint. (1) The ball-joint is screwed into the clutch casing (2) Declutch fork.
Page 146 GEARBOX AND TYRE SPECIFICATIONS Petrol 1.6i 16V 1.1i 1.4i Auto. X - SX X - SX Exclusive Exclusive Trim level X - SX X - SX Exclusive Exclusive Engine type 165/70 R14 185/60 R15 165/70 R14 185/60 R15 Tyres-Rolling circumference 1.804 m 1.828 m 1.804 m...
Page 147 GEARBOX AND TYRE SPECIFICATIONS Diesel 1.4 HDi 1.4 HDi 16V Trim level X – SX - Exclusive Engine type Tyres-Rolling circumference 165/70 R14 1.804 m 185/60 R15 1.828 m MA/50 BE4/5 Gearbox type Gearbox ident. plate 20 CN 33 20 CN 36 (*) 20 DM 25 20 DM 26 Differential ratio...
Page 148 MA/5 GEARBOX Engines : HFX - KFV - NFU - 8HX - 8HW "a" Identification label. "b" Location of engraving of serial and gearbox nos. B2CP3HTC...
Page 149 MA/5 GEARBOX Engines : HFX - KFV - NFU - 8HX - 8HW Draining – filling – level (1) Gearbox drain plug. (2) Filling and level cap. Oil quality. Refer to the manufacturer’s instructions. Oil quantity. After draining : 2 Litres. Draining intervals.
Page 150 MA/5 GEARBOX Engines : HFX - KFV - NFU - 8HX - 8HW (1) Primary shaft. (2) Clutch bearing guide. (3) Clutch housing. (4) Gearbox casing. (5) Intermediate plate. (6) Bearing retaining clip. (7) Drive pinion (5th gear). (8) Secondary shaft. (9) 5th gear synchroniser.
Page 151 MA/5 GEARBOX Engines : HFX - KFV - NFU - 8HX - 8HW Tightening torques: m.daN. (23) Clutch bearing guide (3 fixing screws) : 0.6 ± 0.15. (24) Intermediate plate (11 fixing screws) : 5 ± 0.5. (25) Rear cover (3 fixing screws) : 2.2 ±...
Page 152 BE4/5 GEARBOX Engines : 8HV - 8HY B2CP3BNC B2CP3BPD (a) Engraving zone (sequence and serial no.) (b) Location of identification label.
Page 153 BE4/5 GEARBOX Engines : 8HV - 8HY Draining – filling – levelu (1) Drain plug. (2) Filling and top-up plug. (3) Air vent. NOTE : The air vent aperture can be used for filling. Quality of oil Refer to the manufacturer’s instructions. Quantity of oil Gearbox empty : 1,9 Litres.
Page 154 BE4/5 GEARBOX Engines : 8HV - 8HY Description. (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.
Page 155 BE4/5 GEARBOX Engines : 8HV - 8HY Tightening torques (m.daN). (23) Clutch bearing guide (3 screws) : 1.25 ± 0.2 (24) Clutch housing (13 screws) : 1.3 ± 0.2 (25) Primary shaft nut (1 screw) : 7.25 ± 0.5 (26) Secondary shaft nut (1 screw) : 6.5 ±...
Page 156 AL 4 AUTOMATIC GEARBOX Engine : KFV WARNING : This gearbox benefits from a special CITROEN semi-synthetic oil which cannot be mixed with any other oil. The gearbox is lubricated for life. (a) Part reference. B2CP3H1D...
Page 157 AL 4 AUTOMATIC GEARBOX Engine : KFV Tightening torques: (m.daN). (1) Fixing of electrovalve for modulation of flow of oil into the exchange (EPDE) : 1 ± 0.2 (2) Fixing of oil heat exchanger : 5 ± 1 B2CP3H2D (3) Fixing of gearbox input speed sensor : 1 ±...
Page 158 AL 4 AUTOMATIC GEARBOX Engine : KFV Tightening torques: (m.daN). (7) Fixing of plug : 0.8 ± 0.2 (8) Fixing of converter on the engine diaphragm : Pre-tightening : 1 ± 0.1 Tightening : 3 ± 0.3 (9) Fixing of gearbox on the engine : 5.2 ±...
Page 159 AL 4 AUTOMATIC GEARBOX Engine : KFV Hydraulic valve block fixing. Centre the hydraulic valve block by means of screws (10) and (11). Pre-tightening : 0.9 Slacken : the screws (9). Tightening : 0,75 (respect the order indicated) NOTE : The screw (11) est collared. WARNING: Do not slacken the TORX screw (14), risk of dropping the selection control inside the gearbox.
Page 160 RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX) Engine : KFV 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 deforming the tray and damaging the hydraulic valve block).
Page 161 RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX) Engine : KFV Gearbox only PROCEDURE BEFORE REPAIRS Oil level AL 4 (prior conditions). - Vehicle in horizontal position. - Check gearbox is not in back-up mode. - Remove the oil filler plug (3). - Add 0.5 litres extra oil into the gearbox.
Page 162 RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX) Engine : KFV PROCEDURE BEFORE REPAIRS (continued) When the ECU detects an erroneous or absent value Reading the fault codes. on input or output : Read the fault codes. - It writes the fault in memory. Absence of fault codes: - For each associated context, it writes the context of the oldest Carry out a measure of parameters.
Page 163 RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX) Engine : KFV ECU : Downloading Updating the gearbox ECU by downloading : - Follow the procedure using the diagnostic tool. The downloading operation enables the automatic gearbox to be updated, or adapted to an evolution of the engine ECU. Before commencing the downloading, take the value of the oil usage counter present in the automatic gearbox ECU.
Page 164 RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX) Engine : KFV ECU : Downloading, Configuration, Initialisation (pedal) (continued) Downloading. Pedal initialisation. ECU downloading procedure : A pedal initialisation must be carried out in the following cases : - Follow the diagnostic tooling procedure. - Replacement of the automatic gearbox ECU.
Page 165 RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX) Engine : KFV SHIFT LOCK The shift lock is a system which locks the gear selection lever in the park position «P». Unlocking the «shift lock» (normal operation). Switch on the ignition. Apply the brake pedal and keep it pressed. Using the selection lever, disengage from position «P».
Page 166 MA/5 GEARBOX CONTROLS Engines : HFX - KFV - NFU - 8HX - 8HW (1) Gear control lever. (2) Gear engagement control cable (*) (3) Gear selection control cable (*) (*) The two cables cannot be separated. B2CP3HXD...
Page 167 MA/5 GEARBOX CONTROLS Engines : HFX - KFV - NFU - 8HX - 8HW (4) Gear engagement ball-joint Ø 10 mm. (5) Gear selection ball-joint Ø 10 mm. B2CP3HYC Length D Length C Gear engagement 1015 mm 790 mm control cable (2) Length A Length B Gear selection...
Page 168 MA/5 GEARBOX CONTROLS Engines : HFX - KFV - NFU - 8HX - 8HW Adjustment. WARNING: Do not use any tool to detach the ball- joints. The gear selection control and gear engagement control cables cannot be adjusted. B2CP3J0D To unlock the ball-joint, press at «a» then pull the ball-joint upwards.
Page 169 BE4/5 GEARBOX CONTROLS Engines : 8HV - 8HY (1) Gear control lever (2) Gear engagement control cable (*). (3) Gear selection control cable (*). (*) These two cables cannot be separated. B2CP3J3D...
Page 170 BE4/5 GEARBOX CONTROLS Engines : 8HV - 8HY (4) Gear engagement ball-joint Ø 10 mm. (5) Gear selection ball-joint Ø 10 mm. B2CP3J4C Length A Length B Gear selection 907 mm 645 mm cable (5) Length D Length C Gear selection 965 mm 610 mm...
Page 171 BE4/5 GEARBOX CONTROLS Engines : 8HV - 8HY Adjustment. The gear selection control and gear engagement control cables cannot be adjusted. To release the ball-joint, press at «d» then pull the ball-joint upwards. To release sleeve stops: - Press on the tabs of the clip (6) at «a». - Disengage the sleeve stops from their supports.
Page 172 AL4 GEARBOX CONTROLS Engine : KFV B2CP3H7D...
Page 173 AL4 GEARBOX CONTROLS The gear selection lever is guided by the shape of the stepped grille and by a return spring which holds it to the left. The gear control has 5 positions: - "P" Park (locks and immobilises the vehicle). - "R"...
Page 174 AL4 GEARBOX CONTROLS Engine : KFV Close to the gearbox. Control of the automatic gearbox is by a cable. «c» Push button. (1) Control lever with ball-joint. (2) Automatic adjustment. Pull out the button to permit adjustment of the control. Press in the button to lock the adjustment of the control.
Page 175 AL4 GEARBOX CONTROLS Engine : KFV Unlocking: «Shift lock» function. NOTE : The «shift lock» is a system that locks the gear selection lever in position «P». Unlocking the «shift lock». (Normal operation). Switch on the ignition. Press the brake pedal and keep it pressed. Move the gear selection lever out of position «P».
Page 176 SPECIFICATION OF DRIVESHAFTS Engines : HFX - KFV - NFU - 8HX - 8HW - 8HV - 8HY NOTE : The wheel hubs have bearings with integral magnetic wheels designed for the ABS system. Features. The driveshafts no longer have gearwheels for the ABS system. This function is performed by the wheel bearings.
Page 177 SPECIFICATION OF DRIVESHAFTS Gearbox References Vehicles Engine types Type Differential diameter Wheel end Gearbox end 1.1i MA/5N MA/5N - MA/5L AC/1700i 1.4i Gi 1700i 1.6i 16V MA/5S AC 2000i 1.4 HDi 8HX-8HW MA/50 AC 1700i 1.4 HDi 16V 8HV-8HY BE4/5L Gi 2000i AC 2000i Housing diameter (mm)
Page 178 DRIVESHAFTS - GEARBOX Gearbox oil seal mandrels Tightening torques (m.daN) Driveshaft Driveshaft RH side LH side Tool kit Vehicles Gearbox Engines bearing HFX - KFV None 8HX - 8HW MA/5 7114-T.W 24.5 ± 0.5 7114-T.X 7116-T 2 ± 0.2 (-) 0338 J1 (-) 0338 H1 1 ±...
Page 179 WHEELS AND TYRES Petrol 1.4i 1.1i Manual and automatic gearboxes X – SX - Exclusive X - SX Exclusive Engine type 165/70 R14 81T XT1 – 1.804 m 165/70 R14 81T XT1 – 1.804 m 185/60 R15 84H XH1 – 1.828 m Tyre circumference 165/70 R14 81T XT1 –...
Page 180 WHEELS AND TYRES Petrol 1.6i 16V X-SX-Exclusive Engine type 185/60 R15 84H XH1 – 1.828 m 185/60 R15 84H XH1 – 1.828 m Tyre circumference 185/60 R15 84H XH1 – 1.828 m 6J 15 H2.4.27 - Eagle trims 6J 15 CH.4.27-Lynx Wheel 5.5J 14 CH 4.24 Tiger Front/Rear...
Page 181 WHEELS AND TYRES Diesel 1.4 HDi 1.4 HDi 16V X – SX - Exclusive X – SX - Exclusive Engine type 8HX - 8HW 8HV - 8HY 185/60 R15 84H XH1 – 1.828 m 165/70 R14 84H XH1 – 1.804 m 185/60 R15 84H XH1 –...
Page 182 WHEELS AND TYRES Identification of inflation pressures The label indicating recommended tyre pressures is affixed to the inner panel of one of the front doors. «a»: Recommended tyre inflation pressures. (vehicle empty and vehicle under load). «b»: Type of tyre. «c»: Recommended inflation pressure for the spare tyre.
Page 183 WHEELS AND TYRES Identification of wheel bolts : Wheel bolt. : Light alloy wheel. : Spare wheel. Steel wheel. Bolt for wheel with conical contact surface. Light alloy wheel. Mixed fixing wheel bolts, permitting the securing of the following wheel types: Light alloy wheel (fixing with flat contact surface).
Page 184 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 E1AP09MD Rear height Front height H1 = R1 - L1 H2 = R2 + L2 H1 = Measurement between the measuring zone underneath the front H2 = Measurement between the measuring zone underneath the rear sill...
Page 185 AXLE GEOMETRY B3CP07SD Measuring front height Measuring rear height [1] Gauge for measuring the wheel radius, 4 bolts, tool 8006-T Z1 = Measuring zone underneath the front subframe. Z2 = Measuring zone underneath the rear sill. Measure the radius of the front wheel R1 - Calculate dimension H1 = R1 – L1 Measure the radius of the rear wheel R2 - Calculate dimension H2 = R2 + L2 All types All types...
Page 186 AXLE GEOMETRY Front axle Rear axle Dissymmetry of lower castor at 0° 30’. Dissymmetry of lower camber at 0° 18’. Dissymmetry of lower camber at 0° 18. Distribute symmetrically, LH / RH wheel, the total tracking value. All types (except CRD) King pin Vehicle Tracking...
Page 187 FRONT AXLE Tightening torques (m.daN) (1) Damper nut : 6.5 ± 0.6 (2) Suspension leg (3) Anti-roll bar link rod upper ball-joint : 4.5 ± 0.5 (4) Suspension leg pivot : 5.4 ± 0.5 (5) Anti-roll bar link rod lower ball-joint : 4.5 ±...
Page 188 REAR AXLE Tightening torques (m.daN) (1) Rear fixing screw : 10 ± 1 (2) Anti-roll bar (3) Rear axle crossmember (4) Rear suspension arm mounting yoke (5) Rear suspension arm mounting : 7.6 ± 0.5 (6) Yoke suspension arm fixing screw (7) Rear suspension arm (8) Stub axle bearing nut : 20 ±...
Page 189 SUSPENSION Front axle (1) Suspension leg on bodyshell fixing nut : 6.5 ± 0.6 (2) Damper (3) Anti-roll bar link rod upper ball-joint : 4.5 ± 0.5 (4) Suspension leg pivot : 5.4 ± 0.5 (5) Anti-roll bar link rod lower ball-joint : 4.5 ±...
Page 190 SUSPENSION Front axle (1) Nut fixing suspension leg on body : 6.5 ± 0.6 (2) Damper. (16) Cup. (17) Damper nut. : 6.5 ± 0.6 (18) Damper cup. (19) Ball bearing (20) Spring thrust cup. (21) Travel stop cup. (22) Suspension spring. (23) Damper rod protector.
Page 191 SUSPENSION Rear axle (25) Rear axle fixing screw : 10 ± 1 (26) Anti-roll bar (27) Rear axle crossmember (28) Rear suspension arm flexible mounting yoke (29) Rear suspension arm flexible mounting (30) Suspension arm fixing screw on yoke : 7.6 ± 0.5 (31) Rear suspension arm (32) Stub axle bearing nut : 20±2 (greased)
Page 192 FEATURES OF ELECTRIC POWER STEERING Engines : HFX - KFV - NFU - 8HX - 8HW - 8HY Steering column B3EP13GD B3EP13HC Tightening torques m.daN. Identification (1) Steering wheel fixing : 2 ± 0.3 Identified by the colour of the ring at "a". (2) Steering column fixing on support : 2.2 ±...
Page 193 FEATURES OF ELECTRIC POWER STEERING Engines : HFX – KFV – NFU – 8HX – 8HW – 8HY Steering mechanism Tightening torques m.daN (4) Ball-joint fixing on pivot : 3.5 ± 0.3 (5) Steering rod lock-nut : 5 ± 0.5 (8) Threaded washer (9) Stud : 0.8 ±...
Page 194 FEATURES OF ELECTRIC POWER STEERING Engines : HFX - KFV - NFU - 8HX - 8HW - 8HY Steering assistance B3EP13KC B3EP13LC Supplier: KOYO. Electric power-assisted steering ECU. Only one ECU version, whatever the engine-type. The steering assistance is provided by the assistance motor (12), control- The electric power steering ECU is linked to the following connec- led by the ECU.
Page 195 SPECIAL FEATURES : STEERING Engines : HFX - KFV - NFU - 8HX - 8HW - 8HY Centring the steering rack Preliminary operation. Raise and support the vehicle on a two-column lift. Remove, on the RH side of the steering rack: - Clip (1).
Page 196 BRAKE SPECIFICATIONS (WITHOUT ABS) 1.4i 1.4 HDi 1.1i Engine type Master cylinder 20.6 Master vac 203.2 Caliper/piston Ø LUCAS/TRW C48/13 48 makes Plain Disc Ventilated 13/11 Disc thickness/min. thickness Brake pad grade TEXTAR T 4144 Drum Ø Max. thickness Make 8259 Brake lining grade...
Page 197 BRAKE SPECIFICATIONS (WITH ABS) 1.4 HDi 16V 1.6i 16V Engine type Master cylinder 22.2 Master vac 228.6 Caliper/piston Ø LUCAS/TRW C54/22 54 makes Plain Disc Ventilated Disc thickness/min. thickness 22/20 Brake pad grade TEXTAR T 4144 Cylinder or caliper LUCAS C38 HR 9/13 Ø...
Page 198 BRAKE SPECIFICATIONS Braking circuit without ABS - REF (drum brakes at the rear) Braking system specifications - Braking circuit at «X». - Front brakes with ventilated discs (*). - Rear brakes with eitther drums or discs (*). - Handbrake lever controlling cables acting on the rear wheels.
Page 199 BRAKE SPECIFICATIONS Braking circuit with ABS - REF (drum brakes at the rear) B3FP162D...
Page 200 BRAKE SPECIFICATIONS Braking circuit with ABS - REF (disc brakes at the rear) B3FP163D...
Page 201 BRAKE SPECIFICATIONS Braking circuit with ABS - REF (a) Hydraulic circuit. (b) Electrical circuit. (1) Master cylinder in tandem. (2) Braking servo. (3) Brake caliper (or drum at the rear). (4) Hub equipped with a bearing with an integral magnetic wheel (48 pairs of poles).
Page 202 BRAKE SPECIFICATIONS (7) Hydraulic block Part No. Elements Ref. Supplier Observations ABS MK 60 47 way connector. Electronic Alone on the hydraulic block.. ESP ABS Changing only the ECU is prohibited. MK 60 2 way blue connector. The sensors are inductive-type. Front wheel Mounted on the pivot.
Page 203 BRAKE SPECIFICATIONS Brake pedal gear Front brake Rear brake B3FP166D B3FP164C B3FP165C Tightening torques (m.daN). (16) Servo fixing 2.2 ± 0.3 (12) Yoke fixing on caliper 10.5± 1 (14) Rear caliper fixing on arm 5.3±0.5 (17) Fixing on master cylinder 2 ±...
Page 204 HANDBRAKE (Adjustment) Adjustment Lift and chock the vehicle. Remove: - The rear cover (8). - The nut (9). - The handbrake trim (6). - The gear lever gaiter (5). - The front cover (3). - The screws (1). Disconnect the connectors of the following components: - The cigar lighter (2).
Page 205 HANDBRAKE (Adjustment) Adjustment (continued) A : Drum brakes B : Disc brakes (10) Nut for adjusting cable tensions. Remove: - The rear wheels. - The drums (according to version). Release the handbrake. Use a gauge set to measure at «a» the travel of the lever from its stop.
Page 206 BLEEDING AND FILLING THE BRAKING SYSTEM Tools. [1] Generic bleeding apparatus : «LURO» or similar. Bleeding, refilling. Draining. Drain the brake fluid reservoir (1) to the maximum (if necessary, use a clean syringe). Disconnect the connector (4). Uncouple the pipe (2). Unscrew the shaft (3).
Page 207 BLEEDING AND FILLING THE BRAKING SYSTEM Bleeding, filling (continued). Bleeding the primary braking circuit. WARNING: The ABS should not be active during the bleeding operation. - Front brake caliper: Bleed screw (5). A : Rear brake caliper B : Rear brake drum Bleed screw (6).
Page 208 BLEEDING AND FILLING THE BRAKING SYSTEM Purge. remplissage (Suite). With the bleeding apparatus - Raccorder l’appareil à purger [1] sur le réservoir de liquide de frein (1). - Régler la pression de l’appareil à 2 Bars. For each circuit : - Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container.
Page 209 STARTER MOTORS Types of starter motor Class Climate Vehicles / models VALEO D7E16 H,T,C BOSCH A001 183 027F 1.1i MELCO M002T 13081 VALEO D6RA572 VALEO D7E16 1.1 i Aircon BOSCH A001 183 027F H, T 1.4 i Aircon MELCO M002T 13081 1.6i 16v Aircon VALEO D6RA572 C, VC...
Page 210 ALTERNATORS Classes and types Engine G’box Without aircon Climate With aircon Climate VALEO A11 VI 109 VALEO A11 VI 109 H,T,C,VC C, VC VALEO SG7 S016 VALEO SG7 S016 1.1i VALEO A13 VI 282 H, T VALEO SG8 B022 VALEO A11 VI 109 VALEO A11 VI 109 C, VC H,T,C,VC...
Page 211 ALTERNATORS Classes and types Engine G’box Without aircon Climate With aircon Climate VALEO A11 VI 109 VALEO A13 VI 282 H, T C, VC VALEO SG7 S016 VALEO SG8 B022 1.6i 16 v VALEO A13 VI 282 VALEOA13 VI 282+ C, VC H, T VALEO SG8 B022...
Page 212 PRE-HEATING AND STARTING CIRCUITS Pre-post-heating Vehicles / models Pre-heater plugs Pre-heater control unit (Pre-heating time at 20°C) NGK YE04 NAGARES 960411-P 1.4 HDI CARTIER 735068 NGK YE04 NAGARES 960411-P 1.4 HDI Controlled by CARTIER 735068 the diesel injection ECU NGK YE04 NAGARES 960411-P 1.4 HDI 16v NAGARES 960411-P...
Page 213 CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR. Checking the alternator output Output under 13.5 V Intensity (A) / Alternator speed Connect as shown in the diagram opposite, using an ammeter (A), a volt- meter (V), and a rheostat (R) or a Volt/Ammeter/Rheostat combination. Speed 2000 3000...
Page 214 AIR CONDITIONING R 134 a (HFC) Compressor Refrigerant Vehicle Engine Date Variable Oil quantity refill Capacity reference All Types 11/2001 # 625 + 0 - 50 gr SD 6 V 12 SP 10 Cooling fan FAURE ECIA (250 Watts)
Page 215 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Compressor Condenser C5HP18UD C5HP18VD The drive plate (1) is held on the aircon compressor shaft by ribs. The condenser (5) has a cylinder (6) incorporating the function of aircon New wiring (2). fluid reservoir and with integral filtering cartridge.
Page 216 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Pressure reducer Seals C5HP18WC C5HP18XD The inlet (10) and the outlet (9) are equipped with new seals (3) (MANULLI). MANULLI calibrated seal (3) Pressure reducer: TGK 2,02/2,7/2 Tons Direction of fitting of the seal (3). Evaporator : VALEO 60 mm.
Page 217 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: - The three screws (1). - The plastic cover (2). Tilt the flap (3). Remove the pollen filter (4).
Page 218 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Changing the filtering/drying cartridge Tools. [1] Charge station : (according to workshop equipment) [2] TORX adaptor : TORX 70 FACOM. [3] Inertia extractor : 1671-T. Toolkit 4114-T [4] Endpiece Ø 20 : 1671-T.D20. [5] Set of plugs : (-).0188.T.
Page 219 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Changing the filtering/drying cartridge Refitting Remove the new cartridge from its packaging. Do not expose the cartridge, the filter and seals to pollutants. Lightly oil the seals (compressor oil). Remove tool [5] from the reservoir (6). Insert the new cartridge (5) into the reservoir (6).
Page 220 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 221 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 222 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM CHECKING TEMPERATURES TOOLS Checks. Two thermometers If all these conditions are met, take the following action : - Start the engine, with the air conditioning off, and wait for the cooling fan first speed to cut in. Preliminary conditions.
Page 223 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM CHECKING TEMPERATURES (continued) Vehicle using R134.a fluid (Compressor with variable capacity) Ambient temperature in °C Vehicle Engine types Air temperature from the central vents 15 ± 2 All types 18.5 ± 2 10 ±...
Page 224 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM CHECKING PRESSURES TOOLS - 1 Charging station. CHECK - 2 Thermometers. - The temperature of the air coming from the central vents (see table). Once the preliminary conditions, vehicle equipment and checks have - The High Pressure.
Page 225 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM CHECKING PRESSURES (continued) Low pressure Low pressure Low pressure too low too high normal High pressure - Insufficient fluid charge. - Cooling fan speed unsuitable. - Faulty pressure control valve. too low - Constriction of the HP system.
Page 226 AIR CONDITIONING SYSTEM R 134.a (1) Low pressure valve. (2) High pressure valve. (3) Filter. (4) Pressostat Tightening torque m.daN : 0.6. : 0.6. : 0.6. : 0.6. : 0.6. : 0.6. C5HP17SP...
Page 227 AIR CONDITIONING SYSTEM R 134.a Testing procedure Conditions inside the vehicle Switch on the air conditioning and adjust the engine speed to 2500 rpm. Positions of the air conditioning controls : In an ambient temperature of 40°C, the engine speed will be brought Maximum cold.
Page 228 AIR CONDITIONING SYSTEM R 134.a Checking the air conditioning system Key. T/P = Average temperature (°C ) at the air vents / high pressure (Bars). P = Low pressure (Bars). Te = Exterior temperature (C° ). HP = Pressure at compressor outlet (Bars). BP = Pressure at compressor inlet (Bars).

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