CITROËN 2002 BERLINGO Technical Information

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PRIVATE CARS

SAXO-XSARA-XSARA PICASSO

BERLINGO

«The technical information contained in this document is intended for the exclusive use of the trained personnel of the

motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The

information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full

responsibility to the exclusion of that of the manufacturer».

«The technical information appearing in this brochure is subject to updating as the characteristics of each model in the

range evolve. Motor vehicle repairers are invited to contact the CITROËN network periodically for further information and

to obtain any possible updates».

CAR 050011

Volume 1

2002

Table of Contents

Summary of Contents for CITROËN 2002 BERLINGO

Page 1 PRIVATE CARS 2002 SAXO-XSARA-XSARA PICASSO BERLINGO «The technical information contained in this document is intended for the exclusive use of the trained personnel of the motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full responsibility to the exclusion of that of the manufacturer».
Page 2 PRESENTATION THIS HANDBOOK summarises the characteristics, adjustments, checks and special features of CITROEN vehicles, not including COMMERCIAL vehicles for which there exists a separate handbook. The handbook is divided into nine groups representing the main functions : GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - ELECTRICAL - AIR CONDITIONING.
Page 3 IMPORTANT If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into account when preparing future publications. For example : – INSUFFICIENT INFORMATION – SUPERFLUOUS INFORMATION –...
Page 4 IDENTIFICATION OF VEHICLES SAXO - All Types Engine legislation type RP organisation no. Chassis stamp Manufacturer’s name plate 01/02/99 # Label : - Tyre pressures. - RP organisation no. - Paint code. Paint code. Gearbox ident. reference E1AP07CD...
Page 5 SAXO - All Types IDENTIFICATION OF VEHICLES Saxo petrol 3-door. 1.1 i 1.4 i 1.6 i 1.6i 16V Auto. A-X-SX Administration Exclusive X-SX Exclusive Exclusive IFL5 Emission standard SO HFX1 SO HFXB SO KFWL S6 KFWB SO KFWB S6 NFTB N6 NFXB Type code Engine type...
Page 6 IDENTIFICATION OF VEHICLES SAXO - All Types Saxo petrol 5-door. 1.1i 1.4i A-Administration Auto. Driving school -X-SX X-SX SX-Exclusive Exclusive IFL5 Emission standard S1 HFX1 S1 HFXB S1 KFWL S1 KFWB Type code Engine type 1124 1360 Cubic capacity (cc) Fiscal rating (hp) MA/5 MA/5...
Page 7 SAXO - All Types IDENTIFICATION OF VEHICLES Diesel Entreprise 3-door. 5-door. Petrol 3-door. Diesel 3-door. 1.5 D 1.1i 1.5 D A-Administration A- Administration Driving school Administration Administration X-SX-VTS -Exclusive X-SX-Exclusive Poste-X-SX Poste-X-SX Emission standard SO VJXB S1 VJXB S3 HFXB S3 VJXB Type code Engine type...
Page 8 IDENTIFICATION OF VEHICLES XSARA - All Types # 09/2000 A - Manufacturer’s name plate (Estate). B - Chassis stamp, cold stamp. C - Manufacturer’s name plate (Saloon). D - Label : (label affixed to the front pillar on driver’s side) - Tyre pressures.
Page 9 XSARA - All Types 09/2000 # IDENTIFICATION OF VEHICLES Saloon petrol 3-door. 1.6i 16V 1.4 i Auto. Auto. X-SX X-SX-VTR SX-VTR VTR-VTS X-VTR IFL5 IFL5 Emission standard NO KFWB NO KFW1/IF NO NFUB NO NFUN NO NFU1/IF NO NFU3/IF Type code Engine type 1360 1581...
Page 10 XSARA - All Types 09/2000 # IDENTIFICATION OF VEHICLES Saloon petrol 3-door. Saloon diesel 3-door. 20i.16V 1.9 D 2.0 HDi Auto. Auto. X-SX X-SX-VTR SX-VTR IFL5 Emission standard NO RFN1/IF NO RFNN/IF NO RFSB NO WJYB NO RHYB NO RHZB NO RHZN Type code Engine type...
Page 11 XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES Saloon 3-door versions Petrol Diesel 1.4i 1.9 D 2.0 HDi Emission standard NO KFWB/T (1) NO WJYB/T (1) NO RHYB/T (1) Type code Engine type 1360 1868 1997 Cubic capacity (cc) Fiscal rating (hp) MA/5 BE4/5...
Page 12 XSARA - All Types 09/2000 # IDENTIFICATION OF VEHICLES Saloon petrol 5-door 1.6i 16V 1.4i Auto. X-SX X-SX Exclusive K’ IFL5 K’ Emission standard N1 KFWG N1 KFWB N1 KFW1/IF N1 NFUG N1 NFUU N1NFUB Type code Engine type 1360 1587 Cubic capacity (cc) Fiscal rating (hp)
Page 13 XSARA - All Types 09/2000 # IDENTIFICATION OF VEHICLES Saloon petrol 5-door. 2.0i 16V 16i 16V Auto. Auto. Auto. X-SX Exclusive Exclusive Exclusive Exclusive IFL5 IFL5 Emission standard N1 NFUN N1 NFU1/IF N1 NFU3/IF N1 RFN1/IF N1 RFNN Type code Engine type 1587 1998...
Page 14 XSARA - All Types 09/2000 # IDENTIFICATION OF VEHICLES Saloon diesel 5-door. 1.9 D 2.0 HDi Auto. X-SX X-SX-Exclusive SX-Exclusive Exclusive Emission standard N1 WJYB N1 RHYB N1 RHZB N1 RHZN Type code Engine type 1868 1997 Cubic capacity (cc) Fiscal rating (hp) BE4/5 BE4/5...
Page 15 XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES Saloon diesel Entreprise 5-door. 1.9 D 2.0 HDi Emission standard N1 WJYB/T (1) N RHYB N1 RHYB/T (1) Type code Engine type 1868 1997 Cubic capacity (cc) Fiscal rating (hp) BE4/5 BE4/5 Gearbox type 20 DL 41...
Page 16 XSARA - All Types 09/2000 # IDENTIFICATION OF VEHICLES Estate petrol 1.4i 16. 16V Auto. Auto. X-SX X-SX X-SX Eclusive Exclusive Exclusive Exclusive IFL5 K’ IFL5 Emission standard N2 KFWB KFW1/IF N2 NFUG N2 NFUB N2 NFUN N2 NFU1/IF N2 NFU3/IF Type code Engine type 1360...
Page 17 XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES Estate petrol Estate diesel 2.0i 16V 1.9 D Auto. Exclusive X - SX IFL5 Emission standard N2 RFN1/IF N2 RFNN N2 WJYB Type code Engine type 1998 1868 Cubic capacity (cc) Fiscal rating (hp) BE4/5 BE4/5...
Page 18 XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES Estate diesel 2.0 HDi Auto. X-SX-Eclusive Exclusive IFL5 Emission standard N2 RHYB N2 RHYB/IF N2 RHZN Type code Engine type 1997 Cubic capacity (cc) Fiscal rating (hp) BE4/5 Gearbox type 20 DL 42 20 DM 07 (1) 20 DM 10 20 DM 11 (1)
Page 19 XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES Estate petrol versions Estate diesel versions 1.4i 1.9 D 2.0 HDi Emission standard N2 KFWB/T (1) N2 WJYB/T (1) N2 RHYB/T (1) Type code Engine type 1360 1868 1997 Cubic capacity (cc) Fiscal rating (hp) MA/5 BE4/5...
Page 20 IDENTIFICATION OF VEHICLES XSARA PICASSO - All Types A - Chassis stamp (Cold stamp on bodywork) B - Chassis no. reminder (Label located at bottom of windscreen right hand side)t) C - Manufacturer’s data plate. (Located at bottom of RH central pillar) D - Label : Tyre pressures.
Page 21 XSARA PICASSO - All Types IDENTIFICATION OF VEHICLES Petrol Diesel 1.6i 1.8i 16 V 2.0 HDi IFL5 Emission standard CH NFVB CH 6FZB CH 6FZ/IF CH RHY Type code Engine type 1587 1749 1997 Cubic capacity (cc) Fiscal rating (hp) BE4/5/ J (*) BE4/5 V (*) BE4/5 L (*)
Page 22 IDENTIFICATION OF VEHICLES BERLINGO - All Types Chassis stamp Manufacturer’s name plate. Supplementary plate Weights label 01/02/99 # Label : - Tyre pressures. - RP organisation no. - Paint code. Paint code RP organisation no. Gearbox ident. reference Engine legislation type E1AP07AD...
Page 23 BERLINGO - All Types IDENTIFICATION OF VEHICLES Berlingo petrol 5-seater 1.1i 1.4i X-SX Multispace X-SX L3/W3 L4/W4 L3/W3 L4/W4 Emission standard MF HDZF MF HFX MF KFXG MF KFXF MF KFXF/A MF KFWB Type code Engine type 1124 1360 Cubic capacity (cc) Fiscal rating (hp) MA/5 MA/5...
Page 24 BERLINGO - All Types IDENTIFICATION OF VEHICLES Berlingo petrol 5-seater 1.4i 1.6i 16V Dual fuel Multispace Multispace Multispace L4/W4 L4/W4 IFL5 Emission standard MF KFWB MF KFWB Type code MF KFWB/A MF NFUB MF NFUB/A MF NFU1/IF /MOD GL (1) /A MOD GL (1) Engine type 1360...
Page 25 BERLINGO - All Types IDENTIFICATION OF VEHICLES Berlingo petrol 5-seater Berlingo diesel 5-seater 16i 16V 1.8i 1.9 D X-SX Multispace Multispace Multispace X-SX IFL5 L3/W3 L3/W3 L4/W4 Emission standard MF NFU1/A IF MF LFXF MF LFXF/A MF WJZF MF WJZF/A MF WJYB Type code Engine type...
Page 26 IDENTIFICATION OF VEHICLES BERLINGO - All Types Berlingo diesel 5-seater 1.9 D 2.0 HDi Multispace Multispace Multispace X-SX X-SX Multispace L4/W4 L3/W3 L4/W4 Emission standard MF WJYB Type code MF WJYB/A MF RHYF MF RHYF/A MF RHYB MF RHYB/A /PMF (1) Engine type 1868 1997...
Page 27 ALL TYPES CAPACITIES (in litres) Draining method. The oil capacities are defined according to the following methods. 1/ Vehicle on level surface (in high position, if equipped with hydropneumatic suspension). 2/ Engine warm (oil temperature 80°C). 3/ Draining of the oil sump + removal of the cartridge (duration of draining + dripping = 15 min). 4/ Refit plug + cartridge.
Page 28 SAXO - All Types CAPACITIES (in litres) SAXO Petrol Diesel Ecological oil filter capacity 0.15 litre. 1.1I 1.4I 1.6I 16V 1.6I 1.5D Auto. Engine type Engine with filter change Between Min. and Max. 5-speed gearbox Automatic gearbox after drainage With ABS = 0.45 - Without ABS = 0.36 Hydraulic or brake circuit Cooling system Fuel tank capacity...
Page 29 XSARA - All Types CAPACITIES (in litres) XSARA Petrol Diesel Ecological oil filter capacity 0.15 litre. 1.4I 1.6I 16V 2.0I 16V 1.9D 2.0 HDI Auto. Auto. Auto. Engine type 3.25 4.25 4.75 4.5-4.25 (1) Engine with filter change Between Min. and Max. 5-speed gearbox Automatic gearbox after drainage...
Page 30 CAPACITIES (in litres) XSARA PICASSO - All Types XSARA PICASSO Petrol Diesel Ecological oil filter capacity 0.15 litre. 1.6I 1.8I 16 V 2.0 HDI Engine type 4.25 Engine with filter change Between Min. and Max. 5-speed gearbox Automatic gearbox after drainage 0.58 litres Hydraulic or brake circuit 5.8 (1) and (2)
Page 31 BERLINGO - All Types CAPACITIES (in litres) BERLINGO Petrol Diesel Ecological oil filter capacity 0.15 litre. 1.6i 1.1i 1.4i 1.8i 1.1i 1.4i 1.9 D 2.0 HDi Engine type 4.75 4.75 3.25 Engine with filter change 4.5 (1) 4.5 (1) 4.25 (1) Between Min.
Page 32 LUBRICANTS - TOTAL recommended oils ALL TYPES S.A.E. Norm - Table for selection of engine oil grade E4AP006D...
Page 33 LUBRICANTS - TOTAL recommended oils ALL TYPES Factory evolutions in 2001 model year ESSENTIAL : For all vehicles with a 30.000 km (20.000 miles) maintenance interval, use exclusively TOTAL ACTIVA/QUARTZ CITROËN engines are lubricated at the factory with TOTAL oil of grade 7000 or 9000 or any other oils offering identical specifications to S.A.E.5W-30.
Page 34 LUBRICANTS - TOTAL recommended oils ALL TYPES 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 35 ALL TYPES LUBRICANTS - TOTAL recommended oils Engine oil norms. Norms in force. These engine oils have been classified by the following recognised organisations: S.A.E. : Society of Automotive Engineers. API : American Petroleum Institute. ACEA : Association des Constructeurs Européens d’Automobiles. Recommendations.
Page 36 LUBRICANTS - TOTAL recommended oils ALL TYPES 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 37 LUBRICANTS - TOTAL recommended oils ALL TYPES FRANCE Blended oils for all engines, supplied in bulk Metropolitan FRANCE TOTAL ACTIVRAC S.A.E : 10W-40 Norms TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 9000 5W-40...
Page 38 LUBRICANTS - TOTAL recommended oils ALL TYPES EUROPE TOTAL QUARTZ TOTAL QUARTZ DIESEL (*) = Blended oils for all engines, Oils specifically for petrol and Oils specifically Blended oils for all engines permitting fuel economy. dual-fuel petrol / LPG engines for diesel engines 7000 10W-40 Germany...
Page 39 ALL TYPES 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 40 LUBRICANTS - TOTAL recommended oils ALL TYPES EUROPE (continued) TOTAL QUARTZ TOTAL QUARTZ DIESEL (*) = Blended oils for all engines, permit- Oils specifically for petrol and Oils specifically for diesel Blended oils for all engines ting fuel economy dual-fuel petrol / LPG engines engines 7000 10W-40 Czech Republic...
Page 41 ALL TYPES LUBRICANTS - TOTAL recommended oils TOTAL QUARTZ TOTAL QUARTZ DIESEL Blended oils for all Oils specifically for petrol and Oils specifically for diesel engines dual-fuel petrol / LPG engines engines Australia OCEANIA 7000 10W-40 Nouvelle-Zélande Ivory Coast Egypt Gabon AFRICA Madagascar...
Page 42 LUBRICANTS - TOTAL recommended oils ALL TYPES TOTAL QUARTZ TOTAL QUARTZ DIESEL (*) = Blended oils for all engines, permit- Blended oils for all Oils specifically for petrol and Oils specifically for diesel ting fuel economy engines dual-fuel petrol / LPG engines engines 7000 10W-40 China...
Page 43 ALL TYPES LUBRICANTS - TOTAL recommended oils TOTAL QUARTZ TOTAL QUARTZ DIESEL Blended oils for all Oils specifically for petrol and Oils specifically for diesel engines dual-fuel petrol / LPG engines engines Saudi Arabia Bahrain Dubai United Arab Emirates Iran Israel MIDDLE 9000 5W-40...
Page 44 LUBRICANTS - TOTAL recommended oils ALL TYPES 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 45 ALL TYPES LUBRICANTS - TOTAL recommended oils Engine coolant fluid CITROEN reference Packs GLYSANTIN G 33 REVCOGEL 2000 CITROEN Fluid 2 litres 9979 70 9979 72 All countries Protection : - 35°C 5 litres 9979 71 9979 73 20 litres 9979 76 9979 74 210 litres...
Page 46 LUBRICANTS - TOTAL recommended oils ALL TYPES WARNING: TOTAL LDS fluid cannot be blended with TOTAL LHM PLUS All countries WARNING: CITROËN C5 : Use only TOTAL FLUIDE LDS suspension fluid. Hydraulic circuit rinsing fluid- green in colour All countries TOTAL HYDRAURINCAGE Wash/wipe fluid Packs...
Page 47 ENGINE OIL CONSUMPTION ALL TYPES 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 48 ALL TYPES ENGINE SPECIFICATIONS Engines : HDZ - HFX - KFX – KFW – NFT – NFV – NFU - NFX Petrol All Types 1.1i 1.4i 1.6i 1.6i 16V Engine type 1124 1360 1587 Cubic capacity (cc) Bore / Stroke 72/79 75/77 78.5/82...
Page 49 ALL TYPES ENGINE SPECIFICATIONS Engines : LFX – 6FZ - RFN - RFS Petrol All Types 1.8i 1.8i 16V 2.0i 16V Engine type Cubic capacity (cc) 1761 1749 1997 1998 Bore / Stroke 83/81.5 82.7/81.4 85/88 86/86 Compression ratio 9.5/1 10.8/1 10.8/1 Power ISO or EEC KW - rpm...
Page 50 ALL TYPES ENGINE SPECIFICATIONS Engines : VJX - WJZ – WJY – RHY - RHZ Diesel All Types 1.5 D 1.9 D 2.0 HDi Engine type Cubic capacity (cc) 1527 1868 1997 Bore / Stroke 77/82 82.2/88 85/88 Compression ratio 23/1 23/1 17.6/1...
Page 51 ALL TYPES SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) CYLINDER HEAD (mm) Engine type 0.05 Maximum permissible bow - 0.20 Gasket surface regrinding TIGHTENING TORQUES ( m.daN) Crankshaft Pre-tightening 2 ± 0.2 2 ± 0.2 Angular tightening 45° 50° ± 5° bearing screws Connecting rod Tightening...
Page 52: All Types
SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) ALL TYPES CYLINDER HEAD (mm) Engine type Maximum permissible bow 0.05 0.03 Gasket surface regrinding - 0.20 - 0.30 - 0.20 - 0.40 TIGHTENING TORQUES ( m.daN) (1) Ø 11 : 1 ± 0.1 2 ±...
Page 53 TUD - XU SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) Engines : RFS - VJX SAXO XSARA - Pre-tighten 0.5 - Pre-tighten 0.4 - Tighten to - Tighten to B1DP03BC B1DP01YD...
Page 54 CYLINDER HEAD TU - TUD- All Types Engines : HDZ - HFX - KFW - KFX - NFT - NFV - NFX - NFU - VJX Identification of the cylinder head gasket HDZ - HFX KFW - KFX NFT - NFV NFX - NFU Engine type Identification marks...
Page 55 CYLINDER HEAD (continued) TU - TUD - All Types Engines : HDZ – HFX – KFX - KFW - NFT – NFV - NFX – NFU – VJX Cylinder head tightening (m.daN) Cylinder head bolts HDZ-HFX-KFX-KFW NFV-NFT - Pre-tightening - Angular tightening 240°...
Page 56 CYLINDER HEAD XU - All Types Engine : 6FZ Identification of the cylinder head gasket Nominal Repair dimension dimension Marking zone 4 – 5 2 – 4 – 5 "d" Marking zone "e" Gasket thickness (mm) Supplier MEILLOR Marking " d " Marking zone "...
Page 57 EW 10 - All Types CYLINDER HEAD (continued) Engine : 6FZ Cylinder head tightening (m.daN) Cylinder head bolts Pre-tightening 1.5 ± 0.2 Tightening 5 ± 0.2 Loosening 360 ° (1 turn) Tightening 2 ± 0.2 Angular tightening 285° ± 5° B1DP16FC A = Washer thickness: 4 ±...
Page 58 EW 10 - All Types CYLINDER HEAD (continued) Engine : RFN Identification of the cylinder head gasket Nominal Repair dimension dimension Marking zone 4 – 5 2 – 4 – 5 "d" Marking zone "e" Gasket thickness (mm) Supplier MEILLOR Multilayer metallic gasket B1DP183D...
Page 59 EW 10 - All Types CYLINDER HEAD (continued) Engine : RFN Cylinder head tightening (m.daN) Cylinder head bolts Pre-tightening 1.5 ± 0.1 Tightening 5 ± 0.1 Loosening 360°± 2° Tightening 2 ± 0.75 Angular tightening 285° ± 5° B1DP16FC A = Washer thickness : 4 ± 0.2 mm. X = Length under heads of new bolts = 144.5 ±...
Page 60 CYLINDER HEAD XU - All Types Engines : LFX - RFS Identification of the cylinder head gasket Engine type (Notch on cylinder head gasket) * Identification marks CURTY Suppliers MEILLOR 0 = Without notch 1 = One notch B1BP004C...
Page 61 XU - All Types CYLINDER HEAD (continued) Engines : LFX - RFS Cylinder head tightening (m.daN) Cylinder head bolts - Pre-tightening - Loosening - Tightening - Angular tightening 300° Note : Oil the threads and under the heads of the cylinder head bolts.
Page 62 CYLINDER HEAD DW8 - All Types Engine : WJZ - WJY Identification of the cylinder head gasket WJZ - WJY Thickness Piston Number Number Engine stand-proud (mm) of holes of holes type (mm) (*) ± 0.04 at A at B 0.51 to 0.55 1.26 0.55 to 0.59...
Page 63 DW10 - All Types CYLINDER HEAD Engines : RHY - RHZ Identification of the cylinder head gasket Piston Number Plaque Thickness stand-proud of notches Engine (mm) (mm) at A 0.47 to 0.605 1.30 ± 0.06 0.605 to 0.655 1.35 ± 0.06 0.655 to 0.705 1.40 ±...
Page 64 CYLINDER HEAD (continued) XUD - DW8 - DW10 - All Types Engines : WJZ – DHY - RHY Cylinder head tightening (m.daN) Cylinder head bolts WJZ - WJY RHY - RHZ WJZ - WJY - Pre-tightening - Tightening - Angular tightening 180°...
Page 65 ALL TYPES BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE Tools 4122-T (C.TRONIC.105.5) 4099-T (C.TRONIC.105)
Page 66 AUXILIARY EQUIPMENT DRIVE BELT 2002 ALL TYPES Engines : All Types Petrol and Diesel TOOLS - Belt tension measuring instrument : 4122-T. (C.TRONIC 105.5) - WARNING : If using tool 4099-T (C.TRONIC 105), refer to the correspondence table on page 90. ESSENTIAL.
Page 67 SAXO AUXILIARY EQUIPMENT DRIVE BELT Engines : HDZ – HFX – (KFX – KFW – NFT) saxo Without air conditioning With air conditioning - Fit the tool 4122-T. - Fit the tool 4122-T. - Tighten the tensioning screw (3) - Tighten the tensioning screw (5) to obtain : to obtain : 55 ±...
Page 68 AUXILIARY EQUIPMENT DRIVE BELT XSARA PICASSO Engine : NFV (Xsara Picasso) Without air conditioning. Tools. [1] Plyers for removing plastic pegs : 7504 –T. [2] Belt tension measuring instrument : 4122 –T. [3] TORX spanner. Remove. - Release the central screw (1).tool [3]. - Detension the tensioner roller (2), (flat spanner 27 on flat).
Page 69 XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT Engine : NFV (Xsara Picasso) With air conditioning. Tools. [1] Plyers for removing plastic pegs : 7504 –T. [2] Belt tension measuring instrument : 4122 –T. [3] 10 mm square (drain spanner). [4] TORX spanner. Remove.
Page 70 AUXILIARY EQUIPMENT DRIVE BELT XSARA Engine : KFW (Xsara) Alternator With air conditioning. [1] Belt tension measuring instrument : [1] Belt tension measuring instrument : 4122-T 4122-T - Tension the belt using the screw (2). - Tension the belt using the screw (4). - Tension should be : - Tension should be : 102 ±...
Page 71 SAXO - XSARA AUXILIARY EQUIPMENT DRIVE BELT Engines : NFX - NFU Without air conditioning. (1) Tensioner roller fixing screw (2) Tensioning screw - New belt : 120 SEEM units. - Reused belt : 86.5 ± 3.5 SEEM units. B1BP1AMC With air conditioning.
Page 72 AUXILIARY EQUIPMENT DRIVE BELT SAXO- XSARA Engine : VJX Without air conditioning. - (6) Roller support fixing screw. - (7) Tensioning screw - Pre-tension the belt (8) to : 120 SEEM units. - Rotate the crankshaft by 3 turns (Direction of rotation). - Adjust the belt (8) tension to : 120 SEEM units.
Page 73 XSARA AUXILIARY EQUIPMENT DRIVE BELT Engine : LFX Without air conditioning. - (3) and (5) Roller support fixing screws - (6) Tensioning screw - Tighten the belt, by loosening the screw (6) to : In SEEM units. 100 ± 10 - Tighten the screws (3) and (5).
Page 74 XSARA AUXILIARY EQUIPMENT DRIVE BELT Engines : LFX - RFS With air conditioning. - Fit the drive belt. - The tensioner roller (1). - Tighten the screws (3) to 2 m.daN. - Move the tensioner roller (1) using the tool (9.52 mm square drive (3/8)) at (2), in order to remove the tool or locking peg (Ø...
Page 75 AUXILIARY EQUIPMENT DRIVE BELT XSARA Engine : RFS Without air conditioning. TOOLS [1] Belt tension measuring instrument 4122-T - (1) Tensioning screw. - (2) Roller support fixing screw (3). - Lightly tighten the screws (2). - Place the tool [1] on the belt. - Tension the belt using the screw (1).
Page 76 AUXILIARY EQUIPMENT DRIVE BELT XSARA - XSARA PICASSO Engines : 6FZ – RFN Without air conditioning. With air conditioning. Tools [1] Plyers for removing plastic pegs 7504-T Remove the belt. -Detension the belt (3) by turning the screw (2) of the tensioner roller (1) (anti-clockwise).
Page 77 AUXILIARY EQUIPMENT DRIVE BELT XSARA Engines : WJX Without power-assisted steering Tools : [1] Belt tension measuring instrument 4122-T. Remove. - Loosen the screws (2). - Tighten the screw (1) until it is against its stop. - Remove the belt. Refitting.
Page 78 AUXILIARY EQUIPMENT DRIVE BELT XSARA Engines : WJZ - WJY Without power-assisted steering, with air conditioning Tools : [1] Belt tension measuring instrument : 4122-T. Remove. - Loosen the screws (1). - Tighten the screw (2) until it is against its stop. - Remove the belt.
Page 79 XSARA AUXILIARY EQUIPMENT DRIVE BELT Engines : WJZ - WJY Power-assisted steering, without air conditioning Tools : [1] Belt tension measuring instrument : 4122-T. Removal. WARNING : If the belt is to be reused, measure the tension before removal. - Loosen : - the screw (1).
Page 80 AUXILIARY EQUIPMENT DRIVE BELT XSARA Engines : WJZ - WJY Power-assisted steering, without air conditioning (continued) Refitting. - Refit the belt. - Place the tool [1] on belt at "f". WARNING : Position tool [1], with the knob downwards. - tighten the nut (2) to obtain a value of : Reused belt: Keep the value taken at removal.
Page 81 XSARA AUXILIARY EQUIPMENT DRIVE BELT Engines : WJZ - WJY Power-assisted steering, with air conditioning Tools : [1] Dynamic tensioner peg (-) 0188 H. [2] Belt tension measuring instrument 4122-T. Removal. - Peg the dynamic tensioner (1) at "a", using tool [1]. - Loosen the screw (2) of the roller (3).
Page 82 AUXILIARY EQUIPMENT DRIVE BELT XSARA Engines : WJZ - WJY Power-assisted steering with air conditioning (continued) Refitting. - Refit the belt. - Using a 7 mm square drive at "b", turn the roller (3), until the tool [1] located at "a" becomes free. - Tighten the screw (2).
Page 83 XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT Engines : RHY - RHZ Without air conditioning Tools [1] Belt tension adjusting square : (-).0188 J2 [2] Ø 4 mm peg : (-).0188.Q1 [3] Ø 2 mm peg : (-).0188.Q2 [4] Levier de compression tendeur dynamique : (-).0188.Z Removal Re-use of belt...
Page 84 XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT Engines : RHY - RHZ Without air conditioning (continued) Refitting. Re-used belt - Compress the tensioner roller (2) by action at « a » (in anti-clockwise direction), tool [4]. - Refit the belt. WARNING : Respect the belt-fitting direction.
Page 85 XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT Engines : RHY - RHZ With air conditioning Tools [1] Belt tension adjusting square : (-).0188 J2 [2] Ø 4 mm peg : (-).0188.Q1 [3] Ø 2 mm peg : (-).0188.Q2 [4] Dynamic tensioner compression lever : (-).0188.Z Removal Re-use of belt...
Page 86 AUXILIARY EQUIPMENT DRIVE BELT XSARA - XSARA PICASSO Engines : RHY - RHZ With air conditioning (continued) Refitting. Re-used belt - Compress the tensioner roller (7) by action at « c » (in anti-clockwise direction), tool [4]. - Refit the belt. WARNING : Respect the direction belt was fitted.
Page 87 ALL TYPES CHECKING AND SETTING THE VALVE TIMING (continued) J4RS Engine type SAXO XSARA XSARA PICASSO BERLINGO See pages : 96 to 97 98 to 102 103 to 107 86 to 88 89 to 92...
Page 88 CHECKING AND SETTING THE VALVE TIMING (continued) ALL TYPES ATED Engine type SAXO XSARA XSARA PICASSO BERLINGO See pages : 113 to 117 93 to 95 108 to 112...
Page 89 CHECKING AND SETTING THE VALVE TIMING Engines : HDZ - HFX - KFW - KFX - NFT - NFV TOOLS à - [1] Flywheel locating peg : 4507-T.A - [2] Camshaft pulley locating peg : 4507-T.B Tool kit 4507-T - [3] Square drive : 4507-T.J - [4] Belt tension measuring instrument : 4122-T...
Page 90 CHECKING AND SETTING THE VALVE TIMING Engines : HDZ - HFX - KFW - KFX - NFT - NFV (continued). REFITTING THE TIMING BELT NOTE : Check that the pegs [1] and [2] are in place. WARNING : Ensure the belt is fitted in the right direction : The arrows «a» signify the crankshaft direc- tion of rotation.
Page 91 CHECKING AND SETTING THE VALVE TIMING Engines : HDZ - HFX - KFW - KFX - NFT - NFV (continued). PRE-TENSIONING THE TIMING BELT (Cont.) - Ensure the timing is correctly set by refitting the pegs [1] and [2]. - Remove the cylinder head cover. - Fit the tool [5] (Ensure it is fitted in the right direction in relation to the timing).
Page 92 CHECKING AND SETTING THE VALVE TIMING Engines : NFX - NFU TOOLS - [1] Belt tension measuring instrument : 4122-T à - [2] Flywheel locating peg : 4507-T.A. - [3] Camshaft pulley locating peg, exhaust : 4533-T.A. C2 Tool kit 4507-T - [4] Camshaft pulley locating peg, inlet : 4533-T.A.
Page 93 CHECKING AND SETTING THE VALVE TIMING Engines : NFX - NFU (continued) SETTING THE VALVE TIMING - Loosen the screw (2), remove the belt. -Loosen the six pulley screws (1) on the hubs. (There should be a slight amount of friction between the screws and the pinions). -Check that the rollers (2) and (3) rotate freely.
Page 94 CHECKING AND SETTING THE VALVE TIMING Engines : NFX - NFU (continued) SETTING THE VALVE TIMING - Turn the two pulleys (1) clockwise to the end of the slots. - With the belt strip (e) fully tensioned, place the belt over the pulley, first exhaust side, then inlet side, while ensuring that marks (b) and (c) on the belt are aligned with marks (f) on the pulleys.
Page 95 CHECKING AND SETTING THE VALVE TIMING Engines : NFX - NFU (continued) SETTING THE VALVE TIMING - Remove the tools [1], [2], [3] and [4]. - Rotate the engine by four turns in the normal direction. (do not turn backwards). - Peg the flywheel [2].
Page 96 CHECKING AND SETTING THE VALVE TIMING Engine : VJX TOOLS - Belt tension measuring instrument : 4099-T or 4122-T à - Flywheel locating peg : 4507-T.A. - Injection pump pulley locating peg : 4527-T. S1 Tool kit 4507-T - Camshaft pulley locating peg : 4527-T.
Page 97 CHECKING AND SETTING THE VALVE TIMING Engine : VJX (continued) SETTING THE VALVE TIMING - Fit the belt in the following order : The crankshaft pinion, the injection pump pulley, the camshaft pulley, the water pump pinion. WARNING : When positioning the belt on the injection pump and camshaft pulleys, they should be turned in the opposite direction of rotation so as to engage the nearest tooth.
Page 98 CHECKING AND SETTING THE VALVE TIMING Engine : VJX (continued) SETTING THE VALVE TIMING - Tighten the screws (1) and (3) to 2.3 m.daN (lock the pulleys using tool 6016-T). - Remove the tools. - Rotate the engine by 10 turns. - Peg : The flywheel, the pulleys (2) and (4).
Page 99 CHECKING AND SETTING THE VALVE TIMING Engine : LFX TOOLS - Belt tension measuring instrument : 4099-T or 4122-T à - Camshaft pulley locating peg : 7004-T.G. - Crankshaft locating peg : 7014-T.N. Tool kit 7004-T - Square drive : 7017-T.W. CHECKING THE VALVE TIMING - Remove the protective covers.
Page 100 CHECKING AND SETTING THE VALVE TIMING Engine : LFX (continued) SETTING THE VALVE TIMING - Fit the tension measuring tool to the middle of the belt strip "c". - Turn the tensioner roller (2) (anti-clockwise direction) using the tool 7017-T.W to obtain the following measurement : 30 ±...
Page 101 CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN TOOLS à [1] Camshaft setting pegs : (-).0189.A [2] Crankshaft setting peg : (-).0189.B Tool kit C.0189. [3] Belt locking pin : (-).0189.K [4] Angular tightening adaptor : 4069-T [5] Hub immobilising tool : 6310-T Checking the valve timing.
Page 102 CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN Checking the valve timing. (continued). WARNING : If the pegs do not engage without effort, restart the fitting and tensioning of the timing belt (see below). Setting the valve timing Remove - Remove the screws (2), the pulley (1), upper valve cover (4), lower valve cover (3).
Page 103 CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN Refit (continued) - Refit the belt (10) on the pinion (12). - Hold the belt (10) with tool [3]. - Position the belt (10) in the following order : - The guide roller (11), the inlet camshaft pinion (9), the exhaust camshaft pinion (8), the water pump (5), the tensioner roller (6).
Page 104 CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN Adjusting the tension (continued). - Tighten the screw (7) of the the tensioner roller (6) to 2.1 ± 0.2 m.daN. IMPERATIVE : The hexagonal drive of the tensioner roller (6) must be at 15° below the level of the cylinder head gasket "g".
Page 105 CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ – RFN Checks (continued) Repositioning the flange. - Immobilise the crankshaft using tool [5]. - Loosen the screw (13). - Release the pinion (12) of the crankshaft. - Bring the flange (14) to the pegging position; using tool [5]. - Fit the tool [2].
Page 106 CHECKING AND SETTING THE VALVE TIMING Engine : RFS TOOLS [1] Belt tension measuring instrument : 4122-T à [2] Camshaft pulley locating peg : 9041-T.Z Tool kit 7004-T [3] Crankshaft locating peg : 7014-T.N [4] Camshaft pulley locking peg : 4200-T.G [5] Tensioner spanner : 7017-T.W Tool kit 7004-T...
Page 107 CHECKING AND SETTING THE VALVE TIMING Engine : RFS SETTING THE VALVE TIMING. - Peg the crankshaft using tool [3]. Refit : - Peg the camshaft pulleys using tool [2]. - The pulley (5). - Lock the flywheel using the tool [6]. - The screw (4) (Tighten moderately).
Page 108 CHECKING AND SETTING THE VALVE TIMING Engine : RFS Pretensioning the timing belt. - Peg the crankshaft using the tool [3]. - Peg the camshaft pulleys using the tool [2]. NOTE : Ensure that the camshaft pulleys rotate freely on the hubs. Clean the contact faces of the pulleys and hubs.
Page 109 CHECKING AND SETTING THE VALVE TIMING Engine : RFS Tensioning the timing belt. - Peg the crankshaft using the tool [3]. - Peg the camshaft pulleys using the tool [2]. NOTE : If it is not easy to peg the camshaft hubs, loosen the tensioner roller (7), and turn the camshafts using the screw (10).
Page 110 CHECKING AND SETTING THE VALVE TIMING Engine : RFS - Tension to : (Pulleys slackened). Engine New belt 35 SEEM units - Tighten the screw of the roller (7) to 2 m.daN. - Fit the tool [4]. - Tighten the screws (10) to 7.5 m.daN. - Remove the tools.
Page 111 CHECKING AND SETTING THE VALVE TIMING Engines : WJZ - WJY TOOLS - [1] HM screw : (-) 0 188 E - [2] Locating peg Ø 6 mm : (-) 0 188 H - [3] Flywheel locating peg : (-) 0 188 D ( or 7014-T.J) Tool kit (-) 0 188.
Page 112 CHECKING AND SETTING THE VALVE TIMING Engines : WJZ - WJY SETTING THE VALVE TIMING Peg : - The camshaft hub (1), using tool [1]. - The injection pump pinion (2), using tool [2]. - The flywheel, using tool [3]. - Lock the flywheel, using tool [4].
Page 113 CHECKING AND SETTING THE VALVE TIMING Engines : WJZ - WJY SETTING THE VALVE TIMING (Continued) NOTE : If necessary, slightly turn pinions (6) and (2) in an anti-clockwise direction in order to fit the belt. The angular movement of the belt in relation to the pinions must not exceed 1/2 tooth. - Fit the tool [7] to the belt strap at "a".
Page 114 CHECKING AND SETTING THE VALVE TIMING Engines : WJZ - WJY SETTING THE VALVE TIMING (Continued). Rotate the crankshaft by 8 turns (direction of rotation). Peg : - The hub (1), using tool [1]. - The pinion (2), using tool [2]. - The flywheel, using the tool [3].
Page 115 CHECKING AND SETTING THE VALVE TIMING Engines : WJZ - WJY SETTING THE VALVE TIMING (Continued) Tighten : - The roller (9) to 2.1 m.daN. - The screws (4) and (5) to 2.3 m.daN. - Remove the tool [7]. - Fit the tool [7] to the belt strap at "a". - The tensioning value should be between 42 ±...
Page 116 CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHZ Tools [1] Belt tension measuring instrument : 4122-T [2] Tension lever : (-).188.J2 [3] Engine flywheel peg : (-).0288.D [4] Belt compression spring : (-).0188.K [5] Camshaft pinion peg : (-).0188.M [6] Engine flywheel lock : (-).0188.F...
Page 117 CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHZ SETTING THE VALVE TIMING. Peg : - The engine flywheel, tool [3]. -The camshaft, tool [5]. Loosen : - The three screws (9). - The screw (7) of the tensioner roller (6). Remove the timing belt.
Page 118 CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHZ SETTING THE VALVE TIMING (continued). - Retighten screws (9) by hand. - Turn the pinion (12) (clockwise) to the bottom of the buttonhole. - Refit the belt on the crankshaft, in the following order, using the tool [4] to keep the belt tight at "a".
Page 119 CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHZ SETTING THE VALVE TIMING (continued). - Position tool [1] on the belt at "b". - Turn the roller (6) (anti-clockwise) using tool [2] to attain a tension of : 98 ±...
Page 120 CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHZ SETTING THE VALVE TIMING (continued). Tighten : - The screw (7) of the roller (6) to 2.5 m.daN. - The screw (9) to 2.m.daN. - Remove the tool [1]. - Refit the tool [1].
Page 121 SPECIAL FEATURES OF THE TIMING XSARA Camshaft hub identification Engine "a" engraving Hubs "b" paint marking Inlet BLUE Exhaust B1EP122C...
Page 122 VALVE CLEARANCE SETTINGS ALL TYPES POSSIBLE PROCEDURES The valve clearances must be checked with the engine cold For engines with 4 cylinders in a line (1-3-4-2 ) Rocking Fully open (Exhaust) Exhaust Inlet Valves Rocking Adjust Adjust fully open Petrol all Types 0.20 mm ±...
Page 123 ALL TYPES CHECKING THE OIL PRESSURE To be read with the Petrol and Diesel correspondence tables Tools Tool kit 4103 - T TU all types XU all types XU all types 1.1 i 1.4 i 1.6 i 1.6 i 16V 1.8 i 1.8 i 16V 2.0 i 16V...
Page 124 ALL TYPES ENGINE OIL PRESSURE SWITCH Tightening Warning lamp goes out at : Location Engine type (Bars) torque (m.daN) 1.1 i 1.4 i all types 1.6 i Above the oil filter 1.6i 16v 1.8 i 1.8i 16v 2.0i 16v Close to the oil filter D6AP01MB D6AP01ND...
Page 125 ALL TYPES ENGINE OIL PRESSURE SWITCH Tightening Warning lamp goes out at : Engine type Location torque (m.daN) (Bars) 1.5 D Above the oil filter 1.9 D DW10 2.0 HDi Close to the oil filter D6AP01MB D6AP01ND...
Page 126 ALL TYPES OIL FILTERS TU all Types 2.0 i 16 v 1.1 i 1.4 i 1.6 i 1.6 i 16 V 1.8i16 V 1.8 i FILTRAUTO LS 923 PURFLUX LS 867 B TUD all Types DW10 1.5 D 1.9 D 2.0 HDi LS 923 PURFLUX...
Page 127 FILLING AND BLEEDING THE COOLING CIRCUIT ALL TYPES Filling and bleeding - Fit the cylinder adaptor [2] 4222-T (Picasso) and the filling cylinder [1] 4520-T (all types). - Use the coolant to ensure protection between - 15°C and - 37°C. - Slowly fill the system.
Page 128 IDLING - ANTI-POLLUTION SAXO - All Types Idling speed % Content (± 50 rpm) Emission Vehicles Engine type Make - Injection type standard Man. Auto. gbox : gbox N gear engaged 1.1 i BOSCH M7.4.4. 1.4 i SAGEM 2000 SAXO <...
Page 129 XSARA - All Types IDLING - ANTI-POLLUTION Idling speed % Content (± 50 rpm) Emission Vehicles Engine type Make - Injection type standard Man. Auto. gbox : gbox N gear engaged 1.4 i IFL5/L4 SAGEM S2000 1.6i BOSCH M.7.4.4. XSARA 2 2.0 i MAGNETTI MARELLIMM 48.P2 <...
Page 130 IDLING - ANTI-POLLUTION BERLINGO - All Types Idling speed % Content (± 50 rpm) Emission Vehicles Engine type Make - Injection type standard Auto. gbox : Man. gbox N gear engaged 1.1 i L3 / W3 BOSCH MA3.1 1.1 i L4 / W4 BOSCH M 7.4.4.
Page 131 SAXO - All Types PETROL INJECTION SAXO 1.6 i 1.6 i 1.1 i 1.4 i (100 hp) (100 hp) Engine type Emission standard IFL5 / L4 BOSCH M. MARELLI SAGEM BOSCH Injection make and type M.7.4.4. 48P2 S2000 M.7.4.4. Fuel pressure (bars) 5500 5500 5700...
Page 132: Petrol Injection
PETROL INJECTION XSARA 2 - All Types XSARA 2 XSARA PICASSO 1.4 i 1.6 i 16 V 2.0 i 16 V 2.0 i 16 V 1.6 i 1.8 i 16 V Engine type IFL5 / L4 Emission standard IFL5 / L4 IFL5 / L4 / K’...
Page 133 BERLINGO - All Types PETROL INJECTION BERLINGO 1.1 i 1.1 i 1.4 i 1.4 i (Dual fuel) 1.6 i 16 V 1.8i Engine type L3 / W3 L4 / W4 L4 /W4 L4 / W4 / IFL5 L3 / W3 Emission standard BOSCH BOSCH...
Page 134 ALL TYPES EMISSION STANDARDS APPLICATIONS NOTES STANDARD CHARACTERISTICS E.E.C Engines Vehicle Applicable Private vehicles: Brussels directive 83/351 > 2 litres 06/89 except special derogations • new cyl. < 2 litres 06/92 for certain private vehicles • existing cyl. < 2 litres 12/92 cyl.
Page 135 EMISSION STANDARDS ALL TYPES APPLICATIONS NOTES STANDARD CHARACTERISTICS E.E.C Engines Vehicle Applicable Utility vehicles: Brussels directives 88/76 All Types and 88/436 • new models 01/10/88 Utility vehicle • existing models 01/10/89 limits = private vehicle Petrol 10/94 15.05 W vu R 15.05 Diesel limits of Brussels...
Page 136 EMISSION STANDARDS ALL TYPES APPLICATIONS NOTES STANDARD CHARACTERISTICS E.E.C Engines Vehicle Applicable Private vehicles: Current Adoption of U.S. standard With catalytic • certain non-EEC converter and EGR Diesel US 87 US 87 European countries • certain Export countries Petrol Private vehicles: Current Adoption of U.S.
Page 137 ALL TYPES EMISSION STANDARDS APPLICATIONS NOTES STANDARD CHARACTERISTICS E.E.C Engines Vehicle Applicable Private vehicles: Current Adoption of U.S. standard • certain non-EEC standard for light utility vehicles US 90 Petrol US 90 Diesel European countries • certain Export countries Private vehicles: Brussels directive 89/458 EURO 1 <...
Page 138 ALL TYPES EMISSION STANDARDS APPLICATIONS NOTES STANDARD CHARACTERISTICS E.E.C Engines Vehicle Applicable Utility vehicles: < 3.5 tonnes • new models 01/10/93 Brussels Directive 93/59 • existing models 01/10/9 EURO 1 With oxygen sensor and 3 classes depending on Class 1 : Petrol catalytic converter for vehicle weight :...
Page 139 ALL TYPES EMISSION STANDARDS APPLICATIONS NOTES STANDARD CHARACTERISTICS E.E.C Engines Vehicle Applicable Utility vehicles: Brussels Directive 96/69 < 3.5 tonnes With oxygen sensor and Class 1 : EURO 2 reinforced catalytic converter 3 classes depending on Petrol • new models 01/97 for petrol vehicles.
Page 140 ALL TYPES EMISSION STANDARDS APPLICATIONS NOTES STANDARD CHARACTERISTICS E.E.C Engines Vehicle Applicable Utility vehicles: Brussels Directive 98/69 With 2 oxygen sensors EURO 2 standard (L3) < 3.5 tonnes and catalytic converter for made stricter petrol vehicles. Class 1 : 01/2000 Fiscal incentives EURO 3 With catalytic converter...
Page 141 ALL TYPES EMISSION STANDARDS APPLICATIONS NOTES STANDARD CHARACTERISTICS E.E.C. Engines Vehicles Applicable With 2 oxygen sensors and Brussels Directive: 2001/1 Private vehicles : catalytic converter for petrol Essence 01/2005 EURO 3 standard (L4) made All types EURO 4 IF / L5 Diesel vehicles.
Page 142 ANTI-POLLUTION TECHNICAL CHECKS (FRANCE) ALL TYPES All Types Petrol CO Corrected (In %) All Types Diesel (m -1) Conditions : At idle, engine warm. # 01/96 Features : Less than 4.5 % for vehicles registered before 10/86. Xantia, MMDCM injection on 1.6i (BFZ) engine, 1.8i (LFZ) engine and 2.0i Less than 3.5 % for vehicles registered after 10/86.
Page 143 XSARA - XSARA PICASSO PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM Engines : RHY - RHZ Cleaning. - The use of high pressure cleaners is prohibited - Do not use compressed air. Fuel supply circuit. - Required fuel : diesel. WARNING : Do not use other fuels. Electric circuit.
Page 144 XSARA - XSARA PICASSO PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM Engines: RHY - RHZ High pressure fuel injection common rail. - Do not separate the connectors (7) from the common injection rail (6). - (malfunction). Diesel injectors. WARNING : Diesel and ultrasonic cleaners are prohibited. Do not separate the following components from the diesel injector carrier (9) : - Diesel injector (8) (no replacement parts).
Page 145 SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM XSARA - XSARA PICASSO Engines : RHY - RHZ 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 146 SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM XSARA - XSARA PICASSO Engines : RHY - RHZ 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 147 XSARA - XSARA PICASSO CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engines : RHY - RHZ TOOLS [1] Ø 10 mm low pressure connector : 4215-T [2] Ø 8 mm low pressure connector : 4218-T [3] Pressure gauge for testing boost pressure : 4073-T Tool kit 4073-T Connect the tool [1] between the booster pump and the fuel filter (white mark at "a"...
Page 148 CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT XSARA - XSARA PICASSO Engines: RHY - RHZ (continued) Checks on pressure : dynamic. Engine running, at idle (normal functioning): - Fuel supply pressure shown by the pressure gauge [3] = 2 ± 0.4 Bar. - Fuel return pressure shown by the pressure gauge [3] = 0.7 ±...
Page 149 XSARA - XSARA PICASSO CHECKS : AIR SUPPLY CIRCUIT Engines: RHY - RHZ TOOLS [1] Manual vacuum pump : FACOMM DA 16. IMPERATIVE : Respect the safety and cleanliness requirements. Vacuum pump. - Connect the tool [1] on the vacuum pump (1). - Start the engine.
Page 150 CHECKS : TURBO PRESSURE XSARA - XSARA PICASSO Engine : RHZ Tools. [1] Pressure gauge for checking boost pressure : 4073-T.A Tool kit 4073-T [2] Sleeve for checking boost pressure : 4185-T [3] Adaptor sleeve : 4229-T Checks. IMPERATIVE : respect the following checking requirements : Engine at running temperature.
Page 151 XSARA - XSARA PICASSO CHECKS : TURBO PRESSURE Engines : RHY TOOLS. [1] Pressure gauge for checking boost pressure : 4073-T.A Tool kit 4073-T [2] Sleeve for checking boost pressure : 4185-T Checks. IMPERATIVE : respect the following checking requirements : Engine at running tempe- rature.
Page 152 CHECKS : EXHAUST GASES RECYCLING CIRCUIT XSARA - XSARA PICASSO Engine : RHY TOOLS [1] Manual vacuum pump : FACOMM DA 16. IMPERATIVE : Respect the safety and cleanliness requirements. EGR valve - Connect the tool [1] to the capsule union (1). - Apply, several times in succession, a vacuum of approx.
Page 153 SAXO - XSARA SPECIFICATIONS OF THE SIEMENS INJECTION PUMP PUMP -TYPE - REFERENCE Emission standards TD EURO 3 Equipment Transponder XSARA FTP 6186 D 10/F...
Page 154 SPECIFICATIONS OF THE SIEMENS INJECTION PUMP SAXO - XSARA Static timing Reference Adjustments (rpm) Max. speed Dynamic Injector Pump Engine Initial advance Colour Injector Type timing needle lift Unladen Fast Anti- Laden type Compression code Injector holder Idling Reference pressure checking stall idling...
Page 155 XSARA SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP PUMP - TYPE - REFERENCE Emission standards Equipment Transponder DWLP 12 XSARA R8448 B 371 B...
Page 156 SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP XSARA Static timing Reference Adjustments (rpm) Max. speed Dynamic Injector Pump Engine Initial advance Colour Injector Type timing needle lift Unladen Fast Anti- Laden type Compression code Injector holder Idling Reference pressure checking stall idling Time...
Page 157 XSARA CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP Engines : WJZ - WJY Evolution of the checking of the setting of the LUCAS diesel injection pump Old assembly. NEW ASSEMBLY : RPO 7910 # Diesel injection pump with hole for Diesel injection pump without a hole checking the setting for checking the setting.
Page 158 CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP XSARA Engines : WJZ - WJY (continued) Tools. [1] Flywheel locating peg : 7014-T.J. [2] H M8 screw : (-).0188.E. Tool kit C.0188 [3] Injection pump setting peg Ø 6 mm : (-).0188.H After carrying out the necessary dismantling operations on the vehicle, proceed in the following manner : Remove : - The screws (6), (7), (9), (10) and (12).
Page 159 XSARA CONTROLE-CALAGE DE LA POMPE MECANIQUE DELPHI Engines : WJZ - WJY (continued) Peg : - The camshaft hub, using tool [2]. - The injection pump hub, using tool [3]. Impossible to peg the camshaft. Reset the valve timing (See pages 108 to 112). Possible to peg the camshaft, but not the injection pump.
Page 160 ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS XSARA Engines : WJZ - WJY Adjusting the fast idle. Engine cold. - Ensure that the lever (2) is up against its stop to the right. - If not, adjust the tension of the cable (3) using the cable clamp (1). - Finish tensioning using the sleeve tensioner (4).
Page 161 XSARA ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS Engines : WJZ - WJY (continued) Adjusting the anti-stall (residual output). - Insert a 3 mm thick shim (10) between the throttle lever (6) and the anti-stall screw (7). - Push the stop lever (8). - Insert a 3 mm diameter peg (9) in the lever (2).
Page 162 FITTING DELPHI DIESEL INJECTORS XSARA Engines : WJZ - WJY [1] Tool to remove/refit injectors (2) 7007-T Fitting an injector 7008-T.A Tool kit 4123-T The copper seal (1) and the fire seal washer (3) are to be replaced each time they are removed.
Page 163 SAXO - XSARA BOSCH INJECTION PUMP SPECIFICATIONS PUMP - TYPE - REFERENCE Emission standards L3/L4 Equipment Transponder SAXO XSARA CP1 (*) (*) = The fuel high pressure pump is driven by the timing belt.
Page 164 BOSCH INJECTION PUMP SPECIFICATIONS SAXO - XSARA Static timing Reference Adjustments (rpm) Max. speed Dynamic Injector Pump Colour Engine (1) Initial advance Injector Type timing needle lift Unladen Fast Anti- Laden type Compression Injector holder Idling Reference pressure checking code stall idling Time...
Page 165 SAXO - XSARA CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP Engine : VJX Tools à - Flywheel locating peg : 4507-T.A - Mounting plate locating peg : 4527-T.S1 Tool kit 4507-T - Camshaft peg : 4527-T.S2 Checks - Peg the flywheel. - Visually check the pegging of the camshaft and pump pulleys, or check using the tools 4527-T.S1 and 4527-T.S2.
Page 166 CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP SAXO - XSARA Engine : VJX ADJUSTING THE FAST IDLE SPEED. - Bring the lever (3) into contact with the screw (2). - Use the screw (2) to obtain the fast idle speed : 1100 ± 100 rpm. Engine cold : - Ensure that the lever (3) is up against the screw stop (2).
Page 167 SAXO - XSARA CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP Engine : VJX (continued) ADJUSTING THE ACCELERATOR CONTROL. - Fully depress the accelerator pedal. - Check that the lever (10) is against the stop screw (6). If not, modify the position of the spring clip (7).
Page 168 ADJUSTING THE MECHANICAL CONTROLS OF THE BOSCH INJECTION PUMP SAXO - XSARA Engine : VJX (continued) ANTI-STALL ADJUSTMENT - Insert a 1 mm shim [1] between the throttle lever (10) and the residual output adjustment screw (9). - Turn the residual output adjustment screw (9) to obtain an engine speed of : 835 ±...
Page 169 SAXO - XSARA FITTING BOSCH INJECTORS Engine : VJX [1] Tool to remove/refit injectors (2) 7007-T Fitting an injector 7008-T Tool kit 4123-T The copper seal (1) and the fire seal washer (2) are to be replaced each time they are removed.
Page 170 FITTING BOSCH INJECTORS XSARA - XSARA PICASSO Engine : RHY Evolution : Classification of diesel injector carriers Reminder : RHY and RHZ are equipped with 4 diesel injector carriers marked according to their injection 16/11/98 # duct diameters (flow of diesel fuel). Identification.
Page 171 ALL TYPES SPARKING PLUGS Electrode Tightening Vehicles – Models BOSCH CHAMPION Engine type SAGEM gap setting torque 1.1i HDZ/HDY 1.4i SAXO FR7DE RC8YCL RFN58LZ 1.6i 2.5 mdaN 0.9 mm 1.6i 16v 1.4i FR7DE RC8YCL RFN58LZ 1.6i 16v FR7ME XSARA 2.0i 16v FR8ME REC9YCL RFN52HZ...
Page 172 SPEEDOMETER ALL TYPES An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled. This decree stipulates : -The speed indicated by a speedometer must never be lower than the actual vehicle speed. - Between the speed displayed «SD»...
Page 173 CLUTCH SPECIFICATIONS ALL TYPES 1.4i 1.6i 16V 1.5D 1.1i 1.6i Engine type Gearbox MA/4 - MA/5 Make VALEO 180 CPO Mechanism/Type 180 CP 3400 2200 CPR 3800 180 P 3000 3400 180 XJF Clutch disc 181 XJ (E73) 11 R 10 X 200X(D95) 11A12X 73 C Ext./Int.
Page 174 CLUTCH SPECIFICATIONS ALL TYPES 2.0i 16V 1.8i 16V 1.9TD 2.0 HDi 1.8i Engine type Gearbox BE4/5 Make VALEO 200 CP 215 DT 5250 Mechanism/Type 230 DNG 4700 200 P 3700 230 P 4700 4250 200 B Clutch disc 230 DNG 4700 215 F D95 215 F (D 93) 22 BX (D73) 33AX...
Page 175 SAXO - XSARA CLUTCH : CHECKS AND ADJUSTMENTS Mechanically operated push-action clutch (adjustable) SAXO Adjustable HFX-KFW-NFT-NFX-VJX Engines MA/5 Gearbox XSARA Non-adjustable KFW-NFU (*) See page 175) ESSENTIAL : If the clutch control is new, squeeze the cable sheath before adjusting by declutching successively a minimum of 20 times.
Page 176 XSARA CLUTCH : CHECKS AND ADJUSTMENTS Push-action clutch with automatic adjustment (non-adjustable) ( BE3/5 – BE4/5 Engines Gearboxes LFX - WJZ - WJY Refitting the clutch cable. - Set the pedal to the high position (contact at A). - Attach the cable end-piece to the pedal. - Refit a new clip (3) to the pedal.
Page 177 XSARA - XSARA PICASSO CLUTCH : CHECKS AND ADJUSTMENTS Pull-action clutch with automatic adjustment (non-adjustable) ( BE4/5 Engines RFS – RFN – RHY - RHY Gearbox Refitting the clutch cable. - Set the pedal to the high position (contact at A). - Attach the cable end-piece to the pedal.
Page 178 CLUTCH : CHECKS AND ADJUSTMENTS XSARA - XSARA PICASSO Adjustment of push and pull action clutch with automatic compensation (adjustment of compensation system) Engines : LFX - RFN - RFS - WJX - RHY - RHZ WARNING : If a system blockage is detected when checking, or if the pedal has been removed, the pedal position must be adjusted.
Page 179 CLUTCH : CHECKS AND ADJUSTMENTS XSARA - XSARA PICASSO Engines : LFX - RFN - RFS - WJX - RHY - RHZ B2BP02SC NOTE : This cable has an automatic adjusting device which takes up the clutch disc wear and makes up for the compression of the outer cable. DESCRIPTION 1 - Metallic cable, crimped on both ends.
Page 180 CLUTCH : CHECKS AND ADJUSTMENTS XSARA - XSARA PICASSO Engines : LFX - RFN - RFS - WJX - RHY - RHZ B2BP03QD Operation Clutch disengagement phase Engagement / adjustment phase For the adjusting device to operate correctly, it As soon as the pedal is applied, the attaching The pedal returns to rest on its upper is necessary that : end-piece (4) leaves the sleeve (1) which...
Page 181 SAXO - All Types GEARBOX AND TYRE SPECIFICATIONS Petrol 1.4i 1.1i 1.6i 1.6i 16V Automatic Engine type Tyres-Rolling circumference 155/70 R 13 – 1.67 m 165/65 R14 1.725m 185/55 R14 1.7 m Gearbox type MA/5 MA/4 – MA/5 Gearbox ident. plate 20 CF 03 20 CF 12 20 CN 03 –...
Page 182 GEARBOX AND TYRE SPECIFICATIONS XSARA # 09/2000 Petrol 1.6i 16V 2.0i 16V 1.4i Automatic Automatic Engine type Tyres-Rolling circumference 195/55 R15 - 1.815 m MA/5 BE4/5 BE3/5 Gearbox type Gearbox ident. plate 20 CF 13 20 TP 49 20 DL 40 20 TE 47 20 CN 28 20 TP 47...
Page 183 GEARBOX AND TYRE SPECIFICATIONS XSARA PICASSO Petrol Diesel 1.6i 1.8i 16 V 2.0 HDi Engine type Tyres-Rolling circumference 185/65 R15 – 1.895 m Gearbox type BE4/5 Gearbox ident. plate 20 DL 66 20 DL 68 20 DL 64 Reduction box torque 15x64 19x77 19x72...
Page 184 GEARBOX - MA/5 SAXO - XSARA Engines : HFX - KFW - NFT - NFX - NFU - VJX Filler screw Drain screw B2CP34HP B2CP20FC B2CP20GC...
Page 185 SAXO - XSARA GEARBOX CONTROLS - MA/5 Engines : HFX - KFW - NFT - NFX - NFU - VJX 1 - Gear lever. 2 - Gear control rod. 3 - Gear control rod. A = 11.5 mm. 4 - Gear selection rod. B = 9.5 mm.
Page 186 GEARBOX – BE4/5 XSARA - XSARA PICASSO Engines : NFV - 6FZ - RFN - RFS - WJY - RHY - RHZ (a) = Marking zone (Sequence and serial no.). (b) = Location of identification label. B2CP3BNC B2CP3BPD...
Page 187 XSARA - XSARA PICASSO GEARBOX – BE4/5 Engines : NFV - 6FZ - RFN - RFS - WJY - RHY - RHZ Identification (1) Primary shaft. (14) 1 gear synchroniser (2) Clutch bearing guide. (15) Driven gear (1 gear). (3) Gearbox casing. (16) Secondary shaft.
Page 188 GEARBOX– BE4/5 SAXO - XSARA - XSARA PICASSO Engines : NFV - 6FZ - RFN - RFS - WJY – RHY - RHZ Tightening torques Ref. Description Number of screws m.daN End guide 1.2 ± 0.1 Clutch housing 1.3 ± 0.1 Primary shaft nut 7.2 ±...
Page 189 SAXO - XSARA - XSARA PICASSO GEARBOX CONTROLS - BE4/5 Engines : NFV - 6FZ - RFN - RFS - WJY – RHY - RHZ (1) Gear control lever. (2) Gear engagement control cable (*). (3) Gear selection control cable (*). (4) Gear selection ball-joint Ø...
Page 190 SAXO - XSARA - XSARA PICASSO BE4/5 GEARBOX – CHECKS AND ADJUSTMENTS Engines : NFV - 6FZ - RFN - RFS - WJY – RHY - RHZ Principles of adjusting the gear controls. WARNING : Cables should be adjusted each time the gearbox, gear controls or power unit are removed.
Page 191 SAXO - XSARA - XSARA PICASSO BE4/5 GEARBOX - CHECKS AND ADJUSTMENTS Engines : NFV - 6FZ - RFN - RFS - WJY – RHY - RHZ Adjusting the gear controls. TOOLS. [1] ] Tool for positioning the gear lever : 9607-T.
Page 192 AUTOMATIC GEARBOX - MB3 SAXO Engine : KFW Tightening torques m.daN. - Gearbox to engine fixing - Converter to engine fixing - Converter closing plate fixing - Electrical bracket fixing - Flexible mounting to gearbox fixing - Speedometer drive - Heat exchanger fixing NOTE : When fitting a new automatic gearbox, it is ESSENTIAL that the heat exchanger and the oil be replaced.
Page 193 SAXO RECOMMENDATIONS - PRECAUTIONS (MB3 AUTOMATIC GEARBOX) Engine : KFW 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 WARNING : Never place the gearbox on its lower casing (risk of of the vehicle cannot be raised : deforming the tray and damaging the hydraulic valve block).
Page 194 RECOMMENDATIONS – PRECAUTIONS (AUTOMATIC GEARBOX - MB3) SAXO Engine : KFW PRE-REPAIR PROCEDURE Oil quality If the gearbox has suffered a serious fault resulting in a malfunction or the destruction of a clutch, the oil will overheat and become contaminated with impurities : the oil is said to be "burnt". This is characterised by a black colour and the presence of an unpleasant smell.
Page 195 SAXO RECOMMENDATIONS – PRECAUTIONS (AUTOMATIC GEARBOX - MB3) Engine : KFW PRE-REPAIR PROCEDURE (continued) Negative pressure circuit. Absence of fault codes Measure the parameters. - Check the negative pressure circuit. Anomalies present: - Carry out the necessary repairs. - YES : Carry out the necessary repairs. - NO : Check (adjust the negative pressure capsule).
Page 196 SPECIAL FEATURES: AUTOMATIC GEARBOX - MB3 SAXO Engine : KFW Hydraulic valve block. Refitting. WARNING : On refitting the strainer, ensure that the bracket (6) runs under the washer of the screw (7). - Refit the strainer without tightening the screws. - Observe the following tightening sequence : - Screws 1,2,3,4 and 5 to 0.9 m.daN.
Page 197 SAXO MB3 AUTOMATIC GEARBOX CONTROLS Engine : KFW B2CP352D...
Page 198 MB3 AUTOMATIC GEARBOX CONTROLS - CHECKS AND ADJUSTMENTS SAXO Selection control Adjusting the selection control WARNING: No part must be forced ESSENTIAL : Put the gearbox side while performing these operations control in the 1st imposed position; (careful removal). the 2 markings "a" must be aligned. Removing the gear lever knob.
Page 199 XSARA AUTOMATIC GEARBOX - AL 4 Engines : NFU - RFN - RHZ WARNING : This gearbox benefits from a special CITROEN semi-synthetic oil which cannot be mixed with any other oil. The gearbox is lubricated for life. (a) Part reference. B2CP30ZD...
Page 200 RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 ) XSARA Engines : NFU - RFN - RHZ 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 201 XSARA RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4) Engines : NFU – RFN - RHZ PROCEDURE BEFORE REPAIRS AL 4 gearbox Oil Quality If the gearbox has suffered a serious fault resulting in a malfunction or the destruction of a clutch, the oil will overheat and become contaminated with impurities : the oil is said to be "burnt".
Page 202 RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4) XSARA Engines : NFU - RFN - RHZ AL 4 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).
Page 203 XSARA RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 ) Engines : NFU – RFN - RHZ PROCEDURE BEFORE REPAIRS (continued) When the ECU detects an erroneous or absent valueon input or Reading the fault codes. output : Read the fault codes. - It writes the fault in memory.
Page 204 RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 ) XSARA Engines : NFU - RFN - RHZ ECU : Downloading Updating the gearbox ECU by downloading : - Follow the procedure using the diagnostic tool. The downloading operation enables the automatic gearbox to be updated, or adapted to an evolution of the engine ECU. Before commencing the downloading, take the value of the oil usage counter present in the automatic gearbox ECU.
Page 205 XSARA RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 ) Engines : NFU - RFN - RHZ 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.
Page 206 RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 ) XSARA Engines : NFU - RFN - RHZ SHIFT LOCK - The shift lock is a system which locks the selection lever in the park position "P". Unlocking the SHIFT LOCK (In normal operation) - Switch on the ignition.
Page 207 ALL TYPES DRIVESHAFTS - GEARBOXES Tightening torques Gearbox oil seal mandrels (m.daN) Driveshaft Driveshaft Right Left Toolkit Gearbox Engines bearing MA/4 - MA/5 24.5 HFX-KFW-NFV-NFT-NFX-NFU-VJX KFW-NFU 7114-T.X 7116-T MA/5 XSARA 7114-T.W BE4/5 NFV-RFN-6FZ-WJY-RHY-RHZ 4101-T.E1 4601-T 24.5 +4601-T.E2 Seal extractor RH / LH (-) 0338 C 32.5 (-) 0338 AL 4...
Page 208 AXLE GEOMETRY SAXO - All Types Geometry of the axles at reference height. Front height Rear height H1 = R1 – L1 H2 = R2 + L2 H1 = Distance between the ground and H2 = Distance between the ground the mounting face of the fixings.
Page 209 SAXO - All Types AXLE GEOMETRY Geometry of the axles at reference height. Front height Rear height Reminder : Measuring the front height Reminder : Measuring the rear height H1 = Distance between the ground and the mounting face of the fixings H2 = Distance between the ground and the rear crossmember B3BP07UC B3BP07VD...
Page 210: Axle Geometry
AXLE GEOMETRY SAXO - All Types Geometry of the axles at reference height. Normal suspension Raised suspension Front Rear Front Rear TU1M+ (**) TU1M+ (**) TU1M+ TU1M+ All Types Engine TU3JP – TU5JP All Types TU3JP – TU5JP TU5JP4 – TUD5B TU5JP4 –...
Page 211 SAXO - All Types FRONT AXLE Anti-roll bar Ø 18 and 22 mm Anti-roll bar Ø 19 and 21 mm (1) Suspension leg. (3) Front anti-roll bar. (9) Lower arm. Tightening torques m.daN (2) Anti-roll bar bearing fixing on the bodyshell 5.5 ±...
Page 212 REAR AXLE SAXO - All Types (1) Rear axle. (2) Damper. (5) Rear suspension arm. (7) Rear brake drum. (9) Torsion bar. The Anti-roll bar is located inside the tube of the rear axle. Tightening torques m.daN. (3) Damper upper fixing screw 10 ±...
Page 213 SAXO - All Types REAR AXLE - SUSPENSION Torsion bar TU1M+ (1) (2) – TU3JP (2) TU1M+ - TU3JP TU1M+TUD5B (3) TU5JP4 - TUD5B (1) TU5JP4 – TUD5B Torsion bar Ø (mm) 17.9 18.3 Black White Green Colour reference LH : 2 rings Torsion bar RH : 1 ring (1) = Entreprise.
Page 214 SAXO - All Types STEERING SPECIFICATIONS Manual steering NOTE : The steering assembly is secured to the bulkhead.. Tyres 155/70 R13 165/70 R13 165/65 R14 Pinion (no. of teeth) Length of the steering track rods (Between the centre lines of the ball-joints). Rack (no.
Page 215 MANUAL STEERING SAXO - All Types Tightening torques (m.daN) 1 - Airbag 7 - Pivot ball-joint nut 2 - Airbag fixing to steering wheel 8 - Lock nut M14 3 - Steering wheel fixing 8 - Lock nut M16 4 - Steering column fixing 9 - Track rod articulation 5 - Steering cardan joint fixing 10 - Splined coupling fixing to steering rack...
Page 216 POWER-ASSISTED STEERING SAXO - All Types Tightening torques (m.daN) 1 - Airbag 8 - Track rod lock nut M16 2 - Airbag fixing to steering wheel 9 - Track rod articulation 3 - Steering wheel fixing 10 - Splined coupling fixing to steering rack 4 - Steering column fixing 11 - Steering ram to splined coupling 5 - Steering cardan joint fixing...
Page 217 SAXO - All Types POWER STEERING (continued) Power steering system WARNING : Saxo all types except diesel without aircon 1 - Power steering 2 - Oil dispensing valve 3 - Power-assisted steering ram 4 - Low pressure pipe 5 - High pressure pipe 6 - Upper reservoir 7 - Power steering electro-pump unit and built-in lower reservoir...
Page 218 POWER STEERING (continued) SAXO - All Types POWER STEERING SYSTEM WARNING : Saxo diesel with aircon Description. NOTE : The power steering system on vehicles without aircon is supplied by a mechanical pump driven by the accessories drive belt. (6) Power steering mechanism. (7) Upper reservoir.
Page 219 XSARA - All Types AXLE GEOMETRY Front and rear measuring points XSARA All Types Front height Rear height B3CP046D H1 = Dimension between the centre of the front suspension arm mounting and the ground. H2 = Dimension between the contact face of the rear mounting and the ground. R1 = Front wheel radius under load.
Page 220 AXLE GEOMETRY XSARA - All Types Reference heights Tools [1] Gauge for measuring the radius of wheels with 4 bolts : 8006-T Setting the reference height. Front Rear Measure the dimension «R1». Measure the dimension «R2». Calculate the dim. H1 = R1 - L1. Calculate the dim.
Page 221 XSARA - All Types AXLE GEOMETRY Values of the front and rear suspensions, at reference height ESSENTIAL : When checking the suspensions, the vehicle should be at reference height. Tools used : Compress the suspension, to obtain the values at reference height. [1] Set of two suspension compressors : 9511-T.A [2] Set of four straps...
Page 222 AXLE GEOMETRY XSARA Values of the front and rear suspensions, at reference height Front axle All engines (except 2.0i 16V) 2.0i 16V All CRD engines Adjustable - 1.5 ± 1 Tracking - 0°15' ±10' 0° Castor 3° ± 40’ King pin inclination 11°...
Page 223 XSARA - All Types AXLE GEOMETRY a = Angle which defines the tracking between the front and rear axles. Its value must not exceed 12' B3CP04UC...
Page 224 FRONT AXLE XSARA - All Types Tightening torques (m.daN). (1) Damper nut 4.5 ± 0.4 (2) Cup screw 2.5 ± 0.3 (3) Suspension leg (4) Anti-roll bar link rod upper ball-joint 3.7 ± 0.3 (5) Suspension leg pivot (hollow pivot) 4.5 ±...
Page 225 XSARA - All Types FRONT AXLE Evolution : Suspension arm ball-joint Application from RPO : 7968. New components : - Suspension arm ball-joint. - Pivot. Old fitting ØA = 16 mm. New fitting ØA = 18 mm. Repair requirements. ESSENTIAL : Swapping of old and new components is forbidden. It is permitted to fit a new pivot/ball-joint assembly on one side of an old vehicle.
Page 226 XSARA - All Types FRONT AXLE Anti-roll bars Engines Diameter Colour reference 1.6i-1.6i 16V-1.9D Saloon Blue Estate 2.0i 16V (RFV)-2.0 HDi Yellow Saloon 2.0i 16V (RFS) White...
Page 227 XSARA - All Types FRONT AXLE XSARA # 07/1999 XSARA 07/1999 # 09/2000 XSARA 09/2000 # The angle of castor changes to 3° except for LPG vehicles, DRC vehicles, and Estates All Types. DRC = Difficult Road Conditions : this type of vehicle has axles and suspensions designed for driving on rough road surfaces.
Page 228 REAR AXLE XSARA - All Types Tightening torques (m.daN) (1) Anti-roll bar lever 3.2 ± 0.3 (2) Anti-roll bar (3) Transversal torsion bars (4) Rear crossmember flanges 8.3 ± 0.8 (5) Front mountings 5.5 ± 0.5 (6) Rear mountings 4.5 ± 0.4 (7) Anti-vibration clamp.
Page 229 XSARA - All Types REAR AXLE Vehicles Torsion bars (mm) Anti-roll bars (mm) Engines Diameter Colour reference Diameter Colour reference 3-door Entreprise 19.3 Violet Orange 3- and 5-door TT 19.D 18.7 Yellow Blue exc. Entreprise Grey Green Estates All types 19.3 Violet Orange...
Page 230 REAR AXLE XSARA - All Types Evolution : Rear hub nut Old # 15/12/1999. New 15/12/1999 # Evolution : - New rear hub nut (3). - Washer discontinued (2). Old fitting (A) (1) Rear hub nut. (2) Thrust washer. ESSENTIAL : Tighten to : 27.5 ± 2.7 m.daN New fitting (B) (3) Rear hub nut.
Page 231 REAR AXLE XSARA - All Types - The front mountings are aligned at an angle of 45° in relation to the vehicle’s axis. Operating clearance - X = 1 to 1.4 mm. - The rear mountings are in parallel with the vehicle’s axis. NOTE : The RH torsion bar can be identified by NOTE : There are two suppliers for the mountings: 1 paint line.
Page 232 REAR DAMPER XSARA - All Types Adjusting the rear dummy damper Lengths of the rear dummy damper (mm) Engines Normal driving Grand export 1.9 D 1.6i 16V 3-door 1.6i 16 V 5-door 2.0i 16V (RFN) -2.0 HDi 2.0i 16V (RFS) Estates and Entreprise all types E5AP14WC...
Page 233 MANUAL STEERING SPECIFICATIONS XSARA - All Types Steering wheel - Manual steering - (a) : L.H.D./R.H.D = White. - (L) : Shaft length = 311 ± 1.5 mm. - (1) Steering wheel fitted with AIRBAG. (according to equipment). - (4) Steering column adjustment lever. Tightening torques (m.daN).
Page 234 MANUAL STEERING SPECIFICATIONS XSARA - All Types Manual steering Tightening torques (m.daN) (7) Pivot ball-joint nut (8) Link rod lock nut : 4.5 (9) Ball-joint on steering rack (10) Fixing on cradle (11) Plunger flange screw : 1.2 B3EP042D...
Page 235 MANUAL STEERING SPECIFICATIONS XSARA - All Types Manual steering (continued) Number of teeth Number of Steering rack Steering ratio Steering stop steering wheel travel turns Pinion Steering rack (mm) 6 teeth (13) 22/1 L.H.D. 73.5 (RH helix) Yellow thickness mm - Length of the steering link rods (Pre-adjustment) = 371 mm (Between ball-joint centres) or 391 mm (Between the centre of the pivot ball-joint and the contact face of the steering rack ball-joint).
Page 236 POWER-ASSISTED STEERING SPECIFICATIONS XSARA - All Types Steering wheel - Power-assisted steering - (a) : L.H.D. = Blue. : R.H.D. = White. - (L) : Shaft length = 311 ± 1.5 mm. - (1) Steering wheel fitted with AIRBAG. (according to equipment). - (4) Steering column adjustment lever.
Page 237 XSARA - All Types POWER-ASSISTED STEERING SPECIFICATIONS Power-assisted steering Tightening torques (m.daN) (7) Pivot ball-joint nut (8) Link rod lock nut : 4.5 (9) Ball-joint on steering rack (10) Fixing on subframe (11) Hydraulic pipe connection : 2.5 (12) Valve to housing fixing : 1.2 (13) Plunger flange screw : 1.2...
Page 238 POWER-ASSISTED STEERING SPECIFICATIONS XSARA - All Types Power-assisted steering (continued) Number of teeth Steering rack Number of travel steering wheel Steering ratio (mm) turns Pinion Steering rack 18.8/1 L.H.D. 71.7 (RH helix) Steering valve Vehicles Protector colour Number of teeth ( All types (except 1.8i 16V - 1.9TD) BLACK 1.8 i 16V - 1.9 TD...
Page 239 POWER-ASSISTED STEERING SPECIFICATIONS XSARA - All Types Power-assisted steering assembly Tightening torques (m.daN) High pressure tube (Rubber seal pump side) - Power-assisted valve and pump union : 2.5 Return pipe. - Power-assisted valve union : 2.5 (16) - Upper front fixing (E3) : 2.5 (17) - Upper rear fixing (E3) : 2.2...
Page 240 AXLE GEOMETRY XSARA PICASSO - All Types Measurements at reference height NOTE : To make the setting of reference height easier, it is acceptable to take the measurement from the flange of the jacking point. WARNING : The values shown should only be used as guides. In case of doubt, check the settings at reference height Front height Rear height B3CP05BC...
Page 241 AXLE GEOMETRY XSARA PICASSO - All Types Measurements at reference height (continued). (The reference height of the vehicle is set as per the table below). Front axle Rear axle B3CP05BC B3CP05AC B3DP079C H1 = R1 – L1 H1’ = R1 – L1’ H2 = R2 + L2 FRONT AXLE Essieu rear...
Page 242 AXLE GEOMETRY XSARA PICASSO - All Types Measurements at reference height (continued). Compress the suspension to obtain the calculated values. Vehicle all types Front axle Rear axle Vehicle Tracking Castor King pin inclination Camber Tracking Camber Adjustable Non-adjustable 0 mm ± 1mm 4.8 mm ±...
Page 243 FRONT AXLE XSARA PICASSO - All Types Tightening torques m.daN. (1) Damper nut : 4.5 ± 0.4 (2) Cup screw : 2.5 ± 0.3 (3) Suspension arm. (4) Anti-roll bar link rod ball-joint : 3.7 ± 0.3 (5) Suspension arm swivel : 4.5 ±...
Page 244 XSARA PICASSO - All Types REAR AXLE Tightening torques m.daN. (14) Front flexible mounting on subframe : 9.5 ± 0.9 (15) Anti-roll bar bolt : 5.5 ± 0.5 (16) Rear torsion bar (17) Anti-roll bar (18) Tubular axle (19) Front flexible mounting on bodyshell : 4 ±...
Page 245 XSARA PICASSO - All Types REAR AXLE Evolution : Rear hub nut Old # 15/12/1999. New 15/12/1999 # Evolution : - New rear hub nut (3). - Washer discontinued (2). Old fitting (A) (1) Rear hub nut. (2) Thrust washer. ESSENTIAL : Tighten to : 27.5 ±...
Page 246 SUSPENSION XSARA PICASSO - All Types Height of the vehicle in running order (The vehicle height, when in running order, is set according to the measurements shown in the table below). The vehicle is said to be in running order when it is empty, with all reservoirs full, including the fuel tank.
Page 247 XSARA PICASSO - All Types SUSPENSION Measurements at the front and rear axles, vehicle in running order Vehicles all types (except CRD) Front axle Rear axle 1.6i - 1.8i 16 V Adjustable 1.6i - 1.8i 16 V 2.0 HDi Adjustable 2.0 HDi 2 mm ±...
Page 248 STEERING COLUMN SPECIFICATIONS XSARA PICASSO - All Types Left hand drive = Green marking. Right hand drive = White marking. (1) Steering wheel. (4) Steering column adjustment. Tightening torques m.daN. (2) Airbag to steering wheel fixing 0.8 ± 0.1 (3) Steering wheel fixing 3.3 ±...
Page 249 XSARA PICASSO - All Types STEERING SPECIFICATIONS Tightening torques (m.daN) (7) Pivot ball-joint nut 4 ± 0.4. (8) Steering rod adjusting lock nut 4.5 ± 0.4. (9) Ball-joint on steering rack 6 ± 0.6. (10) Fixing steering on subframe 8 ± 0.8. (11) Hydraulic pipe connection 2.4 ±...
Page 250 STEERING SPECIFICATIONS XSARA PICASSO - All Types Steeringl Rack Number of teeth Number of Turning circle Turning circle rack trave pinion in rack steering wheel turns between walls entre trottoirs Left hand drive LH helix 71.7x2 3.22 12 m 11.48 m Right hand drive RH helix Engines...
Page 251 XSARA PICASSO - All Types POWER-ASSISTED STEERING SPECIFICATIONS Tightening torques (m.daN) Unions between pump unions and power steering valve 2 ± 0.3 (16) Fixing screw 2.2 ± 0.3 (17) Fixing screw 2.2 ± 0.3 (18) Fixing screw 2.2 ± 0.3 NOTE : Coat the threads with product ‘‘E3’’.
Page 252 BRAKE SPECIFICATIONS SAXO - All Types 1.1i - 1.4 i 1.6i (1) Compensator integral with the wheel cylinder. 1.6 i 1.5 D 1.6 i 16V (2) Load sensitive compensator. Power-assisted steering without ABS Master cylinder 20.6 22.2 Master-vac 177.8 203.2 228.6 Caliper/ Ø...
Page 253 SAXO - All Types BRAKE SPECIFICATIONS (continued) 1.6 i Entreprise 1.1 i - 1.4 i (1) Compensator integral with the wheel cylinder. 1.6 i 1.6 i 16V 1.5 D 1.1i-1.5D (2) Load sensitive compensator. Power-assisted steering with ABS Manual steering Master cylinder 20.6 Master-vac...
Page 254 BRAKES SAXO - All Types B3FP06GC Conditions - Vehicle in running order - 5 litres of fuel. - A driver (75 Kg). Adjusting the brake limiter. - Apply the brake pedal to close the limiter. Adjusting the stop lamp switch. - Adjust using the screw (2) to obtain a clearance J of 0.5 to 2 mm.
Page 255 BRAKES (continued) SAXO - All Types Tightening torques (m.daN) ABS - 1.1 i - 1.4 i - 1.6 i Removing the caliper - 1.1 i Manual steering - Screw M8 3.2 ± 0.3 - Screw M12 12 ± 1.2 - 1.1 i - 1.4 i (Except 1.6 i) - 2 Screws M12 12 ±...
Page 256 BRAKES (continued) SAXO - All Types EVOLUTION : Fixing screws for FRONT brake calipers: Type BENDIX STANDARD 4. Application from RPO 8973. Repair. Vehicles concerned. Vehicles equipped with non-ventilated brake discs. (Except VTS trim Removing-refitting the front brake caliper (old and new fitting) level).
Page 257 SAXO - All Types BRAKES (continued) EVOLUTION : Fixing screws for REAR brake calipers: Type BENDIX STANDARD 4. Application from RPO 8973. Repair. Vehicles concerned. Removing-refitting the rear brake caliper (old and new fitting) Vehicles equipped with non-ventilated brake discs. (Except VTS trim level). Vehicles equipped with the following engines: Clean the threads of the fixing screws and coat them with a brake product TU5J4 and TU5JP.
Page 258 HANDBRAKE (Adjustment) SAXO - All Types Prior to adjustment. - Release the handbrake. - Drums rotating freely. - No tight spot (If there is one, check if the primary or secondary cables are correctly routed). - Check that all the parts slide and move correctly. - Bleed the main circuit.
Page 259 SAXO - All Types BLEEDING THE BRAKES The brakes are bled : - Using brake bleeding equipment, in which case the pressure of the equipment should be set to a maximum of 2 Bars. IMPERATIVE order of bleeding Wheel : - Rear left.
Page 260 BRAKE SPECIFICATIONS XSARA 09/2000 Saloons 1.6i 16V 2.0 HDi 1.4i 2.0i 16V 1.9 D Master cylinder Without ABS 23,8 (expansion holes) With ABS 23,8 (valve) Ø Master-vac 228.6 Caliper/piston makes BOSCH 54 LUCAS 57 BOSCH 54 Disc Ventilated Disc thickness/min. thickness 22 /20 Brake pad grade FERF 769...
Page 261 XSARA 09/2000 BRAKE SPECIFICATIONS Estates 1.6i 16V 2.0 HDi 1.4i 2.0i 16V 1.9 D Master cylinder Without ABS 23,8 (expansion holes) With ABS 23,8 (valve) Ø Master-vac 228.6 Caliper/piston makes BOSCH 54 LUCAS 57 BOSCH 54 Disc Ventilated Disc thickness/min. thickness 22 / 20 Brake pad grade FERF 769...
Page 262 BRAKE SPECIFICATIONS XSARA - All Types - Tighten the nuts (1) to 2.3 m.daN. - The clevis pin (2) is held in place by a plastic clip. B3FP10YD...
Page 263 XSARA - All Types BRAKE SPECIFICATIONS Braking system specifications - X braking circuit. - Front : disc brakes, ventilated (according to model). - Rear : drum brakes with automatic adjustment. - Cable operated handbrake acting on the rear wheels. (1) Hydraulic valve block «ABS Bosch 5.3» or (1) Hydraulic valve block «...
Page 264 BRAKE SPECIFICATIONS XSARA - All Types Braking system without ABS (rear drum brakes) Braking system without ABS (rear disc brakes) From RPO 8687 B3FP14FD B3FP14GD...
Page 265 BRAKE SPECIFICATIONS XSARA - All Types Braking system with ABS (rear drum brakes) B3FP14HD...
Page 266 BRAKE SPECIFICATIONS XSARA - All Types Braking system with ABS REF (rear disc brakes) Braking system with ABS REF (rear drum brakes) B3FP14JD B3FP14KD...
Page 267 BRAKE SPECIFICATIONS XSARA - All Types Braking system with ABS REF (rear drum brakes) B3FP14LD...
Page 268 REAR BRAKE SPECIFICATIONS XSARA - All Types Evolution : Rear brake drum hub 01/1999 # Old assembly New assembly B3FP119D B3FP11AD Evolutions New components : - Rear wheel stub. - Stop ring (ref. (4)). - Double shouldered washer (ref. (5)) NOTE : The new assembly is identified by a figure from 1 to 6 cold-stamped on the head of the wheel stub at «a».
Page 269 REAR BRAKE SPECIFICATIONS XSARA - All Types Evolution : Rear brake disc hub 01/99 # Old assembly New assembly B3FP11BD B3FP11CD Evolutions Fixing of the brake disc hub. Sealing of the brake disc hub. New components: New components: - Rear wheel stub. - Sealed bearing incorporated at «b»...
Page 270 CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR XSARA - All Types To perform any checks, it is necessary to calculate the weight on the rear axle in order to refer to the adjustment graphs. Preliminary pre-check operations. Calculate : 1) The rear weight of the vehicle (empty tank + 1 person) # Note the vehicle type Refer to table N°...
Page 271 CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued) XSARA - All Types (Weights in kg) TABLE N° 2 (Weight of fuel in the fuel tank). TABLE N° 1 (Rear weight of the vehicle (Empty tank + 1 person)). Type of fuel Diesel Trim level Petrol...
Page 272 CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued) XSARA - All Types GRAPH N° 1 GRAPH N° 2 B3FP09XD B3FP09YD...
Page 273 XSARA - All Types CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued) GRAPH N°3 B3FP09ZD...
Page 274 CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued) XSARA - All Types TOOLS - Braking pressure checking tool : 4140-T CHECKING THE BRAKE PRESSURE WARNING : Do not touch the plastic nut (1). PRELIMINARY OPERATIONS - Place the vehicle on a 4-column lift if possible. - Fit tool 4140-T.
Page 275 XSARA - All Types CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued) ADJUSTING THE COMPENSATOR WARNING : Do not touch the plastic nut (1). IMPORTANT : When loosening the nut (2), the spring (3) may suddenly force off the nut (2) and lock nut (4) assembly.
Page 276 HANDBRAKE XSARA - All Types CHECKING AND ADJUSTING THE HANDBRAKE - Remove the handbrake console. - Jack up and chock the vehicle with the rear wheels hanging free. - Check the correct routing of the brake cables under the vehicle. - Apply and release the handbrake ten times.
Page 277 XSARA - All Types BLEEDING THE BRAKES Bleeding : The brakes can be bled either : - using brake bleeding equipment, in which case the pressure of the equipment should be set to 2 Bars. - or in the usual way. IMPERATIVE order of bleeding Wheels : - Rear Right.
Page 278 BRAKE SPECIFICATIONS XSARA PICASSO - All Types NOTE : On models equipped with ABS, there is no load-sensitive braking compensator. 1.6 i 1.8 i 16 V 2.0 HDi Master cylinder 23.8 Master-vac Caliper/ Ø LUCAS C 54 piston makes Non-ventilated Disc Ventilated Disc thickness/min.
Page 279 XSARA PICASSO - All Types BRAKE SPECIFICATIONS Braking system specifications - ‘‘X’’ braking circuit. - Front : disc brakes, ventilated - Rear : drum brakes with automatic wear adjustment. - Cable operated handbrake acting on the rear wheels. - Rear: load-sensitive braking compensator (non-ABS models) - (1) Hydraulic valve block ‘‘ABS Bosch 5.3’’.
Page 280 BRAKING SYSTEM SPECIFICATIONS XSARA PICASSO - All Types Without ABS With ABS B3FP11WD B3FP11UD...
Page 281 XSARA PICASSO - All Types CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR Tools [1] Brake pressure checking tool : 4140-T Checking procedure Determining the rear weight of the vehicle Determine the weight on the rear axle and then refer to the adjustment Refer to the tables of different weights.
Page 282 CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR XSARA PICASSO - All Types Tools [1] Brake pressure checking tool : 4140-T Example. Type of vehicle = TU5JP+ Rear weight (tank empty + 1 person). = 542 Kg. Fuel tank half full = 22 Kg Sun roof = 10 Kg...
Page 283 XSARA PICASSO - All Types CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR GRAPH N° 1 GRAPH N° 2 B3FP13RD B3FP13SD Key : P = Rear pressure (in Bars). a = Front pressure 60 ± 3 Bars. M = Weight (in Kg). b = Front pressure 100 ±...
Page 284 CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR XSARA PICASSO - All Types GRAPH N° 3 GRAPH N° 4 B3FP14MD B3FP13UD Key : P = Rear pressure (in Bars). a = Front pressure 60 ± 3 Bars. M = Weight (in Kg). b = Front pressure 100 ±...
Page 285 XSARA PICASSO - All Types CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR GRAPH N° 5 GRAPH N° 6 B3FP14ND B3FP14PD Key : P = Rear pressure (in Bars). a = Front pressure 60 ± 3 Bars. M = Weight (in Kg). b = Front pressure 100 ±...
Page 286 XSARA PICASSO - All Types CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR Checking the braking pressure Preliminary operations : - The vehicle should be placed on all 4 wheels, preferably on a lift. - The tool [1] (in good working order) in place. - Compare the value noted with the graph.
Page 287 XSARA PICASSO - All Types CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR Adjusting the load-sensitive brake compensator - Untighten the screw (1). - Move the spring rod. - Decrease the length of the spring to increase the pressure. - Increase the length of the spring to decrease the pressure. - Tighten the screw (1) to 1,2 ±...
Page 288 HANDBRAKE (Adjustment) XSARA PICASSO - All Types Adjustment : Remove the handbrake trim (1). Unclip the sound-deadening (2). Raise and support the vehicle with the rear wheels hanging free. Check the correct routing of the brake cables under the vehicle. Apply and release the handbrake 4 times.
Page 289 BLEEDING THE BRAKES XSARA PICASSO - All Types Tools Bleeding equipment of type «LURO» or similar. IMPERATIVE : For bleeding the secondary circuit, use ELIT, LEXIA or PROXIA diagnostic tools. Draining. Drain the brake fluid reservoir as empty as possible using a syringe. Disconnect the brake fluid warning lamp connector.
Page 290 STARTER MOTORS SAXO Manufacturer and Ref. Class Climate Vehicles / models VALEO D7E16 H,T,C BOSCH A 001183 027 F 1.1i MELCO M002T13081 VALEO D6 RA 572 VALEO D7E16 BOSCH A 001183 027 F H.,T 1.4i (Aircon) 1.6i (Aircon) MELCO M002T13081 C.
Page 291 XSARA STARTER MOTORS Manufacturer and Ref. Class Climate Vehicles / models VALEO D7E16 1.4i BOSCH A 001183 027 F H, T 1.6i (Power steering MELCO M002T13081 or aircon) C, VC VALEO D6 RA 572 VALEO D7E23 1.4i (Power steering BOSCH E OAL 101 390 and aircon) VALEO D6RA572 C, VC...
Page 292 STARTER MOTORS XSARA Manufacturer and Ref. Class Climate Vehicles / models VALEO D6 RA 109 H, T BOSCH A 001 111 562F MELCO M 001 T 80381 1.9D VALEO D7 R 26 MELCO M 001 T 80481 VALEO D7 R 27 VALEO D6 RA 109 XSARA H, T...
Page 293 XSARA PICASSO STARTER MOTORS Manufacturer and Ref. Class Climate Vehicles / models VALEO D7E16 1.6i H, T BOSCH A 001 183 027F (Power steering MELCO M002T13081 and aircon) C, VC VALEO D6RA572 VALEO D7E23 1.6i H, T (Power steering BOSCH E OAL 101 390 and aircon) VALEO D6RA572 C, VC...
Page 294 STARTER MOTORS ALL TYPES Table of classes of starters CLASS CLASS 2 CLASS 3 CLASS 4 CLASS 5 CLASS 6 Torque C 5.5 Nm 6 Nm 10 Nm 11.5 Nm 11.5 Nm Maximum power for a speed I ≤ 275 A I ≤...
Page 295 SAXO With power-steering ALTERNATORS Classes and types Classes and types Engine Gbox Without aircon Climate With aircon Climate VALEO A13 VI 279+ VALEO A11 VI 55 VALEO A11 VI 55 H, T BOSCH A120310028 BOSCH A120310028 VALEO A13 VI 278 1.1i T, C, VC DENSO C 633217-40...
Page 296 ALTERNATORS SAXO Police Classes and types Engine Gbox Without aircon Climate With aircon Climate SAXO POLICE 11.1i/1.4i VALEO A13 VI 279+ VALEO A13 VI 279+ 1.5D VALEO A13 VI 279+ VALEO A13 VI 279+ CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
Page 297 XSARA With power-steering ALTERNATORS Classes and types Engine Gbox Without aircon Climate With aircon Climate VALEO SG7 VALEO SG7 C, VC H, T, C, VC MELCO A005 TA 6291 MELCO A005 TA 6291 VALEO SG8 DENSO A 115 1.4i MELCO A005 TA 6391 VALEO A13 VI 277 VALEO A13 VI 277+ VALEO SG9...
Page 298 ALTERNATORS XSARA With power-steering Classes and types Engine Gbox Without aircon Climate With aircon Climate VALEO SG7 VALEO SG8 C, VC MELCO A005 TA 6291 DENSO A 115 VALEO SG8 MELCO A005 TA 6391 DENSO A 115 VALEO A13 VI 277 1.6i 16v H, C, VC H, T...
Page 299 XSARA With power-steering ALTERNATORS Classes and types Engine Gbox Without aircon Climate With aircon Climate VALEO A 11 VI 191 VALEO A13 VI 203 T, C, VC VALEO SG7 H, T VALEO SG8 VALEO SG7 CPLE MELCO A002 TB 4791 1.9D VALEO A13 VI 203 VALEO A13 VI 204+...
Page 300 ALTERNATORS XSARA PICASSO With power-steering Classes and types Engine Gbox Without aircon Climate With aircon Climate VALEO A11 VI 191 VALEO A11 VI 191 VALEO SG7 T, C, VC VALEO SG7 VALEO SG7 CPLE VALEO SG7 CPLE VALEO A13 VI 204+ 1.6i VALEO SG10 MELCO A002 TB 4891...
Page 301 XSARA PICASSO With power-steering ALTERNATORS Classes and types Engine Gbox Without aircon Climate With aircon Climate VALEO A11 VI 191 VALEO A13 VI 203 VALEO SG7 T, C VALEO SG8 C, VC 1.8i 16v VALEO SG7 CPLE MELCO A002 TB 4791 VALEO A13 VI 203 VALEO A13 VI 204+ VALEO SG8...
Page 302 CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR ALL TYPES 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 Speed voltmeter (V), and a rheostat (R) or a Volt/Ammeter/Rheostat combination. 2000 3000 4000...
Page 303 SAXO - C3 - XSARA - XSARA PICASSO PRE-HEATING AND STARTING SYSTEMS Pre / Post heating Vehicles - models (pre-heating duration at 20°C) Pre-heater plugs Pre-heater control unit BERU 0 100 226 371 NAGARES 960411-P SAXO 1.5D 10s / 150s CHAMPION CH 185 CARTIER 735068 NGK YE04...
Page 304 AIR CONDITIONING R 134 a (HFC) ALL TYPES Compressor Refrigerant Vehicle Engines Date Variable refill Oil quantity cc Oil reference Capacity TU - TUD-TT AM 2000 # 850 gr +0 - 50 gr SAXO TU TT 825 gr ± 25 gr SD 6 V 12 AM 2001 # TUD TT...
Page 305 ALL TYPES SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Click-fit connector removing/fitting tool Vehicle Circuit Ø Inch Ring colour Tool kit 4164-T SAXO All Types XSARA Black 8005-T.A. XSARA PICASSO 8005-T.C C5HP073C Tightening torques (m.daN). Aircon compressor fixings Unions ESSENTIAL : Tighten the front part of the Steel/Steel Ø...
Page 306 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) XSARA PICASSO « EUROCLIM » Compressor (MANULLI seal) Tools. Tool for removing-refitting air conditioning seals : K.1702 MANULLI seal XSARA PICASSO engine versions : : 10/12/2001 # : 01/04/2002 # : 04/11/2002 # Aircon compressor.
Page 307 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Condenser (MANULLI seal) Seals (MANULLI seal) C5HP18VD C5HP18XD The condenser (5) has a cylinder (6) incorporating the function of aircon MANULLI calibrated seal (3) fluid reservoir and with integral filtering cartridge. Direction of fitting of the seal (3). The inlet (7) and the outlet (8) of the condenser (5) are equipped with Before fitting the seal, amply lubricate the seal with air conditioning new seals (3) (MANULLI).
Page 308 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) ALL TYPES Presence of pollen filter Vehicle Equipment RPO No. Presence of filter Observations SAXO All Types Without aircon YES (Behr) Exc. driving school XSARA Base aircon YES (Larger) XSARA PICASSO Regulated aircon YES (Valeo) Without aircon NO (Valeo)
Page 309 XSARA - All Tyês SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) BEHR plate evaporator Pollen filter C5HP07JC C5FP075D Remove-refit. Remove : - The interior trim (1). - The cover (4). - The pollen filter (3). Concerns vehicles equipped with aircon without temperature regulation. Fitting of a new pollen filter necessistates the following operations : - Engage the pollen filter upwards (following arrow "c").
Page 310 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) XSARA - All Tyes BEHR condenser with integral reservoir (16 Ti) Petrol engine versions The condenser is equpped with a cylinder (1) that acts as the fluid reser- voir which in turn incorporates a filter cartridge. NOTE : As soon as the air conditioning loop has been open for more than 5 minutes, the filter/dryer cartridge assembly should be replaced (no set interval).
Page 311 XSARA PICASSO SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) BEHR plate evaporator Pollen filter Remove: - The three screws (1). - The cover (2). - Remove the pollen filter. C5HP062C B1BP23ED...
Page 312 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) XSARA PICASSO BEHR condenser with integral reservoir (16 Ti) The condenser is equpped with a cylinder (1) that acts as the fluid reservoir which in turn incorporates a filter cartridge. NOTE : As soon as the air conditioning loop has been open for more than 5 minutes, the filter/dryer cartridge assembly should be replaced (no set interval).
Page 313 ALL TYPES SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Compressor lubricant. ESSENTIAL: The compressor lubricant is extremely hygroscopic; always use FRESH oil. Checking the compressor oil level. There are three specific cases : 1) Repairs to a system without leaks. 2) Slow leak.
Page 314 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) ALL TYPES Checking the compressor oil level (continued) 2) Slow leak. - Slow leaks do not lead to oil loss, therefore the same procedure should be followed as if there was no leak at all. 3) Fast leak.
Page 315 ALL TYPES 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 Preliminary conditions.
Page 316 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM ALL TYPES CHECKING TEMPERATURES (continued) Vehicle using R134.a fluid (Compressor with variable capacity) Ambient temperature in °C Vehicle Engine types All Types 17 ± 3 13 ± 3 11 ± 3 9 ± 3 8 ±...
Page 317 ALL TYPES 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 318 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM ALL TYPES CHECKING PRESSURES (continued) Low pressure Low pressure Low pressure too low too high normal - Insufficient fluid charge. - Faulty pressure control valve. High pressure - Cooling fan speed unsuitable. - Constriction of the HP system.
Page 319 AIR CONDITIONING SYSTEM R 134.a SAXO - All Types (3) Click-fit union. C5HP12EC Tightening torques (m.daN). (1) High pressure valve (2) Low pressure valve (3) Click-fit union (4) Pressostat (1 seal Ø 10,82) (5) Dryer (2 seals Ø 7,65) (6) Relief valve, tighten to 0,43 m.daN ± 0,1 (1 seal Ø...
Page 320 SAXO - All Types AIR CONDITIONING SYSTEM R 134.a Checks on the air conditioning circuit Key. T = Scale of Temperature (°C ), and of High Pressure (Bars). P = Scale of Low pressure (Bars). Te = Exterior temperature (°C). HP = Pressure at compressor outlet (Bars).
Page 321 XSARA AIR CONDITIONING SYSTEM R 134.a Plan of air conditioning system Two solutions : 1/ « MANULLI », with « NON EUROCLIM » compressor (O-ring seals). 2/ « EATON », with « EUROCLIM » compressor (quadrilobe seals). (1) - High pressure valve (2) - Low pressure valve (3) - Pressostat (4) - Dryer...
Page 322 XSARA AIR CONDITIONING SYSTEM R 134.a Plan of air conditioning system Solution : 1/ « EATON », with « EUROCLIM » compressor and buffer capacity (quadrilobe seals). (1) - High pressure valve (2) - Low pressure valve (3) - Buffer capacity Tightening torques m.daN.
Page 323 XSARA AIR CONDITIONING SYSTEM R 134.a Plan of air conditioning system Two solutions : 1/ « MANULLI », with « NON EUROCLIM » compressor (O-ring seals). 2/ « EATON », with « EUROCLIM » compressor (quadrilobe seals). (1) - High pressure valve (2) - Low pressure valve (3) - Pressostat (4) - Dryer...
Page 324 AIR CONDITIONING SYSTEM R 134.a XSARA Plan of air conditioning system Two solutions : 1/ « MANULLI », with « NON EUROCLIM » compressor (O-ring seals). 2/ « EATON », with « EUROCLIM » compressor (quadrilobe seals). (1) - High pressure valve (2) - Low pressure valve (3) - Pressostat (4) - Dryer...
Page 325 XSARA AIR CONDITIONING SYSTEM R 134.a Plan of air conditioning system Trois solutions : 1/ « MANULLI », with « NON EUROCLIM » compressor (O-ring seals). 2/ « EATON », with « EUROCLIM » compressor and buffer capacity (quadrilobe seals). 3/ «...
Page 326 AIR CONDITIONING SYSTEM R 134.a XSARA Plan of air conditioning system Two solutions : 1/ « MANULLI », with « NON EUROCLIM » compressor (O-ring seals). 2/ « EATON », with « EUROCLIM » compressor (quadrilobe seals). (1) - High pressure valve (2) - Low pressure valve (3) - Pressostat (4) - Dryer...
Page 327 XSARA AIR CONDITIONING SYSTEM R 134.a Plan of air conditioning system Trois solutions : 1/ « MANULLI », with « NON EUROCLIM » compressor (O-ring seals). 2/ « EATON », with « EUROCLIM » compressor and buffer capacity (quadrilobe seals). 3/ «...
Page 328 XSARA AIR CONDITIONING SYSTEM R 134.a Plan of air conditioning system Two solutions : 1/ « MANULLI », with « NON EUROCLIM » compressor (O-ring seals). 2/ « EATON », with « EUROCLIM » compressor (quadrilobe seals). (1) - High pressure valve (2) - Low pressure valve (3) - Pressostat (4) - Dryer...
Page 329 XSARA PICASSO TU AIR CONDITIONING SYSTEM R 134.a (1) High pressure valve . (2) Low pressure valve. (3) High pressure click-fit union (tool 8005-T.C). (4) Low pressure click-fit union (tool 8005-T.A). (5) Pressostat. 1.8 ± 0.6 m.daN (6) Filtering / drying cartridge plug. Tightening torques m.daN.
Page 330 AIR CONDITIONING SYSTEM R 134.a XSARA PICASSO EW7 (1) High pressure valve . (2) Low pressure valve. (3) High pressure click-fit union (tool 8005-T.C). (4) Low pressure click-fit union (tool 8005-T.A). (5) Pressostat. 1.8 ± 0.6 m.daN (6) Filtering / drying cartridge plug.. Tightening torques m.daN.
Page 331 AIR CONDITIONING SYSTEM R 134.a XSARA PICASSO TU - EW7 Checks on the air conditioning circuit T/P = Scale of: - Temperature (°C), average of air from the central vents. - Pressure, High (Bars). - Pressure, Low (Bars). Te = Exterior temperature (°C). HP = Pressure at compressor outlet (Bars).
Page 332 XSARA PICASSO DW10 AIR CONDITIONING SYSTEM R 134.a (1) High pressure valve . (2) Low pressure valve. (3) High pressure click-fit union (tool 8005-T.C). (4) Low pressure click-fit union (tool 8005-T.A). (5) Pressostat. 1.8 ± 0.6 m.daN (6) Filtering / drying cartridge plug. Tightening torques m.daN.
Page 333 XSARA PICASSO DW10 AIR CONDITIONING SYSTEM R 134.a Checking the air conditioning system T/P = Scale of: - Temperature (°C ), average of air from the central vents. - Pressure, High (Bars). - Pressure, Low (Bars). Te = Exterior temperature (°C). HP = Pressure at compressor outlet (Bars).

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