CITROEN 2001 BERLINGO Handbook
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CITROEN 2001 BERLINGO Handbook

Saxo-xsara
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Table Of Contents
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Table of Contents

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PRIVATE CARS
SAXO-XSARA-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 050008
Book 1
2001

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Summary of Contents for CITROEN 2001 BERLINGO

  • Page 1 PRIVATE CARS 2001 SAXO-XSARA-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: Table Of Contents

    INDEX GENERAL Handbrake LPG safety requirements 166 - 170 Saxo HDi safety requirements 171 - 174 Bleed brakes Saxo 1 - 8 Checking the HDi fuel circuit 175 - 176 Xsara 9/2000 9 - 24 Handbrake Identification Xsara Checking the HDi air circuit Xsara 09/2000 25 - 31 Bleed brakes...
  • Page 5 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 6 SAXO - All Types IDENTIFICATION OF VEHICLES 3-DOOR PETROL SALOONS 1.0 i 1.1 i 1.4 i AUTO. A - X Administration A - X Exclusive IF/L4 Emission standard SO CDZF SO HDZF/GL (1) SO KFXD S6 KFXB/IF SO KFXB/IF Type code Engine type 1124 1360...
  • Page 7 IDENTIFICATION OF VEHICLES SAXO - All Types 3-DOOR PETROL SALOONS 3-DOOR DIESEL SALOONS 1.6 i 1.6 i 16 V 1.5 D A-X-SX Exclusive S - SX Administration Emission standard S6 NFZF S6 NFXF SO VJZF SO VJYF Type code VJZ (1) VJY (2) Engine type 1587...
  • Page 8 SAXO - All Types IDENTIFICATION OF VEHICLES 5-DOOR PETROL SALOONS 1.0 i 1.1 i 1.4 i AUTO. A-SX Administration Driving School SX - Exclusive IF/L4 Emission standard S1 CDZF S1 HDZF/GL (3) S1 KFXD S1 KFXB/IF Type code Engine type 1124 1360 Cubic capacity (cc)
  • Page 9 IDENTIFICATION OF VEHICLES SAXO - All Types 5-DOOR DIESEL SALOONS 1.5 D A-X-SX-Exclusive A-X-SX-Exclusive Driving School Administration Emission standard S1 VJZF (1) S1 VJZF/MOD (2) S1 VJYF (3) Type code Engine type 1527 Cubic capacity (cc) Fiscal rating (hp) MA/5 Gearbox type 20 CE 73 (a) 20 CF 02 (b)
  • Page 10 SAXO - All Types IDENTIFICATION OF VEHICLES Commercial version Entreprise 3 door Petrol Diesel 1.5D 1.0 i 1.1 i A-X-Poste A-X-Poste Administration Administration Emission standard SO HDZF SO CDZF/T (1) S3 CDZF (2) SO VJZF/T (1) S3 VJZF (2) Type code /T.MOD.GL (3) Engine type 1124...
  • Page 11 IDENTIFICATION OF VEHICLES SAXO - All Types 3-DOOR SALOONS Petrol Diesel 1.1i 1.4i 1.6i 1.6i 16V 1.5 D A-X-SX A-X-SX Exclusive SX – Exclusive Exclusive Administration Administration Emission standard SO HFXB S6 KFWB SO KFWB S6 NFTB S6 NFXB SO VJXB Type code Engine type 1124...
  • Page 12 SAXO - All Types IDENTIFICATION OF VEHICLES COMMERCIAL VERSION ENTREPRISE 3 DOOR Petrol Diesel 1.1i 1.5 D A-S-SX A-S-SX Poste Poste Administration Administration Emission standard S3 HFXB S3 VJXB Type code Engine type 1124 1527 Cubic capacity (cc) Fiscal rating (hp) MA/5 MA/5 Gearbox type...
  • Page 13 IDENTIFICATION OF VEHICLES XSARA - All Types # 09/2000 1 Manufacturer’s name plate (Estate). 2 Chassis stamp 3 Manufacturer’s name plate (Saloon).. 4 01/02/1999 # Label : - Tyre pressures. - RP organisation no. - Paint code. Gearbox ident. reference 6 Engine legislation type E1AP08MD...
  • Page 14 XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES 3-DOOR PETROL SALOONS 1.4i 1.6i Dual fuel AUTO. X - X Pack A - X - X Pack X - X Pack X - X Pack X - SX X - X Pack SX - VTR SX - VTR SX - Exclusive...
  • Page 15 IDENTIFICATION OF VEHICLES XSARA - All Types # 09/2000 3-DOOR PETROL SALOONS 1.8i 1.8i 16V 2.0i 16V X Pack - SX X - X Pack VTR - VTS Exclusive Brazil SX - VTR Emission standard Type code NO LFXF NO LFYF N6 LFYF N6 RFSF N6 RFSY...
  • Page 16 XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES 3-DOOR DIESEL SALOONS 1.9 D 1.9 TD 2.0 HDi (1) X - X Pack X - X Pack X - X Pack SX - VTR X - X Pack VTR - VTS VTR - VTS Exclusive Emission standard...
  • Page 17 IDENTIFICATION OF VEHICLES XSARA - All Types # 09/2000 3-DOOR SALOON VERSIONS - ALL TYPES Petrol Diesel 1.4i 1.9 D Dual fuel X Entreprise X Entreprise X Entreprise Emission standard NO KFXF/T (1) NO KFXF/T MOD GL (2) NO WJZF/T (1) N3 WJZF Type code Engine type...
  • Page 18 XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES 5-DOOR PETROL SALOONS 1.6i 1.4 i Dual fuel AUTO. A - X X Pack - SX A - X X - X Pack Exclusive X Pack X-SX X Pack Emission standard N1 KFXG N1 KFXF N1 KFXB...
  • Page 19 IDENTIFICATION OF VEHICLES XSARA - All Types # 09/2000 5-DOOR PETROL SALOONS 1.6i 1.8i 1.8i 16V AUTO. X - X Pack - SX X - X Pack - SX X - X pack - SX Exclusive Exclusive Exclusive Emission standard Type code N1 NFZF N1 NFZM...
  • Page 20 XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES 5-DOOR PETROL SALOONS 1.8i 16V 2.0i 16V Dual fuel AUTO. X - X Pack Brazil X - SX Exclusive Brazil Emission standard N1 LFYY N1 LFYF/GL (1) N1 RFVF N1 RFVB N1 RFVY Type code Engine type...
  • Page 21 IDENTIFICATION OF VEHICLES XSARA - All Types # 09/2000 5-DOOR DIESEL SALOONS 1.5 D 1.9D 2.0 HDi X - X Pack - SX X - X Pack Exclusive Emission standard N1 VJZF N1 WJZF N1 RHYF N1 RHYB Type code Engine type 1527 1868...
  • Page 22 XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES 5-DOOR SALOON VERSIONS – ALL TYPES Petrol Diesel 1.4i 1.8i 1.9 D X Police Unmarked X Police Marked X Police Marked X Gendarmerie X Administration X Police Marked Emission standard N1 KFXF N1 LFXF N1 WJZF N1 WJZC...
  • Page 23 IDENTIFICATION OF VEHICLES XSARA - All Types # 09/2000 5-DOOR SALOON VERSIONS Diesel 1.9 D 1.9 TD 2.0 HDi X Driving School X Entreprise X Police Spain X Entreprise X Entreprise Emission standard Type code N1 WJZF/MOD (1) N1 WJZF/T (2) N1 DHYF N1 RHYF N1 RHYF/T (2)
  • Page 24 XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES PETROL ESTATES 1.4i 1.6i Dual fuel AUTO. AUTO. X - X Pack - SX X Pack X - SX X - X - Pack SX - Exclusive Emission standard N2 KFXF N2 KFXB N2 KFXF/GL N2 NFZU...
  • Page 25 IDENTIFICATION OF VEHICLES XSARA - All Types # 09/2000 PETROL ESTATES 1.8i 1.8i 16V 2.0i 16V Dual fuel AUTO. X – X Pack – SX X – X Pack – SX Brazil Exclusive Exclusive X – SX X – X Pack – SX – Exclusive Emission standard N2 LFXF N2 LFYF...
  • Page 26 XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES DIESEL ESTATES 1.5 D 1.9 D 1.9 TD 2.0 HDi X – X Pack X – X Pack X – X Pack – SX - Exclusive Exclusive Emission standard N2 VJZF N2 WJZF N2 DHYF N2 RHYF...
  • Page 27 IDENTIFICATION OF VEHICLES XSARA - All Types # 09/2000 ESTATE VERSIONS Petrol 1.4i 1.6i Dual fuel X Police Unmarked X Police Marked X Entreprise X – SX Entreprise X Police Unmarked Emission standard N2 KFXF N2 KFXF/T (1) N2 KFXF/T MOD GL (2) N2 LFXF Type code Engine type...
  • Page 28 XSARA - All Types # 09/2000 IDENTIFICATION OF VEHICLES ESTATE VERSIONS Diesel 1.9 D X Police Unmarked X Police Marked X Entreprise Emission standard N2 WJZF WJZF/T (1) N2 WJZF Type code Engine type 1868 Cubic capacity (cc) Fiscal rating (hp) BE3/5 Gearbox type 20 TP 38...
  • Page 29 IDENTIFICATION OF VEHICLES XSARA - All Types # 09/2000 09/2000 # A - Manufacturer’s name plate (Estate). B - Chassis stamp, cold stamp. C - Manufacturer’s name plate (Saloon). D - Label : (affixed on windscreen pillar on driver’s side) - Tyre pressures.
  • Page 30 XSARA - All Types 09/2000 # IDENTIFICATION OF VEHICLES 3-DOOR PETROL SALOONS 2.0i 16V 1.4 i 1.6i 16V AUTO. AUTO. X-SX-VTR X-SX SX-VTR IFL5 Emission standard NO KFWB NO NFUB NO NFUN NO RFN1/IF NO RFN3/IF NO RFSB Type code Engine type 1360 1587...
  • Page 31 IDENTIFICATION OF VEHICLES XSARA - All Types 09/2000 # 3-DOOR PETROL SALOONS PETROL / DIESEL VERSIONS 1.9 D 2.0 HDi 1.4i 1.9 D 2.0 HDi X-SX X-SX-VTR Entreprise Emission standard Type code NO WJZB NO RHYB NO KFWB/T (1) NO WJZB/T (1) NO RHYB/T (1) Engine type 1868...
  • Page 32 XSARA - All Types 09/2000 # IDENTIFICATION OF VEHICLES 5-DOOR PETROL SALOONS 1.6i 16V 1.4 i AUTO. AUTO. X-SX X-SX Exclusive Exclusive K’ K’ Emission standard N1 KFWG N1 KFWB N1 NFUG N1 NFUU N1 NFUB N1 NFUN Type code Engine type 1360 1587...
  • Page 33 IDENTIFICATION OF VEHICLES XSARA - All Types 09/2000 # 5-DOOR PETROL SALOONS 5-DOOR DIESEL SALOONS 2.0i 16V 1.9 D 2.0 HDi AUTO. Exclusive X-SX IFL5 Emission standard N1 RFN1/IF N1 RFN3/IF N1 WJZB N1 RHYB Type code Engine type 1998 1868 1997 Cubic capacity (cc)
  • Page 34 XSARA - All Types 09/2000 # IDENTIFICATION OF VEHICLES PETROL SALOONS / ESTATES 1.6i 16V 2.0i 16V 1.4 i AUTO. AUTO. X-SX Exclusive X-SX Exclusive IFL5 Emission standard N2 KFWB N2 NFUG N2 NFUB N2 NFUN N2 RFN1/IF N2 RFN3/IF Type code Engine type 1360...
  • Page 35 IDENTIFICATION OF VEHICLES XSARA - All Types 09/2000 # DIESEL ESTATES PETROL / DIESEL ESTATE VERSIONS 1.9 D 2.0 HDi 1.4i 1.9 D 2.0 HDi X-SX X-SX Exclusive Entreprise Entreprise Emission standard Type code N2 WJZB N2 RHYB N2 KFWB/T (1) N2 WJZB/T (1) N2 RHYB/T (1) Engine type...
  • Page 36 XSARA PICASSO - All Types IDENTIFICATION OF VEHICLES A - Chassis stamp (Cold stamp on bodywork) B - Chassis no. reminder (Label located at bottom of windscreen right hand side) C - Manufacturer’s data plate. (Located at bottom of RH central pillar). D - Label : Tyre pressures.
  • Page 37 IDENTIFICATION OF VEHICLES XSARA PICASSO - All Types Petrol Diesel 1.6i 1.8i 16 V 2.0 HDi L3 ou L4 Emission standard CH NFZ CH 6FZ CH RHY Type code Engine type 1749 1997 Cubic capacity (cc) Fiscal rating (hp) BE4/5/ J (*) BE4/5 V (*) BE4/5 L (*) Gearbox type...
  • Page 38 BERLINGO - All Types IDENTIFICATION OF VEHICLES 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 39 IDENTIFICATION OF VEHICLES BERLINGO - All Types PETROL 1.1i 1.4i X-SX Multispace X-SX L3/W3 L4/W4 L3/W3 L4/W4 Emission standard MF HDZF MF HFXB MF KFXG MF KFXF MF KFXF/A MF KFWB Type code Engine type 1124 1360 Cubic capacity (cc) Fiscal rating (hp) MA/5 Gearbox type...
  • Page 40 BERLINGO - All Types IDENTIFICATION OF VEHICLES PETROL 1.4i 1.8i Dual fuel Multispace Multispace Multispace L4/W4 L3/W3 Emission standard MF KFXF MF KFXF MF KFWB/A MF LFXF MF LFXF/A Type code /MOD GL /MOD GL Engine type 1360 1761 Cubic capacity (cc) Fiscal rating (hp) MA/5 BE3/5...
  • Page 41 IDENTIFICATION OF VEHICLES BERLINGO - All Types DIESEL 1.9 D 2.0 HDi Multispace Multispace X-SX Multispace X-SX Multispace L3/W3 L4/W4 L3/W3 L4/W4 Emission standard MF WJZF MF WJYB MF RHYF MF RHYB MF WJZF MF WJYB MF RHYF MF RHYB Type code Engine type 1868...
  • Page 42 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 43 CAPACITIES (in litres) SAXO - All Types SAXO Petrol Diesel Ecological oil filter capacity 0.15 litre. 1.0I 1.1I 1.4I 1.6I 1.1I 1.4I 1.6I 1.6I 1.6I 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...
  • Page 44 XSARA - All Types # 09/2000 CAPACITIES (in litres) XSARA # 09/2000 Petrol Diesel 2.0i 1.8i 1.4i 1.6i 1.5D 1.9D 1.9TD 2.0HDi 1.8i 16 V AUTO. AUTO. Engine type 4.75 4.75 4.25 Engine with filter change 4.25 (1) 4.5 (1) 4.25 (1) 4.25 (1) Between Min.
  • Page 45 CAPACITIES (in litres) XSARA - All Types 09/2000 # XSARA 09/2000 # Petrol Diesel Ecological oil filter capacity 0,15 litre. 1.4 i 1.9D 2.0 HDi 1.6 i 16V 2.0i 16V AUTO. AUTO. Engine type 3.25 4.25 4.75 Engine with filter change Between Min.
  • Page 46 XSARA PICASSO - All Types CAPACITIES (in litres) XSARA PICASSO Petrol Diesel Cartouche écologique capacité 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 47 CAPACITIES (in litres) BERLINGO - All Types BERLINGO Petrol Diesel Ecological oil filter capacity 0,15 litre. 1.1I 1.4I 1.8I 1.1I 1.4I 1.9D 2.0 HDI Engine type 4.75 4.75 Engine with filter change 4.5 (1) 4.5 (1) 4.25 (1) Between Min. and Max. 5-speed gearbox Automatic gearbox after drainage...
  • Page 48 ALL TYPES LUBRICANTS - TOTAL recommended oils S.A.E. Norm - Table for selection of engine oil grade Factory evolutions in 2000 model year CITROËN engines are lubricated at the factory with TOTAL oil of grade S.A.E.5W-30. TOTAL oil of grade S.A.E.5W-30 allows improved fuel economies (approx.
  • Page 49 LUBRICANTS - TOTAL recommended oils ALL TYPES Selection of engine oil grades recommended for climatic conditions in countries of distribution API Norms ACEA Norms The first letter corresponds to the type of fuel used by the engine : The first letter corresponds to the type of engine concerned : S : petrol and dual fuel petrol / LPG engines.
  • Page 50 ALL TYPES LUBRICANTS - TOTAL recommended oils Recommendations. Denominations of TOTAL oils, according to country of marketing : TOTAL ACTIVA (France only). TOTAL QUARTZ (outside France). IMPERATIVE : From 1999 model year, to preserve engine performance, all engines fitted in CITROEN vehicles must be lubricated with high quality oils (synthetic or semi-synthetic) These oils must comply with the following norms : Petrol and dual fuel petrol / LPG engines: ACEA A3-98 and API SJ.
  • Page 51 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 52 LUBRICANTS - TOTAL recommended oils ALL TYPES FRANCE Blended oils for all engines Metropolitan FRANCE TOTAL ACTIVRAC S.A.E : 10W-40 Norms TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for petrol and Oils specifically Blended oils for all engines dual-fuel petrol / LPG engines for diesel engines 7000 10 W-40 900 5W-40...
  • Page 53 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 54 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 Blended oils for all engines permitting fuel economy. dual-fuel petrol / LPG engines for diesel engines 7000 10W-40 7000 10W-40...
  • Page 55 LUBRICANTS - TOTAL recommended oils ALL TYPES EUROPE (continued) 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 Czech Republic...
  • Page 56 ALL TYPES LUBRICANTS - TOTAL recommended oils TOTAL QUARTZ TOTAL QUARTZ DIESEL Blended oils Oils specifically for petrol and Oils specifically for all engines dual-fuel petrol / LPG engines for diesel engines Australia OCEANIA 9000 5W-40 7000 10W-40 7000 10W-40 New Zealand Angola - Ivory Coast Egypt- Ecuador - Gabon...
  • Page 57 LUBRICANTS - TOTAL recommended oils ALL TYPES TOTAL QUARTZ TOTAL QUARTZ DIESEL Blended oils Oils specifically for petrol and Oils specifically for all engines dual-fuel petrol / LPG engines for diesel engines 7000 10W-40 China 7000 15W-50 South Korea 7000 10W-40 Hong Kong - India 7000 15W-50 Indonesia...
  • Page 58 ALL TYPES LUBRICANTS - TOTAL recommended oils TOTAL QUARTZ TOTAL QUARTZ DIESEL Blended oils Oils specifically for petrol and Oils specifically for all engines dual-fuel petrol / LPG engines for diesel engines Saudi Arabia Bahrain Dubaï United Arab Emirates Israel MIDDLE 9000 5W-40 7000 15W-50...
  • Page 59 LUBRICANTS - TOTAL recommended oils ALL TYPES Gearbox oils Europe TOTAL TRANSMISSION Manual gearbox Overseas France (new formula) Asia Norms S.A.E 75W-80 TOTAL FLUIDE ATX ou TOTAL FLUIDE AT 42. Automatic gearbox MB3 Special oil distributed by CITROEN (Part No. : 9730 94). TOTAL FLUIDE AT 42 ou Special oil distributed by CITROEN Automatic gearbox 4 HP 14 et 4 HP 18...
  • Page 60 ALL TYPES LUBRICANTS - TOTAL recommended oils Engine coolant 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 9979 77...
  • Page 61 LUBRICANTS - TOTAL recommended oils ALL TYPES Wash / wipe fluid CITROEN reference Concentrate : 250 ml 9980 33 ZC 9875 953 U 9980 56 All countries Liquid ready to use : 1 litre 9980 06 ZC 9875 784 U Liquid ready to use : 5 litres 9980 05 ZC 9885 077 U...
  • Page 62 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 63 ALL TYPES ENGINE SPECIFICATIONS Engines : CDZ - HDZ - HDZ/GPL - HFX - KFX - KFX/GPL - KFW Petrol All Types 1.0i 1.1i 1.4i Engine type HDZ/GPL KFX/GPL 1124 1360 Cubic capacity (cc) Bore / Stroke 70/62 72/79 75/77 9.4/1 9.7/1 10.5/1...
  • Page 64 ALL TYPES ENGINE SPECIFICATIONS Engines : NFZ – NFT – NFU – NFX - LFX Petrol All Types 1.6 i 1.6 i 16 V 1.8 i SAXO PICASSO Engine type 1587 1761 Cubic capacity (cc) Bore / Stroke 78.5/82 83/81.5 9.6/1 10.5/1 11/1...
  • Page 65 ENGINE SPECIFICATIONS ALL TYPES Engines : LFY - LFY/GPL - 6FZ - RFN - RFS - RFV Petrol All Types 2.0i 16V 1.8i 16V Engine type LFY/GPL 1761 1749 1997 1998 Cubic capacity (cc) Bore / Stroke 83/81.4 82.7/81.4 85/88 86/86 10.4/1 10.8/1...
  • Page 66 ALL TYPES ENGINE SPECIFICATIONS Engines :VJZ - VJX - VJY - WJZ - DHV - RHY Diesel All Types 1.5 D 1.9 D 1.9TD 2.0 HDi Engine type 1527 1527 1868 1905 1997 Cubic capacity (cc) Bore / Stroke 77/82 77/82 82.2/88 83/88...

  • Page 67: All Types

    SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) ALL TYPES CYLINDER HEAD (mm) Engine type HDZ-HFX KFX-KFW NFU-NFX VJZ-VJY-VJX 0.05 Maximum permissible bow - 0.20 Gasket surface regrinding TIGHTENING TORQUES ( m.daN) 2 ± 0.2 2 ± 0.2 Crankshaft Pre-tightening bearing screws Loosening Tightening...
  • Page 68 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 : 2 ± 0.1 2.5 ±...
  • Page 69 SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) TUD - XU Engines : LFY -RFV - RFS - VJZ - VJY - VJX SAXO XSARA LFY-RFV-RFS VJZ-VJY-VJX - Pre-tighten 0.5 - Pre-tighten 0.4 - Tighten - Tighten B1DP03BC B1DP01YD...

  • Page 70: Cylinder Head

    CYLINDER HEAD TU - TUD - All Types Engines : CDZ – HDZ – HFX – KFX - KFW – NFZ – NFT – NFU - NFX – VJZ – VJY – VJX IDENTIFICATION OF THE CYLINDER HEAD GASKET Engine type HDZ - KFX HFX - KFW NFZ - NFT NFU - NFX VJZ- VJY - VJX Identification marks...
  • Page 71 CYLINDER HEAD (continued) TU - TUD - All Types Engines : CDZ - HDZ - HFX - KFX - KFW - NFZ - NFT - NFU - NFX - VJX - VJY - VJX Cylinder head tightening (m.daN) Cylinder head bolts CDZ - HDZ - HFX - KFX KFW - NFZ - NFT - Pre-tightening...
  • Page 72 XU - All Types CYLINDER HEAD Engine : 6FZ Identification of the cylinder head gasket Nominal dimension Repair dimension Marking zone 4 – 5 2 – 4 – 5 "d" Marking zone "e" Gasket thickness (mm) Supplier MEILLOR Marking " d " Marking zone "...
  • Page 73 CYLINDER HEAD (continued) EW 10 - All Types 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 74 EW 10 - All Types CYLINDER HEAD (continued) Engine : RFN Identification of the cylinder head gasket Nominal dimension Repair dimension Marking zone 4 – 5 2 – 4 – 5 "d" Marking zone "e" Gasket thickness (mm) Supplier MEILLOR Multilayer metallic gasket B1DP183D...
  • Page 75 CYLINDER HEAD (continued) EW 10 - All Types 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 76 CYLINDER HEAD XU - All Types Engines : LFX - LFY - RFV - RFS IDENTIFICATION OF THE CYLINDER HEAD GASKET Engine type Identification marks (Notch on cylinder head gasket) CURTY Suppliers MEILLOR 0 = Without notch 1 = One notch B1BP004C...
  • Page 77 CYLINDER HEAD (continued) XU - All Types Engines : LFX - LFY - RFV - RFS Cylinder head tightening (m.daN) Cylinder head bolts LFX - LFY - Pre-tightening - Loosening - Tightening - Angular tightening 300° Note : Oil the threads and under the heads of the cylinder head bolts.
  • Page 78 CYLINDER HEAD DW8 - All Types Engine : WJZ Identification of the cylinder head gasket Piston Thickness Number Number Engine stand-proud (mm) of holes of holes type ± 0.04 at A at B (mm) ( 0.51 to 0.55 1.26 0.55 to 0.59 1.30 0.59 to 0.63 1.34...
  • Page 79 CYLINDER HEAD XUD - All Types Engine : DHY Identification of the cylinder head gasket Thickness Piston Marking Engine type (mm) stand-proud (mm) ± 0.06 0.56 to 0.67 1.36 0.68 to 0.71 1.40 0.72 to 0.75 1.44 0.76 to 0.79 1.48 0.80 to 0.83 1.52...
  • Page 80 DW10 - All Types CYLINDER HEAD Engine : RHY Identification of the cylinder head gasket Piston Engine Thickness Number of notches stand-proud type (mm) at A (mm) 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 81 CYLINDER HEAD (continued) XUD - DW8 - DW10 - All Types Engines : WJZ – DHY - RHY Cylinder head tightening (m.daN) Cylinder head bolts - Pre-tightening - Tightening - Angular tightening 180° DHY-RHY - Pre-tightening - Tightening - Angular tightening 220°...
  • Page 82 ALL TYPES BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE Tools 4099-T (C.TRONIC.105) 4122-T (C.TRONIC.105.5)
  • Page 83 AUXILIARY EQUIPMENT DRIVE BELT 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 57. ESSENTIAL.
  • Page 84 SAXO AUXILIARY EQUIPMENT DRIVE BELT Engines : CDZ – HDZ – HFX – (KFX – KFW) Saxo – (NFZ) Saxo - NFT 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 :...
  • Page 85 AUXILIARY EQUIPMENT DRIVE BELT XSARA PICASSO Engine : NFZ (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 86 XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT Engine : NFZ (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 87 AUXILIARY EQUIPMENT DRIVE BELT XSARA Engine : KFX - 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 88 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 89 AUXILIARY EQUIPMENT DRIVE BELT SAXO- XSARA Engine : VJZ - VJY - 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 90 XSARA AUXILIARY EQUIPMENT DRIVE BELT Engines : LFX - LFY - RFV 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 ±...
  • Page 91 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 92 XSARA AUXILIARY EQUIPMENT DRIVE BELT Engines : LFX - LFY - RFV - RFS With air conditioning. - Fit the drive belt. - The tensioner roller (1). - Tightening des vis (3) à 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 93 AUXILIARY EQUIPMENT DRIVE BELT XSARA Engine : RFV With air conditioning. - Loosen : - The screws (4) of the tensioner roller (13 mm angle spanner). - The screw (3). - Tendre la courroie en agissant sur la vis (3) pour obtenir une valeur de : - New belt : 120 SEEM units.
  • Page 94 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 95 AUXILIARY EQUIPMENT DRIVE BELT XSARA Engines : WJZ Without power-assisted steering Tools : [1] Belt tension measuring instrument : 4122-T. Removal. - Loosen the screws (2). - Tighten the screw (1) until it is against its stop. - Remove the belt. Refitting.
  • Page 96 XSARA AUXILIARY EQUIPMENT DRIVE BELT Engine : WJZ Without power-assisted steering With air conditioning. Tools : [1] Belt tension measuring instrument : 4122-T. Removal. - Loosen the screws (1). - Tighten the screw (2) until it is against its stop. - Remove the belt.
  • Page 97 AUXILIARY EQUIPMENT DRIVE BELT XSARA Engine : WJZ 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 98 XSARA AUXILIARY EQUIPMENT DRIVE BELT Engine : WJZ 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 99 AUXILIARY EQUIPMENT DRIVE BELT XSARA Engine : WJZ 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 100 XSARA AUXILIARY EQUIPMENT DRIVE BELT Engine : WJZ 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 101 XSARA AUXILIARY EQUIPMENT DRIVE BELT Engine : DHY Without air conditioning [2] Belt tension measuring instrument : 4122-T - Tension the belt by loosening the screw (4) to obtain : 115 ± 10 SEEM units - Tighten the screws (1) and (3). - Rotate the crankshaft by 4 turns (direction of rotation).
  • Page 102 XSARA AUXILIARY EQUIPMENT DRIVE BELT Engine : DHY With air conditioning Tools (1) Peg : 7019-T. .- Loosen the screws (1). - Tighten or loosen the screw (2) until holes "a" and "b" are superimposed. - Place the peg [1] : (in the hole "a"). - Tighten the screw (2) until it is against its stop.
  • Page 103 AUXILIARY EQUIPMENT DRIVE BELT XSARA - XSARA PICASSO Engine : RHY 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] Dynamic tensioner compression lever : (-).0188.Z REMOVAL Re-used belt...
  • Page 104 XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT Engine : RHY 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. - Remove the tool [4].
  • Page 105 AUXILIARY EQUIPMENT DRIVE BELT XSARA - XSARA PICASSO Engine : RHY 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-used belt.
  • Page 106 XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT Engine : RHY 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. - Remove the tool [4].
  • Page 107 CHECKING AND SETTING THE VALVE TIMING ALL TYPES J4RS Engine type SAXO K 09/2000 XSARA XSARA 09/2000 K XSARA PICASSO See pages : 105 to 107...
  • Page 108 TUD - XUD CHECKING AND SETTING THE VALVE TIMING (continued) Engine type SAXO K 09/2000 XSARA XSARA 09/2000 K XSARA PICASSO See pages : 112 to 114 127 to 131 133 to 137...
  • Page 109 CHECKING AND SETTING THE VALVE TIMING Engines : CDZ - HDZ - HFX - KFX - KFW - NFZ - NFT 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...
  • Page 110 CHECKING AND SETTING THE VALVE TIMING Engines : CDZ - HDZ - HFX - KFX - KFW - NFZ - NFT (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 direction of rotation.
  • Page 111 CHECKING AND SETTING THE VALVE TIMING Engines : CDZ - HDZ - HFX - KFX - KFW - NFZ - NFT (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.
  • Page 112 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 113 CHECKING AND SETTING THE VALVE TIMING Engine : NFX - NFU (continued) SETTING THE VALVE TIMING - Remove the tools [1], [2], [3] and [4]. - 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 114 CHECKING AND SETTING THE VALVE TIMING Engine : 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 115 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 116 CHECKING AND SETTING THE VALVE TIMING Engines : VJZ - VJY - 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 117 CHECKING AND SETTING THE VALVE TIMING Engines : VJZ - VJY - 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 118 CHECKING AND SETTING THE VALVE TIMING Engines : VJZ - VJY - 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 119 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 120 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 121 CHECKING AND SETTING THE VALVE TIMING Engine : 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 122 CHECKING AND SETTING THE VALVE TIMING Engine : 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 123 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 124 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 125 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 126 CHECKING AND SETTING THE VALVE TIMING Engines : LFY - RFV - 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...
  • Page 127 CHECKING AND SETTING THE VALVE TIMING Engines : LFY - RFV - RFS RFV - RFS SETTING THE VALVE TIMING. - Peg the crankshaft using tool [3]. Refit : - Peg the camshaft pulleys using - The pulley (5). tool [2]. - The screw (4) (Tighten moderately).
  • Page 128 CHECKING AND SETTING THE VALVE TIMING Engines : LFY - RFV - RFS RFV - 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 129 CHECKING AND SETTING THE VALVE TIMING Engines : LFY - RFV - RFS RFV - 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 130 CHECKING AND SETTING THE VALVE TIMING Engines : LFY - RFV - RFS RFV - RFS - Tension to : (Pulleys slackened). Engine LFY - RFV - RFS New belt 35 SEEM units - Tighten the screw of the roller (7) to 2 m.daN. - Fit the tool [4].
  • Page 131 CHECKING AND SETTING THE VALVE TIMING Engine : WJZ TOOLS - [1] HM screw : (-) 0 188 E - [2] Locating peg Ø 6 mm : (-) 0 188 H - [3] Flywheel locating peg : (-) 0 188 D ( ou 7014-T.J) Tool kit (-) 0 188.
  • Page 132 CHECKING AND SETTING THE VALVE TIMING Engine : WJZ 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]. - Refit the screw (3) (without tightening it).
  • Page 133 CHECKING AND SETTING THE VALVE TIMING Engine : WJZ 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 134 CHECKING AND SETTING THE VALVE TIMING Engine : WJZ 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]. Loosen : - The screws (4) and (5).
  • Page 135 CHECKING AND SETTING THE VALVE TIMING Engine : WJZ SETTING THE VALVE TIMING (Continued) Tighten : - The roller (9) to 4.5 m.daN. - The screws (4) and (5) to 2.5 m.daN. - Remove the tool [7]. - Fit the tool [7] to the belt strap at "a". - The tensioning value should be between 42 ±...
  • Page 136 CHECKING AND SETTING THE VALVE TIMING Engine : DHY TOOLS - Crankshaft locating peg : 7014 - T.J or 7014 - T.R - Camshaft and injection pump locating peg : 7004 - T.G Tool kit 7004-T. CHECKS - Peg the crankshaft. - Peg the pulleys (1) and (2) at "a"...
  • Page 137 CHECKING AND SETTING THE VALVE TIMING Engine : RHY 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 [7] Set of blocking plugs...
  • Page 138 CHECKING AND SETTING THE VALVE TIMING Engine : RHY 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 139 CHECKING AND SETTING THE VALVE TIMING Engine : RHY 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 140 CHECKING AND SETTING THE VALVE TIMING Engine : RHY 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 ± 2 SEEM units. - Tighten screw (7) of the roller (6), tighten to 2.5 m.daN.
  • Page 141 CHECKING AND SETTING THE VALVE TIMING Engine : RHY 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]. - Tension value should be : 54 ±...
  • Page 142 XSARA SPECIAL FEATURES OF THE TIMING © Camshaft hub marking 11/97 Identification marks a - b Inlet camshaft «a» Exhaust camshaft «b» Number in mark c Inlet camshaft N° 1 N° 2 Exhaust camshaft Note : The identification marks are visible next to the pegging slot. Mark "c", bearing the number, is engraved on the rear side of the hub (1).
  • Page 143 XSARA SPECIAL FEATURES OF THE TIMING Camshaft hub marking LFY - RFV - RFS Engines ‘‘a’’ marking Hubs ‘‘b’’ paint marking Inlet BLUE Exhaust BROWN Inlet GREEN Exhaust BLUE Inlet BLUE Exhaust B1EP122C...

  • Page 144: Valve Clearances

    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 145 CHECKING THE OIL PRESSURE ALL TYPES To be read with the Petrol and Diesel correspondence tables Tools Tool kit 4103-T TU all types XU all types XU all types 1.6i 1.8 i 1.4 i 1.0 i 1.6i 1.8 i 2.0 i 16 V 1.1 i 16 V 16 V...

  • Page 146: Oil Filter

    ALL TYPES ENGINE OIL PRESSURE SWITCH Tightening torque Location Engine type Warning lamp goes out at : (Bars) (m.daN) 1.0 i 1.1 i 1.4 i all types Above the oil filter 1.6 i 1.6 i 16v 1.8 i XU all types 1.8 i 16v 2.0 i 16v XU all types...
  • Page 147 ALL TYPES ENGINE OIL PRESSURE SWITCH Tightening torque Location Engine type Warning lamp goes out at : (Bars) (m.daN) 1.5 D Above the oil filter 1.9 D DW10 2.0 HDi Close to the oil filter D6AP01MB D6AP01ND...
  • Page 148 ALL TYPES OIL FILTERS To be read with the Petrol and Diesel correspondence tables TU all types XU all types XU all types 1.8 i 2.0 i 1.0 i 1.4 i 1.6 i 1.8 i 1.1 i 16 V 16 V 16 V LS 867 PURFLUX...
  • Page 149 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 150 SAXO - All Types IDLING - ANTI-POLLUTION Idling speed % Content (± 50 rpm) Emission Vehicle Engine type Make - Injection type standard Auto. gbox : N Man. gear engaged gbox BOSCH MA3.1 1.0 i BOSCH MA3.1 1.1 i BOSCH MA3.1 1.1 i BOSCH MA3.1(Petrol)/ Dual fuel...
  • Page 151 IDLING - ANTI-POLLUTION XSARA - All Types Idling speed % Content (± 50 rpm) Emission Vehicle Engine type Make - Injection type standard Auto. gbox : N Man. gear engaged gbox 1.4 i K'/L3 M. MARELLI 1AP40 SAGEM SL96 (Petrol)/ 1.4 i BRC FLYING INJECTION Dual fuel...
  • Page 152 XSARA PICASSO - All Types IDLING - ANTI-POLLUTION Idling speed % Content (± 50 rpm) Emission Vehicle Engine type Make - Injection type standard Auto. gbox : N Man. gear engaged gbox 1.6i BOSCH - MP7.2 (90 hp) XSARA < 0.5 >...
  • Page 153 IDLING - ANTI-POLLUTION BERLINGO - All Types Idling speed % Content (± 50 rpm) Emission Vehicle Engine type Make - Injection type standard Auto. gbox : N Man. gear engaged gbox L3 / W3 BOSCH MA3.1 1.1 i L4 / W4 BOSCH M 7.4.4.

  • Page 154: Petrol Injection

    SAXO - All Types PETROL INJECTION SAXO 1.1 i 1.0 i 1.0 i 1.1 i 1.1 i Dual fuel Engine type Emission standard BRC ECOGAS BOSCH BOSCH BOSCH MA3.1 SAGEM M. MARELLI Injection make and type (LPG) MA3.1 MA3.1 (Petrol) M7.4.4 S2000 Fuel pressure (bars)
  • Page 155 SAXO - All Types PETROL INJECTION SAXO 1.4 i 1.6 i AUTO. (90 hp) (100 hp) 16 V Engine type Emission standard IFL4 M. MARELLI BOSCH BOSCH M. MARELLI BOSCH M. MARELLI Injection make and type 1AP81 MP7.3 MP5.2 M.7.4.4 1AP41 48P2 Fuel pressure (bars)
  • Page 156 PETROL INJECTION XSARA - All Types XSARA 1.4 i 1.6 i Dual fuel Engine type Emission standard K'/L3 IFL4 K'/L3 M. MARELLI BOSCH BRC FLYING BOSCH SAGEM SL96 Injection make and type 1AP40 INJECTION (LPG) MP7.3 MP5.2 (petrol) Fuel pressure (bars) Overspeed cut-off (rpm) 6 500 6 400...
  • Page 157 PETROL INJECTION XSARA XSARA 1.6i 16V 2.0I 16V Engine type Emission standard BOSCH M. MARELLI Injection make and type M7.4.4. MM 48.P2 Fuel pressure (bars) 6 530 7 300 Overspeed cut-off (rpm) Injection cut-in during 1 200 1 350 deceleration (rpm) 14.5 Injector resistive value (ohms) Engine coolant temperature...
  • Page 158 XSARA - All Types PETROL INJECTION XSARA 1.8 i 1.8 i 16 V Dual fuel 16 V Engine type Emission standard M. MARELLI NECAM KOLTEC SAGEM SL96 Injection make and type SAGEM SL96 1AP20 (petrol) (LPG) Fuel pressure (bars) Overspeed cut-off (rpm) 6 400 6 500 6 500...
  • Page 159 PETROL INJECTION XSARA - BERLINGO - All Types XSARA BERLINGO 2.0 i 1.1 i 1.4 i 16 V Engine type K'/L3 Emission standard BOSCH M. MARELLI BOSCH BOSCH M. MARELLI Injection make and type MP5.2 1AP40 MA3.1 M7.4.4 1AP10 Fuel pressure (bars) 6 530 7 300 6 510...
  • Page 160 BERLINGO - All Types PETROL INJECTION BERLINGO 1.4 i 1.4 i 1.8 i (Dual fuel ) Engine type L4 /W4 K'/L3 Emission standard M. MARELLI M. MARELLI SAGEM BRC FLYING SAGEM Injection make and type 1AP40 1AP20 SL96 INJECTION S2000 Fuel pressure (bars) 6 500 6 440...
  • Page 161 PETROL INJECTION XSARA PICASSO - All Types XSARA PICASSO 1.8i 1.6 i 16 V Engine type Emission standard BOSCH SAGEM Injection make and type MP7.2 S2000 Fuel pressure (bars) 6 300 6 500 Overspeed cut-off (rpm) Injection cut-in during 1 150 1 300 deceleration (rpm) 14.5...
  • Page 162 EMISSION STANDARDS ALL TYPES 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 163 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 164 ALL TYPES EMISSION STANDARDS 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 165 EMISSION STANDARDS ALL TYPES 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 166 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 167 EMISSION STANDARDS ALL TYPES 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 168 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 169 ANTI-POLLUTION TECHNICAL CHECKS (FRANCE) ALL TYPES All Types Petrol CO Corrected (In %) All Types Diesel (m Conditions : At idle, engine warm. # 01/96 Features : Less than 4.5 % for vehicles registered before 10/86. Less than 3.5 % for vehicles registered after 10/86. Xantia, MMDCM injection on 1.6i (BFZ) engine, 1.8i (LFZ) engine and 2.0i (RFX) engine.Should the check reveal excessive CO, make sure With catalytic converter...
  • Page 170 ALL TYPES SAFETY REQUIREMENTS : PETROL/LPG DUAL FUEL SYSTEM ESSENTIAL : Special precautions should be taken when dealing with gas powered systems SAFETY REQUIREMENTS. Only personnel who have been specially trained to work with petrol/LPG DUAL FUEL vehicles are authorised to carry out repairs to the DUAL FUEL system - Ensure that these qualified personnel are provided with acrylic-free overalls (risk of static electricity)
  • Page 171 SAFETY REQUIREMENTS : PETROL/LPG DUAL FUEL SYSTEM ALL TYPES PRECAUTIONS TO BE TAKEN BEFORE CARRYING OUT ANY REPAIR WORK Any work on a gas powered vehicle must be carried out in a venti- Before removing the fuel tank or working on the gas circuit located lated area.
  • Page 172 ALL TYPES SPECIFICATIONS : PETROL/LPG DUAL FUEL SYSTEM B1HP0Q4P B1CV0Q5P...
  • Page 173 SPECIFICATIONS : PETROL/LPG DUAL FUEL SYSTEM ALL TYPES (1) Fuel tank. (6) Injectors and valves. - Capacity : 70 litres. - location : in the engine compartment, under the air manifold. - Max. pressure : during tests / in operation : 30 bars / 20 bars. (7) Pressure sensor.
  • Page 174 ALL TYPES SPECIFICATIONS : PETROL/LPG DUAL FUEL SYSTEM (11) Evaporator control valve. Setting pressure - 2nd stage. - make : NECAM. - type : MEGA. - Setting pressure for a new evaporator control valve : - 970 ± 10 mb. •...
  • Page 175 PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM XSARA - XSARA PICASSO Engine : RHY 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 176 XSARA - XSARA PICASSO PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM Engine : RHY 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 177 XSARA - XSARA PICASSO SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM Engine : RHY 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 178 SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM XSARA - XSARA PICASSO Engine : RHY 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 179 XSARA - XSARA PICASSO CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engine : RHY 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 180 XSARA - XSARA PICASSO CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engine : RHY (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 181 CHECKS : AIR SUPPLY CIRCUIT XSARA - XSARA PICASSO Engine : RHY 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 182 XSARA - XSARA PICASSO CHECKS : TURBO PRESSURE 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 183 CHECKS : TURBO PRESSURE XSARA - XSARA PICASSO 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 184 XSARA - XSARA PICASSO CHECKS : EXHAUST GASES RECYCLING CIRCUIT 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 185 SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP SAXO - XSARA PUMP -TYPE - REFERENCE Emission standards Equipment Transponder SAXO R 8444 B/ XSARA 662 C DWLP 12 R8448 B 371 B XSARA XUD 110 R8445B/ 081 A...
  • Page 186 SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP SAXO - XSARA Static timing Dynamic Reference Adjustments (rpm) Max. speed Injector Pump Engine Initial advance timing Colour Injector Type needle lift Fast Anti- Unladen Laden type Compression checking code Injector holder Idling Reference pressure idling...
  • Page 187 SAXO - XSARA CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP Engine : VJZ - VJY - 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.
  • Page 188 XSARA CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP Engine : WJZ 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 189 CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP XSARA Engine : WJZ 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 190 XSARA CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP Engine : WJZ (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 127 to 131). Possible to peg the camshaft, but not the injection pump.
  • Page 191 CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP XSARA Engines : DHY TOOLS 4093-T Rep : - Flywheel locating peg : 7014-T.J.Tool kit 7004-T Bracket - Bracket and peg : 4093-T Tool kit 4123-T Dial gauge Flat end Relay lever CHECKING THE PUMP - Peg engaged: The dial gauge should read "X"...
  • Page 192 SAXO - XSARA ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS Engines : VJZ - VJY - VJX ADJUSTING THE FAST IDLE Engine cold. - Ensure that the lever (1) is up against its stop to the right. - If not, adjust the tension of the cable (3) using the cable clamp (2). (Tighten to 0.5 m.daN). - Finish tensioning using the sleeve tensioner (4).
  • Page 193 SAXO - XSARA ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS Engines : VJZ - VJY - VJX (continued) ADJUSTING THE ACCELERATOR CONTROL. Engine stopped. - Fully depress the accelerator pedal. - Check that the lever (5) is against its stop (6), otherwise, alter the position of the clip (7) (Accelerator cable tension).
  • Page 194 SAXO - XSARA ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS Engines : VJZ - VJY - VJX (continued) Checking the engine deceleration. - Move the throttle lever (5) to obtain an engine speed of 3000 rpm. - Release the throttle lever (5). - The deceleration should be between 2 and 3 seconds.
  • Page 195 ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS XSARA Engine : WJZ 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 196 XSARA ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS Engine : WJZ (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 197 ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS XSARA Engine : RHY Engine cold : - Check the fast idle speed. - Ensure that the lever (9) is against its stop by pushing it in the direction of the arrow (‘). If not, adjust with the cable clamp (8), and then the sleeve tensioner (4).
  • Page 198 SAXO - XSARA FITTING DELPHI DIESEL INJECTORS Engines : VJZ - VJY – VJX - DHY Fitting an injector [1] Tool to remove/refit injectors 7007-T 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 199 FITTING DELPHI DIESEL INJECTORS XSARA Engine : WJZ [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 200 SAXO - XSARA - XSARA PICASSO BOSCH INJECTION PUMP SPECIFICATIONS PUMP -TYPE - REFERENCE Emission standards L3/L4 Equipment Transponder SAXO 8 F 25000 XSARA R 611/5 SAXO XUD 213 R 445/3 XSARA CP1 (*) (*) = The fuel high pressure pump is driven by the timing belt.
  • Page 201 SAXO - XSARA - XSARA PICASSO BOSCH INJECTION PUMP SPECIFICATIONS Reference Adjustments (rpm) Max. speed Dynamic Injector Static timing Colour Pump Engine timing needle (1) Initial advance Injector Type Fast Anti- Unladen Laden type checking lift Compression Injector holder Idling code Reference idling...
  • Page 202 SAXO - XSARA CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP Engine : VJZ -VJY - VJX TOOLS à - Flywheel locating peg : 4507-T.A - Mounting plate locating peg : 4507-T.S1 Tool kit 4507-T - Camshaft peg : 4507-T.S2 CHECKS - Peg the flywheel.
  • Page 203 CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP XSARA Engine : DHY TOOLS - Flywheel locating peg : 7017-T.R. Tool kit 7004-T - Ring spanner : 4132-T. - Crescent spanner FACOM 57 : 11 X 13 à - Dial gauge : 3089-T.H.
  • Page 204 CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP XSARA Engine : DHY TOOLS Flywheel setting peg : 7017-T.R Tool kit 7004-T Checking the injection pump. - Remove the tool 7017-T.R. - Rotate the crankshaft (direction of rotation). - Peg the flywheel. - In this position, the dial gauge should show the value ‘‘X’’...
  • Page 205 CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP SAXO - XSARA Engine : VJZ - VJY - 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 206 SAXO - XSARA CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP Engine : VJZ - VJY - 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 207 CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP SAXO - XSARA Engine : VJZ - VJY - 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 208 SAXO - XSARA FITTING BOSCH INJECTORS Engines : VJZ - VJY - VJX - DHY [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 209 PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM 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 210 ALL TYPES SPARKING PLUGS Electrode Tightening Vehicles – Models BOSCH CHAMPION Engine type EYQUEM gap setting torque 1.0i 1.1i SAXO 1.4i FR7DE RC8YCL RFC58 LZ 0.9 mm 1.6i 1.6i 16v 1.4i 1.6i FR7DE RC8YCL RFC58 LZ 2.5 mdaN 1.8i XSARA 0.9 mm 1.8i 16v 2.0i 16v...

  • Page 211: Speedometer

    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 212 CLUTCH SPECIFICATIONS ALL TYPES 1.1 i 1.6 i 1.0 i 1.4 i Engine type Gearbox MA/4 - MA/5 Make VALEO Mechanism/Type 180 CP 3400 180CPO 3400 200 CPR 3800 200X(D95) Clutch disc 181 XJ (E73) 11 R 10 X 180 XJF 73 C 11A12X Ext./Int.
  • Page 213 CLUTCH SPECIFICATIONS ALL TYPES 1.6i 16V 1.6i 1.5 D Engine type Gearbox MA/5 Make VALEO Mechanism/Type 200 CPR 3800 200 CPX 3850 180 P 3000 Clutch disc 200 X (D 95) 11 AX 12 X 200 XSL 73 180 D Ext./Int.
  • Page 214 CLUTCH SPECIFICATIONS ALL TYPES 1.8i 16V 1.9D 1.9TD 2.0 HDi 1.8i 2.0i 16V Engine type Gearbox BE4/5 Make VALEO VALEO 215 DT Mechanism/Type 200 CP 4250 230 DNG 4700 215 DT 5250 200 P 3700 230 P 4700 5250 Clutch disc 215 F 215 FM 200 B (D73) 33AX...
  • Page 215 SAXO - XSARA CLUTCH : CHECKS AND ADJUSTMENTS Mechanically operated push-action clutch (adjustable) SAXO Adjustable CDZ-HDZ-HFX-KFX-KFW-NFZ-NFT-NFX-VJZ-VJY-VJX Engines MA/5 Gearbox XSARA Non-adjustable VJZ-KFX-NFZ (*) See page 214) ESSENTIAL : If the clutch control is new, squeeze the cable sheath before adjusting by declutching successively a minimum of 20 times.
  • Page 216 XSARA CLUTCH : CHECKS AND ADJUSTMENTS Push-action clutch with automatic adjustment (non-adjustable) ( Engines BE3/5 – BE4/5 Gearboxes LFX - LFY - WJZ 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 217 CLUTCH : CHECKS AND ADJUSTMENTS XSARA - XSARA PICASSO Pull-action clutch with automatic adjustment (non-adjustable) ( BE3/5 Engines RFS - RFV - RHY Gearbox 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 218 XSARA - XSARA PICASSO CLUTCH : CHECKS AND ADJUSTMENTS Adjustment of push and pull action clutch with automatic compensation (adjustment of compensation system) Engines : LFX - LFY - RFS - RFV - WJZ - DHY - RHY WARNING : If a system blockage is detected when checking, or if the pedal has been removed, the pedal position must be adjusted.
  • Page 219 CLUTCH : CHECKS AND ADJUSTMENTS XSARA - XSARA PICASSO Engines : LFX - LFY - RFS - RFV - WJZ - RHY 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 220 XSARA - XSARA PICASSO CLUTCH : CHECKS AND ADJUSTMENTS Engines : LFX - LFY - RFS - RFV - WJZ - RHY (continued) 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 :...
  • Page 221 GEARBOX AND TYRE SPECIFICATIONS SAXO - All Types Petrol 1.4i 1.0i 1.1i Automatic Engine type Tyres-Rolling circumference 155/70 R 13 – 1.67 m Gearbox type MA/4 – MA/5 MA/4 – MA/5 20 CF 12 20 CF 03 20 CF 02 20 CF 12 Gearbox ident.
  • Page 222 XSARA # 09/2000 GEARBOX AND TYRE SPECIFICATIONS Petrol 1.4i 1.6i 1.8i 1.8i 16V Automatic Engine type 185/65 R14 – 1.815 m Tyres-Rolling circumference Gearbox type MA/5 BE3/5 20 CE 42 20 CE 42 20 CD 29 20 TP 22 20 TB 91 20 TB 62 Gearbox ident.
  • Page 223 GEARBOX AND TYRE SPECIFICATIONS XSARA 09/2000 # Petrol 1.4i 1.6i 16V 2.0i 16V Automatic Automatic Engine type Tyres-Rolling circumference 195/55 R15 – 1.815 m Gearbox type MA/5 BE4/5 BE4/5 Gearbox ident. plate 20 CF 13 (1) 20 CN 28 (2) 20 TP 49 20 DL 40 20 TP 47...
  • Page 224 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 225 MA/5 GEARBOX SAXO - XSARA Engines : CDZ - HDZ - HFX - KFW - KFX - NFZ - NFT - NFU - NFX - VJZ - VJY - VJX Vent hole Filler screw Drain screw B2CP34HP B2CP20FC B2CP20GC...
  • Page 226 SAXO - XSARA MA/5 GEARBOX CONTROLS Engines : CDZ - HDZ - HFX - KFW - KFX - NFZ - NFT - NFU - NFX - VJZ - VJY - VJX 1 - Gear lever. 2 - Gear control rod. 3 - Gear control rod.
  • Page 227 BE3/5 GEARBOX XSARA - XSARA PICASSO Engines : LFX - LFY - RFS - RFV - WJZ - DHY - RHY Vent hole Filler screw Drain screw B2CP20HC B2CP20JC B2CP34JP...
  • Page 228 XSARA - XSARA PICASSO BE3/5 GEARBOX CONTROLS Engines : LFX - LFY - RFS - RFV - WJZ - DHY - RHY (1) - Gear lever. (2) - Gear control rod. (3) - Gear engagement rod. (4) - Gear selection rod. (5) - Torque rod.
  • Page 229 BE4/5 GEARBOX SPECIFICATIONS XSARA - XSARA PICASSO ENGINES : NFZ - 6FZ - RFN - RFS - WJZ - RHY (a) = Marking zone (Sequence and serial no.). (b) = Location of identification label. B2CP3BNC B2CP3BPD...
  • Page 230 XSARA - XSARA PICASSO BE4/5 GEARBOX SPECIFICATIONS Engines : NFZ - 6FZ - RFN - RFS - WJZ - RHY Description (1) Primary shaft. (14) 1 gear synchroniser (2) Clutch bearing guide. (15) Driven gear (1 gear). (3) Gearbox casing. (16) Secondary shaft.
  • Page 231 BE4/5 GEARBOX SAXO - XSARA - XSARA PICASSO Engines : NFZ - 6FZ - RFN - RFS - WJZ - RHY 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 232 SAXO - XSARA - XSARA PICASSO BE4/5 GEARBOX CONTROLS Engines : NFZ - 6FZ - RFN - RFS - WJZ - RHY (1) Gear control lever. (2) Gear engagement control cable (*). (3) Gear selection control cable (*). (4) Gear selection ball-joint Ø 10 mm. (5) Gear engagement ball-joint Ø...
  • Page 233 SAXO - XSARA - XSARA PICASSO BE4/5 GEARBOX - CHECKS AND ADJUSTMENTS Engines : NFZ - 6FZ - RFN - RFS - WJZ - RHY Principles of adjusting the gear controls. WARNING : Cables should be adjusted each time the gearbox, gear controls or power unit are removed.
  • Page 234 SAXO - XSARA - XSARA PICASSO BE4/5 GEARBOX - CHECKS AND ADJUSTMENTS Engines : NFZ - 6FZ - RFN - RFS - WJZ - RHY Adjusting the gear controls. TOOLS. [1] ] Tool for positioning the gear lever : 9607-T. ADJUSTMENTS.
  • Page 235 MB3 AUTOMATIC GEARBOX SAXO Engine : KFX 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 236: Driveshafts

    SAXO RECOMMENDATIONS - PRECAUTIONS (MB3 AUTOMATIC GEARBOX) Engine : KFX 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 237 RECOMMENDATIONS - PRECAUTIONS (MB3 AUTOMATIC GEARBOX) SAXO Engine : KFX 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 238 SAXO RECOMMENDATIONS - PRECAUTIONS (MB3 AUTOMATIC GEARBOX) Engine : KFX 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 239 SPECIAL FEATURES : MB3 AUTOMATIC GEARBOX SAXO Engine : KFX 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 240 SAXO MB3 AUTOMATIC GEARBOX CONTROLS Engine : KFX B2CP352D...
  • Page 241 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 242 XSARA AL 4 AUTOMATIC GEARBOX Engines : NFZ - NFU - RFN 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 243 RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX XSARA Engines : NFZ - NFU - RFN 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 244 XSARA RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX Engines : NFZ - NFU - RFN 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 245 RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX XSARA Engines : NFZ - NFU - RFN 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 246 XSARA RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX Engines : NFZ - NFU - RFN 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 247 RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX XSARA Engines : NFZ - NFU - RFN 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 248 XSARA RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX Engines : NFZ - NFU - RFN 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 249 RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX XSARA Engines : NFZ - NFU - RFN 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 250 XSARA 4 HP 14 AUTOMATIC GEARBOX Engine : RFV Ref. Torque X (mm) Y (mm) Tightening torques m.daN m.daN letter (1) Gearbox casing screw (2) Oil dipstick tube nut (3) Strainer cover (4) Hydraulic valve block Note : If replacing an automatic gearbox, it is ESSENTIAL also to replace the heat exchanger, as well as the oil.
  • Page 251 4 HP 14 AUTOMATIC GEARBOX CONTROLS XSARA Engine : RFV Tightening torques m.daN. (1) - Fixing to the body. (2) - Gearbox bracket fixing. (3) - Adjusting nuts. (4) - Gearbox selector fixing. NOTE : Ball-joint lubrication ESSO NORVA 275 (G9). B2CP287D...
  • Page 252 XSARA 4 HP 14 AUTOMATIC GEARBOX - CHECKS AND ADJUSTMENTS Engine : RFV Adjusting the gear selector Tools [1] Ball-joint extractor 9040-T.G2 Tool kit 9040-T - Uncouple the ball-joint housing (1) from the selector lever using tool [1]. CAUTION : Do not twist the rod (2) of the selector cable when uncoupling. - Gear lever in position N (Normal).
  • Page 253 4 HP 14 AUTOMATIC GEARBOX - CHECKS AND ADJUSTMENTS XSARA Engine : RFV Checks - Adjustments : Kick down cable Preliminary conditions : - Engine hot. - Idling speed correct. - Automatic cold start device out of action (according to equipment). Accelerator cable adjustment : - Remove the kick down cable (1) from the throttle quadrant.
  • Page 254 ALL TYPES DRIVESHAFTS - GEARBOXES Gearbox oil seal mandrels Tightening torques (m.daN) Driveshaft Driveshaft Right Left Tool kit Gearbox Engines bearing CDZ-HDZ-HFX-KFX-KFW-NFZ 24.5 NONE MA/5 NFT-NFX-NFU-VJZ-VJY-VJX MA/5 XSARA 7114-T.W 7114-T.X 7116-T BE4/5 NFZ - 6FZ - RFN - RHY LFX - LFY - RFS - RFV BE3/5 32.5 WJZ - DHY - RHY...
  • Page 255 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 256 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 257: Axle Geometry

    AXLE GEOMETRY SAXO - All Types Geometry of the axles at reference height. Normal suspension Raised suspension Front Rear Front Rear TU9M TU9M TU1M+ (**) TU1M+ (**) All types TU1M+ Engines TU3JP – TU5JP All types TU1M+ TU3JP – TU5JP TU5J4 –...
  • Page 258 SAXO - All Types SPECIAL FEATURES : SUSPENSION - STEERING EVOLUTIONS : Damper springs – Driveshafts – Wheel hubs. Date of application : 01/1999 - RPO : 06/01/1999 Front suspension springs. Vehicles concerned : Saxo all types. Modification : 5 1/2 spirals instead of 6. Driveshafts.
  • Page 259 FRONT AXLE SAXO - All Types 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 260 SAXO - All Types REAR AXLE (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 261 REAR AXLE - SUSPENSION SAXO - All Types Torsion bar TU9M (1)-TUD5 (1) TU9M - TU1M+ - TU3JP TU1M+ LPG TU1M+ (1) (2) – TU3JP (2) TU5JP – TUD5 TUD5 (3) TU5J4 Torsion bar Ø (mm) 17.9 18.3 Black White Green Colour reference LH : 2 rings...
  • Page 262 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 263 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 264 SAXO - All Types POWER-ASSISTED STEERING 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 265 POWER STEERING (continued) SAXO - All Types 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 266 SAXO - All Types POWER STEERING (continued) 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 267 AXLE GEOMETRY XSARA - All Types Front and rear measuring points XSARA # 09/2000 XSARA 09/2000 # Front height Rear height 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.
  • Page 268 XSARA - All Types AXLE GEOMETRY 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 269 AXLE GEOMETRY XSARA - All Types 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 270 XSARA - All Types AXLE GEOMETRY Values of the front and rear suspensions, at reference height XSARA # 09/2000 Front axle Adjustable Steering All Types Rear axle Adjustable - 1.5 ± 1 (Toe-out) Tracking 4.5 ± 1 mm - 0°15' ±10' 0°...
  • Page 271 AXLE GEOMETRY XSARA Values of the front and rear suspensions, at reference height XSARA 09/2000 # Front axle All types (except 2.0i 16V) 2.0i 16V All Types CRD Adjustable - 1.5 ± 1 Tracking - 0°15' ±10' 0° Castor 3° ± 40’ 11°...
  • Page 272 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 273 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 274 XSARA - All Types FRONT AXLE XSARA # 09/2000 Anti-roll bars Engines Diameter Colour reference 1.4i - 1.5 D - 1.9 TD Violet 1.6i - 1.8i - 1.8i 16V - 1.9 TE Blue XSARA 09/2000 # Anti-roll bars Engines Diameter Colour reference 1.4i et 1.9D Saloons All Types Blue...
  • Page 275 FRONT AXLE XSARA - All Types Evolution : Suspension arm ball-joint 09/98 # Evolution : Application from RPO : 7968. New components : - Suspension arm ball-joint. - Pivot. Old fitting ØA = 16 mm. New fitting ØA = 18 mm. Repair requirements.
  • Page 276 XSARA - All Types FRONT AXLE XSARA # 07/1999 XSARA 07/1999 # 09/2000 XSARA 07/1999 # 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 277 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 278 XSARA - All Types REAR AXLE XSARA # 09/2000 Torsion bars (mm) Torsion bars (mm) Torsion bars (mm) Vehicles Diameter Colour reference Diameter Colour reference All Types except VTS 18.7 Yellow 19.3 Violet XSARA 09/2000 # Vehicles Torsion bars (mm) Anti-roll bars (mm) Engines Diameter...
  • Page 279 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 280 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 281 REAR DAMPER XSARA - All Types XSARA # 09/2000 Adjusting the rear dummy damper All types Adjustment of X = 288 mm. XSARA 09/2000 # Adjusting the rear dummy damper Lengths of the rear dummy damper (mm) Engines Normal driving Grand export 1.4i Saloons All Types 1.9 D...
  • Page 282 XSARA - All Types MANUAL STEERING SPECIFICATIONS 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 283 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 284 MANUAL STEERING SPECIFICATIONS XSARA - All Types Manual steering (continued) Number of teeth Number of Steering rack Steering ratio Steering stop steering wheel travel colour code turns (mm) Pinion Steering rack (13) 6 teeth 22/1 L.H.D. 73.5 Yellow thickness 14 mm (RH helix) - 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 285 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 286 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 287 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 288 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 289 AXLE GEOMETRY XSARA PICASSO - All Types Measurements at reference height. Front height Rear height H1 = R1 - L1 H2 = R2 - L2 H1 = From the front suspension arm linkage bolt axis to the ground. H2 = From the rear axle flexible mounting face to the ground. R1 = Radius of the front wheel when laden.
  • Page 290 XSARA PICASSO - All Types AXLE GEOMETRY Measurements at reference height (continued). (The ref. height of the vehicle is set as per the table below Front axle Rear axle Front axle Rear axle H1 = R1 – 90.5 mm H2 = R2 + 7 mm Measure the radius of the front wheel : R1.
  • Page 291 AXLE GEOMETRY XSARA PICASSO - All Types Measurements at reference height (continued) 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 (See page 286) Front height Rear height B3CP05BC...
  • Page 292 XSARA PICASSO - All Types AXLE GEOMETRY Measurements at reference height (continued). Compress the suspension to obtain the calculated values (see page : 287) Front axle Rear axle King pin Camber Tracking Camber Vehicles Tracking Castor inclination Adjustable ( Non-adjustable ) Adjustable 0 mm ±...
  • Page 293 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 294 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 295 REAR AXLE XSARA PICASSO - 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 ±...
  • Page 296 XSARA PICASSO - All Types SUSPENSION 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 297 XSARA PICASSO - All Types SUSPENSION Checking the front and rear axles, vehicle in running order 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 ± 1 mm 1.7 mm ±...
  • Page 298 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 299 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 300 XSARA PICASSO - All Types STEERING SPECIFICATIONS 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 Hélice à gauche 71.7x2 28 Dents 3.22 12 m 11.48 m Right hand drive...
  • Page 301 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 302 SAXO - All types BRAKE SPECIFICATIONS 1.1 i - 1.4 i 1.6 i (1) Compensator integral with the wheel cylinder. 1.6 i 1.0 i 1.5 D 1.6 i 16V (2) Load sensitive compensator. Manual steering Power-assisted steering without ABS Master cylinder 20.6 20.6 22.2...
  • Page 303 BRAKE SPECIFICATIONS (continued) SAXO - All types 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 1.0i-1.1i-1.5D (2) Load sensitive compensator. Power-assisted steering with ABS Manual steering Master cylinder 20.6 Master-vac...
  • Page 304 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 305 BRAKES (continued) SAXO - All types Tightening torques (m.daN) ABS - 1.1 i - 1.4 i - 1.6 i Removing the caliper - 1.0 i and 1.1 i Manual steering (except 1.0i Entreprise) - Screw M8 3.2 ± 0.3 - Screw M12 12 ±...
  • Page 306 SAXO - All types HANDBRAKE (Adjustment) 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 307 PURGE DES BRAKES SAXO - All types 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 308 XSARA 09/2000 BRAKE SPECIFICATIONS 1.6 i Without ABS 1.4 i 1.8 i 16 V 1.5 D 1.9 D 1.9 TD 1.8 i Master cylinder 22.2 23.8 22.2 Master-vac 228.6 Ø BENDIX TEVES FN LUCAS TEVES FN Caliper/piston makes Série VZO 48 C542013 - 20 Non-ventilated Disc...
  • Page 309 BRAKE SPECIFICATIONS XSARA 09/2000 1.6 i 1.8 D With ABS 1.4 i 1.8 i 16 V 2.0 i 16 V 1.9 TD 1.8 i 1.9 D Master cylinder 22.2 23.8 22.2 Master-vac 228.6 Ø TEVES FN LUCAS LUCAS TEVES FN Caliper/piston makes C542013 - 54 C572213N57...
  • Page 310 XSARA 09/2000 BRAKE SPECIFICATIONS Without ABS With ABS 1.4i-1.9D 1.4i-1.6i 16V-1.9D 2.0i 16V Saloon Estate 2.0 HDi Master cylinder 23.8 23.8 Master-vac 228.6 228.6 Ø BOSCH ZOH 54/2 LUCAS Caliper/piston makes C57 22 13N/57 Non-ventilated Disc Ventilated 22/20 22/20 Disc thickness/min. thickness FERF 769 ASFM 380 Brake pad grade...
  • Page 311 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 312 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». (2) Load sensitive braking compensator (according to model).
  • Page 313 BRAKE SPECIFICATIONS XSARA - All Types Braking system without ABS (rear drum brakes) Braking system without ABS (rear disc brakes) B3FP09ED B3FP09FD...
  • Page 314 XSARA - All Types BRAKE SPECIFICATIONS Braking system with ABS (rear drum brakes) Braking system with ABS (rear disc brakes) B3FP09GD B3FP09KD...
  • Page 315 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 316 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 "c"...
  • Page 317 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 318 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 319 XSARA - All Types CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued) GRAPH N°1 GRAPH N°2 B3FP09XD B3FP09YD...
  • Page 320 XSARA - All Types CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued) GRAPH N°3 B3FP09ZD...
  • Page 321 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 322 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 323 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 324 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 325 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/piston Ø LUCAS C 54 makes Non-ventilated Brake disc Ventilated Disc thickness/min.
  • Page 326 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 327 BRAKING SYSTEM SPECIFICATIONS XSARA PICASSO - All Types Without ABS With ABS B3FP11WD B3FP11UD...
  • Page 328 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 Refer to the tables of different weights. Determine the weight on the rear axle and then refer to the adjustment To obtain the rear weight of the vehicle, add the following weights : graphs.
  • Page 329 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 330 XSARA PICASSO - All Types CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR GRAPH N°1 GRAPH N°2 B3FP09XD B3FP09YD Key : P = Rear pressure (in Bars). a = Front pressure 60 ± 3 Bars. M = Weight (in Kg). b = Front pressure 100 ± 3 Bars.
  • Page 331 CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR XSARA PICASSO - All Types GRAPH N°3 GRAPH N°4 B3FP09ZD B3FP100D Key : P = Rear pressure (in Bars). a = Front pressure 60 ± 3 Bars. M = Weight (in Kg) b = Front pressure 100 ± 3 Bars.
  • Page 332 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, prefera- bly on a lift. - Compare the value noted with the graph. - If the value is outside the tolerance, adjust the - The tool [1] (in good working order) in place.
  • Page 333 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 334 XSARA PICASSO - All Types HANDBRAKE (Adjustment) 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 335 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 336 STARTER MOTORS SAXO Manufacturer and Ref. Class Climat Vehicles / models VALEO D7E7 1.0i BOSCH 1116003 H,T,C 1.1i 1.4i (AIRCON) MELCO M002T13081 1.6i ( AIRCON) VALEO D6 RA 571 VALEO D7E7 SAXO BOSCH 1116003 MELCO M002T13081 1.4i 1.6i VALEO D7E5 BOSCH 1112041 VALEO D6 RA 571 CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
  • Page 337 SAXO - XSARA STARTER MOTORS Manufacturer and Ref. Class Climat Vehicles / models 1.4i (Auto.) VALEO D6 RA 571 H,T,C,VC 1.6i (Auto./ 1.6i 16v SAXO VALEO D7R11 H,T,C 1.5D BOSCH 1108162 VALEO D7R15 VALEO D7E7 BOSCH 1116003 MELCO M002T13081 1.4i 1.6i VALEO D7E5 BOSCH 1112041...
  • Page 338 XSARA STARTER MOTORS Manufacturer and Ref. Class Climate Vehicles / models VALEO D7E5 1.4i (Power-st. + aircon) BOSCH 1112041 1.6i (Power-st. + aircon) VALEO D6 RA 571 C,VC 1.6i (Auto.) VALEO D6 RA 571 H,T,C,VC VALEO D6RA661 XSARA H,T,C 1.8i BOSCH 1107019 1.8i 16v BOSCH 1108085...
  • Page 339 STARTER MOTORS XSARA Manufacturer and Ref. Class Climate Vehicles / models VALEO D7R11 H,T,C 1.5D BOSCH 1108162 VALEO D7R15 VALEO D6RA109 BOSCH XSARA 1.9D MELCO M001T80381 VALEO D7R26 VALEO D7R27 VALEO D7R26 2.0 HDi VALEO D7R27 C,VC CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
  • Page 340 BERLINGO STARTER MOTORS Manufacturer and Ref. Class Climate Vehicles / models VALEO D7E7 BOSCH 1116003 H,T,C 1.1i MELCO M002T13081 VALEO D6 RA 571 VALEO D7E7 BOSCH 1116003 BERLINGO MELCO M002T13081 1.4i VALEO D7E5 BOSCH 1112041 VALEO D6 RA 571 VALEO D7E5 1.4i (Power-st.
  • Page 341 BERLINGO STARTER MOTORS Manufacturer and Ref. Class Climate Vehicles / models VALEO D6RA661 H,T,C 1.8i BOSCH 1107019 BOSCH 1108085 VALEO BOSCH MELCO 1.9D BERLINGO VALEO D7R26 MELCO VALEO D7R27 VALEO D7R26 2.0 HDi MELCO VALEO D7R27 C,VC CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
  • Page 342 XSARA PICASSO STARTER MOTORS Manufacturer and Ref. Class Climate Vehicles / models VALEO D7E7 BOSCH 1116003 MELCO M002T13081 1.6i VALEO D7E5 BOSCH 1112041 VALEO D6 RA 571 XSARA PICASSO VALEO D7E5 BOSCH 1112041 1.6i (Power-st. + aircon) VALEO D6 RA 571 C,VC VALEO D7E7 BOSCH 1116003...
  • Page 343 XSARA PICASSO STARTER MOTORS Manufacturer and Ref. Class Climate Vehicles / models VALEO D6RA661 H,T,C 1.8i 16v BOSCH 1107019 BOSCH 1108085 XSARA PICASSO VALEO D7R26 2.0HDi VALEO D7R27 C,VC CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
  • Page 344 ALL TYPES STARTER MOTORS Table of classes of starter motors 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 345 ALTERNATORS SAXO Without power-steering Classes and types Engine Gbox. Without aircon. Climate With aircon. Climate VALEO A11 VI 55 H,T,C VALEO A11 VI 55 H,T,C 1.0i/L3 1.4i/L3 BOSCH A120310028 BOSCH A120310028 VALEO A11 VI 55 VALEO A13 VI 96 H,T,C 1.1i/L3 BOSCH A120310028 VALEO A11 VI 55...
  • Page 346 SAXO With power-steering ALTERNATORS Classes and types Engine Gbox. Without aircon. Climate With aircon. Climate VALEO A11 VI 55 VALEO A13 VI 141+ BOSCH A120310028 VALEO A13 VI 96 1.1i VALEO A13 VI 96 VALEO A13 VI 141+ C,VC VALEO A11 VI 55 VALEO A13 VI 141+ 1.4i BOSCH A120310028...
  • Page 347 ALTERNATORS SAXO With power-steering Classes and types Engine Gbox. Without aircon. Climate With aircon. Climate VALEO A11 VI 55 VALEO A13 VI 141+ 1.1i BOSCH A120310028 VALEO A13 VI 96 T,C,VC VALEO A13 VI 96 C,VC VALEO A11 VI 55 VALEO A13 VI 141+ 1.4i 1.6i...
  • Page 348 ALTERNATORS SAXO Police Classes and types Engine Gbox. Without aircon. Climate With aircon. Climate SAXO POLICE 1.1i/1.4i VALEO A13 VI 141+ 1.5D VALEO A13 VI 142+ CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
  • Page 349 ALTERNATORS XSARA Without power-steering Classes and types Engine Gbox. Without aircon. Climate With aircon. Climate VALEO A11 VI 55 VALEO A13 VI 96 H,C,VC 1.4i /L3 BOSCH A120310028 C,VC VALEO A11 VI 55 1.6i /L3 VALEO A13 VI 96 C,VC BOSCH A120310028 1.5D VALEO A13 VI 84...
  • Page 350 XSARA With power-steering ALTERNATORS Classes and types Engine Gbox. Without aircon. Climate With aircon. Climate VALEO A11 VI 57 VALEO A13 VI 96 C,VC 1.4i /L3 BOSCH A12220310104 VALEO A11 VI 57 VALEO A13 VI 96 T,C,VC BOSCH A12220310104 VALEO A11 VI 57 VALEO A13 VI 96 H,T,C,VC 1.6i /L3...
  • Page 351 ALTERNATORS XSARA With power-steering Classes and types Engine Gbox. Without aircon. Climate With aircon. Climate BOSCH A120411525 BOSCH A120411523 C,VC BOSCH A120411523 MELCO A002TA1991 MELCO A002TA1991 VALEO A13 VI 102 1.8i 16v /L3 VALEO A13 VI 102 VALEO A13 VI 101+ MELCO A002TA2091 BOSCH A120411525 BOSCH A120411523...
  • Page 352 XSARA With power-steering ALTERNATORS Classes and types Engine Gbox. Without aircon. Climate With aircon. Climate BOSCH A120411523 VALEO A14 VI 14 MELCO A002TA1991 VALEO A13 VI 101+ T,C,VC 2.0i 16v VALEO A13 VI 102 MELCO A002TA2091 VALEO A13 VI 101+ MELCO A002TA2091 C,VC 1.5D (poulie 59.4)
  • Page 353 ALTERNATORS XSARA With power-steering Classes and types Engine Gbox. Without aircon. Climate With aircon. Climate VALEO A13 VI 94+ VALEO A14 VI 13 MELCO A002TA2094 MELCO A002TA5591 BOSCH A120411513 VALEO A13 VI 94+ 1.9TD VALEO A13 VI 95 T,C,VC MELCO A002TA2094 MELCO A002TA1994 BOSCH A120411513 VALEO A13 VI 95...
  • Page 354 XSARA With power-steering - XSARA Police ALTERNATORS Classes and types Engine Gbox. Without aircon. Climate With aircon. Climate VALEO A13 VI 203 VALEO A13 VI 204+ MELCO A002TB2191 MELCO A002TB2291 MELCO A002TB4791 MELCO A002TB4891 2.0 Hdi VALEO A14 VI 27+ VALEO A14 VI 27+ BOSCH A1222051611 T,C,VC...
  • Page 355 ALTERNATORS XSARA PICASSO Classes and types Engine Gbox. Without aircon. Climate With aircon. Climate VALEO A11 VI 91 VALEO A13 VI 204+ BOSCH A120316004 C,VC MELCO A002TB4891 1.6i MELCO A002TB4791 T,C, VALEO A13 VI 203 MELCO A002TB4791 VALEO A13 VI 204+ VALEO A13 VI 203 C,VC MELCO A002TB4891...
  • Page 356 BERLINGO Without power-steering ALTERNATORS Classes and types Engine Gbox. Without aircon. Climate With aircon. Climate 1.1i /L3 VALEO A13 VI 96 VALEO A11 VI 55 VALEO A11 VI 55 1.4i /K BOSCH A120310028 BOSCH A120310028 VALEO A11 VI 55 VALEO A11 VI 55 1.4i /L3 H,T,C H,T,C...
  • Page 357 ALTERNATORS BERLINGO With power-steering Classes and types Engine Gbox. Without aircon. Climate With aircon. Climate VALEO A11 VI 55 BOSCH A120310028 1.1i /L3 VALEO A13 VI 96 VALEO A13 VI 141+ C,VC VALEO A13 VI 96 VALEO A11 VI 55 H,T,C 1.4i /L3 VALEO A11 VI 55...
  • Page 358 BERLINGO With power-steering ALTERNATORS Classes and types Engine Gbox. Without aircon. Climate With aircon. Climate VALEO A13 VI 203 VALEO A13 VI 203 MELCO A002TB2191 MELCO A002TB2191 H,T,C 1.9D /L3 VALEO A13 VI 204+ VALEO A13 VI 204+ MELCO A002TB2291 MELCO A002TB2291 VALEO A11 VI 91 VALEO A11 VI 91...

  • Page 359: Charging Circuit

    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 360 SAXO - XSARA - XSARA PICASSO PRE-HEATING AND STARTING SYSTEMS Pre / Post heating Vehicles / models Pre-heater plugs Pre-heater control unit (pre-heating duration at 20°C) BERU 0 100 226 188 LUCAS R0490001B SAXO 10s / 150s CHAMPION CH 168 BOSCH A 281 023 045 1.5D BERU 0 100 226 188...
  • Page 361 PRE-HEATING AND STARTING SYSTEMS BERLINGO Pre / Post heating Vehicles / models Pre-heater plugs Pre-heater control unit (pre-heating duration at 20°C) CHAMPION CH185 LUCAS R0490001B 1.9D 10s / 150s BERU 0 100 226 371 BOSCH A 281 023 045 BERLINGO CHAMPION CH170 NAGARES 735068 Controlled by the diesel injection...
  • Page 362 ALL TYPES AIR CONDITIONING R 134 a (HFC) Compressor Refrigerant Vehicle Engine Date Variable Oil quantity refill reference Capacity TU - TUD-TT 850 gr +0 - 50 gr SAXO TU TT MY 2000 # 825 gr ± 25 gr SD 6 V 12 TUD TT 795 gr ±...
  • Page 363 AIR CONDITIONING R 134 a (HFC) ALL TYPES Compressor Refrigerant Vehicle Engine Date Variable Oil quantity refill reference Capacity TU-TT SD 6 V 12 SD 6 V 12 EW (1) 570 gr +0 -50 gr SD 7 V 16 DW (1) SD 7 V 16 XSARA 590 gr +0 -50 gr...
  • Page 364 ALL TYPES SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Click-fit connector removing/fitting tool Vehicle Ø Inch Ring colour Tool kit 4164-T SAXO XSARA Black 8005-T.A. XSARA PICASSO 8005-T.C C5HP073C Tightening torques (m.daN). Unions Steel/Steel Ø Pipes Aluminium/Steel 1.7 ± 0.3 M 06 1.3 ±...
  • Page 365 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) ALL TYPES Presence of pollen filter Vehicle Equipment RPO No. Presence of filter Observations AX-SAXO-ZX-BX-C15 All Types Without aircon YES (Behr) Exc. driving school XSARA Base aircon YES (Larger) XSARA PICASSO Regulated aircon YES (Valeo) Without aircon XANTIA I and II...
  • Page 366 XSARA - All Types 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 367 XSARA - All Types SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) BEHR condenser with integral reservoir (16 Ti) Petrol engine 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 368 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 369 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 370 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 371 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 372 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 373 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 Vehicles SAXO 17 ± 3 13 ± 3 11 ± 3 9 ± 3 8 ± 3 Air temperature from the central 21 ±...
  • Page 374 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 375 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 376 SAXO # 09/1999 AIR CONDITIONING SYSTEM R 134.a (3) Click-fit union. # 09/1999 C5HP12EC Tightening torques (m.daN). (1) Click-fit union.. (2) Low pressure valve. (3)Pressostat d - 1.3 (4) High pressure valve. e - 1.3 NOTE : (b) = flange coupling. C5HP12DD...
  • Page 377 SAXO # 09/1999 AIR CONDITIONING SYSTEM R 134.a (3) Click-fit union. # 09/1999 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 ±...
  • Page 378 AIR CONDITIONING SYSTEM R 134.a SAXO 09/1999 # Click-fit union. 09/1999 # C5HP12EC Tightening torques m.daN. (1) High pressure valve (2) Low pressure valve (3) Click-fit union. (4) Pressostat (1 Joint Ø 10.82) (5) Dryer (2 Joints Ø 7.65) (6) Détendeur serrage 0.43 m.daN ± 0.1 (1 Joint Ø...
  • Page 379 SAXO - All Types 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).
  • Page 380 AIR CONDITIONING SYSTEM R 134.a XSARA TU # 09/2000 (1) - High pressure valve (2) - Low pressure valve (3) - Pressostat (4) - Dryer Tightening torques m.daN. (a) 0.8 (b) 4 ± 0.4 (c) 0.8 A Right hand drive. C5HP15VP...
  • Page 381 AIR CONDITIONING SYSTEM R 134.a XSARA TUD # 09/2000 (5) Click-fit union. C5HP12EC (1) - High pressure valve (2) - Low pressure valve (3) - Pressostat (4) - Dryer (5) - Click-fit union Tightening torques m.daN. (a) 0.8 (b) 4 ± 0.4 (c) 0.8 C5HP15YP...
  • Page 382 XSARA TU - TUD # 09/2000 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).
  • Page 383 AIR CONDITIONING SYSTEM R 134.a XSARA XU # 09/2000 (1) - High pressure valve (2) - Low pressure valve (3) - Pressostat (4) - Dryer Tightening torques m.daN. (a) 0.8 (b) 4 ± 0.4 (c) 0.8 A Right hand drive. C5HP15WP...
  • Page 384 XSARA XU # 09/2000 AIR CONDITIONING SYSTEM R 134.a Checking the air conditioning system T = Temperature (C°) and High Pressure (Bars). P = Low pressure (Bars). Te = Exterior temperature (C°). HP = Pressure at compressor outlet (Bars). T Cx = Temperature of air blown from the central air vents (C°). BP = Pressure at compressor inlet (Bars).
  • Page 385 XSARA XUD # 09/2000 AIR CONDITIONING SYSTEM R 134.a (1) - High pressure valve (2) - Low pressure valve (3) - Pressostat (4) - Dryer Tightening torques m.daN. (a) 0.8 (b) 4 ± 0.4 (c) 0.8 A Right hand drive. C5HP15XP...
  • Page 386 XSARA XUD # 09/2000 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).
  • Page 387 XSARA TU 09/2000 # AIR CONDITIONING SYSTEM R 134.a (1) - High pressure valve (2) - Low pressure valve (3) - Pressostat (4) - Dryer Tightening torques m.daN. (a) 0.8 (b) 4 ± 0.4 (c) 0.8 A Right hand drive. C5HP16RP...
  • Page 388 XSARA EW 09/2000 # AIR CONDITIONING SYSTEM R 134.a (1) - High pressure valve (2) - Low pressure valve (3) - Pressostat (4) - Dryer Tightening torques m.daN. (a) 0.8 (b) 4 ± 0.4 (c) 0.8 A Right hand drive. C5HP16SP...
  • Page 389 XSARA DW 09/2000 # AIR CONDITIONING SYSTEM R 134.a (1) - High pressure valve (2) - Low pressure valve (3) - Pressostat (4) - Dryer Tightening torques m.daN. (a) 0.8 (b) 4 ± 0.4 (c) 0.8 A Right hand drive. C5HP16VP...
  • Page 390 XSARA XU10J4RS 09/2000 # AIR CONDITIONING SYSTEM R 134.a (1) - High pressure valve (2) - Low pressure valve (3) - Pressostat (4) - Dryer Tightening torques m.daN. (a) 0.8 (b) 4 ± 0.4 (c) 0.8 A Right hand drive. C5HP16TP...
  • Page 391 AIR CONDITIONING SYSTEM R 134.a XSARA PICASSO TU (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) Filter/dryer cartridge cap. Tightening torques m.daN.
  • Page 392 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) Filter/dryer cartridge cap. Tightening torques m.daN.
  • Page 393 AIR CONDITIONING SYSTEM R 134.a XSARA PICASSO TU - EW7 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).
  • Page 394 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) Filter/dryer cartridge cap Tightening torques m.daN.
  • Page 395 AIR CONDITIONING SYSTEM R 134.a XSARA PICASSO DW10 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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