CITROEN C3 2002 User Manual

Page 1

2002

CAR 050010

«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».

Page 2

PRESENTATION

THIS HANDBOOK summarises the specifications, adjustments, checks and special features of the CITROEN C3.

The handbook is divided into the following sections representing the main functions : GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH - GEARBOX - DRIVESHAFTS - AXLES - SUSPENSION - STEERING - BRAKES -

HYDRAULICS - ELECTRICAL - AIR CONDITIONING.

Page 3

GENERAL

IDENTIFICATION OF VEHICLES

E1AP09HD

A: Chassis stamp

(cold stamp on bodywork). B : Manufacturer’s data plate.

(on the LH centre pillar) C : A-S / RP No. and RP paint code

(label on front pillar close to driver’s door).

D : Inflation pressures and tyre references.

(label on front pillar close to driver’s door)

E : Serial no. on bodywork. F : Gearbox reference – Factory serial no. G : Engine legislation type – Factory serial no.

GENERAL

Page 4

GENERAL

Emission standard L4 IFL5 L4/INF K’

Type code

FC HFXB/T FR HFXB FN HFXB FC HFXB

FN HFXC FC HFXC FC HFXB

FC HFX5

/IF /IF /D

Engine type HFX Cubic capacity (cc) 1124 Fiscal rating (hp) 4 Gearbox type MA/5N Gearbox ident. plate 20 CF 14

IDENTIFICATION OF VEHICLES

PETROL

1.1i

X-SX X

Page 5

GENERAL

IDENTIFICATION OF VEHICLES

(*) = Export.

PETROL

1.4i

SX – Exclusive

Auto.

Emission standard L4 IFL5 Type code FC KFVE FN KFVB FN KFVE FC KFVC/IF FC KFVF/IF FN KFVC/IF Engine type KFV Cubic capacity (cc) 1360 Fiscal rating (hp) 5 Gearbox type AL4 MA/5N AL4 MA/5N AL4 MA/5N

Gearbox ident. plate 20 TP 75

20 CF 15

20 TP 75

20 CF 15

20 TP 75

20 CF 15

20 CF 16 (*) 20 CF 16 (*) 20 CF 16 (*)

Page 6

GENERAL

IDENTIFICATION OF VEHICLES

(*) = Export.

PETROL

JP4

1.6i 16V

1.4i

SX – Exclusive

Auto.

Emission standard IFL5 L4 L4/INF L4 Type code FN KFVF/IF FC KFVB FC KFVB/D FC KFVE/D FN NFUB FC NFUB Engine type KFV NFU Cubic capacity (cc) 1360 1587 Fiscal rating (hp) 56 Gearbox type AL4 MA/5N MA/5S Gearbox ident. plate 20 TP 75 20 CF 15 20 CF 16 (*) 20 CN 40

Page 7

GENERAL

(*) = Export.

IDENTIFICATION OF VEHICLES

DIESEL

1.4 HDi

X - SX

Emission standard L4 Type code FC 8HBXB/T FN 8HXB FC 8HXB FC 8HXB/MOD FC 8HXK FR 8HXB Engine type 8HX Cubic capacity (cc) 1398 Fiscal rating (hp) 4 Gearbox type MA/5O Gearbox ident. plate 20 CN 33 20 CN 36 (*)

Page 8

GENERAL

Emission standard L4 Type code FN 8HWK FC 8HWB FN 8HVB FC 8HVB Engine type 8HW 8HV Cubic capacity (cc) 1398 Fiscal rating (hp) 45 Gearbox type MA/50 BE4/5 Gearbox ident. plate 20 CN 33 20 CN 36 (*) 20 DM 25 20 DM 26

IDENTIFICATION OF VEHICLES

DIESEL

1.4 HDi 1.4 HDi 16V S - SX SX - Exclusive

TED4

(*) = Export.

Page 9

GENERAL

IDENTIFICATION OF VEHICLES

DIESEL

TED4

1.4 HDi 16V

SX - Exclusive SX SX - Exclusive

Emission standard L4 Type code FN 8HYB FC 8HYC FC 8HYB/MOD FC 8HYB/T FC 8HYK FR 8HYB Engine type 8HY Cubic capacity (cc) 1398 Fiscal rating (hp) 5 Gearbox type BE4/5 Gearbox ident. plate 20 DM 25 20 DM 26

Page 10

GENERAL

IDENTIFICATION OF VEHICLES

Manufacturer’s plate.

E1AP09JC

The manufacturer’s plate carries the following information :

(a) Type approval number (*). (b) Type serial number. (c) Gross vehicle weight (*). (d) Gross vehicle weight (*). (e) Maximum weight on front axle (*). (f) Maximum weight on rear axle (*). (g) Manufacturer identification.

(*) = According to marketing country.

Page 11

GENERAL

IDENTIFICATION OF VEHICLES

Factory code.

Structure

The factory code is composed of 6 figures or letters. F = Vehicle family. C = Body shape.

8.H.Y = Engine. B = Version.

Body shape

Ref. Body shape

5 door saloon

5 door saloon (4 seats)

5 door saloon (Van not suitable for conversion)

C N R

Version (Gearbox and emission standard)

Ref. Gearbox

Manual 5 gears

Automatic 4 gears

Gear ratios and/or gearbox different

from base version.

Emissions

Ifl5

K’

IFL4

F K

Example : F.C.8.H.Y.B :

Family

Ref.

Engine Ref. HFX KFV NFU

8HX-8HW 8HY-8HV

Capacity

1124 1360 1587

1398

Engine type

TU1JP/L4/IFL5/L4 INF/K’

TU3JP/L4/IFL5/L4 INF

TU5JP4/L4

DV4TD/L4

DV4TED4/L4

Family

CITROËN C3

Page 12

GENERAL

GENERAL SPECIFICATION : DIMENSIONS

E1AP09KD

Page 13

Exterior dimensions (mm)

GENERAL

GENERAL SPECIFICATION : DIMENSIONS

Interior dimensions and volumes (mm)

Vehicles All types

Wheelbase A 2460 Length overall B 3850 Front overhang C 750 Rear overhang D 640 Rear track on the ground E 1435 Front track on the ground F 1438 Width overall G 1667 Height overall (*) H 1521

ODM = Vehicle in running order (vehicle empty, levels topped up).

(*) = Boot floor with adjustable configuration.

Elbow width, front 1406 Elbow width, rear 1402 Height of boot below parcel shelf 585 Minimum floor width 1040 Length of bootspace at floor level 660 Volume of boot below parcel shelf (dm

) 305

Volume in dm3of boot below Moduboard (*) 282

Page 14

GENERAL

Manual Auto. Manual Versions 1.1i 1 4i 1.6i 1.4i 1.4 HDi 1.4 HDi 16V Engine type HFX KFV NFU KFV 8HX 8HW 8HY 8HV Gearbox type MA/5N AL4 MA/50 BE4/5 Payload 485 465 467 468 479 467 Weight empty in Without options 1053 1080 1133 1114 1097 1147 running order With all options 1138 1147 1200 1182 1177 1214 Gross vehicle weight 1463 1470 1525 1507 1501 1539 Gross train weight 2113 2370 2425 2407 2401 2439 Maximum trailer weight without brakes 526 540 566 557 548 573 Maximum trailer weight with brakes Incline 12% 926 1174 1176 1175 1176 Maximum nose weight 38 47 48 47 48 Maximum roof rack load 60 kg

GENERAL SPECIFICATION : WEIGHTS

Petrol Diesel

Page 15

GENERAL

OPERATIONS TO BE CARRIED OUT AFTER A REPAIR

IMPERATIVE : All these operations are to be performed following a reconnection of the battery. Antiscanning function.

It is necessary to wait 1 minute after the battery has been disconnected in order to be able to start the vehicle.

Tailgate.

The opening of the tailgate is deactivated on reconnection of the battery. Perform locking/unlocking to activate the opening of the tailgate.

Overspeed check.

The vehicle’s overspeed values have to be re-initialised. The button on the wiper stalk operates the following functions:

- Activation of the vehicle’s overspeed function.

- Programming of the overspeed alert.

Electric windows

It is necessary to re-initialise the sequential and anti-pinch function NOTE : If the window is open at the time the battery is reconnected, action the window switch several times to close it, then re-initialise. Open the window fully. Action and release the window switch until the window is completely closed. This operation has to be carried out on each electric window.

Page 16

GENERAL

OPERATIONS TO BE CARRIED OUT AFTER A REPAIR

Sun roof.

The anti-pinch function has to be re-initialised. Place the sun roof switch in the maximum tilt position. Keep the sun roof switch pressed until the sun roof ceases its movement. Release the sun roof switch within 5 seconds. Keep the sun roof switch pressed until the end of the sun roof opening sequence.

Multifunction screen.

It is necessary to adjust the date, time and outside temperature. Adjust the display language of the multifunction screen if necessary.

NOTE : The default display language of the multifunction screen is French.

Navigation.

Vehicle location is only effective after some ten minutes. Reprogramme the customer parameters.

Radio.

Reprogramme the radio stations.

Page 17

GENERAL

GENERAL SPECIFICATION : TOWING THE VEHICLE

Front towing

Rear towing

WARNING : When the engine is not running,

steering and braking are no longer powerassisted.

Towing eye

(1) Towing eye

The towing eye is stowed in the jack protection box inside the spare wheel.

E2AP01KD

E2AP01LC

E2AP01MC

Page 18

GENERAL

GENERAL SPECIFICATION : TOWING THE VEHICLE

Vehicle towing : Precautions to be taken

Manual gearbox AL4 automatic gearbox

ESSENTIAL : Never tow the vehicles with wheels hanging (towing by the wheels).

ESSENTIAL : Never tow the vehicles with wheels hanging

(towing by the wheels).

AL4 autoactive gearbox. Towing.

In the event of impossibility to raise the front of the vehicle :

- It is ESSENTIAL to place the selection lever in position «N».

- Do not add oil.

- Do not exceed a speed of 30 mph over a distance of 30 miles.

Moving the vehicle.

- Never be towed with the ignition switched off.

- Never attempt to push-start the vehicle. NOTE : The automatic gearbox is only lubricated when the engine

is running.

Page 19

GENERAL

Lifting and supporting the vehicle Side liftingFront lifting

Front of the vehicle.

The authorised lifting points at the front of the vehicle are on the rear fixing bolts of the subframe at «a». For front lifting, take weight at the two lifting points at «a», using a crossbeam equipped with blocks. For front lifting from the side, take weight at the lifting point at «a».

ESSENTIAL :

- Never attempt to lift by the front panel mounting. Side lifting

ESSENTIAL :

- Always ensure the jack is correctly positioned at the lifting points.

- Do not place the axle stands under the jack contact lugs.

Position of the axle stand.

B3CP07KC E2AP016C E2AP00GCE2AP018CE2AP017C

GENERAL SPECIFICATION: LIFTING AND SUPPORTING THE VEHICLE

Page 20

GENERAL

GENERAL SPECIFICATION: LIFTING AND SUPPORTING THE VEHICLE

Lifting and supporting the vehicle (continued)

Lifting with the handle jack at the front

Lifting with the handle jack at the rear

Lifting on a two-column lift using the jack supports

Lift accessory with blocks on the jack supports

E2AP01PC

E2AP01RD

E2AP01NC E2AP01QD

NOTE : The handle jack is specific to the vehicle, do not

use it for any other purposes.

Page 21

GENERAL

CAPACITIES (in litres)

Draining method.

Oil capacities are defined as below.

1/ Vehicle on horizontal ground (in the high position, if hydropneumatic suspension).

2/ Engine warm (oil temperature 80°C). 3/ Drain oil sump + remove filter cartidge (time for draining to last drops = 15 minutes). 4/ Refit drain plug + filter cartridge. 5/ Refill the engine. 6/ Start the engine (to allow the cartridge to fill). 7/ Stop the engine (to allow oil to stabilise for 5 minutes).

ESSENTIAL : Systematically check the oil level using the oil dipstick.

Page 22

GENERAL

1.1i 1.4i 1.6i 16V 1.4 HDi 1.4 HDi 16V

Engine type HFX KFV NFU 8HX 8HW 8HV 8HY Drain by gravity

: engine with filter change 2.9 3.8 Between Min. and Max. 1.5 1 2 Drain by suction

: engine

with filter change

3.1

Between Min. and Max. 1.5 1 5-speed gearbox 2 2 1.9 Automatic gearbox

(1)

After oil change

Braking circuit

0.7 Litre version with front calipers Ø 48 / rear drums

0.8 Litre version with front calipers Ø 54 / rear discs

Cooling system 7 5.7 5.6 Fuel tank capacity 45

ESSENTIAL : Systematically check the oil level using the oil dipstick. (1) = The gearbox is lubricated for life. (For your information, the TOTALcapacity is 5.85 litres, after draining: 3 litres)

CAPACITIES (in litres)

Petrol

Diesel

Auto.

Page 23

GENERAL

LUBRICANTS – TOTAL recommended oils

S.A.E. Norm - Table for selection of engine oil grade

E4AP006D

Page 24

LUBRICANTS – TOTAL recommended oils

GENERAL

Factory evolutions in 2001 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 2.5%).

Features of CITROËN C5 :

2.0 and 2.2 HDi engines have a particle filter.

The maintenance interval for normal operation

is 30.000 km (20.000 miles) for petrol engines.

WARNING : HDi engines are high technology engines which imperatively require use of quality SYNTHETIC OILS : TOTAL ACTIVAor TOTAL QUARTZ 5W40.

To maintain engine performances, all countries in Europe should observe this requirement.

NOTE : Only PORTUGAL and GREECE may use 10W40 semi-

synthetic oil.

ESSENTIAL : For all vehicles with a 30.000 km (20.000 miles) maintenance interval, use exclusively TOTALACTIVA/QUARTZ 7000 or 9000 or any other oils offering identical specifications to these. These oils offer specifications that are superior to those defined by norms ACEA A3/98 or API SJ. Failing this, it is essential to adhere to the maintenance programmes covering severe operating conditions.

5W30 cannot be used in the following engines:

XU10J4RS : XSARA VTS 2.0i 16V (3 doors). SOFIM : RELAY 2.8 D and 2.8 TD. 1580 SPI : DISPATCH 1.6i.

2.0 and 2.2 HDi engines equipped with particle filter.

WARNING : CITROËN engines prior to model year 2000 do not have to be lubricated with oils adhering to the norms ACEA A1-98/B1-98 and API SJ/CF EC.

Page 25

GENERAL

LUBRICANTS – TOTAL recommended oils

Selection of engine oil grades recommended for climatic conditions in countries of distribution

ACEA Norms

The first letter corresponds to the type of engine concerned :

A : petrol and dual fuel petrol / LPG engines. B : diesel engines.

The figure following the first letter corresponds to the type of oil.

1 : highly fluid oils, for reducing friction and lowering fuel

consumption.

3 : high performance oils. The number after that (96 or 98) corresponds to the year of creation of the norm.

NOTE : From 01/03/2000, all engine oils must comply with ACEA- 98 norms.

Example : ACEA A1-98 / B1-98 : Blended oils for all engines, permitting fuel

economy (complying with ACEA 98 norms).

API Norms

The first letter corresponds to the type of fuel used by the engine :

S : petrol and dual fuel petrol / LPG engines. C : diesel engines.

The second letter corresponds to the degree of evolution, in ascending order.

Example : The norm SJ is more severe than the norm SH and corresponds to a higher level of performance. The adding of the lettersEC indicates that the engine oil concerned is an oil which permits fuel economy.

EC : Energy Conserving, reduction in fuel consumption. Examples :

API SJ / CF : Blended oils for all engines.

engines API CF / EC: Oils specifically for diesel engines, permitting fuel economy. API SJ / CF / EC : Blended oils for all engines, permetting fuel economy.

Page 26

GENERAL

LUBRICANTS – TOTAL recommended oils

Engine oil norms. Norms in force.

These engine oils have been classified by the following recognised organisations:

S.A.E. : Society of Automotive Engineers. API : American Petroleum Institute. ACEA : Association des Constructeurs Européens d’Automobiles.

Recommendations.

Denominations of TOTAL oils, according to country of marketing:

TOTAL ACTIVA (France only). TOTAL QUARTZ (Outside France).

Summary

Engine oil norms to be respected in 2001 model year

(*) = It is essential not to use engine oils respecting these norms for the following engine-types . XU10J4RS, 1580 SPI, SOFIM 2.8 D and SOFIM 2.8 TD.

ESSENTIAL : To preserve engine performances, all engines fitted in CITROEN vehicles must be lubricated with high

quality oils (synthetic or semi-synthetic)

Model year Types of engine ACEA norms API norms

Petrol and dual fuel petrol / A3-98 or A1-98 (*) SJ or SJ / EC (*)

AM 2001

LPG engines Diesel engines B3-98 or B1-98 (*) CF or CF / EC (*)

Page 27

GENERAL

S.A.E. grades SPI norms ACEA norms

Blended oils for all engines (petrol, dual-fuel petrol / LPG and diesel)

TOTAL ACTIVA9000 TOTAL QUARTZ 9000

5W-40 SJ / CF A3-98 / B3-98

TOTAL ACTIVA9000. (*) TOTAL QUARTZ 9000. (*)

5W-30 SJ / CF EC A1-98 / B1-98

TOTAL ACTIVRAC 10W-40 SJ / CF A3-98 / B3-98 (*) = Blended oils for all engines, permitting fuel economy.

Oils specifically for petrol and dual-fuel petrol / LPG engines

TOTAL ACTIVA7000 TOTAL QUARTZ 7000

10W-40

TOTAL QUARTZ 9000 0W-40 SJ A3-98 TOTAL ACTIVA7000

TOTAL QUARTZ 7000

15W-50

Oils specifically for diesel engines

TOTAL ACTIVADIESEL 7000 TOTAL QUARTZ DIESEL 7000

10W-40

TOTAL ACTIVADIESEL 7000

15W-50

CF B3-98

TOTAL ACTIVADIESEL 9000 5W-40

LUBRICANTS – TOTAL RECOMMENDED OILS

Page 28

GENERAL

FRANCE

Metropolitan FRANCE

New Caledonia Guadeloupe Saint-Martin La Réunion Martinique 9000 5W-40 7000 15W-50 7000 15W-50 Guyana Tahiti Mauritius Mayotte

LUBRICANTS – TOTAL RECOMMENDED OILS

Blended oils for all engines, supplied in bulk

TOTAL ACTIVRAC S.A.E : 10W-40 Norms

TOTAL ACTIVA

9000 5W-40

9000 5W-30 (*)

7000 10 W-40

7000 10W-40

9000 5W-40

TOTAL ACTIVA DIESEL

Blended oils for all engines

Oils specifically for petrol and

dual-fuel petrol / LPG engines

Oils specifically for diesel

engines

(*) = Blended oils for all engines, permitting fuel economy.

Page 29

GENERAL

EUROPE

Germany Austria

Belgium Bulgaria

Cyprus Croatia

Denmark

Spain Estonia Finland Great Britain

LUBRICANTS – TOTAL RECOMMENDED OILS

TOTAL QUARTZ

TOTAL QUARTZ DIESEL

Blended oils for all engines

Oils specifically for petrol and dual-fuel petrol / LPG engines

Oils specifically for diesel

engines

9000 5W-40

9000 5W-30 (*)

(*) = Blended oils for all engines, permitting fuel economy

7000 10W-40

9000 0W-40 7000 10W-40 7000 10W-40

9000 0W-40 7000 10W-40

7000 15W50 7000 10W-40 7000 10W-40

9000 0W-40

7000 10W-40 7000 15W-50

7000.10W-40 7000 10W-40

9000 0W-40

7000 10W-40

Page 30

GENERAL

Oils specifically for diesel

engines

EUROPE (continued)

Greece Holland

Hungary Italy Ireland Iceland Latvia Lithuania Macedonia

Malta Moldova Norway Poland

Portugal Slovak Republic

LUBRICANTS – TOTAL RECOMMENDED OILS

TOTAL QUARTZ TOTAL QUARTZ DIESEL

Blended oils for all engines

Oils specifically for petrol and

dual-fuel petrol / LPG engines

(*) = Blended oils for all engines,

permitting fuel economy

9000 5W-40

9000 5W-30 (*)

7000 10W-40

7000 10W-40 7000 15W-50

7000 10W-40

9000 0W-40 7000 10W-40

7000 10W-40

9000 0W-40 7000 10W-40 7000 10W-40

7000 15W-50 7000 10W-40 7000 10W-40

9000 0W-40 7000 10W-40

Page 31

GENERAL

EUROPE (continued)

Czech Republic

7000 10W-40

9000 0W-40

Romania

7000 10W-40 7000 15W-50

Russia

7000 10W-40

9000 0W-40

Slovenia 7000 10W-40 Sweden

7000 10W-40

9000 0W-40

Switzerland 7000 10W-40

7000 10W-40

Turkey 7000 15W-50

9000 0W-40

Ukraine

7000 10W-40

9000 0W-40

Yugoslavia 7000.10W-40

LUBRICANTS – TOTAL RECOMMENDED OILS

Oils specifically for diesel

engines

TOTAL QUARTZ

TOTAL QUARTZ DIESEL

Blended oils for all engines

Oils specifically for petrol and dual-fuel petrol / LPG engines

(*) = Blended oils for all engines, per-

mitting fuel economy

9000 5W-40

9000 5W-30 (*)

7000 10W-40

Page 32

GENERAL

Oils specifically for diesel

engines

Australia New-Zealand

Ivory Coast Egypt Gabon Madagascar Morocco Senegal Tunisia

Argentina Brazil, Chile Cuba Mexico Paraguay Uruguay

LUBRICANTS – TOTAL RECOMMENDED OILS

TOTAL QUARTZ

TOTAL QUARTZ DIESEL

Blended oils for all

engines

Oils specifically for petrol and

dual-fuel petrol / LPG engines

OCEANIA

AFRICA

CENTRAL

AND SOUTH

AMERICA

9000 5W-40

7000 10W-40

7000 15W-50

7000 10W-40

Page 33

GENERAL

Oils specifically for diesel

engines

China South Korea

Hong-Kong India Indonesia

Japan Malaysia

Pakistan Philippines Singapore

Taiwan Thailand

Vietnam

LUBRICANTS – TOTAL RECOMMENDED OILS

TOTAL QUARTZ

TOTAL QUARTZ DIESEL

Blended oils for all

engines

Oils specifically for petrol and dual-fuel petrol / LPG engines

SOUTH EAST

ASIA

9000 5W-40

9000 5W-40 9000 5W-30

9000 5W-40

7000 10W-40 7000 15W-50

7000 10W-40

7000 15W-50

7000 10W-40 7000 15W-50

7000 15W-50

7000 10W-40 7000 15W-50

7000 15W-50

7000 10W-40

(*) = Blended oils for all engines, permitting

fuel economy

Page 34

GENERAL

Oils specifically for diesel

engines

LUBRICANTS – TOTAL RECOMMENDED OILS

TOTAL QUARTZ

TOTAL QUARTZ DIESEL

Blended oils for all engines

Oils specifically for petrol and

dual-fuel petrol / LPG engines

MIDDLE

EAST

9000 5W-40 7000 15W-50 7000 10W-50

Saudi Arabia Bahrain Dubai United Arab Emirates Iran Israel Jordan Kuwait Lebanon Oman Qatar Yemen

Page 35

GENERAL

Manual gearbox

TOTAL TRANSMISSION BV

Norms S.A.E 75W-80

Special oil distributed by CITROËN

(Part No. 9730 A2)

MB3 automatic gearbox

All countries

TOTAL FLUIDE ATX or

TOTAL FLUIDE AT 42.

Special oils distributed by CITROËN

(Part No. 9730 A3).

4 HP 20 and AL4 automatic gearboxes

Special oil distributed by CITROËN

(Part No. 9736 22).

Transfer box and rear axle TOTAL TRANSMISSION X 4

All countries TOTAL FLUIDE ATX

Power- assisted steering TOTAL FLUIDE DA

Very cold countries Special oil distributed by CITROËN

(Part No. 9730 A1)

LUBRICANTS – TOTAL RECOMMENDED OILS

Gearbox oils

Power steering oils

Page 36

GENERAL

Synthetic brake fluid

LUBRICANTS – TOTAL RECOMMENDED OILS

Packs

CITROEN reference

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 9979 75

Synthetic brake fluid

Packs CITROEN reference

All countries

CITROEN Fluid

0.5 litre 9979 05 1 litre 9979 06

5 litres 9979 07

CITROEN hydraulic circuit fluid

Norm Pack CITROEN reference

TOTAL LHM PLUS

ISO 7308-7309 ZCP 830 095

Green in colour 1 litre 9979.20 (Scandinavia)

All countries

TOTAL FLUIDE LDS Orange in colour 9979.69

WARNING: TOTAL LDS fluid cannot be blended with TOTAL LHM PLUS

WARNING: CITROËN C5 : Use only TOTAL FLUIDE LDS suspension fluid.

Hydraulic circuit rinsing fluid- green in colour

All countries TOTAL HYDRAURINCAGE

Page 37

GENERAL

Packs CITROEN reference Concentrated : 250 ml 9980 33 ZC 9875 953 U 9980 56

All countries

Liquid ready to use: 1 litre 9980 06 ZC 9875 784 U Liquid ready to use: 5 litres 9980 05 ZC 9885 077 U ZC 9875 279 U

Grease

Norms NLGI (1)

TOTAL MULTIS EP2 2

All countries TOTAL MULTIS COMPLEX EP2 2

TOTAL MULTIS N4128 1

TOTAL SMALL MECHANISMS

(1) NLGI = National Lubrificating Grease Institute.

Wash/wipe fluid

LUBRICANTS – TOTAL RECOMMENDED OILS

Page 38

ENGINE OIL CONSUMPTION

I-Oil consumption depends on :

- the engine type.

- how run-in or worn it is.

- the type of oil used.

- the driving conditions.

II - An engine can be considered RUN-IN after:

- 3.000 miles (5.000 km) for a PETROL engine.

- 6.000 miles (10.000 km) for a DIESEL engine.

III - MAXIMUM PERMISSIBLE oil consumption for a RUN-IN engine.

- 0.5 litres per 600 miles (1.000 km) for a PETROL engine.

- 1 litre per 600 miles (1.000 km) for a DIESEL engine. DO NOT WORK BELOW THESE VALUES.

IV - OIL LEVEL : The level should NEVER be above the MAX. mark on the dipstick after changing or topping up the oil.

- This excess oil will be used up rapidly.

- It will reduce the engine output and adversely affect the operation of the air circuits and gas recycling.

GENERAL

Page 39

ENGINE SPECIFICATIONS

DieselPetrol

1.1i 1.4i 1.6i 16V 1.4 HDi 1.4 HDi 16V

Engine type

Cubic capacity (cc)

Bore / Stroke

Compression ratio

Power ISO or EEC KW - rpm)

Power DIN (HP - rpm)

Torque ISO or EEC (m.daN - rpm)

Torque DIN (mkg-rpm)

Max. speed (rpm)

HFX KFV NFU 8HX 8HW 8HY 8HV

1124 1360 1587 1398

72/69 75/77 78/82 73/82

10.5/1 11/1 17.9/1 18.25/1 44-5500 54-5400 80-5800 50-4000 66-4000 61-5500 75-5400 110-5800 70-4000 92-4000

9.4-3400 12-3400 14.7-4000 15-2000 20-2000

9.8-3400 12.5-3400 15.3-4000 15.6-2000 20.8-2000

ENGINE

Page 40

ENGINE SPECIFICATIONS

Engines : HFX - KFV - NFU

Engine identification

B1BP10JC B1BP2GKC

A=Engines: HFX - KFV B = Engine: NFU.

Compulsory engine identification in zone «a» :

- Component reference.

- Engine legislation type.

- Factory serial no.

ENGINE

Page 41

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Crankshaft

Engine types HFX KFV NFU Accessories drive pulley 0.8 ± 0.2 Pinion fixing on crankshaft 10 ± 1 2.5 ± 0.2

Cylinder block

Sump 0.8 ± 0.2 Timing belt tensioner roller 2 ± 0.2 2.2 ± 0.2 Accessories belt tensioner roller 2 ± 0.2 2.5 ± 0.2 Alternator support fixing 1.7 ± 0.3 Alternator fixing on support 3.7 ± 0.3

Cylinder head

Coolant outlet housing 0.8 ± 0.2 Camshaft bearing cap Tightening 2 ± 0.2 2 ± 0.2 Angular tightening 44°±4° 50°±5° Inlet manifold 0.8 ± 0.2 Exhaust manifold 1.7 ± 0.3 2 ± 0.2 Valve rockers adjusting screw 1.75 ± 0.25 Sparking plugs 2.75 ± 0.25 Camshaft pulley screw 8 ± 0.8

ENGINE

Page 42

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Flywheel - Clutch

Engines HFX KFV NFU Flywheel 6.7 ± 0.6 + LOCTITE FRENETANCH Clutch mechanism 2 ± 0.2

Lubrication circuit

Oil pressure switch 2 ± 0.2 Oil pump 0.9 ± 0.1

Cooling circuit

Coolant pump 1.4 ± 0.1 Coolant outlet housing 0.8 ± 0.1

ENGINE

Page 43

CYLINDER HEAD

Engines : HFX - KFV - NFU

Identification of cylinder head gasket

Engine types

HFX KFV NFU

Thicknesses (Standard)

1.2 ± 0.1

0.66 ± 0.04

Thicknesses (repair)

1.4 ± 0.1

Thickness references

2 1 4

ENGINE

References

1,2,3,4 = Type of engine. A,B,D = Suppliers. C = Gasket material. R = Repair.

B1BP10KC

Page 44

ENGINE

CYLINDER HEAD

Engines : HFX - KFV - NFU

Cylinder head tightening (m.daN) Cylinder head bolts

X = MAXIMUM reusable length

Tightening 2 ± 0.2 Angular tightening 240°±5°

(In the order 1 to 10)

Tightening 2 ± 0.2 Angular tightening 260° ± 5°

(In the order 1 to 10)

NOTE : Oil the threads and under the heads of the bolts. (Use engine oil or Molykote G Rapid Plus).

B1BP1DVC

NFU

HFX - KFV

175.5 ± 0.5 122 ± 0.3

NFU

B1DP05BC

NOTE : Retightening of the cylinder head

after a completed repair is prohibited.

Page 45

ENGINE

ENGINE SPECIFICATIONS

Engines : 8HX - 8HW Engine identification

"a" Engine legislation type. "b" Component reference. "c" Factory serial no.

B1CP0BKD

Page 46

ENGINE

CYLINDER HEAD

Engines : 8HX - 8HW

Cylinder head tightening (m.daN) Cylinder head bolts

X = MAXIMUM reusable length

Pre-tightening 2 ± 0.2 m.daN Tightening 4 ± 0.4 m.daN Angular tightening 230° ± 5°

(In the order 1 to 10)

NOTE :

- The bolts should have been thoroughly cleaned and dried with a dry metal brush.

- Oil the threads and under the heads of the bolts. (Use engine oil or Molykote G Rapid Plus).

- Pass a tap into the holes in the cylinder block.

8HX - 8HW

X = 149 mm

B1DP1CLC

B1DP1DBC

NOTE : Retightening of the cylinder head

after a completed repair is prohibited.

The cylinder head gasket is dry-fitted.

Page 47

ENGINE SPECIFICATIONS

Engines : 8HY - 8HV

Engine identification

"a" Engine legislation type. "b" Component reference. "c" Factory serial no.

B1CP0BKD

ENGINE

Page 48

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Crankshaft

Engines 8HY-8HV Bearing cap fixing screw

Tightening 3 ± 0.3 Angular tightening 140°±1°.4'

Crankshaft pullet hub Tightening 3 ± 0.3 Angular tightening 180° ± 5°

Cylinder block

Oil sump 1 ± 0.1 Timing belt tensioner roller 4 ± 0.4 Timing belt guide roller

2.5 ± 0.2

Timing belt guide roller support

Cylinder head

Camshaft bearing cap cover

1 ± 0.1

Inlet manifold Exhaust manifold 2.5 ± 0.2

Cylinder head cover Bolts (M6) to 1 ± 0.2 Camshaft pinion 4.3 ± 0.4

Fuel high pressure pump pinion 5 ± 0.5

ENGINE

Page 49

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Flywheel - Clutch

Engines 8HY-8HV Flywheel 1.7 ± 0.2 Clutch mechanism 2 ± 0.2

Lubrication circuit

Oil pump assembly 0.9 ± 0.1 Oil/coolant heat exchanger 1 ± 0.1 Turbocharger lubrication pipe 2.2 ± 0.2

Injection circuit

Injector fixing flange nut Tightening 0.4 ± 0.1 Angular tightening 65°±5°

Unions on fuel high pressure common injection rail

2.3 ± 0.2

Fuel high pressure pump Union on diesel injector Fuel high pressure pump pinion 5 ± 0.5 Union on fuel high pressure pump 2.3 ± 0.2

Cooling circuit

Coolant pump 1 ± 0.2±

ENGINE

Page 50

ENGINE

CYLINDER HEAD

Identification of cylinder head gasket

Engine types Supplier

Piston

standproud

(mm)

Thicknesses

(mm)

No. of notches

at d

No. of notches

at e

0.675 to 0.725 1.25 1

0.726 to 0.775 1.30 2

8HY-8HV ELRING 0.776 to 0.825 1.35 3 2

0.826 to 0.875 1.40 4

0.876 to 0.983 1.45 5

B1DP1CKD

Engines : 8HY - 8HV

Type of gasket : Metallic

multilayer

"d" Thickness reference. "e" Engine reference

Page 51

ENGINE

CYLINDER HEAD

Engines : 8HY - 8HV

Cylinder head tightening (m.daN) Cylinder head bolts

X = MAXIMUM reusable length

Pre-tightening : 2 ± 0.2 Tightening : 4 ± 0.5 Angular tightening : 230 ° ± 5°

(In the order 1 to 10)

NOTE :

- The bolts should have been thoroughly cleaned and dried with a dry metal brush.

- Oil the threads and under the heads of the bolts. (Use engine oil or Molykote G Rapid Plus).

- Pass a tap into the holes in the cylinder block.

8HY - 8HV

8HY - 8HV X = 149 mm

B1DP1CLC

B1DP1DBC

NOTE : Retightening of the cylinder head

after a completed repair is prohibited.

The cylinder head gasket is dry-fitted.

ENGINE

Page 52

CAMSHAFT

Engines : 8HY - 8HV

Camshaft identification

(1) - Inlet camshaft. (2) - Exhaust camshaft. "f" : Marking zone.

B1EP18AD

ENGINE

Page 53

ENGINE

Tools

BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE

! 4099-T (C.TRONIC.105)

4122-T (C.TRONIC.105.5)

B1EP135D

Page 54

Petrol Diesel

TU DV

13 5 4

JP JP4 TD TED4

Engine type HFX KFV NFU 8HX 8HW 8HV 8HYX

C3 X X X X X X X

See pages : 53 to 54 55 to 56 57

AUXILIARY EQUIPMENT DRIVE BELT

ENGINE

Page 55

AUXILIARY EQUIPMENT DRIVE BELT

Engines : HFX - KFV - NFU

B1BP2LSC B1BP2LTC

Tools. [1] Pliers for removing plastic pegs : 7504-T.

[2] Belt tension measuring instrument : 4122-T.

ehicle without air conditioning.

Refit.

Refit the belt. Respect the following sequence:

- Crankshaft pinion.

- Alternator pulley. Place tool [2] on the belt. Tighten screw (1) to achieve a tension of:

55 ± 3 unités SEEM.

Tighten:

- Screw (3).

- Screw (2). Remove tool [2] and complete the refitting.

Remove.

Slacken:

- Screw (2).

- Screw (3).

- Tensioning screw (1).

Push the alternator back towards the engine. Remove the belt.

ENGINE

Page 56

AUXILIARY EQUIPMENT DRIVE BELT

Engines : HFX - KFV - NFU

B1BP10XC

Vehicle with air conditioning. Remove

Slacken:

- Screws (6), (4) and (5).

- Fully detension the belt by acting on the tensioner roller.

- Remove the accessories drive belt.

Refit.

Respect the following sequence:

- Crankshaft pinion.

- Aircon compressor pulley.

- Guide roller.

- Alternator pulley.

- Tensioner roller. Place tool [2] on the belt.

- Tighten screw (5) to achieve a belt tension of:

120 ± 3 SEEM units.

- Tighten screws (4) and (6).

- Remove tool [2].

- Complete the refitting.

ENGINE

B1BP10VC

Page 57

AUXILIARY EQUIPMENT DRIVE BELT

Engines : 8HX - 8HWWith compressor and alternator

B1BP2MKC

B1BP2MJD

Tools [1] Pliers for removing plastic pegs : 7504-T. [2] Tensioner roller compression lever : (-).0194.E. [3] Tensioner roller setting peg Ø4 mm : (-).0194.F.

Removing.

Disconnect the battery negative cable. Raise and support the vehicle, wheels hanging. Remove the front RH wheel. Move aside the splash-shield, using tool [1].

IMPERATIVE : In the case of belt re-use, mark the direction of rotation of the belt. If the index on the tensioner roller is outside the marks, change the auxiliary equipment drive belt.

Remove : The alternator (1). The aircon compressor (2). Detension the auxiliary belt tensioner roller, using tool [2]. Position the peg [3]. Remove the auxiliary drive belt.

ENGINE

Page 58

AUXILIARY EQUIPMENT DRIVE BELT

Engines : 8HX - 8HW

Markings on the dynamic tensioner roller.

"a" Position of «maximum wear» of the auxiliary drive belt. "b" Normal position.

Refitting

NOTE : Check that the tensioner roller moves freely (no tight spot). If this is not the

case, replace the tensioner roller.

Respect the direction of fitting of the drive belt.

Complete the setting of the belt, of both sides, by means of the tensioner roller. Make sure that the drive belt is correctly positioned in the «V» grooves of the various pulleys.

Move the tool [2] on the tensioner roller to remove the peg [3].

ENGINE

B1EP18UD

Page 59

AUXILIARY EQUIPMENT DRIVE BELT

Engines : 8HY - 8HV

B1BP2MYD B1BP2MZC

Tools. [1a] Dynamic tensioner roller lever : (-).0194-E1.

[1b] Lever extension : (-).0194-E2. [2] Accessories belt roller locking peg Ø 4 mm : (-).0194-F

Removing

Pivot the tensioner roller support (1) (clockwise), using tools [1a] and [1b] at «a». Remove the belt. Immobilise the support (1) of the tensioner roller, using tool [2]. Remove the auxiliary drive belt (2).

IMPERATIVE : Ensure that the tensioner rollers turn freely (no play, no tight spot).

Refitting

Reposer la courroie. Move the tool [1] on the tensioner roller to remove the peg [2].

ESSENTIAL: Make sure that the belt is correctly positioned in the various pulley grooves.

ENGINE

Page 60

Petrol Diesel

TU DV

13 5 4

JP JP4 TD TED4

Engine type HFX KFV NFU 8HX 8HW 8HV 8HY

C3 X X X X X X X

See pages : 59 to 68 69 to76 77 to 85

CHECKING AND SETTING THE VALVE TIMING

ENGINE

Page 61

CHECKING AND SETTING THE VALVE TIMING

Engines : HFX - KFV - NFU

B1BP2M7C B1BP2M9C

B1BP2M8C

Tools. [1] Engine flywheel peg : 4507-T.A [2] Camshaft pulley peg : 4507-T.B [3a] Camshaft peg : 4533-TA.C1 [3b] Camshaft peg : 4533-TA.C2 [4] Dynamic tensioner roller pin : 4200-T.H [5] Belt retaining pin : 4533-T.AD [6] Pliers for removing plastic pins : 7504-T.

Checking the valve timing. Engines HFX - KFV - NFU

Raise and support the front RH side of the vehicle. Disconnect the battery positive terminal. Engage 5th gear. Remove the oil filter (1).

HFX – KFV engine

Remove : The timing top casing (2). Turn the wheel to rotate the engine (normal direction of rotation). Peg the camshaft pulley, using tool [2].

ENGINE

Page 62

CHECKING AND SETTING THE VALVE TIMING

Engine : NFU

B1BP2MAC

Checking the timing (continued)

Engine: NFU

Place a jack under the engine, peg the engine. Remove:

- The engine support (4) complete.

- The timing casing (3).

- The sparking plugs (eases engine rotation).

Turn the wheel to rotate the engine (normal direction of rotation). Position the pegs [3a] and [3b]. Peg the flywheel, using tool [1]. If the setting is not correct, recommence the operation. Remove the tools [1], [2], [3a] and [3b]. Complete the refitting.

B1BP2MBC

ENGINE

B1EP18MC

Page 63

CHECKING AND SETTING THE VALVE TIMING

Engines : HFX - KFV

B1BP2MBCB1BP2M9C B1BP2MDC

Setting the timing Preliminary operation.

Lift and support the vehicle, wheels hanging. Disconnect the battery. Remove:

- The front RH wheel.

- The splash-shield, using tool [6]

- The accessories belt (See corresponding operation).

- The crankshaft pulley.

- The oil filter. Place a jack under the engine, peg the engine.

Removing. HFX – KFV engine

Turn the engine by means of screw (1). (normal direction of rotation). Remove the timing casings. Peg the camshaft pinion, using tool [2]. Peg the flywheel, using tool [1]. Remove:

- The fixing screws (2).

- The upper engine support (3).

ENGINE

B1BP2MCC

Page 64

CHECKING AND SETTING THE VALVE TIMING

Engines : HFX - KFV

B1BP2MEC B1EP18NC

Setting the timing (continued)

HFX – KFV engines

Slacken the screws (4) without removing them.

Remove the bottom engine support assembly (5), and the fixing screws (4).

Slacken the nut (6).

Completely detension the belt by acting on the tensioner roller (7).

Remove the timing belt.

IMPERATIVE : Check that the tensioner roller turns freely (no tight spot).

ENGINE

Page 65

CHECKING AND SETTING THE VALVE TIMING

Engine : NFU

B1BP2MBC

NFU engine.

Setting the timing (continued)

Remove:

The bottom plastic casing.

The engine support (9).

The middle support.

The timing cover (8).

Peg the flywheel, using tool [1].

Position the tools [3a] and [3b].

ENGINE

B1BP2MFC B1EP18MC

Page 66

CHECKING AND SETTING THE VALVE TIMING

Engine : NFU

B1EP18PC

Setting the timing (continued)

NFU Engine

Slacken the tensioer roller.

Turn the tensioner roller so as to be able to position the tool [4], with the aid of an Allen key placed at «a».

Turn the tensioner roller towards the right to bring it to the index «c» in position «b».

Peg the tensioner roller in this position in order to slacken the timing belt to the maximum.

IMPERATIVE : Never make the dynamic tensioner roller turn by a complete rotation.

Remove the timing belt (8).

Check that the rollers (9) and (10) turn freely (no tight spot).

ENGINE

B1EP18QC

Page 67

CHECKING AND SETTING THE VALVE TIMING

Engines : HFX - KFV

B1EP18QC

Setting the timing (continued)

HFX-KFV Engines

Refit. WARNING: Respect the direction of fitting of the belt: (the arrows «d» indicate the direction of rotation of

the crankshaft). Refit the timing belt. Position the timing belt, belt «e» well tensioned, in the following order:

Crankshaft pinion, hold the belt using tool [5]. Camshaft pulley. Coolant pump pulley. Tensioner roller. Remove the pegs [1] and [2].

ENGINE

Page 68

CHECKING AND SETTING THE VALVE TIMING

Engines : KFX - KFV - NFU

Setting the timing (continued) HFX-KFV engines Refitting. NOTE : Check that the pegs [1] and [2] are in place. WARNING: Respect the direction of fitting of the timing belt, the arrows «d» indicate the direction of rotation

of the crankshaft. Refit the timing belt. Position the timing belt, belt «e» well tensioned, in the following order: Crankshaft pinion, hold the belt using tool [5].

- Camshaft pulley.

- Coolant pump pulley.

- Tensioner roller. Remove the tools [1], [2].

NFU engine.

Fit the timing belt in position in the following order:

- Inlet camshaft pulley.

- Exhaust camshaft pulley.

- Guide roller.

- Crankshaft pulley. Position tool [5].

- Coolant pump pulley.

- Dynamic tensioner roller. Remove the tools [1], [3] and [5].

ENGINE

B1EP18RC

Page 69

CHECKING AND SETTING THE VALVE TIMING

Engine : NFU

B1EP18SD

Timing belt overtensioned:

A: Engines HFX – KFV. B : Engine NFU

Turn the tensioner roller (7) with the aid of a hexagonal spanner at «a».

Bring the index «c» to position «f», to tension the belt to the maximum of the interval indicated.

Hold the tensioner roller (7), using tool [4].

Tighten the fixing nut of the tensioner roller, tightening to 1 ± 0,1 m.daN.

Turn the crankshaft by 4 rotations (normal direction of rotation).

IMPERATIVE : Never make the crankshaft rotate backwards.

Make sure that the timing is correctly set by refitting the tools [1], [2] and [3]. Remove the tools [1], [2] and [3].

ENGINE

Page 70

CHECKING AND SETTING THE VALVE TIMING

Engines : HFX - KFV - NFU

B1EP18TD

Adjusting the fitting tension of the timing belt A: Engines HFX – KFV.

B : Engine NFU.

Slacken the nut while maintaining the position of the tensioner roller, with the aid of a hexagonal spanner at «a». Next bring the index «c» to its adjusting position «a». The index «c» should not go beyond the notch «g».

WARNING: The index «c» must not go beyond the notch «g». If it should do this, restart the timing belt tensioning operation.

Hold the tensioner roller (7) in this position, with the aid of a hexagonal spanner. Tighten the tensioner roller fixing nut to :

2 ± 0.2 m.daN. (HFX - KFV engines)

2.2 ± 0.2 m.daN. (NFU engines)

IMPERATIVE : The tensioner roller must not rotate during the tightening of its fixing. If it does, restart the timing belt tensioning operation.

Complete the refitting.

ENGINE

Page 71

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HX - 8HW

B1BP2LXC

Tools. [1] Pliers for removing plastic pegs : 7504-T. [2] Lever for detensioning the dynamic tensioner roller : (-).0194.E [3] Engine flywheel setting peg :.(-).0194.C [4] Camshaft setting peg : (-).0194.B. [5] Crankshaft and high pressure pump setting peg : (-).0194.A.

Preliminary operations.

Remove:

- The front RH wheel.

- The front RH splash-shield, using tool [1].

- The clips of the electrical harness on the upper timing cover.

- The accessories belt, using tool [2] (see corresponding operation).

Check ing the setting.

Disconnect the battery negative cable. Remove the upper timing cover (1). Rotate the engine using the screw (2) of the crankshaft pulley.

NOTE : The locking hole is located under the crankshaft bearing cap cover. Undo the screw (2). Detension the auxiliary drive belt dynamic tensioner roller, using tool [2].

ENGINE

Page 72

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HX - 8HW

B1EP18EC

Check ing the setting (continued)

Remove:

- the accessories drive belt.

- the accessories drive pulley.

- the lower timing cover (3).

IMPERATIVE : The magnetic track should show no signs of damage and should not be approached by any other source of magnetism.

Reposition the screw (2). Remove tool [3]. Rotate the engine by means of the crankshaft pinion screw (2) (clockwise), to bring it to the pegging position. Position the tool [4]. Peg the crankshaft pinion (1), using tool [5]. Peg the high pressure pump pinion, using tool [5]. NOTE : Index «a» of the roller tensioner must be centred within the area «b». Check the correct positioning of i ndex «a». Remove tools [4] and [5]. Rotate the engine ten times. Fit the tools [4] and [5]. If pegging is not possible, carry out the operation to remove/refit the timing belt. (See corresponding operation).

B1JP03SC

B1EP18DC

B1EP18FC

ENGINE

Page 73

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HX - 8HW

B1EP18GC

Setting the timing.

Remove the upper timing cover (1). Rotate the engine by means of the crankshaft screw (2).

NOTE : The pegging hole is located under the crankshaft bearing cap cover. Peg the engine flywheel, using tool [3]. Remove the lower timing cover (3). Uncouple the exhaust line from the manifold.

IMPERATIVE : Uncouple the exhaust line in order to avoid damaging the front flexible pipe. Twisting, pulling and bending the front flexible pipe reduces its life.

Remove:

- The engine speed sensor (6).

- The belt retaining stop (5).

- The screw (2).

- The crankshaft pinion (4) (with its magnetic track «a»).

IMPERATIVE : The magnetic track should show no signs of damage and should not be approached by any other source of magnetism. Should this not be adhered to, it is essential to replace the crankshaft pinion.

Refit the screw (2).

ENGINE

B1BP2LXC

Page 74

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HX - 8HW

Setting the timing (continued).

Remove the tool [3].

Rotate the engine by means of the crankshaft pinion screw (2) (clockwise), to bring it to the pegging position.

Peg the camshaft pulley, using tool [4].

Peg :

- The crankshaft pinion (6), using tool [5].

- The high pressure pump pinion, using tool [5]. Support the engine with the aid of a roller jack equipped with a chock.

Remove:

- The RH engine support (7).

- The intermediate engine support (right hand side) (8).

B1JP03SC B1EP18DC B1EP195C B1BP2LYC

ENGINE

Page 75

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HX - 8HW

B1EP18HC

Setting the timing (continued).

Hold the tensioner roller, using a hexagonal spanner at «b». Slacken the screw (9). Remove the timing belt (10).

Refitting. IMPERATIVE : Check that both the tensioner roller and the fixed roller turn freely (no tight spots). If this is not the case, replace the rollers.

Fitting of the pulleys.

- Camshaft pulley Tighten to 4.3 ± 0.4 m.daN.

- Fuel high pressure pump pulley Tighten to 5 ± 0.5 m.daN. The crankshaft pinion is located without a screw at the end of the crankshaft.

Fitting of the rollers. IMPERATIVE : Check that the tensioner roller turns freely (no tight spot).

Otherwise, replace the rollers.

- Guide roller Tighten to 4.5 ± 0.4 m.daN

- Tensioner roller Pre-tighten to 0.1 m.daN Check the condition of the seals at the camshaft and at the crankshaft pinion..

ENGINE

Page 76

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HX - 8HW

B1EP18JD

Setting the timing (continued).

NOTE : Screw (9) slackened.

Position the timing belt (10) observing the following sequence:

Crankshaft pinion (4).

Guide roller (12).

Camshaft pulley (11), (check that the belt is held correctly against the roller).

Coolant pump pinion (13).

Fuel high pressure pump pulley (15).

Tensioner roller (14).

ENGINE

Page 77

ENGINE

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HX - 8HW

B1EP18KC

Setting the timing (continued).

Turn the tensioner roller to the right to bring the index «c» to position «d», using a hexagonal spanner. Tighten the screw (9) of the tensioner roller, tighten to 3 ± 0.3 m.daN. Remove the tools [4] and [5].

Rotate the engine ten times (check that the timing pinion is correctly up against the crankshaft)..

Check: The pegging of the camshaft. The crankshaft pinion. The fuel high pressure pump pinion (15). The correct positioning of the index of the dynamic tensioner.

If these are not correct, repeat the operation to position the timing belt.

Refit: The engine speed sensor (6). The belt retaining stop (5), tighten to 0,7 m.daN.

Page 78

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HX - 8HW

B1EP18LC B1BP2LZC

Setting the timing (continued).

Refit: The intermediate RH engine support, tighten the screws (16) to 5,5 ± 0,5 m.daN. The RH engine support, tighten the screws (17) to 4,5 ± 0,4 m.daN. The bottom timing cover (3).

Immobilise the engine flywheel, using tool [3]. Remove the screw (2). Refit the accessories drive pulley and tighten to:

Pre-tighten to : 3 ± 0,3 m.daN.

Angular tighten to : 180° ± 1°,8’ Remove tool [3]. Refit: The top cover (1). The accessories belt (see corresponding operation). The exhaust line (see corresponding operation). The front RH splash-shield. The front RH wheel.

ENGINE

Page 79

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

B1BP2N0C

Tools.

[1] Engine flywheel peg Ø 12 mm : (-).0194-C. [2] Camshaft pulley peg Ø 8 mm : (-).0194-B. [3] Crankshaft pulley peg Ø 5 mm : (-).0194-A.

Preliminary operations.

Remove:

- The front RH wheel.

- The front RH splash-shield.

- The accessories belt (see corresponding operation). Uncouple:

- The supply unions (1).

- The air/air heat exchanger inlet/outlet pipes (3).

- The exhaust line (at the flexible pipe). Disconnect the connector (2). Support the engine by means of a roller jack equipped with a chock. Remove the engine supports (4) and (5).

ENGINE

Page 80

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

B1BP2N1C B1BP2N2C

Checks.

Rotate the engine to engage it (normal direction of rotation). Immobilise the engine flywheel at «a», using tool [1]. Move aside the harness (6).

Remove:

- The engine support (7).

- The screw (8).

- The pulley (9).

- The lower timing cover (10).

- The upper timing cover (11).

- The tool [1].

ENGINE

Page 81

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

B1EP18YD

Checks (continued).

Refit the screw (8). Rotate the crankshaft six times (clockwise).

IMPERATIVE : Never rotate the engine backwards.

Peg :

- The camshaft, using tool [2]. (Oil the pegs.)

- The fuel high pressure pump pulley (14), using tool [3] at «c».

WARNING: The magnetic track should show no signs of damage and should not be approached by any source of magnetism.

Peg the crankshaft at «b», using tool [3].

IMPERATIVE: Should it be impossible to peg the camshaft, check that the offset between the hole in the camshaft pinion and the pegging hole is not greater than 1 mm. Otherwise repeat the operation to position the timing belt. (See corresponding operation).

ENGINE

Page 82

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

B1EP18ZC

Checks (continued). NOTE : The index «e» of the dynamic tensioner roller should be centred within the area «d».

Check the correct positioning of the index «e». If it is not correct, repeat the operation to tension the timing belt (see corresponding operation).

Refitting.

Refit the tool [1] at «a». Remove the screw (8). Refit:

- The upper timing cover (11).

- The lower timing cover (10).

- The accessories drive pulley (9).

- The screw (8).

Tightening torque:

- Screw (8) : Pre-tighten to : 3 ± 0,3 m.daN. Angular tightening : 180° ± 5°.

Remove the tool [1].

ENGINE

Page 83

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

B1BP2N0C

Checks (continued).

Refit :

- The engine support (7), tighten to 1,5 ± 0.4 m.daN.

- The engine support (4), tighten to 6,1 ± 0,. m.daN.

- The engine support (5), tighten to 6 ± 0.6 m.daN.

- The electrical harness (6).

Couple:

- The exhaust line, tighten the collar to : 2.5 ± 0.3 m daN

- The fuel supply unions (1).

- The air/air heat exchanger inlet/outlet pipes (3). Connect the connector (2).

Refit :

- The accessories belt (see corresponding operation).

- The front RH splash-shield (see corresponding operation).

- The front RH road wheel, tighten to 9 ± 1 m.daN. Reconnect the battery.

ENGINE

Page 84

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

B1EP18VD

Setting the timing.

Perform the preliminary operations for checking the timing up to removing tool [1] at «a» for immobiling the engine flywheel.

Refit screw (8). Rotate the crankshaft to bring the camshaft towards its pegging point. Peg the camshaft, using tool [2]. (Oil the pegs).

WARNING: Do not press or damage the track which is the target for the engine speed sensor (14).

Peg the crankshaft at «b», using tool [3]. Remove:

- The timing protector (13).

- The engine speed sensor (14). Slacken the screw (12) of the tensioner roller, keeping it slack with t he aid of a hexagonal spanner at «c». Detension the belt by pivoting the tensioner roller (clockwise). Remove the timing belt, commencing with the coolant pump pinion. Peg the pulley (15), using a 5 mm diameter peg at «d».

ENGINE

Page 85

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

B1EP18WD

Setting the timing (continued).

Checking the setting. IMPERATIVE : Just prior to refitting, carry out the following tests:

Check that:

- the rollers and the coolant pump operate freely (no play and no tight spot).

- there are no traces of oil (from the crankshaft and camshaft sealing rings).

- there is no leak of coolant fluid (from the coolant pump).

- the target track of the engine speed sensor (14) is not damaged or scratched. (If necessary replace the defective components).

Refitting

Fit the timing belt on the crankshaft pinion. Position the belt on the guide roller, with the belt well tensioned. Refit:

- The timing protector (13).

- The sensor (14).

ENGINE

Page 86

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

B1EP18XC

Setting the timing (continued).

Checks (continued).

Reposition the timing belt, belt at «e» well tensioned, in the following order:

- Guide roller (17).

- Camshaft pulley (16).

- Fuel high pressure pump pulley (15).

- Coolant pump pinion (18).

- Tensioner roller (19). Remove the 5 mm diameter peg at «d».

Adjusting the fitting tension of the belt.

Action the tensioner roller (19) to align the marks «f» and «g» , avoiding detensioning the timing belt, with the aid of a male hexagonal spanner, at «c». If this is not successful, repeat the operation to tension the belt. Hold the tensioner roller in position (19). Tighten the tensioner roller, tightening to 3,7 ± 0,3 m.daN. Check the position of the tensioner roller (the alignment of the marks «f» and «g» should be correct). Remove tools [2] and [3]. Turn the crankshaft six rotations (clockwise).

ENGINE

Page 87

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

B1EP18XC

Adjusting the timing belt tension (continued).

IMPERATIVE : Never rotate the engine backwards. WARNING : Do not touch or damage the track of the target of the engine speed sensor(14).

Peg the crankshaft, using tool [3]. Check the position of the tensioner roller (the alignment of the marks «f» and «g» should be correct). If this is not the case, repeat the operation to tension the belt. Peg the camshaft pulley, using tool [2].

IMPERATIVE : Should it be impossible to peg the camshaft, check that the offset between the camshaft hole and the pegging hole is not more than 1 mm. If the offset is too great, repeat the operation.

Remove the pegs [2] and [3]. Refit tool [1] at «a». Remove the screw (8).

Complete the refitting.

ENGINE

Page 88

SPECIAL FEATURES : POWER UNIT SUSPENSION

Engines : HFX - KFV - NFU

ightening torques (m.daN)

RH engine support.

(1) : 4.5 ± 0.4 (2) : 6.1 ± 0.6 (3) : 4.5 ± 0.4

Torque reaction rod.

(4) : 6 ± 0.6 (5) : 6 ± 0.6

LH engine support.

(6) : 3 ± 0.3 (7) : 6 ± 0.6

(8) : 5.5 ± 0.5

ENGINE

B1BP2NEP

Page 89

SPECIAL FEATURES : POWER UNIT SUSPENSION

Engines : 8HX - 8HW

ightening torques (m.daN)

RH engine support.

(1) : 4,5 ± 0,4

(2) : 3 ± 0,3

Torque reaction rod.

(3) : 6 ± 0.6 (4) : 6 ± 0.6

LH engine support.

(5) : 5.4 ± 0.5

(6) : 6 ± 0.6

(7) : 5.5 ± 0.5

ENGINE

B1BP2LJP

Page 90

SPECIAL FEATURES : POWER UNIT SUSPENSION

Engines : 8HY - 8HV

ightening torques m.daN.

Upper RH engine support.

(1) Screws : 6 ± 0.6 (2) Screws : 6 ± 0.6

Lower RH engine support.

(3) Screws : 5.7 ± 0.9

Torque reaction rod.

(4) Screws : 6 ± 0.6 (5) Screws : 6 ± 0.6

Lower LH engine support.

(6) Screws : 5.4 ± 0.5

Upper LH engine support.

(7) Screws : 6 ± 0.6

(8) Screws : 5.5 ± 0.5

B1BP2MNP

ENGINE

Page 91

EXHAUST SPECIFICATIONS

Engines : HFX - KFV - NFU

HFX TR PSA K179 PSA 4173 KFV 4,7 ± 0.5 TR PSA K208 4.7 ± 0.5 PSA 4175 PSA 4174 NFU TR PSA K181 PSA 4176

Engine types

(1)

Upstream oxygen

sensor

Tighten to (m.daN)

(2)

Catalytic converter

(3)

Downstream oxygen

sensor

Tighten to (m.daN)

(4)

Front silencer

(5)

Rear silencer

ENGINE

B1JP03TD

Page 92

EXHAUST SPECIFICATIONS

Engines : 8HX - 8HW

8HX - 8HW TR PSA K213

Engine types

(1)

Catalytic converter

(2)

Clip

(3)

Intermediate pipe

(4)

Rear silencer

Tighten to 2,5 ± 0,3

Tighten to 1,5 ± 0,1

PSA 4177

ENGINE

Repair

Respect the precautions to be taken when operating on a vehicle. The flexible pipe must not come into contact with corrosive products. Do not distort the flexible pipe by more than 20° angular (X), 20 mmaxial, 25 mm shear (Y) (flexible pipe not fitted).

Do not distort the flexible pipe by more than 3° angular (X),

0 mm axial, 3 mm shear (Y) (flexible pipe in place). WARNING : Non-respect for these precautions will result

in a reduction in the lifetime of the flexible pipe. It is thus essential to disconnect or remove the exhaust line in any operation necessitating the lifting of the power unit.

B1JP03PD B1JP02JC

Page 93

EXHAUST SPECIFICATIONS

Engines : 8HY – 8HV

Flexible pipe

Respect the precautions to be taken when operating on a vehicle. The flexible pipe must not come into contact with corrosive products. Do not distort the flexible pipe by more than 20°angular (X), 20 mm axial, 25 mm shear (Y) (flexible pipe not fitted).

Do not distort the flexible pipe by more than 3° angular (X),

0 mm axial, 3 mm shear (Y) (flexible pipe in place). WARNING : Non-respect for these precautions will result in

a reduction in the lifetime of the flexible pipe. It is thus essential to disconnect or remove the exhaust line in any operation necessitating the lifting of the power unit.

ENGINE

«a» : Cutting zone (Marked by burrs).

B1JP03ND B1JP02JC

8HY–8HV

TR PSA K213

Engine types

(1)

Catalytic converter

(4)

Clip

(2)

Intermediate pipe

(3)

Rear silencer

Tighten to 2,5 ± 0,3

PSA 4177-PSA 4179

Page 94

HFX KFV NFU

12 and 16 dm

1,4 bars

89°C/101°C

100W (without aircon) 300W (with aircon)

118°C

Managed by the ECU

COOLING SYSTEM SPECIFICATIONS

Engines : HFX - KFV - NFU

Engine type Capacity Radiator surface Pressurisation Opening of thermostatic

regulator Cooling fan 1st speed 2nd speed Warning Post-cooling

1.1i 1.4i 1.6i 16V

ENGINE

Page 95

COOLING SYSTEM SPECIFICATIONS

Engines : HFX - KFV - NFU

Manual gearbox.

(1) Venting chamber. (2) Water pump. (3) Heater matrix. (4) Bleed screw, heater matrix (5) Coolant outlet housing (6) Bleed screw, coolant outlet housing. (7) Calorstat. (8) Cooling radiator.

Thermostat.

Colour of connector : Blue. Colour of seal : Yellow. Tightening torque : 1.7 ± 0.2 m.daN.

B1GP09HP

ENGINE

Page 96

COOLING SYSTEM SPECIFICATIONS

Engines : HFX – KFV – NFU

Automatic gearbox

(1) Venting chamber. (2) Water pump. (3) Heater matrix. (4) Bleed screw, heater matrix (5) Coolant outlet housing (6) Bleed screw, coolant outlet housing. (7) Calorstat. (8) Cooling radiator. (9) Heat exchanger (for automatic gearbox).

Thermostat.

Colour of connector : Blue. Colour of seal : Yellow. Tightening torque : 1.7 ± 0.2 m.daN.

B1GP09JP

ENGINE

Page 97

8HX 8HW 8HY 8HV

5.7 Litres 5.6 Litres 16 dm

1.4 bar

83°C

1x300W

97°C

115°C

118°C

105°C 6 minutes

COOLING SYSTEM SPECIFICATIONS

Engines : 8HX - 8HW - 8HY - 8HV

Engine type Capacity Radiator surface Pressurisation Opening of thermostatic

regulator Cooling fan 1st speed 2nd speed Air conditioning cut-off Warning Post-cooling

1.4 HDi 1.4 HDi 16V

ENGINE

Thermostat : Tightening torque 1.7 ± 0.4 m.daN.

Page 98

COOLING SYSTEM SPECIFICATIONS

Engines : 8HX - 8HW

(1) Bleed screw (with or without aircon)

B1GP09MP

ENGINE

Page 99

COOLING SYSTEM SPECIFICATIONS

Engines : 8HY - 8HV

(1) Venting chamber.

(2) Bleed screw.

(3) Thermostat.

B1GP09QP

ENGINE

Page 100

Petrol

Diesel

OIL FILTERS

ENGINE

1.1i

HFX KFV NFU

XFILTRAUTO X X

1.4i 1.6i 16V

JP4

1.4 HDi

8HX 8HW 8HV 8HY

XMALHEX X X X

1.4 HDi 16V

TED4