CITROEN Saxo 2003, C3 2003, Xsara 2003, Xsara Picasso 2003, Berlingo 2003 Handbook

Page 1

PRIVATE CARS

SAXO-C3-XSARA XSARA PICASSO-BERLINGO

CAR 050014 Volume 1

«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».

2003

Page 2

PRESENTATION

THIS HANDBOOK summarises the specifications, adjustments, checks and special features of CITROEN private vehicles, not including UTILITY

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.

In each section, the vehicles are dealt with in the following order : SAXO - C3 - XSARA - XSARA PICASSO - BERLINGO (1) and all models where applicable.

The information given in this handbook is based on vehicles marketed in EUROPE.

(1) NOTE : The BERLINGO familiale appears only in :

- The correspondance tables for petrol and diesel engines.

- The general chapter.

For all the other chapters, see the Mechanics’ Handbook for UTILITY vehicles.

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 – NEED FOR MORE DETAILS

Please send your comments and suggestions to :

CITROEN U.K. Ltd. 221, Bath Road, SLOUGH, SL1 4BA. U.K.

Page 4

XSARA 2, all types

Operation to reconnect the battery after a vehicle repair

ATTENTION

If the battery has been disconnected, after reconnecting it is ESSENTIAL to wait 1 minute before switching on the ignition, otherwise the engine ECU will lock up.

If the ECU has locked up :

- Switch off the ignition.

- Wait 1 minute.

- Switch the ignition back on, the ECU is unlocked.

Page 5

GENERAL

SAXO - All TypesIDENTIFICATION OF VEHICLES

E1AP07CD

1 Engine legislation type

2 RP organisation no.

3 Chassis stamp

4 Manufacturer’s name plate

5 01/02/99 # Label :

- Tyre pressures.

- RP organisation no.

- Paint code.

6 Paint code.

7 Gearbox ident. reference

GENERAL

Page 6

GENERAL

Emission standard IFL5 L4 L4 L4 L4

Type code SO HFX1 SO HFXB SO KFWL S6 KFWB SO KFWB S6 NFTB N6 NFXB Engine type HFX KFW NFT NFX Cubic capacity (cc) 1124 1360 1587 Fiscal rating (hp) 46558 Gearbox type MA/5 MB3 MA/5 MA/5 Gearbox ident. plate 20 CF 03 312 20 CF 12 20 CF 11 20 CN 05 20 CN 03

SAXO - All Types IDENTIFICATION OF VEHICLES

Saxo petrol 3-door

1.1 i

1.4 i 1.6 i 1.6i 16V

X-SX

A-X-SX

Administration

Exclusive

Exclusive VTS

Exclusive

VTS VTS VTS

Auto.

Page 7

GENERAL

Emission standard IFL5 L4 L4

Type code S1 HFX1 S1 HFXB S1 KFWL S1 KFWB Engine type HFX KFW Cubic capacity (cc) 1124 1360 Fiscal rating (hp) 465

Gearbox type MA/5 MB3 MA/5

Gearbox ident. plate 20 CF 03 312 20 CF 12

SAXO - All TypesIDENTIFICATION OF VEHICLES

Saxo petrol 5-door

1.1i 1.4i A-Administration

Driving school -x-SX

Exclusive

SX-Exclusive

X-SX

Auto.

Page 8

GENERAL

Emission standard L4 L4

Type code SO VJXB S1 VJXB S3 HFXB S3 VJXB Engine type VJX HFX VJX Cubic capacity (cc) 1527 1124 1527 Fiscal rating (hp) 466

Gearbox type MA/5 MA/5 MA/5

Gearbox ident. plate 20 CF 02 20 CF 03 20 CF 02

SAXO - All Types IDENTIFICATION OF VEHICLES

Diesel Entreprise

1.5 D

5-door3-door Diesel 3-doorPetrol 3-door

1.5 D1.1i

A-Administration

Driving school

X-SX-Exclusive

Administration

Poste-X-SX

Administration

Poste-X-SX

A- Administration

X-SX-VTS -Exclusive

Page 9

GENERAL

E1AP09HD

IDENTIFICATION OF VEHICLES

A: Cold stamp

(Cold stamp engraved on the bodywork).

B : Manufacturer’s name plate (On the LH centre pillar)

C : AS/RP No. and RP paint code. (label affixed to the front pillar on driver’s side)

D : Tyre pressures and tyre type. (label affixed to the front pillar on driver’s side)

E : Serial number on bodywork.

F : Gearbox ident. reference – Factory serial no.

G : Engine legislation type– Factory serial no.

C3 - All Types

Page 10

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

C3 - All Types

Page 11

GENERAL

IDENTIFICATION OF VEHICLES

(*) = Export.

PETROL

SX – Exclusive

1.4i

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 (*)

C3 - All Types

Page 12

GENERAL

IDENTIFICATION OF VEHICLES

(*) = Export.

PETROL

1.6i 16V

1.4i

SX – ExclusiveSX – 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

C3 - All Types

Page 13

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 (*)

C3 - All Types

Page 14

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

S - SX SX - Exclusive

1.4 HDi 1.4 HDi 16V

(*) = Export.

C3 - All Types

Page 15

GENERAL

IDENTIFICATION OF VEHICLES

DIESEL

SX - Exclusive SX SX - Exclusive

1.4 HDi 16V

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

C3 - All Types

Page 16

GENERAL

IDENTIFICATION OF VEHICLES

E1AP08WD

A - Manufacturer’s name plate (Estate).

B - Chassis stamp, cold stamp.

C - Manufacturer’s name plate (Saloon).

D - Label :

(label affixed to the front pillar on driver’s side)

- Tyre pressures.

- RP organisation no.

- Paint code.

E - Serial number. (visible through the windscreen)

F - Engine legislation type.

Factory serial no.

G - Gearbox ident. reference.

Factory serial no.

XSARA - All Types

Page 17

GENERAL

Emission standard L4 IFL5 L4 IFL5

Type code NO KFWB NO KFW1/IF NO NFUB NO NFUN NO NFU1/IF NO NFU3/IF Engine type KFW NFU Cubic capacity (cc) 1360 1581 Fiscal rating (hp) 57

Gearbox type MA/5 MA/5 AL4 MA/5 AL4 Gearbox ident. plate 20 CF 13 20 CN 28 20 TP 49 20 CN 28 20 TP 49

XSARA - All Types

IDENTIFICATION OF VEHICLES

Saloon petrol 3-door

1.4 i

1.6i 16V

X-VTR

X-SX-VTR

VTS

VTR-VTSSX-VTR VTR

Auto.

X-SX

VTR

Page 18

GENERAL

Emission standard IFL5 L4 L4

Type code NO RFN1/IF NO RFNN/IF NO RFSB NO WJYB NO RHYB NO RHZB NO RHZN Engine type RFN RFS WJY RHY RHZ Cubic capacity (cc) 1998 1868 1997 Fiscal rating (hp) 8115 6 Gearbox type BE4/5 AL4 BE3/5 BE4/5 AL4

Gearbox ident. plate

20 DL 40 20 DL 41 20 DL 42 20 DM 10

20 TP 48

20 DM 03 (1)

20 TP 47 20 TE 47

20 DM 05 (1) 20 DM 07 (1) 20 DM 11 (1)

IDENTIFICATION OF VEHICLES

Saloon diesel 3-doorSaloon petrol 3-door

20i.16V

1.9 D 2.0 HDi

VTS

X-SX

VTR

X-SX-VTR

VTS

SX-VTR

VTS SX

Auto. Auto.

(1) = Right hand drive : Hydraulic clutch control.

XSARA - All Types

Page 19

GENERAL

Emission standard L4

Type code N0 8HZB N0 8HZB/T N3 8HZB Engine type 8HZ Cubic capacity (cc) 1398 Fiscal rating (hp) 4

Gearbox type MA/5

Gearbox ident. plate

IDENTIFICATION OF VEHICLES

Saloon diesel 3 door

1.4 HDi

Entreprise

XSARA - All Types

Page 20

GENERAL

Emission standard L4 L4

Type code NO KFWB/T (1) NO WJYB/T (1) NO RHYB/T (1) Engine type KFW WJY RHY Cubic capacity (cc) 1360 1868 1997 Fiscal rating (hp) 87 6

Gearbox type MA/5 BE4/5 Gearbox ident. plate 20 CF 13 20 DL 41 20 DL 42

IDENTIFICATION OF VEHICLES

(1) /T = The vehicle cannot be converted back into a private vehicle.

Saloon 3-door versions

DieselPetrol

1.4i 1.9 D 2.0 HDi

XSARA - All Types

Page 21

GENERAL

Emission standard K’ L4 IFL5 K’ L4

Type code N1 KFWG N1 KFWB N1 KFW1/IF N1 NFUG N1 NFUU N1 NFUB Engine type KFW NFU Cubic capacity (cc) 1360 1587 Fiscal rating (hp) 57

Gearbox type MA/5 MA/5 AL4 MA/5 Gearbox ident. plate 20 CN 30 20 CF 13 20 CN 29 20 TP 49 20 CN 28

IDENTIFICATION OF VEHICLES

Saloon petrol 5-door.

1.4i

1.6i 16V

X-SX

Exclusive

Auto.

XSARA - All Types

Page 22

GENERAL

Emission standard L4 IFL5 IFL5 L4

Type code N1 NFUN N1 NFU1/IF N1 NFU3/IF N1 RFN1/IF N1 RFNN Engine type NFU RFN Cubic capacity (cc) 1587 1998 Fiscal rating (hp) 711

Gearbox type AL4 MA/5 AL4 BE4/5 AL4 Gearbox ident. plate 20 TP 49 20 CN 28 20 TP 49 20 DL 40 20 DM 03 (1) 20 TP 47

XSARA - All Types IDENTIFICATION OF VEHICLES

(1) = Right hand drive : Hydraulic clutch control.

Saloons petrol 5-door

16i 16V

2.0i 16V

X-SX

Exclusive

Auto.

Auto. Auto.

Exclusive

Page 23

GENERAL

Emission standard L4 L4

Type code N1 WJYB N1 RHYB N1 RHZB N1 RHZN Engine type WJY RHY RHZ Cubic capacity (cc) 1868 1997 Fiscal rating (hp) 55 6 Gearbox type BE4/5 BE4/5 AL4 Gearbox ident. plate 20 DL 41 20 DM 05 (1) 20 DL 42 20 DM 07 (1) 20DM 10 20 DM 11 (1) 20 TP 48

XSARA - All Types

IDENTIFICATION OF VEHICLES

Saloons diesel 5-door

1.9 D

2.0 HDi

X-SX X-SX-Exclusive SX-Exclusive

Exclusive

Auto.

(1) = Right hand drive : Hydraulic clutch control.

Page 24

GENERAL

Emission standard L4

Type code N1 8HZB N1 8HZB/T Engine type 8HZ Cubic capacity (cc) 1398 Fiscal rating (hp) 4

Gearbox type MA/5

Gearbox ident. plate

IDENTIFICATION OF VEHICLES

Saloons diesel 5-door

1.4 HDi

Entreprise

XSARA - All Types

Page 25

GENERAL

Emission standard L4 L4

Type code N1 WJYB/T (1) N RHYB N1 RHYB/T (1) Engine type WJY RHY Cubic capacity (cc) 1868 1997 Fiscal rating (hp) 75

Gearbox type BE4/5 BE4/5 Gearbox ident. plate 20 DL 41 20 DL 42

IDENTIFICATION OF VEHICLES

(1) /T = The vehicle cannot be converted back into a private vehicle.

Saloons diesel entreprise 5-door

2.0 HDi1.9 D

XSARA - All Types

Page 26

GENERAL

Emission standard L4 IFL5 K’ L4 IFL5

Type code N2 KFWB KFW1/IF N2 NFUG N2 NFUB N2 NFUN N2 NFU1/IF N2 NFU3/IF Engine type KFW NFU Cubic capacity (cc) 1360 1587 Fiscal rating (hp) 57 Gearbox type MA/5 MA/5 AL4 MA/5 AL4 Gearbox ident. plate 20 CN 21 20 CN 29 20 CN 28 20 TP 49 20 CN 28 20 TP 49

IDENTIFICATION OF VEHICLES

Petrol estate

1.4i

16. 16V

X-SX

EclusiveSX

X-SX

Exclusive

Auto.

XSARA - All Types

Page 27

Emission standard IFL5 L4 L4

Type code N2 RFN1/IF N2 RFNN N2 WJYB Engine type RFN WJY Cubic capacity (cc) 1998 1868 Fiscal rating (hp) 11 5 Gearbox type BE4/5 AL4 BE4/5

Gearbox ident. plate 20 DL 40 20 DM 03 (1) 20 DL 41 20 DM 05 (1)

IDENTIFICATION OF VEHICLES

Diesel estatePetrol estate

1.9 D2.0i 16V

Exclusive

X - SX

(1) = Right hand drive : Hydraulic clutch control.

Auto.

GENERAL

XSARA - All Types

Page 28

GENERAL

Emission standard L4 IFL5

Type code N2 RHYB N2 RHYB/IF N2 RHZN

Engine type

RHY RHZ

Cubic capacity (cc) 1997 Fiscal rating (hp) 56 Gearbox type BE4/5 AL4

Gearbox ident. plate 20 DL 42 20 DM 07 (1) 20 DM 10 20 DM 11 (1) 20 TP 48

IDENTIFICATION OF VEHICLES

Diesel estate

2.0 HDi

X-SX-Eclusive

Exclusive

(1) = Right hand drive : Hydraulic clutch control.

Auto.

XSARA - All Types

Page 29

GENERAL

Emission standard L4

Type code N2 8HZB N2 8HZB/T N4 8HZB Engine type 8HZ Cubic capacity (cc) 1398 Fiscal rating (hp) 4

Gearbox type MA/5

Gearbox ident. plate

IDENTIFICATION OF VEHICLES

Diesel saloon and estate

1.4 HDi

Entreprise

XSARA - All Types

Page 30

GENERAL

Emission standard L4 L4

Type code N2 KFWB/T (1) N2 WJYB/T (1) N2 RHYB/T (1) Engine type KFW WJY RHY Cubic capacity (cc) 1360 1868 1997 Fiscal rating (hp) 87 6

Gearbox type MA/5 BE4/5 BE4/5 Gearbox ident. plate 20 CN 21 20 DL 41 20 DL 42

IDENTIFICATION OF VEHICLES

(1) /T = The vehicle cannot be converted back into a private vehicle.

Estate diesel versionsEstate petrol versions

2.0 HDi1.9 D1.4i

XSARA - All Types

Page 31

GENERAL

IDENTIFICATION OF VEHICLES

XSARA PICASSO - All Types

E1AP088D

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. Tyre identification. Spare wheel identification.

(Located on front LH door inner panel). E : Label :

Factory code. A-S / RP N° Paint code.

(Located on fuse box cover)

F : Gearbox identification ref. G : Engine legislation type.

Factory serial number.

Page 32

GENERAL

Emission standard L4 IFL5 L4

Type code CH NFVB CH 6FZB CH 6FZC/IF CH RFNF/IF CH RHYB Engine type NFV 6FZ RFN RHY Cubic capacity (cc) 1587 1749 1998 1997 Fiscal rating (hp) 67 85 Gearbox type BE4/5/ J (*) BE4/5 V (*) AL4 BE4/5 L (*)

Gearbox ident. plate 20 DL 66 20 DL 68 20 TS 02 20 DL 65

IDENTIFICATION OF VEHICLES

Diesel

Petrol

2.0 HDi2.0i 16 V1.8i 16 V1.6i

SX-Exclusive

(*) L,J V = Corresponds to the stepping of the gears.

Auto.

XSARA PICASSO - All Types

Page 33

GENERAL

IDENTIFICATION OF VEHICLES

BERLINGO - All Types

E1AP0AMD

11/2002 #

A Chassis stamp, cold stamp

B Manufacturer’s vehicle plate

C Label

RPO No. Paint colour code Tyre pressures

D Gearbox ident. reference – Factory serial no.

E Engine legislation type – Factory serial no.

Page 34

GENERAL

Emission standard L4/W4 K’ L4/W4 IFL5

Type code GB VHFXB GJ K6D5G GJ KFWB GJ KFWC/IF Engine type HFX KFW Cubic capacity (cc) 1124 1360 Fiscal rating (hp) 56

Gearbox type MA/5S MA/5

Gearbox ident. plate 20 CD 43 20 CN 13

BERLINGO - All Types IDENTIFICATION OF VEHICLES

Berlingo petrol 5-seater 11/2002 #

1.4i

X X X-SX- Multispace

1.1i

Page 35

GENERAL

Emission standard L4/W4 L4 IFL5

Type code GJ KFWB/GL (1) GJ KFWB/GN (2) GJ NFUB GJ NFUC/IF Engine type KFW NFU Cubic capacity (cc) 1360 1587 Fiscal rating (hp) 57

Gearbox type MA/5 BE4/5

Gearbox ident. plate 20 CN 13 20 DM 46

IDENTIFICATION OF VEHICLES

Berlingo petrol 5-seater 11/2002 #

1.6i 16v

Multispace X-SX- Multispace

1.4i

BERLINGO - All Types

Dual fuel

(1) GL = LPG = Liquefied Petroleum Gas, with ring-shaped tank. (2) GN = CNG = Compressed Natural Gas, with cylindrical tank.

Page 36

GENERAL

Emission standard L4/W4 L4/W4

Type code GJ WJYB GJ WJYB/PMF (1) MF RHYF Engine type WJY RHY Cubic capacity (cc) 1868 1997 Fiscal rating (hp) 56

Gearbox type BE4/5 BE4/5

Gearbox ident. plate 20 DM 48 20 DM 50

IDENTIFICATION OF VEHICLES

Berlingo diesel 5-seater 11/2002 #

2.0 HDi

X-SX-Multispace X-SX-Multispace

1.9 D

BERLINGO - All Types

(1) /PMF = Multifunction roof.

Page 37

CAPACITIES (in litres)ALL TYPES

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.

5/ Engine filling.

6/ Engine starting (allowing the cartridge to be filled).

7/ Engine stopped (stationary for 5 min).

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

GENERAL

Page 38

GENERAL

Ecological oil filter

capacity 0.15 litre.

Engine type

Engine with filter change

Between Min. and Max.

5-speed gearbox

Automatic gearbox

after drainage

Hydraulic or brake circuit

Cooling system

Fuel tank capacity

HFX KFW NFX NFT VJX

3 3.5 4.5

1.5 1.5 2

4.5 2

With ABS = 0.45 - Without ABS = 0.36

6.1 45

SAXO - All Types CAPACITIES (in litres)

DieselPetrol

SAXO

1.1i 1.4i 1.6i 16V 1.5D1.6i

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

Auto.

Page 39

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 3.75 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 TOTAL capacity is 5,85 litres, after draining: 3 litres).

CAPACITIES (in litres)

Petrol

Diesel

Auto.

C3 - All Types

Page 40

GENERAL

Engine type

Engine with filter element

Between Min. and Max.

5-speed gearbox

Automatic gearbox

after drainage

Hydraulic or brake circuit

Cooling system

Fuel tank capacity

KFW NFU RFN RFS 8HZ WJZ RHY RHZ

3 3.25 4.25 4 (*) 4.75 4.5-4.25 (1)

1.4 1.5 1.7 1 1 (*) 1.6 1.4

2 1.9 1.9 2 1.8

6 6 8.3 3 3 5.3

With ABS = 0.50 - Without ABS = 0.55

7 8.5

6.5 (1)

5.7 9

11 (1)

XSARA - All Types

CAPACITIES (in litres)

Ecological oil filter

capacity 0.15 litre.

Petrol Diesel

XSARA

(*) = 01/12/03 # from 11/02 to 01/12/03 # Engine with filter element = 3,75 and Between min. and max. = 1,8 (1) = With air conditioning ESSENTIAL : systematically check the oil level using the oil dipstick.

1.4i 1.6i 16V 2.0i 16V 1.9D

1.4 HDi

2.0 HDi

Auto.

Auto. Auto.

Page 41

GENERAL

Ecological oil filter

capacity 0.15 litre

Engine type

Engine with filter change

Between Min. and Max.

5-speed gearbox

Automatic gearbox

- after drainage

Hydraulic or brake circuit

Cooling system

Fuel tank capacity

NFV 6FZ RFN RHY

3 4.25 4.5

1.5 1.7 1.4

1.8 1.8 6 3

0.58 litres

5.8 (1) et (2) 6.5 (1) et (2) 11 (1) et (2) 55 60

XSARA PICASSO - All TypesCAPACITIES (in litres)

DieselPetrol

XSARA PICASSO

1.6i 1.8i 16 V 2.0i 16 V 2.0 HDi

(1) = With air conditioning (2) = Without air conditioning ESSENTIAL : systematically check the oil level using the oil dipstick.

Auto.

Page 42

GENERAL

Ecological oil filter

capacity 0.15 litre

Engine type

Engine with filter change

Between Min. and Max.

5-speed gearbox

Hydraulic or brake circuit

Cooling system

Fuel tank capacity

HFX KFW NFU WJY RHY

3 3.25 4.5

1.5 1.2 1.4 2 1.8 1.8

With ABS = 0.45 - Without ABS = 0.36

55 60

BERLINGO 2 - All Types CAPACITIES (in litres)

DieselPetrol

BERLINGO 2

1.1i 1.4i

1.6i 16V

2.0 HDi

1.9 D

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

Page 43

GENERAL

ALL TYPESLUBRICANTS - TOTAL recommended oils

Evolutions (year 2003).

CITROËN C3 PLURIEL.

Only petrol versions are available.

Normal maintenance interval : 30 000 km (20 000 miles) Severe maintenance interval : 20 000 km (12 000 miles)

ESSENTIAL : For all vehicles with a 30 000 km (20 000 miles) maintenance interval, use exclusively TOTAL ACTIVA/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 OR API SJ/CF. Failing this, it is essential to adhere to the maintenance programmes covering severe operating conditions.

Use of oil grade 10W 40.

It is possible to use semi-synthetic oil 7000 10W40 on HDi and HDi FAP vehicles.

WARNING : To avoid problems with starting from cold, use this oil as allowed by the climatic conditions in the country concerned (see table).

For more details see the oil usage table.

New commercial designation for energy economy oil. The oil TOTAL ACTIVA/QUARTZ 9000 5W30 becomes TOTAL ACTIVA FUTUR 9000 (for France), QUARTZ FUTURE 9000 5W30 (outside France).

The usage exclusions for this oil are the same as before :

- XSARA VTS 2.0i 16V (XU10J4RS).

- RELAY 2.8 TDi; 2.8 HDi (SOFIM engine).

- HDi FAP vehicles.

- C3 1.6i 16V (DV4TED4).

- C8 2.2i (EW12J4)

Page 44

GENERAL

ALL TYPES LUBRICANTS - TOTAL recommended oils

Engine oil norms.

Current norms.

The classification of these engine oils is established by the following recognised organisations :

- S.A.E : Society of Automotive Engineers.

- API : American Petroleum Institute.

- ACEA : Association des Constructeurs Européens

d’Automobiles

E4AP006D

Page 45

GENERAL

ALL TYPES

S.A.E. Norms - Table for selection of engine oil grade Selection of engine oil grades recommended for climatic conditions in countries of distribution

Evolution of the norms as at 01/01/2003

ACEA 2003 norms

The meaning of the first letter has not changed, it still corresponds to the type of engine :

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

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

3 : high performance oils. 4 : oils specifically for direct injection diesel engines. 5 : very high performance oils permitting lower fuel consumption Example : ACEA A3 : high performance oils specifically for petrol and dual fuel

petrol / LPG engines ACEA A/B : blended oils giving very high performance for all engines, also permitting better fuel economy, specifically for direct injection diesel engines NOTE : From 01/01/2003 there is no longer any reference to the year of creation of the norm, (Example : ACEA A3/B3 98 becomes ACEA

A3/B3.

API norms

The meaning of the first letter has not changed, it still corresponds to the type of engine :

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

The second letter corresponds to the degree of evolution of the oil (ascending order).

Example : Norm SL is more severe than norm SJ, corresponding to a higher level of performance.

LUBRICANTS - TOTAL recommended oils

Page 46

GENERAL

ALL TYPES

Recommendations.

ESSENTIAL : To preserve engine performances, all engines fitted in CITROEN vehicles must be lubricated with high quality oils (synthetic or semi-synthetic).

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%).

The oil 5W30 is used only for the following engines (Year 2003) :

- XU10 J4RS : XSARA VTS 2.0i 16V (3-door)

- SOFIM : RELAY 2.8 TDi and 2.8 HDi.

- HDi : With particle filter (FAP).

- DV4 TED4 : CITROËN C3 1.4 HDi 16V

- EW 12J4 : CITROËN C8 2.2i.

WARNING : CITROËN engines prior to model year 2000 do not have to be lubricated with oils adhering to the norms : ACEA AI-98 and API SJ/CF EC or current norms ACEA A5/B5

Denomination of TOTAL oils according to country of marketing : TOTAL ACTIVA (France only). TOTAL QUARTZ (outside France).

LUBRICANTS - TOTAL recommended oils

Page 47

LUBRICANTS - TOTAL recommended oils

ALL TYPES

Year

2003

Petrol and dual fuel

petrol / LPG engines

A3 or A5 5 (*)

SJ or SL

CFB3 or B5 (*)Diesel engines

Types of engine concerned

Norms to be observed for engine oils (year 2003)

ACEA norms API norms

Recapitulation

GENERAL

TOTAL ACTIVATRAC

TOTAL QUARTZ FUTUR 9000 (*)

TOTAL ACTIVA FUTUR 9000 (*)

TOTAL ACTIVA 9000 TOTAL QUARTZ 9000

5W40

A3 / B3

SL / CF

SJ / CF

A5 / B5

A3 / B3

5W30

10W40

S.A.E. norms

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

ACEA norms API norms

(*) It is essential not to use engine oils respecting these norms for the following engine-types : XU10 J4RS , SOFIM 2.8 TDi and SOFIM 2.8 HDi , HDi with particle filter (FAP), EW 12 J4, DV4 TED4.

Classes and grades of TOTAL recommended engine oils.

Oils marketed in each country are adapted to the local climatic conditions.

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

Page 48

GENERAL

LUBRICANTS - TOTAL recommended oilsALL TYPES

TOTAL ACTIVA 7000 TOTAL QUARTZ 7000

TOTAL QUARTZ 9000

TOTAL ACTIVA 7000 TOTAL QUARTZ 7000

10W40

0W40

15W50

S.A.E. norms

Oils specifically for petrol and dual fuel petrol / LPG engines

ACEA norms API norms

TOTAL ACTIVA DIESEL 7000

TOTAL ACTIVA DIESEL 7000 TOTAL QUARTZ DIESEL 7000

10W40

15W50

S.A.E. norms

Oils specifically for diesel engines

ACEA norms API norms

Page 49

GENERAL

LUBRICANTS - TOTAL recommended oils

ALL TYPES

TOTAL ACTIVA QUARTZ

Semi-synthetic 7000Synthetic 9000

0W40 cold

countries

5W30 5W40 10W40

15W50 hot

countries

Engine types

XU10 J4RS (Xsara VTS 2.0i 16V) X

X X

EW 12 J4 (C8 2.2i 16V) Other petrol engines HDi engines with FAP (*) Other HDi engines SOFIM 2.8 TDi and 2.8 HDi (RELAY) DV4 TED4 (C3 1.4 HDi 16V) Indirect injection diesel engines

Petrol

engines

Diesel

engines

Oil usage table

XXX XXX XXX XX XXX XXX XXX XXX

(*) = Particle filter

Page 50

GENERAL

ALL TYPES

LUBRICANTS - TOTAL recommended oils

Selection of TOTAL engine oils, to be used according to the climatic conditions in the country where the vehicle is marketed.

E4AP006D

Page 51

GENERAL

FRANCE

Metropolitan FRANCE

New Caledonia Guadeloupe Saint-martin Reunion

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

Martinique Guyana Tahiti Mauritius Mayotte

LUBRICANTS - TOTAL recommended oils

Blended oils for all engines, supplied in bulk

ENGINE OILS

TOTAL ACTIVRAC S.A.E. norms : 10W40

TOTAL ACTIVA

Blended oils for all engines

900 5W-40

9000 5W-30 (*)

7000 10 W-40

9000 5W-40

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

Oils specifically for diesel

engines

TOTAL ACTIVA DIESEL

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

ALL TYPES

Page 52

GENERAL

EUROPE

7000 10W40

9000 0W40

7000 10W40

9000 0W40

7000 10W40

9000 0W40

7000 10W40

7000 10W40 9000 15W40

7000 10W40

Germany

Austria

Belgium

Bosnia

Bulgaria

Cyprus

Croatia

LUBRICANTS - TOTAL recommended oils

ENGINE OILS

TOTAL ACTIVA

Blended oils for all engines

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

Oils specifically for diesel

engines

TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40

FUTURE 9000 5W30 (*)

7000 10W40

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

Page 53

GENERAL

EUROPE

7000 10W40

9000 0W40

7000 10W40 7000 15W40

7000 10W40

9000 0W40

7000 10W40

7000 10W40 7000 15W40

7000 10W40

9000 0W40

Denmark

Spain

Estonia

Finland

Great Britain

Greece

Holland

LUBRICANTS - TOTAL recommended oils

ENGINE OILS

TOTAL ACTIVA

Blended oils for all engines

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

Oils specifically for diesel

engines

TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40

FUTURE 9000 5W30 (*)

7000 10W40

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

Page 54

GENERAL

EUROPE

7000 10W40

9000 0W40

7000 10W40

9000 0W40

7000 10W40

Hungary

Italy

Ireland

Iceland

Latvia

Lithuania

Macedonia

LUBRICANTS - TOTAL recommended oils

ENGINE OILS

TOTAL ACTIVA

Blended oils for all engines

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

Oils specifically for diesel

engines

TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40

FUTURE 9000 5W30 (*)

7000 10W40

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

Page 55

GENERAL

EUROPE

7000 10W40 7000 15W50

7000 10W40

9000 0W40

7000 10W40

9000 0W40

Malta

Moldavia

Norway

Poland

Portugal

Slovakia

Czech Republic

LUBRICANTS - TOTAL recommended oils

ENGINE OILS

TOTAL ACTIVA

Blended oils for all engines

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

Oils specifically for diesel

engines

TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40

FUTURE 9000 5W30 (*)

7000 10W40

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

Page 56

GENERAL

EUROPE

7000 10W40 7000 15W50

9000 0W40

7000 10W40

9000 0W40

7000 10W40

7000 10W40 9000 15W50

9000 0W40

Romania

Russia

Slovenia

Sweden

Switzerland

Turkey

LUBRICANTS - TOTAL recommended oils

ENGINE OILS

TOTAL ACTIVA

Blended oils for all engines

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

Oils specifically for diesel

engines

TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40

FUTURE 9000 5W30 (*)

7000 10W40

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

Page 57

GENERAL

EUROPE

7000 10W40

9000 0W40

Ukraine

Yugoslavia

LUBRICANTS - TOTAL recommended oils

ENGINE OILS

TOTAL ACTIVA

Blended oils for all engines

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

Oils specifically for diesel

engines

TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40

FUTURE 9000 5W30 (*)

7000 10W40

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

Page 58

GENERAL

OCEANIA

AFRICA

7000 10W40

Australia New Zealand

Algeria, South Africa, Ivory Coast, Egypt, Gabon, Ghana, Kenya, Madagascar, Morocco, Nigeria, Senegal, Tunisia

LUBRICANTS - TOTAL recommended oils

ENGINE OILS

TOTAL ACTIVA

Blended oils for all engines

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

Oils specifically for diesel

engines

TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40

FUTURE 9000 5W30

7000 10W40

7000 15W50

TOTAL ACTIVA

Blended oils for all engines

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

Oils specifically for diesel

engines

TOTAL ACTIVA DIESEL

9000 5W40

7000 10W40

Page 59

GENERAL

CENTRAL AND SOUTH AMERICA

Argentina

Brazil

Chile

Cuba

Mexico

Paraguay

Uruguay

LUBRICANTS - TOTAL recommended oils

7000 10W50 7000 15W50

ENGINE OILS

TOTAL ACTIVA

Blended oils for all engines

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

Oils specifically for diesel

engines

TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40

7000 10W40

Page 60

GENERAL

SOUTH-EAST ASIA

China

South Korea

Hong Kong

India – Indonesia

Japan

Malaysia

Pakistan

LUBRICANTS - TOTAL recommended oils

7000 10W50 7000 15W50

7000 10W40

7000 15W50

7000 10W40 7000 15W50

7000 15W50

ENGINE OILS

TOTAL ACTIVA

Blended oils for all engines

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

Oils specifically for diesel

engines

TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40

FUTURE 9000 5W30

9000 5W40

FUTURE 9000 5W30 (*)

9000 5W40

7000 10W40

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

Page 61

GENERAL

SOUTH-EAST ASIA

Philippines

Singapore

Taiwan

Thailand

Vietnam

LUBRICANTS - TOTAL recommended oils

7000 15W50

7000 10W40 7000 15W50

7000 15W50

ENGINE OILS

TOTAL ACTIVA

Blended oils for all engines

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

Oils specifically for diesel

engines

TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40

7000 10W40

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

Page 62

GENERAL

MIDDLE EAST

7000 15W50

7000 10W40 7000 15W50

7000 15W50

Saudi Arabia – Bahrain Dubai United Arab Emirates

Iran

Israel – Jordan – Kuwait – Lebanon Oman – Qatar – Syria – Yemen

LUBRICANTS - TOTAL recommended oils

ENGINE OILS

TOTAL ACTIVA

Blended oils for all engines

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

Oils specifically for diesel

engines

TOTAL ACTIVA DIESEL

ALL TYPES

9000 5W40

7000 10W40

Page 63

GENERAL

LUBRICANTS - TOTAL recommended oils

GEARBOX OILS

ALL TYPES

TOTAL TRANSMISSION BV

Norms S.A.E. : 75W80

Part No. : 9730 A2

TOTAL FLUIDE ATX

TOTAL FLUIDE AT 42

Special oil distributed by

CITROËN

Part No. : 9730 A3

Special oil distributed by

CITROËN

Part No. : 9736 22

TOTAL TRANSMISSION X4

Part No. : 9730 A4

Manual gearbox and SensoDrive

MB3 automatic gearbox

4HP20 and AL4 autoactive automatic gearboxes

Transfer box and rear axle

All countries

Page 64

GENERAL

LUBRICANTS - TOTAL recommended oils

POWER STEERING OILS

ENGINE COOLANT FLUID

ALL TYPES

TOTAL FLUIDE ATX

TOTAL FLUIDE DAs

Special oil distributed by

CITROËN

Part No. : 9730 A1

Power steering

All countries

Very cold countries

All countries

CITROËN fluid

Protection : - 35C°

2 Litres

5 Litres

20 Litres

210 Litres

9979 70

9979 71

9979 76

9979 77

9979 72

9979 73

9979 74

9979 75

Pack

CITROËN Part No.

REVKOGEL 2000GLYSANTIN G33

Page 65

GENERAL

LUBRICANTS - TOTAL recommended oils

BRAKE FLUID

Synthetic brake fluid

HYDRAULIC CIRCUIT

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

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

All countries TOTAL HYDRAURINCAGE

All countries

CITROËN fluid

0.5 Litre

1 Litre

5 Litres

9979 05

9979 06

9979 07

Pack

CITROËN Part No.

ALL TYPES

Pack

CITROËN Part No.

Norm

Colour

All countries

TOTAL FLUIDE LDS

TOTAL LHM PLUS TOTAL LHM PLUS

Grand Froid

Orange 9979 69

ZCP 830095

9979 20

Green

1 Litre

Page 66

GENERAL

SCREEN WASH FLUID

GREASE

General use

All countries

Concentrated : 250 ml

Fluid ready

for use

9980 33

9980 06

9980 05

ZC 9875 953U

ZC 9875 784U

ZC 9885 077U

9980 56

ZC 9875 279U

Pack

CITROËN Part No.

LUBRICANTS - TOTAL recommended oils

ALL TYPES

1 Litre

5 Litres

Norms NLGI

TOTAL MULTIS 2

TOTAL SMALL MECHANISMS

All countries

Note : NLGI = National Lubricating Grease Institute.

Page 67

GENERAL

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.

ALL TYPES

Page 68

ENGINE

ENGINE SPECIFICATIONS

ALL TYPES

Engines : HFX - KFW - NFT - NFV

Petrol

All Types

1.1i

1.4i

1.6i

Vehicle

Emission standard

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)

Saxo C3 Saxo Xsara Saxo Picasso

L4/IFL5/L4INF K’ L4 K’/L4/IFL5 L4

HFX KFW NFT NFV

1124 1360 1587

72/69 75/77 78.5/82

10.5/1

44.1-5500 55-5500 72-5700 70-5700

60-5500 75-5500 98-5700 95-5700

9.4-3500 9.4-3300 12-3400 12-2800 13.5-3500 13.5-3000

Page 69

ENGINE

ENGINE SPECIFICATIONS

ALL TYPES

Engines : NFX - NFU - 6FZ - RFN - RFS

Petrol

All Types

1.6i 16V

2.0i 16V1.8i 16V

Vehicle

Emission standard

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)

Saxo C3/Xsara Picasso Xsara Picasso Xsara

L4 K’/L4/IFL5 L4/IFL5 L4/IFL5 IFL5 L4

NFX NFU 6FZ RFN RFS

1587 1749 1197 1998

78.5/82 82.7/81.4 85/88 86/86

10.8/1 11/1 10.8/1

87-6600 80-5800 85-5500 100-6000 120-6000

118-6600 109-5800 115-5500 136-6000 163-6000

14.5-5200 14.7-4000 16-4000 19-4100 19.3-5000

Page 70

ENGINE

ENGINE SPECIFICATIONS

ALL TYPES

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

Diesel

All Types

1.4 HDi1.5D

1.4 HDi1.4 16V HDi

2.0 HDi

Vehicle

Emission standard

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)

Saxo C3 Xsara Xsara-Picasso Xsara

L4 L4/IFL5

VJX 8HX-8HW 8HV-8HY 8HZ RHY RHZ

1527 1398 1997

77/82 73.5/82 85/88

23/1 17.9/1 18.4/1 17.9/1 17.6/1

42-5000 50-4000 66-4000 50-4000 66-4000 80-4000

57-5000 70-4000 90-4000 70-4000 90-4000 109-4000

9.5-2250 15-1750 20-1750 16-2000 20.5-1900 25-1750

Page 71

ENGINE

SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

Engine type HFX KFW KFV NFT NFV NFX NFU VJX

Maximum permissible bow

0.05

Gasket surface regrinding

- 0.20

Crankshaft bearing screws

Connecting rod screws

Flywheel screw

Crankshaft pinion screw

Camshaft pulley screw

Camshaft hubs Camshaft

hub screw

CYLINDER HEAD (mm)

TIGHTENING TORQUES ( m.daN)

ALL TYPES

Pre-tightening Angular tightening

Tightening

Pre-tightening Angular tightening

Tightening

2 ± 0.2 2 ± 0.2

45° 50° ± 5°

3.8 ± 0.4

6.5 ± 0.7

10 ± 1

7 ± 0.7

45° ± 4°

8 ± 0.8

4 ± 0.4

20° ± 2°

8 ± 0.8

1 ± 0.1 2.5 ± 0.2

Page 72

ENGINE

SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

Engine type 6FZ RFN RFS WJZ WJY RHY RHZ

Maximum permissible bow 0.05 0.03 Gasket surface regrinding - 0.30 - 0.20 - 0.40

Crankshaft bearing screws

Connecting rod screws

CYLINDER HEAD (mm)

TIGHTENING TORQUES ( m.daN)

ALL TYPES

Pre-tightening

Slackening

Tightening Angular tightening Tightening

Pre-tightening Slackening Tightening Angular tightening

1 ± 0.1

180° (1/2 turn)

2.3 ± 0.2 46° ± 5°

(1) Ø 11 : 1 ± 0.1

(2) Ø 6 : 1 ± 0.1

Ø 11 (only)

Ø 11 to 1 ± 0.1 then

to 2 ± 0.1

Ø 11 to 70° ± 5°

Ø 6 to 1 ± 0.1

2.3 ± 0.2

46° ±4.6°

2 ± 0.1

60° ± 6°

4 ± 0.4

2± 0.2

70° ± 7°

8.5 ± 0.8 7 ± 0.7

2.5 ± 0.3

60° ± 6°

2 ± 0.2

70° ± 7°

Page 73

ENGINE

SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

A = HFX- KFV

B = NFU

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 on gearbox

(6) 3 ± 0.3 (7) 6 ± 0.6 (8) 5.5 ± 0.5

B1BP2NEP

Page 74

ENGINE

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

Page 75

ENGINE

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

Page 76

ENGINE

SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

Engines : 8HX - 8HW

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 on gearbox

(5) 5.4 ± 0.5 (6) 6 ± 0.6 (7) 5.5 ± 0.5

B1BP2LJP

Page 77

ENGINE

SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

Engines 8HW - 8HX

Crankshaft

Bearing cap fixing screw

Pre-tightening 1 Slackening YES Tightening 3 Angular tightening 140°

Con rod nuts

Pre-tightening 1 Slackening YES Tightening 1.5 ± 0.1 Angular tightening 100° ± 5°

Accessories drive pulley

Pre-tightening 3 ± 0.4 Angular tightening 180° ± 5°

Cylinder block Sump 1 ± 0.1 Timing belt guide roller 4.5 ± 0.4 Timing belt tensioner roller 3 ± 0.3

Page 78

ENGINE

SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

Engines 8HW - 8HX

Cylinder head

Camshaft bearing covers

Pre-tightening 0.5 ± Tightening 1 ±

Fixings of camshaft sub-assemblies on cylinder head

Pre-tightening 0.5 Tightening 1

Exhaust manifold 2.5 ± 0.2 Valve cover 2.5 ± 0.2 Camshaft pulley 4.3 ± 0.4

Flywheel

Pre-tightening 1.7 Tightening 70° ± 5°

Clutch mechanism 2 ± 0.2

Lubrication circuit

Oil pump assembly

Pre-tightening 0.5 ± 0.06 Tightening 0.9 ± 0.1

Coolant/oil heat exchanger 1 ± 0.1

Page 79

ENGINE

SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

Engines 8HW - 8HX

Diesel injection circuit

Spherical-base screws for diesel injection fixing fork 0.3 ± 0.1

Fuel high pressure common injection rail on engine block 2 ± 0.2

Unions on fuel high pressure common injection rail

Diesel injection pump on support 2.25 ± 0.2

Union on diesel injection

Diesel injection pump pulley 5 ± 0.5

Union on diesel high pressure pump 2.25 ± 0.2

Cooling circuit

Coolant pump

Pre-tightening 0.3 ± 0.06 Tightening 1 ± 0.1

Coolant outlet housing

Pre-tightening 0.3 ± 0.06 Tightening 0.7 ± 0.08

Page 80

ENGINE

SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

Engines : 8HY - 8HV

RH engine support Screw (1) 6 ± 0.6

Screw (2) 6 ± 0.6

RH lower engine support Screw (3) 5.7 ± 0.5

LH upper engine support Screw (7) 6 ± 0.6

Screw (8) 5.5 ± 0.5

LH lower engine support Screw (6) 5.4 ± 0.5

Torque reaction rod Screw (4) 6 ± 0.6

Screw (5) 6 ± 0.6

B1BP2MNP

Page 81

ENGINE

SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

Engines 8HY - 8HV

Crankshaft

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 Screws (M6) to 1 ± 0.2 Camshaft pinion 4.3 ± 0.4 Fuel high pressure pump pinion 5 ± 0.5

C3 - XSARA

Page 82

ENGINE

SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

Engines 8HY - 8HV

Flywheel -Clutch 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 Fuel high pressure pump 2.3 ± 0.2 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±

C3 - XSARA

Page 83

ENGINE

SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

Engines : RFS - VJX

SAXO

VJX

- Pre-tighten 0.4

- Tighten to 0.7

XSARA

RFS

- Pre-tighten 0.5

- Tighten to 1

TUD - XU

B1DP03BC B1DP01YD

Page 84

ENGINE

CYLINDER HEAD

SAXO - XSARA PICASSO

Engines : HDZ - HFX - KFW - KFV - NFT - NFV - NFX - NFU - VJX

Identification of the cylinder head gasket

Engine type

Identification marks

(Notch on cylinder head gasket)

HFX KFW NFT - NFV NFX - NFU VJX

1 2 3

4 A B D A B D A B D A B D C R

0 (Standard gasket) - 1 (Repair gasket)

0 (With asbestos) - 1 (Without asbestos)

1111 0011 0011 0110

1 1

CURTY

MEILLOR

ELRING

REINZ

Material Repairs

Suppliers

Thickness

0 = Without notch 1 = One notch

B1BP10KC

Page 85

ENGINE

CYLINDER HEAD (continued)

Engines : HDZ – HFX – KFW - NFT – NFV - NFX – NFU – VJX

Cylinder head tightening (m.daN) Cylinder head bolts

X = MAXIMUM reusable length

Note : Oil the threads and under the

heads of the cylinder head bolts. (Use engine oil or Molykote G Rapid Plus).

- Pre-tightening 2

- Angular tightening 260° ± 5°

- Pre-tightening 2

- Angular tightening 240° ± 5°

- Pre-tightening 4

- Angular tightening 300° ± 5°

B1DP059C

B1BP10LC

NFU - NFX

VJX

HDZ-HFX-KFW-NFV-NFT

X= 175.5 ± 0.5 mm X = 197.1 mm X = 122.6 mm

VJX

NFU-NFX

B1DP13NC

SAXO - XSARA - PICASSO

Page 86

ENGINE

CYLINDER HEAD

Engines : HFX - KFV - NFU

Identification of the cylinder head gasket

Engines

HFX KFV NFU

Thicknesses (Standard)

1.2 ± 0.1

0.66 ± 0.04

Thickness (repair)

1.4 ± 0.1

Thickness ref.

2 1 4

References

1.2.3.4 = Type of engine.

A.B.D = Suppliers

C = Gasket material.

R = Repair.

B1BP10KC

Page 87

ENGINE

CYLINDER HEAD

Engines : HFX - KFV - NFU

Cylinder head tightening (m.daN) Cylinder head bolts

X = MAX. re-usable length

Tighten to 2 ± 0.2 Angular tightening 240° ± 5°

(in the order 1 to 10)

Tighten to 2 ± 0.2 Angular tightening 260° ± 5°

(in the order 1 to 10)

NOTE : Oil the threads and under the heads of the cylinder head 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 repair is forbidden.

Page 88

ENGINE

CYLINDER HEAD

Identification of the 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

B1DP1CMD

Engines : 8HY - 8HV

Type of gasket :

Metallic multilayer

"d" Thickness reference.

"e" Engine reference.

Page 89

ENGINE

CYLINDER HEAD

Identification of the cylinder head gasket

Engine types Supplier

Piston

standproud

(mm)

Thicknesses

(mm)

No. of notches

at d

No. of notches

at e

0.771 to 0.820 1.35 1

0.611 to 0.720 1.25 2

8HY - 8HV ELRING 0.721 to 0.770 1.30 3 2

00.821 to 0.870 1.40 4

0.871 to 0.977 1.45 5

B1DP1CKD

Engines : 8HY - 8HV

Type of gasket

Metallic multilayer

"d" Thickness reference.

"e" Engine reference.

Page 90

ENGINE

CYLINDER HEAD

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

Cylinder head tightening (m.daN) Cylinder head bolts

X = MAX. re-usable 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 - 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.

XSARA - C3

Page 91

ENGINE

XSARA PICASSO

CYLINDER HEAD

Engine : 6FZ

Identification of the cylinder head gasket

B1DP183D

Nominal

dimension

Repair dimension

2 – 4 – 54 – 5

R1 R2 R3

1 1.10.8

Gasket thickness

(mm)

Supplier MEILLOR

Marking zone

«e»

Marking zone

«d»

1.3

Marking

« d » Marking zone

« e » Marking zone

NOTE : 3 layer metallic gasket.

Page 92

ENGINE

XSARA PICASSO

CYLINDER HEAD (continued)

Engine : 6FZ

X = MAXIMUM reusable length

NOTE : Oil the threads and

under the heads of the cylinder head bolts. (Use engine oil or Molykote G Rapid Plus).

Pre-tightening 1.5 ± 0.2 Tightening 5 ± 0.2 Loosening 360 ° (1 turn) Tightening 2 ± 0.2 Angular tightening 285° ± 5°

B1DP16FC

B1DP05BC

6FZ

X= 147 mm

Cylinder head tightening (m.daN) Cylinder head bolts

A = Washer thickness: 4 ± 0.2 mm. X = Length under heads of new bolts = 144.5 ± 0.5 mm.

Page 93

ENGINE

XSARA PICASSO

CYLINDER HEAD (continued)

Engine : RFN

Identification of the cylinder head gasket

B1DP183D

Nominal

dimension

Repair dimension

2 – 4 – 54 – 5

R1 R2

1.10.8

Gasket thickness

(mm)

Supplier MEILLOR

Marking zone «e»

Marking zone

«d»

1.4

Multilayer metallic gasket

Page 94

ENGINE

XSARA PICASSO

CYLINDER HEAD (continued)

Engine : RFN

X = MAXIMUM reusable length

NOTE : Oil the threads and

under the heads of the cylinder head bolts. (Use engine oil or Molykote G Rapid Plus).

Pre-tightening 1.5 ± 0.2 Tightening 5 ± 0.2 Loosening 360 ° (1 turn) Tightening 2 ± 0.2 Angular tightening 285° ± 5°

B1DP16FC

B1DP05BC

RFN

X= 147 mm

Cylinder head tightening (m.daN) Cylinder head bolts

A = Washer thickness: 4 ± 0.2 mm. X = Length under heads of new bolts = 144.5 ± 0.5 mm.

Page 95

ENGINE

CYLINDER HEAD

XSARA

Engine : RFS

Identification of the cylinder head gasket

Engine type

Identification marks

(Notch on cylinder head gasket)

RFS

A B C D E

MEILLOR

Suppliers

0 = Without notch 1 = One notch

B1BP004C

Page 96

ENGINE

CYLINDER HEAD (continued)

Engine : RFS

X = MAXIMUM re-usable length

Note : Oil the threads and

under the heads of the cylinder head bolts. (Use engine oil or Molykote G Rapid Plus).

- Pre-tightening 3.5

- Slackening NON

- Tightening 7

- Angular tightening 160°

B1DP13PC

B1DP05BC

RFS

112 mm

Cylinder head tightening (m.daN) Cylinder head bolts

XSARA

Page 97

ENGINE

XSARA

CYLINDER HEAD

Identification of the cylinder head gasket

Number of holes

at B

Number

of holes

at A

Thickness

(mm)

± 0.04

Engine

type

Piston

stand-proud

(mm)*

0.51 to 0.55 1.26 1

0.55 to 0.59 1.30 2

0.59 to 0.63 1.34 3

0.63 to 0.67 1.38 4

0.67 to 0.71 1.42 5

WJY

(A) = Engine identification.

(B) = Thickness identification.

(*) = Take the highest piston as a reference point.

B1DP14QD

Engine : WJY

WJY

Page 98

ENGINE

XSARA - XSARA PICASSO

CYLINDER HEAD

Identification of the cylinder head gasket

Number of notches

at A

Thickness

(mm)

Engine

type

Piston

stand-proud

(mm)

0.47 to 0.605 1.30 ± 0.06 1

0.605 to 0.655 1.35 ± 0.06 2

0.655 to 0.705 1.40 ± 0.06 3

0.705 to 0.755 1.45 ± 0.06 4

0.755 to 0.83 1.50 ± 0.06 5

RHY RHZ

B1DP15AD

Engines : RHY - RHZ

Page 99

ENGINE

XSARA - XSARA PICASSOCYLINDER HEAD (continued)

Engines : WJY - RHY - RHZ

X = MAXIMUM re-usable length

Note : Oil the threads and under the

heads of the cylinder head bolts. (Use engine oil or Molykote G Rapid Plus).

- Pre-tightening 2

- Tightening 6

- Angular tightening 220°

- Pre-tightening 2

- Tightening 6

- Angular tightening 180°

B1DP15EC

B1DP13PC

RHY - RHY

WJY

WJY RHY - RHY

125.5 mm

133.3 mm

Cylinder head tightening (m.daN) Cylinder head bolts

WJY RHY - RHZ

B1DP05BC

Page 100

ENGINE

Tools

ALL TYPES

BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE

! 4099-T (C.TRONIC.105)

4122-T (C.TRONIC.105.5)