Page 1
CITROËN C4
2004
Mechanics’ handbook 050 0019
«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
VERY IMPORTANT
As the booklet is constantly r
e-edited, this one only covers vehicles for this
particular model year.
It is therefore necessary to order a new booklet each year and RETAIN THE
OLD ONES.
UK-C4-Couv 2004 10/11/04 12:12 Page 1
Page 3
PRESENTATION
THIS HANDBOOK summarises the specifications, adjustments, checks and special features of the CITROEN C4.
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
UK-C4-Index-2004 10/11/04 12:21 Page I
Page 4
GENERAL
1
IDENTIFICATION OF THE VEHICLE
E1AP0EWD
A: Manufacturer’s name plate
A1: Front RH chassis member = All versions except
CITROEN C4 Coupé EW10J4S (right hand drive)
A2: LH centre pillar = CITROEN C4 coupé EW10J4S (right
hand drive)
B: Cold stamp
(cold stamp engraved on the bodywork).
C: AS/RP No. and RP paint code
(on the front pillar on driver’s side).
D: Tyre pressures and tyre type
(on 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.
GENERAL
UK-C4-page001-47-2004 15/11/04 9:26 Page 1
Page 5
2
GENERAL
IDENTIFICATION OF THE VEHICLE
Trim level Version
Level 1 X
Level 2 SX - VTR
Level 3 VTR PACK - SX PACK
Level 4 EXCLUSIVE - VTS
UK-C4-page001-47-2004 15/11/04 9:26 Page 2
Page 6
GENERAL
3
Emission standard Euro 4
Type code LA KFUC LA NFUC LA NFUF LA RFNC LA RFKC
Engine type KFU NFU RFN RFK
Cubic capacity (cc) 1360 1587 1997
Fiscal rating (hp)
Gearbox type MAL/5 MA5/N BE4/5 AL4 BE4/5
Gearbox ident. plate 20 CP 42 20 CP 43 20 DM 81 (*) 20 TS 12 20 DM 71 20 DM 74 (*) 20 DM 68
IDENTIFICATION OF THE VEHICLE
ET TU EW
35 10
J4 JP4 J4 J4S
1.4i 16V 1.6i 16V 2.0i 16V
Level 1-2 Level 1-2-3 Level 3-4 Level 4
(*) = Version for outside Western Europe.
C4 Coupé petrol 3-door
AUTO.
UK-C4-page001-47-2004 15/11/04 9:26 Page 3
Page 7
4
GENERAL
Emission standard Euro 4 Euro 3 Euro 4
Type code LA 9HXC LA 9HYB LA 9HZC LA RHRH
Engine type 9HX 9HY 9HZ RHR
Cubic capacity (cc) 1560 1997
Fiscal rating (hp)
Gearbox type BE4/5 ML6C
Gearbox ident. plate 20 DM 75 (1) 20 DM 76 (*) 20 DM 69 (1) 20 DM 69 (2) 20 MB 01 (2)
IDENTIFICATION OF THE VEHICLE
DV DW
610
ATED4 TED4 BTED4
1.6 16V HDi 2.0 16V HDi
Level 1-2-3 Level 1-2-3-4 Level 3-4
(*) = Version for outside Western Europe.
(1) = Without FAP (particle filter).
(2) = With FAP (particle filter).
C4 Coupé diesel 3-door
UK-C4-page001-47-2004 15/11/04 9:26 Page 4
Page 8
GENERAL
GENERAL
Emission standard Euro 4
Type code LC KFUC LC NFUC LC NFUF LC RFNC LC RFJF
Engine type KFU NFU RFN RFJ
Cubic capacity (cc) 1360 1587 1997
Fiscal rating (hp)
Gearbox type MAL/5 MA5/N BE4/5 AL4 BE4/5 AL4
Gearbox ident. plate 20 CP 42 20 CP 43 20 DM 81 (*) 20 TS 12 20 DM 71 20 DM 74 (*) 20 TS 11
IDENTIFICATION OF THE VEHICLE
ET TU EW
35 10
J4 JP4 J4 A
1.4i 16V 1.6i 16V 2.0i 16V
Level 1-2 Level 1-2-3-4 Level 2-3-4 Level 2-3-4
(*) = Version for outside Western Europe.
C4 petrol 5-door
AUTO.
AUTO.
5
UK-C4-page001-47-2004 15/11/04 9:26 Page 5
Page 9
6
GENERAL
Emission standard Euro 4 Euro 3 Euro 4
Type code LC 9HXC LC 9HYB LC 9HZC LC RHRH
Engine type 9HX 9HY 9HZ RHR
Cubic capacity (cc) 1560 1997
Fiscal rating (hp)
Gearbox type BE4/5R ML6C
Gearbox ident. plate 20 DM 75 (1) 20 DM 76 (*) 20 DM 69 (1) 20 DM 69 (2) 20 MB 01 (2)
IDENTIFICATION OF THE VEHICLE
DV DW
610
ATED4 TED4 BTED4
1.6 16V HDi 2.0 16V HDi
(*) = Version for outside Western Europe.
(1) = Without FAP (particle filter).
(2) = With FAP (particle filter).
C4 diesel 5-door
UK-C4-page001-47-2004 15/11/04 9:26 Page 6
Page 10
7
GENERAL
E1AP09JC
IDENTIFICATION OF THE VEHICLE
The manufacturer’s plate carries the following information:
(a) Type approval number (*)
(b) Type serial number (VIN)
(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.
Manufacturer’s plate
UK-C4-page001-47-2004 15/11/04 9:26 Page 7
Page 11
8
GENERAL
IF Fiscal incentives
Variants (5) T Entreprise capable of conversion
P Piloted gearbox
IDENTIFICATION OF THE VEHICLE
Structure
(1) (2) (3) (4) / (5)
Family (1) L CITROËN C4
Body shape (2)
A 3-door saloon
C 5-door saloons
KFU 1360 ET3J4
NFU 1587 TU5JP4
RFN EW10J4
RFJ 1997 EW10A
Engine (3) RFK EW10J4S
9HX DV6ATED4 without FAP
9HY 1560 DV6TED4 without FAP
9HZ DV6TED4 with FAP
RHR 1997 DW10BTED4 with FAP
B 5-speed E3
C gearbox E4
E 4-speed E3
F gearbox E4
G 6-speed E3
H gearbox E4
Version
(Gearbox
and emission
standard)
(4)
Example : LC KFUC/IF
UK-C4-page001-47-2004 15/11/04 9:26 Page 8
Page 12
9
GENERAL
GENERAL SPECIFICATION: DIMENSIONS
E1AP0EXD
UK-C4-page001-47-2004 15/11/04 9:26 Page 9
Page 13
10
GENERAL
GENERAL SPECIFICATION: DIMENSIONS
* = Vehicle in running order (vehicle empty, levels topped up).
Exterior dimensions (mm)
Vehicles 3-door saloons 5-door saloons
Wheelbase A 2608
Length overall B 4273 4260
Front overhang C 730 717
Rear overhang D 935
Rear track at ground level E 1510
Front track at ground level F 1505
Width overall G 1769 1773
Height overall * H 1456 à 1471 (depending on tyres)
Hieght with roof bars
Interior dimensions and volumes (mm)
(*) = Boot floor with adjustable configuration.
Vehicles 3-door saloons 5-door saloons
Elbow width, front 1440
Elbow width, rear 1420
Height of boot below parcel shelf (between boot carpet and parcel shelf) 492 513
Minimum floor width 1040
Volume of boot below parcel shelf (dm
3
) 385 390
UK-C4-page001-47-2004 15/11/04 9:26 Page 10
Page 14
11
GENERAL
(*) Maximum nose weight = Vertical load at the towbar.
GENERAL SPECIFICATION: WEIGHTS
Petrol 3-door Diesel 3-door
1.4i 16V 1.6i 16V 2.0i 16V 1.6 16V HDi
2.0 16V
HDi
Engine type KFU NFU RFN RFK 9HX 9HY 9HZ RHR
Gearbox type MA/5 AL4 BE4/5 ML6C
Payload 520 532 520 456 431 520 521 520 456
Weight empty in running order 1181 1200 1278 1279 1337 1255 1269 1279 1379
Gross Vehicle weight 1701 1720 1798 1735 1768 1775 1790 1799 1835
Gross Train weight 2901 2920 2998 3035 2868 3075 3090 3099 3335
Max. trailer weight without brakes 628 637 628 677 686 665 672 677 727
Max. trailer weight with brakes
Incline 12% 1200 1300 1100
Incline 10% 1500
Incline 8% 1500 1400 1500 1800
Maximum nose weight (*) 63 61 63 65 57 66 73
Maximum weight on roof bars (*) 75
1300
1500
1200
1300
UK-C4-page001-47-2004 15/11/04 9:26 Page 11
Page 15
12
GENERAL
(*) Maximum nose weight = Vertical load at the towbar.
GENERAL SPECIFICATION: WEIGHTS
Petrol 5-door Diesel 5-door
1.4i 16V 1.6i 16V 2.0i 16V 1.6 16V HDi
2.0 16V
HDi
Engine type KFU NFU RFN RFJ 9HX 9HY 9HZ RHR
Gearbox type MA/5 AL4 BE4/5 AL4 BE4/5 ML6C
Payload 520 532 520 530 520 468
Weight empty in running order 1182 1200 1274 1262 1292 1257 1270 1280 1381
Gross Vehicle weight 1702 1732 1794 1782 1812 1777 1800 1849
Gross Train weight 2902 2932 2994 3082 3112 3077 3110 3349
Max. trailer weight without brakes 628 637 674 668 683 666 672 677 728
Max. trailer weight with brakes
Incline 12% 1200 1300 1500
Incline 10%
Incline 8% 1500 1400 1500 1300 1900
Maximum nose weight (*) 63 61 62 66 73
Maximum weight on roof bars (*) 75
1300
1500
1200
UK-C4-page001-47-2004 15/11/04 9:26 Page 12
Page 16
13
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.
Electric windo
ws.
It may be necessary to re-initialise the sequential and anti-pinch functions.
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.
NOTE: This operation has to be carried out on each electric window.
Multifunction screen.
It is necessary to adjust the date, time and outside temperature.
Reconfigure the personalisation menu of the multifunction screen.
Radio.
Reprogramme the radio stations.
T
elematic control unit (RT3 radiotelephone).
Reprogramme the radio stations.
Na
vigation.
Warning: the vehicle has to be out in the open (when you switch on the ignition, the navigation ECU searches for satellites).
Reprogramme the customer parameters.
UK-C4-page001-47-2004 15/11/04 9:26 Page 13
Page 17
14
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.
If it not possible to lift the front of the vehicle:
- It is imperative to place the selection lever in position «N».
- Do not add any oil.
- Do not exceed a speed of 50 km/h (30 mph) over a distance of 50 km
(30 miles).
Driving.
- Never drive with the ignition switched off.
- Never push the vehicle to try to start it.
NOTE: The automatic gearbox is only lubricated when the engine is
running.
UK-C4-page001-47-2004 15/11/04 9:26 Page 14
Page 18
15
GENERAL
GENERAL SPECIFICATION: TOWING THE VEHICLE
WARNING: When the engine is not running, steering and braking
are no longer power-assisted.
Tow ing eye.
(1) To wing eye.
The towing eye is stowed in the jack protection box in the spare
wheel.
Towing.
Vehicles with manual and automatic gearboxes.
IMPERATIVE: Never tow the vehicles with wheels hanging
(towing by the wheels).
Towing.
If it not possible to lift the front of the vehicle:
- It is imperative to place the selection lever in position «N».
- Do not add any oil.
- Do not exceed a speed of 50 km/h (30 mph) over a distance of
50 km (30 miles).
Driving.
- Never drive with the ignition switched off.
- Never push the vehicle to try to start it.
NOTE: The automatic gearbox is only lubricated when the engine is
running.
E2AP021D
E2AP02EC
E2AP01JC
Front towing
Rear towing
UK-C4-page001-47-2004 15/11/04 9:26 Page 15
Page 19
16
GENERAL
GENERAL SPECIFICATION: LIFTING AND SUPPORTING THE VEHICLE
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 mountings.
Side lifting.
Always ensure the jack is correctly positioned
at the lifting points.
Do not place the axle stands under the jack
contact lugs.
Positioning of the axle stand.
E2AP016C
E2AP00GC
E2AP017C
Side lifting
Front lifting
C4AP1GWC
Lifting and supporting the vehicle
E2AP018C
UK-C4-page001-47-2004 15/11/04 9:26 Page 16
Page 20
17
GENERAL
GENERAL SPECIFICATION: LIFTING AND SUPPORTING THE VEHICLE
Lifting and supporting the vehicle (continued)
E2AP02HD
Side lifting crossmember (-).0010
Positioning of the crossmember.
Ta ke weight on the sill rebate with the crossmember as close as possible to the mating edge.
Position the axle stand at the point provided for lifting the vehicle with the jack.
NOTE: To h av e 2 wheels hanging, repeat the operation on the other side.
UK-C4-page001-47-2004 15/11/04 9:26 Page 17
Page 21
18
GENERAL
GENERAL SPECIFICATION: LIFTING AND SUPPORTING THE VEHICLE
Lifting and supporting the vehicle (continued)
Lifting from the rear.
IMPERATIVE: Do not lift the vehicle by the rear.
Equipment involved.
Two-column lift.
Auxiliary lift with blocks.
IMPERATIVE: Position the safety straps, if placing the vehicle on a lift supported from the jacking points
(risk of the vehicle overbalancing when a heavy component is removed).
Using the safety straps.
WARNING: Check the condition of the safety straps before using them, do not use worn safety straps.
Example:
Two-column lift.
Place the safety straps [1] under the arm of the lift and criss-crossing the vehicle.
E2AP02KC
Lifting with the jack at the front
E2AP02JC
Raising the vehicle on a lift, supported from the jacking points
Lifting with the jack at the rear
E5AP2DNC
E2AP02FC
NOTE: The handle jack is specific to the vehicle, do not use it for any other purposes.
Tooling [1] Safety straps
UK-C4-page001-47-2004 15/11/04 9:26 Page 18
Page 22
19
GENERAL
CAPACITIES (in litres)
Draining method.
The oil capacities are defined according to the following methods.
1/ Vehicle on level surface (in high position, if equipped with hydropneumatic suspension).
2/ Engine warm (oil temperature 80°C).
3/ Draining of the oil sump + removal of the cartridge (duration of draining + dripping = 15 min).
4/ Refit plug + cartridge.
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.
UK-C4-page001-47-2004 15/11/04 9:26 Page 19
Page 23
20
GENERAL
Engine type
Oil capacity with change
of cartridge
Between min. and max.
Manual gearbox
Automatic gearbox
After draining
Braking circuit
Cooling circuit
Manual gearbox
Automatic gearbox
Steering electro-pump
reservoir
Fuel tank
KFU NFU RFN RFJ RFK
3,75 3,25 4,25 4,25 5,3
1,2 1,2 1,7 1,7 1,5
2 ± 0,15 2 2
(1) (1)
WITH ESP = 0,85 WITHOUT ESP = 0,75
5,8 6,2 6,2 (2) – 6,6 (3) 6,2 (2) – 6,6 (3) 6,6
6,7 6,8 (2) – 6,9 (3)
0,85
60
CAPACITIES (in litres)
Petrol
C4
1.4i 16V 1.6i 16V 2.0i 16V 2.0i 2.0i 16V
IMPERATIVE: Systematically check the oil level using the oil dipstick.
(1) = The gearbox is lubricated for life (as a guide, the TOTAL capacity is 5.85 litres after draining 3 litres).
(2) = Temperature 37°C. (3) = Temperature 45°C.
AUTO.
(1)
AUTO.
(1)
UK-C4-page001-47-2004 15/11/04 9:26 Page 20
Page 24
21
GENERAL
Engine type
Oil capacity with change
of cartridge
Between min. and max.
Manual gearbox
Braking circuit
Cooling circuit
Additive reservoir
Steering electro-pump
reservoir
Fuel tank
9HX 9HY 9HZ RHR
3,75 5,25
1,8 2
2 2,7
WITH ESP = 0,85 WITHOUT ESP = 0,75
6,5 8,1
2,5 2,5
0,85
60
CAPACITIES (in litres)
Diesel
C4
1.6 HDi 16V 2.0 HDi 16V
NOTE: (*) = Version with additional heating.
IMPERATIVE: Systematically check the oil level using the oil dipstick.
UK-C4-page001-47-2004 15/11/04 9:26 Page 21
Page 25
22
GENERAL
LUBRICANTS - TOTAL recommended oils
Evolutions (year 2004).
CITROËN C4.
Petrol engine versions.
Normal maintenance interval : 30 000 Km (20 000 miles).
Severe maintenance interval : 20 000 Km (12 000 miles).
Diesel engine versions.
WARNING: Vehicles HDi FAP (*) do not accept the energy economy oil
TOTAL ACTIVA FUTUR 9000 5W30 for France, TOTAL QUARTZ
FUTURE 9000 5W30 outside France.
Family DV6:
Normal maintenance interval : 20 000 Km (12 500 miles).
Severe maintenance interval : 15 000 Km (10 000 miles).
Family DW:
Normal maintenance interval : 30 000 Km (20 000 miles).
Severe maintenance interval : 20 000 Km (12 000 miles).
(*) FAP = Particle filter.
CITROËN C5 Restyled
Petrol engine versions.
Normal maintenance interval : 30 000 Km (20 000 miles).
Severe maintenance interval : 20 000 Km (12 000 miles).
Diesel engine versions.
WARNING: Vehicles HDi FAP (*) do not accept the energy economy oil
TOTAL ACTIVA FUTUR 9000 5W30 for France, TOTAL QUARTZ
FUTURE 9000 5W30 outside France.
Family DV6:
Normal maintenance interval : 20 000 Km (12 500 miles).
Severe maintenance interval : 15 000 Km (10 000 miles).
Family DW:
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.
UK-C4-page001-47-2004 15/11/04 9:26 Page 22
Page 26
23
GENERAL
LUBRICANTS - TOTAL recommended oils
Use of oil grade 10W40.
Possibility to use the semi-synthetic oil 7000 10W40 on vehicles HDi
and HDi FAP.
WARNING: To avoid difficulties starting from cold (<20°C),
Use oil 5W40.
For further details, see oil utilisation table.
Commercial description of energy economy oil.
Energy economy oil is called:
TOTAL ACTIVA FUTUR 9000 5W30 in France.
TOTAL QUARTZ FUTURE 9000 5W30 outside France.
Exclusions of use of this oil are:
XSARA VTS 2.0i 16V (XU10J4RS).
JUMPER/RELAY 2.8 TDi ; 2.8 HDi (SOFIM engine).
Vehicles HDi FAP.
CITROËN C3 1.6i 16V (DV4TED4).
CITROËN C8 2.2i (EW12J4).
CITROËN C4 and C5 (EW10A).
UK-C4-page001-47-2004 15/11/04 9:26 Page 23
Page 27
24
GENERAL
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
UK-C4-page001-47-2004 15/11/04 9:26 Page 24
Page 28
25
GENERAL
LUBRICANTS - TOTAL recommended oils
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
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.
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 A
CEA
A3/B3).
UK-C4-page001-47-2004 15/11/04 9:26 Page 25
Page 29
26
GENERAL
LUBRICANTS - TOTAL recommended oils
Recommendations.
ESSENTIAL: To preserve engine performances, all engines fitted in CITROËN 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 2004):
- XU10 J4RS : XSARA VTS 2.0i 16V (3-door).
- SOFIM : JUMPER/RELAY 2.8 TDi and 2.8 HDi.
- HDi :With particle filter (FAP).
- DV4 TED4 : CITROËN C3 1.4 16V HDi.
- EW 12J4 : CITROËN C8 2.2i 16V.
- EW 10A : CITROËN C4 and C5.
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).
UK-C4-page001-47-2004 15/11/04 9:26 Page 26
Page 30
Year
2003
Petrol and dual fuel
petrol/LPG engines
A3 or A5 (*)
SJ or SL
CFB3, B4 or B5 (*)Diesel engines
Types of engine concerned
Norms to be observed for engine oils (year 2003)
ACEA norms API norms
Recapitulation
27
GENERAL
LUBRICANTS - TOTAL recommended oils
TOTAL ACTIVATRAC
TOTAL QUARTZ FUTUR 9000 (*)
TOTAL ACTIVA FUTUR 9000 (*)
TOTAL ACTIVA 9000
TOTAL QUARTZ 9000
5W40
A3 / B3 / B4
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), EW10A, 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.
UK-C4-page001-47-2004 15/11/04 9:26 Page 27
Page 31
28
GENERAL
LUBRICANTS - TOTAL recommended oils
TOTAL ACTIVA 7000
TOTAL QUARTZ 7000
TOTAL QUARTZ 9000
TOTAL ACTIVA 7000
TOTAL QUARTZ 7000
10W40
A3
SJ
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
B3
CF
15W50
S.A.E norms
Oils specifically for diesel engines
ACEA norms API norms
SL
SL
UK-C4-page001-47-2004 15/11/04 9:26 Page 28
Page 32
29
GENERAL
LUBRICANTS - TOTAL recommended oils
Huile TOTAL ACTIVA QUARTZ
Semi-synthetic 7000Synthetic 9000
0W40 5W30 5W40 10W40 15W50
cold countries
temperate countries
hot countries
Engines versions
XU10 J4RS (C4) X
X
X
Other petrol engines
HDi engines with FAP (*)
Other HDi engines
SOFIM 2.8 TDi and 2.8 HDi (RELAY)
DV4 TED4 (C3 1.4 16V HDi)
Indirect injection diesel engines
XU10 J4RS (Xsara VTS 2.0i 16V)
Petrol engines
Diesel engines
Oil usage table
X
X
X
XXX
XXX
XXX
XX (1)
XXX
XXX
XXX
XXX
(*) = Particle filter.
(1) = Do not use this oil in cold climatic conditions.
For the choice of grade of TOTAL engine oils to be used depending on the climatic conditions in the country of marketing: see table below.
X
EW 12 J4 (C8 2.2i 16V)
X
X
XX
UK-C4-page001-47-2004 15/11/04 9:26 Page 29
Page 33
30
GENERAL
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
UK-C4-page001-47-2004 15/11/04 9:26 Page 30
Page 34
31
GENERAL
FRANCE
Metropolitan FRANCE
Metropolitan FRANCE
New Caledonia
Guadeloupe
Saint martin
Reunion
9000 5W40 7000 15W50 7000 15W50
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 5W40
9000 5W30 (*)
7000 10W40
7000 10W40
9000 5W40
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.
UK-C4-page001-47-2004 15/11/04 9:26 Page 31
Page 35
32
GENERAL
EUROPE
7000 10W40
9000 0W40
7000 10W40
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
9000 5W40
FUTURE 9000 5W30 (*)
7000 10W40
(*) Blended oils for all engines, permitting fuel economy.
UK-C4-page001-47-2004 15/11/04 9:26 Page 32
Page 36
33
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
9000 5W40
FUTURE 9000 5W30 (*)
7000 10W40
(*) Blended oils for all engines, permitting fuel economy.
UK-C4-page001-47-2004 15/11/04 9:26 Page 33
Page 37
34
GENERAL
EUROPE
7000 10W40
9000 0W40
7000 10W40
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
9000 5W40
FUTURE 9000 5W30 (*)
7000 10W40
(*) Blended oils for all engines, permitting fuel economy.
UK-C4-page001-47-2004 15/11/04 9:26 Page 34
Page 38
35
GENERAL
EUROPE
7000 10W40
7000 15W50
7000 10W40
7000 10W40
9000 0W40
7000 10W40
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
9000 5W40
FUTURE 9000 5W30 (*)
7000 10W40
(*) Blended oils for all engines, permitting fuel economy.
UK-C4-page001-47-2004 15/11/04 9:26 Page 35
Page 39
36
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
Tu r ke y
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
9000 5W40
FUTURE 9000 5W30 (*)
7000 10W40
(*) Blended oils for all engines, permitting fuel economy.
UK-C4-page001-47-2004 15/11/04 9:26 Page 36
Page 40
37
GENERAL
EUROPE
7000 10W40
9000 0W40
Ukraine
Serbia-Montenegro
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
9000 5W40
FUTURE 9000 5W30 (*)
7000 10W40
(*) Blended oils for all engines, permitting fuel economy.
UK-C4-page001-47-2004 15/11/04 9:26 Page 37
Page 41
38
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
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
(*) Blended oils for all engines, permitting fuel economy.
UK-C4-page001-47-2004 15/11/04 9:26 Page 38
Page 42
39
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
9000 5W40
7000 10W40
UK-C4-page001-47-2004 15/11/04 9:26 Page 39
Page 43
40
GENERAL
SOUTH-EAST ASIA
China
South Korea
Hong Kong
India – Indonésia
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
9000 5W40
FUTURE 9000 5W30
9000 5W40
9000 5W40
FUTURE 9000 5W30 (*)
9000 5W40
7000 10W40
(*) Blended oils for all engines, permitting fuel economy.
UK-C4-page001-47-2004 15/11/04 9:26 Page 40
Page 44
41
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
9000 5W40
7000 10W40
(*) Blended oils for all engines, permitting fuel economy.
UK-C4-page001-47-2004 15/11/04 9:26 Page 41
Page 45
42
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
9000 5W40
7000 10W40
UK-C4-page001-47-2004 15/11/04 9:26 Page 42
Page 46
43
GENERAL
LUBRICANTS - TOTAL recommended oils
GEARBOX OILS
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
Manual gearbox and
piloted manual gearbox
MB3 automatic gearbox
4HP20 and AL4 autoactive
automatic gearboxes
All countries
Special oil distributed by
CITROËN
Part No.: 9980 D4
TOTAL TRANSMISSION X4
Part No.: 9730 A4
AM6 autoactive automatic
gearboxes
Tr ansfer box and rear axle
UK-C4-page001-47-2004 15/11/04 9:26 Page 43
Page 47
44
GENERAL
LUBRICANTS - TOTAL recommended oils
POWER STEERING OILS
ENGINE COOLANT FLUID
TOTAL FLUIDE ATX
TOTAL FLUIDE DA
Special oil distributed by CITROËN
Part No.: 9979 69
Power steering
All 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
TOTAL FLUIDE DA
Special oil distributed by CITROËN
Part No.: 9730 A1
Very cold countries
Power steering
All vehicles except CITROËN C4, C5
Power steering
CITROËN C4, C5
UK-C4-page001-47-2004 15/11/04 9:26 Page 44
Page 48
45
GENERAL
LUBRICANTS - TOTAL recommended oils
BRAKE FLUID
Synthetic brake fluid
HYDRAULIC CIRCUIT
WARNING:TOTAL FLUIDE LDS fluid cannot be blended with TOTAL LHM.
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.
Pack
CITROËN Part No.
Norm
Colour
All countries
TOTAL FLUIDE LDS
TOTAL LHM PLUS
TOTAL LHM PLUS
Very cold countries
Orange 9979 69
ZCP 830095
9979 20
Green
1 Litre
UK-C4-page001-47-2004 15/11/04 9:26 Page 45
Page 49
46
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
1 Litre
5 Litres
Norms NLGI
2
TOTAL MULTIS 2
TOTAL SMALL MECHANISMS
All countries
Note: NLGI = National Lubricating Grease Institute.
UK-C4-page001-47-2004 15/11/04 9:26 Page 46
Page 50
47
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 INTERVENE 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.
UK-C4-page001-47-2004 15/11/04 9:26 Page 47
Page 51
ENGINE SPECIFICATIONS
Petrol
Emission standard
Engine type
Cubic capacity (cc)
Bore / Stroke
Compression ratio
Power ISO or EEC (KW - rpm)
Power DIN (HP - rpm)
Tor que ISO or EEC
(m.daN - rpm)
Tor que DIN
(mkg-rpm)
1.4i 16V 1.6i 16V 2.0i 2.0i 16V
EURO 4 IF EURO 4
KFU NFU RFJ RFN RFK
1360 1587 1997
75/77 78/82 85/88
11/1 10,8/1
65-5250 80-5800 103-6000 99-6000 130-7000
90-5250 110-5800 140-6000 134-6000 177-7000
13,3-4250 14,7-4000 19,5-3000 19-4100 20,2-4750
13,5-4250 15-4000 19,9-3000 19,4-4100 20,6-4750
48
ENGINES
UK-C4-page048-130-2004 15/11/04 9:23 Page 48
Page 52
48
ENGINES
ENGINE SPECIFICATIONS
Diesel
Emission standard
Engine type
Cubic capacity (cc)
Bore / Stroke
Compression ratio
Power ISO or EEC (KW - rpm)
Power DIN (HP - rpm)
Tor que ISO or EEC
(m.daN - rpm)
Tor que DIN
(mkg-rpm)
1.6 16V HDi 2.0 16V HDi
EURO 4 EURO 3 (with or without FAP) EURO 4
9HX 9HY 9HZ RHR
1560 1997
75/88,3 85/88
18/1 18/1
66-4000 80-4000 100-4000
90-4000 110-4000 138-4000
21,5-1750
24-1750
32-2000
(26-1750 with temporary fuel boost (*))
24,97-2000 32,6-2000
(*) = Temporary fuel boost means that in certain operating phases, the quantity of fuel injected is slightly greater in order to increase the engine
torque.
UK-C4-page048-130-2004 15/11/04 9:23 Page 49
Page 53
Gearbox below the engine
SPECIAL FEATURES: TIGHTENING TORQUES
16 ±0,6
26 ±0,1
3 4,5 ± 0,4
11 4 ± 0,4
12 4 ± 0,4
13 4 ± 0,4
14 4 ± 0,4
15 4 ± 0,4
16 2 ± 0,2
17 4 ± 0,4
18 5,4 ± 0,5
B1BP36BD
Suspensions for engine/gearbox assembly
50
ENGINES
Engine: KFU
Gearbox on RH side Gearbox on LH side
B1BP36DD
B1BP36CD
41 ±0,2
5 1,8 ± 0,2
62 ±0,2
73 ±0,3
8 1,9 ± 0,1
9 2,5 ± 0,2
10 6,5 ± 0,6
UK-C4-page048-130-2004 15/11/04 9:23 Page 50
Page 54
51
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Cylinder head
1 Inlet air pressure sensor 0,8 ± 0,1
2 Motorised butterfly housing fixing screws 0,8 ± 0,2
3 Coolant outlet husing screws 0,8 ± 0,2
4 Oxygen sensor 4,7 ± 0,7
Catalytic converter fixing nuts (*)
5 Pre-tightening 2 ± 0,2
Tightening 4 ± 0,4
Check the tightening 4 ± 0,4
6 Exhaust manifold nuts 1,8 ± 0,2
7 Exhaust manifold fixing stud 0,8 ± 0,1
Cylinder head bolts (*)
8 Pre-tightening 1,5 ± 0,2
Tightening 2,5 ± 0,2
Angular tightening 200° ± 5°
9 Inlet manifold screws 0,8 ± 0,1
10 Valve cover screws (*) 0,9 ± 0,1
11 Camshaft bearing cap screws (*) 1 ± 0,1
12 Sparking plugs 2,25 ± 0,2
13
Camshaft dephaser electrovalve fixing screws
0,8 ± 0,2
(VVT)
Engine: KFU
B1BP368P
(*) = IMPERATIVE: Respect the tightening sequence (see following page).
UK-C4-page048-130-2004 15/11/04 9:23 Page 51
Page 55
52
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Engine: KFU
B1JP063C
B1DP05BC
IMPERATIVE: Respect the tightening sequence.
Cylinder head
(8) Cylinder head bolts
(10) Valve cover screws (5) Catalytic converter fixing nuts
(11) Camshaft bearing cap screws
UK-C4-page048-130-2004 15/11/04 9:23 Page 52
Page 56
53
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Cylinder block
14 Crankshaft bearing cap sealing screw (*) 0,8 ± 0,1
15 Knock sensor 2 ± 0,4
16 Coolant pump stud screw 1,6 ± 0,2
17 Coolant pump cover screw 0,6 ± 0,1
18 Screw of coolant pump body on cylinder block 6,5 ± 0,6
19 Cooling circuit plug 3 ± 0,5
20 Oil circuit plugs 3 ± 0,5
21 Flywheel screw (*) 6,7 ± 0,6
22 Con rod cap fixing nut 3,7 ± 0,4
23 Accessories drive belt pulley screw 0,8 ± 0,2
Crankshaft pinion screw
24 Tightening 4 ± 0,4
Angular tightening 45° ± 4°
Crankshaft bearing cap cover screw (*)
25 Tightening 2
Angular tightening 44° ± 4°
Engine: KFU
B1BP368P
(*) = IMPERATIVE: Respect the tightening sequence (see following page).
UK-C4-page048-130-2004 15/11/04 9:23 Page 53
Page 57
54
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Engine: KFU
B1CP0GYC
B1DP05BC
IMPERATIVE: Respect the tightening sequence.
Cylinder block
(14) Crankshaft bearing cap sealing screw
(25) Crankshaft bearing cap cover screw (21) Flywheel screw
UK-C4-page048-130-2004 15/11/04 9:23 Page 54
Page 58
55
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Lubrication
26 Oil gauge screw 0,7 ± 0,1
27 Electric oil gauge fixing screw 3,2 ± 0,5
28 Oil filter support screw 1 ± 0,1
29 Strainer fixing screw 1 ± 0,1
30 Oil pressure switch 2 ± 0,2
31 Oil sump screw 0,8 ± 0,2
32 Drain plug 3 ± 0,5
33 Oil pump screw 0,9 ± 0,1
Engine: KFU
B1BP369P
UK-C4-page048-130-2004 15/11/04 9:23 Page 55
Page 59
56
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Timing
34 Inlet camshaft dephaser plug (VVT) 3,2 ± 0,2
Inlet camshaft dephaser screw (VVT)
35 Pre-tightening 2 ± 0,2
Tightening 6 ± 0,6
36 Guide roller screw 2,1 ± 0,2
37 Exhaust camshaft pulley screw 4,5 ± 0,4
38 Tensioner roller screw 2,1 ± 0,2
Engine: KFU
B1EP1GPD
UK-C4-page048-130-2004 15/11/04 9:23 Page 56
Page 60
57
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Accessories
39 Alternator support fixing screw 2,5 ± 0,3
40 Alternator power circuit fixing nut 1,4 ± 0,2
41 Alternator fixing screw 4 ± 0,4
42 Aircon compressor fixing screw 2,4 ± 0,1
43 Aircon compressor support fixing screw 2,5 ± 0,4
44 Bottom screw fixing tensioner roller support 5,7 ± 1
45 Top screw fixing tensioner roller support 2,5 ± 0,6
Engine: KFU
B1BP36AP
UK-C4-page048-130-2004 15/11/04 9:23 Page 57
Page 61
58
ENGINES
CYLINDER HEAD
Engine: KFU
Identification of cylinder head gasket
Engine types
KFU
Thicknesses (Standard)
1,2 ± 0,1
Thicknesses (repair)
1,5 ± 0,1
Thickness references
3
Engine type : 1 to 4
Supplier (MEILLOR) : A B D
Cylinder head gasket without asbestos : Ref. C
Repair ref. : R
B1BP10KC
UK-C4-page048-130-2004 15/11/04 9:23 Page 58
Page 62
59
ENGINES
CYLINDER HEAD
Engine: KFU
Cylinder head tightening (m.daN) Cylinder head bolts
X = MAXIMUM reusable length
(Sequence from 1 to 10)
Pre-tightening : 1,5 ± 0,2
Tightening : 2,5 ± 0,2
Angular tightening : 200° ± 5°
NOTE: Oil the threads and under
the heads of the bolts (use engine
oil or Molykote G Rapid Plus).
B1BP1DVC
B1DP05BC
Retightening of the cylinder head after a
completed repair is prohibited.
Cleaning to be carried out just prior to refitting.
WARNING: Clean the contact faces with the approved cleaning product. Do not use abrasives or cutting tools on the contact faces.The contact faces
must not bear any traces of impact or scratching.
Brush the threads of the cylinder head bolts.
KFU
X = 119 mm
UK-C4-page048-130-2004 15/11/04 9:23 Page 59
Page 63
60
Gearbox below the engine
SPECIAL FEATURES: TIGHTENING TORQUES
16 ±0,6
26 ±0,6
3 4,5 ± 0,4
13 4 ± 0,4
14 4 ± 0,4
15 5,4 ± 0,5
16 6 ± 0,6
17 4 ± 0,4
18 6 ± 0,6
19 2 ± 0,2
20 4 ± 0,4
21 4 ± 0,4
B1BP35WD
Suspensions for engine/gearbox assembly
Engine: NFU
Gearbox on RH side Gearbox on LH side
B1BP35YD
B1BP35XD
4 1,8 ± 0,2
52 ±0,2
6 6,5 ± 0,6
7 1,9 ± 0,1
84 ±0,4
93 ±0,3
10 1,8± 0,2
11 1 ± 0,2
12 2,5 ± 0,2
(A) MA manual gearbox
(B) AL4 automatic gearbox
ENGINES
UK-C4-page048-130-2004 15/11/04 9:23 Page 60
Page 64
61
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Cylinder head
1 Inlet air pressure sensor 0,8 ± 0,1
2 Motorised butterfly housing fixing screws 0,7 ± 0,1
3 Inlet manifold nuts 0,8 ± 0,2
4Valve cover screws (*) 0,9 ± 0,1
5 Coolant outlet husing screws 0,8 ± 0,2
6 Thermostat fixing screw 0,8 ± 0,2
7 Oxygen sensor 4,7 ± 0,7
Catalytic converter fixing nuts (*)
8 Pre-tightening 1,8 ± 0,3
Tightening 4 ± 0,4
Check the tightening 4 ± 0,4
9 Exhaust manifold nuts 2,3 ± 0,5
10 Exhaust manifold fixing stud 0,8 ± 0,1
11 Lubrication plug 1,5 ± 0,2
Cylinder head bolts (*)
12 Tightening 2 ± 0,2
Angular tightening 260° ± 5°
13 Camshaft bearing cap screws (*) 0,9 ± 0,1
14 Inlet manifold fixing stud 0,8 ± 0,1
15 Engine coolant temperature sensor (CMM) 1,7 ± 0,1
16 Engine coolant temperature sensor (instrument panel) 1,7 ± 0,1
17 Sparking plugs 3 ± 0,1
Engine: NFU
B1BP362P
(*) = IMPERATIVE: Respect the tightening sequence (see following page).
UK-C4-page048-130-2004 15/11/04 9:23 Page 61
Page 65
62
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Cylinder block
18 Coolant pump screw 2 ± 0,1
19 Oil plugs 2,5 ± 0,5
20 Con rod cap bolt 3,8 ± 0,2
21 Seal plate screw, flywheel end 1 ± 0,1
22 Flywheel screw (*) 7 ± 0,7
23 Seal plate screw, timing end 1 ± 0,1
24 Coolant inlet manifold screw 0,8 ± 0,1
25 Crankshaft pinion screw
Tightening 4 ± 0,2
Angular tightening 45° ± 3°
26 Crankshaft bearing cap screw
Tightening 2 ± 0,1
Angular tightening 49° ± 2°
27 Accessories drive belt pulley screw 2,5 ± 0,6
28 Knock sensor 2 ± 0,5
Engine: NFU
B1DP1KUP
(*) = IMPERATIVE: Respect the tightening sequence (see following page).
UK-C4-page048-130-2004 15/11/04 9:23 Page 62
Page 66
63
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Engine: NFU
B1CP0GCC
B1JP063C
Sequence of tightening the nuts (8) (Catalytic converter) (22) Sequence of tightening the flywheel screws
IMPERATIVE: Respect the tightening sequence.
UK-C4-page048-130-2004 15/11/04 9:23 Page 63
Page 67
64
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Lubrication
29 Strainer fixing 0,8 ± 0,2
30 Oil gauge screw 0,8 ± 0,1
31 Piston skirt spray jet 1,5 ± 0,2
32 Drain plug 3 ± 0,5
33 Oil sump screw 0,8 ± 0,1
34 Oil pressure switch 2 ± 0,2
35 Oil circuit plugs 2,5 ± 0,5
36 Oil filter support screw 0,8 ± 0,2
37 Oil level sensor 0,8 ± 0,2
38 Oil pump screw 0,9 ± 0,1
Engine: NFU
B1BP363P
UK-C4-page048-130-2004 15/11/04 9:23 Page 64
Page 68
65
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Timing
39 Camshaft pulley screw 4,5 ± 0,5
40 Guide roller screw 2 ± 0,2
41 Tensioner roller screw 2,1 ± 0,4
Engine: NFU
B1BP1GMP
UK-C4-page048-130-2004 15/11/04 9:23 Page 65
Page 69
66
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Accessories
42 Alternator support fixing screw 2,5 ± 0,6
43 Alternator power circuit fixing nut 1,4 ± 0,2
44 Alternator fixing screw 4 ± 0,4
45 Aircon compressor fixing screw 2,5 ± 0,2
46 Tensioner roller support fixing screw 2,5 ± 0,6
47 Bottom screw fixing tensioner roller support 5,7 ± 1
48 Top screw fixing tensioner roller support 2,5 ± 0,6
Engine: NFU
B1BP364P
UK-C4-page048-130-2004 15/11/04 9:23 Page 66
Page 70
67
ENGINES
67
CYLINDER HEAD
Engine: NFU
Identification of cylinder head gasket
Engine types
NFU
Thicknesses (Standard)
0,66 ± 0,04
Thicknesses (repair) Thickness references
4
Engine type : 1 à 4
Supplier (MEILLOR) : A B D
Cylinder head gasket without asbestos : Ref. C
Repair ref. : R
B1BP10KC
UK-C4-page048-130-2004 15/11/04 9:23 Page 67
Page 71
68
ENGINES
CYLINDER HEAD
Engine: NFU
Cylinder head tightening (m.daN) Cylinder head bolts
X = MAXIMUM reusable length
Pre-tightening :2 ±0,2
Angular tightening : 260° ± 5°
NOTE: Oil the threads and under
the heads of the bolts (use engine
oil or Molykote G Rapid Plus).
B1DP059C
B1DP05BC
Retightening of the cylinder head after a
completed repair is prohibited.
Cleaning to be carried out just prior to refitting.
WARNING: Clean the contact faces with the approved cleaning product. Do not use abrasives or cutting tools on the contact faces.The contact faces
must not bear any traces of impact or scratching.
Brush the threads of the cylinder head bolts.
NFU
X = 122 ± 0,3 mm
UK-C4-page048-130-2004 15/11/04 9:23 Page 68
Page 72
69
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
16 ±0,6
26 ±0,6
3 4,5 ± 0,4
71 ±0,1
85 ±0,5
9 6,5 ± 0,6
10 3 ± 0,3
11 3 ± 0,3
12 6 ± 0,6
13 1,9 ± 0,2
B1BP35TD
Suspensions for engine/gearbox assembly
Engine: RFJ
RH side Torque reaction rod
B1BP35VD
B1BP35UD
4 4,5 ± 0,4
5 3,9 ± 0,4
6 5,4 ± 0,6
UK-C4-page048-130-2004 15/11/04 9:23 Page 69
Page 73
70
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Cylinder head
Valve cover screws (*)
1 Pre-tightening 0,5
Tightening 1,1 ± 0,1
2 Oxygen sensor 4,7 ± 0,5
3 Exhaust manifold nuts 3,5 ± 0,3
4 Coolant outlet housing fixing nuts 1 ± 0,1
5 Coolant outlet housing bolts 0,3
6 Motorised butterfly housing fixing screws 0,8 ± 0,1
7 Inlet manifold fixings 2,2 ± 0,4
8 Inlet manifold fixing studs 0,8 ± 0,2
Cylinder head bolts (*)
Pre-tightening 1 1,5 ± 0,1
Pre-tightening 2 5 ± 0,5
9 Angular tightening 360°
Tightening 2 ± 0,2
Angular tightening 285° ± 5°
10 Sparking plugs 2,7 ± 0,2
Engine: RFJ
B1BP35MP
(*) = IMPERATIVE: Respect the tightening sequence (see following page).
UK-C4-page048-130-2004 15/11/04 9:23 Page 70
Page 74
71
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Cylinder head
11 Camshaft bearing cap screws (*)
Pre-tightening 0,5
Tightening 1 ± 0,1
12 Exhaust manifold fixing stud 0,8 ± 0,2
13 Coolant outlet housing fixing stud 0,8 ± 0,2
14 Engine coolant temperature sensor 1,7 ± 0,1
15 Inner timing cover screw 0,8 ± 0,1
16 Electrovalve fixing screw (VVT) 0,9 ± 0,1
Engine: RFJ
B1BP35MP
(*) = IMPERATIVE: Respect the tightening sequence (see following page).
UK-C4-page048-130-2004 15/11/04 9:23 Page 71
Page 75
72
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Engine: RFJ
B1DP03XD
B1DP05BC
IMPERATIVE: Respect the tightening sequence.
Cylinder head
(1) Valve cover screws
(9) Cylinder head bolts (11) Camshaft bearing cap screws
UK-C4-page048-130-2004 15/11/04 9:23 Page 72
Page 76
73
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Cylinder block
17 Oil circuit plugs 3 ± 0,3
Coolant pump screw (*)
18 Pre-tightening 0,8
Tightening 1,4 ± 0,1
19 Cooling circuit plug 3 ± 0,3
Accessories drive belt pulley screw
20 Tightening 4 ± 0,4
Angular tightening 40° ± 4°
Flywheel screw (*)
21 Pre-tightening 0,8 ± 0,1
Tightening 2 ± 0,2
Angular tightening 21°± 3°
Engine: RFJ
B1DP1KSP
(*) = IMPERATIVE: Respect the tightening sequence (see following page).
UK-C4-page048-130-2004 15/11/04 9:23 Page 73
Page 77
74
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Cylinder block
Crankshaft bearing cap cover screw (*)
Pre-tightening 1
22 Tightening 2 ± 0,2
Angular tightening 72° ± 5°
23 Crankshaft bearing cap sealing screw 1
Con rod cap bolt (*)
Pre-tightening 1
24 Tightening 2,3 ± 0,2
Angular tightening 46° ± 5°
25 Knock sensor 2 ± 0,5
Engine: RFJ
B1DP1KSP
(*) = IMPERATIVE: Respect the tightening sequence (see following page).
UK-C4-page048-130-2004 15/11/04 9:23 Page 74
Page 78
75
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Engine: RFJ
B1GP08WC
B1DP05BC
IMPERATIVE: Respect the tightening sequence.
Cylinder head
(22) Crankshaft bearing cap screws
(24) Con rod cap bolt (21) Flywheel screw (18) Coolant pump screw
B1CP0GCC
UK-C4-page048-130-2004 15/11/04 9:23 Page 75
Page 79
76
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Lubrication
26 Oil gauge screw 1 ± 0,2
27 Oil filter support screw 0,8 ± 0,1
28 Anti-emulsion plate fixing screw 1,9 ± 0,3
29 Oil level sensor fixing screw 1 ± 0,2
30 Drain plug 3,4 ± 0,3
31 Oil sump screw 0,8 ± 0,1
32 Oil pressure switch 2 ± 0,2
33 Oil strainer fixing nuts 0,8 ± 0,1
34 Oil strainer stud 0,6 ± 0,1
Coolant pump screw
35 Pre-tightening 0,7
Tightening 1 ± 0,1
Engine: RFJ
B1BP35NP
UK-C4-page048-130-2004 15/11/04 9:23 Page 76
Page 80
77
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Timing
Exhaust camshaft pulley screw
36 Pre-tightening 3 ± 0,5
Tightening 8,5 ± 0,5
37 Cap 1,1 ± 0,1
Inlet camshaft pulley screw
38 Pre-tightening 2 ± 0,2
Tightening 11 ± 1
39 Tensioner roller screw 2,1 ± 0,2
Guide roller screw
40 Pre-tightening 1,5 ± 0,1
Tightening 3,7 ± 0,7
Engine: RFJ
B1EP1GJP
UK-C4-page048-130-2004 15/11/04 9:23 Page 77
Page 81
78
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Accessories
41 Accessories support fixing stud 0,8 ± 0,1
Accessories support fixings
42 Pre-tightening 1 ± 0,1
Tightening 1,9 ± 0,2
43 Alternator top fixing screw 4,1 ± 0,5
44 Alternator power circuit fixing nut 1,7 ± 0,2
45 Aircon compressor fixing screw 2,3 ± 0,3
46 Alternator bottom fixing screw 4,9 ± 0,5
47 Screw for fixing the automatic tensioner roller
for the accessories drive belt 2 ± 0,2
Engine: RFJ
B1BP35PP
UK-C4-page048-130-2004 15/11/04 9:23 Page 78
Page 82
79
ENGINES
CYLINDER HEAD
Engine: RFJ
B1DP1LPD
Identification of cylinder head gasket
Supplier MEILLOR
A : Timing end
Thickness 0,67 ± 0,04 mm B : Clutch end
C : Engraving zone
D : Marking zone
Multi-layer metallic cylinder head gasket
UK-C4-page048-130-2004 15/11/04 9:23 Page 79
Page 83
80
ENGINES
CYLINDER HEAD
Engine: RFJ
X = MAXIMUM reusable length
NOTE: Retightening of the cylinder head
after a completed repair is prohibited.
Pre-tightening : 1,5 ± 0,1
Tightening :5 ±0,1
Angular tightening : 360° ± 2°
Tightening :2 ±0,75
Angular tightening : 285° ± 5°
(Sequence from 1 to 10)
WARNING: Refit the cylinder head
bolts priorly coated on the threads
and under the heads with
Molykote G Rapid Plus.
B1DP16FC
B1DP05BC
RFJ
X = 127,5 ± 0,5 mm
Cylinder head tightening (m.daN) Cylinder head bolts
A = Thickness of the washer : 4 ± 0,2
UK-C4-page048-130-2004 15/11/04 9:23 Page 80
Page 84
81
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
16 ±0,6
26 ±0,6
3 4,5 ± 0,4
71 ±0,1
85 ±0,5
9 6,5 ± 0,6
10 3 ± 0,3
11 3 ± 0,3
12 6 ± 0,6
13 1,9 ± 0,2
B1BP35TD
Suspensions for engine/gearbox assembly
Engine: RFN
Gearbox on RH side Gearbox at torque reaction rod
B1BP35VD
B1BP35UD
4 4,5 ± 0,4
5 3,9 ± 0,4
6 5,4 ± 0,6
Gearbox on LH side
UK-C4-page048-130-2004 15/11/04 9:23 Page 81
Page 85
82
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Cylinder head
Valve cover screws (*)
1 Pre-tightening 0,5
Tightening 1,1 ± 0,1
2 Exhaust manifold stud 0,7 ± 0,1
Exhaust manifold nuts
3 Tightening on heat shield 2,5 ± 0,2
Tightening apart from on heat shield 3,5 ± 0,3
4 Oxygen sensor 4,7 ± 0,5
5 Coolant outlet housing fixing (BSE)
Tightening of the nuts 1 ± 0,2
Tightening of the screws 1 ± 0,1
6 Thermostat fixing screw 0,8 ± 0,1
7 Coolant outlet housing fixing stud (BSE) 0,3 ± 0,1
8 Engine coolant temperature sensor 1,7 ± 0,1
9 Inlet manifold screws 2,2 ± 0,4
10 Motorised butterfly housing fixing screws 0,8 ± 0,1
Engine: RFN
B1BP34MP
(*) = IMPERATIVE: Respect the tightening sequence (see following page).
UK-C4-page048-130-2004 15/11/04 9:23 Page 82
Page 86
83
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Cylinder head
Cylinder head bolts (*)
1st pre-tightening 1,5 ± 0,1
2nd pre-tightening 5 ± 0,5
11 Angular tightening 360°
Tightening 2 ± 0,2
Angular tightening 285° ± 5°
Camshaft bearing cap cover screws (*)
12 Pre-tightening 0,5
Tightening 1 ± 0,1
13 EGR valve screw 0,8 ± 0,1
14 Valve for injection of air to the exhaust 0,8 ± 0,2
15 Inlet manifold stud 0,8 ± 0,1
16 Inlet manifold fixing nuts 2,2 ± 0,5
17 Sparking plug 2,7 ± 0,2
Engine: RFN
B1BP34MP
(*) = IMPERATIVE: Respect the tightening sequence (see following page).
UK-C4-page048-130-2004 15/11/04 9:23 Page 83
Page 87
ENGINES
84
SPECIAL FEATURES: TIGHTENING TORQUES
Engine: RFN
B1DP03XD
B1DP05BC
IMPERATIVE: Respect the tightening sequence.
Cylinder head
(1) Valve cover screws
(11) Cylinder head bolts (12) Camshaft bearing cap screws
UK-C4-page048-130-2004 15/11/04 9:23 Page 84
Page 88
85
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Cylinder block
18 Oil circuit plug 3 ± 0,3
Coolant pump screw (*)
19 Pre-tightening 0,8
Tightening 1,4 ± 1
20 Cooling circuit plug 3 ± 0,7
Flywheel screw (*)
21 Pre-tightening 0,8 ± 0,1
Tightening 2 ± 0,2
Angular tightening 23° ± 5°
Crankshaft bearing cap cover screw (*)
22 Pre-tightening 1 ± 0,1
Tightening 2 ± 0,1
Angular tightening 60° ± 5°
Engine: RFN
B1DP1KKP
(*) = IMPERATIVE: Respect the tightening sequence (see following page).
UK-C4-page048-130-2004 15/11/04 9:23 Page 85
Page 89
86
ENGINES
86
SPECIAL FEATURES: TIGHTENING TORQUES
Cylinder block
23 Crankshaft bearing cap sealing screw 1 ± 0,1
Con rod cap screw (*)
24 Pre-tightening 1
Tightening 2,3 ± 0,1
Angular tightening 46° ± 3°
25 Knock sensor 2 ± 0,5
Accessories drive belt pulley screw
26 Tightening 4 ± 0,4
Angular tightening 53° ± 5°
Engine: RFN
B1DP1KKP
(*) = IMPERATIVE: Respect the tightening sequence (see following page).
UK-C4-page048-130-2004 15/11/04 9:23 Page 86
Page 90
87
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Engine: RFN
B1GP08WC
B1DP05BC
IMPERATIVE: Respect the tightening sequence.
Cylinder head
(22) Crankshaft bearing cap screws
(24) Con rod cap screws (21) Flywheel screws (19) Coolant pump screws
B1CP0GCC
UK-C4-page048-130-2004 15/11/04 9:23 Page 87
Page 91
88
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Lubrication
27 Oil gauge screw 1 ± 0,2
28 Oil level sensor fixing screw 1 ± 0,2
29 Drain plug 3,4 ± 0,3
30 Oil sump screw 0,8 ± 0,1
31 Oil pressure switch 2 ± 0,2
32 Oil strainer fixing nuts 1,1 ± 0,1
33 Oil strainer stud 0,6 ± 0,1
Oil pump screw
34 Pre-tightening 0,7
Tightening 1 ± 0,1
35 Oil filter support screw 0,8 ± 0,2
36 Anti-emulsion plate fixing screw 1,9 ± 0,3
Engine: RFN
B1BP34NP
UK-C4-page048-130-2004 15/11/04 9:23 Page 88
Page 92
89
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Timing
37 Camshaft pulley screw 7,5 ± 0,5
38 Tensioner roller screw 2 ± 0,3
39 Guide roller screw 3,5 ± 0,5
Engine: RFN
B1EP1G6P
UK-C4-page048-130-2004 15/11/04 9:23 Page 89
Page 93
90
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Accessories
40 Accessories support fixing stud 0,8 ± 0,1
Accessories support fixings
41 Pre-tightening 1 ± 0,1
Tightening 1,9 ± 0,2
42 Alternator top fixing screw 4,1 ± 0,5
43 Alternator power circuit fixing nuts 1,7 ± 0,2
44 Aircon compressor fixing screw 2,3 ± 0,3
45 Alternator bottom fixing screw 4,9 ± 0,5
Screw for fixing the guide roller for the accessories drive belt
46 Pre-tightening 1,5 ± 0,1
Tightening 3,5 ± 0,4
47 Screw for fixing the automatic tensioner roller
for the accessories drive belt 2 ± 0,2
Engine: RFN
B1BP34PP
UK-C4-page048-130-2004 15/11/04 9:23 Page 90
Page 94
91
ENGINES
CYLINDER HEAD
Engine: RFN
Identification of cylinder head gasket
B1DP183D
Nominal
dimension
Repair dimension
2-4-54-5
R1 R2
1,1 1,40,8
Gasket thickness
(mm)
Supplier MEILLOR
Marking zone
"e"
Identification zone
"d"
NOTA : Multilayer metallic gasket.
UK-C4-page048-130-2004 15/11/04 9:23 Page 91
Page 95
92
ENGINES
CYLINDER HEAD (continued)
Engine: RFN
X = MAXIMUM reusable length
Pre-tightening : 1,5 ± 0,1
Tightening :5 ±0,1
Slackening : 360° ± 2°
Tightening :2 ±0,75
Angular tightening : 285° ± 5°
NOTA : Oil the threads and under the
heads of the bolts (use engine oil or
Molykote G Rapid Plus).
B1DP16FC
B1DP05BC
RFN
X = 147 mm
Cylinder head tightening (m.daN) Cylinder head bolts
A = Thickness of the washer : 4 ± 0,2
UK-C4-page048-130-2004 15/11/04 9:23 Page 92
Page 96
93
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
16 ±0,6
26 ±0,6
3 4,5 ± 0,4
71 ±0,1
85 ±0,5
9 6,5 ± 0,6
10 3 ± 0,3
11 3 ± 0,3
12 6 ± 0,6
13 1,9 ± 0,2
B1BP35TD
Suspensions for engine/gearbox assembly
Engine: RFK
Gearbox on RH side Gearbox at torque reaction rod
B1BP35VD
B1BP35UD
4 4,5 ± 0,4
5 3,9 ± 0,4
6 5,4 ± 0,6
Gearbox on LH side
UK-C4-page048-130-2004 15/11/04 9:23 Page 93
Page 97
94
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Cylinder head
1 Exhaust manifold stud 0,7 ± 0,1
Exhaust manifold nuts
2 Tightening on heat shield 2,5 ± 0,2
Tightening apart from on heat shield 3,5 ± 0,3
3 Oxygen sensor 4,7 ± 0,5
Coolant outlet housing fixing
4 Tightening of the nuts 1 ± 0,2
Tightening of the screws 1 ± 0,1
5 Thermostat fixing screw 0,8 ± 0,1
6 Coolant outlet housing fixing stud (BSE) 0,3 ± 0,1
7 Engine coolant temperature sensor 1,7 ± 0,1
8 Motorised butterfly housing fixing screws 0,8 ± 0,1
9 Inlet manifold screws 2,2 ± 0,4
10 Inlet manifold fixing nuts 2,2 ± 0,5
11 Inlet manifold stud 0,8 ± 0,1
Engine: RFK
B1BP35QP
(*) = IMPERATIVE: Respect the tightening sequence (see following page).
UK-C4-page048-130-2004 15/11/04 9:23 Page 94
Page 98
95
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Cylinder head
Cylinder head bolts (*)
Pre-tightening 1 1,5 ± 0,1
12 Pre-tightening 2 5 ± 0,5
Angular slackening 360°
Tightening 2 ± 0,2
Angular tightening 285° ± 5°
Valve cover screws (*)
13 Pre-tightening 0,5
Tightening 1,1 ± 0,1
14 Sparking plug 2,7 ± 0,2
Camshaft bearing cap cover screws (*)
15 Pre-tightening 0,5
Tightening 1,1 ± 0,1
16 Valve for injection of air to the exhaust 0,9 ± 0,2
Engine: RFK
B1BP35QP
(*) = IMPERATIVE: Respect the tightening sequence (see following page).
UK-C4-page048-130-2004 15/11/04 9:23 Page 95
Page 99
96
ENGINES
SPECIAL FEATURES: TIGHTENING TORQUES
Engine: RFK
B1DP03XD
B1DP05BC
IMPERATIVE: Respect the tightening sequence.
Cylinder head
(12) Valve cover screws
(13) Cylinder head bolts (15) Camshaft bearing cap screws
UK-C4-page048-130-2004 15/11/04 9:23 Page 96
Page 100
97
ENGINES
97
SPECIAL FEATURES: TIGHTENING TORQUES
Cylinder block
17 Oil circuit plug 3 ± 0,3
Coolant pump screw (*)
18 Pre-tightening 0,8
Tightening 1,4 ± 1
19 Cooling circuit plug 3 ± 0,7
Flywheel screw (*)
20 Pre-tightening 0,8 ± 0,1
Tightening 2 ± 0,2
Angular tightening 23° ± 5°
Crankshaft bearing cap cover screw (*)
21 Pre-tightening 1 ± 0,1
Tightening 2 ± 0,1
Angular tightening 60° ± 5°
Engine: RFK
B1DP1KTP
(*) = IMPERATIVE: Respect the tightening sequence (see following page).
UK-C4-page048-130-2004 15/11/04 9:23 Page 97
Loading...