Citroën C2 2003 User Manual

Page 1
2003
CAR 050016
«The technical information contained in this document is intended for the exclusive use of the trained personnel of the motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full responsibility to the exclusion of that of the manufacturer». «The technical information appearing in this brochure is subject to updating as the characteristics of each model in the range evolve. Motor vehicle repairers are invited to contact the CITROËN network periodically for further information and to obtain any possible updates».
Page 2
PRESENTATION
THIS HANDBOOK summarises the specifications, adjustments, checks and special features of the CITROEN C2.
The handbook is divided into nine groups representing the main functions :
GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - ELECTRICAL AIR CONDITIONING.
Page 3
GENERAL
1
IDENTIFICATION OF VEHICLES
E1AP0C3D
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. (On the LH centre pillar)
D : Tyre pressures and tyre type. (On the LH centre pillar)
E : Serial number on bodywork.
F : Gearbox ident. reference – Factory serial no.
G : Engine legislation type– Factory serial no.
GENERAL
Page 4
2
GENERAL
Emission standard L4 IFL5 L4 IFL5
Type code JM HFXB
JM JM JM
JM KFVC/IF (*) JM NFUC/IF (*)
HFXC/IF (*) KFVC/P KFVC/PIF (**)
Engine type HFX KFV NFU Cubic capacity (cc) 1124 1360 1585 Fiscal rating (hp) 456
Gearbox type MA5 MA5 MA5 MA5 MA5 MA5 MA5 MA5
Gearbox ident. plate 20 CF 20 (mp) (3) 20 CF 21 (m) (4)
20 CF 25 20 CF 16 20 CN 48 20 CN 50
(1) (m) (4)
(2) (m) (4) (mp) (3) (mp) (3)
IDENTIFICATION OF VEHICLES
Petrol
TU
135
JP4JP
1.1i 1.4i 1.6i 16 V
A - X - SX - SX Pack SX - SX Pack - VTR VTR
(1) = Europe (2) = Export
(3) mp = Piloted manual gearbox (4) m = Manual gearbox
(*) = IF : Fiscal incentive (**) = PIF: Power fiscal incentive
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3
GENERAL
IDENTIFICATION OF VEHICLES
Diesel
DV
4
TD
1.4 HDi
X - SX – SX Pack - VTR
Emission standard L4 IFL5
Type code JM 8HXB JM 8HXC/IF (*) JM 8HXC/PIF (**) Engine type 8HX Cubic capacity (cc) 1398 Fiscal rating (hp) 4
Gearbox type MA5 MA5 MA5 MA5 MA5
Gearbox ident. plate 20 CN 51 (1) (m) (4) 20 CN 33 (2) (m) (4) 20 CN 51 (1) (m) (4) 20 CN 33 (2) (m) (4) 20 CN 49 (mp) (3)
(1) = Europe (2) = Export
(3) mp = Piloted manual gearbox (4) m = Manual gearbox
(*) = IF : Fiscal incentive (**) = PIF: Power fiscal incentive
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4
GENERAL
IDENTIFICATION OF VEHICLES
Manufacturer’s plate.
E1AP09JC
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.
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5
GENERAL
IDENTIFICATION OF VEHICLES
Factory code.
Structure
The factory code is composed of 6 figures or letters.
J = Vehicle family. HFX = Engine. M = Body shape. C = Version.
Body shape
Ref. Body shape
3-door saloon (4-seater)
M
Version (Gearbox and emission standard)
Ref. Gearbox
Manual
5-speed gearbox
Emissions
EURO/3
IF EURO/4
B
C
Example : JM HFXC
Family
Ref.
J
Engine
Ref.
HFX
KFV
NFU
8HX
Capacity
1124
1360
1587
1398
Engine type
TU1JP/EURO/3/IF EURO /4
TU3JP/ EURO /3/IF EURO /4
TU5JP4/IF EURO /4
DV4TD EURO/3
EURO/4
Family
CITROËN C2
Page 8
6
GENERAL
GENERAL SPECIFICATION : DIMENSIONS
E1AP0C4D
Exterior dimensions
Page 9
Exterior dimensions (mm)
7
GENERAL
GENERAL SPECIFICATION : DIMENSIONS
Interior dimensions and volumes (mm)
Vehicles All types Wheelbase A 2315 Length overall B 3666 Front overhang C 760 Rear overhang D 591 Rear track * E 1435 Front track * F 1438 Width overall G 1660 Height overall * H 1462
(*) = Vehicle in running order (vehicle empty, levels topped up).
(*) = Boot floor with adjustable configuration.
Elbow width, front 1406 Elbow width, rear 1402 Height of boot below parcel shelf 585 Minimum floor width 1040 Depth of bootspace at floor level 660 Volume of boot below parcel shelf (dm
3
) 305
Volume in dm3 of boot below Moduboard (*) 282
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8
GENERAL
Versions 1.1i 1 4i 1.6i 16V 1.4 HDi Engine type HFX KFV NFU 8HX Gearbox type MA Payload 485 465 467 479 Weight empty Without options 1053 1080 1133 1097 in running order With all options 1138 1147 1200 1177 Gross vehicle weight 1463 1470 1525 1501 Gross train weight 2113 2370 2425 2401 Maximum trailer weight without brakes 926 1174 1176 1175 Maximum trailer weight with brakes 526 540 566 548 Incline 12% 38 47 48 47 Maximum nose weight 60 60 60 60
GENERAL SPECIFICATION : WEIGHTS
Petrol Diesel
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9
GENERAL
OPERATIONS TO BE CARRIED OUT AFTER A REPAIR
IMPERATIVE : All these operations are to be performed following a reconnection of the battery.
Antiscanning function.
It is necessary to wait 1 minute after the battery has been disconnected in order to be able to start the vehicle.
Tailgate.
The opening of the tailgate is deactivated on reconnection of the battery. Perform locking/unlocking to activate the opening of the tailgate.
Overspeed check.
The vehicle’s overspeed values have to be re-initialised. The button on the wiper stalk (multifunction display B or C ) or the button on the dashboard (multifunction display A or clock) operates the following functions:
- Activation of the vehicle’s overspeed function.
- Programming of the overspeed alert.
Electric windows
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. This operation has to be carried out on each electric window.
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10
GENERAL
OPERATIONS TO BE CARRIED OUT AFTER A REPAIR
Sun roof.
The anti-pinch function has to be re-initialised. Place the sun roof switch in the maximum tilt position. Keep the sun roof switch pressed until the sun roof ceases its movement. Release the sun roof switch within 5 seconds. Keep the sun roof switch pressed until the end of the sun roof opening sequence.
Multifunction screen.
It is necessary to adjust the date, time and outside temperature. Adjust the display language of the multifunction screen if necessary.
NOTE : The default display language of the multifunction screen is French.
Navigation.
Warning, the vehicle has to be in the open air (on switching on the ignition, the ECU searches for satellites). Vehicle location is only effective after some ten minutes. Reprogramme the customer parameters.
Radio.
Reprogramme the radio stations.
Radiotelephone RT3.
Reprogramme the radio stations.
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11
GENERAL
GENERAL SPECIFICATION : TOWING THE VEHICLE
Front towing
Rear towing
WARNING : When the engine is not running,
steering and braking are no longer power-assisted.
Towing eye
(1) Towing eye
The towing eye (1) is to be found in the vehicle toolkit located under one of the front seats.
E2AP029C
E2AP02AC
E2AP02BC
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12
GENERAL
GENERAL SPECIFICATION : TOWING THE VEHICLE
Vehicle towing : Precautions to be taken
Manual gearbox Piloted manual gearbox
ESSENTIAL : Never tow the vehicles with wheels hanging (towing by the wheels).
IMPERATIVE : It is necessary to lift the front of the vehicle in order to tow it, after having positioned the gear lever in neutral.
WARNING : Whether the ignition is switched on or not, an action on
the gear selector will move the clutch fork and the gear engagement lever.
If a gear is engaged, there is more than one way to free it :
- Engage «N», with the aid of a diagnostic tool
- Engage «N», without the diagnostic tool
Essential : Never swap two gearbox ECUs between two vehicles.
IMPERATIVE : If a gear is engaged and it is not possible to free it, The vehicle must be towed with the front wheels raised.
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13
GENERAL SPECIFICATION : TOWING THE VEHICLE
GENERAL
Vehicle towing : Precautions to be taken
Piloted manual gearbox
Engagement of «N», using a diagnostic tool.
Preliminary operation :
- Battery voltage higher than 12 Volts.
- Ignition switched on.
- Connect the diagnostic tool to the vehicle’s diagnostic socket.
Using the menus of the diagnostic tool, select :
- «DIAGNOSIS»
- MA piloted manual gearbox.
- Actuator tests.
- Gearbox actuator test.
- Gear engagement test.
- N (Neutral).
NOTE : The letter «N» should appear on the instrument panel. If this does not happen, see the following solution:
- Engagement of «N», without using a diagnostic tool.
Engagement of «N», without a diagnostic tool.
In this configuration, the gearbox actuator is blocked, gear engaged.
IMPERATIVE : This recovery solution is to be used solely in a case where the methods for setting the gearbox actuators using the diagnostic tool have failed (destruction of the gearbox actuator)
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14
GENERAL
GENERAL SPECIFICATION : TOWING THE VEHICLE
Vehicle towing : Precautions to be taken
Piloted manual gearbox
Preliminary operations:
- Disconnect the battery negative terminal.
- Remove the air filter.
- Position a 22 mm flat spanner.
- Lift the gear engagement lever as far as possible (in the direction of the arrow); use a screwdriver to hold it in this position.
- Turn the spanner until the axis of the gear engagement lever (A) is at right angles to the axis (B).
- When this position is attained, position «N» is engaged.
Moving the vehicle.
IMPERATIVE : Never be towed with the ignition switched on.
Never attempt to push-start the vehicle (impossible with a piloted manual gearbox).
B2CP3L8D
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15
GENERAL
Lifting and supporting the vehicle Side liftingFront lifting
Front of the vehicle.
The authorised lifting points at the front of the vehicle are on the rear fixing bolts of the subframe at «a». For front lifting, take weight at the two lifting points at «a», using a crossbeam equipped with blocks. For front lifting from the side, take weight at the lifting point at «a».
ESSENTIAL : Never attempt to lift by the front panel 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.
Lifting from the rear. IMPERATIVE : Do not lift the vehicle by the rear. Position of the axle stand.
B3CP07KC E2AP016C E2AP00GCE2AP018CE2AP017C
GENERAL SPECIFICATION: LIFTING AND SUPPORTING THE VEHICLE
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16
GENERAL
GENERAL SPECIFICATION: LIFTING AND SUPPORTING THE VEHICLE
Lifting and supporting the vehicle (continued)
Lifting with the handle jack at the front
Lifting with the handle jack at the rear
Lifting on a two-column lift using the jack supports
Lift accessory with blocks on the jack supports
E2AP026C E2AP028D
E2AP025C E2AP027D
NOTE : The handle jack is specific to the vehicle, do not use
it for any other purposes.
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17
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.
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18
GENERAL
1.1i 1.4i 1.6i 16V 1.4 HDi
Engine type HFX KFV NFU 8HX Drain by gravity : engine with filter change 3 3.25 3.75
Between Min. and Max. 1.5
1.8
9
RPO 9844)
1.5 (RPO 9845 9) MA5 5-speed gearbox 2 MA5 piloted 5-speed gearbox 2 ± 0.15
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 5.6 Fuel tank capacity 40 45
CAPACITIES (in litres)
Petrol
C2
Diesel
ESSENTIAL : Systematically check the oil level using the oil dipstick.
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19
GENERAL
LUBRICANTS - TOTAL recommended oils
S.A.E. Norm - Table for selection of engine oil grade
E4AP006D
Page 22
LUBRICANTS – TOTAL recommended oils
20
GENERAL
Factory evolutions in 2001 model year
CITROËN engines are lubricated at the factory with TOTAL oil of grade S.A.E.5W-30. TOTAL oil of grade S.A.E.5W-30 allows improved fuel economies (approx 2.5%).
Features of CITROËN C5 :
2.0 and 2.2 HDi engines have a particle filter.
The maintenance interval for normal operation is 30,000 km (20,000 miles) for petrol engines.
WARNING : HDi engines are high technology engines which imperatively require use of quality SYNTHETIC OILS : TOTAL ACTIVA or TOTAL QUARTZ 5W40. To maintain engine performances, all countries in Europe should observe this requirement.
NOTE : Only PORTUGAL and GREECE may use 10W40 semi­synthetic oil.
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 A3/98 or API SJ. Failing this, it is essential to adhere to the maintenance pro­grammes covering severe operating conditions.
5W30 cannot be used in the following engines:
XU10J4RS : XSARA VTS 2.0i 16V (3 doors). SOFIM : RELAY 2.8 D and 2.8 TD. 1580 SPI : DISPATCH 1.6i.
2.0 and 2.2 HDi engines equipped with particle filter.
WARNING : CITROËN engines prior to model year 2000 do not have to be lubricated with oils adhering to the norms ACEA A1­98/B1-98 and API SJ/CF EC.
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21
GENERAL
LUBRICANTS – TOTAL recommended oils
Selection of engine oil grades recommended for climatic conditions in countries of distribution
ACEA Norms
The first letter corresponds to the type of engine concerned :
A : petrol and dual fuel petrol / LPG engines. B : diesel engines.
The figure following the first letter corresponds to the type of oil.
1 : highly fluid oils, for reducing friction and lowering fuel
consumption.
3 : high performance oils.
The number after that (96 or 98) corresponds to the year of creation of the norm.
NOTE : From 01/03/2000, all engine oils must comply with ACEA-98 norms.
Example : ACEA A1-98 / B1-98 : Blended oils for all engines, permitting fuel
economy (complying with ACEA 98 norms).
API Norms
The first letter corresponds to the type of fuel used by the engine :
S : petrol and dual fuel petrol / LPG engines. C : diesel engines.
The second letter corresponds to the degree of evolution, in ascending order. Example : The norm SJ is more severe than the norm SH and corres­ponds to a higher level of performance. The adding of the letters EC indicates that the engine oil concerned is an oil which permits fuel economy.
EC : Energy Conserving, reduction in fuel consumption. Examples : API SJ / CF : Blended oils for all engines.
engines API CF / EC: Oils specifically for diesel engines, permitting fuel economy. API SJ / CF / EC : Blended oils for all engines, permetting fuel economy.
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22
GENERAL
LUBRICANTS – TOTAL recommended oils
Engine oil norms. Norms in force. These engine oils have been classified by the following recognised organisations:
S.A.E. : Society of Automotive Engineers. API : American Petroleum Institute.
ACEA : Association des Constructeurs Européens d’Automobiles. Recommendations. Denominations of TOTAL oils, according to country of marketing:
TOTAL ACTIVA (France only). TOTAL QUARTZ (Outside France).
Summary
Engine oil norms to be respected in 2001 model year
(*) = It is essential not to use engine oils respecting these norms for the following engine-types . XU10J4RS. 1580 SPI. SOFIM 2.8 D and SOFIM 2.8 TD.
ESSENTIAL : To preserve engine performances, all engines fitted in CITROEN vehicles must be lubricated with high
quality oils (synthetic or semi-synthetic)
Model year Types of engine ACEA norms API norms
Petrol and dual fuel petrol / LPG engines
A3-98 or A1-98 (*) SJ or SJ / EC (*)
AM 2001
Diesel engines B3-98 or B1-98 (*) CF or CF / EC (*)
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23
GENERAL
S.A.E. grades SPI norms ACEA norms
Blended oils for all engines (petrol, dual-fuel petrol / LPG and diesel)
TOTAL ACTIVA 9000 TOTAL QUARTZ 9000
5W-40 SJ / CF A3-98 / B3-98
TOTAL ACTIVA 9000. (*) TOTAL QUARTZ 9000. (*)
5W-30 SJ / CF EC A1-98 / B1-98
TOTAL ACTIVRAC 10W-40 SJ / CF A3-98 / B3-98 (*) = Blended oils for all engines, permitting fuel economy.
Oils specifically for petrol and dual-fuel petrol / LPG engines
TOTAL ACTIVA 7000 TOTAL QUARTZ 7000
10W-40
TOTAL QUARTZ 9000 0W-40 SJ A3-98 TOTAL ACTIVA 7000
TOTAL QUARTZ 7000
15W-50
Oils specifically for diesel engines
TOTAL ACTIVA DIESEL 7000 TOTAL QUARTZ DIESEL 7000
10W-40
TOTAL ACTIVA DIESEL 7000
15W-50
CF B3-98
TOTAL ACTIVA DIESEL 9000 5W-40
LUBRICANTS – TOTAL recommended oils
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24
GENERAL
FRANCE
Metropolitan FRANCE
Metropolitan FRANCE
New Caledonia Guadeloupe Saint-Martin La Réunion Martinique 9000 5W-40 7000 15W-50 7000 15W-50 Guyana Tahiti Mauritius Mayotte
LUBRICANTS – TOTAL RECOMMENDED OILS
Blended oils for all engines, supplied in bulk
TOTAL ACTIVRAC S.A.E : 10W-40 Norms
TOTAL ACTIVA
9000 5W-40
9000 5W-30 (*)
7000 10 W-40
7000 10W-40
9000 5W-40
TOTAL ACTIVA DIESEL
Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol / LPG engines
Oils specifically for diesel
engines
(*) = Blended oils for all engines, permitting fuel economy.
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25
GENERAL
EUROPE
Germany
Austria
Belgium
Bulgaria Cyprus Croatia
Denmark
Spain
Estonia
Finland
Great Britain
LUBRICANTS – TOTAL RECOMMENDED OILS
TOTAL QUARTZ TOTAL QUARTZ DIESEL
Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol / LPG engines
Oils specifically for diesel
engines
9000 5W-40
9000 5W-30 (*)
(*) = Blended oils for all engines, permitting fuel economy
7000 10W-40
9000 0W-40 7000 10W-40 7000 10W-40
9000 0W-40 7000 10W-40
7000 15W50 7000 10W-40 7000 10W-40
9000 0W-40
7000 10W-40 7000 15W-50
7000.10W-40 7000 10W-40
9000 0W-40
7000 10W-40
7000 10W-40
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26
GENERAL
Oils specifically for diesel
engines
EUROPE (continued)
Greece
Holland Hungary Italy Irland Iceland Latvia Lithuania Macedonia
Malta
Moldova
Norway
Poland Portugal Slovak Republic
LUBRICANTS – TOTAL recommended oils
TOTAL QUARTZ TOTAL QUARTZ DIESEL
Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol / LPG engines
(*) = Blended oils for all engines,
permitting fuel economy
9000 5W-40
9000 5W-30 (*)
7000 10W-40
7000 10W-40 7000 15W-50
7000 10W-40
9000 0W-40
7000 10W-40
7000 10W-40
9000 0W-40 7000 10W-40 7000 10W-40
7000 15W-50 7000 10W-40 7000 10W-40
9000 0W-40
7000 10W-40
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27
GENERAL
EUROPE (continued)
Czech Republic
7000 10W-40
9000 0W-40
Roumania
7000 10W-40 7000 15W-50
Russia
7000 10W-40
9000 0W-40
Slovenia 7000 10W-40
Sweden
7000 10W-40
9000 0W-40
Switzerland 7000 10W-40
7000 10W-40
Turkey 7000 15W-50
9000 0W-40
Ukraine
7000 10W-40
9000 0W-40
Yugoslavia 7000 10W-40
LUBRICANTS – TOTAL recommended oils
Oils specifically for diesel
engines
TOTAL QUARTZ
TOTAL QUARTZ DIESEL
Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol / LPG engines
(*) = Blended oils for all engines, per-
mitting fuel economy
9000 5W-40
9000 5W-30 (*)
7000 10W-40
Page 30
28
GENERAL
Oils specifically for diesel
engines
Australia New-Zealand
Ivory Coast Egypt Gabon Madagascar Morocco Senegal Tunisia
Argentina Brazil, Chile Cuba Mexico Paraguay Uruguay
LUBRICANTS – TOTAL recommended oils
TOTAL QUARTZ
TOTAL QUARTZ DIESEL
Blended oils for all
engines
Oils specifically for petrol and dual-fuel petrol / LPG engines
OCEANIA
AFRICA
CENTRAL
AND SOUTH
AMERICA
9000 5W-40
7000 10W-40
7000 15W-50
7000 10W-40
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29
GENERAL
Oils specifically for diesel
engines
China
South Korea
Hong-Kong India Indonesia
Japan
Malaysia Pakistan
Philippines Singapore
Taiwan
Thailand Vietnam
LUBRICANTS – TOTAL recommended oils
TOTAL QUARTZ
TOTAL QUARTZ DIESEL
Blended oils for all
engines
Oils specifically for petrol and dual-fuel petrol / LPG engines
SOUTH EAST
ASIA
9000 5W-40
9000 5W-40 9000 5W-30
9000 5W-40
7000 10W-40 7000 15W-50
7000 10W-40
7000 15W-50
7000 10W-40 7000 15W-50
7000 15W-50
7000 10W-40 7000 15W-50
7000 15W-50
7000 10W-40
(*) = Blended oils for all engines,
permitting fuel economy
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30
GENERAL
Oils specifically for diesel
engines
LUBRICANTS – TOTAL recommended oils
TOTAL QUARTZ
TOTAL QUARTZ DIESEL
Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol / LPG engines
MIDDLE
EAST
9000 5W-40 7000 15W-50 7000 10W-50
Saudi Arabia Bahrain Dubai United Arab Emirates Iran Israel Jordan Kuwait Lebanon Oman Qatar Yemen
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31
GENERAL
Manual gearbox
TOTAL TRANSMISSION BV
Norms S.A.E 75W-80
Special oil distributed by CITROËN
(Part No. 9730 A2)
MB3 automatic gearbox
All countries
TOTAL FLUIDE ATX ou
TOTAL FLUIDE AT 42.
Special oils distributed by CITROËN
(Part No. 9730 A3)
4 HP 20 and AL4 automatic gearboxes
Special oil distributed by CITROËN
(Part No. 9736 22)
Transfer box and rear axle TOTAL TRANSMISSION X 4
All countries TOTAL FLUIDE ATX
Power- assisted steering TOTAL FLUIDE DA
Very cold countries Special oil distributed by CITROËN
(Part No. 9730 A1)
LUBRICANTS – TOTAL recommended oils
Gearbox oils
Power steering oils
Page 34
32
GENERAL
Engine coolant fluid
LUBRICANTS – TOTAL recommended oils
Packs
CITROEN reference
GLYSANTIN G 33 REVCOGEL 2000
CITROEN Fluid 2 litres 9979 70 9979 72
All countries
Protection : - 35°C 5 litres 9979 71 9979 73
20 litres 9979 76 9979 74
210 litres 9979 77 9979 75
Synthetic brake fluid
Packs CITROEN reference
All countries
CITROEN Fluid
0.5 litre 9979 05 1 litre 9979 06
5 litres 9979 07
CITROEN hydraulic circuit fluid
Norme Packs CITROEN reference
TOTAL LHM PLUS
ISO 7308-7309
ZCP 830 095
Green in colour 1 litre 9979.20 (Scandinavia)
All countries
TOTAL FLUIDE LDS Orange in colour 9979.6
WARNING: TOTAL LDS fluid cannot be blended with TOTAL LHM PLUS
WARNING: CITROËN C5 : Use only TOTAL FLUIDE LDS suspension fluid.
Hydraulic circuit rinsing fluid- green in colour
All countries TOTAL HYDRAURINCAGE
Page 35
33
GENERAL
Packs CITROEN reference Concentrated : 250 ml 9980 33 ZC 9875 953 U 9980 56
All countries
Liquid ready to use: 1 litre 9980 06 ZC 9875 784 U Liquid ready to use: 5 litres 9980 05 ZC 9885 077 U ZC 9875 279 U
Grease
Norms NLGI (1)
TOTAL MULTIS EP2 2
All countries TOTAL MULTIS COMPLEX EP2 2
TOTAL MULTIS N4128 1
TOTAL PETITES MECANIQUES
(1) NLGI = National Lubricating Grease Institute.
Wash/wipe fluid
LUBRICANTS – TOTAL recommended oils
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34
ENGINE OIL CONSUMPTION
I-Oil consumption depends on :
- the engine type.
- how run-in or worn it is.
- the type of oil used.
- the driving conditions.
II - An engine can be considered RUN-IN after:
- 3,000 miles (5,000 km) for a PETROL engine.
- 6,000 miles (10,000 km) for a DIESEL engine.
III - MAXIMUM PERMISSIBLE oil consumption for a RUN-IN engine.
- 0.5 litres per 600 miles (1,000 km) for a PETROL engine.
- 1 litre per 600 miles (1,000 km) for a DIESEL engine.
DO NOT WORK BELOW THESE VALUES.
IV - OIL LEVEL : The level should NEVER be above the MAX. mark on the dipstick after changing or topping up the oil.
- This excess oil will be used up rapidly.
- It will reduce the engine output and adversely affect the operation of the air circuits and gas recycling.
GENERAL
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35
ENGINE SPECIFICATIONS
DieselPetrol
1.1i 1.4i 1.6i 16V 1.4 HDi
Engine type
Cubic capacity (cc)
Bore / Stroke
Compression ratio
Power ISO or EEC KW - rpm
Power DIN (HP - rpm)
Torque ISO or EEC (m.daN - rpm)
Torque DIN (mkg-rpm)
HFX KFV NFU 8HX
1124 1360 1587 1398
72/69 75/77 78/82 73/82
10.5/1 11/1 17.9/1
44-5500 54-5400 80-5800 50-4000
61-5500 75-5400 110-5800 70-4000
9.4-3400 12-3400 14.7-4000 15-2000
9.8-3400 12.5-3400 15.3-4000 15.6-2000
ENGINE
Page 38
36
ENGINE SPECIFICATIONS
Engines : HFX - KFV - NFU
Engine identification
B1BP10JC B1BP2GKC
A=Engines : HFX - KFV
B = Engine : NFU
Compulsory engine identification in zone « a »:
- Component reference.
- Engine legislation type.
- Factory serial no.
ENGINE
Page 39
37
CYLINDER HEAD
Engines : HFX - KFV - NFU
Identification of cylinder head gasket
Engine types
HFX KFV NFU
Thicknesses
(Standard)
1.2 ± 0.1
0.66 ± 0.04
Thicknesses (repair)
1.4 ± 0.1
Thickness references
2 1 4
ENGINE
References
1.2.3.4 = Type of engine.
A,B,D = Suppliers.
C = Gasket material.
R = Repair.
B1BP10KC
Page 40
38
CYLINDER HEAD
Engines : HFX - KFV - NFU
Cylinder head tightening (m.daN) Cylinder head bolts
X = MAXIMUM reusable length
Tightening 2 ± 0.2 Angular tightening 240° ± 5°
(In the order 1 to 10)
Tightening 2 ± 0.2 Angular tightening 260° ± 5°
(In the order 1 to 10)
NOTE : Oil the threads and under the heads of the bolts. (Use engine oil or Molykote G Rapid Plus).
B1BP1DVC
NFU
HFX - KFV
HFX - KFV
175.5 ± 0.5 122 ± 0.3
NFU
B1DP05BC
NOTE : Retightening of the cylinder head
after a completed repair is prohibited.
ENGINE
Page 41
39
SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)
Crankshaft
Accessories drive pulley 2.5 ± 0.2 Pinion fixing on crankshaft
- Tightening 4 ± 0.4
- Angular tightening 45° ± 4°
Cylinder block
Sump 0.8 ± 0.2 Timing belt tensioner roller 2.1 ± 0.2 Accessories belt tensioner roller 2.5 ± 0.2 Accessories belt guide roller 2.5 ± 0.2 Alternator support 2.5 ± 0.2 Alternator TU1JP-TU3JP
- Pre-tightening 1 ±
- Tightening 3.7 ± 0.3 Alternator TU5JP4
- Pre-tightening 1 ±
- Tightening
4 ± .04
Aircon compressor support 2.2 ± 0.2 Aircon compressor 2.3 ± 0.2
ENGINE
Page 42
40
SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)
Cylinder head
Coolant outlet housing
- in plastic 0.8 ± 0.2
- in aluminium 0.8 ± 0.2
Camshaft bearing caps (TU1JP-TU3JP)
- Tightening 2 ± 0,2
- Angular tightening 44 °± 4°
Camshaft bearing caps (TU5JP4)
- Tightening 2 ± 0,2
- Angular tightening 50° ± 5°
Inlet manifold 0.8 ± 0.,2
Exhaust manifold 1.8 ± 0.4
Valve rockers adjusting screw 1.75 ± 0.25
Sparking plugs 3
Camshaft pulley screw (TU1JP-TU3JP) 3.7 ± 0.2
Camshaft pulley screw (TU5JP4) 4.5 ± 0.5
ENGINE
Page 43
41
SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)
Flywheel - Clutch
Engine flywheel 6.7 ± 1 (LOCTITE FRENETANCH) Oil pressure mechanism 2 ± 0.2
Lubrication circuit
Oil pressure switch 3.5 ± 0.5 Oil pump 0.9 ± 0.1
Cooling circuit
Coolant pump 1.6 ± 0.2
ENGINE
Page 44
42
TIGHTENING TORQUES : POWER UNIT SUSPENSION
Engines : HFX - KFV - NFU
(1) : 6 ± 0.6 (2) : 6 ± 0.6 (3) : 4.5 ± 0.4 (4) : 6 ± 0.6 (5) : 6 ± 0.6 (6) : 8.5 ± 0.8 (7) : 6 ± 0.6 (8) : 3 ± 0.3 (9) : 6 ± 0.6
(10) : 5.5 ± 0.5
B1BP2Y3P
ENGINE
Page 45
43
ENGINE
ENGINE SPECIFICATIONS
Engine : 8HX
Engine identification
"a" Engine legislation type.
"b"Component reference.
"c" Factory serial no.
B1CP0BKD
Page 46
44
ENGINE
CYLINDER HEAD
Engine : 8HX
Cylinder head tightening (m.daN) Cylinder head bolts
X = MAXIMUM reusable length
Pre-tightening 2 ± 0.2 m.daN Tightening 4 ± 0.4 m.daN Angular tightening 230° ± 5°
(In the order 1 to 10)
NOTE :
- The bolts should have been tho­roughly cleaned and dried with a dry metal brush.
- Oil the threads and under the heads of the bolts. (Use engine oil or Molykote G Rapid Plus).
- Pass a tap into the holes in the cylinder block.
8HX
8HX
X = 149 mm
B1DP1CLC
B1DP1DBC
NOTE : Retightening of the cylinder head
after a completed repair is prohibited.
The cylinder head gasket is dry-fitted.
Page 47
45
SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)
Crankshaft mobile
Bearing cap fixing screws
Pre-tightening 1 ± 0.2
Slackening 180°
Tightening 3 ± 0.3
Angular tightening 140°
Con rod screws
Tightening 1 ± 0.1
Angular tightening 100° ± 5°
Accessories drive pulley
Pre-tightening 3 ± 0.3
Angular tightening 180° ± 5°
Cylinder block
Sump 1.3 ± 0.1
Timing belt guide roller 2.3 ± 0.2
Timing belt tensioner roller 3.7 ± 0.3
ENGINE
Page 48
46
SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)
Cylinder head
Camshaft bearing covers
Pre-tightening 0.3 ± 0.1
Tightening 1 ± 0.1
Fixing of camshaft sub-assemblies on cylinder head
Pre-tightening 0.3 ± 0.1
Tightening 1 ± 0.1
Exhaust manifold 3 ± 0.3
Camshaft pulley
Pre-tightening 0.3 ± 0.1
Tightening 4.3 ± 0.4
Engine flywheel
Flywheel
Pre-tightening 1.7 ± 0.2
Tightening 70° ± 5°
Clutch mechanism 2 ± 0.2
ENGINE
Page 49
47
SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)
Lubrication circuit
Oil pump assembly
Pre-tightening 0.5 ± 0.1 Tightening 0.9 ± 0.1
Coolant/oil heat exchanger 1 ± 0.1
Diesel injection circuit
Spherical-base screws for diesel injection fixing fork 2.5 ± 0.2 Fuel high pressure common injection rail on engine block 2.2 ± 0.2 Unions on fuel high pressure common injection rail 2.5 ± 0.2 Diesel injection pump on support 2.2 ± 0.2 Union on diesel injection 2.5 ± 0.2 Diesel injection pump pulley 5 ± 0.5 Union on diesel high pressure pump 2.5 ± 0.2
Cooling circuit
Coolant pump
Pre-tightening 0.3 ± 0.1 Tightening 0.9 ± 0.1
Coolant outlet housing
Pre-tightening 0.3 ± 0.1 Tightening 0.7 ± 0.1
ENGINE
Page 50
48
TIGHTENING TORQUES : POWER UNIT SUSPENSION
Engine : 8HX
(1) : 6 ± 0.6
(2) : 6 ± 0.6
(3) : 6 ± 0.6
(4) : 6 ± 0.6
(5) : 3 ± 0.3
(6) : 6 ± 0.6
(7) : 5.5± 0.5
(8) : 5.7 ± 0.9
B1BP2Y1P
ENGINE
Page 51
49
Tools
BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE
! 4099-T (C.TRONIC.105)
4122-T (C.TRONIC.105.5) !
!
!
B1EP135D
ENGINE
Page 52
50
Engine type HFX KFV NFU 8HX
C2 X X X X
See pages : 50 to 52 53 to 55
AUXILIARY EQUIPMENT DRIVE BELT
Petrol Diesel
TU DV
1354
JP JP4 TD
ENGINE
Page 53
51
AUXILIARY EQUIPMENT DRIVE BELT
Engines : HFX - KFV - NFU
B1BP2LSC B1BP2LTC
Tools.
[1] Pliers for removing plastic pegs : 7504-T. [2] Belt tension measuring instrument : 4122-T.
Vehicle without air conditioning.
Refit.
Refit the belt. Respect the following sequence:
- Crankshaft pinion.
- Alternator pulley. Place tool [2] on the belt. Tighten screw (1) to achieve a tension of:
55 ± 3 unités SEEM.
Tighten:
- Screw (3).
- Screw (2). Remove tool [2] and complete the refitting.
Remove.
Slacken:
- Screw (2).
- Screw (3).
- Tensioning screw (1).
Push the alternator back towards the engine. Remove the belt.
ENGINE
Page 54
52
AUXILIARY EQUIPMENT DRIVE BELT
Engines : HFX - KFV - NFU
B1BP10XC
Vehicle with air conditioning.
Remove
Slacken:
- Screws (6), (4) and (5).
- Fully detension the belt by acting on the tensioner roller.
- Remove the accessories drive belt.
Refit.
Respect the following sequence:
- Crankshaft pinion.
- Aircon compressor pulley.
- Guide roller.
- Alternator pulley.
- Tensioner roller. Place tool [2] on the belt.
- Tighten screw (5) to achieve a belt tension of: 120 ± 3 SEEM units.
- Tighten screws (4) and (6).
- Remove tool [2].
- Complete the refitting.
ENGINE
B1BP10VC
Page 55
53
AUXILIARY EQUIPMENT DRIVE BELT
Engine : 8HXWith compressor and alternator
B1BP2MKC
B1BP2MJD
Tools [1] Pliers for removing plastic pegs : 7504-T. [2] Tensioner roller compression lever : (-).0194.E. [3] Tensioner roller setting peg Ø4 mm : (-).0194.F.
Removing.
Disconnect the battery negative cable. Raise and support the vehicle, wheels hanging. Remove the front RH wheel. Move aside the splash-shield, using tool [1].
IMPERATIVE : In the case of belt re-use, mark the direc­tion of rotation of the belt. If the index on the tensioner roller is outside the marks, change the auxiliary equip­ment drive belt.
Remove : The alternator (1). The aircon compressor (2). Detension the auxiliary belt tensioner roller, using tool [2]. Position the peg [3]. Remove the auxiliary drive belt.
ENGINE
Page 56
54
AUXILIARY EQUIPMENT DRIVE BELT
Engine : 8HX
Markings on the dynamic tensioner roller
. «a» Position of «maximum wear» of the auxiliary drive belt. «b» Normal position.
Refitting
NOTE : Check that the tensioner roller moves freely (no tight spot). If this is not the
case, replace the tensioner roller.
Respect the direction of fitting of the drive belt.
Complete the setting of the belt, of both sides, by means of the tensioner roller. Make sure that the drive belt is correctly positioned in the «V» grooves of the various pulleys.
Move the tool [2] on the tensioner roller to remove the peg [3].
ENGINE
B1EP18UD
Page 57
55
AUXILIARY EQUIPMENT DRIVE BELT
Engine : 8HY
B1BP2MYD B1BP2MZC
Tools.
[1a] Dynamic tensioner roller lever : (-).0194-E1. [1b] Lever extension : (-).0194-E2. [2] Accessories belt roller locking peg Ø 4 mm : (-).0194-F
Removing
Pivot the tensioner roller support (1) (clockwise), using tools [1a] and [1b] at «a». Remove the belt. Immobilise the support (1) of the tensioner roller, using tool [2]. Remove the auxiliary drive belt (2).
IMPERATIVE : Ensure that the tensioner rollers turn freely (no play, no tight spot).
Refitting Refit the belt. Move the tool [1] on the tensioner roller to remove the peg [2]. ESSENTIAL: Make sure that the belt is correctly positioned in the various pulley grooves.
ENGINE
Page 58
56
ENGINE
Engine type HFX KFV NFU 8HX
C2 X X X X
See pages : 57 to 66 67 to 83
CHECKING AND SETTING THE VALVE TIMING
Petrol Diesel
TU DV
1354
JP JP4 TD
Page 59
57
CHECKING AND SETTING THE VALVE TIMING
Engines : HFX - KFV - NFU
B1BP2M7C B1BP2M9CB1BP2M8C
Tools. [1] Engine flywheel peg : 4507-T.A [2] Camshaft pulley peg : 4507-T.B [3a] Camshaft peg : 4533-TA.C1 [3b] Camshaft peg : 4533-TA.C2 [4] Dynamic tensioner roller pin : 4200-T.H [5] Belt retaining pin : 4533-T.AD [6] Pliers for removing plastic pins : 7504-T.
Checking the valve timing.
Raise and support the front RH side of the vehicle. Disconnect the battery positive terminal. Engage 5th gear. Remove the oil filter (1).
HFX - KFV engine
Remove : The timing top casing (2). Turn the wheel to rotate the engine (normal direction of rotation). Peg the camshaft pulley, using tool [2].
ENGINE
Page 60
58
CHECKING AND SETTING THE VALVE TIMING
Engine : NFU
B1BP2MAC
Checking the timing (continued)
Engine: NFU
Place a jack under the engine, peg the engine. Remove:
- The engine support (4) complete.
- The timing casing (3).
- The sparking plugs (eases engine rotation).
Turn the wheel to rotate the engine (normal direction of rotation). Position the pegs [3a] and [3b]. Peg the flywheel, using tool [1]. If the setting is not correct, recommence the operation. Remove the tools [1], [2], [3a] and [3b]. Complete the refitting.
B1BP2MBC
ENGINE
B1EP18MC
Page 61
59
CHECKING AND SETTING THE VALVE TIMING
Engines : HFX - KFV
B1BP2MBCB1BP2M9C B1BP2MDC
Setting the timing Preliminary operation.
Lift and support the vehicle, wheels hanging. Disconnect the battery. Remove:
- The front RH wheel.
- The splash-shield, using tool [6]
- The accessories belt (See corresponding operation).
- The crankshaft pulley.
- The oil filter. Place a jack under the engine, peg the engine.
Removing. HFX - KFV engine
Turn the engine by means of screw (1). (normal direction of rotation). Remove the timing casings. Peg the camshaft pinion, using tool [2]. Peg the flywheel, using tool [1]. Remove:
- The fixing screws (2).
- The upper engine support (3).
ENGINE
B1BP2MCC
Page 62
60
CHECKING AND SETTING THE VALVE TIMING
Engines : HFX - KFV
B1BP2MEC B1EP18NC
Setting the timing (continued)
HFX - KFV engines
Slacken the screws (4) without removing them.
Remove the bottom engine support assembly (5), and the fixing screws (4).
Slacken the nut (6).
Completely detension the belt by acting on the tensioner roller (7).
Remove the timing belt.
IMPERATIVE : Check that the tensioner roller turns freely (no tight spot).
ENGINE
Page 63
61
CHECKING AND SETTING THE VALVE TIMING
Engine : NFU
B1BP2MBC
NFU engine.
Setting the timing (continued)
Remove:
The bottom plastic casing.
The engine support (9).
The middle support.
The timing cover (8);
Peg the flywheel, using tool [1].
Position the tools [3a] and [3b].
ENGINE
B1BP2MFC B1EP18MC
Page 64
62
CHECKING AND SETTING THE VALVE TIMING
Engine : NFU
B1EP18PC
Setting the timing (continued)
NFU engine.
Slacken the tensioer roller.
Turn the tensioner roller so as to be able to position the tool [4], with the aid of an Allen key placed at «a».
Turn the tensioner roller towards the right to bring it to the index «c» in position «b».
Peg the tensioner roller in this position in order to slacken the timing belt to the maximum.
IMPERATIVE : Never make the dynamic tensioner roller turn by a complete rotation.
Remove the timing belt (8).
Check that the rollers (9) and (10) turn freely (no tight spot).
ENGINE
B1EP18QC
Page 65
63
CHECKING AND SETTING THE VALVE TIMING
Engines : HFX - KFV
B1EP18QC
Setting the timing (continued)
HFX - KFV engines
Refit.
WARNING: Respect the direction of fitting of the belt: (the arrows «d» indicate the direction of rotation of
the crankshaft).
Refit the timing belt.
Position the timing belt, belt «e» well tensioned, in the following order: Crankshaft pinion, hold the belt using tool [5]. Camshaft pulley. Coolant pump pulley. Tensioner roller. Remove the pegs [1] and [2].
ENGINE
Page 66
64
CHECKING AND SETTING THE VALVE TIMING
Engines : KFX - KFV - NFU
Setting the timing (continued) HFX - KFV engines Refitting. NOTE : Check that the pegs [1] and [2] are in place. WARNING: Respect the direction of fitting of the timing belt, the arrows «d» indicate the direction of rotation
of the crankshaft. Refit the timing belt. Position the timing belt, belt «e» well tensioned, in the following order: Crankshaft pinion, hold the belt using tool [5].
- Camshaft pulley.
- Coolant pump pulley.
- Tensioner roller. Remove the tools [1], [2].
NFU engine.
Fit the timing belt in position in the following order:
- Inlet camshaft pulley.
- Exhaust camshaft pulley.
- Guide roller.
- Crankshaft pulley. Position tool [5].
- Coolant pump pulley.
- Dynamic tensioner roller. Remove the tools [1], [3] and [5].
ENGINE
B1EP18RC
Page 67
65
CHECKING AND SETTING THE VALVE TIMING
Engines : KFX - KFV - NFU
B1EP18SD
Timing belt overtensioned:
A: Engine HFX - KFV. B : Engine NFU
Turn the tensioner roller (7) with the aid of a hexagonal spanner at «a».
Bring the index «c» to position «f», to tension the belt to the maximum of the interval indicated. Hold the tensioner roller (7), using tool [4].
Tighten the fixing nut of the tensioner roller, tightening to 1 ± 0,1 m.daN
Turn the crankshaft by 4 rotations (normal direction of rotation).
IMPERATIVE : Never make the crankshaft rotate backwards.
Make sure that the timing is correctly set by refitting the tools [1], [2] and [3]. Remove the tools [1], [2] and [3].
ENGINE
Page 68
66
CHECKING AND SETTING THE VALVE TIMING
Engines : HFX - KFV - NFU
B1EP18TD
Adjusting the fitting tension of the timing belt
A:Engine HFX - KFV. B : Engine NFU
Slacken the nut while maintaining the position of the tensioner roller, with the aid of a hexagonal spanner at «a». Next bring the index «c» to its adjusting position «a». The index «c» should not go beyond the notch «g».
WARNING: The index «c» must not go beyond the notch «g». If it should do this, restart the timing belt tensioning operation.
Hold the tensioner roller (7) in this position, with the aid of a hexagonal spanner. Tighten the tensioner roller fixing nut to :
2 ± 0.2 m.daN. (HFX - KFV engines)
2.2 ± 0.2 m.daN. (NFU engines) IMPERATIVE : The tensioner roller must not rotate during the tightening of its fixing. If it does, restart the timing belt tensioning operation.
Complete the refitting.
ENGINE
Page 69
67
CHECKING AND SETTING THE VALVE TIMING
Engine : 8HX
B1BP2LXC
Tools. [1] Pliers for removing plastic pegs : 7504-T. [2] Lever for detensioning the dynamic tensioner roller : (-).0194.E [3] Engine flywheel setting peg : (-).0194.C [4] Camshaft setting peg : (-).0194.B. [5] Crankshaft and high pressure pump setting peg : (-).0194.A. Preliminary operations.
Remove:
- The front RH wheel.
- The front RH splash-shield, using tool [1].
- The clips of the electrical harness on the upper timing cover.
- The accessories belt, using tool [2] (see corresponding operation).
Check ing the setting.
Disconnect the battery negative cable. Remove the upper timing cover (1). Rotate the engine using the screw (2) of the crankshaft pulley.
NOTE : The locking hole is located under the crankshaft bearing cap cover. Undo the screw (2). Detension the auxiliary drive belt dynamic tensioner roller, using tool [2].
ENGINE
Page 70
68
CHECKING AND SETTING THE VALVE TIMING
Engine : 8HX
B1EP18EC
Checking the setting (continued)
Remove:
- the accessories drive belt.
- the accessories drive pulley.
- the lower timing cover (3).
IMPERATIVE : The magnetic track should show no signs of damage and should not be approached by any other source of magnetism.
Reposition the screw (2). Remove tool [3]. Rotate the engine by means of the crankshaft pinion screw (2) (clockwise), to bring it to the pegging position. Position the tool [4]. Peg the crankshaft pinion (1), using tool [5]. Peg the high pressure pump pinion, using tool [5] NOTE: Index «a» of the roller tensioner must be centred within the area «b». Check the correct positioning of index «a». Remove tools [4] and [5]. Rotate the engine ten times. Fit the tools [4] and [5]. If pegging is not possible, carry out the operation to remove/refit the timing belt. (See corresponding operation).
B1JP03SC
B1EP18DC
B1EP18FC
ENGINE
Page 71
69
CHECKING AND SETTING THE VALVE TIMING
Engine : 8HX
B1EP18GC
Setting the timing.
Remove the upper timing cover (1). Rotate the engine by means of the crankshaft screw (2). NOTE : The pegging hole is located under the crankshaft bearing cap cover. Peg the engine flywheel, using tool [3]. Remove the lower timing cover (3). Uncouple the exhaust line from the manifold.
IMPERATIVE : Uncouple the exhaust line in order to avoid damaging the front flexible pipe. Twisting, pulling and bending the front flexible pipe reduces its life.
Remove:
- The engine speed sensor (6).
- The belt retaining stop (5).
- The screw (2).
- The crankshaft pinion (4) (with its magnetic track «a»).
IMPERATIVE : The magnetic track should show no signs of damage and should not be approached by any other source of magnetism. Should this not be adhered to, it is essential to replace the crankshaft pinion. Refit the screw (2).
ENGINE
B1BP2LXC
Page 72
70
CHECKING AND SETTING THE VALVE TIMING
Engine : 8HX
Setting the timing (continued).
Remove the tool [3].
Rotate the engine by means of the crankshaft pinion screw (2) (clockwise), to bring it to the pegging position.
Peg the camshaft pulley, using tool [4].
Peg :
- The crankshaft pinion (6), using tool [5].
- The high pressure pump pinion, using tool [5]. Support the engine with the aid of a roller jack equipped with a chock.
Remove:
- The RH engine support (7).
- The intermediate engine support (right hand side) (8).
B1JP03SC B1EP18DC B1EP195C B1BP2LYC
ENGINE
Page 73
71
CHECKING AND SETTING THE VALVE TIMING
Engine : 8HX
B1EP18HC
Setting the timing (continued).
Hold the tensioner roller, using a hexagonal spanner at «b». Slacken the screw (9). Remove the timing belt (10).
Refitting. IMPERATIVE : Check that both the tensioner roller and the fixed roller turn freely (no tight spots). If this is not the case, replace the rollers. Fitting of the pulleys.
- Camshaft pulley : Tighten to 4,3 ± 0,4 m.daN.
- Fuel high pressure pump pulley : Tighten to 5 ± 0,5 m.daN.
The crankshaft pinion is located without a screw at the end of the crankshaft. Fitting of the rollers. IMPERATIVE : Check that the tensioner roller turns freely (no tight spot). Otherwise, replace the rollers.
- Guide roller : Tighten to 4,5 ± 0,4 m.daN
- Tensioner roller : Pre-tighten to 0,1 m.daN
Check the condition of the seals at the camshaft and at the crankshaft pinion.
ENGINE
Page 74
72
CHECKING AND SETTING THE VALVE TIMING
Engine : 8HX
B1EP18JD
Setting the timing (continued).
NOTE : Screw (9) slackened.
Position the timing belt (10) observing the following sequence:
Crankshaft pinion (4).
Guide roller (12).
Camshaft pulley (11), (check that the belt is held correctly against the roller).
Coolant pump pinion (13).
Fuel high pressure pump pulley (15).
Tensioner roller (14).
ENGINE
Page 75
73
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : 8HX
B1EP18KC
Setting the timing (continued).
Turn the tensioner roller to the right to bring the index «c» to position «d», using a hexagonal spanner. Tighten the screw (9) of the tensioner roller, tighten to 3 ± 0,3 m.daN. Remove the tools [4] and [5].
Rotate the engine ten times (check that the timing pinion is correctly up against the crankshaft).
Check: The pegging of the camshaft. The crankshaft pinion. The fuel high pressure pump pinion (15). The correct positioning of the index of the dynamic tensioner.
If these are not correct, repeat the operation to position the timing belt.
Refit: The engine speed sensor (6). The belt retaining stop (5), tighten to 0,7 m.daN.
Page 76
74
CHECKING AND SETTING THE VALVE TIMING
Engine : 8HX
B1EP18LC B1BP2LZC
Setting the timing (continued).
Refit:
The intermediate RH engine support, tighten the screws (16) to 5,5 ± 0,5 m.daN. The RH engine support, tighten the screws (17) to 4,5 ± 0,4 m.daN. The bottom timing cover (3).
Immobilise the engine flywheel, using tool [3]. Remove the screw (2). Refit the accessories drive pulley and tighten to:
Pre-tighten to : 3 ± 0,3 m.daN. Angular tighten to : 180° ± 1,8°
Remove tool [3] Refit: The top cover (1). The accessories belt (see corresponding operation). The exhaust line (see corresponding operation). The front RH splash-shield. The front RH wheel.
ENGINE
Page 77
75
CHECKING AND SETTING THE VALVE TIMING
Engine : 8HY
B1BP2N0C
Tools.
[1] Engine flywheel peg Ø 12 mm : (-).0194-C. [2] Camshaft pulley peg Ø 8 mm : (-).0194-B. [3] Crankshaft pulley peg Ø 5 mm : (-).0194-A.
Preliminary operations.
Remove:
- The front RH wheel.
- The front RH splash-shield.
- The accessories belt (see corresponding operation). Uncouple:
- The supply unions (1).
- The air/air heat exchanger inlet/outlet pipes (3).
- The exhaust line (at the flexible pipe). Disconnect the connector (2). Support the engine by means of a roller jack equipped with a chock. Remove the engine supports (4) and (5).
ENGINE
Page 78
76
CHECKING AND SETTING THE VALVE TIMING
Engine : 8HY
B1BP2N1C B1BP2N2C
Checks.
Rotate the engine to engage it (normal direction of rotation). Immobilise the engine flywheel at «a», using tool [1]. Move aside the harness (6).
Remove:
- The engine support (7).
- The screw (8).
- The pulley (9).
- The lower timing cover (10).
- The upper timing cover (11).
- The tool [1].
ENGINE
Page 79
77
CHECKING AND SETTING THE VALVE TIMING
Engine : 8HY
B1EP18YD
Checks (continued).
Refit the screw (8). Rotate the crankshaft six times (clockwise).
IMPERATIVE : Never rotate the engine backwards.
Peg :
- The camshaft, using tool [2]. (Oil the pegs.)
- The fuel high pressure pump pulley (14), using tool [3] at «c».
WARNING: The magnetic track should show no signs of damage and should not be approached by any source of magnetism.
Peg the crankshaft at «b», using tool [3].
IMPERATIVE: Should it be impossible to peg the camshaft, check that the off­set between the hole in the camshaft pinion and the pegging hole is not greater than 1 mm. Otherwise repeat the operation to position the timing belt. (See corresponding operation).
ENGINE
Page 80
78
CHECKING AND SETTING THE VALVE TIMING
Engine : 8HY
B1EP18ZC
Checks (continued). NOTE : The index «e» of the dynamic tensioner roller should be centred within the area «d».
Check the correct positioning of the index «e». If it is not correct, repeat the operation to tension the timing belt (see corresponding operation).
Refitting.
Refit the tool [1] at «a». Remove the screw (8). Refit:
- The upper timing cover (11).
- The lower timing cover (10).
- The accessories drive pulley (9).
- The screw (8).
Tightening torque:
- Screw (8) : Pre-tighten to : 3 ± 0,3 m.daN. Angular tightening : 180° ± 5°.
Remove the tool [1].
ENGINE
Page 81
79
CHECKING AND SETTING THE VALVE TIMING
Engine : 8HY
B1BP2N0C
Checks (continued).
Refit :
- The engine support (7), tighten to 1,5 ± 0,4 m.daN.
- The engine support (4), tighten to 6,1 ± 0,6 m.daN.
- The engine support (5), tighten to 6 ± 0,6 m.daN.
- The electrical harness (6).
Couple:
- The exhaust line, tighten the collar to : 2,5 ± 0,3 m daN
- The fuel supply unions (1).
- The air/air heat exchanger inlet/outlet pipes (3). Connect the connector (2).
Refit :
- The accessories belt (see corresponding operation).
- The front RH splash-shield (see corresponding operation).
- The front RH road wheel, tighten to 9 ± 1 m.daN. Reconnect the battery.
ENGINE
Page 82
80
CHECKING AND SETTING THE VALVE TIMING
Engine : 8HY
B1EP18VD
Setting the timing.
Perform the preliminary operations for checking the timing up to removing tool [1] at «a» for immobiling the engine flywheel. Refit screw (8). Rotate the crankshaft to bring the camshaft towards its pegging point. Peg the camshaft, using tool [2]. (Oil the pegs).
WARNING: Do not press or damage the track which is the target for the engine speed sensor (14).
Peg the crankshaft at «b», using tool [3]. Remove:
- The timing protector (13).
- The engine speed sensor (14). Slacken the screw (12) of the tensioner roller, keeping it slack with the aid of a hexagonal spanner at «c». Detension the belt by pivoting the tensioner roller (clockwise). Remove the timing belt, commencing with the coolant pump pinion. Peg the pulley (15), using a 5 mm diameter peg at «d».
ENGINE
Page 83
81
CHECKING AND SETTING THE VALVE TIMING
Engine : 8HY
B1EP18WD
Setting the timing (continued).
Checking the setting.
IMPERATIVE : Just prior to refitting, carry out the following tests:
Check that:
- the rollers and the coolant pump operate freely (no play and no tight spot).
- there are no traces of oil (from the crankshaft and camshaft sealing rings).
- there is no leak of coolant fluid (from the coolant pump).
- the target track of the engine speed sensor (14) is not damaged or scratched. (If necessary replace the defective components).
Refitting
Fit the timing belt on the crankshaft pinion. Position the belt on the guide roller, with the belt well tensioned. Refit:
- The timing protector (13).
- The sensor (14).
ENGINE
Page 84
82
CHECKING AND SETTING THE VALVE TIMING
Engine : 8HY
B1EP18XC
Setting the timing (continued).
Checks (continued).
Reposition the timing belt, belt at «e» well tensioned, in the following order:
- Guide roller (17).
- Camshaft pulley (16).
- Fuel high pressure pump pulley (15).
- Coolant pump pinion (18).
- Tensioner roller (19). Remove the 5 mm diameter peg at «d».
Adjusting the fitting tension of the belt.
Action the tensioner roller (19) to align the marks «f» and «g» , avoiding detensioning the timing belt, with the aid of a male hexagonal spanner, at «c». If this is not successful, repeat the operation to tension the belt. Hold the tensioner roller in position (19). Tighten the tensioner roller, tightening to 3,7 ± 0,3 m.daN. Check the position of the tensioner roller (the alignment of the marks «f» and «g» should be correct). Remove tools [2] and [3]. Turn the crankshaft six rotations (clockwise).
ENGINE
Page 85
83
CHECKING AND SETTING THE VALVE TIMING
Engine : 8HY
B1EP18XC
Adjusting the timing belt tension (continued).
IMPERATIVE : Never rotate the engine backwards.
WARNING : Do not touch or damage the track of the target of the engine speed sensor (14).
Peg the crankshaft, using tool [3]. Check the position of the tensioner roller (the alignment of the marks «f» and «g» should be correct). If this is not the case, repeat the operation to tension the belt. Peg the camshaft pulley, using tool [2].
IMPERATIVE : Should it be impossible to peg the camshaft, check that the offset between the camshaft hole and the pegging hole is not more than 1 mm. If the offset is too great, repeat the operation.
Remove the pegs [2] and [3]. Refit tool [1] at «a». Remove the screw (8).
Complete the refitting.
ENGINE
Page 86
84
EXHAUST SPECIFICATIONS
Engines: HFX - KFV (Depollution L4)
B1JP03TD
ENGINE
«a» Cutting zone
Page 87
85
EXHAUST SPECIFICATIONS
Engines: HFX - KFV (Depollution IFL5)
B1JP04RD
«a» Cutting zone
ENGINE
Page 88
86
EXHAUST SPECIFICATIONS
Engine: NFU (Depollution IFL5)
B1JP04TD
«a» Cutting zone
ENGINE
Page 89
87
EXHAUST SPECIFICATIONS
Engine: HFX (Depollution L4 and IFL5)
(1) (2) (3) (4) (5) (6)
(1) (2) (3) (4) (5) (6)
(1)
(2)
(3) (4)
(5)
Engine type
Upstream
oxygen sensor
Tightening (m.daN)
Tightening (m.daN)
4.7 ± 0.5 TR PSA K179
TR PSA K208
TR PSA K181
4.7 ± 0.5
4.7 ± 0.5
4.7 ± 0.5
PSA 4173
PSA 4174
PSA 4176
PSA 4175
PSA 4175
PSA 96 362 494 80
PSA 96 362 494 80
0.8 ± 0.2
0.8 ± 0.2
HFX
KFV
NFU
Engine: KFV (Depollution L4 and IFL5)
Catalytic
converter
Downstream
oxygen sensor
Front silencer Rear silencer Air to exhaust injection valve
Upstream
oxygen sensor
Catalytic
converter
Downstream
oxygen sensor
Front silencer Rear silencer Air to exhaust injection valve
Engine type
Tightening (m.daN) Tightening (m.daN)
4.7 ± 0.5 Engine : NFU (Depollution IFL5)
Engine type
ENGINE
Tightening (m.daN)
Tightening (m.daN)
Upstream
oxygen sensor
Catalytic converter
Downstream oxygen
sensor
Front silencer
Rear silencer
Tightening (m.daN) Tightening (m.daN)
4.7 ± 0.5
Page 90
88
EXHAUST SPECIFICATIONS
Engine : 8HX
ENGINE
«a» Flexible pipe
«b» Cutting zone (marked by burrs)
«c» Silencer fixing strap
B1JP03PD
Page 91
89
EXHAUST SPECIFICATIONS
Engine : 8HX
8HX
TR PSA K278
Tightening (m.daN) 2.5 ± 0.3 Tightening (m.daN) 2.5 ± 0.3 Tightening (m.daN) 2.5 ± 0.3
Engine types
Catalytic converter
(1)
Strap
(2)
Intermediate pipe
(3)
Rear silencer
(4)
PSA 4177
ENGINE
Page 92
90
HFX KFV NFU 8HX
7 litres 5.7 Litres
16 dm
3
1.4 bar 1.4 bar
89°C Start of opening 101°C Opening complete 83° C
100W (without aircon) 300W (with aircon) 1 x 300 W
97° C
115 °C
118°C
105°C 6 minutes
COOLING SYSTEM SPECIFICATIONS
Engines : HFX - KFV - NFU - 8HX
Engine type
Capacity
Radiator surface
Pressurisation
Opening of thermostatic regulator
Cooling fan
1st speed
2nd speed
Aircon cut-off
Warning
Post-cooling
1.4i. 1.6i 16V 1.4 HDi1.1i
Temperature sensor : Tighten to 1,7 ± 0,4 m.daN.
ENGINE
Page 93
91
COOLING SYSTEM SPECIFICATIONS
Engines : HFX - KFV - NFU
(1) Venting chamber
(2) Coolant pump
(3) Bleed screw of heater matrix
B1GP0AXP
ENGINE
Page 94
92
ENGINE
COOLING SYSTEM SPECIFICATIONS
Engine : 8HX
(1) Bleed screw (with or without aircon)
B1GP09MP
Page 95
93
Petrol
Diesel
OIL FILTERS
TU
1
JP
1.1i
HFX KFV NFU
X
FILTRAUTO
XX
1.4i 1.6i 16V
35
JP4
DV
TD
1.4 HDi
8HX
X
MALHEX
4
ENGINE
Page 96
94
CHECKING THE OIL PRESSURE
Engine type Temperature (°C) Pressure (Bars) Rpm
Engine type
Diesel engines
1.1i
HFX KFV NFU
90°C
3
2000
1.4i
1.6i 16V
1.4 HDi 8HX
90°C > 1.3 1000
Petrol engines
Temperature (°C) Pressure (Bars)
Rpm
Tools :
Pressure gauge : 2279-T.Bis Toolkit 4103-T. Flexible pipe Engine oil pressure take-off union (TU engine) : 7001-T Toolkit 4103-T. Oil pressure take-off union (DV engine) : 9780-80-T
NOTE : Tightening of the oil pressure switch 2 ± 0,2. (New seal). IMPERATIVE : Respect the safety and cleanliness requirements.
ENGINE
Page 97
95
VALVE CLEARANCES
The valve clearances should be checked with the engine cold.
Inlet
HFX - KFV
NFU
8HX
0.20 mm ± 0.05
Exhaust
0.40 mm ± 0.05
1 mm ± 0.05
Hydraulic adjustment
1 mm ± 0.05
Rocking
Adjust
1 1
3 3
4 4
2 2
4 4
2 2
1 1
3 3
Inlet
Admission
Rocking
Valves
fully
open
Adjust
1
3
4
2
3 4
4 2
2 1
1 3
Fully open (Exhaust)
POSSIBLE METHODS
On engines: 4 cylinders in line (1-3-4-2 )
Engines without hydraulic adjustment : the clearance (J) should be checked opposite the cam.
B1DP13QC
ENGINE
Page 98
96
FILLING AND BLEEDING THE COOLING CIRCUIT
HFX-KFV-NFU
8HX
Tools [1] Filling cylinder : 4520-T [2] Adaptor for filling cylinder : 4222-T. [3] Pliers for removing-refitting elastic clips : 9029-T
Draining.
Perform the operation with the engine cold. Remove the air filter housing. Open the expansion chamber cap. Uncouple bottom hose (1), using tool [3] and bottom hose (2) of the radiator.
Open : The bleed screw on the coolant outlet housing. The bleed screw on the heater matrix. The cylinder block drain plug.
Allow the coolant to flow out. Before any refilling, rinse the cooling circuit with clean water. Couple the bottom hose (1) and (2).
B1BP2LUC B1GP0AQD
ENGINE
Page 99
97
ENGINE
FILLING AND BLEEDING THE COOLING CIRCUIT
Filling and bleeding.
Fit the filling cylinder [1], with the adaptor [2] on the filling aperture. Slowly fill the circuit with the coolant fluid. Reclose the bleed screws when the liquid starts to flow out continuously without air bubbles.
NOTE : The filling cylinder [1] should be filled to the «1 Litre» mark to purge the heater matrix correctly.
Refit the air filter housing. Start the engine. Maintain an engine speed of 1500 to 2000 rpm, until the end of the second cooling cycle. (Starting and stopping of the cooling fan). Keep the filling cylinder full to the «1 Litre» mark. Stop the engine after the second cooling cycle. Remove the filling cylinder [1] with the adaptor [2]. Refit the expansion chamber cap.
B1GP09KC
Page 100
IDLING - DEPOLLUTION
Vehicles Engine type
Emission
standard
L4
MAGNETTI MARELLI
48P
SAGEM S2000
BOSCH M 7.4.4.
850
< 0.5 > 9
HFX
KFW
NFU
1.1 i
1.4 i
1.6 i 16V
IF/L5
L4
IF/L5
L4
Make - Injection type
% Content
CO CO2
Idling speed
(± 50 rpm)
Manual
gearbox
Auto. gearbox: N
gear engaged
C2
98
INJECTION
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