Citroën ZX User Manual

THE

BOOK

Citroen ZX

Service and Repair Manual

Mark Coombs

Models covered

All Citroen ZX Hatchback models with petrol engines,

including special/limited editions 1360 cc, 1580 cc, 1761 cc, 1905 cc and 1998 cc (inc. 16-valve)

Covers most features of Estate models Also covers 1124 cc engine Does not cover Diesel engine models

Printed by J H Haynes & Co Ltd, Sparkford, Nr Yeovil,

in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ISBN 1 85960 149 9 British Library Cataloguing in Publication Data

A catalogue record for this book is available from the British Library.

Somerset BA22 7JJ, England Haynes Publishing

Sparkford, Nr Yeovil, Somerset BA22 7JJ, England

Haynes North America, Inc

861 Lawrence Drive, Newbury Park, California 91320, USA

Editions Haynes S.A.

147/149, rue Saint Honore, 75001 PARIS, France

Haynes Publishing Nordiska AB

Box 1504, 751 45 UPPSALA, Sweden

(1881-320-10X1)

Rage Bad 2004, 2005

Contents

LIVING WITH YOUR CITROEN ZX

Introduction Safety First! General dimensions and weights

MOT Test Checks

Checks carried out from the driver's seat Checks carried out with the vehicle on the ground Checks carried out with the vehicle raised Checks carried out on your vehicle's exhaust emission system

Roadside Repairs

Buying spare parts and vehicle identification numbers Page 0•11 Jacking, towing and wheel changing Booster battery (jump) starting Identifying leaks Radio/cassette unit anti-theft system - precaution Conversion factors

Page 0•4 Page 0•5 Page 0•6

Page 0•7 Page 0•8 Page 0•9 Page 0•10

Page 0•12 Page 0•14 Page 0•15 Page 0•15 Page 0•16

Routine Maintenance

Routine maintenance and servicing Lubricants, fluids and capacities Maintenance schedule

Weekly checks

Every 6000 miles or 6 months Every 12 000 miles or 12 months Every 18 000 miles or 18 months Every 24 000 miles or 2 years

Every 40 000 miles or 2 years

Every 48 000 miles Every 72 000 miles

Page 1•1 Page 1 •2 Page 1 •3 Page 1 •8 Page 1•11 Page 1•14 Page 1•20 Page 1•22 Page 1•23 Page 1•26 Page 1•26

REPAIRS & OVERHAUL

Engine and Associated Systems

TU series engine in-car repair procedures XU series engine in-car repair procedures

Engine removal and general engine overhaul procedures Cooling, heating and ventilation systems Fuel and exhaust systems - carburettor models Fuel and exhaust systems - single-point fuel injection models Fuel and exhaust systems - multi-point fuel injection models Emission control systems Engine electrical systems

Transmission

Clutch Manual transmission

Automatic transmission

Driveshafts

Contents

Page 2A•1 Page 2B•1 Page 2C•1 Page 3•1 Page 4A•1 Page 4B•1 Page 4C•1 Page 4D•1 Page 5•1

Page 6•1 Page 7A•1 Page 7B•1 Page 8•1

Brakes

Braking system

Suspension

Suspension and steering

Body Equipment

Bodywork and fittings

Electrical

Body electrical systems Wiring Diagrams

REFERENCE

Tools and Working Facilities General Repair Procedures Fault Finding Glossary of Technical Terms

Index

Page 9•1

Page 10•1

Page 11•1

Page 12•1 Page 12•19

Page REF• 1 Page REF• 4 Page REF• 5 Page REF•12

Page REF•16

0•4

Introduction

Introduction to the Citroen ZX

The Citroen ZX range was introduced to the UK in June 1991. Originally, the ZX was available with a choice of 1.1 litre (1124 cc),

1.4 litre (1360 cc), 1.6 litre (1580 cc) or 1.9 litre (1905 cc) engines. Not all engine sizes, however, were available in all markets (the

1.1 litre version was not available in the UK).

At first, only five-door Hatchback models

Citroen ZX 1.4 Reflex Plus 5-door

were available. All models have a five-speed manual transmission as standard; a fourspeed automatic transmission was offered as an option on 1.6 and 1.9 litre models.

All engines are derived from the wellproven TU series (1124 cc and 1360 cc) and XU series (1580 cc and 1905 cc models) engines, which have appeared in many

Citroen and Peugeot vehicles. The engines are of four-cylinder overhead camshaft design, mounted transversely and inclined to the rear, with the transmission mounted on

the left-hand side.

In late 1992, a three-door Hatchback variant was introduced. At the same time, three new "sports" models were also introduced, all of which were equipped with new engines. These new models were the

1.8 litre (1761 cc) Furio, the 2.0 litre (1998 cc 8-valve) Volcane, and the 2.0 litre (1998 cc 16-valve) 16-valve model. All of these new models are available in three-door form only.

All three of the new engines are again derived from the XU series engine.

On all models, fully-independent front suspension is fitted, with the components attached to a subframe assembly. The rear suspension is semi-independent, with torsion bars and trailing arms.

All models in the range are comprehensively-equipped, and anti-lock braking (ABS) and air conditioning systems are available as options on certain models (ABS is standard on the 2.0 litre 16-valve).

Provided that regular servicing is carried out in accordance with the manufacturer's recommendations, the Citroen ZX should prove reliable and very economical. The

engine compartment is well-designed, and most of the items requiring frequent attention are easily accessible.

Citroen ZX 2.0 16-valve

Acknowledgements

Thanks are due to Champion Spark Plug, who supplied the illustrations showing spark plug conditions. Certain other illustrations are the copyright of Citroen Cars Ltd, and are used with their permission. Thanks are also due to Sykes-Pickavant Limited, who provided some of the workshop tools, and to all those people at Sparkford who helped in the production of this manual.

Project vehicles

Various project vehicles were used in the preparation of this manual, and appear in many of the photographic sequences. These include a 1360 cc, 1580 cc, 1761 cc, 1905 cc, 1998 cc 8-valve and a 1998 cc 16-valve

Safety First! 0•5

Working on your car can be dangerous. This page shows just some of the potential risks and hazards, with the aim of creating a safety-conscious attitude.

General hazards

Scalding

• Don't remove the radiator or expansion

tank cap while the engine is hot.

• Engine oil, automatic transmission fluid or power steering fluid may also be dangerously hot if the engine has recently been running.

Burning

• Beware of burns from the exhaust system

and from any part of the engine. Brake discs

and drums can also be extremely hot immediately after use.

Crushing

• When working under or near a raised vehicle, always supplement the

jack with axle

stands, or use drive-on ramps.

Never venture

under a car which is only

supported by a jack.

• Take care if loosening or tightening high-

torque nuts when the vehicle is on stands.

Initial loosening and final tightening should be done with the wheels on the ground.

Fire

• Fuel is highly flammable; fuel vapour is explosive.

• Don't let fuel spill onto a hot engine.

• Do not smoke or allow naked lights (including pilot lights) anywhere near a vehicle being worked on. Also beware of creating sparks (electrically or by use of tools).

• Fuel vapour is heavier than air, so don't work on the fuel system with the vehicle over an inspection pit.

• Another cause of fire is an electrical overload or short-circuit. Take care when repairing or modifying the vehicle wiring.

• Keep a fire extinguisher handy, of a type suitable for use on fuel and electrical fires.

Electric shock

• Ignition HT voltage can be dangerous, especially to people with heart problems or a pacemaker. Don't work on or near the ignition system with the engine running or the ignition switched on.

• Mains voltage is also dangerous. Make sure that any mains-operated equipment is correctly earthed. Mains power points should be protected by a residual current device (RCD) circuit breaker.

Fume or gas intoxication

• Exhaust fumes are poisonous; they often contain carbon monoxide, which is rapidly fatal if inhaled. Never run the engine in a confined space such as a garage with the doors shut.

• Fuel vapour is also poisonous, as are the vapours from some cleaning solvents and paint thinners.

Poisonous or irritant substances

• Avoid skin contact with battery acid and with any fuel, fluid or lubricant, especially antifreeze, brake hydraulic fluid and Diesel fuel. Don't syphon them by mouth. If such a substance is swallowed or gets into the eyes, seek medical advice.

• Prolonged contact with used engine oil can cause skin cancer. Wear gloves or use a barrier cream if necessary. Change out of oilsoaked clothes and do not keep oily rags in your pocket.

• Air conditioning refrigerant forms a poisonous gas if exposed to a naked flame (including a cigarette). It can also cause skin burns on contact.

Asbestos

• Asbestos dust can cause cancer if inhaled or swallowed. Asbestos may be found in gaskets and in brake and clutch linings. When dealing with such components it is safest to assume that they contain asbestos.

Remember...

• Do use eye protection when using power

tools, and when working under the vehicle

• Do wear gloves or use barrier cream to protect your hands when necessary.

• Do get someone to check periodically that all is well when working alone on the vehicle,

• Do keep loose clothing and long hair well out of the way of moving mechanical parts.

• Do remove rings, wristwatch etc. before working on the vehicle - especially the electrical system.

• Do ensure that any lifting or lacking equipment has a safe working load rating adequate for the |ob.

Special hazards

Hydrofluoric acid

• This extremely corrosive acid is formed when certain types of synthetic rubber, found in some O-rings, oil seals, fuel hoses etc, are exposed to temperatures above 400°C. The rubber changes into a charred or sticky substance containing the acid. Once formed,

the acid remains dangerous for years. If it gets onto the skin, it may be necessary to amputate the limb concerned.

• When dealing with a vehicle which has suffered a fire, or with components salvaged from such a vehicle, wear protective gloves and discard them after use.

The battery

• Batteries contain sulphuric acid, which attacks clothing, eyes and skin. Take care when topping-up or carrying the battery.

• The hydrogen gas given off by the battery is

highly explosive. Never cause a spark or allow a naked light nearby. Be careful when connecting and disconnecting battery

chargers or jump leads.

Air bags

• Air bags can cause injury if they go off accidentally. Take care when removing the steering wheel and/or facia. Special storage

instructions may apply.

Diesel injection equipment

• Diesel injection pumps supply fuel at very

high pressure. Take care when working on

the fuel injectors and fuel pipes.

Warning: Never expose the hands, face or any other part of the body to injector spray; the

fuel can penetrate the skin with potentially

fatal results.

DON'T

• Don't attempt to lift a heavy component which may be beyond your capability - get

assistance.

• Don't rush to finish a job, or take unverified short cuts.

• Don't use ill-fitting tools which may slip and cause injury.

• Don't leave tools or parts lying around where someone can trip over them. Mop up oil and fuel spills at once.

• Don't allow children or pets to play in or near a vehicle being worked on.

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