PRIVATE CARS

2003
SAXO-C3-XSARA
XSARA PICASSO-BERLINGO
«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».

CAR 050014
Volume 1

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 PRESENTATION

THIS HANDBOOK summarises the specifications, adjustments, checks and special features of CITROEN private vehicles, not including UTILITY
vehicles for which there exists a separate handbook.

The handbook is divided into nine groups representing the main functions :

GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - ELECTRICAL -
AIR CONDITIONING.

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

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

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

- The correspondance tables for petrol and diesel engines.
- The general chapter.
For all the other chapters, see the Mechanics’ Handbook for UTILITY vehicles.

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 IMPORTANT

If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into account
when preparing future publications. For example :

– INSUFFICIENT INFORMATION
– SUPERFLUOUS INFORMATION
– NEED FOR MORE DETAILS

Please send your comments and suggestions to :

CITROEN U.K. Ltd.

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

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 XSARA 2, all types

Operation to reconnect the battery after a vehicle repair

ATTENTION

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

If the ECU has locked up :

- Switch off the ignition.

- Wait 1 minute.
- Switch the ignition back on, the ECU is unlocked.

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 IDENTIFICATION OF VEHICLES SAXO - All Types

1 Engine legislation type

2 RP organisation no.

3 Chassis stamp

GENERAL
4 Manufacturer’s name plate

5 01/02/99 # Label :
- Tyre pressures.
- RP organisation no.
- Paint code.
6 Paint code.

7 Gearbox ident. reference

E1AP07CD

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 SAXO - All Types IDENTIFICATION OF VEHICLES
Saxo petrol 3-door
1.1 i 1.4 i 1.6 i 1.6i 16V
Auto.
A-X-SX SX
Administration SX Exclusive
X-SX Exclusive Exclusive VTS VTS VTS VTS
Emission standard IFL5 L4 L4 L4 L4
GENERAL

Type code SO HFX1 SO HFXB SO KFWL S6 KFWB SO KFWB S6 NFTB N6 NFXB

Engine type HFX KFW NFT NFX
Cubic capacity (cc) 1124 1360 1587
Fiscal rating (hp) 4 6 5 5 8
Gearbox type MA/5 MB3 MA/5 MA/5
Gearbox ident. plate 20 CF 03 312 20 CF 12 20 CF 11 20 CN 05 20 CN 03

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 IDENTIFICATION OF VEHICLES SAXO - All Types
Saxo petrol 5-door
1.1i 1.4i
A-Administration Auto.
Driving school -x-SX
X-SX Exclusive SX-Exclusive

Emission standard IFL5 L4 L4

Type code S1 HFX1 S1 HFXB S1 KFWL S1 KFWB

GENERAL
Engine type HFX KFW
Cubic capacity (cc) 1124 1360
Fiscal rating (hp) 4 6 5
Gearbox type MA/5 MB3 MA/5
Gearbox ident. plate 20 CF 03 312 20 CF 12

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 SAXO - All Types IDENTIFICATION OF VEHICLES
Diesel Entreprise
3-door 5-door Petrol 3-door Diesel 3-door

1.5 D 1.1i 1.5 D

A-Administration A A
A- Administration Driving school Administration Administration
X-SX-VTS -Exclusive X-SX-Exclusive Poste-X-SX Poste-X-SX
GENERAL

Emission standard L4 L4
Type code SO VJXB S1 VJXB S3 HFXB S3 VJXB
Engine type VJX HFX VJX
Cubic capacity (cc) 1527 1124 1527
Fiscal rating (hp) 4 6 6
Gearbox type MA/5 MA/5 MA/5
Gearbox ident. plate 20 CF 02 20 CF 03 20 CF 02

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 IDENTIFICATION OF VEHICLES C3 - All Types

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.

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

D : Tyre pressures and tyre type.

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

E : Serial number on bodywork.

F : Gearbox ident. reference – Factory serial no.

G : Engine legislation type– Factory serial no.

E1AP09HD

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 C3 - All Types IDENTIFICATION OF VEHICLES
PETROL

1.1i

X-SX X
GENERAL

Emission standard L4 IFL5 L4/INF K’

Type code FC HFXB/T FR HFXB FN HFXB FC HFXB FN HFXC FC HFXC FC HFXB FC HFX5
/IF /IF /D
Engine type HFX
Cubic capacity (cc) 1124
Fiscal rating (hp) 4
Gearbox type MA/5N
Gearbox ident. plate 20 CF 14

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 IDENTIFICATION OF VEHICLES C3 - All Types
PETROL

1.4i

Auto. Auto. Auto.

GENERAL
SX – Exclusive
Emission standard L4 IFL5
Type code FC KFVE FN KFVB FN KFVE FC KFVC/IF FC KFVF/IF FN KFVC/IF
Engine type KFV
Cubic capacity (cc) 1360
Fiscal rating (hp) 5
Gearbox type AL4 MA/5N AL4 MA/5N AL4 MA/5N
20 CF 15 20 CF 15 20 CF 15
Gearbox ident. plate 20 TP 75 20 CF 16 (*) 20 TP 75 20 CF 16 (*) 20 TP 75 20 CF 16 (*)

(*) = Export.

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 C3 - All Types IDENTIFICATION OF VEHICLES
PETROL

1.4i 1.6i 16V

Auto.
GENERAL

SX – Exclusive SX – Exclusive
Emission standard IFL5 L4 L4/INF L4
Type code FN KFVF/IF FC KFVB FC KFVB/D FC KFVE/D FN NFUB FC NFUB
Engine type KFV NFU
Cubic capacity (cc) 1360 1587
Fiscal rating (hp) 5 6
Gearbox type AL4 MA/5N MA/5S
Gearbox ident. plate 20 TP 75 20 CF 15 20 CF 16 (*) 20 CN 40

(*) = Export.

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 IDENTIFICATION OF VEHICLES C3 - All Types
DIESEL

1.4 HDi

X - SX

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

(*) = Export.

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 C3 - All Types IDENTIFICATION OF VEHICLES
DIESEL

1.4 HDi 1.4 HDi 16V

S - SX SX - Exclusive
GENERAL

Emission standard L4
Type code FN 8HWK FC 8HWB FN 8HVB FC 8HVB
Engine type 8HW 8HV
Cubic capacity (cc) 1398
Fiscal rating (hp) 4 5
Gearbox type MA/50 BE4/5
Gearbox ident. plate 20 CN 33 20 CN 36 (*) 20 DM 25 20 DM 26

(*) = Export.

10

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 IDENTIFICATION OF VEHICLES C3 - All Types
DIESEL

1.4 HDi 16V

SX - Exclusive SX SX - Exclusive

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

11

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 XSARA - All Types IDENTIFICATION OF VEHICLES

A - Manufacturer’s name plate (Estate).

B - Chassis stamp, cold stamp.

C - Manufacturer’s name plate (Saloon).

GENERAL

D - Label :
(label affixed to the front pillar on driver’s side)
- Tyre pressures.
- RP organisation no.
- Paint code.
E - Serial number. (visible through the windscreen)

F - Engine legislation type.

Factory serial no.

G - Gearbox ident. reference.

Factory serial no.

E1AP08WD

12

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 IDENTIFICATION OF VEHICLES XSARA - All Types
Saloon petrol 3-door
1.4 i 1.6i 16V

Auto. Auto.

X-SX X-SX-VTR
VTR X-VTR VTS SX-VTR VTR-VTS VTR

Emission standard L4 IFL5 L4 IFL5

GENERAL
Type code NO KFWB NO KFW1/IF NO NFUB NO NFUN NO NFU1/IF NO NFU3/IF
Engine type KFW NFU
Cubic capacity (cc) 1360 1581
Fiscal rating (hp) 5 7
Gearbox type MA/5 MA/5 AL4 MA/5 AL4
Gearbox ident. plate 20 CF 13 20 CN 28 20 TP 49 20 CN 28 20 TP 49

13

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 XSARA - All Types IDENTIFICATION OF VEHICLES
Saloon petrol 3-door Saloon diesel 3-door
20i.16V 1.9 D 2.0 HDi
Auto. Auto.

X-SX X-SX-VTR SX-VTR

VTS VTR VTS VTS SX
Emission standard IFL5 L4 L4
GENERAL

Type code NO RFN1/IF NO RFNN/IF NO RFSB NO WJYB NO RHYB NO RHZB NO RHZN

Engine type RFN RFS WJY RHY RHZ
Cubic capacity (cc) 1998 1868 1997
Fiscal rating (hp) 8 11 5 6
Gearbox type BE4/5 AL4 BE3/5 BE4/5 AL4
20 DL 40 20 DL 41 20 DL 42 20 DM 10
Gearbox ident. plate 20 TP 47 20 TE 47 20 TP 48
20 DM 03 (1) 20 DM 05 (1) 20 DM 07 (1) 20 DM 11 (1)

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

14

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 IDENTIFICATION OF VEHICLES XSARA - All Types
Saloon diesel 3 door
1.4 HDi

Entreprise

Emission standard L4

GENERAL
Type code N0 8HZB N0 8HZB/T N3 8HZB
Engine type 8HZ
Cubic capacity (cc) 1398
Fiscal rating (hp) 4
Gearbox type MA/5
Gearbox ident. plate

15

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 XSARA - All Types IDENTIFICATION OF VEHICLES
Saloon 3-door versions
Petrol Diesel

1.4i 1.9 D 2.0 HDi

X X

Emission standard L4 L4
GENERAL

Type code NO KFWB/T (1) NO WJYB/T (1) NO RHYB/T (1)

Engine type KFW WJY RHY
Cubic capacity (cc) 1360 1868 1997
Fiscal rating (hp) 8 7 6
Gearbox type MA/5 BE4/5
Gearbox ident. plate 20 CF 13 20 DL 41 20 DL 42

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

16

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 IDENTIFICATION OF VEHICLES XSARA - All Types
Saloon petrol 5-door.
1.4i 1.6i 16V

Auto.

X-SX
X-SX SX Exclusive

GENERAL
Emission standard K’ L4 IFL5 K’ L4
Type code N1 KFWG N1 KFWB N1 KFW1/IF N1 NFUG N1 NFUU N1 NFUB
Engine type KFW NFU
Cubic capacity (cc) 1360 1587
Fiscal rating (hp) 5 7
Gearbox type MA/5 MA/5 AL4 MA/5
Gearbox ident. plate 20 CN 30 20 CF 13 20 CN 29 20 TP 49 20 CN 28

17

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 XSARA - All Types IDENTIFICATION OF VEHICLES
Saloons petrol 5-door
16i 16V 2.0i 16V

Auto. Auto. Auto.

SX X-SX SX
Exclusive Exclusive Exclusive Exclusive
GENERAL

Emission standard L4 IFL5 IFL5 L4

Type code N1 NFUN N1 NFU1/IF N1 NFU3/IF N1 RFN1/IF N1 RFNN
Engine type NFU RFN
Cubic capacity (cc) 1587 1998
Fiscal rating (hp) 7 11
Gearbox type AL4 MA/5 AL4 BE4/5 AL4
Gearbox ident. plate 20 TP 49 20 CN 28 20 TP 49 20 DL 40 20 DM 03 (1) 20 TP 47

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

18

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 IDENTIFICATION OF VEHICLES XSARA - All Types
Saloons diesel 5-door
1.9 D 2.0 HDi
Auto.

SX
X-SX X-SX-Exclusive SX-Exclusive Exclusive
Emission standard L4 L4

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

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

19

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 XSARA - All Types IDENTIFICATION OF VEHICLES
Saloons diesel 5-door
1.4 HDi

Entreprise

Emission standard L4
GENERAL

Type code N1 8HZB N1 8HZB/T

Engine type 8HZ
Cubic capacity (cc) 1398
Fiscal rating (hp) 4
Gearbox type MA/5
Gearbox ident. plate

20

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 IDENTIFICATION OF VEHICLES XSARA - All Types
Saloons diesel entreprise 5-door
1.9 D 2.0 HDi

X X

Emission standard L4 L4

GENERAL
Type code N1 WJYB/T (1) N RHYB N1 RHYB/T (1)
Engine type WJY RHY
Cubic capacity (cc) 1868 1997
Fiscal rating (hp) 7 5
Gearbox type BE4/5 BE4/5
Gearbox ident. plate 20 DL 41 20 DL 42

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

21

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 XSARA - All Types IDENTIFICATION OF VEHICLES
Petrol estate
1.4i 16. 16V
Auto. Auto.

X-SX SX X-SX SX
X-SX SX Eclusive Exclusive Exclusive Exclusive
Emission standard L4 IFL5 K’ L4 IFL5
GENERAL

Type code N2 KFWB KFW1/IF N2 NFUG N2 NFUB N2 NFUN N2 NFU1/IF N2 NFU3/IF

Engine type KFW NFU
Cubic capacity (cc) 1360 1587
Fiscal rating (hp) 5 7
Gearbox type MA/5 MA/5 AL4 MA/5 AL4
Gearbox ident. plate 20 CN 21 20 CN 29 20 CN 28 20 TP 49 20 CN 28 20 TP 49

22

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 IDENTIFICATION OF VEHICLES XSARA - All Types
Petrol estate Diesel estate
2.0i 16V 1.9 D

Auto.

Exclusive X - SX

Emission standard IFL5 L4 L4

GENERAL
Type code N2 RFN1/IF N2 RFNN N2 WJYB
Engine type RFN WJY
Cubic capacity (cc) 1998 1868
Fiscal rating (hp) 11 5
Gearbox type BE4/5 AL4 BE4/5
Gearbox ident. plate 20 DL 40 20 DM 03 (1) 20 DL 41 20 DM 05 (1)

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

23

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 XSARA - All Types IDENTIFICATION OF VEHICLES
Diesel estate
2.0 HDi

Auto.

SX
X-SX-Eclusive Exclusive

Emission standard L4 IFL5

GENERAL

Type code N2 RHYB N2 RHYB/IF N2 RHZN

Engine type RHY RHZ
Cubic capacity (cc) 1997
Fiscal rating (hp) 5 6
Gearbox type BE4/5 AL4
Gearbox ident. plate 20 DL 42 20 DM 07 (1) 20 DM 10 20 DM 11 (1) 20 TP 48

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

24

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 IDENTIFICATION OF VEHICLES XSARA - All Types
Diesel saloon and estate
1.4 HDi

X Entreprise

Emission standard L4

GENERAL
Type code N2 8HZB N2 8HZB/T N4 8HZB
Engine type 8HZ
Cubic capacity (cc) 1398
Fiscal rating (hp) 4
Gearbox type MA/5
Gearbox ident. plate

25

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 XSARA - All Types IDENTIFICATION OF VEHICLES
Estate petrol versions Estate diesel versions
1.4i 1.9 D 2.0 HDi

X X

Emission standard L4 L4
GENERAL

Type code N2 KFWB/T (1) N2 WJYB/T (1) N2 RHYB/T (1)

Engine type KFW WJY RHY
Cubic capacity (cc) 1360 1868 1997
Fiscal rating (hp) 8 7 6
Gearbox type MA/5 BE4/5 BE4/5
Gearbox ident. plate 20 CN 21 20 DL 41 20 DL 42

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

26

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 IDENTIFICATION OF VEHICLES XSARA PICASSO - All Types

A - Chassis stamp
(Cold stamp on bodywork)
B : Chassis no. reminder
(Label located at bottom of windscreen right hand side)
C : Manufacturer’s data plate.
(Located at bottom of RH central pillar)
D : Label :

GENERAL
Tyre pressures.
Tyre identification.
Spare wheel identification.
(Located on front LH door inner panel).
E : Label :
Factory code.
A-S / RP N°
Paint code.
(Located on fuse box cover)
F : Gearbox identification ref.
G : Engine legislation type.
Factory serial number.
E1AP088D

27

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 XSARA PICASSO - All Types IDENTIFICATION OF VEHICLES
Petrol Diesel
1.6i 1.8i 16 V 2.0i 16 V 2.0 HDi

Auto.

SX-Exclusive

Emission standard L4 IFL5 L4

GENERAL

Type code CH NFVB CH 6FZB CH 6FZC/IF CH RFNF/IF CH RHYB

Engine type NFV 6FZ RFN RHY
Cubic capacity (cc) 1587 1749 1998 1997
Fiscal rating (hp) 6 7 8 5
Gearbox type BE4/5/ J (*) BE4/5 V (*) AL4 BE4/5 L (*)
Gearbox ident. plate 20 DL 66 20 DL 68 20 TS 02 20 DL 65

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

28

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 IDENTIFICATION OF VEHICLES BERLINGO - All Types

11/2002 #

A Chassis stamp, cold stamp

B Manufacturer’s vehicle plate

C Label

GENERAL
RPO No.
Paint colour code
Tyre pressures

D Gearbox ident. reference – Factory serial no.

E Engine legislation type – Factory serial no.

E1AP0AMD

29

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 BERLINGO - All Types IDENTIFICATION OF VEHICLES
Berlingo petrol 5-seater 11/2002 #

1.1i 1.4i

X X X-SX- Multispace

Emission standard L4/W4 K’ L4/W4 IFL5

GENERAL

Type code GB VHFXB GJ K6D5G GJ KFWB GJ KFWC/IF

Engine type HFX KFW
Cubic capacity (cc) 1124 1360
Fiscal rating (hp) 5 6
Gearbox type MA/5S MA/5
Gearbox ident. plate 20 CD 43 20 CN 13

30

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 IDENTIFICATION OF VEHICLES BERLINGO - All Types
Berlingo petrol 5-seater 11/2002 #

1.4i 1.6i 16v

Dual fuel

Multispace X-SX- Multispace

Emission standard L4/W4 L4 IFL5

GENERAL
Type code GJ KFWB/GL (1) GJ KFWB/GN (2) GJ NFUB GJ NFUC/IF
Engine type KFW NFU
Cubic capacity (cc) 1360 1587
Fiscal rating (hp) 5 7
Gearbox type MA/5 BE4/5
Gearbox ident. plate 20 CN 13 20 DM 46

(1) GL = LPG = Liquefied Petroleum Gas, with ring-shaped tank.

(2) GN = CNG = Compressed Natural Gas, with cylindrical tank.

31

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 BERLINGO - All Types IDENTIFICATION OF VEHICLES
Berlingo diesel 5-seater 11/2002 #

1.9 D 2.0 HDi

X-SX-Multispace X-SX-Multispace

Emission standard L4/W4 L4/W4

GENERAL

Type code GJ WJYB GJ WJYB/PMF (1) MF RHYF

Engine type WJY RHY
Cubic capacity (cc) 1868 1997
Fiscal rating (hp) 5 6
Gearbox type BE4/5 BE4/5
Gearbox ident. plate 20 DM 48 20 DM 50

(1) /PMF = Multifunction roof.

32

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 ALL TYPES 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).

GENERAL
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.

33

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 SAXO - All Types CAPACITIES (in litres)
SAXO
Petrol Diesel
Ecological oil filter
capacity 0.15 litre.
1.1i 1.4i 1.6i 16V 1.6i 1.5D

Auto.
GENERAL

Engine type HFX KFW NFX NFT VJX

Engine with filter change 3 3.5 4.5
Between Min. and Max. 1.5 1.5 2
5-speed gearbox 2 2
Automatic gearbox 4.5
after drainage 2
Hydraulic or brake circuit With ABS = 0.45 - Without ABS = 0.36
Cooling system 6.1
Fuel tank capacity 45
ESSENTIAL : systematically check the oil level using the oil dipstick.

34

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 CAPACITIES (in litres) C3 - All Types
C3
Petrol Diesel
1.1i 1.4i 1.6i 16V 1.4 HDi 1.4 HDi 16V
Auto.

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

Drain by gravity : engine with filter change 2.9 3.75
Between min. And max. 1.5 1 2

GENERAL
Drain by suction : engine
3.1
with filter change
Between Min. and Max. 1.5 1
5-speed gearbox 2 2 1.9
Automatic gearbox
(1)
After oil change
0,7 Litre version with front calipers Ø 48 / rear drums
Braking circuit
0,8 Litre version with front calipers Ø 54 / rear discs
Cooling system 7 5.7 5.6
Fuel tank capacity 45
ESSENTIAL : systematically check the oil level using the oil dipstick.
(1) = The gearbox is lubricated for life. (For your information, the TOTAL capacity is 5,85 litres, after draining: 3 litres).

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 XSARA - All Types CAPACITIES (in litres)
XSARA
Petrol Diesel
Ecological oil filter
capacity 0.15 litre.
1.4i 1.6i 16V 2.0i 16V 1.4 HDi 1.9D 2.0 HDi
Auto. Auto. Auto.

Engine type KFW NFU RFN RFS 8HZ WJZ RHY RHZ
GENERAL

Engine with filter element 3 3.25 4.25 4 (*) 4.75 4.5-4.25 (1)
Between Min. and Max. 1.4 1.5 1.7 1 1 (*) 1.6 1.4
5-speed gearbox 2 1.9 1.9 2 1.8
Automatic gearbox 6 6 8.3
after drainage 3 3 5.3
Hydraulic or brake circuit With ABS = 0.50 - Without ABS = 0.55
7 8.5
Cooling system 5.7 9
6.5 (1) 11 (1)
Fuel tank capacity 54

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

36

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 CAPACITIES (in litres) XSARA PICASSO - All Types
XSARA PICASSO
Petrol Diesel
Ecological oil filter
capacity 0.15 litre
1.6i 1.8i 16 V 2.0i 16 V 2.0 HDi
Auto.

Engine type NFV 6FZ RFN RHY

GENERAL
Engine with filter change 3 4.25 4.5
Between Min. and Max. 1.5 1.7 1.4
5-speed gearbox 1.8 1.8
Automatic gearbox 6
- after drainage 3
Hydraulic or brake circuit 0.58 litres
Cooling system 5.8 (1) et (2) 6.5 (1) et (2) 11 (1) et (2)
Fuel tank capacity 55 60

(1) = With air conditioning

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

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 BERLINGO 2 - All Types CAPACITIES (in litres)
BERLINGO 2
Petrol Diesel
Ecological oil filter
capacity 0.15 litre

1.1i 1.4i 1.6i 16V 1.9 D 2.0 HDi

GENERAL

Engine type HFX KFW NFU WJY RHY

Engine with filter change 3 3.25 4.5
Between Min. and Max. 1.5 1.2 1.4
5-speed gearbox 2 1.8 1.8
Hydraulic or brake circuit With ABS = 0.45 - Without ABS = 0.36
Cooling system 8 9
Fuel tank capacity 55 60

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

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 LUBRICANTS - TOTAL recommended oils ALL TYPES
Evolutions (year 2003). Use of oil grade 10W 40.
It is possible to use semi-synthetic oil 7000 10W40 on HDi and HDi FAP
CITROËN C3 PLURIEL. vehicles.

Only petrol versions are available. WARNING : To avoid problems with starting from cold, use this oil as allo-
wed by the climatic conditions in the country concerned (see table).
Normal maintenance interval : 30 000 km (20 000 miles)
Severe maintenance interval : 20 000 km (12 000 miles) For more details see the oil usage table.

GENERAL
ESSENTIAL : For all vehicles with a 30 000 km (20 000 miles) main- New commercial designation for energy economy oil.
tenance interval, use exclusively TOTAL ACTIVA/QUARTZ 7000 or The oil TOTAL ACTIVA/QUARTZ 9000 5W30 becomes
9000 or any other oils offering identical specifications to these. TOTAL ACTIVA FUTUR 9000 (for France),
These oils offer specifications that are superior to those defined QUARTZ FUTURE 9000 5W30 (outside France).
by norms ACEA A3 OR API SJ/CF. The usage exclusions for this oil are the same as before :
Failing this, it is essential to adhere to the maintenance programmes
covering severe operating conditions. - XSARA VTS 2.0i 16V (XU10J4RS).
- RELAY 2.8 TDi; 2.8 HDi (SOFIM engine).
- HDi FAP vehicles.
- C3 1.6i 16V (DV4TED4).
- C8 2.2i (EW12J4)

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 ALL TYPES LUBRICANTS - TOTAL recommended oils

Engine oil norms.

Current norms.
GENERAL

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

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 LUBRICANTS - TOTAL recommended oils ALL TYPES
S.A.E. Norms - Table for selection of engine oil grade
Selection of engine oil grades recommended for climatic conditions in countries of distribution
Evolution of the norms as at 01/01/2003

ACEA 2003 norms

API norms
The meaning of the first letter has not changed, it still corresponds to
the type of engine :
The meaning of the first letter has not changed, it still corresponds to the
A : petrol and dual fuel petrol / LPG engines.
type of engine :
B : diesel engines.

GENERAL
The figure following the first letter corresponds to the type of oil: .
S : petrol and dual fuel petrol / LPG engines.
3 : high performance oils.
C : diesel engines.
4 : oils specifically for direct injection diesel engines.
5 : very high performance oils permitting lower fuel consumption
The second letter corresponds to the degree of evolution of the oil
Example :
(ascending order).
ACEA A3 : high performance oils specifically for petrol and dual fuel
petrol / LPG engines
Example : Norm SL is more severe than norm SJ, corresponding to a
ACEA A/B : blended oils giving very high performance for all engines,
higher level of performance.
also permitting better fuel economy, specifically for direct injection die-
sel engines
NOTE : From 01/01/2003 there is no longer any reference to the year
of creation of the norm, (Example : ACEA A3/B3 98 becomes ACEA
A3/B3.

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 ALL TYPES LUBRICANTS - TOTAL recommended oils
Recommendations.

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

CITROËN engines are lubricated at the factory with TOTAL oil of grade S.A.E.5W-30.
TOTAL oil of grade S.A.E.5W-30 allows improved fuel economies (approx 2.5%).

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

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

- SOFIM : RELAY 2.8 TDi and 2.8 HDi.
- HDi : With particle filter (FAP).
- DV4 TED4 : CITROËN C3 1.4 HDi 16V
- EW 12J4 : CITROËN C8 2.2i.

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

Denomination of TOTAL oils according to country of marketing :

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

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 LUBRICANTS - TOTAL recommended oils ALL TYPES
Recapitulation
Norms to be observed for engine oils (year 2003)
Year Types of engine concerned ACEA norms API norms
Petrol and dual fuel A3 or A5 5 (*) SJ or SL
2003 petrol / LPG engines
Diesel engines B3 or B5 (*) CF
(*) It is essential not to use engine oils respecting these norms for the following engine-types : XU10 J4RS , SOFIM 2.8 TDi

GENERAL
and SOFIM 2.8 HDi , HDi with particle filter (FAP), EW 12 J4, DV4 TED4.
Classes and grades of TOTAL recommended engine oils.
Oils marketed in each country are adapted to the local climatic conditions.
Blended oils for all engines (petrol, diesel and dual fuel petrol / LPG engines).
S.A.E. norms ACEA norms API norms
TOTAL ACTIVA 9000 A3 / B3
5W40
TOTAL QUARTZ 9000
SL / CF
TOTAL ACTIVA FUTUR 9000 (*)
5W30 A5 / B5
TOTAL QUARTZ FUTUR 9000 (*)
TOTAL ACTIVATRAC 10W40 A3 / B3 SJ / CF
(*) Blended oils for all engines, permitting fuel economy.

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 ALL TYPES LUBRICANTS - TOTAL recommended oils

Oils specifically for petrol and dual fuel petrol / LPG engines
S.A.E. norms ACEA norms API norms
TOTAL ACTIVA 7000
10W40
TOTAL QUARTZ 7000
TOTAL QUARTZ 9000 0W40 A3 SJ
GENERAL

TOTAL ACTIVA 7000

15W50
TOTAL QUARTZ 7000

Oils specifically for diesel engines

S.A.E. norms ACEA norms API norms
TOTAL ACTIVA DIESEL 7000
10W40
TOTAL QUARTZ DIESEL 7000 B3 CF
TOTAL ACTIVA DIESEL 7000 15W50

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 LUBRICANTS - TOTAL recommended oils ALL TYPES
Oil usage table

TOTAL ACTIVA QUARTZ

Engine types
Synthetic 9000 Semi-synthetic 7000
0W40 cold 15W50 hot
5W30 5W40 10W40
countries countries
XU10 J4RS (Xsara VTS 2.0i 16V) X X X X
Petrol

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

(*) = Particle filter

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 ALL TYPES LUBRICANTS - TOTAL recommended oils
Selection of TOTAL engine oils, to be used according to the climatic conditions in the country where the vehicle is marketed.
GENERAL

E4AP006D

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 LUBRICANTS - TOTAL recommended oils ALL TYPES
ENGINE OILS
FRANCE
Blended oils for all engines, supplied in bulk

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

TOTAL ACTIVA TOTAL ACTIVA DIESEL

Blended oils for all engines Oils specifically for petrol and Oils specifically for diesel
dual-fuel petrol / LPG engines engines

GENERAL
900 5W-40 7000 10 W-40
Metropolitan FRANCE 7000 10 W-40
9000 5W-30 (*) 9000 5W-40

New Caledonia
Guadeloupe
Saint-martin
Reunion
9000 5W-40 7000 15W-50 7000 15W-50
Martinique
Guyana
Tahiti
Mauritius
Mayotte
(*) = Blended oils for all engines, permitting fuel economy

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 ALL TYPES LUBRICANTS - TOTAL recommended oils
ENGINE OILS
EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL

Oils specifically for petrol and Oils specifically for diesel

Blended oils for all engines
dual-fuel petrol / LPG engines engines

7000 10W40
Germany
9000 0W40
GENERAL

Austria 7000 10W40

7000 10W40
Belgium
9000 0W40
9000 5W40 7000 10W40
Bosnia FUTURE 9000 5W30 (*) 9000 0W40 7000 10W40

Bulgaria 7000 10W40

7000 10W40
Cyprus
9000 15W40

Croatia 7000 10W40

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

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 LUBRICANTS - TOTAL recommended oils ALL TYPES
ENGINE OILS
EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL

Blended oils for all engines Oils specifically for petrol and Oils specifically for diesel
dual-fuel petrol / LPG engines engines

7000 10W40
Denmark 9000 0W40
7000 10W40

GENERAL
Spain 7000 15W40

Estonia
7000 10W40
9000 0W40
Finland 9000 5W40
FUTURE 9000 5W30 (*) 7000 10W40
Great Britain 7000 10W40

Greece 7000 10W40

7000 15W40
Holland 7000 10W40
9000 0W40
(*) = Blended oils for all engines, permitting fuel economy

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 ALL TYPES LUBRICANTS - TOTAL recommended oils
ENGINE OILS
EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL

Oils specifically for petrol and Oils specifically for diesel

Blended oils for all engines
dual-fuel petrol / LPG engines engines

7000 10W40
Hungary
9000 0W40
GENERAL

Italy

Ireland
7000 10W40

Iceland 9000 5W40

FUTURE 9000 5W30 (*) 7000 10W40
Latvia
7000 10W40
Lithuania 9000 0W40

Macedonia 7000 10W40

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

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 LUBRICANTS - TOTAL recommended oils ALL TYPES
ENGINE OILS
EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL

Blended oils for all engines Oils specifically for petrol and Oils specifically for diesel
dual-fuel petrol / LPG engines engines

7000 10W40
Malta
7000 15W50

GENERAL
Moldavia 7000 10W40

Norway 7000 10W40

9000 0W40
9000 5W40
Poland 7000 10W40
FUTURE 9000 5W30 (*)

Portugal 7000 10W40

Slovakia

Czech Republic 7000 10W40

9000 0W40
(*) = Blended oils for all engines, permitting fuel economy

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 ALL TYPES LUBRICANTS - TOTAL recommended oils
ENGINE OILS
EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL

Blended oils for all engines Oils specifically for petrol and Oils specifically for diesel
dual-fuel petrol / LPG engines engines

7000 10W40
Romania 7000 15W50
9000 0W40
GENERAL

Russia

7000 10W40
Slovenia 9000 0W40
9000 5W40
7000 10W40
FUTURE 9000 5W30 (*)
Sweden

Switzerland 7000 10W40

7000 10W40
Turkey 9000 15W50
9000 0W40
(*) = Blended oils for all engines, permitting fuel economy

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 LUBRICANTS - TOTAL recommended oils ALL TYPES
ENGINE OILS
EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL

Blended oils for all engines Oils specifically for petrol and Oils specifically for diesel
dual-fuel petrol / LPG engines engines

Ukraine
9000 5W40 7000 10W40
7000 10W40

GENERAL
FUTURE 9000 5W30 (*) 9000 0W40
Yugoslavia

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

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 ALL TYPES LUBRICANTS - TOTAL recommended oils
ENGINE OILS
OCEANIA TOTAL ACTIVA TOTAL ACTIVA DIESEL

Oils specifically for petrol and Oils specifically for diesel

Blended oils for all engines
dual-fuel petrol / LPG engines engines

Australia 9000 5W40

7000 10W40 7000 10W40
New Zealand FUTURE 9000 5W30
GENERAL

AFRICA TOTAL ACTIVA TOTAL ACTIVA DIESEL

Oils specifically for petrol and Oils specifically for diesel

Blended oils for all engines
dual-fuel petrol / LPG engines engines

Algeria, South Africa,

Ivory Coast, Egypt,
Gabon, Ghana, Kenya, 9000 5W40 7000 15W50 7000 10W40
Madagascar, Morocco,
Nigeria, Senegal, Tunisia

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 LUBRICANTS - TOTAL recommended oils ALL TYPES
ENGINE OILS
CENTRAL AND SOUTH AMERICA TOTAL ACTIVA TOTAL ACTIVA DIESEL

Oils specifically for petrol and Oils specifically for diesel

Blended oils for all engines
dual-fuel petrol / LPG engines engines

Argentina

GENERAL
Brazil

Chile
7000 10W50
Cuba 9000 5W40 7000 15W50 7000 10W40

Mexico

Paraguay

Uruguay

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 ALL TYPES LUBRICANTS - TOTAL recommended oils
ENGINE OILS
SOUTH-EAST ASIA TOTAL ACTIVA TOTAL ACTIVA DIESEL

Oils specifically for petrol and Oils specifically for diesel

Blended oils for all engines
dual-fuel petrol / LPG engines engines

7000 10W50
China 7000 15W50
GENERAL

9000 5W40
South Korea 7000 10W40
FUTURE 9000 5W30

Hong Kong
7000 15W50
India – Indonesia 9000 5W40 7000 10W40

Japan 9000 5W40 7000 10W40

FUTURE 9000 5W30 (*) 7000 15W50
Malaysia
9000 5W40 7000 15W50
Pakistan

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

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 LUBRICANTS - TOTAL recommended oils ALL TYPES
ENGINE OILS
SOUTH-EAST ASIA TOTAL ACTIVA TOTAL ACTIVA DIESEL

Oils specifically for petrol and Oils specifically for diesel

Blended oils for all engines
dual-fuel petrol / LPG engines engines

Philippines
7000 15W50

GENERAL
Singapore

7000 10W40
Taiwan 9000 5W40 7000 10W40
7000 15W50

Thailand
7000 15W50
Vietnam

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

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 ALL TYPES LUBRICANTS - TOTAL recommended oils
ENGINE OILS
MIDDLE EAST TOTAL ACTIVA TOTAL ACTIVA DIESEL

Blended oils for all engines Oils specifically for petrol and Oils specifically for diesel
dual-fuel petrol / LPG engines engines

Saudi Arabia – Bahrain

Dubai 7000 15W50
GENERAL

United Arab Emirates

9000 5W40 7000 10W40 7000 10W40

Iran
7000 15W50

Israel – Jordan – Kuwait – Lebanon

7000 15W50
Oman – Qatar – Syria – Yemen

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 LUBRICANTS - TOTAL recommended oils ALL TYPES
GEARBOX OILS

TOTAL TRANSMISSION BV
Manual gearbox and SensoDrive Norms S.A.E. : 75W80
Part No. : 9730 A2
TOTAL FLUIDE ATX
TOTAL FLUIDE AT 42
MB3 automatic gearbox

GENERAL
Special oil distributed by
All countries CITROËN
Part No. : 9730 A3
Special oil distributed by
4HP20 and AL4 autoactive
CITROËN
automatic gearboxes
Part No. : 9736 22
TOTAL TRANSMISSION X4
Transfer box and rear axle
Part No. : 9730 A4

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 ALL TYPES LUBRICANTS - TOTAL recommended oils
POWER STEERING OILS

All countries TOTAL FLUIDE ATX

Power steering TOTAL FLUIDE DAs

Very cold countries Special oil distributed by
CITROËN
Part No. : 9730 A1
GENERAL

ENGINE COOLANT FLUID

CITROËN Part No.

Pack
GLYSANTIN G33 REVKOGEL 2000
2 Litres 9979 70 9979 72

5 Litres 9979 71 9979 73

CITROËN fluid
All countries
Protection : - 35C° 20 Litres 9979 76 9979 74

210 Litres 9979 77 9979 75

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 LUBRICANTS - TOTAL recommended oils ALL TYPES
BRAKE FLUID
Synthetic brake fluid

Pack CITROËN Part No.

0.5 Litre 9979 05
All countries CITROËN fluid 1 Litre 9979 06
5 Litres 9979 07

GENERAL
HYDRAULIC CIRCUIT
All countries Norm Pack CITROËN Part No.
TOTAL FLUIDE LDS Orange 9979 69
TOTAL LHM PLUS ZCP 830095
Colour 1 Litre
TOTAL LHM PLUS Green
9979 20
Grand Froid

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

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

All countries TOTAL HYDRAURINCAGE

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 ALL TYPES LUBRICANTS - TOTAL recommended oils
SCREEN WASH FLUID

Pack CITROËN Part No.

Concentrated : 250 ml 9980 33 ZC 9875 953U 9980 56

All countries 1 Litre 9980 06 ZC 9875 784U

Fluid ready
for use
GENERAL

5 Litres 9980 05 ZC 9885 077U ZC 9875 279U

GREASE
General use
Norms NLGI
TOTAL MULTIS 2 2
All countries
TOTAL SMALL MECHANISMS

Note : NLGI = National Lubricating Grease Institute.

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 ENGINE OIL CONSUMPTION ALL TYPES

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:

GENERAL
- 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.

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 ENGINE

ALL TYPES ENGINE SPECIFICATIONS

Engines : HFX - KFW - NFT - NFV
Petrol
All Types

1.1i 1.4i 1.6i

Vehicle Saxo C3 Saxo Xsara Saxo Picasso

Emission standard L4/IFL5/L4INF K’ L4 K’/L4/IFL5 L4
Engine type HFX KFW NFT NFV
Cubic capacity (cc) 1124 1360 1587
Bore / Stroke 72/69 75/77 78.5/82
Compression ratio 10.5/1
Power ISO or EEC - KW - rpm 44.1-5500 55-5500 72-5700 70-5700
Power DIN (HP - rpm) 60-5500 75-5500 98-5700 95-5700
Torque ISO or EEC
(m.daN - rpm) 9.4-3500 9.4-3300 12-3400 12-2800 13.5-3500 13.5-3000

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 ENGINE
ENGINE SPECIFICATIONS ALL TYPES
Engines : NFX - NFU - 6FZ - RFN - RFS
Petrol
All Types

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

Vehicle Saxo C3/Xsara Picasso Xsara Picasso Xsara

Emission standard L4 K’/L4/IFL5 L4/IFL5 L4/IFL5 IFL5 L4
Engine type NFX NFU 6FZ RFN RFS
Cubic capacity (cc) 1587 1749 1197 1998
Bore / Stroke 78.5/82 82.7/81.4 85/88 86/86
Compression ratio 10.8/1 11/1 10.8/1
Power ISO or EEC - KW - rpm 87-6600 80-5800 85-5500 100-6000 120-6000
Power DIN (HP - rpm) 118-6600 109-5800 115-5500 136-6000 163-6000
Torque ISO or EEC
(m.daN - rpm) 14.5-5200 14.7-4000 16-4000 19-4100 19.3-5000

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 ENGINE

ALL TYPES ENGINE SPECIFICATIONS

Engines : VJX - 8HX - 8HW - 8HV - 8HY - 8HZ
Diesel
All Types

1.5D 1.4 HDi 1.4 16V HDi 1.4 HDi 2.0 HDi

Vehicle Saxo C3 Xsara Xsara-Picasso Xsara

Emission standard L4 L4/IFL5
Engine type VJX 8HX-8HW 8HV-8HY 8HZ RHY RHZ
Cubic capacity (cc) 1527 1398 1997
Bore / Stroke 77/82 73.5/82 85/88
Compression ratio 23/1 17.9/1 18.4/1 17.9/1 17.6/1
Power ISO or EEC - KW - rpm 42-5000 50-4000 66-4000 50-4000 66-4000 80-4000
Power DIN (HP - rpm) 57-5000 70-4000 90-4000 70-4000 90-4000 109-4000
Torque ISO or EEC
(m.daN - rpm) 9.5-2250 15-1750 20-1750 16-2000 20.5-1900 25-1750

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 ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) ALL TYPES
CYLINDER HEAD (mm)
Engine type HFX KFW KFV NFT NFV NFX NFU VJX

Maximum permissible bow 0.05

Gasket surface regrinding - 0.20
TIGHTENING TORQUES ( m.daN)
Crankshaft Pre-tightening 2 ± 0.2 2 ± 0.2
bearing screws Angular tightening 45° 50° ± 5°
Connecting
Tightening 3.8 ± 0.4
rod screws
Flywheel 6.5 ± 0.7
Tightening
screw
Crankshaft Pre-tightening 7 ± 0.7
Angular tightening 10 ± 1
pinion screw 45° ± 4°
Camshaft Pre-tightening 4 ± 0.4
8 ± 0.8
pulley screw Angular tightening 20° ± 2°
Camshaft hubs 8 ± 0.8
Camshaft
Tightening 1 ± 0.1 2.5 ± 0.2
hub screw

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 ENGINE

ALL TYPES SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

CYLINDER HEAD (mm)
Engine type 6FZ RFN RFS WJZ WJY RHY RHZ

Maximum permissible bow 0.05 0.03

Gasket surface regrinding - 0.30 - 0.20 - 0.40
TIGHTENING TORQUES ( m.daN)
Pre-tightening (1) Ø 11 : 1 ± 0.1 2 ± 0.1 2.5 ± 0.3
(2) Ø 6 : 1 ± 0.1
Slackening Ø 11 (only)
Crankshaft
bearing screws Tightening Ø 11 to 1 ± 0.1 then 8.5 ± 0.8 7 ± 0.7
Angular to 2 ± 0.1
tightening Ø 11 to 70° ± 5° 60° ± 6° 60° ± 6°
Tightening Ø 6 to 1 ± 0.1
Pre-tightening 2 ± 0.2
1 ± 0.1 4 ± 0.4
Slackening
Connecting 180° (1/2 turn)
Tightening
rod screws 2.3 ± 0.2 2.3 ± 0.2 2± 0.2
Angular
46° ± 5° 46° ±4.6° 70° ± 7° 70° ± 7°
tightening

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 ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) C3

A = HFX- KFV
B = NFU

RH engine support

(1) 4.5 ± 0.4

(2) 6.1 ± 0.6
(3) 4.5 ± 0.4

Torque reaction rod

(4) 6 ± 0.6
(5) 6 ± 0.6

LH engine support on gearbox

(6) 3 ± 0.3
(7) 6 ± 0.6
(8) 5.5 ± 0.5

B1BP2NEP

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 ENGINE

C3 SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

Crankshaft
Engine types HFX KFV NFU
Accessories drive pulley 0.8 ± 0.2
Pinion fixing on crankshaft 10 ± 1 2.5 ± 0.2
Cylinder block
Sump 0.8 ± 0.2
Timing belt tensioner roller 2 ± 0.2 2.2 ± 0.2
Accessories belt tensioner roller 2 ± 0.2 2.5 ± 0.2
Alternator support fixing 1.7 ± 0.3
Alternator fixing on support 3.7 ± 0.3
Cylinder head
Coolant outlet housing 0.8 ± 0.2
Camshaft bearing cap
Tightening 2 ± 0.2 2 ± 0.2
Angular tightening 44° ± 4° 50° ± 5°
Inlet manifold 0.8 ± 0.2
Exhaust manifold 1.7 ± 0.3 2 ± 0.2
Valve rockers adjusting screw 1.75 ± 0.25
Sparking plugs 2.75 ± 0.25
Camshaft pulley screw 8 ± 0.8

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 ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) C3
Flywheel -Clutch
Engines HFX KFV NFU
Flywheel 6.7 ± 0.6 + LOCTITE FRENETANCH
Clutch mechanism 2 ± 0.2
Lubrication circuit
Oil pressure switch 2 ± 0.2
Oil pump 0.9 ± 0.1
Cooling circuit
Coolant pump 1.4 ± 0.1
Coolant outlet housing 0.8 ± 0.1

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 ENGINE

C3 SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

Engines : 8HX - 8HW

RH engine support

(1) 4.5 ± 0.4

(2) 3 ± 0.3

Torque reaction rod

(3) 6 ± 0.6
(4) 6 ± 0.6

LH engine support on gearbox

(5) 5.4 ± 0.5

(6) 6 ± 0.6
(7) 5.5 ± 0.5

B1BP2LJP

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 ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) C3
Engines 8HW - 8HX
Crankshaft
Bearing cap fixing screw
Pre-tightening 1
Slackening YES
Tightening 3
Angular tightening 140°
Con rod nuts
Pre-tightening 1
Slackening YES
Tightening 1.5 ± 0.1
Angular tightening 100° ± 5°
Accessories drive pulley
Pre-tightening 3 ± 0.4
Angular tightening 180° ± 5°
Cylinder block
Sump 1 ± 0.1
Timing belt guide roller 4.5 ± 0.4
Timing belt tensioner roller 3 ± 0.3
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 ENGINE

C3 SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

Engines 8HW - 8HX
Cylinder head
Camshaft bearing covers
Pre-tightening 0.5 ±
Tightening 1±
Fixings of camshaft sub-assemblies on cylinder head
Pre-tightening 0.5
Tightening 1
Exhaust manifold 2.5 ± 0.2
Valve cover 2.5 ± 0.2
Camshaft pulley 4.3 ± 0.4
Flywheel
Flywheel
Pre-tightening 1.7
Tightening 70° ± 5°
Clutch mechanism 2 ± 0.2
Lubrication circuit
Oil pump assembly
Pre-tightening 0.5 ± 0.06
Tightening 0.9 ± 0.1
Coolant/oil heat exchanger 1 ± 0.1
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 ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) C3
Engines 8HW - 8HX
Diesel injection circuit

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

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

Unions on fuel high pressure common injection rail

Diesel injection pump on support 2.25 ± 0.2

Union on diesel injection

Diesel injection pump pulley 5 ± 0.5

Union on diesel high pressure pump 2.25 ± 0.2

Cooling circuit
Coolant pump
Pre-tightening 0.3 ± 0.06
Tightening 1 ± 0.1
Coolant outlet housing
Pre-tightening 0.3 ± 0.06
Tightening 0.7 ± 0.08

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 ENGINE

C3 SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

Engines : 8HY - 8HV

RH engine support
Screw (1) 6 ± 0.6
Screw (2) 6 ± 0.6

RH lower engine support

Screw (3) 5.7 ± 0.5

LH upper engine support

Screw (7) 6 ± 0.6
Screw (8) 5.5 ± 0.5

LH lower engine support

Screw (6) 5.4 ± 0.5

Torque reaction rod

Screw (4) 6 ± 0.6
Screw (5) 6 ± 0.6

B1BP2MNP

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 ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) C3 - XSARA
Engines 8HY - 8HV
Crankshaft
Bearing cap fixing screw
Tightening 3 ± 0.3
Angular tightening 140° ± 1°.4’
Crankshaft pullet hub
Tightening 3 ± 0.3
Angular tightening 180° ± 5°
Cylinder block
Oil sump 1 ± 0.1
Timing belt tensioner roller 4 ± 0.4
Timing belt guide roller
2.5 ± 0.2
Timing belt guide roller support
Cylinder head
Camshaft bearing cap cover
1 ± 0.1
Inlet manifold
Exhaust manifold 2.5 ± 0.2
Cylinder head cover Screws (M6) to 1 ± 0.2
Camshaft pinion 4.3 ± 0.4
Fuel high pressure pump pinion 5 ± 0.5

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 ENGINE

C3 - XSARA SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

Engines 8HY - 8HV
Flywheel -Clutch
Flywheel 1.7 ± 0.2
Clutch mechanism 2 ± 0.2
Lubrication circuit
Oil pump assembly 0.9 ± 0.1
Oil/coolant heat exchanger 1 ± 0.1
Turbocharger lubrication pipe 2.2 ± 0.2
Injection circuit
Injector fixing flange nut
Tightening 0.4 ± 0.1
Angular tightening 65° ± 5°
Unions on fuel high pressure common injection rail
Fuel high pressure pump 2.3 ± 0.2
Union on diesel injector
Fuel high pressure pump pinion 5 ± 0.5
Union on fuel high pressure pump 2.3 ± 0.2
Cooling circuit
Coolant pump 1 ± 0.2±
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 ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN ) TUD - XU
Engines : RFS - VJX
SAXO XSARA

VJX RFS

- Pre-tighten 0.4 - Pre-tighten 0.5

- Tighten to 0.7 - Tighten to 1

B1DP03BC B1DP01YD

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 ENGINE

SAXO - XSARA PICASSO CYLINDER HEAD

Engines : HDZ - HFX - KFW - KFV - NFT - NFV - NFX - NFU - VJX
Identification of the cylinder head gasket
Engine type HFX KFW NFT - NFV NFX - NFU VJX
Identification marks (Notch on cylinder head gasket)*
1 1 1 1 1
2 0 0 1 1
Thickness 0 0 1 1
3
4 0 1 1 0
A 0
CURTY B 0
D 0
A 1 1
MEILLOR B 1 1
D 0 0
Suppliers
A 1
ELRING B 0
D 1
A 1
REINZ B 0
D 0 0 = Without notch
Material C 0 (With asbestos) - 1 (Without asbestos) *
1 = One notch
Repairs R 0 (Standard gasket) - 1 (Repair gasket) B1BP10KC

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 ENGINE
CYLINDER HEAD (continued) SAXO - XSARA - PICASSO
Engines : HDZ – HFX – KFW - NFT – NFV - NFX – NFU – VJX
Cylinder head tightening (m.daN) Cylinder head bolts

HDZ-HFX-KFW-NFV-NFT

- Pre-tightening 2
- Angular tightening 240° ± 5°

VJX Note : Oil the threads and under the

heads of the cylinder head bolts.
- Pre-tightening 4 (Use engine oil or Molykote G Rapid Plus).
- Angular tightening 300° ± 5°
B1BP10LC

NFU - NFX

- Pre-tightening 2
B1DP059C
- Angular tightening 260° ± 5°
X = MAXIMUM reusable length

HDZ-HFX-KFW-NFV-NFT VJX NFU-NFX

B1DP13NC X= 175.5 ± 0.5 mm X = 197.1 mm X = 122.6 mm

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 ENGINE

C3 CYLINDER HEAD
Engines : HFX - KFV - NFU
Identification of the cylinder head gasket

Engines Thicknesses (Standard) Thickness (repair) Thickness ref.

HFX 2
1.2 ± 0.1 1.4 ± 0.1
KFV 1
NFU 0.66 ± 0.04 4

References

1.2.3.4 = Type of engine.

A.B.D = Suppliers

C = Gasket material.

R = Repair.

B1BP10KC

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 ENGINE
CYLINDER HEAD C3
Engines : HFX - KFV - NFU
Cylinder head tightening (m.daN) Cylinder head bolts
HFX - KFV

Tighten to 2 ± 0.2
Angular tightening 240° ± 5°
(in the order 1 to 10)

NFU

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

(in the order 1 to 10)

NOTE : Oil the threads and

under the heads of the cylinder B1BP1DVC
head bolts.
(Use engine oil or Molykote G X = MAX. re-usable length
Rapid Plus).
NOTE : Retightening of the cylinder HFX - KFV NFU
head after a repair is forbidden.
B1DP05BC 175.5 ± 0.5 122 ± 0.3

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 ENGINE

C3 CYLINDER HEAD
Engines : 8HY - 8HV

Identification of the cylinder head gasket

Piston
Thicknesses No. of notches No. of notches
Engine types Supplier standproud
(mm) at d at e
(mm) Type of gasket :
0.675 to 0.725 1.25 1 Metallic multilayer

0.726 to 0.775 1.30 2 "d" Thickness reference.

8HY - 8HV ELRING 0.776 to 0.825 1.35 3 2
"e" Engine reference.
0.826 to 0.875 1.40 4
0.876 to 0.983 1.45 5

B1DP1CMD

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 ENGINE
CYLINDER HEAD C3
Engines : 8HY - 8HV

Identification of the cylinder head gasket

Piston
Thicknesses No. of notches No. of notches
Engine types Supplier standproud
(mm) at d at e
(mm) Type of gasket
0.771 to 0.820 1.35 1 Metallic multilayer

0.611 to 0.720 1.25 2 "d" Thickness reference.

8HY - 8HV ELRING 0.721 to 0.770 1.30 3 2
"e" Engine reference.
00.821 to 0.870 1.40 4
0.871 to 0.977 1.45 5

B1DP1CKD

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 ENGINE

XSARA - C3 CYLINDER HEAD

Engines : 8HX - 8HW - 8HY - 8HV
Cylinder head tightening (m.daN) Cylinder head bolts
8HX - 8HW - 8HY - 8HV
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 tho-
roughly 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). B1DP1DBC
- Pass a tap into the holes in the X = MAX. re-usable length
The cylinder head gasket is dry-fitted. cylinder block.
NOTE : Retightening of the cylinder head 8HX - 8HW - 8HY - 8HV
after a completed repair is prohibited. X = 149 mm
B1DP1CLC

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 ENGINE
CYLINDER HEAD XSARA PICASSO
Engine : 6FZ
Identification of the cylinder head gasket

Nominal
Repair dimension
dimension
Marking zone
«d» 4–5 2–4–5
Marking zone
«e» R1 R2 R3

Gasket thickness
0.8 1 1.1 1.3
(mm)
Supplier MEILLOR

Marking

« d » Marking zone
« e » Marking zone

NOTE : 3 layer metallic gasket.

B1DP183D

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 ENGINE

XSARA PICASSO CYLINDER HEAD (continued)

Engine : 6FZ
Cylinder head tightening (m.daN) Cylinder head bolts
6FZ

Pre-tightening 1.5 ± 0.2

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

B1DP16FC

A = Washer thickness: 4 ± 0.2 mm.

X = Length under heads of new bolts = 144.5 ± 0.5 mm.
NOTE : Oil the threads and
under the heads of the cylinder X = MAXIMUM reusable length
head bolts.
(Use engine oil or Molykote G 6FZ
Rapid Plus).
B1DP05BC X= 147 mm

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 ENGINE
CYLINDER HEAD (continued) XSARA PICASSO
Engine : RFN
Identification of the cylinder head gasket

Nominal
dimension Repair dimension

Marking zone
«d» 4–5 2–4–5

Marking zone «e» R1 R2

Gasket thickness
0.8 1.1 1.4
(mm)
Supplier MEILLOR

Multilayer metallic gasket

B1DP183D

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 ENGINE

XSARA PICASSO CYLINDER HEAD (continued)

Engine : RFN
Cylinder head tightening (m.daN) Cylinder head bolts
RFN

Pre-tightening 1.5 ± 0.2

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

B1DP16FC

A = Washer thickness: 4 ± 0.2 mm.

X = Length under heads of new bolts = 144.5 ± 0.5 mm.
NOTE : Oil the threads and
under the heads of the cylinder X = MAXIMUM reusable length
head bolts.
(Use engine oil or Molykote G RFN
Rapid Plus).
B1DP05BC X= 147 mm

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 ENGINE
CYLINDER HEAD XSARA
Engine : RFS
Identification of the cylinder head gasket
Engine type RFS
Identification marks (Notch on cylinder head gasket) *
A 1
B 0
Suppliers MEILLOR C 1
D 0
E 0

0 = Without notch
*
1 = One notch
B1BP004C

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 ENGINE

XSARA CYLINDER HEAD (continued)

Engine : RFS
Cylinder head tightening (m.daN) Cylinder head bolts
RFS

- Pre-tightening 3.5
- Slackening NON
- Tightening 7
- Angular tightening 160°

Note : Oil the threads and

under the heads of the cylinder B1DP13PC
head bolts. X = MAXIMUM re-usable length
(Use engine oil or Molykote G
Rapid Plus). RFS
B1DP05BC 112 mm

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 ENGINE
CYLINDER HEAD XSARA
Engine : WJY

Identification of the cylinder head gasket

Piston Thickness Number Number WJY

Engine
stand-proud (mm) of holes of holes
type
(mm)* ± 0.04 at A at B
0.51 to 0.55 1.26 1
0.55 to 0.59 1.30 2
WJY 0.59 to 0.63 1.34 2 3
0.63 to 0.67 1.38 4
0.67 to 0.71 1.42 5

(A) = Engine identification.

(B) = Thickness identification.

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

B1DP14QD

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 ENGINE

XSARA - XSARA PICASSO CYLINDER HEAD

Engines : RHY - RHZ

Identification of the cylinder head gasket

Piston
Engine Thickness Number of notches
stand-proud
type (mm) at A
(mm)
0.47 to 0.605 1.30 ± 0.06 1
0.605 to 0.655 1.35 ± 0.06 2
RHY
0.655 to 0.705 1.40 ± 0.06 3
RHZ
0.705 to 0.755 1.45 ± 0.06 4
0.755 to 0.83 1.50 ± 0.06 5

B1DP15AD

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 ENGINE
CYLINDER HEAD (continued) XSARA - XSARA PICASSO
Engines : WJY - RHY - RHZ
Cylinder head tightening (m.daN) Cylinder head bolts
WJY WJY RHY - RHZ

- Pre-tightening 2
- Tightening 6
- Angular tightening 180°

RHY - RHY

- Pre-tightening 2
- Tightening 6
- Angular tightening 220°

Note : Oil the threads and under the

heads of the cylinder head bolts. X = MAXIMUM re-usable length
(Use engine oil or Molykote G Rapid Plus). WJY RHY - RHY

B1DP05BC B1DP13PC B1DP15EC

125.5 mm 133.3 mm

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 ENGINE

ALL TYPES BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE

Tools !
!

!
4099-T (C.TRONIC.105) 4122-T (C.TRONIC.105.5)

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 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT ALL TYPES
TU EW XU
1 3 5 7 10
JP J4 JP4 J4 J4RS

Engine type : HFX KFW KFV NFT NFV NFX NFU 6FZ RFN RFS

SAXO X X X X

See pages : 100 100 106

C3 X X X

See pages : 101 to 102 101 to 102 101 to 102

XSARA X X X X

See pages : 105 106 110 108 to 109

XSARA
PICASSO X X X

See pages : 103 to 104 110

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 ENGINE

ALL TYPES AUXILIARY EQUIPMENT DRIVE BELT

TU DV DW
5 4 8 10
B TD TED4 B TD ATED

Engine type VJX 8HX 8HW 8HZ 8HV 8HY WJY RHY RHZ

SAXO X

See pages : 107

C3 X X X X

See pages : 117 to 118 119

XSARA X X X X

See pages : 117 to 118 111 to 116 120 to 123

XSARA
X
PICASSO
See pages : 120 to 123

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 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT ALL TYPES
Engines : All Types Petrol et Diesel

TOOLS

- Belt tension measuring instrument : 4122 -T. (C.TRONIC 105.5)

- WARNING : If using tool 4099-T (C.TRONIC 105), refer to the correspondence table on page 90.

ESSENTIAL

- Before refitting the auxiliary equipment drive belt, check that:

1) The roller(s) rotate freely (no play or stiffness).

2) The belt is correctly engaged in the grooves of the various pulleys.

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 ENGINE

SAXO AUXILIARY EQUIPMENT DRIVE BELT

Engines : HFX - KFW - NFT
Without air conditioning With air conditioning

- Fit the tool 4122 - T. - Fit the tool 4122-T.

- Tighten the tensioning screw (3) - Tighten the tensioning screw (5)
to obtain : to obtain :
55 ± 3 SEEM units. 120 ± 3 SEEM units.

- ighten the screws (2) and (1). - Tighten the screws (6) and (4).

- Remove the tool 4122-T. - Remove the tool 4122-T.

B1BP10UC B1BP10WC B1BP10VC B1BP10XC

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 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT C3
Engines : HFX - KFV - NFU

Tools

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

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

Vehicle without air conditioning.

Remove. Refit.

Slacken: Refit the belt.

Respect the following sequence:
- Screw (2).
- Crankshaft pinion.
- Screw (3).
- Alternator pulley.
- Tensioning screw (1).
Place tool [2] on the belt.
Tighten screw (1) to achieve a tension of:
Push the alternator back towards the engine.
55 ± 3 unités SEEM.
Remove the belt.
Tighten:
- Screw (3).
- Screw (2)
Remove tool [2] and complete the refitting.
B1BP2LSC B1BP2LTC

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 ENGINE

C3 AUXILIARY EQUIPMENT DRIVE BELT

Engines : HFX - KFV - NFU

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.

B1BP10VC B1BP10XC

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 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT XSARA PICASSO
Engine : NFV
Without air conditioning.

Tools.

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

[2] Belt tension measuring instrument : 4122 –T.
[3] TORX spanner.

Remove.
- Release the central screw (1) tool [3].
- Detension the tensioner roller (2), (flat spanner 27 on flat).
- Remove the belt.

Refit.
- Position the belt.
- Hold the belt in position using the tensioner roller (2).
- Pre-tension the belt 120 SEEM units, tool [2].
- Lock the central screw (1) tool [3].
- Remove the tool [2].
- Rotate the crankshaft 2 to 4 times.
- Check the tension, 120 SEEM units.
- If not, restart the operation.
B1BP234C

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 ENGINE

XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT

Engine : NFV
With air conditioning.

Tools.

[1] Plyers for removing plastic pegs : 7504 –T.

[2] Belt tension measuring instrument : 4122 –T.
[3] 10 mm square(drain spanner).
[4] TORX spanner.

Remove.
- Detension the automatic tensioner, tool [3].
- Place a Ø 6 mm peg at (a) to immobilise the automatic tensioner.
- Remove the belt.

Refit.
- Position the belt
- Detension the automatic tensioner, tool [3].
- Remove the Ø 6 mm peg.
- Release the automatic tensioner.
- Remove the tool [3].

B1BP235C

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 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT XSARA
Engine : KFW
Alternator With air conditioning

[1] Belt tension measuring instru- [1] Belt tension measuring instru-
ment : 4122-T ment : 4122-T
- Tension the belt using the screw (2). - Tension the belt using the screw
(4).
- Tension should be :
102 ± 7 SEEM units. - Tension should be:
102 ± 7 unites SEEM.
- Tighten the screws (1).
- Tighten the screws (3).

Power-assisted steering Power steering and air con.

- New belt - New belt

100 SEEM units. 100 SEEM units.

- Reused belt - Reused belt

75 SEEM units. 75 SEEM units.

B1BP1B2C B1BP122C B1BP1B3C B1BP124C

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 ENGINE

SAXO - XSARA AUXILIARY EQUIPMENT DRIVE BELT

Engines :NFX - NFU
Without air conditioning

(1) Tensioner roller fixing screw

(2) Tensioning screw
- New belt : 120 SEEM units.
- Reused belt : 86.5 ± 3.5 SEEM units.

B1BP1AMC

With air conditioning

(3) Tensioner roller fixing screw

(4) Tensioning screw
- CNew belt : 120 SEEM units.
- Reused belt : 86.5 ± 3.5 SEEM units.
NOTE : Removal of the tensioner roller makes it necessary to remove the plate with the upper fixing screw (5).

B1BP1ANC

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 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT SAXO- XSARA
Engine : VJX
Without air conditioning
- (6) Roller support fixing screw.
- (7) Tensioning screw
- Pre-tension the belt (8) to : 120 SEEM units.
- Rotate the crankshaft by 3 turns (Direction of rotation).
- Adjust the belt (8) tension to : 120 SEEM units.
- Tighten the screws (6) to : 2.5 m.daN.
- Run the engine for 10 min.
- Check the tension. B1BP11EC

With air conditioning

- (3) Roller support fixing screw

- (5) Tensioning screw
- Pre-tension the belt (4) to : 120 SEEM units.
- Rotate the crankshaft by 3 turns (Direction of rotation).
- Adjust the belt (4) tension to : 120 SEEM units.
- Tighten the screws (3) to : 2.5 m.daN.
- Run the engine for 10 min.
- Check the tension.
B1BP11DC

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 ENGINE

XSARA AUXILIARY EQUIPMENT DRIVE BELT

Engine : RFS
With air conditioning

- Fit the drive belt.

- The tensioner roller (1).

- Tighten the screws (3) to 2 m.daN.

- Move the tensioner roller (1) using the tool (9.52 mm square drive (3/8)) at (2), in order to remove
the tool or locking peg (Ø 4 mm) at (4).

- Slowly release the tensioner roller (1) so that the roller (5) presses against the belt.

B1BP1HJC

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 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT XSARA
Engine : RFS
Without air conditioning
TOOLS

[1] Belt tension measuring instrument 4122-T

- (1) Tensioning screw.

- (2) Roller support fixing screw (3).

- Lightly tighten the screws (2).

- Place the tool [1] on the belt.
- Tension the belt using the screw (1).
• Reused belt 90 SEEM units.
• New belt 120 SEEM units.
- Tighten the screws (2) to 2 m.daN.
- Remove the tool [1].
- Rotate the crankshaft by 3 turns (direction of rotation).
- Check the belt tension using the tool [1], and adjust (if necessary).

B1EP12XC B1EP12YC

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 ENGINE

XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT

Without air conditioning Engines : 6FZ - RFN With air conditioning

Tools

[1] Pliers for removing plastic pegs 7504-T

Remove the belt.

- Detension the belt (3) by turning the screw (2) of the tensioner roller (1)
(anti-clockwise).

- The screw (2) (WARNING : not left hand screw).

- Remove the belt (3), while keeping the tensioner roller (1) tight.

Refit the belt.

- Refit the belt (3), while keeping the tensioner roller (1) tight.
- Release the tensioner roller (1).

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 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT XSARA
Engine : WJY
Without power-assisted steering

Tools :

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

Removal.
- Loosen the screws (2).
- Tighten the screw (1) until it is against its stop.
- Remove the belt.

Refitting.
- Refit the belt.
- Fit the tool [1] on the belt at "d".
- Tighten the screw (1) to obtain : 106 ± 10 SEEM units.
- Tighten the screws (2) to 2 m.daN.
- Remove the tool [1].

B1BP1SDC B1BP1SEC

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 ENGINE

XSARA AUXILIARY EQUIPMENT DRIVE BELT

Engine : WJY
Without power-assisted steering, with air conditioning

Tools :

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

Removal.
- Loosen the screws (1).
- Tighten the screw (2) until it is against its stop.
- Remove the belt.

Refitting.
- Refit the belt.
- Fit the tool [1] at "e".
- Tighten the screw (2) to obtain : 106 ± 10 SEEM units.
- Tighten the screws (1) to 2 m.daN.
- Remove the tool [1].

B1BP1SFC B1BP1SGC

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 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT XSARA
Engine : WJY
Power-assisted steering, without air conditioning

Tools :

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

Removal.

WARNING : If the belt is to be reused, measure the tension before removal.

- Loosen :
- the screw (1).
- the nut (2).

NOTE : The tensioner arm (3) must be against the alternator.

- Remove the belt.

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 ENGINE

XSARA AUXILIARY EQUIPMENT DRIVE BELT

Engine : WJY
Power-assisted steering, without air conditioning (continued)

Refitting.
- Refit the belt.
- Place the tool [1] on belt at "f".

WARNING : Position tool [1], with the knob downwards.

- tighten the nut (2) to obtain a value of :
Reused belt:
Keep the value taken at removal.
New belt:
Tension should be 110 SEEM units.
- Tighten the screw (1) to 9.5 m.daN.
- Check belt tension (tool [1].
Tension should be 144 ± 3 SEEM units.
- Remove the tool [1].
- Start the engine and run it for 10 seconds.
- Stop the engine.
- Place the tool [1] on the belt at "f".
- Tension should be 130 ± 4 SEEM units.
- Remove the tool [1].

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 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT XSARA
Engine : WJY
Power-assisted steering, with air conditioning

Outillage :
[1] Dynamic tensioner peg : (-) 0188 H.
[2] Belt tension measuring instrument : 4122-T.

Removal.
- Peg the dynamic tensioner (1) at "a", using tool [1].
- Loosen the screw (2) of the roller (3).
- Turn the roller (3) backwards.
- Remove the belt.
NOTE : If it can not be pegged at "a" :
- Loosen the screw (2) of the roller (3).
- Using a 7 mm square drive, turn the roller (3) at "b".
- Peg the tensioner (1) at "a", using tool [1].
NOTE : If the belt is broken :
- Support the engine using a jack (insert a wooden block between the housing and the jack).
- Remove the right engine support.
- Using a square drive at (b) turn the tool (3) in the direction of the arrow "a", so that it can be
pegged at "a" using the tool [1].

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 ENGINE

XSARA AUXILIARY EQUIPMENT DRIVE BELT

Engine : WJY
Power-assisted steering with air conditioning (continued)

Refitting.

- Refit the belt.

- Using a 7 mm square drive at "b", turn the roller (3), until the tool [1] located at "a" becomes free.

- Tighten the screw (2).

- Remove the tool [1].

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 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT C3
With compressor and alternator Engines : 8HX - 8HW
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.
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 ENGINE

C3 AUXILIARY EQUIPMENT DRIVE BELT

Engines : 8HX - 8HW

Markings on the dynamic tensioner roller.

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

Refitting

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

Respect the direction of fitting of the drive belt.

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

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

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 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT C3
Engines : 8HY - 8HV
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.

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 ENGINE

XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT

Engines : RHY - RHZ
Without air conditioning

Tools
[1] Belt tension adjusting square : (-).0188 J2
[2] Ø 4 mm peg : (-).0188.Q1
[3] Ø 2 mm peg : (-).0188.Q2
[4] Dynamic tensioner compression lever : (-).0188.Z

REMOVAL
Re-use of belt

WARNING : Mark the direction the belt was fiited in case of re-use of the same belt.
- Compress the tensioner roller (2) by action at « a » (in anti-clockwise direction), tool [4].
- Keep the tensioner roller (2) compressed and remove the belt.

No re-use of belt
- Compress the tensioner roller (2) by action at « a » (in anti-clockwise direction), tool [4].
- Peg using tool [2], at « b ».
- Keep the tensioner roller (2) compressed and remove the belt.
- Loosen the screw (1).

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 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT XSARA - XSARA PICASSO
Engines : RHY - RHZ
Without air conditioning (continued)

REFITTING.
Re-used belt

- Compress the tensioner roller (2) by action at « a » (in anti-clockwise direction), tool [4].
- Refit the belt.

WARNING : Respect the belt-fitting direction.

Remove the tool [4].

New belt
Refit the belt.
- Turn the eccentric roller (3), tool [1] (clockwise) to free the tool [2] from its pegging
at « b ».
- Hold the eccentric roller (3), tool [1], and tighten the screw (1) to 4.3 m.daN.
Remove the tool [2].
- Rotate the crankshaft 4 times in the direction of rotation.
- Check that it is possible to peg at « b », tool [3].
- If not possible to peg, restart the adjustment.

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 ENGINE

XSARA - XSARA PICASSO AUXILIARY EQUIPMENT DRIVE BELT

Engines : RHY - RHZ
With air conditioning

Tools
[1] Belt tension adjusting square : (-).0188 J2
[2] Pige Ø 4 mm : (-).0188.Q1
[3] Pige Ø 2 mm : (-).0188.Q2
[4] Dynamic tensioner compression lever : (-).0188.Z

REMOVAL

Re-use of belt
WARNING : Mark the direction the belt was fitted in case of re-use of the same belt.
- Compress the tensioner roller (7) by moving it at « c » (in anti-clockwise direction),
tool [4].
- Hold the tensioner roller (7) compressed and remove the belt.
No re-use of belt
- Compress the tensioner roller (7) by moving it at « c » (in anti-clockwise direction), tool [4].
- Peg using tool [2], at « d ».
- Loosen the screw (6).
- Bring the eccentric roller (5) towards the rear.
- Tighten the screw (6) by hand.
- Remove the belt.
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 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT XSARA - XSARA PICASSO
Engines : RHY - RHZ
With air conditioning (continued)

REFITTING.

Re-used belt
- Compress the tensioner roller (7) by action at « c » (in anti-clockwise direction), tool [4].
- Refit the belt.

WARNING : Respect the direction belt was fitted.

Remove the tool [4].

New belt
Refit the belt.
- Turn the eccentric roller (5), tool [1] (clockwise) to free the tool [2] from its pegging
at « d ».
- Hold the eccentric roller (5), tool [1], and tighten the screw (6) to 4.3 m.daN.
Remove the tool [2].
- Rotate the crankshaft 4 times in the direction of rotation.
- Check that it is possible to peg at « d », tool [3].
- If not possible to peg, restart the adjustment.

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 ENGINE

ALL TYPES CHECKING AND SETTING THE VALVE TIMING

TU EW XU
1 3 5 7 10
JP J4 JP4 J4 J4RS
Engine type HFX KFW KFV NFT NFV NFX NFU 6FZ RFN RFS
SAXO X X X X
See pages : 126 to 128 126 to 128 139 to 142
C3 X X X
See pages : 129 to 138 129 to 138 129 to 138
XSARA X X X X
1 2003
163 to 173
See pages : 126 to 128 139 to 142 182 to 186
2003 1
174 to 181
PICASSO X X X
1 2003
163 to 173
See pages : 126 to 128
2003 1
174 to 181
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 ENGINE
CHECKING AND SETTING THE VALVE TIMING ALL TYPES
TUD DV DW
5 4 8 10
B TD TED4 B TD ATED
Engine type VJX 8HX 8HW 8HZ 8HV 8HY WJY RHY RHZ
SAXO X
See pages : 143 to 145
C3 X X X X
See pages : 146 to 153 154 to 162
XSARA X X X X
1 N° RPO 9127
192 to 196
See pages : 146 to 153 187 to 191
N° RPO 9128 1
197 to 205
PICASSO X
1 N° RPO 9127
192 to 196
See pages :
N° RPO 9128 1
197 to 205
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 ENGINE

SAXO - XSARA CHECKING AND SETTING THE VALVE TIMING

Engines : HFX - KFW - NFT - NFV


TOOLS
- [1] Flywheel locating peg : 4507-T.A
- [2] Camshaft pulley locating peg : 4507-T.B Tool kit 4507-T
- [3] Square drive : 4507-T.J
- [4] Belt tension measuring instrument : 4122-T
- [5] Rocker plate : 4533-T.Z

CHECKING THE VALVE TIMING

- Peg the flywheel using the tool [1].
- Peg the camshaft pulley using the tool [2].

SETTING THE VALVE TIMING

NOTE : Remove the spark plugs, to allow the crankshaft to rotate more freely.
- Rotate the engine by the crankshaft screw (1).
- Peg the camshaft gearwheel.
- Peg the flywheel.
- Loosen the nut (2).
- Totally slacken the belt by moving the tensioner roller.
- Remove the belt.
ESSENTIAL : Check that the tensioner roller rotates freely (no stiffness).

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING SAXO - XSARA
Engines : HFX - KFW - NFT - NFV

REFITTING THE TIMING BELT.

NOTE : Check that the pegs [1] and [2] are in place.
WARNING : Ensure the belt is fitted in the right direction : The arrows «a» signify the crankshaft direc-
tion of rotation.
Fit :
- The timing belt, with the belt strip "b" well tightened, in the following order:
Crankshaft pinion, camshaft pulley, water pump pulley, tensioner roller.
- The tool [5] (Ensure it is fitted in the right direction in relation to the timing).
- Bring the tensioner roller into contact with the belt.
- Tighten the nut (2).
PRE-TENSIONING THE TIMING BELT.
- Fit the tool [4] on the tightened belt strip "b".
- Loosen the nut (2).
- Turn the roller (3) in an anti-clockwise direction using a square drive to obtain :
44 SEEM units.
- Tighten the nut (2) to 2 m.daN.
- Remove the tools [1] [2] and [4].
- Rotate the crankshaft by 4 turns in the normal direction.
ESSENTIAL : Never turn the crankshaft backwards.

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 ENGINE

SAXO - XSARA CHECKING AND SETTING THE VALVE TIMING

Engines : HFX - KFW - NFT - NFV

REFITTING THE TIMING BELT

NOTE : Check that the pegs [1] and [2] are in place.
WARNING : Ensure the belt is fitted in the right direction : The arrows «a» signify the crankshaft direction of rotation.
Fit :
- The timing belt, with the belt strip "b" well tightened, in the following order:
Crankshaft pinion, camshaft pulley, water pump pulley, tensioner roller.
- The tool [5] (Ensure it is fitted in the right direction in relation to the timing).
- Bring the tensioner roller into contact with the belt.
- Tighten the nut (2).

PRE-TENSIONING THE TIMING BELT.

- Fit the tool [4] on the tightened belt strip "b".
- Loosen the nut (2).
- Turn the roller (3) in an anti-clockwise direction using a square drive to obtain :
44 SEEM units.
- Tighten the nut (2) to 2 m.daN.
- Remove the tools [1] [2] and [4].
- Rotate the crankshaft by 4 turns in the normal direction.
ESSENTIAL : Never turn the crankshaft backwards.

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING C3
Engines : HFX - KFV - NFU

Tools.
[1] Engine flywheel peg : 4507-T.A
[2] Camshaft pulley peg : 4507-T.B
[3a] Camshaft peg : 4533-TA.C1
[3b] Camshaft peg : 4533-TA.C2
[4] Dynamic tensioner roller pin : 4200-T.H
[5] Belt retaining pin : 4533-T.AD
[6] Pliers for removing plastic pins : 7504-T.
Checking the valve timing
Engines HFX - KFV - NFU
Raise and support the front RH side of the vehicle.
Disconnect the battery positive terminal.
Engage 5th gear.
Remove the oil filter (1).
Engine HFX - KFV
Remove :
The timing top casing (2).
Turn the wheel to rotate the engine (normal direction of rotation).
Peg the camshaft pulley, using tool [2].

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C3 CHECKING AND SETTING THE VALVE TIMING

Engine : NFU

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.

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING C3
Engines : HFX - KFV
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.
Engine HFX - KFV
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).
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C3 CHECKING AND SETTING THE VALVE TIMING

Engines : HFX - KFV

Setting the timing (continued)

Engine HFX - KFV

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).

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING C3
Engine : NFU

Engine NFU.

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].

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C3 CHECKING AND SETTING THE VALVE TIMING

Engine : NFU

Setting the timing (continued)

Engine: NFU

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).

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CHECKING AND SETTING THE VALVE TIMING C3
Engines : HFX - KFV

Setting the timing (continued)

Engines: HFX-KFV

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].

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C3 CHECKING AND SETTING THE VALVE TIMING

Engines : KFX - KFV - NFU
Setting the timing (continued)
Engines: HFX-KFV
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]
Engine: NFU
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.
B1EP18RC
Remove the tools [1], [3] and [5].

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CHECKING AND SETTING THE VALVE TIMING C3
Engine : NFU

Timing belt overtensioned:

A : Engines: HFX – KFV.

B : Engine: NFU

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

Bring the index «c» to position «f», to tension the belt to the maximum of the inter-
val 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].

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 ENGINE

C3 CHECKING AND SETTING THE VALVE TIMING

Engines : HFX - KFV - NFU

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 engine )
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.
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 ENGINE
CHECKING AND SETTING THE VALVE TIMING SAXO - XSARA
Engines : NFX - NFU

TOOLS
- [1] Belt tension measuring instrument : 4122-T


- [2] Flywheel locating peg : 4507-T.A.
- [3] Camshaft pulley locating peg, exhaust : 4533-T.A. C2
- [4] Camshaft pulley locating peg, inlet : 4533-T.A. C1 Tool kit 4507-T
- [5] Tensioning tool : 4707-T.J.

CHECKING THE VALVE TIMING

- Peg the flywheel using the tool [2].
- Peg the exhaust camshaft pulley [3].
- Peg the inlet camshaft pulley [4].

SETTING THE VALVE TIMING.

- Peg the flywheel using the tool [2].
- Peg the camshaft pulleys [3] and [4].

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 ENGINE

SAXO - XSARA CHECKING AND SETTING THE VALVE TIMING

Engines : NFX - NFU

SETTING THE VALVE TIMING

- Loosen the screw (2), remove the belt.

- Loosen the six pulley screws (1) on the hubs.
(There should be a slight amount of friction between the screws and the pinions).
- Check that the rollers (2) and (3) rotate freely.

NOTE : The belt bears three identification marks * (a), (b) and (c), facing its own teeth (1), (52) and (72)
respectively.

* (Identification marks = white paint lines on the back of the belt facing the corresponding teeth).

- Refit the belt.

- Line up mark (A) on the belt with groove (D) of the pinion (4).
- Hold the belt against the pinion (4).

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING SAXO - XSARA
Engines : NFX – NFU

SETTING THE VALVE TIMING

Turn the two pulleys (1) clockwise to the end of the slots.
- With the belt strip (e) fully tensioned, place the belt over the pulley, first exhaust side, then inlet side, while
ensuring that marks (b) and (c) on the belt are aligned with marks (f) on the pulleys.
- Hold the belt in this position, and engage it over the water pump pinion and the tensioner roller.

- Fit the tool [1] on the belt strip (e).

- Rotate the roller (2) (using tool [5] ) in an anti-clockwise direction, to obtain: 63 SEEM units.
- Tighten the roller (2) to 2 m.daN.
- Tighten the six screws (5) to 1 m.daN.

ESSENTIAL : Check that :

- The camshaft pulleys (1) are not at the end of the slots (by removing a screw).
- The markings on the belt are aligned with the markings on the crankshaft and camshaft pulleys.
If not, repeat the setting procedure.

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 ENGINE

SAXO - XSARA CHECKING AND SETTING THE VALVE TIMING

Engines : NFX – NFU

SETTING THE VALVE TIMING

- Remove the tools [1], [2], [3] and [4].
- Rotate the engine by four turns in the normal direction. (do not turn backwards).
- Peg the flywheel [2].
- Loosen the six screws (5), while ensuring there is still a slight amount of friction with the pulley.
- Peg the camshaft hubs using pegs [3] and [4] .

WARNING : In certain cases, it may be necessary to slightly turn the camshaft using the hub fixing screw.

- Fit the tool [1].

- Loosen the tensioner roller screw (2).
- Rotate the roller (2) (using tool [5]) in an anti-clockwise direction to obtain : 37 SEEM units.
- Tighten the tensioner roller screw (2) to 2 m.daN.
- Tighten the six pulley screws (1) to 1m.daN.
- Remove the tools.

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CHECKING AND SETTING THE VALVE TIMING SAXO
Engine : VJX

TOOLS


- Belt tension measuring instrument : 4099-T or 4122-T
- Flywheel locating peg : 4507-T.A.
- Injection pump pulley locating peg : 4527-T. S1 Tool kit 4507-T
- Camshaft pulley locating peg : 4527-T. S2
- Tensioning lever. : 4507-T.J.
- Pinion locking tool : 6016-T.

CHECKING THE VALVE TIMING

- Peg : the flywheel, the injection pump pulley, the camshaft pulley.

SETTING THE VALVE TIMING

- Peg : the flywheel, the injection pump pulley, the camshaft pulley.
- Loosen the tensioner roller, and remove the belt.
ESSENTIAL: Check that the tensioner and guide rollers rotate freely
(no stiffness). If not, replace the roller(s).
- Loosen the screws (1) and (3) (lock the pulley with tool 6016 - T).
- Position pulleys (2) and (4) to the end of the slots (without tightening the screws (1) and (3)).

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SAXO CHECKING AND SETTING THE VALVE TIMING

Engine : VJX

SETTING THE VALVE TIMING

- Fit the belt in the following order :

The crankshaft pinion, the injection pump pulley, the camshaft pulley, the water pump pinion.

WARNING : When positioning the belt on the injection pump and camshaft pulleys, they should
be turned in the opposite direction of rotation so as to engage the nearest tooth.

- Pre-tension (belt strip slightly tightened).

NOTE : Check that the pulley fixings are not at the end of the slots
(adjust by one tooth if necessary).

- Tighten the screws (1) and (3 ) to 0.5 m.daN, loosen by 180°.

(Gently tighten the screws (1) and (3) by hand).
- Loosen the tensioner roller.
- Tension to 100 SEEM units.
- Tighten the tensioner roller to 2.3 m.daN.

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CHECKING AND SETTING THE VALVE TIMING SAXO
Engine : VJX

SETTING THE VALVE TIMING

- Tighten the screws (1) and (3) to 2.3 m.daN (lock the pulleys using tool 6016 - T).
- Remove the tools.
- Rotate the engine by 10 turns.
- Peg : The flywheel, the pulleys (2) and (4).

NOTE : If necessary, lightly slacken the belt (with the tensioner roller).
- Loosen the screws (1) and (3) by 360° (gently tighten the screws (1) and (3) by hand).
- Set a final tension of 55 ± 5 SEEM units.
- Tighten the tensioner roller, and the screws (1) and (3) to 2.3 m.daN (lock the pulleys using tool 6016-T).
- Remove the tools.
- Rotate the engine by two turns.

NOTE : If the belt is not correctly located on the pinions and pulleys, rotate it by an additional two turns.
- Peg the flywheel.
- Check that the camshaft and injection pump pulleys are correctly pegged.

WARNING : If the visual check is not correct, repeat the setting operation.
- Remove the tools.

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C3 CHECKING AND SETTING THE VALVE TIMING

Engines : 8HX - 8HW

SETTING THE VALVE TIMING

- Tighten the screws (1) and (3) to 2.3 m.daN (lock the pulleys using tool 6016 - T).
- Remove the tools.
- Rotate the engine by 10 turns.
- Peg : The flywheel, the pulleys (2) and (4).

NOTE : If necessary, lightly slacken the belt (with the tensioner roller).
- Loosen the screws (1) and (3) by 360° (gently tighten the screws (1) and (3) by hand).
- Set a final tension of 55 ± 5 SEEM units.
- Tighten the tensioner roller, and the screws (1) and (3) to 2.3 m.daN (lock the
pulleys using tool 6016-T).
- Remove the tools.
- Rotate the engine by two turns.

NOTE : If the belt is not correctly located on the pinions and pulleys, rotate it by an
additional two turns.
- Peg the flywheel.
- Check that the camshaft and injection pump pulleys are correctly pegged.

WARNING : If the visual check is not correct, repeat the setting operation.
B1BP2LXC
- Remove the tools.

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Engines : 8HX - 8HW
Check ing the setting (continued)
Remove:
- the accessories drive belt.
- the accessories drive pulley.
- the lower timing cover (3).
IMPERATIVE : The magnetic track should show no signs of damage
and should not be approached by any other source of magnetism.
Reposition the screw (2).
Remove tool [3].
Rotate the engine by means of the crankshaft pinion screw (2)
(clockwise), to bring it to the pegging position.
Position the tool [4].
Peg the crankshaft pinion (1), using tool [5].
Peg the high pressure pump pinion, using tool [5].
NOTE: Index «a» of the roller tensioner must be centred within the
area «b».
Check the correct positioning of 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).
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Engines : 8HX - 8HW
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).

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CHECKING AND SETTING THE VALVE TIMING C3
Engines : 8HX - 8HW

Setting the timing (continued).

Remove the tool [3].

Rotate the engine by means of the crankshaft pinion screw (2)

(clockwise), to bring it to the pegging position.

Peg the camshaft pulley, using tool [4].

Peg :
- The crankshaft pinion (6), using tool [5].
- The high pressure pump pinion, using tool [5].
Support the engine with the aid of a roller jack equipped with a chock.

Remove:
- The RH engine support (7).
- The intermediate engine support (right hand side) (8).

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C3 CHECKING AND SETTING THE VALVE TIMING

Engines : 8HX - 8HW

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.

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING C3
Engines : 8HX - 8HW

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).

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C3 CHECKING AND SETTING THE VALVE TIMING

Engines : 8HX - 8HW

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.

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CHECKING AND SETTING THE VALVE TIMING C3
Engines : 8HX - 8HW

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.

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C3 CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

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).

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CHECKING AND SETTING THE VALVE TIMING C3
Engines : 8HY - 8HV

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].

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C3 CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

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 off-
set between the hole in the camshaft pinion and the pegging hole is not grea-
ter than 1 mm.
Otherwise repeat the operation to position the timing belt. (See correspon-
ding operation).
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CHECKING AND SETTING THE VALVE TIMING C3
Engines : 8HY - 8HV

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].

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C3 CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

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.

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CHECKING AND SETTING THE VALVE TIMING C3
Engines : 8HY - 8HV

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».

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C3 CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

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).
B1EP18WD - The sensor (14).

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CHECKING AND SETTING THE VALVE TIMING C3
Engines : 8HY - 8HV

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).
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C3 CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

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.

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO
Engines : 6FZ - RFN # 2003
TOOLS
[1] Camshaft setting pegs : (-).0189.A
[2] Crankshaft setting peg : (-).0189.B Tool kit C.0189.
[3] Belt locking pin : (-).0189.K
[4] Angular tightening adaptor : 4069-T.
[5] Hub immobilising tool : 6310-T
Checking the valve timing
-Turn the engine by the crankshaft pinion screw (3) to bring it to pegging position.
-Peg the crankshaft, using tool [2].
-Peg the camshaft pulleys, using tools [1].
NOTE : The pegs [1] must go in without effort.
WARNING : If the pegs do not engage without effort, restart the fitting and
tensioning of the timing belt (see below).
Setting the valve timing
Remove
- Remove the screws (2), the pulley (1), upper valve cover (4), lower valve cover (3).
- Turn the engine by the screw (13) of the pinion (12) to bring it to pegging position.
- Peg the pulleys (8) and (9) using tools [1].
- Peg the pinion (12) using tool [2].
- Loosen the screw (7) of the tensioner roller (6).
- Turn the tensioner roller (6) (clockwise).
- Remove the timing belt (10).
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Engines : 6FZ - RFN # 2003

Refit
- Refit the belt (10) on the pinion (12).
- Hold the belt (10) with tool [3].
- Position the belt (10) in the following order :
- The guide roller (11), the inlet camshaft pinion (9), the exhaust camshaft pinion (8), the water pump (5), the
tensioner roller (6).
NOTE : Make sure that the belt (10) is as flush as possilble with the outer face of the various pinions and rollers.
- Remove the tools [3] and [1].
Timing belt tension
Adjusting the tension
- Turn the roller (6) in the direction of the arrow «b»; using an Allen key at «a».
- Position the index «c» in its maximum setting at «d».
IMPERATIVE : The index «c» must stand proud of the notch «f» by an angular value of 10°. If it does not,
replace the tensioner roller (6) or the timing belt and the tensioner roller (6).
Bring the index «c» to its adjusting position «f» by turning the tensioner roller (6) in the direction of the arrow «e»
WARNING: The index «c» must not stand proud of the notch «f» : if it does, restart the timing belt tensioning
operation.
IMPERATIVE : The tensioner roller (6) must not turn while its fixing is being tightened up. If it does,
recommence the adjusting operation.
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CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO
Engines : 6FZ - RFN # 2003

Adjusting the tension (continued).

- Tighten the screw (7) of the the tensioner roller (6) to 2.1 ± 0.2 m.daN.

IMPERATIVE : The hexagonal drive of the tensioner roller (6) must be at 15° below the level of the cylinder
head gasket «g». If not, replace the tensioner roller (6) or the timing belt and the tensioner roller (6).

Refit (continued).
- Remove the tools [1] et [2].
- Turn the crankshaft 10 times in the normal direction of rotation.

IMPERATIVE : No pressure or outside action must be brought to bear on the timing belt.
- Peg the inlet camshaft pulley, using the tool [1].
Checks.
Timing belt tension.
IMPERATIVE : Check the position of the index «c», it should be facing the notch «f». If the position of index
«c» is not correct, restart the adjustment of its position.
Positioning of the crankshaft.
- Fit tool [2].
- As long as it is possible to fit tool [2], continue with the refit operations.
IMPERATIVE : If it is not possible to fit tool [2], reposition the flange (14).
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XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING

Engines : 6FZ - RFN # 2003

Checks (continued)

Repositioning the flange

- Immobilise the crankshaft using tool [5].
- Loosen the screw (13).
- Release the pinion (12) of the crankshaft.
- Bring the flange (14) to the pegging position; using tool [5].
- Fit the tool [2].
- Immobilise the crankshaft using tool [5].
- Tighten screw (13) to 4 ± 0.4 m.daN, then angular tighten :
53° ± 4° (fitting with steel washer, gold colour)
40° ± 4° (fitting with sintered washer, metallic colour)
using tool [4].
- Remove tools [1], [2] and [5].
Refit :
- The lower valve cover (3).
- The upper valve cover (4).
- The crankshaft pulley (1).
- The screws (2).
- Pretighten the screws (2) to 1.5 m.daN.
- Tighten the screws (2) to 2.1 ± 0.5 m.daN.
B1EP14PC B1EP14JD B1BP23XC

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO
Engine : RFN # 2003
Tools.
[1] Crankshaft setting peg : (-).0189-B
[2] Camshaft hub setting pegs : (-).0189-AZ
[3] Belt locking pin : (-).0189-K
[4] Positioning peg : (-).0189-J
[5] Hub immobilising tool : (-).6310-T
Removing.
Disconnect the battery.
Remove:
- The under-engine shield.
- The accessories drive belt (See corresponding operation).
Move aside :
- The fuel delivery pipe.
- The canister purge electrovalve.
- The expansion chamber
Remove :
-The screws (1) and (2).
- The torque reaction rod (3).
- The screws (4), plus the accessories drive pulley.
- The timing cover (5) and (6).
WARNING : Do not slacken the fixing screws (A). B1EK1UDD B1EK1T7D B1EK0V7D

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Engine : RFN # 2003

Removing (continued).

Peg :

- The camshafts, using tool [2].

- The crankshaft, using tool [1].

Slacken screw (7), holding tool [4].

Using the hexagonal key (C), turn the eccentric hub (8) of the tensioner
roller (9) (clockwise), to detension the belt. The cursor (10) presses on
the tool [4].

Remove the timing belt.

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CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO
Engine : RFN # 2003

Refitting.

Systematically replace the timing belt.

IMPERATIVE : Check that the rollers (9) and (11), as well as the coolant pump (12), turn
freely (no tight spot).

If replacing the roller (11), tighten the fixing to 3,5 ± 0,3 m.daN.

Engage the belt on the crankshaft pinion (13), respecting its direction of fitting.

Immobilise the belt, using tool [3].

Refit the timing belt, well tensioned, in the following order :

- Guide roller (11).
- Pinions (14) and (15).
- Coolant pump (12).
- Tensioner roller (9).

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XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING

Engine : RFN # 2003
Fitting tension of the timing belt.
Remove the tool [3].
(D) : Maximum position.
(E) : Nominal tension position.
Using the hexagonal key (C), turn the hub of the roller (anti-clockwise), to bring the index (10) to position (D) so as
to tension the belt to the maximum.
Turn the eccentric hub (8) of the roller (9) (clockwise), until the cursor (10) just comes into contact with the peg [4].
IMPERATIVE : Never turn the eccentric hub (8) by a complete rotation if the tool [4] is in position.
B1EK1T9D
NOTE : This operation enables you to place the index (10) in the nominal position (E).
Tighten the screw (7) to 2 ± 0,2 m.daN holding the roller with the aid of the hexagonal key (C).
Remove pegs [1], [2] and [4].
Checks.
Turn the crankshaft by two rotations (direction of engine rotation).
IMPERATIVE : Never rotate the crankshaft backwards.
Make sure that the timing is correctly set by refitting the pegs [1] and [2].
Remove pegs [1] and [2].
Rotate the crankshaft ten times (direction of engine rotation).
Check the position of the index (10).
If the tensioner index is not at its adjusting position (E), recommence the operation to tension the timing belt.

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CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO
Engine : RFN # 2003

Position of the crankshaft.

NOTE : This operation enables you to position all the pegs in their respective pegging points.

Peg :
- The camshaft pulleys, using tool [2].
- The crankshaft, using tool [1].
If this should not be possible, reposition the flange (17).
B1EK1TBD
IMPERATIVE : This operation guarantees the setting of the timing for subsequent operations.

Slacken the screw (16) so as to free the pinion (17) of the crankshaft.
Bring the flange (17) to the pegging point, using tool [5].
Position the tool [1].
Tighten the screw (16) to : (Tool FACOM D360).
Tighten to : 4 ± 0,4 m.daN
Angular tighten : 53° ± 5°
Remove tools [1], [2] and [5].

ESSENTIAL : When tightening screw (16), hold the pulley (17) by means of tool [5].
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XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING

Engine : RFN # 2003

Refitting (continued).

Refit :

- The timing cover (6).

- The accessories drive pulley.

B1EK0V7D
- Screws (4), tighten to 2,1 ± 0,2 m.daN.

- The timing cover (5).

- The torque reaction rod (3).

- Screws (1) and (2), tighten to 4,5 ± 0,4 m.daN.

Refit the accessories drive belt (See corresponding operation).

Continue the refitting operations in reverse order to removal.

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OLD FITTING # 2003 Engines : 6FZ - RFN # 2003

(1) Crankshaft pinion.

(2) Flange.

(3) Accessories drive pulley.

(4) Screw fixing accessories drive pulley on flange (2).

(5) Screw fixing the flange (2) on the crankshaft.

«a» Integral keyway.

«b» Keyway slot.

The timing belt drive pinion (1) is separate from the flange (2).
With the fixing screw (5) of the flange (2) not slackened, the pinion (1) floats within the limit
of travel of the integral keyway «a» in the keyway slot «b».

NOTE : The flange is immobilised on the crankshaft by a half-moon keyway and by the screw (5).

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XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING

NEW FITTING 2003 # Engines : 6FZ - RFN 2003 #

(6) Crankshaft pinion.

(7) Accessories drive pulley.
(8) Washer.
(9) Screw.
The pinion (6) is fitted as an idler on the crankshaft.
The accessories drive pulley (7) is immobilised on the crankshaft by a half-moon keyway and
by the tightening of washer (8) and screw (9).
A : Pegging on manual gearbox.
B : Pegging on automatic gearbox.
B1EP1B9D
The pegging of the crankshaft is done on the flywheel, or on the converter drive plate (auto-
matic gearbox).
The pegging hole on the cylinder block (exhaust end) is calibrated and reinforced.

IMPERATIVE : Never turn the crankshaft with the accessories drive pulley slackened.

IMPERATIVE : Never remove the accessories drive pulley without pegging the
crankshaft and the camshafts.

IMPERATIVE : Always turn the crankshaft in the direction of engine rotation.

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CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO
Engines : 6FZ - RFN 2003 #

Tools.
[1] Camshaft setting peg : (-) 0189.A
[2] Crankshaft setting peg : (-).0189.R
[3] Timing belt retaining pin : (-).0189.K
[4] Adaptor for angular tightening : 4069-T
[5] Tool for moving and locking the tensioner roller : (-).0189.S
[5a] : (-).0189.S1
[5b] : (-).0189 S2
Pliers for removing plastic pins : 7504-T

Checking the setting of the timing

Removing.
Disconnect the battery negative terminal (See corresponding operation).
Raise and support the vehicle, front wheels hanging.
Remove :
The front RH wheel.
The plastic pins (1).
The splash-shield (2).
The upper timing cover.
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NEW FITTING # 2003 Engines : 6FZ - RFN 2003 #

Checking the setting of the timing (continued).

Turn the engine by means of the crankshaft pinion screw, to bring it to the pegging position.

Peg the crankshaft, using tool [2].

Peg the camshaft pulleys, using tool [3].

B1BP2V5D
WARNING : If the pegs go in only with difficulty, repeat the operation for fitting and tensioning
the timing belt (See corresponding operation).

Refitting.

Remove tools [2] and [3].

Complete the refitting in reverse order to removal.

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CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO
Engines : 6FZ - RFN 2003 #

Setting the timing.

Removing.
Disconnect the battery negative terminal (See corresponding operation).
Raise and support the vehicle, front wheels hanging.
Remove:
The front RH wheel.
The plastic pins (1).
The splash-shield (2).
The accessories drive belt (See corresponding operation).

Unclip and move aside the fuel delivery hose from the timing cover.

Remove the upper timing cover (1).

Turn the engine by means of the screw (3) of the crankshaft pulley (2) to bring it to the pegging position.

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XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING

Engines : 6FZ - RFN 2003 #

Setting the timing (continued)

Peg:
The crankshaft, using tool [2].
The camshaft pulleys (5) and (6), using tool [1].

Remove:
The screw (3) of the crankshaft pulley (2).
The lower timing cover (4) (by moving the engine).

IMPERATIVE : Never remove the crankshaft pulley (2) without pegging the crankshaft
and the camshafts.

Slacken the screw (9) of the tensioner roller (8).

Turn the tensioner roller (8) (clockwise).
Remove the timing belt (7).

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Engines : 6FZ - RFN 2003 #

Setting the timing (continued)

Turn the tensioner roller (8), using tool [5a] to go beyond slot (b).
Position the tool [5b] to lock the index (a) and remove the tool [5a].
Reposition the timing belt (7) on the crankshaft pulley.
Hold the timing belt (7) in place using tool [3].
Fit the timing belt (7) in place, respecting the following order :
- Guide roller (10).
- Inlet camshaft pulley (6).
- Exhaust camshaft pulley (5).
- Coolant pump (11).
-Tensioner roller (8).
NOTE : Make so that the belt (7) is as flush as possible with the exterior face of the various
pinions and rollers.
Remove :
Tool [3].
Tool [1] from the exhaust camshaft pulley.
Tool [5b] from the tensioner roller (8).
Refit :
The lower timing cover (4) (by moving the engine)
The crankshaft pulley (2).
Screw (3) of the crankshaft pulley
Tighten screw (3) to 4 ± 0,4 m.daN, then angular tighten to 53° ± 4°, tool [4].
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Engines : 6FZ-RFN 2003 #
Tensioning the timing belt.
Turn the tensioner roller (8) in the direction of the arrow « c », by means of a hexagonal spanner at « d ».
Positionner l’index « a » en poition « f ».

IMPERATVE : The index «a» should go past the slot « g » by an angular value of 10°.
If it does not, replace the tensioner roller or the timing belt and tensioner roller assembly.
Next bring the index « a » to its adjusting position « g », by turning the tensioner roller in the direction of the arrow « e ».

WARNING : the index « a » should not pass the slot « g ».

B1EP1BEC Otherwise, repeat the operation to tension the timing belt.

IMPERATIVE : The tensioner roller should not turn during the tightening of its fixing.
If it does, repeat the operation to tension the timing belt.

Tighten the screw (9) of the tensioner roller (8) to 2,1 ± 0,2 m.daN.

IMPERATIVE : The hexagonal tensioner roller drive should be approx. 15° below the level of the cylinder
head gasket « h ».
If it is not, replace the tensioner roller or the timing belt and tensioner roller assembly.

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CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO
Engines : 6FZ - RFN 2003 #

Refitting (continued)
Remove the tools [1] and [2].
Rotate the crankshaft ten times (normal direction of rotation).

IMPERATIVE : No pressure or outside force should be brought to bear on the timing belt.

Peg the inlet camshaft pulley, using tool [1].

Checks.
B1EP1BEC

Tension of the timing belt.

ESSENTIAL : Check the position of the index « a », which should be opposite the slot « g ».
If the position of the index « a » is not correct, repeat the operations to tension the timing belt.

Refit the upper timing cover (1).

Clip the fuel delivery hose on the timing cover.
Refit the accessories drive belt (See corresponding operation).
Lower the vehicle.
Reconnect the battery (See corresponding operation).
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XSARA CHECKING AND SETTING THE VALVE TIMING

Engine : RFS

TOOLS

[1] Belt tension measuring instrument : 4122-T

[2]
[3]
Camshaft pulley locating peg
Crankshaft locating peg
:
:
9041-T.Z
7014-T.N  Tool kit 7004-T
[4] Camshaft pulley locking peg : 4200-T.G
[5] Tensioner spanner : 7017-T.W Tool kit 7004-T
[6] Toothed sector for locking the flywheel : 9044-T

CHECKING THE SETTING

- Turn the engine by the crankshaft screw (1).
- Peg the crankshaft using the tool [3].

ESSENTIAL : Check that the crankshaft DAMPERS pulley is in good condition. If the hub/pulley mar-
kings do not line up, the crankshaft pulley must be replaced.

- Peg the camshaft using the tool [2].

(The locating pegs [2] should slide in easily).
- If this is not the case, set the timing.

NOTE : Camshaft hubs (See pages 138 and 139).

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CHECKING AND SETTING THE VALVE TIMING XSARA
Engine : RFS
Setting the valve timing.

Peg the crankshaft using tool [3]. Refit :

- Peg the camshaft pulleys using tool [2].
- Lock the flywheel using the tool [6]. - The pulley (5).
- The screw (4) (Tighten moderately).
- The peg [3].

Remove : Remove :

- The peg [3]. - The tool [6].

- The screw (4) (Brush the screw thread). - The studs (8).
- The pulley (5). - Fit the tool [4].
- The lower cover (6). - Loosen the screws (10).
- Remove the tool [4].
- Slacken the tensioner roller (7).
- Remove the belt (9).

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XSARA CHECKING AND SETTING THE VALVE TIMING

Engine : RFS

Pretensioning the timing belt.

- Peg the crankshaft using the tool [3].
- Peg the camshaft pulleys using the tool [2].
NOTE : Ensure that the camshaft pulleys rotate freely on the hubs. Clean the contact faces of the pulleys and
hubs.
- Turn the camshaft pulleys in a clockwise direction to bring them to the end of the slots.
- Fit the belt (9).
- Fit the tool [1].
Turn the roller (7) using the tool [5].
- Pre-tension to : (Pulleys slackened).

Engine RFS
New belt 55 SEEM units

- Tighten the screws of the roller (7) to 2 m.daN.

- Fit the tool [4].
- Tighten the screws (10) to 4 m.daN.
- Remove the tools.
- Rotate the crankshaft by six turns (Normal direction of rotation).

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CHECKING AND SETTING THE VALVE TIMING XSARA
Engine : RFS

Tensioning the timing belt.

- Peg the crankshaft using the tool [3].
- Peg the camshaft pulleys using the tool [2].
NOTE : If it is not easy to peg the camshaft hubs, loosen the tensioner roller (7), and turn the camshafts using
the screw (10).

- Fit the tool [4].

- Loosen the screws (10).
- Remove the tool [4].
- Loosen the tensioner roller (7).
- Fit the tool [1] to the belt.
- Turn the roller (7) using the tool [5].

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Engine : RFS

- Tension to : (Pulleys slackened).

Engine Engine : RFS

New belt 35 SEEM units

- Tighten the screw of the roller (7) to 2 m.daN.

Fit the tool [4].

- Tighten the screws (10) to 7.5 m.daN.
- Remove the tools.
- Rotate the crankshaft by two turns (Normal direction of rotation).
- Check the pegging of the crankshaft/camshaft using tools [2] and [3].

NOTE : Tools [2] and [3] should slide in easily.

- Remove the tools.

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING XSARA
Engine : WJY

TOOLS

- [1] HM screw : (-) 0 188 E

- [2] Locating peg Ø 6 mm : (-) 0 188 H
- [3] Flywheel locating peg : (-) 0 188 D ( or 7014-T.J) Tool kit (-) 0 188.
- [4] Toothed sector for locking the flywheel : (-) 0 188 F
- [5] Belt retaining clip : (-) 0 188 K
- [6] Square drive for adjusting the tension : (-) 0 188 J
- [7] Belt tension measuring instrument : 4122-T
- [8] Toothed sector for locking the flywheel : 6016-T

Checking the valve timing

- Peg the flywheel using tool [3].

- Visually check that the offset between the camshaft and injection pump hub holes, and the corresponding
pegging holes do not exceed 1 mm.

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XSARA CHECKING AND SETTING THE VALVE TIMING

Engine : WJY

Setting the valve timing

Peg :
- The camshaft hub (1), using tool [1].
- The injection pump pinion (2), using tool [2].
- The flywheel, using tool [3].

- Lock the flywheel, using tool [4].

- Refit the screw (3) (without tightening it). (Coat the threads with E6).

- Tighten the screw (3) to 4 m.daN and finish by carrying out an angular tightening
of 60°.
- Remove the tool [4].
- Retighten screws (4) and (5) by hand.
- Turn the pinions (6) and (2) so that they are at the end of their stops. (Clockwise
direction).
- Place the belt on the crankshaft and hold in place using tool [5].
- Fit the belt in the following order:
Roller (7), pinion (2), pinion (6), pump (8) and roller (9).

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CHECKING AND SETTING THE VALVE TIMING XSARA
Engine : WJY

Setting the valve timing (continued)

NOTE : If necessary, slightly turn pinions (6) and (2) in an anti-clockwise direction in
order to fit the belt.
The angular movement of the belt in relation to the pinions must not exceed half a
tooth.

- Fit the tool [7] to the belt strap at "a".

-Turn the roller (9) (anti-clockwise) using tool [6], to obtain:
106 ± 2 SEEM units.

- Check that pinions (6) and (2) are not at the end of their stops.
Otherwise, repeat the belt fitting procedure from the beginning.

Tighten:
- The roller (9) to 4.5 m.daN.
- The screws (4) and (5) to 2.5 m.daN.
- Remove the tools [7], [5], [1], [2] and [3].

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XSARA CHECKING AND SETTING THE VALVE TIMING

Engine : WJY

Setting the valve timing (continued)

Rotate the crankshaft by 8 turns (direction of rotation).

Peg :
- The hub (1), using tool [1].
- The pinion (2), using tool [2].
- The flywheel, using the tool [3].

Loosen :
- The screws (4) and (5).
- The roller (9).
- Retighten screws (4) and (5) by hand.
- Fit the tool [7] to the belt strap at "a".
- Turn the roller (9) (anti-clockwise direction) using tool [6], to obtain :
42 ± 2 SEEM units.

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CHECKING AND SETTING THE VALVE TIMING XSARA
Engine : WJY

Setting the valve timing (continued)

Tighten :
- The roller (9) to 2.1 m.daN.
- The screws (4) and (5) to 2.3 m.daN.

- Remove the tool [7].

- Fit the tool [7] to the belt strap at "a".

- The tensioning value should be between 42 ± 4 SEEM units.

ESSENTIAL : If the value obtained is outside the set limits, repeat the
tensioning operation.

- Remove the tools [7], [5], [1], [2] and [3].

- Rotate the crankshaft by 2 turns (direction of rotation).

- Check the valve timing.

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XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING

Engines : RHY-RHZ # N° RPO 9127
Tools
[1] Belt tension measuring instrument : 4122-T
[2] Tension lever : (-).188.J2
[3] Engine flywheel peg : (-).188.X
[4] Belt retaining pin : (-).0188.K
[5] Camshaft pinion peg : (-).0188.M
[6] Engine flywheel lock : (-).0188.F
[7] Set of blocking plugs : (-).0188.T
[8] Crankshaft pulley extractor : (-).0188.P
Checking the setting of the valve timing.
Peg :
The engine flywheel, tool [3] (from below the vehicle).
The camshaft, tool [5].
WARNING : On removing the screws (6), (7), (9), and (5) from the timing cover,
refit screw (5) equipped with a spacer (thickness 17 mm)
Tighten to 1,5 ± 0,1m.daN.
(Screw (5) is one of the fixing screws for the coolant pump and is used for its sealing).
WARNING : Should it be impossible to peg the camshaft, check that the
offset between the camshaft pinion hole and the pegging hole is not more
than 1 mm, with the help of a mirror « a » and a Ø 7 mm screw.
IMPERATIVE : If pegging is impossible, restart the adjusting.
(See corresponding operation).

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Engines : RHY-RHZ # N° RPO 9127

Setting the valve timing.

Peg :

The engine flywheel, tool [3] (from below the vehicle).

The camshaft, tool [5].
Slacken :
The three screws (21).
The screw (19) of the tensioner roller (20).
Remove the timing belt (22).

Checks.
IMPERATIVE : Just before refitting, carry out the checks below :

Check that :
- the rollers (20), (23) and the coolant pump turn freely (without play or tightness).
- there are no traces of oil (on camshaft or crankshaft)
- there are no leaks of engine coolant (coolant pump).
Replace defective components if necessary.

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XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING

Engines : RHY - RHZ # N° RPO 9127

Setting the valve timing (continued)

- Setting the valve timing (continued)

- Retighten screws (21) by hand.
- Turn the pinion (24) (clockwise) to the bottom of the buttonhole.
- Refit the belt on the crankshaft (25), in the following order, using the
tool [4] to keep the belt tight at « a ».
- Guide roller (23).
- Fuel high pressure pump pinion (26).
- Camshaft pinion (24).
- Coolant pump pinion (18).
- Tensioner roller (20).

NOTE : If needed, slightly turn the pinion (24) anti-clockwise (the

offset should not be more than one tooth).

- Remove the tool [4].

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CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO
Engines : RHY - RHZ # N° RPO 9127

Setting the valve timing (continued)

Position tool [1] on the belt at « b ».

Turn the roller (20) (anti-clockwise) using tool [2] to attain a tension of :
98 ± 2 SEEM units

Tighten the screw of the roller (19), tighten to 2.5 m.daN.

Remove one screw (21) from the pinion (24).
(to check that the screws are not against the end of the buttonhole).
Tighten the screws (21) to 2 m daN.
Remove tools [1], [2], [3] and [5].
Rotate the crankshaft 8 times (normal direction of rotation).
Fit the tool [3].
Loosen screws (21).
Fit tool [5].
Loosen screw (19) (to free the roller).
Fit tool [1].
Turn the roller (20) (anti-clockwise), tool [2], to attain a tension of :
54 ± 2 SEEM units.

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XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING

Engines : RHY - RHZ # N° RPO 9127

Setting the valve timing (continued)

Tighten :
The screw of the roller (19) to 2.5 ± 0.2 m.daN.
The screw (21) to 2 ± 0.2 m.daN.
Remove the tool [1].
Refit the tool [1].
Tension value should be : 54 ± 3 SEEM units.

IMPERATIVE : If value is incorrect, restart the operation.

- Remove tools [1], [3] and [5].
- Rotate the crankshaft 2 times (normal direction of rotation).
- Fit the tool [3].

WARNING : Should it be impossible to peg the camshaft, check

that the offset between the camshaft pinion hole and the pegging
hole is not more than 1 mm..
In the case of an incorrect value, recommence the operation.

- Remove the tool [3].

- Complete the refitting of components.
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 ENGINE
SPECIAL FEATURES: CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO
Engines : RHY - RHZ N° RPO 9128 #
OLD FITTING # N° RPO 9127 NEW FITTING N° RPO 9128 #

(1) ) «Idler» camshaft pulley The new timing on 8 valve engines DW10TD (RHY) and DW10 ATED
(2) Target for cylinder reference sensor. (RHS-RHZ) requires the following components :
(3) Camshaft hub. «Idler» crankshaft pinion
(4) «Fixed» crankshaft pinion. «Fixed» camshaft pulley.
The determining of the tension of the timing belt is done on the cam-
(5) «Fixed» camshaft pulley (pulley with integral cylinder reference
shaft pulley (1).
sensor target).
(6) «Idler» crankshaft pinion (with increased width keyway groove).
The determining of the tension of the timing belt is done on the crank-
shaft pinion (6).
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XSARA - XSARA PICASSO SPECIAL FEATURES: CHECKING AND SETTING THE VALVE TIMING
Engines : RHY - RHZ N° RPO 9128 #
NEW FITTING : RPO 9128 # (continued)

The new fitting discontinues the following components :

Camshaft hub.
Cylinder reference sensor target.

Repair – Accessories drive pulley

Remove – Refit

WARNING : Peg the camshaft and the crankshaft before ever removing the
accessories drive pulley (the pegging prevents any offsetting of the camshaft).

If necessary, apply a paint spot to mark the accessories drive pulley being
replaced.

Replacement parts.

The Replacement Parts service markets the old as well as the new components.

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CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO
Engines : RHY - RHZ N° RPO 9128 #

Tools.
Removing
[1] Belt tension measuring equipment : 4122-T
IMPERATIVE : Respect the safety and cleanliness requirements
[2] Tension lever : (-).0188.J2.
that are specific to high pressure diesel injection (HDi) engines.
[3] Engine flywheel peg : (-).0188.Y.
Undo the front RH wheel bolts.
Raise and support the vehicle on the front RH side.
[4] Belt clamp : (-).0188.AD
Disconnect the battery negative terminal.
Remove :
[5] Camshaft pulley peg : (-).0188.M
The under-engine sound-deadening.
The front RH wheel.
[6] Engine flywheel lock : (-).0188.F.
The front RH splash-shield.
The engine cover.
[7] Set of blocking plugs : (-).0188.T.
Unclip and move aside the cooling hose.
Remove the accessories drive belt.
[8] Pulley extractor : (-).0188.P.
(See corresponding operation).
[9] 2 mm dia.peg : (-).0188.Q2

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 ENGINE

XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING

Engines : RHY - RHZ N° RPO 9128 #
Uncouple, plug and move aside, using tool [7], the fuel delivery pipe (2) and
return pipe (1).
Remove :
Screws (3), (4) and (6).
Screw (7).
The upper timing cover (5).

WARNING : Refit screw (7) equipped with a spacer (17 mm thick), tighten
the screw (7) to 1,5 ± 0,1 m. daN.

NOTE : The screw (7) is one of the screws securing the coolant pump and
is there for its sealing.
Put the gear lever in 5th gear.
Turn the road wheel to turn the engine in its direction of rotation.
Orient the camshaft pulley in the pegging position, use a mirror if necessary.

Peg the camshaft, using tool [5].

Peg the engine flywheel, using tool [3].

B1BP2R2C B1EP1A7C B1BP2H2C B1BP2H3C

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO
Engines : RHY - RHZ N° RPO 9128 #
Remove :
The fixings of the pipe linking the power steering pump with the rotary valve.
The clutch lower closing plate.
Lock the engine flywheel, using tool [6].
Remove the screw (8).
Refit the screw (8) without its thrust washer.
Remove :
The accessories pulley (9), using tool [8].
Tool [6].
The lower torque reaction rod.
Support the engine by means of a workshop hoist.
Remove :
The bearing shell fitting (10).
The nut (12).
Screws (11).
The bracket (13).
NOTE : Lift then lower the engine with the workshop hoist, to have access to
the timing cover fixing screws.
Remove :
The intermediate timing cover.
The lower timing cover.

B1CP04BC B1BP2R3C B1BP2R4C

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 ENGINE

XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING

Engines : RHY - RHZ N° RPO 9128 #

Slacken the screw (17) of the tensioner roller (18).

Remove the timing belt (14).

Checks.

IMPERATIVE : Just before refitting, carry out the checks below :

Check that :
The rollers (18) and (15) turn freely (without play and without any tight spot).
The coolant pump pulley (16) turns freely (without play and without any tight spot).
There are no traces of oil leaks from the crankshaft and camshaft seals, etc.
The crankshaft pinion travels freely on the keyway.

Replace defective components if necessary.

Peg the crankshaft pinion (19) by inserting tool [9] on the LH side of the keyway.

B1EP1A8D B1EP1A9C

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO
Engines : RHY - RHZ N° RPO 9128 #

Reposition the timimg belt, belt at «a» well tensioned, in the following order :
Fuel high pressure pump pulley (21).
Guide roller (15).
Crankshaft pinion (19).
Coolant pump pinion (16).
Tensioner roller (18).
Position tool [1] on the belt at «a».
Remove tools [4] and [9].
Turn the tensioner roller (18) anti-clockwise, using tool [2], to attain an overtension of :
98 ± 2 SEEM units.
Tighten screw (17) of the tensioner roller to 2,5 ± 0,2 m.da N.
Lock the flywheel by means of tool [6].
Tighten the accessories drive pulley screw (8) to 7 ± 0,7 m.da N.
Remove tools [1], [3], [5] and [6].
Rotate the crankshaft eight times in the normal direction of rotation.
Peg :
The crankshaft, using tool [3].
The camshaft drive pulley, using tool [5].

B1EP1ABD B1EP1ACC

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 ENGINE

XSARA - XSARA PICASSO CHECKING AND SETTING THE VALVE TIMING

Engines : RHY - RHZ N° RPO 9128 #

Lock the engine flywheel, using tool [6].

Slacken : The accessories drive pulley (8).
The screw (17) of the tensioner roller (18).
Fit the tool [1].
Turn the tensioner roller, using tool [2], to attain a tension of :
54 ± 2 SEEM units.
Tighten screw (17) of the tensioner roller (18) to 2,5 ± 0,2 m.daN.
Remove tool [1].
Fit tool [1].
The tension value should be :
54 ± 3 SEEM units.
ESSENTIAL : If the value is incorrect, recommence the operation.

Remove tools [1], [3], [5] and [6].

Rotate the crankshaft two times in the normal direction of rotation.
Peg :
The crankshaft, using tool [3].
The camshaft drive pulley.

IMPERATIVE : If the pegging is not possible, recommence the operation.

B1EP1ACC

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING XSARA - XSARA PICASSO
Engines : RHY - RHZ N° RPO 9128 #
Remove :
Tools [3] and [5].
Screw (7) and the spacer.
Refit :
The lower, intermediate and upper covers (5).
Screw (7), tighten to 1,5 ± 0,1 m.daN.
Screws (3), (4) and (6).
The bracket (13).
Screws (11), tighten to 6,1 ± 0,5 m.daN.
The nut (12), tighten to 4,5 ± 0,5 m.daN.
Fit the bearing shell (10).
Take away the workshop hoist.
Clip the fuel delivery and return pipes.
Remove the tool [7].
Couple :
The fuel delivery pipe (12).
The fuel return pipe (1).
Coat the screw (8) with loctite FRENETANCH.
Refit the tool [6] and the screw (8) with the washer (22),
Tighten to 7 ± 0,2 m.daN and angular tighten to A = 60° ± 5°
Refit the torque reaction rod on the lower engine support.
Remove the tool [6].
Reposition and reclip the cooling hose.
Complete the refitting of components in reverse order to removal.
B1EP1A7C B1BP2R4C B1EP1ADC

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 ENGINE

XSARA SPECIAL FEATURES OF THE TIMING

Camshaft hub identification RFS

Engine Hubs ‘‘a’’ engraving ‘‘b’’ paint marking

Inlet
RFS B BLUE
Exhaust

B1EP122C

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 ENGINE
VALVE CLEARANCE SETTINGS ALL TYPES
POSSIBLE PROCEDURES
The valve clearances must be checked with the engine cold
For engines with 4 cylinders in a line (1-3-4-2 )
Rocking Fully open (Exhaust)
● Inlet Exhaust
Valves fully
Rocking Adjust open
Adjust
Petrol All Types
0.20 mm ± 0.05 0.40 mm ± 0.05
(except 16V - NFU) Inlet 3 ●
1● 1 4● 4 1 4

3● 3 2● 2 3 4 ● 2
NFU 1 mm ± 0.05 1 mm ± 0.05
4● 4 1● ● 4 2 ● 1
1
Exhaust
Petrol - 16V 2● 2 3● 3 2 1 ● 3
1.4 HDi
Hydraulic adjustment
1.4 16V HDi
2.0 HDi
Diesel All Types Engines without hydraulic
(except: 1.4 HDi adjustment : the clearance (J)
0.15 mm ± 0.08 0.30 mm ± 0.08 should be checked opposite
1.4 16V HDi
2.0 HDi) the cam.

B1DP13QC

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 ENGINE

ALL TYPES CHECKING THE OIL PRESSURE

Tools To be read with the Petrol and Diesel correspondence tables
Tool kit 4103 -T TU all Types EW XU all Types

1.1 i 1.4 i 1.6 i 1.6 i 16V 1.8 i 16V 2.0 i 16V

Vehicle TT C3 TT C3 TT TT C3 TT
Engine type HFX KFW KFV NFV NFT NFX NFU 6FZ RFN RFS
Temperature (°C) 90° 90° 80°
Pressure (Bars) 4 3 4 3 4 3 4 5.5
Rpm 4000 2000 4000 2000 4000 2000 4000
TUD all Types DV4TD DV4TED4 DW8 DW10TD
1.5 D 1.4 HDi 1.4 16V HDi 1.9 D 2.0 HDi
Engine type VJX 8HX 8HW 8HV 8HY WJY RHY RHZ
Temperature (°C) 90° 80°
Pressure (Bars) 4 > 1.3 4.5 4
Rpm 4000 1000 4000

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 ENGINE
OIL FILTERS ALL TYPES
TU All Types EW XU
1.1 i 1.4 i 1.6 i 1.6i 16V 1.8i 2.0i 16V
HFX KFW KFV NFT NFV NFX NFU 6FZ RFN RFS
FILTRAUTO 1109 R7
LS 867 B 1109 N3
PURFLUX
LS 923 1109 T1

TUD5 DV4TD DV4TED4 DW8 DW10

1.5 D 1.4 HDi 1.4 16V HDi 1.9D 2.0 HDi
VJX 8HX 8HW 8HZ 8HV 8HY WJY RHY RHZ
MALHE 1109 T3
LS 923 1109 T1
PURFLUX
LS 867 B 1109 N3

Diameter (mm) Height (mm)

LS 923 1109 T1
Specification 76 89
LS 867 B 1109 N3
TU engine (except L4) : The PURFLUX LS 867 filter is still available.
EW and DW engines : The PURFLUX LS 304 filter has been replaced by the PURFLUX LS 923 filter.

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 ENGINE

ALL TYPES FILLING AND BLEEDING THE COOLING CIRCUIT

TOOLS
[1] Filling cylinder : 4520-T
[2] Adaptor for filling cylinder : 4222-T.

IMPERATIVE : Respect the safety and cleanliness requirements.

- The draining and refilling operations can be carried out using WINN’S or similar coolant fluid replacement
equipment; it is essential to follow the instructions as stated for that equipment.

Filling and bleeding

- Fit the cylinder adaptor [2] 4222-T (Picasso and C3) and the filling cylinder [1] 4520-T (all types).
- Use the coolant to ensure protection between - 15°C and - 37°C.
- Slowly fill the system.

NOTE : Keep the cylinder filled up (visible level).

- Close each bleed screw as soon as the coolant flows without air bubbles.
- Start the engine : Engine speed 1500 rpm.
- Maintain this speed until the first cooling cycle (cooling fans cut in and cut out).
- Stop the engine and allow it to cool down.
- Remove the filling cylinder [1] 4520-T (all types) and the cylinder adaptor [2] 4222-T.
- Top up the system to the max. mark, with the engine cold.
- Refit the filler cap. B1GP00AC E5AP1GNC

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 IDLING - DEPOLLUTION SAXO - C3 - XSARA PICASSO
Idling speed
(± 50 rpm) % Content
Emission
Vehicles Engine type Make - Injection type
standard
Man. Auto. gbox : N
CO CO2
gbox gear engaged
1.1 i HFX L4 BOSCH M7.4.4.

INJECTION
1.4 i KFW L4 SAGEM 2000 850
SAXO
1.6 i NFT L4 BOSCH M7.4.4.
1.6 i 16V NFX L4 M. MARELLI 48P2 800 < 0.5 >9
1.1 i HFX L4 -IF/L5 MAGNETTI MARELLI 48P
C3 1.4 i KFW L4 - IF/L5 SAGEM S2000 850
1.6 i 16V NFU L4 BOSCH M 7.4.4.
1.4 i KFW IFL5/L4 SAGEM S2000
1.6i NFU L4 BOSCH M.7.4.4.
C3 850
2.0 i RFN L4 MAGNETTI MARELLI MM 48.P2
< 0.5 >9
2.0 i 16V RFS L3 M. MARELLI 1AP10

XSARA 1.6i NFV L4 BOSCH M7.4.4. 850

PICASSO 1.8i 6FZ L4 SAGEM - S2000 700

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 SAXO PETROL INJECTION
SAXO

1.1 i 1.4 i 1.6 i 1.6 i 16 V

INJECTION

Engine type HFX KFW NFT NFX

Emission standard IFL5 / L4 L4 L4 L4
Injection make BOSCH SAGEM BOSCH M. MARELLI
and type M.7.4.4. S2000 M.7.4.4. 48P2

Fuel pressure (bars) 3 3 3.5 3

Overspeed cut-off (rpm) 5500 5500 5700 6600
Injector resistive value (ohms) 14.5 14.5 14.5 14.5

Engine coolant temperature

sensor resistive value (ohms)
3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C

Idling actuator or stepper

motor resistive value (ohms)
Idle actuator : 11

Air temperature sensor

resistive value (ohms) 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C

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 PETROL INJECTION C3
C3

1.1i 1.4i 1.6i 16 V

INJECTION
Engine type HFX KFW NFU
Emission standard L4 / IFL5 L4 L4

Injection make
M. MARELLI 48P2 SAGEM S2000 BOSCH M.7.4.4.
and type

Fuel pressure (bars) 3.5 3.5 3.5

Overspeed cut-off (rpm) 5500 5500 5800
Injector resistive value (ohms) 14.5 14.5 14.5
Engine coolant temperature
3 800 at 10°C 2500 at 20° C 800 at 50°C 230 at 90° C
sensor resistive value (ohms)

Idling actuator or stepper Idle actuator : 53

motor resistive value (ohms)

Air temperature sensor

resistive value (ohms) 3 800 at 10°C 2500 at 20° C 800 at 50°C 230 at 90° C

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 XSARA - XSARA PICASSO PETROL INJECTION
XSARA XSARA PICASSO

1.4 i 1.6 i 16 V 2.0 i 16 V 2.0 i 16 V 1.6 i 1.8 i 16 V

INJECTION

Engine type KFW NFU RFN RFS NFV 6FZ

Emission standard IFL5 / L4 IFL5 / L4 / K’ IFL5 / L4 L4 L3 IFL5 / L4

Injection make SAGEM BOSCH M. MARELLI M. MARELLI BOSCH SAGEM

and type S2000 M.7.4.4. 48P2 1AP10 M.7.4.4. S2000

Fuel pressure (bars) 3 3 3.5 3 3.5 3.5

Overspeed cut-off (rpm) 5500 5800 6000 6500 5700 5500
Injector resistive value (ohms) 14.5 14.5 12.2 16 14.5 12.2

Engine coolant temperature

sensor resistive value (ohms) 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C

Idling actuator or stepper

motor resistive value (ohms)
Stepper motor: 53

Air temperature sensor

resistive value (ohms) 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C

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 DEPOLLUTION TECHNICAL CHECKS (FRANCE) ALL TYPES
All Types Petrol CO Corrected (In %) All Types Diesel (m-1)

Conditions : At idle, engine warm.

INJECTION
# 01/96
Less than 4.5 % for vehicles registered before 10/86.
Less than 3.5 % for vehicles registered after 10/86. 01/96 #

Atmospheric engine.
With catalytic converter
Greater than 2.0i 89 M.Y. Less than 2.5 m -1
All Types 93 M.Y.
Turbocharged engine.
CO less than 0.5 % at idle speed.
CO less than 0.3 % at fast idle speed between 2500 and 3000 rpm(*)
Less than 3.0 m -1

Lambda Probe value 0,97 to 1,03.

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 ALL TYPES EMISSION STANDARDS
STANDARD APPLICATIONS
PSA NOTES CHARACTERISTICS
E.E.C. Engines Vehicles Applicable
A/S RP
INJECTION

➞ Utility vehicle limits

➞ 10/89 = private vehicle limits
ECE increased by 25 % With oxygen sensor,
K 15.04 Petrol Utility vehicles :
R 15.04 K’ 15.04 without catalytic
Diesel All Types
➞ For private vehicles converter
imminent and utility vehicles
in major export

Private vehicles : Brussels directive 88/76

ECE
15.05 Petrol > 2 litres « Luxembourg Accords »
R 15.05 W vp
• new models 01/10/88 ➞ ➞ Replaced by 89/458
• existing models 01/10/89 ➞ + 91/441

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 EMISSION STANDARDS ALL TYPES
STANDARD APPLICATIONS
PSA NOTES CHARACTERISTICS
E.E.C. Engines Vehicles Applicable
A/S RP

INJECTION
Private vehicles :
Petrol • certain non-EEC ➞ Adoption of the U.S With oxygen sensor and
US 83 Z US 83 Current catalytic converter for
Diesel European countries standard
• certain Export countries petrol vehicles

Private vehicles :
Petrol • certain non-EEC ➞ Adoption of the U.S With catalytic converter
US 87 Y US 87 Current
Diesel European countries standard and EGR
• certain Export countries

Petrol Private vehicles : ➞ Adoption of the U.S

US 93 Y2 US 93 Current
Diesel • certain Export countries standard

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 ALL TYPES EMISSION STANDARDS
STANDARD APPLICATIONS
PSA NOTES CHARACTERISTICS
E.E.C. Engines Vehicles Applicable
A/S RP

Private vehicles :
INJECTION

➞ Adoption of the U.S.

US 84 Petrol • certain non-EEC
X1 US 84 Current standard for light utility
LDT Diesel European countries
vehicles
• certain Export countries

Private vehicles :
➞ Adoption of the U.S.
US 87 Petrol • certain non-EEC
X2 US 87 Current standard for light utility
LDT Diesel European countries
vehicles
• certain Export countries

Private vehicles :
➞ Adoption of the U.S.
US 90 Petrol • certain non-EEC
X3 US 90 Current standard for light utility
LDT Diesel European countries
vehicles
• certain Export countries

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 EMISSION STANDARDS ALL TYPES
STANDARD APPLICATIONS
PSA NOTES CHARACTERISTICS
E.E.C. Engines Vehicles Applicable
A/S RP

With oxygen sensor and

INJECTION
Private vehicles : reinforced catalytic
Brussels Directive 94/12
EURO 2 converter for petrol
Petrol < 6 seats and
CEE vehicles.
L3 < 2.5 tonnes
(EURO 95 Diesel ➞ EURO 93 standard made
• new models 01/96 ➞ With catalytic converter
96) stricter
• existing models 01/97 ➞ and EGR for diesel
vehicles.

Utility vehicles : Brussels Directive 96/69 With oxygen sensor and

< 3.5 tonnes
reinforced catalytic
EURO 2 Class 1 :
Petrol ➞ 3 classes depending on converter for petrol
W3 CEE • new models 01/97 ➞
Diesel vehicle weight : vehicles.
(EURO 95 Gaz
• existing models 10/97 ➞
96) Class 2/3 : Class 1 < 1250 kg With catalytic converter
• new models 01/98 ➞ Class 2 : 1250/1700 kg and EGR for diesel
• existing models 10/98 ➞ Class 3 : 1700 kg vehicles.

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 ALL TYPES EMISSION STANDARDS
STANDARD APPLICATIONS
PSA NOTES CHARACTERISTICS
E.E.C. Engines Vehicles Applicable
A/S RP
Utility vehicles : Brussels Directive 98/69
INJECTION

➞ EURO 2 standard (L3) With 2 oxygen sensors

< 3.5 tonnes and catalytic converter for
made stricter
petrol vehicles.
EURO 3 Petrol Class 1 :
➞ Fiscal incentives With catalytic converter
W3 Diesel • new models ➞ 01/2000 ➞ 3 classes depending on and EGR for diesel
(EURO Gaz
2000) • existing models ➞ 01/2001 vehicle weight : vehicles.
Class 2/3 : Class 1 < 1305 kg
• new models ➞ 01/2001 With EOBD on-board
Class 2 : 1305/1760 kg
• existing models ➞ 01/2002 diagnosis.
Class 3 : 1760 kg

Private vehicles : With 2 oxygen sensors

Brussels Directive 99/102 and catalytic converter for
All Types
➞ EURO 3 standard (L4) made petrol vehicles.
EURO 4 IF / L5 Petrol
• new models ➞ 01/2005 stricter
• existing models ➞ 01/2006 ➞ Fiscal incentives With EOBD on-board
diagnosis.

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 EMISSION STANDARDS ALL TYPES
STANDARD APPLICATIONS
PSA NOTES CHARACTERISTICS
E.E.C. Engines Vehicles Applicable
A/S RP

INJECTION
Private vehicles : Brussels Directive: 2001/1 With 2 oxygen sensors
All Types ➞ EURO 3 standard (L4) made and catalytic converter for
Petrol
Diesel stricter petrol vehicles.
EURO 4 IF / L5
Gaz • new models ➞ 01/2005 ➞ Fiscal incentives
• existing models ➞ 01/2006 With EOBD on-board
diagnosis.

Utility vehicles : Brussels Directives: 99/102 et

2001/1 (Gas)
< 3.5 tonnes ➞ EURO 3 standard (L4) made With 2 oxygen sensors
stricter and catalytic converter for
Petrol Class 1 : ➞ Fiscal incentives petrol vehicles.
EURO 4 IF / L5
Gaz • new models ➞ 01/2005 ➞ 3 classes depending on
• existing models ➞ 01/2006 vehicle weight : With EOBD on-board
Class 2/3 : Class 1 < 1305 kg diagnosis.
• new models ➞ 01/2006 Class 2 : 1305/1760 kg
• existing models ➞ 01/2007 Class 3 : 1760 kg

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 XSARA - XSARA PICASSO SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM
Engines : RHY - RHZ - 8HX - 8HW - 8HY - 8HV

SAFETY REQUIREMENTS
Preamble.
All interventions on the injection system must be carried out to conform with the following requirements and regulations :
- Competent health authorities.
INJECTION

- Accident prevention.
- Environmental protection.
WARNING : Repairs must be carried out by specialised personnel informed of the safety requirements and of the precautions to be taken.

Safety requirements.
IMPERATIVE : Take into account the very high pressures in the high pressure fuel circuit (1350 bars), and respect the requirements below :
- No smoking in proximity to the high pressure circuit when work is being carried out.
- Avoid working close to flame or sparks.
Engine running :
- Do not work on the high pressure fuel circuit.
- Always stay clear of the trajectory of any possible jet of fuel, which could cause serious injuries.
- Do not place your hand close to any leak in the high pressure fuel circuit.
After the engine has stopped, wait 30 seconds before any intervention.
NOTE : This waiting time is necessary in order to allow the high pressure fuel circuit to return to atmospheric pressure.

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 SAFETY REQUIREMENTS : HDI DIRECT INJECTION SYSTEM XSARA - XSARA PICASSO
Engines : RHY - RHZ - 8HX - 8HW - 8HY - 8HV

CLEANLINESS REQUIREMENTS.

Preliminary operations

INJECTION
IMPERATIVE : The technician should wear clean overalls.

Before working on the injection system, it may be necessary to clean the apertures of the following sensitive components :
(refer to corresponding procedures).
- Fuel filter.
- High pressure fuel pump.
- High pressure fuel injection common rail.
- High pressure fuel pipes
- Diesel injector carriers.

IMPERATIVE : After dismantling, immediately block the apertures of the sensitive components with plugs, to avoid the entry of impurities.
Work area.
- The work area must be clean and free of clutter.
- Components being worked on must be protected from dust contamination.

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 SAXO BOSCH INJECTION PUMP SPECIFICATIONS
PUMP -TYPE - REFERENCE
Emission standards L3/L4
Equipement Transponder
INJECTION

SAXO TUD 5B VJX 539

(*) = The fuel high pressure pump is driven by the timing belt.

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 BOSCH INJECTION PUMP SPECIFICATION SAXO
Static timing Dynamic Reference Adjustments (rpm) Max. speed
Injector
Pump
Engine Initial advance timing Injector Colour
Type needle lift Fast Anti- Unladen Laden
type Compression checking Injector holder code Idling
Reference pressure idling stall rpm rpm
Time (at idle) + injector (Bar)
(cylinder N° 4)

INJECTION
Pump
0,60 ± 0,1 mm KCA 120 800 5450 5000
VJX 539 299 No
After BDC 20S106 ±5 ± 100 ± 160 ± 160

(1) = Engine : TDC peg hole

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 SAXO CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP
Engine : VJX

Tools

- Flywheel locating peg : 4507-T.A


INJECTION

- Mounting plate locating peg : 4527-T.S1 Tool kit 4507-T

- Camshaft peg : 4527-T.S2

Checks
- Peg the flywheel.
- Visually check the pegging of the camshaft and injection pump pulleys, or check
using the tools 4527-T.S1 and 4527-T.S2.

Setting the injection pump.

- Peg :
• The flywheel.
• The camshaft pulley.
- Fit the pump and tighten to 2 m.daN.
- Peg the pump mounting plate.
- Fit the pump drive pinion together with the timing belt. Tighten to 2 m.daN.

B1HP0YAC

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 ADJUSTING THE MECHANICAL CONTROLS OF THE BOSCH INJECTION PUMP SAXO
Engine : VJX

ADJUSTING THE FAST IDLE SPEED.

INJECTION
- Bring the lever (3) into contact with the screw (2).
- Use the screw (2) to obtain the fast idle speed : 1100 ± 100 rpm.

Engine cold.

- Ensure that the lever (3) is up against the screw stop (2).
- If not, slightly tension the cable (4) using the cable clamp (1).
- Finish tensioning with the sheath tensioner (5).

Engine hot.

- Ensure that the cable (4) is slack.

- Check the operation of the thermostatic sensor on the coolant outlet housing : there should be a minimum
6 mm cable travel between a cold and a hot engine.
- If not, replace the thermostatic sensor. Tighten to 2.5 m.daN.

B1HP0HQC B1HP0HUC

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 SAXO ADJUSTING THE MECHANICAL CONTROLS OF THE BOSCH INJECTION PUMP
Engine : VJX (continued)

ADJUSTING THE ACCELERATOR CONTROL.

- Fully depress the accelerator pedal.

INJECTION

- Check that the lever (10) is against the stop screw (6). If not, modify
the position of the spring clip (7).
- Check that, at idle, the lever (10) is against its stop (9).

Preliminary conditions.

- Engine hot (The cooling fan is engaged twice).

- Fast idle control released.

ADJUSTING THE IDLE SPEED.

- Slacken the screw (9) by a few turns until it no longer touches the lever (10).
- Adjust the idling speed using the screw (8).

B1HP0HSD

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 ADJUSTING THE MECHANICAL CONTROLS OF THE BOSCH INJECTION PUMP SAXO
Engine : VJX (continued)

ANTI-STALL ADJUSTMENT.

- Insert a 1 mm shim [1] between the throttle lever (10) and the residual

INJECTION
output adjustment screw (9).
- Turn the residual output adjustment screw (9) to obtain an engine speed
of: 835 ± 40 rpm.
- Remove the shim [1].

CHECKING THE ENGINE DECELERATION.

- Move the throttle lever (10) to obtain an engine speed of 3000 rpm.
- Release the throttle lever (10).
- The deceleration should be between 2 and 3 seconds.

ESSENTIAL : Check the operation of the manually-operated «STOP»

control (11).

B1HP0HRD

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 SAXO FITTING BOSCH INJECTORS
Engine :VJX
[1] Tool to remove/refit injectors 7007-T
Fitting an injector
[2] 7008-T Tool kit 4123-T
The copper seal (1) and the
fire seal washer (2) are to be
INJECTION

replaced each time they are

removed.
NOTE : Fitting parts of diffe-
rent makes is PROHIBITED.
WARNING : Ensure that the
fire seal washer (2) is fitted
the right way round.
Tightening of the injector
holder on the cylinder head:

VJZ
7 m.daN
All Types
(3) Tighten lightly to avoid distortion.
9 m.daN Tighten to 7 m.daN.
B1HP0YNC B1HP0YPC B1HP0YGC

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 PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM C3
Engines : 8HX - 8HW

Cleaning.
- The use of high pressure cleaners is prohibited.
- Do not use compressed air.

INJECTION
Fuel supply circuit.
- Required fuel : diesel.

Electric circuit.
- Swapping injection ECUs between two vehicles will render it impossible to start either vehicle.
- It is forbidden to supply a diesel injector with 12 volts.

High pressure fuel pump.

Do not separate the following components from the high pressure fuel pump (5) :
- Sealing ring (a) (no replacement parts).
- High pressure outlet connector (b) (will cause a malfunction).

PS : HDi = High pressure Diesel injection

B1HP1K9C

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 C3 PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM
Engines : 8HX - 8HW

Diesel injectors.

WARNING: Diesel and ultrasonic cleaners are prohibited.

INJECTION

Do not separate the following components from the diesel injector

carrier (2) :
- Diesel injector (f) (no replacement parts).
- Electromagnetic element (c) (no replacement parts).

Do not alter the position of the nut (d) (malfunction).

Do not separate the connector (e) from a diesel injector.

It is forbidden to clean the carbon deposits from the diesel injector

nozzle.

B1HP1KAC B1HP1KBC

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 PROHIBITED OPERATIONS: DELPHI HDI DIRECT INJECTION SYSTEM C3
Engines : 8HY - 8HV

Cleaning.
- The use of high pressure cleaners is prohibited.
- Do not use compressed air.

INJECTION
Fuel supply circuit.
- Required fuel : diesel.

Electric circuit.
- Swapping injection ECUs between two vehicles will render it impossible to start either vehicle.
- It is forbidden to supply a diesel injector with 12 volts.

High pressure fuel pump.

Do not separate the following components from the high pressure fuel pump (5) :
- Sealing ring (a) (no replacement parts).
- High pressure outlet connector (b) (will cause a malfunction).

PS : HDI = HIGH PRESSURE DIESEL INJECTION

B1HP1J6C

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 C3 PROHIBITED OPERATIONS: DELPHI HDI DIRECT INJECTION SYSTEM
Engines : 8HY - 8HV

Fuel high pressure injection common rail.

Do not separate the pressure regulator «c» from the injection

common rail (2) (Risk of malfunction).
INJECTION

Diesel injectors.

WARNING: Diesel and ultrasonic cleaners are

prohibited.

Do not separate the following components from the diesel

injector carrier (3) :
- Diesel injector (e) (no replacement parts).
- Electromagnetic component «d» (no replacement parts).

It is forbidden to clean the carbon deposits from the diesel

injector nozzle..

B1HP1J8C B1HP1J7C

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 CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT C3
Engines : 8HX - 8HW

TOOLS
[1] Ø 10 mm low pressure connector : 4215-T.
[2] Pressure gauge for testing boost pressure : 4073-T.A Tool kit 4073-T

INJECTION
IMPERATIVE : Respect the safety and cleanliness specific to high pressure diesel
injection engines.
Link tools [1] and [2] in series between the fuel high pressure pump and the fuel filter.

ESSENTIAL : Check that the tool [2] is clean.

Check the negative pressure according to the table below:

Vacuum Observations
10 ±5 cmHg Engine driven by the starter motor
20 ±5 cmHg Engine running under full load

Supply circuit obstructed (full tank

60 ±5 cmHg strainer, piping, fuel filter).

B1BP2NWC

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 C3 CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT
Engines : 8HV-8HY

TOOLS
[1] Ø 10 mm low pressure connector : 4215-T.
[2] Pressure gauge for testing boost pressure : 4073-T.A Tool kit 4073-T
INJECTION

IMPERATIVE : Respect the safety and cleanliness specific to high pressure diesel
injection engines.
Remove the air filter duct.
Link tool [1] in series, downstream of the injectors, between the fuel high pressure pump
and the fuel filter at «a» and «b».
WARNING: Any checking of pressure downstream of the fuel filter is prohibited.
Switch on the ignition.
ESSENTIAL : Check that the tool [2] is clean.
Check the negative pressure according to the table below:
Vacuum Observations
10 ± 05 cmhg Engine driven by the starter motor
20 ± 20 cmhg Engine running under full load

Supply circuit obstructed (full tank

60 ± 05 cmhg
strainer, piping, fuel filter).
B1BP2PHC

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 AIR SUPPLY CIRCUIT SPECIFICATION C3
Engines : 8HX - 8HW

Upper integrated air inlet distributor.

INJECTION
The upper integrated air inlet system is composed of the following elements:

(1) Air filter cover.

(2) Air filter chamber.

(3) Flowmeter

(4) Turbocharger inlet.

(5) Resonator.

(6) Turbocharger outlet.

B1HP1JMP

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 C3 AIR SUPPLY CIRCUIT SPECIFICATION
Engines : 8HX - 8HW

Lower integrated air inlet distributor.

INJECTION

The lower integrated air inlet system is composed of the following elements:

(7) Top EGR pipe.

(8) Inlet manifold.

(9) Diesel fuel filter with reheater and water detector (according to country).

(10) Diesel fuel filter support.

(11) Oil trap.

(12) Oil filler cap.

B1HP1JND

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 AIR SUPPLY CIRCUIT SPECIFICATION C3
Engines : 8HX - 8HW
Lower integrated air inlet distributor. Upper integrated air inlet distributor.

INJECTION
B1HP1JPD B1HP1JQD

WARNING: After each removal, replace the seals of components that have been removed, lubricating the new seals when refitting.
Tighten in m.daN. Tighten in m.daN.
Description sequence Description sequence
OIL TRAP FIXING SCREW. 1à8 1 ± 0.1 Air filter housing fixing screw. 13
Diesel fuel filter support fixing screw. 9 à 10 1 ± 0.1 Air filter cover fixing screw. 14 0.5
Diesel fuel filter support fixing screw. 11 0.5 Air inlet duct fixing screw. 15
Integrated air distributor fixing screw. 12 à 13 1 ± 0.1 Resonator on turbocharger fixing screw. 16
0.75
Resonator on oil trap fixing screw. 17
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 C3 AIR SUPPLY CIRCUIT SPECIFICATION
Engines : 8HY - 8HV

(1) Air filter assembly.

INJECTION

(2) Oil trap.

(3) Turbocharger resonance attenuator.

(4) Turbocharger.

(5) Air/air exchanger.

(6) Air distributor.

Air filter : Ref : MARK 4.

Turbocharger : Ref : RHF 3V.
(Supplier: «IHI»)
B1HP1JGP

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 AIR SUPPLY CIRCUIT SPECIFICATION C3
Engines : 8HX - 8HW - 8HY - 8HV

Tools.

INJECTION
[1] Manual pressure-vacuum pump FACOM DA 16.

Vacuum pump :

Connect the tool [1] onto the vacuum pump (1).

Start the engine.

Wait 30 seconds.

The vacuum value should be 0.9 ± 0.1 bar at idle.

B1HP1K8D

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 C3 CHECKS : EXHAUST GASES RECYCLING CIRCUIT
Engines : 8HX - 8HW
TOOLS
[1] Manual pressure-vacuum pump : FACOM DA 16.

IMPERATIVE : Respect the safety and cleanliness specific to high pressure diesel
injection (HDi) engines.
INJECTION

EGR valve
Connect tool [1] on the capsule take-off (2).
Apply a vacuum of approx. 0,6 bar several times to activate the rod «a».
In abruptly suppressing the vacuum, the valve should click and lock itself back on its seating.
Regulation electrovalve (EGR). (Engine: 8HX-8HW).
B1HP15GD
Check to be performed between the electrovalve (1) and the EGR valve (2).
Engines : 8HV - 8HY Link the tool [1] in series, between the electrovalve (1) and the capsule (2).
Compare the values noted with those in the table below.
Regulation electrovalve (EGR). (Engine: 8HV-8HY).
Check to be performed between the electrovalve (2) and the EGR valve (1).
Link the tool [1] in series, between the electrovalve (2) and the capsule (1).
Compare the values noted with those in the table below.

Engine speed (rpm) Vacuum value

780 0.5
B1HP1K6D 2500 0
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 CHECKS : TURBO PRESSURE C3
Engines : 8HX - 8HW

1] Pressure gauge for checking boost pressure : 4073-T.A

[2] Sleeve for checking boost pressure : (-).0171.F
CHECKS
IMPERATIVE : Respect the following test conditions:

INJECTION
- Engine at operating temperature.
- Vehicle in running order.
- Engine under full load.
Preparation.
Remove the clips (1).
B1BP2NXD Fit the tool [2] in the place of the duct (2).
Couple the sleeve [2] on the pressure gauge [1] using the tube «a».
Mode of operation.
Position tool [1] in the vehicle.
Start the engine.
Engage first gear, start the vehicle.
Engage the gears up to third gear.
Decelerate to an engine speed of 1000 rpm.
Check the pressure : 0,6 ± 0,05 bar (1500 rpm).
Accelerate freely (change from fourth gear to third gear)
Check the pressure: 0,9 ± 0,05 bar (between 2500 and 3500 rpm).
Remove tools [1], [2] at «a».
C5FP0F5C
Reposition the tube (2) and tighten the clip (1).

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 C3 CHECKS : TURBO PRESSURE
Engines : 8HV - 8HY

[1] Pressure gauge for checking boost pressure : 4073-T.A

[2] Sleeve for checking boost pressure : (-).0171.F
CHECKS
IMPERATIVE : Respect the following test conditions:
INJECTION

- Engine at operating temperature.

- Vehicle in running order.
- Engine under full load.
Preparation.
Remove the clips (1).
C5FP0EJC Fit the tool [2] in the place of the duct (2).
Couple the sleeve [2] on the pressure gauge [1] using the tube «a».
Mode of operation.
Position tool [1] in the vehicle.
Start the engine.
Engage first gear, start the vehicle.
Engage the gears up to third gear.
Decelerate to an engine speed of 1000 rpm.
Check the pressure : 0,6 ± 0,05 bar (1500 rpm).
Accelerate freely (change from fourth gear to third gear)
Check the pressure: 0,9 ± 0,05 bar (between 2500 and 3500 rpm).
Remove tools [1], [2] at «a».
B1BP2NBD
Reposition the tube (2) and tighten the clip (1).

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 SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP XSARA
PUMP - TYPE - REFERENCE
Emission standards L3
Equipment Transponder

DWLP 12

INJECTION
XSARA DW 8B WJY R8448 B
371 B

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 XSARA SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP
Static timing Dynamic Reference Adjustments (rpm) Max. speed
Injector
Pump
Engine Initial advance timing Injector Colour needle lift
Type Fast Anti- Unladen Laden
type Compression checking Injector holder code pressure Idling
Reference idling stall rpm rpm
Time (at idle) + injector (Bar)
(cylinder N° 4)
INJECTION

Engine
TDC RDNO LDCR 1500
DWLP 12 Pegging hole. 135.5 950 875 875 5350
WJY Value «X» SDC 0260 + 3mm
R 8448 B/ * ±5 ± 25 ± 25 ± 25 ± 125
engraved on the 6903 IAA shim
pump.

(*) = See table, page : 245.

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 CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP XSARA
Engine : WJY
Evolution of the checking of the setting of the LUCAS diesel injection pump
Old assembly. NEW ASSEMBLY : RPO 7910 #

INJECTION
Diesel injection pump with hole for Diesel injection pump without a hole for
checking the setting checking the setting

The setting of the diesel injection pump is

done with the aid of the following tools : The setting of the diesel injection pump
is done with the aid of a peg at «c».
- A peg placed at «a».

- A peg and a dial gauge placed in the See method on following pages.
checking hole at «b»

B1HP1A4C B1HP1A5C

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 XSARA CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP
Engine : WJY (continued)

Tools.

[1] Flywheel locating peg 7014-T.J.

[2] H M8 screw (-).0188.E. Tool kit C.0188
INJECTION

[3] Injection pump setting peg Ø 6 mm (-).0188.H

After carrying out the necessary dismantling operations on the vehicle, proceed in the following manner :

Remove :
- The screws (6), (7), (9), (10) and (12).
- The upper casing (8).
- The intermediate casing (11).

WARNING : Refit the screw (6) equipped with a washer. (Thickness 5 mm).

- Turn the front RH wheel to turn the engine. (Normal direction of rotation).
- Bring the camshaft and injection pump pulleys to their setting point.
- Position the flywheel peg, using tool [1]. (From below the vehicle).
- Turn the engine until the peg [1] engages in the flywheel.

B1EP12NC B1BP1S9C

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 CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP XSARA
Engine : WJY (continued)

Peg :
- The camshaft hub, using tool [2].
- The injection pump hub, using tool [3].

INJECTION
Impossible to peg the camshaft.
Reset the valve timing (See page 245).

Possible to peg the camshaft, but not the injection pump.

Carry out the following operations:
- Loosen the screws of the injection pump hub.
- Turn the injection pump hub.
- Insert the peg [3] into the setting hole.
- Tighten the screws of the injection pump hub. Tighten to 2,3 ± 0,2 m.daN.

ESSENTIAL : If setting the diesel injection pump proves impossible, reset the valve
timing. (See page 245).

Remove:
- The tools [1], [2] and [3].
- The screw (6) and the washer.
Reassemble the components.
B1EP12WD B1BP1S9C

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 XSARA ADJUSTING THE MECHANICAL CONTROLS OF THE DELPHI INJECTION PUMP
Engine : WJY

Adjusting the fast idle.

Engine cold.
- Ensure that the lever (2) is up against its stop to the right.
INJECTION

- If not, adjust the tension of the cable (3) using the cable clamp (1).
- Finish tensioning using the sleeve tensioner (4).
Engine hot.
- Check that the cable (3) is in tension.

Checking the thermostatic sensor.

- There should be a minimum 6 mm cable travel between a cold and a hot engine.

Adjusting the accelerator control.

Prior conditions.
- Engine hot (cooling fan is engaged twice).

Checking the accelerator cable tension.

- Fully depress the accelerator pedal.
- Check that the lever (6) is against its stop (5) otherwise, alter the position of the pin.
- If not, adjust the position of the accelerator cable tensioning retaining pin.
- Ensure that in the idle position the lever (6) is against the stop (7).

B1HP0K9C

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 ADJUSTING THE MECHANICAL CONTROLS OF THE DELPHI INJECTION PUMP XSARA
Engine : WJY (continued)

Adjusting the anti-stall (residual output).

- Insert a 3 mm thick shim (10) between the throttle lever (6) and the anti-stall screw (7).
- Push the stop lever (8).

INJECTION
- Insert a 3 mm diameter peg (9) in the lever (2).
- Adjust the engine speed to 1500 rpm ± 100 using the stop screw (7).
- Remove the shim (10) and the peg (9).

Adjusting the idle speed.

- Adjust the speed using the idle adjustment screw (11).
- Idling speed : 825 ± 25 rpm.

Checking the engine deceleration.

- Move the throttle lever (6) ) to obtain an engine speed of 3000 rpm.
- Release the throttle lever (6).
- The deceleration should be between 2.5 and 3.5 seconds.
- The drop should be approximately 50 rpm in relation to the idle speed.
- Deceleration too fast, (the engine has a tendency to stall) slacken the screw (7) by a quarter turn.
- Deceleration too slow, (engine speed is greater than the idle speed) tighten screw (7) by a quarter turn.
NOTE : In each case, check the idle speed for any necessary adjustments.

B1HP0K9C B1HP0KAC

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 XSARA FITTING DELPHI DIESEL INJECTORS
Engine : WJY

[1] Tool to remove/refit injectors (2) 7007-T

Fitting an injector
[2] 7008-T.A Tool kit 4123-T
The copper seal (1) and the fire
INJECTION

seal washer (3) are to be replaced

each time they are removed.

NOTE : Fitting parts of different

makes is PROHIBITED.

WARNING : Ensure that the

fire seal washer (3) is fitted the
right way round.
Tighten the injector holder
on the cylinder head to :

9 m.daN

(3) Tighten lightly to prevent any distortion.

B1DP158C B1HP12VC B1HP0YGC

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 INJECTION PUMP SPECIFICATIONS (BOSCH and SIEMENS). XSARA PICASSO
Engines Injection system ECU High pressure pump Injectors
BOSCH BOSCH EDC 15C2 BOSCH CP1 9625542580
TD
DW 10 SIEMENS (except PICASSO SIEMENS ECUSID801 5WS 40001 5WS40000

ATED BOSCH BOSCH EDC 15C2 BOSCH CP1 9625542580

INJECTION
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 XSARA PICASSO PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM
Engines : RHY - RHZ

Cleaning.
- The use of high pressure cleaners is prohibited.
- Do not use compressed air.
INJECTION

Fuel supply circuit.

- Required fuel : diesel.
WARNING : Do not use other fuels.

Electric circuit.
- Swapping injection ECUs between two vehicles will render it impossible to start either vehicle.
- It is forbidden to supply a diesel injector with 12 volts.

High pressure fuel pump.

Do not separate the following components from the high pressure fuel pump (5) :
- High pressure fuel pump third piston deactivator (3) (no replacement parts).
- High pressure fuel regulator (4) (no replacement parts).
- Sealing ring (1) (no replacement parts).
- High pressure outlet connector (3) (will cause a malfunction).
PS: HDi = High pressure Diesel injection

B1HP12CC

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 PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM XSARA PICASSO
Engines: RHY - RHZ
High pressure fuel injection common rail.
- Do not separate the connectors (7) from the common injection rail (6)
- (malfunction).
Diesel injectors.

INJECTION
WARNING: Diesel and ultrasonic cleaners are prohibited.
Do not separate the following components from the diesel injector carrier (9) :
- Diesel injector (8) (no replacement parts).
- Electromagnetic element (11) (destruction).
- Do not alter the position of the nut (10) (malfunction).
- Do not separate the connector (12) from a diesel injector.
B1HP12DC - It is forbidden to clean the carbon deposits from the diesel injector nozzle.
- Identification : Injector carrier
- There are two types of diesel injector carrier classed according to fuel flow.
Identification by engraving or paint mark

Injector carrier Engraving Paint mark Location

Class 1 1 Blue On the upper part of the
coil near to the fuel return
Class 2 2 Green aperture
Identification markings: IMPERATIVE: When replacing a diesel
-« a » : Supplier identification. injector carrier, order a component
-« b » : PSA identification number. of the same class.
B1HP12EC -« c » : Class identification. (See repair manual). B1HP16PC

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 XSARA PICASSO CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT
Engines : RHY - RHZ

TOOLS

[1] Ø 10 mm low pressure connector : 4215-T

[2] Ø 8 mm low pressure connector : 4218-T
INJECTION

[3] Pressure gauge for testing boost pressure : 4073-T Tool kit 4073-T

Connect the tool [1] between the booster pump and the fuel filter (white mark at "a"
on the fuel supply pipe).
Connect the tool [2] downstream of the diesel injectors, between the high pressure
fuel pump and the fuel filter (green mark at "b" on the fuel return pipe.

WARNING : Any check of pressure downstream of the fuel filter is PROHIBITED.

Checks on pressure : static.

- Switch on ignition
For 3 seconds (normal functioning):
- Fuel supply pressure shown by the pressure gauge [3] = 1.8 ± 0.4 Bar.
- Fuel return pressure shown by the pressure gauge [3] = 0.5 ± 0.4 Bar.

B1BP1TWD

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 CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT XSARA PICASSO
Engines : RHY - RHZ (continued)
Checks on pressure : dynamic.
Engine running, at idle (normal functioning):
- Fuel supply pressure shown by the pressure gauge [3] = 2 ± 0.4 Bar.
- Fuel return pressure shown by the pressure gauge [3] = 0.7 ± 0.4 Bar.
Abnormal functioning

INJECTION
Fuel supply pressure Fuel return pressure Checks
Between 3 and 3.5 Bar 0.7 ± 0.2 Bar Check the condition of the diesel filter
Check the low pressure regulator incorporated in
More than 3.5 Bar Less than 0.7 Bar the filter (locked shut) : replace.

More than 0.7 Bar Check the fuel return circuit

More than 3.5 Bar (pipe pinched or trapped.......).

Between 0.8 and 1.5 Bar Check the fuel suppy circuit :
Less than 0.7 Bar - Booster pump (low pressure), piping.
Impossible to start the engine : Check : diesel injector return flow. (Table)
Fuel supply pressure less than 0.8 Bar :
- Check the low pressure regulator incorporated in the filter (locked open) Uncouple the diesel injector return pipe.
- Check the high pressure pump distribution valve (locked shut)
Check : Observe :
The flow should be drop by drop Diesel injector functioning correctly
Excessive fuel return Diesel injector locked shut.
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 XSARA PICASSO CHECKS : AIR SUPPLY CIRCUIT
Engines: RHY - RHZ

TOOLS
[1] Manual vacuum pump : FACOMM DA 16.
IMPERATIVE : Respect the safety and cleanliness requirements.
Vacuum pump.
INJECTION

- Connect the tool [1] on the vacuum pump (1).

- Start the engine.
- Pressure should be 0.8 bar at 780 rpm.
Boost pressure regulator electrovalve.
- Connect the tool [1] between the electrovalve (2) and the valve (3) of the boost pressure
regulator.
Compare readings with the values in the table below.

Engine speed (rpm) Pressure (Bar)

780 0.6
4000 0.25

Pressure regulator valve.

- Connect the tool [1] on the valve (3).
- Appy a pressure of 0.5 bar to activate the rod "a" :
- Rod "a" should be moved 12 mm.
B1HP12FD

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 CHECKS : TURBO PRESSURE XSARA PICASSO
Engine : RHZ

Outillages.
[1] Pressure gauge for checking boost pressure : 4073-T.A Tool kit 4073-T
[2] Sleeve for checking boost pressure : 4185-T
[3] Adaptor sleeve : 4229-T

INJECTION
Checks.
IMPERATIVE : respect the following checking requirements : Engine at running
temperature. Vehicle in running order at full load.
Preparation.
- Remove the collar fixing (3).
- Insert the tool [2] connected with tool [3], between the pipe (1) and the duct (2).
- Position tool [1] in the vehicle.
- Connect the sleeve [2] to the tool [1] with its tube « a ».
Procedure.
- Start the engine.
- Engage first gear and start the engine.
- Engage the gears up to third gear.
- Decelerate to 1000 rpm.
- Accelerate hard, and check the pressure : 0.6 ± 0.05 Bar (1500 rpm).
- Accelerate freely in kick-down, (changing from fourth to third gear).
- Check the pressure : 0.95 ± 0.05 Bar (between 2500 and 3500 rpm).
- Remove the tools, reposition the pipe (1) and refit the collar (3).
B1HP12JD

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 XSARA PICASSO CHECKS : TURBO PRESSURE
Engine : RHY

TOOLS.
[1] Pressure gauge for checking boost pressure : 4073-T.A Tool kit 4073-T
[2] Sleeve for checking boost pressure : 4185-T
INJECTION

Checks.
IMPERATIVE : respect the following checking requirements : Engine at running tempe-
rature. Vehicle running at full load.

Preparation.
- Remove the collar (3) and the sleeve.
- Insert the tool [2] between the pipe (1) and the duct (2).
- Position tool [1] in the vehicle.
- Connect the pressure gauge [1] to the tool [2] with its tube « a » long enough for the gauge
to be positioned inside the vehicle.
Procedure.
- Start the engine.
- Engage first gear and start the engine.
- Engage the gears up to third gear.
- Decelerate to 2000 rpm.
- Gradually accelerate.
- Check the pressure : 0.95 ± 0.05 Bar.
- Remove the tools, refit the collars (3) and the sleeve.
B1BP1ZXD

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 CHECKS : EXHAUST GASES RECYCLING CIRCUIT XSARA PICASSO
Engines : RHY - RHZ

TOOLS
[1] Manual vacuum pump : FACOMM DA 16.

IMPERATIVE : Respect the safety and cleanliness requirements.

INJECTION
EGR valve
- Connect the tool [1] to the capsule union (1).
- Apply, several times in succession, a vacuum of approx. 0.6 bar to activate the rod "a".
- In abrupt reaction to the vacuum, the valve should close on its seating with a clicking noise.

Exhaust gas reycling (EGR) electrovalve.

- Check, not under load, between the electrovalve (2) and the EGR valve (1).
- Connect the tool [1] between the electrovalve (2) and the capsule (1).
- Compare readings with the values in the table below.

Engine speed (rpm) Pressure (Bar)

780 0.5
2500 0

B1HP12GD

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 ALL TYPES SPARKING PLUGS

Vehicles – Models Engine Electrode Tightening

BOSCH CHAMPION SAGEM
type gap setting torque

1.1i HFX
1.4i KFW
IGNITION

SAXO
1.6i NFT
1.6i 16v NFX RC8YCL
1.1i HFX
C3 1.4i KFV
1.6i 16v NFU
FR7DE RFN58LZ 0.9 mm 2.5 ± 0.2 mda N
1.4i KFW
1.6i 16v NFU
XSARA
2.0i 16v RFN
2.0i 16v RFS
16i NFV
XSARA PICASSO 1.8i 16v 6FZ
2.0i 16V RFN

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 SPEEDOMETER ALL TYPES

An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled.

This decree stipulates :

- The speed indicated by a speedometer must never be lower than the actual vehicle speed.
- Between the speed displayed «SD» and the speed travelled «ST», there must always be the following relationship :

ST < SD < 1.10 ST + 4 Kph

Example : For an actual speed of 100 Kph the speed displayed by the speedometer may be between 100 and 114 Kph.

DRIVESHAFTS
The speed indicated by the speedometer may be influenced by :

GEARBOX
CLUTCH
- The speedometer.
- The tyres fitted to the vehicle.
- The final drive ratio.
- The speedometer drive ratio.
Any of these components can be checked without removing them from the vehicle. (See information note N° 78-85 TT of 19 October 1978.
NOTE : Before replacing the speedometer, check the conformity of the following points :
- The tyres fitted to the vehicle.
- The gearbox final drive ratio.
- The speedometer drive ratio.

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 C3 - SAXO CLUTCH SPECIFICATIONS

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

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

Gearbox MA/5 BE4/5
Make VALEO LUK
Mechanism/Type 180 CP0 3400 200 P 3900 230 P 4700
Clutch disc 11 R 10X
Ext./Int. lining Ø 180/127 200/134 228/155
Disc lining type F408
DRIVESHAFTS
GEARBOX
CLUTCH

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 CLUTCH SPECIFICATIONS C3
Engines : HFX – KFV – NFU - 8HX – 8HW – 8HV – 8HY

NOTE : All the clutches are «push» type with hydraulic control.

Description.
The declutch control has a declutch fork mounted on a ball-joint.
- The ball-joint is screwed into the clutch casing.
(2) Declutch fork.
(3) Clutch casing.
(4) Bearing.
(5) Clutch plate.

DRIVESHAFTS
The clutch control slave cylinder (7) is fixed by two screws (6) onto the exterior of the clutch casing.

GEARBOX
CLUTCH
Tightening torques (m.daN).

- Fixing of clutch plate / engine flywheel : 2 ± 0.2

- Fixing of clutch control slave cylinder / clutch housing : 2 ± 0. 25
- Fixing of engine flywheel / crankshaft
Pre-tightening : 1.7 ± 0.1
Angular tightening : 70° ± 5°

B2BP047C B2BP04QC

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 XSARA - XSARA PICASSO CLUTCH SPECIFICATIONS

1.4i 1.6i 1.6i 16V 1.8i 16V 2.0i 16V 1.9 D 1.4 HDi 2.0 HDi

Engine type KFW NFV NFU 6FZ RFN RFS WJY 8HZ RHY RHZ
Gearbox MA/5 BE4/5 MA/5 BE4/5
Make VALEO LUK
180CPO 215 DT 200 P 200 P 230 P 235 T
Mechanism/Type 200 CPR 3800 230 DNG 4700
3400 5250 3700 4200 4700 5700
180 XJF 215 F (D
Clutch disc 200X(D95) 11A12X 230 DNG 4700 215 FD 95 228 228D
73 C 93) 22 BX
DRIVESHAFTS

Ext./Int. lining Ø 180/127 200/137 228/155 215/147 200/134 200/134 230/155 235/155
GEARBOX
CLUTCH

Disc lining type F 408 F410 F 808 F408 F202

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 CLUTCH SPECIFICATIONS BERLINGO

1.1i 1.4i 1.6i 16V 1.9 D 2.0 HDi

Engine type HFX KFW NFU WJY RHY

Gearbox MA/5 BE4/5
Make VALEO LUK
Mécanisme/Type 200 CPX 3850 200 P 4700 235 T 5700
Clutch disc 200 XS L73C 11RX 200 XSL 73 200 228
Ext./Int. lining Ø 200/137 228/155

DRIVESHAFTS
Disc lining type F808 F408

GEARBOX
CLUTCH
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 SAXO - XSARA LUTCH : CHECKS AND ADJUSTMENTS
Mechanically operated push-action clutch
SAXO Adjustable HFX-KFW-NFT-NFX-VJX
Engines Gearbox MA/5
XSARA Non-adjustable KFW-NFU

ESSENTIAL : If the clutch control is new, squeeze the cable sheath before adjusting by declutching
successively a minimum of 20 times.

Checks
NOTE : Adjustable steering wheels should be put into the low position
- Record the measurement «X» between positions L1, pedal at rest, and L2, pedal fully depressed.
DRIVESHAFTS

- Measurement «X» should be : (Pedal travel).

GEARBOX
CLUTCH

SAXO
135 ± 5 mm
Adjustments.
- If the measurement is incorrect, adjust the clutch pedal travel «X».
- Loosen the lock nuts (1).
- To adjust the travel to conform with the measurements indicated above, either loosen or tighten the nut (2).
(Tighten the nut to increase the travel, and loosen it to decrease the travel.)
- Tighten the lock nut (1).
B2BP023C B2BP00GC

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 CLUTCH : CHECKS AND ADJUSTMENTS XSARA
Push-action clutch with automatic adjustment (non-adjustable)
Engines WJY Gearbox BE4/5

Refitting the clutch cable.

- Set the pedal to the high position (contact at A).
- Attach the cable end-piece to the pedal.
- Refit a new clip (3) to the pedal.
- Fit the end-piece (4) to the bulkhead (G6 grease).
- Clip the end-piece (5) to the gearbox.
- Refit the cable to the lever (1).
- Depress the clutch cable several times to set the

DRIVESHAFTS
assembly in place.

GEARBOX
CLUTCH
- Check that the end-piece (4) is properly fitted to the
bulkhead.
- Check the operation of the automatic adjusting device.
1) Pull the lever (in direction F), the lever must move when
pulled by hand.
2) Press the clutch pedal very lightly and repeat the same
operation. The lever should not move back.

B2BP03CD

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 XSARA CLUTCH : CHECKS AND ADJUSTMENTS
Pull-action clutch with automatic adjustment (non-adjustable)
Engines RFS - RFN - RHY - RHZ Gearbox BE4/5

Refitting the clutch cable.

- Set the pedal to the high position (contact at A).
- Attach the cable end-piece to the pedal.
- Refit a new clip (3) to the pedal.
- Fit the end-piece (4) to the bulkhead (G6 Grease).
- Clip the end-piece (5) to the gearbox.
- Refit the cable to the lever (1).
DRIVESHAFTS

- Depress the clutch cable several times to set the

GEARBOX

assembly in place.
CLUTCH

- Check that the end-piece (4) is properly fitted to the

bulkhead.
- Check the operation of the automatic adjusting device.
1) Pull the lever (in direction F), the lever must move when
pulled by hand.
2) Press the clutch pedal very lightly and repeat the same
operation. The lever should not move back.

B2BP03DD

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 CLUTCH : CHECKS AND ADJUSTMENTS XSARA
Adjustment of push and pull action clutch with automatic compensation (adjustment of compensation system)
Engines : RFN - RFS - WJY - RHY - RHZ

WARNING : If a system blockage is detected when checking, or if the pedal has been removed, the
pedal position must be adjusted. This position is obtained by the angular displacement of the stop
supports "a" and "b".

Procedure.
- Loosen the nut (6) and the screw (7).
- Using a lever, raise the stop support (8) to its highest position.
- In this position, there must be a substantial free play in the pedal.

DRIVESHAFTS
- Lower the support until there is a free play of 2 ± 1 mm.

GEARBOX
CLUTCH
- Tighten the screw (7) and the nut (6).
- Check that the outer cable slides freely (at rest, the pedal is against its upper stop «A», the outer cable
length should be variable).

Characteristics
- The automatic adjusting device requires no manual adjustment.
- Pedal travel remains constant for all models 145 ± 5 mm.
- Automatic adjustment is achieved by modifying the curvature of the outer cable.
- Take extra care with the routing of the outer cable, and do not add any supplementary fixing points.
B2BP03EC

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 XSARA CLUTCH : CHECKS AND ADJUSTMENTS
Engines : RFN - RFS – WJY – RHY - RHZ
DRIVESHAFTS
GEARBOX
CLUTCH

B2BP02SC

NOTE : This cable has an automatic adjusting device which takes up the clutch disc wear and makes up for the compression of the outer cable.

DESCRIPTION
1 - Metallic cable, crimped on both ends. 5 - Tensioning spring ensuring the maximum length of the cable sleeve.
2 - Outer cable or telescopic duct. 6 - Wear take-up device.
3 - Outer cable stop, bulkhead side (fixed point on the bodyshell). 7 - Hooking yoke.
4 - Outer cable stop, gearbox side (fixed point on the gearbox).

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 CLUTCH : CHECKS AND ADJUSTMENTS XSARA - XSARA PICASSO
Engines : RFN - RFS - WJY - RHY - RHZ

DRIVESHAFTS
B2BP03QD

GEARBOX
CLUTCH
Operation Clutch disengagement phase Engagement / adjustment phase
For the adjusting device to operate correctly, it As soon as the pedal is applied, the attaching The pedal returns to rest on its upper stop.
is necessary that : end-piece (4) leaves the sleeve (1) which Attaching end-piece (4) pushes sleeve (1)
The pedal is at rest (against its upper stop) moves back. The rollers, pushed by spring (5) which frees the rollers. The outer cable (3),
The locking sleeve (1) is slightly compressed, jam the system. The cable behaves like a kept extended by the spring (6) becomes :
the rollers (2) are free, the outer cable (3) length conventional cable. -Shorter if the clutch disc is worn.
may vary. -Longer if the outer cable has been
compressed.

NOTE : The pedal gear has a non-adjustable assisting device.

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 SAXO GEARBOX AND TYRE SPECIFICATIONS
Petrol
1.4i
1.1i 1.6i 1.6i 16V
Auto.
Engine type HFX KFW NFT NFX
Tyres-Rolling circumference 155/70 R 13 – 1.67 m 165/65 R14 1.725m 185/55 R14 1.7 m
Gearbox type MA/5 MB3 MA/5
Gearbox ident. plate 20 CF 03 20 CF 12 312 20 CN 03 – 20 CN 05
Reduction box torque 14x60 17x64 17x56 17x61 16x63
Speedometer ratio 19x17 19x17 21x19 19x17
DRIVESHAFTS

Diesel
GEARBOX
CLUTCH

1.5D
Engine type VJX
Tyres-Rolling circumference 165/65 R14 – 1.725 m
Gearbox type MA/5
20 CF 02
Gearbox ident. plate
29/08/200 ➞
Reduction box torque 17x64
Speedometer ratio 19x17

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 GEARBOX AND TYRE SPECIFICATIONS C3 - All Types
Petrol
1.1i 1.4i 1.6i 16V
Auto..
Trim level X - SX Exclusive X - SX Exclusive X - SX Exclusive X - SX Exclusive
Engine type HFX KFV NFU
Tyres-Rolling circumference 165/70 R 14 1.804 m 185/60 R15 1.828 m 165/70 R 14 1.804 m 185/60 R15 1.828 m
Gearbox type MA/5 AL4 MA/5
Gearbox ident. plate 20 CN 14 20 CF 15 ou 20 CF 16 (*) 20 TP 75 20 CN 40
Reduction box torque 14x60 16x63 ou 14x60 (*) 21x73 17x64
Speedometer ratio 21x18

DRIVESHAFTS
Diesel

GEARBOX
CLUTCH
1.4 HDi 1.4 HDi 16V
Trim level X – SX - Exclsive
Engine type 8HX 8HW 8HV 8HY
Tyres-Rolling circumference 165/70 R14 1.804 185/60 R15 1.828 m
Gearbox type MA/5 BE4/5
Gearbox ident. plate 20 CN 33 ou 20 CN 36(*) 20 DM 25 20 DM26
Reduction box torque 17x61 ou 16x65 (*) 19x72 19x77
Speedometer ratio 21x18 22x19
NOTE : (*) = Export
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 XSARA GEARBOX AND TYRE SPECIFICATIONS
Petrol
1.6i 16V 2.0i 16V
1.4i
Auto. Auto.
Engine type KFW NFU RFN RFS
Tyres-Rolling circumference 195/55 R15 - 1.815 m
Gearbox type MA/5 AL4 BE4/5 AL4 BE3/5
Gearbox ident. plate 20 CF 13 20 CN 28 20 TP 49 20 DL 40 20 TP 47 20 TE 47
Reduction box torque 16x65 21x73 19x72 23x73 14x62
Speedometer ratio 21x18 24x21 22x19 24x21 22x19
Diesel
DRIVESHAFTS
GEARBOX

2.0 Hdi
CLUTCH

1.9D 1.4HDi
Auto.
Engine type WJY 8HZ RHY RHZ
Tyres-Rolling circumference 195/55 R15 – 1.815 m
Gearbox type BE4/5 AL4
Gearbox ident. plate 20 DL 41 20 DM 54 20 DL 42 20 DM 10 20 TP 48
Reduction box torque 19x75 19x70 17x61 14x62
Speedometer ratio 22x19 22x19
Right hand drive : 6FZ-RFN - 20 DM 03 WJZ-WJY - 20 DM 05 8HZ - 20 DM 53 RHY - 20 DM 07 RHZ - 20 DM 11
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 GEARBOX AND TYRE SPECIFICATIONS XSARA PICASSO
Petrol Diesel
1.6i 1.8i 16 V 2.0i 16V 2.0 Hdi
Auto.
Engine type NFV 6FZ RFN RHY
Tyres-Rolling circumference 185/65 R15 – 1.895 m
Gearbox type BE4/5 AL4 BE4/5
Gearbox ident. plate 20 DL 66 20 DL 68 20 TS 02 20 DL 64
Reduction box torque 15x64 19x77 21x73 19x72
Speedometer ratio 22x18 24x20 22x18

DRIVESHAFTS
GEARBOX
CLUTCH
Right hand drive : NFV = 20 DL 67 6FZ = 20 DL 69 RHY = 20 DL 65.

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 SAXO - XSARA GEARBOX - MA/5
Engines : HFX - KFW - NFT - NFX - NFU - VJX - 8HX - 8HW

Vent plug
DRIVESHAFTS
GEARBOX
CLUTCH

Filler screw Drain screw

B2CP34HP B2CP20FC B2CP20GC

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 GEARBOX CONTROLS - MA/5 SAXO - XSARA
Engines : HFX - KFW - NFT - NFX – NFU - VJX– 8HX- 8HW

1 - Gear lever.

2 - Gear control rod.

3 - Gear control rod.

A = 11.5 mm.

DRIVESHAFTS
4 - Gear selection rod.

GEARBOX
B = 9.5 mm.

CLUTCH
5 - Gear selection rod.
C = 3 mm.
6 - Knuckle joint.

7 - Fixed point on the gearbox

B2CP16SP B2CP16TC

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 C3 GEARBOX - MA/5
Engines : HFX - KFV - NFU - 8HX - 8HW

«a» Identification label.

DRIVESHAFTS
GEARBOX
CLUTCH

«b» Location for engraving of serial and gearbox nos..

B2CP3HTC

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 GEARBOX - MA/5 C3
Engines : HFX - KFV - NFU - 8HX - 8HW

Draining – filling – level

(1) Gearbox drain plug.

(2) Filling and level cap.

Oil quality.
Refer to the manufacturer’s instructions.

DRIVESHAFTS
GEARBOX
Oil quantity.

CLUTCH
After draining: 2 Litres.

Draining intervals.

«Lubricated for life »

Check the oil level: Every 37 500/40 000 miles.

B2CP3HWC

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 C3 GEARBOX - MA/5
Engines : HFX - KFV - NFU - 8HX - 8HW

(1) Primary shaft.

(2) Clutch bearing guide.
(3) Clutch housing.
(4) Gearbox casing.
(5) Intermediate plate.
(6) Bearing retaining clip.
(7) Drive pinion (5th gear).
(8) Secondary shaft.
(9) 5th gear synchroniser.
(10) Driven pinion (5th gear).
(11) Driven pinion (4th gear).
DRIVESHAFTS
GEARBOX

(12) 3rd / 4th gear synchroniser.

CLUTCH

(13) Driven pinion (3nd gear).

(14) Driven pinion (2nd gear).
(15) 1st / 2nd gear synchroniser and reverse gear driven pinion.
(16) Driven pinions (1st gear).
(17) Differential gearwheel.
(18) Satellite pinions.
(19) Planet pinions.
(20) Counter drive.
(21) Speedometer screw.
B2CP167P
(22) Differential housing.

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 GEARBOX - MA/5 C3
Engines : HFX - KFV - NFU - 8HX - 8HW

Tightening torques: m.daN.

(23) Clutch bearing guide (3 fixing screws) : 0.6 ± 0.15.

(24) Intermediate plate (11 fixing screws) : 5 ± 0.5.

(25) Rear cover (3 fixing screws) : 2.2 ± 0.2.

(26) Bearing retaining clip (4 fixing screws) : 1.8 ± 0.2.

DRIVESHAFTS
(27) Secondary shaft nut (1 nut) : 14 ± 1.

GEARBOX
CLUTCH
(28) Gearbox casing (15 fixing screws) : 1.8 ± 0.2.

(29) Top-up plug (1) : 2.5 ± 0.5.

(30) Drain plug (1) : 2.5 ± 0.5.

(31) Reverse gear switch (1) : 2.5 ± 0.5.

B2CP3HUD

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 C3 GEARBOX CONTROLS - MA/5
Engines : HFX - KFV - NFU - 8HX - 8HW

(1) Gear control lever.

(2) Gear engagement control cable (*)

(3) Gear selection control cable (*)

DRIVESHAFTS
GEARBOX
CLUTCH

(*) The two cables cannot be separated.

B2CP3HXD

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 GEARBOX CONTROLS - MA/5 C3
Engines : HFX - KFV - NFU - 8HX - 8HW

(4) Gear engagement ball-joint Ø 10 mm.

(5) Gear selection ball-joint Ø 10 mm.

B2CP3HYC

DRIVESHAFTS
GEARBOX
CLUTCH
Length D Length C

Gear engagement
control 1015 mm 790 mm
cable (2)
Length A Length B

Gear selection
control 1093 mm 775 mm
B2CP3HZD cable (3)

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 C3 GEARBOX CONTROLS - MA/5
Engines : HFX - KFV - NFU - 8HX - 8HW

Adjustment.

WARNING: Do not use any tool to detach the ball-

joints.

The gear selection control and gear engagement control

B2CP3J0D cables cannot be adjusted.
DRIVESHAFTS
GEARBOX
CLUTCH

To unlock the ball-joint, press at «a» then pull the ball-joint

upwards.

To release the sleeve stops, pull the needles «b», in the

direction of the arrow, then disengage the sleeve stops
from their supports.

B2CP3J1D

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 GEARBOX – BE4/5 C3 - XSARA - XSARA PICASSO
Engines : NFV - 6FZ – 8HV – 8HY - 8HZ - RFN - RFS - WJY – RHY - RHZ

DRIVESHAFTS
GEARBOX
CLUTCH
B2CP3BNC B2CP3BPD

(a) Marking zone. (Sequence and serial no.).

(b) = Location of identification label.

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 C3 - XSARA - XSARA PICASSO GEARBOX CONTROLS - BE4/5
Engines : NFV - 6FZ – 8HV – 8HY- 8HZ - RFN - RFS - WJY – RHY - RHZ

(1) Drain plug.

(2) Filling and top-up plug.

(3) Air vent.

NOTE : The air vent aperture can be used for filling.

DRIVESHAFTS
GEARBOX
CLUTCH

Quality of oil
Refer to the manufacturer’s instructions.

Quantity of oil
Gearbox empty : 1,9 Litres.
After draining : 2 Litres.

B2CP3BLD

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 GEARBOX – BE4/5 C3 - XSARA - XSARA PICASSO
Engines : NFV - 6FZ – 8HV – 8HY - 8HZ - RFN - RFS - WJY – RHY - RHZ
Description

(1) Primary shaft. (14) 1st / 2nd gear synchroniser

(2) Clutch bearing guide. (15) Driven gear (1st gear).
(3) Gearbox casing. (16) Secondary shaft.
(4) Clutch housing. (17) Differential gear.
(5) Reverse idle. (18) Satellite gears.
(6) Drive gear (3rd gear). (19) Planet gears.
(7) 3rd /4th gear synchroniser

DRIVESHAFTS
(20) Differential housing.

GEARBOX
(8) Drive gear (4th gear).

CLUTCH
(21) Speedometer drive.
(9) Drive gear (5th gear). (22) Extension.
(10) 5th gear synchroniser.
(11) Driven gear (5th gear). « d » Adjusting shims : 0.7 to 2.4 mm
(12) Driven gear (3rd / 4th gear ) ( 0.10 mm and increasing by 0.10 mm).
(13) Driven gear (2nd gear). « c » Adjusting shims: 1.4 to 1.6 mm
( 0.10 mm and increasing by 0.10 mm).

B2CP3BQP

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 C3 GEARBOX - BE4/5
Engines : 8HV - 8HY

Tightening torques (m.daN).

(23) Clutch bearing guide (3 screws) : 1.25 ± 0.2

(24) Clutch housing (13 screws) : 1.3 ± 0.2
(25) Primary shaft nut (1 screw) : 7.25 ± 0.5
(26) Secondary shaft nut (1 screw) : 6.5 ± 0.5
(27) Vis de maintien du jonc (2 vis) : 1.5 ± 0.2
(28) Differential gearwheel screw (2 screws) : 6.5 ± 0.5
DRIVESHAFTS
GEARBOX

Reverse gear switch (1 screw) : 2.5 ± 0.3

CLUTCH

(29) Differential housing (4 screws) : 5 ± 0.5

(30) Breather pipe : 1.7 ± 0.2
(31) Rear housing cover screws (7 screws) : 1.25 ± 0.2
(32) Top-up plug (1 screw) : 2.2 ± 0.2
(33) Differential housing screws (4 screws) : 1.25 ± 0.2
(34) Drain plug (1 screw) : 3.5 ± 0.3

B2CP3BRD

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 GEARBOX – BE4/5 XSARA - XSARA PICASSO
Engines : NFV - 6FZ - RFN - RFS - WJY - 8HZ - RHY - RHZ
Tightening torques
Ref. Description Number of screws m.daN
1 End guide 3 1.2 ± 0.1
2 Clutch housing 13 1.3 ± 0.1
3 Primary shaft nut 1 7.2 ± 0.7
4 Secondary shaft nut 1 6.5 ± 0.7
5 Yoke holding screw 2 1.5 ± 0.1

DRIVESHAFTS
6 Differential gearwheel screw 2 6.5 ± 0.7

GEARBOX
CLUTCH
B2CP3BSP Reverse gear contact 1 2.5 ± 0.3
7 Differential housing 4 5 ± 0.5
8 Breather pipe 1 1.7 ± 0.2
9 Rear housing cover screw 7 1.2 ± 0.1
10 Top-up plug 1 2.2 ± 0.2
11 Differential housing screw 4 1.2 ± 0.1
B2CP3BTD 12 Drain plug screw 1 3.5 ± 0.4

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 C3 GEARBOX CONTROLS - BE4/5
Engines : 8HV - 8HY

(1) Gear control lever

(2) Gear engagement control cable (*)

(3) Gear selection control cable (*)

DRIVESHAFTS
GEARBOX
CLUTCH

(*) These two cables cannot be separated.

B2CP3J3D

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 GEARBOX CONTROLS - BE4/5 C3
Engines : 8HV - 8HY

(4) Gear engagement ball-joint Ø 10 mm.

(5) Gear selection ball-joint Ø 10 mm.

B2CP3J4C

DRIVESHAFTS
GEARBOX
CLUTCH
Length A Length B

Gear
selection 907 mm 645 mm
cable (5)
Length D Length C

Gear
engagement 965 mm 610 mm
B2CP3J5D cable (4)

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 C3 GEARBOX CONTROLS - BE4/5
Engines : 8HV - 8HY

Adjustment.

The gear selection control and gear engagement

control cables cannot be adjusted.
DRIVESHAFTS

To release the ball-joint, press at «d» then pull the

GEARBOX
CLUTCH

ball-joint upwards.

To release sleeve stops:

- Press on the tabs of the clip (6) at «a».

- Disengage the sleeve stops from their supports.

B2CP3J6D

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 GEARBOX CONTROLS - BE4/5 XSARA - XSARA PICASSO
Engines : NFV - 6FZ - RFN - RFS - WJY - 8HZ – RHY - RHZ

(1) Gear control lever

(2) Gear engagement control cable (*)

(3) Gear selection control cable (*)

(4) Gear selection ball-joint Ø 10 mm.

DRIVESHAFTS
(5) Gear engagement ball-joint Ø 10 mm.

GEARBOX
CLUTCH
(6) Flexible insulating grommet through the
bulkhead.

(*) = These two cables cannot be separated.

B2CP3BWD

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 XSARA - XSARA PICASSO BE4/5 GEARBOX - CHECKS AND ADJUSTMENTS
Engines : NFV - 6FZ - RFN - RFS - WJY - 8HZ – RHY - RHZ
Principles of adjusting the gear controls.

WARNING : Cables should be adjusted each time the gearbox,

gear controls or power unit are removed.

Principles. WARNING : Do not use any tool to unclip the

ball-joints.
Lock the gear lever in neutral position,
using tool: 9607-T. To unlock the ball-joint, press at the centre «a»,
DRIVESHAFTS

then pull the ball-joint upwards.

GEARBOX

Place the gearbox in neutral.

CLUTCH

Couple the cables on the lever.

NOTE : Changing an individual ball-joint is possible
Fit the ball-joints on the gearbox lever. as long as the locking key is removed.

Lock the cable lengths with the ball-joint locking Unclip at «b», using two small screwdrivers.
keys.

B2CP3BXC B2CP3BYC

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 BE4/5 GEARBOX - CHECKS AND ADJUSTMENTS XSARA - XSARA PICASSO
Engines : NFV - 6FZ - RFN - RFS - WJY - 8HZ – RHY - RHZ
Adjusting the gear controls.

TOOLS.
[1] Tool for positioning the gear lever : 9607-T.

ADJUSTMENTS. CHECKS.

WARNING : Cables should be adjusted each time - Remove the tool [1].
the gearbox, gear controls or power unit are - Check that all the gears engage without « tightness ».
removed. - Check that the gear lever moves identically

DRIVESHAFTS
forwards and backwards and to right and left. If it

GEARBOX
CLUTCH
Inside the vehicle. does not, repeat the adjustment.
- Remove the trim under the gear lever.
- Lock the gear lever in neutral position, using tool [1]. - Refit the trim under the gear lever.
- Refit the air filter assembly.
Under the bonnet.
- Remove the air filter assembly.
- Unlock the ball-joint keys at «a».
- Place the gear selection and control levers neutral.
Lock the cable lengths with the ball-joint locking keys.

B2CP3C6C B2CP3C0C

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 SAXO AUTOMATIC GEARBOX - MB3
Engine : KFW

Tightening torques m.daN.

- Gearbox to engine fixing 3.5

- Converter to engine fixing 2.5
- Converter closing plate fixing
M8 1.6
M10 2.6
- Electrical bracket fixing 6.5
DRIVESHAFTS

- Flexible mounting to gearbox fixing 8.5

GEARBOX
CLUTCH

- Speedometer drive 1
- Heat exchanger fixing 5

NOTE : When fitting a new automatic gearbox, it is

ESSENTIAL that the heat exchanger and the oil be
replaced.

B2CP14ZP

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 RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - MB3) SAXO
Engine : KFW

PRECAUTIONS TO BE TAKEN

Towing REMOVING - REFITTING. (Automatic gearbox).

The front of the vehicle must be raised in order to be towed. WARNING : Never place the gearbox on its lower casing
If the front of the vehicle cannot be raised : (risk of deforming the tray and damaging the hydraulic valve block).
- Add an extra 2 litres of oil to the automatic gearbox.
- Do not exceed 30 kph over a distance of 50 km. Driveshafts.
- Gear lever in position «N». ESSENTIAL : When moving the left driveshaft, ensure it remains
WARNING : Do not forget to remove the extra oil. horizontal (risk of losing the tri-axe joint needles).

DRIVESHAFTS
GEARBOX
Initialising procedure.

CLUTCH
Driving. The gearbox should be initialised in the following cases :
Never drive with the ignition switched off. - Replacement of the ECU.
Never push the vehicle to try to start it - Clearing of faults.
(impossible with an automatic gearbox). - Replacement of the potentiometer.
NOTE : The automatic gearbox is only lubricated when the engine - Replacement or adjustment of the accelerator cable.
is running. - Incorrect initialisation.
Wait until the vehicle is completely stationary before engaging the NOTE : The initialisation procedure should be checked using a
gear lever in position «P». diagnostic tool.

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 SAXO RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - MB3)
Engine : KFW

PRE-REPAIR PROCEDURE
Oil quality
If the gearbox has suffered a serious fault resulting in a malfunction or the destruction of a clutch, the
oil will overheat and become contaminated with impurities :
the oil is said to be «burnt».
This is characterised by a black colour and the presence of an unpleasant smell.
ESSENTIAL : The gearbox must be replaced.

Oil level (prior conditions)

DRIVESHAFTS

- Oil hot (80°C min.).

GEARBOX
CLUTCH

- Foot on the brake, change through all the gears.

- Vehicle on a level surface.
- Selection lever in position «P».
- Engine running.
The level should be between the min. markings «A» and «B» on the dipstick.

ESSENTIAL : In no case should the oil level exceed the marking «B».
Top up the automatic gearbox oil level (if necessary).

B2CP16WC

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 RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - MB3) SAXO
Engine : KFW

PRE-REPAIR PROCEDURE (continued)

Negative pressure circuit. Absence of fault codes

- Check the negative pressure circuit. Measure the parameters.

- Carry out the necessary repairs. Anomalies present:
- YES : Carry out the necessary repairs.
Checks using the diagnostic tool. - NO : Check (adjust the negative pressure capsule).

Preliminary checks : ESSENTIAL : Initialise the ECU

DRIVESHAFTS
- The adjustment of the gear selection control. Perform a road test.

GEARBOX
CLUTCH
- The adjustment of the accelerator cable.
Carry out the necessary operations Fault codes present
Carry out the necessary repairs.
Reading the fault codes Clear the fault codes.
Read the fault codes.
ESSENTIAL : Initialise the ECU
Perform a road test.

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 SAXO SPECIAL FEATURES: AUTOMATIC GEARBOX - MB3
Engine : KFW

Hydraulic valve block.

Refitting.
WARNING : On refitting the strainer, ensure that the bracket (6) runs under the
washer of the screw (7).

- Refit the strainer without tightening the screws.

- Observe the following tightening sequence :
- Screws 1,2,3,4 and 5 to 0.9 m.daN.
DRIVESHAFTS

ESSENTIAL : Respect the position of the magnets in the lower casing. Clean
GEARBOX

the casing before placing the smooth side of the magnet against the sheet
CLUTCH

metal.

Fitting the casing.

WARNING : The fixing brackets (8) of the lower casing have a fitting direction
(small side = lower casing side).

Tightening torque 0.6 m.daN.

B2CP34PC B2CP13TC B2CP34QC

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 MB3 AUTOMATIC GEARBOX CONTROLS SAXO
Engine : KFW

DRIVESHAFTS
GEARBOX
CLUTCH
B2CP352D

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 SAXO MB3 AUTOMATIC GEARBOX CONTROLS - CHECKS AND ADJUSTMENTS
Selection control Adjusting the selection control

WARNING: No part must be forced ESSENTIAL : Put the gearbox side

while performing these operations control in the 1st imposed position;
(careful removal). the 2 markings «a» must be aligned.
Removing the gear lever knob.
- Remove the screws (1). - Fit the ball joint (1).
- Lift the lever knob (2) by about 10mm. - Fit the lug (2).
- Turn backwards by 1/4 turn, and
raise by approximately 7mm. - Lock the outer cable stop by 1/4 turn
- Press and hold down the locking (in the direction of the arrow).
button (3) - Check that the painted markings «b»
are aligned.
DRIVESHAFTS
GEARBOX
CLUTCH

- Turn forwards by 1/4 turn, remove the gear lever knob (2).
Refitting the gear lever knob.
- Press and hold down the locking button (3).
- Fit the knob (2) on the lever until it touches its stop
(in the direction shown in the diagram).
- Release the locking button (3).
- Turn forwards by 1/4 turn.
- Refit the screws (1).
ESSENTIAL : Check the passage of all the gears, otherwise adjust
the selection control.
B2CP18YC B2CP18WC B2CP18XC

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 AUTOMATIC GEARBOX - AL4 C3 - XSARA - XSARA PICASSO
Engines : KFV - NFU - RFN - RHZ

WARNING : This gearbox benefits from a special CITROEN semi-synthetic oil

which cannot be mixed with any other oil.

The gearbox is lubricated for life.

(a) Part reference.

DRIVESHAFTS
GEARBOX
CLUTCH
B2CP30ZD

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 C3 - XSARA - XSARA PICASSO RECOMMANDATIONS - PRECAUTIONS (BOITE DE VITESSES AUTOMATIQUE AL 4)
Engines : KFV - NFU – RFN - RHZ
PRECAUTIONS TO BE TAKEN

Towing REMOVING - REFITTING. (Automatic gearbox).

The front of the vehicle must be raised in order to be towed.
If the front of the vehicle cannot be raised : WARNING : Never place the gearbox on its lower casing
(risk of deforming the tray and damaging the hydraulic valve block).
IMPERATIVE : - Put gear lever in position «N».. Never use the connections as handles for raising, turning, holding or
- Do not add any oil. pushing the gearbox.
- Do not exceed 50 kph over a distance of 50 km.
ESSENTIAL :
Driving. - Fit the converter retaining peg while the gearbox is removed.
DRIVESHAFTS

Never drive with the ignition switched off. - Fit the centring peg to locate the gearbox on the engine:
GEARBOX
CLUTCH

Never push the vehicle to try to start it; (remove the converter retaining peg just before locating)
(impossible with an automatic gearbox).
WARNING : With the safety programme selected, a snatching can be
Lubrication felt when changing from ‘‘P’’  ‘‘R’’ or ‘‘N’’  ‘‘R’’.
The automatic gearbox is only lubricated when the engine is running.

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 RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 ) C3 - XSARA - XSARA PICASSO
Engines : KFV - NFU - RFN - RHZ

PROCEDURE BEFORE REPAIRS

AL4 gearbox

Oil Quality

If the gearbox has suffered a serious fault resulting in a malfunction or the destruction of a clutch, the oil will overheat and become contaminated
with impurities :
the oil is said to be «burnt».

DRIVESHAFTS
This is characterised by a black colour and the presence of an unpleasant smell.

GEARBOX
CLUTCH
ESSENTIAL : The gearbox must be replaced.

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 C3 - XSARA - XSARA PICASSO RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 )
AL4 gearbox only Engines : KFV - NFU - RFN - RHZ

AL4 PROCEDURE BEFORE REPAIRS

Oil level AL 4 (prior conditions).
- Vehicle in horizontal position.
- Check gearbox is not in back-up mode.
- Remove the oil filler plug (3).
- Add 0.5 litres extra oil into the gearbox.
- Foot on the brake, change through all the gears.
- Selection lever in position "P".
- Engine running, at idle.
- Oil temperature : 60°C (+8°C; -2°C), measured with the aid of a diagnostic tool.
DRIVESHAFTS

- Remove the oil level plug (3).

GEARBOX
CLUTCH

- Thread of oil then "drip-drip": refit plug (3). Tighten 2.4 m.daN.
- "Drip-drip" or nothing : refit the plug (3).
- Stop the engine.
- Add 0.5 litres extra oil into the gearbox.
- Repeat the oil level procedure.
NOTE : The level is correct at the moment the thread of oil becomes drip-drip.
- Refit the oil filler plug (3). Tighten to 2.4 m.daN.
- Initialise the oil usage counter (open the diagnostic tool procedure).
NOTE : Dimension X : TU and EW engines = 81 mm DW engines = 77 mm.

B2CP31FD

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 RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 ) C3 - XSARA - XSARA PICASSO
Engines : KFV - NFU - RFN - RHZ

PROCEDURE BEFORE REPAIRS (continued)

When the ECU detects an erroneous or absent value Reading the fault codes.
on input or output : Read the fault codes.

- It writes the fault in memory. Absence of fault codes:

- For each associated context, it writes the context of the oldest fault Carry out a measure of parameters.
in memory.
- It initiates a back-up mode strategy. Presence of anomalies:
• YES : Carry out the necessary repairs

DRIVESHAFTS
There are two types of back-up modes :
• NO : Read the fault codes – engine ECU

GEARBOX
CLUTCH
- The ECU makes replacement values available (relating to comfort, - Carry out a road test.
gear selection quality, loss of functions).
Following an initialisation of the ECU, for a certain period of time
- Access to emergency programme (only 3rd gear and reverse are there may be an inconsistent gear selection quality (while ECU
available) parameters are adapting to the gearbox.
To achieve a consistent standard, it will be necessary to carry out a
road test taking in frequent gear changes (auto-adaptive laws).

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 C3 - XSARA - XSARA PICASSO RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 )
Engines : KFV - NFU - RFN - RHZ
ECU : Downloading
Updating the gearbox ECU by downloading :
- Follow the procedure using the diagnostic tool.
The downloading operation enables the automatic gearbox to be updated, or adapted to an evolution of the engine ECU.
Before commencing the downloading, take the value of the oil usage counter present in the automatic gearbox ECU.

After the downloading operation, carry out the following:

A clearing of faults.
A pedal initialisation.
An initialisation of the auto-adaptives.
DRIVESHAFTS

A recording of the value of the oil usage counter previously read.

GEARBOX

A road test.
CLUTCH

ESSENTIAL : Every update of the automatic gearbox ECU should be accompanied by an update of the engine ECU.

Updating the value of the oil usage counter.

Using PROXIA Using LEXIA or ELIT.

Access to reading and recording of the oil counter is via the menu : Access to reading and recording of the oil counter is via the menu :
«Configuration (integrated circuit button) / Oil counter ». «Oil counter ».
Adjustment of the oil counter value is done in incremental steps of Adjustment of the oil counter value is done by entering directly the
2750 units. 5 figures of the oil counter.

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 RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 ) C3 - XSARA - XSARA PICASSO
Engines : KFV - NFU - RFN - RHZ

ECU : Configuration, Initialisation (pedal) (continued)

Downloading.
Pedal initialisation.
ECU downloading procedure :
- Follow the diagnostic tooling procedure. A pedal initialisation must be carried out in the following cases :

A new ECU or downloaded update is always configured - Replacement of the automatic gearbox ECU.
with the following options :
- SHIFT LOCK gear selection lever position. - Replacement of the automatic gearbox.
- OBD outlet (emission standard L4).

DRIVESHAFTS
- Downloading of the ECU configuration.

GEARBOX
If the ECU is to be fitted to a vehicle without one or both

CLUTCH
of these options: - Adjustment or replacement of the accelerator cable.
- Carry out a configuration which inhibits the diagnosis of the
option(s) concerned. - Replacement of the throttle potentiometer.

IMPERATIVE : For a certain period of time, while the ECU parameters are adapted to the gearbox, there may be an inconsistent
gear selection quality. To achieve a consistent standard, it will be necessary to carry out a road test taking in frequent gear changes
(auto-adaptive laws).

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 C3 RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 )
Engine : KFV

SHIFT LOCK
- The «shift lock» is a system that locks the gear selection lever in position «P».
Unlocking the «SHIFT LOCK». (Normal operation).
- Switch on the ignition.
- Press the brake pedal and keep it pressed.
- Move the gear selection lever out of position «P».
Unlocking the «SHIFT LOCK». (With an operating fault).
NOTE : It is impossible to unlock the «shift lock» with the «Normal operation» method.
The fault may originate from one of the following components:
C5FP0ETC
- «Shift lock».
DRIVESHAFTS

- Gear lever position switch.

GEARBOX
CLUTCH

- Automatic gearbox ECU.

- Electrical harness.
- Battery voltage.
Remove:
- The gear lever knob (1) (Pull upwards).
- The cover (2) (Unclip).
- The top of the central console (3).
- Unlock the «shift lock» (4) with the aid of a screwdriver.
- Move the gear selection lever out of position «P».

B2CP3GZC

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 RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 ) XSARA - XSARA PICASSO
Engines : NFU - RFN - RHZ

SHIFT LOCK

- The shift lock is a system which locks the selection lever in the park position «P».

Unlocking the SHIFT LOCK (In normal operation)

- Switch on the ignition.

- Press and hold down the brake pedal.
- Using the selection lever, disengage from position «P».

DRIVESHAFTS
NOTE : It is IMPERATIVE to disengage the gear selection lever from position "P" the minute

GEARBOX
CLUTCH
you start applying the brake pedal. Otherwise, release pressure on the brake pedal and then
try again.

Unlocking the SHIFT LOCK (In the event of a malfunction)

- Remove the cover (1).
- Unlock the shift lock (2) using a screwdriver.

B2CP268C B2CP269C

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 SAXO - C3 - XSARA - XSARA PICASSO DRIVESHAFTS - GEARBOX
Tightening torques (m.daN) Gearbox oil seal mandrels

Vehicles Gearbox Engines Driveshaft Driveshaft RH side LH side Tool kit

bearing nut
SAXO HFX-KFW-NFT-NFX-VJX
NONE
HFX-KFV-8HX-8HW 24.5 ± 0.5
C3 MA/5
NFU 2 ± 0.2
XSARA KFW-NFU 7114-T.W 7114-T.X 7116-T

XSARA NFV-RFS-RFN-6FZ-WJY- 1.8 ± 0.1

XSARA PICASSO 32 ± 1.5
BE4/5 8HZ -RHY-RHZ
DRIVESHAFTS

C3 8HV-8HY 2 ± 0.2
GEARBOX
CLUTCH

4101-T.E1 +
SAXO MB3 KFW 24.5 ± 0.5 NONE 4601-T
4601-T.E2
Seal extractor
1.8 ± 0.1 RH / LH
XSARA (-) 0338 C
XSARA PICASSO NFU-RFN-RHZ
AL 4 32.5 ± 2.5 (-) 0338 J1 (-) 0338 H1 (-) 0338
+ (-) 0338 J2 +(-) 0338 H2
(-) 0338 J1 (-) 0338 H1
C3 KFV 1 ± 0.1
+ (-) 0338 J2 +(-) 0338 H2
Tightening torque (m.da.N) for wheel bolts : SAXO – XSARA = 8.5 C3= 9

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 AXLE GEOMETRY SAXO - All Types
Geometry of the axles at reference height.
Front height Rear height

H1 = R1 – L1 H2 = R2 + L2

H1 = Distance between the ground and H2 = Distance between the ground and
the mounting face of the fixings. the mounting face of the rear cross-
R1 = Distance between the centre of member.
the front wheel and the ground. R2 = Distance between the centre of
L1 = Distance between the centre of the the rear wheel and the ground.
front wheel and the mounting face of L2 = Distance between the centre of the
the fixings. rear wheel and the rear crossmember.

The values L1 and L2 are given in the table below.

C4CP0N2C Normal suspension Raised suspension C4CP0N3C

Front axle Rear axle Front axle Rear axle

Dimension L1 L2 L1 L2
Value (mm) 71 ± 10 mm 53 ± 6 mm 36 ± 10 mm 82 ± 6 mm

SUSPENSION
STEERING
Measure the dimension R1. Calculate the dimension H1 = R1 – L1.

AXLES
Measure the dimension R2. Calculate the dimension H2 = R2 + L2.
Compress the suspension until the calculated values «H1» and «H2» are obtained.
NOTE : The difference in height between the two sides at the rear should be less than 7.5 mm.

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 SAXO - All Types AXLE GEOMETRY
Geometry of the axles at reference height.
Front height Rear height

Reminder : Measuring the front height Reminder : Measuring the rear height
H1 = Distance between the ground and the mounting face of the fixings H2 = Distance between the ground and the rear crossmember

B3BP07UC B3BP07VD

The front heights H1 are measured between the ground and the moun- The rear heights H2 are measured between the ground and the mounting
ting face of the arm fixings (1) at the point «a». face of the rear crossmember (2) at «b» and «c».
SUSPENSION
STEERING

WARNING
AXLES

A < B = Positive figure : += TOE-IN

B3CP02UC A > B = Negative figure: –= TOE-OUT
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 AXLE GEOMETRY SAXO - All Types
Geometry of the axles at reference height.
Normal suspension Raised suspension
Front Rear Front Rear

HFX (**) HFX (**)

HFX HFX
Engines KFW - NFT All Types KFW - NFT All Types
(*) (*)
NFX - VJX NFX - VJX

Steering Manual Manual Assisted Manual Manual Assisted

Tracking O° -0°10’to 0°31’ -0°10’to 0°31’ -0°16’to -1°6’ -0°10’to 0°31’ -0°10’to 0°31’ -0°16’to -1°6’
Toe-in mm -1 to -3 +1 to +3 +1.49 to +6.39 -1 to -3 +1 to +3 +1.49 to +6.39

Camber - 0°9’ ± 30’ - 0°40’ ± 30’ - 1°35 ’± 30’ - 0°9’ ± 30’ - 0°40’ ± 30’ - 1°35 ’± 30

Castor 2°13’± 30’ 3°14’± 30’ 2°13’± 30’3° 3°14’± 30’

Pivot angle 12°± 41’± 40’ 12°42’± 40’ 12°± 41’± 40’ 12°42’± 40’

(*) = Without assisted steering option and ABS. (**) = With assisted steering and ABS options.

SUSPENSION
STEERING
AXLES
WARNING : For the vehicle to be at reference height, compress the suspension until
the calculated values «H1» and «H2» are obtained.

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 SAXO - All Types FRONT AXLE
Anti-roll bar Ø 18 and 22 mm Anti-roll bar Ø 19 and 21 mm (1) Suspension leg.
(3) Front anti-roll bar.
(9) Lower arm.
Tightening torques m.daN
(2) Anti-roll bar bearing fixing on the bodyshell 5.5 ± 0.2
(4) Anti-roll bar bearing fixing on the lower arm 2.2 ± 0.2
(5) Suspension leg upper fixing 2.1 ± 0.2
(6) Lower ball-joint fixing screw 3.8 ± 0.4
(7) Anti-roll bar link rod fixing 7 ± 0.6
(8) Suspension arm rear fixing nut 4.2 ± 0.4
(9) Suspension arm front fixing 8.5 ± 0.8
B3CP02SD

Suspension – Front anti-roll bar

HFX (3) Raised suspension

HFX (1)
HFX (2) HFX NFT KFW (3) France
KFW VJX Export
NFX (3) Administration
SUSPENSION

Ø Anti-roll bar None 21 19 18 22 21 19

STEERING

AXLES

(1) = With airbag. (2) = Without option. (3) = VTS level.

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 REAR AXLE SAXO - All Types

(1) Rear axle.

(2) Damper.
(5) Rear suspension arm.
(7) Rear brake drum.
(9) Torsion bar.

The antiroll bar is located inside the tube of the rear axle.

Tightening torques m.daN.

(3) Damper upper fixing screw 10 ± 1

(4) Damper lower fixing screw 10 ± 1
(6) Stub nut 20 ± 1
(8) Rear axle fixing bolt 8.7 ± 1

SUSPENSION
STEERING
AXLES
B3DP02ND

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 SAXO - All Types REAR AXLE - SUSPENSION
Torsion bar

HFX (1) (2) – KFW (2) HFX - KFW

HFX-VJX (3)
NFX - VJX (1) NFX - VJX

Torsion bar Ø (mm) 19 17.9 18.3

Colour reference LH : 2 rings Black White Green

Torsion bar RH : 1 ring
(1) = Entreprise. (2) = VTS trim level (3) = With raised suspension
Antiroll bar
Raised suspension
HFX (2)-KFW HFX (3)-KFW (3)
HFX
NFX-VJX NFX (3) France Export

Ø Anti-roll bar
None 18 22 18 15
(mm)
SUSPENSION

(1) = With airbag. (2) = With airbag or assisted steering or ABS. (3) = VTS trim level.
STEERING

AXLES

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 STEERING SPECIFICATIONS SAXO - All Types
Manual steering
Tyres 155/70 R13 165/70 R13 165/65 R14
Pinion (no. of teeth) 6
Rack (no. of teeth) 28 NOTA : The steering assembly is secured to the bulkhead.
Rack travel 80 72 Length of the steering track rods
(between the centre lines of the ball-joints).
Stop (colour) Black White Pre-adjustment = 520 mm.
Power-assisted steering

Tyres 165/70 R13 165/70 R14 185/55 R14

Pinion (no. of teeth) 7
Rack (no. of teeth) 28
Rack travel 68
Stop (colour)

SUSPENSION
STEERING
AXLES
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 SAXO - All Types MANUAL STEERING

Tightening torques (m.daN)

1 - Airbag 7 - Pivot ball-joint nut 3.5
2 - Airbag fixing to steering wheel 0.8 8 - Lock nut M14 4.5
3 - Steering wheel fixing 3 8 - Lock nut M16 5
SUSPENSION
STEERING

4 - Steering column fixing 2.3 9 - Track rod articulation 2.1

AXLES

5 - Steering cardan joint fixing 2.3 10 - Splined coupling fixing to steering rack 2.4
B3EP02UD
6 - Fixing to bulkhead 2.2
B3EP09SC B3EP09TD

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 POWER-ASSISTED STEERING SAXO - All Types

Tightening torques (m.daN)

1 - Airbag 8 - Track rod lock nut M16 5
2 - Airbag fixing to steering wheel 0.8 9 - Track rod articulation 2.1
3 - Steering wheel fixing 3 10 - Splined coupling fixing to steering rack 2.4
4 - Steering column fixing 2.3 11 - Steering ram to splined coupling 8
5 - Steering cardan joint fixing 2.3 12 - Steering ram to casing 8

SUSPENSION
STEERING
6 - Fixing to bulkhead 2.2 13 - Nut fixing the pinion to the bearing 1.5

AXLES
7 - Pivot ball-joint nut 3.5 14 - Valve/casing fixing 0.7
8 - Track rod lock nut M14 4.5
B3EP02TD B3EP02WD

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 SAXO - All Types POWER-ASSISTED STEERING (continued)
Power steering system
WARNING : Saxo all types except diesel without aircon
1 -
Power steering
2 -
Oil dispensing valve
3 -
Power-assisted steering ram
4 -
Low pressure pipe
5 -
High pressure pipe
6 -
Upper reservoir
7 -
Power steering electro-pump unit and built-in
lower reservoir
8 - Flexible mounting
9 - Electro-pump unit bracket

Tightening torque (m.daN).

Pump support fixing 2
Pump fixing to support 2
High pressure pump
Electro-pump connection 2
Power steering valve connection 2,5
Low pressure pump
SUSPENSION
STEERING

Electro-pump connection 2,5

AXLES

Power steering valve connection 2,5

B3EP09UD
Note : Fluid type TOTAL Fluide ATX capacity : 0.950 L.

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 POWER-ASSISTED STEERING (continued) SAXO - All Types
Power steering system
WARNING : Saxo diesel with aircon
Description.

Note : The power steering system on vehicles without aircon is supplied

by a mechanical pump driven by the accessories drive belt.

(6) Power steering mechanism.

(7) Upper reservoir.
(8) Lower reservoir.
(9) Radiator.
(10) Power steering pump.
(11) The grooves on the connector (6) indicate that the pump (5) is
constant flow.

Max. pressure : 80 Bars.

Pulley diameter : 112 mm.
Fluid quality : TOTAL Fluide ATX

SUSPENSION
Capacity : 1.55 litres.

STEERING
AXLES
B3EP12XD

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 C3 AXLE GEOMETRY
Conditions for checking and adjusting
Tyres inflated to correct pressures.
Vehicle at reference height.
Steering rack locked at mid point (See corresponding operation).
Vehicle heights at reference height

E1AP09MD

Front height Rear height

L1 L2
H1 = R1 - L1 H2 = R2 + L2
SUSPENSION

H1 = Measurement between the measuring zone underneath the front H2 = Measurement between the measuring zone underneath the rear sill
STEERING

subframe and the ground. and the ground.

AXLES

R1 = Front wheel radius under load. R2 =Rear wheel radius under load.
L1 = Distance between the wheel axis and the measuring zone under- L2 = Distance between the wheel axis and the measuring zone under-
neath the front subframe. neath the rear sill.
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 AXLE GEOMETRY C3

B3CP07SD

Measuring front height Measuring rear height

[1] Gauge for measuring the wheel radius, 4 bolts, tool 8006-T
Z1 =Measuring zone underneath the front subframe. Z2 = Measuring zone underneath the rear sill.
Measure the radius of the front wheel R1 - Calculate dimension H1 = R1 – L1 Measure the radius of the rear wheel R2 - Calculate dimension H2 = R2 + L2

Value at reference All Types Value at reference All Types

CRD vehicles (*) CRD vehicles (*)
height (except CRD) (*) height (except CRD) (*)
(+ 6 - 8 mm) (+ 10 - 6 mm)
L1 = 142.5 mm L1 = 132.5 mm L2= 52 mm L2= 62 mm

SUSPENSION
STEERING
(*) = CRD : Difficult road conditions.

AXLES
Definition for a type of vehicle whose axles and suspensions are adapted for driving on rough roads.
Compress the suspension to obtain the calculated values.
The height difference between the two axle dimensions should be less than 10 mm.

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 C3 AXLE GEOMETRY
Front axle Rear axle
Dissymmetry of lower castor at 0° 30’.
Dissymmetry of lower camber at 0° 18’. Dissymmetry of lower camber at 0° 18.
Distribute symmetrically, LH / RH wheel, the total tracking value.
All types (except CRD)
Castor Camber Pivot angle
Vehicle Tracking Tracking Camber (± 0°30’)
(± 0°18’) (± 0°30’) (± 0°30’)
Adjustable Non adjustable Non adjustable
All mm -2±1 + 5.5 ± 1
Types 0° - 0° 19’±0°10’ 3°57’ - 0°28’ 11°24’ + 0°50’ ± 0°10’ - 1°30’
CRD vehicles
Castor Camber Pivot angle
Vehicle Tracking (± 0°30’) Tracking Camber
(±0°18’) (±0°30’)
Adjustable Non adjustable Non adjustable
All mm -2±1 + 5.2 ± 1
Types 0° - 0° 19’±0°10’ 3°53’ - 0°26’ 11°14’ + 0°47’ ± 0°10’ -1°28’
SUSPENSION
STEERING

NOTE
AXLES

A < B = Positive figure: += TOE-IN

B3CP02UC A > B = Negative figure: -= TOE-OUT
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 FRONT AXLE C3
Tightening torques (m.daN)
(1) Nut fixing suspension leg on body : 6,5 ± 0,6
(2) Damper :
(3) Anti-roll bar link rod upper ball-joint : 3,2 ± 0,3
(4) Suspension leg pivot : 5,4 ± 0,5
(5) Anti-roll bar link rod lower ball-joint : 3,2 ± 0,3
(6) Anti-roll bar bearing fixing on subframe : 8 ± 0,8
(7) Hub nut : 24,5 ± 0,5
(8) Wheel bolt : 9±1
(9) Subframe to bodyshell fixing screw : 10 ± 1
(10) Anti-roll bar
(11) Pivot lower ball-joint fixing on lower arm : 5,5 ± 0,5
(12) Pivot lower ball-joint fixing : 4 ± 0,4
(13) Lower arm front and rear mounting fixing : 14 ± 0,4
(14) Stabiliser bar screw : 6,6 ± 0,7
(15) Steering ball-joint fixing : 3,5 ± 0,3

Anti-roll bar

SUSPENSION
Diameter (mm) Colour

STEERING
AXLES
HFX- KFV- NFU
8HX-8HW 19 Blue
B3CP07HP 8HV-8HY

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 C3 REAR AXLE
Tightening torques (m.daN)
(1) Rear axle fixing screw : 10 ± 1
(2) Anti-roll bar :
(3) Rear axle crossmember :
(4) Rear suspension arm rubber mounting yoke :
(5) Rear suspension arm rubber mounting :
(6) Yoke / suspension arm fixing screw : 7,6 ± 0,5
(7) Rear suspension arm :
(8) Stub axle bearing nut : 20 ± 2 greased
(9) Damper :
(10) Damper upper fixing : 4,5 ± 0,4
(11) Damper lower fixing : 9,3 ± 1
(12) Suspension spring :
(13) Suspension arm fixing on rear axle crossmembe : 13 ± 1,3
(14) Secondary brake cable guide and support assembly :
(15) Travel stop :

Anti-roll bar
SUSPENSION

Diameter (mm)
STEERING

AXLES

HFX- KFV- NFU

8HX-8HW 25.5 (tubular)
B3DP09GP 8HV-8HY

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 SUSPENSION C3
Front axle
(1) Nut fixing suspension leg on body : 6,5 ± 0,6
(2) Damper :
(3) Anti-roll bar link rod upper ball-joint : 3,2 ± 0,3
(4) Suspension leg pivot : 5,4 ± 0,5
(5) Anti-roll bar link rod lower ball-joint : 3,2 ± 0,3
(6) Anti-roll bar bearing fixing on subframe : 8 ± 0,8
(7) Hub nut : 24,5 ± 0,5
(8) Wheel bolt :9±1
(9) Subframe to bodyshell fixing screw : 10 ± 1
(10) Anti-roll bar :
(11) Pivot lower ball-joint fixing on lower arm : 5,5 ± 0,5
(12) Pivot lower ball-joint fixing : 4 ± 0,4
(13) Lower arm front and rear mounting fixing : 14 ± 0,4
(14) Stabiliser bar screw : 6,6 ± 0,7
(15) Steering ball-joint fixing : 3,5 ± 0,3
Anti-roll bar
Engines Diameter (mm) Colour
All Types 19 Bue
Pivot
Engines Diameter of bearing Type

SUSPENSION
All Types 72 U (Cast-iron)

STEERING
AXLES
Damper
Engines Damping law
B3CP07RP All Types R 59 M
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 C3 SUSPENSION
Front axle

(1) Nut fixing suspension leg on body : 6,5 ± 0,6

(2) Damper.

(16) Cup.

(17) Damper nut. : 6,5 ± 0,6

(18) Damper cup.

(19) Ball bearing

(20) Spring thrust cup.

(21) Travel stop cup.

(22) Suspension spring.

(23) Damper rod protector.

(24) Travel stop.

SUSPENSION
STEERING

AXLES

B3BP180D

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 SUSPENSION C3
Rear axle
(25) Rear axle fixing screw : 10 ± 1
(26) Anti-roll bar :
(27) Rear axle crossmember :
(28) Rear suspension arm silentblock mounting yoke :
(29) Rear suspension arm silentblock :
(30) Suspension arm fixing screw on yoke : 7,6 ± 0,5
(31) Rear suspension arm :
(32) Stub axle bearing nut : 20±2 (greased).
(33) Damper :
(34) Damper upper fixing screw : 4,2 ± 0,4
(35) Damper lower fixing screw : 10,6 ± 1
(36) Suspension spring :
(37) Travel stop :
(38) Secondary brake cable guide support :
Anti-roll bar
Engines Diameter (mm)
All Types 25.5 (Tubular)
Damper
Engines
1.4i (Auto.) - 1.6i 16V
F168K

SUSPENSION
1.4 HDi 16V

STEERING
AXLES
F77D
1.1i-1.4i (BVM)-1.4 HDi
F77B (*)
B3DP09UP (*) = For CRD vehicle

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 C3 FEATURES OF ELECTRIC POWER STEERING
Engines : HFX - KFV - NFU - 8HX - 8HW - 8HY
Steering column

B3EP13GD B3EP13HC

Tightening torques m.daN. Identification

(1) Steering wheel fixing : 2 ± 0.3 Identified by the colour of the ring at "a".
SUSPENSION
STEERING

(2) Steering column fixing on support : 2.2 ± 0.5

AXLES

Left hand drive : BLUE ring

(3) Steering cardan fixing : 2.2 ± 0.2
Right hand drive : WHITE ring.

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 FEATURES OF ELECTRIC POWER STEERING C3
Engines : HFX - KFV - NFU - 8HX - 8HW - 8HY
Steering mechanism

Tightening torques m.daN

(4) Ball-joint fixing on pivot : 3,5 ± 0,3
(5) Steering rod lock-nut : 5 ± 0,5
(8) Threaded washer
(9) Stud
(10) Flat washers
(11) Fixing of mechanism on subframe : 8 ± 0,8
B3EP13JD

KFV (Auto.)
HFX - KFV - 8HX - 8HW
NFU - 8HY - 8HV
Connectors.
Electric motor 60 A 65 A
Steering rack travel 2x72 2x64 (6) Supply of electric assistance motor.
Steering ratio 45.6/1

SUSPENSION
Number of rotations of (7) Torque sensor signals..

STEERING
3.2 2.8

AXLES
steering wheel
Inner angle of lock 38° 32°30’
Outer angle of lock 32°24’ 28°42’
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 C3 FEATURES OF ELECTRIC POWER STEERING
Engines : HFX - KFV - NFU - 8HX - 8HW - 8HY
Steering assistance

B3EP13KC B3EP13LC

Supplier: KOYO. Electric power-assisted steering ECU.

Only one ECU version, whatever the engine-type.
The steering assistance is provided by the assistance motor (12), control- The electric power steering ECU is linked to the following connectors:
led by the ECU. - (6) Assistance motor supply.
Power delivered to the assistance motor (12) depends on: - (13) Electric power steering ECU supply.
SUSPENSION

- (14) Control signals.

STEERING

- Speed of the vehicle. After changing the electric power steering ECU, it is necessary to
AXLES

perform a configuration. (See corresponding operation).

- Torque applied on the steering wheel.

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 SPECIAL FEATURES : STEERING C3
Engines : HFX - KFV - NFU - 8HX - 8HW - 8HY
Centring the steering rack

Preliminary operation.

Raise and support the vehicle on a two-column lift.

Remove, on the RH side of the steering rack:
- Clip (1).
- Clip (2).

Release the steering rack protection gaiter.

Setting
B3EP13UC Move the steering to full left hand lock.
Measure the dimension X.
Move the steering to full right hand lock.
Measure the dimension Y.

Calculate the dimension: L = (Y – X) : 2.

SUSPENSION
STEERING
Refit:

AXLES
- The steering rack protection gaiter
- New clips (1) and (2).
B3EP13VD

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 C3 AXLE GEOMETRY
Front and rear measuring points
XSARA ALL TYPES # RPO 8666 XSARA ALL TYPES RPO 8667 #
Front height Rear height Front height Rear height

B3CP046D B3CP06ZD

H1 = Dimension between the centre of the front suspension arm mounting and the ground.
H2 = Dimension between the contact face of the rear mounting and the ground.
R1 = Front wheel radius under load.
R2 = Rear wheel radius under load.
SUSPENSION
STEERING

L1 = Distance between the centre of the wheel and the centre of the front suspension arm mounting.
AXLES

L2 = Distance between the centre of the wheel and the contact face of the rear mounting on the bodyshell.

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 AXLE GEOMETRY XSARA - All Types
Reference heights
: 8006-T # N°RPO 9428
Tools [1] Gauge for measuring the radius of wheels with 4 bolts
: 4300-T N°RPO 9429 #
Setting the reference height.
Front Rear

Measure the dimension «R1». Measure the dimension «R2».

Calculate the dim. H1 = R1 - L1. Calculate the dim. H2 = R2 + L2.

Compress the suspension until the values (H1) and (H2) are obtained.
NOTE : The difference in height between the two sides should be less than
10 mm.
B3CP04AD

Front axle Rear axle

2.0i 16V All engines All CRD 2.0i 16V All saloons All CRD
Engines (except 2.0i 16V (except 2.0i 16V Estate

SUSPENSION
(RFS) and CRD) engines (RFS) and CRD) engines

STEERING
AXLES
Reference heights 115.5 75.5 73 88 103
90.5 83
(in mm)

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 XSARA - All Types AXLE GEOMETRY
Values of the front and rear suspensions, at reference height

ESSENTIAL : When checking the suspensions, the vehicle should be at reference height.

Tools used :

Compress the suspension, to obtain the values at reference height.

[1] Set of two suspension compressors : 9511-T.A

[2] Set of four straps : 9511-T.B
[3] Set of four shackles : 9511T.C
SUSPENSION
STEERING

WARNING
AXLES

A < B = Positive figure: += TOE-IN

B3CP04LC A > B = Negative figure: –= TOE-OUT
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 AXLE GEOMETRY XSARA
Values of the front and rear suspensions, at reference height
Front axle
Saloon all engine Saloon CRD (*)
types except KFW all engine types
Tolerances Adjustable Saloon or Saloon CRD (*)
Estate all engine 2.0i 16V (RFS) except KFW
entreprise KFW KFW Estate CRD (*)
types except
CRD (*) all engine types
± 1 mm - 1.5 ± 1 mm
Tracking YES
- 0°15’ ± 10’ (ouverture)
Castor ± 18’ 3° 2°55’ 3° ± 07’ 2°55’
Pivot angle ± 30’ NO 10°40’ 10°44’ 10°22’ 11° ± 07’ 10°26’
Camber ± 30’ 0° 0°12’ - 0° ± 07’ 0°07’
Rear axle

Saloon all engine Saloon CRD (*)

types Estate all engine all engine types
Tolerances Adjustable 2.0i 16V (RFS)
Saloon entreprise types Estate CRD (*)
all engine types
± 1.3 mm 4.54 ± 1.3 mm 5.1 ± 1.3 mm 4.27 ± 1.3 mm 3.45 ± 1.3 mm

SUSPENSION
NO

STEERING
Tracking 0° 41’ ± 11’ 0° 46’ ± 11’ 0° 39’ ± 11’ 0° 31’ ± 10’

AXLES
Camber ± 15’ YES - 0°57’ - 0°58’ - 0°59’
(*) CRD = Difficult road conditions.
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 XSARA - All Types AXLE GEOMETRY

a = Angle which defines the tracking between the front and rear axles.

Its value must not exceed 12'.

SUSPENSION
STEERING

AXLES

B3CP04UC

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 FRONT AXLE XSARA - All Types

Tightening torques (m.daN).

(1) Damper nut 4.5 ± 0.4

(2) Cup screw 2.5 ± 0.3
(3) Suspension leg
(4) Anti-roll bar link rod upper ball-joint 3.7 ± 0.3
(5) Suspension leg pivot (hollow pivot) 4.5 ± 0.5
(5) Suspension leg pivot (pivot «H») 5.5 ± 0.5
(6) Anti-roll bars
(7) Anti-roll bar link rod lower ball-joint 3.7 ± 0.3
(8) Pivot lower ball-joint 4 ± 0.4
(9) Driveshaft nut 32.5 ±2.5
(10) Wheel bolt 9±1
(11) Lower arm front mounting 7.6 ± 0.7
(12) Lower arm rear mounting and anti-roll 6.8 ± 0.6
bar bearing
(13) Screw under rear mounting 3.1 ± 0.3

SUSPENSION
(14) Ball-joint fixing on lower arm 5± 0.5

STEERING
Vehicles RPO 8667 # are all equipped Subframe to bodyshell fixing screw

AXLES
8.5 ± 0.8
as standard with ventilated discs.
B3CP040P B3CP041D

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 XSARA - All Types FRONT AXLE
Evolution : Suspension arm ball-joint

Application from RPO : 7968.

New components :
- Suspension arm ball-joint.
- Pivot.

Old fitting ØA = 16 mm.

New fitting ØA = 18 mm.

Repair requirements.

ESSENTIAL : Swapping of old and new components is forbidden.

It is permitted to fit a new pivot/ball-joint assembly on one side of an old

vehicle.

Replacement Parts.
The old components are still available from Replacement Parts.
SUSPENSION
STEERING

AXLES

B3CP054D

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 FRONT AXLE XSARA - All Types

Anti-roll bars
Engines Diameter Colour reference
1.6i-1.6i 16V-1.9D Saloon 19 Blue
2.0i 16V (RFV)-1.4 HDi -2.0 HDi Estate 20 Yellow
2.0i 16V (RFS) Saloon 21 White

SUSPENSION
STEERING
AXLES
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 XSARA - All Types FRONT AXLE
XSARA # 07/1999 XSARA 07/1999 # 09/2000 XSARA 07/1999 # 09/2000

The angle of castor changes to 3° except

for LPG vehicles, CRD vehicles, and Estates
All Types.
CRD = Difficult Road Conditions : this type of
vehicle has axles and suspensions designed for
driving on rough road surfaces.

Lug "a" to the rear.

Lug "a" to the front.

Pivot ball-joint
Manual steering, groove at "b".
Power-assisted steering, groove at "b".

NOTE : Vehicles after 09/2000 # are all equipped as standard with ball-joints without the groove
at "b".
SUSPENSION
STEERING

AXLES

B3CP042D B3CP049C B3CP043D

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 REAR AXLE XSARA - All Types

Tightening torques (m.daN)*

(1) Anti-roll bar lever 3.2 ± 0.3

(2) Anti-roll bar
(3) Transversal torsion bars
(4) Rear crossmember flanges 8.3 ± 0.8
(5) Front silentblocks 5.5 ± 0.5
(6) Rear silentblocks 4.5 ± 0.4
(7) Anti-vibration clamp.
(8) Damper pin 9.6 ± 0.9
(9) Stub axle nuts (lubricated) 18.5 ± 1

Note

- The RH torsion bar is identified by 1 paint line.

SUSPENSION
STEERING
AXLES
- The LH torsion bar is identified by 2 paint lines.

B3DP04SP

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 XSARA - All Types REAR AXLE

Vehicles Torsion bars (mm) Anti-roll bars (mm)

Engines Diameter Colour reference Diameter Colour reference
3-door Entreprise 19.3 Violet 19 Orange
19.D 3- and 5-door TT exc. 18.7 Yellow 18 Blue
Entreprise
Estates All types 20 Grey 20 Green

1.6i 16V-2.i 16V 3- and 5-door TT 19.3 Violet 19 Orange

1.4 Hdi-2.0 HDi Estates All types 20 Grey 20 Green

2.0i 16V 3-door VTS 21 Light green 23 Without colour,

or white sticker
Grand Export 3- and 5-door TT 19.3 Violet 19 Orange
«GRD» Estates All types 20 Grey 20 Green
SUSPENSION
STEERING

AXLES

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 REAR AXLE XSARA
Evolution : Rear hub nut
Old # 15/12/1999 New 15/12/1999 # Evolution

-New rear hub nut (3).

- Washer discontinued (2).
Old fitting (A)
(1) Rear hub nut.
(2) Thrust washer.
ESSENTIAL : Tighten to : 27,5 ± 2,7 m.daN
New fitting (B)
(3) Rear hub nut.
ESSENTIAL : Tighten to : 25 ± 2,5 m.daN (greased)

NOTE : It is possible to have both types of fitting on the same axle.

The old nut (1) requires the fitting of the thrust washer (2).
WARNING : do not fit a thrust washer (2) with a new nut (3).
ESSENTIAL: Respect the tightening torque to be applied
when fitting.

SUSPENSION
WARNING: Identify the type of fitting, before starting a repair.

STEERING
AXLES
B3DP08AD

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 XSARA - All Types REAR AXLE

Operating clearance - X = 1 to 1.4 mm. - The front silentblocks are aligned at an angle of 45° in relation to the vehicle’s axis.
- The rear silentblocks are in parallel with the vehicle’s axis.
NOTE : The RH torsion bar can be identified by NOTE : There are two suppliers for the silentblocks:
1 paint line. - RBT, identified by a Green or Yellow painted dot on the side of the mounting.
SUSPENSION
STEERING

The LH torsion bar can be identified by 2 paint - PAULSTRA, identified by a Black painted dot on the side of the mounting.
AXLES

lines It is FORBIDDEN to swap components of different suppliers.

B3DP04TC B3DP04UD

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 REAR DAMPER XSARA - All Types
Adjusting the rear dummy damper
Lengths of the rear dummy damper (mm)
Engines
Normal driving Grand export
1.9 D 346
1.6i 16V 3-door 339
339
1.6i 16V 5-door
2.0i 16V (RFN) 346
1.4 HDi -2.0 HDi
2.0i 16V (RFS) 318

Estates and
336 342
Entreprise all types

SUSPENSION
STEERING
AXLES
E5AP14WC

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 XSARA - All Types MANUAL STEERING SPECIFICATIONS
Steering wheel - Manual steering
- (a) : L.H.D./R.H.D. = White.
- (L) : Shaft length = 311 ± 1.5 mm.
- (1) Steering wheel fitted with AIRBAG.
(according to equipment).
- (4) Steering column adjustment lever.

Tightening torques (m.daN).

- (2) AIRBAG to steering wheel fixing : 0.8
- (3) Steering wheel fixing : 3.3
- (5) Steering column to support fixing : 2.3
- (6) Steering cardan joint fixing : 2.3

- (b) = Locating bush.

The locating bush must be centred in the reference window

before tightening the cardan bolts (6).
SUSPENSION
STEERING

AXLES

B3EP08PD

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 MANUAL STEERING SPECIFICATIONS XSARA - All Types
Manual steering

Tightening torques (m.daN)

(7) Pivot ball-joint nut :4

(8) Link rod lock nut : 4.5

(9) Ball-joint on steering rack :6

(10) Fixing on cradle :5

(11) Plunger flange screw : 1.2

SUSPENSION
STEERING
AXLES
B3EP042D

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 XSARA - All Types MANUAL STEERING SPECIFICATIONS
Manual steering (continued)

Steering rack Number of teeth

Steering stop Number of
travel steering wheel Steering ratio
colour code
(mm) turns
Pinion Steering rack

6 teeth (13)
L.H.D. 73.5 29 4.3 22/1
(RH helix) Yellow thickness mm

- Length of the steering track rods (Pre-adjustment) = 371 mm (Between ball-joint centres) or
391 mm (Between the centre of the pivot ball-joint and the contact face of the steering rack ball-joint).
SUSPENSION
STEERING

AXLES

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 POWER-ASSISTED STEERING SPECIFICATIONS XSARA - All Types
Steering wheel - Power-assisted steering

- (a) : L.H.D. = Blue.

: R.H.D. = White.
- (L) : Shaft length = 311 ± 1.5 mm.
- (1) Steering wheel fitted with AIRBAG.
(according to equipment).
- (4) Steering column adjustment lever.

Tightening torques (m.daN).

- (2) AIRBAG to steering wheel fixing : 0.8

- (3) Steering wheel fixing : 3.3
- (5) Steering column to support fixing : 2.3
- (6) Steering cardan joint fixing : 2.3

- (b) = Locating bush.

The locating bush must be centred in the reference

window before tightening the cardan bolts (6).

SUSPENSION
STEERING
AXLES
B3EP08QD

355

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 XSARA - All Types POWER-ASSISTED STEERING SPECIFICATIONS
Power-assisted steering

Tightening torques (m.daN)

(7) Pivot ball-joint nut :4

(8) Link rod lock nut : 4.5
(9) Ball-joint on steering rack :6
(10) Fixing on subframe :5
(11) Hydraulic pipe connection : 2.5
(12) Valve to housing fixing : 1.2
(13) Plunger flange screw : 1.2
(14) Screw fixing the steering ram to the housing : 5.5
(15) Nut fixing the steering ram to the yoke : 5.5
SUSPENSION
STEERING

AXLES

B3EP08RD

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 POWER-ASSISTED STEERING SPECIFICATIONS XSARA - All Types
Power-assisted steering (continued)

Steering rack Number of teeth Number of

travel steering wheel Steering ratio
(mm) Pinion Steering rack turns

(*)
L.H.D. 71.7 28 3.3 18.8/1
(RH helix)

Steering valve
Vehicles Protector colour Number of teeth (*)
All types (except 1.8i 16V - 1.9TD) BLACK 7
1.8 i 16V - 1.9 TD ORANGE 8

SUSPENSION
STEERING
AXLES
- Length of the steering link rods (Pre-adjustment) = 371 mm (Between ball-joint centres) or
391 mm (Between the centre of the pivot ball-joint and the contact face of the steering rack ball-joint).

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 XSARA - All Types POWER-ASSISTED STEERING SPECIFICATIONS
Power-assisted steering assembly

Tightening torques (m.daN).

High pressure tube (Rubber seal pump side)

- Power-assisted valve and pump union : 2.5

Return pipe.
- Power-assisted valve union : 2.5
- (16) Upper front fixing (E3) : 2.5
- (17) Upper rear fixing (E3) : 2.2
- (18) Fixing (E3) : 2.2

Tightening sequence.
-Tighten screws (16) and (18).
-Lightly tighten screw (17), then fully tighten.

Power-assisted steering system capacity = 1 litre. Pressure switch on the pressure circuit.
Oil type: TOTAL FLUIDE ATX. - Switch opens 30 to 35 Bars.
SUSPENSION
STEERING

SAGINAW Pump adjustment = 100 Bars ± 5. - Switch closes 25 Bars.

AXLES

Pump shaft threading 3/8 - 16 threads per inch. - Tighten to : 2 m.daN.

B3EP045D

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 AXLE GEOMETRY XSARA PICASSO - All Types
Measurements at reference height
NOTE : To make the setting of reference height easier, it is acceptable to take the measurement from the flange of the jacking point.
WARNING : The values shown should only be used as guides. In case of doubt, check the settings at reference height
Front height Rear height

B3CP05BC B3CP058D B3DP079C

H1 = R1 – L1 H1’ = R1 – L1’ H2 = R2 - L2

H1 = From the front suspension arm linkage bolt axis to the ground. H2 = From the rear axle silentblock face to the ground.
R1 =Radius of the front wheel when laden. R2 = Radius of the rear wheel when laden.

SUSPENSION
L1 = From the centre of the wheel to the front suspension arm linkage L2 = From the centre of the wheel to the rear axle silentblock face.

STEERING
AXLES
bolt axis.
H1’ = From the front jacking point to the ground.
L1’ = From the front jacking point to the radius of the front wheel when laden.

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 XSARA PICASSO - All Types AXLE GEOMETRY
Measurements at reference height (continued). (The reference height of the vehicle is set as per the table below).
Front axle Rear axle

B3CP05BC B3CP05AC B3DP079C

H1 = R1 – L1 ou H1’ = R1 – L1’ H2 = R2 + L2
Front axle Rear axle
Vehicles all types
L1 = 90.5mm L1’ = 124 mm H2 = R2 + 8.5 mm
CRD vehicles (Difficult Road Conditions)
H1 = R1 – L1 or H1’ = R1 – L1’ H2 = R2 + L2
6FZ - RHZ
L1 L1’ L2
75.5 23.5
SUSPENSION

109
STEERING

Measure the radius of the front wheel : R1. Measure the radius of the rear wheel: R2.
AXLES

Calculate dimension H1 or H1’. Calculate dimension H2.

Compress the suspension to obtain the calculated values. The difference in height between the two sides should be less than 10 mm.
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 AXLE GEOMETRY XSARA PICASSO - All Types
Measurements at reference height (continued). Compress the suspension to obtain the calculated values.
Vehicle All Types
Front axle Rear axle
Vehicle Tracking Castor Pivot angle Camber Tracking Camber
Adjustable Yes No
0 ± 1mm 4.8 mm ± 1mm
All Types 3° ± 18’ 10° 43’ ± 30’’ 0° ± 30’ - 1°13’ ± 18’
- 0°09’ à +0°09’ - 0° 43’ ± 0° 09’
Vehicle All Types CRD (Condition de route difficile)
Front axle Rear axle
Vehicle Tracking Castor Pivot angle Camber Tracking Camber
Adjustable Yes No
- 1 ± 1mm 3.8 mm ± 1mm
All Types 2°56’ ± 18’ 10°25’ ± 30’ 0°07’ ± 30’ - 1°14’ ± 18’
- 0°18’ à 0°0’ - 0°34’ ± 0° 09’

NOTE : When checking axles, the vehicle should be at reference height.

SUSPENSION
(*) = Fuel tank full.

STEERING
WARNING

AXLES
All Types Ground clearance A < B = Positive figure: += TOE-IN
Unladen (*) 150 mm (Minimum value) A > B = Negative figure: –= TOE-OUT
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 XSARA PICASSO - All Types FRONT AXLE
Tightening torques m.daN.
(1) Damper nut : 4.5 ± 0.4.
(2) Cup screw : 2.5 ± 0.2.
(3) Suspension arm.
(4) Anti-roll bar link rod ball-joint : 4 ± 0.4.
(5) Suspension arm swivel : 4.5 ± 0.4.
(6) Anti-roll bar.
(7) Anti-roll bar link rod ball-joint : 4 ± 0.4.
(8) Lower swivel ball-joint : 4 ± 0.4.
(9) Hub nut : 32.5 ± 2 (greased).
(10) Wheel bolts :9±1
(Face and threads not greased).
(11) Lower arm front pivot : 8 ± 0.8.
(12) Lower arm rear pivot and
anti-roll bar bearing : 6.5 ± 0.6.
(13) Screw under rear pivot : 3.5 ± 0.3.
Fixing bolt : subframe on bodyshell: 8.5 ± 0.8.

Anti-roll bar
SUSPENSION
STEERING

Engine Diameter Colour ref.

AXLES

Damper upper bracket : NFV-6FZ

Lug «a» to the front. 21 WHITE
B3CP056P B3CP057D B3CP043D RFN-RHY
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 REAR AXLE XSARA PICASSO - All Types
Tightening torques m.daN.
(14) Front silentblock on subframe : 9.5 ± 0.9.
(15) Anti-roll bar bolt : 5.5 ± 0.5.
(16) Rear torsion bar
(17) Anti-roll bar
(18) Tubular axle
(19) Front silentblock on bodyshell : 4 ± 0.4.
(20) Rear upper arm.
(21) Wheel bolt : 9 ± 1.
(Face and threads not lubricated)
(22) Damper
(23) Rear silentblock on subframe : 5.5 ± 0.5.
(24) Damper pin nut : 11 ± 1.
(25) Stub axle nuts (lubricated) : 25 ± 2.
(26) Rear silentblock on bodyshell : 5.5 ± 0.5.
Torsion bar Anti-roll bar

Engine Ø (mm) Colour Ø (mm) Colour

mark mark

SUSPENSION
NFV-6FZ

STEERING
19.6 PINK 21 ORANGE
RFN-RHY

AXLES
NOTE : - The RH torsion bar can be identified by 1 paint line.
B3DP078D - The LH torsion bar can be identified by 2 paint lines.

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 XSARA PICASSO - All Types REAR AXLE
Evolution : Rear hub nut
Old # 15/12/1999. New 15/12/1999 #
Evolution :
- New rear hub nut (3).
- Washer discontinued (2).
Old fitting (A)
(1) Rear hub nut.
(2) Thrust washer.
ESSENTIAL : Tighten to : 27,5 ± 2,7 m.daN
New fitting (B)
(3) Rear hub nut.
ESSENTIAL : Tighten to : 25 ± 2,5 m.daN.

NOTE : It is possible to have both types of fitting on the same axle.

The old nut (1) requires the fitting of the thrust washer (2).
WARNING : do not fit a thrust washer (2) with a new nut (3).
SUSPENSION
STEERING

AXLES

ESSENTIAL: Respect the tightening torque to be applied when fitting.

WARNING : Identify the type of fitting, before starting a repair.
B3DP08AD

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 SUSPENSION XSARA PICASSO - All
Height of the vehicle in running order
(The vehicle height, when in running order, is set according to the measurements shown in the table below).

Checking conditions :
- Vehicle empty.
- All reservoirs full.
- Tyre pressures correct.
- Steering rack locked straight ahead : point zero (see corresponding
operation).

B3CP058D

Vehicles all types (except CRD)

Front Rear
H1 = R1 – L1 ou H1’ = R1 – L1’ H2 = R2 – L2

SUSPENSION
STEERING
Engine NFV - 6FZ RHY Engine NFV - 6FZ - RHY

AXLES
L1 62.5 66.5 mm L2 51 mm
L1’ 96 100 mm

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 XSARA PICASSO - All Types SUSPENSION
Measurements at the front and rear axles, vehicle in running order
Vehicles all types (except CRD)
Front axle Rear axle

Adjustable NFV – 6FZ RHY Adjustable NFV – 6FZ - RHY

2 ± 1 mm 1.7 ± 1 mm Tracking 1.2 ± 1 mm

Tracking Yes 0° 18’ ± 0° 09’ 0° 15’ ± 0° 09’ 0° 11’ ± 0° 09’
No
Castor 2° 54’ ± 20’ Camber 1° 15’ ± 20’
Pivot No 10° 6’ ± 30’ 10° 12’ ± 30’
angle
Camber 0° 20’ ± 30’ 0° 15’ ± 30’
SUSPENSION

WARNING
STEERING

AXLES

A < B = Positive figure: += TOE-IN

A > B = Negative figure: –= TOE-OUT
B3CP02UC

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 STEERING COLUMN SPECIFICATIONS XSARA PICASSO - All Types

Left hand drive = Green marking.

Right hand drive = White marking.

(1) Steering wheel.

(4) Steering column adjustment.

Tightening torques m.daN.

- (2) Airbag to steering wheel fixing : 0.8 ± 0.1

- (3) Steering wheel fixing : 3.3 ± 0.6
- (5) Steering column to support fixing : 4 ± 1
- (6) Steering cardan joint fixing : 2.3 ± 0.2

SUSPENSION
STEERING
AXLES
B3EP116D

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 XSARA PICASSO - All Types STEERING SPECIFICATIONS

Tightening torques (m.daN)

(7) Pivot ball-joint nut : 4 ± 0.4

(8) Steering rod adjusting lock nut : 4.5 ± 0.4
(9) Ball-joint on steering rack : 6 ± 0.6
(10) Fixing steering on subframe : 8 ± 0.8
(11) Hydraulic pipe connection : 2.4 ± 0.2
(12) Power steering valve : 1.2 ± 0.2
(13) Plunger flange screws : 1.2 ± 0.2
(14) Steering ram screw on housing : 9 ± 1
(15) Steering ram screw on yoke : 9 ± 1

NOTE : When removing the steering, it is imperative to replace screws

SUSPENSION

(14) and (15) (new screws).

STEERING

AXLES

B3EP117D

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 STEERING SPECIFICATIONS XSARA PICASSO - All Types

Steering rack Rack pinion Number of teeth Number of steering Turning circle Turning circle
travel in rack wheel turns between walls between kerbs
Left hand drive LH helix
71.7x2 28 teeth 3.22 12 m 11.48 m
Right hand drive RH helix

Motorisation Steering valve

NFV - 6FZ - RFN - RHY Number of teeth : 7

Length of the steering link rods (pre-adjustment):

- Between ball-joint centres = 392 mm
- Between the centre of the pivot ball-joint and the contact face of the steering rack ball-joint = 412 mm.

SUSPENSION
STEERING
AXLES
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 XSARA PICASSO - All Types POWER-ASSISTED STEERING SPECIFICATIONS

Tightening torques (m.daN).

Unions between pump unions and power steering valve 2 ± 0.3

(16) Fixing screw 2.2 ± 0.3
(17) Fixing screw 2.2 ± 0.3
(18) Fixing screw 2.2 ± 0.3

NOTE : Coat the threads with product ‘‘E3’’.

A pressure switch is implanted in the hydraulic piping between the high

pressure pump and the power steering valve.
- Opening pressure = 30 / 35 Bars.
- Closing pressure = 25 Bars minimum.
Tightening torque = 2 ± 0.2
Capacity of power steering circuit = 1 Litre.
Oil quality = TOTAL FLUIDE ATX.
Power steering pump : Supplier SAGINAW.
SUSPENSION
STEERING

Pump adjustment = 100 ± 5 Bars.

AXLES

Pump shaft threading 3/8 - 16 threads per inch

B3EP118D

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 BRAKES
BRAKE SPECIFICATIONS SAXO - All Types
1.1 i - 1.4 i 1.6 i
(1) Compensator integral with the wheel cylinder. 1.6 i
1.5 D 1.6 i 16V
(2) Load sensitive compensator.
Power-assisted steering without ABS
Master cylinder 19 20.6 22.2
Master-vac 177.8 203.2 228.6

Ø Caliper/piston
BENDIX Standard 4/48 TEVES FN48/48
makes
mm
Fr Non-ventilated 247
Disc
Ventilated 247
Disc thickness/min. thickness 10/8 20.4/18.4
GALFER 3726
Brake pad grade TEXTART 4900 AS – FM 380
TEXTART 4009
Cylinder or caliper 19 30
Ø
Drum / Ø max. 180/182
mm
Disc Non-ventilated 247
Rr Disc thickness/min. thickness 8/6
Make BENDIX RAD BENDIX S4
Brake lining grade DON 8259 AS FM 380
Compensator (1) 20 (2) 13
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 BRAKES

SAXO - All Types BRAKE SPECIFICATIONS (continued)

1.1 i - 1.4 i 1.6 i Entreprise
(1) Compensator integral with the wheel cylinder. 1.6 i
1.5 D 1.6 i 16V 1.1i-1.5D
(2) Load sensitive compensator.
Power-assisted steering with ABS Manual steering
Master cylinder 20.6
Master-vac 203.2

Ø Caliper/piston BENDIX Standard TEVES FN BENDIX Standard

makes 4/48 48/48 4/48
mm
Fr Non-ventilated 247 247
Disc
Ventilated 247
Disc thickness/min. thickness 10/8 20.4/18.4 10/8
GALFER 3726
Brake pad grade JURID 519 AS FM 380
TEXTART 4009
Cylinder or caliper 20.6 30 19
Ø
Drum / Ø max. 203/205 180/182
mm
Disc Non-ventilated 247
Rr Disc thickness/min. thickness 8/6
Make LUCAS RAI BENDIX S4 BENDIX RAD
Brake lining grade JURID E 558 AS FM 380 DON 8259
Compensator (2) 13 (1) 20
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 BRAKES
BRAKES SAXO - All Types

B3FP06GC

Conditions
- Vehicle in running order - 5 litres of fuel.
- A driver (75 Kg).
Adjusting the brake limiter.
- Apply the brake pedal to close the limiter.
Adjusting the stop lamp switch.
Clearance J = 2 to 3 mm. - Adjust using the screw (2) to obtain a clearance J of 0.5 to 2 mm.
After adjustment, tighten the lock nut (1) to 1 m.daN. NOTE : Do not touch (3) which has been adjusted at the factory.
B3FP06FC

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 BRAKES

SAXO - All Types BRAKES (continued)

Auto. - 1.1 i - 1.4 i - 1.6 i Tightening torques (m.daN)

Removing the caliper

- 1.1i Manual steering

- Screw M8 3.2 ± 0.3
- Screw M12 12 ± 1.2

- 1.1 i - 1.4 i
(Except 1.6 i)
- 2 Screws M12 12 ± 1.2

- 1.6 i
- 2 Screws M12 10.5 ± 1

NOTE : See evolution on following pages 254 to 256.

B3FP10ND

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 BRAKES
BRAKES (Continued) SAXO - All Types
EVOLUTION : Fixing screws for FRONT brake calipers: Type BENDIX STANDARD 4.
Application from RPO 8973.
Vehicles concerned. Repair.
Vehicles equipped with non-ventilated brake discs. (Except VTS trim
level). Removing-refitting the front brake caliper (old and new fitting)
Vehicles equipped with the following engines:
TUD5 – TU1JP – TU3JP Clean the threads of the fixing screws and coat them with a brake product
TU1M+ (Entreprise) and TU9M (Entreprise). of type «E3».
Evolutions.
Evolutions of the following components: Tightening : 3.5 m.daN ± 0.3
Front brake caliper fixing screws. Angular tightening : 87° ± 3°
Stop plates for front brake caliper fixing screws.
Evolutions of the fixing screws: Interchangeability
Coating on the threads of the fixing screws. The new fixing screws matched to the new stop plates can be fitted on the
Flanges for better centring of the fixing screws. old front brake calipers.
NOTE : The fixing screws are matched to the stop plates.
IMPERATIVE : Respect the matching of the stop plates and fixing
IMPERATIVE : Respect the tightening torques.
screws.
Old fitting: tighten to 12 m.daN.± 1.2 (up to RPO 8972).
Replacement parts.
NEW FITTING (from RPO 8973). The Replacement Parts service markets both the old and the new
Tightening : 3.5 m.daN ± 0.3 components.
Angular tightening : 87° ± 3°

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 BRAKES

SAXO - All Types BRAKES (Continued)

EVOLUTION : Fixing screws for REAR brake calipers: Type BENDIX STANDARD 4.

Application from RPO 8973.

Repair.
Vehicles concerned.
Vehicles equipped with non-ventilated brake discs. (Except VTS trim Removing-refitting the rear brake caliper (old and new fitting)
level).
Vehicles equipped with the following engines: Clean the threads of the fixing screws and coat them with a brake product
TU5J4 and TU5JP. of type «E3».
Evolutions.
Evolutions of the following components: Tightening : 7.5 m.daN ± 0.7
Rear brake caliper fixing screws.
Stop plates for rear brake caliper fixing screws. Interchangeability
Evolutions of the fixing screws: The new fixing screws matched to the new stop plates can be fitted on the
Coating on the threads of the fixing screws. old rear brake calipers.
Flanges for better centring of the fixing screws.
NOTE : The fixing screws are matched to the stop plates. IMPERATIVE : Respect the matching of the stop plates and fixing
IMPERATIVE : Respect the tightening torques. screws.

Old fitting: tighten to 11 m.daN ± 1 (up to RPO 8972). Replacement parts.

The Replacement Parts service markets both the old and the new com-
NEW FITTING (from RPO 8973).
ponents.
Tightening : 7.5 m.daN ± 0.7

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 BRAKES
HANDBRAKE (Adjustment) SAXO - All Types

Prior to adjustment.

- Release the handbrake.

- Drums rotating freely.
- No tight spot (If there is one, check if the primary or secondary cables are
correctly routed).
- Check that all the parts slide and move correctly.
- Bleed the main circuit.

Adjustment.

- Set the brake to the 4th notch.

- Tighten the nut (3) until the rear brakes are applied.
- Check that:
- there is a total travel of between 4 and 7 notches.
- the two secondary cables (1) on the balance lever (2) move together.
- the wheels rotate freely when the brake is released.
- Check that the brake warning lamp comes on from the 4th notch.

NOTE : The handbrake operates on the rear wheels.

B3FP106JC

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 BRAKES

SAXO BLEEDING THE BRAKES

The brakes are bled :

- Using brake bleeding equipment, in which case the pressure of the equipment should be set to a maximum of 2 Bars.

IMPERATIVE order of bleeding

Wheel :
- Rear left.
- Front right.
- Rear right.
- Front left.

Top up to level using the brake fluid sold by the CITROEN Replacement Parts Division.

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 BRAKES
BRAKE SPECIFICATIONS (WITHOUT ABS) C3

1.1i 1.4i 1.4 HDi

Engine type HFX KFV 8HX 8HW

Master cylinder 20.6
Master vac 203.2

Ø Caliper/piston
LUCAS/TRW C48/13 48
makes
mm
Fr Plain 266
Disc
Ventilated
Disc thickness/min. thickness 13/11

Brake pad grade TEXTAR T 4144

Ø Drum 203
mm Max. thickness 205
Rr
Make DON
Brake lining grade 8259

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 BRAKES

C3 BRAKE SPECIFICATIONS (WITH ABS)

1.6i 16V 1.4 HDi 16V

Engine type NFU 8HV 8HY

Master cylinder 22.2
Master vac 228.6

Ø Caliper/piston
LUCAS/TRW C54/22 54
makes
mm
Fr Plain
Disc
Ventilated 266
Disc thickness/min. thickness 22/20

Brake pad grade TEXTAR T 4144

Ø Cylinder or caliper LUCAS C38 HR 9/13

mm Disc Ventilated 247
Rr Disc thickness/min. thickness 9/7
Make GALFER
Brake pad grade G 4554

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 BRAKES
BRAKE SPECIFICATIONS C3
Braking circuit without ABS - REF (drum brakes at the rear) Braking system specifications

Braking circuit at «X».

- Front brakes with ventilated discs (*).

- Rear brakes with eitther drums or discs (*).

- Handbrake lever controlling cables acting on the

rear wheels.

The compensator and main brake limiter functions are

assured by the ABS EBD system.

NOTE : REF = Electronic Brakeforce Distribution

(*) = according to version

B3FP161D

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 BRAKES

C3 BRAKE SPECIFICATIONS
Braking circuit with ABS - REF (drum brakes at the rear)

B3FP162D

382

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 BRAKES
BRAKE SPECIFICATIONS C3
Braking circuit with ABS - REF (Disc brakes at the rear)

B3FP163D

383

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 BRAKES

C3 BRAKE SPECIFICATIONS
Braking circuit with ABS - REF

(a) Hydraulic circuit.

(b) Electrical circuit.

(1) Master cylinder in tandem.

(2) Braking servo.
(3) Brake caliper (or drum at the rear).
(4) Hub equipped with a bearing with an integral magnetic wheel
(48 pairs of poles).
(5) Wheel sensor.
(6) Brake fluid level sensor.
(7) Hydraulic block plus ECU.
(8) Stoplamp switch.
(9) Instrument panel.
(10) Diagnostic socket.
(11) Built-in systems interface (BSI).

B3GP02RP

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 BRAKES
BRAKE SPECIFICATIONS C3
ABS hydraulic block # N°OPR 9423 ABS hydraulic block: RPO 9424 #

B3GP03DC B3GP03EC

Components Supplier Part No. Observations Components Supplier Part No. Observations
Installed on the front LH Installed on the front LH
ABS ABS MK 60 : ABS
chassis member : ABS MK 70 : chassis member :
hydraulic TEVES 96 394 937 80 hydraulic TEVES
4 adjustment channels 96 419 653 80 4 adjustment channels
block block
47-way connector. 26-way connector.
Vehicle equipped with ABS and ESP systems
Components Supplier Part No. Observations
Installed on the front LH chassis
ESP -ABS
ABS hydraulic block TEVES member : 4 adjustment channels
MK 60 : 96 418 772 80
47-way connector.
NOTE : ESP = Electronic Stability Programme
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 BRAKES

C3 BRAKE SPECIFICATIONS
Brake pedal gear Front brake Rear brake

B3FP166D B3FP164C B3FP165C

Tightening torques (m.daN).

(16) Servo fixing 2.2 ± 0.3 (12) Yoke fixing on caliper 10.5± 1 (14) Rear caliper fixing on arm 5.3±0.5
(17) Fixing on master cylinder 2 ± 0.5 (13) Yoke fixing on caliper 3± 0.3 (15) Yoke fixing on caliper 3.8±0.3

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 BRAKES
HANDBRAKE (Adjustment) C3

Adjustment
Lift and chock the vehicle.

Remove:
- The rear cover (8)
- The nut (9).
- The handbrake trim (6).
- The gear lever gaiter (5).
- The front cover (3).
- The screws (1).

Disconnect the connectors of the following components:

- The cigar lighter (2).
- The electric window buttons (4).
Remove the central console (7).

WARNING: Check that the brake cables are correctly

routed under the vehicle.

Slacken the handbrake lever.

Press gently on the brake pedal (Then repeat the ope-
ration 3 times).
C5FP0ELD Pull vigorously on the handbrake lever 4 or 5 times.

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 BRAKES

C3 HANDBRAKE (Adjustment)
Adjustment (continued)

(10) Nut for adjusting cable tensions.

Remove:
- The rear wheels.
- The drums (according to version).
Release the handbrake.
Use a gauge set to measure at «a» the travel of the lever
from its stop.
Adjust the nut (10) to obtain a travel of less than or equal to
1 mm at «a».
Refit the brake drums without tightening them (according to
version).
Action the handbrake lever 8 times with an effort of 40 m.daN.
With the handbrake released, check the travel of the lever
at «a», using a gauge set.
NOTE : The travel should be less than 1 mm and more than
0,05 mm.
Refit:
- The brake drums.
- The wheels.
- The central console.
B3FP16ED Check the operation of the handbrake.

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 BRAKES
BLEEDING AND FILLING THE BRAKING SYSTEM C3
Tools.
[1] Generic bleeding apparatus : ‘‘LURO’’ or similar.
Bleeding, refilling.
Draining.
Drain the brake fluid reservoir (1) to the maximum (if necessary, use a clean syringe).
Disconnect the connector (4).
Uncouple the pipe (2).
Unscrew the shaft (3).
Remove the reservoir (1).
- Empty the brake fluid reservoir (1).
- Clean the brake fluid reservoir (1).
Refit:
The brake fluid reservoir (1).
The shaft (3).
Couple the pipe (2).
Reconnect the connector (4).
Filling the braking system.
WARNING : Use only those hydraulic fluids that are approved and recommended.
- Fill the brake fluid reservoir (1).
Bleeding the braking system.
WARNING: During the bleeding operation, take care to maintain the level of brake fluid in the
B3FP15XC reservoir and to top it up, using only brake fluid that is clean and clear.

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 BRAKES

C3 BLEEDING AND FILLING THE BRAKING SYSTEM (CONTINUED)

Bleeding the primary braking circuit.

WARNING: The ABS should not be active during the

bleeding operation.

Front brake caliper: Bleed screw (5).

A : Rear brake caliper
B : Rear brake drum

Bleed screw (6).

Bleed each wheel cylinder, proceeding in the following

order :

Front LH wheel.
Front RH wheel.
Rear LH wheel.
Rear RH wheel

B3FP15YC B3FP15ZD

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 BRAKES
BLEEDING AND FILLING THE BRAKING SYSTEM (CONTINUED) C3

With the bleeding apparatus

- Connect the bleeding apparatus [1] on the brake fluid reservoir (1).
- Adjust the apparatus pressure to 2 Bars.
For each circuit :
- Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container.
- Open the bleed screw, wait until the fluid is flowing out without air bubbles.
- Close the bleed screw.
- Remove the bleeding apparatus [1].
- Check the brake fluid level (Should be between «MINI» level and «MAXI» level).
- Fill if necessary with the approved and recommended synthetic brake fluid.
Without the bleeding apparatus.
NOTE : Two operators are necessary.
For each circuit :
- Apply the brake pedal to place the circuit under pressure.
- Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container.
- Open the bleed screw, wait until the fluid is flowing out without air bubbles.
- Close the bleed screw.
- Remove the tool [1].
NOTE : Recommence the process a second time if that is necessary.
- Check the brake fluid level, (Should be between «MINI» level and «MAXI» level).
- Fill if necessary with the approved and recommended synthetic brake fluid.
B3FP160C

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 BRAKES

XSARA BRAKE SPECIFICATIONS

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

KFW NFU RFN RFS WJY 8HZ RHY RHZ

Master cylinder Without ABS 23,8 (expansion holes) With ABS 23,8 (valve)
Ø Master-vac 228.6
mm Caliper/piston makes BOSCH 54 LUCAS 57 BOSCH 54
Fr Disc Ventilated 266 283 266
Disc thickness/min. thickness 22 /20
Brake pad grade FERF 769 ASFM 380 FERF 769
Thickness/min. thickness 13 / 2
Ø Drum - Ø min./max. 203/205 203/205
mm Disc non-ventilated 247 247
Disc thickness/min. thickness 8/6 8/6
Make BENDIX JURID TEXTAR BENDIX JURID
Rr
Brake lining grade D 8259 519 428 D 8259 E 558 519
Make/Type BOSCH / Load-sensitive compensator
Cut-off pressure in Bars 32
Ramp/Paint reference 0.3 - White

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 BRAKES
BRAKE SPECIFICATIONS XSARA
Estates
1.4i 1.6i 16V 2.0i 16V 1.9 D 1.4 HDi 2.0 HDi

KFW NFU RFN RFS WJY 8HZ RHY RHZ

Master cylinder Without ABS 23,8 (expansion holes) With ABS 23,8 (valve)
Ø Master-vac 228.6
mm Caliper/piston makes BOSCH 54 LUCAS 57 BOSCH 54
Fr Disc Ventilated 266 283 266
Disc thickness/min. thickness 22 /20
Brake pad grade FERF 769 ASFM 380 FERF 769
Thickness/min. thickness 13 / 2
Ø Drum - Ø min./max. 228/230 228 / 230
mm Disc non-ventilated 247 247
Disc thickness/min. thickness 8/6 8/6
Make JURID
Rr
Brake lining grade E 558 519 E 558 519
Make BOSCH / Load-sensitive compensator
Cut-off pressure in Bars 32
Ramp/Paint reference 0.3 - White

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 BRAKES

XSARA - All Types BRAKE SPECIFICATIONS

Tighten the nuts (1) to 2.3 m.daN.

- The clevis pin (2) is held in place by a plastic clip.

B3FP10YD

394

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 BRAKES
BRAKE SPECIFICATIONS XSARA - All Types
Braking system specifications
1

- ‘X’ braking circuit.

- Front : disc brakes, ventilated (according to model).

- Rear : drum brakes with automatic adjustment.

- Cable operated handbrake acting on the rear wheels.

2 (1) Hydraulic valve block « ABS Bosch 5.3 » or
(1) Hydraulic valve block « ABS Bosch 5.3 REF » or
(1) Hydraulic valve block « ABS with ESP Bosch 5.7 ».

- (2) Load sensitive braking compensator (according to model).

B3FP09HC B3FP09JC

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 BRAKES

XSARA - All Types BRAKE SPECIFICATIONS

Braking system without ABS (rear drum brakes)
Braking system without ABS (rear disc brakes)
Up to RPO 8687

B3FP14FD B3FP14GD

396

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 BRAKES
BRAKE SPECIFICATIONS XSARA - All Types
Braking system with ABS (rear drum brakes)

B3FP14HD

397

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 BRAKES

XSARA - All Types BRAKE SPECIFICATIONS

Braking system with ABS REF (rear disc brakes) Braking system with ABS REF (rear drum brakes)

B3FP14JD B3FP14KD

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 BRAKES
BRAKE SPECIFICATIONS XSARA - All Types
Braking system with ABS REF (rear drum brakes)

B3FP14LD

399

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 BRAKES

XSARA - All Types BRAKE SPECIFICATIONS

Braking circuit with ESP (BOSCH 5.7)

(A) Hydraulic circuit.

(B) Electrical circuit.

(1) Master cylinder in tandem.

(2) Braking servo.
(3) Brake caliper (or drum at the rear).
(4) Toothed wheel.
(5) Wheel sensor.
(6) Brake fluid level sensor.
(7) Hydraulic block plus ECU.
(8) Stoplamp switch.
(9) Instrument panel.
(10) Diagnostic socket.
(11) Built-in systems interface (BSI).
(12) Steering angle sensor.
(13) Gyrometer/accelerometer sensor.
(14) Switch.

B3HP004P

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 BRAKES
BRAKE SPECIFICATIONS XSARA - All Types
Electrical circuit
Components Ref. Supplier Part No. Observations
42-way connector.
Electronic ECU 7 5.7 ESP Alone on the hydraulic block.
Changing only the ECU is prohibited.
2-way grey connector.
Front wheel sensor 0 265 006 389 The sensors are inductive-type.
Tightening torque: 0,8 ± 0,2 m.daN
2-way grey connector.
BOSCH The sensors are inductive-type.
Rear wheel sensor 0 265 006 202 Mounted on the brake caliper support.
(disc brakes) 5 Non-adjustable airgap: 0,3 to 1,2 mm.
Tightening torque: 0.8 ± 0.2 m.daN
Rear wheel sensor 2-way grey connector.
(Saloon : drum brakes) 0 265 006 203 The sensors are inductive-type.
Mounted on the suspension arm.
Rear wheel sensor Non-adjustable airgap: 0,3 to 1,2 mm.
(Estate : drum brakes) 0 265 006 441
Tightening torque: 0,8 ± 0,2 m.daN.
Steering angle sensor 12 VALEO Incorporated in the COM 2000.
6-way blue connector.
13 Located on the central console.
Gyrometer/accelerometer sensor BOSCH 6-way connector.
Toothed wheel: 48 teeth.
GKN Integral with the driveshaft stub housing for
Toothed wheel 4 the front wheels, joined to the hub bearing for
the rear wheels.

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 BRAKES

XSARA - All Types BRAKE SPECIFICATIONS

(7) Hydraulic block Gyrometer sensor

B3HP002C C4AP17YC

Components Supplier Part No. Observations

IMPERATIVE : Respect the direction of fitting of the gyrometer/accele-
rometer sensor (connector towards the rear of the vehicle).
Located on the front LH WARNING : The gyrometer/accelerometer sensor should not be
ESP hydraulic subjected to any impact. Any gyrometer/accelerometer sensor
BOSCH 5.7 ESP wheelarch :
block
4 adjustment channels. having suffered an impact must be replaced.
Tightening torque (15) : 0,6 ± 0,1 m.daN.

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 BRAKES
REAR BRAKE SPECIFICATIONS XSARA - All Types
Evolution : Rear brake drum hub 01/1999 #
Old assembly New assembly

B3FP119D B3FP11AD

Evolutions.
New components : Rear wheel stub. - Stop ring (ref. (4)). - Double shouldered washer (ref. (5))
NOTE : The new assembly is identified by a figure from 1 to 6 cold-stamped on the head of the wheel stub at «a».

(1) Washer exterior diameter = 38 mm. Ref. «a»: Figure from 1 to 6 cold-stamped.
(2) Stop ring (4) Stop ring.
(3) Circlip. (5) Double shouldered washer, exterior diameter = 48 mm.
NOTE : This assembly is equipped with either part (2) or part (3).

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 BRAKES

XSARA - All Types REAR BRAKE SPECIFICATIONS

Evolution : Rear brake disc hub 01/99 #
Old assembly New assembly

B3FP11BD B3FP11CD

Evolutions
Fixing of the brake disc hub. Sealing of the brake disc hub.
New components: New components:
- Rear wheel stub. - Sealed bearing incorporated at «b» (ref. (6)).
- Double shouldered washer (ref. (7)). - Spacer without seal face (ref. (5)).
- Cap (ref. (8) ).
NOTE : The new assembly is identified by a figure from 1 to 6 cold-stamped on the head of the wheel stub at «c».

New assembly
Ref. «c» : Figure from 1 to 6 cold-stamped.
(5) Spacer without seal face. (7) Double shouldered washer, exterior diameter = 48 mm.
(6) Sealed bearing incorporated at «b». (8) Cap.

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 BRAKES
CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR XSARA - All Types
To perform any checks, it is necessary to calculate the weight on the rear axle in order to refer to the adjustment graphs.
Preliminary pre-check operations.

Calculate :
1) The rear weight of the vehicle (empty tank + 1 person) # Note the vehicle type Refer to table N° 1
2) The weight of fuel in the fuel tank # Note the fuel level Refer to table N° 2
3) The weight of options fitted to the vehicle # Note the vehicle options Refer to table N° 3

4) Add these three weights together to obtain the TOTAL REAR VEHICLE WEIGHT; remove all objects from the vehicle totalling more than
10 kg in weight.
5) Select the adjustment graph that corresponds to the vehicle model. ( Refer to table N° 4).
6) Check the brake pressure.
7) Adjust the load sensitive brake compensator if necessary.

Example
- The rear weight of the vehicle (empty tank + 1 person) = 412 kg
- The weight of fuel in the fuel tank (tank 1/2 full) = 18 kg
- The weight of options fitted to the vehicle (sun roof) = 8 kg
- Total rear vehicle weight = 438 kg
- Corresponding graph (Graph N° 1).

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 BRAKES

XSARA - All Types CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued)

(Weights in kg)

TABLE N° 1 (Rear weight of the vehicle (Empty tank + 1 person)). TABLE N° 2 (Weight of fuel in the fuel tank).

Trim level Type of fuel Petrol Diesel

X SX Exclusive VTS
Engine 5 litres 4 4
1.4 i 392 405 416 1/4 9 10
1.6 i 412 423 1/2 18 20
1.8 i 422 424 3/4 27 30
1.8 i 16 V 424 428 431 Plein 36 40
1.9 D 405 425 432
1.9 TD 436 449 447 450
(Weights in Kg)
TABLE N° 3 (Weight of options fitted to the vehicle). TABLE N° 4 (Graph selection).

Options Vehicle Model Graph

Electric sun roof 8 1.4 i - 1.6 i - 1.8 i - 1.8 i (BVA) 1.9 D 1
Protective grille 5 1.8 i 16 V 2
Towing equipment (All models) 20 1.9 TD 3
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 BRAKES
CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued) XSARA - All Types
GRAPH N° 1 GRAPH N° 2

B3FP09XD B3FP09YD

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XSARA - All Types CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued)

GRAPH N° 3

B3FP09ZD

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 BRAKES
CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued) XSARA - All Types
TOOLS
- Braking pressure checking tool : 4140-T.
CHECKING THE BRAKE PRESSURE
WARNING : Do not touch the plastic nut (1).
PRELIMINARY OPERATIONS
- Place the vehicle on a 4-column lift if possible.
- Fit tool 4140-T.
- Calculate the rear vehicle weight (see tables on preceding pages). - Check that no hydraulic fluid is leaking and
that the pipes are not obstructed.
- Refer to the graph which corresponds to the vehicle type (see preceding pages).
CHECKS
- Perform the checks between the wheels as follows : front left and rear right - front right and rear left.
- With the engine running, increase the pressure at the rear to obtain a front pressure of 60 Bars.
ESSENTIAL : The checking pressure must be obtained by progressively increasing the pressure (never
reduce the pressure to adjust it).
- Check the increased measurement against the graph. (If the measurement is not within the limits, adjust the
compensator) (see following page).
- To check that the compensator works correctly, increase the rear pressure to 100 bars. (If the measurement is not
within the limits, replace the compensator).
- Bleed the brake system and carry out a road test.

B3FP101C

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 BRAKES

XSARA - All Types CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR (continued)

ADJUSTING THE COMPENSATOR

WARNING : Do not touch the plastic nut (1).

IMPORTANT : When loosening the nut (2), the spring (3) may suddenly force off the nut (2) and lock nut
(4) assembly. Calculate the spring length (3) before loosening the nut (2), and use a spanner to hold the
lock-nut (4) in place, thus restraining the spring.

- Loosen the nut (2) while ensuring the lock-nut (4) is held firmly in place.

- Adjust the length of the spring (3) :

- Reduce the spring length (3) to increase brake pressure.
- Increase the spring length (3) to reduce brake pressure.

- Tighten the nut (2) to 1.5 m.daN.

- Check the brake pressure.

B3FP101C B3FP102C

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 BRAKES
HANDBRAKE XSARA - All Types

CHECKING AND ADJUSTING THE HANDBRAKE

- Remove the handbrake console.

- Jack up and chock the vehicle with the rear wheels hanging free.
- Check the correct routing of the brake cables under the vehicle.
- Apply and release the handbrake ten times.
- Set the handbrake to the 3rd notch.
- Tighten the nut (1) until the rear brakes are applied.
- Pull the handbrake lever vigorously 4 to 5 times.
- Set the handbrake to the 3rd notch.
- Check that the rear brakes are applied.
- Check that the wheels can be turned freely by hand with the
handbrake released.
- Lower the vehicle.
- Refit the handbrake console.

B3FP095D

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 BRAKES

SAXO - All Types BLEEDING THE BRAKES

Bleeding :
The brakes can be bled either :
- using brake bleeding equipment, in which case the pressure of the equipment should be set to 2 Bars.
- or in the usual way.

IMPERATIVE order of bleeding

Wheels :

- Rear Right.
- Front Left.
- Rear Left.
- Front Right.

Top up using brake fluid supplied by CITROEN Replacement Parts.

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 BRAKES
BRAKE SPECIFICATIONS XSARA PICASSO - All Types
NOTE : On models equipped with ABS, there is 1.6i - 1.8i 16V - 2.0i 16V - 2.0 HDi 1.8i 16V - 2.0i 16V - 2.0 HDi
no load-sensitive braking compensator.
(*) ESP = Electronic Stability Programme Without ESP (*) With ESP (*)

Master cylinder 23.8

Master-vac 254

Ø Caliper/piston
BOSCH ZOH 54
makes
mm
Fr Non-ventilated
Disc
Ventilated 266 283
Disc thickness/min. thickness 22/20 26/24

Brake pad grade FERODO 769(37)

Cylinder or caliper 22.2

Ø
Drum / Ø max. 228.6/230
mm
Disc non-ventilated 247/-
Rr Disc thickness/min. thickness 9/7
Make LUCAS TRW
Brake lining grade ABEX 4930/2 GALFER G4554
Compensator – cut-off in Bars 20/61.6
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XSARA PICASSO - All Types BRAKE SPECIFICATIONS

Braking system specifications

‘X’ braking circuit.

- Front : disc brakes, ventilated.

- Rear : drum brakes with automatic wear adjustment.

- Cable operated handbrake acting on the rear wheels.

Rear : load-sensitive braking compensator (non-ABS models).

- (1) Hydraulic valve block « ABS Bosch 5.3 » or
- (1) Hydraulic valve block + ECU.
- (2) Load sensitive rear braking compensator.

B3FP11VD B3FP08ND

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 BRAKES
BRAKING SYSTEM SPECIFICATIONS XSARA PICASSO - All Types
Without ABS With ABS

B3FP11WD B3FP7B9D

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 BRAKES

XSARA PICASSO - All Types BRAKING SYSTEM SPECIFICATIONS

With ESP (Electronic Stability Programme) Handbrake

B3FP7BRD B3FP11XD

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 BRAKES
XSARA PICASSO - All Types CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR
Tools [1] Brake pressure checking tool : 4140-T

Checking procedure Determining the rear weight of the vehicle

Determine the weight on the rear axle and then refer to the adjustment Refer to the tables of different weights.
graphs. To obtain the rear weight of the vehicle, add the following weights :
The allocation table enables you to choose which graph to use for - Rear weight of the vehicle (tank empty + 1 person).
each type of vehicle. - Weight of fuel in the fuel tank.
Connect the tool [1] in order to check the rear pressure values relati- - Weight of the options on the vehicle.
ve to the front pressures (60 and 100 bars). Remove from the vehicle any object weighing more than 1 Kg.

Rear weight of the vehicle (tank empty + 1 person) Weight of fuel in the fuel tank
Note the vehicle type. Note the level of fuel in the vehicle and from this deduce the weight
Consult the correspondence table. according to the table.
Level of fuel Weight of fuel in the fuel tank (Kg)
Engine type Rear weight (tank empty + 1 person)
(Litres) Petrol Diesel
NFZ 542 5 4 4
6FZ 531 1/4 11 12
RFN 532 1/2 22 24
RHY 540 3/4 33 36
Full 44 48

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 BRAKES

XSARA PICASSO - All Types CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR
Tools [1] Brake pressure checking tool : 4140-T

Example.
Type of vehicle = TU5JP+
Rear weight (tank empty + 1 person). = 542 Kg
Fuel tank half full : = 22 Kg
Sun roof = 10 Kg
Rear weight of the vehicle = 542 + 22 + 10 = 574 Kg.

(1) CRD # OPR 8885

Weight of the options on the vehicle (2) CRD
Note the options on the vehicle and deduce the weight according to (3) OPR 8886 #
this table (4) OPR 8886 #
CRD = Difficult road conditions.

Options Weight (Kg) Table of allocation of graphs

Electric sun roof 10 Vehicle engine version Graph N°
Bicycle carrier 5
NFV – RHY 1
Roof bars 4
6FZ 2
Refrigeration/heating module 10
NFV – RHY (1) 3
Under-engine shield 9
6FZ – RFN (2) 4
Towbar all versions 19
RFN (3) 5
RHY (4) 6

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CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR XSARA PICASSO - All Types
GRAPH N° 1 GRAPH N° 2

B3FP13RD B3FP13SD

Key :
P = Rear pressure (in Bars). a = Front pressure 60 ± 3 Bars.
M = Weight (in Kg). b = Front pressure 100 ± 3 Bars

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XSARA PICASSO - All Types CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR
GRAPH N° 3 GRAPH N° 4

B3FP14MD B3FP13UD

Key :
P = Rear pressure (in Bars). a = Front pressure 60 ± 3 Bars.
M = Weight (in Kg). b = Front pressure 100 ± 3 Bars

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CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR XSARA PICASSO - All Types
GRAPH N° 5 GRAPH N°6

B3FP14ND B3FP14PD

Key :
P = Rear pressure (in Bars). a = Front pressure 60 ± 3 Bars.
M = Weight (in Kg).) b = Front pressure 100 ± 3 Bars

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XSARA PICASSO - All Types CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR
Checking the braking pressure
Preliminary operations :
The vehicle should be placed on all 4 wheels,
preferably on a lift.
- The tool [1] (in good working order) in place.
- Rear weight of the vehicle determined. - Compare the value noted with the graph.
- Check there are no hydraulic leaks. - If the value is outside the tolerance, adjust the
- Check the absence of pinching on the pipes. compensator.
- In order to check that the compensator is working
- Refer to the graph corresponding to the vehicle
properly, note the rear pressure when the front
engine version.
pressure is 100 ± 3 Bars.
- Checks are done between the following compo- - If the value is outside the tolerance, replace the
nents : compensator.
Front LH wheel and rear RH wheel. NOTE : Any large discrepancy between the two cir-
Front RH wheel and rear LH wheel. cuits will mean that the braking compensator
- On the vehicle, engine running, note the rear should be replaced.
pressure when the front pressure is 60 ± 3 Bars. - After completing these operations, bleed the bra-
king circuit (see corresponding operation).
ESSENTIAL : The control pressure should be - Carry out a road test.
obtained by progressively increasing the pressure
(without ever releasing the pressure to adjust it).

E5-P01IC

422

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 BRAKES
CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR XSARA PICASSO - All Types

Adjusting the load-sensitive brake compensator

- Untighten the screw (1).

- Move the spring rod.
- Decrease the length of the spring to increase the pressure.
- Increase the length of the spring to decrease the pressure.
- Tighten the screw (1) to 1,2 ± 0,25 m.daN.
- Check the brake pressure.

After the operation :

- Remove the checking tool [1].

- Bleed the braking circuit (see corresponding operation).
- Carry out a road test.

B3FP13VC

423

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 BRAKES

XSARA PICASSO - All Tpes HANDBRAKE (Adjustment)

Adjustment :

Remove the handbrake trim (1).

Unclip the sound-deadening (2).
Raise and support the vehicle with the rear
wheels hanging free.
Check the correct routing of the brake cables under
the vehicle.
Apply and release the handbrake 4 times.
Set the handbrake to the 5th notch.
Tighten the nut (3) until the rear brakes are applied.
Pull the handbrake lever vigorously 4 to 5 times.
Set the handbrake to the 5th notch.
Check that the rear brakes are applied.
With the handbrake released, check that the wheels
can be turned freely by hand.
Lower the vehicle.
Refit the sound-deadening (2) and the handbrake
trim (1).

B3FP11YD

424

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 BRAKES
BLEEDING THE BRAKES XSARA PICASSO - Alll Types
Tools Bleeding equipment of type «LURO» or similar.
IMPERATIVE : For bleeding the secondary circuit, use ELIT, LEXIA or PROXIA diagnostic tools.
Draining.
Drain the brake fluid reservoir as empty as possible using a syringe.
Disconnect the brake fluid warning lamp connector.
Retrieve the brake fluid reservoir from its supply pipes by pulling upwards.
Finish emptying the reservoir of brake fluid.
Clean the brake fluid reservoir.
Refit the brake fluid reservoir.
Reconnect the brake fluid warning lamp connector.
Filling
Refill the reservoir with brake fluid.
WARNING : Use only the recommended hydraulic fluids.
Bleeding.
NOTE : Two technicians are required.

IMPERATIVE: During bleed operations, ensure that the level of brake fluid is maintained in
the reservoir and top it up, use only new brake fluid.
Bleed each wheel cylinder, proceeding in the following order :
Rear right hand wheel.
Front left hand wheel.
Rear left hand wheel.
Front right hand wheel.

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 ALL TYPES STARTER MOTORS
Abbreviations and definitions

Coding of climates is as follows : Meaning of abbreviations :

ELECTRICAL

CLIMATES :
SYSTEM

C Hot : Starting possible as low as -18°C BV : Gearbox

T Temperate : Starting possible as low as -18°C BVM : Manual gearbox
F Cold : Starting possible as low as -25°C
BVA : Automatic gearbox
GF Very cold : Starting possible as low as -30°C
BVMP : Piloted manual gearbox
DA : Power-assisted steering
WHIT AIRCON : Air conditioning

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 STARTER MOTORS ALL TYPES
Vehicles / models Manufacturer and Ref. Class Climate
Table of classes of starter motors

CLASS CLASS 2 CLASS 3 CLASS 4 CLASS 5 CLASS 6

ELECTRICAL
Torque C 5.5 Nm 6 Nm 10 Nm 11.5 Nm 11.5 Nm

SYSTEM
Maximum power for
I ≤ 275 A I ≤ 300 A I ≤ 430 A I ≤ 470 A I ≤ 500 A
a speed of 1200 rpm

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 SAXO STARTER MOTORS
Vehicles / models Manufacturer and Ref. Class Climate

VALEO D7E16
BOSCH A 001183 027 F 1 H, T, C
1.1i
MELCO M002T13081
ELECTRICAL

VALEO D6 RA 572 3 VC
SYSTEM

VALEO D7E16
1.4i (Aircon) BOSCH A 001183 027 F 1 C, T
1.6i (Aircon) MELCO M002T13081
VALEO D6 RA 572 3 C, VC
VALEO D7E16
SAXO
BOSCH A 001 183 027F 1 H.T
1.4i MELCO M002T13081
1.6i VALEO D7E23
2 C
BOSCH E OAL 101 390
VALEO D6RA572 VC
1.6i 16v 3
VALEO D6 RA 572 H, T, C, VC
1.4i Automatic
VALEO D6RA100 4 H, T, C
1.5D
VALEO D7R151 5 VC
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
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 STARTER MOTORS C3
Vehicles / models Manufacturer and Ref. Class Climate

VALEO D7E16
BOSCH A001 183 027F 1 H, T, C
1.1i
MELCO M002T 13081

ELECTRICAL
SYSTEM
VALEO D6RA572 3 VC
VALEO D7E16
1.1 i Aircon 1 H, T
BOSCH A001 183 027F
1.4 i Aircon
1.6i 16v Aircon MELCO M002T 13081
VALEO D6RA572 3 C, VC
C3 VALEO D7E16
BOSCH A001 183 027F 1 H, T
1.4 i MELCO M002T 13081
1.6 i 16v VALEO D7E23 2 C
BOSCH E OAL 101 390
VALEO D6RA572 3 VC
1.4I Automatic VALEO D6RA572 3 H, T, C, VC
1.4 HDi VALEO D6RA110 4 H, T
1.4 HDi 16v VALEO D7GP09 5 C, VC
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
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 XSARA STARTER MOTORS
Vehicles / models Manufacturer and Ref. Class Climate
VALEO D7E16
1.4i
1.6i BOSCH A 001183 027 F 1 H, T
(Power steering MELCO M002T13081
ELECTRICAL

or aircon)
SYSTEM

VALEO D6 RA 572 3 C, VC
1.4i VALEO D7E23
2 H, T
(Power steering BOSCH E OAL 101 390
and aircon) VALEO D6RA572 C, VC
1.6 i
XSARA VALEO D6 RA 572 C, VC, H, T
1.6i Automatic
3
VALEO D6 RA 72
2.0i 16 v MELCO M000T82081 F, T
2.0i 16 v Automatic
EW10J4 BOSCH E OAL 098 390
MELCO M 000 T 85 381 4 C, VC
VALEO D6 RA 661
2.0i 16v 3 H, T
BOSCH A 001 110 140 F
XU10J4RS
BOSCH A 001 111 473 4 C, VC
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
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 STARTER MOTORS XSARA
Vehicles / models Manufacturer and Ref. Class Climate

VALEO D6 RA 109
BOSCH A 001 111 562F 4 H, T
MELCO M 001 T 80381

ELECTRICITE
1.9D
VALEO D7 R 26
5 C
MELCO M 001 T 80481
VALEO D7 R 27 6 VC
VALEO D6 RA 109
2.0 HDi 4 H, T
BOSCH A 001 111 562F
90 CV
XSARA MELCO M 001 T 80381
VALEO D7 R 27 6 C, VC
2.0 HDi VALEO D7 R 26
5 H, T
110 CV MELCO M 001 T 80481
VALEO D7 R 27 6 C, VC
2.0 HDI Automatic VALEO D7 R 27 6 C, VC
110 CV MELCO A 001 236 000 6+ C, VC
VALEO D6RA110 4 H, T
1.4 HDi
VALEO D7GP09 5 C, VC
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)
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 XSARA PICASSO STARTER MOTORS
Vehicles / models Manufacturer and Ref. Class Climate
VALEO D7E16
1.6i (Power steering BOSCH A 001 183 027F 1 H, T
or aircon) MELCO M002T13081
ELECTRICAL
SYSTEM

VALEO D6RA572 3 C, VC
VALEO D7E23
1.6i (Power steering 2 H, T
and aircon) BOSCH E OAL 101 390
VALEO D6RA572 C, VC
XSARA PICASSO VALEO D6 RA 72
3
1.8i 16v MELCO M000T82081 H, T, C
2.0i 16v Automatic BOSCH E OAL 098 390
MELCO M 000 T 85 381 VC
VALEO D6 RA 109
4
BOSCH A 001 111 562F H, T
2.0 HDi
MELCO M 001 T 80381
VALEO D7 R 27 6 C, VC
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very cold)

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 ALTERNATORS ALL TYPES
Abbreviations and definitions

Coding of climates is as follows : Meaning of abbreviations :

ELECTRICAL
CLIMATES : BV : Gearbox

SYSTEM
BVM : Manual gearbox
BVA : Automatic gearbox
C : Hot (45°C/37°C) BVMP : Piloted manual gearbox
T : Temperate (37°C/17°C) Whitout aircon : Without air conditioning
F : Cold (17°C/-25°C) Whit aircon : With air conditioning
DA : Power-assisted steering
GF : Very cold (<-25°C)
GEP : Electro-pump motor
DP : Double lug
3 Pts : 3-Point
NC : Not marketed
TT : All Types
N : Level
SOP : Without Option
TOP : All Options
L.C. : Heated rear screen
DAG : Left hand drive
DAD : Right hand drive

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 SAXO ALTERNATORS
Refer to the correspondance table for petrol or diesel engine
Without aircon With aircon
Engine/gearbox Climate
Non DA or SAGINAW DA DA by GEP Non DA or SAGINAW DA DA by GEP
ELECTRICAL

H 7 8 9
SYSTEM

TU1JP T
7
BVM C 7 8
8
VC
H 8
TU3JP/TU5JP/ 7 9
T 7
TU5JP4
BVM C 7
8 8
VC
H 8
7
TU3JP T
8 9
Automatic C 9
8
VC
H 8
9
TUD5 T 7
7 7
BVM C 8
VC 8 8 9
Meaning of abbreviations, see page : 433

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 ALTERNATORS SAXO
Refer to the correspondance table for petrol or diesel engine

Engine/gearbox Climate ALL APPLICATIONS

ELECTRICAL
SYSTEM
TU All Types
TUD5 T 9
BVM

Meaning of abbreviations, see page : 433

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 C3 ALTERNATORS
Refer to the correspondance table for petrol or diesel engine
Whitout aircon
Engine/gearbox Climate
Base RT3 N 1 or 2 RT3 N 3 Cold Pack Cold Pack + RT3 N 1 or 2 Cold Pack + RT3 N 3
H 6
6
TU1JP T
ELECTRICAL

7
BVM C 7
SYSTEM

7
VC 8
H
TU3JP 6
T
BVM C 7
7
VC 8
H
TU3JP 7 7
T
Automatic C
8
VC 8
H 6 6
TU5JP4 T 7
BVM C 7
7 8
VC
H 6 6
TU5JP4 7 7
T 7
BVMP 7 8
C 8
VC 8 9
DV4TD - DV4TED4 - BVM H,T,C,VC 15
Meaning of abbreviations, see page : 433
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 ALTERNATORS C3
Refer to the correspondance table for petrol or diesel engine
With aircon
Engine/gb Climate
Base RT3 N 1 or 2 RT3 N 3 Cold Pack Cold Pack + RT3 N 1 or 2 Cold Pack + RT3 N 3
H 8
TU1JP T

ELECTRICAL
BVM C 7

SYSTEM
7
VC 8
H 8 8
TU3JP T 7
7 7 7
BVM C
VC 8
H 9
TU3JP T 8 8
Automatic C 7
VC 8 8 9
H
TU5JP4 8
T
BVM C 7
7
VC 8
H 9 9
9 9
TU5JP4 T 8
8
BVMP C 7 8 8
8
VC 8 9
DV4TD - DV4TED4 - BVM H,T,C,VC 15
Meaning of abbreviations, see page : 433
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 XSARA ALTERNATORS
Refer to the correspondance table for petrol or diesel engine
Whitout aircon Whit aircon
Engine/gb Climate Without Cold Pack Cold Pack Without Cold Pack Cold Pack
Base RT2 Base RT2 Base RT2+NAV Base RT2+NAV
H 9
ELECTRICAL

TU3JP T 7 8
7
SYSTEM

BVM C
7
VC 8
H 9
TU5JP4 T 7 8
7
BVM C 7 7
VC 8 8
H 8 9 12 9 12
TU5JP4 T 7 8 9 9
8
Automatic C 8 8
VC 9
H 9 9 9 9
EW10J4 T 8 8
NC
BVM C 7 8
VC 8
H 12
EW10J4 9
T 9
Automatic NC 8
C
VC 9
H
XU10J4RS T
C NC 8
BVM
VC
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 ALTERNATORS XSARA
Refer to the correspondance table for petrol or diesel engine
Whitout aircon Whit aircon
Engine/gb Climate Without Cold Pack Cold Pack Without Cold Pack Cold Pack
Base RT2 Base RT2 Base RT2+NAV Base RT2+NAV
H

ELECTRICAL
8 9
DW8B T 8

SYSTEM
9
BVM C 9
8
VC 9 9
H 8(8) 9(8) 8(8) 9(8) 9(8) 12(8) 9(8) 12(8)
DW10TD T 15(9) 15(9)
15(9) 15(12) 15(9) 15(12)
BVM C 15(12) 15(12)
VC 12(8) 12(8)
H 9(8) 9(8) 12(8) 9(8) 12(8)
DW10ATED T 15(9) 15(9)
15(9) 15(12) 15(9) 15(12)
BVM C 15(12) 15(12)
VC 12(8) 12(8)
H 9(8) 15
DW10ATED T
15(12) 15(15)
Automatic C
VC 12(8) 15 15
H NC NC
DV4TD T
15(15) 15(15)
BVM C
VC 15 15
NOTE : ( ) Allocation of climates for alternators on vehicles with additional heating.

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 XSARA PICASSO ALTERNATORS
Refer to the correspondance table for petrol or diesel engine
Whitout aircon Whit aircon
Engine/gb Climate
Base Nav. + Radio-telephone Base Nav. + Radio-telephone
ELECTRICAL

H NC 9
SYSTEM

TU5JP4 T
L3 et L4 7
C 7 8
BVM
VC 8
H 7
9
EW7J4/L4 T
BVM C 8
8
VC
H 9 9
DW10TD T
BVM C 15 15
VC

Meaning of abbreviations, see page : 433

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 ALTERNATORS XSARA PICASSO
Refer to the correspondance table for petrol or diesel engine
Whitout aircon Whit aircon
Engine/gb Climate Heated Nav.+ Siège Heated Nav.+
Base Navigation chauffant Base Navigation Heated seat
seat seat
H NC

ELECTRICAL
9
TU5JP/L4 T 7

SYSTEM
BVM C
8 8
VC
H NC 9
DW10TD T 7
BVM C 8
8 8
VC
H NC 12
DW10ATED T 9
8 8
BVM C 8 8 8
8
VC 9 9 9
H NC
DW10ATED T
15
Automatic C 15
VC
H NC
DV4TD T
15 15
BVM C
VC
Meaning of abbreviations, see page : 433
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 ALL TYPES CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR
Checking the alternator output
Connect as shown in the diagram opposite, using an ammeter (A), a voltmeter (V),
and a rheostat (R) or a Volt/Ammeter/Rheostat combination.
Referring to the vehicle’s equipment specification (see table opposite), adjust the
engine speed and rheostat charge to obtain U=13.5V.
ELECTRICAL

Reminder : The excitation energising current will flow through the warning lamp;
SYSTEM

check that the warning lamp comes on when the ignition is switched on. It should
go out when the engine has started (accelerate slightly).

Checking the voltage regulator

Set the rheostat to zero and disconnect all the electrical consumers.
Display 3000 alternator rpm. If U alternator is > 14.7 V, the regulator is faulty.
Note: These tests should be performed with the engine hot and the battery fully
charged.
A : Ammeter
Method of reading the alternator speed
B : Battery
Fit a reflecting shim on the pulley of the alternator.
G : Generator
Adjust a stroboscope to the frequency equivalent to the control speed.
L : Warning lamp
(e.g. 2000 rpm = 2000/60 = 83 Hz)
K1 and K2 : Switch
Adjust the engine speed so that the shim appears fixed.
R : Electric charge
S : Shunt 200mV/200A
V : Voltmeter
1 : Alternator.
D1AP025C

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 CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR ALL TYPES
MINIMUM OUTPUTS (in A)
Alternator Class
Min. output
speed 6 7 8 9 12 15 18
1800 rpm 11 27 39 46 61 73 89 108

ELECTRICAL
2000 rpm 12 34 46 54 68 80 105 123

SYSTEM
3000 rpm 13 47 60 68.5 84 100 139 164
4000 rpm 14 55 65 75 92 110 145 176
6000 rpm 15 61 69 78.5 96 120 151 183
8000 rpm 16 63 70 80 97 123 157 188
15000 rpm 17 64 73 82 97 124 157 188

MINIMUM YIELDS (in %)

Class
Alternator speed
6 7 8 9 12 15 18
1800 rpm 49 50 52 57 58 60 61
2000 rpm 48 49 51 54 55 57 60
3000 rpm 45 46 48 51 52 54 56
4000 rpm 43 44 46 48 50 52 53
6000 rpm 39 40 42 43 48 50 50
8000 rpm 26 37 39 40 45 48 48
15000 rpm 24 25 27 29 34 38 38
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 ALL TYPES PRE-HEATING AND STARTING SYSTEMS

Pre / Post heating

Vehicles / models Pre-heater plugs Pre-heater control unit
(pre-heating duration at 20°C)

BERU 0 100 226 371 NAGARES 960411-P

SAXO 1.5D VJX 10s / 150s
ELECTRICAL

CHAMPION CH 185 CARTIER 735068

SYSTEM

8HW NGK YE04 NAGARES 960411-P

1.4 HDI
8HX CARTIER 735068
C3 Controlled by the diesel injection ECU.
8HV NGK YE04 NAGARES 960411-P
1.4 HDI 16v 8HY NAGARES 960411-P
BERU 0 100 226 371 CARTIER 735068
1.9D WJY 10s / 150s
CHAMPION CH 185 NAGARES 960411-P
NGK YE04 NAGARES 960411-P
1.4 HDI 8HZ Controlled by the diesel injection ECU.
CARTIER 735068
XSARA
CHAMPION CH170 CARTIER 735068
2.0 HDI RHY Controlled by the diesel injection ECU.
NAGARES 960411-P
CHAMPION CH 170 CARTIER 735068
2.0 HDI RHZ Controlled by the diesel injection ECU.
NAGARES 960411-P
CHAMPION CH 170 CARTIER 735068
PICASSO 2.0 HDI RHY Controlled by the diesel injection ECU.
NAGARES 960411-P

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 AIR CONDITIONING R 134 a (HFC) ALL TYPES
Compressor
Refrigerant
Vehicle Engines Date Variable
refill Oil quantity cc Oil reference
Capacity
TU - TUD All types AM 2000 # 850 gr +0 - 50 gr
SAXO TU All types 825 gr ± 25 gr
AM 2001 #
TUD All types 795 gr ± 25 gr
SD 6 V 12
C3 All types 11/2001 # 625 + 0 - 50 gr

CONDITIONING
TU EW 135 SP 10
590 gr +0 –50 gr
XSARA DW 09/2000 #

AIR
SD 7 V 16
XU10 725 gr +0 –50 gr
TU SD 6 V 12
XSARA 12/1999 # 675 gr ± 50 gr
EW7-DW10
PICASSO SD 7 V 16
BRESIL All types 03/2001 # 775 gr ± 25 gr

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 ALL TYPES SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
Click-fit connector removing/fitting tool
Vehicles Circuit Ø Inch Ring colour Tool kit 4164-T
SAXO
All Types
XSARA 5/8 Black 8005-T.A.

XSARA BP
C5HP073C
PICASSO HP 3/8 Red 8005-T.C

Unions
CONDITIONING
ALTERNATORS

Aircon compressor fixings

Ø Pipes Steel/Steel Aluminium/Steel
ESSENTIAL : Tighten the front part of the compressor
AIR

M 06 1.7 ± 0.3 1.3 ± 0.3

(timing belt end), before the rear part of the compressor.
M 08 3.8 ± 0.3 2 ± 0.2
M 10 4 ± 0.3 2.5 ± 0.3

NOTE : Tighten the union to the recommended torque using a retaining spanner whenever possible.

NOTE : For operations concerning draining, drying (empty), checking and recharging of a system: refer to BRE 0290.
WARNING : For R 134.a quantities (See table on preceding page).

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 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) C3 - XSARA PICASSO
«EUROCLIM» Compressor (MANULLI seal)

Tools.

Tool for removing-refitting air conditioning seals : K.1702

MANULLI seal

C3 engine versions : All types

XSARA PICASSO engine versions :
NFV : 10/12/2001 #

CONDITIONING
6FZ : 01/04/2002 #
RHY : 04/11/2002 #

AIR
Aircon compressor.
The drive plate (1) is held on the aircon compressor shaft by ribs.
XSARA PICASSO engine versions : 6FZ and RHY New wiring (2).
Discontinuation of compressor SD 6 V 12 New seals (3) (MANULLI).
Replaced by compressor SD 7 V 16 : 04/11/2002 # Identification label (4) for aircon compressor.

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 C3 - XSARA PICASSO SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
Condenser (MANULLI seal) Seals (MANULLI seal)
CONDITIONING
ALTERNATORS
AIR

C5HP18VD C5HP18XD

The condenser (5) has a cylinder (6) incorporating the function of aircon MANULLI calibrated seal (3).
fluid reservoir and with integral filtering cartridge. Direction of fitting of the seal (3).
The inlet (7) and the outlet (8) of the condenser (5) are equipped with Before fitting the seal, amply lubricate the seal with air conditioning
new seals (3) (MANULLI). compressor oil (SP10).

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 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) ALL TYPES
Presence of pollen filter
Vehicle Equipment RPO No. Presence of filter Observations

SAXO NO
All Types
C3 YES
Without aircon YES (Larger) Except driving school
XSARA
Base aircon YES (Plus grand)
XSARA PICASSO
Regulated aircon YES (Valeo)
Without aircon NO (Valeo)
BERLINGO

CONDITIONING
Base aircon YES (Valeo)

AIR
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 C3 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
Pollen filter

Note: The pollen filter is located in the engine compartment on the RH

side.

Removing
Remove:

- The three screws (1).

- The plastic cover (2).
CONDITIONING
ALTERNATORS

Tilt the flap (3).

AIR

Remove the pollen filter (4)

Refitting
Proceed in reverse order.

C4AP169C C4AP16AC C4AP16BC

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 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) C3
Changing the filtering/drying cartridge

Tools.

[1] Charge station : (according to workshop equipment)

[2] TORX adaptor : TORX 70 FACOM.
[3] Inertia extractor : 1671-T. Tool kit 4114-T
[4] Endpiece Ø 20 : 1671-T.D20.
[5] Set of plugs : (-).0188.T.
[6] Circlip pliers : FACOM.

Removing
Depressurise the aircon circuit, using tool [1].

CONDITIONING
Remove the grille.
At «a», remove the pin and the plastic cover.

AIR
Unclip the condenser at «b» and «c», using a screwdriver.
Tilt the condenser towards the front.
Lift and release the condenser.
Clean the area around the cap (3).
Remove the plastic cap (3), using tool [2].
Remove the safety circlip (4), using tool [6].
Position the tool [3] and [4] in the aperture of the cartridge (5).
Extract the cartridge from the reservoir (6), using tool [3] and [4].
Block the reservoir (6), using tool [5].
C4AP163C C4AP164C C4AP165C C4AP166C

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 C3 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
Changing the filtering/drying cartridge

Refitting
Remove the new cartridge from its packaging.
Do not expose the cartridge, the filter and seals to pollutants.
Lightly oil the seals (compressor oil).
Remove tool [5] from the reservoir (6).
Insert the new cartridge (5) into the reservoir (6).
Refit the safety circlip (4), using tool [6].
Make sure that the circlip (4) is correctly positioned in its location.

WARNING : Not more than 5 minutes should elapse between the removal
of the cartridge (6) from its packaging and its being fitted.
CONDITIONING

Refit:
AIR

- The plastic cap (3), using tool [5] - Tighten to 1,2 ± 0,1 m.daN.
- The condenser (reclip, pushing at «b» and «c»).
- The plastic cover and the pins at «a».
- The grille (2).
- The screws (1).
Proceed to:
- Recharge the circuit (see corresponding operation).
- Check the operation of the air conditioning (see corresponding operation).
C4AP167C C4AP165C C4AP163C C4AP164C

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 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) XSARA - All Types
BEHR plate evaporator Pollen filter

CONDITIONING
C5HP07JC C5FP075D

Remove-refit.
Remove :

AIR
- The interior trim (1).
- The cover (4).
- The pollen filter (3).
Concerns vehicles equipped with aircon without temperature regulation.
Fitting of a new pollen filter necessitates the following operations:
- Engage the pollen filter upwards (following arrow «c»)
- Slide the pollen filter towards the rear (following arrow «d»)
- Position the index (4) on the cover forward of the pollen filter.
C5HP062C ((4) Index on the cover).

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 XSARA - All Types SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
BEHR condenser with integral reservoir (16 Ti)

Petrol engine versions The condenser is equpped with a cylinder (1) that acts as the fluid reservoir
which in turn incorporates a filter cartridge.

NOTE : As soon as the air conditioning loop has been open for more than
5 minutes, the filter/dryer cartridge assembly should be replaced (no set
interval).

C5HP07BC
CONDITIONING

Instruction for replacing the filter/dryer cartridge.

Diesel engine versions
AIR

-After undoing the cap (TORX 70), the cold loop must be depressurised.
-Unscrew the cap and clean the cap’s thread.
-Take out the filter/dryer cartridge.
-Clean the threaded zone of the condenser reservoir.
-Fit the new filter/dryer cartridge.
-Lubricate the cap’s O-ring seals with compresser oil.
(New seals).
-Screw the cap back on, tighten to 1,4 ± 0,2 m.daN.
C5HP060C

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 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) XSARA PICASSO
BEHR plate evaporator Pollen filter

CONDITIONING
AIR
Remove:
- The three screws (1).
- The cover (2).
C5HP062C B1BP23ED
- Remove the pollen filter.

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 XSARA PICASSO SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
BEHR condenser with integral reservoir (16 Ti)

The condenser is equpped with a cylinder (1) that acts as the fluid reservoir which
in turn incorporates a filter cartridge.

NOTE : As soon as the air conditioning loop has been open for more than
5 minutes, the filter/dryer cartridge assembly should be replaced (no set interval).

Instruction for replacing the filter/dryer cartridge.

-After undoing the cap (TORX 70), the cold loop must be depressurised.
-Unscrew the cap and clean the cap’s thread.
CONDITIONING

-Take out the filter/dryer cartridge.

-Clean the threaded zone of the condenser reservoir.
-Fit the new filter/dryer cartridge.
AIR

-Lubricate the cap’s O-ring seals with compresser oil.

(New seals).
-Screw the cap back on, tighten to 1,4 ± 0,2 m.daN.

C5HP07BC

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 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) ALL TYPES
Compressor lubricant.

ESSENTIAL: The compressor lubricant is extremely hygroscopic; always use FRESH oil.

Checking the compressor oil level.

There are three specific cases :

- 1/ Repairs to a system without leaks.
- 2/ Slow leak.
- 3/ Fast leak.

1/ Repairing a system without leaks.

CONDITIONING
a) - Using draining/recovery equipment not fitted with an oil decanter.
- Drain the system as slowly as possible via the LOW PRESSURE valve, so as not to lose any oil.

AIR
- No more oil should be added when filling the system with R 134.a fluid.
b) - Using draining/filling equipment fitted with an oil decanter.
- Drain the R 134.a fluid from the system in accordance with the instructions in the equipment handbook.
- Measure the amount of oil recovered.
- Add the same amount of NEW oil when filling the system with R 134.a fluid.
c) - Replacing a compressor.
- Remove the old compressor, drain it and measure the oil quantity.
- Drain the new compressor (supplied full), so that the same amount of NEW oil is left in the compressor as was in the old compressor.
- No more oil should be added when filling the system with R 134.a fluid.

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 ALL TYPES SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
Checking the compressor oil level (continued)

2) Slow leak.

- Slow leaks do not lead to oil loss, therefore the same procedure should be followed as if there was no leak at all.

3) Fast leak.

This type of leak causes both oil loss as well as allowing air to enter the system.
CONDITIONING

It is therefore necessary to :

- Replace the dehydrator.

AIR

- Drain as much oil as possible (when replacing the faulty component).

Either before or during filling of the system with R 134.a fluid, introduce 80 cc of NEW oil into the system.

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 AIR CONDITIONING SYSTEM R 134.a ALL TYPES
Testing procedure

Conditions inside the vehicle Switch on the air conditioning and adjust the engine speed to 2500 rpm.
Positions of the air conditioning controls : In an ambient temperature of 40°C, the engine speed will be brought
Maximum cold. down to 2000 rpm, in order for the pressure safety threshold to cut off
Maximum blower power. the compressor.
Air distribution on «ventilation» with the air vents open.
Position the air inlet flap to outside air. For further temperatures/pressures: see Tables and Graphs on following
WARNING: For RFTA (1), disconnect the air inlet motor connector, first pages.
ensuring that it is in the outside air position.
(1) RFTA = Fully automatic air conditioning. After 3 minutes of operation, note down the following 3 parameters:
- The temperature of the blown air coming out of the 2 central air vents

CONDITIONING
Test procedure. (take the average).
When all these conditions are met, proceed in the following order: - The high pressure, via the intermediary of the clickfit union (at the pres-
Measure the temperature in the workshop approx. one metre in front of sure reducer inlet).

AIR
the vehicle’s air inlet grille. - The low pressure, via the intermediary of the clickfit union (at the pres-
Start the engine (without the air conditioning, or the blower, operating) sure reducer outlet).
and wait for the cooling fan slow speed to trigger (should the engine tem- NOTE: The low and high pressures are absolute pressures.
perature not rise sufficiently, it is permissable to increase the engine When measuring the blown air temperatures, avoid any contact between
speed to 2000 rpm). the thermocouple and the air vents.
Once it is sufficiently hot in the engine compartment, return the engine to
idle and commence the test. At the conclusion of the test involving vehicles with «RFTA», do not
forget to reconnect the air inlet motor connector.

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 ALL TYPES CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
CHECKING TEMPERATURES (continued)

Vehicle using R134.a fluid (Compressor with variable capacity)

Ambient temperature in °C 40 35 30 25 20 15
Vehicle Engine types
SAXO All Types 17 ± 3 13 ± 3 11 ± 3 9±3 8±3
C3 All Types 18.5 ± 2 15 ± 2 12.5 ± 2 10 ± 2 8.5 ± 2 6.5 ± 2
Temperature
at the central TU 18 ± 2 17 ± 2 14.5 ± 2 11 ± 2 8.5 ± 2
CONDITIONING

8±2
air vents XSARA EW 19 ± 2 18 ± 2 15 ± 2 12 ± 2 10 ± 2
in °C
AIR

DW 15 ± 2 15.5 ± 2 11 ± 2 9±2 7±2 5±2

XSARA
PICASSO All Types 22 ± 3 16 ± 3 12.5 ± 3 10 ± 3 8±3 6.5 ± 3

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 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM ALL TYPES
CHECKING PRESSURES
TOOLS - 1 charging station. - 2 thermometers. CHECK - The temperature of the air coming from the central vents (see table).
Once the preliminary conditions, vehicle equipment and checks - The High Pressure. - The Low Pressure.
have been fulfilled (see table) : After the air conditioning has been Compare the values recorded with the table below, or the graphs.
on for three minutes, record the following parameters : Vehicle using R134.a fluid (Compressor with variable capacity)
Ambient temperature in °C 40 35 30 25 20 15
Vehicles Engines
High pressure (Bars) 20 ± 3 18 ± 3 16 ± 3 13 ± 3 11 ± 3 9±3
SAXO All types
Low pressure (Bars) 3 ± 0.3
High pressure (Bars) 14.5 ± 2 17.6 ± 2 20 ± 2 21.4 ± 2 23.6 ± 2 25.2 ± 2
C3 All types
Low pressure (Bars) 2.4 ± 0.2 2.5 ± 0.2 2.8 ± 0.2 3 ± .02 3.5 ± .02

CONDITIONING
High pressure (Bars) 23 ± 2 22.5 ± 2 20 ± 2 17 ± 2 15.5 ± 2 14.5 ± 2
TU
Low pressure (Bars) 3.8 ± 0.2 3.6 ± 0.2 3.5 ± 0.2 3.1 ± 0.2 3 ± 0.2 2.9 ± 0.2

AIR
High pressure (Bars) 24.5 ± 2 21.5 ± 2 18.5 ± 2 17 ± 2 15.5 ± 2
XSARA EW
Low pressure (Bars) 4± 0.2 3.8 ± 0.2 3.5 ± 0.2 3.2 ± 0.2 3 ± 0.2
High pressure (Bars) 21.5 ± 2 22.5 ± 2 20 ± 2 18 ± 2 16.5 ± 2 15.6 ± 2
DW
Low pressure (Bars) 3.2 ± 0.2 3.3 ± 0.2 3 ± 0.2 2.8 ± 0.2 2.6 ± 0.2
High pressure (Bars) TU 25.5 ± 3 20.5 ± 3 18 ± 3 20 ± 3 13.5 ± 3 11 ± 3
Low pressure (Bars) XSARA EW 4 ± 0.3 3.5 ± 0.3 3 ± 0.3
High pressure (Bars) PICASSO 25 ± 3 22.5 ± 3 20 ± 3 17 ± 3 15 ± 3
Low pressure (Bars) DW
4 ± 0.3 3.5 ± 0.3 3 ± 0.3

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 SAXO - All Types AIR CONDITIONING SYSTEM R 134.a
Click-fit union.
CONDITIONING

C5HP12EC

Tightening torques (m.daN).

AIR

(1) High pressure valve

(2) Low pressure valve
(3) Click-fit union
(4) Pressostat (1 seal Ø 10,82)
(5) Dryer (2 seals Ø 7,65)
(6) Relief valve, tighten to 0,43 m.daN ± 0,1
(1 seal Ø 7,65 – 1seal Ø 16,5)
(7) Compressor fixing flange 3 ± 0,8 m.daN (2 seals Ø 20)
(8) (O-ring seal Ø 7,65).
C5HP15UP

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 AIR CONDITIONING SYSTEM R 134.a SAXO - All Types
Checks on the air conditioning circuit

Key.

T = Scale of Temperature (°C ), and of High

Pressure (Bars).
P = Scale of Low pressure (Bars).

Te = Exterior temperature (°C).

CONDITIONING
HP = Pressure at compressor outlet (Bars).

AIR
Ta = Temperature (°C) of air blown from the vents.

BP = Pressure at compressor inlet (Bars).

C5HP067D

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 C3 AIR CONDITIONING SYSTEM R 134.a

(1) Low pressure valve.

(2) High pressure valve.

(3) Filter.

(4) Pressostat
CONDITIONING

Tightening torque m.daN

(a) : 0.6
AIR

(b) : 0.6
(c) : 0.6
(d) : 0.6
(e) : 0.6
(f) : 0.6

C5HP17SP

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 AIR CONDITIONING SYSTEM R 134.a C3
Checks on the air conditioning circuit

Keys.

T/P = Average temperature (°C ) at the air vents /

high pressure (Bars).

P = Low pressure (Bars).

CONDITIONING
TE = Exterior temperature (C°).

AIR
HP = Pressure at compressor outlet (Bars).

BP = Pressure at compressor inlet (Bars).

TA = Average temperature (°C) of air blown from the

central vents.

C5HP18GD

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 XSARA - All Types AIR CONDITIONING SYSTEM R 134.a
Plan of air conditioning system

Two solutions :

1 « MANULLI », with « NON EUROCLIM » compressor (O-ring seals).

2 « EATON », with « EUROCLIM » compressor (quadrilobe seals).

(1) - High pressure valve

(2) - Low pressure valve
CONDITIONING

(3) - Pressostat
(4) - Dryer
AIR

Tightening torques m.daN.

(a) 0,8
(b) 4 ± 0,4
(c) 0,8

A Right hand drive.

C5HP16RP

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 AIR CONDITIONING SYSTEM R 134.a XSARA - All Types
Plan of air conditioning system

Solution :

1 « EATON », with « EUROCLIM » compressor and buffer capacity (quadrilobe seals).

(1) - High pressure valve

(2) - Low pressure valve
(3) - Buffer capacity

CONDITIONING
Tightening torques m.daN.

AIR
(a) 0,8
(b) 4 ± 0,4
(c) 0,8

A Right hand drive.

C5HP17WP

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 XSARA - All Types AIR CONDITIONING SYSTEM R 134.a
Plan of air conditioning system

Two solutions :

1 « MANULLI », with « NON EUROCLIM » compressor (O-ring seals).

2 « EATON », with « EUROCLIM » compressor (quadrilobe seals).

(1) - High pressure valve

(2) - Low pressure valve
CONDITIONING

(3) - Pressostat
(4) - Dryer
AIR

Tightening torques m.daN.

(a) 0,8
(b) 4 ± 0,4
(c) 0,8

A Right hand drive.

C5HP16SP

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 AIR CONDITIONING SYSTEM R 134.a XSARA - All Types

Plan of air conditioning system

Two solutions :

1 « MANULLI », with « NON EUROCLIM » compressor (O-ring seals).

2 « EATON », with « EUROCLIM » compressor (quadrilobe seals).

(1) - High pressure valve

CONDITIONING
(2) - Low pressure valve
(3) - Pressostat

AIR
(4) - Dryer
Tightening torques m.daN.
(a) 0,8
(b) 4 ± 0,4
(c) 0,8

A Right hand drive.

C5HP16VP

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 XSARA - All Types AIR CONDITIONING SYSTEM R 134.a
Plan of air conditioning system

Three solutions :

1) « MANULLI », with « NON EUROCLIM » compressor (O-ring seals).

2) « EATON », with « EUROCLIM » compressor and buffer capacity (quadrilobe seals).

3) « EATON », with « NON EUROCLIM » compressor and buffer capacity (O-ring seals).

(1) - High pressure valve

CONDITIONING

(2) - Low pressure valve

(3) - Buffer capacity
AIR

Tightening torques m.daN.

(a) 0,8
(b) 4 ± 0,4
(c) 0,8

A Right hand drive.

C5HP17XP

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 AIR CONDITIONING SYSTEM R 134.a XSARA - All Types

Plan of air conditioning system

Two solutions :

1 « MANULLI », with « NON EUROCLIM » compressor (O-ring seals).

2 « EATON », with « EUROCLIM » compressor (quadrilobe seals).

(1) - High pressure valve

(2) - Low pressure valve

CONDITIONING
(3) - Pressostat
(4) - Dryer

AIR
Tightening torques m.daN.
(a) 0,8
(b) 4 ± 0,4
(c) 0,8

A Right hand drive.

C5HP16TP

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 XSARA - All Types AIR CONDITIONING SYSTEM R 134.a
Plan of air conditioning system.

Three solutions :

1) « MANULLI », with « NON EUROCLIM » compressor (O-ring seals).

2) « EATON », with « EUROCLIM » compressor and buffer capacity (quadrilobe seals).

3) « EATON », with « NON EUROCLIM » compressor and buffer capacity (O-ring seals).
CONDITIONING

(1) - High pressure valve

(2) - Low pressure valve
AIR

(3) - Buffer capacity.

Tightening torques m.daN.

(a) 0,8
(b) 4 ± 0,4
(c) 0,8

A Right hand drive.

C5HP17YP

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 AIR CONDITIONING SYSTEM R 134.a XSARA - All Types

Plan of air conditioning system

Two solutions :

1 « MANULLI », with « NON EUROCLIM » compressor (O-ring seals).

2 « EATON », with « EUROCLIM » compressor (quadrilobe seals).

(1) - High pressure valve

CONDITIONING
(2) - Low pressure valve
(3) - Pressostat

AIR
(4) - Dryer

Tightening torques m.daN.

(a) 0,8
(b) 4 ± 0,4
(c) 0,8

A Right hand drive.

C5HP16UP

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 AIR CONDITIONING SYSTEM R 134.a XSARA PICASSO TU

(1) High pressure valve.

(2) Low pressure valve.
(3) High pressure clickfit union (tool 8005-T.C).
(4) Low pressure clickfit union (tool 8005-T.A).
(5) Pressostat. 1,8 ± 0,6 m.daN
(6) Filtering / drying cartridge plug.
CONDITIONING

Tightening torques m.daN.

AIR

- a 0,8.± 0,1
- b 0,5.± 0,1
- c 1,4 ± 0,2.
- d 2,5 ± 0,25.

C5HP13PP

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 AIR CONDITIONING SYSTEM R 134.a XSARA PICASSO EW7

(1) High pressure valve.

(2) Low pressure valve.
(3) High pressure clickfit union (tool 8005-T.C).
(4) Low pressure clickfit union (tool 8005-T.A).
(5) Pressostat. 1,8 ± 0,6 m.daN
(6) Filtering / drying cartridge plug.

CONDITIONING
Tightening torques m.daN.

AIR
-a 0,8.± 0,1
-b 0,5.± 0,1
-c 1,4 ± 0,2.

HP/LP compressor flange fixing 2,5 ± 0,25.

C5HP13QP

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 XSARA PICASSO TU - EW7 AIR CONDITIONING SYSTEM R 134.a
Checks on the air conditioning circuit

Key.

T/P = Scale of:

- Temperature (°C), average of air from the central
vents.
- Pressure, High (Bars).
- Pressure, Low (Bars).
CONDITIONING

Te = Exterior temperature (°C).

AIR

HP = Pressure at compressor outlet (Bars).

Ta = Temperature (°C) of air blown from the vents.

BP = Pressure at compressor inlet (Bars).

C5HP150D

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 AIR CONDITIONING SYSTEM R 134.a XSARA PICASSO DW10

(1) High pressure valve.

(2) Low pressure valve.
(3) High pressure clickfit union (tool 8005-T.C).
(4) Low pressure clickfit union (tool 8005-T.A).
(5) Pressostat. 1,8 ± 0,6 m.daN
(6) Filtering / drying cartridge plug.

CONDITIONING
Tightening torques m.daN.

AIR
-a 0,8.± 0,1
-b 0,5.± 0,1
-c 1,4 ± 0,2.

HP/LP compressor flange fixing 2,5 ± 0,25.

C5HP13RP

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 XSARA PICASSO DW10 AIR CONDITIONING SYSTEM R 134.a
Checks on the air conditioning circuit

Key.

T/P = Scale of:

- Temperature (°C), average of air from the central vents.
- Pressure, High (Bars).
- Pressure, Low (Bars).

Te = Exterior temperature (°C).

CONDITIONING

HP = Pressure at compressor outlet (Bars).

AIR

Ta = Temperature (°C) of air blown from the vents.

BP = Pressure at compressor inlet (Bars).

C5HP14ZD

478

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