private cars xantia-xm
PRIVATE CARS
PRIVATE CARS
AC.QCAV/MTD
Méthodes Techniques Documentation
’’The intellectual property rights relating to the technical information contained in this document belong
exclusively to the manufacturer. Reproduction, translation or distribution in whole or in part without
prior written authorisation from the manufacturer is forbidden.‘‘
2001
XANTIA-XM-SYNERGIE
«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 050008
Book 2
2001
PRESENTATION
THIS HANDBOOK summarises the characteristics, adjustments, checks and special features of CITROEN vehicles, not including COMMERCIAL
vehicles for which there exists a separate handbook.
The handbook is divided into the following groups representing the main functions :
GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES HYDRAULICS - ELECTRICAL - AIR CONDITIONING.
In each section, the vehicles are dealt with in the following order : XANTIA-XM-SYNERGIE and all models where applicable.
The information given in this handbook is based on vehicles marketed in EUROPE.
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.
INDEX
GENERAL
Identification
of vehicles
Capacities
XANTIA
XM
SYNERGIE
XANTIA
XM
SYNERGIE
Lubricants
ENGINE
Specifications
Cyl. head marking and tightening
Auxiliary equipment drive belt
Checking and setting valve timing
Valve clearances
Oil pressure
Oil filter
INJECTION
Idling, anti-pollution
Petrol injection
Anti-pollution technical checks
Emission standards
LPG safety requirements
1-8
9 - 13
14 - 15
17 - 18
19
20
21 - 34
36
51
62
83
- 38
- 61
- 78
- 84
121
122
125
127
128 - 129
130
131 - 137
138 - 142
HDi safety requirements
143 Checks: HDi fuel circuit
147 Checks: HDi air circuit
Checks: Turbo pressure
150 Checks: HDi exhaust gas recycling
DELPHI checking, timing
153 BOSCH checking, timing
157 IGNITION
146
148
149
151
152
156
163
Sparking plugs
CLUTCH-GEARBOX-DRIVESHAFTS
164
Speedometer
Clutch adjustments
Driveshafts
165
169 - 176
214
AXLES-SUSPENSION-STEERING
Axle
geometry
XANTIA
215 - 223
XM
224 - 230
SYNERGIE 231 - 236
BRAKES
Brake specifications
XANTIA
XM
SYNERGIE
237 - 238
243
246
XANTIA
XM
SYNERGIE
SUSPENSION
De-pressurising
HYDRAULICS
Parking brake
Bleed of brakes
Parking brake
Bleed of brakes
Parking brake
XANTIA
Pneumatic
units
XM
ELECTRICITY
Starter motors
Alternators
Charging circuit
Preheater plugs
AIR CONDITIONING
R 134 a quantities
Special features
Checking temperatures
Checking pressures
XANTIA
Aircon
XM
system
SYNERGIE
240 - 241
242
244
245
249
250 - 260
261 - 265
266 - 269
270 - 272
273 - 279
280
281
282
283 - 288
289 - 290
291
293 - 297
298 - 301
302 - 303
PRESENTATION
THIS HANDBOOK summarises the characteristics, adjustments, checks and special features of CITROEN vehicles, not including COMMERCIAL
vehicles for which there exists a separate handbook.
The handbook is divided into the following groups representing the main functions :
GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES HYDRAULICS - ELECTRICAL - AIR CONDITIONING.
In each section, the vehicles are dealt with in the following order : XANTIA-XM-SYNERGIE and all models where applicable.
The information given in this handbook is based on vehicles marketed in EUROPE.
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.
INDEX
GENERAL
Identification
of vehicles
Capacities
XANTIA
XM
SYNERGIE
XANTIA
XM
SYNERGIE
Lubricants
ENGINE
Specifications
Cyl. head marking and tightening
Auxiliary equipment drive belt
Checking and setting valve timing
Valve clearances
Oil pressure
Oil filter
INJECTION
Idling, anti-pollution
Petrol injection
Anti-pollution technical checks
Emission standards
LPG safety requirements
1-8
9 - 13
14 - 15
17 - 18
19
20
21 - 34
36
51
62
83
- 38
- 61
- 78
- 84
121
122
125
127
128 - 129
130
131 - 137
138 - 142
HDi safety requirements
143 Checks: HDi fuel circuit
147 Checks: HDi air circuit
Checks: Turbo pressure
150 Checks: HDi exhaust gas recycling
DELPHI checking, timing
153 BOSCH checking, timing
157 IGNITION
146
148
149
151
152
156
163
Sparking plugs
CLUTCH-GEARBOX-DRIVESHAFTS
164
Speedometer
Clutch adjustments
Driveshafts
165
169 - 176
214
AXLES-SUSPENSION-STEERING
Axle
geometry
XANTIA
215 - 223
XM
224 - 230
SYNERGIE 231 - 236
BRAKES
Brake specifications
XANTIA
XM
SYNERGIE
237 - 238
243
246
XANTIA
XM
SYNERGIE
SUSPENSION
De-pressurising
HYDRAULICS
Parking brake
Bleed of brakes
Parking brake
Bleed of brakes
Parking brake
XANTIA
Pneumatic
units
XM
ELECTRICITY
Starter motors
Alternators
Charging circuit
Preheater plugs
AIR CONDITIONING
R 134 a quantities
Special features
Checking temperatures
Checking pressures
XANTIA
Aircon
XM
system
SYNERGIE
240 - 241
242
244
245
249
250 - 260
261 - 265
266 - 269
270 - 272
273 - 279
280
281
282
283 - 288
289 - 290
291
293 - 297
298 - 301
302 - 303
E1AP07ED
1
XANTIA - All Types
1
Manufacturer’s cold stamp.
2
R.P. organisation N°.
3
Paint code.
4
01/02/99 # Label :
- Pression de gonflage.
- N° organisation P.R.
- Code peinture
5
Automatic gearbox identification ref.
6
Manual gearbox identification ref.
7
Manufacturer’s name plate.
8
XU5 - XU7 - ES9J4 engine plate.
9
XU10 - XUD engine plate.
GENERAL
IDENTIFICATION OF VEHICLES
IDENTIFICATION OF VEHICLES
XANTIA - All Types
PETROL SALOON
1.6 i
1.8 i
1.8 i 16 V
Auto.
SX
SX
GENERAL
X1 BFZF
X1 BFXF
Engine type
BFZ
BFX
Cubic capacity (cc)
1580
Fiscal rating (hp)
L4
X1 LFYM
X1 LFYF
X1 LFYB
LFY
7
20 TE 00
X1 LFYN
1761
8
BE3/5
Gearbox type
Gearbox ident. plate
SX
L3
Emission standard
Type code
Auto.
20 TE 35
AL4
BE3/5
AL4
BE3/5
20 TP 52
20 TE 35 (*)
20 TP 52
20 TE 36
( ) = Long gearbox.
*
2
IDENTIFICATION OF VEHICLES
XANTIA - All Types
PETROL SALOON
1.8i 16 V
2.0i 16 V
SX
Exclusive
X1 LFYN/IF (*)
L3
X1 LFYB/IF (*)
X1 RFVM
X1 RFVF
Engine type
LFY
RFV
Cubic capacity (cc)
1761
1998
Gearbox ident. plate
X7 XFZF
X7 XFZM
XFZ
2946
9
Fiscal rating (hp)
Gearbox type
SX
Exclusive
Activa
13
14
AL4
BE3/5
AL4
BE3/5
ML/5
4HP20
20 TP 52
20 TE 36
20 TE 53
20 TE 37
20 LE 89
20 HZ XX
( ) = IF = Fiscal incentive.
*
3
GENERAL
L4
Emission standard
Type code
SX
30.i V6
XANTIA - All Types
IDENTIFICATION OF VEHICLES
DIESEL SALOON
2.0 HDi (1)
1.9 D
Auto.
SX
SX Aircon Pack
GENERAL
Emission standard
L3
X1 DHXM
X1 RFYF
DHX
RHY
Cubic capacity (cc)
1905
Fiscal rating (hp)
Gearbox type
Gearbox ident. plate
L4
X1 RHZF
X1 RHZB
RHZ
1997
7
6
AL4
BE3/5
ML/5
20 TP 50
20 TE 40
20 LE 84
(1) HDi = High pressure Diesel injection
4
SX
Activa
SX
Exclusive
L3
Engine type
Type code
SX - SX Aircon Pack
Exclusive
Activa
SX
SX Aircon Pack
X7 RHZB
IDENTIFICATION OF VEHICLES
XANTIA - All Types
PETROL ESTATE
SX
Emission standard
Type code
Engine type
SX - SX Aircon Pack
SX
L3
L4
L3
X2 LFXF
X2 LFYF
X2 LFYC
LFX
Cubic capacity (cc)
Fiscal rating (hp)
1761
7
8
7
BE3/5
Gearbox type
Gearbox ident. plate
X2 LFYB/IF (*)
LFY
20TE 35
20 TE 36
20 TE 35
( ) = IF = Fiscal incentive.
*
5
20 TE 36
X2 LFYB
GENERAL
1.8i 16V
1.8i
IDENTIFICATION OF VEHICLES
XANTIA - All Types
PETROL ESTATE
2.0i 16V
3.0i V6
Auto.
SX
Auto.
SX Aircon Pack
Exclusive
GENERAL
X2 RFVM
X2 RFVF
Engine type
X2 XFZF
X7 XFZM
XFZ
1998
Fiscal rating (hp)
Gearbox ident. plate
X2 RFVM
RFV
Cubic capacity (cc)
Gearbox type
Exclusive
L3
Emission standard
Type code
SX Aircon Pack
Exclusive
SX
2946
9
9
14
13
AL4
BE3/5
4HP20
ML/5
20 TP 53
20 TE 37
20 HZ XX
20 LE 89
6
XANTIA - All Types
IDENTIFICATION OF VEHICLES
DIESEL ESTATE
1.9 TD
2.0 HDi (*)
Auto.
SX
SX Aircon Pack
L3
L3
Emission standard
X2 DHXM
X2 RHYF
Engine type
DHX
RHY
Cubic capacity (cc)
1905
Type code
Fiscal rating (hp)
Gearbox type
Gearbox ident. plate
SX - SX Aircon Pack
Exclusive
SX
Exclusive
L4
X2 RHZF
X2 RHZB
RHZ
1997
7
6
AL4
BE3/5
ML/5
20 TP 50
20 TE 40
20 LE 84
(1) HDi = High pressure Diesel injection
7
GENERAL
SX
SX Aircon Pack
XANTIA - All Types
IDENTIFICATION OF VEHICLES
COMMERCIAL VERSIONS ALL TYPES
DUAL FUEL PETROL/LPG (1)
Diesel
Petrol
Saloon
Estate
1.8i 16V
SX Ambulance
GENERAL
X - SX Company
SX Company
X1 RHYF
Type code
Engine type
RHY
X1 RHZF
X2 RHYF/T (3)
X1 LFYC/GPL
RHZ
RHY
SX
SX Aircon Pack
L3
X1 LFYC/GPL
X2 LFYC/GPL
LFY/GPL
1761
6
Fiscal rating (hp)
Gearbox ident. plate
SX
1997
Cubic capacity (cc)
Gearbox type
SX Entreprise
L3
Emission standard
Estate
Saloon
2.0HDi (2)
7
BE3/5
ML/5
BE3/5
20 TE 40
20 LE 84
20 TE 40
(1) = Liquid Petroleum Gas.
(2) HDi = High pressure Diesel injection.
(3) /T = Can be converted.
8
BE3/5
20 TE 36
20 TE 35
IDENTIFICATION OF VEHICLES
1
Bodyshell N°
2
Manufacturer’s cold stamp
3
6 cyl. engine plate
4
R.P. organisation N°. (*) 01/02/1999 #
Label :
- Tyre pressures.
- R.P. organisation N°.
- Paint code
5
R.P. organisation N°. # 01/02/99 (*)
6
BE3 gearbox ident.
7
4HP 18 gearbox ident.
8
MG gearbox ident.
9
ME5T gearbox ident.
10 Paint code # 01/02/99 (*)
11 Manufacturer’s plate
(*) : Applicable only to 1999 model year saloons
12 4 cyl. engine plate
E1AP07FD
9
GENERAL
XM - All Types
XM - All Types
IDENTIFICATION OF VEHICLES
PETROL SALOON
2.0i 16 V
2.0i Turbo CT
Auto.
SX
Y4-CZ
Y4-TV
GENERAL
Gearbox ident. plate
Y4-GG
RFV
Y4-TT
Y4-WG
RGX
9
Y4-WH
XFZ
1998
Cubic capacity (cc)
Gearbox type
SX - Exclusive
L3
Engine type
Fiscal rating (hp)
Auto.
SX
Emission standard
Type code
3.0i V6
Auto.
2946
11
13
14
BE3/5
4 HP 18
10
ME/5
4 HP 18
ML/5
4 HP20
20 TD 01
20 GZ 5G
20 GM 32
20 GZ 1G
20 LE 59
20 HZ YY
10
IDENTIFICATION OF VEHICLES
XM Diesel
DIESEL SALOON
2.1 TD
2.5 TD
Auto.
Emission standard
Type code
SX - Exclusive
L3
Y4-GZ
Y4-RN
L4
L3
Y4-WE
Y4-NZ
Engine type
P8C
THY
Cubic capacity (cc)
2088
2446
Fiscal rating (hp)
Gearbox type
Gearbox ident. plate
7
8
7
9
ME/5
4 HP 18
ME/5
MG/5
20 GM 31
20 GZ 5D
20 GM 31
20 KM 70
11
GENERAL
SX
XM - All Types
IDENTIFICATION OF VEHICLES
PETROL ESTATE
2.0i
2.0i Turbo CT
Auto.
SX
SX-Commerce
Y4-GB
Y4-TU
GENERAL
Gearbox ident. plate
SX
Y4-TS
Y4-WJ
RGX
Y4-TN
XFZ
1998
Cubic capacity (cc)
Gearbox type
SX
Y4-GM
RFV
Engine type
Fiscal rating (hp)
Auto.
L3
Emission standard
Type code
3.0i V6
Auto.
2946
9
10
9
10
13
14
BE3/5
4 HP 18
ME/5
4 HP 18
ML/5
4 HP 20
20 GM 36
20 GZ 5G
20 GM 33
20 GZ 1G
20 LE 59
20 HZ YY
12
IDENTIFICATION OF VEHICLES
XM - All Types
DIESEL ESTATE
Commercial Estate
2.1 TD
2.5 TD
2.1 TD
SX
Commerce
SX
Ambulance
Emission standard
SX
L3
L4
Y4-RM
Y4-GZ
P8C
THY
P8C
Cubic capacity (cc)
2088
2446
2088
Fiscal rating (hp)
Gearbox type
Gearbox ident. plate
Y4-CW
Y4-WF
L3
Engine type
Type code
Y4-MZ
SX
Commerce
7
8
7
9
7
ME/5
4 HP 18
ME/5
MG/5
ME/5
20 GM 31
20 GZ 5D
20 GM 31
20 KM 70
20 GM 31
13
GENERAL
Auto.
SYNERGIE - All Types
IDENTIFICATION OF VEHICLES
GENERAL
E1AP07GD
14
1
Manufacturer’s cold stamp
2
R.P. organisation No.
3
Paint code
4
01/02/99 # Label :
- Tyre pressures.
- R.P. Organisation No.
- Paint code.
5
Gearbox ident.
6
Engine plate
7
Manufacturer’s plate
SYNERGIE - All Types
IDENTIFICATION OF VEHICLES
PETROL
DIESEL
2.0i 16 V
2.0 16 V HDi
2.0 HDi
Auto.
Emission standard
Type code
IF L5 (*)
AF RFNC/IF
L3
AF RFNF/IF
AF RHZA/T
RFN
Engine type
Gearbox type
Gearbox ident. plate
L4
AF RHZA
RHZ
Cubic capacity (cc)
Fiscal rating (hp)
X Taxi – SX
Exclusive
X – SX
RHW
1997
9
10
BE4/5
AL4
ML5
20 TP 31
20 LE 91
DL26 - DL27
6
15
AF RHWB
GENERAL
X – SX
Exclusive
CAPACITIES
ALL TYPES
Draining method.
The oil capacities are defined according to the following methods.
1) - Vehicle on level surface (in high position, if equipped with hydropneumatic suspension).
2) - Engine warm (oil temperature 80°C).
GENERAL
3) - Draining of the oil sump + removal of the cartridge (duration of draining + dripping = 15 mm).
4) - Refit plug + cartridge.
5) - Engine filling.
6) - Engine starting (allowing the cartridge to be filled).
7) - Engine stopped (stationary for 5 mm).
ESSENTIAL : Systematically check the oil level using the oil dipstick.
16
CAPACITIES (in litres)
XANTIA - All Types
XANTIA
Petrol
1.8i
1.8i 16V
2.0i 16V
Auto.
BFZ
Engine type
BFX
LFX
3.0i 6V
Auto.
Auto.
LFY
RFV
XFZ
4.75 - 4.25 (1)
4.25
5.25
30°
Engine angle
4.75
Engine with filter change
1.3
Between Min. and Max.
1
1.8
5-speed gearbox
Automatic gearbox
after oil change
7 - 8.3 (2)
6
6
8.3
3
3
5.3
7.5
7.5 - 8.5 (2)
65
Fuel tank capacity
(1) Air conditioning
1.8
5.8
Hydraulic or brake circuit
Cooling system
2
1.8
(2) Depending on equipment
- NOTE : Engine, systematically check the oil level using the oil dipstick.
17
10
GENERAL
1.6i
CAPACITIES (in litres)
XANTIA - All
XANTIA
Diesel
1.9 D
2.0 HDi
Auto.
DHX
Engine type
RHY
RHZ
GENERAL
30°
Engine angle
4.25 - 4 (1)
Engine with filter change
4.5 - 4.25 (1)
1.5
Between Min. and Max.
1.8
5-speed gearbox
8
Automatic gearbox
after oil change
3
5.8
Hydraulic or brake circuit
Cooling system
9
8.5 - 11 (1)
65
Fuel tank capacity
(1) Air conditioning
- NOTE : Engine, systematically check the oil level using the oil dipstick.
18
CAPACITIES (in litres)
XM - All Types
XM
Petrol
2.0i 16 V
Auto.
Auto.
Automatic gearbox
after oil change
P8C
THY
4.75 - 4.5 (1)
4.25
5.25
5 - 4.5 (1)
8
2
1.45 - 1.25 (1)
1.8
1.85
7.5
8.3
7.5
2.4
2.4
5.3
2.4
5.4
10.8 - 11.3 (2)
5
8.8 - 11.5 (2)
9.4
80
(2) Depending on equipment
5.4
11.4 - 12 (2)
13.2
80
- NOTE : Engine, systematically check the oil level using the oil dipstick.
19
3
2.2
7.5
Fuel tank capacity
(1) Air conditioning
1
1.9
Hydraulic or brake circuit
Cooling system
Auto.
XFZ
1.9
5-speed gearbox
Auto.
2.5 TD
RFV
1.4 - 1.2 (1)
Between Min. and Max. (b)
2.1 TD
RGX
Engine type
Engine with filter change (a)
3.0i
GENERAL
2.0i Turbo CT
Diesel
CAPACITIES (in litres)
SYNERGIE - All Types
SYNERGIE
Petrol
Diesel
2.0i 16V
2.0 HDi
2.0 HDi 16V
RHZ
RHW
Auto.
RFN
Engine type
GENERAL
21°
Engine angle
Engine with filter change
Between Min. and Max.
4.25
4.5
4.75
1.7
1.4
1.9
1.8
5-speed gearbox
1.8
8
Automatic gearbox
3
after oil change
Sans ABR : 0.47 - Avec ABR : 0.52
Hydraulic or brake circuit
Cooling system
Fuel tank capacity
(1) Air conditioning
7
8.5
80
80
- NOTE : Engine, systematically check the oil level using the oil dipstick.
20
ALL TYPES
LUBRICANTS - TOTAL recommended oils
S.A.E. Norm - Table for selection of engine oil grade
Factory evolutions in 2000 model year
This oil is not used in the following engines :
- XU10 4 RS – XSARA VTS 2.0i 16V (3-door)
- SOFIM – RELAY 2.8 D and 2.8 TD.
Engine oil norms
These engine oils have been classified by the following recognised
organisations:
SAE : Society of Automotive Engineers.
API : American Petroleum Institute.
ACEA : Association des Constructeurs Européens
d'Automobiles
E4AP006D
21
GENERAL
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%).
ALL TYPES
LUBRICANTS - TOTAL recommended oils
Selection of engine oil grades recommended for climatic conditions in countries of distribution
API Norms
ACEA Norms
GENERAL
The first letter corresponds to the type of engine concerned :
A : petrol and dual fuel petrol / LPG engines.
B : diesel engines.
The first letter corresponds to the type of fuel used by the engine :
S : petrol and dual fuel petrol / LPG engines.
C : diesel engines.
The figure following the first letter corresponds to the type of oil.
1 : highly fluid oils, for reducing friction and lowering fuel
onsumption.
3 : high performance oils.
The second letter corresponds to the degree of evolution, in ascending order.
Example : The norm SJ is more severe than the norm SH and corresponds to a higher level of performance.
The adding of the letters EC indicates that the engine oil concerned is an
oil which permits fuel economy.
EC : Energy Conserving, reduction in fuel consumption.
The number after that (96 or 98) corresponds to the year of creation of
the norm.
NOTE : From 01/03/2000, all engine oils must comply with ACEA98 norms.
Example :
ACEA A1-98 / B1-98 : Blended oils for all engines, permetting fuel economy (complying with ACEA 98 norms).
Examples :
API SJ / CF : Blended oils for diesel and dual fuel petrol / LPG engines
API CF / EC : Oils specifically for diesel engines, permitting fuel economy.
API SJ / CF / EC : Blended oils for all engines, permetting fuel economy.
22
LUBRICANTS - TOTAL recommended oils
ALL TYPES
Recommendations.
Denominations of TOTAL oils, according to country of marketing :
TOTAL ACTIVA
(France only).
TOTAL QUARTZ
(outside France).
These oils must comply with the following norms :
Petrol and dual fuel petrol / LPG engines: ACEA A3-98 and API SJ.
Diesel engines: ACEA B3-98 and API CF.
ATTENTION : Engines fitted in CITROEN vehicles prior to 2000 model year must not be lubricated with oil complying
w
i
t
h
standards ACEA A1-98 / B1-98 and API SJ/CF EC.
Summary
Model year
2001 model year
Types of engine
ACEA norms
API norms
Petrol and dual fuel petrol /
LPG engines
A3-98 or A1-98 (*)
SJ or SJ / EC (*)
Diesel engines
B3-98 or B1-98 (*)
CF or CF / EC (*)
Engine oil norms to be respected in 2001 model year.
23
GENERAL
IMPERATIVE : From 1999 model year, to preserve engine performance, all engines fitted in CITROEN vehicles must be
lubricated with high quality oils (synthetic or semi-synthetic)
LUBRICANTS - TOTAL recommended oils
ALL TYPES
S.A.E. grades
SPI norms
ACEA norms
Blended oils for all engines (petrol, dual-fuel petrol / LPG and diesel)
GENERAL
TOTAL ACTIVA 9000
TOTAL QUARTZ 9000
TOTAL ACTIVA 9000 (*)
TOTAL QUARTZ 9000 (*)
TOTAL ACTIVRAC
(*) = Blended oils for all engines, permitting fuel economy.
5W-40
SJ / CF
A3-98 / B3-98
5W-30
SJ / CF EC
A1-98 / B1-98
10W-40
SJ / CF
A3-98 / B3-98
SJ
A3-98
CF
B3-98
Oils specifically for petrol and dual-fuel petrol / LPG engines
TOTAL ACTIVA 7000
TOTAL QUARTZ 7000
TOTAL QUARTZ 9000
TOTAL ACTIVA 7000
TOTAL QUARTZ 7000
10W-40
0W-40
15W-50
Oils specifically for diesel engines
TOTAL ACTIVA DIESEL 7000
TOTAL QUARTZ DIESEL 7000
TOTAL ACTIVA DIESEL 7000
TOTAL QUARTZ DIESEL 7000
TOTAL ACTIVA 9000
10W-40
15W-50
5W-40
24
ALL TYPES
LUBRICANTS - TOTAL recommended oils
FRANCE
Blended oils for all engines
TOTAL ACTIVRAC
S.A.E : 10W-40 Norms
TOTAL ACTIVA DIESEL
TOTAL ACTIVA
Metropolitan FRANCE
New Caledonia
Guadeloupe
Saint-Martin
La Réunion
Martinique
Guyana
Tahiti
Mauritius
Mayotte
Blended oils for all engines
Oils specifically for petrol and
dual-fuel petrol / LPG engines
Oils specifically
for diesel engines
900 5W-40
9000 5W-30 (*)
7000 10 W-40
7000 10 W-40
9000 5W-40
9000 5W-40
7000 15W-50
7000 15W-50
(*) = Blended oils for all engines, permitting fuel economy.
25
GENERAL
Metropolitan FRANCE
ALL TYPES
LUBRICANTS - TOTAL recommended oils
EUROPE
TOTAL QUARTZ
(*) = Blended oils for all engines,
permitting fuel economy
Blended oils for all engines
GENERAL
Austria
Belgium
Bulgaria
Cyprus
Croatia
Oils specifically for petrol and
dual-fuel petrol / LPG engines
7000
9000
7000
7000
9000
7000
Germany
9000 5W-40
9000 5W-30 (*)
Spain
Finland
Great Britain
26
Oils specifically
for diesel engines
10W-40
0W-40
10W-40
10W-40
0W-40
10W-40
7000 10W-40
7000 15W-50
7000 10W-40
7000 15W-50
7000
7000
9000
7000
7000
7000
9000
7000
Denmark
TOTAL QUARTZ DIESEL
10W-40
10W-40
0W-40
10W-40
15W-50
10W-40
0W-40
10W-40
7000 10W-40
7000 10W-40
7000 15W-50
7000 10W-40
LUBRICANTS - TOTAL recommended oils
ALL TYPES
EUROPE (continued)
(*) = Blended oils for all engines,
permitting fuel economy
Blended oils for all engines
TOTAL QUARTZ DIESEL
Oils specifically for petrol and
dual-fuel petrol / LPG engines
Greece
7000 10W-40
7000 15W-50
Holland
7000 10W-40
Hungary
9000 0W-40
Italy
7000 10W-40
Latvia
7000 10W-40
Lithuania
Macedonia
9000 5W-40
9000 5W-30 (*)
Oils specifically
for diesel engines
7000 10W-40
7000 15W-50
7000 10W-40
9000 0W-40
7000 10W-40
Malta
7000 10W-40
7000 15W-50
Norway
7000 10W-40
9000 0W-40
Poland
7000 10W-40
7000 15W-50
7000 10W-40
Portugal
7000 10W-40
Slovak Republic
27
GENERAL
TOTAL QUARTZ
ALL TYPES
LUBRICANTS - TOTAL recommended oils
EUROPE (continued)
TOTAL QUARTZ
(*) = Blended oils for all engines,
permitting fuel economy
Blended oils for all engines
TOTAL QUARTZ DIESEL
Oils specifically for petrol and
dual-fuel petrol / LPG engines
GENERAL
Czech Republic
7000 10W-40
9000 0W-40
Romania
7000 10W-40
7000 15W-50
Russia
7000 10W-40
9000 0W-40
Slovenia
Sweden
7000 10W-40
9000 5W-40
9000 5W-30 (*)
7000 10W-40
9000 0W-40
7000 10W-40
Switzerland
Oils specifically
for diesel engines
7000 10W-40
7000 10W-40
7000 15W-50
7000 10W-40
Turkey
7000 10W-40
7000 15W-50
9000 0W-40
7000 10W-40
7000 15W-50
Ukraine
7000 10W-40
9000 0W-40
7000 10W-40
28
TOTAL QUARTZ
Blended oils for all
engines
Australia
New Zealand
Oils specifically for petrol and
dual-fuel petrol / LPG engines
ALL TYPES
TOTAL QUARTZ DIESEL
Oils specifically
for diesel engines
OCEANIA
9000 5W-40
7000 10W-40
7000 10W-40
AFRICA
9000 5W-40
7000 15W-50
7000 15W-50
9000 5W-40
7000 15W-50
7000 15W-50
Angola - Ivory Coast
Egypt - Ecuador - Gabon
Madagascar - Morocco
Dominican Republic
Senegal - Tunisia
Argentina - Brazil - Chile
Colombia - Cuba
Guatemala - Paraguay
SOUTH
AMERICA
Peru - El Salvador
Uruguay
29
GENERAL
LUBRICANTS - TOTAL recommended oils
ALL TYPES
LUBRICANTS - TOTAL recommended oils
TOTAL QUARTZ
Blended oils for all
engines
Oils specifically for petrol and
dual-fuel petrol / LPG engines
GENERAL
China
7000 10W-40
7000 15W-50
South Korea
7000 10W-40
Hong Kong - India
Indonesia
7000 15W-50
Japan
Malaysia
Oils specifically
for diesel engines
7000 10W-40
7000 15W-50
SOUTH & EAST
ASIA
TOTAL QUARTZ DIESEL
7000 15W-50
9000 5W-40
7000 15W-50
Singapore
Taiwan
7000 10W-40
7000 15W-50
Thaïland
7000 15W-50
Vietnam
30
LUBRICANTS - TOTAL recommended oils
ALL TYPES
TOTAL QUARTZ
TOTAL QUARTZ DIESEL
Blended oils for all
engines
Oils specifically for petrol and
dual-fuel petrol / LPG engines
Oils specifically
for diesel engines
9000 5W-40
7000 15W-50
7000 15W-50
GENERAL
Saudi Arabia
Bahrain
Dubai
United Arab Emirates
Israel
Jordan
MIDDLE
EAST
Kuwaït
Lebanon
Qatar
Yemen
31
ALL TYPES
LUBRICANTS - TOTAL recommended oils
Gearbox oils
Manual gearbox
Europe
Overseas France
Asia
TOTAL FLUIDE ATX ou
TOTAL FLUIDE AT 42.
Special oil distributed by CITROEN
(Part No. : 9730 94).
Automatic gearbox MB3
GENERAL
Automatic gearbox 4 HP 14 et 4 HP 18
TOTAL TRANSMISSION
(new formula)
Norms S.A.E 75W-80
All countries
TOTAL FLUIDE AT 42 ou
Special oil distributed by CITROEN
(Part No. : 9730 94).
Special oil distributed by CITROEN
(Part No. : 9736 22).
Automatic gearbox 4 HP 20 et AL4
Transfer box and differential
TOTAL TRANSMISSION X 4
C MATIC gearbox
TOTAL FLUIDE T
Oils for power-assisted steering
Power-assisted steering
All countries
32
TOTAL FLUIDE ATX
ALL TYPES
LUBRICANTS - TOTAL recommended oils
Engine coolant
All countries
CITROEN Fluid
Protection : - 35°C
GLYSANTIN G 33
REVCOGEL 2000
2 litres
9979 70
9979 72
5 litres
9979 71
9979 73
20 litres
210 litres
9979 76
9979 77
9979 74
9979 75
Synthetic brake fluid
All countries
CITROEN Fluid
Packs
CITROEN Reference
0.5 litre
9979 05
1 litre
9979 06
5litres
9979 07
CITROEN hydraulic circuit fluid
Mineral fluid for hydraulic circuit – green colour
TOTAL LHM PLUS
All countries
Packs
Norms ISO 7308-7309
1 litre
Hydraulic circuit rinsing fluid – green colour
TOTAL HYDRAURINCAGE
33
CITROEN Reference
ZCP 830 095
GENERAL
CITROEN Reference
Packs
ALL TYPES
LUBRICANTS - TOTAL recommended oils
Wash / wipe fluid
CITROEN Reference
All countries
Concentrate : 250 ml
9980 33
ZC 9875 953 U
Liquid ready to use : 1 litre
9980 06
ZC 9875 784 U
Liquid ready to use : 5 litres
9980 05
ZC 9885 077 U
9980 56
ZC 9875 279 U
Grease
GENERAL
Norms NLGI (1)
All countries
TOTAL MULTIS EP2
TOTAL MULTIS COMPLEX EP2
TOTAL MULTIS N4128
2
2
1
TOTAL SMALL MECHANISMS
(1) NLGI = National Lubrificating Grease Institute.
34
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.
- 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.
35
GENERAL
II - An engine can be considered RUN-IN after:
ENGINE
ALL TYPES
ENGINE SPECIFICATIONS
Engines : BFZ BFX LFX LFY
Petrol
All Types
1.6i
1.8 i
1.8 i 16 V
Dual fuel
Engine type
BFZ
Cubic capacity (cc)
1580
1761
Bore / Stroke
83/73
83/81.4
Compression ratio
9.25/1
9.5/1
Power ISO or EEC KW-rpm
65-6000
66-5000
81-5500
79-5500
Power DIN (HP-rpm)
89-6000
90-5000
112-5500
109-5500
Torque ISO or EEC (m.daN-rpm)
13-2600
14.7-2600
15.5-4250
13.5-2600
15.3-2600
16.1-4250
6800
6300
6400
Torque DIN (mkg-rpm)
Max. speed (rpm)
BFX
36
LFX
LFY
LFY/GPL
10.4/1
Engines : RGX RFN RFV XFZ
Petrol
3.0i V6
2.0i 16V
2.0I TURBO CT
Engine type
RGX
RFN
RFV
XFZ
Cubic capacity (cc)
1998
1997
1998
2946
Bore / Stroke
86/86
85/88
86/86
87/82.6
Compression ratio
7.9/1
10.8/1
10.4/1
10.5/1
Power ISO or EEC KW-rpm
108-5300
99-6000
97.4-5500
140-5750
Power DIN (HP-rpm)
150-5300
136-6000
135-5500
194-5750
Torque ISO or EEC (m.daN-rpm)
23.5-2500
19-4600
18-4200
26.7-4000
Torque DIN (mkg-rpm)
24.5-2500
19.8-4600
18.7-4200
27.7-4000
6800
6520
Max. speed (rpm)
6300
37
ENGINE
ALL TYPES
ENGINE SPECIFICATIONS
ENGINE
ENGINE SPECIFICATIONS
ALL TYPES
Engines : DHX - RHZ – RHY - RFW - P8C - THY
Diesel
All Types
1.9 TD
2.0 HDi
2.0 HDi 16V
2.1 TD
2.5 TD
RHW
P8C
THY
2088
2445
Engine type
DHX
Cubic capacity (cc)
1905
Bore / Stroke
83/88
85/88
85/88
95/92
92/92
Compression ratio
21.8/1
17.6/1
18/1
21.5/1
22/1
RHZ
RHY
1997
Power ISO or EEC KW-rpm
66-4000
80-4000
66-4000
80-4000
80-4300
94.5-4300
Power DIN (HP-rpm)
90-4000
110-4000
90-4000
110-4000
110-4300
130-4300
Torque ISO or EEC (m.daN-rpm)
19.6-2250
25-1750
20.5-1750
27-1750
25-2000
28.5-2000
Torque DIN (mkg-rpm)
20.5-2250
26-1750
21.3-1750
-1750
26-2000
30-2000
4300
5100
Max. speed (rpm)
4500
5300
38
ENGINE
COMPRESSION
RATIO
MINIMUM VALUE
(- 20 ‰)
ALL TYPES
MAX. SPACING
BETWEEN CYLINDERS
in Bars
XUD 7 / 9
25 to 30
20
XUD 11
19 to 21
15
DW10
DK5
30 ± 5
25 to 30
20
39
5
ENGINE
COMPRESSION RATIO - DIESEL ENGINES
ENGINE
XANTIA - XM
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN )
Engines : BFZ – BFX - LFX - LFY - RFV - RGX
CYLINDER HEAD (mm)
Engine type
BFZ
BFX
LFX
LFY
Maximum permissible bow
0.05
Gasket surface regrinding
- 0.20
RFV
RGX
TIGHTENING TORQUES (m.daN)
Crankshaft bearing screws :
- Pre-tightening
- Tightening
- Angular tightening
5.5 ± 0.5
-
Connecting rod screws
- Pre-tightening
- Tightening
- Angular tightening
4±0.4
2±0.2
70°±7°
5
Flywheel screw
12
Crankshaft pulley screw
Pulley screw at end of camshaft
7 ± 0.7
-
5.5±0.5
7.5±0.7
WARNING : After removing the crankshaft pulley, carry out the following operations :
- Clean the thread (Tap 14X150)
- Fit a NEW washer
- Fit a NEW screw.
- Tighten (see table above)
40
5.5±0.5
SYNERGIE
Engine : RFN
Maximum permissible bow
0.05
Gasket surface regrinding
- 0.20
Crankshaft
Bearing cap screws.
- Pre-tightening
- Angular tightening
Con-rod cap screws.
- Tightening
- Untightening
- Tightening
- Angular tightening
2 ± 0.1
60° ± 6°
Accessories drive pulley hub
- Pre-tightening
- Angular tightening (Sintered washer)
- Angular tightening (Steel washer)
7.5 ± 0.7
Engine flywheel
- Pre-tightening
- Tightening
2 ± 0.2
21° ± 3°
Clutch plate
2 ± 0.2
2.3 ± 0.2
46° + 2° - 4°
Con-rod nuts.
- Pre-tightening
- Angular tightening
Accessories drive pulley
- Tightening
- Angular tightening
Camshaft pulley hubs
2.1 ± 0.1
4 ± 0.4
40° ± 4°
53° ± 5°
41
ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN )
ENGINE
XANTIA - XM
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN )
Engines : LFY - RFV
CYLINDER HEAD COVER
XM - XANTIA
LFY - RFV
- Pre-tighten : 0.5
- Tighten
:1±0.1
B1DP01YD
42
XANTIA - XM - V6
Engine : XFZ
B1BP1HAP
43
(1) Compact coil unit
1 ± 0.1
(9) Flywheel
- Tightening
- Angular tightening
1
60°± 6°
(11) Connecting rod caps
- Tightening
- Angular tightening
2±
74° ± 7
(12) Crankshaft hub
- Tightening
- Angular tightening
4 ± 0.4
80° ± 8°
(13) Crankshaft pulley
2.5 ± 0.2
ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN )
ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN )
XANTIA - XM - V6
Engine : XFZ
- 2 Cylinder head cover (A) Front cyl. head - (B) Rear cyl. head
- 3 Bearing caps housing (A) Front cyl. head - (B) Rear cyl. head
B1DP08UD
B1DP08TD
WARNING : Tighten screw by screw in the order shown.
- Pre-tighten
- Tighten
0.5
1 ± 0.1
- Pre-tighten
- Tighten
44
0.2
0.8
XANTIA - XM - V6
Engine : XFZ
- 5 Air inlet manifold
- 6 Lower manifold (A) Front cyl. head - (B) Rear cyl. head
B1DP097C
B1HPOLJC
WARNING : Tighten screw by screw in the order shown.
- Pre-tighten
- Tighten
1 ± 0.1
2 ± 0.2
- Pre-tighten
- Tighten
45
1 ± 0.1
2.5 ± 0.2
ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN )
ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN )
XANTIA - XM - V6
Engine : XFZ
- 7 Exhaust manifold (NEW seal)
- 10 Oil sump
B1BP1GXD
B1BP1GZD
WARNING : Tighten screw by screw in the order shown.
- Pre-tighten
- Tighten
1 ± 0.1
3 ± 0.3
- Pre-tighten
- Tighten
46
0.5 ±
0.8 ±
XANTIA - XM - V6
Engine : XFZ
- 8 Crankshaft bearing
- Clean the threads of the screws with a brush.
- Refit the screws with a coating of grease ( MOLYKOTE G RAPID PLUS ).
- Check that the 8 centring pins are in place.
Maximum length under the heads of the screws :
- M11 = 131.5 mm.
- M8 = 119 mm.
- Pre-tighten the M11 screws to 3 m.daN ± 0,3 (1 to 8).
- Pre-tighten the M8 screws to 1 m.daN ± 0,1 (A to H).
- Tighten the M6 screws to 1 m.daN ± 0,1 (a to m).
- Slacken the M11 and M8 screws (screw by screw).
- Tighten the M11 screws to 3 m.daN ± 0,3 (1 to 8).
- Tighten the M8 screws to 1 m.daN ± 0,1 (A to H).
B1BP1GYD
47
ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN )
ENGINE
ENGINE
XANTIA - XM - V6
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN )
Engine : XFZ
B1BP1HBD
48
(14) Water pump
- Pre-tighten
- Tightening
0.5
0.8
(15) Oil pump
- Pre-tighten
- Tightening
0.5
0.8
(16) Guide roller
8 ± 0.8
(17) Tensioner roller
8 ± 0.8
(18) Camshaft hubs
- Pre-tighten
- Tightening
2 ± 0.2
57° ± 5°
(19) Camshaft pulley
1 ± 0.1
Engine : XFZ
- 20 Oil fumes recovery unit.
WARNING : Tighten screw by screw in the order shown.
- Pre-tighten 0.5 ±
- Tightening
B1BP1H1D
49
1 ± 0.1
ENGINE
XANTIA - XM - V6
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN )
ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN )
DIESEL - All Types
Engines : DHX - P8C - RHY - RHZ - RHW - THY
CYLINDER HEAD (mm)
Engine type
DHX
P8C
Maximum permissible bow
0.07
0.05
RHY
RHZ
0.03
- 0.40
- 0.20
Gasket surface regrinding
RHW
THY
0.05
TIGHTENING TORQUES (m.daN)
Crankshaft bearing screws :
- Pre-tightening
- Tightening
- Angular tightening
1.5 ± 0.1
60° ± 6°
2.5 ± 0.2
60 ± 6°
Connecting rod screws :
- Pre-tightening
- Angular tightening
2 ± 0.2
70° ± 7°
2 ± 0.2
60°±6°
2 ± 0.2
65° ± 6°
5 ± 0.5
Flywheel screw
Crankshaft pulley screw :
- Pre-tightening
- Angular tightening
4 ± 0.4
51° ± 5°
Pulley screw at end of camshaft
4.5 ± 0.4
7 ± 0.7
60° ± 6°
4 ± 0.4
51° ± 5°
4.3 ± 0.4
WARNING : After removing the crankshaft pulley, carry out the following operations : (Except for THY engines).
- Clean the thread (Tap 14X150)
- Fit a NEW washer
-Fit a NEW screw.
- Tighten (see table above)
50
7 ± 0.7
51° ± 5°
XANTIA - XM
Engines : BFZ – BFX - LFX - LFY - RGX - RFV
IDENTIFICATION OF THE CYLINDER HEAD GASKET
Engine types
BFZ
Identification marks
CURTY
Suppliers
MEILLOR
BFX
LFX
LFY
RGX
(Notch on cylinder head gasket)
A
1
B
0
RFV
*
C
0
D
0
E
0
A
0
0
0
B
1
0
0
0
C
0
1
0
1
D
0
0
0
0
E
0
0
1
0
1
*
B1BP004C
51
0 = Without notch
1 = One notch
ENGINE
CYLINDER HEAD
ENGINE
XANTIA - XM
CYLINDER HEAD (continued)
Engines : BFZ – BFX - LFX - LFY - RGX - RFV
Cylinder head tightening (m.daN)
Cylinder head bolts
BFZ – BFX - LFX – LFY
- Pre-tightening
- Loosening
- Tightening
- Angular tightening
6
YES
2
300°
Note : Oil the threads
and under the heads of
the cylinder head bolts.
(Use engine oil or
Molykote G Rapid Plus).
RGX – RFV
- Pre-tightening
- Loosening
- Tightening
- Angular tightening
3.5
NO
7
160°
B1DP05BC
52
B1DP13PC
X = MAXIMUM reusable length
BFZ - BFX
LFX
LFY
RGX
RFV
171.5 mm
160.5 mm
122 mm
112 mm
Engine : RFN
Identification of the cylinder head gasket
Nominal dimension
Repair dimension
4-5
2-4-5
Marking zone
"d"
Marking zone
"e"
Gasket thickness
(mm)
Supplier
0.8
R1
R2
1.1
1.4
MEILLOR
Multilayer metallic gasket
B1DP183D
53
ENGINE
SYNERGIE
CYLINDER HEAD
ENGINE
CYLINDER HEAD (continued)
SYNERGIE
Engine : RFN
Cylinder head tightening (m.daN)
Cylinder head bolts
RFN
Pre-tightening
Tightening
Loosening
Tightening
Angular tightening
1.5 ± 0.1
5 ± 0.1
360° ± 2°
2 ± 0.75
285° ± 5°
B1DP16FC
Note : Oil the threads and
under the heads of the cylinder
head bolts. (Use engine oil or
Molykote G Rapid Plus).
A = Washer thickness : 4 ± 0.2 mm.
X = Length under heads of new bolts = 144.5 ± 0.5 mm.
X = MAXIMUM reusable length
RFN
X = 147 mm
B1DP05BC
54
Engine : XFZ
IDENTIFICATION OF THE CYLINDER HEAD GASKET
Supplier
Thickness
(mm)
Ident. marks
(1) and (2)
ERLING
1.45 ± 0.04
Centre tab
Front
Rear
B1DP09TC
55
ENGINE
XANTIA - XM
CYLINDER HEAD
ENGINE
CYLINDER HEAD (continued)
XANTIA - XM
Engine : XFZ
Cylinder head tightening (m.daN)
Cylinder head bolt
- Pre-tighten
Front
- Loosen
2
YES
- Tightening
1.5
- Angular tightening
225°
Note : Oil the threads and under the
heads of the cylinder head bolts.
(Use engine oil or Molykote G Rapid
Plus).
Rear
X = MAXIMUM reusable length
XFZ
B1DP09UC B1DP09VC
56
149.5 mm
Engine : DHX
IDENTIFICATION OF THE CYLINDER HEAD GASKET
Engine type
DHX
Piston
stand-proud (mm)
Thickness
(mm)
± 0.06
0.56 to 0.67
1.36
0.68 to 0.71
1.40
0.72 to 0.75
1.44
0.76 to 0.79
1.48
0.80 to 0.83
1.52
DHX
Marking
(B)
(A) = Engine identification.
(B) = Thickness identification.
B1BP10TC
57
Engine
Ident. (A)
Ident. (B)
DHX
3 notches
1 to 5 notches
ENGINE
XANTIA
CYLINDER HEAD
ENGINE
ENGINE
XM
CYLINDER HEAD (continued)
Engine : P8C
IDENTIFICATION OF THE CYLINDER HEAD GASKET
Engine type
P8C
Piston stand-proud
(mm)
Thickness
(mm)
Position of
hole(s)
0.65 to 0.76
1.52
B - A1
0.77 to 0.81
1.57
B - A2
0.82 to 0.86
1.62
B - A3
0.87 to 0.91
1.67
B - A4
0.92 to 0.96
1.72
B - A5
Reconditioning
Ident.
(A) and (B)
B - A1 - A5
B1BP1DTC
58
Engine : RHZ - RHY
IDENTIFICATION OF THE CYLINDER HEAD GASKET
Engine
type
RHZ
RHY
Piston standproud (mm)
Thickness
(mm)
No. of notches
at A
0.47 to 0.605
1.30 ± 0.06
1
0.605 to 0.655
1.35 ± 0.06
2
0.655 to 0.705
1.40 ± 0.06
3
0.705 to 0.755
1.45 ± 0.06
4
0.755 to 0.83
1.50 ± 0.06
5
B1DP15AD
59
ENGINE
XANTIA - SYNERGIE
CYLINDER HEAD
ENGINE
CYLINDER HEAD
XANTIA - XM - SYNERGIE
Engines : DHX - RHZ - RHY - P8C
Cylinder head tightening (m.daN)
Cylinder head bolts
DHX - P8C
P8C
- Pre-tightening
2
- Tightening
- Angular tightening
RHZ - RHY
6
180°
DHX - RHZ - RHY
- Pre-tightening
2
- Tightening
6
- Angular tightening
220°
Note : Oil the threads and under the heads of the cylinder
head bolts. (Use engine oil or Molykote G Rapid Plus).
X = MAXIMUM reusable length
B1DP05BC
B1DP13PC B1DP15EC
60
DHX
P8C
RHZ - RHY
150.5 mm
151.5 mm
133.3 mm
Engine : THY
Identification of the cylinder head gasket
Engine type
Thickness
(mm)
Ident.
THY
1.6
None
Cylinder head tightening ( m.daN)
Cylinder head bolts
Pre-tightening the bolts :
- 1 à 14
(Bolt Ø 12)
- 15 à 22
(Bolt Ø 10)
5
3.5
Angular tightening :
- 1 à 22
(Bolt Ø 12 and 10)
120° ± 5°
Note : Oil the threads and under
the heads of the cylinder head
bolts. (Use engine oil or
Molykote G Rapid Plus). B1DP15EC
X = MAXIMUM reusable length
B1DP03XC
61
Bolt Ø 12
Bolt Ø 10
153.5 mm
162.5 mm
ENGINE
XM
CYLINDER HEAD
4099-T (C.TRONIC.105)
Tools
B1EP135D
62
!
!
BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE
!
ENGINE
ALL TYPES
4122-T (C.TRONIC.105.5)
!
Engines : All Types Petrol and Diesel
TOOL
- 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 62.
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.
63
ALL TYPES
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
ENGINE
XANTIA - XM
AUXILIARY EQUIPMENT DRIVE BELT
Engines : BFZ - LFX - LFY - RFV - RGX
Without air conditioning
[1] Belt tension measuring instrument :
4122-T
- (3) and (5) Roller support fixing screws.
- (6) Tensioning screw.
- Tighten the belt, by loosening the screw (6) to : In SEEM units
BFZ-LFX
LFY
RFV-RGX
100 ± 10
120 ± 10
100 ± 10
- Tighten the screws (3) and (5).
- Rotate the crankshaft by 4 turns (direction of rotation).
- Loosen the screws (3) and (5).
- Tension the belt, by slackening the screws (6) to : In SEEM units.
BFZ-LFX
LFY
RFV-RGX
115 ± 5
120 ± 10
105 ± 10
- Tighten the screws (3) and (5) to 2 m.daN.
64
B1BP00HC
B1BP00IC
Engines : BFZ - LFX - LFY - RFV - RGX (Continued)
With air conditioning
- Loosen :
- The screws (4) of the tensioner roller (13 mm angle spanner).
- The screw (3).
- Tension the belt using the screw (3) to obtain :
- New belt :
120 SEEM units.
- Reused belt :
90 SEEM units.
- Tighten the screws (4) to 2 m.daN.
- Rotate the crankshaft by 4 turns (direction of rotation).
- Adjust the belt tension (if necessary).
B1EP05FC
65
XANTIA - XM
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
ENGINE
XANTIA - XM
AUXILIARY EQUIPMENT DRIVE BELT
Engines : BFZ - LFX - LFY - RFV - RGX (Continued)
With air conditioning
- Fit the drive belt.
- The tensioner roller (1).
- Tighten the screws (3) to 2 m.daN.
- Turn 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
66
SYNERGIE
Engine : RFN
Without air conditioning
With air conditioning
Tools
[1] Plyers 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).
B1BP23PC
B1BP23QC
B1BP23PC
67
B1BP23RC
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
ENGINE
XANTIA - XM
AUXILIARY EQUIPMENT DRIVE BELT
Engine : XFZ
With air conditioning
Removal :
- Release the bolt (3).
- Keep the dynamic tensioner (1) tensioned by holding the hexagonal fixture «a».
- Release the shoulder of the screw (2) from the oblong hole of the dynamic tensioner.
- Release the dynamic tensioner (1) using the hexagonal fixture «a».
- Remove the belt.
Refitting :
- Locate the dynamic tensioner (1) in its operating position using the hexagonal fixture «a».
(The tensioner (1) will automatically tension it).
- Tighten the screws (2) and (3) to 2.5 m.daN.
B1BP1EXC
68
Engines : DHX - P8C
Without air conditioning
[2] Belt tension measuring instrument
4122-T
- Tighten the belt, by loosening the screw (4) to obtain:
- 115 ± 10 SEEM units.
- Tighten the screws (1) and (3).
- Rotate the crankshaft by 4 turns (Direction of rotation).
- Loosen the screws (1) and (3).
- Tighten the belt to :
- 115 ± 10 SEEM units (if necessary).
- Tighten the screws (1) and (3) to 2 m.daN.
B1BP10GC
69
B1BP10HC
ENGINE
XANTIA - XM
AUXILIARY EQUIPMENT DRIVE BELT
ENGINE
XANTIA
AUXILIARY EQUIPMENT DRIVE BELT
Engines : DHX
With air conditioning
- Loosen the screws (1).
- Tighten or loosen the screw (2) until holes «a» and «b» are superimposed.
- Locate the peg [1] : (in the hole «a»).
DHX peg 7019-T.
- Tighten the screw (2) until it stops..
- Loosen the screw (2), so the peg [1] can be removed.
- Tighten the screws (1) to 2 m.daN.
B1BP1HHC
70
Engines : P8C
With air conditioning
- Engage the square drive tool [2] (9.52 mm - 3/8), in its location in the tensioner
arm (b).
- Compress the damper (1) using the tool [2].
- Peg the damper (1) at «a» using the tool [3] 7019- T.
(Tensioner in locking position).
- Remove the tool [2] and loosen the screw (2) of the roller (3).
- Position the belt on :
The crankshaft, the tensioner roller, the high pressure pump, the eccentric roller,
the air conditioning compressor.
- Tighten the belt, roller (3) tool [4] 5711- T.E.
NOTE : Tighten the screw (2) of the roller (3) when the tool [3] slides freely into its
pegging location.
- Tighten the screw (2) to 5 m.daN.
B1BP1HFC
B1BP1HEC
B1BP1HDC
71
B1BP1HCC
ENGINE
XM
AUXILIARY EQUIPMENT DRIVE BELT
ENGINE
XANTIA - SYNERGIE
AUXILIARY EQUIPMENT DRIVE BELT
Engine : RHY - RHZ
Without air conditioning
Tools
[1]
[2]
[3]
[4]
Belt tension adjusting square
Ø 4 mm peg
Ø 2 mm peg
Dynamic tensioner compression lever
: (-).0188 J2
: (-).0188.Q1
: (-).0188.Q2
: (-).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».
- Hold the tensioner roller (2) compress and remove the belt.
- Loosen the screw (1).
B1BP1YKD
72
Engine : RHY - RHZ
Without air conditioning (continued)
Refit.
Re-used belt.
- Compress the tensioner roller (2) by action at «a» (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 (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.
B1BP1YMD
73
ENGINE
XANTIA - SYNERGIE
AUXILIARY EQUIPMENT DRIVE BELT
ENGINE
XANTIA - SYNERGIE
AUXILIARY EQUIPMENT DRIVE BELT
Engine : RHY - RHZ
With air conditioning
[1]
[2]
[3]
[4]
Tools
Belt tension adjusting square
Ø 4 mm peg
Ø 2 mm peg
Dynamic tensioner compression lever
:
:
:
:
(-).0188 J2
(-).0188.Q1
(-).0188.Q2
(-).0188.Z
Remove
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.
B1BP1YLD
74
XANTIA - SYNERGIE
Engine : RHY - RHZ
With air conditioning (continued)
Refit.
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.
B1BP1YND
75
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
ENGINE
XM
AUXILIARY EQUIPMENT DRIVE BELT
Engine : THY
With air conditioning
WORN BELT.
- Loosen the screw (2) using tool [2] 5714-T.R (6 mm across the flats).
- Move the roller (3), using tool [3] 5714-T.S (6 mm across the flats) until tool [1] 5714 - T.Q.
(Ø 4 mm) fits in the hole (5) of the automatic tensioner (4).
NOTE :If there is insufficient roller movement (3), move the tensioner (4) using a ratchet wrench (9.52 mm) plus
extension, so that the tool [1] (Ø 4 mm) fits in the hole (5).
- Remove the belt.
BROKEN BELT.
- Move the tensioner (4) using a ratchet wrench (9.52 mm) plus extension so that the tool [1] 5714-T.Q (Ø 4 mm)
fits in the hole (5).
B1BP051C
B1BP052C
76
XM
Engine : THY
With air conditioning (continued)
NEW BELT.
- ove the roller (3), with tool [3] 5714-T.S (6 mm across the flats) until tool [1] 5714-T.Q (Ø 4 mm) is released.
- Hold the roller (3) in this position and tighten the screw (2) using tool [2]. Tighten to 3.2 m.daN.
- Rotate the crankshaft by 5 turns (Direction of rotation) = 1 turn of the belt.
- Check the tension by inserting the tool [1] (Ø 2 mm) in the hole (5) of the automatic tensioner (4).
- If the tension is not correct, repeat the tensioning procedure.
B1BP051C
77
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
ENGINE
XM
AUXILIARY EQUIPMENT DRIVE BELT
Engine : THY
With air conditioning (continued)
REUSED BELT
- Continue in the same way as for a new belt.
NOTE : In certain cases the roller (3) is in its maximum stop position, and it is not possible to remove the tool
[1] 5714-T.Q (Ø 4 mm) .
- Move the roller (4) using a ratchet wrench (9.52 mm) plus extension to release the tool [1].
- Rotate the crankshaft by 5 turns (Direction of rotation) = 1 turn of the belt.
Measure distance X :
- If measurement X is less than 98 mm, the belt is correctly tensioned.
- If measurement X is more than 98 mm, the belt must be replaced.
B1BP054C
78
XM
Engine : THY
TOOLS
-
[5] Belt tension measuring instrument
[1] Flywheel locating peg
[2] Camshaft pinion locating peg
[3] Injection pump peg
[4] Balance shaft peg
[6] Tensioning lever
: 4122-T
: 7014-T.J.
: 5711-T.A.
: 5711-T.B.
: 5711-T.D.
: 5711-T.E.
Tool kit 7004-T
Tool kit 5711-T
Removal
- The auxiliary equipment and timing belt (See pages 76 to 78 and 115 to 117).
- Peg the balance shafts using the tools [4].
- Remove the guide roller (1).
- Loosen the screw (2) (freeing the roller).
- Remove the balance shaft belt.
B1BP04QC
79
ENGINE
BALANCE SHAFT BELT
ENGINE
XM
BALANCE SHAFT BELT
Engine : THY (continued)
Refitting
- Check that the rollers work properly.
- The balance shaft belt.
- Remove the tool [4].
- Fit the tool [5] to the belt.
- Pre-adjust the tension using the tool [6]. (Placed in the square locating hole of the tensioner roller).
Adjust the tension to :
- New belt 70 SEEM units.
- Reused belt 51 SEEM units.
- Tighten the roller to 4.5 m.daN.
Checking the fitting pre-tensioning.
- Remove and refit the tool [5]. ( Make any necessary corrections).
Fit :
- The guide roller (1), tighten to 4.5 m.daN.
- The timing belt (See pages 115 to 117).
- Pre-tension, then tension the timing belt (See pages 115 to 117).
B1BP04RC
80
DK5 - All Types
Engine : THY (continued)
NOTE : Rotate the crankshaft by 10 turns (if this wasn’t carried ort when refitting the timing belt).
- Loosen the screw (2) to release the tensioner roller.
- Fit the tool [5].
- Adjust the belt tension using the tool [6]. (Inserted in the square hole in the tensioner roller).
Adjust the tension to :
- New belt 31 SEEM units.
- Reused belt 26 SEEM units.
- Tighten the tensioner roller to 4.5 m.daN.
CHECKING THE FITTING TENSION
- Remove and refit the tool [5]. (Make any necessary corrections).
- Remove the tool [5].
B1BP04SC
CHECKS
- Rotate the crankshaft by 2 turns.
- Peg the flywheel, (behind the engine) using the tool [1].
- To check that a tooth hasn’t been missed, visually check the pegging of the following components :
- the injection pump.
- the camshaft.
- the balance shafts.
- Remove the tool [1].
81
ENGINE
BALANCE SHAFT BELT
ENGINE
XM
WATER PUMP BELT
Engine : THY
Removal
- Loosen the screw (19).
- Turn the screw (20) in the same direction as if tightening in order to slacken the belt.
- Remove the belt (21).
Refitting
- Refit the belt (21).
- Fit the measuring instrument [2] 4122-T to the belt.
- Loosen the screw (20) to tighten the belt.
NEW belt = 46 SEEM units.
Reused belt = 38 SEEM units.
- Remove the tool [2].
- Rotate the crankshaft by 3 turns (direction of rotation).
- Fit the tool [2].
- Check the belt tension:
NEW belt = 46 SEEM units.
Reused belt = 38 SEEM units.
- Retighten the screw (19).
- Remove the tool [2].
•
•
•
•
B1GP016C
82
ALL TYPES
EW
XU
5
7
JB
JP
Engine type
XANTIA
10
JP
JP4
J2TE
1.8 i
1.8 i 16 V
BFZ
LFX
LFY
# 11/97
LFY
11/97 #
X
X
X
X
RGX
X
9
J4R
2.0 i
Turbo CT
1.6 i
XM
J4
2.0 i 16 V
3.0 i
RFV
# 11/97
RFV
11/97 #
X
X
X
X
X
X
SYNERGIE
See pages :
ES
RFN
XFZ
X
85 to 86
87 to 91
82 to 96
83
85 to 86
87 to 91
92 to 96
97 to 101
102 to 106
ENGINE
CHECKING AND SETTING THE VALVE TIMING
ENGINE
ALL TYPES
CHECKING AND SETTING THE VALVE TIMING (continued)
XUD
DW
XUD
DK
9
10
11
5
ATED4
BTE
ATE
2.0 HDi 16V
2.1 TD
2.5 TD
RHW
P8C
THY
X
X
113 to 114
115 to 117
BTF
TD
2.0 HDi
1.9 TD
Engine type
XANTIA
ATED
DHX
RHY
RHZ
X
X
X
XM
SYNERGIE
See pages :
X
107
108 to 112
84
X
Engine : BFZ - LFX - RGX
TOOLS
-
Belt tension measuring instrument
Camshaft pulley locating peg
Crankshaft locating peg
Square drive
: 4099-T or 4122-T
: 7004-T.G.
: 7014-T.N.
Tool kit 7004-T
: 7017-T.W.
CHECKING THE VALVE TIMING
- Remove the protective covers.
- Peg the camshaft pulley at «a» using the tool 7004 - T.G.
- Peg the crankshaft at «b» using the tool 7014 - T.N.
SETTING THE VALVE TIMING
- Check that the pegs can be engaged correctly at «a» and «b».
- Fit the belt in the following order : camshaft pulley, crankshaft pinion, water pump pinion,
tensioner roller.
- Peg the camshaft pulley at «a» and the crankshaft at «b».
- Remove the peg at «b» only.
- Bring the tensioner roller (2) into contact with the belt.
B1EP07RC
85
ENGINE
CHECKING AND SETTING THE VALVE TIMING
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines : BFZ - LFX - RGX (continued)
SETTING THE VALVE TIMING
- Fit the tension measuring tool to the middle of the belt strip «c».
- Turn the tensioner roller (2) (anti-clockwise direction) using the tool 7017-T.W to obtain the following
measurements :
- Engines : LFZ - LFW : 30 ± 2 SEEM units.
- Engines : RGX - RFU : 16 ± 2 SEEM units.
- Tighten the screw (1) to 2m.daN.
- Remove the tools.
- Rotate the crankshaft by two turns (do not turn backwards).
- Check the setting by positioning the pegs at «a» and «b».
- Remove the pegs.
CHECKING THE TENSION
- Rotate the crankshaft by two turns (do not turn backwards).
- Peg the camshaft pulley at «a».
- Fit the tension measuring tool on the belt strip at «c».
- The tension measurement should be 44 ± 2 SEEM units.
(If the measurement is not correct, repeat the tensioning procedure).
- Remove the tools.
B1EP07SC
86
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : LFY - RFV # 11/97
TOOLS
- Belt tension measuring instrument.
- Crankshaft locating peg
- Camshaft pulley locating peg.
- Tensioning tool
- Toothed sector for locking the flywheel XM
- Toothed sector for locking the flywheel XANTIA
: 4099-T or 4122-T
: 7014-T.N.
: 9041-T.Z.
Tool kit 7004-T
: 7017-T.W.
: 6012-T
: 9044-T
CHECKING THE SETTING
- Turn the engine by the crankshaft screw (1).
- Ensure that the slot (a) for pegging the camshaft hubs can be seen (Conformity of hubs).
- Turn the engine by the screw (1) and peg the crankshaft at (2).
ESSENTIAL : Check that the crankshaft DAMPERS pulley is in good condition.
If the hub/pulley markings do not line up, the crankshaft pulley must be replaced.
- Peg the camshaft pulleys at (3). (The locating pegs should slide in easily).
If this is not the case :
- Check that the crankshaft pegs can be engaged correctly.
-Slacken the six screws (4) of pulleys (7) and (8).
-Peg the hubs at (3). (If necessary, turn the camshaft by the screw (5)).
-Tighten the screws (4) to 1 m.daN.
-Remove the pegs.
B1EP08JC
87
B1EP08KC
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines : LFY - RFV # 11/97 (continued)
RFV
SETTING THE VALVE TIMING
- Peg the crankshaft at (2).
- Peg the camshaft pulleys at (3).
- Loosen the tensioner roller (6).
- Remove the belt..
LFY
PREPARATION
- Loosen the three screws (4) of pulleys (7) and (8).
- Ensure that the pulleys (7) and (8) move freely on the hubs.
If this is not the case :
- Remove the pulleys (7) and (8).
- Clean the contact faces of pulleys (7) and (8) and of the camshaft hubs at (b).
- Fit the pulleys (7) and (8) onto the hubs, without tightening them.
NOTE : Pulleys (7) and (8) are identical.
(Timing angles, see pages: 118 (LFY) - 119 (RFV)
LFY and RFV engines = The camshaft hubs are different.
REFITTING THE TIMING BELT
- Fit the belt on the pulley (7).
- Fit a plastic clamping collar (c) to hold it in place.
- Wind the belt around the : pulley (8), roller (9), pinion (10), water pump (11) and
tensioner roller (6).
B1EP08LC
B1EP11UC
B1EP08UC
88
ENGINE
CHECKING AND SETTING THE VALVE TIMING
LFY
Engines : LFY - RFV # 11/97 (continued)
RFV
PRE-TENSIONING THE TIMING BELT
- Fit the tool 4122-T.
- Turn the roller (6) with the tool 7017-T.W.
Pre-tension to :
Engines
LFY - RFV
New belt
45 SEEM units
- Tighten the roller (6) to 2 m.daN, and the six screws (4) to 1 m.daN.
- Remove the tool 4122-T, the pegs (3) and the plastic clamp at “c”.
- Fit the timing cover (12), the pulley (13), the screw (1) (LOCTITE
E6 on the threading, tighten to 12 m.daN).
B1EP11VC
B1EP08VC
89
ENGINE
CHECKING AND SETTING THE VALVE TIMING
LFY
Engines : LFY - RFV # 11/97 (continued)
RFV
TENSIONING THE TIMING BELT
- Rotate :
Engines LFY - RFV = 2 turns of the crankshaft.
- Peg the crankshaft at (2).
- Loosen the six screws (4) of pulleys (7) and (8).
- Peg the hubs at (3).
(If necessary, turn the camshaft by the screw (5)).
- Desserrer le galet (6).
- Poser l’ortil 4122-T.
- Effectuer une tension de :
Engines
LFY - RFV
New belt
26 SEEM units
- Tighten the roller (6) to 2 m.daN.
- Remove the tools.
B1EP11WC
B1EP08WC
90
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines : LFY - RFV # 11/97 (continued)
SETTING THE VALVE TIMING (Cont.)
- Rotate the crankshaft by 2 turns.
- Peg the crankshaft at (2).
- Loosen the screws (4).
- Peg the hubs of pulleys (7) et (8) at (3).
(If necessary, turn the camshaft using the screw (5)).
- Tighten the screws (4) to 1 m.daN.
- Remove the pegs.
CHECKING THE BELT TENSION
- Rotate the crankshaft by 1/4 turn to align the locating peg hole (2) of the pulley (13), with the screw (14).
(Do not turn backwards).
- The tension measurements must be between:
Engines
LFY - RFV
New belt
36 ± 4 SEEM units
If the measurements are different, repeat the tensioning procedure.
B1EP08XC
91
B1EP08KC
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : LFY - RFV 11/97 #
TOOLS
-
[1] Belt tension measuring instrument
[2] Camshaft locating peg
[3] Crankshaft locating peg
[4] Camshaft pulley locking peg
[5] Tensioning tool
[6] Toothed sector for locking the flywheel
:
:
:
:
:
:
4122-T
9041-T.Z
7014-T.N
4200-T.G
7017-T.W
9044-T
Tool kit 7004-T
CHECKING THE SETTING
- Turn the engine using 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 markings do not line up, the crankshaft pulley must be replaced.
- Peg the camshafts 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 page 120).
B1EP12FC
92
B1EP12GC
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines : LFY - RFV 11/97 # (continued)
LFY
SETTING THE VALVE TIMING.
REFIT :
- Peg the crankshaft using tool [3].
- 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 screw (4) (Brush the screw thread).
- The pulley (5).
- The lower cover (6).
B1EP11XC
RFV
- The tool [6].
- The studs (8).
- Fit the tool [4].
- Loosen the screws (10).
- Remove the tool [4].
- Slacken the tensioner roller (7).
- Remove the belt (9).
B1EP120C
B1EP11ZC
93
ENGINE
CHECKING AND SETTING THE VALVE TIMING
LFY
Engines : LFY - RFV 11/97 # (continued)
RFV
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).
Engines
LFY - RFV
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).
B1EP11YC
B1EP121C
B1EP120C
94
ENGINE
CHECKING AND SETTING THE VALVE TIMING
LFY
Engines : LFY - RFV 11/97 # (continued)
RFV
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].
B1EP11YC
B1EP121C
B1EP120C
95
ENGINE
CHECKING AND SETTING THE VALVE TIMING
LFY
Engines : LFY - RFV 11/97 # (continued)
RFV
- Tension to : (Pulleys slackened).
Engines
LFY - RFV
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.
B1EP11YC
B1EP121C
B1EP120C
96
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : RFN
TOOLS
[1]
[2]
[3]
[4]
[5]
Camshaft setting pegs
Crankshaft setting peg
Belt locking pin
Angular tightening adaptor
Hub immobilising tool
:
:
:
:
:
(-).0189.B
(-).0189.B
(-).0189.K
4069-T.
6310-T
Tool kit C.0189.
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.
B1BP22SC
97
B1BP25PC
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : RFN
Checking the valve timing (continued)
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).
B1BP23XC
98
B1EP14JD
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : RFN
Refit (continued)
- 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.
B1EP14JD
99
B1EP14KC
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : RFN
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).
B1EP14LC B1EP14NC
100
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : RFN
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° with 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
101
B1BP23XC
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : XFZ
TOOLS
-
[1] Belt tension measuring instrument
[2] Crankshaft locating peg
[3] Camshaft pulley locating peg
[4] Timing checking peg
[5] Dynamic tensioner calibration shim
[6] Camshaft locking lever
[7] Belt retaining pin
:
:
:
:
:
:
:
4122-T
(-).0187 A
(-).0187 B
(-).0187 C.Z.
(-).0187 E.Z.
(-).0187 F
(-).0187 J.
Tool kit (-).0187
CHECKS
- Rotate the crankshaft by 2 turns (clockwise).
- Peg the crankshaft at (a), using tool [2].
- Check that the peg [4] can be freely engaged in the cylinder heads at the camshaft pulleys at (b).
B1EP09AC
102
B1EP103C
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : XFZ (continued)
SETTING THE VALVE TIMING
- Peg the crankshaft at (a) using tool [2].
- Loosen the camshaft pulley screws.
- Peg the camshaft pulleys at (b) using tool [3] in the following order :
- Camshaft pulley (1),(2),(3) and (4).
NOTE : If necessary use tool [6].
Preparation
- Remove the screws (5) and the plate (6).
- Screw in a M8x75 screw (7) to its stop.
- Fit a M8x40 screw (8).
- Fit the tool [5] by loosening the screw (7) if necessary.
- Tighten the screw (8) until it locks the tool [5].
- Loosen the screws (9).
- Loosen the screws (7) to slacken the belt.
- Mark the direction of fitting of the belt (if being reused).
- Remove the belt.
B1EP09CC
B1EP09EC
B1EP09DC
103
B1EP09FC
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : XFZ (continued)
SETTING THE VALVE TIMING
Refitting the belt.
- Check that the rollers (10), (11), (14) and (12) rotate freely.
- Rotate the camshaft pulleys (anti-clockwise) as far as the slots allow.
- Tighten the camshaft pulley screws to 0.5 m.daN.
- Loosen the camshaft pulley screws by 45°.
- Tighten the screws (9) to 1 m.daN.
- Loosen the screws (9) by 45°.
WARNING :Ensure that the belt is fitted in the right direction :
Facing the timing side, it should be possible to read the writing on the belt.
- Put the belt in place in the following order :
- Crankshaft pinion (hold the belt using the tool [7]), the guide roller (14)
camshaft pulleys (4) and (3), guide roller (10), camshaft pulleys (2) and (1),
tensioner roller (11), water pump pulley (15), guide roller (12).
B1EP09GD
104
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : XFZ (continued)
SETTING THE VALVE TIMING
NOTE : When positioning the belt on the camshaft pulleys, rotate it in an anti-clockwise direction in order
to engage the nearest tooth.
The angular displacement of the pulleys must not exceed one tooth.
- Lightly tighten the screw (7) so that the belt is lightly tensioned.
- Remove the tool [7].
- Fit the tool [1].
- Tighten the belt using the screw (7) to obtain a tension of : 83 ± 2 SEEM units = 50 daN.
ESSENTIAL : Check that the camshaft pulleys are not against the end of the slots.
(Otherwise, repeat the belt fitting operation).
- Remove the tools.
- Tighten the camshaft pulley screws in the following order: (1), (2), (3) and (4) Tighten to 1 m.daN.
- Tighten the screws (9) to 2.5 m.daN in the order indicated.
- Rotate the crankshaft by 2 turns (clockwise). Do not turn backwards.
- Peg the crankshaft using the tool [2].
- Loosen the camshaft pulley screws and the screws (9).
B1EP09HC
105
B1EP09JC
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : XFZ (continued)
SETTING THE VALVE TIMING
- Remove the screw (8).
- Loosen the screw (7) so that the tool [5] can move without any play..
- Wait for 1 minute (Damper action).
- Check that the tool [5] can move without any play.
- Remove the tool [5].
- Tighten the screws (9) to 2.5 m.daN (In the order indicated).
- Remove the screw (7) and the tool [2].
- Rotate the crankshaft by 2 turns (clockwise). (Do not turn backwards).
- Peg the camshafts in the order 4, 3, 2 and 1 as follows :
- Peg [3] ENGAGES : Loosen the camshaft pulley screws by 45°.
- Peg [3] DOES NOT ENGAGE : Loosen the camshaft pulley screws by 45° and turn the hub using the tool [6] until
the peg engages.
- The camshaft pulley screws must not be against the end of the slots.
(Otherwise, repeat the belt fitting operation).
- Tighten the camshaft pulley screws in the following order : 4, 3, 2 and 1. Tighten to 1 m.daN.
- Remove the tools.
- Rotate the engine by 2 turns.
- Check the timing.
B1EP102C
106
B1EP09BC
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines : DHX
TOOLS
- Crankshaft locating peg
- Camshaft and injection pump locating peg
: 7014-T.J. or 7014-T.R.
: 7004-T.G.
Tool kit 7004-T
CHECKS
- Peg the crankshaft.
- Peg the pulleys (1) and (2) at «a» and «b».
SETTING THE VALVE TIMING.
- Peg the crankshaft.
- Peg the pulleys (1) at «a» and (2) at «b».
- Fit the belt in the following order :
Crankshaft pinion, guide roller (3), injection pump pulley (2), camshaft pulley (1), tensioner roller (5), water
pump (4).
- Remove the pegs.
- Free the tensioner roller (5) (nut (6) and screw (7)), retighten the screw (7).
- Rotate the crankshaft by 2 turns. Do not turn backwards.
- Loosen the tensioner roller (5), allow the tensioner to operate.
- Retighten the screw (7) and the nut (6). Tighten to 1.8 m.daN.
- Check the setting.
NOTE : The injection pump is removed without changing the valve timing.
(immobilise the injection pump pulley using the screws (8x125) at «b»).
B1EP09KC
107
B1EP080C
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : RHY - RHZ
Tools
[1] Belt tension measuring instrument
[2] Tension lever
[3] Engine flywheel peg
[4] Belt compression spring
[5] Camshaft pinion peg
[6] Engine flywheel lock
[7] Set of blocking plugs
[8] Crankshaft pulley extractor
:
:
:
:
:
:
:
:
4122-T
(-).188.J2
(-).0288.D
(-).0188.K
(-).0188.M
(-).0188.F
(-).0188.T
(-).0188.P
Checking the setting of the valve timing.
Peg :
- The engine flywheel, tool [3].
- The camshaft, tool [5].
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).
B1BP1TTC
B1CP04CC B1BP1TSC
108
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : RHY - RHZ
Setting the valve timing.
Peg :
- The engine flywheel, tool [3].
- The camshaft, tool [5].
Loosen :
- The three screws (9).
- The screw (7) of the tensioner roller (6).
Remove the timing belt.
Checks.
IMPERATIVE : Just before refitting, carry out the checks below :
Check that :
- The rollers (6), (11) and the water pump (10) turn freely (without play or tightness).
- There are no traces of oil (on camshaft or crankshaft).
B1EP13DD
109
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : RHY- RHZ
Setting the valve timing (continued).
- Retighten screws (9) by hand.
- Turn the pinion (12) (clockwise) to the bottom of the
buttonhole.
- Refit the belt on the crankshaft, in the following
order, using the tool [4] to keep the belt tight at «a».
- Guide roller (11).
- Fuel high pressure pump pinion (13).
- Camshaft pinion (12).
- Water pump pinion (10).
- Tensioner roller (6).
NOTE : If needed, slightly turn the pinion (12) anticlockwise (not by more than one tooth).
- Remove the tool [4].
B1EP13ED
B1EP13FC
B1EP13GD
110
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : RHY - RHZ
Setting the valve timing (continued).
- Position tool [1] on the belt at «b».
- Turn the roller (6) (anti-clockwise) using tool [2] to attain a tension of :
98 ± 2 SEEM units
- Tighten screw (7) of the roller (6), tighten to 2.5 m.daN.
- Remove one screw (9) from the pinion (12).
(to check that the screws are not against the end of the buttonhole).
- Tighten the screws (9) 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 (9).
- Fit tool [5].
- Loosen screw (7) (to free the roller (6)).
- Fit tool [1].
- Turn the roller (6) (anti-clockwise), tool [2], to attain a tension of :
54 ± 2 SEEM units .
B1EP13HD
111
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : RHY - RHZ
Setting the valve timing (continued).
Tighten :
- The screw (7) of the roller (6) to 2.5 m.daN.
- The screw (9) to 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].
B1EP13HD
112
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : P8C
TOOLS
- Crankshaft peg
- Camshaft pulley and injection pump peg
: 7014-J or 7017-T.R.
: 7004-T.G.
Tool kit 7004-T
CHECKS
- Peg the crankshaft.
- Peg the camshaft pulley at «a» and the injection pump pulley at «b».
SETTING THE VALVE TIMING
- Peg the crankshaft.
- Peg the camshaft pulley at «a».
- Peg the injection pump pulley at «b».
To slacken the belt.
- Loosen the nut (9).
- Loosen the nut (3) and the screw (7) (5 mm six-sided spanner, 10 mm flat spanner).
- Move the tensioner roller eccentric (8).
- Retighten the nut (9).
- Remove the belt.
B1EP09LC
113
B1EP09MC
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : P8C (continued)
SETTING THE VALVE TIMING
- Fit the belt in the following order :
Injection pump pulley (2) (strap tensioned), engage half the width of the belt on :
the guide roller (4), the crankshaft pinion, the water pump pinion (5), the camshaft pulley (1),
the tensioner roller (6).
- Align the belt.
- Remove the three pegs.
- Loosen the nut (9).
- Rotate the crankshaft by 2 turns until the pegs can be engaged (without refitting the pegs).
- ESSENTIAL : Never turn the crankshaft backwards.
- Tighten the nut (9) Tighten to 1 m.daN.
- Rotate the crankshaft by 2 turns to reach the pegging point (without refitting the pegs).
- ESSENTIAL : Never turn the crankshaft backwards.
- Loosen the nut (9) by one turn and allow the spring to operate.
- Tighten the nut (9) and the screw (3). Tighten to 1 m.daN.
- Refit the three pegs.
NOTE : If it is impossible to refit one of the pegs, restart the belt fitting operation.
- Remove the pegs.
B1EP081C
114
B1EP082C
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : THY
TOOLS
- Belt tension measuring instrument
- Crankshaft locating peg
- Camshaft pulley locating peg
- Injection pump pulley locating peg
- Tensioner lever
: 4099-T or 4122-T.
: 7014-T.J.
Tool kit 7004-T
: 5711-T.A.
: 5711-T.B.
Tool kit 5711-T
: 5711-T.E.
CHECKS
- Peg the flywheel (behind the engine).
- Visually check the pegging of the following components :
- The camshaft pulley (1).
- The injection pump pulley (3).
SETTING THE VALVE TIMING
- Peg the flywheel (behind the engine).
- Peg the camshaft pulley (1).
- Peg the injection pump pulley (3).
- Loosen the screws (2) and (4), then manually retighten,
then loosen again by 1/6 of a turn.
- Turn the pulleys (1) and (3) to the end of the slots (clockwise).
B1EP11HC
115
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : THY (continued)
SETTING THE VALVE TIMING (continued)
- Fit the belt in the following order :
The crankshaft pinion (6),the guide roller (5), the injection pump pulley (3),
the camshaft pulley (1),the tensioner roller (7).
- If necessary, turn the pulleys (1) and (3) to make it easier to fit the belt.
- Fit the tool 4099-T or 4122-T.
- Pre-tension using the tool 5711-T.E to obtain a value of :
• New belt
: 107 SEEM units
• Reused belt : 80 SEEM units
- Tighten the tensioner roller (7) to 4.5 m.daN.
- Tighten the screws (2) and (4) to 2.5 m.daN.
- Remove the tools.
- Rotate the engine by 10 turns.
- Peg the flywheel.
- Loosen the screws (2) and (4) then manually retighten, then tighten again by 1/6 turn.
- Loosen the tensioner roller (7).
B1EP11JC
116
Engine : THY (continued)
CHECKING THE VALVE TIMING
- Peg the camshaft pulley (1).
- Peg the injection pump pulley (3).
- Fit the tool 4099-T or 4122-T.
- Tension using the tool 5711-T.E to obtain a value of :
• New belt
: 58 SEEM units
• Reused belt : 51 SEEM units
- Tighten the tensioner roller (7) to 4.5 m.daN.
- Tighten the screws (2) and (4) to 2.5 m.daN.
- Remove the tools.
- Rotate the engine by 2 turns.
- Check the setting.
B1EP11KC
117
ENGINE
CHECKING AND SETTING THE VALVE TIMING
ENGINE
SPECIAL FEATURES OF THE TIMING
XANTIA
LFY
Camshaft hub marking # 11/97
Identification marks a - b
Inlet camshaft
«a»
Exhaust camshaft
«b»
Number in mark c
Inlet camshaft
N° 1
Exhaust camshaft
N°2
Note : The identification marks are visible next to the pegging slot. Mark «c», bearing the number, is engraved on
the rear side of the hub (1).
B1EP11LC
B1EP11MC
118
XANTIA - XM
RFV
Camshaft hub marking # 11/97
1st possibility
2nd possibility
Identification marks a - b - c
Inlet camshaft
No mark
«b»
Exhaust camshaft
«a»
«c»
Mark number d
Inlet camshaft
N° 3
Exhaust camshaft
N° 4
Note : The identification marks are visible next to the pegging slot. Mark «c», bearing the number, is engraved on the
rear side of the hub (1).
B1EP11NC
B1EP11PC
119
ENGINE
SPECIAL FEATURES OF THE TIMING
ENGINE
SPECIAL FEATURES OF THE TIMING
XANTIA - XM
LFY - RFV
Camshaft hub marking 11/97 #
Engines
Hubs
‘‘a’’ Marking
‘‘b’’ Paint marking
Inlet
C
BLUE
Exhaust
D
BROWN
Inlet
A
GREEN
Exhaust
B
BLUE
LFY
RFV
B1EP122C
120
POSSIBLE PROCEDURES
For engines with 4 cylinders in a line (1-3-4-2 )
The valve clearances must be checked with the engine cold
● Inlet
Rocking
Petrol all types
(except 2.0i 16V
and 3.0i)
Petrol
2.0i 16V,
3.0i Diesel, 2.0HDi
0.20 mm ± 0.05
0.40 mm ± 0.05
Hydraulic adjustment
XM Diesel
Diesel All types
(except XM and 2.0 HDi)
0.15 mm ± 0.08
Fully open (Exhaust)
Rocking
Exhaust
Valves fully
open
Adjust
1●
1 4●
4
3●
3 2●
2
4●
4 1●
1
2●
2 3●
3
Exhaust
●
Inlet
1
Adjust
3 ●
4
3
4 ●
2
4
2 ●
1
2
1 ●
3
Engines without hydraulic
adjustment : the clearance (J)
should be checked opposite
the cam.
0.30 mm ± 0.08
B1DP13QC
121
ENGINE
ALL TYPES
VALVE CLEARANCE SETTING
ENGINE
CHECKING THE OIL PRESSURE
ALL TYPES
To be read with the Petrol and Diesel correspondence tables
XU All Types
Tool kit 4103-T
Engine type
1.6 i
1.8 i
1.8 i 16 V
BFZ
LFX
LFY
RFV
6
6.4
XUD
DHX
Temperature (°C)
Rpm
RGX
XFZ
RFN
2.0 HDi
RHY
RHZ
80°
4
5
4 000
122
90°
80°
4
5.5
5
3 000
DW
1.9 TD
Pressure (Bars)
3.0 i
4 000
Rpm
V6
2.0 i
Turbo CT
90°
5.3
Pressure (Bars)
XU
2.0 i 16V
80°
Temperature (°C)
Engine type
EW
XUD
DK
2.0 HDi 16V
2.1 TD
2.5 TD
RFW
P8C
THY
100°
90°
2.5
3
4 000
2 000
Engine type
1.6 i
BFZ
1.8 i
LFX
XU
All Types
Location
Tightening
torque (m.daN)
Above the oil filter
2.8
1.8 i 16 V
LFY
2.0 i
Turbo CT
RGX
EW
2.0 i 16 V
RFN
XU TT
2.0 i 16 V
RFV
Above the starter motor
3.4
V6 TT
3.0 i V6
XFZ
Near the oil filter
3.5
Warning lamp goes out at :
(Bars)
0.5
D6AP01MB
123
D6AP01ND
ENGINE
ALL TYPES
ENGINE OIL PRESSURE SWITCH
ENGINE
ENGINE OIL PRESSURE SWITCH
ALL TYPES
Engine type
1.9 TD
DHX
2.0 TD
P8C
Location
Tightening
torque (m.daN)
Above the oil filter
3.4
Near the oil filter
2.8
Warning lamp goes out at :
(Bars)
XUD
All Types
RHY
20 HDi
DW10
All Types
DK5
0.5
RHZ
2.0 HDi 16V
RHW
2.5 TD
THY
Above the starter motor
2.3
D6AP01MB
124
D6AP01ND
ALL TYPES
To be read with the Petrol and Diesel correspondence tables
Type of oil filters
to be fitted after
the 1st revision
PURFLUX
XU All Types
1.6 i
1.8 i
1.8 i 16 V
BFZ
LFX
LS 867
●
LS 304
●
ES9J4
2.0 i T.CT
2.0HDi 16V
LFY
2.0 i 16 V
RFV
RGX
RFN
●
●
●
●
●
●
●
●
3.0 i V6
XFZ
●
●
LS 880
Type of oil filters
to be fitted after
the 1st revision
XUD
DHX
PURFLUX
DW
1.9 TD
LS 867
●
LS 304
●
2.0 HDi
RHZ
RHY
KD
2.1 TD
2.5 TD
RHW
P8C
THY
●
●
●
●
●
●
LS 867
SPECIFICATION
XUD
2.0 HDi 16V
LS 304
LS 880
125
Ø (mm)
Height (mm)
76
89
86
97
ENGINE
OIL FILTERS
ENGINE
ALL TYPES
FILLING AND BLEEDING THE COOLING CIRCUIT
FILLING AND BLEEDING
- Fit the filling cylinder 4520-T to the filler orifice.
- 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 cooling fans have cut in and cut out.
- Stop the engine and allow it to cool down.
- Remove the filling cylinder 4520-T.
- Top up the system to the max. mark, with the engine cold.
- Refit the filler cap.
E5AP141C
126
XANTIA - XM - SYNERGIE
IDLING - ANTI-POLLUTION
Engine type
Idling speed (± 50 rpm)
Make - Injection type
1.6 i
BFZ
1.8 i
LFX
M. MARELLI 1AP20
LFY
SAGEM SL96 (Manual)/
BOSCH MP7.2 (Automatic)
1.8 i 16V
XANTIA
Emission
standard
Manual
gearbox
Auto. Gbox : N
gear engaged
850
800
% Content
CO
CO2
< 0.5
>9
< 0.5
>9
M. MARELLI 8P13
L3
1.8 i 16V
Dual fuel
LFY
1.8 i 16V
LFY
2.0 i 16V
RFV
BOSCH MP5.2
800
3.0 i V6
XFZ
BOSCH MP7.0
650 *
650
2.0 i 16V
RFV
XM
800
800
2.0 i Turbo CT
RGX
3.0 i V6
XFZ
650 (*)
650
SYNERGIE
2.0 i 16V
RFN
INJECTION
Vehicles
SAGEM SL96 (Petrol)/
NEKAM KOLTEC (LPG)
L4
L3
BOSCH MP7.3
BOSCH MP5.2
BOSCH MP3.2
BOSCH MP7.0
IF L5
M. MARELLI 48P2
*Variable speed depending on : Battery voltage, parking manoeuvre, temperature.
127
800
PETROL INJECTION
XANTIA
XANTIA
Engine type
1.6 i
1.8 i
1.8 i 16 V
Dual fuel
BFZ
LFX
LFY
INJECTION
Emission standard
Make
Injection type
Fuel pressure (bars)
L3
M. MARLELLI
8P13
M. MARELLI
1AP20
2.5
1.8 i 16 V
2.0 i 16 V
3.0 i V6
LFY
RFV
XFZ
L4
SAGEM
SL96
BOSCH
MP 7.3
3
/
3
L3
BOSCH
MP5.2
BOSCH
MP7.0
3
Overspeed cut-off (rpm)
6 300
6400
6500
M. MARELLI
1AP40
6500
6530
6520
Injection cut-in during
deceleration (rpm)
1 500
1400
1500
3
1500
1200
1100
16
14.5
16
6 500
14.5
14.5
12
Résistance injecteurs (en ohms)
Engine coolant temperature
sensor resistive value (ohms)
2 500 at 20° C
3800 at 10° C
Idling actuator or stepper
motor resistive value (ohms)
Air temperature sensor
resistive value (ohms)
800 at 50° C
230 at 90° C
800 at 50° C
230 at 90° C
Stepper motor : 53
3800 at 10° C
2 500 at 20° C
128
PETROL INJECTION
XM - SYNERGIE
Engine type
2.0 i 16 V
2.0 i Turbo CT
3.0 i V6
2.0 i 16 V
RFV
RGX
XFZ
RFN
L3
Emission standard
Make
Injection type
SYNERGIE
BOSCH
MP5.2
BOSCH
MP3.2
Fuel pressure (bars)
IF L5
BOSCH
MP7.0
3
Overspeed cut-off (rpm)
6 530
6 400
6 520
Injection cut-in during
deceleration (rpm)
1 200
1 400
1 100
14.5
16
12
Injector resistive value (ohms)
Engine coolant temperature
sensor resistive value (ohms
Idling actuator or stepper
motor resistive value (ohms)
Air temperature sensor
resistive value (ohms)
M. MARELLI
48P2
3 800 at 10°C
Stepper motor : 53
3 800 at 10°C
2 500 at 20° C
E.V. : 22
2 500 at 20° C
129
800 at 50°C
E.V. : 11
800 at 50°C
230 at 90° C
Stepper motor : 53
230 at 90° C
INJECTION
XM
ALL TYPES
ANTI-POLLUTION TECHNICAL CHECKS (FRANCE)
All Types Diesel (m-1)
All Types Petrol CO Corrected (In %)
Conditions : At idle, engine warm.
Features :
# 01/96
INJECTION
Less than 4.5 % for vehicles registered before 10/86.
Less than 3.5 % for vehicles registered after 10/86.
With catalytic converter
Greater than 2.0i 89 M.Y.
All Types
93 M.Y.
CO less than 0.5 % at idle speed.
CO less than 0.3 % at fast idle speed between 2500 and 3000 rpm (*)
(*) Except
TU5 JP
XU5JP
XU7JP
:
Xantia, MMDCM injection on 1.6i (BFZ) engine, 1.8i (LFZ)
engine and 2.0i (RFX) engine.
Should the check reveal excessive CO, make sure that the
ECU channel 25 is not connected to earth in error.
(See Info-rapid N° 77)
01/96
#
Atmospheric engine.
: 2200 rpm ± 100.
: 1500 rpm or 3100 rpm (± 100).
: 1500 rpm or 3100 rpm (± 100).
Less than 2.5 m-1
NOTE : On XU5JP and XU7JP engines at 1500 rpm, the check should be carried out
with main beams, rear heated screen and cabin ventilation switched on and with the
front wheels on maximum lock (if the vhicle has power-assisted steering).
Lambda Probe value 0.97 to 1.03.
130
Turbocharged engine.
Less than 3.0 m-1
EMISSION STANDARDS
APPLICATION
E.E.C.
PSA
A-S
RP
Engines
Vehicles
Private vehicles :
> 2 litres
• new cyl. < 2 litres
• existing cyl. < 2 litres
ECE
R 15.04
K
K’
15.04
15.04
W vp
15.05
➞ 06/89
➞ 06/92
➞ 12/92
Petrol
Brussels directive
83/351
➞ except special
derogations for certain
private vehicles
cyl. > 2 litres
➞ Utility vehicle limits
Private vehicles :
> 2 litres
• new models
• existing models
CHARACTERISTICS
Applicable
Petrol
Diesel
Utility vehicles :
All Types
ECE
R 15.05
ALL TYPES
NOTES
➞ 10/89
imminent
01/10/88 ➞
01/10/89 ➞
131
= private vehicle
limits increased
by 25 %
➞ For private vehicles
and utility vehicles
in major export
Brussels directive 88/76
" Luxembourg Accords "
➞ Replaced by 89/458
+ 91/441
INJECTION
STANDARD
With oxygen sensor,
without catalytic converter
ALL TYPES
EMISSION STANDARDS
APPLICATION
STANDARD
E.E.C.
INJECTION
ECE
R 15.05
US 83
PSA
A-S
RP
W vu 15.05
Z
US 83
Engines
Petrol
Diesel
Petrol
Diesel
Vehicles
Utility vehicles :
All Types
• new models
• existing models
Private vehicles :
• certain non-EEC
European countries
NOTES
CHARACTERISTICS
Applicable
01/10/88 ➞
01/10/89 ➞
➞ 10/94
Current
Brussels directives 88/76
and 88/436
➞ Utility vehicle limits
private vehicle limits of
Brussels directive 88/436
7 classes of limits by
vehicle weight
➞ Adoption of the U.S.
With oxygen sensor
and catalytic converter
for petrol vehicles
• certain Export countries
132
EMISSION STANDARDS
US 87
US 93
US 84
LDT
US 87
LDT
A-S
Y
Y2
X1
X2
Engines
Vehicles
Diesel
Private vehicles :
• certain non-EEC
European countries
• certain Export countries
Current
Petrol
Diesel
Private vehicles :
• certain Export countries
Current
US 84
Petrol
Diesel
Utility vehicles :
• certain non-EEC
European countries
• certain Export countries
Current
US 87
Petrol
Diesel
Utility vehicles :
• certain non-EEC
European countries
• certain Export countries
Current
RP
US 87
US 93
NOTES
CHARACTERISTICS
Applicable
➞ Adoption of the U.S.
standard
➞ Adoption of the U.S.
standard
133
➞ Adoption of the U.S.
standard for light utility vehicles
➞ Adoption of the U.S.
standard for light utility vehicles
With catalytic converter
and EGR
INJECTION
E.E.C.
PSA
ALL TYPES
APPLICATION
STANDARD
ALL TYPES
EMISSION STANDARDS
APPLICATION
STANDARD
E.E.C.
INJECTION
US 90
LDT
PSA
A-S
X3
RP
US 90
Engines
Petrol
Diesel
EURO 1
( EURO
93)
L1
CEE
19.5
Petrol
Diesel
Vehicles
CHARACTERISTICS
Applicable
Private vehicles :
• certain non-EEC
Current
European countries
• certain Export countries
Private vehicles :
< 1.4 litres
• new models
• existing models
NOTES
07/92 ➞
➞ 01/07/93
➞ 31/12/94
➞ Adoption of the U.S.
standard for light utility vehicles
Brussels directive
89/458
➞ Possible alternative to emission
standard L from 1992 to 1994
EURO 1
( EURO
93)
CEE
19.5
L
Petrol
Diesel
Private vehicles :
All Types
• new models
• existing models
• new models
• existing models
07/92 ➞
01/93 ➞
➞ 01/96
➞ 01/97
134
EU Brussels Directive 93/59
(91/441)
With oxygen sensor
and catalytic converter
for petrol vehicles.
With catalytic converter
and EGR for diesel
vehicles.
EMISSION STANDARDS
A-S
EURO 1
W2
(EURO
93)
RP
CEE
W2
Engines
Petrol
Diesel
Vehicles
Utility vehicles :
< 3.5 tonnes
• new models
• existing models
Class 1 :
• new models
• existing models
Class 2/3 :
• new models
• existing models
EURO2
(EURO
96)
L3
CEE
95
Petrol
Diesel
Private vehicles :
< 6 seats and
< 2.5 tonnes
• new models
• existing models
NOTES
CHARACTERISTICS
Applicable
01/10/93 ➞
01/10/94 ➞
➞ 01/97
➞ 10/97
Brussels directive 93/59
➞ 3 classes depending on
vehicle weight :
Class 1 < 1250 kg
Class 2 : 1250/1700 kg
Class 3 > 1700 kg
With oxygen sensor
and catalytic converter
for petrol vehicles
➞ 01/98
➞ 10/98
01/96 ➞
01/97 ➞
Brussels directive 94/12
➞ EURO 93 standard made
stricter
135
With oxygen sensor and
reinforced catalytic
converter for petrol
vehicles. With catalytic
converter and EGR for
diesel vehicles.
INJECTION
E.E.C.
PSA
ALL TYPES
APPLICATION
STANDARD
EMISSION STANDARDS
ALL TYPES
APPLICATION
STANDARD
E.E.C.
PSA
A-S
RP
INJECTION
EURO 2
(EURO
96)
W3
Petrol
Diesel
Gas
Petrol
EURO 3
L4
(EURO
2000)
CEE
95
Engines
CEE
Diesel
2000
Gas
Vehicles
Utility vehicles :
< 3.5 tonnes
Class 1 :
• new models
• existing models
Class 2/3 :
• new models
• existing models
Private vehicles :
All Types
• new models
• existing models
NOTES
CHARACTERISTICS
Applicable
Brussels directive 96/69
➞ 3 classes depending on
01/97 ➞
10/97 ➞
01/98 ➞
10/98 ➞
➞ 01/2000
➞ 01/2001
136
vehicle weight :
Class 1 < 1250 kg
Class 2 : 1250/1700 kg
Class 2 : 1 700 kg
Brussels directive 98/69
➞ EURO 2 standard (L3)
made stricter
➞ Fiscal incentives
With oxygen sensor and
reinforced catalytic
converter for petrol
vehicles. With catalytic
converter and EGR for
diesel vehicles.
With 2 oxygen sensors
and catalytic converter for
petrol vehicles.
With catalytic converter
and EGR for diesel
vehicles.With EOBD
on-board diagnosis.
ALL TYPES
EMISSION STANDARDS
APPLICATION
E.E.C.
PSA
A-S
EURO 3
W3
(EURO
2000)
RP
Engines
Petrol
Diesel
Gas
Vehicles
Utility vehicles :
< 3.5 tonnes
Class 1 :
• new models
• existing models
Class 2/3 :
• new models
• existing models
IF/ L5
Petrol
• new models
• existing models
CHARACTERISTICS
Applicable
➞ 01/2000
➞ 01/2001
➞ 01/2001
➞ 01/2002
Private vehicles :
All Types
EURO 4
NOTES
Brussels directive 98/69
➞ EURO 2 standard (L3
made stricter
➞ Fiscal incentives
➞ 3 classes depending on
vehicle weight :
Class 1 < 1305 kg
Class 2 : 1305/1760 kg
Class 2 : 1760 kg
Brussels directive 98/69
➞ EURO 3 standard (L4) )
➞ 01/2001
➞ 01/2003
diagnostic embarqué
EOBD
137
made stricter
➞ Fiscal incentives
With 2 oxygen sensors
and catalytic converter
for petrol vehicles.
With catalytic converter
and EGR for diesel
vehicles.
With EOBD on-board
diagnosis.
With 2 oxygen sensors
and catalytic converter
for petrol vehicles.
With EOBD on-board
diagnosis.
INJECTION
STANDARD
SAFETY REQUIREMENTS : PETROL/LPG DUAL FUEL SYSTEM
ESSENTIAL : Special precautions should be taken when dealing with gas powered systems
INJECTION
SAFETY REQUIREMENTS.
Only personnel who have been specially trained to work with petrol/LPG DUAL FUEL vehicles are authorised to carry out repairs to the
DUAL FUEL system.
- Ensure that these qualified personnel are provided with acrylic-free overalls (risk of static electricity).
In the event of a major gas leak
- Isolate the vehicle in the open air, away from any buildings.
- Call the emergency services (police and fire brigade) should the situation get out of hand.
138
SAFETY REQUIREMENTS : PETROL/LPG DUAL FUEL SYSTEM
ALL TYPES
Before removing the fuel tank or working on the gas circuit located
downstream of the safety electrovalve (on the gauge valve), perform
the following operations :
- Close the safety electrovalve.
- Switch the engine to use gas.
- Wait for the engine to stop due to lack of fuel.
Any work on a gas powered vehicle must be carried out in a ventilated
area.
Disconnect the battery negative terminal.
Ensure the vehicle is connected to earth.
Ensure the vehicle is kept away from the following hazards :
- Sparks.
- Flames.
- Slow combustion (lit cigarette).
After each operation, check that the circuit is sealed using one of the
following systems :
- Electronic detector .
- Soapy water.
- Any other leak detection product.
Remove the fuel tank when the vehicle is to be subject to high temperatures (above 50oC) (spray booth).
Do not clean the engine compartment with a high pressure device and
do not use detergents.
Drain the fuel tank using "flare" type material (following the
instructions for this material) before performing one of the following
operations :
- Remove the gauge valve.
- Working on the fuel tank.
139
INJECTION
PRECAUTIONS TO BE TAKEN BEFORE CARRYING OUT ANY REPAIR WORK
ALL TYPES
SPECIFICATIONS : PETROL/LPG DUAL FUEL SYSTEM
INJECTION
B1HPOQ5P
B1HPOQ4P
140
SPECIFICATIONS : PETROL/LPG DUAL FUEL SYSTEM
1) Fuel tank
- Capacity : 70 litres.
- Max. pressure : during tests / in operation : 30 bars / 20 bars.
- Max. operating temperature : 50°C.
- Location : in the boot.
ALL TYPES
7) Pressure sensor.
- Ssupply voltage : 5 volts.
- Location : on the evaporator control valve support.
2) Fuel gauge
- Supply voltage : 12 volts.
- Resistance : 0 to 15 ohms empty, 280 to 315 ohms full.
- Location : on the gauge valve.
8) Temperature sensor 15°C.
- Location : on the control valve reheating circuit.
3) LPG gauge valve.
- Location : on the fuel tank.
9) LPG filter.
- Type : paper.
- Replacement intervals: every 37,500 miles.
- Location : on the evaporator control valve inlet union.
4) Safety electrovalve.
- Supply voltage : 12 volts.
- Power : 8W.
- resistance : 18 ohms.
- Location : on the gauge valve.
10) Supply electrovalve.
- Supply voltage : 12 volts.
- Power : 8W.
- Resistance : 18 ohms.
- Location : on the evaporator control valve inlet union.
5) Filler orifice with safety valve.
- Location : on the rear right wing.
141
INJECTION
6) Injectors and valves.
- Location : in the engine compartment, under the air manifold.
ALL TYPES
SPECIFICATIONS : PETROL/LPG DUAL FUEL SYSTEM
11) Evaporator control valve.
- Make : NECAM.
- Typt : MEGA.
Setting pressure - 2nd stage.
- Setting pressure for a new evaporator control valve :
• - 970 ± 10 mb
INJECTION
- Setting pressure for a used evaporator control valve :
ESSENTIAL :
• - 960 ± 10 mb
Before checking and setting the pressure, it is essential that you
read through and follow closely BROCHURE : BRE 0332.
12) Stepper motor
- Location : on the distributor.
Setting pressure - 1st stage.
13) Distributor.
- Location : on the evaporator control valve support.
- Pression de réglage vaporisateur-détendeur neuf :
• 1450 ± 50 mb.
14) Distributor electrovalve.
- Supply voltage : 12 volts.
- Resistance : 25 ohms.
- Pression de réglage vaporisateur-détendeur ayant déjto servi :
•
1400 ± 50 mb.
142
PROHIBITED OPERATIONS: HDI DIRECT INJECTION SYSTEM
XANTIA - SYNERGIE
Engines : RHZ - RHY
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 regulateur (4) (no replacement parts).
- Sealing ring (1) (no replacement parts).
- High pressure outlet connector (3) (will cause a malfunction).
B1HP12CC
143
INJECTION
Cleaning.
- The use of high pressure cleaners is prohibited.
- Do not use compressed air.
XANTIA - SYNERGIE
PROHIBITED OPERATIONS: HDI DIRECT INJECTION SYSTEM
Engines : RHZ - RHY
INJECTION
B1HP12DC
B1HP12EC
High pressure fuel injection common rail.
- Do not separate the connectors (7) from the common injection rail (6)
(malfunction).
Diesel injectors.
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.
- It is forbidden to clean the carbon deposits from the diesel injector nozzle.
- Identification : Injector carrier.
There are 2 types of diesel injector carrier classed according to fuel flow.
Identification by engraving or paint mark
Injector carrier
Engraving
Class 1
1
Paint mark
Blue
Class 2
2
Green
Identification markings:
- "a" : Supplier identification.
- "b" : PSA identification number.
- "c" : Class identification.
Location
On the upper part of the
coil near to the fuel return
aperture
IMPERATIVE: When replacing a diesel injector carrier, order a component of the same class.
(See repair manual).
144
B1HP16PC
SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM
XANTIA - SYNERGIE
SAFETY REQUIREMENTS
Preamble.
All interventions on the injection system must be carried out to conform with the following requirements and regulations :
- Competent health authorities.
- 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.
145
INJECTION
Engines : RHZ - RHY
XANTIA - SYNERGIE
SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM
Engines : RHZ - RHY
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.
146
CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT
XANTIA - SYNERGIE
Engines : RHZ - RHY
[1] Ø 10 mm low pressure connector
[2] Ø 8 mm low pressure connector
[3] Pressure gauge for testing boost pressure
: 4215-T
: 4218-T
: 4073-T
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
147
INJECTION
TOOLS
CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT
XANTIA - SYNERGIE
Engines : RHZ - RHY (continued)
INJECTION
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
Fuel supply pressure
Fuel return pressure
Between 3 and 3.5 Bar
0.7 ± 0.2 Bar
Check the condition of the diesel filter
More than 3.5 Bar
Less than 0.7 Bar
Check the low pressure regulator incorporated in
the filter (locked shut) : replace.
More than 3.5 Bar
More than 0.7 Bar
Check the fuel return circuit (pipe pinched or trapped...).
Between 0.8 and 1.5 Bar
Less than 0.7 Bar
Check the fuel suppy circuit :
- Booster pump (low pressure), piping.
Impossible to start the engine :
Fuel supply pressure less than 0.8 Bar :
- Check the low pressure regulator incorporated in the filter (locked open).
- Check the high pressure pump distribution valve (locked shut).
Checks
Check : diesel injector return flow. (Table below)
Uncouple the diesel injector return pipe.
Check :
Observe :
The flow should be drop by drop.
Diesel injector functioning correctly.
Excessive fuel return.
Diesel injector locked shut.
148
CHECKS : AIR SUPPLY CIRCUIT
XANTIA - SYNERGIE
TOOLS
[1] Manual vacuum pump
: FACOMM DA 16.
IMPERATIVE : Respect the safety and cleanliness requirements.
Vacuum pump.
- 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
149
INJECTION
Engines : RHZ - RHY
XANTIA - SYNERGIE
CHECKS : TURBO PRESSURE
Engine : RHZ
INJECTION
TOOLS
[1] Pressure gauge for checking boost pressure
[2] Sleeve for checking boost pressure
[3] Adaptor sleeve
: 4073-T.A Kit 4073-T
: 4185-T
: 4229-T
Checks.
C5FP06RC
B1HP12JD
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).
150
CHECKS : TURBO PRESSURE
XANTIA
Engine : RHY
: 4073-T.A Kit 4073-T
: 4185-T
Checks.
IMPERATIVE : respect the following checking requirements : Engine at running temperature. Vehicle running at full load.
C5FP06RC
B1BP20MC
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.
151
INJECTION
TOOLS
[1] Pressure gauge for checking boost pressure
[2] Sleeve for checking boost pressure
XANTIA - SYNERGIE
CHECKS : EXHAUST GASES RECYCLING CIRCUIT
Engines : RHZ - RHY
TOOLS
[1] ] Manual vacuum pump
: FACOMM DA 16.
INJECTION
IMPERATIVE : Respect the safety and cleanliness requirements.
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
152
ALL TYPES
SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP
PUMP - TYPE - REFERENCE
Emission standards
L3
XUDLP01
R 8640 A
051 A
XM
X
U
D
Acoustic (2)
INJECTION
Compacted (1)
Equipment
11
BTE
P8C
XUDLP01
R 8640 A
102 A
SYNERGIE
(1) = Without acoustic bonnet.
(2) = With acoustic bonnet and foam.
153
SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP
ALL TYPES
Static timing
Engine
type
INJECTION
P8C
Pump
Type
Reference
Initial advance
Compression
Time
(cylinder N° 4)
Dynamic
timing
checking
(at idle)
Crankshaft
TDC
hole
pump
pre-positioned
by pegging
XUDLP01
R 8640A/*
Reference
Injector
6751 H
Injector
holder
+ injector
Colour
code
Injector
needle
lift
pressure
Bar)
002R01AE2
ORANGE 163.5±3.5
6734 302H
0 with aircon - ( ) See table on page : 153.
(a) : 850 +- 50
*
154
Adjustments (rpm)
Fast
idling
Antistall
Idling
Max. speed
Unladen
rpm
NOT ADJUSTABLE
Laden
rpm
SETTING THE DELPHI ELECTRONIC INJECTION PUMP
XM
Engine : P8C
TOOLS
: 7017-T.J
: 9043-T
Kit 7004-T
Kit 4123-T
INJECTION
- Flywheel locating peg
- EPIC injection pump setting rod
SETTING THE PUMP
NOTE : This operation is a pre-positioning of the injection pump.
- Peg the flywheel.
- Tilt the pump towards the outer section of the engine.
- Remove the plug (1).
- Introduce the peg 9043-T into the orifice "a".
- Turn the pump towards the inner section of the engine, pushing locating peg 9043-T fully home.
- Tighten the front and rear nuts of the pump to 2 m.daN.
- Remove the tools.
- Refit the plug (1). Tighten to 0.5 m.daN.
NOTE : No adjustment of the pump controls (managed by the ECU).
B1HP0BBC
155
B1HP0NRC
XM
FITTING DELPHI DIESEL INJECTORS
Engine : P8C
Fitting an injector
[1] Tool to remove/refit injectors (2) 7007-T
[2] 7008-T.A Tool kit 4123-T
INJECTION
The copper seal (1) and the fire seal washer (2) are to be
replaced each time they are removed.
NOTE : Fitting parts of different makes is PROHIBITED.
WARNING : Ensure that the fire seal washer (2) is fitted the
right way round.
- The needle-lift injector (4) is positioned on the cylinder
No. 3.
WARNING : Should the needle lift sensor fail to operate, the
complete injector holder must be replaced.
IMPERATIVE : Do not reset the injector holder (4).
Tighten the injector holder on the cylinder head to :
(3) Tighten lightly to prevent any distortion:
1 m.daN + 20° or 6 m.daN.
9 m.daN
B1HPOYHC
B1HPOYJC
B1HPOYGC
156
ALL TYPES
SPECIFICATIONS OF THE BOSCH INJECTION PUMP
PUMP - TYPE - REFERENCE
L3
Equipment
X
U
D
9
BTF
DHX
XM
D
K
5
ATE
THY
TD
RHY
XANTIA
D
W
10
XANTIA
SYNERGIE
SYNERGIE
Automatic
gearbox
ADC 7 keys
Transponder
ADC II
XUDBP02
R 601/3
XUDBP02
R 601/2
XUDBP02
R 601/5
XUDBP02
R 601/5
Damper
Aircon
Damper
VP36535
VER 520
CP1 (*)
ATED
ADC
Damper
INJECTION
Emission standards
RHZ
(*) = The fuel high pressure is driven by the timing belt.
157
ALL TYPES
Engine
type
Pump
Type
Reference
SPECIFICATIONS OF THE BOSCH INJECTION PUMP
INJECTION
Static timing
Dynamic
(1) Initial advance
Compression
Time
(cylinder N° 4)
timing
checking
(at idle)
Reference
Injector
Injector
Colour
code
Injector
holder
+ injector
needle
lift
pressure
(Bar)
Adjustments (rpm)
Fast
idling
(2)
DHX
XUDBP02
VE R 601 / *
Pump
0.57 mm
ABDC
RHY
RHZ
CP1
Non adjustable
96255
42580
VP 36
No setting :
KCE
30S5
535
managed
VE R 520 / *
by ECU
THY
(1) Engine : Trou de Pige P.M.H
(3) 850 = +0-50 with air conditioning.
-
299C
KCA
17S92
GREEN
312
YELLOW
170
+5 -0
Cylinder N° 3
KCE
30S5
316
175
+50
-0
950
± 50
Antistall
Idling
Max. speed
Unladen
rpm
(3)
1500
± 100
800
+ 3 mm
+0
-50
shim
NONE
*See table on page : 157
NOTE : For all pumps on 1.9TD engines with a "B" index : the static timing is 0.82 mm (instead of 0.66 mm)
158
5100
± 80
ADJUSTABLE WITH DIAGNOSTIC TOOL
(2) Clearance at the fast idle control 1 mm
-
Laden
rpm
SETTING THE BOSCH MECHANICAL INJECTION PUMP
XANTIA
Engine : DHX
TOOLS
: 7017-T.R.
: 4132-T.
: 11 X 13
: 3089-T.H.
: 7010.T.
: 5003-T.D.
Kit 7004-T
Kit 4123-T.
SETTING THE INJECTION PUMP
-Tilt the pump in the retarded direction (away from the engine).
- Fit the timing tool.
- Turn the engine (direction of engine rotation) until the peg engages in the flywheel.
- Ensure that the pump pinion can be pegged (if not, rotate the crankshaft by 1 turn).
- Remove the tool 7017-T.R.
- Find the B.D.C. position of the pump (by turning the crankshaft backwards) and set the dial
gauge to "0".
- Turn the crankshaft (direction of engine rotation) until locating peg 7017-T.R engages.
- Turn the pump, in the advance direction (towards the engine) until the dial gauge shows
(See the table on page : 158).
NOTE : The dial gauge needle must not move when tightening.
B1HPOYKD
159
INJECTION
- Flywheel locating peg
- Ring spanner
- Crescent spanner FACOM 57
- Dial gauge
- Dial gauge bracket
- 31 mm lever
XANTIA
SETTING THE BOSCH MECHANICAL INJECTION PUMP
Engine : DHX (continued)
CHECKING THE INJECTION PUMP SETTING
INJECTION
- Remove the tool 7017-T.R.
- Rotate the crankshaft by 1/4 of a turn (opposite direction of rotation).
- Rotate the crankshaft (direction of rotation).
- Peg the flywheel.
- In this position, the dial gauge should show the value "X" (See the table on page : 158).
- The value "X" corresponds to the travel of the pump piston in relation to the B.D.C.
- Remove the tool.
B1HP0NQC
160
B1HP0NPC
ADJUSTING THE BOSCH MECHANICAL INJECTION PUMP CONTROLS
XANTIA
Engine cold.
- Check the fast idle speed.
- Ensure that the lever (3) is against its screw stop (1) by pushing it in the direction of the arrow # .
If not, adjust with the cable clamp (2), and then the cable tightener (6).
Engine hot.
- Ensure that the cable (9) is slack.
- Engine stopped : fully depress the accelerator pedal, check that the lever (8) is against its stop (7).
If not, move the position of the spring clip (B).
Adjusting the idle speed.
- Loosen the screw (5) until there is no longer any contact with the end of the screw.
- Move the screw (4) to obtain an engine speed of (see the table on page: 158).
Adjusting the residual output.
- Insert a shim "A" of (see the table on pages 158), between the lever (8) and the screw (5).
Adjust the screw (5) to obtain a speed of (see the table on page 158).
Adjusting the fast idle speed.
- Place the lever (3) against the screw (1) and turn the screw to obtain an engine speed of (see table
on page 158) .
- Check the operation of the manually-operated "STOP" control.
Adjusting the throttle lever switch (C).
- The contacts will open for an accelerator cable travel of 11 mm or a clearance of 8.5 mm at A".
B1HP0YLD
161
INJECTION
Engine : DHY
XANTIA - SYNERGIE
FITTING BOSCH INJECTORS
Engines : RHY - RHZ
Evolution : Classification of diesel injector carriers
16/11/98
#
INJECTION
Reminder : RHY and RHZ are equipped with 4 diesel injector carriers marked according to their injection duct diameters (flow of diesel fuel).
Identification.
The injector carriers have an engraving or paint mark on the upper part of the coil, close to the diesel
fuel return aperture
Mark 1 = BLUE paint mark = Injector class 1.
Mark 2 = GREEN paint mark = Injector class 2.
Identification marking:
a : Supplier identification.
b : PSA identification no.
c : Identification of class.
After Sales operations.
ESSENTIAL : When changing a diesel injector carrier, order a component of the same class.
# 15/11/98 (RPO No.) (injector carrier without marking), always order a class 2 injector carrier.
B1HP16PC
162
XM
FITTING BOSCH INJECTORS (continued)
Engine : THY
[1] Injector spanner 77510-T
[2] 7008-T
Kit 4123-T
INJECTION
Fitting an injector.
The copper seal (1) and the fire seal washer (2) are to
be replaced each time they are removed.
NOTE : Fitting parts of different makes is PROHIBITED.
WARNING : Ensure that the fire seal washer (2) is
fitted the right way round
The needle lift type injector (4) is located on cylinder
No. 3.
WARNING : Should the needle lift sensor fail, the
injector holder assembly must be replaced.
IMPERATIVE: Do not reset the pressure of the injector
holder (4).
Tighten the injector holder on
the cylinder head to : 4.5 m.daN.
B1HPOYHC
B1HPOYJC
(3) Tighten lightly to avoid distortion.
Tighten to: 7 m.daN.
B1HPOYGC
163
ALL TYPES
SPARKING PLUGS
Vehicles - Models
IGNITION
XANTIA
XM
SYNERGIE
Engine type
BOSCH
CHAMPION
SAGEM
Electrode gap
setting
Tightening
torque
FR7DE
RC8YCL
RFC58 LZ
0.9 mm
2.5 mdaN
FR 8 KDC
PFR 6 E -10
1 mm
10 Nm+90° (*)
FR7DE
RC8YCL
0.9 mm
2.5 mdaN
1 mm
10 Nm+90°*
0.9 mm
2.5 mdaN
1.6i
BFZ
1.8i
LFX
1.8i 16v
LFY
2.0i 16v
RFV
3.0i V6
XFZ
2.0i 16v
RFV
2.0i TcT
RGX
3.0i V6
XFZ
FR 8 KDC
PFR 6 E -10
2.0i 16v
RFN
FR7DE
RC8YCL
* : Retightening => 2.5 mdaN
164
RFC58 LZ
RFC58 LZ
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 :
Example : For an actual speed of 100 Kph the speed displayed by the speedometer may be between 100 and 114 Kph.
The speed indicated by the speedometer may be influenced by :
- 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.
165
CLUTCH
GEARBOX
DRIVESHAFTS
ST < SD < 1.10 ST + 4 Kph
ALL TYPES
CLUTCH SPECIFICATIONS
XU
5
7
JP
10
JB
JP4
J4R
All Types
Engine type
1.6i
1.8i
1.8i 16V
2.0i 16V
BFZ
LFX
LFY
RFV
Gearbox type
Make
CLUTCH
GEARBOX
DRIVESHAFTS
Mechanism/Type
Clutch disc
Ext./Int. lining Ø
Disc lining type
XM Saloon
BE3/5
ME/5
LUK
VALEO
LUK
VALEO
LUK
VALEO
200 P 4100
200 CP 4250
200 P 4100
200 CP 4250
200 P 4100
215 DT5250
200
200 B (D73)
33 AX
200
200 B (D73)
33 AX
200
215 F (D93)
22 BX
200/134
200/137
200/134
200/137
200/134
215/147
F 408
166
F 808
CLUTCH SPECIFICATIONS
XU
ES
10
J4
Synergie
9
J4R
XM Estate
J2TE
Synergie
Xantia
2.0i 16V
Engine type
Gearbox type
RFN
BE3/5
Make
RFV
ME/5 – ML/5
ML/5
VALEO
J4
XM
Synergie
All Types
2.0i Turbo CT
3.0i V6
RGX
XFZ
ME/5 – ML/5
LUK
ML/5
VALEO
Mécanisme/Type
230 DING
4700
235 CP 5650
235 T 5700
235 CP 5650
242 DT 6500
Clutch disc
228 D 73
12 R 14 X
228 SH
11 A 15X
228 D
228 D 62
32 BX
242 SH (D31)
11 A 15 X
Ext./Int. lining Ø
Disc lining type
235/155
228/155
F 808 DS
F 202
167
242/162
F 808
CLUTCH
GEARBOX
DRIVESHAFTS
EW
ALL TYPES
CLUTCH SPECIFICATIONS
ALL TYPES
XUD
DW
DK
11
10
5
BTF
TD
XM- Synergie
RHD
XM
LHD
All
Types
2.1 TD
Engine type
Gearbox type
P8C
CLUTCH
GEARBOX
DRIVESHAFTS
Clutch disc
RHY
ME/5
BE3/5
VALEO
Mechanism/Type
Synergie
RHZ
BE3/5-ML/5
All
Types
2.5 TDi
THY
ML/5
LUK
235 CP 5650
228 SH
11 A 15X
Xantia
ATE
2.0 HDi
ME/5-ML/5
Make
ATED
MG/5
VALEO
230 P 4700
235 T 5700
225 T 5700
(1)
228
228D
225
242 SH (D95)
31 Q
228 F (D95)
32 AX
242 DT 6500
Ext./Int. lining Ø
235/155
230/
235/155
225/
242/162
Disc lining type
F 202
F 408
F 202
F 808
F 206
(1) DVA = Damped double flywheel.
168
CLUTCH : CHECKS AND ADJUSTMENTS
XANTIA - SYNERGIE
Push-action clutch with automatic adjustment (Non-adjustable) (*)
Gearbox
BFZ - LFX - LFY – RFN – RHY
BE3/5
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 assembly
in place.
- 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.
(*) See pages : 172 to 173).
B2BP03PD
169
CLUTCH
GEARBOX
DRIVESHAFTS
Engines
XANTIA - XM - SYNERGIE
CLUTCH : CHECKS AND ADJUSTMENTS
Pull-action clutch with automatic adjustment (Non-adjustable) (*)
Engines
Xantia - XM
: RFV - DHX
XM
: RGX
Synergie
: RFV
BE3/5
Gearboxes
ME/5
ML/5
CLUTCH
GEARBOX
DRIVESHAFTS
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
assembly in place.
- 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.
(*) See pages : 172 to 173).
B2BP03DD
170
XANTIA - XM - SYNERGIE
CLUTCH : CHECKS AND ADJUSTMENTS
Adjustment of push and pull action clutch with automatic compensation (adjustment of compensation system)
Engines : BFZ - LFX - LFY - RFV – RGX - RFN - DHX - 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".
- 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.
- Lower the support until there is a free play of 2 ± 1 mm.
- 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
171
CLUTCH
GEARBOX
DRIVESHAFTS
Procedure
CLUTCH : CHECKS AND ADJUSTMENTS
Engines : BFZ - LFX - LFY - RFV – RGX - RFN - DHX - RHY - RHZ
CLUTCH
GEARBOX
DRIVESHAFTS
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.
1
2
3
4
-
Metallic cable, crimped on both ends.
Outer cable or telescopic duct.
Outer cable stop, bulkhead side (fixed point on the bodyshell).
Outer cable stop, gearbox side (fixed point on the gearbox).
DESCRIPTION
5 - Tensioning spring ensuring the maximum length of the outer cable.
6 - Wear take up device.
7 - Attaching end-piece.
172
CLUTCH : CHECKS AND ADJUSTMENTS
XANTIA - XM - SYNERGIE
B2BP03QD
Operation
Clutch disengagement phase
Engagement / adjustment phase
For the adjusting device to operate correctly, it
is necessary that :
The pedal is at rest (against its upper stop)
The locking sleeve (1) is slightly compressed,
the rollers (2) are free, the outer cable (3) length
may vary.
As soon as the pedal is applied, the attaching
end-piece (4) leaves the sleeve (1) which
moves back. The rollers, pushed by spring (5)
jam the system. The cable behaves like a
conventional cable.
The pedal returns to rest on its upper stop.
Attaching end-piece (4) pushes sleeve (1)
which frees the rollers.
Outer cable (3), kept extended by the spring (6)
becomes :
- Shorter if the clutch disc is worn.
- Longer if the outer cable has been compressed.
NOTE : The pedal gear has a non-adjustable assisting device
173
CLUTCH
GEARBOX
DRIVESHAFTS
Engines : BFZ - LFX - LFY - RFV - RGX - RFN - DHX - RHY - RHZ (Continued)
XANTIA - XM - SYNERGIE
CLUTCH : CHECKS AND ADJUSTMENTS
Hydraulically operated pull-action clutch (Non-adjustable)
XM
Engines
ME/5
: RGX -P8C
Xantia - XM - Synergie
: RGX - XFZ - RHZ
XM
: THY
Gearboxes
ML/5
MG/5
CLUTCH
GEARBOX
DRIVESHAFTS
B2BP03RC
(1) Quick-fit union Tool 9040-T.H.
E5AP14VC B2BP03SC
174
CLUTCH : CHECKS AND ADJUSTMENTS
XANTIA - XM - SYNERGIE
Hydraulically operated pull-action clutch (Non-adjustable)
A / Old assembly, supplied complete and filled with hydraulic
fluid.
B / New assembly :
- The components supplied separately.
- The circuit is filled with fluid after being fitted to the vehicle.
(1) Clutch transmitter.
(2) Clutch receiver.
(3) Hydraulic clutch control reservoir.
(4) Link pipe.
(5) Click-fit union, sealed (after dismantling).
(6) Click-fit union, non-sealed (after dismantling).
(7) Bleed screw.
Le nouveau montage est composé des pièces suivantes :
The new assembly consists of the the following parts :
- Clutch transmitter, anchored in place after a 1/4 turn.
- Clutch receiver, with push-rod.
- Hydraulic clutch control reservoir, with feed pipe.
- Link pipe, between clutch transmitter and receiver.
B2BP03ZD
175
CLUTCH
GEARBOX
DRIVESHAFTS
Engines : RGX - XFZ – RHZ - P8C - THY
XANTIA - XM - SYNERGIE
CLUTCH : CHECKS AND ADJUSTMENTS
Hydraulically operated pull-action clutch (Non-adjustable)
Engines : RGX - XFZ – RHZ - P8C - THY
CLUTCH
GEARBOX
DRIVESHAFTS
After fitting on the vehicle, the circuit should be filled with a
«DOT 4» type brake fluid.
Clutch control reservoir capacity 120 cc.
(Bleeding is carried out not under pressure).
Repair
The new clutch control components are not compatible with the
old parts.
Both the old and the new components are marketed by
«Replacement Parts».
Draining-Filling - Top-up
- Check the level after each repair visit.
- Fill the circuit (after drainage), using a filling cylinder
specifically designed for this operation.
- Use the circuit’s bleed screw (7).
- The level of fluid inside the clutch control reservoir should be
between the min. and max. marks.
NOTE : Wear on the clutch causes a slight increase in the level
of fluid inside the control reservoir.
B2BP03ZD
176
GEARBOX AND TYRE SPECIFICATIONS
XANTIA
Petrol
1.6i
1.8i
1.8i 16V
Engine type
BFZ
LFX
LFY
2.0i 16V
Auto.
Tyres-Rolling circumference
175/70R14
1.85 m
185/65 R14 - 1.815 m
Gearbox type
Gearbox ident. plate
Reduction box torque
BE3/5
20 TD 00
20 TB 94
15X64
19X75
Speedometer ratio
(1) = Plastic pinion
Engine type
Reduction box torque
Speedometer ratio
RGX
XFZ
Auto.
20 TP 52
20 TB 97
20 TP 53
23X73
19X79
23X73
20X16
22X18
Diesel
20X16
ML/5
1.9 TD
Auto.
DHX
205/60 R15 - 1.92 m
15X67
185/65R15
1.895 m
AL4
28X18
3.0i V6
20 LE 90
205/55R15
1.85 m
BE3/5
19X79
2.0i
Turbo CT
Gearbox type
185/65R15
1.895 m
AL4
20 TB 95 (*)
22X18
Petrol
Tyres-Rolling circumference
Gearbox ident. plate
20 TB 95
Auto.
RFV
205/60R15 - 1.92m
2.0 HDi
RHY
RHZ
205/60 R15 - 1.92 m
4 HP 20
AL4
BE3/5
ML/5
20 LE 89
20 HZ XX
20 TP 50
20 TB 53
20 LE 84
16X69
20X69
20X16
25x71
20x16
19X75
22X18
16X65
25X20 (1)
25X20 (1)
177
CLUTCH
GEARBOX
DRIVESHAFTS
(*) = Long gearbox.
XM
GEARBOX AND TYRE SPECIFICATIONS
Petrol
2.0i 16V
3.0i V6
Auto.
Engine type
Tyres-Rolling circumference
Gearbox type
2.0i Turbo CT
Auto.
RFV
XFZ
195/65R15 - 1.93 m
BE3/5
4 HP 18
ML/5
RGX
205/65R15 - 1.97 m
4 HP 20
ME/5
20 TD 01
20 GZ 5G
20 LE 59
20 HZ YY
Reduction box torque
14X62
18X77
17X71
Speedometer ratio
22X18
25X20
25X20
Gearbox ident. plate
CLUTCH
GEARBOX
DRIVESHAFTS
Diesel
2.1 TD
(1) = Plastic pinion
2.5 TD
Auto.
Engine type
Tyres-Rolling circumference
Gearbox type
P8C
THY
195/65R15 - 1.93 m
ME/5
4 HP 18
205/65R15 - 1.97 m
MG/5
Gearbox ident. plate
20 GM 31
20 GZ 5D
20 KM 70
Reduction box torque
15X59
21X26 (1)
18X77
25X20
16X65
16X20 (1)
Speedometer ratio
Auto.
178
4 HP 18
20 GM 33
20 GZ 1G
20X69
14X59
18X77
20X16
21X26 (1)
25X20
GEARBOX AND TYRE SPECIFICATIONS
SYNERGIE
Petrol
Diesel
2.0i 16V
Engine type
RFN
20 DL 26
20 DL 27
14x62
18x14
AL4
ML/5
20 TP 31
20 LE 91 (*)
21x73
20x16
15x67
25x20
CLUTCH
GEARBOX
DRIVESHAFTS
Speedometer ratio
RHY
BE4/5
Gearbox type
Reduction box torque
2.0 HDi
205/65 R15 - 1.97 m
Tyres-Rolling circumference
Gearbox ident. plate
Auto.
(*) DVA = Double damped flywheel
179
XANTIA- XM
BE3/5 GEARBOX
Engines : BFZ - LFX - LFY - RFV 03 - RHY
CLUTCH
GEARBOX
DRIVESHAFTS
Filler screw
B2CP34JP
Drain screw
Vent hole
B2CP20HC B2CP20JC
180
BE3/5 GEARBOX CONTROLS
XANTIA- XM
Engines : BFZ - LFX – LFY – RFV - RHY
Tightening torques m.daN.
(1) Pinion/subframe fixing
(2) Bar /lever fixing
2.7 ± 0.2
1 ± 0.1
(3) Length selection rod
(4) Length engagement rod
100 ± 1 mm
245 ± 1 mm
Note : The adjustment dimensions are the distances
between ball-joint centres.
B2BP005D
181
CLUTCH
GEARBOX
DRIVESHAFTS
Adjustment of the control rods
XANTIA- XM
BE3/5 GEARBOX CONTROLS
Engine : RFV
(1)
(2)
(3)
CLUTCH
GEARBOX
DRIVESHAFTS
B2CP34ZD
182
100 ± 1 mm.
100 ± 1 mm.
246 ± 1 mm.
BE4/5 GEARBOX
SYNERGIE
CLUTCH
GEARBOX
DRIVESHAFTS
ENGINE : RFN
(a) = Marking zone (Sequence and serial no.).
(b) = Location of identification label.
B2CP3BNC
B2CP3BPD
183
SYNERGIE
BE4/5 GEARBOX SPECIFICATIONS
Engines : RFN
Description (Continued)
CLUTCH
GEARBOX
DRIVESHAFTS
(1) Primary shaft.
(2) Clutch bearing guide.
(3) Gearbox casing.
(4) Clutch housing.
(5) Reverse idle.
(6) Drive gear (3rd gear).
(7) 3rd /4th gear synchroniser
(8) Drive gear (4th gear).
(9) Drive gear (5th gear).
(10) 5th gear synchroniser.
(11) Driven gear (5th gear).
(12) Driven gear (2nd / 4th gear )
(13) Driven gear (2nd gear).
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
1st / 2nd gear synchroniser
Driven gear (1st gear)
Secondary shaft.
Differential gear.
Satellite gears
Planet gears.
Boîtier de différentiel.
Differential housing.
Extension.
«d» Adjusting shims : 0.7 to 2.4 mm
(0.10 mm and increasing by 0.10 mm).
"c" Adjusting shims : 1.4 to 1.6 mm
(0.10 mm and increasing by 0.10 mm).
B2CP3BQP
184
BE4/5 GEARBOX
SYNERGIE
Engine : RFN
Ref.
B2CP3BSP
B2CP3BTD
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
6
Differential gearwheel screw
2
6.5 ± 0.7
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
12
Drain plug screw
1
3.5 ± 0.4
185
CLUTCH
GEARBOX
DRIVESHAFTS
Tightening torques
SYNERGIE
BE4/5 GEARBOX CONTROLS
Engines : RFN
(1) Gear control lever
(2) Gear engagement control cable (*)
(3) Gear selection control cable (*)
CLUTCH
GEARBOX
DRIVESHAFTS
(4) Gear selection ball-joint Ø 10 mm.
(5) Gear engagement ball-joint Ø 10 mm.
(6) Flexible insulating grommet through the bulkhead
(*) = These two cables cannot be separated.
B2CP3BWD
186
SYNERGIE
BE4/5 GEARBOX - CHECKS AND ADJUSTMENTS
Engines : RFN
Principles of adjusting the gear controls.
WARNING : Cables should be adjusted each time the gearbox,
gear controls or power unit are removed.
Lock the gear lever in neutral position,
using tool: 9607-T.
WARNING : Do not use any tool to unclip the
ball-joints.
To unlock the ball-joint, press at the centre «a»,
then pull the ball-joint upwards.
Place the gearbox in neutral.
Couple the cables on the lever.
Note : Changing an individual ball-joint is
possible as long as the locking key is removed.
Fit the ball-joints on the gearbox lever.
Unclip at «b», using two small screwdrivers.
Lock the cable lengths with the ball-joint locking keys.
B2CP3BXC
187
B2CP3BYC
CLUTCH
GEARBOX
DRIVESHAFTS
Principles.
SYNERGIE
BE4/5 GEARBOX - CHECKS AND ADJUSTMENTS
Engines : RFN
Adjusting the gear controls.
TOOL
[1] Tool for positioning the gear lever
ADJUSTMENTS
WARNING : Cables should be adjusted each
time the gearbox, gear controls or power unit
are removed.
CLUTCH
GEARBOX
DRIVESHAFTS
Inside the vehicle
- Remove the trim under the gear lever.
- Lock the gear lever in neutral position,using tool [1].
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.
: 9607-T.
CHECKS
- Remove the tool [1].
- Check that all the gears engage without
«tightness ».
- Check that the gear lever moves identically
forwards and backwards and to right and left. If
it does not, repeat the adjustment.
- Refit the trim under the gear lever.
- Refit the air filter assembly.
B2CP3C6C
188
B2CP3C0C
XM
ME/5 GEARBOX
Filler screw
B2CP34KP
Drain screw
B2CP20KC B2CP20LC
189
CLUTCH
GEARBOX
DRIVESHAFTS
Engines : RGX - P8C
XM
ME/5 GEARBOX CONTROLS
Engines : RGX - P8C
CLUTCH
GEARBOX
DRIVESHAFTS
B2CP351D
190
(1)
(2)
Z
Z
3 ± 2 mm
3 ± 2 mm
(3)
X
Y
8.5 mm
8.5 mm
XANTIA - XM - SYNERGIE
ML/5 GEARBOX
Engines : XFZ - RHZ -
Tightening torque : m.daN.
Drain screw
Filler screw
B2CP34LC
191
1.8
1.5
6
8.5
CLUTCH
GEARBOX
DRIVESHAFTS
- Gearbox casing/clutch bell housing fixing
- Speedometer cable housing/engine fixing
- Clutch bell housing/engine fixing :
• Screws H10 x 150 L 75
• Screws M12 x 175 L 70
XANTIA - XM - SYNERGIE
ML/5 GEARBOX CONTROLS
Engines : XFZ - RHZ
CLUTCH
GEARBOX
DRIVESHAFTS
B2CP0350P
192
ML/5 GEARBOX CONTROLS
XANTIA - SYNERGIE
CLUTCH
GEARBOX
DRIVESHAFTS
Engines : XFZ - RHZ
B2CP16FP
193
XM
MG/5 GEARBOX
Engine : THY
CLUTCH
GEARBOX
DRIVESHAFTS
Drain screw
B2CP34MD
Filler screw
B2CP34NC
194
MG/5 GEARBOX CONTROLS
XM
CLUTCH
GEARBOX
DRIVESHAFTS
Engines : THY
B2CP16GP
195
XANTIA - XM
4 HP 18 AUTOMATIC GEARBOX
Engines : RFV - RGX - P8C
CLUTCH
GEARBOX
DRIVESHAFTS
B2CP34UD
Ref.
letter
X (mm)
Y (mm)
Torque
m.daN
A
B
C
D
E
80
80
75
65
60
12
10
12
10
10
0.8
0.6
0.8
0.6
0.6
Tightening torques m.daN
(1)
(2)
(3)
(4)
Gearbox casing screw
Oil dipstick tube nut
Strainer cover
Hydraulic valve block
1 ± 0.1
4.5± 0.4
0.8
Note : When replacing an automatic gearbox, it is ESSENTIAL to replace the
heat exchanger, as well as the oil.
B2CP34SC
196
B2CP34TC
GEARBOX CONTROLS - 4 HP 18 AUTOMATIC GEARBOX
XANTIA- XM
CLUTCH
GEARBOX
DRIVESHAFTS
Engines : RFV - RGX - P8C
B2CP35AD
B2CP35BC
197
XANTIA - XM
CHECKS AND ADJUSTMENTS - 4 HP 18 AUTOMATIC GEARBOX
Engines : RFV - RGX - P8C
Checks - Adjustments : Kick down cable
Preliminary conditions :
- Engine hot.
- Idling speed correct.
- Cable routing correct
CLUTCH
GEARBOX
DRIVESHAFTS
Accelerator cable adjustment :
- Remove the kick down cable from the drum.
- Pull out the sleeve stop (1) and fit the spring clip (2) so as to obtain a small
clearance at «a».
Kick down cable adjustment :
- Pull out the cable until the start of the kick down command, the lug (3) should be
at: X = 39 mm from the end of the sleeve.
- The lug (3) should then be positioned and crimped on the cable.
- Refit the kick down cable on the drum.
- Adjust the clearance (B) from 0.5 mm to 1 mm max. by tightening the nuts (4).
B2CP35CC B2CP35DC
B2CP013C
198
B2CP35EC
RECOMMENDATIONS - PRECAUTIONS : AL 4 and 4 HP 20 AUTOMATIC GEARBOXES
XANTIA - XM - SYNERGIE
Engines : LFY - RFV - RFN - XFZ - DHX
PRECAUTIONS TO BE TAKEN
IMPERATIVE : - Put gear lever in position «N»..
- Do not add any oil.
- Do not exceed 50 kph over a distance of 50 km.
WARNING : Never place the gearbox on its lower casing
(risk of deforming the tray and damaging the hydraulic valve block).
Never use the connections as handles for raising, turning, holding or
pushing the gearbox.
Driving
- Never drive with the ignition switched off.
- Never push the vehicle to try to start it;
(impossible with an automatic gearbox).
ESSENTIAL :
- Fit the converter retaining peg while the gearbox is removed.
- Fit the centring peg to locate the gearbox on the engine:
(remove the converter retaining peg just before locating)
Lubrication
The automatic gearbox is only lubricated when the engine is running.
WARNING :With the safety programme selected, a snatching can be
felt when changing from ‘‘P’’ ‘‘R’’ or ‘‘N’’ ‘‘R’’.
199
CLUTCH
GEARBOX
DRIVESHAFTS
REMOVING - REFITTING. (Automatic gearbox).
Towing
The front of the vehicle must be raised in order to be towed.
If the front of the vehicle cannot be raised :
XANTIA - XM - SYNERGIE
RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX
Engines : LFY - RFV - RFN - DHX
PROCEDURE BEFORE REPAIRS
AL 4 gearbox
CLUTCH
GEARBOX
DRIVESHAFTS
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.
200
RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX
XANTIA - XM - SYNERGIE
Engines : LFY - RFV - RFN - DHX
Oil level AL 4 (prior conditions).
- Vehicle in horizontal position.
- Check gearbox is not in back-up mode.
- Remove the oil filler plug (2).
- 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.
- Remove the oil level plug (3).
- 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).
B2CP31FD
201
CLUTCH
GEARBOX
DRIVESHAFTS
PROCEDURE BEFORE REPAIRS
XANTIA - XM
RECOMMENDATIONS - PRECAUTIONS : 4 HP 20 AUTOMATIC GEARBOX
Engine : XFZ
Tools
[1] Hose clamp pliers
[2] Filling cylinder
[3] Specific end-piece
: 4517-T
Tool kit 4507-T
: (-).0341.
: (-).0341.B.
Checking the oil level.
CLUTCH
GEARBOX
DRIVESHAFTS
Preliminary conditions
- Vehicle in horizontal position, handbrake released.
- Engine idling, without using power (headlamps, heated rear screen etc.).
- Check absence of gearbox back-up mode; using a diagnostic tool.
- Apply the brake, change through all the gears.
- Gear selection lever at position P.
- The check is to be carried out when the oil has reached a temperature of 55°C ± 1°C; using a diagnostic tool.
- Remove the oil filler plug (3).
B1BP202C
202
RECOMMENDATIONS - PRECAUTIONS : 4 HP 20 AUTOMATIC GEARBOX
XANTIA- XM
Engine : XFZ
Checking the oil level (continued)
Flowing of oil from the oil filler aperture.
- As soon as the oil temperature reaches 60°C ± 1°C, refit the oil filler plug (*).
Note : The oil level is correct.
- Refit the oil filler plug (3).
- Stop the engine.
- Remove the air vent assembly (1) and (2) from the gearbox; using tool [1].
- Add 0.5 litre of additional oil into the gearbox; using tool [2].
- Repeat the procedure of topping up the oil.
- Remove the tools [2] and [3].
- Refit the metallic part (1) of the air vent assembly, using a Ø 18 mm drift and a mallet.
- Clip on the plastic part (2) of the air vent assembly.
- Refit the air filter housing.
(*) Note : The method of topping up gearbox oil with an oil gauge remains unchanged.
B2CP3ACD B2CP3ABC
203
CLUTCH
GEARBOX
DRIVESHAFTS
No flowing of oil from the oil filler aperture.
XANTIA - XM
RECOMMENDATIONS - PRECAUTIONS : AL 4 and 4 HP 20 AUTOMATIC GEARBOXES
Engines : LFY - RFV - RFN - XFZ - DHX
PROCEDURE BEFORE REPAIRS (continued)
When the ECU detects an erroneous or non-existent value
on input or output :
Reading the fault codes.
- Read the fault codes.
- It writes the fault in memory.
- For each associated context, it writes the context of the oldest fault
in memory.
- It initiates a back-up mode strategy.
No fault codes present :
Carry out a measure of parameters.
CLUTCH
GEARBOX
DRIVESHAFTS
Anomalies present :
• YES : Carry out the necessary repairs.
• NO : Read the fault codes – engine ECU
There are two types of back-up modes :
- The ECU makes replacement values available (relating to comfort,
gear selection quality, loss of functions).
- Carry out a road test.
Following an initialisation of the ECU, for a certain period of time
there may be an inconsistent gear selection quality (while ECU
parameters are adapted 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).
- Access to emergency programme (only 3rd ratio and reverse are
available).
Note : 4 HP 20 : A snatching may be felt when changing :
P/R - N/R - N/D.
204
RECOMMENDATIONS - PRECAUTIONS : 4 HP 20 AUTOMATIC GEARBOX
XANTIA- XM
Engine : XFZ
ECU : Downloading, Configuration, Initialisation (Pedal).
Downloading (4 HP 20)
Updating the gearbox ECU by downloading :
- Follow the procedure using the diagnostic equipment
The operation of downloading is used to update the automatic gearbox ECU or to adapt it to the engine ECU.
Following the diagnostic tool procedure.
- A reinitialisation of the auto adaptor (4 HP 20).
- A road test (4 HP 20).
IMPERATIVE : Every update of the automatic gearbox ECU
must be accompanied by an update of the engine ECU.
205
CLUTCH
GEARBOX
DRIVESHAFTS
After downloading, carry out the following :
XANTIA - XM - SYNERGIE
RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX
Engines : LFY-RFV-DHX-RFN
ECU : Downloading
Updating the gearbox ECU by downloading :
- SFollow 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.
CLUTCH
GEARBOX
DRIVESHAFTS
After the downloading operation, carry out the following:
A clearing of faults.
A pedal initialisation.
An initialisation of the auto-adaptives.
A recording of the value of the oil usage counter previously read.
A road test.
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 LEXIA or ELIT.
Access to reading and recording of the oil counter is via the menu :
«Oil counter».
Adjustment of the oil counter value is done by entering directly the
5 figures of the oil counter.
Using PROXIA
Access to reading and recording of the oil counter is via the menu :
«Configuration (integrated circuit button) / Oil counter».
Adjustment of the oil counter value is done in incremental steps of
2750 units.
206
RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX
XANTIA - XM - SYNERGIE
Engines : LFY-RFV-DHX-RFN
ECU : Downloading, 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 :
- Replacement of the automatic gearbox ECU.
A new ECU or downloaded update is always configured
with the following options :
- SHIFT LOCK gear selection lever position.
- OBD outlet (emission standard L4).
- Downloading of the ECU configuration.
- Adjustment or replacement of the accelerator cable.
If the ECU is to be fitted to a vehicle without one or both
of these options:
- 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).
207
CLUTCH
GEARBOX
DRIVESHAFTS
- Replacement of the automatic gearbox.
SYNERGIE
RECOMMENDATIONS - PRECAUTIONS : AL4 AUTOMATIC GEARBOX
Engine : RFN
Gear control is by a cable linked to the selection lever located on the
dashboard.
The gear selection control has 5 positions :
CLUTCH
GEARBOX
DRIVESHAFTS
«P» Park (immobilisation of the vehicle, whatever the slope).
«R» Reverse gear.
«N» Neutral.
«D» Drive (autoadaptative mode, eco-law).
«M» Manual mode (M+, M-).
The vehicle can only be started when the selection lever is in position «P»
or «N».
Shift-Lock
The «shift-lock» is a system which locks the gear selection lever in
position «P».
To unlock the gear selection lever from position «P», switch on the
ignition and press the brake pedal.
During a repair, the shift-lock can be unlocked by pressing the locking
finger «a» (see corresponding operation).
B2CP3CFD
208
RECOMMENDATIONS - PRECAUTIONS : 4 HP 20 AUTOMATIC GEARBOX
XANTIA- XM
Engine : XFZ
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)
CLUTCH
GEARBOX
DRIVESHAFTS
- Switch on the ignition.
- Press and hold down the brake pedal.
- Using the selection lever, disengage from position «P».
NOTE : It is IMPERATIVE to disengage the gear selection lever from position "P" the minute
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.
- Using the selection lever, disengage from position «P».
B2CP268C
209
B2CP269C
XANTIA - XM - SYNERGIE
AL 4 AUTOMATIC GEARBOX
Engine : LFY - RFV - RFN - DHX
WARNING : CITROEN special semi-synthetic oil cannot be mixed with other oils.
The gearbox is lubricated for life.
CLUTCH
GEARBOX
DRIVESHAFTS
(a) Component reference.
B2CP30ZD
210
4 HP 20 AUTOMATIC GEARBOX
XANTIA- XM
(1) Oil/water exchanger.
(2) Selection lever position switch.
(3) Torque converter.
(4) Differential.
(5) Secondary shaft.
(6) Clutch.
(7) Brake.
B2CP34VP
211
CLUTCH
GEARBOX
DRIVESHAFTS
Engine : XFZ
XANTIA - XM
GEARBOX CONTROLS - 4 HP 20 AUTOMATIC GEARBOX
Engines : XFZ
4 HP 20
Adjusting the selection mechanism.
- Put selection lever (5) in position : parking.
- Untighten nut (2) and the lock nut (4) on either side of the linkage (3)
so as to connect the ball-joint (1) to the selector.
CLUTCH
GEARBOX
DRIVESHAFTS
- Apply grease G9.
- Tighten the nut (2) and the lock nut (4) to 1 m.daN.
B2CP37FD
212
GEARBOX CONTROLS - AL 4 and 4 HP 20 AUTOMATIC GEARBOXES
XANTIA- XM
Engines : LFY - RFV - DHX - XFZ
Adjusting the selection mechanism
4 HP 20
- If the selection mechanism is NEW, pull out the locking key (1) 1/4 of
a turn.
If the selection mechanism is OLD and not set correctly, press on
component (2), without flexing the cable, then release.
B2CP35FD
AL 4
Adjusting the selection mechanism.
- If the selection mechanism is NEW or removed from the vehicle,
component (1) is locked..
When fitting the selection mechanism, press on component (2),
without flexing the cable, then release. (Component (1) unlocks).
- Check the passage through all the gears.
B2CP37ED
213
CLUTCH
GEARBOX
DRIVESHAFTS
- Check the passage through all the gears.
ALL TYPES
TRANSMISSION - GEARBOX
Tightening torque (m.daN)
Gearbox
Engines
BE3/5
BFZ-LFX-LFY-RFV-RHY
BE4/5
ME/5
RFN
RGX-P8C
RGX-XFZ-RHZ
ML/5
Driveshaft
bearing
1
RFV-RGX
DHX-RHZ-P8C (Synergie)
CLUTCH
GEARBOX
DRIVESHAFTS
MG/5
THY
4 HP 18
RGX - RFV - P8C
Gearbox oil seal mandrels
Driveshaft
nut
Right
Left
Tool kit
32.5
7114-T.W
7114-T.X
7116-T
34.5
9017.T.B
9017-TC
9017-T
9017.T.C
5701-T.A
NO
5708-T.J
5708-T.H
5708-T
32.5
10 + 60°
1.9
34.5
Seal extractor
Right/Left (-) 0338 C
AL 4
LFY - RFV - DHX
1
32.5
4 HP 20
XFZ
Tightening torque (m da.N) of the wheel bolts : XANTIA - XM = 9 - SYNERGIE = 10.
214
(-) 0338 J1
+ (-) 0338 J2
(-) 0338 H1
+ (-) 0338 H2
8010-T.K2 +
8010-T.J.
Rep. : rouge
8010-T.K1 +
8010-T.J.
Rep. : noir
(-) 0338
8010-T
XANTIA
AXLE GEOMETRY
General conditions required for adjustment
- Check the tyre pressures.
- Parking brake released.
- Manually set the height to the «NORMAL DRIVING» position.
- Engine running
NOTE : After each body movement, and before each measurement :
- Move the vehicle backwards and forwards slightly by pushing the road
wheel by hand.
Front height
H1 = R1 - L1
H2 = R2 - L2
H1 = Front height
All Types (+ 7 - 10 mm)
SC CAR (± 3.5 mm)
R1 = Wheel radius in mm.
L1 = Theoretical dimension between
the front subframe contact surface and
the wheel axis.
H1 = Rear height
All Types (+ 7 - 10 mm)
SC CAR (± 3.5 mm)
R2 = Wheel radius in mm.
L2 = Theoretical dimension between
the bearing surface of the bodyshell
and the wheel axis.
Example : front height
- Measure dimension R1 (centre of the wheel) on the vehicle.
- Subtract L1 from R1 (See the table on page 214) and calculate H1.
- Measure H1 on the vehicle.
- The measured dimension H1 should be the same as the calculated dimension H1
(+ 7 - 10 mm).
- Adjust the heights if necessary.
215
B3BP12YC
AXLES
SUSPENSION
STEERING
B3BP12XC
Rear height
XANTIA
AXLE GEOMETRY (continued)
Measuring the rear height
Measuring the front height
AXLES
SUSPENSION
STEERING
B3BP04EC
B3BP04GC
Vehicles
L1 (mm)
Vehicles
L2 (mm)
All types
121
All types
136
216
XANTIA
AXLE GEOMETRY (continued)
NOTE
A < B = Positive figure :
A > B = Negative figure :
Tracking
Castor
Camber
King pin
inclination
Tracking
0 to - 3 mm
0° à - 0° 25’
3° ± 30’
0° ± 30’
Camber
( Non adjustable )
( Non adjustable )
All Types
TOE-IN
TOE-OUT
Rear axle
Front axle
Vehicle
+ =
- =
+ 1 to + 6 mm
13° 15’ ± 35’
– 1°15’ ± 20’
+ 0°10’ to + 0°50’
Power-assisted steering
R1 towards the rear of the vehicle.
B3CP04LC
B3BP00ZC
217
AXLES
SUSPENSION
STEERING
WARNING : The castor angle is
determined by the direction of fitting
of the pneumatic unit support.
FRONT AXLE
XANTIA
AXLES
SUSPENSION
STEERING
Hauteur de la biellette :
X = 323 ± 1 mm
B3CP00UD
1
2
3
3
3
4
4
4
5
6
7
8
9
10
11
12
-
Tightening torques ( m.daN)
Suspension leg upper fixing (coat with LOCTITE FRENETANCH)
Suspension leg fixing on bodyshell
Link rod upper fixing : up to RPO N° 6615 ball joint stem ø 10mm
Link rod upper fixing : from RPO N° 6616 ball joint stem ø 12mm
SC.CAR ram upper fixing
Link rod lower fixing : up to RPO N° 6615 ball joint stem ø 10mm
Link rod lower fixing : from RPO N° 6616 ball joint stem ø 12mm
SC.CAR ram lower fixing
Ball joint fixing
Ball joint/swivel fixing
Suspension leg fixing on swivel
Driveshaft fixing on hub
Wheel fixing
Arm front fixing
Arm rear fixing
Arm rear fixing/anti-roll bar rear fixing
218
6.5
2.5
4
7
7
4
7
7
4.5
25
5.5
32
9
8.5
8.5
8.5
XANTIA
REAR AXLE
Evolution : Rear hub nut
Old # 15/12/1999 (A)
New 15/12/1999 # (B)
Evolution :
- New rear hub nut (3).
- Washer discontinued (2).
Old fitting (A)
(1) Rear hub nut.
(2) Thrust washer.
IESSENTIAL : 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).
ESSENTIAL: Respect the tightening torque to be applied when
fitting.
WARNING: Identify the type of fitting, before starting a repair.
B3DP08AD
219
AXLES
SUSPENSION
STEERING
WARNING : do not fit a thrust washer (2) with a new nut (3).
XANTIA
REAR AXLE
Saloon
Tightening torques (m.daN)
AXLES
SUSPENSION
STEERING
1
2
3
4
- Anti-roll bar fixing
- Rear silentblock/bodyshell fixing
- Subframe rear fixing
- Subframe/bodyshell front fixing
Estate
NOTE : (3) and (4) Face and threads not lubricated
9.5
3.4
11
8
B3DP06LD
220
B3DP02DC
B3DP02EC
XANTIA
REAR AXLE (continued)
Adjustment of a suspension arm
ESSENTIAL :
The clearance «J1» should be equal to or
less than 0.5 mm.
It must be obtained using a single shim (8).
Thickness of available shims :
0.5 - 1 - 1.5 mm.
Selecting the shim thickness (8)
- J1 less than or equal to 0.5 mm
( No shim (8) required).
5 - Arm/shaft fixing
6 - Hub/stub fixing
7 - Wheel fixing
13
28
9
9 - Front runner mountings oriented at 18°
(marking: notch at ‘‘a’’).
10 - Washer
11 - Rubber mounting
- J1> 0.5 mm ; less than or equal to 1 mm :
( Fit a 0.5 mm shim).
- J1> 1 mm less than or equal to 1.5 mm
( Fit a 1 mm shim).
- J1> 1.5 mm, fit a 1.5 mm shim.
B3DP02GD B3DP02HC
221
AXLES
SUSPENSION
STEERING
Tightening torques (m.daN)
SUSPENSION
XANTIA
Height control : Saloon and Estate
Ø Anti-roll bars (mm)
Engines
Saloons
Front
Rear
22
21
RGX - RFN - XFZ - P8C - RHZ
22
22
ACTIVA
28
25
BFZ - LFX - LFY
RFV - DHX - RHY
Engines
All Types
AXLES
SUSPENSION
STEERING
(1) Automatic control clamp
Tighten to 1,5m.daN
Grease G6 (TOTAL MULTIS)
B3BP12ZD
222
Estate
Front
Rear
23
23
XANTIA
STEERING
All Types
Steering
Power-assisted
Pinion (no. of teeth)
8
Rack (no. of teeth)
34
Steering rack travel
74.3
Tightening torques (m.daN)
Steering wheel fixing
3
2
4
Cardan joint fixing
2
5
B3EP001D
B3EP00JD
3
Steering column fixing
1.5
6
Flange/push-rod fixing
1
7
9 mm spacer
(mechanical steering)
8
Steering/crossmember fixing
8
9
Steering rack ball-joint fixing
6
10 Link-rod lock nuts
223
4.5
11
Swivel ball joint fixing
12
Steering rack/ram fixing
3.5
6
14
Steering/ram fixing
9
15
Valve/casing fixing
1.2
13
Travel limiting stop, fitted
to the power- steering :
74.3 mm
16
3 mm spacer
(Power- steering)
AXLES
SUSPENSION
STEERING
1
AXLE GEOMETRY
XM
General conditions required for adjustment
-
Check the tyre pressures.
Parking brake released.
Manually set the height to the «NORMAL DRIVING» position.
Engine running.
Note : After each body movement, and before each measurement :
Move the vehicle backwards and forwards slightly by pushing the
road wheel by hand.
Front height
Rear height
H2 = R2 + L2
H1 = R1 – L1
H1 : Front height (+7. – 10 mm)
R1 : Wheel radius in mm.
L1 : Theoretical dimension between
the front subframe contact surface
and the wheel axis
AXLES
SUSPENSION
STEERING
B3BP130C
H2 : Rear height (+7. – 10 mm)
R2 : Wheel radius in mm.
L2 : heoretical dimension between
the bearing surface of the bodyshell
and the wheel axis
Example : front height
- Measure dimension R1 (centre of the wheel) on the vehicle.
- Subtract L1 from R1 (See the table on page 223) and calculate H1.
- Measure H1 on the vehicle.
- The measured dimension H1 should be the same as the calculated
dimension H1 (+ 7. – 10 mm)
- Adjust the heights if necessary.
224
B3BP131C
AXLE GEOMETRY
Front height
XM
Rear height
NOTE
+ =
- =
A < B = Positive figure :
A > B = Negative figure :
Front
Anti-rearing device
All Types (mm)
L1
141.5
1.2
H2
Tracking
(Toe in/out)
B3BP133C
4°
0°
0° to - 0°27’
+ 0°5’ to + 1°
mm
0 to - 3
+ 0.5 to + 6.5
Castor angle (max.
left-right difference 30’)
B3BP132C
2°30’ ± 30’
Camber angle
0° ± 30’
King pin inclination
13° 15’
225
Rear
- 0°50’ ± 20’
AXLES
SUSPENSION
STEERING
B3BP051D
TOE-IN
TOE-OUT
XM
AXLES
SUSPENSION
STEERING
B3CP04NP
FRONT AXLE
B3CP044D
226
B3DP06MD
B3DP06NC
B3DP06PD
227
XM
AXLES
SUSPENSION
STEERING
REAR AXLE
XM
AXLES
SUSPENSION
STEERING
B3BP135D
SUSPENSION
B3BP134C
228
XM
SUSPENSION (continued)
Ø Anti-roll bars (mm)
Saloons and Estate
Saloons
Front
Rear
RGX
23
RFV
23
XFZ - P8C - THY
Ambulance (P8C)
Engines
Ø piston rods
22
RFV
22
21
RGX
24
22
XFZ
24
22.5
P8C - THY
40
Estate
Engines
All Types
25
Ø pistons
Front
Rear
25
22.5
Rear suspension cylinders
Saloons : Ø 37 mm.
Estate : Ø 42.5 mm
229
AXLES
SUSPENSION
STEERING
Engines
Front suspension units
XM
STEERING
All Types
Steering
Pinion (teeth)
8
Steering rack
(teeth)
34
Rack travel
83
(1) 4 and 6 cm3 rams :
- Tighten to 9 m.daN.
AXLES
SUSPENSION
STEERING
(2) 4 cm3 ram :
- Tighten to 6 m.daN.
6 cm3 ram
- Tighten to 9 m.daN.
B3EP09XD
B3EP09YD
230
Assistée
AXLE GEOMETRY
SYNERGIE
Reference height
NOTE
+ =
- =
A > B = Negative figure :
CONDITIONS FOR ADJUSTING THE HEIGHTS
(Tyre pressures correctly set.)
Heights (mm)
Rear
H1
Tyres
H2
158
195/70R 14
163
161
195/65R 15
166
166
205/65R 15
171
Tracking
(Toe-in/toe-out)
0°
+0°8’ to +0°25’
mm
+1 to +3
Castor angle max.
(left-right difference : 30’)
Camber angle
The reference heights must be checked between the jacking
points and the ground.
B3BP051D King pin (inclination)
231
TOE-OUT
Rear
Front
B3BP051D
Front
PINCEMENT
3°30’ to ± 30’
0° ± 30’
11°28’ ± 40’
-1° ± 30’
AXLES
SUSPENSION
STEERING
A < B = Positive figure :
SYNERGIE
AXLES
SUSPENSION
STEERING
B3CP04PD
FRONT AXLE
B3CP04QD
232
FRONT AXLE
SYNERGIE
Evolution : Tightening torque on front subframe
28/05/1999 #
(1) Fixing screw (front).
(2) Fixing screw (rear).
Tightening torque
Old fitting
Tighten the screw (1) to 13.5 m.daN.
Tighten the screw (2) to 13.5 m.daN.
NOTE : Replacement Parts markets the old as well as the
new components.
B3CP055D
233
AXLES
SUSPENSION
STEERING
New fitting.
Tighten the screw (1) to 10.7 m.daN.
Tighten the screw (2) to 10.7 m.daN.
SYNERGIE
REAR AXLE
AXLES
SUSPENSION
STEERING
B3DP06QD
234
SUSPENSION
SYNERGIE
All Types
Shock absorber
(ref.)
Anti-roll bar Ø
(mm)
Ft
F 23
Rr
F 254
Ft
25
Rr
30
Withoutair-con
1 grey+ 1 yellow
Ft
2 grey+ 1 yellow
With air-con
Rr
3 yellow
235
AXLES
SUSPENSION
STEERING
Spring
(ref.)
SYNERGIE
STEERING
Steering
All Types
Assisted
Steering rack travel
(mm)
152
Number of teeth
Steering rack
Number of turns of
the steering wheel
Steering ratio
Pinion
9
33
2.98
15.75
AXLES
SUSPENSION
STEERING
B3EP09ZD
236
XANTIA
1.9 TD
2.0i CT
3.0i V6
2.0 HDi
1.6i
1.8i
1.8i16V
1.9D
2.0HDi
.0i16V
Auto.
Ø
mm
Ft
BENDIX SVG-Z0
60
BENDIX 5G
54
288
266
283
Disc thickness
28
20.4
22
Minimum disc thickness
26
18.4
20
Disc
Brake pad grade
FERF 949
Ø
CITROEN
33
mm
Rr
Caliper/piston makes
Caliper/piston makes
224
Disc
9
Disc thickness
7
Minimum disc thickness
Brake pad grade
FERF 949
(1) With active anti-roll
237
BRAKES
BRAKE SPECIFICATIONS
BRAKES
XANTIA
BRAKE SPECIFICATIONS
1.9 TD
2.0i CT
3.0i V6
2.0 HDi
1.8i
1.8i 16V
2.0i 16V
2.0 HDi
Auto.
BENDIX 5G
54
BENDIX 5G
57
288
266
283
Disc thickness
28
20.4
22
Minimum disc thickness
26
18.4
20
Ø
mm
Ft
Disc
BENDIX SVG-Z0
60
Brake pad grade
FERF 949
Ø
CITROEN
33
mm
Rr
Caliper/piston makes
Caliper/piston makes
Disc
224
Disc thickness
9
Minimum disc thickness
7
Brake pad grade
FERF 949
238
XANTIA
Front
Rear
Tightening torques (m.daN)
- Stud (1) = 5
- Fixing to bodyshell (4) = 1.5
- Caliper fixing (2) = 10.5
- Control valve fixing (5) = 2
B3FP00QC
B3FP00TC
239
- Caliper fixing (3) = 4.7
B3FP00SC
BRAKES
BRAKES
BRAKES
HANDBRAKE
XANTIA
- The calipers have a handbrake travel self-adjusting
mechanism.
NOTE : The handbrake operates on the front wheels.
B3FP00WD
240
Automatic wear adjustment.
Engine running.
Handbrake in the fully released position.
Press the brake pedal 10 times with an effort
of 20 m daN.
Release the brake pedal.
Adjusting the parking brake sheaths.
NOTE : Before carrying out this operation,
ensure that the parking brake sheaths are
properly bedded-in.
Operate the handbrake lever 10 times with
an effort of 40 m daN.
- Set the steering in the straight-ahead position.
- Put the handbrake in the fully released position.
- Carry out the following operations on each
side of the vehicle :
- Slacken the lock nut (1).
- Put the lock nut (1) against its stop at «a».
- Slacken the nut (2).
XANTIA
Start adjusting with the right side.
Pull the end-piece (3) of the parking brake
cable by hand.
Slightly tighten, by hand, the nut (2) so that it is
against the brake caliper (the end-piece (3)
should be in contact with the lever (4).
Mark one face of the nut (2) using a felt-tip
marker pen.
RHD vehicles up to RPO N° 6375 : Slacken the
nut (2) by 3 turns.
LHD vehicles all types, RHD vehicles from
RPO N° 6376 : Slacken the nut (2) by 1/2 turn.
Tighten the lock nut to 3 m.daN.
Dimension «L» should be the same on both
sides to within 1.5 mm (correct balance of the
parking brake equaliser).
NOTE : With the brake lever at rest, the levers
(4) must not be pulled by the cables, whatever
the steering lock angle and the vehicle height.
241
B3FP10RC
B3AQ00DC
BRAKES
HANDBRAKE (continued)
BRAKES
XANTIA
BLEEDING THE BRAKES
- Bleed the brakes with the suspension in the high position, after having
operated the suspension as follows..
Position
:
LOW ➔ HIGH ➔ LOW ➔ HIGH.
- Jack up the vehicle with the road wheels hanging free.
- Remove the wheels.
XANTIA fitted with ABS.
- The circuit bleeding operation can be made easier by activating the
hydraulic valve block using the LEXIA or PROXIA diagnostic stations or
the ELIT test unit.
242
- Bleed the brakes in the following order : -
Rear right.
Rear left.
Front right.
Front left.
- Engine running.
- Connect the bleed screw to a receptacle using a transparent pipe.
- Press the brake pedal lightly, or load the pedal with a weight of
5 to 6 kg.
- Slacken the bleed screw, let the fluid escape until it is free of air
bubbles.
- Retighten the screw.
- Top up the LHM reservoir
Petrol
Diesel
2.0 i Turbo CT
2.0 i 16 V
Saloon
Ø
mm
Ft
Caliper/piston makes
Disc
Estate
3.0 i V6
Saloon
Estate
2.5 TD
Saloon
BENDIX Série S5G
57
BENDIX Série 5ZO
60
BENDIX Série S5G
57
BENDIX Série 5ZO
60
283
288
283
288
Disc thickness
26
28
26
28
Minimum disc thickness
24
26
24
26
ABEX-FERF 949
Brake pad grade
CITROEN
33
CITROEN
33
CITROEN
40
CITROEN
33
CITROEN
40
224
232
251
224
251
Disc thickness
9
9
12
9
12
Minimum disc thickness
7
7
10
7
10
Ø
mm
Rr
2.1 TD
Caliper/piston makes
Disc
Brake pad grade
ABEX-FERF 949
243
BRAKES
XM
BRAKE SPECIFICATIONS (continued)
BRAKES
XM
HANDBRAKE
adjustment
- Apply the main brake pedal so that the brake pads
are in contact with the brake discs, release the
pressure.
- Set the handle (5) to the locked position.
- Press the pedal (6) to the 4th notch of the
quadrant.
- Turn the nuts (2) to obtain an equaliser (3) balance
to within 1.5 mm.
- Unlock the handle (5), the pedal should return to
its rest position.
- The levers (1), should not be pulled by the cables,
whatever the steering angle and height of the
vehicle.
- Tighten the lock nuts to 2 m.daN.
- Apply the parking brake several times, ensuring it
returns to its rest position.
- The pedal should be between the 6th and 12th
notch of the quadrant.
B3FP10SD
244
XM
All Types
- Bleed the brakes with the suspension in the high position, after having operated the suspension as follows.
Position : LOW ➔ HIGH ➔ LOW ➔ HIGH.
- Bleed the brakes in the following order : -
Rear right.
Rear left.
Front right.
Front left.
- Engine running.
- Connect the bleed screw to a receptacle using a transparent pipe.
- Press the brake pedal lightly, or load the pedal with a weight of 5 to 6 kg.
- Slacken the bleed screw, let the fluid escape until it is free of air bubbles.
- Tighten the screw.
- Top up the LHM reservoir.
XM equipped with ABS.
- The circuit bleeding operation can be made easier by activating the hydraulic valve block using the LEXIA or PROXIA stations or ELIT test unit.
245
BRAKES
BLEEDING THE BRAKES
BRAKES
SYNERGIE
BRAKE SPECIFICATIONS
2 0 HDi
2.0i 16V
23.8
Master cylinder
Ø
mm
Master-vac
203 + 230 (Tandem)
279
GIRLING C57
57
Caliper/piston makes
Ft
Disc
281 (Ventilated)
Disc thickness
26
Minimum disc thickness
24
Brake pad grade
Ø
mm
GALFER 3314
Cylinder or caliper
20.6
Drum
255
36
295
Disc
Rr
10/8
x./ min. thickness
Make
Brake lining grade
Compensator cut-off in Bars
BENDIX FN 36
DON 7124
Front 65 - Rear brake 65
246
GALFER 36212
Front brake 85 - Rear brake 85
SYNERGIE
Mechanical adjustment of the compensator
- Set the vehicle at reference height (see page 229).
ESSENTIAL : Never alter the position of the upper nut (1).
- Refit the flanged nut (2).
- Fit the tool 8204-T.
At shim A
At shim B
Drum
Disc
Yellow
Blue
Red
- Adjust the nut (3) to allow the free passage, without play, of the red shim (B), without
moving the lever (4) downwards.
- Tighten the lock nut (5) without modifying the adjustment.
- Remove the threaded rod at C.
- Tighten the flanged nut (2) over the nut (3).
B3FP10TC
247
BRAKES
BRAKES
BRAKES
SYNERGIE
BRAKES (continued)
Checks and hydraulic adjustment of the compensator
- Use the brake pressure checking equipment 4104-T, connect diagonally and bleed:
Ø bleed screw : caliper 8x125 - Wheel cylinder 7x100.
- Set the vehicle at setting height (See the table on page 229).
Engines : RFU - DHX
P8C
Disc
Drum
Engine : RGX
Disc
Rear
Front
40
40
50
50
65
65
85
85
135
86
135
100
- If the pressures are not correct, adjust as follows :
- Refit the nut (1).
- Adjust using the nut (2) to obtain the braking pressure.
- Tighten the lock nut (3).
- Hold the threaded rod (4).
- Tighten the flanged nut (1) over the nut (2).
B3FP10UC
248
Rear
Front
B3FP10VC
SYNERGIE
B3FP10WC
- Slacken the cables using the nut (1).
- Remove the blanking plug from hole A.
- Position hole A opposite the toothed wheel (adjusting mechanism).
- Turn the toothed wheel using a flat screwdriver until the disc locks.
- LH side upwards.
- RH side downwards.
- Unlock the disc by turning in the opposite direction by 6 notches.
B3FP10XC
- Position the blade B of the blanking plug perpendicular to the line passing through the centre of the disc and the centre of the hole. Tighten
the nut (1) to obtain a handbrake lever travel of 4 to 5 notches.
- Tighten the lock nut (2).
249
BRAKES
HANDBRAKE
DE-PRESSURISING THE SUSPENSION CIRCUITS
ALL TYPES
Consequences
Carry out the following operations
Vehicle without hydractive suspension (Without SC.MAC valve)
SUSPENSION
1
Height control set to «LOW» position.
The suspension spheres are de-pressurised, wait for the vehicle to
lower fully.
2
Unscrew the pressure regulator release screw by 1 turn
The main accumulator is de-pressurised.
Vehicle without hydractive suspension in running order (With SC.MAC valve)
1
Start the engine.
Open the SC.MAC valves.
2
Height control set to «LOW» position if the vehicle is on stands :
raise the wheel(s) concerned.
The suspension spheres + SC.MAC accumulator are de-pressurised.
3
Unscrew the pressure regulator release screw by 1 turn
The main accumulator is de-pressurised
Vehicle with hydractive suspension in running order (With or without SC.MAC valve)
1
The electrovalves of the hydractive regulators are energised.
Open the SC.MAC valves.
Start the engine.
250
DE-PRESSURISING THE SUSPENSION CIRCUITS (continued)
ALL TYPES
Carry out the following operations
2
Height control set to «LOW» position if the vehicle is on stands :
raise the wheel(s) concerned.
The suspension spheres + hydractive regulator accumulators
+ SC.MAC regulator are de-pressurised.
3
Unscrew the pressure regulator release screw by 1 turn
The main accumulator is de-pressurised.
Vehicle with hydractive suspension not in running order (With or without SC.MAC valve)
1
Unscrew the pressure regulator release screw by 1 turn
The main accumulator is de-pressurised.
2
Height control set to «LOW» position.
The SC.MAC accumulator is de-pressurised.
3
Uncouple the pressure regulator outlet pipe.
Couple the outlet pipe with the pump 4135-T + union(s) or 4034-T +
union (S) and (O) from tool kit 4146-T.
4
Switch on the ignition.
The electrovalves of the hydractive regulators are energised.
251
SUSPENSION
Consequences
DE-PRESSURISING THE SUSPENSION CIRCUITS (continued)
ALL TYPES
Consequences
Carry out the following operations
SUSPENSION
5
Establish a pressure of 150 to 180 Bars if the vehicle is on stands :
raise the wheel(s) concerned.
The suspension spheres + hydractive regulator accumulators are
de-pressurised.
6
Open the bleed screw of the pump 4135-T or 4034-T, remove the
tools.
The supply circuit is de-pressurised.
Vehicle with SC.CAR, Citroën Active Roll Control, in running order
1
2
Start the engine
The electrovalves of the hydractive regulators are energised, and the
SC.MAC valves are opened.
Height control set to «LOW» position.
The suspension spheres + hydractive regulator accumulators
+ SC.MAC regulator are de-pressurised.
3
Stop the engine.
4
Unscrew the pressure regulator release screw by 1 turn.
The main accumulator is de-pressurised.
5
Open the SC.CAR regulator bleed screw.
The SC.CAR regulator accumulator is de-pressurised.
252
DE-PRESSURISING THE SUSPENSION CIRCUITS (continued)
Consequences
Activate 4 to 5 times alternately the two SC.CAR corrector link rods.
The SC.CAR accumulator is de-pressurised.
Vehicle with SC.CAR, Citroën Active Roll Control, not in running order
1
Unscrew the pressure regulator release screw by 1 turn.
The main accumulator is de-pressurised.
2
Height control set to «LOW» position.
The SC.MAC accumulator is de-pressurised.
3
Open the SC.CAR regulator bleed screw.
The SC.CAR regulator accumulator is de-pressurised.
Activate 4 to 5 times alternately the two SC.CAR corrector link rods.
The SC.CAR accumulator is de-pressurised.
4
5
Uncouple the SC.CAR accumulator supply pipe, plug the pipe using
the unions 4146-T (M) and (V).
6
Uncouple the pressure regulator outlet pipe, couple the pipe to the
pump 4135-T + 4146-T.S or 4034-T + 4136-T (S) and (O).
253
SUSPENSION
Carry out the following operations
6
ALL TYPES
DE-PRESSURISING THE SUSPENSION CIRCUITS (continued)
ALL TYPES
Consequences
Carry out the following operations
SUSPENSION
7
Switch on the ignition.
The electrovalves of the hydractive regulators are energised.
8
Establish a pressure of 150 to 180 Bars if the vehicle is on stands :
raise the wheel(s) concerned.
The suspension spheres + hydractive regulator accumulators are
de-pressurised.
9
Open the bleed screw of the pump 4135-T or 4034-T, remove the
tools.
The supply circuit is de-pressurised.
254
DE-PRESSURISING THE SUSPENSION CIRCUITS (continued)
ALL TYPES
Carry out the following operations
SUSPENSION
SPECIFIC CASES
The suspension can be de-pressurised on each axle individually.
ESSENTIAL : The height corrector must be operated in the «LOW» position.
Consequences
Vehicle with or without hydractive suspension - Front axle (With SC.MAC valves)
1
Unscrew the pressure regulator release screw by 1 turn.
2
Uncouple the pressure inlet pipe (1) from the height corrector.
Connect the pump 4135-T or 4034-T - 4146-T.O.
The main accumulator is de-pressurised.
B3BP136C
3
The electrovalves of the hydractive regulators are energised.
Hydractive Vehicle : Switch on the ignition.
255
ALL TYPES
DE-PRESSURISING THE SUSPENSION CIRCUITS (continued)
SUSPENSION
Carry out the following operations
Consequences
4
Establish a pressure (100 to 180 Bars) to control the slide valves of
the SC.MAC valve and hydractive regulator.
The suspension spheres + hydractive regulator accumulators +
SC.MAC accumulator (front suspension settling) are de-pressurised.
5
Open the bleed screw of the pump 4135-T or 4034-T, remove the tools.
The supply circuit is de-pressurised.
Vehicle with or without hydractive suspension - Rear axle (With SC.MAC valves)
1
Unscrew the pressure regulator release screw by 1 turn.
2
Uncouple the pipe (2) of the SC.MAC valve. Couple the pump
4135-T or 4034-T.O + 4146-T.O to the SC/MAC valve.
The main accumulator is de-pressurised.
B3BP137C B3BP138C
256
A = Without hydractive
B = With hydractive
DE-PRESSURISING THE SUSPENSION CIRCUITS (continued)
ALL TYPES
3
Vehicle with hydractive suspension : switch on the ignition
The electrovalves of the hydractive regulators are energised.
4
Establish a pressure (80 to 180 Bars) to control the slide valves of
the SC.MAC valve and hydractive regulator.
The suspension spheres + hydractive regulator accumulators
+ SC.MAC accumulator (front suspension settling) are de-pressurised.
5
Open the bleed screw of the pump 4135-T or 4034-T, remove the tools.
The supply circuit is de-pressurised.
Vehicle with hydractive suspension (without SC.MAC valve)
Work on the hydractive regulator which controls the axle to be repaired.
1
Unscrew the pressure regulator release screw by 1 turn.
2
Uncouple the pipe (3) of the hydractive regulator. Couple the pump
4135-T or 4034-T + 4146-T.O.
The main accumulator is de-pressurised.
B3BP139C
257
SUSPENSION
Consequences
Carry out the following operations
DE-PRESSURISING THE SUSPENSION CIRCUITS (continued)
ALL TYPES
Consequences
Carry out the following operations
SUSPENSION
3
Switch on the ignition.
The electrovalves of the hydractive regulators are energised.
4
Establish a pressure (80 to 180 Bars) to control the slide valves of
the hydractive regulator.
The suspension spheres + hydractive regulator accumulators
(suspension settling) are de-pressurised.
5
Open the bleed screw of the pump 4135-T or 4034-T, remove the
tools.
The supply circuit is de-pressurised.
Vehicle with SC.CAR: Citroën Active Roll Control
1
Unscrew the pressure regulator release screw by 1 turn.
The main accumulator is de-pressurised
2
Height control set to «LOW» position.
The SC.MAC accumulator is de-pressurised.
3
Open the SC.CAR regulator bleed screw.
The SC.CAR regulator accumulator is de-pressurised.
4
Activate 4 to 5 times alternately the two SC.CAR corrector link rods.
The SC.CAR accumulator is de-pressurised
258
DE-PRESSURISING THE SUSPENSION CIRCUITS (continued)
Carry out the following operations
Consequences
Uncouple the SC.CAR accumulator supply pipe, plug the pipe with
the unions 4146-T.M and V.
SUSPENSION
5
ALL TYPES
Front suspension : special case (without SC.MAC valve)
(See page 242)
Rear suspsion : special case (without SC.MAC valve)
(See page 240)
259
FILLING AND BLEEDING THE SUSPENSION CIRCUITS (continued)
Carry out the following operations
Consequences
SUSPENSION
1
LHM fluid level to the max. mark.
2
Loosen the pressure regulator release screw.
3
Start the engine.
4
Tighten and slacken the pressure regulator release screw several
times, then retighten it.
Priming of the high pressure (HP) pump.
5
Height control set to «HIGH» position.
Wait for the vehicle to rise fully.
6
Top up the level : engine running, vehicle in the high position.
LHM fluid topped up.
260
PNEUMATIC UNITS – DAMPERS
(5)
(6)
(7)
(8)
Main accumulator.
Front suspension sphere
Rear suspension sphere
Front hydractive regulator
accumulator
Rear hydractive regulator
accumulator.
SC..MAC accumulator
SC.CAR accumulator.
SC.CAR regulator accumulator
Diaphragm types :
• D = Desmopan
• U = Urepan
• M = Multi-layer
B4BP017D
WARNING : The pneumatic unit nos. shown in the tables ARE NOT REPLACEMENT PART NOS.
MAIN ACCUMULATOR ( 1 )
Vehicle
Pneumatic unit nos.
All types
accept SC.CAR
96 154 588
D
95 451 376
U
SC.CAR
95 437 354
D
Volume (cc)
Pressure (bars)
Damper
400
62 (+5 ; – 32)
None
(*) SC.CAR : Citroen Active Roll Control - SC.MAC : Citroen Anti-Sink
261
HYDRAULIC
SYSTEM
(1)
(2)
(3)
(4)
XANTIA
XANTIA
PNEUMATIC UNITS – DAMPERS
NON-HYDRACTIVE SUSPENSION
Front suspension sphere (2)
Vehicle type
All Types
Pneumatic unit nos.
96 178 589
D
96 194 444
U
96 199 318
M
Volume (cc)
Pressure (bars)
400
55 (+5 ; – 20)
450
50
Volume (cc)
Pressure (bars)
Damper hole diameter mm
30 (+5 ; – 10)
1.2
40 (+5 ; – 10)
1.25
Damper hole diameter mm
1.5
Rear suspension sphere (3)
Vehicle type
HYDRAULIC
SYSTEM
Saloon
Estate
SC.MAC accumulator (6)
Vehicle type
All Types
Pneumatic unit nos.
96 238 977
D
96 239 023
U
96 239 029
D
96 239 028
U
400
NOTE : This pneumatic unit is located at the rear of the vehicle.
Pneumatic unit nos.
96 145 672
D
96 198 613
U
Volume (cc)
Pressure (bars)
Damper
400
50 (+5 ; – 20)
None
SC.MAC : Citroen Anti-Sink
262
PNEUMATIC UNITS – DAMPERS
XANTIA
HYDRACTIVE SUSPENSION
Front suspension sphere ( 2 )
Vehicle type
All Types
Pneumatic unit nos.
96 238 949
Volume (cc)
Pressure (bars)
Damper hole diameter mm
450
45
0.7
Volume (cc)
Pressure (bars)
Damper hole diameter mm
30 (+5 ; – 10)
0.6
40 (+5 ; – 10)
0.8
M
Vehicle type
Saloon
Estate
Hydractive regulator accumulator.
Vehicle
Pneumatic unit nos.
96 238 950
D
U
400
96 239 027
D
500
96 239 026
U
400
96 238 951
NOTE: (*) The dampers are incorporated in the hydractive regulator.
Hydractive
regulator
(Axle)
All types (except V6)
Pneumatic
unit nos.
96 181 131
Front (4)
V6
All Types
Volume
(cc)
M
96 045 530
263
U
Damper hole
diameter (mm)
*
75
1.1
70
1.2
50 (+5 ; – 20)
1.3
450
96 281 798
Rear (5)
Pressure (bars)
400
HYDRAULIC
SYSTEM
Rear suspension sphere (3)
PNEUMATIC UNITS – DAMPERS
XANTIA
HYDRACTIVE SUSPENSION (Continued)
SC.MAC accumulator ( 6 )
Vehicle type
All Types
NOTE : This pneumatic unit is located at the rear of the vehicle.
Pneumatic unit nos.
96 145 672
96 198 613
Volume (cc)
Pressure (bars)
Amortisseur
400
50 (+5 ; – 20)
None
D
U
SUSPENSION SC.CAR (*)
Suspension sphere.
HYDRAULIC
SYSTEM
Vehicle
ACTIVA
NOTE : (*) SC.CAR : Citroen Active Roll Control
Cylinder
All types (except V6)
Pneumatic
unit nos.
96 221 189
Front (2)
V6 Manual Gearbox
Pressure
(bars)
45
M
450
96 289 689
V6 Manual Gearbox
All types (except V6)
Volume
(cc)
96 289 687
264
0.7
40
0.7
96 222 870
Rear (3)
Damper hole
diameter (mm)
*
U
400
30 (+5 ; – 10)
0.6
XANTIA
PNEUMATIC UNITS – DAMPERS
SUSPENSION SC.CAR (*)
Hydractive regulator
Vehicle
ACTIVA
NOTE: (*) The dampers are incorporated in the hydractive regulator.
Pneumatic unit nos.
Hydractive
regulator
(Axle)
All Types (Except V6)
Volume (cc)
Pneumatic
unit nos.
Volume
(cm3)
96 181 131
Front (4)
V6 Manual gearbox
All Types
Pressure (bars)
M
96 221 207
U
Pressure
(bars)
Damper hole
diameter (mm)
*
75
1.1
70
1.2
55 (+5 ; – 10)
1.1
450
96 281 798
Rear (5)
Damper hole diameter mm
400
Additional accumulator
Type
Pneumatic unit nos.
SC.MAC accumulator (6)
96 198 613
SC.CAR accumulator (7)
96 212 198
Volume (cc)
D
Pressure (bars)
50 (+5 ; – 20)
400
U
62 (+5 ; – 32)
SC.CAR accumulator regulator
Regulator
SC.CAR (8)
Pneumatic unit nos.
U
96 208 710
265
Volume (cc)
Pressure (bars)
400
30 (+5 ; – 10)
HYDRAULIC
SYSTEM
Hydractive regulator accumulator.
PNEUMATIC UNITS – DAMPERS
XM
(1) Main accumulator.
Diaphragm types :
(2) Front suspension sphere
• D = Desmopan
(3) Rear suspension sphere
• U = Urepan
(4) Front hydractive regulator
accumulator
• M = Multi-layer
(5) Rear hydractive regulator
accumulato
(6) SC.MAC accumulator
HYDRAULIC
SYSTEM
NOTA : SC.MAC : Citroen Anti-Sink
B4BP018D
WARNING : |The pneumatic unit nos. shown in the tables ARE NOT REPLACEMENT PART NOS.
MAIN ACCUMULATOR ( 1 )
Vehicle
All Types
Pneumatic unit nos.
95 451 376
Volume (cc)
Pressure (bars)
Damper
400
62 (+5 ; – 32)
None
U
266
PNEUMATIC UNITS – DAMPERS
XM
NON-HYDRACTIVE SUSPENSION
Front suspension sphere ( 2 )
Vehicle type
Saloon and Estate
(Except 2.1 DT)
Estate All Types
(Except 2.1TD)
Saloon and Estate
2.1 TD
Pneumatic unit nos.
96 051 819
96 222 864
96 069 918
96 212 110
96 222 866
96 222 865
Volume (cc)
Pressure (bars)
400
450
400
450
400
450
70 (+5 ; – 25)
65
70 (+5 ; – 25)
65
70 (+5 ; – 25)
65
Volume (cc)
Pressure (bars)
D
M
D
M
D
M
Damper hole diameter mm
1.65
1.4
1.65
Vehicle type
Saloon All Types
Estate All Types
SC.MAC accumulator ( 6 )
Vehicle type
Saloon and Estate
Pneumatic unit nos.
96 222 874
D
400
40 (+5 ; – 15)
U
96 222 873
U
500
96 120 324
NOTE : This pneumatic unit is located at the rear of the vehicle..
Pneumatic unit nos.
96 198 613
Damper hole diameter mm
1.25
1.5
Volume (cc)
Pressure (bars)
Damper
400
50 (+5 ; – 20)
None
U
267
HYDRAULIC
SYSTEM
Rear suspension sphere ( 3 )
XM - All Types
PNEUMATIC UNITS – DAMPERS
HYDRACTIVE SUSPENSION
Front suspension sphere ( 2 )
Vehicle type
Pneumatic unit nos.
Saloon/Estate TT (Except V6)
96 222 867
Saloon/Estate V6
96 290 048
Volume (cc)
M
450
Pressure (bars)
Damper hole diameter mm
50 (+5 ; – 20)
0.8
40 (+5 ; –15)
0.7
Pressure (bars)
Damper hole diameter mm
Rear suspension sphere ( 3 )
Vehicle type
Volume (cc)
Pneumatic unit nos.
96 222 871
HYDRAULIC
SYSTEM
Saloon All Types
Except V6)
96 222 870
Saloon/Estate V6
96 238 950
Estate All Types
(Except : V6 2.5 TD)
96 222 872
D
30 (+5 ; – 15)
U
400
U
0.6
40 (+5 ; – 15)
268
0.7
0.7
PNEUMATIC UNITS – DAMPERS
XM
HYDRACTIVE SUSPENSION (continued)
Hydractive regulator accumulator.
Saloon/Estate 2.0 i 16 V
NOTE : The dampers are incorporated in the hydractive regulator.
96 281 798
Saloon (5)
96 045 530
Estate (5)
96 468 115
Vehicle type
2.0 i - 2.5 TD - 2.1 TD
2.0 i Turbo - CT
Pressure (bars)
Damper hole diameter mm
75
96 181 131
Saloon/Estate (4)
(Except 2.0 i 16 V)
SC.MAC accumulator ( 6 )
Volume (cc)
Pneumatic unit nos.
M
450
70
1.25
U
400
50 (+5 ; – 20)
500
40 (+5 ; – 15)
NOTE : This pneumatic unit is located at the rear of the vehicle
Pneumatic unit nos.
96 198 613
Volume (cc)
Pressure (bars)
Damper
400
50 (+5 ; – 20)
None
U
269
HYDRAULIC
SYSTEM
Vehicle type
XANTIA
STARTER MOTORS
Manufacturer and Ref.
Vehicles / models
VALEO D6 RA 661
1.6i / 1.8i
1.8i 16v
3
BOSCH 107019
BOSCH 1108084
VALEO D6 RA 661
XANTIA
Class
1.8i 16v (Auto.)
2.0i 16v
Climate
H,T
C
4
VC
3
H,T
BOSCH 107019
BOSCH 1108084
3.0i V6
4
VALEO D7 R17
VALEO D7 R8
1.9TD
2.0i HDi
C,VC
H,T,C,VC
5
H,T
6
C,VC
MELCO M001T80082
VALEO D7 R12
ELECTRICAL
SYSTEM
CLIMATE : T (Temperate), H ( Hot), C (Cold), VC (Very Cold)
270
XM
STARTER MOTORS
Manufacturer and Ref.
VALEO D6 RA 661
2.0i 16v
Class
Climate
3
H,T
4
C,VC
BOSCH 107019
2.0i Turbo CT (Auto.)
BOSCH 1108084
VALEO D6 RA 661
2.0i Turbo CT
XM
3.0i V6
3
BOSCH 107019
C
BOSCH 1108084
VC
4
VALEO D7 R17
VALEO D7 R8
2.1 TD
MELCO M001T80082
2.5 TD
MELCO M002T84771
VALEO D7 R12
CLIMATE : T (Temperate), H ( Hot), C (Cold), VC (Very Cold)
271
H,T
H,T,C,VC
5
6
H,T
C,VC
H,T,C,VC
ELECTRICAL
SYSTEM
Vehicles / models
SYNERGIE
STARTER MOTORS
Vehicles / models
Manufacturer and Ref.
Class
VALEO D6 RA 661
2.0i 16v
Climate
H,T
3
BOSCH 107019
C
BOSCH 1108084
SYNERGIE
VALEO D7 R26
2.0 Hdi
4
VC
5
H,T
6
C,VC
MELCO M001T80082
2.0 16v Hdi
VALEO D7 R27
Classes of starter motors
ELECTRICAL
SYSTEM
CLASS
CLASS 2
CLASS 3
CLASS 4
CLASS 5
CLASS 6
Torque C
5.5 Nm
6 Nm
10 Nm
11.5 Nm
11.5 Nm
Maximum current
for a speed
of 1200 rpm
I £ 275 A
I ≤ 300 A
I ≤ 430 A
I ≤ 470 A
I ≤ 500 A
CLIMATE : T (Temperate), H ( Hot), C (Cold), VC (Very Cold)
272
ALTERNATORS
ALL TYPES
Classes and types
Engine
Gbox.
Without air con.
7
Climate
VALEO A11 VI 57
H
With air con.
9
BOSCH A120310104
1.6i
M
8
H
MELCO A003TA0591
MELCO A002TA0291
T,C
8
VALEO A13 VI 189
9
VALEO A13 VI 191
Climate
MELCO A002TA0291
T,C,VC
VALEO A13 VI 189
VALEO A13 VI 191
VC
MELCO A003TA0591
7
BOSCH A120411525
8
MELCO A002TA1991
H
BOSCH A120411523
1.8i
M
2.0i 16v
9
VALEO A13 VI 101+
H,T,C
MELCO A002TA2091
VC
T,C
VALEO A13 VI 102
9
VALEO A13 VI 101+
VC
CLIMATE : T (Temperate), H ( Hot), C (Cold), VC (Very Cold)
273
ELECTRICAL
SYSTEM
MELCO A002TA2091
ALTERNATORS
ALL TYPES
Classes and types
Engine
Gbox.
Without air con.
7
Climate
BOSCH A120411525
H
With air con.
9
BOSCH A120411523
1.8i 16v
M
8
H,T,VC
MELCO A002TA2091
MELCO A002TA1991
T,C
VALEO A13 VI 102
9
VALEO A13 VI 101+
Climate
BOSCH A120411523
8
VALEO A13 VI 101+
MELCO A002TA1991
C
VALEO A13 VI 102
VC
MELCO A002TA2091
9
1.8i 16v
A
2.0i 16v
VALEO A13 VI 101+
T
MELCO A002TA2091
C,VC
BOSCH A120411523
8
12
9
VALEO A14 VI 14
VALEO A13 VI 101+
MELCO A002TA2091
MELCO A002TA1991
H
VALEO A13 VI 102
ELECTRICAL
SYSTEM
CLIMATE : T (Temperate), H ( Hot), C (Cold), VC (Very Cold)
274
H
T,C,VC
ALTERNATORS
ALL TYPES
Classes and types
Engine
Gbox.
Without air con.
Climate
3.0i V6
With air con.
12
VALEO A14 VI 24
Climate
H,T,C
VC
BOSCH A120411513
M
8
9
VALEO A13 VI 95
H,T
VALEO A13 VI 94+
H,T
MELCO A002TA2094
C,VC
MELCO A002TA1994
VALEO A13 VI 94+
9
1.9 TD
C,VC
MELCO A002TA2094
VALEO A13 VI 94+
H,T
MELCO A002TA2094
C,VC
12
VALEO A13 VI 13
C,VC
MELCO A003TA5591
9
A
VALEO A13 VI 94+
T
MELCO A002TA2094
BOSCH A12051611
MELCO A004TF0091
CLIMATE : T (Temperate), H ( Hot), C (Cold), VC (Very Cold)
275
H
ELECTRICAL
SYSTEM
VALEO A14 VI 27+
15
ALL TYPES
ALTERNATORS
Classes and types
Engine
Gbox.
2.0 HDi
M
Without air con.
Climate
With air con.
VALEO A14 VI 27+
15
Climate
VALEO A14 VI 27+
H,T,C,VC
BOSCH A12051611
MELCO A004TF0091
15
BOSCH A12051611
MELCO A004TF0091
ELECTRICAL
SYSTEM
CLIMATE : T (Temperate), H ( Hot), C (Cold), VC (Very Cold)
276
H,T,C
VC
ALTERNATORS
ALL TYPES
Classes and types
Gbox.
Without air con.
9
M
Climate
VALEO A13 VI 191
H,T
15
VALEO A14 VI 15+
H
C,VC
12
MELCO A004TA0091
T
9
A
M
9
9
2.0i 16v
A
9
Climate
MELCO A003TA0591
2.0i Turbo CT
3.0i V6
With air con.
VALEO A13 VI 191
H,T
MELCO A003TA0591
C,VC
VALEO A13 VI 101+
H,T
MELCO A002TA2091
C,VC
VALEO A13 VI 101+
H,T
MELCO A002TA2091
C,VC
M/A
15
9
12
9
15
9
15
CLIMATE : T (Temperate), H ( Hot), C (Cold), VC (Very Cold)
277
VALEO A13 VI 191
MELCO A003TA0591
VALEO A14 VI 15+
VALEO A13 VI 191
MELCO A003TA0591
VALEO A14 VI 14
VALEO A13 VI 101+
MELCO A002TA2091
VALEO A14 VI 15+
VALEO A13 VI 101+
MELCO A002TA2091
VALEO A14 VI 25+
C,VC
H,T
C,VC
H,T
C,VC
H,T
C,VC
H,T,C
VC
ELECTRICAL
SYSTEM
Engine
ALTERNATORS
ALL TYPES
Classes and types
Engine
Gbox.
Without air con.
12
M
Climate
H,T
VALEO A14 VI 13
C,VC
With air con.
Climate
15
VALEO A14 VI 16+
T
12
VALEO A14 VI 13
C,VC
12
VALEO A14 VI 13
2.1 TD
A
12
H,T
VALEO A14 VI 13
C,VC
2.5 TD
M
12
H,T
VALEO A14 VI 13
C,VC
ELECTRICAL
SYSTEM
CLIMATE : T (Temperate), H ( Hot), C (Cold), VC (Very Cold)
278
T
C,VC
12
VALEO A14 VI 13
T
C,VC
ALTERNATORS
ALL TYPES
Classes and types
Engine
Gbox.
Without air con.
8
Climate
BOSCH 0123310011
H,T
With air con.
12
MELCO A002TA0291
M
9
C,VC
9
MELCO A003TA0591
2.0i 16v
8
VALEO A14 VI 10
MELCO A004TA0091
VALEO A13 VI 81
Climate
VALEO A13 VI 81
H,T
C,VC
MELCO A003TA0591
BOSCH 0123310011
|H
15
T,C,VC
12
H
MELCO A002TA0291
A
2.0 HDi
15
VALEO A13 VI 81
VALEO A14 VI 10
MELCO A003TA0591
MELCO A004TA0091
VALEO A14 VI 27+
VALEO A14 VI 27+
MELCO A004TF0091
H,T,C,VC
BOSCH A12051611
15
MELCO A004TF0091
T,C,VC
H,T,C
VC
BOSCH A12051611
CLIMATE : T (Temperate), H ( Hot), C (Cold), VC (Very Cold)
279
ELECTRICAL
SYSTEM
9
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 Voltmeter/Ammeter/Rheostat
combination.
Adjust the engine speed (table opposite) and rheostat charge according to the vehicle's equipment specification in order to obtain U = 13.5 V.
Output under 13.5 VCurrent (A) /
Alternator speed
Speed
Class
2000
rpm
3000
rpm
4000
rpm
5
29 A
39 A
43 A
Reminder : The excitation energising current will flow through the
warning lamp - check that the warning lamp comes on when the ignition is switched on. It must go out when the engine has started (accelerate slightly).
7
42 A
54 A
59 A
CHECKING THE VOLTAGE REGULATOR
8
49 A
62 A
68 A
9
62 A
76 A
83 A
12
72 A
90 A
100 A
15
99 A
128 A
140 A
Set the rheostat to zero and disconnect all the electrical consumers.Display 5000 alternator rpm. If U alternator is > 14.7 V, the regulator is faulty.
ELECTRICAL
SYSTEM
Note : These tests should be performed with the engine hot and the
battery fully charged.
D1AP01SC
280
Vehicles / models
1.9TD
XANTIA
2.0 HDi
2.1TD
XM
2.5TD
SYNERGIE
Pre-heater plugs
Pre-heater control unit
BERU 0 100 226 186
BOSCH 0 281 003 005
BOSCH 0 250 201 039
VALEO 73507212
CHAMPION CH170
NAGARES 735068
BOSCH 0250202032
CARTIER 960411-P
BERU 0 100 226 186
VALEO 73506802
BOSCH 0 250 201 039
BERU 0 100 226 186
VALEO 73506802
BOSCH 0 250 201 039
2.0 Hdi
CHAMPION CH170
NAGARES 735068
2.0 16v HDi
BOSCH 0250202032
CARTIER 960411-P
Preheater plug resistance : 0.4 Ω
≤ R ≤ 0.6 W
281
ALL TYPES
Pre / Post heating
(pre-heating duration at 20°C)
6s / 180s
Controlled
by diesel
injection ECU
ELECTRICAL
SYSTEM
PRE-HEATING AND STARTING SYSTEMS
AIR CONDITIONING R 134 a (HFC)
ALL TYPES
Compressor
Engine
Vehicle
XANTIA
XM
AIR
CONDITIONING
SYNERGIE
Date
Refrigerant refill
(± 25 gr)
XU All types
10/94 3.0 i V6
01/97 XUD All types
DW 10 All types
(Except 2.1 TD)
02/96 2.1 TD
05/97 850 gr
XU All types
10/93 725 gr
3.0 I V6
05/97 825 gr
XUD All types
(Except 2.5 TD)
10/93 725 gr
2.5 TD
07/94 825 gr
All types
06/94 1000 ± 50 gr
Capacity
Variable
Oil quantity
cc
Oil reference
SD 7 V 16
135
SP 10
DELPHI V5
(1)
265 ± 15
PLANETELF
488
SD 7 V 16
135
SP 10
875 gr
825 gr
(1) HARRISON Division
282
ALL TYPES
Click-fit union removal/fitting tool
Vehicle
C5HP073C
XANTIA
SYNERGIE
All types
XM
3.0 i V6
XM
All types
(except V6)
Ø Inch
Ring colour
Tool kit 4164-T
5/8
Black
8005-T.A.
Blue
8005-T.B.
1/2
Tightening torques (m.daN).
Unions
Ø Pipes
Steel/Steel
Aluminium/Steel
M 06
1.7 ± 0.3
1.3 ± 0.3
M 08
3.8 ± 0.3
2 ± 0.2
M 10
4 ± 0.3
2.5 ± 0.3
REMINDER : Refilling the air conditioning system should be done through the LOW PRESSURE valve whenever possible.
NOTE : The diameters of the High Pressure and Low Pressure valves are different, to avoid mixing them up.
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 page: 280)
283
AIR
CONDITIONING
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
AIR
CONDITIONING
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.
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.
- 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.
284
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.It is therefore necessary to :
- Replace the dehydrator.
- 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
285
ALL TYPES
AIR
CONDITIONING
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
AIR
CONDITIONING
ALL TYPES
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
Presence of pollen filter
Vehicle
AX-SAXO-ZX-BX-C15
XSARA
XSARA PICASSO
XANTIA I and II
XM I and II
Equipment
RPO No.
All Types
Without aircon
Base aircon
Regulated aircon
Without aircon
Regulated aircon
All Types
Without aircon
Base aircon
# 8148
8148 # 8421
SYNERGIE
Automatic aircon
8421 #
BERLINGO
DISPATCH
RELAY
Without aircon
Base aircon
All Types
Base aircon
Without aircon
Base or double aircon
286
Presence of filter
NO
YES (Behr)
YES (Larger)
YES (Valeo)
NO
YES
NO
NO
NO
Do not fit
YES (Behr)
YES if Exclusive
NO if X and SX
NO (Valeo)
YES (Valeo)
NO
NO
NO
YES
Observations
Exc. driving school
Except Brazil
Ingress of water
Body modification
2 blowers
1 blower
XANTIA
Removing/refitting the pollen filter
Remove.
- Access from below the dashboard on passenger's side, remove the sounddeadening (1).
- Remove the three screws (2) and the cover (3).
Remove the filter (4).
Refit.
- Proceed in the opposite order to removal.
C5HP00UC
C5HP00VC
C5HP00WC
287
AIR
CONDITIONING
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
AIR
CONDITIONING
XANTIA
POINTS PARTICULIERS : CIRCUIT DE REFRIGERATION (R 134.a)
Evaporator.
OLD
C5HP063C
:
01/97
NEW 01/97
:
C5HP062C
The evaporator makes use of new technology and is called a "plate evaporator".
The coils around which the R 134.a fluid flowed previously, are replaced by plates which offer a greater area of contact with the air, thus increasing
evaporator efficiency.
288
ALL TYPES
CHECKING TEMPERATURES.
TOOLS
CHECKS.
If all these conditions are met, take the following action :
Two thermometers.
- Start the engine, with the air conditioning off, and wait for the cooling fan
first speed to cut in.
- Operate the air conditioning and set the engine speed to 2500 rpm.
Preliminary conditions.
Position of the air conditioning controls :
- Maximum cold air.
- Air blower in maximum position.
- Air distributor in "ventilation" position, with the dashboard vents open.
- Air intake flap in "exterior air" position.
NOTE : If the exterior temperature reaches 40 °C, the engine speed will
return to 2000 rpm in order to prevent the compressor from being cut off
by the High Pressure safety device (Pressostat).
After the air conditioning has been on for three minutes, measure :
- the exterior temperature in the workshop,
- the temperature of the air coming out of the central vents.
Conditions and vehicle equipment.
Compare the two values using the table overleaf.
- Bonnet closed.
- Doors and windows shut.
- Ensure the vehicle is in a sheltered area (away from wind, sun, etc..).
289
AIR
CONDITIONING
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
AIR
CONDITIONING
ALL TYPES
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
CHECKING TEMPERATURES. (continued)
Vehicle using R134.a fluid (Compressor with variable capacity)
40
35
30
25
20
15
XANTIA
20 ± 3
16 ± 3
13 ± 3
11 ± 3
9 ± 3 (*)
8±3
XM
24 ± 3
18 ± 3
15 ± 3
13 ± 3
10 ± 3
8±3
Exterior temperature in °C
Vehicles
Temperature in °Cat the
central vents
12 ± 3
SYNERGIE
(*) At exterior temperature 20°C, air temperature from the central vents is for second speed of the ventilator fan.
If fan operates at first speed, then air temperature from the central vents becomes 8.4 ± 3 °C.
NOTE : In general, the temperature of the air being blown from the central vents should be around 5°C to 8°C.
290
8±3
ALL TYPES
CHECKING PRESSURES
TOOLS : 1 Charging station and 2 Thermometers.Observing the
preliminary conditions, as well as vehicle equipment and checks
(see page 287) :After the air conditioning has been operating for
three minutes, record the following parameters :
40
Exterior temperature in °C
- The temperature of the air coming out of the central vents See the table on
page 290).
- The High Pressure.
- The Low Pressure.Compare the values recorded with the table below, or
the graphs.
Vehicle using R134.a fluid (Compressor with variable capacity)
35
30
25
20
15
Vehicles
High pressure (Bars)
Low pressure (Bars)
High pressure (Bars)
Low pressure (Bars)
High pressure (Bars)
Low pressure (Bars)
High pressure (Bars)
Low pressure (Bars)
XANTIA (1)
24 ± 3
XANTIA (2)
XM
21 ± 3
2.5 ± 3
4±3
4 ± 0.3
21 ± 3
1.9 ± 3
24 ± 0;3
3 ± 0.3
SYNERGIE
18 ± 3
16 ± 3
14 ± 3
1.4 ± 0.3
17 ± 3
15 ± 3
1.8 ± 0.3
13 ± 3
19 ± 3
2.5 ± 0.3
16 ± 3
2.1 ± 0.3
(1) SANDEN Compressor (Petrol engines : all types) - (2) = HARRISON Compressor (Diesel engines : all types).
If the parameters recorded do not correspond to those in the above table, refer to the table (see page 290).
291
14 ± 3
4 ± 0.3
1.8 ± 0.3
AIR
CONDITIONING
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
AIR
CONDITIONING
ALL TYPES
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
CHECKING PRESSURES (continued)
Low pressuretoo low
Low pressuretoo high
Low pressurenormal
High pressuretoo low
- Insufficient fluid charge.
- Constriction of the HP system.
- Dirty pressure control valve.
- Cooling fan speed unsuitable.
- Faulty compressor.
- Faulty pressure control valve.
- Faulty compressor.
High pressurenormal
- Faulty compressor.
- Dirty evaporator.
- Circuit normal.
- Cooling fan speed unsuitable
- Presence of solid matter in the
system.
- Dirty condenser.
-
High pressuretoo high
- Faulty pressure control valve.
- System blocked.
- Water in the system.
Checking the pressure at temperatures between 15°C and 35°C for information only.
In general, the pressure should be approximately :
- for R134.a fluid, less than 2 Bars (Low pressure), and between 13 and 24 Bars (High pressure).
292
Excessive fluid charge.
Dirty condenser.
Faulty pressure control valve.
Cooling fan speed unsuitable.
XANTIA All Types (Except V6 - XUD)
C5HP12EC
Tightening torques (m.daN).
abcdefC5HP12GD
293
1.8
1.8
1.8
1
3.5
0.7
(1) High pressure valve
(2) Low pressure valve
(3) Clickfit union
AIR
CONDITIONING
AIR CONDITIONING SYSTEM R134.a
AIR
CONDITIONING
XANTIA V6
AIR CONDITIONING SYSTEM R134.a
C5HP12EC
(1)
(2)
(3)
(4)
C5HP12HD
294
High pressure valve
Low pressure valve
Clickfit union
Pressostat
XANTIA All Types (Except XUD)
Checking the air conditioning circuit
Key
T = Temperature (C°) and High Pressure
(Bars).
P = Low pressure (Bars).
Te = Exterior temperature (C°).
HP = Pressure at compressor outlet (Bars).
Ta = Temperature of air blown from the
central air vents (C°).
BP = Pressure at compressor inlet (Bars).
C5HP01ZD
295
AIR
CONDITIONING
AIR CONDITIONING SYSTEM R134.a
AIR
CONDITIONING
XANTIA - XUD
AIR CONDITIONING SYSTEM R134.a
(1) - High pressure valve
(2) - Low pressure valve
Air conditioned XANTIA XUD All Types are equipped with a new
"HARRISON" refrigeration compressor, with variable capacity.
All other models are fitted with a "SANDEN" compressor.
Parts modified.
(5) - "HARRISON" variable capacity compressor, reference
"DELPHI V5".
(3) - Air conditioning pipes, secured to the compressor with nuts
instead of clamps.
(4) - Modified seals to suit the new attachments.Belt length : 1710 mm
instead of 1700 mm.
C5HP05XD
296
XANTIA - XUD
Checking the air conditioning circuit
Key
T = Temperature (C°) and High Pressure
(Bars).
P = Low pressure (Bars).
Te = Exterior temperature (C°).
HP = Pressure at compressor outlet (Bars).
Ta = Temperature of air blown from the
central air vents (C°).
BP = Pressure at compressor inlet (Bars).
C5HP122D
297
AIR
CONDITIONING
AIR CONDITIONING SYSTEM R134.a
AIR
CONDITIONING
XM - All Types (Except V6 - 2.5 TD)
AIR CONDITIONING SYSTEM R134.a
C5HP12KC
(1) High pressure valve
(2) Low pressure valve
(3) Clickfit union.
C5HP12JD
298
C5HP12EC
(1) High pressure valve
(2) Low pressure valve
(3) Clickfit union.
C5HP12HD
299
AIR
CONDITIONING
XM - V6
AIR CONDITIONING SYSTEM R134.a
AIR
CONDITIONING
XM - 2.5 TD
AIR CONDITIONING SYSTEM R134.a
C5HP12KC
(1) High pressure valve
(2) Low pressure valve
(3) Clickfit union.
C5HP12LD
300
XM - All Types
Checking the air conditioning circuit
Key
T = Temperature (C°) and High Pressure
(Bars).
P = Low pressure (Bars).
Te = Exterior temperature (C°).
HP = Pressure at compressor outlet (Bars).
Ta = Temperature of air blown from the
central air vents (C°).
BP = Pressure at compressor inlet (Bars).
C5HP068D
301
AIR
CONDITIONING
AIR CONDITIONING SYSTEM R134.a
AIR
CONDITIONING
SYNERGIE - XU - EW10
AIR CONDITIONING SYSTEM R134.a
C5HP12EC
Tightening torques.
(1)
(2)
(3)
(4)
(5)
a
b
c
C5HP15PP
302
High pressure valve
Low pressure valve
Pressostat, tighten to 1.8 m.daN
Dryer
Clickfit union
0.8 m.daN
4 m.daN
0.8 m.daN
SYNERGIE - DW10
C5HP12EC
Tightening torques.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
C5HP15EP
303
High pressure valve
Low pressure valve
Clickfit union
Pressostat, tighten to 1,8 m.daN
Flange fixing, tighten to 0,8 m.daN.
Flange fixing, tighten to 0,8 m.daN.
Flange fixing, tighten to 4 m.daN.
AIR
CONDITIONING
AIR CONDITIONING SYSTEM R134.a
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