Downloaded From Manuals Search Engine: Ac - Qcav/Mtd Méthodes Techniques Documentation

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 CITRON network periodically for further information and
to obtain any possible updates.
CAR 050016
Downloaded from www.Manualslib.com manuals search engine
2003
PRESENTATION
THIS HANDBOOK summarises the specifications, adjustments, checks and special features of the CITROEN C2.
The handbook is divided into nine groups representing the main functions :
GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - ELECTRICAL
AIR CONDITIONING.
IDENTIFICATION OF VEHICLES
A : Cold stamp
(Cold stamp engraved on the bodywork).
C : AS/RP No. and RP paint code.

(On the LH centre pillar)
D : Tyre pressures and tyre type.
E : Serial number on bodywork.
F : Gearbox ident. reference Factory serial no.
G : Engine legislation type Factory serial no.
E1AP0C3D
GENERAL
B : Manufacturers name plate

Petrol
TU
1
JP
GENERAL
Emission standard
Type code
JP4
1.1i
1.4i
1.6i 16 V
A - X - SX - SX Pack
SX - SX Pack - VTR
VTR
L4
IFL5
L4
JM HFXB
JM
HFXC/IF (*)
JM
KFVC/P
IFL5
JM
KFVC/PIF (**)
JM KFVC/IF (*)
JM NFUC/IF (*)
Engine type
HFX
KFV
NFU
Cubic capacity (cc)
1124
1360
1585
Fiscal rating (hp)

Gearbox type
MA5
Gearbox ident. plate

(1) = Europe
(2) = Export
MA5
20 CF 20 (mp) (3)
(3) mp = Piloted manual gearbox

(4) m = Manual gearbox
MA5
MA5
20 CF 21 (m) (4)
MA5
MA5
MA5
20 CF 16
(2) (m) (4)
20 CN 48
(mp) (3)
20 CN 50
(mp) (3)
(*) = IF : Fiscal incentive

(**) = PIF: Power fiscal incentive
2
MA5
20 CF 25
(1) (m) (4)
Diesel
DV
4
TD
1.4 HDi
Emission standard
L4
Type code
IFL5
JM 8HXB
JM 8HXC/IF (*)
Engine type
8HX
Cubic capacity (cc)
1398
Fiscal rating (hp)

Gearbox type
Gearbox ident. plate
(1) = Europe
(2) = Export
JM 8HXC/PIF (**)
4
MA5
MA5
MA5
MA5
MA5
20 CN 51 (1) (m) (4)
20 CN 33 (2) (m) (4)
20 CN 51 (1) (m) (4)
20 CN 33 (2) (m) (4)
20 CN 49 (mp) (3)
(3) mp = Piloted manual gearbox

(4) m = Manual gearbox
(*) = IF : Fiscal incentive

(**) = PIF: Power fiscal incentive
3
GENERAL
X - SX SX Pack - VTR
Manufacturers plate.
The manufacturers plate carries the following information :
(a) Type approval number (*).
(b) Type serial number (VIN).
GENERAL
(c) Gross vehicle weight (*).

(d) Gross vehicle weight (*).
(e) Maximum weight on front axle (*).
(f) Maximum weight on rear axle (*).
(g) Manufacturer identification.
(*) = according to marketing country.
E1AP09JC
Factory code.
Structure
The factory code is composed of 6 figures or letters.
J = Vehicle family.
M = Body shape.
HFX = Engine.
C = Version.
Body shape
Family
Ref.
Family
CITRON C2
Engine
Ref.
Body shape
3-door saloon (4-seater)
Version (Gearbox and emission standard)
Ref.
Capacity
Engine type
Ref.
Gearbox
Emissions
HFX
1124
TU1JP/EURO/3/IF EURO /4
EURO/3
KFV
1360
TU3JP/ EURO /3/IF EURO /4
Manual
5-speed gearbox
NFU
1587
TU5JP4/IF EURO /4
8HX
1398
DV4TD EURO/3
EURO/4
5
IF EURO/4
GENERAL
Example : JM HFXC
GENERAL SPECIFICATION : DIMENSIONS

Exterior dimensions
GENERAL
E1AP0C4D
GENERAL SPECIFICATION : DIMENSIONS

Vehicles
Wheelbase
Length overall
Front overhang
Rear overhang
Rear track *
Front track *
Width overall
Height overall *
All types
2315
3666
760
591
1435
1438
1660
1462
A
B
C
D
E
F
G
H
(*) = Vehicle in running order (vehicle empty, levels topped up).

Interior dimensions and volumes (mm)
Elbow width, front
Elbow width, rear
Height of boot below parcel shelf
Minimum floor width
Depth of bootspace at floor level
Volume of boot below parcel shelf (dm3)
Volume in dm3 of boot below Moduboard (*)
1406
1402
585
1040
660
305
282
(*) = Boot floor with adjustable configuration.

7
GENERAL
Exterior dimensions (mm)
GENERAL SPECIFICATION : WEIGHTS

Petrol
Versions
1.1i
1 4i
Engine type
HFX
KFV
Gearbox type
Diesel
1.6i 16V
1.4 HDi
NFU
8HX
MA
Payload
GENERAL
Weight empty
Without options
in running order
With all options
485
465
467
479
1053
1080
1133
1097
1138
1147
1200
1177
Gross vehicle weight
1463
1470
1525
1501
Gross train weight
2113
2370
2425
2401
Maximum trailer weight without brakes
926
1174
1176
1175
Maximum trailer weight with brakes
526
540
566
548
Incline 12%
38
47
48
47
Maximum nose weight
60
60
60
60
OPERATIONS TO BE CARRIED OUT AFTER A REPAIR

IMPERATIVE : All these operations are to be performed following a reconnection of the battery.
Antiscanning function.
It is necessary to wait 1 minute after the battery has been disconnected in order to be able to start the vehicle.
Overspeed check.
The vehicles overspeed values have to be re-initialised.
The button on the wiper stalk (multifunction display B or C ) or the button on the dashboard (multifunction display A or clock) operates the following
functions:
- Activation of the vehicles overspeed function.
- Programming of the overspeed alert.
Electric windows
It may be necessary to re-initialise the sequential and anti-pinch functions.
NOTE : If the window is open at the time the battery is reconnected, action the window switch several times to close it, then re-initialise.
Open the window fully.
Action and release the window switch until the window is completely closed.
This operation has to be carried out on each electric window.
GENERAL
Tailgate.
The opening of the tailgate is deactivated on reconnection of the battery.
Perform locking/unlocking to activate the opening of the tailgate.
OPERATIONS TO BE CARRIED OUT AFTER A REPAIR

Sun roof.
The anti-pinch function has to be re-initialised.
Place the sun roof switch in the maximum tilt position.
Keep the sun roof switch pressed until the sun roof ceases its movement.
Release the sun roof switch within 5 seconds.
Keep the sun roof switch pressed until the end of the sun roof opening sequence.
GENERAL
Multifunction screen.
It is necessary to adjust the date, time and outside temperature.
Adjust the display language of the multifunction screen if necessary.
NOTE : The default display language of the multifunction screen is French.
Navigation.
Warning, the vehicle has to be in the open air (on switching on the ignition, the ECU searches for satellites).
Vehicle location is only effective after some ten minutes.
Reprogramme the customer parameters.
Radio.
Reprogramme the radio stations.
Radiotelephone RT3.
Reprogramme the radio stations.
10
GENERAL SPECIFICATION : TOWING THE VEHICLE

Front towing
Towing eye
(1) Towing eye
Rear towing
The towing eye (1) is to be found in the vehicle

toolkit located under one of the front seats.
E2AP02AC
E2AP029C
11
E2AP02BC
GENERAL
WARNING : When the engine is not running,

steering and braking are no longer power-assisted.

Vehicle towing : Precautions to be taken
Manual gearbox
Piloted manual gearbox

IMPERATIVE : It is necessary to lift the front of the vehicle in
order to tow it, after having positioned the gear lever in neutral.
GENERAL
WARNING : Whether the ignition is switched on or not, an action on

the gear selector will move the clutch fork and the gear engagement
lever.
If a gear is engaged, there is more than one way to free it :
- Engage N, with the aid of a diagnostic tool
- Engage N, without the diagnostic tool
ESSENTIAL : Never tow the vehicles with wheels hanging

(towing by the wheels).
Essential : Never swap two gearbox ECUs between two vehicles.

IMPERATIVE : If a gear is engaged and it is not possible to free it,
The vehicle must be towed with the front wheels raised.
12

Engagement of N, using a diagnostic tool.
Engagement of N, without a diagnostic tool.
Preliminary operation :
- Battery voltage higher than 12 Volts.
- Ignition switched on.
- Connect the diagnostic tool to the vehicles diagnostic socket.
IMPERATIVE : This recovery solution is to be used solely in a case

where the methods for setting the gearbox actuators using the
diagnostic tool have failed (destruction of the gearbox actuator)
Using the menus of the diagnostic tool, select :

- DIAGNOSIS
- MA piloted manual gearbox.
- Actuator tests.
- Gearbox actuator test.
- Gear engagement test.
- N (Neutral).
NOTE : The letter N should appear on the instrument panel. If this
does not happen, see the following solution:
- Engagement of N, without using a diagnostic tool.
13
GENERAL
In this configuration, the gearbox actuator is blocked, gear engaged.

Preliminary operations:
- Disconnect the battery negative terminal.
- Remove the air filter.
GENERAL
- Position a 22 mm flat spanner.

- Lift the gear engagement lever as far as possible (in the direction of
the arrow); use a screwdriver to hold it in this position.
- Turn the spanner until the axis of the gear engagement lever (A) is at
right angles to the axis (B).
- When this position is attained, position N is engaged.
Moving the vehicle.
IMPERATIVE : Never be towed with the ignition switched on.
Never attempt to push-start the vehicle (impossible with a piloted manual
gearbox).
B2CP3L8D
14
GENERAL SPECIFICATION: LIFTING AND SUPPORTING THE VEHICLE

Front lifting
Lifting and supporting the vehicle
Side lifting
Front of the vehicle.
ESSENTIAL : Never attempt to lift by the front

panel mountings.
Side lifting
Always ensure the jack is correctly positioned at the
lifting points.
Do not place the axle stands under the jack contact
lugs.
Lifting from the rear.
IMPERATIVE : Do not lift the vehicle by the rear.
Position of the axle stand.
B3CP07KC
E2AP016C
E2AP017C
E2AP018C
15
E2AP00GC
GENERAL
The authorised lifting points at the front of the vehicle are on the rear fixing bolts of
the subframe at a.
For front lifting, take weight at the two lifting points at a, using a crossbeam equipped
with blocks.
For front lifting from the side, take weight at the lifting point at a.
GENERAL SPECIFICATION: LIFTING AND SUPPORTING THE VEHICLE

Lifting and supporting the vehicle (continued)
Lifting with the handle jack at the front
Lifting on a two-column lift using the jack supports
GENERAL
E2AP025C
E2AP027D
Lifting with the handle jack at the rear
NOTE : The handle jack is specific to the vehicle, do not use

it for any other purposes.
Lift accessory with blocks on the jack supports
E2AP026C
E2AP028D
16
CAPACITIES (in litres)

Draining method.
The oil capacities are defined according to the following methods.
1/ Vehicle on level surface (in high position, if equipped with hydropneumatic suspension).
3/ Draining of the oil sump + removal of the cartridge (duration of draining + dripping = 15 min).
4/ Refit plug + cartridge.
5/ Engine filling.
6/ Engine starting (allowing the cartridge to be filled).
7/ Engine stopped (stationary for 5 min).
ESSENTIAL : Systematically check the oil level using the oil dipstick.
17
GENERAL
2/ Engine warm (oil temperature 80C).
CAPACITIES (in litres)

C2
Petrol
1.1i
Engine type
GENERAL
Drain by gravity : engine with filter change
HFX
1.4i
1.6i 16V
KFV
NFU
8HX
3.25
3.75
Between Min. and Max.
Braking circuit
1.4 HDi
1.8 9 RPO 9844)

1.5 (RPO 9845 9)
1.5
MA5 5-speed gearbox

MA5 piloted 5-speed gearbox
Diesel
2
2 0.15
0.7 Litre version with front calipers 48 / rear drums
0.8 Litre version with front calipers 54 / rear discs
Cooling system
5.6
Fuel tank capacity
40
45
ESSENTIAL : Systematically check the oil level using the oil dipstick.
18
LUBRICANTS - TOTAL recommended oils
GENERAL
S.A.E. Norm - Table for selection of engine oil grade
E4AP006D
19
LUBRICANTS TOTAL recommended oils

Factory evolutions in 2001 model year
ESSENTIAL : For all vehicles with a 30,000 km (20,000 miles)

maintenance interval, use exclusively TOTAL ACTIVA/QUARTZ
7000 or 9000 or any other oils offering identical specifications to
these.
These oils offer specifications that are superior to those defined
by norms ACEA A3/98 or API SJ.
Failing this, it is essential to adhere to the maintenance programmes covering severe operating conditions.
CITRON 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%).
GENERAL
Features of CITRON C5 :
2.0 and 2.2 HDi engines have a particle filter.
The maintenance interval for normal operation
is 30,000 km (20,000 miles) for petrol engines.
5W30 cannot be used in the following engines:

XU10J4RS : XSARA VTS 2.0i 16V (3 doors).
SOFIM : RELAY 2.8 D and 2.8 TD.
1580 SPI : DISPATCH 1.6i.
2.0 and 2.2 HDi engines equipped with particle filter.
WARNING : HDi engines are high technology engines which

imperatively require use of quality SYNTHETIC OILS : TOTAL
ACTIVA or TOTAL QUARTZ 5W40.
To maintain engine performances, all countries in Europe
should observe this requirement.
WARNING : CITRON engines prior to model year 2000 do not

have to be lubricated with oils adhering to the norms ACEA A198/B1-98 and API SJ/CF EC.
NOTE : Only PORTUGAL and GREECE may use 10W40 semisynthetic oil.
20
ACEA Norms
The first letter corresponds to the type of engine concerned :
A : petrol and dual fuel petrol / LPG engines.
B : diesel engines.
API Norms
The first letter corresponds to the type of fuel used by the engine :
S : petrol and dual fuel petrol / LPG engines.
C : diesel engines.
The figure following the first letter corresponds to the type of oil.
1 : highly fluid oils, for reducing friction and lowering fuel
consumption.
3 : high performance oils.
The number after that (96 or 98) corresponds to the year of
creation of the norm.
The second letter corresponds to the degree of evolution, in ascending

order.
Example : The norm SJ is more severe than the norm SH and corresponds to a higher level of performance.
The adding of the letters EC indicates that the engine oil concerned is
an oil which permits fuel economy.
EC : Energy Conserving, reduction in fuel consumption.
Examples :
API SJ / CF : Blended oils for all engines.
engines API CF / EC: Oils specifically for diesel engines, permitting fuel
economy.
API SJ / CF / EC : Blended oils for all engines, permetting fuel economy.
NOTE : From 01/03/2000, all engine oils must comply with ACEA-98
norms.
Example :
ACEA A1-98 / B1-98 : Blended oils for all engines, permitting fuel
economy (complying with ACEA 98 norms).
21
GENERAL
Selection of engine oil grades recommended for climatic conditions in countries of distribution
GENERAL
Engine oil norms.

Norms in force.
These engine oils have been classified by the following recognised organisations:
S.A.E. : Society of Automotive Engineers.
API : American Petroleum Institute.
ACEA : Association des Constructeurs Europens dAutomobiles.
Recommendations.
Denominations of TOTAL oils, according to country of marketing:
TOTAL ACTIVA
(France only).
TOTAL QUARTZ
(Outside France).
ESSENTIAL : To preserve engine performances, all engines fitted in CITROEN vehicles must be lubricated with high
quality oils (synthetic or semi-synthetic)
Summary
Engine oil norms to be respected in 2001 model year
Model year
AM 2001
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 (*)
(*) = It is essential not to use engine oils respecting these norms for the following engine-types .
XU10J4RS. 1580 SPI. SOFIM 2.8 D and SOFIM 2.8 TD.
22

S.A.E. grades
SPI norms
ACEA norms
Blended oils for all engines (petrol, dual-fuel petrol / LPG and diesel)
TOTAL ACTIVA 9000
TOTAL QUARTZ 9000
TOTAL ACTIVA 9000. (*)
TOTAL QUARTZ 9000. (*)
TOTAL ACTIVRAC
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
GENERAL
(*) = Blended oils for all engines, permitting fuel economy.

Oils specifically for petrol and dual-fuel petrol / LPG engines
TOTAL ACTIVA 7000
TOTAL QUARTZ 7000
10W-40
TOTAL QUARTZ 9000
0W-40
TOTAL ACTIVA 7000

TOTAL QUARTZ 7000
15W-50
Oils specifically for diesel engines
TOTAL ACTIVA DIESEL 7000

TOTAL QUARTZ DIESEL 7000
10W-40
15W-50
5W-40
23
LUBRICANTS TOTAL RECOMMENDED OILS

FRANCE
Blended oils for all engines, supplied in bulk
TOTAL ACTIVRAC
Metropolitan FRANCE
S.A.E : 10W-40 Norms

TOTAL ACTIVA DIESEL
TOTAL ACTIVA
GENERAL
Metropolitan FRANCE
New Caledonia
Guadeloupe
Saint-Martin
La Runion
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
9000 5W-40
9000 5W-30 (*)
7000 10 W-40
7000 10W-40
9000 5W-40
9000 5W-40
7000 15W-50
(*) = Blended oils for all engines, permitting fuel economy.

24
7000 15W-50
LUBRICANTS TOTAL RECOMMENDED OILS

EUROPE
(*) = Blended oils for all engines,
permitting fuel economy
TOTAL QUARTZ DIESEL

Germany
7000 10W-40
9000 0W-40
Austria
7000 10W-40
Belgium
7000 10W-40
9000 0W-40
Bulgaria
Cyprus
Croatia
Denmark
7000 10W-40
7000 15W50
7000 10W-40
9000 5W-40
9000 5W-30 (*)
7000 10W-40
9000 0W-40
7000 10W-40
7000 15W-50
Spain
Estonia
7000.10W-40
Finland
7000 10W-40
9000 0W-40
Great Britain
7000 10W-40
25

engines
GENERAL
TOTAL QUARTZ
7000 10W-40

EUROPE (continued)
TOTAL QUARTZ
TOTAL QUARTZ DIESEL

GENERAL
Greece
7000 10W-40
7000 15W-50
Holland
Hungary
Italy
Irland
Iceland
Latvia
Lithuania
Macedonia
7000 10W-40
9000 0W-40
7000 10W-40
7000 10W-40
9000 0W-40
7000 10W-40
7000 10W-40
7000 15W-50
7000 10W-40
7000 10W-40
9000 0W-40
9000 5W-40
9000 5W-30 (*)
Malta
Moldova
Norway
Poland
Portugal
Slovak Republic
7000 10W-40
26

engines
7000 10W-40

EUROPE (continued)
TOTAL QUARTZ
TOTAL QUARTZ DIESEL

Czech Republic
7000 10W-40
9000 0W-40
Roumania
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
Switzerland
7000 10W-40
Turkey
7000 10W-40
7000 15W-50
9000 0W-40
Ukraine
7000 10W-40
9000 0W-40
Yugoslavia
7000 10W-40
27

engines
GENERAL
(*) = Blended oils for all engines, permitting fuel economy
7000 10W-40

TOTAL QUARTZ
Blended oils for all
engines
GENERAL
Australia
New-Zealand
OCEANIA
Ivory Coast
Egypt
Gabon
Madagascar
Morocco
Senegal
Tunisia
AFRICA
Argentina
Brazil, Chile
Cuba
Mexico
Paraguay
Uruguay
CENTRAL
AND SOUTH
AMERICA


engines
7000 10W-40
7000 10W-40
9000 5W-40
7000 15W-50
28
TOTAL QUARTZ DIESEL

TOTAL QUARTZ
Blended oils for all

engines
South Korea
GENERAL
7000 10W-40
9000 5W-40
Hong-Kong
India
Indonesia
Malaysia
Pakistan
Philippines
Singapore

engines
7000 10W-40
7000 15W-50
China
Japan

TOTAL QUARTZ DIESEL
7000 15W-50
SOUTH EAST
ASIA
7000 10W-40
7000 15W-50
9000 5W-40
9000 5W-30
7000 15W-50
9000 5W-40
7000 10W-40
7000 15W-50
Taiwan
Thailand
7000 15W-50
Vietnam
29
7000 10W-40

TOTAL QUARTZ DIESEL
TOTAL QUARTZ


engines
9000 5W-40
7000 15W-50
7000 10W-50
Saudi Arabia
GENERAL
Bahrain
Dubai
United Arab Emirates
Iran
Israel
Jordan
MIDDLE
EAST
Kuwait
Lebanon
Oman
Qatar
Yemen
30

Gearbox oils
Manual gearbox
MB3 automatic gearbox
All countries
TOTAL FLUIDE ATX ou

TOTAL FLUIDE AT 42.
Special oils distributed by CITRON
(Part No. 9730 A3)
Special oil distributed by CITRON
(Part No. 9736 22)
4 HP 20 and AL4 automatic gearboxes

Transfer box and rear axle
TOTAL TRANSMISSION X 4
Power steering oils

All countries
TOTAL FLUIDE ATX
Very cold countries
TOTAL FLUIDE DA
(Part No. 9730 A1)
Power- assisted steering
31
GENERAL
TOTAL TRANSMISSION BV
Norms S.A.E 75W-80
(Part No. 9730 A2)

Engine coolant fluid
Packs
GENERAL
All countries
CITROEN Fluid
Protection : - 35C
All countries
CITROEN Fluid
TOTAL LHM PLUS

All countries
TOTAL FLUIDE LDS
2 litres
5 litres
20 litres
210 litres
Synthetic brake fluid
CITROEN reference
GLYSANTIN G 33
REVCOGEL 2000
9979 70
9979 72
9979 71
9979 73
9979 76
9979 74
9979 77
9979 75
Packs
CITROEN reference
0.5 litre
1 litre
5 litres
CITROEN hydraulic circuit fluid
Norme
ISO 7308-7309
Green in colour
Orange in colour
9979 05
9979 06
9979 07
Packs
1 litre
WARNING: TOTAL LDS fluid cannot be blended with TOTAL LHM PLUS
WARNING: CITRON C5 : Use only TOTAL FLUIDE LDS suspension fluid.
Hydraulic circuit rinsing fluid- green in colour
All countries
TOTAL HYDRAURINCAGE
32
CITROEN reference
ZCP 830 095
9979.20 (Scandinavia)
9979.6

Wash/wipe fluid
Packs
All countries
CITROEN reference
Concentrated : 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
Norms NLGI (1)

All countries
TOTAL MULTIS EP2
TOTAL MULTIS COMPLEX EP2

TOTAL MULTIS N4128
2
1
TOTAL PETITES MECANIQUES
(1) NLGI = National Lubricating Grease Institute.
33
GENERAL
Grease
ENGINE OIL CONSUMPTION

I - Oil consumption depends on :
-
the engine type.

how run-in or worn it is.
the type of oil used.
the driving conditions.
II - An engine can be considered RUN-IN after:

GENERAL
- 3,000 miles (5,000 km) for a PETROL engine.

- 6,000 miles (10,000 km) for a DIESEL engine.
III - MAXIMUM PERMISSIBLE oil consumption for a RUN-IN engine.
- 0.5 litres per 600 miles (1,000 km) for a PETROL engine.
- 1 litre per 600 miles (1,000 km) for a DIESEL engine.
DO NOT WORK BELOW THESE VALUES.
IV - OIL LEVEL : The level should NEVER be above the MAX. mark on the dipstick after changing or topping up the oil.
- This excess oil will be used up rapidly.
- It will reduce the engine output and adversely affect the operation of the air circuits and gas recycling.
34
Petrol
Diesel
1.1i
1.4i
1.6i 16V
Engine type
HFX
KFV
NFU
8HX
Cubic capacity (cc)
1124
1360
1587
1398
Bore / Stroke
72/69
75/77
78/82
73/82
11/1
17.9/1
Compression ratio
10.5/1
1.4 HDi
Power ISO or EEC KW - rpm
44-5500
54-5400
80-5800
50-4000
Power DIN (HP - rpm)
61-5500
75-5400
110-5800
70-4000
Torque ISO or EEC (m.daN - rpm)
9.4-3400
12-3400
14.7-4000
15-2000
Torque DIN (mkg-rpm)
9.8-3400
12.5-3400
15.3-4000
15.6-2000
35
ENGINE
ENGINE SPECIFICATIONS
ENGINE
Engines : HFX - KFV - NFU
Engine identification
A = Engines :
HFX - KFV
B = Engine :
NFU
Compulsory engine identification

in zone a :
- Component reference.
- Engine legislation type.
- Factory serial no.
B1BP10JC
B1BP2GKC
36
ENGINE
CYLINDER HEAD
Identification of cylinder head gasket
Engine types
Thicknesses
(Standard)
Thicknesses (repair)
1.2 0.1
1.4 0.1
HFX
KFV
Thickness references
2
1
0.66 0.04
NFU
References
1.2.3.4 = Type of engine.
A,B,D
= Suppliers.
= Gasket material.
= Repair.
B1BP10KC
37
ENGINE
CYLINDER HEAD
Cylinder head tightening (m.daN)
Cylinder head bolts

HFX - KFV
Tightening
Angular tightening
2 0.2
240 5
(In the order 1 to 10)

NFU
Tightening
Angular tightening
2 0.2
260 5
NOTE : Retightening of the cylinder head

after a completed repair is prohibited.
NOTE : Oil the threads and

under the heads of the bolts.
(Use engine oil or Molykote G
Rapid Plus).
B1DP05BC
38
B1BP1DVC
X = MAXIMUM reusable length

HFX - KFV
NFU
175.5 0.5
122 0.3
Crankshaft
Accessories drive pulley
2.5 0.2
Pinion fixing on crankshaft

- Tightening
4 0.4
- Angular tightening
45 4
Cylinder block
Sump
Timing belt tensioner roller
Accessories belt tensioner roller
Accessories belt guide roller
Alternator support
0.8
2.1
2.5
2.5
2.5
0.2
0.2
0.2
0.2
0.2
Alternator TU1JP-TU3JP
- Pre-tightening
- Tightening
Alternator TU5JP4
1
3.7 0.3
- Pre-tightening
- Tightening
Aircon compressor support
Aircon compressor
1
4 .04
2.2 0.2
2.3 0.2
39
ENGINE
SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)
ENGINE

Cylinder head
Coolant outlet housing
- in plastic
0.8 0.2
- in aluminium
0.8 0.2
Camshaft bearing caps (TU1JP-TU3JP)

- Tightening
2 0,2
44 4
Camshaft bearing caps (TU5JP4)

- Tightening
2 0,2
50 5
Inlet manifold
0.8 0.,2
Exhaust manifold
1.8 0.4
Valve rockers adjusting screw
1.75 0.25
Sparking plugs
Camshaft pulley screw (TU1JP-TU3JP)
3.7 0.2
Camshaft pulley screw (TU5JP4)
4.5 0.5
40
Flywheel - Clutch
Engine flywheel
6.7 1 (LOCTITE FRENETANCH)
Oil pressure mechanism
2 0.2
Lubrication circuit
Oil pressure switch
3.5 0.5
Oil pump
0.9 0.1
Cooling circuit
Coolant pump
1.6 0.2
41
ENGINE
ENGINE
TIGHTENING TORQUES : POWER UNIT SUSPENSION

(1)
: 6 0.6
(2)
: 6 0.6
(3)
: 4.5 0.4
(4)
: 6 0.6
(5)
: 6 0.6
(6)
: 8.5 0.8
(7)
: 6 0.6
(8)
: 3 0.3
(9)
(10)
B1BP2Y3P
42
: 6 0.6
: 5.5 0.5
ENGINE
Engine : 8HX
Engine identification
"a" Engine legislation type.

"b"Component reference.
"c" Factory serial no.
B1CP0BKD
43
ENGINE
CYLINDER HEAD
Engine : 8HX
Cylinder head tightening (m.daN)
Cylinder head bolts

8HX
Pre-tightening
2 0.2 m.daN
Tightening
4 0.4 m.daN
Angular tightening 230 5

NOTE :
- The bolts should have been thoroughly cleaned and dried with a
dry metal brush.
- Oil the threads and under the
heads of the bolts. (Use engine
oil or Molykote G Rapid Plus).
The cylinder head gasket is dry-fitted.
NOTE : Retightening of the cylinder head
after a completed repair is prohibited.
- Pass a tap into the holes in the

cylinder block.
X = MAXIMUM reusable length

8HX
X = 149 mm
B1DP1CLC
44
B1DP1DBC
Crankshaft mobile
Bearing cap fixing screws
Pre-tightening
1 0.2
Slackening
180
Tightening
3 0.3
Angular tightening
140
Con rod screws

Tightening
1 0.1
Angular tightening
100 5
Accessories drive pulley

Pre-tightening
3 0.3
Angular tightening
180 5
Cylinder block
Sump
1.3 0.1
Timing belt guide roller
2.3 0.2
Timing belt tensioner roller
3.7 0.3
45
ENGINE
ENGINE

Cylinder head
Camshaft bearing covers
Pre-tightening
0.3 0.1
Tightening
1 0.1
Fixing of camshaft sub-assemblies on cylinder head

Pre-tightening
0.3 0.1
Tightening
1 0.1
Exhaust manifold
3 0.3
Camshaft pulley
Pre-tightening
0.3 0.1
Tightening
4.3 0.4
Engine flywheel
Flywheel
Pre-tightening
1.7 0.2
Tightening
70 5
Clutch mechanism
2 0.2
46
Lubrication circuit
Oil pump assembly
Pre-tightening
0.5 0.1
Tightening
Coolant/oil heat exchanger
0.9 0.1
1 0.1
Diesel injection circuit
Spherical-base screws for diesel injection fixing fork

Fuel high pressure common injection rail on engine block
Unions on fuel high pressure common injection rail
Diesel injection pump on support
Union on diesel injection
Diesel injection pump pulley
Union on diesel high pressure pump
2.5 0.2
2.2 0.2
2.5 0.2
2.2 0.2
2.5 0.2
5 0.5
2.5 0.2
Cooling circuit
Coolant pump
Pre-tightening
0.3 0.1
Tightening
Coolant outlet housing
Pre-tightening
0.9 0.1
Tightening
0.7 0.1
0.3 0.1
47
ENGINE
ENGINE
TIGHTENING TORQUES : POWER UNIT SUSPENSION

Engine : 8HX
B1BP2Y1P
48
(1)
: 6 0.6
(2)
: 6 0.6
(3)
: 6 0.6
(4)
: 6 0.6
(5)
: 3 0.3
(6)
: 6 0.6
(7)
: 5.5 0.5
(8)
: 5.7 0.9
Tools
B1EP135D
49
4122-T (C.TRONIC.105.5)
ENGINE
4099-T (C.TRONIC.105)
BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
Petrol
Diesel
TU
DV
3
JP
Engine type
C2
JP4
TD
HFX
KFV
NFU
8HX
See pages :
50 to 52
50
53 to 55
ENGINE

Tools.
[1] Pliers for removing plastic pegs
[2] Belt tension measuring instrument
: 7504-T.
: 4122-T.
Vehicle without air conditioning.

Remove.
Slacken:
- Screw (2).
- Screw (3).
- Tensioning screw (1).
Push the alternator back towards the engine.
Remove the belt.
B1BP2LSC
B1BP2LTC
51
Refit.
Refit the belt.
Respect the following sequence:
- Crankshaft pinion.
- Alternator pulley.
Place tool [2] on the belt.
Tighten screw (1) to achieve a tension of:
55 3 units SEEM.
Tighten:
- Screw (3).
- Screw (2).
Remove tool [2] and complete the refitting.
ENGINE

Vehicle with air conditioning.
Remove
Slacken:
- Screws (6), (4) and (5).
- Fully detension the belt by acting on the tensioner roller.
- Remove the accessories drive belt.
Refit.
Respect the following sequence:
- Crankshaft pinion.
- Aircon compressor pulley.
- Guide roller.
- Alternator pulley.
- Tensioner roller.
Place tool [2] on the belt.
- Tighten screw (5) to achieve a belt tension of:
120 3 SEEM units.
- Tighten screws (4) and (6).
- Remove tool [2].
- Complete the refitting.
B1BP10VC
B1BP10XC
52
ENGINE

With compressor and alternator
Engine : 8HX
Tools
[2] Tensioner roller compression lever
[3] Tensioner roller setting peg 4 mm
: 7504-T.
: (-).0194.E.
: (-).0194.F.
Removing.
Disconnect the battery negative cable.
Raise and support the vehicle, wheels hanging.
Remove the front RH wheel.
Move aside the splash-shield, using tool [1].
IMPERATIVE : In the case of belt re-use, mark the direction of rotation of the belt. If the index on the tensioner
roller is outside the marks, change the auxiliary equipment drive belt.
Remove :
The alternator (1).
The aircon compressor (2).
Detension the auxiliary belt tensioner roller, using tool [2].
Position the peg [3]. Remove the auxiliary drive belt.
B1BP2MJD
B1BP2MKC
53
ENGINE

Engine : 8HX
Markings on the dynamic tensioner roller.
a
Position of maximum wear of the auxiliary drive belt.
b
Normal position.
Refitting
NOTE : Check that the tensioner roller moves freely (no tight spot). If this is not the
case, replace the tensioner roller.
Respect the direction of fitting of the drive belt.
Complete the setting of the belt, of both sides, by means of the tensioner roller.
Make sure that the drive belt is correctly positioned in the V grooves of the
various pulleys.
Move the tool [2] on the tensioner roller to remove the peg [3].
B1EP18UD
54
ENGINE

Engine : 8HY
Tools.
[1a] Dynamic tensioner roller lever
[1b] Lever extension
[2] Accessories belt roller locking peg 4 mm
: (-).0194-E1.
: (-).0194-E2.
: (-).0194-F
Removing
Pivot the tensioner roller support (1) (clockwise), using tools [1a] and [1b] at a.
Remove the belt.
Immobilise the support (1) of the tensioner roller, using tool [2].
Remove the auxiliary drive belt (2).
IMPERATIVE : Ensure that the tensioner rollers turn freely
(no play, no tight spot).
Refitting
Refit the belt.
Move the tool [1] on the tensioner roller to remove the peg [2].
ESSENTIAL: Make sure that the belt is correctly positioned in the various pulley
grooves.
B1BP2MYD
B1BP2MZC
55
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Petrol
Diesel
TU
DV
3
JP
Engine type
C2
JP4
TD
HFX
KFV
NFU
8HX
See pages :
57 to 66
67 to 83
56

Tools.
[1] Engine flywheel peg
[2] Camshaft pulley peg
[3a] Camshaft peg
[3b] Camshaft peg
[4] Dynamic tensioner roller pin
[5] Belt retaining pin
[6] Pliers for removing plastic pins
:
:
:
:
:
:
:
4507-T.A
4507-T.B
4533-TA.C1
4533-TA.C2
4200-T.H
4533-T.AD
7504-T.
Checking the valve timing.

Raise and support the front RH side of the vehicle.
Disconnect the battery positive terminal.
Engage 5th gear.
Remove the oil filter (1).
HFX - KFV engine
Remove :
The timing top casing (2).
Turn the wheel to rotate the engine (normal direction of rotation).
Peg the camshaft pulley, using tool [2].
B1BP2M7C
B1BP2M8C
B1BP2M9C
57
ENGINE
ENGINE

Engine : NFU
Checking the timing (continued)
Engine: NFU
Place a jack under the engine, peg the engine.
Remove:
- The engine support (4) complete.
- The timing casing (3).
- The sparking plugs (eases engine rotation).
Turn the wheel to rotate the engine (normal direction of rotation).
Position the pegs [3a] and [3b].
Peg the flywheel, using tool [1].
If the setting is not correct, recommence the operation.
Remove the tools [1], [2], [3a] and [3b].
Complete the refitting.
B1BP2MAC
B1EP18MC
B1BP2MBC
58
Engines : HFX - KFV

Setting the timing
Preliminary operation.
Lift and support the vehicle, wheels hanging.
Disconnect the battery.
Remove:
- The front RH wheel.
- The splash-shield, using tool [6]
- The accessories belt (See corresponding operation).
- The crankshaft pulley.
- The oil filter.
Place a jack under the engine, peg the engine.
Removing.
HFX - KFV engine
Turn the engine by means of screw (1). (normal direction of rotation).
Remove the timing casings.
Peg the camshaft pinion, using tool [2].
Remove:
- The fixing screws (2).
- The upper engine support (3).
B1BP2MCC
B1BP2M9C
B1BP2MBC B1BP2MDC
59
ENGINE
ENGINE

Engines : HFX - KFV
Setting the timing (continued)
HFX - KFV engines
Slacken the screws (4) without removing them.
Remove the bottom engine support assembly (5), and the fixing screws (4).
Slacken the nut (6).
Completely detension the belt by acting on the tensioner roller (7).
Remove the timing belt.
IMPERATIVE : Check that the tensioner roller turns freely (no tight spot).
B1BP2MEC
B1EP18NC
60
Engine : NFU
NFU engine.
Remove:
The bottom plastic casing.
The engine support (9).
The middle support.
The timing cover (8);
Position the tools [3a] and [3b].
B1BP2MFC
B1BP2MBC
B1EP18MC
61
ENGINE
ENGINE

Engine : NFU
NFU engine.
Slacken the tensioer roller.
Turn the tensioner roller so as to be able to position the tool [4], with the aid of an Allen key placed at a.
Turn the tensioner roller towards the right to bring it to the index c in position b.
Peg the tensioner roller in this position in order to slacken the timing belt to the maximum.
IMPERATIVE : Never make the dynamic tensioner roller turn by a complete rotation.
Remove the timing belt (8).
Check that the rollers (9) and (10) turn freely (no tight spot).
B1EP18PC
B1EP18QC
62
Engines : HFX - KFV

HFX - KFV engines
Refit.
WARNING: Respect the direction of fitting of the belt: (the arrows d indicate the direction of rotation of
the crankshaft).
Refit the timing belt.
Position the timing belt, belt e well tensioned, in the following order:
Crankshaft pinion, hold the belt using tool [5].
Camshaft pulley.
Coolant pump pulley.
Tensioner roller.
Remove the pegs [1] and [2].
B1EP18QC
63
ENGINE
ENGINE

Engines : KFX - KFV - NFU
B1EP18RC

HFX - KFV engines
Refitting.
NOTE : Check that the pegs [1] and [2] are in place.
WARNING: Respect the direction of fitting of the timing belt, the arrows d indicate the direction of rotation
of the crankshaft.
Refit the timing belt.
Position the timing belt, belt e well tensioned, in the following order:
Crankshaft pinion, hold the belt using tool [5].
- Camshaft pulley.
- Coolant pump pulley.
- Tensioner roller.
Remove the tools [1], [2].
NFU engine.
Fit the timing belt in position in the following order:
- Inlet camshaft pulley.
- Exhaust camshaft pulley.
- Guide roller.
- Crankshaft pulley.
Position tool [5].
- Coolant pump pulley.
- Dynamic tensioner roller.
Remove the tools [1], [3] and [5].
64
Engines : KFX - KFV - NFU

Timing belt overtensioned:
A : Engine HFX - KFV.
B : Engine NFU
Turn the tensioner roller (7) with the aid of a hexagonal spanner at a.
Bring the index c to position f, to tension the belt to the maximum of the
interval indicated.
Hold the tensioner roller (7), using tool [4].
Tighten the fixing nut of the tensioner roller, tightening to 1 0,1 m.daN
Turn the crankshaft by 4 rotations (normal direction of rotation).
IMPERATIVE : Never make the crankshaft rotate backwards.
Make sure that the timing is correctly set by refitting the tools [1], [2] and [3].
Remove the tools [1], [2] and [3].
B1EP18SD
65
ENGINE
ENGINE

Adjusting the fitting tension of the timing belt
A : Engine HFX - KFV.
B : Engine NFU
Slacken the nut while maintaining the position of the tensioner roller, with the aid of
a hexagonal spanner at a.
Next bring the index c to its adjusting position a.
The index c should not go beyond the notch g.
WARNING: The index c must not go beyond the notch g. If it should do this,
restart the timing belt tensioning operation.
Hold the tensioner roller (7) in this position, with the aid of a hexagonal spanner.
Tighten the tensioner roller fixing nut to :
2 0.2 m.daN.
(HFX - KFV engines)
2.2 0.2 m.daN.
(NFU engines)
IMPERATIVE : The tensioner roller must not rotate during the tightening of its
fixing. If it does, restart the timing belt tensioning operation.
B1EP18TD
66
Engine : 8HX
Tools.
: 7504-T.
[2] Lever for detensioning the dynamic tensioner roller
: (-).0194.E
[3] Engine flywheel setting peg
: (-).0194.C
[4] Camshaft setting peg
: (-).0194.B.
[5] Crankshaft and high pressure pump setting peg
: (-).0194.A.
Preliminary operations.
Remove:
- The front RH splash-shield, using tool [1].
- The clips of the electrical harness on the upper timing cover.
- The accessories belt, using tool [2] (see corresponding operation).
Check ing the setting.
Disconnect the battery negative cable.
Remove the upper timing cover (1).
Rotate the engine using the screw (2) of the crankshaft pulley.
NOTE : The locking hole is located under the crankshaft bearing cap cover.
Undo the screw (2).
Detension the auxiliary drive belt dynamic tensioner roller, using tool [2].
B1BP2LXC
67
ENGINE
ENGINE

Engine : 8HX
Checking the setting (continued)
Remove:
- the accessories drive belt.
- the accessories drive pulley.
- the lower timing cover (3).
IMPERATIVE : The magnetic track should show no signs of
damage and should not be approached by any other source of
magnetism.
Reposition the screw (2).
Remove tool [3].
Rotate the engine by means of the crankshaft pinion screw (2)
(clockwise), to bring it to the pegging position.
Position the tool [4].
Peg the crankshaft pinion (1), using tool [5].
Peg the high pressure pump pinion, using tool [5]
NOTE: Index a of the roller tensioner must be centred within the
area b.
Check the correct positioning of index a.
Remove tools [4] and [5].
Rotate the engine ten times.
Fit the tools [4] and [5].
If pegging is not possible, carry out the operation to remove/refit the
timing belt. (See corresponding operation).
B1JP03SC
B1EP18EC
B1EP18DC
68
B1EP18FC
Engine : 8HX
Setting the timing.
Remove the upper timing cover (1).
Rotate the engine by means of the crankshaft screw (2).
NOTE : The pegging hole is located under the crankshaft bearing cap cover.
Peg the engine flywheel, using tool [3].
Remove the lower timing cover (3).
Uncouple the exhaust line from the manifold.
IMPERATIVE : Uncouple the exhaust line in order to avoid damaging the front flexible pipe. Twisting,
pulling and bending the front flexible pipe reduces its life.
Remove:
- The engine speed sensor (6).
- The belt retaining stop (5).
- The screw (2).
- The crankshaft pinion (4) (with its magnetic track a).
IMPERATIVE : The magnetic track should show no signs of damage and should not be approached
by any other source of magnetism. Should this not be adhered to, it is essential to replace the
crankshaft pinion.
Refit the screw (2).
B1BP2LXC
B1EP18GC
69
ENGINE
ENGINE

Engine : 8HX
Setting the timing (continued).
Remove the tool [3].
Rotate the engine by means of the crankshaft pinion screw (2)
(clockwise), to bring it to the pegging position.
Peg :
- The crankshaft pinion (6), using tool [5].
- The high pressure pump pinion, using tool [5].
Support the engine with the aid of a roller jack equipped with a
chock.
Remove:
- The RH engine support (7).
- The intermediate engine support (right hand side) (8).
B1JP03SC
B1EP18DC
B1EP195C
70
B1BP2LYC
Engine : 8HX
Hold the tensioner roller, using a hexagonal spanner at b.
Slacken the screw (9).
Remove the timing belt (10).
Refitting.
IMPERATIVE : Check that both the tensioner roller and the fixed roller turn
freely (no tight spots). If this is not the case, replace the rollers.
Fitting of the pulleys.
- Camshaft pulley
: Tighten to 4,3 0,4 m.daN.
- Fuel high pressure pump pulley
: Tighten to 5 0,5 m.daN.
The crankshaft pinion is located without a screw at the end of the crankshaft.
Fitting of the rollers.
IMPERATIVE : Check that the tensioner roller turns freely (no tight spot).
Otherwise, replace the rollers.
- Guide roller
- Tensioner roller
: Tighten to 4,5 0,4 m.daN

: Pre-tighten to 0,1 m.daN
Check the condition of the seals at the camshaft and at the crankshaft pinion.
B1EP18HC
71
ENGINE
ENGINE

Engine : 8HX
NOTE : Screw (9) slackened.
Position the timing belt (10) observing the following sequence:
Crankshaft pinion (4).
Guide roller (12).
Camshaft pulley (11), (check that the belt is held correctly against the roller).
Coolant pump pinion (13).
Fuel high pressure pump pulley (15).
Tensioner roller (14).
B1EP18JD
72
Engine : 8HX
Turn the tensioner roller to the right to bring the index c to position d, using a
hexagonal spanner.
Tighten the screw (9) of the tensioner roller, tighten to 3 0,3 m.daN.
Remove the tools [4] and [5].
Rotate the engine ten times (check that the timing pinion is correctly up against the
crankshaft).
Check:
The pegging of the camshaft.
The crankshaft pinion.
The fuel high pressure pump pinion (15).
The correct positioning of the index of the dynamic tensioner.
If these are not correct, repeat the operation to position the timing belt.
B1EP18KC
Refit:
The engine speed sensor (6).
The belt retaining stop (5), tighten to 0,7 m.daN.
73
ENGINE
ENGINE

Engine : 8HX
Refit:
The intermediate RH engine support, tighten the screws (16) to 5,5 0,5 m.daN.
The RH engine support, tighten the screws (17) to 4,5 0,4 m.daN.
The bottom timing cover (3).
Immobilise the engine flywheel, using tool [3].
Remove the screw (2).
Refit the accessories drive pulley and tighten to:
Pre-tighten to
: 3 0,3 m.daN.
Angular tighten to
: 180 1,8
Remove tool [3]
Refit:
The top cover (1).
The accessories belt (see corresponding operation).
The exhaust line (see corresponding operation).
The front RH splash-shield.
The front RH wheel.
B1EP18LC
B1BP2LZC
74
Engine : 8HY
Tools.
[1] Engine flywheel peg 12 mm
[2] Camshaft pulley peg 8 mm
[3] Crankshaft pulley peg 5 mm
: (-).0194-C.
: (-).0194-B.
: (-).0194-A.
Preliminary operations.
Remove:
- The front RH splash-shield.
- The accessories belt (see corresponding operation).
Uncouple:
- The supply unions (1).
- The air/air heat exchanger inlet/outlet pipes (3).
- The exhaust line (at the flexible pipe).
Disconnect the connector (2).
Support the engine by means of a roller jack equipped with a chock.
Remove the engine supports (4) and (5).
B1BP2N0C
75
ENGINE
ENGINE

Engine : 8HY
Checks.
Rotate the engine to engage it (normal direction of rotation).
Immobilise the engine flywheel at a, using tool [1].
Move aside the harness (6).
Remove:
- The engine support (7).
- The screw (8).
- The pulley (9).
- The lower timing cover (10).
- The upper timing cover (11).
- The tool [1].
B1BP2N1C
B1BP2N2C
76
Engine : 8HY
Checks (continued).
Refit the screw (8).
Rotate the crankshaft six times (clockwise).
IMPERATIVE : Never rotate the engine backwards.
Peg :
- The camshaft, using tool [2]. (Oil the pegs.)
- The fuel high pressure pump pulley (14), using tool [3] at c.
WARNING: The magnetic track should show no signs of damage and should not
be approached by any source of magnetism.
Peg the crankshaft at b, using tool [3].
IMPERATIVE: Should it be impossible to peg the camshaft, check that the offset between the hole in the camshaft pinion and the pegging hole is not
greater than 1 mm.
Otherwise repeat the operation to position the timing belt. (See corresponding
operation).
B1EP18YD
77
ENGINE
ENGINE

Engine : 8HY
Checks (continued).
NOTE : The index e of the dynamic tensioner roller should be centred within the area d.
Check the correct positioning of the index e.
If it is not correct, repeat the operation to tension the timing belt (see corresponding operation).
Refitting.
Refit the tool [1] at a.
Refit:
- The upper timing cover (11).
- The lower timing cover (10).
- The accessories drive pulley (9).
- The screw (8).
Tightening torque:
- Screw (8) :
Pre-tighten to
: 3 0,3 m.daN.
Angular tightening
: 180 5.
Remove the tool [1].
B1EP18ZC
78
Engine : 8HY
Checks (continued).
Refit :
- The engine support (7), tighten to 1,5 0,4 m.daN.
- The engine support (4), tighten to 6,1 0,6 m.daN.
- The engine support (5), tighten to 6 0,6 m.daN.
- The electrical harness (6).
Couple:
- The exhaust line, tighten the collar to : 2,5 0,3 m daN
- The fuel supply unions (1).
- The air/air heat exchanger inlet/outlet pipes (3).
Connect the connector (2).
Refit :
- The accessories belt (see corresponding operation).
- The front RH splash-shield (see corresponding operation).
- The front RH road wheel, tighten to 9 1 m.daN.
Reconnect the battery.
B1BP2N0C
79
ENGINE
ENGINE

Engine : 8HY
Setting the timing.
Perform the preliminary operations for checking the timing up to removing tool [1] at a for immobiling the
engine flywheel.
Refit screw (8).
Rotate the crankshaft to bring the camshaft towards its pegging point.
Peg the camshaft, using tool [2]. (Oil the pegs).
WARNING: Do not press or damage the track which is the target for the engine speed
sensor (14).
Peg the crankshaft at b, using tool [3].
Remove:
- The timing protector (13).
- The engine speed sensor (14).
Slacken the screw (12) of the tensioner roller, keeping it slack with the aid of a hexagonal spanner at c.
Detension the belt by pivoting the tensioner roller (clockwise).
Remove the timing belt, commencing with the coolant pump pinion.
Peg the pulley (15), using a 5 mm diameter peg at d.
B1EP18VD
80
Engine : 8HY
Checking the setting.
IMPERATIVE : Just prior to refitting, carry out the following tests:
Check that:
- the rollers and the coolant pump operate freely
(no play and no tight spot).
- there are no traces of oil
(from the crankshaft and camshaft sealing rings).
- there is no leak of coolant fluid (from the coolant pump).
- the target track of the engine speed sensor (14) is not damaged or scratched.
(If necessary replace the defective components).
B1EP18WD
Refitting
Fit the timing belt on the crankshaft pinion.
Position the belt on the guide roller, with the belt well tensioned.
Refit:
- The timing protector (13).
- The sensor (14).
81
ENGINE
ENGINE

Engine : 8HY
Checks (continued).
Reposition the timing belt, belt at e well tensioned, in the following order:
- Guide roller (17).
- Camshaft pulley (16).
- Fuel high pressure pump pulley (15).
- Coolant pump pinion (18).
- Tensioner roller (19).
Remove the 5 mm diameter peg at d.
Adjusting the fitting tension of the belt.
Action the tensioner roller (19) to align the marks f and g , avoiding detensioning the timing belt,
with the aid of a male hexagonal spanner, at c.
If this is not successful, repeat the operation to tension the belt.
Hold the tensioner roller in position (19).
Tighten the tensioner roller, tightening to 3,7 0,3 m.daN.
Check the position of the tensioner roller (the alignment of the marks f and g should be correct).
Remove tools [2] and [3].
Turn the crankshaft six rotations (clockwise).
B1EP18XC
82
Engine : 8HY
Adjusting the timing belt tension (continued).
IMPERATIVE : Never rotate the engine backwards.
WARNING : Do not touch or damage the track of the target of the engine speed sensor (14).
Peg the crankshaft, using tool [3].
Check the position of the tensioner roller (the alignment of the marks f and g should be correct).
If this is not the case, repeat the operation to tension the belt.
IMPERATIVE : Should it be impossible to peg the camshaft, check that the offset between the
camshaft hole and the pegging hole is not more than 1 mm. If the offset is too great, repeat the
operation.
Remove the pegs [2] and [3].
Refit tool [1] at a.
B1EP18XC
83
ENGINE
ENGINE
EXHAUST SPECIFICATIONS
Engines: HFX - KFV (Depollution L4)
a Cutting zone
B1JP03TD
84
ENGINE
Engines: HFX - KFV (Depollution IFL5)
a Cutting zone
B1JP04RD
85
ENGINE
Engine: NFU (Depollution IFL5)
a Cutting zone
B1JP04TD
86
ENGINE
Engine: HFX (Depollution L4 and IFL5)
Engine type
(1)
(2)
(3)
(4)
(5)
(6)
Upstream
oxygen sensor
Catalytic
converter
Downstream
oxygen sensor
Front silencer
Rear silencer
Air to exhaust injection valve
Tightening (m.daN)
HFX
Engine type
TR PSA K179
(1)
(2)
Upstream
oxygen sensor
Catalytic
converter
Downstream
oxygen sensor
Front silencer
PSA 96 362 494 80
0.8 0.2
(5)
(6)
Rear silencer
Air to exhaust injection valve
Tightening (m.daN)
TR PSA K208
4.7 0.5
PSA 4173
4.7 0.5
Engine: KFV (Depollution L4 and IFL5)
(3)
(4)
Tightening (m.daN)
KFV
Tightening (m.daN)
Tightening (m.daN)
4.7 0.5
Tightening (m.daN)
4.7 0.5
PSA 4175
PSA 4174
PSA 96 362 494 80
0.8 0.2
Engine : NFU (Depollution IFL5)
Engine type
(1)
(2)
(3)
(4)
(5)
Upstream
oxygen sensor
Catalytic converter
Downstream oxygen
sensor
Front silencer
Rear silencer
PSA 4175
PSA 4176
Tightening (m.daN)
NFU
4.7 0.5
Tightening (m.daN)
4.7 0.5
TR PSA K181
87
ENGINE
Engine : 8HX
a Flexible pipe
b Cutting zone (marked by burrs)
c Silencer fixing strap
B1JP03PD
88
ENGINE
Engine : 8HX
Engine types
(1)
(2)
(3)
(4)
Catalytic converter
Strap
Intermediate pipe
Rear silencer
TR PSA K278
8HX
Tightening (m.daN) 2.5 0.3
PSA 4177
89
ENGINE
COOLING SYSTEM SPECIFICATIONS

Engines : HFX - KFV - NFU - 8HX
Engine type
1.1i
1.4i.
1.6i 16V
1.4 HDi
HFX
KFV
NFU
8HX
Capacity
7 litres
5.7 Litres
Radiator surface
16 dm3
1.4 bar
Pressurisation
1.4 bar
Opening of thermostatic
regulator
89C Start of opening
101C Opening complete
83 C
Cooling fan
100W (without aircon)
300W (with aircon)
1 x 300 W
1st speed
97 C
2nd speed
Aircon cut-off
115C
Warning
118C
105C
Post-cooling
Temperature sensor : Tighten to 1,7 0,4 m.daN.
90
6 minutes
(1)
B1GP0AXP
91
Venting chamber
(2)
Coolant pump
(3)
Bleed screw of heater matrix
ENGINE
ENGINE

Engine : 8HX
(1)
B1GP09MP
92
Bleed screw (with or without aircon)
ENGINE
OIL FILTERS
Petrol
TU
1
3
JP
FILTRAUTO
1.1i
1.4i
1.6i 16V
HFX
KFV
NFU
Diesel
DV
4
TD
1.4 HDi
8HX
X
MALHEX
93
5
JP4
ENGINE
CHECKING THE OIL PRESSURE

Petrol engines
1.1i
Engine type
HFX
Temperature (C)
1.4i
1.6i 16V
KFV
NFU
90C
Pressure (Bars)
Rpm
2000
Diesel engines
1.4 HDi
Engine type
8HX
Temperature (C)
Pressure (Bars)
90C
> 1.3
Rpm
1000
Tools :
Pressure gauge
: 2279-T.Bis
Flexible pipe
Engine oil pressure take-off union (TU engine)
: 7001-T
Oil pressure take-off union (DV engine)
: 9780-80-T
NOTE : Tightening of the oil pressure switch 2 0,2. (New seal).
IMPERATIVE : Respect the safety and cleanliness requirements.
94
Toolkit 4103-T.
Toolkit 4103-T.
ENGINE
VALVE CLEARANCES
POSSIBLE METHODS
On engines: 4 cylinders in line (1-3-4-2 )
The valve clearances should be checked with the engine cold.

Inlet
Rocking
HFX - KFV
NFU
8HX
0.20 mm 0.05
1 mm 0.05
Fully open (Exhaust)

Valves
fully
Adjust
open
Rocking
Exhaust
0.40 mm 0.05
1 mm 0.05
Adjust
1 4
3 2
4 1
2 3
Inlet
Admission
Hydraulic adjustment
Engines without hydraulic
adjustment : the clearance (J)
should be checked opposite
the cam.
B1DP13QC
95
ENGINE
FILLING AND BLEEDING THE COOLING CIRCUIT

HFX-KFV-NFU
Tools
[1] Filling cylinder
[2] Adaptor for filling cylinder
[3] Pliers for removing-refitting elastic clips
: 4520-T
: 4222-T.
: 9029-T
Draining.
8HX
Perform the operation with the engine cold.

Remove the air filter housing.
Open the expansion chamber cap.
Uncouple bottom hose (1), using tool [3] and bottom hose (2) of the radiator.
Open :
The bleed screw on the coolant outlet housing.
The bleed screw on the heater matrix.
The cylinder block drain plug.
Allow the coolant to flow out.
Before any refilling, rinse the cooling circuit with clean water.
Couple the bottom hose (1) and (2).
B1BP2LUC B1GP0AQD
96
Filling and bleeding.

Fit the filling cylinder [1], with the adaptor [2] on the filling aperture.
Slowly fill the circuit with the coolant fluid.
Reclose the bleed screws when the liquid starts to flow out continuously without air bubbles.
NOTE : The filling cylinder [1] should be filled to the 1 Litre mark to purge the heater matrix correctly.
Refit the air filter housing.
Start the engine.
Maintain an engine speed of 1500 to 2000 rpm, until the end of the second cooling cycle.
(Starting and stopping of the cooling fan).
Keep the filling cylinder full to the 1 Litre mark.
Stop the engine after the second cooling cycle.
Remove the filling cylinder [1] with the adaptor [2].
Refit the expansion chamber cap.
B1GP09KC
97
ENGINE
FILLING AND BLEEDING THE COOLING CIRCUIT
INJECTION
IDLING - DEPOLLUTION
Vehicles
Engine type
Emission
standard
L4
1.1 i
HFX
IF/L5
Idling speed
( 50 rpm)
Make - Injection type
Manual
gearbox
Auto. gearbox: N
gear engaged
% Content
CO
CO2
< 0.5
>9
MAGNETTI MARELLI
48P
L4
C2
1.4 i
KFW
SAGEM S2000
IF/L5
1.6 i 16V
NFU
L4
BOSCH
M 7.4.4.
98
850
PETROL INJECTION
1.1i
1.4i
1.6i 16 V
HFX
KFW
NFU
L4 / IFL5
L4
L4
M. MARELLI 48P2
SAGEM S2000
BOSCH M.7.4.4.
Engine type
Emission standard
Make
Injection type
3.5
Fuel pressure (bars)

Overspeed cut-off (rpm)
5500
5800
Injector resistive value (ohms)

Engine coolant temperature
sensor resistive value (ohms)
14.5
3 800 at 10C
2500 at 20 C
Idling actuator or stepper

motor resistive value (ohms)
Air temperature sensor
resistive value (ohms)
800 at 50C
230 at 90 C
Stepper motor : 53
3 800 at 10C
2500 at 20 C
99
800 at 50C
230 at 90 C
INJECTION
C2
EMISSION STANDARDS
APPLICATIONS
STANDARD
E.E.C.
PSA
A/S
RP
Engines
Vehicles
Applicable
INJECTION
10/89
ECE
R 15.04
K
K
15.04
15.04
Petrol
Diesel
Utility vehicles :
All Types
en cours
NOTES
CHARACTERISTICS
Utility vehicle limits

= private vehicle limits
increased by 25 %
For private vehicles and
utility vehicles in major export
With oxygen sensor,
without catalytic converter
ECE
R 15.05
W vp
15.05
Petrol
Private vehicles :
> 2 litres
new models
existing models
01/10/88
01/10/89
100
Brussels directive 88/76

Luxembourg Accords
Replaced by 89/458
+ 91/441
NORMES DE DEPOLLUTION
APPLICATIONS
E.E.C.
US 83
PSA
A/S
RP
US 83
NOTES
CHARACTERISTICS
Engines
Vehicles
Applicable
Petrol
Diesel
Private vehicles :
certain non-EEC
European countries
certain Export countries
Current
Adoption of U.S. standard
With oxygen sensor and

catalytic converter for
petrol vehicles
Current
With catalytic converter

and EGR
Current
US 87
US 87
Diesel
Private vehicles :
certain non-EEC
European countries
US 93
Y2
US 93
Petrol
Diesel
Private vehicles :
101
INJECTION
STANDARD
APPLICATIONS
STANDARD
E.E.C.
INJECTION
US 84
LDT
PSA
A/S
X1
NOTES
Engines
Vehicles
Applicable
US 84
Petrol
Diesel
Utility vehicles :
certain non-EEC
European countries
Current
Adoption of the U.S.

standard for light utility
vehicles
Utility vehicles :
certain non-EEC
European countries
Current

vehicles
Private vehicles :
certain non-EEC
European countries
Current

vehicles
RP
US 87
LDT
X2
US 87
Petrol
Diesel
US 90
LDT
X3
US 90
Petrol
Diesel
102
CHARACTERISTICS
APPLICATIONS
E.E.C.
PSA
A/S
RP
Engines
Petrol
Diesel
Private vehicles :
< 6 seats and
< 2.5 tonnes
new models
existing models
Petrol
Diesel
Gas
Utility vehicles :
< 3.5 tonnes
Class 1 :
new models
existing models
Class 2/3 :
new models
existing models
EURO 2
(EURO
96)
L3
CEE
95
EURO 2
(EURO
96)
W3
CEE
95
Vehicles
Applicable
Brussels Directive 94/12

01/96
01/97
EURO 93 standard made

stricter

01/97
10/97
01/98
10/98
103
NOTES
3 classes depending on
vehicle weight :
Class 1 < 1250 kg
Class 2 : 1250/1700 kg
Class 3 : 1700 kg
CHARACTERISTICS

reinforced catalytic
converter for petrol
vehicles.
and EGR for diesel
vehicles.

reinforced catalytic
converter for petrol
vehicles.
and EGR for diesel
vehicles
INJECTION
STANDARD
APPLICATIONS
STANDARD
E.E.C.
PSA
A/S
RP
Engines
Vehicles
Applicable
INJECTION
Utility vehicles :
< 3.5 tonnes
NOTES
EURO 2 standard (L3)

EURO 3
(EURO
2000)
W3
Petrol
Diesel
Gas
Class 1 :
new models
existing models
Class 2/3 :
new models
existing models
01/2000
01/2001
01/2001
01/2002
Private vehicles :
All Types
EURO 4
IF / L5
Petrol
new models
existing models
01/2005
01/2006
104
made stricter
Fiscal incentives
vehicle weight :
Class 1 < 1305 kg
Class 2 : 1305/1760 kg
Class 3 : 1760 kg
EURO 3 standard (L4)

made stricter
Fiscal incentives
CHARACTERISTICS
With 2 oxygen sensors

and catalytic converter for
petrol vehicles.
and EGR for diesel
vehicles.
With EOBD on-board
diagnosis.

petrol vehicles.
With EOBD on-board
diagnosis.
APPLICATIONS
E.E.C.
PSA
A/S
RP
Engines
Vehicles
Applicable
NOTES
Private vehicles :
All Types
EURO 4
IF / L5
Petrol
Diesel
Gas
new models
existing models
01/2005
01/2006
Utility vehicles :
< 3.5 tonnes
EURO 4 IF / L5
Petrol
Gas
Class 1 :
new models
existing models
Class 2/3 :
new models
existing models
01/2005
01/2006
01/2006
01/2007
105
Brussels Directive: 2001/1

EURO 3 standard (L4) made
stricter
Fiscal incentives
Brussels Directives: 99/102 and

2001/1 (Gas)
EURO 3 standard (L4) made
stricter
Fiscal incentives
vehicle weight :
Class 1 < 1305 kg
Class 2 : 1305/1760 kg
Class 3 : 1760 kg
CHARACTERISTICS

petrol vehicles.
With EOBD on-board
diagnosis.

petrol vehicles.
With EOBD on-board
diagnosis.
INJECTION
STANDARD
PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM

Engine : 8HX
Cleaning.
- The use of high pressure cleaners is prohibited.
- Do not use compressed air.
INJECTION
Fuel supply circuit.

- Required fuel : diesel.
Electric circuit.
- Swapping injection ECUs between two vehicles will render it impossible to start either vehicle.
- It is forbidden to supply a diesel injector with 12 volts.
High pressure fuel pump.
Do not separate the following components from the high pressure fuel pump (5) :
- Sealing ring (a) (no replacement parts).
- High pressure outlet connector (b) (will cause a malfunction).
PS : HDi = High pressure Diesel injection
B1HP1K9C
106
PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM

Engine : 8HX
INJECTION
Diesel injectors.
WARNING: Diesel and ultrasonic cleaners are prohibited.
Do not separate the following components from the diesel injector
carrier (2) :
- Diesel injector (f) (no replacement parts).
- Electromagnetic element (c) (no replacement parts).
Do not alter the position of the nut (d) (malfunction).

Do not separate the connector (e) from a diesel injector.
It is forbidden to clean the carbon deposits from the diesel injector
nozzle.
B1HP1KBC
B1HP1KAC
107
SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM

Engine : 8HX
INJECTION
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.
108
SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM

Engine : 8HX
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.
- Third piston deactivator.
- High pressure regulator.
- High pressure sensor.
- 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.
109
INJECTION
CLEANLINESS REQUIREMENTS.
Preliminary operations
CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT

Engine : 8HX
TOOLS
[1] 10 mm low pressure connector
[2] Pressure gauge for testing boost pressure
: 4215-T.
: 4073-T.A
Toolkit 4073-T
INJECTION
IMPERATIVE : Respect the safety and cleanliness specific to high pressure diesel
injection engines.
Link tools [1] and [2] in series between the fuel high pressure pump and the fuel filter.
ESSENTIAL : Check that the tool [2] is clean.
Check the negative pressure according to the table below:
B1BP2NWC
110
Vacuum
Observations
10 5 cmHg
Engine driven by the starter motor
20 5 cmHg
Engine running under full load
60 5 cmHg
Supply circuit obstructed (full tank

strainer, piping, fuel filter).
AIR SUPPLY CIRCUIT SPECIFICATION
Upper integrated air inlet distributor.

The upper integrated air inlet system is composed of the following elements:
(1) Air filter cover.
(2) Air filter chamber.
(3) Flowmeter
(4) Turbocharger inlet.
(5) Resonator.
(6) Turbocharger outlet.
B1HP1JMP
111
INJECTION
Engine : 8HX

Engine : 8HX
Lower integrated air inlet distributor.

INJECTION
The lower integrated air inlet system is composed of the following elements:
(7) Top EGR pipe.
(8) Inlet manifold.
(9) Diesel fuel filter with reheater and water detector (according to country).
(10) Diesel fuel filter support.
(11) Oil trap.
(12) Oil filler cap.
B1HP1JND
112

Engine : 8HX
Upper integrated air inlet distributor.
INJECTION
Lower integrated air inlet distributor.
B1HP1JPD
B1HP1JQD
WARNING: After each removal, replace the seals of components that have been removed, lubricating the new seals when refitting.
Description
Oil trap fixing screw.
Diesel fuel filter support fixing screw.
Diesel fuel filter support fixing screw.
Integrated air distributor fixing screw.
Tightening
sequence
1 to 8
9 to 10
11
12 to 13
m.daN.
1 0.1
1 0.1
0.5
1 0.1
Description
Air filter housing fixing screw.
Air filter cover fixing screw.
Air inlet duct fixing screw.
Resonator on turbocharger fixing screw.
Resonator on oil trap fixing screw.
113
Tightening
sequence
13
14
15
16
17
m.daN.
0.5
0.75

Engine : 8HX
INJECTION
(1) Air filter assembly.

(2) Oil trap.
(3) Turbocharger resonance attenuator.
(4) Turbocharger.
(5) Air/air exchanger.
(6) Air distributor.
Air filter
Turbocharger
(Supplier: IHI)
B1HP1JGP
114
: Ref : MARK 4.
: Ref : RHF 3V.
CHECKS : AIR SUPPLY CIRCUIT
Tools.
[1] Manual pressure-vacuum pump
FACOM DA 16.
Vacuum pump :
Connect the tool [1] onto the vacuum pump (1).
Start the engine.
Wait 30 seconds.
The vacuum value should be 0.9 0.1 bar at idle.
NOTE : Depollution EURO 4 : The exhaust gas recycling valve is not
linked to the air supply circuit.
The exhaust gas recycling valve is controlled by the engine ECU.
B1HP1K8D
115
INJECTION
Engine : 8HX
CHECKS : EXHAUST GAS RECYCLING CIRCUIT

Engine : 8HX
Tools : [1] Manual pressure-vacuum pump : FACOM DA 16.
IMPERATIVE : Respect the safety and cleanliness requirements.
INJECTION
Depollution EURO 3
EGR valve
Connect tool [1] on the capsule take-off (2).
Apply a vacuum of approx. 0,6 bar several times to activate the rod a.
In abruptly suppressing the vacuum, the valve should click and lock itself back on its seating.
EGR regulation electrovalve
Check to be performed between the electrovalve (1) and the EGR valve (2).
Link the tool [1] in series, between the electrovalve (1) and the capsule (2).
Compare the values noted with those in the table below.
Engine speed
Vacuum value
780 rpm
0,5 bar
2500 rpm
0 Bar
Depollution EURO 4
NOTE : The EGR valve is controlled by the engine ECU.
B1HP1K6D
Carry out the check with the aid of a diagnostic tool.

Make the following selections in the diagnostic tool:
- INJECTION menu.
- Actuator test.
- EGR electrovanne.
Check to hear the clicking of the EGR regulation electrovalve.
116
CHECKS : TURBO PRESSURE
B1BP2NXD
Tools.
[1] Pressure gauge for checking boost pressure
: 4073-T.A
[2] Sleeve for checking boost pressure
: (-).0171.F
Checks
IMPERATIVE : Respect the following test conditions:
- Engine at operating temperature.
- Vehicle in running order.
- Engine under full load.
Preparation.
Remove the clips (1).
Fit the tool [2] in the place of the duct (2).
Couple the sleeve [2] on the pressure gauge [1] using the tube a.
Mode of operation.
Position tool [1] in the vehicle.
Start the engine.
Engage first gear, start the vehicle.
Engage the gears up to third gear.
Decelerate to an engine speed of 1000 rpm.
Check the pressure : 0,6 0,05 bar (1500 rpm).
Accelerate freely (change from fourth gear to third gear)
Check the pressure: 0,9 0,05 bar (between 2500 and 3500 rpm).
Remove tools [1], [2] at a.
Reposition the tube (2) and tighten the clips (1).
C5FP0F5C
117
INJECTION
Engine : 8HX
FEATURES OF MULTIPOINT INJECTION SYSTEM

Summary
INJECTION
(1) Vehicle speed sensor.

(2) Catalytic converter.
(3) Downstream oxygen sensor.
(4) Upstream oxygen sensor.
(5) Canister purge electrovalve.
(6) Canister reservoir.
(7) Fuel pump, fuel filter, gauge, pressure regulator.
(8) Injectors.
(9) Ignition coil.
(10) Thermoswitch engine coolant thermostat.
(11) Engine coolant temperature sensor.
(12) Accelerator pedal pressure sensor (KFVNFU).
(13) Butterfly housing.
(14) Knock sensor.
(15) Engine speed sensor.
(16) Inlet air pressure sensor.
(17) Diagnostic warning lamp, engine ECU.
(18) Ignition injection ECU.
(19) Gate valve (HFX-KFV).
(20) Air pump (HFX-KFV).
B1HP1TGP
118

Fuel circuit
Component
Supplier
Reference
Fuel
5
Electrovalve
Unleaded 95 RON or 98 RON

2-way brown connector Location : under the front
RH wing.
SAGEM
Capacity : 40 Litres.
Fuel tank
6
Canister reservoir
Pump, gauge and petrol filter
assembly
Pressure regulator
Observations
2-way black connector Location : on the side of the

fuel tank.
MGI COUTIER
6-way black connector Voltage: 2 V Pressure : 3.5 Bars

Electric pump submerged in the tank.
BOSCH
MAGNETI
MARELLI
Pressure : 3.5 Bars Fixing : integrated in the fuel pump and

gauge assembly.
SAGEM
(KFV)
8
Petrol injector
2-way black connector.

Resistance : 14.5 0.05
BOSCH EV6
(HFX)
BOSCH
(NFU)
119
INJECTION
(diagr.)

Air inlet circuit
(diagr.)
12
Component
Accelerator pedal position sensor
(HFX NFU)
INJECTION
Idle regulation stepper motor (KFX)
13
Butterfly housing (HFX)
Supplier
Reference
2-way connector.
VD0
4-way black connector.

Fixing : on the butterfly housing
MAGNETI
MARELLI
SONCEBOZ
The butterfly housing comprises : butterfly potentiometer, stepper motor

3-way black connector
Fixing : on the butterfly housing.
6-way black connector Fixing : on the butterfly housing.
Tighten to: 0,8 0,1 m.daN Fixing : on the air inlet
manifold.
6-way connector.
Fixing : on the air inlet manifold.
Fixing : on the air inlet manifold..
Norm IfL5
Fixing of cylinder head : Tighten to 0.8 0.2 m.daN
Norm IFL5
Fixing on support : Tighten to 0.8 0.2 m.daN
MAGNETI
MARELLI
Potentiometer (KFX)
Motorised butterfly housing assembly
(KFV)
SIEMENS
VD0
Butterfly housing (NFU)

BOSCH
16
Inlet air pressure sensor
19
Gate valve (HFX KFV)
SAGEM
20
Air pump (HFX KFV)
SAGEM
120
Observations

Ignition circuit
Component
Vehicle speed sensor
10
Engine coolant thermoswitch
11
Engine coolant temperature sensor
14
Knock sensor
15
Engine speed sensor
Supplier
Reference
Observations
3-way white connector
Fixing : on the gearbox differential casing.
Fixing : on the cylinder head, alert temperature : 118 C
Tighten to : 1.7 0.1 m.daN
3-way blue connector
Fixing : on the coolant outlet housing.
Fixing : on the rear part of the engine block.
IMPERATIVE : Respect the tightening torque 0.1 m.daN
Fixing : on the clutch housing.
IMPERATIVE : Respect the tightening torque 2 0.1 m.daN
EATON
DAV
ELECTRIC FIL
BOSCH
ELECTRIC FIL
SIEMENS
MAGNETI
MARELLI
48P2 (HFX)
18
Ignition injection ECU
Flash type Eprom

(Reprogrammable Eprom)
SAGEM S20000
PM1 (KFV)
BOSCH ME7 4.4
(NFU)
121
INJECTION
(diagr.)

Ignition circuit
(diagr.)
Component
Supplier
Reference
Observations
SAGEM
Sparking plugs
INJECTION
Electrode gap : 0.9 mm

Tighten to : 3 m.daN
BOSCH
CHAMPION
Downstream oxygen sensor
4-way blue connector

Location : on the exhaust manifold
Upstream oxygen sensor
4-way green connector

Location : on the exhaust manifold
Ignition coils
SAGEM
4-way grey connector
ELECTRIC FIL
122
FEATURES OF SIEMENS HDI DIRECT INJECTION SYSTEM
INJECTION
Summary
B1HP1JFP
123

Electrical circuit
(diagr.)
1
Component
Diesel injection ECU
INJECTION
Engine speed sensor
Camshaft position sensor
Engine coolant temperature sensor
5
6
7
8
9
10
11
12
13
14
17
Vehicle speed sensor

Atmospheric pressure sensor
Battery
Injection double relay
Diagnostic warning lamp
Central diagnostic socket
Electronic immobiliser
Consumption information
Supplier
SIEMENS
Reference
SID 802
3-way black connector - Location : Close to crankshaft pulley.

Tighten to 0.7 0.2 m.daN
ELECTRIFIL
3-way grey connector On cylinder head.

3-way green connector on coolant housing.
ELTH
SIEMENS
Incorporated in the engine ECU.

12 Volts
Incorporated in the BSM.
Incorporated in the instrument panel.
In the passenger compartment.
Incorporated in the BSI transponder, and engine ECU.
SIEMENS
Incorporated in the instrument panel.
Rev counter
Preheating warning lamp
Accelerator pedal sensor
124
Observations
112-way grey connector : sequential injection

Ignition circuit
Component
Supplier
Reference
CARTIER
15
Pre-postheating unit
16
Preheater plugs
5-way connector
NAGARES
NGK
YE04
125
Observations
Tighten to : 0.8 0.1 m.daN.
INJECTION
(diagr.)

Fuel circuit
(diagr.)
18
Component
Supplier
Reference
Fuel
Observations
Diesel fuel
INJECTION

Fixed on the fuel high pressure pump
19
Fuel high pressure sensor
20
Fuel tank
21
Fuel filter
22
Low pressure regulator
23
Fuel cooler
24
Fuel heater
Incorporated in the fuel filter cover
25
Fuel high pressure pump
The fuel high pressure pump is driven by the timing belt.
26
Fuel high pressure common

injection rail
27
Diesel injector
Diesel injectors with Piezo-electric control
28
Fuel high pressure regulator
Fixed on the fuel high pressure pump
SIEMENS
Capacity = 45 litres Composition = Polyethylene.
Fixed on the fuel high pressure pumpt
Volume = 14 cc - Pressure = 1800 Bars
SIEMENS
126

Air circuit
Component
29
Air flowmeter
30
Air filter
31
Turbocharger
32
Exhaust gas recycling (EGR) valve
33
EGR recycling regulation

electrovalve
34
Exhaust line
35
Vacuum pump
Supplier
Reference
SIEMENS
39071LS.F
MECAPLAST
50557LLP.A
KKK
Type KP35
SAGEM
Type
2580132-A
PIEBURG
PIEBURG
127
Observations
Incorporated in the inlet manifold

INJECTION
(diagr.)
SPARKING PLUGS
Vehicles Models
IGNITION
C2
Engine
type
1.1i
HFX
1.4i
KFV
1.6i 16v
NFU
BOSCH
CHAMPION
FR7DE
RC8YCL
FR7ME
128
SAGEM
RFN58LZ
Electrode
gap
0.9 mm
Tightening
torque
2.5 mda.N
Engine type
Gearbox type
Supplier
1.1i
1.4i
1.6i 16V
1.4 HDi
HFX
KFV
NFU
8HX
BVM
BVM/BVMP (*)
BVM/BVMP (*)
BVM/BVMP (*)
MA 5/S
MA 5 N/L
MA 5 S/L
MA 5/0
Mechanism / type
Engine type
VALEO
LUK
180 CP0 3400
200 P 3900
Bearing supplier / height
SKF 17 mm
Clutch disc
11 R 10
of lining. Ext/Int
180/127
?
200/134
408
Quality of lining
(*) : BVM = Manual gearbox.

: BVMP = Piloted manual gearbox.
129
CLUTCH
GEARBOX
DRIVESHAFTS
CLUTCH SPECIFICATION
CLUTCH SPECIFICATION
NOTE : All the clutches are push type with hydraulic control.
Description.
The declutch control has a declutch fork mounted on a ball-joint.
(1) The ball-joint is screwed into the clutch casing.
(2) Declutch fork.
(3) Clutch casing.
(4) Bearing.
(5) Clutch plate.
CLUTCH
GEARBOX
DRIVESHAFTS
The clutch control slave cylinder (7) is fixed by two screws (6) onto the exterior of the clutch casing.
It has a bleed screw (8).
Tightening torques (m.daN).

- Fixing of clutch plate/engine flywheel
- Fixing of engine flywheel/crankshaft
Pre-tightening
Angular tightening
B2BP047C
B2BP04QC
130
: 1.2 0.2 (HFX -KFV)

: 1.7 0.1
: 70 5
2 0.2 (NFU)
GEARBOX AND TYRE SPECIFICATIONS

MA5 gearbox
Petrol
1.1i
1.4i
1.4 HDi
HFX
KFV
8HX
165/70 R14
1.804 m
165/70 R14
1.804 m
185/55 R14
1.781 m
Gearbox type
MA 5/S
MA 5/N
MA 5/L
Gearbox plate
20 CF 20
20 CF 25
20 CF 16
Tyres-Rolling circumference
Differential ratio
16x65
14X60
Speedo drive ratio
21x18
131
165/70 R14
1.804 m
185/55 R15
1.781 m
MA 5/0
20 CN 33
20 CN 51
17X61
CLUTCH
GEARBOX
DRIVESHAFTS
Engine type
Diesel
MA/5 GEARBOX
Engines : HFX - KFV - 8HX
a Location of engraving of serial and gearbox nos.

CLUTCH
GEARBOX
DRIVESHAFTS
b Identification label.
B2CP3SQC
132
MA/5 GEARBOX
B2CP3SRP
(1) Circlip
(2).Secondary shaft
(3) Drive pinion (5th gear)
(4) Bearing stop screw
(5) Gearbox casing
(6) Intermediate plate
(7) Gearbox casing fixing screw
(8) Clutch bearing guide screw
(9) Clutch housing
(10) Bearing guide
(11) Primary shaft
(12) Differential housing
(13) Speedometer screw
(14) Counter drive
(15) Planet pinions
(16) Satellite pinions
(17) Differential gearwheel
(18) Driven pinion (1st gear)
(19) 1st / 2nd gear synchroniser and reverse gear driven pinion.
(20) Driven pinion (2nd gear).
(21) Driven pinion (3rd gear).
(22) 3rd and 4th gear synchroniser
133
CLUTCH
GEARBOX
DRIVESHAFTS
MA/5 GEARBOX
(23) Driven pinion (4th gear).

(25) 5th gear synchroniser.
CLUTCH
GEARBOX
DRIVESHAFTS
Tightening torques (m.daN)

(x4)
: 1,8 0,2
(11 fixing screws)
: 5 0,5
(7) Gearbox casing
(15 fixing screws)
: 1,9 0,2
(8) Clutch bearing guide screw (3 fixing screws)
B2CP3SRP
134
: 0,6 0,15
MA/5 GEARBOX
(26)
(27)
(28)
(29)
5th gear cover fixing screw

Reverse gear switch
Drain plug
Level plug
(3
(1
(1
(1
screws)
screw)
screw)
screw)
:
:
:
:
2,2
2,5
3,3
3,3
0,2
0,5
0,3
0,3
Lubrication.
Oil capacity
Oil level check
Lubrication intervals
: 2 0,15 litres.
: No oil level check (*)
: Lubricated for life.
(*) = Only a visual check of the sealing at each engine oil change interval.
B2CP3SSD
135
CLUTCH
GEARBOX
DRIVESHAFTS
Features.
This gearbox :
Has no adjustment.
Includes a reverse gear braking device (5th gear synchroniser).
Incorporates a device for prohibiting change from 5th gear to reverse gear.
The declutch control has a balljoint-mounted declutch fork.
GEARBOX AND TYRE SPECIFICATIONS

MA5 piloted manual gearbox
Petrol
Engine type
Tyres-Rolling circumference
Diesel
1.4i
1.6i 16v
1.4 Hdi
KFV
NFU
8HX
165/70 R14
1.804 m
185/55 R15
1.781 m
185/55 R14
1.781 m
195/45 R16
1.772 m
185/70 R15
1.804 m
165/70 R14
1.804 m
CLUTCH
GEARBOX
DRIVESHAFTS
Gearbox type
MA 5/N
MA 5/S
MA 5/L
MA 5/0
Gearbox plate
20 CF 21
20 CN 48
20 CN 50
20 CN 49
Differential ratio
16x65
16x63
14x60
16X63
Speedo drive ratio
21x18
21xN0
136
MA/5 PILOTED MANUAL GEARBOX

Engines : KFV - 8HX
b Location of engraving of serial and gearbox nos.
B2CP3STC
137
CLUTCH
GEARBOX
DRIVESHAFTS
a Identification label.

Engines : KFV - 8HX
CLUTCH
GEARBOX
DRIVESHAFTS
B2CP3SRP
(1) Circlip
(2) Secondary shaft
(3) Drive pinion (5th gear)
(5) Gearbox casing
(7) Gearbox casing fixing screw
(9) Clutch housing
(10) Bearing guide
(11) Primary shaft
(12) Differential housing
(13) Speedometer screw
(14) Counter drive
(15) Planet pinions
(16) Satellite pinions
(17) Differential gearwheel
(18) Driven pinion (1st gear)
(19) 1st / 2nd gear synchroniser and reverse gear driven pinion.
(20) Driven pinion (2nd gear).
(21) Driven pinion (3rd gear).
(22) 3rd and 4th gear synchroniser.
138

Engines : KFV - 8HX

(x4)
: 1.8 0.2
(11 fixing screws)
: 5 0.5
(7) Gearbox casing
(15 fixing screws)
: 1.9 0.2
(3 fixing screws)
: 0.6 0.15
B2CP3SRP
139
CLUTCH
GEARBOX
DRIVESHAFTS

(25) 5th gear synchroniser

Engines : KFV - 8HX
CLUTCH
GEARBOX
DRIVESHAFTS
(26) 5th gear cover fixing screw
(3 screws)
: 2,2 0,2
(27) Gearbox input speed sensor
(1 screw)
: 0,8 0,2
(28) Reverse gear switch
(1 screw)
: 2,5 0,5
(29) Drain plug
(1 screw)
: 3,3 0,3
(30) Level plug
(1 screw)
: 3,3 0,3
B2CP3SUD
140

Features.
The piloted gearbox is a modern manual gearbox with technology that offers
enhancements in every driving situation.
The piloted manual gearbox has two operating programmes:
Sequential programme
Automatic programme
The piloted manual gearbox has :
A gearbox ECU (supplier: SIEMENS)
A gearbox actuator with two electric motors (supplier: SACHS)
A clutch actuator with one electric motor (supplier: SACHS)
A gearbox input speed sensor.
The piloted manual gearbox has no gear control cable and no clutch cable. Changes
of gear and clutching/declutching are activated by the gearbox actuator and the
clutch actuator.
Lubrication.
Oil capacity
: 2 0,15 litres.
Checking of oil level
: No oil level check (*)
Lubrication intervals
: Lubricated for life.
(*) = Only a visual check of the sealing at each engine oil change interval.
B2CP3SUD
141
CLUTCH
GEARBOX
DRIVESHAFTS
Engines : KFV - 8HX
RECOMMENDATIONS - PRECAUTIONS : MA TYPE PILOTED MANUAL GEARBOX
Safety requirements
IMPERATIVE : When initialising the clutch actuator and/or gearbox

actuator, do not allow any person to walk or stand in front of the
vehicle.
ESSENTIAL : Given the special features of the MA type piloted

manual gearbox, observe the requirements detailed below.
WARNING : When the engine is running, it is forbidden to perform

repairs on the clutch and gearbox actuators on the vehicle (whether
manually or using a diagnostic tool).
IMPERATIVE : Always disconnect the battery negative terminal

before operating on the actuators.
CLUTCH
GEARBOX
DRIVESHAFTS
NOTE : After disconnecting the battery, never try to remove the clutch
actuator on the vehicle before having checked that it is in the closed
position.(rod pushed in).
WARNING : Each time the drivers door is opened and each time the
igntion is switched on, the gearbox ECU prompts the initialising of the
clutch and gearbox actuators (there is movement of the clutch fork and
of the gear lever).
IMPERATIVE : After Sales checks done with the engine running must
be performed with Neutral engaged and the handbrake on (unless
there is a clear mention otherwise in the repair procedures)
WARNING : Whether the ignition is switched on or not, an action on

the gear selector causes the clutch to move and the gear engagement
lever to move on the gearbox.
IMPERATIVE : The areas of movement of the clutch fork and of the

gear engagement lever must always be kept free during the actuator
operating phases.
142

Operations on electrical components :
Do not disconnect :
The battery when the engine is running.
The ECU with the ignition switched on.
The clutch and gearbox actuators with the ignition switched on.
Towing.
Conditions for towing.
When carrying out electrical checks :

The battery must be correctly charged.
Never use a voltage source higher than 16V.
Never use a lamp to supply an actuator directly.
If a gear is engaged, the conditions for immobilisation of the

vehicle are :
Combustion engine stopped (the engine should not be started).
The clutch is open (clutched).
Befor disconnecting connector, check :

The condition of the various contacts (for deformation, corrosion etc.)
The presence and the status of the mechanical unlocking.
In these conditions are met, you can lift the front of the vehicle to tow it.
Driving the vehicle.
IMPERATIVE : Never move the vehicle with the ignition switched off.
If it should not be possibe to lift the front of the vehicle, there are
ways to unblock it :
Never push the vehicle to attempt to start it (impossible with a piloted

manual gearbox.
Engage N, using a diagnostic tool.

Engage N, without using a diagnostic tool.
143
CLUTCH
GEARBOX
DRIVESHAFTS
It is necessary to lift the front of the vehicle to tow it, after having
positioned the gear lever in neutral. If there is a gearbox fault or
malfunction, the vehicle can remain immobilised depending on the
seriousness of the fault.
Engaging of N, using a diagnostic tool.
Engaging of N, without using a diagnostic tool.
Preliminary operations:
Battery voltage higher than 12,5 volts.
Ignition switched on.
Connect the diagnostic tool to the vehicles diagnostic socket.
In this configuration, the gearbox actuator is blocked, gear engaged.

NOTE : This recovery solution is to be used solely in a case where the
attempt to make the gearbox actuator engage N via the diagnostic
tool has failed.
From the diagnostic tool menus, select :

CLUTCH
GEARBOX
DRIVESHAFTS
DIAGNOSIS
MA type piloted manual gearbox.
Actuator test.
Gearbox actuator test.
Gear engagement test.
N (neutral)
NOTE : The letter N should appear on the instrument panel.
If not, see the following solution:
Engaging of N, without using a diagnostic tool.
144
Engaging of N, without using a diagnostic tool (continued).

Preliminary operation:
Disconnect the battery negative terminal.
Use a 22 mm spanner.
Use the spanner to lift the gear engagement lever the maximum possible until the
axis A of the engagement lever is perpendicular to the axis B (mid point of
the gear engagement lever).
When this position is attained, position N is engaged.
B2CP3L8D
145
CLUTCH
GEARBOX
DRIVESHAFTS
Remove the air filter.
MA/5 GEARBOX CONTROLS

(1) Gear control lever.
(2) Gear engagement control cable (*)
CLUTCH
GEARBOX
DRIVESHAFTS
(3) Gear selection control cable (*)
(*) The two cables cannot be separated.
B2CP3HXD
146

(4) Gear engagement ball-joint 10 mm.
B2CP3HYC
Gear engagement
control
cable (2)
Gear selection
control
cable (3)
B2CP3HZD
147
Length D
Length C
1040 mm
815 mm
Length A
Length B
1149 mm
800 mm
CLUTCH
GEARBOX
DRIVESHAFTS
(5) Gear selection ball-joint 10 mm.

Adjustment.
WARNING: Do not use any tool to detach the

ball-joints.
CLUTCH
GEARBOX
DRIVESHAFTS
The gear selection control and gear engagement control

cables cannot be adjusted.
B2CP3J0D
To unlock the ball-joint, press at a then pull the

ball-joint upwards.
To release the sleeve stops, pull the needles b, in the
direction of the arrow, then disengage the sleeve stops
from their supports.
B2CP3J1D
148
DRIVESHAFTS - GEARBOX
Vehicles
MA/5
Driveshaft
bearing
Engines
HFX - KFV
8HX
NONE
NFU
2 0.2
Driveshaft
nut
RH side
LH side
Tool kit
24.5 0.5
7114-T.X
7114-T.W
7116-T
CLUTCH
GEARBOX
DRIVESHAFTS
C2
Gearbox
Gearbox oil seal mandrels
Tightening torques for wheel bolts (m.daN)
CITRON C2
Steel
Aluminium
149
9 0.1
WHEELS AND TYRES

Standard fitting
Engines
Trim levels
Tyres
(Circumference)
Wheels
Trims
A-X
SX - SX - Pack
AXLES
SUSPENSION
STEERING
1.6i 16V
Tyres
Wheels
165/70 R14 81 T XT1
5.5J 14 H2 4.24
5.5J 14 H2 4.24
MILAN
1.1i
1.1i
Spare wheel
165/70 R14 81 T XT1

1.804 m
5.5J 14 H2 4.24
CONDOR
A-X
5.5J 14 H2 4.24
MILAN
SX - SX - Pack
5.5J 14 H2 4.24
CONDOR
VTR
185/55 R15 82 H XH1

1.781 m
6J 15 4.27
PELICAN
185/55 R15 84 H
6J 15 4.27
VTR - VTS
195/45 R16 80V

1.772 m
PRIMACY/SPORT
6J 16 4.27
LEOPARD
195/45 R16 80V
6J 16 4.27
(1) = Normal operating pressure
(Max. 4 persons and 40 kg in boot).
150
WHEELS AND TYRES

Standard fitting
Trim levels
A-X
1.4 HDi
SX - SX - Pack
Wheels
Trims
165/70 R14 81 T XT1

1.804 m
185/55 R15 82 H XH1
1.781 m
VTR
(1) = Normal operating pressure
Tyres
(Circumference)
(Max. 4 persons and 40 kg in boot).
151
5.5J 14 H2 4.24
MILAN
Spare wheel
Tyres
Wheels
165/70 R14 81 T XT1
5.5J 14 H2 4.24
185/55 R15 82 H
6J 15 4.27
5.5J 14 H2 4.24
CONDOR
6J 16 4.27
AXLES
SUSPENSION
STEERING
Engines
WHEELS AND TYRES

Optional fitting
Engines
1.1i
Spare wheel
Tyre
Wheels
Trims
Tyres
Wheels
165/70R14 81 T XT1
5.5 J14 CH 4.24 TIGRE
165/70R14 81 T XT1
5.5J 14 H2 4.24
185/60 R15 84 H XH1
6J 15CH 4.27 LYNX
185/60 R15 84 H XH1
1.4i
6J 15CH 4.27
1.6i 16V
165/70R14 81 T XT1
5.5 J14 CH 4.24 TIGRE
165/70R14 81 T XT1
5.5J 14 H2 4.24
1.4 HDi
185/60 R15 84 H XH1
AXLES
SUSPENSION
STEERING
6J 15CH 4.27 COYOTE
152
185/60 R15 84 H XH1
6J 15CH 4.27
WHEELS AND TYRES

Tyre pressures, vehicle empty
Tyre dimensions
Pressure (Bars)
Front
Rear
165/70 R14 (81T) XT1
2.1
2.1
185/55 R15 (84H) XH1
2.1
2.3
195/45 R16 (80V)
2.4
2.4
Spare wheel
2.8
Tyre pressures, vehicle under load

Pressure (Bars)
165/70 R14 (81T) XT1
Front
Rear
2.1
2.8
2.4
2.4
185/55 R15 (84H) XH1

195/45 R16 (80V)
153
Spare wheel
2.8
AXLES
SUSPENSION
STEERING
Tyre dimensions
WHEELS AND TYRES

Identification of inflation pressures
The label indicating recommended tyre pressures is affixed to the

inner panel of one of the front doors.
a: Recommended tyre inflation pressures.

(vehicle empty and vehicle under load).
b: Type of tyre.
c: Recommended inflation pressure for the spare tyre.

AXLES
SUSPENSION
STEERING
B2GP010D
154
WHEELS AND TYRES

Identification of wheel bolts
(1)
(2)
(3)
: Wheel bolt.
: Light alloy wheel.
: Spare wheel.
Steel wheel.
Bolt for wheel with conical contact surface.

Light alloy wheel.
Mixed fixing wheel bolts, permitting the securing of the following wheel
types:
Light alloy wheel (fixing with flat contact surface).
Tightening torque:
9 1 m.daN.
B2GP00JD
155
AXLES
SUSPENSION
STEERING
Steel spare wheel (fixing with tapered contact surface).
AXLE GEOMETRY
Conditions for checking and adjusting
Tyres inflated to correct pressures.
Vehicle at reference height.
Steering rack locked at mid point (See corresponding operation).
Vehicle heights at reference height
E1AP0BZD
Front height
Rear height
L1
L2
H1 = R1 - L1
AXLES
SUSPENSION
STEERING
H1 = Measurement between the measuring zone underneath the front

subframe and the ground.
R1 = Front wheel radius under load.
L1 = Distance between the wheel axis and the measuring zone
underneath the front subframe.
H2 = R2 + L2
H2 = Measurement between the measuring zone underneath the rear sill
and the ground.
R2 =Rear wheel radius under load.
L2 = Distance between the wheel axis and the measuring zone
underneath the rear sill.
156
AXLE GEOMETRY
B3CP07SD
Measuring front height
Measuring rear height
[1] Gauge for measuring the wheel radius, 4 bolts, tool 8006-T
Z1 = Measuring zone underneath the front subframe.
Z2 = Measuring zone underneath the rear sill.
Measure the radius of the front wheel R1 - Calculate dimension H1 = R1 L1
Measure the radius of the rear wheel R2 - Calculate dimension H2 = R2 + L2
HFX - KFV - 8HX
NFU
L1 = 142.5 mm
L1 = 152.5 mm
Value at reference
height
(+ 10 - 6 mm)
Compress the suspension to obtain the calculated values.

The height difference between the two axle dimensions should be less than 10 mm.
(*) = CRD : Difficult road conditions.
157
Except CRD (*)

HFX - KFV - 8HX
NFU
L2= 52 mm
L2= 42 mm
AXLES
SUSPENSION
STEERING
Value at reference
height
(+ 6 - 8 mm)
Except CRD (*)
AXLE GEOMETRY
Front axle
Rear axle
Dissymmetry of lower castor at 0 30.

Dissymmetry of lower camber at 0 18
Distribute symmetrically, LH / RH wheel, the total tracking value.
Vehicle
Tracking
Adjustable
All
Types
mm
21
0 18009
Vehicle
Tracking
All types (except CRD)

HFX - KFV - 8HX
Camber
Pivot angle
Castor
0 30
0 30
0 18
Non adjustable
358
NFU
Castor
0 18
Adjustable
All
Types
mm
21
0 18009
Dissymmetry of lower camber at 0 18.
- 031
1126
HFX - KFV - 8HX

Tracking
Camber
Non adjustable
5.5 1
053 009
- 130
NFU
Camber
0 30
Non adjustable
Pivot angle
0 30
Tracking
Camber
Non adjustable
5.8 1
4
- 032
1135
049 009
- 131
AXLES
SUSPENSION
STEERING
WARNING
B3CP02UC
158
A < B = Positive figure :
+=
TOE-IN
A > B = Negative figure :
-=
TOE-OUT
B3CP07RP

(1) Nut fixing suspension leg on body
(2) Damper
(3) Anti-roll bar link rod upper ball-joint
(4) Suspension leg pivot
(5) Anti-roll bar link rod lower ball-joint
(6) Anti-roll bar bearing fixing on subframe
(7) Hub nut
(8) Wheel bolt
(9) Subframe to bodyshell fixing screw
(10) Anti-roll bar
(11) Pivot lower ball-joint fixing on lower arm
(12) Pivot lower ball-joint fixing
(13) Lower arm front and rear mounting fixing
(14) Stabiliser bar screw
(15) Steering ball-joint fixing
Anti-roll
Private vehicles Europe
Diameter (mm)
HFX - KFV
18
NFU
20
8HX
19
Entreprise vehicles
Diameter (mm)
HFX - 8HX
18
CRD vehicles
Diameter (mm)
KFV - 8HX
18
NFU
20
159
: 6,5 0,6
:
: 3,2 0,3
: 5,4 0,5
: 3,2 0,3
: 8 0,8
: 24,5 0,5
:91
: 10 1
:
: 5,5 0,5
: 4 0,4
: 14 0,4
: 6,6 0,7
: 3,5 0,3
bar
Colour
Violet
Green
Blue
Colour
Violet
Colour
Violet
Green
AXLES
SUSPENSION
STEERING
FRONT AXLE
REAR AXLE
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)

Rear axle fixing screw
Anti-roll bar
Rear axle crossmember
Rear suspension arm silentblock yoke
Rear suspension arm silentblock
Yoke / suspension arm fixing screw
Rear suspension arm
Stub axle bearing nut
Damper
Damper upper fixing
Damper lower fixing
Suspension springs
Travel stop
Secondary brake cable guide support
Private vehicles Europe
AXLES
SUSPENSION
STEERING
B3DP09UP
HFX- KFV
8HX
NFU
Entreprise vehicles
8HX
CRD vehicles
8HX
NFU
160
:
:
:
:
:
:
:
:
:
:
:
:
:
:
10 1
7 0,5
20 2
4,5 0,4
9,3 0,9
Anti-roll bar
Diameter (mm)
20.5 (hollow)
23.5 (hollow)
25 (solid)
Diameter (mm)
20.5 (hollow)
Diameter (mm)
20.5 (hollow)
25.5 (hollow)
SUSPENSION
FRONT AXLE
(1) Nut fixing suspension leg on body
: 6,5 0,6
(2) Damper.
(16) Cup.
(17) Damper nut.
: 6,5 0,6
(18) Damper cup.

(19) Ball bearing
(20) Spring thrust cup.
(21) Travel stop cup.
(23) Damper rod protector.

(24) Travel stop.
B3BP180D
161
AXLES
SUSPENSION
STEERING
(22) Suspension spring.
FEATURES OF ELECTRIC POWER STEERING

Steering column
B3EP13HC
B3EP13GD
Tightening torques m.daN.
Identification
AXLES
SUSPENSION
STEERING
(1) Steering wheel fixing
2 0,3
Identified by the colour of the ring at a.
(2) Steering column fixing on support
2,2 0,5
Left hand drive
: BLUE ring.
(3) Steering cardan fixing
2,2 0,2
Right hand drive
: WHITE ring.
162

Steering mechanism
Tightening torques m.daN
(4) Ball-joint fixing on pivot
(5) Steering rod lock-nut
(8) Threaded washer
(9) Stud
(10) Flat washers
(11) Fixing of mechanism on subframe
: 3,5 0,3
: 5 0,5
: 0,8 0,1
: 8 0,8
B3EP13JD
Number of rotations
of steering wheel
Inner angle of lock
Outer angle of lock
NFU
60 A
2x72
45.6/1
65 A
2x64
3.2
2.8
38
3224
3230
2842
(6) Supply of electric assistance motor.
163
Connectors.
(7) Torque sensor signals.
AXLES
SUSPENSION
STEERING
Electric motor
Steering rack travel
Steering ratio
HFX - KFV - 8HX

Steering assistance
Electric steering assistance ECU
B3EP13KC
B3EP13LC
Supplier: KOYO.
The steering assistance is provided by the assistance motor (12), controlled by the ECU.
Power delivered to the assistance motor (12) depends on:
AXLES
SUSPENSION
STEERING
- Speed of the vehicle.

- Torque applied on the steering wheel.
164
Only one ECU version, whatever the engine-type.

The electric power steering ECU is linked to the following connectors:
- (6) Assistance motor supply.
- (13) Electric power steering ECU supply.
- (14) Control signals.
After changing the electric power steering ECU, it is necessary to
perform a configuration.
SPECIAL FEATURES : STEERING

Centring the steering rack
Preliminary operation.
Raise and support the vehicle on a two-column lift.
Remove, on the RH side of the steering rack:
- Clip (1).
- Clip (2).
Release the steering rack protection gaiter.
Setting
Move the steering to full left hand lock.
Measure the dimension X.
Move the steering to full right hand lock.
Measure the dimension Y.
Calculate the dimension:
L = (Y X) : 2.
Refit:
- The steering rack protection gaiter
- New clips (1) and (2).
B3EP13VD
165
AXLES
SUSPENSION
STEERING
B3EP13UC
BRAKE SPECIFICATIONS (WITHOUT ABS)
Engine type
mm
1.4i
1.4 HDi
HFX
KFV
8HX
Master cylinder
20.6
Master vac
203.2
Caliper/piston makes
Disc
FT
1.1i
LUCAS .TRW-/-C 48/13-/-48

266
Plain
Disc thickness/minimum thickness
13/11
0.05
Maximum run-out (mm)

Difference in max. thickness on same
circumference (mm)
0.01
TEXTAR-/-T 4144
Supplier / Brake pad grade
RR
Original thickness/minimum thickness
13/3
Original drum/maximum
203/205
mm
Width
BRAKES
38
DON-/-8259/1
Supplier / grade
166
Engine type
1.1i
1.4i
1.4i
1.4 HDi
HFX
KFV
NFU
8HX
Master cylinder
22.2 (*)
228.6
Master vac
mm
FT
Caliper/piston makes
Disc
Plain
266
13/11
22/20
Plain
247
9/7
LUCAS .TRW C 38 HR 9/13
mm Original drum/maximum/
width
203/205-/-38
Supplier / Lining grade
DON 8259/1
(*) = With emergency braking assistance (AFU)

167
13/11
TEXTAR-/-T 4144

RR
LUCAS .TRW C 54/22-/-54 LUCAS.TRW-/-C 48/13-/-48
Ventilated

mm Disc
LUCAS .TRW-/-C 48/13-/-48

266
203/205-/-38
GALFER G 4554
DON 8259/1
BRAKES
BRAKE SPECIFICATIONS (WITH ABS)
BRAKES
BRAKE SPECIFICATIONS
Braking circuit without ABS - REF (drum brakes at the rear)
Braking system specifications

- Braking circuit at X.
- Front brakes with ventilated discs (*).
- Rear brakes with eitther drums or discs (*).
- Handbrake lever controlling cables acting on the
rear wheels.
The compensator and main brake limiter functions are
assured by the ABS EBD system.
NOTE : REF = Electronic Brakeforce Distribution
(*) = according to version
B3FP7BSD
168
Braking circuit with ABS - REF (drum brakes at the rear)
B3FP7BTD
169
BRAKES
BRAKES
Braking circuit with ABS - REF (disc brakes at the rear)
B3FP7BUD
170
Braking circuit with ABS - REF
(a) Hydraulic circuit.

(b) Electrical circuit.
(1) Master cylinder in tandem.
(2) Braking servo.
(3) Brake caliper (or drum at the rear).
(4) Hub equipped with a bearing with an integral magnetic wheel
(48 pairs of poles).
(5) Wheel sensor.
(6) Brake fluid level sensor.
(7) Hydraulic block plus ECU.
(8) Stoplamp switch.
(9) Instrument panel.
(10) Diagnostic socket.
(11) Built-in systems interface (BSI).
B3GP02RP
171
BRAKES
BRAKES
(7) Hydraulic block
Ref.
Elements
Supplier
Mounted on the front LH chassis member.

ESP -ABS MK.60 4 adjustment channels
96 490 288 80
ABS MK.70
26-way connector.
ESP -ABS MK 60 Integral to the hydraulic block
ECU
96 387 201 80
2-way blue connector.
The sensors are inductive-type.
Mounted on the suspension arm.
Non-adjustable airgap: 0,35 to 1,6 mm.
Tightening torque: 0,8 0,2 m.daN
Rear wheel
sensor.
Hub bearing.
SNR
B3FP7BVC
172
2-way blue connector.

The sensors are inductive-type.
Mounted on the pivot.
Non-adjustable airgap: 0,16 to 1,6 mm.
Tightening torque: 0,8 0,2 m.daN
TEVES
Observations
ABS MK 70
96 514 120 80
Hydraulic
block
Front wheel
sensor.
Part No.
Hub equipped with a bearing with an integral

magnetic wheel (48 pairs of poles).
BRAKES
Brake pedal gear
Front brake
B3FP166D
Rear brake
B3FP164C
B3FP165C
Tightening torques (m.daN).

(16) Servo fixing
2,2 0,3.
(12) Yoke fixing on caliper
10,5 1
(14) Rear caliper fixing on arm
5,30,5
(17) Fixing on master cylinder
2 0,5.
3 0,3
3,80,3
173
BRAKES
HANDBRAKE (Adjustment)
Adjustment
Lift and chock the vehicle.
Remove:
- The rear cover (8)
- The nut (9)
- The handbrake trim (6).
- The gear lever gaiter (5).
- The front cover (3).
- The screws (1).
Disconnect the connectors of the following components:
- The cigar lighter (2).
- The electric window buttons (4).
Remove the central console (7).
WARNING: Check that the brake cables are correctly
routed under the vehicle.
Slacken the handbrake lever.
Press gently on the brake pedal (Then repeat the
operation 3 times).
Pull vigorously on the handbrake lever 4 or 5 times.
C5FP0ELD
174
Adjustment (continued)
A : Drum brakes
B : Disc brakes
(10) Nut for adjusting cable tensions.
Remove:
- The rear wheels.
- The drums (according to version).
Release the handbrake.
Use a gauge set to measure at a the travel of the lever
from its stop.
Adjust the nut (10) to obtain a travel of less than or equal
to 1 mm at a.
Refit the brake drums without tightening them (according
to version).
Action the handbrake lever 8 times with an effort
of 40 m.daN.
With the handbrake released, check the travel of the
lever at a, using a gauge set.
NOTE : The travel should be less than 1 mm and more
than 0,05 mm.
Refit:
- The brake drums.
- The wheels.
- The central console.
Check the operation of the handbrake.
B3FP16ED
175
BRAKES
HANDBRAKE (Adjustment)
BRAKES
BLEEDING AND FILLING THE BRAKING SYSTEM

Tools.
[1] Generic bleeding apparatus
: LURO or similar.
Bleeding, refilling.
Draining.
Drain the brake fluid reservoir (1) to the maximum (if necessary, use a clean syringe).
Disconnect the connector (4).
Uncouple the pipe (2).
Unscrew the shaft (3).
Remove the reservoir (1).
- Empty the brake fluid reservoir (1).
- Clean the brake fluid reservoir (1).
Refit:
The brake fluid reservoir (1).
The shaft (3).
Couple the pipe (2).
Reconnect the connector (4).
Filling the braking system.
WARNING : Use only those hydraulic fluids that are approved and recommended.
- Fill the brake fluid reservoir (1).
Bleeding the braking system.
WARNING: During the bleeding operation, take care to maintain the level of brake fluid in the
reservoir and to top it up, using only brake fluid that is clean and clear.
B3FP15XC
176
Bleeding, filling (continued)
Bleeding the primary braking circuit.

WARNING: The ABS should not be active during the
bleeding operation.
- Front brake caliper: Bleed screw (5).
A : Rear brake caliper
B : Rear brake drum
Bleed screw (6).
Bleed each wheel cylinder, proceeding in the following
order :
Front LH wheel.
Front RH wheel.
Rear LH wheel.
Rear RH wheel.
B3FP15YC
B3FP15ZD
177
BRAKES
BRAKES

Bleeding, filling (continued)
With the bleeding apparatus
- Connect the bleeding apparatus [1] on the brake fluid reservoir (1).
- Adjust the apparatus pressure to 2 Bars.
For each circuit :
- Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container.
- Open the bleed screw, wait until the fluid is flowing out without air bubbles.
- Close the bleed screw.
- Remove the bleeding apparatus [1].
- Check the brake fluid level (Should be between MINI level and MAXI level).
- Fill if necessary with the approved and recommended synthetic brake fluid.
Without the bleeding apparatus.
NOTE : Two operators are necessary.
For each circuit :
- Apply the brake pedal to place the circuit under pressure.
- Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container.
- Open the bleed screw, wait until the fluid is flowing out without air bubbles.
- Close the bleed screw.
- Remove the tool [1].
NOTE : Recommence the process a second time if that is necessary.
- Check the brake fluid level, (Should be between MINI level and MAXI level).
- Fill if necessary with the approved and recommended synthetic brake fluid.
B3FP160C
178
FEATURES OF THE PRE-POSTHEATING CIRCUIT

ESSENTIAL : Respect the safety and cleanliness requirements.
The pre-post heating control unit is managed by the engine ECU.

Pre-post heating control unit
Supplier
Reference
CARTIER
96 399 073 80
NAGARES
96 399 074 80
Pre-heater plug
A Marking zone
Supplier
Reference
NGK
YE04
Tightening torques
Plugs on cylinder head

Bar on plugs
D1AP01SC
179
: 0,85 0,08 m daN

: 0,12 0,03 m.daN
ELECTRICAL
SYSTEM
The pre-heating time varies according to the engine coolant temperature.
STARTER MOTORS
Abbreviations and definitions
ELECTRICAL
SYSTEM
Coding of climatees is as follows :
Meaning of abbreviations :
CLIMATEES :
C
T
F
GF
Hot
Temperate
Cold
Very cold
:
:
:
:
Starting
Starting
Starting
Starting
possible
possible
possible
possible
as
as
as
as
low
low
low
low
as
as
as
as
BVM
BVMP
REFRI
-18C
-18C
-25C
-30C
180
: Manual gearbox
: Piloted manual gearbox
: Air conditioning
STARTER MOTORS
Types of starter
Gearbox
1.1i
BVM
1.1i REFRI
C2
1.4i
BVM - BVMP
1.4i REFRI
VALEO D7E16
BOSCH A001183027F
MELCO M002T13081
VALEO D6RA572
VALEO D7E16
BOSCH A001183027F
MELCO M002T13081
VALEO D6RA572
VALEO D7E16
BOSCH A001183027F
MELCO M002T13081
VALEO D7E23
BOSCH A0001180093F
VALEO D6RA572
VALEO D7E16
BOSCH A001183027F
MELCO M002T13081
VALEO D6RA572
Meanings of abbreviations : see page 180

181
Class
1
3
1
3
Climate
C
T
F
GF
C
T
F
GF
C-T
GF
C
T
F
GF
1
3
ELECTRICAL
SYSTEM
Vehicles / models
STARTER MOTORS
Vehicles / models
Gearbox
ELECTRICAL
SYSTEM
1.6i 16V
BVMP
14.HD i
BVM
Types of starter
Class
VALEO D6RA572
VALEO D6RA110
VALEO D7GP09
DENSO 5S228000-001
C2
Meanings of abbreviations : see page 180

182
Climate
C
T
F
GF
C
T
F
GF
ALTERNATORS
Abbreviations and definitions
CLIMATES :
C
T
F
GF
Hot
Temperate
Cold
Very cold
:
:
:
:
Starting
Starting
Starting
Starting
possible
possible
possible
possible
as
as
as
as
low
low
low
low
as
as
as
as
BVM
BVMP
NON REFRI
REFRI
-18C
-18C
-25C
-30C
183
:
:
:
:
Manual gearbox
Without air conditioning
With air conditioning
ELECTRICAL
SYSTEM
Meaning of abbreviations :
Coding of climates is as follows :
ALTERNATORS
Gearbox
Climate
NON REFRI
Without cold pack
With cold pack
Base
ELECTRICAL
SYSTEM
1.1i
BVM
1.4i
BVMP
1.6i 16V
BVM
1.4 HDi
BVM
1.4 HDi
ECO
BVMP
Meanings
RT3
N1 or N2
C
6
T
F
7
GF
C
T
7
F
GF
C
T
7
F
GF
C
T
F
GF
C
T
F
GF
of abbreviations : see page 183
RT3
N3
6
RT3
N1 or N2
Base
7
RT3
N3
6
Base
RT3
N1 or N2
With cold pack
RT3
N3
RT3
N1 or N2
Base
7
7
9
8
8
7
9
8
7
8
8
15
8
15
7
8
9
8
9
8
RT3
N3
9
8
8
7
184
REFRI
Without cold pack
9
8
9
8
9
8
9
8
Checking the alternator output

Connect as shown in the diagram opposite, using an ammeter (A), a voltmeter (V), and a rheostat (R) or
a Volt/Ammeter/Rheostat combination.
Referring to the vehicles equipment specification (see table opposite), adjust the engine speed and
rheostat charge to obtain U=13.5V.
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 should go out when the engine has started (accelerate
slightly).
A : Ammeter
B : Battery
G : Generator
L : Warning lamp
K1 and K2 : Switch
R : Electric charge
S : Shunt 200mV/200A
V : Voltmeter
1 : Alternator.
Checking the voltage regulator

Set the rheostat to zero and disconnect all the electrical consumers.
Display 3000 alternator rpm. If U alternator is > 14.7 V, the regulator is faulty.
Note: These tests should be performed with the engine hot and the battery fully charged.
Method of reading the alternator speed
Fit a reflecting shim on the pulley of the alternator.
Adjust a stroboscope to the frequency equivalent to the control speed.
(e.g. 2000 rpm = 2000/60 = 83 Hz)
Adjust the engine speed so that the shim appears fixed.
D1AP025C
185
ELECTRICAL
SYSTEM
CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR
CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR
ELECTRICAL
SYSTEM
Alternator
speed
Min. output
1800 rpm
2000 rpm
3000 rpm
4000 rpm
6000 rpm
8000 rpm
15000 rpm
11
I2
I3
I4
I5
I6
I7
Alternator speed
1800 rpm
2000 rpm
3000 rpm
4000 rpm
6000 rpm
8000 rpm
15000 rpm
MINIMUM OUTPUTS (in A)

Class
7
8
9
12
15
18
61
68
84
92
96
97
97
73
80
100
110
120
123
124
89
105
139
145
151
157
157
108
123
164
176
183
188
188
Class
9
12
15
18
52
51
48
46
42
39
27
57
54
51
48
43
40
29
58
55
52
50
48
45
34
60
57
54
52
50
48
38
61
60
56
53
50
48
38
27
34
47
55
61
63
64
39
46
60
65
69
70
73
46
54
68.5
75
78.5
80
82
MINIMUM YIELDS (in %)
49
48
45
43
39
26
24
50
49
46
44
40
37
25
186
Vehicles - models
C2
1.4 HDI
8HX
Pre-heater plugs
Pre-heater control unit
Pre / Post heating

(pre-heating duration at 20C)
NGK YE04
NAGARES 960411-P
CARTIER 735068
Controlled by the diesel injection

ECU
187
ELECTRICAL
SYSTEM
PRE-HEATING AND STARTING SYSTEMS
AIR CONDITIONING R 134 a (HFC)

Compressor
AIR
CONDITIONING
Vehicle
Engine
Date
Refrigerant
refill
C2
All types
05/2003 #
600 + 0 - 50 gr
188
Variable
Capacity
Oil quantity
cc
Oil
reference
SD 6 V 12
135
SP 10
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)

Condenser
C5HP18VD
C5HP18UD
The condenser (5) has a cylinder (6) incorporating the function of

aircon fluid reservoir and with integral filtering cartridge.
Tools
Removing-refitting tool
FACOM : K .1702
The inlet (7) and the outlet (8) of the condenser (5) are equipped with
new seals (3) (MANULLI).
Condenser : MODINE 16 dm_
The drive plate (1) is held on the aircon compressor shaft by ribs.
New wiring (2).
New seals (3) (MANULLI).
Identification label (4) for aircon compressor.
189
AIR
CONDITIONING
Compressor

Pressure reducer
Seals
AIR
CONDITIONING
C5HP18WC
C5HP18XD
The inlet (10) and the outlet (9) are equipped with new seals (3)
(MANULLI).
MANULLI calibrated seal (3)

Direction of fitting of the seal (3).
Before fitting the seal, amply lubricate the seal with air conditioning
compressor oil (SP10).
190

Pollen filter
Note: The pollen filter is located in the engine compartment on the RH side.
Removing
Pull on the tab of the plastic cover (1), at a.
AIR
CONDITIONING
Tilt the flap (2).

Remove the pollen filter (3)
Refitting
Proceed in reverse order.
C4AP1BRC
C4AP1BSC
C4AP1BTC
191

Changing the filtering/drying cartridge
Tools.
[1] Charge station
[2] TORX adaptor
[3] Inertia extractor
[4] Endpiece 20
[5] Set of plugs
[6] Circlip pliers
: (according to workshop equipment)

: TORX 70 FACOM.
:1671-T.
Toolkit 4114-T
: 1671-T.D20.
: (-).0188.T.
: FACOM.
AIR
CONDITIONING
Removing
Depressurise the aircon circuit, using tool [1].
Remove the front bumper (see corresponding operation).
Remove the pin (1).
Unclip the condenser at a and b, using a screwdriver.
Tilt the condenser towards the front.
Lift and release the condenser.
Clean the area around the cap (2).
Remove the plastic cap (2), using tool [2].
Remove the safety circlip (3), using tool [6].
Position the tool [3] and [4] in the aperture of the cartridge (5).
Extract the cartridge (5) from the reservoir (4), using tool [3] and [4].
Block the reservoir (4), using tool [5].
C4AP1BUC
C4AP1BWC
C4AP1BVC
192
C4AP1BXC

Changing the filtering/drying cartridge
WARNING : Not more than 5 minutes should elapse between the removal
of the cartridge (5) from its packaging and its being fitted.
Refit:
- The plastic cap (2), using tool [5]
- Tighten to 1,2 0,1 m.daN.
- The condenser (reclip, pushing at a and b).
- The pin (1).
- The front bumper (see corresponding operation).
Proceed to:
- Recharge the circuit (see corresponding operation).
- Check the operation of the air conditioning (see corresponding operation).
C4AP1BYC
C4AP1BWC
C4AP1BUC
193
C4AP1BVC
AIR
CONDITIONING
Refitting
Remove the new cartridge from its packaging.
Do not expose the cartridge, the filter and seals to pollutants.
Lightly oil the seals (compressor oil).
Remove tool [5] from the reservoir (4).
Insert the new cartridge (5) into the reservoir (4).
Refit the safety circlip (3), using tool [6].
Make sure that the circlip (3) is correctly positioned in its location.

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.
AIR
CONDITIONING
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.
194

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.
It is therefore necessary to :
- Replace the dryer.
- 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.
195
AIR
CONDITIONING
This type of leak causes both oil loss as well as allowing air to enter the system.
AIR CONDITIONING CIRCUIT R 134.a
(1) High pressure valve.

(2) Low pressure valve
(3) Pressostat
(4) Filter.
AIR
CONDITIONING
Tightening torque m.daN

(a)
(b)
(c)
(d)
(e)
(f)
C5HP19UP
196
:
:
:
:
:
:
0.6
0.6
0.6
0.6
0.6
0.7

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The technical information contained in this document is intended for the exclusive use of the trained personnel of the

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C : AS/RP No. and RP paint code.

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B : Manufacturers name plate

Cubic capacity (cc)

Fiscal rating (hp)

Gearbox ident. plate

(3) mp = Piloted manual gearbox

(*) = IF : Fiscal incentive

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Cubic capacity (cc)

Fiscal rating (hp)

20 CN 51 (1) (m) (4)

20 CN 33 (2) (m) (4)

20 CN 51 (1) (m) (4)

20 CN 33 (2) (m) (4)

(3) mp = Piloted manual gearbox

(*) = IF : Fiscal incentive

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(c) Gross vehicle weight (*).

(*) = according to marketing country.

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3-door saloon (4-seater)

Version (Gearbox and emission standard)

TU3JP/ EURO /3/IF EURO /4

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GENERAL SPECIFICATION : DIMENSIONS

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GENERAL SPECIFICATION : DIMENSIONS

(*) = Vehicle in running order (vehicle empty, levels topped up).

(*) = Boot floor with adjustable configuration.

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Exterior dimensions (mm)

GENERAL SPECIFICATION : WEIGHTS

With all options

Gross vehicle weight

Gross train weight

Maximum trailer weight without brakes

Maximum trailer weight with brakes

Maximum nose weight

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OPERATIONS TO BE CARRIED OUT AFTER A REPAIR

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OPERATIONS TO BE CARRIED OUT AFTER A REPAIR

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GENERAL SPECIFICATION : TOWING THE VEHICLE

The towing eye (1) is to be found in the vehicle

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WARNING : When the engine is not running,

GENERAL SPECIFICATION : TOWING THE VEHICLE

Piloted manual gearbox

WARNING : Whether the ignition is switched on or not, an action on

ESSENTIAL : Never tow the vehicles with wheels hanging

Essential : Never swap two gearbox ECUs between two vehicles.

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GENERAL SPECIFICATION : TOWING THE VEHICLE

Engagement of N, using a diagnostic tool.

Engagement of N, without a diagnostic tool.

IMPERATIVE : This recovery solution is to be used solely in a case

Using the menus of the diagnostic tool, select :

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