carte citroen

8/18/2019 Carte Citroen

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CORRESPONDENCE TABLE FOR PETROL ENGINES

XSARA

XSARA

PICASSO

BERLINGO

Enginefamilies

Engine types

VERY IMPORTANT

A s t h e b o o k l e t i s c o n s t a n t l y r e - e d i t e d , t h i s o n e o n l y c o v e r s v e h i c l e s f o r t h i s

p a r t i c u l a r m o d e l y e a r .

I t i s t h e r e f o r e n e c e s s a r y t o o r d e r a n e w b o o k l e t e a c h y e a r a n d R E T A I N T H E

O L D O N E S .

TU ET TU EW

1 3 5 7 10

JP J4 JP + JP4 J4 A J4 J4S

1.1i 1.4i 1.4i 16V 1.6i 1.6i 16V 1 .8i 16V 2.0i 2.0i 16V

HFX KFW KFU NFV NFU 6FZ RFJ RFN RFK

X X X X X

X X X

X X X

X X X

C4

XSARA

XSARA

PICASSO

BERLINGO

Enginefamilies

Engine types

4

TD

1.4 H

8HX

X

C4


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PRIVATE C

C4-XSARA

BERLINGO P R I V A T E C A R S

CAR 000 000 Volume 2

2005 AC/QCAV/MTD

Méthodes techniques documentation «The intellectual property rights relating to the technical information contained in this document belongexclusively to the manufacturer. Reproduction, translation or distribution in whole or in part without priorwritten authorisation from the manufacturer is forbidden».

«The technical information contained inel of the motor vehicle repair trade. Ity of the vehicle. The information is toand they alone would assume full resp«The technical information appearingmodel in the range evolve. Motor vehicfurther information and to obtain any


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PRESENTATION

THIS HANDBOOK summarises the specifications, adjustments, checks and special features of CITROËN private vehicles, not incluhandbook.

The handbook is divided into groups representing the main functions:

GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES -

In each section, the vehicles are dealt with in the following order: C4 - XSARA - XSARA PICASSO - BERLINGO and all models wh

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


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IMPORTANT

If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions whichFor example:

- INSUFFICIENT INFORMATION- SUPERFLUOUS INFORMATION- NEED FOR MORE DETAILS

Please send your comments and suggestions to:

CITROEN U.K. Ltd.

221, Bath Road,

SLOUGH,

SL1 4BA.U.K.


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GENERAL

C4 1 - 2

XSARA 3 - 4

XSARA PICASSO 5 - 6

BERLINGO 7 - 8

Operations following a repair: C4 9

C4 11 - 12XSARA 13 - 14

XSARA PICASSO 15

BERLINGO 16

Lubricants 17 - 39

ENGINE

Specifications 40 - 41

Tightening torques: engines all types 42 - 147

Cylinder head tightening: all types 148 - 150

Auxiliary drive belt 152 - 153

Checking and setting the valve timing 181 - 182

C4 279

XSARA 280

XSARA PICASSO 281 Valve clearances 282

ChecXsara

Chec

Chec

Chec

Check

ChecXsar

ChecXsara

ChecXsara

ChecXsar

IGNIT

Spark

CLUT

CONTENTS

Vehicleidentification

Capacities

INJECTION

Checking the low pressure fuel supplycircuit: Xsara (DV4TD) 283

Checking the low pressure fuel supplycircuit: C4 (DV6TED4/ATED4) 284

Checking the low pressure fuel supplycircuit: Xsara Picasso (DV6TED4) 285

Checking the low pressure fuel supplycircuit: C4 (DW10BTED4) 286

Checking the low pressure fuel supplycircuit: Xsara (DW10TD) 287

Checking the low pressure fuel supplycircuit: Xsara Picasso (DW10TD/ATED) 288 - 289

Checking the turbo pressure: Xsara (DV4TD) 290Checking the turbo pressure:C4 (DV6TED4/ATED4) 291

Checking the turbo pressure:Xsara Picasso (DV6TED4) 292

Checking the turbo pressure:C4 (DW10BTED4) 293

Checking the turbo pressure:Xsara picasso (DW10TD) 294

Checking the oilpressure

spe


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CLUTCH - GEARBOX - TRANSMISSION (continued)

Gearbox specifications 312 - 314

Clutch specifications 315 - 316

Checking and adjusting the hydraulicclutch control 317 - 318

Tightening torques: manual gearbox 319 - 330

Manual gearbox controls 331 - 343Recommendations - precautions:automatic gearbox 344 - 346

Tightening torques: manual gearbox 347 - 349 Automatic gearbox controls 350 - 359Driveshafts 360

AXLES - SUSPENSION - STEERING

Axle geometry: C4 361 - 364

Tightening torques: front axle 365 - 366

Tightening torques: rear axle 367

Tightening torques: power steering 368 - 369

Setting the steering rack mid-point 370

Checking the power steering pressure 371 - 374

Axle geometry: Xsara 375 - 379

CONTENTS

Tightening torques: front axle 380

Tightening torques: rear axle 382

Tightening torques: steering 383 - 384

Tightening torques: power steering 385 - 387

Axle geometry: Xsara Picasso 388 - 392

Tightening torques: front axle 393

Tightening torques: rear axle 394Tightening torques: power steering 395 - 397

BRAKES

Brake specifications: C4 398 - 399

Tightening torques: Brakes 401 - 403

Adjusting the handbrake 405

Filling, bleeding the brakes 406 - 410

Brake specifications: Xsara 411

Tightening torques 414

Brake specifications 415 - 418 Adjusting the handbrake 419

Filling, bleeding the brakes 420

Brake specifications: Xsara Picasso 421 - 422

Brake specifications 423 - 424


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IDENTIFICATION OF THE VEHICLE

E1AP0EWD

A - Manufacturer'A1 - Front RH chaCITROËN C4 CouA2 - LH centre pi(right hand drive).

B - Cold stamp(cold stamp engra

C - AS/RP No. an(on the front pillar

D - Tyre pressure(on the front pillar

E - Serial number

F - Gearbox ident

G - Engine legisla


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Structure VersionL Family (1)A Bodywork (2) L3 L4 L5

LA KFUC KFU Engine (3) W3C Version (4) Manual 5-speed gearbox A B C/IF Variant (5) Manual 4-speed gearbox E F

Family (1) Manual 6-speed gearbox G HL C4 Automatic 6-speed gearbox D J

Body shape (2) Axle and/or gearbox gears K LA 3-door saloon Other possible combinations MC 5-door saloon No gearbox

G3-door saloon not

convertible from van

R5-door saloon not

convertible from vanEngine (3) Varian

KFU 1.4i 16V ET3J4 Entreprise convertibleNFU 1.6i 16V TU5JP4 Integral alternator-starter (ADIN)RFJ EW10A Without FAPRFN 2.0i 16V EW10J4 Fiscal incentivesRFK EW10J4S Piloted manual gearbox9HY

DV6TED4Downgraded depollution

9HZ 1.6 16V HDi LPG dual fuel9HX DV6ATED4 CNG dual fuelRHR 2.0 16V HDi DW10BTED4 STT2 (Stop and start)

IDENTIFICATION OF THE VE

Type approval

C4


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E1AP08WD

A - Manufacturer's

B - Chassis stamp

C - Manufacturer's

D - Label:(label affixed to the

- Tyre press- RP organis- Paint code

E - Serial number

F - Engine legislat

G - Gearbox ident


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Structure VersionN Family (1)2 Bodywork (2) 15.04 Spécif US 93/

N2 RFN1/IFRFN Engine (3) K ≠ CEE L/W

1 Version (4) Manual 4-speed gearbox/IF Variant (5) Manual 5-speed gearbox G H E

Family (1) Manual 6-speed gearboxN XSARA Automatic 3-speed gearbox T

Body shape (2) Automatic 4-speed gearbox U R2 Estate Axle and/or gearbox gears W S J

Manual 5-speed gearboxMercosur/Iran

X

No gearboxEngine (3) Varian

KFW 1.4i TU3JP Entreprise convertibleNFU 1.6i 16V TU5JP4 Integral alternator-starter (ADIN)RFN 2.0i 16V EW10J4 Without FAP

8HZ 1.4 HDi DV4TD Fiscal incentives8HY 1.4 16V HDi DV4TED4 Piloted manual gearbox

WJY 1.9D DW8B Downgraded depollution D (car or converRHY

2.0 HDiDW10TD LPG dual fuel GPL (cylind

RHZ DW10ATED STT2 (stop and start)

IDENTIFICATION OF THE VE

Type approval

XSARA


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5


E1AP088D

A - Chassis stamp(cold stamp on

B - Chassis no. re(label located

C - Manufacturer'

(located at botD - Label:

(located on fro

- Tyre- Tyre- Spar

E - Label:(located on fus

- Fact- A-S

- PainF - Gearbox ident

G - Engine legisla


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6

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Structure VersionC Family (1)H Bodywork (2) L3 L4 L5

CH 6FZC/IF 6FZ Engine (3) W3C Version (4) Manual 5-speed gearbox A B C

/IF Variant (5) Manual 4-speed gearbox E FFamily (1) Manual 6-speed gearbox G HC XSARA PICASSO Automatic 6-speed gearbox D J

Body shape (2) Axle and/or gearbox gears K LH Monoshell Other possible combinations M

No gearboxEngine (3)

NFV 1.6i TU5JP Entreprise convertible6FZ 1.8i 16V EW7J4 Integral alternator-starter (ADIN)RFN 2.0i 16V EW10J4 Without FAP9HZ

1.6 16V HDi DV6TED4Fiscal incentives

9HY Piloted manual gearbox

RHY 2.0 HDi DW10TD Downgraded depollutionD (car or

conveLPG dual fuel GPL (cylindSTT2 (stop and start)

IDENTIFICATION OF THE

Type approval

XSARA PICASSO


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7


E1AP0AMD

A - Chassis sta

B - Manufacture

C - Label- RPO No- Paint col- Tyre pre

D - Gearbox ide

E - Engine legis


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8

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Structure Version

G Family (1)J Bodywork (2) L3 L4

EuroGJ NFUC/IF NFU Engine (3) W3

C Version (4) Manual 5-speed gearbox A B C/IF Variant (5) Manual 4-speed gearbox E F

Family (1) Manual 6-speed gearbox G HAutomatic 6-speed gearbox D J

Body shape (2) Axle and/or gearbox gears K LOther possible combinations MNo gearbox

Engine (3)

KFW 1.4i TU3JP 2 sliding side doors standard for 800 Kg WJY PNFU 1.6i 16V TU5JP4 Multi-function roof standard for Car WJY PWJY 1.9D DW8B Without FAPRHY 2.0 HDi DW10TD Fiscal incentives

4x4 DANGEL DDowngraded depollutionBi-carburation GPLBi-carburation GNV GSTT2 (stop and stard)

IDENTIFICATION OF THE

Type approval

BERLINGO


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9

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 v

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 timOpen the window fully.Action and release the window switch until the window is completely closed.NOTE: This operation has to be carried out on each electric window.

Multifunction screen.It is necessary to adjust the date, time and outside temperature.Reconfigure the personalisation menu of the multifunction screen.

Radio.Reprogramme the radio stations.Telematic unit (radiotelephone RT3) .Reprogramme the radio stations.

Warning: the vehicle has to be in the open air (on switching on the ignition, the ECU searches foReprogramme the customer parameters.


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Draining methods

Oil capacities are defined according to the following m

CAPACITIES (in litres)

Draining of the engine lubrication system by GRAVITY

Place the vehicle on horizontal ground (in the high position ifhydropneumatic suspension) .

The engine should be hot (oil temperature 80°C ) .

Drain the sump by gravity.

Remove the oil filter cartridge (time for draining and drip-drip = 15 minutes approx.) .

Refit the cap with a new seal.

Refit a new oil filter cartridge.

Refill the engine with oil (see table for oil capacity) .

Start the engine to fill the oil filter cartridge.

Stop the engine (allow to stabilise for 5 minutes) .

Draining of the

Place the vehicle on hohydropneumatic suspe

The engine should be

Remove the oil by suct

Remove the oil filter ca

Maintain the suction of

Refit a new oil filter car

Refill the engine with o

Start the engine to fill t

Stop the engine (allow

WARNING: Remove t

ESSENTIAL: Systematically check the oil level using the


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11


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

KFU NFU RFN

3,75 3,25 4,25

1,2 1,5 1,72 ± 0,15 2

(1)

With ESP = 0,85 Without ESP =

5,8 6,2 6,2 (2) - 6,6 (3)

6,7

0,85

60

Petrol

IMPERATIVE: Systematically check the oil level using the oil dipstick.(1) = The gearbox is lubricated for life (as a guide, the TOTAL capacity is 5.85 litres after draining 3 litres) .(2) = Temperature 37°C. (3) = Temperature 45°C.

Engine type

Oil capacity with changeof cartridge

Between Min. and Max.Manual gearbox

Automatic gearbox

After drainingBraking circuit

Cooling circuit

Manual gearbox

Automatic gearbox

Steering electro-pumpreservoir

Fuel tank

AUTO.


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Engine type

Oil capacity with changeof cartridge

Between Min. and Max.

Manual gearbox

Braking circuit

Cooling circuit

Additive reservoir

Steering electro-pumpreservoir

Fuel tank

9HX 9HY

3,75

1,55

2

With ESP = 0,85 Wi

6,5

0,85

60

CAPACITIES (in litre

Diesel

1.6 HDi 16V

NOTE: (*) = Version with additional heating.IMPERATIVE: Systematically check the oil level using the oil dipstick.

C4


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13

Engine typeEngine with filter element


5-speed gearbox

Automatic gearbox

After draining

Hydraulic or brake circuit

Cooling circuit

Fuel tank

KFW NFU3 3,25

1,5 1,5

2

6

3

With ABS = 0,50 Without ABS = 0

76,56,5 (1)

54


Petrol

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

1.4i 1.6i 16V

AUTO.


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Engine typeEngine with filter element


5-speed gearbox

Automatic gearbox

After draining


Cooling circuit

Fuel tank

8HX 8HZ 8HX 8HZ 8HY WJY3,75 4,5

1,8 1,5 1,8 1,5 1,2

2

With ABS = 0,50 With5,7 9

54

XSARA CAPACITIES (in litre

Diesel

(1) =➔ RPO 9337 (manual dipstick with two twists).(2) = RPO 9338 ➔ (manual dipstick without twists but with a sphere).ESSENTIAL: Systematically check the oil level using the oil dipstick.

1.4 HDi 1.4 16V HDi 1.9D

➔ RPO RPO ➔ RPO RPO9884 9885 ➔ 9884 9885 ➔ (1)


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15

Engine type

Engine with filter element filtrante


5-speed gearbox

Automatic gearbox

After draining


Cooling circuit

Fuel tank capacity

NFV 6FZ RFN 9HZ

3 4,25

1,5 1,7

1,8

6

3

0,58 litres

5,8 (1) and (2) 6,5 (1) and (2)

55


Petrol

1.6i 1.8i 16 V 2.0i 16V 1.

(1) = With air conditioning.(2) = Without air conditioning.(3) = RPO 9884 ➔ = Restyled XSARA PICASSO.ESSENTIAL: Systematically check the oil level using the oil dipstick.

AUTO.


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Engine type

Engine with filter element


5-speed gearbox


Cooling circuit

Fuel tank capacity

HFX KFW NFU 9H

3 3,25 3,7

1,5 1,5

2

With ABS = 0,45 - Without A

8

55

BERLINGO CAPACITIES (in litre

Petrol

1.1i 1.4i 1.6i 16V

(1) = Manual dipstick without twists but with a sphere.ESSENTIAL: Systematically check the oil level using the oil dipstick.

1.4i 16


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17

LUBRICANTS - TOTAL recommended oils

EVOLUTIONS (YEAR 2004).

CITROËN C4

Petrol engine versions except 2.0 i 16V 180 hp (132 kW) :Normal maintenance interval: 30 000 km (20 000 miles) .Severe maintenance interval: 20 000 km (12 000 miles) .

Petrol engine version 2.0L i 16V 180 hp (132 kW) :Normal maintenance interval: 20 000 km (12 500 miles) .Severe maintenance interval: 15 000 km (10 000 miles) .

Diesel engine versions:WARNING: Vehicles HDi FAP (*) do not accept the energy economyoil TOTAL ACTIVA FUTUR 9000 5W30 for France, TOTAL QUARTZFUTURE 9000 5W30 outside France .

DV6 engines:Normal maintenance interval: 20 000 km (12 500 miles).Severe maintenance interval: 15 000 km (10 000 miles).

DW engines:Normal maintenance interval: 30 000 km (20 000 miles).Severe maintenance interval: 20 000 km (12 000 miles).

New Look CITROËN C5

Petrol engine versions:Normal maintenance intervaSevere maintenance interva

Diesel engine versions:

WARNING: Vehicles HDi FA

oil TOTAL ACTIVA FUTUR FUTURE 9000 5W30 outsid

DV6 engines:Normal maintenance intervaSevere maintenance interva

DW engines :Normal maintenance intervaSevere maintenance intervaESSENTIAL: For all vehicletenance interval, use exclu

9000 or any other oils offerThese oils offer specificationorms ACEA A3 OR API SJFailing this, it is essential tocovering severe operating c


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LUBRICANTS - TOTAL recommended o

Use of oil grade 10W40.It is possible to use the semi-synthetic oil 7000 10W40 on HDi and HDiFAP vehicles.

WARNING: To avoid difficulties when starting from cold (< 20°C) , use5W40 oil.For more details, see the oil usage table (paragraph 3.3) .

Commercial description for energy economy oil.

TOTAL ACTIVA FUTUR 9000 5W30 (France only) .TOTAL QUARTZ FUTUR 9000 5W30 (except France) .The exclusions for use of this oil are the following:- XSARA VTS 2.0 16V (XU10J4RS).- JUMPER/RELAY 2.8 HDi and 2.8 TDi (SOFIM engine).- HDi FAP vehicles.- CITROËN C3 HDi 16V (DV4TED4).- CITROËN C8 2.2i (EW12J4).- CITROËN C4 and C5 2.0i (EW10A).- CITROËN C4 (EW10J4S).

Engine oil norms.

Current norms.The classification of these engine oils is established by the followingrecognised organisations:- S.A.E : Society of Automotive Engineers.- API : American Petroleum Institute.- ACEA : Association des Constructeurs Européens d'Automobiles.

S.A.E. Norms - Table foSelection of engine oil gcountries of distribution

Evolution of the normsACEA 2003 norms.The meaning of the first lto the type of engine:

A: petrol and dua

B: diesel enginesThe figure following the f3: high performance oils4: oils specifically for dire5: very high performancedirect injection diesel eng

Example:- ACEA A3: high performLPG engines.- ACEA A/B: blended oilpermitting better fuel eco

NOTE: From 01/01/200creation of the norm (ex


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19


API Norms:The meaning of the first letter has not changed, it still corresponds to thetype of engine:S: petrol and dual fuel petrol / LPG engines.C: diesel engines.The second letter corresponds to the degree of evolution of the oil(ascending order) .Example: Norm SL is more severe than norm SJ, corresponding to

a higher level of performance.Recommendations.ESSENTIAL: To preserve engine performances, all engines fitted inCITROËN vehicles must be lubricated with high quality oils (synthetic or semi-synthetic) .CITROËN engines are lubricated at the factory with TOTAL oil of gradeS.A.E 5W-30.TOTAL oil of grade S.A.E 5W-30 allows improved fuel economies(approx 2.5% ) .The oil 5W30 is used only for the following engines (year 2004) :- XU10 J4RS : XSARA VTS 2.0i 16V (3-door).- SOFIM : JUMPER / RELAY 2.8 TDi and 2.8 HDi.

- HDi : With particle filter (FAP).- DV4 TED4 : CITROËN C3 1.4 16V HDi.- EW 12J4 : CITROËN C8 2.2i.- EW 10A : CITROËN C4 and C5 2.0i.- EW10J4S engine : CITROËN C4.

WARNING: CITROËN engineto be lubricated with oils adh- ACEA AI-98 and API SJ/CF

Denomination of TOTAL oils a- TOTAL ACTIVA (France only- TOTAL QUARTZ (outside Fr

Summary.Norms to be respected for eng

Year Engine types conc

Petrol and LPG dua2003

Diesel engines

(*) It is essential not to use eng

XU10J4RS, SOFIM 2.8 TDi anwith particle filter EW10A, EW


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20

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Classes and grades of TOTAL recommended engine oils.

The oils distributed in each country are suited to the local climaticconditions.Blended oils for all engines (petrol, diesel and dual fuel petrol/LPG) :

S.A.E. ACEA APInorms norms norms

TOTAL ACTIVA 9000 A3/B3/ TOTAL QUARTZ 9000

5W40B4

TOTAL ACTIVA FUTUR 9000 (*) SL/CFTOTAL QUARTZ FUTUR 9000 (*)

5W30 A5/B5

TOTAL ACTIVRAC 10W40 A3/B3

(*) Blended oils for all engines giving fuel economy.Oils for petrol, diesel and dual fuel petrol/LPG engines:

S.A.E. ACEA APInorms norms norms

TOTAL ACTIVA 7000

TOTAL QUARTZ 700010W40

TOTAL QUARTZ 9000 0W40 A3 SL

TOTAL ACTIVA 7000TOTAL QUARTZ 7000

15W50

Oils specifically for d

TOTAL ACTIVA DIESETOTAL QUARTZ DIES

TOTAL ACTIVA DIESE


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21


TOTAL

Synthetic 9000

0W40 5W30

Temp

Cold countries

Engine types

EW10J4S (CITROËN C4) X

X

X

EW12J4 (CITROËN C8 2.2i 16V)

EW10A(CITROËN C4 and C5)

HDi engines with FAP (*)

Others HDi engines

SOFIM 2.8 HDi and 2.8 TDi (RELAY)

DV4 TED4 (C3 1.6 16V HDi)

Indirect injection diesel engines

Petrol engines

Diesel engines

Oil usage table

X

X

X

(*) Do not use this oil in cold climatic conditions (temperature less than - 20°C ) .See the table below for the choice of TOTAL engine oil grades to be used according to the climatic co

Others petrol engines X

X

X

X


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22

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E4AP006D


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23

FRANCE

Metropolitan FRANCE

Metropolitan FRANCE

New CaledoniaGuadeloupeSaint martinReunion

9000 5W407000 15W50

Martinique 7000 10W40GuyanaTahitiMauritiusMayotte


Blended oils for all engines, su

ENGINE OILS

TOTAL ACTIVRAC

TOTAL ACTIVA

Blended oils for all engines

9000 5W40FUTUR 9000 5W30 (*)

7000 10W40

Oils specifically for petrdual-fuel petrol / LPG en

(*) Blended oils for all engines, giving fuel economy.


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EUROPE

7000 10

9000 0W

7000 10

7000 109000 0W

7000 109000 0W

7000 10

7000 109000 15

7000 10

Germany

Austria

Belgium

Bosnia

Bulgaria

Cyprus

Croatia


ENGINE

TOTAL QUARTZ

Blended oils for all engines Oils specifically fdual-fuel petrol /

9000 5W40FUTUR 9000 5W30 (*)



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25

EUROPE

7000 10W40

9000 0W407000 10W407000 15W40

7000 10W409000 0W40

7000 10W40

7000 10W40

7000 15W40

7000 10W409000 0W40

Denmark

Spain

Estonia

Finland

Great Britain

Greece

Holland


ENGINE OILS

TOTAL QUARTZ

Blended oils for all engines Oils specifically for petrdual-fuel petrol / LPG e

9000 5W40FUTUR 9000 5W30 (*)


LUBRICANTS TOTAL d d


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EUROPE

7000 10W

9000 0W

7000 10W

7000 10W9000 0W

7000 10W

Hungary

Italy

Ireland

Iceland

Latvia

Lithuania

Macedonia


ENGINE

TOTAL QUARTZ


9000 5W40FUTUR 9000 5W30 (*)


LUBRICANTS TOTAL d d il


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27

EUROPE

7000 10W40

7000 15W50

7000 10W40

7000 10W409000 0W40

7000 10W40

7000 10W409000 0W40

Malta

Moldavia

Norway

Poland

Portugal

Slovakia

Czech Republic


ENGINE OILS

TOTAL QUARTZ

Blended oils for all engines Oils specifically for petrdual-fuel petrol / LPG en

9000 5W40FUTUR 9000 5W30 (*)


LUBRICANTS TOTAL d d


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28

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EUROPE

7000 10W7000 15W9000 0W

7000 10W9000 0W

7000 10W

7000 10W9000 15W9000 0W

Romania

Russia

Slovenia

Sweden

Switzerland

Turkey


ENGINE

TOTAL QUARTZ


9000 5W40FUTUR 9000 5W30 (*)


LUBRICANTS TOTAL recommended oils


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29

EUROPE

7000 10W409000 0W40

Ukraine

Serbia-Montenegro


ENGINE OILS

TOTAL QUARTZ


9000 5W40FUTUR 9000 5W30 (*)


LUBRICANTS TOTAL recommended o


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OCEANIA

AFRICA

7000 10W

Australia

New Zealand

Algeria, South Africa,Ivory Coast, Egypt,Gabon, Ghana, Kenya,Madagascar, Morocco,Nigeria, Senegal, Tunisia


ENGINE

TOTAL QUARTZ


9000 5W40

FUTUR 9000 5W30 (*)

7000 10W

7000 15W

TOTAL QUARTZ


9000 5W40




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31

CENTRAL AND SOUTH AMERICA

Argentina

Brazil

Chile

Cuba

Mexico

Paraguay

Uruguay


7000 10W407000 15W50

ENGINE OILS

TOTAL QUARTZ


9000 5W40



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SOUTH-EAST ASIA

China

South Korea

Hong Kong

India - Indonesia

Japan

Malaysia

Pakistan


7000 10W

7000 15W7000 10W

7000 15W

7000 10W7000 15W

7000 15W

ENGINE

TOTAL QUARTZ

Blended oils for all engines Oils specifically fodual-fuel petrol / L

9000 5W40FUTUR 9000 5W30 (*)

9000 5W40

9000 5W40FUTUR 9000 5W30 (*)

9000 5W40




39/461

33

SOUTH-EAST ASIA

Philippines

Singapore

Taiwan

Thailand

Vietnam


7000 15W50

7000 10W407000 15W50

7000 15W50

ENGINE OILS

TOTAL QUARTZ


9000 5W40




40/461

34

GE NE RAL

MIDDLE EAST

7000 15W

7000 10W7000 15W

7000 15W

Saudi Arabia - Bahrain

DubaiUnited Arab Emirates

Iran

Israel - Jordan - Kuwait - Lebanon

Oman - Qatar - Syria - Yemen

LUBRICANTS TOTAL recommended o

ENGINE

TOTAL QUARTZ


9000 5W40



41/461

35


GEARBOX OILS

TOTN

T

TSp

Sp

Manual and piloted manualgearboxes

MB3 automatic gearbox

4HP20 and AL4 autoactiveautomatic gearboxes

All countries

Sp

TOT

AM6 autoactive automatic gearbox

Transfer box and rear axle



42/461

36

GE NE RAL

U C S O eco e ded o

POWER STEERING OILS

ENGINE COOLANT FLUID

Power steering

All countries

All countries CITROËN fluidProtection: -35C°

2 Litres

5 Litres

20 Litres

210 Litres

99

99

99

99

PacksGLYS

Very cold countries

Power steering all vehicles(except CITROËN C4 and C5)

Power steeringC4 and C5



43/461

37

BRAKE FLUIDSynthetic brake fluid

HYDRAULIC SYSTEM

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

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

All countries TOTAL HY

All countries CITROËN fluid

0,5 Litre

1 Litre

5 Litres

Packs

PacksNorm

Colour

All countries

TOTAL FLUIDE LDS

TOTAL LHM PLUS

TOTAL LHM PLUSVery cold countries

Orange

Green1 Litre



44/461

38

GE NE RAL

SCREEN WASH FLUID

GREASINGGeneral use

All countries

Concentrated: 250 ml

Fluid readyto use

9980 33

9980 06

9980 05

ZC 9

ZC 9

ZC 9

Packs CITROË

1 Litre

5 Litres

TOTAL MULTIS 2

TOTAL SMALL MECHANISMSAll countries

Note: NLGI = National Lubrificating Grease Institude.

ENGINE OIL CONSUMPTION


45/461

39

I - Oil consumption depends on:- the engine type.- how run-in or worn it is.- the type of oil used.- the driving conditions.

II - An engine can be considered RUN-IN after:- 3,000 miles (5,000 km) for a PETROL engine.- 6,000 miles (10,000 km) for a DIESEL engine.

III - MAXIMUM PERMISSIBLE oil consumption for a RUN-IN engine:- 0.5 litres per 600 miles (1,000 km) for a PETROL engine.- 1 litre per 600 miles (1,000 km) for a DIESEL engine.

DO NOT INTERVENE BELOW THESE VALUES.

IV - OIL LEVEL: The level should NEVER be above the MAX. mark on the dipstick after cha- This excess oil will be used up rapidly.

- It will reduce the engine output and adversely affect the operation of the air circuits a

ENGINE SPECIFICATIONSE N


46/461

Petrol engine

Engine type

Cubic capacity (cc)

Bore/stroke

Compression ratio

Power ISO or EEC (KW - rpm)

Torque ISO or EEC (m.daN - rpm)

TU1JP TU3JP ET3J4 TU5JP+ TU5JP4

HFX KFW KFU NFV NFU

1124 1360 1587

72/69 75/77 78,5/82

10,5/1 11/1 10,5/1 11/1

44,1-5500 55-5500 65-5250 70-5700 80-5800

94-3500 12-2800 13,3-4250 13,5-3000 14,7-4000

40

GI NE

All Types

ENGINE SPECIFICATIONS


47/461

41

Diesel engines

Engine type

Cubic capacity (cc)

Bore/stroke

Compression ratio

Power ISO or EEC (KW - rpm)

Torque ISO or EEC (m.daN - rpm)

DV4TD DV6TED4DV6

ATED4D

8HX 8HZ 9HY 9HZ 9HX W

1398 1560 1

73,7/82 75/88,3 82

17,9/1 18/1 2

50-4000 80-4000 66,2-4000 51

15-1750 16-2000 24-1750 21,5-1750 12,

All Types

E N G SPECIAL FEATURES - TIGHTENINXSARA


48/461

42

GI NE

Pow

1

2

3

4

5

67

Engine: KFW

B1BP1EYD

SPECIAL FEATURES - TIGHTENINGINGING TORQUES (m.daN)


49/461

43

Power un

1

2

3

4

5

67

8

9

10

Engine: NFV

B1BP21HP

E N G SPECIAL FEATURES - TIGHTENINXSARA


50/461

44

GI NE

Pow

1

2

3

4

5

67

8

9

Engine: NFU

B1BP2GGP

SPECIAL FEATURES - TIGHTENINGING TORQUES (m.daN)


51/461

45

Tighteninging torques (m.d

Engine type KFW NFV

Crankshaft Pre-tightening 2 ± 0,2

bearing screws Angular tightening 45°

Connecting rod

screwsTightening 3,8 ± 0,4

Flywheel screw Tightening 6,5 ± 0,7

Crankshaft

pinion screw Tightening 10 ± 1

Camshaft pulley

screw Tightening 8 ± 0,8

Camshaft hubs

Camshaft hub

screwTightening

SPECIAL FEATURES - TIGHTENINGING

S /

E N G C4


52/461

Gearbox under the engine

1 6 ± 0,6

2 6 ± 0,1

3 4,5 ± 0,4

11 4 ± 0,4

12 4 ± 0,4

13 4 ± 0,4

14 4 ± 0,4

15 4 ± 0,416 2 ± 0,2

17 4 ± 0,4

18 5,4 ± 0,5

B1BP36BD

Suspensions for engine/gearbox assembly

46

GI NE

Engine: KFU

Gearbox on RH side

B1BP36DD

B1BP36CD

SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)

E i KFU


53/461

47

Cylinder he

1 Inlet air pressure sensor2 Motorised butterfly housing fixing scre3 Coolant outlet housing screw

4 Oxygen sensorCatalytic converter fixing nuts (*)

5 Pre-tightening

TighteningCheck the tightening

6 Exhaust manifold nuts7 Exhaust manifold fixing stud

Cylinder head bolts (*)8 Pre-tightening

TighteningAngular tightening

9 Inlet manifold screws10 Valve cover screws (*)11 Camshaft bearing cap screws (*)

12 Sparking plugs13 Camshaft dephaser electrovalve fixing

(VVT)

Engine: KFU

B1BP368P

(*) = IMPERATIVE: Respect the tightening sequence (see following page) .


54/461


Engine: KFU


55/461

49

Cylinder bl

14 Crankshaft bearing cap sealing screw

15 Knock sensor

16 Coolant pump stud screw

17 Coolant pump cover screw

18 Screw of coolant pump body on cylind

19 Cooling circuit plug20 Oil circuit plugs

21 Flywheel screw (*)

22 Con rod cap fixing nut

23 Accessories drive belt pulley screw

Crankshaft pinion screw

24 Tightening

Angular tightening

Crankshaft bearing cap cover screw (*)

25 Tightening

Angular tightening

Engine: KFU

B1DP1KVP


E N GI

SPECIAL FEATURES - TIGHTENING TO

Engine: KFU

C4


56/461

50

INE

Engine: KFU

B1DP05BC

IMPERATIVE: Respect the tightening sequence

Cylinder block

(14) Crankshaft bearing cap sealing screw

(25) Crankshaft bearing cap cover screw (21) Flywheel screw


Engine: KFU


57/461

51

Lubricatio

26 Oil gauge screw

27 Electric oil gauge fixng screw

28 Oil filter support screw

29 Strainer fixing screw

30 Oil pressure switch

31 Oil sump screw

32 Drain plug

33 Oil pump screw

Engine: KFU

B1BP369P

E N GI


Engine: KFU

C4


58/461

52

NE

T

34 Inlet camshaft dephaser plug (VV

Inlet camshaft dephaser screw (V

35 Pre-tightening

Tightening

36 Guide roller screw37 Exhaust camshaft pulley screw

38 Tensioner roller screw

Engine: KFU

B1EP1GPD

SPECIAL FEATURES - TIGHTENING TORQUES (m

Engine: KFU


59/461

53

Accessori

39 Alternator support fixing screw

40 Alternator power circuit fixing nut

41 Alternator fixing screw

42 Aircon compressor fixing screw

43 Aircon compressor support fixing scre

44 Bottom screw fixing tensioner roller su

45 Top screw fixing tensioner roller suppo

Engine: KFU

B1BP36AP



E N GI N

C4


60/461

54

Gearbox below the engine

1 6 ± 0,62 6 ± 0,63 4,5 ± 0,4

13 4 ± 0,414 4 ± 0,415 5,4 ± 0,516 6 ± 0,617 4 ± 0,4

18 6 ± 0,619 2 ± 0,220 4 ± 0,421 4 ± 0,4

B1BP35WD


Engine: NFU

Gearbox on RH side

B1BP35YD

B1BP35XD

(A) MA manual gearbo(B) AL4 automatic gea

NE

SPECIAL FEATURES - TIGHTENING TORQUES (m.

Engine: NFU


61/461

55

Cylinder he1 Inlet air pressure sensor2 Motorised butterfly housing fixing scre3 Inlet manifold nuts4 Valve cover screws (*)5 Coolant outlet housing screw6 Thermostat fixing screw7 Oxygen sensor

Catalytic converter fixing nuts (*)8 Pre-tightening

TighteningCheck the tightening

9 Exhaust manifold nuts10 Exhaust manifold fixing stud11 Lubrication plug

Cylinder head bolts (*)12 Tightening

Angular tightening13 Camshaft bearing cap screws (*)14 Inlet manifold fixing stud15 Engine coolant temperature sensor (CM16 Engine coolant temperature sensor (ins17 Sparking plugs

g

B1BP362P


E N GI N


Engine: NFU

C4


62/461

56

NE

Cylin

18 Coolant pump screw

19 Oil plug

20 Con rod cap bolt

21 Seal plate screw, flywheel end

22 Flywheel screw (*)

23 Seal plate screw, timing end24 Coolant inlet manifold screw

25 Crankshaft pinion screw

Tightening

Angular tightening

26 Crankshaft bearing cap screw

Tightening

Angular tightening

27 Accessories drive belt pulley scr

28 Knock sensor

g

B1DP1KUP



Engine: NFU


63/461

57

g

B1JP063C

Sequence of tightening the nuts (8) (Catalytic converter) (22) Sequence of

IMPERATIVE: Respect the tightening sequence.

E N GI N


Engine: NFU

C4


64/461

58

NE

Lub

29 Strainer fixing

30 Oil gauge screw

31 Piston skirt spray jet

32 Drain plug

33 Oil sump screw


35 Oil circuit plugs


37 Oil level sensor

38 Oil pump screw

B1BP363P


Engine: NFU


65/461

59

Timing

39 Camshaft pulley screw

40 Guide roller screw


B1BP1GMP

E N GI N


Engine: NFU

C4


66/461

60

E

Acce

42 Alternator support fixing screw

43 Alternator power circuit fixing nu



46 Tensioner roller support fixing sc

47 Bottom screw fixing tensioner ro

48 Top screw fixing tensioner roller

B1BP364P

SPECIAL FEATURES - TIGHTENING TORQUES (m.



67/461

61

1 6 ± 0,62 6 ± 0,63 4,5 ± 0,4

7 1 ± 0,18 5 ± 0,59 6,5 ± 0,610 3 ± 0,311 3 ± 0,312 6 ± 0,613 1,9 ± 0,2

B1BP35TD

Engine: RFJ

RH side Tor

B1BP35VD

B1BP35UD

E N GI NE


Engine: RFJ

C4


68/461

62

E

Cylin

Valve cover screws (*)1 Pre-tightening

Tightening

2 Oxygen sensor

3 Exhaust manifold nuts

4 Coolant outlet housing fixing nut

5 Coolant outlet housing bolts

6 Motorised butterfly housing fixing

7 Inlet manifold fixings

8 Inlet manifold fixing studs

Cylinder head bolts (*)Pre-tightening 1

Pre-tightening 29 Angular slacken


10 Sparking plugs

B1BP35MP

(*) = IMPERATIVE: Respect the tightening sequence (see following page).


Engine: RFJ


69/461

63

Cylinder he

11 Camshaft bearing cap screws (*)

Pre-tightening

Tightening

12 Exhaust manifold fixing stud

13 Coolant outlet housing fixing stud

14 Engine coolant temperature sensor

15 Inner timing cover screw

16 Electrovalve fixing screw (VVT)

B1BP35MP


E N GI NE


Engine: RFJ

C4


70/461

64

E

B1DP05BC


Cylinder head

(1) Valve cover screws

(9) Cylinder head bolts (11) Camshaft bearing


Engine: RFJ


71/461

65

Cylinder blo


Coolant pump screw (*)

18 Pre-tighteningTightening

19 Cooling circuit plug

Accessories drive belt pulley screw

20 TighteningAngular tightening

Flywheel screw (*)21 Pre-tightening

Tightening

Angular tightening

B1DP1KSP


E N GI NE


C li

Engine: RFJ

C4


72/461

66

E

Cylin

Crankshaft bearing cap cover scr

Pre-tightening

22 Tightening

Angular tightening

23 Crankshaft bearing cap sealing s

Con rod cap screw (*)

Pre-tightening

24 Tightening

Angular tightening

25 Knock sensor

B1DP1KSP



Engine: RFJ

C li d h d


73/461

67

B1DP05BC


Cylinder head

(22) Crankshaft bearing cap screws

(24) Con rod cap screws (21) Flywheel screw (1

B1CP0GCC

E N GI NE


Lub

Engine: RFJ

C4


74/461

68

Lub

26 Oil gauge screw


28 Anti-emulsion plate fixing screw

29 Oil level sensor fixing screw

30 Drain plug

31 Oil sump screw


33 Oil strainer fixing nuts

34 Oil strainer stud

Coolant pump screw

35 Pre-tightening

Tightening

B1BP35NP


Timing

Engine: RFJ


75/461

69

Timing

Exhaust camshaft pulley screw

36 Pre-tightening

Tightening

37 Cap

Inlet camshaft pulley screw



Guide roller screw

40 Pre-tightening

Tightening

B1EP1GJP

E N GI NE


Acce

Engine: RFJ

C4


76/461

70

Acce

41 Accessories support fixing stud

Accessories support fixings

42 Pre-tightening

Tightening

43 Alternator top fixing screw



46 Alternator bottom fixing screw

47 Screw for fixing the automatic ten

for the accessories drive belt

B1BP35PP


Power un

Engines: 6FZ - RFN


77/461

71

Power un

1

2

3

4

5

6

78

9

10

B1BP21AP

E N GI NE

SPECIAL FEATURES - TIGHTE

Crankshaft

Engine: RFN

XSARA - XSARA PICASSO


78/461

72

Crankshaft

Bearing cap fixing screws

Pre-tightening

Angular tightening

Bearing cap screws

Pre-tightening

Angular tightening

Accessories belt automatic tensioner roller

Accessories belt guide roller

Pre-tightening

Tightening

Accessories support block

Tightening (2 studs)

Pre-tightening (4 screws)

Tightening

Cylinder block

Sump

Timing belt guide roller

Pre-tighteningTightening

Timing belt tensioner roller

RH engine support


Cylinder head

Engine: RFN


79/461

73

Cylinder head

Camshaft bearing cover

Exhaust manifold

Valve cover

Camshaft pulley

Pre-tightening

Tightening

Pulley on hubTiming pinion on crankshaft

Pre-tightening

Angular tightening

Flywheel / clutch

Clutch mechanism

Flywheel

Pre-tightening (sequence 1,5,3,7,2,6,4,

Angular tightening (sequence 1,5,3,7,2,6,4,

B1CP089C

E N GI NE

SPECIAL FEATURES - TIGHTE

Lubrication ci

Engine: RFN

XSARA - XSARA PICASSO


80/461

74

b ca o c

Oil pump closing plate

Oil pump

Pre-tightening

Tightening

Injection circ

Common injection rail fixing screws

Cooling circ

Coolant pump

Pre-tightening (sequence 1,2

Tightening (sequence 1,2

Coolant inlet housing

B1GP08WC



Engine: RFN


81/461

75

1 6 ± 0,62 6 ± 0,63 4,5 ± 0,4

7 1 ± 0,18 5 ± 0,59 6,5 ± 0,610 3 ± 0,311 3 ± 0,312 6 ± 0,6

13 1,9 ± 0,2

B1BP35TD

g

Gearbox on RH side Gearbox

B1BP35VD

B1BP35UD

Gearbox on LH side

E N GI NE


Cylin

Engine: RFN

C4


82/461

76

y

Valve cover screws (*)

1 Pre-tightening

Tightening

2 Exhaust manifold stud

Exhaust manifold nuts

3 Tightening on heat shield

Tightening apart from on heat shield4 Oxygen sensor

5 Coolant outlet housing fixing (BS

Tightening of the nuts

Tightening of the screws

6 Thermostat fixing screw

7 Coolant outlet housing fixing stu

8 Engine coolant temperature sens

9 Inlet manifold screws


B1BP34MP



Cylinder he

Engine: RFN


83/461

77

Cylinder head bolts (*)

1st pre-tightening

2nd pre-tightening

11 Angular slackening

Tightening

Angular tightening

Camshaft bearing cap cover screws (*)12 Pre-tightening

Tightening

13 EGR valve screw

14 Valve for injection of air to the exhaust

15 Inlet manifold stud

16 Inlet manifold fixing nuts

17 Sparking plugs

B1BP34MP


E N GI NE


Engine: RFN

Cylinder head

C4


84/461

78

B1DP05BC



(11) Cylinder head bolts (12) Camshaft bearin


Cylinder blo

Engine: RFN


85/461

79


Coolant pump screw (*)19 Pre-tightening

Tightening


Flywheel screw (*)

21 Pre-tighteningTighteningAngular tightening

Crankshaft bearing cap cover screw (*)22 Pre-tightening


B1DP1KKP


E N GI NE


Cylin

Engine: RFN

C4


86/461

8080


Con rod cap bolt (*)

24 Pre-tightening

Tightening

Angular tightening

25 Knock sensor

Accessories drive belt pulley scre

26 Tightening

Angular tightening

B1DP1KKP


SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)Engine: RFN

Cylinder head


87/461

81

B1DP05BC



(24) Con rod cap screws (21) Flywheel screws (1

B1CP0GCC

E N GI NE


Lub

Engine: RFN

C4


88/461

82

27 Oil gauge screw


29 Drain plug

30 Oil sump screw




Oil pump screw

34 Pre-tightening

Tightening



B1BP34NP


Timing

Engine: RFN


89/461

83




B1EP1G6P

E N GI NE


Acce


Engine: RFN

C4


90/461

84


Accessories support fixings

41 Pre-tightening

Tightening



44 Aircon compressor fixing screw45 Alternator bottom fixing screw

Screw for fixing the guide roller f

46 Pre-tightening

Tightening

47Screw for fixing the automatic tens

for the accessories drive belt

B1BP34PP

SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)Suspensions for engine/gearbox assembly

Engine: RFK


91/461

85

1 6 ± 0,62 6 ± 0,63 4,5 ± 0,4

7 1 ± 0,18 5 ± 0,59 6,5 ± 0,610 3 ± 0,311 3 ± 0,312 6 ± 0,6

13 1,9 ± 0,2

B1BP35TD

Gearbox on RH side Gearbox

B1BP35VD

B1BP35UD

Gearbox on LH side

E N GI NE


Cylin


Engine: RFK

C4


92/461

86


Exhaust manifold nuts

2 Tightening on heat shield

Tightening apart from on heat shield

3 Oxygen sensor

Coolant outlet housing fixing

4 Tightening of the nutsTightening of the screws

5 Thermostat fixing screw

6 Coolant outlet housing fixing stu

7 Engine coolant temperature sens


9 Inlet manifold screws

10 Inlet manifold fixing nuts

11 Inlet manifold stud

B1BP35QP



Cylinder he

Cylinder head bolts (*)

Engine: RFK


93/461

87

Cylinder head bolts ( )

1st pre-tightening

12 2nd pre-tightening

Angular slackening

Tightening

Angular tightening

Valve cover screws (*)

13 Pre-tightening

Tightening

14 Sparking plugs

Camshaft bearing cap cover screws (*)

15 Pre-tightening

Tightening

16 Valve for injection of air to the exhaust

B1BP35QP


E N GI NE

SPECIAL FEATURES - TIGHTENING TOEngine: RFK

IMPERATIVE R t th ti ht i

Cylinder head

C4


94/461

88

B1DP05BC



(13) Cylinder head bolts (15) Camshaft bearin


Cylinder blo


Engine: RFK


95/461

8989


Coolant pump screw (*)

18 Pre-tightening

Tightening


Flywheel screw (*)


Angular tightening

Crankshaft bearing cap cover screw (*)

21 Pre-tightening

Tightening

Angular tightening

B1DP1KTP


E N GI NE


Cylin


Engine: RFKC4


96/461

90


Con rod cap bolt (*)

23 Pre-tightening

Tightening

Angular tightening

24 Knock sensor

Accessories drive belt pulley scre

25 Tightening

Angular tightening

B1DP1KTP


SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)Engine: RFK


Cylinder head


97/461

9191

B1DP05BC



(23) Con rod cap screws (20) Flywheel screws (1

B1CP0GCC

E N GI NE


Lub

26 Oil gauge screw

Engine: RFKC4


98/461

92

g g


28 Drain plug

29 Oil sump screw



Oil pump screw32 Pre-tightening

Tightening




B1BP35RP


Timing


Engine: RFK


99/461

93

p y

37 Camshaft dephaser cap (VVT)

Inlet camshaft pulley screw

38 Pre-tightening

Tightening



B1EP1GKP

E N GI NE


Acce


Engine: RFKC4


100/461

94

Accessories support fixings42 Pre-tightening

Tightening




46 Alternator bottom fixing screw

Screw for fixing the guide roller f47 Pre-tightening

Tightening

48Screw for fixing the automatic tensfor the accessories drive belt

B1BP35SP


101/461

E N GI NE

SPECIAL FEATURES - TIGHTENINGEngines 8HX

Cran


XSARA


102/461

96

Pre-tightening

Slackening Y

Tightening

Angular tightening 1

Con rod nuts

Pre-tighteningSlackening Y

Tightening 1,5


Accessories drive pulley

Pre-tightening 3


Cylind

Sump 1

Timing belt guide roller 4,5 ± 0,4Timing belt tensioner roller 3 ± 0,3

SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)Engines 8HX

Cylin

Camshaft bearing covers

P ti ht i


103/461

97

Pre-tightening

Tightening

Fixing of camshaft sub-assemblies on cylinder head

Pre-tightening

Tightening

Exhaust manifold 2,5

Valve cover 2,5Camshaft pulley 4,3

Fly

Flywheel

Pre-tightening 1,7

Angular tightening 70° ± 5°

Clutch mechanism 2

Lubrica

Oil pump assembly

Pre-tightening 0,5

Tightening 0,9Coolant/oil heat exchanger 1

E

N GI NE

SPECIAL FEATURES - TIGHTENINGEngines

Spherical-base screws for diesel injection fixing fork

XSARA


104/461

98

p j g

Fuel high pressure common injection rail on engine block

Unions on fuel high pressure common injection rail

Pre-tightening

Tightening

Diesel injection pump on support

Union on diesel injection pump

Diesel injection pump pulley

Union on diesel high pressure pump

Coolant pump

Pre-tightening

Tightening

Coolant outlet housing

Pre-tightening

Tightening

SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)Suspensions for engine/gearbox assembly

Engines: 9HX - 9HY - 9HZ

RH engine support Tor


105/461

99

Impact absorber LH engin

1 6 ± 0,6

2 5,5 ± 0,5

3 6 ± 0,6

7

8

9 4 ± 0,4

10

11

B1BP38CC

B1BP38EC

B1BP38DC

B1BP38FC

E

N GI NE


Cylin

1 Air inlet manifold

2 Oil t

Engine: 9HYC4


106/461

100

2 Oil trap


3 Pre-tightening

Tightening

B1BP39YP B1DP1D7D

(3) Camshaft bearing co

(4) Camshaft bearing co


Cylinder he

Camshaft bearing cover studs

4 Pre-tightening

Engine: 9HX


107/461

101

4 Pre tightening

Tightening

5 Exhaust gas recycling electrovalve (EG

Cylinder head

6 Pre-tightening

Tightening

Angular tightening7 Vacuum pump


8 Pre-tightening

Tightening

B1DP05BC

(6) Sequence for tightening the cylinder head bolts

B1BP39YP

E

N GI NE


Cylin

9 Exhaust manifold

10 E h t if ld t d

Engine: 9HXC4


108/461

102


11 Turbocompressor nuts

12 Catalytic converter nuts

Air flowmeter

13 Pre-tightening

Tightening

B1BP39YP


Cylinder blo

Coolant pump14 Pre-tightening

Engine: 9HX


109/461

103

g g

Tightening

Con rod screws15 Pre-tightening

Angular tightening

Flywheel (according to equipment)

16 Pre-tighteningAngular tightening

Clutch mechanism

B1DP1LKP B1CP0GKC

(16) Sequence for tightening the flywheel screws

E

N GI NE


Cylin


Pre-tightening

Engine: 9HXC4


110/461

104

Pre tightening

17 Slackening

Tightening

Angular tightening

18 Crankshaft bearing cap cover scr


19 Pre-tightening

Tightening


20 Pre-tightening

Angular tightening

B1DP1LKP


Cylinder blo

Crankshaft bearing cap cover

Tightening me

Engine: 9HX


111/461

105

Tightening me

Pre-tighten the 10 screws (17) (from 1 to 1

Pre-tighten the 14 screws (19) (from 11 to

Tighten the 2 screws (18) (inside the flywhe

Slacken the screws (17) by

Tighten the 10 screws (17) (from 1 to 10) t

Tighten the screws (17) (from 1 to 10) byTighten the 14 screws (19) (from 11 to 24)

B1DP1LLD

Sequence for tightening the sc

(17) Bearing cap fixing screws (screw M9)

(18) Crankshaft bearing cap cover screws (screw M

(19) Crankshaft bearing cap cover screws (screw M

E

N GI NE


Lub

21Turbocharger lubrication pipe

22

Engine: 9HXC4


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106

22


24 Oil gauge

25 Electric oil gauge

26 Piston skirt spray jets

27 Oil filter cover28 Oil filter support

29 Coolant/oil heat exchanger

30 Drain plug

31 Oil induction strainer

32 Sump

33 Oil pump assembly

B1DP1LMD


Timing

34 Camshaft bearing caps

Camshaft pulleys

Engine: 9HX


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107

Camshaft pulleys

35 Pre-tightening

Angular tightening

36 Timing belt guide roller

37 Timing belt tensioner roller

38 Timing chain tensioner

B1EP1HQD

E

N GI NE


Inject

Union on injector

39 Pre-tightening

Engine: 9HXC4


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Tightening

Injector fixing flange but

40 Pre-tightening

Angular tightening

41 Diesel injection pump on support

42 Diesel injection pump pulley43 Diesel fuel high pressure pump fr

B1HP22SD


Injection cir

44 Diesel fuel high pressure pump rear sup

Union on diesel fuel high pressure pum

Engine: 9HX


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g p p

45 Pre-tightening

Tightening

46 Fuel high pressure common injection ra

Unions on fuel high pressure common i

47 Pre-tightening

Tightening

48 Fuel filter support

B1HP22SD

E

N GI NE


Acce

49 Multifunction support


Engine: 9HX

Version without particle filter

C4


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110



52 Accessories tensioner roller

D1AP02NC


Accessorie

53 Accessories support

54 Guide roller

Engine: 9HX

Version without air conditioning


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111

D1AP02PC

D1AP02QD

Accessorie

55 Aircon compressor support

56 Aircon compressor screw

Version with air conditioning


118/461


Cylinder he

Camshaft bearing cover studs4 Pre-tightening

Tightening

Engines: 9HY - 9HZ


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113

Tightening

5 Exhaust gas recycling electrovalve (EG

Cylinder head6 Pre-tightening


7 Vacuum pump

Coolant outlet housing8 Pre-tightening

Tightening

B1DP05BC

(6) Sequence for tightening the cylinder head bolts

B1BP39XP

E N GI NE


Cylin

9 Exhaust manifold


Engines: 9HY - 9HZ

C4


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114

11 Turbocompressor nuts

12 Catalytic converter nuts

Double butterfly housing (accord

13 Pre-tightening

Tightening

B1BP39XP


121/461

E N GI NE


Cylin


Pre-tightening

17 Slackening

Engines: 9HY - 9HZ

C4


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116

17 Slackening

Tightening

Angular tightening

18 Crankshaft bearing cap cover scr




20 Pre-tightening

Angular tightening

B1DP1LKP


Cylinder blo

Crankshaft bearing cap cover.

Tighteni

P i h h 10 (17) (f 1

Engines: 9HY - 9HZ


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117



Tighten the 2 screws (18) (inside the flywh

Slacken the screws (17) by

Tighten the 10 screws (17) (from 1 to 10)

Tighten the screws (17) (from 1 to 10) by

Tighten the 14 screws (19) (from 11 to 24)

B1DP1LLD

(17) Bearing cap fixing screws (screws M9)

(18) Crankshaft bearing cap cover screws (screws M

(19) Crankshaft bearing cap cover screws (screws M

E N

GI NE


Lub

21Turbocharger lubrication pipe


Engines: 9HY - 9HZ

C4


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118118

p24 Oil gauge25 Oil level sensor 26 Piston skirt spray jets27 Oil filter cover28 Oil filter support

29 Coolant/oil heat exchanger30 Drain plug31 Oil induction strainer32 Oil sump33 Oil pump assembly

B1DP1LMD


Timing

34 Camshaft bearing caps

Camshaft pulleys

35 Pre tightening

Engines: 9HY - 9HZ


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119

35 Pre-tightening

Angular tightening

36 Timing belt guide roller

37 Timing belt tensioner roller

38 Timing chain tensioner

B1EP1HQD

E N

GI NE


Inject

Union on injector

39 Pre-tightening

Tightening

Engines: 9HY - 9HZ

C4


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120

g g

Injector fixing flange but

40 Pre-tightening

Angular tightening

41 Diesel injection pump on support

42 Diesel injection pump pulley43 Diesel fuel high pressure pump fr

B1HP22SD


Injection cir

44 Diesel fuel high pressure pump rear sup

Union on diesel fuel high pressure pum

45 Pre tightening

Engines: 9HY - 9HZ


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121

45 Pre-tightening

Tightening

46 Fuel high pressure common injection ra

Unions on fuel high pressure common i


48 Fuel filter support

B1HP22SD

E N

GI NE


Acce



51 Alternator po er circ it fi ing n t

Engines: 9HY - 9HZ

Version without particle filter

C4


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122122


52 Accessories tensioner roller

D1AP02NC


Accessori

53 Accessories support

54 Guide roller

Engines: 9HY - 9HZ

Version without air conditioning


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123

D1AP02PC

D1AP02QD

Accessori

55 Aircon compressor support

56 Aircon compressor screw

Version with air conditioning

E N

GI NE


Acce


Engines: 9HY - 9HZ

Version with particle filter

C4


130/461

124

D1AP02RC


Torque reac

(1)

(2)

(13)


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125

(13)

LH upper en

(3)

(4)

Lower LH e(5)

(6)

RH lower en

(7)

RH engine s

(8)

(9)

(10)

(11)

(12)B1BP2Z4P

E N

GI NE

SPECIAL FEATURES - TIGHTENING

Engines


Pre-tightening

Slackening

XSARA PICASSO


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126

Slackening

Tightening

Angular tightening

Con rod screws



Pre-tightening

Angular tightening

Sump




Engines


Pre-tightening

Tightening


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127

Exhaust manifold

Camshaft pulley

Pre-tightening

Angular tighteningCylinder head

Pre-tightening

Tightening

Angular tightening

EGR valve

F

Flywheel

Pre-tightening

Angular tighteningClutch mechanism

E N

GI NE


Engines

Oil pump assembly

Pre-tightening

Tightening

XSARA PICASSO


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128

Oil/coolant heat exchanger

Turbocharger lubrication pipe

Injector fixing flange nutPre-tightening

Angular tightening

Fuel high pressure common injection rail on engine block

Union on fuel high pressure common injection rail

Pre-tightening

Tightening

Diesel injection pump on support

Union on injector diesel

Pre-tightening

Tightening


Engines

Diesel inj

Diesel injection pump pulley

Union on fuel high pressure pump

Pre-tightening


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Pre tightening

Tightening

Coolant pump

Pre-tightening

Tightening


Pre-tightening

Tightening

E N

GI NE


Engine

1

2

3

4

Engine: WJY

XSARA


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130

4

5

6

7

8

9

10

11

12

13

14

B1BP1U5P


Crankshaft


Con rod nuts

Pre-tightening

Angular tightening

Engine: WJY


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Angular tightening

Accessories drive pulley hub

Pre-tightening

Angular tightening


Cylinder block

Piston skirt spray jet

Sump



Cylinder head


Exhaust manifold

Valve cover

Camshaft / hub

Camshaft pinion / hub

E N

GI NE


Crankshaft


Con rod nuts

Pre-tightening

Angular tightening

Engine: WJY

XSARA


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132

Angular tightening

Accessories drive pulley hub

Pre-tightening

Angular tightening


Cylinder block

Piston spray jet

Sump



Cylinder head


Exhaust manifold

Valve cover

Camshaft / hub

Camshaft pinion / hub


Flywheel

Flywheel

Clutch mechanism

Lubrication circuit

Engine: WJY


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133

Oil pump

Coolant/oil heat exchanger

Injection circuit

Injector on cylinder headDiesel fuel heater

Injection pump

Union on injector

Injection pump pulley

Cooling circuit

Coolant pump


E N GI NE


Engine

1

2

3

4

Engines: RHY - RHZ

XSARA


140/461

134

4

5

6

7

89

10

11

12

13

B1BP1YDP


CrankshaftBearing cap fixing screwsPre-tightening

Angular tightening

Con rod nuts

Engines: RHY - RHZ


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135

Pre-tightening

Angular tightening

Accessories drive pulley hubPre-tightening

Angular tighteningCylinder block

Piston skirt spray jetSumpTiming belt guide rollerTiming belt tensioner roller

Cylinder headCamshaft bearing coversExhaust manifoldValve cover

Camshaft / hubCamshaft pinion / camshaft hub

E N GI NE


FlywheelFlywheelClutch mechanism

Lubrication circuitOil pump

Engines: RHY - RHZ

XSARA


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136

p pCoolant oil heat exchangerTurbocharger lubrication pipeEngine end

Turbocharger end

Injection circuitInjector fixing flange nutUnions on fuel high pressure common injection railInjection pump on supportUnion on diesel injectorInjection pump pulleyUnion on fuel high pressure pump

Cooling circuitCoolant pump



1 5,5 ± 0,52 6 ± 0,53


Engine: RHR

RH engine support LH


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137

Lower engine support

34 5,5 ± 0,55

13 6 ± 0,614

1 ± 0,11516 5,5 ± 0,517 4 ± 0,418 6 ± 0,6

B1BP35HD

B1BP35KD

B1BP35JD

E N GI NE


CylinExhaust manifold


2 Turbocompressor

Engine: RHR

C4


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138

3 Exhaust clipCylinder head bolts (*)Pre-tightening

4 Tightening

SlackeningTighteningAngular tightening

B1DP1LCP

(*) (4) Sequence of tightening


145/461

E N G

I NE


Engine: RHR

(*) Bolts (5) and (7) Sequence of tightening (*) B

Cylinder head

(5) Camshaft bearing cap cover screws(7) Camshaft bearing cap cover studs (8) Inlet valve cover s

C4


146/461

140

B1DP1LED


Cylinder bl

9 Oil circuit plug

10 Coolant pump screw

Crankshaft bearing cap screws (*)11 Pre-tightening

Engine: RHR


147/461

141

Angular tightening

Con rod cap nutsTightening

12 SlackeningTightening

Angular tightening

B1CP0GNP

(*) (11) Crankshaft bearing cap screws

E N G

I NE


Cylin

13 Front closing plate screw

Flywheel screws14 Pre-tightening

Tightening

Engine: RHR

C4


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142

Accessories drive pulley screw15 Pre-tightening

Angular tightening

B1CP0GNP


Lubricatio16 Oil pump screw17 Piston skirt spray jet screw18 Drain plug

Oil sump (length 40 mm )19 Pre-tightening

Engine: RHR


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143

19 Pre tighteningTightening

Oil sump (length 21 mm)20 Pre-tightening

Tightening21 Electric oil gauge

B1CP0GPP

E N G

I NE


Lub


Oil filter support (*)

23 Tightening

Tightening

Engine: RHR

C4


150/461

144

24 Oil filter cover

B1CP0GPP

(*) (23) Sequence of tightening


TimingCamshaft drive pulley screw

25 TighteningAngular tighteningGuide roller screw

26 Pre-tightening

Engine: RHR


151/461

145

g gTightening


B1EP1HPD

E N G

I NE


Inject

28 High pressure pipe union on inje

Diesel injector nuts

29Do up both nuts by hand

Tightening

Engine: RHR

C4


152/461

146

g e g

Angular tightening

30 Fuel high pressure pump screw

31 High pressure pipe union on fuel

32 Fuel high pressure supply comm

33 Union on fuel high pressure supp

B1HP22LD


Accessori

34 Alternator support

35 Alternator

36 Aircon compressor

37 Accessories belt tensioner roller

Engine: RHR


153/461

147

B1BP390D

E N G

I NE

SPECIAL FEATURES - CYLINDER HEAD TIGH

Engines all typesCleaning to be carried out just prior to refitting the cylin

WARNING: Clean the contact faces with the approved CITROËN cleaning product.Do not use abrasives or cutting tools on the contact faces.

The contact faces must not bear any traces of impact or scratching.

Insert a tap in the threads of the holes in the cylinder block receiving the cylinder head bolts.

Brush the threads of the cylinder head bolts..


154/461

148

B1DP05BC

Oil the threads and under the heads of the bolts, using MOLYKOTE G RAPID PLUS.

Engines Tightenin(m.daN)

NFU TighteningAngular tightening

Pre-tighteningKFU Tightening

Angular tightening

6FZ - RFN Pre-tighteningTightening

RFJ Angular slackeningTightening

RFK Angular tightening

NOTE: Tightening of the cylinder head after a repair is prohibited.

SPECIAL FEATURES - CYLINDER HEAD TIGHTEN

Engines all typesCleaning to be carried out just prior to refitting the cylinder he




Brush the threads of the cylinder head bolts..

Oil th th d d d th h d f th b lt i MOLYKOTE G RAPID PLUS


155/461

149

B1DP05BC

Oil the threads and under the heads of the bolts, using MOLYKOTE G RAPID PLUS.

Engines Tightening(m.daN)

Pre-tighteningWJY TighteningAngular tightening

Pre-tighteningRHY - RHZ Tightening

Angular tightening

Pre-tighteningTightening

RHR SlackeningPre-tighteningTighteningAngular tightening


E N G

I NE

SPECIAL FEATURES - CYLINDER HEAD TIGH

Engines all typesCleaning to be carried out just prior to refitting the cylin




Brush the threads of the cylinder head bolts. Oil the threads and under the heads of the bolts, usin


156/461

150

B1DP1CLC

Engines Tightenin(m.daN)

Pre-tighteningKFW - NFV Angular tightening

Pre-tightening8HX - 8HZ Tightening

8HY Angular tightening

Pre-tightening9HY - 9HZ Tightening

9HX Angular tightening


B1BP10LC

Tools

BELT TENSION/SEEM UNITS CORRESPONDENCE T

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


157/461

151

E N G

I NE

AUXILIARY EQUIPMENT DRIVE BELT

TU

JP

3

J4

Engine type

C4

KFW KFU NFV NFU 6FZ

X X

5 7ET TU

JP4 J4JP+


158/461

152

XSARA

XSARA PICASSO

See pages:

X X

X X

155 156 to 157 158 156 to 157 160 162


159/461

E N G

I NE

AUXILIARY EQUIPMENT DRIVE BELT

Engines: All Types Petrol and Diesel

Tools.

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

WARNING If i l 4099 T (C TRONIC 105)


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154

WARNING: If using tool 4099-T (C.TRONIC 105).

Essential.

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

- 1 / The roller(s) rotate f

carte citroen

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