Saxo Xsara Berlingo

7/22/2019 Saxo Xsara Berlingo

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PRIVATE CARS

SAXO-XSARA-BERLINGO

CAR 050008Book 1

The technical information contained in this document is intended for the exclusive use of the trained personnel of themotor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. Theinformation is to be used by the professional vehicle repairers for whom it is intended and they alone would assume fullresponsibility to the exclusion of that of the manufacturer.The technical information appearing in this brochure is subject to updating as the characteristics of eachmodel in the range evolve. Motor vehicle repairers are invited to contact the CITRON network periodicallyfor further information and to obtain any possible updates. 2


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PRESENTATION

THIS HANDBOOK summarises the characteristics, adjustments, checks and special features of CITROvehicles for which there exists a separate handbook.

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

GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSIOAIR CONDITIONING.

In each section, the vehicles are dealt with in the following order : SAXO - XSARA XSARA PICASSO - BE

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 ywhen preparing future publications. For example :

INSUFFICIENT INFORMATION SUPERFLUOUS INFORMATION NEED FOR MORE DETAILS

Please send your comments and suggestions to :

CITROEN U.K. Ltd.221, Bath Road,

SLOUGH,SL1 4BA.U.K.


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GENERAL

Saxo 1 - 8

Xsara 9/2000 9 - 24

Xsara 09/2000 25 - 31

Xsara Picasso 32 - 33

Berlingo 34 - 37

Saxo 39

Xsara 9/2000 40

Xsara 09/2000 41

Xsara Picasso 42

Berlingo 43

Lubricants 44 - 58

ENGINE

Specifications 59 - 62Cylinder head marking, tightening 66 - 77Auxiliary drive belt 78 - 102Checking, setting valve timing 103 - 104

Valve clearances 140Checking oil pressure 141Oil filter 144

INJECTION

Idling, anti-pollution 146 - 149Petrol injection 150 - 157

ELEC

Start

Alter

Char

Preh

AIR C

Qua

Spec

Chec

Chec

INDEX

Identification

of vehicles

Capacities

Axle geometry

Brakespecifications

Air c

LPG safety requirements 166 - 170HDi safety requirements 171 - 174

Checking the HDi fuel circuit 175 - 176Checking the HDi air circuit 177Checking turbo pressure 178 - 179Checking the HDi recycling circuit 180

Checking, setting DELPHI injection 181 - 195

Checking, setting BOSCH injection 196 - 205IGNITION

Sparking plugs 206

CLUTCH-GEARBOX-TRANSMISSION

Speedometer 207

Checking, adjust ing the clutch 211 - 216Driveshafts 250

AXLES-SUSPENSION-STEERING

Saxo 251 - 258

Xsara TT 263 - 267Xsara Picasso 292 - 293

BRAKES

Saxo 298 - 299Xsara 304 - 306

Xsara Picasso 321

P


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1

IDENTIFICATION OF VEHICLES

E1AP07CD

1 Engine leg

2 RP organis

3 Chassis st

4 Manufactu

5 01/02/99

6 Paint code

7 Gearbox id


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GENERAL

Emission standard L3

Type code SO CDZF SO HDZF/GL (1) SO KFXD

Engine type CDZ HDZ

Cubic capacity (cc) 954 1124

Fiscal rating (hp) 4 6

Gearbox type MA/5 MB3

Gearbox ident. plate20 CE 81 (2)

31220 CF 03 (3)

2

SAXO - All Types IDENTIFICATION OF VEH

(1) = LPG.(2) = # 28/08/2000.(3) = 29/08/2000 #

3-DOOR PETROL SALOON

1.1 i1.0 i

A - XSX

ExclusiveA - X

Administration

AUTO.


7/3953


Type code S6 NFZF S6 NFXF SO VJZ

Engine type NFZ NFX VJZ (1

Cubic capacity (cc) 1587


Gearbox type MA/5

Gearbox ident. plate20 CD 60 (3) 20 CD 46 (3)20 CN 05 (4) 20 CN 03 (4)


(1) = With EGR(2) = Catalytic converter with EGR(3) = # 28/08/2000.(4) = 29/08/2000 #NOTE : EGR = Exhaust Gas Recycling device.

3-3-DOOR PETROL SALOONS

1.6 i 1.6 i 16 V

VTS

A-X-SXExclusiv

AdministraVTS


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GENERAL

4


Type code S1 CDZF S1 HDZF/GL (3)

Engine type CDZ HDZ


Fiscal rating (hp) 4

Gearbox type MA/5

Gearbox ident. plate20 CE 81 (4)20 CF 03 (5)


5-DOOR PETROL SALOO

1.1 i1.0 i

A-SXDriving School

(1) (2)

A-XAdministration

(1) = Cylindrical tank(2) = Ring-shaped tank.(3) = LPG.(4) = # 28/08/2000(5) = 29/08/2000 #


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5

Emission standard L3Type code S1 VJZF (1) S1 VJZF/MOD (2)

Engine type VJZ



Gearbox type MA/5

Gearbox ident. plate 20 CE 73 (a) 20 CF 02 (b)


(1) = With EGR

(2) MOD = Modifiable.(3) = Catalytic converter(a) = # 28/08/2000.(b) =.29/08/2000 #NOTE : EGR = Exhaust Gas Recycling device.

5-DOOR DIESEL SALOONS

1.5 D

Driving SchoolA-X-SX-Exclusive


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GENERAL

6


Type code SO CDZF/T (1) S3 CDZF (2) SO HDZF/T.MOD.GL (3)

Engine type CDZ HDZ



Gearbox type MA/5



Commercial version Entrepris

1.1 i

Petrol

A

1.0 i

A-X-PosteAdministration

(1) = Can be converted.(2) = Non-convertible van.(3) /T.MOD.GL = Convertible to LPG.(4) = # 28/08/2000.(5) = 29/08/2000 #


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7


(1) = # 02/05/2000(2) = 03/05/2000 #

3-DOOR SALOONS

Petrol

1.1i 1.4i 1.6i

VTS SX ExclusiveVTS VTS

A-X-SXExclusive

Administration


Type code SO HFXB S6 KFWB SO KFWB S6 NFTB

Engine type HFX KFW NFT


Fiscal rating (hp) 4 5 6

Gearbox type MA/5

Gearbox ident. plate20 CF 03 (1) 20 CE 95 (1)

20 CF 0320 C

20 CF 02 (2) 20 CF 12 (2) 20 C


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GENERAL

8


Type code S3 HFXB

Engine type HFX



Gearbox type MA/5



(1) = Non-convertible van(2) = # 28/08/2000(3) = 29/08/2000 #

COMMERCIAL VERSION ENTREPR

Petrol

1.1i(1)

A-S-SXPoste

Administration


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E1AP08MD

1 Manufacture

2 Chassis stam

3 Manufacture

4 01/02/1999 #

5 Gearbox iden

6 Engine legis

9


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GENERAL

10

XSARA - All Types # 09/2000 IDENTIFICATION O

(*) = Differential diameter 68 mm.(1) GL = LPG (Liquid Petroleum Gas) with ring-shaped tank.

3-DOOR PETROL SALOO

1.4i

Dual f

A - X - X PackSX - VTR

X - X PackSX X - SX - X Pack

Emission standard K' L3 IF L4

Type code NO KFXG NO KFXF NO KFXB NO KXF/

Engine type KFX



Gearbox type MA/5

Gearbox ident. plate 20 CE 42 (*)


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L3

NO LFXF NO LFYF N6 LFYF

LFX LFY

1761

6 7

BE3/5

20 TB 91 20 TB 62

11

IDENTIFICATION OF VEHICLES3-DOOR PETROL SALOONS

1.8i 16V1.8i

VTR - VTSX - X PackSX - VTR

X Pack - SXExclusive

Emission standard

Type code

Engine type

Cubic capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident. plate


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GENERAL

12

X - X PackSX - VTRExclusive

X - X PackVTR


Type code NO WJZF NO DHYF N6 DHYF NO RHYF

Engine type WJZ DHY



Gearbox type BE3/5

Gearbox ident. plate 20 TB 38 20 TB 59


(1) = High pressure Diesel injection

3-DOOR DIESEL SALOON

1.9 D 1.9 TD

X - X PackSXVTS


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13


Type code NO KFXF/T (1) NO KFXF/T MOD GL (2) NO WJZF

Engine type KFX



Gearbox type MA/5

Gearbox ident. plate 20 CE 42


(1) /T = The vehicle can be converted back into a private vehicle.(2) /T MOD GL :

/T = The vehicle can be converted back into a private vehicle.MOD = Modifiable.GL = LPG (Liquid Petroleum Gas) with ring-shaped tank.

3-DOOR SALOON VERSIONS - ALL TY

Petrol

X Entreprise

SX

Dual fuel

X Entreprise

1.4i


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GENERAL

14

Emission standard K' L3 L4 L3

Type code N1 KFXG N1 KFXF N1 KFXB N1 KFXF

Engine type KFX



Gearbox type MA/5

Gearbox ident. plate 20 CE 42 (1)

XSARA - All Types # 09/2000 IDENTIFICATION OF

(1) = Differential diameter 68 mm.

5-DOOR PETROL SALOO

1.4 i

A - XX Pack - SXExclusive

X - X PackSX X-S

Dual f

A - XX Pack


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15

L3

N1 NFZF N1 NFZM N1 LFXF

NFZ LFX

1587

6

MA/5 AL4

20 CD 29 20 TP 22 20 TB 91

IDENTIFICATION OF VEHICLES5-DOOR PETROL SALOONS

1.8i1.6i

X - X Pack - SXExclusive

X - X Pack - SXExclusive

AUTO.

X

Emission standard

Type code

Engine type

Cubic capacity (cc)

Fiscal rating (hp)

Gearbox type



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GENERAL

16


Type code N1 LFYY N1 LFYF/GL (1) N1 RFVF

Engine type LFY



Gearbox type BE3/5 BE3/5

Gearbox ident. plate 20 TD 05 20 TB 84 20 TB 39

XSARA - All Types# 09/2000 IDENTIFICATION O

5-DOOR PETROL SALOO

1.8i 16V

X - XExclX - SXBrazil

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

Dual fuel


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17

Emission standard L3Type code N1 VJZF N1 WJZF N1 RHY

Engine type VJZ WJZ



Gearbox type MA/5 BE3/5

Gearbox ident. plate 20 CE 46 (*) 20 TB 38


(*) = Differential diameter 68 mm.

5-DOOR DIESEL SALOONS

1.9D1.5 D

X - X PackSXSX


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GENERAL

18

Emission standard L3Type code N1 KFXF N1 LFXF N

Engine type KFX LFX




Gearbox ident. plate 20 CE 42 20 TB 22

XSARA - All Types# 09/2000 IDENTIFICATION O

(1) /T = The vehicle can be converted back into a private vehicle.(2) /T MOD GL :/T = The vehicle can be converted back into a private vehicleMOD = Modifiable.GL = LPG (Liquid Petroleum Gas) with ring-shaped tank.

5-DOOR SALOON VERSIONS A

Petrol

1.8i1.4i

X Police MarkedX PolX Ge

X Police UnmarkedX Police Marked


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19

L3

N1 WJZF/MOD (1) N1 WJZF/T (2) N1 DHYF

WJZ DHY

1868 1905

5 6

BE3/5

20 TB 38 20 TB 59

IDENTIFICATION OF VEHICLES5-DOOR SALOON VERSIONS

Diesel

1.9 TD1.9 D

X EntrepriseX EntrepriseX Driving School X

Emission standard

Type code

Engine type

Cubic capacity (cc)

Fiscal rating (hp)

Gearbox type


(1) /T = The vehicle can be converted back into a private vehicle.(2) MOD = Modifiable.


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GENERAL

20

X - X Pack - SX

Emission standard L3 L4

Type code N2 KFXF N2 KFXB N2 KFXF/GL N2 NFZU

Engine type KFX



Gearbox type MA/5 AL4

Gearbox ident. plate 20 CD 28 (*) 20 TP 22


(1) /GL = LPG (Liquid Petroleum Gas).


PETROL ESTATES

1.4i

X Pack

(1)

X - SX

Dual fuel AUTO.


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21


Type code N2 LFXF N2 LFYF N2 LFYF/GL N2 LFYY

Engine type LFX LFY



Gearbox type BE3/5 BE3/5

Gearbox ident. plate 20 TB 22 20 TB 62 20 TD 05


(1) GL = LPG (Liquid Petroleum Gas).

PETROL ESTATES

1.8i 1.8i 16V

BrazilX X Pack SX

Exclusive(1)

X SXX X Pack SX

Exclusive

Dual fuel


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GENERAL

22


Type code N2 VJZF N2 WJZF N2 DHYF

Engine type VJZ WJZ DHY

Cubic capacity (cc) 1527 1868 1905



Gearbox ident. plate 20 CD 33 (*) 20 TB 38 20 TB 59


DIESEL ESTATES

1.9 TD1.9 D1.5 D

X X PackSX

ExclusiveX X Pack

SXSX



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23


Type code N2 KFXF N2 KFXF/T (1) N2 KFXF/T MO

Engine type KFX



Gearbox type MA/5

Gearbox ident. plate 20 CD 28


(1) /T = The vehicle can be converted back into a private vehicle.(2) /T MOD GL :

/T = The vehicle can be converted back into a private vehicleMOD = Modifiable.GL = LPG (Liquid Petroleum Gas) with ring-shaped tank.

ESTATE VERSIONS

Petrol

1.4i

X Entreprise

Dual fu

X SX EntreX Police Unmarked

X Police Marked


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GENERAL

24


Type code N2 WJZF WJZF/T (1)

Engine type WJZ



Gearbox type BE3/5

Gearbox ident. plate 20 TP 38

IDENTIFICATION O

(1) = Can be converted.

ESTATE VERSIONS

Diesel

1.9 D

X Police UnmarkedX Police Marked

XSARA - All Types# 09/2000


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25


E1AP08WD

A - Manufacturer

B - Chassis stam

C - Manufacturer

D - Label :(affixed on windsc

E - Serial No. (vis

F - Engine legislaFactory Serial

G - Gearbox iden

Factory Seria

09/2000 #


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GENERAL

26


Type code NO KFWB NO NFUB NO NFUN NO RFN

Engine type KFW NFU



Gearbox type MA/5 AL4 AL4

Gearbox ident. plate 20 CF 13 (1) 20 CN 28 (2) 20 TP 49 20TP

XSARA - All Types 09/2000# IDENTIFICATION O

(1) = Grand Export 20 CN 30(2) = Grand Export 20 CN 29(3) = Right Hand Drive 20 DM 03

3-DOOR PETROL SALOO

1.6i 16V1.4 i

X-SX-VTRVTS SX-VTR

AUTO. AUTO

X-SXVTR


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27

L4

NO WJZB NO RHYB NO KFWB/T (1) N

WJZ RHY KFW

1868 1997 1360

5

BE4/5 MA/5

20 DL (2)-(3) 20 DL (4)-(5) 20 CF 13 (6)

IDENTIFICATION OF VEHICLESPETROL3-DOOR PETROL SALOONS

1.4i2.0 HDi1.9 D

X-SX-VTRVTS

X-SXVTR

Emission standard

Type code

Engine type

Cubic capacity (cc)

Fiscal rating (hp)

Gearbox type


(1) /T = The vehicle can be converted back into a private vehicle

(2) = Left Hand Drive version 20 DL 41(3) = Right Hand Drive version 20 DM 05(4) = Left Hand Drive version 20 DL 42(5) = Right Hand Drive version 20 DM 07(6) = Grand Export 20 CN 30


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GENERAL

28

Emission standard K L4 K

Type code N1 KFWG N1 KFWB N1 NFUG N1 NF

Engine type KFW




Gearbox ident. plate 20 CF 21 20 CN 28 (1) 20 TP

XSARA - All Types 09/2000 # IDENTIFICATION O

(1) = Grand Export 20 CN 29

5-DOOR PETROL SALOO

1.4 i

X-SX SX

AUTO

X



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29

Emission standard IFL5

Type code N1 RFN1/IF N1 RFN3/IF N1 WJZ

Engine type RFN WJZ



Gearbox type BE4/5 AL4

Gearbox ident. plate 20 DL (1) (2) 20 TP 47 20 DL (3)


(1) = Left Hand Drive version 20 DL 40 (5) = Left Hand Drive version 20 DL 42(2) = Right Hand Drive version 20 DM 03 (6) = Right Hand Drive version 20 DM 07(3) = Left Hand Drive version 20 DL 41(4) = Right Hand Drive version 20 DM 05

5-5-DOOR PETROL SALOONS

1.9 D2.0i 16V

AUTO.

Exclusive

XSARA All T 09/2000 # IDENTIFICATION O


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GENERAL

30

Emission standard L4 K' L4

Type code N2 KFWB N2 NFUG N2 NFUB N2 NF

Engine type KFW NFU




Gearbox ident. plate 20 CN 21 20 CN 29 (1) 20 CN 28 20 TP

XSARA - All Types 09/2000 # IDENTIFICATION O

(1) = Grand Export 20 CN 29(2) = Left Hand Drive version 20 DL 40(3) = Right Hand Drive version 20 DM 03

PETROL SALOONS / ESTA

1.4 i 1.6i 16V

SX X-SX

SX

Exclu

AUT

X-SX



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31

L4

N2 WJZB N2 RHYB N2 KFWB/T (1) N

WJZ RHY KFW

1868 1997 1360

5

BE4/5 MA/5

20 DL (2)-(3) 20 DL (4)-(5) 20 CN 21 (6)

IDENTIFICATION OF VEHICLESPETROL / DIEDIESEL ESTATES

1.4i2.0 HDi1.9 D

X-SXExclusiveX-SX Entreprise

Emission standard

Type code

Engine type

Cubic capacity (cc)

Fiscal rating (hp)

Gearbox type


(1) /T = The vehicle can be converted back into a private vehicle(2)

= Left Hand Drive version20 DL 41

(3) = Right Hand Drive version 20 DM 05(4) = Left Hand Drive version 20 DL 42(5) = Right Hand Drive version 20 DM 07(6) = Grand Export 20 CN 30

IDENTIFICATION OXSARA PICASSO All Types


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GENERAL

32

IDENTIFICATION OXSARA PICASSO - All Types

E1AP088D

A - Chassis(Cold stam

B - Chassi(Label loca

C - Manufa(Located a

D - Label :TTS

(Located o

E - Label :FAP

(Located o

F - GearboG - EngineFactory ser



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33


Type code CH NFZ CH 6FZ

Engine type NFZ 6FZ



Gearbox type BE4/5/ J (*) BE4/5 V (*)

Gearbox ident. plate 20 DL 66 20 DL 68


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

Petrol

1.8i 16 V1.6i

IDENTIFICATION OF VBERLINGO - All Types


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GENERAL

34

IDENTIFICATION OF VBERLINGO - All Types

E1AP07AD

1 Ch

2 Ma

3 Su

4 We

5 01/

6 Pa

7 RP

8 Ge

9 En



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35

Emission standard L3/W3 L4/W4 K' LType code MF HDZF MF HFXB MF KFXG MF KFXF

Engine type HDZ HFX KFX



Gearbox type MA/5

Gearbox ident. plate20 CN 43 # 09/200

20 CN 02 09/2000 #20 CN 12


PETROL

1.1i

X-SXXX

BERLINGO - All Types IDENTIFICATION OF V


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GENERAL

36

Emission standard L4/W4 L3

Type code MF KFWB/A MF KFXF MF KFXF/MOD GL /MOD GL

Engine type KFW KFX



Gearbox type MA/5

Gearbox ident. plate 20 CN 13 20 CN 12 20 CN 13

BERLINGO All Types IDENTIFICATION OF V

PETROL

1.4i

MultispaceXMultispace

Dual fuel



41/395

37

Emission standard L3/W3 L4/W4 L3/W3

Type code MF WJZF MF WJZF MF WJYB MF WJYB MF RHYF/A /A

Engine type WJZ WJY



Gearbox type BE3/5

Gearbox ident. plate 20 TE 22 20 TE 24 20 TE 49 20 TE 24 20 TE 28


DIESEL

1.9 D

Multispace MX-SXMultispaceX-SX

CAPACITIES (in litresALL TYPES


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GENERAL

38

CAPACITIES (in litresALL TYPES

Draining method.

The oil capacities are defined according to the following

1/ Vehicle on level surface (in high position, if equipped with hydropneumatic suspension).

2/ Engine warm (oil temperature80C

).

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 for5 min).

ESSENTIAL : Systematically check the oil level using the

CAPACITIES (in litres)


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39

CDZ HDZ KFX KFW NFZ NFX KFX KFW NFZ

3 3

1.4 1.5

2 2

4.5

2

With ABS : 0.45 - Without ABS : 0.

6.1

45

( )

Ecological oil filtercapacity 0.15 litre.

Petrol

SAXO

Engine type

Engine with filter change

Between Min. and Max.

5-speed gearbox

Automatic gearbox

after drainage

Hydraulic or brake circuit

Cooling system

Fuel tank capacity

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

1.0I 1.1I 1.4I 1.6I 1.1I 1.4I 1.6I 1.6I

AUTO.

CAPACITIES (in XSARA - All Types # 09/2000


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AUTO. AUTO.

GENERAL

40

Engine type



5-speed gearbox

Automatic gearbox

after drainage


Cooling system

Fuel tank capacity

KFX NFZ LFX LFY RFV3

4.754.25

4.25 (1)

1.4 1.3 1

2 1.8 1.9

6 6

3 3

With ABS = 0.50 - Without A

7 - 6.5 (1) 7 9

54

(ypXSARA # 09/2000

Petrol

1.4i 1.6i 1.8i 1.8i16V

2.0i16 V

(1) With aircon - ESSENTIAL : Engine : systematically check the oil level using the oil dip



45/395

Ecological oil filtercapacity 0,15 litre.

Engine type



5-speed gearbox

Automatic gearbox

after drainage


Cooling system

Fuel tank capacity

41

KFW NFU RFN3 3.25 4.25

1.5 1.5 1.7

2 1.9

6 6

3 3

With ABS = 0.50 - Without ABS = 0.5

7 - 6.5 (1)

54

1.6 i 16V 2.0i 16V

AUTO.

1.4 i

Petrol

XSARA 09/2000 #

AUTO.

(1) = With aircon - ESSENTIAL : Engine : systematically check the oil level using the oil dipstick.

XSARA PICASSO - All Types CAPACITIES (


46/395

GENERAL

Cartouche cologiquecapacit 0.15 Litre.

42

Engine type



5-speed gearbox

Automatic gearbox

after drainage


Cooling system

Fuel tank capacity

NFZ 6FZ

3 4.25

1.5 1.7

1.8

0.58 litres

5.8 (1) and (2) 6.5 (1) and (2)

55

Petrol

XSARA PICASSO

1.6I 1.8I 16 V

(1) = With aircon(2) = Without airconESSENTIAL : Engine : systematically check the oil level using the oil dipstick.



47/395

Engine type



5-speed gearbox

Automatic gearbox

after drainage


Cooling systemFuel tank capacity

43

HDZ HFX KFX KFW LFX HFX KF

3.54.75

4.5 (1)3

1.5 1.3 1

2 1.8 2

With ABS = 0.62 - Without ABS = 0.525

6.5 6.5-7 (1) 8 6.555

Ecologicacapacity

Petrol

BERLINGO

(1) = With aircon - ESSENTIAL : Engine : systematically check the oil level using the oil dipstick.

1.1I 1.4I 1.8I 1.1I

ALL TYPES LUBRICANTS - TOTAL recomm


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GENERAL

44

S.A.E. Norm - Table for selection of engine oil grade Fac

CITRON engingrade S.A.E.5WTOTAL oil of gra(approx. 2.5%).

This oil is not us

- XU10 4 RS - X- SOFIM - RELA

These engine oi

organisations:

SAE : Society o

API : American ACEA : Associad'Automobiles.

E4AP006D

LUBRICANTS - TOTAL recommended oils


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45

Selection of engine oil grades recommended for climatic conditions in count

ACEA Norms

The first letter corresponds to the type of engine concerned :A : petrol and dual fuel petrol / LPG engines..

B : 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 ofthe norm.

NOTE : From 01/03/2000, all engine oils must comply with ACEA-98norms.

Example :ACEA A1-98 / B1-98 : Blended oils for all engines, permetting fueleconomy (complying with ACEA 98 norms).

A

The first letter corresponds to thS : petrol and dual fuel pC : diesel engines.

The second letter corresponds toExample : The norm SJ is moreto a higher level of performanThe adding of the letters EC inoil which permits fuel economy.EC : Energy Conserving, redExamples :API SJ / CF : Blended oils for dAPI CF / EC : Oils specifically foAPI SJ / CF / EC : Blended oils

LUBRICANTS - TOTAL recommALL TYPES


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GENERAL

46

Recommendations.Denominations of TOTAL oils, according to country of marketing :

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

IMPERATIVE : From 1999 model year, to preserve engine performance, all enginelubricated with high quality oils (synthetic or semi-synthetic)

These oils must comply with the following norms :

Petrol and dual fuel petrol / LPG engines: ACEAA3-98 and API SJ.Diesel engines: ACEA B3-98 and API CF.

ATTENTION : Engines fitted in CITROEN vehicles prior to 2000 model year must nostandards ACEA A1-98 / B1-98 and API SJ/CF EC.

SummaryEngine oil norms to be respected in 2001 model year.

(*) = 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.

Model year

2001 model year

Petrol and dual fuel petrol /

LPG engines

A3-98 or A1-98

B3-98 or B1-98 Diesel engines

Types of engine ACEA norms



51/395

47

S.A.E. grades

Blended oils for all engines (petrol, dual-fuel petrol / LPG and d

TOTAL ACTIVA 9000

TOTAL QUARTZ 90005W-40

TOTAL ACTIVA 9000 (*)

TOTAL QUARTZ 9000 (*)5W-30

TOTAL ACTIVRAC 10W-40

(*) = Blended oils for all engines, permitting fuel economy.Oils specifically for petrol and dual-fuel petrol / LPG engine

TOTAL ACTIVA 7000


TOTAL QUARTZ 9000 0W-40TOTAL ACTIVA 7000


Oils specifically for diesel engines

TOTAL ACTIVA DIESEL 7000

TOTAL QUARTZ DIESEL 700010W-40

TOTAL ACTIVA DIESEL 7000

TOTAL QUARTZ DIESEL 700015W-50

TOTAL ACTIVA 9000 5W-40



52/395

GENERAL

FRANCE

Metropolitan FRANCE

Metropolitan FRANCE

New CaledoniaGuadeloupeSaint-martinLa Runion

9000 5W-40 7000 15WMartiniqueGuyana

TahitiMauritiusMayotte

48

Blended oils for a

TOTAL ACTIVRAC

TOTAL ACTIVA

Blended oils for all engines

900 5W-409000 5W-30 (*)

7000 10 W

Oils specifically fodual-fuel petrol / L

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



53/395

49

EUROPE

Germany7000 10W-409000 0W-40

Austria 7000 10W-40Belgium

7000 10W-409000 0W-40

Bulgaria 7000 10W-40

Cyprus 7000 15W-50

Croatia 7000 10W-40

Denmark7000 10W-409000 0W-40

Spain

7000 10W-40

7000 15W-50

Finland7000 10W-409000 0W-40

Great Britain 7000 10W-40

TOTAL QUARTZ

Blended oils for all enginesOils specifically for petrodual-fuel petrol / LPG en

9000 5W-409000 5W-30 (*)

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

EUROPE ( ti d)



54/395

GENERAL

50

EUROPE (continued)

Greece7000 10W7000 15W

Holland 7000 10W

Hungary 9000 0W-

Italy 7000 10W

Latvia 7000 10W

Lithuania 9000 0W-

Macedonia 7000 10W

Malta7000 10W7000 15W

Norway7000 10W

9000 0W-Poland

Portugal 7000 10W

Slovak Republic

TOTAL QUARTZ

Blended oils for all enginesOils specifically fodual-fuel petrol / L

9000 5W-409000 5W-30 (*)


EUROPE ( ti d)



55/395

51

EUROPE (continued)

Czech Republic7000 10W-409000 0W-40

Romania7000 10W-407000 15W-50

Russia7000 10W-409000 0W-40

Slovenia 7000 10W-40

Sweden7000 10W-409000 0W-40

Switzerland 7000 10W-40

Turkey

7000 10W-40

7000 15W-509000 0W-40

Ukraine7000 10W-409000 0W-40

TOTAL QUARTZ

Blended oils for all enginesOils specifically for petrodual-fuel petrol / LPG en

9000 5W-409000 5W-30 (*)




56/395

GENERAL

52

Australia

New ZealandOCEANIA 9000 5W-40 7000 10W-

Angola - Ivory Coast

Egypt- Ecuador - Gabon

Madagascar - Morocco AFRICA 9000 5W-40 7000 15W-

Dominican Republic

Senegal - Tunisia

Argentina - Brazil - Chile

Colombia - CubaSOUTH

Guatemala - ParaguayAMERICA

9000 5W-40 7000 15W-

Peru - El Salvador

Uruguay

TOTAL QUARTZ

Blended oilsfor all engines




57/395

53

China7000 10W-40

7000 15W-50

South Korea 7000 10W-40

Hong Kong - India

Indonesia7000 15W-50

Japan7000 10W-40

SOUTH & EAST 7000 15W-50

Malaysia ASIA9000 5W-40

7000 15W-50Singapore

Taiwan 7000 10W-40

7000 15W-50

Thaland7000 15W-50

Vietnam

TOTAL QUARTZ


Oils specifically for petrodual-fuel petrol / LPG en



58/395

GENERAL

54

Saudi Arabia

Bahrain

Duba

United Arab Emirates

Israel MIDDLE9000 5W-40 7000 15W-

Jordan EAST

Kuwat

Lebanon

Qatar

Yemen

TOTAL QUARTZ




Gearbox oils


59/395

55

Manual gearboxEurope T

Overseas France

Asia

T

TAutomatic gearbox MB3

Specia

TO

Automatic gearbox 4 HP 14 et 4 HP 18 All countries Specia

Automatic gearbox 4 HP 20 et AL4Specia

Transfer box and differential TOT

C MATIC gearbox

Power-assisted steering All countries

Gearbox oils

Oils for power-assisted steering

Engine coolant



60/395

GENERAL

56

Engine coolant

PacksGLY

CITROEN Fluid 2 litresAll countries

Protection : - 35C 5 litres

20 litres

210 litres

Synthetic brake fluid

Packs

All countries CITROEN Fluid0.5 litre

1 litre

5litres

CITROEN hydraulic circuit fluid

Mineral fluid for hydraulic circuit - gr

TOTAL LHM PLUS Packs

All countries Norms ISO 7308-7309 1 litre

Hydraulic circuit rinsing fluid - green c

TOTAL HYDRAURINCAGE

Wash / wipe fluid



61/395

57

CITROEN

Concentrate : 250 ml 9980 33 ZC 9875

All countries Liquid ready to use : 1 litre 9980 06 ZC 9875

Liquid ready to use : 5 litres 9980 05 ZC 9885

Grease

All countries TOTAL MULTIS EP2

TOTAL MULTIS COMPLEX EP2

TOTAL MULTIS N4128

TOTAL SMALL MECHANISMS

(1) NLGI = National Lubricating Grease Institute.

Wash / wipe fluid

ENGINE OIL CONSUMPTALL TYPES


62/395

GENERAL

58

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 WORK BELOW THESE VALUES.

IV - OIL LEVEL : The level should NEVER be above the MAX. mark on the dipstick after- This excess oil will be used up rapidly.- It will reduce the engine output and adversely affect the operation of the air circuits

ENGINE SPECIFICATIONS

Engines : CDZ - HDZ - HDZ/GPL - HFX - KF


63/395

59

g

Petrol

All Types

1.0i 1.1i

Engine type

Cubic capacity (cc)

Bore / Stroke

Compression ratio

Power ISO or EEC KW-rpm

Power DIN (HP-rpm)

Torque ISO or EEC (m.daN-rpm)

Torque DIN (mkg-rpm)

Max. speed (rpm)

CDZ HDZ HDZ/GPL HFX

954 1124

70/62 72/79

9.4/1 9.7/1 10.5/1

37-6000 44.1-6200 43.2-6200 44.1-5500

50-6000 60-6200 58.8-6200 60-5500

7.35-3700 8.75-3800 8.31-3800 9.4-3500

7.5-3700 9.1-3800 8.65-3800 -3500

6400 6500

ENGIN

ENGINE SPECIFICATIOALL TYPES

Engines : NFZ NFT NF


64/395

60

NE

Engine type

Cubic capacity (cc)

Bore / Stroke

Compression ratio


Power DIN (HP-rpm)



Max. speed (rpm)

g

Petrol

All Types

1.6 i

SAXO PICASSO

NFZ NFT

1587

78.5/82

9.6/1 10.5/1

65-5600 70-5700 72-5700 80

90-5600 95-5700 98-5700 11

13.5-3000 13.5-3500 14

14-3000 13.8-3000 ?-3500 15

6100

ENGINE SPECIFICATIONS

Engines : LFY - LFY/GPL - 6FZ - RFN


65/395

61

Engine type

Cubic capacity (cc)

Bore / Stroke

Compression ratio


Power DIN (HP-rpm)



Max. speed (rpm)

g

Petrol

All Types

1.8i 16V

LFY LFY/GPL 6FZ RFN

1761 1749 1997

83/81.4 82.7/81.4 85/88

10.4/1 10.8/1

81-5500 72-5500 85-5500 99-6000

112-5500 109-5500 115-5500 136-6000

15.5-4250 16.3-4000 19-4100

16.1-4250 16.6-4000 19.8-4100

6400 6500

ENGIN

ENGINE SPECIFICATIOALL TYPES

Engines :VJZ - VJX - VJY - W


66/395

Engine type

Cubic capacity (cc)

Bore / Stroke

Compression ratio


Power DIN (HP-rpm)



Max. speed (rpm)

VJZ VJX DHY

1527 1527

77/82 77/82 8

23/1 23/1

42-5000 40-5000 5

58-5000 55-5000 70

9.5-2250 12

9.68-2250 14

5450

62

E

Diesel

All Types

1.5 D

SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

CYLINDER HEAD (mm)


67/395

63

Engine type CDZ HDZ-HFX KFX-KFW NFZ

Maximum permissible bow 0.05

Gasket surface regrinding - 0.20

TIGHTENING TORQUES ( m.d

Crankshaft Pre-tighteningbearing screws Loosening

Tightening

Angular tighteningTightening

Pre-tighteningConnecting rod Looseningscrews Tightening

Angular tightening

Flywheel screw

Pre-tighteningTighteningAngular tightening

Crankshaft Tighteningpinion screw Angular tightening

Crankshaft Pre-tighteningpulley screw Tightening

Camshaft Pre-tighteningpulley screw Angular tightening

Camshaft hubs

Camshaft end pulley screw

Camshaft hub Pre-tighteningscrew Tightening

2 0.2

45

3.8 0.4

6.5 0.7

10 1

8 0.8

ENGINE

ALL TYPES SPECIAL FEATURES - TIGHTENING

CYLINDER HEAD (mm)


68/395

(1) 11 : 2 0.11 0.1

(2) 6 :1 0.1

5.5 0.5 (only) 7 11 to 1 0.1then to 2 0.1 11 to 70 5 60 6 6 to 1 0.1

4 0.4 1 0.1180(1/2 turn)

2 0.2 2.3 0.2 2.3 0.270 7 46 5 46 4.6

0.8 0.15 0.5 2 0.2 2 0.2

26 3 21 3

4 0.453 4

1.5 0.212 1.2 2.1 0.2

5.5 0.5

3 0.37.5 0.7

64

E

Engine type LFX LFY 6FZ RFN RF

Maximum permissible bow 0.05

Gasket surface regrinding - 0.20 - 0.30

TIGHTENING TORQUES

Pre-tightening

Loosening

Crankshaft Tighteningbearing screws

Angular tighteningTightening

Pre-tighteningConnecting rod Looseningscrews Tightening

Angular tightening

Flywheel screwPre-tighteningTighteningAngular tightening

Crankshaft Tighteningpinion screw Angular tightening

Crankshaft Pre-tighteningpulley screw Tightening

Camshaft pulley Pre-tighteningscrew Angular tighteningCamshaft end pulley screws

Camshaft hub Pre-tighteningscrew Tightening

SPECIAL FEATURES - TIGHTENING TORQUES ( m.daN )

Engines : LFY -RFV - RFS - VJZ - VJY - VJX


69/395

65

SAXO

VJZ-VJY-VJX

- Pre-tighten 0.4

- Tighten 0.7

XSARA

LFY-RFV-RFS

- Pre-tighten 0.5

- Tighten 1

B1DP03BC

ENGINE

ENGINE

CYLINDER HEATU - TUD - All Types

Engines : CDZ HDZ HFX KFX - KFW NFZ NFT NFU - NFX


70/395

E

66

E

IDENTIFICATION OF THE CYLINDER HEAD GASK

Engine type

Identification marks (Notch on cylinder head gasket) *

CDZ HDZ - KFX HFX - KFW NFZ - NFT NFU - NFX VJZ- VJY - V

1

2

3

4A

B

D

A

B

D

A

B

D

A

BD

C

R 0 (Standard gasket) - 1 (Repair gasket)

0 (With asbestos) - 1 (Without asbestos)

00

1

1

0

1

0

1

1

0

000 0 1 1 0

0 0 0 1 1

0 0 0 1 1

0 1 1 1 1

1

1

0

CURTY

MEILLOR

ELRING

REINZ

Material

Repairs

Suppliers

Thickness

CYLINDER HEAD (continued)

Engines : CDZ - HDZ - HFX - KFX - KFW - NFZ - NFT - NFU - NFX - VJX


71/395

67

Cylinder head tightening (m.daN)

X = MA

Noof t(Us

- Pre-tightening 2

- Angular tightening 260 5

- Pre-tightening 2

- Angular tightening 240 5

- Pre-tightening 4

- Angular tightening 300 5B1BP10LC

NFU - NFX

VJZ - VJY - VJX

CDZ - HDZ - HFX - KFXKFW - NFZ - NFT

CDZ - HDZ - HFX - KFKFW - NFZ - NFT

X = 175.5 0.5 mmB1DP13NC

ENGINE

XU - All Types CYLINDER HEAD

Engine : 6FZ


72/395

68

E

Identification of the cylinder head gasket

Nominal dimension Repair dimension

2 4 54 5

R1 R2 R3

10.8Gasket thickness

(mm)

Supplier MEILLOR

Marking zone

"e"

Marking zone"d"

1.1 1.3

Marking

" d " Marking zone

" e " Marking zone

NOTE : 3 layer metallic gasket.


Engine : 6FZ

C li d h d ti ht i ( d N)


73/395

69

X = MA

NOTE : Oil the threads andunder the heads of the cylinder

head bolts. (Use engine oil orMolykote G Rapid Plus).

Pre-tightening 1.5 0.2

Tightening 5 0.2

Loosening 360 (1 turn)

Tightening 2 0.2Angular tightening 285 5

B1DP05BC

6FZ


A = Washer thicknessX = Length under hea

ENGINE

EW 10 - All Types CYLINDER HEAD (con

Engine : RFN

Id tifi ti f th li d h d g k t


74/395

70


Nominal dimension Repair dimension

2 4 54 5

R1 R2

1.10.8Gasket thickness

(mm)

Supplier MEILLOR

Marking zone"e"

Marking zone"d"

1.4

Multilayer metallic gasket


Engine : RFN

Cylinder head tightening (m daN)


75/395

71

X = MA

NOTE : Oil the threads andunder the heads of the cylinder

head bolts. (Use engine oil orMolykote G Rapid Plus).

Pre-tightening 1.5 0.1

Tightening 5 0.1

Loosening 360 2

Tightening 2 0.75Angular tightening 285 5

B1DP05BC

RFN


A = Washer thicknessX = Length under hea

ENGINE

CYLINDER HEADXU - All Types

Engines : LFX - LFY - RFV - RFS



76/395

72


Engine type

Identification marks (Notch on cylinder head gasket) *

LFYLFX RFV

A 1

B 0

C 0D 0

E 0

A 0 0

0

1

0

0

B 1

C 0

D 0

E 0

CURTY

MEILLOR

Suppliers

B1BP004C



Cylinder head tightening (m daN)


77/395

73

X = MA

Note : Oil the threadthe heads of the cylbolts. (Use engine oMolykote G Rapid P

- Pre-tightening 3.5

- Loosening NO

- Tightening 7

- Angular tightening 160

- Pre-tightening 6

- Loosening YES

- Tightening 2


B1DP05BC

RFV - RFS

LFX - LFY

LFX

171.5 mm


ENGINE

DW8 - All Types CYLINDER HEAD

Id tifi ti f th li d h d k t

Engine : WJZ


78/395

74


Numberof holes

at B

Numberof holes

at A

Thickness(mm) 0.04

Enginetype

Pistonstand-proud

(mm) (*)

0.51 to 0.55 1.26 1

0.55 to 0.59 1.30 2

0.59 to 0.63 1.34 3

0.63 to 0.67 1.38 4

0.67 to 0.71 1.42 5

WJZ

(A) = Engine identification.

(B) = Thickness identification.

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

2

CYLINDER HEAD

Id tifi ti f th li d h d k t

Engine : DHY


79/395

75

0.56 to 0.67 1.36

0.68 to 0.71 1.40

0.72 to 0.75 1.44

0.76 to 0.79 1.48

0.80 to 0.83 1.52


Marking(B)

Thickness(mm) 0.06

Engine typePiston

stand-proud (mm)

DHY

(A) = Engine identification.

(B) = Thickness identification.

Engine Id

DHY 3B1BP10TC

ENGINE

DW10 - All Types CYLINDER HEA


Engine : RHY


80/395

76


Number of notchesat A

Thickness(mm)

Enginetype

Pistonstand-proud

(mm)

0.47 to 0.605 1.30 0.06 1

0.605 to 0.655 1.35 0.06 2

0.655 to 0.705 1.40 0.06 3

0.705 to 0.755 1.45 0.06 4

0.755 to 0.83 1.50 0.06 5

RHY


Engines : WJZ DHY - RHY



81/395

77

X = MANote : Oil the threads and under theheads of the cylinder head bolts. (Use

engine oil or Molykote G Rapid Plus).

- Pre-tightening 2

- Tightening 6


- Pre-tightening 2

- Tightening 6


B1DP14NC B1DP15ECB1DP13PC

DHY-RHY

WJZ

WJZ

125.5 mm

y g g ( )

WJZ

B1DP05BC

ENGINE Tools

ALL TYPES BELT TENSION/SEEM UNITS CORRESP

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


82/395

78

AUXILIARY EQUIPMENT DRIVE BELT

Engines : All Types Petrol and Diesel


83/395

79

TOOLS

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

- WARNING : If using tool 4099-T (C.TRONIC 105) refer to the correspondence table on page 57

ESSENTIAL.

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

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

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

ENGINE

SAXO AUXILIARY EQUIPMENT DRIVE

Without air conditioning

Engines : CDZ HDZ HFX (KFX KFW) Saxo (NFZ) S


84/395

80


- Fit the tool 4122-T.

- Tighten the tensioning screw (3)

to obtain :

55 3 SEEM units.

- Tighten the screws (2) and (1).

- Remove the tool 4122-T.

B1BP10UC B1BP10WC


Engine : NFZ (Xsara Picasso)

Without air conditio


85/395

81

Tools.

[1] Plyers for removing plastic pegs[2] Belt tension measuring instrument[3] TORX spanner

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

Refit.- Position the belt.- Hold the belt in position using the tensioner roller (2).- Pre-tension the belt 120 SEEM units, tool [2].- Lock the central screw (1) tool [3].- Remove the tool [2].

- Rotate the crankshaft 2 to 4 times.- Check the tension, 120 SEEM units.- If not, restart the operation.

B1BP234C

ENGINE

AUXILIARY EQUIPMENT

Engine : NFZ (Xsara Picasso)

With air cond

XSARA PICASSO


86/395

82

B1BP235C

Tools

[1] Plyers for removing plastic pegs : 75[2] Belt tension measuring instrument : 41[3] 10 mm square (drain spanner).[4] TORX spanner.

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

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

- Remove the tool [3].


Alternator

Engine : KFX - KFW (Xsara)


87/395

83

[1] Belt tension measuring instrument :4122-T

- Tension the belt using the screw (2).

- Tension should be :102 7 SEEM units.

- Tighten the screws (1).

- New belt100 SEEM units.

- Reused belt75 SEEM units.

Power-assisted steering

B1BP1B2C B1BP122C

ENGINE

AUXILIARY EQUIPMENT DRSAXO - XSARA

Without air conditioni

Engines : NFX - NFU


88/395

84

(1) Tensioner roller fixing screw.

(2) Tensioning screw.

- New belt : 120 SEEM units.

- Reused belt : 86.5 3.5 SEEM units.

(3) Tensioner roller fixing screw.

(4) Tensioning screw.

- New belt : 120 SEEM units.

- Reused belt : 86.5 3.5 SEEM UNITS.

NOTE : Removal of the tensioner roller makes it necessary to remov

With air conditioning

B1BP1ANC

B1BP1AMC



Engine : VJZ - VJY - VJX


89/395

85

- (6) Roller support fixing screw.

- (7) Tensioning screw.

- Pre-tension the belt (8) to : 120 SEEM units.

- Rotate the crankshaft by 3 turns (Direction of rotation).

- Adjust the belt (8) tension to : 120 SEEM units.

- Tighten the screws (6) to : 2.5 m.daN.

- Run the engine for 10 mm.

- Check the tension.

- (3) Roller support fixing screw


- Pre-tension the belt (4) to : 120 SEEM units.


- Adjust the belt (4) tension to : 120 SEEM units.

- Tighten the screws (3) to : 2.5 m.daN.- Run the engine for 0 mm.

- Check the tension.

With air conditioning.

ENGINE

XSARA AUXILIARY EQUIPMENT DRIVE

Without air condition

Engines : LFX - LFY - RFV


90/395

86

- (3) and (5) Roller support fixing screws.


- Tighten the belt, by loosening the screw (6) to : In SEEM units.



- Loosen the screws (3) and (5).

- Tighten the belt, by loosening the screw (6) to : In SEEM units.

- Tighten the screws (3) and (5) to 2 m.daN.

LFX

100 10 120 10

LFY

LFX

115 5 120 10

LFY



Engine : RFS


91/395

87

TOOLS

[1] Belt tension measuring instrument 4122-T

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

- Lightly tighten the screws (2).

- Place the tool [1] on the belt.

- Tension the belt using the screw (1).

Reused belt 90 SEEM units.

New belt 120 SEEM units.

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


- Rotate the crankshaft by 3 turns (direction of rotation).

- Check the belt tension using the tool [1], and adjust (if necessary).

B1EP12YCB1EP12XC

ENGINE

AUXILIARY EQUIPMENT DRIVEXSARA

With air condi



92/395

88

- Fit the drive belt.

- The tensioner roller (1).

- Tightening des vis (3) 2 m.daN.

- Move the tensioner roller (1) using the tool (9.52 mm

the tool or locking peg ( 4 mm) at (4).

- Slowly release the tensioner roller (1) so that the rol

B1BP1HJC

AUXILIARY EQUIPMENT DRIVE BELTEngine : RFV

With air conditioning.


93/395

89

- Loosen :- The screws (4) of the tensioner roller (13 mmangle spanner).- The screw (3).

- Tendre la courroie en agissant sur la vis (3) pour obtenir une v

- New belt : 120 SEEM units.- Reused belt : 90 SEEM units.



- Adjust the belt tension (if necessary ).

B1EP05FC

ENGINE

AUXILIARY EQUIPMEXSARA - XSARA PICASSOEngines : 6FZ - RFNWithout air conditioning

Tools


94/395

90

[1] Plyers for removing plastic pegs : 7504-T

Remove the belt.- Detension the belt (3) by turning the screw (2) of the tensioner ro

(anti-clockwise).

- The screw (2) (WARNING :not left hand screw).- Remove the belt (3), while keeping the tensioner roller (1) tight.

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

B1BP23PC B1BP23QC B1B


Without power-assisted steering

Engines : WJZ


95/395

91

Tools :

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

Removal.

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

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

B1BP1SDC

ENGINE


Without power-assisted steering With air condition

Engine : WJZ


96/395

92

Tools :

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

Removal.

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

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

B1BP1SFC


Power-assisted steering

Engine : WJZ


97/395

93

Too

[1] Belt tension measuring instrument :

Removal.

WARNING : If the belt is to be reused, me- Loosen :- The screw (1).- The nut (2).

NOTE : The tensioner arm (3) must be aga

- Remove the belt.

B1BP1SHD

ENGINE

AUXILIARY EQUIPMENT DRIVEEngine : WJZ

Power-assisted steering,

XSARA

Refitting


98/395

94

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

WARNING : Position tool [1], with- Tighten the nut (2) to obtain a val

Reused belt :Keep the value taken at removal.

New belt :Tension should be 110 SEEM units- Tighten the screw (1) to 9.5 m.da- Check belt tension (tool [1]).Tension should be 144 3 SEEM u- Remove the tool [1].- Start the engine and run it for 10 s- Stop the engine.- Place the tool [1] on the belt at "f

- Tension should be 130 4 SEEM- Remove the tool [1].


Power-assisted steering With

Engine : WJZ


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95

Tools :

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

Removal- Peg the dynamic tensioner (1) at "a", using tool [1].- Loosen the screw (2) of the roller (3).- Turn the roller (3) backwards.- Remove the belt.

NOTE : If it can not be pegged at "a" :- Loosen the screw (2) of the roller (3).- Using a 7 mm square drive, turn the roller (3) at "b".- Peg the tensioner (1) at "a", using tool [1].

NOTE : If the belt is broken :- Support the engine using a jack (insert a wooden blo- Remove the right engine support.

- Using a square drive at (b) turn the tool (3) in the direpegged at "a" using the tool [1].

B1BP1SKC

ENGINE


Power-assisted steering with

Engine : WJZ


100/395

96

Refitting.

- Refit the belt.

- Using a 7 mm square drive at "b", turn the roller

- Tighten the screw (2).


B1BP1SLC



Engine : DHY


101/395

97

[2] Belt tension measuring instrument : 4122-T

- Tension the belt by loosening the screw (4) to obtain :115 10 SEEM units



- Loosen the screws (1) and (3).

- Tension the belt to :115 10 SEEM units (if necessary)..

- Tighten the screws (1) and (3) to 2 m.daN.

ENGINE


With air condition

Engine : DHY


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98

Tools

(1) Peg : 7019-T.

.- Loosen the screws (1).

- Tighten or loosen the screw (2) until holes "a" and "b" are

- Place the peg [1] : (in the hole "a").

- Tighten the screw (2) until it is against its stop.

- Loosen the screw (2), in order to remove the peg [1].


AUXILIARY EQUIPMENT DRIVE BELTEngine : RHY

Without air co

Too


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99

Too

[1] Belt tension adjusting square[2] 4 mm peg[3] 2 mm peg[4] Dynamic tensioner compression lever

REMOVALRe-used belt

WARNING : Mark the direction the belt was- Compress the tensioner roller (2) by action - Keep the tensioner roller (2) compressed a

No re-use of belt.- Compress the tensioner roller (2) by action - Peg using tool [2], at "b".- Keep the tensioner roller (2) compressed a- Loosen the screw (1).

ENGINE

XSARA - XSARA PICASSO AUXILIARY EQUIPMENEngine : RHY

Without air co

REFITTING.


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100

REFITTING.Re-used belt.

- Compress the tensioner roller (2) by-Refit the belt.

WARNING : Respect the belt-fitting


New belt.

Refit the belt.

- Turn the eccentric roller (3), tool [1] (cl

- Hold the eccentric roller (3), tool [1

Remove the tool [2].

- Rotate the crankshaft 4 times in th

- Check that it is possible to peg at "

- If not possible to peg, restart the ad

AUXILIARY EQUIPMENT DRIVE BELTEngine : RHY

With air con

Too


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101

Too[1] Belt tension adjusting square[2] 4 mm peg [3] 2 mm peg [4] Dynamic tensioner compression lever

REMOVAL

Re-used belt.WARNING : Mark the direction the belt was- Compress the tensioner roller (7) by moving - Hold the tensioner roller (7) compressed aNo re-use of belt.- Compress the tensioner roller (7) by moving - Peg using tool [2], at "d".- Loosen the screw (6)- Bring the eccentric roller (5) towards the r- Tighten the screw (6) by hand.

- Remove the belt.

E

NGINE

XSARA - XSARA PICASSO AUXILIARY EQUIPMEEngine : RHY

With air con

REFITTING.


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102

Re-used belt.- Compress the tensioner roller (7) by- Refit the belt.WARNING : Respect the direction- Remove the tool [4].

New belt.- Refit the belt.- Turn the eccentric roller (5), tool [1

at "d".- Hold the eccentric roller (5), tool [1Remove the tool [2].- Rotate the crankshaft 4 times in th- Check that it is possible to peg at "- If not possible to peg, restart the ad

CHECKING AND SETTING THE VALVE TIMINGXTU

M

9

M+ JP JP+ 14 JP4

1 3 5

JB


107/395

Engine type CDZ HDZ HFX KFX KFW NFZ NFT NFU NFX LFX

SAXO X X X X X X X X

K 09/2000 XSARA X X X

XSARA 09/2000K X X

XSARA PICASSO X

See pages : 105 to 107

103

M M+ JP JP+ 14 JP4 JB

108 115to to

111 116

E

NGINE

CHECKING AND SETTING THE VALVE TIMTUD XUD

TUD - XUD

95

B TD


108/395

Engine type VJZ VJY VJX DHY

SAXO X X X

K 09/2000 XSARA X X

XSARA 09/2000K

XSARA PICASSO

See pages : 112 to 114 132

104

B TD

TOOLS

- [1] Flywheel locating peg : 4507-T.A[2] Camshaft pulley locating peg : 4507 T B

CHECKING AND SETTING THE VALVE TIMINGEngines : CDZ - HDZ - HFX - KFX - KFW - NFZ - NFT

Tool kit


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105

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

CHECKING THE VALVE TIMING.

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

SETTING THE VALVE TIMING.

NOTE : Remove the spark plugs, to allow the crankshaft to rotate more f- Rotate the engine by the crankshaft screw (1).- Peg the camshaft gearwheel.- Peg the flywheel.- Loosen the nut (2).- Totally slacken the belt by moving the tensioner roller.- Remove the belt.

ESSENTIAL : Check that the tensioner roller rotates freely (no stiffn

Tool kit

B1EP067C B1EP066C

E

NGINE

CHECKING AND SETTING THE VALVE TIMEngines : CDZ - HDZ - HFX - KFX - KFW - NFZ - NFT (Co

REFITTING THE TIMING

NOTE Ch k th t th [1] d [2] i l


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106

NOTE : Check that the pegs [1] and [2] are in place.WARNING : Ensure the belt is fitted in the right direction : The of rotation.Fit :- The timing belt, with the belt strip "b" well tightened, in the follow

Crankshaft pinion, camshaft pulley, water pump pulley, tensioner

-The tool [5] (Ensure it is fitted in the right direction in relation to th- Bring the tensioner roller into contact with the belt.-Tighten the nut (2).

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

CHECKING AND SETTING THE VALVE TIMINGEngines : CDZ - HDZ - HFX - KFX - KFW - NFZ - NFT (Continue

PRE-TENSIONING THE TIMING BELT (Cont.).

- Ensure the timing is correctly set by refitting the pegs [1] and [2]


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107

Ensure the timing is correctly set by refitting the pegs [1] and [2].- Remove the cylinder head cover.- Fit the tool [5] (Ensure it is fitted in the right direction in relation to the timing).

ADJUSTING THE BELT FITTING TENSION.

- Fit the tool [4] to the tightened belt strip.

- Loosen the nut (2).- Slacken the belt (not excessively).- Tighten the timing belt to obtain : 31 2 SEEM units.- Tighten the nut (2) to 2.2 m.daN.- Remove the tools [1] [2] [4] and [5].

CHECKING THE BELT TENSION.

- Rotate the crankshaft by 2 turns in the normal direction of rotation.- Check that the following components can still be pegged :- Flywheel.- Camshaft.

ESSENTIAL : If the components cannot be pegged, repeat the belt tensioning procedure.

E

NGINE

CHECKING AND SETTING THE VALVE TIMEngines : NFX - NFU

TOOLS


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108

- [1] Belt tension measuring instrument : 4122-T- [2] Flywheel locating peg : 4507-T.A.- [3] Camshaft pulley locating peg, exhaust : 4533-T.A.- [4] Camshaft pulley locating peg, inlet : 4533-T.A.- [5] Tensioning tool : 4707-T.J.

CHECKING THE VALVE

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

SETTING THE VALVE T

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

CHECKING AND SETTING THE VALVE TIMINGEngine : NFX - NFU (continued)

SETTING THE VALVE TIMING


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109

- Remove the tools [1], [2], [3] and [4].- Loosen the six pulley screws (1) on the hubs.

(There should be a slight amount of friction between the screws and th- Check that the rollers (2) and (3) rotate freely.

NOTE : The belt bears three identification marks *(a), (b) and (c), facing it* (Identification marks = white paint lines on the back of the belt facing

- Refit the belt.

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

- Hold the belt against the pinion (4).

E

NGINE

CHECKING AND SETTING THE VALVE TIMEngine : NFX - NFU (continued)

SETTING THE VALVE TIM

T h ll ( ) l k i h d f h l


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110

- Turn the two pulleys (1) clockwise to the end of the slots.

- With the belt strip (e) fully tensioned, place the belt over the pul

ensuring that marks (b) and (c) on the belt are aligned with mar

- Hold the belt in this position, and engage it over the water pump

- Fit the tool [1] on the belt strip (e).- Rotate the roller (2) (using tool [5]) in an anti-clockwise directio

- Tighten the roller (2) to 2 m.daN.

- Tighten the six screws (5) to 1m.daN.

ESSENTIAL : Check that :

- The camshaft pulleys (1) are not at the end of the slots (by rem

- The markings on the belt are aligned with the markings on the c

- If not, repeat the setting procedure.

CHECKING AND SETTING THE VALVE TIMINGEngines : NFX - NFU (Continued)



115/395

- Remove the tools [1] , [2] , [3] and [4].

- Rotate the engine by four turns in the normal direction. (do not turn backwards).

- Peg the flywheel [2].

- Loosen the six screws (5), while ensuring there is still a slight amount of friction with the pulley.

- Peg the camshaft hubs using pegs [3] and [4].

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

- Fit the tool [1].

- Loosen the tensioner roller screw (2).

- Rotate the roller (2) (using tool [5]) in an anti-clockwise direction to obtain : 37 SEEM units.

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

- Tighten the six pulley screws (1) to 1m.daN.

- Remove the tools.

111

E

NGINE

CHECKING AND SETTING THE VALVE TIMEngines : VJZ - V

TOOLS

- Belt tension measuring instrument : 4099-T or


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112

- Flywheel locating peg : 4507-T.A.

- Injection pump pulley locating peg : 4527-T. S1

- Camshaft pulley locating peg : 4527-T. S2

- Tensioning lever. : 4507-T.J.

- Pinion locking tool : 6016-T.

CHECKING THE VA

- Peg : the flywheel, the injection pump pulley, the cams

SETTING THE VAL

- Peg : the flywheel, the injection pump pulley, the cams

- Loosen the tensioner roller, and remove the belt.

ESSENTIAL: Check that the tensioner and guide rolle

the roller(s).

- Loosen the screws (1) and (3) (lock the pulley with too

- Position pulleys (2) and (4) to the end of the slots (with

B1EP07PC

CHECKING AND SETTING THE VALVE TIMINGEngines : VJZ - VJY - VJX (C

SETTING THE VALVE TIM


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113

- Fit the belt in the following order :The crankshaft pinion, the injection pump pulley, the camshaf

WARNING : When positioning the belt on the injection pum

be turned in the opposite direction of rotation so as to eng

- Pre-tension (belt strip slightly tightened).

NOTE : Check that the pulley fixings are not at the end of the

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

(Gently tighten the screws(1)and (3)by hand).

- Loosen the tensioner roller.

- Tension to 100 SEEM units.

- Tighten the tensioner roller to 2.3 m.daN.

B1EP07QC

E

NGINE

CHECKING AND SETTING THE VALVE TIMEngines : VJZ - VJY - VJX (Continued)


- Tighten the screws (1) and (3) to 2.3 m.daN (lock the pulleys using tool 6016-T).


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114

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

NOTE : If necessary, lightly slacken the belt (with the tensioner roller).

- Loosen the screws (1) and (3) by 360 (gently tighten the screws (1)and (3)by hand).- Set a final tension of 55 5 SEEM units.

- Tighten the tensioner roller, and the screws (1) and (3) to 2.3 m.daN (lock the pulleys using tool

- Remove the tools.

- Rotate the engine by two turns.

NOTE : If the belt is not correctly located on the pinions and pulleys, rotate it by an additional two

- Peg the flywheel.

- Check that the camshaft and injection pump pulleys are correctly pegged.

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

- Remove the tools.

CHECKING AND SETTING THE VALVE TIMINGEngine : LFX

TOOLS

Belt tension measuring instrument : 4099 T or 4122


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115

- Belt tension measuring instrument : 4099-T or 4122

- Camshaft pulley locating peg : 7004-T.G.

- Crankshaft locating peg : 7014-T.N.

- Square drive : 7017-T.W.

CHECKING THE VALVE T

- Remove the protective covers.

- Peg the camshaft pulley at "a" using the tool 7004-T.G.

- Peg the crankshaft at "b" using the tool 7014 - T.N.

SETTING THE VALVE TI

- Check that the pegs can be engaged correctly at "a" and "- Fit the belt in the following order : camshaft pulley, crankshaft p- Peg the camshaft pulley at "a" and the crankshaft pinion a- Remove the peg at "b" only.- Bring the tensioner roller (2) into contact with the belt.

B1EP07SC

ENGINE

CHECKING AND SETTING THE VALVE TIM

Engine : LFX (

SETTING THE VA

- Fit the tension measuring tool to the middle of the b


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116

- Turn the tensioner roller (2) (anti-clockwise direction)

measurement : 30 2 SEEM units.

- Tighten the screw (1) to 2 m.daN.

- Remove the tools.

- Rotate the crankshaft by two turns (do not turn ba

- Check the setting by positioning the pegs at "a" an- Remove the pegs.

CHECKING THE

- Rotate the crankshaft by two turns (do not turn ba

- Peg the camshaft pulley at "a".

- Fit the tension measuring tool on the belt strip at "c

- The tension measurement should be 44 2 SEEM

(If the measurement is not correct, repeat the tensi

- Remove the tools.

B1EP07RC

TOOLS

[1] Camshaft setting pegs : (-).0189.A[2] Crankshaft setting peg : (-).0189.B

CHECKING AND SETTING THE VALVE TIMING

Engine : 6FZ - RFN


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117

Tool kit C.0[3] Belt locking pin : (-).0189.K[4] Angular tightening adaptor : 4069-T[5] Hub immobilising tool : 6310-T

CHECKING THE VALVE TIMING..

- Turn the engine by the crankshaft pinion screw (3) to bring it to pegging- Peg the crankshaft, using tool [2].- Peg the camshaft pulleys, using tools [1].

NOTE : The pegs [1] must go in without effort.

ENGINE

CHECKING THE VALVE TIMING. (continued).


Engine : 6FZ - RFN


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118

WARNING : If the pegs do not engage without effort, restart t(see below).


Remove

- Remove the screws (2), the pulley (1), upper valve cover (4), lower - Turn the engine by the screw (13) of the pinion (12) to bring it to peg- Peg the pulleys (8) and (9) using tools [1].- Peg the pinion (12) using tool [2].- Loosen the screw (7) of the tensioner roller (6).- Turn the tensioner roller (6) (clockwise).- Remove the timing belt (10).

Refit (continued)- Refit the belt (10) on the pinion (12).- Hold the belt (10) with tool [3].- Position the belt (10) in the following order :


Engines : 6FZ - RFN


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119

Position the belt (10) in the following order :- The guide roller (11), the inlet camshaft pinion (9), the exhaust camsh

tensioner roller (6).

NOTE : Make sure that the belt (10) is as flush as possilble with the oute-Remove the tools [3] and [1].

Timing belt tensionAdjusting the tension- Turn the roller (6) in the direction of the arrow "b"; using an Allen key at-Position the index "c" in its maximum setting at "d".

IMPERATIVE : The index "c" must stand proud of the notch "f" by replace the tensioner roller (6) or the timing belt and the tensioner ro

- Bring the index "c" to its adjusting position "f" by turning the tenarrow "e" ;

WARNING: The index "c" must not stand proud of the notch "f" : if it does, r

IMPERATIVE : The tensioner roller (6) must not turn while its fixing is

mence the adjusting operation.

ENGINE

Adjusting the tension (continued).- Tighten the screw (7) of the the tensioner roller (6) to 2.1 0.2 m

IMPERATIVE : The hexagonal drive of the tensioner roller (6) m


Engines : 6FZ - RFN


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120

IMPERATIVE : The hexagonal drive of the tensioner roller (6) mhead gasket "g". If not, replace the tensioner roller (6) or the t

Refit (continued).- Remove the tools [1] and [2].

- Turn the crankshaft 10 times in the normal direction of rotation.IMPERATIVE : No pressure or outside action must be brought- Peg the inlet camshaft pulley, using the tool [1].

Checks.Timing belt tension

MPERATIVE : Check the position of the index "c", it should be facinot correct, restart the adjustment of its position.

Positioning of the crankshaft.- Fit tool [2].

- As long as it is possible to fit tool [2], continue with the refit operaIMPERATIVE : If it is not possible to fit tool [2], reposition the

Checks (continued)

Repositioning the flange


Engines : 6FZ RFN


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121

Repositioning the flange.- Immobilise the crankshaft using tool [5].- Loosen the screw (13).- Release the pinion (12) of the crankshaft.- Bring the flange (14) to the pegging position; using tool [5].

- Fit the tool [2].- Immobilise the crankshaft using tool [5].- Tighten screw (13) to 4 0.4 m.daN, then angular tighten 53 4with- Remove tools [1], [2] and [5].

Refit :- The lower valve cover (3).- The upper valve cover (4).- The crankshaft pulley (1).- The screws (2).- Pretighten the screws (2) to 1.5 m.daN.- Tighten the screws (2) to 2.1 0.5 m.daN.

EN

GINE


Engines : LFY - RFV - RFS

TOOLS

[1] Belt tension measuring instrument : 4122-T[2] Camshaft pulley locating peg : 9041-T.Z


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122

p y g p g[3] Crankshaft locating peg : 7014-T.N[4] Camshaft pulley locking peg : 4200-T.G[5] Tensioner spanner : 7017-T.W [6] Toothed sector for locking the flywheel : 9044-T

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

ESSENTIAL : Check that the crankshaft DAMPERS pullemarkings do not line up, the crankshaft pulley must be repl

- Peg the camshaft using the tool [2](The locating pegs [2] should slide in easily).

- If this is not the case, set the timing.

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


Engines : LFY - RFV - RFSLFY

Refit :Peg the crankshaft using tool [3]

SETTING THE VALVE TIMING.


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123

Refit :

- The pulley (5).- The screw (4) (Tighten mode- The peg [3].

Remove :- The tool [6].- The studs (8).- Fit the tool [4].- Loosen the screws (10).- Remove the tool [4].- Slacken the tensioner roller - Remove the belt (9).

- Peg the crankshaft using tool [3].- Peg the camshaft pulleys using

tool [2].- Lock the flywheel using the tool

[6].

Remove :

- The peg [3].- The screw (4) (Brush the screw

thread).- The pulley (5).- LThe lower cover (6).

B1EP12OCB1EP11XC

EN

GINE



Pretensioning the timing belt.

- Peg the crankshaft using the tool [3].- Peg the camshaft pulleys using the tool [2].NOTE : Ensure that the camshaft pulleys rotate freely on the h


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

- Tighten the screws of the roller (7) to 2 m.daN.- Fit the tool [4].- Tighten the screws (10) to 4 m.daN.- Remove the tools.- Rotate the crankshaft by six turns (Normal direction of rotation).

B1EP12OCB1EP11YC

Engine

New belt

LFY - RFV - RFS

55 SEEM units



Tensioning the timing belt.


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125

- Peg the crankshaft using the tool [3].- Peg the camshaft pulleys using the tool [2].

NOTE : If it is not easy to peg the camshaft hubs, loosen the tensioner

and turn the camshafts using the screw (10).

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

B1EP12OCB1EP11YC

EN

GINE



- Tension to : (Pulleys slackened).


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126

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

- Fit the tool [4].- Tighten the screws (10) to 7.5 m.daN.- Remove the tools.- Rotate the crankshaft by two turns (Normal direction of rotation).- Check the pegging of the crankshaft/camshaft using tools [2] and

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

- Remove the tools.

B1EP12OCB1EP11YC

Engine

New belt

LFY - RFV - RFS

35 SEEM units


Engine : WJZ

TOOLS

[1] HM screw : ( ) 0 188 E


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127

- [1] HM screw : (-) 0 188 E- [2] Locating peg 6 mm : (-) 0 188 H- [3] Flywheel locating peg : (-) 0 188 D ( ou 7014- [4] Toothed sector for locking the flywheel : (-) 0 188 F- [5] Belt retaining clip : (-) 0 188 K

- [6] Square drive for adjusting the tension : (-) 0 188 J- [7] Belt tension measuring instrument : 4122-T- [8] Toothed sector for locking the flywheel : 6016-T

Checking the valve timing

- Peg the flywheel using tool [3].- Visually check that the offset between the camshaft and injection pump

ging holes do not exceed 1 mm.

B1CP045C

EN

GINE


Engine : WJZ


Peg :The camshaft hub (1) using tool [1]


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128

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

- Lock the flywheel, using tool [4].

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

- Tighten the screw (3) to 4 m.daN and finish by carrying out an anof 60.

- Remove the tool [4].- Retighten screws (4) and (5) by hand.- Turn the pinions (6) and (2) so that they are at the end of their sto

direction).- Place the belt on the crankshaft and hold in place using tool [5].- Fit the belt in the following order:- Roller (7), pinion (2), pinion (6), pump (8) and roller (9).

B1EP131C B1B1EP130C


Engine : WJZ

SETTING THE VALVE TIMING (Continued)

NOTE : If necessary, slightly turn pinions (6) and (2) in an anti-clockwise diorder to fit the belt


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129

order to fit the belt.The angular movement of the belt in relation to the pinions must not exceed

- Fit the tool [7] to the belt strap at "a".- Turn the roller (9) (anti-clockwise) using tool [6], to obtain:

106 2 SEEM units.- Check that pinions (6) and (2) are not at the end of their stops.Otherwise, repeat the belt fitting procedure from the beginning.

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

B1EP134C B1CP045CB1EP133C

EN

GINE

EN

GINE


Engine : WJZ

SETTING THE VALVE TIMING (Continued).

Rotate the crankshaft by 8 turns (direction of rotation)


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130130

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

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

- The flywheel, using the tool [3].

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

B1EP134CB1EP133C


Engine : WJZ

SETTING THE VALVE TIMING (Continued)

Tighten :


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131

Tighten :- The roller (9) to 4.5 m.daN.- The screws (4) and (5) to 2.5 m.daN.


- Fit the tool [7] to the belt strap at "a".- The tensioning value should be between 42 2 SEEM units.

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

- Remove the tools [7]. [5]. [1]. [2] and [3].- Rotate the crankshaft by 2 turns (direction of rotation).

- Check the valve timing.

B1EP134CB1EP133C B1CP045C

EN

GINE


Engine :

TOOLS- Crankshaft locating peg- Camshaft and injection pump locating peg

CHECK


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132

- Peg the crankshaft.- Peg the pulleys (1) and (2) at "a" and b.

SETTING THE VAL- Peg the crankshaft.

- Peg the pulleys (1) at "a" and (2) at b.- Fit the belt in the following order :

Crankshaft pinion, guide roller (3), injection pump puwater pump (4).

- Remove the pegs.- Free the tensioner roller (5) (nut (6) and screw (7)), r- Rotate the crankshaft by 2 turns. Do not turn backw- Loosen the tensioner roller (5), allow the tensioner to- Retighten the screw (7) and the nut (6). Tighten to 1- Check the setting.NOTE : The injection pump is removed without changin

pulley using the screws (8x125)at b).B1EP09KC B1EP080C


Engine : RHY

Tools[1] Belt tension measuring instrument : 4122-T[2] Tension lever : (-).188.J2[3] Engine flywheel peg : (-).0288.D[4] Belt compression spring : (-).0188.K


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[ ] p p g ( )[5] Camshaft pinion peg : (-).0188.M[6] Engine flywheel lock : (-).0188.F[7] Set of blocking plugs : (-).0188.T[8] Crankshaft pulley extractor : (-).0188.P

Checking the setting of the valve timing.Peg :- The engine flywheel, tool [3].- The camshaft, tool [5].

WARNING : Should it be impossible to peg the camshaft, check that tbetween the camshaft pinion hole and the pegging hole is not more thawith the help of a mirror " a " and a 7 mm screw.

B1BP1TSCB1CP04CC

IMPERATIVE : If pegging is impossible, restart the adjusting(See corresponding operation).

EN

GINE


Eng

SETTING THEPeg :

- The engine flywheel, tool [3].

7/22/2019 S

Saxo Xsara Berlingo

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