Cylinder Citroen C4 2005 2.G Repair Manual

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ENGINEVALVE CLEARANCE SETTINGS
The valve clearances must be checked with the engine cold.
●Inlet
TU1JP - TU3JP
(except TU5JP4)
WJY
TU5JP4
DV4/DV6/EW10
All typesExhaust
Hydraulic adjustment 0,15 mm ± 0,08
0,30mm ± 0,08
Rocking
Adjust
1 ●1
3 ●3
4 ●4
2 ●24 ●4
2 ●2
1 ●1
3 ●3
Exhaust
●
Inlet Rocking
Valves
fully
openAdjust
1
3
4
23 ●4
4 ●2
2 ●1
1 ●3
Fully open (exhaust) POSSIBLE PROCEDURES
For engines with 4 cylinders in a line (1-3-4-2 )
Engines without hydraulic
adjustment: the clearance (J)
should be checked opposite
the cam.
B1DP13QC
0,20 mm ± 0,05
0,40 mm ± 0,05
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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS
Engines: KFU - NFU - RFN - RFJ - RFK - 9HX - 9HY - 9HZ - RHR
NOTE:All the clutches are «push»type with hydraulic control.
NOTE:The DV6TED4and DW10BTED4engines are equipped with a double damping flywheel (DVA).
Description.
The declutch control has a declutch fork with a ball-joint on the axis.
(1)The ball-joint is screwed into the clutch casing
(2) Declutch fork
(3)Clutch casing
(4)Bearing
(5) Clutch plate
The clutch control slave cylinder(7)is fixed by two screws (6) into the exterior of the clutch casing.
B2BP047C
B2CP3FAC
C4
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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS
Engines: KFW - NFU - NFV - 6FZ - RFN - 8HX - 8HZ - 9HY - 9HZ - WJY - RHY - RHZ
NOTE:All the clutches are «push»type with hydraulic control.
Description.
The declutch control has a declutch fork mounted on a ball-joint.
(1)The ball-joint is screwed into the clutch casing
(2)Declutch fork
(3)Clutch casing
(4)Bearing
(5)Clutch plate
The clutch control slave cylinder (7)is fixed by two screws (6)onto the exterior of the clutch casing.
T
ightening torques (m.daN).
Fixing of clutch plate/engine flywheel: 2 ± 0,2.
Fixing of clutch control slave cylinder / clutch housing: 2 ± 0,25.
Fixing of engine flywheel/crankshaft
Pre-tightening: 1,75 ± 0,2.
Angular tightening: 75° ± 5°.
Checking torque: 6,3 ± 2,2.
B2BP047CB2BP05SC
XSARA - XSARA PICASSO
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CLUTCH
GEARBOX
TRANSMISSION
HYDRAULIC CLUTCH CONTROL: CHECKS AND ADJUSTMENTS
B2BP04XC
IMPERATIVE: Use only new brake brake fluid that is not emulsified, avoid any
ingress of impurities into the hydraulic circuit.
IMPERATIVE: Do not use automatic bleeding equipment
(risk of the brake fluid
emulsifying in the hydraulic circuit).
Couple a transparent tube (5)on the bleed screw, at «c».
Submerge the end of the tube (5)in the recipient containing the brake fluid, located
below the level of the clutch slave cylinder.
Use the transparent tube (5) to act as a siphon, at «b».
WARNING: the end of the tube (5) must be submerged in the brake fluid.
Open the bleed screw at «c».
XSARA PICASSO
Bleeding the hydraulic clutch control
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CLUTCH
GEARBOX
TRANSMISSION
TIGHTENING TORQUES: MA/5 GEARBOX
Engines: KFU - NFU
Tightening torques (m.daN).
(6)Clutch bearing guide screw: 1 ± 0,1
(7)Bearing retaining clip screw: 1,8 ± 0,2
Intermediate plate fixing: 5 ± 0,5
Hydraulic clutch slave cylinder fixing: 3 ± 0,3
B2CP3ZJD
C4
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CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: ML6 GEARBOX CONTROLS
Engine: RHR
Peform the following operations simultaneously:
- Move the cylinder «f»in the direction of the arrow «e».
- Pull the locking key «c»in the direction of the arrow «d».
Check that the gear lever (18)is in the mid position on the control housing (17).
Couple the ball-joint (19).
Press on the locking key «c».
IMPERATIVE: Check that all the gears engage.
B2CP3ZWD
Adjustment of the gear selection control cable
C4
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BRAKES
22,2 (in valve) (1)
22,86/BOSCH/EVA2 (2)25,4/ BOSCH/MCT8 (2)
BOSCH/ZOH 54/22 BOSCH/ZOH 54/26
266 283
22/20 26/24
FEDERAL MODUL/F769 GALFER/G4554
BOSCH/TRW C38
249
9/7
GALFER/G4554
BRAKE SPECIFICATIONS
Master cylinder
ØAmplifier
FT mm Supplier/pistons
Disc Ventilated
Disc thickness
Brake pad grade
ØCylinder or caliper
RR mm Disc Plain
Disc thickness
Brake pad gradeWith ABS
ET3J4 TU5JP4 DV6 TU5JP4
Manual Auto.
(1) AFU system (EBA) =Emergency Brake Assist (incorporated as standard).(2) AFD system =Automatic lighting of hazard warning lamps on emergency braking (incorporated as standard).Brake fluid reservoir.Supplier: BOSCH, brake fluid quality: DOT 4.
The brake fluid reservoir is in 2 parts: the principal reservoir (equipped with a level detector)and a separate reservoir, they are linked by a rislan
pipe by means of a clickfit union.
C4
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BRAKES
23,8 (in click) (1)
25,4/ BOSCH/MCT8 (2)
BOSCH/ZOH 54/26TEVES/F
BOSCH/ZOH 54/26TEVES/F
N3 57/26 N3 57/26
283 302 283 302
26/24
GALFER/G4554 JURID 976 GALFER/G4554 JURID 976
BOSCH/TRW C38
249
9/7
GALFER/G4554
BRAKE SPECIFICATIONS
Master cylinder
ØAmplifier
mm
Supplier
FTpistons
Disc Ventilated
Disc thickness
Brake pad grade
ØCylinder or caliper
RR mm Disc Plain
Disc thickness
Brake pad gradeWith ESP
ET3J4 TU5JP4 EW10A/J4 EW10J4S DV6TED4/ATED4DW10
BTED4
Manual/Automatic
(1) AFU system (EBA) =Emergency Brake Assist (incorporated as standard).(2) AFD system =Automatic lighting of hazard warning lamps on emergency braking (incorporated as standard).Brake fluid reservoir.Supplier: BOSCH, brake fluid quality: DOT 4.The brake fluid reservoir is in 2 parts: the principal reservoir (equipped with a level detector)and a
separate reservoir, they are linked by a rislan pipe by means of a clickfit union.
C4
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BRAKESTIGHTENING TORQUES: BRAKING SYSTEM
Front brakes
7Braking amplifier2,2 ± 0,3
8Master cylinder on braking amplifier2 ± 0,5
Parking brake
9Parking brake lever1,5 ± 0,2
B3FP7DXD
B3FP7DYC
C4
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BRAKES
Without ABS 23,8 (expansion holes)With ABS 23,8 (valve)
228,6
BOSCH 54 LUCAS 57 BOSCH 54
266 283 266
22 / 20
FERF 769 ASFM 380 FERF 769
13 / 2
228 / 230 228 / 230
247 247
8 / 6 8 / 6
JURID
E 558 519 E 558 519
BOSCH/Load-sensitive compensator
32
0,3 - White
BRAKE SPECIFICATIONS
Estates
TU3JP TU5JP4 EW10J4 DW8 DV4TD DW10TDDW10
ATED
FTØ
mmMaster cylinder
Amplifier
Caliper makes/pistons
Disc
Disc thickness/min. thicknessVentilated
Brake pad grade
Thickness/min. thickness
RRØ
mmDrum - Ø min./max.
Disc non-ventilated
Make
Brake lining grade
Make/type
Cut-off pressure in bars
Ramp/paint reference
Disc thickness/min. thickness
XSARA
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