brake Citroen C4 2005 2.G Workshop Manual

Downloaded from www.Manualslib.com manuals search engine PRESENTATION
THIS HANDBOOKsummarises the specifications, adjustments, checks and special features of CITROËN private vehicles, not including UTILITY vehicles for which there exists a separate
handbook.
The handbook is divided into groups representing the main functions:
GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - AIR CONDITIONING.
In each section, the vehicles are dealt with in the following order: C4 - XSARA - XSARA PICASSO - BERLINGO and all models where applicable.
The information given in this handbook is based on vehicles marketed in EUROPE.
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Downloaded from www.Manualslib.com manuals search engine CLUTCH - GEARBOX - TRANSMISSION (continued)
Gearbox specifications312 - 314
Clutch specifications315 - 316
Checking and adjusting the hydraulic
clutch control317 - 318
Tightening torques: manual gearbox
319 - 330
Manual gearbox controls
331 - 343
Recommendations - precautions:
automatic gearbox344 - 346
Tightening torques: manual gearbox
347 - 349
Automatic gearbox controls
350 - 359
Driveshafts360
AXLES - SUSPENSION - STEERING
Axle geometry: C4361 - 364
Tightening torques: front axle365 - 366
Tightening torques: rear axle367
Tightening torques: power steering368 - 369
Setting the steering rack mid-point370
Checking the power steering pressure371 - 374
Axle geometry: Xsara375 - 379Adjusting the handbrake 426
Filling, bleeding the brakes427
AIR CONDITIONING
R134.a: quantities428
Checking the compressor lubricant429 - 430
Pollen filter: all types431 - 433
Filtering and drying cartridge434 - 436
Checking the efficiency of the circuit437 - 446
C4447 - 451
Xsara452
Xsara picasso453 - 456
CONTENTS
Tightening torques: front axle380
Tightening torques: rear axle382
Tightening torques: steering 383 - 384
Tightening torques: power steering385 - 387
Axle geometry: Xsara Picasso388 - 392
Tightening torques: front axle393
Tightening torques: rear axle394
Tightening torques: power steering395 - 397
BRAKES
Brake specifications: C4398 - 399
Tightening torques: Brakes401 - 403
Adjusting the handbrake 405
Filling, bleeding the brakes406 - 410
Brake specifications: Xsara411
Tightening torques 414
Brake specifications415 - 418
Adjusting the handbrake 419
Filling, bleeding the brakes420
Brake specifications: Xsara Picasso421 - 422
Brake specifications423 - 424
Aircon circuit
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GENERAL
Engine type
Engine with filter element
Between Min. and Max.
5-speed gearbox
Automatic gearbox
After draining
Hydraulic or brake circuit
Cooling circuit
Fuel tankKFW NFU RFN
3 3,25 4,25
1,5 1,5 1,7
21,9
66
33
With ABS = 0,50 Without ABS = 0,55
7
6,5
6,5 (1)
54
XSARA
CAPACITIES (in litres)
Petrol
ESSENTIAL: Systematically check the oil level using the oil dipstick.
1.4i 1.6i 16V 2.0i 16V
AUTO.AUTO.
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GENERAL
Engine type
Engine with filter element
Between Min. and Max.
5-speed gearbox
Automatic gearbox
After draining
Hydraulic or brake circuit
Cooling circuit
Fuel tank8HX 8HZ 8HX 8HZ 8HY WJY WJY RHY RHZ
3,75 4,5 3,75 4,5
1,8 1,5 1,8 1,5 1,2 1,8 1,4
2 1,8
8,3
5,3
With ABS = 0,50 Without ABS = 0,55
5,7 9 8,5
54
XSARA
CAPACITIES (in litres)
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
AUTO.
2.0 HDi
➔ RPO RPO➔ RPO RPO
9884 9885 ➔9884 9885 ➔(1) (2)
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GENERAL
Engine type
Engine with filter element filtrante
Between Min. and Max.
5-speed gearbox
Automatic gearbox
After draining
Hydraulic or brake circuit
Cooling circuit
Fuel tank capacity
NFV 6FZ RFN 9HZ 9HY RHY
3 4,25 3,75 4,5
1,5 1,7 1,55 (3) 1,4
1,81,8
6
3
0,58 litres
5,8 (1) and (2) 6,5 (1) and (2) 11 11 (1) and (2)
55 60
XSARA PICASSO CAPACITIES (in litres)
Diesel Petrol
1.6i1.8i 16 V 2.0i 16V 1.6 16V HDi
(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.
2.0 HDi
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GENERALEngine type
Engine with filter element
Between Min. and Max.
5-speed gearbox
Hydraulic or brake circuit
Cooling circuit
Fuel tank capacity
HFX KFW NFU 9HX WJY RHY
3 3,25 3,75 4,5
1,5 1,55 1,2 1,4
2 1,8
With ABS = 0,45 - Without ABS = 0,36
89
55 60
BERLINGO CAPACITIES (in litres)
Diesel Petrol
1.1i 1.4i1.6i 16V
2.0 HDi
1.9 D
(1)
(1) = Manual dipstick without twists but with a sphere.
ESSENTIAL: Systematically check the oil level using the oil dipstick.
1.4i 16V HDi
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GENERAL
LUBRICANTS - TOTAL recommended oils
BRAKE FLUID
Synthetic brake fluid
HYDRAULIC SYSTEM
WARNING: TOTAL FLUIDE LDS fluid cannot be blended withTOTAL LHM PLUS.
WARNING: CITROËN C5: Use exclusively TOTAL FLUIDE LDS suspension fluid.
All countriesTOTAL HYDRAURINCAGE
All countriesCITROËN fluid0,5Litre
1 Litre
5 Litres9979 05
9979 06
9979 07 PacksCITROËN Part No.
PacksCITROËN Part No.
Norm
Colour All countries
TOTAL FLUIDE LDS
TOTAL LHM PLUS
TOTAL LHM PLUS
Very cold countriesOrange 9979 A3
9979 A1
9979 A2 Green1 Litre
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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
HYDRAULIC CLUTCH CONTROL: CHECKS AND ADJUSTMENTS
Bleeding the hydraulic clutch control
Action the clutch pedal manually through its full travel: 7 timesrapidly down and up.
Allow the clutch pedal to come back up to its high position.
Fill the brake fluid reservoir to the maximum of its capacity.
Open the bleed screw at «c».
Action the clutch pedal manually through its entire travel: 7 times
rapidly down and up.
The last time, keep the clutch pedal fully down.
Reclose the bleed screw, at «c».
If necessary, repeat the operation.
Top up the brake fluid to the MAX.level of the brake fluid reservoir.
Work the clutch vigorously 40 times
.
Start the engine.
Apply the handbrake.
Engage a gear.
Check that the clutch starts to engage at a dimension (X)greater than or equal to 45 mm
(the dimension (X)is
given as a guide).
Repeat the bleed operations if necessary.
C5FP0FQC
XSARA PICASSO
B2BP04YC
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CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS/PRECAUTIONS: AL4 AUTOMATIC GEARBOX (SHIFT LOCK)
Engines: NFU - RFJ
C5FP0NZC
C5FP0P0C
SHIFT LOCK.
The «shift lock»is a system that locks the gear selection lever in position «P».
Unlocking the «SHIFT LOCK»
(normal operation).Switch on the ignition.
Press the brake pedal and keep it pressed.
Move the gear selection lever out of position «P».
Unlocking the «SHIFT LOCK»
(with an operating fault).
NOTE:It is impossible to unlock the «shift lock»with the «Normal operation»
method.
The fault may originate from one of the following components:
- «Shift lock».
- Gear lever position switch.
- Automatic gearbox ECU.
- Electrical harnesses.
- Battery voltage.
Remove:
- The gear lever cover (1)
(pull upwards).
- Unlock the «shift lock»by pressing at “a”with the aid of a screwdriver.
- Move the gear selection lever out of position «P».
C4
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