daN Citroen XSARA 2004 1.G Workshop Manual

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BRAKES
B3FP16ED
HANDBRAKE (Adjustment)
Adjustment (continued).
A
: Drum brakes.B:Disc brakes.(10)Nut for adjusting cable tensions.
Remove:
The rear wheels.
The drums
(according to version).
Release the handbrake.Use a gauge set to measure at
«a»the travel of the lever
from its stop.
Adjust the nut
(10)to obtain a travel of less than or equal
to 1 mmat «a».
Refit the brake drums without tightening them (according
to version).
Action the handbrake lever 8 times with an effort of 40 m.daN.
With the handbrake released, check the travel of the
lever at
«a», using a gauge set.NOTE:The travel should be less than 1 mmand more
than 0,05 mm.
Refit:
The brake drums. The wheels.
The central console.
Check the operation of the handbrake.
C2

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BRAKESBRAKE SPECIFICATIONS
Brake pedal gear Front brakes Rear brakes
(16)
Servo fixing: 2,2 ± 0,3
(17) Fixing on master cylinder: 2 ± 0,5(12)Yoke fixing on caliper:10,5 ±1
(13)Yoke fixing on caliper: 3 ± 0,3(14)
Rear caliper fixing on arm: 5,3 ± 0,5
(15)Yoke fixing on caliper:2,7 ± 0,5
Tightening torques (m.daN).
B3FP166DB3FP164CB3FP165C
C3 C3 PLURIEL

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BRAKES
B3FP16ED
HANDBRAKE (Adjustment)
Adjustment (continued).
(10)
Nut for adjusting cable tensions
Remove:
The rear wheels.
The drums
(according to version).
Release the handbrake.Use a gauge set to measure at
«a»the travel of the lever
from its stop.
Adjust the nut
(10)to obtain a travel of less than or equal
to 1 mmat «a».
Refit the brake drums without tightening them (accor
ding to version).
Action the handbrake lever 8 times with an effort of
40 m.daN.
With the handbrake released, check the travel of the
lever at
«a», using a gauge set.NOTE:The travel should be less than 1 mm and more
than 0,05 mm.
Refit: The brake drums.
The wheels.
The central console.Check the operation of the handbrake.
C3 C3 PLURIEL

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BRAKES
BRAKE SPECIFICATIONS
XSARA
Tighten the nuts (1)to 2.3 m.daN.
The clevis pin
(2)is held in place by a plastic clip.
B3FP10YD

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BRAKESBRAKE SPECIFICATIONS
Electrical circuit
ComponentsRef.
SupplierPart no.Observations
42wayconnector.
Integral to the hydraulic block..Changing only the ECU is prohibited.
2waygrey connector.
The sensors are inductivetype.Tightening torque:
0,8 ± 0,2 m.daN.
2waygrey connector.
The sensors are inductivetype.Mounted on the brake caliper support.
Nonadjustable airgap:
0,3 to 1,2 mm.
Tightening torque:0,8 ±0,2 m.daN.
2waygrey connector.
The sensors are inductivetype.
Mounted on the suspension arm.
Nonadjustable airgap:
0,3 to 1,2 mm.
Tightening torque:0,8 ±0,2 m.daN.
Incorporated in the COM 2000.
6wayblue connector.
Located on the central console.
6way connector.
Toothed wheel:
48 teeth.
Integral with the driveshaft stub housing for
the front wheels, joined to the hub bearing for
the rear wheels.
XSARA
5.7 ESP
0 265 006 389
0 265 006 202
0 265 006 203
0 265 006 441 BOSCH
VALEO
BOSCH
GKNElectronic
ECU
Front wheel sensor
Rear wheel sensor
(disc brakes)
Rear wheel sensor(Saloon: drum brakes)
Rear wheel sensor(Estate: drum brakes)
Steering angle sensor
Gyrometer/accelerometer sensor
Toothed wheel7
5
12
13
4

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BRAKES
BRAKE SPECIFICATIONS
Gyrometer sensor
(7) Hydraulic b lock
C4AP17YCB3HP002C
Observations
P art no.
Supplier
Components
XSARA
ESP
hydraulic blockBOSCH 5.7 ESPLocated on the front LH
wheelarch:4adjustment channels.
IMPERATIVE:Respect the direction of fitting of the gyrometer/accelero
meter sensor (connector towards the rear of the vehicle).
WARNING:The gyrometer/accelerometer sensor should not be subjected to any impact.Any gyrometer/accelerometer sensor havingsuffered an impact must be replaced.Tightening torque (15):0,6 ± 0,1 m.daN.

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ELECTRICAL
SYSTEM
C5HP073C
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Clickfit connector removing/fitting tool
Ø Inch
V ehicle
XSARA
XSARA
PICASSOTT
BP
HP5/8Black
8005T.A
3/8Red
8005T.C Ring colour Tool kit 4164T
Tightening torques (m.daN).
Unions
Steel/Steel
Aluminium/Steel Ø Pipes
1,7 ±0,3
1,3 ± 0,3 M 06
3,8 ± 0,3
2 ± 0,2
M 08
4 ± 0,3
2,5 ± 0,3 M 10
NOTE:Tighten the union to the recommended torque using a retaining spanner whenever possible.
NOTE:For operations concerning draining, drying (empty), checking and recharging of a system:refer to BRE 0290.
WARNING: For R 134.a quantities (see table on preceding page:483).
Aircon compressor fixings.
ESSENTIAL: Tighten the front part of the compressor(timing belt end), before the rear part of the compressor.

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AIRCON
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Changing the filtering/drying cartridge
Refitting.
Remove the new cartridge from its packaging.
Do not expose the cartridge, the filter and seals to pollutants.
Lightly oil the seals
(compressor oil).
Remove tool [5] from the reservoir (6).
Insert the new cartridge (5)into the reservoir (6).
Refit the safety circlip (4), using tool [6].
Make sure that the circlip (4)is correctly positioned in its location.
WARNING: Not more than 5 minutes should elapse between the removal of
the cartridge (6) from its packaging and its being fitted.
Refit:
The plastic cap (3), using tool [5] Tighten to 1,2 ±0,1 m.daN.
The condenser (reclip, pushing at «b»and «c»).
The plastic cover and the pins at «a».
The grille (2).
The screws (1).
Proceed to:
Recharge the circuit
(see corresponding operation).
Check the operation of the air conditioning (see corresponding operation).
C4AP167CC4AP165CC4AP164CC4AP163C
C2 C3 C3 PLURIEL

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AIRCON
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Changing the filtering/drying cartridge
Move aside the radiator/condenser assembly.
Remove the plug (6), using tool [2].
Support the radiator/condenser assembly thus moved aside.
Remove the filtering/drying cartridge
(7), using pliers.
Refitting.Refit the filtering/drying cartridge (7).
Clean the threads of the plug (6).
It is essntial to change the Oring seals (8).
Lubricate the Oring seals (8)with aircon compressor oil.
Refit:
The plug
(6), using tool [2], tighten to 1,4 ±0,2 m.daN.
The brackets (5).
The screws (4).
The cardboard from the radiator harness.
The nuts
(1).
The air filter assembly (3).
Couple the hose (2).
Recharge the circuit (R134.a) (according to equipment)
(see corresponding operation).
Check the operation of the air conditioning.
C5HP14NCC5HP14PCC5HP14QC
XSARA PICASSO

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SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Compressor lubricant
ESSENTIAL: The compressor lubricant is extremely hygroscopic; always use FRESH oil.
Checking the compressor oil level
There are three specific cases:
1/
Repairs to a system without leaks.2/Slow leak.3/Fast leak.
1/ Repairing a system without leaks.
a)Using draining/recovery equipment not fitted with an oil decanter.
Drain the system as slowly as possible via the LOW PRESSUREvalve, so as not to lose any oil.
No more oil should be added when filling the system with
R 134.a fluid.
b) Using draining/filling equipment fitted with an oil decanter. Drain the R 134.afluid from the system in accordance with the instructions in the equipment handbook.
Measure the amount of oil recovered.
Add the same amount of
NEWoil when filling the system with R 134.afluid.
c) Replacing a compressor. Remove the old compressor, drain it and measure the oil quantity.
Drain the new compressor (supplied full), so that the same amount of NEWoil is left in the compressor as was in the old compressor.
No more oil should be added when filling the system with R 134.afluid.
AIRCONAIRCON