engine cover Citroen XSARA 2004 1.G Workshop Manual

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GENERAL
IDENTIFICATION OF VEHICLESXSARA PICASSO
E1AP088D
A Chassis stamp
(Cold stamp on bodywork)
B Chassis no. reminder
(Label located at bottom of windscreen right hand side)
C Manufacturer’s data plate.
(Located at bottom of RH central pillar)
D Label :
Tyre pressures.
Tyre identification.
Spare wheel identification.
(Located on front LH door inner panel).
E Label :
Factory code.
AS / RP N°
Paint code.
(Located on fuse box cover)
F Gearbox identification ref.
G Engine legislation type.
Factory serial number.

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38
GENERAL
LUBRICANTS TOTAL recommended oils
Evolutions (year 2004).
CITROËN C2, C3 PLURIEL, DISPATCH and DV6 engines.
Only petrol versions are available.
Normal maintenance interval:
30 000 km (20 000 miles).
Severe maintenance interval:20 000 km (12 000 miles).
ESSENTIAL:For all vehicles with a 30 000 km (20 000 miles)main
tenance interval, use exclusively
TOTAL ACTIVA/QUARTZ 7000or
9000or any other oils offering identical specifications to these.
These oils offer specifications that are superior to those defined bynorms
ACEA A3 OR API SJ/CF.
Failing this, it is essential to adhere to the maintenance programmes
covering severe operating conditions.
Use of oil grade 10W 40.
It is possible to use semisynthandic oil 7000 10W40on PETROL and
DIESEL
vehicles.
WARNING:To avoid problems with starting from cold, use this oil as
allowed by the climatic conditions in the corntry concerned
(see table).
For more dandails see the oil usage table.
New commercial designation for energy economy oil.
The oil TOTAL ACTIVA/QUARTZ 9000 5W30becomes
TOTAL ACTIVA FUTUR 9000(for France),
QUARTZ FUTURE 9000 5W30(outside France).
The usage exclusions for this oil are the same as before:
XSARA VTS 2.0i 16V(XU10J4RS)
RELAY 2.8 TDi ;2.8 HDi(SOFIM engine)
HDi FAPvehicles
C3 1.6i 16V(DV4TED4)
C8 2.2i (EW12J4)

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ENGINE
SPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engine8HX
Cylinder head
Camshaft bearing covers
Pretightening
0,3 ± 0,1
Tightening1 ± 0,1
Fixing of camshaft subassemblies on cylinder head
Pretightening
0,3 ± 0,1
Tightening1 ± 0,1
Exhaust manifold3 ± 0,3
Camshaft pulley
Pretightening
0,3 ± 0,1
Tightening4,3 ± 0,4
Engine flywheel
Flywheel
Pretightening
1,7 ±0,2
Tightening70°±5°
Clutch mechanism2 ± 0,2
C2

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ENGINE
SPECIAL FEATURES TIGHTENING TORQUES (m.daN )
EngineKFU
Crankshaft
Accessories drive pulley0,8 ± 0,2
Pinion fixing on crankshaft
Pretightening
4 ± 0,4
Angular tightening45 ± 4°
Cylinder block
Sump0,8 ± 0,2
Accessories belt guide roller4 ± 0,4
Timing belt tensioner roller2,1 ± 0,2
Accessories belt tensioner roller2,5 ± 0,2
Alternator support2,5 ± 0,3
Crankshaft bearing caps
Tightening
2 ±0,3
Angular tightening44°(reused screws cleaned and greased)
Cylinder head
Coolant outlet housing0,8 ± 0,2
Camshaft bearing caps1 ± 0,2
Camshaft bearing cap covers0,9 ± 0,1
Inlet manifold0,8 ± 0,2
C3

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ENGINESPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engines 8HX 8HW 8HZ
Cylinder head
Camshaft bearing covers
Pretightening0,5 ±
Tightening1 ±
Fixings of camshaft subassemblies on cylinder head
Pretightening0,5
Tightening1
Exhaust manifold2,5 ± 0,2
Valve cover2,5 ± 0,2
Camshaft pulley4,3 ±0,4
Flywheel
Flywheel
Pretightening1,7 1,7
Tightening70°±5° 75° ± 5°
Clutch mechanism 2 ± 0,2
Lubrication circuit
Oil pump assembly
Pretightening0,5 ± 0,06
Tightening0,9 ± 0,1
Coolant/oil heat exchanger1 ± 0,1
C3 C3 PLURIEL XSARA

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ENGINE
SPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engines8HV 8HY
Crankshaft
Bearing cap fixing screw
Tightening3 ± 0,3
Angular tightening140° ± 1°,4’
Crankshaft pullet hub
Angular tightening180°±5°
Cylinder block
Oil sump1 ±0,1
Timing belt tensioner roller 4 ± 0,4
Timing belt guide roller
2,5 ±0,2
Timing belt guide roller support
Cylinder head
Camshaft bearing cap cover
1 ±0,1
Inlet manifold
Exhaust manifold2,5 ± 0,2
Cylinder head cover Screws (M6) to 1 ± 0,2
Camshaft pinion4,3 ± 0,4
Fuel high pressure pump pinion 5 ± 0,5
C3

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ENGINE
SPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engines9HZ 9HY
Cylinder head
Camshaft bearing covers
Pretightening0,5 ± 0,1
Tightening1 ± 0,1
Exhaust manifold 3 ± 0,3
Camshaft pulley
Pretightening2 ± 0,2
Angular tightening50 ±5°
Cylinder head
Pretightening2 ± 0,2
Tightening4 ± 0,5
Angular tightening260 ± 5°
EGR valve1 ±0,1
Flywheel Clutch
Flywheel
Pretightening3 ± 0,3
Angular tightening90 ±5°
Clutch mechanism2 ± 0,2
XSARA PICASSO

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engine: NFU
B1BP2MBC
Engine:NFU.
Setting the timing (continued).
Remove:
The bottom plastic casing.
The engine support
(9).
The middle support.
The timing cover
(8).
Peg the flywheel, using tool
[1].
Position the tools
[3a]and [3b].
B1BP2MFCB1EP18MC
C2 C3 C3 PLURIEL

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: KFW NFV
Pretensioning the timing belt (continued).
Make sure of the timing setting by refitting the pegs [1]and [2].
Remove the valve cover.
Position the tool
[5](respect the direction of fitting relative to the valve timing).
Adjusting the belt tension.
Place tool [4]on the tensioned part of the belt.
Slacken the nut (2).
Detension the belt, but too much.
Tension the timing belt to obtain a value of:
31 ± 2 SEEM units.
Tighten the nut (2)to 2 m.daN.
Remove tools [1], [2], [4] and [5].
Checking the belt tension.
Rotate the crankshaft 2 turnsin the normal direction of rotation.
Check that it is still possible to peg the following components. Flywheel.
Camshaft.
IMPERATIVE: Repeat the belt tensioning operation if the pegging is not possible.
XSARA XSARA PICASSO

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165
CHECKING AND SETTING THE VALVE TIMING
Engine: KFU
Tools.
[1]
Flywheel peg :4507T
[2]Camshaft peg: 4533TA.C1
[3]Crankshaft setting peg: ().0194.A
Checks.
Raise and support the vehicle, front wheels hanging.
Disconnect the battery.Remove:
The oil filter. The engine cover.
The upper timing cover
(1).
The sparking plugs, to ease rotation of the engine.
Rotate the engine by means of the crankshaft screw
(never turn the engine backwards).
B1BP2ZJD
C3