condition Citroen XSARA 2005 1.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 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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GENERAL
LUBRICANTS - TOTAL recommended oils
EVOLUTIONS (YEAR 2004).
CITROËN C4
Petrol engine versions except 2.0 i 16V 180 hp
(132 kW):
Normal maintenance interval: 30 000 km (20 000 miles).
Severe maintenance interval: 20 000 km (12 000 miles).
Petrol engine version 2.0L i 16V 180 hp
(132 kW):
Normal maintenance interval: 20 000 km (12 500 miles).
Severe maintenance interval: 15 000 km (10 000 miles).
Diesel engine versions:
WARNING: Vehicles HDi FAP (*) do not accept the energy economy
oil TOTAL ACTIVA FUTUR 9000 5W30 for France, TOTAL QUARTZ
FUTURE 9000 5W30 outside France .
DV6 engines:
Normal maintenance interval: 20 000 km
(12 500 miles).Severe maintenance interval: 15 000 km (10 000 miles).
DW engines:
Normal maintenance interval: 30 000 km (20 000 miles).Severe maintenance interval: 20 000 km (12 000 miles).
New Look CITROËN C5
Petrol engine versions:
Normal maintenance interval: 30 000 km
(20 000 miles).
Severe maintenance interval: 20 000 km (12 000 miles).
Diesel engine versions:
WARNING: Vehicles HDi FAP (*) do not accept the energy economy
oil TOTAL ACTIVA FUTUR 9000 5W30 for France, TOTAL QUARTZ
FUTURE 9000 5W30 outside France.
DV6 engines:
Normal maintenance interval: 20 000 km
(12 500 miles).Severe maintenance interval: 15 000 km (10 000 miles).
DW engines :
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 7000 or
9000 or any other oils offering identical specifications to these.
These oils offer specifications that are superior to those defined by
norms ACEA A3 OR API SJ/CF.
Failing this, it is essential to adhere to the maintenance programmes
covering severe operating conditions.
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GENERAL
LUBRICANTS - TOTAL recommended oils
Use of oil grade 10W40.
It is possible to use the semi-synthetic oil 7000 10W40on HDi and HDi
FAP vehicles.
WARNING: To avoid difficulties when starting from cold
(< 20°C), use
5W40 oil.
For more details, see the oil usage table
(paragraph 3.3).
Commercial description for energy economy oil.
TOTAL ACTIVA FUTUR 9000 5W30
(France only).
TOTAL QUARTZ FUTUR 9000 5W30 (except France).
The exclusions for use of this oil are the following:
- XSARA VTS 2.0 16V (XU10J4RS).
- JUMPER/RELAY 2.8 HDi and 2.8 TDi (SOFIM engine).
- HDi FAP vehicles.
- CITROËN C3 HDi 16V (DV4TED4).
- CITROËN C8 2.2i (EW12J4).
- CITROËN C4 and C5 2.0i (EW10A).
- CITROËN C4 (EW10J4S).
Engine oil norms.
Current norms.
The classification of these engine oils is established by the following
recognised organisations:
- S.A.E : Society of Automotive Engineers.
- API: American Petroleum Institute.
- ACEA: Association des Constructeurs Européens d'Automobiles.S.A.E. Norms - Table for selection of engine oil grade.
Selection of engine oil grades recommended for climatic conditions in
countries of distribution
(see table, paragraph 3.3).
Evolution of the norms to 01/01/2003.
ACEA 2003 norms.
The meaning of the first letter has not changed, it still corresponds
to the type of engine:
A: petroland dual fuelpetrol / LPG engines.
B: dieselengines.
The figure following the first letter corresponds to the type of oil:
3:high performance oils.
4:oils specifically for direct injection diesel engines.
5:very high performance oils permitting lower fuel consumption, specific to
direct injection diesel engines.
Example:
- ACEA A3: high performance oils specifically for petrol and dual fuel petrol/
LPG engines.
- ACEA A/B: blended oils giving very high performance for all engines, also
permitting better fuel economy, specifically for direct injection diesel engines.
NOTE: From 01/01/2003there is no longer any reference to the year of
creation of the norm
(example : ACEA A3/B3 98becomes ACEA A3/B3).
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GENERAL
LUBRICANTS - TOTAL recommended oils
Classes and grades of TOTAL recommended engine oils.
The oils distributed in each country are suited to the local climatic
conditions.
Blended oils for all engines
(petrol, diesel and dual fuel
petrol/LPG):
S.A.E. ACEA API
norms norms norms
TOTAL ACTIVA 9000 A3/B3/
TOTAL QUARTZ 90005W40
B4
TOTAL ACTIVA FUTUR 9000 (*)SL/CF
TOTAL QUARTZ FUTUR 9000 (*)5W30 A5/B5
TOTAL ACTIVRAC 10W40 A3/B3
(*) Blended oils for all engines giving fuel economy.
Oils for petrol, diesel and dual fuel petrol/LPG engines:
S.A.E. ACEA API
norms norms norms
TOTAL ACTIVA 7000
TOTAL QUARTZ 700010W40
TOTAL QUARTZ 9000 0W40 A3 SL
TOTAL ACTIVA 7000
TOTAL QUARTZ 700015W50Oils specifically for diesel engines:
S.A.E. ACEA API
norms norms norms
TOTAL ACTIVA DIESEL 7000
TOTAL QUARTZ DIESEL 700010W40
B3 CF
TOTAL ACTIVA DIESEL 7000 15W50
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GENERAL
LUBRICANTS - TOTAL recommended oils
TOTAL ACTIVA QUARTZ
Semi-synthetic 7000 Synthetic 9000
0W40 5W30 5W40 10W40 15W50
Hot countries
Temperate countries
Cold countries Engine types
EW10J4S (CITROËN C4) X
X
X EW12J4 (CITROËN C8 2.2i 16V)
EW10A (CITROËN C4 and C5)
HDi engines with FAP (*)
Others HDi engines
SOFIM 2.8 HDi and 2.8 TDi (RELAY)
DV4 TED4 (C3 1.6 16V HDi)
Indirect injection diesel engines Petrol engines
Diesel enginesOil usage table
X
X
XX
XX
X
XX
X
XX
X
X (*)
X
XX
X
XX
X
XX
X
XX
(*) Do not use this oil in cold climatic conditions
(temperature less than - 20°C).
See the table below for the choice of TOTALengine oil grades to be used according to the climatic conditions in the country of marketing.X Others petrol engines
X
X
X
X
X
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GENERAL
ENGINE OIL CONSUMPTION
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-INafter:
- 3,000 miles
(5,000 km)for a PETROLengine.
- 6,000 miles (10,000 km)for a DIESELengine.
III - MAXIMUM PERMISSIBLEoil consumption for a RUN-IN engine:
- 0.5 litres per 600 miles
(1,000 km)for a PETROLengine.
- 1 litre per 600 miles (1,000 km)for a DIESELengine.
DO NOT INTERVENE BELOW THESE VALUES.
IV - OIL LEVEL:The level should NEVERbe above the MAX.mark on the dipstick after changing or topping up the oil:
- This excess oil will be used up rapidly.
- It will reduce the engine output and adversely affect the operation of the air circuits and gas recycling.
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ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)
Accessories
53 Accessories support 2 ± 0,5
54 Guide roller 4,5 ± 0,5Engine: 9HX
D1AP02PC
Version without air conditioning
D1AP02QD
Accessories
55 Aircon compressor support 2 ± 0,5
56 Aircon compressor screw 2,4 ± 0,5
Version with air conditioning
C4
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123
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)
Accessories
53 Accessories support 2 ± 0,5
54 Guide roller 4,5 ± 0,5Engines: 9HY - 9HZ
D1AP02PC
Version without air conditioning
D1AP02QD
Accessories
55 Aircon compressor support 2 ± 0,5
56 Aircon compressor screw 2,4 ± 0,5
Version with air conditioning
C4
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