C8 2002 PDF

PRIVATE CARS
«The technical information contained in this document is intended for the exclusive use of the trained personnel of the
motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The
information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full
responsibility to the exclusion of that of the manufacturer».
«The technical information appearing in this brochure is subject to updating as the characteristics of each model in the
range evolve. Motor vehicle repairers are invited to contact the CITROËN network periodically for further information and
to obtain any possible updates».
2002
AC/QCAV/MTD ’’The intellectual property rights relating to the technical information contained in this document belong
Méthodes Techniques Documentation exclusively to the manufacturer. Reproduction, translation or distribution in whole or in part without
prior written authorisation from the manufacturer is forbidden.‘‘ 2002 CAR 050013
PRESENTATION
THIS HANDBOOK summarises the specifications, adjustments, checks and special features of the CITROEN C8.
The handbook is divided into the following sections representing the main functions :
GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH - GEARBOX - DRIVESHAFTS - AXLES - SUSPENSION - STEERING - BRAKES - HYDRAULICS -
ELECTRICAL - AIR CONDITIONING.
IDENTIFICATION OF VEHICLES
(A) Chassis stamp (cold stamp on bodywork).
(B) Manufacturer’s data plate (under RH centre pillar).
(C) A-S / RP No. and RP paint code

(label on front pillar).
GENERAL
(D) Inflation pressures and tyre references.
(label on front pillar)
(E) Gearbox reference – Factory serial no.
(F) Engine legislation type – Factory serial no.
E1AP0A2D
1
Petrol
2.0i 16V 2.2i 16V

Manual Automatic Manual
SX
X - SX SX X – SX Captain Chair
Captain Chair Exclusive Exclusive
Captain Chair
GENERAL
Emission standard IFL5

Type code EB RFNC/IF EB RFNF/IF EA RFNF/IF EB 3FZC/IF EA 3FZC/IF
Engine type RFN 3FZ
Cubic capacity (cc) 1998 2230
Fiscal rating (hp) 9 11
Gearbox type BE4/5 AL4 ML5C
Gearbox ident. plate 20 DL 27 (1) 20 DL 26 (2) 20 TP 74 20 LM 09
(1) = Right hand drive

(2) = Left hand drive.
2
Petrol
3.0i V6 S24
Automatic
Exclusive
Exclusive
Captain Chair
GENERAL
Emission standard IFL5
Type code SEB XFWF/IF EA XFWF/IF

Engine type XFW
Cubic capacity (cc) 2946
Fiscal rating (hp) 14
Gearbox type 4 HP 20
Gearbox ident. plate 20 HZ 27
3
Diesel
2.0 HDi (*) 2.0 HDi (**)

Manual Automatic Manual Automatic
SX SX
X – SX – Exclusive X – SX – Exclusive
Captain Chair Captain Chair
GENERAL
Emission standard L4
Type code EB RHTB EB RHTE EA RHTE EB RHWB EB RHWE EA RHWE
Engine type RHT RHW
Gearbox type ML5C AL4 ML5C AL4
Gearbox ident. plate 20 LM 05 20 TS 04 20 LM 05 20 TS 04
(*) = With particle filter.

(**) = Without particle filter.
4
Diesel
2.2 HDi (*)
Manual
SX
SX Captain Chair
Captain Chair Exclusive
Captain Chair
GENERAL
Emission standard L4
Type code EB 4HWB EA 4HWB

Engine type 4HW
Gearbox type ML5C
Gearbox ident. plate 20 LM 01
(*) = With particle filter.
5
GENERAL SPECIFICATION: LIFTING AND SUPPORTING THE VEHICLE
Tooling.
[1] Crossbeam : (-). 0010.
Front lifting on one side.
Position the jack (4) at the strongpoints provided for this purpose on each side
of the front crossmember between the bumper (2) and the engine (3).
Front central lifting.
Using a jack equipped with a crossbeam (sufficiently rigid) take the weight at the
two strongpoints on the front crossmember.
GENERAL
Side lifting.
At the front and at the rear
Take the weight at the sill, by means of the crossbeam [1], as close as possible
to the jacking point.
Position a stand at the jacking point provided for the purpose of lifting the
vehicle with the jack.
WARNING : Avoid the battery tray on the right hand side.
Side lifting at both front and rear
Take the weight at the sill, by means of the crossbeam [1].
Position stands at the jacking points provided for the purpose of lifting the
vehicle with the jack.
WARNING : Lifting at the rear of the vehicle using the crossbeam is
STRICTLY PROHIBITED.
E2AK02ZD E2AF006C E2AK030D E2AK031D
6
GENERAL SPECIFICATION: LIFTING AND SUPPORTING THE VEHICLE
Lifting by means of a two-column workshop lift
WARNING : The removing of components such as the engine/gearbox, rear sub-
frame etc, can cause a displacement of the centre of gravity: Use a lift equipped
with retaining devices to keep the body stable on the lift.
Without body clamps.
Place the lift’s guide pads at each jacking point.
WARNING : To prevent any risk of the vehicle toppling, it is prohibited to
remove mechanical components.
GENERAL
With body clamps
WARNING : These clamps are fitted only on FOG lifts.
Position the clamps at the sill in the jacking points provided, screw heads oriented
towards the outside of the vehicle. Tighten the clamps using the gudgeon pin and,
after tightening, engage the pin in the hole (A).
Towing (front).
Lift the blank with the aid of the flat part of the towing eye (1) and then screw the
eye home.
NOTE : The towing eye is to be found on the front panel inside the engine com-
partment.
Towing (rear).
Lift the blank (1) and screw the towing eye home.
E2AF004D E5AF022D E2AK02YD E2AK02XD
7
CAPACITIES (in litres)
Petrol Diesel
2.0i 16V 2.2i 16V 3.0i 24V 2.0 HDi 2.2 HDi
Auto. Auto. Auto.
Engine type RFN 3FZ XFW RHT - RHW 4HW

Engine angle
Engine with filter change 4.25 5.25 4.75
Between Min. and Max. 1.7 2 1.9 1.5
GENERAL
5-speed gearbox 1.8 2 2 2

Automatic gearbox 6 8.3 6
After oil change 3 5.3 3
Hydraulic or brake circuit 0.66 0.66
Cooling system 7 7.2 10.5 10 10.2 11.3
Fuel tank capacity 80 80
8
ENGINE
ENGINE SPECIFICATIONS
Engines : RFN - 3FZ - XFW - RHW - RHT - 4HW
Petrol Diesel
All Types
2.0i 16V 2.2i 16V 3.0i 24V 2.0 HDi 2.2 HDi
Engine type RFN 3FZ XFW RHT- RHW 4HW
Cubic capacity (cc) 1997 2230 2946 1997 2179
Bore / Stroke 85/88 86/96 87/82.6 85/88 85/96
Compression ratio 10.8/1 10.9/1 17.3/1 17.6/1
Power ISO or EEC KW - rpm 100-6000 116-5650 150-6000 79-4000 94-4000
Power DIN (HP - rpm) 138-6000 160-5650 204-6000 109-4000 130-4000
Torque ISO or EEC (m.daN - rpm) 19-4100 21.7-3900 28.5-3750 27-1750 31.4-2000
9
ENGINE
Engines : RFN – 3FZ
(1) Compulsory engine plate :
(A) Engine legislation type.
(B) Component reference.
(C) Factory serial no.
B1BB010D
10
ENGINE
SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)
Crankshaft bearing cap cover (15)
Description M11 M6
Pre-tightening 1 ± 0.1 0.5
Slackening Yes No
Re-tightening 1 ± 0.1 puis 2 ± 0.2 1 ± 0.1
Angular tightening 70° ± 5°
Crankshaft
(17) Flywheel/
Description (16) Con-rod caps
crankshaft fixing
Pre-tightening 1 ± 0.1 2.5 ± 0.2
Slackening Yes 18°± 1°
Re-tightening 2.5 ± 0.2 1 ± 0.1
Angular tightening 46° ± 5° 22° ± 2°
B1BK1X8D
11
ENGINE
Equipment on cylinder head
Engine : RFN Engine : 3FZ
B1BK1X9D B1BK1XAD
Description (18) Camshaft bearing cap covers (19) Valve covers

Pre-tightening 0.5 0.5
Tightening 1 ± 0.1 1.5 ± 0.1
Description (20) Inlet manifold (21) Exhaust manifold
Tightening 1 ± 0.1 3.5 ± 0.3
12
ENGINE
SPECIAL FEATURES: POWER UNIT SUSPENSION
Upper RH engine support Engines : RFN – 3FZ
Description RFN 3FZ
Ref.
(1) Rod/body fixing screw.. 5 ± 0.5
Engine support/torque reaction rod
(2) 4.5 ± 0.4
flexible stop pin
Upper support/intermediate 6.5 ± 0.6
(3)
support fixing screw.
(4) Upper support/body fixing screw 3 ± 0.3
B1BK1X5D
(5) Upper support/flexible
4.5 ± 0.4
support fixing nut.
Intermediate engine support
(6) Support
LH flexible support/LH engine
(7) 6.5 ± 0.6
support fixing nut.
(8) LH flexible support/body 3 ± 0.3

fixing screw.
(9) Intermediate engine support/gearbox 4.5 ± 0.4
casing fixing screw.
(10) LH intermediate support/gearbox 6 ± 0.6 4.5 ± 0.4
fixing screw.
B1BK1X6D (11) Flexible support pin. 5 ± 0.5
13
ENGINE
SPECIAL FEATURES: POWER UNIT SUSPENSION
Intermediate engine support Engines : RFN – 3FZ
Description RFN 3FZ
Ref.
Lower RH rod/subframe 9 ± 0.9
(12)
fixing screw.
Lower RH engine support/cylinder
(13) 4.5 ± 0.4
block fixing screw.
(14) Lower rod/lower RH engine

6.5 ± 0.6
support fixing screw
B1BK1X7D
14
ENGINE
CYLINDER HEAD
Cylinder head gasket identification Cylinder head tightening (m.daN) Cylinder head bolts
B1BK24QD B1DK001C B1DB002C
Multi-layer metallic gasket. Tighten in the order indicated X = MAXI re-usable

Cylinder head gasket thickness RFN 3FZ
(mm) 1/ : 1.5
Ref. Pre-tightening RFN 3FZ
2/ : 5
RFN 3FZ
Slackening 360°
(1B) : Nominal dimension E – H = 0.8 E – G = 0.8 Tightening 2
(1C) : Repair dimension E – F – H =0.99 E – F – G sans
Angular 144.5 mm 127.5 mm
(1D) : Manufacturer 285° 270°
tightening
identification.
15
ENGINE
SPECIAL FEATURES: VALVE TIMING
Engines : RFN - 3FZ
The camshafts are referenced following two methods.

- (1) Marking position (2) Paint rings.
- (3) Marking position (4) Marking at end of shaft.
- (5) Target for camshaft position sensor.
Marking position:
(1) Paint ring : Repair reference.
(2) Green paint ring : Factory reference.
(3) Inlet D1309 : Exhaust D1348.
(4) Inlet 96 332 713 99 : Exhaust 96 3425433 99.
Timing belt.
Width : 25.4 mm
Number of teeth : 153
Material : HSN
Valve clearances when cold

Inlet (A) : NON adjustable
Exhaust (E) : NON adjustable
B1EK1UCD
16
ENGINE
Engine : XFW
(A) Component reference.
(B) Engine legislation type.
(C) Factory serial no.
B1BK1JWD
17
ENGINE
Engine : XFW
Power unit suspension
RH engine support (Suspension) Gearbox suspension
B1BK24RD B1BK24SD
(2) Link rod fixing : 5 ± 0.5

(8) Fixing of gearbox support on LH flexible mounting : 6.5 ± 0.6
(3) Link rod fixing : 4.5 ± 0.4
(9) Shaft : 6.5 ± 0.6
(4) Fixing of upper RH engine support on intermediate engine
(10) Fixing of flexible mounting on support : 3 ± 0.3
support flexible mounting : 6 ± 0.6
(11) Fixing of flexible mounting support on body : 2.5 ± 0.2
(5) Fixing of RH engine support on flexible mounting : 4.5 ± 0.4
(12) Fixing of flexible mounting support on body : 2.5 ± 0.2
(6) Fixing of flexible mounting : 3 ± 0.3
(7) Fixing of RH intermediate engine support on cylinder block : 6 ± 0.6
18
ENGINE
Engine : XFW
Power unit suspension – Engine support (Lower) Crankshaft
B1BK24TD B1BK24UD
(17) Bearing cap Tightening : 2 ± 0.2

(13) Torque reaction link rod fixing : 9 ± 0.9 + Angular tightening : 74° ± 7°
(18) Timing pinion Tightening : 4 ± 0.4
(14) Fixing of link rod on torque reaction flexible mounting : 6.5 ± 0.6 + Angular tightening : 80° ± 8°
(15) Fixing of torque reaction flexible mounting : 4.5 ± 0.4 (19) Fixing of starter gear support flange, plus crankshaft
converter support Tightening : 2 ± 0.2
(16) Fixing of heat shield on torque reaction flexible mounting : 1 ± 0.1 Angular tightening : 60° ± 6°
(20) Accessory pulley on timing pinion : 2.5 ± 0.2
19
ENGINE
Engine : XFW
Cylinder block
Bearing cap cover
Respect the sequence of stages and the order of tightening

M11 M8
Reference/description Bolts from 1 Bolts from 9 M6
to 8 to 16)
(21) Fixings of bearings/cap covers or Stage 1 Stage 2 Stage 3

bearings/caps 3 ± 0.3 1 ± 0.1 1 ± 0.1
21) Fixings of bearings/cap covers or

Stage 4 Stage 4
bearings/caps NO
YES YES
(Slacken to zero torque.)
(21) Fixings of bearing cap cover or

Stage 5 Stage 6
bearing caps (Tighten bolt by bolt)
Tightening
3 ± 0.3 1 ± 0.1
+ Angular tightening
B1BK24VD 180° 180°
20
ENGINE
Engine : XFW
Lubrication circuit
Lubrication circuit. Oil sump
B1BK24WD B1BK24XD

(22) Oil separator : 0.8
Stage 1 : Do up bolts 13,15 and 17.
(23) Strainer : 0.8 Stage 2 : Tighten bolts 13,15 and 17 to : 0.2
(24) Induction pipe : 0.8 Stage 3 : Do up the 17 remaining bolts.
(25) Drain plug : 3 ± 0.3 Stage 4 : Tighten the remaining bolts to : 0.5
(26) Oil filter sleeve (with coolant/oil exchanger) : 0.5 Stage 5 : Tighten all the bolts : 0.8
Stage 6 : Repeat the tightening a few times in the same order to obtain
Oil filter : 0.2
a tightening torque of 0.8 m.daN on all the bolts.
21
ENGINE
Engine : XFW
Lubrication circuit Cooling circuit
Oil pump Coolant pump
B1BK3B6D B1BK3B7D
Stage 1 : Position the screws and do them up by hand. Stage 1 : Position the screws and do them up by hand.
Stage 2 : Pre-tighten the screws : 0.5 Stage 2 : Pre-tighten the screws : 0.5
Stage 3 : Tighten the screws : 0.8 Stage 3 : Tighten the screws : 0.8
Stage 4 : Repeat the tightening a few times in the same order to obtain Stage 4 : Repeat the tightening a few times in the same order to obtain a
a tightening torque of 0.8 m.daN on all the screws. tightening torque of 0.8 m.daN on all the screws.
22
ENGINE
Engine : XFW
Lubrication circuit Cylinder head equipment
Coolant manifold
B1BK24YD
(27) Screws : 2.5 ± 0.2

(28) Screws : 0.8
(29) Screws : 0.8
B1BK24ZD
23
ENGINE
Engine : XFW
Cylinder head equipment
Camshaft bearing cap cover (right hand side) Camshaft bearing cap cover (left hand side)
B1EK0GCC B1BK3B8D
(30) Camshaft bearing cap cover or camshaft bearing:
Pre-tighten to : 0.2
Tighten to :1
24
ENGINE
Engine : XFW
Valve covers (right hand side) Valve covers (left hand side)
B1EK0GEC B1EK0GFC
(31) Valve cover :
Tighten to : 0.8
25
ENGINE
Engine : XFW
Inlet manifold
B1BK251D
(32) Inlet manifold:
Tighten to : 0.8
26
ENGINE
Engine : XFW
Exhaust manifold (right hand side) Exhaust manifold (left hand side)
B1JK03ND B1JK03LD
(33) Exhaust manifold:
Pre-tighten to :1
Tighten to : 3 ± 0.3
27
ENGINE
Engine : XFW
Inlet distributor
B1BK252D
(34) Inlet distributor:
Tighten to : 0.8
28
ENGINE
CYLINDER HEAD
Engine : XFW
Identification of cylinder head gaskets
The RH and LH cylinder head gaskets are specific, of multilayer metallic type.
B1DK0QKD B1DK0QLD
Cylinder head gasket thicknesses

(a) : RH cylinder head gasket.
(1A) : Engine ref : G-H
(b) : LH cylinder head gasket.
(1B) : Nominal dimension: Without marking = 0.75 mm
V : Engine flywheel side.
(1C) : CRepair dimension : E (1st repair dimension R1) = 0.95 mm
(1C) : Repair dimension: E-F (2nd repair dimension R2) = 1.15 mm
29
ENGINE
CYLINDER HEAD
Engine : XFW
Cylinder head tightening (m.daN) Cylinder head bolts
Pre-tightening :2
Slackening : YES
Tightening : 1.5
Angular tightening : 225°
NOTE : Grease the bolts on the

threads and under the heads,
using engine oil or Molykote G
plus).
B1DK0QPD
X = MAX. re-usable
B1EK0XAD
149.5 mm
30
ENGINE
CYLINDER HEAD
Engine : XFW
Identification of camshafts
B1EK0WVD
The camshafts are identified by the following references:

A = Inlet camshaft (1) Exhaust camshaft E389 (Front)
(2) Inlet camshaft. A423 (Front)
E = Exhaust camshaft (3) Inlet camshaft. A422 (Rear)
(4) AExhaust camshaft E388 (Rear)
Timing belt
Width: 32 mm Number of teeth: 259
31
ENGINE
CYLINDER HEAD
Engines : RHT – RHW - 4HW
Identification of cylinder head gasket Cylinder head tightening (m.daN) Cylinder head bolts
NOTE : Grease the bolts on

the threads and under the
heads, using engine oil or
Molykote G plus).G Plus)
B1DK0Q6C B1DK00SC B1DK1M6D
Piston Hole at F Tighten in the order indicated X = MAX. re-usable

stand-proud Thickness Hole at
(mm) RHT 4HW G
(mm) Pre-tightening : 1/ 2
RHW RHT - RHW 4HW
2/ 6
0.55 to 0.60 1.25 ± 0.04 0 1 1 Slackening : 360°
0.61 to 0.65 1.30 ± 0.04 0 1 2 Tightening : 1/ 2
0.66 to 0.70 1.35 ± 0.04 0 1 3 2/ 6 134 mm 134.5 mm
Angular tightening : 220°
0.71 to 0.75 1.40 ± 0.04 0 1 4
32
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
Engines : RFN-3FZ
Tools
[1] Peg for dynamic tensioner roller (-).0189-E
Removing.
Remove:
The front RH wheel.
The front RH splash-shield.
BXXK08DD Detension the auxiliary drive belt by actioning the screw (1).
Peg the dynamic tensioner roller (2), using tool [1].
Remove the auxiliary drive belt.
ESSENTIAL : Check that the rollers (3) and (4) turn freely (no tight spot).
Refitting.
Refit the auxiliary drive belt.

Check that the auxiliary drive belt is correctly positioned in the grooves of the various pulleys.
Remove tool [1].
Continue the refitting operations in reverse order to removal.
BXXK0AUD
33
ENGINE
Engine : XFW
Tools
[1] Ratchet spanner FACOM (1/2" square).

[2] Reduction box FACOM S.230 (1/2" - 3/8" square).
Removing.
Move aside the power steering oil low pressure pipe flange.
Pivot the support (1) of the tensioner roller clockwise, as far as it will go, using tools [1] and [2].
B1EK0VAD Remove the auxiliary drive belt.
IMPERATIVE : Check the operation of the rollers (no play, no tight spot).
Refitting.
Position the auxiliary drive belt.

Commence with the crankshaft pulley (2).
Finish with the tensioner roller (3).
Free the support (1) of the tensioner roller, pivoting it anti-clockwise, using tools [1] and [2].
ESSENTIAL : Check that the belt is correctly positioned in the grooves of the various pulleys.

B1EK0VBD
34
ENGINE
Engine : RHT - RHW
Tools.
[1] Tensioning lever : (-).0188-J2.
[2] Peg for dynamic roller Ø 4 mm : (-) 0188-Q1.
[3] Peg for dynamic roller Ø 2 mm : (-).0188-Q2.
[4] Dynamic roller compression lever : (-).1888-Z.
(A) Pegging hole.

(B) Belt wear check mark (fixed on engine).
E5AK0E9C
(C) Zero wear mark.
(D) Maximum wear mark.
This marking system permits checking of the belt wear; if the marks (D) and (B) coincide, it implies that the belt
requires replacing.
Tighten the screw (1) to 4.5 ± 0.4 m.daN.
Removing
Remove:
- The front RH wheel.
- The front RH splash-shield.
- The under-engine shield.
B3EK0DHD
IMPERATIVE : Mark the direction of rotation of the belt if to be re-used.
35
ENGINE
Engine : RHT - RHW
Removing (continued).
Slacken the fixing (2).
Action the roller (3), using tool [1], until the tool [2] is positioned in the pegging hole (A).
Bring the roller (3) back towards the rear.
Gently tighten the screw (2).
Remove the belt.
ESSENTIAL : Check that the rollers (3) and (4) turn freely (no play, no tight spot).
Refitting.
IMPERATIVE: If re-using the belt, refit it respecting the direction of rotation marked on removal.
Refit the belt, finishing with the tensioner roller (4).
Action the roller (3), using tool [1] (clockwise) to free the tool [2].
Tighten the fixing (2) to 4.5 ± 0.5 m.daN, without altering the position of the roller.
Remove the tool [1].
Rotate the engine four times.
Check that the marks (B) and (C) coincide.
Tool [3] should be able to engage freely, if not, repeat the adjustment.
Complete the refitting.
B1BK1A4C
36
ENGINE
Engine : 4HW
Tools.
[1] Peg for dynamic roller : (-) 0188-Q1

[2] Dynamic roller compression lever : (-).1888-Z.
(A) Pegging hole.

(B) Belt wear check mark (fixed on engine).
(C) Zero wear mark.
E5AK0EDC
(D) Maximum wear mark. B3EK09PC
This marking system permits checking of the belt wear; if the marks (D) and (B)
coincide, it implies that the belt requires replacing.
Tighten the screw (1) to 4.5 ± 0.4 m.daN.
Removing.
Remove:
- The front RH wheel.
- The front RH splash-shield.
IMPERATIVE : Mark the direction of rotation of the belt if to be re-used.
E5AK0E8C
37
ENGINE
Engine : 4HW
Action the roller (3), using tool [2], until the tool [1] is positioned in the pegging hole (A).
Remove the belt.
ESSENTIAL : Check that the rollers (3) and (4) turn freely (no play, no tight spot).
Refitting.
IMPERATIVE: If re-using the belt, refit it respecting the direction of rotation marked on removal.
Refit the belt, finishing with the tensioner roller (3).
Rotate the engine four times.
Complete the refitting.
B1BK1IWD
38
ENGINE
BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE
Tools !
!
!
!
4099-T (C.TRONIC.105) 4122-T (C.TRONIC.105.5)
B1EP135D
39
ENGINE
Engines : All Types Petrol and Diesel
TOOLS
Belt tension measuring instrument : 4122 - T .(C.TRONIC 105.5)
WARNING : If using tool 4099-T (C.TRONIC 105), refer to the correspondence table on page 39.
ESSENTIAL:
Before refitting the auxiliary equipment drive belt, check that:
- 1 / The roller(s) rotate freely (no play or stiffness)
- 2 / The belt is correctly engaged in the grooves of the various pulleys.
40
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine : RFN
Tools.
[1] Crankshaft setting peg : (-).0189-B
[2] Camshaft hub setting pegs : (-).0189-AZ
[3] Belt retaining pin : (-).0189-K
[4] Positioning peg : (-).0189-J
[5] Tool for immobilising hub : (-).6310-T
Removing.
Disconnect the battery.
Remove:
B1EK1UDD B1EK0V7D
- The auxiliary drive belt (see corresponding operation).
Move aside:
- The fuel delivery pipe.
- The canister purge electrovalve.
- The expansion chamber.
Remove:
- The screws (1) and (2).
- The torque reaction rod (3).
- The screws (4), plus the auxiliary drive pulley.
- The timing covers (5) and (6).
WARNING : Do not slacken the fixing screws (A).
B1EK1T7D
41
ENGINE
Engine : RFN
Peg :
- The camshafts, using tool [2].

- The crankshaft, using tool [1].
Slacken the screw (7) while holding tool [4].
Using the hexagonal recess (C), turn the eccentric hub (8) of the tensioner roller
(9) (clockwise), to detension the belt. The cursor (10) moves against the tool [4].
Remove the timing belt.
B1EK1UED B1EK1UFD
42
ENGINE
Engine : RFN
Refitting.
Systematically replace the timing belt.
IMPERATIVE : Check that the rollers (9) and (11), as well as the coolant pump (12) turn freely (no
tight spot).
When replacing the belt (11), tighten the fixing to 3.5 ± 0.3 m.daN.
Position the belt on the crankshaft pinion (13), respecting its direction of fitting.
Immobilise the belt, using tool [3].
Refit the timing belt, well-tensioned, in the following sequence:

- Guide roller (11).
- Pinions (14) and (15).
- Coolant pump (12).
- Tensioner roller (9).
B1EK1T8D
43
ENGINE
Engine : RFN
Tensioning the timing belt.

Remove tool [3].
(D) : Max. position.
(E) : Nominal tension position.
Using the hexagonal recess (C), turn the roller hub (anti-clockwise), to bring the index (10) to position (D) to
tension the belt to the maximum.
Turn the eccentric hub (8) of the roller (9) (clockwise), to bring the cursor (10) into light contact with the peg [4].
IMPERATIVE : Never make a complete rotation of the eccentric hub (8) when tool [4] is in position.
B1EK1T9D
NOTE : This operation places the index (10) in the nominal position (E).
Tighten the screw (7) to 2 ± 0.2 m.daN while holding the roller by means of the hexagonal recess (C).
Remove the pegs [1], [2] and [4].
Checks.
Make two rotations of the crankshaft (direction of rotation of the engine).
IMPERATIVE : Never turn the crankshaft backwards.
Make sure that the timing is correctly set, by refitting the pegs [1] and [2].
Remove the pegs [1] and [2].
Make ten rotations of the crankshaft (direction of rotation of the engine).
Check the position of the index (10).
If the tensioner index is not in its adjustment position (E), recommence the operations to tension the timing belt.
B1EK1TAD
44
ENGINE
Engine : RFN
Positioning the crankshaft.
NOTE : This operation positions all the pegs in their respective pegging points.
Peg:
- The camshaft pulleys, using tool [2].
If this is not possible, reposition the flange (17).
B1EK1TBD
IMPERATIVE : This operation guarantees the setting of the timing for subsequent operations.
Slacken the screw (16) so as to free the crankshaft pinion (17).

Bring the flange (17) to the pegging point, using tool [5].
Position tool [1].
Tightening of screw (16) (Tool FACOM D360).
Tighten to : 4 ± 0.4 m.daN
Angular tighten to : 53° ± 5°.
Remove tools [1], [2] and [5].
IMPERATIVE : When tightening screw (16), hold the pulley (17) in position, using tool [5].
B1EK1TCD
45
ENGINE
Engine : RFN
Refitting (continued).
Refit:
- The timing cover (6).
- The auxiliary drive pulley.
- The screws (4), tighten to 2.1 ± 0.2 m.daN.

B1EK0V7D
- The screws (1) and (2), tighten to 4.5 ± 0.4 m.daN.
Refit the auxiliary drive belt (see corresponding operation).
B1EK1T7D
46
ENGINE
Engine : 3FZ
Tools.
[1] Crankshaft setting peg : (-).0189-B
[2] Exhaust camshaft setting peg : (-).0189-AZ
[3] Inlet camshaft setting peg : (-).0189-L
[4] Positioning peg : (-).0189-J
B1EK0V1D
[5] Tool for immobilising hub : 6310-T
[6] Belt retaining pin : (-).0189.K
[7] Engine support crossmember : 4090-T
Removing.
Remove:
B1EK1SJD - The under-engine shield.
Uncouple the exhaust line (to avoid damaging the flexible pipe).
Position the tool [7].
Move aside:
- The fuel delivery pipe.
- The canister purge electrovalve.
- The expansion chamber.
B1EK1SLD
47
ENGINE
Engine : 3FZ
Remove:
- The screws (1) and (2).

- The nut (4).
- The 3 screws (5).
- The RH engine support (6).
- The screws (7), plus the auxiliary drive pulley.
B1EK1SUD - The timing covers (8) and (9). B1EK1SMD
WARNING : Do not slacken the fixing screws (A).
IMPERATIVE : Do not slacken the fixing screws (B).
Peg:
- The exhaust camshaft, using tool [2].

- The inlet camshaft, using tool [3].
B1EK1SKD
48
ENGINE
Engine : 3FZ
Position tool [4].

Slacken the screw (10) while holding tool [4].
Using the hexagonal recess (D), turn the eccentric hub (11) of the tensioner roller (12) (clockwise), to detension
the belt. The cursor (13) moves against the tool [4].
Remove the timing belt.
Refitting.
Systematically replace the timing belt.

B1EK1SMD
IMPERATIVE : Check that the rollers (12) and (14), as well as the coolant pump (15) turn freely (No play,
no tight spot).
When replacing the belt (14), tighten the fixing to 3.5 ± 0.3 m.daN.
Position the belt on the crankshaft pinion (16), respecting its direction of fitting.
Refit the timing belt, well-tensioned, in the following sequence:
- Guide roller (14).
- Pinion (17).
- Pinion (18).
- Coolant pump (15).
- Tensioner roller (12).
B1EK1SND
49
ENGINE
Engine : 3FZ

Remove tool [6].
(E) : Max. position.
(F) : Nominal tension position.
Using the hexagonal recess (D), turn the roller hub (anti-clockwise), to bring the index (13) to position (E) to ten-
sion the belt to the maximum.
Turn the excentric hub (11) of the roller (12) (clockwise), to bring the cursor (13) into light contact with the tool [4].
IMPERATIVE : Never make a complete rotation of the eccentric hub (11) when tool [4] is in tension.
B1EK1SPD
NOTE : This operation places the index (13) in the nominal position (F).
Tighten the screw (10) to 2 ± 0.2 m.daN while holding the roller by means of the hexagonal recess (D).
Remove the tools [1], [2], [3], and [4].
Checks.
Make two rotations of the crankshaft (direction of rotation of the engine).
Make sure that the timing is correctly set, by refitting the camshaft and crankshaft setting pegs.
Remove the pegs.
Make ten rotations of the crankshaft (direction of rotation of the engine).
Check the position of the index (13).
If the tensioner index is not in its adjustment position (F), recommence the operations to tension the timing belt.
B1EK1SQD
50
ENGINE
Engine : 3FZ
Positioning the crankshaft.
NOTE : This operation positions all the pegs in their respective pegging points.
Peg:
- The inlet camshaft pulley, using tool [3].
If this is not possible, reposition the flange (20).
B1EK1SRD
IMPERATIVE : This operation guarantees the setting of the timing for subsequent operations.
Immobilise the crankshaft, using tool [5].

Slacken the screw (19) so as to free the crankshaft pinion (16).
Bring the flange (20) to the pegging point, using tool [5].
Position tool [1].
Tightening of screw (19) (Tool FACOM D360).
Tighten to : 4 ± 0.4 m.daN
Angular tighten to : 53° ± 5°.
B1EK1SSD
51
ENGINE
Engine : 3FZ
Refit:
- The auxiliary drive pulley.
B1EK1STD - The torque reaction rod (3).
Tighten:
- Screws (5) to 6 ± 0.6 m.daN
- Nut (4) to 4.5 ± 0.4 m.daN
- Screws (1) and (2) to 4.5 ± 0.4 m.daN
B1EK1SUD
52
ENGINE
Engine : XFW
Tools.
[1] Camshaft setting pegs : (-).0187-B
[2] Crankshaft setting peg : (-).0187-A
[3] Belt retaining pin : (-).0187-J
[4] Peg for checking camshaft settings : (-).0187-CZ
[5] Tool for immobilising inlet camshaft hubs : (-).0187-C
[6] Tool for immobilising exhaust camshaft hubs : (-).0187-F
[7] Instrument for measuring belt tension : (-).0192
Removing.
Remove:
The front RH wheel
The RH wheelarch.
The front RH tie-bar.
The auxiliary drive belt (see corresponding operation).
The tensioner roller assembly (1).
The crankshaft pulley (2).
Support the engine using a stand.

Remove:
The upper RH torque reaction rod.
B1EK004D The RH engine support.
53
ENGINE
Engine : XFW
Remove:
The twelve screws (3) (6 mm external hexagonal adaptor).

The seven screws (4) (7 mm external hexagonal adaptor).
The two covers (5).
The cover (6).
B1EK005D The fixing screws of the power steering pump, then suspend the latter. B1EK007D
The support (7).
NOTE : The camshaft pegging operation can be performed without slackening the
pinion screws or rotating the camshafts (using tools [5] and [6]; lightly oil the pegs
[1] and [2] prior to fitting.
Peg in the sequence:
Camshafts, using tool [1].

Crankshaft, using tool [2].
B1EK006D
54
ENGINE
Engine : XFW
Remove screw (8).

Slacken screws (9) and (10) and nut (11).
Pivot the tensioner roller eccentric (clockwise), using tool FACOM R 161 at «B».
Remove the guide roller (12).
Remove the timing belt, commencing with the tensioner roller and the coolant pump.
Refitting.
B1EK008D
Make sure that the camshafts, as well as the crankshaft, are correctly pegged.
Check that the rollers (13) and (14), as well as the coolant pump (15) turn freely (no tight
spots).
If replacing the belt, tighten the rollers (13) and (14) to 8 ± 0.8 m.daN.
Slacken screws (16) by a 1/4 turn.
Ensure that the camshaft pinions rotate freely on their hubs.
Turn the four camshaft pinions (clockwise), to end of slots.
Engage the timing belt on the crankshaft pinion.
B1EK009D
55
ENGINE
Engine : XFW
Position the belt on the guide roller (13), belt at (C) well tensioned.
NOTE : Carefully turn the camshaft pinion in the opposite direction to the rotation of the
engine in order to engage the belt on the pinion.
B1EK00AD
Engage the belt on the LH exhaust camshaft pinion (17).
IMPERATIVE : The angular displacement value of the pinion relative to the timing
belt should not be greater than the width of one tooth.
Engage the belt on the LH inlet camshaft pinion (18), as before.

Refit the roller (12), tighten to 8 ± 0.8 m.daN.
B1EK00BD
56
ENGINE
Engine : XFW
Engage the belt on:

The roller (13).
The camshaft pinions, inlet (19) then RH exhaust (20), as before for the camshafts.
Simultaneously engage the belt on:
The roller (21).
The pump (15).
B1EK00CD The roller (14).
Using tool FACOM S.161, at «A», pivot the plate to be able to engage the screw (8).
Tighten screws (8), (9) and (10) to 2.5 ± 0.2 m.daN.
Pivot the tensoner roller to tension the belt to the maximum (anti-clockwise), using tool FACOM R.161 at «B» :
- SEEM CTI 901-1 : 440 ± 15 SEEM units,
- SEEM CTG 105.5 : 83 ± 2 SEEM units,
- SEEM CTG 105.6 : 86 ± 2 SEEM units.
Tighten the nut (11) of the tensioner roller to 1 ± 0.1 m.daN.
IMPERATIVE : Check that the camshaft pinions are not at end of slots (by removing a screw).
If they are, repeat the operation to refit the belt.
B1EK00DD
57
ENGINE
Engine : XFW
Tighten at least two screws (16) per hub to 1 ± 0.1 m.daN, in the order indicated (17), (18),
(19) and (20).
Remove tools [4], [7], [1] and [2].
Effect two rotations of the crankshaft (direction of rotation of the engine).
WARNING : Never rotate the engine backwards.
B1EK00ED Peg the crankshaft, using tool [2].

Slacken the nut (11) a 1/4 turn.
Align the marks (D) and (E) of the tensioner roller, using tool FACOM R.161.
Tighten the nut (11) to 2.5 ± 0.2 m.daN, without altering the position of the roller.
Remove the crankshaft setting peg [2].
Effect two rotations of the crankshaft.
WARNING : Never rotate the engine backwards.
Peg the crankshaft, using tool [2].

Check the position of the tensioner roller.
If the marks are not aligned, recommence the alignment of the marks (D) and (E) of the
tensioner roller.
B1EK0VRD
58
ENGINE
Engine : XFW
Peg the camshaft hubs, starting with LH exhaust (17) then (18), (19) and (20), using tool
[1], proceeding in the following way:
- The peg goes in: slacken by 45° the fixing screws of the pinion on the camshaft hub,
- The peg does not go in: slacken by 45° the fixing screws of the pinion on the camshaft
hub until the peg will go in.
ESSENTIAL : Check that the camshaft pinions are not at end of slots (by removing
a screw).
If they are, repeat the operation to refit the belt.
B1EK00GD
Tighten the pinions in the sequence below:
Pinions (17), (18), (19), (20) tighten to 1 ± 0.1 m.daN.
Remove tools [1] and [2]
Checking the setting of the timing.

Effect two rotations (Normal direction of rotation of the engine).
IMPERATIVE : Never turn the engine backwards.
Refit the crankshaft peg [2].
Check that the peg for checking the camshaft settings [4] engages freely in the cylinder
heads (J), as far as the camshaft pinions.
B1EK00HD
59
ENGINE
Engine : XFW
Checking the setting of the timing (continued).
Should this not be the case, repeat the operation to refit the belt.
Remove the crankshaft peg [2].
Refit:
The power steering pump.
The support (7).
The tensioner roller assembly (1).
Tighten:
Screw (22) to 2.5 m.daN + LOCTITE FRNETANCH.
Tighten the crankshaft pulley screws to 2.5 ± 0.2 m.daN.
Complete the refitting operations in the opposite order to removal.
B1EK00JD
60
ENGINE
Engines : RHT-4HW
Tools :
[1] Instrument for measuring belt tension SEEM C.TRONIC : (-).0192

[2] Crankshaft setting peg (engine DW12TED4) : (-).0188-X
[3] Camshaft peg : (-).0188-M
[4] Belt retaining pin : (-).0188-K
[5] Engine flywheel stop : (-).0188-F
[7] Tensioning lever : (-).0188-J2
[8] Pulley extractor : (-).0188-P
[9] Crankshaft setting peg (engine DW10ATED4) : (-).0188-Y
[10] Crossmember : 4090-T
[11] Tie-bar support : 4176-T
[12] Retaining support : (-).0911-J
[13] Support with adjustable screw : (-).0911-H
[14] Set of plugs : (-).0188-T
Removing.
Remove:
- The front RH splashshield.
61
ENGINE
Engines : RHT-4HW
Removing.
Remove:
- The closing panel of the clutch casing (block the engine flywheel, tool [5]).
- The auxiliary drive pulley screw.
Refit the screw without the washer.
Remove:
B1EK0TVC - The auxiliary drive pulley, using tool [8]. B1EK0TUC
- The tool [5].
Turn the crankshaft.
Peg:
- The engine flywheel, tool [2] (engine DW12TED4).

- The engine flywheel, tool [9] (engine DW10ATED4).
B1EK1T4D
62
ENGINE
Engines : RHT-4HW
Move aside the header tank.
Position the tools for supporting the engine [10], [11], [12] and [13].
Remove:
- The scuttle panel grille.
- The fuel unions (2).
B1EK1TTD IMPERATIVE : Plug the apertures using tool [13].
Protect the radiator harness with strong cardboard cut out to the dimensions of the radiator.
Remove:
- The timing covers (3).
- The lower timing cover.
Peg the camshaft pulley, using tool [3].
Slacken the tensioner roller fixing (5).
Retighten the fixing to the position of maximum de-tension. (Tighten to 0.1 m.daN).
Remove the timimg belt.
B1EK1T2D
63
ENGINE
Engines : RHT-4HW
Refitting.
IMPERATIVE : Check that the rollers (5) and (6) as well as the coolant pump (7) turn freely (no play, no tight
spot), check also that these rollers are not noisy and/or that they are not throwing out grease.
In the event of replacement, tighten the roller (6) to 4.3 ± 0.4 m.daN.
Slacken the screws (8).
Check that the pulley (9) turns freely on its hub.
Tighten the screws (8) by hand.
Slacken the screws (8) by a 1/6 turn.
Turn the pulley (9) (clockwise), to end of slots.
B1EK0TXC
Refit the timing belt, well tensioned, in the following order:
- Crankshaft (immobilise the belt, using tool [4]).
- Guide roller (6).
Engage the timing belt on the pulley (10).
Carefully turn the camshaft pinion in the opposite direction to the rotation of the engine in order to engage the belt
on the pinion.
WARNING : The angular displacement «a» of the pulley relative to the belt should not be greater than the width of
one tooth.
Engage the belt on the tensioner roller (5) and on the coolant pump pinion (7).
Turn the tensioner roller (5) (anti-clockwise), so as to put the tensioner roller (5) in contact with the belt.
Pre-tighten the fixing screw of the tensioner roller to 0.1 m.daN.
B1EK0TYC
64
ENGINE
Engines : RHT-4HW
Pre-tensioning the timing belt.
Position the tool [1].
NOTE : Check that the tool is not in contact with anything else around it.
Turn the roller (5) (anti-clockwise), using tool [7] to obtain a tension of:
98 ± 2 SEEM units.
Tighten the screw (11) to 2.3 ± 0.2 m.daN (without modifying the position of the roller).
IMPERATIVE : By removing one of the screws (8) on the pulley (9), make sure that
these screws (8) are not at end of slots. (If they are, repeat the operation to refit the
timing belt).
Bring the screws (8) into contact with the pulleys.

Tighten the screws (8) to 2 ± 0.2 m.daN.
Remove the setting pegs [3] and [2].
Effect eight turns of the engine in the normal direction of rotation.

B1EK1TSD
65
ENGINE
Engines : RHT-4HW
Refit the pegs [2] and [3].

Slacken the screws (8).
Tighten the screws (8), by hand.
Slacken the screws (8) by a 1/6 turn.
Slacken screw (11).
Place tool [1] on the belt at (A).
Turn the roller (anti-clockwise),using tool [7] to obtain a tension of:
51 ± 2 SEEM units.
Tighten screw (11) to 2.3 ± 0.2 m.daN. (without modifying the position of the roller).
Tighten the screws (8) to 2 ± 0.2 m.daN.
Remove tool [1] to release the internal forces.
Refit the tool [1].
The tension value should be between 48 and 55 SEEM units.
IMPERATIVE : Value noted outside the tolerance: detension the belt and recommen-
ce the operation
B1EK1T1D
66
ENGINE
Engines : RHT-4HW
Checking the timing setting.

Effect two turns of the engine in the normal direction of rotation, without turning the engine
backwards.
Refit the peg [2].
IMPERATIVE : Check visually that the offset between the hole in the camshaft hubs
and the corresponding pegging hole is not more than 1 mm.
Remove the peg [2].
Refit:
- The lower timing cover.
- The elements (3) of the timing cover.
- The engine support (4).
- The nut (12), tighten to 4.5 ± 0.4 m.daN.
IMPERATIVE : Apply an opposite torque at (A).
Refit:
- Screw (14), tighten to 5 ± 0.5 m.daN.
- Screw (15), tighten to 5 ± 0.5 m.daN.
B1EK1T0D
67
ENGINE
Engines : RHT-4HW
Refit:
- The tool [5].
- The auxiliary drive pulley
Clean the threads of the pulley screw going into the crankshaft, (Tap M16x150).
Brush the screw threads.
Nettoyer le taraudage de la screws de poulie dans le vilebrequin. (Taraud M16x150).

Brosser le filetage de la screws.
Tightening torque for the screw:

Tighten to : 7 ± 0.7 m.daN (+ LOCTITE FRENETANCH)
Angular tighten : 60° ± 6° (Outil FACOM D360).
Check the tightening: 26 ± 2.6 m.daN
Remove tool [5].

Refit the closing plate, tighten to 0.7 m.daN.
Tighten the wheel bolts to 10 m.daN.
Complete the refitting in reverse order to removal.
Initialise the various ECUs.
B1EK0TVC
68
ENGINE
COOLING SYSTEM SPECIFICATIONS
Vehicle with air conditioning
Engines : RFN – 3FZ – XFW – RHT – 4HW
2.0i 16V 2.2i 16V 3.0i 24V 2.0 HDi 2.2 HDi
Circuit capacity 7 litres 7.2 litres 10.5 litres 10 litres (*) 11.3 litres
Radiator surface 25 dm3
Pressurisation 1.4 Bar
Opening of thermostatic 89°C 78°C 89°C
regulator
Cooling fan 1x350W (**) 1x350W 1x350W +1x300W 1x400W +1x300W (***) 1x460 + 1x300W
97°C or 10 Bars 97°C or 10 Bars
1st speed in aircon circuit in aircon circuit
101°C or 17 Bars 97°C or 10 Bars 101°C or 17 Bars 105°C or 22 Bars
2nd speed in aircon in aircon in aircon in aircon
circuit circuit circuit
105°C or 22 Bars
3rd speed in aircon circuit
Aircon cut-out 115°C 112°C 115°C
Warning 118°C
Post-cooling No
(*) = (*) = With automatic gearbox : 10.2 litres ; (**) = With automatic gearbox = 1x460W ; (***) = With automatic gearbox = 1x350W+1x300W
69
ENGINE
EXHAUST SPECIFICATIONS
Petrol engines all types
Repair
Respect the precautions to be taken when operating on a vehicle.

The flexible pipe must not come into contact with corrosive products.
Do not distort the flexible pipe by more than 20° angular (X), 20mm axial, 25 mm shear (Y)
(flexible pipe not fitted).
Do not distort the flexible pipe by more than 3° angular (X), 0 mm axial, 3 mm shear (Y)
(flexible pipe in place).
WARNING : Non-respect for these precautions will result in a reduction in the lifetime of
the flexible pipe. It is thus essential to disconnect or remove the exhaust line in any ope-
ration necessitating the lifting of the power unit.
B1JP02JC
70
ENGINE
Engines : RFN-3FZ
Tightening torques (m.daN)
(1) Bicone collar Ø 74.5 mm

Fixing of catalytic converter/manifold pipework : 2.5 ± 0.4
(2) Flexible metallic pipe
(3) Lambda probes take-off : 4.7 ± 0.7
(4) Catalytic converter
(5) Intermediate silencer
(6) Rear silencer
A and A’ : After sales cutting zones.

Connecting sleeve Ø 55 mm : 5.2 ± 0.7
B1JK05YD
71
ENGINE
Engine : XFW
(1) Front precatalyser
(3) Bicone collar Ø 66 mm

(front/rear precatalyser assembly) : 2.5 ± 0.4
(4) Rear precatalyser
(6) Catalytic converters
(8) Rear silencer
(9) Upstream lambda probe take-off : 4.7 ± 0.7
(10) Downstream lambda probe take-off : 4.7 ± 0.7
A and A’ After sales cutting zones.

B1JK05ZD
72
ENGINE
Engines : RHT-4HW
With particle filter
(1) Ball-joint front fixing bracket : 4.5 ± 0.7
(2) Precatalyser
(4) Particle filter
(5) Bicone collar Ø 74.5 mm : 2.5 ± 0.4
(6) Rear silencer
(7) Catalytic converter bracket (P. filter) : 3.3 ± 0.5
(8) C. converter and p. filter pressure take-off : 1.7 ± 0.1
B1JK060D
73
ENGINE
Engine : RHW
Without particle filter
(1) Ball-joint front fixing bracket : 4.5 ± 0.7
(2) Precatalyser
(5) Rear silencer
A and A’ After sales cutting zones.

B1JK061D
74
ENGINE
CHECKING THE OIL PRESSURE
Petrol engines
2.0i 16V 2.2i 16V 3.0i 24V
Engine type RFN 3FZ XFW
Temperature (°C) 80°C
Pressure (Bars) 1.5 5 3.4 6.3 6.9 1.2 2 5
Rpm 1000 3000 1000 2000 4000 650 900 3000
Diesel engines
2.0 HDi 2.2 HDi

Engine type RHT- RHW 4HW
Temperature (°C) 80°C
Pressure (Bars) 2.0 4.0 2.0 4.0
Rpm 1000 2000 1000 2000
Tools (Toolkit 4103-T).
[1] Pressure gauge
[2] Flexible pipe
[3] Union 4202-T
ESSENTIAL : Respect the safety and cleanliness recommendations.
WARNING : Checking the oil pressure should be done when the engine is hot, after having checked the oil level.
75
ENGINE
OIL FILTERS
To be read together with the Petrol and Diesel correspondence tables
2.0i 16V – 2.2i 16V 3.0i 24V 2.0 HDi – 2.2 HDi
LS 880 X
PURFLUX
LS 923 X X
Ø (mm) Height (mm)

LS 880
Specifications 86 140
LS 923
76
CLUTCH SPECIFICATION
Petrol Diesel
2.0i 16V 2.2i 16V 2.0 HDi 2.2 HDi
DRIVESHAFTS
GEARBOX
CLUTCH
Engine type RFN 3FZ RHT - RHW 4HW
Gearbox type BE4/5 ML5C
Feature «Push» clutch «Pull» clutch
Supplier VALEO LUK
Mechanism / type 230 DNG 4700 230 DNG 5100 225 T 5700 242 T 6500
Clutch disc 11 R 14 X Clutch with double damping flywheel (DVA)
No. of splines
Ø of lining. Ext/Int 228/155 225/150 242/162
Quality of lining F 808
77
CLUTCH SPECIFICATION
Engines: RFN – 3FZ – RHT – RHW – 4HW
«Push» clutch
DRIVESHAFTS
GEARBOX
CLUTCH
«Push» clutch and «Pull» clutch.
(1) Clutch disc.

B2BB000D
«Pull» clutch (2) Clutch plate.
(3) Clutch bearing.
B2BK22WD
78
HYDRAULIC CLUTCH CONTROL SPECIFICATION
Engines : RFN-3FZ-RHT-RHW-4HW
Bleeding the hydraulic clutch control.

Composition of the hydraulic circuit.
- Brake fluid reservoir located on the master cylinder.
DRIVESHAFTS
- Hydraulic control sender located in the passenger compartment and fixed on the pedal gear.
GEARBOX
CLUTCH
- Clutch pedal.
- Hydraulic control receiver fixed on or inside the clutch housing, depending on gearbox type.
Bleed.
IMPERATIVE : Use only new, clear brake fluid, avoid entry of any foreign bodies or impurities into the hydraulic circuit.
Use only hydraulic fluid that is approved and recommended : DOT4.
IMPERATIVE : Do not use any automatic bleed apparatus (risk of the fluid emulsifying in the reservoir).
Remove:
- The pollen filter and its support (see corresponding operation in chapter on aircon).
- The air filter and its union.
- The under-engine sound-deadening.
Refill the brake fluid reservoir to the maximum of its capacity.
79
Bleeding the hydraulic clutch control.

DRIVESHAFTS
GEARBOX
Couple a transparent pipe onto the bleed screw (1).

CLUTCH
Submerge the end of the pipe in a receptacle containing brake fluid, situated lower than
the clutch slave cylinder (2).
Create a syphon at «A» above the clutch slave cylinder, using the transparent pipe.
Open the bleed screw (1).

B2BK22XD Action the clutch pedal (3) manually through all its travel, with seven rapid down-up
movements.
On the final movement, hold the clutch pedal (3) at the end of its travel.
Reclose the bleed screw (1).
Allow the clutch pedal (3) to rise back up again.
Fill the brake fluid reservoir to the maximum of its capacity.
NOTE : For new bleed operations: open the bleed screw (1).
If necessary, repeat the operation.
B2BK064C
80
Bleeding the hydraulic clutch control (continued).
DRIVESHAFTS
GEARBOX
CLUTCH
Top up the brake fluid level to the MAXIMUM of the brake fluid reservoir capacity.
Declutch and clutch rapidly 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 35 mm
(Dimension (X) is given as a guide).
NOTE : If incorrect, repeat the bleed operations.
Tighten the bleed screw (1) to 0.75.m.daN.
B2BK065C
81
GEARBOX AND TYRE SPECIFICATIONS
Petrol
2.0i 16V 2.2i 16V 3.0i 24V
Auto. Auto.
Engine type RFN 3FZ XFW
DRIVESHAFTS
GEARBOX
Tyres-Rolling circumference
CLUTCH
205/65 R 15 – 1.973 m 215/65 R15-2.016 m 215/60 R16-2.025 m

Gearbox type BE4/5 AL4 ML5C 4 HP 20
Gearbox ident. plate 20 DL 26 (*) 20 DL 27 (**) 20 TP 74 20 LM 09 20 HZ 27
Reduction box torque 14x62 21 x 73 14x65 19 x 73
Speedometer ratio 18x14 20 x 16 25x20 –
Diesel
2.0 HDi 2.2 HDi
Auto.
Engine type RHT - RHW RHT 4HW
Tyres-Rolling circumference 215/65 R 15 - 2.016 M
Gearbox type ML5C AL4 ML5C
Gearbox ident. plate 20 LM 05 20 TP 74 20 LM 01
Reduction box torque 15x67 21 x 73 16x69
Speedometer ratio 27x21 20 x 16 27x21
82
BE4/5 GEARBOX SPECIFICATION
Engine : RFN
DRIVESHAFTS
GEARBOX
CLUTCH
(A) Marking zone including:
- Component reference.
- Factory serial no.
B2CKU3PD
83
Engine : RFN
Tightening torques m.daN.

DRIVESHAFTS
GEARBOX
CLUTCH
(1) Gearbox rear casing : 1.5 ± 0.1

(2) Gearbox casing / clutch casing fixings : 1.5 ± 0.1
(3) Reverse gear rocker shaft fixing nut : 4.5 ± 0.4
(4) Breather pipe : 1.5 ± 0.1
(5) Reverse gear switch : 2.5 ± 0.2
(6) Drain plug : 3.5 ± 0.2
(7) Top-up plug : 2 ± 0.2
(8) Speedo drive support : 1.5 ± 0.1
(9) Differential housing fixings (M7) : 1.5 ± 0.1
(10) Differential housing fixings (M10) : 5 ± 0.5
(11) Clutch bearing guide fixing screw : 1.5 ± 0.1
(12) Differential extension fixing : 1.5 ± 0.1
B2CKUB0D
84
Engine : RFN
DRIVESHAFTS
GEARBOX
CLUTCH
(13) Primary shaft nut : 7.5 ± 0.7
(14) Secondary shaft nut : 6.5 ± 0.6
(15) Bearing retaining screw : 1.5 ± 0.1
(16) Differential gearwheel screw : 6 ± 0.6
(17) Gear control support screw : 1.5 ± 0.1
B2CKUB1D
85
ML5C GEARBOX SPECIFICATION
Engines : 3FZ – RHT – RHW – 4HW
DRIVESHAFTS
GEARBOX
(A) Label.
CLUTCH
(B) Gearbox reference.
(C) Sequence no.
B2CKUC2D
(D) Bar code.
(E) Marking zone:
Gearbox reference.
Sequence no.
B2CKUCAD
86
Gearbox lubrication.
DRIVESHAFTS
Oil type: ESSO 75W80 EZL 848 or TOTAL 75W 80W H 6965
GEARBOX
CLUTCH
Oil capacity: 2.1 litres.
Lubricated for life.
NOTE : If the gearbox is drained, refilling of the gearbox is via the venting hole.
(1) Differential housing fixing (M8 L45) : 1,8 ± 0,1

(2) Differential housing fixing (M8 L70) : 1,8 ± 0,1
(3) Differential housing fixing (M10 L70) : 4 ± 0,4
(6) Drain plug : 3 ± 0,3
(7) Speedo control support : 1 ± 0.1
WARNING : Do not use the plug on the differential housing, this does not
allow the gearbox oil level to be checked.
B2CKUC4D
87
DRIVESHAFTS
GEARBOX

CLUTCH
(8) Fixing of gearbox cover on gearbox casing : 2 ± 0,2
(9) Bearing stop plate : 2 ± 0,2
(10) Vent hole.
(11) Reverse gear switch : 2,5 ± 0,2
(12) Fixing of gearbox casing on clutch casing : 2 ± 0.2
B2CKUC4D
88
DRIVESHAFTS
GEARBOX
CLUTCH
Tightening torques m.daN..
(13) Flange fixing screws : 2 ± 0,2

B2CKUC5D
(14) Secondary shaft nut : 17 ± 1,7
(15) Gear control support screw : 1,5 ± 0,1
(16) Differential gearwheel screw : 7.7 ± 0.7
B2CKUC6D
89
AL4 AUTOMATIC GEARBOX SPECIFICATION
Engines : RFN - RHT
DRIVESHAFTS
GEARBOX
CLUTCH
The automatic gearbox is identified by a self-adhesive label (A) or, failing that,
by a marking (B).
(1) Component reference.
(2) Serial no.
B2CA085D
90
Engines : RFN - RHT
DRIVESHAFTS
(1) Converter:
GEARBOX
Pre-tightening : 1 ± 0.1
CLUTCH
Tightening : 3 ± 0.3
B2CKU7AD
(2) Fixing of gearbox on cylinder block : 5,2 ± 0,5
(3) Speedometer drive : 0,8
(4) Electrovalve and/or regulators on hydraulic block : 0,9
(5) Hydraulic block : 0,8

B2CKU7BD
(6) Hydraulic block casing : 0,8
(7) Automatic gearbox input speed sensor : 1 ± 0,1
(8) Automatic gearbox input speed sensor : 1 ± 0,1
(9) Line pressure sensor : 0,9

B2CKU7CD
91
Engines : RFN - RHT
(10) Electrovalve controlling flow into the exchanger : 1 ± 0,1

DRIVESHAFTS
GEARBOX
CLUTCH
(11) Multifunction switch : 1,5 ± 0,1
(12) Sleeve stop : 1,5 ± 0,1
(13) Automatic gearbox heat exchanger : 5 ± 0,5

B2CKU7AD
(14) Filler cap : 2,4 ± 0,2
(15) Top-up plug : 2,4 ± 0,2
(16) Gearbox drain plug : 4 ± 0,4
(17) Gearbox support : 4,5 ± 0,4
Driveshaft nut (M24x150) : 32,5 ± 3
B2CKU7BD
92
DRAIN / REFILL /TOP-UP : 4 HP 20 GEARBOX
Engine : XFW
Preliminary conditions:
Tools.
DRIVESHAFTS
Checks there are no faults , using the diagnostic tool.
GEARBOX
CLUTCH
[1] Filling kit : (-).0341
Place the vehicle on a lift, keep vehicle horizontal.
[1a] Filling cylinder : (-).0341-A
[1b] 4 HP 20 adaptor without gauge : (-).0341-B Gear lever in position «P», without applying the handbrake.
NOTE : Heavy electrical consumers disconnected.
Connect the diagnostic tool.

- The 4 HP 20 automatic gearbox is lubricated for life.
Select the parameter measures function.
- Check the level every 20 000 miles.
Make starting this operation, make sure that the oil temperature is well
Checks below 55°C; if it is not, allow the oil to cool.
Press the brake pedal.

IMPERATIVE : Use only ESSO LT 71141.
Start the engine and allow it to run at idling speed, engage all the gears
using the gear selector. Return to «P».
93
Engine : XFW
Checks (continued)
DRIVESHAFTS
With the engine running at the temperature 55° ± 1°C, open the top-up plug (3).
GEARBOX
CLUTCH
Wait for the temperature to reach 60° ± 1°C.
1st possibility :
- Oil flows out, the level is correct.

- Refit the top-up plug (3), tighten to 2,5 ± 0,2 m.daN.
2nd possibility :
- Oil does not flow out.

- Refit the top-up plug (3).
- Add 0,5 litres of oil. (Refer to the chapter on refilling).
Repeat the procedure of checking the oil level.
Refit the metallic part of the vent plug (2), using an 18mm dia. punch and a mallet.
Clip the plastic part of the vent plug (2).
B2CK0JQC
94
Engine : XFW
Draining.
Preliminary conditions:
- Draining should be carried out with the engine hot, to eliminate impurities in
DRIVESHAFTS
suspension in the oil.
GEARBOX
The draining is partial since the converter cannot be totally emptied.
CLUTCH
In draining, approx. 3 litres is removed.
Tighten the cap (1) to 4,5 ± 0,4 m.daN.
Filling.
IMPERATIVE : Use only ESSO LT 71141.
Place the vehicle on a lift.
Move aside the air filter assembly.
ESSENTIAL : Leave the air temperature sensor connected.
Remove the air vent assembly (2).
Raise the vehicle.
Remove the top-up plug (3).
Using tool [1], pour new oil through the air vent aperture, until oil flows out via the top-up hole.
Start the engine and allow it to run at idling speed (applying the brake pedal) and
engage all the gears using the gear selector. Return to «P».
Add oil until it flows out via the top-up hole.
Reclose the top-up hole.
Stop the engine.
IMPERATIVE : Check the oil level.
B2CK17KC B2CK0JPC B2CK0JQC
95
DRIVESHAFTS - GEARBOX
Tightening torques (m.daN) Gearbox oil seal mandrels
Driveshaft Driveshaft
Vehicles Gearbox Engines Right Left Tool kit
bearing nut
RFN
DRIVESHAFTS
BE4/5 7114-T.X 7114-T.W 7116-T

GEARBOX
3FZ
CLUTCH
RHT - RHW
ML5C 9017-T.C 5701-T.A 9017-T
4HW
C8 1.0 10 + 60°
RFN (-).0338.J1 (-).0338.H1
AL4 (-).0338.J3 (-).0338
RHT (-).0338.H2
(-).8010-T.D (-).8010-T.J
4 HP 20 XFW (-).8010-T
(-).8010-T.K1 (-).8010-T.K2
Tightening torques (m.daN) for the wheel bolts
Steel
CITROËN C8 10 ± 0.5
Light alloy
96
WHEELS AND TYRES
2.0i 16V 2.2i 16V 3.0i 24S 2.0 HDi 2.2 HDi
MICHELIN XH1 MICHELIN MICHELIN MICHELIN XH1 MICHELIN XH1

Tyre HX MXM
S 205x65 R 15 94 H PRIMACY 205x65 R 15 94 H 205x65 R 15 94 H
circumference 1.973 m 215x65 R 15 96 H 215x60 R16 99H 1.973 m 1.973 m
2.016 m 2.025 m
T 6.5 J 15-5-27 Non 6.5 J 15-5-27
Wheel CHARMES DOUGLAS CHARMES
A
6.5J15-5-27 (*) 7J16-5-27 6.5J15-5-27 (*)
Pressure Front/ Rear (1) 2.5/2.5 2.4/2.4 2/2 2.4/2.4
(Bars) Front/ Rear (2) 2.5/3.2 2.4/3 2/3 2.4/3
SUSPENSION
STEERING
Tyre
AXLES
Spare circumference This tyre is the same size as the tyres fitted on the wheels.
wheel Wheel
Pressure (Bars) 3.2 3 3
Vehicles equipped with the under-inflation detection system are identifiable by the presence of aluminium valves.
Electronic under-inflation
The under-inflation detection option can only be fitted on vehicles equipped with light alloy wheels.
detection
Symbols and abbreviations used : S = Standard fitting T = Alu-steel wheel. A = Alloy wheel (*) = Option fitting
(1) = Normal operating pressure (Max. 4 persons and 40 kg in the boot).
(2) = Pressure under load (More than 4 persons and «MAX» load in the boot).
Winter fitting : NOTE : All the above tyres can take chains on the front wheels. (Snow chain for 205/65/15 = KOeNIG Ref : 9410.26).
97
WHEELS AND TYRES
Inflation pressures
The label giving the recommended inflation pressures is affixed to one of the front door pillars.
a: Type of tyre.
b: Tyre specifications.
c: Recommended tyre inflation pressures (unladen and laden).
d: Recommended tyre inflation pressures for the spare wheel.
Tightening torque: 10 m.daN.

SUSPENSION
STEERING
AXLES
B2GP00ND
98
WHEELS AND TYRES
Wheel bolts. Spare wheel
(1) Bolt for steel wheel. Anti-theft securing of the spare wheel.
(2) Bolt for light alloy wheel. (5) Winch.
(3) Anti-theft bolt for light alloy wheel. (e) Winch control.
(4) Anti-theft socket.
The wheel is retained at the centre by a cable linking its hub to the
Post-equipment for alloy wheels: fit the correct type of wheel bolt. floor of the boot.
Anti-theft bolts for light alloy wheels: light alloy wheels are equipped
as standard with anti-theft bolts which are protected by chrome caps. The cable cannot be accessed from under the vehicle.
SUSPENSION
STEERING
AXLES
B2GP014D C4BP1CCD
99
WHEELS AND TYRES
Special features
Under-inflation detection device.
(6) High frequency transmitter module.

(7) Seal.
(8) Valve.
(9) Nut.
Composition :
- Four HF transmitter modules (6) incorporated in the wheels in place of the valves, each including a
SUSPENSION
lithium battery.
STEERING
AXLES
- A HF receiver incorporated in the switching module under the steering wheel.
- The tightening torque for the nut (9) is 0.6 ± 0.1 m.daN.
WARNING :
- Each time a tyre is replaced, the valve (8) must be replaced.
- Each time a rim is replaced, the seal (7) must be replaced.
- Each time a valve is replaced, it is necessary to have the transmitter recognised by the BSI, with the
aid of a diagnostic tool.
B2GP015C
100
AXLE GEOMETRY
Front axle
Wheel tracking King pin
Engines Specification H1 Camber Castor
(mm) (°) inclination
RFN 205/65 R15 170
3FZ
RHT 174 +2 ± 1 0° ± 30’ 3° 30’ ± 30’ 12°24’ ± 40’
215/65 R15 +0°18’ ± 0° 9’
RHW
4HW
XFW 215/60 R16 178
SUSPENSION
STEERING
AXLES
NOTE
A < B = Positive figure : += TOE-IN
E1AP0A5D A > B = Negative figure : –= TOE-OUT
101
AXLE GEOMETRY
Front axle
Wheel tracking Camber
Engines Specification H1
(mm) (°) (°)
RFN 205/65 R15 390
3FZ
RHT 394 5±1 1 ± 30’
215/65 R15 0°46’ ± 0°8’
RHW
4HW
XFW 215/60 R16 398

SUSPENSION
STEERING
AXLES
102
AXLE GEOMETRY (SETTING AT REFERENCE HEIGHT)
Tools.
[1] Set of two suspension compressors : 9511-T.A
[2] Set of two shackles : 9511-T.C
[3] Under body height gauge : 2305-T
[4] Set of two straps : 9511-T.B
[5] Set of two slings : 9511-T.D
The front tracking can be checked and adjusted in running order (Systematic use of two tyres).
To check all the angles, it is necessary to set the vehicle at reference height (Castor, camber, tracking).
Setting at reference height.

Requirements prior to setting at reference height.
SUSPENSION
STEERING
WARNING : The checks of the front and rear axle geometry values, as well as the adjusting of the front suspension should be carried out at precise
AXLES
positions of suspension compression (reference height) on a suspension test bed.
Make sure that :
- Tyres are in conformity and at the correct inflation pressures.

- The front wheels are straight ahead.
Remove wheel trims.
103
At the front (H1).
Engage the straps [4] with their shackles [2] on the subframe.
Position the suspension compressor [1], selecting the separation (A) most suited to pull
the straps as far upwards as possible.
B3BKAEGD Compress the suspension so as to obtain, on the RH and LH sides, the bodyshell height
SUSPENSION
H1 (reference height), to be measured between the lowermost edge (B) and the ground.
STEERING
AXLES
WARNING : take account of pivoting surfaces when measuring the reference height H1.
NOTE : Only the tracking is adjustable.
WARNING : The tracking value varies as a function of the vehicle height.
B3BKAEJD
104
At the rear (H2).
Engage the slings [5] on the rear longerons.
Position the suspension compressor [1] selecting the separation (A) most suited to pull the
straps as far upwards as possible.
B3BKAEHD
Compress the suspension so as to obtain, on the RH and LH sides, the bodyshell height
SUSPENSION
STEERING
H2 (reference height), to be measured between the lowermost edge (C) and the ground.
AXLES
WARNING : take account of pivoting surfaces when measuring the reference height H2.
Check that the height H1, measured already at the front, has not changed.
WARNING : The rear axle angles are not adjustable.
B3BKAEKD
105
Adjusting the rolling axles.
NOTE : Only the tracking is adjustable (at the front).

SUSPENSION
If the value is incorrect, adjust the track rods (1).

STEERING
AXLES
One turn of the rod = 2 mm approx.
Tighten the nuts (2), tighten to 4 ± 0.4 m.daN.
B3BKAELD
106
FRONT AXLE
Identification
(1) Crossmember
(2) Tie-rods
(3) Springs
(4) Front suspension leg
(5) Anti-roll bar
(6) Subframe
SUSPENSION
STEERING
AXLES
Anti-roll bar
Engines Diameter (mm)
RFN-3FZ-RHT-RHW-4HW 21.5
XFW 22
B3CK09JD
107
FRONT AXLE
Vehicle in running order
Fixing of subframe on body : 10.5 ± 1

Fixing on tie-rod on body : 6.5 ± 0.6
Fixing of crossmember on body : 8 ± 0.8
Fixing of tie-rod on subframe : 6.5 ± 0.6
Fixing of damper on pivot : 9 ± 0.9
Fixing of damper rod on upper cup : 9 ± 0.9
SUSPENSION
Fixing of upper cup on body : 3.5 ± 0.3

STEERING
Fixing of anti-roll bar on subframe : 10.5 ± 1

AXLES
Driveshaft nut : 10 ± 1
Fixing of wishbone on subframe : 7 ± 0.7
Fixing of ball-joint on pivot : 7 ± 0.7
Fixing of steering track rod on pivot : 4 ± 0.4
(H) Height between the ground and the jacking point. Fixing of track rod on damper body : 5.5 ± 0.5
(P) Wheel tracking. Fixation biellette sur barre antidévers : 5.5 ± 0.5
(I) Tolerance ± 0.5 mm.
B3CK08KD
108
REAR AXLE
Identification
(1) Damper.
SUSPENSION
STEERING
(2) Spring.
AXLES
(3) Stabiliser bar.
B2CP3J3D
109
REAR AXLE
(5) Fixing of rear axle on body : 8 ± 0,8
(6) Fixing of stabiliser bar on rear axle : 8 ± 0,8

SUSPENSION
(7) Fixing of stabiliser bar on body : 6 ± 0,6

STEERING
AXLES
(8) Hub nut : 38 ± 3,8
(9) Fixing of damper on body : 9 ± 0,9
(10) Fixing of damper on rear axle : 9 ± 0,9
B3DK0AGD
110
REAR AXLE
Engines : RFN –3FZ – XFW – RHT – RHW – 4HW
Identification
(X) Pre-adjustment.
(1) Steering mechanism.
(2) Distributor valve.
(3) Power steering reservoir.
SUSPENSION
STEERING
(4) Power steering pump.
AXLES
(5) High pressure union.
(6) Low pressure union.
(7) Steering oil radiator fitted on the front panel.

(according to equipment)
B3EK0J9D
111
SPECIFICATIONS OF POWER-ASSISTED STEERING
Engines : RFN – 3FZ – XFW – RHT – RHW – 4HW

Features Power steering with integral ram
Travel (mm) 166 156 162
Angle of lock 40°48’ 37°18’ 39°24’
for inside wheel
Angle of lock for 34°36’ 32°24’ 33°42’
outside wheel
SUSPENSION
Type of pump Falling flow

STEERING
AXLES
Pump pressure (bars) 100 110

Circuit capacity (litres) 1.3
Number of steering wheel 3.25 3.05 3.17
rotations
Number of teeth on drive 9
pinion
112
SPECIFICATIONS OF POWER-ASSISTED STEERING
(8) Steering wheel fixing nut : 2 ± 0,2
(9) Fixing of steering column to support : 2 ± 0,2
(10) Fixing of upper and lower shafts to steering column : 2,5 ± 0,2
(11) Fixing of ram valve supply unions : 1 ± 0,1
(12) Fixing of steering mechanism : 14,5 ± 1,4
SUSPENSION
STEERING
AXLES
(13) Fixing of pump/valve supply unions
Pump : 2 ± 0,2
Valve : 2,5 ± 0,2
(14) Fixing of ball-joint housing on steering rack : 9 ± 0,9
(15) Steering rod locking nut : 6 ± 0,6
(16) Steering ball-joint nut : 4 ± 0,4

B3EK0K0D
113
BRAKE SPECIFICATIONS
2.0i 16V 2.2i 16V 3.0i 24S 2.0 HDi 2.2 HDi

Master cylinder 22,2 (valve type) 23,8 (valve type) 22,2 (valve type)
Master-vac 254 203.2 + 228.6 254
Ø
Caliper/piston LUCAS BREMBO LUCAS
mm
FT makes 60 40 + 44 60
Disc Ventilated 285 310 285
Disc thickness/min. thickness 28/26 32/30 28/26
Brake pad grade GALFER 3366 (8) - FERODO 782 (2)
FREINS
Caliper/piston LUCAS C38HR

Ø makes
mm 38
Disc Ventilated 272
RR
Disc thickness/min. thickness 12/10
Make TEXTAR
Brake pad grade T 4131
114
BRAKE TIGHTENING TORQUES (m.daN)
Fixing of disc on hub : 1.5 ± 0.1

Fixing of front brake caliper on support : 3.5 ± 0.3
Fixing of front brake caliper support on pivot : 16 ± 1.6
Fixing of brake pipe unions : 1.5 ± 0.1
Fixing of rear brake caliper on support : 3.5 ± 0.3
Fixing of rear brake caliper support on pivot : 9.5 ± 0.9
Fixing of brake servo on pedal gear : 2 ± 0.2
Fixing of master-cylinder on servo : 2 ± 0.2
Fixing of handbrake lever on body : 4 ± 0.4
BRAKES
115
ADJUSTING THE HANDBRAKE
Identification
(A) Zone for fixing on floor.
(B) Clips for retaining on bodyshell.

BRAKES
B3FK263D
116
ADJUSTING THE HANDBRAKE
Adjustment
Raise and support the vehicle, wheels hanging.
WARNING : Bleed the braking circuit.
Detension the secondary brake cables by slackening the nut (1).

With the engine running and the handbrake released, press 40 times on the brake
pedal.
Carefully tighten the nut (1), until the brake cables begin to come under tension.
Pull the handbrake lever about ten times in a normal fashion.
Engage the handbrake lever at the 2nd notch of its travel relative to its position of
rest.
Turn the nut (1) until the brake pads start touching.
Check that:
- The normal travel of the handbrake lever does not exceed 6 notches.
- The two secondary brake cables on the slide are moving together.
With the handbrake slackened, make sure that the road wheels turn freely when
moved by hand.
Check that the handbrake warning lamp lights up from the 1st notch of the lever’s
total travel.
BRAKES
B3FK264D
117
DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM
Tools.
[1] Generic bleeding apparatus : «LURO» or similar
[2] Filler plug : (-).0810
[3] PROXIA diagnostic tool : 4165-T
[4] LEXIA diagnostic tool : 4171-T
Draining.
Remove the pollen filter (See corresponding operation).
Take out the filter from the brake fluid reservoir.
Drain the brake fluid reservoir with the aid of a clean syringe.
Refit the filter in the brake fluid reservoir.
Filling.
IMPERATIVE : Use only new, clear brake fluid, avoiding any ingress of impurities into the hydraulic circuit.
WARNING : Use only hydraulic fluid(s) that are approved and recommended.
Renew the brake fluid in the calipers, bleeding the circuit until clean fluid flows out.
WARNING : During the bleed operations, take care to maintain the level of brake fluid in the reservoir, topping up if necessary.
BRAKES
118
DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM
Pre-conditions for bleeding a braking circuit: Use of the diagnostic tool will be necessary in cases where the following
After a repair on the master cylinder or ABS block, bleed in the following conditions all come together simultaneously:
order: - Air in the circuit.
Front LH wheel. - Regulation block active.
Front RH wheel. - Action on the brake pedal.
Rear LH wheel.
Rear RH wheel. Bleeding.
After a repair on a caliper or on a wheel cylinder, bleed in this order IMPERATIVE : Start the engine.
(caliper or wheel cylinder removed) : WARNING : Respect the order of opening of the bleed screws.
Automatic bleed:
Front LH wheel. Position tool [2] on the brake fluid reservoir.
Front RH wheel. Connect tool [2] to an approved automatic bleed apparatus (See Tools).
Rear LH wheel. Bleed the circuit, referring to the user instructions provided with the
Rear RH wheel. apparatus.
Manual bleed (using the pedal):
NOTE : If removing/refitting the master cylinder, it is advised to comple- Two operators are necessary.
te the automatic bleed with a manual bleed. Connect a transparent pipe on the bleed screw.
ABS :
Press slowly on the brake pedal.
The hydraulic valve blocks are delivered pre-filled; it is thus possible to
Open the bleed screw.
perform:
- a manual bleed (using the pedal), Keep the pedal pressed fully down.
- an automatic bleed. Close the bleed screw.
Should the bleed of the circuit prove unsatisfactory, it is possible to bleed Allow the brake pedal to rise gradually.
BRAKES
the ABS block using a diagnostic tool (See Tools), following the instruc- Repeat the operation until the brake fluid flows out clean and free of air
tions given by the diagnostic tool. bubbles.
Proceed in an identical fashion in the case of all the other wheels.
119
AIR CONDITIONING SYSTEM (R 134A) (HFC)
Compressor
Refrigerant
Vehicle Engines Date refill
(± 25 gr) Variable capacity Quantity of oil (cc) Quality of oil
RFN
3FZ
C8 XFW 13/06/02 1 750 SD 7 V 16 135 ± 15 SP10
RHT - RHW
4HW
CONDITIONING
AIR
120
CONDITIONING
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134A)
AIR
Tightening torques (m.daN).
Unions
Pipe diameters Steel / Steel Aluminium / Steel
M 06 1.7 ± 3 1.3 ± 3
M 08 3.8 ± 3 2±2
M 10 4±3 2.5 ± 3
NOTE : Tighten the unions to the recommended torques using a retaining spanner whenever possible.
NOTE : For operations concerning draining, drying (empty), checking and refilling of a system: refer to BRE 0290.
WARNING : For R 134A quantities: see table on page: 120).
121
CONDITIONING
AIR SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
Pollen filter
C5HP183C
NOTE : The pollen filter is located under the bonnet on the LH side.
Removing.
Remove the handle (1).
Uncouple the evacuation pipe (2).
Release at (3), on the RH and LH sides.
Slacken the screws (4) on the RH and LH sides by a quarter turn.
Pull the assembly (6) outwards.
Remove the pollen filter (5).
Refitting.
C5HP182D Proceed in reverse order.
122
CONDITIONING
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
AIR
Removing-refitting the drying cartridge
Removing.
Depressurise the air conditioning circuit.
Remove the hose (1).
Disconnect the connector (2).
Remove the air filter (3).
Turn the plastic pins (4) by a quarter turn.
Move aside the condenser (5).
Clean the area around the skirt (6) of the reservoir (7).
Remove the screw (8) of the fixing (9).
B1BP2MGC B1BP2MHC C5HP184C C5HP185C
123
CONDITIONING
AIR SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
Removing-refitting the drying cartridge (continued)
Unscrew the reservoir (7) (Adaptor: TORX 70 FACOM)
Unscrew the reservoir (7), and the protection skirt (6).
WARNING : This operation should remain clean before the fitting of the new reservoir.
Cap the base (10).
WARNING: Do not allow more than 5 minutes to elapse between unwrapping the cartridge (reservoir (7)) and
fitting it.
C5HP186C C5HP187C
124
CONDITIONING
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
AIR
Removing-refitting the drying cartridge (continued)
Refitting.
Note: Check, before you refit the reservoir (7), that the base (10) is clean.
(If it is not, clean in and around the base with a paper towel (10)).
Preparing the new drying reservoir
Remove the protection cap from the neck of the reservoir (7).
Leave in place the protection at the other end of the neck of the reservoir (7), before fitting.
- Grease the threads of the reservoir (7) (sachet of grease in the kit).
- Oil the reservoir’s two O-ring seals (7) (sachet of oil in the kit).
Remove:
- The protection cap fitted at the time of removal, from the base (10).
- The protection at the other end of the reservoir (7).
Engage the reservoir (7) equipped with its skirt (6) on the threads of the base (10).
Manually screw on the reservoir (7), until the reservoir (7) is touching the foot of the base (10).
NOTE : Check that the bottom edge of the skirt (6) covers the base (10) all around it.
Tighten the reservoir (7) (TORX 70 FACOM).
Tighten to 1,4 ± 0,1 m.daN.
Fit the plastic clip (9) and the screw (8) (new, in exchange kit).
Complete the fitting in reverse order to the removing.
Proceed to:
- Recharge the circuit. (See corresponding operation).
- Check that the air conditioning system functions correctly. (See corresponding operation).
C5HP188C
125
CONDITIONING
AIR SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134A)
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 PRESSURE valve, so as not to lose any oil.
- No more oil should be added when filling the system with R 134A fluid.
b) - Using draining/filling equipment fitted with an oil decanter.
- Drain the R 134A fluid from the system in accordance with the instructions in the equipment handbook.
- Measure the amount of oil recovered.
- Add the same amount of NEW oil when filling the system with R 134A fluid.
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 NEW oil is left in the compressor as was in the old compressor.
- No more oil should be added when filling the system with R 134A fluid.
126
CONDITIONING
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134A)
AIR
Checking the compressor oil level (continued)
2/ Slow leak.
- Slow leaks do not lead to oil loss, therefore the same procedure should be followed as if there was no leak at all.
3/ Fast leak.
This type of leak causes both oil loss as well as allowing air to enter the system.
It is therefore necessary to :
- Replace the dryer.

- Drain as much oil as possible (when replacing the faulty component).
Either before or during filling of the system with R 13A fluid, introduce 80 cc of NEW oil into the system.
127
CONDITIONING
AIR CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
CHECKING PRESSURES
Low pressure Low pressure Low pressure

too low normal too high
- Insufficient fluid charge. - Cooling fan speed unsuitable. - Faulty pressure control valve.
High pressure
- Constriction of the HP system. - Faulty compressor. - Faulty compressor.
too low
- Dirty pressure control valve.
High pressure - Faulty compressor. - Circuit normal. - Cooling fan speed unsuitable.
normal - Dirty evaporator.
- Faulty pressure control valve. - Presence of solid matter in the - Excessive fluid charge.
High pressure - System blocked. system. - Dirty condenser.
too high - Water in the system. - Dirty condenser. - Faulty pressure control valve.
- Cooling fan speed unsuitable.
Checking the pressure at temperatures between 15°C and 35°C for information only.
In general, the pressure should be approximately :
- for R134A fluid, less than 2 Bars (Low pressure), and between 13 and 24 Bars (High pressure).
128
CONDITIONING
AIR CONDITIONING SYSTEM R 134A
AIR
Engines : RFN-3FZ
1 Drying cartridge.
2 Clickfit union.
3 Buffer capacity.
4 Clickfit union.
5 High pressure valve
6 Low pressure valve
C5HP17TP
129
CONDITIONING
AIR AIR CONDITIONING SYSTEM R 134A
Engine : XFW
1 High pressure valve
2 Low pressure valve
3 Buffer capacity.
4 Drying cartridge.
5 Pressostat
6 Clickfit union. (Tool 8005-T.C)
Tightening torques (m.daN).
a 0.8
b 1.4
c
d
e 0.8
C5HP18TP
130
CONDITIONING
AIR CONDITIONING SYSTEM R 134A
AIR
Engines : RHT-4HW
1 Drying cartridge.
2 Clickfit union.
3 Buffer capacity.
4 Clickfit union.
5 High pressure valve (Tool 8005-T.C)
6 Low pressure valve (Tool 8005-T.A)
C5HP17UP
131

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PRIVATE CARS

(A) Chassis stamp (cold stamp on bodywork).

(B) Manufacturer’s data plate (under RH centre pillar).

(C) A-S / RP No. and RP paint code

(E) Gearbox reference – Factory serial no.

(F) Engine legislation type – Factory serial no.

2.0i 16V 2.2i 16V

Emission standard IFL5

(1) = Right hand drive

Type code SEB XFWF/IF EA XFWF/IF

2.0 HDi (*) 2.0 HDi (**)

(*) = With particle filter.

2.2 HDi (*)

Type code EB 4HWB EA 4HWB

(*) = With particle filter.

E2AF004D E5AF022D E2AK02YD E2AK02XD

Engine type RFN 3FZ XFW RHT - RHW 4HW

5-speed gearbox 1.8 2 2 2

Engine type RFN 3FZ XFW RHT- RHW 4HW

Cubic capacity (cc) 1997 2230 2946 1997 2179

Bore / Stroke 85/88 86/96 87/82.6 85/88 85/96

Compression ratio 10.8/1 10.9/1 17.3/1 17.6/1

Power ISO or EEC KW - rpm 100-6000 116-5650 150-6000 79-4000 94-4000

Power DIN (HP - rpm) 138-6000 160-5650 204-6000 109-4000 130-4000

(1) Compulsory engine plate :

(A) Engine legislation type.

(B) Component reference.

(C) Factory serial no.

Description (18) Camshaft bearing cap covers (19) Valve covers

(8) LH flexible support/body 3 ± 0.3

(14) Lower rod/lower RH engine

B1BK24QD B1DK001C B1DB002C

Multi-layer metallic gasket. Tighten in the order indicated X = MAXI re-usable

The camshafts are referenced following two methods.

Valve clearances when cold

(A) Component reference.

(B) Engine legislation type.

(C) Factory serial no.

(2) Link rod fixing : 5 ± 0.5

(17) Bearing cap Tightening : 2 ± 0.2

Respect the sequence of stages and the order of tightening

(21) Fixings of bearings/cap covers or Stage 1 Stage 2 Stage 3

21) Fixings of bearings/cap covers or

(21) Fixings of bearing cap cover or

Respect the sequence of stages and the order of tightening

Respect the sequence of stages and the order of tightening

(27) Screws : 2.5 ± 0.2

Respect the sequence of stages and the order of tightening

(30) Camshaft bearing cap cover or camshaft bearing:

Respect the sequence of stages and the order of tightening

(31) Valve cover :

Respect the sequence of stages and the order of tightening

(32) Inlet manifold:

Respect the sequence of stages and the order of tightening

(33) Exhaust manifold:

Respect the sequence of stages and the order of tightening

(34) Inlet distributor:

Respect the sequence of stages and the order of tightening

Cylinder head gasket thicknesses