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1. CHECKS TURBO PRESSURE NOTE The engine has to be switched off Uncouple the tube at b using tool 4 Couple tool 3 on the tube at b Check the inlet manifold pressure sensor using the diagnostic tool Make the following selections in the diagnostic tool Menu PARAMETER MEASURES INJECTION INFO TURBO PRESSURE Apply a pressure on the pressure sensor by means of tool 3 Check the pressure value in parameter measures by means of the diagnostic tool Checks IMPERATIVE Respect the following test conditions Engine at operating temperature vehicle in running order engine under full load NOTE Carry out the checks either during a road test or on a roller test bed Perform the checking with the aide of a diagnostic tool Start the engine Stage A Engage first gear start the vehicle Engage the gears up to third gear Decelerate to an engine speed of 1000 rpm Check the pressure 0 6 0 05 bar 1500 rpm Stage B Accelerate freely change from fourth gear to third gear Check the pressure 0 9 0 05 bar between 2500 and 3500 rpm INJECTION 121 AIR SUPPLY CIRCUIT SPECIFICATIONS Identification Upper integrated air inlet manifold The upper integrated air inlet system is composed of the following components 1 Air filter cover 2 Air filter housing 3 Air duct 4 Flowmeter 5 Turbocharger inlet elbow 6 Resonator 7 Turbocharger outlet elbow
2. NOILOAPNI Lower integrated air inlet manifold The lower integrated air inlet system is composed of the following components 8 EGR upper pipe 9 Inlet distributor 10 Diesel fuel filter with heater and water detector according to country 11 Diesel fuel filter support 12 Oil separator 13 Oil filler cap 14 Air meter housing EURO 4 Features WARNING At each removal it is essential to replace the seals on the components that have been removed lubricating the new seals prior to fitting 122 AIR SUPPLY CIRCUIT SPECIFICATIONS Engine 8HT Tightening torques m daN Lower integrated air inlet manifold Tightening sequence Tightening Oi separator fixing serow j tos 1594 9119 Diesel fuel fiter support fixing screw n o __ 132t013 101 Diesel fuel filter support fixing screw INJECTION Integrated air inlet distributor screw Upper integrated air inlet manifold Re Description Tightening 15 Jar mier housing fixing screw x 16 Air filter cover fixing screw o Screw fixing the resonator on the turbocharger 0 75 Screw fixing the resonator on the oil separator 123
3. B1H2010D Do not move the nut d will cause a malfunction Do not separate the union e from a diesel injector It is forbidden to clean the carbon deposits from the diesel injector nozzle Fuel high pressure common injection rail Do not separate the pressure regulator g from the common injection rail 3 will cause a mal function 115 NOILOAPNI SPECIFICATIONS PRE POSTHEATING CIRCUIT Engine 8HT The pre heating time varies as a function of the engine coolant temperature The pre postheating control unit is piloted by the engine ECU Pre postheating control unit Supplier Reference NAGARES 96 456 686 80 CARTIER 96 456 692 80 Pre heater plugs a Marking zone Supplier Reference NGK YEO4 BERU 0 100 276 004 Tightening torques m daN Plugs on cylinder head tighten to 0 85 0 08 m daN Bar on plugs tighten to 0 12 0 03 m daN 116 CONTROLE CIRCUIT D ALIMENTATION CARBURANT BASSE PRESSION Engine 8HT Tools 1 10 mm low pressure connector 4215 T 2 Pressure gauge for testing boost pressure 4073 T A Toolkit 4073 T IMPERATIVE Respect the safety and cleanliness specific to high pressure diesel injection engines INJECTION Disconnect the battery Remove the engine cover B1B200LD IMPERATIVE Clean the unons before uncoupling them if necessary see corresponding operation
4. B3F201YD 170 TIGHTENING TORQUES BRAKES L Ref Description Tightening 2 0 2 2 0 2 2 2 0 2 TIGHTENING TORQUES BRAKES FER Tightening 0 5 55205 1 5201 0 8 20 0 820 1 B3F201UD B3F201WD 171 BRAKES SEMIS B3F2010D CHECKING THE BRAKE PEDAL IMPERATIVE Respect the safety and cleanliness requirements Height A of the brake pedal in relation to the floor engine running 135 8 to 145 8 mm for left hand drive models 121 6 to 131 6 mm for right hand drive models If the pedal height is not correct adjust it Disconnect the connector of the stoplamps switch 1 Unscrew the stoplamps switch 1 Remove the stoplamps switch 1 Slacken the push rod locking nut 2 Adjust the height relative to the floor A of the brake pedal by rotating the push rod 2 Tighten the push rod locking nut 2 Tightening torque 2 2 0 2 m daN 172 CHECKING THE BRAKE PEDAL BRAKES Do up the stoplamps switch 1 in its support 3 until it is flush with the brake pedal 4 IMPORTANT Do not press on the brake pedal a shaft Make a quarter turn to secure the stoplamps switch 1 in place IMPORTANT Do not press on the brake pedal NOTE Rotational torque for refitting the stoplamps switch 1 0 15 m daN maximum Check the gap of the stoplamps switch 1 5 to 2 5 mm Connect the connector of the
5. 5 door saloon 4 seats Engine 3 CFA 384F E4 8HT 1 4 HDi DV4TD E4 IDENTIFICATION OF VEHICLES Emission standard PN CFAC CFA 1 0 8HTC code Co L Engine type Cubic capacity cc 1 4 HDi GENERAL Fiscal rating hp MT MMT MMT C 551 m C 551A mp C 552 m Gearbox type Gearbox ident plate Manual gearbox Piloted manual gearbox TWHANAD IDENTIFICATION OF VEHICLES Manufacturer s plate The manufacturer s plate carries the following information a Type approval number b Type serial number VIN c Gross vehicle weight d Gross vehicle weight e Maximum weight on front axle f Maximum weight on rear axle g Manufacturer identification according to marketing country E1A2002D GENERAL SPECIFICATION DIMENSIONS Exterior dimensions mm lt Lu E1A2001D GENERAL SPECIFICATION DIMENSIONS Exterior dimensions mm Lenghoveal D Reartrackatgroundlevel E Front track at ground level F Width oueral j G Heightoveral LH Height with longitudinal roof bars ODM Vehicle in running order vehicle empty levels topped up TWHANAD Interior dimensions and volumes mm _ Sdoorvesin Sdoorversion Minimum floor width 13388 1580 uwa Height of boot below shelf
6. Adjustment of inlet valves closing 10 after BDC 55 after BDC Adjustment of exhaust valves opening 40 before BDC Adjustment of exhaust valves closing 2 after TDC Ignition sequence 1 2 3 Fuel Unleaded petrol Octane 95 or above Oil quality API SJ SL EC or ILSAC EURO 4 Emission standard Weight empty in running order kg 75 kg approx weight full of oil and coolant 25 PRESENTATION OF ENGINE 384 F CFA Valve adjustments angle of opening of inlet valve angle of opening of exhaust valve TDC BDC a operating range of VVT i B1B201YD Engine block Valve cover The valve cover 1 is made of plastic and incorporates the air filter housing so reducing weight The valve cover gasket 2 is made of acrylic rubber This material is known for its resistance to heat as well as for long life 1 20120 26 PRESENTATION OF ENGINE 384 F CFA Cylinder head gasket A A transversal section 3 shim The cylinder head gasket used is in laminated steel The gasket surface is coated with NBR in order to make the cylinder head more air tight NOTE NBR Nitrile Butadiene Rubber rubber material known for its resistance to heat oil and wear A A Cylinder head The sparking plugs are placed at the centre of the combustion chambers so as to make the engine less subject
7. IMPERATIVE The magnetic track j of the crankshaft pinion should show no signs of damage and should not be approached by any other source of magnetism Remove the engine speed sensor 16 the belt retaining stop 15 72 CHECKING AND SETTING THE VALVE TIMING Remove the nut 17 In the engine compartment Move aside the header tank Support the engine with a roller jack equipped with a block B1E2005D Remove the bottom support of the expansion chamber 20 the engine support 19 the intermediate engine support 18 Lower the engine by 3 cm WARNING Operate the jack with care Do not leave the engine without support Take care with the routing of the header tank hose Check for any interference between the lower crossmember and the heat shield of the catalytic converter B1B200GD 73 CHECKING AND SETTING THE VALVE TIMING Engine 8HT NOTE The engine has to be lowered by 3 cm so that you can position the crankshaft by means of the peg Rotate the engine by means of the crankshaft pinion screw 12 clockwise to bring it to the pegging position Position the camshaft pinion using the peg 2 the fuel high pressure pump using the peg 3 the crankshaft pinion using the peg 3 Hold the tensioner roller in place by means of a hexagonal spanner at Slacken the screw 21 Detension the timing belt by pivoting the tensioner
8. Injection time Cycle of ignition and injection Sequential injection the injectors are commanded separately in the order of injection 3 2 1 just prior to the inlet phase Static ignition one coil per cylinder The ECU manages the injection and the ignition simultaneously metering of the petrol air mixture The quantity of fuel injected is proportional to the time of opening of the injectors which is determined as a function of 3 main parameters Engine load Speed of rotation of the engine TDC sensor The information from the oxygen sensor Numerous other corrections are also applied during operation in order to take account of the variations In the heat status of the engine coolant temperature sensor In the operating conditions idle phase stable phase full load phase transitory engine speed phases injection cut off phase In the atmospheric pressure altimetric correction Injection Correction of starting engine cold The injection ECU corrects the flow from the injectors during the action of the starter motor This quantity is injected in asynchronous mode thus constant in time depending only on the temperature of the coolant fluid The engine once started receives an injected quantity synchronous with the ignition which varies in permanence with its thermal evolution 98 OPERATING PHASES BOSCH ME 7 9 5 INJECTION SYSTEM Regulation of the idling speed The engine is
9. Charging system 1 DMIT 12V 70 A 80 A 1300 rpm maximum Starting system The starter motor used is of the controlled pinion type D7E VALEO 3000 R70M BOSCH 1 1 kW 12V 2760 ALLUMAGE SPEEDOMETER An E E C decree of 25 June 1976 regulates the speed displayed by the speedmeter in relation to the actual speed travelled This decree stipulates The speed indicated by a speedometer must never be lower than the actual vehicle speed Between the speed displayed SD and the speed travelled ST there must always be the following relationship ST lt SD 1 10 ST 4 Kph Example For an actual speed of 100 Kph the speed displayed by the speedometer may be between 100 and 114 Kph The speed indicated by the speedometer may be influenced by The speedometer The tyres fitted to the vehicle The final drive ratio The speedometer drive ratio Any of these components can be checked without removing them from the vehicle See information note N 78 85 TT of 19 October 1978 NOTE Before replacing the speedometer check the conformity of the following points The tyres fitted to the vehicle The gearbox final drive ratio The speedometer drive ratio NOISSINSNVu L H LNTO 126 CLUTCH SPECIFICATIONS Engine type CFA Gearbox type MT MMT MT Gearbox make
10. Never use a warning lamp Never supply an actuator directly NOISSINSNVu L H LNTO Before reconnecting a connector check The condition of the various contacts for deformation corrosion etc The presence and the status of the mechanical unlocking IMPERATIVE Never swap two gearbox ECUs between two vehicles B2C201SD 138 RECOMMENDATIONS PRECAUTIONS MMT PILOTED MANUAL GEARBOX Driving Never push the vehicle to attempt to start it impossible with a piloted manual gearbox Towing a Conditions for towing It is necessary to lift the front of the vehicle to tow it after having positioned the gear lever in As neutral If there is a gearbox fault or malfunction the vehicle can remain immobilised depending on the seriousness of the fault If a gear is engaged the conditions for immobilisation of the vehicle are Engine stopped the engine should not be started The clutch is open clutched If these conditions are met you can lift the front of the vehicle to tow it If it should not be possibe to lift the front of the vehicle there are ways to unblock it Engage N using a diagnostic tool Engage N without using a diagnostic tool Engaging of N using a diagnostic tool Preliminary operations Vehicle and engine stopped Battery voltage higher than 12 5 volts Ignition switched on Gear selector on position N Connect the diagnostic tool
11. fixing step For more information refer to the lubricants bulletin for the model year in Laser under PDI MAINTENANCE NOTE For C1 petrol use of TOTAL 15 W 40 ACTIVA 5000 norm API SL CF or ACEA A2 B2 is recommended WARNING For vehicles with a maintenance interval of 30 000 km 20 000 miles use exclusively TOTAL ACTIVA QUARTZ 7000 or TOTAL ACTIVA QUARTZ FUTURE 9000 or any other oil with specifications equivalent to these Failing this you can follow the maintenance intervals for severe operating conditions NOTE These oils have specifications higher than those defined by norms ACEA A3 or API SJ SL 19 RECOMMENDED LUBRICANTS GEARBOX OIL All countries All Types of gearbox ExxonMobil LV 75 W GL 4 ENGINE COOLANT PETROL ENGINE All countries S LLC pink fluid 9735 Y6 WARNING Never use PSA coolant G33 on C1 petrol engines ENGINE COOLANT DIESEL ENGINE CITRO N Part No GLYSANTIN G33 REVKOGEL 2000 CITRO N fluid idi All countries ion 35C rotection 20 Litres 9979 76 9979 74 210 Litres 9979 77 9979 75 TIWHANAD 20 RECOMMENDED LUBRICANTS BRAKE FLUID Synthetic brake fluid 0 5 Litre 9979 05 9979 07 LIQUIDE LAVE VITRES Concentrate 250 ml 9980 33 ZC 9875 953U 9980 56 All countries GENERAL Fluid 1 Litre 9980 06 ZC 9875 784U ready to use 5 Litres 9980 05 ZC 9885 077U ZC 9875 279U GRAISSAGE Utilisation g n rale Norms NLGI All
12. 100 000 miles Subsequent replacements Every 60 000 km 40 000 miles WARNING The coolant is already a blended product 50 coolant and 50 de ionised water the refore no further mixing mut be done when topping up or replacing coolant 84 COOLING SYSTEM SPECIFICATIONS 1 Coolant pump 2 Thermostat 3 Heater matrix 4 Cylinder block drain screw b Cooling radiator 6 Top hose B1G200YD 85 COOLING SYSTEM SPECIFICATIONS 1 Bleed screw 2 Exhaust gas recycling EGR heat exchange EURO 4 version B1H200ZD 86 CHECKING THE OIL PRESSURE CFA Temperature C Pressure Bars N Pressure Bars Pressure Bars Pressure Bars 4386 T 4601 T 1503 L 2279 T Bis 4103 T 1503 J NOTE The oil pressure should be checked with the engine hot after the oil level has been checked VALVE CLEARANCES CFA petrol engine Adjust by change of cam followers See presentation of 384F engine 8HT diesel engine Hydraulic compensator 88 DRAINING FILLING AND BLEEDING THE ENGINE COOLING CIRCUIT Engine CFA IMPERATIVE Respect the safety and cleanliness requirements WARNING To avoid all risk of burns do not remove the radiator cap while the engine and the radiator are hot Thermal expansion may cause coolant fluid and steam to escape from the radiator Slacken the drain screw 1 and drain the coolant
13. 45504 81 EXHAUST LINE SPECIFICATIONS Engine 8HT B1J2001D Tightening m daN Reference 1 2 3 4 5 6 7 Rubber Silencer Rubber Clip Catalytic Intermediate Clip suspension suspension converter pipe 82 COOLING SYSTEM SPECIFICATIONS 4 4 Capacity 4 Radiator surface 12 2 dm Pressurisation Opening of thermostatic regulator Cooling fan Triggering threshold 97 C 115 C 118 C 105 C for 6 minutes Aircon cut off Post cooling Coolant temperature sensor and alert located on the coolant outlet housing Engine coolant level sensor On the expansion chamber Temperature sensor tightening torque 2 x 0 2 m daN 83 Engine CFA B1B202ED COOLING SYSTEM SPECIFICATIONS Cooling circuit y towards the heater unit Z from the heater unit 32 bypass pipe 34 radiator A thermostat 33 with bypass valve is fitted at the inlet end of the coolant pump 31 on the cooling circuit The engine uses a specific coolant that has very long life Specifications Thermostat with opening temperature 82 C Coolant fluid Type Coolant with very long life for petrol or equivalent engine Capacity litres 4 System diagram 35 heater unit Specifications of coolant fluid Type Coolant with very long life for petrol or equivalent engine Colour Pink 1 replacement of fluid 150 000 km
14. Angular tightening 100 5 Accessories drive pulley Tightening 3 0 3 Angular tightening 180 5 Cylinder block 1 3 0 1 Timing belt guide roller 3 7 0 3 Timing belt tensioner roller 2 3 0 2 39 TIGHTENING TORQUES DIESEL ENGINE Camshaft bearing cap covers Pre tightening Tightening Fixing of camshaft sub assemblies on cylinder head Pre tightening 0 3 0 1 Tightening 1 0 1 Camshaft pulleys Pre tightening 2 0 2 Angular tightening 50 5 Cylinder head Pre tightening 2 0 2 Tightening 4 0 4 Angular tightening 230 5 EGR valve Flywheel Pre tightening Angular tightening Clutch mechanism 40 TIGHTENING TORQUES DIESEL ENGINE Oil pump assembly Pre tightening Tightening Unions on fuel high pressure common injection rail Pre tightening Tightening Diesel injection pump on support Union on diesel injector Pre tightening Tightening Diesel injection pump pulle Union on diesel high pressure pump Pre tightening Tightening Coolant pump Pre tightening 0 3 0 1 Tightening 0 9 0 1 Coolant outlet housing Pre tightening 0 3 0 1 Tightening 0 7 0 1 H e 41 TIGHTENING TORQUES CYLINDER HEAD Petrol and Diesel engines Operation to be performed prior to refitting the cylinder head Clean the seal faces with the CITROEN approved product Do not us
15. Detach the pipe at a Move aside the diesel fuel filter top cover 1 Checks Uncouple the clickfit union at b ESSENTIAL Make sure that the tool 2 is clean Link tools 1 and 2 in series between the fuel high pressure pump and the fuel filter Prime the circuit using the manual priming pump so as not to falsify the measurement Normal vacuum values 117 NOILOAPNI B1B200LD CHECKS LOW PRESSURE FUEL SUPPLY CIRCUIT Engine 8HT Normal vacuum values 10 05 cmhg Engine driven by the starter motor 20 20 cmhg Engine running under full load Supply circuit obstructed 60 05 cmh 9 full tank strainer piping fuel filter Refitting Remove tools 1 and 2 Proceed in the reverse order to removal Action the manual priming pump for 120 seconds in order to prime the fuel circuit Checking the sealing Reconnect the negative terminal of the battery Start the engine Let the engine run at idle for 2 minutes Check that there is no leak Check that there are no air bubbles in the return circuit IMPERATIVE Perform the operations that are required following a battery reconnection see corresponding operation 118 CHECKS TURBO PRESSURE Engine 8HT Tools 1 Pressure gauge for checking boost pressure 4073 T A 2 Sleeve for checking boost pressure 0171 F 3 Manual pressure vacuum pump FACOM DA 16 4 Pliers for removing clic clips
16. 0172 Z IMPERATIVE Respect the safety requirements Checks IMPERATIVE Respect the following test conditions Engine at operating temperature vehicle in running order engine under full load INJECTION B1B2007D Preparation Remove the engine cover IMPERATIVE Do not disconnect the air temperature sensor 3 If the warning lamp in the instrument panel should come on delete the faults using the diagnostic tool Remove the clips 1 Move aside the duct 2 without disconnecting the air temperature sensor 3 Fit the tool 2 in the place of the duct 2 Couple the pressure gauge 2 on the sleeve 1 using the tube a 119 NOILOAPNI CHECKS TURBO PRESSURE Engine 8HT Mode of operation Position tool 1 in the vehicle Start the engine Engage first gear start the vehicle Engage the gears up to third gear Decelerate to an engine speed of 1000 rpm Check the pressure 0 6 0 05 bar 1500 rpm Accelerate freely change from fourth gear to third gear Check the pressure 0 9 0 05 bar between 2500 and 3500 rpm Remove tools 1 2 Reposition the tube 2 Tighten the clips 1 NOTE Confirm the measurement with the aid of the diagnostic tool parameter measures Parameter measures diagnostic tool Checks on the inlet manifold pressure sensor Remove the engine cover 4 inlet manifold pressure sensor 120
17. 4 B2C202MD NOISSINSNVu L HOLNT9 B2C202ND 146 TIGHTENING TORQUES FOR MMT TOYOTA PILOTED MANUAL GEARBOX Tightening torques m daN Re Description Number ot screws Tightening 10 Differential gearwheel fixing screws 6 124512 HIMEN EE EES 12 Fixing screw for reverse gear shaft plate _ 13 Closing panel fixing soen 3 404 _ Fixing screw for coupling of engine on EN RR ses B2C202QD 147 CLUTCH GEARBOX TRANSMISSION NOISSINSNVu L HOLNT9D DRIVESHAFTS GEARBOX EE Tightening torques m daN Gearbox oil seal mandrels I Driveshaft Driveshaft Tightening torque m daN for wheel bolts C1 z 10 m daN 148 WHEELS AND TYRES Standard fit Tyres Spare wheel Circumference Wheel 155 65 R14 75T 155 65 R14 75T All types 1 699 m 4 1 2 J14 H2 1 699 m Steel 4 1 2 J14 H2 Inflation pressures Normal operating pressure Pressure under load maximum Pressure Bars Pressure Bars Tyre dimensions Front Rear Spare Tyre dimensions Front Rear Spare wheel wheel Tightening torques Tighten the wheel bolts to 10 m daN AXLES SUSPENSION STEERING H 149 AXLE GEOMETRY Tyres inflated to correct pressures Vehicle at reference height Steering rack locked at mid point see corresponding operation NOIS
18. 6 x2 7 3 3 x 0 3 4 8 0 5 12 8 1 2 8 5 0 8 5 2 x 0 5 12 8 1 2 4 8 0 5 STEERING SUSPENSION B3C2010D 155 NOISN3dS S S3 XV SPECIFICATIONS REAR AXLE Rear axle 1 Rear axle crossmember 2 Rear hub 3 Rear axle rubber bush Machine welded rear axle of trailing arm type with deformable axle crossmember Engines all types Thickness of crossmember panel Rear hub 2 Rear hub Union on rear axle fixing 4 screws 4 Vehicle geometry NOTE The geometry specifications are given with the values for checking and adjusting the axle geometries B3D200ED 156 TIGHTENING TORQUES REAR AXLE Tightening torques m daN L Ref D Description AXLES SUSPENSION STEERING Tightening 3 Damper upper fixing 2 5 0 2 2 Damper lower fixing 4 8 x 0 4 NE NE Fixing of yoke on rear axle 12 3 1 2 lt Fixing of rear hub on rear axle 6 0 6 B3D200FD 157 NOISN3dS nS SE IXV B3C200VD SUSPENSION SPECIFICATIONS Front axle Anti roll bars Engines all types Travel stop Travel stop height A Rear axle Rear axle crossmember Machine welded rear axle of trailing arm type with deformable axle crossmember Engines all types 5 5 mm Suspension spring During a repair on a suspension spring IMPERATIVE Check the presence and condition of the rubber protections
19. B1G200TD 91 B1G200TD B1B2013D DRAINING FILLING AND BLEEDING THE ENGINE COOLING CIRCUIT Engine 8HT Filling and bleeding the circuit Fit the filling cylinder 1 plug 3 and adaptor 2 assembly on the filling aperture Slowly fill the cooling circuit 1 with coolant fluid up to the 1 litre mark to pressurise the circuit Hemove the clip 2 from the tube Uncouple the tube at a Couple the tube at when the fluid flows out clean and without air bubbles Reconnect the negative terminal of the battery Start the engine Maintain an engine speed of 1500 rpm up to the first cooling cycle starting and stopping of the cooling fan Plug the filling cylinder 1 with the plug 3 Remove the filling cylinder 1 plug 3 and adaptor 2 assembly Stop the engine and wait for it to cool down If necessary top up the level to the maximum mark with the engine cold Refit the header tank cap IMPERATIVE Carry out the operations that are necessary following a reconnection of the battery see corresponding operation CH BOSCH ME 7 9 5 INJECTION SPECIFICATIONS Presentation BOSCH ME 7 9 5 Injection Introduction Application This principle of operation for injection ignition applies to the 384F engine the BOSCH injection system satisfies the following norms Depollution norm L5 EOBD depollution NOTE EOBD European On Board Diagnosis for diagnosis of de
20. MMT gearbox Camshaft sensor Absence of communication with the immobiliser control module 103 OPERATING PHASES BOSCH ME 7 9 5 INJECTION SYSTEM Driver s information function Lighting of engine diagnosis EOBD warning lamp The engine diagnosis warning lamp indicates a failure of a component or of a system relating to emissions if it is causing an increase in emissions to exceed the legal limits Ignition misfirings which carry the risk of destroying the catalytic converter cause the engine diagnosis warning lamp to flash The engine diagnosis warning lamp is not used for any other purpose except if there a risk of destruction of the engine or a risk for the safety of the vehicle occupants NOILOAPNI Access to the EOBD fault codes Access to the memorised fault codes is open to any trained person equipped with a normalised diagnostic tool known as SCANTOOL with which the ECU permits dialogue Access to the diagnostic codes is as follows Mode 1 reading of the number of fault codes and of the engine speed dynamic Mode 2 reading of the fixed datastream associated variables Mode 3 reading of the fault codes Mode 4 deletion of fault codes 104 OPERATING PHASES BOSCH ME 7 9 5 INJECTION SYSTEM MMT piloted manual gearbox The injection ECU dialogues with the automatic gearbox ECU in order to guarantee optimal functioning of the gearbox as well as of the engine WARNING Follow
21. between boot carpet and parcel shelf Pe ABS 50 O Volume of boot below parcel shelf dm 99 GENERAL SPECIFICATION WEIGHTS oor oor o Engine type 384F E4 Gearbox type Payload 30 355 355 30 35 35 Weight empty running order 790 845 80 MEME Gross Vehicle weight 1160 1180 135 1170 1190 145 Gross Train weight _ 1160 180 1235 1170 1190 1245 Max trailer weight with brakes 8 incline SS Bee in Max trailer weight with brakes 10 incline I Max trailer weight with brakes 12 incline I n3 Max trailer weight without brakes LL h i Maximum nose weight j sr un es Maximum weight on roof bars kg OPERATION TO BE CARRIED OUT FOLLOWING A RECONNECTION OF THE BATTERY Before disconnecting the battery make a note of the customer s rado stations Q m Z m 20 P r After reconnecting the battery reprogramme the radio stations GENERAL SPECIFICATION TOWING THE VEHICLE Vehicle towing Towing eye Ci WARNING When the engine is not running steering and braking are no longer power assisted The towing eye 1 is to be found in the vehicle toolkit E2A200CD GENERAL NOTE The vehicle toolkit is stowed in the boot E2A200DD GENERAL SPECIFICATION TOWING THE VEHICLE Vehicle
22. moving arms IMPERATIVE Position the safety straps if placing the vehicle on a lift supported from the jacking points risk of the vehicle overbalancing when a heavy component is removed Equip the moving arms with rubber blocks as indicated To use this lift align the middle of it as far as possible with the centre of gravity of vehicle Present the vehicle as far as possible in the axis of the moving arms Adjust the moving arms to the vehicle s jacking points WARNING Do not raise the vehicle too high to avoid all risk of instability Lock the moving arms while the repairs are being carried out Raise the vehicle just off the ground and check that it is stable TWHANAD Example 2 column lift Place the safety straps 1 under the lift arm and criss crossing the vehicle E2A200BD 14 GENERAL SPECIFICATION LIFTING AND SUPPORTING THE VEHICLE Lifting and supporting the vehicle Note on use of a platform lift Respect the safety requirements set out in the user instructions Use blocks for a platform lift B lift with moving arms C platform lift a rubber block Dimensions of block D 85 mm fr 70 mm Z g 200 mm O h 100 mm Use the following table in order to position the vehicle correctl Right left adjustment Place the vehicle in the middle of the lift Align the bottom of the blocks on
23. on the fixed and sliding cups of the spring compressor IMPERATIVE Do not put a suspension spring in direct contact with a metallic object or tool IMPERATIVE Check the condition of the suspension springs absence of signs of impacts scratches or rust spots The paint coating on the suspension springs should not be damaged no bare metal 158 SUSPENSION TIGHTENING TORQUES Tightening torques m daN Tightening Damper upper cup fixing nut 5 5 0 5 Anti roll bar fixing 1 8 0 2 Pivot lower ball joint nut 9 8 0 9 ub nut 21 6 2 1 Steering ball joint on pivot 3 3 0 3 Suspension leg fixing on pivot 4 8 0 4 Screw fixing subframe on body 8 5 0 8 Screw fixing subframe on body 12 8 1 2 Screw fixing subframe on body 4 8 0 4 Anti roll bar bearing fixing on subframe 1 8 0 1 Screws steering mechanism on subframe 8 7 0 8 Indexed nuts steering mechanism on subframe SUSPENSION STEERING B3B200MD stelle d B3B200ND 159 Tightening torques m daN Ref S Description Tightening 7713 f Damper upper fixing 25502 14 Damperowerhing 48504 15 Fhigofrearadeonbody 123312 NOISN3dS nS S3 XV 1e 16 Fixing of rear hub on rear axle 6 0 6 8 B3D200GD 160 MANUAL STEERING SPECIFICATIONS Manual steering AXLES SUSPENSION STEERING 5 steering wheel fixing 6 fixing of steering column
24. stoplamps switch 1 B3F2012D 173 SEMIS B3F2013D B3F2014D wm Ab wee or em CHECKING THE BRAKE PEDAL Press several times on the brake pedal until any vacuum in the braking amplifier disappears totally engine stopped Press on the pedal until you feel the start of resistance Measure the play as indicated in the dia gram Play C of the brake pedal 1 0 to 6 0 mm If it is not in conformity check the braking circuit Slacken the handbrake With the engine running press on the brake pedal Measure the reserve travel D of the pedal as indicated in the diagram Reserve travel D of the brake pedal relative to the floor more than 48 mm at 490 N If it is not in conformity check the braking circuit Slacken the handbrake With the engine running press on the brake pedal Measure the reserve travel D of the pedal as indicated in the diagram Reserve travel D of the brake pedal relative to the floor more 48 mm at 490 N If it is not in conformity check the braking circuit 174 CHECKING THE BRAKING AMPLIFIER BRAKES IMPERATIVE Respect the safety and cleanliness requirements A in conformity B not in conformity Check the air tightness Start the engine Stop the engine 1 or 2 minutes later Press several times but slowly on the brake pedal NOTE If the brake pedal descends to the floor a at the 1st press but does not descend as far as b at the 2nd pre
25. the brake fluid reservoir 1 Use a diagnostic tool Select the ABS menu Follow the instructions of the diagnostic tool At the end of the bleed programme check the level of the brake fluid top up if necessary Check the travel of the brake pedal it must not be excessive If it is restart the bleed procedure B3F202DD 183 BRAKES O 2 z lt 2 G gt gt Vehicule C 384 F 06 05 gt AIR CONDITIONING R 134 a HFC Compressor refill Fixed Oil 30 gr Capacity fan quantity cc T Refrigerant Oil reference VALEO ZEXEL ZXL 200PG SPECIFICATIONS OF AIR CONDITIONING CIRCUIT R 134 a Compressor condenser 1 Air conditioning compressor drive plate 2 Connector 3 Seals 3 Seals 4 Condenser b Filtering cartridge 6 Condenser inlet 7 Condenser outlet C5H2022D AIR CONDITIONING 185 C5H2023D ONINOILIGNOO SPECIFICATIONS OF AIR CONDITIONING CIRCUIT R 134 a Pressure reducer 8 Pressure reducer inlet 9 Pressure reducer outlet 3 Seals Lubricant WARNING As these oils have a pronounced tendancy to absorb moisture avoid stocking them in containers that have been opened Type of oil used ZXL 200PG IMPERATIVE Never use any other type of oil It is not obligatory to check the level of oil in the compressor when you fill the air conditioning c
26. the extreme edges of the platform rubber Front rear adjustment i and j Align the top of the blocks on one of the blocks k on the front jacking point lug Raise the vehicle just off the ground and check that it is stable E2A2002D 15 TWHANAD CAPACITIES in litres Oil capacities are defined according to the following methods Draining of the engine lubrication system by GRAVITY Place the vehicle on horizontal ground in the high position if hydro pneumatic suspension Draining of the engine lubrication system by SUCTION Place the vehicle on horizontal ground in the high position if hydro pneumatic suspension The engine should be hot oil temperature 80 C The engine should be hot oil temperature 80 C Drain the sump by gravity Remove the oil by suction through the dipstick tube Remove the oil filter cartridge time for draining and drip drip 15 minutes approx Remove the oil filter cartridge Maintain the suction of oil in the sump 15 minutes approx Sea Refit a new oil filter cartridge now Orere re Refill the engine with oil see table for oil capacity Refill the engine with oil see table for oil capacity Start the engine to fill the oil filter cartridge Start the engine to fill the oil filter cartridge Stop the engine allow to stabilise for 5 minutes WARNING Remove the suction con
27. towing Precautions to be taken Manual gearbox Piloted manual gearbox Vehicle equipped with a piloted manual gearbox IMPERATIVE It is necessary to lift the front of the vehicle in order to tow it having placed the gear selector in neutral If there is a gearbox malfunction or fault the vehicle may remain immobilised depending on the seriousness of the fault If a gear is engaged the conditions for immobilisation of the vehicle may engine stopped no starting clutch open clutched TWHANAD ESSENTIAL Never tow the vehicles with wheels hanging towing by the wheels IMPERATIVE If a gear is engaged and it is impossible to disengage it it is compulsory to tow the vehicle with the front wheels lifted If it not possible to lift the front of the vehicle there is more than one way of unjamming the gearbox engaging N with the aid of a diagnostic tool engaging N without the aid of a diagnostic tool 10 GENERAL SPECIFICATION TOWING THE VEHICLE Vehicle towing Precautions to be taken Piloted manual gearbox Engaging N with the aid of a diagnostic tool Preliminary operations Vehicle stationary engine stopped Engaging N without the aid of a diagnostic tool Battery voltage higher than 12 5 volts Ignition switched on In this configuration the gearbox actuator is jammed gear engaged Gear selector on position N Connect the diagnostic tool to the vehicle s diagnosti
28. ASIN LUCK Mechanism Type 200 CPXV Ext Int lining 0 181 133 190 133 200 134 CO MT Manual gearbox MMT Piloted manual gearbox CLUTCH GEARBOX TRANSMISSION 127 CLUTCH TIGHTENING TORQUES Tightening torques m daN Ref Description Tightening the top screw a Align the reference b Screws for clutch m mechanism on flywheel Screws for flywheel 78 07 Position the mechanism using NOISSINSNVu L HOLNT9D B2B2017D 128 CHECKING AND ADJUSTING THE CLUTCH PEDAL TRAVEL Move aside the floor carpet a Pedal height adjustment point Height A of the pedal in relation to the floor between 135 and 145 mm Adjust the height A of the pedal Slacken the locking nut and turn the stop screw until you obtain the correct height B2B2000D Tighten the locking nut Tightening torque 2 5 0 2 m daN CLUTCH GEARBOX TRANSMISSION Press on the pedal until you feel the start of resistance Play B in the pedal 18 to 28 mm B2B2001D 129 CHECKING AND ADJUSTING THE CLUTCH PEDAL TRAVEL Turn the clutch adjustment nut b until you obtain the correct play B in the pedal After adjusting the play B in the pedal check the height A of the pedal Tighten the parking brake lever and fit a wheel chock Start the engine and let it run at idle Without pressing the clutch pedal bring the gear lever slowly in
29. CHECKING THE AIR SUPPLY CIRCUIT Tools 1 Manual pressure vacuum pump FACOM DA 16 IMPERATIVE Respect the safety and cleanliness requirements Checks Vacuum pump NOILOAPNI Connect the tool 1 onto the vacuum pump 1 Start the engine Wait 30 seconds The vacuum value should be 0 9 0 1 bar at idling speed B1H201GD NOTE The exhaust gas recycling valve is not linked to the air supply circuit The exhaust gas recycling electrovalve is controlled by the engine ECU Turbocharging pressure regulation valve Connect the tool 1 on the valve 2 tube identified by the colour grey Appy a vacuum of approx 0 8 bar Rod a should move 12 2 mm 124 SPARKING PLUGS ak conventional type The sparking plugs are of the long thread type aj This permits an increased thickness of the cylinder head in the zone where the sparking plugs are siuated The coolant liners j can thus be extended around the combustion chambers to improve cooling Specifications CITROEN PEUGEOT Electrode gap The charging system uses an alternator that is compact and light but of conventional type Specifications Type Supplier Nominal voltage Nominal output voltage Initial output starting speed Specifications Type Supplier Output power Nominal voltage Weight grammes option 1 0 kW 12V DENSO 596086 DENSO 596085 1 1
30. N3dS nS SE XV Vehicle heights at reference height L2 H1 R1 L1 H2 R2 L2 H2 Measurement between the measuring zone underneath the rear sill and the ground H1 Measurement between the measuring zone underneath the front sub frame and the ground R1 Front wheel radius under load R2 Rear wheel radius under load L2 Distance between the wheel axis and the measuring zone underneath the rear sill 150 L1 Distance between the wheel axis and the measuring zone underneath the front subframe AXLE GEOMETRY AXLES SUSPENSION STEERING B3B200DD Measuring front height Measuring rear height 1 Gauge for measuring the wheel radius 4 bolts tool 4801 T Value at reference Value at reference height L1 88 mm height 6 8 mm 10 6 mm Compress the suspension to obtain the calculated values The height difference between the two axle dimensions should be less than 10 mm 151 AXLE GEOMETRY Dissymmetry of lower castor at 0 30 Dissymmetry of lower camber at 0 30 Dissymmetry of lower camber at 0 30 All Types SE EIA SEERE NOISN3dS nS CFA 8HT CFA 8HT 155 65 R 14 5 0 A ml Adjustable Non adjustable Non adjustable m wert fo 3 6 22 wes o osora zur our oas 0 24 0718 Angle of steering full 38 55 2 lock A B Positi
31. VE TIMING Refit the valve cover gasket in the groove of the valve cover and on the centring bosses indicated by the arrows WARNING Check the positioning of the gasket which must be well seated around the bases of the bosses 3 to 4 mm Apply a strip of seal paste j on the sealing faces of the cylinder head and of the timing cover Seal paste AUTOJOINT OR WARNING Refit the valve cover within 3 minutes and tighten the screws and nuts within 15 minutes following application of the strip of seal paste j B1D200VD 67 CHECKING AND SETTING THE VALVE TIMING B1D201QD Tighten the 13 bolts and 2 nuts to the correct torque in the sequence indicated Tightening torque 0 8 m daN After tightening all the screws and nuts check that 1 and 2 are tightened to the correct torque Hefit the crankshaft position sensor WARNING Do not use any component that has been dropped or knocked WARNING Check the condition of the O ring seal before refitting it Coat the O ring seal with a thin layer of engine oil Refit the crankshaft position se
32. VE TIMING Refit the keyway in the groove of the crankshaft Align the groove of the crankshaft pinion with the keyway of the crankshaft and refit the crankshaft pinion Refit the chain guide with the 2 screws Tightening torque 0 9 gt 0 1 m daN B1D202HD 59 CHECKING AND SETTING THE VALVE TIMING B1D202KD Engine CFA To refit the timing chain align the link c yellow in colour with the setting mark b on the crankshaft pinion as indicated To complete the refitting of the timing chain align the 2 links d orange in colour with the setting marks a on the camshaft pulleys as indicated Refit the chain tensioner guide with the screw Tightening torque 1 9 0 2 m daN 60 CHECKING AND SETTING THE VALVE TIMING Turn the hexagonal part of the inlet camshaft anti clockwise in order to detension the timing towards the tensioner Refit the tensioner with the 2 screws Tightening torque between 0 8 and 1 3 m daN Remove the peg rotate the crankshaft by 2 full turns and unlock the chain tensioner B1D202MD 61 CHECKING AND SETTING THE VALVE TIMING Check that the setting mark a on the camshaft pulley is on top with the chain in tension Refit the timing cover Coat the lip of a new lip seal with engine oil B1D202PD 62 CHECKING AND SETTING THE VALVE TIMING Fit the new crankshaft seal using to
33. VERY IMPORTANT As the booklet is constantly re edited this one only covers vehicles for this particular model year It is therefore necessary to order a new booklet each year and RETAIN THE OLD ONES PRIVATE CARS CITROEN C1 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 CITROEN network periodically for further information and to obtain any possible updates PRIVATE CARS CITROEN AC QCAV MTD The intellectual property rights relating to the technical information contained in this document belong 2005 M thodes techniques documentation exclusively to the manufacturer Reproduction translation or distribution in whole or in part without prior written authorisation from the manufacturer is forbidden CAR 000 022 PRESENTATION THIS HANDBOOK summarises the specifications adjustments checks and special features concerning CITRO N C1 The handbook is divided into gro
34. amplifier Remove the screw 2 Uncouple the vacuum pipe at a B3F202ED 177 SEMIS CHECKING THE VACUUM PUMP B3F202FD Insert the union 2 between the vacuum pump and the braking amplifier Connect the tool 1 on the union 2 Run the engine at idling speed Check the vacuum value Remove the tools Uncouple the vacuum pipe at a Refit The screw 2 The scuttle panel The wiper motor The top scuttle panel ventilation grilles The upper seal between bonnet and scuttle panel The windscreen wiper arm The windscreen wiper arm mounting cap Values to check NOTE The vacuum value should be higher than or equal to 0 850 bar Engine oil temperature Minimum Maximum time in seconds vacuuml to attain the minimum vacuum 500mbar A8 800mba 18 202 If the value is outside the tolerance Check the vacuum pump directly Check the sealing of the circuit on the link pipes as well as on the braking amplifier 178 ADJUSTING THE HANDBRAKE The handbrake adjustment is under the central console BRAKES IMPERATIVE Respect the safety and cleanliness requirements Adjust the handbrake shoe clearance Check the travel of the handbrake lever Slowly pull the handbrake lever to the maximum high position counting the number of clicks Travel of the handbrake lever 5 to 8 clicks at 196 N B3F2021D Remove the central console Turn the adjustment nut until the h
35. andbrake lever travel corresponds to the value indicated Travel of the handbrake lever 5 to 8 clicks at 196 N Action the handbrake lever 3 to 4 times and check its travel Check that the handbrake is not rubbing when it is in the released position Check that the handbrake warning lamp lights up when the handbrake is applied Standard operation the handbrake warning lamp always lights up from the first click Refit the central console B3F200ZD 179 SEMIS B3F202AD DRAINING FILLING AND BLEEDING THE BRAKING SYSTEM Tools 1 Generic bleeding apparatus LURO or similar IMPERATIVE Respect the safety and cleanliness requirements NOTE Bleeding of the secondary braking circuit is done with the aid of a diagnostic tool Draining Disconnect the negative terminal of the battery Hemove The windscreen wiper arm mounting cap The windscreen wiper arm The upper seal between bonnet and scuttle panel The top scuttle panel ventilation grilles The wiper motor The scuttle panel Drain the brake fluid reservoir 1 to the maximum if necessary use a clean syringe Disconnect the connector at a 180 DRAINING FILLING AND BLEEDING THE BRAKING SYSTEM Drain the brake fluid reservoir 1 to the maximum if necessary use a clean syringe Disconnect the connector at a Remove the brake fluid reservoir 1 by moving aside the tabs at b of the pins 2 Clean the brake flu
36. ar driven pinion 14 2nd gear driven pinion 15 3rd gear driven pinion 16 4th gear driven pinion 17 5th gear driven pinion B2C2011D 17 16 15 141312115 132 TIGHTENING TORQUES FOR MT TOYOTA MANUAL GEARBOX Tightening torques m daN Description umber of screws Tightening Closing plate fixing 4 0 4 ixing of gearbox on engine 6 4 0 6 Fixing of gearbox support on body E 5 2 0 5 Fixing of clutch fork support 3 3 0 3 Fixing of gear controls plate 1 1 x 0 1 B2C201DD CLUTCH GEARBOX TRANSMISSION B2C201ED 133 TIGHTENING TORQUES FOR MT TOYOTA MANUAL GEARBOX j gt o 2 oct uu o Me OQI O z 134 TIGHTENING TORQUES FOR MT TOYOTA MANUAL GEARBOX Tightening Fixings of gearbox casing and clutch o 2 9 0 3 housing CLUTCH GEARBOX TRANSMISSION B2C201HD 135 DRAINING AND FILLING MT TOYOTA MANUAL GEARBOX Presentation 1 gearbox drain plug 2 filler and level plug Oil quality Refer to the manufacturer s instructions NOISSINSNVu L H LNTO Oil quantity After draining 1 7 litres B2C2000D 136 RECOMMENDATIONS PRECAUTIONS MMT PILOTED MANUAL GEARBOX Safety requirements ESSENTIAL Given the special features of the MMT piloted manual gearbox observe the requirements detailed below IMPERATIVE Always disconnect the battery neg
37. atio OCR Information on the noise of combustion nformation on the engine coolant temperature Analogue Nature the signal Information on the cooling circuit Analogue pressure INJECTION Control of the canister purge electrovalve Control of the motorised butterfly MMT piloted manual gearbox Open cycle ratio Control of the variable valve OCR timing electrovalve Control of the cooling fan Supply of the ignition coils All or nothing Control of the petrol injectors Information on the position of the accelerator pedal Information on the inlet air pressure Information on engine speed ratio OCR Information on the oxygen content of the 7 17 exhaust gases after the cat converter Analogue Information on the oxygen content of the exhaust gases before the cat converter Information on the brake switch All or nothing Information on the inlet air temperature 97 NOILOAPNI OPERATING PHASES BOSCH ME 7 9 5 INJECTION SYSTEM Engine management The engine ECU manages the injection on the basis of the information on engine torque The engine ECU calculates the need for engine torque from the accelerator pedal sensor The engine torque requested takes account of various corrections The engine torque requested is obtained by acting on the following components Butterfly angle motorised butterfly housing Ignition advance knock regulation
38. ative terminal before operating on the actuators NOTE After disconnecting the battery never try to remove the clutch actuator on the vehicle before having checked that it is in the closed position rod pushed in IMPERATIVE After Sales checks done with the engine running must be performed with Neutral engaged and the handbrake on unless there is a clear mention otherwise in the repair procedures IMPERATIVE The area of movement of the clutch fork must always be kept free during the actuator operating phases CLUTCH GEARBOX TRANSMISSION IMPERATIVE When initialising the clutch actuator and or gearbox actuator do not allow any person to walk or stand in front of the vehicle WARNING When the engine is running it is forbidden to perform repairs on the clutch and gearbox actuators on the vehicle whether manually or using a diagnostic tool B2C201SD 137 RECOMMENDATIONS PRECAUTIONS MMT PILOTED MANUAL GEARBOX Repairs on the gearbox Gearbox removed position a block 1 so as not to damage the gear sensor 2 Operations on electrical components Do not disconnect The battery when the engine is running The ECU with the ignition switched on The clutch and gearbox actuators with the ignition switched on When carrying out electrical checks The battery must be correctly charged Never use a voltage source higher than 16V
39. bleed apparatus 1 on the brake fluid reservoir 1 Adjust the apparatus pressure to 2 bars For each brake circuit Couple a transparent tube on the bleed screw Submerge the other end of the tube in a clean container Open the bleed screw Wait until the brake fluid flows out without air bubbles Close the bleed screw Remove the bleed apparatus 1 Check the level of the brake fluid between the MINI level and the MAXI level Fill if necessary with the the approved and recommended synthetic brake fluid 182 DRAINING FILLING AND BLEEDING THE BRAKING SYSTEM Bleeding the braking circuit without the bleed apparatus NOTE Two operators are necessary For each brake circuit Apply the brake pedal to place the circuit under pressure Couple a transparent tube on the bleed screw Submerge the other end of the tube in a clean container Open the bleed screw Wait until the fluid flows out without air bubbles Close the bleed screw NOTE Recommence the process a second time if that is necessary Check the level of the brake fluid between the MINI level and the MAXI level Fill if necessary with the the approved and recommended synthetic brake fluid B3F202CD Bleeding the secondary braking circuit WARNING During the bleed operations take care to maintain the level of the brake fluid in the reservoir keep it topped up NOTE The bleed apparatus 1 is still connected on
40. c socket IMPERATIVE This emergency solution is to be used only where Using the diagnostic tool menus select the above solutions for setting the gearbox actuators using the dia DIAGNOSIS gnostic tool have failed destruction of the gearbox actuator MMT piloted manual gearbox Preliminary operations Actuator tests Gearbox actuator test Disconnect the negative terminal of the battery Engaging Neutral Remove the blank on the gearbox actuator GENERAL NOTE The letter N should appear in the instrument panel If not see the following solution engage N without the help of a diagnostic tool 11 GENERAL SPECIFICATION TOWING THE VEHICLE Vehicle towing Precautions to be taken Piloted manual gearbox a Neutral b 1 5h 274 4 reverse gear Using a large screwdriver move the screw 3 to bring the gearbox actuator to the neutral position When this position is reached is engaged Driving IMPERATIVE Never drive with the ignition switched off Never push the vehicle to attempt to start it impossible with a piloted manual gearbox B2C201TD 12 E2A2001D GENERAL SPECIFICATION LIFTING AND SUPPORTING THE VEHICLE Lifting and supporting the vehicle Note on status of the vehicle before lifting The vehicle
41. countries 21 ENGINE SPECIFICATIONS Engine type CFA 8HT Cubic capacity cc 998 1398 Bore Stroke 71 84 73 7 85 Compression ratio 18 1 Power ISO or EEC KW rpm 10 5 1 50 6000 40 3000 Maximum power DIN hp rpm Torque ISO or EEC m daN rpm 68 6000 9 3 3600 54 3000 13 3000 PRESENTATION OF ENGINE 384 F CFA Description The petrol engine 384F used on the new vehicle has been developed recently This is a 1 0 engine with 3 cylinders in line with 12 overhead valves This engine is light and compact giving good fuel economy It uses DIS Direct Ignition System and VVT i Variable Valve Timing intelligent The search for high performance silence in operation reduced fuel consumption and low emissions were all decisive in its design B1B201XD 23 PRESENTATION OF ENGINE 384 F CFA Number of cylinders and arrangement Timing Combustion chamber Manifolds Fuel delivery system Ignition system Cylindrical capacity cc Bore Travel mm Compression ratio Maximum power SAE NET Maximum torque SAE NET 24 3 cylinders in line 12 valves overhead camshaft driven by chain with VVT i Wedge shaped Cross flow Electronic injection DIS 998 71x 84 10 5 1 50 kW at 6000 rpm 93 Nm at 3600 rpm PRESENTATION OF ENGINE 384 F CFA Adjustment of inlet valves opening 40 after TDC 5 after TDC
42. crew ST c B1B201DD Cylinder head bolts Tightening 3 2 0 3 Angular tightening 180 5 1 5 0 1 1 3 0 1 2 4 0 2 0 8 gt 0 1 47 0 4 0 IN o B1B201ED 34 TIGHTENING TORQUES PETROL ENGINE Crankshaft RH engine support Tightening of screws on block Tightening of screws on body Timing chain cover screw Timing chain cover screw B1B201FD 35 TIGHTENING TORQUES PETROL ENGINE Engine CFA Lubrication Flywheel clutch 16 Flywheel screws 17 Clutch plate screws B1B201GD B1B2015D 36 TIGHTENING TORQUES PETROL ENGINE Injection circuit 18 Injection rail screw on block 2 7 0 3 Cooling circuit Coolant pump screws Coolant inlet housing screws Accessories Alternator screw Tensioner screw Aircon compressor screw B1B201XD D1A2004D 37 TIGHTENING TORQUES ENGINE SUSPENSION RH engine support Lower RH engine support 3 52205 Oper 5 2 0 5 8 5 2 0 5 Engine gearbox assembly suspension 1 5 2 0 5 4 57206 au 242 9 52205 Engine 8HT 2 5 2 0 5 Torque reaction rod LH engine support on gearbox 10 5220 B1B201BD TIGHTENING TORQUES DIESEL ENGINE Engine 8HT Crankshaft Bearing cap fixing screws Pre tightening Slackening Tightening Angular tightening Con rod screws Tightening 1 0 1
43. ction Engine operating for at least 6 minutes No fault in the oxygen sensors downstream oxygen sensor upstream oxygen sensor No combustion misfirings Outside the fixed limit a fault is recorded in the injection ECU and the diagnostic warning lamp comes on 102 OPERATING PHASES BOSCH ME 7 9 5 INJECTION SYSTEM Display of faults The engine diagnosis warning lamp lights up if there is a fault on any of Ageing of the catalytic converter the following components or types of information Vehcle speed sensor signal z Idle stepper motor signal Control of the variable valve timing electrovalve Supply of sensors T Inlet air temperature sensor Battery voltage too low a Engine coolant temperature sensor Battery voltage too high 2 Motorised butterfly signal 1 2 Brake switch signal MMT gearbox Heating of the upstream oxygen sensor Inlet manifold pressure sensor Heating of the downstream oxygen sensor Signal internal to the ECU Richness regulation Control of the motorised butterfly MMT gearbox Command of injector for a given cylinder 1 2 3 Jamming of the motorised butterfly MMT gearbox Ignition misfiring cylinder undetermined Position of the motorised butterfly MMT gearbox Ignition misfiring for a given cylinder 1 2 3 Incoherent information coming from the accelerator pedal sensor MMT Knock sensor signal gearbox Engine speed sensor signal Accelerator pedal position sensor signal 1 2
44. ction system Engine phase detector camshaft position sensor Camshaft dephaser VVT Sequential injection Air temperature sensor incorporated in the air pressure sensor in the inlet manifold Engine cooling function integral to the injection ECU Dialogue between the injection ECU and the piloted manual gearbox ECU type MMT CAN network Accelerator pedal sensor incorporated in the accelerator pedal Motorised butterfly housing with the MMT piloted manual gearbox Features of the fuel circuit Injection rail without fuel return Fuel pump gauge module with integral fuel filter NOILOAPNI 94 GENERAL SYNOPSIS BOSCH ME 7 9 5 INJECTION SYSTEM z o O mr 2 m O O Z GENERAL SYNOPSIS BOSCH ME 7 9 5 INJECTION SYSTEM Engine speed sensor Engine ECU Injector cylinder N 1 Injector cylinder N 2 Injector cylinder N 3 Canister purge electrovalve Engine coolant temperature sensor Inlet air temperature sensor Accelerator pedal position sensor MMT piloted manual gearbox Motorised butterfly housing Variable valve timing electrovalve VVT Inlet air pressure sensor Downstream oxygen sensor Upstream oxygen sensor Cooling fan Brake dual function switch Linear pressure sensor for the coolant fluid with aircon GENERAL SYNOPSIS BOSCH ME 7 9 5 INJECTION SYSTEM Engine CFA signal 7 Open cycle Information on the position of the camshaft r
45. e abrasives or cutting tools on the seal faces The seal faces must not show any traces of impacts or scratches Pass a tap into the threads in the cylinder block that receive the cylinder head bolts Brush the threads of the cylinder head bolts Coat the threads and under the heads with MOLYKOTE G RAPIDE PLUS Tiahteni Cylinder head bolts ightening Max re usable length i n mm Tightening Angular tightening B1D2028D Pre tightening Tightening Angular tightening B1D2019D 42 BELT TENSION SEEM UNITS CORRESPONDENCE TABLE 1 daM 1 Kg ud Lime MET Tel o aes seen roa uo solos ie TYPE DE COURROIES EHE AUXILIARY EQUIPMENT DRIVE BELT See pages 46 to 47 48 to 49 44 AUXILIARY EQUIPMENT DRIVE BELT TOOLS Belt tension measuring instrument 4122 T C TRONIC 105 5 WARNING If using tool 4099 T C TRONIC 105 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 45 AUXILIARY EQUIPMENT DRIVE BELT Engine CFA Removing a Tension pulley b Alternator pulley c Compressor pulley d Crankshaft pulley B With aircon C Without aircon Slacken the screw 1 Slacken the screw 2 Do up the screw 2 without tig
46. ect injection MMT piloted manual gearbox 137 140 33 37 Pre postheating system Specifications Checking the pressure fuel Supply circuit Tightening torques Auxiliary drive belt hecking turbo pressure 119 121 MMT piloted manual gearbox 145 147 Checking and setting the valve timing ir supply circuit 122 124 Driveshafts gt memi leegen 89 Axle geometry mae Draining filling bleeding the braking 180 183 mme 359 umasa ara JS Wem ee Tightening torques rear axle a S Tightening torques suspension 159 160 Filtering cartridge 188 189 Manual steering 161 Aircon circuit CFA engine Setting the steering rack e mid point BRAKES IDENTIFICATION OF VEHICLES A Manufacturer s plate On the centre pillar 3 door version On the rear door aperture 5 door version A AS RP No and RP paint code GENERAL B Chassis stamp Cold stamp on the crossmember under the front RH seat C Tyre pressures and tyre type Label on the front pillar on driver s side E1A2004D TWHANAD IDENTIFICATION OF VEHICLES Type approval Version Depollution gearbox 4 Family 1 Gearbox Depollution EH Bodywork 2 E5 5 speed gearbox PN CFAC T CFA Engine 3 E Version 4 Variants 5 Variant 5 Fiscal incentives Family 1 Entreprise van convertible Body shape 2 3 door saloon 4 seats
47. ecycling canister function Engine stopped the electrovalve is closed the canister absorbs the fuel vapours coming from the tank The electrovalve piloted by the injection ECU recycles the petrol vapours stored in the canister The quantity of petrol stored in the canister is determined by the injection ECU As soon as the canister has to be purged the ECU temporarily makes the engine operate on a homogeneous mixture Overspeed protection The injection ECU permanently monitors the engine speed As soon as the engine speed exceeds the maximum value 6 400 rpm there is an injection cut off INJECTION 101 NOILOAPNI OPERATING PHASES BOSCH ME 7 9 5 INJECTION SYSTEM EOBD diagnostic function EOBD European On Board Diagnosis for diagnosis of depollution equipment This diagnosis informs the driver if the depollution equipment is no longer fulfilling its role The on board diagnosis system monitors Elements of the injection system polluting emissions destruction of the catalytic converter The efficiency of the catalytic converter K Catalytic converter in good condition L Catalytic converter in poor condition a Upstream oxygen sensor b Downstream oxygen sensor The efficiency of the catalytic converter is determined by comparing the signals coming from the ups tream and downstream oxygen sensors The detection is performed 6 minutes after the starting of the engine Conditions of dete
48. equipped with an idle regulation stepper motor Important variations in the engine idling speed due to the different accessories on the vehicles depending on their operating status aircon alternator Variations in engine idling speed due to the ageing of the engine This device enables a progressive return to idling speed Role of the idle regulation function To regulate the idling speed To obtain a fast idle speed that decreases with the warming up of the engine To improve the idling speed for the vehicle in motion Engine starting Entry into starting phase occurs as soon as the injection ECU is powered During starting the injection ECU commands the following components Priming pump low pressure cut off after 3 seconds provided the starter motor has not operated The electrical supply of the oxygen sensors Functioning of the transitory engine speeds Command of the injectors is corrected as a function of the following variations Butterfly position Pressure in the inlet manifold The detection of these engine speeds accelerations decelerations is by intermediary of the butterfly potentiometer or of the pressure sensor In these operating modes the quantity of fuel injected depends on the variation of the butterfly angle or on the variation of the pressure Correction for full load Approaching full load the air fuel mixture has to be made richer in order to obtain optimum engine performance In the case of a syste
49. fluid NOTE The drain screw 1 is situated close to the lower edge of the timing cover Remove the radiator cap a Uncouple the radiator outlet hose to drain the coolant fluid Couple the radiator outlet hose on the engine side Refit the drain screw 1 Tightening torque 2 0 2 m daN Fill the radiator with engine coolant fluid until it overflows Capacity 4 Litres WARNING Do not replace coolant fluid with water NOTE Use of coolant fluid that is inappropriate may damage the cooling system NOTE Use only Toyota Super Long Life Coolant engine coolant fluid or any other similar high quality coolant fluid based on ethylene glycol without silicate without amine without nitrite and without borate but with hybrid organic acid properties that guarantee long life this type of fluid is a blend of organic acids and phosphates in low concentration B1G200PD 89 DRAINING FILLING AND BLEEDING THE ENGINE COOLING CIRCUIT Engine CFA Press the radiator inlet and outlet hoses several times to test the level of coolant in the radiator If the level goes down add more coolant fluid Screw the radiator cap a back on securely Slowly pour engine coolant into the expansion chamber up to the maximum mark Warm up the engine until the cooling fan triggers Adjust the air conditioning as indicated during the rise in engine temperature Manual air conditionin
50. g system Adjust the controls as indicated Speed of cooling fan all adjustments except temperature in position OFF button turned towards hot air air conditioning control in position OFF Maintain the engine speed between 2000 and 2500 rpm until the cooling fan triggers Press several times on the radiator inlet and outlet hoses several times during the rise in engine temperature Stop the engine and wait for the coolant temperature to come down If the coolant level is below the maximum mark repeat the 10 previous stages until the coolant level is up to add more coolant fluid Again check the level of engine coolant in the expansion chamber If it is below the maximum mark add more coolant fluid Fill the radiator with coolant fluid and fix on it a radiator cap tester Pump to obtain a pressure of 1 37 bar and check that there is no leak 90 DRAINING FILLING AND BLEEDING THE ENGINE COOLING CIRCUIT Engine 8HT 1 Filling cylinder 2 Adaptor for filling cylinder 4222 T 3 Control rod for filling cylinder Draining Disconnect the negative terminal of the battery Remove the header tank cap with care Place a draining tray under the cooling radiator Drain the radiator by uncoupling the bottom hose Place a draining tray under the engine Drain the engine by removing the plug 1 accessible from above the engine Refit the drain plug 1 with a new O ring seal and clip
51. he screw 12 new Tighten the screw of the accessories drive pulley 12 Pre tightening 3 0 3 m daN Angular tightening 180 5 Remove tool 1 Refit the exhaust clip using tool 5 In the engine compartment Refit the upper timing cover 5 the expansion chamber 8 the accessories drive belt see corresponding operation 2 Proceed in the reverse order to the removal operations ei UU EE Reconnect the battery negative terminal N IMPERATIVE Perform the operations that are required following a battery reconnection see B1E2004D corresponding operation 71 EXHAUST LINE SPECIFICATIONS Engine CFA Inlet and exhaust system General 37 Silencer An inlet manifold 36 made of plastic to reduce weight The butterfly body 40 is of plastic The valve cover 1 is of plastic It incorporates the air filter housing 38 The exhaust manifold 39 and piping are of stainless steel These reduce weight and have better resistance to corrosion B1B202FD 78 EXHAUST LINE SPECIFICATIONS Butterfly body manual gearbox 42 butterfly position sensor The butterfly body 40 is of plastic to reduce weight An idle control valve 41 of the stepper motor type is fitted inside the butterfly body 40 Inlet manifold The inlet manifold 43 is of plastic to reduce weight and the quantity of the heat transmitted by the cylinde
52. horities Accident prevention Environmental protection WARNING Repairs must be carried out by specialised personnel informed of the safety requirements and of the precautions to be taken NOILOAPNI Safety requirements IMPERATIVE Take into account the very high pressures in the high pressure fuel circuit 1350 bars and respect the requirements below No smoking in proximity to the high pressure circuit when work is being carried out Do not work close to flame or sparks Always stay clear of the trajectory of any possible jet of fuel which could cause serious injuries Do not place your hand close to any leak in the high pressure fuel circuit After the engine has stopped wait 30 seconds before any intervention NOTE This waiting time is necessary in order to allow the high pressure fuel circuit to return to atmospheric pressure Catalytic converter Make sure that there are no aerosols or inflammable products in the vehicle boot Protect yourself with high temperature gloves Connect the vehicle to an approved gas extractor for this type of operation 112 SAFETY REQUIREMENTS HDi DIRECT INJECTION SYSTEM Cleanliness Requirements Preliminary operations IMPERATIVE The technician should wear clean overalls Before working on the injection system it may be necessary to clean the apertures of the following sensitive components refer to corresponding procedures Low p
53. htening it until there is no more play A Slacken the screw 3 Remove the trapezoidal belt from the ventilator and from the alternator 46 AUXILIARY EQUIPMENT DRIVE BELT Engine CFA Refitting Hefit the trapezoidal belt on the ventilator and on the alternator a Tension pulley b Alternator pulley c Compressor pulley d Crankshaft pulley B With aircon C Without aircon Do up the screw 2 without tightening it until there is no more play A Tighten the screw 3 to tension the trapezoidal belt on the ventilator and on the alternator Check the trapezoidal belt on the ventilator and on the alternator Tighten the screw 2 Tightening torque 3 4 0 3 m daN Tighten the screw 1 Tightening torque between 4 3 and 5 5 m daN Visually check the cabling of the alternator and listen for any abnormal noise Check the circuit of the discharge alert warning lamp B1B2000D 47 B1B2010D AUXILIARY EQUIPMENT DRIVE BELT Engine 8HT Tools 1 Compression lever for dynamic tensioner 0194 E3 2 Peg for dynamic tensioner roller 0194 F References on the dynamic tensioner roller b Nominal position a Position for maximum wear of the auxiliary drive belt Removing Disconnect the battery negative cable Raise and support the vehicle wheels hanging Lock the front wheels on full RH lock Move aside the spla
54. id reservoir 1 Refit the brake fluid reservoir 1 Reconnect the connector at a Refit the windscreen wiper arm mounting cap the windscreen wiper arm the upper seal between bonnet and scuttle panel the top ventilation grilles of the scuttle panel the wiper motor the scutt le panel Reconnect the negative terminal of the battery IMPERATIVE Carry out the operations that are necessary following a reconnection of the battery see corresponding operation Filling the braking circuit WARNING Use only the approved and recommended hydraulic fluids IMPERATIVE Only use new brake fluid that has not emulsified avoid any introduction of impurities into the hydraulic circuit Fill the brake fluid reservoir 1 Bleeding the primary braking circuit WARNING During the bleed operations take care to maintain the level of the brake fluid in the reservoir keep it topped up WARNING The ABS system must not be in action during the bleed operation WARNING Respect the sequence for the opening of the bleed screws 181 BRAKES SEMIS DRAINING FILLING AND BLEEDING THE BRAKING SYSTEM B3F202CD B3F202DD Front brake caliper Bleed screw 3 Rear brake caliper Bleed screw 4 Bleed each brake cylinder proceeding in the following sequence Front LH wheel Front RH wheel Rear LH wheel Rear RH wheel Bleeding the braking circuit with the bleed apparatus Connect the
55. ing any incident concerning the injection it is essential to read the faults in the injection ECU and the piloted manual gearbox ECU The piloted manual gearbox ECU receives the following information from the injection ECU Engine load as a function of the position of the accelerator pedal Engine speed Engine temperature The piloted manual gearbox ECU sends the following information from the injection ECU Information on request for torque reduction Information on request for compensation of idling speed Gear changing quality is enhanced by an order to reduce engine torque given by the gearbox ECU to the injection ECU When there a change of gear the gearbox ECU Pilots the engine ECU in terms of engine torque and engine speed in making the change of gear Pilots the changing of the gear inside the gearbox INJECTION 105 AIR FILTER SPECIFICATION Engine CFA Air filter NOILOAPNI 45 air filter cartridge 46 air filter cover The valve cover 1 incorporating the air filter housing 38 is made of plastic to reduce weight B1B202JD 106 FUEL SUPPLY SYSTEM SPECIFICATIONS Engine CFA General Injectors 54 with 4 holes are used in order to enhance the spraying of the fuel The non return fuel supply system reduces emissions by evaporation The fuel tank 52 is made of plastic The fuel pump module 53 is compact and light comprising the fuel gauge which incorporate
56. ions that must be taken prior to a repair AXLES SUSPENSION STEERING BRAKE SPECIFICATIONS SEMIS Disc thickness minimum thickness 20 18 Ventilated 247 Brake pad supplier grade JURID 682 Drum 200 201 Original maximum width Lining supplier grade FERODO 3627 F 166 BRAKE SPECIFICATIONS Braking system BRAKES Braking circuit in the form of an X Ventilated disc brakes at the front drum brakes at the rear NOTE The front brake pads have no wear warning lamp Handbrake lever controlled by cables acting on the rear wheels The compensator and main brake limiter functions are assured by the ABS REF systems NOTE EBD REF Electronic Brakeforce Distribution B3F201ZD 167 SEMI BRAKE SPECIFICATIONS Hydraulic valve block Make BOSCH Type ABS REF 8 0 Installed on the master cylinder B3F2020D 168 TIGHTENING TORQUES BRAKES Tightening torques m daN Description BRAKES Tightening Front brake disc 0 5 Yoke on brake caliper 3 0 3 3 0 3 Front brake caliper 8 9 gt 0 9 ABS hydraulic valve block support 1 9 x 0 2 Front wheel sensor 0 8 0 1 B3F201VD 169 Front brakes Tightening torques m daN SEMIS Master cylinder 8 Braking amplifier 9 Handbrake lever
57. ircuit NOTE The oil level must be checked in cases of leaks in the air conditioning circuit see corresponding operation Pressostat Linear pressure sensor Filler valves Type of valves clickfit with protection cap NOTE The high pressure and low pressure valves have different diameters to avoid any error in fitting Seal O ring seal 186 SPECIAL FEATURES AIR CONDITIONING CIRCUIT R 134 a The pollen filter is located in the passenger compartment under the dashboard on RH side Remove the pollen filter 1 Refitting Clean the pollen filter housing Fit a new pollen filter Check the flow of air through the air blower operating it at its different speeds C5H202JD AIR CONDITIONING SPECIAL FEATURES AIR CONDITIONING CIRCUIT R 134 a Filtering drying cartridge ove the screw and the filtering drying cartridge ove the 4 O ring seals from the condenser ONINOILIGNOO SPECIAL FEATURES AIR CONDITIONING CIRCUIT R 134 a Filtering drying cartridge Refitting Lubricate 4 new O ring seals as well as the contact surface of the filtering drying cartridge using compressor oil ZXL 200PG or equivalent Compressor oil Fit the 4 O ring seals on the condenser Refit the filtering drying cartridge with the screw 1 3 0 1m daN Tightening torque Refit the supp
58. llowers 25 are not adjusted using shims this to reduce weight NOTE Adjustment of valve clearances is done by replacing the existing cam followers with cam followers of the appropriate thickness Cam followers are available in 29 thicknesses going in inter vals of 0 02 mm from 5 12 mm to 5 68 mm lt Fuller information can be found in the repair manual B1B2029D 31 PRESENTATION OF ENGINE 384 F CFA B1B202BD Timing chain and tensioner 19 chain guide 27 chain damper 28 timing pinion on crankshaft A high resistance roller chain 18 with a pitch of 8 mm gives reliability and makes the engine more compact The chain tensioner 20 uses a spring and hydraulic pressure system to retain the correct tension at all times The chain tensioner 20 suppresses the noise generated by the chain An oil jet x lubricates the chain as well as the timing pinion on the crankshaft Timing cover The cover 29 of the oil pump 30 is incorporated in the timing cover made of aluminium on which the water pump 31 is mounted 32 TIGHTENING TORQUES ENGINE SUSPENSION Engine gearbox suspension Engine CFA LH engine support RH engine support A Screw on box B z Screw on body B1B201SD 33 TIGHTENING TORQUES PETROL ENGINE Crankshaft Crankshaft bearing cap screws Con rod cap screws Tightening Angular tightening Crankshaft pulley screw Seal carrier plate s
59. loy The piston crowns are conical for enhanced combustion A new LFA coating low friction resin and aluminium oxide is used on the piston skirts The low tension piston rings give lower friction and thus reduced fuel consumption 28 PRESENTATION OF ENGINE 384 F CFA Con rods and big end bearing shells 12 gudgeon pin The forged steel con rods have increased rigidity and reduced weight The con rod caps are fixed with extended tension screws 11 The glide surfaces of the big end bearing shells have micro grooves for optimal oil release This solution results in the engine starting more readily from cold also reducing vibrations Crankshaft and crankshaft bearings r hole for the oil 13 upper bearing shells 14 lower bearing shells The crankshaft possesses 4 journals and 6 counterweights All the journal contact surfaces are roll finished s in order to maintain the appropriate rigidity The crankshaft bearing shells are in aluminium alloy The surfaces of the crankshaft bearing shells have micro grooves q for optimal oil release This solution results in the engine starting more readily from cold The upper bearing shells have an oil groove p on the inner circumference B1B2025D 29 PRESENTATION OF ENGINE 384 F CFA B1B2027D Engine CFA Oil sump 15 protection plate 17 oil sump The oil strainer 16 is made of plastic to reduce weight Valve ti
60. m with an oxygen sensor loop the information on this is not taken into account by the ECU The ECU then controls the injection in open loop INJECTION 99 Air supply function Motorised butterfly housing for MMT piloted manual gearbox The torque requested by the injection ECU determines an angle of opening of the butterfly The angle of opening of the butterfly varies with the demand coming from the driver Engine load is commanded by the butterfly housing Injection function The quantity of fuel to be injected is calculated from the following parameters Position of the accelerator pedal Point of engine operation engine speed temperatures pressures As a function of the quantity of fuel to be injected the injection ECU determines the following parameters Start of injection Time of injection The injection ECU draws on the specific strategies for starting and stopping of the engine Determination of the quantity of fuel to be injected The quantity of fuel to be injected is calculated from the demand coming from the driver provided by the position of the accelerator pedal To determine the quantity of fuel to be injected the injection ECU takes account of the following elements Demand from the driver after filtering Quantity of air entering the engine calculation The quantity of fuel to be injected is transformed into an injection time Cut off in deceleration During deceleration with the engine h
61. ming system General 18 timing chain 19 chain guide 20 chain tensioner 21 inlet camshaft 21 exhaust camshaft Each cylinder has 2 inlet valves and 2 exhaust valves The performance of the inlet and exhaust circuits is increased by the greater width of the ports Opening and closing of the valves is controlled directly by 2 camshafts The engine has 12 valves and 2 overhead camshafts driven by chain one for inlet and the other for exhaust The VVT i system 21 serves to reduce fuel consumption increase performance and also to reduce pollutant emissions Fuller information on the control of the VVT i system 21 is to be found in the repair manual 30 PRESENTATION OF ENGINE 384 F CFA Camshaft t oil channel retard u oil channel advance The end of the inlet camshaft 22 is provided with holes for suppling the VVT i system with engine oil under pressure The control for the VVT i system 21 is fitted on the front end of the inlet camshaft 22 it modifies the adjustment of the inlet valves Inlet valves exhaust valves and cam followers v thickness of cam follower w reference N 24 camshaft The valve stems are of reduced diameter to reduce resistance to the inlet mixture and to the exhaust gases The inlet valves 26 and the exhaust valves 26 use identical springs These are variable rate springs to make the valves operate correctly The cam fo
62. ndations IMPERATIVE After any repair involving removal of the timing belt systematically replace The timing belt The tensioner roller fixing nut 52 CHECKING AND SETTING THE VALVE TIMING MPERATIVE Respect the safety and cleanliness requirements Removing Raise and support the vehicle wheels hanging Disconnect the battery negative cable see corresponding operation Drain the engine oil see corresponding operation Drain the gearbox oil see corresponding operation Drain the cooling circuit see corresponding operation Remove the auxiliary drive belt see corresponding operation Hemove the sump Remove the driveshafts see corresponding operation Remove the engine gearbox assembly see corresponding operation Move aside the elastic clip on the coolant pump Remove the alternator see corresponding operation Remove the screw and the guide tube of the oil gauge Remove the O ring seal on the guide tube of the oil gauge B1D201ND 53 2 Ne MY CHECKING AND SETTING THE VALVE TIMING B1D201RD Engine CFA Disconnect the camshaft position sensor Remove the screw and the crankshaft position sensor Remove the 13 screws and the 2 nuts in the sequence indicated Remove the valve cover with its gasket Remove the val
63. nsor with the screw Tightening torque 0 8 m daN Connect the connector of the crankshaft position sensor 68 CHECKING AND SETTING THE VALVE TIMING Fit a new O ring seal on the guide tube of the oil level gauge Coat the O ring seal with a thin layer of engine oil Refit the guide tube of the oil level gauge with the screw Tightening torque 1 0 1 m daN Refit the alternator see corresponding operation Position the elastic clip for the coolant pump Apply seal paste AUTOJOINT OR on the surround of the sump Refit the engine gearbox assembly see corresponding operation Refit the driveshafts see corresponding operation Refit the sump Refit the auxiliary drive belt see corresponding operation Fill and top up the engine and the gearbox see corresponding operation Fill and bleed the engine cooling circuit see corresponding operation Check all the levels Reconnect the battery negative terminal IMPERATIVE Perform the operations that are required following a battery reconnection see corresponding operation B1D201MD 69 CHECKING AND SETTING THE VALVE TIMING 1 Engine flywheel setting peg 0194 C 2 Camshaft setting peg 0194 B 3 Crankshaft setting peg 0194 A 4 Movable mirror b Tool for removing exhaust clips C 193 A 6 Hose clamp 0188 AD Removing Preliminary operations Disconnect the bat
64. ol 2 0196 B Degrease the sealing faces of the cylinder block and of the timing cover References Dimensions mm References Dimensions mm fo sess Apply a strip of seal paste on the cylinder block at g and on the timing cover at h as indicated oH EN Oz and refit the timing cover h Lo C J 3 D 35to45 Seal paste AUTOJOINT OR WARNING Refit the timing cover within 3 minutes following the application of the strips of seal paste B1D202RD 63 CHECKING AND SETTING THE VALVE TIMING B1D201TD Engine CFA Tighten the 11 screws in the sequence indicated Tightening torque for screws 1 2 4 0 2m daN Tightening torque for screws 2 4 0 4 m daN Remove the excess seal paste Fit a new coolant pump seal on the timing cover and refit the coolant pump 64 CHECKING AND SETTING THE VALVE TIMING Tighten the 5 screws in the sequence indicated Tightening torque 2 8 0 3 m daN Lock the crankshaft pulley using tool 1 and tighten the screw 1 C 0132 AA Tightening torque 17 1 7 m daN B1D202UD 65 CHECKING AND SETTING THE VALVE TIMING Refit the oil filter seal on the timing cover and refit the oil filter support Tighten the 3 screws in the sequence indicated Tightening torque between 1 9 and 2 9 m daN B1D202VD 66 CHECKING AND SETTING THE VAL
65. on support 7 fixing of upper steering cardan 8 fixing of lower steering cardan Steering mechanism Number of turns of the steering wheel 3 27 Steering rack travel mm 2x 70 2 Steering ratio 1 43 Inside angle of full lock 36 55 to 40 55 Outside angle of full lock 32 23 B3E200WD 161 POWER STEERING SPECIFICATIONS Top of column NOISN3dS nS SE XV 1 driver s airbag 2 steering wheel 3 rotary switch 4 controls under steering wheel Steering column Electric power steering b steering wheel fixing 6 fixing of steering column on support 7 fixing of upper steering cardan 8 fixing of lower steering cardan B3E2005D 162 POWER STEERING SPECIFICATIONS Steering assistance Supplier KOYO Electric motor 33 A The steering assistance is provided by the electric assistance motor 9 controlled by an ECU Power delivered to the electric assistance motor 9 depends on Vehicle speed Engine speed Torque applied on the steering wheel Electric power steering ECU Only one ECU version whatever the engine type The electric power steering ECU 10 is linked to the following connectors Electric assistance motor supply Electric power steering ECU supply Signals from the torque sensor Information on engine speed and vehicle speed NOTE After changing the electric power s
66. ort with the screw Refit the condenser See corresponding operation C5H2009D AIR CONDITIONING ONINOILIGNOD AIR CONDITIONING CIRCUIT R 134 a 10 Low pressure valve 11 High pressure valve 12 Pressostat a Pressure reducer outlet b Pressure reducer inlet c Condenser outlet d Aircon compressor inlet e Aircon compressor outlet f Condenser inlet C5H2024D 190 AIR CONDITIONING CIRCUIT R 134 a 10 Low pressure valve 11 High pressure valve 12 Pressostat Pressure reducer outlet b Pressure reducer inlet Condenser outlet d Aircon compressor inlet e Aircon compressor outlet Condenser inlet C5H2025D AIR CONDITIONING
67. ot gas butterfly closed foot off the injection of fuel is cut off in order to Reduce fuel consumption Minimise pollution Prevent the temperature of the catalytic converter from rising NOILOAPNI 100 OPERATING PHASES BOSCH ME 7 9 5 INJECTION SYSTEM OPERATING PHASES BOSCH ME 7 9 5 INJECTION SYSTEM Correction by oxygen sensor At idling speed engine hot stable with partial load the signal emitted by the sensor causes an adjustment of the flow from the injector so as to remain on stoechiometric richness R 1 15 or lambda 1 Altimetric correction The mass of air absorbed by the engine varies according to the atmospheric pressure thus with altitude The altimetric corrector takes account of this variation in pressure and proportionally corrects the injection command time quantity of fuel injected This measure of pressure occurs as the ignition is switched on and when the engine is operating at low engine speed Ignition function The ignition advance is determined from the following information Engine speed Engine load Engine temperature This correction stabilises the engine by varying the advance from one TDC to the next positively or negatively relative to the mapping value Corrections in injection advance are also applied during the transitory phases Synchronisation of ignition is achieved by the cylinder reference sensor N 1 Petrol vapour r
68. pollution equipment Features Features of the injection system This ECU is of the Engine speed pressure type This injection system controls the engine injection and ignition thanks notably to the information on inlet air pressure and engine speed Multipoint injection 3 electromechanical injectors Sequential injection Integral electronic ignition Depollution L5 European norm EUROA Marketing of vehicles respecting the depollution norm IFL5 according to country of marketing The new depollution norm L5 is more severe than the previous norm depollution L4 The maximum pollution rate is reduced Impregnation of precious metals is increased 93 INJECTION BOSCH ME 7 9 5 INJECTION SPECIFICATIONS System of on board diagnosis EOBD This diagnostic system informs the driver when the depollution equipment is no longer fulfilling its role Faults in the system causing polluting emissions are memorised in the injection ECU The engine diagnosis warning lamp in addition to its usual functions signals any faults in the depollution function EOBD NOTE EOBD European On Board Diagnosis for diagnosis of depollution equipment The on board diagnosis system monitors Combustion misfiring Efficiency of the catalytic converter Deterioration of the oxygen sensors EOBD requires the installing of an oxygen sensor downstream of the catalytic converter Features Features of the inje
69. r by use of a mirror Move the tensioner roller at anti clockwise by means of a hexagonal spanner Rotate the tensioner roller to bring the index p to position q Tighten the screw 21 of the tensioner roller to 3 0 3 m daN Remove the pegs 2 and 3 IMPERATIVE Check that the crankshaft pinion is firmly on the crankshaft Rotate the engine 10 turns Check the pegging of the camshaft the pegging of the crankshaft pinion the pegging of the fuel high pressure pump and the correct positioning of the index on the dynamic ten sioner See diagram use a mirror If these are not correct restart the operation to position the timing belt In the engine compartment Raise the engine back to its initial position Hefit the intermediate engine support 18 tighten the screws to 5 7 0 5 m daN the RH engine support 19 the bottom support of the expansion chamber 20 and the screws 29 and 28 without tightening them Remove the jack Tighten the screws 29 to 6 0 6 m daN the screws 30 to 5 2 0 5 m daN 76 CHECKING AND SETTING THE VALVE TIMING Under the vehicle Refit the nut 17 tighten to 6 x 0 6 m daN Refit the engine speed sensor 16 the belt retaining stop 15 tighten to 0 7 0 1 m daN the lower timing cover 11 Lock the engine flywheel using tool 1 Hemove the screw 12 Refit the accessories drive pulley 14 t
70. r head This solution reduces the temperature of the inlet air and increases the inlet perfor mance by volume The inlet manifold comprises a depressiometer 44 for measurement of inlet vacuum and a sensor for measurement of inlet air temperature B1B202HD 79 B1B202LD EXHAUST LINE SPECIFICATIONS Exhaust manifold aa view from above ab front view The exhaust manifold 39 made of stainless steel is designed both to enhance the rise in temperature of the 3 way catalytic converter and to reduce weight The catalytic converter uses ceramics with ultra thin walls with high cell density The optimisation of cell density of the catalytic converter serves to reduce pollutant emissions Exhaust pipe ac from the exhaust manifold 47 tightening clip 48 front pipe 49 rear pipe 50 gasket The silencer 37 has been optimised with the aim of making it both compact and light The junction between the front and rear parts H of the exhaust pipe is by means of the insertion E making a gasket no longer necessary The junction of the exhaust pipe to the exhaust manifold G uses a spherical seal F This solution simplifies the construction and improves reliability 80 EXHAUST LINE SPECIFICATIONS Engine CFA B1J2000D 1 4 5 6 7 Exhaust Upstream Rear silencer Downstream Screws Catalytic manifold oxygen sensor oxygen sensor converter Tightening m daN 2 4 0 2 4 4 0 4 32203 44 0
71. rbox actuator Description 32 Electric motor for gearbox actuator selection 33 Electric motor for gearbox actuator engagement 34 Gearbox actuator body 35 Engagement angular sensor 36 Selection angular sensor B2C201ND 143 SPECIFICATIONS OF MMT TOYOTA PILOTED MANUAL GEARBOX b Selection c Engagement Features IMPERATIVE Perform an initialisation of the gearbox actuator after refitting see corresponding operation 37 Gear engagement screw Neutral e 1st 3rd 5th f 2nd 4th Reverse IMPERATIVE Before refitting a gearbox actuator check that it is in neutral position H LNTO Piloted manual gearbox ECU NOISSINSNVu L The gearbox ECU decides on the changing of gear It is located in the vehicle dashboard on the front LH side B2C201QD 144 TIGHTENING TORQUES FOR MMT TOYOTA PILOTED MANUAL GEARBOX Description Number of screws REESEN 2 Gearbox actuator fixing screws 6 L8 OT B2C202LD 145 CLUTCH GEARBOX TRANSMISSION TIGHTENING TORQUES FOR MMT TOYOTA PILOTED MANUAL GEARBOX Tightening torques m daN Tightening H Serben Gear engaged sensor BE Fixi ew for gearbox input speed ixing screw g x input sp 0 8 0 1 Sensor Drain plug 2 9 0 3 7 Oil level plug Angular sensor fixing screw 1 Fixing screw for clutch housing on gearbox 2 9 0 3 casing 3 9 0
72. ressure circuit Fuel filter Fuel gauge Unions on fuel pipes High pressure circuit Fuel high pressure pump Fuel high pressure injection common rail Fuel high pressure pipes Diesel injector carriers IMPERATIVE After dismantling immediately block the apertures of sensitive components with plugs to avoid the entry of impurities INJECTION Work area The work area must be clean and free of clutter Components being worked on must be protected from dust contamination 113 PROHIBITED OPERATIONS HDi DIRECT INJECTION SYSTEM Engine 8HT Cleaning The use of high pressure cleaners is prohibited Fuel supply circuit Required fuel diesel NOILOAPNI Electrical circuit Swapping injection ECUs between two vehicles will render it impossible to start either vehicle It is forbidden to supply a diesel injector with 12 volts Fuel high pressure pump Do not separate the fuel high pressure pump 1 from the following components Sealing ring a no replacement parts High pressure outlet connector b will cause a malfunction 114 PROHIBITED OPERATIONS HDi DIRECT INJECTION SYSTEM Diesel injectors WARNING Diesel and ultrasonic cleaners are prohibited Do not separate the diesel injector carrier 2 from the following components INJECTION Diesel injector f no replacement parts Electromagnetic component c no replacement parts
73. roller clockwise at Remove the timing belt 74 CHECKING AND SETTING THE VALVE TIMING Refitting Preliminary operations IMPERATIVE Check the condition of the seals for the camshaft and the crankshaft pinion If in doubt don t hesitate to change the seals Check that there are no leaks at the coolant pump If in doubt don t hesitate to change it Check that both the tensioner roller and the guide roller can turn freely no tight spots If this is not the case replace the rollers Refitting the belt IMPERATIVE Replace the belt as well as the crankshaft pinion screw 12 with new at each removal Do not twist or bend the belt NOTE Pegging the high pressure pump serves to increase the life of the timing belt NOTE Use of the tool 6 on the camshaft pinion 23 makes the operation to fit the timing belt easier WARNING The setting pegs have to be in place on the engine NOTE If the belt sections I m and n are not kept taut during the tensioning of the belt the timing becomes offset The engine suffers damage Reposition the timing belt sections I m and kept taut on the following components Crankshaft pinion 25 guide roller 24 camshaft pinion 23 fuel high pressure pump pulley 22 coolant pump pinion 26 tensioner roller 27 B1E2007D 75 CHECKING AND SETTING THE VALVE TIMING Engine 8HT NOTE The tensioning operation is made easie
74. ry shaft 7 Secondary shaft 8 Speedometer 9 Planet pinions 10 Satellite pinions 11 Differential gearwheels 12 1st gear driven pinion 13 1st 2nd gear synchroniser 14 Reverse gear driven pinion 15 2nd gear driven pinion 16 3rd gear driven pinion 17 4th gear driven pinion 18 5th gear driven pinion CLUTCH GEARBOX TRANSMISSION 15 14 13 12 B2C2012D 141 SPECIFICATIONS OF MMT TOYOTA PILOTED MANUAL GEARBOX Description 19 Reversing lamps sensor 20 Gear engaged sensor 21 Gearbox input speed sensor 22 Gearbox actuator 23 Electric motor for clutch actuator 24 Clutch actuator HOLNT9 25 Electric motor for gearbox actuator selection NOISSINSNVu L 26 Electric motor for gearbox actuator engagement B2C201LD 142 SPECIFICATIONS OF MMT TOYOTA PILOTED MANUAL GEARBOX Clutch actuator Description 27 Declutch angular sensor 28 Electric motor for clutch actuator 29 Push rod 30 Clutch actuator body 31 Declutch fork Features IMPERATIVE Before each removal and after each refitting of the gearbox actuator use a diagnostic tool to perform an initialisation see corresponding operation IMPERATIVE At each refitting of the clutch actuator perform a position adjustment pre loading see corresponding operation CLUTCH GEARBOX TRANSMISSION Gea
75. s a car bon fuel vapour absorber The fuel supply rail 51 is made of plastic INJECTION B1B202MD Fuel tank af HDPE high density polyethylene The fuel tank 52 is made of plastic The interior ag and exterior ad surfaces are coated with a layer of flourate polyethylene ae to prevent any penetration of fuel B1B202ND 107 NOILOAPNI B1B202PD B1B202QD FUEL SUPPLY SYSTEM SPECIFICATIONS Engine CFA Fuel tank A marking indicates the lowest point of the fuel tank 52 During dismantling destruction of the vehicle drill a hole at the spot indicated ah in order to drain the fuel Fuel filler piping The fuel filler piping 55 includes the tank breather pipe for greater compactness and saving of actual space 108 FUEL SUPPLY SYSTEM SPECIFICATIONS Fuel pump module 56 fuel pump stop ring 58 pump 59 reserve cup 60 fuel filter 61 pressure regulator 62 cut off valve 63 foam filter for venting the canister INJECTION The fuel pump module includes the carbon fuel vapour absorber 57 for saving of actual space Fuel supply rail The fuel supply rail 51 is made of plastic to reduce weight B1B202SD 109 NOILOAPNI FUEL SUPPLY SYSTEM SPECIFICATIONS Non return fuel supply system 64 pulse damper 65 fuel pump module This type of fuel supply
76. sh shield IMPERATIVE In the case of belt re use mark the direction of rotation of the belt If the index on the tensioner roller is outside the marks change the auxiliary equipment drive belt A Vehicle with air conditioning B Vehicle without air conditioning 1 and 4 Alternator pulley 3 and 6 Auxiliary drive belt pulley 5 Guide roller 2 Aircon compresseur pulley 48 AUXILIARY EQUIPMENT DRIVE BELT Engine 8HT Compress the dynamic tensioner roller using tool 1 Position the peg 2 Remove the auxiliary drive belt 7 Refitting NOTE Check that the tensioner roller moves freely no tight spot If this is not the case replace the tensioner roller Respect the direction of fitting of the drive belt Position the auxiliary drive belt Move the tool 2 on the tensioner roller to remove the peg 3 Make sure that the drive belt is correctly positioned in the V grooves of the various pulleys Refit the splash shield Reconnect the battery negative cable IMPERATIVE Carry out the operations that are necessary following a reconnection of the battery see corresponding operation B1B2011D 49 BELT TENSION SEEM UNITS CORRESPONDENCE TABLE 1 daN 1 Kg mu g Be TYPE DE COURROIES uu TYPE DE COURROIES CHECKING AND SETTING THE VALVE TIMING See pages 70 to 77 51 RECOMMENDATIONS TIMING BELT Recomme
77. should be unloaded before any lifting operation Never place a loaded vehicle on a jack or on a lift When you remove a heavy component such as the engine or the gearbox the vehicle s centre of gravity moves Note on use of a 4 column lift Respect the safety requirements set out in the user instructions Immobilise the vehicle with wheel locks Note on use of jacks and axle stands Work on a flat surface and always use wheel blocks Use axle stands with rubber blocks a as indicated Place the jack and the axle stands on the prescribed lifting points on the vehicle Do not use the jack without axle stands To raise the front wheels release the parking brake and place blocks at the rear of the rear wheels only To raise the rear wheels place blocks at the front of the front wheels only To raise the front wheels only or the rear wheels only place blocks on either side of the wheels that are in contact with the ground To relower a vehicle raised at the front release the parking brake and place blocks at the front of the rear wheels only To relower a vehicle raised at the rear place blocks at the rear of the front wheels only b jacking point c pantograph jacking point lugs d centre of gravity of the vehicle excluding load GENERAL A 3 door OFFSET 331 mm LEVEL 1370 mm 5 door OFFSET 349 mm LEVEL 1387 mm 13 GENERAL SPECIFICATION LIFTING AND SUPPORTING THE VEHICLE Note on use of a 4 point lift with
78. ss and as far as at the 3rd press the braking amplifier is air tight With the engine running press on the brake pedal Keep the pedal pressed down and stop the engine NOTE If the reserve travel does not change after 30 seconds of keeping the pedal pressed down the braking amplifier is air tight Check the operation of the brakes Ignition switched off press several times on the brake pedal Check the reserve travel of the brake pedal Press on the brake pedal and start the engine NOTE If the pedal goes down a few millimetres it is working normally Check the vacuum valve Remove the vacuum hose Confirm that air is circulating in the direction from the amplifier to the engine but not in the oppo site direction from the engine to the amplifier B3F2019D 175 SEMIS B3F201AD CHECKING THE BRAKING AMPLIFIER C circulation of air D absence of circulation of air In the event of a fault replace the vacuum hose Refit the vacuum hose 176 CHECKING THE VACUUM PUMP BRAKES 1 Pressure tester 2 Pressure take off union 1602 A Coffret S 1602 1602 B Checks Remove The windscreen wiper arm mounting cap The windscreen wiper arm The upper seal between bonnet and scuttle panel The top scuttle panel ventilation grilles The wiper motor The scuttle panel Locate the vacuum pipe 1 between the vacuum pump and the braking
79. system reduces emissions by evaporation The diagram shows that by integration of the fuel filter 60 the pressure regulator 61 and the fuel gauge with the fuel pump 53 there is no return of fuel from the engine and an increase of temperature inside the fuel tank is avoided B1B202TD INJECTOR SPECIFICATIONS Engine CFA Injectors Injectors 54 with 4 holes are used in order to enhance the spraying of the fuel Ignition system This is a Direct Ignition System DIS It enhances the precision of the point of ignition reduces the loss of voltage and increases the general reliability of the ignition system thanks to the elimination of the distributor The direct ignition system DIS on this engine is an independent ignition system with an ignition coil for each cylinder B1B202UD INJECTION Ignition coil 66 secondary coil 67 primary coil 69 iron core The DIS system has 3 ignition coils one for each cylinder The caps 68 which establish contact with the sparking plugs are integral to the coils With a view to simplification of the system an igniter 70 is also incorporated in each coil B1B202VD 111 SAFETY REQUIREMENTS HDi DIRECT INJECTION SYSTEM SAFETY REQUIREMENTS Preamble All interventions on the injection system must be carried out to conform with the following requirements and regulations Competent health aut
80. tainer before starting the engine ESSENTIAL Systematically check the oil level using the oil dipstick Stop the engine allow to stabilise for 5 minutes 16 CAPACITIES in litres O Engine plate FA 8HT oO N Draining by gravity engine with filter change Between min and max GENERAL MT 5 speed gearbox MMT piloted 5 speed gearbox N Braking circuit Cooling system Fuel tank capacity ESSENTIAL Systematically check the oil level using the oil dipstick 17 TWHANAD LUBRICATION CIRCUIT SPECIFICATIONS Engine CFA Lubrication system The lubrication circuit is fully pressurised and all of the oil passes through the oil filter The rotary oil pump 30 is driven directly by the crankshaft Oil capacity in litres With oil filter 3 1 Without oil filter B1B202CD 18 RECOMMENDED LUBRICANTS TOTAL ACTIVA or TOTAL ACTIVA QUARTZ Commercial description Synthetic 9000 Semi synthetic 7000 Mineral 5000 Cold Temperate D ACEA A3 ACEA A5 ACEA A3 ACEA A3 ACEA A2 B2 lt Petrol engines 5 SL API SL CF Diesel engines Prohibited ACEA DY ACEN UAR Medios ACEA BO Prohibited o API CF In winter on the HDi engine it is advised to use 5 W 30 or 5 W 40 oil instead of 10 W 40 oil this to enhance starting from cold Oil filter specific to C1 petrol with a U S
81. teering ECU it is necessary to perform a configu ration see corresponding operation B3E200YD 163 SUSPENSION STEERING POWER STEERING TIGHTENING TORQUES Tightening torques m daN Ref Description Tightening 1 Ssemgwhee eng 5405 2 Fixing of steering column on support 2502 35203 35203 33203 47504 7 89208 NOISN3dS S S3 XV B3E2003D 164 B3E2000D B3E2001D SETTING THE STEERING RACK MID POINT Preliminary operation Raise and support the vehicle on a 2 column lift Remove the clips 1 and 2 Detach the steering rack protection gaiter Setting Turn the steering wheel to full LH lock Measure the dimension X Turn the steering wheel to full RH lock Measure the dimension Y Calculate the dimension L Y X 2 Position the steering rack to the dimension L steering rack mid point Additional operation Refit the protection gaiter In order to be able to fit the clip 1 remove The steering ball joint gudgeon pin The steering ball joint nut Uncouple the steering ball joint from the pivot Fit a new clip 1 Refit The clip 2 The new clip 1 The steering ball joint The steering ball joint nut The steering ball joint gudgeon pin 165 IMPERATIVE Respect the precaut
82. tery negative terminal Place the vehicle on a 2 column lift Remove the screws 1 Move aside the bumper at a Remove the plastic rivet 4 Apply a force upwards at f Detach in the sequence b c q e Move aside the bumper 3 Remove the headlamp 2 C4A2004D 70 CHECKING AND SETTING THE VALVE TIMING In the engine compartment Remove the screw 9 Disconnect the connector at g Move aside the header tank 8 Detach the harness 6 on the timing cover 5 Hefit the screws 7 the upper timing cover 5 Put the header tank 8 back in its initial position Remove the accessories drive belt see corresponding operation Under the vehicle Remove the exhaust clip 10 using tool 5 Uncouple the exhaust line NOTE Removing the exhaust clip prevents the front flexible pipe from being damaged Twisting pulling and bending reduces the life of the front flexible exhaust pipe Rotae the engine by means of the crankshaft pulley screw to bring it to the flywheel locking posi tion using tool 1 NOTE The locking hole is under the engine B1J2002D T1 B1E2004D CHECKING AND SETTING THE VALVE TIMING Remove the screw 12 the accessories drive pulley 14 Refit the screw 12 Remove the peg 1 Disconnect the connector at h Slacken the screws 13 Remove the lower timing cover 11
83. to knock The angle formed between the inlet valves and the exhaust valves is more closed It has been fixed at 33 5 h to permit a cylinder head of a more compact construction The combustion chambers are double wedge shaped k The shape of the inlet ducts has been optimised for improved combustion The cylinder head is fixed with extended tension bolts The extension of the coolant channels j into the cylinder head has been optimised for better cooling B1B2021D 27 PRESENTATION OF ENGINE 384 F CFA B1B2023D Engine block 5 oil separator cover An aluminium engine block 4 with a wall thickness of 7 mm between the cylinder bores produces an engine that is light and compact An oil separator 6 incorporated in the engine block 4 where the exhaust gases pass thus sepa rates the engine oil from the gases passing from the combustion chambers to the sump so as to preserve the quality of the engine oil and to reduce oil consumption It is not possible to rebore the engine block given the type of channels 7 The channels 7 present an exterior fin like structure which allows a larger surface of contact with the aluminium block by dint of the numerous irregularities I This solution enhances heat dissipation thus reducing overall temperature and deformation of the bores Pistons m resin coating 8 compression ring 21 9 compression ring N 2 10 scraper ring The pistons are in aluminium al
84. to reverse gear until the gearing meets a resistance from the clutch Progressively press on the clutch pedal and measure the travel from the point where the gear noise disappears point of release c to the position of maximum travel d 25 mm or more from the position of maximum travel d to the point of release c If the travel is not correct proceed to the following operations Check the height A of the pedal Check the play B in the pedal Check the clutch mechanism and disc Check the travel C of the pedal Travel C of the pedal j gt O 2 2L S75 o Me OQI O 2 130 SPECIFICATIONS OF MT TOYOTA MANUAL GEARBOX Gearbox Fam SES C 551 uro cs pe MT Manual gearbox MMT Piloted manual gearbox 131 CLUTCH GEARBOX TRANSMISSION NOISSINSNVu L H LNTO SPECIFICATIONS OF MT TOYOTA MANUAL GEARBOX Identification a identification zone for gearbox no Reference C 551 Petrol engine version C 552 Diesel engine version Description 1 5th gear synchroniser 2 3rd 4th gear synchroniser 3 Gearbox casing 4 Reverse gear motor pinion 5 Clutch housing 6 Primary shaft 7 Secondary shaft 8 Planet pinions 9 Satellite pinions 10 Differential gearwheels 11 1st gear driven pinion 12 1st 2nd gear synchroniser 13 Reverse ge
85. to the vehicle s diagnostic socket CLUTCH GEARBOX TRANSMISSION B2C201TD 139 RECOMMENDATIONS PRECAUTIONS MMT PILOTED MANUAL GEARBOX From the diagnostic tool menus select DIAGNOSIS MMT piloted manual gearbox a Actuator test Gearbox actuator test H Engage N neutral As NOTE The letter N should appear on the instrument panel If not see the following solution Engaging of N without using a diagnostic tool Engaging of N without using a diagnostic tool In this configuration the gearbox actuator is blocked gear engaged NOTE This recovery solution is to be used solely in a case where the attempt to make the gearbox actuator engage b via the diagnostic tool has failed Preliminary operation Disconnect the battery negative terminal Remove the plug on the gearbox actuator a neutral b 1st 3rd 5th c 2nd 4th reverse gear Using a large screwdriver move the screw 3 to place the gearbox actuator in the neutral position When this position is reached position N is engaged NOISSINSNVu L HOLNT9 B2C201TD 140 Identification a gearbox no identification zone Ref C 551 A piloted SPECIFICATIONS OF MMT TOYOTA PILOTED MANUAL GEARBOX Presentation 1 5th gear synchroniser 2 3rd 4th gear synchroniser 3 Gearbox casing 4 Reverse gear motor pinion 5 Clutch housing 6 Prima
86. ups representing the main functions GENERAL ENGINE INJECTION IGNITION CLUTCH GEARBOX DRIVESHAFTS AXLES SUSPENSION STEERING BRAKES AIR CONDITIONING IMPORTANT If you find that this handbook does not always meet your requirements we invite you to send us your suggestions which we will take into account when preparing future publications For example INSUFFICIENT INFORMATION SUPERFLUOUS INFORMATION NEED FOR MORE DETAILS Please send your comments and suggestions to CITROEN U K Ltd 221 Bath Road SLOUGH SL1 4BA U K CONTENTS GENERAL Exhaust specifications 78 82 IGNITION Vehicle identification Cooling system specifications 83 86 Sparking plugs Specifications amp dimensions Checking the oil pressure 2 CLUTCH GEARBOX TRANSMISSION Weight specifications 7 Valve clearances Operations to be performed following Draining filling and bleeding the EO Clutch specifications 127 Towing specifications cooling circuit Tightening torques clutch Lifting and supporting the vehicle INJECTION Checking and adusting clutch pedal ae 16 17 BOSCH ME 7 9 5 injection Specifications Air filter on CFA engine MT TOYOTA manual gearbox Fuel supply system 107 110 Tightening torques MT ENGINES TOYOTA manual gearbox specifications Safety requirements HDi direct injection 112 113 Recommendations precautions Lubrication system Prohibited operations HDi dir
87. ve cover gasket 54 ANISNA n O c Hemove the 3 screws the support for the oil filter and its seal Remove the 5 screws the coolant pump and its seal O lt H 5 gt LLI O LLI o e lt O x O LLI L O 40 gt COG B1D201SD B1D201TD B1D201VD CHECKING AND SETTING THE VALVE TIMING Engine CFA Turn the crankshaft pulley clockwise in order to align the setting mark a on the toothed wheel 0 degrees with those on the timing cover Make sure that the setting mark a on the camshaft pulley is on top as indicated NOTE Failing this turn the crankshaft pulley by one full turn 360 degrees to bring the setting mark to the top Lock the crankshaft pulley using tool 1 and remove it 1 C 0132 AA Remove the timing cover 56 CHECKING AND SETTING THE VALVE TIMING Engine CFA Turn the chain tensioner stop plate clockwise and compress the piston Insert peg into the hole in the stop plate so as to lock the tensioner with the thrust piston in the compressed position Remove the 2 screws and the chain tensioner Remove the screw the chain tensioner guide and the timing chain B1D201XD 57 CHECKING AND SETTING THE VALVE TIMING Remove the 2 screws the chain guide and the crankshaft toothed wheel Remove the keyway B1D201ZD 58 CHECKING AND SETTING THE VAL
88. ve figure TOE IN gt B Negative figure p TOE OUT B3C200SD 152 SPECIAL FEATURES FRONT AXLE AXLES SUSPENSION STEERING Tracking adjustment IMPERATIVE Distribute the total tracking value symme trically between the LH wheel and the RH wheel Remove the clip 1 Slacken the nut 3 Adjust the rod 2 Tighten the nut 3 4 7 0 4 m daN Refit the clip 1 B3B200FD 153 3 I EERES NOISN3dS nS SE XV B3C200UD SPECIFICATIONS FRONT AXLE B3C200VD Subframe 1 subframe 2 suspension arm Subframe in two steel shells fixed by means of six screws on the body with a yoke for the lower engine suspension rod and lateral yokes 2 LH 2 RH for the suspension arm fixings The two rear fixing points for the subframe under the floorpan are via two link brackets LH RH welded on the subframe Pivot Pivot type pinched Pivot bearing diameter 69 mm Bearing with double row of balls with integral magnetic wheel Suspension leg Front suspension with independent wheels type pseudo Mac Pherson Travel stop height A96 mm Anti roll bar All engine types 22 mm 154 Tightening torques m daN Ret Descripion Tightening 1 Damperuppercupfxngnu 55 05 _ 2 Dame 2 7 3 Anirolbarbeanngfxing 18502 _ 4 jana E 5 PivelowerbalKontnut 981 Hub nut 21

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