CITROEN 2005 C4-XSARA-XSARA PICASSO BERLINGO User manual

CORRESPONDENCE TABLE FOR PETROL ENGINES
XSARA
XSARA
PICASSO
BERLINGO
Engine
families
Engine types
VERY IMPORTANT
As the booklet is constantly re-edited, this one only covers vehicles for this
particular model year.
It is therefore necessarytoorder a new booklet each year and RETAIN THE
OLD ONES.
TU ET TU EW
13 57 10
JP J4 JP + JP4 J4 A J4 J4 S
1.1i 1.4i 1.4i 16V 1.6i 1.6i 16V 1.8i 16V 2.0i 2.0i 16V
HFX KFW KFU NFV NFU 6FZ RFJ RFN RFK
XXXXX
XXX
XXX
XX X
C4
CORRESPONDENCE TABLE FOR DIESEL ENGINES
XSARA
XSARA
PICASSO
BERLINGO
Engine
families
Engine types
DV DW
46810
TD TED4 ATED4 B TD ATED BTED4
1.4 HDi 1.6 16V HDi 1.9D 2.0 HDi 2.0 16V
HDi
8HX 8HZ 9HY 9HZ 9HX WJY RHY RHZ RHR
XX X X
XX XXX
XX X
XXX
C4
COUV-CARNET-TOME2-2005 9/01/06 10:02 Page 1

PRIVATE CARS
C4-XSARA-XSARA PICASSO
BERLINGO
PRIVATE CARS
CAR 000 000
Volume 2
2005
AC/QCAV/MTD
Méthodes techniques documentation
쏘 «The intellectual property rights relating to the technical information contained in this document belong
exclusively to the manufacturer. Reproduction, translation or distribution in whole or in part without prior
written authorisation from the manufacturer is forbidden».
«The technical information contained in this document is intended for the exclusive use of the trained person-
nel of the motor vehicle repair trade. In some instances, this information could concern the security and safe-
ty of the vehicle. The information is to be used by the professional vehicle repairers for whom it is intended
and they alone would assume full responsibility to the exclusion of that of the manufacturer».
«The technical information appearing in this brochure is subject to updating as the characteristics of each
model in the range evolve. Motor vehicle repairers are invited to contact the CITROËN network periodically for
further information and to obtain any possible updates».
2005
COUV-CARNET-TOME2-2005 9/01/06 10:02 Page 2

PRESENTATION
THIS HANDBOOK summarises the specifications, adjustments, checks and special features of CITROËN private vehicles, not including UTILITY vehicles for which there exists a separate
handbook.
The handbook is divided into groups representing the main functions:
GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - AIR CONDITIONING.
In each section, the vehicles are dealt with in the following order: C4 - XSARA - XSARA PICASSO - BERLINGO and all models where applicable.
The information given in this handbook is based on vehicles marketed in EUROPE.
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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.
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GENERAL
C4 1 - 2
XSARA 3 - 4
XSARA PICASSO 5 - 6
BERLINGO 7 - 8
Operations following a repair: C4 9
C4 11 - 12
XSARA 13 - 14
XSARA PICASSO 15
BERLINGO 16
Lubricants 17 - 39
ENGINE
Specifications 40 - 41
Tightening torques: engines all types 42 - 147
Cylinder head tightening: all types 148 - 150
Auxiliary drive belt 152 - 153
Checking and setting the valve timing 181 - 182
C4 279
XSARA 280
XSARA PICASSO 281
Valve clearances 282
Checking the turbo pressure:
Xsara picasso (DW10ATED) 295
Checking the air supply circuit: Xsara (DV4TD) 296
Checking the air supply circuit: C4 (DV6ATED4) 297
Checking the air supply circuit: C4 (DV6TED4) 298
Checking the air supply circuit: C4 (DW10BTED4) 299 - 300
Checking the air supply circuit:
Xsara picasso (DW10TD/ATED) 301
Checking the exhaust gas recycling circuit:
Xsara (DV4TD) 302
Checking the exhaust gas recycling circuit:
Xsara picasso (DV6TED4) 303
Checking the exhaust gas recycling circuit:
Xsara picasso (DW10TD/ATED) 304
IGNITION
Sparking plugs 305
CLUTCH - GEARBOX - TRANSMISSION
C4 307 - 308
Xsara 309 - 310
Xsara picasso 311
CONTENTS
Vehicle
identification
Capacities
INJECTION
Checking the low pressure fuel supply
circuit: Xsara (DV4TD) 283
Checking the low pressure fuel supply
circuit: C4 (DV6TED4/ATED4) 284
Checking the low pressure fuel supply
circuit: Xsara Picasso (DV6TED4) 285
Checking the low pressure fuel supply
circuit: C4 (DW10BTED4) 286
Checking the low pressure fuel supply
circuit: Xsara (DW10TD) 287
Checking the low pressure fuel supply
circuit: Xsara Picasso (DW10TD/ATED) 288 - 289
Checking the turbo pressure: Xsara (DV4TD) 290
Checking the turbo pressure:
C4 (DV6TED4/ATED4) 291
Checking the turbo pressure:
Xsara Picasso (DV6TED4) 292
Checking the turbo pressure:
C4 (DW10BTED4) 293
Checking the turbo pressure:
Xsara picasso (DW10TD) 294
Checking the oil
pressure Clutch
specifications
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CLUTCH - GEARBOX - TRANSMISSION (continued)
Gearbox specifications 312 - 314
Clutch specifications 315 - 316
Checking and adjusting the hydraulic
clutch control 317 - 318
Tightening torques: manual gearbox 319 - 330
Manual gearbox controls 331 - 343
Recommendations - precautions:
automatic gearbox 344 - 346
Tightening torques: manual gearbox 347 - 349
Automatic gearbox controls 350 - 359
Driveshafts 360
AXLES - SUSPENSION - STEERING
Axle geometry: C4 361 - 364
Tightening torques: front axle 365 - 366
Tightening torques: rear axle 367
Tightening torques: power steering 368 - 369
Setting the steering rack mid-point 370
Checking the power steering pressure 371 - 374
Axle geometry: Xsara 375 - 379
Adjusting the handbrake 426
Filling, bleeding the brakes 427
AIR CONDITIONING
R134.a: quantities 428
Checking the compressor lubricant 429 - 430
Pollen filter: all types 431 - 433
Filtering and drying cartridge 434 - 436
Checking the efficiency of the circuit 437 - 446
C4 447 - 451
Xsara 452
Xsara picasso 453 - 456
CONTENTS
Tightening torques: front axle 380
Tightening torques: rear axle 382
Tightening torques: steering 383 - 384
Tightening torques: power steering 385 - 387
Axle geometry: Xsara Picasso 388 - 392
Tightening torques: front axle 393
Tightening torques: rear axle 394
Tightening torques: power steering 395 - 397
BRAKES
Brake specifications: C4 398 - 399
Tightening torques: Brakes 401 - 403
Adjusting the handbrake 405
Filling, bleeding the brakes 406 - 410
Brake specifications: Xsara 411
Tightening torques 414
Brake specifications 415 - 418
Adjusting the handbrake 419
Filling, bleeding the brakes 420
Brake specifications: Xsara Picasso 421 - 422
Brake specifications 423 - 424
Aircon circuit
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GENERAL
1
IDENTIFICATION OF THE VEHICLE
E1AP0EWD
A-Manufacturer's name plate
A1 - Front RH chassis member = All versions except
CITROËN C4 Coupé EW10J4S (right hand drive).
A2 - LH centre pillar = CITROËN C4 coupé EW10J4S
(right hand drive).
B - Cold stamp
(cold stamp engraved on the bodywork).
C - AS/RP No. and RP paint code
(on the front pillar on driver's side).
D - Tyre pressures and tyre type
(on the front pillar on driver's side).
E - Serial number on bodywork.
F - Gearbox ident. reference - Factory serial no.
G - Engine legislation type - Factory serial no.
GENERAL
C4
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2
GENERAL
Structure Version (4)
L Family (1) Depollution levels
A Bodywork (2) L3 L4 L5 US Others K Alcohol
LA KFUC KFU Engine (3) W3 83/87 K' L3/L4 L5
C Version (4) Manual 5-speed gearbox A B C P V 5 8 1
/IF Variant (5) Manual 4-speed gearbox E F R W 6 9 2
Family (1) Manual 6-speed gearbox G H S X 3
L C4 Automatic 6-speed gearbox D J N U
Body shape (2) Axle and/or gearbox gears K L T Y 7 0 4
A 3-door saloon Other possible combinations M
C 5-door saloon No gearbox Z
G3-door saloon not
convertible from van
R5-door saloon not
convertible from van
Engine (3) Variants (5)
KFU 1.4i 16V ET3J4 Entreprise convertible T
NFU 1.6i 16V TU5JP4 Integral alternator-starter (ADIN) AD
RFJ EW10A Without FAP SF
RFN 2.0i 16V EW10J4 Fiscal incentives IF
RFK EW10J4S Piloted manual gearbox P
9HY DV6TED4 Downgraded depollution D
9HZ 1.6 16V HDi LPG dual fuel GL
9HX DV6ATED4 CNG dual fuel GN
RHR 2.0 16V HDi DW10BTED4 STT2 (Stop and start) S
IDENTIFICATION OF THE VEHICLE
Type approval
C4
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GENERAL
3
IDENTIFICATION OF THE VEHICLE
E1AP08WD
A- Manufacturer's name plate (estate).
B - Chassis stamp, cold stamp.
C - Manufacturer's name plate (saloon).
D - Label:
(label affixed to the front pillar on driver's side)
- Tyre pressures.
- RP organisation no.
- Paint code.
E - Serial number (visible through the windscreen).
F - Engine legislation type - Factory serial no.
G - Gearbox ident. reference - Factory serial no.
XSARA
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4
GENERAL
Structure Version (4)
N Family (1) Depollution levels
2 Bodywork (2) 15.04 Spécif US 93/59 96/69 98/69A 98/69B Alcohol
N2 RFN1/IF RFN Engine (3) K ≠ CEE L/W2 L3/W3 L4 L5 L3/L4
1 Version (4) Manual 4-speed gearbox V
/IF Variant (5) Manual 5-speed gearbox G H E F B 1 K
Family (1) Manual 6-speed gearbox
N XSARA Automatic 3-speed gearbox T D L 2
Body shape (2) Automatic 4-speed gearbox U R M N 3 4
2 Estate Axle and/or gearbox gears W S J C P 9
Manual 5-speed gearbox
Mercosur/Iran XYA5
No gearbox Z
Engine (3) Variants (5)
KFW 1.4i TU3JP Entreprise convertible T
NFU 1.6i 16V TU5JP4 Integral alternator-starter (ADIN) AD
RFN 2.0i 16V EW10J4 Without FAP SF
8HZ 1.4 HDi DV4TD Fiscal incentives IF
8HY 1.4 16V HDi DV4TED4 Piloted manual gearbox P
WJY 1.9D DW8B Downgraded depollution D (car or van not TD (van convertible)
convertible)
RHY 2.0 HDi DW10TD LPG dual fuel GPL (cylindrical tank) GL (ring-shaped tank)
RHZ DW10ATED STT2 (stop and start) S
IDENTIFICATION OF THE VEHICLE
Type approval
XSARA
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GENERAL
GENERAL
5
IDENTIFICATION OF THE VEHICLE XSARA PICASSO
E1AP088D
A- Chassis stamp
(cold stamp on bodywork).
B - Chassis no. reminder
(label located at bottom of windscreen right hand side).
C - Manufacturer's data plate
(located at bottom of RH central pillar).
D - Label:
(located on front LH door inner panel)
- Tyre pressures.
- Tyre identification.
- Spare wheel identification.
E - Label:
(located on fuse box cover)
- Factory code.
- A-S / RP N°.
- Paint code.
F - Gearbox identification ref.
G - Engine legislation type - Factory serial number.
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6
GENERAL
Structure Version (4)
C Family (1) Depollution levels
H Bodywork (2) L3 L4 L5 US Others K Alcohol
CH 6FZC/IF 6FZ Engine (3) W3 83/87 K' L3/L4 L5
C Version (4) Manual 5-speed gearbox A B C P V 5 8 1
/IF Variant (5) Manual 4-speed gearbox E F R W 6 9 2
Family (1) Manual 6-speed gearbox G H S X 3
C XSARA PICASSO Automatic 6-speed gearbox D J N U
Body shape (2) Axle and/or gearbox gears K L T Y 7 0 4
H Monoshell Other possible combinations M
No gearbox Z
Engine (3) Variants (5)
NFV 1.6i TU5JP Entreprise convertible T
6FZ 1.8i 16V EW7J4 Integral alternator-starter (ADIN) AD
RFN 2.0i 16V EW10J4 Without FAP SF
9HZ 1.6 16V HDi DV6TED4 Fiscal incentives IF
9HY Piloted manual gearbox P
RHY 2.0 HDi DW10TD Downgraded depollution D (car or van not
convertible) TD (van convertible)
LPG dual fuel GPL (cylindrical tank) GL (ring-shaped tank)
STT2 (stop and start) S
IDENTIFICATION OF THE VEHICLE
Type approval
XSARA PICASSO
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7
GENERAL
BERLINGOIDENTIFICATION OF THE VEHICLE
E1AP0AMD
A- Chassis stamp, cold stamp.
B - Manufacturer's vehicle plate.
C - Label
- RPO No.
- Paint colour code.
- Tyre pressures.
D - Gearbox ident. reference - Factory serial no.
E - Engine legislation type - Factory serial no.
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8
GENERAL
Structure Version (4)
G Family (1) Depollution levels
J Bodywork (2) L3 L4 Euro IV US Others K Alcohol
GJ NFUC/IF NFU Engine (3) W3 83/87 K' L3/L4 Euro IV
C Version (4) Manual 5-speed gearbox A B C P V 5 8 1
/IF Variant (5) Manual 4-speed gearbox E F R W 6 9 2
Family (1) Manual 6-speed gearbox G H S X 3
Automatic 6-speed gearbox D J N U
Body shape (2) Axle and/or gearbox gears K L T Y 7 0 4
Other possible combinations M
No gearbox Z
Engine (3) Variants (5)
KFW 1.4i TU3JP 2 sliding side doors standard for 800 Kg WJY PLC Van Turkey TR
NFU 1.6i 16V TU5JP4 Multi-function roof standard for Car WJY PMF Van Spain ES
WJY 1.9D DW8B Without FAP SF Car/Van 5-seater PL
RHY 2.0 HDi DW10TD Fiscal incentives IF
4x4 DANGEL DGL
Downgraded depollution D
Bi-carburation GPL GL
Bi-carburation GNV GN
STT2 (stop and stard) S
IDENTIFICATION OF THE VEHICLE
Type approval
BERLINGO
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9
GENERAL
OPERATIONS TO BE CARRIED OUT AFTER A REPAIR
IMPERATIVE: All these operations are to be performed following a reconnection of the battery.
Antiscanning function.
It is necessary to wait 1 minute after the battery has been disconnected in order to be able to start the vehicle.
Electric windows.
It may be necessary to re-initialise the sequential and anti-pinch functions.
NOTE: If the window is open at the time the battery is reconnected, action the window switch several times to close it, then re-initialise.
Open the window fully.
Action and release the window switch until the window is completely closed.
NOTE: This operation has to be carried out on each electric window.
Multifunction screen.
It is necessary to adjust the date, time and outside temperature.
Reconfigure the personalisation menu of the multifunction screen.
Radio.
Reprogramme the radio stations.
Telematic unit (radiotelephone RT3) .
Reprogramme the radio stations.
Warning: the vehicle has to be in the open air (on switching on the ignition, the ECU searches for satellites) .
Reprogramme the customer parameters.
C4
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10
GENERAL
Draining methods
Oil capacities are defined according to the following methods
CAPACITIES (in litres)
Draining of the engine lubrication system by GRAVITY
Place the vehicle on horizontal ground (in the high position if
hydropneumatic suspension) .
The engine should be hot
(oil temperature 80°C) .
Drain the sump by gravity.
Remove the oil filter cartridge (time for draining and drip-drip = 15
minutes approx.) .
Refit the cap with a new seal.
Refit a new oil filter cartridge.
Refill the engine with oil
(see table for oil capacity) .
Start the engine to fill the oil filter cartridge.
Stop the engine
(allow to stabilise for 5 minutes) .
Draining of the engine lubrication system by SUCTION
Place the vehicle on horizontal ground
(in the high position if
hydropneumatic suspension).
The engine should be hot (oil temperature 80°C).
Remove the oil by suction through the dipstick tube.
Remove the oil filter cartridge.
Maintain the suction of oil in the sump
(15 minutes approx.) .
Refit a new oil filter cartridge.
Refill the engine with oil
(see table for oil capacity) .
Start the engine to fill the oil filter cartridge.
Stop the engine (allow to stabilise for 5 minutes) .
WARNING: Remove the suction container before starting the engine.
ESSENTIAL: Systematically check the oil level using the oil dipstick.
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11
GENERAL
C4CAPACITIES (in litres)
1.4i 16V 1.6i 16V 2.0i 16V 2.0i 2.0i 16V
KFU NFU RFN RFJ RFK
3,75 3,25 4,25 5 5,5
1,2 1,5 1,7 1,7 1,5
2 ± 0,15 2 2
(1) (1)
With ESP = 0,85 Without ESP = 0,75
5,8 6,2 6,2 (2) - 6,6 (3) 6,2 (2) - 6,6 (3) 6,6
6,7 6,8 (2) - 6,9 (3)
0,85
60
Petrol
IMPERATIVE: Systematically check the oil level using the oil dipstick.
(1) = The gearbox is lubricated for life ( as a guide, the TOTAL capacity is 5.85 litres after draining 3 litres) .
(2) = Temperature 37°C. (3) = Temperature 45°C.
Engine type
Oil capacity with change
of cartridge
Between Min. and Max.
Manual gearbox
Automatic gearbox
After draining
Braking circuit
Cooling circuit
Manual gearbox
Automatic gearbox
Steering electro-pump
reservoir
Fuel tank
AUTO. AUTO.
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12
GENERAL
Engine type
Oil capacity with change
of cartridge
Between Min. and Max.
Manual gearbox
Braking circuit
Cooling circuit
Additive reservoir
Steering electro-pump
reservoir
Fuel tank
9HX 9HY 9HZ RHR
3,75 5,25
1,55 1,9
2 2,7
With ESP = 0,85 Without ESP = 0,75
6,5 8,1
2,5 2,5
0,85
60
CAPACITIES (in litres)
Diesel
1.6 HDi 16V 2.0 HDi 16V
NOTE: (*) = Version with additional heating.
IMPERATIVE: Systematically check the oil level using the oil dipstick.
C4
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13
GENERAL
Engine type
Engine with filter element
Between Min. and Max.
5-speed gearbox
Automatic gearbox
After draining
Hydraulic or brake circuit
Cooling circuit
Fuel tank
KFW NFU RFN
3 3,25 4,25
1,5 1,5 1,7
21,9
66
33
With ABS = 0,50 Without ABS = 0,55
76,5
6,5 (1)
54
XSARA
CAPACITIES (in litres)
Petrol
ESSENTIAL: Systematically check the oil level using the oil dipstick.
1.4i 1.6i 16V 2.0i 16V
AUTO. AUTO.
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14
GENERAL
Engine type
Engine with filter element
Between Min. and Max.
5-speed gearbox
Automatic gearbox
After draining
Hydraulic or brake circuit
Cooling circuit
Fuel tank
8HX 8HZ 8HX 8HZ 8HY WJY WJY RHY RHZ
3,75 4,5 3,75 4,5
1,8 1,5 1,8 1,5 1,2 1,8 1,4
2 1,8
8,3
5,3
With ABS = 0,50 Without ABS = 0,55
5,7 9 8,5
54
XSARA CAPACITIES (in litres)
Diesel
(1) =➔RPO 9337 (manual dipstick with two twists).
(2) = RPO 9338 ➔ (manual dipstick without twists but with a sphere).
ESSENTIAL: Systematically check the oil level using the oil dipstick.
1.4 HDi 1.4 16V HDi 1.9D
AUTO.
2.0 HDi
➔ RPO RPO ➔ RPO RPO
9884 9885 ➔9884 9885 ➔(1) (2)
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