CITROEN ZX 1991 User manual

Contents
LIVINGWITHYOURCITROENZX
Introduction
SafetyFirst!
Generaldimensionsandweights
MOTTestChecks
Checkscarriedoutfromthedriver'sseat
Checkscarriedoutwiththevehicleontheground
Checkscarriedoutwiththevehicleraised
Checkscarriedoutonyourvehicle'sexhaustemissionsystem
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RoadsideRepairs
BuyingsparepartsandvehicleidentificationnumbersPage0•11
Jacking,towingandwheelchanging
Boosterbattery(jump)starting
Identifyingleaks
Radio/cassetteunitanti-theftsystem- precaution
Conversionfactors
RoutineMaintenance
Routinemaintenanceandservicing
Lubricants,fluidsandcapacities
Maintenanceschedule
Weeklychecks
Every6000milesor6 months
Every12000milesor12months
Every18000milesor18months
Every24000milesor2 years
Every40000milesor2 years
Every48000miles
Every72000miles
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Contents
REPAIRS& OVERHAUL
EngineandAssociatedSystems
TUseriesenginein-carrepairprocedures
XUseriesenginein-carrepairprocedures
Engineremovalandgeneralengineoverhaulprocedures
Cooling,heatingandventilationsystems
Fuelandexhaustsystems- carburettormodels
Fuelandexhaustsystems- single-pointfuelinjectionmodels
Fuelandexhaustsystems- multi-pointfuelinjectionmodels
Emissioncontrolsystems
Engineelectricalsystems
Transmission
Clutch
Manualtransmission
Automatictransmission
Driveshafts
Brakes
Brakingsystem
Suspension
Suspensionandsteering
BodyEquipment
Bodyworkandfittings
Electrical
Bodyelectricalsystems
WiringDiagrams
REFERENCE
ToolsandWorkingFacilities
GeneralRepairProcedures
FaultFinding
GlossaryofTechnicalTerms
Index
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PageREF•1
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0•4Introduction
IntroductiontotheCitroenZX
TheCitroenZXrangewasintroducedtothe
UKinJune1991.Originally,theZXwas
availablewitha choiceof1.1litre(1124cc),
1.4litre(1360cc),1.6litre(1580cc)or1.9litre
(1905cc)engines.Notallenginesizes,
however,wereavailableinallmarkets(the
1.1litreversionwas notavailableintheUK).
Atfirst,onlyfive-doorHatchbackmodels
wereavailable.Allmodelshavea five-speed
manualtransmissionasstandard;a four-
speedautomatictransmissionwasofferedas
anoptionon1.6and1.9litremodels.
Allenginesarederivedfromthewell-
provenTUseries(1124ccand1360cc)and
XUseries(1580ccand1905ccmodels)
engines,whichhaveappearedinmany
CitroenZX1.4ReflexPlus5-door
CitroenZX2.016-valve
CitroenandPeugeotvehicles.Theengines
areoffour-cylinderoverheadcamshaft
design,mountedtransverselyandinclinedto
therear,withthetransmissionmountedon
theleft-handside.
Inlate1992,a three-doorHatchback
variantwasintroduced.Atthesametime,
threenew"sports"modelswerealso
introduced,all ofwhichwereequippedwith
newengines.Thesenewmodelswerethe
1.8litre(1761cc)Furio,the2.0litre(1998cc
8-valve)Volcane,andthe2.0litre(1998cc
16-valve)16-valvemodel.Allofthesenew
modelsareavailableinthree-doorformonly.
Allthreeofthenewenginesareagainderived
fromtheXUseriesengine.
Onallmodels,fully-independentfront
suspensionisfitted,withthecomponents
attachedtoa subframeassembly.Therear
suspensionissemi-independent,withtorsion
barsandtrailingarms.
Allmodelsintherangeare
comprehensively-equipped,andanti-lock
braking(ABS)andairconditioningsystems
areavailableasoptionsoncertainmodels
(ABSisstandardonthe2.0litre16-valve).
Providedthatregularservicingiscarried
outinaccordancewiththemanufacturer's
recommendations,theCitroenZXshould
provereliableandveryeconomical.The
enginecompartmentiswell-designed,and
mostoftheitemsrequiringfrequentattention
areeasilyaccessible.
Acknowledgements
ThanksareduetoChampionSparkPlug,
whosuppliedtheillustrationsshowingspark
plugconditions.Certainotherillustrationsare
thecopyrightofCitroenCarsLtd,andare
usedwiththeirpermission.Thanksarealso
duetoSykes-PickavantLimited,who
providedsomeoftheworkshoptools,andto
all thosepeopleatSparkfordwhohelpedin
theproductionofthismanual.
Projectvehicles
Variousprojectvehicleswereusedinthe
preparationofthismanual,andappearin
manyofthephotographicsequences.These
includea 1360cc,1580cc,1761cc,1905cc,
1998cc8-valveanda 1998cc16-valve

Safety First! 0•5
Workingonyourcarcanbedangerous.
Thispageshowsjustsomeofthepotential
risksandhazards,withtheaimofcreatinga
safety-consciousattitude.
Generalhazards
Scalding
•Don'tremovetheradiatororexpansion
tankcapwhiletheengineishot.
•Engineoil,automatictransmissionfluidor
powersteeringfluidmayalsobedangerously
hotiftheenginehasrecentlybeenrunning.
Burning
•Bewareofburnsfromtheexhaustsystem
andfromanypartoftheengine.Brakediscs
anddrumscanalsobeextremelyhot
immediatelyafteruse.
Crushing
•Whenworkingunderor neara
raisedvehicle,always
supplementthe
jackwithaxle
stands,oruse
drive-onramps.
Never venture
under a car
which is only
supported by
ajack.
•Takecareiflooseningortighteninghigh-
torquenutswhenthevehicleisonstands.
Initiallooseningandfinaltighteningshouldbe
donewiththewheelsontheground.
Fire
•Fuelishighlyflammable;fuelvapouris
explosive.
•Don'tletfuelspillontoa hotengine.
•Donotsmokeorallownakedlights
(includingpilotlights)anywhereneara vehicle
beingworkedon.Alsobewareofcreating
sparks
(electricallyorbyuseoftools).
•Fuelvapourisheavierthanair,sodon't
workonthefuelsystemwiththevehicleover
aninspectionpit.
•Anothercauseoffireisanelectrical
overloadorshort-circuit.Takecarewhen
repairingormodifyingthevehiclewiring.
•Keepa fireextinguisherhandy,ofa type
suitableforuseonfuelandelectricalfires.
Electricshock
•IgnitionHT
voltagecanbe
dangerous,
especiallyto
peoplewith
heartproblems
ora pacemaker.
Don'tworkonor
neartheignition
systemwiththe
enginerunningorthe
ignitionswitchedon.
•Mainsvoltageisalsodangerous.Makesure
thatanymains-operatedequipmentis
correctlyearthed.Mainspowerpointsshould
beprotectedbya residualcurrentdevice
(RCD)circuitbreaker.
Fumeorgasintoxication
•Exhaustfumesare
poisonous;theyoften
containcarbon
monoxide,whichis
rapidlyfatalifinhaled.
Neverrunthe
engineina
confinedspace
suchasa garage
withthedoorsshut.
•Fuelvapourisalso
poisonous,asarethevapoursfromsome
cleaningsolventsandpaintthinners.
Poisonousorirritantsubstances
•Avoidskincontactwithbatteryacidand
withanyfuel,fluidorlubricant,especially
antifreeze,brakehydraulicfluidandDiesel
fuel.Don'tsyphonthembymouth.Ifsucha
substanceisswallowedorgetsintotheeyes,
seekmedicaladvice.
•Prolongedcontactwithusedengineoil can
causeskincancer.Wearglovesorusea
barriercreamifnecessary.Changeoutofoil-
soakedclothesanddonotkeepoilyragsin
yourpocket.
•Airconditioningrefrigerantformsa
poisonousgasifexposedtoa nakedflame
(includinga cigarette).Itcanalsocauseskin
burnsoncontact.
Asbestos
•Asbestosdustcancausecancerifinhaled
orswallowed.Asbestosmaybefoundin
gasketsandinbrakeandclutchlinings.
Whendealingwithsuchcomponentsitis
safesttoassumethattheycontainasbestos.
Specialhazards
Hydrofluoricacid
•Thisextremelycorrosiveacidisformed
whencertaintypesofsyntheticrubber,found
insomeO-rings,oilseals,fuelhosesetc,are
exposedtotemperaturesabove400°C.The
rubberchangesintoa charredorsticky
substancecontainingtheacid.Once formed,
the acid remains dangerous foryears. If it
gets onto the skin, it may be necessary to
amputate the limb concerned.
•Whendealingwitha vehiclewhichhas
suffereda fire,orwithcomponentssalvaged
fromsucha vehicle,wearprotectivegloves
anddiscardthemafteruse.
Thebattery
•Batteriescontainsulphuricacid,which
attacksclothing,eyesandskin.Takecare
whentopping-uporcarryingthebattery.
•Thehydrogengasgivenoffbythebatteryis
highlyexplosive.Nevercausea sparkor
allowa nakedlightnearby.Becarefulwhen
connectinganddisconnectingbattery
chargersorjumpleads.
Airbags
•Airbags cancauseinjuryiftheygooff
accidentally.Takecarewhenremovingthe
steeringwheeland/orfacia.Specialstorage
instructionsmayapply.
Dieselinjectionequipment
•Dieselinjectionpumpssupplyfuelatvery
highpressure.Takecarewhenworkingon
thefuelinjectorsandfuelpipes.
Warning: Never expose the
hands, face or any other part of
the body to injector spray; the
fuel can penetrate the skin with potentially
fatal results.
Remember...
DO
•Douseeyeprotectionwhenusingpower
tools,andwhenworkingunderthevehicle
•Dowearglovesorusebarriercreamto
protectyourhandswhennecessary.
•Dogetsomeonetocheckperiodicallythat
alliswellwhenworkingaloneonthe
vehicle,
•Dokeeplooseclothingandlonghairwell
outofthewayofmovingmechanicalparts.
•Doremoverings,wristwatchetc.before
workingonthevehicle- especiallythe
electricalsystem.
•Doensurethatanyliftingorlacking
equipmenthasa safeworkingloadrating
adequateforthe|ob.
DON'T
•Don'tattempttolifta heavycomponent
whichmaybebeyondyourcapability- get
assistance.
•Don'trushtofinisha job,ortake
unverifiedshortcuts.
•Don'tuseill-fittingtoolswhichmayslip
andcauseinjury.
•Don'tleavetoolsorpartslyingaround
wheresomeonecantripoverthem.Mopup
oilandfuelspillsatonce.
•Don'tallowchildrenorpetstoplayinor
neara vehiclebeingworkedon.

0•6 General Dimensions & Weights
Dimensions
Overalllength:
Volcane,Funoand16-valvemodels4090mm
Allothermodels4070mm
Overallwidth(excludingmirrors):
Volcaneand16-valvemodels1710mm
Funomodels1690mm
Allothermodels1700mm
Overallheight
Volcane,Funoand16-valvemodels1400mm
Allothermodels1390mm
Wheelbase- allmodels2540mm
Frontandreartrack:
ReflexandAvantagemodels1410mm
Allothermodels1420mm
Turningcircle:
Modelswithmanualsteering10.5m
Modelswithpower-assistedsteering10.7m
Weights
Kerbweights(approximate):
1124ccand1360ccmodels:
Three-doormodels935kg
Five-doormodels945kg
1580ccmodels:
Three-doormodels995kg
Five-doormodels1015kg
1761cc models:
Three-doormodels1008kg
Five-doormodels1024kg
1905ccmodels:
Three-doormodels1055kg
Five-doormodels1085kg
1998cc8-valvemodels:
Three-doormodels1060kg
Five-doormodels1091kg
1998cc16-valvemodels1150kg
Maximumgrossvehicleweight:
1124ccand1360ccmodels1490kg
1580ccmodels1540kg
1761ccmodels1550kg
1905ccmodels1570kg
1998cc8-valvemodels1600kg
1998cc16-valvemodels1630kg
Maximumroofrackload75kg
Maximumtowingnoseweight70kg
Maximumtowingweight:
Brakedtrailer:
1905ccand1998ccmodels1100kg
Allothermodels1000kg
Unbrakedtrailer:
1124ccand1360ccmodels470kg
1580ccmodels490kg
1761ccmodels500kg
1905ccmodels510 kg
1998ccmodels530 kg

MOT Test Checks 0•7
Thisisa guidetogettingyourvehiclethroughtheMOTtest.
Obviouslyitwillnotbepossibletoexaminethevehicletothesame
standardastheprofessionalMOTtester.However,workingthrough
thefollowingcheckswillenableyoutoidentifyanyproblemareas
beforesubmittingthevehicleforthetest.
Wherea testablecomponentisinborderlinecondition,thetester
hasdiscretionindecidingwhethertopassorfailit.Thebasisofsuch
discretioniswhetherthetesterwouldbehappyfora closerelativeor
friendtousethevehiclewiththecomponentinthatcondition.Ifthe
vehiclepresentediscleanandevidentlywellcaredfor,thetestermay
be moreinclinedto passa borderlinecomponentthanif thevehicleis
scruffyandapparentlyneglected.
Ithasonlybeenpossibletosummarisethetestrequirementshere,
basedontheregulationsinforceatthetimeofprinting.Teststandards
arebecomingincreasinglystringent,althoughtherearesome
exemptionsforoldervehicles.Forfulldetailsobtaina copyoftheHaynes
publicationPasstheMOT!(availablefromstockistsofHaynesmanuals).
Anassistantwillbeneededtohelpcarryoutsomeofthesechecks.
The checks have been sub-divided into four categories, as follows:
Handbrake
•Testtheoperationofthehandbrake.
Excessivetravel(toomanyclicks)indicates
incorrectbrakeorcableadjustment.
•Checkthatthehandbrakecannotbe
releasedbytappingtheleversideways.Check
thesecurityofthelevermountings.
Footbrake
•Depressthebrakepedalandcheckthatit
doesnotcreepdowntothefloor,indicatinga
mastercylinderfault.Releasethepedal,wait
afewseconds,thendepressitagain.Ifthe
pedaltravelsnearlytothefloorbeforefirm
resistanceisfelt,brakeadjustmentorrepairis
necessary.Ifthepedalfeelsspongy,thereis
airinthehydraulicsystemwhichmustbe
removedbybleeding.
•Checkthatthebrakepedalissecureandin
goodcondition.Checkalsoforsignsoffluid
leaksonthepedal,floororcarpets,which
wouldindicatefailedsealsinthebrakemaster
cylinder.
•Checktheservounit(whenapplicable)by
operatingthebrakepedalseveraltimes,then
keepingthepedaldepressedandstartingthe
engine.Astheenginestarts,thepedalwill
movedownslightly.Ifnot,thevacuumhoseor
theservoitselfmaybefaulty.
Steering wheel and column
Examinethesteeringwheelforfracturesor
loosenessofthehub,spokesorrim.
•Movethesteeringwheelfromsidetoside
andthenupanddown.Checkthatthe
steeringwheelisnotlooseonthecolumn,
indicatingwearOKa looseretainingnut.
Continuemovingthesteeringwheelasbefore,
butalsoturnitslightlyfromlefttoright.
•Checkthatthesteeringwheelisnotloose
onthecolumn,andthatthereisnoabnormal
movementofthesteeringwheel,indicating
wearinthecolumnsupportbearingsor
couplings.
Windscreen and mirrors
•Thewindscreenmustbefreeofcracksor
othersignificantdamagewithinthedriver's
fieldofview.(Smallstonechipsare
acceptable.)Rearviewmirrorsmustbe
secure,intact,andcapableofbeingadjusted.
Checkscarriedout
FROMTHEDRIVER'S
SEAT
Checkscarriedout
WITHTHEVEHICLE
ONTHEGROUND
Checkscarriedout
WITHTHEVEHICLE
RAISEDANDTHE
WHEELSFREETO
TURN
Checkscarriedouton
YOURVEHICLE'S
EXHAUSTEMISSION
SYSTEM
Checkscarriedout
FROMTHEDRIVER'SSEAT
1
2 3
4
1

0•8
MOT Test Checks
Electrical equipment
•Switchontheignitionandcheckthe
operationofthehorn.
•Checkthewindscreenwashersandwipers,
examiningthewiperblades;renewdamaged
orperishedblades.Alsochecktheoperation
ofthestop-lights.
•Inspectbothfrontbrakeflexiblehosesfor
cracksordeteriorationoftherubber.Turnthe
steeringfromlocktolock,andensurethatthe
hosesdonotcontactthewheel,tyre,orany
partofthesteeringorsuspensionmechanism.
Withthebrakepedalfirmlydepressed,check
thehosesforbulgesorleaksunderpressure.
Seat belts and seats
Note:The following checks are applicable to
all seat belts, front and rear.
•Examinethewebbingofallthebelts
(includingrearbeltsiffitted)forcuts,serious
frayingordeterioration.Fastenandunfasten
eachbelttocheckthebuckles.Ifapplicable,
checktheretractingmechanism.Checkthe
securityofallseatbeltmountingsaccessible
frominsidethevehicle.
•Thefrontseatsthemselvesmustbe
securelyattachedandthebackrestsmust
lockintheuprightposition.
Doors
•Bothfrontdoorsmustbeabletobeopened
andclosedfromoutsideandinside,andmust
latchsecurelywhenclosed.
Vehicle identification
•Number platesmustbeingoodcondition,
secureandlegible,withlettersandnumbers
correctlyspaced- spacingat (A)shouldbe
twicethatat(B).
•Checktheoperationofthesidelightsand
numberplatelights.Thelensesandreflectors
mustbesecure,cleanandundamaged.
•Checktheoperationandalignmentofthe
headlights.Theheadlightreflectorsmustnot
betarnishedandthelensesmustbe
undamaged.
•Switchontheignitionandcheckthe
operationofthedirectionindicators(including
theinstrumentpaneltell-tale)andthehazard
warninglights.Operationofthesidelightsand
stop-lightsmustnotaffecttheindicators- ifit
does,thecauseisusuallya badearthatthe
rearlightcluster.
•Checktheoperationoftherearfoglight(s),
includingthewarninglightontheinstrument
panelorintheswitch.
Footbrake
•Examinethemastercylinder,brakepipes
andservounitforleaks,loosemountings,
corrosionorotherdamage.
Steering and suspension
•Haveyourassistantturnthesteeringwheel
fromsidetosideslightly,uptothepointwhere
thesteeringgearjustbeginstotransmitthis
movementtotheroadwheels.Checkfor
excessivefreeplaybetweenthesteering
wheelandthesteeringgear,indicatingwearor
insecurityofthesteeringcolumnjoints,the
column-to-steeringgearcoupling,orthe
steeringgearitself.
•Haveyourassistantturnthesteeringwheel
morevigorouslyineachdirection,sothatthe
roadwheelsjustbegintoturn.Asthisisdone,
examineallthesteeringjoints,linkages,
fittingsandattachments.Renewany
componentthatshowssignsofwearor
damage.Onvehicleswithpowersteering,
checkthesecurityandconditionofthe
steeringpump,drivebeltandhoses.
•Checkthatthevehicleisstandinglevel,
andatapproximatelythecorrectrideheight.
Shock absorbers
•Depresseachcornerofthevehicleinturn,
thenreleaseit.Thevehicleshouldriseand
thensettleinitsnormalposition.Ifthevehicle
continuestoriseandfall,theshockabsorber
isdefective.A shockabsorberwhichhas
seizedwillalsocausethevehicletofail.
•TheVINplate(A)andhomologationplate
(B)mustbelegible.
•Thefluidreservoirmustbesecureandthe
fluidlevelmustbebetweentheupper(A)and
lower(B)markings.
Checkscarriedout
WITHTHEVEHICLEONTHE
GROUND
2

MOT Test Checks 0•9
Exhaust system
•Starttheengine.Withyourassistant
holdinga ragoverthetailpipe,checkthe
entiresystemforleaks.Repairorrenew
leakingsections.
Jackupthefrontandrearofthevehicle,
andsecurelysupportitonaxlestands.
Positionthestandsclearofthesuspension
assemblies.Ensurethatthewheelsare
clearofthegroundandthatthesteering
canbeturnedfromlocktolock.
Steering mechanism
•Haveyourassistantturnthesteeringfrom
locktolock.Checkthatthesteeringturns
smoothly,andthatnopartofthesteering
mechanism,includinga wheelortyre,fouls
anybrakehoseorpipeoranypartofthebody
structure.
•Examinethesteeringrackrubbergaiters
fordamageorinsecurityoftheretainingclips.
Ifpowersteeringisfitted,checkforsignsof
damageorleakageofthefluidhoses,pipesor
connections.Alsocheckforexcessive
stiffnessorbindingofthesteering,a missing
splitpinorlockingdevice,orseverecorrosion
ofthebodystructurewithin30cmofany
steeringcomponentattachmentpoint.
Front and rear suspension and
wheel bearings
•Startingatthefrontright-handside,grasp
theroadwheelatthe3 o'clockand9 o'clock
positionsandshakeitvigorously.Checkfor
freeplayorinsecurityatthewheelbearings,
suspensionballjoints,orsuspensionmount-
ings,pivotsandattachments.
•Nowgraspthewheelatthe12o'clockand
6o'clockpositionsandrepeattheprevious
inspection.Spinthewheel,andcheckfor
roughnessortightnessofthefrontwheel
bearing.
•Ifexcessfreeplayissuspectedata
componentpivotpoint,thiscanbeconfirmed
byusinga largescrewdriverorsimilartool
andleveringbetweenthemountingandthe
componentattachment.Thiswillconfirm
whetherthewearisinthepivotbush,its
retainingbolt,orinthemountingitself(the
boltholescanoftenbecomeelongated).
•Carryoutalltheabovechecksattheother
frontwheel,andthenatbothrearwheels.
Springs and shock absorbers
•Examinethesuspensionstruts(when
applicable)forseriousfluidleakage,
corrosion,ordamagetothecasing.Also
checkthesecurityofthemountingpoints.
•Ifcoilspringsarefitted,checkthatthe
springendslocateintheirseats,andthatthe
springisnotcorroded,crackedorbroken.
•Ifleafspringsarefitted,checkthatall
leavesareintact,thattheaxleissecurely
attachedtoeachspring,andthatthereisno
deteriorationofthespringeyemountings,
bushes,andshackles.
•Thesamegeneralchecksapplytovehicles
fittedwithothersuspensiontypes,suchas
torsionbars,hydraulicdisplacerunits,etc.
Ensurethatallmountingsandattachments
aresecure,thattherearenosignsof
excessivewear,corrosionordamage,and(on
hydraulictypes)thattherearenofluidleaksor
damagedpipes.
•Inspecttheshockabsorbersforsignsof
seriousfluidleakage.Checkforwearofthe
mountingbushesorattachments,ordamage
tothebodyoftheunit.
Driveshafts
(fwd vehicles only)
•Rotateeachfrontwheelinturnandinspect
theconstantvelocityjointgaitersforsplitsor
damage.Alsocheckthateachdriveshaftis
straightandundamaged.
Braking system
•Ifpossiblewithoutdismantling,check
brakepadwearanddisccondition.Ensure
thatthefrictionliningmaterialhasnotworn
excessively,(A)andthatthediscsarenot
fractured,pitted,scoredorbadlyworn(B).
•Examinealltherigidbrakepipes
underneaththevehicle,andtheflexible
hose(s)attherear.Lookforcorrosion,chafing
orinsecurityofthepipes,andforsignsof
bulgingunderpressure,chafing,splitsor
deteriorationoftheflexiblehoses.
•Lookforsignsoffluidleaksatthebrake
calipersoronthebrakebackplates.Repairor
renewleakingcomponents.
•Slowlyspineachwheel,whileyour
assistantdepressesandreleasesthe
footbrake.Ensurethateachbrakeisoperating
anddoesnotbindwhenthepedalisreleased.
Checkscarriedout
WITHTHEVEHICLERAISED
ANDTHEWHEELSFREETO
TURN
3

MOT Test Checks
•Examinethehandbrakemechanism,
checkingforfrayedorbrokencables,
excessivecorrosion,orwearorinsecurityof
thelinkage.Checkthatthemechanismworks
oneachrelevantwheel,andreleasesfully,
withoutbinding.
•Itisnotpossibletotestbrakeefficiency
withoutspecialequipment,buta roadtest
canbecarriedoutlatertocheckthatthe
vehiclepullsupina straightline.
Fuel and exhaust systems
•Inspectthefueltank(includingthefiller
cap),fuelpipes,hosesandunions.All
componentsmustbesecureandfreefrom
leaks.
•Examinetheexhaustsystemoveritsentire
length,checkingforanydamaged,brokenor
missingmountings,securityoftheretaining
clampsandrustorcorrosion.
Wheels and tyres
•Examinethesidewallsandtreadareaof
eachtyreinturn.Checkforcuts,tears,
lumps,bulges,separationofthetread,and
exposureoftheplyorcordduetowearor
damage.Checkthatthetyrebeadiscorrectly
seatedonthewheelrim,thatthevalveis
soundandproperlyseated,andthatthe
wheelisnotdistortedordamaged.
•Checkthatthetyresareofthecorrectsize
forthevehicle,thattheyareofthesamesize
andtypeoneachaxle,andthatthepressures
arecorrect.
•Checkthetyretreaddepth.Thelegal
minimumatthetimeofwritingis1.6mmover
atleastthree-quartersofthetreadwidth.
Abnormaltreadwearmayindicateincorrect
frontwheelalignment.
Body corrosion
Checktheconditionoftheentirevehicle
structureforsignsofcorrosioninload-
bearingareas.(Theseincludechassisbox
sections,sidesills,cross-members,pillars,
andall suspension,steering,brakingsystem
andseatbeltmountingsandanchorages.)
Anycorrosionwhichhasseriouslyreduced
thethicknessofa load-bearingareaislikely
tocausethevehicletofail.Inthiscase
professionalrepairsarelikelytobeneeded.
•Damageorcorrosionwhichcausessharp
orotherwisedangerousedgestobeexposed
willalsocausethevehicletofail.
Petrol models
•Havetheengineatnormaloperating
temperature,andmakesurethatitisingood
tune(ignitionsystemingoodorder,airfilter
elementclean,etc).
•Beforeanymeasurementsarecarriedout,
raisetheenginespeedtoaround2500rpm,
andholditatthisspeedfor20seconds.
Allowtheenginespeedtoreturntoidle,and
watchforsmokeemissionsfromtheexhaust
tailpipe.Iftheidlespeedisobviouslymuch
toohigh,orifdenseblueorclearly-visible
blacksmokecomesfromthetailpipeformore
than5 seconds,thevehiclewillfail.Asa rule
ofthumb,bluesmokesignifiesoilbeingburnt
(enginewear)whileblacksmokesignifies
unburntfuel(dirtyaircleanerelement,or
othercarburettororfuelsystemfault).
•Anexhaustgasanalysercapableof
measuringcarbonmonoxide(CO)and
hydrocarbons(HC)isnowneeded.Ifsuchan
instrumentcannotbehiredorborrowed,a
localgaragemayagreetoperformthecheck
fora smallfee.
CO emissions (mixture)
•Atthetimeorwriting,themaximumCO
levelatidleis3.5%forvehiclesfirstused
afterAugust1986and4.5%forolder
vehicles.FromJanuary1996a muchtighter
limit(around0.5%)appliestocatalyst-
equippedvehiclesfirstusedfromAugust
1992.IftheCOlevelcannotbereducedfar
enoughtopassthetest(andthefueland
ignitionsystemsareotherwiseingood
condition)thenthecarburettorisbadlyworn,
orthereissomeprobleminthefuelinjection
systemorcatalyticconverter(asapplicable).
HC emissions
•WiththeCOemissionswithinlimits,HC
emissionsmustbenomorethan1200ppm
(partspermillion).Ifthevehiclefailsthistest
atidle,itcanbere-testedataround2000
rpm;iftheHClevelisthen1200ppmorless,
thiscountsasa pass.
•ExcessiveHCemissionscanbecausedby
oil beingburnt,buttheyaremorelikelytobe
duetounburntfuel.
Diesel models
•TheonlyemissiontestapplicabletoDiesel
enginesisthemeasuringofexhaustsmoke
density.Thetestinvolvesacceleratingthe
engineseveraltimestoitsmaximum
unloadedspeed.
Note:Itisofthe utmost importance that the
engine timing belt is in good condition before
the test is carried out.
•Excessivesmokecanbecausedbya dirty
aircleanerelement.Otherwise,professional
advicemaybeneededtofindthecause.
0•10
Checkscarriedouton
YOURVEHICLE'SEXHAUST
EMISSIONSYSTEM
4

Roadside Repairs
Buyingsparepartsandvehicleidentificationnumbers
Buying spare parts
Sparepartsareavailablefrommany
sources;forexample,Citroengarages,other
garagesandaccessoryshops,andmotor
factors.Ouradviceregardingsparepart
sourcesis as follows.
Officially-appointed Citroen garages - This
isthebestsourceforpartswhicharepeculiar
toyourcar,andarenotgenerallyavailable(eg
completecylinderheads,gearboxinternal
components,badges,interiortrimetc).Itis
alsotheonlyplaceatwhichyoushouldbuy
partsifthevehicleisstillunderwarranty.To
besureofobtainingthecorrectparts,itwill
benecessarytogivethestoremanyourcar's
vehicleidentificationnumber.Ifpossible,take
theoldpartsalongforpositiveidentification.
Manypartsareavailableundera factory
exchangescheme- anypartsreturnedshould
alwaysbeclean.Itobviouslymakesgood
sensetogostraighttothespecialistsonyour
carforthistypeofpart,astheyarebest
equippedtosupplyyou.
Other garages and accessory shops -
Theseareoftenverygoodplacestobuy
materialsandcomponentsneededforthe
maintenanceofyourcar(egoilfilters,spark
plugs,bulbs,drivebelts,oilsandgreases,
touch-uppaint,fillerpaste,etc).Theyalsosell
generalaccessories,usuallyhaveconvenient
openinghours,chargelowerprices,andcan
oftenbefoundnotfarfromhome.
Motor factors - Goodfactorswillstockall
themoreimportantcomponentswhichwear
outcomparativelyquickly(egexhaust
systems,brakepads,sealsandhydraulic
parts,clutchcomponents,bearingshells,
pistons,valvesetc).Motorfactorswilloften
provideneworreconditionedcomponentson
apart-exchangebasis- thiscansavea
considerableamountofmoney.
Vehicle identification numbers
Modificationsarea continuingand
unpublicisedprocessinvehiclemanufacture,
quiteapartfrommajormodelchanges.Spare
partsmanualsandlistsarecompiledupona
numericalbasis,theindividualvehicle
identificationnumbersbeingessentialto
correctidentificationofthecomponent
concerned.
Whenorderingspareparts,alwaysgiveas
muchinformationaspossible.Quotethecar
model,yearofmanufacture,bodyandengine
numbersasappropriate(seeillustration).
Thevehicle identification plate isstamped
ona platelocatedunderthebonnetonthe
lowerright-handwheelarch(seeillustration).
Thechassis number isstampedonthe
bodypanelunderthebonnetontheright-
handsideofthebulkheadonmodels
producedupto1993,orontheright-hand
wheelarchonmodelsproducedfrom1993
(seeillustration).
Thepaint code number islocatedonthe
bodypanelunderthebonnetontheleft-hand
upperwheelarch.
Theengine number isstampedona plate
rivetedtothefrontofthecylinderblock(refer
toChapter2Aor2Bforfurtherinformation).
Vehicleidentificationnumberlocations
0•11
0000001
UPTO 1993
FROM1993
FROM1993
UP TO1993
BE 3
20CJ84
0000001A
P.T.C

0•12Roadside Repairs
Jacking,towingandwheelchanging
Jacking
Thejacksuppliedwiththevehicletoolkit
shouldonlybeusedforchangingthe
roadwheels- see"Wheel changing" laterinthis
Section.Whencarryingoutanyotherkindof
work,raisethevehicleusinga hydraulicjack,
andalwayssupplementthejackwithaxlestands
positionedunderthevehiclejackingpoints.
Whenusinga hydraulicjackoraxlestands,
alwayspositionthejackheadoraxlestand
headunderoneoftherelevantjackingpoints
(notethatthejackingpointsforusewitha
hydraulicjackoraxlestandsaredifferentto
thoseforusewiththevehiclejack)(see
illustrations).Donot jackthevehicleunder
thesumporanyofthesteeringorsuspension
components.Neverwork under, around, or
near a raised vehicle, unless it is adequately
supported in at least two places.
Notethefollowingwhenusinga hydraulic
jack:
(a) When raising the side ofthe vehicle,
ensure that the load is taken by the raised
jacking plates on the sill panels (refer to
the accompanying illustration) - do not
jack under the body panel behind the sill
panels.
(b) When raising the front of the vehicle, use
asuitable metal or strong wooden bar
and wooden spacer blocks under the
front suspension subframe (refer to the
accompanying illustration).
(c) When raising the rear of the vehicle,
position the jack or axle stands under the
rear suspension tubular crossmember
(refer to the accompanying illustration).
Towing
Towingeyesarefittedtothefrontandrear
ofthevehicleforattachmentofa towrope.
Notethat,oncertainmodels,plasticcovers
mustbeunclippedfromthebumpersfor
accesstothetowingeyes(seeillustrations).
Alwaysturntheignitionkeytoposition"A"
whenthevehicleisbeingtowed,sothatthe
steeringlockisreleased,andthedirection
indicatorandbrakelightsareoperational.
Beforebeingtowed,releasethehandbrake
andplacethegearleverinneutralonmanual
transmissionmodels,or"N"onautomatic
transmissionmodels.Notethatgreater-than-
usualpedalpressurewillberequiredto
operatethebrakes,sincethevacuumservo
unitisonlyoperationalwiththeengine
running.Similarly,onmodelswithpower
steering,greater-than-usualsteeringeffort
willberequired.
Wherepossible,modelswithautomatic
transmissionshouldideallybetowedwiththe
frontwheelsofftheground,particularlyifa
transmissionfaultissuspected.Ifthevehicle
istobetowedwithitsfrontwheelsonthe
ground,itmustalwaysbetowedforwardsat
speedsnotexceeding30mph(50km/h),orfor
adistancenofurtherthan30miles(50km).
Alsonotethat,toavoiddamagingthe
automatictransmission,thefluidlevelmustbe
topped-uptothedipstickmaximummarkas
describedinChapter1,thenanextra1.5litres
offluidadded.Theexcessfluidmustbe
drainedoffbeforethevehicleisdrivenagain.
SidejackingpointsFrontandrearjackingpoints

Roadside Repairs
Frontandreartowingeyelocations
Wheel changing
Thesparewheelandjackarelocatedina
cradleundertherearofthevehicle.Thecradle
isloweredbyturningthecradleretaining
screw,locatedundertheluggage
compartmentcarpet,nearthetailgatelock.
Thecradleretainingscrewcanbeturnedby
engagingtheendofthewheelbrace(located
inclipsontheright-handsideoftheluggage
compartment)withtheslotinthescrew.Lift
thecradletoreleasetheretainingcatch,then
loweritforaccesstothesparewheel.Note
thatthejackismountedinsidea plasticcase
toprotectitfromroaddirtanddebris(see
illustrations).
Tochangea wheel,removethesparewheel
andjack(asdescribedpreviously),applythe
handbrakeandplacechocksatthefrontand
rearofthewheeldiagonallyoppositetheone
tobechanged.A wheelchockissuppliedwith
thetoolkit,andislocatedinthewellofthe
sparewheel.Onautomatictransmission
models,placetheselectorleverinposition
"P".Makesurethatthevehicleislocatedon
firmlevelground,andthenslightlyloosenthe
wheelboltswiththebraceprovided(where
applicable,removethewheeltrimfirst).
Locatethejackheadinthejackingpointon
therelevantsideofthevehicletoberaised,
andraisethejackbyturningthescrewusing
thewheelbrace.Whenthewheelisclearof
Coverremovedtoexposefronttowing
eye(arrowed)- Volcanemodels
Wheelbraceandsparewheelcradle
retainingscrew(arrowed)inluggage
compartment
Sparewheelcradleretainingcatch
(arrowed)andjackcase(A)
theground,removetheboltsandliftoffthe
wheel.Fitthesparewheel,andmoderately
tightenthebolts.Lowerthevehicleandthen
tightentheboltsfully.Refitthetrimwhere
applicable.Ifpossible,checkthetyre
pressureonthesparewheel.
Removethechocksandstowthejack,
tools,andthedamagedwheel.Havethe
damagedtyreorwheelrepairedorrenewed
assoonaspossible.
0•13

Roadside Repairs
Boosterbattery(jump)starting
Whenjump-startinga carusinga
boosterbattery,observethefollowing
precautions:
A)Beforeconnectingthebooster
battery,makesurethattheignitionis
switchedoff.
B)Ensurethatallelectricalequipment
(lights,heater,wipers,etc)is
switchedoff.
C)Makesurethattheboosterbatteryis
thesamevoltageasthedischarged
oneinthevehicle.
D)Ifthebatteryisbeingjump-started
fromthebatteryinanothervehicle,
thetwovehclesMUSTNOTTOUCH
eachother.
E)Makesurethatthetransmissionisin
neutral(orPARK,inthecaseof
automatictransmission).
Connectoneendoftheredjumpleadto
thepositive(+)terminaloftheflat
battery
Connecttheotherendoftheredleadto
thepositive(+)terminalofthebooster
battery.
Connectoneendoftheblackjumplead
tothenegative(-)terminalofthe
boosterbattery
Connecttheotherendoftheblack
jumpleadtoa boltorbracketonthe
engineblock,wellawayfromthe
battery,onthevehicletobestarted
Makesurethatthejumpleadswillnot
comeintocontactwiththefan,drive-
beltsorothermovingpartsofthe
engine.
Starttheengineusingthebooster
battery,thenwiththeenginerunningat
idlespeed,disconnectthejumpleadsin
thereverseorderofconnection.
0•14
Jumpstartingwillgetyouout
oftrouble,butyoumustcorrect
whatevermadethebatterygo
flat in the first place. There are
threepossibilities:
The battery has been drained by
repeated attempts to start, or by
leaving the lights on.
The charging system is not working
properly (alternator drivebelt slack
or broken, alternator wiring fault or
alternator itself faulty).
The battery itself is at fault
(electrolyte low, or battery worn out).

Roadside Repairs
Identifyingleaks
Puddlesonthegaragefloorordrive,or
obviouswetnessunderthebonnetor
underneaththecar,suggesta leakthatneeds
investigating.Itcansometimesbedifficultto
decidewheretheleakiscomingfrom,
especiallyiftheenginebayisverydirty
already.Leakingoilorfluidcanalsobeblown
rearwardsbythepassageofairunderthecar,
givinga falseimpressionofwherethe
problemlies.
Sumpoil
Warning: Most automotive oils
and fluids are poisonous. Wash
them off skin, and change out of
contaminated clothing, without
delay.
Oilfromfilter Gearboxoil
Engineoil mayleakfromthedrainplug...
Antifreeze
...orfromthebaseoftheoil filter.
Brakefluid
Gearboxoilcanleakfromthesealsatthe
inboardendsofthedriveshafts.
Powersteeringfluid
Leakingantifreezeoftenleavesa crystalline
depositlikethis.Aleakoccurringata wheelisalmost
certainlybrakefluid.Powersteeringfluidmayleakfromthepipe
connectorsonthesteeringrack.
Radio/cassetteunitanti-theftsystem- precaution
Theradio/cassetteunitfittedas standard
equipmentbyCitroenisequippedwitha built-
insecuritycode,todeterthieves.Ifthepower
sourcetotheunitiscut,theanti-theftsystem
willactivate.Evenifthepowersourceis
immediatelyreconnected,theradio/cassette
unitwillnotfunctionuntilthecorrectsecurity
codehasbeenentered.Therefore,ifyoudo
notknowthecorrectsecuritycodeforthe
radio/cassetteunitdonot disconnecteitherof
thebatteryterminals,orremovethe
radio/cassetteunitfromthevehicle.
Toenterthesecuritycode,firstswitchtheunit
on;thedisplaywillshow"Cod".Thesecurity
codecanthenbeenteredusingbuttons1 to4
ontheunit;eachbuttonaltersthecorresponding
digitofthecode.Note:There isnofacility onthe
radio display to show the number 0 for the first
digit of the security code. For the first digit, 0 is
indicated bya blank. Oncethecorrectcodeis
displayed,pressthe"up"sectionofthefour-way
tuningbuttontoenterthecode.
Ifanincorrectcodeisentered,thedisplay
willshowthreedashes,afterwhichtheradio
willbelockedfor10seconds.Onthefirsttwo
attempts,after10secondstheradiodisplay
willshowthe"Cod"promptagain,andallow
youtoenterthesecuritycodeagain.However,
ifthecorrectsecuritycodeisnotenteredon
thethirdattempt,theunitwillbelockedfor1
hour.Tomakeanyfurtherattempts,theunit
mustbeswitchedonandleftuntouchedfor
approximately1 hourbeforethedisplay
showsthe"Cod"promptagain,andallows
youtore-enterthesecuritycode.Note that
aftertwentyattempts,theunitwillbecome
permanentlylocked.
Ifthishappens,orifthesecuritycodeislost
orforgotten,seektheadviceofyourCitroen
dealer.Onpresentationofproofofownership,
aCitroendealerwillbeabletounlocktheunit
andprovideyouwitha newsecuritycode.
0•15
The smell of a fluid leaking
from the car may provide a
clue to what's leaking. Some
fluids are distictively coloured.
It may help to clean the car carefully
and to park it over some clean paper
overnight as an aid to locating the
source of the leak.
Remember that some leaks may only
occur while the engine is running.

Conversion Factors
Length (distance)
Inches(in)
Feet(ft)
Miles
Volume (capacity)
Cubicinches(cuin;in3)
Imperialpints(Imppt)
Imperialquarts(Impqt)
Imperialquarts(Impqt)
USquarts(USqt)
Imperialgallons(impgal)
Imperialgallons(Impgal)
USgallons(USgal)
Mass (weight)
Ounces(oz)
Pounds(Ib)
Force
Ounces-force(ozf;oz)
Pounds-force(Ibf;Ib)
Newtons(N)
Pressure
Pounds-forcepersquareinch
(psi;Ibf/in2;Ib/in2)
Pounds-forcepersquareinch
(psi;Ibf/in2;Ib/in2)
Pounds-forcepersquareinch
(psi;Ibf/in2;Ib/in2)
Pounds-forcepersquareinch
(psi;Ibf/in2;Ib/in2)
Kilopascals(kPa)
Millibar (mbar)
Millibar (mbar)
Millibar (mbar)
Millibar(mbar)
Millimetresofmercury(mmHg)
Inchesofwater(inH2O)
Torque (moment of force)
Pounds-forceinches
(Ibf in; Ibin)
Pounds-forceinches
(Ibf in; Ibin)
Pounds-forceinches
(Ibf in; Ibin)
Pounds-forcefeet(Ibfft;Ibft)
Pounds-forcefeet(Ibfft;Ibft)
Newtonmetres(Nm)
Power
Horsepower(hp)
Velocity(speed)
Milesperhour(miles/hr;mph)
Fuel consumption*
Milespergallon(mpg)
Temperature
x25.4= Millimetres(mm)x
x0.305= Metres(m)x
x1.609= Kilometres(km)x
x16.387= Cubiccentimetres(cc;cm3)x
x0.568= Litres(l)x
x1.137= Litres(I)x
x1.201= USquarts(USqt)x
x0.946= Litres(I)x
x4.546= Litres(I)x
x1.201= USgallons(USgal)x
x3.785= Litres(I)x
x28.35= Grams(g)x
x0.454= Kilograms(kg)x
x0.278= Newtons(N)x
x4.448= Newtons(N)x
x0.1= Kilograms-force(kgf;kg)x
x0.070= Kilograms-forcepersquarex
centimetre(kgf/cm2;kg/cm2)
x0.068= Atmospheres(atm)x
x0.069= Barsx
x6.895= Kilopascals(kPa)x
x0.01= Kilograms-forcepersquarex
centimetre(kgf/cm2;kg/cm2)
x100= Pascals(Pa)x
x0.0145=Pounds-forcepersquareinchx
(psi;Ibf/in2;Ib/in2)
x0.75= Millimetresof mercury(mmHg)x
x0.401= Inchesofwater(inH2O)x
x0.535= Inchesof water(inH2O)x
x0.036= Pounds-forcepersquareinchx
(psi;Ibf/in2;Ib/in2)
x1.152= Kilograms-forcecentimetrex
(kgf cm; kgcm)
x0.113= Newtonmetres(Nm)x
*
x0.083= Pounds-forcefeet(Ibfft;Ibft)x
x0.138= Kilograms-forcemetres. x
(kgfm;kgm)
x1.356= Newtonmetres(Nm)x
x0.102= Kilograms-forcemetresx
(kgfm;kgm)
x745.7= Watts(W)x
x1.609= Kilometresperhour(km/hr;kph)x
x0.354= Kilometresperlitre(km/I)x
0.0394=
3.281=
0.621=
0.061=
1.76=
0.88=
0.833=
1.057=
0.22=
0.833=
0.264=
0.035=
2.205=
3.6
0.225=
9.81=
14.223=
14.696=
14.5=
0.145=
98.1=
0.01=
68.947=
1.333=
2.491=
1.868=
27.68=
0.868=
8.85=
12
7.233=
0.738=
9.804=
0.0013 =
0.621=
2.825=
DegreesFahrenheit= (°Cx 1.8)+ 32DegreesCelsius(DegreesCentigrade;°C)=
Inches(in)
Feet(ft)
Miles
Cubicinches(cuin;in3)
Imperialpints(Imppt)
Imperialquarts(Impqt)
Imperialquarts(Impqt)
USquarts(USqt)
Imperialgallons(Impgal)
Imperialgallons(Impgal)
USgallons(USgal)
Ounces(oz)
Pounds(Ib)
Ounces-force(ozf;oz)
Pounds-force(Ibf;Ib)
Newtons(N)
Pounds-forcepersquareinch
(psi;Ibf/in2;Ib/in2)
Pounds-forcepersquareinch
(psi;Ibf/in2;Ib/in2)
Pounds-forcepersquareinch
(psi;Ibf/in2;Ib/in2)
Pounds-forcepersquareinch
(psi;Ibf/in2;Ib/in2)
Kilopascals(kPa)
Millibar(mbar)
Millibar(mbar)
Millibar(mbar)
Millibar(mbar)
Millimetresofmercury(mmHg)
Inchesofwater(inH2O)
Pounds-forceinches
(Ibf in; Ibin)
Pounds-forceinches
(Ibf in; Ibin)
Pounds-forceinches
(Ibf in; Ibin)
Pounds-forcefeet(Ibfft;Ibft)
Pounds-forcefeet(Ibfft;Ibft)
Newtonmetres(Nm)
Horsepower(hp)
Milesperhour(miles/hr;mph)
Milespergallon(mpg)
(°F- 32)x 0.56
*It is common practice to convert from miles pergallon (mpg) to litres/100 kilometres (l/100km), where mpg x 1/100 km = 282
0•16

1•1
Chapter1 Routinemaintenanceandservicing
Contents
Airconditioningsystemrefrigerantcheck14
Airfilterrenewal26
Automatictransmissionfluidlevelcheck10
Automatictransmissionfluidrenewal29
Auxiliarydrivebeltcheckingandrenewal21
Batterycheck6
Brakefluidrenewal30
Clutchadjustmentcheckandcontrolmechanismlubrication22
Coolantrenewal31
Driveshaftgaitercheck12
Electricalsystemcheck5
Emissioncontrolsystemscheck20
Engineoilandfilterrenewal8
Fluidlevelchecks.:3
Frontbrakepadconditioncheck13
Fuelfilterrenewal- carburettormodels17
Fuelfilterrenewal- fuelinjectionmodels32
Hingeandlocklubrication27
Degreesofdifficulty
Hoseandfluidleakcheck9
Idlespeedandmixturecheckandadjustment19
Ignitionsystemcheck18
intensivemaintenance2
Introduction1
Manualtransmissionoillevelcheck28
Manualtransmissionoilrenewal34
Rearbrakepadconditioncheck- modelswithreardiscbrakes...24
Rearbrakeshoeconditioncheck- modelswithreardrumbrakes. 23
Roadtest25
Sparkplugrenewal16
SpecificationsSeeendofChapter
Steeringandsuspensioncheck11
Timingbeltrenewal33
Tyrechecks4
Valveclearancecheckandadjustment-1124ccand1360cc
models15
Wiperbladecheck7
Easy,suitablefor
novicewithlittle
experience
Fairlyeasy,suitable
forbeginnerwith
someexperience
Fairtydifficult,suitable
forcompetentDIY
mechanic
Difficult,suitablefor
experiencedDIY
mechanic
Verydifficult,
suitableforexpertDIY
orprofessional

Lubricants, Fluids & Capacities
Lubricantsandfluids
Componentorsystem
1Engine
2Coolingsystem
3Manualtransmission
4Automatictransmission
5Brakingsystem
6Powersteering
Capacities
Engine oil
Excludingfilter:
1124ccand1360ccmodels3.2litres
1580ccand1905ccmodels4.5litres
1761ccmodels4.4litres
1998ccmodels4.7litres
Includingfilter:
1124ccand1360ccmodels3.5litres
1580ccand1905ccmodels5.0litres
1761ccmodels4.9litres
1998ccmodels5.4litres
Differencebetween"MIN"and"MAX"dipstickmarks(approximate):
Modelswithoutair conditioning1.5litres
Modelswithairconditioning1.3litres
Lubricanttype/specification
Multigradeengineoil,viscositySAE10W/40or15W/50,toAPISG/CD
Ethyleneglycol-basedantifreeze
TotaltransmissionBV75/80W
DexrontypeIIATF
TotalUniversalBrakeandClutchFluid
DexrontypeIIATF
Cooling system
1124ccand1360ccmodels:
Modelswithoutairconditioning6.5litres
Modelswithairconditioning7.5litres
1580ccand1905ccmodels:
Modelswithmanualtransmission7.5litres
Modelswithautomatictransmission8.0litres
1761ccmodels8.0litres
1998ccmodels8.5litres
Transmission
Manual2.0litres
Automatic:
Fromdry6.2litres
Drainandrefill2.4litres
Power-assisted steering 1.7litres
Fuel tank 56litres
1•2

Maintenance schedule
Maintenanceschedule
1Themaintenanceintervalsinthismanualareprovidedonthe
assumptionthatyou,notthedealer,willbecarryingoutthework.
Thesearetheminimummaintenanceintervalsrecommendedbythe
manufacturerforvehiclesdrivendaily.Ifyouwishtokeepyourvehicle
inpeakconditionatalltimes,youmaywishtoperformsomeofthese
proceduresmoreoften.Weencouragefrequentmaintenance,because
itenhancestheefficiency,performanceandresalevalueofyour
vehicle.Ifthevehicleisdrivenindustyareas,usedtotowa trailer,oris
drivenfrequentlyatslowspeeds(idlingintraffic)oronshortjourneys,
morefrequentmaintenanceintervalsarerecommended.
2Vehicleswhichcovera lowmileage(lessthan12000miles/20000km
peryear)shouldbeservicedfollowingthetimeintervalinsteadofthe
mileageinterval.Thisisnecessarybecausemanylubricantsandfluids,as
wellassomecomponents,deterioratewithtimeasmuchaswithuse.
3Whenthevehicleisnew,itshouldbeservicedbya factory-authorised
dealerservicedepartment,inordertopreservethefactorywarranty.
1•3
Every250miles(400km)orweekly
•Checktheengineoillevel(Section3)
•Checktheenginecoolantlevel(Section3)
•Checkthebrakefluidlevel(Section3)
•Checkthepowersteeringfluidlevel(Section3)
•Checkthescreenwasherfluidlevel(Section3)
•Checkthetyresforwearordamage(Section4)
•Checkandadjustthetyrepressures(Section4)
•Checktheconditionofthebattery(Section6)
•Checktheoperationofthehorn,alllights,andthewipers
andwashers(Sections5 and7)
Every6000miles(10000km)or
6months- whichevercomesfirst
•Renewtheengineoilandfilter*(Section8)
•Checkallcomponentsandhosesforfluidleaks(Section9)
•Checktheautomatictransmissionfluidlevel(Section10)
•Checkthesteeringandsuspensioncomponentsfor
conditionandsecurity(Section11)
•Checktheconditionofthedriveshaftgaiters(Section12)
•Checktheconditionofthefrontbrakepads,andrenewif
necessary(Section13)
The manufacturer specifies that the oil filter should be renewed at the
first 6000 mile service, and then at 12 000 miles intervals, with only the
oil being drained and renewed every 6000 miles. Owners may prefer to
carryoutfilterrenewalatthe6000-mileinterval,asaprecautionarytask.
Every12000miles(20000km)or
12months- whichevercomesfirst
In addition to all the items listed above, carry out the following:
•Checktheconditionoftheairconditioningsystem
refrigerant- whereapplicable(seeSection14)
•Checkand,ifnecessary,adjustthevalveclearances-
1124ccand1360ccmodels(Section15)*
•Renewthesparkplugs(Section16)
•Renewthefuelfilter- carburettormodels(Section17)
•Checktheignitionsystemandignitiontiming(Section18)
•Checktheidlespeedandmixtureadjustment(Section19)
•Checktheconditionoftheemissioncontrolsystemhoses
andcomponents(Section20)
•Checktheconditionoftheauxiliarydrivebelt,andrenewif
necessary(Section21)
•Checktheclutchmechanismadjustment(Section22)
•Lubricatetheclutchcontrolmechanism(Section22)
Every40000miles(60000km)or
2years- whichevercomesfirst
•Renewthecoolant(Section31)
•Renewthefuelfilter- fuelinjectionmodels(Section32)
Every24000miles(40000km)or
2years- whichevercomesfirst
In addition to all the items listed above, carry out the following:
•Checkthemanualtransmissionoillevel,andtop-upif
necessary(Section28)
•Renewtheautomatictransmissionfluid(Section29)
•Renewthebrakefluid(Section30)
Every18000miles(30000km)or
18months- whichevercomesfirst
In addition to all the items listed above, carry out the following:
•Renewtheairfilter(Section26)
•Lubricateallhingesandlocks(Section27)
Every72000miles(116000km)
•Renewthemanualtransmissionoil(Section34)
Every48000miles(80000km)
•Renewthetimingbelt(Section33)
Note:Onall 1998 ccmodels, Citroen have extended the timing belt
renewal interval to 72 000 miles. However, it is also stated that,
should the vehicle be subjected to intensive use, ie. mainly short
journeys or a lot of stop-start driving, the belt should be renewed
every 36 000 miles. The actual belt renewal interval is therefore very
much up to the individual owner. That being said, it is highly
recommended to err on the side of safety, and renew the belt at the
earlier interval. It is certainly not advisable to exceed the 48 000 mile
interval recommended for all other models, bearing in mind the
drastic consequences resulting from belt failure.
•Checktheconditionoftherearbrakeshoes,andrenewif
necessary- reardrumbrakemodels(Section23)
•Checktheconditionofthereardiscbrakepads,and
renewifnecessary- reardiscbrakemodels(Section24)
•Carryouta roadtest(Section25)
*Themanufacturer suggests this operation atthe first 12000 mile
service only. After that, checking and adjusting of the valve
clearances is not part of the recommended maintenance schedule.