2005 Citroen Xsara Picasso 1.6 16V HDi Service & Repair Manual

CORRESPONDENCE TABLE FOR PETROL ENGINES XSARA XSARA PICASSO BERLINGO Engine families Engine types VERY IMPORTANT TU ET TU EW 1 3 5 7 10 JP J4 JP + JP4 J4 A J4 J4S 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 X X X X X X X X X X X X X X C4 CORRESPONDENCE TABLE FOR DIESEL ENGINES XSARA XSARA PICASSO BERLINGO Engine families Engine types DV DW 4 6 8 10 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 X X X X X X X X X X X X X X X C4

PRIVATE CARS C4-XSARA-XSARA PICASSO BERLINGO PRIVATE CARS CAR 000 000 Volume 2 2005 AC/QCAV/MTD Méthodes techniques documentation  «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

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.

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.

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

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

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

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 G 3-door saloon not convertible from van R 5-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

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

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 X Y A 5 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

2005 Citroen Xsara Picasso 1.6 16V HDi Service & Repair Manual

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