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C4 2004
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65
ENGINES
SPECIAL FEA
TURES:
TIGHTENING
TORQ
UES
Timing
39
Camshaft pulley screw
4,5 ±
0,5
40
Guide roller scre
w
2 ±
0,2
41
T
ensioner roller scre
w
2,1 ±
0,4
Engine:
NFU
B1BP1GMP
UK-C4-page048-130-2004 15/11/04 9:23 Page 65
67
69
Table of Contents
Main Page
General
4
Identification of the Vehicle
4
Level
6
Level
7
Level
8
Manufacturer’s Plate
10
Structure
11
General Specification: Dimensions
12
Exterior Dimensions
13
Interior Dimensions and Volumes
13
Level
13
Weights
14
Operations to be Carried out after a Repair
16
Vehicle Towing: Precautions to be Taken
17
Lifting and Supporting the Vehicle
19
Capacities
22
Draining Method
22
Total Recommended Oils
25
Total Quartz
25
Total Activa
25
Total Activa
26
Total Quartz
26
Table of Contents
31
Oil Usage Table
32
Total Activa Diesel
34
Gearbox Oils
46
Power Steering Oils
47
Engine Coolant Fluid
47
Brake Fluid
48
Screen Wash Fluid
49
Grease
49
Engine Oil Consumption
50
Engine Specifications
51
Special Features: Tightening Torques
53
Suspensions for Engine/Gearbox Assembly
53
Engine: KFU
54
Cylinder Head
55
Cylinder Block
56
Lubrication
58
Timing
59
Accessories
60
Identification of Cylinder Head Gasket
61
Cylinder Head Tightening
62
Cylinder Head Bolts
62
Engine: NFU
63
Gearbox on RH/LH Side
63
Gearbox below the Engine
63
Engine: RFJ
72
RH Side
72
Torque Reaction Rod
72
Cylinder Head
83
Engine: RFN
84
Gearbox at Torque Reaction Rod
84
Engine: RFK
96
Engines: 9HX - 9HY - 9HZ
108
RH/LH Engine Support
108
Impact Absorber
108
Engine: 9HX
109
Injection Circuit
117
Engines: 9HY - 9HZ
121
Engine: RHR
136
Lower Engine Support
136
Auxiliary Equipment Drive Belt
149
Engines: KFU - NFU
150
Engines: RFJ
152
Checking and Setting the Valve Timing
158
Belt Tension Correspondance Table/Seem Units
159
Recommendations: Timing Belt
160
Checking the Valve Timing
161
Checking and Setting the Valve Timing
184
Adjusting the Timing Belt Tension
201
Adjusting the Camshaft Position Sensor
211
Checking the Engine Compression Rates
212
Tightening Torques - Exhaust Line
217
Exhaust Specifications
220
Cooling System Specifications
226
Engine: NFU Automatic Gearbox
230
Oil Filters
236
Oil Pressure Checks
237
Valve Clearance Settings
238
Filling and Bleeding the Cooling Circuit
239
Injection
241
Idling - Depollution
241
Petrol Injection
242
Emission Standards
243
Prohibited Operations: Bosch Hdi Direct Injection System
247
Safety Requirements: Hdi Direct Injection System
252
Cleanliness Requirements
253
Particle Filter Safety and Cleanliness Requirements
254
Special Features: Forced Regeneration of the Particle Filter
256
Additive System
257
Filling the Additive Reservoir
257
Checking the Additive Level
259
Checking the Additive Pump Pressure/Sealing of the Additive Injector
260
Air Supply Circuit Specification
262
Checking the Air Supply Circuit
264
Checks: Turbo Pressure
266
Low Pressure Fuel Supply Circuit
267
Turbo Pressure
270
Specifications of the Diesel System Injection Pump
272
Ignition
273
Sparking Plugs
273
Clutch Gearbox Driveshafts
274
Speedometer
274
Clutch Specifications
275
Clutch Specifications
277
Features
278
Gearbox and Tyre Specifications
279
MA/5 Gearbox
282
Tightening Torques: MA/5 Gearbox
285
MA/5 Gearbox Controls
288
Unlocking a Sleeve Stop
290
BE4/5 Gearbox
291
Tightening Torques: BE4/5 Gearbox
294
BE4/5 Gearbox Controls
297
ML6 Gearbox
300
Tightening Torques: ML6 Gearbox
303
ML6 Gearbox Controls
306
Adjustment of the Gear Selection Control Cable
307
AL4 Automatic Gearbox
309
Recommendations - Precautions
310
Draining - Filling
311
Checking the Oil Level
312
Procedure before a Repair
313
ECU: Initialisation
314
Tiqhtening Torques: Automatique AL4
315
Shift Lock
318
AL4 Automatic Gearbox Controls
319
Gearbox End
321
Driveshaft Specifications
322
Axles Suspension Steering
325
Wheel and Tyres
325
Identification of Inflation Pressures
335
Identification of the Wheel Bolts
336
Deflation Detection System
337
Conditions for Checking and Adjusting
338
Vehicle Heights at Reference Height
338
Axle Geometry
338
Axle Geometry
339
Front Axle
340
Rear Axle
341
General Specifications:front Axle
342
Tightening Torques: Front Axle
343
General Specifications: Rear Axle
345
Tightening Torques: Rear Axle
346
General Specifications: Suspension
347
Front Suspension Spring
348
Rear Suspension Spring
348
Tightening Torques: Suspension
349
Suspension Leg
349
Subframe
350
General Specifications: Power-Assisted Steering
352
Fixed Central Controls Steering Wheel
353
Steering Column
354
Steering Mechanism
355
Steering Assistance Circuit
356
Steering Mechanism with Integral Ram
357
Steering Assistance Electrovalve
358
Setting the Steering Rack MID-Point
359
Special Features: Steering
359
Checking the Power Steering Assistance Pressure
360
Preliminary Operations
361
Checking the Valve Sealing
362
Brakes
364
Brake Specifications
364
Braking System
366
ABS/ESP Hydraulic Block
367
Tightening Torques: Braking System
368
Front Brakes
368
Handbrake
369
Rear Brakes
370
Values for Checking and Adjusting the Braking System
371
Handbrake Adjustment
373
Bleeding and Filling the Braking System
374
Filling the Braking Circuit
376
Bleeding the Primary Braking Circuit
376
Bleeding the Braking Circuit with the Bleed Apparatus
377
Bleeding the Braking Circuit Without the Bleed Apparatus
378
Bleeding the Secondary Braking Circuit
378
Electricals
379
Starter Motors
379
Alternators
381
Without Air Conditioning
381
Pre-Heating and Starting System
386
Checking the Voltage Regulator
387
Checking the Alternator Output
387
Charging Circuit - Alternator with Mono-Function Regulator
387
Air Conditioning R 134A: Capacities
388
Special Features: Air Conditioning System
389
Compressor
389
Condenser
389
Tightening
390
Pollen Filter
391
Compressor Lubricant
392
Checking the Compressor Oil Level
392
Checking the Efficiency of the Air Conditioning System
394
Air Conditioning Evaporator Icing Safety
395
Air Conditioning Fluid Pressure Safety
395
Air Conditioning Compressor Safety
395
Management of the Air Conditioning Compressor
395
Safety as a Function of the Outside Temperature
396
Safety as a Function of Electric Diagnosis
396
Manual Air Conditioning
397
Automatic Bi-Zone Air Conditioning
398
Operating the Air Conditioning Function
399
Operating the Air Flow Function
399
Operating the LH/RH Cabin Temperature Function
399
Interpretation of the Measurements
401
Values for Over-Heating (SC)
401
Interpretation of the Diagnosis
403
Aircon Circuit Diagnosis Table
404
Air Conditioning System R 134.A
408
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