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CITROEN
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XSARA 2002
CITROEN XSARA 2002 User Manual
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GENERAL
1
SAXO
- All T
ypes
IDENTIFICA
TION
OF VEHICLES
E1AP07CD
1
Engine legislation
type
2
RP
organisation
no.
3
Chassis stamp
4
Manufacturer
’s name plate
5
01/02/99
#
Label
:
- T
yre pressures.
- RP
organisation no.
- Paint
code.
6
Paint code.
7
Gearbox ident.
reference
GENERAL
3
5
Table of Contents
Presentation
2
Identification of Vehicles
4
Capacities
27
Draining Method
27
TOTAL Recommended Oils
32
S.A.E. Norm - Table for Selection of Engine Oil Grade
32
ACEA Norms
34
API Norms
34
Blended Oils for All Engines
36
Oils Specifically for Petrol and Dual-Fuel Petrol / LPG Engines
36
Oils Specifically for Diesel Engines
36
Engine Oil Consumption
47
Engine Specifications
48
Special Features - Tightening Torques
52
All Types
52
Cylinder Head
54
Identification of the Cylinder Head Gasket
58
Cylinder Head Bolts
59
Cylinder Head Tightening (M.dan)
64
Belt Tension/Seem Units Correspondence Table
65
Auxiliary Equipment Drive Belt 2002
66
Auxiliary Equipment Drive Belt
67
Alternator
70
Power-Assisted Steering
70
Plyers for Removing Plastic Peg
76
Without Power-Assisted Steering
77
Belt Tension Measuring Instrument
77
Without Power-Assisted Steering, with Air Conditioning
78
Power-Assisted Steering, Without Air Conditioning
79
Power-Assisted Steering, with Air Conditioning
81
Without Air Conditioning
83
No Re-Use of Belt
83
Checking the Valve Timing
89
Setting the Valve Timing
89
Refitting the Timing Belt
90
Pre-Tensioning the Timing Belt
90
Adjusting the Belt Fitting Tension
91
Checking the Belt Tension
91
Checking the Valve Timing.
101
Timing Belt Tension
103
Adjusting the Tension
103
Positioning of the Crankshaft
104
Repositioning the Flange
105
Checking the Setting
106
Setting the Valve Timing.
107
Pretensioning the Timing Belt
108
Tensioning the Timing Belt
109
Camshaft Hub Identification
121
Special Features of the Timing
121
Valve Clearance Settings
122
Possible Procedures
122
Checking the Oil Pressure
123
Engine Oil Pressure Switch
124
Oil Filters
126
Filling and Bleeding the Cooling Circuit
127
Idling - Anti-Pollution
128
Petrol Injection
131
Petrol Injection
132
Emission Standards
134
Anti-Pollution Technical Checks (France)
142
Fuel Supply Circuit
143
Electric Circuit
143
High Pressure Fuel Pump
143
Identification Markings
144
Safety Requirements
145
Cleanliness Requirements
146
Preliminary Operations
146
Checks : Low Pressure Fuel Supply Circuit
147
Checks: Air Supply Circuit
149
Manual Vacuum Pump
149
Vacuum Pump
149
Pressure Regulator Valve
149
Checks: Turbo Pressure
150
Checks: Exhaust Gases Recycling Circuit
152
Exhaust Gas Reycling (EGR) Electrovalve
152
Specifications of the Siemens Injection Pump
153
Specifications of the Delphi Diesel Injection Pump
156
Old Assembly
157
Checking and Setting the Delphi Mechanical Injection Pump
158
Impossible to Peg the Camshaft
159
Adjusting the Delphi Mechanical Injection Pump Controls
160
Adjusting the Fast Idle
160
Checking the Thermostatic Sensor
160
Adjusting the Accelerator Control
160
Adjusting the Anti-Stall (Residual Output)
161
Adjusting the Idle Speed
161
Checking the Engine Deceleration
161
Fitting Delphi Diesel Injectors
162
Fitting an Injector
162
Bosch Injection Pump Specifications
163
Checking and Setting the Bosch Mechanical Injection Pump
165
Setting the Injection Pump
165
Adjusting the Fast Idle Speed
166
Engine Cold
166
Engine Hot
166
Anti-Stall Adjustment
168
Checking the Engine Deceleration.e
168
Fitting Bosch Injectors
169
Sparking Plugs
171
Speedometer
172
Clutch Specifications
173
Clutch: Checks and Adjustments
175
Mechanically Operated Push-Action Clutch (Adjustable)
175
Push-Action Clutch with Automatic Adjustment (Non-Adjustable)
176
Refitting the Clutch Cable
177
Adjustment of Push and Pull Action Clutch with Automatic Compensation
178
Gearbox and Tyre Specifications
181
Gearbox - Ma/5
184
Gearbox Controls - Ma/5
185
Gearbox – Be4/5
186
Be4/5 Gearbox – Checks and Adjustments
190
Principles of Adjusting the Gear Controls
190
Be4/5 Gearbox - Checks and Adjustments
191
Adjusting the Gear Controls
191
Inside the Vehicle
191
Under the Bonnet
191
Automatic Gearbox - Mb3
192
Recommendations - Precautions (Mb3 Automatic Gearbox)
193
Precautions to be Taken
193
Recommendations – Precautions (Automatic Gearbox - Mb3)
194
Oil Quality
194
Oil Level (Prior Conditions)
194
Negative Pressure Circuit
195
Checks Using the Diagnostic Tool
195
Absence of Fault Codes
195
Fault Codes Present
195
Special Features: Automatic Gearbox - Mb3
196
Hydraulic Valve Block
196
Fitting the Casing
196
Mb3 Automatic Gearbox Controls
197
Mb3 Automatic Gearbox Controls - Checks and Adjustments
198
Selection Control
198
Adjusting the Selection Control
198
Automatic Gearbox - al 4
199
Recommendations - Precautions (Automatic Gearbox - al 4 )
200
Procedure before Repairs
201
Reading the Fault Codes
203
Presence of Anomalies
203
Updating the Gearbox ECU by Downloading
204
Updating the Value of the Oil Usage Counter
204
Using PROXIA
204
Using LEXIA or ELIT
204
Shift Lock
206
Unlocking the SHIFT LOCK (in Normal Operation)
206
Unlocking the SHIFT LOCK (in the Event of a Malfunction)
206
Driveshafts - Gearboxes
207
Geometry of the Axles at Reference Height
208
Axle Geometry
209
Normal Suspension
210
Raised Suspension
210
Axle Geometry
210
Front Axle
211
Suspension – Front Anti-Roll Bar
211
Rear Axle - Suspension
213
Steering Specifications
214
Manual Steering
214
Power Steering System
217
Front and Rear Measuring Points
219
Reference Heights
220
Setting the Reference Height
220
Values of the Front and Rear Suspensions, at Reference Height
221
Pivot Ball Joint
227
Rear Axle
231
Adjusting the Rear Dummy Damper
232
Manual Steering Specifications
233
Steering Wheel - Manual Steering
233
Power-Assisted Steering Specifications
236
Steering Wheel - Power-Assisted Steering
236
Power-Assisted Steering Assembly
239
Measurements at Reference Height
240
Evolution: Rear Hub Nut
245
Height of the Vehicle in Running Order
246
Measurements at the Front and Rear Axles, Vehicle in Running Order
247
Steering Column Specifications
248
Brake Specifications
252
Brakes
254
Adjusting the Brake Limiter
254
Removing the Caliper
255
Application from RPO 8973
256
Bleeding the Brakes
259
Checking the Brake Pressure
274
Adjusting the Compensator
275
Checking and Adjusting the Handbrake
276
Braking System Specifications
279
Checking and Adjusting the Load-Sensitive Brake Compensator
281
Brake Pressure Checking Tool
281
Weight of Fuel in the Fuel Tank
281
Determining the Rear Weight of the Vehicle
281
Weight of the Options on the Vehicle
282
Checking the Braking Pressure
286
Adjusting the Load-Sensitive Brake Compensator
287
Starter Motors
290
Alternators
295
Checking the Alternator Output
302
Checking the Voltage Regulator
302
BEHR Plate Evaporator
309
Pollen Filter
309
BEHR Condenser with Integral Reservoir (16 Ti)
310
Compressor Lubricant
313
Checking the Compressor Oil Level
313
Checking Temperatures
315
Two Thermometers
315
Checks on the Air Conditioning Circuit
320
Plan of Air Conditioning System
321
4
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CITROEN XSARA 2002 Specifications
General
Brand
CITROEN
Model
XSARA 2002
Category
Automobile
Language
English
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