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The handbook is divided into nine groups representing the main functions: GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - ELECTRICAL - AIR CONDITIONING. 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. If the ECU has locked up: - Switch off the ignition. Antiscanning function. It is necessary to wait 1 minute after the battery has been disconnected in order to be able to start the vehicle. Tailgate. The anti-pinch function has to be re-initialised. Place the sun roof switch in the maximum tilt position. Keep the sun roof switch pressed until the sun roof ceases its movement. Release the sun roof switch within 5 seconds. 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 - Engine legislation type - Factory serial no. E1AP0AMD. Use of oil grade 10W 40. DIESEL vehicles. Only petrol versions are available. WARNING: To avoid problems with starting from cold, use this oil as allowed by the climatic conditions in the corntry concerned (see table). ESSENTIAL: To preserve engine performances, all engines fitted in CITROEN vehicles must be lubricated with high quality oils (synthan- dic or semi-synthandic).Pack GLYSANTIN G33 REVKOGEL 2000 2 Litres 9979 70. All countries Norm TOTAL FLUIDE LDS Orange. Concentrated: 250 ml 9980 33 9980 56 ZC 9875 953U 9980 06 1 Litre ZC 9875 784U All countries Fluid ready for use 5 Litres 9980 05 ZC 9885 077U ZC 9875 279U GREASE. II - An engine can be considered RUN-IN after: - 3,000 miles (5,000 km) for a PETROL engine. Remove Slacken: - Screws (6), (4) and (5). - Fully detension the belt by acting on the tensioner roller. - Remove the accessories drive belt. Refit. {-Variable.fc_1_url-

Raise and support the vehicle, front wheels hanging. Disconnect the battery. Vehicle without air conditioning. Completely detension the belt by acting on the tensioner roller. Remove the auxiliary equipment drive belt. Refitting. Refit the auxiliary equipment drive belt. Respect the following sequence: - Crankshaft pinion, aircon compressor pulley, alternator pulley guide roller and guide roller. WARNING: If the belt is to be reused, measure the tension before removal. Loosen: - the screw (1). - the nut (2). If this is not the case, replace the tensioner roller. Remove: - The front RH wheel. WARNING: Belt to be re-used, mark the direction of fitting of the belt. Refit the accessories drive belt.Remove the belt. Vehicle with air conditioning. WARNING: Mark the direction of fitting of the accessories drive belt, if it is to be re-used. IMPERATIVE: After any repair involving removal of the timing belt, systematically replace: The timing belt, The tensioner roller fixing nut. Engine: NFU. Place a jack under the engine, peg the engine. Remove: - The engine support (4) complete. - The timing casing (3). - The sparking plugs (eases engine rotation). Preliminary operation. Lift and support the vehicle, wheels hanging. Disconnect the battery.Remove the bottom engine support assembly (5), and the fixing screws (4). Slacken the nut (6). Setting the timing (continued).Engine: NFU. Slacken the tensioner roller.Adjusting the belt tension. Disconnect the battery. Remove: - The oil filter. - The engine cover. NOTE: If the setting is not correct, recommence the operation. Refit: - The oil filter. - The timing cover (1). Disconnect the battery. Support the engine. IMPERATIVE: Check that the tensioner roller turns freely (no tight spot). Refitting. The accessories drive pulley (7) is immobilised on the crankshaft by a half-moon keyway and by the tightening of washer (8) and screw (9). A: Pegging on the manual gearbox. B: Pegging on the automatic gearbox.

Turn the engine by means of the crankshaft pinion screw, to bring it to the pegging position.Raise and support the vehicle, front wheels hanging. Remove: - The front RH wheel. - The plastic pins (1). A: Pegging on the manual gearbox. Remove: - The screw (3) of the crankshaft pulley (2). Reposition the timing belt (7) on the crankshaft pulley. Rotate the crankshaft ten times (normal direction of rotation). IMPERATIVE: No pressure or outside force should be brought to bear on the timing belt.NOTE: Ensure that the camshaft pulleys rotate freely on the hubs. Clean the contact faces of the pulleys and hubs. NOTE: If it is not easy to peg the camshaft hubs, loosen the tensioner roller (7), and turn the camshafts using the screw (10). Remove: - the accessories drive belt. - the accessories drive pulley. - the lower timing cover (3). IMPERATIVE: The magnetic track should show no signs of damage and should not be approached by any other source of magnetism. Remove the upper timing cover (1). Rotate the engine by means of the crankshaft screw (2). NOTE: The pegging hole is located under the crankshaft bearing cap cover.Rotate the engine by means of the crankshaft pinion screw (2) (clock- wise), to bring it to the pegging position. Slacken the screw (9). Remove the timing belt (10). Refitting. NOTE: Screw (9) slackened. Position the timing belt (10) observing the following sequence: - Crankshaft pinion (4). - Guide roller (12). Remove: - The front RH wheel. Rotate the engine to engage it (normal direction of rotation). Move aside the harness (6). Remove: - The engine support (7). - The screw (8). Refit the screw (8). Rotate the crankshaft six times (clockwise). IMPERATIVE: Never rotate the engine backwards. WARNING: The magnetic track should show no signs of damage and should not be approached by any source of magnetism. If it is not correct, repeat the operation to tension the timing belt (see corresponding operation). Refitting. Refit screw (8).

Rotate the crankshaft to bring the camshaft towards its pegging point.Checking the setting. IMPERATIVE: Just prior to refitting, carry out the following tests. Check that: - the rollers and the coolant pump operate freely (no play and no tight spot). - there are no traces of oil (from the crankshaft and camshaft sealing rings). IMPERATIVE: Never rotate the engine backwards. WARNING: Do not touch or damage the track of the target of the engine speed sensor (14).Disconnect the positive and negative terminals of the battery. Move aside the harness (7). Remove: - The engine support (8). - The screw (10). Rotate the crankshaft six times (clockwise). IMPERATIVE: Never turn it backwards. WARNING: The magnetic track should not show any sign of damage and should not be approached by any other magnetic source. Remove the screw (10). Disconnect the positive and negative terminals of the battery. Remove: - The engine support (8). - The screw (10). Turn the crankshaft to bring the camshaft towards its pegging point. WARNING: Do not press or damage the track of the engine speed sensor target (13). Fit the timing belt on the crankshaft pinion. Position the belt on the guide roller, belt well tensioned. Refit: - The timing belt protector (13). - The engine speed sensor (14).Should this fail, repeat the operation to tension the timing belt. Refitting (continued). Couple: - The tube (2).NOTE: If necessary, you can slightly rotate the pinions (10) and (7) anti-clockwise in order to engage the belt.Remove: - Screws (3), (4) and (6). - Screw (7). Remove the timing belt (14). Checks. IMPERATIVE: Just before refitting, carry out the checks below. Check that: - The rollers (18) and (15) turn freely (without play and without any tight spot). Slacken: - The accessories drive pulley (8). - The screw (17) of the tensioner roller (18).Less than 2.5 m With catalytic converter Turbocharged engine. WARNING: Repairs must be carried out by specialised personnel informed of the safety requirements and of the precautions to be taken. Preliminary operations. IMPERATIVE: The technician should wear clean overalls. Before working on the injection system, it may be necessary to clean the apertures of the following sensitive components: (refer to corresponding procedures) - Fuel filter. Fuel supply circuit. - Required fuel: diesel. Electric circuit. WARNING: Diesel and ultrasonic cleaners are prohibited. Do not separate the following components from the diesel injector carrier (2): - Diesel injector (f) (no replacement parts). - Electromagnetic element (c) (no replacement parts). Fuel supply circuit. - Required fuel: diesel. Electric circuit. - Swapping injection ECUs between two vehicles will render it impossible to start either vehicle. - It is forbidden to supply a diesel injector with 12 volts. Diesel injectors. WARNING: Diesel and ultrasonic cleaners are prohibited. Do not separate the following components from the diesel injector carrier (3): - Diesel injector (e) (no replacement parts). Fuel supply circuit. - Required fuel: diesel. WARNING: Do not use other fuels. Electric circuit. Diesel injectors. WARNING: Diesel and ultrasonic cleaners are prohibited. Do not separate the following components from the diesel injector carrier (9): - Diesel injector (8) (no replacement parts). Impossible to peg the camshaft. Reset the valve timing (See page 245). Possible to peg the camshaft, but not the injection pump. Engine cold. - Ensure that the lever (2) is up against its stop to the right. - If not, adjust the tension of the cable (3) using the cable clamp (1). - Finish tensioning using the sleeve tensioner (4). Preparation. IMPERATIVE: Respect the following test conditions: - Engine at operating temperature. - Vehicle in running order. - Engine under full load. Connect the diagnostic tool to the vehicle’s diagnostic socket, carry out parameter measures. Mode of operation. IMPERATIVE: respect the following checking requirements: Engine at running temperature. IMPERATIVE: respect the following checking requirements: Engine at running temperature. Vehicle running at full load. Preparation. Apply a vacuum of approx. Perform the check with the aid of a diagnostic tool.ESSENTIAL: Given the very high pressures prevailing in the fuel high pressure circuit (1600 Bars), respect the following regulations. - It is forbidden to smoke in the immediate proximity of the high pressure circuit during a repair. - Avoid working close to flames or sparks. IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves that are resistant to hydrocarbons. The work area must be ventilated. In the event of any significant dispersion of additive: - Wear a breathing mask for filtering the particles. Diagnostic stations: LEXIA or PROXIA Imperative: Respect the safety and cleanliness requirements. Forced regeneration of the particle filter. IMPERATIVE: Respect the safety and cleanliness requirements specific to HDi engines. ESSENTIAL: Connect the vehicle to a gas extractor approved for this type of operation. IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves that are resistant to hydrocarbons. Description. The declutch control has a declutch fork mounted on a ball-joint. (1) The ball-joint is screwed into the clutch casing. Description. B2BP002C Unclip the cable from the gearbox by actioning B2BP001C. Place the pedal in the high position (contact at “a”). Attach the cable yoke on the hook of the clutch pedal. Loosen the nut (6) and the screw (7). Using a lever, raise the stop support (8) to its highest position. IMPERATIVE: Do not use automatic bleeding equipment (risk of the brake fluid emulsifying in the hydraulic circuit). Allow the clutch pedal to come back up to its high position. Fill the brake fluid reservoir to the maximum of its capacity. Conditions for towing. - The ECU with the ignition switched on. - The clutch and gearbox actuators with the ignition switched on. In this configuration, the gearbox actuator is blocked, gear engaged. Preliminary operations: - Battery voltage higher than 12.5 volts. Preliminary operation: - Disconnect the battery negative terminal. - Remove the air filter. - Use a 22 mm spanner.The piloted gearbox is a modern manual gearbox with technology that offers enhancements in every driving situation. The piloted manual gearbox has: - A gearbox ECU (supplier: SIEMENS). B2CP3HYC Length D Length C Length D Length C. WARNING: Do not use any tool to detach the ball-joints. The gear selection control and gear engagement control cables cannot be adjusted. B2CP3J4C Length A Length B Gear selection 907 mm 645 mm cable (5) Length D Length C Gear 965 mm 610 mm. The gear selection control and gear engagement control cables cannot be adjusted.WARNING: Cables should be adjusted each time the gearbox, gear controls or power unit are removed. The front of the vehicle must be raised in order to be towed. Do not disconnect: If the front of the vehicle cannot be raised: - The battery when the engine is running. Repairs on mechanical components. Modification of the oil usage counter value. Exchanging the gearbox ECU: Never place the gearbox on the ground without protection. In order to avoid breaking the input shaft ring, it is imperative that - Note down the gearbox counter value. Updating the gearbox ECU by downloading: - Follow the procedure using the diagnostic tool. The downloading operation enables the automatic gearbox to be updated, or adapted to an evolution of the engine ECU. Downloading. Using PROXIA. ECU downloading procedure: Access to reading and recording of the oil counter is via the menu: - Follow the diagnostic tool procedure. WARNING: This gearbox benefits from a special CITROEN semi-synthetic oil, which cannot be mixed with any other oil. The gearbox is lubricated for life. B2CP3ECD. Centre the hydraulic block, using screws (11) and (12). Pre-tighten (no strict order): 0,9 Slacken: All 7 screws. The gear selector is guided by the shape of the stepped gate and by a retaining spring which pulls it to the left hand side.The information is transmitted to the gearbox ECU. Two switches placed on the gear control gate permit the driver to choose one of the following three driving programmes: - Normal programme: Operates as the default programme (eco law, autoadaptive mode). XSARA PICASSO (2) Automatic adjustment (pull out the button to adjust the control, push it in to lock the adjustment of the control). New gear selection control Couple the ball-joint (3). Push in the component (a) without bending the cable. Check all the gear selection control positions. Re-used gear selection control. Release the component (a). Couple the ball-joint (3). Proceed in the opposite order to removal. IMPERATIVE: To adjust the gear selection control, place the gear selection lever in the park position. Press on the component (25) without bending the cable, then release. IMPERATIVE: Check that all the gears can engage. Proceed in the opposite order to removal. Lubricate the support (13). New gear selection control. Couple the ball-joint (6). WARNING: Do not deform the selection lever on the automatic gearbox. Check all the gear selection control positions. Prior conditions: - Vehicle in horizontal position. - Check gearbox is not in back-up mode. - Remove the oil filler cap (2). Refit the oil level plug (3). Stop the engine. Vehicle at reference height. Steering rack locked at mid point (see corresponding operation).All types (except CRD) HFX - KFV - 8HX HFX - KFV - 8HX Castor Camber. Only one ECU version, whatever the engine-type. The steering assistance is rpovided by the assistance motor (12), The electric power steering ECU is linked to the following connectors: controlled by the ECU. Raise and support the vehicle on a two-column lift. Remove, on the RH side of the steering rack: - Clip (1). - Clip (2). Release the steering rack rpotection gaiter. Vehicle at reference height. Steering rack locked at mid point (see corresponding operation).All types (except CRD) Raised suspension - Sports Castor Camber Pivot angle. Vehicle at reference height. Steering rack locked at mid point (see corresponding operation).All types Castor Camber Pivot angle. Electric power-assisted steering ECU. Only one ECU version, whatever the engine-type. The steering assistance is rpovided by the assistance motor (12), controlled The electric power steering ECU is linked to the following connectors: by the ECU. Raise and support the vehicle on a two-column lift. Remove, on the RH side of the steering rack: - Clip (1). Its value must not exceed 12'. B3CP04UC. ESSENTIAL: Swapping of old and new components is forbidden.Entreprise Estates All types Grey Green 19,3 Orange 3- and 5-door TT Violet 1.6i 16V - 2.i 16V. NOTE: The RH torsion bar can be identified by 1 NOTE: There are two suppliers for the silentblocks: paint line. Tightening torques (m.daN). Tightening torques (m.daN). In case of doubt, check the settings at reference height Conditions for checking and adjusting: Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point (see corresponding operation). Components Supplier Part no. Observations ABS MK 70 Mounted on the front LH chassis Hydraulic block 96 514 120 80 member. ESP -ABS MK.60 4 adjustment channels. 96 490 288 80 ABS MK.70 ESP -ABS 26-way connector. Lift and chock the vehicle.A: Drum brakes. B: Disc brakes. (10) Nut for adjusting cable tensions. Remove: - The rear wheels. - The drums (according to version). Release the handbrake.Bleeding, refilling. Draining. Drain the brake fluid reservoir (1) to the maximum (if necessary, use a clean syringe). Disconnect the connector (4). Uncouple the pipe (2). Unscrew the shaft (3).