Citroen ZXService and Repair ManualMark CoombsModels coveredAll Citroen ZX Hatchback models with petrol engines,including special/limited editions1360 cc, 1580 cc, 1761 cc, 1905 cc and 1998 cc (inc. 16-valve)Covers most features of Estate models
A book in the Haynes Service and Repair Manual Series
All rights reserved. No part of this book may be reproduced or transmittedin any form or by any means, electronic or mechanical, includingphotocopying, recording or by any information storage or retrieval system,without permission in writing from the copyright holder.
ISBN 1 85960 149 9
British Library Cataloguing in Publication DataA catalogue record for this book is available from the British Library.
Printed by J H Haynes & Co Ltd, Sparkford, Nr Yeovil,Somerset BA22 7JJ, England
Haynes PublishingSparkford, Nr Yeovil, Somerset BA22 7JJ, England
Haynes North America, Inc861 Lawrence Drive, Newbury Park, California 91320, USA
Editions Haynes S.A.147/149, rue Saint Honore, 75001 PARIS, France
Haynes Publishing Nordiska ABBox 1504, 751 45 UPPSALA, Sweden
THEBOOK
RageBad2004,2005
ContentsLIVING WITH YOUR CITROEN ZXIntroduction
Safety First!
General dimensions and weights
MOT Test ChecksChecks carried out from the driver's seat
Checks carried out with the vehicle on the ground
Checks carried out with the vehicle raised
Checks carried out on your vehicle's exhaust emission system
Page 0•4
Page 0•5
Page 0•6
Page 0•7
Page 0•8
Page 0•9
Page 0•10
Roadside RepairsBuying spare parts and vehicle identification numbers Page 0•11
Jacking, towing and wheel changing
Booster battery (jump) starting
Identifying leaks
Radio/cassette unit anti-theft system - precaution
Conversion factors
Routine MaintenanceRoutine maintenance and servicing
Lubricants, fluids and capacities
Maintenance schedule
Weekly checks
Every 6000 miles or 6 months
Every 12 000 miles or 12 months
Every 18 000 miles or 18 months
Every 24 000 miles or 2 years
Every 40 000 miles or 2 years
Every 48 000 miles
Every 72 000 miles
Page 0•12
Page 0•14
Page 0•15
Page 0•15
Page 0•16
Page 1•1
Page 1 •2
Page 1 •3
Page 1 •8
Page 1•11
Page 1•14
Page 1•20
Page 1•22
Page 1•23
Page 1•26
Page 1•26
ContentsREPAIRS & OVERHAULEngine and Associated SystemsTU series engine in-car repair procedures
XU series engine in-car repair procedures
Engine removal and general engine overhaul procedures
Cooling, heating and ventilation systems
Fuel and exhaust systems - carburettor models
Fuel and exhaust systems - single-point fuel injection models
Fuel and exhaust systems - multi-point fuel injection models
Emission control systems
Engine electrical systems
TransmissionClutch
Manual transmission
Automatic transmission
Driveshafts
BrakesBraking system
SuspensionSuspension and steering
Body EquipmentBodywork and fittings
ElectricalBody electrical systems
Wiring Diagrams
REFERENCETools and Working Facilities
General Repair Procedures
Fault Finding
Glossary of Technical Terms
Index
Page 2A•1
Page 2B•1
Page 2C•1
Page 3•1
Page 4A•1
Page 4B•1
Page 4C•1
Page 4D•1
Page 5•1
Page 6•1
Page 7A•1
Page 7B•1
Page 8•1
Page 9•1
Page 10•1
Page 11•1
Page 12•1
Page 12•19
Page REF• 1
Page REF• 4
Page REF• 5
Page REF•12
Page REF•16
0•4 Introduction
Introduction to the Citroen ZXThe Citroen ZX range was introduced to the
UK in June 1991. Originally, the ZX wasavailable with a choice of 1.1 litre (1124 cc),1.4 litre (1360 cc), 1.6 litre (1580 cc) or 1.9 litre(1905 cc) engines. Not all engine sizes,however, were available in all markets (the1.1 litre version was not available in the UK).
At first, only five-door Hatchback models
were available. All models have a five-speedmanual transmission as standard; a four-speed automatic transmission was offered asan option on 1.6 and 1.9 litre models.
All engines are derived from the well-proven TU series (1124 cc and 1360 cc) andXU series (1580 cc and 1905 cc models)engines, which have appeared in many
Citroen ZX 1.4 Reflex Plus 5-door
Citroen ZX 2.0 16-valve
Citroen and Peugeot vehicles. The enginesare of four-cylinder overhead camshaftdesign, mounted transversely and inclined tothe rear, with the transmission mounted onthe left-hand side.
In late 1992, a three-door Hatchbackvariant was introduced. At the same time,three new "sports" models were alsointroduced, all of which were equipped withnew engines. These new models were the1.8 litre (1761 cc) Furio, the 2.0 litre (1998 cc8-valve) Volcane, and the 2.0 litre (1998 cc16-valve) 16-valve model. All of these newmodels are available in three-door form only.All three of the new engines are again derivedfrom the XU series engine.
On all models, fully-independent frontsuspension is fitted, with the componentsattached to a subframe assembly. The rearsuspension is semi-independent, with torsionbars and trailing arms.
All models in the range arecomprehensively-equipped, and anti-lockbraking (ABS) and air conditioning systemsare available as options on certain models(ABS is standard on the 2.0 litre 16-valve).
Provided that regular servicing is carriedout in accordance with the manufacturer'srecommendations, the Citroen ZX shouldprove reliable and very economical. Theengine compartment is well-designed, andmost of the items requiring frequent attentionare easily accessible.
AcknowledgementsThanks are due to Champion Spark Plug,
who supplied the illustrations showing sparkplug conditions. Certain other illustrations arethe copyright of Citroen Cars Ltd, and areused with their permission. Thanks are alsodue to Sykes-Pickavant Limited, whoprovided some of the workshop tools, and toall those people at Sparkford who helped inthe production of this manual.
Project vehiclesVarious project vehicles were used in the
preparation of this manual, and appear inmany of the photographic sequences. Theseinclude a 1360 cc, 1580 cc, 1761 cc, 1905 cc,1998 cc 8-valve and a 1998 cc 16-valve
Safety First! 0•5
Working on your car can be dangerous.This page shows just some of the potentialrisks and hazards, with the aim of creating asafety-conscious attitude.
General hazardsScalding• Don't remove the radiator or expansiontank cap while the engine is hot.• Engine oil, automatic transmission fluid orpower steering fluid may also be dangerouslyhot if the engine has recently been running.
Burning• Beware of burns from the exhaust systemand from any part of the engine. Brake discsand drums can also be extremely hotimmediately after use.
Crushing• When working under or near araised vehicle, alwayssupplement thejack with axlestands, or usedrive-on ramps.Never ventureunder a carwhich is onlysupported bya jack.• Take care if loosening or tightening high-torque nuts when the vehicle is on stands.Initial loosening and final tightening should bedone with the wheels on the ground.
Fire• Fuel is highly flammable; fuel vapour isexplosive.• Don't let fuel spill onto a hot engine.• Do not smoke or allow naked lights(including pilot lights) anywhere near a vehiclebeing worked on. Also beware of creatingsparks(electrically or by use of tools).• Fuel vapour is heavier than air, so don'twork on the fuel system with the vehicle overan inspection pit.• Another cause of fire is an electricaloverload or short-circuit. Take care whenrepairing or modifying the vehicle wiring.• Keep a fire extinguisher handy, of a typesuitable for use on fuel and electrical fires.
Electric shock• Ignition HTvoltage can bedangerous,especially topeople withheart problemsor a pacemaker.Don't work on ornear the ignitionsystem with theengine running or theignition switched on.
• Mains voltage is also dangerous. Make surethat any mains-operated equipment iscorrectly earthed. Mains power points shouldbe protected by a residual current device(RCD) circuit breaker.
Fume or gas intoxication• Exhaust fumes arepoisonous; they oftencontain carbonmonoxide, which israpidly fatal if inhaled.Never run theengine in aconfined spacesuch as a garagewith the doors shut.• Fuel vapour is alsopoisonous, as are the vapours from somecleaning solvents and paint thinners.
Poisonous or irritant substances• Avoid skin contact with battery acid andwith any fuel, fluid or lubricant, especiallyantifreeze, brake hydraulic fluid and Dieselfuel. Don't syphon them by mouth. If such asubstance is swallowed or gets into the eyes,seek medical advice.• Prolonged contact with used engine oil cancause skin cancer. Wear gloves or use abarrier cream if necessary. Change out of oil-soaked clothes and do not keep oily rags inyour pocket.• Air conditioning refrigerant forms apoisonous gas if exposed to a naked flame(including a cigarette). It can also cause skinburns on contact.
Asbestos• Asbestos dust can cause cancer if inhaledor swallowed. Asbestos may be found ingaskets and in brake and clutch linings.When dealing with such components it issafest to assume that they contain asbestos.
Special hazardsHydrofluoric acid• This extremely corrosive acid is formedwhen certain types of synthetic rubber, foundin some O-rings, oil seals, fuel hoses etc, areexposed to temperatures above 400°C. Therubber changes into a charred or stickysubstance containing the acid. Once formed,the acid remains dangerous for years. If itgets onto the skin, it may be necessary toamputate the limb concerned.• When dealing with a vehicle which hassuffered a fire, or with components salvagedfrom such a vehicle, wear protective glovesand discard them after use.
The battery• Batteries contain sulphuric acid, whichattacks clothing, eyes and skin. Take carewhen topping-up or carrying the battery.• The hydrogen gas given off by the battery ishighly explosive. Never cause a spark orallow a naked light nearby. Be careful whenconnecting and disconnecting batterychargers or jump leads.
Air bags• Air bags can cause injury if they go offaccidentally. Take care when removing thesteering wheel and/or facia. Special storageinstructions may apply.
Diesel injection equipment• Diesel injection pumps supply fuel at veryhigh pressure. Take care when working onthe fuel injectors and fuel pipes.
Warning: Never expose thehands, face or any other part ofthe body to injector spray; the
fuel can penetrate the skin with potentiallyfatal results.
Remember...DO• Do use eye protection when using powertools, and when working under the vehicle
• Do wear gloves or use barrier cream toprotect your hands when necessary.
• Do get someone to check periodically thatall is well when working alone on thevehicle,
• Do keep loose clothing and long hair wellout of the way of moving mechanical parts.
• Do remove rings, wristwatch etc. beforeworking on the vehicle - especially theelectrical system.
• Do ensure that any lifting or lackingequipment has a safe working load ratingadequate for the |ob.
DON'T• Don't attempt to lift a heavy componentwhich may be beyond your capability - getassistance.
• Don't rush to finish a job, or takeunverified short cuts.
• Don't use ill-fitting tools which may slipand cause injury.
• Don't leave tools or parts lying aroundwhere someone can trip over them. Mop upoil and fuel spills at once.
• Don't allow children or pets to play in ornear a vehicle being worked on.
0•6 General Dimensions & Weights
DimensionsOverall length:
Volcane, Funo and 16-valve models 4090 mmAll other models 4070 mm
Overall width (excluding mirrors):Volcane and 16-valve models 1710 mmFuno models 1690 mmAll other models 1700 mm
Overall heightVolcane, Funo and 16-valve models 1400 mmAll other models 1390 mm
Wheelbase - all models 2540 mmFront and rear track:
Reflex and Avantage models 1410 mmAll other models 1420 mm
Turning circle:Models with manual steering 10.5 mModels with power-assisted steering 10.7 m
WeightsKerb weights (approximate):
1124 cc and 1360 cc models:Three-door models 935 kgFive-door models 945 kg
1580 cc models:Three-door models 995 kgFive-door models 1015 kg
1761 cc models:Three-door models 1008 kgFive-door models 1024 kg
1905 cc models:Three-door models 1055 kgFive-door models 1085 kg
1998 cc 8-valve models:Three-door models 1060 kgFive-door models 1091 kg
1998 cc 16-valve models 1150 kgMaximum gross vehicle weight:
1124 cc and 1360 cc models 1490 kg1580 cc models 1540 kg1761 cc models 1550 kg1905 cc models 1570 kg1998 cc 8-valve models 1600 kg1998 cc 16-valve models 1630 kg
Maximum roof rack load 75 kgMaximum towing nose weight 70 kgMaximum towing weight:
Braked trailer:1905 cc and 1998 cc models 1100 kgAll other models 1000 kg
Unbraked trailer:1124 cc and 1360 cc models 470 kg1580 cc models 490 kg1761 cc models 500 kg1905 cc models 510 kg1998 cc models 530 kg
MOT Test Checks 0•7
This is a guide to getting your vehicle through the MOT test.Obviously it will not be possible to examine the vehicle to the samestandard as the professional MOT tester. However, working throughthe following checks will enable you to identify any problem areasbefore submitting the vehicle for the test.
Where a testable component is in borderline condition, the testerhas discretion in deciding whether to pass or fail it. The basis of suchdiscretion is whether the tester would be happy for a close relative orfriend to use the vehicle with the component in that condition. If thevehicle presented is clean and evidently well cared for, the tester maybe more inclined to pass a borderline component than if the vehicle isscruffy and apparently neglected.
It has only been possible to summarise the test requirements here,based on the regulations in force at the time of printing. Test standardsare becoming increasingly stringent, although there are someexemptions for older vehicles. For full details obtain a copy of the Haynespublication Pass the MOT! (available from stockists of Haynes manuals).
An assistant will be needed to help carry out some of these checks.
The checks have been sub-divided into four categories, as follows:
Handbrake• Test the operation of the handbrake.Excessive travel (too many clicks) indicatesincorrect brake or cable adjustment.• Check that the handbrake cannot bereleased by tapping the lever sideways. Checkthe security of the lever mountings.
Footbrake
• Depress the brake pedal and check that itdoes not creep down to the floor, indicating amaster cylinder fault. Release the pedal, waita few seconds, then depress it again. If thepedal travels nearly to the floor before firmresistance is felt, brake adjustment or repair isnecessary. If the pedal feels spongy, there isair in the hydraulic system which must beremoved by bleeding.
• Check that the brake pedal is secure and ingood condition. Check also for signs of fluidleaks on the pedal, floor or carpets, whichwould indicate failed seals in the brake mastercylinder.• Check the se rvo unit (when applicable) byoperating the brake pedal several times, thenkeeping the pedal depressed and starting theengine. As the engine starts, the pedal willmove down slightly. If not, the vacuum hose orthe servo itself may be faulty.
Steering wheel and columnExamine the steering wheel for fractures or
looseness of the hub, spokes or rim.• Move the steering wheel from side to sideand then up and down. Check that thesteering wheel is not loose on the column,indicating wear OK a loose retaining nut.Continue moving the steering wheel as before,but also turn it slightly from left to right.• Check that the steering wheel is not looseon the column, and that there is no abnormal
movement of the steering wheel, indicatingwear in the column support bearings orcouplings.
Windscreen and mirrors• The windscreen must be free of cracks orother significant damage within the driver'sfield of view. (Small stone chips areacceptable.) Rear view mirrors must besecure, intact, and capable of being adjusted.
Checks carried outFROM THE DRIVER'SSEAT
Checks carried outWITH THE VEHICLEON THE GROUND
Checks carried outWITH THE VEHICLERAISED AND THEWHEELS FREE TOTURN
Checks carried out onYOUR VEHICLE'SEXHAUST EMISSIONSYSTEM
Checks carried outFROM THE DRIVER'S SEAT
1 2 3 4
1
0•8 MOT Test ChecksElectrical equipment• Switch on the ignition and check theoperation of the horn.• Check the windscreen washers and wipers,examining the wiper blades; renew damagedor perished blades. Also check the operationof the stop-lights.
• Inspect both front brake flexible hoses forcracks or deterioration of the rubber. Turn thesteering from lock to lock, and ensure that thehoses do not contact the wheel, tyre, or anypart of the steering or suspension mechanism.With the brake pedal firmly depressed, checkthe hoses for bulges or leaks under pressure.
Seat belts and seatsNote: The following checks are applicable toall seat belts, front and rear.
• Examine the webbing of all the belts(including rear belts if fitted) for cuts, seriousfraying or deterioration. Fasten and unfasteneach belt to check the buckles. If applicable,check the retracting mechanism. Check thesecurity of all seat belt mountings accessiblefrom inside the vehicle.• The front seats themselves must besecurely attached and the backrests mustlock in the upright position.
Doors• Both front doors must be able to be openedand closed from outside and inside, and mustlatch securely when closed.
Vehicle identification• Number plates must be in good condition,secure and legible, with letters and numberscorrectly spaced - spacing at (A) should betwice that at (B).
• Check the operation of the sidelights andnumber plate lights. The lenses and reflectorsmust be secure, clean and undamaged.• Check the operation and alignment of theheadlights. The headlight reflectors must notbe tarnished and the lenses must beundamaged.• Switch on the ignition and check theoperation of the direction indicators (includingthe instrument panel tell-tale) and the hazardwarning lights. Operation of the sidelights andstop-lights must not affect the indicators - if itdoes, the cause is usually a bad earth at therear light cluster.• Check the operation of the rear foglight(s),including the warning light on the instrumentpanel or in the switch.
Footbrake• Examine the master cylinder, brake pipesand servo unit for leaks, loose mountings,corrosion or other damage.
Steering and suspension• Have your assistant turn the steering wheelfrom side to side slightly, up to the point wherethe steering gear just begins to transmit thismovement to the roadwheels. Check forexcessive free play between the steeringwheel and the steering gear, indicating wear orinsecurity of the steering column joints, thecolumn-to-steering gear coupling, or thesteering gear itself.• Have your assistant turn the steering wheelmore vigorously in each direction, so that theroadwheels just begin to turn. As this is done,examine all the steering joints, linkages,fittings and attachments. Renew anycomponent that shows signs of wear ordamage. On vehicles with power steering,check the security and condition of thesteering pump, drivebelt and hoses.• Check that the vehicle is standing level,and at approximately the correct ride height.
Shock absorbers• Depress each corner of the vehicle in turn,then release it. The vehicle should rise andthen settle in its normal position. If the vehiclecontinues to rise and fall, the shock absorberis defective. A shock absorber which hasseized will also cause the vehicle to fail.
• The VIN plate (A) and homologation plate(B) must be legible.
• The fluid reservoir must be secure and thefluid level must be between the upper (A) andlower (B) markings.
Checks carried outWITH THE VEHICLE ON THEGROUND
2
MOT Test Checks 0•9
Exhaust system• Start the engine. With your assistantholding a rag over the tailpipe, check theentire system for leaks. Repair or renewleaking sections.
Jack up the front and rear of the vehicle,and securely support it on axle stands.Position the stands clear of the suspensionassemblies. Ensure that the wheels areclear of the ground and that the steeringcan be turned from lock to lock.
Steering mechanism• Have your assistant turn the steering fromlock to lock. Check that the steering turnssmoothly, and that no part of the steeringmechanism, including a wheel or tyre, foulsany brake hose or pipe or any part of the bodystructure.• Examine the steering rack rubber gaitersfor damage or insecurity of the retaining clips.If power steering is fitted, check for signs ofdamage or leakage of the fluid hoses, pipes orconnections. Also check for excessivestiffness or binding of the steering, a missingsplit pin or locking device, or severe corrosionof the body structure within 30 cm of anysteering component attachment point.
Front and rear suspension andwheel bearings• Starting at the front right-hand side, graspthe roadwheel at the 3 o'clock and 9 o'clockpositions and shake it vigorously. Check forfree play or insecurity at the wheel bearings,suspension balljoints, or suspension mount-ings, pivots and attachments.• Now grasp the wheel at the 12 o'clock and6 o'clock positions and repeat the previousinspection. Spin the wheel, and check forroughness or tightness of the front wheelbearing.
• If excess free play is suspected at acomponent pivot point, this can be confirmedby using a large screwdriver or similar tooland levering between the mounting and thecomponent attachment. This will confirmwhether the wear is in the pivot bush, itsretaining bolt, or in the mounting itself (thebolt holes can often become elongated).
• Carry out all the above checks at the otherfront wheel, and then at both rear wheels.
Springs and shock absorbers• Examine the suspension struts (whenapplicable) for serious fluid leakage,corrosion, or damage to the casing. Alsocheck the security of the mounting points.• If coil springs are fitted, check that thespring ends locate in their seats, and that thespring is not corroded, cracked or broken.• If leaf springs are fitted, check that allleaves are intact, that the axle is securelyattached to each spring, and that there is nodeterioration of the spring eye mountings,bushes, and shackles.
• The same general checks apply to vehiclesfitted with other suspension types, such astorsion bars, hydraulic displacer units, etc.Ensure that all mountings and attachmentsare secure, that there are no signs ofexcessive wear, corrosion or damage, and (onhydraulic types) that there are no fluid leaks ordamaged pipes.
• Inspect the shock absorbers for signs ofserious fluid leakage. Check for wear of themounting bushes or attachments, or damageto the body of the unit.
Driveshafts(fwd vehicles only)• Rotate each front wheel in turn and inspectthe constant velocity joint gaiters for splits ordamage. Also check that each driveshaft isstraight and undamaged.
Braking system• If possible without dismantling, checkbrake pad wear and disc condition. Ensurethat the friction lining material has not wornexcessively, (A) and that the discs are notfractured, pitted, scored or badly worn (B).
• Examine all the rigid brake pipesunderneath the vehicle, and the flexiblehose(s) at the rear. Look for corrosion, chafingor insecurity of the pipes, and for signs ofbulging under pressure, chafing, splits ordeterioration of the flexible hoses.• Look for signs of fluid leaks at the brakecalipers or on the brake backplates. Repair orrenew leaking components.• Slowly spin each wheel, while yourassistant depresses and releases thefootbrake. Ensure that each brake is operatingand does not bind when the pedal is released.
Checks carried outWITH THE VEHICLE RAISEDAND THE WHEELS FREE TOTURN
3
MOT Test Checks
• Examine the handbrake mechanism,checking for frayed or broken cables,excessive corrosion, or wear or insecurity ofthe linkage. Check that the mechanism workson each relevant wheel, and releases fully,without binding.• It is not possible to test brake efficiencywithout special equipment, but a road testcan be carried out later to check that thevehicle pulls up in a straight line.
Fuel and exhaust systems• Inspect the fuel tank (including the fillercap), fuel pipes, hoses and unions. Allcomponents must be secure and free fromleaks.• Examine the exhaust system over its entirelength, checking for any damaged, broken ormissing mountings, security of the retainingclamps and rust or corrosion.
Wheels and tyres• Examine the sidewalls and tread area ofeach tyre in turn. Check for cuts, tears,lumps, bulges, separation of the tread, andexposure of the ply or cord due to wear ordamage. Check that the tyre bead is correctlyseated on the wheel rim, that the valve is
sound and properly seated, and that thewheel is not distorted or damaged.• Check that the tyres are of the correct sizefor the vehicle, that they are of the same sizeand type on each axle, and that the pressuresare correct.• Check the tyre tread depth. The legalminimum at the time of writing is 1.6 mm overat least three-quarters of the tread width.Abnormal tread wear may indicate incorrectfront wheel alignment.
Body corrosionCheck the condition of the entire vehicle
structure for signs of corrosion in load-bearing areas. (These include chassis boxsections, side sills, cross-members, pillars,and all suspension, steering, braking systemand seat belt mountings and anchorages.)Any corrosion which has seriously reducedthe thickness of a load-bearing area is likelyto cause the vehicle to fail. In this caseprofessional repairs are likely to be needed.• Damage or corrosion which causes sharpor otherwise dangerous edges to be exposedwill also cause the vehicle to fail.
Petrol models• Have the engine at normal operatingtemperature, and make sure that it is in goodtune (ignition system in good order, air filterelement clean, etc).• Before any measurements are carried out,raise the engine speed to around 2500 rpm,and hold it at this speed for 20 seconds.Allow the engine speed to return to idle, and
watch for smoke emissions from the exhausttailpipe. If the idle speed is obviously muchtoo high, or if dense blue or clearly-visibleblack smoke comes from the tailpipe for morethan 5 seconds, the vehicle will fail. As a ruleof thumb, blue smoke signifies oil being burnt(engine wear) while black smoke signifiesunburnt fuel (dirty air cleaner element, orother carburettor or fuel system fault).• An exhaust gas analyser capable ofmeasuring carbon monoxide (CO) andhydrocarbons (HC) is now needed. If such aninstrument cannot be hired or borrowed, alocal garage may agree to perform the checkfor a small fee.
CO emissions (mixture)• At the time or writing, the maximum COlevel at idle is 3.5% for vehicles first usedafter August 1986 and 4.5% for oldervehicles. From January 1996 a much tighterlimit (around 0.5%) applies to catalyst-equipped vehicles first used from August1992. If the CO level cannot be reduced farenough to pass the test (and the fuel andignition systems are otherwise in goodcondition) then the carburettor is badly worn,or there is some problem in the fuel injectionsystem or catalytic converter (as applicable).
HC emissions• With the CO emissions within limits, HCemissions must be no more than 1200 ppm(parts per million). If the vehicle fails this testat idle, it can be re-tested at around 2000rpm; if the HC level is then 1200 ppm or less,this counts as a pass.• Excessive HC emissions can be caused byoil being burnt, but they are more likely to bedue to unburnt fuel.
Diesel models• The only emission test applicable to Dieselengines is the measuring of exhaust smokedensity. The test involves accelerating theengine several times to its maximumunloaded speed.
Note: It is of the utmost importance that theengine timing belt is in good condition beforethe test is carried out.
• Excessive smoke can be caused by a dirtyair cleaner element. Otherwise, professionaladvice may be needed to find the cause.
0•10
Checks carried out onYOUR VEHICLE'S EXHAUSTEMISSION SYSTEM
4
Roadside Repairs
Buying spare parts and vehicle identification numbers
Buying spare partsSpare parts are available from many
sources; for example, Citroen garages, othergarages and accessory shops, and motorfactors. Our advice regarding spare partsources is as follows.
Officially-appointed Citroen garages - Thisis the best source for parts which are peculiarto your car, and are not generally available (egcomplete cylinder heads, gearbox internalcomponents, badges, interior trim etc). It isalso the only place at which you should buyparts if the vehicle is still under warranty. Tobe sure of obtaining the correct parts, it willbe necessary to give the storeman your car'svehicle identification number. If possible, takethe old parts along for positive identification.Many parts are available under a factoryexchange scheme - any parts returned shouldalways be clean. It obviously makes goodsense to go straight to the specialists on yourcar for this type of part, as they are bestequipped to supply you.
Other garages and accessory shops -These are often very good places to buymaterials and components needed for themaintenance of your car (eg oil filters, sparkplugs, bulbs, drivebelts, oils and greases,touch-up paint, filler paste, etc). They also sellgeneral accessories, usually have convenientopening hours, charge lower prices, and canoften be found not far from home.
Motor factors - Good factors will stock allthe more important components which wearout comparatively quickly (eg exhaustsystems, brake pads, seals and hydraulicparts, clutch components, bearing shells,pistons, valves etc). Motor factors will oftenprovide new or reconditioned components ona part-exchange basis - this can save aconsiderable amount of money.
Vehicle identification numbersModifications are a continuing and
unpublicised process in vehicle manufacture,quite apart from major model changes. Spareparts manuals and lists are compiled upon anumerical basis, the individual vehicleidentification numbers being essential tocorrect identification of the componentconcerned.
When ordering spare parts, always give asmuch information as possible. Quote the carmodel, year of manufacture, body and enginenumbers as appropriate (see illustration).
The vehicle identification plate is stampedon a plate located under the bonnet on thelower right-hand wheel arch (see illustration).
The chassis number is stamped on thebody panel under the bonnet on the right-hand side of the bulkhead on modelsproduced up to 1993, or on the right-handwheel arch on models produced from 1993(see illustration).
The paint code number is located on thebody panel under the bonnet on the left-handupper wheel arch.
The engine number is stamped on a plateriveted to the front of the cylinder block (referto Chapter 2A or 2B for further information).
Vehicle identification number locations
0•11
0000001
UP TO 1993
FROM 1993
FROM 1993
UP TO 1993
BE 3
20CJ840000001 A
P.T.C
0•12 Roadside Repairs
Jacking, towing and wheel changingJacking
The jack supplied with the vehicle tool kitshould only be used for changing theroadwheels - see "Wheel changing" later in thisSection. When carrying out any other kind ofwork, raise the vehicle using a hydraulic jack,and always supplement the jack with axle standspositioned under the vehicle jacking points.
When using a hydraulic jack or axle stands,always position the jack head or axle standhead under one of the relevant jacking points(note that the jacking points for use with ahydraulic jack or axle stands are different tothose for use with the vehicle jack) (seeillustrations). Do not jack the vehicle underthe sump or any of the steering or suspensioncomponents. Never work under, around, ornear a raised vehicle, unless it is adequatelysupported in at least two places.
Note the following when using a hydraulicjack:(a) When raising the side of the vehicle,
ensure that the load is taken by the raised
jacking plates on the sill panels (refer tothe accompanying illustration) - do notjack under the body panel behind the sillpanels.
(b) When raising the front of the vehicle, usea suitable metal or strong wooden barand wooden spacer blocks under thefront suspension subframe (refer to theaccompanying illustration).
(c) When raising the rear of the vehicle,position the jack or axle stands under therear suspension tubular crossmember(refer to the accompanying illustration).
TowingTowing eyes are fitted to the front and rear
of the vehicle for attachment of a tow rope.Note that, on certain models, plastic coversmust be unclipped from the bumpers foraccess to the towing eyes (see illustrations).Always turn the ignition key to position "A"when the vehicle is being towed, so that thesteering lock is released, and the directionindicator and brake lights are operational.
Before being towed, release the handbrakeand place the gear lever in neutral on manualtransmission models, or "N" on automatictransmission models. Note that greater-than-usual pedal pressure will be required tooperate the brakes, since the vacuum servounit is only operational with the enginerunning. Similarly, on models with powersteering, greater-than-usual steering effortwill be required.
Where possible, models with automatictransmission should ideally be towed with thefront wheels off the ground, particularly if atransmission fault is suspected. If the vehicleis to be towed with its front wheels on theground, it must always be towed forwards atspeeds not exceeding 30 mph (50 km/h), or fora distance no further than 30 miles (50 km).Also note that, to avoid damaging theautomatic transmission, the fluid level must betopped-up to the dipstick maximum mark asdescribed in Chapter 1, then an extra 1.5 litresof fluid added. The excess fluid must bedrained off before the vehicle is driven again.
Side jacking points Front and rear jacking points
Roadside Repairs
Front and rear towing eye locations
Wheel changing
The spare wheel and jack are located in acradle under the rear of the vehicle. The cradleis lowered by turning the cradle retainingscrew, located under the luggagecompartment carpet, near the tailgate lock.The cradle retaining screw can be turned byengaging the end of the wheel brace (locatedin clips on the right-hand side of the luggagecompartment) with the slot in the screw. Liftthe cradle to release the retaining catch, thenlower it for access to the spare wheel. Notethat the jack is mounted inside a plastic caseto protect it from road dirt and debris (seeillustrations).
To change a wheel, remove the spare wheeland jack (as described previously), apply thehandbrake and place chocks at the front andrear of the wheel diagonally opposite the oneto be changed. A wheel chock is supplied withthe tool kit, and is located in the well of thespare wheel. On automatic transmissionmodels, place the selector lever in position"P". Make sure that the vehicle is located onfirm level ground, and then slightly loosen thewheel bolts with the brace provided (whereapplicable, remove the wheel trim first).
Locate the jack head in the jacking point onthe relevant side of the vehicle to be raised,and raise the jack by turning the screw usingthe wheel brace. When the wheel is clear of
Cover removed to expose front towingeye (arrowed) - Volcane models
Wheel brace and spare wheel cradleretaining screw (arrowed) in luggage
compartment
Spare wheel cradle retaining catch(arrowed) and jack case (A)
the ground, remove the bolts and lift off thewheel. Fit the spare wheel, and moderatelytighten the bolts. Lower the vehicle and thentighten the bolts fully. Refit the trim whereapplicable. If possible, check the tyrepressure on the spare wheel.
Remove the chocks and stow the jack,tools, and the damaged wheel. Have thedamaged tyre or wheel repaired or renewedas soon as possible.
0•13
Roadside RepairsBooster battery (jump) startingWhen jump-start ing a car using abooster battery, observe the followingprecautions:
A) Before connecting the boosterbattery, make sure that the ignition isswitched off.
B) Ensure that all electrical equipment(lights, heater, wipers, etc) isswitched off.
C) Make sure that the booster battery isthe same voltage as the dischargedone in the vehicle.
D) If the battery is being jump-startedfrom the battery in another vehicle,the two vehcles MUST NOT TOUCHeach other.
E) Make sure that the transmission is inneutral (or PARK, in the case ofautomatic transmission).
Connect one end of the red jump lead tothe positive (+) terminal of the flatbattery
Connect the other end of the red lead tothe positive (+) terminal of the boosterbattery.
Connect one end of the black jump leadto the negative (-) terminal of thebooster battery
Connect the other end of the blackjump lead to a bolt or bracket on theengine block, well away from thebattery, on the vehicle to be started
Make sure that the jump leads will notcome into contact with the fan, drive-belts or other moving parts of theengine.
Start the engine using the boosterbattery, then with the engine running atidle speed, disconnect the jump leads inthe reverse order of connection.
0•14
Jump starting will get you outof trouble, but you must correctwhatever made the battery goflat in the first place. There arethree possibilities:
The battery has been drained byrepeated attempts to start, or by
leaving the lights on.
The charging system is not workingproperly (alternator drivebelt slack
or broken, alternator wiring fault oralternator itself faulty).
The battery itself is at fault(electrolyte low, or battery worn out).
Roadside Repairs
Identifying leaksPuddles on the garage floor or drive, or
obvious wetness under the bonnet orunderneath the car, suggest a leak that needsinvestigating. It can sometimes be difficult todecide where the leak is coming from,especially if the engine bay is very dirtyalready. Leaking oil or fluid can also be blownrearwards by the passage of air under the car,giving a false impression of where theproblem lies.
Sump oil
Warning: Most automotive oilsand fluids are poisonous. Washthem off skin, and change out ofcontaminated clothing, withoutdelay.
Oil from filter Gearbox oil
Engine oil may leak from the drain plug...
Antifreeze
...or from the base of the oil filter.
Brake fluid
Gearbox oil can leak from the seals at theinboard ends of the driveshafts.
Power steering fluid
Leaking antifreeze often leaves a crystallinedeposit like this.
A leak occurring at a wheel is almostcertainly brake fluid.
Power steering fluid may leak from the pipeconnectors on the steering rack.
Radio/cassette unit anti-theft system - precautionThe radio/cassette unit fitted as standard
equipment by Citroen is equipped with a built-in security code, to deter thieves. If the powersource to the unit is cut, the anti-theft systemwill activate. Even if the power source isimmediately reconnected, the radio/cassetteunit will not function until the correct securitycode has been entered. Therefore, if you donot know the correct security code for theradio/cassette unit do not disconnect either ofthe battery terminals, or remove theradio/cassette unit from the vehicle.
To enter the security code, first switch the uniton; the display will show "Cod". The security
code can then be entered using buttons 1 to 4on the unit; each button alters the correspondingdigit of the code. Note: There is no facility on theradio display to show the number 0 for the firstdigit of the security code. For the first digit, 0 isindicated by a blank. Once the correct code isdisplayed, press the "up" section of the four-waytuning button to enter the code.
If an incorrect code is entered, the displaywill show three dashes, after which the radiowill be locked for 10 seconds. On the first twoattempts, after 10 seconds the radio displaywill show the "Cod" prompt again, and allowyou to enter the security code again. However,
if the correct security code is not entered onthe third attempt, the unit will be locked for 1hour. To make any further attempts, the unitmust be switched on and left untouched forapproximately 1 hour before the displayshows the "Cod" prompt again, and allowsyou to re-enter the security code. Note thatafter twenty attempts, the unit will becomepermanently locked.
If this happens, or if the security code is lostor forgotten, seek the advice of your Citroendealer. On presentation of proof of ownership,a Citroen dealer will be able to unlock the unitand provide you with a new security code.
0•15
The smell of a fluid leakingfrom the car may provide aclue to what's leaking. Somefluids are distictively coloured.
It may help to clean the car carefullyand to park it over some clean paperovernight as an aid to locating thesource of the leak.Remember that some leaks may onlyoccur while the engine is running.
x 25.4 = Millimetres (mm) xx 0.305 = Metres (m) xx 1.609 = Kilometres (km) x
x 16.387 = Cubic centimetres (cc; cm3) xx 0.568 = Litres (l) xx 1.137 = Litres (I) xx 1.201 = US quarts (US qt) xx 0.946 = Litres (I) xx 4.546 = Litres (I) xx 1.201 = US gallons (US gal) xx 3.785 = Litres (I) x
x 28.35 = Grams (g) xx 0.454 = Kilograms (kg) x
x 0.278 = Newtons (N) xx 4.448 = Newtons (N) xx 0.1 = Kilograms-force (kgf; kg) x
x 0.070 = Kilograms-force per square xcentimetre (kgf/cm2; kg/cm2)
x 0.068 = Atmospheres (atm) x
x 0.069 = Bars x
x 6.895 = Kilopascals (kPa) x
x 0.01 = Kilograms-force per square xcentimetre (kgf/cm2; kg/cm2)
x 100 = Pascals (Pa) xx 0.0145= Pounds-force per square inch x
(psi; Ibf/in2; Ib/in2)x 0.75 = Millimetres of mercury (mmHg) xx 0.401 = Inches of water (inH2O) xx 0.535 = Inches of water (inH2O) xx 0.036 = Pounds-force per square inch x
(psi; Ibf/in2; Ib/in2)
x 1.152 = Kilograms-force centimetre x(kgf cm; kg cm)
x 0.113 = Newton metres (Nm) x*
x 0.083 = Pounds-force feet (Ibf ft; Ib ft) x
x 0.138 = Kilograms-force metres . x(kgf m; kg m)
x 1.356 = Newton metres (Nm) xx 0.102 = Kilograms-force metres x
