Page 3 of 259

Downloaded from www.Manualslib.com manuals search engine INJECTION
Idling - antipollution 111
Petrol injection 112
Emission standards 113 - 119
Prohibited operations : HDi 120 - 121
Safety requirements : HDi 122 - 123
Checking the fuel supply circuit 124 - 125
Checking the air supply circuit 126 - 130
Exhaust gas recycling 131 - 134
Checking turbo pressure 135 - 138
Features of injection systems 139 - 168
IGNITION
Sparking plugs 169
CLUTCH-GEARBOX
Speedometers 170
Clutch specifications 171 - 172
Gearbox and tyre specifications 173 - 174
BE4/5 gearbox controls 175 - 183
ML/5 gearbox controls 184 - 192
AL4-4HP20 gearbox controls 193 - 203
Driveshafts 204
AXLES-SUSPENSION
Wheels and tyres 205 - 211
Axle geometry 212 - 214
Front and rear axle 215 - 216Suspension 217 - 220
Steering specifications 221 - 222
BRAKES
Brake specifications 223 - 228
Handbrake adjustment 229
Bleeding and filling braking system 230 - 233
HYDRAULICS
Specifications 234 - 237
Suspension spheres 238 - 240
ELECTRICAL
Starter motors 241
Alternators 242
Charging circuit 243
AIR CONDITIONING
Quantities in R 134a aircon system 244
Special features 245
Pollen filter 246
Dryer cartridge 247 - 249
Checking oil level 250 - 251
Checking pressures 252
Air conditioning : 6FN-RFN-RLZ 253
Air conditioning circuit : XFX 254
Air conditioning circuit : RHY-RHZ 255
Air conditioning circuit : 4HX 256
INDEX
GENERAL
Identification of vehicles 1 - 4
General : Dimensions 5 - 6
Weight specifications 7 - 8
Towing specifications 9 - 10
Lifting / supporting the vehicle 11 - 14
Capacities 15 - 18
Lubricants 19 - 32
ENGINES
Engine specifications 34 - 58
Cylinder head marking / tightening
6FZ-RFN-RLZ 38
XFX 51 - 52
RHY-RLZ 55 - 56
4HX 57 - 58
Auxiliaries drive belt 59 - 68
Checking and setting valve timing 69 - 90
Power unit suspension 91 - 95
Exhaust system 96 - 100
Cooling system 101 - 107
Checking oil pressures 108
Oil filter 109
Filling and bleeding engine coolant 110
Page 12 of 259
Downloaded from www.Manualslib.com manuals search engine GENERAL
9
GENERAL SPECIFICATION : TOWING THE VEHICLE
Remorquage avant
Remorquage arrière
WARNING : When the engine is not running, steering and braking
are no longer power-assisted.
Towing eye
(1) Towing eye
The towing eye is stowed in the jack protection box inside the spare
wheel.
Vehicle with either manual or automatic gearbox.
ESSENTIAL : Never tow the vehicles with wheels hanging
(towing by the wheels).
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Page 13 of 259
Downloaded from www.Manualslib.com manuals search engine GENERAL
GENERAL SPECIFICATION : TOWING THE VEHICLE
Vehicle towing : Precautions to be taken
4 HP 20 automatic gearbox. AL4 automatic gearbox.
Towing.
In the event of impossibility to raise the front of the vehicle :
It is ESSENTIALto place the selection lever in position«N».
Do not add oil.
Do not exceed a speed of 30 mphover a distance of 30 miles.
Moving the vehicle.
Never be towed with the ignition switched off.
Never attempt to push-start the vehicle. (Impossible with an automatic gearbox).
Note : The automatic gearbox is only lubricated when the engine is running.Towing.
In the event of impossibility to raise the front of the vehicle :
It is ESSENTIALto place the selection lever in position «N».
Do not add oil.
Do not exceed a speed of 45 mph over a distance of 60 miles.
10
Page 68 of 259
Downloaded from www.Manualslib.com manuals search engine ENGINE
65
AUXILIARY EQUIPMENT DRIVE BELT
Engines : RHY - RHZ
With air conditioning
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TOOLS
[1] Belt tension adjusting square : (-).0188 J2
[2] Ø 4 mm peg :(-).0188.Q1
[3] Ø 2 mm peg :(-).0188.Q2
[4] Dynamic tensioner compression lever :(-).0188.Z
Remove
Re-use of belt
WARNING : Mark the direction the belt was fitted in case of re-use of the same belt.
- Compress the tensioner roller (7) by moving it at «c»(in anti-clockwise direction), tool [4].
- Hold the tensioner roller(7) compressed and remove the belt.
No re-use of belt.
- Compress the tensioner roller (7)by moving it at «c»(in anti-clockwise direction), tool[4].
- Peg using tool [2], at «d».
- Loosen the screw (6).
- Bring the eccentric roller (5)towards the rear.
- Tighten the screw (6)by hand.
- Remove the belt.
Page 199 of 259

Downloaded from www.Manualslib.com manuals search engine 196
RECOMMENDATIONS - PRECAUTIONS (AL 4 and 4 HP 20 AUTOMATIC GEARBOXES)
Engines : 6FZ - RFN - RHZ - XFX - 4HX
Towing
The front of the vehicle must be raised in order to be towed.
If the front of the vehicle cannot be raised :
IMPERATIVE : - Put gear lever in position «N».
- Do not add any oil.
AL4 gearbox
- Do not exceed 50 km/h (30mph) over a distance of 50 km (30 m).
4 HP 20 gearbox
- Do not exceed 70 km/h (45mph) over a distance of 100 km (60 m).
Driving.
Never drive with the ignition switched off.
Never push the vehicle to try to start it;
(impossible with an automatic gearbox).
Lubrication
The automatic gearbox is only lubricated when the engine is running.Removing - refitting. (Automatic gearbox).
WARNING : Never place the gearbox on its lower casing
(risk of deforming the tray and damaging the hydraulic valve block).
Never use the connections as handles for raising, turning, holding or
pushing the gearbox.
ESSENTIAL :
- Fit the converter retaining peg while the gearbox is removed.
- Fit the centring peg to locate the gearbox on the engine:
(remove the converter retaining peg just before locating)
WARNING :With the emergency programme selected, an impact is
felt when changing from ‘‘P’’‘‘R’’or ‘‘N’’‘‘R’’.
Precautions to be taken
CLUTCH
GEARBOX
DRIVESHAFTS
Page 205 of 259

Downloaded from www.Manualslib.com manuals search engine 202
CLUTCH
GEARBOX
DRIVESHAFTS
4 HP 20 GEARBOX CONTROLS
Engines : XFX - 4HX
Selection control.
The gear selection control has 5 positions.
The selection lever is guided by the shape of the stepped gate and by a retaining spring which holds it
towards the left.
The gear selection control is equipped with the «shift lock», so you have to switch on the ignition and
apply the brake pedal to unlock the selection lever from the park position.
Selection (P): Park(locking and immobilisation of the vehicle).
Selection (R): Reverse gear.
Selection (N) : Neutral.
Selection (D): Drive (Use of the four gears in their autoadaptive automatic function).
Selection (M) : Manual (M + M -)allowing the driver to select gears by pulling and pushing the gear lever.
In position M, selection is by an electronic sensor located close to the gear lever.
The variation of flux necessary to the movement of the sensor cells is obtained by a magnet located on
the lever itself. This enables the change of status.
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