Citroen ZX Repair Manual.pdf

THE

BOOK

Citroen ZX

Service and Repair Manual

Mark Coombs

Models covered

All Citroen ZX Hatchback models with petrol engines,

including special/limited editions

1360 cc, 1580 cc, 1761 cc, 1905 cc and 1998 cc (inc. 16-valve)

Covers most features of Estate models

Also covers 1124 cc engine

Does not cover Diesel engine models

(1881-320-10X1)

Printed by J H Haynes & Co Ltd, Sparkford, Nr Yeovil,

Somerset BA22 7JJ, England

A book in the Haynes Service and Repair Manual Series

in any form or by any means, electronic or mechanical, including

photocopying, 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 Data

A catalogue record for this book is available from the British Library.

Haynes Publishing

Sparkford, Nr Yeovil, Somerset BA22 7JJ, England

Haynes North America, Inc

861 Lawrence Drive, Newbury Park, California 91320, USA

Editions Haynes S.A.

147/149, rue Saint Honore, 75001 PARIS, France

Haynes Publishing Nordiska AB

Box 1504, 751 45 UPPSALA, Sweden

Rage

Bad

2004,

2005

Contents

LIVING WITH YOUR CITROEN ZX

Introduction

Safety First!

General dimensions and weights

Page

0•4

Page

0•5

Page

0•6

MOT Test Checks

Checks 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•7

Page 0•8

Page 0•9

Page 0•10

Roadside Repairs

Buying 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

Page 0•12

Page 0•14

Page 0•15

Page 0•16

Routine Maintenance

Routine 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 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

Contents

REPAIRS & OVERHAUL

Engine and Associated Systems

TU 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

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

Transmission

Clutch

Manual transmission

Automatic transmission

Driveshafts

Page 6•1

Page 7A•1

Page 7B•1

Page

8•1

Brakes

Braking system

Page

9•1

Suspension

Suspension and steering

Page 10•1

Body Equipment

Bodywork and fittings

Page 11•1

Electrical

Body electrical systems

Wiring Diagrams

Page 12•1

Page 12•19

REFERENCE

Tools and Working Facilities

General Repair Procedures

Fault Finding

Glossary of Technical Terms

Page REF• 1

Page REF• 4

Page REF• 5

Page REF•12

Index

Page REF•16

0•4

Introduction

Introduction to the Citroen ZX

The Citroen ZX range was introduced to the

UK in June 1991. Originally, the ZX was

available 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 (the

1.1 litre version was not available in the UK).

At first, only five-door Hatchback models

were available. All models have a five-speed

manual transmission as standard; a four-

speed automatic transmission was offered as

an option on 1.6 and 1.9 litre models.

All engines are derived from the well-

proven TU series (1124 cc and 1360 cc) and

XU series (1580 cc and 1905 cc models)

engines, which have appeared in many

Citroen and Peugeot vehicles. The engines

are of four-cylinder overhead camshaft

design, mounted transversely and inclined to

the rear, with the transmission mounted on

the left-hand side.

In late 1992, a three-door Hatchback

variant was introduced. At the same time,

three new "sports" models were also

introduced, all of which were equipped with

new engines. These new models were the

1.8 litre (1761 cc) Furio, the 2.0 litre (1998 cc

8-valve) Volcane, and the 2.0 litre (1998 cc

16-valve) 16-valve model. All of these new

models are available in three-door form only.

All three of the new engines are again derived

from the XU series engine.

On all models, fully-independent front

suspension is fitted, with the components

attached to a subframe assembly. The rear

suspension is semi-independent, with torsion

bars and trailing arms.

All models in the range are

comprehensively-equipped, and anti-lock

braking (ABS) and air conditioning systems

are available as options on certain models

(ABS is standard on the 2.0 litre 16-valve).

Provided that regular servicing is carried

out in accordance with the manufacturer's

recommendations, the Citroen ZX should

prove reliable and very economical. The

engine compartment is well-designed, and

most of the items requiring frequent attention

are easily accessible.

Acknowledgements

Thanks are due to Champion Spark Plug,

who supplied the illustrations showing spark

plug conditions. Certain other illustrations are

the copyright of Citroen Cars Ltd, and are

used with their permission. Thanks are also

due to Sykes-Pickavant Limited, who

provided some of the workshop tools, and to

all those people at Sparkford who helped in

the production of this manual.

Project vehicles

Various project vehicles were used in the

preparation of this manual, and appear in

many of the photographic sequences. These

include a 1360 cc, 1580 cc, 1761 cc, 1905 cc,

1998 cc 8-valve and a 1998 cc 16-valve

Citroen ZX 1.4 Reflex Plus 5-door

Citroen ZX 2.0 16-valve

Safety First!

0•5

Working on your car can be dangerous.

This page shows just some of the potential

risks and hazards, with the aim of creating a

safety-conscious attitude.

General hazards

Scalding

• Don't remove the radiator or expansion

tank cap while the engine is hot.

• Engine oil, automatic transmission fluid or

power steering fluid may also be dangerously

hot if the engine has recently been running.

Burning

• Beware of burns from the exhaust system

and from any part of the engine. Brake discs

and drums can also be extremely hot

immediately after use.

Crushing

• When working under or near a

raised vehicle, always

supplement the

jack with axle

stands, or use

drive-on ramps.

Never venture

under a car

which is only

supported by

a jack.

• Take care if loosening or tightening high-

torque nuts when the vehicle is on stands.

Initial loosening and final tightening should be

done with the wheels on the ground.

Fire

• Fuel is highly flammable; fuel vapour is

explosive.

• Don't let fuel spill onto a hot engine.

• Do not smoke or allow naked lights

(including pilot lights) anywhere near a vehicle

being worked on. Also beware of creating

sparks

(electrically or by use of tools).

• Fuel vapour is heavier than air, so don't

work on the fuel system with the vehicle over

an inspection pit.

• Another cause of fire is an electrical

overload or short-circuit. Take care when

repairing or modifying the vehicle wiring.

• Keep a fire extinguisher handy, of a type

suitable for use on fuel and electrical fires.

Electric shock

• Ignition HT

voltage can be

dangerous,

especially to

people with

heart problems

or a pacemaker.

Don't work on or

near the ignition

system with the

engine running or the

ignition switched on.

• Mains voltage is also dangerous. Make sure

that any mains-operated equipment is

correctly earthed. Mains power points should

be protected by a residual current device

(RCD) circuit breaker.

Fume or gas intoxication

• Exhaust fumes are

poisonous; they often

contain carbon

monoxide, which is

rapidly fatal if inhaled.

Never run the

engine in a

confined space

such as a garage

with the doors shut.

• Fuel vapour is also

poisonous, as are the vapours from some

cleaning solvents and paint thinners.

Poisonous or irritant substances

• Avoid skin contact with battery acid and

with any fuel, fluid or lubricant, especially

antifreeze, brake hydraulic fluid and Diesel

fuel. Don't syphon them by mouth. If such a

substance is swallowed or gets into the eyes,

seek medical advice.

• Prolonged contact with used engine oil can

cause skin cancer. Wear gloves or use a

barrier cream if necessary. Change out of oil-

soaked clothes and do not keep oily rags in

your pocket.

• Air conditioning refrigerant forms a

poisonous gas if exposed to a naked flame

(including a cigarette). It can also cause skin

burns on contact.

Asbestos

• Asbestos dust can cause cancer if inhaled

or swallowed. Asbestos may be found in

gaskets and in brake and clutch linings.

When dealing with such components it is

safest to assume that they contain asbestos.

Special hazards

Hydrofluoric acid

• This extremely corrosive acid is formed

when certain types of synthetic rubber, found

in some O-rings, oil seals, fuel hoses etc, are

exposed to temperatures above 400°C. The

rubber changes into a charred or sticky

substance containing the acid. Once formed,

the acid remains dangerous for years. If it

gets onto the skin, it may be necessary to

amputate the limb concerned.

• When dealing with a vehicle which has

suffered a fire, or with components salvaged

from such a vehicle, wear protective gloves

and discard them after use.

The battery

• Batteries contain sulphuric acid, which

attacks clothing, eyes and skin. Take care

when topping-up or carrying the battery.

• The hydrogen gas given off by the battery is

highly explosive. Never cause a spark or

allow a naked light nearby. Be careful when

connecting and disconnecting battery

chargers or jump leads.

Air bags

• Air bags can cause injury if they go off

accidentally. Take care when removing the

steering wheel and/or facia. Special storage

instructions may apply.

Diesel injection equipment

• Diesel injection pumps supply fuel at very

high pressure. Take care when working on

the fuel injectors and fuel pipes.

Warning: Never expose the

hands, face or any other part of

the body to injector spray; the

fuel can penetrate the skin with potentially

fatal results.

Remember...

• Do use eye protection when using power

tools, and when working under the vehicle

• Do wear gloves or use barrier cream to

protect your hands when necessary.

• Do get someone to check periodically that

all is well when working alone on the

vehicle,

• Do keep loose clothing and long hair well

out of the way of moving mechanical parts.

• Do remove rings, wristwatch etc. before

working on the vehicle - especially the

electrical system.

• Do ensure that any lifting or lacking

equipment has a safe working load rating

adequate for the |ob.

DON'T

• Don't attempt to lift a heavy component

which may be beyond your capability - get

assistance.

• Don't rush to finish a job, or take

unverified short cuts.

• Don't use ill-fitting tools which may slip

and cause injury.

• Don't leave tools or parts lying around

where someone can trip over them. Mop up

oil and fuel spills at once.

• Don't allow children or pets to play in or

near a vehicle being worked on.

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