Manual sections
Wiring diagrams- Battery
- Body
- Bodywork
- Braking
- Comfort and convenience
- Current generation
- Dashboard
- Electrical harnesses
- Engine
- Front anti -roll bar
- Front axle
- Front doors
- Front seats
- Front section
- Front shock absorbers
- Gearbox assembly
- General points about the vehicle
- Instruments and controls
- Lighting - signalling
- Mechanical
- Panel on dashboard
- Power unit
- Pre-heating
- Protections and doors
- Re-assembling
- Rear axle
- Rear doors
- Rear section
- Rear springs
- Roof panel
- Side structure
- Steering
- Suspension
- Transmission
- Washing and wiping
Repair manual
Engine Citroen Saxo I
Step-by-step instructions on "Engine" for Citroen Saxo I (1996–2003). Pick an article — removal, installation, adjustment and diagnostics with illustrations.
Crankshaft
- Data: reciprocating gear
- Data: conrods
- Data: liners - pistons - piston rings
- Data: reciprocating gear — variant 2
- Data: conrods — variant 2
- Data: pistons - piston rings
- Data: conrods (TU1JP, 1.4, 1.1, TU9M, TU5JP, TU3JP)
- Data: pistons - piston rings (TU3JP, 1.4, TU5JP, TU9M, 1.1, TU1JP)
- Data: crankshaft - crankshaft half shells (TU3JP, 1.4, TU9M, TU1JP, 1.1, TU5JP)
- Check: liner protrusion (aluminium block) (1.1, TU5JP, TU3JP, 1.1i (TU1M+), TU1JP, 1.4, TU9M)
- Removing - refitting: ancillary drive belt (without air conditioning and with power steering) (TU5J4)
- Removing - refitting: ancillary drive belt (with air conditioning and without power steering) (TU5J4)
- Removing - refitting: ancillary drive belt (with air conditioning and with power steering) (TU5JP)
- Removing - refitting: ancillary drive belt (without power steering and without air conditioning) (TU5J4)
- Dismantling - re-assembly: pistons/con.rods
- Check: liner protrusion
- Matching: bearing shells
- Dismantling - re-assembly: pistons/con.rods — variant 2
- Matching: bearing shells — variant 2
- Dismantling - re-assembly: conrods - pistons (TU1JP, 1.1, TU5JP, 1.1i (TU1M+), TU9M, TU3JP, 1.4)
- Matching: crankshaft bearing shells (TU5JP, TU1JP, 1.1i (TU1M+), TU9M, 1.4, TU3JP, 1.1)
- Dismantling - re-assembly: dynamic seals - tu engine - 8 valves (TU5JP, 1.4, 1.1i (TU1M+), TU3JP, 1.1, TU1JP, TU9M)
- Modification: the piston shaft (engine TU9) (TU9M)
- Modification: tightening torques (TUD5, TUD5B)
Timing gear
- Data: camshafts
- Data: camshafts — variant 2
- Data: camshafts (TU9M, TU1JP, TU3JP, TU5JP, 1.4, 1.1)
- Data: valve rockers (TU1JP, 1.4, TU5JP, TU9M, 1.1, TU3JP)
- Removing - refitting: camshaft seal (TU9M, TU5JP, TU3JP, 1.1i (TU1M+))
- Removing - refitting: camshaft (TU9M, TU5JP, TU3JP, 1.1i (TU1M+))
- Removing - refitting: camshaft bearing seal (TUD5B, TUD5)
- Removing - refitting: camshaft (TUD5, TUD5B)
- Removing - refitting: camshaft seal (TU5J4)
- Removing - refitting: camshaft (TU5J4)
- Check: setting the valve timing (TU9M, TU5JP, TU3JP, 1.1i (TU1M+))
- Check: setting the valve timing (TUD5, TUD5B)
- Check: setting the valve timing (TU5J4)
- Removing - refitting: timing belt (TU9M, TU5JP, TU3JP, 1.1i (TU1M+))
- Removing - refitting: timing belt (TUD5, TUD5B)
- Removing - refitting: timing belt (TU5J4)
Exhaust
Engine block
- Data: cylinder housings of aluminium alloy
- Data: cast iron cylinder block
- Data: dynamic seals (TU1JP, TU3JP, TU9M, 1.4, 1.1, TU5JP)
- Data: aluminium cylinder block (1.4, TU3JP, 1.1i (TU1M+), TU9M, TU1JP, 1.1, TU5JP)
- Data: cast cylinder block (TU9M, TU5JP, TU1JP, 1.1, 1.4, TU3JP, 1.1i (TU1M+))
- Modification: cylinder block (engine TUD5) (TUD5, TUD5B)
- Modification: cylinder block - cylinder head gasket (TU5J4)
- Description: mechanism housing
Cylinder head
- Data: identification of the cylinder head
- Data: valves
- Data: valve springs
- Data: valve guides
- Data: valve seats
- Data: cylinder head gasket
- Data: identification of the cylinder head — variant 2
- Data: valves — variant 2
- Data: valve springs — variant 2
- Data: valve guides — variant 2
- Data: valve seats — variant 2
- Data: cylinder head gasket — variant 2
- Data: valves and valve springs (TU9M, TU3JP, 1.4, 1.1i (TU1M+), 1.1, TU1JP, TU5JP)
- Data: valve seats and guides (1.1, TU5JP, 1.4, TU1JP, TU3JP, TU9M)
- Data: cylinder head (1.1i (TU1M+), TU1JP, TU5JP, TU9M, TU3JP, 1.1, 1.4)
- Stripping - re-assembling: cylinder head
- Stripping - re-assembling: cylinder head — variant 2
- Stripping-assembling: cylinder head (TU3JP, 1.4, TU5JP, 1.1i (TU1M+), TU9M, 1.1, TU1JP)
- Stripping - re-assembling: engine (TU3JP, TU1JP, 1.4, 1.1, TU5JP, TU9M, 1.1i (TU1M+))
- Removing - refitting: cylinder head on the vehicle (TU9M, TU5JP, TU3JP, 1.1i (TU1M+))
- Removing - refitting: cylinder head (on vehicle) (TUD5, TUD5B)
- Removing - refitting: cylinder head on the vehicle (TU5J4)
- Modification: engines TU petrol all types (TU9M, TU5JP, TU3JP, 1.1i (TU1M+))
- Modification: cylinder head cover (TU9M, TU5JP, TU3JP, 1.1i (TU1M+))
- Checks and adjustments: valve clearances when cold (TUD5, TUD5B)
- Presentation: tool 4533-T (TUD5, TUD5B)
Lubrication
- Summary: engine oil filter cartridges (–04.1996)
- Engine oil capacities: (96 - 97 Model Year)
- Engine oil capacities: (1999 Model Year)
- Engine oil capacities: 2000 model year
- Summary: engine oil filter cartridges (05.1999–12.2001)
- Summary: engine oil filter cartridges (05.2000–12.2001)
- Engine oil capacities: 2001 model year
- Summary: engine oil filter cartridges (year 2002)
- Engine oil capacities: 2002 model year
- Summary: engine oil filter cartridges (year 2003)
- Engine oil capacities: 2003 model year
- Check: oil pressure (1.1i (TU1M+), TU5JP, TU3JP)
- Check: oil pressure (TUD5, TUD5B)
- Modification: dipstick - dipstick guide tube (TU9M, TU3JP, 1.1i (TU1M+))
- Modification: oil filter (1.1i (TU1M+), TU5JP, TU3JP)
- Modification: oil sump fixing
- Removing - refitting: suction strainer
- Maintenance: TOTAL recommended lubricants
- Lubrication: engine oil
- Maintenance: recommended ingredients, year 2006
Cooling system
- Repair operation: temperature sensor (MOTEUR ELECTRIQUE SA13)
- Data: cooling circuits (TU9M, TU5JP, TU3JP, 1.1i (TU1M+))
- Data: cooling system (TUD5, TUD5B)
- Data: cooling circuits (TU5J4)
- Data: battery cooling system (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: coolant pump
- Removing - refitting: battery cooling radiator (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: engine cooling air blower (MOTEUR ELECTRIQUE SA13)
- Drain and refill - refilling - bleeding: cooling system
- Filling and bleeding: battery cooling system (MOTEUR ELECTRIQUE SA13)
- Modification: coolant outlet housing (1.6 i 100, TU1JP, TU3JP)
- Principles of operation: additional and independent heating systems (MOTEUR ELECTRIQUE SA13)
- Data - identification: heating unit (MOTEUR ELECTRIQUE SA13)
- General: additional and independent heating systems (MOTEUR ELECTRIQUE SA13)
- Data: additional heating (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: heating unit (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: fuel tank (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: heating controls (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: coolant pump — variant 2
- Removing - refitting: air turbine (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: incandescent finger and flame controller (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: combustion boiler (MOTEUR ELECTRIQUE SA13)
- Filling and bleeding: heater fluid system (MOTEUR ELECTRIQUE SA13)
- Modification: WEBASTO THERMOTOP C additional heating (MOTEUR ELECTRIQUE SA13)
- Diagnostic: heating unit (MOTEUR ELECTRIQUE SA13)
- Diagnostic: additional and independent heating systems (MOTEUR ELECTRIQUE SA13)
- Presentation: passenger compartment heating (MOTEUR ELECTRIQUE SA13)
Air and fuel supply
- Modification: click-fit connectors for the lower front and rear battery compartments (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: fuel tank (TU9M, TU5JP, TU3JP, 1.1i (TU1M+))
- Removing - refitting: fuel tank filler pipe (TUD5)
- Removing - refitting: fuel tank (TUD5)
- Removing - refitting: mechanical component of the LPG gauge (1.1i (TU1M+))
- Removing - refitting: filling valve - safety valve (1.1i (TU1M+))
- Removing - refitting: outlet union - safety valve (1.1i (TU1M+))
- Removing - refitting: cylindrical LPG tank (1.1i (TU1M+))
- Removing - refitting: mechanical component of the safety electrovalve (1.1i (TU1M+))
- Removing - refitting: cylindrical LPG tank (TU3JP)
- Removing - refitting: LPG gauge valve. safety solenoid valve (TU3JP)
- Modification: cylindrical LPG tank
- Repair operations: accelerator cable (TU3JP, TU5JP)
- Data - identification: charging cord and socket (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: charging socket harness (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: charging flap locking device (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: charging socket light bulb (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: lower part of the charging socket (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: charging flap sensor (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: charging cable plug body (MOTEUR ELECTRIQUE SA13)
- Modification: mains filter (MOTEUR ELECTRIQUE SA13)
- Data: nickel-cadmium battery (MOTEUR ELECTRIQUE SA13)
- Check: sealing of the battery electrolyte topping up system (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: lower battery pack (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: upper battery pack (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: rear battery pack (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: filler connections (MOTEUR ELECTRIQUE SA13)
- Replacement: cooling hoses - traction batteries (MOTEUR ELECTRIQUE SA13)
- Topping up: nickel-cadmium battery electrolyte (MOTEUR ELECTRIQUE SA13)
- Modification: Nickel Cadmium traction battery with increased reserve (MOTEUR ELECTRIQUE SA13)
- Data: high voltage fuse circuit breaker (MOTEUR ELECTRIQUE SA13)
- Data - identification: electronic unit (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: electronic unit (MOTEUR ELECTRIQUE SA13)
- Removing - refitting: accelerator sensor (MOTEUR ELECTRIQUE SA13)
- Modification: electronic unit (MOTEUR ELECTRIQUE SA13)
- Data: traction battery charges (MOTEUR ELECTRIQUE SA13)