Chapter 3

Cooling, heating and ventilation systems

Contents
Air conditioning compressor (auxiliary) drivebelt - Cooling system electrical switches and sensors - testing,
checking and renewal See Chapter 1 removal and refitting 6
Air conditioning system - general information and precautions . . . . 11 Cooling system hoses - disconnection and renewal 2
Air conditioning system components - removal and refitting 12 Electric cooling fan(s) - testing, removal and refitting 5
Air conditioning system refrigerant check See Chapter 1 General information and precautions 1
Antifreeze mixture See Chapter 1 Heating and ventilation system - general information 8
Coolant level check See Chapter 1 Heater/ventilation components - removal and refitting 9
Coolant pump - removal and refitting 7 Heater vents - removal and refitting 10
Cooling system - draining See Chapter 1 Radiator - removal, inspection and refitting 3
Cooling system - filling See Chapter 1 Thermostat - removal, testing and refitting 4
Cooling system - flushing See Chapter 1

Degrees of difficulty
Easy, suitable for Fairly easy, suitable Fairly difficult, suitable Difficult, suitable for Very difficult,
novice with little for beginner with for competent DIY experienced DIY suitable for expert DIY
experience some experience mechanic mechanic or professional

Specifications
General
Maximum system pressure 1.4 bars

Thermostat
Opening temperatures:
Starts to open 89°C
Fully-open 101°C

Electric cooling fan(s)

Cooling fan(s) cut in:
Single-speed cooling fan:
1998 cc 8-valve models 95°C
All other models 97°C
Twin-speed cooling fan(s):*
Slow speed 97°C
Fast speed 101°C
Cooling fan(s) cut out:
Single-speed cooling fan:
1998 cc 8-valve models 86°C
All other models 92°C
Twin-speed cooling fan(s):*
Slow speed -. 92°C
Fast speed 96°C
'Twin-speed cooling fans are fitted to all models with air conditioning, and to models supplied to countries with a hot climate.

Torque wrench settings Nm ibf ft

Coolant pump bolts:
1124 cc and 1360 cc models:
Lower bolt 7 5
Upper bolt 16 12
1580 cc and larger-engined models 15 11
Temperature switches/sensors:
Screwed into radiator 35 26
Screwed into cylinder head/coolant outlet housing 18 13
3•2 Cooling, heating and ventilation systems

until a hissing sound is heard. When the flat-bladed screwdriver), but do not apply too
1 General information and hissing has stopped, indicating that the much force, and take care not to damage the
precautions pressure has reduced, slowly unscrew the pipe stubs or hoses. Note in particular that the
filler cap until it can be removed; if more radiator inlet stub is fragile; do not use
hissing sounds are heard, wait until they excessive force when attempting to remove
General information have stopped before unscrewing the cap the hose.
The cooling system is of pressurised type, completely. At all times, keep well away
comprising a coolant pump driven by the from the filler cap opening, and protect If all else fails, cut the hose
timing belt, an aluminium crossflow radiator your hands. with a sharp knife, then slit H
with integral expansion tank, electric cooling Warning: Do not allow antifreeze so that it can be peeled off in
fan(s), a thermostat, heater matrix, and all to come into contact with your two pieces. Although this may
associated hoses and switches. skin, or with the painted surfaces prove expensive if the hose is
The system functions as follows. Cold of the vehicle. Rinse off spills otherwise undamaged, It is preferable
coolant in the bottom of the radiator passes immediately, with plenty of water. Never to buying a new radiator. Check first,
through the bottom hose to the coolant pump, leave antifreeze lying around in an open however, that a new hose is readily
where it is pumped around the cylinder block container, or in a puddle in the driveway or available.
and head passages, and through the oil on the garage floor. Children and pets are
cooler(s) (where fitted). After cooling the attracted by its sweet smell, but antifreeze
cylinder bores, combustion surfaces and can be fatal if ingested. 7 When fitting a hose, first slide the clips onto
valve seats, the coolant reaches the Warning: If the engine is hot, the the hose, then work the hose into position. If
underside of the thermostat, which is initially electric cooling fan may start crimped-type clips were originally fitted, use
closed. The coolant passes through the rotating even if the engine is not standard worm-drive clips when refitting the
heater, and is returned via the cylinder block running. Be careful to keep your hose. If the hose is stiff, use a little soapy
to the coolant pump. hands, hair, and any loose clothing well water as a lubricant, or soften the hose by
When the engine is cold, the coolant clear when working in the engine soaking it in hot water. Do not use oil or
circulates only through the cylinder block, compartment. grease, which may attack the rubber.
cylinder head, and heater. When the coolant Warning: Refer to Section 11 for 8 Work the hose into position, checking that it
reaches a predetermined temperature, the precautions to be observed when is correctly routed, then slide each clip back
thermostat opens, and the coolant passes working on models equipped along the hose until it passes over the flared
through the top hose to the radiator. As the with air conditioning. end of the relevant inlet/outlet, before
coolant circulates through the radiator, it is tightening the clip securely.
cooled by the inrush of air when the car is in 9 Refill the cooling system with reference to
forward motion. The airflow is supplemented 2 Cooling system hoses - Chapter 1.
by the action of the electric cooling fan(s) disconnection and renewal 10 Check thoroughly for leaks as soon as
when necessary. Upon reaching the bottom of possible after disturbing any part of the
the radiator, the coolant has now cooled, and Note: Refer to the warnings given in Section 1 cooling system.
the cycle is repeated. of this Chapter before proceeding. Hoses
should only be disconnected once the engine
Radiator bottom hose
When the engine is at normal operating
temperature, the coolant expands, and some has cooled sufficiently to avoid scalding. Removal
of it is displaced into the expansion tank. 1 If the checks described in Chapter 1 reveal
Coolant collects in the tank, and is returned to a faulty hose, it must be renewed as follows. 11 Turn the locking ring ("2") anti-clockwise
the radiator when the system cools. until it contacts the stop ("1") (see
2 First drain the cooling system (see Chap-
illustration).
On models with automatic transmission, a ter 1). If the coolant is not due for renewal, it
proportion of the coolant is recirculated from may be re-used, providing it is collected in a 12 Press the connector away from the hose,
the bottom of the radiator through the clean container. to ensure that the two retaining lugs are free
transmission fluid cooler mounted on the (see illustration).
3 To disconnect a hose, proceed as follows,
transmission. On 16-valve models, the according to the type of hose connection. 13 Pull the hose, complete with the
coolant is also passed through the engine oil connector, from the radiator.
cooler. Conventional hose connections -
The electric cooling fan(s) mounted in front general instructions
of the radiator are controlled by a 4 On conventional connections, the clips
thermostatic switch. At a predetermined used to secure the hoses in position may be
coolant temperature, the switch/sensor either standard worm-drive clips or
actuates the fan. disposable crimped types. The crimped type
of clip is not designed to be re-used and
Precautions should be replaced with a worm drive type on
Warning: Do not attempt to reassembly.
remove the expansion tank filler 5 To disconnect a hose, use a screwdriver to
cap, or to disturb any part of the slacken or release the clips, then move them
cooling system, while the engine along the hose, clear of the relevant
is hot, as there is a high risk of scalding. If inlet/outlet. Carefully work the hose free (see
the expansion tank filler cap must be illustration). The hoses can be removed with
removed before the engine and radiator relative ease when new - on an older car, they
have fully cooled (even though this is not may have stuck.
recommended), the pressure in the cooling 6 If a hose proves to be difficult to remove, try
system must first be relieved. Cover the to release it by rotating its ends before
cap with a thick layer of cloth, to avoid attempting to free it. Gently prise the end of
scalding, and slowly unscrew the filler cap the hose with a blunt instrument (such as a 2.5 Disconnecting the radiator top hose
 Cooling, heating and ventilation systems 3•3

2.16 On refitting, fit a new O-ring

(arrowed) to the hose union
2.11 To release the radiator bottom hose 2.12 Press the connector away from the
connection, turn the locking ring (2) until it hose, to ensure that the two retaining
contacts the stop (1) lugs (3) are free

14 Recover the O-ring from the connector, Radiator bypass hose connection
and discard it; a new one must be used on
Removal
refitting.
23 The hose is secured by means of a
Refitting bayonet-fit connector.
15 Wipe the connector and the stub on the 24 Turn the connector on the end of the hose
radiator thoroughly with a clean, lint-free anti-clockwise as far as it will go (see
cloth. illustration).
16 Fit a new O-ring to the male half of the 25 Rock the connector back and forth to
connector, ensuring that it is correctly seated release it from the radiator outlet. Remove the
(see illustration). O-ring, and discard it; a new must be used on
2.18 Offer the hose to the radiator, with
17 Turn the locking ring clockwise until it refitting.
the cut-out (arrowed) at the bottom
clicks. Refitting
18 Offer the hose to the stub on the radiator, the guide rails on the connector with the lugs
26 Wipe the connector and the stub on the on the radiator (see illustration).
with the locating cut-out in the male part of radiator thoroughly with a clean, lint-free
the connector located at the bottom (see 29 Push the connector fully home to
cloth. compress the O-ring.
illustration). 27 Fit a new O-ring to the male half of the 30 Turn the connector clockwise as far as the
19 Push the connector into the stub until connector. stop.
both the retaining lugs click into position. 28 Offer the connector to the outlet on the 31 Refill the cooling system with reference to
Make sure that the O-ring is not trapped. radiator, and twist anti-clockwise to engage Chapter 1.
20 Pull the connector rearwards (away from 32 Check thoroughly for leaks as soon as
the stub) to adjust the position of the retaining possible after disturbing any part of the
lugs if necessary. cooling system.
21 Refill the cooling system with reference to
Chapter 1. Heater matrix hose connections
22 Check thoroughly for leaks as soon as Removal
possible after disturbing any part of the 33 The two hoses are connected to the
cooling system. matrix by means of a single connector.
34 Prise the metal retaining clip from the top
of the connector (see illustration).

2.24 To release the radiator bypass hose, 2.28 On refitting, engage the guide rails (1) 2.34 Remove the metal clip from the top of
turn the connector on the end of the hose with the lugs on the radiator, then twist the the heater matrix connector on the engine
anti-clockwise hose end in a clockwise direction compartment bulkhead . . .
3•4 Cooling, heating and ventilation systems

2.35 . . . then release the plastic retaining 2.36 . . . and pull the connector away from 3.3 Removing the cover panel from the
clip . . . the bulkhead - recover the O-rings (arrowed) radiator

35 Release the plastic retaining clip by 4 Disconnect the wiring plug from the cooling 11 If the radiator is to be sent for repair or
pushing it towards the left-hand hose fan switch (where fitted) on the left-hand side renewed, remove all hoses, and the cooling
connection (see illustration). of the radiator (see illustration). fan switch (where fitted).
36 Pull the connector assembly from the 5 Disconnect the radiator upper hose(s) (left- 12 Inspect the condition of the radiator
heater matrix. Recover the O-ring seals from hand side), and the lower hoses (right-hand mounting rubbers, and renew them if
the connector, and discard them; new ones side), with reference to Section 2. necessary.
should be used on refitting (see illustration). 6 Depress the two retaining clips, located at
the top ends of the radiator, then carefully lift Refitting
Refitting
the radiator from the vehicle. Note the locating 13 Refitting is a reversal of removal, bearing
37 Refitting is a reversal of the removal lugs at the bottom of the radiator, which
procedure, using new O-rings. in mind the following points:
locate in the mounting rubbers in the lower (a) Ensure that the lower lugs on the radiator
38 Refill the cooling system with reference to body panel (see illustrations).
Chapter 1. are correctly engaged with the mounting
39 Check thoroughly for leaks as soon as Inspection rubbers in the body panel.
possible after disturbing any part of the (b) Reconnect the hoses with reference to
7 If the radiator has been removed due to Section 2, using new O-rings where
cooling system.
suspected blockage, reverse-flush it as applicable.
described in Chapter 1. Clean dirt and debris (c) On completion, refill the cooling system
3 Radiator - from the radiator fins, using an air line (in as described in Chapter 1.
removal, inspection and refitting which case, wear eye protection) or a soft
brush. Be careful, as the fins are sharp, and
Note: New sealing rings must be used when easily damaged. 4 Thermostat -
reconnecting the radiator lower hoses - see 8 If necessary, a radiator specialist can removal, testing and refitting
Section 2. If leakage is the reason for perform a "flow test" on the radiator, to
removing the radiator, bear in mind that minor establish whether an internal blockage exists.
Removal
leaks can often be cured using a radiator 9 A leaking radiator must be referred to a
sealant with the radiator in situ. specialist for permanent repair. Do not 1 Disconnect the battery negative lead.
attempt to weld or solder a leaking radiator, 2 Drain the cooling system as described in
Removal as damage to the plastic components may Chapter 1.
1 Disconnect the battery negative lead. result. 3 Where necessary, release any relevant
2 Drain the cooling system as described in 10 In an emergency, minor leaks from the wiring and hoses from the retaining clips, and
Chapter 1. radiator can be cured by using a suitable position clear of the thermostat housing to
3 Undo the three retaining screws, and radiator sealant, in accordance with its improve access. On 1905 cc models, access
remove the plastic cover panel from above the manufacturer's instructions, with the radiator is also improved if the air cleaner duct is
radiator (see illustration). in situ. removed (see Chapter 4).

3.4 Disconnecting the cooling fan switch 3.6a Depress the retaining clips . . . 3.6b . . . and withdraw the radiator
wiring plug
 Cooling, heating and ventilation systems 3•5

4.4a Thermostat housing cover retaining 4.4b Thermostat housing cover retaining 4.5 Removing the sealing ring from the
bolts (arrowed) - 1360 cc models bolts (arrowed) -1905 cc models thermostat flange

4 Unscrew the retaining bolts, and carefully earth point on the body; if not, then the earth
withdraw the thermostat housing cover to 5 Electric cooling fan(s) - connection is faulty, and must be re-made.
expose the thermostat. Take care not to strain testing, removal and refitting 4 If the switch and the wiring are in good
the coolant hoses connected to the cover condition, the fault must lie in the motor itself.
(see illustrations). The motor can be checked by disconnecting it
5 Lift the thermostat from the housing, and Testing from the wiring loom, and connecting a
recover the sealing ring(s) (see illustration). 1 Current supply to the cooling fan(s) is via 12-volt supply directly to it.
the ignition switch (see Chapter 5) and a fuse
Testing Removal
(see Chapter 12). The circuit is completed by
6 A rough test of the thermostat may be the cooling fan thermostatic switch, which (on 5 Remove the radiator as described in
made by suspending it with a piece of string in most models) is mounted in the left-hand side Section 3.
a container full of water. Heat the water to of the radiator. On models with air 6 Disconnect the wiring plug from the rear of
bring it to the boil - the thermostat must open conditioning, the cooling fans are controlled the motor (see illustration).
by the time the water boils. If not, renew it. by the "Bitron" sensor - see Section 6. 7 On models with a plastic radiator shroud
7 If a thermometer is available, the precise 2 If a fan does not appear to work, run the (both single- and twin-fan arrangements),
opening temperature of the thermostat may engine until normal operating temperature is unscrew the three motor retaining nuts,
be determined; compare with the figures reached, then allow it to idle. The fan should rotating the fan blades as necessary so that
given in the Specifications. The opening cut in within a few minutes (before the the bolts can be counterheld from the front as
temperature is also marked on the thermostat. temperature gauge needle enters the red the nuts are unscrewed. Withdraw the motor
8 A thermostat which fails to close as the section, or before the coolant temperature assembly, complete with the fan, from the
water cools must also be renewed. warning light comes on). If not, switch off the front of the vehicle (see illustration).
ignition and disconnect the wiring plug from 8 On models with a single cooling fan where
Refitting the cooling fan switch. Bridge the two the motor is secured to the body by a metal
9 Refitting is a reversal of removal, bearing in contacts in the wiring plug using a length of frame, undo the retaining bolts, then remove
mind the following points: spare wire, and switch on the ignition. If the the motor and mounting frame from the
(a) Examine the sealing ringfs) for signs of fan now operates, the switch is probably vehicle.
damage or deterioration, and if necessary, faulty, and should be renewed. 9 If desired, the fan blades can be removed
renew. 3 If the fan still fails to operate, check that from the motor shaft, after its retaining screw
(b) Ensure that the thermostat is fitted the battery voltage is available at the feed wire to or clip (as applicable) has been removed.
correct way round, with the spring(s) the switch; if not, then there is a fault in the 10 If the motor is faulty, the complete unit
facing into the housing. feed wire (possibly due to a fault in the fan must be renewed, as no spares are available.
(cj On completion, refill the cooling system motor, or a blown fuse). If there is no problem
as described in Chapter 1. with the feed, check that there is continuity Refitting
between the switch earth terminal and a good
11 Refitting is a reversal of removal. Refit the
radiator as described in Section 3.

6 Cooling system electrical

switches and sensors -
testing, removal and refitting

Electric cooling fan thermostatic

switch - models without air
conditioning
Testing
1 Testing of the switch is described in
5.6 Disconnecting the wiring plug from a 5.7 Withdrawing a cooling fan motor Section 5, as part of the electric cooling fan
cooling fan assembly - twin-fan arrangement test procedure.
 3•6 Cooling, heating and ventilation systems

10 On completion, start the engine and run it 16 If the gauge needle remains at the "cold"
until it reaches normal operating temperature. end of the scale when the engine is hot,
Continue to run the engine, and check that the disconnect the sender wiring plug, and earth
cooling fan cuts in and out correctly. the relevant wire to the cylinder head. If the
needle then deflects when the ignition is
Electric cooling fan thermostatic switched on, the sender unit is proved faulty,
switch - models with air and should be renewed. If the needle still
conditioning
does not move, remove the instrument panel
11 The cooling fans are controlled by the (Chapter 12) and check the continuity of the
"Bitron" sensor. This is located in the wire between the sender unit and the gauge,
thermostat housing, which is bolted onto the and the feed to the gauge unit. If continuity is
left-hand end of the cylinder head - see shown, and the fault still exists, then the
paragraphs 20 to 22. gauge is faulty, and the gauge unit should be
renewed.
6.2 Electric cooling fan thermostatic Coolant temperature
17 If the gauge needle remains at the "hot"
switch - models without air conditioning gauge/temperature warning light
end of the scale when the engine is cold,
sender
disconnect the sender wire. If the needle then
Testing returns to the "cold" end of the scale when
Note: On models with air conditioning, the the ignition is switched on, the sender unit is
sender provides a signal to the gauge only. proved faulty, and should be renewed. If the
The coolant temperature warning light is needle still does not move, check the
operated by the "Bitron" temperature sensor remainder of the circuit as described
described later in this Section. previously.
12 The coolant temperature gauge/warning 18 The same basic principles apply to testing
light sender is screwed into the thermostat the warning light. The light should illuminate
housing, which is bolted onto the left-hand when the relevant sender wire is earthed.
end of the cylinder head. The sender can be
Removal and refitting
identified by its blue wiring connector (see
illustration). 19 The procedure is similar to that described
13 The temperature gauge (where fitted) is previously in this Section for the electric
fed with a stabilised voltage from the cooling fan thermostatic switch. On some
6.12 Coolant temperature
instrument panel feed (via the ignition switch models, access to the switch is very poor, and
gauge/temperature warning light sender
and a fuse). The gauge earth is controlled by other components may need to be removed
(arrowed) -1360 cc models
the sender. The sender contains a thermistor - before the sender unit can be reached.
Removal an electronic component whose electrical
"Bitron" temperature sensor -
2 The switch is located in the left-hand side resistance decreases at a predetermined rate
models with air conditioning
of the radiator (see illustration). The engine as its temperature rises. When the coolant is
and radiator should be cold before removing cold, the sender resistance is high, current Testing
the switch. flow through the gauge is reduced, and the 20 The sensor forms part of the air
3 Disconnect the battery negative lead. gauge needle points towards the blue (cold) conditioning "Bitron" control system (see
4 Partially drain the cooling system to just end of the scale. As the coolant temperature Section 11). Testing of the sensor should be
below the level of the switch (as described in rises and the sender resistance falls, current entrusted to a Citroen dealer.
Chapter 1). Alternatively, have ready a flow increases, and the gauge needle moves
towards the upper end of the scale. If the Removal and refitting
suitable bung to plug the switch aperture in
the radiator when the switch is removed. If sender is faulty, it must be renewed. 21 The "Bitron" temperature sensor is
this method is used, take great care not to 14 On models with a temperature warning screwed into the thermostat housing, which is
damage the radiator, and do not use anything light, the light is fed with a voltage from the bolted onto the left-hand end of the cylinder
which will allow foreign matter to enter the instrument panel. The light earth is controlled head. The sensor can be identified by its
radiator. by the sender. The sender is effectively a brown wiring connector.
5 Disconnect the wiring plug from the switch. switch, which operates at a predetermined 22 The procedure is similar to that described
6 Carefully unscrew the switch from the temperature to earth the light and complete previously in this Section for the electric
radiator, and recover the sealing ring (where the circuit. If the light is fitted in addition to a cooling fan thermostatic switch. On some
applicable). If the system has not been gauge, the senders for the gauge and light are models, access to the switch is very poor, and
drained, plug the switch aperture to prevent incorporated in a single unit, with two wires, other components may need to be removed
further coolant loss. one each for the light and gauge earths. On before the sender unit can be reached.
models with air conditioning, the light is
Refitting operated via the "Bitron" sensor - see
Coolant temperature sensor - fuel
7 If the switch was originally fitted using paragraphs 20 to 22.
injection models
sealing compound, clean the switch threads 15 If the gauge develops a fault, first check Testing
thoroughly, and coat them with fresh sealing the other instruments; if they do not work at 23 The fuel injection system coolant
compound. all, check the instrument panel electrical feed. temperature sensor is screwed into the
8 If the switch was originally fitted using a If the readings are erratic, there may be a fault thermostat housing, which is bolted onto the
sealing ring, use a new sealing ring on in the voltage stabiliser, which will necessitate left-hand end of the cylinder head. The sensor
refitting. renewal of the stabiliser (the stabiliser is can be identified by its green wiring
9 Refitting is a reversal of removal. Tighten integral with the instrument panel printed connector.
the switch to the specified torque, and refill (or circuit board - see Chapter 12). If the fault lies 24 The sensor is a thermistor (see para-
top-up) the cooling system as described in in the temperature gauge alone, check it as graph 13). The fuel injection/engine
Chapter 1. follows. management ECU supplies the sensor with a
 Cooling, heating and ventilation systems 3•7

are contained in the air distribution housing,

which acts as a central distribution unit,
passing air to the various ducts and vents.
3 Cold air enters the system through the grille
at the rear of the engine compartment. If
required, the airflow is boosted by the blower,
and then flows through the various ducts,
according to the settings of the controls. Stale
air is expelled through ducts at the rear of the
vehicle. If warm air is required, the cold air is
passed over the heater matrix, which is
heated by the engine coolant.
4 On models fitted with air conditioning, a
recirculation switch enables the outside air
supply to be closed off, while the air inside the
vehicle is recirculated. This can be useful to
7.3a On 1580 cc and larger-engined 7.3b . . . and remove the coolant pump prevent unpleasant odours entering from
models, unscrew the retaining bolts outside the vehicle, but should only be used
(arrowed)... briefly, as the recirculated air inside the
set voltage and then, by measuring the pump and the cylinder block are clean and vehicle will soon become stale.
current flowing in the sensor circuit, it dry.
determines the engine's temperature. This 5 On 1124 cc and 1360 cc models, fit a new
information is then used, in conjunction with O-ring to the rear of the pump. Refit the pump
other inputs, to control the injector opening to the engine, and tighten its retaining bolts to 9 Heater/ventilation components
time (pulse width). On some models, the idle the specified torque. - removal and refitting
speed and/or ignition timing settings are also 6 On 1580 cc and larger-engined models,
temperature-dependent. position a new gasket on the rear of the
pump. Offer the pump to the engine, ensuring
Heater/ventilation control unit
25 If the sensor circuit should fail to provide
adequate information, the ECU'S back-up facility that the gasket remains correctly positioned.
Removal
will override the sensor signal. In this event, the Install the pump retaining bolts, and tighten
them to the specified torque. 1 Disconnect the battery negative lead.
ECU assumes a predetermined setting which
7 Refit the timing belt as described in Chap- 2 Remove the centre console as described in
will allow the fuel injection/engine management
ter 2. Chapter 11. On lower-specification models
system to run, albeit at reduced efficiency.
8 Refill the cooling system as described in where no centre console is fitted, undo the
When this occurs, the warning light on the
Chapter 1. retaining screws and remove the heater duct
instrument panel will come on, and the advice of
cover (where fitted) from the centre of the
a Citroen dealer should be sought. The sensor
facia assembly.
itself can only be tested using special Citroen
diagnostic equipment. Do not attempt to test the 3 Where a radio/cassette player is fitted,
8 Heating and ventilation system - remove it as described in Chapter 12, then
circuit using any other equipment, as there is a
general information undo the two retaining screws and remove the
high risk of damaging the ECU.
mounting bracket from the radio aperture (see
Removal and refitting 1 The heating/ventilation system consists of a illustrations). Where no radio/cassette player
26 The procedure is similar to that described four-speed blower motor (housed behind the is fitted, carefully prise out the storage box
previously in this Section for the electric facia), face level vents in the centre and at from the centre of the facia panel.
cooling fan thermostatic switch. On some each end of the facia, and air ducts to the 4 Undo the four centre vent panel retaining
models, access to the switch is very poor, and front footwells. screws (two located above the heater
certain components may need to be removed 2 The control unit is located in the facia, and controls, and two directly below), then unclip
before the sensor can be reached. the controls operate flap valves to deflect and the panel and withdraw it from the facia.
mix the air flowing through the various parts of Disconnect the wiring connectors from the
the heating/ventilation system. The flap valves cigarette lighter and ashtray illumination bulb,
7 Coolant pump -
removal and refitting

Removal
1 Drain the cooling system as described in
Chapter 1.
2 Remove the timing belt as described in
Chapter 2.
3 Slacken and remove the retaining bolts,
and withdraw the pump from the cylinder
block (see illustrations). Recover the pump
O-ring (1124 cc and 1360 cc models) or
gasket (1580 cc and larger-engined models).
A new O-ring or gasket should be used on
refitting.

Refitting 9.3a Undo the two retaining screws 9.3b . . . and remove the mounting bracket
4 Ensure that the mating surfaces of the (arrowed)... from the radio aperture
3•8 Cooling, heating and ventilation systems

9.4a Undo the four centre vent panel 9.4b . . . and withdraw the panel from the 9.5 Undo the heater panel retaining
retaining screws (arrowed)... facia screws, and release the clip (arrowed)
and remove the centre vent panel assembly 6 Disconnect the control cables and the Refitting
from the vehicle (see illustrations). wiring connector(s) from the rear of the heater
5 Undo the two heater control panel retaining 10 Refitting is a reversal of removal.
control panel, noting their locations, and
screws, then release the lower panel retaining withdraw the panel from the vehicle. Heater matrix
clip and manoeuvre the panel out from the Removal
centre of the facia (see illustration). Refitting
11 Remove the facia assembly as described
7 Refitting is reversal of removal, bearing in
in Chapter 11.
mind the following points:
12 Remove the retaining screws, and release
(a) Ensure that the control cables are
the wiring retaining brackets from the top of
correctly reconnected to the control
the heater unit, noting their locations (see
panel, as noted before removal.
illustration).
(b) Refit the radio/cassette player with
13 Working inside the vehicle, disconnect the
reference to Chapter 12.
wiring plug from the right-hand side of the
Heater/ventilation control cables heater unit (see illustration).
14 Remove the heater assembly lower
Removal
retaining bolt (see illustration).
8 Remove the complete heater assembly as 15 Working in the engine compartment,
described later in this Section. remove the two heater unit retaining nuts from
9 The cables can now be disconnected from the bulkhead (below the heater matrix hose
the heater assembly and the heater control connector), and recover the washers (see
9.9 Control cable connection (1) and panel (see illustration). Note the locations of illustration).
retaining clip (2) at heater assembly the cables before disconnecting them. 16 Drain the cooling system as described in

9.12 Heater unit wiring bracket retaining 9.13 Disconnect the wiring plug from the 9.14 Heater assembly lower retaining bolt
screws (arrowed) right-hand side of the heater (arrowed)

9.15 Heater unit retaining nut on engine 9.17a Remove the two retaining screws 9.17b . . . and withdraw the retaining plate
compartment bulkhead (arrowed)... from the bulkhead
 Cooling, heating and ventilation systems 3•9

9.18 Withdrawing the heater unit 9.19 Withdrawing the heater matrix from 9.20a Undo the retaining bolts .
the heater assembly
Chapter 1. Disconnect the heater hose lower facia panel (left-hand-drive models) or 27 Open the bonnet, and remove the six
connector from the heater matrix, with the glovebox (right-hand-drive models), as wiper motor cover/vent panel retaining
reference to Section 2. applicable, with reference to Chapter 11. screws. Carefully ease the cover out from
17 Remove the two retaining screws, and 22 Unscrew the three blower motor retaining behind the windscreen sealing strip.
withdraw the retaining plate from the heater screws, and lower the assembly from the facia Disengage its front locating pegs, and
matrix hose connector (see illustrations). (see illustration). manoeuvre the panel away from the vehicle.
18 Working inside the vehicle, withdraw the 23 Pull off the cover and disconnect the two 28 Remove the plastic cover from the heater
heater unit, complete with the control panel wiring plugs, then withdraw the assembly blower motor intake duct.
(see illustration). Be careful not to spill from the vehicle (see illustration). 29 Twist the resistor anti-clockwise to
coolant inside the car. release it from the bracket, then disconnect
Refitting
19 Remove the retaining screws, where the wiring plug and withdraw the unit (see
applicable, then release the clips and 24 Refitting is a reversal of removal. illustrations). Tie a piece of string to the
withdraw the heater matrix from the heater wiring connector, to prevent it falling back out
assembly (see illustration). Heater blower motor resistor of the duct.
Refitting Removal
20 Refitting is a reversal of the removal 25 Disconnect the battery negative lead. Refitting
procedure, bearing in mind the following 26 Remove the wiper arm as described in 30 Refitting is a reversal of removal, refitting
points: Chapter 12. the wiper arm with reference to Chapter 12.
(a) If a new matrix is to be fitted, unbolt the
hose connector elbow from the old
matrix, and fit it to the new matrix using
new O-rings (see illustrations).
(b) Reconnect the heater hoses to the matrix
with reference to Section 2.
(c) Refit the facia assembly as described in
Chapter 11.
(d) Refill the cooling system as described in
Chapter 1.
Heater blower motor
Removal
21 Working inside the vehicle, remove the
facia felt undercover and the driver's side 9.20b . . . and remove the hose connector 9.20c Fit the elbow to the new matrix,
elbow from the old heater matrix using new O-rings

9.22 Unscrewing a heater blower motor 9.23 Pull off the cover (arrowed) and 9.29a To remove the heater blower motor
retaining screw disconnect the wiring plugs resistor...
3•10 Cooling, heating and ventilation systems

evaporator, where it changes from liquid

under high pressure to gas under low
pressure. This change is accompanied by a
drop in temperature, which cools the
evaporator. The refrigerant returns to the
compressor, and the cycle begins again.
3 Air blown through the evaporator passes to
the air distribution unit, where it is blown
through the heater matrix to achieve the
desired temperature in the passenger
compartment.
4 The heating side of the system works in the
same way as on models without air
conditioning (see Section 8).
9.29b . . . twist the unit anti-clockwise and 10.1 Withdrawing a facia side vent
5 The operation of the system is controlled
disconnect the wiring plug
electronically by the "Bitron" control unit,
Complete heater assembly Facia centre vents which controls the electric cooling fan(s), the
compressor, and the facia-mounted warning
Removal Removal light. Any problems with the system should be
31 Removal of the complete heater assembly 3 Remove the centre vent panel from the facia referred to a Citroen dealer.
is described in paragraphs 11 to 18, as part of as described in Section 9, paragraphs 1 to 4. Precautions
the heater matrix removal and refitting 4 Working at the rear of the centre vent panel, 6 When an air conditioning system is fitted, it
procedure. remove the retaining screws, then withdraw is necessary to observe special precautions
Refitting the vent assembly from the panel. whenever dealing with any part of the system,
Refitting or its associated components. If for any
32 Refitting is a reversal of removal, with
reference to paragraph 20. 5 Refitting is a reversal of removal. reason the system must be disconnected,
entrust this task to your Citroen dealer or a
11 Air conditioning system - refrigeration engineer.
10 Heater vents - Warning: The refrigeration circuit
general information and
removal and refitting contains a liquid refrigerant
precautions
(Freon), and it is therefore
Facia side vents dangerous to disconnect any part
General information of the system without specialised
Removal 1 An air conditioning system is available on knowledge and equipment.
1 Carefully release the relevant vent from the certain models (see illustration). It enables 7 The refrigerant is potentially dangerous,
facia, using a screwdriver (with a piece of card the temperature of incoming air to be lowered, and should only be handled by qualified
under the blade to avoid damage to the facia and also dehumidifies the air, which makes for persons. If it is splashed onto the skin, it can
trim), then withdraw the vent (see rapid demisting and increased comfort. cause frostbite. It is not itself poisonous, but
illustration). 2 The cooling side of the system works in the in the presence of a naked flame (including a
same way as a domestic refrigerator. cigarette) it forms a poisonous gas.
Refitting Refrigerant gas is drawn into a belt-driven Uncontrolled discharging of the refrigerant is
2 Simply push the nozzle into its housing in compressor, and passes into a condenser dangerous, and potentially damaging to the
the facia, ensuring that it is correctly engaged mounted on the front of the radiator, where it environment.
with the heater duct, until the retaining lugs loses heat and becomes liquid. The liquid 8 Do not operate the air conditioning system
click into place. passes through an expansion valve to an if it is known to be short of refrigerant, as this
may damage the compressor.

12 Air conditioning system

components -
removal and refitting

Warning: Do not attempt to open

the refrigerant circuit. Refer to
the precautions given in
Section 11.
1 The only operation which can be carried out
easily without discharging the refrigerant is
renewal of the compressor drivebelt. This is
described in Chapter 1, Section 2 1 . (The
"Bitron" temperature sensor may be renewed
11.1 Schematic diagram of air using the information in Section 6.) All other
conditioning system operations must be referred to a Citroen
1 Compressor 5 Control valve dealer or an air conditioning specialist.
2 Condenser 6 Evaporator 2 If necessary, the compressor can be
3 Drier bottle 7 Heater/ventilation unbolted and moved aside, without
4 Pressostat booster motor disconnecting its flexible hoses, after
removing the drivebelt.