📚 Vehicle Manual Information

1990-1998 Citroen ZX Workshop Service Repair Manual

🏷️ Basic Information

Make:

Citroën

Model:

ZX

Year Range:

1990-1998

Platform Code:

PSA ZX

Internal Project Name:

Project 'S-90'

👋 Introduction

Segment:

Compact family hatchback, positioned as a practical and affordable European offering.

Key Selling Points:

Comfortable ride, innovative design, good packaging, fuel efficiency.

Key Rivals:

Ford Escort, Volkswagen Golf, Opel Astra, Renault Mégane, Peugeot 306.

Design Innovations:

Innovative rear beam suspension (torsion bars), distinctive dashboard layout, emphasis on occupant comfort and ergonomics.

Chassis Technology:

PSA's renowned chassis engineering, often featuring an agile and comfortable ride with good road holding.

📋 Manual Details

Primary Coverage:

Mechanical, Electrical, Bodywork, Diagnostics, Maintenance

Specific Systems Covered:

Engine, Transmission, Suspension, Brakes, Steering, Fuel System, Cooling System, Exhaust System, HVAC, Body Control Modules, Lighting, Instrument Panel, SRS (Airbag) System

Estimated Pages:

1500+

Type:

Workshop Service Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Powertrain:

Comprehensive coverage of all engine variants, including petrol and diesel, manual and automatic transmissions, clutch, drivetrain components.

Chassis And Suspension:

Detailed information on front and rear suspension (including hydropneumatic elements if applicable to certain export models), steering system, braking system (including ABS if equipped), wheels and tires.

Overview:

Extensive electrical schematics, component locations, wiring diagrams for all major systems, including lighting, ignition, charging, starting, infotainment, and driver controls.

Maintenance:

Scheduled maintenance procedures, fluid changes, filter replacements, lubrication points, inspections.

Repair And Overhaul:

Step-by-step instructions for major component removal, disassembly, inspection, repair, and reassembly of engine, transmission, suspension, brakes, steering, and body components.

Diagnostics And Troubleshooting:

Fault finding guides, diagnostic trouble codes (DTCs) for relevant ECUs, common problems and their solutions, component testing procedures.

Level:

Professional workshop level, suitable for experienced mechanics and advanced DIY enthusiasts.

Specific Procedures:

Torque specifications for all fasteners, machining limits for engine components, calibration procedures for steering and suspension components, diagnostic flowcharts.

📊 Manual Specifications

Searchability:

Fully searchable PDF text for quick information retrieval.

Resolution:

High-resolution scans of original factory documents ensuring clarity of diagrams and text.

Physical Equivalent:

Comparable to a factory-bound manual, but delivered digitally.

Digital Equivalent:

Digital pages with clear, legible text and graphics.

⚙️ Engine Specifications

Petrol Variants:

1.1L (TU1), 1.4L (TU3), 1.6L (XU5/TU5), 1.8L (XU7), 2.0L (XU10J2/J4).

Diesel Variants:

1.9L (XUD7), 1.9L Turbo-D (XUD7TE/T).

Horsepower Range:

55 hp to 130 hp (depending on engine and trim).

Torque Range:

90 Nm to 180 Nm (depending on engine).

Injection Type:

Carburetted (early models) or multi-point fuel injection (MPI).

Fuel Type:

Unleaded Petrol (Octane 95/98 recommended for MPI), Diesel.

ECU Types:

Bosch Motronic, SAGEM, Lucas (varies by engine and year).

🔧 Transmission

Type:

5-speed Manual Transaxle.

Type:

4-speed Automatic Transaxle (e.g., ZF 4HP18/20).

Clutch Type:

Dry, single-plate diaphragm spring clutch.

Transmission Fluid Manual:

API GL-4, SAE 75W-90 or 80W-90 gear oil.

Transmission Fluid Automatic:

Dexron III / Mercon ATF.

📐 Dimensions

Length Hatchback:

Approx. 4031 mm

Width:

Approx. 1670 mm

Height:

Approx. 1380 mm

Wheelbase:

Approx. 2550 mm

Curb Weight Range:

Approx. 1050 kg - 1250 kg (depending on engine and equipment).

Gross Vehicle Weight:

Varies by model, typically around 1600 kg.

Luggage Capacity:

Approx. 350-400 litres (rear seats up).

🛡️ Safety Features

Euro Ncap:

Not formally rated under modern Euro NCAP protocols, but crashworthiness considered competitive for its era.

Braking System:

Front: Ventilated Discs; Rear: Drums (or solid discs on performance variants). ABS available on higher trims/later models.

Steering Assistance:

Power steering available on most variants.

Airbags:

Driver airbag standard on later models, passenger airbag optional.

Seatbelts:

Pre-tensioned front seatbelts.

Body Structure:

Designed with crumple zones and a reinforced passenger cell.

💡 Technology Features

Audio System:

Factory fitted radio-cassette players, often with RDS and speaker balance controls. CD players became available on later models.

Dashboard Display:

Digital or analogue instrument clusters, including tachometer, speedometer, fuel gauge, engine temperature, and warning lights.

Cruise Control:

Optional on higher trim levels and larger engine variants.

Connectivity Features:

Limited by era; typically only factory-fitted alarm systems or basic immobilizers.

🔧 Maintenance

Oil Change:

Every 10,000 km or 12 months, whichever comes first (depending on driving conditions).

Air Filter Replacement:

Every 20,000 km or 24 months.

Spark Plug Replacement:

Every 40,000 km (standard) or 60,000 km (platinum).

Engine Oil:

SAE 10W-40, API SJ or ACEA A2/B2 (check owner's manual for specific engine variant requirements).

Coolant:

Ethylene glycol-based antifreeze, mixture of 50% coolant and 50% distilled water.

Brake Fluid:

DOT 4.

Power Steering Fluid:

Citroën LHM Plus (if equipped with hydropneumatic suspension) or a generic ATF (for hydraulic power steering).

Suspension Wear:

Rear torsion bar bearings can wear, leading to knocking sounds; front suspension bushes and ball joints are common wear items.

Electrical Gremlins:

Wiring loom chafing, intermittent dashboard lights, central locking issues.

Engine Peripherals:

Water pump leaks, alternator failures, ignition coil pack issues (on later models).

Exhaust System:

Corrosion and leaks, particularly on older vehicles.

📚 Vehicle History

Citroen Philosophy:

Citroën's long history of innovation, comfort, and distinctive design.

Introduction Year:

1990

Facelift:

Minor facelift around 1994/1995, with updated styling and interior features.

Manufacturing Locations:

Primary production in France (Aulnay-sous-Bois), also produced in other PSA facilities and licensed in various countries (e.g., Iran Khodro).

Production End Year:

1998 (replaced by the Citroën Xsara).

🏆 Awards & Recognition

Design Awards:

Praised for its distinctive styling and interior ergonomics at launch.

Safety Accolades:

Considered a safe vehicle for its time, with a focus on passenger protection.

Owner Satisfaction:

Generally positive for comfort and practicality, though reliability can vary with age and maintenance.