CITROEN C5 2005 Service manual
CITROEN C5 2005 is a reliable and versatile vehicle that offers a range of features to enhance your driving experience. With its efficient engines, comfortable interior, and advanced safety systems, the CITROEN C5 2005 is an excellent choice for both everyday commutes and long road trips. Whether you're looking for a vehicle that can handle the challenges of city driving or one that provides a comfortable and safe ride for your family, the CITROEN C5 2005 is an excellent option.
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COUV-Angl-C5C8-2005.qxd 9/01/06 18:18 Page 2
AC/DTAV/PRME/MMCB/MMEC
Méthodes Mécaniques
©
«The intellectual property rights relating to the technical information contained in this document belong exclusively to the manufacturer. Reproduction, translation or distribution in whole or in part without prior written authorisation from the manufacturer is forbidden».
2005
PRIVATE CARS
CITROËN C5 - CITROËN C8
«The technical information contained in this document is intended for the exclusive use of the trained personnel of the motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full responsibility to the exclusion of that of the manufacturer».
«The technical information appearing in this brochure is subject to updating as the characteristics of each model in the range evolve. Motor vehicle repairers are invited to contact the CITROËN network periodically for further information and to obtain any possible updates».
22000055
CAR 000.020
Volume 3
COUV-Angl-C5C8-2005.qxd 9/01/06 18:18 Page 1
Engine families
Engine types
C5
7
J4
1.8i 16V
6FZ
X
CORRESPONDENCE TABLE FOR PETROL ENGINES
EW
10 12
A J4
2.0i 16V 2.2i 16V HPi
RFJ RFN 3FZ
A
XFU
ES
9
3.0i 24V
J4
XFW
X X
C8
X
X X
particular model year.
OLD ONES.
VERY IMPORTANT
Engine families
Engine types
DV
6
TED4
1,6 16V HDi
9HZ
CORRESPONDENCE TABLE FOR DIESEL ENGINES
DW
RHM
TED4
RHT
10
2,0 16VHDi
RHW
RHL
BTED4
RHR
C5 X X
X
C8 X X
X
12
TED ATED4
2,2 16VHDi
4HX
4HW
X
X
COUV-Angl-C5C8-2005.qxd 9/01/06 18:18 Page 1
Engine families
Engine types
C5
7
J4
1.8i 16V
6FZ
X
CORRESPONDENCE TABLE FOR PETROL ENGINES
EW
10 12
A J4
2.0i 16V 2.2i 16V HPi
RFJ RFN 3FZ
A
XFU
ES
9
3.0i 24V
J4
XFW
X X
C8
X
X X
particular model year.
OLD ONES.
VERY IMPORTANT
Engine families
Engine types
DV
6
TED4
1,6 16V HDi
9HZ
CORRESPONDENCE TABLE FOR DIESEL ENGINES
DW
RHM
TED4
RHT
10
2,0 16VHDi
RHW
RHL
BTED4
RHR
C5 X X
X
C8 X X
X
12
TED ATED4
2,2 16VHDi
4HX
4HW
X
X
COUV-Angl-C5C8-2005.qxd 9/01/06 18:18 Page 1
Engine families
Engine types
C5
7
J4
1.8i 16V
6FZ
X
CORRESPONDENCE TABLE FOR PETROL ENGINES
EW
10 12
A J4
2.0i 16V 2.2i 16V HPi
RFJ RFN 3FZ
A
XFU
ES
9
3.0i 24V
J4
XFW
X X
C8
X
X X
particular model year.
OLD ONES.
VERY IMPORTANT
Engine families
Engine types
DV
6
TED4
1,6 16V HDi
9HZ
CORRESPONDENCE TABLE FOR DIESEL ENGINES
DW
RHM
TED4
RHT
10
2,0 16VHDi
RHW
RHL
BTED4
RHR
C5 X X
X
C8 X X
X
12
TED ATED4
2,2 16VHDi
4HX
4HW
X
X
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IDENTIFICATION OF VEHICLES
A - Chassis stamp
(cold stamp on bodywork).
B - Manufacturer's data plate
(under the rear bench seat).
C - A-S/RP No. and RP paint code
(label on front pillar close to driver's door).
D - Inflation pressures and tyre references
(label on front pillar close to driver's door).
E - Serial no. on bodywork.
F - Gearbox reference - Factory serial no.
G - Engine legislation type - Factory serial no.
C5
E1APO8RD
1
Angl. T3 page001-31-2005 4/02/05 14:15 Page 2
C5
DC
RFNC/IF
D
C
E
6FZ
RFJ
XFU
9HZ
RHL
RHR
4HX
Structure
D
C
RFN
C
/IF
Family (1)
Bodywork (2)
Engine (3)
Version (4)
Variant (5)
Family (1)
C5
Body shape (2)
5-door saloon
Estate
Engine (3)
EW7J4
EW10A
ES9A
DV6TED4
DW10BTED4
1.8i 16V
2.0i 16V
3.0i 24S
1.6i 16 HDi
2.0i 16V HDi
DW12TED4 2.2 16V HDi
IDENTIFICATION OF VEHICLES
Type approval
Version (4)
Manual 5-speed gearbox
Manual 4-speed gearbox
Manual 6-speed gearbox ts
Automatic 6-speed gearbox
Axle and/or gearbox gears
Other possible combinations
No gearbox
L3
W3
A
L4 Euro IV
B
E
G
D
K
M
C
F
H
J
L
Depollution levels
US
83/87
P
R
S
N
T
Other
V
W
X
Y
K
K’
5
6
7
Z
Variants (5)
Entreprise convertible
Integral alternator-starter (ADIN)
Without FAP
Fiscal incentives
Piloted manual gearbox
Downgraded depollution
LPG dual fuel
STT2 (stop and start)
P
D
GL
S
T
AD
SF
IF
2
Alcohol
L3/L4 Euro IV
8 1
9 2
3
0
U
4
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IDENTIFICATION OF VEHICLES
A - Chassis stamp
(cold stamp on bodywork).
B - Manufacturer's data plate
(under RH centre pillar).
C - A-S / RP No. and RP paint code
(label on front pillar).
D - Inflation pressures and tyre references
(label on front pillar).
E - Gearbox reference - Factory serial no.
F - Engine legislation type - Factory serial no.
C8
E1AP0A2D
3
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C8
EA
XFWF/IF
E
A
B
RFN
3FZ
XFW
RHM
RHT
RHW
4HW
Structure
E
A
XFW
F
/IF
Family (1)
Bodywork (2)
Engine (3)
Version (4)
Variant (5)
Family (1)
C8
Body shape (2)
Monospace 7 seats maximum
Monospace 8 seats maximum
Engine (3)
EW10J4
EW12J4
ES9J4
2.0i 16V
2.2i 16V Hpi
3.0i 24S
DW10TED4
DW12ATED4
2.0i 16V HDi
2.2i 16V HDi
IDENTIFICATION OF VEHICLES
Type approval
Version (4)
Manual 5-speed gearbox
Manual 4-speed gearbox
Manual 6-speed gearbox ts
Automatic 6-speed gearbox
Axle and/or gearbox gears
Other possible combinations
No gearbox
L3
W3
A
L4 Euro IV
B
E
G
D
K
M
C
F
H
J
L
Depollution levels
US
83/87
P
R
S
N
T
Other
V
W
X
Y
K
K’
5
6
7
Z
Variants (5)
Entreprise convertible
Integral alternator-starter (ADIN)
Without FAP
Fiscal incentives
Piloted manual gearbox
Downgraded depollution
LPG dual fuel
STT2 (stop and start)
P
D
GL
S
T
AD
SF
IF
4
Alcohol
L3/L4 Euro IV
8 1
9 2
3
0
U
4
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CAPACITIES (in litres)
Draining methods
Oil capacities are defined according to the following methods
Draining of the engine lubrication system by GRAVITY Draining of the engine lubrication system by SUCTION
Place the vehicle on horizontal ground (in the high position if
hydropneumatic suspension).
Place the vehicle on horizontal ground (in the high position if
hydropneumatic suspension).
The engine should be hot (oil temperature 80°C).
Remove the oil by suction through the dipstick tube.
Remove the oil filter cartridge.
The engine should be hot (oil temperature 80°C).
Drain the sump by gravity.
Remove the oil filter cartridge (time for draining and drip-drip = 15
minutes approx.).
Refit the cap with a new seal.
Refit a new oil filter cartridge.
Refill the engine with oil (see table for oil capacity).
Start the engine to fill the oil filter cartridge.
Stop the engine (allow to stabilise for 5 minutes).
Maintain the suction of oil in the sump (15 minutes approx.).
Refit a new oil filter cartridge.
Refill the engine with oil (see table for oil capacity).
Start the engine to fill the oil filter cartridge.
Stop the engine (allow to stabilise for 5 minutes).
WARNING: Remove the suction container before starting the engine.
ESSENTIAL: Systematically check the oil level using the oil dipstick.
5
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1.8i 16V
CAPACITIES (in litres)
C5
Petrol
2.0i 16V
AUTO.
Engine type
Engine with filter change
Between Min. and Max.
5-speed gearbox
Automatic gearbox
After oil change
Braking circuit
Hydraulic circuit
Cooling system
Fuel tank capacity
6FZ
4,25
1,8
1,7
8,8
IMPERATIVE: Systematically check the oil level using the oil dipstick.
6
1,8
RFJ
5
4,3
65
6
3
1,8
3.0i 24S
AUTO.
XFU
5,25
2
7
4
14
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CAPACITIES (in litres)
C5
Diesel
2.0 16V HDi 1.6 16V HDi
Engine type
Engine with filter change
Between Min. and Max.
5-speed gearbox
Automatic gearbox
After oil change
Braking circuit
Hydraulic circuit
Cooling system
Fuel tank capacity
9HZ
3,75
1,55
RHL
1,8
5,25
1,9
RHR
4,3
10,5 11,7 (with additional heating)
65
IMPERATIVE: Systematically check the oil level using the oil dipstick.
7
1,8
2.2 16V HDi
AUTO.
4HX
4,75
1,5
8,3
5,3
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Engine type
Engine with filter change
Between Min. and Max.
5-speed gearbox
Automatic gearbox
After oil change
Hydraulic circuit
Cooling system
Fuel tank capacity
2.0i 16v
RFN
4,25
1,7
Petrol
2.2i 16V
CAPACITIES (in litres)
C8
3.0i 24V
AUTO.
3FZ XFW
5,25
2
RHM
1,8 2
8,3
5,3
0,66
7 7,2 10,5
80
2.0 16V HDi
RHT
4,75
1,9
10
2
Diesel
RHW
8
2.2 16V HDi
AUTO.
4HW
4,75
1,5
6
3
11,3
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LUBRICANTS - TOTAL recommended oils
EVOLUTIONS (YEAR 2004).
CITROËN C4
Petrol engine versions except 2.0 i 16V 180 hp (132 kW):
- Normal maintenance interval: 30 000 km (20 000 miles).
- Severe maintenance interval: 20 000 km (12 000 miles).
Petrol engine version 2.0L i 16V 180 hp (132 kW):
- Normal maintenance interval: 20 000 km (12 500 miles).
- Severe maintenance interval: 15 000 km (10 000 miles).
Diesel engine versions.
WARNING: Vehicles HDi FAP (*) do not accept the energy economy oil TOTAL ACTIVA FUTUR 9000 5W30 for France, TOTAL QUARTZ
FUTURE 9000 5W30 outside France .
DV6 engines:
- Normal maintenance interval: 20 000 km (12 500 miles).
- Severe maintenance interval: 15 000 km (10 000 miles).
DW engines:
- Normal maintenance interval: 30 000 km (20 000 miles).
- Severe maintenance interval: 20 000 km (12 000 miles).
New Look CITROËN C5
Petrol engine versions:
- Normal maintenance interval: 30 000 km (20 000 miles).
- Severe maintenance interval: 20 000 km (12 000 miles).
Diesel engine versions.
WARNING: Vehicles HDi FAP (*) do not accept the energy economy oil TOTAL ACTIVA FUTUR 9000 5W30 for France, TOTAL QUARTZ
FUTURE 9000 5W30 outside France.
DV6 engines:
- Normal maintenance interval: 20 000 km (12 500 miles).
- Severe maintenance interval: 15 000 km (10 000 miles).
DW engines :
- Normal maintenance interval: 30 000 km (20 000 miles).
- Severe maintenance interval: 20 000 km (12 000 miles).
ESSENTIAL: For all vehicles with a 30 000 km (20 000 miles) maintenance interval, use exclusively TOTAL ACTIVA/QUARTZ 7000 or
9000 or any other oils offering identical specifications to these.
These oils offer specifications that are superior to those defined by norms ACEA A3 OR API SJ/CF.
Failing this, it is essential to adhere to the maintenance programmes covering severe operating conditions.
9
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LUBRICANTS - TOTAL recommended oils
Use of oil grade 10W40.
It is possible to use the semi-synthetic oil 7000 10W40 on HDi and HDi
FAP vehicles.
WARNING: To avoid difficulties when starting from cold (< 20°C), use
5W40 oil.
For more details, see the oil usage table (paragraph 3.3).
Commercial description for energy economy oil.
TOTAL ACTIVA FUTUR 9000 5W30 (France only).
TOTAL QUARTZ FUTUR 9000 5W30 (except France).
The exclusions for use of this oil are the following:
- XSARA VTS 2.0 16V (XU10J4RS).
- JUMPER/RELAY 2.8 HDi and 2.8 TDi (SOFIM engine).
- HDi FAP vehicles.
- CITROËN C3 HDi 16V (DV4TED4).
- CITROËN C8 2.2i (EW12J4).
- CITROËN C4 and C5 2.0i (EW10A).
- CITROËN C4 (EW10J4S).
Engine oil norms.
Current norms.
The classification of these engine oils is established by the following recognised organisations:
- S.A.E
- API
- ACEA
: Society of Automotive Engineers.
: American Petroleum Institute.
: Association des Constructeurs Européens d'Automobiles.
S.A.E. Norms - Table for selection of engine oil grade.
Selection of engine oil grades recommended for climatic conditions in countries of distribution (see table, paragraph 3.3).
Evolution of the norms to 01/01/2003.
ACEA 2003 norms.
The meaning of the first letter has not changed, it still corresponds to the type of engine:
- A: petrol and dual fuel petrol / LPG engines.
- B: diesel engines.
The figure following the first letter corresponds to the type of oil:
- 3: high performance oils.
- 4: oils specifically for direct injection diesel engines.
- 5: very high performance oils permitting lower fuel consumption, specific to direct injection diesel engines.
Example:
- ACEA A3: high performance oils specifically for petrol and dual fuel petrol/
LPG engines.
- ACEA A/B: blended oils giving very high performance for all engines, also permitting better fuel economy, specifically for direct injection diesel engines.
NOTE: From 01/01/2003 there is no longer any reference to the year of creation of the norm (example : ACEA A3/B3 98 becomes ACEA A3/B3).
10
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LUBRICANTS - TOTAL recommended oils
API Norms:
The meaning of the first letter has not changed, it still corresponds to the type of engine:
- S: petrol and dual fuel petrol / LPG engines.
- C: diesel engines.
The second letter corresponds to the degree of evolution of the oil
(ascending order).
Example: Norm SL is more severe than norm SJ, corresponding to a higher level of performance.
Recommendations.
ESSENTIAL: To preserve engine performances, all engines fitted in
CITROËN vehicles must be lubricated with high quality oils (synthetic
or semi-synthetic).
CITROËN engines are lubricated at the factory with TOTAL oil of grade
S.A.E 5W-30.
TOTAL oil of grade S.A.E 5W-30 allows improved fuel economies
(approx 2.5%).
The oil 5W30 is used only for the following engines (year 2004):
- XU10 J4RS
: XSARA VTS 2.0i 16V (3-door).
- SOFIM
- HDi
- DV4 TED4
- EW 12J4
- EW 10A
- EW10J4S engine
: JUMPER / RELAY 2.8 TDi and 2.8 HDi.
: With particle filter (FAP).
: CITROËN C3 1.4 16V HDi.
: CITROËN C8 2.2i.
: CITROËN C4 and C5 2.0i.
: CITROËN C4.
WARNING: CITROËN engines prior to model year 2000 do not have to be lubricated with oils adhering to the norms:
- ACEA AI-98 and API SJ/CF EC or current norms ACEA A5/B5.
Denomination of TOTAL oils according to country of marketing:
- TOTAL ACTIVA (France only).
- TOTAL QUARTZ (outside France).
Summary.
Norms to be respected for engine oils (year 2004).
Year Engine types concerned
2003
Petrol and LPG dual fuel engines
Diesel engines
ACEA
Norms
A3 or A5
(*)
B3, B4 or B5 (*)
API
Norms
SJ or SL
CF
(*) It is essential not to use engine oils respecting these norms for
XU10J4RS, SOFIM 2.8 TDi and SOFIM 2.8 HDi engines, HDi engines with particle filter EW10A, EW12J4, DV4TED4.
11
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LUBRICANTS - TOTAL recommended oils
Classes and grades of TOTAL recommended engine oils.
The oils distributed in each country are suited to the local climatic conditions.
Blended oils for all engines (petrol, diesel and dual fuel
petrol/LPG):
API norms
TOTAL ACTIVA 9000
TOTAL QUARTZ 9000
TOTAL ACTIVA FUTUR 9000 (*)
TOTAL QUARTZ FUTUR 9000 (*)
TOTAL ACTIVRAC
S.A.E. ACEA norms norms
5W40
5W30
A3/B3/
B4
A5/B5
10W40 A3/B3
(*) Blended oils for all engines giving fuel economy.
Oils for petrol, diesel and dual fuel petrol/LPG engines:
S.A.E. ACEA norms norms
TOTAL ACTIVA 7000
TOTAL QUARTZ 7000
10W40
SL/CF
API norms
TOTAL QUARTZ 9000 0W40 A3 SL
Oils specifically for diesel engines:
TOTAL ACTIVA DIESEL 7000
TOTAL QUARTZ DIESEL 7000
TOTAL ACTIVA DIESEL 7000
S.A.E. ACEA norms norms
10W40
15W50
B3
TOTAL ACTIVA 7000
TOTAL QUARTZ 7000
15W50
12
API norms
CF
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LUBRICANTS - TOTAL recommended oils
Oil usage table
Petrol engines
Diesel engines
Engine types
EW10J4S (CITROËN C4)
EW12J4 (CITROËN C8 2.2i 16V)
EW10A (CITROËN C4 and C5)
Others petrol engines
HDi engines with FAP (*)
Others HDi engines
SOFIM 2.8 HDi and 2.8 TDi (RELAY)
DV4 TED4 (C3 1.6 16V HDi)
Indirect injection diesel engines
0W40
X
X
X
X
X
X
X
TOTAL ACTIVA QUARTZ
Synthetic 9000 Semi-synthetic 7000
15W50 5W30 5W40 10W40
Hot countries
Temperate countries
Cold countries
X
X
X X
X
X X
X
X
X X
X
X (*) X
X
X
X X
X
X
X
X
X
X
X
X
X
X
(*) Do not use this oil in cold climatic conditions (temperature less than - 20°C).
See the table below for the choice of TOTAL engine oil grades to be used according to the climatic conditions in the country of marketing.
13
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LUBRICANTS - TOTAL recommended oils
E4AP006D
14
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FRANCE
Metropolitan FRANCE
LUBRICANTS - TOTAL recommended oils
ENGINE OILS
Blended oils for all engines, supplied in bulk
TOTAL ACTIVRAC
TOTAL ACTIVA
Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol/LPG engines
Metropolitan FRANCE
9000 5W40
FUTUR 9000 5W30 (*)
New Caledonia
Guadeloupe
Saint martin
Reunion
Martinique
Guyana
Tahiti
Mauritius
Mayotte
(*) Blended oils for all engines, giving fuel economy.
9000 5W40
7000 10W40
7000 15W50
7000 10W40
15
Norms S.A.E: 10W40
TOTAL ACTIVA DIESEL
Oils specifically for diesel engines
7000 10W40
9000 5W40
7000 15W50
7000 10W50
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EUROPE
Germany
Austria
Belgium
Bosnia
Bulgaria
Cyprus
LUBRICANTS - TOTAL recommended oils
ENGINE OILS
TOTAL QUARTZ
Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol/LPG engines
9000 5W40
FUTUR 9000 5W30 (*)
7000 10W40
9000 0W40
7000 10W40
7000 10W40
9000 0W40
7000 10W40
9000 0W40
7000 10W40
7000 10W40
9000 15W40
7000 10W40
Croatia
(*) Blended oils for all engines, giving fuel economy.
16
TOTAL QUARTZ DIESEL
Oils specifically for diesel engines
7000 10W40
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EUROPE
LUBRICANTS - TOTAL recommended oils
ENGINE OILS
TOTAL QUARTZ
Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol/LPG engines
7000 10W40
9000 0W40
7000 10W40
7000 15W40
Denmark
Spain
Estonia
Finland
9000 5W40
FUTUR 9000 5W30 (*)
Great Britain
Greece
Holland
(*) Blended oils for all engines, giving fuel economy.
7000 10W40
9000 0W40
7000 10W40
7000 10W40
7000 15W40
7000 10W40
9000 0W40
17
TOTAL QUARTZ DIESEL
Oils specifically for diesel engines
7000 10W40
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EUROPE
LUBRICANTS - TOTAL recommended oils
ENGINE OILS
TOTAL QUARTZ
Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol/LPG engines
7000 10W40
9000 0W40
Hungary
Italy
Ireland
Iceland
9000 5W40
FUTUR 9000 5W30 (*)
Latvia
Lithuania
Macedonia
(*) Blended oils for all engines, giving fuel economy.
7000 10W40
7000 10W40
9000 0W40
7000 10W40
18
TOTAL QUARTZ DIESEL
Oils specifically for diesel engines
7000 10W40
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EUROPE
Malta
Moldavia
Norway
Poland
Portugal
Slovakia
Czech Republic
(*) Blended oils for all engines, giving fuel economy.
LUBRICANTS - TOTAL recommended oils
ENGINE OILS
TOTAL QUARTZ
Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol/LPG engines
7000 10W40
7000 15W50
7000 10W40
7000 10W40
9000 0W40
9000 5W40
FUTUR 9000 5W30 (*)
7000 10W40
7000 10W40
9000 0W40
19
TOTAL QUARTZ DIESEL
Oils specifically for diesel engines
7000 10W40
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EUROPE
LUBRICANTS - TOTAL recommended oils
ENGINE OILS
TOTAL QUARTZ
Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol/LPG engines
7000 10W40
7000 15W50
9000 0W40
Romania
Russia
Slovenia
Sweden
Switzerland
Turkey
(*) Blended oils for all engines, giving fuel economy.
9000 5W40
FUTUR 9000 5W30 (*)
7000 10W40
9000 0W40
7000 10W40
7000 10W40
9000 15W50
9000 0W40
20
TOTAL QUARTZ DIESEL
Oils specifically for diesel engines
7000 10W40
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EUROPE
Ukraine
Serbia-Montenegro
LUBRICANTS - TOTAL recommended oils
ENGINE OILS
TOTAL QUARTZ
Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol/LPG engines
TOTAL QUARTZ DIESEL
Oils specifically for diesel engines
9000 5W40
FUTUR 9000 5W30 (*)
7000 10W40
9000 0W40
7000 10W40
(*) Blended oils for all engines, giving fuel economy.
21
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OCEANIA
Australia
New Zealand
LUBRICANTS - TOTAL recommended oils
ENGINE OILS
TOTAL QUARTZ
Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol/LPG engines
9000 5W40
FUTUR 9000 5W30 (*)
7000 10W40
AFRICA
TOTAL QUARTZ
Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol/LPG engines
Algeria, South Africa,
Ivory Coast, Egypt,
Gabon, Ghana, Kenya,
Madagascar, Morocco,
Nigeria, Senegal, Tunisia
(*) Blended oils for all engines, giving fuel economy.
9000 5W40
7000 10W40
7000 15W50
22
TOTAL QUARTZ DIESEL
Oils specifically for diesel engines
7000 10W40
TOTAL QUARTZ DIESEL
Oils specifically for diesel engines
7000 10W40
Angl. T3 page001-31-2005 4/02/05 14:15 Page 23
CENTRAL AND SOUTH AMERICA
LUBRICANTS - TOTAL recommended oils
ENGINE OILS
TOTAL QUARTZ
Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol/LPG engines
TOTAL QUARTZ DIESEL
Oils specifically for diesel engines
Argentina
Brazil
Chile
Cuba
Mexico
Paraguay
Uruguay
9000 5W40
7000 10W40
7000 15W50 7000 10W40
23
Angl. T3 page001-31-2005 4/02/05 14:15 Page 24
SOUTH-EAST ASIA
China
South Korea
LUBRICANTS - TOTAL recommended oils
ENGINE OILS
TOTAL QUARTZ
Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol/LPG engines
7000 10W50
7000 15W50
9000 5W40
FUTUR 9000 5W30 (*)
7000 10W40
Hong Kong
India - Indonesia
Japan
9000 5W40
9000 5W40
FUTUR 9000 5W30 (*)
Malaysia
Pakistan
(*) Blended oils for all engines, giving fuel economy.
9000 5W40
24
7000 15W50
7000 10W40
7000 15W50
7000 15W50
TOTAL QUARTZ DIESEL
Oils specifically for diesel engines
7000 10W40
Angl. T3 page001-31-2005 4/02/05 14:15 Page 25
SOUTH-EAST ASIA
LUBRICANTS - TOTAL recommended oils
ENGINE OILS
TOTAL QUARTZ
Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol/LPG engines
Philippines
Singapore
Taiwan
Thailand
Vietnam
(*) Blended oils for all engines, giving fuel economy.
9000 5W40
7000 15W50
7000 10W40
7000 15W50
7000 15W50
TOTAL QUARTZ DIESEL
Oils specifically for diesel engines
7000 10W40
25
Angl. T3 page001-31-2005 4/02/05 14:15 Page 26
MIDDLE EAST
Saudi Arabia - Bahrain
Dubai
United Arab Emirates
Iran
Israel - Jordan - Kuwait - Lebanon
Oman - Qatar - Syria - Yemen
LUBRICANTS - TOTAL recommended oils
ENGINE OILS
TOTAL QUARTZ
Blended oils for all engines
Oils specifically for petrol and dual-fuel petrol/LPG engines
TOTAL QUARTZ DIESEL
Oils specifically for diesel engines
9000 5W40
7000 15W50
7000 10W40
7000 15W50
7000 15W50
7000 10W40
26
Angl. T3 page001-31-2005 4/02/05 14:15 Page 27
Manual and piloted manual gearboxes
MB3 automatic gearbox
4HP20 and AL4 autoactive automatic gearboxes
Transfer box and rear axle
LUBRICANTS - TOTAL recommended oils
GEARBOX OILS
AM6 autoactive automatic gearbox
All countries
TOTAL TRANSMISSION BV
Norms S.A.E: 75W80
Part No.: 9730 A2
TOTAL FLUIDE ATX
TOTAL FLUIDE AT 42
Special oil distributed by
CITROËN
Part No.: 9730 A6
Special oil distributed by
CITROËN
Part No.: 9736 22
Special oil distributed by
CITROËN
Part No.: 9980 D4
TOTAL TRANSMISSION X4
Part No.: 9730 A7
27
Angl. T3 page001-31-2005 4/02/05 14:15 Page 28
Power steering all vehicles
(except CITROËN C4 and C5)
LUBRICANTS - TOTAL recommended oils
POWER STEERING OILS
All countries
Power steering
C4 and C5
TOTAL FLUIDE ATX
TOTAL FLUIDE LDS
Special oil distributed by CITROËN
Part No.: 9979 A3
Power steering
Very cold countries
TOTAL FLUIDE DA
Special oil distributed by CITROËN
Part No.: 9730 A1
ENGINE COOLANT FLUID
All countries
CITROËN fluid
Protection: -35C°
Packs
2 Litres
5 Litres
20 Litres
210 Litres
CITROËN Part No.
GLYSANTIN G33 REVKOGEL 2000
9979 70 9979 72
9979 71
9979 76
9979 77
9979 73
9979 74
9979 75
28
Angl. T3 page001-31-2005 4/02/05 14:15 Page 29
All countries
LUBRICANTS - TOTAL recommended oils
BRAKE FLUID
Synthetic brake fluid
CITROËN fluid
Norm
Orange
Packs
0,5 Litre
1 Litre
5 Litres
HYDRAULIC SYSTEM
Packs
All countries
TOTAL FLUIDE LDS
TOTAL LHM PLUS
TOTAL LHM PLUS
Very cold countries
Colour
Green
1 Litre
WARNING: TOTAL FLUIDE LDS fluid cannot be blended with TOTAL LHM PLUS.
CITROËN Part No.
9979 05
9979 06
9979 07
CITROËN Part No.
9979 A3
9979 A1
9979 A2
WARNING: CITROËN C5: Use exclusively TOTAL FLUIDE LDS suspension fluid.
All countries
TOTAL HYDRAURINCAGE
29
Angl. T3 page001-31-2005 4/02/05 14:15 Page 30
All countries
All countries
LUBRICANTS - TOTAL recommended oils
SCREEN WASH FLUID
Packs
Concentrated: 250 ml
1 Litre
Fluid ready to use
5 Litres
9980 33
9980 06
9980 05
CITROËN Part No.
ZC 9875 953U
ZC 9875 784U
ZC 9885 077U
GREASING
General use
TOTAL MULTIS 2
TOTAL SMALL MECHANISMS
9980 56
ZC 9875 279U
Norms NLGI
2
Note: NLGI = National Lubrificating Grease Institude.
30
Angl. T3 page001-31-2005 4/02/05 14:15 Page 31
ENGINE OIL CONSUMPTION
I - Oil consumption depends on:
- the engine type.
- how run-in or worn it is.
- the type of oil used.
- the driving conditions.
II - An engine can be considered RUN-IN after:
- 3,000 miles (5,000 km) for a PETROL engine.
- 6,000 miles (10,000 km) for a DIESEL engine.
III - MAXIMUM PERMISSIBLE oil consumption for a RUN-IN engine:
- 0.5 litres per 600 miles (1,000 km) for a PETROL engine.
- 1 litre per 600 miles (1,000 km) for a DIESEL engine.
DO NOT INTERVENE BELOW THESE VALUES.
IV - OIL LEVEL: The level should NEVER be above the MAX. mark on the dipstick after changing or topping up the oil:
- This excess oil will be used up rapidly.
- It will reduce the engine output and adversely affect the operation of the air circuits and gas recycling.
31
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C5 - C8
Engine type
Cubic capacity (cc)
Bore/stroke
Compression ratio
Power ISO or EEC (KW - rpm)
Torque ISO or EEC (m.daN - rpm)
1.8i 16V
6FZ
1749
82,7/81,4
10,8/1
85-5500
16-4000
ENGINE SPECIFICATIONS
Engines: 6FZ - RFJ - RFN - 3FZ - XFU - XFW
Petrol
2.0i 16V 2.2i 16V
RFJ RFN
11/1
103-6000
20-4000
1997
85/88
100-6000
19-4100
10,8/1
3FZ
2230
86/96
116-5650
21,7-3900
3.0i 24S
XFU
2946
87/82,5
10,9/1
152-6000
28,5-3750
XFW
32
Angl.T3-page032-190-2005 4/02/05 15:15 Page 33
Engine type
Cubic capacity (cc)
Bore/stroke
Compression ratio
Power ISO or EEC (KW - rpm)
Torque ISO or EEC (m.daN - rpm)
ENGINE SPECIFICATIONS
Engines: 9HZ - RHM - RHT - RHW - RHL - RHR - 4HX - 4HW
Diesel
1.6 16V
HDi
2.0 16V HDi
9HZ
1560
75/88,3
18/1
80-4000
24-1750
RHM RHT RHW
1997
85/88
79-4000
25-1750
17,3/1
27-1750
80-4000
C5 - C8
2.2 16V HDi
RHL RHR 4HX
2179
4HW
85/96
17,6/1 18/1
93-4000 100-4000 98-4000 94-4000
32-2000 31,4-2000
33
Angl.T3-page032-190-2005 4/02/05 15:15 Page 34
C5 COMPRESSION RATIO - DIESEL ENGINES
ENGINE
DV6 DW12
DW10
COMPRESSION
RATIO
20 ± 5
30 ± 5
In bars
MAX. DIFFERENCE
BETWEEN CYLINDERS
5
34
Angl.T3-page032-190-2005 4/02/05 15:15 Page 35
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: 6FZ - RFJ
6
7
4
5
1
2
3
8
9
10
11
Fitting of the LH support.
A = EW10A and EW7J4 engines with BE4 gearbox.
B = EW10A engine with AL4 gearbox.
B1BP32ZP
35
C5
4,5 ± 0,5
6 ± 0,6
6 ± 0,6
5,5 ± 0,5
4,5 ± 0,4
6 ± 0,6
2,8 ± 0,2
4,5 ± 0,4
6 ± 0,6
6 ± 0,6
6 ± 0,6
Angl.T3-page032-190-2005 4/02/05 15:15 Page 36
C5
Accessories drive pulley
Tightening
Angular tightening
Con rod cap screws
Pre-tightening
Tightening
Angular tightening
Sump
Timing belt guide roller
Timing belt tensioner roller
Accessories drive belt guide roller
Pre-tightening
Tightening
Accessories drive belt tensioner roller
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: 6FZ - RFJ
Crankshaft
6FZ
4 ± 0,4
53° ± 4°
Cylinder block
1 ± 0,1
2,3 ± 0,2
46° ± 5°
0,8 ± 0,2
3,7 ± 0,3
2,1 ± 0,2
1,5 ± 0,1
3,7 ± 0,3
2 ± 0,2
RFJ
4 ± 0,4
40° ± 4°
36
Angl.T3-page032-190-2005 4/02/05 15:15 Page 37
Camshaft bearing covers
Exhaust manifold
Valve cover
Camshaft pulley
Pre-tightening
Tightening
Inlet camshaft pulley
Pre-tightening
Tightening
Exhaust camshaft pulley
Pre-tightening
Tightening
Cap
Flywheel
Pre-tightening
Angular tightening
Clutch mechanism
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: 6FZ - RFJ
Cylinder block
C5
6FZ RFJ
0,9 ± 0,1
3,5 ± 0,3
1,1 ± 0,1
3 ± 0,5
8,5 ± 0,5
2 ± 0,2
11 ± 1
3 ± 0,5
8,5 ± 0,5
1,1 ± 0,1
Flywheel/clutch
2,5 ± 0,2
21° ± 3°
2 ± 0,2
37
Angl.T3-page032-190-2005 4/02/05 15:15 Page 38
C5
Oil pump
Common injection rail fixing screw
Coolant pump
Coolant outlet housing
Coolant outlet housing
Tightening the screws to:
Tightening the nuts to:
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: 6FZ - RFJ
6FZ
Lubrication circuit
0,9 ± 0,1
RFJ
Injection circuit
0,9 ± 0,1
Cylinder block
0,9 ± 0,1
1,4 ± 0,1
0,3 ± 0,1
1 ± 0,1
38
Angl.T3-page032-190-2005 4/02/05 15:15 Page 39
SPECIAL FEATURES: POWER UNIT SUSPENSION
Upper RH engine support
Intermediate engine support
B1BK1X5D
Ref.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Engines: RFN - 3FZ
Description
Gearbox type
Rod/body fixing screw
Engine support/torque reaction rod flexible stop pin
Upper support/intermediate support fixing screw
Upper support/body fixing screw
Upper support/flexible support fixing nut
Support
LH flexible support/LH engine support fixing nut
BE4/5
RFN
AL4
5 ± 0,5
4,5 ± 0,4
6,5 ± 0,6
3 ± 0,3
4,5 ± 0,4
6,5 ± 0,6
(8)
3 ± 0,3
B1BK1X6D
(9)
(10)
(11)
LH flexible support/body fixing screw
Intermediate engine support/gearbox casing fixing screw
LH intermediate support/gearbox fixing screw
Flexible support pin
39
6 ± 0,6
4,5 ± 0,4
5 ± 0,5
C8
3FZ
ML5C
4,5 ± 0,4
Angl.T3-page032-190-2005 4/02/05 15:15 Page 40
C8
Intermediate engine support
SPECIAL FEATURES: POWER UNIT SUSPENSION
Engines: RFN - 3FZ
Ref.
Description
Gearbox type BE4/5
RFN
AL4
(12) 9 ± 0,9
(13)
(14)
Lower RH rod/subframe fixing screw
Lower RH engine support/cylinder block fixing screw
Lower rod/lower RH engine support fixing screw
4,5 ± 0,4
6,5 ± 0,6
3FZ
ML5C
B1BK1X7D
40
Angl.T3-page032-190-2005 4/02/05 15:15 Page 41
B1BK1X8D
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: RFN - 3FZ
Crankshaft bearing cap cover (15)
Description
Pre-tightening
Slackening
Re-tightening
Angular tightening
M11
1 ± 0,1
Yes
1 ± 0,1 then 2 ± 0,2
70° ± 5°
Crankshaft
M6
0,5
No
1 ± 0,1
C8
Description
Pre-tightening
Slackening
Re-tightening
Angular tightening
(16) Con rod caps
1 ± 0,1
Yes
2,5 ± 0,2
46° ± 5°
(17) Crankshaft flywheel fixing
2,5 ± 0,2
18° ± 1°
1 ± 0,1
22° ± 2°
41
Angl.T3-page032-190-2005 4/02/05 15:15 Page 42
C8
Engine: RFN
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Equipment on cylinder head
Engine: 3FZ
Description
Pre-tightening
Tightening
Description
Tightening
B1BK1X9D
(18) Camshaft bearing cap covers
0,5
1 ± 0,1
(20) Inlet manifold
1 ± 0,1
42
(19) Cylinder head covers
0,5
1,5 ± 0,1
(21) Exhaust manifold
3,5 ± 0,3
B1BK1XAD
Angl.T3-page032-190-2005 4/02/05 15:15 Page 43
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: XFU
Lower RH engine support/torque reaction rod
1
2
3
LH engine support
4
5
6
7
RH engine support
8 and 9
10
11
12
C5
6 ± 0,5
1 ± 0,1
6 ± 0,5
3 ± 0,3
6,5 ± 0,6
5 ± 0,5
4,5 ± 0,4
6 ± 0,6
4,5 ± 0,4
6 ± 0,6
6 ± 0,6
B1BP32YP
43
Angl.T3-page032-190-2005 4/02/05 15:15 Page 44
C5
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
1
2
3
4
Engine: XFU
Pencil type ignition coil
Sparking plug
Pre-tightening
Angular tightening
Valve cover
Pre-tightening
Tightening
Camshaft bearing cap cover
Pre-tightening
Tightening
Cylinder block
Pre-tightening
Slackening
Tightening
Angular tightening
B1BP27DP
44
0,8 ± 0,3
1 ± 0,1
90° ± 5°
0,5 ± 0,1
1 ± 0,1
0,2 ± 0,1
1 ± 0,1
2 ± 0,2
Yes
1,5 ± 0,1
225° ± 5°
Angl.T3-page032-190-2005 4/02/05 15:15 Page 45
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
5
6
7
Engine: XFU
Exhaust manifold
(with a new gasket)
Pre-tightening (sequence from 1 to 10)
Tightening (sequence from 1 to 10)
Con rod caps
Pre-tightening
Angular tightening
Flywheel
Pre-tightening
Angular tightening
C5
1 ± 0,1
3 ± 0,3
2 ± 0,2
74° ± 5°
2 ± 0,2
60° ± 5°
B1JP02LD
45
Angl.T3-page032-190-2005 4/02/05 15:15 Page 46
C5
B1BP2D3D
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
8
Crankshaft bearing
Engine: XFU
NOTE: Maximum length under heads for screws M11 = 131,5 mm.
NOTE: Maximum length under heads for screws M8 = 119 mm.
Perform the following operations:
- Brush the screw threads.
- Refit the screws having first pre-coated them with «MOLYKOTE G
RAPID PLUS» grease on the threads and under heads.
Check the presence of the eight centring pins
Pre-tighten the screws M11 (sequence from 1 to 8)
Pre-tighten the screws M8 (sequence from A to H)
Tighten the screws M6 (sequence from a to 1)
Slacken the screws M11 and M8
3 ± 0,3
1 ± 0,1
1 ± 0,1
Yes
Proceeding screw by screw
Tighten the screws M11 (sequence from 1 to 8)
Angular tightening
Tighten the screws M8 (sequence from A to H)
Angular tightening
3 ± 0,3
180°
1 ± 0,1
180°
46
Angl.T3-page032-190-2005 4/02/05 15:15 Page 47
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
9
10
11
12
13
Engine: XFU
Sump
Pre-tightening (sequence from 1 to 20)
Tightening (sequence from 1 to 20)
Crankshaft pinion
Pre-tightening
Angular tightening
Crankshaft pulley
Inlet distributor (with new seals)
Pre-tightening
Tightening
Air inlet manifold
Pre-tightening
Tightening
C5
0,5 ± 0,1
0,8 ± 0,1
4 ± 0,4
80°± 5°
2,5 ± 0,2
0,4 ± 0,1
0,8 ± 0,1
0,4 ± 0,1
0,8 ± 0,1
B1BP1GZD
47
Angl.T3-page032-190-2005 4/02/05 15:15 Page 48
C5
B1EP1FXD
B1FP04KC
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
14
15
16
17
18
20
21
22
19
Engine: XFU
Camshaft hubs
Pre-tightening
Angular tightening
Cap
Guide roller
Camshaft pulleys
Pre-tightening
Angular tightening
Camshaft pulleys
Timing belt tensioner roller
Plate for the dynamic tensioner roller
Coolant pump
Pre-tightening
Tightening
Oil pump
Pre-tightening
Tightening
48
2 ± 0,2
57° ± 5°
1,5 ± 0,1
8 ± 0,8
2 ± 0,2
115° ± 5°
1 ± 0,1
2,5 ± 0,2
2,5 ± 0,2
0,5 ± 0,1
0,8 ± 0,1
0,5 ± 0,1
0,8 ± 0,1
Angl.T3-page032-190-2005 4/02/05 15:15 Page 49
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: XFW
Power unit suspension
RH engine support (suspension) Gearbox suspension
C8
B1BK24RD
(2) Link rod fixing
(3) Link rod fixing
: 5 ± 0,5
: 4,5 ± 0,4
(4) Fixing of upper RH engine support on intermediate engine support flexible mounting
(5) Fixing of RH engine support on flexible mounting
(6) Fixing of flexible mounting
: 6 ± 0,6
: 4,5 ± 0,4
: 3 ± 0,3
(7) Fixing of RH intermediate engine support on cylinder block : 6 ± 0,6
(8) Fixing of gearbox support on LH flexible mounting
(9) Shaft
(10) Fixing of flexible mounting on suppor
(11) Fixing of flexible mounting support on body
(12) Fixing of flexible mounting support on body
49
B1BK24SD
: 6,5 ± 0,6
: 6,5 ± 0,6
: 3 ± 0,3
: 2,5 ± 0,2
: 2,5 ± 0,2
Angl.T3-page032-190-2005 4/02/05 15:15 Page 50
C8 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: XFW
Power unit suspension - Engine support (lower) Crankshaft
(13) Torque reaction link rod fixing
(14) Fixing of link rod on torque reaction flexible mounting
(15) Fixing of torque reaction flexible mounting
B1BK24TD
: 9 ± 0,9
: 6,5 ± 0,6
: 4,5 ± 0,4
(16) Fixing of heat shield on torque reaction flexible mounting : 1 ± 0,1
B1BK24UD
(17) Bearing plug
(18) Timing pinion
Tightening
Angular tightening
Tightening
Angular tightening
: 2 ± 0,2
: 74° ± 7°
: 4 ± 0,4
: 80° ± 8°
(19) Fixing of starter gear support flange, plus crankshaft converter support
Tightening
: 2 ± 0,2
Angular tightening
(20) Accessory pulley on timing pinion
: 60° ± 6°
: 2,5 ± 0,2
50
Angl.T3-page032-190-2005 4/02/05 15:15 Page 51
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: XFW
Crankshaft
Bearing cap cover
C8
B1BK24VD
Respect the sequence of stages and the order of tightening
Ref./description
M11 (bolts from 1 to 8)
M8 (bolts from 9 to 16)
(21) Fixings of bearings/plug covers or bearings/plugs
21) Fixings of bearings/plug covers or bearings/plugs
(slacken to zero torque)
Stage 1
3 ± 0,3
Stage 4
YES
Stage 2
1 ± 0,1
Stage 4
YES
M6
Stage 3
1 ± 0,1
NO
(21) Fixings of bearing plug cover or bearing plugs (tighten bolt by bolt)
Tightening
+ Angular tightening
51
Stage 5
3 ± 0,3
180°
Stage 6
1 ± 0,1
180°
Angl.T3-page032-190-2005 4/02/05 15:15 Page 52
C8
Lubrication circuit.
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: XFW
Lubrication circuit
Oil sump
(22) Oil separator
(23) Strainer
(24) Induction pipe
(25) Drain plug
(26) Oil filter sleeve (with coolant/oil exchanger)
Oil filter
B1BK24WD
: 0,8
: 0,8
: 0,8
: 3 ± 0,3
: 0,5
: 0,2
B1BK24XD
Respect the sequence of stages and the order of tightening
Stage 1: Do up bolts 13,15 and 17.
Stage 2: Tighten bolts 13,15 and 17 to
: 0,2.
Stage 3: Do up the 17 remaining bolts.
Stage 4: Tighten the remaining bolts to
Stage 5: Tighten all the bolts
: 0,5.
: 0,8.
Stage 6: Repeat the tightening a few times in the same order to obtain a tightening torque of 0,8 m.daN on all the bolts.
52
Angl.T3-page032-190-2005 4/02/05 15:15 Page 53
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: XFW
Lubrication circuit
Oil pump
Cooling circuit
Coolant pump
C8
B1BK3B6D
Respect the sequence of stages and the order of tightening
Stage 1: Position the screws and do them up by hand.
Stage 2: Pre-tighten the screws
Stage 3: Tighten the screws
Stage 4: Repeat the tightening a few times in the same order to obtain a tightening torque of 0,8 m.daN on all the screws.
: 0,5.
: 0,8.
B1BK3B7D
Stage 1: Position the screws and do them up by hand.
Stage 2: Pre-tighten the screws
: 0,5.
Stage 3: Tighten the screws
: 0,8.
Stage 4: Repeat the tightening a few times in the same order to obtain a tightening torque of 0,8 m.daN on all the screws.
53
Angl.T3-page032-190-2005 4/02/05 15:15 Page 54
C8
Lubrication circuit
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: XFW
Cylinder head equipment
Coolant manifold
(27) Screws
(28) Screws
(29) Screws
B1BK24YD
: 2,5 ± 0,2
: 0,8
: 0,8
54
B1BK24ZD
Angl.T3-page032-190-2005 4/02/05 15:15 Page 55
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Camshaft bearing cap cover (right hand side)
Engine: XFW
Cylinder head equipment
Camshaft bearing cap cover (left hand side)
C8
B1EK0GCC
Respect the sequence of stages and the order of tightening
(30) Camshaft bearing cap cover or camshaft bearing:
- Pre-tightening
- Tightening
: 0,2
: 1
55
B1BK3B8D
Angl.T3-page032-190-2005 4/02/05 15:15 Page 56
C8
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: XFW
Cylinder head equipment
Valve covers (right hand side) Valve covers (left hand side)
(31) Valve cover:
- Pre-tightening
- Tightening
B1EK0GEC
Respect the sequence of stages and the order of tightening
: 0,5
: 0,8
56
B1EK0GFC
Angl.T3-page032-190-2005 4/02/05 15:15 Page 57
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: XFW
Cylinder head equipment
Inlet manifold
C8
(32) Inlet manifold:
- Pre-tightening
- Tightening
Respect the sequence of stages and the order of tightening
: 0,4
: 0,8
57
B1BK251D
Angl.T3-page032-190-2005 4/02/05 15:15 Page 58
C8
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: XFW
Cylinder head equipment
Exhaust manifold (right hand side) Exhaust manifold (left hand side)
(33) Exhaust manifold:
- Pre-tightening
- Tightening
B1JK03ND
Respect the sequence of stages and the order of tightening
: 1
: 3 ± 0,3
58
B1JK03LD
Angl.T3-page032-190-2005 4/02/05 15:15 Page 59
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: XFW
Cylinder head equipment
Inlet distributor
C8
(34) Inlet distributor:
- Pre-tightening
- Tightening
Respect the sequence of stages and the order of tightening
: 0,4
: 0,8
59
B1BK252D
Angl.T3-page032-190-2005 4/02/05 15:15 Page 60
C5
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: 9HZ
Torque reaction rod
1
2
10
Upper LH engine support
3
Lower LH engine support
4
Lower RH engine support
5
RH engine support
6
7
8
9
B1BP32EP
60
6 ± 0,6
6 ± 0,6
6 ± 0,6
5,5 ± 0,5
6 ± 0,6
5,5± 0,5
4,5 ± 0,4
6 ± 0,6
6 ± 0,6
6 ± 0,6
Angl.T3-page032-190-2005 4/02/05 15:15 Page 61
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: 9HZ
Crankshaft
Bearing cap fixing screws
Pre-tightening
Slackening
Tightening
Angular tightening
Con rod screws
Pre-tightening
Angular tightening
Accessories drive belt pulley
Pre-tightening
Angular tightening
Cylinder block
Sump
Timing belt guide roller
Timing belt tensioner roller
61
C5
1 ± 0,2
180° ± 5°
3 ± 0,3
140° ± 5°
1 ± 0,1
100° ± 5°
3,5 ± 0,3
190° ± 5°
1,3 ± 0,1
3,7 ± 0,3
2,7 ± 0,2
Angl.T3-page032-190-2005 4/02/05 15:15 Page 62
C5
Camshaft bearing covers
Pre-tightening
Tightening
Oil trap
Air inlet manifold
Tightening
Pre-tightening
Tightening
Exhaust manifold
Camshaft pulleys
Pre-tightening
Angular tightening
Cylinder block
Pre-tightening
Tightening
Angular tightening
Exhaust gas recycling (EGR) electrovalve
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: 9HZ
Cylinder block
62
0,5 ± 0,1
1 ± 0,1
1 ± 0,1
1 ± 0,1
0,1
0,9 ± 0,1
3 ± 0,3
2 ± 0,2
50° ± 5°
2 ± 0,2
4 ± 0,4
260° ± 5°
1 ± 0,1
Angl.T3-page032-190-2005 4/02/05 15:15 Page 63
Double damping flywheel
Pre-tightening
Angular tightening
Clutch mechanism
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: 9HZ
Flywheel
Lubrication circuit
Oil pump assembly
Pre-tightening
Tightening
Oil/coolant heat exchanger
Lubrication pipe for turbocharger
63
C5
3 ± 0,3
90° ± 5°
2 ± 0,2
0,5 ± 0,1
0,9 ± 0,1
1 ± 0,1
3 ± 0,3
Angl.T3-page032-190-2005 4/02/05 15:15 Page 64
C5
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: 9HZ
Diesel injection circuit
Injector fixing flange nut
Pre-tightening
Angular tightening
Fuel high pressure common injection rail on engine block
Unions on fuel high pressure common injection rail
Pre-tightening
Tightening
Union on diesel injector
Pre-tightening
Tightening
Diesel injection pump on support
Diesel injection pump pulley
Union on diesel high pressure pump
Pre-tightening
Tightening
Cooling circuit
Coolant pump
Pre-tightening
Tightening
Coolant outlet housing
Pre-tightening
Tightening
64
0,4 ± 0,1
65° ± 5°
2,2 ± 0,2
2 ± 0,2
2,5 ± 0,2
2 ± 0,2
2,5 ± 0,2
2,2 ± 0,2
5 ± 0,5
2 ± 0,2
2,5 ± 0,2
0,3 ± 0,1
0,9 ± 0,1
0,3 ± 0,1
0,7 ± 0,1
Angl.T3-page032-190-2005 4/02/05 15:15 Page 65
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: RHL - RHR
6
7
4
5
1
2
3
10
11
8
9
C5
6 ± 0,6
6 ± 0,6
6 ± 0,6
5,6 ± 0,5
4,5 ± 0,4
5 ± 0,5
5 ± 0,5
5 ± 0,5
5,5 ± 0,5
6 ± 0,6
5 ± 0,5
B1BP337P
65
Angl.T3-page032-190-2005 4/02/05 15:15 Page 66
C5
Bearing cap fixing screws
Pre-tightening
Angular tightening
Con rod nuts
Pre-tightening
Slackening
Tightening
Angular tightening
Accessories drive pulleys
Pre-tightening
Angular tightening
Piston skirt spray jet (renovation)
Sump
Timing belt guide roller
Timing belt tensioner roller
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: RHL RHR
Crankshaft
Cylinder block
66
2,5 ± 0,2
60° ± 5°
1 ± 0,1
180° ± 5°
2,3 ± 0,2
45° ± 5°
7 ± 0,7
60° ± 5°
1 ± 0,1
1,6 ± 0,1
2,5 ± 0,2
2,1 ± 0,2
Angl.T3-page032-190-2005 4/02/05 15:15 Page 67
Camshaft bearing covers
Exhaust manifold
Inlet valve cover
Camshaft pinion
Cylinder head
Pre-tightening
Tightening
Slackening (1 turn)
Tightening
Angular tightening
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: RHL RHR
Cylinder block
Flywheel/clutch
Flywheel
Pre-tightening
Tightening
Clutch mechanism
67
C5
1 ± 0,1
3 ± 0,3
0,9 ± 0,1
4,3 ± 0,4
2,2 ± 0,2
6 ± 0,6
360°
6 ± 0,6
220° ± 5°
1,5 ± 0,1
4,8 ± 0,4
2 ± 0,2
Angl.T3-page032-190-2005 4/02/05 15:15 Page 68
C5
Oil pump
Oil/coolant heat exchanger
Lubrication pipe for turbocharger
Engine end
Turbocharger end
Diesel injector
Tightening by hand
Tightening
Angular tightening
Union on injection rail
Injection pump
Union on diesel injector
Union on injection pump
Coolant pump
Coolant inlet housing
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: RHL - RHR
Lubrication circuit
Diesel injection circuit
Cooling circuit
68
1,3 ± 0,1
5,8 ± 0,5
4,7 ± 0,4
2,2 ± 0,2 yes
0,4 ± 0,1
45° ± 5°
2,5 ± 0,2
2 ± 0,2
2,5 ± 0,2
2,5 ± 0,2
1,6 ± 0,1
2 ± 0,2
Angl.T3-page032-190-2005 4/02/05 15:15 Page 69
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: RHL - RHR
Diesel injection circuit
Injector fixing flange nut
Pre-tightening
Angular tightening
Fuel high pressure common injection rail on engine block
Unions on fuel high pressure common injection rail
Pre-tightening
Tightening
Injection on diesel injector
Pre-tightening
Tightening
Diesel injection pump on support
Diesel injection pump pulley
Union on diesel high pressure pump
Pre-tightening
Tightening
Cooling circuit
Coolant pump
Pre-tightening
Tightening
Coolant outlet housing
Pre-tightening
Tightening
69
C5
0,4 ± 0,1
65° ± 5°
2,2 ± 0,2
2 ± 0,2
2,5 ± 0,2
2 ± 0,2
2,5 ± 0,2
2,2 ± 0,2
5 ± 0,5
2 ± 0,2
2,5 ± 0,2
0,3 ± 0,1
0,9 ± 0,1
0,3 ± 0,1
0,7 ± 0,1
Angl.T3-page032-190-2005 4/02/05 15:15 Page 70
C8
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: RHM - RHT - RHW
B1BK3EPD
Crankshaft
(1) Pulley screw M14x150-70
Pre-tightening
Angular tightening
(2) Screws M7x100-20 (x 4)
Pre-tightening
Tightening
(3) Screws M7x100-40 (x 2) (*)
Pre-tightening
Tightening
(4) Plug CHC M12x150-16 (x 1)
(5) Plug M15x150 (x 1)
(6) Plugs M15x150 (x 2)
(7) Screws M9x100-24 (+loctite FRENETANCH) (x8)
(8) Screws M12x150-81 (x10)
Pre-tightening
Angular tightening (**)
(9) Nuts M9x100 (x8)
Pre-tightening
Angular tightening
(10) Screws M16x10-16 (x4)
(*) = Re-use prohibited.
(**) = Tighten in a spiral commencing from the inside.
70
5 ± 0,5
62°
0,7 ± 0,1
1,5 ± 0,1
0,7 ± 0,1
1,5 ± 0,1
2,5 ± 0,2
2,5 ± 0,2
4 ± 0,4
4,8 ± 0,5
2,5 ± 0,2
60°
2 ± 0,2
70°
1 ± 0,1
Angl.T3-page032-190-2005 4/02/05 15:15 Page 71
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: RHM - RHT - RHW
Engine suspension (identification)
(1)
Upper RH torque reaction rod
B1BK3EED
(2)
Upper RH engine support
(3)
RH engine flexible support
(4)
Upper RH intermediate engine support
(5)
Lower RH engine support
(6)
Torque reaction rod
(7)
Upper LH intermediate engine support
(8)
LH engine support
(9)
LH engine flexible support
(10)
Lifting attachment, flywheel end
(11)
Lifting attachment, timing end
C8
71
Angl.T3-page032-190-2005 4/02/05 15:15 Page 72
C8
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: RHM - RHT - RHW
B1BK3EDD
Engine suspension (tightening torques)
(12)
Spherical-base screw M10x150-75 (x 1)
(13)
Shaft screw (x 1)
(14)
Nut M10x150 (x 1)
(15)
Screws M10x150-60 (x 3)
(16)
Screws M8x125-25 (x 2)
(17)
Shouldered shaft screw M8x125-15 (x 1)
(18)
Locking screw M10x125-85 (x 1)
(19)
Locking screw M10x125-70 (x 2)
(20)
Spherical-base screw M10x150-35 (x 3)
(21)
Spherical-base screw M10x150-72 (x 1)
(22)
Spherical-base screw M12x175-60 (x 1)
(23)
Nut M10x150 (x 1)
(24)
Screws M10 x150-55 (x 2)
(25)
Support shaft (x 1)
(26)
Screws M8x125-25 (x 4)
(27)
Screws M8x125-25 (x 2)
(28)
Locking nut M12x175-18 (x 1)
(29)
Screws M8x125-25 (x 1)
(30)
Screws M6x100-20 (x 2)
72
5 ± ,05
4,5 ± 0,4
4,5 ± 0,4
6 ± 0,6
3 ± 0,3
2 ± 0,2
4,5 ± 0,4
4,5 ± 0,4
4,5 ± 0,4
6,5 ± 0,6
9 ± 0,9
4,5 ± 0,4
4,5 ± 0,4
5 ± 0,5
2,5 ± 0,2
3 ± 0,3
6,5 ± 0,6
1,5 ± 0,1
1,2 ± 0,1
Angl.T3-page032-190-2005 4/02/05 15:15 Page 73
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
C8
Engines: RHM - RHT - RHW
Power steering pump
(1)
Power steering pump
(2)
Screws M8x125-30 (x 1)
(3)
Shouldered shaft screw M8x125-22 (x 1)
2,5 ± 0,2
2,2 ± 0,2
(4)
Shouldered shaft screw M8x125-48 (x 1)
2,2 ± 0,2
NOTE: Tightening the fixings (2) and (3) before the fixing (4), to ensure that the auxiliary drive belt is correctly aligned.
B1BK3E8D
Alternator
(5)
Alternator
(6)
Spherical-base screw M10 x150-50 (x 2)
(7)
Screws M10x150-40 (x 1)
4,1 ± 0,4
3,9 ± 0,4
NOTE: Tightening the fixings (6) before the fixing (7), to ensure that the auxiliary drive belt is correctly aligned.
B1BK3E7D
73
Angl.T3-page032-190-2005 4/02/05 15:15 Page 74
C8
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: RHM - RHT - RHW
Air conditioning compressor
(8)
(9)
Air conditioning compressor
Spherical-base screw M10x150-60 (x 1)
(10)
Shouldered shaft screw M10x150-52 (x 2)
4 ± 0,4
4,2 ± 0,4
NOTE: Tightening the fixing (9) before the fixing (10), to ensure that the auxiliary drive belt is correctly aligned.
B1EK3E9D
B1EK3EAD
Accessories support
(11)
Power steering pump support
(12)
Spherical-base screw M8 x125-35 (x 2) (*)
Pre-tightening
Tightening
(13)
Screws M8x125-80 (x 1) (*)
Pre-tightening
Tightening
(*) = In the order indicated (1 to 5).
74
1 ± 0,1
2 ± 0,2
1 ± 0,2
2 ± 0,2
Angl.T3-page032-190-2005 4/02/05 15:15 Page 75
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: RHM - RHT - RHW
(14)
Dynamic tensioner roller
Guide roller
(15)
(16)
(17)
Eccentric guide roller
Screws M10x150-50 (x 1)
Pre-tightening
Tightening
Screws M8x150-60 (x 1)
Pre-tightening
Tightening
B1BK3EWD
C8
1 ± 0,1
4,3 ± 0,4
2 ± 0,2
4,5 ± 0,4
75
Angl.T3-page032-190-2005 4/02/05 15:15 Page 76
C5
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: 4HX
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Tightening torques (m.daN).
: 4,5 ± 0,5
: 5 ± 0,5
: 5 ± 0,5
: 2,7 ± 0,3
: 4,5 ± 0,5
: 2,1 ± 0,2
: 4,5 ± 0,5
: 6,1 ± 0,6
: 4,5 ± 0,5
: 5 ± 0,5
: 5 ± 0,5
B1BP284P
76
Angl.T3-page032-190-2005 4/02/05 15:15 Page 77
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: 4HX
Crankshaft
Crankshaft bearing cap screws
Pre-tightening
Angular tightening
Con rod cap screws
Tightening
Slackening
Tightening
Angular tightening
Accessories drive pulley
Tightening
Angular tightening
2,5 ± 0,2
60°
1 ± 0,1
180°
2,3 ± 0,1
46° ± 5°
7 ± 0,25
60° ± 5°
C5
77
Angl.T3-page032-190-2005 4/02/05 15:15 Page 78
C5
Piston skirt spray jets
Sump
Pre-tightening
Tightening
Timing belt guide roller
Pre-tightening
Tightening
Timing belt tensioner roller
RH engine support
Pre-tightening the 4 screws
Tightening the screws Ø 8
Tightening the screws Ø 10
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: 4HX
Cylinder block
1 ± 0,1
1 ± 0,1
1,6 ± 0,3
1,5 ± 0,1
4,3 ± 0,4
2,5 ± 0,2
1 ± 0,1
2 ± 0,2
4,5 ± 0,2
78
Angl.T3-page032-190-2005 4/02/05 15:15 Page 79
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: 4HX
Cylinder block
Camshaft bearing cap cover
Tightening
Pre-tightening the 28 screws Ø 6
Tightening the 28 screws Ø 6
Exhaust manifold
Pre-tightening the 8 nuts
Tightening the 8 nuts
Valve cover
Pre-tightening the 13 screws
Tightening the 13 screws
Camshaft pulley hub
Pulley on hub
Flywheel - Clutch
Flywheel
Pre-tightening
Tightening
Clutch mechanism
1 ± 0,1
6 ± 0,5
1 ± 0,1
1,5 ± 0,1
0,3 ± 0,3
0,5 ± 0,15
9 ± 0,1
4,3 ± 0,4
2 ± 0,2
1,5 ± 0,1
4,7 ± 0,4
2 ± 0,2
79
C5
Angl.T3-page032-190-2005 4/02/05 15:15 Page 80
C5
Oil pump
Pre-tightening
Tightening
Oil/coolant heat exchanger
Turbocharger lubrication tube
Engine end
Turbocharger end
Diesel injector
Do up the 2 nuts
Tightening
Angular tightening
Union on injection rail
Injection pump on support
Union on diesel injector
Injection pump pulley
Union on injection pump
Coolant pump
Coolant inlet housing
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: 4HX
Lubrication circuit
0,7
0,9 ± 0,1
5,8 ± 0,5
3 ± 0,3
2 ± 0,2
Diesel injection circuit
By hand
4 ± 0,3
45° ± 5°
2 ± 0,2
2,25 ± 0,3
2 ± 0,2
5 ± 0,5
2 ± 0,2
Cooling circuit
1,6 ± 0,3
2 ± 0,2
80
Angl.T3-page032-190-2005 4/02/05 15:15 Page 81
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: 4HW
Crankshaft
(1) Pulley screw M14x150-70
Pre-tightening
Angular tightening
(2) Screws M7x100-40 (x 2) (*)
Pre-tightening
Tightening
(3) Screws M7x100-20 (x 4)
Pre-tightening
Tightening
(4) Plug CHC M12x150-16 (x 1)
(5) Plugs M15x150 (x 2)
(6) Screws M9x100-24 (+loctite FRENETANCH) (x8)
Pre-tightening
Tightening
(7) Screws M12x150-81 (x10) (**)
Pre-tightening
Tightening
Angular tightening
B1BK3EMD
(*) = Re-use prohibited.
(**) = Tighten in a spiral commencing from the inside.
81
C8
7 ± 0,5
82°
0,7 ± 0,1
1,5 ± 0,1
0,7 ± 0,1
1,5 ± 0,1
2,5 ± 0,2
4 ± 0,4
1,5 ± 0,1
5 ± 0,5
1 ± 0,1
2,5 ± 0,2
60°
Angl.T3-page032-190-2005 4/02/05 15:15 Page 82
C8
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: 4HW
Crankshaft (continued)
(8)
Screws M7x100-20 (x8) (*) (screw by screw and part stage)
Stage 1: Tightening
Stage 2: Slackening
Stage 3: Tightening
Stage 4: Angular tightening
(9) Screws M9x100-45 (x4) (*)
(10)
Screws M8x125-60 (x8) (***)
Pre-tightening
Tightening
Angular tightening
1
180°
2,3 ± 0,2
46°
1 ±
0,5
1 ± 0,1
60°
(*)
(**)
(***)
= Re-use prohibited.
= Tighten in a spiral, commencing from the inside.
= Tighten in the order indicated 1 to 8.
B1BK3EMD
82
Angl.T3-page032-190-2005 4/02/05 15:15 Page 83
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: 4HW
Engine suspension (identification)
(1)
Upper RH torque reaction rod
(2)
Upper RH engine support
(3)
RH engine flexible support
(4)
Upper RH intermediate engine support
(5)
Lower RH engine support
(6)
Torque reaction rod
(7)
Upper LH intermediate engine support
(8)
LH engine support
(9)
LH engine flexible support
(10)
Lifting attachment, flywheel end
(11)
Lifting attachment, timing end
B1BK3EED
C8
83
Angl.T3-page032-190-2005 4/02/05 15:15 Page 84
C8
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(27)
(28)
(29)
(30)
Engine: 4HW
B1BK3EDD
Engine suspension (tightening torques)
Spherical-base screw M10x150-75 (x 1)
Shaft screw (x 1)
Nut M10x150 (x 1)
Screws M10x150-60 (x 3)
Screws M8x125-25 (x 2)
Shouldered shaft screw M8x125-15 (x 1)
Locking screw M10x125-85 (x 1)
Locking screw M10x125-70 (x 2)
Spherical-base screw M10x150-35 (x 3)
Spherical-base screw M10x150-72 (x 1)
Spherical-base screw M12x175-60 (x 1)
Nut M10x150 (x 1)
Screws M10 x150-55 (x 2)
Support shaft (x 1)
Screws M8x125-25 (x 4)
Screws M8x125-25 (x 2)
Locking nut M12x175-18 (x 1)
Screws M8x125-25 (x 1)
Screws M6x100-20 (x 2)
84
5 ± ,05
4,5 ± 0,4
4,5 ± 0,4
6 ± 0,6
3 ± 0,3
2 ± 0,2
4,5 ± 0,4
4,5 ± 0,4
4,5 ± 0,4
6,5 ± 0,6
9 ± 0,9
4,5 ± 0,4
4,5 ± 0,4
5 ± 0,5
2,5 ± 0,2
3 ± 0,3
6,5 ± 0,6
1,5 ± 0,1
1,2 ± 0,1
Angl.T3-page032-190-2005 4/02/05 15:15 Page 85
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
C8
Engine: 4HW
(2)
(4)
Power steering pump
(1)
Power steering pump
(3)
Screws M8x125-30 (x 1)
Shouldered shaft screw M8x125-22 (x 1)
Shouldered shaft screw M8x125-48 (x 1)
2,5 ± 0,2
2,2 ± 0,2
2,2 ± 0,2
NOTE: Tightening the fixings (2) and (3) before the fixing (4), to ensure that the auxiliary drive belt is correctly aligned.
B1BK3E8D
Alternator
(5)
Alternator
(6)
(7)
Spherical-base screw M10 x150-50 (x 2)
Screws M10x150-40 (x 1)
4,1 ± 0,4
3,9 ± 0,4
NOTE: Tightening the fixings (6) before the fixing (7), to ensure that the auxiliary drive belt is correctly aligned.
B1BK3E7D
85
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C8
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: 4HW
Air conditioning compressor
(8)
Air conditioning compressor
(9)
(10)
Spherical-base screw M10x150-60 (x 1)
Shouldered shaft screw M10x150-52 (x 2)
4 ± 0,4
4,2 ± 0,4
NOTE: Tightening the fixing (9) before the fixing (10), to ensure that the auxiliary drive belt is correctly aligned.
B1EK3E9D
Accessories support
(11) Power steering pump support
(12) Spherical-base screw M8 x125-35 (x 2) (*)
Pre-tightening
Tightening
(13) Screws M8x125-80 (x 1) (*)
Pre-tightening
Tightening
B1EK3EAD
(*) = In the order indicated (1 to 5).
86
1 ± 0,1
2 ± 0,2
1 ± 0,2
2,3 ± 0,2
Angl.T3-page032-190-2005 4/02/05 15:15 Page 87
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: 4HW
(14)
Dynamic tensioner roller
(15)
Eccentric guide roller
(16)
Screws M10x150 (x 1)
Pre-tightening
Tightening
(17)
Screws M8x150-60 (x 1)
Pre-tightening
Tightening
Guide roller
B1BK3EBD
C8
1,5 ± 0,1
3 ± 0,3
2 ± 0,2
4,5 ± 0,4
87
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SPECIAL FEATURES - CYLINDER HEAD TIGHTENING
Engines all types
Cleaning to be carried out just prior to refitting the cylinder head
WARNING: Clean the contact faces with the approved CITROËN cleaning product.
Do not use abrasives or cutting tools on the contact faces.
The contact faces must not bear any traces of impact or scratching.
Insert a tap in the threads of the holes in the cylinder block receiving the cylinder head bolts.
Brush the threads of the cylinder head bolts.
Oil the threads and under the heads of the bolts, using MOLYKOTE G RAPID PLUS.
Engines Tightening (m.daN)
B1DP05BC
6FZ
RFJ
RFN
3FZ
Pre-tightening
Tightening
Slackening
Tightening
Angular tightening
Pre-tightening
Tightening
Slackening
Tightening
Angular tightening
Pre-tightening
Tightening
Slackening
Tightening
Angular tightening
NOTE: Tightening of the cylinder head after a repair is prohibited.
88
1,5 ± 0,1
5 ± 0,5
360°
2 ± 0,2
285° ± 5°
1,5 ± 0,1
5 ± 0,5
360°
2 ± 0,2
285° ± 5°
1,5 ± 0,1
5 ± 0,5
360°
2 ± 0,2
270° ± 5°
Cylinder head bolts
(Max. reusable length in mm)
147
129,5
147
129,5
Angl.T3-page032-190-2005 4/02/05 15:15 Page 89
SPECIAL FEATURES - CYLINDER HEAD TIGHTENING
Engines all types
Cleaning to be carried out just prior to refitting the cylinder head
WARNING: Clean the contact faces with the approved CITROËN cleaning product.
Do not use abrasives or cutting tools on the contact faces.
The contact faces must not bear any traces of impact or scratching.
Insert a tap in the threads of the holes in the cylinder block receiving the cylinder head bolts.
Brush the threads of the cylinder head bolts.
Oil the threads and under the heads of the bolts, using MOLYKOTE G RAPID PLUS.
Engines Tightening (m.daN)
B1DP05BC
RHM RHT
RHW RHL
RHR
4HX 4HW
Pre-tightening
Tightening
Slackening
Pre-tightening
Tightening
Angular tightening
2 ± 0,2
6 ± 0,6
360°
2 ± 0,2
6 ± 0,6
220° ± 5°
Cylinder head bolts
(Max. reusable length in mm)
134,5
9HZ
Pre-tightening
Tightening
Angular tightening
B1DP1CLC
NOTE: Tightening of the cylinder head after a repair is prohibited.
89
2 ± 0,2
4 ± 0,4
230° ± 5°
147
Angl.T3-page032-190-2005 4/02/05 15:15 Page 90
SPECIAL FEATURES - CYLINDER HEAD TIGHTENING
Engines all types
Cleaning to be carried out just prior to refitting the cylinder head
WARNING: Clean the contact faces with the approved CITROËN cleaning product.
Do not use abrasives or cutting tools on the contact faces.
The contact faces must not bear any traces of impact or scratching.
Insert a tap in the threads of the holes in the cylinder block receiving the cylinder head bolts.
Brush the threads of the cylinder head bolts.
Oil the threads and under the heads of the bolts, using MOLYKOTE G RAPID PLUS.
Engines Tightening (m.daN)
XFU
Pre-tightening
Slackening
Pre-tightening
Angular tightening
2 ± 0,2
360°
1,5 ± 0,2
225° ± 5°
B1DP1KCC
A = Front cylinder head.
B = Rear cylinder head.
Cylinder head bolts
(Max. reusable length in mm)
149,5
B1DP1KHC
NOTE: Tightening of the cylinder head after a repair is prohibited.
90
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SPECIAL FEATURES - CYLINDER HEAD TIGHTENING
Engines all types
Cleaning to be carried out just prior to refitting the cylinder head
WARNING: Clean the contact faces with the approved CITROËN cleaning product.
Do not use abrasives or cutting tools on the contact faces.
The contact faces must not bear any traces of impact or scratching.
Insert a tap in the threads of the holes in the cylinder block receiving the cylinder head bolts.
Brush the threads of the cylinder head bolts.
Oil the threads and under the heads of the bolts, using MOLYKOTE G RAPID PLUS.
Engines Tightening (m.daN)
XFW
Pre-tightening
Slackening
Pre-tightening
Angular tightening
2 ± 0,2
360°
1,5 ± 0,2
225° ± 5°
Cylinder head bolts
(Max. reusable length in mm)
149,5
B1EK0XAD
NOTE: Tightening of the cylinder head after a repair is prohibited.
91
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!
4099-T (C.TRONIC.105)
BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE
Tools
4122-T (C.TRONIC.105.5)
!
B1EP135D
Angl.T3-page032-190-2005 4/02/05 15:15 Page 93
Engine type
C5
C8
See pages:
7
J4
6FZ
1.8i
16V
A
RFJ
EW
10
RFN
AUXILIARY EQUIPMENT DRIVE BELT
Petrol
J4
12
3FZ
A
XFU
ES
9
J4
XFW
DV
6
9HZ
Diesel
DW
10
TED4 BTED4
RHM RHT RHW RHL RHR
2.0i
16V
3.0i
24S
1.6
16V
HDi
2.0 16V HDi
12
TED ATED4
4HX 4HW
2.2
16V
HDi
95 96 97
2.2i
16V
HPi
98 99
100 to
101
2.0 16V HDi
102 to 103 104
2.2
16V
HDi
105 to
106
107 to
108
93
Angl.T3-page032-190-2005 4/02/05 15:15 Page 94
AUXILIARY EQUIPMENT DRIVE BELT
Engines: All types Petrol and Diesel
Tools.
Belt tension measuring instrument : 4122-T .(C.TRONIC 105.5).
WARNING: If using tool 4099-T (C.TRONIC 105), refer to the correspondence table on page 93.
Essential.
Before refitting the auxiliary equipment drive belt, check that:
- 1 / The roller(s) rotate freely (no play or stiffness).
- 2 / The belt is correctly engaged in the grooves of the various pulleys.
94
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Without aircon
AUXILIARY EQUIPMENT DRIVE BELT
Engine: 6FZ
Tool.
[1] Pliers for removing plastic pegs
: 7504-T
Remove the belt.
Detension the belt (3) by turning the tensioner roller (1), by the screw (2)
(anti-clockwise).
WARNING: the screw (2) has a left hand thread.
Remove the belt (3), while keeping the tensioner roller (1) tensioned.
Refit the belt.
Compress the tensioner roller (1).
Fit the belt (3).
Release the tensioner roller (1).
Tensioner roller screw (4)
Guide roller screw (5)
Tightening torques (m.daN).
: 2 ± 0,2
: 3,5 ± 0,3
B1BP23PC B1BP23QC B1BP23PC B1BP23RC
95
With aircon
C5
Angl.T3-page032-190-2005 4/02/05 15:15 Page 96
C5
B1EP1FUD
B1EP1FVC
AUXILIARY EQUIPMENT DRIVE BELT
Engine: RFJ
Tool.
[1] «Junior» T extension
: (-).1608.E
Removing.
Engage tool [1] in the notch «a».
Exert on the roller (1) an effort upwards to hold it at maximum.
Remove the auxiliaries drive belt.
Carefully release the tensioner roller (1) to reach its minimum.
Remove tool [1].
IMPERATIVE: Check that the roller (1) turns freely (without play and without tight spots).
Refitting.
If removing the auxiliaries drive belt tensioner roller, tighten the screws 2 ± 0,2 m.daN.
Engage tool [1] in the notch at «a».
Exert on the roller (1) an effort upwards to hold it at maximum.
Position the (new) auxiliaries drive belt, in the following sequence:
- Auxiliaries drive pulley (4), aircon compressor pulley (3), tensioner roller (1) and alternator pulley (2).
IMPERATIVE: Make sure that the auxiliaries drive belt is correctly positioned in the grooves of the various pulleys.
Release the tensioner roller (1).
Remove tool [1].
Check the tension of the auxiliaries drive belt:
- Mark «b» at the level of mark «c», new belt.
- Mark «b» at the level of mark «d», belt to be changed.
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BXXK08DD
AUXILIARY EQUIPMENT DRIVE BELT
Engines: RFN - 3FZ
Tool.
[1] Peg for dynamic tensioner roller
: (-).0189-E
Removing.
Remove:
- The front RH wheel.
- The front RH splash-shield.
- Detension the auxiliary drive belt by actioning the screw (1).
- Peg the dynamic tensioner roller (2), using tool [1].
Remove the auxiliary drive belt.
ESSENTIAL: Check that the rollers (3) and (4) turn freely (no tight spot).
Refitting.
Refit the auxiliary drive belt.
Check that the auxiliary drive belt is correctly positioned in the grooves of the various pulleys.
Remove tool [1].
Continue the refitting operations in reverse order to removal.
C8
BXXK0AUD
97
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C5
B1BP27EC
AUXILIARY EQUIPMENT DRIVE BELT
Engine: XFU
Tools.
[1] Ratchet spanner S.171 FACOM (1/2" square)
[2] Reduction box S.230 FACOM (1/2" - 3/8" square)
: S 171
: S 230
Remove.
Remove the engine cover.
Pivot the tensioner roller bracket (1) clockwise, until it locks, using tools
[1] and [2] at «a».
Remove the auxiliary equipment drive belt.
ESSENTIAL: Check that the guide rollers are turning freely (no play
and no tightness).
Refit.
Refit the auxiliary equipment drive belt.
Respect the following order of assembly:
- The crankshaft pulley (2).
- The tensioner roller (3).
Release the tensioner roller bracket (1), by turning it anti-clockwise, using tools [1] and [2].
ESSENTIAL: Make sure that the belt is correctly positioned in the grooves of the various pulleys.
98
B1BP27FC
Angl.T3-page032-190-2005 4/02/05 15:15 Page 99
AUXILIARY EQUIPMENT DRIVE BELT
Engine: XFW
Tools.
[1] Ratchet spanner FACOM (1/2" square)
[2] Reduction box FACOM S.230 (1/2" - 3/8" square)
C8
Removing.
B1EK0VAD
Move aside the power steering oil low pressure pipe flange.
Pivot the support (1) of the tensioner roller clockwise, as far as it will go, using tools [1] and [2].
Remove the auxiliary drive belt.
IMPERATIVE: Check the operation of the rollers (no play, no tight spot).
Refitting.
Position the auxiliary drive belt.
Commence with the crankshaft pulley (2).
Finish with the tensioner roller (3).
Free the support (1) of the tensioner roller, pivoting it anti-clockwise, using tools [1] and [2].
ESSENTIAL: Check that the belt is correctly positioned in the grooves of the various pulleys.
Continue the refitting operations in reverse order to removal.
B1EK0VBD
99
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C5
Without aircon
AUXILIARY EQUIPMENT DRIVE BELT
Engine: 9HZ
Tools.
[1] Dynamic tensioner compressure lever
[2] Peg for dynamic tensioner roller
: (-).0188.Z
: (-).0494.F
IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions.
Disconnect the battery.
Remove the front RH wheel and the under-engine sound-deadening.
Removing.
WARNING: Mark the direction of fitting of the accessories drive belt, if it is to be re-used.
Compress the dynamic tensioner roller (1) by acting at «a» (clockwise), using tool [1].
Peg at «b», using tool [2].
Keeping the dynamic tensioner roller (1) compressed, remove the accessories drive belt.
IMPERATIVE: Check that the rollers (1) and (2) can turn freely (without play
and without tight spots).
B1BP2Z6D
100
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With aircon
AUXILIARY EQUIPMENT DRIVE BELT C5
Engine: 9HZ
Refitting.
WARNING: Belt to be re-used, mark the direction of fitting of the belt.
Refit the auxiliaries drive belt.
Compress the tensioner roller (1) by acting at «c» (clockwise), using tool [1].
Remove tool [2].
IMPERATIVE: Make sure that the auxiliaries drive belt is correctly positioned in the grooves of the various pulleys.
Refit:
- the front RH wheel, the sound-deadening under the engine.
- Reconnect the battery.
IMPERATIVE: Carry out the operations that are necessary following a reconnection of the battery (see corresponding operation).
B1BP2ZCD
101
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C8
E5AK0E9C
AUXILIARY EQUIPMENT DRIVE BELT
Engines: RHM - RHT - RHW
Tools.
[1] Tensioning lever
[2] Peg for dynamic roller Ø 4 mm
[3] Peg for dynamic roller Ø 2 mm
[4] Dynamic roller compressure lever
(A) Pegging hole
(B) Belt wear check mark (fixed on engine)
(C) Zero wear mark
(D) Maximum wear mark
: (-).0188-J2
: (-) 0188-Q1
: (-).0188-Q2
: (-).1888-Z
This marking system permits checking of the belt wear; if the marks (D) and (B) coincide, it implies that the belt requires replacing.
Tighten the screw (1) to 4,5 ± 0,4 m.daN.
Removing.
Remove:
- The front RH wheel.
- The front RH splash-shield.
- The under-engine shield.
IMPERATIVE: Mark the direction of rotation of the belt if to be re-used.
B3EK0DHD
102
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B1BK1A4C
AUXILIARY EQUIPMENT DRIVE BELT
Engines: RHM - RHT - RHW
C8
Removing (continued).
Slacken the fixing (2).
Action the roller (3), using tool [1], until the tool [2] is positioned in the pegging hole (A).
Bring the roller (3) back towards the rear.
Gently tighten the screw (2).
Remove the belt.
ESSENTIAL : Check that the rollers (3) and (4) turn freely (no play, no tight spot).
Refitting.
IMPERATIVE: If re-using the belt, refit it respecting the direction of rotation marked on removal.
Refit the belt, finishing with the tensioner roller (4).
Action the roller (3), using tool [1] (clockwise) to free the tool [2].
Tighten the fixing (2) to 4,5 ± 0,5 m.daN, without altering the position of the roller.
ESSENTIAL: Check that the belt is correctly positioned in the grooves of the various pulleys.
Remove the tool [1].
Rotate the engine four times.
Check that the marks (B) and (C) coincide.
Tool [3] should be able to engage freely, if not, repeat the adjustment.
Complete the refitting.
103
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C5
B1BP31AD
AUXILIARY EQUIPMENT DRIVE BELT
Engines: RHL - RHR
Tools.
[1] Dynamic tensioner compressure lever
[2] Dynamic tensioner roller retaining peg Ø 4mm
: (-).0188.Z
: (-).0188.Q1
Removing.
Remove the splash-shield, under-engine sound-deadening, front RH wheel.
WARNING: Mark the direction of fitting of the auxiliaries drive belt in the case of re-use of the belt.
Compress the dynamic tensioner roller (1) by acting at «b» (anti-clockwise), using tool [1].
Peg using tool [2] at «a».
IMPERATIVE: Check that the roller (1) turns freely (without play and without tight spots).
Refitting.
Refit the auxiliaries drive belt.
IMPERATIVE: Make sure that the auxiliaries drive belt is correctly positioned in the grooves of the various pulleys.
Compress the dynamic tensioner roller (1) by acting at «b», using tool [1].
Remove tool [2] at «a».
Refit the splash-shield, under-engine sound-deadening, front RH wheel.
104
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B1BP270D
B1BP272D
AUXILIARY EQUIPMENT DRIVE BELT
Engine: 4HX
Without air conditioning
Tools.
[1] Dynamic tensioner compressure lever
[2] Peg Ø 4 mm
: (-).0188.Z
: (-).0188.Q1
Remove.
WARNING: Mark the direction of fitting in case the belt is to be reused.
Compress the tensioner roller (1) by action at «a» (anti-clockwise), using tool [1].
Peg at «b», using tool [2].
Remove the auxiliaries drive belt.
Refit.
Refit the auxiliaries drive belt.
Compress the tensioner roller (1) by action at «a» (anti-clockwise), using tool [1].
Remove the tool [2] at «b».
C5
105
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C5
B1BP271D
AUXILIARY EQUIPMENT DRIVE BELT
Engine: 4HX
Without air conditioning
Tools.
[1] Dynamic tensioner compressure lever
[2] Peg Ø 4 mm
Remove.
: (-).0188.Z
: (-).0188.Q1
WARNING: Mark the direction of fitting in case the belt is to be reused.
Compress the tensioner roller (4) by action at «c» (anti-clockwise), using tool [1].
Peg at «d», using tool [2].
Remove the auxiliaries drive belt.
Refit.
Refit the auxiliaries drive belt.
Compress the tensioner roller (4) by action at «c» (anti-clockwise), using tool [1].
Remove the tool [2] at «d».
B1BP273D
106
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AUXILIARY EQUIPMENT DRIVE BELT
Engine: 4HW
[1] Peg for dynamic roller
[2] Dynamic roller compressure lever
Tools.
: (-) 0188-Q1
: (-).1888-Z
E5AK0EDC
(A) Pegging hole
(B) Belt wear check mark (fixed on engine)
(C) Zero wear mark
(D) Maximum wear mark
This marking system permits checking of the belt wear; if the marks (D) and (B) coincide, it implies that the belt requires replacing.
Tighten the screw (1) to 4,5 ± 0,4 m.daN.
Removing.
Remove:
- The front RH wheel.
- The front RH splash-shield.
- The under-engine shield.
IMPERATIVE: Mark the direction of rotation of the belt if to be re-used.
E5AK0E8C
107
C8
B3EK09PC
Angl.T3-page032-190-2005 4/02/05 15:15 Page 108
C8
AUXILIARY EQUIPMENT DRIVE BELT
Engine: 4HW
Removing (continued).
Action the roller (3), using tool [2], until the tool [1] is positioned in the pegging hole (A).
Remove the belt.
ESSENTIAL: Check that the rollers (3) and (4) turn freely (no play, no tight spot).
Refitting.
IMPERATIVE: If re-using the belt, refit it respecting the direction of rotation marked on removal.
Refit the belt, finishing with the tensioner roller (3).
ESSENTIAL: Check that the belt is correctly positioned in the grooves of the various pulleys.
Rotate the engine four times.
Complete the refitting.
B1BK1IWD
108
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Engine type
C5
C8
See pages:
7
J4
6FZ
1.8i
16V
A
RFJ
EW
10
CHECKING AND SETTING THE VALVE TIMING
RFN
Petrol
J4
12
3FZ
A
XFU
ES
9
J4
XFW
DV
6
9HZ
Diesel
DW
10
TED4 BTED4
RHM RHT RHW RHL RHR
2.0i
16V
3.0i
24S
1.6
16V
HDi
2.0 16V HDi
12
TED ATED4
4HX 4HW
2.2
16V
HDi
2.2i
2.0i 3.0i
16V
16V 24S
HPi
110 to
115
116 to
122
123 to
130
131 to
138
139 to
144
145 to
152
153 to
163
180 to 187 164 to 173
2.2
16V
HDi
174 to
179
180 to
187
109
Angl.T3-page032-190-2005 4/02/05 15:15 Page 110
C5
B1BP27JC
CHECKING THE VALVE TIMING
Engine: 6FZ
Tools.
[1] Camshaft setting peg
[2] Crankshaft setting peg
Checking the setting of the timing.
: (-).0189.A
: (-).0189.B
Removing.
Disconnect the battery negative terminal.
Raise and support the vehicle, front wheels hanging.
Remove the front RH wheel, the splash-shield and the upper timing cover.
Turn the engine by means of the crankshaft pinion screw (1), clockwise, to bring it to the pegging position.
Peg the crankshaft, using tool [2].
Peg the camshaft pulleys, using tool [1].
NOTE: The peg [1] should go in without effort.
WARNING: If the pegs go in only with difficulty, repeat the operation for fitting and tensioning the timing belt (see corresponding operation).
Refitting.
Remove the pegs [1] and [2].
Refit the upper timing cover, the splash-shield, the plastic pins and the front RH wheel.
B1BP25PC
110
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CHECKING AND SETTING THE VALVE TIMING
Engine: 6FZ
B1BP2V4C
C5
Tools.
[1] Camshaft setting peg
[2] Crankshaft setting peg
[3] Timing belt retaining pin
[4] Adaptor for angular tightening
[5] Tool for moving and locking the tensioner roller
[5a]
[5b]
Removing.
Disconnect the battery negative terminal.
Raise and support the vehicle, front wheels hanging.
Remove the accessories drive belt (see corresponding operation).
Remove the upper timing cover (1).
: (-).0189.A
: (-).0189.R
: (-) 0189.K
: 4069-T
: (-).0189.S
: (-).0189.S1
: (-).0189 S2
Turn the engine by means of the screw (3) of the crankshaft pinion (2), to bring it to the pegging position.
A: Pegging on the manual gearbox.
B: Pegging on the automatic gearbox.
Peg the crankshaft, using tool [2].
B1BP2V3D
111
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C5
B1EP1BBD
CHECKING AND SETTING THE VALVE TIMING
Engine: 6FZ
Peg the camshaft pulleys (5) and (6), using tool [1].
Remove:
- The screw (3).
- The crankshaft pulley (2).
- The lower timing cover (4).
IMPERATIVE: Never remove the crankshaft pulley (2) without pegging the crankshaft and camshafts.
Slacken the screw (9) of the tensioner roller (8).
Turn the tensioner roller (8) clockwise.
Remove the timing belt (7).
Refitting.
Turn the tensioner roller (8), using tool [5a], to go past the slot «b».
Position the tool [5b] to lock the index «a» and remove the tool [5a].
B1EP1BCD
112
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CHECKING AND SETTING THE VALVE TIMING
Engine: 6FZ
C5
Reposition the timing belt (7) on the crankshaft pulley (1).
Hold the timing belt (7) in place using tool [3].
Fit the timing belt (7) in place, respecting the following order:
- The guide roller (10), the inlet camshaft pulley (6), the exhaust camshaft pulley (5), the coolant pump (11), the tensioner roller (8).
NOTE: Make so that the belt (7) is as flush as possible with the exterior face of the various pinions and rollers.
Remove:
- Tool [3].
- Tool [1] from the exhaust camshaft pulley.
- Tool [5b] from the tensioner roller (8).
Refit:
- The lower timing cover (4).
- The crankshaft pulley (2).
- Screw (3) of the crankshaft pulley.
Tightening
Angular tightening
Using tool [4].
: 4 ± 0,4 m.daN.
: 53 ± 4°.
B1EP1BDC
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C5
CHECKING AND SETTING THE VALVE TIMING
Engine: 6FZ
B1EP1BEC
Tensioning the timing belt.
Turn the tensioner roller (8) in the direction of the arrow «c», by means of a hexag. spanner at «d».
Place the index «a» in position «f».
IMPERATIVE: The index «a» should go past the slot «g» by an angular value of 10°.
If it does not, replace the tensioner roller or the timing belt and tensioner roller assembly.
Next bring the index «a» to its adjusting position «g», by turning the tensioner roller in the direction of the arrow «e».
WARNING: the index «a» should not pass the slot «g».
Otherwise, repeat the operation to tension the timing belt.
IMPERATIVE: The tensioner roller should not turn during the tightening of its fixing.
If it does, repeat the operation to tension the timing belt.
Tighten the screw (9) of the tensioner roller (8) to 2,1 ± 0,2 m.daN.
IMPERATIVE: The hexagonal tensioner roller drive should be approx. 15° below the level of the cylinder head gasket «h».
If it is not, replace the tensioner roller or the timing belt and tensioner roller assembly.
Refitting.
Remove the tools [1] and [2].
Rotate the crankshaft ten times (normal direction of rotation).
B1EP1BFC
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CHECKING AND SETTING THE VALVE TIMING
Engine: 6FZ
IMPERATIVE: No pressure or outside force should be brought to bear on the timing belt.
Peg the inlet camshaft pulley, using tool [1].
Checks.
Tension of the timing belt.
ESSENTIAL: Check the position of the index «a», which should be opposite the slot «g».
If the position of the index «a» is not correct, repeat the operations to tension the timing belt.
B1EP1BEC
Refitting.
Refit the upper timing cover (1).
Clip the fuel delivery hose on the timing cover.
Refit the accessories drive belt (see corresponding operation).
Lower the vehicle.
Reconnect the battery (see corresponding operation).
C5
B1EP1BFC
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C5
B1BP2V3D
CHECKING THE VALVE TIMING
Engine: RFJ
[1] Camshaft pinion peg
[2] Crankshaft setting peg
[3] Engine lifting crossmember
Tools.
: (-).0194.A
: (-).0189.R
Removing.
Disconnect the battery negative terminal.
Raise and support the vehicle, front wheels hanging.
Remove:
- The front RH wheel
- The plastic pins holding the splash-shield (press on the central axis to release them).
- The splash-shield.
A: Pegging on the manual gearbox.
B: Pegging on the automatic gearbox.
Turn the engine by means of the crankshaft pinion screw, to bring it to the pegging position.
Peg the crankshaft, using the peg [2].
Position tool [3].
Suspend the engine.
Remove:
- The RH engine support.
- The upper timing cover.
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CHECKING THE VALVE TIMING
Peg the camshaft pulleys, using tool [1].
Engine: RFJ
C5
NOTE: The pegs [1] should go in without forcing.
WARNING: If the pegs go in only with difficulty, repeat the operation for fitting and tensioning the timing belt (see corresponding operation).
Refitting.
Remove the pegs [1] and [2].
Refit:
- The upper timing cover.
- The RH engine support.
Remove tool [3].
Refit :
- The splash-shield.
- The plastic pins.
- The front RH wheel.
B1BP32GC
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C5
B1BP310C
B1BP2V3D
CHECKING AND SETTING THE VALVE TIMING
[1] Camshaft setting peg
[2] Crankshaft setting peg
[3] Timing belt retaining pin
[4] Adaptor for angular tightening
[5] Hub immobilising tool
[5a]
[5b]
[6] Engine lifting crossmember
Engine: RFJ
Tools.
: (-).0194.B
: (-).0189.R
: (-) 0189.K
: 4069-T
: (-).0189.S
: (-).0189.S1
: (-).0189.S2
Removing.
Disconnect the negative terminal of the battery.
Raise and support the vehicle, front wheels hanging.
Remove the auxiliaries drive belt (see corresponding operation).
Unclip and move aside the fuel supply hose from the timing cover.
Remove the upper timing cover (1).
Position the tool [6].
Suspend the engine.
Remove the RH engine support and the upper timing cover (1).
Turn the engine by means of the screw (3) of the crankshaft pinion (2) to bring it to the pegging position.
A: Pegging on the manual gearbox.
B: Pegging on the automatic gearbox.
Peg the crankshaft, using tool [2].
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CHECKING AND SETTING THE VALVE TIMING
Engine: RFJ
Peg the camshaft pulleys (5) and (6), using tool [1].
C5
IMPERATIVE: Never remove the crankshaft pulley (2) without pegging the crankshaft and the camshafts.
Remove:
B1EP1EUD
- The screw (3).
- The crankshaft pulley (2).
- The lower timing cover (4).
Slacken the screw (9) of the tensioner roller (8).
Turn the tensioner roller (8) clockwise.
Remove the timing belt (7).
Refitting.
Turn the tensioner roller (8), using tool [5a], to go past the slot «b».
Position the tool [5b] to lock the index «a» and remove the tool [5a].
B1EP1EVD
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C5 CHECKING AND SETTING THE VALVE TIMING
Engine: RFJ
NOTE: Check the presence of the keyway (12).
Reposition the timing belt (7) on the crankshaft pulley (1).
Hold the timing belt (7) in place using tool [3].
Fit the timing belt (7) in place, respecting the following order:
- The guide roller (10), the inlet camshaft pulley (6), the exhaust camshaft pulley (5), the coolant pump
(11), the tensioner roller (8).
B1EP1EWC
NOTE: Make so that the belt (7) is as flush as possible with the exterior face of the various pinions and rollers.
Remove:
- Tool [3].
- Tool [1] from the exhaust camshaft pulley.
- Tool [5b] from the tensioner roller (8).
Refit:
- The lower timing cover (4).
- The crankshaft pulley (2).
- Screw (3) of the crankshaft pulley
Tightening
: 4 ± 0,4 m.daN
Angular tightening
: 53 ± 4°
using tool [4].
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CHECKING AND SETTING THE VALVE TIMING
Engine: RFJ
C5
B1EP1EXC
Tensioning the timing belt.
Turn the tensioner roller (8) clockwise, using a hexagonal spanner at «c».
Place the index «a» in position «e».
IMPERATIVE: The index «a» should go past the slot «f» by an angular value of 10°.
If it does not, replace the tensioner roller or the tensioner roller and timing belt assembly.
Then bring the index «a» to its adjustment position «f», by turning the tensioner roller in the direction of the arrow «d».
WARNING : The index «a» must not go past the slot «f».
If it does, restart the operation to tension the timing belt.
IMPERATIVE: The tensioner roller must not turn during the tightening of its fixing.
If it does turn, restart the operation to tension the timing belt.
Tighten the screw (9) of the tensioner roller (8) to 2,1 ± 0,2 m.daN.
IMPERATIVE: The hexagonal tensioner roller drive should be at approx. 15° below the level of the cylinder head gasket «g».
Otherwise, replace the tensioner roller or the tensioner roller and timing belt assembly.
Refitting.
Remove the tools [1] and [2].
Rotate the crankshaft ten times (normal direction of rotation).
B1EP1EYC
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C5
CHECKING AND SETTING THE VALVE TIMING
Engine: RFJ
IMPERATIVE: No exterior pressure or action should be applied on the timing belt.
Peg the inlet camshaft pulley, using tool [1].
Checking.
Timing belt tension.
B1EP1EXC
IMPERATIVE: Check the position of the index «a», it should be opposite the slot «f».
If the position of the index «a» is not correct, repeat the operations to tension the timing belt.
Refitting.
Refit the upper timing cover (1).
Refit the RH engine support.
Remove tool [6].
Clip the fuel supply hose on the timing cover.
Refit the auxiliaries drive belt (see corresponding operation).
Lower the vehicle.
Reconnect the battery (see corresponding operation).
B1EP1EYC
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CHECKING AND SETTING THE VALVE TIMING
Engine: RFN
Tools.
[1] Camshaft setting peg
[2] Crankshaft setting peg
[3] Timing belt retaining pin
[4] Adaptor for angular tightening
[5] Tool for moving and locking the tensioner roller
[5a]
[5b]
[6] Peg for positioning the dynamic tensioner roller
Removing.
Disconnect the battery.
Remove:
- The under-engine shield.
- The auxiliary drive belt (see corresponding operation).
Move aside:
- The fuel delivery pipe.
- The canister purge electrovalve.
- The expansion chamber.
Remove:
- The screws (1) and (2).
- The torque reaction rod (3).
B1EK1T7D
123
: (-) 0189.A
: (-).0189.R
: (-).0189.K
: 4069-T
: (-).0189.S
: (-).0189.S1
: (-).0189 S2
: (-).0189.J
C8
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C8 CHECKING AND SETTING THE VALVE TIMING
Engine: RFN
Setting the timing (continued).
Remove the upper timing cover (4).
WARNING: Do not slacken the screws «a».
Turn the engine by means of the crankshaft pinion screw (5), to bring it to the pegging position.
B1BP2WBC
A: Pegging on the manual gearbox, tool [2].
B: Pegging on the automatic gearbox, tool [2].
B1BP2V3D
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CHECKING AND SETTING THE VALVE TIMING
Engine: RFN
Setting the timing (continued).
Peg the camshaft pulleys (8) and (9), using tool [1].
The screw (13).
The crankshaft pulley (12).
The timing cover (6).
C5
IMPERATIVE: Never remove the crankshaft pulley without pegging the crankshaft and camshafts.
Slacken the screw (7) of the tensioner roller.
Turn the tensioner roller (clockwise).
Remove the timing belt (9).
B1EP1BWD
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C8
B1EP1BQD
CHECKING AND SETTING THE VALVE TIMING
Engine: RFN
Refitting.
IMPERATIVE: Check that the tensioner roller, guide roller and coolant pump can turn freely (without play and without tight spots); check also that these rollers are not noisy and/or that they are not splashed with grease.
If replacing the tensioner roller: Tighten to 3,5 ± 0,3 m.daN.
Turn the tensioner roller, using tool [5a], to go past the slot «c».
Position the tool [5b] to lock the index «b» and remove the tool [5a].
IMPERATIVE: Systematically replace the following components: Timing belt, exhaust manifold fixing nuts, timing belt tensioner roller nut.
Reposition the timing belt (10) on the crankshaft pinion.
Hold the timing belt (10) in place using tool [3].
B1EP1BRC
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CHECKING AND SETTING THE VALVE TIMING
Engine: RFN
Fit the timing belt (10) in place, respecting the following order:
- Guide roller (11).
- Inlet camshaft pulley (9).
- Exhaust camshaft pulley (8).
- Coolant pump.
- Tensioner roller.
NOTE: Make so that the belt (10) is as flush as possible with the exterior face of the various pinions and rollers.
Remove:
- Tool [2].
- Tool [3].
- Tool [1] from the exhaust camshaft pulley.
- Tool [5b] from the tensioner roller.
Refit:
- The lower timing cover.
- The crankshaft pulley (12).
- The screw (13).
- Tighten screw (13) to 4 ± 0,4 m.daN, then angular tighten to 53° ± 4°, tool [4].
127
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C8
B1EP1BXD
CHECKING AND SETTING THE VALVE TIMING
Engine: RFN
Tensioning the timing belt.
IMPERATIVE: This operation must be one with the engine cold.
«e» Max. position
«d» Nominal tension position
Using the hexagonal bracket «f», turn the hub of the tensioner roller (14) (anti-clockwise), to bring the index «b» to position «e» to tension the belt to the maximum.
Turn the eccentric hub (15) of the roller (14) (clockwise), until the cursor (b) comes into gentle contact with the peg [6].
IMPERATIVE: Never turn the eccentric hub (15) by a complete rotation when the tool [6] is in position.
NOTE: This operation enables you to position the index «b» in the nominal position «d».
Tighten screw (7) to 2 m.daN, holding the roller by means of the hexagonal bracket «f».
Remove the pegs [1], [2] and [6].
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CHECKING AND SETTING THE VALVE TIMING
Engine: RFN
Checks.
C8
Make two rotations of the crankshaft (direction of rotation of the engine).
IMPERATIVE: Never turn the crankshaft backwards.
Make sure that the timing is correctly set, by refitting the camshaft and crankshaft setting pegs.
Remove the setting pegs.
Make ten rotations of the crankshaft (direction of rotation of the engine).
Check the position of the index (15).
If the index (15) is not in its adjustment position «e», recommence the operations to tension the timing belt.
B1EP1BTC
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C8 CHECKING AND SETTING THE VALVE TIMING
Engine: RFN
Refitting (continued).
Refit:
- The upper timing cover.
- The torque reaction rod (3).
- The screw (1), tighten to 4,5 m.daN.
- The screw (2), tighten to 4,5 m.daN.
- Continue the refitting operations in reverse order to removal.
- Refit the auxiliary drive belt (see corresponding operation).
B1EK1T7D
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CHECKING AND SETTING THE VALVE TIMING
Engine: 3FZ
[1] Camshaft setting peg
[2] Crankshaft setting peg
[3] Timing belt retaining pin
[4] Adaptor for angular tightening
[5] Tool for moving and locking the tensioner roller
[5a]
[5b]
[6] Peg for positioning the dynamic tensioner roller
[7] Camshaft setting peg
Removing.
Disconnect the battery.
Remove:
- The under-engine shield.
- The auxiliary drive belt (see corresponding operation).
Move aside:
- The fuel delivery pipe.
- The canister purge electrovalve.
- The expansion chamber.
Place a jack under the vehicle to support the engine.
Tools.
: (-) 0189.A
: (-).0189.R
: (-).0189.K
: 4069-T
: (-).0189.S
: (-).0189.S1
: (-).0189 S2
: (-).0189.J
: (-).0189.L
131
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C8 CHECKING AND SETTING THE VALVE TIMING
Engine: 3FZ
Remove:
- The screws (1) and (6).
- The torque reaction rod (3).
- The nut (4).
- The three screws (3).
B1EP1BMC
- The RH engine support (2).
IMPERATIVE: Uncouple the exhaust line to avoid any damage to the flexible pipe caused by twisting, pulling and bending it while removing one of the power unit supports.
A: Pegging on the manual gearbox, tool [2].
B: Pegging on the automatic gearbox, tool [2].
B1BP2V3D
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CHECKING AND SETTING THE VALVE TIMING
B1EP1BNC
C8
Engine: 3FZ
Remove the timing cover (7).
WARNING: Do not slacken the screws (a).
Rotate the engine by means of the screw (8) of the crankshaft pinion to bring it to the pegging position.
Peg the camshaft pulleys (13) and (14), using tools [1] and [7].
Remove:
- The screw (8).
- The crankshaft pulley (16).
- The timing cover (9).
IMPERATIVE: Never remove the crankshaft pulley without pegging the crankshaft and camshafts.
Slacken the screw (12) of the tensioner roller (11).
Turn the tensioner roller (11) (clockwise).
Remove the timing belt.
B1EP1BPD
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C8 CHECKING AND SETTING THE VALVE TIMING
Engine: 3FZ
Refitting.
IMPERATIVE: Check that the tensioner roller, guide roller and coolant pump can turn freely
(without play and without tight spots); check also that these rollers are not noisy and/or that they are not splashed with grease.
B1EP1BQD
If replacing the tensioner roller (15): Tighten to 3,5.
Turn the tensioner roller, using tool [5a], to go past the slot «c».
Position the tool [5b] to lock the index «b» and remove the tool [5a].
IMPERATIVE: Systematically replace the following components: Timing belt, exhaust manifold fixing nuts, timing belt tensioner roller nut.
Reposition the timing belt on the crankshaft pinion.
Hold the timing belt in place using tool [3].
B1EP1BRC
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CHECKING AND SETTING THE VALVE TIMING
B1EP1BRC
C8
Engine: 3FZ
Fit the timing belt in place, respecting the following order:
- Guide roller (15).
- Inlet camshaft pulley (14).
- Exhaust camshaft pulley (13).
- Coolant pump (10).
- Tensioner roller (11).
NOTE: Make so that the belt is as flush as possible with the exterior face of the various pinions and rollers.
Remove:
- Tool [3].
- Tool [1] from the exhaust camshaft pulley.
- Tool [5b] from the tensioner roller.
Refit:
- The lower timing cover (9).
- The crankshaft pulley (16).
- The screw (8) of the crankshaft pulley.
- Tighten screw (8) to 4 ± 0,4 m.daN, then angular tighten to 53° ± 4°, tool [4].
B1EP1BPD
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C8
B1EP1BXD
CHECKING AND SETTING THE VALVE TIMING
Engine: 3FZ
Tensioning the timing belt.
IMPERATIVE: This operation must be done with the engine cold.
«e» Max. position
«d» Nominal tension position
Using the hexagonal bracket «f», turn the hub of the tensioner roller (18) (anti-clockwise), to bring the index «b» to position «e» to tension the belt to the maximum.
Turn the eccentric hub (17) of the roller (18) (clockwise), until the cursor (b) comes into gentle contact with the peg [6].
IMPERATIVE: Never turn the eccentric hub (8) by a complete rotation when the tool [4] is in position.
NOTE: This operation enables you to position the index «e» in the nominal position «d».
Tighten screw (12) to 2 m.daN, holding the roller by means of the hexagonal bracket «f».
Remove the pegs [7], [2] and [4].
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CHECKING AND SETTING THE VALVE TIMING
Engine: 3FZ
C8
Checks.
Make two rotations of the crankshaft (direction of rotation of the engine).
IMPERATIVE: Never turn the crankshaft backwards.
Make sure that the timing is correctly set, by refitting the camshaft and crankshaft setting pegs.
Remove the setting pegs.
Make ten rotations of the crankshaft (direction of rotation of the engine).
Check the position of the index (b).
If the index (b) is not in its adjustment position «e», recommence the operations to tension the timing belt.
B1EP1BTC
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C8 CHECKING AND SETTING THE VALVE TIMING
Engine: 3FZ
Refitting (continued).
Refit:
- The upper timing cover.
- The RH engine support (2).
- The torque reaction rod (5).
The screw (1), tighten to 4,5 m.daN.
The screw (6), tighten to 4,5 m.daN.
Continue the refitting operations in reverse order to removal.
Refit the auxiliary drive belt (see corresponding operation).
B1EP1BUC
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B1BP2BKC
CHECKING THE VALVE TIMING
Engine: XFU
Tools.
[1] Camshaft setting pegs
[2] Crankshaft setting peg
[3] Fuel pressure take-off union
[4] Belt retaining pin
[5] Exhaust camshaft hubs immobilising tool
[6] Inlet camshaft hubs immobilising tool
Remove the auxiliaries drive belt (see corresponding operation).
Checking the valve timing.
Remove:
- The power steering pulley.
- The roller/dynamic tensioner assembly (11).
- The crankshaft pulley (12).
- The upper timing covers (9) and (10).
- The lower timing cover (13).
: (-).0187.B
: (-).0187.A
: 4192-T
: (-).0187.J
: (-).0187.F
: (-).0187.F
C5
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C5
B1EP08TC
CHECKING THE VALVE TIMING
Engine: XFU
Checking the valve timing (continued).
Peg the crankshaft, using tool [1].
Check that the tool [2] engages without effort in the cylinder heads at the camshaft pulleys.
Remove the tools [1] and [2].
Refit:
- The lower timing cover (13).
- The upper timing covers (9) and (10).
- The crankshaft pulley (12).
- The roller/dynamic tensioner assembly (11).
- The power steering pulley.
Complete the refitting of components.
Initialise the ignition injection ECU.
B1EP15UD
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B1EP15VD
CHECKING AND SETTING THE VALVE TIMING
Engine: XFU
C5
Setting the valve timing.
Remove the components as necessary for the operation.
Remove the screws (19) and the plate (20).
Peg the crankshaft, using tool [2].
NOTE: Damp the rotation of the camshafts (15) and (17), using tool [6].
Untighten the camshaft pulley screws (15) and (17).
NOTE: Damp the rotation of the camshafts (14) and (18), using tool [5].
Untighten the camshaft pulley screws (14) and (18).
NOTE: Lubricate the tools [1], with grease G6 (TOTAL MULTIS).
Peg the camshafts, using tools [1], [5] and [6].
Remove the screw (21) of the panel (25).
Untighten the nut (23) of the tensioner roller (24).
Untighten the screws (22) of the panel (25).
Remove the guide roller (16).
WARNING: Mark the direction of fitting of the timing belt, in case the belt is to be reused.
Remove the timing belt.
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C5
B1EP15VD
B1BP2BLC
CHECKING AND SETTING THE VALVE TIMING
Engine: XFU
Setting the valve timing (continued).
Refitting.
Check that the camshafts and the crankshaft are correctly pegged.
Check that the rollers and the water pump pulley are turning freely (no tightness).
Loosen the camshaft pulley screws by a 1/4 turn.
Make sure that the pulleys are turning freely on the camshaft hub.
Turn the camshaft pulleys in a clockwise direction, to end of slots.
WARNING: Respect the direction of fitting of the belt: facing the timing, the inscriptions on the belt should be readable the correct way up.
Fit the timing belt on the crankshaft pinion.
Position the tool [6].
Position the timing belt in the following sequence (belt well tensioned):
- The roller (26), the pulley (18), the pulley (17).
Keep the timing belt well tensioned:
- Refit the guide roller (16), tighten to 8 ± 0,8 m.daN.
Position the timing in the following sequence:
- The camshaft pulley (15), the camshaft pulley (14), the tensioner roller (24), the water pump pulley and the guide roller (27).
NOTE: When positioning the belt on the camshaft pulleys, turn these clockwise so as to engage the next tooth. The angular displacement of the pulleys should not be more than the equivalent of one tooth.
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B1EP15WC
B1EP15XC
CHECKING AND SETTING THE VALVE TIMING
Engine: XFU
Setting the valve timing (continued).
C5
Adjusting the timing belt tension.
Pivot the plate (25) of the tensioner roller (24), using a spanner (type FACOM S.161).
Engage the screw (21) on the plate (25).
Tighten the screws (21) and (22), tighten to 2,5 ± 0,1 m.daN.
Position the belt under maximum tension; pivot the tensioner roller (24),using a spanner (type
FACOM R 161).
Tighten the nut (23) of the tensioner roller (24), tighten to 1 ± 0,1 m.daN.
Check that the camshaft pinion screws are not at the end of slots (by loosening one screw).
Otherwise, restart the operation of positioning the timing belt.
Tighten at least 2 screws per camshaft pulley to 1 ± 0,1 m.daN.
Remove the tools [1], [2] and [4].
Rotate the crankshaft 2 turns in a clockwise direction.
IMPERATIVE: Never turn it back.
Peg the crankshaft, using tool [2], and the camshaft pulleys, using tool [1].
Untighten the nut (23) of the tensioner roller (24).
Adjust the belt tension, pivoting the roller (24) using tool (type FACOM S.161).
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C5
B1EP15XC
CHECKING AND SETTING THE VALVE TIMING
Engine: XFU
Setting the valve timing (continued).
Align the marks «c» and «d», without detensioning the timing belt (failing this, restart the operation
of adjusting the belt tension).
Hold the tensioner roller (24).
Tighten the nut (23), tighten to 1 ± 0,1 m.daN.
Check the position of the tensioner roller.
Remove the tools [1], [2] and [4].
Turn the crankshaft 2 rotations in the direction of engine rotation.
IMPERATIVE: Never turn it back.
Peg the crankshaft, using tool [2].
Check the roller position (24) (the alignment of the marks «c» and «d» should be correct).
Peg the camshaft pinions, using tool [1].
If the peg [1] goes in, loosen the camshaft pulley screws by 45°.
If the peg [1] does not go in, then loosen the camshaft pulley screws by 45° and manœuvre the hub using tool [5] until pegging is achieved.
WARNING: Check that the camshaft pinion pulleys are not at the end of slots. Otherwise, restart the operation of positioning the timing belt.
Tighten the camshaft pinion screws to 1 ± 0,1 m.daN.
Remove the tools [1] and [2].
Refit the panel (20), the screws (19) and tighten to 4 ± 0, m.daN.
Complete the refitting of all components.
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CHECKING AND SETTING THE VALVE TIMING
Engine: XFW
[1] Camshaft setting pegs
[2] Crankshaft setting peg
[3] Belt retaining pin
[4] Peg for checking camshaft settings
[5] Tool for immobilising inlet camshaft hubs
[6] Tool for immobilising exhaust camshaft hubs
[7] Instrument for measuring belt tension
Tools.
Removing.
Remove:
- The front RH wheel
- The RH wheelarch.
- The front RH tie-bar.
- The auxiliary drive belt (see corresponding operation).
- The tensioner roller assembly (1).
- The crankshaft pulley (2).
Support the engine using a stand.
Remove:
- The upper RH torque reaction rod.
- The RH engine support.
B1EK004D
145
: (-).0187-B
: (-).0187-A
: (-).0187-J
: (-).0187-CZ
: (-).0187-C
: (-).0187-F
: (-).0192
C8
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C8 CHECKING AND SETTING THE VALVE TIMING
Engine: XFW
Removing (continued).
B1EK005D
Remove:
- The twelve screws (3) (6 mm external hexagonal adaptor).
- The seven screws (4) (7 mm external hexagonal adaptor).
- The two covers (5).
- The cover (6).
- The fixing screws of the power steering pump, then suspend the latter.
- The support (7).
NOTE: The camshaft pegging operation can be performed without slackening the pinion screws or rotating the camshafts (using tools [5] and [6]; lightly oil the pegs
[1] and [2] prior to fitting).
Peg in the sequence:
- Camshafts, using tool [1].
- Crankshaft, using tool [2].
B1EK006D
146
B1EK007D
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CHECKING AND SETTING THE VALVE TIMING
Engine: XFW
Removing (continued).
C8
Remove screw (8).
Slacken screws (9) and (10) and nut (11).
Pivot the tensioner roller eccentric (clockwise), using tool FACOM R 161 at «B».
Remove the guide roller (12).
Remove the timing belt, commencing with the tensioner roller and the coolant pump.
B1EK008D
Refitting.
Make sure that the camshafts, as well as the crankshaft, are correctly pegged.
Check that the rollers (13) and (14), as well as the coolant pump (15) turn freely (no tight spots).
If replacing the belt, tighten the rollers (13) and (14) to 8 ± 0,8 m.daN.
Slacken screws (16) by a 1/4 turn.
Ensure that the camshaft pinions rotate freely on their hubs.
Turn the four camshaft pinions (clockwise), to end of slots.
Engage the timing belt on the crankshaft pinion.
Immobilise the belt, using tool [4].
B1EK009D
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C8 CHECKING AND SETTING THE VALVE TIMING
Engine: XFW
Refitting (continued).
Position the belt on the guide roller (13), belt at (C) well tensioned.
NOTE: Carefully turn the camshaft pinion in the opposite direction to the rotation of the engine in order to engage the belt on the pinion.
B1EK00AD
Engage the belt on the LH exhaust camshaft pinion (17).
IMPERATIVE: The angular displacement value of the pinion relative to the timing belt should not be greater than the width of one tooth.
Engage the belt on the LH inlet camshaft pinion (18), as before.
Refit the roller (12), tighten to 8 ± 0,8 m.daN.
B1EK00BD
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CHECKING AND SETTING THE VALVE TIMING
Engine: XFW
Refitting (continued).
C8
B1EK00CD
Engage the belt on:
- The roller (13).
- The camshaft pinions, inlet (19) then RH exhaust (20), as before for the camshafts.
Simultaneously engage the belt on:
- The roller (21).
- The pump (15).
- The roller (14).
Using tool FACOM S.161, at «A», pivot the plate to be able to engage the screw (8).
Tighten screws (8), (9) and (10) to 2,5 ± 0,2 m.daN.
Pivot the tensoner roller to tension the belt to the maximum (anti-clockwise), using tool FACOM R.161 at «B»:
- SEEM CTI 901-1: 440 ± 15 SEEM units,
- SEEM CTG 105.5: 83 ± 2 SEEM units,
- SEEM CTG 105.6: 86 ± 2 SEEM units.
Tighten the nut (11) of the tensioner roller to 1 ± 0,1 m.daN.
IMPERATIVE: Check that the camshaft pinions are not at end of slots (by removing a screw).
If they are, repeat the operation to refit the belt.
B1EK00DD
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C8 CHECKING AND SETTING THE VALVE TIMING
Engine: XFW
Refitting (continued).
Tighten at least two screws (16) per hub to 1 ± 0,1 m.daN, in the order indicated:
- (17), (18), (19) and (20).
Remove tools [4], [7], [1] and [2].
Effect two rotations of the crankshaft (direction of rotation of the engine).
WARNING: Never rotate the engine backwards.
B1EK00ED
Peg the crankshaft, using tool [2].
Slacken the nut (11) a 1/4 turn.
Align the marks (D) and (E) of the tensioner roller, using tool FACOM R.161.
Tighten the nut (11) to 2,5 ± 0,2 m.daN, without altering the position of the roller.
Remove the crankshaft setting peg [2].
Effect two rotations of the crankshaft.
WARNING: Never rotate the engine backwards.
Peg the crankshaft, using tool [2].
Check the position of the tensioner roller.
If the marks are not aligned, recommence the alignment of the marks (D) and (E) of the tensioner roller.
B1EK0VRD
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CHECKING AND SETTING THE VALVE TIMING
Engine: XFW
C8
B1EK00GD
Refitting (continued).
Peg the camshaft hubs, starting with LH exhaust (17) then (18) and (20), using tool [1], proceeding in the following way:
- The peg goes in: slacken by 45° the fixing screws of the pinion on the camshaft hub.
- The peg does not go in: slacken by 45° the fixing screws of the pinion on the camshaft hub until the peg will go in.
ESSENTIAL:
- Check that the camshaft pinions are not at end of slots (by removing a screw).
If they are, repeat the operation to refit the belt.
Tighten the pinions in the sequence below:
- Pinions (17), (18), (19), (20) tighten to 1 ± 0,1 m.daN.
Remove tools [1] and [2].
B1EK00HD
Checking the setting of the timing.
Effect two rotations (normal direction of rotation of the engine).
Imperative: Never turn the engine backwards.
Refit the crankshaft peg [2].
Check that the peg for checking the camshaft settings [4] engages freely in the cylinder heads
(J), as far as the camshaft pinions.
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C8
CHECKING AND SETTING THE VALVE TIMING
Engine: XFW
Checking the setting of the timing (continued).
Should this not be the case, repeat the operation to refit the belt.
Remove the crankshaft peg [2].
Refitting (continued).
Refit:
- The power steering pump.
- The support (7).
- The tensioner roller assembly (1).
Tighten:
- Screw (22) to 2,5 m.daN + LOCTITE FRNETANCH.
- Screw (23) to 4,0 m.daN + LOCTITE FRNETANCH.
- Screw (24) to 2,5 m.daN + LOCTITE FRNETANCH.
- Screw (25) to 6,0 m.daN + LOCTITE FRNETANCH.
Tighten the crankshaft pulley screws to 2,5 ± 0,2 m.daN.
Refit the auxiliary drive belt (see corresponding operation).
Complete the refitting operations in the opposite order to removal.
B1EK00JD
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B1BP32CC
CHECKING THE VALVE TIMING C5
[1] Flywheel setting peg
[2] Camshaft setting peg
[3] Crankshaft setting peg
Engine: 9HZ
Tools.
: (-).0194.C
: (-).0194.B
: (-).0194.A
Removing.
IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure
Diesel injection (HDi) engine versions.
Raise and support the vehicle, wheels hanging.
Disconnect the positive and negative terminals of the battery.
Remove:
- The front RH wheel
- The front RH splash-shield.
- The auxiliary drive belt (see corresponding operation).
Uncouple:
- The fuel supply unions (1).
- The air/air heat exchanger inlet and outlet pipes (2).
- The exhaust line (at the flexible pipe).
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C5 CHECKING THE VALVE TIMING
Engine: 9HZ
B1BP32DC
Support the engine with a roller jack equipped with a block.
Disconnect the connector at "a".
Slacken the screw (4).
Remove:
- The screw (6).
- The nut (3).
- The 3 screws (5).
- The RH engine support and upper torque reaction rod assembly.
Turn the engine in the normal direction of rotation.
Peg the flywheel using the peg [1] at "b".
B1BP305C
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CHECKING THE VALVE TIMING C5
Engine: 9HZ
B1EP1E3D
Move aside the electrical harness (7).
Remove:
- The engine support (8).
- The screw (10).
- The accessories drive pulley (9).
- The lower timing cover (11).
- The upper timing cover (12).
- The tool [1].
Refit the screw (10).
Rotate the crankshaft six times (clockwise).
IMPERATIVE: Never turn it backwards.
Peg the camshaft at «c», using tool [2] (oil the pegs).
WARNING: The magnetic track should not show any sign of damage and should not be approached by any other magnetic source.
Peg the crankshaft at «d», using tool [3].
ESSENTIAL: Should it not be possible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm.
If it is more, repeat the operation to position the timing belt (see corresponding
operation).
B1EP1E4D
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C5
B1EP1E5C
CHECKING THE VALVE TIMING
Engine: 9HZ
NOTE: The index «e» of the dynamic tensioner roller should be centred in the interval «f».
Check the correct positioning of the index «e».
If it is not correct, repeat the operation to tension the timing belt (see corresponding operation).
Remove tools [2] and [3].
Refitting.
Refit tool using tool [1] at «b».
Remove the screw (10).
Refit the upper timing cover (12), lower timing cover (11), the accessories drive pulley (9), the screw (10).
Tightening method for the screw (10):
- Pre-tightening
: 3 ± 0,3 m.daN.
- Angular tightening
: 180° ± 5°.
Remove the tool [1].
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CHECKING THE VALVE TIMING
Engine: 9HZ
Refit:
- The engine support (8), tighten to : 5,5 ± 0,9 m.daN.
- The RH engine support and upper torque reaction rod assembly.
- The nut (3), tighten to
- The three screws (5), tighten to
- The screw (6), tighten to
- The screw (4), tighten to
- The electrical harness (7).
: 4,5 ± 0,5 m.daN.
: 5,5 ± 0,8 m.daN.
: 6 ± 0,6 m.daN.
: 6 ± 0,6 m.daN.
Couple:
- The exhaust line, tighten to
- The fuel supply unions (1).
- The air/air heat exchanger inlet and outlet pipes (2).
Connect the connector at "a".
: 2,5 ± 0,3 m.daN.
Refit:
- The auxiliary drive belt (see corresponding operation).
- The front RH splash-shield.
- The front RH wheel.
Reconnect the positive and negative terminals of the battery.
C5
IMPERATIVE: Carry out the operations that are necessary following a reconnection of the battery (see corresponding operation).
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C5
B1BP32CC
CHECKING AND SETTING THE VALVE TIMING
Engine: 9HZ
Tools.
[1] Flywheel setting peg
[2] Camshaft setting peg
[3] Crankshaft setting peg
: (-).0194.C
: (-).0194.B
: (-).0194.A
Removing.
IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions.
Raise and support the vehicle, wheels hanging.
Disconnect the positive and negative terminals of the battery.
Remove:
- The front RH wheel.
- The front RH splash-shield.
- The auxiliary drive belt (see corresponding operation).
Uncouple:
- The fuel supply unions (1).
- The air/air heat exchanger inlet and outlet pipes (2).
- The exhaust line (at the flexible pipe).
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CHECKING AND SETTING THE VALVE TIMING
Engine: 9HZ
Support the engine with a roller jack equipped with a block.
Disconnect the connector at "a".
Slacken the screw (4).
B1BP32DC
Remove:
- The screw (6).
- The nut (3).
- The 3 screws (5).
- The RH engine support and upper torque reaction rod assembly.
Turn the engine in the normal direction of rotation.
Peg the flywheel using the peg [1] at "b".
B1BP305C
159
C5
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C5
CHECKING AND SETTING THE VALVE TIMING
Engine: 9HZ
Move aside the electrical harness (7).
Remove:
- The engine support (8).
- The screw (10).
- The accessories drive pulley (9).
- The lower timing cover (11).
- The upper timing cover (12).
- The tool [1].
Refit the screw (10).
B1EP1E3D
Turn the crankshaft to bring the camshaft to its pegging point.
Peg the camshaft at «c», using tool [2] (oil the pegs).
WARNING: Do not damage or bear against the track of the target of the engine speed sensor (13).
Peg the crankshaft at «e», using tool [3].
Remove the timing belt protector (13) and the engine speed sensor (14).
Slacken the screw (12) of the tensioner roller and keep it slackened using an allen spanner at «d».
Detension the timing belt by pivoting the tensioner roller (clockwise).
Remove the timing belt, starting with the coolant pump pinion.
B1EP1E6D
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CHECKING AND SETTING THE VALVE TIMING
Engine: 9HZ
B1EP1E6D
C5
Checks.
ESSENTIAL: Just prior to refitting, proceed to the checks as below.
Check:
- That the rollers and the coolant pump pulley turn freely (without play and without tight spot).
- That there are no signs of oil leaks (at the crankshaft and camshaft seals).
- That there are no leaks of coolant fluid (at the coolant pump).
- That the track of the target of the engine speed sensor (14) is not damaged or scratched.
Replace any components that are defective (if necessary).
Refitting.
Fit the timing belt on the crankshaft pinion.
Position the belt on the guide roller, belt well tensioned.
Refit:
- The timing belt protector (13).
- The engine speed sensor (14).
Reposition the timing belt, strip «f» well tensioned, in the following sequence:
- Guide roller (16).
- Camshaft pulley (20).
- Fuel high pressure pump pulley (19).
- Coolant pump pulley (17).
- Tensioner roller (18).
B1EP1E7D
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C5
B1EP1E8C
CHECKING AND SETTING THE VALVE TIMING
Engine: 9HZ
Adjusting the timing belt tension.
Act on the tensioner roller (18) to align the marks «g» and «h», avoiding detensioning the timing belt, using an allen spanner at «d».
Should this fail, repeat the operation to tension the timing belt.
Hold the tensioner roller (18).
Tighten the tensioner roller fixing nut to 3,7 ± 0,3 m.daN.
Check the position of the tensioner roller (the alignment of the marks «g» and «h» has to be correct).
Remove tools [2] and [3].
Rotate the crankshaft six times (clockwise).
IMPERATIVE: Never rotate the engine backwards.
WARNING: Do not touch or damage the track of the target of the engine speed sensor (14).
Peg the crankshaft, using tool [3].
Check the position of the tensioner roller (the alignment of the marks «g» and «h» has to be correct).
If this is not the case, repeat the operation to tension the timing belt.
Peg the camshaft pulley, using tool [2].
IMPERATIVE: Should it be impossible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm. If the value is not correct, repeat the operation.
Remove the tools [2] and [3].
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CHECKING AND SETTING THE VALVE TIMING
Engine: 9HZ
Remove the screw (10).
Refit the upper timing cover (11), the lower timing cover (12), the pulley (9) and the screw (10).
Tightening method for the screw (10):
- Pre-tighten to
- Angular tighten
Remove tool [1].
: 3 ± 0,3 m.daN.
: 180° ± 5°.
Refit:
- The engine support (8), tighten to
- The RH engine support and upper torque reaction rod assembly.
- The nut (3), tighten to
- The three screws (5), tighten to
- The screw (6), tighten to
- The screw (4), tighten to
- The electrical harness (7).
Couple:
- The exhaust line, tighten to
- The fuel supply unions (1).
- The air/air heat exchanger inlet and outlet pipes (2).
Connect the connector at «a».
: 5,5 ± 0,9 m.daN.
: 4,5 ± 0,5 m.daN.
: 5,5 ± 0,8 m.daN.
: 6 ± 0,6 m.daN.
: 6 ± 0,6 m.daN.
: 2,5 ± 0,3 m.daN.
Refit:
- The accessories drive belt (see corresponding operation).
- The front RH splash-shield, the front RH wheel.
Reconnect the positive and negative terminals of the battery.
IMPERATIVE: Perform the operations that are necessary following a reconnection of the battery (see corresponding operation).
C5
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C5
B1BP31DC
B1EP1FMC
CHECKING THE VALVE TIMING
Engines: RHL - RHR
Tools.
[1] Kit of plugs
[2] Double flywheel setting peg
[3] Camshaft setting peg
: (-).0188.T
: (-).0188.X
: (-).0188.M
IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection
(HDi) engine versions
Remove the engine cover and the battery.
Disconnect the negative terminal of the battery.
Raise and support the front of the vehicle.
Remove the under-engine sound-deadening and the front RH splash-shield (see corresponding operation).
Uncouple, plug and move aside, using tool [1], the fuel supply (1) and fuel return (2) pipes.
Suspend the engine, using a workshop hoist.
Remove the torque reaction rod (3) and the RH engine support (4).
Move aside the electrical harness (5).
Remove:
- The camshaft position sensor.
- The inlet cylinder head cover (6).
- The upper timing cover screws.
- The upper timing cover (6).
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CHECKING THE VALVE TIMING
Engines: RHL - RHR
Checks.
Turn the crankshaft in the normal direction of rotation.
Line up the black markings «b» and «c» on the chain with the teeth «a» and «d» of the camshaft drive pinions (40 turns of the camshafts maximum).
C5
B1EP1FND
IMPERATIVE: If it is impossible to line up the markings on the chain with the camshaft drive pinions, repeat the setting of the camshafts (see operation: removing-refitting of
camshafts).
Peg:
- The crankshaft, using tool [2].
- The camshaft pinion, using tool [3].
IMPERATIVE: Should it be impossible to peg the camshaft, check that the offset between the camshaft hole and the pegging hole is not more than 1 mm (use a screw
7 mm in dia.).
If the offset is more than 1 mm, repeat the operation to set the timing
(see corresponding operation).
Remove tools [1] and [3].
B1BP31FC
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C5
B1BP2XLD
B1EP1FPC
CHECKING THE VALVE TIMING
Engines: RHL - RHR
Additional operations.
Refit:
- The inlet valve cover (7).
- The 16 fixing screws and the 2 screws at refs. 1 and 2 for the camshaft bearing caps cover.
- The camshaft position sensor (without tightening its fixing screw).
Tighten the 19 screws
Adjusting the camshaft position sensor.
Peg the engine flywheel, using tool [2].
: 9 ± 0,1 m.daN (in the sequence indicated).
Sensor re-used:
- Position a drill Ø 8,5 at "e" (between the inlet valve cover (7) and the camshaft position sensor (9)).
- Remove the tool [2].
New sensor:
- Place the camshaft position sensor (9) in contact with the target (camshaft pinion).
- Tighten the screw (8)
: 2 ± 0,2 m.daN.
- Remove the tool [2].
Complete the refitting.
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CHECKING AND SETTING THE VALVE TIMING
Engines: RHL - RHR
C5
Tools.
[1] Kit of plugs
[2] Double flywheel setting peg
[3] Camshaft setting peg
[4] Belt clamp
[5] Pinion centrer
[6] Flywheel lock
[7] Pulley extractor
: (-).0188.T
: (-).0188.X
: (-).0188.M
: (-).0188.AD
: (-).0188.AH
: (-).0188.F
: (-).0188.P
Removing.
IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions.
Slacken the front RH wheel bolts.
Raise and support the front RH side of the vehicle.
Disconnect the negative terminal of the battery.
Remove the under-engine sound-deadening, the front RH wheel, the front RH splash-shield, the engine cover.
Remove the auxiliaries drive belt (see corresponding operation).
Uncouple, plug and move aside, using tool [1]:
- The fuel delivery pipe (1).
- The fuel return pipe (2).
Suspend the engine, using a workshop hoist.
Remove the torque reaction rod (3) and the RH engine support (4).
B1BP31DC
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C5
CHECKING AND SETTING THE VALVE TIMING
Engines: RHL - RHR
Move aside the electrical harness (5).
Remove:
- The upper timing cover screws.
- The upper timing cover (6).
Rotate the engine by means of the auxiliaries drive pulley.
B1EP1FAC
Orient the camshaft pinion in the pegging position, use a mirror if necessary.
Peg the camshaft, using tool [3].
Peg the engine flywheel, using tool [2].
Lock the flywheel, using tool [6].
B1EP1FBC
168
B1BP31EC
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CHECKING AND SETTING THE VALVE TIMING
Engines: RHL - RHR
B1EP1FCC
Remove:
- The screw (8) and the auxiliaries drive pulley (7).
- The crankshaft position sensor (11).
- The lower timing cover (9).
- The target of the crankshaft position sensor (10), using tool [7].
- The lower torque reaction rod.
- The tool [6].
Slacken the screw (12) of the tensioner roller (17).
Remove the timing belt (13).
Checks.
IMPERATIVE: Just before refitting, carry out the checks below.
Check:
- That the rollers (14) and (17) turn freely (without play and without any tight spot).
- That the coolant pump pulley (16) turns freely (without play and without any tight spot).
- That there are no signs of oil leaks from the crankshaft and camshaft seals, etc.
- That the crankshaft pinion travels freely on the keyway (15).
Replace defective components if necessary.
B1EP1FDC
169
C5
B1EP1FEC
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C5
CHECKING AND SETTING THE VALVE TIMING
Engines: RHL - RHR
Refitting.
Centre the crankshaft pinion (15), using tool [5].
Reposition the timimg belt on the pulley (18).
Put the tool [4] in place (tighten moderately).
B1EP1FFC
Reposition the timimg belt, strip «a» well tensioned, in the following order:
- Guide roller (14).
- Crankshaft pinion (15).
- Coolant pump pinion (16).
- Tensioner roller (17).
Remove tools [4] and [5].
B1EP1FGC
170
B1EP1FHC
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CHECKING AND SETTING THE VALVE TIMING
Engines: RHL - RHR
C5
Bring the index «d» outside the plate at «c», by turning the tensioner roller in the direction of the arrow
«b», using a hexagonal spanner at «e».
Tighten screw (12) of the tensioner roller (17) to 2,1 ± 0,2 m.daN.
Lock the flywheel, by means of tool [6].
Refit the auxiliaries drive pulley (7).
Tighten the screw (8) to 7 ± 0,7 m.daN.
Remove tools [6], [2] and [3].
Rotate the crankshaft ten times (in the direction of rotation of the engine).
Peg:
- The crankshaft, using tool [2].
- The camshaft drive pinion, using tool [3].
Lock the flywheel, using tool [6].
Slacken:
- The screw (8) of the auxiliaries drive pulley (7).
- The screw (12) of the tensioner roller (17).
B1EP1FJC
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C5
B1EP1FKC
CHECKING AND SETTING THE VALVE TIMING
Engines: RHL - RHR
Turn the tensioner roller (clockwise), using a hexagonal spanner at «e».
Position the index «d» opposite the notch «f».
Tighten:
- The screw (12) of the tensioner roller (17) to 2,1 ± 0,2 m.daN.
- The auxiliaries drive pulley to 7 ± 0,7 m.daN.
Remove tools [3] and [6].
Rotate the crankshaft two times (in the direction of rotation of the engine).
Refit tools [2] and [3].
Check the position of the index «d», it should be opposite the notch «f».
IMPERATIVE: If the position of the index «d» is not correct, restart the operations to tension the timing belt (for this, slightly slacken the screw (12) of the tensioner roller).
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CHECKING AND SETTING THE VALVE TIMING
Engines: RHL - RHR
C5
Refit tool [6].
Remove the auxiliaries drive pulley (7).
Refit the crankshaft position sensor target (10), the lower timing cover (9), the crankshaft position sensor (11), the torque reaction rod on the lower engine support.
Take away the workshop hoist.
Coat the screw (8) with Loctite FRENETANCH.
Refit the auxiliaries drive pulley (7) and the screw (8) with its washer.
Tighten the screw (8) to 7 ± 0,7 m.daN, then angular tighten by A = 60° ± 5°.
Remove tools [2], [3] and [6].
B1EP1FLC
Refit the upper timing cover (6).
Reposition the electrical harness (5).
Refit the RH engine support (4), the torque reaction rod (3).
Reclip the fuel supply and return pipes.
Connect the fuel supply pipe (1), the fuel return pipe (2).
Refit:
- The auxiliaries drive belt (see corresponding operation).
Complete the refitting.
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C5
CHECKING AND SETTING THE VALVE TIMING
Engine: 4HX
Tools.
[1] Belt tension measuring instrument
[2] Engine flywheel peg
[3] Tension lever
[4] Belt compressure spring
[5] Camshaft pinion peg
[6] Engine flywheel lock
[7] Set of blocking plugs
: 4122-T
: (-).0188.X
: (-).0188.Y
: (-).0188.K
: (-).0188.M
: (-).0188.F
: (-).0188.T
IMPERATIVE: Respect the safety and cleanliness recommendations specific to high pressure diesel injection (HDi) engines.
Checking the setting of the valve timing.
Turn the crankshaft (normal direction of rotation) and line up the black markings on the chain (b) and (c) with the teeth marked (a) and (d) of the camshaft drive pinions (40 turns max. of the camshaft).
B1EP159D
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B1BP298C
CHECKING AND SETTING THE VALVE TIMING
Engine: 4HX
C5
Checking the setting of the valve timing (continued).
IMPERATIVE: If it is impossible to line up the marks on the chain and on the camshaft drive pinions, restart the camshaft setting (see operation for removing and refitting camshafts).
If the marks on the chains and pinions are coinciding, continue the checking operations.
Peg:
- The crankshaft, using tool [2].
- The camshaft pinion, using tool [5].
IMPERATIVE: Should it be impossible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm (use a screw 7 mm in dia.).
If the offset is more than 1 mm, restart the setting of the valve timing (see corresponding operation).
Remove the tools [2] and [5].
B1EP15AD
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C5
B1BP298C
CHECKING AND SETTING THE VALVE TIMING
Engine: 4HX
Setting the valve timing.
Turn the crankshaft to bring camshaft to its pegging point.
Peg the crankshaft, using tool [2].
Peg the camshaft, using tool [5].
Slacken:
- The three screws (25).
- The screw (23) of the tensioner roller (24).
Remove the timing belt (26).
Checks.
IMPERATIVE: just prior to refitting, carry out the checks below.
Check:
- That the rollers (24) and (27) and the coolant pump (22) are turning freely (without play and without tightness).
- Absence of traces of oil leaks (crankshaft and camshaft sealing rings).
- Absence of leaks of coolant fluid (coolant pump).
NOTE: Replace defective components (if necessary).
B1EP15AD
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B1EP15BD
B1EP15CC
CHECKING AND SETTING THE VALVE TIMING
Engine: 4HX
Setting the valve timing (continued).
Refit.
- Retighten the screws (25) by hand.
- Turn the pinion (29) (clockwise) to the bottom of the buttonhole.
- Refit the belt on the crankshaft (28).
- Hold the belt, using tool [4].
Reposition the timing belt, keeping the belt tight at «a», in the following order:
- Guide roller (27).
- Fuel high pressure pump pinion (30).
- Camshaft pinion (29).
- Water pump pinion (22).
- Tensioner roller (24).
NOTE: If needed, slightly turn the pinion (29) anti-clockwise (not by more
than one tooth).
- Remove the tool [4].
B1EP15DD
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C5
B1EP15ED
CHECKING AND SETTING THE VALVE TIMING
Engine: 4HX
Setting the valve timing (continued).
Position tool [1] on the belt at «b».
Turn the tensioner roller (24) (anti-clockwise) using tool [2] to attain a tension of: 106 ± 2 SEEM units.
Tighten screw (23) of the tensioner roller, tighten to 2.5 m.daN.
Remove one screw (25) from the pinion (29) (to check that the screws are not
against the end of the buttonhole).
Tighten the screws (25) to 2 m daN.
Remove tools [1], [2], [3] and [5].
Rotate the crankshaft 8 times (normal direction of rotation).
Fit the tool [3].
Loosen screws (25).
Fit tool [5].
Loosen screw (23) (to free the tensioner roller (24)).
Fit tool [1].
Turn the tensioner roller (24) (anti-clockwise),using tool [3], to attain a tension of:
Tighten:
51 ± 3 SEEM units.
- The screw (23) of the tensioner roller (24) to 2,5 ± 0,2 m.daN.
- The screws (25) to 2 ± 0,2 m.daN.
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CHECKING AND SETTING THE VALVE TIMING
C5
Engine: 4HX
Setting the valve timing (continued).
Remove the tool [1].
Refit the tool [1].
Tension value should be: 51 ± 3 SEEM units.
IMPERATIVE: If value is incorrect, restart the operation.
Remove tools [1], [2] and [5].
Rotate the crankshaft 2 times (normal direction of rotation).
Fit the tool [3].
IMPERATIVE: Should it be impossible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm. In the case of an incorrect value, recommence the operation.
Remove the tool [2].
Complete the refitting of components.
B1EP15ED
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C8 CHECKING AND SETTING THE VALVE TIMING
Engines: RHM - RHT - RHW - 4HW
Tools.
[1] Instrument for measuring belt tension SEEM C.TRONIC
[2] Crankshaft setting peg (engine DW12TED4)
[3] Camshaft peg
[4] Belt retaining pin
[5] Engine flywheel stop
[7] Tensioning lever
[8] Pulley extractor
[9] Crankshaft setting peg (engine DW10ATED4)
[10] Crossmember
[11] Tie-bar support
[12] Retaining support
[13] Support with adjustable screw
[14] Set of plugs
: (-).0192
: (-).0188-X
: (-).0188-M
: (-).0188-K
: (-).0188-F
: (-).0188-J2
: (-).0188-P
: (-).0188-Y
: 4090-T
: 4176-T
: (-).0911-J
: (-).0911-H
: (-).0188-T
Removing.
Remove:
- The front RH splashshield.
- The under-engine shield.
- The auxiliary drive belt (see corresponding operation).
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CHECKING AND SETTING THE VALVE TIMING
Engines: RHM - RHT - RHW - 4HW
Removing.
Remove:
- The closing panel of the clutch casing (block the engine flywheel, tool [5]).
- The auxiliary drive pulley screw.
Refit the screw without the washer.
B1EK0TVC
Remove:
- The auxiliary drive pulley, using tool [8].
- The tool [5].
Turn the crankshaft.
Peg:
- The engine flywheel, tool [2] (engine DW12TED4).
- The engine flywheel, tool [9] (engine DW10ATED4).
181
C8
B1EK0TUC
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C8
B1EK1TTD
CHECKING AND SETTING THE VALVE TIMING
Engines: RHM - RHT - RHW - 4HW
Removing (continued).
Disconnect the battery.
Move aside the header tank.
Position the tools for supporting the engine [10], [11], [12] and [13].
Remove:
- The scuttle panel grille.
- The torque reaction rod (1).
- The fuel unions (2).
IMPERATIVE: Plug the apertures using tool [13].
Protect the radiator harness with strong cardboard cut out to the dimensions of the radiator.
Remove:
- The RH engine support (4).
- The timing covers (3).
- The lower timing cover.
Peg the camshaft pulley, using tool [3].
Slacken the tensioner roller fixing (5).
Retighten the fixing to the position of maximum de-tension (tighten to 0,1 m.daN).
Remove the timimg belt.
B1EK1T2D
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CHECKING AND SETTING THE VALVE TIMING
Engines: RHM - RHT - RHW - 4HW
C8
B1EK0TXC
Refitting.
IMPERATIVE: Check that the rollers (5) and (6) as well as the coolant pump (7) turn freely (no play, no
tight spot), check also that these rollers are not noisy and/or that they are not throwing out grease.
In the event of replacement, tighten the roller (6) to 4,3 ± 0,4 m.daN.
Slacken the screws (8).
Check that the pulley (9) turns freely on its hub.
Tighten the screws (8) by hand.
Slacken the screws (8) by a 1/6 turn.
Turn the pulley (9) (clockwise), to end of slots.
Refit the timing belt, well tensioned, in the following order:
- Crankshaft (immobilise the belt, using tool [4]).
- Guide roller (6).
Engage the timing belt on the pulley (10).
Carefully turn the camshaft pinion in the opposite direction to the rotation of the engine in order to engage the belt on the pinion.
WARNING: The angular displacement «a» of the pulley relative to the belt should not be greater than the width of one tooth.
Engage the belt on the tensioner roller (5) and on the coolant pump pinion (7).
Turn the tensioner roller (5) (anti-clockwise), so as to put the tensioner roller (5) in contact with the belt.
Pre-tighten the fixing screw of the tensioner roller to 0,1 m.daN.
Remove the tool [4].
B1EK0TYC
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C8
CHECKING AND SETTING THE VALVE TIMING
Engines: RHM - RHT - RHW - 4HW
Pre-tensioning the timing belt.
Position the tool [1].
NOTE: Check that the tool is not in contact with anything else around it.
Turn the roller (5) (anti-clockwise), using tool [7] to obtain a tension of: 98 ± 2 SEEM units.
Tighten the screw (11) to 2,3 ± 0,2 m.daN (without modifying the position of the roller).
Remove the tool [1].
IMPERATIVE: By removing one of the screws (8) on the pulley (9), make sure that these screws (8) are not at end of slots (if they are, repeat the operation to refit the
timing belt).
Bring the screws (8) into contact with the pulleys.
Tighten the screws (8) to 2 ± 0,2 m.daN.
Remove the setting pegs [3] and [2].
Effect eight turns of the engine in the normal direction of rotation.
IMPERATIVE: Never turn the crankshaft backwards.
B1EK1TSD
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CHECKING AND SETTING THE VALVE TIMING
Engines: RHM - RHT - RHW - 4HW
Tensioning the timing belt.
C8
Refit the pegs [2] and [3].
Slacken the screws (8).
Tighten the screws (8) by hand.
Slacken the screws (8) by a 1/6 turn.
Slacken screw (11).
Place tool [1] on the belt at (A).
Turn the roller (anti-clockwise),using tool [7] to obtain a tension of: 51 ± 2 SEEM units.
Tighten screw (11) to 2,3 ± 0,2 m.daN (without modifying the position of the roller).
Tighten the screws (8) to 2 ± 0,2 m.daN.
Remove tool [1] to release the internal forces.
Refit the tool [1].
The tension value should be between 48 and 55 SEEM units.
IMPERATIVE: Value noted outside the tolerance: detension the belt and recommence the operation.
Remove tools [1], [2] and [3].
B1EK1T1D
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C8 CHECKING AND SETTING THE VALVE TIMING
Engines: RHM - RHT - RHW - 4HW
Checking the timing setting.
Effect two turns of the engine in the normal direction of rotation, without turning the engine backwards.
Refit the peg [2].
IMPERATIVE: Check visually that the offset between the hole in the camshaft hubs and the corresponding pegging hole is not more than 1 mm.
Remove the peg [2].
Refit:
- The lower timing cover.
- The elements (3) of the timing cover.
- The engine support (4).
- The screws (13), tighten to 6,1 ± 0,6 m.daN.
- The nut (12), tighten to 4,5 ± 0,4 m.daN.
IMPERATIVE: Apply an opposite torque at (A).
Refit:
- The torque reaction rod (1).
- Screw (14), tighten to 5 ± 0,5 m.daN.
- Screw (15), tighten to 5 ± 0,5 m.daN.
B1EK1T0D
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CHECKING AND SETTING THE VALVE TIMING
Engines: RHM - RHT - RHW - 4HW
Refit:
- The tool [5].
- The auxiliary drive pulley.
Clean the threads of the pulley screw going into the crankshaft (tap M16x150).
Brush the screw threads.
Tightening torque for the screw:
- Tighten to
: 7 ± 0,7 m.daN (+ LOCTITE FRENETANCH).
- Angular tighten : 60° ± 6° (Tool FACOM D360).
Check the tightening: 26 ± 2,6 m.daN.
Refit the auxiliary drive belt (see corresponding operation).
Remove tool [5].
Refit the closing plate, tighten to 0,7 m.daN.
Tighten the wheel bolts to 10 m.daN.
Complete the refitting in reverse order to removal.
Initialise the various ECUS.
B1EK0TVC
187
C8
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Engine type
Temperature (°C)
Pressure (bars)
Rpm
Pressure (bars)
Rpm
Pressure (bars)
Rpm
6FZ
CHECKING THE OIL PRESSURE
To be read with the Petrol and Diesel correspondence tables
RFJ
1,5
RFN 3FZ XFU
80°C
3,4 2
1000 900
5
3000
6,9
4000
5
3000
2279-T.Bis
4103-T.B
7001-T
4202-T
(-).0710.F1
(-).0710.B1
X
X
X
X
X
X
NOTE: Oil pressure should be checked with the engine cold, after checking the oil level.
188
X
X
XFW
1,2
650
X
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Engine type
Temperature (°C)
Pressure (bars)
Rpm
Pressure (bars)
Rpm
Pressure (bars)
Rpm
9HZ
1,3
CHECKING THE OIL PRESSURE
To be read with the Petrol and Diesel correspondence tables
RHM RHT RHW RHL RHR
80°C
2
1000
4
2000
3,5
4000
2279-T.Bis
4103-T.B
7001-T
4202-T
(-).1503.J
X
X X X
X
X
NOTE: Oil pressure should be checked with the engine cold, after checking the oil level.
189
X
1,9
X
4HX
2
4HW
X X
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VALVE CLEARANCES
The valve clearances must be checked with the engine cold.
POSSIBLE PROCEDURES
For engines with 4 cylinders in a line (1-3-4-2).
All types
●
Inlet
Exhaust
Hydraulic adjustment
Rocking
Rocking Adjust
1
●
3
●
4
●
2
●
1 4
●
3 2
●
4 1
●
2
3
●
1
3
4
2
●
Inlet
Exhaust
Fully open (exhaust)
Valves fully open
Adjust
1 3
●
4
3
4
●
2
4 2
●
1
2 1
●
3
190
Engines without hydraulic adjustment:
The clearance (J) should be checked opposite the cam.
B1DP13QC
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CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT
Engines: RHL - RHR
C5
[1] Ø 10 mm low pressure connector
[2] Pressure gauge for testing boost pressure
Tools.
: 4215-T
: 4073-T.A
Toolkit 4073-T
IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines.
Link tools [1] and [2] in series between the fuel high pressure pump and the fuel filter.
ESSENTIAL: Check that the tool [2] is clean.
Normal vacuum values.
Engine driven by the starter motor
Engine running under full load
: 10 ± 0,5 cmHg.
: 20 ± 10 cmHg.
Abnormal vacuum values.
Supply circuit obstructed (full tank strainer, piping, fuel filter)
: 60 ± 20 cmHg.
B1BP33RD
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C5 CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT
Engine: 4HX
[1] Ø 10 mm low pressure connector
[2] Ø 8 mm low pressure connector
[3] Pressure gauge for testing boost pressure
[4] Extension
Tools.
: 4215-T
: 4218-T
: 4073-T Kit 4073 -T
: 4251-T
Connect the tool [1] between the booster pump and the fuel filter (white mark at "a" on
the fuel supply pipe).
Connect the tool [2] downstream of the diesel injectors, between the high pressure fuel pump and the fuel filter (green mark at "b" on the fuel return pipe).
WARNING: Any check of pressure downstream of the fuel filter is PROHIBITED.
B1BP27BD
NOTE: To check the pressures while the vehicle is being driven, insert tool [4] between tool [3] and tools [1] et [2].
Checks on pressure: static.
Switch on ignition.
For 3 seconds (normal functioning):
- Fuel supply pressure shown by the pressure gauge [3] = 2.6 ± 0.4 bar.
- Fuel return pressure shown by the pressure gauge [3] = 0.6 ± 0.4 bar.
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CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT
Engine: 4HX
Checks on pressure: dynamic.
Engine running, at idle (normal functioning):
- Fuel supply pressure shown by the pressure gauge [3] = 2 ± 0.4 bar.
- Fuel return pressure shown by the pressure gauge [3] = 0.8 ± 0.4 bar.
Abnormal functioning.
Fuel supply pressure
Between 3.3 and 4 bar
More than 4 bar
More than 4 bar
Between 0.8 and 1.5 bar
Fuel return pressure
0.8 ± 0.4 bar
Less than 0.8 bar
More than 0.8 bar
Less than 0.8 bar
C5
Checks
Check the condition of the diesel filter
Check the low pressure regulator incorporated in the filter (locked shut): replace.
Check the fuel return circuit (pipe pinched or trapped…)
Check the fuel suppy circuit:
- Booster pump (low pressure), piping
Impossible to start the engine:
Fuel supply pressure less than 0.8 bar:
- Check the low pressure regulator incorporated in the filter (locked open).
- Check the high pressure pump distribution valve (locked shut).
Check: diesel injector return flow (table below).
Uncouple the diesel injector return pipe.
Checks
The flow should be drop by drop
Excessive fuel return
193
Observe
Diesel injector functioning correctly
Diesel injector locked shut
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C5
CHECKS: TURBO PRESSURE
Engine: 9HZ
Preparation.
IMPERATIVE: Respect the following test conditions:
- Engine at operating temperature.
- Vehicle in running order.
- Engine under full load.
Connect the diagnostic tool to the vehicle's diagnostic socket, carry out parameter measures.
Mode of operation.
Start the engine.
Engage first gear, start the vehicle.
Engage the gears up to third gear.
Decelerate to an engine speed of 1000 rpm.
Check the pressure: 0,6 ± 0,05 bar (1500 rpm).
Accelerate freely (change from 4th gear to 3rd gear).
Check the pressure: 0,9 ± 0,05 bar (between 2500 and 3500 rpm).
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B1BP33PC
B1HP1ZEC
CHECKS: TURBO PRESSURE
Engines: RHL - RHR
C5
Tools.
[1] Pressure gauge for checking the pressure
[2] Pressure take-off extension
[3] Pressure take-off union and hose
[4] Sleeve for checking the turbo pressure
[5] Adaptor sleeve
: 7073-T
: 8607-T.A
: 8607-T.B
: 4185-T
: 4219-T
Checks.
IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines.
Preliminary operations.
Slacken the clip (1).
Uncouple the air supply duct (2).
Fit tool [1] on tool [2].
Checking.
Insert the tools [4] and [5] between the air duct (2) and the turbo air cooler outlet at «a».
Fit the tool [3] on tool [4].
Position tool [1] inside the vehicle.
Start the engine.
Accelerate the engine to 4000 rpm.
The pressure should be
Returning the vehicle to conformity
Remove tools [1], [2], [3], [4] and [5].
Recouple the air duct (2) on the turbo air cooler.
Tighten the clip (1).
: 1 ± 0,2 bar.
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C5
B1BP28DC
E5AP1SUC
CHECKS: TURBO PRESSURE
Engine: 4HX
Tools.
[1] Pressure gauge for checking pressure
[2] Extension cable for taking pressure
[3] Union and hose for taking pressure
[4] Adaptor for taking pressure
[5] Unions and hoses for taking pressure
: 7073-T.A
: 8607-T.A
: 8607-T.B
: 8607-T.C
: 4088-T
Checks.
ESSENTIAL: Respect the safety and cleanliness requirements specific to high pressure diesel injection (HDi) engines.
Preliminary operations.
Carry out the following operations:
- Remove the screw (1).
- Disconnect the tube (2).
- Move aside the pressure sensor (3).
Preparation of tools: In position on the vehicle.
Fit as follows:
- Remove the hose (a) of tool [5], screw in its place the tool [3], remove the hose (b) of tool [5], screw the hose (b) of tool [5] on the pressure gauge [1], screw the adaptor [4] into the tool [5].
Connect the tube (2) of the pressure sensor (3) on the tool [4], tighten the tube (2) with a
Serflex type collar.
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B1BP28EC
C5FPOBLC
CHECKS: TURBO PRESSURE
Engine: 4HX
Preparation of tools: In position on the vehicle (continued).
Screw the tool [3] on the take-off of the turbo air radiator at «c».
Place the pressure gauge on the cup holder at «d».
Connect the extension [2] on the hose «b» and tool [5].
ESSENTIAL: Observe the following checking requirements.
Start the engine.
Engage first gear and start the vehicle.
Engage the gears up to third gear.
Decelerate to 1500 rpm.
Accelerate gradually: the pressures should be the following:
- 1.1 ± 0.05 b at 2000 rpm
- 1.2 ± 0.05 b at 3000 rpm.
Return the vehicle to normal.
Remove the tools [1], [2], [3], [4] and [5].
Reposition the pressure sensor (3).
Couple the tube (2).
Refit and tighten the screw (1).
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C5
CHECKING THE AIR SUPPLY CIRCUIT
Engine: 9HZ
Tool.
[1] Manual pressure-vacuum pump
Checks.
B1HP1UGC
Vacuum pump.
Connect the tool [1] into the vacuum pump (1).
Start the engine.
Wait 30 seconds.
The vacuum value should be 0.9 ± 0.1 bar at idle.
: FACOM DA 16
NOTE: The exhaust gas recycling valve is not linked to the air supply circuit.
The exhaust gas recycling electrovalve is controlled by the engine ECU.
Turbocharging pressure regulation valve.
Connect the tool [1] on the valve (2) (tube identified by the colour grey).
Appy a vacuum of approx. 0.8 bar.
Rod "a" should move 12 ± 2 mm.
B1HP1UHC
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B1BP33ZC
B1BP340C
CHECKING THE AIR SUPPLY CIRCUIT
Engines: RHL - RHR
[1] Manual pressure-vacuum pump
Checks.
Tool.
: FACOM DA 16
IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines.
Checking the vacuum source (vacuum pump).
Connect the tool [1] on the take-off «a».
Start the engine.
The value should be
: 1 ± 0,2.
Turbocharging pressure electrovalve.
Connect the tool [1] on the vacuum supply «b» of the electrovalve (1).
Start the engine.
The value should be
: 1 ± 0,2
Cold air circuit electrovalve.
Connect the tool [1] on the vacuum supply «c» of the electrovalve (2).
Start the engine.
The value should be
: 1 ± 0,2
Warm air circuit electrovalve.
Connect the tool [1] on the vacuum supply «d» of the electrovalve (3).
Start the engine.
The value should be : 1 ± 0,2.
199
B1BP341C
B1BP342C
C5
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C5
B1BP343C
B1BP344C
CHECKING THE AIR SUPPLY CIRCUIT
Engines: RHL - RHR
Checking the warm air opening.
Remove:
- The air duct (4).
- The air duct (5).
- The air duct (6).
Connect the tool [1] on the warm air butterfly control diaphragm at «e».
Apply a vacuum of 0,7 ± 0,2, the warm air butterfly «f» should be fully open.
B1BP345C
Checking the cold air closing.
Connect the tool [1] on the cold air butterfly control diaphragm at «g».
Apply a vacuum of 0,65 ± 0,2, the cold air butterfly «h» should be fully closed.
Refit:
- The air duct (4).
- The air duct (5).
- The air duct (6).
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CHECKING THE AIR SUPPLY CIRCUIT
C5
Engine: 4HX
ESSENTIAL: Respect the safety and cleanliness recommendations.
Tool.
[1] Manual vacuum pump
: FACOM DA 16
Checks.
ESSENTIAL: Respect the safety and cleanliness recommendations that are specific to high pressure diesel injection (HDi) engines.
B1HP1ARP
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C5
CHECKING THE AIR SUPPLY CIRCUIT
Engine: 4HX
Vacuum pump.
Connect the tool [1] on the vacuum pump (3).
Start the engine.
The vacuum should be 0.8 bar at 750 rpm.
Turbo vacuum regulation electrovalve.
Connect the tool [1] between the electrovalve (2) and the valve (1).
Compare readings with the values in the table below.
Engine speed (rpm)
780
Vacuum (bar)
0,6 bar
4000
0,25 bar
Turbo pressure regulation valve.
Connect the tool [1] on the valve (1) (grey marking on pipe).
Appy a vacuum of 0.8 bar. The rod "a" should move 12 ± 2 mm.
Rod "a" should be moved 12 mm.
«Swirl» control electrovalve.
Connect the tool [1] as an adaptor between the electrovalve (4) and the control diaphragm of the «Swirl» (5).
Compare readings with the values in the table below.
Engine speed (rpm)
780
«Swirl» control diaphragm.
4000
Connect the tool [1] on the control diaphragm of the «Swirl» (5).
Apply a vacuum of approx. 0.6 bar; the pin (6) should be at the end stop, at «b».
Vacuum (bar)
0 bar
0,6 bar
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CHECKS: EXHAUST GASES RECYCLING CIRCUIT
Engine: 9HZ
Exhaust gas recycling (EGR) electrovalve (1).
NOTE: The engine ECU pilots the EGR valve.
B1HP1UPC
Perform the check with the aid of a diagnostic tool.
Carry out the following operations with the diagnostic tool:
- «INJECTION» menu.
- Actuator tests.
- EGR electrovalve.
Check that you can hear the click from the EGR regulation electrovalve.
Double butterfly housing (vehicle with particle filter) (2).
Perform the check with the aid of a diagnostic tool.
Carry out the following operations with the diagnostic tool:
- «INJECTION» menu.
- Actuator tests.
- EGR butterfly.
- Exchanger butterfly.
Check that you can hear the click from the double butterfly housing.
B1HP1Z5C
203
C5
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C5
B1HP1B8D
CHECKS: EXHAUST GASES RECYCLING CIRCUIT
Engine: 4HX
[1] Manual vacuum pump
Tool.
: FACOM DA 16
ESSENTIAL: Respect the safety and cleanliness requirements specific to high pressure diesel injection (HDi) engines.
Electrovalve (EGR).
Check, not under load, between the electrovalve (3) (blue connector) and the EGR valve (2)
(tube with blue marking).
Connect the tool [1] between the electrovalve (3) and the EGR valve (2).
Compare readings with the values in the table below.
Butterfly housing electrovalve.
Check, not under load, between the electrovalve (4) (black connector) and the butterfly housing
(1) (metering pump cold), (tube with white marking).
Connect the tool [1] between the electrovalve (4) and the butterfly housing (1).
Compare readings with the values in the table below.
Engine speed (rpm)
780
2500
Valeur de la dépression
0,5 bar
0 bar
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CHECKS: EXHAUST GASES RECYCLING CIRCUIT
Engine: 4HX
EGR valve.
Connect tool [1] on the take-off (a) of the EGR valve capsule (2).
Apply a vacuum of approx. 0.6 bar to activate the EGR valve.
In abruptly suppressing the vacuum, the valve should click and lock itself back on its seating.
Repeat the operation several times.
Butterfly housing.
Remove the air duct between the air/air exchanger and the butterfly housing (1).
Disconnect the tube (white marking) on the electrovalve (4) (black connector).
Connect tool [1] on the tube with the white marking.
Apply a vacuum of approx. 0.8 bar, the flap (b) of the butterfly housing (1) should be closed.
C5
B1BP29NC B1BP29PC
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C5 - C8
C5
C8
Vehicles
1.8I 16V
2.0i 16V HPi
3.0i 24S
2.0i 16V
2.2i 16V HPi
3.0i 24S
Engine types
6FZ
RFJ
XFU
RFN
3FZ
XFW
BOSCH
FR 8 ME
ZR 8 TPP 15
FGR 8 MQPE
FR 8 ME
FGR 8 MQPE
Electrode gap
0,9 ± 0,1
1,0 ± 0,1
0,55 ± 0,2
SPARKING PLUGS
EYQUEM
RFN 52 HZ
Electrode gap
0,9 ± 0,05
0,9 ± 0,1
RFN 52 HZ 0,9 ± 0,05
0,55 ± 0,2
CHAMPION
Electrode gap
Tightening torque
REC 9 YCL
REC 9 YCL
0,9 ± 0,05
2,75 ± 0,2
2,25 ± 0,2
1 ± 0,1
90°
0,9 ± 0,05 2,75 ± 0,2
1 ± 0,1
90°
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SPEEDOMETER
An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled.
This decree stipulates:
- The speed indicated by a speedometer must never be lower than the actual vehicle speed.
- Between the speed displayed «SD» and the speed travelled «ST», there must always be the following relationship:
ST < SD < 1.10 ST + 4 Kph
Example: For an actual speed of 100 Kph the speed displayed by the speedometer may be between 100 and 114 Kph.
The speed indicated by the speedometer may be influenced by:
- The speedometer.
- The tyres fitted to the vehicle.
- The final drive ratio.
- The speedometer drive ratio.
Any of these components can be checked without removing them from the vehicle (see information note N° 78-85 TT of 19 October 1978).
NOTE: Before replacing the speedometer, check the conformity of the following points:
- The tyres fitted to the vehicle.
- The gearbox final drive ratio.
- The speedometer drive ratio.
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C5
Engine type
Gearbox type
Feature
Flywheel
Supplier
Mechanism/type
Clutch disc
Ø of lining. Ext/Int
Quality of lining
(*) DVA = Double damping flywheel.
CLUTCH SPECIFICATIONS
Diesel
Petrol
1.8i 16V
6FZ
Single
230 DNG 4700
11 R 10 X
228,5/155
BE4/5
VALEO
1.6 16V HDi 2.0 16V HDi
9HZ RHL
ML/6
«Pull» clutch
Double
LUK
225 DNG 5450 235 P 7400
Clutch with double damping flywheel (DVA) (*)
225/150 235/150
810 DS
RHR
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Engine type
Gearbox type
Feature
Flywheel
Supplier
Mechanism/type
Clutch disc
Ø of lining. Ext/Int
Quality of lining
(*) DVA = Double damping flywheel.
2.0i 16V
CLUTCH SPECIFICATIONS
Petrol
2.2i 16V HPi
RFN
BE4/5
«Push» clutch
Single
VALEO
3FZ
230 DGN 5100 230 DGN 5300
11 R 14 X
228/155
2.0 16V HDi
Diesel
RHM RHT
ML/5
RHW
«Pull» clutch
Double
LUK
225 T 5700
Clutch with double damping flywheel (DVA) (*)
225/150
F 808
C8
2.2 16V HDi
4HW
242 T 6500
242/162
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Vehicle
C5
C8
C8
C8
Engine
EW7J4
EW10A
DV6TED4
EW10J4
EW12J4
DW10TED4
DW12ATED4
DW12 TED4
MANUAL GEARBOX SPECIFICATIONS
Gearbox type
BE4/5J
BE4/5J
BE4/5N
BE4/5R
BE4/5J
ML5C
ML5C
ML5C
ML6C
Sequence
Type BE4/5
20 DM 70
20 DM 66
20 DM 85
20 DM 65
20 DM 00
20 DM 01
Type ML5
20 LM 31
20 LM 06
20 LM 30
Type ML6
20 MB 09
Torque ratio
17X71
17x81
17x71
14x62
14x65
15x67
16x69
16x69
Drive ratio
None
25x20
25x20
210
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Vehicle
C5
C5
C5
C8
Engine
EW10A
ES9A
DW12TED4
ES9J4
GEARBOX SPECIFICATIONS
Gearbox type Sequence
Type AL4
AL4
AM6
4 HP 20
20 TS 10
Type AM6
20.GH 07
Type 4 HP 20
20 HZ 20
20 HZ 27
Torque ratio
21x73
15x53
23x66
19x73
Drive ratio
52x67
49x52
59x68
211
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C5
B2BP047C
B2CP3FAC
CLUTCH SPECIFICATIONS
Engines: 6FZ - 9HZ
Clutch types: (BE4/5).
«Push» clutch with hydraulic control.
Description.
The declutch control has a declutch fork mounted on a ball-joint.
(1) The ball-joint is screwed into the clutch casing
(2) Declutch fork
(3) Clutch casing
(4) Bearing
(5) Clutch plate
The clutch control slave cylinder (7) is fixed by two screws (6) onto the exterior of the clutch casing.
Clutch plate/flywheel
Flywheel/crankshaft
Double damping flywheel/crankshaft
- Tightening
- Angular tightening
Tightening torques (m.daN).
: 2 ± 0,2
: 4,8 ± 0,5
: 2,5 ± 0,2
: 21° ± 3°
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CLUTCH SPECIFICATIONS
Engines: XFX - RHS - RHZ - 4HX
Clutch types: (ML5C-ML6C).
«Pull» clutch with hydraulic control.
Description.
The clutch control slave cylinder (8) is secured on the clutch housing (9) by rotation (1/3 turn).
Clutch plate/flywheel
Flywheel/crankshaft
- Tightening
- Angular tightening
Tightening torques (m.daN).
: 2 ± 0,2
: 2 ± 0,2
: 60° ± 5°
C5
B2BP04LC
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C5 HYDRAULIC CLUTCH CONTROL SPECIFICATION
Bleeding the hydraulic clutch control.
Composition of the hydraulic circuit.
Brake fluid reservoir located on the master cylinder.
Hydraulic control sender located in the passenger compartment and fixed on the pedal gear.
Clutch pedal.
Hydraulic control receiver fixed on or inside the clutch housing, depending on gearbox type.
Bleed.
IMPERATIVE: Use only new, clear brake fluid, avoid entry of any foreign bodies or impurities into the hydraulic circuit.
Use only hydraulic fluid that is approved and recommended: DOT4.
IMPERATIVE: Do not use any automatic bleed apparatus (risk of the fluid emulsifying in the reservoir).
Remove:
- The pollen filter and its support (see corresponding operation in chapter on aircon).
- The air filter and its union.
- The under-engine sound-deadening.
Refill the brake fluid reservoir to the maximum of its capacity.
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HYDRAULIC CLUTCH CONTROL SPECIFICATION C5
B2BK22XD
Bleeding the hydraulic clutch control (continued).
Couple a transparent pipe onto the bleed screw (1).
Submerge the end of the pipe in a receptacle containing brake fluid, situated lower than the clutch slave cylinder (2).
Create a syphon at «A» above the clutch slave cylinder, using the transparent pipe.
Open the bleed screw (1).
Action the clutch pedal (3) manually through all its travel, with seven rapid down-up movements.
On the final movement, hold the clutch pedal (3) at the end of its travel.
Reclose the bleed screw (1).
Allow the clutch pedal (3) to rise back up again.
Fill the brake fluid reservoir to the maximum of its capacity.
NOTE: For new bleed operations: open the bleed screw (1).
If necessary, repeat the operation.
B2BK064C
215
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C5 HYDRAULIC CLUTCH CONTROL SPECIFICATION
B2BK065C
Bleeding the hydraulic clutch control (continued).
Top up the brake fluid level to the MAXIMUM of the brake fluid reservoir capacity.
Declutch and clutch rapidly 40 times.
Start the engine.
Apply the handbrake.
Engage a gear.
Check that the clutch starts to engage at a dimension (X) greater than or equal to 35 mm
(dimension (X) is given as a guide).
NOTE: If incorrect, repeat the bleed operations.
Tighten the bleed screw (1) to 0,75.m.daN.
216
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BE4/5 GEARBOX: TIGHTENING TORQUES
Engines: 6FZ - RFN - 9HZ
Tightening torques
B2CP3BSP
B2CP3BTD
7
8
9
10
11
12
Ref.
1
4
5
2
3
6
Description
End guide
Clutch housing
Primary shaft nut
Secondary shaft nut
Yoke holding screw
Differential gearwheel screwss
Reverse gear contact
Differential housing
Breather pipe
Rear housing cover screw
Top-up plug
Differential housing screw
Drain plug screw
No. of screws
3
2
1
4
13
1
1
2
1
4
1
7
1
217
C5 - C8
Tightening
1,2 ± 0,1
1,3 ± 0,1
7,2 ± 0,7
6,5 ± 0,7
1,5 ± 0,1
6,5 ± 0,7
2,5 ± 0,3
5 ± 0,5
1,7 ± 0,2
1,2 ± 0,1
2,2 ± 0,2
1,2 ± 0,1
3,5 ± 0,4
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C5 - C8 BE4/5 GEARBOX: TIGHTENING TORQUES
Engines: 6FZ - RFN - 9HZ
Tightening torques (m.daN).
(1) Gearbox rear casing
(2) Gearbox casing/clutch casing fixings
(3) Reverse gear rocker shaft fixing nut
(4) Breather pipe
(5) Reverse gear switch
(6) Drain plug
(7) Top-up plug
(8) Speedo drive support
(9) Differential housing fixings (M7)
(10) Differential housing fixings (M10)
(11) Clutch bearing guide fixing screw
(12) Differential extension fixing
: 1,5 ± 0,1
: 1,5 ± 0,1
: 4,5 ± 0,4
: 1,5 ± 0,1
: 2,5 ± 0,2
: 3,5 ± 0,2
: 2 ± 0,2
: 1,5 ± 0,1
: 1,5 ± 0,1
: 5 ± 0,5
: 1,5 ± 0,1
: 1,5 ± 0,1
B2CKUB0D
218
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BE4/5 GEARBOX: TIGHTENING TORQUES
Engines: 6FZ - RFN - 9HZ
Tightening torques (m.daN).
(13) Primary shaft nut
(14) Secondary shaft nut
(15) Bearing retaining screw
(16) Differential gearwheel screws
(17) Gear control support screw
C5 - C8
: 7,5 ± 0,7
: 6,5 ± 0,6
: 1,5 ± 0,1
: 6 ± 0,6
: 1,5 ± 0,1
B2CKUB1D
219
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C8
B2CKUC4D
ML5C GEARBOX: TIGHTENING TORQUES
Engines: 3FZ - RHM - RHT - RHW - 4HW
Ref.
1
6
7
8
4
5
2
3
9
10
11
12
Description
1 screw M8-45
1 screw M8-70
1 screw M10-70
1 screw M10-50
1 screw M10-85
Screw
Speedometer control support
Fixing of gearbox cover on gearbox casing
Differential bearing stop plate
Air vent
Reverse gear switch
Fixing of gearbox casing on clutch casing
220
Tightening
1,8 ± 0,1
1,8 ± 0,1
4 ± 0,4
4 ± 0,4
4 ± 0,4
3 ± 0,3
1 ± 0,1
2 ± 0,2
2 ± 0,2
2,5 ± 0,2
2 ± 0,2
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ML5C GEARBOX: TIGHTENING TORQUES
Engines: 3FZ - RHM - RHT - RHW - 4HW
Ref.
13
14
15
16
Description
Flange fixing screws
Secondary shaft nut
Gear control support screws
Differential gearwheel screws
B2CKUC5D
C8
Tightening
2 ± 0,2
17 ± 1,7
1,5 ± 0,1
7,7 ± 0,7
B2CKUC6D
221
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C5
ML6C GEARBOX: TIGHTENING TORQUES
Engines: RHL - RHR
Ref.
1
4
5
2
3
6
7
8
Description
Reversing lamp switch
Top-up plug
Drain plug
Differential bearing stop plate screw
Screw fixing gearbox casing on clutch casing
Screw fixing 6th housing
Differential housing fixings (screws M8)
Differential housing fixings (screws M10)
Fixing screw for coupling of engine on gearbox
Gearbox support stud
B2CP419P
222
Tightening
2,5 ± 0,2
3 ± 0,3
3 ± 0,3
3 ± 0,3
3 ± 0,3
2 ± 0,2
1,8 ± 0,1
4 ± 0,4
5,5 ± 0,5
3 ± 0,3
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ML6C GEARBOX: TIGHTENING TORQUES
Engines: RHL - RHR
Ref.
9
10
11
12
Description
Primary shaft screw
Stop guide screw
Differential gearwheel screws
Secondary shaft screw
C5
Tightening
10 ± 0,1
2 ± 0,2
7,7 ± 0,7
13 ± 1,5
B2CP41AD
223
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C5 BE4/5 GEARBOX: CONTROL SPECIFICATIONS
Engines: 6FZ - 9HZ
Gear controls.
[1] Gear lever positioning tool
(1) Gear engagement ball-joint Ø 10 mm
(2) Gear engagement control cable
(3) Gear control lever
(4) Gear selection control cable
(5) Gear selection ball-joint Ø 10 mm
(6) Cable selection locking key
: 8605-T
B2CP3XAD
224
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BE4/5 GEARBOX: CONTROL SPECIFICATIONS
Engines: 6FZ - 9HZ
Gear selection control cable Gear engagement control cable
C5
B2CP3XBD
Length A
Length B
Left hand drive Right hand drive
707 mm
829,6 mm
B2CP3XCD
Length C
Length D
225
Left hand drive
680 mm
831 mm
Right hand drive
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C5
B2CP3XDD
B2CP3XED
BE4/5 GEARBOX CONTROLS: CHECKS AND ADJUSTMENTS
Engines: 6FZ - 9HZ
Adjustments.
IMPORTANT: The control cables must be adjusted every time a cable is changed.
Features.
E: Position locked
F: Position unlocked
To unlock the length of the gear control cable sleeve:
- Move the cylinder "c" in the direction of the arrow "b".
- Pull the locking key "e" in the direction of the arrow "d".
To unlock a sleeve stop:
- Press on the tabs of the fixing (6) at "f".
- Disengage the sleeve stops from their supports.
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BE4/5 GEARBOX: CONTROL SPECIFICATIONS
Engine: RFN
Gear control cable
C8
B2CKUBND
227
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C5 ML/6C GEARBOX: CONTROL SPECIFICATIONS
Engines: RHL - RHR
Gear controls.
Gear control is by means of cables:
- Gear selection control cable.
- Gear engagement control cable.
- Reverse gear control cable.
[1] Gear lever positioning tool
: 8605-T
(1) Gear engagement ball-joint
(2) Gear engagement control cable
(3) Gear control lever
(4) Gear selection control cable
(5) Gear selection ball-joint
(6) Reverse gear unlocking cable
(7) O-ring seal
(8) Reverse gear unlocking device
: Ø 10 mm
: Ø 10 mm
B2CP3KXD
228
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ML/6C GEARBOX: CONTROL SPECIFICATIONS
Engines: RHL - RHR
Gear selection control cable Gear engagement control cable
C5
B2CP3XBD
Adjustment
Length A
Length B
Left hand drive yes
757 mm
908 mm
Right hand drive
B2CP3XND
Adjustment
Length C
Length D
229
Left hand drive no
798 mm
965 mm
Right hand drive
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C5 ML/6C GEARBOX: CONTROL SPECIFICATIONS
Engines: RHL - RHR
Reverse gear unlocking cable
B2CP3XUD
Adjustment
Length E
Left hand drive
230
no
1060 mm
Right hand drive
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B2CP3XPD
ML/6C GEARBOX CONTROLS: CHECKS AND ADJUSTMENTS
Engines: RHL - RHR
Adjustments.
NOTE: The gear engagement control cable is not adjustable.
IMPORTANT: Adjust the selection control cable each time it is changed.
E: Position locked
F: Position unlocked
To unlock the length of the gear selection control cable sleeve:
- Move the cylinder "c" in the direction of the arrow "b".
- Pull the locking key "e" in the direction of the arrow "d".
To unlock a sleeve stop:
- Press on the tabs of the fixing (9) at "f".
- Disengage the sleeve stops from their supports, by lifting them.
C5
B2CP3XQC
231
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C5 ML/6C GEARBOX CONTROLS: CHECKS AND ADJUSTMENTS
Engines: RHL - RHR
Device for unlocking reverse gear (8), external to the gearbox.
The system for locking/unlocking reverse gear utilises the 5th gear synchroniser.
IMPERATIVE: Systematically replace the O-ring seal (9) at each removal.
B2CP3KZD
232
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AL 4 AUTOMATIC GEARBOX: RECOMMENDATIONS - PRECAUTIONS
Precautions to be taken
Repairs on mechanical components.
Never place the gearbox on the ground without protection.
In order to avoid breaking the input shaft ring, it is imperative that the converter retaining bracket should be in place when handling the gearbox.
It is imperative to use the centring peg and the converter retaining bracket to couple the gearbox on the engine.
After coupling the gearbox on the engine, remove the centring peg.
Modification of the oil usage counter value.
Exchanging the gearbox ECU:
- Note down the gearbox counter value.
- Transfer the value read into the the new gearbox ECU.
Exchanging the gearbox:
- Initialise the oil usage counter to 0.
Draining the gearbox:
- Initialise the oil usage counter (follow the diagnostic tool procedure).
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AL 4 AUTOMATIC GEARBOX: RECOMMENDATIONS - PRECAUTIONS
Procedure to be followed prior to carrying out repairs on AL4 autoactive gearbox
If a gearbox malfunction occurs, there are two possible configurations depending on the seriousness of the fault:
- Gearbox in back-up mode with a replacement programme of (the fault
values are taken in substitution).
- Gearbox in back-up mode with an emergency programme (3rd hydraulic).
WARNING: In the emergency programme, an impact is felt when changing P/R, N/R and N/D.
Réception client.
Discuss with the customer, to find out all the malfunction symptoms.
Oil quality - Oil level.
Oil quality.
If the gearbox has suffered a serious fault resulting in a malfunction or the destruction of a clutch, the oil will overheat and become contaminated with impurities: the oil is said to be «burnt».
This is characterised by a black colour and the presence of an unpleasant smell.
ESSENTIAL: The gearbox must be replaced.
Oil level (see corresponding operation).
An excessive oil level can result in the following consequences:
- Excessive heating of the oil.
- Oil leaks.
An insufficent level causes the destruction of the gearbox.
Top up the level of oil in the gearbox (if necessary).
Check using a diagnostic tool.
Read the fault codes (engine and gearbox).
Absence of fault codes.
Carry out parameter measures, actuator tests and a road test.
Presence of fault codes.
Carry out the necessary repairs.
Delete the fault codes.
Carry out a road test to check the repair and, if need be, modify the gearbox ECU parameters (this is essential after an initialisation of the
ECU).
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Downloading.
AL 4 AUTOMATIC GEARBOX: RECOMMENDATIONS - PRECAUTIONS
Procedure for initialising the automatic gearbox ECU
Updating the value of the oil usage counter.
Updating the gearbox ECU by downloading:
- Follow the procedure using the diagnostic tool.
Using PROXIA.
Access to reading and recording of the oil counter is via the menu:
The downloading operation enables the automatic gearbox to be updated, or adapted to an evolution of the engine ECU.
Before commencing the downloading, take the value of the oil usage counter present in the automatic gearbox ECU.
- «Configuration (integrated circuit button)/Oil counter».
- Adjustment of the oil counter value is done in incremental steps of
2750 units.
After the downloading operation, carry out the following:
- A clearing of faults.
- An initialisation of the auto-adaptives.
- A writing of the value of the oil usage counter previously read.
- A road test.
Using LEXIA.
Access to reading and recording of the oil counter is via the menu:
- «Oil counter».
ESSENTIAL: Every update of the automatic gearbox ECU should be accompanied by an update of the engine ECU.
- Adjustment of the oil counter value is done by entering directly the
5 figures of the oil counter.
235
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C5 AL4 GEARBOX: TIGHTENING TORQUES
Engine: RFJ
Tightening torques (m.daN).
B2CP3EDD
(1) Oil flow modulation electrovalve fixing
(2) Heat exchanger fixing
(3) Output speed sensor fixing
(4) Output speed sensor fixing
(5) Oil overflow and drain fixing
X = 48 mm (EW10 engine versions)
(6) Oil level plug
(7) Oil pressure sensor fixing
B2CP311D
236
: 1 ± 0,2
: 5 ± 1
: 1 ± 0,2
: 1 ± 0,2
: 0,9 ± 0,1
: 3,3 ± 0,4
: 0,8 ± 0,1
Angl.T3-page207-255-2005. 4/02/05 15:19 Page 237
AL4 GEARBOX: TIGHTENING TORQUES
Engine: RFJ
C5
Tightening torques (m.daN).
(8) Fixing of converter on diaphragm
Pre-tightening
Tightening
(9) Plug fixing
(10) Gearbox fixing on engine
: 1 ± 0,1
: 3 ± 0,3
: 0,8 ± 0,2
: 5,2 ± 1
B2CP3EED
237
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C5
B2CP3X8C
AL4 GEARBOX: TIGHTENING TORQUES
Engine: RFJ
Tightening torques (m.daN).
Hydraulic block fixing.
Centre the hydraulic block, using screws (11) and (12).
Pre-tighten
Slacken
Tighten
(no strict order)
: 0,9.
: All 9 screws.
(respect the order indicated) : 0,75.
(13) Fixing of selector lever position switch
(14) Oil filler plug
: 1,5 ± 0,2
: 2,4 ± 0,4
B2CP3EGC
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AL4 GEARBOX: CONTROL SPECIFICATIONS
Engine: RFJ
C5
Gearbox end.
The automatic gearbox is controlled by a cable.
«c» Clip for unlocking the push-button in pushed-in position
(1) Control lever with ball-joint
(2) Automatic adjustment (pull out the button to adjust the control, push it in to lock the adjustment of the
control)
(3) Sleeve stop
B2CP3DLC
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C5
AL4 GEARBOX: CONTROL SPECIFICATIONS
Engine: RFJ
On refitting.
Refitting the gearbox control.
New gear selection control.
Couple the ball-joint (3).
Push in the component (16) without bending the cable.
Release the component (16).
Lock the adjustment by means of component (17).
Check all the gear selection control positions.
Re-used gear selection control.
Unlock component (17).
Release the component (16).
Couple the ball-joint (3).
Push in the component (16) without bending the cable.
Release the component (16).
Lock the adjustment by means of component (17).
Check all the gear selection control positions.
B2CP3DWD
240
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AL4 “SHIFT LOCK” GEARBOX CONTROL SPECIFICATIONS AND PRECAUTIONS
Engine: RFJ
C5FP0CTC
SHIFT LOCK.
NOTE: The “shift lock” is a system that locks the gear selection lever in position «P».
Unlocking the SHIFT LOCK (normal operation).
Switch on the ignition.
Press the brake pedal and keep it pressed.
Move the gear selection lever out of position «P».
Unlocking the SHIFT LOCK (with an operating fault).
Should it be impossible to unlock the “shift lock” with the normal operation method, the fault may originate from one of the following components:
- “Shift lock”.
- Gear lever position switch.
- Automatic gearbox ECU.
- Electrical harnesses.
- Battery voltage.
Remove:
- The gear lever knob (1) (pull upwards).
- The cover (2) (unclip).
- The grid (3).
- Unlock the “shift lock” (4) with the aid of a screwdriver.
- Move the gear selection lever out of position «P».
C5FP0CUD
C5
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C5 - C8 4 HP 20 AUTOMATIC GEARBOX: RECOMMENDATIONS - PRECAUTIONS
Engines: 4HX - XFW - 4HW
Precautions to be taken
Towing.
The front of the vehicle must be raised in order to be towed.
If the front of the vehicle cannot be raised.
When performing electrical checks:
- The battery should be correctly charged.
- Never use a voltage source higher than 16V.
- Never use a test lamp.
IMPERATIVE:
- Put gear lever in position «N».
- Do not add any oil.
- Do not exceed 45 mph over a distance of 60 miles maximum.
Driving.
Never drive with the ignition switched off.
NOTE: The automatic gearbox is only lubricated when the engine is running.
Repairs on electrical components.
Do not disconnect:
- The battery when the engine is running.
- The ECU when the ignition is switched on.
Repairs on mechanical components.
Never place the gearbox on the ground without protection.
Do not use the unions on the gearbox as handles for moving the gearbox.
It is imperative that the converter retaining peg should be in place when removing the gearbox.
It is imperative to use the centring pegs to couple the gearbox on the engine.
Remove the converter retaining peg before coupling the gearbox on the engine.
Before reconnecting a switch, check:
- The condition of the various contacts (for deformation, corrosion etc).
- The presence and condition of the mechanical locking.
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B2CP3CZC
4 HP 20 GEARBOX: TIGHTENING TORQUES
Engines: 4HX - XFW - 4HW
Tightening torques (m.daN).
Gearbox exterior.
(2) Oil channel union fixing
(3) Exterior fixing of converter cover on clutch housing
(4) Speedometer take-off aperture plug
(5) Steel casing fixing
(6) Converter fixing on engine
(7) Interior fixing of converter cover on clutch housing
(8) Torx fixing of converter cover on clutch housing
Drain plug
Heat exchanger fixing
Selector lever position switch fixing
Converter cover fixing on engine cover (XFX engine)
Converter cover fixing on engine cover (4HX engine)
: 2,5 ± 0,5
: 2,3 ± 0,5
: 1 ± 0,1
: 0,6 ± 0,1
: 6 ± 1
: 2,3 ± 0,5
: 2,3 ± 0,5
: 4,5 ± 0,8
: 3,5 ± 0,5
: 1 ± 0,2
: 6,5 ± 1
: 5,8 ± 1
B2CP24CC
C5 - C8
B2CP24BC
243
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C5 - C8 4 HP 20 GEARBOX: TIGHTENING TORQUES
Engines: 4HX - XFW - 4HW
Tightening torques (m.daN).
Gearbox interior.
(9) Input speed sensor fixing
(10) Hydraulic block fixing (large head)
(11) Output speed sensor fixing
: 0,8 ± 0,1
: 0,8 ± 0,1
: 1 ± 0,2
B2CP24DC B2CP24EC
244
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B2CP3DLC
4 HP 20 GEARBOX: CONTROL SPECIFICATIONS
Engine: 4HX
C5
Selection control.
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. The information is transmitted to the gearbox ECU.
Two switches placed on the gear control gate permit the driver to choose one of the following three driving programmes:
- Normal: The normal programme operates in the absence of the other two (eco law, auto-adaptive mode).
- Sport: Permits a more dynamic, sporty performance.
- Snow: Facilitates starting and adhesion on slippery surfaces.
To return to the normal programme, press a second time on the sport switch or snow switch.
Only when the selector is in position (P) or (N) can the engine be started.
(1) Control linkage with ball-joint
(2) Automatic adjustment (push-button «c», pressed in to lock the control adjustment, springs out for the
adjustment to be made)
(3) Cable sleeve stop
The automatic gearbox is controlled by a cable.
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C5 4 HP 20 “SHIFT LOCK” GEARBOX CONTROL SPECIFICATIONS AND PRECAUTIONS
Engine: 4HX
C5FP0CUD
SHIFT LOCK.
The “shift lock” is a system which locks the gear selection lever in the park position «P».
Unlocking the “shift lock” (normal operation).
Switch on the ignition.
Apply the brake pedal and keep it pressed.
Using the selection lever, disengage from position «P».
Unlocking the “shift lock” (with a fault).
If it should be impossible to unlock the shift lock with the normal operation method, the causes of the fault may arise from the following components:
- “Shift lock”.
- Gear lever position switch.
- Automatic gearbox ECU.
- Electrical harnesses.
- Battery voltage.
Remove:
- The gear lever knob (1) by pulling upwards.
- The cover (2) (unclip).
- The shutter.
Unlock the “shift lock” (4) using a screwdriver.
Move the selection lever to disengage from position «P».
C5FP0CTC
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4 HP 20 GEARBOX: CONTROL SPECIFICATIONS
Engine: 4HX
C5
B2CP3DWD
On refitting.
New gear selection control.
Couple the ball-joint (3).
Push in the component (16) without bending the cable.
Release the component (16).
Lock the adjustment by means of component (17).
Check all the gear selection control positions.
Re-used gear selection control.
Unlock component (17).
Release the component (16).
Couple the ball-joint (3).
Push in the component (16) without bending the cable
Release the component (16).
Lock the adjustment by means of component (17).
Check all the gear selection control positions.
Complete the fitting in the opposite order to removal (see corresponding procedure).
247
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C8 4 HP 20 “SHIFT LOCK” GEARBOX CONTROL SPECIFICATIONS AND PRECAUTIONS
Engines: XFW - 4HW
SHIFT LOCK.
The “shift lock” is a system which locks the gear selection lever in the park position «P».
Unlocking the “shift lock” (normal operation).
Switch on the ignition.
Apply the brake pedal and keep it pressed.
Using the selection lever, disengage from position «P».
Unlocking the “shift lock” (with a fault).
If it should be impossible to unlock the shift lock with the normal operation method, the causes of the fault may arise from the following components:
- “Shift lock”.
- Gear lever position switch.
- Automatic gearbox ECU.
- Electrical harnesses.
- Battery voltage.
Remove:
- Unlock the “shift lock” (4) using a screwdriver, placed in the aperture of the gear selection control grid.
- Move the selection lever to disengage from position «P».
B2CP3N8C
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4 HP 20 GEARBOX CONTROLS: CHECKS AND ADJUSTMENTS
Engines: XFW - 4HW
C8
B2CKUBXD
On refitting.
IMPERATIVE: Fit new clips and collars.
WARNING: Check that the gear control cables are correctly routed.
Proceed in opposite order to removal.
IMPERATIVE: To clip the ball-joint (8) position tool [1] (ball-joint extractor (-).0338.E) under the selection lever (9).
If necessary, adjust the selection control (if new or maladjusted).
Adjusting the selection control.
Selection lever in position «P».
Engagement lever (10) as far as possible towards the rear of the vehicle (B).
Lock the adjustments of the gears by pressing on the plastic component (11).
The adjustment is complete.
Check all the gear selection control positions.
NOTE: to unlock the gear control adjustment system, press on the plastic component (12).
B2CKUBYD
249
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C5 AM6 AUTOMATIC GEARBOX: RECOMMENDATIONS - PRECAUTIONS
Engine: XFU
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.
- Do not exceed 45 mph over a distance of 60 miles maximum.
Precautions to be taken
When performing electrical checks:
- The battery should be correctly charged.
- Never use a voltage source higher than 16V.
- Never use a test lamp.
Driving.
Never drive with the ignition switched off.
NOTE: The automatic gearbox is only lubricated when the engine is running.
Repairs on electrical components.
Do not disconnect:
- The battery when the engine is running.
- The ECU when the ignition is switched on.
Repairs on mechanical components.
Never place the gearbox on the ground without protection.
Do not use the unions on the gearbox as handles for moving the gearbox.
It is imperative that the converter retaining peg should be in place when removing the gearbox.
It is imperative to use the centring pegs to couple the gearbox on the engine.
Remove the converter retaining peg before coupling the gearbox on the engine.
Before reconnecting a switch, check:
- The condition of the various contacts (for deformation, corrosion, etc).
- The presence and condition of the mechanical locking.
250
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AM6 GEARBOX: TIGHTENING TORQUES
Engine: XFU
B2CP3YTD
Tightening torques (m.daN).
(3) Filler cap
(4) Hydraulic valve block casing
(5) Auto. gearbox heat exchanger
(4) Input speed sensor fixing
(6) Torque converter
Pre-tightening
Tightening
(7) Engine speed sensor
(8) Gearbox support
(9) Sleeve stop
(10) Closing panel fixing
(11) Fixting of gearbox on cylinder block
B2CP3YUD
251
C5
: 4 ± 0,4
: 1,5 ± 2
: 4,2 ± 0,4
: 1 ± 0,2
: 2 ± 0,2
: 6 ± 0,6
: 0,8 ± 0,1
: 5,5 ± 0,5
: 3,5 ± 0,3
: 2 ± 0,2
: 6 ± 0,6
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C5 AM6 GEARBOX: TIGHTENING TORQUES
Engine: XFU
Tightening torques (m.daN).
B2CP3YVD
(12) Oil temperature sensor tightening plate
(13) Hydraulic valve block (sequence indicated)
(14) Oil induction cover
(15) ECU screws
(16) Oil drain and overflow plug
(17) Oil level plug
: 1 ± 0,1
: 1 ± 0,1
: 1 ± 0,1
: 2,5 ± 0,2
: 1 ± 0,1
: 4,8 ± 0,5
B2CP3YWD
252
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AM6 GEARBOX: CONTROL SPECIFICATIONS C5
Engine: XFU
The gear selector is guided by the shape of the stepped gate and by a retaining spring which pulls it to the left hand side.
The 2 switches placed on the gear control gate permit the driver to choose one of the following three driving programmes:
B2CP3DKD
- Normal programme: Operates as the default programme (eco law, autoadaptive mode).
- Sport programme (a): Permits a more dynamic, sporty performance.
- Snow programme (b): Facilitates starting and adhesion on slippery surfaces.
NOTE: To return to the normal programme, press a second time on the sport switch or snow switch.
Gearbox end.
The automatic gearbox is controlled by a cable.
«c» Push-button in pushed-in position
(1) Sleeve stop
(2) Control lever with ball-joint
(3) Automatic adjustment
Automatic adjustment:
- Pull out button «c» to adjust the control.
- Push in button «c» to lock the adjustment of the control.
B2CP3WVC
253
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C5 AM6 “SHIFT LOCK” GEARBOX CONTROL SPECIFICATIONS AND PRECAUTIONS
Engine: XFU
C5FP0CTC
C5FP0CUD
SHIFT LOCK.
NOTE: The «shift lock» is a system that locks the gear selection lever in position «P».
Unlocking the «SHIFT LOCK» (normal operation).
Switch on the ignition.
Press the brake pedal and keep it pressed.
Move the gear selection lever out of position «P».
Unlocking the «SHIFT LOCK» (with an operating fault).
Should it be impossible to unlock the «shift lock» with the «Normal operation» method, the fault may originate from one of the following components:
- «Shift lock».
- Gear lever position switch.
- Automatic gearbox ECU.
- Electrical harnesses.
- Battery voltage.
Remove:
- The gear lever knob (1) (pull upwards).
- The cover (2) (unclip).
- The grid (3).
- Unlock the «shift lock» (4) with the aid of a screwdriver.
- Move the gear selection lever out of position «P».
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Vehicles
C5
C8
Gearbox
BE4/5
ML/5
ML/6
AM6
AL4
4 HP20
DRIVESHAFTS - GEARBOX
Tightening torques (m.daN)
Engines
Driveshaft bearing
Driveshaft nut
C5
6FZ - RFN - 9HZ
3FZ - RHM - RHT
RHW - 4HW
RHL - RHR
2 ± 0,2 32,5 ± 1,5
C8 XFU
RFJ
4HX - XFW - 4HW
1 ± 0,1 10 + 60°
Tightening torques (m.daN) of the wheel bolts
CITROËN
C5
C8
255
Steel
Aluminium
9 ± 0,5
10 ± 0,5
Gearbox oil seal mandrels
Right
7114-T.W
9017-T.C
(-).0336.U
0338 J1
0338 J3
8010-T.D
8010-T.K1
Left
7114-T.X
5701-T.A
(-).0336.V
0338 H1
0338 H2
8010-T.J
8010-T.K2
C5 - C8
Tool kit
7116-T
9017-T
0336
0338
8010-T
Angl. T3-page256-281-2005 4/02/05 15:25 Page 256
C5 AXLE GEOMETRY
Conditions for checking and adjusting: Tyre pressures in conformity, setting at reference height, steering rack set at zero point (see corresponding
operation).
Tools. Gauge for measuring radius of wheels with 4 fixing bolts
: 4300-T
All types except CARLSSON
Measuring front height
Measuring rear height
B3BP166D
H1 = R1 – L1
H1 = Front height (± 6 mm).
R1 = Wheel radius (mm).
L1 = Theoretical dimension between the level of the front subframe and the wheel axis.
The measurement of the front dimension «H1» is between ground level and the measuring zone on the front subframe (to the rear of the front
yokes fixing the suspension arm).
L1 = 140 mm
The dimension L1 for checking front height is between the level “b” of the front subframe and the wheel axis “a”.
256
B3BP168D
H2 = R2 + L2
H2 = Rear height (± 6 mm).
R2 = Wheel radius (mm).
L2 = Theoretical dimension between the measuring zone on the crossmember support and the wheel axis.
The measurement of the rear dimension «H2» is between ground level and the measuring zone on the rear axle crossmember (forward of the
rear fixing of the rear axle crossmember on the body).
L2 = 68 mm
The dimension L2 for checking rear height is between the measuring zone “b” and the wheel axis “a”.
Angl. T3-page256-281-2005 4/02/05 15:25 Page 257
Vehicle
All types
AXLE GEOMETRY
All types except CARLSSON
Front axle
Tracking Castor Camber
King pin inclination
Adjustable
0 to -3 mm
0° to -0° 25’
3° 03' ± 30'
No adjustable
-0° ± 30' 12° 56' ± 30'
Tracking
4,5 ± 1,3 mm
0° 38’ ± 0° 11’
Camber
Rear axle
No adjustable
: Dissymmetry less than 0° ± 30'.
Castor
Camber
King pin inclination
: Dissymmetry less than 0° ± 30'.
: Dissymmetry less than 0° ± 30'.
: Dissymmetry less than 0° ± 30'.
IMPERATIVE: Distribute the total tracking symmetrically between the LH wheel and the RH wheel.
Camber
- 1° ± 20'
C5
B3CP02UC
NOTE: Front of the vehicle indicated by the arrow.
A < B = Positive figure:
A > B = Negative figure:
+ =
– =
NOTE
TOE-IN
TOE-OUT
Angl. T3-page256-281-2005 4/02/05 15:25 Page 258
C5 AXLE GEOMETRY
Conditions for checking and adjusting: Tyre pressures in conformity, setting at reference height, steering rack set at zero point (see corresponding
operation).
Tools. Gauge for measuring radius of wheels with 4 fixing bolts
: 4300-T
CARLSSON
Measuring front height
Measuring rear height
B3BP166D
H1 = R1 – L1
H1 = Front height (± 6 mm).
R1 = Wheel radius (mm).
L1 = Theoretical dimension between the level of the front subframe and the wheel axis.
The measurement of the front dimension «H1» is between ground level and the measuring zone on the front subframe (to the rear of the front
yokes fixing the suspension arm).
L1 = 155 mm
The dimension L1 for checking front height is between the level “b” of the front subframe and the wheel axis “a”.
B3BP168D
H2 = R2 + L2
H2 = Rear height (± 6 mm).
R2 = Wheel radius (mm).
L2 = Theoretical dimension between the measuring zone on the crossmember support and the wheel axis.
The measurement of the rear dimension «H2» is between ground level and the measuring zone on the rear axle crossmember (forward of the
rear fixing of the rear axle crossmember on the body).
L2 = 64 mm
The dimension L2 for checking rear height is between the measuring zone “b” and the wheel axis “a”.
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Vehicle
All types
AXLE GEOMETRY
Front axle
Tracking Castor Camber
CARLSSON
King pin inclination
Adjustable
0 to - 2 mm
0° to - 0° 15'
No adjustable
3° 03' ± 30' -0° 04' ± 30' 12° 56' ± 30'
Tracking
5,1 ± 1,3 mm
0° 41’ ± 0° 12’
Rear axle
No adjustable
C5 CARLSON
Camber
- 1° 03' ± 20'
B3CP02UC
NOTE: Front of the vehicle indicated by the arrow.
259
A < B = Positive figure:
A > B = Negative figure:
+ =
– =
NOTE
TOE-IN
TOE-OUT
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C5 AXLE GEOMETRY: CHECKING AND ADJUSTING VEHICLE HEIGHT
Tools.
[1] Gauge for measuring radius of wheels (4 bolts)
[2] Gauge for height under bodyshell
[3] LEXIA station
[4] PROXIA station
: 8006-T
: 2305-T
: 4171-T
: 4165-T
Preliminary operations.
Check the level of LDS fluid (see corresponding operation).
Check the tyre pressures.
Place the vehicle on a 4 column lift.
Put the vehicle in the normal position.
Release the handbrake.
Start the engine.
Checks by axle.
Lift the vehicle by hand.
Release when the weight becomes too great.
The vehicle descends, then re-ascends and stabilises.
Meaure the height.
Push down the vehicle by hand.
Hold the vehicle in this position, release when it rises.
The vehicle ascends, then descends and stabilises.
Measure the height.
Take the average of the 2 measures.
260
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B3CP06AC
B3CP06BC
AXLE GEOMETRY: CHECKING AND ADJUSTING VEHICLE HEIGHT C5
Measuring of heights.
Measuring the wheel radius.
To determine the centre of the wheel, place tool [1] on the heads of the wheel bolts.
Meaure the radius R1 using tool [2] (distance from ground to centre of wheel).
Measuring the front height H1M.
The front height H1M is measured between the ground and the subframe, to the rear of the front fixing yokes of the suspension tripod.
Calculating the front height H1C.
All types except CARLSSON
H1C = R1 - 140 mm
R1 = Radius of front wheel (mm)
CARLSSON
H1C = R1 - 155 mm
R1 = Radius of front wheel (mm)
Compare:
- The value measured H1M.
- The value calculated H1C.
- Adjust the front height if necessary.
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C5
B3DP08HC
B3CP06CC
AXLE GEOMETRY: CHECKING AND ADJUSTING VEHICLE HEIGHT
Measuring the rear height H2M.
The rear height H2M is measured between the ground and zone «a» on the crossmember.
Calculating the rear height H2C.
All types except CARLSSON
H2C = R2 + 68 mm.
R2 = Radius of rear wheel (mm)
CARLSSON
H2C = R2 + 64 mm.
R2 = Radius of rear wheel (mm)
Compare:
- The value measured H2M.
- The value calculated H2C.
- Adjust the front height if necessary.
Adjustment of heights.
Adjustment using a diagnostic tool.
This adjustment is done when the heights measured are within the tolerance of the heights calculated.
Mechanical pre-adjustment.
This adjustment is done when the heights measured are not within the tolerance of the heights calculated
(± 10 mm).
262
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B3CP06CC
AXLE GEOMETRY: CHECKING AND ADJUSTING VEHICLE HEIGHT
Front height.
Slacken by one turn the screw (1) on the collar (2).
Retighten the screw by hand.
To decrease the height, turn the collar (2) towards the front of the vehicle.
To increase the height, turn the collar (2) towards the rear of the vehicle.
Repeat the operation to obtain the dimension calculated H1C (± 10 mm).
Tighten the screw (1) to 0,6 m.daN.
Adjust using tool [3] or tool [4].
Rear height.
Slacken by one turn the screw (3) on the collar (4).
Retighten the screw by hand.
To decrease the height, turn the collar (4) towards the front of the vehicle.
To increase the height, turn the collar (4) towards the rear of the vehicle.
Repeat the operation to obtain the dimension calculated H2C (± 10 mm).
Tighten the screw (3) to 0,6 m.daN.
Adjust using tool [3] or tool [4].
B3DP08JC
263
C5
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C5
B3BP164C
B3BP165C
AXLE GEOMETRY: CHECKING AND ADJUSTING VEHICLE HEIGHT
Adjustment of heights using tool [3] or tool [4].
Connect either tool [3] or [4] to the vehicle's diagnostic socket.
Go into the menu:
- Adjustment of reference heights.
- Configuration.
NOTE: H1M = Front measured height, in mm.
All Types except CARLSSON
CARLSSON
Enter this value in the diagnostic tool.
NOTE: H2M = Rear measured height, in mm.
Calculate (R2 - H2M).
Enter this value in the diagnostic tool.
Wait for the vehicle height to correct itself.
Measure the front height (H1M).
Check that: H1M = H1C ± 2 mm.
Measure the rear height (H2M).
Check that: H2M = H2C ± 2 mm.
: Calculate: 280 - (R1 - H1M).
: Calculate: (R1 - H1M).
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FRONT AXLE
C5
Tightening torques (m.daN).
(1) Suspension leg upper fixing
Pre-tightening
Angular tightening
(2) Suspension leg fixing on bodyshell
(3) Anti-roll bar link rod upper fixing
(4) Suspension leg fixing on pivot
(5) Anti-roll bar link rod lower fixing
(6) Ball-joint fixing
(7) Ball-joint fixing on pivot
(8) Hub nut
(9) Wheel bolt
(10) Arm front fixing
(11) Arm rear fixing
(12) Anti-roll bar bearing fixing on subframe
: 5 ± 0,6
: 65° ± 5°
: 4,3 ± 0,6
: 6,4 ± 0,6
: 5,4 ± 0,5
: 6,4 ± 0,6
: 4,5 ± 0,4
: 25 ± 2,5
: 32,5 ± 2,6
: 9 ± 1
: 13 ± 1,3
: 10,5 ± 1
: 4,2 ± 0,6
B3CP05VP B3CP05WD
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C5
B3CP08ND
FRONT AXLE
The front subframe is equipped with a stabiliser bar linking between the two front extensions.
(13) Stabiliser bar fixing
(14) Fixing of subframe on body
(15) Fixing of subframe rear yoke on body
: 6,6 ± 0,9
: 14 ± 1,4
: 10 ± 1
Saloons and Estates and CARLSSON
266
Anti-roll bar
Engines
All types Saloons and CARLSSON
Estates except ES9J4
Diameter (mm)Colour ref.
23,5 Yellow
ES9J4
+ CARLSSON Saloons
24,5 White
NOTE: The geometry specifications are given with the suspension specifications.
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REAR AXLE C5
Tightening torques (m.daN).
(16) Anti-roll bar fixing
(17) Front subframe fixing on body
(18) Rear subframe fixing
(19) Rear rubber mounting fixing on bodyshell
(20) Suspension shaft fixing
(21) Hub nut
(22) Wheel bolt
: 13 ± 1,3
: 11,1 ± 1,1
: 11,5 ± 1,1
: 9 ± 1,3
: 14,9 ± 1,3
: 25 ± 2,5
: 9 ± 1
B3DP0BBD
B3DP0BCD
Engines
All types (except ES9J4)
ES9J4
Estates all types
CARLSSON
Anti-roll bar
Diameter (mm) Colour ref.
21,5 Blue
22,5 Yellow
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C5 REAR AXLE
Height control.
(23) Height sensor clip screw
: 0,6
B3CP08RD
268
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POWER-STEERING SPECIFICATIONS
Engines: All types
B3EP124D
Tightening torques (m.daN).
(1) Steering wheel fixing
(2) (3) Column fixing on mounting
(4) Cardan fixing
(5) Ball-joint fixing on pivot
(6) Link rod locking nut
(7) Valve fixing on cover
(8) Piping fixing on ram
(9) Mechanism fixing on subframe
(10) Steering rack ball-joint
: 2 ± 0,3
: 2,3 ± 0,4
: 2,3 ± 0,3
: 3,5 ± 0
: 6 ± 0,4
: 2,3 ± 0,1
: 0,8 ± 0,8
: 8 ± 0,9
: 9 ± 0,9
C5
B3EP125D
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C5 POWER-STEERING SPECIFICATIONS
Tightening torque (m.daN).
(12) Heat shield fixing on casing
: 1,2 ± 0,2
B3EP126D
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B3EP13UC
B3EP13VD
POWER-STEERING SPECIFICATIONS C5
IMPERATIVE: Respect the precautions to be taken prior to any operation (refer to the brochure
"Recommendations-precautions").
Preliminary operation.
Raise and support the vehicle on 2-column lift.
Remove (on the RH side):
- The clip (1).
- The clip (2).
Detach the steering rack protection gaiter.
Setting.
Turn the steering wheel to full LH lock.
Measure the dimension X.
Turn the steering wheel to full RH lock.
Measure the dimension Y.
Calculate the dimension L = (Y - X) : 2.
Position the steering rack to the dimension "L" (mid point of the steering rack).
Additional operation.
Refit:
- The protection gaiter.
- The clip (2).
- The clip (1) (new).
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C8 AXLE GEOMETRY
Setting at reference height
Requirements prior to setting at reference height
WARNING: The checks of the front and rear axle geometry values, as well as the adjusting of the front suspension should be carried out at precise positions of suspension compression (reference height) on a suspension test bed.
Check the pressures in the tyres.
Check the conformity of the tyres.
Remove the wheel trims.
Lock the steering rack at point zero: straight ahead (see corresponding operation).
[1] Set of two compressors
[2] Set of two shackles
[3] Set of four straps
[4] Set of two slings
[5] Under body height gauge
Tooling required.
: 9511-T.A
: 9511-T.C
: 9511-T.B
: 9511-T.D
: 2305-T
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AXLE GEOMETRY
Setting at reference height
Measuring front height (H1)
C8
Measuring rear height (H2)
C4AP1AUC
Front height
H1 = R1 - L1
H1 = Measurement between the bottom of the subframe (b) at the front fixing of the suspension wishbone and the ground.
R1 = Radius of front wheel under load.
L1 = Distance between the centre of the wheel and the bottom of the subframe at the front fixing of the suspension wishbone.
273
E1AP0AYD B3BP18GC
Rear height
H2 = R2 + L2
H2 = Measurement between bottom of longeron (c) and the ground.
R2 = Radius of rear wheel under load.
L2 = Distance between the centre of the wheel and the bottom of the longeron.
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C8
FRONT AXLE GEOMETRY
Setting at reference height
Height of the vehicle at the front at reference height (H1 = R1 - L1)
Engage the straps [3] with their shackles [2] on the subframe.
Position the suspension compressor [1], selecting the separation (a) most suited to pull the straps as far upwards as possible.
C4AP1ATD
Compress the suspension so as to obtain, on the RH and LH sides, the bodyshell height
H1 (reference height), to be measured between the bottom of the subframe (b) at the front fixing of the wishbone, and the ground.
WARNING: Take account of pivoting surfaces when measuring the reference height H1.
NOTE: Only the tracking is adjustable.
WARNING: The tracking value varies as a function of the vehicle height.
C4AP1AUC
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REAR AXLE GEOMETRY
Setting at reference height
Height of the vehicle at the rear at reference height (H2 = R2 + L2)
C8
Engage the slings [4] on the rear longerons.
Position the suspension compressor [1] selecting the separation (a) most suited to pull the straps as far upwards as possible.
C4BP1CND
Compress the suspension so as to obtain, on the RH and LH sides, the bodyshell height H2 (reference height), to be measured between the bottom of the longeron «c» and the ground.
WARNING: Take account of pivoting surfaces when measuring the reference height H2.
Check that the height H1, measured already at the front, has not changed.
WARNING: The rear axle angles are not adjustable.
B3BP18GC
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C8
Engines
Tyres
L1 (mm)
L2 (mm)
Tracking (mm)
Values for front suspension angles
RFN
205x65 R15
3FZ - RHM - RHT
RHW - 4HW
215x65 R15
126
94
Adjustable
2 ± 1
Tracking (degrees)
Camber
Castor
Angle of pivot
0° 17’ ± 0° 08’
No adjustable
0° 0’ ± 30’
3° 30’ ± 30’
12° 24’ ± 30’
XFW
215x60 R16
AXLE GEOMETRY
Values for rear suspension angles
Engines
Tyres
L1 (mm)
L2 (mm)
Tracking (mm)
RFN
205x65 R15
3FZ - RHM - RHT
RHW - 4HW
215x65 R15
126
94
No adjustable
5 ± 1
Tracking (degrees)
0° 45’ ± 0° 08’
XFW
215x60 R16
0° 42 ± 0° 08’
Camber
No adjustable
1° ± 30’
NOTE
TOE-IN
TOE-OUT
B3CP02UC
A < B = Positive figure:
A > B = Negative figure:
+ =
– =
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AXLE GEOMETRY
Adjusting the rolling axles
NOTE: Only the tracking is adjustable (at the front).
If the value is incorrect, adjust the track rods (1).
One turn of the rod = 2 mm approx.
Tighten the nuts (2), tighten to 4 ± 0,4 m.daN.
C8
B3BKAELD
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C8
B3CK09JD
278
FRONT AXLE
(1) Crossmember
(2) Tie-rods
(3) Springs
(4) Front suspension leg
(5) Anti-roll bar
(6) Subframe
Identification.
Engines
RFN - 3FZ - RHT - RHW
RHM - 4HW
XFW
Anti-roll bar
Diameter (mm)
21,5
22
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B3BP18FD
FRONT AXLE
C8
Tightening torques (m.daN).
Fixing of subframe on body
Fixing on tie-rod on body
Fixing of crossmember on body
Fixing of tie-rod on front subframe
Fixing of damper on pivot
(12) Fixing of damper on pivot
(8) Fixing of damper rod on upper cup
: 10,7 ± 1
: 6,3 ± 0,6
: 8 ± 0,8
: 6,3 ± 0,6
: 9 ± 0,9
: 9,2 ± 0,9
: 9 ± 0,9
(7) Fixing of upper cup on body
Fixing of anti-roll bar on subframe
: 4,5 ± 0,4
: 10,5 ± 1
Driveshaft nut
: 10 ± 1
(9) Front fixing of wishbone on subframe (screw length 30 mm)
: 10,5 ± 1
(10) Front fixing of wishbone on subframe (screw length 85 mm)
: 12,5 ± 1
(11) Rear fixing of wishbone on subframe
: 10,5 ± 1
Fixing of ball-joint on pivot
Fixing of steering track rod on pivot
: 7 ± 0,7
: 3,8 ± 0,3
Fixing of track rod on damper body
Fixation biellette sur barre antidévers
: 5,5 ± 0,5
: 5,5 ± 0,5
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C8
B3DP0AGD
280
REAR AXLE
Tightening torques (m.daN).
(4) Fixing of damper on body
(5) Fixing of stabiliser bar on rear axle
(6) Fixing of stabiliser bar on body
(7) Fixing of rear axle on body
(8) Fixing of damper on rear axle
(9) Hub nut
: 9 ± 0,9
: 8 ± 0,8
: 6 ± 0,6
: 8 ± 0,8
: 9 ± 0,9
: 38 ± 3,8
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B3EK0K0D
POWER-STEERING SPECIFICATIONS
Engines: RFN - 3FZ - XFW - RHM - RHT - RHW - 4HW
Tightening torques (m.daN).
(8) Steering wheel fixing nut
(9) Fixing of steering column to support
(10) Fixing of upper and lower shafts to steering column
(11) Fixing of ram valve supply unions
(12) Fixing of steering mechanism
(13) Fixing of pump/valve supply unions
Pump
Valve
(14) Fixing of ball-joint housing on steering rack
(15) Steering rod locking nut
(16) Steering ball-joint nut
C8
: 2 ± 0,2
: 2 ± 0,2
: 2,5 ± 0,2
: 1 ± 0,1
: 14,5 ± 1,4
: 2 ± 0,2
: 2,5 ± 0,2
: 9 ± 0,9
: 6 ± 0,6
: 4 ± 0,4
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C5
Engine type
FT
RR
Ø mm
Master cylinder
Master-vac
Caliper makes/
Pistons
Disc Ventilated
Disc thickness/min. thickness
Brake pad thickness
Brake pad grade
Ø Cylinder or caliper mm Disc Plain
Disc thickness/min. thickness
Brake pad thickness
Brake pad grade
BRAKE SPECIFICATIONS
1.8i 16V
Saloon Estate
6FZ
2.0i 16V
RFJ
22,2 (valve type)
254
BOSCH BIR ZO
54/22
BOSCH BIR ZO
57/26
266 283
22/20 26/24
17,3/2,5 17,8/2,5
FERODO 749/1
PSA - 32 (double piston)
276
14/12
11,9/3
TEXTAR T 4110 ABEX 949/1
3.0i 24S
XFU
BOSCH BIR ZO
57/28
288
28/26
282
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Engine type
FT
RR
Ø mm
Master cylinder
Master-vac
Caliper makes/ pistons
Disc Ventilated
Disc thickness/min. thickness
Brake pad thickness
Brake pad grade
Ø Cylinder or caliper mm Disc Plain
Disc thickness/min. thickness
Brake pad thickness
Brake pad grade
BRAKE SPECIFICATIONS
1.6 16V HDi 2.0 16V HDi
9HZ
BOSCH BIR ZO
57/26
283
26/24
RHL
RHR
22,2 (valve type)
254
BOSCH BIR ZO
57/28
288
28/26
17,8/2,5
FERODO 749/1
PSA - 32 (double piston)
276
14/12
11,9/3
TEXTAR T 4110 ABEX 949/1
C5
2.2 16V HDi
4HX
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C5
B3FP7DKD
Braking circuit
BRAKE SPECIFICATIONS
Braking system specifications
Braking circuit at «X».
Front brakes with ventilated discs.
Rear brakes with non-ventilated discs.
Handbrake lever controlling cables acting on the front wheels.
The compensator and main brake limiter functions are assured by the ABS EBD system fitted as standard at the factory on all versions.
ESP is fitted as standard on the entire range.
NOTE: EBD = Electronic Brakeforce Distribution.
ESP = Electronic Stability Programme.
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BRAKE SPECIFICATIONS
Tightening torques (m.daN).
(12) Brake fluid pressure sensor on master-cylinder
B3FP7A0C
(16) Fixing of gyrometer/accelerometer sensor on support
: 2,5 ± 0,5
: 0,9 ± 0,1
(17) Fixing of support on body
: 0,9 ± 0,1
Piping on master-cylinder
: 1,5 ± 0,3
B3FP79ZC
285
C5
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C5
Brake pedal carriage
BRAKE SPECIFICATIONS
Front brakes Rear brakes
B3FP7DNC
(21) Fixing on bodyshell
(22) Servo fixing
: 1,8 ± 0,3
: 1,7 ± 0,25
B3FP7DLC
Tightening torques (m.daN).
(18) Caliper fixing on pivot
(19) Yoke fixing on caliper
: 12 ± 1,8
: 3,1 ± 0,1
B3FP7DMC
(20) Rear caliper fixing on suspension arm
286
: 7 ± 0,7
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CHECKING THE VACUUM PUMP
B3FP7DQD
Tool.
[1] Pressure checker
Checks.
: Toolkit S.1602
A: Engines DW10 and DV6
B: Engine DW12
Locate the vacuum pipe (1) between the vacuum pump and the braking servo.
Uncouple the vacuum pipe at "a".
Connect the tool [1] onto the vacuum pipe (1).
Run the engine at idle.
Check the vacuum value.
C5
B3FP15RC
NOTE: The vacuum value should be higher than or equal to 0,850 bar.
Engines DW10, DW12 and DV6:
Engine oil temperature
80°C ± 5°
Minimum vacuum
500 mbars
800 mbars
Maximum time (in seconds) to wait for minimum vacuum
4,5
18
If the value is lower, check:
- The vacuum pump directly.
- The sealing of the circuit on the link pipes and on the brake servo.
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C5 CHECKING AND ADJUSTING THE PARKING BRAKE
ESSENTIAL: Respect the safety and cleanliness requirements.
Remove the central console (see corresponding operation).
Raise and supprt the vehicle on a 2-column lift.
To bed in the parking brake cables, operate as follows:
With the engine running:
- Press 5 times on the brake pedal in order to place the braking circuit under pressure.
- Apply and release the parking brake lever 5 times.
Conditions for adjustment:
- Parking brake lever in the released position.
- Check that the parking brake cables are correctly routed.
- Check that the LH and RH caliper levers (2) are against the screws (1).
Admissible clearance between the caliper lever (2) and the parking brake cable attachment:
X = 0 to 1 mm.
B3FP7DCD
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CHECKING AND ADJUSTING THE PARKING BRAKE C5
(3) Nut for adjusting the tension of the parking brake cables
Apply and release the parking brake lever 5 times.
Place the parking brake lever in the released position.
Tighten the nut (3) until it is in contact with the component (4).
Apply and release the parking brake lever 5 times.
Place the parking brake lever in the released position.
Check:
- That there is no clearance between the extremities of the parking brake cables and the slide.
- That the RH and LH caliper levers (2) are against the screws (1).
IMPERATIVE: If these two checks are not satisfactory, repeat the adjustment procedure.
Lower the vehicle.
Refit the central console.
B3FP7DDD
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C5 DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM
[1] Generic bleeding apparatu
[2] LEXIA statio
[3] PROXIA station
Tools.
: «LURO» or similar
: 4171-T
: 4165-T
NOTE: Bleeding of the secondary braking circuit is done with the help of diagnostic tools [2] or [3].
Draining the brake fluid reservoir.
Drain the brake fluid reservoir (1) to the maximum extent (if necessary, use a clean syringe).
Disconnect the connector (3).
Uncouple the pipe (2).
Remove the reservoir (1) by separating the lugs «a» from the shaft (4).
Empty the brake fluid reservoir (1).
Clean the brake fluid reservoir (1).
Refit the brake fluid reservoir (1) and the shaft (4).
Couple the pipe (2).
Reconnect the connector (3).
Filling the braking system.
WARNING: Use only those hydraulic fluids that are approved and recommended.
Fill the brake fluid reservoir (1).
Bleeding the primary braking system.
WARNING: During the bleeding operation, take care to maintain the level of brake fluid in the reservoir and to top it up, using only brake fluid that is clean and clear.
WARNING: The ABS should not be active during the bleeding operation.
B3FP139C B3FP13AC
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DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM
Front brake caliper
Rear brake caliper
: Bleed screw (5).
: Bleed screw (6).
B3FP13BC
Bleed each wheel cylinder, proceeding in the following order:
- Front LH wheel.
- Front RH wheel..
- Rear LH wheel.
- Rear RH wheel
Using the bleeding apparatus.
Connect the bleeding apparatus [1] on the brake fluid reservoir (1).
Adjust the apparatus pressure to 2 bars.
For each brake circuit:
- Connect a transparent tube onto the bleed screw.
- Submerge the other end of the tube in a clean container.
- Open the bleed screw
- Wait until the fluid is flowing out without air bubbles.
- Close the bleed screw.
- Remove the bleeding apparatus.
- Check the brake fluid level (should be between «DANGER» level and
«MAXI» level).
- Fill if necessary with the approved and recommended synthetic brake fluid.
B3FP13DC
B3FP13CC
291
C5
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C5
B3FP13DC
DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM
Without bleeding apparatus.
NOTE: Two operators are necessary.
For each brake circuit:
- Apply the brake pedal to place the circuit under pressure.
- Connect a transparent tube onto the bleed screw.
- Submerge the other end of the tube in a clean container.
- Open the bleed screw.
- Wait until the fluid is flowing out without air bubbles.
- Close the bleed screw.
- Remove the equipment [1].
NOTE: Recommence the process a second time if that is necessary.
Check the brake fluid level (should be between «DANGER» level and «MAXI» level).
Fill if necessary with the approved and recommended synthetic brake fluid.
Bleeding the secondary braking system.
WARNING: During the bleeding operation, take care to maintain the level of brake fluid in the reservoir and to top it up, using only brake fluid that is clean and clear.
NOTE: The bleeding apparatus is still connected on the brake fluid reservoir.
Use the diagnostic tools [2] or [3].
Select the menu corresponding to the vehicle: ABS menu and ESP menu.
Follow the instructions given by the diagnostic tool.
At the end of the bleeding programme, check the brake fluid level and top up, if necessary.
Check the brake pedal travel (no lengthening), if it is not satisfactory repeat the bleeding procedure.
Remove the tools.
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Engine type
Ø mm
Master cylinder
Master-vac
Caliper makes/ pistons
FT
RR
Disc Ventilated
Disc thickness/min. thickness
Brake pad grade
Ø mm
Caliper makes/ pistons
Disc Ventilated
Disc thickness/min. thickness
Brake pad grade
BRAKE SPECIFICATIONS
2.0i 16V 2.2i 16V
RFN 3FZ
22,2 (valve type)
254
LUCAS
60
285
28/26
GALFER 3366 (8)
C8
2.2 HDi 3.0i 24S 2.0 HDi
XFW
23,8 (valve type)
203.2 + 228.6
BREMBO
40 + 44
310
32/30
-
LUCAS C38HR
38
272
12/10
TEXTAR T 4131
RHM - RHT - RHW 4HW
22,2 (valve type)
254
LUCAS
60
285
28/26
FERODO 782 (2)
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C8
Fixing of disc on hub
Fixing of front brake caliper on support
Fixing of front brake caliper support on pivot
Fixing of brake pipe unions
Fixing of rear brake caliper on support
Fixing of rear brake caliper support on pivot
Fixing of brake servo on pedal gear
Fixing of master-cylinder on servo
Fixing of handbrake lever on body
BRAKE TIGHTENING TORQUES (m.daN)
Engines: RFN - 3FZ - XFW - RHT - RHW - RHM - 4HW
Tightening torques (m.daN).
: 1,5 ± 0,1
: 3,5 ± 0,3
: 16 ± 1,6
: 1,5 ± 0,1
: 3,5 ± 0,3
: 9,5 ± 0,9
: 2 ± 0,2
: 2 ± 0,2
: 4 ± 0,4
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ADJUSTING THE HANDBRAKE
Identification
(A) Zone for fixing on floor
(B) Clips for retaining on bodyshell
C8
B3FK263D
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C8
B3FK264D
ADJUSTING THE HANDBRAKE
Adjustment
Raise and support the vehicle, wheels hanging.
WARNING: Bleed the braking circuit.
Detension the secondary brake cables by slackening the nut (1).
With the engine running and the handbrake released, press 40 times on the brake pedal.
Carefully tighten the nut (1), until the brake cables begin to come under tension.
Pull the handbrake lever about ten times in a normal fashion.
Engage the handbrake lever at the 2nd notch of its travel relative to its position of rest.
Turn the nut (1) until the brake pads start touching.
Check that:
- The normal travel of the handbrake lever does not exceed 6 notches.
- The two secondary brake cables on the slide are moving together.
With the handbrake slackened, make sure that the road wheels turn freely when moved by hand.
Check that the handbrake warning lamp lights up from the 1st notch of the lever's total travel.
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DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM
[1] Brake fluid reservoir filler plug
[1] Approved automatic bleeding apparatus
[1] LEXIA diagnostic tool
[1] PROXIA diagnostic tool
Tools.
: (-).0810
: «LURO» or similar
: 4171-T
: 4165-T
C8
Draining.
Remove the pollen filter (see corresponding operation).
Take out the filter from the brake fluid reservoir.
Drain the brake fluid reservoir to the maximum extent, with the aid of a syringe.
Drain the brake fluid reservoir (1) to the maximum extent (if necessary, use a clean syringe).
Disconnect the connector at “a”.
Remove the shaft (1).
Remove brake fluid reservoir (2).
Clean the brake fluid reservoir (2).
Refit the brake fluid reservoir (2) and the shaft (1).
Disconnect the connector at “a”.
Refit the filter in the brake fluid reservoir.
Filling.
IMPERATIVE: Use only new, clear brake fluid, avoiding any ingress of impurities into the hydraulic circuit.
Use only hydraulic fluid(s) that are approved and recommended: DOT 4.
Renew the brake fluid in the calipers, by bleeding the circuit until clean fluid flows out.
B3FP7CKC
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C8
B3FP7CLD
DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM
Bleeding the primary braking circuit.
WARNING: Respect the sequence for opening the bleed screws: From 1 to 6.
A: Brake calipers: LUCAS (at the front)
B: Brake calipers: BREMBO (at the front)
Tightening toques for the bleed screws:
- Front brake calipers: 1,5 ± 0,1 m.daN.
- Rear brake calipers: 1,5 ± 0,1 m.daN.
WARNING: During the bleeding operation, take care to maintain the level of brake fluid in the reservoir and to top it up, using only brake fluid that is clean and clear.
Using the bleeding apparatus.
Position the tool [1] on the brake fluid reservoir (2).
Connect the tool [1] to the approved automatic bleeding apparatus.
Adjust the apparatus pressure to 2 bars.
For each brake circuit:
- Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container.
- Open the bleed screw: wait until the fluid is flowing out without air bubbles.
- Close the bleed screw.
- Remove the bleeding apparatus.
- Check the brake fluid level (should be between «MINI» level and «MAXI»
level).
- Fill if necessary with the approved and recommended synthetic brake fluid.
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B3FP7CLD
DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM C8
Without bleeding apparatus.
NOTE: Two operators are necessary.
Connect a transparent pipe on the bleed screw.
Press slowly on the brake pedal.
Open the bleed screw.
Keep the pedal pressed fully down.
Close the bleed screw.
Allow the brake pedal to rise by itself.
Repeat the operation until the brake fluid flows out clean and free of air bubbles.
Proceed in an identical fashion in the case of all the other wheels.
Check the brake fluid level (should be between «MINI» level and «MAXI»
level).
Fill if necessary with the approved and recommended synthetic brake fluid.
Bleeding the secondary braking system.
NOTE: The bleeding apparatus is still connected on the brake fluid reservoir.
Use the diagnostic tools LEXIA or PROXIA.
Select the menu corresponding to the vehicle: ABS menu or ESP menu.
Follow the instructions given by the diagnostic tool.
At the end of the bleeding programme, check the brake fluid level and top up, if necessary.
Check the brake pedal travel (no lengthening), if it is not satisfactory repeat the bleeding procedure.
Remove the tools.
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C5 SAFETY REQUIREMENTS: HYDRACTIVE 3 HYDRAULIC SUSPENSION
All operations on the Hydractive 3 hydraulic circuit must be performed in conformity with the following requirements and regulations:
Authorities competent in matters of health:
- Accident prevention.
- Environmental protection.
WARNING: Operations should be carried out by specialised personnel who have had training in the safety requirements and precautions to be taken.
Safety requirements.
ESSENTIAL: In view of the special features of the hydraulic suspension system, observe the requirements below, before undertaking any repair.
IMPERATIVE: Depending on the operation to be carried out, respect the requirements for supporting and securing the vehicle.
Wheels hanging Wheels not hanging
2-column lift or secure the vehicle on 4 axle stands
Vehicle on the ground
Depressurisation of the circuit
(see corresponding operation)
Vehicle 4-column lift
Checking and adjusting of heights (switch on ignition)
Other operations (depressurisation of
the hydraulic circuit)
During the operation.
Wait for the pressure in the hydraulic circuit to fall fully before disconnecting the unions on the following components (risk of sudden sinking of the
vehicle):
- Built-in Hydro-electronic Interface (BHI).
- Front suspension cylinder.
- Rear suspension cylinder.
- Front stiffener regulator .
- Rear stiffener regulator.
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SAFETY REQUIREMENTS: HYDRACTIVE 3 HYDRAULIC SUSPENSION
IMPERATIVE: Do not operate on the hydraulic circuit without making the prssure drop (see corresponding operation).
Engine running:
- Do not operate on the hydraulic suspension circuit.
- Always remain out of range of any possible projections of fluid, as these could cause serious injuries.
C5
Preliminary operations.
The work area must be kept clean and uncluttered.
The technician must wear clean overalls.
Components being stored during the repair must be protected from dust.
The tooling required for an operation on the suspension system should always be cleaned prior to the operation.
During the operation.
Before operating on the suspension circuit, proceed to clean the hydraulic components and unions.
NOTE: In the event of contact of LDS fluid with the eyes, rinse them with copious amounts of water and seek specialist advice.
NOTE: In the event of lengthy contact of LDS fluid with the skin, wash it with soap and water.
WARNING: After the engine has stopped, wait 30 seconds before commencing any operation.
IMPERATIVE: Approved cleaner: SODIMAC degreaser.
IMPERATIVE: After a dismantling, immediately blank the hydraulic components and unions with plugs. The plugs should be used for one operation only.
IMPERATIVE: Do not remain underneath the vehicle during an operation to adjust vehicle heights or during actuator (electrovalve) tests.
Any component that has been removed must be plugged and placed in a clean plastic bag.
Cleanliness requirements.
WARNING: Non respect of the cleanliness requirements may cause a contamination of the circuit and a malfunctioning of the suspension.
IMPERATIVE: After a dismantling, any cleaning using compressed air or products is strictly prohibited. Any LDS fluid that is collected must not be re-used. Ny top-up must be done with new fluid.
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C5
SPECIFICATION - IDENTIFICATION: SUSPENSION SPHERES
(1) Front suspension sphere
(2) Rear suspension sphere
(3) Front hydractive 3 + regulator accumulator
(4) Rear hydractive 3 + regulator accumulator
B4BP01DD
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SPECIFICATION - IDENTIFICATION: SUSPENSION SPHERES
Special features
Identification.
The «slimline» spheres are grey in colour, with multilayer membranes.
IMPERATIVE: It is impossible to recharge or overhaul the «slimline» spheres with nitrogen.
The number marked on the suspension sphere is the component reference and not the Replacement Parts No.
The two-figure number marked on the suspension sphere indicates the initial pressure rating value.
Example:
Suspension sphere marking
HF
Day in year of manufacture
066
Year of manufacture
00
Time of manufacture
13h59
Pressure rating
(bars)
57
The pressure rating of this type of suspension sphere is given merely as a guide.
When checking, the value read could be higher than the nominal value.
Suspension cylinders on the same axle should be equipped with the same type of suspension spheres.
IMPERATIVE: Tightening torques for suspension spheres : 2,7 ± 0,5 m.daN.
C5
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C5
All types
Engines
6FZ
RFJ
9HZ
RHL - RHR
Saloon
Estate
Engines
6FZ
RFJ
9HZ
RHL - RHR
6FZ
RFJ
9HZ
RHL - RHR
SPECIFICATION - IDENTIFICATION: SUSPENSION SPHERES
Hydractive 3 hydraulic suspension
(1) Front suspension spheres
Suspension sphere marking
HF
Volume (cc) Pressure rating (bars)
HG
385 57
KC
Suspension sphere marking
(2) Rear suspension spheres
Volume (cc) Pressure rating (bars)
KB
31
KD
385
HT
44
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All types
Saloon
Estate
Saloon/
Estate
Engines
SPECIFICATION - IDENTIFICATION: SUSPENSION SPHERES
Hydractive 3 + hydraulic suspension
(1) Front suspension spheres
Suspension sphere marking Volume (cc)
XFU
4HX
HI 385
XFU - CARLSON
Suspension sphere marking
(2) Rear suspension spheres
Volume (cc) Engines
XFU
4HX
XFU
4HX
KE
HW
385
XFU - CARLSON
HT
C5
Pressure rating (bars)
52
Pressure rating (bars)
25
44
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C5
Saloon
Estate
Saloon/
Estate
Engines
XFU
4HX
XFU
4HX
XFU - CARLSON
Saloon
Estate
Saloon
Estate
Engines
XFU
4HX
XFU
4HX
XFU - CARLSON
SPECIFICATION - IDENTIFICATION: SUSPENSION SPHERES
Hydractive regulator accumulators
(3) Front hydractive regulator accumulator
Suspension sphere marking Volume (cc) Pressure rating (bars)
HQ
62
HD
385
KA
Suspension sphere marking
HR
GV
(4) Rear hydractive regulator accumulator
Volume (cc)
HR
385
HW
HR
31
Pressure rating (bars)
44
306
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B4CP01GP
HYDRAULIC SPECIFICATIONS
Location of components
(D) High pressure hydraulic circuit
(E) Low pressure hydraulic circuit
(F) Electric circuit
(22) Front «slimline» suspension sphere
(23) Front suspension cylinder
(24) Front hydractive 3 + regulator
(25) Front hydractive 3 + regulator accumulator
(26) Sequential control suspension switch
(27) LDS fluid reservoir
(28) Rear height sensor
(29) Rear hydractive 3 + regulator
(30) Rear hydractive 3 + regulator accumulator
(31) Rear suspension cylinder
(32) Rear «slimline» suspension sphere
(33) Built-in Hydro-electronic Interface (BHI)
(34) Front height sensor
C5 + CARLSON
NOTE: LDS = Liquide direction suspension (fluid for steering/suspension).
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C5 + CARLSON
B4BP01BC
HYDRAULIC SPECIFICATIONS
Type of suspension
Hydractive 3
Hydractive 3
Hydractive 3 +
All engines except XFX
Hydractive 3 +
All engines except XFX
Hydractive 3 +
Engine XFX
Hydractive 3 +
Engine XFX
Hydraulic fluid
Type of steering
Left hand drive
Right hand drive
Left hand drive
Right hand drive
Left hand drive
Right hand drive
Capacity (litres)
4,5
4,7
5,2
5,4
5,6
(LDS suspension fluid is orange in colour and 100% synthetic (TOTAL LDS).
Reference
«c»
«d»
«e»
«f»
Return
Hydraulic fluid reservoir
Function
Return
Induction
Component
Suspension cylinders
Built-in Hydro-electronic Interface
Power steering pump
Built-in Hydro-electronic Interface
Power steering pump
The LDS fluid level is checked with the vehicle in the low position (see corresponding
operation).
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HYDRAULIC SPECIFICATIONS
Built-in Hydro-electronic Interface (BHI)
C5 + CARLSON
Component Ref.
(36)
(38)
(35)
(37)
Function
Electronic control unit
Hydraulic unit comprising:
Pump with 5 axial pistons
Anti-pulse hydropneumatic accumulator
Safety valve
Electric motor
Suspension inlet electrovalve (front)
Suspension inlet electrovalve (rear)
Suspension exhaust electrovalve (front)
Suspension exhaust electrovalve (rear)
Throughput = 0,7 l/min at 2300 rpm
Diameters of the pistons = 6,35 mm
Safety valve rating = 180 bars
2350 ± 150 tr/min
The vehicle's anti-sink function is assured by the exhaust electrovalves
B3BP16PP
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C5 + CARLSON
Hydractive 3 + regulator
HYDRAULIC SPECIFICATIONS
Hydraulic unions
B4BP01KD B4DP003D
(39) Electrovalve
(40) Hydractive regulator
Reference
Tube diameter
(mm)
(41) «Slimline» suspension sphere
(42) Depressurisation screw
G
H
3,5
6,35
J 10
IMPERATIVE: At each operation, it is necessary to change the hydraulic seals.
WARNING: Each time you remove a hydraulic union, reference G: Remove the O-ring seal from its housing.
310
Tightening torque m.daN
1,5 ± 0,3
2,5 ± 0,5
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DE-PRESSURISING THE HYDRAULIC SUSPENSION CIRCUIT
Tools.
[1] PROXIA station
[2] LEXIA station
: 4165-T
: 4171-T
De-pressurisation.
NOTE: It is possible to de-pressurise the suspension by individual axle.
Using a diagnostic tool.
Start the engine.
Place the height control in the «LOW» position.
Wait for the vehicle height to reach the position required.
Stop the engine.
Connect the diagnostic tool [1] or [2] to the vehicle's diagnostic socket.
Switch on the ignition.
Go into the menus:
- Suspension.
- Actuator tests.
Select and validate the electrovalves line for front descent.
Wait for the vehicle's front suspension to sink completely.
Select and validate the electrovalves line for rear descent.
Wait for the vehicle's rear suspension to sink completely.
311
C5
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C5
B3BP16GC
B3BP16HC
DE-PRESSURISING THE HYDRAULIC SUSPENSION CIRCUIT
Without using a diagnostic tool.
IMPERATIVE: Any LDS fluid that is collected must not be re-used.
NOTE: Collect the LDS fluid in order to keep the work area clean.
Respect the environment.
Start the engine.
Place the height control in the «LOW» position.
Stop the engine.
Vehicle with suspension Hydractive 3.
Front suspension: undo the pressure release screw (1) by one turn.
Wait for the pressure in the hydraulic circuit to drop fully.
Rear suspension: undo the pressure release screw (2) by one turn.
Wait for the pressure in the hydraulic circuit to drop fully.
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DE-PRESSURISING THE HYDRAULIC SUSPENSION CIRCUIT
B3BP16JC
Vehicle with suspension Hydractive 3 +.
Front suspension: undo the pressure release screw (3) by one turn.
Wait for the pressure in the hydraulic circuit to drop fully.
Rear suspension: undo the pressure release screw (4) by one turn.
Wait for the pressure in the hydraulic circuit to drop fully.
C5
B3BP16KC
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C5 DRAINING - FILLING - BLEEDING: HYDRAULIC SUSPENSION/STEERING CIRCUIT
[1] Pliers for CLIC clips
[2] LEXIA station
[3] PROXIA station
Tools.
: 4121-T
: 4171-T
: 4165-T
Identification.
Sequential control suspension switch.
A: Suspension Hydractive 3
B: Suspension Hydractive 3 +
Draining.
B4BP01ED
IMPERATIVE: Any LDS fluid that is collected must not be re-used.
Start the engine.
Place the suspension height control in the "LOW" position.
Stop the engine.
Raise and support the vehicle, wheels hanging.
WARNING: The LDS fluid reservoir is pressurised.
Open the cap of the LDS fluid reservoir.
Remove:
- The front RH wheel.
- The front RH splash-shield.
Release the clip (1), using tool [1].
Disengage the hose (2) from the LDS fluid reservoir.
Drain the LDS fluid reservoir.
C4CP0SDC
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DRAINING - FILLING - BLEEDING: HYDRAULIC SUSPENSION/STEERING CIRCUIT
Filling.
Couple the hose (2).
Refit:
- A new clip (1).
- The front RH splash-shield.
- The front RH wheel.
Lower the vehicle.
Open the cap (3).
Add LDS fluid to bring the level between the minimum mark "b" and the maximum mark "a".
Bleeding.
Apply a pressure of 0,5 bars in the LDS fluid reservoir (using tool: FACOM 920).
Start the engine.
Wait for the vehicle height to stabilise.
Place the suspension height control in the "HIGH" position.
Place the suspension height control in the "LOW" position.
Move the steering in both directions, from lock to lock.
Stop the engine.
Check that the LDS fluid level is between the minimum mark "b" and the maximum mark "a".
C5
B4BP01MC
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C5 DRAINING - FILLING - BLEEDING: HYDRAULIC SUSPENSION/STEERING CIRCUIT
Checking and toppping up the LDS fluid level.
Start the engine.
Place the suspension height control in the "LOW" position.
Wait until the vehicle height is in the position required.
Stop the engine.
Connect the tool [1] or [2] to the vehicle diagnostic socket.
Switch on the ignition.
Successively select the following menus:
- Suspension.
- De-pressurising.
Follow the instructions given on the screen:
- Switch off the ignition, once there is de-pressurisation.
- Wait 1 minute.
Disconnect the battery
NOTE: Non-compliance with this procedure re-pressurises the suspension circuit.
Remove the engine cover.
Open the cap (3).
If the LDS fluid level is below the minmum mark "b": Add LDS fluid up to the level.
B4BP01MC
316
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DRAINING - FILLING - BLEEDING: HYDRAULIC SUSPENSION/STEERING CIRCUIT
Measurement of heights.
B3CP06AC
C5
Measuring the wheel radius.
To determine the centre of the wheel, place the tool [1] on the heads of the wheel bolts.
Meaure the radius R1 with the tool [2] (distance between the ground and the centre of the wheel).
Measuring the front height H1M.
The front height H1M is measured between the ground and the subframe, at the rear of the front fixing yokes of the suspension triangle.
Calculating the front height H1C.
Except CARLSSON : H1C = R1 - 140 mm.
CARLSSON
R1 = Radius of front wheel (mm).
: H1C = R1 - 155 mm.
Compare:
- The value measured H1M.
- The value calculated H1C.
Adjust the front height if necessary.
B3CP06BC
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C5 DRAINING - FILLING - BLEEDING: HYDRAULIC SUSPENSION/STEERING CIRCUIT
Measuring the rear height H2M.
The rear height H2M is measured between the ground and the zone "a" on the crossmember.
Calculating the rear height H2C.
Except CARLSSON
CARLSSON
R2 = Radius of rear wheel (mm).
Compare:
- The value measured H2M.
: H2C = R2 + 68 mm.
: H2C = R2 + 64 mm.
- The value calculated H2C.
Adjust the rear height if necessary.
B3DP08HC
B3CP06CC
Adjusting the heights.
Adjustment using a diagnostic tool.
This adjustment is done when the heights measured are within the tolerance of the heights calculated.
Mechanical pre-adjustment.
This adjustment is done when the heights measured are not within the tolerance of the heights calculated
(± 10 mm).
Front height:
- Slacken, by one turn, the screw (1) on the clip (2).
- Retighten the screw by hand.
- To decrease the height, turn the clip (2) towards the front of the vehicle.
- To increase the height, turn the clip (2) towards the rear of the vehicle.
Repeat the operation until you obtain the calculated dimension H1C (± 10 mm).
Tighten the screw (1) to 0,6 m.daN.
Adjust with diagnostic tool [2] or [3].
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DRAINING - FILLING - BLEEDING: HYDRAULIC SUSPENSION/STEERING CIRCUIT
Rear height:
Slacken, by one turn, the screw (3) on the clip (4).
Retighten the screw by hand.
To decrease the height, turn the clip (4) towards the rear of the vehicle.
To increase the height, turn the clip (4) towards the front of the vehicle.
Repeat the operation until you obtain the calculated dimension H2C (± 10 mm).
Tighten the screw (3) to 0,6 m.daN.
Adjust with diagnostic tool [2] or [3].
B3DP08JC
319
C5
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C5 DRAINING - FILLING - BLEEDING: HYDRAULIC SUSPENSION/STEERING CIRCUIT
Adjusting of heights using diagnostic tool [2] or [3].
Connect diagnostic tool [2] or [3] to the vehicle diagnostic socket.
Go into the menu:
- Adjustment of reference heights.
- Configuration.
NOTE: H1M = front measured height (mm).
B3BP164C
Except CARLSSON
CARLSSON
Re-enter this value in the diagnostic tool.
NOTE: H2M = rear measured height (mm).
Calculate (H2M-R2) for the rear.
Re-enter this value in the diagnostic tool.
Wait for the correction of the vehicle height.
Measure the front height (H1M).
Check that: H1C ± 2 mm.
Measure the rear height (H2M).
Check that: H2M = H2C ± 2 mm.
: Calculate 280 - (R1-H1M) for the front.
: Calculate (R1-H1M) for the front.
B3BP165C
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CHECKING AND ADJUSTING THE VEHICLE HEIGHT
[1] Gauge for measuring the radius of wheels with 4 bolts
[2] Gauge for under-body height
[3] LEXIA station
[4] PROXIA station
Tools.
: 4300-T
: 2305-T
: 4171-T
: 4165-T
(see chapter on axle geometry).
Preliminary operations.
Check the level of LDS fluid (see corresponding operation).
Check the tyre pressures.
Place the vehicle on a 4-column lift.
Place the vehicle in the normal position.
Release the parking brake.
Start the engine.
Checking by axle.
Lift the vehicle by hand.
Release when you cannot lift any further.
The vehicle descends, then re-ascends and stabilises.
Measure the height.
Push the vehicle down by hand.
Hold the vehicle in this position, release when it re-ascends.
The vehicle ascends, then re-descends and stabilises.
Measure trhe height.
Make an average of the 2 measurements.
321
C5
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C5 - C8
Vehicle Engine version
C5
C8
Date
All types
All types except ES9J4
ES9J4
09/04 >
06/02 >
AIR CONDITIONING R 134.a (HFC)
Compressor
Refrigerant
Refill
(± 25 gr)
Variable capacity
Oil quantity cc
625 SD 7 C16
135
600
SD 6 V12
SD 7 V16
Oil reference
SP 10
322
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SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Summary table for presence of pollen filter
Vehicle
C5
C8
Equipment
Aircon all types
C5 - C8
RPO no.
Presence of filter
YES
Observations
Located under the dashboard
Located in the engine compartment
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C5 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Pollen filter
C5FP0C5C
Remove:
- The trim (1) under the dashboard (driver's side).
- The cover (2).
Unclip at «a» and pull out the pollen filter (3).
Remove the pollen filter (3).
C5FP0C6D
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SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Pollen filter
C8
C5HP182D
325
C5HP183C
NOTE: The pollen filter is located under the bonnet on the LH side.
Removing.
Remove the jack handle (1).
Disconnect the evacuation pipe (2).
Unlock at (3), on the right and on the left.
Undo by a 1/4 turn the screws (4), on right and on left.
Pull the assembly (6) towards the outside.
Remove the pollen filter (5).
Refitting.
Proceed in the opposite order to removal.
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C5 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Drying cartridge
Tools.
[1] Filling and recycling station
[2] TORX adaptor
: MULLER - ECOTECHNICS
: 70 FACOM
[3] After Sales kit
: (bottle/skirt/bottle nozzle/grease/compressor oil)
Reminder: All repairs on an aircon circuit require the aircon circuit to be drained.
After carrying out the dismantling operations necessary to gain access to the condenser, proceed to clean the area of the skirt (8) of the reservoir (6) using a cloth, then replace the dryer reservoir (6).
Removing the plastic bracket holding the reservoir (6):
- Remove the screw (3) (Torx 20), from the bracket assembly/plastic counter-bracket (4) and (5).
- Remove the counter-bracket (5) (rotate it round the hinge in a clockwise direction).
- Disengage the bracket from the harness (1) (rotate it round the reservoir (6) anti-clockwise).
- Remove the bracket (5) from the reservoir body (6).
Unscrewing the reservoir (6).
Unscrew the reservoir (6) using the tool [2].
C5HP16EC
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C5HP16EC
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Condenser with integral reservoir
C5
Removing the reservoir (6) from the base (8).
WARNING: This operation requires the greatest care, the base (8) should be kept clean prior to fitting the new reservoir.
Remove the reservoir (6) and the protection skirt (7), avoiding WITHOUT FAIL any contact or collision with other items under the bonnet (risk of impurities entering the base (8)).
Check before refitting the reservoir (6) that the base (8) is clean (if it is not, clean in and around the
base (8) with a paper cloth).
Preparing the new dryer reservoir.
Remove the black plastic protection cap from the reservoir neck (6), leaving in place the green protection at the other end, in order to keep the new reservoir (6) sealed when mounting it in the base (8) of the condenser.
Use the grease sachet in the replacement kit, to lubricate the threads of the reservoir.
Use the oil sachet in the replacement kit, to lubricate the two O-ring seals of the reservoir (6).
Position the reservoir (6), with its new protection skirt (7) from the replacement kit, and engage the threads of the reservoir (6) in the base (8).
Check that the downward edge of the skirt (7), covers the base (8) all around it.
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C5
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Condenser with integral reservoir (continued)
WARNING: The reservoir (6) contains a drying agent. As soon as the black protection is removed, the reservoir must be mounted in the base (8), otherwise there is a risk of damaging the air conditioning circuit.
Screwing the reservoir (6) into the base (8).
Screw on the reservoir (6) manually, until the neck of the reservoir (6) is in contact with the bottom of the base
(8).
Tighten with a torque spanner and tool [2] at (2) to 1,3 ± 0,1 m.daN.
Fitting the plastic bracket (new, from the Replacement Parts kit).
Proceed in the opposite order to removal, tighten the screw (3) to 0,15 m.daN.
C5HP16EC
328
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SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Removing-refitting the drying cartridge
Removing.
Depressurise the air conditioning circuit.
Remove the hose (1).
Disconnect the connector (2).
Remove the air filter (3).
Turn the plastic pins (4) a quarter turn.
Move aside the condenser (5).
Clean the area of the skirt (6) of the reservoir (7).
Remove the screw (8) of the clip (9).
B1BP2MGC B1BP2MHC
329
C5HP184C C5HP185C
C8
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C8 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Removing-refitting the drying cartridge (continued)
Unscrew the reservoir (7) (using adaptor TORX 70 FACOM).
Unscrew the reservoir (7) and the protection skirt (6).
WARNING: Components must be kept clean prior to a new reservoir being fitted.
Plug the base (10).
WARNING: Do not allow more than 5 minutes to elapse between unpacking the cartridge (reservoir (7)) and fitting it.
C5HP186C C5HP187C
330
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SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Removing-refitting the drying cartridge (continued)
C8
Refitting.
Note: Before fitting the reservoir (7), make sure that the base is clean (10) (if it is not, use paper towel
to clean inside the base (10)).
Preparation of the new dryer reservoir.
Remove the protection plug from the neck of the reservoir (7).
Leave the protection in place on the end of the reservoir (7) until fitting.
Treatments:
- Grease the threads of the reservoir (7) (sachet of grease in the kit).
- Lubricate the two O-ring seals of the reservoir (7) (sachet of oil in the kit).
Remove:
- The protection plug fitted at the time of removal, from the base (10).
- The protection from the end of the reservoir (7).
Engage the reservoir (7) with its skirt (6) on the threads of the base (10).
Screw on the reservoir by hand (7), until the neck of the reservoir (7) makes contact with the base (10).
NOTE: Check that the bottom edge of the skirt (6) covers the base (10) all the way round.
Tighten the reservoir (7) (TORX 70 FACOM), Tighten to 1,4 ± 0,1 m.daN.
Fit the plastic clip (9) and the screw (8) (new, from exchange kit).
Complete the refitting, in reverse order to removal.
Proceed to:
- Recharge the circuit (see corresponding operation).
- Check that the air conditioning functions correctly (see corresponding operation).
C5HP188C
331
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All types SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Compressor lubricant
ESSENTIAL: The compressor lubricant is extremely hygroscopic; always use FRESH oil.
Checking the compressor oil level
There are three specific cases:
- 1) Repairs to a system without leaks.
- 2) Slow leak.
- 3) Fast leak.
1) Repairing a system without leaks.
a) - Using draining/recovery equipment not fitted with an oil decanter.
- Drain the system as slowly as possible via the LOW PRESSURE valve, so as not to lose any oil.
- No more oil should be added when filling the system with R 134.a fluid.
b) - Using draining/filling equipment fitted with an oil decanter.
- Drain the R 134.a fluid from the system in accordance with the instructions in the equipment handbook.
- Measure the amount of oil recovered.
- Add the same amount of NEW oil when filling the system with R 134.a fluid.
c) - Replacing a compressor.
- Remove the old compressor, drain it and measure the oil quantity.
- Drain the new compressor (supplied full), so that the same amount of NEW oil is left in the compressor as was in the old compressor.
- No more oil should be added when filling the system with R 134.a fluid.
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SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Checking the compressor oil level (continued)
2) Slow leak.
Slow leaks do not lead to oil loss, therefore the same procedure should be followed as if there was no leak at all.
3) Fast leak.
This type of leak causes both oil loss as well as allowing air to enter the system.
It is therefore necessary to:
- Replace the dryer.
- Drain as much oil as possible (when replacing the faulty component).
Either before or during filling of the system with R 134.a fluid, introduce 80 cc of NEW oil into the system.
If changing one of the following components, add as below:
- A drying bottle
- A condenser or an evaporator
- A high pressure or low pressure pipe
- A drying cartridge
: 15 cc of compressor oil.
: 20 cc of compressor oil.
: 5 cc of compressor oil.
: 15 cc of compressor oil.
333
All types
Angl.T3-page322-351-2005 4/02/05 15:38 Page 334
Exxoclim
Mode d’emploi
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
Outillage VALEO Outillage EXXOTest
Outillage (flash équipent & materiel)
: 2.4.2-1
: Voir notice constructeur
Procédure de l’essai
Contrôle
Mettre en place l’outil CLIM TEST II (selon notice du constructeur)
E5AP2N4D
Clim test 2
Outillage
: 4372-T
Opération préliminaires.
Fermer tous les aérateurs frontaux.
Démarer le moteur.
Ouvrir l’aérateur frontal gauche.
Positionner la commande du répartiteur d’air sur “débit frontal”.
Activer la commande “recirculation d’air”.
Activer la commande “air
conditioning”.
Position des commandes de air conditioning :
Commande de température sur froid maxi.
Commande de pulseur en position vitesse maximum.
E5AP2N5D
334
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CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
Tool.
[1] Clim test 2 VALEO
: 4372-T
Checks.
Position the tool [1] (depending on manufacturer's instructions).
E5AP2ECC
335
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CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
E5AP2FAC
Checking.
Position the tool CLIM TEST II (according to the manufacturer's instructions).
Preliminary operations.
Close all the front air vents.
Start the engine.
Open the front LH air vent.
Position the air distribution control to «frontal flow».
Activate the «air recirculation» control.
Activate the «air conditioning» control.
Positions of the air conditioning controls:
- Temperature control on maximum cold.
- Blower control in maximum speed position.
Let the air conditioning operate for 5 minutes.
336
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CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
Interpretation of the measurements.
«m»: High pressure.
«n»: High temperature.
«p»: Under-cooling (SR).
«q»: Low pressure.
«s»: Over-heating (SC).
«t»: Ambient air temperature.
«u»: Blown air temperature.
«v»: Humidity.
«r»: Low temperature.
Under-cooling.
«w»: Temperature T3.
The under-cooling represents the difference between the condensation temperature and the aircon fluid temperature at the aircon condenser outlet.
The under-cooling gives the quantity of aircon fluid (in the liquid state) in the air conditioning circuit.
Values for under-cooling (SR).
Values «p» Origins Solutions
SR < 2°C
Lack of aircon fluid in the aircon condenser (should be
more than 150 grammes)
Add some aircon fluid
E5AP2FBC
2°C < SR <4°C
Lack of aircon fluid in the aircon condenser (should be
around 100 to 150 grammes)
4°C < SR < 10°C/12°C
SR > 10°C/12°C
SR > 15°C
Correct quantity
Excess aircon fluid in the aircon condenser
Blown air temperature «u».
The blown air temperature should be between 2°C and 10°C.
Remove some aircon fluid
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CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
Interpretation of the measurements.
«m»: High pressure.
«n»: High temperature.
«p»: Under-cooling (SR).
«q»: Low pressure.
«s»: Over-heating (SC).
«t»: Ambient air temperature.
«u»: Blown air temperature.
«v»: Humidity.
«r»: Low temperature.
Over-heating (SC).
«w»: Temperature T3.
The over-heating represents the difference between the aircon fluid temperature at the evaporator outlet and the evaporation temperature.
The over-heating gives the quantity of aircon fluid (in the liquid state) in the air conditioning circuit
Values for over-heating (SC).
Values «p»
2° < SC < 15°C
SC > 15°C
Origins
Correct quantity
Lack of aircon fluid in the cooling circuit
Solutions
SC < 2°C
Excess aircon fluid in the cooling circuit
Add some aircon fluid
Remove some aircon fluid
E5AP2FBC
Blown air temperature «u».
The blown air temperature should be between 2°C and 10°C.
338
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CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
Interpretation of the diagnosis
«x» Check satisfactory
«y» Lack of aircon fluid in the aircon circuit
«z» Excess aircon fluid in the aircon circuit
«aa» Filtering and drying cartridge clogged
«ab» Other problems (see table on previous page)
339
E5AP2FCD
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CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
Principal problem
Aircon circuit diagnosis table
Symptom
The aircon compressor does not turn or stops suddenly
The clutch of the aircon compressor does not engage, or disengages suddenly
The clutch of the aircon compressor remains engaged and stops suddenly
Possible causes
Aircon compressor clutch
Lack of aircon fluid in the aircon circuit
Aircon pressostat
Aircon evaporator sensor
Electrical circuit (wiring, fuses, etc.)
Auxiliaries drive belt
Aircon compressor
Filtering and drying cartridge
Aircon pressure reducer
Leak of aircon fluid
Aircon compressor clutch
340
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CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
Principal problem
Aircon circuit diagnosis table
Symptom
The aircon compressor makes an abnormal noise
The clutch of the aircon compressor remains engaged
The clutch of the aircon compressor remains engaged and slips
Possible causes
Incorrect adjustment of the aircon compressor clutch
Aircon fluid quantity
Aircon compressor defective
Lack of aircon fluid in the aircon circuit
Aircon compressor valves defective
Aircon compressor clutch
Auxiliaries drive belt
341
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CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
Principal problem
Abnormal levels of pressure
Aircon circuit diagnosis table
Symptom
Low pressure and high pressure too high
Possible causes
Aircon pressure reducer defective
Duct clogged
Low pressure too high and high pressure too low Aircon compressor seal defective
Aircon evaporator sensor defective
Low pressure too low and high pressure too high Aircon pressure reducer jammed too high
Filtering and drying cartridge obstructed
Duct clogged
Low pressure and high pressure too low
Duct clogged
Aircon pressure reducer jammed
Lack of aircon fluid in the aircon circuit
Aircon compressor defective
342
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Abnormal levels of pressure
Air conditioning operating in back-up mode
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
Principal problem
Aircon circuit diagnosis table
Symptom Possible causes
Low pressure normal and high pressure too high Presence of air in the aircon circuit
Aircon pressostat defective
Low pressure normal and high pressure too low
Evaporator sensor defective
Low pressure too high and high pressure normal Aircon pressure reducer jammed open
Filtering and drying cartridge saturated or
Low pressure too low and high pressure normal clogged
Under cooling too weak
Aircon pressure reducer iced up
Lack of aircon fluid
Under cooling excessive
Excess aircon fluid
Presence of air in the aircon circuit
Filtering and drying cartridge clogged
NOTE: In all cases, measure the excessive heating (SC) and the blow air temperature.
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C5
Engines: All types
AIR CONDITIONING SYSTEM (R 134.a)
Evolution of the HP/LP filling valves
(1) High pressure valve (two versions)
(2) Low pressure valve (one version)
C5HP1A9D
344
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AIR CONDITIONING SYSTEM (R 134.a)
Engines: 6FZ - RFJ
(1) High pressure valve
(2) Low pressure valve
(3) Pressostat
(4) Capacity
(a) Condenser bracket
Tighten to 0,8 m.daN
(b) Pressure control valve
Tighten to 0,8 m.daN
(c) Compressor bracket
Tighten to 2,5 ± 0,1 m.daN
(d) Condenser dryer reservoir
Tighten to 1,4 ± 0,2 m.daN
C5
C5HP15QP
345
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C5
AIR CONDITIONING SYSTEM (R 134.a)
Engine: XFX
(1) High pressure valve
(2) Low pressure valve
(3) Pressostat
(4) Capacity
(a) Condenser bracket
Tighten to 0,8 m.daN
(b) Pressure control valve
Tighten to 0,8 m.daN
(c) Compressor bracket
Tighten to 2,5 ± 0,1 m.daN
(d) Condenser dryer reservoir
Tighten to 1,4 ± 0,2 m.daN
C5HP15RP
346
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AIR CONDITIONING SYSTEM (R 134.a)
Engines: RHL - RHR
(1) High pressure valve
(2) Low pressure valve
(3) Pressostat
(4) Capacity
(a) Condenser bracket
Tighten to 0,8 m.daN
(b) Pressure control valve
Tighten to 0,8 m.daN
(c) Compressor bracket
Tighten to 2,5 ± 0,1 m.daN
(d) Condenser dryer reservoir
Tighten to 1,4 ± 0,2 m.daN
C5
C5HP15SP
347
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C5
AIR CONDITIONING SYSTEM (R 134.a)
Engine: 4HX
(1) High pressure valve
(2) Low pressure valve
(3) Pressostat
(4) Capacity
(a) Condenser bracket
Tighten to 0,8 m.daN
(b) Pressure control valve
Tighten to 0,8 m.daN
(c) Compressor bracket
Tighten to 2,5 ± 0,1 m.daN
(d) Condenser dryer reservoir
Tighten to 1,4 ± 0,2 m.daN
C5HP15TP
348
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AIR CONDITIONING SYSTEM (R 134.a)
Engines: RFN - 3FZ
1 - Drying cartridge
2 - Clickfit union (tool 8005-T.C)
3 - Buffer capacity
4 - Clickfit union (tool 8005-T.A)
5 - High pressure valve
6 - Low pressure valve
C5HP17TP
349
C8
Angl.T3-page322-351-2005 4/02/05 15:38 Page 350
C8
C5HP18TP
Engine: XFW
AIR CONDITIONING SYSTEM (R 134.a)
1 - High pressure valve
2 - Low pressure valve
3 - Buffer capacity
4 - Drying cartridge
5 - Pressostat
6 - Clickfit union (tool 8005-T.C)
Tightening torques (m.daN).
c d
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AIR CONDITIONING SYSTEM (R 134.a)
Engines: RHM - RHT - RHW - 4HW
1 - Drying cartridge
2 - Clickfit union (tool 8005-T.C)
3 - Buffer capacity
4 - Clickfit union (tool 8005-T.A)
5 - High pressure valve
6 - Low pressure valve
C5HP17UP
351
C8
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Key features
Efficient engines provide excellent fuel economy and performance
Comfortable interior with ample space for passengers and cargo
Advanced safety systems including airbags, ABS, and stability control
Available in a variety of trims and configurations to meet your needs
User-friendly infotainment system with Bluetooth connectivity and navigation
Spacious trunk with ample room for luggage or cargo
Stylish exterior design that turns heads
Excellent handling and road holding for a comfortable and safe ride
Frequently asked questions
The CITROEN C5 2005 is available with a range of efficient engines, including petrol and diesel options. The petrol engines include a 1.8-liter 16V, a 2.0-liter 16V, and a 3.0-liter 24V. The diesel engines include a 1.6-liter 16V HDi, a 2.0-liter 16V HDi, and a 2.2 16V HDi.
Yes, the CITROEN C5 2005 has a spacious and comfortable interior with ample room for passengers and cargo. The front seats are supportive and offer a wide range of adjustment, while the rear seats provide plenty of legroom and headroom. The trunk is also spacious, with enough room for luggage or cargo.
The CITROEN C5 2005 comes with a range of advanced safety features to protect you and your passengers. These features include airbags, ABS, and stability control. The airbags help to protect you in the event of a collision, while the ABS helps to prevent the wheels from locking up during braking. The stability control helps to keep the vehicle stable during cornering and other maneuvers.