CITROEN C5 2005 Service manual

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

Angl. T3 page001-31-2005 4/02/05 14:15 Page 16

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

Angl. T3 page001-31-2005 4/02/05 14:15 Page 18

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

Angl.T3-page032-190-2005 4/02/05 15:15 Page 32

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

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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

Angl.T3-page032-190-2005 4/02/05 15:15 Page 86

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

Angl.T3-page032-190-2005 4/02/05 15:15 Page 88

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

Angl.T3-page032-190-2005 4/02/05 15:15 Page 92

!

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

Angl.T3-page032-190-2005 4/02/05 15:15 Page 95

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.

96

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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

Angl.T3-page032-190-2005 4/02/05 15:15 Page 98

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

Angl.T3-page032-190-2005 4/02/05 15:15 Page 100

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

Angl.T3-page032-190-2005 4/02/05 15:15 Page 102

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

Angl.T3-page032-190-2005 4/02/05 15:15 Page 103

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

Angl.T3-page032-190-2005 4/02/05 15:15 Page 104

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

Angl.T3-page032-190-2005 4/02/05 15:15 Page 106

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

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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

113

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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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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

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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

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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

177

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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

Angl.T3-page032-190-2005 4/02/05 15:15 Page 189

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

Angl.T3-page032-190-2005 4/02/05 15:15 Page 190

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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Angl.T3-page207-255-2005. 4/02/05 15:19 Page 235

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

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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

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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

Angl.T3-page207-255-2005. 4/02/05 15:19 Page 252

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”.

258

Angl. T3-page256-281-2005 4/02/05 15:25 Page 259

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

Angl. T3-page256-281-2005 4/02/05 15:25 Page 260

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.

261

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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).

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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

Angl. T3-page256-281-2005 4/02/05 15:25 Page 264

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

304

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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

305

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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

Angl.T3-page300-321-2005 4/02/05 15:33 Page 311

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

317

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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

323

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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

324

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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.

Angl.T3-page322-351-2005 4/02/05 15:38 Page 326

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

326

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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

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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

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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

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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

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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

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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

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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.

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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.

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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

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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

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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

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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

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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

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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

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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

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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

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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