CITROEN C5 2005 Service Manual
  1. Manuals
  2. Brands
  3. CITROEN Manuals
  4. Automobile
  5. C5 2005
  6. Service manual

CITROEN C5 2005 Service Manual

Hide thumbs Also See for C5 2005:
Table of Contents

Advertisement

Quick Links

Download this manual See also: Handbook
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».
CAR 000.020
Volume 3
2 2 0 0 0 0 5 5

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the C5 2005 and is the answer not in the manual?

Questions and answers

Related Manuals for CITROEN C5 2005

Summary of Contents for CITROEN C5 2005

  • Page 1 2 2 0 0 0 0 5 5 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.
  • Page 2 CORRESPONDENCE TABLE FOR PETROL ENGINES Engine families 2.0i 16V 2.2i 16V HPi 1.8i 16V 3.0i 24V Engine types...
  • Page 3 CORRESPONDENCE TABLE FOR DIESEL ENGINES Engine families TED4 TED4 BTED4 ATED4 1,6 16V HDi 2,0 16VHDi 2,2 16VHDi Engine types...
  • Page 4 VERY IMPORTANT As the booklet is constantly re-edited, this one only covers vehicles for this particular model year. It is therefore necessary to order a new booklet each year and RETAIN THE OLD ONES.
  • Page 5 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).
  • Page 6 IDENTIFICATION OF VEHICLES Type approval Structure Version (4) Family (1) Depollution levels Bodywork (2) Alcohol Euro IV Other Engine (3) 83/87 K’ L3/L4 Euro IV RFNC/IF Version (4) Manual 5-speed gearbox Variant (5) Manual 4-speed gearbox Manual 6-speed gearbox ts Family (1) Automatic 6-speed gearbox Axle and/or gearbox gears...
  • Page 7 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).
  • Page 8 IDENTIFICATION OF VEHICLES Type approval Structure Version (4) Family (1) Depollution levels Bodywork (2) Alcohol Euro IV Other Engine (3) 83/87 K’ L3/L4 Euro IV XFWF/IF Version (4) Manual 5-speed gearbox Variant (5) Manual 4-speed gearbox Manual 6-speed gearbox ts Family (1) Automatic 6-speed gearbox Axle and/or gearbox gears...
  • Page 9 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 Place the vehicle on horizontal ground (in the high position if hydropneumatic suspension).
  • Page 10 CAPACITIES (in litres) Petrol 3.0i 24S 1.8i 16V 2.0i 16V AUTO. AUTO. Engine type Engine with filter change 4,25 5,25 Between Min. and Max. 5-speed gearbox Automatic gearbox After oil change Braking circuit Hydraulic circuit Cooling system Fuel tank capacity IMPERATIVE: Systematically check the oil level using the oil dipstick.
  • Page 11 CAPACITIES (in litres) Diesel 2.2 16V HDi 1.6 16V HDi 2.0 16V HDi AUTO. Engine type Engine with filter change 3,75 5,25 4,75 Between Min. and Max. 1,55 5-speed gearbox Automatic gearbox After oil change Braking circuit Hydraulic circuit Cooling system 10,5 11,7 (with additional heating) Fuel tank capacity IMPERATIVE: Systematically check the oil level using the oil dipstick.
  • Page 12 CAPACITIES (in litres) Petrol Diesel 2.2 16V HDi 2.0i 16v 2.2i 16V 3.0i 24V 2.0 16V HDi AUTO. AUTO. Engine type Engine with filter change 4,25 5,25 4,75 4,75 Between Min. and Max. 5-speed gearbox Automatic gearbox After oil change Hydraulic circuit 0,66 Cooling system...
  • Page 13 LUBRICANTS - TOTAL recommended oils EVOLUTIONS (YEAR 2004). New Look CITROËN C5 CITROËN C4 Petrol engine versions: - Normal maintenance interval: 30 000 km (20 000 miles). Petrol engine versions except 2.0 i 16V 180 hp (132 kW): - Severe maintenance interval: 20 000 km (12 000 miles). - Normal maintenance interval: 30 000 km (20 000 miles).
  • Page 14 LUBRICANTS - TOTAL recommended oils Use of oil grade 10W40. S.A.E. Norms - Table for selection of engine oil grade. It is possible to use the semi-synthetic oil 7000 10W40 on HDi and HDi Selection of engine oil grades recommended for climatic conditions in FAP vehicles.
  • Page 15 LUBRICANTS - TOTAL recommended oils API Norms: WARNING: CITROËN engines prior to model year 2000 do not have The meaning of the first letter has not changed, it still corresponds to the to be lubricated with oils adhering to the norms: type of engine: - ACEA AI-98 and API SJ/CF EC or current norms ACEA A5/B5.
  • Page 16 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): Oils specifically for diesel engines: S.A.E.
  • Page 17 LUBRICANTS - TOTAL recommended oils Oil usage table TOTAL ACTIVA QUARTZ Synthetic 9000 Semi-synthetic 7000 Engine types 0W40 5W30 5W40 10W40 15W50 Hot countries Temperate countries Cold countries EW10J4S (CITROËN C4) EW12J4 (CITROËN C8 2.2i 16V) Petrol engines EW10A (CITROËN C4 and C5) Others petrol engines X (*) HDi engines with FAP (*)
  • Page 18 LUBRICANTS - TOTAL recommended oils E4AP006D...
  • Page 19 LUBRICANTS - TOTAL recommended oils ENGINE OILS FRANCE Blended oils for all engines, supplied in bulk TOTAL ACTIVRAC Norms S.A.E: 10W40 Metropolitan FRANCE TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines 7000 10W40...
  • Page 20 LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines 7000 10W40 Germany 9000 0W40 Austria 7000 10W40 7000 10W40 Belgium 9000 0W40 9000 5W40...
  • Page 21 LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines 7000 10W40 Denmark 9000 0W40 7000 10W40 Spain 7000 15W40 Estonia 7000 10W40 9000 0W40...
  • Page 22 LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines 7000 10W40 Hungary 9000 0W40 Italy Ireland 7000 10W40 9000 5W40 Iceland FUTUR 9000 5W30 (*)
  • Page 23 LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines 7000 10W40 Malta 7000 15W50 Moldavia 7000 10W40 7000 10W40 Norway 9000 0W40 9000 5W40...
  • Page 24 LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines 7000 10W40 Romania 7000 15W50 9000 0W40 Russia 7000 10W40 Slovenia 9000 0W40 9000 5W40...
  • Page 25 LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines Ukraine 9000 5W40 7000 10W40 7000 10W40 FUTUR 9000 5W30 (*) 9000 0W40 Serbia-Montenegro (*) Blended oils for all engines, giving fuel economy.
  • Page 26 LUBRICANTS - TOTAL recommended oils ENGINE OILS OCEANIA TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines Australia 9000 5W40 7000 10W40 7000 10W40 New Zealand FUTUR 9000 5W30 (*) AFRICA TOTAL QUARTZ...
  • Page 27 LUBRICANTS - TOTAL recommended oils ENGINE OILS CENTRAL AND SOUTH AMERICA TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines Argentina Brazil Chile 7000 10W40 7000 15W50 7000 10W40 9000 5W40 Cuba...
  • Page 28 LUBRICANTS - TOTAL recommended oils ENGINE OILS SOUTH-EAST ASIA TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines 7000 10W50 China 7000 15W50 9000 5W40 South Korea 7000 10W40 FUTUR 9000 5W30 (*) Hong Kong...
  • Page 29 LUBRICANTS - TOTAL recommended oils ENGINE OILS SOUTH-EAST ASIA TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines Philippines 7000 15W50 Singapore 7000 10W40 9000 5W40 Taiwan 7000 10W40 7000 15W50...
  • Page 30 LUBRICANTS - TOTAL recommended oils ENGINE OILS MIDDLE EAST TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol/LPG engines Saudi Arabia - Bahrain Dubai 7000 15W50 United Arab Emirates 9000 5W40 7000 10W40 7000 10W40...
  • Page 31 LUBRICANTS - TOTAL recommended oils GEARBOX OILS TOTAL TRANSMISSION BV Manual and piloted manual Norms S.A.E: 75W80 gearboxes Part No.: 9730 A2 TOTAL FLUIDE ATX TOTAL FLUIDE AT 42 MB3 automatic gearbox Special oil distributed by CITROËN Part No.: 9730 A6 All countries Special oil distributed by 4HP20 and AL4 autoactive...
  • Page 32 LUBRICANTS - TOTAL recommended oils POWER STEERING OILS Power steering all vehicles TOTAL FLUIDE ATX (except CITROËN C4 and C5) All countries TOTAL FLUIDE LDS Power steering Special oil distributed by CITROËN C4 and C5 Part No.: 9979 A3 TOTAL FLUIDE DA Power steering Very cold countries Special oil distributed by CITROËN...
  • Page 33 LUBRICANTS - TOTAL recommended oils BRAKE FLUID Synthetic brake fluid CITROËN Part No. Packs 9979 05 0,5 Litre CITROËN fluid All countries 1 Litre 9979 06 5 Litres 9979 07 HYDRAULIC SYSTEM Packs CITROËN Part No. All countries Norm TOTAL FLUIDE LDS Orange 9979 A3 TOTAL LHM PLUS...
  • Page 34 LUBRICANTS - TOTAL recommended oils SCREEN WASH FLUID Packs CITROËN Part No. Concentrated: 250 ml 9980 33 ZC 9875 953U 9980 56 9980 06 1 Litre ZC 9875 784U All countries Fluid ready to use 5 Litres 9980 05 ZC 9885 077U ZC 9875 279U GREASING General use...

  • Page 35: Engine Oil Consumption

    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.
  • Page 36 C5 - C8 ENGINE SPECIFICATIONS Engines: 6FZ - RFJ - RFN - 3FZ - XFU - XFW Petrol 1.8i 16V 2.2i 16V 2.0i 16V 3.0i 24S Engine type Cubic capacity (cc) 1749 1997 2230 2946 Bore/stroke 82,7/81,4 85/88 86/96 87/82,5 Compression ratio 10,8/1 11/1...
  • Page 37 C5 - C8 ENGINE SPECIFICATIONS Engines: 9HZ - RHM - RHT - RHW - RHL - RHR - 4HX - 4HW Diesel 1.6 16V 2.0 16V HDi 2.2 16V HDi Engine type Cubic capacity (cc) 1560 1997 2179 Bore/stroke 75/88,3 85/88 85/96 Compression ratio...
  • Page 38 COMPRESSION RATIO - DIESEL ENGINES COMPRESSION MAX. DIFFERENCE ENGINE RATIO BETWEEN CYLINDERS In bars DV6 DW12 20 ± 5 DW10 30 ± 5...
  • Page 39 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engines: 6FZ - RFJ 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 Fitting of the LH support.
  • Page 40 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engines: 6FZ - RFJ Crankshaft Accessories drive pulley Tightening 4 ± 0,4 4 ± 0,4 Angular tightening 53° ± 4° 40° ± 4° Con rod cap screws Pre-tightening 1 ± 0,1 Tightening 2,3 ± 0,2 Angular tightening 46°...
  • Page 41 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engines: 6FZ - RFJ Cylinder block Camshaft bearing covers 0,9 ± 0,1 Exhaust manifold 3,5 ± 0,3 Valve cover 1,1 ± 0,1 Camshaft pulley Pre-tightening 3 ± 0,5 Tightening 8,5 ± 0,5 Inlet camshaft pulley Pre-tightening 2 ±...
  • Page 42 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engines: 6FZ - RFJ Lubrication circuit Oil pump 0,9 ± 0,1 Injection circuit Common injection rail fixing screw 0,9 ± 0,1 Cylinder block Coolant pump 1,4 ± 0,1 Coolant outlet housing 0,9 ± 0,1 Coolant outlet housing Tightening the screws to: 0,3 ±...
  • Page 43 SPECIAL FEATURES: POWER UNIT SUSPENSION Upper RH engine support Engines: RFN - 3FZ Description Ref. Gearbox type BE4/5 ML5C Rod/body fixing screw 5 ± 0,5 Engine support/torque reaction rod 4,5 ± 0,4 flexible stop pin Upper support/intermediate 6,5 ± 0,6 support fixing screw Upper support/body fixing screw 3 ±...
  • Page 44 SPECIAL FEATURES: POWER UNIT SUSPENSION Intermediate engine support Engines: RFN - 3FZ Description Ref. Gearbox type BE4/5 ML5C (12) 9 ± 0,9 Lower RH rod/subframe fixing screw Lower RH engine support/cylinder 4,5 ± 0,4 (13) block fixing screw Lower rod/lower RH engine support (14) 6,5 ±...
  • Page 45 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engines: RFN - 3FZ Crankshaft bearing cap cover (15) Description Pre-tightening 1 ± 0,1 Slackening Re-tightening 1 ± 0,1 then 2 ± 0,2 1 ± 0,1 Angular tightening 70° ± 5° Crankshaft (17) Crankshaft Description (16) Con rod caps flywheel fixing Pre-tightening...
  • Page 46 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Equipment on cylinder head Engine: RFN Engine: 3FZ B1BK1X9D B1BK1XAD Description (18) Camshaft bearing cap covers (19) Cylinder head covers Pre-tightening Tightening 1 ± 0,1 1,5 ± 0,1 Description (20) Inlet manifold (21) Exhaust manifold Tightening 1 ±...
  • Page 47 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: XFU Lower RH engine support/torque reaction rod 6 ± 0,5 1 ± 0,1 6 ± 0,5 LH engine support 3 ± 0,3 6,5 ± 0,6 5 ± 0,5 4,5 ± 0,4 RH engine support 8 and 9 6 ±...
  • Page 48 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: XFU Pencil type ignition coil 0,8 ± 0,3 Sparking plug Pre-tightening 1 ± 0,1 Angular tightening 90° ± 5° Valve cover Pre-tightening 0,5 ± 0,1 Tightening 1 ± 0,1 Camshaft bearing cap cover Pre-tightening 0,2 ±...
  • Page 49 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: XFU Exhaust manifold (with a new gasket) Pre-tightening (sequence from 1 to 10) 1 ± 0,1 Tightening (sequence from 1 to 10) 3 ± 0,3 Con rod caps Pre-tightening 2 ± 0,2 Angular tightening 74°...
  • Page 50 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: XFU Crankshaft bearing 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»...
  • Page 51 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: XFU Sump Pre-tightening (sequence from 1 to 20) 0,5 ± 0,1 Tightening (sequence from 1 to 20) 0,8 ± 0,1 Crankshaft pinion Pre-tightening 4 ± 0,4 Angular tightening 80°± 5° Crankshaft pulley 2,5 ± 0,2 Inlet distributor (with new seals) Pre-tightening 0,4 ±...
  • Page 52 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: XFU Camshaft hubs Pre-tightening 2 ± 0,2 Angular tightening 57° ± 5° 1,5 ± 0,1 Guide roller 8 ± 0,8 Camshaft pulleys Pre-tightening 2 ± 0,2 Angular tightening 115° ± 5° B1EP1FXD Camshaft pulleys 1 ±...
  • Page 53 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: XFW Power unit suspension RH engine support (suspension) Gearbox suspension B1BK24RD B1BK24SD (2) Link rod fixing : 5 ± 0,5 (8) Fixing of gearbox support on LH flexible mounting : 6,5 ± 0,6 (3) Link rod fixing : 4,5 ±...
  • Page 54 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: XFW Power unit suspension - Engine support (lower) Crankshaft B1BK24TD B1BK24UD (17) Bearing plug Tightening : 2 ± 0,2 (13) Torque reaction link rod fixing : 9 ± 0,9 Angular tightening : 74° ± 7° (18) Timing pinion Tightening : 4 ±...
  • Page 55 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: XFW Crankshaft Bearing cap cover Respect the sequence of stages and the order of tightening M11 (bolts M8 (bolts Ref./description from 1 to 8) from 9 to 16) (21) Fixings of bearings/plug covers or Stage 1 Stage 2 Stage 3...
  • Page 56 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: XFW Lubrication circuit Lubrication circuit. Oil sump B1BK24WD B1BK24XD Respect the sequence of stages and the order of tightening (22) Oil separator : 0,8 Stage 1: Do up bolts 13,15 and 17. (23) Strainer : 0,8 Stage 2: Tighten bolts 13,15 and 17 to : 0,2.
  • Page 57 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: XFW Lubrication circuit Cooling circuit Oil pump Coolant pump B1BK3B6D B1BK3B7D Respect the sequence of stages and the order of tightening Stage 1: Position the screws and do them up by hand. Stage 1: Position the screws and do them up by hand. Stage 2: Pre-tighten the screws : 0,5.
  • Page 58 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: XFW Lubrication circuit Cylinder head equipment Coolant manifold B1BK24YD (27) Screws : 2,5 ± 0,2 (28) Screws : 0,8 (29) Screws : 0,8 B1BK24ZD...
  • Page 59 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: XFW Cylinder head equipment Camshaft bearing cap cover (right hand side) Camshaft bearing cap cover (left hand side) B1EK0GCC B1BK3B8D Respect the sequence of stages and the order of tightening (30) Camshaft bearing cap cover or camshaft bearing: - Pre-tightening : 0,2 - Tightening...
  • Page 60 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: XFW Cylinder head equipment Valve covers (right hand side) Valve covers (left hand side) B1EK0GEC B1EK0GFC Respect the sequence of stages and the order of tightening (31) Valve cover: - Pre-tightening : 0,5 - Tightening : 0,8...
  • Page 61 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: XFW Cylinder head equipment Inlet manifold B1BK251D Respect the sequence of stages and the order of tightening (32) Inlet manifold: - Pre-tightening : 0,4 - Tightening : 0,8...
  • Page 62 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: XFW Cylinder head equipment Exhaust manifold (right hand side) Exhaust manifold (left hand side) B1JK03ND B1JK03LD Respect the sequence of stages and the order of tightening (33) Exhaust manifold: - Pre-tightening - Tightening : 3 ± 0,3...
  • Page 63 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: XFW Cylinder head equipment Inlet distributor B1BK252D Respect the sequence of stages and the order of tightening (34) Inlet distributor: - Pre-tightening : 0,4 - Tightening : 0,8...
  • Page 64 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: 9HZ Torque reaction rod 6 ± 0,6 6 ± 0,6 6 ± 0,6 Upper LH engine support 5,5 ± 0,5 Lower LH engine support 6 ± 0,6 Lower RH engine support 5,5± 0,5 RH engine support 4,5 ±...
  • Page 65 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: 9HZ Crankshaft Bearing cap fixing screws Pre-tightening 1 ± 0,2 Slackening 180° ± 5° Tightening 3 ± 0,3 Angular tightening 140° ± 5° Con rod screws Pre-tightening 1 ± 0,1 Angular tightening 100° ± 5° Accessories drive belt pulley Pre-tightening 3,5 ±...
  • Page 66 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: 9HZ Cylinder block Camshaft bearing covers Pre-tightening 0,5 ± 0,1 Tightening 1 ± 0,1 Oil trap 1 ± 0,1 Air inlet manifold Tightening 1 ± 0,1 Pre-tightening Tightening 0,9 ± 0,1 Exhaust manifold 3 ± 0,3 Camshaft pulleys Pre-tightening 2 ±...
  • Page 67 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: 9HZ Flywheel Double damping flywheel Pre-tightening 3 ± 0,3 Angular tightening 90° ± 5° Clutch mechanism 2 ± 0,2 Lubrication circuit Oil pump assembly Pre-tightening 0,5 ± 0,1 Tightening 0,9 ± 0,1 Oil/coolant heat exchanger 1 ±...
  • Page 68 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: 9HZ Diesel injection circuit Injector fixing flange nut Pre-tightening 0,4 ± 0,1 Angular tightening 65° ± 5° Fuel high pressure common injection rail on engine block 2,2 ± 0,2 Unions on fuel high pressure common injection rail Pre-tightening 2 ±...
  • Page 69 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engines: RHL - RHR 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...
  • Page 70 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engines: RHL RHR Crankshaft Bearing cap fixing screws Pre-tightening 2,5 ± 0,2 Angular tightening 60° ± 5° Con rod nuts Pre-tightening 1 ± 0,1 Slackening 180° ± 5° Tightening 2,3 ± 0,2 Angular tightening 45° ± 5° Accessories drive pulleys Pre-tightening 7 ±...
  • Page 71 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engines: RHL RHR Cylinder block Camshaft bearing covers 1 ± 0,1 Exhaust manifold 3 ± 0,3 Inlet valve cover 0,9 ± 0,1 Camshaft pinion 4,3 ± 0,4 Cylinder head Pre-tightening 2,2 ± 0,2 Tightening 6 ± 0,6 Slackening (1 turn) 360°...
  • Page 72 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engines: RHL - RHR Lubrication circuit Oil pump 1,3 ± 0,1 Oil/coolant heat exchanger 5,8 ± 0,5 Lubrication pipe for turbocharger Engine end 4,7 ± 0,4 Turbocharger end 2,2 ± 0,2 Diesel injection circuit Diesel injector Tightening by hand Tightening 0,4 ±...
  • Page 73 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engines: RHL - RHR Diesel injection circuit Injector fixing flange nut Pre-tightening 0,4 ± 0,1 Angular tightening 65° ± 5° Fuel high pressure common injection rail on engine block 2,2 ± 0,2 Unions on fuel high pressure common injection rail Pre-tightening 2 ±...
  • Page 74 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engines: RHM - RHT - RHW Crankshaft Pulley screw M14x150-70 Pre-tightening 5 ± 0,5 Angular tightening 62° Screws M7x100-20 (x 4) Pre-tightening 0,7 ± 0,1 Tightening 1,5 ± 0,1 Screws M7x100-40 (x 2) (*) Pre-tightening 0,7 ±...
  • Page 75 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engines: RHM - RHT - RHW Engine suspension (identification) Upper RH torque reaction rod Upper RH engine support RH engine flexible support Upper RH intermediate engine support Lower RH engine support Torque reaction rod Upper LH intermediate engine support LH engine support LH engine flexible support (10)
  • Page 76 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engines: RHM - RHT - RHW Engine suspension (tightening torques) (12) Spherical-base screw M10x150-75 (x 1) 5 ± ,05 (13) Shaft screw (x 1) 4,5 ± 0,4 (14) Nut M10x150 (x 1) 4,5 ± 0,4 (15) Screws M10x150-60 (x 3) 6 ±...
  • Page 77 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engines: RHM - RHT - RHW Power steering pump Power steering pump Screws M8x125-30 (x 1) 2,5 ± 0,2 Shouldered shaft screw M8x125-22 (x 1) 2,2 ± 0,2 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.
  • Page 78 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engines: RHM - RHT - RHW Air conditioning compressor Air conditioning compressor Spherical-base screw M10x150-60 (x 1) 4 ± 0,4 (10) Shouldered shaft screw M10x150-52 (x 2) 4,2 ± 0,4 NOTE: Tightening the fixing (9) before the fixing (10), to ensure that the auxiliary drive belt is correctly aligned.
  • Page 79 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engines: RHM - RHT - RHW Guide roller (14) Dynamic tensioner roller (15) Eccentric guide roller (16) Screws M10x150-50 (x 1) Pre-tightening 1 ± 0,1 Tightening 4,3 ± 0,4 (17) Screws M8x150-60 (x 1) Pre-tightening 2 ±...
  • Page 80 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: 4HX 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 ±...
  • Page 81 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: 4HX Crankshaft Crankshaft bearing cap screws Pre-tightening 2,5 ± 0,2 Angular tightening 60° Con rod cap screws Tightening 1 ± 0,1 Slackening 180° Tightening 2,3 ± 0,1 Angular tightening 46° ± 5° Accessories drive pulley Tightening 7 ±...
  • Page 82 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: 4HX Cylinder block Piston skirt spray jets 1 ± 0,1 Sump Pre-tightening 1 ± 0,1 Tightening 1,6 ± 0,3 Timing belt guide roller Pre-tightening 1,5 ± 0,1 Tightening 4,3 ± 0,4 Timing belt tensioner roller 2,5 ±...
  • Page 83 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: 4HX Cylinder block Camshaft bearing cap cover Tightening 1 ± 0,1 Pre-tightening the 28 screws Ø 6 6 ± 0,5 Tightening the 28 screws Ø 6 1 ± 0,1 Exhaust manifold Pre-tightening the 8 nuts 1,5 ±...
  • Page 84 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: 4HX Lubrication circuit Oil pump Pre-tightening Tightening 0,9 ± 0,1 Oil/coolant heat exchanger 5,8 ± 0,5 Turbocharger lubrication tube Engine end 3 ± 0,3 Turbocharger end 2 ± 0,2 Diesel injection circuit Diesel injector Do up the 2 nuts By hand Tightening...
  • Page 85 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: 4HW Crankshaft Pulley screw M14x150-70 Pre-tightening 7 ± 0,5 Angular tightening 82° Screws M7x100-40 (x 2) (*) Pre-tightening 0,7 ± 0,1 Tightening 1,5 ± 0,1 Screws M7x100-20 (x 4) Pre-tightening 0,7 ± 0,1 Tightening 1,5 ±...
  • Page 86 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: 4HW Crankshaft (continued) Screws M7x100-20 (x8) (*) (screw by screw and part stage) Stage 1: Tightening Stage 2: Slackening 180° Stage 3: Tightening 2,3 ± 0,2 Stage 4: Angular tightening 46° Screws M9x100-45 (x4) (*) 1 ±...
  • Page 87 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: 4HW Engine suspension (identification) Upper RH torque reaction rod Upper RH engine support RH engine flexible support Upper RH intermediate engine support Lower RH engine support Torque reaction rod Upper LH intermediate engine support LH engine support LH engine flexible support (10)
  • Page 88 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: 4HW Engine suspension (tightening torques) (12) Spherical-base screw M10x150-75 (x 1) 5 ± ,05 (13) Shaft screw (x 1) 4,5 ± 0,4 (14) Nut M10x150 (x 1) 4,5 ± 0,4 (15) Screws M10x150-60 (x 3) 6 ±...
  • Page 89 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: 4HW Power steering pump Power steering pump Screws M8x125-30 (x 1) 2,5 ± 0,2 Shouldered shaft screw M8x125-22 (x 1) 2,2 ± 0,2 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.
  • Page 90 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: 4HW Air conditioning compressor Air conditioning compressor Spherical-base screw M10x150-60 (x 1) 4 ± 0,4 (10) Shouldered shaft screw M10x150-52 (x 2) 4,2 ± 0,4 NOTE: Tightening the fixing (9) before the fixing (10), to ensure that the auxiliary drive belt is correctly aligned.
  • Page 91 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) Engine: 4HW Guide roller (14) Dynamic tensioner roller (15) Eccentric guide roller (16) Screws M10x150 (x 1) Pre-tightening 1,5 ± 0,1 Tightening 3 ± 0,3 (17) Screws M8x150-60 (x 1) Pre-tightening 2 ± 0,2 Tightening 4,5 ±...
  • Page 92 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.
  • Page 93 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.
  • Page 94 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.
  • Page 95 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.
  • Page 96 BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE Tools 4122-T (C.TRONIC.105.5) 4099-T (C.TRONIC.105) B1EP135D...
  • Page 97 AUXILIARY EQUIPMENT DRIVE BELT Diesel Petrol TED4 BTED4 ATED4 Engine type 1.8i 2.0i 3.0i 2.0 16V HDi 2.2i 2.0 16V HDi 105 to 107 to 100 to See pages: 102 to 103...
  • Page 98 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).
  • Page 99 AUXILIARY EQUIPMENT DRIVE BELT Engine: 6FZ Without aircon With aircon 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.
  • Page 100 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].
  • Page 101 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). BXXK08DD - Peg the dynamic tensioner roller (2), using tool [1].
  • Page 102 AUXILIARY EQUIPMENT DRIVE BELT Engine: XFU Tools. [1] Ratchet spanner S.171 FACOM (1/2" square) : S 171 [2] Reduction box S.230 FACOM (1/2" - 3/8" square) : S 230 Remove. Remove the engine cover. Pivot the tensioner roller bracket (1) clockwise, until it locks, using tools [1] and [2] at «a».
  • Page 103 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) Removing. 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.
  • Page 104 AUXILIARY EQUIPMENT DRIVE BELT Engine: 9HZ Without aircon Tools. [1] Dynamic tensioner compressure lever : (-).0188.Z [2] Peg for dynamic tensioner roller : (-).0494.F IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions. Disconnect the battery.
  • Page 105 AUXILIARY EQUIPMENT DRIVE BELT Engine: 9HZ With aircon 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].
  • Page 106 AUXILIARY EQUIPMENT DRIVE BELT Engines: RHM - RHT - RHW Tools. [1] Tensioning lever : (-).0188-J2 [2] Peg for dynamic roller Ø 4 mm : (-) 0188-Q1 [3] Peg for dynamic roller Ø 2 mm : (-).0188-Q2 [4] Dynamic roller compressure lever : (-).1888-Z (A) Pegging hole (B) Belt wear check mark (fixed on engine)
  • Page 107 AUXILIARY EQUIPMENT DRIVE BELT Engines: RHM - RHT - RHW 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).
  • Page 108 AUXILIARY EQUIPMENT DRIVE BELT Engines: RHL - RHR Tools. [1] Dynamic tensioner compressure lever : (-).0188.Z [2] Dynamic tensioner roller retaining peg Ø 4mm : (-).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.
  • Page 109 AUXILIARY EQUIPMENT DRIVE BELT Engine: 4HX Without air conditioning Tools. [1] Dynamic tensioner compressure lever : (-).0188.Z [2] Peg Ø 4 mm : (-).0188.Q1 Remove. WARNING: Mark the direction of fitting in case the belt is to be reused. B1BP270D Compress the tensioner roller (1) by action at «a»...
  • Page 110 AUXILIARY EQUIPMENT DRIVE BELT Engine: 4HX Without air conditioning Tools. [1] Dynamic tensioner compressure lever : (-).0188.Z [2] Peg Ø 4 mm : (-).0188.Q1 Remove. WARNING: Mark the direction of fitting in case the belt is to be reused. B1BP271D Compress the tensioner roller (4) by action at «c»...
  • Page 111 AUXILIARY EQUIPMENT DRIVE BELT Engine: 4HW Tools. [1] Peg for dynamic roller : (-) 0188-Q1 [2] Dynamic roller compressure lever : (-).1888-Z (A) Pegging hole (B) Belt wear check mark (fixed on engine) (C) Zero wear mark (D) Maximum wear mark E5AK0EDC B3EK09PC This marking system permits checking of the belt wear;...
  • Page 112 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.
  • Page 113 CHECKING AND SETTING THE VALVE TIMING Diesel Petrol TED4 BTED4 ATED4 Engine type 1.8i 2.0i 3.0i 2.0 16V HDi 2.2i 2.0i 3.0i 2.0 16V HDi 116 to 131 to 139 to 174 to 180 to 110 to 123 to 145 to 153 to See pages: 180 to 187...
  • Page 114 CHECKING THE VALVE TIMING Engine: 6FZ Tools. [1] Camshaft setting peg : (-).0189.A [2] Crankshaft setting peg : (-).0189.B Checking the setting of the timing. 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.
  • Page 115 CHECKING AND SETTING THE VALVE TIMING Engine: 6FZ Tools. [1] Camshaft setting peg : (-).0189.A [2] Crankshaft setting peg : (-).0189.R [3] Timing belt retaining pin : (-) 0189.K [4] Adaptor for angular tightening : 4069-T [5] Tool for moving and locking the tensioner roller : (-).0189.S [5a] : (-).0189.S1...
  • Page 116 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.
  • Page 117 CHECKING AND SETTING THE VALVE TIMING Engine: 6FZ 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).
  • Page 118 CHECKING AND SETTING THE VALVE TIMING Engine: 6FZ 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.
  • Page 119 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»...
  • Page 120 CHECKING THE VALVE TIMING Engine: RFJ Tools. [1] Camshaft pinion peg : (-).0194.A [2] Crankshaft setting peg : (-).0189.R [3] Engine lifting crossmember 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).
  • Page 121 CHECKING THE VALVE TIMING Engine: RFJ Peg the camshaft pulleys, using tool [1]. 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.
  • Page 122 CHECKING AND SETTING THE VALVE TIMING Engine: RFJ Tools. [1] Camshaft setting peg : (-).0194.B [2] Crankshaft setting peg : (-).0189.R [3] Timing belt retaining pin : (-) 0189.K [4] Adaptor for angular tightening : 4069-T [5] Hub immobilising tool : (-).0189.S [5a] : (-).0189.S1...
  • Page 123 CHECKING AND SETTING THE VALVE TIMING Engine: RFJ Peg the camshaft pulleys (5) and (6), using tool [1]. IMPERATIVE: Never remove the crankshaft pulley (2) without pegging the crankshaft and the camshafts. Remove: - The screw (3). - The crankshaft pulley (2). B1EP1EUD - The lower timing cover (4).
  • Page 124 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).
  • Page 125 CHECKING AND SETTING THE VALVE TIMING Engine: RFJ 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.
  • Page 126 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. IMPERATIVE: Check the position of the index «a», it should be opposite the slot «f». If the position of the index «a»...
  • Page 127 CHECKING AND SETTING THE VALVE TIMING Engine: RFN Tools. [1] Camshaft setting peg : (-) 0189.A [2] Crankshaft setting peg : (-).0189.R [3] Timing belt retaining pin : (-).0189.K [4] Adaptor for angular tightening : 4069-T [5] Tool for moving and locking the tensioner roller : (-).0189.S [5a] : (-).0189.S1...
  • Page 128 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].
  • Page 129 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). IMPERATIVE: Never remove the crankshaft pulley without pegging the crankshaft and camshafts.
  • Page 130 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 ±...
  • Page 131 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].
  • Page 132 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»...
  • Page 133 CHECKING AND SETTING THE VALVE TIMING Engine: RFN 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.
  • Page 134 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).
  • Page 135 CHECKING AND SETTING THE VALVE TIMING Engine: 3FZ Tools. [1] Camshaft setting peg : (-) 0189.A [2] Crankshaft setting peg : (-).0189.R [3] Timing belt retaining pin : (-).0189.K [4] Adaptor for angular tightening : 4069-T [5] Tool for moving and locking the tensioner roller : (-).0189.S [5a] : (-).0189.S1...
  • Page 136 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.
  • Page 137 CHECKING AND SETTING THE VALVE TIMING 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].
  • Page 138 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. If replacing the tensioner roller (15): Tighten to 3,5.
  • Page 139 CHECKING AND SETTING THE VALVE TIMING 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.
  • Page 140 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»...
  • Page 141 CHECKING AND SETTING THE VALVE TIMING Engine: 3FZ 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.
  • Page 142 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.
  • Page 143 CHECKING THE VALVE TIMING Engine: XFU Tools. [1] Camshaft setting pegs : (-).0187.B [2] Crankshaft setting peg : (-).0187.A [3] Fuel pressure take-off union : 4192-T [4] Belt retaining pin : (-).0187.J [5] Exhaust camshaft hubs immobilising tool : (-).0187.F [6] Inlet camshaft hubs immobilising tool : (-).0187.F Remove the auxiliaries drive belt (see corresponding operation).
  • Page 144 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).
  • Page 145 CHECKING AND SETTING THE VALVE TIMING Engine: XFU 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).
  • Page 146 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.
  • Page 147 CHECKING AND SETTING THE VALVE TIMING Engine: XFU Setting the valve timing (continued). 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 ±...
  • Page 148 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.
  • Page 149 CHECKING AND SETTING THE VALVE TIMING Engine: XFW Tools. [1] Camshaft setting pegs : (-).0187-B [2] Crankshaft setting peg : (-).0187-A [3] Belt retaining pin : (-).0187-J [4] Peg for checking camshaft settings : (-).0187-CZ [5] Tool for immobilising inlet camshaft hubs : (-).0187-C [6] Tool for immobilising exhaust camshaft hubs : (-).0187-F...
  • Page 150 CHECKING AND SETTING THE VALVE TIMING Engine: XFW Removing (continued). 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.
  • Page 151 CHECKING AND SETTING THE VALVE TIMING Engine: XFW Removing (continued). 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. Refitting.
  • Page 152 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).
  • Page 153 CHECKING AND SETTING THE VALVE TIMING Engine: XFW Refitting (continued). 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).
  • Page 154 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).
  • Page 155 CHECKING AND SETTING THE VALVE TIMING Engine: XFW 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°...
  • Page 156 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).
  • Page 157 CHECKING THE VALVE TIMING Engine: 9HZ Tools. [1] Flywheel setting peg : (-).0194.C [2] Camshaft setting peg : (-).0194.B [3] Crankshaft setting peg : (-).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.
  • Page 158 CHECKING 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). Remove: - The screw (6). B1BP32DC - The nut (3). - The 3 screws (5). - The RH engine support and upper torque reaction rod assembly.
  • Page 159 CHECKING 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].
  • Page 160 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].
  • Page 161 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 : 4,5 ± 0,5 m.daN. - The three screws (5), tighten to : 5,5 ±...
  • Page 162 CHECKING AND SETTING THE VALVE TIMING Engine: 9HZ Tools. [1] Flywheel setting peg : (-).0194.C [2] Camshaft setting peg : (-).0194.B [3] Crankshaft setting peg : (-).0194.A Removing. IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions.
  • Page 163 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). Remove: - The screw (6). B1BP32DC - The nut (3). - The 3 screws (5). - The RH engine support and upper torque reaction rod assembly.
  • Page 164 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].
  • Page 165 CHECKING AND SETTING THE VALVE TIMING Engine: 9HZ 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).
  • Page 166 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).
  • Page 167 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 : 3 ± 0,3 m.daN. - Angular tighten : 180°...
  • Page 168 CHECKING THE VALVE TIMING Engines: RHL - RHR Tools. [1] Kit of plugs : (-).0188.T [2] Double flywheel setting peg : (-).0188.X [3] Camshaft setting peg : (-).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.
  • Page 169 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). 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).
  • Page 170 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 : 9 ±...
  • Page 171 CHECKING AND SETTING THE VALVE TIMING Engines: RHL - RHR Tools. [1] Kit of plugs : (-).0188.T [2] Double flywheel setting peg : (-).0188.X [3] Camshaft setting peg : (-).0188.M [4] Belt clamp : (-).0188.AD [5] Pinion centrer : (-).0188.AH [6] Flywheel lock : (-).0188.F [7] Pulley extractor...
  • Page 172 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. Orient the camshaft pinion in the pegging position, use a mirror if necessary. B1EP1FAC B1BP31EC Peg the camshaft, using tool [3].
  • Page 173 CHECKING AND SETTING THE VALVE TIMING Engines: RHL - RHR 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.
  • Page 174 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). Reposition the timimg belt, strip «a» well tensioned, in the following order: B1EP1FFC B1EP1FHC - Guide roller (14).
  • Page 175 CHECKING AND SETTING THE VALVE TIMING Engines: RHL - RHR 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].
  • Page 176 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 ±...
  • Page 177 CHECKING AND SETTING THE VALVE TIMING Engines: RHL - RHR 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.
  • Page 178 CHECKING AND SETTING THE VALVE TIMING Engine: 4HX Tools. [1] Belt tension measuring instrument : 4122-T [2] Engine flywheel peg : (-).0188.X [3] Tension lever : (-).0188.Y [4] Belt compressure spring : (-).0188.K [5] Camshaft pinion peg : (-).0188.M [6] Engine flywheel lock : (-).0188.F [7] Set of blocking plugs : (-).0188.T...
  • Page 179 CHECKING AND SETTING THE VALVE TIMING Engine: 4HX 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.
  • Page 180 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).
  • Page 181 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].
  • Page 182 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 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).
  • Page 183 CHECKING AND SETTING THE VALVE TIMING 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).
  • Page 184 CHECKING AND SETTING THE VALVE TIMING Engines: RHM - RHT - RHW - 4HW Tools. [1] Instrument for measuring belt tension SEEM C.TRONIC : (-).0192 [2] Crankshaft setting peg (engine DW12TED4) : (-).0188-X [3] Camshaft peg : (-).0188-M [4] Belt retaining pin : (-).0188-K [5] Engine flywheel stop : (-).0188-F...
  • Page 185 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. Remove: B1EK0TVC B1EK0TUC...
  • Page 186 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).
  • Page 187 CHECKING AND SETTING THE VALVE TIMING Engines: RHM - RHT - RHW - 4HW 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 ±...
  • Page 188 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 ±...
  • Page 189 CHECKING AND SETTING THE VALVE TIMING Engines: RHM - RHT - RHW - 4HW Tensioning the timing belt. 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).
  • Page 190 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 engi- ne 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.
  • Page 191 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 ±...
  • Page 192 CHECKING THE OIL PRESSURE To be read with the Petrol and Diesel correspondence tables Engine type Temperature (°C) 80°C Pressure (bars) 1000 Pressure (bars) 3000 3000 Pressure (bars) 4000 2279-T.Bis 4103-T.B 7001-T 4202-T (-).0710.F1 (-).0710.B1 NOTE: Oil pressure should be checked with the engine cold, after checking the oil level.
  • Page 193 CHECKING THE OIL PRESSURE To be read with the Petrol and Diesel correspondence tables Engine type Temperature (°C) 80°C Pressure (bars) 1000 Pressure (bars) 2000 Pressure (bars) 4000 2279-T.Bis 4103-T.B 7001-T 4202-T (-).1503.J NOTE: Oil pressure should be checked with the engine cold, after checking the oil level.
  • Page 194 VALVE CLEARANCES POSSIBLE PROCEDURES The valve clearances must be checked with the engine cold. For engines with 4 cylinders in a line (1-3-4-2). Rocking Fully open (exhaust) Exhaust Inlet Valves Rocking Adjust Adjust fully open All types Hydraulic adjustment Inlet Exhaust Engines without hydraulic adjustment: The clearance (J) should be checked...
  • Page 195 CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT Engines: RHL - RHR Tools. [1] Ø 10 mm low pressure connector : 4215-T [2] Pressure gauge for testing boost pressure : 4073-T.A Toolkit 4073-T IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines.
  • Page 196 CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT Engine: 4HX Tools. [1] Ø 10 mm low pressure connector : 4215-T [2] Ø 8 mm low pressure connector : 4218-T [3] Pressure gauge for testing boost pressure : 4073-T Kit 4073 -T [4] Extension : 4251-T Connect the tool [1] between the booster pump and the fuel filter (white mark at "a"...
  • Page 197 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.
  • Page 198 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.
  • Page 199 CHECKS: TURBO PRESSURE Engines: RHL - RHR Tools. [1] Pressure gauge for checking the pressure : 7073-T [2] Pressure take-off extension : 8607-T.A [3] Pressure take-off union and hose : 8607-T.B [4] Sleeve for checking the turbo pressure : 4185-T [5] Adaptor sleeve : 4219-T Checks.
  • Page 200 CHECKS: TURBO PRESSURE Engine: 4HX Tools. [1] Pressure gauge for checking pressure : 7073-T.A [2] Extension cable for taking pressure : 8607-T.A [3] Union and hose for taking pressure : 8607-T.B [4] Adaptor for taking pressure : 8607-T.C [5] Unions and hoses for taking pressure : 4088-T Checks.
  • Page 201 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.
  • Page 202 CHECKING THE AIR SUPPLY CIRCUIT Engine: 9HZ Tool. [1] Manual pressure-vacuum pump : FACOM DA 16 Checks. Vacuum pump. Connect the tool [1] into the vacuum pump (1). Start the engine. Wait 30 seconds. B1HP1UGC The vacuum value should be 0.9 ± 0.1 bar at idle. NOTE: The exhaust gas recycling valve is not linked to the air supply circuit.
  • Page 203 CHECKING THE AIR SUPPLY CIRCUIT Engines: RHL - RHR Tool. [1] Manual pressure-vacuum pump : FACOM DA 16 Checks. 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». B1BP341C Start the engine.
  • Page 204 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 ±...
  • Page 205 CHECKING THE AIR SUPPLY CIRCUIT 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...
  • Page 206 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.
  • Page 207 CHECKS: EXHAUST GASES RECYCLING CIRCUIT Engine: 9HZ Exhaust gas recycling (EGR) electrovalve (1). NOTE: The engine ECU pilots the EGR valve. Perform the check with the aid of a diagnostic tool. Carry out the following operations with the diagnostic tool: - «INJECTION»...
  • Page 208 CHECKS: EXHAUST GASES RECYCLING CIRCUIT Engine: 4HX Tool. [1] Manual vacuum pump : 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).
  • Page 209 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.
  • Page 210 C5 - C8 SPARKING PLUGS Electrode Engine Electrode Electrode Tightening CHAMPION Vehicles EYQUEM BOSCH types torque 1.8I 16V FR 8 ME REC 9 YCL 2,75 ± 0,2 0,9 ± 0,1 RFN 52 HZ 0,9 ± 0,05 0,9 ± 0,05 ZR 8 TPP 15 2.0i 16V HPi 1,0 ±...
  • Page 211 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»...
  • Page 212 CLUTCH SPECIFICATIONS Diesel Petrol 1.8i 16V 1.6 16V HDi 2.0 16V HDi Engine type Gearbox type BE4/5 ML/6 Feature «Pull» clutch Flywheel Single Double Supplier VALEO 230 DNG 4700 225 DNG 5450 235 P 7400 Mechanism/type 11 R 10 X Clutch with double damping flywheel (DVA) (*) Clutch disc 228,5/155...
  • Page 213 CLUTCH SPECIFICATIONS Diesel Petrol 2.0i 16V 2.2i 16V HPi 2.0 16V HDi 2.2 16V HDi Engine type Gearbox type BE4/5 ML/5 Feature «Push» clutch «Pull» clutch Flywheel Single Double Supplier VALEO 230 DGN 5100 230 DGN 5300 225 T 5700 242 T 6500 Mechanism/type 11 R 14 X...
  • Page 214 MANUAL GEARBOX SPECIFICATIONS Vehicle Engine Gearbox type Sequence Torque ratio Drive ratio Type BE4/5 EW7J4 BE4/5J 20 DM 70 17X71 BE4/5J 20 DM 66 EW10A BE4/5N 20 DM 85 17x81 None DV6TED4 BE4/5R 20 DM 65 17x71 20 DM 00 EW10J4 BE4/5J 14x62...
  • Page 215 GEARBOX SPECIFICATIONS Vehicle Engine Gearbox type Sequence Torque ratio Drive ratio Type AL4 EW10A 20 TS 10 21x73 52x67 Type AM6 ES9A 20.GH 07 15x53 49x52 Type 4 HP 20 DW12TED4 20 HZ 20 23x66 4 HP 20 59x68 ES9J4 20 HZ 27 19x73...
  • Page 216 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 B2BP047C (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.
  • Page 217 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). Tightening torques (m.daN). Clutch plate/flywheel : 2 ±...
  • Page 218 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.
  • Page 219 HYDRAULIC CLUTCH CONTROL SPECIFICATION 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).
  • Page 220 HYDRAULIC CLUTCH CONTROL SPECIFICATION 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).
  • Page 221 BE4/5 GEARBOX: TIGHTENING TORQUES C5 - C8 Engines: 6FZ - RFN - 9HZ Tightening torques Ref. Description No. of screws Tightening End guide 1,2 ± 0,1 Clutch housing 1,3 ± 0,1 Primary shaft nut 7,2 ± 0,7 Secondary shaft nut 6,5 ±...
  • Page 222 C5 - C8 BE4/5 GEARBOX: TIGHTENING TORQUES Engines: 6FZ - RFN - 9HZ Tightening torques (m.daN). (1) Gearbox rear casing : 1,5 ± 0,1 (2) Gearbox casing/clutch casing fixings : 1,5 ± 0,1 (3) Reverse gear rocker shaft fixing nut : 4,5 ±...
  • Page 223 C5 - C8 BE4/5 GEARBOX: TIGHTENING TORQUES Engines: 6FZ - RFN - 9HZ Tightening torques (m.daN). (13) Primary shaft nut : 7,5 ± 0,7 (14) Secondary shaft nut : 6,5 ± 0,6 (15) Bearing retaining screw : 1,5 ± 0,1 (16) Differential gearwheel screws : 6 ±...
  • Page 224 ML5C GEARBOX: TIGHTENING TORQUES Engines: 3FZ - RHM - RHT - RHW - 4HW Ref. Description Tightening 1 screw M8-45 1,8 ± 0,1 1 screw M8-70 1,8 ± 0,1 1 screw M10-70 4 ± 0,4 1 screw M10-50 4 ± 0,4 1 screw M10-85 4 ±...
  • Page 225 ML5C GEARBOX: TIGHTENING TORQUES Engines: 3FZ - RHM - RHT - RHW - 4HW Ref. Description Tightening Flange fixing screws 2 ± 0,2 Secondary shaft nut 17 ± 1,7 Gear control support screws 1,5 ± 0,1 Differential gearwheel screws 7,7 ± 0,7 B2CKUC5D B2CKUC6D...
  • Page 226 ML6C GEARBOX: TIGHTENING TORQUES Engines: RHL - RHR Ref. Description Tightening Reversing lamp switch 2,5 ± 0,2 Top-up plug 3 ± 0,3 Drain plug 3 ± 0,3 Differential bearing stop plate screw 3 ± 0,3 Screw fixing gearbox casing on clutch casing 3 ±...
  • Page 227 ML6C GEARBOX: TIGHTENING TORQUES Engines: RHL - RHR Ref. Description Tightening Primary shaft screw 10 ± 0,1 Stop guide screw 2 ± 0,2 Differential gearwheel screws 7,7 ± 0,7 Secondary shaft screw 13 ± 1,5 B2CP41AD...
  • Page 228 BE4/5 GEARBOX: CONTROL SPECIFICATIONS Engines: 6FZ - 9HZ Gear controls. [1] Gear lever positioning tool : 8605-T (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 B2CP3XAD...
  • Page 229 BE4/5 GEARBOX: CONTROL SPECIFICATIONS Engines: 6FZ - 9HZ Gear selection control cable Gear engagement control cable B2CP3XBD B2CP3XCD Left hand drive Right hand drive Left hand drive Right hand drive Length A 707 mm Length C 680 mm Length B 829,6 mm Length D 831 mm...
  • Page 230 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: B2CP3XDD - Move the cylinder "c"...
  • Page 231 BE4/5 GEARBOX: CONTROL SPECIFICATIONS Engine: RFN Gear control cable B2CKUBND...
  • Page 232 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 : Ø...
  • Page 233 ML/6C GEARBOX: CONTROL SPECIFICATIONS Engines: RHL - RHR Gear selection control cable Gear engagement control cable B2CP3XBD B2CP3XND Left hand drive Right hand drive Left hand drive Right hand drive Adjustment Adjustment Length A 757 mm Length C 798 mm Length B 908 mm Length D...
  • Page 234 ML/6C GEARBOX: CONTROL SPECIFICATIONS Engines: RHL - RHR Reverse gear unlocking cable B2CP3XUD Left hand drive Right hand drive Adjustment Length E 1060 mm...
  • Page 235 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: B2CP3XPD - Move the cylinder "c"...
  • Page 236 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...
  • Page 237 AL 4 AUTOMATIC GEARBOX: RECOMMENDATIONS - PRECAUTIONS Precautions to be taken Modification of the oil usage counter value. Repairs on mechanical components. Exchanging the gearbox ECU: Never place the gearbox on the ground without protection. - Note down the gearbox counter value. In order to avoid breaking the input shaft ring, it is imperative that the - Transfer the value read into the the new gearbox ECU.
  • Page 238 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 Oil level (see corresponding operation). depending on the seriousness of the fault: - Gearbox in back-up mode with a replacement programme of (the fault An excessive oil level can result in the following consequences: values are taken in substitution).
  • Page 239 AL 4 AUTOMATIC GEARBOX: RECOMMENDATIONS - PRECAUTIONS Procedure for initialising the automatic gearbox ECU Downloading. 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, - «Configuration (integrated circuit button)/Oil counter».
  • Page 240 AL4 GEARBOX: TIGHTENING TORQUES Engine: RFJ Tightening torques (m.daN). (1) Oil flow modulation electrovalve fixing : 1 ± 0,2 (2) Heat exchanger fixing : 5 ± 1 (3) Output speed sensor fixing : 1 ± 0,2 B2CP3EDD (4) Output speed sensor fixing : 1 ±...
  • Page 241 AL4 GEARBOX: TIGHTENING TORQUES Engine: RFJ Tightening torques (m.daN). (8) Fixing of converter on diaphragm Pre-tightening : 1 ± 0,1 Tightening : 3 ± 0,3 (9) Plug fixing : 0,8 ± 0,2 (10) Gearbox fixing on engine : 5,2 ± 1 B2CP3EED...
  • Page 242 AL4 GEARBOX: TIGHTENING TORQUES Engine: RFJ Tightening torques (m.daN). Hydraulic block fixing. Centre the hydraulic block, using screws (11) and (12). Pre-tighten (no strict order) : 0,9. Slacken : All 9 screws. B2CP3X8C Tighten (respect the order indicated) : 0,75. (13) Fixing of selector lever position switch : 1,5 ±...
  • Page 243 AL4 GEARBOX: CONTROL SPECIFICATIONS Engine: RFJ 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...
  • Page 244 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.
  • Page 245 AL4 “SHIFT LOCK” GEARBOX CONTROL SPECIFICATIONS AND PRECAUTIONS Engine: RFJ 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».
  • Page 246 C5 - C8 4 HP 20 AUTOMATIC GEARBOX: RECOMMENDATIONS - PRECAUTIONS Engines: 4HX - XFW - 4HW Precautions to be taken Towing. When performing electrical checks: The front of the vehicle must be raised in order to be towed. - The battery should be correctly charged. If the front of the vehicle cannot be raised.
  • Page 247 C5 - C8 4 HP 20 GEARBOX: TIGHTENING TORQUES Engines: 4HX - XFW - 4HW Tightening torques (m.daN). Gearbox exterior. (2) Oil channel union fixing : 2,5 ± 0,5 (3) Exterior fixing of converter cover on clutch housing : 2,3 ± 0,5 (4) Speedometer take-off aperture plug : 1 ±...
  • Page 248 C5 - C8 4 HP 20 GEARBOX: TIGHTENING TORQUES Engines: 4HX - XFW - 4HW Tightening torques (m.daN). Gearbox interior. (9) Input speed sensor fixing : 0,8 ± 0,1 (10) Hydraulic block fixing (large head) : 0,8 ± 0,1 (11) Output speed sensor fixing : 1 ±...
  • Page 249 4 HP 20 GEARBOX: CONTROL SPECIFICATIONS Engine: 4HX 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.
  • Page 250 4 HP 20 “SHIFT LOCK” GEARBOX CONTROL SPECIFICATIONS AND PRECAUTIONS Engine: 4HX 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.
  • Page 251 4 HP 20 GEARBOX: CONTROL SPECIFICATIONS Engine: 4HX 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.
  • Page 252 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.
  • Page 253 4 HP 20 GEARBOX CONTROLS: CHECKS AND ADJUSTMENTS Engines: XFW - 4HW 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).
  • Page 254 AM6 AUTOMATIC GEARBOX: RECOMMENDATIONS - PRECAUTIONS Engine: XFU Precautions to be taken Towing. When performing electrical checks: The front of the vehicle must be raised in order to be towed. - The battery should be correctly charged. If the front of the vehicle cannot be raised. - Never use a voltage source higher than 16V.
  • Page 255 AM6 GEARBOX: TIGHTENING TORQUES Engine: XFU Tightening torques (m.daN). (3) Filler cap : 4 ± 0,4 (4) Hydraulic valve block casing : 1,5 ± 2 (5) Auto. gearbox heat exchanger : 4,2 ± 0,4 (4) Input speed sensor fixing : 1 ± 0,2 (6) Torque converter B2CP3YTD Pre-tightening...
  • Page 256 AM6 GEARBOX: TIGHTENING TORQUES Engine: XFU Tightening torques (m.daN). (12) Oil temperature sensor tightening plate : 1 ± 0,1 (13) Hydraulic valve block (sequence indicated) : 1 ± 0,1 B2CP3YVD (14) Oil induction cover : 1 ± 0,1 (15) ECU screws : 2,5 ±...
  • Page 257 AM6 GEARBOX: CONTROL SPECIFICATIONS 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: - Normal programme: Operates as the default programme (eco law, autoadaptive mode).
  • Page 258 AM6 “SHIFT LOCK” GEARBOX CONTROL SPECIFICATIONS AND PRECAUTIONS Engine: XFU 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».
  • Page 259 C5 - C8 DRIVESHAFTS - GEARBOX Gearbox oil seal mandrels Tightening torques (m.daN) Driveshaft Driveshaft Right Left Tool kit Vehicles Gearbox Engines bearing BE4/5 6FZ - RFN - 9HZ 7114-T.W 7114-T.X 7116-T 3FZ - RHM - RHT ML/5 RHW - 4HW 2 ±...
  • Page 260 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 B3BP168D...
  • Page 261 AXLE GEOMETRY All types except CARLSSON Front axle Rear axle King pin Vehicle Tracking Castor Camber Tracking Camber inclination Adjustable No adjustable No adjustable 0 to -3 mm 4,5 ± 1,3 mm All types 3° 03' ± 30' -0° ± 30' 12°...
  • Page 262 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 B3BP168D B3BP166D...
  • Page 263 C5 CARLSON AXLE GEOMETRY Front axle Rear axle CARLSSON King pin Vehicle Tracking Castor Camber Tracking Camber inclination Adjustable No adjustable No adjustable 0 to - 2 mm 5,1 ± 1,3 mm All types 3° 03' ± 30' -0° 04' ± 30' 12° 56' ± 30' - 1°...
  • Page 264 AXLE GEOMETRY: CHECKING AND ADJUSTING VEHICLE HEIGHT Tools. [1] Gauge for measuring radius of wheels (4 bolts) : 8006-T [2] Gauge for height under bodyshell : 2305-T [3] LEXIA station : 4171-T [4] PROXIA station : 4165-T Preliminary operations. Checks by axle. Lift the vehicle by hand.
  • Page 265 AXLE GEOMETRY: CHECKING AND ADJUSTING VEHICLE HEIGHT 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.
  • Page 266 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 CARLSSON H2C = R2 + 64 mm. H2C = R2 + 68 mm.
  • Page 267 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 (±...
  • Page 268 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 : Calculate: 280 - (R1 - H1M).
  • Page 269 FRONT AXLE Tightening torques (m.daN). (1) Suspension leg upper fixing Pre-tightening : 5 ± 0,6 Angular tightening : 65° ± 5° (2) Suspension leg fixing on bodyshell : 4,3 ± 0,6 (3) Anti-roll bar link rod upper fixing : 6,4 ± 0,6 (4) Suspension leg fixing on pivot : 5,4 ±...
  • Page 270 FRONT AXLE The front subframe is equipped with a stabiliser bar linking between the two front extensions. (13) Stabiliser bar fixing : 6,6 ± 0,9 (14) Fixing of subframe on body : 14 ± 1,4 (15) Fixing of subframe rear yoke on body : 10 ±...
  • Page 271 REAR AXLE Tightening torques (m.daN). (16) Anti-roll bar fixing : 13 ± 1,3 (17) Front subframe fixing on body : 11,1 ± 1,1 (18) Rear subframe fixing : 11,5 ± 1,1 (19) Rear rubber mounting fixing on bodyshell : 9 ± 1,3 (20) Suspension shaft fixing : 14,9 ±...
  • Page 272 REAR AXLE Height control. (23) Height sensor clip screw : 0,6 B3CP08RD...
  • Page 273 POWER-STEERING SPECIFICATIONS Engines: All types Tightening torques (m.daN). (1) Steering wheel fixing : 2 ± 0,3 (2) (3) Column fixing on mounting : 2,3 ± 0,4 (4) Cardan fixing : 2,3 ± 0,3 (5) Ball-joint fixing on pivot : 3,5 ± 0 B3EP124D (6) Link rod locking nut : 6 ±...
  • Page 274 POWER-STEERING SPECIFICATIONS Tightening torque (m.daN). (12) Heat shield fixing on casing : 1,2 ± 0,2 B3EP126D...
  • Page 275 POWER-STEERING SPECIFICATIONS 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.
  • Page 276 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.
  • Page 277 AXLE GEOMETRY Setting at reference height Measuring front height (H1) Measuring rear height (H2) C4AP1AUC E1AP0AYD B3BP18GC Front height Rear height H1 = R1 - L1 H2 = R2 + L2 H2 = Measurement between bottom of longeron (c) and the ground. H1 = Measurement between the bottom of the subframe (b) at the front fixing of the suspension wishbone and the ground.
  • Page 278 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.
  • Page 279 REAR AXLE GEOMETRY Setting at reference height Height of the vehicle at the rear at reference height (H2 = R2 + L2) 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.
  • Page 280 AXLE GEOMETRY Values for front suspension angles Values for rear suspension angles 3FZ - RHM - RHT 3FZ - RHM - RHT Engines Engines RHW - 4HW RHW - 4HW Tyres 205x65 R15 215x65 R15 215x60 R16 Tyres 205x65 R15 215x65 R15 215x60 R16 L1 (mm)
  • Page 281 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. B3BKAELD...
  • Page 282 FRONT AXLE Identification. (1) Crossmember (2) Tie-rods (3) Springs (4) Front suspension leg (5) Anti-roll bar (6) Subframe Anti-roll bar Engines Diameter (mm) RFN - 3FZ - RHT - RHW 21,5 RHM - 4HW B3CK09JD...
  • Page 283 FRONT AXLE Tightening torques (m.daN). Fixing of subframe on body : 10,7 ± 1 Fixing on tie-rod on body : 6,3 ± 0,6 Fixing of crossmember on body : 8 ± 0,8 Fixing of tie-rod on front subframe : 6,3 ± 0,6 Fixing of damper on pivot : 9 ±...
  • Page 284 REAR AXLE Tightening torques (m.daN). (4) Fixing of damper on body : 9 ± 0,9 (5) Fixing of stabiliser bar on rear axle : 8 ± 0,8 (6) Fixing of stabiliser bar on body : 6 ± 0,6 (7) Fixing of rear axle on body : 8 ±...
  • Page 285 POWER-STEERING SPECIFICATIONS Engines: RFN - 3FZ - XFW - RHM - RHT - RHW - 4HW Tightening torques (m.daN). (8) Steering wheel fixing nut : 2 ± 0,2 (9) Fixing of steering column to support : 2 ± 0,2 (10) Fixing of upper and lower shafts to steering column : 2,5 ±...
  • Page 286 BRAKE SPECIFICATIONS 1.8i 16V 2.0i 16V 3.0i 24S Saloon Estate Engine type Master cylinder 22,2 (valve type) Master-vac Ø BOSCH BIR ZO BOSCH BIR ZO BOSCH BIR ZO mm Caliper makes/ Pistons 54/22 57/26 57/28 Disc Ventilated Disc thickness/min. thickness 22/20 26/24 28/26...
  • Page 287 BRAKE SPECIFICATIONS 1.6 16V HDi 2.0 16V HDi 2.2 16V HDi Engine type Master cylinder 22,2 (valve type) Master-vac Ø BOSCH BIR ZO BOSCH BIR ZO mm Caliper makes/ pistons 57/26 57/28 Disc Ventilated Disc thickness/min. thickness 26/24 28/26 Brake pad thickness 17,8/2,5 Brake pad grade FERODO 749/1...
  • Page 288 BRAKE SPECIFICATIONS Braking circuit 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.
  • Page 289 BRAKE SPECIFICATIONS Tightening torques (m.daN). (12) Brake fluid pressure sensor on master-cylinder : 2,5 ± 0,5 B3FP7A0C (16) Fixing of gyrometer/accelerometer sensor on support : 0,9 ± 0,1 (17) Fixing of support on body : 0,9 ± 0,1 Piping on master-cylinder : 1,5 ±...

  • Page 290: Brake Specifications

    BRAKE SPECIFICATIONS Brake pedal carriage Front brakes Rear brakes B3FP7DNC B3FP7DLC B3FP7DMC Tightening torques (m.daN). (21) Fixing on bodyshell : 1,8 ± 0,3 (18) Caliper fixing on pivot : 12 ± 1,8 (20) Rear caliper fixing on (22) Servo fixing : 1,7 ±...
  • Page 291 CHECKING THE VACUUM PUMP Tool. [1] Pressure checker : Toolkit S.1602 Checks. 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.
  • Page 292 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.
  • Page 293 CHECKING AND ADJUSTING THE PARKING BRAKE (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.
  • Page 294 DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM Tools. [1] Generic bleeding apparatu : «LURO» or similar [2] LEXIA statio : 4171-T [3] PROXIA station : 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.
  • Page 295 DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM Front brake caliper : Bleed screw (5). Rear brake caliper : Bleed screw (6). 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.
  • Page 296 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.
  • Page 297 BRAKE SPECIFICATIONS 2.0i 16V 2.2i 16V 3.0i 24S 2.0 HDi 2.2 HDi Engine type RHM - RHT - RHW Master cylinder 22,2 (valve type) 23,8 (valve type) 22,2 (valve type) Master-vac 203.2 + 228.6 Ø LUCAS BREMBO LUCAS Caliper makes/ pistons 40 + 44 Disc...
  • Page 298 BRAKE TIGHTENING TORQUES (m.daN) Engines: RFN - 3FZ - XFW - RHT - RHW - RHM - 4HW Tightening torques (m.daN). Fixing of disc on hub : 1,5 ± 0,1 Fixing of front brake caliper on support : 3,5 ± 0,3 Fixing of front brake caliper support on pivot : 16 ±...
  • Page 299 ADJUSTING THE HANDBRAKE Identification (A) Zone for fixing on floor (B) Clips for retaining on bodyshell B3FK263D...
  • Page 300 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.
  • Page 301 DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM Tools. [1] Brake fluid reservoir filler plug : (-).0810 [1] Approved automatic bleeding apparatus : «LURO» or similar [1] LEXIA diagnostic tool : 4171-T [1] PROXIA diagnostic tool : 4165-T Draining. Remove the pollen filter (see corresponding operation). Take out the filter from the brake fluid reservoir.
  • Page 302 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 ±...
  • Page 303 DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM 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.
  • Page 304 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.
  • Page 305 SAFETY REQUIREMENTS: HYDRACTIVE 3 HYDRAULIC SUSPENSION Preliminary operations. IMPERATIVE: Do not operate on the hydraulic circuit without The work area must be kept clean and uncluttered. making the prssure drop (see corresponding operation). The technician must wear clean overalls. Components being stored during the repair must be protected from dust. Engine running: The tooling required for an operation on the suspension system should - Do not operate on the hydraulic suspension circuit.
  • Page 306 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...
  • Page 307 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.
  • Page 308 SPECIFICATION - IDENTIFICATION: SUSPENSION SPHERES Hydractive 3 hydraulic suspension (1) Front suspension spheres Engines Suspension sphere marking Volume (cc) Pressure rating (bars) types RHL - RHR (2) Rear suspension spheres Engines Suspension sphere marking Volume (cc) Pressure rating (bars) Saloon RHL - RHR Estate RHL - RHR...
  • Page 309 SPECIFICATION - IDENTIFICATION: SUSPENSION SPHERES Hydractive 3 + hydraulic suspension (1) Front suspension spheres Engines Suspension sphere marking Volume (cc) Pressure rating (bars) types XFU - CARLSON (2) Rear suspension spheres Engines Suspension sphere marking Volume (cc) Pressure rating (bars) Saloon Estate Saloon/...
  • Page 310 SPECIFICATION - IDENTIFICATION: SUSPENSION SPHERES Hydractive regulator accumulators (3) Front hydractive regulator accumulator Engines Suspension sphere marking Volume (cc) Pressure rating (bars) Saloon Estate Saloon/ XFU - CARLSON Estate (4) Rear hydractive regulator accumulator Engines Suspension sphere marking Volume (cc) Pressure rating (bars) Saloon Estate...
  • Page 311 HYDRAULIC SPECIFICATIONS C5 + CARLSON 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...
  • Page 312 HYDRAULIC SPECIFICATIONS C5 + CARLSON Hydraulic fluid Type of suspension Type of steering Capacity (litres) Hydractive 3 Left hand drive Hydractive 3 Right hand drive Hydractive 3 + Left hand drive All engines except XFX Hydractive 3 + Right hand drive All engines except XFX Hydractive 3 + Left hand drive...
  • Page 313 HYDRAULIC SPECIFICATIONS C5 + CARLSON Built-in Hydro-electronic Interface (BHI) Ref. Function Component (36) Electronic control unit Hydraulic unit comprising: Pump with 5 axial pistons Throughput = 0,7 l/min at 2300 rpm (38) Anti-pulse hydropneumatic Diameters of the pistons = 6,35 mm accumulator Safety valve rating = 180 bars Safety valve...
  • Page 314 C5 + CARLSON HYDRAULIC SPECIFICATIONS Hydractive 3 + regulator Hydraulic unions B4BP01KD B4DP003D Tube diameter Tightening torque Reference (39) Electrovalve (mm) m.daN (40) Hydractive regulator (41) «Slimline» suspension sphere 1,5 ± 0,3 6,35 (42) Depressurisation screw 2,5 ± 0,5 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.
  • Page 315 DE-PRESSURISING THE HYDRAULIC SUSPENSION CIRCUIT Tools. [1] PROXIA station : 4165-T [2] LEXIA station : 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.
  • Page 316 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»...
  • Page 317 DE-PRESSURISING THE HYDRAULIC SUSPENSION CIRCUIT 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. B3BP16JC Rear suspension: undo the pressure release screw (4) by one turn. Wait for the pressure in the hydraulic circuit to drop fully.
  • Page 318 DRAINING - FILLING - BLEEDING: HYDRAULIC SUSPENSION/STEERING CIRCUIT Tools. [1] Pliers for CLIC clips : 4121-T [2] LEXIA station : 4171-T [3] PROXIA station : 4165-T Identification. Sequential control suspension switch. A: Suspension Hydractive 3 B: Suspension Hydractive 3 + Draining.
  • Page 319 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.
  • Page 320 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.
  • Page 321 DRAINING - FILLING - BLEEDING: HYDRAULIC SUSPENSION/STEERING CIRCUIT Measurement of heights. 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.
  • Page 322 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 : H2C = R2 + 68 mm. CARLSSON : H2C = R2 + 64 mm.
  • Page 323 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.
  • Page 324 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). Except CARLSSON : Calculate 280 - (R1-H1M) for the front.
  • Page 325 CHECKING AND ADJUSTING THE VEHICLE HEIGHT Tools. [1] Gauge for measuring the radius of wheels with 4 bolts : 4300-T [2] Gauge for under-body height : 2305-T [3] LEXIA station : 4171-T [4] PROXIA station : 4165-T (see chapter on axle geometry). Preliminary operations.
  • Page 326 C5 - C8 AIR CONDITIONING R 134.a (HFC) Compressor Refrigerant Vehicle Engine version Date Refill Variable capacity Oil quantity cc Oil reference (± 25 gr) All types 09/04 > SD 7 C16 All types SP 10 SD 6 V12 except ES9J4 06/02 >...
  • Page 327 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) C5 - C8 Summary table for presence of pollen filter Vehicle Equipment RPO no. Presence of filter Observations Located under the dashboard Aircon all types Located in the engine compartment...
  • Page 328 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Pollen filter Remove: - The trim (1) under the dashboard (driver's side). - The cover (2). C5FP0C5C Unclip at «a» and pull out the pollen filter (3). Remove the pollen filter (3). C5FP0C6D...
  • Page 329 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Pollen filter 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.
  • Page 330 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Drying cartridge Tools. [1] Filling and recycling station : MULLER - ECOTECHNICS [2] TORX adaptor : 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).
  • Page 331 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Condenser with integral reservoir 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)).
  • Page 332 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.
  • Page 333 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).
  • Page 334 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).
  • Page 335 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Removing-refitting the drying cartridge (continued) 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.
  • Page 336 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.

  • Page 337: All Types

    SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) All types 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.
  • Page 338 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Outillage EXXOTest Outillage VALEO Outillage (flash équipent & materiel) Procédure de l’essai Exxoclim : 2.4.2-1 Mode d’emploi : Voir notice constructeur Contrôle Mettre en place l’outil CLIM TEST II (selon notice du constructeur) Opération préliminaires.
  • Page 339 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...
  • Page 340 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM 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»...
  • Page 341 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Interpretation of the measurements. «m»: High pressure. «s»: Over-heating (SC). «n»: High temperature. «t»: Ambient air temperature. «p»: Under-cooling (SR). «u»: Blown air temperature. «q»: Low pressure. «v»: Humidity. «r»: Low temperature. «w»: Temperature T3.
  • Page 342 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Interpretation of the measurements. «m»: High pressure. «s»: Over-heating (SC). «n»: High temperature. «t»: Ambient air temperature. «p»: Under-cooling (SR). «u»: Blown air temperature. «q»: Low pressure. «v»: Humidity. «r»: Low temperature. «w»: Temperature T3.
  • Page 343 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Interpretation of the diagnosis E5AP2FCD «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)
  • Page 344 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table Principal problem Symptom Possible causes Aircon compressor clutch Lack of aircon fluid in the aircon circuit The clutch of the aircon compressor does not Aircon pressostat engage, or disengages suddenly Aircon evaporator sensor The aircon compressor does not turn Electrical circuit (wiring, fuses, etc.)
  • Page 345 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table Principal problem Symptom Possible causes Incorrect adjustment of the aircon compressor clutch The clutch of the aircon compressor Aircon fluid quantity remains engaged The aircon compressor makes an abnormal Aircon compressor defective noise Lack of aircon fluid in the aircon circuit...
  • Page 346 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table Principal problem Symptom Possible causes Aircon pressure reducer defective Low pressure and high pressure too high 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...
  • Page 347 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table Principal problem 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 Abnormal levels of pressure Low pressure too high and high pressure normal...
  • Page 348 AIR CONDITIONING SYSTEM (R 134.a) Engines: All types Evolution of the HP/LP filling valves (1) High pressure valve (two versions) (2) Low pressure valve (one version) C5HP1A9D...
  • Page 349 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 ±...
  • Page 350 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 ±...
  • Page 351 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 ±...
  • Page 352 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 ±...
  • Page 353 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...
  • Page 354 AIR CONDITIONING SYSTEM (R 134.a) Engine: XFW 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). : 0,8 : 1,4 : 0,8 C5HP18TP...
  • Page 355 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...

This manual is also suitable for:

C8 2005

Table of Contents

Save PDF