CITROEN C8 2002 Handbook
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CITROEN C8 2002 Handbook

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2002
«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 050013

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  • Page 1 2002 «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».
  • Page 2 PRESENTATION THIS HANDBOOK summarises the specifications, adjustments, checks and special features of the CITROEN C8. The handbook is divided into the following sections representing the main functions : GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH - GEARBOX - DRIVESHAFTS - AXLES - SUSPENSION - STEERING - BRAKES - HYDRAULICS -...

  • Page 3: Identification Of Vehicles

    IDENTIFICATION OF VEHICLES (A) Chassis stamp (cold stamp on bodywork). (B) Manufacturer’s data plate (under RH centre pillar). (C) A-S / RP No. and RP paint code (label on front pillar). (D) Inflation pressures and tyre references. (label on front pillar) (E) Gearbox reference –...
  • Page 4 IDENTIFICATION OF VEHICLES Petrol 2.2i 16V 2.0i 16V Manual Automatic Manual X – SX Captain Chair X - SX Captain Chair Exclusive Exclusive Captain Chair IFL5 Emission standard EB RFNC/IF EB RFNF/IF EA RFNF/IF EB 3FZC/IF EA 3FZC/IF Type code Engine type 1998 2230...
  • Page 5 IDENTIFICATION OF VEHICLES Petrol 3.0i V6 S24 Automatic Exclusive Exclusive Captain Chair IFL5 Emission standard SEB XFWF/IF EA XFWF/IF Type code Engine type 2946 Cubic capacity (cc) Fiscal rating (hp) 4 HP 20 Gearbox type 20 HZ 27 Gearbox ident. plate...
  • Page 6 IDENTIFICATION OF VEHICLES Diesel 2.0 HDi (**) 2.0 HDi (*) Manual Automatic Manual Automatic X – SX – Exclusive X – SX – Exclusive Captain Chair Captain Chair Emission standard EB RHTB EB RHTE EA RHTE EB RHWB EB RHWE EA RHWE Type code Engine type...
  • Page 7 IDENTIFICATION OF VEHICLES Diesel 2.2 HDi (*) Manual Captain Chair Captain Chair Exclusive Captain Chair Emission standard EB 4HWB EA 4HWB Type code Engine type 2179 Cubic capacity (cc) Fiscal rating (hp) ML5C Gearbox type 20 LM 01 Gearbox ident. plate (*) = With particle filter.

  • Page 8: General Specification Lifting And Supporting Vehicle

    GENERAL SPECIFICATION: LIFTING AND SUPPORTING THE VEHICLE Tooling. [1] Crossbeam : (-). 0010. Front lifting on one side. Position the jack (4) at the strongpoints provided for this purpose on each side of the front crossmember between the bumper (2) and the engine (3). Front central lifting.
  • Page 9 GENERAL SPECIFICATION: LIFTING AND SUPPORTING THE VEHICLE Lifting by means of a two-column workshop lift WARNING : The removing of components such as the engine/gearbox, rear sub- frame etc, can cause a displacement of the centre of gravity: Use a lift equipped with retaining devices to keep the body stable on the lift.

  • Page 10: Capacities

    CAPACITIES (in litres) Petrol Diesel 2.0i 16V 2.2i 16V 3.0i 24V 2.0 HDi 2.2 HDi Auto. Auto. Auto. Engine type RHT - RHW Engine angle Engine with filter change 4.25 5.25 4.75 Between Min. and Max. 5-speed gearbox Automatic gearbox After oil change Hydraulic or brake circuit 0.66...
  • Page 11 ENGINE SPECIFICATIONS Engines : RFN - 3FZ - XFW - RHW - RHT - 4HW Petrol Diesel All Types 2.0i 16V 2.2i 16V 3.0i 24V 2.0 HDi 2.2 HDi RHT- RHW Engine type 1997 2230 2946 1997 2179 Cubic capacity (cc) 85/88 86/96 87/82.6...
  • Page 12 ENGINE SPECIFICATIONS Engines : RFN – 3FZ (1) Compulsory engine plate : (A) Engine legislation type. (B) Component reference. (C) Factory serial no. B1BB010D...
  • Page 13 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 puis 2 ± 0.2 1 ± 0.1 Angular tightening 70° ± 5° Crankshaft (17) Flywheel/ Description (16) Con-rod caps crankshaft fixing...
  • Page 14 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Equipment on cylinder head Engine : RFN Engine : 3FZ B1BK1X9D B1BK1XAD Description (18) Camshaft bearing cap covers (19) Valve covers Pre-tightening Tightening 1 ± 0.1 1.5 ± 0.1 Description (20) Inlet manifold (21) Exhaust manifold Tightening 1 ±...
  • Page 15 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.
  • Page 16 SPECIAL FEATURES: POWER UNIT SUSPENSION Intermediate engine support Engines : RFN – 3FZ Description Ref. Gearbox type BE4/5 ML5C Lower RH rod/subframe (12) 9 ± 0.9 fixing screw. Lower RH engine support/cylinder (13) 4.5 ± 0.4 block fixing screw. Lower rod/lower RH engine (14) 6.5 ±...
  • Page 17 CYLINDER HEAD Engines : RFN – 3FZ Cylinder head gasket identification Cylinder head tightening (m.daN) Cylinder head bolts B1BK24QD B1DK001C B1DB002C Tighten in the order indicated Multi-layer metallic gasket. X = MAXI re-usable Cylinder head gasket thickness (mm) 1/ : 1.5 Pre-tightening Ref.
  • Page 18 SPECIAL FEATURES: VALVE TIMING Engines : RFN - 3FZ The camshafts are referenced following two methods. - (1) Marking position (2) Paint rings. - (3) Marking position (4) Marking at end of shaft. - (5) Target for camshaft position sensor. Marking position: (1) Paint ring : Repair reference.
  • Page 19 ENGINE SPECIFICATIONS Engine : XFW (A) Component reference. (B) Engine legislation type. (C) Factory serial no. B1BK1JWD...
  • Page 20 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 21 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFW Power unit suspension – Engine support (Lower) Crankshaft B1BK24TD B1BK24UD (17) Bearing cap Tightening : 2 ± 0.2 (13) Torque reaction link rod fixing : 9 ± 0.9 + Angular tightening : 74°...
  • Page 22 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFW Cylinder block Bearing cap cover Respect the sequence of stages and the order of tightening Reference/description Bolts from 1 Bolts from 9 to 8 to 16) (21) Fixings of bearings/cap covers or Stage 1 Stage 2 Stage 3...
  • Page 23 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...
  • Page 24 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.
  • Page 25 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 26 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-tighten to : 0.2 Tighten to...
  • Page 27 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-tighten to : 0.5 Tighten to : 0.8...
  • Page 28 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-tighten to : 0.4 Tighten to : 0.8...
  • Page 29 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-tighten to Tighten to : 3 ±...
  • Page 30 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-tighten to : 0.4 Tighten to : 0.8...
  • Page 31 CYLINDER HEAD Engine : XFW Identification of cylinder head gaskets The RH and LH cylinder head gaskets are specific, of multilayer metallic type. B1DK0QKD B1DK0QLD Respect the sequence of stages and the order of tightening Cylinder head gasket thicknesses (a) : RH cylinder head gasket. (1A) : Engine ref : G-H (b) : LH cylinder head gasket.
  • Page 32 CYLINDER HEAD Engine : XFW Cylinder head tightening (m.daN) Cylinder head bolts Pre-tightening Slackening : YES Tightening : 1.5 Angular tightening : 225° NOTE : Grease the bolts on the threads and under the heads, using engine oil or Molykote G plus).
  • Page 33 CYLINDER HEAD Engine : XFW Identification of camshafts B1EK0WVD The camshafts are identified by the following references: A = Inlet camshaft (1) Exhaust camshaft E389 (Front) (2) Inlet camshaft. A423 (Front) E = Exhaust camshaft (3) Inlet camshaft. A422 (Rear) (4) AExhaust camshaft E388 (Rear) Timing belt...
  • Page 34 CYLINDER HEAD Engines : RHT – RHW - 4HW Identification of cylinder head gasket Cylinder head tightening (m.daN) Cylinder head bolts NOTE : Grease the bolts on the threads and under the heads, using engine oil or Molykote G plus).G Plus) B1DK1M6D B1DK0Q6C B1DK00SC...
  • Page 35 AUXILIARY EQUIPMENT DRIVE BELT Engines : RFN-3FZ Tools [1] Peg for dynamic tensioner roller (-).0189-E Removing. Remove: The front RH wheel. The front RH splash-shield. BXXK08DD Detension the auxiliary drive belt by actioning the screw (1). Peg the dynamic tensioner roller (2), using tool [1]. Remove the auxiliary drive belt.
  • Page 36 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 37 AUXILIARY EQUIPMENT DRIVE BELT Engine : 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 compression lever : (-).1888-Z.
  • Page 38 AUXILIARY EQUIPMENT DRIVE BELT Engine : 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 39 AUXILIARY EQUIPMENT DRIVE BELT Engine : 4HW Tools. [1] Peg for dynamic roller : (-) 0188-Q1 [2] Dynamic roller compression 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 40 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 41 BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE Tools 4122-T (C.TRONIC.105.5) 4099-T (C.TRONIC.105) B1EP135D...
  • Page 42 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 39. ESSENTIAL: Before refitting the auxiliary equipment drive belt, check that: - 1 / The roller(s) rotate freely (no play or stiffness) - 2 / The belt is correctly engaged in the grooves of the various pulleys.
  • Page 43 CHECKING AND SETTING THE VALVE TIMING Engine : RFN Tools. [1] Crankshaft setting peg : (-).0189-B [2] Camshaft hub setting pegs : (-).0189-AZ [3] Belt retaining pin : (-).0189-K [4] Positioning peg : (-).0189-J [5] Tool for immobilising hub : (-).6310-T Removing.
  • Page 44 CHECKING AND SETTING THE VALVE TIMING Engine : RFN Removing (continued). Peg : - The camshafts, using tool [2]. - The crankshaft, using tool [1]. Slacken the screw (7) while holding tool [4]. Using the hexagonal recess (C), turn the eccentric hub (8) of the tensioner roller (9) (clockwise), to detension the belt.
  • Page 45 CHECKING AND SETTING THE VALVE TIMING Engine : RFN Refitting. Systematically replace the timing belt. IMPERATIVE : Check that the rollers (9) and (11), as well as the coolant pump (12) turn freely (no tight spot). When replacing the belt (11), tighten the fixing to 3.5 ± 0.3 m.daN. Position the belt on the crankshaft pinion (13), respecting its direction of fitting.
  • Page 46 CHECKING AND SETTING THE VALVE TIMING Engine : RFN Tensioning the timing belt. Remove tool [3]. (D) : Max. position. (E) : Nominal tension position. Using the hexagonal recess (C), turn the roller hub (anti-clockwise), to bring the index (10) to position (D) to tension the belt to the maximum.
  • Page 47 CHECKING AND SETTING THE VALVE TIMING Engine : RFN Positioning the crankshaft. NOTE : This operation positions all the pegs in their respective pegging points. Peg: - The camshaft pulleys, using tool [2]. - The crankshaft, using tool [1]. If this is not possible, reposition the flange (17). B1EK1TBD IMPERATIVE : This operation guarantees the setting of the timing for subsequent operations.
  • Page 48 CHECKING AND SETTING THE VALVE TIMING Engine : RFN Refitting (continued). Refit: - The timing cover (6). - The auxiliary drive pulley. - The screws (4), tighten to 2.1 ± 0.2 m.daN. B1EK0V7D - The timing cover (5). - The torque reaction rod (3). - The screws (1) and (2), tighten to 4.5 ±...
  • Page 49 CHECKING AND SETTING THE VALVE TIMING Engine : 3FZ Tools. [1] Crankshaft setting peg : (-).0189-B [2] Exhaust camshaft setting peg : (-).0189-AZ [3] Inlet camshaft setting peg : (-).0189-L [4] Positioning peg : (-).0189-J B1EK0V1D [5] Tool for immobilising hub : 6310-T [6] Belt retaining pin : (-).0189.K...
  • Page 50 CHECKING AND SETTING THE VALVE TIMING Engine : 3FZ Remove: - The screws (1) and (2). - The torque reaction rod (3). - The nut (4). - The 3 screws (5). - The RH engine support (6). - The screws (7), plus the auxiliary drive pulley. B1EK1SUD B1EK1SMD - The timing covers (8) and (9).
  • Page 51 CHECKING AND SETTING THE VALVE TIMING Engine : 3FZ Position tool [4]. Slacken the screw (10) while holding tool [4]. Using the hexagonal recess (D), turn the eccentric hub (11) of the tensioner roller (12) (clockwise), to detension the belt. The cursor (13) moves against the tool [4]. Remove the timing belt.
  • Page 52 CHECKING AND SETTING THE VALVE TIMING Engine : 3FZ Tensioning the timing belt. Remove tool [6]. (E) : Max. position. (F) : Nominal tension position. Using the hexagonal recess (D), turn the roller hub (anti-clockwise), to bring the index (13) to position (E) to ten- sion the belt to the maximum.
  • Page 53 CHECKING AND SETTING THE VALVE TIMING Engine : 3FZ Positioning the crankshaft. NOTE : This operation positions all the pegs in their respective pegging points. Peg: - The inlet camshaft pulley, using tool [3]. - The crankshaft, using tool [1]. If this is not possible, reposition the flange (20).
  • Page 54 CHECKING AND SETTING THE VALVE TIMING Engine : 3FZ Refitting (continued). Refit: - The timing cover (9). - The auxiliary drive pulley. - The screws (7), tighten to 2.1 ± 0.2 m.daN. - The timing cover (8). - The RH engine support (6). - The torque reaction rod (3).
  • Page 55 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 56 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). B1EK005D B1EK007D The fixing screws of the power steering pump, then suspend the latter. The support (7).
  • Page 57 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.
  • Page 58 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.
  • Page 59 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 60 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 61 CHECKING AND SETTING THE VALVE TIMING Engine : XFW Refitting (continued). Peg the camshaft hubs, starting with LH exhaust (17) then (18), (19) 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 62 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 63 CHECKING AND SETTING THE VALVE TIMING Engines : RHT-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 [7] Tensioning lever...
  • Page 64 CHECKING AND SETTING THE VALVE TIMING Engines : RHT-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 - The auxiliary drive pulley, using tool [8].
  • Page 65 CHECKING AND SETTING THE VALVE TIMING Engines : RHT-4HW Removing (continued). Disconnect the battery. Move aside the header tank. Position the tools for supporting the engine [10], [11], [12] and [13]. Remove: - The scuttle panel grille. - The torque reaction rod (1). - The fuel unions (2).
  • Page 66 CHECKING AND SETTING THE VALVE TIMING Engines : RHT-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 67 CHECKING AND SETTING THE VALVE TIMING Engines : RHT-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 ±...
  • Page 68 CHECKING AND SETTING THE VALVE TIMING Engines : RHT-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). Place tool [1] on the belt at (A).
  • Page 69 CHECKING AND SETTING THE VALVE TIMING Engines : RHT-4HW Checking the timing setting. Effect two turns of the engine in the normal direction of rotation, without turning the engine backwards. Refit the peg [2]. IMPERATIVE : Check visually that the offset between the hole in the camshaft hubs and the corresponding pegging hole is not more than 1 mm.
  • Page 70 CHECKING AND SETTING THE VALVE TIMING Engines : RHT-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. Nettoyer le taraudage de la screws de poulie dans le vilebrequin. (Taraud M16x150). Brosser le filetage de la screws.
  • Page 71 COOLING SYSTEM SPECIFICATIONS Vehicle with air conditioning Engines : RFN – 3FZ – XFW – RHT – 4HW 2.0i 16V 2.2i 16V 3.0i 24V 2.0 HDi 2.2 HDi Engine type RHT - RHW Circuit capacity 7 litres 7.2 litres 10.5 litres 10 litres (*) 11.3 litres Radiator surface...
  • Page 72 EXHAUST SPECIFICATIONS Petrol engines all types Repair Respect the precautions to be taken when operating on a vehicle. The flexible pipe must not come into contact with corrosive products. Do not distort the flexible pipe by more than 20° angular (X), 20mm axial, 25 mm shear (Y) (flexible pipe not fitted).
  • Page 73 EXHAUST SPECIFICATIONS Engines : RFN-3FZ Tightening torques (m.daN) (1) Bicone collar Ø 74.5 mm Fixing of catalytic converter/manifold pipework : 2.5 ± 0.4 (2) Flexible metallic pipe (3) Lambda probes take-off : 4.7 ± 0.7 (4) Catalytic converter (5) Intermediate silencer (6) Rear silencer A and A’...
  • Page 74 EXHAUST SPECIFICATIONS Engine : XFW Tightening torques (m.daN) (1) Front precatalyser (2) Flexible metallic pipe (3) Bicone collar Ø 66 mm (front/rear precatalyser assembly) : 2.5 ± 0.4 (4) Rear precatalyser (5) Flexible metallic pipe (6) Catalytic converters (7) Intermediate silencer (8) Rear silencer (9) Upstream lambda probe take-off : 4.7 ±...
  • Page 75 EXHAUST SPECIFICATIONS Engines : RHT-4HW With particle filter Tightening torques (m.daN) (1) Ball-joint front fixing bracket : 4.5 ± 0.7 (2) Precatalyser (3) Catalytic converter (4) Particle filter (5) Bicone collar Ø 74.5 mm : 2.5 ± 0.4 (6) Rear silencer (7) Catalytic converter bracket (P.
  • Page 76 EXHAUST SPECIFICATIONS Engine : RHW Without particle filter Tightening torques (m.daN) (1) Ball-joint front fixing bracket : 4.5 ± 0.7 (2) Precatalyser (3) Catalytic converter (4) Intermediate silencer (5) Rear silencer A and A’ After sales cutting zones. Connecting sleeve Ø 55 mm : 5.2 ±...
  • Page 77 CHECKING THE OIL PRESSURE Petrol engines 2.0i 16V 2.2i 16V 3.0i 24V Engine type Temperature (°C) 80°C Pressure (Bars) 3000 1000 2000 4000 3000 1000 Diesel engines 2.0 HDi 2.2 HDi RHT- RHW Engine type Temperature (°C) 80°C Pressure (Bars) 1000 2000 1000...
  • Page 78 OIL FILTERS To be read together with the Petrol and Diesel correspondence tables 2.0i 16V – 2.2i 16V 3.0i 24V 2.0 HDi – 2.2 HDi LS 880 PURFLUX LS 923 Height (mm) Ø (mm) LS 880 Specifications LS 923...
  • Page 79 CLUTCH SPECIFICATION Petrol Diesel 2.0i 16V 2.2i 16V 2.0 HDi 2.2 HDi Engine type RHT - RHW Gearbox type BE4/5 ML5C Feature «Push» clutch «Pull» clutch Supplier VALEO Mechanism / type 230 DNG 4700 230 DNG 5100 225 T 5700 242 T 6500 Clutch disc 11 R 14 X...
  • Page 80 CLUTCH SPECIFICATION Engines: RFN – 3FZ – RHT – RHW – 4HW «Push» clutch «Push» clutch and «Pull» clutch. (1) Clutch disc. B2BB000D «Pull» clutch (2) Clutch plate. (3) Clutch bearing. B2BK22WD...

  • Page 81: Hydraulic Clutch Control Specification

    HYDRAULIC CLUTCH CONTROL SPECIFICATION Engines : RFN-3FZ-RHT-RHW-4HW 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.
  • Page 82 HYDRAULIC CLUTCH CONTROL SPECIFICATION Engines : RFN-3FZ-RHT-RHW-4HW Bleeding the hydraulic clutch control. 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»...
  • Page 83 HYDRAULIC CLUTCH CONTROL SPECIFICATION Engines : RFN-3FZ-RHT-RHW-4HW 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.
  • Page 84 GEARBOX AND TYRE SPECIFICATIONS Petrol 2.0i 16V 2.2i 16V 3.0i 24V Auto. Auto. Engine type Tyres-Rolling circumference 205/65 R 15 – 1.973 m 215/65 R15-2.016 m 215/60 R16-2.025 m Gearbox type BE4/5 ML5C 4 HP 20 Gearbox ident. plate 20 DL 26 (*) 20 DL 27 (**) 20 TP 74 20 LM 09...

  • Page 85: Be4/5 Gearbox Specification

    BE4/5 GEARBOX SPECIFICATION Engine : RFN (A) Marking zone including: - Component reference. - Factory serial no. B2CKU3PD...
  • Page 86 BE4/5 GEARBOX SPECIFICATION Engine : RFN 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 ± 0.4 (4) Breather pipe : 1.5 ±...
  • Page 87 BE4/5 GEARBOX SPECIFICATION Engine : RFN 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 screw : 6 ± 0.6 (17) Gear control support screw : 1.5 ±...
  • Page 88 ML5C GEARBOX SPECIFICATION Engines : 3FZ – RHT – RHW – 4HW (A) Label. (B) Gearbox reference. (C) Sequence no. B2CKUC2D (D) Bar code. (E) Marking zone: Gearbox reference. Sequence no. B2CKUCAD...
  • Page 89 ML5C GEARBOX SPECIFICATION Engines : 3FZ – RHT – RHW – 4HW Gearbox lubrication. Oil type: ESSO 75W80 EZL 848 or TOTAL 75W 80W H 6965 Oil capacity: 2.1 litres. Lubricated for life. NOTE : If the gearbox is drained, refilling of the gearbox is via the venting hole. Tightening torques m.daN.
  • Page 90 ML5C GEARBOX SPECIFICATION Engines : 3FZ – RHT – RHW – 4HW Tightening torques m.daN. (8) Fixing of gearbox cover on gearbox casing : 2 ± 0,2 (9) Bearing stop plate : 2 ± 0,2 (10) Vent hole. (11) Reverse gear switch : 2,5 ±...
  • Page 91 ML5C GEARBOX SPECIFICATION Engines : 3FZ – RHT – RHW – 4HW Tightening torques m.daN.. (13) Flange fixing screws : 2 ± 0,2 B2CKUC5D (14) Secondary shaft nut : 17 ± 1,7 (15) Gear control support screw : 1,5 ± 0,1 (16) Differential gearwheel screw : 7.7 ±...
  • Page 92 AL4 AUTOMATIC GEARBOX SPECIFICATION Engines : RFN - RHT The automatic gearbox is identified by a self-adhesive label (A) or, failing that, by a marking (B). (1) Component reference. (2) Serial no. B2CA085D...
  • Page 93 AL4 AUTOMATIC GEARBOX SPECIFICATION Engines : RFN - RHT Tightening torques m.daN. (1) Converter: Pre-tightening : 1 ± 0.1 Tightening : 3 ± 0.3 B2CKU7AD (2) Fixing of gearbox on cylinder block : 5,2 ± 0,5 (3) Speedometer drive : 0,8 (4) Electrovalve and/or regulators on hydraulic block : 0,9 (5) Hydraulic block...
  • Page 94 AL4 AUTOMATIC GEARBOX SPECIFICATION Engines : RFN - RHT Tightening torques m.daN. (10) Electrovalve controlling flow into the exchanger : 1 ± 0,1 (11) Multifunction switch : 1,5 ± 0,1 (12) Sleeve stop : 1,5 ± 0,1 (13) Automatic gearbox heat exchanger : 5 ±...
  • Page 95 DRAIN / REFILL /TOP-UP : 4 HP 20 GEARBOX Engine : XFW Preliminary conditions: Tools. Checks there are no faults , using the diagnostic tool. [1] Filling kit : (-).0341 Place the vehicle on a lift, keep vehicle horizontal. [1a] Filling cylinder : (-).0341-A [1b] 4 HP 20 adaptor without gauge : (-).0341-B...
  • Page 96 DRAIN / REFILL /TOP-UP : 4 HP 20 GEARBOX Engine : XFW Checks (continued) With the engine running at the temperature 55° ± 1°C, open the top-up plug (3). Wait for the temperature to reach 60° ± 1°C. 1st possibility : - Oil flows out, the level is correct.
  • Page 97 DRAIN / REFILL /TOP-UP : 4 HP 20 GEARBOX Engine : XFW Draining. Preliminary conditions: - Draining should be carried out with the engine hot, to eliminate impurities in suspension in the oil. The draining is partial since the converter cannot be totally emptied. In draining, approx.
  • Page 98 DRIVESHAFTS - GEARBOX Gearbox oil seal mandrels Tightening torques (m.daN) Driveshaft Driveshaft Right Left Tool kit Vehicles Gearbox Engines bearing BE4/5 7114-T.X 7114-T.W 7116-T RHT - RHW 5701-T.A 9017-T.C 9017-T ML5C 10 + 60° (-).0338.J1 (-).0338.H1 (-).0338 (-).0338.J3 (-).0338.H2 (-).8010-T.D (-).8010-T.J 4 HP 20 (-).8010-T...
  • Page 99 WHEELS AND TYRES 2.0i 16V 2.2i 16V 3.0i 24S 2.0 HDi 2.2 HDi RHT - RHW Engine type MICHELIN MICHELIN MICHELIN XH1 Tyre MICHELIN XH1 MICHELIN XH1 PRIMACY HX MXM 205x65 R 15 94 H 205x65 R 15 94 H 205x65 R 15 94 H circumference 215x60 R16 99H...
  • Page 100 WHEELS AND TYRES Inflation pressures The label giving the recommended inflation pressures is affixed to one of the front door pillars. a: Type of tyre. b: Tyre specifications. c: Recommended tyre inflation pressures (unladen and laden). d: Recommended tyre inflation pressures for the spare wheel. Tightening torque: 10 m.daN.
  • Page 101 WHEELS AND TYRES Wheel bolts. Spare wheel (1) Bolt for steel wheel. Anti-theft securing of the spare wheel. (5) Winch. (2) Bolt for light alloy wheel. (e) Winch control. (3) Anti-theft bolt for light alloy wheel. (4) Anti-theft socket. The wheel is retained at the centre by a cable linking its hub to the Post-equipment for alloy wheels: fit the correct type of wheel bolt.
  • Page 102 WHEELS AND TYRES Special features Under-inflation detection device. (6) High frequency transmitter module. (7) Seal. (8) Valve. (9) Nut. Composition : - Four HF transmitter modules (6) incorporated in the wheels in place of the valves, each including a lithium battery. - A HF receiver incorporated in the switching module under the steering wheel.
  • Page 103 AXLE GEOMETRY Front axle Wheel tracking King pin Engines Specification Camber Castor inclination (mm) (°) 205/65 R15 +2 ± 1 0° ± 30’ 3° 30’ ± 30’ 12°24’ ± 40’ 215/65 R15 +0°18’ ± 0° 9’ 215/60 R16 NOTE A < B = Positive figure : TOE-IN A >...
  • Page 104 AXLE GEOMETRY Front axle Wheel tracking Camber Engines Specification (mm) (°) (°) 205/65 R15 5 ± 1 1 ± 30’ 215/65 R15 0°46’ ± 0°8’ 215/60 R16...
  • Page 105 AXLE GEOMETRY (SETTING AT REFERENCE HEIGHT) Tools. [1] Set of two suspension compressors : 9511-T.A [2] Set of two shackles : 9511-T.C [3] Under body height gauge : 2305-T [4] Set of two straps : 9511-T.B [5] Set of two slings : 9511-T.D The front tracking can be checked and adjusted in running order (Systematic use of two tyres).
  • Page 106 AXLE GEOMETRY (SETTING AT REFERENCE HEIGHT) At the front (H1). Engage the straps [4] 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. B3BKAEGD Compress the suspension so as to obtain, on the RH and LH sides, the bodyshell height H1 (reference height), to be measured between the lowermost edge (B) and the ground.
  • Page 107 AXLE GEOMETRY (SETTING AT REFERENCE HEIGHT) At the rear (H2). Engage the slings [5] on the rear longerons. Position the suspension compressor [1] selecting the separation (A) most suited to pull the straps as far upwards as possible. B3BKAEHD Compress the suspension so as to obtain, on the RH and LH sides, the bodyshell height H2 (reference height), to be measured between the lowermost edge (C) and the ground.
  • Page 108 AXLE GEOMETRY (SETTING AT REFERENCE HEIGHT) 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 109 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-4HW 21.5 B3CK09JD...
  • Page 110 FRONT AXLE Vehicle in running order Tightening torques (m.daN) Fixing of subframe on body : 10.5 ± 1 Fixing on tie-rod on body : 6.5 ± 0.6 Fixing of crossmember on body : 8 ± 0.8 Fixing of tie-rod on subframe : 6.5 ±...
  • Page 111 REAR AXLE Identification (1) Damper. (2) Spring. (3) Stabiliser bar. B2CP3J3D...
  • Page 112 REAR AXLE Tightening torques (m.daN) (5) Fixing of rear axle on body : 8 ± 0,8 (6) Fixing of stabiliser bar on rear axle : 8 ± 0,8 (7) Fixing of stabiliser bar on body : 6 ± 0,6 (8) Hub nut : 38 ±...
  • Page 113 REAR AXLE Engines : RFN –3FZ – XFW – RHT – RHW – 4HW Identification (X) Pre-adjustment. (1) Steering mechanism. (2) Distributor valve. (3) Power steering reservoir. (4) Power steering pump. (5) High pressure union. (6) Low pressure union. (7) Steering oil radiator fitted on the front panel. (according to equipment) B3EK0J9D...
  • Page 114 SPECIFICATIONS OF POWER-ASSISTED STEERING Engines : RFN – 3FZ – XFW – RHT – RHW – 4HW Engine type RHT - RHW Features Power steering with integral ram Travel (mm) Angle of lock 40°48’ 37°18’ 39°24’ for inside wheel Angle of lock for 34°36’...
  • Page 115 SPECIFICATIONS OF POWER-ASSISTED STEERING Engines : RFN – 3FZ – XFW – 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 116 BRAKE SPECIFICATIONS 2.0i 16V 2.2i 16V 3.0i 24S 2.0 HDi 2.2 HDi Engine type 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/piston makes 40 + 44 Disc Ventilated Disc thickness/min.
  • Page 117 BRAKE TIGHTENING TORQUES (m.daN) Engines : RFN – 3FZ – XFW – RHT – RHW – 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 118: Adjusting The Handbrake

    ADJUSTING THE HANDBRAKE Identification (A) Zone for fixing on floor. (B) Clips for retaining on bodyshell. B3FK263D...
  • Page 119 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 120: Draining/Filling/Bleeding Braking System

    DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM Tools. [1] Generic bleeding apparatus : «LURO» or similar [2] Filler plug : (-).0810 [3] PROXIA diagnostic tool : 4165-T [4] LEXIA diagnostic tool : 4171-T Draining. Remove the pollen filter (See corresponding operation). Take out the filter from the brake fluid reservoir.
  • Page 121 DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM Pre-conditions for bleeding a braking circuit: Use of the diagnostic tool will be necessary in cases where the following After a repair on the master cylinder or ABS block, bleed in the following conditions all come together simultaneously: order: - Air in the circuit.

  • Page 122: Air Conditioning System

    AIR CONDITIONING SYSTEM (R 134A) (HFC) Compressor Refrigerant Vehicle Engines Date refill Variable capacity Quantity of oil (cc) Quality of oil (± 25 gr) 13/06/02 SD 7 V 16 135 ± 15 SP10 RHT - RHW...
  • Page 123 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134A) Tightening torques (m.daN). Unions Pipe diameters Steel / Steel Aluminium / Steel M 06 1.7 ± 3 1.3 ± 3 M 08 3.8 ± 3 2 ± 2 M 10 4 ± 3 2.5 ±...
  • Page 124 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 handle (1). Uncouple the evacuation pipe (2). Release at (3), on the RH and LH sides. Slacken the screws (4) on the RH and LH sides by a quarter turn.
  • Page 125 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) by a quarter turn. Move aside the condenser (5).
  • Page 126 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Removing-refitting the drying cartridge (continued) Unscrew the reservoir (7) (Adaptor: TORX 70 FACOM) Unscrew the reservoir (7), and the protection skirt (6). WARNING : This operation should remain clean before the fitting of the new reservoir. Cap the base (10).
  • Page 127 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Removing-refitting the drying cartridge (continued) Refitting. Note: Check, before you refit the reservoir (7), that the base (10) is clean. (If it is not, clean in and around the base with a paper towel (10)). Preparing the new drying reservoir Remove the protection cap from the neck of the reservoir (7).
  • Page 128 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134A) 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 129 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134A) 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 130 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM CHECKING PRESSURES Low pressure Low pressure Low pressure too low too high normal - Insufficient fluid charge. - Cooling fan speed unsuitable. - Faulty pressure control valve. High pressure - Constriction of the HP system. - Faulty compressor.
  • Page 131 AIR CONDITIONING SYSTEM R 134A Engines : RFN-3FZ 1 Drying cartridge. 2 Clickfit union. 3 Buffer capacity. 4 Clickfit union. 5 High pressure valve 6 Low pressure valve C5HP17TP...
  • Page 132 AIR CONDITIONING SYSTEM R 134A 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). C5HP18TP...
  • Page 133 AIR CONDITIONING SYSTEM R 134A Engines : RHT-4HW 1 Drying cartridge. 2 Clickfit union. 3 Buffer capacity. 4 Clickfit union. 5 High pressure valve (Tool 8005-T.C) 6 Low pressure valve (Tool 8005-T.A) C5HP17UP...

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