CITROEN C5 Handbook
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CITROEN C5 Handbook

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PRIVATE CARS
C5-SYNERGIE
«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 050011
Volume 2
2002

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Summary of Contents for CITROEN C5

  • Page 1 PRIVATE CARS 2002 C5-SYNERGIE «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 GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - ELECTRICAL - AIR CONDITIONING. In each section, the vehicles are dealt with in the following order : C5 - SYNERGIE and all models where applicable. The information given in this handbook is based on vehicles marketed in EUROPE.
  • Page 3 If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into account when preparing future publications. For example : – INSUFFICIENT INFORMATION – SUPERFLUOUS INFORMATION – NEED FOR MORE DETAILS Please send your comments and suggestions to : CITROEN U.K. Ltd. 221, Bath Road, SLOUGH, SL1 4BA. U.K.
  • Page 4 IDENTIFICATION OF VEHICLES (A) Chassis stamp (cold stamp on bodywork). (B) Manufacturer’s data plate. (under the rear bench seat) (C) A-S / RP No. and RP paint code (label on front pillar close to driver’s door). (D) Inflation pressures and tyre references. (label on front pillar close to driver’s door) (E) Serial no.
  • Page 5 IDENTIFICATION OF VEHICLES C5 - All Types Petrol saloons 1.8i 16V 2.0i 16V Automatic Automatic X-SX-Exclusive X-SX Emission standard Type code DC 6FZB DC 6FZC/IF DC 6FZE DC RFNC/IF DC RFNB DC RFNE Engine type Cubic capacity (cc) 1749 1997...
  • Page 6 IDENTIFICATION OF VEHICLES C5 - All Types Petrol saloons 2.0 HPi 30.i 24V V6 Automatic Exclusive Emission standard DC RLZB DC XFXC/IF DC XFXF/IF Type code Engine type 1997 2946 Cubic capacity (cc) Fiscal rating (hp) BE4/5 ML/5C ML/5T 4 HP 20...
  • Page 7 C5 - All Types IDENTIFICATION OF VEHICLES Diesel saloons 2.0 HDi Automatic Automatic X-Exclusive Emission standard DC RHYB DC RHSB DC RHSE DC RHZB DC RHZE Type code Engine type 1997 Cubic capacity (cc) Fiscal rating (hp) BE4/5 ML/5C ML/5T (*)
  • Page 8 IDENTIFICATION OF VEHICLES C5 - All Types Diesel saloons 2.2 HDi Automatic SX-Exclusive Emission standard DC 4HXB DC 4HXE Type code Engine type 2179 Cubic capacity (cc) Fiscal rating (hp) Gearbox type ML/5C ML/5T 4 HP 20 20 LM 17...
  • Page 9 IDENTIFICATION OF VEHICLES C5 - All Types Petrol estates 1.8i 16V 2.0i 16V 2.0 HPi 3.0i 24V V6 Automatic Automatic X-SX Exclusive Exclusive Emission standard Type code DE 6FZC/IF DE 6FZB DE RFNC/IF DE RFNE DE RLZB DE XFX/IF DE XFXF/IF...
  • Page 10 IDENTIFICATION OF VEHICLES C5 - All Types Diesel estates 2.0 HDi Automatic Automatic X-Exclusive Emission standard DE RHYB DE RHSB DE RHSE DE RHZB DE RHZE Type code Engine type 1997 Cubic capacity (cc) Fiscal rating (hp) BE4/5 ML/5C ML/5T...
  • Page 11 C5 - All Types IDENTIFICATION OF VEHICLES Diesel estates 2.2 HDi Automatic SX-Exclusive Emission standard DE 4HXB DE 4HXE Type code Engine type 2179 Cubic capacity (cc) Fiscal rating (hp) Gearbox type ML/5C ML/5T 4 HP 20 20 LM 17...
  • Page 12 IDENTIFICATION OF VEHICLES SYNERGIE - All Types Manufacturer’s cold stamp R.P. organisation No. Paint code 01/02/99 # Label : - Tyre pressures. - R.P. Organisation No. - Paint code. Gearbox ident. Engine plate Manufacturer’s plate E1AP07GD...
  • Page 13 IDENTIFICATION OF VEHICLES SYNERGIE - All Types Petrol Diesel 2.0i 16 V 2.0 16 V HDi 2.0 HDi Automatic X – SX X Taxi – SX Exclusive X – SX Exclusive Emission standard IF L5 (*) AF RFNC/IF AF RFNF/IF AF RHZA/T AF RHZA AF RHWB...
  • Page 14 CAPACITIES ALL TYPES Draining method. The oil capacities are defined according to the following methods. 1) - Vehicle on level surface (in high position, if equipped with hydropneumatic suspension). 2) - Engine warm (oil temperature 80°C). 3) - Draining of the oil sump + removal of the cartridge (duration of draining + dripping = 15 mm). 4) - Refit plug + cartridge.
  • Page 15 C5 - All Types CAPACITIES (in litres) Petrol 2.0 HPi 1.8i 16V 2.0i 16V 3.0i V6 Automatic Automatic Automatic Engine type 4.25 5.25 Engine with filter change Between Min. and Max. 5-speed gearbox Automatic gearbox After oil change Braking circuit Hydraulic circuit 8.8 –...
  • Page 16 CAPACITIES (in litres) C5 - All Types Diesel 2.0 HDi 2.2 HDi Automatic Automatic Automatic Engine type Engine with filter change 4.75 4.5 (1) 4.75 Between Min. and Max. 1.7 (1) 5-speed gearbox 8.3 - 6 (1) 8.3 - 6 (1) Automatic gearbox 5.3 –...
  • Page 17 CAPACITIES (in litres) SYNERGIE - All Types Synergie Petrol Diesel 2.0i 16V 2.0 HDi 2.0 HDi 16V Automatic Engine type 21° Engine angle 4.25 4.75 Engine with filter change Between Min. and Max. 5-speed gearbox Automatic gearbox After oil change Without ABS : 0.47 - With ABS : 0.52 Hydraulic or brake circuit Cooling system...
  • Page 18 ALL TYPES LUBRICANTS - TOTAL recommended oils S.A.E. Norm - Table for selection of engine oil grade E4AP006D...

  • Page 19: Total Quartz

    (approx 2.5%). by norms ACEA A3/98 or API SJ. Failing this, it is essential to adhere to the maintenance pro- Features of CITROËN C5 : grammes covering severe operating conditions. 2.0 and 2.2 HDi engines have a particle filter. The maintenance interval for normal operation 5W30 cannot be used in the following engines: is 30,000 km (20,000 miles) for petrol engines.
  • Page 20 ALL TYPES LUBRICANTS - TOTAL recommended oils Selection of engine oil grades recommended for climatic conditions in countries of distribution ACEA Norms API Norms The first letter corresponds to the type of engine concerned : The first letter corresponds to the type of fuel used by the engine : A : petrol and dual fuel petrol / LPG engines.
  • Page 21 TOTAL ACTIVA (France only). TOTAL QUARTZ (Outside France). ESSENTIAL : To preserve engine performances, all engines fitted in CITROEN vehicles must be lubricated with high quality oils (synthetic or semi-synthetic) Summary Engine oil norms to be respected in 2001 model year.

  • Page 22: Table Of Contents

    LUBRICANTS - TOTAL recommended oils ALL TYPES S.A.E. grades SPI norms ACEA norms Blended oils for all engines (petrol, dual-fuel petrol / LPG and diesel) TOTAL ACTIVA 9000 5W-40 SJ / CF A3-98 / B3-98 TOTAL QUARTZ 9000 TOTAL ACTIVA 9000 (*) 5W-30 SJ / CF EC A1-98 / B1-98...

  • Page 23: Blended Oils For All Engines, Permitting Fuel Economy

    ALL TYPES LUBRICANTS - TOTAL recommended oils FRANCE Blended oils for all engines, supplied in bulk Metropolitan FRANCE TOTAL ACTIVRAC S.A.E : 10W-40 Norms TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically Oils specifically for petrol and Blended oils for all engines for diesel engines dual-fuel petrol / LPG engines Metropolitan FRANCE...

  • Page 24: Table Of Contents

    LUBRICANTS - TOTAL recommended oils ALL TYPES EUROPE TOTAL QUARTZ TOTAL QUARTZ DIESEL (*) = Blended oils for all engines, Oils specifically for petrol and Oils specifically for diesel Blended oils for all engines permitting fuel economy dual-fuel petrol / LPG engines engines 7000 10W-40 Germany...

  • Page 25: Table Of Contents

    ALL TYPES LUBRICANTS - TOTAL recommended oils EUROPE (continued) TOTAL QUARTZ TOTAL QUARTZ DIESEL (*) = Blended oils for all engines, Oils specifically for petrol and Oils specifically for diesel Blended oils for all engines permitting fuel economy dual-fuel petrol / LPG engines engines 7000 10W-40 Greece...

  • Page 26: Table Of Contents

    LUBRICANTS - TOTAL recommended oils ALL TYPES EUROPE (continued) TOTAL QUARTZ TOTAL QUARTZ DIESEL (*) = Blended oils for all engines, Oils specifically for petrol and Oils specifically for diesel Blended oils for all engines permitting fuel economy dual-fuel petrol / LPG engines engines 7000 10W-40 Czech Republic...

  • Page 27: Total Quartz Diesel

    ALL TYPES LUBRICANTS - TOTAL recommended oils TOTAL QUARTZ TOTAL QUARTZ DIESEL Blended oils for all Oils specifically for petrol and Oils specifically for diesel engines dual-fuel petrol / LPG engines engines Australia OCEANIA 7000 10W-40 New-Zealand Ivory Coast Egypt Gabon AFRICA Madagascar...

  • Page 28: Oils Specifically For Petrol And Dual-Fuel Petrol / Lpg Engines

    LUBRICANTS - TOTAL recommended oils ALL TYPES TOTAL QUARTZ TOTAL QUARTZ DIESEL (*) = Blended oils for all engines, Blended oils for all Oils specifically for petrol and Oils specifically for diesel permitting fuel economy engines dual-fuel petrol / LPG engines engines 7000 10W-40 China...
  • Page 29 ALL TYPES LUBRICANTS - TOTAL recommended oils TOTAL QUARTZ TOTAL QUARTZ DIESEL Blended oils for all Oils specifically for petrol and Oils specifically for diesel engines dual-fuel petrol / LPG engines engines Saudi Arabia Bahrain Dubai United Arab Emirates Iran Israel MIDDLE 9000 5W-40...
  • Page 30 LUBRICANTS - TOTAL recommended oils ALL TYPES Gearbox oils TOTAL TRANSMISSION BV Norms S.A.E 75W-80 Manual gearbox Special oil distributed by CITROËN (Part No. 9730 A2) TOTAL FLUIDE ATX or TOTAL FLUIDE AT 42. All countries MB3 automatic gearbox Special oil distributed by CITROËN (Part No.
  • Page 31 CITROEN reference 0.5 litre 9979 05 All countries CITROEN Fluid 1 litre 9979 06 5litres 9979 07 CITROEN hydraulic circuit fluid Norm Pack CITROEN reference ISO 7308-7309 ZCP 830 095 TOTAL LHM PLUS All countries Green in colour 9979.20 (Scandinavia)
  • Page 32 LUBRICANTS - TOTAL recommended oils ALL TYPES WARNING: TOTAL LDS fluid cannot be blended with TOTAL LHM PLUS. All countries WARNING: CITROËN C5 : Use only TOTAL FLUIDE LDS suspension fluid. Hydraulic circuit rinsing fluid- green in colour All countries TOTAL HYDRAURINCAGE...
  • Page 33 ENGINE OIL CONSUMPTION ALL TYPES 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.
  • Page 34 ENGINE SPECIFICATIONS ALL TYPES Engines : 6FZ - RFN - RLZ - XFX Petrol 1.8i 16V 2.0i 16V 2.0 HPi 3.0i-V6 Engine type Cubic capacity (cc) 1749 1997 2946 Bore / Stroke 82.7/81.4 85/88 87/82.6 Compression ratio 10.8/1 11.4/1 10.9/1 Power ISO or EEC KW - rpm 85-5500 100-6000...
  • Page 35 ALL TYPES ENGINE SPECIFICATIONS Engines : RHS - RHZ - RHY - RHW - 4HX Diesel 2.0 HDi 2.0 HDi 16V 2.2 HDi Engine type Cubic capacity (cc) 1997 2179 Bore / Stroke 85/88 85/96 Compression ratio 17.6/1 18/1 Power ISO or EEC KW - rpm 79-4000 80-4000 66-4000...
  • Page 36 COMPRESSION RATIO - DIESEL ENGINES ALL TYPES COMPRESSION MAX. SPACING ENGINE RATIO BETWEEN CYLINDERS In bars 30 ± 5 DW10 20 ± 5 DW12...
  • Page 37 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engines : 6FZ - RFN - RLZ - RHY - RHS - RHZ - 4HX Crankshaft Petrol Diesel Bearing cap screws. - Pre-tightening 2 ± 0.1 2.5 ± 0.2 - Angular tightening 60° ± 6° 60°...
  • Page 38 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engines : 6FZ - RFN - RLZ - RHY - RHS - RHZ - 4HX Cylinder block Petrol Diesel Piston skirt spray jet 1 ± 0.1 Sump - Pre-tightening - Tightening 0.8 ± 0.2 1.6 ±...
  • Page 39 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engines : 6FZ - RFN - RLZ - RHY - RHS - RHZ - 4HX Cylinder head Petrol Diesel Camshaft bearing cover - Tightening 1 ± 0.1 - Pre-tightening 0.5 ± 0.1 0.5 (Ø6) - Tightening 0.9 ±...
  • Page 40 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engines : 6FZ - RFN - RLZ - RHY - RHZ - 4HX Lubrication circuit Petrol Diesel Oil pump - Pre-tightening - Tightening 0.9 ± 0.1 1.3 ± 0.1 0.9 ± 0.1 Coolant / oil heat exhanger 5.8 ±...
  • Page 41 C5 - All Types CYLINDER HEAD Engines : 6FZ - RFN - RLZ Cylinder head gasket identification Nominal dimension Repair dimension RFN - RLZ Marking zone 4 - 5 2-4-5 "d" Marking zone "e" Gasket thickness (mm) Supplier MEILLOR (d) Marking zone (e) Marking zone Multilayer metallic cylinder head gasket.
  • Page 42 CYLINDER HEAD Engines : 6FZ - RFN - RLZ Cylinder head tightening (m.daN) Cylinder head bolts 6FZ - RFN - RLZ Pre-tightening 1.5 ± 0.1 Tightening 5 ± 0.1 Slackening 360°± 2° Tightening 2 ± 0.2 Angular tightening 285° ± 5° (in the order 1 to 10) B1DP16FC A = Washer thickness : 4 ±...
  • Page 43 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFZ (1) Compact coil unit 1 ± 0.1 (9) Flywheel - Tightening - Angular tightening 60°± 6° (11) Connecting rod caps - Tightening 2 ± - Angular tightening 74° ± 7 (12) Crankshaft hub - Tightening 4 ±...
  • Page 44 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFZ - 2 Cylinder head cover (A) Front cyl. head - (B) Rear cyl. head - 3 Bearing caps housing (A) Front cyl. head - (B) Rear cyl. head B1DP08UD B1DP08TD WARNING : Tighten screw by screw in the order shown. - Pre-tighten : - Pre-tighten : - Tighten :...
  • Page 45 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFZ - 5 Air inlet manifold - 6 Lower manifold (A) Front cyl. head - (B) Rear cyl. head B1HPOLJC B1DP097C WARNING : Tighten screw by screw in the order shown. - Pre-tighten : 1 ±...
  • Page 46 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFZ - 7 Exhaust manifold (NEW seal) - 10 Oil sump B1BP1GXD B1BP1GZD WARNING : Tighten screw by screw in the order shown. - Pre-tighten : 1 ± 0.1 - Pre-tighten : 0.5 ±...
  • Page 47 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFZ - 8 Crankshaft bearing - Clean the threads of the screws with a brush. - Refit the screws with a coating of grease ( MOLYKOTE G RAPID PLUS ). - Check that the 8 centring pins are in place. Maximum length under the heads of the screws : - M11 = 131.5 mm.
  • Page 48 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFZ (14) Water pump - Pre-tighten - Tighten (15) Oil pump - Pre-tighten - Tighten (16) Guide roller 8 ± 0.8 (17) Tensioner roller 8 ± 0.8 (18) Camshaft hubs - Pre-tighten 2 ±...
  • Page 49 SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) Engine : XFZ - 20 Oil vapour recovery housing. WARNING : Tighten screw by screw in the order shown. - Pre-tighten 0.5 ± - Tighten 1 ± 0.1 B1BP1H1D...
  • Page 50 CYLINDER HEAD Engine : XFZ Cylinder head gasket identification Thickness Supplier Thickness reference (Standard) (mm) Central lug ERLING 0.75 Exhaust end (1) LH cylinder head gasket. Multilayer metallic cylinder head seal. (2) RH cylinder head gasket. B1DP18YD...
  • Page 51 CYLINDER HEAD Engine : XFX Cylinder head tightening (m.daN) Cylinder head bolts In the order indicated. - Pre-tightening 2 ± 0.2 - Slackening - Pre-tightening 1.5 ± 0.2 - Angular tightening 225° Note : Oil the threads and under the heads of the bolts.
  • Page 52 CYLINDER HEAD Engines : RHY - RHS - RHZ Cylinder head gasket identification Piston Engine Thickness Number stand-proud plate (mm) of notches at A (mm) 0.47 to 0.605 1.30 ± 0.06 0.605 to 0.655 1.35 ± 0.06 0.655 to 0.705 1.40 ±...
  • Page 53 CYLINDER HEAD Engines : RHY - RHS - RHZ Cylinder head gasket identification Cylinder head tightening (m.daN) Cylinder head bolts RHY - RHS - RHZ RHY - RHS - RHZ - Pre-tightening - Tightening - Angular tightening 220° B1DP15EC NOTE : Oil the threads and under the X = MAX.
  • Page 54 CYLINDER HEAD Engine : 4HX Cylinder head gasket identification Number of notches Piston Engine Thickness stand-proud At A At B plate (mm) (mm) 0.55 to 0.60 1.25 ± 0.04 0.61 to 0.65 1.30 ± 0.04 0.66 to 0.70 1.35 ± 0.04 0.71 to 0.75 1.40 ±...
  • Page 55 CYLINDER HEAD (continued) Engine : 4HX Cylinder head tightening (m.daN) Cylinder head bolts ESSENTIAL : Tighten screw by screw and in the order indicated. - Pre-tightening 2 ± 0.2 (Order 1 to 10) - Tightening 6 ± 0.6 (Order 1 to 10) - Slackening 360°...
  • Page 56 BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE ALL TYPES Tooling 4099-T (C.TRONIC.105) 4122-T (C.TRONIC.105.5) B1EP135D...
  • Page 57 C5 - SYNERGIE AUXILIARY EQUIPMENT DRIVE BELT ATED ATED4 Engine type SYNERGIE See pages : 58 to 61 62 to 63...
  • Page 58 ALL TYPES 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 53. ESSENTIAL - Before refitting the auxiliary equipment drive belt, check that : 1) The roller(s) rotate freely (no play or stiffness)
  • Page 59 SYNERGIE AUXILIARY EQUIPMENT DRIVE BELT Engines : 6FZ - RFN - RLZ Without aircon With aircon Tools [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).
  • Page 60 AUXILIARY EQUIPMENT DRIVE BELT C5 - All Types Engine : XFX Tools [1] Ratchet spanner S.171 FACOM (1/2 square) S 171. [2] Reduction box S.230 FACOM (1/2-3/8) 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 61 SYNERGIE AUXILIARY EQUIPMENT DRIVE BELT Engines : RHY - RHS - RHZ Without air conditioning Tools [1] Belt tension adjusting square : (-).0188 J2 [2] Ø 4 mm peg : (-).0188.Q1 [3] Ø 2 mm peg : (-).0188.Q2 [4] Dynamic tensioner compression lever : (-).0188.Z Remove Re-use of belt...
  • Page 62 SYNERGIE AUXILIARY EQUIPMENT DRIVE BELT Engines : RHY - RHZ Without air conditioning (continued) Refit. Re-used belt. - Compress the tensioner roller (2) by action at « a » (anti-clockwise), tool [4]. - Refit the belt. WARNING : Respect the direction in which the belt is fitted. - Remove the tool [4].
  • Page 63 SYNERGIE AUXILIARY EQUIPMENT DRIVE BELT Engines : RHY - RHZ With air conditioning Tools [1] Belt tension adjusting square : (-).0188 J2 [2] Ø 4 mm peg : (-).0188.Q1 [3] Ø 2 mm peg : (-).0188.Q2 [4] Dynamic tensioner compression lever : (-).0188.Z Remove Re-use of belt...
  • Page 64 AUXILIARY EQUIPMENT DRIVE BELT SYNERGIE Engines : RHY - RHZ With air conditioning (continued) Refit. Re-used belt. - Compress the tensioner roller (7) by action at « c » (in anti-clockwise direction), tool [4]. - Refit the belt. WARNING : Respect the direction in which the belt is fitted. - Remove the tool [4].
  • Page 65 C5 - All Types AUXILIARY EQUIPMENT DRIVE BELT Engine : 4HX Without air conditioning TOOLS [1] Dynamic tensioner compression 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.
  • Page 66 AUXILIARY EQUIPMENT DRIVE BELT C5 - All Types Engine : 4HX With air conditioning TOOLS [1] Dynamic tensioner compression 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.
  • Page 67 C5 - All Types CHECKING AND SETTING THE VALVE TIMING ATED ATED4 Engine type SYNERGIE See pages : 65 to 68 69 to 74 75 to 79 80 to 85...
  • Page 68 CHECKING AND SETTING THE VALVE TIMING C5 - All Types Engines : 6FZ - RFN - RLZ TOOLS [1] Camshaft setting pegs : (-).0189.A [2] Crankshaft setting peg : (-).0189.B Toolkit C.0189. [3] Belt retaining pin : (-).0189.K [4] Adaptor for angular tightening...
  • Page 69 C5 - All Types CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN - RLZ Refit (continued) - Refit the belt (10) on the pinion (12). - Hold the belt (10) with tool [3]. - Position the belt (10) in the following order : - The guide roller (11), the inlet camshaft pinion (9), the exhaust camshaft pinion (8), the water pump (5), the tensioner roller (6).
  • Page 70 CHECKING AND SETTING THE VALVE TIMING C5 - All Types Engines : 6FZ - RFN - RLZ Adjusting the tension (continued). -Tighten the screw (7) of the the tensioner roller (6) to 2.1 ± 0.2 m.daN. IMPERATIVE : The hexagonal drive of the tensioner roller (6) must be at 15° below the level of the cylinder head gasket «g».
  • Page 71 C5 - All Types CHECKING AND SETTING THE VALVE TIMING Engines : 6FZ - RFN - RLZ Checks (continued) Repositioning the flange. -Immobilise the crankshaft using tool [5]. -Loosen the screw (13). -Release the pinion (12) of the crankshaft. -Bring the flange (14) to the pegging position; using tool [5].
  • Page 72 CHECKING AND SETTING THE VALVE TIMING C5 - All Types Engine : XFX OUTILLAGES [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...
  • Page 73 C5 - All Types CHECKING AND SETTING THE VALVE TIMING Engine : XFX Checking the valve timing setting (continued). - Peg the crankshaft, using tool [1]. - Check that the tool [2] engages without effort in the cylinder heads at the camshaft pulleys.
  • Page 74 C5 - All Types CHECKING AND SETTING THE VALVE TIMING Engine : XFX 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].
  • Page 75 C5 - All Types CHECKING AND SETTING THE VALVE TIMING Engine : XFX Setting the valve timing (continued) Refit. - Check that the camshafts and the crankshaft are correctly pegged. - Check that the rollers and the water pump pulley are turning freely. (No tightness).
  • Page 76 CHECKING AND SETTING THE VALVE TIMING C5 - All Types Engine : XFX 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).
  • Page 77 C5 - All Types CHECKING AND SETTING THE VALVE TIMING Engine : XFX 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).
  • Page 78 C5 - All Types CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHS - RHZ Tools [1] Belt tension measuring instrument : 4122-T [2] Tension lever : (-).188.J2 [3] Engine flywheel peg : (-).188.X [4] Belt retaining pin : (-).0188.K...
  • Page 79 C5 - All Types CHECKING AND SETTING THE VALVE TIMING Engines : RHY-RHS-RHZ Setting the valve timing. Peg : - The engine flywheel, tool [3]. (From under the vehicle) - The camshaft, tool [5]. Loosen : - The three screws (9).
  • Page 80 C5 - All Types CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHS - RHZ Setting the valve timing (continued). - Retighten the screws (21) by hand. - Turn the pinion (24) (clockwise) to the bottom of the buttonhole.
  • Page 81 CHECKING AND SETTING THE VALVE TIMING C5 - All Types Engines : RHY - RHS - RHZ Setting the valve timing (continued). - Position tool [1] on the belt at « b ». - Turn the roller (20) (anti-clockwise) using tool [2] to attain a tension of : 98 ±...
  • Page 82 C5 - All Types CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHS - RHZ Setting the valve timing (continued). Tighten : - The screw of the roller (19) to 2.5 ± 0.2 m.daN. - The screws (21) to 2 ± 0.2 m.daN.
  • Page 83 C5 - All Types 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 compression spring : (-).0188.K. [5] Camshaft pinion peg : (-).0188.M.
  • Page 84 C5 - All Types 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.
  • Page 85 C5 - All Types 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 [3]. - Peg the camshaft, using tool [5].
  • Page 86 C5 - All Types 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).
  • Page 87 C5 - All Types CHECKING AND SETTING THE VALVE TIMING Engine : 4HX Setting the valve timing (continued) - Position tool [1] on the belt at « b ». - Turn the tensioner roller (24) (anti-clockwise) using tool [2] to attain a tension of : 106 ±...
  • Page 88 C5 - All Types 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.
  • Page 89 ALL TYPES 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) Inlet Exhaust Valves Rocking fully Adjust Adjust open All Types Hydraulic adjustment Inlet Exhaust...
  • Page 90 CHECKING THE OIL PRESSURE C5 - All Types Petrol engines Tools Toolkit 4103 -T 1.8i 16V 3.0i V6 2.0 HPi 2.0i 16V Engine type Temperature (°C) 90°C Pressure (Bars) 1000 3000 1000 3000 1000 3000 3000 Diesel engines 2.0 HDi 2.2 HDi...
  • Page 91 C5 - All Types OIL FILTERS To be read together with the petrol and diesel correspondence tables LS 304 PURFLUX LS 880 Ø (mm) Height (mm) LS 304 Specifications LS 880...
  • Page 92 C5 - All Types FILLING AND BLEEDING THE COOLING CIRCUIT TOOLS [1] Filling cylinder : 4520-T [2] Adaptor for filling cylinder : 4222-T. ESSENTIAL : Respect the safety and cleanliness recommendations. - The draining and refilling operations can be carried out by means of a WINN’S coolant replacement appa- ratus or similar;...
  • Page 93 C5 - All Types IDLING - ANTIPOLLUTION Idling speed % Content (± 50 rpm) Emission Vehicles Engine type Make - Injection type standard Manual Auto. gearbox: N engaged gearbox 1.8 i 16V SAGEM S2000 7000 IF/L5 MAGNETTI MARELLI < 0.5 >...

  • Page 94: Petrol Injection

    C5 - All Types PETROL INJECTION SYNERGIE 1.8I 16V 2.0I 16V 2.0 HPi 3.0I 24S V6 2.0 i 16 V Engine type Emission standard L4 - IF/L5 L4 - IF/L5 IF/L5 IF L5 Make SAGEM MAGNETTI MARELLI SIEMENS BOSCH M. MARELLI...
  • Page 95 ALL TYPES ANTI-POLLUTION TECHNICAL CHECKS (FRANCE) All Types Petrol CO Corrected (In %) All Types Diesel (m -1) Conditions : At idle, engine warm. 01/96 01/96 Less than 4.5 % for vehicles registered before 10/86. Less than 3.5 % for vehicles registered after 10/86. Atmospheric engine.
  • Page 96 EMISSION STANDARDS ALL TYPES APPLICATIONS NOTES STANDARD CHARACTERISTICS E.E.C. Engines Vehicles Applicable Brussels directive Private vehicles : 83/351 > 2 litres 06/89 except special • new cyl. < 2 litres 06/92 derogations for certain • existing cyl. < 2 litres 12/92 private vehicles cyl.
  • Page 97 ALL TYPES EMISSION STANDARDS APPLICATIONS NOTES STANDARD CHARACTERISTICS E.E.C. Engines Vehicles Applicable Brussels directives 88/76 and 88/436 Utility vehicle limits Utility vehicles : private vehicle limits of 01/10/88 All Types Petrol Brussels directive 88/436 01/10/89 W vu 15.05 R 15.05 •...
  • Page 98 EMISSION STANDARDS ALL TYPES APPLICATIONS NOTES STANDARD CHARACTERISTICS E.E.C. Engines Vehicles Applicable Private vehicles : • certain non-EEC With catalytic converter Current Adoption of the U.S. US 87 US 87 Diesel European countries and EGR standard • certain Export countries Petrol Private vehicles : Adoption of the U.S.
  • Page 99 ALL TYPES EMISSION STANDARDS APPLICATIONS NOTES STANDARD CHARACTERISTICS E.E.C. Engines Vehicles Applicable Private vehicles : • certain non-EEC Adoption of the U.S. US 90 Petrol Current US 90 European countries standard for light utility vehicles Diesel • certain Export countries Private vehicles : Brussels directive EURO 1...
  • Page 100 EMISSION STANDARDS ALL TYPES APPLICATIONS NOTES STANDARD CHARACTERISTICS E.E.C. Engines Vehicles Applicable Utility vehicles : < 3.5 tonnes • new models 01/10/93 With oxygen sensor Brussels directive 93/59 and catalytic converter • existing models 01/10/94 3 classes depending on EURO 1 Petrol for petrol vehicles Class 1 :...
  • Page 101 ALL TYPES EMISSION STANDARDS APPLICATIONS NOTES STANDARD CHARACTERISTICS E.E.C. Engines Vehicles Applicable Utility vehicles : Brussels directive 96/69 < 3.5 tonnes With oxygen sensor and Class 1 : 3 classes depending on EURO 2 reinforced catalytic Petrol • new models 01/97 vehicle weight : converter for petrol...
  • Page 102 ALL TYPES EMISSION STANDARDS APPLICATIONS NOTES STANDARD CHARACTERISTICS E.E.C. Engines Vehicles Applicable Utility vehicles : Brussels directive 98/69 With 2 oxygen sensors < 3.5 tonnes EURO 2 standard (L3 and catalytic converter Class 1 : made stricter for petrol vehicles. EURO 3 Petrol •...
  • Page 103 ALL TYPES EMISSION STANDARDS APPLICATIONS NOTES STANDARD CHARACTERISTICS E.E.C. Engines Vehicles Applicable With 2 oxygen sensors and Private vehicles : Brussels Directive: 2001/1 catalytic converter for petrol Petrol 01/2005 All types EURO 3 standard (L4) made EURO 4 IF / L5 Diesel vehicles.
  • Page 104 C5 - All Types PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM Engines : RHY - RHS - RHZ - 4HX Cleaning. - The use of high pressure cleaners is prohibited. - Do not use compressed air. Fuel supply circuit. - Required fuel : diesel.
  • Page 105 C5 - All Types PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM Engines : RHY - RHS - RHZ - 4HX Diesel injectors. WARNING: Diesel and ultrasonic cleaners are prohibited. Do not separate the following components from the diesel injector carrier (2) : - Diesel injector (e) (no replacement parts).
  • Page 106 SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM C5 - All Types Engines : RHY - RHS - RHZ -4 HX SAFETY REQUIREMENTS Preamble. All interventions on the injection system must be carried out to conform with the following requirements and regulations : - Competent health authorities.
  • Page 107 C5 - All Types SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM Engines: RHY - RHS - RHZ - 4HX CLEANLINESS REQUIREMENTS. Preliminary operations IMPERATIVE : The technician should wear clean overalls. Before working on the injection system, it may be necessary to clean the apertures of the following sensitive components : (refer to corresponding procedures).
  • Page 108 C5 - All Types CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engines : RHY - RHS - RHZ - 4HX Engines : RHY - RHS - RHZ TOOLS [1] Ø 10 mm low pressure connector : 4215-T. [2] Ø 8 mm low pressure connector : 4218 -T.
  • Page 109 C5 - All Types CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engines : RHY - RHS - RHZ - 4HX (continued) Checks on pressure : dynamic. Engine running, at idle (normal functioning): - Fuel supply pressure shown by the pressure gauge [3] = 2 ± 0.4 Bar.
  • Page 110 C5 - All Types AIR SUPPLY CIRCUIT SPECIFICATION Engine : RHY (1) Air filter PSA 7899 (2) Flowmeter SIEMENS (3) Water / recycled gas exchanger VALEO (4) EGR valve PURFLUX (5) Turbocharger KKK K03 (6) Air butterfly MAGNETI MARELLI 48W7 Ref. 648...
  • Page 111 C5 - All Types AIR SUPPLY CIRCUIT SPECIFICATION Engines : RHS - RHZ (7) Air / air heat exchanger VALEO. (8) Turbocharger KKK K03. (9) EGR valve PURFLUX. (10) Air butterfly MAGNETI MARELLI 48W7 Ref. 648. (11) Air filter PSA 7899.
  • Page 112 C5 - All Types AIR SUPPLY CIRCUIT SPECIFICATION Engine : 4HX (1) Air / air exchanger (2) Air / water exchanger (3) Warm air metering device BOSCH. (4) Cold air metering device BOSCH. (5) Turbocharger ALLIEDSIGNAL GT1549P. (6) Flowmeter SIEMENS.
  • Page 113 C5 - All Types CHECKS : AIR SUPPLY CIRCUIT Engine : 4HX ESSENTIAL : Respect the safety and cleanliness recommendations. Tool. [1] Manual vacuum pump: FACOMM DA 16. Checks. ESSENTIAL : Respect the safety and cleanliness recommendations that are specific to high pressure diesel injection (HDi) engines.
  • Page 114 C5 - All Types CHECKS : 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. Boost vacuum regulation electrovalve.
  • Page 115 C5 - All Types CHECKS : EXHAUST GAS RECYCLING CIRCUIT Engines : RHY - RHS - RHZ (1) Butterfly housing (3) Electrovalve (black connector) (2) EGR valve (tube with blue marking) (4) Electrovalve (blue connector) Tools [1] Manual vacuum pump : FACOM DA 16.
  • Page 116 CHECKS : EXHAUST GAS RECYCLING CIRCUIT C5 - All Types Engines : RHY - RHS - RHZ EGR valve - Connect tool [1] on the EGR valve capsule take-off (2). - Apply a vacuum of approx. 0.6 bar to activate the EGR valve.
  • Page 117 CHECKS : EXHAUST GAS RECYCLING CIRCUIT C5 - All Types Engine : 4HX TOOLS [1] Manual vacuum pump : FACOM DA 16. ESSENTIAL : Respect the safety and cleanliness requirements specific to high pressure diesel injection (HDi) engines. Electrovanne (EGR).
  • Page 118 CHECKS : EXHAUST GAS RECYCLING CIRCUIT C5 - All Types 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.
  • Page 119 C5 - All Types CHECKS : TURBO PRESSURE Engine : RHY Engines : RHY - RHS - RHZ TOOLS. [1] Pressure gauge for checking boost pressure : 4073-T.A Kit 4073-T [2] Sleeve for checking boost pressure : 4185-T [3] Adaptor sleeve : 4219-T Checks.
  • Page 120 C5 - All Types CHECKS : TURBO PRESSURE Engines : RHY - RHS - RHZ Procedure. ESSENTIAL : Observe the following checking requirements : - Engine at running temperature. - Vehicle in running order. - Engine at full load. - Start the engine.
  • Page 121 C5 - All Types 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.
  • Page 122 CHECKS : TURBO PRESSURE C5 - All Types 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.».
  • Page 123 C5 - All Types SPECIFICATIONS OF THE SIEMENS INJECTION PUMP PUMP -TYPE - REFERENCE Emission standard L3 / L4 Equipment Transponder SIEMENS 5WS 40001...
  • Page 124 SPECIFICATIONS OF THE SIEMENS INJECTION PUMP SYNERGIE PUMP -TYPE - REFERENCE Emission standard L3 / L4 Equipment Transponder SYNERGIE CP1 (*) ) = The fuel high pressure pump is driven by the timing belt.
  • Page 125 SYNERGIE FITTING BOSCH INJECTORS Engines : RHY - RHZ Evolution : Classification of diesel injector carriers Reminder : RHY and RHZ are equipped with 4 diesel injector carriers marked according to their 16/11/98 injection duct diameters (flow of diesel fuel). Identification.
  • Page 126 SPARKING PLUGS SYNERGIE - C5 Tightening Engine Electrode Vehicles - Models BOSCH CHAMPION EYQUEM torque type (m.daN) 1.8I 16V FR8ME REC94CL RFN52HZ 2.0i 16v 2.75 ± 0.2 2.0i HPi ZR8TPP15 1 mm 3.0i 24S FGR8MQPE 2.25 ± 0.2 SYNERGIE 2.0i 16v...
  • Page 127 ALL TYPES 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 128 CLUTCH SPECIFICATIONS Petrol 1.8i 16V 2.0i 16V 2.0 HPi 3.0i V6 Engine type Gearbox type BE4/5 ML/5 Supplier VALEO Mechanism / type 230 DNG 4700 230 DING 4700 230 DNG 4700 R 242 T 6500 228 D 73 Clutch disc 11 R 10X 12 R 14X 11 R 14X...
  • Page 129 CLUTCH SPECIFICATIONS Diesel 2.0 HDi 2.2 HDi Engine type Gearbox type BE4/5 ML/5 Supplier Mechanism / type 230 P 4700 225 T 5700 242 T 6500 Clutch disc Damping performed by engine flywheel Ø of lining. Ext/Int 228/155 225/150 242/162 Quality of lining F 408 F 808...
  • Page 130 C5 - All Types BE4/5 GEARBOX CONTROL SPECIFICATIONS Engines : 6FZ - RFN - RLZ - RHY Gear controls [1] Gear lever positioning tool 8605-T. (1) Gear engagement ball-joint Ø 10 mm. (2) Gear control lever (3) Gear engagement control cable.
  • Page 131 C5 - All Types BE4/5 GEARBOX CONTROL SPECIFICATIONS Engines : 6FZ - RFN - RLZ - RHY Gear selection control cable. Gear engagement control cable. B2CP3CKD B2CP3CLD Left hand drive Right hand drive Left hand drive Right hand drive Length A 730 ±...
  • Page 132 C5 - All Types CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS Engines : 6FZ - RFN - RLZ - RHY Adjustments. WARNING : Control cables should be adjusted each time the gearbox is removed or cables changed. WARNING : Do not use oil to detach the ball-joints.
  • Page 133 C5 - All Types CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS Engines : 6FZ - RFN - RLZ - RHY Tools. [1] Tool for positioning the gearbox control lever 8605-T Toolkit 9040-T Adjustments. Cables should be adjusted each time the gearbox, gear controls or power unit are removed Adjustment principles : - Lock the gear lever in neutral position, using tool [1].
  • Page 134 C5 - All Types CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS Engines : 6FZ - RFN - RLZ - RHY Adjustments (continued) Under the bonnet. - Remove the air filter assembly. - Unlock the gear engagement cable ball-joint (b). - Unlock the gear selection cable ball-joint (c).
  • Page 135 C5 - All Types ML/5 GEARBOX SPECIFICATION Engines : XFX - RHZ - RHS - 4HX [1] Gear lever positioning tool 8605-T. (1) Gear engagement ball-joint Ø 10 mm. (2) Gear control lever (3) Gear engagement control cable. (4) Gear selection control cable.
  • Page 136 C5 - All Types ML/5 GEARBOX SPECIFICATION Engines : XFX - RHZ - RHS - 4HX Gear selection control cable. Gear engagement control cable. B2CP3CRD B2CP3CSD Left hand drive Right hand drive Left hand drive Right hand drive Length A 750 ±...
  • Page 137 C5 - All Types CHECKS AND ADJUSTMENTS : ML/5 GEARBOX CONTROLS Engines : XFX - RHZ - RHS - 4HX Adjustments. WARNING : Control cables should be adjusted each time the gearbox is removed or cables changed. WARNING : Do not use oil to detach the ball-joints.
  • Page 138 C5 - All Types CHECKS AND ADJUSTMENTS : ML/5 GEARBOX CONTROLS Engines : XFX - RHZ - RHS - 4HX Tools [1] Tool for positioning the gearbox control lever 8605-T Toolkit 9040-T Adjustments. Cables should be adjusted each time the gearbox, gear controls or power unit are removed.
  • Page 139 C5 - All Types CHECKS AND ADJUSTMENTS : ML/5 GEARBOX CONTROLS Engines : XFX - RHZ - RHS - 4HX Adjustments (continued) Under the bonnet. - Remove the air filter assembly. - Unlock the gear engagement and selection cable ball-joint (b).
  • Page 140 SYNERGIE BE4/5 GEARBOX CONTROL SPECIFICATIONS Engines : RFN (1) Gear control lever (2) Gear engagement control cable (*) (3) Gear selection control cable (*) (4) Gear selection ball-joint Ø 10 mm. (5) Gear engagement ball-joint Ø 10 mm. (6) Flexible insulating grommet through the bulkhead. (*) = These two cables cannot be separated.
  • Page 141 SYNERGIE CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS Engines : RFN Principles of adjusting the gear controls. WARNING : Cables should be adjusted each time the gearbox, gear controls or power unit are removed. Principles. WARNING : Do not use any tool to unclip the ball-joints.
  • Page 142 SYNERGIE CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS Engines : RFN Adjusting the gear controls. TOOLS : [1] Tool for positioning the gear lever : 9607-T. ADJUSTMENTS. CHECKS. WARNING : Cables should be adjusted each time - Remove the tool [1]. the gearbox, gear controls or power unit are removed.
  • Page 143 SYNERGIE CLUTCH : CHECKS AND ADJUSTMENTS Adjustment of push and pull action clutch with automatic compensation (adjustment of compensation system) Engines : RFN - RHZ WARNING : If a system blockage is detected when checking, or if the pedal has been removed, the pedal position must be adjusted.
  • Page 144 CLUTCH : CHECKS AND ADJUSTMENTS SYNERGIE Engines : RFN - RHZ B2BP02SC NOTE : This cable has an automatic adjusting device which takes up the clutch disc wear and makes up for the compression of the outer cable. DESCRIPTION 1 - Metallic cable, crimped on both ends. 5 - Tensioning spring ensuring the maximum length of the outer cable.
  • Page 145 SYNERGIE CLUTCH : CHECKS AND ADJUSTMENTS Engines : RFN - RHZ (continued) B2BP03QD Operation Clutch disengagement phase Engagement / adjustment phase For the adjusting device to operate correctly, it As soon as the pedal is applied, the attaching The pedal returns to rest on its upper stop. is necessary that : end-piece (4) leaves the sleeve (1) which Attaching end-piece (4) pushes sleeve (1)
  • Page 146 CLUTCH : CHECKS AND ADJUSTMENTS SYNERGIE Hydraulically operated pull-action clutch (Non-adjustable) Engine Synergie : RHZ Gearbox ML/5 (1) Quick-fit union: Tool 9040-T.H. B2BP03RC E5AP14VC B2BP03SC...
  • Page 147 SYNERGIE CLUTCH : CHECKS AND ADJUSTMENTS Hydraulically operated pull-action clutch (Non-adjustable) Engine : RHZ A Old assembly, supplied complete and filled with hydraulic fluid. B New assembly : - The components supplied separately. - The circuit is filled with fluid after being fitted to the vehicle. (1) Clutch master cylinder.
  • Page 148 SYNERGIE CLUTCH : CHECKS AND ADJUSTMENTS Hydraulically operated pull-action clutch (Non-adjustable) Engines : RHZ After fitting on the vehicle, the circuit should be filled with a «DOT 4» type brake fluid. Clutch control reservoir capacity 120 cc. (Bleeding is carried out not under pressure). Repair.
  • Page 149 SYNERGIE ML/5 GEARBOX CONTROLS Engine : RHZ B2CP16FP...
  • Page 150 C5 - All Types GEARBOX AND TYRE SPECIFICATIONS Petrol 18i 16V 2.0i 16V 2.0 HPi Automatic Automatic Engine type Tyres-Rolling circumference 195/65 R15 – 1.93 m 195/65 R15 – 1.93 m Gearbox type BE4/5 BE4/5 BE4/5 20 DL 29 20 TP 44...
  • Page 151 C5 - All Types GEARBOX AND TYRE SPECIFICATIONS Diesel 2.0 HDi 2.2 HDi Automatic RHS - RHZ Engine type Tyres-Rolling circumference 195/65 R15 – 1.93 m 215/65 R16-1.96 m Gearbox type BE4/5 ML/5C ML/5T ML/5C Gearbox ident. plate 20 DL 32...
  • Page 152 GEARBOX AND TYRE SPECIFICATIONS SYNERGIE Petrol Diesel 2.0i 16V 2.0 HDi Automatic Engine type 205/65 R15 - 1.97 m Tyres-Rolling circumference BE4/5 ML/5 Gearbox type 20 DL 26 20 DL 27 20 TP 31 20 LE 91 ( Gearbox ident. plate Reduction box torque 14x62 21x73...
  • Page 153 SYNERGIE - C5 BE4/5 GEARBOX Engine : RFN (a) Marking zone (sequence and serial no.). (b) Location of identification label. B2CP3BNC B2CP3BPD...
  • Page 154 BE4/5 GEARBOX SYNERGIE - C5 Engine : RFN Description (1) Primary shaft. (14) 1st / 2nd gear synchroniser (2) Clutch bearing guide. (15) Driven gear (1st gear). (3) Gearbox casing. (16) Secondary shaft. (4) Clutch housing. (17) Differential gear. (5) Reverse idle.
  • Page 155 SYNERGIE - C5 BE4/5 GEARBOX Engine : RFN Tightening torques Ref. Description Number of screws m.daN End guide 1.2 ± 0.1 Clutch housing 1.3 ± 0.1 Primary shaft nut 7.2 ± 0.7 Secondary shaft nut 6.5 ± 0.7 Yoke holding screw 1.5 ±...
  • Page 156 ML/5 GEARBOX SPECIFICATION C5 - All Types Engines : XFX - RHZ - RHS - 4HX Identification. Identification (a) Marking zone (Sequence and serial no.). (b) Location of identification label. B2CP3CMC...
  • Page 157 C5 - All Types ML/5 GEARBOX SPECIFICATION Engines : XFX - RHZ - RHS - 4HX Identification (continued) (1) Primary shaft. (18) Driven gear (2nd) (2) Clutch bearing guide. (19) Driven gears (3rd) (20) 3rd/4th gear synchroniser. (3) Clutch housing (21) Driven gears (4th) (4) Gearbox casing.
  • Page 158 ML/5 GEARBOX SPECIFICATION C5 - All Types Engines : XFX - RHZ - RHS - 4HX Identification (continued) Tightening torques m.daN. (28) Reverse lamp switch 2,5 ± 0,2 (29) Gearbox casing /clutch housing fixing screws 2 ± 0,2 (30) Differential bearing stop plate screws 2 ±...
  • Page 159 C5 - All Types ML/5 GEARBOX SPECIFICATION Engines : XFX - RHZ - RHS - 4HX Recommendations - Precautions (1) Drain plug. (2) Filler and top-up plug. Oil quality. - See chapter on lubricants: page 19. Oil quantity. - After draining = 1.8 litres...
  • Page 160 4 HP 20 AUTOACTIVE GEARBOX SPECIFICATION C5 - All Types Engines : XFX - 4HX Identification. (1) Identification plate (riveted on the casing). (a) Serial no. (b) ZF number. (last digits taken into account) (c) Type of automatic gearbox. (d) Component reference Oil quality and quantity (See chapter, page 19).
  • Page 161 C5 - All Types 4 HP 20 AUTOACTIVE GEARBOX SPECIFICATION Engines : XFX - 4HX Tightening torques m.daN. Gearbox exterior. (2) Oil channel union fixing Exteror fixing of 2.5 ± 0.5 (3) Exterior fixing of converter cover on clutch housing 2.3 ±...
  • Page 162 C5 - All Types 4 HP 20 AUTOACTIVE GEARBOX SPECIFICATION Engines : XFX - 4HX 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 163 C5 - All Types RECOMMENDATIONS - PRECAUTIONS (AL 4 and 4 HP 20 AUTOMATIC GEARBOXES) Engines : 6FZ - RFN - RHZ - XFX - 4HX Precautions to be taken Towing. REMOVING - REFITTING. (Automatic gearbox). The front of the vehicle must be raised in order to be towed.
  • Page 164 C5 - All Types RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX) Engines : 6FZ - RFN - RHZ 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.
  • Page 165 C5 - All Types RECOMMENDATIONS - PRECAUTIONS (AL 4 and 4 HP 20 AUTOMATIC GEARBOXES) Engines : 6FZ - RFN - RHZ - XFX - 4HX Procedure prior to carrying out repairs (continued) When the ECU detects an erroneous or non-existent value Reading the fault codes.
  • Page 166 C5 - All Types RECOMMENDATIONS - PRECAUTIONS (AL 4 and 4 HP 20 AUTOMATIC GEARBOXES) Engines : 6FZ - RFN - RHZ - XFX - 4HX ECU : Downloading, Configuration, Initialisation (Pedal). Downloading. (AL 4 and 4 HP 20) Updating the gearbox ECU by downloading : - Follow the procedure using the diagnostic equipment.
  • Page 167 C5 - All Types RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX) Engines : 6FZ - RFN - RHZ ECU : Downloading, Configuration, Initialisation (Pedal) (continued) Downloading (AL 4 only). Pedal initialisation. (AL 4 only). ECU downloading procedure : A pedal initialisation must be carried out in the following cases : - Follow the diagnostic tooling procedure.
  • Page 168 C5 - All Types RECOMMENDATIONS - PRECAUTIONS (4 HP 20 AUTOMATIC GEARBOX) Engines : XFX - 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).
  • Page 169 4 HP 20 GEARBOX CONTROLS Engines : XFX - 4HX Selection control. The gear selection control has 5 positions. The selection lever is guided by the shape of the stepped gate and by a retaining spring which holds it towards the left. The gear selection control is equipped with the «shift lock», so you have to switch on the ignition and apply the brake pedal to unlock the selection lever from the park position.
  • Page 170 C5 - All Types 4 HP 20 GEARBOX CONTROLS Engines : XFX - 4HX Selection control (continued). 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 171 SYNERGIE RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX) Engine : RFN (Synergie) Gear control is by a cable linked to the selection lever located on the dashboard. The gear selection control has 5 positions : «P» Park (immobilisation of the vehicle, whatever the slope). «R»...
  • Page 172 SYNERGIE - C5 DRIVESHAFTS - GEARBOX Gearbox oil seal mandrels Tightening torques (m.daN) Driveshaft Driveshaft Right Left Tool kit Vehicles Gearbox Engines bearing 6FZ - RFN - RLZ BE4/5 7114-T.W 7114-T.X 7116-T 5701-T.A ML/5 9017-T.C 9017-T RHZ - 4HX 32.5 ± 1.5 2 ±...
  • Page 173 C5 - All Types AXLE GEOMETRY Measuring front height Measuring rear height The measurement of the front dimension «H1» is between ground level and the measuring zone on the front subframe (to the rear of the front yokes fixing the suspension arm).
  • Page 174 AXLE GEOMETRY C5 - All Types Front axle Rear axle King pin Véhicle Tracking Castor Camber Tracking Camber inclination Adjustable Non adjustable Adjustable Non adjustable 0 to - 3 mm 5.4 ± 1.3 mm All Types 3° 03' ± 30' 0°...
  • Page 175 C5 - All Types FRONT AXLE Tightening torques m.daN. (1) Suspension leg upper fixing 7 ± 0.7 (2) Suspension leg fixing on bodyshell 4.3 ± 0.6 (3) Anti-roll bar link rod upper fixing 6.4 ± 0.6 (4) Anti-roll bar link rod upper fixing 6.4 ±...
  • Page 176 REAR AXLE C5 - All Types Tightening torques m.daN. (1) Anti-roll bar fixing 13.1± 1.4 (2) Rear rubber mounting fixing on bodyshell 8 ± 1.2 (3) Rear subframe fixing 11.5 ± 1.1 (4) Front subframe fixing on bodyshell 11.5 ± 1.1 (5) Suspension shaft fixing 14.9 ±...
  • Page 177 C5 - All Types SUSPENSION Front suspension Tightening torques m.daN. (10) Arm front fixing 13 ± 1.3 11) Arm rear fixing 8 ± 0.8 (12) Anti-roll bar bearing fixing on subframe 4.2 ± 0.6 Hydractive 3+ hydraulic suspension (power steering) Suspension piston diameter = 35 mm.
  • Page 178 SUSPENSION Rear suspension Tightening torques m.daN. (13) Subframe rear fixing 11.5 ± 1.1 (14) Rear rubber mounting fixing on bodyshell 8 ± 1.2 (15) Anti-roll bar fixing 13.1 ± 1.4 (16) Front fixing of subframe on bodyshell 11.5 ± 1.1 NOTE : (13) and (16) Face and threads greased.
  • Page 179 C5 - All Types SUSPENSION Height control Tightening torques m.daN. (20) Collars B3CP06TD...
  • Page 180 AXLE GEOMETRY C5 - All Types Front axle Rear axle King pin Véhicle Tracking Castor Camber Tracking Camber inclination (Adjustable ) (Non adjustable) (Non adjustable) (Non adjustable) 0 to - 3 mm 5.4 ± 1.3 mm All Types 3° 03' ± 30' 0°...
  • Page 181 C5 - All Types SPECIFICATIONS OF POWER-ASSISTED STEERING Engines : 6FZ - RFN - XFX - RHY - RHS - RHZ - 4HX Tightening torques m.daN. (1) Steering wheel fixing 2 ± 0,3 (2) Column fixing on mounting 2.3 ± 0.4 (3) Column fixing on mounting 2.3 ±...
  • Page 182 C5 - All Types SPECIFICATIONS OF POWER-ASSISTED STEERING Engines : 6FZ - RFN - RLZ - XFX - RHY - RHS - RHZ - 4HX Number of teeth Number of Angle of lock Steering rack Steering Engines turns of the...
  • Page 183 AXLE GEOMETRIES SYNERGIE Reference height NOTE A < B = Positive figure : TOE-IN A > B = Negative figure : TOE-OUT Conditions for adjusting the heights (Tyre pressures correctly set) Front Rear B3BP051D Frontt Heights (mm) Rear +0°8’ to +0°25’ 0°...
  • Page 184 FRONT AXLE SYNERGIE B3CP04PD B3CP04QD...
  • Page 185 SYNERGIE FRONT AXLE Evolution : Tightening torques on front subframe 28/05/1999 # (1) Fixing screw (front). (2) Fixing screw (rear). Tightening torque. Old fitting. Tighten the screw (1) to 13.5 m.daN. Tighten the screw (2) to 13.5 m.daN. New fitting. Tighten the screw (1) to 10.7 m.daN.
  • Page 186 REAR AXLE SYNERGIE B3DP06QD...
  • Page 187 SUSPENSION SYNERGIE All Types F 23 Shock absorber (ref.) F 254 Anti-roll bar Ø (mm) Without 1 Grey + 1 Yellow air-con Spring With 2 Grey = 1 Yellow air-con (ref.) 3 Yellow...
  • Page 188 STEERING SYNERGIE Number of teeth Number of turns of Steering rack travel Steering Steering ratio the steering wheel (mm) Pinion Steering rack Power-assisted 2.98 15.75 All Types B3EP09ZD...
  • Page 189 C5 - All Types BRAKE SPECIFICATIONS 2.0i 16V 3.0i V6 1.8i 16V 2.0 HPi Engine type Master cylinder 22.2 (Valve type) Master-vac BOSCH ZO 54/55 BOSCH ZO 57/56 BOSCH ZO Caliper/piston Ø makes BIR 54 BIR 57 57/28BIR 57 Non-ventilated...
  • Page 190 BRAKE SPECIFICATIONS 2.0 HDi 2.2 HDi Engine type Master cylinder 22.2 (Valve type) Master-vac BOSCH ZO 57/26 Caliper/piston Ø BOSCH ZO 57/28 BIR 57 makes BIR 57 Non-ventilated Brake disc Ventilated Disc thickness/min. thickness 26/24 28/26 TEXTAR T 4110 Brake pad grade Cylinder or caliper PSA - 32 (Double piston) Ø...
  • Page 191 C5 - All Types 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 stan- dard at the factory on all versions.
  • Page 192 BRAKE SPECIFICATIONS C5 - All Types Braking circuit diagram (a) Hydraulic circuit. (b) Electrical circuit. (1) Master cylinder in tandem. (2) Braking servo. (3) Brake caliper. (4) Hub equipped with a bearing with an integral magnetic wheel (48 pairs of poles).
  • Page 193 BRAKE SPECIFICATIONS C5 - All Types (7) Hydraulic block Part No. Elements Ref. Supplier Observations ABS MK.60 Electronic 47 way connector ITT - A ECU. Alone on the hydraulic block. BASR MK.60 2 way black connector. The sensors are inductive-type.
  • Page 194 BRAKE SPECIFICATIONS C5 - All Types Brake pedal carriage Front brake Rear brake B3FP130C B3FP12YC B3FP12ZC Tightening torques (m.daN). (15) Fixing on bodyshell 1.8 ± 0.25. (12) Caliper fixing on pivot 12± 1.8 (14) Rear caliper fixing on suspension arm 7 ± 0.7 (16) Servo fixing 2.1 ±...
  • Page 195 C5 - All Types HANDBRAKE (Adjustment) Adjustment - Remove the rear ashtray from the handbrake console. - (1) Nut for adjusting the tension of the handbrake cables. - Raise and support the vehicle with the front wheels hanging free. - Check the correct routing of the brake cables under the vehicle.
  • Page 196 BLEEDING AND FILLING THE BRAKING SYSTEM C5 - All Types Tools. [1] Generic bleeding apparatus : "LURO" or similar. [2] PROXIA station : 4165-T. [3] LEXIA station : 4171-T. Bleeding, filling. Draining the brake fluid reservoir. - Drain the brake fluid reservoir (1) to the maximum (if necessary, use a clean syringe).
  • Page 197 C5 - All Types BLEEDING AND FILLING THE BRAKING SYSTEM Bleeding, filling (continued). Filling the braking system. WARNING : Use only those hydraulic fluids that are approved and recommended. - Fill the brake fluid reservoir (1). Bleeding the braking system.
  • Page 198 BLEEDING AND FILLING THE BRAKING SYSTEM C5 - All Types Bleeding, filling (continued). With the bleeding apparatus - Connect the bleeding apparatus [1] on the brake fluid reservoir (1). - Adjust the apparatus pressure to 2 Bars. For each circuit : - Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container.
  • Page 199 BLEEDING AND FILLING THE BRAKING SYSTEM Bleeding, filling (continued). Bleeding the secondary circuit. NOTE : The bleeding apparatus is connected on the brake reservoir. - Use LEXIA or PROXIA diagnostic tools. Select the menu corresponding to the vehicle : - ABS menu. - ESP menu.
  • Page 200 BRAKE SPECIFICATIONS SYNERGIE 2 0 HDi 2.0i 16V 23.8 Master cylinder Master-vac 203 + 230 (Tandem) Ø GIRLING C57 Caliper/piston makes Disc 281 (Ventilated) Disc thickness Minimum disc thickness Brake pad grade GALFER 3314 20.6 Cylinder or caliper Ø Drum Disc 10/8 Max./ min.
  • Page 201 SYNERGIE BRAKES Manual adjustment of the compensator - Set the vehicle at reference height (see page 180). ESSENTIAL : Never alter the position of the upper nut (1). - Refit the flanged nut (2). - Fit the tool 8204-T. Drum Disc At shim A Yellow...
  • Page 202 BRAKES (continued) SYNERGIE Checks and hydraulic adjustment of the compensator - Use the brake pressure checking equipment 4104-T, connect diagonally and bleed: Ø bleed screw : Caliper 8x125 - Wheel cylinder 7x100. - Set the vehicle at setting height. - Pressure chart : Engine : 2.0i 16V Engine : 2 0 HDi Disc...
  • Page 203 SYNERGIE HANDBRAKE B3FP10VC B3FP10WC B3FP10XC Slacken the cables using the nut (1). - Position the blade B of the blanking plug perpendicular to the line - Remove the blanking plug from hole A. passing through the centre of the disc and the centre of the hole. - Position hole A opposite the toothed wheel (adjusting mechanism).
  • Page 204 C5 - All Types HYDRAULIC SPECIFICATIONS Location of components (A) High pressure hydraulic circuit. (B) Low pressure hydraulic circuit. (C) Electric circuit. (21) Built-in Hydro-electronic Interface (BHI). (22) Front slimline sphere. (23) Front suspension cylinder. (24) Rear slimline sphere. (25) Rear suspension cylinder.
  • Page 205 C5 - All Types HYDRAULIC SPECIFICATIONS Reservoir Function Component Reference (BHI) Built-in Hydro-electronic Interface "d" Induction Power steering pump "e" (BHI) Built-in Hydro-electronic Interface "f" Return Power steering pump "c" Suspension cylinders Synthetic fluid TOTAL FLUIDE LDS. Capacity of the circuit 4.3 litres.
  • Page 206 C5 - All Types HYDRAULIC SPECIFICATIONS Built-in Hydro-electronic Interface (BHI). Reference Component Specifications (36) Electric motor 2350 ± 150 rpm Hydraulic unit comprising : Pump with 5 axial pistons Throughput = 0,7 l/min at 2300 rpm (35) - Anti-pulse hydropneumatic...
  • Page 207 C5 - All Types HYDRAULIC SPECIFICATIONS Hydractive 3+ regulator Hydraulic unions B4BP01CD B4DP003D Tube diameter Tightening torque Reference (40) Slimline sphere. (mm) m.daN (39) Hydractive regulator. (38) Electrovalve. 1,5 ± 0,3 (41) Depressurisation screw. 6,35 2,5 ± 0,5...
  • Page 208 SPECIFICATION - IDENTIFICATION : SUSPENSION SPHERES C5 - All Types Special features Identification. - Fitting of new slimline spheres with multilayer membranes, stone grey in colour. - It is forbidden to recharge or overhaul this type of sphere. - The number marked on the suspension sphere is the reference no. of the component and not the Part No.
  • Page 209 C5 - All Types 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 210 SPECIFICATION - IDENTIFICATION : SUSPENSION SPHERES Hydractive 3 suspension Front suspension sphere (1) WARNING : The number marked on the suspension sphere is the reference no. of the component and not the Part No. Engines Suspension sphere marking Volume(cc) Pressure(Bars) Diameter of damper hole (mm) 96 420 906 80 1.9/1.3...
  • Page 211 STARTER MOTORS Petrol engines Vehicle Engine Gearbox Reference Class Climate Manual 1.8i 16V Automatic 2.0HPi Manual CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page 212...
  • Page 212 STARTER MOTORS Petrol engines Vehicle Engine Gearbox Reference Class Climate Manual 2.0i 16V Automatic 2.0i 24S All Types CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page 212...
  • Page 213 STARTER MOTORS Diesel engines Vehicle Engine Gearbox Reference Class Climate 2.0 HDi (RHY) Manual 2.0 HDi (RHS-RHZ) Automatic CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page 212...
  • Page 214 STARTER MOTORS Diesel engines Vehicle Engine Gearbox Reference Class Climate Manual 2.2 HDi Automatic CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page 212...
  • Page 215 STARTER MOTORS Alternator reference Vehicle Engine Reference Make VALEO MELCO BOSCH Petrol 1.8i 16V D6 RA 72 M000T 82 081 EOAL 098390 2.0i 16V M000T 85 381 2.0 Hpi 3.0i 24S D6 RA 661 Diesel D6 RA 109 M001 T8 0381 A001 111 562F D7 R 26 M001 T8 0481...
  • Page 216 STARTER MOTORS SYNERGIE Petrol engines Vehicle Engine Gearbox Reference Class Climate Manual 2.0i 16V Automatic Diesel engines SYNERGIE 2.0 Hdi Manual 2.0 16V HDi CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page 214...
  • Page 217 SYNERGIE STARTER MOTORS Alternator reference Vehicle Engine Reference Make VALEO MELCO BOSCH Petrol D6 RA 72 M000T8 2081 E0AL 098 390 2.0I 16V M000 T8 2081 SYNERGIE Diesel D7 R 26 M001 T8 5381 2.0 HDi 2.0 16V HDi D7 R 27 Table of classes of starter motors CLASS CLASS 2...
  • Page 218 ALTERNATORS Class of alternator Without aircon With aircon Climate Model Gearbox Vehicle Without Cold Pack With Cold Pack Without Cold Pack With Cold Pack Base With GPS Base With GPS Base With GPS Base With GPS Manual 1.8i 16V Automatic Manual 2.0i 16V Automatic...
  • Page 219 ALTERNATORS Class of alternator Vehicle Model Gearbox Without aircon With aircon Climate Without Cold Pack With Cold Pack Without Cold Pack With Cold Pack Base With GPS Base With GPS Base With GPS Base With GPS Manual 3.0i 24V Automatic 2.0HDi Manual 2.2 HDi...
  • Page 220 ALTERNATORS Alternator reference Engine Gearbox Class Vehicle Make VALEO MELCO BOSCH A 13 VI 204+ A002 TB 4891 1.8i 16V 2.0i 16V SG 10 B0 21 2.0 HPi A003 TA 0891 3.0i 24S A14 VI 25+ SG 15 S0 16 A004 TF 0091 A 120 51 611 2.0 HDi...
  • Page 221 SYNERGIE ALTERNATORS Class of alternator Vehicle Model Gearbox Climate Without aircon With aircon Manual 2.0i 16V Synergie Automatic 2.0 HDi Manual 2.0 HDi CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page : 219...
  • Page 222 ALTERNATORS SYNERGIE Alternator reference Model Gearbox Class Vehicle Make VALEO MELCO BOSCH A13 VI 2A6 A005 TA 6391 SG 8 B0 21 A13 VI 277+ 2.0i 16V SG 10 B0 22 A003 TB 2691 Synergie types A14 VI 40+ SG 15 S0 17 2.0 HDi SG 15 S0 18 2.0 16V...
  • Page 223 ALL TYPES CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR CHECKING THE ALTERNATOR OUTPUT Output under 13.5 V Intensity (A) / Alternator speed Connect as shown in the diagram opposite, using an ammeter (A), Speed a voltmeter (V), and a rheostat (R) or a Volt/Ammeter/Rheostat com- 2000 3000 4000...
  • Page 224 PRE-HEATING AND STARTING CIRCUITS C5 - SYNERGIE Pre-post-heating Vehicles Engines Pre-heater plugs Pre-heater control unit (Pre-heating time at 20°C) CARTIER 51299011A 2.0 HDI CHAMPION CH 170 2.0 16V HDI NAGARES 960411-P Piloted by the diesel injection ECU Synergie CARTIER 51299011A 2.2 HDI...
  • Page 225 C5 - SYNERGIE AIR CONDITIONING R 134 a (HFC) Compressor Refrigerant Vehicle Engine version Date refill Variable capacity Oil quantity cc Oil reference (± 25 gr) 1.8i 16V-2.0i 16V 2.0 HPi SD 7 V16 SD 7 V16 SP 10 3.0i 24S 16V 2.2 HDi...
  • Page 226 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) SYNERGIE Click-fit union removal/fitting tool Vehicle Ø Inch Ring colour Tool kit 4164-T SYNERGIE All Types Black 8005-T.A. C5HP073C Tightening torques (m.daN). Unions Ø Pipes Steel/Steel Aluminium/Steel Aircon compressor fixings. 1.7 ± 0.3 M 06 1.3 ±...
  • Page 227 C5 - SYNERGIE SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Summary table for presence of pollen filter Vehicle Equipment RPO no. Presence of filter Observations Aircon all types Without aircon Base aircon # 8148 Do not fit Water ingress...
  • Page 228 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Pollen filter Remove : - The trim (1) under the dashboard (driver’s side). - The cover (2). Unclip at « a » and pull out the pollen filter (3). Remove the pollen filter (3). C5FP0C5C C5FP0C6D...
  • Page 229 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 230 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Condenser with integral reservoir (continued) 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 231 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 reser- voir must be mounted in the base (8), otherwise there is a risk of damaging the air conditioning circuit. Screwing the reservoir (6) into the base (8).
  • Page 232 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 233 ALL TYPES SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) Checking the compressor oil level (continued) 2) Slow leak. - Slow leaks do not lead to oil loss, therefore the same procedure should be followed as if there was no leak at all. 3/ Fast leak.
  • Page 234 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM ALL TYPES CHECKING TEMPERATURES. TOOLS CHECKS. Two thermometers. If all these conditions are met, take the following action : Preliminary conditions. - Start the engine, with the air conditioning off, and wait for the cooling fan first speed to cut in.
  • Page 235 SYNERGIE CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM CHECKING TEMPERATURES. (continued) Vehicle using R134.a fluid (Compressor with variable capacity) Exterior temperature in °C Vehicles Temperature in °C at the central vents SYNERGIE 12 ± 3 8 ± 3 ) At exterior temperature 20°C, air temperature from the central vents is for second speed of the ventilator fan. If fan operates at first speed, then air temperature from the central vents becomes 8.4 ±...
  • Page 236 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM ALL TYPES CHECKING PRESSURES TOOLS : 1 Charging station and 2 Thermometers. - The temperature of the air coming out of the central vents Observing the preliminary conditions, as well as vehicle (See the table on page 288).
  • Page 237 AIR CONDITIONING SYSTEM R 134.a Engines : 6FZ - RFN - RLZ (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 ±...
  • Page 238 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 239 AIR CONDITIONING SYSTEM R 134.a Engines : RHY - RHZ (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 ±...
  • Page 240 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 241 SYNERGIE - XU - EW10 AIR CONDITIONING SYSTEM R 134.a C5HP12EC Tightening torques. (1) High pressure valve (2) Low pressure valve (3) Pressostat, tighten to 1,8 m.daN (4) Dryer (5) Clickfit union. a) 0,8 m.daN b) 4 m.daN c) 0,8 m.daN C5HP15PP...
  • Page 242 AIR CONDITIONING SYSTEM R 134.a SYNERGIE - DW10 C5HP12EC Tightening torques. (1) High pressure valve (2) Low pressure valve (3) Clickfit union. (4) Pressostat, tighten to 1,8 m.daN (5) Flange fixing, tighten to 0,8 m.daN. (6) Flange fixing, tighten to 0,8 m.daN. (7) Flange fixing, tighten to 4 m.daN.

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