Page 1 CORRESPONDENCE TABLE FOR PETROL ENGINES Engine JP4S TED4 ATED4 families 1.4 16V 1.6 16V 1.1i 1.4i 1.4i 16V 1.6i 16V 1.4 HDi Engine types C3 PLURIEL VERY IMPORTANT As the booklet is constantly re-edited, this one only covers vehicles for this particular model year.
Page 2 2005 PRIVATE CARS C2-C3-C3 PLURIEL «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 3: C3 Pluriel
GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES SUSPENSION, STEERING - BRAKES - AIR CONDITIONING. In each section, the vehicles are dealt with in the following order: C2-C3-C3 PLURIEL and all models where applicable. The information given in this handbook is based on vehicles marketed in EUROPE.
Page 4 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 5: Table Of Contents
Checking the air supply circuit: C2, C3 (DV4ATED4) BE4/5 gearbox controls Tightening torques: engines all types 39 - 72 Checking the air supply circuit: C2, C3 BE4/5 gearbox: checks/adjustments 173 - 174 Cylinder head tightening: all types 73 - 74...
Page 6 229 - 233 Tightening torques: power steering C2 197 - 198 Brake specifications: C3 Pluriel 234 - 238 Setting the steering rack mid-point: C2 Adjusting the handbrake: C3, C3 Pluriel 239 - 240 Axle geometry: C3 201 - 205 Filling, bleeding the brakes: C3, C3 Pluriel...
Page 7 IDENTIFICATION OF VEHICLES A - Cold stamp (cold stamp engraved on the bodywork). B - Manufacturer's name plate (on the LH centre pillar). C - AS/RP No. and RP paint code (on the LH centre pillar). D - Tyre pressures and tyre type (on the LH centre pillar).
Page 8 IDENTIFICATION OF VEHICLES Type approval Structure Version (4) Family (1) Depollution levels Bodywork (2) Others Alcohol JM HFXC/IF Engine (3) 83/87 L3/L4 Version (4) Manual 5-speed gearbox Variant (5) Manual 4-speed gearbox Family (1) Manual 6-speed gearbox Automatic 6-speed gearbox Bodywork (2) Axle and/or gearbox gears 3-door saloon not...
Page 9 IDENTIFICATION OF VEHICLES A - Cold stamp (cold stamp engraved on the bodywork). B - Manufacturer's name plate (on the LH centre pillar). C - AS/RP No. and RP paint code (on the front pillar on driver's side). D - Tyre pressures and tyre type (on the front pillar on driver's side).
Page 10 IDENTIFICATION OF VEHICLES Type approval Structure Version (4) Family (1) Depollution levels Bodywork (2) Others Alcohol FC HFXC/IF Engine (3) 83/87 L3/L4 Version (4) Manual 5-speed gearbox Variant (5) Manual 4-speed gearbox Family (1) Manual 6-speed gearbox Axle and/or gearbox gears Bodywork (2) Other possible combinations 5-door saloon...
Page 11 IDENTIFICATION OF VEHICLES Type approval (continued) Engine (3) Variants (5) 1.1i TU1JP-TU1A Entreprise convertible 1.4i TU3JP-TU3A Integral alternator-starter (ADIN) 1.4i 16V ET3JA Without FAP 1.6i 16V TU5JP4 Fiscal incentives 1.6i 16V TU5JP4 TR Piloted manual gearbox 1.4 HDi DV4TD Downgraded depollution D (car or van not convertible) TD (van convertible) 1.4 HDi...
Page 12 C3 Pluriel IDENTIFICATION OF VEHICLES A - Cold stamp (cold stamp engraved on the bodywork). B - Manufacturer's name plate (on the LH centre pillar). C - AS/RP No. and RP paint code (on the front pillar on driver's side). D - Tyre pressures and tyre type (on the front pillar on driver's side).
Page 13 IDENTIFICATION OF VEHICLES Type approval Structure Version (4) Family (1) Depollution levels Bodywork (2) Others Alcohol HN KFVC/IF Engine (3) 83/87 L3/L4 Version (4) Manual 5-speed gearbox Variant (5) Manual 4-speed gearbox Family (1) Manual 6-speed gearbox C3 Pluriel Automatic 6-speed gearbox Bodywork (2) Axle and/or gearbox gears Cabriolet...
Page 14 C2 - C3 OPERATIONS TO BE CARRIED OUT AFTER A REPAIR IMPERATIVE: All these operations are to be performed following a reconnection of the battery. Antiscanning function. It is necessary to wait 1 minute after the battery has been disconnected in order to be able to start the vehicle.
Page 15 OPERATIONS TO BE CARRIED OUT AFTER A REPAIR Sun roof. The anti-pinch function has to be re-initialised. Place the sun roof switch in the maximum tilt position. Keep the sun roof switch pressed until the sun roof ceases its movement. Release the sun roof switch within 5 seconds.
Page 16 CAPACITIES (in litres) Draining methods Oil capacities are defined according to the following methods Draining of the engine lubrication system by GRAVITY Draining of the engine lubrication system by SUCTION Place the vehicle on horizontal ground (in the high position if Place the vehicle on horizontal ground (in the high position if hydropneumatic suspension) .
Page 17 CAPACITIES (in litres) Petrol Diesel DV4TD TU1JP TU3JP TU5JP4 TU5JP4S ➔ RPO 9884 RPO 9885 ➔ RPO ➔ 1.1i 1.4i 1.6i 16V 1.4 HDi Engine type 3,25 3,75 Engine with filter change Between min. and max. MA5 5-speed gearbox 2 ± 0,15 MA5 piloted 5-speed gearbox 0,7 Litre version with front calipers Ø...
Page 18 CAPACITIES (in litres) Petrol Diesel TU1JP DV6ATED4 TU3JP ET3J4 TU5JP4 DV4TD DV4ATED4 ➔ RPO ➔ RPO ➔ 9885 ➔ 9885 ➔ 9884 9884 1.6 16V 1.1i 1.4i 1.4i 16V 1.6i 16V 1.4 HDi 1.4 16V HDi Engine type 3,75 3,25 3,75 Engine with filter change Between min.
Page 19 CAPACITIES (in litres) C3 PLURIEL C3 Pluriel Petrol Diesel TU3JP TU5JP4 DV4TD RPO ➔ 1.4i 1.6i 16V 1.4 HDi Engine type Engine with filter change 3,25 3,75 Between min. and max. 5-speed gearbox 0,7 Litre version with front calipers Ø 48 / rear drums Braking circuit 0,8 Litre version with front calipers Ø...
Page 20: Specifications
LUBRICANTS - TOTAL recommended oils EVOLUTIONS (YEAR 2004). New Look CITROËN C5 CITROËN C4 Petrol engine versions: Petrol engine versions except 2.0 i 16V 180 hp (132 kW) : Normal maintenance interval: 30 000 km (20 000 miles) . Normal maintenance interval: 30 000 km (20 000 miles) . Severe maintenance interval: 20 000 km (12 000 miles) .
Page 21 LUBRICANTS - TOTAL recommended oils Use of oil grade 10W40. S.A.E. Norms - Table for selection of engine oil grade. It is possible to use the semi-synthetic oil 7000 10W40 on HDi and HDi Selection of engine oil grades recommended for climatic conditions in FAP vehicles.
Page 22 LUBRICANTS - TOTAL recommended oils API NORMS: WARNING: CITROËN engines prior to model year 2000 do not have to The meaning of the first letter has not changed, it still corresponds to be lubricated with oils adhering to the norms: the type of engine: - ACEA AI-98 and API SJ/CF EC or current norms ACEA A5/B5.
Page 23 LUBRICANTS - TOTAL recommended oils Classes and grades of TOTAL recommended engine oils The oils distributed in each country are suited to the local climatic conditions. Blended oils for all engines (petrol, diesel and dual fuel Oils specifically for diesel engines: petrol/LPG): S.A.E.
Page 24 LUBRICANTS - TOTAL recommended oils Oil usage table TOTAL ACTIVA QUARTZ Synthetic 9000 Semi-synthetic 7000 Engine types 0W40 5W30 5W40 10W40 15W50 Hot countries Temperate countries Cold countries EW10J4S (CITROËN C4) EW12J4 (CITROËN C8 2.2i 16V) Petrol engines EW10A (CITROËN C4 and C5) Other petrol engines X (*) HDi engines with FAP (*)
Page 25 LUBRICANTS - TOTAL recommended oils E4AP006D...
Page 26 LUBRICANTS - TOTAL recommended oils ENGINE OILS FRANCE Blended oils for all engines, supplied in bulk Metropolitan FRANCE TOTAL ACTIVRAC Norms S.A.E: 10W40 TOTAL ACTIVA TOTAL ACTIVA DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 7000 10W40...
Page 27 LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 7000 10W40 Germany 9000 0W40 Austria 7000 10W40 7000 10W40 Belgium 9000 0W40...
Page 28 LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 7000 10W40 Denmark 9000 0W40 7000 10W40 Spain 7000 15W40 Estonia...
Page 29 LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 7000 10W40 Hungary 9000 0W40 Italy Ireland 7000 10W40 9000 5W40 Iceland...
Page 30 LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 7000 10W40 Malta 7000 15W50 Moldavia 7000 10W40 7000 10W40 Norway 9000 0W40...
Page 31 LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 7000 10W40 7000 15W50 Romania 9000 0W40 Russia 7000 10W40 Slovenia...
Page 32 LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines Ukraine 9000 5W40 7000 10W40 7000 10W40 FUTUR 9000 5W30 (*) 9000 0W40 Serbia-Montenegro...
Page 33 LUBRICANTS - TOTAL recommended oils ENGINE OILS OCEANIA TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines Australia 9000 5W40 7000 10W40 7000 10W40 FUTUR 9000 5W30 (*) New Zealand AFRICA...
Page 34 LUBRICANTS - TOTAL recommended oils ENGINE OILS CENTRAL AND SOUTH AMERICA TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines Argentina Brazil Chile 7000 10W40 7000 15W50 7000 10W40 Cuba...
Page 35 LUBRICANTS - TOTAL recommended oils ENGINE OILS SOUTH-EAST ASIA TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines 7000 10W50 China 7000 15W50 9000 5W40 South Korea 7000 10W40 FUTUR 9000 5W30 (*)
Page 36 LUBRICANTS - TOTAL recommended oils ENGINE OILS SOUTH-EAST ASIA TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines Philippines 7000 15W50 Singapore 7000 10W40 9000 5W40 Taiwan 7000 10W40...
Page 37 LUBRICANTS - TOTAL recommended oils ENGINE OILS MIDDLE EAST TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel Oils specifically for petrol and Blended oils for all engines engines dual-fuel petrol / LPG engines Saudi Arabia - Bahrain Dubai 7000 15W50 United Arab Emirates 9000 5W40 7000 10W40...
Page 38 LUBRICANTS - TOTAL recommended oils GEARBOX OILS TOTAL TRANSMISSION BV Manual and piloted manual Norms S.A.E: 75W80 gearboxes Part No.: 9730 A2. TOTAL FLUIDE ATX TOTAL FLUIDE AT 42 MB3 automatic gearbox Special oil distributed by CITROËN Part No.: 9730 A6 All countries Special oil distributed by CITROËN 4HP20 and AL4 autoactive...
Page 39 LUBRICANTS - TOTAL recommended oils POWER STEERING OILS Power steering all vehicles TOTAL FLUIDE ATX (except CITROËN C4 and C5) All countries TOTAL FLUIDE LDS Power steering Special oil distributed by CITROËN C4 and C5 Part No.: 9979 A3 TOTAL FLUIDE DA Very cold countries Power steering Special oil distributed by CITROËN...
Page 40 LUBRICANTS - TOTAL recommended oils BRAKE FLUID Synthetic brake fluid Packs CITROËN Part No. 9979 05 0,5 Litre CITROËN fluid All countries 1 Litre 9979 06 5 Litres 9979 07 HYDRAULIC SYSTEM Packs All countries Norm CITROËN Part No. TOTAL FLUIDE LDS Orange 9979 A3 TOTAL LHM PLUS...
Page 41 LUBRICANTS - TOTAL recommended oils SCREEN WASH FLUID Packs CITROËN Part No. Concentrated: 250 ml 9980 33 9980 56 ZC 9875 953U 9980 06 1 Litre ZC 9875 784U All countries Fluid ready to use 5 Litres 9980 05 ZC 9885 077U ZC 9875 279U GREASING General use...
Page 42 ENGINE OIL CONSUMPTION I - Oil consumption depends on: - The engine type. - How run-in or worn it is. - The type of oil used. - The driving conditions. II - An engine can be considered RUN-IN after: - 3,000 miles (5,000 km) for a PETROL engine. - 6,000 miles (10,000 km) for a DIESEL engine.
Page 43 ENGINE SPECIFICATIONS Petrol engines All Types 1.6i 16V 1.1i 1.4i 1.4i 16V Engine type Cubic capacity (cc) 1124 1360 1587 Bore / Stroke 72/69 75/77 78,5/82 Compression ratio 10,5/1 11,1/1 11/1 Power ISO or EEC (KW - rpm) 44,1-5500 54-5400 65-5250 80-5800 90-6500...
Page 44 ENGINE SPECIFICATIONS Diesel engines All Types 1.4 HDi 1.4 16V HDi 1.6 16V HDi Engine type Cubic capacity (cc) 1398 1560 Bore / Stroke 73,7/82 75/88,3 17,9/1 18,4/1 18/1 Compression ratio 50-4000 66-4000 66,2-4000 Power ISO or EEC (KW - rpm) Torque ISO or EEC 15-1750 16-2000...
Page 45 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines: HFX - KFV - NFU - NFS A = HFX - KFV B = NFU - NFS RH engine support : 6 ± 0,4 : 6 ± 0,6 : 4,5 ± 0,4 Torque reaction rod : 6 ±...
Page 46 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines HFX - KFV - NFU - NFS Crankshaft Accessories drive pulley 2,5 ± 0,2 Pinion fixing on crankshaft Tightening 4 ± 0,4 Angular tightening 45° ± 4° Cylinder block Sump 0,8 ± 0,2 Timing belt tensioner roller 2,1 ±...
Page 47 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines HFX - KFV - NFU - NFS Cylinder head Coolant outlet housing In plastic 0,8 ± 0,2 In aluminium 0,8 ± 0,2 Camshaft bearing caps (TU1JP - TU3JP) Tightening 2 ± 0,2 Angular tightening 44 °±...
Page 48 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines HFX - KFV - NFU - NFS Flywheel - clutch Engine flywheel 6,7 ± 1 (LOCTITE FRENETANCH) Oil pressure mechanism 2 ± 0,2 Lubrication circuit Oil pressure switch 3,5 ± 0,5 Oil pump 0,9 ±...
Page 49 TIGHTENING TORQUES: POWER UNIT SUSPENSION Engines: 8HX - 8HZ : 6 ± 0,6 : 6 ± 0,6 : 6 ± 0,6 : 6 ± 0,6 : 3 ± 0,3 : 6 ± 0,6 : 5,5 ± 0,5 : 5,7 ± 0,9 B1BP2Y1P...
Page 50 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines 8HX - 8HZ Crankshaft Bearing cap fixing screws Pre-tightening 1 ± 0,2 Slackening 180° Tightening 3 ± 0,3 Angular tightening 140° Con rod screws Tightening 1 ± 0,1 Angular tightening 100° ± 5° Accessories drive pulley Pre-tightening 3 ±...
Page 51 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines 8HX - 8HZ Cylinder head Camshaft bearing covers Pre-tightening 0,3 ± 0,1 Tightening 1 ± 0,1 Fixing of camshaft sub-assemblies on cylinder head Pre-tightening 0,3 ± 0,1 Tightening 1 ± 0,1 Exhaust manifold 3 ±...
Page 52 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines 8HX - 8HZ Lubrication circuit Oil pump assembly Pre-tightening 0,5 ± 0,1 Tightening 0,9 ± 0,1 Coolant/oil heat exchanger 1 ± 0,1 Diesel injection circuit Spherical-base screws for diesel injection fixing fork 2,5 ± 0,2 Fuel high pressure common injection rail on engine block 2,2 ±...
Page 53 C3 - C3 PLURIEL SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines: HFX - KFV - NFU C3 Pluriel A = HFX - KFV A = KFV B = NFU B = NFU RH engine support RH engine support : 4,5 ± 0,4 : 6 ±...
Page 54 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Crankshaft Engines Accessories drive pulley 0,8 ± 0,2 Pinion fixing on crankshaft 10 ± 1 2,5 ± 0,2 Cylinder block Sump 0,8 ± 0,2 Timing belt tensioner roller 2 ± 0,2 2,2 ± 0,2 Accessories belt tensioner roller 2 ±...
Page 55 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Flywheel - Clutch Engines Flywheel 6,7 ± 0,6 + LOCTITE FRENETANCH Clutch mechanism 2 ± 0,2 Lubrication circuit Oil pressure switch 2 ± 0,2 Oil pump 0,9 ± 0,1 Cooling circuit Coolant pump 1,4 ± 0,1 Coolant outlet housing 0,8 ±...
Page 56 TIGHTENING TORQUES: POWER UNIT SUSPENSION Engine: KFU RH engine support : 6 ± 0,6 : 6 ± 0,6 Torque reaction rod : 6 ± 0,6 : 6 ± 0,6 LH engine support on gearbox : 3 ± 0,3 : 6 ± 0,6 : 5,5 ±...
Page 57 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine Crankshaft Accessories drive pulley 0,8 ± 0,2 Pinion fixing on crankshaft Pre-tightening 4 ± 0,4 Angular tightening 45 ± 4° Cylinder block Sump 0,8 ± 0,2 Accessories belt guide roller 4 ± 0,4 Timing belt tensioner roller 2,1 ±...
Page 58 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Cylinder head (continued) Exhaust manifold 1,8 ± 0,2 Sparking plugs 2,2 ± 0,2 VVT pulley cap 4 ± 0,4 VVT control electrovalve 0,8 ± 0,2 VVT inlet camshaft pulley screw Pre-tightening 2 ± 0,2 Tightening 6,1 ±...
Page 59 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) C3 - C3 PLURIEL Engines: 8HX - 8HZ RH engine support : 4,5 ± 0,4 : 3 ± 0,3 Torque reaction rod : 6 ± 0,6 : 6 ± 0,6 LH engine support on gearbox : 5,4 ±...
Page 60 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) C3 - C3 PLURIEL Engines Crankshaft Bearing cap fixing screw Pre-tightening Slackening Tightening Angular tightening 140° Con rod nuts Pre-tightening Slackening Tightening 1,5 ± 0,1 Angular tightening 100° ± 5° Accessories drive pulley Pre-tightening 3 ±...
Page 61 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) C3 - C3 PLURIEL Engines Cylinder head Camshaft bearing covers Pre-tightening 0,5 ± Tightening 1 ± Fixing of camshaft sub-assemblies on cylinder head Pre-tightening Tightening Exhaust manifold 2,5 ± 0,2 Valve cover 2,5 ± 0,2 Camshaft pulley 4,3 ±...
Page 62 C3 - C3 PLURIEL SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engines 8HX - 8HZ Diesel injection circuit Spherical-base screws for diesel injection fixing fork 0,3 ± 0,1 Fuel high pressure common injection rail on engine block 2 ± 0,2 Unions on fuel high pressure common injection rail Pre-tightening 1,7 ±...
Page 63 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 8HY RH engine support Screw (1) : 6 ± 0,6 Screw (2) : 6 ± 0,6 RH lower engine support Screw (3) : 5,7 ± 0,5 LH upper engine support Screw (7) : 6 ± 0,6 Screw (8) : 5,5 ±...
Page 64 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine Crankshaft Bearing cap fixing screw Tightening 3 ± 0,3 Angular tightening 140° ± 1°,4’ Crankshaft pullet hub Tightening 3 ± 0,3 Angular tightening 180° ± 5° Cylinder block Oil sump 1 ± 0,1 Timing belt tensioner roller 4 ±...
Page 65 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine Flywheel - Clutch Flywheel 1,7 ± 0,2 Clutch mechanism 2 ± 0,2 Lubrication Circuit Oil pump assembly 0,9 ± 0,1 Oil/coolant heat exchanger 1 ± 0,1 Turbocharger lubrication pipe 2,2 ± 0,2 Injection circuit Injector fixing flange nut Tightening 0,4 ±...
Page 66 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX RH engine support Screw (1) : 6 ± 0,6 Screw (2) : 6 ± 0,6 RH lower engine support Screw (3) : 5,7 ± 0,5 LH upper engine support Screw (7) : 6 ± 0,6 Screw (8) : 5,5 ±...
Page 67 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Cylinder head Air inlet manifold 1 ± 0,1 Oil trap 1 ± 0,1 Camshaft bearing covers Pre-tightening 0,5 ± 0,1 Tightening 1 ± 0,1 (3) camshaft bearing cover screws (4) camshaft bearing cover studs B1BP39YP B1DP1D7D...
Page 68 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Cylinder head Camshaft bearing cover studs Pre-tightening 0,5 ± 0,1 Tightening 1 ± 0,1 Exhaust gas recycling electrovalve (EGR) 1 ± 0,1 Cylinder head Pre-tightening 2 ± 0,2 Tightening 4 ± 0,5 Angular tightening 260°...
Page 69 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Cylinder head Exhaust manifold 2,5 ± 0,2 Exhaust manifold stud 1 ± 0,2 Turbocompressor nuts 2,6 ± 0,6 Catalytic converter nuts 2 ± 0,1 Air flowmeter Pre-tightening Tightening 0,9 ± 0,2 B1BP39YP...
Page 70 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Cylinder block Coolant pump Pre-tightening 0,3 ± 0,1 Tightening 0,9 ± 0,1 Con rod screws Pre-tightening 1 ± 0,1 Angular tightening 100° ± 5° Flywheel (according to equipment) Pre-tightening 1,7 ± 0,2 Angular tightening 75°...
Page 71 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Cylinder block Bearing cap fixing screwss Pre-tightening 1 ± 0,2 Slackening 180° Tightening 3 ± 0,3 Angular tightening 140° ± 5° Crankshaft bearing cap cover screws 0,8 ± 0,3 Crankshaft bearing cap cover screws Pre-tightening 0,6 ±...
Page 72 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Cylinder block Crankshaft bearing cap cover Tightening Method: Pre-tighten the 10 screws (17) (from 1 to 10) to Pre-tighten the 14 screws (19) (from 11 to 24) to Tighten the 2 screws (18) (inside the flywheel bell housing) to Slacken the screws (17) by 180°...
Page 73 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Lubrification 3 ± 0,5 Turbocharger lubrication tube 2,1 ± 0,3 Oil pressure switch 2 ± 0,2 Oil gauge 0,8 ± 0,2 Electric oil gauge 2,7 ± 0,5 Piston skirt spray jets 2 ± 0,5 Oil filter cover 2,5 ±...
Page 74 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Timing Camshaft bearing caps 1 ± 0,1 Camshaft pulleys Pre-tightening 2 ± 0,2 Angular tightening 50° ± 5° Timing belt guide roller 3,7 ± 0,3 Timing belt tensioner roller 2,7 ± 0,2 Timing chain tensioner 1 ±...
Page 75 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Injection circuit Union on injector Pre-tightening 2 ± 0,5 Tightening 2,5 ± 0,3 Injector fixing flange but Pre-tightening 0,5 ± 0,5 Angular tightening 65° ± 5° Diesel injection pump on support 2,2 ± 0,3 Diesel injection pump pulley 5 ±...
Page 76 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Injection circuit Diesel fuel high pressure pump rear support 2 ± 0,5 Union on diesel high pressure pump Pre-tightening 2 ± 0,5 Tightening 2,5 ± 0,3 Fuel high pressure common injection rail on engine block 2,2 ±...
Page 77 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Accessories Version without particle filter Multifunction support 2 ± 0,4 Alternator fixing screw 4,9 ± 1,2 Alternator power circuit fixing nuts 1,4 ± 0,2 Accessories tensioner roller 2,1 ± 0,2 D1AP02NC...
Page 78 SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) Engine: 9HX Accessories Version without aircon Accessories support 2 ± 0,5 Guide roller 4,5 ± 0,5 D1AP02PC Accessories Version with aircon Aircon compressor support 2 ± 0,5 Aircon compressor screw 2,4 ± 0,5 D1AP02QD...
Page 79 SPECIAL FEATURES - CYLINDER HEAD TIGHTENING Petrol engines Cleaning to be carried out just prior to refitting. WARNING: Clean the contact faces with the approved CITROËN cleaning product. Do not use abrasives or cutting tools on the contact faces. The contact faces must not bear any traces of impact or scratching. Insert a tap in the threads of the holes in the cylinder block receiving the cylinder head bolts.
Page 80 SPECIAL FEATURES - CYLINDER HEAD TIGHTENING Diesel engines Cleaning to be carried out just prior to refitting. WARNING: Clean the contact faces with the approved CITROËN cleaning product. Do not use abrasives or cutting tools on the contact faces. The contact faces must not bear any traces of impact or scratching. Insert a tap in the threads of the holes in the cylinder block receiving the cylinder head bolts.
Page 81 All Types BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE Tools 4122-T (C.TRONIC.105.5) 4099-T (C.TRONIC.105)
Page 82 AUXILIARY EQUIPMENT DRIVE BELT JP4S ATED4 TED4 Engine type KFU (*) C3 Pluriel See pages: 80 to 81 82 to 83 84 to 86 80 to 81 87 to 88 90 to 91 (*) = Accessories drive belt for STOP AND START.
Page 83 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) 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 84 C2 - C3 - C3 PLURIEL AUXILIARY EQUIPMENT DRIVE BELT Engines: HFX - KFV - NFU - NFS Tools. [1] Pliers for removing plastic pegs : 7504 -T [2] Belt tension measuring instrument : 4122-T Vehicle without air conditioning. Removing.
Page 85 AUXILIARY EQUIPMENT DRIVE BELT C2 - C3 - C3 PLURIEL Engines: HFX - KFV - NFU - NFS Vehicle with air conditioning. Removing. Slacken: - Screws (6), (4) and (5). - Fully detension the belt by acting on the tensioner roller.
Page 86 AUXILIARY EQUIPMENT DRIVE BELT Engine: KFU Tools. [1] Plyers for removing plastic pegs : 7504 -T [2] Belt tension measuring instrument (SEEM) : 4122 -T Removing. Raise and support the vehicle, front wheels hanging. Disconnect the battery. Remove the front RH wheel and the front RH splash-shield, using tool [1]. Vehicle without air conditioning.
Page 87 AUXILIARY EQUIPMENT DRIVE BELT Engine: KFU Vehicle with air conditioning. Removing. Slacken the tension, screw (6), screw (4) and screw (5). Completely detension the belt by acting on the tensioner roller. Remove the auxiliary equipment drive belt. Refitting. B1BP10VC Refit the auxiliary equipment drive belt. Respect the following sequence: - Crankshaft pinion, aircon compressor pulley, alternator pulley guide roller and guide roller.
Page 88 AUXILIARY EQUIPMENT DRIVE BELT for «STOP AND START» Engine: KFU Tools. [1] Compression tool : 4388-T IMPERATIVE: Respect the precautions to be taken prior to any operation. Checking the «stop and start» accessories belt. Checking the belt extension. Disconnect the battery. Using a vernier gauge, measure the extension of the tensioner.
Page 89 AUXILIARY EQUIPMENT DRIVE BELT for «STOP AND START» Engine: KFU Dynamic checking. Raise and support the vehicle, front wheels hanging. Start the engine, engage 1st gear, keep your foot on the brake. Accelerate up to 1500 rpm and visually check the thrashing of the belt. The thrashing value for the belt should be less than Y = 40 mm.
Page 90 AUXILIARY EQUIPMENT DRIVE BELT for «STOP AND START» Engine: KFU Tools. [1] Compression tool : 4388-T [2] Pliers for removing plastic pins : 7504-T IMPERATIVE: Respect the precautions to be taken prior to any operation. Removing-refitting the «stop and start» accessories belt. Raise and support the vehicle, front wheels hanging.
Page 91 C2 - C3 - C3 PLURIEL AUXILIARY EQUIPMENT DRIVE BELT With compressor and alternator Engines: 8HX - 8HZ Tools. [1] Pliers for removing plastic pegs : 7504-T [2] Tensioner roller compression lever : (-).0194.E [3] Tensioner roller setting peg Ø 4 mm : (-).0194.F...
Page 92 C2 - C3 - C3 PLURIEL AUXILIARY EQUIPMENT DRIVE BELT Engines: 8HX - 8HZ Markings on the dynamic tensioner roller. «a» Position of «maximum wear» of the auxiliary drive belt. «b» Normal position. Refitting. NOTE: Check that the tensioner roller moves freely (no tight spot) . If this is not the case, replace the tensioner roller.
Page 93 AUXILIARY EQUIPMENT DRIVE BELT Engine: 8HY Tools. [1a] Dynamic tensioner roller lever : (-).0194-E1 [1b] Lever extension : (-).0194-E2 [2] Accessories belt roller locking peg Ø 4 mm : (-).0194-F Removing. Pivot the tensioner roller support (1) (clockwise) , using tools [1a] and [1b] at «a». Remove the belt.
Page 94 AUXILIARY EQUIPMENT DRIVE BELT Engine: 9HX Tools. [1a] Dynamic tensioner roller lever : (-).0194-E1 [1b] Lever extension : (-).0194-E2 [2] Dynamic tensioner roller locking peg : (-).0194-F IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions. Markings on the dynamic tensioner roller.
Page 95 AUXILIARY EQUIPMENT DRIVE BELT Engine: 9HX Refitting. WARNING: Belt to be re-used, mark the direction of fitting of the belt. Refit the auxiliaries drive belt. Compress the tensioner roller (1) by acting at «c» (clockwise) , using tool [1]. Remove tool [2]. IMPERATIVE: Make sure that the auxiliaries drive belt is correctly positioned in the grooves of the various pulleys.
Page 96: Checking And Setting The Valve Timing
CHECKING AND SETTING THE VALVE TIMING JP4S ATED4 TED4 Engine type KFU (*) C3 Pluriel See pages: 94 to 103 104 to 109 94 to 103 110 to 117 118 to 126 127 to 134 (*) = STOP AND START accessories drive belt.
Page 97 RECOMMENDATIONS: TIMING BELT Engines all types Recommendations. IMPERATIVE: After any repair involving removal of the timing belt, systematically replace: - The timing belt, - The tensioner roller fixing nut.
Page 98 C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engines: HFX - KFV - NFU - NFS Tools. [1] Engine flywheel peg : 4507-T.A [2] Camshaft pulley peg : 4507-T.B [3a] Camshaft peg : 4533-TA.C1 [3b] Camshaft peg : 4533-TA.C2...
Page 99 CHECKING AND SETTING THE VALVE TIMING C2 - C3 - C3 PLURIEL Engines: NFU - NFS Checking the timing (continued). Engines: NFU - NFS Place a jack under the engine, peg the engine. Remove: - The engine support (4) complete.
Page 100 C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engines: HFX - KFV Setting the timing. Preliminary operation. Lift and support the vehicle, wheels hanging. Disconnect the battery. Remove: - The front RH wheel. - The splash-shield, using tool [6].
Page 101 CHECKING AND SETTING THE VALVE TIMING C2 - C3 - C3 PLURIEL Engines: HFX - KFV Setting the timing (continued). Engines: HFX - KFV. Slacken the screws (4) without removing them. Remove the bottom engine support assembly (5) and the fixing screws (4).
Page 102 C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engines: NFU - NFS Engines: NFU - NFS. Setting the timing (continued). Remove: - The bottom plastic casing. - The engine support (9). - The middle support. - The timing cover (8).
Page 103 C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engines: NFU - NFS Setting the timing (continued). Engines: NFU - NFS. Slacken the tensioer roller. Turn the tensioner roller so as to be able to position the tool [4], with the aid of an Allen key placed at «a».
Page 104 C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engines: HFX - KFV Setting the timing (continued). Engines: HFX - KFV. Refitting. WARNING: Respect the direction of fitting of the belt: (the arrows «d» indicate the direction of rotation of the crankshaft) .
Page 105 CHECKING AND SETTING THE VALVE TIMING C2 - C3 - C3 PLURIEL Engines: HFX - KFV - NFU - NFS Setting the timing (continued). Engines: HFX - KFV. Refitting. NOTE: Check that the pegs [1] and [2] are in place.
Page 106 C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engines: HFX - KFV - NFU - NFS Timing belt overtensioned. A: Engine: HFX - KFV. B: Engine: NFU - NFS. Turn the tensioner roller (7) with the aid of a hexagonal spanner at «a».
Page 107 CHECKING AND SETTING THE VALVE TIMING C2 - C3 - C3 PLURIEL Engines: HFX - KFV - NFU - NFS Adjusting the fitting tension of the timing belt. A: Engine: HFX - KFV. B: Engine: NFU - NFS. Slacken the nut while maintaining the position of the tensioner roller, with the aid of a hexagonal spanner at «a».
Page 108 CHECKING AND SETTING THE VALVE TIMING Engine: KFU Tools. [1] Flywheel setting peg : 4507-TA [2] Camshaft peg : 4533-TA.C1 [3] Crankshaft setting peg : (-).0194.A Checking. Raise and support the vehicle, wheels hanging. Deconnect the battery. Remove: - the oil filter. - the engine cover.
Page 109 CHECKING AND SETTING THE VALVE TIMING Engine: KFU Position the tools [3] and [2]. Peg the flywheel, using tool [1]. NOTE: If the setting is not correct, recommence the operation. Remove the pegs [2] and [3]. Refit: - The oil filter. - The timing cover (1).
Page 110 CHECKING AND SETTING THE VALVE TIMING Engine: KFU Tools. [1] Flywheel setting peg : 4507-T [2] Engine support crossmember [3] Crankshaft setting peg : (-).0194.A [4] Camshaft peg : 4533-TA.C1 [5] Belt retaining pin : 4533-T.AD Removing. Raise and support the vehicle, front wheels hanging. Disconnect the battery.
Page 111 CHECKING AND SETTING THE VALVE TIMING Engine: KFU Rotate the engine by means of the crankshaft pinion screw (2) (clockwise) to bring it to the pegging position. Peg the flywheel, using tool [1]. Position the tools [3] and [4]. Position the tool [2]. Support the engine.
Page 112 CHECKING AND SETTING THE VALVE TIMING Engine: KFU Remove: - The lower engine support assembly (5) and the fixing screw (4). - Remove the lower timing cover (6). - Slacken the nut (7). - Remove the timing belt. IMPERATIVE: Check that the tensioner roller turns freely (no tight spot) . Refitting.
Page 113 CHECKING AND SETTING THE VALVE TIMING Engine: KFU Overtensioning the belt. Position «a»: Tensioner roller in slackened position. Position «b»: Tensioner roller in normal position. Position «c»: Tensioner roller in overtensioned position. Turn the tensioner roller (8) using an allen spanner at «e». Position the index «d»...
Page 114 CHECKING AND SETTING THE VALVE TIMING C2 - C3 - C3 PLURIEL Engines: 8HX - 8HZ Tools. [1] Pliers for removing plastic pegs : 7504-T [2] Lever for detensioning the dynamic tensioner roller : (-).0194.E [3] Engine flywheel setting peg : (-).0194.C...
Page 115 C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engines: 8HX - 8HZ Checking the setting (continued). Remove: - The accessories drive belt. - The accessories drive pulley. - The lower timing cover (3). IMPERATIVE: The magnetic track should show no signs of damage and should not be approached by any other source of magnetism.
Page 116 C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engines: 8HX - 8HZ Setting the timing. Remove the upper timing cover (1). Rotate the engine by means of the crankshaft screw (2). NOTE: The pegging hole is located under the crankshaft bearing cap cover.
Page 117 C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engines: 8HX - 8HZ Setting the timing (continued). Remove the tool [3]. Rotate the engine by means of the crankshaft pinion screw (2) (clockwise) to bring it to the pegging position.
Page 118 C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engines: 8HX - 8HZ Setting the timing (continued). Hold the tensioner roller, using a hexagonal spanner at «b». Slacken the screw (9). Remove the timing belt (10). Refitting.
Page 119 C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engines: 8HX - 8HZ Setting the timing (continued). NOTE: Screw (9) slackened. Position the timing belt (10) observing the following sequence: - Crankshaft pinion (4). - Guide roller (12).
Page 120 C2 - C3 - C3 PLURIEL CHECKING AND SETTING THE VALVE TIMING Engines: 8HX - 8HZ Setting the timing (continued). Turn the tensioner roller to the right to bring the index «c» to position «d», using a hexagonal spanner. Tighten the screw (9) of the tensioner roller, tighten to 3 ± 0,3 m.daN.
Page 121 CHECKING AND SETTING THE VALVE TIMING C2 - C3 - C3 PLURIEL Engines: 8HX - 8HZ Setting the timing (continued). Refit: - The intermediate RH engine support, tighten the screws (16) to 5,5 ± 0,5 m.daN. - The RH engine support, tighten the screws (17) to 4,5 ± 0,4 m.daN.
Page 122 CHECKING AND SETTING THE VALVE TIMING Engine: 8HY Tools. [1] Engine flywheel peg Ø 12 mm : (-).0194-C [2] Camshaft pulley peg Ø 8 mm : (-).0194-B [3] Crankshaft pulley peg Ø 5 mm : (-).0194-A Preliminary operations. Remove: - The front RH wheel. - The front RH splash-shield.
Page 123 CHECKING AND SETTING THE VALVE TIMING Engine: 8HY Checks. Rotate the engine to engage it (normal direction of rotation) . Immobilise the engine flywheel at «a», using tool [1]. Move aside the harness (6). Remove: - The engine support (7). - The screw (8).
Page 124 CHECKING AND SETTING THE VALVE TIMING Engine: 8HY Checks (continued). Refit the screw (8). Rotate the crankshaft six times (clockwise) . IMPERATIVE: Never rotate the engine backwards. Peg: - The camshaft, using tool [2] (oil the pegs) . - The fuel high pressure pump pulley (14), using tool [3] at «c». WARNING: The magnetic track should show no signs of damage and should not be approached by any source of magnetism.
Page 125 CHECKING AND SETTING THE VALVE TIMING Engine: 8HY Checks (continued). NOTE: The index «e» of the dynamic tensioner roller should be centred within the area «d». Check the correct positioning of the index «e». If it is not correct, repeat the operation to tension the timing belt (see corresponding operation) . Refitting.
Page 126 CHECKING AND SETTING THE VALVE TIMING Engine: 8HY Checks (continued). Refit: - The engine support (7), tighten to 1,5 ± 0,4 m.daN. - The engine support (4), tighten to 6,1 ± 0,6 m.daN. - The engine support (5), tighten to 6 ± 0,6 m.daN. - The electrical harness (6).
Page 127 CHECKING AND SETTING THE VALVE TIMING Engine: 8HY Setting the timing. Perform the preliminary operations for checking the timing up to removing tool [1] at «a» for immobiling the engine flywheel. Refit screw (8). Rotate the crankshaft to bring the camshaft towards its pegging point. Peg the camshaft, using tool [2] (oil the pegs) .
Page 128 CHECKING AND SETTING THE VALVE TIMING Engine: 8HY Setting the timing (continued). Checking the setting. IMPERATIVE: Just prior to refitting, carry out the following tests. Check that: - The rollers and the coolant pump operate freely (no play and no tight spot) . - There are no traces of oil (from the crankshaft and camshaft sealing rings) .
Page 129 CHECKING AND SETTING THE VALVE TIMING Engine: 8HY Setting the timing (continued). Checks (continued). Reposition the timing belt, belt at «e» well tensioned, in the following order: - Guide roller (17). - Camshaft pulley (16). - Fuel high pressure pump pulley (15). - Coolant pump pinion (18).
Page 130 CHECKING AND SETTING THE VALVE TIMING Engine: 8HY Adjusting the timing belt tension (continued). IMPERATIVE: Never rotate the engine backwards. WARNING: Do not touch or damage the track of the target of the engine speed sensor (14). Peg the crankshaft, using tool [3]. Check the position of the tensioner roller (the alignment of the marks «f»...
Page 131 CHECKING THE VALVE TIMING Engine: 9HX Tools. [1] Flywheel setting peg : (-).0194.C [2] Camshaft setting peg : (-).0194.B [3] Crankshaft setting peg : (-).0194.A IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions. Checking the timing.
Page 132 CHECKING THE VALVE TIMING Engine: 9HX Move aside the harness (6). Remove: - The engine support (7). - The screw (8). - The accessories drive pulley (9). - The lower timing cover (10). - The upper timing cover (11). - The tool [1]. Refit the screw (8).
Page 133 CHECKING THE VALVE TIMING Engine: 9HX Note: The index «c» of the dynamic tensioner roller should be centred in the interval «d». Check the correct positioning of the index «c». If it is not correct, repeat the operation to tension the timing belt (see corresponding operation) . Remove tools [2] and [3].
Page 134 CHECKING AND SETTING THE VALVE TIMING Engine: 9HX Tools. [1] Flywheel setting peg : (-).0194.C [2] Camshaft setting peg : (-).0194.B [3] Crankshaft setting peg : (-).0194.A IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions. Checking the timing.
Page 135 CHECKING AND SETTING THE VALVE TIMING Engine: 9HX Move aside the harness (6). Remove: - The engine support (7). - The screw (8). - The accessories drive pulley (9). - The lower timing cover (10). - The upper timing cover (11). - The tool [1].
Page 136 CHECKING AND SETTING THE VALVE TIMING Engine: 9HX Checks. ESSENTIAL: Just prior to refitting, proceed to the checks as below. Check: - That the rollers and the coolant pump pulley turn freely (without play and without tight spot) . - That there are no signs of oil leaks (at the crankshaft and camshaft seals) . - That there are no leaks of coolant fluid (at the coolant pump) .
Page 137 CHECKING AND SETTING THE VALVE TIMING Engine: 9HX Adjusting the timing belt tension. Act on the tensioner roller (19) to align the marks «f» and «g», avoiding detensioning the timing belt, using an allen spanner at «c». Should this fail, repeat the operation to tension the timing belt. Hold the tensioner roller (19).
Page 138 CHECKING AND SETTING THE VALVE TIMING Engine: 9HX ESSENTIAL: Should it not be possible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm. If it is more, repeat the operation to position the timing belt (see corresponding operation) . Remove tools [2] and [3].
Page 139 CHECKING THE OIL PRESSURE Petrol Diesel Engines TU1JP TU3JP ET3J4 DV4TD DV4TED4 DV6ATED4 JP4/JP4S Temperature (°C) 90° 80° Pressure (bars) 1000 Pressure (bars) 2000 Pressure (bars) Pressure (bars) 4000 Tools (Toolkit 4103) 2279-T.Bis 4103-T (-).1503.J 7001-T NOTE: The oil pressure should be checked with the engine hot, after the oil level has been checked.
Page 140 VALVE CLEARANCE SETTINGS 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 Adjust Rocking Adjust fully TU1JP open 0,20 mm ± 0,05 0,40 mm ±...
Page 141 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 142 CLUTCH SPECIFICATIONS TU1JP TU3JP TU5JP4S TU5JP4 DV4TD Engine type BVM (*) BVM/BVMP (**) BVM/BVMP (**) BVM (*) BVM/BVMP (**) Gearbox MA 5/S MA 5 N/L MA 5 S/L MA 5 S MA 5/0 Make VALEO Mechanism/type 180 CP0 3400 200 P 3900 200 CPX 3850 200 P 3900 Clutch disc...
Page 143 CLUTCH SPECIFICATIONS C3 - C3 PLURIEL TU1JP TU3JP ET3J4 TU5JP4 DV4TD DV4TED4 DV6ATED4 Engine type Gearbox MA/5 MA/5S MAP MA/5N MA/5O BE4/5L BE4R/5L Make VALEO SACHS 200 MF Mechanism/type 180 CPO 3400 200 P 3900 230 P 4700 235 P 4800 3850 Clutch disc 11 R 10 X...
Page 144 C2 - C3 - C3 PLURIEL CLUTCH SPECIFICATIONS NOTE: All the clutches are «push» type with hydraulic control. Description. The declutch control has a declutch fork mounted on a ball-joint. (1) The ball-joint is screwed into the clutch casing (2) Declutch fork...
Page 145 SPECIAL FEATURES: CLUTCH TIGHTENING TORQUES Clutch Screws for clutch plate / flywheel 2 ± 0,2 Screw for gasket plate at flywheel end / crankshaft 6,7 ± 0,6 (TU and ET3 engines) Flywheel / crankshaft (DV engine) Pre-tightening 1,7 ± 0,2 Angular tightening 70°...
Page 146 C2 - C3 - C3 PLURIEL HYDRAULIC CLUTCH CONTROL: CHECKS AND ADJUSTMENTS Bleeding the hydraulic clutch control IMPERATIVE: Use only new brake brake fluid that is not emulsified, avoid any ingress of impurities into the hydraulic circuit. IMPERATIVE: Do not use automatic bleeding equipment (risk of the brake fluid emulsifying in the hydraulic circuit) .
Page 147 C2 - C3 - C3 PLURIEL HYDRAULIC CLUTCH CONTROL: CHECKS AND ADJUSTMENTS Bleeding the hydraulic clutch control Action the clutch pedal manually through its full travel: 7 times rapidly down and up. Allow the clutch pedal to come back up to its high position.
Page 148 MA MANUAL GEARBOX SPECIFICATIONS Vehicle Engine Gearbox type Sequence Torque ratio Drive ratio TU1JP MA/5S (1) 20 CQ 12 16x65 MA/5N (2) 20 CQ 13 21x18 TU3JP MA/5L (4) 20 CQ 10 14x60 MA/5S (1) MAP (5) 20 CP 64 16x63 TU5JP4 MA/5S (1)
Page 149 MA MANUAL GEARBOX SPECIFICATIONS Vehicle Engine Gearbox type Sequence Torque ratio Drive ratio MA/5N (2) 20 CQ 08 14x60 TU1A MA/5N (2) et (6) 20 CQ 09 16x63 20 CQ 08 14x60 MA/5N (2) TU1JP 20 CQ 11 13x61 21x18 MA/5N (2) et (6) 20 CQ 09 13x63...
Page 150 BE4 MANUAL GEARBOX SPECIFICATIONS Vehicle Engine Gearbox type Sequence Torque ratio Drive ratio 20 DM 25 17x61 DV4TED4 BE4/5 None 20 DM 26 19x77 BE4/5N 20 DM 44 17x76 22x19 DV6ATED4 BE4/5L 20 DM 84 17x61 None...
Page 151 AL4 AUTOMATIC GEARBOX SPECIFICATIONS Vehicle Engine Gearbox type Sequence Torque ratio Descent ratio 20 TP 65 TU3JP 23x73 52x67 20 TP 75...
Page 152 C2 - C3 - C3 PLURIEL MA/5 GEARBOX: TIGHTENING TORQUES Tightening torques (m.daN). Ref. Description Number of screws Tightening Bearing retaining clip 1,8 ± 0,2 Intermediate plate 5 ± 0,5 # # RPO 9784 Gearbox casing 1,9 ± 0,2 RPO 9786 # # Clutch bearing guide screw 0,6 ±...
Page 153 C2 - C3 - C3 PLURIEL MA/5 GEARBOX: TIGHTENING TORQUES Tightening torques (m.daN). Ref. Description Number of screws Tightening 5th gear cover fixing screw 2,2 ± 0,2 Reverse gear switch 2,5 ± 0,5 Drain plug 3,3 ± 0,3 Top-up plug 3,3 ±...
Page 154 C2 - C3 RECOMMENDATIONS - PRECAUTIONS: MA PILOTED MANUAL GEARBOX Safety requirements ESSENTIAL: Given the special features of the MA type piloted IMPERATIVE: When initialising the clutch actuator and/or manual gearbox, observe the requirements detailed below. gearbox actuator, do not allow any person to walk or stand in front of the vehicle.
Page 155 RECOMMENDATIONS - PRECAUTIONS: MA PILOTED MANUAL GEARBOX C2 - C3 Operations on electrical components: Towing. Do not disconnect: - The battery when the engine is running. Conditions for towing. - The ECU with the ignition switched on. - The clutch and gearbox actuators with the ignition switched on.
Page 156 C2 - C3 RECOMMENDATIONS - PRECAUTIONS: MA PILOTED MANUAL GEARBOX Engaging of «N», using a diagnostic tool. Engaging of «N», without using a diagnostic tool. Preliminary operations: In this configuration, the gearbox actuator is blocked, gear engaged. - Battery voltage higher than 12.5 volts.
Page 157 C2 - C3 RECOMMENDATIONS - PRECAUTIONS: MA PILOTED MANUAL GEARBOX Engaging of «N», without using a diagnostic tool (continued). Preliminary operation: - Disconnect the battery negative terminal. - Remove the air filter. - Use a 22 mm spanner. Use the spanner to lift the gear engagement lever the maximum possible until the axis «A»...
Page 158 C2 - C3 MA PILOTED MANUAL GEARBOX: TIGHTENING TORQUES Tightening torques (m.daN). Ref. Description Number of screws Tightening Vis de Bearing retaining clip 1,8 ± 0,2 Intermediate plate 5 ± 0,5 Gearbox casing 1,9 ± 0,2 Clutch bearing guide screw 0,6 ±...
Page 159 C2 - C3 MA PILOTED MANUAL GEARBOX: TIGHTENING TORQUES Tightening torques (m.daN). Ref. Description Number of screws Tightening 5th gear cover fixing screw 2,2 ± 0,2 Gearbox input speed sensor 0,8 ± 0,2 Reverse gear switch 2,5 ± 0,5 Drain plug 3,3 ±...
Page 160 BE4/5 ENHANCED TRACTION GEARBOX: TIGHTENING TORQUES Tightening torques (m.daN). Ref. Description Number of screws Tightening Bearing guide 1,25 ± 0,2 Clutch housing 1,3 ± 0,2 Primary shaft nut 7,25 ± 0,7 Secondary shaft nut 6,5 ± 0,6 Clip retaining screw 1,5 ±...
Page 161 BE4/5 ENHANCED TRACTION GEARBOX: TIGHTENING TORQUES Tightening torques (m.daN). Ref. Description Number of screws Tightening Differential housing 5 ± 0,5 Breather 1,7 ± 0,2 Gearbox rear casing screw 1,25 ± 0,2 Top-up plug 2,2 ± 0,2 Differential housing screw 1,25 ± 0,2 Drain plug 3,5 ±...
Page 162 BE4/5 GEARBOX: TIGHTENING TORQUES Tightening torques (m.daN). Ref. Description Number of screws Tightening Air vent hole 1,5 ± 0,2 Reverse gear rocker shaft fixing nut 4,5 ± 0,2 Differential housing fixing nut 1,5 ± 0,2 Differential housing screw Ø 10 5 ±...
Page 163 BE4/5 GEARBOX: TIGHTENING TORQUES Tightening torques (m.daN) Ref. Description Number of screws Tightening Fork shaft stop screw 1,5 ± 0,2 Differential gearwheel screw 7 ± 0,5 Bearing retaining screw 1,5 ± 0,2 Secondary shaft nut 6,5 ± 0,5 Primary shaft nut 7,3 ±...
Page 164 BE4/5 GEARBOX: TIGHTENING TORQUES Tightening torques (m.daN). Ref. Description Number of screws Tightening Gear control support fixing screw 1,5 ± 0,2 Bearing guide screw 1,25 ± 0,2 Speedometer housing fixing screw 1,5 ± 0,2 Gearbox support fixing screw Ø 10 5,5 ±...
Page 165 C2 - C3 - C3 PLURIEL MA/5 GEARBOX CONTROLS (1) Gear control lever (2) Gear engagement control cable (*) (3) Gear selection control cable (*) (*) The two cables cannot be separated. B2CP3HXD...
Page 166 C2 - C3 - C3 PLURIEL CHECKS AND ADJUSTMENTS: MA/5 GEARBOX CONTROLS (4) Gear engagement ball-joint Ø 10 mm (5) Gear selection ball-joint Ø 10 mm B2CP3HYC Length D Length C Length D Length C Gear engagement control cable 1040 mm...
Page 167 C2 - C3 - C3 PLURIEL CHECKS AND ADJUSTMENTS: MA/5 GEARBOX CONTROLS Adjustment. WARNING: Do not use any tool to detach the ball-joints. The gear selection control and gear engagement control cables cannot be adjusted. B2CP3J0D To unlock the ball-joint, press at «a» then pull the ball-joint upwards.
Page 168: Be4/5 Gearbox Controls
BE4/5 GEARBOX CONTROLS (1) Gear control lever (2) Gear engagement control cable (*) (3) Gear selection control cable (*) (*) The two cables cannot be separated. B2CP3J3D...
Page 169 CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS (4) Gear engagement ball-joint Ø 10 mm (5) Gear selection ball-joint Ø 10 mm B2CP3J4C Length A Length B Gear engagement control cable 907 mm 645 mm Length D Length C Gear engagement control cable 965 mm 610 mm B2CP3J5D...
Page 170 CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS Adjustment. The gear selection control and gear engagement control cables cannot be adjusted. To release the ball-joint, press at «b» then pull the ball-joint upwards. To release sleeve stops: - Press on the tabs of the clip (6) at «a». - Disengage the sleeve stops from their supports.
Page 171 RECOMMENDATIONS - PRECAUTIONS: AL4 AUTOMATIC GEARBOX PRECAUTIONS TO BE TAKEN. Towing. Repairs on electrical components. The front of the vehicle must be raised in order to be towed. If the front of the vehicle cannot be raised. Do not disconnect: - The battery when the engine is running.
Page 172 RECOMMENDATIONS - PRECAUTIONS: AL4 AUTOMATIC GEARBOX PRECAUTIONS TO BE TAKEN. Repairs on mechanical components. Modification of the oil usage counter value. Never place the gearbox on the ground without protection. Exchanging the gearbox ECU: In order to avoid breaking the input shaft ring, it is imperative that - Note down the gearbox counter value.
Page 173 RECOMMENDATIONS - PRECAUTIONS: AL4 AUTOMATIC GEARBOX Procedure to be followed prior to carrying out repairs on AL4 autoactive gearbox Oil level (see corresponding operation) . If a gearbox malfunction occurs, there are two possible configurations depending on the seriousness of the fault: - Gearbox in back-up mode with a replacement programme of (the fault An excessive oil level can result in the following consequences: values are taken in substitution) .
Page 174 RECOMMENDATIONS - PRECAUTIONS: AL4 AUTOMATIC GEARBOX Procedure for initialising the automatic gearbox ECU Downloading. Updating the value of the oil usage counter. Updating the gearbox ECU by downloading: - Follow the procedure using the diagnostic tool. Using PROXIA. Access to reading and recording of the oil counter is via the menu: The downloading operation enables the automatic gearbox to be updated, or adapted to an evolution of the engine ECU.
Page 175 AL4 AUTOMATIC GEARBOX: TIGHTENING TORQUES Tightening torques (m.daN). (1) Oil flow modulation electrovalve fixing : 1 ± 0,2 (2) Heat exchanger fixing : 5 ± 1 (3) Output speed sensor fixing : 1 ± 0,2 (4) Output speed sensor fixing : 1 ±...
Page 176 AL4 AUTOMATIC GEARBOX: TIGHTENING TORQUES Tightening torques (m.daN). (8) Fixing of converter on diaphragm Pre-tightening : 1 ± 0,1 Tightening : 3 ± 0,3 (9) Plug fixing : 0,8 ± 0,2 (10) Gearbox fixing on engine : 5,2 ± 1 B2CP3EED...
Page 177 AL4 AUTOMATIC GEARBOX: TIGHTENING TORQUES Tightening torques (m.daN). A: EW7 and EW10 engines Hydraulic block fixing. Centre the hydraulic block, using screws (11) and (12). Pre-tighten (no strict order) : 0,9. Slacken : All 7 screws. Tighten (respect the order indicated) : 0,75.
Page 178: Al4 Gearbox Controls
AL4 GEARBOX CONTROLS In passenger compartment. The gear selector is guided by the shape of the stepped gate and by a retaining spring which pulls it to the left hand side. The gear selector control has 5 positions. Position «P»: Park (locking and immobilisation of the vehicle) . Position «R»: Reverse gear.
Page 179 AL4 GEARBOX CONTROLS In passenger compartment (continued). The information is transmitted to the gearbox ECU. NOTE: The vehicle is equipped with the «shift loc»: you have to switch on the ignition and press the brake pedal to unlock the selector lever from position «P». Two switches placed on the gear control gate permit the driver to choose one of the following three driving programmes: - Normal programme: Operates as the default programme (eco law, autoadaptive mode) .
Page 180 AL4 GEARBOX CONTROLS Gearbox end. The automatic gearbox is controlled by a cable. «c» or «d» Push-button. (1) Control lever with ball-joint (2) Automatic adjustment (pull out the button to adjust the control, push it in to lock the adjustment of the control) (3) Sleeve stop (4) Selection control locking clip (5) on the sleeve stop (3) B2CP3H8C...
Page 181 AL4 GEARBOX CONTROLS (SHIFT LOCK) SHIFT LOCK. NOTE: The «shift lock» is a system that locks the gear selection lever in position «P». Unlocking the «SHIFT LOCK» (normal operation) . - Switch on the ignition. - Press the brake pedal and keep it pressed. - Move the gear selection lever out of position «P».
Page 182 DRAINING / FILLING / TOP-UP: AL4 GEARBOX Tools. [1] Filling cylinder : (-).0341 Draining. IMPERATIVE: The gearbox should be drained when the oil is warm (at least 60°C) , to eliminate the impurities in suspension in the oil. NOTE: Draining is partial, the converter cannot be completely emptied. Remove the drain plug (1).
Page 183 DRAINING / FILLING / TOP-UP: AL4 GEARBOX Checking the oil level. Prior conditions: - Vehicle in horizontal position. - Check gearbox is not in back-up mode. - Remove the oil filler cap (2). - Add 0.5 litres extra oil into the gearbox. - Foot on the brake, change through all the gears.
Page 184 DRAINING / FILLING / TOP-UP: AL4 GEARBOX Thread of oil then "drip-drip". Refit the plug (3). Tighten to 2,4± 0,2 m.daN. "Drip-drip" or nothing. Refit the oil level plug (3). Stop the engine. Add 0.5 litres extra oil into the gearbox. Repeat the oil level procedure.
Page 185 (-) 0338 C 1,8 ± 0,1 32,5 ± 2,5 TU3JP (-) 0338 (-) 0338 J1 (-) 0338 H1 + (-) 0338 J3 + (-) 0338 H3 Tightening torque (m.daN) for wheel bolts: C2 C3 C3 PLURIEL = 9 ± 1.
Page 186 CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT C2 - C3 Engine: DV4TD Tools. [1] Ø 10 mm low pressure connector : 4215-T [2] Pressure gauge for testing boost pressure : 4073-T.A Toolkit 4073-T IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines.
Page 187 CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT Engine: DV4ATED4 Tools. [1] Ø 10 mm low pressure connector : 4215-T [2] Pressure gauge for testing boost pressure : 4073-T.A Toolkit 4073-T IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines.
Page 188 CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT Engine: DV6ATED4 Tools. [1] Ø 10 mm low pressure connector : 4215-T [2] Pressure gauge for testing boost pressure : 4073-T.A Toolkit 4073-T IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines.
Page 189 CHECKS: TURBO PRESSURE C2 - C3 Engine: DV4TD Tools. [1] Pressure gauge for checking boost pressure : 4073-T.A [2] Sleeve for checking boost pressure : (-).0171.F Checks. IMPERATIVE: Respect the following test conditions: - Engine at operating temperature. - Vehicle in running order.
Page 190 CHECKS: TURBO PRESSURE Engine: DV4TED4 Tools. [1] Pressure gauge for checking boost pressure : 4073-T.A [2] Sleeve for checking boost pressure : (-).0171.F Checks. IMPERATIVE: Respect the following test conditions: - Engine at operating temperature. - Vehicle in running order. - Engine under full load.
Page 191 CHECKS: TURBO PRESSURE Engine: DV6ATED4 IMPERATIVE: Respect the safety and cleanliness requirements. Preparation. IMPERATIVE: Respect the following test conditions: - Engine at operating temperature. - Vehicle in running order. - Engine under full load. Connect the diagnostic tool to the vehicle's diagnostic socket, carry out parameter measures. Mode of operation.
Page 192 CHECKING THE AIR SUPPLY CIRCUIT C2 - C3 Engine: DV4TED4 Tools. [1] Manual pressure-vacuum pump : FACOM DA 16 Vacuum pump: - Connect the tool [1] onto the vacuum pump (1). - Start the engine. - Wait 30 seconds. - The vacuum value should be 0.9 ± 0.1 bar at idle.
Page 193 CHECKING THE AIR SUPPLY CIRCUIT Engine: DV6ATED4 Tools. [1] Manual pressure-vacuum pump : FACOM DA 16 Checks. Vacuum pump. Connect the tool [1] onto the vacuum pump (1). Start the engine. B1HP1UGC The vacuum value should be 0,9 ± 0,1 bar at idling speed (after 30 seconds of running) . NOTE: The EGR valve is not linked to the air supply circuit.
Page 194 CHECKS: EXHAUST GASES RECYCLING CIRCUIT C2 - C3 Engine: DV4TD Tools. [1] Manual pressure-vacuum pump : FACOM DA 16 IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection (HDi) engines. EGR valve. Connect tool [1] on the capsule take-off (2).
Page 195 SPARKING PLUGS Vehicles Engine Electrode Electrode Electrode Tightening BOSCH EYQUEM CHAMPION Models type gap setting gap setting gap setting torque 1.1i FR 7 DE RFN 58 LZ RC 8 YLC 1.4i 1.6i 16V FR 7 ME 0,9 ± 0,1 RFN 58 HZ 1.1i RFN 58 LZ RC 8 YLC...
Page 196 AXLE GEOMETRY Conditions for checking and adjusting Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point (see corresponding operation) . Vehicle heights at reference height E1APOBZD Front height Rear height H1 = R1 – L1 H2 = R2 + L2 H1 = Measurement between the measuring zone underneath the front H2 = Measurement between the measuring zone underneath the rear...
Page 197: Axle Geometry
AXLE GEOMETRY B3CP07SD Measuring front height Measuring rear height [1] Gauge for measuring the wheel radius, 4 bolts, tool 8006-T Z1 = Measuring zone underneath the front subframe. Z2 = Measuring zone underneath the rear sill. Measure the radius of the front wheel R1 - Calculate dimension H1 = R1-L1 Measure the radius of the rear wheel R2 - Calculate dimension H2 = R2+L2 Except CRD vehicles (*) Except CRD vehicles (*) TU1JP/3JP - DV4TD...
Page 198 AXLE GEOMETRY Front axle Rear axle Dissymmetry of lower castor at 0° 30'. Dissymmetry of lower camber at 0° 18. Dissymmetry of lower camber at 0° 18'. Distribute symmetrically, LH / RH wheel, the total tracking value. All types (except CRD vehicles) TU1JP/3JP - DV4TD TU1JP/3JP - DV4TD Castor...
Page 199 AXLE GEOMETRY Front axle Rear axle Dissymmetry of lower castor at 0° 30'. Dissymmetry of lower camber at 0° 18. Dissymmetry of lower camber at 0° 18'. Distribute symmetrically, LH / RH wheel, the total tracking value. CRD vehicles TU1JP/3JP - DV4TD TU1JP/3JP - DV4TD Castor Camber...
Page 200: Front Axle
FRONT AXLE Tightening torques (m.daN). (1) Nut fixing suspension leg on body : 6,5 ± 0,6 (2) Damper (3) Anti-roll bar link rod upper ball-joint : 3,2 ± 0,3 (4) Suspension leg pivot : 5,4 ± 0,5 (5) Anti-roll bar link rod lower ball-joint : 3,2 ±...
Page 201: Rear Axle
REAR AXLE Tightening torques (m.daN) (25) Rear axle fixing screw : 10 ± 1 (26) Anti-roll bar (27) Rear axle crossmember (28) Rear suspension arm silentblock yoke (29) Rear suspension arm silentblock (30) Yoke / suspension arm fixing screw : 7 ± 0,5 (31) Rear suspension arm (32) Stub axle bearing nut : 20 ±...
Page 202 SUSPENSION Front axle (1) Nut fixing suspension leg on body : 6,5 ± 0,6 (2) Damper (16) Cup (17) Damper nut : 6,5 ± 0,6 (18) Damper cup (19) Ball bearing (20) Spring thrust cup (21) Travel stop cup (22) Suspension spring (23) Damper rod protector (24) Travel stop B3BP180D...
Page 203 FEATURES OF ELECTRIC POWER STEERING Steering column B3EP13GD B3EP13HC Tightening torques (m.daN). Identification Identified by the colour of the ring at «a». (1) Steering wheel fixing : 2 ± 0,3 Left hand drive : BLUE ring. (2) Steering column fixing on support : 2,2 ±...
Page 204 FEATURES OF ELECTRIC POWER STEERING Steering mechanism Tightening torques (m.daN) (4) Ball-joint fixing on pivot : 3,5 ± 0,3 (5) Steering rod lock-nut : 5 ± 0,5 (8) Threaded washer (9) Stud : 0,8 ± 0,1 (10) Flat washers (11) Fixing of mechanism on subframe : 8 ±...
Page 205 FEATURES OF ELECTRIC POWER STEERING Steering assistance Electric power steering ECU B3EP13KC B3EP13LC Only one ECU version, whatever the engine-type. Supplier: KOYO. The electric power steering ECU is linked to the following connectors: The steering assistance is provided by the assistance motor (12), - (6) Assistance motor supply.
Page 206 SPECIAL FEATURES: STEERING Centring the steering rack Preliminary operation. Raise and support the vehicle on a two-column lift. Remove, on the RH side of the steering rack: - Clip (1). - Clip (2). Release the steering rack protection gaiter. Setting. Move the steering to full left hand lock.
Page 207 AXLE GEOMETRY Conditions for checking and adjusting Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point (see corresponding operation) . Vehicle heights at reference height E1AP09MD Front height Rear height H1 = R1 - L1 H1 = R1 - L1 H1 = Measurement between the measuring zone underneath the front H2 = Measurement between the measuring zone underneath the rear...
Page 208 AXLE GEOMETRY Checks at reference height B3CP07SD Measuring front height Measuring rear height [1] Gauge for measuring the wheel radius, 4 bolts, tool 4003-T or 8006-T (according to version) . Z1 = Measuring zone underneath the front subframe. Z2 = Measuring zone underneath the rear sill.. Measure the radius of the front wheel R1 - Calculate dimension H1 = R1–L1 Measure the radius of the rear wheel R2 - Calculate dimension H2 = R2+L2 All types except CRD (*)
Page 209 AXLE GEOMETRY Dissymmetry of lower castor at 0° 30'. Dissymmetry of lower camber at 0° 18'. (*) CRD = Difficult road conditions. ESSENTIAL: Distribute symmetrically, LH / RH wheel, the total tracking value. NOTE A < B = Positive figure: TOE-IN A >...
Page 210 AXLE GEOMETRY All types except: CRD (*), Raised suspension, Administration vehicle, C3 version XTR Front axle Wheel Castor Camber Pivot angle Engines Tracking dimensions (± 0°18') (± 0°30') (± 0°30') (in inches) Adjustable Non adjustable - 2 ± 1 TU1JP TU3JP BV MA (except Exclusive) 0°...
Page 211 AXLE GEOMETRY All types except: CRD (*), Raised suspension, Administration vehicle, C3 version XTR Front axle Wheel Castor Camber Pivot angle Tracking dimensions (± 0°18') (± 0°30') (± 0°30') (in inches) Adjustable Non adjustable - 2 ± 1 0° - 0°19' ± 0°10' 3°...
Page 212 C3 PLURIEL AXLE GEOMETRY Conditions for checking and adjusting Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point (see corresponding operation) . Vehicle heights at reference height E1AP0AUD Front height Rear height H1 = R1 - L1 H2 = R2 + L2 H1 = Measurement between the measuring zone underneath the front H2 = Measurement between the measuring zone underneath the rear sill...
Page 213 AXLE GEOMETRY C3 PLURIEL Checks at reference height B3CP07SD Measuring front height Measuring rear height [1] Gauge for measuring the wheel radius, 4 bolts, tool 4003-T Z1 = Measuring zone underneath the front subframe. Z2 = Measuring zone underneath the rear sill. Measure the radius of the front wheel R1 - Calculate dimension H1 = R1-L1 Measure the radius of the rear wheel R2 - Calculate dimension H2 = R2+L2 Value at reference...
Page 214 C3 PLURIEL AXLE GEOMETRY Front axle Rear axle Dissymmetry of lower castor at 0° 30'. Dissymmetry of lower camber at 0° 18' Dissymmetry of lower camber at 0° 18. Distribute symmetrically, LH / RH wheel, the total tracking value. All types Castor Camber Pivot angle...
Page 215 C3 - C3 PLURIEL FRONT AXLE Tightening torques (m.daN). (1) Nut fixing suspension leg on body : 6,5 ± 0,6 (2) Suspension leg (3) Anti-roll bar link rod upper ball-joint : 3,2 ± 0,3 (4) Suspension leg pivot : 5,4 ± 0,5 (5) Anti-roll bar link rod lower ball-joint : 3,2 ±...
Page 216 C3 - C3 PLURIEL REAR AXLE Tightening torques (m.daN). (1) Rear axle fixing screw : 10 ± 1 (2) Anti-roll bar (3) Rear axle crossmember (4) Rear suspension arm rubber mounting yoke (5) Rear suspension arm rubber mounting (6) Yoke / suspension arm fixing screw : 7,6 ±...
Page 217 C3 - C3 PLURIEL SUSPENSION Front axle (1) Nut fixing suspension leg on body : 6,5 ± 0,6 (2) Damper (3) Anti-roll bar link rod upper ball-joint : 3,2 ± 0,3 (4) Suspension leg pivot : 5,4 ± 0,5 (5) Anti-roll bar link rod lower ball-joint : 3,2 ±...
Page 218 C3 - C3 PLURIEL SUSPENSION Front axle (1) Nut fixing suspension leg on body : 6,5 ± 0,6 (2) Damper (16) Cup (17) Damper nut : 6,5 ± 0,6 (18) Damper cup (19) Ball bearing (20) Spring thrust cup (21) Travel stop cup (22) Suspension spring (23) Damper rod protector (24) Travel stop...
Page 219 C3 - C3 PLURIEL SUSPENSION Rear axle (25) Rear axle fixing screw : 10 ± 1 (26) Anti-roll bar (27) Rear axle crossmember (28) Rear suspension arm silentblock mounting yoke (29) Rear suspension arm silentblock (30) Suspension arm fixing screw on yoke : 7,6 ±...
Page 220 FEATURES OF ELECTRIC POWER STEERING C3 - C3 PLURIEL Steering column B3EP13GD B3EP13HC Tightening torques (m.daN). Identification. (1) Steering wheel fixing : 2 ± 0,3 Identified by the colour of the ring at «a». (2) Steering column fixing on support : 2,2 ±...
Page 221 C3 - C3 PLURIEL FEATURES OF ELECTRIC POWER STEERING Engines: HFX - KFV - KFU - NFU - 8HX - 8HW - 8HV - 8HY Steering mechanism Tightening torques (m.daN). (4) Ball-joint fixing on pivot : 3,5 ± 0,3 (5) Steering rod lock-nut : 5 ±...
Page 222 C3 - C3 PLURIEL FEATURES OF ELECTRIC POWER STEERING Steering assistance B3EP13KC B3EP13LC Electric power-assisted steering ECU. Supplier: KOYO. Only one ECU version, whatever the engine-type. The steering assistance is provided by the assistance motor (12), The electric power steering ECU is linked to the following connectors: controlled by the ECU.
Page 223 C3 - C3 PLURIEL SPECIAL FEATURES: STEERING Centring the steering rack Preliminary operation. Raise and support the vehicle on a two-column lift. Remove, on the RH side of the steering rack: - Clip (1). - Clip (2). Release the steering rack protection gaiter. Setting.
Page 224 BRAKE SPECIFICATIONS (WITHOUT ABS) TU1JP TU3JP DV4TD Master cylinder 20,6 Master vac 203,2 Ø mm Caliper makes/pistons LUCAS.TRW-/-C 48/13-/-48 Disc Plain Disc thickness/minimum thickness 13/11 Maximum run-out (mm) 0,05 Difference in max. thickness on same 0,01 circumference (mm) Brake pad supplier/grade TEXTAR-/-T 4144 Original thickness/minimum thickness 13/3...
Page 225 BRAKE SPECIFICATIONS (WITH ABS) DV4TD TU5JP4 TU1JP TU3JP TU5JP4S Master cylinder 22,2 (*) Master vac 228,6 LUCAS .TRW LUCAS .TRW-/- Caliper makes/ Ø LUCAS .TRW-/-C 48/13-/-48 C 54/22-/-54 C 48/13-/-48 pistons Plain Disc Ventilated Disc thickness/minimum thickness 13/11 22/20 13/11 Brake pad supplier/grade TEXTAR-/-T 4144 Ø...
Page 226 BRAKE SPECIFICATIONS Braking circuit without ABS - REF (drum brakes at the rear) Braking system specifications - Braking circuit at «X». - Front brakes with ventilated discs (*). - Rear brakes with eitther drums or discs (*). - Handbrake lever controlling cables acting on the rear wheels.
Page 227 BRAKE SPECIFICATIONS Braking circuit with ABS - REF (drum brakes at the rear) B3FP7C8D...
Page 228 BRAKE SPECIFICATIONS Braking circuit with ABS - REF (disc brakes at the rear) B3FP7C9D...
Page 229: Brake Specifications
BRAKE SPECIFICATIONS Brake pedal gear Front brakes Rear brakes B3FP166D B3FP164C B3FP165C Tightening torques (m.daN). (14) Rear caliper fixing on arm : 5,3 ± 0,5 (16) Servo fixing : 2,2 ± 0,3 (12) Yoke fixing on caliper : 10,5 ± 1 (15) Yoke fixing on caliper : 3,8 ±...
Page 230 HANDBRAKE (adjustment) Adjustment. Lift and chock the vehicle. Remove: - The rear cover (8). - The nut (9). - The handbrake trim (6). - The gear lever gaiter (5). - The front cover (3). - The screws (1). Disconnect the connectors of the following components: - The cigar lighter (2).
Page 231 HANDBRAKE (adjustment) Adjustment (continued). A: Drum brakes B: Disc brakes (10) Nut for adjusting cable tensions Remove: - The rear wheels. - The drums (according to version) . Release the handbrake. Use a gauge set to measure at «a» the travel of the lever from its stop.
Page 232 BLEEDING AND FILLING THE BRAKING SYSTEM Tools. [1] Generic bleeding apparatus : «LURO» or similar Bleeding, refilling. Draining. Drain the brake fluid reservoir (1) to the maximum (if necessary, use a clean syringe) . Disconnect the connector (4). Uncouple the pipe (2). Unscrew the shaft (3).
Page 233 BLEEDING AND FILLING THE BRAKING SYSTEM Bleeding, filling (continued). Bleeding the primary braking circuit. WARNING: The ABS should not be active during the bleeding operation. - Front brake caliper: Bleed screw (5). A: Rear brake caliper B: Rear brake drum Bleed screw (6).
Page 234 BLEEDING AND FILLING THE BRAKING SYSTEM 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. - Open the bleed screw, wait until the fluid is flowing out without air bubbles.
Page 235 BRAKE SPECIFICATIONS (WITHOUT ABS REF) ET3J4 DV4TD DV6ATED4 TU1JP TU3JP Engines KFU (*) Master cylinder 20,6 Ø Master vac 203,2 Caliper makes/ LUCAS/TRW LUCAS/TRW LUCAS/TRW LUCAS/TRW pistons C 48/13/48 C 54/22/54 C 48/13/48 C 54/22/54 Disc Plain Disc thickness/minimum thickness 13/11 13/11 Ø...
Page 236 BRAKE SPECIFICATIONS (WITH ABS REF) TU1JP TU3JP ET3J4 TU5JP4 TU5JP4S DV4TD DV4TED4 ATED4 Engines KFU (*) Master cylinder 22,2 (**) Ø Master vac 228,6 Caliper makes/ LUCAS/TRW LUCAS/TRW LUCAS/TRW LUCAS/TRW pistons C 48/13 48 C 54/22 54 C 48/13 48 C 54/22 54 Disc Plain...
Page 237 BRAKE SPECIFICATIONS Braking circuit without ABS - REF (drum brakes at the rear) Braking system specifications - Braking circuit at «X». - Front brakes with ventilated discs (*). - Rear brakes with eitther drums or discs (*). - Handbrake lever controlling cables acting on the rear wheels.
Page 238 BRAKE SPECIFICATIONS Braking circuit with ABS - REF (drum brakes at the rear) B3FP162D...
Page 239 BRAKE SPECIFICATIONS Braking circuit with ABS - REF (disc brakes at the rear) B3FP163D...
Page 240 C3 PLURIEL BRAKE SPECIFICATIONS (WITH AND WITHOUT ABS REF) With ABS REF Without ABS REF TU3JP DV4TD TU3JP TU5JP4 DV4TD Engines Master cylinder 20,6 22,2 (***) Ø Master vac 203,2 228,6 Caliper makes/pistons LUCAS/TRW C 54/22/54 Disc Ventilated Disc thickness/minimum thickness 22/20 Brake pad supplier/grade TEXTAR T 4144...
Page 241 BRAKE SPECIFICATIONS C3 PLURIEL Braking circuit without ABS - REF (drum brakes at the rear) Braking system specifications - Braking circuit at «X». - Front brakes with ventilated discs (*). - Rear brakes with eitther drums or discs (*). - Handbrake lever controlling cables acting on the rear wheels.
Page 242 C3 PLURIEL BRAKE SPECIFICATIONS Braking circuit with ABS - REF (drum brakes at the rear) B3FP7BTD...
Page 243 BRAKE SPECIFICATIONS C3 PLURIEL Braking circuit with ABS - REF (disc brakes at the rear) B3FPBUD...
Page 244 C3 - C3 PLURIEL BRAKE SPECIFICATIONS Brake pedal gear Front brakes Rear brakes B3FP166D B3FP164C B3FP165C Tightening torques (m.daN). (16) Servo fixing : 2,2 ± 0,3 (14) Rear caliper fixing on arm : 5,3 ± 0,5 (12) Yoke fixing on caliper : 10,5 ±...
Page 245 HANDBRAKE (adjustment) C3 - C3 PLURIEL Adjustment. Lift and chock the vehicle. Remove the access cover (1). (2) Nut for adjusting the tension of the handbrake cables WARNING: Check that the brake cables are correctly routed under the vehicle. Slacken the handbrake lever. Press gently on the brake pedal (then repeat the operation 3 times) .
Page 246 HANDBRAKE (adjustment) C3 - C3 PLURIEL Adjustment (continued). A: Drum brakes B: Disc brakes (2) Nut for adjusting cable tensions. Remove: - The rear wheels. - The drums (according to version) . Release the handbrake lever. Use a gauge set to measure at «a» the travel of the lever from its stop.
Page 247 BLEEDING AND FILLING THE BRAKING SYSTEM C3 - C3 PLURIEL Tools. [1] Generic bleeding apparatus : «LURO» or similar Bleeding, refilling. Draining. Drain the brake fluid reservoir (1) to the maximum (if necessary, use a clean syringe) . Disconnect the connector (4). Uncouple the pipe (2).
Page 248 C3 - C3 PLURIEL BLEEDING AND FILLING THE BRAKING SYSTEM (continued) Bleeding, filling (continued). Bleeding the primary braking circuit. WARNING: The ABS should not be active during the bleeding operation. - Front brake caliper: Bleed screw (5). A: Rear brake caliper B: Rear brake drum Bleed screw (6).
Page 249 BLEEDING AND FILLING THE BRAKING SYSTEM C3 - C3 PLURIEL 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. - Open the bleed screw, wait until the fluid is flowing out without air bubbles.
Page 250 AIR CONDITIONING R 134.a (HFC) Compressor Refrigerant Vehicle Engines Date Variable refill Oil quantity cc Oil reference Capacity All types EUROPE 500 ± 25 gr All types 600 ± 25 gr MERCOSUR SP 10 07/04 # SD 6 V 12 All types EUROPE 500 ±...
Page 251 C2 - C3 - C3 PLURIEL SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) «EUROCLIM» Compressor (MANULLI seal) Tools. Tool for removing-refitting air conditioning seals : FACOM (-).1702 IMPERATIVE: Removing-refitting the MANULLI seal: see corresponding operation. MANULLI seal C2 C3 : All engine-versions.
Page 252 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Pollen filter Note: The pollen filter is located in the engine compartment on the RH side. Removing. To remove: - Pull on the tab of the plastic cover (1) at «a». - Tilt the flap (2). Remove the pollen filter (3).
Page 253 C3 - C3 PLURIEL SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Pollen filter Note: The pollen filter is located in the engine compartment on the RH side. Removing. Remove: - The three screws (1). - The plastic cover (2). Tilt the flap (3). Remove the pollen filter (4).
Page 254 C2 - C3 - C3 PLURIEL SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Changing the filtering/drying cartridge Tools. [1] Charge station : (according to workshop equipment) [2] TORX adaptor : TORX 70 FACOM [3] Inertia extractor : 1671-T. Toolkit 4114-T [4] Endpiece Ø...
Page 255 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) C2 - C3 - C3 PLURIEL Changing the filtering/drying cartridge Refitting. Remove the new cartridge from its packaging. Do not expose the cartridge, the filter and seals to pollutants. Lightly oil the seals (compressor oil) .
Page 256 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Compressor lubricant ESSENTIAL: The compressor lubricant is extremely hygroscopic; always use FRESH oil. Checking the compressor oil level There are three specific cases: - 1/ Repairs to a system without leaks. - 2/ Slow leak. - 3/ Fast leak.
Page 257 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 258 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Tool EXXOTest Checks. Tool (flash équipement & matériel). Exxoclim : 2.4.2-1 Position the tool CLIM TEST II (depending on manufacturer's instructions). Mode d’emploi : Voir notice constructeur Preliminary operations. Close all the front air vents. Start the engine.
Page 259: Filtering And Drying Cartridge
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Setting the checking tool [1] to measurement mode. Operate the checking tool, press on button "j". Select the type of aircon fluid: R134.a or R12: - Press on button "l", validate by pressing on button "k". Select the type of aircon fluid: with filtering and drying cartridge, or calibrated aperture: - Press on button "l", validate by pressing on button "k".
Page 260 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Interpretation of the measurements. «m»: High pressure. «s»: Over-heating (SC). «n»: High temperature. «t»: Ambient air temperature. «p»: Under-cooling (SR). «u»: Blown air temperature. «q»: Low pressure. «v»: Humidity. «r»: Low temperature. «w»: Temperature T3.
Page 261 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Interpretation of the measurements. «m»: High pressure. «s»: Over-heating (SC). «n»: High temperature. «t»: Ambient air temperature. «p»: Under-cooling (SR). «u»: Blown air temperature. «q»: Low pressure. «v»: Humidity. «r»: Low temperature. «w»: Temperature T3.
Page 262 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Interpretation of the diagnosis E5AP2FCD «x» Check satisfactory «y» Lack of aircon fluid in the aircon circuit «z» Excess aircon fluid in the aircon circuit «aa» Filtering and drying cartridge clogged «ab» Other problems (see table above)
Page 263 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table Principal problem Symptom Possible causes Aircon compressor clutch Lack of aircon fluid in the aircon circuit The clutch of the aircon compressor does not Aircon pressostat engage, or disengages suddenly Aircon evaporator sensor Electrical circuit (wiring, fuses, etc.) The aircon compressor does not turn...
Page 264 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table Principal problem Symptom Possible causes Incorrect adjustment of the aircon compressor clutch The clutch of the aircon compressor Aircon fluid quantity remains engaged Aircon compressor defective The aircon compressor makes an abnormal Lack of aircon fluid in the aircon circuit noise Aircon compressor valves defective...
Page 265 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table Principal problem Symptom Possible causes Aircon pressure reducer defective Low pressure and high pressure too high Duct clogged Low pressure too high and high pressure too low Aircon compressor seal defective Aircon evaporator sensor defective Low pressure too low and high pressure Aircon pressure reducer jammed...
Page 266 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table Principal problem Symptom Possible causes Low pressure normal and high pressure Presence of air in the aircon circuit too high Low pressure normal and high pression too Aircon pressostat defective Evaporator sensor defective Abnormal levels of pressure Low pressure too high and high pressure...
Page 267 AIR CONDITIONING SYSTEM R 134.a (1) High pressure valve (2) Low pressure valve (3) Pressostat (4) Filter Tightening torques (m.daN). : 0,6 : 0,6 : 0,6 : 0,6 : 0,6 : 0,7 C5HP19UP...
Page 268 AIR CONDITIONING SYSTEM R 134.a C3 - C3 PLURIEL (1) Low pressure valve (2) High pressure valve (3) Filter (4) Pressostat Tightening torques (m.daN). : 0,6 : 0,6 : 0,6 : 0,6 : 0,6 : 0,6 C5HP17SP...

This manual is also suitable for:

C3 pluriel C3 2005 c2 2005 c3 pluriel

CITROEN C2 Handbook

Axles - Suspension - Steering

C3, C3 Pluriel

Brake Specifications C3

Quick Links

CORRESPONDENCE TABLE FOR PETROL ENGINES

Summary of Contents for CITROEN C2

Page 3: C3 Pluriel

Page 5: Table Of Contents

Page 20: Specifications

Page 96: Checking And Setting The Valve Timing

Page 168: Be4/5 Gearbox Controls

Page 178: Al4 Gearbox Controls

Page 197: Axle Geometry

Page 200: Front Axle

Page 201: Rear Axle

Page 229: Brake Specifications

Page 259: Filtering And Drying Cartridge

This manual is also suitable for:

CITROEN C2 Handbook

Axles - Suspension - Steering

C3, C3 Pluriel

Brake Specifications C3

Quick Links

CORRESPONDENCE TABLE FOR PETROL ENGINES

Related Manuals for CITROEN C2

Summary of Contents for CITROEN C2

This manual is also suitable for:

Table of Contents