CITROEN C8 2005 Minivan Manuals

Manuals and User Guides for CITROEN C8 2005 Minivan. We have 1 CITROEN C8 2005 Minivan manual available for free PDF download: Service Manual

CITROEN C8 2005 Service Manual (356 pages)

Brand: CITROEN | Category: Automobile | Size: 7 MB

Correspondence Table for Petrol Engines
2
Сorrespondence Table for Diesel Engines
3
Very Important
4
Identification of Vehicles
5
Type Approval
6
Capacities (in Litres)
9
Draining Methods
9
Draining of the Engine Lubrication System by Gravity
9
Draining of the Engine Lubrication System by Suction
9
Petrol
10
Diesel
11
New Look Citroën C5
13
Evolutions (Year 2004)
13
Lubricants - Total Recommended Oils
13
Use of Oil Grade 10W40
14
Commercial Description for Energy Economy Oil
14
Engine Oil Norms
14
S.A.E. Norms - Table for Selection of Engine Oil Grade
14
API Norms
15
Classes and Grades of Total Recommended Engine Oils
16
Blended Oils for All Engines (Petrol, Diesel and Dual Fuel Petrol/Lpg)
16
Oils for Petrol, Diesel and Dual Fuel Petrol/Lpg Engines
16
Oils Specifically for Diesel Engines
16
Oil Usage Table
17
Blended Oils for All Engines, Supplied in Bulk
19
France
19
Europe
20
Oceania
26
Central and South America
27
South-East Asia
28
Middle East
30
Gearbox Oils
31
Power Steering Oils
32
Engine Coolant Fluid
32
Synthetic Brake Fluid
33
Hydraulic System
33
Screen Wash Fluid
34
Greasing
34
General Use
34
Maximum Permissible Oil Consumption for a Run-In Engine and Oil Level
35
An Engine Can be Considered RUN-IN after
35
Oil Consumption Depends on
35
Engine Oil Consumption
35
Engine Specifications
36
Engines: 6FZ-RFJ-RFN-3FZ-XFU-XFW
36
Engines: 9HZ-RHM-RHT-RHW-RHL-RHR-4HX-4HW
37
Сompression Ratio - Diesel Engines
38
Special Features: Tightening Torques
39
Engines: 6FZ - RFJ
40
Crankshaft
40
Cylinder Block
40
Flywheel/Clutch
41
Lubrication Circuit
42
Injection Circuit
42
Intermediate Engine Support
43
Upper RH Engine Support
43
Engines: RFN - 3FZ
43
Special Features: Power Unit Suspension
43
Table of Contents
45
Crankshaft Bearing Cap Cover (15)
45
Equipment on Cylinder Head
46
Engine: RFN
46
Engine: 3FZ
46
Engine: XFU
47
Lower RH Engine Support/Torque Reaction Rod
47
RH Engine Support
47
Pencil Type Ignition Coil
48
Valve Cover
48
Camshaft Bearing Cap Cover
48
Flywheel
49
Exhaust Manifold
49
Con Rod Caps
49
Crankshaft Bearing
50
Perform the Following Operations
50
Sump
51
Crankshaft Pinion/Pulley
51
Inlet Distributor (with New Seals)
51
Air Inlet Manifold
51
Camshaft Hubs/Pulleys
52
Cap and Guide Roller
52
Timing Belt Tensioner Roller/Plate for the Dynamic Tensioner Roller
52
Coolant/Oil Pump
52
Gearbox Suspension
53
RH Engine Support (Suspension)
53
Engine: XFW
53
Power Unit Suspension
53
Power Unit Suspension - Engine Support (Lower)
54
Crankshaft View
54
Bearing Cap Cover
55
Oil Sump
56
Cooling Circuit
57
Coolant Pump
57
Coolant Manifold
58
Cylinder Head Equipment
58
Camshaft Bearing Cap Cover (Right Hand Side)
59
Camshaft Bearing Cap Cover (Left Hand Side)
59
Valve Covers (Right Hand Side)
60
Valve Covers (Left Hand Side)
60
Pre-Tightening 1
61
Inlet Manifold
61
SPECIAL FEATURES: TIGHTENING TORQUES (M.dan) C8
61
Exhaust Manifold (Right/Left Hand Side)
62
Re-Tightening
62
Pre-Tightening 1 ± 0,1 2,5
62
- Inlet Distributor
  63
- Engine: 9HZ
  64
- Torque Reaction Rod
  64
- Upper LH Engine Support
  64
- Lower LH/RH Engine Support and RH Engine Support
  64
Slackening
65
- Diesel Injection Circuit
  68
- Engines: RHL - RHR
  69
- Engines: RHL RHR
  71
- Engines: RHM - RHT - RHW
  74
- Plug CHC M12X150-16 (X 1) /M15X150 (X 1 and 2)
  74
- Pulley Screw M14X150-70
  74
- Screws M7X100-20 (X 4)/M7X100-40 (X 2)/M12X150-81 (X10)/M16X10-16 (X4)
  74
- Engine Suspension (Identification)
  75
- Engine Suspension (Tightening Torques)
  76
- Power Steering Pump
  77
- Alternator
  77
- Air Conditioning Compressor
  78
- Accessories Support
  78
- Guide Roller
  79
- Engine: 4HX
  80
- Tightening Torques
  80
- Flywheel - Clutch
  83
- Plug CHC M12X150-16 (X 1)/M15X150 (X 2)
  85
- Screws M7X100-40 (X 2)/M7X100-20 (X 4)/M12X150-81 (X10)
  85
- Screws M7X100-20 (X8)/M9X100-45 (X4)/M8X125-60 (X8)
  86
- Special Features - Cylinder Head Tightening
  92
- Belt Tension/Seem Units Correspondence Table
  96
- Auxiliary Equipment Drive Belt
  97
- Engines: All Types Petrol and Diesel
  98
- Engine: 6FZ
  99
- Engine: RFJ
  100
- «Junior» T Extension
  100
- Removing
  100
- Refitting
  100
- Peg for Dynamic Tensioner Roller
  101
- Reduction Box FACOM S.230 (1/2" - 3/8" Square)
  103
- Ratchet Spanner FACOM (1/2" Square)
  103
- Dynamic Tensioner Compressure Lever
  104
- Tensioning/Dynamic Roller Compressure Lever
  106
- Peg for Dynamic Roller 4/2 MM
  106
- Dynamic Tensioner Roller Retaining Peg 4Mm
  108
- Without Air Conditioning
  109
- Peg 4 MM
  109
- Peg for Dynamic Roller
  111
- Dynamic Roller Compressure Lever
  111
- Сhecking and Setting the Valve Timing
  113
- Сhecking the Valve Timing
  114
- Camshaft/Crankshaft Setting Peg
  114
- Checking the Setting of the Timing
  114
- Tool for Moving and Locking the Tensioner Roller
  115
- Adaptor for Angular Tightening
  115
- Timing Belt Retaining Pin
  115
- Tensioning the Timing Belt
  118
- Camshaft Pinion Peg
  120
- Crankshaft Setting Peg
  120
- Engine Lifting Crossmember
  120
- Peg for Positioning the Dynamic Tensioner Roller
  127
- Checks
  133
- Fuel Pressure Take-Off Union
  143
- Belt Retaining Pin
  143
- Exhaust Camshaft Hubs Immobilising Tool
  143
- Inlet Camshaft Hubs Immobilising Tool
  143
- Setting the Valve Timing
  145
- Adjusting the Timing Belt Tension
  147
- Instrument for Measuring Belt Tension
  149
- Peg for Checking Camshaft Settings
  149
- Tool for Immobilising Exhaust Camshaft Hubs
  149
- Tool for Immobilising Inlet Camshaft Hubs
  149
- Flywheel Setting Peg
  157
- Double Flywheel Setting Peg
  168
- Kit of Plugs
  168
- Additional Operations
  170
- Adjusting the Camshaft Position Sensor
  170
- Sensor Re-Used
  170
- New Sensor
  170
- Flywheel Lock
  171
- Pulley Extractor
  171
- Pinion Centrer
  171
- Belt Clamp
  171
- Belt Compressure Spring
  178
- Set of Blocking Plugs
  178
- Checking the Setting of the Valve Timing
  178
- Engine Flywheel Peg/Lock/Tension Lever
  178
- Engines: RHM-RHT-RHW-4HW
  184
- Pre-Tensioning the Timing Belt
  188
- Checking the Oil Pressure
  192
- Valve Clearances
  194
- The Valve Clearances Must be Checked with the Engine Cold
  194
- Possible Procedures
  194
- Rocking/Fully Open (Exhaust)
  194
- Pressure Gauge for Testing Boost Pressure
  195
- Normal/Abnormal Vacuum Values
  195
- 10 MM Low Pressure Connector
  195
- Checks: Low Pressure Fuel Supply Circuit
  195
- 8 MM Low Pressure Connector
  196
- Extension
  196
- Checks on Pressure: Dynamic
  197
- Abnormal Functioning
  197
- Impossible to Start the Engine
  197
- Mode of Operation
  198
- Checks: Turbo Pressure
  199
- Pressure Gauge for Checking the Pressure
  199
- Pressure Take-Off Extension/Union and Hose
  199
- Sleeve for Checking the Turbo Pressure and Adaptor Sleeve
  199
- Adaptor for Taking Pressure
  200
- Union and Hose/Unions and Hoses for Taking Pressure
  200
- Extension Cable for Taking Pressure
  200
- Pressure Gauge for Checking Pressure
  200
- Manual Pressure-Vacuum Pump
  202
- Turbocharging Pressure Regulation Valve
  202
- Checking the Vacuum Source (Vacuum Pump)
  203
- Turbocharging Pressure Electrovalve
  203
- Cold/Warm Air Circuit Electrovalve
  203
- Checking the Warm Air Opening
  204
- Checking the Cold Air Closing
  204
- Manual Vacuum Pump
  205
- Vacuum Pump
  206
- Turbo Vacuum Regulation Electrovalve
  206
- Turbo Pressure Regulation Valve
  206
- «Swirl» Control Diaphragm
  206
- Double Butterfly Housing (Vehicle with Particle Filter)
  207
- Exhaust Gas Recycling (EGR) Electrovalve
  207
- Electrovalve (EGR)
  208
- Butterfly Housing Electrovalve
  208
- EGR Valve
  209
- Butterfly Housing
  209
- Sparking Plugs
  210
- Speedometer
  211
- Clutch Specifications
  212
- Manual Gearbox Specifications
  214
- Gearbox Specifications
  215
- «Push» Clutch with Hydraulic Control
  216
- Description
  216
- Clutch Types: (BE4/5)
  216
- Engines: 6FZ - 9HZ
  216
- Clutch Types: (ML5C-ML6C)
  217
- Engines: XFX-RHS-RHZ-4HX
  217
- Hydraulic Clutch Control Specification
  218
- Bleeding the Hydraulic Clutch Control.
  218
- BE4/5 Gearbox: Tightening Torques
  221
- Engines: 6FZ-RFN-9HZ
  221
- Gearbox Rear Casing and Casing/Clutch Casing Fixings
  222
- Breather Pipe/Reverse Gear Switch
  222
- Drain/Top-Up Plug and Speedo Drive Support
  222
- Differential Housing Fixings (M7-M10)
  222
- Differential Gearwheel Screws
  223
- Gear Control Support Screw
  223
- Bearing Retaining Screw
  223
- Primary/Secondary Shaft Nut
  223
- ML5C Gearbox: Tightening Torques
  224
- Engines: 3FZ-RHM-RHT-RHW-4HW
  224
- Engines: RHL-RHR
  226
- ML6C Gearbox: Tightening Torques
  226
- BE4/5 Gearbox: Control Specifications
  228
- Gear Controls
  228
- Gear Lever Positioning Tool
  228
- Gear Selection Control Cable
  229
- Gear Engagement Control Cable
  229
- Adjustments
  230
- To Unlock the Length of the Gear Control Cable Sleeve
  230
- To Unlock a Sleeve Stop
  230
- Reverse Gear Unlocking Cable
  234
- To Unlock the Length of the Gear Selection Control Cable Sleeve
  235
- AL 4 Automatic Gearbox: Recommendations - Precautions
  237
- Precautions to be Taken
  237
- Repairs on Mechanical Components
  237
- Modification of the Oil Usage Counter Value
  237
- Procedure to be Followed Prior to Carrying out Repairs on AL4 Autoactive Gearbox
  238
- Oil Quality - Oil Level
  238
- Absence/Presence of Fault Codes
  238
- Procedure for Initialising the Automatic Gearbox ECU
  239
- Updating the Gearbox ECU by Downloading
  239
- After the Downloading Operation, Carry out the Following
  239
- Updating the Value of the Oil Usage Counter
  239
- Output Speed Sensor Fixing
  240
- Oil Overflow and Drain Fixing
  240
- Heat Exchanger Fixing
  240
- AL4 Gearbox: Tightening Torques
  240
- Fixing of Converter on Diaphragm
  241
- Plug Fixing
  241
- Gearbox Fixing on Engine
  241
- Hydraulic Block Fixing
  242
- Fixing of Selector Lever Position Switch
  242
- Oil Filler Plug
  242
- Gearbox End
  243
- New Gear Selection Control
  244
- Re-Used Gear Selection Control
  244
- AL4 “Shift Lock” Gearbox Control Specifications and Precautions
  245
- Unlocking the Shift Lock (with an Operating Fault)
  245
- When Performing Electrical Checks
  246
- 4 HP 20 Automatic Gearbox: Recommendations - Precautions
  246
- Repairs on Electrical Components
  246
- Engines: 4HX-XFW-4HW
  246
- 4 HP 20 Gearbox: Tightening Torques
  247
- Gearbox Exterior
  247
- Gearbox Interior
  248
- Input Speed Sensor Fixing
  248
- Hydraulic Block Fixing (Large Head)
  248
- 4 HP 20 Gearbox: Control Specifications
  249
- Selection Control
  249
- 4 HP 20 “Shift Lock” Gearbox Control Specifications and Precautions
  250
- Unlocking the “Shift Lock” (Normal Operation, with a Fault)
  250
- Engines: XFW - 4HW
  252
- Adjusting the Selection Control
  253
- 4 HP 20 Gearbox Controls: Checks and Adjustments
  253
- AM6 Automatic Gearbox: Recommendations - Precautions
  254
- Towing
  254
- Driving
  254
- AM6 Gearbox: Tightening Torques
  255
- Torque Converter/Engine Speed Sensor
  255
- Gearbox Support/Closing Panel Fixing
  255
- Fixting of Gearbox on Cylinder Block
  255
- Oil Temperature Sensor Tightening Plate
  256
- Hydraulic Valve Block (Sequence Indicated)
  256
- Oil Induction Cover/Ecu Screws
  256
- Oil Drain and Overflow/Oil Level Plug
  256
- Automatic Adjustment
  257
- Unlocking the «SHIFT LOCK» (with an Operating Fault)
  258
- AM6 “Shift Lock” Gearbox Control Specifications and Precautions
  258
- Driveshafts - Gearbox
  259
- Axle Geometry
  260
- Measuring Front Height
  260
- Measuring Rear Height
  260
- Carlsson
  262
- Axle Geometry: Checking and Adjusting Vehicle Height
  264
- Preliminary Operations
  264
- Checks by Axle
  264
- Measuring the Wheel Radius
  265
- Measuring the Front Height H1M
  265
- Calculating the Front Height H1C
  265
- Calculating the Rear Height H2C
  266
- Adjustment of Heights
  266
- Mechanical Pre-Adjustment
  266
- Rear Height
  267
- Front Height
  267
- Front Axle
  269
- Saloons and Estates and Carlsson
  270
- Rear Axle
  271
- Height Control
  272
- Power-Steering Specifications
  273
- Heat Shield Fixing on Casing
  274
- Additional Operation
  275
- Setting at Reference Height
  276
- Requirements Prior to Setting at Reference Height
  276
- Tooling Required
  276
- Measuring Front Height (H1)
  277
- Measuring Rear Height (H2)
  277
- Height of the Vehicle at the Front at Reference Height (H1 = R1 - L1)
  278
- Height of the Vehicle at the Rear at Reference Height (H2 = R2 + L2)
  279
- Values for Front Suspension Angles
  280
- Values for Rear Suspension Angles
  280
- Adjusting the Rolling Axles
  281
- Identification
  282
- Crossmember
  282
- Tie-Rods/Springs
  282
- Front Suspension Leg/Anti-Roll Bar
  282
- Fixing of Damper on Body/Rear Axle
  284
- Fixing of Stabiliser Bar on Rear Axle/Body
  284
- Fixing of Rear Axle on Body
  284
- Hub Nut
  284
- Fixing of Upper and Lower Shafts to Steering Column/Of Ball-Joint Housing on Steering Rack
  285
- Fixing of Steering Column to Support/Of Ram Valve Supply Unions
  285
- Steering Wheel Fixing/Rod Locking/Ball-Joint Nut
  285
- Engines: RFN-3FZ-XFW-RHM-RHT-RHW-4HW
  285
- Brake Specifications
  286
- Braking Circuit
  288
- Braking System Specifications
  288
- Brake Fluid Pressure Sensor on Master-Cylinder
  289
- Fixing of Gyrometer/Accelerometer Sensor on Support
  289
- Fixing of Support on Body
  289
- Brake Specifications
  290
- Checking the Vacuum Pump
  291
- Pressure Checker
  291
- Engines DW10, DW12 and DV6
  291
- Conditions for Adjustment
  292
- To Bed in the Parking Brake Cables, Operate as Follows
  292
- Checking and Adjusting the Parking Brake
  292
- Nut for Adjusting the Tension of the Parking Brake Cables
  293
- Draining, Filling and Bleeding the Braking System
  294
- Draining the Brake Fluid Reservoir
  294
- Bleeding the Primary Braking System
  294
- Filling the Braking System
  294
- Front/Rear Brake Caliper
  295
- Using the Bleeding Apparatus
  295
- Without Bleeding Apparatus
  296
- Bleeding the Secondary Braking System
  296
- Brake Tightening Torques
  298
- Engines: RFN-3FZ-XFW-RHT-RHW-RHM-4HW
  298
- Adjusting the Handbrake
  299
- Bleeding the Primary Braking Circuit
  302
- During the Operation
  304
- Safety Requirements: Hydractive 3 Hydraulic Suspension
  304
- Engine Running
  305
- Cleanliness Requirements
  305
- Specification - Identification: Suspension Spheres
  306
- Special Features
  307
- Hydractive 3 Hydraulic Suspension
  308
- Front/Rear Suspension Spheres
  308
- Hydractive 3 + Hydraulic Suspension
  309
- Hydractive Regulator Accumulators
  310
- Front/Rear Hydractive Regulator Accumulator
  310
- Hydraulic Specifications
  311
- Location of Components
  311
- Hydraulic Fluid Reservoir
  312
- Built-In Hydro-Electronic Interface (BHI)
  313
- Hydractive 3 + Regulator
  314
- Hydraulic Unions
  314
- DE-Pressurising the Hydraulic Suspension Circuit
  315
- Using a Diagnostic Tool
  315
- Without Using a Diagnostic Tool
  316
- Vehicle with Suspension Hydractive 3
  316
- Vehicle with Suspension Hydractive 3 +
  317
- Draining - Filling - Bleeding: Hydraulic Suspension/Steering Circuit
  318
- Pliers for CLIC Clips
  318
- Bleeding
  319
- Checking and Toppping up the LDS Fluid Level
  320
- Measurement of Heights
  321
- Measuring the Rear Height H2M
  322
- Adjusting the Heights
  322
- Measure the Front/Rear Height (H1M)
  324
- Checking and Adjusting the Vehicle Height
  325
- Checking by Axle
  325
- Air Conditioning
  326
- Special Features: Air Conditioning System
  327
- Summary Table for Presence of Pollen Filter
  327
- Pollen Filter
  328
- Drying Cartridge
  330
- Condenser with Integral Reservoir
  331
- Preparing the New Dryer Reservoir
  331
- Removing-Refitting the Drying Cartridge
  333
- Compressor Lubricant
  336
- Checking the Compressor Oil Level
  336
- Repairing a System Without Leaks
  336
- All Types
  337
- Checking the Compressor Oil Level (Continued)
  337
- Checking the Efficiency of the Air Conditioning System
  338
- Clim Test 2 Valeo
  339
- Positions of the Air Conditioning Controls
  340
- Interpretation of the Measurements
  341
- Under-Cooling
  341
- Values for Under-Cooling (SR)
  341
- Blown Air Temperature «U»
  341
- Values for Over-Heating (SC)
  342
- Interpretation of the Diagnosis
  343
- Aircon Circuit Diagnosis Table
  344
- Air Conditioning System
  348
- Evolution of the HP/LP Filling Valves
  348
- Engine: XFX
  350

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CITROEN C8 2005 Service Manual (356 pages)

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