correspondence table for petrol ... - .correspondence table for diesel engines engine families...

EW DWES

CORRESPONDENCE TABLE FOR DIESEL ENGINES

Engine families

Engine types

CORRESPONDENCE TABLE FOR PETROL ENGINES

7 10 12 9 12

C5

C8

C5

C8

Enginefamilies

Enginetypes

VERY IMPORTANT

As the booklet is constantly re-edited, this one only covers vehicles for thisparticular model year.

It is therefore necessary to order a new booklet each year and RETAIN THEOLD ONES.

AJ4 J4 A

6FZ RFJ 3FZRFN XFWXFU

1.8i 16V 2.0i 16V 2.2i 16V HPi

X

3.0i 24V

X

X X

XXX

10

TED4

1,6 16V HDi9HZ

TED4

2,0 16VHDi

BTED4 TED ATED4

DV

6

RHM RHT RHW RHL 4HX 4HW

X X

RHR

J4

XX

X X X

2,2 16VHDi

COUV-Angl-C5C8-2005.qxd 9/01/06 18:18 Page 1

PRIVATE CARSCITRON C5 - CITRON C8

PR

IVA

TE

CA

RS

CAR 000.020Volume 3

2005AC/DTAV/PRME/MMCB/MMECMthodes Mcaniques

The intellectual property rights relating to the technical information contained in this document belongexclusively to the manufacturer. Reproduction, translation or distribution in whole or in part without priorwritten authorisation from the manufacturer is forbidden.

The technical information contained in this document is intended for the exclusive use of the trained personnelof the motor vehicle repair trade. In some instances, this information could concern the security and safety ofthe vehicle. The information is to be used by the professional vehicle repairers for whom it is intended and theyalone would assume full responsibility to the exclusion of that of the manufacturer.The technical information appearing in this brochure is subject to updating as the characteristics of eachmodel in the range evolve. Motor vehicle repairers are invited to contact the CITRON network periodically forfurther information and to obtain any possible updates.

22000055

COUV-Angl-C5C8-2005.qxd 9/01/06 18:18 Page 2

PRESENTATION

THIS HANDBOOK summarises the specifications, adjustments, checks and special features of CITRON private vehicles, not including UTILITYvehicles for which there exists a separate handbook.

The handbook is divided into groups representing the main functions:

GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES -HYDRAULICS - AIR CONDITIONING.

In each section, the vehicles are dealt with in the following order: C5 - C8 and all models where applicable.

The information given in this handbook is based on vehicles marketed in EUROPE.

Angl. T3-Index-2005. 4/02/05 14:09 Page I

IMPORTANT

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 accountwhen 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.

Angl. T3-Index-2005. 4/02/05 14:09 Page II

CONTENTSGENERAL

C5 1 - 2

C8 3 - 4

C5 6 - 7

C8 8

Lubricants 9 - 31

ENGINE

Specifications 32 - 33

Compression ratios 34

Tightening torques: engines all types 35 - 87

Cylinder head tightening: all types 88 - 91

Auxiliary drive belt 93

Checking and setting the valve timing 109

Checking the oil pressure 188 - 189

Valve clearances 190

INJECTION

Checking the low pressure fuelsupply circuit: C5 (DW10BTED4) 190

Checking the low pressure fuelsupply circuit : C5 (DW12TED)

192 - 193

Vehicleidentification

Capacities

Checking the turbo pressure:194

C5 (DV6TED4)

Checking the turbo pressure: 195C5 (DW10BTED4)

Checking the turbo pressure: 196 - 197C5 (DW12TED)

Checking the air supply circuit: 198C5 (DV6TED4)

Checking the air supply circuit: 199 - 200C5 (DW10BTED4)

Checking the air supply circuit: 201 - 202C5 (DW12TED)

Checking the exhaust gas recycling 203circuit: (DV6TED4)

Checking the exhaust gas recycling 204 - 205circuit: (DW12TED)

IGNITION

Sparking plugs 206

CLUTCH - GEARBOX - TRANSMISSION

Speedometer 207

Clutch specifications: C5 208

Clutch specifications: C8 209

Manual/automatic gearbox: 201 - 211

all types

Tightening torques: clutch 212 - 214

Hydraulic clutch control 215 - 216

Tightening torques217 - 223

manual gearbox: all typesChecks and adjustments:

224 - 232manual gearbox all types

Recommendations/precautions: 233 - 235

AL4 automatic gearbox

Tightening torques: AL4 236 - 238

AL4 gearbox controls 239 - 240

AL4 gearbox controls 241

Recommendations/precautions: 242

4 HP 20 automatic gearbox

Tightening torques:4HP 20 gearbox 243 - 244

4HP 20 gearbox controls 245

Angl. T3-Index-2005. 4/02/05 14:09 Page III

Draining, filling, bleeding297 - 299

the braking circuit : C8

HYDRAULICSSafety requirements: Hydractive 300 - 3013 hydraulic suspension

Specification / identification: 302 - 306suspension spheres

Hydraulic specifications 307 - 310

Depressurising the hydraulic 311 - 313suspension circuit

Draining and filling the hydraulic 314 - 320suspension and steering circuit

Checking/adjusting vehicle height 321AIR CONDITIONINGR134.a: quantities 322Pollen filter 324 - 325Filtering and drying cartridge 326 - 331Compressor lubricant 332 - 333

Checking the efficiency of the circuit 334 - 343

Air conditioning circuit: C5 344 - 348Air conditioning circuit: C8 349 - 351

CLUTCH - GEARBOX - TRANSMISSION4 HP 20 Shift lock: C5 246

Checks and adjustments: 2474 HP 20: C5

4 HP 20 Shift lock: C8 248

Checks and adjustments: 2494 HP 20: C8

Recommendations/precautions: 250AM6 gearbox: C5

Tightening torques: AM6 gearbox 251 - 252

AM6 gearbox controls 253

AM6 Shift lock: C5 254

Driveshafts 255

AXLES - SUSPENSION - STEERING

Axle geometry: C5 all types 256 - 257except CARLSSON

Axle geometry: C5 CARLSSON 258 - 259

Checking/adjusting vehicle height:C5

260 - 264

Tightening torques: front axle: C5 265 - 266

Tightening torques: rear axle: C5 267 - 268

Tightening torques:power steering: C5

269 - 271

Axle geometry: C8 272 - 276

Adjusting the rolling axles: C8 277

Tightening torques: front axle: C8 278 - 279

Tightening torques: rear axle: C8 280

Tightening torques:power steering: C8

281

BRAKESBrake specifications: C5 282 - 284

Brake tightening torques: C5 285 - 286

Checking/adjustingvacuum pump: C5

287

Adjusting the handbrake: C5 288 - 289

Draining, filling, bleeding 290 - 292the braking circuit: C5

Brake specifications: C8 293

Brake tightening torques: C8 294Adjusting the handbrake: C8 295 - 296

CONTENTS

Angl. T3-Index-2005. 4/02/05 14:09 Page IV

1

GE

NE

RA

LG

EN

ER

AL

IDENTIFICATION OF VEHICLES

E1APO8RD

A - Chassis stamp (cold stamp on bodywork).

B - Manufacturer's data plate(under the rear bench seat).

C - A-S/RP No. and RP paint code(label on front pillar close to driver's door).

D - Inflation pressures and tyre references(label on front pillar close to driver's door).

E - Serial no. on bodywork.

F - Gearbox reference - Factory serial no.

G - Engine legislation type - Factory serial no.

C5

Angl. T3 page001-31-2005 4/02/05 14:15 Page 1

GE

NE

RA

L

2

C5 IDENTIFICATION OF VEHICLESType approval

Manual 5-speed gearbox A B C P V 5 8 1Manual 4-speed gearbox E F R W 6 9 2Manual 6-speed gearbox ts G H S X 3Automatic 6-speed gearbox D J N UAxle and/or gearbox gears K L T Y 7 0 4Other possible combinations MNo gearbox Z

Structure

Depollution levels

DCRFNC/IF

Version (4)

Family (1)

Body shape (2)

Engine (3)

D Family (1)C Bodywork (2)

RFN Engine (3)C Version (4)/IF Variant (5)

D C5

C 5-door saloonE Estate

6FZ EW7J4 1.8i 16VRFJ EW10A 2.0i 16VXFU ES9A 3.0i 24S9HZ DV6TED4 1.6i 16 HDiRHL DW10BTED4 2.0i 16V HDiRHR4HX DW12TED4 2.2 16V HDi

L3L4 Euro IV

USOther

K AlcoholW3 83/87 K L3/L4 Euro IV

Variants (5)Entreprise convertible TIntegral alternator-starter (ADIN) ADWithout FAP SFFiscal incentives IFPiloted manual gearbox PDowngraded depollution DLPG dual fuel GLSTT2 (stop and start) S

Angl. T3 page001-31-2005 4/02/05 14:15 Page 2

3

GE

NE

RA

LG

EN

ER

AL

IDENTIFICATION OF VEHICLES

E1AP0A2D

A - Chassis stamp(cold stamp on bodywork).

B - Manufacturer's data plate(under RH centre pillar).

C - A-S / RP No. and RP paint code(label on front pillar).

D - Inflation pressures and tyre references(label on front pillar).

E - Gearbox reference - Factory serial no.

F - Engine legislation type - Factory serial no.

C8

Angl. T3 page001-31-2005 4/02/05 14:15 Page 3

4

GE

NE

RA

L

C8 IDENTIFICATION OF VEHICLESType approval

Manual 5-speed gearbox A B C P V 5 8 1Manual 4-speed gearbox E F R W 6 9 2Manual 6-speed gearbox ts G H S X 3Automatic 6-speed gearbox D J N UAxle and/or gearbox gears K L T Y 7 0 4Other possible combinations MNo gearbox Z

Structure

Depollution levels

EAXFWF/IF

Version (4)

Family (1)

Body shape (2)

Engine (3)

E Fam