PRIVATE CARS

2004
C5 and C8
«The technical information contained in this document is intended for the exclusive use of the trained
personnel of the motor vehicle repair trade. In some instances, this information could concern the security
and safety of the vehicle. The information is to be used by the professional vehicle repairers for whom it is
intended and they alone would assume full responsibility to the exclusion of that of the manufacturer».
«The technical information appearing in this brochure is subject to updating as the characteristics of each
model in the range evolve. Motor vehicle repairers are invited to contact the CITROËN network periodically
for further information and to obtain any possible updates».

CAR 050014
Volume 2
 IMPORTANT
As the booklet is constantly re-edited, this one only covers vehicles for this
particular model year.

It is therefore necessary to order a new booklet each year and RETAIN THE
OLD ONES.
 CORRESPONDENCE TABLE FOR PETROL ENGINES
EW ES
Engine
families 7 10 12 9
J4 D J4 J4S
Engine
types 6FZ RFN RLZ 3FZ XFX XFW

C5 1.8i 16V 2.0i 16V 2.0 16V HPi 3.0i 24V

C8 2.0i 16V 2.2 16V HPi 3.0i 24V

 CORRESPONDENCE TABLE FOR DIESEL ENGINES
DW
Engine families 10 12
TD ATED ATED4 TED TED4

Engine types RHY RHS RHZ RHW RHT RHM 4HX 4HW

C5 2.0 HDi 2.0 HDi 2.0 HDi 2.2 HDi

C8 2.0 16V 2.0 16V 2.0 16V 2.0 HDi

HDi HDi HDi
 PRESENTATION

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

The handbook is divided into nine groups representing the main functions:

GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES,

SUSPENSION, STEERING - BRAKES - ELECTRICAL - AIR CONDITIONING.

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

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

 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 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.
 IDENTIFICATION OF VEHICLES C5

(A) Chassis stamp

(cold stamp on bodywork).

(B) Manufacturer’s data plate.

(under the rear bench seat)

GENERALITES
(C) A-S / RP No. and RP paint code

GENERAL
(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.

E1APO8RD

1
 C5 IDENTIFICATION OF VEHICLES
Petrol saloons

1.8i 16V 2.0i 16V

Auto. Auto.
Pack Pack - Ambiance pack - Exclusive
Emission standard L4 L5 L4 L5 L4 L5
GENERAL

Type code DC 6FZB DC 6FZC/IF DC 6FZE DC RFNB DC RFNC/IF DC RFNE DC RFNF/IF

Engine type 6FZ RFN
Cubic capacity (cc) 1749 1997
Fiscal rating (hp) 7 8 9
Gearbox type BE4/5 AL4 BE4/5 AL4
Gearbox ident. plate 20 DL 29 20 TP 95 20 DL 30 20 TP 93

2
 IDENTIFICATION OF VEHICLES C5
Petrol saloons

2.0 16V HPi 3.0i 24V

Auto.
Exclusive
Emission standard L4 IF/L5

GENERALITES
GENERAL
Type code DC RLZB DC XFXC/IF DC XFXF/IF
Engine type RLZ XFX
Cubic capacity (cc) 1997 2946
Fiscal rating (hp) 9 13 14
Gearbox type BE4/5 ML/5C 4 HP 20
Gearbox ident. plate 20 DL31 20 LM 21 20 HZ 26

3
 C5 IDENTIFICATION OF VEHICLES
Diesel saloons

2.0 HDi

Auto.
Leader Pack- Leader pack - Ambiance pack - Exclusive Pack- Ambiance pack Exclusive
Emission standard L4
GENERAL

Type code DC RHYB DC RHSB DC RHZB DC RHSE DC RHZE

Engine type RHY RHS RHZ RHS RHZ
Cubic capacity (cc) 1997
Fiscal rating (hp) 6 7
Gearbox type BE4/5 ML/5C AL4
Gearbox ident. plate 20 DL 32 20 LM 23 20 TP 94

(*) FAP = Particle filter

4
 IDENTIFICATION OF VEHICLES C5
Diesel saloons

2.2 HDi

Auto.
Pack - Leader pack - Ambiance pack - Exclusive Ambiance pack- Exclusive
Emission standard L4

GENERALITES
GENERAL
Type code DC 4HXB DC 4HXG DC 4HXE
Engine type 4HX
Cubic capacity (cc) 2179
Fiscal rating (hp) 8
Gearbox type ML5C ML/6C 4 HP 20
Gearbox ident. plate 20 LM 17 20 MB 04 20 HZ 20

5
 C5 IDENTIFICATION OF VEHICLES
Petrol estates

1.8i 16V 2.0i 16V

Auto.

Pack Pack- Exclusive

GENERAL

Emission standard L4 / IFL5

Type code DE 6FZC/IF DE 6FZB DE RFNC/IF DE RFNB DE RFNE DE RFNF/IF
Engine type 6FZ RFN

Cubic capacity (cc) 1749 1997

Fiscal rating (hp) 7 9
Gearbox type BE4/5 AL4
Gearbox ident. plate 20 DL 29 20 DL 30 20 TP 93

6
 IDENTIFICATION OF VEHICLES C5
Petrol estates

2.0 HPi 3.0i 24V

Auto.

Pack Exclusive

GENERALITES
Emission standard L4/IFL5

GENERAL
Type code DE RLZB DE XFXC / IF DE XFXF / IF
Engine type RLZ XFX
Cubic capacity (cc) 1997 2946
Fiscal rating (hp) 9 14
Gearbox type BE4/5 ML/5C 4 HP 20
Gearbox ident. plate 20 DL 31 20 LM 21 20 HZ 26

7
 C5 IDENTIFICATION OF VEHICLES
Diesel estates

2.0 HDi

Auto. Auto.
Pack - Ambiance pack
Emission standard L4
GENERAL

Type code DE RHYB DE RHSB DE RHSE DE RHZB DE RHZE

Engine type RHY RHS RHZ
Cubic capacity (cc) 1997
Fiscal rating (hp) 6 7 6 7
Gearbox type BE4/5 ML/5C AL4 ML/5C AL4
Gearbox ident. plate 20 DL 32 20 LM 23 20 TP 94 20 LM 23 20 TP 94

8
 IDENTIFICATION OF VEHICLES C5
Diesel estates

2.2 HDi

Auto.
Ambiance pack
Emission standard L4

GENERALITES
Type code DE 4HXB DE 4HXG DE 4HXE
Engine type 4HX
Cubic capacity (cc) 2179
Fiscal rating (hp) 8
Gearbox type ML5C ML/6C 4 HP 20
Gearbox ident. plate 20 LM 17 20 MB 04 20 HZ 20

9
 C8 IDENTIFICATION OF VEHICLES

(A) Chassis stamp (cold stamp on bodywork).

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

(C) A-S / RP No. and RP paint code

GENERAL

(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.

E1AP0A2D

10
 IDENTIFICATION OF VEHICLES C8
Petrol

2.0i 16V 2.2i 16V

Auto.

Pack Pack
Exclusive
Emission standard IFL5

GENERALITES
GENERAL
Type code EA RFNC/IF EB RFNC/IF EA RFNE EB RFNE EB 3FZC/IF EA 3FZC/IF

Engine type RFN 3FZ

Cubic capacity (cc) 1997 2230
Fiscal rating (hp) 9 11
Gearbox type BE4/5 AL4 ML5C
Gearbox ident. plate 20 DM 01 (1)
20 TP 74 20 LM 25
20 DM 00 (2)

(1) = Right hand drive

(2) = Left hand drive

11
 C8 IDENTIFICATION OF VEHICLES
Petrol

3.0i 24V

Auto.

Exclusive
GENERAL

Emission standard IFL5

Type code EA XFWF/IF EB XFWF/IF

Engine type XFW
Cubic capacity (cc) 2946
Fiscal rating (hp) 14
Gearbox type 4 HP 20
Gearbox ident. plate 20 HZ 27

12
 IDENTIFICATION OF VEHICLES C8
Diesel

2.0 HDi (*) 2.0 HDi (**)

Auto.

Pack - Exclusive

GENERALITES
GENERAL
Emission standard L4
Type code EA RHWB EB RHWB EA RHTB EB RHTB EA RHME EB RHME
Engine type RHW RHT RHM
Cubic capacity (cc) 1997
Fiscal rating (hp) 7 8
Gearbox type ML5C AL4
Gearbox ident. plate 20 LM 24 20 TS 04

(*) = Without FAP (Particle filter)

(**) = With FAP (Particle filter)

13
 C8 IDENTIFICATION OF VEHICLES
Diesel

2.2 HDi (*)

Pack - Exclusive
GENERAL

Emission standard L4

Type code EA 4HWB EB 4HWB

Engine type 4HW
Cubic capacity (cc) 2179
Fiscal rating (hp) 8
Gearbox type ML5C ML6C
Gearbox ident. plate 20 LM 01 20 MB 05

(*) = With FAP (Particle filter).

14
 LUBRICATION CIRCUIT

Draining method.

The oil capacities are defined according to the following methods.

1) - Vehicle on level surface (in high position, if equipped with hydropneumatic suspension).

2) - Engine warm (oil temperature 80°C).

GENERALITES
GENERAL
3) - Draining of the oil sump + removal of the cartridge (duration of draining + dripping = 15 min).

4) - Refit plug + cartridge.

5) - Engine filling.

6) - Engine starting (allowing the cartridge to be filled).

7) - Engine stopped (stationary for 5 min).

ESSENTIAL: Systematically check the oil level using the oil dipstick.

15
 C5 CAPACITIES (in litres)
C5
Petrol

1.8i 16V 2.0i 16V 2.0i HPi 3.0i V6

Auto. Auto. Auto.

Engine type 6FZ RFN RLZ XFX

Engine with filter change 4,25 5,25
GENERAL

Between Min. and Max. 1,7 2

5-speed gearbox 1,8 1,8 1,8
Automatic gearbox 6 6 8,3
After oil change 3 3 5,3
Braking circuit
Hydraulic circuit 4,3
Cooling system 8,8 – 9,3 (*) 8,8 14
Fuel tank capacity 65
(*) = With automatic gearbox
ESSENTIAL: Systematically check the oil level using the oil dipstick.

16
 CAPACITIES (in litres) C5
C5
Diesel

2.0 HDi 2.2 HDi

Auto. Auto. Auto.

Engine type RHY RHS RHZ 4HX

GENERALITES
Engine with filter change 4,5 4,75

GENERAL
Between Min. and Max. 1,4 1,5
5-speed gearbox 1,8 1,8 1,8
Automatic gearbox 8,3 - 6 8,3 - 6 8,3
After oil change 5,3 – 3 5,3 – 3 5,3
Braking circuit
Hydraulic circuit 4,3
Cooling system 10,7 – 11,7 (With additional heating)
Fuel tank capacity 65

ESSENTIAL: Systematically check the oil level using the oil dipstick.

17
 C8 CAPACITIES (in litres)
Petrol Diesel
2.0i 16V 2.2i 16V 3.0i 24V 2.0 16V HDi 2.2 HDi
HPi
Auto. Auto. Auto.

Engine type RFN 3FZ XFW RHW RHT RHM 4HW

Engine with filter change 4,25 5,25 4,75
Between Min. and Max. 1,7 2 1,9 1,5
GENERAL

5-speed gearbox 1,8 2 2 2

Automatic gearbox 6 8,3 6
After oil change 3 5,3 3
Hydraulic or brake circuit 0,66
Cooling system 7 7,2 10,5 10 10,2 11,3
Fuel tank capacity 80

18
 LUBRICANTS - TOTAL recommended oils

Evolutions (year 2004). Use of oil grade 10W 40.

It is possible to use semi-synthetic oil 7000 10W40 on PETROL
CITROËN C2, C3 PLURIEL, DISPATCH and DV6 engines. and DIESEL vehicles.

Only petrol versions are available. WARNING: To avoid problems with starting from cold, use this oil
as allowed by the climatic conditions in the country concerned
Normal maintenance interval : 30 000 km (20 000 miles) (see table).

GENERALITES
Severe maintenance interval : 20 000 km (12 000 miles).

GENERAL
For more details see the oil usage table.
ESSENTIAL: For all vehicles with a 30 000 km (20 000 miles)
maintenance interval, use exclusively TOTAL ACTIVA/QUARTZ New commercial designation for energy economy oil.
7000 or 9000 or any other oils offering identical specifications to The oil TOTAL ACTIVA/QUARTZ 9000 5W30 becomes TOTAL
these. ACTIVA FUTUR 9000 (for France),
These oils offer specifications that are superior to those defined QUARTZ FUTURE 9000 5W30 (outside France).
by norms ACEA A3 OR API SJ/CF. The usage exclusions for this oil are the same as before:
Failing this, it is essential to adhere to the maintenance
programmes covering severe operating conditions. - XSARA VTS 2.0i 16V (XU10J4RS).
- RELAY 2.8 TDi; 2.8 HDi (SOFIM engine).
- HDi FAP vehicles.
- C3 1.4i 16V HDi (DV4TED4).
- C8 2.2i (EW12J4)

19
 LUBRICANTS - TOTAL recommended oils

Engine oil norms.

Current norms.
GENERAL

The classification of these engine oils is established

by the following recognised organisations:

- S.A.E : Society of Automotive Engineers.

- API : American Petroleum Institute.

- ACEA : Association des Constructeurs Européens

d’Automobiles

E4AP006D

20
 LUBRICANTS - TOTAL recommended oils
S.A.E. Norms - Table for selection of engine oil grade
Selection of engine oil grades recommended for climatic conditions in countries of distribution

Evolution of the norms as at 01/01/2003

ACEA 2003 norms API norms

The meaning of the first letter has not changed, it still corresponds to
the type of engine: The meaning of the first letter has not changed, it still corresponds to

GENERALITES
A: petrol and dual fuel petrol / LPG engines. the type of engine:

GENERAL
B: diesel engines.
The figure following the first letter corresponds to the type of oil: . S: petrol and dual fuel petrol / LPG engines.
3: high performance oils. C: diesel engines.
4: oils specifically for direct injection diesel engines.
5: very high performance oils permitting lower fuel consumption The second letter corresponds to the degree of evolution of the oil
Example: (ascending order).
ACEA A3: high performance oils specifically for petrol and dual fuel
petrol / LPG engines Example: Norm SL is more severe than norm SJ, corresponding to
ACEA A/B: blended oils giving very high performance for all a higher level of performance.
engines, also permitting better fuel economy, specifically for direct
injection diesel engines
NOTE: From 01/01/2003 there is no longer any reference to the year
of creation of the norm, (Example: ACEA A3/B3 98 becomes
ACEA A3/B3.

21
 LUBRICANTS - TOTAL recommended oils
Recommendations.

ESSENTIAL: To preserve engine performances, all engines fitted in CITROEN vehicles must be lubricated with high quality oils
(synthetic or semi-synthetic).

CITROËN engines are lubricated at the factory with TOTAL oil of grade S.A.E.5W-30.
TOTAL oil of grade S.A.E.5W-30 allows improved fuel economies (approx 2.5%).

The oil 5W30 is used only for the following engines (Year 2003):
GENERAL

- XU10 J4RS : XSARA VTS 2.0i 16V (3-door)

- SOFIM : RELAY 2.8 TDi and 2.8 HDi.
- HDi : With particle filter (FAP).
- DV4 TED4 : CITROËN C3 1.4 16V HDi.
- EW 12J4 : CITROËN C8 2.2i16V HPi.

WARNING: CITROËN engines prior to model year 2000 do not have to be lubricated with oils adhering to the norms:
ACEA AI-98 and API SJ/CF EC or current norms ACEA A5/B5

Denomination of TOTAL oils according to country of marketing:

TOTAL ACTIVA (France only).
TOTAL QUARTZ (outside France).

22
 LUBRICANTS - TOTAL recommended oils
Recapitulation
Norms to be observed for engine oils (year 2003)
Year Types of engine concerned ACEA norms API norms
Petrol and dual fuel petrol/
LPG engines A3 or A5 5 (*) SJ or SL
2003
Diesel engines B3 or B5 (*) CF
(*) It is essential not to use engine oils respecting these norms for the following engine-types: XU10 J4RS , SOFIM 2.8 TDi

GENERALITES
and SOFIM 2.8 HDi , HDi with particle filter (FAP), EW 12 J4, DV4 TED4.

GENERAL
Classes and grades of TOTAL recommended engine oils.
Oils marketed in each country are adapted to the local climatic conditions.

Blended oils for all engines (petrol, diesel and dual fuel petrol / LPG engines).
S.A.E. norms ACEA norms API norms
TOTAL ACTIVA 9000 5W40 A3 / B3
TOTAL QUARTZ 9000
SL / CF
TOTAL ACTIVA FUTUR 9000 (*) 5W30 A5 / B5
TOTAL QUARTZ FUTUR 9000 (*)
TOTAL ACTIVATRAC 10W40 A3 / B3 SJ / CF
(*) Blended oils for all engines, permitting fuel economy.

23
 LUBRICANTS - TOTAL recommended oils
Oils specifically for petrol and dual fuel petrol / LPG engines
S.A.E. norms ACEA norms API norms
TOTAL ACTIVA 7000
10W40
TOTAL QUARTZ 7000

TOTAL QUARTZ 9000 0W40 A3 SJ

TOTAL ACTIVA 7000

15W50
GENERAL

TOTAL QUARTZ 7000

Oils specifically for diesel engines

S.A.E. norms ACEA norms API norms

TOTAL ACTIVA DIESEL 7000

10W40
TOTAL QUARTZ DIESEL 7000 B3 CF
TOTAL ACTIVA DIESEL 7000 15W50

24
 LUBRICANTS - TOTAL recommended oils
Oil usage table

Engine types TOTAL ACTIVA QUARTZ

Synthetic 9000 Semi-synthetic 7000

0W40 15W50
5W30 5W40 10W40
cold countries hot countries

GENERALITES
GENERAL
XU10 J4RS (Xsara VTS 2.0i 16V) X X X X
Petrol engines EW 12 J4 (C8 2.2i 16V) X X X X

Other petrol engines X X X X X

HDi engines with FAP (*) X X X

Other HDi engines X X X X

Diesel engines SOFIM 2.8 TDi and 2.8 HDi (RELAY) X X X

DV4 TED4 (C3 1.4 16V HDi) X X X

Indirect injection diesel engines X X X X

(*) = Particle filter

25
 LUBRICANTS - TOTAL recommended oils
Selection of TOTAL engine oils, to be used according to the climatic conditions in the country where the vehicle is marketed.
GENERAL

E4AP006D

26
 LUBRICANTS - TOTAL recommended oils
ENGINE OILS
FRANCE
Blended oils for all engines, supplied in bulk

Metropolitan FRANCE TOTAL ACTIVRAC S.A.E. norms: 10W40

TOTAL ACTIVA TOTAL ACTIVA DIESEL

Oils specifically for diesel

GENERALITES
Blended oils for all engines Oils specifically for petrol and

GENERAL
dual-fuel petrol / LPG engines engines

Metropolitan FRANCE 9000 5W40 7000 10W40 7000 10 W40

9000 5W30 (*) 9000 5W40
New Caledonia
Guadeloupe
Saint-martin
Reunion 9000 5W40 7000 15W50 7000 15W50
Martinique
Guyana
Tahiti
Mauritius
Mayotte

(*) = Blended oils for all engines, permitting fuel economy

27
 LUBRICANTS - TOTAL recommended oils
ENGINE OILS
EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL
Oils specifically for petrol Oils specifically for diesel
Blended oils for all engines and dual-fuel petrol / LPG engines
engines
7000 10W40
Germany
9000 0W40
GENERAL

Austria 7000 10W40

7000 10W40
Belgium
9000 0W40
9000 5W40 7000 10W40
Bosnia FUTURE 9000 5W30 (*) 9000 0W40 7000 10W40

Bulgaria 7000 10W40

7000 10W40
Cyprus
9000 15W40

Croatia 7000 10W40

(*) = Blended oils for all engines, permitting fuel economy

28
 LUBRICANTS - TOTAL recommended oils
ENGINE OILS
EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL

Oils specifically for petrol and Oils specifically for diesel

Blended oils for all engines
dual-fuel petrol / LPG engines engines

7000 10W40
Denmark 9000 0W40

GENERALITES
7000 10W40

GENERAL
Spain 7000 15W40

Estonia
7000 10W40
9000 0W40
Finland 9000 5W40
FUTURE 9000 5W30 (*) 7000 10W40
Great Britain 7000 10W40

Greece 7000 10W40

7000 15W40

Holland 7000 10W40

9000 0W40
(*) = Blended oils for all engines, permitting fuel economy

29
 LUBRICANTS - TOTAL recommended oils
ENGINE OILS
EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL

Oils specifically for petrol and Oils specifically for diesel

Blended oils for all engines
dual-fuel petrol / LPG engines engines

7000 10W40
Hungary
9000 0W40
GENERAL

Italy

Ireland 7000 10W40

9000 5W40
Iceland
FUTURE 9000 5W30 (*) 7000 10W40

Latvia
7000 10W40
9000 0W40
Lithuania

Macedonia 7000 10W40

(*) = Blended oils for all engines, permitting fuel economy

30
 LUBRICANTS - TOTAL recommended oils
ENGINE OILS
EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL

Oils specifically for petrol and Oils specifically for diesel

Blended oils for all engines
dual-fuel petrol / LPG engines engines

7000 10W40
Malta
7000 15W50

GENERALITES
GENERAL
Moldavia 7000 10W40

Norway 7000 10W40

9000 0W40
9000 5W40
Poland 7000 10W40
FUTURE 9000 5W30 (*)

Portugal 7000 10W40

Slovakia

7000 10W40
Czech Republic
9000 0W40
(*) = Blended oils for all engines, permitting fuel economy

31
 LUBRICANTS - TOTAL recommended oils
ENGINE OILS
EUROPE TOTAL ACTIVA DIESEL
TOTAL ACTIVA

Oils specifically for petrol and Oils specifically for diesel

Blended oils for all engines
dual-fuel petrol / LPG engines engines

7000 10W40
Romania 7000 15W50
9000 0W40
GENERAL

Russia

7000 10W40
Slovenia 9000 0W40
9000 5W40
7000 10W40
FUTURE 9000 5W30 (*)
Sweden

Switzerland 7000 10W40

7000 10W40
Turkey 9000 15W50
9000 0W40
(*) = Blended oils for all engines, permitting fuel economy

32
 LUBRICANTS - TOTAL recommended oils
ENGINE OILS
EUROPE
TOTAL ACTIVA TOTAL ACTIVA DIESEL

Oils specifically for petrol and Oils specifically for diesel

Blended oils for all engines
dual-fuel petrol / LPG engines engines

Ukraine
9000 5W40 7000 10W40

GENERALITES
7000 10W40
FUTURE 9000 5W30 (*) 9000 0W40

GENERAL
Yugoslavia

(*) = Blended oils for all engines, permitting fuel economy

33
 LUBRICANTS - TOTAL recommended oils
ENGINE OILS
OCEANIA
TOTAL ACTIVA TOTAL ACTIVA DIESEL

Oils specifically for petrol and Oils specifically for diesel

Blended oils for all engines
dual-fuel petrol / LPG engines engines

Australia 9000 5W40

7000 10W40 7000 10W40
New Zealand FUTURE 9000 5W30 (*)
GENERAL

AFRICA
TOTAL ACTIVA TOTAL ACTIVA DIESEL

Oils specifically for petrol and Oils specifically for diesel

Blended oils for all engines
dual-fuel petrol / LPG engines engines

Algeria, South Africa,

Ivory Coast, Egypt, Gabon, Ghana,
Kenya, Madagascar, Morocco, Nigeria, 9000 5W40 7000 15W50 7000 10W40
Senegal, Tunisia

(*) = Blended oils for all engines, permitting fuel economy

34
 LUBRICANTS - TOTAL recommended oils
ENGINE OILS
CENTRAL AND SOUTH AMERICA
TOTAL ACTIVA TOTAL ACTIVA DIESEL

Oils specifically for petrol and Oils specifically for diesel

Blended oils for all engines
dual-fuel petrol / LPG engines engines

Argentina

GENERALITES
GENERAL
Brazil

Chile

Cuba 9000 5W40 7000 10W40 7000 10W40

7000 15W50

Mexico

Paraguay

Uruguay

35
 LUBRICANTS - TOTAL recommended oils
ENGINE OILS
SOUTH-EAST ASIA TOTAL ACTIVA TOTAL ACTIVA DIESEL

Oils specifically for petrol and Oils specifically for diesel

Blended oils for all engines
dual-fuel petrol / LPG engines engines

7000 10W50
China 7000 15W50
9000 5W40
GENERAL

South Korea FUTURE 9000 7000 10W40

5W30 (*)
Hong Kong
7000 15W50
India – Indonesia 9000 5W40 7000 10W40

9000 5W40 7000 10W40

Japan
FUTURE 9000 5W30 (*) 7000 15W50

Malaysia
9000 5W40 7000 15W50
Pakistan

(*) = Blended oils for all engines, permitting fuel economy

36
 LUBRICANTS - TOTAL recommended oils
ENGINE OILS
SOUTH-EAST ASIA
TOTAL ACTIVA TOTAL ACTIVA DIESEL

Oils specifically for petrol and Oils specifically for diesel

Blended oils for all engines
dual-fuel petrol / LPG engines engines

Philippines

GENERALITES
7000 15W50

GENERAL
Singapore

Taiwan 9000 5W40 7000 10W40 7000 10W40

7000 15W50

Thailand
7000 15W50
Vietnam

37
 LUBRICANTS - TOTAL recommended oils
ENGINE OILS
MIDDLE EAST
TOTAL ACTIVA TOTAL ACTIVA DIESEL

Oils specifically for petrol and Oils specifically for diesel

Blended oils for all engines
dual-fuel petrol / LPG engines engines

Saudi Arabia – Bahrain

GENERAL

Dubai 7000 15W50

United Arab Emirates

Iran 9000 5W40 7000 10W40 7000 10W40

7000 15W50

Israel – Jordan – Kowait

Lebanon – Oman – Qatar 7000 15W50

Syria - Yemen

38
 LUBRICANTS - TOTAL recommended oils
GEARBOX OILS

TOTAL TRANSMISSION BV
Manual gearbox and SensoDrive Norms S.A.E.: 75W80
Part No.: 9730 A2.
TOTAL FLUIDE ATX

GENERALITES
TOTAL FLUIDE AT 42
MB3 automatic gearbox

GENERAL
Special oil distributed by
All countries CITROËN
Part No .: 9730 A3
Special oil distributed by
4HP20 and AL4 autoactive
CITROËN
automatic gearboxes
Part No.: 9736 22
TOTAL TRANSMISSION X4
Transfer box and rear axle
Part No.: 9730 A4

39
 LUBRICANTS - TOTAL recommended oils
POWER STEERING OILS

All countries TOTAL FLUIDE ATX

Power steering TOTAL FLUIDE DAS

Very cold countries Special oil distributed by
CITROËN
Part No.: 9730 A1
GENERAL

ENGINE COOLANT FLUID

CITROËN Part No.

Pack
GLYSANTIN G33 REVKOGEL 2000
2 Litres 9979 70 9979 72

5 Litres 9979 71 9979 73

CITROËN fluid
All countries
Protection: - 35C° 20 Litres 9979 76 9979 74

210 Litres 9979 77 9979 75

40
 LUBRICANTS - TOTAL recommended oils
BRAKE FLUID
Synthetic brake fluid

Pack CITROËN Part No.

0,5 Litre 9979 05
All countries CITROËN fluid 1 Litre 9979 06
5 Litres 9979 07

GENERALITES
GENERAL
HYDRAULIC CIRCUIT
All countries Norm Pack CITROËN Part No.
TOTAL FLUIDE LDS Orange 9979 69
TOTAL LHM PLUS ZCP 830095
Colour 1 Litre
TOTAL LHM PLUS Green
9979 20
Very cold countries

WARNING: TOTAL FLUIDE LDS fluid cannot be blended with TOTAL LHM

WARNING: CITROËN C5: Use exclusively TOTAL FLUIDE LDS suspension fluid.

All countries TOTAL HYDRAURINCAGE

41
 LUBRICANTS - TOTAL recommended oils
SCREEN WASH FLUID

Pack CITROËN Part No.

Concentrated: 250 ml 9980 33 ZC 9875 953U 9980 56

All countries 1 Litre 9980 06 ZC 9875 784U

Fluid ready
for use
GENERAL

5 Litres 9980 05 ZC 9885 077U ZC 9875 279U

GREASE
General use
Norms NLGI
TOTAL MULTIS 2 2
All countries
TOTAL SMALL MECHANISMS

Note: NLGI = National Lubricating Grease Institute.

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:

GENERALITES
- 3,000 miles (5,000 km) for a PETROL engine.

GENERAL
- 6,000 miles (10,000 km) for a DIESEL engine.

III - MAXIMUM PERMISSIBLE oil consumption for a RUN-IN engine.

- 0.5 litres per 600 miles (1,000 km) for a PETROL engine.
- 1 litre per 600 miles (1,000 km) for a DIESEL engine.
DO NOT INTERVENE BELOW THESE VALUES.

IV - OIL LEVEL: The level should NEVER be above the MAX. mark on the dipstick after changing or topping up the oil.
- This excess oil will be used up rapidly.
- It will reduce the engine output and adversely affect the operation of the air circuits and gas recycling.

43
 C5 - C8 ENGINE SPECIFICATIONS
Engines: 6FZ-RFN-RLZ-3FZ-XFX XFW
Petrol
C5 C8 C5 C8

1.8i 16V 2.0i 16V 2.0 Hpi 2.2i 16V 3.0i 24V

Engine type 6FZ RFN RLZ 3FZ XFX XFW

ENGINE

Cubic capacity (cc) 1749 1997 2230 2946

Bore / Stroke 82,7/81,4 85/88 86/96 87/82,6
Compression ratio 10,8/1 11,5/1 10,8/1 10,9/1
Power ISO or EEC KW - rpm 85-5500 100-6000 103-6000 116-5650 152-6000 150-6000
Power DIN (HP - rpm) 117-5500 136-6000 138-6000 143-6000 160-5650 210-6000 204-6000
Torque ISO or EEC (m.daN - rpm) 16-4000 19-4100 19,2-4100 21,7-3900 28,5-3750

44
 ENGINE
ENGINE SPECIFICATIONS C5 - C8
Engines: RHY-RHS-RHZ-RHT-RHM-RHW-4HX-4HW
Diesel

2.0 HDi 2.0 16V HDi 2.2 HDi

Engine type RHY RHS RHZ RHT RHM RHW 4HX 4HW

Cubic capacity (cc) 1997 2179

Bore / Stroke 85/88 86/96

Compression ratio 17,6/1 17,3/1 17,6/1

Power ISO or EEC KW - rpm 66-4000 79-4000 80-4000 79-4000 80-4000 98-4000 94-4000

Power DIN (HP - rpm) 90-4000 107-4000 110-4000 110-4000 136-4000 130-4000

Torque ISO or EEC (m.daN - rpm) 20,5-1900 25-1750 27-1750 31,4-2000

45
ENGINE
C5 COMPRESSION RATIO - DIESEL ENGINES

COMPRESSION MAX. DIFFERENCE

ENGINE
RATIO BETWEEN CYLINDERS

In bars

RHY
RHS
DW10 30 ± 5
RHZ 5
RHW

4HX DW12 20 ± 5

46
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C5
Engines: 6FZ RFN RLZ

(1) : 4,5 ± 0,5

(2) : 6,1 ± 0,6

(3) : 5 ± 0,5

(4) : 5 ± 0,5

(5) : 5 ± 0,5

(6) : 5 ± 0,5

(7) : 4,5 ± 0,5

(8) : 6,5 ± 0,6

(9) : 2,7 ± 0,3

(10) : 4,5 ± 0,5

(11) : 4,5 ± 0,5

B1BP2BSP

47
ENGINE
C5 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: 6FZ RFN RLZ
Crankshaft

Accessories drive pulley 2,1 ± 0,1

(1st solution) Fitting with washer in sintered steel (*)
Accessories drive pulley hub
Pre-tightening 4
Angular tightening 40° ± 4°
(2nd solution) Fitting with washer in steel.(*)
Accessories drive pulley hub
Pre-tightening 4
Angular tightening 53°± 5°
Con rod cap screws
Pre-tightening 2,3 ± 0,2
Tightening 46° ± 0,3°
Bearing cap screws
Pre-tightening 2 ± 0,1
Tightening 60° ± 0,5°

(*) = The washer in sintered steel is of metallic appearance, whereas the washer in steel is of golden appearance.

48
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C5
Engines: 6FZ RFN RLZ
6FZ - RFN RLZ
Cylinder block
Sump 0,8 ± 0,2
Timing belt tensioner roller 3,7 ± 0,3
Timing belt tensioner roller 2,1 ± 0,2
Accessories belt guide roller 3,5 ± 0,3
Accessories belt tensioner roller 2 ± 0,2
Cylinder head
Camshaft bearing covers 0,9 ± 0,1
Exhaust manifold 3,5 ± 0,3
Valve cover 1,1 ± 0,1
Magnesium valve cover 0,9 ± 0,1
Camshaft pulley hub 7,5 ± 0,7
Hollow screw for camshaft dephaser (VTC) 5,5 ± 0,5
Exhaust camshaft pulley screw 7,5 ± 0,7

49
ENGINE
C5 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: 6FZ RFN RLZ
6FZ - RFN RLZ
Flywheel - Clutch
Flywheel
Tightening 2 ± 0,2
Angular tightening 21° ± 3°
Clutch mechanism 2 ± 0,2
Lubrication circuit
Oil pump 0,9 ± 0,1
Diesel injection circuit
Common injection rail fixing screw 0,9 ± 0,1 0,8 ± 0,1
Pressure sensor on common injection rail 2 ± 0,2
Regulation electrovalve on common injection rail 0,7 ± 0,1
High pressure petrol injection pump 0,5 ± 0,1
High pressure link pipe 2,6 ± 0,3
Cooling circuit
Coolant pump 1,4 ± 0,1
Coolant outlet housing 0,9 ± 0,1

50
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES C8
Engines: RFN – 3FZ
Crankshaft bearing cap cover (15)

Description M11 M6
Pre-tightening 1 ± 0,1 0,5
Slackening Yes No
Re-tightening 1 ± 0,1 then 2 ± 0,2 1 ± 0,1
Angular tightening 70° ± 5°

Crankshaft

(17) Flywheel/
Description (16) Con-rod caps
crankshaft fixing
Pre-tightening 1 ± 0,1 2,5 ± 0,2
Slackening Yes 18° ± 1°
Re-tightening 2,5 ± 0,2 1 ± 0,1
Angular tightening 46° ± 5° 22° ± 2°

B1BK1X8D

51
ENGINE
C8 SPECIAL FEATURES: TIGHTENING TORQUES
Equipment on cylinder head
Engine: RFN Engine: 3FZ

B1BK1X9D B1BK1XAD

Description (18) Camshaft bearing cap covers (19) Valve covers

Pre-tightening 0,5 0,5
Tightening 1 ± 0,1 1,5 ± 0,1
Description (20) Inlet manifold (21) Exhaust manifold
Tightening 1 ± 0,1 3,5 ± 0,3
52
 ENGINE
SPECIAL FEATURES: POWER UNIT SUSPENSION C8
Upper RH engine support Engines: RFN 3FZ
Description RFN 3FZ
Ref.
Gearbox type BE4/5 AL4 ML5C
(1) Rod/body fixing screw. 5 ± 0,5
Engine support/torque reaction rod
(2) 4,5 ± 0,4
flexible stop pin
Upper support/intermediate support 6,5 ± 0,6
(3)
fixing screw.
(4) Upper support/body fixing screw 3 ± 0,3
B1BK1X5D
(5) Upper support/flexible
4,5 ± 0,4
support fixing nut.
Intermediate engine support
(6) Support
LH flexible support/LH
(7) 6,5 ± 0,6
engine support fixing nut.

(8) LH flexible support/body fixing screw. 3 ± 0,3

(9) Intermediate engine support/gearbox 4,5 ± 0,4

casing fixing screw.
(10) LH intermediate support/gearbox fixing 6 ± 0,6 4,5 ± 0,4
screw.
B1BK1X6D (11) Flexible support pin. 5 ± 0,5

53
ENGINE
C8 SPECIAL FEATURES: POWER UNIT SUSPENSION
Intermediate engine support Engines: RFN 3FZ
Description RFN 3FZ
Ref.
Gearbox type BE4/5 AL4 ML5C

(12) Lower RH rod/subframe fixing screw. 9 ± 0,9

Lower RH engine support/cylinder

(13) 4,5 ± 0,4
block fixing screw.

(14) Lower rod/lower RH engine

6,5 ± 0,6
support fixing screw

B1BK1X7D

54
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C5
Engine: XFX
LH engine support.
(A) Manual gearbox (B) Automatic gearbox

(1) : 4,5 ± 0,5 (5) : 6 ± 0,6

(2) : 5 ± 0,5 (6) : 5,5 ± 0,5
(3) : 3 ± 0,3 (7) : 0,8 ± 0,1
(4) : 6,5 ± 0,6 (8) : 2,7 ± 0,3
(9) : 2,8 ± 0,1
Upper RH engine support

(10) and (11) : 6,1 ± 0,6

(12) : 4,5 ± 0.,5
(13) : 5 ± 0,5
(14) : 5 ± 0,5

Lower RH engine support – Torque reaction rod

(15) : 1 ± 0,1
(16) : 5 ± 0,5
(17) : 5 ± 0,5

B1BP27GP

55
ENGINE
C5 SPECIAL FEATURES: TIGHTENING TORQUES
Engine: XFX

(1) Compact coil unit 1 ± 0,1

(9) Flywheel
- Tightening 1
- Angular tightening 60°± 6°

(11) Connecting rod caps

- Tightening 2±
- Angular tightening 74° ± 7°

(12) Crankshaft hub

- Tightening 4 ± 0,4
- Angular tightening 80° ± 8°

(13) Crankshaft pulley 2,5 ± 0,2

B1BP1HAP

56
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C5
Engine: XFX
- 2 Cylinder head cover (A) Front cyl. head (B) Rear cyl. head - 3 Bearing caps housing (A) Front cyl. head (B) Rear cyl. head

B1DP08UD B1DP08TD

WARNING: Tighten screw by screw in the order shown.

- Pre-tighten: 0,5 - Pre-tighten: 0,2
- Tighten: 1 ± 0,1 - Tighten: 0,8

57
ENGINE
C5 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: XFX
- 5 Air inlet manifold - 6 Lower manifold (A) Front cyl. head (B) Rear cyl. head

B1HP0LJC B1DP097C

WARNING: Tighten screw by screw in the order shown.

- Pre-tighten: 1 ± 0,1 - Pre-tighten: 1 ± 0,1

- Tighten: 2 ± 0,2 - Tighten: 2,5 ± 0,2

58
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C5
Engine: XFX
- 7 Exhaust manifold (NEW gasket) - 10 Oil sump

B1BP1GXD B1BP1GZD

WARNING: Tighten screw by screw in the order shown.

- Pre-tighten: 1 ± 0,1 - Pre-tighten: 0,5 ±
- Tighten: 3 ± 0,3 - Tighten: 0,8 ±

59
ENGINE
C5 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: XFX

- 8 Crankshaft bearing

- Clean the threads of the screws with a brush.

- Refit the screws with a coating of grease
( MOLYKOTE G RAPID PLUS ).
- Check that the 8 centring pins are in place.

Maximum length under the heads of the screws:

- M11 = 131.5 mm.
- M8 = 119 mm.

- Pre-tighten the M11 screws to 3 m.daN ± 0,3 (1 to 8).

- Pre-tighten the M8 screws to 1 m.daN ± 0,1 (A to H).
- Tighten the M6 screws to 1 m.daN ± 0,1 (a to m).
- Slacken the M11 and M8 screws (screw by screw).
- Tighten the M11 screws to 3 m.daN ± 0,3 (1 to 8).
- Tighten the M8 screws to 1 m.daN ± 0,1 (A to H).

B1BP1GYD

60
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C5
Engine: XFX

(14) Coolant pump

-Pre-tighten 0,5
-Tighten 0,8

(15) Oil pump

-Pre-tighten 0,5
-Tighten 0,8

(16) Guide roller 8±0,8

(17) Tensioner roller 8±0,8

(18) Camshaft hubs

- Pre-tighten 2±0,2
- Tighten 57°±5°

(19) Camshaft pulley 1±0,1

B1BP1HBD

61
ENGINE
C5 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: XFX

- 20 Oil vapour recovery housing.

WARNING: Tighten screw by screw in the order shown.

- Pre-tighten 0.5 ±

- Tighten 1 ± 0,1

B1BP1H1D

62
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C8
Engine: XFW
Power unit suspension
RH engine support (Suspension) Gearbox suspension

B1BK24RD B1BK24SD

(2) Link rod fixing : 5 ± 0,5

(8) Fixing of gearbox support on LH flexible mounting : 6,5 ± 0,6
(3) Link rod fixing : 4,5 ± 0,4
(9) Shaft : 6,5 ± 0,6
(4) Fixing of upper RH engine support on intermediate engine
(10) Fixing of flexible mounting on support : 3 ± 0,3
support flexible mounting : 6 ± 0,6
(11) Fixing of flexible mounting support on body : 2,5 ± 0,2
(5) Fixing of RH engine support on flexible mounting : 4,5 ± 0,4
(12) Fixing of flexible mounting support on body : 2,5 ± 0,2
(6) Fixing of flexible mounting : 3 ± 0,3
(7) Fixing of RH intermediate engine support on cylinder block : 6 ± 0,6

63
ENGINE
C8 SPECIAL FEATURES: TIGHTENING TORQUES
Engine: XFW
Power unit suspension – Engine support (Lower) Crankshaft

B1BK24TD B1BK24UD

(17) Bearing cap Tightening : 2 ± 0,2

(13) Torque reaction link rod fixing : 9 ± 0,9 Angular tightening : 74° ± 7°
(18) Timing pinion Tightening : 4 ± 0,4
(14) Fixing of link rod on torque reaction flexible mounting : 6,5 ± 0,6 Angular tightening : 80° ± 8°
(15) Fixing of torque reaction flexible mounting : 4,5 ± 0,4 (19) Fixing of starter gear support flange, plus crankshaft
converter support Tightening : 2 ± 0,2
(16) Fixing of heat shield on torque reaction flexible mounting : 1 ± 0,1 Angular tightening : 60° ± 6°
(20) Accessory pulley on timing pinion : 2,5 ± 0,2

64
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES C8
Engine: XFW
Cylinder block
Bearing cap cover

Respect the sequence of stages and the order of tightening

M11 M8
Reference/description M6
Bolts from 1 to 8 Bolts from 9 to 16

(21) Fixings of bearings/cap covers or Stage 1 Stage 2 Stage 3

bearings/caps 3 ± 0,3 1 ± 0,1 1 ± 0,1

(21) Fixings of bearings/cap covers or

Stage 4 Stage 4
bearings/caps NO
YES YES
(Slacken to zero torque.)

(21) Fixings of bearing cap cover or

Stage 5 Stage 6
bearing caps (Tighten bolt by bolt)
Tightening
3 ± 0,3 1 ± 0,1
+ Angular tightening
B1BK24VD 180° 180°

65
ENGINE
C8 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: XFW
Lubrication circuit
Lubrication circuit. Oil sump

B1BK24WD B1BK24XD

Respect the sequence of stages and the order of tightening

(22) Oil separator : 0,8
Stage 1: Do up bolts 13,15 and 17.
(23) Strainer : 0,8 Stage 2: Tighten bolts 13,15 and 17 to : 0,2
(24) Induction pipe : 0,8 Stage 3: Do up the 17 remaining bolts.
(25) Drain plug : 3 ± 0,3 Stage 4: Tighten the remaining bolts to : 0,5
(26) Oil filter sleeve (with coolant/oil exchanger) : 0,5 Stage 5: Tighten all the bolts : 0,8
Stage 6: Repeat the tightening a few times in the same order to obtain a
Oil filter : 0,2
tightening torque of 0,8 m.daN on all the bolts.

66
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C8
Engine: XFW
Lubrication circuit Cooling circuit
Oil pump Coolant pump

B1BK3B6D B1BK3B7D

Respect the sequence of stages and the order of tightening

Stage 1: Position the screws and do them up by hand. Stage 1: Position the screws and do them up by hand.
Stage 2: Pre-tighten the screws : 0,5 Stage 2: Pre-tighten the screws : 0,5
Stage 3: Tighten the screws : 0,8 Stage 3: Tighten the screws : 0,8
Stage 4: Repeat the tightening a few times in the same order to obtain a Stage 4: Repeat the tightening a few times in the same order to obtain a
tightening torque of 0,8 m.daN on all the screws. tightening torque of 0,8 m.daN on all the screws.

67
ENGINE
C8 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: XFW
Lubrication circuit Cylinder head equipment
Coolant manifold

B1BK24YD

(27) Screws : 2,5 ± 0,2

(28) Screws : 0,8
(29) Screw : 0,8
B1BK24ZD

68
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C8
Engine: XFW
Cylinder head equipment
Camshaft bearing cap cover (right hand side) Camshaft bearing cap cover (left hand side)

B1EK0GCC B1BK3B8D

Respect the sequence of stages and the order of tightening

(30) Camshaft bearing cap cover or camshaft bearing:

Pre-tighten to : 0,2
Tighten to :1

69
ENGINE
C8 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: XFW
Cylinder head equipment
Valve covers (right hand side) Valve covers (left hand side)

B1EK0GEC B1EK0GFC

Respect the sequence of stages and the order of tightening

(31) Valve cover:

Pre-tighten to : 0,5
Tighten to : 0,8

70
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C8
Engine: XFW
Cylinder head equipment
Inlet manifold

B1BK251D

Respect the sequence of stages and the order of tightening

(32) Inlet manifold:

Pre-tighten to : 0,4
Tighten to : 0,8

71
ENGINE
C8 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: XFW
Cylinder head equipment
Exhaust manifold (right hand side) Exhaust manifold (left hand side)

B1JK03ND B1JK03LD

Respect the sequence of stages and the order of tightening

(33) Exhaust manifold:

Pre-tighten to :1
Tighten to : 3 ± 0,3

72
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C8
Engine: XFW
Cylinder head equipment
Inlet distributor

B1BK252D

Respect the sequence of stages and the order of tightening

(34) Inlet distributor:

Pre-tighten to : 0,4
Tighten to : 0,8

73
ENGINE
C5 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: RHY

Tightening torques

(1) 4,5 ± 0,5

(2) 5 ± 0,5
(3) 5 ± 0,5
(4) 2,7 ± 0,3
(5) 6,5 ± 0,6
(6) 4,5 ± 0,5
(7) 2,1 ± 0,2
(8) 4,5 ± 0,5
(9) 6,1 ± 0,6
(10) 4,5 ± 0,5
(11) 5 ± 0,5
(12) 5 ± 0,5

B1BP27KP

74
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C5
Engines: RHS RHZ

Tightening torques

(13) 4,5 ± 0,5

(14) 5 ± 0,5
(15) 5 ± 0,5
(16) 2,7 ± 0,3
(17) 4,5 ± 0,5
(18) 2,1 ± 0,2
(19) 4,5 ± 0,5
(20) 6,1 ± 0,6
(21) 4,5 ± 0,5
(22) 5 ± 0,5
(23) 5 ± 0,5

B1BP27LP

75
ENGINE
C5 SPECIAL FEATURES: TIGHTENING TORQUES
Engines: RHY RHZ RHS
Crankshaft
Bearing cap fixing screws
Pre-tightening 2,5 ± 0,2
Angular tightening 60°
Con rod nuts
Pre-tightening 2 ± 0,2
Angular tightening 70°
Accessories drive pulley RPO 9 8631 RPO 8631 9
Pre-tightening 4 ± 0,4 5 ± 0,5
Angular tightening 51° 62° ± 5°
Cylinder block
Piston skirt spray jet 1 ± 0,1
Sump 1,6 ± 0,2
Timing belt guide roller 2,5 ± 0,2
Timing belt tensioner roller 2,5 ± 0,2

76
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C5
Engines: RHY RHZ RHS
Cylinder head
Camshaft bearing covers 1 ± 0,1
Exhaust manifold 2 ± 0,2
Valve cover 0,8 ± 0,1
Camshaft pulley 4,3 ± 0,5
Hub pulley 2 ± 0,2
Flywheel - Clutch
Flywheel 4,8 ± 0,5
Clutch mechanism 2 ± 0,2
Lubrication circuit
Oil pump 1,3 ± 0,1
Coolant/oil hear exchanger 5,8 ± 0,5
Turbocharger lubrication pipe
Engine end 3 ± 0,3
Turbocharger end 2 ± 0,2

77
ENGINE
C5 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: RHY RHZ RHS
Diesel injection circuit
Injector fixing flange nut 3 ± 0,3
Union on high pressure common injection rail 2 ± 0,2
Injection pump on support 2,25 ±0,3
Union on diesel injection 2,2 ± 0,2
Injection pump pulley 5 ± 0,5
Union on fuel high pressure pump 2,2 ± 0,2
Cooling circuit
Coolant pump 1,5 ± 0,1
Coolant inlet housing 2 ± 0,2

78
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C8
Engines: RHW RHT RHM
Crankshaft
(1) Pulley screw M14x150-70
Pre-tightening 5 ± 0,5
Angular tightening 62°
(2) Screw M7x100-20 (x 4)
Pre-tightening 0,7 ± 0,1
Tightening 1,5 ± 0,1
(3) Screw M7x100-40 (x 2) (*)
Pre-tightening 0,7 ± 0,1
Tightening 1,5 ± 0,1
(4) Plug CHC M12x150-16 (x 1) 2,5 ± 0,2
(5) Plug M15x150 (x 1) 2,5 ± 0,2
(6) Plugs M15x150 (x 2) 4 ± 0,4
(7) Screw M9x100-24 (+loctite FRENETANCH) (x8) 4,8 ± 0,5
(8) Screw M12x150-81 (x10)
Pre-tightening 2,5 ± 0,2
Angular tightening (**) 60°
(9) Nut M9x100 (x8)
Pre-tightening 2 ± 0,2
Angular tightening 70°
B1BK3EPD (10) Screw M16x10-16 (x4) 1 ± 0,1
(*) = Re-use prohibited.
(**) = Tighten in a spiral commencing from the inside.
79
ENGINE
C8 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: RHW RHT RHM
Engine suspension (identification)
(1) Upper RH torque reaction rod
(2) Upper RH engine support
(3) RH engine flexible support
(4) Upper RH intermediate engine support
(5) Lower RH engine support
(6) Torque reaction rod
(7) Upper LH intermediate engine support
(8) LH engine support
(9) LH engine flexible support
(10) Lifting attachment, flywheel end
B1BK3EED (11) Lifting attachment, timing end

80
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C8
Engines: RHW RHT RHM
Engine suspension (Tightening torques)
(12) Spherical-base screw M10x150-75 (x 1) 5 ± ,05
(13) Shaft screw (x 1) 4,5 ± 0,4
(14) Nut M10x150 (x 1) 4,5 ± 0,4
(15) Screw M10x150-60 (x 3) 6 ± 0,6
(16) Screw M8x125-25 (x 2) 3 ± 0,3
(17) Shouldered shaft screw M8x125-15 (x 1) 2 ± 0,2
(18) Locking screw M10x125-85 (x 1) 4,5 ± 0,4
(19) Locking screw M10x125-70 (x 2) 4,5 ± 0,4
(20) Spherical-base screws M10x150-35 (x 3) 4,5 ± 0,4
(21) Spherical-base screws M10x150-72 (x 1) 6,5 ± 0,6
(22) Spherical-base screws M12x175-60 (x 1) 9 ± 0,9
(23) Nut M10x150 (x 1) 4,5 ± 0,4
(24) Screw M10 x150-55 (x 2) 4,5 ± 0,4
(25) Support shaft (x 1) 5 ± 0,5
(26) Screw M8x125-25 (x 4) 2,5 ± 0,2
(27) Screw M8x125-25 (x 2) 3 ± 0,3
(28) Locking nut M12x175-18 (x 1) 6,5 ± 0,6
(29) Screw M8x125-25 (x 1) 1,5 ± 0,1
B1BK3EDD (30) Screw M6x100-20 (x 2) 1,2 ± 0,1

81
ENGINE
C8 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: RHW RHT RHM
Power steering pump
(1) Power steering pump
(2) Screw M8x125-30 (x 1) 2,5 ± 0,2
(3) Shouldered shaft screw M8x125-22 (x 1) 2,2 ± 0,2
(4) Shouldered shaft screw M8x125-48 (x 1) 2,2 ± 0,2
NOTE: Tighten the fixings (2) and (3) before the fixing (4), to ensure that the
auxiliary drive belt is correctly aligned.

B1BK3E8D

Alternator
(5) Alternator
(6) Spherical-base screw M10 x150-50 (x 2) 4,1 ± 0,4
(7) Screw M10x150-40 (x 1) 3,9 ± 0,4
NOTE: Tighten the fixings (6) before the fixing (7), to ensure that the auxil-
iary drive belt is correctly aligned.

B1BK3E7D

82
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C8
Engines: RHW RHT RHM
Air conditioning compressor
(8) Air conditioning compressor
(9) Spherical-base screw M10x150-60 (x 1) 4 ± 0,4
(10) Shouldered shaft screw M10x150-52 (x 2) 4,2 ± 0,4
NOTA: Tighten the fixing (9) before the fixing (10), to ensure that the auxil-
iary drive belt is correctly aligned.

B1EK3E9D

Accessories support
(11) Power steering pump support
(12) Spherical-base screw M8 x125-35 (x 2) (*)
Pre-tightening 1 ± 0,1
Tightening 2 ± 0,2
(13) Screws M8x125-80 (x 1) (*)
Pre-tightening 1 ± 0,2
Tightening 2 ± 0,2
(*) = In the order indicated (1 to 5)
B1EK3EAD

83
ENGINE
C8 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engines: RHW RHT RHM
Guide roller
(14) Dynamic tensioner roller
(15) Eccentric guide roller
(16) Screw M10x150-50 (x 1)
Pre-tightening 1 ± 0,1
Tightening 4,3 ± 0,4
(17) Screw M8x150-60 (x 1)
Pre-tightening 2 ± 0,2
Tightening 4,5 ± 0,4

B1BK3EWD

84
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C5
Engine: 4HX

Tightening torques

(1) 4,5 ± 0,5

(2) 5 ± 0,5
(3) 5 ± 0,5
(4) 2,7 ± 0,3
(5) 4,5 ± 0,5
(6) 2,1 ± 0,2
(7) 4,5 ± 0,5
(8) 6,1 ± 0,6
(9) 4,5 ± 0,5
(10) 5 ± 0,5
(11) 5 ± 0,5

B1BP284P

85
ENGINE
C5 SPECIAL FEATURES: TIGHTENING TORQUES
Engine: 4HX
Crankshaft

Crankshaft bearing cap screws

Pre-tightening 2,5 ± 0,2
Angular tightening 60°
Con rod cap screws
Tighten 1 ± 0,1
Slacken 180°
Tighten 2,3 ± 0,1
Angular tighten 46° ± 5°
Auxiliary drive belt pulley
Tightening 7 ± 0,25
Angular tightening 60° ± 5°

86
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C5
Engine: 4HX
Cylinder block
Piston skirt spray jets 1 ± 0,1
Sump
Pre-tightening 1 ± 0,1
Tightening 1,6 ± 0,3
Timing belt guide roller
Pre-tightening 1,5 ± 0,1
Tightening 4,3 ± 0,4
Timing belt tensioner roller 2,5 ± 0,2
RH engine support
Pre-tighten the 4 screws 1 ± 0,1
Tighten the screw Ø 8 2 ± 0,2
Tighten the screws Ø 10 4,5 ± 0,2

87
ENGINE
C5 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: 4HX
Cylinder head
Camshaft bearing cap cover
Tighten 1 ± 0,1
Pre-tighten the 28 screws Ø 6 6 ± 0,5
Tighten the 28 screws Ø 6 1 ± 0,1
Exhaust manifold
Pre-tighten the 8 nuts 1,5 ± 0,1
Tighten the 8 nuts 0,3 ± 0,3
Valve cover
Pre-tighten the 13 screws 0,5 ± 0,15
Tighten the 13 screws 9 ± 0,1
Camshaft pulley hub 4,3 ± 0,4
Pulley on hub 2 ± 0,2
Flywheel - Clutch
Flywheel
Pre-tighten 1,5 ± 0,1
Tighten 4,7 ± 0,4
Clutch mechanism 2 ± 0,2

88
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C5
Engine: 4HX
Lubrication circuit
Oil pump
Pre-tighten 0,7
Tighten 0,9 ± 0,1
Coolant/oil heat exchanger 5,8 ± 0,5
Turbocharger lubrication tube
Engine end 3 ± 0,3
Turbocharger end 2 ± 0,2
Diesel injection circuit
Diesel injector
Do up the 2 nuts By hand
Tighten 4 ± 0,3
Angular tighten 45° ± 5°
Union on injection rail 2 ± 0,2
Injection pump on support 2,25 ±0,3
Union on diesel injector 2 ± 0,2
Injection pump pulley 5 ± 0,5
Union on injection pump 2 ± 0,2
Cooling circuit
Coolant pump 1,6 ± 0,3
Coolant inlet housing 2 ± 0,2
89
ENGINE
C8 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: 4HW
Crankshaft
(1) Pulley screw M14x150-70
Pre-tightening 7 ± 0,5
Angular tightening 82°
(2) Screw M7x100-40 (x 2) (*)
Pre-tightening 0,7 ± 0,1
Tightening 1,5 ± 0,1
(3) Screw M7x100-20 (x 4)
Pre-tightening 0,7 ± 0,1
Tightening 1,5 ± 0,1
(4) Plug CHC M12x150-16 (x 1) 2,5 ± 0,2
(5) Plugs M15x150 (x 2) 4 ± 0,4
(6) Screw M9x100-24 (+loctite FRENETANCH) (x8)
Pre-tighten 1,5 ± 0,1
Tighten 5 ± 0,5
(7) Screw M12x150-81 (x10) (**)
Pre-tighten 1 ± 0,1
Tighten 2,5 ± 0,2
B1BK3EMD Angular tighten 60°

(*) = Re-use prohibited.

(**) = Tighten in a spiral, commencing from the inside.

90
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C8
Engine: 4HW
Crankshaft (continued)
(8) Screw M7x100-20 (x8) (*) [Screw by screw
and part stage]
Stage 1: Tighten 1
Stage 2: Slacken 180°
Stage 3: Tighten 2,3 ± 0,2
Stage 4: Angular tighten 46°
(9) Screw M9x100-45 (x4) (*) 1±
(10) Screw M8x125-60 (x8) (***)
Pre-tighten 0,5
Tighten 1 ± 0,1
Angular tighten 60°

B1BK3EMD

(*) = Re-use prohibited.

(**) = Tighten in a spiral, commencing from the inside.
(***) = Tighten in the order indicated 1 to 8

91
ENGINE
C8 SPECIAL FEATURES: TIGHTENING TORQUES
Engine: 4HW
Engine suspension (identification)
(1) Upper RH torque reaction rod
(2) Upper RH engine support
(3) RH engine flexible support
(4) Upper RH intermediate engine support
(5) Lower RH engine support
(6) Torque reaction rod
(7) Upper LH intermediate engine support
(8) LH engine support
(9) LH engine flexible support
(10) Lifting attachment, flywheel end
(11) Lifting attachment, timing end
B1BK3EED

92
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C8
Engine: 4HW
Engine suspension (Tightening torques)
(12) Spherical-base screw M10x150-75 (x 1) 5 ± ,05
(13) Shaft screw (x 1) 4,5 ± 0,4
(14) Nut M10x150 (x 1) 4,5 ± 0,4
(15) Screw M10x150-60 (x 3) 6 ± 0,6
(16) Screw M8x125-25 (x 2) 3 ± 0,3
(17) Shouldered shaft screw M8x125-15 (x 1) 2 ± 0,2
(18) Locking screw M10x125-85 (x 1) 4,5 ± 0,4
(19) Locking screw M10x125-70 (x 2) 4,5 ± 0,4
(20) Spherical-base screws M10x150-35 (x 3) 4,5 ± 0,4
(21) Spherical-base screws M10x150-72 (x 1) 6,5 ± 0,6
(22) Spherical-base screws M12x175-60 (x 1) 9 ± 0,9
(23) Nut M10x150 (x 1) 4,5 ± 0,4
(24) Screw M10 x150-55 (x 2) 4,5 ± 0,4
(25) Support shaft (x 1) 5 ± 0,5
(26) Screw M8x125-25 (x 4) 2,5 ± 0,2
(27) Screw M8x125-25 (x 2) 3 ± 0,3
(28) Locking nut M12x175-18 (x 1) 6,5 ± 0,6
(29) Screw M8x125-25 (x 1) 1,5 ± 0,1
B1BK3EDD (30) Screw M6x100-20 (x 2) 1,2 ± 0,1

93
ENGINE
C8 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: 4HW
Power steering pump
(1) Power steering pump
(2) Screw M8x125-30 (x 1) 2,5 ± 0,2
(3) Shouldered shaft screw M8x125-22 (x 1) 2,2 ± 0,2
(4) Shouldered shaft screw M8x125-48 (x 1) 2,2 ± 0,2
NOTE: Tighten the fixings (2) and (3) before the fixing (4), to ensure that the
auxiliary drive belt is correctly aligned.

B1BK3E8D

Alternator
(5) Alternator
(6) Spherical-base screw M10 x150-50 (x 2) 4,1 ± 0,4
(7) Screw M10x150-40 (x 1) 3,9 ± 0,4
NOTE: Tighten the fixings (6) before the fixing (7), to ensure that the auxiliary
drive belt is correctly aligned.

B1BK3E7D

94
 ENGINE
SPECIAL FEATURES: TIGHTENING TORQUES (m.daN) C8
Engine: 4HW
Air conditioning compressor
(8) Air conditioning compressor
(9) Spherical-base screw M10x150-60 (x 1) 4 ± 0,4
(10) Shouldered shaft screw M10x150-52 (x 2) 4,2 ± 0,4
NOTE: Tighten the fixing (9) before the fixing (10), to ensure that the auxiliary
drive belt is correctly aligned.

B1EK3E9D

Accessories support
(11) Power steering pump support
(12) Spherical-base screw M8 x125-35 (x 2) (*)
Pre-tightening 1 ± 0,1
Tightening 2 ± 0,2
(13) Screws M8x125-80 (x 1) (*)
Pre-tightening 1 ± 0,2
Tightening 2,3 ± 0,2
(*) = In the order indicated (1 à 5)
B1EK3EAD

95
ENGINE
C8 SPECIAL FEATURES: TIGHTENING TORQUES (m.daN)
Engine: 4HW
Guide roller
(14) Dynamic tensioner roller
(15) Eccentric guide roller
(16) Screw M10x150-50 (x 1)
Pre-tightening 1,5 ± 0,1
Tightening 3 ± 0,3
(17) Screw M8x150-60 (x 1)
Pre-tightening 2 ± 0,2
Tightening 4,5 ± 0,4

B1BK3EBD

96
 ENGINE
CYLINDER HEAD C5
Engines: 6FZ-RFN-RLZ
Cylinder head gasket identification

Nominal dimension Repair dimension

6FZ RFN - RLZ

Marking zone 4-5 1-4 2-4-5

«d»

Marking zone
R1 R2
«e»

Gasket thickness 0,8 mm 1,1 mm 1,4 mm

Supplier MEILLOR

(d) Reference zone

(e) Marking zone.
Multilayer metallic cylinder head gasket.
B1DP183D

97
ENGINE
C5 CYLINDER HEAD
Engines: 6FZ-RFN-RLZ
Cylinder head tightening (m.daN) Cylinder head bolts
6FZ-RFN-RLZ
Pre-tightening 1,5 ± 0,1
Tightening 5 ± 0,1
Slackening 360°± 2°
Tightening 2 ± 0,2
Angular tightening 285° ± 5°

(in the order 1 to 10)

A = Washer thickness: 4 ± 0,2 mm.

X= Length under heads of the new bolts = 144,5 ± 0,5 mm.
NOTE: Oil the threads and B1DP16FC

NOTE: Retightening of the cylinder head under the heads of the cylinder X =MAX. re-usable length
after a completed repair is prohibited. head bolts. (Use engine oil or 6FZ - RFN - RLZ
Molykote G Rapid Plus.)
B1DP05BC X= 147 mm

98
 ENGINE
CYLINDER HEAD C8
Engines: RFN – 3FZ
Cylinder head gasket identification
Multilayer metallic gasket.

Cylinder head gasket thickness (mm)

Ref.
RFN 3FZ

(1B): Nominal dimension E – H = 0,8 E – G = 0,8

(1C): Repair dimension E – F – H = 0,99 E – F – G none

(1D): Manufacturer
identification.

B1BK24QD

99
ENGINE
C8 CYLINDER HEAD
Engines: RFN – 3FZ
Cylinder head tightening (m.daN) Cylinder head bolts

B1DK001C B1DB002C

Tighten in the order indicated X =MAX. re-usable length

RFN 3FZ RFN 3FZ
1/: 1,5
Pre-tightening
2/: 5
144,5 mm 127,5 mm
Slackening 360°
Tightening 2

Angular
285° 270°
tightening

100
 ENGINE
CYLINDER HEAD C5
Engine: XFX
Cylinder head gasket identification
Thickness
Supplier Thickness reference
(Standard) (mm)

Central lug
ERLING 0,75
Exhaust end

(2) Front cylinder head gasket.

Multilayer metallic cylinder head gasket. (3) Rear cylinder head gasket. B1DP18YD

101
ENGINE
C5 CYLINDER HEAD
Engine: XFX
Cylinder head tightening (m.daN) Cylinder head bolts

In the order indicated.

Pre-tightening 2 ± 0,2.
Slackening YES
Pre-tightening 1,5 ± 0,2.
Angular tightening 225°.

NOTE: Oil the threads and under the

heads of the cylinder head bolts. (Use
engine oil or Molykote G Rapid Plus.)

X =MAX. re-usable length

XFX
B1DP18ZD B1DP09VC 149,5 mm

102
 ENGINE
CYLINDER HEAD C8
Engine: XFW
Cylinder head gasket identification
The RH and LH cylinder head gaskets are specific, of multilayer metallic type.

B1DK0QKD B1DK0QLD

Cylinder head gasket thicknesses:

(1A): Engine ref: G-H (a): RH cylinder head gasket.
(1B): Nominal dimension: Without marking = 0,75 mm (b): LH cylinder head gasket.
(1C): Repair dimension: E (1st repair dimension R1) = 0,95 mm V: Engine flywheel side.
(1C): Repair dimension: E-F (2nd repair dimension R2) = 1,15 mm

103
ENGINE
C8 CYLINDER HEAD
Engine: XFW
Cylinder head tightening (m.daN) Cylinder head bolts

Pre-tightening :2

Slackening : YES

Tightening : 1,5

Angular tightening : 225°

NOTE: Oil the threads and

under the heads of the cylinder
head bolts. (Use engine oil or
Molykote G Rapid Plus.)
B1DK0QPD

X =MAX. RE-USABLE LENGTH

B1EK0XAD
149,5 mm

104
 ENGINE
CYLINDER HEAD C5
Engines: RHY-RHS-RHZ

Cylinder head gasket identification

Piston
Engine Thickness Number
stand-proud
plate (mm) of notches at A
(mm)
0,470 to 0,605 1,30 ± 0,06 1
0,605 to 0,655 1,35 ± 0,06 2
RHY
RHS 0,655 to 0,705 1,40 ± 0,06 3
RHZ
0,705 to 0,755 1,45 ± 0,06 4
0,755 to 0,80 1,50 ± 0,06 5

B1DP15AD

105
ENGINE
C5 CYLINDER HEAD
Engines: RHY-RHS-RHZ
Cylinder head gasket identification
Cylinder head tightening (m.daN) Cylinder head bolts
RHY-RHS-RHZ RHY-RHS-RHZ

- Pre-tightening 2 ± 0,2
- Tightening 6 ± 0,6
- Angular tightening 220°± 5°

NOTE: Oil the threads and B1DP15EC

under the heads of the cylinder X =MAX. re-usable length

head bolts. (Use engine oil or Molykote G
Rapid Plus.) RHY - RHS - RHZ

B1DP05BC 133,3 mm

106
 ENGINE
CYLINDER HEAD C8
Engines: RHT RHW 4HW
Cylinder head gasket identification
Piston Hole at F
Thickness Hole at
stand-proud
(mm) RHT 4HW G
(mm)
RHW
0,55 to 0,60 1,25 ± 0,04 0 1 1
0,61 to 0,65 1,30 ± 0,04 0 1 2
0,66 to 0,70 1,35 ± 0,04 0 1 3
0,71 to 0,75 1,40 ± 0,04 0 1 4

B1DK0Q6C

107
ENGINE
C8 CYLINDER HEAD
Engines: RHT RHW 4HW
Cylinder head tightening (m.daN) Cylinder head bolts

Tighten in the order indicated

Pre-tighten: 1/ 2
2/ 6
Slacken: 360°
Tighten: 1/ 2
2/ 6
Angular-tighten: 220°

NOTE: Oil the threads and under the heads of

the cylinder head bolts. (Use engine oil or
Molykote G Rapid Plus.)
B1DK1M6D

X =MAX. re-usable length

RHT - RHW 4HW

134 mm 134,5 mm
B1DK00SC

108
 ENGINE
CYLINDER HEAD C5
Engine: 4HX

Cylinder head gasket identification

Number of notches

Piston
Engine Thickness
stand-proud At A At B
plate (mm)
(mm)
0,55 to 0,60 1,25 ± 0,04 1
0,61 to 0,65 1,30 ± 0,04 2
4HX 1
0,66 to 0,70 1,35 ± 0,04 3
0,71 to 0,75 1,40 ± 0,04 4

Cylinder head gasket.

Multilayer cylinder head gasket.
Select seal thickness as a function of the piston stand-proud.

B1DP18XD

109
ENGINE
C5 CYLINDER HEAD (continued)
Engine: 4HX
Cylinder head tightening (m.daN) Cylinder head bolts
4HX 4HX

ESSENTIAL: Proceed screw by screw in the

order indicated.

Pre-tighten 2 ± 0,2
Tighten 6 ± 0,6
Slacken 360°
Pre-tighten 2 ± 0,2
Tighten 6 ± 0,6
Angular-tighten 220° ± 5°
NOTE: Oil the threads and under the
heads of the cylinder head bolts. (Use
engine oil or Molykote G Rapid Plus.) B1DP15EC
(in 2 attempts max.)
(Order 1 to10) X =MAX. re-usable length
4HX

B1DP05BC X = 134,5 MM

110
 ENGINE
BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE C5 - C8
! Tools !

!
4099-T (C.TRONIC.105) 4122-T (C.TRONIC 105.5)

B1EP135D

111
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
EW ES DW
7 10 12 9 10 12
J4 D J4 J4S TD ATED ATED4 TED TED4
Engine plate 6FZ RFN RLZ 3FZ XFX XFW RHY RHS RHZ RHW RHT RHM 4HX 4HW

2.0i
1.8i 2.0i 3.0i 2.0 2.0 2.0 2.2
C5 16V
16V 16V 24V HDi HDi HDi HDi
HPi

124 to
See pages: 114 116 118 to 121 125
2.2 2.0 2.0 2.0
2.0i 3.0i 2.2
C8 16V 16V 24S 16V 16V 16V
HDi
HPi HDi HDi HDi

See pages: 115 115 117 122 126

112
 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
Engines: all types Petrol and Diesel

TOOLS

- Belt tension measuring instrument: 4122 - T. (C.TRONIC 105.5)

WARNING: If using tool 4099-T (C.TRONIC 105), refer to the correspondence table on page 93.

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.

113
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
Without aircon Engines: 6FZ-RFN-RLZ With aircon

Tools

[1] Pliers for removing plastic pegs 7504-T

Remove the belt.

- Detension the belt (3) by turning the tensioner roller (1), by the screw (2)
(anti-clockwise).

WARNING: the screw (2) has a left hand thread.

- Remove the belt (3), while keeping the tensioner roller (1) tensioned.

Refit the belt.

- Compress the tensioner roller (1)
- Fit the belt (3).
- Release the tensioner roller (1).

Tightening torques m.daN.

Tensioner roller screw (4) 2 ± 0,2
Guide roller screw (5) 3,5 ± 0,3

B1BP23PC B1BP23QC B1BP23PC B1BP23RC

114
 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
Engines: RFN-3FZ

Tools

[1] Peg for dynamic tensioner roller (-).0189-E

Removing.

Remove:
The front RH wheel.
The front RH splash-shield.
BXXK08DD Detension the auxiliary drive belt by actioning the screw (1).
Peg the dynamic tensioner roller (2), using tool [1].
Remove the auxiliary drive belt.
ESSENTIAL: Check that the rollers (3) and (4) turn freely (no tight spot).

Refitting.

Refit the auxiliary drive belt.

Check that the auxiliary drive belt is correctly positioned in the grooves of the various pulleys.
Remove tool [1].
Continue the refitting operations in reverse order to removal.

BXXK0AUD

115
ENGINE
C5 AUXILIARY EQUIPMENT DRIVE BELT
Engine: XFX

Tools
[1] Ratchet spanner S.171 FACOM (_ square) S 171.
[2] Reduction box S.230 FACOM (1/2-3/8) S 230.

Remove.
Remove the engine cover.
Pivot the tensioner roller bracket (1) clockwise, until it locks,
using tools [1] and [2] at «a».
Remove the auxiliary equipment drive belt.
ESSENTIAL: Check that the guide rollers are turning freely. (No play
and no tightness).

Refit.

Refit the auxiliary equipment drive belt:

Respect the following order of assembly:
- The crankshaft pulley (2).
- The tensioner roller (3)
Release the tensioner roller bracket (1), by turning it anti-clockwise, using
tools [1] and [2].
ESSENTIAL: Make sure that the belt is correctly positioned in the
grooves of the various pulleys.
B1BP27EC B1BP27FC

116
 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT C8
Engine: XFW

Tools

[1] Ratchet spanner FACOM (1/2" square).

[2] Reduction box FACOM S.230 (1/2" - 3/8" square).

Removing.

Move aside the power steering oil low pressure pipe flange.
Pivot the support (1) of the tensioner roller clockwise, as far as it will go, using tools [1] and [2].
B1EK0VAD
Remove the auxiliary drive belt.
IMPERATIVE: Check the operation of the rollers (no play, no tight spot).

Refitting.
Position the auxiliary drive belt.
Commence with the crankshaft pulley (2).
Finish with the tensioner roller (3).
Free the support (1) of the tensioner roller, pivoting it anti-clockwise, using tools [1] and [2].
ESSENTIAL: Check that the belt is correctly positioned in the grooves of the various pulleys.

B1EK0VBD Continue the refitting operations in reverse order to removal.

117
ENGINE
C5 AUXILIARY EQUIPMENT DRIVE BELT
Engines: RHY - RHS - RHZ
Without air conditioning
Tools
[1] Belt tension adjusting square : (-).0188 J2
[2] Ø 4 mm peg : (-).0188.Q1
[3] Ø 2 mm peg : (-).0188.Q2
[4] Dynamic tensioner compression lever : (-).0188.Z

Remove
Re-use of belt
WARNING: Mark the direction the belt was fitted in case of re-use of the
same belt.
- Compress the tensioner roller (2) by action at «a» (in anti-clockwise direction),
tool [4].
- Keep the tensioner roller (2) compressed and remove the belt.

No re-use of belt.
- Compress the dynamic tensioner roller (2) by action at «a» (anti-clockwise), using
tool [4].
- Peg using tool [2], at «b».
- Hold the dynamic tensioner roller (2) compressed and remove the belt.
- Loosen the screw (1).
B1BP1YKD

118
 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT C5
Engines: RHY RHS RHZ
Without air conditioning (continued)

Refit.
Re-used belt.
- Compress the tensioner roller (2) by action at «a» (anti-clockwise), tool [4].
- Refit the belt.

WARNING: Respect the direction in which the belt is fitted.

Remove the tool [4].

New belt.
Refit the belt.
- Turn the eccentric roller (3), tool [1] (clockwise) to free the tool [2] from its
pegging at «b».
- Hold the eccentric roller (3), tool [1], and tighten the screw (1) to 4.3 ± 0.5 m.daN.
Remove the tool [2].
- Rotate the crankshaft 4 times in the direction of rotation.
- Check that it is possible to peg at «b», tool [3].
- If not possible to peg, restart the adjustment.
B1BP1YMD

119
ENGINE
C5 AUXILIARY EQUIPMENT DRIVE BELT
Engines: RHY - RHS - RHZ
With air conditioning

Tools
[1] Belt tension adjusting square : (-).0188 J2
[2] Ø 4 mm peg : (-).0188.Q1
[3] Ø 2 mm peg : (-).0188.Q2
[4] Dynamic tensioner compression lever : (-).0188.Z

Remove
Re-use of belt
WARNING: Mark the direction the belt was fitted in case of re-use of the same belt.
- Compress the tensioner roller (7) by moving it at «c» (in anti-clockwise direction),
tool [4].
- Hold the tensioner roller (7) compressed and remove the belt.

No re-use of belt.
- Compress the tensioner roller (7) by moving it at «c» (in anti-clockwise direction),
tool [4].
- Peg using tool [2], at «d».
- Loosen the screw (6)
- Bring the eccentric roller (5) towards the rear.
- Tighten the screw (6) by hand.
- Remove the belt.
B1BP1YLD

120
 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT C5
Engines: RHY – RHS – RHZ
With air conditioning (continued)

Refit.
Re-used belt.

- Compress the tensioner roller (7) by action at «c» (in anti-clockwise direction),
tool [4].
- Refit the belt.

WARNING: Respect the direction in which the belt is fitted.

Remove the tool [4].

New belt.

Refit the belt.

- Turn the eccentric roller (5), tool [1] (clockwise) to free the tool [2] from its peg-
ging at «d».
- Hold the eccentric roller (5), tool [1], and tighten the screw (6) to 4.3 ± 0.5 m.daN.
Remove the tool [2].
- Rotate the crankshaft 4 times in the normal direction of rotation.
- Check that it is possible to peg at «d», tool [3].
- If not possible to peg, restart the adjustment.

B1BP1YND

121
ENGINE
C8 AUXILIARY EQUIPMENT DRIVE BELT
Engines: RHT - RHW - RHM

Tools.
[1] Tensioning lever : (-).0188-J2.
[2] Peg for dynamic roller Ø 4 mm : (-) 0188-Q1.
[3] Peg for dynamic roller Ø 2 mm : (-).0188-Q2.
[4] Dynamic roller compression lever : (-).1888-Z.

(A) Pegging hole.

(B) Belt wear check mark (fixed on engine).
(C) Zero wear mark.
E5AK0E9C
(D) Maximum wear mark.

This marking system permits checking of the belt wear; if the marks (D) and (B) coincide, it implies
that the belt requires replacing.
Tighten the screw (1) to 4,5 ± 0,4 m.daN.
Removing.

Remove:
- The front RH wheel.
- The front RH splash-shield.
- The under-engine shield.
IMPERATIVE: Mark the direction of rotation of the belt if to be re-used.
B3EK0DHD

122
 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT C8
Engines: RHT RHW RHM

Removing (continued).
Slacken the fixing (2).
Action the roller (3), using tool [1], until the tool [2] is positioned in the pegging hole (A).
Bring the roller (3) back towards the rear.
Gently tighten the screw (2).
Remove the belt.
ESSENTIAL: Check that the rollers (3) and (4) turn freely (no play, no tight spot).

Refitting.
IMPERATIVE: If re-using the belt, refit it respecting the direction of rotation marked on removal.
Refit the belt, finishing with the tensioner roller (4).
Action the roller (3), using tool [1] (clockwise) to free the tool [2].
Tighten the fixing (2) to 4,5 ± 0,5 m.daN, without altering the position of the roller.
ESSENTIAL: Check that the belt is correctly positioned in the grooves of the various pulleys.
Remove the tool [1].
Rotate the engine four times.
Check that the marks (B) and (C) coincide.
Tool [3] should be able to engage freely, if not, repeat the adjustment.
Complete the refitting.

B1BK1A4C

123
ENGINE
C5 AUXILIARY EQUIPMENT DRIVE BELT
Engine: 4HX
Without air conditioning

Tools
[1] Dynamic tensioner compression lever : (-).0188.Z
[2] Peg Ø 4 mm : (-).0188.Q1

Remove.

WARNING: mark the direction of fitting in case the belt is to be reused.

- Compress the tensioner roller (1) by action at «a» (anti-clockwise), using tool [1].
- Peg at «b», using tool [2].
- Remove the auxiliaries drive belt.

Refit.
- Refit the auxiliaries drive belt.
- Compress the tensioner roller (1) by action at «a» (anti-clockwise), using tool [1].
- Remove the tool [2] at «b».

B1BP270D B1BP272D

124
 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT C5
Engine: 4HX
With air conditioning

Tools
[1] Dynamic tensioner compression lever : (-).0188.Z
[2] Peg Ø 4 mm : (-).0188.Q1

Remove.

WARNING: mark the direction of fitting in case the belt is to be reused.

- Compress the tensioner roller (4) by action at «c» (anti-clockwise), using tool [1].
- Peg at «d», using tool [2].
- Remove the auxiliaries drive belt.

Refit.
- Refit the auxiliaries drive belt.
- Compress the tensioner roller (4) by action at «c» (anti-clockwise), using tool [1].
- Remove the tool [2] at «d».

B1BP271D B1BP273D

125
ENGINE
C8 AUXILIARY EQUIPMENT DRIVE BELT
Engine: 4HW

Tools.

[1] Peg for dynamic roller : (-) 0188-Q1

[2] Dynamic roller compression lever : (-).1888-Z.

(A) Pegging hole.

(B) Belt wear check mark (fixed on engine).
(C) Zero wear mark.
E5AK0EDC
(D) Maximum wear mark. B3EK09PC
This marking system permits checking of the belt wear; if the marks (D) and (B)
coincide, it implies that the belt requires replacing.
Tighten the screw (1) to 4,5 ± 0,4 m.daN.
Removing.
Remove:
- The front RH wheel.
- The front RH splash-shield.
- The under-engine shield.
IMPERATIVE: Mark the direction of rotation of the belt if to be re-used.
E5AK0E8C

126
 ENGINE
AUXILIARY EQUIPMENT DRIVE BELT C8
Engine: 4HW

Removing (continued).

Action the roller (3), using tool [2], until the tool [1] is positioned in the pegging hole (A).
Remove the belt.

ESSENTIAL: Check that the rollers (3) and (4) turn freely (no play, no tight spot).

Refitting.

IMPERATIVE: If re-using the belt, refit it respecting the direction of rotation marked
on removal.

Refit the belt, finishing with the tensioner roller (3).

ESSENTIAL: Check that the belt is correctly positioned in the grooves of the various
pulleys.

Rotate the engine four times.

Complete the refitting.

B1BK1IWD

127
ENGINE
CHECKING AND SETTING THE VALVE TIMING
EW ES DW
7 10 12 9 10 12
J4 D J4 J4S TD ATED ATED4 TED TED4
Engine plate 6FZ RFN RLZ 3FZ XFX XFW RHY RHS RHZ RHW RHT RHM 4HX 4HW

2.0i
1.8i 2.0i 3.0i 2.0 2.0 2.0 2.2
C5 16V
16V 16V 24V HDi HDi HDi HDi
HPi

156 à 179 à
See pages: 129 à 137 161 170 à 178 184
2.2 2.0 2.0 2.0
2.0i 3.0i 2.2
C8 16V 16V 24V 16V 16V 16V
HDi
HPi HDi HDi HDi

See pages: 138 to 147 to 162 to 185 to 192 185 to

146 155 169 192

128
 ENGINE
CHECKING AND SETTING THE VALVE TIMING C5
NEW ASSEMBLY 2003 9 Engines: 6FZ-RFN-RLZ 2003 9

(6) Crankshaft pinion.

(7) Accessories drive pulley.
(8) Washer.
(9) Screw.
The pinion (6) is fitted as an idler on the crankshaft.
The accessories drive pulley (7) is immobilised on the crankshaft by a half-moon keyway and by
the tightening of washer (8) and screw (9).
A: Pegging on manual gearbox.
B: Pegging on automatic gearbox.
B1EP1B9D
The pegging of the crankshaft is done on the flywheel, or on the converter drive plate (automatic
gearbox).
The pegging hole on the cylinder block (exhaust end) is calibrated and reinforced.

IMPERATIVE: Never turn the crankshaft with the accessories drive pulley slackened.

IIMPERATIVE: Never remove the accessories drive pulley without pegging the crankshaft
and the camshafts.

IMPERATIVE: Always turn the crankshaft in the direction of engine rotation.

B1BP2V2D

129
ENGINE
C5 CHECKING AND SETTING THE VALVE TIMING
Engines: 6FZ-RFN-RLZ 2003 9
Tools.
[1] Union relieving the fuel pressure : 4192-T
[2] Crankshaft setting peg : (-).0189.R
[3] Camshaft setting peg : (-).0189.A
[4] Camshaft setting peg : (-).0189.L
[5] Tool for moving and locking the tensioner roller : (-).0189.S
[5a] : (-).0189.S1
[5b] : (-).0189 S2
[6] Adaptor for angular tightening : 4069-T
[7] Plug kit : (-) 0189.Q
[8] Timing belt retaining pin : (-) 0189.K

Checking the setting of the timing

Removing.
Disconnect the battery negative terminal (See corresponding operation).
Raise and support the vehicle, front wheels hanging.
Detach, move aside and plug the fuel supply pipe, using tool [7]
Remove:
The front RH wheel.
The splash-shield.
The upper timing cover.

130
 ENGINE
CHECKING AND SETTING THE VALVE TIMING C5
Engines: 6FZ-RFN-RLZ 2003 9
Checking the setting of the timing (continued).

A: Pegging on the manual gearbox, tool [2].

B: Pegging on the automatic gearbox, tool [2].

Turn the engine by means of the crankshaft pinion screw (1), to bring it to the pegging position.

Peg:
B1BP2V3D The crankshaft, using tooll [2].
The camshaft pulleys, using tools [3] and [4].

NOTE: The pegs [1] and [3] should go in without effort.

WARNING: If the pegs go in only with difficulty, repeat the operation for fitting and tensioning the
timing belt (See corresponding operation).

Refitting.

Remove tools [2], [3], [4] and [7].

Complete the refitting in reverse order to removal.
B1BP2WAD

131
ENGINE
C5 CHECKING AND SETTING THE VALVE TIMING
Engines: 6FZ-RFN-RLZ 2003 9

Setting the timing.

Removing.
Remove:
The engine cover
The battery cover
Disconnect the battery negative terminal (See corresponding operation).
Raise and support the vehicle, front wheels hanging.
Remove:
B1BP2AMC The front RH wheel.
The splash-shield.
The accessories drive belt (See corresponding operation).
Unclip:
The electrical harness (on the timing cover).
The petrol delivery pipe.
Place tool [1] on the valve (1) in order to reduce the fuel supply circuit pressure.
WARNING: Position a cloth to protect yourself from any projections of fuel.
Uncouple the fuel delivery (2), blanking it with a plug, tool [7].
Remove the fixing nut from the expansion chamber.
Detach the hose from the cooling radiator and from the front crossmember.
Disengage the expansion chamber.
B1BP2AND Remove the torque reaction rod.

132
 ENGINE
CHECKING AND SETTING THE VALVE TIMING C5
Engines: 6FZ-RFN-RLZ 2003 9
Setting the timing (continued)

Remove the upper timing cover (3).

Rotate the engine by means of the screw (5) of the crankshaft pulley (4) to bring it to the pegging
position.

Pegging on the gearbox.

B1BP2WBC A: Pegging on the manual gearbox, tool [2].

B: Pegging on the automatic gearbox, tool [2].

B1BP2V3D

133
ENGINE
C5 CHECKING AND SETTING THE VALVE TIMING
Engines: 6FZ-RFN-RLZ 2003 9

Setting the timing (continued)

Peg the camshaft pulleys (7) and (8), using tools [3] and [4].
Remove:
The screw (5).
The crankshaft pulley (4).
The lower timing cover (6).

IMPERATIVE: Never remove the crankshaft pulley without pegging the crankshaft and
B1EP1BYD camshafts.

Slacken the screw (11) of the tensioner roller (10).

Turn the tensioner roller (10) (clockwise).
Remove the timing belt (9).
Turn the tensioner roller (10), using tool [5a], to go past the slot «b».
Position the tool [5b] to lock the index «a» and remove the tool [5a].

IMPERATIVE: Systematically replace the following components: timing belt, exhaust

manifold fixing nuts, timing belt tensioner roller nut.

B1EP1BZD

134
 ENGINE
CHECKING AND SETTING THE VALVE TIMING C5
Engines: 6FZ-RFN-RLZ 2003 9
Setting the timing (continued)

Reposition the timing belt (9) on the crankshaft pulley.

Hold the timing belt (9) in place using tool [3].
Fit the timing belt (9) in place, respecting the following order:
- Guide roller (12).
- Inlet camshaft pulley (8).
- Exhaust camshaft pulley (7).
- Coolant pump (13).
- Tensioner roller (10).
NOTE: Make so that the belt (9) is as flush as possible with the exterior face of the various
pinions and rollers.
Remove:
Tool [2].
Tool [3] from the exhaust camshaft pulley.
Tool [5b] from the tensioner roller (10).
Refit:
The lower timing cover (6) (by moving the engine)
The crankshaft pulley (4)
Screw (4) of the crankshaft pulley
B1EP1C0C Tighten screw (5) to 4 ± 0,4 m.daN, then angular tighten to 53° ± 4°, tool [6].

135
ENGINE
C5 CHECKING AND SETTING THE VALVE TIMING
Engines: 6FZ-RFN-RLZ 2003 9

Tensioning the timing belt.

Turn the tensioner roller (10) in the direction of the arrow «c», by means of a hexagonal spanner at «d».
Positionner l’index «a» en position «f»

IMPERATIVE: The index «a» should go past the slot «g» by an angular value of 10°.
If it does not, replace the tensioner roller or the timing belt and tensioner roller assembly.

Next bring the index «a» to its adjusting position «g», by turning the tensioner roller in the direction of the arrow «e».
B1EP1C1C WARNING: the index «a» should not pass the slot «g».
Otherwise, repeat the operation to tension the timing belt.

IMPERATIVE: The tensioner roller should not turn during the tightening of its fixing.
If it does, repeat the operation to tension the timing belt.

Tighten the screw (11) of the tensioner roller (8) to 2,1 ± 0,2 m.daN.

IMPERATIVE: The hexagonal tensioner roller drive should be approx. 15° below the level of the cylinder
head gasket «h».
If it is not, replace the tensioner roller or the timing belt and tensioner roller assembly.
B1EP1C2C

136
 ENGINE
CHECKING AND SETTING THE VALVE TIMING C5
Engines: 6FZ-RFN-RLZ 2003 9

Refitting (continued)
Remove the tools.
Rotate the crankshaft ten times (normal direction of rotation).

IMPERATIVE: No pressure or outside force should be brought to bear on the timing belt.

Peg the inlet camshaft pulley, using tool [4].

B1EP1C1C Checks.

Tension of the timing belt.

ESSENTIAL: Check the position of the index «a», which should be opposite the slot «g».
If the position of the index «a» is not correct, repeat the operations to tension the timing belt.

Refit the upper timing cover (6).

Clip the fuel delivery hose on the timing cover.
Refit the accessories drive belt (See corresponding operation).
Lower the vehicle.
Reconnect the battery (See corresponding operation).
B1EP1C2C

137
ENGINE
C8 CHECKING AND SETTING THE VALVE TIMING
NEW ASSEMBLY 2003 9 Engine: RFN 2003 9

(6) Crankshaft pinion.

(7) Accessories drive pulley.
(8) Washer.
(9) Screw.
The pinion (6) is fitted as an idler on the crankshaft.
The accessories drive pulley (7) is immobilised on the crankshaft by a half-moon keyway and by
the tightening of washer (8) and screw (9).
A: Pegging on manual gearbox.
B: Pegging on automatic gearbox.
B1EP1B9D
The pegging of the crankshaft is done on the flywheel, or on the converter drive plate (automatic
gearbox).
The pegging hole on the cylinder block (exhaust end) is calibrated and reinforced.

IMPERATIVE: Never turn the crankshaft with the accessories drive pulley slackened.

IMPERATIVE: Never remove the accessories drive pulley without pegging the crankshaft
and the camshafts.

IMPERATIVE: Always turn the crankshaft in the direction of engine rotation.

B1BP2V2D

138
 ENGINE
CHECKING AND SETTING THE VALVE TIMING C8
Engine: RFN 2003 9
Tools.
[1] Camshaft setting peg : (-) 0189.A
[2] Crankshaft setting peg : (-).0189.R
[3] Timing belt retaining pin : (-).0189.K
[4] Adaptor for angular tightening : 4069-T
[5] Tool for moving and locking the tensioner roller : (-).0189.S
[5a] : (-).0189.S1
[5b] : (-).0189 S2
[6] Peg for positioning the dynamic tensioner roller : (-).0189.J

Removing.
Disconnect the battery.
Remove:
- The under-engine shield.
- The auxiliary drive belt (see corresponding operation).
Move aside:
- The fuel delivery pipe.
- The canister purge electrovalve.
- The expansion chamber.
Remove:
- The screws (1) and (2).
- The torque reaction rod (3).
B1EK1T7D

139
ENGINE
C8 CHECKING AND SETTING THE VALVE TIMING
Engine: RFN 2003 9

Setting the timing (continued).

Remove the upper timing cover (4).

WARNING: Do not slacken the screws «a».

Turn the engine by means of the crankshaft pinion screw (5), to bring it to the pegging position.

A: Pegging on the manual gearbox, tool [2].

B1BP2WBC B: Pegging on the automatic gearbox, tool [2].

B1BP2V3D

140
 ENGINE
CHECKING AND SETTING THE VALVE TIMING C5
Engine: RFN 2003 9

Setting the timing (continued)

Peg the camshaft pulleys (8) and (9), using tool [1].
The screw (13).
The crankshaft pulley (12).
The timing cover (6).

IMPERATIVE: Never remove the crankshaft pulley without pegging the crank-
shaft and camshafts.

Slacken the screw (7) of the tensioner roller.

Turn the tensioner roller (clockwise).
Remove the timing belt (9).

B1EP1BWD

141
ENGINE
C8 CHECKING AND SETTING THE VALVE TIMING
Engine: RFN 2003 9
Refitting.

IMPERATIVE: Check that the tensioner roller, guide roller and coolant pump can turn
freely (without play and without tight spots); check also that these rollers are not noisy
and/or that they are not splashed with grease.

If replacing the tensioner roller: Tighten to 3,5 ± 0,3 m.daN.

Turn the tensioner roller, using tool [5a], to go past the slot «c».
Position the tool [5b] to lock the index «b» and remove the tool [5a].
B1EP1BQD

IMPERATIVE: Systematically replace the following components: timing belt, exhaust

manifold fixing nuts, timing belt tensioner roller nut.

Reposition the timing belt (10) on the crankshaft pinion.

Hold the timing belt (10) in place using tool [3].

B1EP1BRC

142
 ENGINE
CHECKING AND SETTING THE VALVE TIMING C8
Engine: RFN 2003 9

Fit the timing belt (10) in place, respecting the following order:
- Guide roller (11).
- Inlet camshaft pulley (9).
- Exhaust camshaft pulley (8).
- Coolant pump.
- Tensioner roller.
NOTE: Make so that the belt (10) is as flush as possible with the exterior face of the various pinions and rollers.
Remove:
Tool [2].
Tool [3].
Tool [1] from the exhaust camshaft pulley.
Tool [5b] from the tensioner roller.
Refit:
The lower timing cover.
The crankshaft pulley (12).
The screw (13).
Tighten screw (13) to 4 ± 0,4 m.daN, then angular tighten to 53° ± 4°, tool [4].

143
ENGINE
C8 CHECKING AND SETTING THE VALVE TIMING
Engine: RFN 2003 9
Tensioning the timing belt.

IMPERATIVE: This operation must be one with the engine cold.

«e» Max. position.

«d» Nominal tension position.

Using the hexagonal bracket «f», turn the hub of the tensioner roller (14) (anti-clockwise), to bring the
index «b» to position «e» to tension the belt to the maximum.

Turn the eccentric hub (15) of the roller (14) (clockwise), until the cursor (b) comes into gentle contact with
the peg [6].

IMPERATIVE: Never turn the eccentric hub (15) by a complete rotation when the tool [6] is in
position.

NOTE: This operation enables you to position the index «b» in the nominal position «d».

Tighten screw (7) to 2 m.daN, holding the roller by means of the hexagonal bracket «f».

Remove the pegs [1], [2] and [6].

B1EP1BXD

144
 ENGINE
CHECKING AND SETTING THE VALVE TIMING C8
Engine: RFN 2003 9
Checks.

Make two rotations of the crankshaft (direction of rotation of the engine).

IMPERATIVE: Never turn the crankshaft backwards.

Make sure that the timing is correctly set, by refitting the camshaft and crankshaft setting pegs.

Remove the setting pegs.

Make ten rotations of the crankshaft (direction of rotation of the engine).

Check the position of the index (15).

If the index (15) is not in its adjustment position «e», recommence the operations to tension the timing belt.

B1EP1BTC

145
ENGINE
C8 CHECKING AND SETTING THE VALVE TIMING
Engine: RFN 2003 9

Refitting (continued).

Refit:

The upper timing cover.

The torque reaction rod (3).

The screw (1), tighten to 4,5 m.daN

The screw (2), tighten to 4,5 m.daN.

Continue the refitting operations in reverse order to removal.

Refit the auxiliary drive belt (see corresponding operation).

B1EK1T7D

146
 ENGINE
CHECKING AND SETTING THE VALVE TIMING C8
NEW ASSEMBLY 2003 9 Engine: 3FZ 2003 9
(6) Crankshaft pinion.
(7) Accessories drive pulley.
(8) Washer.
(9) Screw.
The pinion (6) is fitted as an idler on the crankshaft.
The accessories drive pulley (7) is immobilised on the crankshaft by a half-moon keyway and by
the tightening of washer (8) and screw (9).
A: Pegging on manual gearbox.
B: Pegging on automatic gearbox.
B1EP1B9D
The pegging of the crankshaft is done on the flywheel, or on the converter drive plate (automatic
gearbox).
The pegging hole on the cylinder block (exhaust end) is calibrated and reinforced.

IMPERATIVE: Never turn the crankshaft with the accessories drive pulley slackened.

IMPERATIVE: Never remove the accessories drive pulley without pegging the crankshaft
and the camshafts.

IMPERATIVE: Always turn the crankshaft in the direction of engine rotation.

B1BP2V2D

147
 C8
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine: 3FZ 2003 9

Tools.
[1] Camshaft setting peg : (-) 0189.A
[2] Crankshaft setting peg : (-).0189.R
[3] Timing belt retaining pin : (-).0189.K
[4] Adaptor for angular tightening : 4069-T
[5] Tool for moving and locking the tensioner roller : (-).0189.S
[5a] : (-).0189.S1
[5b] : (-).0189 S2
[6] Peg for positioning the dynamic tensioner roller : (-).0189.J
[7] Camshaft setting peg : (-).0189.L

Removing.
Disconnect the battery.
Remove:
- The under-engine shield.
- The auxiliary drive belt (see corresponding operation).
Move aside:
- The fuel delivery pipe.
- The canister purge electrovalve.
- The expansion chamber.
Place a jack under the vehicle to support the engine.

148
 ENGINE
CHECKING AND SETTING THE VALVE TIMING C8
Engine: 3FZ 2003 9
Remove:

- The screws (1) and (26).

- The torque reaction rod (3).

- The nut (4).

- The three screws (3).

B1EP1BMC
- The RH engine support (2).

IMPERATIVE: Uncouple the exhaust line to avoid any damage to the flexible pipe caused
by twisting, pulling and bending it while removing one of the power unit supports.

A: Pegging on the manual gearbox, tool [2].

B: Pegging on the automatic gearbox, tool [2].

B1BP2V3D

149
ENGINE
C8 CHECKING AND SETTING THE VALVE TIMING
Engine: 3FZ 2003 9
Remove the timing cover (7).

WARNING: Do not slacken the screws (a).

Rotate the engine by means of the screw (8) of the crankshaft pinion to bring it to the pegging
position.
Peg the camshaft pulleys (13) and (14), using tools [1] and [7].
Remove:
The screw (8).
B1EP1BNC The crankshaft pulley (16).
The timing cover (9).

IMPERATIVE: Never remove the crankshaft pulley without pegging the crankshaft and
camshafts.

Slacken the screw (12) of the tensioner roller (11).

Turn the tensioner roller (11) (clockwise).
Remove the timing belt.

B1EP1BPD

150
 ENGINE
CHECKING AND SETTING THE VALVE TIMING C8
Engine: 3FZ 2003 9
Refitting.

IMPERATIVE: Check that the tensioner roller, guide roller and coolant pump can turn free-
ly (without play and without tight spots); check also that these rollers are not noisy and/or
that they are not splashed with grease.

If replacing the tensioner roller (15): Tighten to 3,5.

Turn the tensioner roller, using tool [5a], to go past the slot «c».
Position the tool [5b] to lock the index «b» and remove the tool [5a].
B1EP1BQD

IMPERATIVE: Systematically replace the following components: timing belt, exhaust

manifold fixing nuts, timing belt tensioner roller nut.

Reposition the timing belt on the crankshaft pinion.

Hold the timing belt in place using tool [3].

B1EP1BRC

151
ENGINE
C8 CHECKING AND SETTING THE VALVE TIMING
Engine: 3FZ 2003 9
Fit the timing belt in place, respecting the following order:
- Guide roller (15).
- Inlet camshaft pulley (14).
- Exhaust camshaft pulley (13).
- Coolant pump (10).
- Tensioner roller (11).
NOTE: Make so that the belt is as flush as possible with the exterior face of the various pinions
and rollers.
Remove:
B1EP1BRC Tool [3].
Tool [1] from the exhaust camshaft pulley.
Tool [5b] from the tensioner roller.
Refit:
The lower timing cover (9).
The crankshaft pulley (16).
The screw (8) of the crankshaft pulley.
Tighten screw (8) to 4 ± 0,4 m.daN, then angular tighten to 53° ± 4°, tool [4].

B1EP1BPD

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CHECKING AND SETTING THE VALVE TIMING C8
Engine: 3FZ 2003 9
Tensioning the timing belt.

IMPERATIVE: This operation must be done with the engine cold.

«e» Max. position.

«d» Nominal tension position.

Using the hexagonal bracket «f», turn the hub of the tensioner roller (18) (anti-clockwise), to bring the
index «b» to position «e» to tension the belt to the maximum.

Turn the eccentric hub (17) of the roller (18) (clockwise), until the cursor (b) comes into gentle contact with
the peg [6].

IMPERATIVE: Never turn the eccentric hub (8) by a complete rotation when the tool [4] is in posi-
tion.

NOTE: This operation enables you to position the index «e» in the nominal position «d».

Tighten screw (12) to 2 m.daN, holding the roller by means of the hexagonal bracket «f».

Remove the pegs [7], [2] and [4].

B1EP1BXD

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C8 CHECKING AND SETTING THE VALVE TIMING
Engine: 3FZ 2003 9
Checks.

Make two rotations of the crankshaft (direction of rotation of the engine).

IMPERATIVE: Never turn the crankshaft backwards.

Make sure that the timing is correctly set, by refitting the camshaft and crankshaft setting pegs.

Remove the setting pegs.

Make ten rotations of the crankshaft (direction of rotation of the engine).

Check the position of the index (b).

If the index (b) is not in its adjustment position «e», recommence the operations to tension the timing belt.

B1EP1BTC

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CHECKING AND SETTING THE VALVE TIMING C8
Engine: 3FZ 2003 9

Refitting (continued).

Refit:

The upper timing cover.

The RH engine support (2).
The torque reaction rod (5).

The screw (1), tighten to 4,5 m.daN

The screw (6), tighten to 4,5 m.daN.

Continue the refitting operations in reverse order to removal.

Refit the auxiliary drive belt (see corresponding operation).

B1EP1BUC

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ENGINE
C5 CHECKING AND SETTING THE VALVE TIMING
Engine: XFX

Tools.

[1] Camshaft setting pegs (-).0187.B

[2] Crankshaft setting peg (-).0187.A.
[3] Fuel pressure take-off union 4192-T
[4] Belt retaining pin (-).0187.J
[5] Exhaust camshaft hubs immobilising tool (-).0187.F.
[6] Inlet camshaft hubs immobilising tool (-).0187.F

Remove the auxiliaries drive belt (See corresponding operation).

Checking the valve timing setting.

Remove:
- The power steering pulley.
- The roller / dynamic tensioner assembly (11).
- The crankshaft pulley (12).
- The upper timing covers (9) and (10).
B1BP2BKC - The lower timing cover (13).

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING C5
Engine: XFX

Checking the valve timing setting (continued).

- Peg the crankshaft, using tool [1].

- Check that the tool [2] engages without effort in the cylinder heads at the camshaft pulleys.
- Remove the tools [1] and [2].

Refit:
- The lower timing cover (13).
- The upper timing covers (9) and (10).
- The crankshaft pulley (12).
- The roller / dynamic tensioner assembly (11).
- The power steering pulley.

- Complete the refitting of components.

- Initialise the ignition injection ECU.

B1EP08TC B1EP15UD

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ENGINE
C5 CHECKING AND SETTING THE VALVE TIMING
Engine: XFX

Setting the valve timing

- Remove the components as necessary for the operation.
- Remove the screws (19) and the plate (20).
- Peg the crankshaft, using tool [2].
NOTE: Damp the rotation of the camshafts (15) and (17), using tool [6]
- Untighten the camshaft pulley screws (15) and (17).
NOTE: Damp the rotation of the camshafts (14) and (18), using tool [5]
- Untighten the camshaft pulley screws (14) and (18).
NOTE: Lubricate the tools [1], with grease G6 (TOTAL MULTIS).
Peg the camshafts, using tools [1], [5] and [6].
Remove the screw (21) of the panel (25).
Untighten the nut (23) of the tensioner roller (24).
Untighten the screws (22) of the panel (25).
Remove the guide roller (16)

WARNING: mark the direction of fitting of the timing belt, in case the belt is to be
reused
- Remove the timing belt.

B1EP15VD

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CHECKING AND SETTING THE VALVE TIMING C5
Engine: XFX

Setting the valve timing (continued)

Refit.
- Check that the camshafts and the crankshaft are correctly pegged.
- Check that the rollers and the water pump pulley are turning freely. (No tightness)
- Loosen the camshaft pulley screws by a _ turn.
- Make sure that the pulleys are turning freely on the camshaft hub.
- Turn the camshaft pulleys in a clockwise direction, to end of slots.
WARNING: Respect the direction of fitting of the belt: facing the timing, the inscriptions on
the belt should be readable the correct way up.
- Fit the timing belt on the crankshaft pinion.
- Position the tool [6].
Position the timing belt in the following sequence: (Belt well tensioned).
- The roller (26), the pulley (18), the pulley (17),
- Keep the timing belt well tensioned:
- Refit the guide roller (16), tighten to 8 ± 0,8 m.daN.
Position the timing in the following sequence:
- The camshaft pulley (15), the camshaft pulley (14), the tensioner roller (24), the water pump
pulley, and the guide roller (27).

NOTE: When positioning the belt on the camshaft pulleys, turn these clockwise so as to
engage the next tooth. The angular displacement of the pulleys should not be more than the
equivalent of one tooth.
B1EP15VD B1BP2BLC

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ENGINE
C5 CHECKING AND SETTING THE VALVE TIMING
Engine: XFX

Setting the valve timing (continued)

Adjusting the timing belt tension.

- Pivot the plate (25) of the tensioner roller (24), using a spanner. (type FACOM S.161).
- Engage the screw (21) on the plate (25).
- Tighten the screws (21) and (22), tighten to 2,5 ± 0,1 m.daN.
- Position the belt under maximum tension; pivot the tensioner roller (24),using a spanner
(type FACOM R 161).
Tighten the nut (23) of the tensioner roller (24), tighten to 1 ± 0,1 m.daN.
- Check that the camshaft pinion screws are not at the end of slots.
(By loosening one screw).
- Otherwise, restart the operation of positioning the timing belt.
- Tighten at least 2 screws per camshaft pulley to 1 ± 0,1 m.daN.
- Remove the tools [1], [2] and [4].
- Rotate the crankshaft 2 turns in a clockwise direction.
IMPERATIVE: Never turn it back.
- Peg the crankshaft, using tool [2], and the camshaft pulleys, using tool [1].
- Untighten the nut (23) of the tensioner roller (24).
Adjust the belt tension, pivoting the roller (24) using tool (type FACOM S.161).

B1EP15WC B1EP15XC

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING C5
Engine: XFX

Setting the valve timing (continued)

- Align the marks «c» and «d», without detensioning the timing belt.
(Failing this, restart the operation of adjusting the belt tension).
- Hold the tensioner roller (24).
- Tighten the nut (23), tighten to 1 ± 0,1 m.daN.
- Check the position of the tensioner roller.
- Remove the tools [1], [2] and [4]
- Turn the crankshaft 2 rotations in the direction of engine rotation.
IMPERATIVE: Never turn it back.
- Peg the crankshaft, using tool [2]
- Check the roller position (24) (the alignment of the marks «c» and «d» should be correct)
- Peg the camshaft pinions, using tool [1]..
- If the peg [1] goes in, loosen the camshaft pulley screws by 45°
- If the peg [1] does not go in, then loosen the camshaft pulley screws by 45° and manoeuvre the
hub using tool [5] until pegging is achieved.
- WARNING: Check that the camshaft pinion pulleys are not at the end of slots. Otherwise, restart the
operation of positioning the timing belt.
- Tighten the camshaft pinion screws to 1 ± 0,1 m.daN.
- Remove the tools [1] and [2].
- Refit the panel (20), the screws (19) and tighten to 4 ± 0, m.daN.
- Complete the refitting of all components.
B1EP15XC

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ENGINE
C8 CHECKING AND SETTING THE VALVE TIMING
Engine: XFW

Tools.
[1] Camshaft setting pegs : (-).0187-B
[2] Crankshaft setting peg : (-).0187-A
[3] Belt retaining pin : (-).0187-J
[4] Peg for checking camshaft settings : (-).0187-CZ
[5] Tool for immobilising inlet camshaft hubs : (-).0187-C
[6] Tool for immobilising exhaust camshaft hubs : (-).0187-F
[7] Instrument for measuring belt tension : (-).0192

Removing.
Remove:
The front RH wheel
The RH wheelarch.
The front RH tie-bar.
The auxiliary drive belt (see corresponding operation).
The tensioner roller assembly (1).
The crankshaft pulley (2).

Support the engine using a stand.

Remove:
The upper RH torque reaction rod.
B1EK004D The RH engine support.

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CHECKING AND SETTING THE VALVE TIMING C8
Engine: XFW

Removing (continued).

Remove:
The twelve screws (3) (6mm external hexagonal adaptor).
The seven screws (4) (7mm external hexagonal adaptor).
The two covers (5)
The cover (6)
The fixing screws of the power steering pump, then suspend the latter.
B1EK005D The support (7). B1EK007D

NOTE: The camshaft pegging operation can be performed without slackening the
pinion screws or rotating the camshafts (using tools [5] and [6]; lightly oil the pegs
[1] and [2] prior to fitting.

Peg in the sequence:

Camshafts, using tool [1].

Crankshaft, using tool [2]

B1EK006D

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ENGINE
C8 CHECKING AND SETTING THE VALVE TIMING
Engine: XFW

Removing (continued).

Remove screw (8).

Slacken screws (9) and (10) and nut (11).
Pivot the tensioner roller eccentric (clockwise), using tool FACOM R 161 at «B».
Remove the guide roller (12).
Remove the timing belt, commencing with the tensioner roller and the coolant pump.

B1EK008D Refitting.

Make sure that the camshafts, as well as the crankshaft, are correctly pegged.
Check that the rollers (13) and (14), as well as the coolant pump (15) turn freely (no tight
spots).
If replacing the belt, tighten the rollers (13) and (14) to 8 ± 0,8 m.daN.
Slacken screws (16) by a _ turn.
Ensure that the camshaft pinions rotate freely on their hubs.
Turn the four camshaft pinions (clockwise), to end of slots.
Engage the timing belt on the crankshaft pinion.
Immobilise the belt, using tool [4].

B1EK009D

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING C8
Engine: XFW

Refitting (continued).

Position the belt on the guide roller (13), belt at (C) well tensioned.

NOTE: Carefully turn the camshaft pinion in the opposite direction to the rotation of the
engine in order to engage the belt on the pinion.

B1EK00AD
Engage the belt on the LH exhaust camshaft pinion (17).

IMPERATIVE: The angular displacement value of the pinion relative to the timing belt
should not be greater than the width of one tooth.

Engage the belt on the LH inlet camshaft pinion (18), as before.

Refit the roller (12), tighten to 8 ± 0,8 m.daN.

B1EK00BD

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ENGINE
C8 CHECKING AND SETTING THE VALVE TIMING
Engine: XFW
Refitting (continued).

Engage the belt on:

The roller (13).
The camshaft pinions, inlet (19) then RH exhaust (20), as before for the camshafts.
Simultaneously engage the belt on:
The roller (21).
The pump (15).
The roller (14).
B1EK00CD
Using tool FACOM S.161, at «A», pivot the plate to be able to engage the screw (8).
Tighten screws (8), (9) and (10) to 2,5 ± 0,2 m.daN.
Pivot the tensoner roller to tension the belt to the maximum (anti-clockwise), using tool FACOM R.161
at «B»:
- SEEM CTI 901-1: 440 ± 15 SEEM units,
- SEEM CTG 105.5: 83 ± 2 SEEM units,
- SEEM CTG 105.6: 86 ± 2 SEEM units.
Tighten the nut (11) of the tensioner roller to 1 ± 0,1 m.daN.

IMPERATIVE: Check that the camshaft pinions are not at end of slots (by removing a screw).
If they are, repeat the operation to refit the belt.

B1EK00DD

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING C8
Engine: XFW
Refitting (continued).
Tighten at least two screws (16) per hub to 1 ± 0,1 m.daN, in the order indicated (17), (18),
(19) and (20).
Remove tools [4], [7], [1] and [2].
Effect two rotations of the crankshaft (direction of rotation of the engine).

WARNING: Never rotate the engine backwards.

Peg the crankshaft, using tool [2].

B1EK00ED Slacken the nut (11) a _ turn.
Align the marks (D) and (E) of the tensioner roller, using tool FACOM R.161.
Tighten the nut (11) to 2,5 ± 0,2 m.daN, without altering the position of the roller.
Remove the crankshaft setting peg [2].
Effect two rotations of the crankshaft.

WARNING: Never rotate the engine backwards.

Peg the crankshaft, using tool [2].

Check the position of the tensioner roller.
If the marks are not aligned, recommence the alignment of the marks (D) and (E) of the
tensioner roller.
B1EK0VRD

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ENGINE
C8 CHECKING AND SETTING THE VALVE TIMING
Engine: XFW
Refitting (continued).
Peg the camshaft hubs, starting with LH exhaust (17) then (18), (19) and (20), using tool
[1], proceeding in the following way:
- The peg goes in: slacken by 45° the fixing screws of the pinion on the camshaft hub.
- The peg does not go in: slacken by 45° the fixing screws of the pinion on the camshaft
hub until the peg will go in.
ESSENTIAL:
Check that the camshaft pinions are not at end of slots (by removing a screw).
If they are, repeat the operation to refit the belt..
B1EK00GD
Tighten the pinions in the sequence below:
Pinions (17), (18), (19), (20) tighten to 1 ± 0,1 m.daN.
Remove tools [1] and [2]

Checking the setting of the timing.

Effect two rotations (Normal direction of rotation of the engine).
Imperative: Never turn the engine backwards.
Refit the crankshaft peg [2].
Check that the peg for checking the camshaft settings [4] engages freely in the cylinder
heads (J), as far as the camshaft pinions.

B1EK00HD

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING C8
Engine: XFW

Checking the setting of the timing (continued).

Should this not be the case, repeat the operation to refit the belt.
Remove the crankshaft peg [2].

Refitting (continued).
Refit:
The power steering pump.
The support (7).
The tensioner roller assembly (1).
Tighten:
Screw (22) to 2,5 m.daN + LOCTITE FRNETANCH.
Screw (23) to 4,0 m.daN + LOCTITE FRNETANCH.
Screw (24) to 2,5 m.daN + LOCTITE FRNETANCH.
Screw (25) to 6,0 m.daN + LOCTITE FRNETANCH.
Tighten the crankshaft pulley screws to 2,5 ± 0,2 m.daN.
Refit the auxiliary drive belt (see corresponding operation).
Complete the refitting operations in the opposite order to removal.

B1EK00JD

169
ENGINE
C5 SPECIAL FEATURES: CHECKING AND SETTING THE VALVE TIMING
Engines: RHY-RHS-RHZ RPO 9128 9
OLD FITTING: 9 RPO 9127 NEW FITTING: RPO 9128 9

B1EP176D B1EP177D

(1) «Idler» camshaft pulley The new timing on 8 valve engines DW10TD (RHY) and DW10 ATED
(2) Target for cylinder reference sensor. (RHS-RHZ) requires the following components:
(3) Camshaft hub. «Idler» crankshaft pinion
(4) «Fixed» crankshaft pinion. «Fixed» camshaft pulley.
The determining of the tension of the timing belt is done on the camshaft
pulley (1). (5) «Fixed» camshaft pulley (pulley with integral cylinder reference sen-
sor target).
(6) «Idler» crankshaft pinion (with increased width keyway groove).
The determining of the tension of the timing belt is done on the crank-
shaft pinion (6).

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SPECIAL FEATURES: CHECKING AND SETTING THE VALVE TIMING C5
Engines: RHY - RHS - RHZ RPO 9128 9
NEW FITTING: RPO 9128 9 (continued)

The new fitting discontinues the following components:

Camshaft hub.
Cylinder reference sensor target.

Repair – Accessories drive pulley

Remove – Refit

WARNING: Peg the camshaft and the crankshaft before ever removing the
accessories drive pulley (the pegging prevents any offsetting of the camshaft).

If necessary, apply a paint spot to mark the accessories drive pulley being
replaced.

Replacement parts.

The Replacement Parts service markets the old as well as the new components.

B1EP177D

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ENGINE
C5 CHECKING AND SETTING THE VALVE TIMING
NOTE: Checking and setting the valve timing on engines: RHY-RHS-RHZ 9 RPO 9127
See Mechanic’s Handbook 2003 pages 151 to 154
Engines: RHY-RHS-RHZ RPO 9128 9
Tools. Removing

[1] Belt tension measuring equipment : 4122-T IMPERATIVE: Respect the safety and cleanliness requirements
that are specific to high pressure diesel injection (HDi)
[2] Tension lever : (-).0188.J2. engines.
[3] Engine flywheel peg : (-).0188.Y. Undo the front RH wheel bolts.
Raise and support the vehicle on the front RH side.
[4] Belt clamp : (-).0188.AD
Disconnect the battery negative terminal.
[5] Camshaft pulley peg : (-).0188.M Remove:
The under-engine sound-deadening.
[6] Engine flywheel lock : (-).0188.F. The front RH wheel.
The front RH splash-shield.
[7] Set of blocking plugs : (-).0188.T. The engine cover.
Unclip and move aside the cooling hose.
[8] Pulley extractor : (-).0188.P. Remove the accessories drive belt.
(See corresponding operation).
[9] 2 mm dia.peg : (-).0188.Q2

B1EP159D

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING C5
ENGINES: RHY-RHS-RHZ RPO 9128 9

Uncouple, plug and move aside, using tool [7] , the fuel delivery pipe (2) and
return pipe (1).
Remove:
Screws (3), (4) and (6).
Screw (7).
The upper timing cover (5).

WARNING: Refit screw (7) equipped with a spacer (17 mm thick), tighten the
screw (7) to 1,5 ± 0,1 m. daN.

NOTE: The screw (7) is one of the screws securing the coolant pump and is
there for its sealing.
Put the gear lever in 5th gear.
Turn the road wheel to turn the engine in its direction of rotation.
Orient the camshaft pulley in the pegging position, use a mirror if necessary.

Peg the camshaft, using tool [5]

Peg the engine flywheel, using tool [3].

B1BP2R2C B1EP1A7C B1BP2H2C B1BP2H3C

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ENGINE
C5 CHECKING AND SETTING THE VALVE TIMING
ENGINES: RHY-RHS-RHZ RPO 9128 9
Remove:
The fixings of the pipe linking the power steering pump with the rotary valve.
The clutch lower closing plate.
Lock the engine flywheel, using tool [6].
Remove the screw (8).
Refit the screw (8) without its thrust washer.
Remove:
The accessories pulley (9), using tool [8].
Tool [6].
B1CP04BC The lower torque reaction rod.
Support the engine by means of a workshop hoist. B1BP2R4C
Remove:
The bearing shell fitting (10).
The nut (12).
Screws (11).
The bracket (13).
NOTE: Lift then lower the engine with the workshop hoist, to have access to the
timing cover fixing screws.
Remove:
The intermediate timing cover.
The lower timing cover.
B1BP2R3C

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING C5
Engines: RHY-RHS-RHZ RPO 9128 9
Slacken the screw (17) of the tensioner roller (18).

Remove the timing belt (14).

Checks.

IMPERATIVE: Just before refitting, carry out the checks below:

Check that:
B1EP1A8D
The rollers (18) and (15) turn freely (without play and without any tight spot).
The coolant pump pulley (16) turns freely (without play and without any tight spot).
There are no traces of oil leaks from the crankshaft and camshaft seals, etc.
The crankshaft pinion travels freely on the keyway.

Replace defective components if necessary.

Peg the crankshaft pinion (19) by inserting tool [9] on the LH side of the keyway.

B1EP1A9C

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ENGINE
C5 CHECKING AND SETTING THE VALVE TIMING
Engines: RHY-RHS-RHZ RPO 9128 9
Reposition the timimg belt, belt at «a» well tensioned, in the following order:
Fuel high pressure pump pulley (21).
Guide roller (15).
Crankshaft pinion (19).
Coolant pump pinion (16).
Tensioner roller (18).
Position tool [1] on the belt at «a».
Remove tools [4] and [9]
Turn the tensioner roller (18) anti-clockwise, using tool [2], to attain an overtension of:
B1EP1ABD
98 ± 2 SEEM units.
Tighten screw (17) of the tensioner roller to 2,5 ± 0,2 m.da N.
Lock the flywheel by means of tool [6].
Tighten the accessories drive pulley screw (8) to 7 ± 0,7 m.da N.
Remove tools [1], [3], [5] and [6].
Rotate the crankshaft eight times in the normal direction of rotation.
Peg:
The crankshaft, using tool [3].
The camshaft drive pulley, using tool [5].

B1EP1ACC

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING C5
Engines: RHY-RHS-RHZ RPO 9128 9

Lock the engine flywheel, using tool [6].

Slacken: The accessories drive pulley (8).
The screw (17) of the tensioner roller (18).
Fit the tool [1].
Turn the tensioner roller, using tool [2], to attain a tension of:
54 ± 2 SEEM units.
Tighten screw (17) of the tensioner roller (18) to 2,5 ± 0,2 m.daN.
Remove tool [1].
Fit tool [1].
The tension value should be:
54 ± 3 SEEM units.
ESSENTIAL: If the value is incorrect, recommence the operation.

Remove tools [1], [3], [5] and [6].

Rotate the crankshaft two times in the normal direction of rotation.
Peg:
The crankshaft, using tool [3].
The camshaft drive pulley.

IMPERATIVE: If the pegging is not possible, recommence the operation.

B1EP1ACC

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ENGINE
C5 CHECKING AND SETTING THE VALVE TIMING
Engines: RHY-RHS-RHZ RPO 9128 9
Remove:
Tools [3] and [5].
Screw (7) and the spacer.
Refit:
The lower, intermediate and upper covers (5)
Screw (7), tighten to 1,5 ± 0,1 m.daN
Screws (3), (4) and (6).
The bracket (13).
Screws (11) , tighten to 6,1 ± 0,5 m.daN
The nut (12), tighten to 4,5 ± 0,5 m.daN
Fit the bearing shell (10).
Take away the workshop hoist.
Clip the fuel delivery and return pipes.
Remove the tool [7].
Couple:
The fuel delivery pipe (12). The fuel return pipe (1).
Coat the screw (8) with loctite FRENETANCH.
Refit the tool [6] and the screw (8) with the washer (22),
Tighten to 7 ± 0,2 m.daN and angular tighten to A = 60° ± 5°
Refit the torque reaction rod on the lower engine support.
Remove the tool [6].
Reposition and reclip the cooling hose.
Complete the refitting of components in reverse order to removal.
B1EP1A7C B1BP2R4C B1EP1ADC

178
 ENGINE
CHECKING AND SETTING THE VALVE TIMING C5
Engine: 4HX

Tools
[1] Belt tension measuring instrument : 4122-T
[2] Engine flywheel peg : (-).0188.X.
[3] Tension lever : (-).0188.Y.
[4] Belt compression spring : (-).0188.K.
[5] Camshaft pinion peg : (-).0188.M.
[6] Engine flywheel lock : (-).0188.F.
[7] Set of blocking plugs : (-).0188.T.

IMPERATIVE: Respect the safety and cleanliness recommendations

specific to high pressure diesel injection (HDi) engines.

Checking the setting of the valve timing.

- Turn the crankshaft (normal direction of rotation) and line up the black mar-
kings on the chain (b) and (c) with the teeth marked (a) and (d) of the cam-
B1EP159D shaft drive pinions (40 turns max. of the camshaft).

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ENGINE
C5 CHECKING AND SETTING THE VALVE TIMING
Engine: 4HX

Checking the setting of the valve timing (continued).

IMPERATIVE: If it is impossible to line up the marks on the chain and on the camshaft drive
pinions, restart the camshaft setting.
(See operation for removing and refitting camshafts).

If the marks on the chains and pinions are coinciding, continue the checking operations.

Peg:
- The crankshaft, using tool [2].
- The camshaft pinion, using tool [5]

IMPERATIVE: Should it be impossible to peg the camshaft, check that the offset between the
camshaft pinion hole and the pegging hole is not more than 1 mm (use a screw 7 mm in dia.).
If the offset is more than 1 mm, restart the setting of the valve timing
(See corresponding operation).
- Remove the tools [2] and [5].

B1BP298C B1EP15AD

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 ENGINE
CHECKING AND SETTING THE VALVE TIMING C5
Engine: 4HX

Setting the valve timing.

- Turn the crankshaft to bring camshaft to its pegging point.
- Peg the crankshaft, using tool [2].
- Peg the camshaft, using tool [5].

Untighten:
- The three screws (25).
- The screw (23) of the tensioner roller (24).
- Remove the timing belt (26).

Checks.

IMPERATIVE: just prior to refitting, carry out the checks below:

Check:
- That the rollers (24) and (27) and the water pump (22) are turning freely.
(Without play and without tightness).
- Absence of traces of oil leaks (Crankshaft and camshaft sealing rings).
- Absence of leaks of coolant fluid (Water pump).
NOTE: Replace defective components (If necessary).
B1BP298C B1EP15AD

181
ENGINE
C5 CHECKING AND SETTING THE VALVE TIMING
Engine: 4HX

Setting the valve timing (continued).

Refit
- Retighten the screws (25) by hand.
- Turn the pinion (29) (clockwise) to the bottom of the buttonhole.
- Refit the belt on the crankshaft (28)
- Hold the belt, using tool [4].

Reposition the timing belt, keeping the belt tight at «a»,

in the following order:
- Guide roller (27).
- Fuel high pressure pump pinion (30).
- Camshaft pinion (29).
- Water pump pinion (22).
- Tensioner roller (24).
NOTE: If needed, slightly turn the pinion (29) anti-clockwise (not by more
than one tooth).

- Remove the tool [4].

B1EP15BD B1EP15CC B1EP15DD

182
 ENGINE
CHECKING AND SETTING THE VALVE TIMING C5
Engine: 4HX

Setting the valve timing (continued)

Position tool [1] on the belt at «b».
Turn the tensioner roller (24) (anti-clockwise) using tool [2] to attain a tension
of:
106 ± 2 SEEM units.
Tighten screw (23) of the tensioner roller, tighten to 2.5 m.daN.
Remove one screw (25) from the pinion (29).
(to check that the screws are not against the end of the buttonhole).
Tighten the screws (25) to 2 m daN.
Remove tools [1], [2], [3] and [5].
Rotate the crankshaft 8 times (normal direction of rotation).
Fit the tool [3].
Loosen screws (25).
Fit tool [5].
Loosen screw (23) (to free the tensioner roller (24).
Fit tool [1].
Turn the tensioner roller (24) (anti-clockwise),using tool [3], to attain a tension
of:
51 ± 3 SEEM units.
- Tighten:
- The screw (23) of the tensioner roller (24) to 2,5 ± 0,2 m.daN.
- The screws (25) to 2 ± 0,2 m.daN.
B1EP15ED

183
ENGINE
C5 CHECKING AND SETTING THE VALVE TIMING
Engine: 4HX

Setting the valve timing (continued)

Remove the tool [1].

Refit the tool [1].
Tension value should be:
51 ± 3 SEEM units.

IMPERATIVE: If value is incorrect, restart the operation.

Remove tools [1], [2] and [5].

Rotate the crankshaft 2 times (normal direction of rotation).
Fit the tool [3].

IMPERATIVE: Should it be impossible to peg the camshaft, check that the

offset between the camshaft pinion hole and the pegging hole is not more
than 1 mm. In the case of an incorrect value, recommence the operation.

- Remove the tool [2].

- Complete the refitting of components.

B1EP15ED

184
 ENGINE
CHECKING AND SETTING THE VALVE TIMING C8
Engines: RHT-RHW-RHM-4HW
Tools:

[1] Instrument for measuring belt tension SEEM C.TRONIC : (-).0192

[2] Crankshaft setting peg (engine DW12TED4) : (-).0188-X
[3] Camshaft peg : (-).0188-M
[4] Belt retaining pin : (-).0188-K
[5] Engine flywheel stop : (-).0188-F
[7] Tensioning lever : (-).0188-J2
[8] Pulley extractor : (-).0188-P
[9] Crankshaft setting peg (engine DW10ATED4) : (-).0188-Y
[10] Crossmember : 4090-T
[11] Tie-bar support : 4176-T
[12] Retaining support : (-).0911-J
[13] Support with adjustable screw : (-).0911-H
[14] Set of plugs : (-).0188-T

Removing.
Remove:
- The front RH splashshield.
- The under-engine shield.
- The auxiliary drive belt (see corresponding operation).

185
ENGINE
C8 CHECKING AND SETTING THE VALVE TIMING
Engines: RHT-RHW-RHM-4HW
Removing.

Remove:
- The closing panel of the clutch casing (block the engine flywheel, tool [5].
- The auxiliary drive pulley screw.

Refit the screw without the washer.

Remove:
B1EK0TVC - The auxiliary drive pulley, using tool [8]. B1EK0TUC

- The tool [5].

Turn the crankshaft.

Peg:

- The engine flywheel, tool [2] (engine DW12TED4).

- The engine flywheel, tool [9] (engine DW10ATED4).

B1EK1T4D

186
 ENGINE
CHECKING AND SETTING THE VALVE TIMING C8
Engines: RHT-RHW-RHM-4HW

Removing (continued).
Disconnect the battery.
Move aside the header tank.
Position the tools for supporting the engine [10], [11], [12] and [13].
Remove:
- The scuttle panel grille.
- The torque reaction rod (1).
- The fuel unions (2).

B1EK1TTD IMPERATIVE: Plug the apertures using tool [13].

Protect the radiator harness with strong cardboard cut out to the dimensions of the radiator.
Remove:
- The RH engine support (4).
- The timing covers (3).
- The lower timing cover.
Peg the camshaft pulley, using tool [3].
Slacken the tensioner roller fixing (5).
Retighten the fixing to the position of maximum de-tension. (Tighten to 0,1 m.daN).
Remove the timimg belt.

B1EK1T2D

187
ENGINE
C8 2004 CHECKING AND SETTING THE VALVE TIMING
Engines: RHT-RHW-RHM-4HW

Refitting.
IMPERATIVE: Check that the rollers (5) and (6) as well as the coolant pump (7) turn freely (no play, no
tight spot), check also that these rollers are not noisy and/or that they are not throwing out grease.
In the event of replacement, tighten the roller (6) to 4,3 ± 0,4 m.daN.
Slacken the screws (8)
Check that the pulley (9) turns freely on its hub.
Tighten the screws (8) by hand.
Slacken the screws (8) by a 1/6 turn.
Turn the pulley (9) (clockwise), to end of slots.
B1EK0TXC Refit the timing belt, well tensioned, in the following order:
- Crankshaft (immobilise the belt, using tool [4] ).
- Guide roller (6).
Engage the timing belt on the pulley (10).
Carefully turn the camshaft pinion in the opposite direction to the rotation of the engine in order to engage the
belt on the pinion.
WARNING: The angular displacement «a» of the pulley relative to the belt should not be greater than the width
of one tooth.
Engage the belt on the tensioner roller (5) and on the coolant pump pinion (7).
Turn the tensioner roller (5) (anti-clockwise), so as to put the tensioner roller (5) in contact with the belt.
Pre-tighten the fixing screw of the tensioner roller to 0,1 m.daN.
Remove the tool [4].
B1EK0TYC

188
 ENGINE
CHECKING AND SETTING THE VALVE TIMING C8
Engines: RHT-RHW-RHM-4HW

Pre-tensioning the timing belt.

Position the tool [1].

NOTE: Check that the tool is not in contact with anything else around it.

Turn the roller (5) (anti-clockwise), using tool [7] to obtain a tension of:

98 ± 2 SEEM units.

Tighten the screw (11) to 2,3 ± 0,2 m.daN (without modifying the position of the roller).
Remove the tool [1].

IMPERATIVE: By removing one of the screws (8) on the pulley (9), make sure that
these screws (8) are not at end of slots. (If they are, repeat the operation to refit the
timing belt).

Bring the screws (8) into contact with the pulleys.

Tighten the screws (8) to 2 ± 0,2 m.daN.
Remove the setting pegs [3] and [2].
Effect eight turns of the engine in the normal direction of rotation.

B1EK1TSD
IMPERATIVE: Never turn the crankshaft backwards.

189
ENGINE
C8 CHECKING AND SETTING THE VALVE TIMING
Engines: RHT-RHW-RHM-4HW

Tensioning the timing belt.

Refit the pegs [2] and [3].

Slacken the screws (8).
Tighten the screws (8), by hand.
Slacken the screws (8) by a 1/6 turn.
Slacken screw (11).
Place tool [1] on the belt at (A).
Turn the roller (anti-clockwise),using tool [7] to obtain a tension of:
51 ± 2 SEEM units.
Tighten screw (11) to 2,3 ± 0,2 m.daN. (without modifying the position of the roller).
Tighten the screws (8) to 2 ± 0,2 m.daN.
Remove tool [1] to release the internal forces.
Refit the tool [1].
The tension value should be between 48 and 55 SEEM units.

IMPERATIVE: Value noted outside the tolerance: detension the belt and recommence
the operation

B1EK1T1D Remove tools [1], [2] and [3].

190
 ENGINE
CHECKING AND SETTING THE VALVE TIMING C8
Engines: RHT-RHW-RHM-4HW

Checking the timing setting.

Effect two turns of the engine in the normal direction of rotation, without turning the engine
backwards.
Refit the peg [2].
IMPERATIVE: Check visually that the offset between the hole in the camshaft hubs
and the corresponding pegging hole is not more than 1 mm.
Remove the peg [2].
Refit:
- The lower timing cover.
- The elements (3) of the timing cover.
- The engine support (4).
- The screws (13), tighten to 6,1 ± 0,6 m.daN.
- The nut (12), tighten to 4,5 ± 0,4 m.daN.

IMPERATIVE: Apply an opposite torque at (A).

Refit:
- The torque reaction rod (1).
- Screw (14), tighten to 5 ± 0,5 m.daN.
B1EK1T0D - Screw (15), tighten to 5 ± 0,5 m.daN.

191
ENGINE
C8 CHECKING AND SETTING THE VALVE TIMING
Engines: RHT-RHW-RHM-4HW

Refit:
- The tool [5].
- The auxiliary drive pulley

Clean the threads of the pulley screw going into the crankshaft, (Tap M16x150).
Brush the screw threads.

Tightening torque for the screw:

Tighten to: 7 ± 0,7 m.daN (+ LOCTITE FRENETANCH)
Angular tighten: 60° ± 6° (Tool FACOM D360).

Check the tightening: 26 ± 2,6 m.daN

Refit the auxiliary drive belt (see corresponding operation).

Remove tool [5].

Refit the closing plate, tighten to 0,7 m.daN.
Tighten the wheel bolts to 10 m.daN.
Complete the refitting in reverse order to removal.
Initialise the various ECUs.
B1EK0TVC

192
 ENGINE
VALVE CLEARANCES
POSSIBLE PROCEDURES
The valve clearances must be checked with the engine cold
For engines with 4 cylinders in a line (1-3-4-2 )
Rocking Fully open (Exhaust)
● Inlet Exhaust
Valves fully
Rocking Adjust open
Adjust
●
All Types Hydraulic adjustment 1● 1 4● 4 Inlet 1 3 ● 4
3● 3 2● 2 3 4 ● 2
4● 4 1● 1 4 2 ● 1
Exhaust
2● 2 3● 3 2 1 ● 3

Engines without hydraulic

adjustment: the clearance (J)
should be checked opposite
the cam.
B1DP13QC

193
ENGINE
C5 CHECKING THE OIL PRESSURE
To be read with the Petrol and Diesel correspondence tables
C5
Engine type 6FZ RFN RLZ XFX RHY RHS RHZ 4HX
Temperature (°C) 90°C
Pressure (Bars) 1,5 5 7-8 2 4
Rpm 1000 3000 900 - 3000 1000 4000
Tools (Kit 4103)
2279-T.Bis X X X X X X X X
4103-T.B X X X X X X X X
7001-T X X X
4202-T X X X X X

WARNING: Oil pressure should be checked with the engine cold, after checking the oil level.

194
 ENGINE
CHECKING THE OIL PRESSURE C8
To be read with the Petrol and Diesel correspondence tables
C8
Engine type RFN 3FZ XFW RHW RHT RHM 4HW
Temperature (°C) 80°C
Pressure (Bars) 1,5 - 5 3,4 - 6,9 1,2 - 5 2 4
Rpm 1000 - 3000 1000 - 4000 650 - 3000 1000 2000
Tools (Kit 4103)
2279-T.Bis X X X X X X X
4103-T.B X X X X X X X
7001-T X
4202-T X X X X X X

WARNING: Oil pressure should be checked with the engine cold, after checking the oil level.

195
ENGINE
C5 C8 OIL FILTERS

Petrol Diesel
EW ES9J4S DW
1.8i 16V 2.0i 16V 2.0i 16V HPi 3.0i 24V 2.0 HDi 2.2 HDi
6FZ RFN RLZ XFX RHY RHS RHZ 4HX
1109 T1 1109 T1
C5
1109 S8

Petrol Diesel
EW ES9J4S DW
2.0i 16V 2.2 16V HPi 3.0i 24V 2.0 16V HDi 2.2 HDi
RFN 3FZ XFW RHW RHT RHM 4HW
1109 T1 1109 T1
C8
1109 S8

PURFLUX = 1109 T1 – 1109 S8

196
 ENGINE
FILLING AND BLEEDING THE COOLING CIRCUIT C5 C8

TOOLS
[1] Filling cylinder : 4520-T
[2] Adaptor for filling cylinder : 4222-T.

ESSENTIAL: Respect the safety and cleanliness recommendations.

- The draining and refilling operations can be carried out by means of a WINN’S coolant replacement
apparatus or similar; it is essential to follow the instructions when using this apparatus.
Filling and bleeding

- Fit the cylinder adaptor [2] 4222-T and the filling cylinder [1] 4520 -T.
- Use the coolant to ensure protection between -1 5°C and - 37°C.
- Slowly fill the system.

NOTE: Keep the cylinder filled up (visible level).

- Close each bleed screw as soon as the coolant flows without air bubbles.
- Start the engine: Engine speed 1500 rpm.
- Maintain this speed until the third cooling cycle (cooling fans have cut in and cut out).
- Stop the engine and allow it to cool down.
- Remove the filling cylinder [1] 4520 – T and the adaptor [2] 4222-T.
- Top up the system to the maximum mark, with the engine cold.
- Refit the filler cap. B1GP00AC E5AP1GNC

197
INJECTION
C5 - C8 IDLING - DEPOLLUTION
Idling speed % Content
Emission (± 50 rpm)
Vehicle Engine type Make - Injection type
standard Manual Auto. gearbox: CO CO2
gearbox N engaged

L4 SAGEM
1.8i 16V 6FZ 700
IF/L5 S2000

RFN IF/L5 M. MARELLI

2.0i 16V 800
48P2
C5 < 0,5 >9
RLZ L4 SIEMENS
2.0i 16V HPi 900
SIRIUS 81

XFX IF/L5 BOSCH 600

3.0i V6 650
ME 7.4.6.

RFN IF/L5 M. MARELLI

2.0i 16V 800
4MP2

C8 3FZ IF/L5 M. MARELLI < 0,5 >9

2.2i 16v 4MP2

XFW IF/L5 BOSCH 600

3.0i V6 650
ME 7.4.6.

198
 PETROL INJECTION C5 - C8

C5 C8

1.8i 16V 2.0i 16V 2.0i 16V HPi 3.0i V6 2.0i 16 V 2.2i 16 V 3.0i V6

INJECTION
Engine type 6FZ RFN RLZ XFX RFN 3FZ XFW
Emission standard L4 - IF/L5 IF L5 L4 IF/L5 IF L5 IF L5 IF/L5
Make SAGEM M.MARELLI SIEMENS BOSCH M.MARELLI M.MARELLI BOSCH
Injection type S2000 48P2 SIRIUS 81 ME 7.4.6 4MP2 4MP2 ME 7.4.6
Fuel pressure (bars) 3,5 3,5 5 3,5 3,5 3,5 3,5
Overspeed cut-off (rpm) 6500 6530 5500 6520 6000 5650 6520
Injection cut-in during deceleration
(rpm) 12,2 14,5 1,88 16 14,5 14,5 16

Injector resistive value (ohms) 3 800 at 10°C 2500 at 20°C 800 at 50°C 230 at 90°C

Engine coolant temperature

sensor resistive value (ohms) Stepper motor: 53

Idling actuator or stepper

motor resistive value (ohms) 3 800 at 10°C 2500 at 20°C 800 at 50°C 230 at 90°C

199
 DEPOLLUTION TECHNICAL CHECKS (FRANCE)
All Types Petrol CO Corrected (In %) All Types Diesel (m-1)
INJECTION

Conditions: At idle, engine warm.

9 01/96
Less than 4,5 % for vehicles registered before 10/86. 01/96 9
Less than 3,5 % for vehicles registered after 10/86.
Atmospheric engine.
With catalytic converter
Less than 2.5 m-1
Greater than 2.0i 89 M.Y.
All Types 93 M.Y. Turbocharged engine.
CO less than 0,5 % at idle speed.
CO less than 0,3 % at fast idle speed between 2500 and 3000 rpm (*) Less than 3.0 m-1

Lambda Probe value 0,97 to 1,03.

200
 EMISSION STANDARDS
STANDARD APPLICATIONS
PSA NOTES CHARACTERISTICS
E.E.C. Engines Vehicles Applicable
A/S RP

INJECTION
➞ Utility vehicle limits
➞ 10/89 =private vehicle limits
ECE Petrol Utility vehicles: increased by 25 %
K 15.04
R 15.04 K’ Diesel All Types ➞ For private vehicles
15.04
and utility vehicles
imminent in major export
With oxygen sensor,
without catalytic converter

Brussels directive 88/76

Private vehicles:
ECE « Luxembourg Accords »
15.05 Petrol > 2 litres
R 15.05 W vp ➞ Replaced by 89/458
• new models 01/10/88 ➞ + 91/441
• existing models 01/10/89 ➞

201
 EMISSION STANDARDS
STANDARD APPLICATIONS
PSA NOTES CHARACTERISTICS
E.E.C. Engines Vehicles Applicable
A/S RP

Private vehicles:
INJECTION

Petrol • certain non-EEC With oxygen sensor and

US 83 Z US 83 Diesel European countries Current ➞ Adoption of U.S. standard catalytic converter for
• certain Export petrol vehicles
countries

Private vehicles:
• certain non-EEC
➞ Adoption of the U.S. With catalytic converter
US 87 Y US 87 Diesel European countries Current
standard and EGR
• certain Export
countries

Petrol Private vehicles:

➞ Adoption of the U.S.
US 93 Y2 US 93 Diesel • certain Export Current
standard
countries

202
 EMISSION STANDARDS
STANDARD APPLICATIONS
PSA NOTES CHARACTERISTICS
E.E.C. Engines Vehicles Applicable
A/S RP

Private vehicles:

INJECTION
Petrol • certain non-EEC
US 84 ➞ Adoption of the U.S.
X1 US 84 Diesel European countries Current
LDT standard for light utility vehicles
• certain Export
countries

Private vehicles:
• certain non-EEC
US 87 Petrol ➞ Adoption of the U.S.
X2 US 87 European countries Current
LDT Diesel standard for light utility vehicles
• certain Export
countries

Private vehicles:
Petrol • certain non-EEC
US 90 ➞ Adoption of the U.S.
X3 US 90 Diesel European countries Current
LDT standard for light utility vehicles
• certain Export
countries

203
 EMISSION STANDARDS
STANDARD APPLICATIONS
PSA NOTES CHARACTERISTICS
E.E.C. Engines Vehicles Applicable
A/S RP

With oxygen sensor and

INJECTION

Private vehicles: Brussels Directive 94/12 reinforced catalytic conver-

EURO 2
Petrol < 6 seats and ter for petrol vehicles.
CEE
L3 Diesel < 2.5 tonnes With catalytic converter
(EURO 95 ➞ EURO 93 standard
• new models 01/96 ➞
96) made stricter and EGR for diesel
• existing models 01/97 ➞
vehicles.

With oxygen sensor and

Utility vehicles: Brussels Directive 96/69
reinforced catalytic
< 3,5 tonnes
EURO 2 Petrol Class 1 converter for petrol
➞ 3 classes depending on
CEE Diesel • new models 01/97 ➞ vehicles.
W3 vehicle weight:
(EURO 95 Gas • existing models 10/97 ➞ With catalytic converter
96) Class 2/3: Class 1 < 1250 kg
and EGR for diesel
• new models 01/98 ➞ Class 2: 1250/1700 kg
vehicles.
• existing models 10/98 ➞ Class 3: 1700 kg

204
 EMISSION STANDARDS
STANDARD APPLICATIONS
PSA NOTES CHARACTERISTICS
E.E.C. Engines Vehicles Applicable
A/S RP
Utility vehicles: Brussels Directive 98/69
With 2 oxygen sensors

INJECTION
and catalytic converter for
<3.5 tonnes ➞ EURO 2 standard (L3) petrol vehicles.
EURO 3 Petrol made stricter With catalytic converter
Diesel Class 1: ➞ Fiscal incentives and EGR for diesel
W3 Gas • new models ➞ 01/2000 ➞ 3 classes depending on
(EURO vehicles.
2000) • existing models ➞ 01/2001 vehicle weight:
Class 2/3: Class 1 < 1305 kg With EOBD on-board
• new models ➞ 01/2001 diagnosis.
Class 2: 1305/1760 kg
• existing models ➞ 01/2002 Class 3: 1760 kg

With 2 oxygen sensors

Private vehicles: Brussels Directive 99/102 and catalytic converter for
All Types petrol vehicles.
EURO 4 IF / L5 Petrol ➞ EURO 3 standard (L4)
• new models ➞ 01/2005 With EOBD on-board
made stricter
• existing models ➞ 01/2006 diagnosis.
➞ Fiscal incentives

205
 EMISSION STANDARDS
STANDARD APPLICATIONS
PSA NOTES CHARACTERISTICS
E.E.C. Engines Vehicles Applicable
A/S RP

With 2 oxygen sensors

Brussels Directive: 2001/1
INJECTION

Private vehicles:
and catalytic converter for
Petrol All types
Diesel petrol vehicles.
EURO 4 IF / L5 ➞ EURO 3 standard (L4)
Gas • new models ➞ 01/2005 made stricter With EOBD on-board
• existing models ➞ 01/2006 diagnosis.
➞ Fiscal incentives

Utility vehicles: Brussels Directives: 99/102

et 2001/1 (Gas)
➞ EURO 3 standard (L4) With 2 oxygen sensors
< 3,5 tonnes
made stricter and catalytic converter for
Petrol ➞ Fiscal incentives petrol vehicles.
IF / L5 Class 1:
EURO 4 Gas
• new models ➞ 01/2005 ➞ 3 classes depending on
vehicle weight: With EOBD on-board
• existing models ➞ 01/2006
Class 1 < 1305 kg diagnosis.
Class 2/3:
• new models ➞ 01/2006 Class 2: 1305/1760 kg
• existing models ➞ 01/2007 Class 3: 1760 kg

206
 PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM C5 - C8
Engines: RHY RHS RHZ RHW RHT RHM 4HX 4HW

Cleaning.
- The use of high pressure cleaners is prohibited
- Do not use compressed air.

INJECTION
Fuel supply circuit.
- Required fuel: diesel.

Electric circuit.
- Swapping injection ECUs between two vehicles will render it impossible to start either vehicle.
- It is forbidden to supply a diesel injector with 12 volts.

High pressure fuel pump.

Do not separate the following components from the high pressure fuel pump (5):
- Sealing ring (b) (no replacement parts).
- High pressure outlet connector (a) (will cause a malfunction).

HDi = High pressure Diesel injection

B1HP19LC

207
 C5 - C8 PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM
Engines: RHY-RHS-RHZ-4HX Engines: RHY RHS RHZ 4HX RHW RHT RHM 4HW Engines: RHW-RHT-RHM-4HW

Diesel injectors.
INJECTION

WARNING: Diesel and ultrasonic cleaners are prohibited.

Do not separate the following components from the diesel injector carrier (2):

- Diesel injector (e) (no replacement parts).

- Electromagnetic element (c) (no replacement parts).

Do not alter the position of the nut (d) (malfunction).

Do not separate the connector (f) from a diesel injector.

It is forbidden to clean the carbon deposits from the diesel injector nozzle.

B1HP19NC B1HP19MC

208
 SAFETY REQUIREMENTS: HDi DIRECT INJECTION SYSTEM C5 - C8
Engines: RHY RHS RHZ RHW RHT RHM 4HX 4HW

SAFETY REQUIREMENTS
Preamble.
All interventions on the injection system must be carried out to conform with the following requirements and regulations:

INJECTION
- Competent health authorities.
- Accident prevention
- Environmental protection.
WARNING: Repairs must be carried out by specialised personnel informed of the safety requirements and of the precautions to be taken.

Safety requirements.
IMPERATIVE: Take into account the very high pressures in the high pressure fuel circuit (1350 bars), and respect
the requirements below:
- No smoking in proximity to the high pressure circuit when work is being carried out.
- Avoid working close to flame or sparks.

Engine running:
- Do not work on the high pressure fuel circuit.
- Always stay clear of the trajectory of any possible jet of fuel, which could cause serious injuries.
- Do not place your hand close to any leak in the high pressure fuel circuit.
After the engine has stopped, wait 30 seconds before any intervention.
NOTE: This waiting time is necessary in order to allow the high pressure fuel circuit to return to atmospheric pressure.

209
 C5 - C8 SAFETY REQUIREMENTS: HDi DIRECT INJECTION SYSTEM
Engines: RHY RHS RHZ RHW RHT RHM 4HX 4HW

CLEANLINESS REQUIREMENTS.
Preliminary operations
INJECTION

IMPERATIVE: The technician should wear clean overalls.

Before working on the injection system, it may be necessary to clean the apertures of the following sensitive components:
(refer to corresponding procedures).
- Fuel filter.
- High pressure fuel pump.
- Third piston deactivator.
- High pressure regulator.
- High pressure sensor.
- High pressure fuel injection common rail.
- High pressure fuel pipes
- Diesel injector carriers.

IMPERATIVE: After dismantling, immediately block the apertures of the sensitive components with plugs, to avoid the entry of impurities.
Work area.
- The work area must be clean and free of clutter.
- Components being worked on must be protected from dust contamination.

210
 CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT C5
Engines: RHY-RHS-RHZ Engines: RHY-RHS-RHZ-4HX

TOOLS
[1] Ø 10 mm low pressure connector : 4215-T.
[2] Ø 8 mm low pressure connector : 4218 -T.
[3] Pressure gauge for testing boost pressure : 4073-T Kit 4073-T

INJECTION
[4] Extension : 4251-T.

Connect the tool [1] between the booster pump and the fuel filter (white mark at "a" on the
fuel supply pipe).
Connect the tool [2] downstream of the diesel injectors, between the high pressure fuel
pump and the fuel filter (green mark at "b" on the fuel return pipe).
Engine: 4HX WARNING: Any check of pressure downstream of the fuel filter is PROHIBITED.

NOTE: To check the pressures while the vehicle is being driven, insert tool [4] between
tool [3] and tools [1] and [2].
Checks on pressure: static.
- Switch on ignition
- For 3 seconds (normal functioning):
- Fuel supply pressure shown by the pressure gauge [3] = 2.6 ± 0.4 Bar.
- Fuel return pressure shown by the pressure gauge [3] = 0.6 ± 0.4 Bar.

B1BP20JD B1BP27BD

211
 C5 CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT
Engines: RHY-RHS-RHZ-4HX (continued)
Checks on pressure: dynamic.
Engine running, at idle (normal functioning):
- Fuel supply pressure shown by the pressure gauge [3] = 2 ± 0.4 Bar.
- Fuel return pressure shown by the pressure gauge [3] = 0.8 ± 0.4 Bar.
Abnormal functioning
INJECTION

Fuel supply pressure Fuel return pressure Checks

Between 3.3 and 4 Bar 0.8 ± 0.4 Bar Check the condition of the diesel filter
Check the low pressure regulator incorporated in
More than 4 Bar Less than 0.8 Bar the filter (locked shut): replace.
Check the fuel return circuit
More than 4 Bar More than 0.8 Bar (pipe pinched or trapped.......).
Between 0.8 and 1.5 Bar Less than 0.8 Bar Check the fuel suppy circuit:
- Booster pump (low pressure), piping.
Impossible to start the engine: Check: diesel injector return flow (Table below)
Fuel supply pressure less than 0.8 Bar:
- Check the low pressure regulator incorporated in the filter (locked open) Uncouple the diesel injector return pipe.
- Check the high pressure pump distribution valve (locked shut)

Check: Observe:
The flow should be drop by drop Diesel injector functioning correctly
Excessive fuel return Diesel injector locked shut.
212
 AIR SUPPLY CIRCUIT SPECIFICATION C5
Engine: RHY

(1) Air filter PSA 7899.

INJECTION
(2) Flowmeter SIEMENS.

(3) Water / recycled gas exchanger VALEO.

(4) EGR valve. PURFLUX.

(5) Turbocharger KKK K03.

(6) Air butterfly MAGNETI MARELLI

48W7 Ref. 648

B1HP1A6D

213
 C5 AIR SUPPLY CIRCUIT SPECIFICATION
Engines: RHS-RHZ

(7) Air / air heat exchanger VALEO.

INJECTION

(8) Turbocharger KKK K03.

(9) EGR valve PURFLUX.

(10) Air butterfly MAGNETI MARELLI

48W7 Ref. 648.

(11) Air filter PSA 7899.

(12) Turbocharging pressure sensor NIPPON DENSO.

B1HP1A7P

214
 AIR SUPPLY CIRCUIT SPECIFICATION C5
Engine: 4HX

(1) Air / air exchanger

INJECTION
(2) Air / water exchanger

(3) Cold air metering device BOSCH.

(4) Warm air metering device BOSCH.

(5) Turbocharger ALLIEDSIGNAL GT1549P.

(6) Flowmeter SIEMENS.

(7) Air filter PSA 7885.

B1HP1BYP

215
 C5 CHECKS: AIR SUPPLY CIRCUIT
Engine: 4HX

ESSENTIAL: Respect the safety and cleanliness

recommendations.
INJECTION

Tool.

[1] Manual vacuum pump: FACOM DA 16.

Checks.

ESSENTIAL: Respect the safety and cleanliness

recommendations that are specific to high pressure
diesel injection (HDi) engines.

B1HP1ARP

216
 CHECKS: AIR SUPPLY CIRCUIT C5
Engine: 4HX
Vacuum pump.
- Connect the tool [1] on the vacuum pump (3).
- Start the engine.
- The vacuum should be 0.8 bar at 750 rpm.
Boost vacuum regulation electrovalve.

INJECTION
- Connect the tool [1] between the electrovalve (2) and the valve (1).
Compare readings with the values in the table below.
Engine speed (rpm) Vacuum (Bar)
780 0,6 Bar
4000 0,25 Bar
Boost pressure regulation valve.
- Connect the tool [1] on the valve (1). (Grey marking on pipe).
- Appy a vacuum of 0.8 bar. The rod "a" should move 12 ± 2 mm.
- Rod "a" should be moved 12 mm
«Swirl» control electrovalve.
- Connect the tool [1] as an adaptor between the electrovalve (4) and the control diaphragm of the «Swirl» (5).
- Compare readings with the values in the table below:
Engine speed (rpm) Vacuum (Bar)
780 0 Bar
4000 0,6 Bar
«Swirl» control diaphragm.
- Connect the tool [1] on the control diaphragm of the «Swirl» (5).
- Apply a vacuum of approx. 0.6 Bar ; the pin (6) should be at the end stop, at «b».

217
 C5 CHECKS: EXHAUST GAS RECYCLING CIRCUIT
Engines: RHY-RHS-RHZ

(1) Butterfly housing (3) Electrovalve (blue connector)

(2) EGR valve (tube with blue marking) (4) Electrovalve (blue connector)
Tools
INJECTION

[1] Manual vacuum pump : FACOM DA 16.

ESSENTIAL: Respect the safety and cleanliness requirements specific to

high pressure diesel injection (HDi) engines.
EGR electrovalve
- Check, not under load, between the electrovalve (4) and the EGR valve (2).
- Connect the tool [1] between the electrovalve (3) and the butterfly housing (1).
- Compare readings with the values in the table below.

Butterfly housing electrovalve.

- Check, not under load, between the electrovalve (3) and the butterfly housing (1).
- Connect the tool [1] between the electrovalve (3) and the butterfly housing (1).
- Compare readings with the values in the table below.

Engine speed (rpm) Vacuum value (bar)

780 0,5 Bar
2500 0 Bar
B1HP1BVD

218
CHECKS: EXHAUST GAS RECYCLING CIRCUIT C5
Engines: RHY-RHS-RHZ

EGR valve

INJECTION
- Connect tool [1] on the EGR valve capsule take-off (2).
- Apply a vacuum of approx. 0.6 bar to activate the EGR valve..
- In abruptly suppressing the vacuum, the valve should click and lock itself back on its seating
- Repeat the operation several times.

Butterfly housing

- Remove the air duct between the air/air exchanger and the butterfly housing (5), (1).
- Connect tool [1] on the butterfly housing vacuum capsule (1).
- Apply a vacuum of approx. 0.8 bar, the flap (a) of the butterfly housing (1) should be closed.

B1HP1BWC B1BP2ADC

219
 C5 CHECKS: EXHAUST GAS RECYCLING CIRCUIT
Engine: 4HX

TOOLS
[1] Manual vacuum pump : FACOM DA 16.

ESSENTIAL: Respect the safety and cleanliness requirements specific to

INJECTION

high pressure diesel injection (HDi) engines.

Electrovalve (EGR).
- Check, not under load, between the electrovalve (3) (blue connector) and the EGR valve (2)
(tube with blue marking).
- Connect the tool [1] between the electrovalve (3) and the EGR valve (2).
- Compare readings with the values in the table below.
Butterfly housing electrovalve
- Check, not under load, between the electrovalve (4) (black connector) and the butterfly
housing (1) (Metering pump cold), (tube with white marking).
- Connect the tool [1] between the electrovalve (4) and the butterfly housing (1).
- Compare readings with the values in the table below.

Engine speed (rpm) Vacuum value (bar)

780 0,5 Bar
2500 0 Bar
B1HP1B8D

220
CHECKS: EXHAUST GAS RECYCLING CIRCUIT C5
Engine: 4HX

EGR valve

INJECTION
- Connect tool [1] on the take-off (a) of the EGR valve capsule (2).
- Apply a vacuum of approx. 0.6 bar to activate the EGR valve.
- In abruptly suppressing the vacuum, the valve should click and lock itself back on
its seating.
- Repeat the operation several times.

Butterfly housing
- Remove the air duct between the air/air exchanger and the butterfly housing (1).
- Disconnect the tube (white marking) on the electrovalve (4) (black connector).
- Connect tool [1] on the tube with the white marking.
- Apply a vacuum of approx. 0.8 bar, the flap (b) of the butterfly housing (1) should be closed.

B1BP29NC B1BP29PC

221
 PARTICLE FILTER SAFETY AND CLEANLINESS REQUIREMENTS

General.
ESSENTIAL: Given the very high pressures prevailing in the fuel high pressure circuit (1600 Bars), respect the following regulations.
- It is forbidden to smoke in the immediate proximity of the high pressure circuit during a repair.
- Avoid working close to flames or sparks.
INJECTION

When the engine is running:

- Do touch the fuel high pressure circuit.
- Always keep out of range of possible projections of fuel, which could cause serious injuries.
- Do not place your hand near to any leak on the fuel high pressure circuit.
- After the engine has stopped, wait 30 seconds before starting any operation.
NOTE: The waiting time is necessary to allow the fuel high pressure circuit to return to atmospheric pressure.
Safety rules.
IMPERATIVE: Wait at least an hour before starting any repair on the exhaust line.
Forced regeneration of the particle filter:
Check that there are no aerosols or inflammable products inside the vehicle’s boot.
Wear high temperature gloves.
Connect the vehicle to a gas extractor approved for this type of operation.
IMPERATIVE: In the absence of the required installations, carry out the forced regeneration of the particle filter outside the workshop,
in a concreted area well away from any inflammable materials. Place the vehicle in the high position.

222
 PARTICLE FILTER SAFETY AND CLEANLINESS REQUIREMENTS

Operations on the fuel additive circuit.

IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves that are resistant to hydrocarbons.
The work area must be ventilated.
In the event of any significant dispersion of additive:

INJECTION
- Wear a breathing mask for filtering the particles.
- Recover as much of the product as possible.
- Place the product thus recovered in an appropriately labelled container.
- Wash the soiled area with copious amounts of water.
- Dispose of materials and solid residues in an authorised recovery point.
IIMPERATIVE: The filling kit should be recycled following a repair. All «Eolys» additive containers that have been opened should be disposed of.
Cleanliness rules.
ESSENTIAL: The operator should wear clean overalls.
Before working on the injection circuit, it may be necessary to clean the unions of the following sensitive components (see corresponding
operations):
- Fuel filter.
- Fuel high pressure pump.
- Fuel high pressure regulator.
- Fuel high pressure common injection rail.
- Fuel high pressure piping.
- Diesel injector carriers.
IMPERATIVE: After dismantling, immediately blank the unions of the sensitive components with plugs, to prevent any ingress of
impurities.

223
 SPECIAL FEATURES: FORCED REGENERATION OF THE PARTICLE FILTER

Tools
Diagnostic stations : LEXIA or PROXIA.
Imperative: Respect the safety and cleanliness requirements.
INJECTION

Forced regeneration of the particle filter.

IMPERATIVE: Respect the safety and cleanliness requirements specific to HDi engines.
ESSENTIAL: Connect the vehicle to a gas extractor approved for this type of operation.
In the absence of the required installations, carry out the forced regeneration of the particle filter outside the workshop,
in a concreted area well away from any inflammable materials. Place the vehicle in the high position.
WARNING: Check that the fuel level is sufficient (at least 20 litres).
Start the engine and allow it to warm up (60°C minimum).
Connect the diagnostic tool to the vehicle’s central socket.
Trigger the regeneration cycle, with the diagnostic tool.
Automatic running of the regeneration cycle of the particle filter:
Autocheck by the engine ECU.
Stabilisation of engine speed at 4000 rpm, operating with post injection.
Change to idling speed (for 30 seconds).
Stabilisation of engine speed at 3000 rpm, checking of the efficiency of the regeneration of the particle filter.
Change to idling speed.
NOTE: Let the engine run at idling speed for the benefit of cooling.
Stop the engine.
IMPERATIVE: Wait for at least an hour before any operation on the exhaust line.

224
 SPECIAL FEATURES OF THE PARTICLE FILTER (FAP)
Evolution / particle filter additive
Vehicle concerned.
C5 (RHS RHZ 4HX) BOSCH EDC15C2 injection system
C8 (RHT 4HW) BOSCH EDC15C2 injection system

INJECTION
Evolution.
Application RPO 9492‡
New additive «EOLYS 176» to permit maintenance of the particle filter system every 120 000 Km. (75 000 miles).
Old type of additive «DPX42»..
Change of particle filter, every 80 000 Km (50 000 miles).
Filling of additive reservoir, every 80 000 Km (50 000 miles).
New type of additive «EOLYS 176»..
The evolution of the additive necessitates the following components to be fitted:
New injection ECU with new mapping : RPO 9457‡
New fuel additive ECU with new mapping : RPO 9492‡
Injection ECU.
New ECU mapping to permit adaptation to the various types of additive.
Additive : DPX42
Additive : EOLYS 176.
Fuel additive ECU.
New ECU mapping to permit adaptation to the various types of additive.
Additive : DPX42
Additive : EOLYS 176.

225
 SPECIAL FEATURES OF THE PARTICLE FILTER (FAP)
Evolution / particle filter additive
Additive “EOLYS 176”

New composition:
Cérine : 6,5% in volume.
INJECTION

Catalyser : Brown colour.

Solvent product : Combustible hydrocarbon.

Additive reservoir:
Identification : Green ring on the clickfit cap.
Filling of additive reservoir (partial) : Refer to the corresponding procedure.

Repair.
Replacement part.
The Replacement Parts service markets both types of additive.
Additive «EOLYS 176»:
1 litre container : Part No. 9736.85.
3 litre container : Part No. 9736.86.

IMPERATIVE: Use only new additive, any particle risks a seizing of the additive injector.
Interchangeability.

226
 SPECIAL FEATURES OF THE PARTICLE FILTER (FAP)
Evolution / particle filter additive

IMPERATIVE: It is forbidden to mix the 2 types of additive.

Use of the new type of additive on a old vehicle is prohibited (will cause a malfunctioning of the particle filtration system).
Check the type of additive.

INJECTION
3 Method of checking:
- Diagnostic tools, 2 methods.
- Visual.
IMPERATIVE: You are advised to check the coherence between the different methods.
Diagnostic tools:
Action: Connect the diagnostic tool - Perform a global test - Select: Diesel fuel additive ECU - Configuration (Read the type of additive
in the programming)
On vehicle RPO 9492‡
Action: Connect the diagnostic tool - Perform a global test - Select: Diesel engine - Configuration (Read the type of additive in the
programming)
Visual:
Creation of a colour code on the cap of the additive reservoir.
Additive : Colour of the additive reservoir cap.
DPX 42 :Black with white ring.
EOLYS 176 : Black with green ring.

227
 C5 SPECIAL FEATURES OF THE PARTICLE FILTER / FILLING THE ADDITIVE RESERVOIR
IMPERATIVE: Respect the safety and cleanliness requirements.
Tools.
Diagnostic tool: LEXIA or PROXIA
1 litre filling kit comprising the following items:
1 Container of Eolys.. 2 Filters. 2 Tubes
INJECTION

1 Empty container 2 Hooks.

Filling
NOTE: There exists a 5 litre filling kit (see corresponding procedure).

IMPERATIVE: Respect the safety and cleanliness requirements specific to HDi engines.
IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves that are
B1HP1DFC
resistant to hydrocarbons.
Place the vehicle on a lift.
Disconnect the battery negative terminal.
Remove the heat shield located under the diesel fuel additive reservoir.
Uncouple the union (1). Remove the filler cap (2).
Connect:
The pipe (4) of the filling kit on the clickfit union (1).
The pipe (3) of the filling kit in the place of the filler cap (2).
Position the empty container in one of the nets from the filling kit and suspend it, using a hook.
Insert the pipe into the empty container.

B1HP1DGC

228
SPECIAL FEATURES OF THE PARTICLE FILTER / FILLING THE ADDITIVE RESERVOIR C5
Screw the filler connector on the additive container (5) at «b».
Place the additive container (5) on a component lift.
Open the tap located on the filler connector at «a».
Tilt the additive container (5) (to facilitate the end of filling).
Fill until the additive starts to overflow.

INJECTION
Close the tap at «a».
Remove:
- the filler union,
- the pipe (4).
Couple the union (1).
Remove the pipe (3)
Refit:
- the cap (2),
- the heat shield located under the diesel fuel additive reservoir.
Reconnect the battery negative terminal

Cleanliness requirements:

IMPERATIVE: The filling kit should be recycled after this operation. Any «Eolys» additive containers
that have been opened should not be kept.

C4BP19HC

229
 C5 SPECIAL FEATURES OF THE PARTICLE FILTER / CHECKING THE ADDITIVE PUMP
IMPERATIVE: Respect the safety and cleanliness requirements.

Tools.

[1] Union for releving the fuel pressure Ø 10 mm : 4215-T

INJECTION

[2] Extension for relieving the pressure : 4251-T

[3] Pressure gauge for checking the pressure : 4073-T Toolkit 4073-T.
[4] Set of two hose clamps : 4153-T

Checks

IMPERATIVE: Respect the safety and cleanliness requirements specific to HDi engines.

IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves that are
resistant to hydrocarbons.

Place the vehicle on a 4 column lift.

Remove the heat shield located under the diesel fuel additive reservoir.

Pressure of the additive pump.

Fit tool [1] in series in the additive pump pressure circuit.
Connect tool [2] on tool [1].
Fit tool [4] at «a».
B1HP1JUC

230
SPECIAL FEATURES OF THE PARTICLE FILTER / CHECKING THE ADDITIVE PUMP C5
Place the pressure gauge [3] inside the vehicle.
Connect tool [2] to tool [3].

WARNING: From switching on the ignition, the additive pump is supplied for 5 seconds.

INJECTION
Switch on the ignition, check the pressure value indicated by the pressure gauge [3].
Interpretation of the result of the check:

The pressure value is 3 ± 0,5 Bars : The additive pump is okay.

The pressure value is less than 3 ± 0,5 Bars : The additive pump is defective.

Sealing of the additive injector.

Remove tool [4].

Switch on the ignition, check the pressure value indicated by the pressure gauge [3].
Interpretation of the result of the check:

The pressure value is 3 ± 0,5 Bars : The additive pump is okay.

The pressure value is less than 3 ± 0,5 Bars : The additive pump is defective.

Remove tools [1], [2], [3] and [4].

C5FP0D1C

231
 C8 SPECIAL FEATURES OF THE PARTICLE FILTER / FILLING THE ADDITIVE RESERVOIR
IMPERATIVE: Respect the safety and cleanliness requirements.
Tools.
Diagnostic tool: LEXIA or PROXIA
Filling kit comprising the following items:
1 Container of Eolys.(5 litres or 5 containers each of 1 litre)
INJECTION

1 Empty container
1 Filler pipe with cap and clickfit union
1 Overflow pipe
1 Means of suspending the container of product.

Filling

IMPERATIVE: Respect the safety and cleanliness requirements specific to HDi

engines.
IMPERATIVE: For all operations on the additive circuit, wear protective
goggles and gloves that are resistant to hydrocarbons.

Place the vehicle on a lift.

Uncouple the clickfit union (1) from the air vent of the additive reservoir.
Remove the overflow cap (2) of the additive reservoir.
Couple the female clickfit union of the container of EOLYS on the clickfit (1) of the
circuit of the air vent of the additive reservoir.

B1KK02RD

232
SPECIAL FEATURES OF THE PARTICLE FILTER / FILLING THE ADDITIVE RESERVOIR C8
Couple the pipe of the collection container (3) on the overflow of the additive
reservoir.
Suspend the container of EOLYS at a level higher than that of the additive
reservoir.
Pierce the container of EOLYS at «a» (marked by a triangle on the container).

INJECTION
When all the fluid has flowed out, uncouple the clickfit union.
Recommence the filling until the fluid flows out through the overflow of the
additive reservoir.

NOTE: The capacity of the additive reservoir is 5 litres. The filling operation
B1KK010D requires a maximum of 5 containers.

Refit the overflow cap (2) of the additive reservoir.

Couple the clickfit union (1) to the air vent of the additive reservoir.

Cleanliness requirements:

IMPERATIVE: The filling kit should be recycled after this operation. Any
«Eolys» additive containers that have been opened should not be kept.

B1KK02TD

233
 C8 SPECIAL FEATURES OF THE PARTICLE FILTER / FILLING THE ADDITIVE RESERVOIR
Re-initialisation of the engine management ECU
Re-initialise the engine ECU information on the total quantity of additive, following the
procedure in the diagnostic tool:
Select the function «diagnosis».
«Choice of vehicle»
INJECTION

Enter the RPO no. of the vehicle.

Global test.
- Choice of injection.
- Diesel engine.
- A/S commands, FAP.
Re-initialisation of total quantity of additive (Reset).
Perform:
- Reading then deletion of the parameter of the total quantity of additive.
- Reading of the engine ECU fault codes.
Simulate a filling of the fuel tank in order to switch off the particle filter warning lamp:
- Open the fuel cap.
- Put in 5 litres of diesel fuel.
- Close the fuel cap.
Check the status of the particle filter in parameter measures, at the same level as the after-sales
repair (particle filter / additive ECU, using the parameters of the particle filter status and the dif-
ference in pressures at the FAP inlet/outlet).
If the particle filter has regenerated : Correct.
If not : Check the sealing of the exhaust line and sensor.
E5AK0BWD

234
 CHECKS: TURBO PRESSURE C5
Engine: RHY Engines: RHY-RHS-RHZ

TOOLS.
[1] Pressure gauge for checking boost pressure : 4073-T.A Kit 4073-T
[2] Sleeve for checking boost pressure : 4185-T
[3] Adaptor sleeve : 4219-T

INJECTION
Checks.

Preparation for RHY engine

Remove:
- The collars (3).
- The sleeve.
Engines: RHS-RHZ - Insert the tool [2] between the tube (1) and the duct (2).
- Position the tool [1] in the vehicle.
- Connect the pressure gauge [1] to the tool l [2] with its tube (a) long enough for
the gauge to be positioned inside the vehicle.

Checks.
Preparation for RHZ engine
- Remove the collar fixing (3).
- Insert the tool [2] equipped with tool [3], between the tube (1) and the duct (2).
- Position the tool [1] in the vehicle.
- Connect the sleeve [2] on the pressure gauge [1] with the tube (a).
B1BP1ZXD B1HP12JD

235
 C5 CHECKS: TURBO PRESSURE
Engines: RHY-RHS-RHZ

Procedure.

ESSENTIAL: Observe the following checking requirements:

INJECTION

- Engine at running temperature.

- Vehicle in running order.
- Engine at full load.

- Start the engine.

- Engage first gear and start the vehicle.
- Engage the gears up to third gear.
- Decelerate to 2000 rpm.
- Gradually accelerate.
- Check the pressure: 0.95 ± 0.05 Bar .
- Remove the tools [1] and [2]
Refit:
- The sleeve.
- The collars (3).
- Tighten the collars (3).

C5FP0ACC

236
CHECKS: TURBO PRESSURE C5
Engine: 4HX

TOOLS.
[1] Pressure gauge for checking pressure 7073-T.A.
[2] Extension cable for taking pressure 8607-T.A

INJECTION
[3] Union and hose for taking pressure 8607-T.B.
[4] Adaptor for taking pressure 8607-T.C.
[5] Unions and hoses for taking pressure 4088-T
Checks.
ESSENTIAL: Respect the safety and cleanliness requirements specific to
high pressure diesel injection (HDi) engines.
Preliminary operations.
Carry out the following operations:
Remove the screw (1).
Disconnect the tube (2).
Move aside the pressure sensor (3).
Preparation of tools: in position on the vehicle.
Fit as follows:
Remove the hose (a) of tool [5], screw in its place the tool [3], remove the hose (b) of tool
[5], screw the hose (b) of tool [5] on the pressure gauge [1], screw the adaptor [4] onto
the tool [5]
Connect the tube (2) of the pressure sensor (3) on the tool [4], tighten the tube (2) with a
Serflex type collar.
B1BP28DC E5AP1SUC

237
 C5 CHECKS: TURBO PRESSURE
Engine: 4HX

Preparation of tools: in position on the vehicle (continued).

Screw the tool [3] on the take-off of the turbo air radiator at «c».
Place the pressure gauge on the cup holder at «d.».
INJECTION

Connect the extension [2] on the hose «b» and tool [5].

ESSENTIAL: Observe the following checking requirements.

- Start the engine.

- Engage first gear and start the vehicle.
- Engage the gears up to third gear.
- Decelerate to 1500 rpm.
Accelerate gradually: the pressures should be the following:
1.1 ± 0.05 b at 2000 rpm
1.2 ± 0.05 b at 3000 rpm.

Return the vehicle to normal.

Remove the tools [1], [2], [3], [4] and [5].
Reposition the pressure sensor (3).
Couple the tube (2).
Refit and tighten the screw (1).

B1BP28EC C5FPOBLC

238
 INJECTION PUMP SPECIFICATIONS (BOSCH and SIEMENS). C5
Engines Injection system ECU High pressure pump Injectors
BOSCH BOSCH EDC 15C2 BOSCH CP1 9625542580
TD
10 SIEMENS (except PICASSO) SIEMENS ECUSID801 5WS 40001 5WS40000
DW
ATED 9625542580

INJECTION
BOSCH BOSCH EDC 15C2 BOSCH CP1
12 TED4 96372277980

239
 C5 - C8 SPARKING PLUGS

Vehicles Engine Electrode EYQUEM Electrode CHAMPION Electrode Tightening

BOSCH
types gap gap gap torque

1.8i 16V 6FZ

FR 8 ME 0,9 ± 0,1 RFN 52 HZ 0,9 ± 0,05 REC 9 YCL 0,9 ± 0,05 2,75 ± 0,2
2.0i 16V RFN
IGNITION

C5 2.0i 16V HPi RLZ ZR 8 TPP 15 1,0 ± 0,1 2,25 ± 0,2

0,55 ± 0,2 1 ± 0,1

3.0i 24S XFX FGR 8 MQPE
90°
2.0i 16V RFN
FR 8 ME 0,9 ± 0,1 RFN 52 HZ 0,9 ± 0,05 REC 9 YCL 0,9 ± 0,05 2,75 ± 0,2
2.2i 16V HPi 3FZ
C8
1 ± 0,1
3.0i 24S XFW FGR 8 MQPE 0,5 ± 0,2
90°

240
 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» and the speed travelled «ST», there must always be the following relationship:

VR < VL < 1,10 VR + 4 Km/h

Example: For an actual speed of 100 Kph the speed displayed by the speedometer may be between 100 and 114 Kph.
The speed indicated by the speedometer may be influenced by:

- The speedometer.
- The tyres fitted to the vehicle.
- The final drive ratio.
- The speedometer drive ratio.
Any of these components can be checked without removing them from the vehicle. (See information note N° 78-85 TT of 19 October 1978).
NOTE: Before replacing the speedometer, check the conformity of the following points:

TRANSMISSION
- The tyres fitted to the vehicle.

GEARBOX
CLUTCH
- The gearbox final drive ratio.
- The speedometer drive ratio.

241
 C5 CLUTCH SPECIFICATIONS
Petrol

1.8i 16V 2.0i 16V 2.0 HPi 3.0i V6

Engine type 6FZ RFN RLZ XFX

Gearbox type BE4/5 ML5C
Supplier VALEO
Mechanism /type 230 DNG 4700 242 T 6500

Clutch disc 11 R 10X 12 R 14X 11 R 14X 11 A 14X

Ø of lining. Ext/Int 228/155 242/162

Quality of lining F 410 F 808 DS F 410 F 808
TRANSMISSION
GEARBOX
CLUTCH

242
 CLUTCH SPECIFICATIONS C5
Diesel

2.0 HDi 2.2 HDi

Engine type RHY RHS RHZ 4HX

Gearbox type BE4/5 ML/5 ML6C
Supplier LUK
Mechanism/type 230 P 4700 225 T 5700 242 T 6500

Clutch disc Damping performed by engine flywheel

Ø of lining. Ext/Int 228/155 225/150 242/162

Quality of lining F 408 F 808

TRANSMISSION
GEARBOX
CLUTCH
243
 C8 CLUTCH SPECIFICATIONS
Petrol Diesel

2.0i 16V 2.1 16V 2.0 HDi 2.2 HDi

Engine type RFN 3FZ RHW RHT 4HW

Gearbox type BE4/5 ML5C ML6C
Feature «Push» clutch «Pull» clutch
Supplier VALEO LUK
Mechanism/type 230 DNG 4700 230 DNG 5100 225 T 5700 242 T 6500
Clutch disc 11 R 14 X Clutch with double damping flywheel (DVA)
Ø of lining. Ext/Int 228/155 225/150 242/162
Quality of lining F 808
TRANSMISSION
GEARBOX
CLUTCH

244
 CLUTCH SPECIFICATIONS C5
Engines: 6FZ RFN RLZ RHY

Clutch types: (BE4/5))

«Push» clutch 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.
B2BP047C (3) Clutch casing.
(4) Bearing.
(5) Clutch plate.

The clutch control slave cylinder (7) is fixed by two screws (6) onto the exterior of the clutch casing.

Tightening torques (m.daN).

- Fixing of clutch plate/engine flywheel : 2 ± 0,2

TRANSMISSION
- Fixing of engine flywheel/crankshaft : 4,8 ± 0,5

GEARBOX
CLUTCH
B2CP3FAC

245
 C5 CLUTCH SPECIFICATIONS
Moteurs: XFX RHS RHZ 4HX

Clutch types: (ML5C-ML6C)

«Pull» clutch with hydraulic control.

Description.

The clutch control slave cylinder (8) is secured on the clutch housing (9) by rotation (1/3 turn).

Tightening torques (m.daN).

- Fixing of clutch plate/engine flywheel : 2 ± 0,2

- Fixing of engine flywheel/crankshaft

Tightening : 2 ± 0,2
Angular tightening : 60° ± 5°
TRANSMISSION
GEARBOX
CLUTCH

B2BP04LC

246
 CLUTCH SPECIFICATIONS C8
Engines: RFN 3FZ RHW RHT 4HW
«Push» clutch

«Push» clutch and «Pull» clutch

(1) Clutch disc.

B2BK22WD

«Pull» clutch (2) Clutch plate.

(3) Clutch bearing.

TRANSMISSION
GEARBOX
CLUTCH
B2BB000D

247
 C5 C8 HYDRAULIC CLUTCH CONTROL SPECIFICATION

Bleeding the hydraulic clutch control.

Composition of the hydraulic circuit.
- Brake fluid reservoir located on the master cylinder.
- Hydraulic control sender located in the passenger compartment and fixed on the pedal gear.
- Clutch pedal.
- Hydraulic control receiver fixed on or inside the clutch housing, depending on gearbox type.

Bleed.

IMPERATIVE: Use only new, clear brake fluid, avoid entry of any foreign bodies or impurities into the hydraulic circuit.

Use only hydraulic fluid that is approved and recommended: DOT4.

IMPERATIVE: Do not use any automatic bleed apparatus (risk of the fluid emulsifying in the reservoir).

Remove:
- The pollen filter and its support (see corresponding operation in chapter on aircon).
- The air filter and its union.
TRANSMISSION

- The under-engine sound-deadening.

GEARBOX
CLUTCH

Refill the brake fluid reservoir to the maximum of its capacity.

248
HYDRAULIC CLUTCH CONTROL SPECIFICATION C5 C8

Bleeding the hydraulic clutch control (continued).

Couple a transparent pipe onto the bleed screw (1).

Submerge the end of the pipe in a receptacle containing brake fluid, situated lower than
the clutch slave cylinder (2).
Create a syphon at «A» above the clutch slave cylinder, using the transparent pipe.

Open the bleed screw (1).

B2BK22XD Action the clutch pedal (3) manually through all its travel, with seven rapid down-up
movements.
On the final movement, hold the clutch pedal (3) at the end of its travel.
Reclose the bleed screw (1).
Allow the clutch pedal (3) to rise back up again.
Fill the brake fluid reservoir to the maximum of its capacity.

NOTE: For new bleed operations: open the bleed screw (1).

TRANSMISSION
If necessary, repeat the operation.

GEARBOX
CLUTCH
B2BK064C

249
 C5 C8 HYDRAULIC CLUTCH CONTROL SPECIFICATION

Bleeding the hydraulic clutch control (continued).

Top up the brake fluid level to the MAXIMUM of the brake fluid reservoir capacity.

Declutch and clutch rapidly 40 times.

Start the engine.

Apply the handbrake.

Engage a gear.

Check that the clutch starts to engage at a dimension (X) greater than or equal to 35 mm
(Dimension (X) is given as a guide).

NOTE: If incorrect, repeat the bleed operations.

TRANSMISSION

Tighten the bleed screw (1) to 0,75.m.daN.

GEARBOX
CLUTCH

B2BK065C

250
 GEARBOX AND TYRE SPECIFICATIONS C5
Petrol
18i 16V 2.0i 16V 2.0 HPi
Automatic Automatic
Engine type 6FZ RFN RLZ
Tyres-Rolling circumference 195/65 R15 1,93 m 195/65 R15 1,93 m
Gearbox type BE4/5 AL4 BE4/5 AL4 BE4/5
Gearbox ident. plate 20 DL 29 20 TP 95 20 DL 30 20 TP 93 20 DL 31
Reduction box torque 19x79 21x73 19x79 23x73 19x77
Speedometer ratio None 52x67 None 52x67 None
Petrol
3.0i V6
Automatic
Engine type XFX
Tyres-Rolling circumference 215/55 R16 1,96 m

TRANSMISSION
Gearbox type ML/5C 4 HP 20

GEARBOX
Gearbox ident. plate 20 LM 21 20 HZ 2

CLUTCH
Reduction box torque 16x65 20x69
Speedometer ratio None 59x68
251
 C5 GEARBOX AND TYRE SPECIFICATIONS
Diesel
2.0 HDi
Automatic Automatic
Engine type RHY RHS RHZ

Tyres-Rolling circumference 195/65 R15 1,93 m

Gearbox type BE4/5 ML5C AL4 ML5C AL4
Gearbox ident. plate 20 DL 32 20 LM 23 20 TP 43 20 LM 23 20 TP 43
Reduction box torque 19 x 75 17 x 65 25 x 68 17 x 65 25 x 68
Speedometer ratio None None 52 x 67 None 52 x 67
Diesel
2.2 HDi
Automatic
Engine type 4HX
Tyres-Rolling circumference 215/65 R16 1,96 m
Gearbox type ML5C ML6C 4 HP 20
TRANSMISSION
GEARBOX

Gearbox ident. plate 20 LM 17 20 MB 04 20 HZ 20

CLUTCH

Reduction box torque 17 x 67 17 x 67 23 x 66

Speedometer ratio None None 59 x 68
252
 GEARBOX AND TYRE SPECIFICATIONS C8
(1) = Right hand drive Petrol
(2) = Left hand drive 2.0i 16V 2.2i 16V 3.0i 24V
Automatic Automatic
Engine type RFN 3FZ XFW

Tyres-Rolling circumference 205/65 R15 1,973 m 215/65 R15 2,016 m 215/60 R16 - 2,025 m
Gearbox type BE4/5 AL4 ML5C 4 HP 20
Gearbox ident. plate 20 DM 01 (1) 20 DM 00 (2) 20 TP 74 20 LM 25 20 HZ 27
Reduction box torque 14 x 62 21 x 73 14x65 19 x 73
Speedometer ratio None 20 x 16 None
Diesel
2.0 HDi 2.2 HDi
Automatic
Engine type RHW RHT RHM 4HW
Tyres-Rolling circumference 215/65 R15 2,016 m

TRANSMISSION
Gearbox type ML5C AL4 ML5C ML6C

GEARBOX
Gearbox ident. plate

CLUTCH
20 LM 24 20 TS 04 20LM 01 20MB 05
Reduction box torque 15 x 67 21 x 73 16 x 69 16 x 69
Speedometer ratio 27 x 21 20 x 16 None None
253
 C5 C8 BE4/5 GEARBOX
ENGINES: 6FZ RFN RLZ RHY
TRANSMISSION
GEARBOX
CLUTCH

(a) Marking zone (sequence and serial no.).

(b) Location of identification label.
B2CP3BNC B2CP3BPD

254
 BE4/5 GEARBOX C5 C8
Engines: 6FZ RFN RLZ RHY
Description

1) Primary shaft. (14) 1st/2nd gear synchroniser

(2) Clutch bearing guide. (15) Driven gear (1st gear).
(3) Gearbox casing. (16) Secondary shaft.
(4) Clutch housing. (17) Differential gear.
(5) Reverse idle. (18) Satellite gears.
(6) Drive gear (3rd gear). (19) Planet gears.
(7) 3rd /4th gear synchroniser (20) Differential housing.
(8) Drive gear (4th gear). (21) Speedometer drive.
(9) Drive gear (5th gear). (22) Extension.
(10) 5th gear synchroniser.
(11) Driven gear (5th gear).
«d» Adjusting shims: 0,7 to 2,4 mm.
(12) Driven gear (2nd/4th gear )
(From 0,10 to 0,10 mm)

TRANSMISSION
(13) Driven gear (2nd gear).

GEARBOX
«c» Adjusting shims:1,4 to 1,6 mm.

CLUTCH
(From 0,10 to 0,10 mm)

B2CP3BQP

255
 C5 C8 BE4/5 GEARBOX
Engines: 6FZ RFN RLZ RHY
Tightening torques
Ref. Description No. of screws m.daN
1 End guide 3 1,2 ± 0,1
2 Clutch housing 13 1,3 ± 0,1
3 Primary shaft nut 1 7,2 ± 0,7
4 Secondary shaft nut 1 6,5 ± 0,7
5 Yoke holding screw 2 1,5 ± 0,1
6 Differential gearwheel screw 2 6,5 ± 0,7
B2CP3BSP
Reverse gear contact 1 2,5 ± 0,3
7 Differential housing 4 5 ± 0,5
8 Breather pipe 1 1,7 ± 0,2
9 Rear housing cover screw 7 1,2 ± 0,1
TRANSMISSION

10 Top-up plug 1 2,2 ± 0,2

GEARBOX
CLUTCH

11 Differential housing screw 4 1,2 ± 0,1

B2CP3BTD 12 Drain plug screw 1 3,5 ± 0,4

256
 BE4/5 GEARBOX C5 C8
Engines: 6FZ RFN RLZ RHY

Tightening torques m.daN.

(1) Gearbox rear casing : 1,5 ± 0,1

(2) Gearbox casing/clutch casing fixings : 1,5 ± 0,1
(3) Reverse gear rocker shaft fixing nut : 4,5 ± 0,4
(4) Breather pipe : 1,5 ± 0,1
(5) Reverse gear switch : 2,5 ± 0,2
(6) Drain plug : 3,5 ± 0,2
(7) Top-up plug : 2 ± 0,2
(8) Speedo drive support : 1,5 ± 0,1
(9) Differential housing fixings (M7) : 1,5 ± 0,1
(10) Differential housing fixings (M10) : 5 ± 0,5
(11) Clutch bearing guide fixing screw : 1,5 ± 0,1
(12) Differential extension fixing : 1,5 ± 0,1

TRANSMISSION
GEARBOX
CLUTCH
B2CKUB0D

257
 C5 C8 BE4/5 GEARBOX
Engines: 6FZ RFN RLZ RHY

Tightening torques m.daN.

(13) Primary shaft nut : 7,5 ± 0,7

(14) Secondary shaft nut : 6,5 ± 0,6

(15) Bearing retaining screw : 1,5 ± 0,1

(16) Differential gearwheel screw : 6 ± 0,6

(17) Gear control support screw : 1,5 ± 0,1

TRANSMISSION
GEARBOX
CLUTCH

B2CKUB1D

258
 ML/5C GEARBOX C5 C8
Engines: 3FZ XFX RHS RHZ RHW RHT

Identification.

«a» Location of identification label.

«b»Marking zone.

TRANSMISSION
GEARBOX
CLUTCH
B2CP3KBC

259
 C5 C8 ML/5C GEARBOX
Engines: 3FZ XFX RHS RHZ RHW RHT
Recommendations - Precautions

(1) Drain plug.

(2) Filler and top-up plug.(Discontinuation of the plug from RPO 9345 9)

Oil quality.
- See chapter on lubricants.

Oil quantity.
- After draining = 1.8 litres

Features.
The ML/5 compact gearbox is an evolution of the ML/5T gearbox:
Length reduced by 14 mm.
Enhancements in gear changing effort and travel.
New «chandelier» type gearbox control grille with special gear lever gaiter.
Unlocking device for reverse gear.
New support for the sender duct on the hydraulic clutch control.
TRANSMISSION

New reverse gear switch.

GEARBOX
CLUTCH

Increase in oil quantity resulting from engine tilt.

B2CP3CUC

260
 ML/5C GEARBOX C5 C8
Engines: 3FZ XFX RHS RHZ RHW RHT

(1) 5th gear synchroniser (13) Satellite pinion

(2) 5th gear drive pinion (14) Differential housing
(3) Reverse gear intermediate pinion (15) Planet pinion
(4) Reverse gear slide pinion (16) Differential bearing stop plate
(5) Gearbox casing (17) Reverse gear driven pinion
(6) Clutch housing (18) 1st gear driven pinion
(7) Reverse gear slide pinion (19) 1st and 2nd gear synchroniser
(8) Reverse gear pin (20) 2nd gear driven pinion
(9) Reverse gear needle bearing (21) 3rd gear driven pinion
(10) Primary shaft (22) 3rd and 4th gear synchroniser
(11) Secondary shaft (23) 4th gear driven pinion
(24) 5th gear driven pinion
(12) Differential crown
(25) Steel casing

TRANSMISSION
GEARBOX
CLUTCH
B2CP3KCP

261
 C5 C8 ML/5C GEARBOX
Engines: 3FZ XFX RHS RHZ RHW RHT

Tightening torques m.daN

(26) Secondary shaft nut : 17 ± 1,5

(27) Differential gearwheel screws : 7,7 ± 0,3

(28) Bearing guides : 2 ± 0,2

TRANSMISSION
GEARBOX
CLUTCH

B2CP3KDD

262
 ML/5C GEARBOX C5 C8
Engines: 3FZ XFX RHS RHZ RHW RHT

Tightening torques m.daN

(29) Reversing lamp switch : 3 ± 0,1

(30) Clutch housing/gearbox casing fixing screws : 2 ± 0,2
(31) Selection lever screw : 4 ± 0,5
(32) Filler and top-up plug (*) : 3 ± 0,3
(33) Drain plug : 3 ± 0,3
(34) Differential bearing stop plate screws : 2 ± 0,2
(35) Gearbox rear casing screws : 2 ± 0,2
(36) Differential housing fixings (M8 screws) : 2 ± 0,2
(37) Differential housing fixings (M10 screws) : 4 ± 0,5

(*) = Discontinuation of the plug from RPO 9345 9

TRANSMISSION
GEARBOX
CLUTCH
B2CP3KEP

263
 C5 ML/6C GEARBOX SPECIFICATION
Engine: 4HX

Identification.

«a» Location of identification label

«b» Engraving zone

Features.
The ML/6C compact gearbox is an evolution of the ML/5C
gearbox:
Length increased by 11,5mm
Weight increased by 2 kg
New gear ratios
New gearbox control grille
New gearbox ratio
NOTE: This gearbox has a reverse gear unlocking device.
The gear control is specific (6-speed gearbox).
It is necessary to lift the ring located under the gear lever knob to
engage reverse gear.
TRANSMISSION
GEARBOX
CLUTCH

B2CP3SAC B2CP3SBC

264
 ML/6C GEARBOX SPECIFICATION C5
Engine: 4HX

Lubrication.
Oil capacity:
2,1 litres (minimum).
2,4 litres ± 0,3 (maximum). EW engine
2,6 litres ± 0,3 (maximum). DW engine

Oil quality: ESSO 75W80 EZL 848 or TOTAL 75W80W H6959.

Checking the oil level: No level check (*)

Lubrication for life

IMPERATIVE: Necessary to drain the gearbox and put back the exact oil quantity, in the
case of an external or following a repair.

TRANSMISSION
GEARBOX
CLUTCH
(*) NOTE: Do a visual check of the sealing at each engine oil change interval.

B2CP3SFC

265
 C5 ML6C GEARBOX
Engine: 4HX
Description

(1) Primary shaft bearing play adjustment (16) Differential housing

shim (17) Planet gear adjustment shims
(2) 6th gear drive pinion (18) Planet pinions
(3) 5th and 6th gear synchroniser (19) Satellite shaft
(4) 5th gear drive pinion (20) Differential bearing stop plate
(5) Gearbox casing (21) Reverse gear driven pinion
(6) Reverse gear intermediate pinion (22) 1st gear driven pinion
(7) Reverse gear synchroniser (23) 1st and 2nd gear synchroniser
(8) Reverse gear slide pinion (24) 2nd gear driven pinion
(9) Clutch housing (25) 3rd gear driven pinion
(10) Reverse gear pin (26) 3rd and 4th gear synchroniser
(27)) 4th gear driven pinion
(11) Reverse gear needle bearing
(28) 5th gear driven pinion
(12) Primary shaft
(29) 6th gear driven pinion
(13) Secondary shaft
(30) 6th gear housing
(14) Differential gearwheel
TRANSMISSION

(15) Satellite pinions

GEARBOX
CLUTCH

B2CP3SCP

266
 ML6C GEARBOX C5
Engine: 4HX

Tightening torques m.daN

(31) Primary shaft screw : 8 ± 0,8

(32) Bearing guide screws : 2 ± 0,2
(33) Differential gearwheel screws : 7,7 ± 0,3
(34) Secondary shaft screw : 13 ± 1,5
(35) Reversing lamp switch : 2,5 ± 0,2
(36) Level plug : 3 ± 0,2
(37) Drain plug : 3 ± 0,5
(38) Differential bearing stop plate
screw : 3 ± 0,3
(39) Clutch housing/gearbox casing
fixing screws : 3 ± 0,3
(40) 6th gear housing fixing screws : 2 ± 0,2
(41) Differential housing fixings
(M8 screws)) : 1,8 ± 0,2

TRANSMISSION
(42) Differential housing fixings

GEARBOX
(M10 screws) : 4 ± 0,5

CLUTCH
B2CP3SDD B2CP3SEP

267
 C5 C8 BE4/5 GEARBOX CONTROL SPECIFICATIONS
Engines: 6FZ RFN RLZ RHY

Gear controls

[1] Gear lever positioning tool 8605-T

(1) Gear engagement ball-joint Ø 10 mm

(2) Gear control lever
(3) Gear engagement control cable
(4) Gear selection control cable
(5) Cable selection locking ley
(6) Gear selection ball-joint Ø 10 mm
TRANSMISSION
GEARBOX
CLUTCH

B2CP3CJD

268
 BE4/5 GEARBOX CONTROL SPECIFICATIONS C5 C8
Engines: 6FZ RFN RLZ RHY
Gear selection control cable. Gear engagement control cable.

B2CP3CKD B2CP3CLD

Left hand drive Right hand drive Left hand drive Right hand drive
Length A 730 ± 3mm Length G 700 ± 3 mm

TRANSMISSION
GEARBOX
CLUTCH
Length B 937,5 ± 7,5mm Length H 983 ± 7,5 mm

Note: See adjustment: page 270.

269
 C5 C8 CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS
Engines: 6FZ RFN RLZ RHY

Adjustments.

WARNING: Control cables should be adjusted each time the gearbox is

removed or cables changed.

WARNING: Do not use oil to detach the ball-joints.

To release the ball-joint, press at the centre «a» then pull the ball-joint upwards.

Ball-joints alone can be changed by removing the unlocking key with the aid of
two thin screwdrivers, unclip at «b».

To unlock the ball-joint, turn in the direction of the arrow «c».

TRANSMISSION
GEARBOX
CLUTCH

B2CP3CVD B2CP3CWC B2CP3CXC

270
 CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS C5 C8
Engines: 6FZ RFN RLZ RHY

Tools.
[1] Tool for positioning the gearbox control lever 8605-T Toolkit 9040-T

Adjustments.

Cables should be adjusted each time the gearbox, gear controls or power unit are removed.

Adjustment principles:
- Lock the gear lever in neutral position, using tool [1].
- Position the gearbox in neutral.
- Anchor the ball-joints on the gearbox levers.
- Lock the cable lengths with the ball-joint locking keys.

Inside the vehicle.

- Remove the central console (See corresponding operation).
- Remove the plastic blank at (a).

TRANSMISSION
- Insert tool [1] fully and rotate a quarter turn to lock the gear control lever.

GEARBOX
CLUTCH
- At neutral.

B2CP3E7C

271
 C5 C8 CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS
Engines: 6FZ RFN RLZ RHY

Adjustments (continued)

Under the bonnet.

- Remove the air filter assembly.

- Unlock the gear engagement cable ball-joint ( b ).
- Unlock the gear selection cable ball-joint ( c )
- Make sure the gear levers (engagement and selection) are in neutral position.
- Lock the cable lengths with the ball-joint locking keys.
- Remove the tool [1].

Checks.

- Check that all the gears engage without «tightness ».

- Check that t he gear lever moves identically forwards and backwards and to right and left. If not:
- Repeat the adjustment.
TRANSMISSION

Refit the console and the air filter assembly.

GEARBOX
CLUTCH

B2CP3E8C B2CP3E9C

272
 ML/5C - ML/6C GEARBOX SPECIFICATIONS C5 C8
Engines: 3FZ XFX RHY RHZ RHT RHW 4HW 4HX
Gear controls.
Gear control is by means of cables:
Gear selection control cable
Gear engagement control cable
Reverse gear control cable

[1] Gear lever positioning tool 8605-T.

(1) Gear engagement ball-joint : Ø 10 mm

(2) Gear engagement control cable
(3) Gear control lever
(4) Gear selection control cable
(5) Gear selection ball-joint : Ø 10 mm
(6) Reverse gear unlocking cable

TRANSMISSION
(7) O-ring seal

GEARBOX
(8) Reverse gear unlocking device

CLUTCH
B2CP3KXD

273
 C5 C8 ML/5C - ML/6C GEARBOX CONTROL SPECIFICATIONS
Engines: 3FZ XFX RHY RHZ RHT RHW 4HW 4HX
ML/5C ML/6C

Features

New «chandelier» type gearbox control grille with special gear lever gaiter.
It is necessary to lift the ring located under the gear lever knob to engage
reverse gear.
Unlocking device for reverse gear (8) external to the gearbox.
The reverse gear locking/unlocking system uses the 5th gear synchroniser.

IMPERATIVE: Systematically replace the O-ring seal (7) at each removal.

Adjustments

WARNING: Cables should be adjusted each time the gear controls are removed
or a cable changed.
TRANSMISSION
GEARBOX
CLUTCH

B2CP3HRC B2CP3SBC B2CP3KZC

274
 ML/5C - ML/6C GEARBOX CONTROL SPECIFICATIONS C5 C8
Engines: 3FZ XFX RHY RHZ RHT RHW 4HW
Gear selection control cable. Gear engagement control cable.

B2CP3CRD B2CP3CSD

Left hand drive Right hand drive Left hand drive Right hand drive
Adjustment yes Adjustment yes
Length A (mm) 750 Length C (mm) 781

TRANSMISSION
GEARBOX
Length B 1015 Length D (mm) 1115

CLUTCH
275
 C5 C8 ML/5C - ML/6C GEARBOX CONTROL SPECIFICATIONS
Engine: 4HX
Gear selection control cable. Gear engagement control cable.

B2CP3SGD B2CP3SHD

Left hand drive Right hand drive Left hand drive Right hand drive
Adjustment yes Adjustment yes
Length A (mm) 750 Length C (mm) 781
TRANSMISSION
GEARBOX

Length B (mm) 1012 Length D (mm) 1120

CLUTCH

276
 ML/5C - ML/6C GEARBOX CONTROL SPECIFICATIONS C5 C8
Engines: 3FZ XFX RHY RHZ RHT RHW 4HW 4HX
Reverse gear unlocking cable

B2CP3KYD

Left hand drive Right hand drive

Adjustment no
Length E (mm) 1332

TRANSMISSION
GEARBOX
Length F (mm) 1460

CLUTCH
277
 C5 C8 CHECKS AND ADJUSTMENTS: ML/5C - ML/6C GEARBOX CONTROLS
Engines: 3FZ XFX RHY RHZ RHT RHW 4HW 4HX

Tools
[1] Tool for positioning the gearbox control lever 8605-T Toolkit 9040-T

To be carried out after the gearbox control cables are refitted (see corresponding procedure).

Adjustments.
Cables should be adjusted each time the gearbox, gear controls or power unit are removed.

Lock the gear lever in neutral position, using tool [1].

Using two thin screwdrivers, release at «f».
Adjust the cable lengths.
Lock the cable lengths by pressing at «e».

Checks.
Remove tool [1].
Check:
- that all the gears engage without «tightness».
TRANSMISSION

- that the gear lever moves identically forwards and backwards and to right and left. If not:
GEARBOX
CLUTCH

Repeat the adjustment.

B2CP3SJC B2CP3SKC
Complete the refitting ( see corresponding procedure).

278
 RECOMMENDATIONS - PRECAUTIONS: AL 4 AUTOMATIC GEARBOX C5 C8
Engines: 6FZ RFN RHS RHZ RHM
Procedure to be followed prior to carrying out repairs on AL4 autoactive gearbox

If a gearbox malfunction occurs, there are two possible configurations Oil level (See corresponding operation).
depending on the seriousness of the fault:
- Gearbox in back-up mode with a replacement programme of An excessive oil level can result in the following consequences:
(the fault values are taken in substitution). - Excessive heating of the oil.
- Gearbox in back-up mode with an emergency programme - Oil leaks.
(3rd hydraulic) An insufficent level causes the destruction of the gearbox.
WARNING: In the emergency programme, an impact is felt when Top up the level of oil in the gearbox (if necessary).
changing P/R, N/R and N/D.
Customer reception. Check using a diagnostic tool.
Discuss with the customer, to find out all the malfunction symptoms. Read the fault codes (engine and gearbox)

Oil quality – Oil level. Absence of fault codes.

If the gearbox has suffered a serious fault resulting in a malfunction Carry out parameter measures, actuator tests and a road test.
or the destruction of a clutch, the oil will overheat and become
contaminated with impurities: the oil is said to be «burnt». Presence of fault codes.
This is characterised by a black colour and the presence of an Carry out the necessary repairs.

TRANSMISSION
unpleasant smell. Delete the fault codes.

GEARBOX
Carry out a road test to check the repair and, if need be, modify the

CLUTCH
ESSENTIAL: The gearbox must be replaced. gearbox ECU parameters (this is essential after an initialisation of
the ECU).

279
 C5 C8 RECOMMENDATIONS - PRECAUTIONS: AL 4 AUTOMATIC GEARBOX
Engines: 6FZ RFN RHS RHZ RHM
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.
IMPERATIVE: - Put gear lever in position «N».. The ECU when the ignition is switched on.
- Do not add any oil.
- Do not exceed 30 mph over a distance of 30 miles of maximum. Before reconnecting a switch, check:
The condition of the various contacts.(for deformation, corrosion etc.)
Driving. The presence and condition of the mechanical locking.
Never drive with the ignition switched off.
Never push the vehicle to try to start it; When performing electrical checks:
(impossible with an automatic gearbox). The battery should be correctly charged.
Never use a voltage source higher than 16V.
Never use a test lamp.
Lubrication
The automatic gearbox is only lubricated when the engine is running.
TRANSMISSION
GEARBOX
CLUTCH

280
 RECOMMENDATIONS - PRECAUTIONS: AL 4 AUTOMATIC GEARBOX C5 C8
Engines: 6FZ RFN RHS RHZ RHM
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 the Note down the gearbox counter value.
converter retaining bracket should be in place when handling the Transfer the value read into the the new gearbox ECU.
gearbox.
Exchanging the gearbox:
It is imperative to use the centring peg and the converter retaining
bracket to couple the gearbox on the engine. Initialise the oil usage counter to 0.

After coupling the gearbox on the engine, remove the centring peg. Draining the gearbox:

Initialise the oil usage counter.

(follow the diagnostic tool procedure).

TRANSMISSION
GEARBOX
CLUTCH
281
 C5 C8 RECOMMENDATIONS - PRECAUTIONS: AL 4 AUTOMATIC GEARBOX
Engines: 6FZ RFN RHS RHZ RHM
Procedure for initialising the automatic gearbox ECU

Downloading

Updating the gearbox ECU by downloading:

Follow the procedure using the diagnostic tool.

The downloading operation enables the automatic gearbox to be updated, or adapted to an evolution of the engine ECU.
Before commencing the downloading, take the value of the oil usage counter present in the automatic gearbox ECU.

After the downloading operation, carry out the following:

A clearing of faults.
A pedal initialisation.
A re-initialisation of the auto-adaptives.
A downloading (if necessary).
A writing of the value of the oil usage counter previously read.
A road test.
TRANSMISSION

ESSENTIAL: Every update of the automatic gearbox ECU should be accompanied by an update of the engine ECU.
GEARBOX
CLUTCH

282
 RECOMMENDATIONS - PRECAUTIONS: AL 4 AUTOMATIC GEARBOX C5 C8
Engines: 6FZ RFN RHS RHZ RHM
Procedure for initialising the automatic gearbox ECU
Downloading
Updating the value of the oil usage counter

ECU downloading procedure:

Using PROXIA - Follow the diagnostic tool procedure.
Access to reading and recording of the oil counter is via the menu: A new ECU or downloaded update is always configured
with the following options:
«Configuration (integrated circuit button)/Oil counter». - SHIFT LOCK gear selection lever position.
- Without OBD outlet (depollution L4).
Adjustment of the oil counter value is done in incremental steps of If the ECU is to be fitted to a vehicle with depollution L4 or not
2750 units. equipped with gear lever locking safety:
Perform a downloading operation.

Using LEXIA or ELIT Pedal initialisation.

Access to reading and recording of the oil counter is via the menu: A pedal initialisation must be carried out in the following cases:
- Replacement of the automatic gearbox ECU.
«Oil counter». - Replacement of the automatic gearbox.

TRANSMISSION
- Downloading of the ECU configuration.

GEARBOX
CLUTCH
Adjustment of the oil counter value is done by entering directly the - Adjustment or replacement of the accelerator cable.
5 figures of the oil counter. - Replacement of the butterfly potentiometer.

283
 C5 C8 AL4 AUTOMATIC GEARBOX SPECIFICATIONS
Engines: 6FZ RFN RHS RHZ RHM

Identification

«a» Component reference.

WARNING: This gearbox benefits from

a special CITROËN semi-synthetic oil,
which cannot be mixed with any other oil.

The gearbox is lubricated for life.

TRANSMISSION
GEARBOX
CLUTCH

B2CP3ECD

284
SPECIAL FEATURES – TIGHTENING TORQUES: AL4 AUTOMATIC GEARBOX C5 C8
Engines: 6FZ RFN RHS RHZ RHM

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

B2CP3EDD (4) Output speed sensor fixing : 1 ± 0,2

(5) Oil overflow and drain fixing

X = 75 mm (EW7 and EW10 engine versions) : 4 ± 0,2
X = 77 mm (DW10 engine version) : 4 ± 0,2

(6) Oil level plug : 2,4 ± 0,4

TRANSMISSION
GEARBOX
CLUTCH
(7) Oil pressure sensor fixing : 0,8 ± 0,1

B2CP311D

285
 C5 C8 SPECIAL FEATURES – TIGHTENING TORQUES: AL4 AUTOMATIC GEARBOX
Engines: 6FZ RFN RHS RHZ RHM

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

TRANSMISSION
GEARBOX
CLUTCH

B2CP3EED

286
SPECIAL FEATURES – TIGHTENING TORQUES: AL4 AUTOMATIC GEARBOX C5 C8
Engines: 6FZ RFN RHS RHZ RHM

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

NOTE: The screw (11) is shouldered.

B2CP3EFD
B: DW10 engine
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

TRANSMISSION
NOTE: The screw (11) is shouldered

GEARBOX
CLUTCH
(13) Fixing of selector lever position switch : 1,5 ± 0,2
(14) Oil filler plug : 2,4 ± 0,4
B2CP3EGC

287
 C5 AL4 GEARBOX CONTROL SPECIFICATIONS
Engines: 6FZ RFN RHS RHZ
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.
Position «N»: Neutral.
Position «D»: Drive (Use of the 4 gears in their autoadaptive automatic
function)

Position «M»: Manual (this position lets the driver select his own gears in
sequential mode by pulling the gear selector to «M - » or pushing it to
«M +»).

NOTE: Only the positions «P» or «N» authorise the starting of the engine.
In position «M», selection is by an electronic sensor located close to the
TRANSMISSION

gear lever.
GEARBOX
CLUTCH

The variation of flux necessary to the movement of the sensor cells is

obtained by a magnet located on the lever itself. This enables the change
B2CP3DKD of status.

288
AL4 GEARBOX CONTROL SPECIFICATIONS C5
Engines: 6FZ RFN RHS RHZ

In passenger compartment (continued)

The information is transmitted to the gearbox ECU.

NOTE: The vehicle is equipped with the «shift lock»: 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).

- Sport programme (a): Permits a more dynamic, sporty performance.

- Snow programme (b): Facilitates starting and adhesion on slippery

surfaces.

TRANSMISSION
GEARBOX
CLUTCH
NOTE: To return to the normal programme, press a second time on the
sport switch or snow switch.
B2CP3DKD

289
 C5 AL4 GEARBOX CONTROL SPECIFICATIONS
Engines: 6FZ RFN RHS RHZ

Gearbox end

The automatic gearbox is controlled by a cable.

«c» Clip for unlocking the push-button in pushed-in position.

(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.

TRANSMISSION
GEARBOX
CLUTCH

B2CP3DLC

290
AL4 GEARBOX CONTROL SPECIFICATIONS C5
Engines: 6FZ RFN RHS RHZ
On refitting.

Refitting the gearbox control.

New gear selection control

Couple the ball-joint (3).

Push in the component (16) without bending the cable.
Release the component (16).
Lock the adjustment by means of component (17).
Check all the gear selection control positions.

Re-used gear selection control.

Unlock component (17).

Release the component 16).
Couple the ball-joint (3).
Push in the component (16) without bending the cable.

TRANSMISSION
Release the component (16).

GEARBOX
Lock the adjustment by means of component (17).

CLUTCH
Check all the gear selection control positions.

B2CP3DWD

291
 C8 AL4 GEARBOX CONTROL SPECIFICATIONS: CHECKS AND ADJUSTMENTS
Engines: RFN RHM
On refitting.

IMPERATIVE: Fit new clips and collars.

WARNING: Check that the gear control cables are correctly routed.
Proceed in opposite order to removal.

IMPERATIVE: To clip the ball-joint (8) position tool [1]

(Ball-joint extractor (-).0338.E) under the selection lever (9).
B2CKUF5D
If necessary, adjust the selection control (if new or maladjusted).

Adjusting the selection control.

To unlock the gear control adjustment system, pull the white ring (12) towards the
front of the vehicle and lift the orange plastic component (11).
Selection lever in position «P».
Engagement lever (10) as far as possible towards the rear of the vehicle (B).
Lock the adjustments of the gears by pressing on the orange plastic component (11).
TRANSMISSION

Release the white ring (12).

GEARBOX

The adjustment is complete.

CLUTCH

Check all the gear selection control positions.

B2CKUF6D

292
AL4 GEARBOX CONTROL SPECIFICATIONS AND PRECAUTIONS: «SHIFT LOCK» C5
Engines: 6FZ RFN RHS RHZ

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».

Unlocking the «SHIFT LOCK» (with an operating fault).

C5FP0CTC Should it be impossible to unlock the «shift lock» with the «Normal operation» method,
the fault may originate from one of the following components:
- «Shift lock».
- Gear lever position switch.
- Automatic gearbox ECU.
- Electrical harnesses.
- Battery voltage.
Remove:

TRANSMISSION
- The gear lever knob (1) (pull upwards).
- The cover (2) (Unclip).

GEARBOX
CLUTCH
- The grid (3).
- Unlock the «shift lock» (4) with the aid of a screwdriver.
C5FP0CUD - Move the gear selection lever out of position «P».

293
 C8 AL4 GEARBOX CONTROL SPECIFICATIONS AND PRECAUTIONS: «SHIFT LOCK»
Engines: RFN RHM
SHIFT LOCK
NOTE: The «shift lock» is a system that locks the gear selection lever in position «P».

Unlocking the «SHIFT LOCK».

- Switch on the ignition.
- Press the brake pedal and keep it pressed.
- Move the gear selection lever out of position «P».

Impossible to unlock the «shift lock»:

B2CK007D
Probable causes of the fault.
The fault may originate from one of the following components:
- Battery voltage.
- Electro-magnet on the gear engagement lever housing.
- Gear lever position switch.
- Automatic gearbox ECU.
- Electrical harness.
- Brake pedal switch.
TRANSMISSION
GEARBOX

Breakdown solution.
CLUTCH

Detach the gear control embellisher (1) commencing from the bottom.
Release the «shift lock» with a screwdriver.
B2CK008D

294
DRAIN/REFILL/TOP-UP: AL4 GEARBOX C5 C8
Engines: 6FZ RFN RHS RHZ RHM

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).
NOTE: Approx. 3 litres of oil should flow out.
B2CP3AYD
Filling.
Refit the drain plug (1) (equipped with a new seal), tighten to 4 ± 0,8 m.daN.
Remove the oil filler cap (2).
Use tool [1].
Oil capacity for dry gearbox:
EW engine: 5,85 litres
DW engine: 5,40 litres
Oil remaining after draining: 3 litres (approx.)

TRANSMISSION
Quantity of oil to be put in: 3 litres approx.)

GEARBOX
Refit the oil filler cap (2) (equipped with a new seal), tighten to 2,4± 0,2 m.daN.

CLUTCH
Initialise the oil wear counter (follow the diagnostic tool procedure).

B2CP31GC

295
 C5 C8 DRAIN/REFILL/TOP-UP: AL4 GEARBOX
Engines: 6FZ RFN RHS RHZ RHM

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.
- Selection lever in position “P”.
- Engine running, at idle.
- Oil temperature: 60°C (+8°C; -2°C).
- Remove the oil level plug (3).

C5 EW10 and DW10 engines Dimension «X» = 81 mm

TRANSMISSION

C8 EW10 and DW10 engines Dimension «X» = 81 mm

GEARBOX
CLUTCH

B2CP3AZD

296
DRAIN/REFILL/TOP-UP: AL4 GEARBOX C5 C8
Engines: 6FZ RFN RHS RHZ RHM

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.

NOTE: The level is correct at the moment the thread of oil becomes drip-drip.

Refit the oil level plug (3) (equipped with a new seal), tighten to 2,4± 0,2 m.daN.

Checking the oil level (continued).

Refit the oil filler plug (3) (equipped with a new seal), tighten to 2,4± 0,2 m.daN.
An excessive level of oil can lead to the following consequences:

TRANSMISSION
- Oil heating up abnormally,

GEARBOX
- Oil leaks.

CLUTCH
A level that is too low will result in the destruction of the gearbox.

B2CP3AZD

297
 C5 C8 AL4 GEARBOX CHECKS AND ADJUSTMENTS: MULTIFUNCTION SWITCH
Engines: 6FZ RFN RHS RHZ RHM
Adjustment of MULTIFUNCTION SWITCH

- Place the selection lever in position «N».

- Slacken the screws (1).
- Place the multifunction switch as far out as possible on the screw at «A».
- Connect a multimeter in the ohmmeter position on the electrical contacts (2).
- Turn the multifunction switch to close the circuit between the electrical contacts:
R = 0 Ω.
- Mark the position of the multifunction switch at «B» in relation to the gearbox casing
B2CKU1DD at «C».
- Continue to turn the multifunction switch to open the circuit between the electrical
contacts.
- Mark the position of the multifunction switch at «B» in relation to the gearbox casing
at «D».
- Bring the switch back to position the mark «B» at midway between marks «C» and «D».
TRANSMISSION

- Tighten the screws (1) to 1,5 ± 0,1 m.daN.

GEARBOX
CLUTCH

- Check the correspondance between the position of the gear selector and the
indication on the instrument panel.
B2CKU1ED

298
AL4 GEARBOX CHECKS AND ADJUSTMENTS: INTERNAL SELECTION CONTROL C5 C8
Engines: 6FZ RFN RHS RHZ RHM
Adjustment of INTERNAL SELECTION CONTROL

Tools.

[1] Locking screw : (-).0338-M1.

[2] Indexing roller adjustment shim : (-).0338-M2.

Adjustment.
Prior conditions: Hydraulic block in place.
- Place the gear selection lever in position 2 (A).
B2CA08MC - Remove the screw (1)
- Slacken the screw (2).
- Fit tools [1] and [2].
- Position the indexing roller on the notched sector (B).
- Lock tool [2], using tool [1].
- Tighten the screw (2) to 0,8 ± 0,1 m.daN.
- Check that the gear engagement lever is securely locked.

TRANSMISSION
- Check the operation of the gear selection lever in all the positions.

GEARBOX
CLUTCH
IMPERATIVE: There must not be any excessive travel on the gear selection lever when it is
in position 2. Adjust the multifunction switch.
B2CA08NC

299
 C5 C8 RECOMMENDATIONS - PRECAUTIONS: 4 HP 20 AUTOMATIC GEARBOX
Engines: XFX 4HX XFW
Procedure to be followed prior to carrying out repairs on 4HP20 autoactive gearbox
If a gearbox malfunction occurs, there are two possible configurations Oil level. (See corresponding operation).
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). - Excessive heating of the oil.
- Gearbox in back-up mode with an emergency programme - Oil leaks.
(3rd hydraulic) An insufficent level causes the destruction of the gearbox.
WARNING: In the emergency programme, an impact is felt when Top up the level of oil in the gearbox (if necessary).
changing P/R, N/R and N/D.
Customer reception. Check using a diagnostic tool.
Discuss with the customer, to find out all the malfunction symptoms. Read the fault codes (engine and gearbox).

Oil quality – Oil level. Absence of fault codes.

If the gearbox has suffered a serious fault resulting in a malfunction Carry out parameter measures, actuator tests and a road test.
or the destruction of a clutch, the oil will overheat and become Presence of fault codes.
contaminated with impurities: the oil is said to be «burnt». Carry out the necessary repairs.
This is characterised by a black colour and the presence of an Delete the fault codes.
Carry out a road test to check the repair and, if need be, modify the
TRANSMISSION

unpleasant smell.
gearbox ECU parameters (this is essential after an initialisation of
GEARBOX
CLUTCH

ESSENTIAL: The gearbox must be replaced. the ECU).

300
 RECOMMENDATIONS - PRECAUTIONS: 4 HP 20 AUTOMATIC GEARBOX C5 C8
Engines: XFX 4HX XFW
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.
IMPERATIVE: - Put gear lever in position «N». The ECU when the ignition is switched on.
- Do not add any oil.
- Do not exceed 45 mph over a distance of 60 miles maximum. Before reconnecting a switch, check:
The condition of the various contacts.(for deformation, corrosion etc.)
Driving. The presence and condition of the mechanical locking.
Never drive with the ignition switched off.
Never push the vehicle to try to start it; When performing electrical checks:
(impossible with an automatic gearbox). The battery should be correctly charged.
Never use a voltage source higher than 16V.
Never use a test lamp.
Lubrication

TRANSMISSION
The automatic gearbox is only lubricated when the engine is running.

GEARBOX
CLUTCH
301
 C5 C8 RECOMMENDATIONS - PRECAUTIONS: 4 HP 20 AUTOMATIC GEARBOX
Engines: XFX 4HX XFW
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.
the converter retaining bracket should be in place when handling the Transfer the value read into the the new gearbox ECU.
gearbox.
Exchanging the gearbox:
It is imperative to use the centring peg and the converter retaining
bracket to couple the gearbox on the engine. Initialise the oil usage counter to 0.

After coupling the gearbox on the engine, remove the centring peg. Draining the gearbox:

Initialise the oil usage counter.

(follow the diagnostic tool procedure).
TRANSMISSION
GEARBOX
CLUTCH

302
 RECOMMENDATIONS - PRECAUTIONS: 4 HP 20 AUTOMATIC GEARBOX C5 C8
Procedure for initialising the automatic gearbox ECU

Downloading

Updating the gearbox ECU by downloading:

Follow the procedure using the diagnostic tool.

The downloading operation enables the automatic gearbox to be updated, or adapted to an evolution of the engine ECU.
Before commencing the downloading, take the value of the oil usage counter present in the automatic gearbox ECU.

After the downloading operation, carry out the following:

A clearing of faults.
A pedal initialisation.
A re-initialisation of the auto-adaptives.
A downloading (if necessary).
A writing of the value of the oil usage counter previously read.
A road test.

ESSENTIAL: Every update of the automatic gearbox ECU should be accompanied by an update of the engine ECU.

TRANSMISSION
GEARBOX
CLUTCH
303
 C5 C8 RECOMMENDATIONS - PRECAUTIONS: 4 HP 20 AUTOMATIC GEARBOX
Procedure for initialising the automatic gearbox ECU

Updating the value of the oil usage counter Downloading

ECU downloading procedure:

Using PROXIA - Follow the diagnostic tool procedure.
Access to reading and recording of the oil counter is via the menu:
A new ECU or downloaded update is always configured
«Configuration (integrated circuit button)/Oil counter». with the following options:

Adjustment of the oil counter value is done in incremental steps of - SHIFT LOCK gear selection lever position.
2750 units. - Without OBD outlet (depollution L4).

If the ECU is to be fitted to a vehicle with depollution L4 or not

Using LEXIA or ELIT equipped with gear lever locking safety:
Access to reading and recording of the oil counter is via the menu: Perform a downloading operation.

«Oil counter». Pedal initialisation.

A pedal initialisation must be carried out in the following cases:
TRANSMISSION

Adjustment of the oil counter value is done by entering directly the - Replacement of the automatic gearbox ECU.
5 figures of the oil counter. - Replacement of the automatic gearbox.
GEARBOX
CLUTCH

- Downloading of the ECU configuration.

- Adjustment or replacement of the accelerator cable.
- Replacement of the butterfly potentiometer.

304
 4 HP 20 AUTOACTIVE GEARBOX SPECIFICATION C5 C8
Engines: XFX 4HX XFW

Identification.

(1) Identification plate

(riveted on the casing).

(a) Serial no..

(b) ZF number.
(last digits taken into account)

(c) Type of automatic gearbox.

(d) Component reference

TRANSMISSION
GEARBOX
CLUTCH
B2CP3CYD

305
 C5 C8 SPECIAL FEATURES – TIGHTENING TORQUES: 4 HP 20 AUTOACTIVE GEARBOX
Engines: XFX 4HX XFW

Tightening torques m.daN.

Gearbox exterior.

(2) Oil channel union fixing 2,5 ± 0,5

(3) Exterior fixing of converter cover on clutch housing 2,3 ± 0,5
(4) Speedometer take-off aperture plug 1 ± 0,1
(5) Steel casing fixing 0,6 ± 0,1
(6) Converter fixing on engine 6±1
(7) Interior fixing of converter cover on clutch housing 2,3 ± 0,5
(8) Torx fixing of converter cover on clutch housing 2,3 ± 0,5

Drain plug 4,5 ± 0,8

Heat exchanger fixing 3,5 ± 0,5
Selector lever position switch fixing 1 ± 0,2
Converter cover fixing on engine cover (XFX engine) 6,5 ± 1
TRANSMISSION

Converter cover fixing on engine cover (4HX engine) 5,8 ± 1

GEARBOX
CLUTCH

B2CP3CZC B2CP24BC B2CP24CC

306
SPECIAL FEATURES – TIGHTENING TORQUES: 4 HP 20 AUTOACTIVE GEARBOX C5 C8
Engines: XFX 4HX XFW

Tightening torques m.daN.

Gearbox interior.

(9) Input speed sensor fixing 0,8 ± 0,1

(10) Hydraulic block fixing (Large head) 0,8 ± 0,1

(11) Output speed sensor fixing 1 ± 0,2

TRANSMISSION
GEARBOX
CLUTCH
B2CP24DC B2CP24EC

307
 C5 4 HP 20 GEARBOX CONTROL SPECIFICATIONS
Engines: XFX - 4HX

Selection control.
The gear selection control has 5 positions.
The selection lever is guided by the shape of the stepped gate and by a retaining spring which holds
it towards the left.

The gear selection control is equipped with the «shift lock», so you have to switch on the ignition and
apply the brake pedal to unlock the selection lever from the park position.

Selection (P) : Park (locking and immobilisation of the vehicle).

Selection (R) : Reverse gear.
Selection (N) : Neutral.
Selection (D) : Drive (Use of the four gears in their autoadaptive automatic function).
Selection (M): Manual (M + M -) allowing the driver to select gears by pulling and pushing the gear
lever.
In position M, selection is by an electronic sensor located close to the gear lever.
The variation of flux necessary to the movement of the sensor cells is obtained by a magnet located
on the lever itself.
TRANSMISSION

This enables the change of status.

GEARBOX
CLUTCH

B2CP3DKD

308
4 HP 20 GEARBOX CONTROL SPECIFICATIONS C5
Engines: XFX-4HX

Selection control (continued).

In position M, selection is by an electronic sensor located close to the gear lever.
The variation of flux necessary to the movement of the sensor cells is obtained by a magnet located
on the lever itself. This enables the change of status. The information is transmitted to the gearbox ECU.
Two switches placed on the gear control gate permit the driver to choose one of the following three
driving programmes:
- Normal: The normal programme operates in the absence of the other two ( Eco law, autoadaptative
mode).
- Sport: Permits a more dynamic, sporty performance.
- Snow: Facilitates starting and adhesion on slippery surfaces.
To return to the normal programme, press a second time on the sport switch or snow switch.

Only when the selector is in position (P) or (N) can the engine be started.
- (1) Control linkage with ball-joint.
- (2) Automatic adjustment (Push-button «c», pressed in to lock the control adjustment, springs out for
the adjustment to be made).
- (3) Cable sleeve stop.

TRANSMISSION
The automatic gearbox is controlled by a cable.

GEARBOX
CLUTCH
B2CP3DLC

309
 C5 4 HP 20 GEARBOX CONTROL SPECIFICATIONS AND PRECAUTIONS: «SHIFT LOCK»
Engines: XFX-4HX
SHIFT LOCK

The shift lock is a system which locks the gear selection lever in the park position «P».

Unlocking the «shift lock» (normal operation).

Switch on the ignition.
Apply the brake pedal and keep it pressed.
Using the selection lever, disengage from position «P».

Unlocking the «shift lock» (with a fault).

C5FP0CUD
If it should be impossible to unlock the «shift lock» with the «normal operation» method, the causes
of the fault may arise from the following components:
- «Shift lock».
- Gear lever position switch.
- Automatic gearbox ECU.
- Electrical harnesses.
- Battery voltage.
Remove:
TRANSMISSION

- The gear lever knob (1) by pulling upwards.

- The cover (2) (unclip).
GEARBOX
CLUTCH

- The shutter.
Unlock the «shift lock» (4) using a screwdriver.
C5FP0CTC Move the selection lever to disengage from position «P».
310
4 HP 20 GEARBOX CONTROL SPECIFICATIONS AND PRECAUTIONS: «SHIFT LOCK» C8
Engine: XFW

SHIFT LOCK

The shift lock is a system which locks the gear selection lever in the park position «P».

Unlocking the «shift lock» (normal operation).

Switch on the ignition.
Apply the brake pedal and keep it pressed.
Using the selection lever, disengage from position «P».

Unlocking the «shift lock» (with a fault).

If it should be impossible to unlock the «shift lock» with the «normal operation» method, the causes of
the fault may arise from the following components:
- «Shift lock».
- Gear lever position switch.
- Automatic gearbox ECU.
- Electrical harnesses.
- Battery voltage.
Remove:

TRANSMISSION
Unlock the «shift lock» by pressing at «a» with a screwdriver placed in the aperture of the gear selection

GEARBOX
CLUTCH
control grid.

Move the selection lever to disengage from position «P».

B2CPN8C

311
 C5 4 HP 20 GEARBOX CONTROLS: CHECKS AND ADJUSTMENTS
Engines: XFX-4HX

On refitting.
New gear selection control

- Couple the ball-joint (3).

- Push in the component (16) without bending the cable.
- Release the component (16).
- Lock the adjustment by means of component (17).
- Check all the gear selection control positions.

Re-used gear selection control.

- Unlock component (17).

- Release the component 16).
- Couple the ball-joint (3).
- Push in the component (16) without bending the cable
- Release the component (16).
- Lock the adjustment by means of component (17).
- Check all the gear selection control positions.
TRANSMISSION
GEARBOX
CLUTCH

Complete the fitting in the opposite order to removal (see corresponding procedure).

B2CP3DWD

312
4 HP 20 GEARBOX CONTROLS: CHECKS AND ADJUSTMENTS C8
Engine: XFW

On refitting.

IMPERATIVE: Fit new clips and collars.

WARNING: Check that the gear control cables are correctly routed.

Proceed in opposite order to removal.

IMPERATIVE: To clip the ball-joint (8) position tool [1]

B2CKUBXD
(Ball-joint extractor (-).0338.E) under the selection lever (9).

If necessary, adjust the selection control (if new or maladjusted).

Adjusting the selection control.

Selection lever in position «P».

Engagement lever (10) as far as possible towards the rear of the vehicle (B).
Lock the adjustments of the gears by pressing on the plastic component (11).

TRANSMISSION
The adjustment is complete.

GEARBOX
CLUTCH
Check all the gear selection control positions.

B2CKUBYD NOTE: to unlock the gear control adjustment system, press on the plastic component (12).

313
 C5 C8 DRAIN/REFILL/TOP-UP: 4 HP 20 GEARBOX
Engines: XFX 4HX XFW

IMPERATIVE: Respect the precautions to be taken before any repair ( refer to the
procedure «RECOMMENDATIONS – PRECAUTIONS»).
Tools.
[1] Circlip pliers : 4517-T Toolkit 4507-T
[2] Filling cylinder : (-).0341.
[3] Specific adaptor : (-).0341.B.

NOTE:
- The 4 HP 20 automatic gearbox is lubricated for life.
- Top up the oil every 37,000/40,000 miles.

Filling.
Oil capacities.
Oil capacity, gearbox dry : 7,7 Litres (minimum).
: 8,3 Litres (maximum).
Oil remaining after draining : 4,7 Litres (minimum).
: 5,3 Litres (maximum).
Quantity of oil to be added : 3 Litres (approx.).
TRANSMISSION
GEARBOX
CLUTCH

Remove:
- The air filter housing.
B2CP3DXD - The air vent assembly (1) and (2) of the gearbox, using tool [1].

314
 DRAIN/REFILL/TOP-UP: 4 HP 20 GEARBOX C5 C8
Engines: XFX 4HX XFW

Fill with oil, using tools [2] and [3].

Refit the metallic component (1) of the air vent, using a punch of Ø 18 mm and a mallet.

Clip on the plastic component (2) of the air vent.

NOTE: The air vent for the gearbox is available from Replacement Parts.
B1BP2AGC
Oil top-up.

Prior conditions.

Vehicle on level ground, handbrake off.

Engine running at idle, without any power consumers operating (aircon, heating, etc.)
Check the absence of gearbox back-up mode, using a diagnostic tool.
Pressing on the brake, change through all the gears.
Gear selection lever in position «P».

TRANSMISSION
The check should be done when the oil has reached a temperature of 55°C ± 1°C, using a diagnostic

GEARBOX
CLUTCH
tool.
Remove the top-up plug (3).
B2CP3DYC

315
 C5 C8 DRAIN/REFILL/TOP-UP: 4 HP 20 GEARBOX
Engines: XFX 4HX XFW

Oil should flow out through the oil top-up orifice.

As soon as the oil temperature reaches 60°C ± 1°C, refit the top-up plug (3).

NOTE:The oil level is correct.

Tighten the plug (3) to 2,5 ± 0,2 m.daN.

B1BP2AGC
If oil does not flow out through the oil top-up orifice.

Refit the top-up plug (3).

Stop the engine.
Remove the gearbox air vent assembly, using tool [1].
Add 0,5 litre extra oil into the gearbox, using tools [2] and [3].
Repeat the top-up procedure.
Remove tools [2] and [3].
Refit the metallic component (1) of the air vent, using a punch of Ø 18 mm and a mallet.
TRANSMISSION

Clip on the metallic component (2) of the air vent.

GEARBOX
CLUTCH

Refit the air filter housing.

B2CP3DYC

316
 DRIVESHAFTS - GEARBOX C5 - C8
Tightening torques
Gearbox oil seal mandrels
(m.daN)
Driveshaft Driveshaft
Vehicles Gearbox Engines Right Left Tool kit
bearing nut
6FZ-RFN-RLZ
BE4/5 C5 7114-T.W 7114-T.X 7116-T
RHY
XFX-RHS-RHZ
ML/5
3FZ-RHT-RHW 2 ± 0,2 32,5 ± 1,5
9017-T.C 5701-T.A 9017-T
C5
ML/6 4HX-4HW
C8
6FZ-RFN-RHS C8 0338 J1 0338 H1
AL4 0338
RHZ-RHM 0338 J3 0338 H2

4 HP20 XFX-XFW-4HX 8010-T.D 8010-T.J

1 ± 0,1 10 + 60° 8010-T
8010-T.K1 8010-T.K2

Tightening torques (m.daN) of the wheel bolts

TRANSMISSION
GEARBOX
CLUTCH
C5 Steel 9 ± 0,5
CITROËN
C8 Aluminium 10 ± 0,5

317
 C5 + CARLSON AXLE GEOMETRY
This method eliminates all the variations in measurements due to the following parameters:
Type of wheels fitted. Vehicle load. Wear or incorrect inflation of tyres
Measuring front height Measuring rear height

B3BP166D B3BP168D
H1 = R1 – L1 H2 = R2 + L2
H1 = Front height (± 6mm). H2 = Rear height (± 6mm).
R1 = Wheel radius (mm). R2 = Wheel radius (mm).
L1 = Theoretical dimension between the level of the front subframe and L2 = Theoretical dimension between the measuring zone on the
the wheel axis. crossmember support and the wheel axis.
The measurement of the front dimension «H1» is between ground level The measurement of the rear dimension «H2» is between ground level
and the measuring zone on the front subframe and the measuring zone on the rear axle crossmember (forward of the
(to the rear of the front yokes fixing the suspension arm).
SUSPENSION

rear fixing of the rear axle crossmember on the body).

STEERING

L1 = 140 mm L2 = 73 mm
AXLES

The dimension L1 for checking front height is between the level “b” of the The dimension L2 for checking rear height is between the measuring
front subframe and the wheel axis “a”. zone “b” and the wheel axis “a”.

318
 SUSPENSION
STEERING
AXLE GEOMETRY C5

AXLES
Front axle 9 RPO 9435
All types (except CARLSSON) Rear axle
King pin
Vehicle Tracking Castor Camber Tracking Camber
inclination
Adjustable Non adjustable Non adjustable
0 à - 3 mm 5,4 ± 1,3 mm
All types 3° 03’ ± 30’ 0° ± 30’ 12° 56’ ± 30’ - 1° ± 20’
0° à - 0° 27’ 0° 49’ ± 0° 12’
RPO 9436 9
Rear axle
Tracking Camber
Non adjustable
4,5 ± 1,3 mm
- 1° ± 20’
0° 41’ ± 0° 12’

NOTE
A < B = Positive figure: += TOE-IN
NOTE: Front of the vehicle indicated by the arrow A > B = Negative figure: –= TOE-OUT
B3CP02UC

319
SUSPENSION
STEERING

AXLES C5 CARLSON AXLE GEOMETRY

Front axle Rear axle
CARLSSON
King pin
Vehicle Tracking Castor Camber Tracking Camber
inclination
Adjustable Non adjustable Non adjustable
0 à - 2 mm 5,1 ± 1,3 mm
All types 3° 03’ ± 30’ -0° 04’ ± 30’ 12° 56’ ± 30’ - 1° 03’ ± 20’
0° à - 0° 15’ 0° 41’ ± 0° 12’

NOTE
A < B = Positive figure: += TOE-IN
NOTE: Front of the vehicle indicated by the arrow A > B = Negative figure: –= TOE-OUT
B3CP02UC

320
 SUSPENSION
STEERING
C5 + CARLSON

AXLES
AXLE GEOMETRY: CHECKING AND ADJUSTING VEHICLE HEIGHT
Tools.
[1] Gauge for measuring radius of wheels (4 bolts) : 8006-T
[2] Gauge for height under bodyshell : 2305-T
[3] LEXIA station : 4171-T
[4] PROXIA station : 4165-T

Checks by axle.

Preliminary operations. Lift the vehicle by hand.

Release when the weight becomes too great

Check the level of LDS fluid (see corresponding operation).
The vehicle descends, then re-ascends and stabilises
Check the tyre pressures.
Measure the height.
Place the vehicle on a 4 column lift.
Push down the vehicle by hand.
Put the vehicle in the normal position.
Hold the vehicle in this position, release when it rises
Release the handbrake. The vehicle ascends, then descends and stabilises.
Start the engine. Measure the height.

Take the average of the 2 measures.

321
SUSPENSION
STEERING

AXLES C5 + CARLSON AXLE GEOMETRY: CHECKING AND ADJUSTING VEHICLE HEIGHT

Measuring of heights.

Measuring the wheel radius

To determine the centre of the wheel, place tool [1] on the heads of the wheel bolts.
Meaure the radius R1 using tool [2] (distance from ground to centre of wheel).

Measuring the front height H1M.

The front height H1M is measured between the ground and the subframe, to the rear of the front
B3CP06AC fixing yokes of the suspension tripod.

Calculating the front height H1C

H1C = R1 – 140 mm
R1 = Radius of front wheel (mm).

Compare:
The value measured H1M.
The value calculated H1C
Adjust the front height if necessary.

B3CP06BC

322
 SUSPENSION
STEERING
AXLE GEOMETRY: CHECKING AND ADJUSTING VEHICLE HEIGHT C5 + CARLSON

AXLES
Measuring the rear height H2M

The rear height H2M is measured between the ground and zone «a» on the crossmember.

Calculating the rear height H2C.

H2C = R2 + 73 mm.
R2 = Radius of rear wheel (mm).

Compare:
B3DP08HC The value measured H2M.
The value calculated H2C
Adjust the front height if necessary.

Adjustment of heights.

Adjustment using a diagnostic tool.

This adjustment is done when the heights measured are within the tolerance of the heights calculated.

Mechanical pre-adjustment.
This adjustment is done when the heights measured are not within the tolerance of the heights calculated.
(± 10 mm).
B3CP06CC

323
SUSPENSION
STEERING

AXLES C5 + CARLSON AXLE GEOMETRY: CHECKING AND ADJUSTING VEHICLE HEIGHT

Front height.

Slacken by one turn the screw (1) on the collar (2).

Retighten the screw by hand.
To decrease the height, turn the collar (2) towards the front of the vehicle.
To increase the height, turn the collar (2) towards the rear of the vehicle.
Repeat the operation to obtain the dimension calculated H1C (± 10 mm).
Tighten the screw (1) to: 0,6 m.daN.
Adjust using tool [3] or tool [4].

B3CP06CC Rear height

Slacken by one turn the screw (3) on the collar (4).

Retighten the screw by hand.
To decrease the height, turn the collar (4) towards the front of the vehicle.
To increase the height, turn the collar (4) towards the rear of the vehicle.
Repeat the operation to obtain the dimension calculated H2C (± 10 mm).
Tighten the screw (3) to: 0,6 m.daN.
Adjust using tool [3] or tool [4].

B3DP08JC

324
 SUSPENSION
STEERING
AXLE GEOMETRY: CHECKING AND ADJUSTING VEHICLE HEIGHT C5 + CARLSON

AXLES
Adjustment of heights using tool [3] or tool [4].
Connect either tool [3] or [4] to the vehicle’s diagnostic socket.
Go into the menu:
Adjustment of reference heights.
Configuration

NOTE: H1M = Front measured height, in mm.

Calculate 280 - (R1 - H1M)
Enter this value in the diagnostic tool.

B3BP164C NOTE: H2M = Rear measured height, in mm.

Calculate (R2 – H2M)
Enter this value in the diagnostic tool.

Wait for the vehicle height to correct itself.

Measure the front height (H1M).

Check that: H1M = H1C ± 2 mm.

Measure the rear height (H2M).

Check that: H2M = H2C ± 2 mm

B3BP165C

325
SUSPENSION
STEERING

AXLES C5 + CARLSON FRONT AXLE

Tightening torques m.daN.
(1) Suspension leg upper fixing : 7 ± 0,7
(2) Suspension leg fixing on bodyshell : 4,3 ± 0,6
(3) Anti-roll bar link rod upper fixing : 6,4 ± 0,6
(4) Suspension leg fixing on pivot : 5,4 ± 0,5
(5) Anti-roll bar link rod lower fixing : 6,4 ± 0,6
(6) Ball-joint fixing : 4,5± 0,4
(7) Ball-joint fixing on pivot : 25 ± 2,5
(8) Hub nut : 32,5± 2,6
(9) Wheel bolt :9±1
(10) Arm front fixing : 13 ± 1,3
(11) Arm rear fixing : 8 ± 0,8
(12) Anti-roll bar bearing fixing on subframe : 4,2 ± 0

WARNING: From RPO 9429, evolution of head of fixing screw for steel
and aluminium wheels.
Dimension on flat 17mm (instead of 19mm).

B3CP05VP B3CP05WD

326
 SUSPENSION
STEERING
FRONT AXLE C5 + CARLSON

AXLES
The front subframe is equipped with a stabiliser bar linking between
the two front extensions.

Tightening torque for screws (13) : 6,6 ± 0,6 m.daN.

Saloons and estates and CARLSSON

Anti-roll bar
Engines Diameter (mm) Colour ref.
All types and CARLSSON
23,5 Yellow
(except ES9J4)
ES9J4 24,5 White
NOTE: The geometry specifications are given with the suspension
specifications.
B3CP071D

327
SUSPENSION
STEERING

AXLES C5 FRONT / REAR AXLE

Evolution: Wheels – Wheel bolts
Old fitting

Alu-steel wheels (with flat seat fixing)

(1) Wheel bolt with flat seat fixing.

B2GP018C

New fitting : RPO 9682 9

Alu-steel wheels (with conical seat fixing)

(1) Wheel bolt with conical seat fixing.

WARNING: New tightening torque : 10 ± 0,1 m.daN.

IMPERATIVE: Swapping of old and new parts is prohibited. Mixing of parts of both designs
(new and old) is prohibited on the same vehicle.

B2GP019C

328
 SUSPENSION
STEERING
REAR AXLE C5 + CARLSON

AXLES
Tightening torques m.daN

(1) Anti-roll bar fixing 13,1± 1,4

(2) Rear rubber mounting fixing on bodyshell 8 ± 1,2
(3) Rear subframe fixing 11,5 ± 1,1
(4) Front subframe fixing on bodyshell 11,5 ± 1,1
(5) Suspension shaft fixing 14,9 ± 1,3
(6) Hub nut 25 ± 2,5
(7) Wheel bolt

NOTE : (3) and (4) Face and threads not greased.

Anti-roll bar
Engines Diameter (mm) Colour ref.
All types (except ES9J4) 21,5 Blue
ES9J4
Estates all types 22,5 Yellow
CARLSSON
NOTE: The geometry specifications are given with the suspension speci-
fications.
B3DP08BD B3DP08CD

329
SUSPENSION
STEERING

AXLES C5 REAR AXLE

Evolution: Fixing of rear axle rear rubber bushes
RPO 9606 9

Evolutions:
New bolts.
New tightening torque.

IMPERATIVE: The types of fixing bolts should be identical, on

RH and LH sides.

IMPERATIVE: Respect the tightening torques.

Replacement Parts.

The new bolts replace the old bolts.

B3DP0B2D

RPO N° Description (mm) Tighten (mdaN)

(1) Fixing bolt M12 x175 L 55 9 9605 Fixing bolts x175 L 35 8,5 ± 1,2
9606 9 Fixing bolts M12 x175 L 55 9 ± 1,3

330
 SUSPENSION
STEERING
REAR AXLE C5

AXLES
Evolution: Rear axle crossmember – Rear wheel sensors (Application RPO 9528 9)
Old fitting (9 RPO 9527)

(1) Rear wheel sensors.

(2) Support
(3) Support.
(4) Clips.
(5) Support
(6) Clips

B3DP0APD

New fitting (RPO 9528 9)

Evolutions.

New installation of electrical harnesses for rear wheel sensors.

Suppression of fixing holes for supports (2) and (5), on the rear axle crossmember.
Suppression of supports (2) and (5).
New rear wheel sensors (length 1670 mm instead of 1767 mm).

B3DP0AQD

331
SUSPENSION
STEERING

AXLES C5 REAR AXLE

Evolution: Rear axle crossmember – Rear wheel sensors (Application RPO 9528 9)
New fitting (RPO 9528 9)
(7) Rear wheel sensors.
(8) Support.
(9) Support.
(10) Clips.
(11) Clips.

Replacement Parts.
The Replacement Parts service currently markets:
The new rear axle crossmembers.
The components for the new fitting.
The components for the old fitting.

Fitting of a new rear axle crossmember (Vehicle 9 RPO 9527).

WARNING: Identify the type of fitting, before any repair.

It is necessary to carry out the following operations:

Use a template to drill the rear axle crossmember.
Prepare the rear axle crossmember.

NOTE: See procedure: Preparation of rear axle.

B3DP0AQD

332
 SUSPENSION
STEERING
REAR AXLE C5

AXLES
Evolution: Rear suspension cylinder fixing flange
Old fitting

(1) Rear suspension cylinder.

(2) Rear suspension cylinder fixing flange.

(3) ABS sensor fixing bracket.

(4) Screw

B3BP173C

New fitting

Evolutions.

(1) Rear suspension cylinder

(5) Rear suspension cylinder fixing flange.
(6) ABS sensor fixing bracket.
(7) Screw : Tighten to 2 ± 0,2 m.daN.

B3BP174C

333
SUSPENSION
STEERING

AXLES C5 REAR AXLE

Evolution: Rear suspension cylinder fixing flange (continued)

Repair
WARNING: Identify the type of fitting, before attempting any operation.
IMPERATIVE: Swapping of old and new components is prohibited.
Tools.
[1] Positioning tool for drilling of the rear suspension arm.
[2] Drill Ø 6,75 mm.

Removing

E5AP1YWC IMPERATIVE: Respect the precautions to be taken before a repair (see brochure
BRE 0747)

IMPERATIVE: Refer to the instructions for the operation «depressurising of

suspension circuits» (see brochure BRE 0755)

Raise and support the vehicle, rear wheels hanging.

Remove the rear suspension cylinder (see brochure BRE 0755).
Remove the ABS sensor fixing bracket (3).
A = Drilling at top RH for the LH suspension cylinder fixing.
B = Drilling at top LH for the RH suspension cylinder fixing.
Position the tool [1].
B3BP175D

334
 SUSPENSION
STEERING
REAR AXLE C5

AXLES
Evolution: Rear suspension cylinder fixing flange (continued))
Drill the suspension crossmember, using tool [2].
NOTE: Use a small air drill (maximum length excluding bit: 145 mm)
Tap the hole, using a tap M 8x125 (at «a»).
Clean the threads.

Refitting
Refit the rear suspension cylinder (new fitting) (see brochure BRE 0755)

C = LH side, LH rear suspension cylinder

D = RH side, RH rear suspension cylinder
B3BP176C B3BP178C
«a» notch for direction of fitting of the rear suspension cylinder fixing flange.
Refit the ABS sensor fixing bracket (6).
Tighten the screws (7) to : 2 ± 0,2 m.daN.

Replacement Parts.
The Replacement Parts service now only markets the new components.

B3BP177C

335
SUSPENSION
STEERING

AXLES C5 + CARLSSON SUSPENSION

Front suspension

Tightening torques m.daN.

(10) Arm front fixing : 13 ± 1,3

(11) Arm rear fixing : 8 ± 0,8
(12) Anti-roll bar bearing fixing on subframe : 4,2 ± 0,6

Hydractive 3 hydraulic suspension.

Steering: : Power-assisted
Engine versions : EW7J4 DW10TD DW10TED DW10ATED
Suspension piston diameter
Saloon : 37 mm.
Estate : 40 mm.

Hydractive 3+ hydraulic suspension

Steering: : Power-assisted
Engine versions : EW10D EW10J4 ES9J4S DW12TED4
Suspension piston diameter
Saloon : 37 mm.
Estat : 40 mm.
CARLSSON : 40 mm.
Suspension leg.
B3CP05WD B3BP167D Bump stop, height «A» = 97 mm.

336
 SUSPENSION
STEERING
SUSPENSION C5 + CARLSSON

AXLES
Rear suspension

Tightening torques m.daN.

(13) Subframe rear fixing 11,5 ± 1,1

(14) Rear rubber mounting fixing on bodyshell 8 ± 1,2
(15) Anti-roll bar fixing 13,1 ± 1,4
(16) Front fixing of subframe on bodyshell 11,5 ± 1,1
NOTE: (13) and (16) Face and threads greased.
(17) Arm shaft fixing 14,9 ± 1,3
(18) Hub nut 25 ± 2,5
(19) Wheel fixing 9±1
Stabiliser bar fixing on subframe 6,6 ± 0,6

Hydractive 3+ hydraulic suspension (power-assisted steering)

Suspension piston diameter = 37 mm.
Anti-roll bar diameter
- Saloon = 21,5 mm
- Estate and CARLSSON = 22,5 mm.
Anti-roll bar colour reference
- Saloon = Blue
- Estate = Yellow

B3DP08ND B3DP08PD

337
SUSPENSION
STEERING

AXLES C5 SUSPENSION

Front axle
Rear axle
King pin
Vehicle Tracking Castor Camber Tracking Camber
inclination
Adjustable Non adjustable Non adjustable
0 to – 3 mm 5,4 ± 1,3 mm
All types 3° 03’ ± 30’ 0° ± 30’ 12° 56’ ± 30’ - 1° ± 20’
0° to – 0° 27’ 0° 49’ ± 0° 12’
RPO 9436 9
Rear axle
Tracking Camber
Non adjustable
4,5 ± 1,3 mm
- 1° ± 20’
0° 41’ ± 0° 12’

WARNING
A < B = Positive figure: += TOE-IN
NOTE: Front of the vehicle (following arroow) A > B = Negative figure: –= TOE-OUT
B3CP02UC

338
 SUSPENSION
STEERING
POWER-STEERING SPECIFICATIONS C5

AXLES
Engines: 6FZ-RFN-RLZ-XFX-RHY-RHS-RHZ-4HX

Tightening torques m.daN.

(1) Steering wheel fixing 2 ± 0,3

(2) Column fixing on mounting 2,3 ± 0,4
(3) Column fixing on mounting 2,3 ± 0,2
(4) Cardan fixing 2,3 ± 0,3
(5) Ball-joint fixing on pivot 3,5 ± 0,6
(6) Link rod locking nut 6 ± 0,4
(7) Valve fixing on cover 2,3 ± 0,1
(8) Piping fixing on ram 0,8 ± 0,8
(9) Mechanism fixing on subframe 8 ± 0,9
(10) Steering rack ball-joint 9 ± 0,9

(7) Adjustment shim:

Saloon : thickness 3 mm.
Estate : thickness 2 mm.

Quantity of oil = 4,3 litres

Quality of oil = TOTAL FLUIDE LDS
B3EP124D B3EP12YD

339
SUSPENSION
STEERING

AXLES C5 POWER-STEERING SPECIFICATIONS

Tightening torque m.daN.

(12) Heat shield fixing on casing: 1,2 ± 0,2

B3EP12ZD

340
 SUSPENSION
STEERING
POWER-STEERING SPECIFICATIONS C5

AXLES
Engines: 6FZ-RFN-RLZ-XFX-RHY-RHS-RHZ-4HX

Saloons Estates
6FZ RFN RLZ
Vehicles XFX 4HX All Types
RHY RHS RHZ
Steering rack
Number of teeth 33
Steering rack travel 2x83 2x74
Steering rack pinion
Number of teeth 9
Left hand drive LH helix
Left hand drive RH helix
No. of steering wheel rotations (lock to lock) 3,3 3
Steering reduction ratio 50,4/1
Angle of lock for inside wheel 39,74° 34,29°
Angle of lock for ouside wheel 35,65° 31,58°
Diameter at full lock between walls 11,39 m 12,46m

NOTE: On XFX engine, a proportional electrovalve, integral to the steering valve, modulates power-assistance as a function of vehicle speed.

341
SUSPENSION
STEERING

AXLES C5 POWER-STEERING SPECIFICATIONS

Engines: 6FZ-RFN-RLZ-XFX-RHY-RHS-RHZ-4HX
Power steering pump – Saloons and Estates
Vehicles 6FZ RFN RLZ RHY-RHS RHZ 4HX XFX
Supplier ZF SAGINAW
Type of flow Falling Constant
Regulation pressure 100 Bars
Diameter of pulley 129 mm
Tightening torque: m.daN
6FZ RFN RLZ RHY-RHS RHZ 4HX XFX
(13)
(14) 2,2 ± 0,3 2,5 ± 0,6
(15)
Power steering pump (XFX engine).
Hand-tighten the screws (13), (14), (15)
Tighten to the torque : screws (14) and (15)
Tighten to the torque : screw (13).
Power-assisted steering pressure switch (petrol engine)
A power-assisted steering pressure switch is installed on the hydraulic piping, between the high pressure
pump and the steering valve:
Opening pressure : 35 (+ 0-5) Bars
Closing pressure : Higher than or equal to 25 Bars
B3EP130D
Pressure switch - tighten to : 2 ± 0,2
342
 SUSPENSION
STEERING
STEERING ADJUSTMENT BUTTON C5

AXLES
Tools.

[1] Adaptor : ALLEN FACOM ST.17

[2] Tap for steering mechanism : 8612-T

Removing.

Remove the steering (see corresponding operation).

B3EP12KD Immobilise the steering mechanism in a vice.
Remove the assembly composing the following components, using tool [1]:
Plug (1).
Washer (2).
Rubber spacer (3)
Push-button (4).
Tap the threads of the steering casing, using tool [2], until the tight spots disappear.

WARNING: Operate with care to prevent entry of polluting particles.

Clean the components as well as the seating of the push-button in the steering.

B3EP12LC

343
SUSPENSION
STEERING

AXLES C5 STEERING ADJUSTMENT BUTTON

Refitting.

Position the steering rack at the mid point.

Remove the assembly composing the following components:
Plug (1).
Washer (2).
Rubber spacer (3).
Push-button (4).

Grease the push-button (TOTAL N 3924 grease).

Tighten to 1 ± 0,1 m.daN, using tool [1].

Make marks «a» and «b» on the steering casing.

Make a mark «c» on the plug (1) opposite the mark «a».
Slacken the plug (1), until the mark «c» lines up with the mark «b» (position 60°).
Peen the plug (1) in relation to the steering casing, by striking it with a punch.
Check the absence of tight spots throughout the travel of the steering rack.
Refit the steering (see corresponding operation).

B3EP12MC

344
 SUSPENSION
STEERING
C8

AXLES
AXLE GEOMETRY
Setting at reference height
Requirements prior to setting at reference height
WARNING: The checks of the front and rear axle geometry values, as well as the adjusting of the front suspension should be carried out at precise
positions of suspension compression (reference height) on a suspension test bed

Check the pressures in the tyres.

Check the conformity of the tyres.
Remove the wheel trims.
Lock the steering rack at point zero: straight ahead (See corresponding operation).

Tooling required

[1] Set of two compressors : 9511-T.A

[2] Set of two shackles : 9511-T.C
[3] Set of four straps : 9511-T.B
[4] Set of two slings : 9511-T.D
[5] Under body height gauge : 2305-T

345
SUSPENSION
STEERING

AXLES C8 AXLE GEOMETRY

Setting at reference height (continued)
Measuring front height (H1) Measuring rear height (H2)

C4AP1AUC E1AP0AYD B3BP18GC

Front height Rear height

H1 = R1 - L1 H2 = R2 + L2
H1 = Measurement between the bottom of the subframe (b) at the front H2 = Measurement between bottom of longeron (c) and the ground.
fixing of the suspension wishbone, and the ground.
R2 = Radius of rear wheel under load.
R1 = Radius of front wheel under load.
L1 = Distance between the centre of the wheel and the bottom of the L2 = Distance between the centre of the wheel and the bottom of the
subframe at the front fixing of the suspension wishbone. longeron.

346
 SUSPENSION
STEERING
FRONT AXLE GEOMETRY C8

AXLES
Setting at reference height (continued)
Height of the vehicle at the front at reference height (H1 = R1 - L1)

Engage the straps [3] with their shackles [2] on the subframe.
Position the suspension compressor [1], selecting the separation (a) most suited to pull
the straps as far upwards as possible.

Compress the suspension so as to obtain, on the RH and LH sides, the bodyshell height
H1 (reference height), to be measured between the bottom of the subframe (b) at the
C4AP1ATD
front fixing of the wishbone, and the ground.

WARNING: take account of pivoting surfaces when measuring the reference height H1.

NOTE: Only the tracking is adjustable.

WARNING: The tracking value varies as a function of the vehicle height.

C4AP1AUC

347
SUSPENSION
STEERING

AXLES C8 REAR AXLE GEOMETRY

Setting at reference height (suite)
Height of the vehicle at the rear at reference height (H2 = R2 + L2)

Engage the slings [4] on the rear longerons.

Position the suspension compressor [1] selecting the separation (a) most suited to pull
the straps as far upwards as possible.

Compress the suspension so as to obtain, on the RH and LH sides, the bodyshell height
C4BP1CND H2 (reference height), to be measured between the bottom of the longeron «c» and the
ground.

WARNING: take account of pivoting surfaces when measuring the reference height H2.

Check that the height H1, measured already at the front, has not changed.

WARNING: The rear axle angles are not adjustable.

B3BP18GC

348
 SUSPENSION
STEERING
AXLE GEOMETRY C8

AXLES
Values for front suspension angles Values for rear suspension angles
3FZ-RHT-RHW 3FZ-RHT-RHW
Engines RFN XFW Engines RFN XFW
RHM-4HW RHM-4HW
Tyres 205x65 R15 215x65 R15 215x60 R16 Tyres 205x65 R15 215x65 R15 215x60 R16
L1 (mm) 126 L1 (mm) 126
L2 (mm) 94 L2 (mm) 94
Adjustable Non adjustable
Tracking (mm) 2±1 Tracking (mm) 5±1

Tracking (degrees) 0° 17’ ± 0° 08’ Tracking (degrees) 0° 45’ ± 0° 08’ 0° 42 ± 0° 08’

Non adjustable Non adjustable

Camber 0° 0’ ± 30’ Camber 1° ± 30’
Castor 3° 30’ ± 30’
Angle of pivot 12° 24’ ± 30’

WARNING
A < B = Positive figure: += TOE-IN
A > B = Negative figure: –= TOE-OUT
B3CP02UC

349
SUSPENSION
STEERING

AXLES C8 AXLE GEOMETRY

Adjusting the rolling axles

NOTE: Only the tracking is adjustable (at the front).

If the value is incorrect, adjust the track rods (1)

One turn of the rod = 2 mm approx.

Tighten the nuts (2), tighten to 4 ± 0,4 m.daN.

B3BKAELD

350
 SUSPENSION
STEERING
FRONT AXLE C8

AXLES
Identification

(1) Crossmember
(2) Tie-rods
(3) Springs
(4) Front suspension leg
(5) Anti-roll bar
(6) Subframe

Anti-roll bar
Engines Diameter (mm)

RFN-3FZ-RHT-
21,5
RHW-RHM-4HW
XFW 22

B3CK09JD

351
SUSPENSION
STEERING

AXLES C8 FRONT AXLE

Tightening torques (m.daN)

Fixing of subframe on body : 10,7 ± 1

Fixing on tie-rod on body : 6,3 ± 0,6
Fixing of crossmember on body : 8 ± 0,8
Fixing of tie-rod on front subframe : 6,3 ± 0,6
Fixing of damper on pivot : 9 ± 0,9
(12) Fixing of damper on pivot : 9,2 ± 0,9
(8) Fixing of damper rod on upper cup : 9 ± 0,9
(7) Fixing of upper cup on body : 4,5 ± 0,4
Fixing of anti-roll bar on subframe : 10,5 ± 1
Driveshaft nut : 10 ± 1
(9) Front fixing of wishbone on subframe (screw length 30 mm) : 10,5 ± 1
(10) Front fixing of wishbone on subframe (screw length 85 mm) : 12,5 ± 1
(11) Rear fixing of wishbone on subframe : 10,5 ± 1
Fixing of ball-joint on pivot : 7 ± 0,7
Fixing of steering track rod on pivot : 3,8 ± 0,3
Fixing of track rod on damper body : 5,5 ± 0,5
Fixing of track rod on anti-roll bar : 5,5 ± 0,5

B3BP18FD

352
 SUSPENSION
STEERING
C8

AXLES
REAR AXLE

Identification

(1) Damper.

(2) Spring.

(3) Stabiliser bar.

B3DK0AFD

353
SUSPENSION
STEERING

AXLES C8 REAR AXLE

Tightening torques (m.daN)

(4) Fixing of damper on body : 9 ± 0,9

(5) Fixing of stabiliser bar on rear axle : 8 ± 0,8

(6) Fixing of stabiliser bar on body : 6 ± 0,6

(7) Fixing of rear axle on body. : 8 ± 0,8

(8) Fixing of damper on rear axle : 9 ± 0,9

(9) Hub nut : 38 ± 3,8

B3DP0AGD

354
 SUSPENSION
STEERING
POWER-STEERING SPECIFICATIONS C8

AXLES
Engines: RFN 3FZ XFW RHT RHW RHM 4HW

Identification

(X) Pre-adjustment.

(1) Steering mechanism.

(2) Distributor valve.

(3) Power steering reservoir.

(4) Power steering pump.

(5) High pressure union.

(6) Low pressure union

(7) Steering oil radiator fitted on the front panel.

(according to equipment)

B3EK0J9D

355
SUSPENSION
STEERING

AXLES C8 POWER-STEERING SPECIFICATIONS

Engines: RFN 3FZ XFW RHT RHW RHM 4HW

Engine type RFN 3FZ XFW RHT - RHW - RHM 4HW

Features Power steering with integral ram
Travel (mm) 166 156 162
Angle of lock for
40°48’ 37°18’ 39°24’
inside wheel
Angle of lock for 34°36’ 32°24’ 33°42’
outside wheel
Type of pump Falling flow
Pump pressure (bars) 100 110
Circuit capacity (litres) 1,3
Number of steering wheel
3,25 3,05 3,17
rotations
Number of teeth on drive
pinion 9

356
 SUSPENSION
STEERING
C8

AXLES
POWER-STEERING SPECIFICATIONS
Engines: RFN 3FZ XFW RHT RHW RHM 4HW

Tightening torques (m.daN)

(8) Steering wheel fixing nut : 2 ± 0,2

(9) Fixing of steering column to support : 2 ± 0,2

(10) Fixing of upper and lower shafts to steering column : 2,5 ± 0,2

(11) Fixing of ram valve supply unions : 1 ± 0,1

(12) Fixing of steering mechanism : 14,5 ± 1,4

(13) Fixing of pump/valve supply unions

Pump : 2 ± 0,2
Valve : 2,5 ± 0,2

(14) Fixing of ball-joint housing on steering rack: : 9 ± 0,9

(15) Steering rod locking nut : 6 ± 0,6

(16) Steering ball-joint nut : 4 ± 0,4

B3EK0K0D

357
BRAKES
C5 BRAKE SPECIFICATIONS
1.8i 16V 2.0i 16V 2.0 HPi 3.0i V6
Saloon Estate
Engine type 6FZ RFN RLZ XFX
Master cylinder 22,2 (Valve type)
Master-vac 254
Ø
mm Caliper/piston makes BOSCH ZO 54/22 BOSCH ZO 54/26 BOSCH ZO 57/26 BOSCH ZO 57/28
BIR 54 BIR 57 BIR 57 BIR 57
FT
Disc Ventilated 266 283 283 288
Disc thickness/min. thickness 22/20 26/24 26/24 28/26
Brake pad thickness 17,3/2,5 17,8/2,5 17,8/2,5
Brake pad grade ABEX 949/1 TEXTAR T 4110
Ø Cylinder or caliper PSA - 32 (Double piston)
mm Disc Plain 276
Disc thickness/min. thickness 14/12
RR
Brake pad thickness 11,9/3
Supplier ABEX or TEXTAR
Grade 949/1 or T 4110

358
 BRAKE SPECIFICATIONS C5

2.0 HDi 2.2 HDi

Engine type RHY RHS RHZ 4HX

Master cylinder 22,2 (Valve type)

BRAKES
Master-vac 254
Ø Caliper/piston makes BOSCH ZO 57/26 BOSCH ZO 57/28
mm BIR 57
FT BIR 57
Disc Ventilated 283 288
Disc thickness/min. thickness 26/24 28/26
Brake pad grade TEXTAR T 4110
Ø Cylinder or caliper PSA - 32 (Double piston)
mm Disc Plain 276
RR Disc thickness/min. thickness 14/12
Supplier TEXTAR or ABEX
Grade T 4110 or 949/1

359
 C5 BRAKE SPECIFICATIONS
Braking circuit Braking system specifications

- Braking circuit at «X».

BRAKES

- Front brakes with ventilated discs.

- Rear brakes with non-ventilated discs.

- Handbrake lever controlling cables acting on the

front wheels.

- The compensator and main brake limiter functions

are assured by the ABS EBD system fitted as stan-
dard at the factory on all versions.

NOTE: EBD = Electronic Brakeforce Distribution

B3FP12WD

360
 BRAKE SPECIFICATIONS C5
Braking circuit diagram
(a) Hydraulic circuit.
(b) Electrical circuit.
(1) Master cylinder in tandem.
(2) Braking servo.

BRAKES
(3) Brake caliper.
(4) Hub equipped with a bearing with an integral magnetic wheel
(48 pairs of poles).
(5) Wheel sensor.
(6) Brake fluid level sensor.
(7) Hydraulic block plus ECU.
(8) Stoplamp switch.
(9) Instrument panel.
(10) Diagnostic socket.
(11) Built-in systems interface (BSI).
(12) Brake fluid pressure sensor
(13) Steering wheel angle sensor.
(14) Gyrometer/accelerometer sensor.
(15) Switch.

B3HP003P

361
 C5 BRAKE SPECIFICATIONS
Electrical circuit
Elements Ref. Supplier Part No. Observations
Hub equipped with a bearing with an integral
Hub bearing. 4 SNR
magnetic wheel (48 pairs of poles).
2 way black connector.
BRAKES

The sensors are inductive-type.

Front wheel
96 332 952 80 Mounted on the pivot.
sensor
Non-adjustable airgap: 0,2 to 1,5 mm.
Tightening torque: 0,8 ± 0,2 m.daN
5 ITT - A
2 way black connector.
The sensors are inductive-type.
Rear wheel
96 332 954 80 Mounted on the brake caliper support.
sensor.
Non-adjustable airgap: 0,15 to 1,6 mm.
Tightening torque: 0,8 ± 0,2 m.daN
94 045 426 88 47 way connector.
ECU
Integral to the hydraulic block.
94 045 427 68 Change of the ECU alone is authorised.

(7) Hydraulic block « ESP » 7 TEVES

Hydraulic 94 045 416 38
(Reference MK60 ESP) Installed on the brake tandem master cylinder:
block.
94 045 417 18 4 adjustment channels.
B3FP12XC

362
 BRAKE SPECIFICATIONS C5
Electrical circuit

Elements Ref. Supplier Part No. Observations

Integral to the master-cylinder.

Brake fluid pressure sensor 12 TEVES
3 way connector.

BRAKES
Integral to the control unit under the steering wheel.
Steering wheel angle sensor 13 BOSCH
6 way blue connector.
Installed under the central console.
Gyrometer/accelerometer sensor 14 TEVES
6 way connector.

363
 C5 BRAKE SPECIFICATIONS

Tightening torques: m.daN.

(16) Fixing of gyrometer/accelerometer sensor on support : 0,9 ± 0,1.

BRAKES

(17) Fixing of support on body : 0,9 ± 0,1.

(12) Brake fluid pressure sensor on master-cylinder : 2,5 ± 0,5

Piping on master-cylinder : 1,5 ± 0,3

B3FP79ZC B3FP7A0C

364
 BRAKE SPECIFICATIONS C5
Brake pedal carriage Front brakes Rear brakes

BRAKES
B3FP130C B3FP12YC B3FP12ZC

Tightening torques: m.daN.

(15) Fixing on bodyshell 1,8 ± 0,25. (12) Caliper fixing on pivot 12± 1,8 (14) Rear caliper fixing on suspension arm
(16) Servo fixing 2,1 ± 0,1. (13) Yoke fixing on caliper 3,1± 0,1 7 ± 0,7

365
 C5 SPECIAL FEATURES: FRONT AND REAR BRAKE CALIPERS

Front brakes

Brake caliper

Floating brake caliper with handbrake control equipped with an automatic wear compensation
BRAKES

mechanism (BOSCH SVZO).

Automatic handbrake adjustment mechanism: BIR (Ball In Ramp).

WARNING: To push back the front brake caliper pistons, the direction of rotation differs between
the RH side and the LH side.

Front RIGHT HAND caliper:

Turn the brake piston anti-clockwise using tool 8603-T.D.

Front LEFT HAND caliper:

Turn the brake piston clockwise using tool 8603-T.G.

Rear brakes

ESSENTIAL: When refitting the rear brake caliper, coat the face which will be in contact
with the suspension arm with sealing product of type FORMAJOINT 510.

B3FP12YC B3FP12ZC

366
 SPECIAL FEATURES: REAR BRAKE CALIPERS C5
Old fitting
Evolution.

New components:

Rear brake caliper (3).

BRAKES
Rear brake pads (4).

Old fitting.

(1) Rear brake caliper.

(2) Rear brake pads
New fitting
New fitting.

(3) Rear brake caliper; drilled with holes at «a» and at «b».
(4) Rear brake pads.

B3FP146D B3FP147D

367
 C5 SPECIAL FEATURES: FRONT AND REAR BRAKE CALIPERS

Repair.

WARNING: Identify the type of fitting, prior to any operation.

Two types of fixing may be found on the new, drilled brake calipers.
BRAKES

IMPERATIVE: The type of fixing screws should be identical, on RH and LH sides.

Fixing screws not bonded.

Do not bond during a repair (refer to the remove-refit method for the rear brake caliper).

Fixing screws bonded.

Bond during a repair (refer to the remove-refit method hereafter).

IMPERATIVE: The fitting of brake pads (2) is prohibited.

B3FP148C B3FP149C

368
SPECIAL FEATURES: FRONT AND REAR BRAKE CALIPERS C5

Removing.
Raise and support the vehicle, rear wheels hanging.
Remove:
The rear wheels.
The rear brake pads(see corresponding operation).

BRAKES
Fit the pin (7).
Tighten the nut (8) so as to keep the two half-calipers tight.
Uncouple the supply pipe (5).
Plug the union and the brake caliper.
Undo the screws (6).
Remove the brake caliper (3).
WARNING: The holes should be cleaned without damaging them.

On the bench:
Force out the screws (6), with a hammer, in order to remove the used bonding on the screw
threads.
Remove the screws (6), using a punch.
Immobilise a 10 mm drill bit in a vice.
Clean the brake caliper fixing screw holes, using the 10 mm drill bit.
Remove the bonding plugs, at «a» and at «b».

B3FP148C B3FP149C

369
 C5 SPECIAL FEATURES: FRONT AND REAR BRAKE CALIPERS
Cleaning.

IMPERATIVE: Do not use compressed air to clean the brakes.

1st possibility.
Clean the disc and the caliper using an approved cleaning product.
BRAKES

Leave to dry out.

Wipe with a cloth.
2nd possibility.
Use an approved de-dusting product (see Tools and Equipment catalogue).
Refitting.
WARNING: Systematically replace the brake caliper fixing screws.
On the screws (6) spray activation aerosol LOCTITE 7649.

IMPERATIVE: Coat the surface between the brake caliper and the rear arm with sealing
product of type FORMAJOINT 510.

Position the brake caliper.

Tighten the screws (6) to 7 ± 0,7 m.daN.
Couple the supply pipe (5).
Inject in the holes «a» product LOCTITE 121078, until product appears in holes «b».
WARNING: After injecting the product, clean the surfaces to avoid runs of product.

B3FP14AC

370
SPECIAL FEATURES: FRONT AND REAR BRAKE CALIPERS C5
On product LOCTITE 121078, spray the activation aerosol LOCTITE 7649, at «a» and at «b».
Remove the pin (7).
Refit the new brake pads (see corresponding operation).
Bleed the braking circuit (see corresponding operation).

IMPERATIVE: Respect the times for setting of the product LOCTITE 121078. Respect the

BRAKES
required distances, depending on the materials being used, in order to avoid any damage
to surrounding components through heating.

Setting times:
Ambient temperature 75°C, 2 hours (with application of heat).
Ambient temperature between 10°C and 25°C, 12 hours (without application of heat).
Types of material to help setting (with application of heat):
TRISK short wave, model ETS HH02-850W, distance 20 cm from the brake caliper.
TECALEMIT lamp with 8 bulbs of 2000W, distance 45 cm from the brake caliper.
This is not an exhaustive list (see Tools and Equipment catalogue).
Refit the rear wheels.
Lower the vehicle.
Tighten the wheel bolts to 9 ± 1 m.daN.

Replacement parts.
The Replacement Parts service only markets the components for the new fitting.

B3FP14BC

371
 C5 CHECKS: BRAKE PEDAL TRAVEL
Checking conditions.
Vehicle stationary.
Engine stopped.
Handbrake on.
For a better feel, all the operations should be done with the hand and not with the foot.
BRAKES

Draining the brake servo.

Press slowly by hand on the brake pedal (it should take 10 seconds to press the brake pedal to the
end of its travel).
Let the brake pedal return slowly, keeping your hand on it (let it move at the same speed as it
travelled when being pressed down).
Perform this operation 5 times (pressing the brake pedal down and allowing it to return
as described).

Checking the brake pedal travel.

Press the brake pedal down as rapidly as possible by hand, as far as the end of its travel.
Keep the brake pedal pressed at the end of its travel.
Place a ruler with its end on the floor carpet at «a» (mark the position «a»).
Measure the distance X1 between the floor carpet at «a» and the edge of the pedal at «b» using the
ruler.
NOTE: Note down the value «X1».

Let the brake pedal return slowly, keeping your hand on it.
B3FP14CC B3FP14DC

372
CHECKS: BRAKE PEDAL TRAVEL C5

Press extremely slowly by hand on the brake pedal (take 20 seconds to press
the brake pedal to the end of its travel).
Keep the brake pedal pressed at the end of its travel.

Measure the distance X2 between the floor carpet at «a» and the edge of the pedal

BRAKES
at «b» using the ruler.

NOTE: Note down the value «X2».

Let the brake pedal return slowly, keeping your hand on it.
Repeat this operation (slow pressing and measuring the brake pedal travel)
3 times, measuring for each of the operations the distance «X2».

Interpretation of results.

If, for each of the 3 measures of «X2» the difference between «X1» and «X2»
is less than 10mm, the brake master-cylinder is in conformity.

If, for at least one of the 3 measures of «X2» the difference between «X1» and
«X2» is greater than 10mm, the brake master-cylinder is not in conformity.

B3FP14CC B3FP14DC

373
 C5 HANDBRAKE (Adjustment)

Adjustment

- Remove the rear ashtray from the handbrake console.

- (1) Nut for adjusting the tension of the handbrake
BRAKES

cables.
- Raise and support the vehicle with the front wheels
hanging free.
- Check the correct routing of the brake cables under the
vehicle.
- Apply and release the handbrake 10 times.
- Set the handbrake to the 5th notch.
- Tighten the nut (1) until the front brakes are applied.
- Pull the handbrake lever vigorously 4 to 5 times.
- Set the handbrake to the 5th notch.
- Check that the front brakes are applied.
- With the handbrake released, check that the wheels
can be turned freely by hand.
- Lower the vehicle.
- Refit the rear ashtray to the handbrake console.
B3FP12JD

374
BLEEDING AND FILLING THE BRAKING SYSTEM C5

Tools.
[1] Generic bleeding apparatus : «LURO» or similar.
[2] PROXIA station : 4165-T.
[3] LEXIA station : 4171-T.

BRAKES
Bleeding, filling.
Draining the brake fluid reservoir.
- Drain the brake fluid reservoir (1) to the maximum (if necessary, use a clean syringe).
- Disconnect the connector (3).
- Uncouple the pipe (2).
- Remove the reservoir (1) by separating the lugs «a» from the shaft (4).
- Empty the brake fluid reservoir (1).
- Clean the brake fluid reservoir (1).
Remove:
- The brake fluid reservoir (1).
- The shaft (4).
- Couple the pipe (2).
- Reconnect the connector (3).

B3FP139C B3FP13AC

375
 C5 BLEEDING AND FILLING THE BRAKING SYSTEM

Bleeding, filling (continued).

Filling the braking system.

WARNING: Use only those hydraulic fluids that are approved and recommended.
BRAKES

- Fill the brake fluid reservoir (1).

Bleeding the braking system.

WARNING: During the bleeding operation, take care to maintain the level of brake fluid in the reser-
voir and to top it up, using only brake fluid that is clean and clear.

Bleeding the primary circuit.

WARNING: The ABS should not be active during the bleeding operation.
- Front brake caliper: Bleed screw (5).
- Rear brake caliper: Bleed screw (6).
- Bleed each wheel cylinder, proceeding in the following order:

Front LH wheel.
Front RH wheel.
Rear LH wheel.
Rear RH wheel.

B3FP13BC B3FP13CC

376
 BLEEDING AND FILLING THE BRAKING SYSTEM C5
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:

BRAKES
- 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.
- Close the bleed screw.
- Remove the bleeding apparatus [1].
- Check the brake fluid level (Should be between «DANGER» level and «MAXI» level).
- Fill if necessary with the approved and recommended synthetic brake fluid.
Without the bleeding apparatus.
NOTE: Two operators are necessary.
For each circuit:
- Apply the brake pedal to place the circuit under pressure.
- 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.
- Close the bleed screw.
- Remove the tool [1].
NOTE: Recommence the process a second time if that is necessary.
- Check the brake fluid level, (Should be between «DANGER» level and «MAXI» level).
B3FP13DC
- Fill if necessary with the approved and recommended synthetic brake fluid.

377
 C5 BLEEDING AND FILLING THE BRAKING SYSTEM

Bleeding, filling (continued).

Bleeding the secondary circuit.

BRAKES

NOTE: The bleeding apparatus is connected on the brake reservoir.

- Use LEXIA or PROXIA diagnostic tools.

Select the menu corresponding to the vehicle:

- ABS menu.
- ESP menu.

- Follow the instructions on the diagnostic tool.

- At the end of the bleeding process, check and top up, if necessary, the brake fluid level.
- Check that the brake pedal travel has not been lengthened, otherwise repeat the bleeding procedure.
- Remove the tools.

378
 BRAKE SPECIFICATIONS C8

2.0i 16V 2.2i 16V 3.0i 24V 2.0 HDi 2.2 HDi

Engine type RFN 3FZ XFW RHT - RHW - RHM 4HW

Master cylinder 22,2 (valve type) 23,8 (valve type) 22,2 (valve type)

BRAKES
Master-vac 254 203.2 + 228.6 254
Ø
Caliper/piston makes LUCAS BREMBO LUCAS
mm
FT 60 40 + 44 60
Disc Ventilate 285 310 285
Disc thickness/min. thickness 28/26 32/30 28/26
Brake pad grade GALFER 3366 (8) - FERODO 782 (2)
Caliper/piston makes LUCAS C38HR
Ø
mm 38
Disc Ventilate 272
RR
Disc thickness/min. thickness 12/10
Make TEXTAR
Brake pad grade T 4131

379
 C8 BRAKE TIGHTENING TORQUES (m.daN)
Engines: RFN 3FZ XFW RHT RHW RHM 4HW

Tightening torques (m.daN)

Fixing of disc on hub : 1,5 ± 0,1

BRAKES

Fixing of front brake caliper on support : 3,5 ± 0,3

Fixing of front brake caliper support on pivot : 16 ± 1,6

Fixing of brake pipe unions : 1,5 ± 0,1

Fixing of rear brake caliper on support : 3,5 ± 0,3

Fixing of rear brake caliper support on pivot : 9,5 ± 0,9

Fixing of brake servo on pedal gear : 2 ± 0,2

Fixing of master-cylinder on servo : 2 ± 0,2

Fixing of handbrake lever on body : 4 ± 0,4

380
ADJUSTING THE HANDBRAKE C8
Identification

BRAKES
(A) Zone for fixing on floor.

(B) Clips for retaining on bodyshell.

B3FK263D

381
 C8 ADJUSTING THE HANDBRAKE
Adjustment

Raise and support the vehicle, wheels hanging.

WARNING: Bleed the braking circuit.

FREINS

Detension the secondary brake cables by slackening the nut (1).

With the engine running and the handbrake released, press 40 times on the brake
pedal.
Carefully tighten the nut (1), until the brake cables begin to come under tension.
Pull the handbrake lever about ten times in a normal fashion.
Engage the handbrake lever at the 2nd notch of its travel relative to its
position of rest.
Turn the nut (1) until the brake pads start touching.
Check that:
- The normal travel of the handbrake lever does not exceed 6 notches.
- The two secondary brake cables on the slide are moving together.
With the handbrake slackened, make sure that the road wheels turn freely when
moved by hand.
Check that the handbrake warning lamp lights up from the 1st notch of the lever’s
total travel.

B3FK264D

382
 DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM C8

Tools.
[1] Filler plug : (-).0810
Generic bleeding apparatus : «LURO» or similar
PROXIA diagnostic tool : 4165-T

BRAKES
LEXIA diagnostic tool : 4171-T

Draining.
Remove the pollen filter.
Take out the filter from the brake fluid reservoir.
Drain the brake fluid reservoir with the aid of a syringe.
Refit the filter in the brake fluid reservoir.

Filling.

IMPERATIVE: Use only new, clear brake fluid, avoiding any ingress of impurities into the hydraulic circuit.

WARNING: Use only hydraulic fluid(s) that are approved and recommended: DOT 4.
Renew the brake fluid in the calipers, bleeding the circuit until clean fluid flows out.
WARNING: During the bleed operations, take care to maintain the level of brake fluid in the reservoir, topping up if necessary.

383
 C8 DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM
Precautions to be taken before bleeding a braking circuit.
Precautions:
After a repair on the master cylinder or ABS block, bleed in the following order:
Front LH wheel.
Front RH wheel.
Rear LH wheel.
Rear RH wheel.
BRAKES

After a repair on a caliper or on a wheel cylinder, bleed in this order:

Front LH wheel.
Front RH wheel.
Rear LH wheel.
Rear RH wheel.
NOTE: If removing/refitting the master cylinder, complete the automatic bleed with a manual bleed.
ABS requirements:
The hydraulic valve blocks are delivered pre-filled; it is thus possible to perform:
- a manual bleed (using the pedal),
- an automatic bleed.
Should the bleed of the circuit prove unsatisfactory, it is possible to bleed the ABS block using a diagnostic tool, following the instructions
given by the diagnostic tool.
Use of the diagnostic tool is necessary if not all of the following conditions apply at the same time:
Air in the circuit.
Regulation block active.
Action on the brake pedal.

384
 DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM C8
Bleeding.

IMPERATIVE: Start the engine.

WARNING: Respect the order of opening of the bleed screws.

BRAKES
Automatic bleed:

Position tool [2] on the brake fluid reservoir.

Connect tool [2] to an approved automatic bleed apparatus (See Tools).
Bleed the circuit, referring to the user instructions provided with the apparatus.

Manual bleed (using the pedal):

NOTE: Two operators are necessary.

Connect a transparent pipe on the bleed screw.
Press slowly on the brake pedal.
Open the bleed screw.
Keep the pedal pressed fully down.
Close the bleed screw.
Allow the brake pedal to rise gradually.
Repeat the operation until the brake fluid flows out clean and free of air bubbles.
Proceed in an identical fashion in the case of all the other wheels.

385
 C5 SAFETY REQUIREMENTS: HYDRACTIVE 3 HYDRAULIC SUSPENSION
All operations on the Hydractive 3 hydraulic circuit must be performed in conformity with the following requirements and regulations:
Authorities competent in matters of health:
- Accident prevention
- Environmental protection
WARNING: Operations should be carried out by specialised personnel who have had training in the safety requirements and precautions
to be taken.
HYDRAULIC

Safety requirements
ESSENTIAL: In view of the special features of the hydraulic suspension system, observe the requirements below, before undertaking
any repair.
IMPERATIVE: Depending on the operation to be carried out, respect the requirements for supporting and securing the vehicle.

Wheels hanging Wheels not hanging

2-column lift or secure the vehicle
Vehicle on the ground Vehicle 4-column lift
on 4 axle stands
Depressurisation of the circuit Checking and adjusting of Other operations (depressurisation of
(see corresponding operation) heights (switch on ignition) the hydraulic circuit)

During the operation.

Wait for the pressure in the hydraulic circuit to fall fully before disconnecting the unions on the following components (risk of sudden sinking of the
vehicle):
Built-in Hydro-electronic Interface (BHI).
Front suspension cylinder.
Rear suspension cylinder.
Front stiffener regulator .
Rear stiffener regulator
386
 SAFETY REQUIREMENTS: HYDRACTIVE 3 HYDRAULIC SUSPENSION C5
IMPERATIVE: Do not operate on the hydraulic circuit without Preliminary operations.
making the prssure drop (see corresponding operation). The work area must be kept clean and uncluttered.
The technician must wear clean overalls.
Engine running: Components being stored during the repair must be protected from
Do not operate on the hydraulic suspension circuit. dust.
Always remain out of range of any possible projections of fluid, as these The tooling required for an operation on the suspension system should
could cause serious injuries. always be cleaned prior to the operation.
During the operation.
NOTE: In the event of contact of LDS fluid with the eyes, rinse them with Before operating on the suspension circuit, proceed to clean the
copious amounts of water and seek specialist advice. hydraulic components and unions.
NOTE: In the event of lengthy contact of LDS fluid with the skin, wash
it with soap and water. IMPERATIVE: Approved cleaner: SODIMAC degreaser.
WARNING: After the engine has stopped, wait 30 seconds before
IMPERATIVE: After a dismantling, immediately blank the

HYDRAULIC
commencing any operation.
hydraulic components and unions with plugs. The plugs should be
IMPERATIVE: Do not remain underneath the vehicle during an used for one operation only.
operation to adjust vehicle heights or during actuator (electrovalve)
tests. Any component that has been removed must be plugged and placed in
a clean plastic bag.
Cleanliness requirements.
IMPERATIVE: After a dismantling, any cleaning using compressed
WARNING: Non respect of the cleanliness requirements may cause a air or products is strictly prohibited. Any LDS fluid that is collected
contamination of the circuit and a malfunctioning of the suspension. must not be re-used. Ny top-up must be done with new fluid.

387
 SPECIFICATION - IDENTIFICATION: SUSPENSION SPHERES

(1) Front suspension sphere.

(2) Rear suspension sphere.

(3) Front hydractive 3+ regulator accumulator.

HYDRAULIC

(4) Rear hydractive 3+ regulator accumulator.

B4BP01DD

388
 SPECIFICATION - IDENTIFICATION: SUSPENSION SPHERES
Special features

Identification.

The «slimline» spheres are grey in colour, with multilayer membranes.

IMPERATIVE: It is impossible to recharge or overhaul the «slimline» spheres with nitrogen.

The number marked on the suspension sphere is the component reference and not the Replacement Parts No.
The two-figure number marked on the suspension sphere indicates the initial pressure rating value.

Example:
Suspension sphere Day in year of Year of Time of Pressure rating

HYDRAULIC
marking manufacture manufacture manufacture (Bars)

HF 066 00 13h59 57

The pressure rating of this type of suspension sphere is given merely as a guide.
When checking, the value read could be higher than the nominal value.
Suspension cylinders on the same axle should be equipped with the same type of suspension spheres.

IMPERATIVE: Tightening torques for suspension spheres : 2,7 ± 0,5 m.daN.

389
 C5 SPECIFICATION - IDENTIFICATION: SUSPENSION SPHERES
Hydractive 3 hydraulic suspension
(1) Front suspension spheres.
Engines Suspension sphere marking Volume (cc) Pressure rating (Bars)
All 6FZ HF
385 57
Types RHY-RHS-RHZ HG
(2) Rear suspension spheres.
Engines Suspension sphere marking Volume (cc) Pressure rating (Bars)
HJ
Saloon 31
6FZ KA
RHY-RHS-RHZ 385
HYDRAULIC

HP
Estate 44
HT

390
 SPECIFICATION - IDENTIFICATION: SUSPENSION SPHERES
Hydractive 3+ hydraulic suspension
(1) Front suspension spheres.
Engines Suspension sphere marking Volume (cc) Pressure rating (Bars)
All RFN-RLZ HH 44
385
Types XFX-4HX HI 52
(2) Rear suspension spheres.
Engines Suspension sphere marking Volume (cc) Pressure rating (Bars)
HE
Saloon RFN-RLZ-XFX-4HX 25
HZ

HYDRAULIC
HO 385
RFN-RLZ-XFX-4HX 44
Estate HW
CARLSSON HT

391
 SPECIFICATION - IDENTIFICATION: SUSPENSION SPHERES
Hydractive regulator accumulators
(3) Front hydractive regulator accumulator.
Engines Suspension sphere marking Volume (cc) Pressure rating (Bars)
All Types RFN-RLZ-4HX HD
except 62
CARLSSON HQ 385
XFX
CARLSSON HT 44
(4) Rear hydractive regulator accumulator.
Engines Suspension sphere marking Volume (cc) Pressure rating (Bars)
RFN-RLZ-4HX GP 45
HYDRAULIC

All Types
385
XFX HR 44
CARLSSON

NOTE: The dampers are integral to the hydractive regulators, depending on the versions of hydractive accumulator.

392
HYDRAULIC SPECIFICATIONS
Location of components

(D) High pressure hydraulic circuit

(E) Low pressure hydraulic circuit
(F) Electric circuit
(22)Front «slimline» suspension sphere
(23)Front suspension cylinder
(24) Front hydractive 3+ regulator
(25) Front hydractive 3+ regulator accumulator
(26) Sequential control suspension switch
(27) LDS fluid reservoir
(28) Rear height sensor

HYDRAULIC
(29) Rear hydractive 3+ regulator
(30) Rear hydractive 3+ regulator accumulator
(31) Rear suspension cylinder
(32) Rear «slimline» suspension sphere
(33) Built-in Hydro-electronic Interface (BHI).
(34) Front height sensor

NOTE: LDS = Liquide direction suspension (fluid for steering/suspension)

B4CP01GP

393
 HYDRAULIC SPECIFICATIONS
Hydraulic fluid
Type of suspension Type of steering Capacity (litres)
Hydractive 3 Left hand drive 4,5
Hydractive 3 Right hand drive 4,7
Hydractive 3 +
Left hand drive 5,2
All engines except XFX
Hydractive 3 +
Right hand drive
All engines except XFX 5,4
Hydractive 3 +
Left hand drive
Engine XFX
Hydractive 3 +
Engine XFX Right hand drive 5,6

(LDS suspension fluid is orange in colour and 100% synthetic

HYDRAULIC

(TOTAL LDS)
Hydraulic fluid reservoir
Reference Function Component
«c» Return Suspension cylinders
«d» Built-in Hydro-electronic Interface
Induction
Power steering pump
«e» Built-in Hydro-electronic Interface
Return
«f» Power steering pump
The LDS fluid level is checked with the vehicle in the low position (see corresponding
B4BP01BC operation).

394
HYDRAULIC SPECIFICATIONS C5 + CARLSSON
Built-in Hydro-electronic Interface (BHI).

Ref. Component Specifications

(36) Electronic control unit

Hydraulic unit comprising:
Pump with 5 axial pistons Throughput = 0,7 l/min at 2300 rpm
(38) - Anti-pulse hydropneumatic Diameters of the pistons = 6,35 mm
accumulator Safety valve rating = 180 Bars
A safety valve

HYDRAULIC
(35) Electric motor 2350 ± 150 rpm
Suspension inlet electrovalve (front)
Suspension inlet electrovalve (rear) The vehicle’s anti-sink function is
(37) Suspension exhaust electrovalve (front) assured by the exhaust electrovalves.
Suspension exhaust electrovalve (rear)

B3BP16PP

395
 C5 + CARLSSON HYDRAULIC SPECIFICATIONS
Hydractive 3+ regulator Hydraulic unions
HYDRAULIC

B4BP01KD B4DP003D

Tube diameter Tightening torque

(39) Electrovalve. Reference
(mm) m.daN
(40) Hydractive regulator.
G 3,5
(41) «Slimline» suspension sphere. 1,5 ± 0,3
H 6,35
(42) Depressurisation screw.
J 10 2,5 ± 0,5
IMPERATIVE: At each operation, it is necessary to change the hydraulic seals.
WARNING: Each time you remove a hydraulic union, reference G: Remove the O-ring seal from its housing.

396
 DE-PRESSURISING THE HYDRAULIC SUSPENSION CIRCUIT
Tools.

[1] PROXIA station : 4165-T

[2] LEXIA station : 4171-T

De-pressurisation.

NOTE: It is possible to de-pressurise the suspension by individual axle.

Using a diagnostic tool

Start the engine.

Place the height control in the «LOW» position.

HYDRAULIC
Wait for the vehicle height to reach the position required.
Stop the engine.
Connect the diagnostic tool [1] or [2] to the vehicle’s diagnostic socket.
Switch on the ignition.
Go into the menus:
- Suspension.
- Actuator tests.
Select and validate the electrovalves line for front descent.
Wait for the vehicle’s front suspension to sink completely.
Select and validate the electrovalves line for rear descent.
Wait for the vehicle’s rear suspension to sink completely.

397
 DE-PRESSURISING THE HYDRAULIC SUSPENSION CIRCUIT

Without using a diagnostic tool.

IMPERATIVE: Any LDS fluid that is collected must not be re-used.

NOTE: Collect the LDS fluid in order to keep the work area clean.
Respect the environment.

Start the engine.

Place the height control in the «LOW» position.
Stop the engine.
HYDRAULIC

Vehicle with suspension Hydractive 3

Front suspension: undo the pressure release screw (1) by one turn.
Wait for the pressure in the hydraulic circuit to drop fully.

Rear suspension: undo the pressure release screw (2) by one turn.
Wait for the pressure in the hydraulic circuit to drop fully.

B3BP16GC B3BP16HC

398
DE-PRESSURISING THE HYDRAULIC SUSPENSION CIRCUIT C5

Vehicle with suspension Hydractive 3 +

Front suspension: undo the pressure release screw (3) by one turn.

Wait for the pressure in the hydraulic circuit to drop fully.

HYDRAULIC
Rear suspension: undo the pressure release screw (4) by one turn.

Wait for the pressure in the hydraulic circuit to drop fully.

B3BP16JC B3BP16KC

399
 C5 CHECK AND TOP-UP: LDS FLUID LEVEL
IMPERATIVE: Respect the safety and cleanliness requirements (refer to brochure:
«RECOMMENDATIONS-PRECAUTIONS»).
NOTE: LDS = Liquide direction suspension (fluid for steering/suspension).

Tools.
[1] PROXIA station : 4165-T
[2] LEXIA station : 4171-T
Evolutions:
The window for checking the LDS fluid level (BASE, HYD, MAX) is discontinued.
Checking the LDS fluid level is done via the reservoir filler cap.

Checking and topping up the LDS fluid level.

Start the engine.
Place the height control in the «LOW» position.
HYDRAULIC

Wait for the vehicle height to reach the position required.

Stop the engine.
Connect the diagnostic tool [1] or [2] to the vehicle’s diagnostic socket.
Switch on the ignition.
Go into the menus:
- Suspension.
- Actuator tests.
Select and validate the electrovalves line for front descent.
Wait for the vehicle’s front suspension to sink completely.
Select and validate the electrovalves line for rear descent.
Wait for the vehicle’s rear suspension to sink completely.
Remove the engine cover.
B4BP01GC

400
 CHECK AND TOP-UP: LDS FLUID LEVEL C5
LDS fluid reservoir (new type)

Open the cap (1).

If the LDS fluid level is below the min. mark «b»:

Add LDS fluid to bring the level to between the min. mark «b» and the max. mark «a».

LDS fluid reservoir (old type)

Open the cap (1).

If the LDS fluid level is below the min. mark «b»:

HYDRAULIC
Add LDS fluid to bring the level to 10 mm above the min. mark «b».

IMPERATIVE: A container of LDS fluid that has been opened should be re-capped and carefully
stored in a clean place. A container of LDS fluid should be used up within 2 weeks of first
opening. After this date, unused LDS fluid should be disposed of.

B4BP01LC

401
 C5 FILLING – BLEEDING: HYDRAULIC SUSPENSION/STEERING CIRCUIT
IMPERATIVE: Respect the safety and cleanliness requirements (refer to brochure
«RECOMMENDATIONS-PRECAUTIONS»).
Tools.
[1] Pliers for CLIC clips : 4121-T.

Identification:
Sequential control suspension switch.
A: Suspension Hydractive 3
B: Suspension Hydractive 3 +
Draining.
B4BP01ED
Start the engine.
Place the vehicle in the low position.
Stop the engine.
HYDRAULIC

Raise and support the vehicle, wheels hanging.

WARNING: The LDS fluid reservoir is pressurised.
Open the cap of the LDS fluid reservoir.
Remove:
- The front RH wheel.
- The front RH splash-shield.
Release the clip (1), using tool [1].
Disengage the hose (2) from the LDS fluid reservoir.
Drain the LDS fluid reservoir.
IMPERATIVE: Any LDS fluid that is collected must not be re-used.
C4CP0SDC

402
FILLING – BLEEDING: HYDRAULIC SUSPENSION/STEERING CIRCUIT C5
Filling.
Refit:
- The hose (2).
- The clip (1)
- The front RH splash-shield.
- The front RH wheel.
Lower the vehicle.
Fill the LDS fluid reservoir up to the MAX. mark.
Bleeding.
Apply a pressure of 0,5 Bars in the LDS fluid reservoir (using tool: FACOM 920).
Start the engine
B4BP01FC Wait for the vehicle height to stabilise.
Place the vehicle in the high position.

HYDRAULIC
Place the vehicle in the low position.
Move the steering in both directions, from lock to lock.
Stop the engine.
Check the LDS fluid level.
Check and if necessary top up the LDS fluid level.
NOTE: Checking the LDS fluid level is done with the vehicle in the low position.
«a» minimum level of LDS fluid.
If the level is below the mark «a», add 1 litre of LDS fluid.
MAX. mark on the LDS fluid reservoir:
Maximum level of LDS fluid:
Suspension Hydractive 3 : Mark «BASSE».
B4BP01GC Suspension Hydractive 3 + : Mark«HYD».

403
 C5 - C8 STARTER MOTORS
Abbreviations and definitions

Coding of climates is as follows: Meaning of abbreviations:

CLIMATES:

C Hot : Starting possible as low as -18°C BV : Gearbox

T Temperate : Starting possible as low as -18°C BVM : Manual gearbox
F Cold : Starting possible as low as -25°C BVA : Automatic gearbox
GF Very cold : Starting possible as low as -30°C MAP : Piloted manual gearbox
ELECTRICAL

DA REFRI : Mechanical power steering, aircon

404
 STARTER MOTORS C5
Vehicles / models Gearbox Class Climate
C
1.i 16V 3 T
F
4 GF
M
C
3 T
F
4 GF
2.0i 16V
C
3 T
C5 A
F
4
GF
C
T
M F
3.0i 24V GF

ELECTRICAL
4 C
T
A F
GF
405
 C5 STARTER MOTORS
Vehicles / models Gearbox Class Climate
C
4
T
F
6
GF
M
C
2.0 HDi 5
T
F
6
GF
C
6
T
C5 A
F
6+
GF
C
5
T
M F
6+ GF
2.2 HDi
ELECTRICAL

C
5 T
A F
6+
GF
406
 STARTER MOTORS C8
Vehicles / models Gearbox Class Climate
C
3 T
2.0i 16V M-A
F
4
GF
C
3
T
C8 M
2.2 16V HPi F
4
GF
C
T
A 4
3.0i 24V F
GF

ELECTRICAL
407
 C8 STARTER MOTORS
Vehicles / models Gearbox Class Climate
C
5 T
M
F
6+
2.0 16V HDi GF
C
6
T
C8 A
F
6+
GF
C
5
T
2.2 HDi M
F
6+
GF
ELECTRICAL

408
 ALTERNATORS C5 - C8
Abbreviations and definitions

Coding of climates is as follows: Meaning of abbreviations:

BV : Gearbox
CLIMATES: BVM : Manual gearbox
BVA : Automatic gearbox
C : Hot BVMP : Piloted manual gearbox
T : Temperate NON REFRI : Without air conditioning
F : Cold REFRI : With air conditioning
GF : Very cold DA : Power-assisted steering
GEP : Electro-pump motor
DP : Double lug
3 Pts : 3-Point
NC : Not marketed
TT : All Types
N : Level
SOP : Without Option

ELECTRICAL
TOP : All Options
L.C. : Heated rear screen
DAG : Left hand drive
DAD : Right hand drive

409
 C5 ALTERNATORS
Without hi-fi pack With hi-fi pack
Engine/
Without heated seat With heated seat Without heated seat With heated seat
Gearbox Climate
Mono Colour Mono Colour Mono Colour Mono Colour
Base Base Base Base
Navig. Navig. Navig. Navig. Navig. Navig. Navig. Navig.
C 12
1.8i 16V 12
2.0i 16V T
2.0i 16V 9
F
HPi 9
BVM GF
C 15 15
12 12 12
1.8i 16V T 12 12
BVA F 9
9 9
GF 12
C 15
12
2.0i 16V T 12
BVA F 9 9 12
ELECTRICAL

9 9
GF 12 12

Meaning of abbreviations, see page: 409

410
 ALTERNATORS C5
Without hi-fi pack With hi-fi pack
Engine/ Without heated seat With heated seat Without heated seat With heated seat
Climate
Gearbox Mono Colour Mono Colour Mono Colour Mono Colour
Base Base Base Base
Navig. Navig. Navig. Navig. Navig. Navig. Navig. Navig.
C
3.0i 24V
T
BVM 15 15
BVA F
GF
C 12 12
2.0 16V 12 12 12
T
HPi
BVM F 9 9
9 9 9
GF
2.0 HDi C
2.0 16V T
15
HDi F
BVM GF
C
2.0 HDi T

ELECTRICAL
15
BVA F
GF
Meaning of abbreviations, see page: 409

411
 C8 ALTERNATORS
REFRI
Engine/ Level 1 Level 2 or 3
Gearbox Climate Without heated seats With heated seats Without heated seats With heated seats
RT3 RT3 RT3 RT3
Base Base Base Base
N1 N2 N3 N1 N2 N3 N1 N2 N3 N1 N2 N3
C
2.0i 16V T
9
BVM F
GF
C
15
2.0i 16V T
BVA F 9
9
GF 15
C
2.2 16V T
HPi F 9
BVM GF
ELECTRICAL

Meaning of abbreviations, see page: 409

412
 ALTERNATORS C8
REFRI
Engine/ Level 1 Level 2 or 3
Gearbox Climate Without heated seats With heated seats Without heated seats With heated seats
RT3 RT3 RT3 RT3
Base Base Base Base
N1 N2 N3 N1 N2 N3 N1 N2 N3 N1 N2 N3
C
3.0i 24V T
BVA F
GF
C
2.0 16V
T
HDi 15
BVA F
GF
C
2.0 16V
HDi T
2.2 HDi F
BVM GF

ELECTRICAL
Meaning of abbreviations, see page: 409

413
 CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR
Checking the alternator output
Connect as shown in the diagram opposite, using an ammeter (A), a voltmeter (V), and a rheostat (R)
or a Volt/Ammeter/Rheostat combination.
Referring to the vehicle’s equipment specification (see table opposite), adjust the engine speed and
rheostat charge to obtain U=13.5V.
Reminder: The excitation energising current will flow through the warning lamp; check that the warning
lamp comes on when the ignition is switched on. It should go out when the engine has started (accele-
rate slightly).

Checking the voltage regulator

D1AP025C Set the rheostat to zero and disconnect all the electrical consumers.
Display 3000 alternator rpm. If U alternator is > 14.7 V, the regulator is faulty.
A: Ammeter Note: These tests should be performed with the engine hot and the battery fully charged.
B: Battery
G: Generator Method of reading the alternator speed
L: Warning lamp
Fit a reflecting shim on the pulley of the alternator.
K1 and K2: Switch
Adjust a stroboscope to the frequency equivalent to the control speed.
R: Electric charge
(e.g. 2000 rpm = 2000/60 = 83 Hz)
ELECTRICAL

S: Shunt 200mV/200A
Adjust the engine speed so that the shim appears fixed.
V: Voltmeter
1: Alternator.

414
 CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR
MINIMUM OUTPUTS (in A)
Alternator Class
Min. output
speed 6 7 8 9 12 15 18
1800 rpm I 1 27 39 46 61 73 89 108
2000 rpm I 2 34 46 54 68 80 105 123
3000 rpm I 3 47 60 68.5 84 100 139 164
4000 rpm I 4 55 65 75 92 110 145 176
6000 rpm I 5 61 69 78.5 96 120 151 183
8000 rpm I 6 63 70 80 97 123 157 188
15000 rpm I 7 64 73 82 97 124 157 188
MINIMUM OUTPUTS (in A)
Class
Alternator speed
6 7 8 9 12 15 18
1800 rpm 49 50 52 57 58 60 61
2000 rpm 48 49 51 54 55 57 60
3000 rpm 45 46 48 51 52 54 56

ELECTRICAL
4000 rpm 43 44 46 48 50 52 53
6000 rpm 39 40 42 43 48 50 50
8000 rpm 26 37 39 40 45 48 48
15000 rpm 24 25 27 29 34 38 38
415
 PRE-HEATING AND STARTING CIRCUITS

Pre-post-heating
Vehicles Engine Pre-heater plugs Pre-heater control unit
(Pre-heating time at 20°C)

2.0 HDi CARTIER 51299011A

2.0 16V CHAMPION CH 170
NAGARES 960411-P
HDi Piloted by the diesel
C5
injection ECU
CARTIER 51299011A
2.2 HDi BERU A0100 226 344
NAGARES 960411-P
ELECTRICITÉ

Preheater plug resistance: 0.4 Ω ≤ R ≤ 0.6 Ω

416
 CONDITIONING
AIR CONDITIONING R 134 a (HFC) C5 - C8

AIR
Compressor
Refrigerant
Vehicle Engine version Date
refill Variable capacity Oil quantity cc Oil reference

1.8i 16V - 2.0i 16V

2.0 HPi
SD 7 V16 135 SP 10
3.0i 24V 16V 650
C5 2.2 HDi 11/2000 K
+0 -50 gr

2.0 HPi DELPHI V5 (1) 265 ± 15 PLANETELF 488

C8 All Types 06/2002 650 (± 20 gr) SD 7 V 16 135 SP 10

(1) = HARRISON Division.

417
CONDITIONING
AIR C5 - C8 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Summary table for presence of pollen filter

Vehicle Equipment RPO no. Presence of filter Observations

C5 Located under the dashboard.
Aircon all types YES
C8 Located in the engine compartment.

418
 CONDITIONING
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) C5

AIR
Pollen filter

Remove:

- The trim (1) under the dashboard (driver’s side).

- The cover (2).

Unclip at «a» and pull out the pollen filter (3).

Remove the pollen filter (3).

C5FP0C5C C5FP0C6D

419
CONDITIONING
AIR C8 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134. a)
Pollen filter

C5HP183C

NOTE: The pollen filter is located under the bonnet on the LH side.
Removing.
Remove the jack handle (1).
Disconnect the evacuation pipe (2).
Unlock at (3), on the right and on the left.
Undo by a _ turn the screws (4), on right and on left.
Pull the assembly (6) towards the outside.
Remove the pollen filter (5).
Refitting.
C5HP182D Proceed in the opposite order to removal.

420
 CONDITIONING
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) C5

AIR
Drying cartridge

Tools
[1] Filling and recycling station MULLER - ECOTECHNICS
[2] TORX adaptor 70 FACOM
[3] After Sales kit (Bottle / skirt / bottle nozzle / grease / compressor oil)
Reminder: All repairs on an aircon circuit require the aircon circuit to be drained.

After carrying out the dismantling operations necessary to gain access to the condenser, proceed to
clean the area of the skirt (8) of the reservoir (6) using a cloth, then replace the dryer reservoir (6).

Removing the plastic bracket holding the reservoir (6):

- Remove the screw (3) (Torx 20), from the bracket assembly/plastic counter-bracket (4) and (5).
- Remove the counter-bracket (5).(Rotate it round the hinge in a clockwise direction).
- Disengage the bracket from the harness (1) (Rotate it round the reservoir (6) anti-clockwise).
- Remove the bracket (5) from the reservoir body (6).

Unscrewing the reservoir (6).

- Unscrew the reservoir (6) using the tool [2].

C5HP16EC

421
CONDITIONING
AIR C5 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Condenser with integral reservoir (continued)

Removing the reservoir (6) from the base (8).

WARNING: This operation requires the greatest care, the base (8) should be kept clean prior to fitting the
new reservoir.
- Remove the reservoir (6) and the protection skirt (7), avoiding WITHOUT FAIL any contact or collision
with other items under the bonnet (Risk of impurities entering the base (8)).
- Check before refitting the reservoir (6) that the base (8) is clean.
(If it is not, clean in and around the base (8) with a paper cloth.)

Preparing the new dryer reservoir

- Remove the black plastic protection cap from the reservoir neck (6), leaving in place the green protec-
tion at the other end, in order to keep the new reservoir (6) sealed when mounting it in the base (8) of the
condenser.
- Use the grease sachet in the replacement kit, to lubricate the threads of the reservoir.
- Use the oil sachet in the replacement kit, to lubricate the two O-ring seals of the reservoir (6)
- Position the reservoir (6), with its new protection skirt (7) from the replacement kit, and engage the
threads of the reservoir (6) in the base (8).
- Check that the downward edge of the skirt (7), covers the base (8) all around it.

C5HP16EC

422
 CONDITIONING
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) C5

AIR
Condenser with integral reservoir (continued)

WARNING: The reservoir (6) contains a drying agent. As soon as the black protection is removed, the reser-
voir must be mounted in the base (8), otherwise there is a risk of damaging the air conditioning circuit.

Screwing the reservoir (6) into the base (8).

- Screw on the reservoir (6) manually, until the neck of the reservoir (6) is in contact with the bottom of
the base (8).

- Tighten with a torque spanner and tool [2] at (2) to 1,3 ± 0,1 m.daN.

Fitting the plastic bracket. (New, from the Replacement Parts kit).

Proceed in the opposite order to removal, tighten the screw (3) to 0,15 m.daN.

C5HP16EC

423
CONDITIONING
AIR C8 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Removing-refitting the drying cartridge

Removing.

Depressurise the air conditioning circuit.

Remove the hose (1).

Disconnect the connector (2).

Remove the air filter (3).

Turn the plastic pins (4) a quarter turn.

Move aside the condenser (5).

Clean the area of the skirt (6) of th reservoir (7).

Remove the screw (8) of the clip (9)

B1BP2MGC B1BP2MHC C5HP184C C5HP185C

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 CONDITIONING
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) C8

AIR
Removing-refitting the drying cartridge (continued)

Unscrew the reservoir (7) (using adaptor TORX 70 FACOM)

Unscrew the reservoir (7), and the protection skirt (6).

WARNING: Components must be kept clean prior to a new reservoir being fitted.

Plug the base (10).

WARNING: Do not allow more than 5 minutes to elapse between unpacking the cartridge (reservoir (7) and
fitting it.

C5HP186C C5HP187C

425
CONDITIONING
AIR C8 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Removing-refitting the drying cartridge (continued)

Refitting.
Note: Before fitting the reservoir (7), make sure that the base is clean (10).
(If it is not, use paper towel to clean inside the base (10)).
Preparation of the new dryer reservoir.
Remove the protection plug from the neck of the reservoir (7)
Leave the protection in place on the end of the reservoir (7) until fitting.
Treatments:
- Grease the threads of the reservoir (7) (sachet of grease in the kit).
- Lubricate the two O-ring seals of the reservoir (7) (sachet of oil in the kit).
Remove:
- The protection plug fitted at the time of removal, from the base (10).
- The protection from the end of the reservoir (7).
Engage the reservoir (7) with its skirt (6) on the threads of the base (10).
Screw on the reservoir by hand (7), until the neck of the reservoir (7) makes contact with the base (10).
NOTE: Check that the bottom edge of the skirt (6) covers the base (10) all the way round.
Tighten the reservoir (7) (TORX 70 FACOM)
Tighten to 1,4 ± 0,1 m.daN
Fit the plastic clip (9) and the screw (8). (New, from exchange kit).
Complete the refitting, in reverse order to removal.
Proceed to:
- Recharge the circuit (see corresponding operation).
- Check that the air conditioning functions correctly (see corresponding operation).
C5HP188C

426
 CONDITIONING
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)

AIR
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.

1) Repairing a system without leaks.

a) - Using draining/recovery equipment not fitted with an oil decanter.
- Drain the system as slowly as possible via the LOW PRESSURE valve, so as not to lose any oil.
- No more oil should be added when filling the system with R 134.a fluid.
b) - Using draining/filling equipment fitted with an oil decanter.
- Drain the R 134.a fluid from the system in accordance with the instructions in the equipment handbook.
- Measure the amount of oil recovered.
- Add the same amount of NEW oil when filling the system with R 134.a fluid.
c) - Replacing a compressor.
- Remove the old compressor, drain it and measure the oil quantity.
- Drain the new compressor (supplied full), so that the same amount of NEW oil is left in the compressor as was in the old compressor.
- No more oil should be added when filling the system with R 134.a fluid.

427
CONDITIONING
AIR 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.

This type of leak causes both oil loss as well as allowing air to enter the system.

It is therefore necessary to:

- Replace the dryer.
- Drain as much oil as possible (when replacing the faulty component).

Either before or during filling of the system with R 134.a fluid, introduce 80 cc of NEW oil into the system.

428
 CONDITIONING
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM TOUS TYPES

AIR
CHECKING TEMPERATURES.
TOOLS Checks.

Two thermometers. If all these conditions are met, take the following action:

Preliminary conditions. - Start the engine, with the air conditioning off, and wait for the cooling fan
first speed to cut in.
Position of the air conditioning controls: - Operate the air conditioning and set the engine speed to 2500 rpm.
- Maximum cold air.
- Air blower in maximum position. NOTE: If the exterior temperature reaches 40 °C, the engine speed will
- Air distributor in "ventilation" position, with the dashboard vents open. return to 2000 rpm in order to prevent the compressor from being cut off
- Air intake flap in "exterior air" position. by the High Pressure safety device (Pressostat).

After the air conditioning has been on for three minutes, measure:
Conditions and vehicle equipment. - the exterior temperature in the workshop,
- the temperature of the air coming out of the central vents.
- Bonnet closed.
- Doors and windows shut.
- Ensure the vehicle is in a sheltered area (away from wind, sun, etc.). Compare the two values using the table overleaf.

429
CONDITIONING
AIR C8 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
CHECKING TEMPERATURES (continued)

Vehicle using R 134. a fluid (Compressor with variable capacity)

Ambient temperature in °C 40 35 30 25 20 15
Vehicle Engines
DW10
Temperature C8 (1) 23 ± 2 18 ± 2 14 ± 2 11 ± 2 8±2 7±2
DW12
at the central air vents
in °C

(1) For information: C8 (EW10-EW12 and ES9J4S) - Temperatures virtually identical.

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 CONDITIONING
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM C8

AIR
CHECKING PRESSURES
TOOLS - 1 charging station.
- 2 thermometers.
Once the preliminary conditions, vehicle equipment and checks have been - The temperature of the air coming from the central vents (see table).
fulfilled (see table). - The High Pressure.
After the air conditioning has been on for three minutes, record the follo- - The Low Pressure.
wing parameters: Compare the values recorded with the table below, or the graphs.

Vehicle using R134.a fluid (Compressor with variable capacity)

Ambient temperature in °C 40 35 30 25 20 15
Vehicle Engines
High pressure (Bars) 26 ± 2 23 ± 2 20 ± 2 20 ± 2 20 ± 2 17 ± 2
C8 All Types
Low pressure (Bars) 3,8 ± 2 3,4 ± 2 3±2 2,7 ± 2 2,6 ± 2 2,7 ± 2
High pressure (Bars)
Low pressure (Bars)
High pressure (Bars)
Low pressure (Bars)
High pressure (Bars)
Low pressure (Bars)
High pressure (Bars)
Low pressure (Bars)
431
CONDITIONING
AIR C5 AIR CONDITIONING SYSTEM R 134.a
Engines: 6FZ RFN RLZ XFX THY RHS RHZ 4HX Evolution of the HP/LP filling valves

(1) High pressure valve. (Two versions)

(2) Low pressure valve. (One version)

C5HP1A9D

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 CONDITIONING
AIR CONDITIONING SYSTEM R 134.a C5

AIR
Engines: 6FZ – RFN - RLZ

(1) High pressure valve.

(2) Low pressure valve.
(3) Pressostat.
(4) Capacity.

(a) Condenser bracket

Tighten to 0,8 m.daN
(b) Pressure control valve
Tighten to 0,8 m.daN
(c) Compressor bracket
Tighten to 2,5 ± 0,1 m.daN
(d) Condenser dryer reservoir
Tighten to 1,4 ± 0,2 m.daN.

C5HP15QP

433
CONDITIONING
AIR C5 AIR CONDITIONING SYSTEM R 134.a
Engine: XFX

(1) High pressure valve.

(2) Low pressure valve.
(3) Pressostat.
(4) Capacity

(a) Condenser bracket

Tighten to 0,8 m.daN
(b) Pressure control valve
Tighten to 0,8 m.daN
(c) Compressor bracket
Tighten to 2,5 ± 0,1 m.daN
(d) Condenser dryer reservoir
Tighten to 1,4 ± 0,2 m.daN.

C5HP15RP

434
 CONDITIONING
AIR CONDITIONING SYSTEM R 134.a C5

AIR
Engines: RHY - RHZ

(1) High pressure valve.

(2) Low pressure valve.
(3) Pressostat.
(4) Capacity

(a) Condenser bracket

Tighten to 0,8 m.daN
(b) Pressure control valve
Tighten to 0,8 m.daN
(c) Compressor bracket
Tighten to 2,5 ± 0,1 m.daN
(d) Condenser dryer reservoir
Tighten to 1,4 ± 0,2 m.daN.

C5HP15SP

435
CONDITIONING
AIR C5 AIR CONDITIONING SYSTEM R 134.a
Engine: 4HX

(1) High pressure valve.

(2) Low pressure valve.
(3) Pressostat.
(4) Capacity.

(a) Condenser bracket

Tighten to 0,8 m.daN
(b) Pressure control valve
Tighten to 0,8 m.daN
(c) Compressor bracket
Tighten to 2,5 ± 0,1 m.daN
(d) Condenser dryer reservoir
Tighten to 1,4 ± 0,2 m.daN.

C5HP15TP

436
 CONDITIONING
AIR CONDITIONING SYSTEM R 134.a C8

AIR
Engines: RFN-3FZ

1 Drying cartridge.

2 Clickfit union. (Tool 8005-T.C)

3 Buffer capacity.

4 Clickfit union. (Tool 8005-T.A)

5 High pressure valve.

6 Low pressure valve.

C5HP17TP

437
CONDITIONING
AIR C8 AIR CONDITIONING SYSTEM R 134.a
Engine: XFW

1 High pressure valve

2 Low pressure valve

3 Buffer capacity.

4 Drying cartridge

5 Pressostat

6 Clickfit union. (Tool 8005-T.C)

Tightening torques (m.daN)

a 0,8
b 1,4
c
d
e 0,8

C5HP18TP

438
 CONDITIONING
AIR CONDITIONING SYSTEM R 134.a C8

AIR
Engines: RHT-4HW

1 Drying cartridge.

2 Clickfit union. (Tool 8005-T.C)

3 Buffer capacity.

4 Clickfit union. (Tool 8005-T.A)

5 High pressure valve.

6 Low pressure valve.

C5HP17UP

439