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PRIVATE CARS
2003
C5 - 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
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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 and C8, or 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
– ISUPERFLUOUS INFORMATION
– INEED 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)
(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

C5 IDENTIFICATION OF VEHICLES
Petrol saloons
1.8i 16V 2.0i 16V
Auto. Auto.
X-SX X-SX-Exclusive
Emission standard L4 L5 L4 L5 L4 L5
GENERAL
Type code DC 6FZB DC 6FZC/IF DC 6FZE DC RFNC/IF DC RFNB DC RFNE

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 44 20 BL 30 20 TP 42

Petrol saloons
2.0 HPi 30.i 24S V6
Auto.
Exclusive
Emission standard L4 L5
GENERAL
Type code DC RLZB DC XFXC/IF DC XFXF/IF
Engine type RLZ XFX
Fiscal rating (hp) 8 13 14
Gearbox type BE4/5 ML/5C ML/5T 4 HP 20
Gearbox ident. plate 20 DL31 20 LM 21 20 LE 95 20 HZ 13

Diesel saloons
2.0 HDi
Auto. Auto.
X X-Exclusive
Emission standard L4
GENERAL
Type code DC RHYB DC RHSB DC RHSE DC RHZB DC RHZE

Engine type RHY RHS RHZ
Cubic capacity (cc) 1997
Fiscal rating (hp) 6 7 6 7
Gearbox type BE4/5 ML/5C ML/5T (*) AL4 ML/5C ML/5T AL4
Gearbox ident. plate 20 DL 32 20 LM 18 20 LE 94 20 TP 43 20 LM 18 20 LE 94 20 TP 43
(*) FAP = Particle filter

Diesel saloons
2.2 HDi
Auto.
SX-Exclusive
GENERAL
Type code DC 4HXB DC 4HXE
Engine type 4HX
Fiscal rating (hp) 8
Gearbox type ML/5C ML/5T 4 HP 20
Gearbox ident. plate 20 LM 17 20 LE 96 20 HZ 20

Petrol estates
1.8i 16V 2.0i 16V 2.0 HPi 3.0i 24S V6
Auto. Auto.
SX
X-SX Exclusive Exclusive
GENERAL
Emission standard L4 L5 L4 L5
Type code DE 6FZC/IF DE 6FZB DE RFNC/IF DE RFNE DE RLZB DE XFX/IF DE XFXF/IF
Engine type 6FZ RFN RLZ XFX
Cubic capacity (cc) 1749 1997 2946
Fiscal rating (hp) 7 9 8 13 14
Gearbox type BE4/5 AL4 BE4/5 ML/5C ML/5T 4 HP 20
Gearbox ident. plate 20 DL 29 20 DL 30 20 TP 42 20 DL 31 20 LM 21 20 LE 95 20 HZ 13

Diesel estates
2.0 HDi
Auto. Auto.
X X-Exclusive
GENERAL
Type code DE RHYB DE RHSB DE RHSE DE RHZB DE RHZE
Engine type RHY RHS RHZ
Fiscal rating (hp) 6 7 6 7
Gearbox type BE4/5 ML/5C ML/5T AL4 ML/5C ML/5T AL4
Gearbox ident. plate 20 DL 32 20 LM 18 20 LE 94 (*) 20 TP 43 (*) 20 LM 18 20 LE 94 20 TP 48 (*)
(*) FAP = Particle filter

Diesel estates
2.2 HDi
Auto.
SX-Exclusive
GENERAL
Type code DE 4HXB DE 4HXE

Engine type 4HX
Gearbox ident. plate 20 LM 17 20 LE 96 20 HZ 20

(A) Chassis stamp (cold stamp on bodywork).
(B) Manufacturer’s data plate (under RH centre pillar).
(C) A-S / RP No. and RP paint code

(label on front pillar).
GENERAL
(D) Inflation pressures and tyre references.
(label on front pillar)
(E) Gearbox reference – Factory serial no.
(F) Engine legislation type – Factory serial no.
E1AP0A2D

Petrol
2.0i 16V 2.2i 16V

Manual Automatic Manual
SX
X - SX SX X – SX Captain Chair
Captain Chair Exclusive Exclusive
Captain Chair
GENERAL
Emission standard IFL5

Type code EB RFNC/IF EB RFNF/IF EA RFNF/IF EB 3FZC/IF EA 3FZC/IF
Engine type RFN 3FZ
Fiscal rating (hp) 9 11
Gearbox type BE4/5 AL4 ML5C
Gearbox ident. plate 20 DL 27 (1) 20 DL 26 (2) 20 TP 74 20 LM 09
(1) = Right hand drive

(2) = Left hand drive.
10

Petrol
3.0i V6 S24
Automatic
Exclusive
Exclusive
Captain Chair
GENERAL
Emission standard IFL5
Type code SEB XFWF/IF EA XFWF/IF

Engine type XFW
Gearbox type 4 HP 20
Gearbox ident. plate 20 HZ 27
11

Diesel
2.0 HDi (*) 2.0 HDi (**)

Manual Automatic Manual Automatic
SX SX
X – SX – Exclusive X – SX – Exclusive
Captain Chair Captain Chair
GENERAL
Type code EB RHTB EB RHTE EA RHTE EB RHWB EB RHWE EA RHWE
Engine type RHT RHW
Gearbox type ML5C AL4 ML5C AL4
Gearbox ident. plate 20 LM 05 20 TS 04 20 LM 05 20 TS 04
(*) = With FAP (Particle filter).

(**) = Without FAP (Particle filter).
12

Diesel
2.2 HDi (*)
Manual
SX
SX Captain Chair
Captain Chair Exclusive
Captain Chair
GENERAL
Type code EB 4HWB EA 4HWB
Engine type 4HW
Gearbox type ML5C
Gearbox ident. plate 20 LM 01
(*) = FAP (Particle filter).
13

ALL TYPES CAPACITIES (in litres)
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).

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.
14

CAPACITIES (in litres) C5
C5
Petrol
1.8i 16V 2.0i 16V 2.0 HPi 3.0i V6

Auto. Auto. Auto.

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 66
(*) = With automatic gearbox
15

C5 CAPACITIES (in litres)
C5
Diesel
2.0 HDi 2.2 HDi

Auto. Auto. Auto.
Engine type RHY RHS RHZ 4HX

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 (1) 8.3 - 6 (1) 8.3
After oil change 5.3 – 3 (1) 5.3 – 3 (1) 5.3
Braking circuit
Hydraulic circuit 4.3

Cooling system 10.7 – 11.7 (With additional heating)
Fuel tank capacity 68
16

CAPACITIES (in litres) C8
Petrol Diesel
2.0i 16V 2.2i 16V 3.0i 24S 2.0 HDi 2.2 HDi
Auto. Auto. Auto.
Engine type RFN 3FZ XFW RHT - RHW 4HW

Engine angle
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 0.66
Cooling system 7 7.2 10.5 10 10.2 11.3
Fuel tank capacity 80 80
17

ALL TYPES LUBRICANTS - TOTAL recommended oils
Evolutions (year 2003). Use of oil grade 10W 40.

It is possible to use semi-synthetic oil 7000 10W40 on HDi and HDi
CITROËN C3 PLURIEL. FAP 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 (see
Normal maintenance interval : 30 000 km (20 000 miles) table).
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
these. TOTAL 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 pro-
grammes covering severe operating conditions. - XSARA VTS 2.0i 16V (XU10J4RS).
- RELAY 2.8 TDi; 2.8 HDi (SOFIM engine).
- HDi FAP vehicles.
- C3 1.6i 16V (DV4TED4).
- C8 2.2i (EW12J4)
18

LUBRICANTS - TOTAL recommended oils ALL TYPES
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
19

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
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 engines, a higher level of performance.
also permitting better fuel economy, specifically for direct injection die-
sel 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.
20

LUBRIFIANTS - PRECONISATIONS DE LA GAMME TOTAL ALL TYPES
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 HDi 16V
- EW 12J4 : CITROËN C8 2.2i.
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).
21

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
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.
22

S.A.E. norms ACEA norms API norms
Oils specifically for petrol and dual fuel petrol / LPG engines
TOTAL ACTIVA 7000

10W-40
TOTAL QUARTZ 7000
TOTAL QUARTZ 9000 0W-40 A3 SJ
TOTAL ACTIVA 7000

15W-50
GENERAL
TOTAL QUARTZ 7000
Oils specifically for diesel engines

TOTAL ACTIVA DIESEL 7000
10W-40
TOTAL QUARTZ DIESEL 7000 B3 CF
TOTAL ACTIVA DIESEL 7000 15W-50
23

Oil usage table
TOTAL ACTIVA QUARTZ

Engine types
Synthetic 9000 Semi-synthetic 7000
0W40 15W50
5W30 5W40 10W40
cold countries hot countries
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
Other HDi engines X X X
Diesel engines SOFIM 2.8 TDi and 2.8 HDi (RELAY) X X X
DV4 TED4 (C3 2.0 HDi 16V) X X X
Indirect injection diesel engines X X X X
(*) = Particle filter
24

Selection of TOTAL engine oils, to be used according to the climatic conditions in the country where the vehicle is marketed.
GENERAL
E4AP006D
25

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 petrol and Oils specifically for diesel

Blended oils for all engines
GENERAL
dual-fuel petrol / LPG engines engines
900 5W-40 7000 10 W-40 7000 10 W-40

Metropolitan FRANCE 9000 5W-30 (*) 9000 5W-40
New Caledonia
Guadeloupe
Saint Martin
Reunion
Martinique 9000 5W-40 7000 15W-50 7000 15W-50
Guyana
Tahiti
Mauritius
Mayotte
(*) = Blended oils for all engines, permitting fuel economy
26

ENGINE OILS
EUROPE TOTAL ACTIVA TOTAL ACTIVA DIESEL

7000 10W40
Germany
9000 0W40
GENERAL
Austria 7000 10W40
7000 10W40
Belgium
9000 0W40
9000 5W40 7000 10W40
Bosnia 7000 10W40
FUTURE 9000 5W30 (*) 9000 0W40
Bulgaria 7000 10W40
7000 10W40
Cyprus
9000 15W40
Croatia 7000 10W40
27

ENGINE OILS

7000 10W40
Denmark 9000 0W40
7000 10W40
GENERAL
Spain 7000 15W40
Estonia
7000 10W40
9000 5W40 9000 0W40
Finland 7000 10W40
FUTURE 9000 5W30 (*)
Great Britain 7000 10W40
Greece 7000 10W40

7000 15W40
Holland 7000 10W40
9000 0W40
28

ENGINE OILS

7000 10W40
Hungary
9000 0W40
GENERAL
Italy
Ireland
7000 10W40
Iceland 9000 5W40

7000 10W40
FUTURE 9000 5W30 (*)
Latvia
7000 10W40
Lithuania 9000 0W40
Macedonia 7000 10W40
29

ENGINE OILS

7000 10W40
Malta
7000 15W50
GENERAL
Moldavia 7000 10W40
Norway 7000 10W40

9000 0W40
9000 5W40
Poland 7000 10W40
FUTURE 9000 5W30 (*)
Portugal 7000 10W40
Slovakia
Czech Republic 7000 10W40

9000 0W40
30

ENGINE OILS

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
31

ENGINE OILS
EUROPE

Ukraine
9000 5W40 7000 10W-40 7000 10W-40
FUTURE 9000 5W30 (*) 9000 0W-40
GENERAL
Yugoslavia
32

ENGINE OILS
OCEANIA

Australia 9000 5W40

7000 10W-40 7000 10W-40
New Zealand FUTURE 9000 5W30 (*)
GENERAL
AFRICA

Algeria, South Africa,

Ivory Coast, Egypt, Gabon, Ghana,
Kenya, Madagascar, Morocco, Nigeria, 9000 5W40 7000 15W-50 7000 10W-40
Senegal, Tunisia

33

ENGINE OILS
CENTRAL AND SOUTH AMERICA

Argentina
GENERAL
Brazil
Chile
Cuba 9000 5W40 7000 10W-40 7000 10W-40

7000 15W-50
Mexico
Paraguay
Uruguay
34

ENGINE OILS
SOUTH-EAST ASIA TOTAL ACTIVA TOTAL ACTIVA DIESEL

7000 10W50
China 7000 15W50
GENERAL
9000 5W40
South Korea 7000 10W40
FUTURE 9000 5W30
Hong Kong
7000 15W50
India – Indonesia 9000 5W40 7000 10W40
Japan 9000 5W40 7000 10W40

FUTURE 9000 5W30 (*) 7000 15W50
Malaysia
9000 5W40 7000 15W50
Pakistan
35

ENGINE OILS
SOUTH-EAST ASIA

Philippines
7000 15W-50
GENERAL
Singapore
Taiwan 9000 5W40 7000 10W-40 7000 10W-40

7000 15W-50
Thailand
7000 15W-50
Vietnam
36

ENGINE OILS
MIDDLE EAST

Saudi Arabia – Bahrain
GENERAL
Dubai 7000 15W-50
United Arab Emirates
9000 5W40 7000 10W-40 7000 10W-40

Iran
7000 15W-50
Israel – Jordan – Kuwait
Lebanon – Oman – Qatar – Syria - 7000 15W-50
Yemen
37

GEARBOX OILS
TOTAL TRANSMISSION BV
Manual gearbox and SensoDrive Norms S.A.E. : 75W80
Part No. : 9730 A2.
TOTAL FLUIDE ATX
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
38

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
39

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
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 LDS
WARNING : CITROËN C5 : Use exclusively TOTAL FLUIDE LDS suspension fluid.
All countries TOTAL HYDRAURINCAGE
40

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.
41

ALL TYPES 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:

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

- 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 WORK 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.
42

ENGINE
ENGINE SPECIFICATIONS C5 - C8
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 24S
Engine type 6FZ RFN RLZ 3FZ XFZ XFW

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 11.4/1 10.8/1 10.9/1
Power ISO or EECKW - 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 19-4600 19-41000 19.2-4100 21.7-3900 28.5-3750
43

ENGINE
C5 - C8 ENGINE SPECIFICATIONS
Engines : RHS - RHZ - RHT - RHW - RHY - RHW - 4HX - 4HW
Diesel
2.0 HDi 2.0 HDi 16V 2.2 HDi
Engine type RHS RHZ RHT RHW RHY RHW 4HX 4HW
Bore / Stroke 85/88 86/96
Compression ratio 17.6/1 17.3/1 17.6/1 18/1 17.6/1
Power ISO or EEC KW - rpm 79-4000 80-4000 79-4000 66-4000 80-4000 98-4000 94-4000
Power DIN (HP - rpm) 107-4000 110-4000 109-4000 90-4000 110-4000 13.6-4000 130-4000
Torque ISO or EEC (m.daN - rpm) 25-1750 27-1750 20.5-1750 27-1750 31.7-2000 31.4-2000
44

ENGINE
COMPRESSION RATIO - DIESEL ENGINES C5
COMPRESSION MAX. DIFFERENCE

ENGINE
RATIO BETWEEN CYLINDERS
In bars
RHY
RHS
DW10 30 ± 5
RHZ 5
RHW
4HX DW12 20 ± 5
45

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

Engines : 6FZ - RFN - RLZ - RHY - RHS - RHZ - 4HX
Crankshaft Petrol Diesel
6FZ RFN RLZ RHY RHS RHZ 4HX
Bearing cap screws.

- Pre-tightening 2 ± 0.1 2.5 ± 0.2
- Angular tightening 60° ± 6° 60°
Con-rod cap screws.
- Tightening
1
- Slackening 180°
- Tightening 2.3 ± 0.2 2.3 ± 0.1
- Angular tightening 46° + 2° - 4° 46° ± 5
Con-rod nuts
- Pre-tightening 2 ± 0.2
- Angular tightening 70°
Accessories drive pulley
- Tightening 2.1 ± 0.1 4 ± 0.4 7 ± 0.25
- Angular tightening 51° 60°
Accessories drive pulley hub
- Angular tightening (Sintered washer) 40° ± 4°
- Angular tightening (Steel washer) 53° ± 5°
46

ENGINE
SPECIAL FEATURES : TIGHTENING TORQUES (m.daN) C5
Cylinder block Petrol Diesel
Piston skirt spray jet 1 ± 0.1

Sump
- Pre-tightening 1
- Tightening 0.8 ± 0.2 1.6 ± 0.2 1.6 ± 0.3
Timing belt guide roller
- Pre-tightening 1.5
- Tightening 3.7 ± 0.3 2.5 ± 0.2 4.3 ± 0.4
Timing guide roller
- Tightening 2.5 ± 0.2 4.3 ± 0.4
Timing belt tensioner roller 2.1 ± 0.2 2.5 ± 0.2

RH engine mounting
- Pre-tightening 1 (4 scews)
- Tightening 2 ± 0.2
(Ø 8)
- 4.5±0.2
- Tightening 6.1 ± 0.6 2.7 ± 0.2 (Ø10)
47

ENGINE

Cylinder head Petrol Diesel
Camshaft bearing cover

- Pre-tightening 0.5 ± 0.1 0.5 (Ø6)
- Tightening 0.9 ± 0.1 1 ± 0.1 1±0.1(Ø10)
Exhaust manifold
- Tightening 3.5 ± 0.3 2 ± 0.2 3 ± 0.3
Valve cover
- Pre-tightening 0.5 0.5 ± 0.15
- Tightening 1.1 ± 0.1 0.9 ± 0.1 0.8 ± 0.1 0.9 ± 0.1
Camshaft pulley hub 7.5 ± 0.7 4.3 ± 0.5
Hub pulley 2 ± 0.2
Flywheel / Clutch
Flywheel
- Pre-tightening 2 ± 0.2 1.5
- Tightening 21° ± 3° 4.8 ± 0.5 4.7 ± 0.4
Clutch plate 2 ± 0.2 2 ± 0.2
48

ENGINE
Lubrication circuit Petrol Diesel
Oil pump
- Tightening 0.9 ± 0.1 1.3 ± 0.1 0.9 ± 0.1
Coolant / oil heat exhanger 5.8 ± 0.5
Lubrication pipe
- Engine end 3 ± 0.3
- Turbocompressor end 2 ± 0.2
Injection circuit
Injector (Flange nut)
- Tightening 3 ± 0.3 0.4 ± 0.03
- Angular tightening 45° ± 5°
Union on injection rail 2 ± 0.2
Injection pump 0.5 ± 0.1 2.25 ±0.3
Union on injector 2 ± 0.2
Common rail fixing screw 0.9 ± 0.1 0.8 ± 0.1
Injection pump pulley 5 ± 0.5
Union on injection pump 2.6 ± 0.3 2 ± .02
Cooling circuit
Coolant pump 1.4 ± 0.1 1.6 ± 0.3
Coolant inlet housing 0.9 ± 0.1 2 ± .02
49

ENGINE
C5 CYLINDER HEAD
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 1.1 1.4
(mm)
Supplier MEILLOR
(d) Marking zone.

(e) Marking zone.
Multilayer metallic cylinder head gasket.
B1DP183D
50

ENGINE
CYLINDER HEAD C5
Cylinder head tightening (m.daN) Cylinder head bolts
6FZ - RFN - RLZ
Pre-tightening 1.5 ± 0.1

Tightening 5 ± 0.1
Slackening 360°± 2°
Tightening 2 ± 0.2
Angular tightening 285° ± 5°
(in the order 1 to 10)
B1DP16FC
A = Washer thickness : 4 ± 0.2 mm.

X = Length under heads of the new bolts = 144.5 ± 0.5 mm.
NOTE : Oil the threads and
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
Intervention est interdit. Molykote G Rapid Plus.) 6FZ - RFN - RLZ
B1DP05BC X= 147 mm
51

ENGINE

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 puis 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 No
Re-tightening 2.5 ± 0.2 1 ± 0.1
Angular tightening 46° ± 5° 22° ± 2°
B1BK1X8D
52

ENGINE
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
53

ENGINE
C8 SPECIAL FEATURES: POWER UNIT SUSPENSION

Upper RH engine support Engines : RFN – 3FZ
Description RFN 3FZ
Ref.
(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 engine support
(7) 6.5 ± 0.6
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 6 ± 0.6 4.5 ± 0.4
fixing screw.
B1BK1X6D (11) Flexible support pin. 5 ± 0.5
54

ENGINE
SPECIAL FEATURES: POWER UNIT SUSPENSION C8
Intermediate engine support Engines : RFN – 3FZ
Description RFN 3FZ
Ref.
(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 support

6.5 ± 0.6
fixing screw
B1BK1X7D
55

ENGINE
C8 CYLINDER HEAD
Engines : RFN - 3FZ
Multi-layer 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
56

ENGINE
CYLINDER HEAD C8
Engines : RFN - 3FZ
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
57

ENGINE

Engine : XFZ
(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

- Angular tightening 80° ± 8°
(13) Crankshaft pulley 2.5 ± 0.2
B1BP1HAP
58

ENGINE
Engine : XFZ
- 2 Cylinder head cover (A) Front cyl. head - (B) Rear cyl. head - 3 Bearing caps housing (A) Front cyl. head - (B) Rear cyl. head
B1DP08UD B1DP08TD
WARNING : Tighten screw by screw in the order shown.

- Pre-tighten 0.5 - Pre-tighten 0.2
- Tighten 1 ± 0.1 - Tighten 0.8
59

ENGINE

Engine : XFZ
- 5 Air inlet manifold - 6 Lower manifold (A) Front cyl. head - (B) Rear cyl. head
B1HPOLJC B1DP097C

- Pre-tighten 1 ± 0.1 - Pre-tighten 1 ± 0.1
- Tighten 2 ± 0.2 - Tighten 2.5 ± 0.2
60

ENGINE
Engine : XFZ
-7 Exhaust manifold (NEW gasket) -10 Oil sump
B1BP1GXD B1BP1GZD

- Pre-tighten 1 ± 0.1 - Pre-tighten 0.5 ±
- Tighten 3 ± 0.3 - Tighten 0.8 ±
61

ENGINE

Engine : XFZ
- 8 Crankshaft bearing
- Clean the threads of the screws with a brush.

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

- M11 = 131.5 mm.
- 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
62

ENGINE
Engine : XFZ
(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
63

ENGINE

Engine : XFZ
- 20 Oil vapour recovery housing.
WARNING : Tighten screw by screw in the order shown
- Pre-tighten 0.5 ±
- Tighten 1 ± 0.1
B1BP1H1D
64

ENGINE
CYLINDER HEAD C5
Engine : XFZ
Thickness
Supplier Thickness reference
(Standard) (mm)
Central lug
ERLING 0.75
Exhaust end
(1) LH cylinder head gasket.

Multilayer metallic cylinder head seal. (2) RH cylinder head gasket. B1DP18YD
65

ENGINE
C5 CYLINDER HEAD
Engine : XFX
In the order indicated.
- Slackening YES
- Pre-tightening 1.5 ± 0.2
- Angular tightening 225°
Note : Oil the threads and under the

heads of the bolts. (Use engine oil or
Molykote G Rapid Plus).
X = MAX. re-usable length

XFX
B1DP18ZD B1DP09VC 149.5 mm
66

ENGINE
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
(10) Fixing of flexible mounting on support : 3 ± 0.3
engine 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
67

ENGINE

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
68

ENGINE
Engine : XFW
Cylinder block
Bearing cap cover
Respect the sequence of stages and the order of tightening

M11 M8
Reference/description Bolts from 1 Bolts from 9 M6
to 8 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°
69

ENGINE

Engine : XFW
Lubrication circuit.
Lubrication circuit. Oil sump
B1BK24WD B1BK24XD

(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
Oil filter : 0.2
a tightening torque of 0,8 m.daN on all the bolts.
70

ENGINE
Engine : XFW
Lubrication circuit Cooling circuit
Oil pump Coolant pump
B1BK3B6D B1BK3B7D
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 Stage 4 : Repeat the tightening a few times in the same order to obtain a
a tightening torque of 0,8 m.daN on all the screws. tightening torque of 0,8 m.daN on all the screws.
71

ENGINE

Engine : XFW
Lubrication circuit Cylinder head equipment
Coolant manifold
B1BK24YD
(27) Screws : 2.5 ± 0.2

(28) Screws : 0.8
(29) Screws : 0.8
B1BK24ZD
72

ENGINE
Engine : XFW
Cylinder head equipment
Camshaft bearing cap cover (right hand side) Camshaft bearing cap cover (left hand side)
B1EK0GCC B1BK3B8D
(30) Camshaft bearing cap cover or camshaft bearing:

Pre-tighten to : 0.2
Tighten to :1
73

ENGINE

Engine : XFW
Valve covers (right hand side) Valve covers (left hand side)
B1EK0GEC B1EK0GFC
(31) Valve cover :
Tighten to : 0.8
74

ENGINE
Engine : XFW
Inlet manifold
B1BK251D
(32) Inlet manifold:

Tighten to : 0.8
75

ENGINE

Engine : XFW
Exhaust manifold (right hand side) Exhaust manifold (left hand side)
B1JK03ND B1JK03LD
(33) Exhaust manifold:
Pre-tighten to :1
Tighten to : 3 ± 0.3
76

ENGINE
Engine : XFW
Inlet distributor
B1BK252D
(34) Inlet distributor:

Tighten to : 0.8
77

ENGINE
C8 CYLINDER HEAD
Engine : XFW
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
78

ENGINE
CYLINDER HEAD C8
Engine : XFW
Pre-tightening :2
Slackening : YES
Tightening : 1.5
Angular tightening : 225°
NOTE : Grease the bolts on the

threads and under the heads,
using engine oil or Molykote G
plus).
B1DK0QPD
B1EK0XAD
149.5 mm
79

ENGINE

Engine : XFZ
- 7 Exhaust manifold (NEW gasket) - 10 Oil sump
B1BP1GXD B1BP1GZD
WARNING : Tighten screw by screw in the order indicated.

- Pre-tighten 1 ± 0.1 - Pre-tighten 0.5 ±
- Tighten 3 ± 0.3 - Tighten 0.8 ±
80

ENGINE
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
81

ENGINE

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
82

ENGINE
Engines : RHS - RHZ
Crankshaft Flywheel – Clutch

Bearing cap fixing screws Flywheel 4,8 ± 0,5
Pre-tightening 2,5 ± 0,2 Clutch plate 2 ± 0,2
Angular tightening 60° Lubrication circuit
Con rod nuts Oil pump 1,3 ± 0,1
Pre-tightening 2 ± 0,2 Coolant/oil hear exchanger 5,8 ±0,5
Angular tightening 70°
Accessories drive pulley Turbocharger lubrication pipe
9 RPO 8631 RPO 8631 9 Engine end 3 ± 0,3
Pre-tightening 4 ± 0.4 5 ± 0.5 Turbocharger end 2 ± 0,2
Angular tightening 51° ± 5° 62° ± 5° Diesel.injection circuit
Cylinder block Injector fixing flange nut 3 ± 0,3
Piston skirt spray jet 1 ± 0,1 Union on high pressure common injection rail
Sump 1,6 ± 0,2 Fuel 2 ± 0,2
Timing belt guide roller 2,5 ± 0,2 Injection pump on support 2,25 ± 0,2
Timing belt tensioner roller 2,5 ± ,02 Union on diesel injection 2,2 ± 0,2
RH engine support 2,7 ± ,02 Injection pump pulley 5 ± 0,5
Cylinder head
Union on fuel high pressure pump 2,2 ± 0,2
Camshaft bearing covers 1 ± 0,1
Exhaust manifold 2 ± 0,2 Cooling circuit
Valve cover 0,8 ± 0,1 Coolant pump 1,5 ± 0,1
Camshaft pulley 4,3 ± 0,5 Coolant inlet housing 2 ± ,02
Pulley on hub 2 ± 0,2
Poulie sur moyeu 2 ± 0.2
83

ENGINE
C5 CYLINDER HEAD
Engines : RHY - RHS - RHZ
Piston
Engine Thickness Number
stand-proud
plate (mm) of notches at A
(mm)
0.47 to 0.605 1.30 ± 0.06 1
0.605 to 0.655 1.35 ± 0.06 2
RHZ
0.655 to 0.705 1.40 ± 0.06 3
RHY
0.705 to 0.755 1.45 ± 0.06 4
0.755 to 0.83 1.50 ± 0.06 5
B1DP15AD
84

ENGINE
CYLINDER HEAD C5
RHY - RHS - RHZ RHY - RHS - RHZ
- Angular tightening 220°± 5°
NOTE : Oil the threads and under the B1DP15EC
heads of the bolts. (Use engine oil or X = MAX. re-usable length

Molykote G Rapid Plus).
RHY - RHS - RHZ
B1DP05BC 133.3 mm
85

ENGINE

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
86

ENGINE
Engine : 4HX
Crankshaft Cylinder block (continued)

Bearing cap fixing screws RH engine support
Pre-tighten 2,5 ± 0,2 Pre-tighten (the four screws to) 1
Angular-tighten 60° Tighten (the screws Ø 8 to) 2 ± 0,2
Rod cap screws Tighten (the screws Ø 10 to) 4,5 ± 0,2
Tighten 1 ± 0,1
Cylinder head
Slacken 180°
Camshaft bearing covers
Tighten 2,3 ± 0,1
Angular-tighten 46° ± 5° Tighten the studs to 1 ± 0,1
Accessories drive pulley Pre-tighten the 28 screws Ø 6 0,5
Tighten 7 ± 0,25 Tighten the 28 screws Ø 6 1 ± 0,1
Angular-tighten 60° ± 5° Exhaust manifold
Cylinder block Pre-tighten the 8 nuts to 1,5 ± 0,1
Piston skirt spray jet 1 ± 0,1 Tighten the 8 nuts to 3 ± 0,3
Sump Valve cover
Pre-tighten 1 ± 0,1 Pre-tighten the 13 screws to 0,5
Tighten 1,6 ± 0,3 Tighten the 13 screws to 9 ± 0,1
Timing belt guide roller Camshaft puley hub 4,3 ± 0,4
Pre-tighten 1,5 Pulley on hub 2 ± 0,2
Tighten 4,3 ± 0,4
Timing belt tensioner roller 2,5 ± ,02
87

ENGINE

Engine : 4HX
Flywheel – Clutch Diesel.injection.circuit

Flywheel Diesel injector (do up by hand)
Pre-tighten 1,5 Tighten 0,4 ± 0,04
Tighten 4,7 ± 0,4 Angular-tighten 45° ± 5°
Clutch plate 2 ± 0,2 Union on injection rail 2 ± 0,2
Lubrication circuit Injection pump on support 2,25 ± 0,2
Oil pump Union on diesel injection 2,2 ± 0,2
Pre-tighten 0,7 Injection pump pulley 5 ± 0,5
Tighten 0,9 ± 0,1 Union on injection pump 2,2 ± 0,2
Coolant/oil heat exchanger 5,8 ±0,5 Cooling circuit
Turbocharger lubrication pipe Coolant pump 1,6 ± 0,3
Engine end 3 ± 0,3 Coolant outlet housing 2 ± ,02
Turbocharger end 2 ± 0,2
88

ENGINE
CYLINDER HEAD C5
Engine : 4HX
Number of notches
Piston
Engine Thickness At At
stand-proud
plate (mm) A B
(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
89

ENGINE
C5 CYLINDER HEAD (Continued)

Engine : 4HX
4HX 4HX
ESSENTIAL : Proceed screw by screw in the

order indicated.
- Pre-tighten 2 ± 0.2 (Order 1 to 10).

- Tighten 6 ± 0.6 (Order 1 to 10).
- Destighten 360° (Ordre 10 to 1)
- Pre-tighten 2 ± 0.2 (Order 1 to 10).
- Tighten 6 ± 0.6 (Order 1 to 10).
- Angular-tighten 220° ± 5° (Order 1 to 10).
(in 2 attempts max.) NOTE : Oil the threads and under the
heads of the bolts. (Use engine oil or
Molykote G Rapid Plus). B1DP15EC

4HX
B1DP05BC X = 134.5 MM
90

ENGINE
CYLINDER HEAD C8
Engines : RHT - RHW - 4HW
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
91

ENGINE
C8 CYLINDER HEAD
Tighten cylinder head (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 bolts. (Use engine oil or Molykote G
Rapid Plus).
B1DK1M6D
RHT - RHW 4HW
134 mm 134.5 mm
B1DK00SC
92

ENGINE
BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE C5 - C8
Tools 4122-T (C.TRONIC.105.5) !
!
!
4099-T (C.TRONIC.105)
B1EP135D
93

ENGINE
C5 - C8 AUXILIARY EQUIPMENT DRIVE BELT

EW ES DW
7 10 12 9 10 12
J4 D J4 J4 TD ATED ATED4 TED TED4
Engine type 6FZ RFN RLZ 3FZ XFX XFW RHY RHS RHZ RHW RHT 4HX 4HW
C5 X X X X X X X X
106 to
See pages : 96 98 100 to 103
107
C8 X X X X X X
108 to
See pages : 97 97 99 104 to 105
109
94

ENGINE
AUXILIARY EQUIPMENT DRIVE BELT C5 - C8
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.
95

ENGINE
C5 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
96

ENGINE
AUXILIARY EQUIPMENT DRIVE BELT C8
Engines : RFN-3FZ
Tools
[1] Peg for dynamic tensioner roller (-).0189-E
Removing.
Remove:
The front RH wheel.
BXXK08DD
The front RH splash-shield.
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
97

ENGINE

Engine : XFX
Tools
[1] Ratchet spanner S.171 FACOM (1/2 square) S 171.
[2] Reduction box S.230 FACOM (1/2-3/8) S 230.
Remove.
Remove the engine cover.
Pivot the tensioner roller bracket (1) clockwise, until it locks,
using tools [1] and [2] at «a».
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
98

ENGINE
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.
Continue the refitting operations in reverse order to removal.

B1EK0VBD
99

ENGINE

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
100

ENGINE
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.
- 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
101

ENGINE

With air conditioning
Outillages
[1] Belt tension adjusting square : (-).0188 J2
[2] Ø 4 mm peg : (-).0188.Q1
[3] Ø 2 mm peg : (-).0188.Q2
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 ».
- Bring the eccentric roller (5) towards the rear.
- Tighten the screw (6) by hand.
- Remove the belt. B1BP1YLD
102

ENGINE
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.

New belt.
Refit the belt.

- Turn the eccentric roller (5), tool [1] (clockwise) to free the tool [2] from its pegging
at « d ».
- Hold the eccentric roller (5), tool [1], and tighten the screw (6) to 4.3 ± 0.5 m.daN.
- 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
103

ENGINE

Engines : RHT - RHW
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).
E5AK0E9C
(C) Zero wear mark.
(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.
B3EK0DHD
IMPERATIVE : Mark the direction of rotation of the belt if to be re-used.
104

ENGINE
Engine : RHT - RHW
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.
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
105

ENGINE

Engine : 4HX
Without air conditioning
Tools
[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
106

ENGINE
Engine : 4HX
With air conditioning
Tools
[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
107

ENGINE

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.
IMPERATIVE : Mark the direction of rotation of the belt if to be re-used.
E5AK0E8C
108

ENGINE
Engine : 4HW
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).
Rotate the engine four times.
Complete the refitting.
B1BK1IWD
109

ENGINE
C5 - C8 CHECKING AND SETTING THE VALVE TIMING

EW ES DW
7 10 12 9 10 12
J4 D J4 J4 TD ATED ATED4 TED TED4
Engine type 6FZ RFN RLZ 3FZ XFX XFW RHY RHS RHZ RHW RHT 4HX 4HW
C5 X X X X X X X X
9 2003 9 N° RPO 9128
111 to 114 136 to 141 150 to 154 164 to 169

See pages :
2003 9 N° RPO 9128 9
129 to 135 157 to 163
C8 X X X X X X
9 2003
115 to 120 121 to 126 142 to 149 170 to 177 170 to 177
See pages :
2003 9
129 to 135 129 to 135
110

ENGINE
CHECKING AND SETTING THE VALVE TIMING C5
Engines : 6FZ - RFN - RLZ 9 2003
Tools
[1] Camshaft setting pegs : (-).0189.A
[2] Crankshaft setting peg : (-).0189.B Toolkit C.0189.
[3] Belt retaining pin : (-).0189.K
[4] Adaptor for angular tightening : 4069-T
[5] Hub immobilising tool : 6310-T
Checking the valve timing.
- Turn the engine by the crankshaft pinion screw (1) to bring it to pegging position.
- Peg the crankshaft, using tool [2].
- Peg the camshaft pulleys, using tools [1].
NOTE : The pegs [1] should engage without effort.
WARNING : if the pegs do not engage without effort, restart the fitting and
tensioning of the timing belt (see below).
Setting the valve timing.
Remove.
- Remove the screws (2), the pulley (1), upper valve cover (4), lower valve cover (3).
- Turn the engine by the screw (13) of the pinion (12) to bring it to pegging position.
- Peg the pulleys (8) and (9) using tools [1].
- Peg the pinion (12) using tool [2].
- Loosen the screw (7) of the tensioner roller (6).
- Turn the tensioner roller (6) (clockwise).
- Remove the timing belt (10).
B1BP27JC B1BP25PC B1BP23XC B1EP14JD
111

ENGINE
C5 CHECKING AND SETTING THE VALVE TIMING

Refit
- Refit the belt (10) on the pinion (12).
- Hold the belt (10) with tool [3].
- Position the belt (10) in the following order :
- The guide roller (11), the inlet camshaft pinion (9), the exhaust camshaft pinion (8), the water pump (5), the ten-
sioner roller (6).
NOTE : Make sure that the belt (10) is as flush as possilble with the outer face of the various pinions and rollers.
- Remove the tools [3] and [1].
Timing belt.
Adjusting the tension.
- Turn the roller (6) in the direction of the arrow «b»; using an Allen key at «a».
- Position the index «c» in its maximum setting at «d».
IMPERATIVE : The index «c» must stand proud of the notch «f» by an angular value of 10°. If it does not,
replace the tensioner roller (6) or the timing belt and the tensioner roller (6)
Bring the index «c» to its adjusting position «f» by turning the tensioner roller (6) in the direction of the arrow «e»
WARNING: The index «c» must not stand proud of the notch «f» : if it does, restart the timing belt tensioning
operation.
IMPERATIVE : The tensioner roller (6) must not turn while its fixing is being tightened up. If it does, recom-
mence the adjusting operation.
B1EP14JD B1EP14KC
112

ENGINE
Adjusting the tension (continued).

-Tighten the screw (7) of the the tensioner roller (6) to 2.1 ± 0.2 m.daN.
IMPERATIVE : The hexagonal drive of the tensioner roller (6) must be at 15° below the level of the cylinder
head gasket «g». If not, replace the tensioner roller (6) or the timing belt and the tensioner roller (6).
Refit (continued).
-Remove the tools [1] and [2].
-Turn the crankshaft 10 times in the normal direction of rotation.
IMPERATIVE : No pressure or outside action must be brought to bear on the timing belt.
-Peg the inlet camshaft pulley, using the tool [1].
Checks.
Timing belt tension.
IMPERATIVE : Check the position of the index «c», it should be facing the notch «f». If the position of
index «c» is not correct, restart the adjustment of its position.
Positioning of the crankshaft.
-Fit tool [2].
-As long as it is possible to fit tool [2], continue with the refit operations.
IMPERATIVE : If it is not possible to fit tool [2], reposition the flange (14).
B1EP14MC B1EP14VC
113

ENGINE

Checks (continued)
Repositioning the flange.

- Immobilise the crankshaft using tool [5].
- Release the pinion (12) of the crankshaft.
- Bring the flange (14) to the pegging position; using tool [5].
- Fit the tool [2].
- Immobilise the crankshaft using tool [5].
- Tighten screw (13) to 4 ± 0.4 m.daN, then angular tighten to :
53° ± 4° (Assembly with steel washer, gold in colour)
40° ± 4° (Assembly with sintered washer, metallic in colour)
using the tool [4].
Remove tools [1], [2] and [5].
Refit :
- The lower valve cover (3).
- The upper valve cover (4).
- The screws (2).
- Pretighten the screws (2) to 1.5 m.daN.
- Tighten the screws (2) to 2.1 ± 0.5 m.daN.
B1EP14PC B1EP14JD B1BP23XC
114

ENGINE
Engine : RFN 9 2003
Tools.
[1] Crankshaft setting peg : (-).0189-B
[2] Camshaft hub setting pegs : (-).0189-AZ
[3] Belt retaining pin : (-).0189-K
[4] Positioning peg : (-).0189-J
[5] Tool for immobilising hub : (-).6310-T
Removing.
Disconnect the battery.
Remove:
B1EK1UDD B1EK0V7D
- 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).
- The screws (4), plus the auxiliary drive pulley.
- The timing covers (5) and (6).
WARNING : Do not slacken the fixing screws (A).
B1EK1T7D
115

ENGINE

Engine : RFN 9 2003
Peg :
- The camshafts, using tool [2].

- The crankshaft, using tool [1].
Slacken the screw (7) while holding tool [4].
Using the hexagonal recess (C), turn the eccentric hub (8) of the tensioner roller
(9) (clockwise), to detension the belt. The cursor (10) moves against the tool [4].
Remove the timing belt.
B1EK1UED B1EK1UFD
116

ENGINE
Engine : RFN 9 2003
Refitting.
Systematically replace the timing belt.
IMPERATIVE : Check that the rollers (9) and (11), as well as the coolant pump (12) turn freely (no
tight spot).
When replacing the belt (11), tighten the fixing to 3,5 ± 0,3 m.daN.
Position the belt on the crankshaft pinion (13), respecting its direction of fitting.
Immobilise the belt, using tool [3].
Refit the timing belt, well-tensioned, in the following sequence:

- Guide roller (11).
- Pinions (14) and (15).
- Coolant pump (12).
- Tensioner roller (9).
B1EK1T8D
117

ENGINE

Engine : RFN 9 2003
Tensioning the timing belt.

Remove tool [3].
(D) : Max. position.
(E) : Nominal tension position.
Using the hexagonal recess (C), turn the roller hub (anti-clockwise), to bring the index (10) to position (D) to
tension the belt to the maximum.
Turn the eccentric hub (8) of the roller (9) (clockwise), to bring the cursor (10) into light contact with the peg [4].
IMPERATIVE : Never make a complete rotation of the eccentric hub (8) when tool [4] is in position.
B1EK1T9D NOTE : This operation places the index (10) in the nominal position (E).
Tighten the screw (7) to 2 ± 0,2 m.daN while holding the roller by means of the hexagonal recess (C).
Remove the pegs [1], [2] and [4].
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 pegs [1] and [2].
Remove the pegs [1] and [2].
Make ten rotations of the crankshaft (direction of rotation of the engine).
Check the position of the index (10).
If the tensioner index is not in its adjustment position (E), recommence the operations to tension the timing belt.
B1EK1TAD
118

ENGINE
Engine : RFN 9 2003
Positioning the crankshaft.
NOTE : This operation positions all the pegs in their respective pegging points.
Peg:
- The camshaft pulleys, using tool [2].
If this is not possible, reposition the flange (17).
B1EK1TBD
IMPERATIVE : This operation guarantees the setting of the timing for subsequent operations.
Slacken the screw (16) so as to free the crankshaft pinion (17).

Bring the flange (17) to the pegging point, using tool [5].
Position tool [1].
Tightening of screw (16) (Tool FACOM D360).
Tighten to : 4 ± 0,4 m.daN
Angular tighten to : 53° ± 5°.
IMPERATIVE : When tightening screw (16), hold the pulley (17) in position, using tool [5].
B1EK1TCD
119

ENGINE

Engine : RFN 9 2003
Refitting (continued).
Refit:
- The timing cover (6).
- The auxiliary drive pulley.
- The screws (4), tighten to 2,1 ± 0,2 m.daN.

B1EK0V7D
- The screws (1) and (2), tighten to 4,5 ± 0,4 m.daN.
Refit the auxiliary drive belt (see corresponding operation).
B1EK1T7D
120

ENGINE
Engine : 3FZ 9 2003
Tools.
[1] Crankshaft setting peg : (-).0189-B
[2] Exhaust camshaft setting peg : (-).0189-AZ
[3] Inlet camshaft setting peg : (-).0189-L
[4] Positioning peg : (-).0189-J
B1EK0V1D
[5] Tool for immobilising hub : 6310-T
[7] Engine support crossmember : 4090-T
Removing.
Remove:
B1EK1SJD - The under-engine shield.
Uncouple the exhaust line (to avoid damaging the flexible pipe).
Position the tool [7].
Move aside:
- The fuel delivery pipe.
- The canister purge electrovalve.
- The expansion chamber.
B1EK1SLD
121

ENGINE

Engine : 3FZ 9 2003
Remove:
- The screws (1) and (2).
- The nut (4).
- The 3 screws (5).
- The RH engine support (6).
- The screws (7), plus the auxiliary drive pulley.
- The timing covers (8) and (9).
B1EK1SUD B1EK1SMD
WARNING : Do not slacken the fixing screws (A).
IMPERATIVE : Do not slacken the fixing screws (B).
Peg:
- The exhaust camshaft, using tool [2].
- The inlet camshaft, using tool [3].
B1EK1SKD
122

ENGINE
Engine : 3FZ 9 2003
Position tool [4].

Slacken the screw (10) while holding tool [4].
Using the hexagonal recess (D), turn the eccentric hub (11) of the tensioner roller (12) (clockwise), to detension the
belt. The cursor (13) moves against the tool [4].
Refitting.
Systematically replace the timing belt.

B1EK1SMD
IMPERATIVE : Check that the rollers (12) and (14), as well as the coolant pump (15) turn freely (No play,
no tight spot).
When replacing the belt (14), tighten the fixing to 3,5 ± 0,3 m.daN.
Position the belt on the crankshaft pinion (16), respecting its direction of fitting.
Refit the timing belt, well-tensioned, in the following sequence:
- Pinion (17).
- Pinion (18).
B1EK1SND - Tensioner roller (12).
123

ENGINE

Engine : 3FZ 9 2003

Remove tool [6].
(E) : Max. position.
(F) : Nominal tension position.
Using the hexagonal recess (D), turn the roller hub (anti-clockwise), to bring the index (13) to position (E) to
tension the belt to the maximum.
Turn the excentric hub (11) of the roller (12) (clockwise), to bring the cursor (13) into light contact with the tool [4].
IMPERATIVE : Never make a complete rotation of the eccentric hub (11) when tool [4] is in tension.
B1EK1SPD NOTE : This operation places the index (13) in the nominal position (F).
Tighten the screw (10) to 2 ± 0,2 m.daN while holding the roller by means of the hexagonal recess (D).
Remove the tools [1], [2], [3], and [4].
Checks.
Make two rotations of the crankshaft (direction of rotation of the engine).
Make sure that the timing is correctly set, by refitting the camshaft and crankshaft setting pegs.
Remove the pegs.
Make ten rotations of the crankshaft (direction of rotation of the engine).
Check the position of the index (13).
If the tensioner index is not in its adjustment position (F), recommence the operations to tension the timing belt.
B1EK1SQD
124

ENGINE
Engine : 3FZ 9 2003
Positioning the crankshaft.
NOTE : This operation positions all the pegs in their respective pegging points.
Peg:
- The inlet camshaft pulley, using tool [3].
If this is not possible, reposition the flange (20).
B1EK1SRD
IMPERATIVE : This operation guarantees the setting of the timing for subsequent operations.
Immobilise the crankshaft, using tool [5].

Slacken the screw (19) so as to free the crankshaft pinion (16).
Bring the flange (20) to the pegging point, using tool [5].
Position tool [1].
Tightening of screw (19) (Tool FACOM D360).
Tighten to : 4 ± 0,4 m.daN
Angular tighten to : 53° ± 5°.
B1EK1SSD
125

ENGINE

Engine : 3FZ 9 2003
Refit:
- The auxiliary drive pulley.

B1EK1STD
Tighten:
- Screws (5) to 6 ± 0,6 m.daN.
- Nut (4) to 4,5 ± 0,4 m.daN.
- Screws (1) and (2) to 4,5 ± 0,4 m.daN.
B1EK1SUD
126

ENGINE
CHECKING AND SETTING THE VALVE TIMING ALL TYPES
OLD FITTING 9 2003 Engine : 6FZ - RFN - RLZ - 3FZ 9 2003
(1) Crankshaft pinion.
(2) Flange.
(3) Accessories drive pulley.
(4) Screw for fixing accessories drive pulley on the flange (2).
(5) Screw for fixing the flange (2) on the crankshaft.
«a» Integral keyway.
«b» Keyway slot.
The timing belt drive pinion (1) is separate from the flange (2).
With the screw (5) for fixing the flange (2) not tightened, the pinion (1) floats within the limit of
travel of the integral keyway «a» in the keyway slot «b».
NOTE : The flange is immobilised on the crankshaft by a half-moon keyway and by the screw (5).
B1EP1B8D
127

ENGINE
ALL TYPES CHECKING AND SETTING THE VALVE TIMING

NEW FITTING 2003 9 Engine : 6FZ - RFN - RLZ - 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 the shouldering of the washer (8) with the screw (9).
A : Pegging on manual gearbox.
B : Pegging on automatic gearbox.
B1EP1B9D
The crankshaft is pegged on the flywheel or on the converter drive plate (automatic gearbox).
The peg hole on the cylinder block (exhaust side) 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 camshafts.
IMPERATIVE : Always turn the crankshaft in the direction of rotation of the engine.
B1BP2V2D
128

ENGINE
Engines : 6FZ - RFN - RLZ - 3FZ 2003 9
Tools.
[1] Camshaft setting peg : (-).0189.A
[2] Crankshaft setting peg : (-).0189.R
[4] Adaptor for angular tightening : 4069-T
[5] Tool for manœuvring and locking the tensioner roller : (-).0189.S
[5a] : (-).0189.S1
[5b] : (-).0189 S2
Pliers for removing plastic pins : 7504-T
Checking the setting of the timing
Removing.
Disconnect the battery negative terminal (See corresponding operation).
Raise and support the vehicle, front wheels hanging.
Remove:
The front RH wheel.
The plastic pins (1)
The splash-shield (2)
The upper timing cover.
C4AP12TC
129

ENGINE

Engine : 6FZ - RFN - RLZ - 3FZ 2003 9
Checking the setting of the timing (continued).
Rotate the engine using the crankshaft pinion screw to bring it to the pegging position..
Peg the crankshaft, using tool [2].
Peg the camshaft pulleys, using tool [3]
B1BP2V5D WARNING : If the pegs are difficult to engage, repeat the operation to fit and tension the timing
belt (See corresponding operation)
Refitting.
Remove tools [2] and [3].
Complete the refitting in the opposite order to removal.
B1EP1BAC
130

ENGINE
Setting the timing.
Removing.
Disconnect the battery negative terminal (See corresponding operation).
Raise and support the vehicle, front wheels hanging.
Remove:
The front RH wheel.
The plastic pins (1)
The splash-shield (2)
The accessories drive belt (See corresponding operation).
Unclip and move aside the fuel delivery pipe from the timing cover.
Remove the upper timing cover (1).
Rotate the engine using the screw (3) of the crankshaft pulley (2) to bring it to the pegging position.
C4AP12TC
131

ENGINE

Engine : 6FZ - RFN - RLZ - 3FZ 2003 9
Setting the timing (continued)
Peg:
The crankshaft, using tool [2]
The camshaft pulleys (5) and (6), using tool [1]
Remove:
B1EP1B9D The screw (3) of the crankshaft pulley (2).
The lower timing cover (4) (by moving the engine).
IMPERATIVE : Never remove the crankshaft pulley (2) without pegging the crankshaft and
camshafts.
Slacken the screw (9) of the tensioner roller (8).

Turn the tensioner roller (8) (clockwise).
Remove the timing belt (7).
B1EP1BBD
132

ENGINE
Setting the timing (continued)
Turn the tensioner roller (8), using tool [5a] to go past the notch (b).
Position tool [5b] to lock the index (a) and remove tool [5a].
Reposition the timing belt (7) on the crankshaft pulley.
Hold the timing belt (7) using tool [3].
Fit the timing belt (7) in place, strictly in the following sequence:
- Inlet camshaft pulley (6).
- Exhaust camshaft pulley (5).
B1EP1BCD
NOTE : Make sure that the belt (7) is as flush as possible with the outer face of the various pinions and
rollers.
Remove :
- Tool [3].
- Tool [1] from the exhaust camshaft pulley.
- Tool [5b] from the tensioner roller (8).
Refit :
- The lower timing cover (4) (by moving the engine).
- The crankshaft pulley (2)
- The screw (3) of the crankshaft pulley.
Tighten the screw (3) to 4 ± 0,4 m.daN, then angular-tighten to 53° ± 4°, using tool [4].
B1EP1BDC
133

ENGINE

Turn the tensioner roller (8) in the direction of the arrow « c », by means of a hexagonal spanner at « d ».
Positionner l’index « a » en poition « f »
IMPERATVE : 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 ».
B1EP1BEC
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 (9) 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 ».
B1EP1BFC
If it is not, replace the tensioner roller or the timing belt and tensioner roller assembly.
134

ENGINE
Refitting (continued)
Remove the tools [1] and [2].
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 [1].
B1EP1BEC 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 (1).

Clip the fuel delivery hose on the timing cover.
Refit the accessories drive belt (See corresponding operation).
Lower the vehicle.
B1EP1BFC
Reconnect the battery (See corresponding operation).
135

ENGINE

Engine : XFX
OUTILLAGES
[1] Camshaft setting pegs (-).0187.B

[2] Crankshaft setting peg (-).0187.A.
[3] Fuel pressure take-off union 4192-T
[4] Belt retaining pin (-).0187.J
[5] Exhaust camshaft hubs immobilising tool (-).0187.F.
[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 upper timing covers (9) and (10).
- The lower timing cover (13).
B1BP2BKC
136

ENGINE
Engine : XFX
Checking the valve timing setting (continued).

- Check that the tool [2] engages without effort in the cylinder heads at the camshaft pulleys.
Refit :
- The lower timing cover (13).

- The upper timing covers (9) and (10).
- The roller / dynamic tensioner assembly (11).
- The power steering pulley.
- Complete the refitting of components.
- Initialise the ignition injection ECU.
B1EP08TC B1EP15UD
137

ENGINE

Engine : XFX
Setting the valve timing

- Remove the components as necessary for the operation.
- Remove the screws (19) and the plate (20).
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
138

ENGINE
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 1/4 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 enga-
ge the next tooth. The angular displacement of the pulleys should not be more than the equiva-
lent of one tooth.
B1EP15VD B1BP2BLC
139

ENGINE

Engine : XFX
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
140

ENGINE
Engine : XFX

- 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.
- 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.
- Refit the panel (20), the screws (19) and tighten to 4 ± 0, m.daN.
- Complete the refitting of all components.
B1EP15XC
141

ENGINE

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.
142

ENGINE
Engine : XFW
Remove:
The twelve screws (3) (6mm external hexagonal adaptor).

The seven screws (4) (7mm external hexagonal adaptor).
The two covers (5).
The cover (6).
B1EK005D The fixing screws of the power steering pump, then suspend the latter. B1EK007D
The support (7).
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
143

ENGINE

Engine : XFW
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 1/4 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.
B1EK009D
144

ENGINE
Engine : XFW
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
145

ENGINE

Engine : XFW
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
146

ENGINE
Engine : XFW
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.

B1EK00ED
Slacken the nut (11) a 1/4 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.

Check the position of the tensioner roller.
If the marks are not aligned, recommence the alignment of the marks (D) and (E) of the
B1EK0VRD tensioner roller.
147

ENGINE

Engine : XFW
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
148

ENGINE
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].
Refit:
The power steering pump.
The support (7).
The tensioner roller assembly (1).
Tighten:
Screw (22) to 2,5 m.daN + LOCTITE FRNETANCH.
Tighten the crankshaft pulley screws to 2,5 ± 0,2 m.daN.
Complete the refitting operations in the opposite order to removal.
B1EK00JD
149

ENGINE

9 N° RPO 9127
Tools
[1]Belt tension measuring instrument : 4122-T
[2]Tension lever : (-).188.J2
[3]Engine flywheel peg : (-).188.X
[4]Belt retaining pin : (-).0188.K
[5]Camshaft pinion peg : (-).0188.M
[6]Engine flywheel lock : (-).0188.F
[7]Set of blocking plugs : (-).0188.T
[8]Crankshaft pulley extractor : (-).0188.P
Checking the setting of the valve timing.
Peg : - The engine flywheel, using tool [3]. (From under the vehicle)
- The camshaft, using tool [5].
WARNING : On removing screws (6), (7), (9), and (5) of the timing cover, refit the
screw (5) equipped with a spacer (thickness: 17 mm)
Tighten to 1,5 ± 0,1 m.daN.
(The screw (5) is one of the screws fixing and sealing the water pump).
WARNING : Should it be impossible to peg the camshaft, check that the off-
set between the camshaft pinion hole and the pegging hole is not more than
1 mm, with the help of a mirror " a " and a Ø 7 mm screw.
IMPERATIVE : If pegging is impossible, restart the adjusting.
(See corresponding operation).
B1EP14AC B1BP282C B1EP152D B1BP1YSC
150

ENGINE
Engines : RHY - RHS - RHZ 9 N° RPO 9127
Peg :
The engine flywheel, tool [3]. (From under the vehicle)
The camshaft, tool [5].
Slacken :
The three screws (9).
The screw (7) of the tensioner roller (6).
Checks :
IMPERATIVE : Just before refitting, carry out the checks below:
Check that :
- The rollers (20), (23) and the water pump turn freely (without play or tightness).
- There are no traces of oil (on camshaft or crankshaft).
- There are no leaks of coolant fluid (from water pump).
- Replace defective components (if necessary).
B1BP282C B1EP152D
151

ENGINE

9 N° RPO 9127
Setting the valve timing (continued).
- Retighten the screws (21) by hand.

- Turn the pinion (24) (clockwise) to the bottom of the buttonhole.
- Refit the belt on the crankshaft (25)
- Hold the belt, using tool [4].
Reposition the timing belt, keeping the belt tight at "a", in the follo-
wing order :
- Fuel high pressure pump pinion (26).
- Camshaft pinion (24).
- Water pump pinion (18).
NOTE : If needed, slightly turn the pinion (24) anti-clockwise (not by

more than one tooth).
- Remove the tool [4].
B1EP153D B1EP154C B1EP155D
152

ENGINE
Position tool [1] on the belt at "b".

Turn the roller (20) (anti-clockwise) using tool [2] to attain a tension of :
98 ± 2 SEEM units
Tighten the screw of the roller (19), tighten to 2.5 m.daN.
Remove one screw (21) from the pinion (24).
(to check that the screws are not against the end of the buttonhole).
Tighten the screws (21) to 2 m daN.
Rotate the crankshaft 8 times (normal direction of rotation).
Fit the tool [3].
Loosen screws (21).
Fit tool [5].
Loosen screw (19) (to free the roller.
Fit tool [1].
Turn the roller (20) (anti-clockwise), tool [2], to attain a tension of :
54 ± 2 SEEM units.
B1EP156D
153

ENGINE


Tighten :
The screw of the roller (19) to 2.5 ± 0.2 m.daN.
The screws (21) to 2 ± 0.2 m.daN
Refit the tool [1].
Tension value should be :
54 ± 3 SEEM units
IMPERATIVE : If value is incorrect, restart the operation.

Fit the tool [3].
WARNING : 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.
- Déposer l'outil [3].
- Terminer la repose des éléments.
B1EP156D
154

ENGINE
SPECIAL FEATURES : CHECKING AND SETTING THE VALVE TIMING C5
Engines : RHY - RHS - RHZ N° 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 DW 10ATED
(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 sensor
target).
(6) "Idler" crankshaft pinion (with increased width keyway groove).
The determining of the tension of the timing belt is done on the crankshaft
pinion (6).
155

ENGINE
C5 SPECIAL FEATURES : CHECKING AND SETTING THE VALVE TIMING

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
156

ENGINE
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.
Remove :
[5] Camshaft pulley peg : (-).0188.M The under-engine sound-deadening.
The front RH wheel.
[6] Engine flywheel lock : (-).0188.F. The front RH splash-shield.
The engine cover.
[7] Set of blocking plugs : (-).0188.T. Unclip and move aside the cooling hose.
Remove the accessories drive belt.
[8] Pulley extractor : (-).0188.P. (See corresponding operation).
[9] 2 mm dia.peg : (-).0188.Q2
B1EP159D
157

ENGINE

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
158

ENGINE
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
159

ENGINE

Slacken the screw (17) of the tensioner roller (18).
Remove the timing belt (14).
Checks.
IMPERATIVE : Just before refitting, carry out the checks below :

B1EP1A8D
Check that :
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
160

ENGINE
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.
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
161

ENGINE

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.

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
162

ENGINE
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.
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.
Reposition and reclip the cooling hose.
Complete the refitting of components in reverse order to removal.
B1EP1A7C B1BP2R4C B1EP1ADC
163

ENGINE

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 spe-

cific 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
markings on the chain (b) and (c) with the teeth marked (a) and (d) of the
camshaft drive pinions (40 turns max. of the camshaft).
B1EP159D
164

ENGINE
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 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).
B1BP298C B1EP15AD
165

ENGINE

Engine : 4HX

- Turn the crankshaft to bring camshaft to its pegging point.
- 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
166

ENGINE
Engine : 4HX
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 :
- Fuel high pressure pump pinion (30).
- Camshaft pinion (29).
- Water pump pinion (22).
NOTE : If needed, slightly turn the pinion (29) anti-clockwise (not by more
than one tooth).
B1EP15BD B1EP15CC B1EP15DD
167

ENGINE

Engine : 4HX

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.
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
168

ENGINE
Engine : 4HX

Refit the tool [1].
Tension value should be :
51 ± 3 SEEM units.
IMPERATIVE : If value is incorrect, restart the operation.

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.

- Complete the refitting of components.
B1EP15ED
169

ENGINE

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.
170

ENGINE
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
171

ENGINE

Move aside the header tank.
Position the tools for supporting the engine [10], [11], [12] and [13].
Remove:
- The scuttle panel grille.
- 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 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
172

ENGINE
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.
B1EK0TYC
173

ENGINE

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).
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
174

ENGINE
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 recommen-
ce the operation

B1EK1T1D
175

ENGINE

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 nut (12), tighten to 4,5 ± 0,4 m.daN.6
IMPERATIVE : Apply an opposite torque at (A).
Refit:
- Screw (14), tighten to 5 ± 0,5 m.daN.
- Screw (15), tighten to 5 ± 0,5 m.daN.
B1EK1T0D
176

ENGINE
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
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
177

ENGINE
ALL TYPES VALVE CLEARANCES

POSSIBLE PROCEDURES
The valve clearances must be checked with the engine cold
For engines with 4 cylinders in a line (1-3-4-2 )
Rocking Fully open (Exhaust)
● Inlet Exhaust
Valves
Rocking Adjust fully Adjust
open
ALL TYPES Hydraulic adjustment 1● 1 4● 4 Inlet 1 3 ● 4
3● 3 2● 2 3 4 ● 2
4● 4 1● ● 4 2 ● 1
1
Exhaust
2● 2 3● 3 2 1 ● 3
Engines without hydraulic

adjustment : the clearance (J)
should be checked opposite
the cam.
B1DP13QC
178

ENGINE
CHECKING THE OIL PRESSURE C5
Tools Petrol engines
Toolkit 4103 -T
1.8i 16V 2.0i 16V 2.0 HPi 3.0i V6

Temperature (°C) 90°C
Pressure (Bars) 1.5 5 1.5 5 1.5 5 7 8
Rpm 1000 3000 1000 3000 1000 3000 900 3000
Diesel engines
2.0 HDi 2.2 HDi
Engine type RHY - RHS - RHZ 4HX

Temperature (°C) 90°
Pressure (Bars) 2 4 2 4 2 4
Rpm 1000 2000 1000 2000 1000 2000
ESSENTIAL : Respect the safety and cleanliness recommendations.
WARNING : Oil pressure should be checked with the engine cold, after checking the oil level.
179

ENGINE
C8 CHECKING THE OIL PRESSURE

Petrol engines
2.0i 16V 2.2i 16V 3.0i 24S
Engine type RFN 3FZ XFW
Pressure (Bars) 1.5 5 3.4 6.3 6.9 1.2 2 5
Rpm 1000 3000 1000 2000 4000 650 900 3000
Diesel engines
2.0 HDi 2.2 HDi

Engine type RHT- RHW 4HW
Pressure (Bars) 2.0 4.0 2.0 4.0
Rpm 1000 2000 1000 2000
WARNING : Oil pressure should be checked with the engine cold, after checking the oil level.
180

ENGINE
FILTRES A HUILE C5
To be read together with the petrol and diesel correspondence tables
6FZ RFN RLZ XFX RHY RHS RHZ 4HX
LS 923 X X X X X X X
PURFLUX
LS 880 A X
Ø (mm) Height (mm)

LS 923 76 89
Specifications
LS 880 A 86 97
181

ENGINE
C8 CHECKING THE OIL PRESSURE

To be read together with the petrol and diesel correspondence tables
RFN - 3FZ XFW RHW - RHT - 4HW
LS 923 X X
PURFLUX
LS 880 A X
Ø (mm) Height (mm)

LS 880 A 76 89
Specifications
LS 923 86 97
182

ENGINE
FILLING AND BLEEDING THE COOLING CIRCUIT C5
TOOLS
[1] Filling cylinder : 4520-T
[2] Adaptor for filling cylinder : 4222-T.

- 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 - 15°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
183

INJECTION
C5 - C8 IDLING - DEPOLLUTION
Idling speed
% Content
Emission (± 50 rpm)
Vehicles Engine type Make - Injection type
standard Manual Auto. gearbox: CO CO2
gearbox N engaged
1.8i 16V L4 SAGEM

6FZ 700
EW7J4 IF/L5 S2000
2.0i 16V M. MARELLI

RFN IF/L5 800
EW10J4 48P2
C5 < 0.5 >9
2.0i 16V HPi SIEMENS
RLZ L4 900
EW10D SIRIUS 81
3.0i V6 BOSCH 600

XFZX IF/L5 650
ES9J4 ME 7.4.6.
2.0i 16V M. MARELLI

RFN IF/L5 800
EW10J4 4MP2
2.2i 16v M. MARELLI

C8 3FZ IF/L5 < 0.5 >9
EW12J4 4MP2
3.0i V6 BOSCH
XFZX IF/L5 650 600
ES9J4 ME 7.4.6
184

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
EW7J4 EW10J4 EW10D ES9J4S EW10J4 EW12J4 ES9J4S
INJECTION
Engine type 6FZ RFN RLZ XFX RFN 3FZ XFX
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
12.2 14.5 1.88 16 14.5 14.5 16
deceleration (rpm)
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
185

ALL TYPES DEPOLLUTION TECHNICAL CHECKS (FRANCE)
All Types Petrol CO Corrected (In %) All Types Diesel (m-1)
Conditions : At idle, engine warm.

INJECTION
# 01/96
Less than 4.5 % for vehicles registered before 10/86. 01/96 #
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.
186

EMISSION STANDARDS ALL TYPES
STANDARD APPLICATIONS
PSA NOTES CHARACTERISTICS
E.E.C. Engines Vehicles Applicable
A/S RP
INJECTION
➞ Utility vehicle limits
➞ 10/89 = private vehicle limits
With oxygen sensor,
ECE increased by 25 %
K 15.04 Petrol Utility vehicles : without catalytic
R 15.04 K’ 15.04 Diesel converter
All Types
➞ For private vehicles
imminent and utility vehicles
in major export
Private vehicles : Brussels directive 88/76

ECE
15.05 Petrol > 2 litres « Luxembourg Accords »
R 15.05 W vp
• new models 01/10/88 ➞ ➞ Replaced by 89/458
• existing models 01/10/89 ➞ + 91/441
187

ALL TYPES EMISSION STANDARDS
A/S RP
Private vehicles :
INJECTION
Petrol • certain non-EEC With oxygen sensor and

US 83 Z US 83 Current ➞ Adoption of U.S. standard catalytic converter for
Diesel European countries
• certain Export countries petrol vehicles
Private vehicles :
Petrol • certain non-EEC ➞ Adoption of U.S. standard With catalytic converter
US 87 Y US 87 Current
Diesel European countries and EGR
• certain Export countries
Petrol Private vehicles :

US 93 Y2 US 93 Current ➞ Adoption of U.S. standard
Diesel • certain Export countries
188

A/S RP
INJECTION
Private vehicles :
US 84 Petrol • certain non-EEC ➞ Adoption of U.S. standard
X1 US 84 Current
LDT Diesel European countries Utility vehicles légers
Private vehicles :
X2 US 87 Current
Private vehicles :
X3 US 90 Current
189

A/S RP
With oxygen sensor and

INJECTION
reinforced catalytic
Private vehicles : Brussels Directive 94/12
EURO 2 converter for petrol
Petrol < 6 seats and
CEE vehicles.
L3 < 2.5 tonnes
(EURO 95 Diesel ➞ EURO 93 standard made
• new models 01/96 ➞ With catalytic converter
96) stricter
• existing models 01/97 ➞ and EGR for diesel
vehicles.
Utility vehicles : Brussels Directive 96/69

With oxygen sensor and
< 3.5 tonnes reinforced catalytic
EURO 2
Petrol
Class 1 : ➞ 3 class depending on converter for petrol
W3 CEE • new models 01/97 ➞
Diesel vehicle weight vehicles.
(EURO 95 Gas
• existing models 10/97 ➞
96) Class 2/3 : Class 1 < 1250 kg With catalytic converter
• new models 01/98 ➞ Class 2 : 1250/1700 kg and EGR for diesel
• existing models 10/98 ➞ Class 3 : 1700 kg vehicles.
190

A/S RP
Utility vehicles : Brussels Directive 98/69
INJECTION
With 2 oxygen sensors
< 3.5 tonnes ➞ EURO 2 standard (L3) and catalytic converter for
made stricter petrol vehicles.
EURO 3 Petrol Class 1 : ➞ Fiscal incentives With catalytic converter
W3 Diesel • new models ➞ 01/2000 ➞ 3 classes depending on and EGR for diesel
(EURO Gas
2000) • existing models ➞ 01/2001 vehicle weight : vehicles.
Class 2/3 : Class 1 < 1305 kg
• new models ➞ 01/2001 With EOBD on-board
Class 2 : 1305/1760 kg
• existing models ➞ 01/2002 diagnosis.
Class 3 : 1760 kg
Private vehicles : Brussels Directive 99/102 With 2 oxygen sensors

All Types and catalytic converter for
petrol vehicles.
EURO 4 IF / L5 Petrol ➞ EURO 3 standard (L4)
• new models ➞ 01/2005 made stricter
• existing models ➞ 01/2006 With EOBD on-board
➞ Fiscal incentives diagnosis.
191

A/S PR
Brussels Directive: 2001/1 With 2 oxygen sensors

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

2001/1 (Gas)
< 3.5 tonnes ➞ EURO 3 standard (L4) made With 2 oxygen sensors
stricter and catalytic converter for
Petrol Class 1 : ➞ Fiscal incentives petrol vehicles.
EURO 4 IF / L5
Gas • new models ➞ 01/2005 ➞ 3 classes depending on
• existing models ➞ 01/2006 vehicle weight : With EOBD on-board
Class 2/3 : Class 1 < 1305 kg diagnosis.
• new models ➞ 01/2006 Class 2 : 1305/1760 kg
• existing models ➞ 01/2007 Class 3 : 1760 kg
192

PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM C5 - C8
Engines : RHY - RHS - RHZ - 4HX - RHW - RHT - 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
193

C5 - C8 PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM
Engines : RHY - RHS - RHZ -4HX Engines : RHY - RHS - RHZ - 4HX - RHW - RHT - 4HW Engines : RHW - RHT - 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
194

SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM C5 - C8
Engines : RHY - RHS - RHZ - 4 HX
SAFETY REQUIREMENTS
Preamble.
All interventions on the injection system must be carried out to conform with the following requirements and regulations :
- Competent health authorities.
INJECTION
- 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.
195

C5 - C8 SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM
Engines: RHY - RHS - RHZ - 4HX
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.
196

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] et [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
197

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.
More than 4 Bar More than 0.8 Bar Check the fuel return circuit (pipe pinched or trapped....).
Check the fuel suppy circuit :
Between 0.8 and 1.5 Bar Less than 0.8 Bar - 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 : Notes
The flow should be drop by drop Diesel injector functioning correctly
Excessive fuel return Diesel injector locked shut.
198

AIR SUPPLY CIRCUIT SPECIFICATION C5
Engine : RHY
INJECTION
(1) Air filter PSA 7899.
(2) Flowmeter SIEMENS.
(3) Water / recycled gas exchanger VALEO.
(4) EGR valve PURFLUX.
(5) Turbocharger KKK K03.
(6) Air butterfly MAGNETI MARELLI

48W7 Ref. 648
B1HP1A6D
199

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.
(12) Turbocharging pressure sensor NIPPON DENSO.
B1HP1A7P
200

AIR SUPPLY CIRCUIT SPECIFICATION C5
Engine : 4HX
(1) Air / air exchanger
INJECTION
(2) Air / water exchanger
(3) Warm air metering device BOSCH.
(4) Cold air metering device BOSCH.
(5) Turbocharger ALLIEDSIGNAL GT1549P.
(6) Flowmeter SIEMENS.
B1HP1BYP
201

C5 AIR SUPPLY CIRCUIT SPECIFICATION
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
202

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 0.6 Bar
4000 0.25 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».
203

C5 CHECKS : EXHAUST GAS RECYCLING CIRCUIT
(1) Butterfly housin (3) Electrovalve (black 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).
Engine speed (rpm) Vacuum value (bar)
780 0.5 Bar
2500 0 Bar
B1HP1BVD
204

CHECKS : EXHAUST GAS RECYCLING CIRCUIT C5
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
205

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).
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).
Engine speed (rpm) Vacuum value (bar)

780 0.5 Bar
2500 0 Bar
B1HP1B8D
206

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
207

C5 CHECKS : TURBO PRESSURE
Engine : RHY Engines : RHY - RHS - RHZ
TOOLS.
[1] Pressure gauge for checking boost pressure : 4073-T.A Kit 4073-T
[2] Sleeve for checking boost pressure : 4185-T
[3] Adaptor sleeve : 4219-T
INJECTION
Checks.
Preparation for RHY engine
Remove :
- The collars (3).
- The sleeve.
- Insert the tool [2] between the tube (1) and the duct (2).
Engines : RHS - RHZ
- Position the tool [1] in the vehicle.
- Connect the pressure gauge [1] to the tool [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 BHP12JD
208

CHECKS : TURBO PRESSURE C5
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.
Refit:
- The sleeve.
- The collars (3).
- Tighten the collars (3).
C5FP0ACC
209

C5 CHECKS : TURBO PRESSURE
Engine : 4HX
Tools
[1] Pressure gauge for checking pressure 7073-T.A.
[2] Extension cable for taking pressure 8607-T.A
[3] Union and hose for taking pressure 8607-T.B.
INJECTION
[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
210

CHECKS : TURBO PRESSURE C5
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.».
Connect the extension [2] on the hose «b» and tool [5].
INJECTION
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
211

C5 INJECTION PUMP SPECIFICATIONS (BOSCH and SIEMENS).
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
212

SPARKING PLUGS C5 - C8
Vehicles - Models EYQUEM Tightening torque

Engine type BOSCH Electrode gap
(m.daN)
1.8I 16V 6FZ

RFN 52 HZ 0.9 ± 0.05 2.75 ± 0.2
2.0i 16V RFN
C5 2.0i 16V HPi RLZ ZR8PTT15 2.25 ± 0.2
1 (1) 1 ± 0.1
3.0i 24S XFX FGR8MQPE
(2) 90°
2.0i 16V RFN
RFN 52 HZ 0.9 ± 0.05 2.75 ± 0.2
2.0i 16V HPi 3FZ
C8
ALUMAGE
(1) 1 ± 0.1
3.0i 24S XFW FR8KDC 1
(2) 90°
213

ALL TYPES SPEEDOMETER
An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled.
This decree stipulates :
- The speed indicated by a speedometer must never be lower than the actual vehicle speed.
- Between the speed displayed «SD» 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 :
DRIVESHAFTS
GEARBOX
CLUTCH
- 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 :
- The tyres fitted to the vehicle.
- The gearbox final drive ratio.
- The speedometer drive ratio.
214

CLUTCH SPECIFICATIONS C5
Petrol
1.8i 16V 2.0i 16V 2.0 HPi 3.0i V6

Gearbox type BE4/5 ML/5
Marque VALEO
Mécanisme / Type 230 DNG 4700 230 DING 4700 230 DNG 4700 R 242 T 6500
228 D 73
Clutch disc 11 R 10X 12 R 14X 12 R 14 X 11 R 14X 11 A 14X
Ø of lining. Ext/Int 228/155 242/162

Quality of lining F 808 F 410 F 808 DS F 410
DRIVESHAFTS
GEARBOX
CLUTCH
215

C5 CLUTCH SPECIFICATIONS
Diesel
2.0 HDi 2.2 HDi

Gearbox type BE4/5 ML/5
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
DRIVESHAFTS
GEARBOX
CLUTCH
216

CLUTCH SPECIFICATIONS C8
Petrol Diesel
2.0i 16V 2.2i 16V 2.0 HDi 2.2 HDi
Engine type RFN 3FZ RHT - RHW 4HW

Gearbox type BE4/5 ML5C
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)
No. of splines
Ø of lining. Ext/Int 228/155 225/150 242/162
Quality of lining F 808
DRIVESHAFTS
GEARBOX
CLUTCH
217

C5 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.
DRIVESHAFTS
GEARBOX
CLUTCH
B2CP3CJD
218

BE4/5 GEARBOX CONTROL SPECIFICATIONS C5
Gear selection control cable. Gear engagement control cable
B2CP3CKD B2CP3CLD
Left hand drive Right hand drive Left hand drive Right hand drive
Lenght A 730 ± 3mm Lenght G 700 ± 3 mm
DRIVESHAFTS
GEARBOX
CLUTCH
Lenght B 937.5 ± 7.5mm Lenght H 983 ± 7.5 mm
Note : See adjustment : page 220.
219

C5 CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS
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».

DRIVESHAFTS
GEARBOX
CLUTCH
B2CP3CVD B2CP3CWC B2CP3CXC
220

CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS C5
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).
DRIVESHAFTS
- Insert tool [1] fully and rotate a quarter turn to lock the gear control lever.
GEARBOX
CLUTCH
- At neutral.
B2CP3E7C
221

C5 CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS
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.
Checks.
- Check that all the gears engage without «tightness ».

- Check that the gear lever moves identically forwards and backwards and to right and left. If not :
- Repeat the adjustment.
DRIVESHAFTS
GEARBOX
CLUTCH
Refit the console and the air filter assembly.
B2CP3E8C B2CP3E9C
222

ML/5 GEARBOX CONTROL SPECIFICATIONS C5
Engines : XFX - RHZ - RHS - 4HX
[1] Gear lever positioning tool 8605-T.
(1) Gear engagement ball-joint Ø 10 mm.

(2) Gear control lever
(3) Gear engagement control cable.
(4) Gear selection control cable.
(5) Gear selection ball-joint Ø 10 mm.
DRIVESHAFTS
GEARBOX
CLUTCH
B2CP3CQD
223

C5 ML/5 GEARBOX CONTROL SPECIFICATIONS
Gear selection control cable. Gear engagement control cable.
B2CP3CRD B2CP3CSD
Left hand drive Right hand drive Left hand drive Right hand drive
Lenght A 750 ± 3mm Lenght C 771 ± 3 mm
DRIVESHAFTS
GEARBOX
Lenght B 1012 ± 7.5mm Lenght D 1094 ± 7.5 mm

CLUTCH
Note : See adjustment: page 225.
224

CHECKS AND ADJUSTMENTS : ML/5 GEARBOX CONTROLS C5
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».
DRIVESHAFTS
GEARBOX
CLUTCH
B2CP3CTD B2CP3BYC
225

C5 CHECKS AND ADJUSTMENTS : ML/5 GEARBOX CONTROLS
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.
Inside the vehicle.

- Remove the central console (See corresponding operation).
- Remove the plastic blank at (a).
- Insert tool [1] fully and rotate a quarter turn to lock the gear control lever.
DRIVESHAFTS
GEARBOX
- At neutral.
CLUTCH
B2CP3E7C
226

CHECKS AND ADJUSTMENTS : ML/5 GEARBOX CONTROLS C5
Adjustments (continued)
Under the bonnet.
- Remove the air filter assembly.

- Unlock the gear engagement and selection cable ball-joint (b)
- Make sure the gear levers (engagement and selection) are in neutral position.
Checks.

- Check that all the gears engage without «tightness ».
- Check that the gear lever moves identically forwards and backwards and to right and left. If not :
DRIVESHAFTS
- Repeat the adjustment.
GEARBOX
CLUTCH
- Refit the console and the air filter assembly.
B2CP3EBC
227

C8 CLUTCH SPECIFICATIONS
Engines: RFN - 3FZ - RHT - RHW - 4HW
«Push» clutch
«Push» clutch and «Pull» clutch
(1) Clutch disc.

B2BB000D
«Pull» clutch (2) Clutch plate.
(3) Clutch bearing.

DRIVESHAFTS
GEARBOX
CLUTCH
B2BK22WD
228

HYDRAULIC CLUTCH CONTROL SPECIFICATION C8
Engines : RFN - 3FZ - RHT - RHW - 4HW
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.
DRIVESHAFTS
- The under-engine sound-deadening.
GEARBOX
CLUTCH
Refill the brake fluid reservoir to the maximum of its capacity.
229

C8 HYDRAULIC CLUTCH CONTROL SPECIFICATION
Engines : RFN-3FZ-RHT-RHW-4HW
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).
DRIVESHAFTS
GEARBOX
If necessary, repeat the operation.

CLUTCH
B2BK064C
230

HYDRAULIC CLUTCH CONTROL SPECIFICATION C8
Engines : RFN - 3FZ - RHT - RHW - 4HW
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.
DRIVESHAFTS
Tighten the bleed screw (1) to 0,75.m.daN.
GEARBOX
CLUTCH
B2BK065C
231

C5 GEARBOX AND TYRE SPECIFICATIONS
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 44 20 DL 30 20 TP 42 20 DL 31
Reduction box torque 19x79 21x73 19x79 23x73 19x77
Speedometer ratio 22x18 52x67 22x18 52x67 Sans
Petrol
3.0i V6
Automatic
Engine type XFX
Tyres-Rolling circumference 215/55 R16 – 1.96 m
DRIVESHAFTS
GEARBOX
Gearbox ident. plate 20 LE 95 20 LE 95 20 HZ 13

CLUTCH
Reduction box torque 16x65 20x69

Speedometer ratio Sans 59x68
232

GEARBOX AND TYRE SPECIFICATIONS C5
Diesel
2.0 HDi 2.2 HDi
Automatic
Engine type RHY RHS - RHZ 4HX
Tyres-Rolling circumference 195/65 R15 – 1.93 m 215/65 R16-1.96 m

Gearbox type BE4/5 ML/5C ML/5T AL4 ML/5C
Gearbox ident. plate 20 DL 32 20 LM 18 20 LE 94 20 TP 43 20 LM 17
Reduction box torque 19x75 16x65 25x68 17x67
Speedometer ratio Sans None 52x67 Sans
Diesel
2.2 HDi
Automatic
Engine type 4HX
Tyres-Rolling circumference 215/65 R16-1.96 m
Gearbox type ML/5T 4 HP 20
DRIVESHAFTS
GEARBOX
20 LE 96 20 HZ 20
CLUTCH
Gearbox ident. plate
Reduction box torque 17x67 23x66
Speedometer ratio Sans 59x68
233

C5 BE4/5 GEARBOX
ENGINE : RFN
DRIVESHAFTS
GEARBOX
CLUTCH
(a) = Marking zone (sequence and serial no.).

(b) = Location of identification label.
B2CP3BNC B2CP3BPD
234

BE4/5 GEARBOX C5
Engine : RFN
Description
(1) Primary shaft. (14) 1st / 2nd gear synchroniser

(2) Clutch bearing guide. (15) Driven gear (1st gear).
(3) Gearbox casing. (16) Secondary shaft.
(4) Clutch housing. (17) Differential gear.
(5) Reverse idle. (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)
(13) Driven gear (2nd gear).
DRIVESHAFTS
GEARBOX
"c" Adjusting shims: 1,4 to 1,6 mm.
CLUTCH
(From 0,10 to 0,10 mm)
B2CP3BQP
235

C5 BE4/5 GEARBOX
Engine : RFN
Tightening torques
Ref. Description Number 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
R everse 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
DRIVESHAFTS
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
236

ML/5 GEARBOX SPECIFICATION C5
Identification
Identification.
(a) Marking zone

(Sequence and serial no.).
(b) Location of identification label.
DRIVESHAFTS
GEARBOX
CLUTCH
B2CP3CMC
237

C5 ML/5 GEARBOX SPECIFICATION
Identification (continued)
(1) Primary shaft. (18) Driven gear (2nd)

(2) Clutch bearing guide. (19) Driven gears (3rd)
(3) Clutch housing (20) 3rd/4th gear synchroniser.
(4) Gearbox casing. (21) Driven gears (4th)
(5) Oil channel (22) Driven gears (5th)
(6) Primary shaft bearing adjustment shim. (23) 5th gear synchroniser.
(7) Drive gear (5th) (24) Planet gear adjustment shim.
(8) Secondary shaft.
(9) Driven gear (1st)
(10) Satellite gears.
(11) Speedometer screw. Tightening torques m.daN.
(12) Speedometer drive.
(13) Planet gears.
(25) Clutch bearing guide 2 ± 0,2
(14) Differential housing
(26) Secondary shaft nut 17 ± 1,5
(15) Differential gearwheel.
(27) Differential screw 7,5 ± 0,5
(16) Differential bearing stop plate.
DRIVESHAFTS
(17) 1st/2nd gear synchroniser and reverse

GEARBOX
CLUTCH
gear driven gear.
B2CP3CNP
238

ML/5 GEARBOX SPECIFICATION C5
Identification (continued)
(28) Reverse lamp switch 2,5 ± 0,2

(29) Gearbox casing /clutch housing fixing screws 2 ± 0,2
(30) Differential bearing stop plate screws 2 ± 0,2
(31) Gearbox rear casing screws 2 ± 0,2
(32) Drain plug 3 ± 0,3
(33) Filling / top-up plug 3 ± 0,3
(34) M8 screw (Differential housing fixing) 2 ± 0,2
(35) M10 screw (Differential housing fixing) 4 ± 0,5
(36) Selector guide screw 4 ± 0,5
DRIVESHAFTS
GEARBOX
CLUTCH
B2CP3CPD
239

C5 ML/5 GEARBOX SPECIFICATION
Recommendations - Precautions
(1) Drain plug.

(2) Filler and top-up plug.
Oil quality.
- See chapter on lubricants: page 23.
Oil quantity.
- After draining = 1.8 litres
DRIVESHAFTS
GEARBOX
CLUTCH
B2CP3CUC
240

4 HP 20 AUTOACTIVE GEARBOX SPECIFICATION C5
Engines : XFX - 4HX
Identification.
(1) Identification plate

(riveted on the casing).
(a) Serial no..
(b) ZF number.
(last digits taken into account)
(c) Type of automatic gearbox.
(d) Component reference
Oil quality and quantity
DRIVESHAFTS
GEARBOX
(See chapter, page 23).
CLUTCH
B2CP3CYD
241

C5 4 HP 20 AUTOACTIVE GEARBOX SPECIFICATION
Engines : XFX - 4HX
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
DRIVESHAFTS
Converter cover fixing on engine cover (XFX engine) 6,5 ± 1

GEARBOX
Converter cover fixing on engine cover (4HX engine) 5,8 ± 1

CLUTCH
B2CP3CZC B2CP24BC B2CP24CC
242

4 HP 20 AUTOACTIVE GEARBOX SPECIFICATION C5
Engines : XFX - 4HX
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
DRIVESHAFTS
GEARBOX
CLUTCH
B2CP24DC B2CP24EC
243

C5 RECOMMENDATIONS - PRECAUTIONS (AL 4 and 4 HP 20 AUTOMATIC GEARBOXES)
Engines : 6FZ - RFN - RHZ - XFX - 4HX
Precautions to be taken
Towing. REMOVING - REFITTING. (Automatic gearbox).
The front of the vehicle must be raised in order to be towed.
If the front of the vehicle cannot be raised : WARNING : Never place the gearbox on its lower casing
IMPERATIVE : - Put gear lever in position «N». (risk of deforming the tray and damaging the hydraulic valve block).
- Do not add any oil. Never use the connections as handles for raising, turning, holding or
pushing the gearbox.
AL4 gearbox
- Do not exceed 50 km/h (30mph) over a distance of 50 km (30m). ESSENTIAL :
4 HP 20 gearbox - Fit the converter retaining peg while the gearbox is removed.
- Do not exceed 70 km/h (45mph) over a distance of 100 km (60m). - Fit the centring peg to locate the gearbox on the engine:
(remove the converter retaining peg just before locating)
Driving.
Never drive with the ignition switched off. WARNING : With the emergency programme selected, an impact is
Never push the vehicle to try to start it; felt when changing from ‘‘P’’ ‘‘R’’ ou ‘‘N’’ ‘‘R’’.
(impossible with an automatic gearbox).
Lubrication
The automatic gearbox is only lubricated when the engine is running.
DRIVESHAFTS
GEARBOX
CLUTCH
244

RECOMMENDATIONS - PRECAUTIONS (AL 4 and 4 HP 20 AUTOMATIC GEARBOXES) C5
Engines : 6FZ - RFN - RHZ
Procedure to be followed prior to carrying out repairs on AL4 autoactive gearbox
If a gearbox malfunction occurs, there are two possible configurations Oil level.
depending on the seriousness of the fault : See corresponding operation.
- 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 (3rd - Oil leaks.
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. Check using a diagnostic tool.
Réception client. Read the fault codes (engine and gearbox)
Discuss with the customer, to find out all the malfunction symptoms.. Absence of fault codes.
Oil quality – Oil level. Carry out parameter measures, actuator tests and a road test.
Oil quality. Presence of fault codes.
If the gearbox has suffered a serious fault resulting in a malfunction or Carry out the necessary repairs.
the destruction of a clutch, the oil will overheat and become Delete the fault codes.
contaminated with impurities : the oil is said to be «burnt». Carry out a road test to check the repair and, if need be, modify the
This is characterised by a black colour and the presence of an gearbox ECU parameters (this is essential after an initialisation of the
DRIVESHAFTS
unpleasant smell. ECU).
GEARBOX
ESSENTIAL : The gearbox must be replaced.
CLUTCH
245

Procedure prior to carrying out repairs (continued)
When the ECU detects an erroneous or non-existent value Reading the fault codes.
on input or output : Read the fault codes.
- It writes the fault in memory. No fault codes present :

- For each associated context, it writes the context of the oldest fault Carry out a measure of parameters.
in memory.
- It initiates a back-up mode strategy. Anomalies present :
There are two types of back-up modes : • YES : Carry out the necessary repairs.
• NO : Read the fault codes – engine ECU
- The ECU makes replacement values available (relating to comfort, - Carry out a road test.
gear selection quality, loss of functions).
Following an initialisation of the ECU, for a certain period of time there
- Access to emergency programme (only 3rd ratio and reverse are may be an inconsistent gear selection quality (while ECU parameters
available) are adapted to the gearbox).
To achieve a consistent standard, it is necessary to carry out a road test
NOTE : 4 HP 20 : A snatching may be felt when changing : P/R - N/R - N/D.
DRIVESHAFTS
taking in frequent gear changes (auto-adaptive laws).

GEARBOX
CLUTCH
246

RECOMMENDATIONS - PRECAUTIONS (AL 4 and 4 HP 20 AUTOMATIC GEARBOXES) C5
ECU : Downloading, Configuration, Initialisation (Pedal).
Downloading. ( AL 4 and 4 HP 20 )
Updating the gearbox ECU by downloading :
- Follow the procedure using the diagnostic equipment.
The operation of downloading is used to update the automatic gearbox ECU or to adapt it to evolutions of the engine ECU.
After downloading, carry out the following :
- Note down the value in the oil usage counter present in the automatic gearbox ECU.
- Delete the fault codes.
- Again note down the value in the oil usage counter and compare it with the value previously read.
- Pedal initialisation ( AL 4 )
- Configuration (if needed) ( AL 4 ) Following the diagnostic tool procedure.
- A reinitialisation of the autoadaptives (AL4 and 4 HP 20).
- A road test ( AL 4 and 4 HP 20 ).)
24
DRIVESHAFTS
IMPERATIVE : Every update of the automatic gearbox ECU must
GEARBOX
CLUTCH
be accompanied by an update of the engine ECU.
247

Engines : 6FZ - RFN - RHZ
ECU : Downloading, Configuration, Initialisation (Pedal) (continued)
Downloading (AL 4 only). Pedal initialisation. (AL 4 only).
ECU downloading procedure : A pedal initialisation must be carried out in the following cases :
- Follow the diagnostic tooling procedure.
- Replacement of the automatic gearbox ECU.
A new ECU or downloaded update is always configured
with the following options : - Replacement of the automatic gearbox.
- SHIFT LOCK gear selection lever position.
- OBD outlet (emission standard L4). - Downloading of the ECU configuration.
If the ECU is to be fitted to a vehicle without one or both - Adjustment or replacement of the accelerator cable.
of these options:
- Carry out a configuration which inhibits the diagnosis of the - Replacement of the throttle potentiometer.
option(s) concerned.
DRIVESHAFTS
- IMPERATIVE : For a certain period of time, while the ECU parameters are adapted to the gearbox, there may be an inconsistent
GEARBOX
CLUTCH
gear selection quality. To achieve a consistent standard, it will be necessary to carry out a road test taking in frequent gear changes
(auto adaptive laws).
248

RECOMMENDATIONS - PRECAUTIONS (4 HP 20 AUTOMATIC GEARBOX) C5
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).
NOTE : It is 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 :
- The gear lever knob (1) by pulling upwards.
- The cover (2) (unclip).
DRIVESHAFTS
- The shutter.
GEARBOX
CLUTCH
Unlock the «shift lock» (4) using a screwdriver.
Using the selection lever, disengage from position «P».
C5FPOCUD C5FPOCTC
249

C5 4 HP 20 GEARBOX CONTROLS
Engines : XFX - 4HX
Selection control.
The gear selection control has 5 positions.
The selection lever is guided by the shape of the stepped gate and by a retaining spring which holds it
towards the left.
The gear selection control is equipped with the «shift lock», so you have to switch on the ignition and
apply the brake pedal to unlock the selection lever from the park position.
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.
This enables the change of status.
DRIVESHAFTS
GEARBOX
CLUTCH
B2CP3DKD
250

4 HP 20 GEARBOX CONTROLS 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 (a) : Permits a more dynamic, sporty performance.
- Snow (b) : 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.
DRIVESHAFTS
The automatic gearbox is controlled by a cable.
GEARBOX
CLUTCH
B3CP3DLC
251

C8 GEARBOX AND TYRE SPECIFICATIONS
Petrol
2.0i 16V 2.2i 16V 3.0i 24S
Automatic Automatic
Engine type RFN 3FZ XFW
Tyres-Rolling circumference 205/65 R 15 – 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 DL 26 (*) 20 DL 27 (**) 20 TP 74 20 LM 09 20 HZ 27
Reduction box torque 14x62 21 x 73 14x65 19 x 73
Speedometer ratio 18x14 20 x 16 25x20 –
Diesel
2.0 HDi 2.2 HDi
Automatic
Engine type RHT - RHW RHT 4HW
Tyres-Rolling circumference 215/65 R 15 - 2.016 M
Gearbox type ML5C AL4 ML5C
DRIVESHAFTS
GEARBOX
Gearbox ident. plate 20 LM 05 20 TP 74 20 LM 01

CLUTCH
Reduction box torque 15x67 21 x 73 16x69

Speedometer ratio 27x21 20 x 16 27x21
252

BE4/5 GEARBOX SPECIFICATION C8
Engine : RFN
(A) Marking zone including:
- Component reference.
- Factory serial no.
DRIVESHAFTS
GEARBOX
CLUTCH
B2CKU3PD
253

C8 BE4/5 GEARBOX TIGHTENING TORQUES (m.daN)
Engine : RFN
(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
DRIVESHAFTS
GEARBOX
CLUTCH
B2CKUB0D
254

BE4/5 GEARBOX TIGHTENING TORQUES (m.daN) C8
Engine : RFN
(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
DRIVESHAFTS
GEARBOX
CLUTCH
B2CKUB1D
255

C8 ML5C GEARBOX SPECIFICATION
Engines : 3FZ - RHT - RHW - 4HW
(A) Label.
(B) Gearbox reference.
(C) Sequence no.

B2CKUC2D
(D) Bar code.
(E) Marking zone:
Gearbox reference.
Sequence no.
DRIVESHAFTS
GEARBOX
CLUTCH
B2CKUCAD
256

ML5C GEARBOX SPECIFICATION C8
Gearbox lubrication.
Oil type: ESSO 75W80 EZL 848 or TOTAL 75W 80W H 6965
Oil capacity: 2.1 litres.
Lubricated for life.
NOTE : If the gearbox is drained, refilling of the gearbox is via the venting hole.
(1) Differential housing fixing (M8 L45) : 1,8 ± 0,1

(2) Differential housing fixing (M8 L70) : 1,8 ± 0,1
(3) Differential housing fixing (M10 L70) : 4 ± 0,4
(6) Drain plug : 3 ± 0,3
(7) Speedo control support : 1 ± 0,1
DRIVESHAFTS
WARNING : Do not use the plug on the differential housing, this does not
GEARBOX
CLUTCH
allow the gearbox oil level to be checked.
B2CKUC4D
257

C8 ML5C GEARBOX SPECIFICATION
Engines : 3FZ – RHT – RHW – 4HW
Tightening torques (m.daN).
(8) Fixing of gearbox cover on gearbox casing : 2 ± 0,2
(9) Bearing stop plate : 2 ± 0,2
(10) Vent hole.
(11) Reverse gear switch : 2,5 ± 0,2
(12) Fixing of gearbox casing on clutch casing : 2 ± 0,2

DRIVESHAFTS
GEARBOX
CLUTCH
B2CKUC4D
258

ML5C GEARBOX SPECIFICATION C8
Tightening torques (m.daN).
(13) Flange fixing screws : 2 ± 0,2
B2CKUC5D (14) Secondary shaft nut : 17 ± 1,7
(15) Gear control support screw : 1,5 ± 0,1
(16) Differential gearwheel screw : 7,7 ± 0,7
DRIVESHAFTS
GEARBOX
CLUTCH
B2CKUC6D
259

C8 AL4 AUTOMATIC GEARBOX SPECIFICATION
Engines : RFN - RHT
The automatic gearbox is identified by a self-adhesive label (A) or, failing that,
by a marking (B).
(1) Component reference.
(2) Serial no.

DRIVESHAFTS
GEARBOX
CLUTCH
B2CA085D
260

AL4 AUTOMATIC GEARBOX SPECIFICATION C8
Engines : RFN - RHT
(1) Converter:
Pre-tightening : 1 ± 0,1
Tightening : 3 ± 0,3
B2CKU7AD
(2) Fixing of gearbox on cylinder block : 5,2 ± 0,5
(3) Speedometer drive : 0,8
(4) Electrovalve and/or regulators on hydraulic block : 0,9
(5) Hydraulic block : 0,8

B2CKU7BD
(6) Hydraulic block casing : 0,8
(7) Automatic gearbox input speed sensor : 1 ± 0,1
DRIVESHAFTS
(8) Automatic gearbox input speed sensor : 1 ± 0,1
GEARBOX
CLUTCH
(9) Line pressure sensor : 0,9
B2CKU7CD
261

C8 AL4 AUTOMATIC GEARBOX SPECIFICATION
Engines : RFN - RHT
(10) Electrovalve controlling flow into the exchanger : 1 ± 0,1
(11) Multifunction switch : 1,5 ± 0,1
(12) Sleeve stop : 1,5 ± 0,1
(13) Automatic gearbox heat exchanger : 5 ± 0,5

B2CKU7AD
(14) Filler cap : 2,4 ± 0,2
(15) Top-up plug : 2,4 ± 0,2
(16) Gearbox drain plug : 4 ± 0,4
(17) Gearbox support : 4,5 ± 0,4

DRIVESHAFTS
GEARBOX
Driveshaft nut (M24x150) : 32,5 ± 3

CLUTCH
B2CKU7BD
262

DRAIN / REFILL / TOP-UP : 4 HP 20 GEARBOX C8
Engine : XFW
Preliminary conditions:
Tools.
Checks there are no faults , using the diagnostic tool.
[1] Filling kit : (-).0341
Place the vehicle on a lift, keep vehicle horizontal.
[1a] Filling cylinder : (-).0341-A
[1b] 4 HP 20 adaptor without gauge : (-).0341-B Gear lever in position «P», without applying the handbrake.
NOTE : Heavy electrical consumers disconnected.
Connect the diagnostic tool.

- The 4 HP 20 automatic gearbox is lubricated for life.
Select the parameter measures function.
- Check the level every 20 000 miles.
Make starting this operation, make sure that the oil temperature is well
Checks below 55°C ; if it is not, allow the oil to cool.
DRIVESHAFTS
Press the brake pedal.
IMPERATIVE : Use only ESSO LT 71141.
GEARBOX
CLUTCH
Start the engine and allow it to run at idling speed, engage all the gears
using the gear selector. Return to «P».
263

C8 DRAIN / REFILL / TOP-UP : 4 HP 20 GEARBOX
Engine : XFW
Checks (continued)
With the engine running at the temperature 55° ± 1°C, open the top-up plug (3).
Wait for the temperature to reach 60° ± 1°C.
1st possibility :
- Oil flows out, the level is correct.

- Refit the top-up plug (3), tighten to 2,5 ± 0,2 m.daN.
2nd possibility :
- Oil does not flow out.

- Refit the top-up plug (3).
- Add 0,5 litres of oil. (Refer to the chapter on refilling).
Repeat the procedure of checking the oil level.
Refit the metallic part of the vent plug (2), using an 18mm dia. punch and a
DRIVESHAFTS
mallet.
GEARBOX
CLUTCH
Clip the plastic part of the vent plug (2).
B2CK0JQC
264

DRAIN / REFILL / TOP-UP : 4 HP 20 GEARBOX C8
Engine : XFW
Draining.
Preliminary conditions:
- Draining should be carried out with the engine hot, to eliminate impurities in
suspension in the oil.
The draining is partial since the converter cannot be totally emptied.
In draining, approx. 3 litres is removed.
Tighten the cap (1) to 4,5 ± 0,4 m.daN.
Filling.
IMPERATIVE : Use only ESSO LT 71141.
Place the vehicle on a lift.
Move aside the air filter assembly.
ESSENTIAL : Leave the air temperature sensor connected.
Remove the air vent assembly (2).
Raise the vehicle.
Remove the top-up plug (3).
Using tool [1], pour new oil through the air vent aperture, until oil flows out via the
top-up hole.
Start the engine and allow it to run at idling speed (applying the brake pedal) and
engage all the gears using the gear selector. Return to «P».
Add oil until it flows out via the top-up hole.
DRIVESHAFTS
GEARBOX
Reclose the top-up hole.
CLUTCH
Stop the engine.
IMPERATIVE : Check the oil level.
B2CK17KC B2CK0JPC B2CK0JQC
265

C5 - C8 DRIVESHAFTS - GEARBOX
Tightening torques (m.daN) Gearbox oil seal mandrels
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 - RHZ - 4HX
ML/5 2 ± 0.2 32.5 ± 1.5 9017-T.C 5701-T.A 9017-T
C5 RHT- RHW
C8 6FZ - RFN - RHZ 0338 J1 0338 H1
AL4 C8 0338
RHT 0338 J3 0338 H2
4 HP20 XFX - XFW - 4HX 8010-T.D 8010-T.J

1.0 10 + 60° 8010-T
8010-T.K1 8010-T.K2
Tightening torques (m.daN) of the wheel bolts

DRIVESHAFTS
GEARBOX
CLUTCH
C5 Steel 9 ± 0.5
CITROËN
C8 Aluminium 10 ± 0.5
266

SUSPENSION
STEERING
C5
AXLES
AXLE GEOMETRY
Measuring front height Measuring rear height
The measurement of the front dimension «H1» is between ground level

and the measuring zone on the front subframe
(to the rear of the front yokes fixing the suspension arm).
B3BP166D B3BP168D
L1 (mm) L2 (mm)
Theoretical dimension between the level of the front subframe and Theoretical dimension between the measuring zone on the
the wheel axis. crossmember support and the wheel axis.
140 73
267

SUSPENSION
STEERING
C5 AXLE GEOMETRY
AXLES
Front axle Rear axle

King pin
Vehicle Tracking Castor Camber Tracking Camber
inclination
Adjustable Non adjustable 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’
NOTE
A < B = Positive figure : += TOE-IN
A > B = Negative figure : –= TOE-OUT
B3CP02UC
268

SUSPENSION
STEERING
AXLES
FRONT AXLE C5

(1) Suspension leg upper fixing 7 ± 0,7
(2) Suspension leg fixing on bodyshell 4,3 ± 0,6
(3) Anti-roll bar link rod upper fixing 6,4 ± 0,6
(4) Anti-roll bar link rod upper fixing 6,4 ± 0,6
(5) Ball-joint fixing 4,5± 0,4
(6) Ball-joint fixing on pivot 25 ± 2,5
(7) Suspension leg upper fixing on pivot 5,4 ± 0,5
(8) Hub nut 32,5± 2,6
(9) Wheel fixing 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 ± 0,6
Stabiliser bar fixing on subframe 6,6 ± 0,6
Anti-roll bar
Engines Diameter (mm) Colour ref.
All types (except ES9J4) 23.5 Yellow
ES9J4 24.5 White
NOTE : The geometry specifications are given with the suspension

B3CP05VP B3CP05WD specifications
269

SUSPENSION
STEERING
C5 REAR AXLE
AXLES
(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 fixing 9± 1
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
22 Yellow
All types estates
NOTE : The geometry specifications are given with the suspension

specifications.
B3DP08BD B3DP08CD
270

SUSPENSION
STEERING
C5
AXLES
SUSPENSION
Front suspension
(10) Arm front fixing 13 ± 1,3
(11) Arm rear fixing 8 ± 0,8
(12) Anti-roll bar bearing fixing on subframe 4,2 ± 0,6
Hydractive 3+ hydraulic suspension (power steering)
Suspension piston diameter = 35 mm.

Anti-roll bar diameter = 23,5 mm.
Anti-roll bar colour reference = Yellow.
Suspension leg.
Bump stop, height «A» = 97 mm.

B3CP05WD B3BP167D
271

SUSPENSION
STEERING
C5 SUSPENSION
AXLES
Rear suspension
(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 steering)

Suspension piston diameter = 37 mm
Anti-roll bar diameter
- Saloon = 21,5 mm
- Estate = 22 mm
Anti-roll bar colour reference
- Saloon = Blue
- Estate = Green
B3DP08ND B3DP08PD
272

SUSPENSION
STEERING
AXLES
SUSPENSION C5
Height control
(20) Clips 0.6
B3CP06TD
273

SUSPENSION
STEERING
C5 SUSPENSION
AXLES
Front axle Rear axle

King pin
Vehicle Tracking Castor Camber Tracking Camber
inclination
Adjustable Non adjustable Adjustable Non adjustable
0 à - 3 mm 5.4 ± 1.3 mm
Tous types 3° 03' ± 30' 0° ± 30' 12° 56' ± 30' - 1° ± 20'
0° à - 0° 27' 0° 49’ ± 0° 12’
NOTE
B3CP02UC
274

SUSPENSION
STEERING
C5
AXLES
SPECIFICATIONS OF POWER-ASSISTED STEERING
Engines : 6FZ - RFN - RLZ - XFX - RHY - RHS - RHZ - 4HX
(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 lock 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
Quantity of oil = 4.3 litres

Quality of oil = TOTAL FLUIDE LDS
B3EP124D B3EP125D
275

SUSPENSION
STEERING
C5 SPECIFICATIONS OF POWER-ASSISTED STEERING

AXLES
Engines : 6FZ - RFN - RLZ - XFX - RHY - RHS - RHZ - 4HX
Steering rack Number of teeth Number of Angle of lock

Engines Steering
travel (mm) turns of the
Pinion Rack ratio Inner Outer
wheel
6FZ RFN-RLZ-
2x83 3.3 39.74° 35.65°
RHY-RHS-RHZ 9 33 50.4/1
XFX 4HX 2x74 3 34.29° 31.58°
Engines Supplier Flow type Regulation pressure Pulley diameter

6FZ RFN-RLZ
ZF Falling
RHY RHS RHZ 4HX 100 bars 129 mm
XFX SAGINAW Constant
Tightening torques m.daN Engine XFX : A converter, integral with the valve,
Engine types EW-DW ES9J4 modulates the assistance according to the vehicle
speed.
(12) Screw
(13) Screw 2.2 ± 0.3 2.5 ± 0.6 Length of steering rods (Adjustment)
(14) Screw between ball-joints = 362 mm.
Petrol engine : A power-assisted steering pressure switch Power-assisted steering hydraulic circuit.
is installed on the hydraulic piping, between the high pres- The oil supplies both the steering circuit and the sus-
sure pump and the steering valve. pension circuit.
B3EP127D
276

SUSPENSION
STEERING
C8
AXLES
AXLE GEOMETRY (SETTING AT REFERENCE HEIGHT)
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
277

SUSPENSION
STEERING
C8 AXLE GEOMETRY
AXLES
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 longeron.
subframe at the front fixing of the suspension wishbone.
278

SUSPENSION
STEERING
C8
AXLES
AXLE GEOMETRY
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
279

SUSPENSION
STEERING
C8 AXLE GEOMETRY
AXLES

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
280

SUSPENSION
STEERING
C8
AXLES
AXLE GEOMETRY
Values for front suspension angles Values for rear suspension angles
3FZ-RHT 3FZ-RHT
Engines RFN XFW Engines RFN XFW
RHW-4HW RHW-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 Tracking
(degrees) 0° 17’ ± 0° 08’ (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’
NOTE
B3CP02UC
281

SUSPENSION
STEERING
C8 AXLE GEOMETRY
AXLES
Réglage des trains roulants
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
282

SUSPENSION
STEERING
FRONT AXLE
AXLES
C8
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-RHW-4HW 21.5
XFW 22
B3CK09JD
283

SUSPENSION
STEERING
C8 FRONT AXLE
AXLES
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
Fixation biellette sur barre antidévers : 5,5 ± 0,5
B3BP18FD
284

SUSPENSION
STEERING
C8
AXLES
REAR AXLE
Identification
(1) Damper.
(2) Spring.
(3) Stabiliser bar.
B3DK0AFD
285

SUSPENSION
STEERING
C8 REAR AXLE
AXLES
(5) Fixing of rear axle on body : 8 ± 0,8
(6) Fixing of stabiliser bar on rear axle : 8 ± 0,8
(7) Fixing of stabiliser bar on body : 6 ± 0,6
(8) Hub nut : 38 ± 3,8
(9) Fixing of damper on body : 9 ± 0,9
(10) Fixing of damper on rear axle : 9 ± 0,9
B3DK0AGD
286

SUSPENSION
STEERING
SPECIFICATIONS OF POWER-ASSISTED STEERING C8
AXLES
Engines : RFN - 3FZ - XFW - RHT - RHW - 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
287

SUSPENSION
STEERING
C8 SPECIFICATIONS OF POWER-ASSISTED STEERING

AXLES
Engines : RFN – 3FZ – XFW – RHT – RHW – 4HW
Engine Type RFN 3FZ XFW RHT - RHW 4HW

Features Power steering with integral ram
Travel (mm 166 156 162
Angle of lock for inside wheel 40°48’ 37°18’ 39°24’
Angle of lock for outside wheel 34°36’ 32°24’ 33°42’
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
9
drive pinion
288

SUSPENSION
STEERING
AXLES
SPECIFICATIONS OF POWER-ASSISTED STEERING C8
(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
289

BRAKES
C5 BRAKE SPECIFICATIONS
1.8i 16V 2.0i 16V 2.0 HPi 3.0i V6

Master cylinder 22.2 (valve type)
Master-vac 254
Ø Caliper/piston BOSCH ZO 54/55 BOSCH ZO 57/56 BOSCH ZO

makes BIR 54 BIR 57 57/28BIR 57
mm
FR Non-ventilated
Brake disc
Ventilated 266 283 288
Disc thickness/min. thickness 22/20 26/24 28/26
ABEX ABEX TEXTAR
Brake pad grade
949/1 949/1 T 4110
Cylinder or caliper PSA - 32 (double piston)
Ø
Drum / Ø max.
mm
Brake disc Non-ventilated 276
RR
Disc thickness/min. thickness 14/12
Make ABEX or TEXTAR
Brake lining grade 949/1 or T 4110
290

BRAKE SPECIFICATIONS C5
2.0 HDi 2.2 HDi

Master cylinder 22.2 (valve type)
BRAKES
Master-vac 254
Ø Caliper/piston BOSCH ZO 57/26

BOSCH ZO 57/28 BIR 57
makes BIR 57
mm
FR Non-ventilated
Brake disc
Ventilated 283 288
Disc thickness/min. thickness 26/24 28/26
Brake pad grade TEXTAR T 4110
Cylinder or caliper PSA - 32 (double piston)

Ø
Drum / Ø max.
mm
Brake disc Non-ventilated 276
RR
Make TEXTAR or ABEX
Brake lining grade T 4110 or 949/1
291

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
292

Braking circuit diagram
(a) Hydraulic circuit.

(b) Electrical circuit.
BRAKES
(1) Master cylinder in tandem.
(2) Braking servo.
(3) Brake caliper.
(4) Hub equipped with a bearing with an integral magnetic wheel
(48 pairs of poles).
(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).
B3GP02HP
293

(7) Hydraulic block
Elements Ref. Supplier Part No. Observations
ABS MK.60
Electronic 47 way connector.
7 ITT - A
ECU. Alone on the hydraulic block.
BASR MK.60
BRAKES
2 way black connector.

The sensors are inductive-type.
Front wheel
5 ITT - A 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
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 à 1.6 mm.
Tightening torque: 0.8 ± 0.2 m.daN
Hub Hub equipped with a bearing with an integral
4 SNR
bearing. magnetic wheel (48 pairs of poles).
ABS MK.60
Hydraulic 96 371 711 80 Installed on the front LH wheelarch.
7 TEVES
block. BASK MK.60 4 adjustment channels.
B3FP12XC 96 371 712 80
294

Brake pedal carriage Front brake Rear brake
BRAKES
B3FP130C B3FP12YC B3FP12ZC
Couple de serrage (m.daN).
(15) Fixing on bodyshell 1.8 ± 0.25. (12) Caliper fixing on pivot 12± 1.8
(16) Servo fixing 2.1 ± 0.1. (13) Yoke fixing on caliper 3.1± 0.1 (14) Rear caliper fixing on suspension arm 7 ± 0.7
295

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
296

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
297

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 reservoir
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 AB3FP13CC
298

BLEEDING AND FILLING THE BRAKING SYSTEM C5
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.
NOTE : Recommence the process a second time if that is necessary.
- Check the brake fluid level, (Should be between «DANGER» level and «MAXI» level).
- Fill if necessary with the approved and recommended synthetic brake fluid.
B3FP13DC
299

C5 BLEEDING AND FILLING THE BRAKING SYSTEM
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.
300

2.0i 16V 2.2i 16V 3.0i 24S 2.0 HDi 2.2 HDi
Engine type RFN 3FZ XFW RHT - RHW 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 LUCAS BREMBO LUCAS
mm
FR makes 60 40 + 44 60
Disc Ventilated 285 310 285
Disc thickness/min. thickness 28/26 32/30 28/26
Brake pad grade GALFER 3366 (8) - FERODO 782 (2)
Caliper/piston LUCAS C38HR
Ø
mm makes 38
Disc Ventilated 272
RR
Make TEXTAR
Brake pad grade T 4131
301

C8 BRAKE 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
302

ADJUSTING THE HANDBRAKE C8
Identification
BRAKES
(A) Zone for fixing on floor.
(B) Clips for retaining on bodyshell.
B3FK263D
303

C8 ADJUSTING THE HANDBRAKE
Adjustment
Raise and support the vehicle, wheels hanging.
WARNING : Bleed the braking circuit.

BRAKES
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
304

DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM C8
Tools.
[1] Generic bleeding apparatus : «LURO» or similar

[2] Filler plug : (-).0810
[3] PROXIA diagnostic tool : 4165-T.
BRAKES
[4] LEXIA diagnostic tool : 4171-T
Draining.
Remove the pollen filter (See corresponding operation).
Take out the filter from the brake fluid reservoir.
Drain the brake fluid reservoir with the aid of a clean 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.
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.
305

C8 DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM
Pre-conditions for bleeding a braking circuit: Use of the diagnostic tool will be necessary in cases where the following
After a repair on the master cylinder or ABS block, bleed in the following conditions all come together simultaneously:
order: - Air in the circuit.
Front LH wheel. - Regulation block active.
Front RH wheel. - Action on the brake pedal.
Rear LH wheel.
Rear RH wheel. Bleeding.
BRAKES
IMPERATIVE : Start the engine.

After a repair on a caliper or on a wheel cylinder, bleed in this order (cali-
WARNING : Respect the order of opening of the bleed screws.
per or wheel cylinder removed) :
Automatic bleed:
Front LH wheel. Position tool [2] on the brake fluid reservoir.
Front RH wheel. Connect tool [2] to an approved automatic bleed apparatus (See Tools).
Rear LH wheel. Bleed the circuit, referring to the user instructions provided with the
Rear RH wheel. apparatus.
Manual bleed (using the pedal):
NOTE : If removing/refitting the master cylinder, it is advised to complete the Two operators are necessary.
automatic bleed with a manual bleed. Connect a transparent pipe on the bleed screw.
ABS : Press slowly on the brake pedal.
The hydraulic valve blocks are delivered pre-filled; it is thus possible to
Open the bleed screw.
perform:
Keep the pedal pressed fully down.
- a manual bleed (using the pedal),
- an automatic bleed. Close the bleed screw.
Should the bleed of the circuit prove unsatisfactory, it is possible to bleed Allow the brake pedal to rise gradually.
the ABS block using a diagnostic tool (See Tools), following the instruc- Repeat the operation until the brake fluid flows out clean and free of air
tions given by the diagnostic tool. bubbles.
Proceed in an identical fashion in the case of all the other wheels.
306

HYDRAULIC SPECIFICATIONS C5
Location of components
(A) High pressure hydraulic circuit.

(B) Low pressure hydraulic circuit.
(C) Electric circuit.
(21) Built-in Hydro-electronic Interface (BHI).
(22) Front slimline sphere.
(23) Front suspension cylinder.
(24) Rear slimline sphere.
(25) Rear suspension cylinder.
(26) Front hydractive 3+ regulator accumulator.
HYDRAULIC
(27) Front hydractive 3+ regulator.
SYSTEM
(28) Rear hydractive 3+ regulator accumulator.
(29) Rear hydractive 3+ regulator
(30) Front height sensor.
(31) Rear height sensor.
(32) LDS fluid reservoir .
(33) Suspension switch.
B4CP01FP
307

C5 HYDRAULIC SPECIFICATIONS
Reservoir
Reference Function Component
(BHI) Built-in Hydro-electronic

"d" Induction
InterfacePower steering pump
"e" (BHI) Built-in Hydro-electronic Interface
"f" Return Power steering pump

HYDRAULIC
SYSTEM
"c" Suspension cylinders
Synthetic fluid TOTAL FLUIDE LDS.

Capacity of the circuit 4.3 litres.
B4BP01BC
308

HYDRAULIC SPECIFICATIONS C5
Built-in Hydro-electronic Interface (BHI).
Ref. Component Specifications
(36) Electric motor 2350 ± 150 tr/min

Hydraulic unit comprising :
Pump with 5 axial pistons Throughput = 0,7 l/min at 2300 rpm
(35) - Anti-pulse hydropneumatic Diameters of the pistons = 6,35 mm
accumulator Safety valve rating = 180 Bars
A safety valve
HYDRAULIC
(34) Electronic control unit
SYSTEM
4 electrovalves:
Front suspension inlet The vehicle’s anti-sink function is
(37) Rear suspension inlet assured by the exhaust
Front suspension exhaust electrovalves
Rear suspension exhaust
B3BP169P
309

C5 HYDRAULIC SPECIFICATIONS
Hydractive 3+ regulator Hydraulic unions
HYDRAULIC
SYSTEM
B4BP01CD B4DP003D
Tube diameter Tightening torque

(40) Slimline sphere. Reference
(mm) m.daN
(39) Hydractive regulator.
(38) Electrovalve. G 3.5
1.5 ± 0.3
(41) Depressurisation screw. H 6.35
J 10 2.5 ± 0.5
310

SPECIFICATION - IDENTIFICATION : SUSPENSION SPHERES C5
Special features
Identification
- Fitting of new slimline spheres with multilayer membrane and earth grey colour.
- It is prohibited either to recharge or repair this type of sphere.
- The number marked on the suspension sphere is the reference number for the component, not the Replacement Parts No.
- The 2-digit number on the suspension sphere indicates the value of the initial inflation pressure.
Example :
Suspension Day Year Time Pressure rating

Batch
HYDRAULIC
sphere marking of manufacture of manufacture of manufacture (Bars)
SYSTEM
96 420 906 80 AG2 066 0 13.59 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.
NOTE : Suspension cylinders on the same axle should be equipped with the same type of membranes.
IMPERATIVE : Tightening torques for the spheres : 2.7 ± 0.5 mda.N.
311

C5 SPECIFICATION - IDENTIFICATION : SUSPENSION SPHERES
(1) Front suspension sphere.
(2) Rear suspension sphere.
(3) Front hydractive 3+ regulator accumulator.

HYDRAULIC
SYSTEM
(4) Rear hydractive 3+ regulator accumulator.
B4BP01DD
312

CARACTERISTIQUES-IDENTIFICATIONS : BLOCS PNEUMATIQUES C5
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 two-figure number marked on the suspension sphere indicates the initial pressure rating value.
Example
Suspension Day in year of Year Time Pressure rating

sphere marking manufacture of manufacture of manufacture (Bars)
HYDRAULIC
SYSTEM
HF 066 00 13.59 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.
NOTE : 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 mda.N.
313

Hydractive 3 hydraulic suspension
(1) Front suspension spheres
Engines Suspension sphere marking Volume (cc) Pressure rating (Bars)
All 6FZ HF
385 57
Type RHY-RHS-RHZ HG
(2) Rear suspension spheres
HJ
Saloon 31
KA
RHY-RHS-RHZ 385
HYDRAULIC
HP
SYSTEM
Estate 44
HT
314

SPECIFICATION - IDENTIFICATION : SUSPENSION SPHERES C5
Hydractive 3+ hydraulic suspension
(1) Front suspension spheres
All RFN HH 44
385
Types XFX-4HX HI 52
(2) Rear suspension spheres
HE
Saloon 25
HZ
HYDRAULIC
RFN-XFX-4HX 385
SYSTEM
HO
Estate 44
HW
315

Hydractive 3+ hydraulic suspension
(3) Front hydractive regulator accumulator
All RFN-4HX HD
385 62
Types XFX HQ
(4) Rear hydractive regulator accumulator
All RFN-4HX GP 45
385
Types XFX HR 44
HYDRAULIC
SYSTEM
NOTE : The dampers are integral to the hudractive regulators, depending on the versions of hydractive accumulator.
316

STARTER MOTORS C5 - C8
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 MANUEL : Manual gearbox
F Cold : Starting possible as low as -25°C AUTOMATIC : Automatic gearbox
GF Very cold : Starting possible as low as -30°C MAP : Piloted manual gearbox
DA REFRI : Mechanical power steering, aircon
ELECTRICAL
SYSTEM
317

C5 STARTER MOTORS
Petrol engines
Engine Gearbox Reference Class Climate
U 3 C.T.F
M
V 4 GF
1.8i 16 V
U 3 C.T
A
V 4 F.GF
U 3 C.T
2.0 16V HPi M
V 4 F.GF
U 3 C.T
M
V 4 F.GF
2.0 16V
U 3 C.T
A
V 4 F.GF
ELECTRICAL
SYSTEM
M R2 4 C.T.F.GF
2.0i 24 S
A R2 4 C.T.F.GF
318

STARTER MOTORS C5
Diesel engines
Engines Gearbox Reference Class Climate
X 4 C.T
Z1 6 F.GF
M
Y 5 C.T
2.0 HDi
Z1 6 F.GF
Z1 6 C.T
A
Z3 6+ F.GF
Y 5 C.T
M
Z3 6+ F.GF
2.2 HDi
Y 5 C.T
A
Z3 6+ F.GF
ELECTRICAL
SYSTEM
319

C8 STARTER MOTORS
Petrol engines
Engines Gearbox Reference Class Climate
U 3 C.T
1.8i 16 V
V 4 F.GF
M
U 3 C.T
2.2 16 V HPi
V 4 F.GF
3.0i 24 S A R2 4 C.T.F.GF
Diesel engines
Y 5 C.T
2.0 16 V HDi
Z1 6 F.GF
ELECTRICAL
M
SYSTEM
Y 5 C.T
2.2 HDi
Z3 6+ F.GF
320

ALTERNATORS C5 - C8
Abbreviations and definitions
Meaning of abbreviations :
Coding of climates is as follows :
BV : Gearbox
MANUEL : Manual gearbox
CLIMATES : AUTOMATIC : Automatic gearbox
MANUELP : Piloted manual gearbox
C : Hot NON REFRI : Without air conditioning
T : Temperate REFRI : With air conditioning
F : Cold DA : Power-assisted steering
GF : Very cold GEP : Electro-pump motor
DP : Double lug
3 Pts : 3-Point
NC : Not marketed
TT : All Types
N : Level
SOP : Without Option
TOP : All Options
ELECTRICAL
L.C. : Heated rear screen
SYSTEM
DAG : Left hand drive
DAD : Right hand drive
321

C5 ALTERNATORS
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 12
1.8i 16V 12
2.0i 16V T
2.0i 16 V HPi F 9
MANUEL 9
GF
C 15 15
12 12 12
1.8i 16 V T 12 12
AUTOMATIC F 9
9 9
GF 12
C 15
12
2.0i 16V T 12
AUTOMATIC F 9 9 12
ELECTRICAL
12 9
SYSTEM
GF 12 12
Meaning of abbreviations, see page: 321
322

ALTERNATORS C5
Without hi-fi pack With hi-fi pack
Engine Without heated seat With heated seat Without heated seat With heated seat
Climat
Boîte Mono Colour Mono Colour Mono Colour Mono Colour
Base Base Base Base
Navig. Navig. Navig. Navig. Navig. Navig. Navig. Navig.
C
3.0i 24 S
T
MANUEL 15 15
AUTOMATIC F
GF
C 12 12
12 12 12
2.0 16V HPi T
MANUEL F 9 9
9 9 9
GF
C
2.0 HDi
T
2.0 16 V HDi 15
MANUEL F
GF
C
ELECTRICAL
2.0 HDi T 15
SYSTEM
AUTOMATIC F
GF
Meaning of abbreviations, see page: 321
323

C8 ALTERNATORS
AIRCON
Engine/ Without heated seats With heated seats
Climate
gearbox Base RT3 Base RT3
N1 N2 N3 N1 N2 N3 N1 N2 N3 N1 N2 N3
15 C
2.0i 16 V 9
T
2.2 16 V HPi 9
9 F
MANUEL 8
GF
15 15 15 C
15
2.0i 16 V 9 9 T
AUTOMATIC 8 8 F
9 9
9 9 GF
C
3.0i 24 S
T
2.016 V HDi 15
AUTOMATIC F
GF
C
ELECTRICAL
SYSTEM
2.0 HDi T
MANUEL F
GF
324

CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR ALL TYPES
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.
A : Ammeter Display 3000 alternator rpm. If U alternator is > 14.7 V, the regulator is faulty.
B : Battery Note: These tests should be performed with the engine hot and the battery fully charged.
G : Generator
L : Warning lamp Method of reading the alternator speed
K1 and K2 : Switch Fit a reflecting shim on the pulley of the alternator.
R : Electric charge
Adjust a stroboscope to the frequency equivalent to the control speed.
ELECTRICAL
S : Shunt 200mV/200A
SYSTEM
V : Voltmeter (e.g. 2000 rpm = 2000/60 = 83 Hz)
1 : Alternator. Adjust the engine speed so that the shim appears fixed.
325

ALL TYPES 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 I1 27 39 46 61 73 89 108
2000 rpm I2 34 46 54 68 80 105 123
3000 rpm I3 47 60 68.5 84 100 139 164
4000 rpm I4 55 65 75 92 110 145 176
6000 rpm I5 61 69 78.5 96 120 151 183
8000 rpm I6 63 70 80 97 123 157 188
15000 rpm I7 64 73 82 97 124 157 188
MINIMUM YIELDS (in %)
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
4000 rpm 43 44 46 48 50 52 53
ELECTRICAL
SYSTEM
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
326

PRE-HEATING AND STARTING CIRCUITS ALL TYPES
Pre-post-heating
Vehicles Engine Pre-heater plugs Pre-heater control unit
(Pre-heating time at 20°C)
2.0 HDI CARTIER 51299011A

CHAMPION CH 170
2.0 16V HDI NAGARES 960411-P
Piloted by the diesel
C5
injection ECU
CARTIER 51299011A
2.2 HDI BERU A0100 226 344
NAGARES 960411-P
ELECTRICAL
SYSTEM
Preheater plug resistance : 0.4 Ω ≤ R ≤ 0.6 Ω
327

C5 - C8 AIR CONDITIONING R 134 a (HFC)
Compressor
Refrigerant
Vehicle Engine version Date refill
(± 25 gr) Variable capacity Oil quantity cc Oil reference
1.8i 16V - 2.0i 16V

2.0 HPi
SD 7 V16 SD 7 V16 SP 10
3.0i 24S 16V
C5 2.2 HDi 11/2000 : 650`+ 0 - 50 gr
2.0 HPi DELPHI V5 (1) 265 ± 15 PLANETELF 488
2.0i 16V - 2.2 16V HPi

C8 3.0i 24S - 2.0 16V HDi 06/2002 750 (± 25 gr) SD 7 V16 135 SP 10
2.2 HDi
CONDITIONING
(1) HARRISON Division.

AIR
328

CONDITIONING
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) C5 - C8
AIR
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.
329

CONDITIONING
C5 SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)

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
330

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
331

CONDITIONING

AIR
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 protection
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
332

CONDITIONING
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 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
333

CONDITIONING
ALL TYPES 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.
334

CONDITIONING
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) ALL TYPES
AIR
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.
335

CONDITIONING
ALL TYPES CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM

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).
Conditions and vehicle equipment. After the air conditioning has been on for three minutes, measure :
- the exterior temperature in the workshop,
- Bonnet closed. - the temperature of the air coming out of the central vents.
- 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.
336

CONDITIONING
AIR CONDITIONING SYSTEM R 134.a C5
AIR
(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
(c) Compressor bracket
Tighten to 2,5 ± 0,1 m.daN
(d) Condenser dryer reservoir
C5HP15QP
337

CONDITIONING
C5 AIR CONDITIONING SYSTEM R 134.a

AIR
Engine : XFX

(3) Pressostat.
(4) Capacity.

C5HP15RP
338

CONDITIONING
AIR
Engines : RHY - RHZ

(3) Pressostat.
(4) Capacity.

C5HP15SP
339

CONDITIONING

AIR
Engine : 4HX

(3) Pressostat.
(4) Capacity.

C5HP15TP
340

CONDITIONING
AIR
Pollen filter
C5HP183C
NOTE : The pollen filter is located under the bonnet on the LH side.
Removing.
Remove the handle (1).
Uncouple the evacuation pipe (2).
Release at (3), on the RH and LH sides.
Slacken the screws (4) on the RH and LH sides by a quarter turn.
Pull the assembly (6) outwards.
Remove the pollen filter (5).
Refitting.
C5HP182D Proceed in reverse order.
341

CONDITIONING

AIR
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) by a quarter turn.
Move aside the condenser (5).
Clean the area around the skirt (6) of the reservoir (7).
Remove the screw (8) of the fixing (9).
B1BP2MGC B1BP2MHC C5HP184C C5HP185C
342

CONDITIONING
AIR
Removing-refitting the drying cartridge (continued)
Unscrew the reservoir (7) (Adaptor: TORX 70 FACOM)
Unscrew the reservoir (7), and the protection skirt (6).
WARNING : This operation should remain clean before the fitting of the new reservoir.
Cap the base (10).
WARNING: Do not allow more than 5 minutes to elapse between unwrapping the cartridge (reservoir (7)) and
fitting it.
C5HP186C C5HP187C
343

CONDITIONING

AIR
Removing-refitting the drying cartridge (continued)
Refitting.
Note: Check, before you refit the reservoir (7), that the base (10) is clean.
(If it is not, clean in and around the base with a paper towel (10)).
Preparing the new drying reservoir
Remove the protection cap from the neck of the reservoir (7).
Leave in place the protection at the other end of the neck of the reservoir (7), before fitting.
- Grease the threads of the reservoir (7) (sachet of grease in the kit).
- Oil the reservoir’s two O-ring seals (7) (sachet of oil in the kit).
Remove:
- The protection cap fitted at the time of removal, from the base (10).
- The protection at the other end of the reservoir (7).
Engage the reservoir (7) equipped with its skirt (6) on the threads of the base (10).
Manually screw on the reservoir (7), until the reservoir (7) is touching the foot of the base (10).
NOTE : Check that the bottom edge of the skirt (6) covers the base (10) all around it.
Tighten the reservoir (7) (TORX 70 FACOM).
Fit the plastic clip (9) and the screw (8) (new, in exchange kit).
Complete the fitting in reverse order to the removing.
Proceed to:
- Recharge the circuit. (See corresponding operation).
- Check that the air conditioning system functions correctly. (See corresponding operation).
C5HP188C
344

CONDITIONING
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
345

CONDITIONING

AIR
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)
a 0.8
b 1.4
c
d
e 0.8
C5HP18TP
346

CONDITIONING
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
347

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

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CITROEN U.K. Ltd.

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(A) Chassis stamp

(B) Manufacturer’s data plate.

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

(D) Inflation pressures and tyre references.

(E) Serial no. on bodywork.

(F) Gearbox reference – Factory serial no.

(G) Engine legislation type – Factory serial no.

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1.8i 16V 2.0i 16V

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

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2.0 HPi 30.i 24S V6

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

(*) FAP = Particle filter

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1.8i 16V 2.0i 16V 2.0 HPi 3.0i 24S V6

Type code DE 6FZC/IF DE 6FZB DE RFNC/IF DE RFNE DE RLZB DE XFX/IF DE XFXF/IF

Engine type 6FZ RFN RLZ XFX

Cubic capacity (cc) 1749 1997 2946

Fiscal rating (hp) 7 9 8 13 14

Gearbox type BE4/5 AL4 BE4/5 ML/5C ML/5T 4 HP 20

Gearbox ident. plate 20 DL 29 20 DL 30 20 TP 42 20 DL 31 20 LM 21 20 LE 95 20 HZ 13

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(*) FAP = Particle filter

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Type code DE 4HXB DE 4HXE

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(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

(E) Gearbox reference – Factory serial no.

(F) Engine legislation type – Factory serial no.

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2.0i 16V 2.2i 16V

Emission standard IFL5

(1) = Right hand drive

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Type code SEB XFWF/IF EA XFWF/IF

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2.0 HDi (*) 2.0 HDi (**)

(*) = With FAP (Particle filter).

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2.2 HDi (*)

(*) = FAP (Particle filter).

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The oil capacities are defined according to the following methods.

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

4) - Refit plug + cartridge.

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

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