2008 CITROEN C2 Service and Repair Manual

CORRESPONDENCE TABLE FOR PETROL ENGINES C3 C3 PLURIEL Engine families Engine types VERY IMPORTANT As the booklet is constantly re-edited, this one only covers vehicles for this particular model year . It is therefore necessary to order a new booklet each year and RET AIN THE OLD ONES. TU ET TU DV 1 3 5 4 6 JP J4 JP4 JP4S TD TED4 ATED4 1.1i 1.4i 1.4i 16V 1.6i 16V 1.4 HDi 1.4 16V 1.6 16V HDi HDi HFX KFV KFU NFU NFS 8HX 8HZ 8HY 9HX X X X X X X X X X X X X X X X X X X C2

PRIVATE CARS C2-C3-C3 PLURIEL PRIVATE CARS CAR 000 020 Volume 1 2005 AC/QCAV/MTD Méthodes techniques documentation © «The intellectual property rights relating to the technical information contained in this document belong exclusively to the manufacturer. Reproduction, translation or distribution in whole or in part without prior written authorisation from the manufacturer is forbidden». «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». 2005

PRESENTATION THIS HANDBOOK summarises the specifications, adjustments, checks and special features concerning CITROËN private vehicles, not including UTILITY vehicles for which there exists a separate handbook. The handbook is divided into groups representing the main functions: GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES SUSPENSION, STEERING - BRAKES - AIR CONDITIONING. In each section, the vehicles are dealt with in the following order: C2-C3-C3 PLURIEL and all models where applicable. The information given in this handbook is based on vehicles marketed in EUROPE.

IMPORTANT If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into account when preparing future publications. For example: - INSUFFICIENT INFORMATION - SUPERFLUOUS INFORMATION - NEED FOR MORE DETAILS Please send your comments and suggestions to: CITROEN U.K. Ltd. 221, Bath Road, SLOUGH, SL1 4BA. U.K.

GENERAL C2 1 - 2 C3 3 - 5 C3 Pluriel 6 - 7 Operations following a repair 8 - 9 C2 11 C3 12 C3 Pluriel 13 TOTAL recommended lubricants 14 - 36 ENGINE Specifications 37 - 38 Tightening torques: engines all types 39 - 72 Cylinder head tightening: all types 73 - 74 Auxiliary drive belt 76 Checking and setting the valve timing 90 Checking the oil pressure 133 Valve clearances 134 CLUTCH-GEARBOX-TRANSMISSION Clutch specifications: C2 146 Clutch specifications: C3, C3 Pluriel 147 Gearbox specifications 152 - 155 Tightening torques: MA gearbox 156 - 157 Recommendations - precautions: MA 158 - 161 Tightening torques MA piloted g'box 162 - 163 Tightening torques: BE4/5 reinforced 164 - 165 Tightening torques: BE4/5 gearbox 166 - 168 MA gearbox controls 169 MA gearbox: checks and adjustments 170 - 171 BE4/5 gearbox controls 172 BE4/5 gearbox: checks/adjustments 173 - 174 AL4: recommendations - precautions 175 - 178 Tightening torques: AL4 gearbox 179 - 181 AL4 gearbox controls 182 - 185 Drain - refill: AL4 gearbox 186 - 188 Gearbox - driveshafts 189 CONTENTS Vehicle identification Capacities INJECTION Checking the low pressure fuel supply circuit: C2, C3 (DV4TD) 135 Checking the low pressure fuel supply circuit: C3 (DV4ATD4) 136 Checking the low pressure fuel supply circuit: C2, C3 (DV6ATD4) 137 Checking the turbo pressure: C2, C3 (DV4TD) 138 Checking the turbo pressure: C3 (DV6ATD4) 139 Checking the air supply circuit: C2, C3 (DV4ATED4) 140 Checking the air supply circuit: C2, C3 141 Checking the air supply circuit: C3 142 Checking the exhaust gas recycling circuit: C2, C3 (DV4TD) 143 IGNITION Sparking plugs 144

AXLES - SUSPENSION - STEERING Axle geometry: C2 190 - 193 Tightening torques: front axle: C2 194 Tightening torques: rear axle: C2 195 Tightening torques: suspension: C2 196 Tightening torques: power steering C2 197 - 198 Setting the steering rack mid-point: C2 200 Axle geometry: C3 201 - 205 Axle geometry: C3 Pluriel 206 - 208 Tightening torques: front axle: C3, C3 Pluriel 209 Tightening torques: rear axle: C3, C3 Pluriel 210 Tightening torques: suspension: C3, C3 Pluriel 211 - 213 Tightening torques: power steering: C3, C3 Pluriel 214 - 215 Setting the steering rack mid-point: C2, C3 Pluriel 217 Aircon circuit: all Types: C3, C3 Pluriel 262 CONTENTS BRAKES Brake specifications: C2 218 - 223 Adjusting the handbrake: C2 224 - 225 Filling, bleeding the brakes: C2 226 - 228 Brake specifications: C3 229 - 233 Brake specifications: C3 Pluriel 234 - 238 Adjusting the handbrake: C3, C3 Pluriel 239 - 240 Filling, bleeding the brakes: C3, C3 Pluriel 241 - 243 AIR CONDITIONING R134.a: quantities 244 Special features of aircon circuit 245 Pollen filter: C2 246 Pollen filter: C3, C3 Pluriel 247 Filtering and drying cartridge: C2, C3, C3 Pluriel 248 - 249 Compressor lubricant 250 - 251 Checking the efficiency of the circuit 252 - 260 Aircon circuit: all Types: C2 261

1 C2 IDENTIFICATION OF VEHICLES E1AP0C3D A- Cold stamp (cold stamp engraved on the bodywork). B - Manufacturer's name plate (on the LH centre pillar). C - AS/RP No. and RP paint code (on the LH centre pillar). D - Tyre pressures and tyre type (on the LH centre pillar). E - Serial number on bodywork. F - Gearbox ident. reference - Factory serial no. G - Engine legislation type - Factory serial no. GENERAL

2 GENERAL Structure Version (4) J Family (1) Depollution levels M Bodywork (2) L3 L4 L5 US Others K Alcohol JM HFXC/IF HFX Engine (3) W3 83/87 K' L3/L4 L5 C Version (4) Manual 5-speed gearbox A B C P V 5 8 1 /IF Variant (5) Manual 4-speed gearbox E F R W 6 9 2 Family (1) Manual 6-speed gearbox G H S X 3 J C2 Automatic 6-speed gearbox D J N U Bodywork (2) Axle and/or gearbox gears K L T Y 7 0 4 G 3-door saloon not convertible from van Other possible combinations M M 3-door saloon (4 seater) No gearbox Z Engine (3) Variants (5) HFX 1.1i TU1JP Entreprise convertible T KFV 1.4i TU3JP Integral alternator-starter (ADIN) AD NFU 1.6i 16V TU5JP4 Without FAP SF NFS 1.6i 16V TU5JP4S Fiscal incentives IF 8HX 1.4 HDi DV4TD Piloted manual gearbox P 8HZ 1.4 HDi DV4TD Downgraded depollution D (car or van not convertible from van) TD (convertible from van) LPG dual fuel GPL (cylindrical tank) GL (ring-shaped tank) STT2 (stop and start) S IDENTIFICATION OF VEHICLES Type approval

GENERAL 3 E1AP09HD IDENTIFICATION OF VEHICLES A- Cold stamp (cold stamp engraved on the bodywork). B - Manufacturer's name plate (on the LH centre pillar). C - AS/RP No. and RP paint code (on the front pillar on driver's side). D - Tyre pressures and tyre type (on the front pillar on driver's side). E - Serial number on bodywork. F - Gearbox ident. reference - Factory serial no. G - Engine legislation type - Factory serial no. C3

4 GENERAL Structure Version (4) F Family (1) Depollution levels C Bodywork (2) L3 L4 L5 US Others K Alcohol FC HFXC/IF HFX Engine (3) W3 83/87 K' L3/L4 L5 C Version (4) Manual 5-speed gearbox A B C P V 5 8 1 /IF Variant (5) Manual 4-speed gearbox D E F R W 6 9 2 Family (1) Manual 6-speed gearbox G H S X 3 F C3 Axle and/or gearbox gears J K L T Y 7 0 4 Bodywork (2) Other possible combinations M N U C 5-door saloon (5-seater) No gearbox Z L Sport or leisure (if different from base C) R 5-door saloon not convertible from van T 5-door saloon (if different from base N) IDENTIFICATION OF VEHICLES Type approval

2008 CITROEN C2 Service and Repair Manual

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