2005 Citroen C5 2.0 16V HDi Service & Repair Manual

EW DW ES CORRESPONDENCE TABLE FOR DIESEL ENGINES Engine families Engine types CORRESPONDENCE TABLE FOR PETROL ENGINES 7 10 12 9 12 C5 C8 C5 C8 Engine families Engine types VERY IMPORTANT A J4 J4 A 6FZ RFJ 3FZ RFN XFW XFU 1.8i 16V 2.0i 16V 2.2i 16V HPi X 3.0i 24V X X X X X X 10 TED4 1,6 16V HDi 9HZ TED4 2,0 16VHDi BTED4 TED ATED4 DV 6 RHM RHT RHW RHL 4HX 4HW X X RHR J4 X X X X X 2,2 16VHDi

PRIVATE CARS CITROËN C5 - CITROËN C8 PRIVATE CARS CAR 000.020 Volume 3 2005 AC/DTAV/PRME/MMCB/MMEC Méthodes Mécaniques © «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 of 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 - HYDRAULICS - AIR CONDITIONING. In each section, the vehicles are dealt with in the following order: C5 - C8 and all models where applicable. The information given in this handbook is based on vehicles marketed in EUROPE .

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.

CONTENTS GENERAL C5 1 - 2 C8 3 - 4 C5 6 - 7 C8 8 Lubricants 9 - 31 ENGINE Specifications 32 - 33 Compression ratios 34 Tightening torques: engines all types 35 - 87 Cylinder head tightening: all types 88 - 91 Auxiliary drive belt 93 Checking and setting the valve timing 109 Checking the oil pressure 188 - 189 Valve clearances 190 INJECTION Checking the low pressure fuel supply circuit: C5 (DW10BTED4) 190 Checking the low pressure fuel supply circuit : C5 (DW12TED) 192 - 193 Vehicle identification Capacities Checking the turbo pressure: 194 C5 (DV6TED4) Checking the turbo pressure: 195 C5 (DW10BTED4) Checking the turbo pressure: 196 - 197 C5 (DW12TED) Checking the air supply circuit: 198 C5 (DV6TED4) Checking the air supply circuit: 199 - 200 C5 (DW10BTED4) Checking the air supply circuit: 201 - 202 C5 (DW12TED) Checking the exhaust gas recycling 203 circuit: (DV6TED4) Checking the exhaust gas recycling 204 - 205 circuit: (DW12TED) IGNITION Sparking plugs 206 CLUTCH - GEARBOX - TRANSMISSION Speedometer 207 Clutch specifications: C5 208 Clutch specifications: C8 209 Manual/automatic gearbox: 201 - 211 all types Tightening torques: clutch 212 - 214 Hydraulic clutch control 215 - 216 Tightening torques 217 - 223 manual gearbox: all types Checks and adjustments: 224 - 232 manual gearbox all types Recommendations/precautions: 233 - 235 AL4 automatic gearbox Tightening torques: AL4 236 - 238 AL4 gearbox controls 239 - 240 AL4 gearbox controls 241 Recommendations/precautions: 242 4 HP 20 automatic gearbox Tightening torques: 4HP 20 gearbox 243 - 244 4HP 20 gearbox controls 245

Draining, filling, bleeding 297 - 299 the braking circuit : C8 HYDRAULICS Safety requirements: Hydractive 300 - 301 3 hydraulic suspension Specification / identification: 302 - 306 suspension spheres Hydraulic specifications 307 - 310 Depressurising the hydraulic 311 - 313 suspension circuit Draining and filling the hydraulic 314 - 320 suspension and steering circuit Checking/adjusting vehicle height 321 AIR CONDITIONING R134.a: quantities 322 Pollen filter 324 - 325 Filtering and drying cartridge 326 - 331 Compressor lubricant 332 - 333 Checking the efficiency of the circuit 334 - 343 Air conditioning circuit: C5 344 - 348 Air conditioning circuit: C8 349 - 351 CLUTCH - GEARBOX - TRANSMISSION 4 HP 20 Shift lock: C5 246 Checks and adjustments: 247 4 HP 20: C5 4 HP 20 Shift lock: C8 248 Checks and adjustments: 249 4 HP 20: C8 Recommendations/precautions: 250 AM6 gearbox: C5 Tightening torques: AM6 gearbox 251 - 252 AM6 gearbox controls 253 AM6 Shift lock: C5 254 Driveshafts 255 AXLES - SUSPENSION - STEERING Axle geometry: C5 all types 256 - 257 except CARLSSON Axle geometry: C5 CARLSSON 258 - 259 Checking/adjusting vehicle height: C5 260 - 264 Tightening torques: front axle: C5 265 - 266 Tightening torques: rear axle: C5 267 - 268 Tightening torques: power steering: C5 269 - 271 Axle geometry: C8 272 - 276 Adjusting the rolling axles: C8 277 Tightening torques: front axle: C8 278 - 279 Tightening torques: rear axle: C8 280 Tightening torques: power steering: C8 281 BRAKES Brake specifications: C5 282 - 284 Brake tightening torques: C5 285 - 286 Checking/adjusting vacuum pump: C5 287 Adjusting the handbrake: C5 288 - 289 Draining, filling, bleeding 290 - 292 the braking circuit: C5 Brake specifications: C8 293 Brake tightening torques: C8 294 Adjusting the handbrake: C8 295 - 296 CONTENTS

1 GENERAL GENERAL IDENTIFICATION OF VEHICLES E1APO8RD A- Chassis stamp (cold stamp on bodywork). B - Manufacturer's data plate (under the rear bench seat). C - A-S/RP No. and RP paint code (label on front pillar close to driver's door). D - Inflation pressures and tyre references (label on front pillar close to driver's door). E - Serial no. on bodywork. F - Gearbox reference - Factory serial no. G - Engine legislation type - Factory serial no. C5

GENERAL 2 C5 IDENTIFICATION OF VEHICLES Type approval Manual 5-speed gearbox A B C P V 5 8 1 Manual 4-speed gearbox E F R W 6 9 2 Manual 6-speed gearbox ts G H S X 3 Automatic 6-speed gearbox D J N U Axle and/or gearbox gears K L T Y 7 0 4 Other possible combinations M No gearbox Z Structure Depollution levels DC RFNC/IF Version (4) Family (1) Body shape (2) Engine (3) D Family (1) C Bodywork (2) RFN Engine (3) C Version (4) /IF Variant (5) D C5 C 5-door saloon E Estate 6FZ EW7J4 1.8i 16V RFJ EW10A 2.0i 16V XFU ES9A 3.0i 24S 9HZ DV6TED4 1.6i 16 HDi RHL DW10BTED4 2.0i 16V HDi RHR 4HX DW12TED4 2.2 16V HDi L3 L4 Euro IV US Other K Alcohol W3 83/87 K’ L3/L4 Euro IV Variants (5) Entreprise convertible T Integral alternator-starter (ADIN) AD Without FAP SF Fiscal incentives IF Piloted manual gearbox P Downgraded depollution D LPG dual fuel GL STT2 (stop and start) S

3 GENERAL GENERAL IDENTIFICATION OF VEHICLES E1AP0A2D A- Chassis stamp (cold stamp on bodywork). B - Manufacturer's data plate (under RH centre pillar). C - A-S / RP No. and RP paint code (label on front pillar). D - Inflation pressures and tyre references (label on front pillar). E - Gearbox reference - Factory serial no. F - Engine legislation type - Factory serial no. C8

4 GENERAL C8 IDENTIFICATION OF VEHICLES Type approval Manual 5-speed gearbox A B C P V 5 8 1 Manual 4-speed gearbox E F R W 6 9 2 Manual 6-speed gearbox ts G H S X 3 Automatic 6-speed gearbox D J N U Axle and/or gearbox gears K L T Y 7 0 4 Other possible combinations M No gearbox Z Structure Depollution levels EA XFWF/IF Version (4) Family (1) Body shape (2) Engine (3) E Family (1) A Bodywork (2) XFW Engine (3) F Version (4) /IF Variant (5) E C8 A Monospace 7 seats maximum B Monospace 8 seats maximum RFN EW10J4 2.0i 16V 3FZ EW12J4 2.2i 16V Hpi XFW ES9J4 3.0i 24S RHM DW10TED4 2.0i 16V HDi RHT RHW 4HW DW12ATED4 2.2i 16V HDi L3 L4 Euro IV US Other K Alcohol W3 83/87 K’ L3/L4 Euro IV Variants (5) Entreprise convertible T Integral alternator-starter (ADIN) AD Without FAP SF Fiscal incentives IF Piloted manual gearbox P Downgraded depollution D LPG dual fuel GL STT2 (stop and start) S

2005 Citroen C5 2.0 16V HDi Service & Repair Manual

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