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243

CLUTCH

GEARBOX

TRANSMISSION

4 HP 20 GEARBOX: TIGHTENING TORQUES

Engines: 4HX - XFW - 4HW

ightening torques (m.daN).

Gearbox exterior.

(2) Oil channel union fixing : 2,5 ± 0,5

(3) Exterior fixing of converter cover on clutch housing : 2,3 ± 0,5

(4) Speedometer take-off aperture plug : 1 ± 0,1

(5) Steel casing fixing : 0,6 ± 0,1

(6) Converter fixing on engine : 6 ± 1

(7) Interior fixing of converter cover on clutch housing : 2,3 ± 0,5

(8) Torx fixing of converter cover on clutch housing : 2,3 ± 0,5

Drain plug : 4,5 ± 0,8

Heat exchanger fixing : 3,5 ± 0,5

Selector lever position switch fixing : 1 ± 0,2

Converter cover fixing on engine cover (XFX engine) : 6,5 ± 1

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

B2CP3CZC

B2CP24BC

B2CP24CC

C5 - C8

Angl.T3-page207-255-2005. 4/02/05 15:19 Page 243

Correspondence Table for Petrol Engines2
Сorrespondence Table for Diesel Engines3
Very Important4
Identification of Vehicles5
Type Approval6
Capacities (in Litres)9
Draining Methods9
Draining of the Engine Lubrication System by Gravity9
Draining of the Engine Lubrication System by Suction9
Petrol10
Diesel11
New Look Citroën C513
Evolutions (Year 2004)13
Lubricants - Total Recommended Oils13
Use of Oil Grade 10W4014
Commercial Description for Energy Economy Oil14
Engine Oil Norms14
S.A.E. Norms - Table for Selection of Engine Oil Grade14
API Norms15
Classes and Grades of Total Recommended Engine Oils16
Blended Oils for All Engines (Petrol, Diesel and Dual Fuel Petrol/Lpg)16
Oils for Petrol, Diesel and Dual Fuel Petrol/Lpg Engines16
Oils Specifically for Diesel Engines16
Oil Usage Table17
Blended Oils for All Engines, Supplied in Bulk19
France19
Europe20
Oceania26
Central and South America27
South-East Asia28
Middle East30
Gearbox Oils31
Power Steering Oils32
Engine Coolant Fluid32
Synthetic Brake Fluid33
Hydraulic System33
Screen Wash Fluid34
Greasing34
General Use34
Maximum Permissible Oil Consumption for a Run-In Engine and Oil Level35
An Engine Can be Considered RUN-IN after35
Oil Consumption Depends on35
Engine Oil Consumption35
Engine Specifications36
Engines: 6FZ-RFJ-RFN-3FZ-XFU-XFW36
Engines: 9HZ-RHM-RHT-RHW-RHL-RHR-4HX-4HW37
Сompression Ratio - Diesel Engines38
Special Features: Tightening Torques39
Engines: 6FZ - RFJ40
Crankshaft40
Cylinder Block40
Flywheel/Clutch41
Lubrication Circuit42
Injection Circuit42
Intermediate Engine Support43
Upper RH Engine Support43
Engines: RFN - 3FZ43
Special Features: Power Unit Suspension43
Table of Contents45
Crankshaft Bearing Cap Cover (15)45
Equipment on Cylinder Head46
Engine: RFN46
Engine: 3FZ46
Engine: XFU47
Lower RH Engine Support/Torque Reaction Rod47
RH Engine Support47
Pencil Type Ignition Coil48
Valve Cover48
Camshaft Bearing Cap Cover48
Flywheel49
Exhaust Manifold49
Con Rod Caps49
Crankshaft Bearing50
Perform the Following Operations50
Sump51
Crankshaft Pinion/Pulley51
Inlet Distributor (with New Seals)51
Air Inlet Manifold51
Camshaft Hubs/Pulleys52
Cap and Guide Roller52
Timing Belt Tensioner Roller/Plate for the Dynamic Tensioner Roller52
Coolant/Oil Pump52
Gearbox Suspension53
RH Engine Support (Suspension)53
Engine: XFW53
Power Unit Suspension53
Power Unit Suspension - Engine Support (Lower)54
Crankshaft View54
Bearing Cap Cover55
Oil Sump56
Cooling Circuit57
Coolant Pump57
Coolant Manifold58
Cylinder Head Equipment58
Camshaft Bearing Cap Cover (Right Hand Side)59
Camshaft Bearing Cap Cover (Left Hand Side)59
Valve Covers (Right Hand Side)60
Valve Covers (Left Hand Side)60
Pre-Tightening 161
Inlet Manifold61
SPECIAL FEATURES: TIGHTENING TORQUES (M.dan) C861
Exhaust Manifold (Right/Left Hand Side)62
Re-Tightening62
Pre-Tightening 1 ± 0,1 2,562
- Inlet Distributor63
- Engine: 9HZ64
- Torque Reaction Rod64
- Upper LH Engine Support64
- Lower LH/RH Engine Support and RH Engine Support64
Slackening65
- Diesel Injection Circuit68
- Engines: RHL - RHR69
- Engines: RHL RHR71
- Engines: RHM - RHT - RHW74
- Plug CHC M12X150-16 (X 1) /M15X150 (X 1 and 2)74
- Pulley Screw M14X150-7074
- Screws M7X100-20 (X 4)/M7X100-40 (X 2)/M12X150-81 (X10)/M16X10-16 (X4)74
- Engine Suspension (Identification)75
- Engine Suspension (Tightening Torques)76
- Power Steering Pump77
- Alternator77
- Air Conditioning Compressor78
- Accessories Support78
- Guide Roller79
- Engine: 4HX80
- Tightening Torques80
- Flywheel - Clutch83
- Plug CHC M12X150-16 (X 1)/M15X150 (X 2)85
- Screws M7X100-40 (X 2)/M7X100-20 (X 4)/M12X150-81 (X10)85
- Screws M7X100-20 (X8)/M9X100-45 (X4)/M8X125-60 (X8)86
- Special Features - Cylinder Head Tightening92
- Belt Tension/Seem Units Correspondence Table96
- Auxiliary Equipment Drive Belt97
- Engines: All Types Petrol and Diesel98
- Engine: 6FZ99
- Engine: RFJ100
- «Junior» T Extension100
- Removing100
- Refitting100
- Peg for Dynamic Tensioner Roller101
- Reduction Box FACOM S.230 (1/2" - 3/8" Square)103
- Ratchet Spanner FACOM (1/2" Square)103
- Dynamic Tensioner Compressure Lever104
- Tensioning/Dynamic Roller Compressure Lever106
- Peg for Dynamic Roller 4/2 MM106
- Dynamic Tensioner Roller Retaining Peg 4Mm108
- Without Air Conditioning109
- Peg 4 MM109
- Peg for Dynamic Roller111
- Dynamic Roller Compressure Lever111
- Сhecking and Setting the Valve Timing113
- Сhecking the Valve Timing114
- Camshaft/Crankshaft Setting Peg114
- Checking the Setting of the Timing114
- Tool for Moving and Locking the Tensioner Roller115
- Adaptor for Angular Tightening115
- Timing Belt Retaining Pin115
- Tensioning the Timing Belt118
- Camshaft Pinion Peg120
- Crankshaft Setting Peg120
- Engine Lifting Crossmember120
- Peg for Positioning the Dynamic Tensioner Roller127
- Checks133
- Fuel Pressure Take-Off Union143
- Belt Retaining Pin143
- Exhaust Camshaft Hubs Immobilising Tool143
- Inlet Camshaft Hubs Immobilising Tool143
- Setting the Valve Timing145
- Adjusting the Timing Belt Tension147
- Instrument for Measuring Belt Tension149
- Peg for Checking Camshaft Settings149
- Tool for Immobilising Exhaust Camshaft Hubs149
- Tool for Immobilising Inlet Camshaft Hubs149
- Flywheel Setting Peg157
- Double Flywheel Setting Peg168
- Kit of Plugs168
- Additional Operations170
- Adjusting the Camshaft Position Sensor170
- Sensor Re-Used170
- New Sensor170
- Flywheel Lock171
- Pulley Extractor171
- Pinion Centrer171
- Belt Clamp171
- Belt Compressure Spring178
- Set of Blocking Plugs178
- Checking the Setting of the Valve Timing178
- Engine Flywheel Peg/Lock/Tension Lever178
- Engines: RHM-RHT-RHW-4HW184
- Pre-Tensioning the Timing Belt188
- Checking the Oil Pressure192
- Valve Clearances194
- The Valve Clearances Must be Checked with the Engine Cold194
- Possible Procedures194
- Rocking/Fully Open (Exhaust)194
- Pressure Gauge for Testing Boost Pressure195
- Normal/Abnormal Vacuum Values195
- 10 MM Low Pressure Connector195
- Checks: Low Pressure Fuel Supply Circuit195
- 8 MM Low Pressure Connector196
- Extension196
- Checks on Pressure: Dynamic197
- Abnormal Functioning197
- Impossible to Start the Engine197
- Mode of Operation198
- Checks: Turbo Pressure199
- Pressure Gauge for Checking the Pressure199
- Pressure Take-Off Extension/Union and Hose199
- Sleeve for Checking the Turbo Pressure and Adaptor Sleeve199
- Adaptor for Taking Pressure200
- Union and Hose/Unions and Hoses for Taking Pressure200
- Extension Cable for Taking Pressure200
- Pressure Gauge for Checking Pressure200
- Manual Pressure-Vacuum Pump202
- Turbocharging Pressure Regulation Valve202
- Checking the Vacuum Source (Vacuum Pump)203
- Turbocharging Pressure Electrovalve203
- Cold/Warm Air Circuit Electrovalve203
- Checking the Warm Air Opening204
- Checking the Cold Air Closing204
- Manual Vacuum Pump205
- Vacuum Pump206
- Turbo Vacuum Regulation Electrovalve206
- Turbo Pressure Regulation Valve206
- «Swirl» Control Diaphragm206
- Double Butterfly Housing (Vehicle with Particle Filter)207
- Exhaust Gas Recycling (EGR) Electrovalve207
- Electrovalve (EGR)208
- Butterfly Housing Electrovalve208
- EGR Valve209
- Butterfly Housing209
- Sparking Plugs210
- Speedometer211
- Clutch Specifications212
- Manual Gearbox Specifications214
- Gearbox Specifications215
- «Push» Clutch with Hydraulic Control216
- Description216
- Clutch Types: (BE4/5)216
- Engines: 6FZ - 9HZ216
- Clutch Types: (ML5C-ML6C)217
- Engines: XFX-RHS-RHZ-4HX217
- Hydraulic Clutch Control Specification218
- Bleeding the Hydraulic Clutch Control.218
- BE4/5 Gearbox: Tightening Torques221
- Engines: 6FZ-RFN-9HZ221
- Gearbox Rear Casing and Casing/Clutch Casing Fixings222
- Breather Pipe/Reverse Gear Switch222
- Drain/Top-Up Plug and Speedo Drive Support222
- Differential Housing Fixings (M7-M10)222
- Differential Gearwheel Screws223
- Gear Control Support Screw223
- Bearing Retaining Screw223
- Primary/Secondary Shaft Nut223
- ML5C Gearbox: Tightening Torques224
- Engines: 3FZ-RHM-RHT-RHW-4HW224
- Engines: RHL-RHR226
- ML6C Gearbox: Tightening Torques226
- BE4/5 Gearbox: Control Specifications228
- Gear Controls228
- Gear Lever Positioning Tool228
- Gear Selection Control Cable229
- Gear Engagement Control Cable229
- Adjustments230
- To Unlock the Length of the Gear Control Cable Sleeve230
- To Unlock a Sleeve Stop230
- Reverse Gear Unlocking Cable234
- To Unlock the Length of the Gear Selection Control Cable Sleeve235
- AL 4 Automatic Gearbox: Recommendations - Precautions237
- Precautions to be Taken237
- Repairs on Mechanical Components237
- Modification of the Oil Usage Counter Value237
- Procedure to be Followed Prior to Carrying out Repairs on AL4 Autoactive Gearbox238
- Oil Quality - Oil Level238
- Absence/Presence of Fault Codes238
- Procedure for Initialising the Automatic Gearbox ECU239
- Updating the Gearbox ECU by Downloading239
- After the Downloading Operation, Carry out the Following239
- Updating the Value of the Oil Usage Counter239
- Output Speed Sensor Fixing240
- Oil Overflow and Drain Fixing240
- Heat Exchanger Fixing240
- AL4 Gearbox: Tightening Torques240
- Fixing of Converter on Diaphragm241
- Plug Fixing241
- Gearbox Fixing on Engine241
- Hydraulic Block Fixing242
- Fixing of Selector Lever Position Switch242
- Oil Filler Plug242
- Gearbox End243
- New Gear Selection Control244
- Re-Used Gear Selection Control244
- AL4 “Shift Lock” Gearbox Control Specifications and Precautions245
- Unlocking the Shift Lock (with an Operating Fault)245
- When Performing Electrical Checks246
- 4 HP 20 Automatic Gearbox: Recommendations - Precautions246
- Repairs on Electrical Components246
- Engines: 4HX-XFW-4HW246
- 4 HP 20 Gearbox: Tightening Torques247
- Gearbox Exterior247
- Gearbox Interior248
- Input Speed Sensor Fixing248
- Hydraulic Block Fixing (Large Head)248
- 4 HP 20 Gearbox: Control Specifications249
- Selection Control249
- 4 HP 20 “Shift Lock” Gearbox Control Specifications and Precautions250
- Unlocking the “Shift Lock” (Normal Operation, with a Fault)250
- Engines: XFW - 4HW252
- Adjusting the Selection Control253
- 4 HP 20 Gearbox Controls: Checks and Adjustments253
- AM6 Automatic Gearbox: Recommendations - Precautions254
- Towing254
- Driving254
- AM6 Gearbox: Tightening Torques255
- Torque Converter/Engine Speed Sensor255
- Gearbox Support/Closing Panel Fixing255
- Fixting of Gearbox on Cylinder Block255
- Oil Temperature Sensor Tightening Plate256
- Hydraulic Valve Block (Sequence Indicated)256
- Oil Induction Cover/Ecu Screws256
- Oil Drain and Overflow/Oil Level Plug256
- Automatic Adjustment257
- Unlocking the «SHIFT LOCK» (with an Operating Fault)258
- AM6 “Shift Lock” Gearbox Control Specifications and Precautions258
- Driveshafts - Gearbox259
- Axle Geometry260
- Measuring Front Height260
- Measuring Rear Height260
- Carlsson262
- Axle Geometry: Checking and Adjusting Vehicle Height264
- Preliminary Operations264
- Checks by Axle264
- Measuring the Wheel Radius265
- Measuring the Front Height H1M265
- Calculating the Front Height H1C265
- Calculating the Rear Height H2C266
- Adjustment of Heights266
- Mechanical Pre-Adjustment266
- Rear Height267
- Front Height267
- Front Axle269
- Saloons and Estates and Carlsson270
- Rear Axle271
- Height Control272
- Power-Steering Specifications273
- Heat Shield Fixing on Casing274
- Additional Operation275
- Setting at Reference Height276
- Requirements Prior to Setting at Reference Height276
- Tooling Required276
- Measuring Front Height (H1)277
- Measuring Rear Height (H2)277
- Height of the Vehicle at the Front at Reference Height (H1 = R1 - L1)278
- Height of the Vehicle at the Rear at Reference Height (H2 = R2 + L2)279
- Values for Front Suspension Angles280
- Values for Rear Suspension Angles280
- Adjusting the Rolling Axles281
- Identification282
- Crossmember282
- Tie-Rods/Springs282
- Front Suspension Leg/Anti-Roll Bar282
- Fixing of Damper on Body/Rear Axle284
- Fixing of Stabiliser Bar on Rear Axle/Body284
- Fixing of Rear Axle on Body284
- Hub Nut284
- Fixing of Upper and Lower Shafts to Steering Column/Of Ball-Joint Housing on Steering Rack285
- Fixing of Steering Column to Support/Of Ram Valve Supply Unions285
- Steering Wheel Fixing/Rod Locking/Ball-Joint Nut285
- Engines: RFN-3FZ-XFW-RHM-RHT-RHW-4HW285
- Brake Specifications286
- Braking Circuit288
- Braking System Specifications288
- Brake Fluid Pressure Sensor on Master-Cylinder289
- Fixing of Gyrometer/Accelerometer Sensor on Support289
- Fixing of Support on Body289
- Brake Specifications290
- Checking the Vacuum Pump291
- Pressure Checker291
- Engines DW10, DW12 and DV6291
- Conditions for Adjustment292
- To Bed in the Parking Brake Cables, Operate as Follows292
- Checking and Adjusting the Parking Brake292
- Nut for Adjusting the Tension of the Parking Brake Cables293
- Draining, Filling and Bleeding the Braking System294
- Draining the Brake Fluid Reservoir294
- Bleeding the Primary Braking System294
- Filling the Braking System294
- Front/Rear Brake Caliper295
- Using the Bleeding Apparatus295
- Without Bleeding Apparatus296
- Bleeding the Secondary Braking System296
- Brake Tightening Torques298
- Engines: RFN-3FZ-XFW-RHT-RHW-RHM-4HW298
- Adjusting the Handbrake299
- Bleeding the Primary Braking Circuit302
- During the Operation304
- Safety Requirements: Hydractive 3 Hydraulic Suspension304
- Engine Running305
- Cleanliness Requirements305
- Specification - Identification: Suspension Spheres306
- Special Features307
- Hydractive 3 Hydraulic Suspension308
- Front/Rear Suspension Spheres308
- Hydractive 3 + Hydraulic Suspension309
- Hydractive Regulator Accumulators310
- Front/Rear Hydractive Regulator Accumulator310
- Hydraulic Specifications311
- Location of Components311
- Hydraulic Fluid Reservoir312
- Built-In Hydro-Electronic Interface (BHI)313
- Hydractive 3 + Regulator314
- Hydraulic Unions314
- DE-Pressurising the Hydraulic Suspension Circuit315
- Using a Diagnostic Tool315
- Without Using a Diagnostic Tool316
- Vehicle with Suspension Hydractive 3316
- Vehicle with Suspension Hydractive 3 +317
- Draining - Filling - Bleeding: Hydraulic Suspension/Steering Circuit318
- Pliers for CLIC Clips318
- Bleeding319
- Checking and Toppping up the LDS Fluid Level320
- Measurement of Heights321
- Measuring the Rear Height H2M322
- Adjusting the Heights322
- Measure the Front/Rear Height (H1M)324
- Checking and Adjusting the Vehicle Height325
- Checking by Axle325
- Air Conditioning326
- Special Features: Air Conditioning System327
- Summary Table for Presence of Pollen Filter327
- Pollen Filter328
- Drying Cartridge330
- Condenser with Integral Reservoir331
- Preparing the New Dryer Reservoir331
- Removing-Refitting the Drying Cartridge333
- Compressor Lubricant336
- Checking the Compressor Oil Level336
- Repairing a System Without Leaks336
- All Types337
- Checking the Compressor Oil Level (Continued)337
- Checking the Efficiency of the Air Conditioning System338
- Clim Test 2 Valeo339
- Positions of the Air Conditioning Controls340
- Interpretation of the Measurements341
- Under-Cooling341
- Values for Under-Cooling (SR)341
- Blown Air Temperature «U»341
- Values for Over-Heating (SC)342
- Interpretation of the Diagnosis343
- Aircon Circuit Diagnosis Table344
- Air Conditioning System348
- Evolution of the HP/LP Filling Valves348
- Engine: XFX350

Brand	CITROEN
Model	C8 2005
Category	Automobile
Language	English

CITROEN C8 2005 User Manual

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CITROEN C8 2005 Specifications

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