CITROEN C2 User 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 RETAIN THE
OLD ONES.
TU ET TU DV
13 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
XX XXXX
XXXX XXXX
XX XX
C2
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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
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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.
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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.
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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
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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
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GENERAL
1
C2IDENTIFICATION 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
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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
G3-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
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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
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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
C5-door saloon
(5-seater) No gearbox Z
LSport or leisure
(if different from base C)
R5-door saloon not
convertible from van
T5-door saloon
(if different from base N)
IDENTIFICATION OF VEHICLES
Type approval
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5
GENERAL
Engine (3) Variants (5)
HFX 1.1i TU1JP-TU1A Entreprise convertible T
KFV 1.4i TU3JP-TU3A Integral alternator-starter (ADIN) AD
KFU 1.4i 16V ET3JA Without FAP SF
NFU 1.6i 16V TU5JP4 Fiscal incentives IF
N6A 1.6i 16V TU5JP4 TR Piloted manual gearbox P
8HX 1.4 HDi DV4TD Downgraded depollution D (car or van not convertible) TD (van convertible)
8HZ 1.4 HDi DV4TD LPG dual fuel GPL (cylindrical tank) GL (ring-shaped tank)
8HY 1.4 16V HDi DV4TED4 STT2 (stop and start) S
9HZ 1.6 16V HDi DV6ATED4
FAP Flex Fuel FF
IDENTIFICATION OF VEHICLES
Type approval (continued)
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6
GENERAL
IDENTIFICATION OF VEHICLESC3 Pluriel
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.
E1AP0B2D
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7
GENERAL
Structure Version (4)
H Family (1) Depollution levels
N Bodywork (2) L3 L4 L5 US Others K Alcohol
HN KFVC/IF KFV 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
H C3 Pluriel Automatic 6-speed gearbox D J N U
Bodywork (2) Axle and/or gearbox gears K L T Y 7 0 4
B Cabriolet Other possible combinations M
No gearbox Z
Engine (3) Variants (5)
KFV 1.4i TU3JP Entreprise convertible T
NFU 1.6i 16V TU5JP4 Integral alternator-starter (ADIN) AD
8HX 1.4 HDi DV4TD Without FAP SF
8HZ 1.4 HDi DV4TD Fiscal incentives IF
Piloted manual gearbox P
Downgraded depollution D (Car or van not
convertible from) TD (van convertible)
LPG dual fuel GPL (cylindrical tank) GL (ring-shaped tank)
STT2 (stop and start) S
IDENTIFICATION OF VEHICLES
Type approval
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OPERATIONS TO BE CARRIED OUT AFTER A REPAIRC2 - C3
8
GENERAL
IMPERATIVE: All these operations are to be performed following a reconnection of the battery.
Antiscanning function.
It is necessary to wait 1 minute after the battery has been disconnected in order to be able to start the vehicle.
Tailgate.
The opening of the tailgate is deactivated on reconnection of the battery.
Perform locking/unlocking to activate the opening of the tailgate.
Overspeed check.
The vehicle's overspeed values have to be re-initialised.
The button on the wiper stalk (multifunction display Bor C) or the button on the dashboard (multifunction display Aor clock) operates the following
functions:
- Activation of the vehicle's overspeed function.
- Programming of the overspeed alert.
Electric windows.
It may be necessary to re-initialise the sequential and anti-pinch functions.
NOTE: If the window is open at the time the battery is reconnected, action the window switch several times to close it, then re-initialise.
Open the window fully.
Action and release the window switch until the window is completely closed.
This operation has to be carried out on each electric window.
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9
C2OPERATIONS TO BE CARRIED OUT AFTER A REPAIR
GENERAL
Sun roof.
The anti-pinch function has to be re-initialised.
Place the sun roof switch in the maximum tilt position.
Keep the sun roof switch pressed until the sun roof ceases its movement.
Release the sun roof switch within 5 seconds.
Keep the sun roof switch pressed until the end of the sun roof opening sequence.
Multifunction screen.
It is necessary to adjust the date, time and outside temperature.
Adjust the display language of the multifunction screen if necessary.
NOTE: The default display language of the multifunction screen is French.
Navigation.
Warning, the vehicle has to be in the open air (on switching on the ignition, the ECU searches for satellites) .
Vehicle location is only effective after some ten minutes.
Reprogramme the customer parameters.
Radio.
Reprogramme the radio stations.
Radiotelephone RT3.
Reprogramme the radio stations.
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Draining methods
Oil capacities are defined according to the following methods
10
GENERAL
CAPACITIES (in litres)
Draining of the engine lubrication system by GRAVITY
Place the vehicle on horizontal ground (in the high position if
hydropneumatic suspension) .
The engine should be hot
(oil temperature 80°C) .
Drain the sump by gravity.
Remove the oil filter cartridge (time for draining and drip-drip =
15 minutes approx.) .
Refit the cap with a new seal.
Refit a new oil filter cartridge.
Refill the engine with oil
(see table for oil capacity) .
Start the engine to fill the oil filter cartridge.
Stop the engine
(allow to stabilise for 5 minutes) .
Draining of the engine lubrication system by SUCTION
Place the vehicle on horizontal ground
(in the high position if
hydropneumatic suspension) .
The engine should be hot (oil temperature 80°C) .
Remove the oil by suction through the dipstick tube.
Remove the oil filter cartridge.
Maintain the suction of oil in the sump
(15 minutes approx.) .
Refit a new oil filter cartridge.
Refill the engine with oil
(see table for oil capacity) .
Start the engine to fill the oil filter cartridge.
Stop the engine (allow to stabilise for 5 minutes) .
WARNING: Remove the suction container before
starting the engine
ESSENTIAL: Systematically check the oil level using the oil dipstick.
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11
C2CAPACITIES (in litres)
GENERAL
TU1JP TU3JP TU5JP4 TU5JP4S DV4TD
➔RPO 9884 RPO 9885 ➔RPO ➔
1.1i 1.4i 1.6i 16V 1.4 HDi
HFX KFV NFU NFS 8HX 8HZ
3 3,25 3,75
1,5 1,5 1,8 1,5
2
2 ± 0,15
0,7 Litre version with front calipers Ø 48 / rear drums
0,8 Litre version with front calipers Ø 54 / rear discs
7 5,6
40 45
DieselPetrol
C2
ESSENTIAL: Systematically check the oil level using the oil dipstick.
Engine type
Engine with filter change
Between min. and max.
MA5 5-speed gearbox
MA5 piloted 5-speed gearbox
Braking circuit
Cooling system
Fuel tank capacity
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12
GENERAL
Engine type
Engine with filter change
Between min. and max.
5-speed gearbox
Automatic gearbox
Braking circuit
Cooling system
Fuel tank capacity
HFX KFV KFU NFU 8HX 8HZ 8HY 9HZ
3 3,75 3,25 3,75
1,5 1,2 1,5 1,8 1,5 1,8 1,5
22
(1)
0, 7 litre version with front calipers Ø 48 / rear drums
0,8 Litre version with front calipers Ø 54 / rear discs
7 6 7 5,7 5,6
45
C3 CAPACITIES (in litres)
DieselPetrol
C3
TU1JP TU3JP ET3J4 DV4ATED4
ESSENTIAL: Systematically check the oil level using the oil dipstick.
(1) = The gearbox is lubricated for life (for your information, the TOTAL capacity is 5,85 litres, after draining: 3 litres).
BVA
DV4TDTU5JP4 DV6ATED4
1.1i 1.4i 1.4i 16V 1.4 16V HDi1.4 HDi
1.6i 16V 1.6 16V
HDi
➔ RPO
9884
RPO
9885 ➔
RPO
➔
➔ RPO
9884
RPO
9885 ➔
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13
GENERAL
TU3JP TU5JP4 DV4TD
1.4i 1.6i 16V RPO ➔
1.4 HDi
Engine type KFV NFU 8HX 8HZ
Engine with filter change 3 3,25 3,75
Between min. and max. 1,5
5-speed gearbox 2
Braking circuit 0,7 Litre version with front calipers Ø 48 / rear drums
0,8 Litre version with front calipers Ø 54 / rear discs
Cooling system 7 5,7
Fuel tank capacity 45
ESSENTIAL: Systematically check the oil level using the oil dipstick.
CAPACITIES (in litres)
Petrol
C3 Pluriel
Diesel
C3 PLURIEL
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14
GENERAL
LUBRICANTS - TOTAL recommended oils
EVOLUTIONS (YEAR 2004).
CITROËN C4
Petrol engine versions except 2.0 i 16V 180 hp
(132 kW) :
Normal maintenance interval: 30 000 km (20 000 miles) .
Severe maintenance interval: 20 000 km (12 000 miles) .
Petrol engine version 2.0L i 16V 180 hp
(132 kW) :
Normal maintenance interval: 20 000 km (12 500 miles) .
Severe maintenance interval: 15 000 km (10 000 miles) .
Diesel engine versions:
WARNING: Vehicles HDi FAP (*) do not accept the energy economy
oil TOTAL ACTIVA FUTUR 9000 5W30 for France, TOTAL QUARTZ
FUTURE 9000 5W30 outside France .
DV6 engines:
Normal maintenance interval: 20 000 km
(12 500 miles).
Severe maintenance interval: 15 000 km (10 000 miles).
DW engines:
Normal maintenance interval: 30 000 km (20 000 miles).
Severe maintenance interval: 20 000 km (12 000 miles).
New Look CITROËN C5
Petrol engine versions:
Normal maintenance interval: 30 000 km
(20 000 miles) .
Severe maintenance interval: 20 000 km (12 000 miles) .
Diesel engine versions:
WARNING: Vehicles HDi FAP (*) do not accept the energy economy
oil TOTAL ACTIVA FUTUR 9000 5W30 for France, TOTAL QUARTZ
FUTURE 9000 5W30 outside France.
DV6 engines:
Normal maintenance interval: 20 000 km
(12 500 miles) .
Severe maintenance interval: 15 000 km (10 000 miles) .
DW engines:
Normal maintenance interval: 30 000 km
(20 000 miles) .
Severe maintenance interval: 20 000 km (12 000 miles) .
ESSENTIAL: For all vehicles with a 30 000 km (20 000 miles) mainte-
nance interval, use exclusively TOTAL ACTIVA/QUARTZ 7000 or
9000 or any other oils offering identical specifications to these.
These oils offer specifications that are superior to those defined by
norms ACEA A3 OR API SJ/CF.
Failing this, it is essential to adhere to the maintenance programmes
covering severe operating conditions.
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