Citroën C8 2002 User Manual

2002

CAR 050013

«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».

PRESENTATION

THIS HANDBOOK summarises the specifications, adjustments, checks and special features of the CITROEN C8.

The handbook is divided into the following sections representing the main functions :

GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH - GEARBOX - DRIVESHAFTS - AXLES - SUSPENSION - STEERING - BRAKES - HYDRAULICS ELECTRICAL - AIR CONDITIONING.

GENERAL

IDENTIFICATION OF VEHICLES

E1AP0A2D

(A) Chassis stamp (cold stamp on bodywork).

(B) Manufacturer’s data plate (under RH centre pillar).

(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.

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 Cubic capacity (cc) 1998 2230 Fiscal rating (hp) 911

Gearbox type BE4/5 AL4 ML5C Gearbox ident. plate 20 DL 27 (1) 20 DL 26 (2) 20 TP 74 20 LM 09

IDENTIFICATION OF VEHICLES

Petrol

2.0i 16V

2.2i 16V

X – SX

Exclusive

Captain Chair

Exclusive

Captain Chair

Automatic

ManualManual

X - SX

(1) = Right hand drive (2) = Left hand drive.

GENERAL

Automatic

Emission standard IFL5 Type code SEB XFWF/IF EA XFWF/IF

Engine type XFW Cubic capacity (cc) 2946 Fiscal rating (hp) 14

Gearbox type 4 HP 20 Gearbox ident. plate 20 HZ 27

IDENTIFICATION OF VEHICLES

Petrol

3.0i V6 S24

Exclusive

Captain Chair

Exclusive

GENERAL

Emission standard L4 Type code EB RHTB EB RHTE EA RHTE EB RHWB EB RHWE EA RHWE

Engine type RHT RHW Cubic capacity (cc) 1997 Fiscal rating (hp) 7

Gearbox type ML5C AL4 ML5C AL4 Gearbox ident. plate 20 LM 05 20 TS 04 20 LM 05 20 TS 04

IDENTIFICATION OF VEHICLES

Diesel

2.0 HDi (*)

2.0 HDi (**)

X – SX – Exclusive

Captain Chair

Automatic

Manual AutomaticManual

Captain Chair

X – SX – Exclusive

(*) = With particle filter. (**) = Without particle filter.

GENERAL

(*) = With particle filter.

Manual

Emission standard L4 Type code EB 4HWB EA 4HWB

Engine type 4HW Cubic capacity (cc) 2179 Fiscal rating (hp) 8

Gearbox type ML5C Gearbox ident. plate 20 LM 01

IDENTIFICATION OF VEHICLES

Diesel

2.2 HDi (*)

Captain Chair

Exclusive

Captain Chair

GENERAL SPECIFICATION: LIFTING AND SUPPORTING THE VEHICLE

GENERAL

Tooling.

[1] Crossbeam : (-). 0010. Front lifting on one side.

Position the jack (4) at the strongpoints provided for this purpose on each side of the front crossmember between the bumper (2) and the engine (3).

Front central lifting.

Using a jack equipped with a crossbeam (sufficiently rigid) take the weight at the two strongpoints on the front crossmember.

Side lifting. At the front and at the rear

Take the weight at the sill, by means of the crossbeam [1], as close as possible to the jacking point. Position a stand at the jacking point provided for the purpose of lifting the vehicle with the jack.

WARNING : Avoid the battery tray on the right hand side. Side lifting at both front and rear

Take the weight at the sill, by means of the crossbeam [1]. Position stands at the jacking points provided for the purpose of lifting the vehicle with the jack.

WARNING : Lifting at the rear of the vehicle using the crossbeam is STRICTLY PROHIBITED.

E2AK02ZD E2AF006C E2AK030D E2AK031D

GENERAL SPECIFICATION: LIFTING AND SUPPORTING THE VEHICLE

GENERAL

Lifting by means of a two-column workshop lift WARNING : The removing of components such as the engine/gearbox, rear sub-

frame etc, can cause a displacement of the centre of gravity: Use a lift equipped with retaining devices to keep the body stable on the lift.

Without body clamps.

Place the lift’s guide pads at each jacking point.

WARNING : To prevent any risk of the vehicle toppling, it is prohibited to remove mechanical components.

With body clamps WARNING : These clamps are fitted only on FOG lifts.

Position the clamps at the sill in the jacking points provided, screw heads oriented towards the outside of the vehicle. Tighten the clamps using the gudgeon pin and, after tightening, engage the pin in the hole (A).

Towing (front).

Lift the blank with the aid of the flat part of the towing eye (1) and then screw the eye home. NOTE : The towing eye is to be found on the front panel inside the engine compartment.

Towing (rear). Lift the blank (1) and screw the towing eye home.

E2AF004D E5AF022D E2AK02YD E2AK02XD

GENERAL

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 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

CAPACITIES (in litres)

Petrol Diesel

Auto.

Auto. Auto.

2.0i 16V 2.2i 16V 3.0i 24V 2.0 HDi 2.2 HDi

ENGINE SPECIFICATIONS

Diesel

Engines : RFN - 3FZ - XFW - RHW - RHT - 4HW

Petrol

All Types

2.0i 16V 2.2i 16V 3.0i 24V 2.0 HDi 2.2 HDi

Engine type

Cubic capacity (cc)

Bore / Stroke

Compression ratio

Power ISO or EEC KW - rpm

Power DIN (HP - rpm)

Torque ISO or EEC (m.daN - rpm)

RFN 3FZ XFW RHT- RHW 4HW

1997 2230 2946 1997 2179

85/88 86/96 87/82.6 85/88 85/96

10.8/1 10.9/1 17.3/1 17.6/1 100-6000 116-5650 150-6000 79-4000 94-4000 138-6000 160-5650 204-6000 109-4000 130-4000

19-4100 21.7-3900 28.5-3750 27-1750 31.4-2000

ENGINE

ENGINE SPECIFICATIONS

Engines : RFN – 3FZ

(1) Compulsory engine plate :

(A) Engine legislation type.

(B) Component reference.

B1BB010D

ENGINE

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Engines : RFN – 3FZ

Crankshaft

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°

B1BK1X8D

Description

(16) Con-rod caps

(17) Flywheel/

crankshaft fixing

Pre-tightening 1 ± 0.1 2.5 ± 0.2 Slackening Yes 18°± 1° Re-tightening 2.5 ± 0.2 1 ± 0.1

22°±2°Angular tightening 46° ± 5°

ENGINE

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Equipment on cylinder head

Engine : RFN Engine : 3FZ

B1BK1X9D B1BK1XAD

Description (18) Camshaft bearing cap covers (19) Valve covers

0.5 0.5

1 ± 0.1 1.5 ± 0.1

(20) Inlet manifold (21) Exhaust manifold

1 ± 0.1 3.5 ± 0.3

Pre-tightening Tightening Description Tightening

ENGINE

SPECIAL FEATURES: POWER UNIT SUSPENSION

Upper RH engine support Engines : RFN – 3FZ

Description RFN 3FZ

Gearbox type

Rod/body fixing screw..(1)

(2)

(3) (4) (5) (6) (7)

(8)

(9)

(10) (11)

Engine support/torque reaction rod

flexible stop pin

Upper support/intermediate

support fixing screw.

Upper support/body fixing screw

Upper support/flexible

support fixing nut.

Support

LH flexible support/LH engine

support fixing nut.

LH flexible support/body

fixing screw.

Intermediate engine support/gearbox

casing fixing screw.

LH intermediate support/gearbox

fixing screw.

Flexible support pin.

BE4/5 AL4

5 ± 0.5

4.5 ± 0.4

6.5 ± 0.6 3 ± 0.3

4.5 ± 0.4

6.5 ± 0.6

3 ± 0.3

4.5 ± 0.4

5 ± 0.5

6 ± 0.6 4.5 ± 0.4

ML5C

Intermediate engine support

B1BK1X5D

B1BK1X6D

Ref.

ENGINE

SPECIAL FEATURES: POWER UNIT SUSPENSION

Intermediate engine support Engines : RFN – 3FZ

Description RFN 3FZ

Gearbox type

(12)

(13)

(14)

Lower RH rod/subframe

fixing screw.

Lower RH engine support/cylinder

block fixing screw.

Lower rod/lower RH engine

support fixing screw

BE4/5 AL4

9 ± 0.9

4.5 ± 0.4

6.5 ± 0.6

ML5C

B1BK1X7D

Ref.

ENGINE

CYLINDER HEAD

Engines : RFN – 3FZ

Cylinder head gasket identification Cylinder head tightening (m.daN) Cylinder head bolts

(1D) : Manufacturer

identification.

Angular

tightening

Tightening

Slackening

Pre-tightening

285°

360°

2/ : 5

1/ : 1.5

3FZ

RFN

Tighten in the order indicated

X = MAXI re-usable

270°

(1C) : Repair dimension

E – F – H =0.99 E – F – G sans

E – H = 0.8 E – G = 0.8

RFN 3FZ

Cylinder head gasket thickness

(mm)

Ref.

Multi-layer metallic gasket.

(1B) : Nominal dimension

3FZ

144.5 mm 127.5 mm

B1BK24QD B1DK001C B1DB002C

ENGINE

SPECIAL FEATURES: VALVE TIMING

Engines : RFN - 3FZ

The camshafts are referenced following two methods.

- (1) Marking position (2) Paint rings.

- (3) Marking position (4) Marking at end of shaft.

- (5) Target for camshaft position sensor.

Marking position: (1) Paint ring : Repair reference. (2) Green paint ring : Factory reference. (3) Inlet D1309 : Exhaust D1348. (4) Inlet 96 332 713 99 : Exhaust 96 3425433 99.

Timing belt.

Width : 25.4 mm Number of teeth : 153 Material : HSN

Valve clearances when cold

Inlet (A) : NON adjustable Exhaust (E) : NON adjustable

B1EK1UCD

ENGINE

ENGINE SPECIFICATIONS

Engine : XFW

(A) Component reference.

(B) Engine legislation type.

B1BK1JWD

ENGINE

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Engine : XFW

Power unit suspension

Gearbox suspensionRH engine support (Suspension)

(2) Link rod fixing : 5 ± 0.5 (3) Link rod fixing : 4.5 ± 0.4 (4) Fixing of upper RH engine support on intermediate engine

support flexible mounting : 6 ± 0.6 (5) Fixing of RH engine support on flexible mounting : 4.5 ± 0.4 (6) Fixing of flexible mounting : 3 ± 0.3 (7) Fixing of RH intermediate engine support on cylinder block : 6 ± 0.6

(8) Fixing of gearbox support on LH flexible mounting : 6.5 ± 0.6 (9) Shaft : 6.5 ± 0.6 (10) Fixing of flexible mounting on support : 3 ± 0.3 (11) Fixing of flexible mounting support on body : 2.5 ± 0.2 (12) Fixing of flexible mounting support on body : 2.5 ± 0.2

B1BK24RD B1BK24SD

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Engine : XFW

CrankshaftPower unit suspension – Engine support (Lower)

(13) Torque reaction link rod fixing : 9 ± 0.9 (14) Fixing of link rod on torque reaction flexible mounting : 6.5 ± 0.6

(15) Fixing of torque reaction flexible mounting : 4.5 ± 0.4 (16) Fixing of heat shield on torque reaction flexible mounting : 1 ± 0.1

(17) Bearing cap Tightening : 2 ± 0.2

+ Angular tightening : 74° ± 7°

(18) Timing pinion Tightening : 4 ± 0.4

+ Angular tightening : 80° ± 8°

(19) Fixing of starter gear support flange, plus crankshaft

converter support Tightening : 2 ± 0.2

Angular tightening : 60° ± 6°

(20) Accessory pulley on timing pinion : 2.5 ± 0.2

B1BK24TD B1BK24UD

ENGINE

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Engine : XFW

Cylinder block

Bearing cap cover

Respect the sequence of stages and the order of tightening

Reference/description

(21) Fixings of bearings/cap covers or

bearings/caps

21) Fixings of bearings/cap covers or bearings/caps (Slacken to zero torque

(21) Fixings of bearing cap cover or bearing caps (Tighten bolt by bolt

) Tightening + Angular tightening

M11

Bolts from 1

to 8

Stage 1

3 ± 0.3

Stage 2

1 ± 0.1

Stage 3

1 ± 0.1

Stage 4

YES

Stage 4

YES

Stage 5

3 ± 0.3

180°

Stage 6

1 ± 0.1

180°

Bolts from 9

to 16)

B1BK24VD

ENGINE

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Engine : XFW

Lubrication circuit

Oil sumpLubrication circuit.

(22) Oil separator : 0.8 (23) Strainer : 0.8 (24) Induction pipe : 0.8 (25) Drain plug : 3 ± 0.3 (26) Oil filter sleeve (with coolant/oil exchanger) : 0.5 Oil filter : 0.2

Stage 1 : Do up bolts 13,15 and 17. Stage 2 : Tighten bolts 13,15 and 17 to : 0.2 Stage 3 : Do up the 17 remaining bolts. Stage 4 : Tighten the remaining bolts to : 0.5 Stage 5 : Tighten all the bolts : 0.8 Stage 6 : Repeat the tightening a few times in the same order to obtain a tightening torque of 0.8 m.daN on all the bolts.

B1BK24WD B1BK24XD

ENGINE

Respect the sequence of stages and the order of tightening

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Engine : XFW

Cooling circuitLubrication circuit

Coolant pumpOil pump

Stage 1 : Position the screws and do them up by hand. Stage 2 : Pre-tighten the screws : 0.5 Stage 3 : Tighten the screws : 0.8 Stage 4 : Repeat the tightening a few times in the same order to obtain a tightening torque of 0.8 m.daN on all the screws.

B1BK3B6D B1BK3B7D

Respect the sequence of stages and the order of tightening

ENGINE

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Engine : XFW

Cylinder head equipmentLubrication circuit

Coolant manifold

(27) Screws : 2.5 ± 0.2 (28) Screws : 0.8 (29) Screws : 0.8

B1BK24YD

B1BK24ZD

ENGINE

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Engine : XFW

Cylinder head equipment

Camshaft bearing cap cover (left hand side)Camshaft bearing cap cover (right hand side)

(30) Camshaft bearing cap cover or camshaft bearing:

Pre-tighten to : 0.2 Tighten to : 1

B1EK0GCC B1BK3B8D

Respect the sequence of stages and the order of tightening

ENGINE

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Engine : XFW

Cylinder head equipment

Valve covers (left hand side)Valve covers (right hand side)

(31) Valve cover :

Pre-tighten to : 0.5 Tighten to : 0.8

B1EK0GEC B1EK0GFC

Respect the sequence of stages and the order of tightening

ENGINE

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Engine : XFW

Cylinder head equipment

Inlet manifold

(32) Inlet manifold:

Pre-tighten to : 0.4 Tighten to : 0.8

B1BK251D

Respect the sequence of stages and the order of tightening

ENGINE

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Engine : XFW

Cylinder head equipment

Exhaust manifold (left hand side)Exhaust manifold (right hand side)

(33) Exhaust manifold:

Pre-tighten to : 1 Tighten to : 3 ± 0.3

B1JK03ND B1JK03LD

Respect the sequence of stages and the order of tightening

ENGINE

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Engine : XFW

Cylinder head equipment

Inlet distributor

(34) Inlet distributor:

Pre-tighten to : 0.4 Tighten to : 0.8

B1BK252D

Respect the sequence of stages and the order of tightening

ENGINE

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