CITROEN C2 User manual

CORRESPONDENCE TABLE FOR PETROL ENGINES

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

COUV-ang.-TOME1-2005 9/01/06 9:07 Page 1

PRIVATE CARS

C2-C3-C3 PLURIEL

PRIVATE CARS

CAR 000 020

Volume 1

2005

AC/QCAV/MTD

Méthodes techniques documentation

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

COUV-ang.-TOME1-2005 9/01/06 9:07 Page 2

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.

Angl.-t1-Index-2005 9/01/06 9:10 Page I

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.

Angl.-t1-Index-2005 9/01/06 9:10 Page II

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

Angl.-t1-Index-2005 9/01/06 9:10 Page III

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

Angl.-t1-Index-2005 9/01/06 9:10 Page IV

GENERAL

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

Angl-t1-page001-36-2005 9/01/06 9:12 Page 1

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

Angl-t1-page001-36-2005 9/01/06 9:12 Page 2

GENERAL

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.

Angl-t1-page001-36-2005 9/01/06 9:12 Page 3

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

Angl-t1-page001-36-2005 9/01/06 9:12 Page 4

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