Turbo Citroen C5 2000 (DC/DE) / 1.G Owner's Manual

Downloaded from www.Manualslib.com manuals search engine INJECTION
Idling - antipollution 111
Petrol injection 112
Emission standards 113 - 119
Prohibited operations : HDi 120 - 121
Safety requirements : HDi 122 - 123
Checking the fuel supply circuit 124 - 125
Checking the air supply circuit 126 - 130
Exhaust gas recycling 131 - 134
Checking turbo pressure 135 - 138
Features of injection systems 139 - 168
IGNITION
Sparking plugs 169
CLUTCH-GEARBOX
Speedometers 170
Clutch specifications 171 - 172
Gearbox and tyre specifications 173 - 174
BE4/5 gearbox controls 175 - 183
ML/5 gearbox controls 184 - 192
AL4-4HP20 gearbox controls 193 - 203
Driveshafts 204
AXLES-SUSPENSION
Wheels and tyres 205 - 211
Axle geometry 212 - 214
Front and rear axle 215 - 216Suspension 217 - 220
Steering specifications 221 - 222
BRAKES
Brake specifications 223 - 228
Handbrake adjustment 229
Bleeding and filling braking system 230 - 233
HYDRAULICS
Specifications 234 - 237
Suspension spheres 238 - 240
ELECTRICAL
Starter motors 241
Alternators 242
Charging circuit 243
AIR CONDITIONING
Quantities in R 134a aircon system 244
Special features 245
Pollen filter 246
Dryer cartridge 247 - 249
Checking oil level 250 - 251
Checking pressures 252
Air conditioning : 6FN-RFN-RLZ 253
Air conditioning circuit : XFX 254
Air conditioning circuit : RHY-RHZ 255
Air conditioning circuit : 4HX 256
INDEX
GENERAL
Identification of vehicles 1 - 4
General : Dimensions 5 - 6
Weight specifications 7 - 8
Towing specifications 9 - 10
Lifting / supporting the vehicle 11 - 14
Capacities 15 - 18
Lubricants 19 - 32
ENGINES
Engine specifications 34 - 58
Cylinder head marking / tightening
6FZ-RFN-RLZ 38
XFX 51 - 52
RHY-RLZ 55 - 56
4HX 57 - 58
Auxiliaries drive belt 59 - 68
Checking and setting valve timing 69 - 90
Power unit suspension 91 - 95
Exhaust system 96 - 100
Cooling system 101 - 107
Checking oil pressures 108
Oil filter 109
Filling and bleeding engine coolant 110

Downloaded from www.Manualslib.com manuals search engine ENGINE
43 Oil pump
- Pre-tightening0.7
- Tightening0.9 ± 0.1 1.3 ± 0.1 0.9 ± 0.1
Water / oil heat exhanger5.8 ± 0.5
Lubrication pipe
- Engine end3 ± 0.3
- Turbocompressor end2 ± 0.2
Injection circuit
Injector(Flange nut)
- Tightening3 ± 0.3 4 ± 0.3
- Angular tightening45°±5°
Union on injection rail2 ± 0.2
Injection pump0.5 ± 0.1 2.25 ±0.3
Union on injector 2 ± 0.2
Common rail fixing screw 0.9 ± 0.1 0.8 ± 0.1
Injection pump pulley5 ± 0.5
Union on injection pump 2.6 ± 0.3 2 ± .02
Cooling circuit
Water pump 1.4 ± 0.1 1.6 ± 0.3
Water inlet housing 0.9 ± 0.1 2 ± .02
Engines : 6FZ-RFN-RLZ-RHY-RHZ-4HX
Lubrication circuit Diesel Petrol
6FZ RFN RJZ RHY RHZ 4HX
SPECIAL FEATURES : TIGHTENING TORQUES ( m.daN)

Downloaded from www.Manualslib.com manuals search engine 126
INJECTION
AIR SUPPLY CIRCUIT SPECIFICATION
Engine : RHY
(1) Air filterPSA 7899.
(2) FlowmeterSIEMENS
(3)Water / recycled gas exchangerVALEO
(4) E.G.R. valvePURFLUX
(5) Turbocharger KKK K03
(6) Air butterflyMAGNETI MARELLI
48W7 Ref. 648
B1HP1A6D

Downloaded from www.Manualslib.com manuals search engine 127
INJECTION
(7) Air / air heat exchanger VALEO.
(8) Turbocharger KKK K03.
(9)EGR valvePURFLUX.
(10)Air butterflyMAGNETI MARELLI
48W7 Ref. 648.
(11)Air filter PSA 7899.
(12) Turbocharging pressure sensorNIPPON DENSO.
AIR SUPPLY CIRCUIT SPECIFICATION
Engine : RHZ
B1HP1A7P

Downloaded from www.Manualslib.com manuals search engine 128
INJECTION
AIR SUPPLY CIRCUIT SPECIFICATION
Engine : 4HX
(1) Air / air exchanger
(2) Air / water exchanger
(3) Warm air metering device BOSCH.
(4) Cold air metering deviceBOSCH.
(5) Turbocharger ALLIEDSIGNAL GT1549P.
(6) FlowmeterSIEMENS.
(7) Air filter PSA 7885.
B1HP1BYP

Downloaded from www.Manualslib.com manuals search engine CHECKS : TURBO PRESSURE
Engines : RHY - RHZ
TOOLS.
[1] Pressure gauge for checking boost pressure: 4073-T.A Tool kit 4073-T
[2]Sleeve for checking boost pressure: 4185-T
[3] Adaptor sleeve : 4219-T
Checks.
Preparation for RHY engine
Remove :
- The collars(3).
- The sleeve.
- Insert the tool [2]between the tube(1)and the duct(2).
- Position the tool[1]in the vehicle.
- Connect the pressure gauge[1] to the tool [2]with its tube (a)long enough for
the gauge to be positioned inside the vehicle.
Checks.
Preparation for RHZ engine
- Remove the collar fixing (3).
- Insert the tool [2]equipped with tool[3], between the tube (1)and the duct(2).
- Position the tool [1]in the vehicle.
- Connect the sleeve [2]on the pressure gauge[1]with the tube(a).
BHP12JDB1BP1ZXD
Engine RHZ Engine RHY
135
INJECTION

Downloaded from www.Manualslib.com manuals search engine 136
INJECTION
CHECKS : TURBO PRESSURE
Engines : RHY - RHZ
Procedure.
ESSENTIAL : Observe the following checking requirements :
- Engine at running temperature.
- Vehicle in running order.
- Engine at full load.
- Start the engine.
- Engage first gear and start the vehicle.
- Engage the gears up to third gear.
- Decelerate to 2000 rpm.
- Gradually accelerate.
- Check the pressure : 0.95 ± 0.05 Bar.
- Remove the tools [1]and [2].
Refit
- The sleeve.
- The collars(3).
- Tighten the collars (3).
C5FP0ACC

Downloaded from www.Manualslib.com manuals search engine CHECKS : TURBO PRESSURE
Engine : 4HX
TOOL
[1]Pressure gauge for checking pressure7073-T.A.
[2] Extension cable for taking pressure8607-T.A
[3]Union and hose for taking pressure8607-T.B.
[4] Adaptor for taking pressure8607-T.C.
[5]Unions and hoses for taking pressure4088-T
Checks.
ESSENTIAL : Respect the safety and cleanliness requirements specific to
high pressure diesel injection (HDi) engines.
Preliminary operations.
Carry out the following operations:
Remove the screw (1).
Disconnect the tube (2).
Move aside the pressure sensor (3).
Preparation of tools : in position on the vehicle.
Fit as follows :
Remove the hose(a)of tool [5], screw in its place the tool [3], remove the hose (b)of tool [5],
screw the hose (b)of tool [5]on the pressure gauge[1], screw the adaptor [4]onto the tool [5]
Connect the tube(2) of the pressure sensor(3) on the tool [4], tighten the tube(2) with a
Serflex type collar.
B1BP28DCE5AP1SUC
137
INJECTION

Downloaded from www.Manualslib.com manuals search engine 138
INJECTION
B1BP28ECC5FPOBLC
CHECKS : TURBO PRESSURE
Engine : 4HX
Preparation of tools : in position on the vehicle (continued).
Screw the tool [3] on the take-off of the turbo air radiator at «c».
Place the pressure gauge on the cup holder at «d».
Connect the extension [2]on the hose «b»and tool [5].
ESSENTIAL : Observe the following checking requirements.
- Start the engine.
- Engage first gear and start the vehicle.
- Engage the gears up to third gear.
- Decelerate to1500 rpm.
Accelerate gradually : the pressures should be the following :
1,1 ± 0,05 b at 2000 rpm
1,2 ± 0,05 b at 3000 rpm.
Return the vehicle to normal.
Remove the tools [1],[2], [3], [4]and [5].
Reposition the pressure sensor (3).
Couple the tube(2).
Refit and tighten the screw (1).

Downloaded from www.Manualslib.com manuals search engine 156
INJECTION
Component (diagr.) Supplier Reference Observations
Diesel injectors22BOSCH9625542580Reference 1 –Blue marking : injector Class 1.
Reference 2 – Green marking : injector Class 2.
If changing a diesel injector-carrier, order a
component of the same class.
Fuel high pressure regulator27BOSCHFixed on the fuel high pressure pump.
Fuel high pressure pump 3rd piston
deactivator28BOSCHFixed on the fuel high pressure pump.
Air circuit
Component (diagr.) Supplier Reference Observations
Air flowmeter4SIEMENS
Air filter23PSA 7899
Turbocompressor24KKK /
Exhaust gas recycling valve
(EGR)25PIERBURG Shim reference: violet.
Recycling regulation electrovalve
(EGR)26BOSCH
Exhaust line29
Vacuum pump44
EGR butterfly housing46MARK IV
EGR butterfly housing electrovalve45BOSCH
FEATURES OF BOSCH HDi DIRECT INJECTION SYSTEM
Fuel circuit (continued)