Manual sections
Wiring diagrams- Battery
- Body
- Braking
- Comfort and convenience
- Confort
- Current generation
- Dashboard
- Driver information
- Driving assistance
- Electrical harnesses
- Engine
- Front anti -roll bar
- Front axle
- Front doors
- Front seats
- Front section
- Front shock absorbers
- Front springs
- Gearbox assembly
- General points
- General points about the vehicle
- Instrument panel
- Instruments and controls
- Lighting - signalling
- Mechanical
- Noises and vibrations
- Other
- Power unit
- Pre-heating
- Protections and doors
- Re-assembling
- Rear axle
- Rear section
- Rear shock absorbers
- Rear springs
- Roof panel
- Side structure
- Starting
- Steering
- Suspension
- Transmission
- Washing and wiping
Repair manual
Engine Citroen C2 I
Step-by-step instructions on "Engine" for Citroen C2 I (2003–2009). Pick an article — removal, installation, adjustment and diagnostics with illustrations.
Crankshaft
- Data: conrods (TU5JP4)
- Data: pistons - piston rings - the piston shaft (TU5JP4)
- Data: half shells (TU5JP4)
- Data: conrods - bearing shells (DV4TD)
- Data: pistons, piston rings, the piston shaft (DV4TD, DV6TED4)
- Data: conrods - connecting rod half shells (DV6TED4)
- Data: crankshaft - crankshaft bearing shells (DV4TD, DV6TED4)
- Data: conrods (TU1A, TU1JP, TU3A, TU3JP)
- Data: pistons - piston rings (TU3JP, TU1JP, TU3A, TU1A)
- Data: crankshaft - crankshaft half shells (TU3A, TU3JP, TU1A, TU1JP)
- Data: pistons - piston rings (ET3J4)
- Data: connecting rods / connecting rod bearing halfshells (ET3J4)
- Data - identifications: crankshaft - half shells (ET3J4)
- Data: conrods (TU5JP4S, TU5JP4)
- Data: half shells (TU5JP4, TU5JP4S)
- Data: pistons - piston rings - the piston shaft (TU5JP4, TU5JP4S)
- Data: crankshaft (TU5JP4, TU5JP4S)
- Check: liner protrusion (aluminium block) (TU1JP, ET3J4, TU1A, TU3JP, TU3A)
- Removing - refitting: ancillary drive belt (DV6TED4)
- Removing - refitting: engine ring seals (DV6TED4)
- Removing - refitting: ancillary drive belt (without air conditioning and with power steering) (TU5JP4)
- Removing - refitting: ancillary drive belt (with air conditioning and without power steering) (TU5JP4)
- Removing - refitting: ancillary drive belt (with air conditioning and with power steering) (TU5JP4S)
- Removing - refitting: ancillary drive belt (without power steering and without air conditioning) (TU5JP4)
- Dismantling - re-assembly: conrods - pistons (TU1JP, TU5JP4, TU5JP4S, TU3JP, ET3J4, TU1A, TU3A)
- Matching: crankshaft bearing shells (TU3JP, TU3A, TU1JP, TU1A)
- Dismantling - re-assembly: dynamic seals - tu engine - 8 valves (TU1A, TU1JP, TU3JP, TU3A)
- Dismantling - re-assembly: dynamic seals (engine et3j4) (ET3J4)
- Dismantling - re-assembly: dynamic seals (tu 16 -valve engine) (TU5JP4, TU5JP4S)
- Removing - refitting: flexible ancillary drive belt (with air conditioning compressor) (DV6TED4, DV4TD)
- Removing - refitting: flexible ancillary drive belt (without air conditioning compressor) (DV4TD, DV6TED4)
- Dismantling - refitting: connecting rod/piston assemblies (DV4TD, DV6TED4)
- Removing - refitting: elastic auxiliary drive belt check the electrical operation of the equipment (DV4TD, DV6TED4)
- Removing - refitting: elastic auxiliary drive belt (without air conditioning compressor) (DV4TD, DV6TED4)
Timing gear
- Data: camshaft (TU5JP4)
- Data: camshafts (DV6TED4)
- Data: camshaft (DV4TD)
- Data: camshafts (TU3A, TU1A, TU3JP, TU1JP)
- Data: valve rockers (TU3JP, TU1A, TU1JP, TU3A)
- Data: camshafts (ET3J4)
- Data: camshaft (TU5JP4, TU5JP4S)
- Data: timing gear (DV6TED4)
- Removing - refitting: camshaft carrier (DV6TED4)
- Removing - refitting: camshaft (DV6TED4)
- Removing - refitting: camshaft bearing seal (DV4TD)
- Removing - refitting: camshafts (DV4TD)
- Removing - refitting: camshaft (TU1JP, TU5JP4S, TU5JP4, TU3JP)
- Removing - refitting: camshaft (ET3J4)
- Removing - refitting: camshaft (TU3A, TU1A)
- Removing - refitting: camshaft seal (TU3A, TU1A)
- Removing - refitting: camshaft seals (ET3J4)
- Check: setting the valve timing (DV6TED4)
- Check: setting the valve timing (DV4TD)
- Check: setting the valve timing (TU1JP, TU5JP4S, TU5JP4, TU3JP)
- Check: setting the valve timing (ET3J4)
- Check: setting the valve timing (TU3A, TU1A)
- Check: setting the valve timing (second fit) (DV4TD)
- Removing - refitting: timing belt (DV6TED4)
- Removing - refitting: timing belt (DV4TD)
- Removing - refitting: timing belt (TU1JP, TU5JP4S, TU5JP4, TU3JP)
- Removing - refitting: timing belt (ET3J4)
- Removing - refitting: timing belt (TU1A, TU3A)
- Removing - refitting: timing belt (second fit) (DV4TD)
Engine block
- Data: cylinder block (TU5JP4)
- Data: cylinder block (DV4TD)
- Data: cylinder block (DV6TED4)
- Data: dynamic seals (TU1A, TU3JP, TU1JP, TU5JP4, ET3J4, TU3A, TU5JP4S)
- Data: aluminium cylinder block (TU1JP, TU1A, TU3JP, TU3A)
- Data: cast cylinder block (TU3JP, TU1A, TU3A, TU1JP)
- Data: cylinder block (ET3J4)
- Data: cylinder block (TU5JP4S, TU5JP4)
Cylinder head
- Data: valves and valve springs
- Data: valve seats and guides (TU5JP4)
- Data: cylinder head gasket (TU5JP4)
- Data: cylinder head bolts - cylinder head tightening (TU5JP4)
- Data: cylinder head (TU5JP4)
- Data: cylinder head bolts - cylinder head tightening (DV6TED4, DV4TD)
- Data: cylinder head (DV4TD)
- Data: cylinder head (DV6TED4)
- Data: valves and valve springs — variant 2
- Data: valve seats and guides (DV6TED4)
- Data: valve seats and guides (DV4TD)
- Data: valves and valve springs — variant 3
- Data: valves and valve springs — variant 4
- Data: valve seats and guides (TU3JP, TU1A, TU1JP, TU3A)
- Data: cylinder head (TU3JP, TU1A, TU1JP, TU3A)
- Data: valves and valve springs — variant 5
- Data: valve seats (ET3J4)
- Data: cylinder head (ET3J4)
- Data: valve guides (ET3J4)
- Data: cylinder head (TU5JP4, TU5JP4S)
- Data: valve seats and guides (TU5JP4, TU5JP4S)
- Data: valves and valve springs — variant 6
- Data: Cylinder head seal (DV4TD, DV6TED4)
- Stripping - re-assembling: cylinder head (TU5JP4)
- Stripping - re-assembling: cylinder head (DV4TD)
- Stripping - re-assembling: cylinder head (DV6TED4)
- Stripping-assembling: cylinder head (TU3JP, TU1A, TU1JP, TU3A)
- Stripping - re-assembling: engine (TU1A, TU3JP, TU3A, TU1JP)
- Stripping-assembling: cylinder head (ET3J4)
- Stripping-assembling: cylinder head (TU5JP4, TU5JP4S)
- Removing - refitting: cylinder head (DV6TED4)
- Removing - refitting: cylinder head on the vehicle (DV4TD)
- Removing - refitting: cylinder head on the vehicle (TU1JP, TU5JP4S, TU5JP4, TU3JP)
- Removing - refitting: cylinder head on the vehicle (ET3J4)
- Removing - refitting: cylinder head on the vehicle (TU3A, TU1A)
- Modification: cylinder head tightening (DV4TD engine) (DV4TD)
- Modification: work on diesel injector (DV6TED4 type engine) (DV6TED4)
Lubrication
- Summary: engine oil filter cartridges (year 2003)
- Engine oil capacities: 2003 model year
- Engine oil capacities: 2004 model year
- Engine oil capacities: CITROEN C2 (from RPO No. 10380)
- Check: oil pressure (TU1A, TU3A)
- Check: oil pressure (DV4TD)
- Check: oil pressure (TU3JP, TU5JP4, TU5JP4S, TU1JP)
- Check: oil pressure (ET3J4)
- Check: oil pressure (DV6TED4)
- Removing - refitting: oil pump (DV6TED4)
- Removing - refitting: oil pump (engines types DV4TD - DV4TED) (DV4TD)
- Removing - refitting: oil filter DV4TD engine type (DV4TD)
- Removing - refitting: oil filter (DV6TED4 type engine) (DV6TED4)
- Maintenance: recommended ingredients, year 2006
Cooling system
- Data: cooling system (engine DV4TD) (DV4TD)
- Data: cooling system (TU1JP, TU5JP4S, TU5JP4, TU3JP)
- Data: cooling system (ET3J4)
- General specifications: cooling system (TU1 and TU3 engines) (TU3A, TU1A)
- General specifications: cooling system (engine DV6TED4) (DV6TED4)
- Removing - refitting: coolant temperature sensor (DV6TED4)
- Removing - refitting: coolant outlet housing (TU5JP4)
- Removing - refitting: engine cooling radiator (DV6TED4)
- Removing - refitting: coolant outlet housing (DV6TED4)
- Removing - refitting: engine cooling radiator (ET3J4)
- Drain and refill - refilling - bleeding: cooling system
Air and fuel supply
- Check: air supply circuit (DV6TED4)
- Removing - refitting: fuel filter (DV6TED4)
- Removing - refitting: double inlet air doser unit (DV6TED4)
- Removing - refitting: fuel pump and gauge assembly (DV6TED4)
- Removing - refitting: fuel tank (DV6TED4)
- Removing - refitting: fuel filter (DV4TD)
- Removing - refitting: fuel pump and gauge assembly (DV4TD)
- Removing - refitting: fuel pump and gauge assembly (TU5JP4, ET3J4, TU3JP, TU1JP, TU5JP4S, TU1A, TU3A)
- Removing - refitting: fuel tank (TU1JP, TU3JP, TU3A, TU5JP4S, TU1A, TU5JP4)
- Removing - refitting: fuel tank (DV4TD)
- Removing - refitting: fuel tank (ET3J4)
- Removing - refitting: integrated air intake system (DV6TED4)
- Check: fuel additive circuit
- Replacement: flexible additive reservoir (DV6TED4)
- Modification: particle filter additive
Exhaust
- Data: exhaust system (engine DV4TD) (DV4TD)
- Data: exhaust system (TU1JP, TU5JP4S, TU5JP4, TU3JP)
- Tightening torques: exhaust system (TU1A, TU3A)
- General specifications: exhaust system (engine DV6TED4) (DV6TED4)
- Tightening torques: exhaust system (ET3J4)
- Removing - refitting: exhaust system (DV6TED4)
- Removing - refitting: catalytic converter/monobloc particle emission filter assembly (DV6TED4)
- Removing - refitting: exhaust system (DV4TD)
- Removing - refitting: exhaust system (TU1JP, TU5JP4S, TU3JP, TU5JP4)
- Removing - refitting: exhaust system (ET3J4)
- Removing - refitting: exhaust system (TU1A, TU3A)
- Removing - refitting: exhaust manifold (TU3A, TU1A)
- Removing - refitting: catalytic converter and exhaust manifold (ET3J4)
- Modifications: connecting sleeve / intermediate exhaust line
- Removing - refitting: particle filter (DV6TED4)
- Removing - refitting: exhaust gas pressure sensor pressure take-off (DV6TED4)
- Forced regeneration: particle filter
Turbocharging
Emission control
- Check: exhaust gas recirculation circuit (DV4TD)
- Removing - refitting: exhaust gas recycling valve (EGR) (DV4TD)
- Removing - refitting: exhaust gas recycling (EGR) heat exchanger (DV4TD)
- Check: exhaust gas recirculation circuit (DV6TED4)
- Removing - refitting: exhaust gas recycling solenoid valve (DV6TED4)
- Removing - refitting: air pump (TU3JP, TU1JP)
- Removing - refitting: exhaust gas temperature sensors (DV6TED4)
- Removing - refitting: exhaust gas pressure sensor (DV6TED4)
- Modification: oxygen sensor
- Table: fault codes - sensor O2 engine ET3 (MAGNETI MARELLI MM6LP) (ET3J4)
- Help in diagnosis: electric EGR valve DV6 engine type (BOSCH) (Summary) (DV6TED4)
- Help in diagnosis: electric EGR valve DV4 BOSCH engine type (Summary) (DV4ATD, DV4TD)
- Help in diagnosis: electric EGR valve DV4 SIEMENS engine type (Summary) (DV4TD, DV4ATD)
- Help in diagnosis: lambda sensors (Summary) (ET3J4)