start Citroen BERLINGO 2004 1.G User Guide

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INJECTION
PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM
Engines: 8HX 8HW 8HZ
Cleaning.
The use of high pressure cleaners is prohibited.
Do not use compressed air.
Fuel supply circuit.
Required fuel: diesel.
Electric circuit.
Swapping injection ECUs between two vehicles will render it impossible to start either vehicle.
It is forbidden to supply a diesel injector with
12 volts.
High pressure fuel pump.
Do not separate the following components from the high pressure fuel pump (5):
Sealing ring
(a)(no replacement parts).
High pressure outlet connector
(b)(will cause a malfunction).
PS: HDi = High pressure Diesel injection
B1HP1K9C
C2 C3 XSARA

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INJECTION
PROHIBITED OPERATIONS: DELPHI HDI DIRECT INJECTION SYSTEM
Engines: 8HY 8HV
Cleaning.
The use of high pressure cleaners is prohibited.
Do not use compressed air.
Fuel supply circuit.
Required fuel: diesel.
Electric circuit.
Swapping injection ECUs between two vehicles will render it impossible to start either vehicle.
It is forbidden to supply a diesel injector with
12 volts.
High pressure fuel pump.
Do not separate the following components from the high pressure fuel pump (5):
Sealing ring
(a) (no replacement parts).
High pressure outlet connector
(b)(will cause a malfunction).
PS:HDi = High pressure Diesel injection
B1HP1J6C
C3

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INJECTION
PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM
Engines: RHY RHZ
XSARA PICASSO
Cleaning.
The use of high pressure cleaners is prohibited.
Do not use compressed air.
Fuel supply circuit.
Required fuel: diesel.WARNING:Do not use other fuels.
Electric circuit.
Swapping injection ECUs between two vehicles will render it impossible to start either vehicle.
It is forbidden to supply a diesel injector with
12 volts.
High pressure fuel pump.
Do not separate the following components from the high pressure fuel pump (5):
High pressure fuel pump third piston deactivator (3)(no replacement parts).
High pressure fuel regulator (4)(no replacement parts).
Sealing ring (1)(no replacement parts).
High pressure outlet connector (3)(will cause a malfunction).
PS:HDi = High pressure Diesel injection
B1HP12CC

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INJECTION
CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT
Engines: 8HX 8HW
Tools.
[1] Ø 10 mmlow pressure connector: 4215T.
[2]Pressure gauge for testing boost pressure: 4073T.A Tool kit 4073T
IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel
injection engines.
Link tools [1]and [2]in series between the fuel high pressure pump and the fuel filter.
ESSENTIAL:Check that the tool [2] is clean.
Check the negative pressure according to the table below:
Vacuum Observations
10 ±5 cmHg
Engine driven by the starter motor
20 ±5 cmHg
60 ±5 cmHgEngine running under full load
Supply circuit obstructed
(full tank
strainer, piping, fuel filter).
B1BP2NWC
C2 C3

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INJECTION
CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT
Engines: 8HV 8HY 9HZ 9HY
Tools.
[1] Ø 10 mmlow pressure connector: 4215T.
[2]Pressure gauge for testing boost pressure: 4073T.A Tool kit 4073T
IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel
injection engines.
Remove the air filter duct.
Link tool [1]in series, downstream of the injectors, between the fuel high pressure pump
and the fuel filter at «a»and «b».
WARNING:Any checking of pressure downstream of the fuel filter is prohibited.
Switch on the ignition.
ESSENTIAL: Check that the tool [2] is clean.
Check the negative pressure according to the table below:
VacuumObservations
10 ±05 cmhg
Engine driven by the starter motor
20 ± 20 cmhg
60 ± 05 cmhgEngine running under full load
Supply circuit obstructed
(full tank
strainer, piping, fuel filter).B1BP2PHC
C3 XSARA PICASSO

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INJECTION
XSARA PICASSO CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT
Engines: RHY RHZ (continued)
Checks on pressure: dynamic.Engine running, at idle (normal functioning):
Fuel supply pressure shown by the pressure gauge [3] = 2 ± 0.4 Bar. Fuel return pressure shown by the pressure gauge [3] = 0.7 ± 0.4 Bar.
Abnormal functioning
Impossible to start the engine:
Fuel supply pressure less than 0.8 Bar:
Check the low pressure regulator incorporated in the filter (locked open). Check the high pressure pump distribution valve (locked shut).
Check: diesel injector return flow.(Table below)
Uncouple the diesel injector return pipe.
Fuel supply pressure Fuel return pressure Checks
Between 3and 3.5 Bar 0,7 ± 0,2 BarCheck the condition of the diesel filter
More than
3.5 Bar
More than 3.5 Bar
Less than 0.7 Bar
More than 0.7 Bar
Check the low pressure regulator incorporated in
the filter (locked shut): replace.
Check the fuel return circuit
(pipe pinched or trapped…)
Between 0.8 and 1.5 BarLess than 0.7 BarCheck the fuel suppy circuit:
Booster pump (low pressure), piping.
Check:
Observe:
The flow should be drop by drop.
Diesel injector functioning correctly.
Excessive fuel return.
Diesel injector locked shut.

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INJECTION
CHECKS: TURBO PRESSURE
Engines: 8HX 8HW
B1BP2NXD
C5FP0F5C
C2 C3
Tools.
[1]Pressure gauge for checking boost pressure: 4073T.A
[2]Sleeve for checking boost pressure: ().0171.F
Checks.IMPERATIVE: Respect the following test conditions:
Engine at operating temperature.
Vehicle in running order. Engine under full load.Preparation.
Remove the clips (1).
Fit the tool [2]in the place of the duct (2).
Couple the sleeve [2]on the pressure gauge [1]using the tube «a».Mode of operation.Position tool [1]in the vehicle.
Start the engine.
Engage first gear, start the vehicle.
Engage the gears up to third gear.
Decelerate to an engine speed of
1000 rpm.
Check the pressure:0,6 ± 0,05 bar (1500 rpm).
Accelerate freely (change from fourth gear to third gear).
Check the pressure:0,9 ± 0,05 bar(between 2500 and 3500 rpm).
Remove tools [1], [2]at «a».
Reposition the tube (2)and tighten the clips (1).

Downloaded from www.Manualslib.com manuals search engine 264
INJECTION
CHECKS: TURBO PRESSURE
Engines: 8HV 8HY
Tools.
[1]Pressure gauge for checking boost pressure: 4073T.A
[2]Sleeve for checking boost pressure: ().0171.F
Checks.
IMPERATIVE:
Respect the following test conditions:
Engine at operating temperature.
Vehicle in running order. Engine under full load.
Preparation.Remove the clips (1).
Fit the tool [2]in the place of the duct (2).
Couple the sleeve [2]on the pressure gauge [1] using the tube «a».Mode of operation.Position tool [1]in the vehicle.
Start the engine.
Engage first gear, start the vehicle.
Engage the gears up to third gear.
Decelerate to an engine speed of
1000 rpm.
Check the pressure:0,6 ± 0,05 bar (1500 rpm).
Accelerate freely (change from fourth gear to third gear)Check the pressure:0,9 ± 0,05 bar(between 2500 and 3500 rpm).
Remove tools[1],[2]at «a».
Reposition the tube (2)and tighten the clip (1).
C5FP0EJC
B1BP2NBD
C3

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INJECTION
CHECKS: TURBO PRESSURE
Engines: 9HZ 9HY
IMPERATIVE: Respect the safety and cleanliness requirements.
Preparation.
IMPERATIVE: Respect the following test conditions:
Engine at operating temperature.
Vehicle in running order.
Engine under full load.
Connect the diagnostic tool to the vehicle’s diagnostic socket, carry out parameter measures.
Mode of operation.
Start the engine.
Engage first gear, start the vehicle.
Engage the gears up to third gear.
Decelerate to an engine speed of
1000 rpm.
Check the pressure:0,6 ± 0,05 bar (1500 rpm).
Accelerate freely (change from fourth gear to third gear).
Check the pressure:0,9 ±0,05 bar(between 2500 and 3500 rpm).
XSARA PICASSO

Downloaded from www.Manualslib.com manuals search engine 266
INJECTION
CHECKS: TURBO PRESSURE
Engine: RHZ
XSARA PICASSO
Tools.
[1]
Pressure gauge for checking boost pressure: 4073T.A Kit 4073T
[2]Sleeve for checking boost pressure: 4185T
[3]Adaptor sleeve: 4229T
Checks.
IMPERATIVE: respect the following checking requirements: Engine at running
temperature. Vehicle in running order at full load.
Preparation.
Remove the collar fixing (3).
Insert the tool [2]connected with tool [3], between the pipe (1)and the duct (2).
Position tool [1]in the vehicle.
Connect the sleeve [2]to the tool [1]with its tube «a».Procedure. Start the engine.
Engage first gear and start the engine.
Engage the gears up to third gear.
Decelerate to
1000 rpm.
Accelerate hard, and check the pressure:0.6 ± 0.05 Bar (1500 rpm).
Accelerate freely in kickdown (changing from fourth to third gear).
Check the pressure:0.95 ± 0.05 Bar(between 2500 and 3500 rpm).
Remove the tools, reposition the pipe (1)and refit the collar (3).B1HP12JD