Fuel Citroen C2 2004 1.G Service Manual

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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines: 9HZ 9HY
B1BP304D
Tools.
[1]
Flywheel setting peg: ().0194.C
[2]
Camshaft setting peg:().0194.B
[3]
Crankshaft setting peg: ().0194.A
Checking and setting the timing.
Removing.
Raise and support the vehicle, wheels hanging.
Disconnect the positive and negative terminals of the battery.
Remove: The front RH wheel.
The front RH splashshield.
The accessories drive belt
(see corresponding operation).
Uncouple:
The fuel supply unions
(1).
The air/air heat exchanger inlet and outlet pipes
(3).
The exhaust line
(at the flexible pipe).
Disconnect the connecter at
«a».
Remove and move aside the power steering fluid reservoir
(6).
Uncouple, plug and move aside the tube
(2).
Support the engine with a roller jack equipped with a block.Remove the engine supports
(4)and (5).
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines: 9HZ 9HY
B1EP1E7D
Refitting.
Fit the timing belt on the crankshaft pinion.
Position the belt on the guide roller, belt well tensioned.
Refit:
The timing belt protector
(13).
The engine speed sensor
(14).
Reposition the timing belt, strip
«f»well tensioned, in the following sequence:
Guide roller
(16).
Camshaft pulley
(20).
Fuel high pressure pump pulley
(19).
Coolant pump pulley
(17).
Tensioner roller
(18).
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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: 9HZ 9HY
Refitting (continued).
Refit tool [1]at «b».
Remove the screw (10).
Refit:
The upper timing cover
(12).
The lower timing cover (11).
The accessories drive pulley (9).
The screw (10).
Tightening torqueScrew (10)Pretighten to:3 ± 0,3 m.daN.
Angular tighten:180°±5°.
Remove tool [1].
Refit:
The engine support
(8), tighten to5,5 ± 0,4 m.daN.
The engine support (4), tighten to 6,1 ±0,6 m.daN.
The engine support (5), tighten to 2,5 ±0,2 m.daN.
The electrical harness (7).
The power steering fluid reservoir (6).
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Disengage the jack from under the engine.
Couple:
The tube
(2).
The exhaust line, tighten the clip to 2,5 ± 0,3 m.daN.
The fuel unions (1).
The air/air heat exchanger inlet and outlet pipes (3).
Connect the connector at «a».
Refit:
The accessories drive belt
(see corresponding operation).
The front RH splashshield (see corresponding operation).
The front RH wheel, tighten to 9 ± 1 m.daN.
Reconnect the positive and negative terminals of the battery.
IMPERATIVE: Perform the operations that are necessary following a
reconnection of the battery (see corresponding operation).

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engine: WJY
B1BP2FTC
Setting the timing.
Removing.
Disconnect the battery.
Remove the front RH lower splashshield, using tool [1].
Remove the accessories drive belt (see corresponding operation).
Uncouple and plug the diesel fuel delivery and return hoses. Support the engine, using a workshop hoist.
Remove the RH engine support.
Engage 5th gear to permit rotation of the engine. Remove the upper cover
(1).
Remove the intermediate cover (2).
Remove the lower cover (3).
WARNING:Refit the screw (4)equipped with a washer (5 mm thick).
Rotate the front RH wheel to drive the engine in its normal direction of
rotation. Bring the camshaft drive and injection pump pinions to their setting points.
Position the peg
[2](from underneath the vehicle).
Continue turning the engine until the peg [2]engages in the flywheel.
B1BP30BC
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine: WJY
Setting the timing (continued).
Tighten:
Screw (9)to 2.1 ± 0.2 m.daN.
Screws (5)to 2,3 ± 0.2 m.daN.
Screws (6)to 2,3 ± 0.2 m.daN.
Remove and refit tool [7].
The tension value should be between 38 and 46 SEEM units.
Remove tools [7], [2], [3] and [4].
Turn the crankshaft 2 timesin the normal direction of rotation.
Peg the flywheel, using the peg [2].
Visually check the peggings of the camshaft and injection pump.
ESSENTIAL:Visually check that the offsets between the holes of
the camshaft and injection pump hubs and the correspondingpegging holes are not more than 1 mm.If necessary, recommence
the procedure for fitting the timing belt.
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Setting the timing (continued).
Remove the peg [2].
Remove the screw (4)and the washer.
Refit the lower cover (3).
Refit the intermediate cover (2).
Refit the upper cover (1).
Remove the RH engine support.
Take away the workshop hoist. Remove the plugs and recouple the diesel fuel delivery and return
hoses. Refit the accessories drive belt
(see corresponding operation).
Refit the RH lower splashshield. Disengage
5th gear.
Connect the battery.

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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
Uncouple, plug and move aside, using tool [7], the fuel delivery pipe (2)and return
pipe (1).
Remove:
Screws
(3), (4) and (6).
Screw (7).
The upper timing cover (5).
WARNING:Refit screw (7)equipped with a spacer (17 mm thick), tighten the
screw (7)to 1,5 ± 0,1 m. daN.
NOTE:The screw (7)is one of the screws securing the coolant pump and is there
for its sealing.
Put the gear lever in 5th gear.Turn the road wheel to turn the engine in its direction of rotation.
Orient the camshaft pulley in the pegging position, use a mirror if necessary.
Peg the camshaft, using tool
[5].
Peg the engine flywheel, using tool
[3].
B1EP1A7CB1BP2H3CB1BP2H2CB1BP2R2C
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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
Reposition the timimg belt, belt at «a»well tensioned, in the following order:
Fuel high pressure pump pulley
(21).
Guide roller
(15).
Crankshaft pinion
(19).
Coolant pump pinion
(16).
Tensioner roller
(18).
Position tool
[1]on the belt at «a».
Remove tools
[4]and [9].
Turn the tensioner roller
(18)anticlockwise, using tool [2], to attain an overtension of:
98 ± 2 SEEM units.
Tighten screw
(17)of the tensioner roller to 2,5 ± 0,2 m.da N.
Lock the flywheel by means of tool
[6].
Tighten the accessories drive pulley screw
(8)to 7 ± 0,7 m.da N.
Remove tools
[1], [3], [5] and [6].
Rotate the crankshaft eight times in the normal direction of rotation.
Peg:
The crankshaft, using tool
[3].
The camshaft drive pulley, using tool
[5].
B1EP1ABDB1EP1ACC
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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
Remove:
Tools [3]and [5].
Screw (7)and the spacer.
Refit: The lower, intermediate and upper covers
(5).
Screw (7), tighten to 1,5 ± 0,1 m.daN.
Screws (3), (4)and (6).
The bracket (13).
Screws (11), tighten to 6,1 ± 0,5 m.daN.
The nut (12), tighten to 4,5 ± 0,5 m.daN.
Fit the bearing shell (10).
Take away the workshop hoist.
Clip the fuel delivery and return pipes. Remove the tool
[7].
Couple:
The fuel delivery pipe
(12).
The fuel return pipe (1).
Coat the screw (8)with loctite FRENETANCH.
Refit the tool [6]and the screw (8)with the washer (22),
Tighten to 7 ± 0,2 m.daNand angular tighten to A = 60° ± 5°
[6].
Reposition and reclip the cooling hose.
Complete the refitting of components in reverse order to removal.
B1EP1A7CB1BP2R4CB1EP1ADC
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INJECTION
Emission standard Engine type
Injection make
and type
PETROL INJECTION
Air temperature sensor
resistive value (ohms)
C2
M. MARELLI 48P2 SAGEM S2000 BOSCH M.7.4.4.
Fuel pressure (bars)
Overspeed cutoff (rpm)
Injector resistive value (ohms)
Engine coolant temperature
sensor resistive value (ohms)
Idling actuator or stepper
motor resistive value (ohms)
HFX KFV NFU
L4/IFL5 L4/IFL5 IFL5
1.1i 1.4i 1.6i 16V
333
5500 5500 6600
14,5 12,2 14,5
Stepper motor: 53 3 800 at 10°C 2500 at 20° C 800 at 50°C 230 at 90° C
3 800 at 10°C 2500 at 20° C 800 at 50°C 230 at 90° C
C2

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INJECTION
Emission standard Engine type
Injection make
and type
PETROL INJECTION
C3 C3 PLURIEL
Air temperature sensor
resistive value (ohms)
C3 PLURIEL
C3
M. MARELLI
48P2M. MARELLI
6LP SAGEM
S2000BOSCH
M.7.4.4.SAGEM
S2000BOSCH
M.7.4.4.
Fuel pressure (bars)
Overspeed cutoff (rpm)
Injector resistive value (ohms)
Engine coolant temperature
sensor resistive value (ohms)
Idling actuator or stepper
motor resistive value (ohms)
HFX
K’L4INFL4/IFL5 L5 K’L4INFL4/IFL5 L4 L4/IFL5 IFL5
1.1i 1.4i 1.4i 16V 1.6i 16V
1.6i 16V
1.4i
KFU
KFV NFU KFV NFU
3,53,5
3,5
3,5 3,5 3,5
14,5 14,5 14,5
12,214,5 14,5
5500
5800
5500
5500
5500 5800
Stepper motor:53 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C
3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C