Pump Citroen C2 2004 1.G Service Manual

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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
SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP
PUMP TYPE REFERENCE
Dépollution
EquipmentL3
Transponder
XSARA
XSARA
8B
DWWJYDWLP 12
R8448 B
371 B

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INJECTION
SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP XSARA
Engine
typePump
Type
ReferenceStatic timing
Initial advance
Compression
Time
(cylinder N° 4)Dynamic
timing
checking
(at idle)Reference
InjectorInjector
holder
+ injectorCode
colourInjector
needle lift
pressure
(Bar)Adjustments (rpm) Max. speed
Fast
idlingAntistall
IdlingUnladen
rpmLaden
rpm
WJYDWLP 12
R 8448 B/*RDNO
SDC
6903LDCR
0260
IAA135,5
±5950
±25875
±25875
±255350
± 125
Engine
TDC
Pegging hole.
Value «X»
engraved on
the pump.
(*) = See table page: 251.1500
+ 3
mm
shim

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INJECTION
XSARACHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP
Tools.
[1]
Flywheel locating peg: 7014T.J
[2] H M8 screw: ().0188.E Tool kit C.0188
[3]Injection pump setting peg Ø 6 mm : ().0188.H
After carrying out the necessary dismantling operations on the vehicle, proceed in the following manner:
Remove:
The screws
(6), (7), (9), (10)and (12).
The upper casing (8).
The intermediate casing (11).
WARNING:Refit the screw (6)equipped with a washer.(Thickness 5 mm)
Turn the front RH wheel to turn the engine.(Normal direction of rotation) Bring the camshaft and injection pump pulleys to their setting point.
Position the flywheel peg, using tool [1].(From below the vehicle) Turn the engine until the peg [1]engages in the flywheel.
B1EP12NC
Engine: WJY
B1BP1S9C

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INJECTION
CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP
Engine: WJY (continued)
Peg:
The camshaft hub, using tool [2].
The injection pump hub, using tool [3].
Impossible to peg the camshaft.Reset the valve timing (See page 245).
Possible to peg the camshaft, but not the injection pump.Carry out the following operations:
Loosen the screws of the injection pump hub.
Turn the injection pump hub.
Insert the peg
[3]into the setting hole.
Tighten the screws of the injection pump hub.Tighten to 2,3 ±0,2 m.daN.
ESSENTIAL:If setting the diesel injection pump proves impossible, reset the valve
timing.(See page 251)
Remove:
The tools [1], [2]and [3].
The screw (6)and the washer.
Reassemble the components.
B1EP12WDB1BP1S9C
XSARA

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INJECTION
ADJUSTING THE MECHANICAL CONTROLS OF THE DELPHI INJECTION PUMP
Engine: WJY
Adjusting the fast idle.
Engine cold.
Ensure that the lever (2)is up against its stop to the right.
If not, adjust the tension of the cable (3)using the cable clamp (1).
Finish tensioning using the sleeve tensioner (4).
Engine hot. Check that the cable (3)is in tension.
Checking the thermostatic sensor. There should be a minimum 6 mmcable travel between a cold and a hot engine.
Adjusting the accelerator control.
Prior conditions.
Engine hot (cooling fan is engaged twice).
Checking the accelerator cable tension. Fully depress the accelerator pedal.
Check that the lever (6)is against its stop (5)otherwise, alter the position of the pin.
If not, adjust the position of the accelerator cable tensioning retaining pin.
Ensure that in the idle position the lever
(6)is against the stop (7).
B1HP0K9C
XSARA

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INJECTION
ADJUSTING THE MECHANICAL CONTROLS OF THE DELPHI INJECTION PUMP
Engine: WJY (continued)
Adjusting the antistall (residual output).
Insert a 3 mmthick shim (10)between the throttle lever (6)and the antistall screw (7).
Push the stop lever (8).
Insert a 3 mmdiameter peg (9)in the lever (2).
Adjust the engine speed to 1500 rpm ± 100using the stop screw (7).
Remove the shim (10)and the peg (9).
Adjusting the idle speed.
Adjust the speed using the idle adjustment screw (11).
Idling speed:825 ± 25 rpm.
Checking the engine deceleration.
Move the throttle lever (6)to obtain an engine speed of 3000 rpm.
Release the throttle lever (6).
The deceleration should be between 2.5and 3.5seconds.
The drop should be approximately 50 rpmin relation to the idle speed.
Deceleration too fast, (the engine has a tendency to stall)slacken the screw (7)by a quarter turn.
Deceleration too slow, (engine speed is greater than the idle speed)tighten screw (7)by a quarter turn.
NOTE:In each case, check the idle speed for any necessary adjustments.
B1HP0K9CB1HP0KAC
XSARA

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INJECTION
INJECTION PUMP SPECIFICATIONS (BOSCH and SIEMENS)
Engines Injection system ECU High pressure pump Injectors
BOSCH
BOSCH EDC 15C2
SIEMENS ECUSID801
BOSCH EDC 15C2BOSCH CP1
5WS 40001
BOSCH CP19625542580
5WS40000
9625542580 SIEMENS (except PICASSO)
BOSCH
DW
10TD
ATED
XSARA PICASSO
DV 6 TEBOSCH EDC 16C3BOSCH CP 3.2
760680

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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