ESP Citroen C2 2004 1.G Repair Manual

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INJECTION
SAFETY REQUIREMENTS: HDi DIRECT INJECTION SYSTEM
Engines: HDi ALL TYPES
SAFETY REQUIREMENTS.
Preamble.
All interventions on the injection system must be carried out to conform with the following requirements and regulations:
Competent health authorities.
Accident prevention.
Environmental protection.
WARNING:Repairs must be carried out by specialised personnel informed of the safety requirements and of the precautions to be taken.
Safety requirements.
IMPERATIVE: Take into account the very high pressures in the high pressure fuel circuit (1350 bars), and respect the requirements below: No smoking in proximity to the high pressure circuit when work is being carried out.
Avoid working close to flame or sparks.
Engine running: Do not work on the high pressure fuel circuit.
Always stay clear of the trajectory of any possible jet of fuel, which could cause serious injuries.
Do not place your hand close to any leak in the high pressure fuel circuit.
After the engine has stopped, wait
30 secondsbefore any intervention.
NOTE:This waiting time is necessary in order to allow the high pressure fuel circuit to return to atmospheric pressure.

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INJECTION
SAFETY REQUIREMENTS: HDi DIRECT INJECTION SYSTEM
Engines: HDi ALL TYPES
CLEANLINESS REQUIREMENTS.
Preliminary operations.
IMPERATIVE: The technician should wear clean overalls.
Before working on the injection system, it may be necessary to clean the apertures of the following sensitive components:(refer to corresponding procedures) Fuel filter.
High pressure fuel pump.
High pressure fuel injection common rail. High pressure fuel pipes
Diesel injector carriers.
IMPERATIVE: After dismantling, immediately block the apertures of the sensitive components with plugs, to avoid the entry of impurities.
Work area.
The work area must be clean and free of clutter.
Components being worked on must be protected from dust contamination.

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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
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).

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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

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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

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INJECTION
CHECKS: TURBO PRESSURE
Engine: RHY
Tools.
[1]
Pressure gauge for checking boost pressure: 4073T.A Kit 4073T
[2]Sleeve for checking boost pressure: 4185T
Checks.
IMPERATIVE: respect the following checking requirements: Engine at running temperature.
Vehicle running at full load.
Preparation.
Remove the collar (3) and the sleeve.
Insert the tool [2]between the pipe (1)and the duct (2).
Position 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.
Procedure. Start the engine.
Engage first gear and start the engine.
Engage the gears up to third gear.
Decelerate to
2000 rpm.
Gradually accelerate.
Check the pressure:
0.95 ± 0.05 Bar Remove the tools, refit the collars (3)and the sleeve.B1BP1ZXD
XSARA PICASSO

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INJECTION
CHECKING THE AIR SUPPLY CIRCUIT
Engines: RHY RHZ
XSARA PICASSO
Tools.
[1]Manual vacuum pump : FACOM DA 16
IMPERATIVE: Respect the safety and cleanliness requirements.
Vacuum pump.
Connect the tool [1]on the vacuum pump (1).
Start the engine.
Pressure should be
0.8 barat 780 rpm.Boost pressure regulator electrovalve. Connect the tool [1]between the electrovalve (2)and the valve (3)of the boost pressure
regulator.
Compare readings with the values in the table below.
Pressure regulator valve. Connect the tool [1]on the valve (3).
Appy a pressure of 0.5 barto activate the rod "a":
Rod "a"should be moved 12 mm.
Engine speed (rpm) Pressure (Bar)
780 0,6
4000 0,25
B1HP12FD