Actuator Citroen C2 2004 1.G Workshop Manual

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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

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INJECTION
Emission standard Engine type
Injection make
and type
PETROL INJECTION
XSARA XSARA PICASSO
Air temperature sensor
resistive value (ohms)
XSARA PICASSO
XSARA 2
SAGEM
S2000M. MARELLI
6LP BOSCH
M.7.4.4.BOSCH
M.7.4.4.SAGEM
S2000M. MARELLI
6LP
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)
KFW
L4/IFL5/L5 L4/IFL5 L4/IFL5 L4 IFL5L4/IFL5
1.4i 1.6i 16V 2.0i 16V 1.6i
2.0i 16V
1.8i 16V
RFN
NFU NFV 6FZ RFN
3,53,5
3
3 3,5 3,5
14,5 14,5 14,5
14,512,2 14,5
5500
5700
6000
5800
5500 6000
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

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INJECTION
CHECKS: EXHAUST GASES RECYCLING CIRCUIT
Engines: 9HZ 9HY
B1HP1UPC
B1HP1UQC
XSARA PICASSO
Exhaust gas recycling (EGR) valve.
(1)
Exhaust gas recycling (EGR) electrovalve
NOTE:The engine ECU pilots the EGR valve.
Perform the check with the aid of a diagnostic tool.
Carry out the following operations with the diagnostic tool:
«INJECTION» menu.
Actuator tests.
EGE electrovalve.
Check that you can hear the click from the EGR regulation electrovalve.
Double butterfly housing (vehicle with particle filter).
(2)
Double butterfly housing.
Perform the check with the aid of a diagnostic tool.
Carry out the following operations with the diagnostic tool:
«INJECTION» menu.
Actuator tests.
Butterfly.
EGR exchanger butterfly.
Check that you can hear the click from the double butterfly housing.

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INJECTION
SPECIAL FEATURES: PARTICLE FILTER / CHECKING THE ADDITIVE PUMP
Engine: 9 HZ
IMPERATIVE: Respect the safety and cleanliness requirements.
Tools.
[1]
Manual pressure/vacuum pump: FACOM DA 16
[2]Additive container: ().1613.G Kit 1613
Checks.
IMPERATIVE: Respect the safety and cleanliness requirements specific to HDi engines.
IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves that are
resistant to hydrocarbons.
Place the vehicle on a lift.
Raise the vehicle
To test the flow of the additive pump :
Uncouple the tube
(1).
Couple tool [2]on the outlet «a»of the additive reservoir.
Operate for 50 secondsthe actuator test «Additive pump»with the aid of LEXIA or PROXIA.
IMPERATIVE:The volume collected by the tool [2] should be 20 ± 5 ml.
NOTE:
Replace the additive pump if it is defective.
Couple the tube (1).
Operate the actuator test «Filling the tube: additive pump – additive injector», with the aid of LEXIAorPROXIA.
B1HP1UTC
XSARA PICASSO

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INJECTION
SPECIAL FEATURES: PARTICLE FILTER / CHECKING THE ADDITIVE PUMP
Sealing of the additive injector.
Couple tool [1] to the tube (1).
Action the manual pump [1].
WARNING:The additive injector should open at a pressure of 100 ± 20 Bars.
Action the manual pump in vacuum
[1]at 800 m.bars.
WARNING:The downstream pressure should not fall rapidly.
NOTE:Replace the fuel tank if the injector is defective.
Couple the tube
(1).
Operate the actuator test «Filling the tube: additive pump – additive injector», with the aid ofLEXIAor PROXIA.
Check the additive level.
The checking of the additive level is done with reference to the gradations «a»marked on the additive
reservoir.
The top graduation indicates maximum filling
(3 Litres).
The difference between the two gradations equates to 0,25 Litres.
XSARA PICASSO
B1HP1UUC
B1KP019C

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RECOMMENDATIONS PRECAUTIONS: MA PILOTED MANUAL GEARBOX
Safety requirements.
ESSENTIAL:Given the special features of the MA type piloted
manual gearbox, observe the requirements detailed below.
IMPERATIVE: Always disconnect the battery negative terminal
before operating on the actuators.
NOTE:
After disconnecting the battery, never try to remove the clutch
actuator on the vehicle before having checked that it is in the closed
position
(rod pushed in).
IMPERATIVE:After Sales checks done with the engine running must be
performed with «Neutral»engaged and the handbrake on (unless there
is a clear mention otherwise in the repair procedures).
IMPERATIVE:The areas of movement of the clutch fork and of the gear
engagement lever must always be kept free during the actuatoroperating phases.
CLUTCH
GEARBOX
TRANSMISSION
IMPERATIVE:When initialising the clutch actuator and/or gearbox
actuator, do not allow any person to walk or stand in front of the vehicle.
WARNING:When the engine is running, it is forbidden to perform
repairs on the clutch and gearbox actuators on the vehicle (whether
manually or using a diagnostic tool).
WARNING:Each time the driver’s door is opened and each time the
igntion is switched on, the gearbox ECU prompts the initialising of the
clutch and gearbox actuators
(there is movement of the clutch fork and
of the gear lever).
WARNING:Whether the ignition is switched on or not, an action on the
gear selector causes the clutch fork and the gear engagement lever to
move on the gearbox.
Engines: HFX KFV NFU 8HX
C2

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CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS PRECAUTIONS: MA PILOTED MANUAL GEARBOX
Operations on electrical components.Do not disconnect:
The battery when the engine is running.
The ECU with the ignition switched on.
The clutch and gearbox actuators with the ignition switched on.
When carrying out electrical checks: The battery must be correctly charged.
Never use a voltage source higher than 16V.
Never use a lamp to supply an actuator directly.
Before disconnecting connector, check: The condition of the various contacts (for deformation, corrosion, etc).
The presence and the status of the mechanical unlocking.
Driving the vehicle.
IMPERATIVE:
Never move the vehicle with the ignition switched off.
Never push the vehicle to attempt to start it
(impossible with a piloted
manual gearbox).
Towing.
Conditions for towing.
It is necessary to lift the front of the vehicle to tow it, after having
positioned the gear lever in neutral. If there is a gearbox fault or
malfunction, the vehicle can remain immobilised depending on theseriousness of the fault.
If a gear is engaged,the conditions for immobilisation of the
vehicle are:
Combustion engine stopped (the engine should not be started).
The clutch is open (clutched).
In these conditions are met, you can lift the front of the vehicle to tow it.
If it should not be possibe to lift the front of the vehicle, there are
ways to unblock it:
Engage «N», using a diagnostic tool.
Engage «N», without using a diagnostic tool.
Engines: HFX KFV NFU 8HX
C2

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CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS PRECAUTIONS: MA PILOTED MANUAL GEARBOX
Engaging of «N», using a diagnostic tool.
Preliminary operations:
Battery voltage higher than 12.5 volts.
Ignition switched on.
Connect the diagnostic tool to the vehicle’s diagnostic socket.
From the diagnostic tool menus, select:
«DIAGNOSIS»
MA type piloted manual gearbox.
Actuator test.
Gearbox actuator test.
Gear engagement test.
N(neutral).
NOTE:The letter «N»should appear on the instrument panel.
If not, see the following solution:
Engaging of
«N», without using a diagnostic tool.
Engaging of «N», without using a diagnostic tool.
In this configuration, the gearbox actuator is blocked, gear engaged.
NOTE:This recovery solution is to be used solely in a case where the
attempt to make the gearbox actuator engage b via the diagnostic toolhas failed.
Engines: HFX KFV NFU 8HX
C2

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 PILOTED MANUAL GEARBOX
Engines: KFV 8HX
Features.
The piloted gearbox is a modern manual gearbox with technology that offers
enhancements in every driving situation.
The piloted manual gearbox has two operating programmes:

«Sequential»programme.
«Automatic»programme.
The piloted manual gearbox has:
A gearbox ECU
(supplier:SIEMENS). A gearbox actuator with two electric motors (supplier:SACHS).
A clutch actuator with one electric motor (supplier:SACHS).
A gearbox input speed sensor.
The piloted manual gearbox has no gear control cable and no clutch cable.Changes of gear and clutching/declutching are activated by the gearbox
actuator and the clutch actuator.
Lubrication.
Oil capacity : 2 ± 0,15 litres.
Checking of oil level : No oil level check.(*)Lubrication intervals : Lubricated «for life».
(*)= Only a visual check of the sealing at each engine oil change interval.
B2CP3SUD
C2