Ignition Citroen C2 2004 1.G Workshop Manual

Downloaded from www.Manualslib.com manuals search engine PRESENTATION
THIS HANDBOOKsummarises the specifications, adjustments, checks and special features of CITROEN
private vehicles, not including UTILITY vehicles for which there exists a separate handbook.
The handbook is divided into nine groups representing the main functions :
GENERAL ENGINE INJECTION IGNITION CLUTCH, GEARBOX, DRIVESHAFTS AXLES,
SUSPENSION, STEERING BRAKES ELECTRICAL AIR CONDITIONING.
In each section, the vehicles are dealt with in the following order: C2C3C3 PLURIEL XSARA XSARA PICASSO BERLINGO (1)
and all models where applicable.
The information given in this handbook is based on vehicles marketed in EUROPE.
(1) NOTE : The BERLINGO familiale appears only in :
The correspondance tables for petrol and diesel engines.
The general chapter.
For all the other chapters, see the Mechanics’ Handbook for UTILITY vehicles.

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Operation to reconnect the battery after a vehicle repair
WARNING
If the battery has been disconnected, after reconnecting it is ESSENTIALto wait 1 minutebefore switching on the ignition,
otherwise the engine ECU will lock up.
If the ECU has locked up :
Switch off the ignition.
Wait
1 minute.
Switch the ignition back on, the ECU is unlocked.

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C2
OPERA TIONS TO BE CARRIED ORT AFTER A REPAIR
GENERAL
Sun roof.The antipinch function has to be reinitialised.
Place the sun roof switch in the maximum tilt position.
Keep the sun roof switch pressed until the sun roof ceases its movement.
Release the sun roof switch within 5 seconds.
Keep the sun roof switch pressed until the end of the sun roof opening sequence.
Multifunction screen.It is necessary to adjust the date, time and ortside temperature.
Adjust the display language of the multifunction screen if necessary.
NOTE:The default display language of the multifunction screen is French.
Navigation.Warning, the vehicle has to be in the open air (on switching on the ignition, the ECU searches for satellites).
Vehicle location is only effective after some ten minutes.Reprogramme the customer paramanders.
Radio.Reprogramme the radio stations.
Radiotelephone RT3.Reprogramme the radio stations.

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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
Tools.
[1] Ø 10 mm
low pressure connector: 4215T.
[2] Ø 8 mmlow pressure connector: 4218 T.
[3]Pressure gauge for testing boost pressure: 4073 T Kit 4073 T
Connect the tool [1]between the booster pump and the fuel filter (white mark at "a" on the
fuel supply pipe).
Connect the tool [2]downstream of the diesel injectors, between the high pressure fuel
pump and the fuel filter (green mark at "b"on the fuel return pipe).
WARNING: Any check of pressure downstream of the fuel filter is PROHIBITED.
Checks on pressure:static.
Switch on ignition
For 3 seconds(normal functioning):
Fuel supply pressure shown by the pressure gauge [3] = 1.8 ± 0.4 Bar. Fuel return pressure shown by the pressure gauge [3] = 0.5 ± 0.4 Bar.
B1BP1TWD

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1.1iHFX
FR7 DE RFN 58 LZ RC 8 YLC
C2 1.4i KFV
1.6i 16V NFU FR7 ME 0,9 ± 0,1 RFN 58 HZ
1.1i HFX
FR7 DERFN 58 LZ RC 8 YLC
1.4i KFV
C3 1.4i 16V KFU VR8 SE 0,9 ± 0,05
1.6i 16V NFU FR7 ME RFN 58 HZ
C3 1.4i KFV FR7 DE RFN 58 LZ RC 8 YLC
PLURIEL1.6i 16VNFUFR7 MERFN 58 HZ
0,9 ± 0,05 0,9 ± 0,05 2.5 ± 0,2
1.4iKFWFR7 DE0,9 ±0,1 RFN 58 LZ RC 8 YLC mda.N
XSARA 1.6i 16V NFU FR7 ME RFN 58 HZ
2.0i 16V RFN FR8 ME RFN 52 HZ REC 9 YCL
RFSFR6 DE RFN 62 LZ
1.6i90 hp
NFVRFN 58 LZ
XSARA100 hpFR7 DE RC 8 YLC
PICASSO 1.8i 16V 6FZ
FR8 ME0,9 ± 0,1
RFN 52 HZ REC 9 YCL
2.0i 16V RFN
SPARKING PLUGS ALL TYPES
Vehicles
BOSCH Engine
typeEYQUEM
CHAMPION Electrode
gap settingTightening
torque
IGNITION
Electrode
gap settingElectrode
gap setting

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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
RECOMMENDATIONS PRECAUTIONS: AL4 AUTOMATIC GEARBOX
Engines: KFV NFU RFN RHZ
Precautions to be taken.
Towing.
The front of the vehicle must be raised in order to be towed.
If the front of the vehicle cannot be raised:
IMPERATIVE: Put gear lever in position «N».
Do not add any oil.
Do not exceed
30 mphover a distance of 30 milesof maximum.
Driving.
Never drive with the ignition switched off.
Never push the vehicle to try to start it
(impossible with an automatic gearbox).
NOTE:The automatic gearbox is only lubricated when the engine is
running.
Repairs on electrical components.
Do not disconnect:
The battery when the engine is running.
The ECU when the ignition is switched on.
Before reconnecting a switch,check: The condition of the various contacts (for deformation, corrosion etc).
The presence and condition of the mechanical locking.
When performing electrical checks: The battery should be correctly charged.
Never use a voltage source higher than 16V.
Never use a test lamp.
C3 XSARA XSARA PICASSO