Reservoir Citroen C2 2004 1.G Workshop Manual

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201
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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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: 9HZ 9HY
Refitting.
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 to 5,5 ± 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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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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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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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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INJECTION
SPECIAL FEATURES: PARTICLE FILTER / FILLING OF THE ADDITIVE RESERVOIR
Imperative: Respect the safety and cleanliness requirements.
Tools.
Filling kit comprising the following items:1Container of Eolys2Filters2Tubes1Empty container2Hooks1Adaptor
Filling.
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.
Disconnect the battery negative terminal.
Unclip the the factory filler connector
(1).
Couple the container of additive to the tube (2)using the adaptor and the tube (with tap)from the
filling kit.
Screw the filler connector on the additive container
(3)at «b».
Place the additive container (3)on the component lift.
Open the tap located on the filler connector at «a».
Tilt the additive container (3)(to facilitate the end of filling).
Close the tap at «a».
Remove the filler connector and the tube (4).
Couple the tube (2).
Reconnect the battery negative terminal.
IMPERATIVE: The filling kit should be recycled after this operation. Any «Eolys» additive
containers that have been opened should not be kept.
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B1HP1UVC
C4BP1EGC

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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
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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.
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B1HP1UUC
B1KP019C

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS HYDRAULIQUE
Bleeding the hydraulic clutch control
Action the clutch pedal manually through its full travel:7 times rapidlydown and up.
Allow the clutch pedal to come back up to its high position.
Fill the brake fluid reservoir to the maximum of its capacity.
Open the bleed screw, at
«c».
Action the clutch pedal manually through its entire travel:7 timesrapidly down and up.
The last time, keep the clutch pedal fully down.
Reclose the bleed screw, at
«c».
If necessary, repeat the operation.
Top up the brake fluid to the MAX. level of the brake fluid reservoir.
Work the clutch vigorously
40 times.
Start the engine.
Apply the handbrake.
Engage a gear.
Check that the clutch starts to engage at a dimension
(X)greater than or equal to 45 mm(the dimension (X)is
given as a guide).
Repeat the bleed operations if necessary.
C5FP0FQCB2BP04YC
C2 C3 C3 PLURIEL
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BRAKES
B3FP15XC
BLEEDING AND FILLING THE BRAKING SYSTEM
Tools.
[1]
Generic bleeding apparatus :«LURO»Bleeding, refilling.
Draining.
Drain the brake fluid reservoir (1)to the maximum(if necessary, use a clean syringe).
Disconnect the connector (4).
Uncouple the pipe (2).
Unscrew the shaft (3).
Remove the reservoir (1).
Empty the brake fluid reservoir (1).
Clean the brake fluid reservoir (1).
Refit:
The brake fluid reservoir
(1).
The shaft (3).
Couple the pipe (2).
Reconnect the connector (4).
Filling the braking system.WARNING:Use only those hydraulic fluids that are approved and recommended.
Fill the brake fluid reservoir (1).
Bleeding the braking system.WARNING:During the bleeding operation, take care to maintain the level of brake fluid in the reservoir
and to top it up, using only brake fluid that is clean and clear.
C2

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BRAKES
B3FP160C
BLEEDING AND FILLING THE BRAKING SYSTEM (Continued)
With the bleeding apparatus.
Connect the bleeding apparatus [1]on the brake fluid reservoir (1).
Adjust the apparatus pressure to
2 Bars.
For each circuit:
Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container.
Open the bleed screw, wait until the fluid is flowing out without air bubbles. Close the bleed screw.
Remove the bleeding apparatus
[1].
Check the brake fluid level
(should be between «MINI»level and «MAXI»level).
Fill if necessary with the approved and recommended synthetic brake fluid.
Without the bleeding apparatus.
NOTE:Two operators are necessary.
For each circuit:
Apply the brake pedal to place the circuit under pressure.
Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container.
Open the bleed screw, wait until the fluid is flowing out without air bubbles.
Close the bleed screw. Remove the tool
[1].
NOTE:Recommence the process a second time if that is necessary.
Check the brake fluid level
(should be between «MINI»level and «MAXI»level).
Fill if necessary with the approved and recommended synthetic brake fluid.
C2