plug Citroen C3 2004 1.G User Guide

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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine: WJY
Setting the timing (continued).
Tighten:
Screw (9)to 2.1 ± 0.2 m.daN.
Screws (5)to 2,3 ± 0.2 m.daN.
Screws (6)to 2,3 ± 0.2 m.daN.
Remove and refit tool [7].
The tension value should be between 38 and 46 SEEM units.
Remove tools [7], [2], [3] and [4].
Turn the crankshaft 2 timesin the normal direction of rotation.
Peg the flywheel, using the peg [2].
Visually check the peggings of the camshaft and injection pump.
ESSENTIAL:Visually check that the offsets between the holes of
the camshaft and injection pump hubs and the correspondingpegging holes are not more than 1 mm.If necessary, recommence
the procedure for fitting the timing belt.
XSARA
Setting the timing (continued).
Remove the peg [2].
Remove the screw (4)and the washer.
Refit the lower cover (3).
Refit the intermediate cover (2).
Refit the upper cover (1).
Remove the RH engine support.
Take away the workshop hoist. Remove the plugs and recouple the diesel fuel delivery and return
hoses. Refit the accessories drive belt
(see corresponding operation).
Refit the RH lower splashshield. Disengage
5th gear.
Connect the battery.

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ENGINECHECKING AND SETTING THE VALVE TIMING
NOTE: Checking and setting the valve timing on engines: RHYRHZ N° ⁄ RPO 9127
See Mechanic’s Handbook 2003: pages 193 to196
Tools.
[1]
Belt tension measuring equipment :4122T
[2]
Tension lever:().0188.J2
[3]
Engine flywheel peg: ().0188.Y
[4]
Belt clamp: ().0188.AD
[5]
Camshaft pulley peg: ().0188.M
[6]
Engine flywheel lock: ().0188.F
[7]
Set of blocking plugs:().0188.T
[8]
Pulley extractor:().0188.P
[9]
2 mm dia.peg: ().0188.Q2Removing.
IMPERATIVE: Respect the safety and cleanliness requirements
that are specific to high pressure diesel injection (HDi) engines.
Undo the front RH wheel bolts.
Raise and support the vehicle on the front RH side.
Disconnect the battery negative terminal.
Remove:
The underengine sounddeadening.
The front RH wheel.
The front RH splashshield. The engine cover.
Unclip and move aside the cooling hose.
Remove the accessories drive belt
(see corresponding operation).
XSARA XSARA PICASSO
Engines: RHY RHZ N° RPO 9128 #

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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
Uncouple, plug and move aside, using tool [7], the fuel delivery pipe (2)and return
pipe (1).
Remove:
Screws
(3), (4) and (6).
Screw (7).
The upper timing cover (5).
WARNING:Refit screw (7)equipped with a spacer (17 mm thick), tighten the
screw (7)to 1,5 ± 0,1 m. daN.
NOTE:The screw (7)is one of the screws securing the coolant pump and is there
for its sealing.
Put the gear lever in 5th gear.Turn the road wheel to turn the engine in its direction of rotation.
Orient the camshaft pulley in the pegging position, use a mirror if necessary.
Peg the camshaft, using tool
[5].
Peg the engine flywheel, using tool
[3].
B1EP1A7CB1BP2H3CB1BP2H2CB1BP2R2C
XSARA XSARA PICASSO

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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
PARTICLE FILTER SAFETY AND CLEANLINESS REQUIREMENTS
Operations on the fuel additive circuit.
IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves that are resistant to hydrocarbons.
The work area must be ventilated.
In the event of any significant dispersion of additive:
Wear a breathing mask for filtering the particles.
Recover as much of the product as possible.
Place the product thus recovered in an appropriately labelled container. Wash the soiled area with copious amounts of water.
Dispose of materials and solid residues in an authorised recovery point.
IMPERATIVE:The filling kit should be recycled following a repair. All «Eolys» additive containers that have been opened should be
disposed of.
Cleanliness rules.
ESSENTIAL: The operator should wear clean overalls.
Before working on the injection circuit, it may be necessary to clean the unions of the following sensitive components(see corresponding operations).
Fuel filter.
Fuel high pressure pump.
Fuel high pressure regulator.
Fuel high pressure common injection rail. Fuel high pressure piping. Diesel injector carriers.
IMPERATIVE: After dismantling, immediately blank the unions of the sensitive components with plugs, to prevent any ingress of impurities.
ALL TYPES

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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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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: HFX KFV NFU 8HX 8HW
Tightening torques (m.daN).
(26)
5th gear cover fixing screw(3 screws): 2,2 ± 0,2
(27) Reverse gear switch (1 screw): 2,5 ± 0,5
(28)Drain plug (1 screw):3,3 ± 0,3
(29) Topup plug (1 screw): 3,3 ± 0,3 (*)
(*) =
The oil topup plug is discontinued from RPO 9919
Features.This gearbox:
has no adjustment. has a reverse gear braking device
(5th gear synchroniser).
has a device for prohibiting a change from 5th gear into reverse gear.
The clutch control has a balljoint mounted declutch fork.
Lubrication.Oil capacity :2 ±0,15 Litres.Checking the oil level: No oil level check (*)Lubrication interval:Lubricated «for life».
NOTE:There should be a visual check on the sealing at each engine oil
change.
B2CP3SSD
C2 C3 C3 PLURIEL

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: KFW NFU
(29)Topup plug (x1): 2,5 ± 0,5.
(30)Drain plug (x1): 2,5 ± 0,5.
(31)Reverse gear switch (x1): 2,5 ± 0,5.
Strengthened MA gearboxes are marked with the letter «B»or «C»:«B»= Differential diameter 77 mm+ strengthened bearings.«C»= Differential diameter 77 mm+ strengthened bearings + strengthened
intermediate plate.
NOTE:All vehicles are equipped with clutch control by cable.
Features.
This gearbox:
has no adjustment.
has a reverse gear braking device
(5th gear synchroniser).
has a device for prohibiting a change from 5th gear into reverse gear.
The clutch control has a balljoint mounted declutch fork.
Lubrication.
Oil capacity : 2 ± 0,15 Litres.
Checking the oil level : Every 37,500 miles.
Lubrication interval : Lubricated «for life».
B2CP169D
XSARA

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 PILOTED MANUAL GEARBOX
Engines: KFV 8HX
Tightening torques (m.daN).
(26)
5th gear cover fixing screw(3 screws):2,2 ±0,2
(27)
Gearbox input speed sensor(1 screw): 0,8 ± 0,2
(28)
Reverse gear switch(1 screw): 2,5 ± 0,5
(29)
Drain plug(1 screw): 3,3 ± 0,3
(30)
Level plug(1 screw): 3,3 ± 0,3
B2CP3SUD
C2

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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX
Engines: NFV 6FZ RFN RFS 8HV 8HY 9HZ 9HY WJY RHY RHZ
(1)Drain plug.
(2)Filling and topup plug.
(3)Air vent.
NOTE:The air vent aperture can be used for filling.
Quality of oil.Refer to the manufacturer’s instructions.
Quantity of oil.Gearbox empty:1,9 Litres.
After draining:2 Litres.
B2CP3BLD
C3 XSARA XSARA PICASSO