Dri Citroen C3 2004 1.G Manual PDF

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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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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
Reposition the timimg belt, belt at «a»well tensioned, in the following order:
Fuel high pressure pump pulley
(21).
Guide roller
(15).
Crankshaft pinion
(19).
Coolant pump pinion
(16).
Tensioner roller
(18).
Position tool
[1]on the belt at «a».
Remove tools
[4]and [9].
Turn the tensioner roller
(18)anticlockwise, using tool [2], to attain an overtension of:
98 ± 2 SEEM units.
Tighten screw
(17)of the tensioner roller to 2,5 ± 0,2 m.da N.
Lock the flywheel by means of tool
[6].
Tighten the accessories drive pulley screw
(8)to 7 ± 0,7 m.da N.
Remove tools
[1], [3], [5] and [6].
Rotate the crankshaft eight times in the normal direction of rotation.
Peg:
The crankshaft, using tool
[3].
The camshaft drive pulley, using tool
[5].
B1EP1ABDB1EP1ACC
XSARA XSARA PICASSO

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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
Lock the engine flywheel, using tool [6].
Slacken:
The accessories drive pulley
(8).
The screw (17) of the tensioner roller (18).
Fit the tool [1].
Turn the tensioner roller, using tool [2], to attain a tension of:54 ± 2 SEEM units.
Tighten screw (17)of the tensioner roller (18)to 2,5 ± 0,2 m.daN.
Remove tool [1].
Fit tool [1].
The tension value should be:
54 ±3 SEEM units.ESSENTIAL: If the value is incorrect, recommence the operation.
Remove tools [1], [3], [5]and [6].
Rotate the crankshaft two times in the normal direction of rotation.
Peg:
The crankshaft, using tool
[3].
The camshaft drive pulley.
IMPERATIVE:If the pegging is not possible, recommence the operation.
B1EP1ACC
XSARA XSARA PICASSO

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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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SPEEDOMETERALL TYPES
An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled.
This decree stipulates:
The speed indicated by a speedometer must never be lower than the actual vehicle speed.
Between the speed displayed «SD»and the speed travelled «ST», there must always be the following relationship:
ST < SD < 1.10 ST + 4 Kph
Example: For an actual speed of 100 Kphthe speed displayed by the speedometer may be between 100and 114 Kph.
The speed indicated by the speedometer may be influenced by:
The speedometer.
The tyres fitted to the vehicle.
The final drive ratio.
The speedometer drive ratio.
Any of these components can be checked without removing them from the vehicle
(see information note N° 78-85 TT of 19 October 1978).NOTE:Before replacing the speedometer, check the conformity of the following points:
The tyres fitted to the vehicle.
The gearbox final drive ratio.
The speedometer drive ratio.
CLUTCH
GEARBOX
TRANSMISSION

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CLUTCH
GEARBOX
TRANSMISSION
GEARBOX AND TYRE SPECIFICATIONS
Petrol
XSARA
Engine type
Tyresrolling Circumference
Speedometer ratio Gearbox type
Gearbox ident. plate
Reduction box torque
Engine type
Tyresrolling Circumference
Speedometer ratio Gearbox type
Gearbox ident. plate
Reduction box torque1.4i1.6i 16V
AUTOMATIC AUTOMATIC
2.0i 16V
KFW NFU RFN RFS
195/55 R15 1,815 m
MA/5 AL4 BE4/5 AL4 BE3/5
20 CP 13
(1)20 CP 51 (2)20 TP 49
20 DL 40
20 TP 4720 TE 47
16x65 21x73 19x72 23x73 14x62
21x18 24x21 22x19 24x21 22x19
Diesel
1.9 D
1.4 HDi2.0 Hdi
WJY 8HZ RHY (3) RHZAUTOMATIC
195/55 R15 – 1,815 m
BE4/5
AL4
20 DL 41
19x75
22x19 20 DM 54 20 DL 42
19x7020 DM 10
17x6120 TP 48
14x62
22x19
NOTE:(RHY engine BE4/5 gearbox) (1) Estate = 20 CP 44 (16x65) (21x18) (2) DAIC = 20 CP 52 (14x60) (21x18) (3)XSARA DAIC RHD = 20 DM 08Right hand drive: 6FZRFN= 20 DM 03 WJY= 20 DM 05 8HZ= 20 DM 53 RHY = 20 DM 07 RHZ= 20 DM 11

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CLUTCH
GEARBOX
TRANSMISSION
GEARBOX AND TYRE SPECIFICATIONS XSARA PICASSO
Engine typeNFV 6FZ RFN
Tyresrolling
185/65 R15
Circumference1,895 m
Gearbox type BE4/5 AL4
Gearbox ident. plate20 DL 67 20 DL 69 20 TS 02
Reduction box torque15x6419x77 21x73
Speedometer ratio22x1824x20
Diesel
1.6 16V HDi 2.0 HDi
Engine type 9HZ 9HY RHYTyresrolling
185/65 R15
Circumference1,895 m
Gearbox typeBE4/5
Gearbox ident. plate20 DM 62 20 DL 65
Reduction box torque19x70 19x72
Speedometer ratio22x18 22x18
Right hand drive:NFV = 20 DL 676FZ = 20 DL 69RHY = 20 DL 65.
1.6i
1.8i 16V2.0i 16V PetrolAUTOMATIC

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: HFX KFV NFU 8HX 8HW
(1)Retaining clip.(2)Secondary shaft.(3)Drive pinion (5th gear).(4) Bearing retaining clip screw.(5)Gearbox casing.(6)Intermediate plate.(7)Gearbox casing fixing screw.(8)Clutch bearing guide screw.(9) Clutch housing.(10)Bearing guide.(11)Primary shaft.(12)Differential housing.(13)Speedometer screw.(14)Counter drive.(15)Planet pinions.(16) Satellite pinions.(17)Differential gearwheel.(18)Driven pinion (1st gear).(19)1st / 2nd gear synchroniser and reverse gear driven pinion.(20)Driven pinion (2nd gear).(21) Driven pinion (3rd gear).(22) 3rd / 4th gear synchroniser.B2CP3SRP
C2 C3 C3 PLURIEL

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: HFX KFV NFU 8HX 8HW
(23)Driven pinion (4th gear).(24)Driven pinion (5th gear).(25)5th gear synchroniser.
Tightening torques (m.daN).
(4)
Bearing retaining clip screw(x4):1,8 ± 0,2
(6)
Intermediate plate (11 fixing screws): 5 ± 0,5
(7)
Gearbox casing(15 fixing screws):1,9 ± 0,216 fixing screws RPO 9784
17 fixing screws RPO 9786

(8)Clutch bearing guide screw(3 fixing screws):0,6 ±0,15
B2CP3SRP
C2 C3 C3 PLURIEL