Citroen C5 2000 (DC/DE) / 1.G Owner's Manual

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INJECTION
STANDARD
W3 CEE Petrol Utility vehicles : Brussels Directive 96/69
95 Diesel < 3.5 tonnes
Gaz Class 1 :
 3 classes depending on
• new models 01/97
 vehicle weight :
• existing models 10/97
 Class 1 < 1250 kg
Class 2/3 : Class 2 : 1250/1700 kg
• new models 01/98
 Class 3 : 1700 kg
• existing models 10/98

L4 CEE Petrol Private vehicles : Brussels Directive 98/69
2000 Diesel All Types
 EURO 2 standard (L3)
Gaz • new models
 01/2000 made stricter
• existing models
 01/2001  Fiscal incentives
EMISSION STANDARDS
PSA
A-S RPEngines ApplicableVehicles
EURO 2
(EURO
96)
EURO 3
(EURO
2000)E.E.C.
APPLICATION NOTES
CHARACTERISTICS
With oxygen sensor and
reinforced catalytic
converter for petrol
vehicles.
With catalytic converter
and EGR for diesel
vehicles.
With 2 oxygen sensors
and catalytic converter
for petrol vehicles. With
catalytic converter and
EGR for diesel vehicles.
With EOBD on-board
diagnosis.

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INJECTION
STANDARD
W3 Petrol Utility vehicles : Brussels Directive 98/69
Diesel < 3.5 tonnes
 EURO 2 standard (L3)
Gaz
made stricter
Class 1 : Fiscal incentives
• new models
 01/2000 3 classes depending on
• existing models
 01/2001 vehicle weight :
Class 2/3 :
Class 1 < 1305 kg
• new models  01/2001Class 2 : 1305/1760 kg
• existing models  01/2002Class 3 : 1760 kg
IF / L5 Petrol Private vehicles : Brussels Directive 98/69
All Types
 EURO 3 standard (L4)
• new models
 01/2001 made stricter
• existing models
 01/2003  Fiscal incentives
EMISSION STANDARDS
PSA
A-S RPEngines ApplicableVehicles
EURO 3
(EURO
2000)
EURO 4E.E.C.
APPLICATION NOTES
CHARACTERISTICS
With 2 oxygen sensors
and catalytic converter
for petrol vehicles.
With catalytic converter
and EGR for diesel
vehicles.
With EOBD on-board
diagnosis.
With 2 oxygen sensors
and catalytic converter
for petrol vehicles.
With EOBD on-board
diagnosis.

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INJECTION
PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM
Engines : RHY - RHZ - 4HX
Cleaning.
- The use of high pressure cleaners is prohibited.
- Do not use compressed air.
Fuel supply circuit.
- Required fuel : diesel.
Electric circuit.
- Swapping injection ECUs Between two vehicles will render it impossible to start either vehicle.
- It is forbidden to supply a diesel injector with 12 volts.
High pressure fuel pump.
Do not separate the following components from the high pressure fuel pump (5):
- Sealing ring (b)(no replacement parts).
- High pressure outlet connector (a)(will cause a malfunction).
PS : HDi = High pressure diesel injection.
B1HP19LC

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INJECTION
PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM
Engines : RHY - RHZ - 4HX
Diesel injectors.
WARNING: Diesel and ultrasonic cleaners are prohibited.
Do not separate the following components from the diesel injector carrier (2):
- Diesel injector(e) (no replacement parts).
- Electromagnetic element(c)(no replacement parts).
Do not alter the position of the nut(d)(malfunction).
Do not separate the connector(f)from a diesel injector.
It is forbidden to clean the carbon deposits from the diesel injector nozzle.
B1HP19NC

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INJECTION
SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM
Engines : RHY - RHZ - 4HX
SAFETY REQUIREMENTS
Preamble.
All interventions on the injection system must be carried out to conform with the following requirements and regulations :
- Competent health authorities.
- Accident prevention.
- Environmental protection.
WARNING :Repairs must be carried out by specialised personnel informed of the safety requirements and of the precautions to be taken.
Safety requirements.
IMPERATIVE : Take into account the very high pressures in the high pressure fuel circuit (1350 bars), and respect
the requirements below :
- No smoking in proximity to the high pressure circuit when work is being carried out.
- Avoid working close to flame or sparks.
Engine running :
- Do not work on the high pressure fuel circuit.
- Always stay clear of the trajectory of any possible jet of fuel, which could cause serious injuries.
- Do not place your hand close to any leak in the high pressure fuel circuit.
After the engine has stopped, wait 30 secondsbefore any intervention.
NOTE :This waiting time is necessary in order to allow the high pressure fuel circuit to return to atmospheric pressure.

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INJECTION
SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM
Engines : RHY - RHZ - 4HX
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.
- Third piston deactivator.
- High pressure regulator.
- High pressure sensor.
- 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
CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT
Engines : RHY - RHZ - 4HX
Engines : RHY - RHZ
Engine : 4HX
TOOLS
[1] Ø 10 mmlow pressure connector: 4215-T.
[2] Ø 8 mmlow pressure connector: 4218 -T.
[3] Pressure gauge for testing boost pressure : 4073-T Tool kit 4073-T
[4] Extension: 4251-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.
NOTE : To check the pressures while the vehicle is being driven, insert tool[4] Between
tool[3] and tools[1] et[2].
Checks on pressure : static.
- Switch on ignition
- For 3 seconds(normal functioning):
- Fuel supply pressure shown by the pressure gauge [3] = 2.6 ± 0.4 Bar.
- Fuel return pressure shown by the pressure gauge [3] = 0.6 ± 0.4 Bar.
B1BP20JDB1BP27BD

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INJECTION
CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT
Engines : RHY - RHZ - 4HX (continued)
Checks on pressure : dynamic.
Engine running, at idle (normal functioning):
- Fuel supply pressure shown by the pressure gauge [3] = 2 ± 0.4 Bar.
- Fuel return pressure shown by the pressure gauge [3] = 0.8 ± 0.4 Bar.
Abnormal functioning
Impossible to start the engine :
Fuel supply pressure less than 0.8 Bar:
- Check the low pressure regulator incorporated in the filter(locked open)
- Check the high pressure pump distribution valve (locked shut)Check : diesel injector return flow. (Table below)
Uncouple the diesel injector return pipe.
Fuel supply pressure Fuel return pressure Checks
Between 3.3et 4 Bars 0.8 ± 0.4 BarCheck the condition of the diesel filter
More than 4 Bars
More than 4 BarsLess than 0.8 Bar
More than 0.8 BarCheck the low pressure regulator incorporated in
the filter (locked shut) : replace.
Check the fuel return circuit (pipe pinched or trapped...).
Between 0.8et 1.5 BarLess than 0.8 BarCheck the fuel suppy circuit :
- Booster pump(low pressure), piping.
Check :
Observe :
The flow should be drop by drop
Diesel injector functioning correctly
Excessive fuel return
Diesel injector locked shut.

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INJECTION
AIR SUPPLY CIRCUIT SPECIFICATION
Engine : RHY
(1) Air filterPSA 7899.
(2) FlowmeterSIEMENS
(3)Water / recycled gas exchangerVALEO
(4) E.G.R. valvePURFLUX
(5) Turbocharger KKK K03
(6) Air butterflyMAGNETI MARELLI
48W7 Ref. 648
B1HP1A6D

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INJECTION
(7) Air / air heat exchanger VALEO.
(8) Turbocharger KKK K03.
(9)EGR valvePURFLUX.
(10)Air butterflyMAGNETI MARELLI
48W7 Ref. 648.
(11)Air filter PSA 7899.
(12) Turbocharging pressure sensorNIPPON DENSO.
AIR SUPPLY CIRCUIT SPECIFICATION
Engine : RHZ
B1HP1A7P