Xsara 2 Citroen XSARA 2004 1.G Workshop Manual

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INJECTION
Emission standard Engine type
Injection make
and type
PETROL INJECTION
XSARA XSARA PICASSO
Air temperature sensor
resistive value (ohms)
XSARA PICASSO
XSARA 2
SAGEM
S2000M. MARELLI
6LP BOSCH
M.7.4.4.BOSCH
M.7.4.4.SAGEM
S2000M. MARELLI
6LP
Fuel pressure (bars)
Overspeed cutoff (rpm)
Injector resistive value (ohms)
Engine coolant temperature
sensor resistive value (ohms)
Idling actuator or stepper
motor resistive value (ohms)
KFW
L4/IFL5/L5 L4/IFL5 L4/IFL5 L4 IFL5L4/IFL5
1.4i 1.6i 16V 2.0i 16V 1.6i
2.0i 16V
1.8i 16V
RFN
NFU NFV 6FZ RFN
3,53,5
3
3 3,5 3,5
14,5 14,5 14,5
14,512,2 14,5
5500
5700
6000
5800
5500 6000
Stepper motor:53 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C
3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C

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INJECTION
PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM
Engines: 8HX 8HW 8HZ
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
(a)(no replacement parts).
High pressure outlet connector
(b)(will cause a malfunction).
PS: HDi = High pressure Diesel injection
B1HP1K9C
C2 C3 XSARA

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INJECTION
PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM
Engines: 8HX 8HW 8HZ
Diesel injectors.
WARNING: Diesel and ultrasonic c
leaners are prohibited.
Do not separate the following components from the diesel injector
carrier
(2):
Diesel injector
(f)(no replacement parts).
Electromagnetic element
(c)(no replacement parts).
Do not alter the position of the nut
(d)(malfunction).
Do not separate the connector
(e)from a diesel injector.
It is forbidden to clean the carbon deposits from the diesel injector
nozzle.
B1HP1KACB1HP1KBC
C2 C3 XSARA

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INJECTION
PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM
Engines: RHY RHZ
XSARA PICASSO
Cleaning.
The use of high pressure cleaners is prohibited.
Do not use compressed air.
Fuel supply circuit.
Required fuel: diesel.WARNING:Do not use other fuels.
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):
High pressure fuel pump third piston deactivator (3)(no replacement parts).
High pressure fuel regulator (4)(no replacement parts).
Sealing ring (1)(no replacement parts).
High pressure outlet connector (3)(will cause a malfunction).
PS:HDi = High pressure Diesel injection
B1HP12CC

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INJECTION
PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM
Engines: RHY RHZ
XSARA PICASSO
High pressure fuel injection common rail. Do not separate the connectors (7)from the common injection rail (6)(malfunction).
Diesel injectors.
WARNING:Diesel and ultrasonic cleaners are prohibited.
Do not separate the following components from the diesel injector carrier (9):
Diesel injector (8)(no replacement parts).
Electromagnetic element (11)(destruction).
Do not alter the position of the nut (10)(malfunction).
Do not separate the connector (12)from a diesel injector.
It is forbidden to clean the carbon deposits from the diesel injector nozzle.
Identification: Injector carrier
There are two types of diesel injector carrier classed according to fuel flow.
Identification by engraving or paint mark
B1HP12EC
B1HP12DC
B1HP16PC
IMPERATIVE: When replacing a
diesel injector carrier, order a
component of the same class.
(See repair manual)
Identification markings:
«a»:Supplier identification.
«b»:PSA identification number.
«c»:Class identification.
Injector carrier
Class 1
Class 2
Engraving
1
2
Paint mark
Blue
Green
Location
On the upper part of the
coil near to the fuel return
aperture

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INJECTION
SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP
PUMP TYPE REFERENCE
Dépollution
EquipmentL3
Transponder
XSARA
XSARA
8B
DWWJYDWLP 12
R8448 B
371 B

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INJECTION
SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP XSARA
Engine
typePump
Type
ReferenceStatic timing
Initial advance
Compression
Time
(cylinder N° 4)Dynamic
timing
checking
(at idle)Reference
InjectorInjector
holder
+ injectorCode
colourInjector
needle lift
pressure
(Bar)Adjustments (rpm) Max. speed
Fast
idlingAntistall
IdlingUnladen
rpmLaden
rpm
WJYDWLP 12
R 8448 B/*RDNO
SDC
6903LDCR
0260
IAA135,5
±5950
±25875
±25875
±255350
± 125
Engine
TDC
Pegging hole.
Value «X»
engraved on
the pump.
(*) = See table page: 251.1500
+ 3
mm
shim

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INJECTION
XSARACHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP
Tools.
[1]
Flywheel locating peg: 7014T.J
[2] H M8 screw: ().0188.E Tool kit C.0188
[3]Injection pump setting peg Ø 6 mm : ().0188.H
After carrying out the necessary dismantling operations on the vehicle, proceed in the following manner:
Remove:
The screws
(6), (7), (9), (10)and (12).
The upper casing (8).
The intermediate casing (11).
WARNING:Refit the screw (6)equipped with a washer.(Thickness 5 mm)
Turn the front RH wheel to turn the engine.(Normal direction of rotation) Bring the camshaft and injection pump pulleys to their setting point.
Position the flywheel peg, using tool [1].(From below the vehicle) Turn the engine until the peg [1]engages in the flywheel.
B1EP12NC
Engine: WJY
B1BP1S9C

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INJECTION
CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP
Engine: WJY (continued)
Peg:
The camshaft hub, using tool [2].
The injection pump hub, using tool [3].
Impossible to peg the camshaft.Reset the valve timing (See page 245).
Possible to peg the camshaft, but not the injection pump.Carry out the following operations:
Loosen the screws of the injection pump hub.
Turn the injection pump hub.
Insert the peg
[3]into the setting hole.
Tighten the screws of the injection pump hub.Tighten to 2,3 ±0,2 m.daN.
ESSENTIAL:If setting the diesel injection pump proves impossible, reset the valve
timing.(See page 251)
Remove:
The tools [1], [2]and [3].
The screw (6)and the washer.
Reassemble the components.
B1EP12WDB1BP1S9C
XSARA

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INJECTION
ADJUSTING THE MECHANICAL CONTROLS OF THE DELPHI INJECTION PUMP
Engine: WJY
Adjusting the fast idle.
Engine cold.
Ensure that the lever (2)is up against its stop to the right.
If not, adjust the tension of the cable (3)using the cable clamp (1).
Finish tensioning using the sleeve tensioner (4).
Engine hot. Check that the cable (3)is in tension.
Checking the thermostatic sensor. There should be a minimum 6 mmcable travel between a cold and a hot engine.
Adjusting the accelerator control.
Prior conditions.
Engine hot (cooling fan is engaged twice).
Checking the accelerator cable tension. Fully depress the accelerator pedal.
Check that the lever (6)is against its stop (5)otherwise, alter the position of the pin.
If not, adjust the position of the accelerator cable tensioning retaining pin.
Ensure that in the idle position the lever
(6)is against the stop (7).
B1HP0K9C
XSARA