Idle Citroen XSARA 2004 1.G Workshop Manual

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171
CHECKING AND SETTING THE VALVE TIMING
Engines: 6FZ RFN 2003 # NEW ASSEMBLY2003 #
(6)Crankshaft pinion
(7)Accessories drive pulley
(8)Washer
(9)Screw
The pinion
(6)is fitted as an idler on the crankshaft.
The accessories drive pulley
(7)is immobilised on the crankshaft by a halfmoon keyway and
by the tightening of washer
(8)and screw (9).
A:Pegging on manual gearbox.
B:Pegging on automatic gearbox.
The pegging of the crankshaft is done on the flywheel, or on the converter drive plate
(automatic gearbox).
The pegging hole on the cylinder block
(exhaust end)is calibrated and reinforced.
IMPERATIVE: Never turn the crankshaft with the accessories drive pulley slackened.
IMPERATIVE: Never remove the accessories drive pulley without pegging the crank
shaft and the camshafts.
IMPERATIVE: Always turn the crankshaft in the direction of engine rotation.
B1EP1B9D
B1BP2V2D
XSARA XSARA PICASSO

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ENGINE
(1) «Idler»camshaft pulley(2)Target for cylinder reference sensor.(3)Camshaft hub.(4)«Fixed»crankshaft pinion.
The determining of the tension of the timing belt is done on the cam
shaft pulley
(1).
The new timing on 8 valveengines DW10TD (RHY)and DW10
ATED (RHS-RHZ)requires the following components:«Idler»crankshaft pinion«Fixed»camshaft pulley.
(5) «Fixed»pulley with integral cylinder reference
sensor target).(6) «Idler»crankshaft pinion (with increased width keyway groove).
The determining of the tension of the timing belt is done on the crankshaft pinion
(6).
CHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
OLD FITTING:# N° RPO 9127 NEW FITTING N° RPO 9128 #
B1EP176DB1EP177D
XSARA XSARA PICASSO

Downloaded from www.Manualslib.com manuals search engine DEPOLLUTION TECHNICAL CHECKS (FRANCE)ALL TYPES
All Types Petrol CO Corrected (In %)
All Types Diesel (m1)
Conditions:
At idle, engine warm.
#01/96
Less than 4.5 %for vehicles registered before 10/86.
Less than 3.5 %for vehicles registered after 10/86.
With catalytic converter
Greater than 2.0i89 M.Y.
All Types 93 M.Y.
COless than 0.5 % at idle speed.COless than 0.3 % at fast idle speedbetween 2500 and 3000 rpm (*)
Lambda Probe value 0,97 to 1,03.01/96
#
Atmospheric engine.
Less than 2.5 m
1
Turbocharged engine.
Less than 3.0 m
1
236
INJECTION

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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
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

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INJECTION
ADJUSTING THE MECHANICAL CONTROLS OF THE DELPHI INJECTION PUMP
Engine: WJY (continued)
Adjusting the antistall (residual output).
Insert a 3 mmthick shim (10)between the throttle lever (6)and the antistall screw (7).
Push the stop lever (8).
Insert a 3 mmdiameter peg (9)in the lever (2).
Adjust the engine speed to 1500 rpm ± 100using the stop screw (7).
Remove the shim (10)and the peg (9).
Adjusting the idle speed.
Adjust the speed using the idle adjustment screw (11).
Idling speed:825 ± 25 rpm.
Checking the engine deceleration.
Move the throttle lever (6)to obtain an engine speed of 3000 rpm.
Release the throttle lever (6).
The deceleration should be between 2.5and 3.5seconds.
The drop should be approximately 50 rpmin relation to the idle speed.
Deceleration too fast, (the engine has a tendency to stall)slacken the screw (7)by a quarter turn.
Deceleration too slow, (engine speed is greater than the idle speed)tighten screw (7)by a quarter turn.
NOTE:In each case, check the idle speed for any necessary adjustments.
B1HP0K9CB1HP0KAC
XSARA

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INJECTION
XSARA PICASSO CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT
Engines: RHY RHZ (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] = 0.7 ± 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 3and 3.5 Bar 0,7 ± 0,2 BarCheck the condition of the diesel filter
More than
3.5 Bar
More than 3.5 Bar
Less than 0.7 Bar
More than 0.7 Bar
Check the low pressure regulator incorporated in
the filter (locked shut): replace.
Check the fuel return circuit
(pipe pinched or trapped…)
Between 0.8 and 1.5 BarLess than 0.7 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
CHECKING THE AIR SUPPLY CIRCUIT
Tools.
[1]
Manual pressurevacuum pump: FACOM DA 16
Vacuum pump:
Connect the tool [1]onto the vacuum pump (1).
Start the engine.
Wait 30 seconds.
The vacuum value should be
0.9 ±0.1 barat idle.
B1HP1K8D
Engines: 8HX 8HW 8HY 8HV
C2 C3

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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX
Engines: NFV 6FZ RFN RFS 8HV 8HY 9HZ 9HY WJY RHY RHZ
Description
(1)
Primary shaft.
(2)Clutch bearing guide.
(3)Gearbox casing.
(4)Clutch housing.
(5)Reverse idle.
(6)Drive gear (3rd gear).
(7)3rd / 4th gear synchroniser.
(8)Drive gear (4th gear).
(9)Drive gear (5th gear).
(10)5th gear synchroniser.
(11)Driven gear (5th gear).
(12)Driven gear (2nd / 4th gear).
(13) Driven gear (2nd gear).
(14)1st / 2nd gear synchroniser.
(15)Driven gear (1st gear).
(16)Secondary shaft.
(17)Differential gear.
(18)Satellite gears.
(19)Planet gears.
(20)Differential housing.
(21)Speedometer drive.
(22)Extension.
«d» Adjusting shims: 0.7 to 2.4 mm
(0.10 mm and increasing by 0.10 mm).
«c»Adjusting shims:1.4 to 1.6 mm
(0.10 mm and increasing by 0.10 mm).
B2CP3BQP
C3 XSARA XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
DRAINING / FILLING / TOPUP: AL4 GEARBOX
Checking the oil level.
Prior conditions:
Vehicle in horizontal position.
Check gearbox is not in backup mode.
Remove the oil filler cap
(2).
Add 0.5 litres extra oilinto the gearbox.
Foot on the brake, change through all the gears.
Selection lever in position
"P".
Engine running, at idle.
Oil temperature:
60°C (+8°C; 2°C).
Remove the oil level plug (3).
C3 TU3enginesDimension «X» = 81 mm
XSARA TU5
and EW10 enginesDimension «X» = 81 mm
XSARADW10
enginesDimension «X» = 77 mm
XSARA PICASSO EW10
enginesDimension «X» = 81 mm
Engines: KFV NFU RFN RHZ
C3 XSARA XSARA PICASSO
B2CP3AZD