fuel pump Citroen XSARA 2004 1.G Workshop Manual

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ENGINESPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engine8HX
Lubrication circuit
Oil pump assembly
Pretightening
0,5 ± 0,1
Tightening0,9 ± 0,1
Coolant/oil heat exchanger1 ± 0,1
Diesel injection circuit
Sphericalbase screws for diesel injection fixing fork2,5 ± 0,2
Fuel high pressure common injection rail on engine block2,2 ± 0,2
Unions on fuel high pressure common injection rail2,5 ± 0,2
Diesel injection pump on support2,2 ± 0,2
Union on diesel injection2,5 ±0,2
Diesel injection pump pulley5 ± 0,5
Union on diesel high pressure pump2,5 ± 0,2
Cooling circuit
Coolant pump
Pretightening
0,3 ±0,1
Tightening0,9 ± 0,1
Coolant outlet housing
Pretightening
0,3 ±0,1
Tightening0,7 ± 0,1
C2

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ENGINE
SPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engines8HX 8HW 8HZ
Diesel injection circuit
Sphericalbase screws for diesel injection fixing fork 0,3 ± 0,1Fuel high pressure common injection rail on engine block 2 ± 0,2
Unions on fuel high pressure common injection rail
Pretightening1,7± 0,2
Tightening2,25 ± 0,2
Diesel injection pump on support
Union on diesel injection 2,25 ± 0,2
Diesel injection pump pulley 5 ± 0,5
Union on diesel high pressure pump2,25 ±0,2
Cooling circuit
Coolant pump
Pretightening0,3 ± 0,06
Tightening1 ± 0,1
Coolant outlet housing
Pretightening0,3 ± 0,06
Tightening0,7 ±0,08
C3 C3 PLURIEL XSARA

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ENGINE
SPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engines8HV 8HY
Crankshaft
Bearing cap fixing screw
Tightening3 ± 0,3
Angular tightening140° ± 1°,4’
Crankshaft pullet hub
Angular tightening180°±5°
Cylinder block
Oil sump1 ±0,1
Timing belt tensioner roller 4 ± 0,4
Timing belt guide roller
2,5 ±0,2
Timing belt guide roller support
Cylinder head
Camshaft bearing cap cover
1 ±0,1
Inlet manifold
Exhaust manifold2,5 ± 0,2
Cylinder head cover Screws (M6) to 1 ± 0,2
Camshaft pinion4,3 ± 0,4
Fuel high pressure pump pinion 5 ± 0,5
C3

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ENGINESPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engines8HV 8HY
Flywheel Clutch
Flywheel 1,7 ± 0,2
Clutch mechanism 2 ± 0,2
Lubrication circuit
Oil pump assembly0,9 ± 0,1
Oil/coolant heat exchanger 1 ± 0,1
Turbocharger lubrication pipe2,2 ± 0,2
Injection circuit
Injector fixing flange nut
Tightening0,4 ±0,1
Angular tightening65° ± 5°
Fuel high pressure pump
Union on diesel injector
Fuel high pressure pump pinion 5 ± 0,5
Union on fuel high pressure pump2,3 ± 0,2
Cooling circuit
Coolant pump1 ± 0,2±
C3

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ENGINESPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engines9HZ 9HY
Lubrication circuit
Oil pump assembly
Pretightening0,5 ± 0,1
Tightening0,9 ± 0,1
Oil/coolant heat exchanger 1 ± 0,2
Turbocharger lubrication pipe3 ± 0,5
Diesel injection circuit
Injector fixing flange nut
Pretightening4 ± 0,1
Angular tightening65° ± 5°
Fuel high pressure common injection rail on engine block 2,2 ± 0,2Union on fuel high pressure common injection rail
Pretightening1,7 ±0,2
Tightening2,2 ±0,2
Diesel injection pump on support2,2 ± 0,2
Union on diesel injector
Pretightening2 ± 0,5
Tightening2,5 ±0,3
XSARA PICASSO

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XSARA PICASSO
ENGINE
SPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engines9HZ 9HY
Diesel injection circuit
Diesel injection pump pulley5 ± 0,5
Union on fuel high pressure pump
Pretightening2 ± 0,5
Tightening2,5 ± 0,3
Cooling circuit
Coolant pump
Pretightening0,3 ± 0,1
Tightening0,9 ±0,1
Coolant outlet housing
Pretightening0,3 ± 0,1
Tightening0,7 ±0,1

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: 8HX 8HW 8HZ
B1EP18HC
Setting the timing (continued).
Hold the tensioner roller, using a hexagonal spanner at «b».
Slacken the screw (9).
Remove the timing belt (10).
Refitting.
IMPERATIVE: Check that both the tensioner roller and the fixed roller turn freely
(no tight spots). If this is not the case, replace the rollers.
Fitting of the pulle
ys.
Camshaft pulley: Tighten to 4,3 ± 0,4 m.daN.
Fuel high pressure pump pulley: Tighten to 5 ± 0,5 m.daN.
The crankshaft pinion is located without a screw at the end of the crankshaft.
Fitting of the rollers.
IMPERATIVE: Check that the tensioner roller turns freely (no tight spot).Otherwise, replace the rollers.
Guide roller:Tighten to 4,5 ± 0,4 m.daN.
Tensioner roller :Pretighten to 0,1 m.daN.
Check the condition of the seals at the camshaft and at the crankshaft pinion.
C2 C3 C3 PLURIEL XSARA

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189
CHECKING AND SETTING THE VALVE TIMING
Engines: 8HX 8HW 8HZ
B1EP18JD
Setting the timing (continued).
NOTE:
Screw (9)slackened.
Position the timing belt
(10)observing the following sequence:
Crankshaft pinion
(4).
Guide roller
(12).
Camshaft pulley
(11)(check that the belt is held correctly against the roller).
Coolant pump pinion
(13).
Fuel high pressure pump pulley
(15).
Tensioner roller
(14).
C2 C3 C3 PLURIEL XSARA

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: 8HX 8HW 8HZ
B1EP18KC
Setting the timing (continued).
Turn the tensioner roller to the right to bring the index «c»to position «d», using a
hexagonal spanner.
Tighten the screw
(9)of the tensioner roller, tighten to 3 ± 0,3 m.daN.
Remove the tools [4]and [5].
Rotate the engine
ten times(check that the timing pinion is correctly up against the
crankshaft).
Check:
The pegging of the camshaft.
The crankshaft pinion.
The fuel high pressure pump pinion
(15).
The correct positioning of the index of the dynamic tensioner.
If these are not correct, repeat the operation to position the timing belt.Refit:
The engine speed sensor
(6).
The belt retaining stop (5), tighten to 0,7 m.daN.
C2 C3 C3 PLURIEL XSARA

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: 8HY 8HV
B1EP18YD
Checks (continued).
Refit the screw (8).
Rotate the crankshaft six times
(clockwise).
IMPERATIVE: Never rotate the engine backwards.
Peg:
The camshaft, using tool
[2](oil the pegs).
The fuel high pressure pump pulley (14), using tool [3]at «c».
WARNING:The magnetic track should show no signs of damage and should not be
approached by any source of magnetism.
Peg the crankshaft at
«b», using tool [3].
IMPERATIVE:Should it be impossible to peg the camshaft, check that the
offset between the hole in the camshaft pinion and the pegging hole is not
greater than 1 mm.Otherwise repeat the operation to position the timing belt
(see corresponding
operation)
.
C3