injection Citroen XSARA PICASSO 2004 1.G Workshop Manual

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THIS HANDBOOKsummarises the specifications, adjustments, checks and special features of CITROEN
private vehicles, not including UTILITY vehicles for which there exists a separate handbook.
The handbook is divided into nine groups representing the main functions :
GENERAL ENGINE INJECTION IGNITION CLUTCH, GEARBOX, DRIVESHAFTS AXLES,
SUSPENSION, STEERING BRAKES ELECTRICAL AIR CONDITIONING.
In each section, the vehicles are dealt with in the following order: C2C3C3 PLURIEL XSARA XSARA PICASSO BERLINGO (1)
and all models where applicable.
The information given in this handbook is based on vehicles marketed in EUROPE.
(1) NOTE : The BERLINGO familiale appears only in :
The correspondance tables for petrol and diesel engines.
The general chapter.
For all the other chapters, see the Mechanics’ Handbook for UTILITY vehicles.

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GENERAL
ALL TYPES
LUBRICANTS TOTAL recommended oils
S.A.E. Norms Table for selection of engine oil gradeSelection of engine oil grades recommended for climatic conditions in corntries of distribution.Evolution of the norms as at 01/01/2003
ACEA 2003 norms
The meaning of the first landter has not changed, it still corresponds
to the type of engine:
A:petrol and dual fuel petrol / LPG engines.B: dieselengines.
The figure following the first landter corresponds to the type of oil:
3:high performance oils.4:oils specifically for direct injection diesel engines.5:very high performance oils permitting lower fuel consumption.Example:
ACEA A3:high performance oils specifically for petrol and dual fuel
petrol / LPG engines.
ACEA A/B:blended oils giving very high performance for all engines,
also permitting bandter fuel economy, specifically for direct injection dieselengines
NOTE:From 01/01/2003there is no longer any reference to the year
of creation of the norm (example:ACEA A3/B3 98becomes ACEAA3/B3).
API norms
The meaning of the first landter has not changed, it still corresponds to
the type of engine:
S: petrol and dual fuel petrol / LPGengines.C: dieselengines.
The second landter corresponds to the degree of evolution of the oil
(ascending order).
Example:Norm SLis more severe than norm SJ, corresponding to a
higher level of performance.

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GENERAL
LUBRICANTS TOTAL recommended oils
ALL TYPES
TOTAL ACTIVA QUARTZ
Semisynthetic 7000
Synthetic 9000
0W40
cold
contries5W30 5W40 10W4015W50
hot
countries Engine types
XU10 J4RS (Xsara VTS 2.0i 16V) X
XX EW 12 J4 (C8 2.2i 16V)
Other petrol engines
HDi engines with FAP (*)Other HDi engines
SOFIM 2.8 TDi and 2.8 HDi (RELAY)DV4 TED4 (C3 1.4 16V HDi)
Indirect injection diesel engines
Petrol engines
Diesel enginesOil usage table
X
X
XXXX
XXX
XXX
XX
XXX
XXX
XXX
XXX
(*) = Particle filter
X

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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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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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ENGINE
XSARA
AUXILIARY EQUIPMENT DRIVE BELT 2002
Tools.
[1]
Dynamic tensioner compression lever: ().0188.Z
[2]Peg for dynamic tensioner roller: ().0194.F
Removing.
IMPERATIVE: Respect the safety and cleanliness requirements specific to high pressure
diesel injection engines (HDi).
Remove:
The front RH wheel.
The underengine sounddeadening.
The splashshield.
WARNING: Mark the direction of fitting of the accessories drive belt, if it is to be reused.
Compress the tensioner roller (1)by acting at «a»(clockwise), using tool [1].
Peg at «b», using tool [2].
Keeping the tensioner roller (1)compressed, remove the accessories drive belt.
IMPERATIVE: Check that the rollers (1) and (2) can turn freely (without play and without
tight spots).B1BP2VZD
Engine: 8HZ

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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine: WJY
Tools.
[1]
Pliers for remving plastic pins: 7504T or ().1311
[2]Flywheel peg: 7014T.J or ().0188 Y
[3]Injection pump setting peg Ø 6 mm: ().0188 H
[4]Screw H M8: ().0188 E
[5]Belt retaining pin: ().0188 K
[6]Square for adjusting belt tension: ().0188 J1
[7]Belt tension measuring instrument, with digital display: SEEM CTG 105.5M
Checking the timing.
Peg the flywheel, using tool [2].
Peg the camshaft hub, using tool [4].
Peg the injection pump hub, using tool [3].
IMPERATIVE: If the pegging proves impossible, repeat the setting of the timing.
B1BP2FTCB1EP16PD
XSARA