fuel pressure Citroen BERLINGO 2004 1.G Owner's Manual

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INJECTION
PROHIBITED OPERATIONS: DELPHI HDI DIRECT INJECTION SYSTEM
Engines: 8HY 8HV
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
B1HP1J6C
C3

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INJECTION
PROHIBITED OPERATIONS: DELPHI HDI DIRECT INJECTION SYSTEM
Engines: 8HY 8HV
B1HP1J7CB1HP1J8C
Fuel high pressure injection common rail.
Do not separate the pressure regulator «c»from the injection
common rail (2)(Risk of malfunction).
Diesel injectors.
WARNING:
Diesel and ultrasonic cleaners are prohibited.
Do not separate the following components from the diesel
injector carrier
(3):
Diesel injector (e)(no replacement parts).
Electromagnetic component «d»(no replacement parts).
It is forbidden to clean the carbon deposits from the diesel
injector nozzle..
C3

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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
CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT
Engines: 8HX 8HW
Tools.
[1] Ø 10 mmlow pressure connector: 4215T.
[2]Pressure gauge for testing boost pressure: 4073T.A Tool kit 4073T
IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel
injection engines.
Link tools [1]and [2]in series between the fuel high pressure pump and the fuel filter.
ESSENTIAL:Check that the tool [2] is clean.
Check the negative pressure according to the table below:
Vacuum Observations
10 ±5 cmHg
Engine driven by the starter motor
20 ±5 cmHg
60 ±5 cmHgEngine running under full load
Supply circuit obstructed
(full tank
strainer, piping, fuel filter).
B1BP2NWC
C2 C3

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INJECTION
CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT
Engines: 8HV 8HY 9HZ 9HY
Tools.
[1] Ø 10 mmlow pressure connector: 4215T.
[2]Pressure gauge for testing boost pressure: 4073T.A Tool kit 4073T
IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel
injection engines.
Remove the air filter duct.
Link tool [1]in series, downstream of the injectors, between the fuel high pressure pump
and the fuel filter at «a»and «b».
WARNING:Any checking of pressure downstream of the fuel filter is prohibited.
Switch on the ignition.
ESSENTIAL: Check that the tool [2] is clean.
Check the negative pressure according to the table below:
VacuumObservations
10 ±05 cmhg
Engine driven by the starter motor
20 ± 20 cmhg
60 ± 05 cmhgEngine running under full load
Supply circuit obstructed
(full tank
strainer, piping, fuel filter).B1BP2PHC
C3 XSARA PICASSO

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INJECTION
XSARA PICASSO
CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT
Engines: RHY RHZ
Tools.
[1] Ø 10 mm
low pressure connector: 4215T.
[2] Ø 8 mmlow pressure connector: 4218 T.
[3]Pressure gauge for testing boost pressure: 4073 T Kit 4073 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.
Checks on pressure:static.
Switch on ignition
For 3 seconds(normal functioning):
Fuel supply pressure shown by the pressure gauge [3] = 1.8 ± 0.4 Bar. Fuel return pressure shown by the pressure gauge [3] = 0.5 ± 0.4 Bar.
B1BP1TWD

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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
PARTICLE FILTER SAFETY AND CLEANLINESS REQUIREMENTS
General.
ESSENTIAL: Given the very high pressures prevailing in the fuel high pressure circuit (1600 Bars), respect the following regulations.
It is forbidden to smoke in the immediate proximity of the high pressure circuit during a repair.
Avoid working close to flames or sparks.When the engine is running:
Do touch the fuel high pressure circuit.
Always keep out of range of possible projections of fuel, which could cause serious injuries.
Do not place your hand near to any leak on the fuel high pressure circuit. After the engine has stopped, wait 30 seconds before starting any operation.
NOTE:The waiting time is necessary to allow the fuel high pressure circuit to return to atmospheric pressure.
Safety rules.
IMPERATIVE:Wait at least an hour before starting any repair on the exhaust line.
Forced regeneration of the particle filter:
Check that there are no aerosols or inflammable products inside the vehicle’s boot.
Wear high temperature gloves.
Connect the vehicle to a gas extractor approved for this type of operation.
IMPERATIVE: In the absence of the required installations, carry out the forced regeneration of the particle filter outside the workshop,
in a concreted area well away from any inflammable materials. Place the vehicle in the high position.
ALL TYPES

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INJECTION
PARTICLE FILTER SAFETY AND CLEANLINESS REQUIREMENTS
Operations on the fuel additive circuit.
IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves that are resistant to hydrocarbons.
The work area must be ventilated.
In the event of any significant dispersion of additive:
Wear a breathing mask for filtering the particles.
Recover as much of the product as possible.
Place the product thus recovered in an appropriately labelled container. Wash the soiled area with copious amounts of water.
Dispose of materials and solid residues in an authorised recovery point.
IMPERATIVE:The filling kit should be recycled following a repair. All «Eolys» additive containers that have been opened should be
disposed of.
Cleanliness rules.
ESSENTIAL: The operator should wear clean overalls.
Before working on the injection circuit, it may be necessary to clean the unions of the following sensitive components(see corresponding operations).
Fuel filter.
Fuel high pressure pump.
Fuel high pressure regulator.
Fuel high pressure common injection rail. Fuel high pressure piping. Diesel injector carriers.
IMPERATIVE: After dismantling, immediately blank the unions of the sensitive components with plugs, to prevent any ingress of impurities.
ALL TYPES