Citroen BERLINGO 2005 1.G Workshop Manual

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INJECTION
CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT
Tools.
[1] Ø 10 mm low pressure connector: 4215-T
[2] Pressure gauge for testing boost pressure: 4073-T.A Toolkit 4073-T
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:
Vacuum Observations
10 ± 05 cmhgEngine driven by the starter motor
20 ± 20 cmhgEngine running under full load
60 ± 05 cmhgSupply circuit obstructed
(full tank strainer, piping, fuel filter
B1BP2PHC
Engines: 9HZ - 9HY
XSARA PICASSO
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INJECTION
CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT
Tools.
[1] Ø 10 mmlow pressure connector: 4215-T
[2]Pressure gauge for testing boost pressure: 4073-T.A Toolkit 4073-T
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.
Normal vacuum values.
Engine driven by the starter motor: 10 ± 0,5 cmHg.
Engine running under full load: 20 ± 10 cmHg.
Abnormal vacuum values.
Supply circuit obstructed
(full tank strainer, piping, fuel filter): 60 ± 20 cmHg.
B1BP33RD
Engine: RHR
C4
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INJECTION
CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT
Tools.
[1] Ø 10 mmlow pressure connector: 4215-T
[2] Pressure gauge for testing boost pressure: 4073-T.A Toolkit 4073-T
Checks.
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.
Vacuum Observations
10 ± 05 cmhgEngine driven by the starter motor
20 ± 20 cmhgEngine running under full load
60 ± 05 cmhgSupply circuit obstructed
(full tank strainer, piping, fuel filter)
B1BP2KUC
Engine: RHY
XSARA
Angl.-t2-page283-305-2005 9/01/06 10:18 Page 287

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INJECTION
CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT
Tools.
[1] Ø 10 mm low pressure connector: 4215-T
[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
Engines: RHY - RHZ
XSARA PICASSO
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INJECTION
CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT
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
Fuel supply pressure Fuel return pressure Checks
Between 3and 3.5bar0.7 ± 0.2 bar Check the condition of the diesel filter
More than 3.5bar Less than 0.7barCheck the low pressure regulator incorporated
in the filter
(locked shut): replace.
More than 3.5bar More than 0.7barCheck the fuel return circuit
(pipe pinched or trapped…)
Between 0.8and 1.5bar Less than 0.7barCheck the fuel supply circuit:
- Booster pump (low pressure), piping
Impossible to start the engine:Check: diesel injector return flow
(table below).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).Uncouple the diesel injector return pipe.
Check: Observe:
The flow should be drop by drop Diesel injector functioning correctly
Excessive fuel return Diesel injector locked shutEngines: RHY - RHZ (continued)
XSARA PICASSO
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INJECTION
CHECKS: TURBO PRESSURE
Tools.
[1]Pressure gauge for checking boost pressure: 4073-T.A
[2] Sleeve for checking boost pressure: (-).0171.F
Checks.
IMPERATIVE: Respect the following test conditions:
- Engine at operating temperature.
- Vehicle in running order.
- Engine under full load.
Preparation.
Remove the clips (1).
Fit the tool [2]in the place of the duct (2).
Couple the sleeve [2] on the pressure gauge[1]using the tube «a».
Mode of operation.
Position tool [1]in the vehicle.
Start the engine.
Engagefirst gear, start the vehicle.
Engage the gears up to third gear.
Decelerate to an engine speed of 1000 rpm.
Check the pressure: 0,6 ± 0,05bar
(1500 rpm).
Accelerate freely (change from fourth gear to third gear).Check the pressure: 0,9 ± 0,05bar (between 2500and 3500rpm).
Remove tools [1], [2] and «a».
Reposition the tube (2)and tighten the clips(1).
B1BP2NXD
C5FP06RC
Engines: 8HX - 8HZ
XSARA
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Downloaded from www.Manualslib.com manuals search engine INJECTION
291
CHECKS: TURBO PRESSURE
IMPERATIVE: Respect the safety and cleanliness requirements.
Preparation.
IMPERATIVE: Respect the following test conditions:
- Engine at operating temperature.
- Vehicle in running order.
- Engine under full load.
Connect the diagnostic tool to the vehicle's diagnostic socket, carry out parameter measures.
Mode of operation.
Start the engine.
Engage first gear, start the vehicle.
Engage the gears up to third gear.
Decelerate to an engine speed of 1000 rpm.
Check the pressure: 0,6 ± 0,05 bar
(1500 rpm).
Accelerate freely (change from fourth gear to third gear).Check the pressure: 0,9 ± 0,05 bar (between 2500and 3500rpm).
Engines: 9HX - 9HY - 9HZ
C4
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INJECTION
CHECKS: TURBO PRESSURE
IMPERATIVE: Respect the safety and cleanliness requirements.
Preparation.
IMPERATIVE: Respect the following test conditions:
- Engine at operating temperature.
- Vehicle in running order.
- Engine under full load.
Connect the diagnostic tool to the vehicle's diagnostic socket, carry out parameter measures.
Mode of operation.
Start the engine.
Engage first gear, start the vehicle.
Engage the gears up to third gear.
Decelerate to an engine speed of 1000 rpm.
Check the pressure: 0,6 ± 0,05 bar
(1500 rpm).
Accelerate freely (change from fourth gear to third gear).Check the pressure: 0,9 ± 0,05 bar (between 2500and 3500rpm).
Engines: 9HZ - 9HY
XSARA PICASSO
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INJECTION
CHECKS: TURBO PRESSURE
Tools.
[1] Pressure gauge for checking the turbo pressure: 4073-T Toolkit 4073-T
[2]Pressure take-off extension: 8607-T.A
[3]Pressure take-off union and hose: 8607-T.B
[4] Sleeve for checking the turbo pressure: 4185-T
[5]Adaptor sleeve: 4219-T
IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection
engines.
Preliminary operation.
Slacken the clip (1).
Uncouple the air duct (2).
Connect the tool [1]on tool [2]and the tool [3]on tool [2].
Positioning on the vehicle.
Insert the tools [4]and [5]between the air duct (2)and the turbo air cooler outlet at «a».
Connect the tool [3]on tool [4].
Position the tool [1]inside the vehicle.
Start the engine.
Accelerate to 4000 rpm.
The value should be: 1 ± 0,2.
Return the vehicle to conformity.
Remove tools [1], [2], [3], [4]and [5].
Recouple the air duct (2)on the turbo air cooler.
Tighten the clip (1).
B1BP356C
B1HP1ZXC
Engine: RHR
C4
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INJECTION
CHECKS: TURBO PRESSURE
Tools.
[1]Pressure gauge for checking boost pressure: 4073-T.A Kit 4073-T
[2]Sleeve for checking boost pressure: 4185-T
Checks.
IMPERATIVE: respect the following checking requirements: Engine at running temperature.
Vehicle running at full load.
Preparation.
Remove the collar (3)and the sleeve.
Insert the tool [2]between the pipe (1)and the duct (2).
Position tool [1]in the vehicle.
Connect the pressure gauge [1]to the tool [2] with its tube «a»long enough for the gauge to be
positioned inside the vehicle.
Procedure.
Start the engine.
Engage first gearand start the engine.
Engage the gears up to third gear.
Decelerate to 2000 rpm.
Gradually accelerate.
Check the pressure: 0.95 ± 0.05 bar.
Remove the tools, refit the collars (3) and the sleeve.
B1BP1ZXD
Engine: RHY
XSARA PICASSO
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