Diesel Citroen BERLINGO 2005 1.G Repair Manual

Downloaded from www.Manualslib.com manuals search engine 286
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
Angl.-t2-page283-305-2005 9/01/06 10:18 Page 286

Downloaded from www.Manualslib.com manuals search engine 287
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

Downloaded from www.Manualslib.com manuals search engine 288
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
Angl.-t2-page283-305-2005 9/01/06 10:18 Page 288

Downloaded from www.Manualslib.com manuals search engine 289
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
Angl.-t2-page283-305-2005 9/01/06 10:18 Page 289

Downloaded from www.Manualslib.com manuals search engine 293
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
Angl.-t2-page283-305-2005 9/01/06 10:18 Page 293

Downloaded from www.Manualslib.com manuals search engine 299
INJECTION
CHECKING THE AIR SUPPLY CIRCUIT
B1BP33ZC
B1BP340C
Engine: RHR
B1BP341C
B1BP342C
Tool.
[1]Manual pressure-vacuum pump: FACOM DA 16
IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel
injection engines.
WARNING: After switching off the ignition, wait 15 minutes before disconnecting
the battery
(to guarantee memorisation of the initialisations of the different ECUS).
Checking the vacuum source
(vacuum pump).
Connect the tool [1] on the take-off «a».
Start the engine.
The value should be: 1 ± 0,2.
Turbocharging pressure electrovalve.
Connect the tool [1]on the vacuum supply «b»of the electrovalve (1).
Start the engine.
The value should be: 1 ± 0,2.
Cold air circuit electrovalve.
Connect the tool [1]on the vacuum supply «c»of the electrovalve (2).
Start the engine.
The value should be: 1 ± 0,2.
Warm air circuit electrovalve.
Connect the tool [1]on the vacuum supply «d»of the electrovalve (3).
Start the engine.
The value should be: 1 ± 0,2.
C4
Angl.-t2-page283-305-2005 9/01/06 10:18 Page 299

Downloaded from www.Manualslib.com manuals search engine 308
CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS
Engine type 9HY (*) 9HZ (*) 9HX RHR (**)
Gearbox type BE4/5L ML6C
SupplierLUK
Mechanism/type235 P 4800 235 P 7400
Hub disc
Ø of lining. ext/int234/165 235/150
Quality of lining810 DS
NOTE: (*) DVAR: Equipped with a Double Damping Flywheel with springs in the radial position in relation to the axis of the crankshaft.
NOTE: (**) DVA: Equipped with a Double Damping Flywheel with springs arranged concentrically.
DV6TED4 DV6ATED4 DW10BTED4
Diesel
C4
Angl.-t2-page306-360-2005 9/01/06 10:20 Page 308

Downloaded from www.Manualslib.com manuals search engine 354
CLUTCH
GEARBOX
TRANSMISSION
AL4 GEARBOX CONTROLS
In passenger compartment.
The selector control has 6 positions.
The gear selector is guided by the shape of the stepped gate and by a retaining spring
which pulls it to the left hand side.
Push the lever to the right to exit from position «P».
NOTE: The vehicle is equipped with the «shift lock»: you have to switch on the ignition
and press the brake pedal to unlock the selector lever from position «P».
P:Park
(system locked).
R:Reverse gear.
N:Neutral.
D:Automatic
(1st to 4th gear).
3:Automatic (1st to 3rd gear).
2:Automatic (1st to 2nd gear).
A switch located to the left of the gear control allows the driver to choose from these
programmes:
- Normal: Conventional use of the automatic gearbox.
- Sport:This programme favours performance.
- Snow:In position «D», starting is in 2ndgear for diesel and in 3rdgear for petrol.
NOTE:Only the positions «P»or «N»authorise the starting of the engine.
Engines: NFU - RFN - RHZ
XSARA
B2CP3ADC
Angl.-t2-page306-360-2005 9/01/06 10:20 Page 354