gauge Citroen C2 2004 1.G Workshop Manual

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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
CHECKS: TURBO PRESSURE
Engines: 8HX 8HW
B1BP2NXD
C5FP0F5C
C2 C3
Tools.
[1]Pressure gauge for checking boost pressure: 4073T.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.
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 2500 and 3500 rpm).
Remove tools [1], [2]at «a».
Reposition the tube (2)and tighten the clips (1).

Downloaded from www.Manualslib.com manuals search engine 264
INJECTION
CHECKS: TURBO PRESSURE
Engines: 8HV 8HY
Tools.
[1]Pressure gauge for checking boost pressure: 4073T.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.
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 2500 and 3500 rpm).
Remove tools[1],[2]at «a».
Reposition the tube (2)and tighten the clip (1).
C5FP0EJC
B1BP2NBD
C3

Downloaded from www.Manualslib.com manuals search engine 266
INJECTION
CHECKS: TURBO PRESSURE
Engine: RHZ
XSARA PICASSO
Tools.
[1]
Pressure gauge for checking boost pressure: 4073T.A Kit 4073T
[2]Sleeve for checking boost pressure: 4185T
[3]Adaptor sleeve: 4229T
Checks.
IMPERATIVE: respect the following checking requirements: Engine at running
temperature. Vehicle in running order at full load.
Preparation.
Remove the collar fixing (3).
Insert the tool [2]connected with tool [3], between the pipe (1)and the duct (2).
Position tool [1]in the vehicle.
Connect the sleeve [2]to the tool [1]with its tube «a».Procedure. Start the engine.
Engage first gear and start the engine.
Engage the gears up to third gear.
Decelerate to
1000 rpm.
Accelerate hard, and check the pressure:0.6 ± 0.05 Bar (1500 rpm).
Accelerate freely in kickdown (changing from fourth to third gear).
Check the pressure:0.95 ± 0.05 Bar(between 2500 and 3500 rpm).
Remove the tools, reposition the pipe (1)and refit the collar (3).B1HP12JD

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INJECTION
CHECKS: TURBO PRESSURE
Engine: RHY
Tools.
[1]
Pressure gauge for checking boost pressure: 4073T.A Kit 4073T
[2]Sleeve for checking boost pressure: 4185T
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 gear and 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
XSARA PICASSO

Downloaded from www.Manualslib.com manuals search engine AXLES
SUSPENSION
STEERING
356
C2 AXLE GEOMETRY
B3CP07SD
Measuring front height Measuring rear height
[1]
Gauge for measuring the wheel radius, 4 bolts, tool 8006T
Z1
= Measuring zone underneath the front subframe.Z2= Measuring zone underneath the rear sill.
Measure the radius of the front wheel
R1 Calculate dimension H1 = R1 – L1Measure the radius of the rear wheel R2 Calculate dimension H2 = R2 + L2
Value at referenceExcept CRD (*)Value at referenceExcept CRD (*)heightHFX KFV 8HX NFUheightHFX KFV 8HX NFU
(+ 6 8 mm)L1 = 142,5 mmL1 = 152,5 mm(+ 10 6 mm)L2 = 52 mm L2 = 42 mm
Compress the suspension to obtain the calculated values.
The height difference between the two axle dimensions should be less than 10 mm.(*) = CRD: Difficult road conditions.

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AXLES
SUSPENSION
STEERING
C3 AXLE GEOMETRY
B3CP07SD
Measuring front height Measuring rear height
[1]
Gauge for measuring the wheel radius, 4 bolts, tool4003T or8006T (according to version).
Z1 = Measuring zone underneath the front subframe.Z2 = Measuring zone underneath the rear sill.
Measure the radius of the front wheel
R1 Calculate dimension H1 = R1 – L1Measure the radius of the rear wheel R2 Calculate dimension H2 = R2 + L2
Value at reference All types Except CRD (*) Vehicle CRD (*) Value at reference All types Except CRD (*) Vehicle CRD (*)
heightRaised suspensionRaised suspensionheightRaised suspensionRaised suspension
(+ 6 8 mm)Sports Sports
(+ 10 6 mm)Sports Sports
L1 = 142,5 mm L1 = 132,5 mm L2 = 52 mm L2 = 62 mm
(*) = CRD: Difficult road conditions.
Definition for a type of vehicle whose axles and suspensions are adapted for driving on rough roads.
Compress the suspension to obtain the calculated values. The height difference between the two axle dimensions should be less than
10 mm.
Checks at reference height