exhaust Citroen C3 2004 1.G User Guide

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169
CHECKING AND SETTING THE VALVE TIMING
Engine: KFU
Remove:
The lower engine support assembly(5)and the fixing screw (4).
Remove the lower timing cover (6).
Slacken the nut (7).
Remove the timing belt.
IMPERATIVE: Check that the tensioner roller turns freely (no tight spot).
Refitting.
Fit the (new)timing belt, in the following sequence:
Inlet camshaft pulley.
Exhaust camshaft pulley. Guide roller.
Crankshaft pulley.
Position the tool
[5].
Coolant pump pulley.
Dynamic tensioner roller.Remove tools
[3],[4]and [5].
B1CP0F2DB1CP0F1D
C3

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171
CHECKING AND SETTING THE VALVE TIMING
Engines: 6FZ RFN 2003 # NEW ASSEMBLY2003 #
(6)Crankshaft pinion
(7)Accessories drive pulley
(8)Washer
(9)Screw
The pinion
(6)is fitted as an idler on the crankshaft.
The accessories drive pulley
(7)is immobilised on the crankshaft by a halfmoon keyway and
by the tightening of washer
(8)and screw (9).
A:Pegging on manual gearbox.
B:Pegging on automatic gearbox.
The pegging of the crankshaft is done on the flywheel, or on the converter drive plate
(automatic gearbox).
The pegging hole on the cylinder block
(exhaust end)is calibrated and reinforced.
IMPERATIVE: Never turn the crankshaft with the accessories drive pulley slackened.
IMPERATIVE: Never remove the accessories drive pulley without pegging the crank
shaft and the camshafts.
IMPERATIVE: Always turn the crankshaft in the direction of engine rotation.
B1EP1B9D
B1BP2V2D
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175
CHECKING AND SETTING THE VALVE TIMING
Engines: 6FZ RFN 2003 #
Setting the timing (continued).
A:
Pegging on the manual gearbox.
B:Pegging on the automatic gearbox.
Peg:
The crankshaft, using tool
[2].
The camshaft pulleys
(5)and (6), using tool [1].
Remove:
The screw
(3)of the crankshaft pulley (2).
The lower timing cover
(4)(by moving the engine).
IMPERATIVE: Never remove the crankshaft pulley (2) without pegging the crankshaft
and the camshafts.
Slacken the screw (9)of the tensioner roller (8).
Turn the tensioner roller
(8)(clockwise).
Remove the timing belt
(7).
I
MPERATIVE: Systematically replace the following components: timing belt, exhaust
manifold fixing nuts, timing belt tensioner roller nut.
B1BP2V3DB1EP1BBD
XSARA XSARA PICASSO

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: 6FZ RFN 2003 #
Setting the timing (continued).Turn the tensioner roller (8), using tool [5a]to go beyond slot «b».
Position the tool [5b]to lock the index «a»and remove the tool [5a].
Reposition the timing belt (7)on the crankshaft pulley.
Hold the timing belt (7)in place using tool [3].
Fit the timing belt (7)in place, respecting the following order:
Guide roller (10).
Inlet camshaft pulley (6).
Exhaust camshaft pulley (5).
Coolant pump (11).
Tensioner roller (8).NOTE:Make so that the belt (7)is as flush as possible with the exterior face of the various
pinions and rollers.
Remove: Tool
[3].
Tool [1]from the exhaust camshaft pulley.
Tool [5b]from the tensioner roller (8).
Refit: The lower timing cover
(4)(by moving the engine). The crankshaft pulley (2).
Screw (3)of the crankshaft pulley
Tighten screw (3)to 4 ± 0,4 m.daN, then angular tighten to 53° ± 4°, tool [4].
B1EP1BCDB1EP1BDC
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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: 8HX 8HW 8HZ
B1EP18GC
Setting the timing.
Remove the upper timing cover (1).
Rotate the engine by means of the crankshaft screw (2).
NOTE:The pegging hole is located under the crankshaft bearing cap cover.
Peg the engine flywheel, using tool
[3].
Remove the lower timing cover (3).
Uncouple the exhaust line from the manifold.
IMPERATIVE: Uncouple the exhaust line in order to avoid damaging the front flexible pipe. Twisting,
pulling and bending the front flexible pipe reduces its life.
Remove:
The engine speed sensor (6).
The belt retaining stop (5).
The screw (2).
The crankshaft pinion (4)(with its magnetic track «a»).
IMPERATIVE: The magnetic track should show no signs of damage and should not be approached
by any other source of magnetism.Should this not be adhered to,it is essential to replace the crank
shaft pinion.
Refit the screw (2).
B1BP2LXC
C2 C3 C3 PLURIEL XSARA

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191
CHECKING AND SETTING THE VALVE TIMING
Engines: 8HX 8HW 8HZ
B1EP18LCB1BP2LZC
Setting the timing (continued).
Refit:
The intermediate RH engine support, tighten the screws
(16)to 5,5 ± 0,5 m.daN.
The RH engine support, tighten the screws
(17)to 4,5 ± 0,4 m.daN.
The bottom timing cover
(3).
Immobilise the engine flywheel, using tool
[3].
Remove the screw
(2).
Refit the accessories drive pulley and tighten to:
Pretighten to
: 3 ± 0,3 m.daN.
Angular tighten to
:180° ± 1,8°.
Remove tool
[3].
Refit:
The top cover
(1).
The accessories belt
(see corresponding operation).
The exhaust line
(see corresponding operation).
The front RH splashshield. The front RH wheel.
C2 C3 C3 PLURIEL XSARA

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: 8HY 8HV
B1BP2N0C
Tools.
[1]
Engine flywheel peg Ø 12 mm : ().0194C
[2]
Camshaft pulley peg Ø 8 mm : ().0194B
[3]
Crankshaft pulley peg Ø 5 mm : ().0194A
Preliminar
y operations.
Remove:
The front RH wheel.
The front RH splashshield.
The accessories belt
(see corresponding operation).
Uncouple:
The supply unions
(1).
The air/air heat exchanger inlet/outlet pipes
(3).
The exhaust line
(at the flexible pipe).
Disconnect the connector
(2).
Support the engine by means of a roller jack equipped with a chock.
Remove the engine supports
(4) and(5).
C3

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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines: 8HY 8HV
B1BP2N0C
Checks (continued).
Refit:
The engine support (7), tighten to 1,5 ± 0,4 m.daN.
The engine support
(4), tighten to 6,1 ± 0,6 m.daN.
The engine support
(5), tighten to 6 ± 0,6 m.daN.
The electrical harness
(6).
Couple:
The exhaust line, tighten the collar to : 2,5 ± 0,3 m daN.
The fuel supply unions
(1).
The air/air heat exchanger inlet/outlet pipes
(3).
Connect the connector
(2).
Refit:
The accessories belt (see corresponding operation).
The front RH splashshield
(see corresponding operation).
The front RH road wheel, tighten to
9 ±1 m.daN.
Reconnect the battery.
C3

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201
CHECKING AND SETTING THE VALVE TIMING
Engines: 9HZ 9HY
B1BP304D
Tools.
[1]
Flywheel setting peg: ().0194.C
[2]
Camshaft setting peg:().0194.B
[3]
Crankshaft setting peg: ().0194.A
Checking and setting the timing.
Removing.
Raise and support the vehicle, wheels hanging.
Disconnect the positive and negative terminals of the battery.
Remove: The front RH wheel.
The front RH splashshield.
The accessories drive belt
(see corresponding operation).
Uncouple: The fuel supply unions
(1).
The air/air heat exchanger inlet and outlet pipes
(3).
The exhaust line
(at the flexible pipe).
Disconnect the connecter at
«a».
Remove and move aside the power steering fluid reservoir
(6).
Uncouple, plug and move aside the tube
(2).
Support the engine with a roller jack equipped with a block.
Remove the engine supports
(4)and (5).
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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: 9HZ 9HY
Refitting.
Refit tool [1]at «b».
Remove the screw (10).
Refit:
The upper timing cover
(12).
The lower timing cover (11).
The accessories drive pulley (9).
The screw (10).
Tightening torqueScrew (10)Pretighten to:3 ± 0,3 m.daN.
Angular tighten:180°±5°.
Remove tool [1].
Refit:
The engine support
(8), tighten to 5,5 ± 0,4 m.daN.
The engine support (4), tighten to 6,1 ±0,6 m.daN.
The engine support (5), tighten to 2,5 ±0,2 m.daN.
The electrical harness (7).
The power steering fluid reservoir (6).
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Couple:
The tube (2).
The exhaust line, tighten the clip to 2,5 ± 0,3 m.daN.
The fuel unions (1).
The air/air heat exchanger inlet and outlet pipes (3).
Connect the connector at «a».
Refit:
The accessories drive belt
(see corresponding operation).
The front RH splashshield
(see corresponding operation).
The front RH wheel, tighten to 9 ±1 m.daN.
Reconnect the positive and negative terminals of the battery.
IMPERATIVE:Perform the operations that are necessary following a
reconnection of the battery (see corresponding operation).