par Citroen C3 2004 1.G Service Manual

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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

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INJECTION
SPECIAL FEATURES: FORCED REGENERATION OF THE PARTICLE FILTER
Tools.
Diagnostic stations: LEXIA or PROXIA
Imperative: Respect the safety and cleanliness requirements.
Forced regeneration of the particle filter.
IMPERATIVE: Respect the safety and cleanliness requirements specific to HDi engines.
ESSENTIAL: Connect the vehicle to a gas extractor approved for this type of operation.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.
WARNING:
Check that the fuel level is sufficient (at least 20 litres).
Start the engine and allow it to warm up (60°C minimum).
Connect the diagnostic tool to the vehicle’s central socket.
Trigger the regeneration cycle, with the diagnostic tool.
Automatic running of the regeneration cycle of the particle filter:
Autocheck by the engine ECU. Stabilisation of engine speed at
4000 rpm, operating with post injection.
Change to idling speed (for 30 seconds).
Stabilisation of engine speed at 3000 rpm, checking of the efficiency of the regeneration of the particle filter.
Change to idling speed.
NOTE:Let the engine run at idling speed for the benefit of cooling.
Stop the engine.
IMPERATIVE: Wait for at least an hour before any operation on the exhaust line.
ALL TYPES

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INJECTION
SPECIAL FEATURES: PARTICLE FILTER / FILLING OF THE ADDITIVE RESERVOIR
Imperative: Respect the safety and cleanliness requirements.
Tools.
Filling kit comprising the following items:1Container of Eolys2Filters2Tubes1Empty container2Hooks1Adaptor
Filling.
IMPERATIVE: Respect the safety and cleanliness requirements specific to HDi engines.
IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves
that are resistant to hydrocarbons.
Place the vehicle on a lift.
Disconnect the battery negative terminal.
Unclip the the factory filler connector
(1).
Couple the container of additive to the tube (2)using the adaptor and the tube (with tap)from the
filling kit.
Screw the filler connector on the additive container
(3)at «b».
Place the additive container (3)on the component lift.
Open the tap located on the filler connector at «a».
Tilt the additive container (3)(to facilitate the end of filling).
Close the tap at «a».
Remove the filler connector and the tube (4).
Couple the tube (2).
Reconnect the battery negative terminal.
IMPERATIVE: The filling kit should be recycled after this operation. Any «Eolys» additive
containers that have been opened should not be kept.
XSARA PICASSO
B1HP1UVC
C4BP1EGC

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INJECTION
SPECIAL FEATURES: PARTICLE FILTER / CHECKING THE ADDITIVE PUMP
Engine: 9 HZ
IMPERATIVE: Respect the safety and cleanliness requirements.
Tools.
[1]
Manual pressure/vacuum pump: FACOM DA 16
[2]Additive container: ().1613.G Kit 1613
Checks.
IMPERATIVE: Respect the safety and cleanliness requirements specific to HDi engines.
IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves that are
resistant to hydrocarbons.
Place the vehicle on a lift.
Raise the vehicle
To test the flow of the additive pump :
Uncouple the tube
(1).
Couple tool [2]on the outlet «a»of the additive reservoir.
Operate for 50 secondsthe actuator test «Additive pump»with the aid of LEXIA or PROXIA.
IMPERATIVE:The volume collected by the tool [2] should be 20 ± 5 ml.
NOTE:
Replace the additive pump if it is defective.
Couple the tube (1).
Operate the actuator test «Filling the tube: additive pump – additive injector», with the aid of LEXIAorPROXIA.
B1HP1UTC
XSARA PICASSO

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INJECTION
SPECIAL FEATURES: PARTICLE FILTER / CHECKING THE ADDITIVE PUMP
Sealing of the additive injector.
Couple tool [1] to the tube (1).
Action the manual pump [1].
WARNING:The additive injector should open at a pressure of 100 ± 20 Bars.
Action the manual pump in vacuum
[1]at 800 m.bars.
WARNING:The downstream pressure should not fall rapidly.
NOTE:Replace the fuel tank if the injector is defective.
Couple the tube
(1).
Operate the actuator test «Filling the tube: additive pump – additive injector», with the aid ofLEXIAor PROXIA.
Check the additive level.
The checking of the additive level is done with reference to the gradations «a»marked on the additive
reservoir.
The top graduation indicates maximum filling
(3 Litres).
The difference between the two gradations equates to 0,25 Litres.
XSARA PICASSO
B1HP1UUC
B1KP019C

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1.1iHFX
FR7 DE RFN 58 LZ RC 8 YLC
C2 1.4i KFV
1.6i 16V NFU FR7 ME 0,9 ± 0,1 RFN 58 HZ
1.1i HFX
FR7 DERFN 58 LZ RC 8 YLC
1.4i KFV
C3 1.4i 16V KFU VR8 SE 0,9 ± 0,05
1.6i 16V NFU FR7 ME RFN 58 HZ
C3 1.4i KFV FR7 DE RFN 58 LZ RC 8 YLC
PLURIEL1.6i 16VNFUFR7 MERFN 58 HZ
0,9 ± 0,05 0,9 ± 0,05 2.5 ± 0,2
1.4iKFWFR7 DE0,9 ±0,1 RFN 58 LZ RC 8 YLC mda.N
XSARA 1.6i 16V NFU FR7 ME RFN 58 HZ
2.0i 16V RFN FR8 ME RFN 52 HZ REC 9 YCL
RFSFR6 DE RFN 62 LZ
1.6i90 hp
NFVRFN 58 LZ
XSARA100 hpFR7 DE RC 8 YLC
PICASSO 1.8i 16V 6FZ
FR8 ME0,9 ± 0,1
RFN 52 HZ REC 9 YCL
2.0i 16V RFN
SPARKING PLUGS ALL TYPES
Vehicles
BOSCH Engine
typeEYQUEM
CHAMPION Electrode
gap settingTightening
torque
IGNITION
Electrode
gap settingElectrode
gap setting

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS HYDRAULIQUE
B2BP04XC
Bleeding the hydraulic clutch control
IMPERATIVE: Use only new brake brake fluid that is not emulsified, avoid any
ingress of impurities into the hydraulic circuit.
IMPERATIVE: Do not use automatic bleeding equipment
(risk of the brake fluid
emulsifying in the hydraulic circuit).
Couple a transparent tube (5) on the bleed screw, at «c».
Submerge the end of the tube
(5)in the recipient containing the brake fluid, located
below the level of the clutch slave cylinder.
Use the transparent tube
(5)to act as a siphon, at «b».
WARNING:the end of the tube (5)must be submerged in the brake fluid.
Open the bleed screw, at
«c».
C3 PLURIEL XSARA
C2C3XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX CONTROLS
Engines: HFX KFV KFU NFU 8HX 8HW
(1)Gear control lever.
(2)Gear engagement control cable.(*)
(3)
Gear selection control cable.(*)
(*)
The two cables cannot be separated.
B2CP3HXD
C2 C3 C3 PLURIEL

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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX CONTROLS
Engines: 8HV 8HY
(1)Gear control lever.
(2)Gear engagement control cable.(*)
(3)
Gear selection control cable.(*)
(*)
These two cables cannot be separated.
B2CP3J3D
C3