ring Citroen C4 2005 2.G Workshop Manual

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: 9HZ - 9HY
Refitting (continued).
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 torque
- Screw (10)Pre-tighten 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).
XSARA PICASSO
Disengage the jack from under the engine.
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 splash-shield (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).
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine: WJY
Tools.
[1]Pliers for remving plastic pins: 7504-T or (-).1311
[2]Flywheel peg: 7014-T.J or (-).0188 Y
[3]Injection pump setting peg Ø 6 mm : (-).0188 H
[4]Screw H M8 : (-).0188 E
[5]Belt retaining pin: (-).0188 K
[6] Square for adjusting belt tension: (-).0188 J1
[7] Belt tension measuring instrument, with digital display: SEEM CTG 105.5M
Checking the timing.
Peg the flywheel, using tool [2].
Peg the camshaft hub, using tool [4].
Peg the injection pump hub, using tool[3].
IMPERATIVE: If the pegging proves impossible, repeat the setting of the timing.
B1BP2FTC
B1EP16PD
XSARA
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ENGINECHECKING AND SETTING THE VALVE TIMING
Engine: WJY
B1BP2FTC
Setting the timing.
Removing.
Disconnect the battery.
Remove the front RH lower splash-shield, using tool [1].
Remove the accessories drive belt
(see corresponding operation).Uncouple and plug the diesel fuel delivery and return hoses.
Support the engine, using a workshop hoist.
Remove the RH engine support.
Engage 5th gearto permit rotation of the engine.
Remove the upper cover (1).
Remove the intermediate cover (2).
Remove the lower cover (3).
WARNING: Refit the screw (4) equipped with a washer
(5 mm thick).
Rotate the front RH wheel to drive the engine in its normal direction of
rotation.
Bring the camshaft drive and injection pump pinions to their setting
points.
Position the peg [2]
(from underneath the vehicle).
Continue turning the engine until the peg [2]engages in the flywheel.
B1BP30BC
XSARA
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ENGINECHECKING AND SETTING THE VALVE TIMING
Tools.
[1]Belt tension measuring equipment : 4122-T
[2]Tension lever: (-).0188.J2
[3]Engine flywheel peg: (-).0188.Y
[4] Belt clamp: (-).0188.AD
[5]Camshaft pulley peg: (-).0188.M
[6] Engine flywheel lock: (-).0188.F
[7] Set of blocking plugs: (-).0188.T
[8] Pulley extractor: (-).0188.P
[9] 2 mm Øpeg: (-).0188.Q2Removing.
IMPERATIVE: Respect the safety and cleanliness requirements
that are specific to high pressure diesel injection (HDi) engines.
Undo the front RH wheel bolts.
Raise and support the vehicle on the front RH side.
Disconnect the battery negative terminal.
Remove:
- The under-engine sound-deadening.
- The front RH wheel.
- The front RH splash-shield.
- The engine cover.
Unclip and move aside the cooling hose.
Remove the accessories drive belt
(see corresponding operation).
XSARA - XSARA PICASSO
Engines: RHY - RHZ
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines: RHY - RHZ
Uncouple, plug and move aside, using tool [7], the fuel delivery pipe(2)and return
pipe (1).
Remove:
- Screws (3), (4)and (6).
- Screw (7).
- The upper timing cover (5).
WARNING: Refit screw (7) equipped with a spacer
(17 mm thick), tighten the
screw (7) to 1,5 ± 0,1 m. daN.
NOTE: The screw (7)is one of the screws securing the coolant pump and is there
for its sealing.
Put the gear lever in 5th gear.
Turn the road wheel to turn the engine in its direction of rotation.
Orient the camshaft pulley in the pegging position, use a mirror if necessary.
Peg the camshaft, using tool [5].
Peg the engine flywheel, using tool [3].
B1EP1A7CB1BP2H3CB1BP2H2CB1BP2R2C
XSARA - XSARA PICASSO
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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: RHY - RHZ
Remove:
- The fixings of the pipe linking the power steering pump with the rotary valve.
- The clutch lower closing plate.
- Lock the engine flywheel, using tool [6].
Remove the screw (8).
Refit the screw (8)without its thrust washer.
Remove:
- The accessories pulley (9), using tool [8].
- Tool [6].
- The lower torque reaction rod.
Support the engine by means of a workshop hoist.
Remove:
- The bearing shell fitting (10).
- The nut (12).
- Screws (11).
- The bracket (13).
NOTE:Lift then lower the engine with the workshop hoist, to have access to the
timing cover fixing screws.
Remove:
- The intermediate timing cover.
- The lower timing cover.
B1CP04BCB1BP2R3CB1BP2R4C
XSARA - XSARA PICASSO
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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: RHY - RHZ
Remove:
- Tools [3]and [5], Screw (7)and the spacer.
Refit:
- The lower, intermediate and upper covers (5).
- Screw (7), tighten to 1,5 ± 0,1 m.daN.
- Screws (3), (4)and (6).
- The bracket (13).
Screws (11), tighten to 6,1 ± 0,5 m.daN.
The nut (12), tighten to 4,5 ± 0,5 m.daN.
Fit the bearing shell (10).
Take away the workshop hoist.
Clip the fuel delivery and return pipes.
Remove the tool [7].
Couple:
- The fuel delivery pipe (12).
- The fuel return pipe (1).
- Coat the screw (8)with loctite FRENETANCH.
Refit the tool [6]and the screw (8)with the washer (22), tighten to 7 ± 0,2 m.daN
and angular tighten to A= 60°±5°.
Refit the torque reaction rod on the lower engine support.
Remove the tool [6].
Reposition and reclip the cooling hose.
Complete the refitting of components in reverse order to removal.
B1EP1A7CB1BP2R4CB1EP1ADC
XSARA - XSARA PICASSO
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ENGINECHECKING AND SETTING THE VALVE TIMING
Engine: RHR
Refitting.
Centre the crankshaft pinion (15), using tool [5].
Reposition the timimg belt on the pulley (18).
Put the tool [4]in place
(tighten moderately).
Reposition the timimg belt, strip «a»well tensioned
in the following order:
- Guide roller (14).
- Crankshaft pinion (15).
- Coolant pump pinion (16).
- Tensioner roller (17).
Remove tools [4]and [5].
Bring the index «d»outside the plate at «c», by
turning the tensioner roller in the direction of the
arrow «b», using a hexagonal spanner at «e».
Tighten screw (12)of the tensioner roller (17)to
2,1 ± 0,2 m.daN.
Lock the flywheel, by means of tool [6].
Refit the auxiliaries drive pulley (7).
Tighten the screw (8)to 7 ± 0,7 m.daN.
Remove tools [6], [2]and [3].
B1EP1FFC
B1EP1FGC
B1EP1FHC
B1EP1FJC
C4
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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
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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS
Engines: KFU - NFU - RFN - RFJ - RFK - 9HX - 9HY - 9HZ - RHR
NOTE:All the clutches are «push»type with hydraulic control.
NOTE:The DV6TED4and DW10BTED4engines are equipped with a double damping flywheel (DVA).
Description.
The declutch control has a declutch fork with a ball-joint on the axis.
(1)The ball-joint is screwed into the clutch casing
(2) Declutch fork
(3)Clutch casing
(4)Bearing
(5) Clutch plate
The clutch control slave cylinder(7)is fixed by two screws (6) into the exterior of the clutch casing.
B2BP047C
B2CP3FAC
C4
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