Electrical Citroen C4 2005 2.G Workshop Manual

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: 8HX - 8HZ
B1BP2LXC
Tools.
[1] Pliers for removing plastic pegs: 7504-T
[2]Lever for detensioning the dynamic tensioner roller: (-).0194.E
[3]Engine flywheel setting peg: (-).0194.C
[4] Camshaft setting peg: (-).0194.B
[5]Crankshaft and high pressure pump setting peg: (-).0194.A
Preliminary operations.
Remove:
- The front RH wheel.
- The front RH splash-shield, using tool [1].
- The clips of the electrical harness on the upper timing cover.
- The accessories belt, using tool [2]
(see corresponding operation).
Checking the setting.
Disconnect the battery negative cable.
Remove the upper timing cover (1).
Rotate the engine using the screw (2)of the crankshaft pulley.
NOTE:The locking hole is located under the crankshaft bearing cap cover.
Undo the screw (2).
Detension the auxiliary drive belt dynamic tensioner roller, using tool [2].
XSARA
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ENGINE
CHECKING THE VALVE TIMING
Engines: 9HX - 9HY - 9HZ
Turn the engine in the normal direction of rotation until the peg [1]engages in the setting hole.
Peg the flywheel at «b», using tool [1].
Move aside the electrical harness (6).
Remove:
- The engine support (7).
- The screw (8).
- The accessories drive pulley (9).
- The lower timing cover (10).
- The upper timing cover (11).
- The tool [1].
Refit the screw (8).
Rotate the crankshaft six times
(clockwise).
IMPERATIVE: Never turn it backwards.
B1BP305C
B1EP1HJD
C4
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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: 9HX - 9HY - 9HZ
Checking and setting the timing (continued).
Turn the engine in the normal direction of rotation until the peg [1]engages in the setting hole.
Peg the flywheel at «b», using tool [1].
Move aside the electrical harness (6).
Remove:
- The engine support (7).
- The screw (8).
- The accessories drive pulley (9).
- The lower timing cover (10).
- The upper timing cover (11).
- The tool [1].
Refit the screw (8).
Rotate the crankshaft to bring the camshaft to its pegging point.
Peg:
- The camshaft at «c», using tool [2]
(oil the pegs).
- The fuel high pressure pump pulley (15)at «f»using a 5 mmdiameter peg.
WARNING: Do not touch or damage the track of the engine speed sensor target (14).
B1BP305C
B1EP1HJD
C4
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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: 9HX - 9HY - 9HZ
IMPERATIVE: Should it be impossible to peg the camshaft, check that the offset between the camshaft hole and the pegging hole is not
more than 1 mm. If the offset is too great, repeat the operation to position the timing belt
(see corresponding operation).
Remove the tools [2]and [3].
Refit tool [1]at «b».
Remove the screw (8).
Refit:
- The upper timing cover (11).
- The lower timing cover (12).
- The pulley (9).
- The screw (8).
Tightening methodfor the screw (8):
- Pre-tighten to 3 ± 0,3 m.daN.
- Angular tighten 180° ± 5°.
Remove tool [1].Refit:
- The engine support (7), tighten to 5,5 ± 0,9 m.daN.
- The engine support (3).
- The four screws (5), tighten to 5,5 ± 0,8 m.daN.
- The three screws (4), tighten to 5,5 ± 0,8 m.daN.
- The electrical harness (6).
Disengage the jack from under the engine.
Complete the refitting.
IMPERATIVE: Carry out the operations that are necessary following
a reconnection of the battery
(see corresponding operation).
C4
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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 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
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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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 THE VALVE TIMING
Engine: RHR
Tools.
[1] Kit of plugs: (-).0188.T
[2] Double flywheel setting peg: (-).0188.X Toolkit 0188-T
[3]Camshaft setting peg: (-).0188.M
IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel
injection (HDi) engine versions.
Remove the engine cover and the battery.
Disconnect the negative terminal of the battery.
Raise and support the front of the vehicle.
Remove the under-engine sound-deadening and the front RH splash-shield.
Uncouple, plug and move aside, using tool [1], the fuel supply and fuel return pipes..
Suspend the engine, using a workshop hoist.
Remove the engine support bracket and the engine support.
Move aside the electrical harness (1).
Remove:
- The camshaft position sensor.
- The inlet cylinder head cover (2).
- The upper timing cover screws.
- The upper timing cover (3).
B1EP1GFC
C4
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ENGINE
274
CHECKING AND SETTING THE VALVE TIMING
Engine: RHR
Uncouple, plug and move aside, using tool [7],
the fuel delivery pipe (1)and the fuel return pipe (2).
Suspend the engine, using a workshop hoist.
Remove the bracket (3)and the RH engine
support (4).
Move aside the electrical harness (5).
Remove:
- The upper timing cover screws.
- The upper timing cover (6).
Rotate the engine by means of the auxiliaries drive
pulley.
Orient the camshaft pinion in the pegging position,
use a mirror if necessary.
Peg the camshaft, using tool [3].
Peg the engine flywheel, using tool [2].
Lock the flywheel, using tool [6].
B1BP351C
B1EP1FAC
B1EP1FBC
B1BP31EC
C4
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CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS/PRECAUTIONS: AL4 AUTOMATIC GEARBOX (SHIFT LOCK)
Engines: NFU - RFJ
C5FP0NZC
C5FP0P0C
SHIFT LOCK.
The «shift lock»is a system that locks the gear selection lever in position «P».
Unlocking the «SHIFT LOCK»
(normal operation).Switch on the ignition.
Press the brake pedal and keep it pressed.
Move the gear selection lever out of position «P».
Unlocking the «SHIFT LOCK»
(with an operating fault).
NOTE:It is impossible to unlock the «shift lock»with the «Normal operation»
method.
The fault may originate from one of the following components:
- «Shift lock».
- Gear lever position switch.
- Automatic gearbox ECU.
- Electrical harnesses.
- Battery voltage.
Remove:
- The gear lever cover (1)
(pull upwards).
- Unlock the «shift lock»by pressing at “a”with the aid of a screwdriver.
- Move the gear selection lever out of position «P».
C4
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CLUTCH
GEARBOX
TRANSMISSION
XSARARECOMMENDATIONS/PRECAUTIONS: AL4 AUTOMATIC GEARBOX (SHIFT LOCK)
Engines: NFU - RFN - RHZ
SHIFT LOCK.
NOTE: The«shift lock» is a system that locks the gear selection lever in position«P».
Unlocking the «SHIFT LOCK»
(normal operation).
- Switch on the ignition.
- Press the brake pedal and keep it pressed.
- Move the gear selection lever out of position«P».
Unlocking the «SHIFT LOCK»
(with an operating fault).
NOTE: It is impossible to unlock the«shift lock» with the«Normal operation» method.
The fault may originate from one of the following components:
- «Shift lock».
- Gear lever position switch.
- Automatic gearbox ECU.
- Electrical harnesses.
- Battery voltage.
Remove:
- The cover(1).
- Unlock the«shift lock» (2) with the aid of a screwdriver.
- Move the gear selection lever out of position«P».
C5FP06ZC
C5FP06YC
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