Injection Citroen C5 2000 (DC/DE) / 1.G User Guide

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INJECTION
STANDARD
X3 US 90 Petrol Private vehicles : Current
 Adoption of the U.S.
Diesel • certain non-EEC standard for light utility vehicles
European countries
• certain Export countries
L1 CEE Petrol Private vehicles : Brussels directive
19.5 Diesel < 1.4 litres 07/92
89/458
• new models
 01/07/93 Possible alternative to
• existing models
 31/12/94 emission standard L from
1992 to 1994
L CEE Petrol Private vehicles : EU Brussels Directive
19.5 Diesel All Types 93/59 (91/441)
• new models 07/92

• existing models 01/93 
• new models  01/96
• existing models
 01/97
EMISSION STANDARDS
PSA
A-S RPEngines ApplicableVehicles
US 90
LDT
EURO 1
(EURO
93)
EURO 1
(EURO
93)E.E.C.
APPLICATION NOTES
CHARACTERISTICS
With oxygen sensor and
catalytic converter for
petrol vehicles.
With catalytic converter
and EGR for diesel
vehicles.

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INJECTION
STANDARD
W2 CEE Petrol Utility vehicles : Brussels Directive 93/59
W2 Diesel < 3.5 tonnes
• new models 01/10/93
 3 classes depending on
• existing models 01/10/94
vehicle weight :
Class 1 : Class 1 < 1250 kg
• new models
 01/97 Class 2 : 1250/1700 kg
• existing models
 10/97 Class 3 > 1700 kg
Class 2/3 :
• new models
 01/98
• existing models
 10/98
L3 CEE Petrol Private vehicles : Brussels Directive 94/12
95 Diesel < 6 seats and
< 2.5 tonnes
 EURO 93 standard made
• new models 01/96
 stricter
• existing models 01/97

All Types EMISSION STANDARDS
PSA
A-S RPEngines ApplicableVehicles
EURO 1
(EURO
93)
EURO 2
(EURO
96)E.E.C.
APPLICATION NOTES
CHARACTERISTICS
With oxygen sensor and
catalytic converter for
petrol vehicles
With oxygen sensor and
reinforced catalytic converter
for petrol vehicles.
With catalytic converter
and EGR for diesel
vehicles.

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INJECTION
STANDARD
W3 CEE Petrol Utility vehicles : Brussels Directive 96/69
95 Diesel < 3.5 tonnes
Gaz Class 1 :
 3 classes depending on
• new models 01/97
 vehicle weight :
• existing models 10/97
 Class 1 < 1250 kg
Class 2/3 : Class 2 : 1250/1700 kg
• new models 01/98
 Class 3 : 1700 kg
• existing models 10/98

L4 CEE Petrol Private vehicles : Brussels Directive 98/69
2000 Diesel All Types
 EURO 2 standard (L3)
Gaz • new models
 01/2000 made stricter
• existing models
 01/2001  Fiscal incentives
EMISSION STANDARDS
PSA
A-S RPEngines ApplicableVehicles
EURO 2
(EURO
96)
EURO 3
(EURO
2000)E.E.C.
APPLICATION NOTES
CHARACTERISTICS
With oxygen sensor and
reinforced catalytic
converter for petrol
vehicles.
With catalytic converter
and EGR for diesel
vehicles.
With 2 oxygen sensors
and catalytic converter
for petrol vehicles. With
catalytic converter and
EGR for diesel vehicles.
With EOBD on-board
diagnosis.

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INJECTION
STANDARD
W3 Petrol Utility vehicles : Brussels Directive 98/69
Diesel < 3.5 tonnes
 EURO 2 standard (L3)
Gaz
made stricter
Class 1 : Fiscal incentives
• new models
 01/2000 3 classes depending on
• existing models
 01/2001 vehicle weight :
Class 2/3 :
Class 1 < 1305 kg
• new models  01/2001Class 2 : 1305/1760 kg
• existing models  01/2002Class 3 : 1760 kg
IF / L5 Petrol Private vehicles : Brussels Directive 98/69
All Types
 EURO 3 standard (L4)
• new models
 01/2001 made stricter
• existing models
 01/2003  Fiscal incentives
EMISSION STANDARDS
PSA
A-S RPEngines ApplicableVehicles
EURO 3
(EURO
2000)
EURO 4E.E.C.
APPLICATION NOTES
CHARACTERISTICS
With 2 oxygen sensors
and catalytic converter
for petrol vehicles.
With catalytic converter
and EGR for diesel
vehicles.
With EOBD on-board
diagnosis.
With 2 oxygen sensors
and catalytic converter
for petrol vehicles.
With EOBD on-board
diagnosis.

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INJECTION
PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM
Engines : RHY - RHZ - 4HX
Cleaning.
- The use of high pressure cleaners is prohibited.
- Do not use compressed air.
Fuel supply circuit.
- Required fuel : diesel.
Electric circuit.
- Swapping injection ECUs Between two vehicles will render it impossible to start either vehicle.
- It is forbidden to supply a diesel injector with 12 volts.
High pressure fuel pump.
Do not separate the following components from the high pressure fuel pump (5):
- Sealing ring (b)(no replacement parts).
- High pressure outlet connector (a)(will cause a malfunction).
PS : HDi = High pressure diesel injection.
B1HP19LC

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INJECTION
PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM
Engines : RHY - RHZ - 4HX
Diesel injectors.
WARNING: Diesel and ultrasonic cleaners are prohibited.
Do not separate the following components from the diesel injector carrier (2):
- Diesel injector(e) (no replacement parts).
- Electromagnetic element(c)(no replacement parts).
Do not alter the position of the nut(d)(malfunction).
Do not separate the connector(f)from a diesel injector.
It is forbidden to clean the carbon deposits from the diesel injector nozzle.
B1HP19NC

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INJECTION
SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM
Engines : RHY - RHZ - 4HX
SAFETY REQUIREMENTS
Preamble.
All interventions on the injection system must be carried out to conform with the following requirements and regulations :
- Competent health authorities.
- Accident prevention.
- Environmental protection.
WARNING :Repairs must be carried out by specialised personnel informed of the safety requirements and of the precautions to be taken.
Safety requirements.
IMPERATIVE : Take into account the very high pressures in the high pressure fuel circuit (1350 bars), and respect
the requirements below :
- No smoking in proximity to the high pressure circuit when work is being carried out.
- Avoid working close to flame or sparks.
Engine running :
- Do not work on the high pressure fuel circuit.
- Always stay clear of the trajectory of any possible jet of fuel, which could cause serious injuries.
- Do not place your hand close to any leak in the high pressure fuel circuit.
After the engine has stopped, wait 30 secondsbefore any intervention.
NOTE :This waiting time is necessary in order to allow the high pressure fuel circuit to return to atmospheric pressure.

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INJECTION
SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM
Engines : RHY - RHZ - 4HX
CLEANLINESS REQUIREMENTS.
Preliminary operations
IMPERATIVE : The technician should wear clean overalls.
Before working on the injection system, it may be necessary to clean the apertures of the following sensitive components :
(refer to corresponding procedures).
- Fuel filter.
- High pressure fuel pump.
- Third piston deactivator.
- High pressure regulator.
- High pressure sensor.
- High pressure fuel injection common rail.
- High pressure fuel pipes
- Diesel injector carriers.
IMPERATIVE : After dismantling, immediately block the apertures of the sensitive components with plugs, to avoid the entry of impurities.
Work area.
- The work area must be clean and free of clutter.
- Components being worked on must be protected from dust contamination.

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INJECTION
CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT
Engines : RHY - RHZ - 4HX
Engines : RHY - RHZ
Engine : 4HX
TOOLS
[1] Ø 10 mmlow pressure connector: 4215-T.
[2] Ø 8 mmlow pressure connector: 4218 -T.
[3] Pressure gauge for testing boost pressure : 4073-T Tool kit 4073-T
[4] Extension: 4251-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.
NOTE : To check the pressures while the vehicle is being driven, insert tool[4] Between
tool[3] and tools[1] et[2].
Checks on pressure : static.
- Switch on ignition
- For 3 seconds(normal functioning):
- Fuel supply pressure shown by the pressure gauge [3] = 2.6 ± 0.4 Bar.
- Fuel return pressure shown by the pressure gauge [3] = 0.6 ± 0.4 Bar.
B1BP20JDB1BP27BD

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INJECTION
CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT
Engines : RHY - RHZ - 4HX (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] = 0.8 ± 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 3.3et 4 Bars 0.8 ± 0.4 BarCheck the condition of the diesel filter
More than 4 Bars
More than 4 BarsLess than 0.8 Bar
More than 0.8 BarCheck the low pressure regulator incorporated in
the filter (locked shut) : replace.
Check the fuel return circuit (pipe pinched or trapped...).
Between 0.8et 1.5 BarLess than 0.8 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.