ESP Citroen C5 2000 (DC/DE) / 1.G Owner's Guide

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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
AIR SUPPLY CIRCUIT SPECIFICATION
Engine : 4HX
ESSENTIAL : Respect the safety and cleanliness
recommendations.
Tool.
[1] Manual vacuum pump: FACOMM DA 16.
Checks.
ESSENTIAL : Respect the safety and cleanliness
recommendations that are specific to high pressure
diesel injection (HDi) engines.
B1HP1ARP

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INJECTION
CHECKS : EXHAUST GASES RECYCLING CIRCUIT
Engines : RHZ - RHY
(1) Butterfly housing(3) Electrovalve (black connector)
(2) EGR valve(tube with blue marking)(4) Electrovalve(blue connector)
TOOL
[1] Manual vacuum pump : FACOM DA 16.
ESSENTIAL : Respect the safety and cleanliness requirements specific to
high pressure diesel injection (HDi) engines.
EGR electrovalve
- Check, not under load, between the electrovalve(4)and the EGR valve (2).
- Connect the tool[1] between the electrovalve (3)and the butterfly housing (1).
- Compare readings with the values in the table below.
Butterfly housing electrovalve.
- Check, not under load, between the electrovalve (3)and the butterfly housing (1).
- Connect the tool[1]between the electrovalve(3) and the butterfly housing(1).
- Compare readings with the values in the table below.
Engine speed (rpm) Vacuum value (bar)
7800.5 Bar
25000 Bar
B1HP1BVD

Downloaded from www.Manualslib.com manuals search engine CHECKS : EXHAUST GASES RECYCLING CIRCUIT
Engine : 4HX
TOOL
[1] Manual vacuum pump : FACOMM DA 16.
ESSENTIAL : Respect the safety and cleanliness requirements specific to
high pressure diesel injection (HDi) engines..
Electrovalve (EGR).
- Check, not under load, between the electrovalve(3)(blue connector) and the EGRvalve (2)
(tube with blue marking).
- Connect the tool[1]between the electrovalve (3) and the EGRvalve(2).
- Compare readings with the values in the table below.
Butterfly housing electrovalve
- Check, not under load, between the electrovalve (4) (black connector)and the butterfly housing (1)
(Metering pump cold), (tube with white marking).
- Connect the tool[1]between the electrovalve (4) and the butterfly housing(1).
- Compare readings with the values in the table below.
Engine speed (rpm) Vacuum value (bar)
7800.5 Bar
25000 Bar
B1HP1B8D
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INJECTION

Downloaded from www.Manualslib.com manuals search engine CHECKS : TURBO PRESSURE
Engine : 4HX
TOOL
[1]Pressure gauge for checking pressure7073-T.A.
[2] Extension cable for taking pressure8607-T.A
[3]Union and hose for taking pressure8607-T.B.
[4] Adaptor for taking pressure8607-T.C.
[5]Unions and hoses for taking pressure4088-T
Checks.
ESSENTIAL : Respect the safety and cleanliness requirements specific to
high pressure diesel injection (HDi) engines.
Preliminary operations.
Carry out the following operations:
Remove the screw (1).
Disconnect the tube (2).
Move aside the pressure sensor (3).
Preparation of tools : in position on the vehicle.
Fit as follows :
Remove the hose(a)of tool [5], screw in its place the tool [3], remove the hose (b)of tool [5],
screw the hose (b)of tool [5]on the pressure gauge[1], screw the adaptor [4]onto the tool [5]
Connect the tube(2) of the pressure sensor(3) on the tool [4], tighten the tube(2) with a
Serflex type collar.
B1BP28DCE5AP1SUC
137
INJECTION

Downloaded from www.Manualslib.com manuals search engine FEATURES OF MULTIPOINT INJECTION SYSTEM
Electrical circuit
(diagr.) Component Supplier Reference Observations
35Engine management ECU
with «FRIC»
26Camshaft position sensor
10Knock sensor
9Engine coolant temperature
sensor
1Accelerator pedal position sensor
24Engine speed sensor
28Power steering pressure sensor
25Inlet camshaft dephaser electrovalve.112 way connector.
3 way grey connector, fixed on the cylinder head.
2 way black connector, fixed on the front part of the engine
block.
ESSENTIAL:Respect the tightening torque 2,5±0,5 m.daN.
2 way green connector, fixed on the coolant outlet housing.
4 way black connector, fixed on the pedal carriage.
2 way black connector, fixed on the clutch casing.
2 way blue connector, fixed on the power steering high pressure
pump outlet tube, tighten to 2 ± 0,2 m.daN.
2 way green connector, fixed on the upper part of the cylinder
head. SIEMENS
ELECTRIFIL
SIEMENS
ELECTRIFIL
BITRON
UNISIASIRIUS 81
F207 326
145
INJECTION

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INJECTION
FEATURES OF BOSCH ME 7.4.6 MULTIPOINT INJECTION SYSTEM
Electrical circuit
(diagr.) Component Supplier Reference Observations
30Ignition injection ECU
29Multifunction double relay
(incorporated in the engine fusebox)
24Power steering pressure sensor
27Inlet air thermal sensor
13Camshaft position sensor
23Knock sensor
22Engine coolant thermal sensor
12Engine speed sensor128 way connector, flash eprom type sequential injection
(reprogrammable eprom). Installed in the ECU compartment.
Main relay 1, 16 way grey connector.
Main relay 2, 16 way green connector
Power relay 3, 16 way black connector
Installed in the ECU compartment.
2 way blue connector, switch opens at 20 Bars, for ECU
information (steering wheel on full lock). Ring seal marked
violet, fixed on the power steering 4 way hydraulic union,
beneath the vehicle.
2 way grey connector, fixed on the air filter inlet duct.
3 way grey connector, fixed on the inlet camshaft bearing
cap cover.
3 way green connector, fixed on the central part of the engine
block V.
ESSENTIAL : respect the tightening torque 2 ± 0,2 m.daN.
2 way green connector, fixed on the coolant outlet housing.
Tighten to 2 ± 0.2 m.daN
2 way black connector, fixed on the gearbox clutch casing. BOSCH
SIEMENS
BITRON
JAEGER
ELECTRIFIL
BOSCH
DAV
ELECTRIFIL
ELECTRIFILME 7.4.6
0261206418
S210500000
402 084 01
14 43 25
026123125
402 243 03
14 43 32
14 43 28

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INJECTION
FEATURES OF BOSCH HDi DIRECT INJECTION SYSTEM
Electrical circuit (continued)
Component (diagr.) Supplier Reference Observations
Coolant temperature sensor46ELECTRIFIL 962859028A Fixed on the coolant outlet housing
Accelerator pedal sensor54
Brake pedal switch36PHILIPS
56
Clutch pedal switch55
Additional heating control
relay1
Additional heating2 aOpen at rest
Boiler elements2 bClosed at rest
Air conditioning compressor 30
Automatic gearbox ECU22
Cruise control switch34
Heated rear screen20
ESP ECU21
«Service» warning lamp25
Cooling fan29
Fuel cap warning lamp28
Coolant temperature alert warning lamp31
Coolant temperature indicator32

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CLUTCH
GEARBOX
DRIVESHAFTS
BE4/5 GEARBOX CONTROLS
Engines : 6FZ - RFN - RLZ - RHY
Tools.
[1]Tool for positioning the gearbox control lever8605-T Tool kit 9040-T
Adjustments.
Cables should be adjusted each time the gearbox, gear controls or power unit are removed.
Adjustment principles :
- Lock the gear lever in neutral position, using tool [1].
- Position the gearbox in neutral.
- Anchor the ball-joints on the gearbox levers.
- Lock the cable lengths with the ball-joint locking keys.
Inside the vehicle.
- Remove the central console (See corresponding operation).
- Remove the plastic blank at (a).
- Insert tool[1]fully and rotate a quarter turn to lock the gear control lever.
- At neutral.
B2CP3E7C