Replacement Citroen XSARA PICASSO 2004 1.G Workshop Manual

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ENGINE
The new fitting discontinues the following components:
Camshaft hub.
Cylinder reference sensor target.
Repair – Accessories drive pulley
Remove – Refit
WARNING:
Peg the camshaft and the crankshaft before ever removing the
accessories drive pulley (the pegging prevents any offsetting of the camshaft).
If necessary, apply a paint spot to mark the accessories drive pulley being
replaced.
Replacement parts.
The Replacement Parts service markets the old as well as the new components.
CHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
NEW FITTING N° RPO 9128 # (Continued)
B1EP177D
XSARA XSARA PICASSO

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ENGINE
ALL TYPES FILLING AND BLEEDING THE COOLING CIRCUIT
Tools.
[1]
Filling cylinder: 4520T
[2]Adaptor for filling cylinder: 4222T
IMPERATIVE: Respect the safety and cleanliness requirements.
The draining and refilling operations can be carried out using WINN’S or similar coolant fluid replacement
equipment;it is essential to follow the instructions as stated for that equipment.
Filling and bleeding.
Fit the cylinder adaptor [2] 4222T (Picasso,C2,C3)and the filling cylinder [1] 4520T (all types).
Use the coolant to ensure protection between 15°C and 37°C.
Slowly fill the system.
NOTE:Keep the cylinder filled up (visible level).
Close each bleed screw as soon as the coolant flows without air bubbles.
Start the engine :Engine speed
1500 rpm.
Maintain this speed until the first cooling cycle (cooling fans cut in and cut out).
Stop the engine and allow it to cool down.
Remove the filling cylinder
[1] 4520T (all types)and the cylinder adaptor [2] 4222T.
Top up the system to the max. mark, with the engine cold.
Refit the filler cap.
E5AP1GNCB1GP00AC

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INJECTION
PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM
Engines: 8HX 8HW 8HZ
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
(a)(no replacement parts).
High pressure outlet connector
(b)(will cause a malfunction).
PS: HDi = High pressure Diesel injection
B1HP1K9C
C2 C3 XSARA

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INJECTION
PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM
Engines: 8HX 8HW 8HZ
Diesel injectors.
WARNING: Diesel and ultrasonic c
leaners are prohibited.
Do not separate the following components from the diesel injector
carrier
(2):
Diesel injector
(f)(no replacement parts).
Electromagnetic element
(c)(no replacement parts).
Do not alter the position of the nut
(d)(malfunction).
Do not separate the connector
(e)from a diesel injector.
It is forbidden to clean the carbon deposits from the diesel injector
nozzle.
B1HP1KACB1HP1KBC
C2 C3 XSARA

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INJECTION
PROHIBITED OPERATIONS: DELPHI HDI DIRECT INJECTION SYSTEM
Engines: 8HY 8HV
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
(a) (no replacement parts).
High pressure outlet connector
(b)(will cause a malfunction).
PS:HDi = High pressure Diesel injection
B1HP1J6C
C3

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INJECTION
PROHIBITED OPERATIONS: DELPHI HDI DIRECT INJECTION SYSTEM
Engines: 8HY 8HV
B1HP1J7CB1HP1J8C
Fuel high pressure injection common rail.
Do not separate the pressure regulator «c»from the injection
common rail (2)(Risk of malfunction).
Diesel injectors.
WARNING:
Diesel and ultrasonic cleaners are prohibited.
Do not separate the following components from the diesel
injector carrier
(3):
Diesel injector (e)(no replacement parts).
Electromagnetic component «d»(no replacement parts).
It is forbidden to clean the carbon deposits from the diesel
injector nozzle..
C3

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INJECTION
PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM
Engines: RHY RHZ
XSARA PICASSO
Cleaning.
The use of high pressure cleaners is prohibited.
Do not use compressed air.
Fuel supply circuit.
Required fuel: diesel.WARNING:Do not use other fuels.
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):
High pressure fuel pump third piston deactivator (3)(no replacement parts).
High pressure fuel regulator (4)(no replacement parts).
Sealing ring (1)(no replacement parts).
High pressure outlet connector (3)(will cause a malfunction).
PS:HDi = High pressure Diesel injection
B1HP12CC

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INJECTION
PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM
Engines: RHY RHZ
XSARA PICASSO
High pressure fuel injection common rail. Do not separate the connectors (7)from the common injection rail (6)(malfunction).
Diesel injectors.
WARNING:Diesel and ultrasonic cleaners are prohibited.
Do not separate the following components from the diesel injector carrier (9):
Diesel injector (8)(no replacement parts).
Electromagnetic element (11)(destruction).
Do not alter the position of the nut (10)(malfunction).
Do not separate the connector (12)from a diesel injector.
It is forbidden to clean the carbon deposits from the diesel injector nozzle.
Identification: Injector carrier
There are two types of diesel injector carrier classed according to fuel flow.
Identification by engraving or paint mark
B1HP12EC
B1HP12DC
B1HP16PC
IMPERATIVE: When replacing a
diesel injector carrier, order a
component of the same class.
(See repair manual)
Identification markings:
«a»:Supplier identification.
«b»:PSA identification number.
«c»:Class identification.
Injector carrier
Class 1
Class 2
Engraving
1
2
Paint mark
Blue
Green
Location
On the upper part of the
coil near to the fuel return
aperture

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CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS PRECAUTIONS: AL4 AUTOMATIC GEARBOX
Engines: KFV NFU RFN RHZ
If a gearbox malfunction occurs, there are two possible
configurations depending on the seriousness of the fault:
Gearbox in backup mode with a replacement programme of
(the
fault values are taken in substitution).
Gearbox in backup mode with an emergency programme (3rd
hydraulic).WARNING:In the emergency programme, an impact is felt
when changing P/R, N/R and N/D.
Réception client.
Discuss with the customer, to find out all the malfunction symptoms.Oil quality Oil level.
Oil quality.
If the gearbox has suffered a serious fault resulting in a malfunction
or the destruction of a clutch, the oil will overheat and become
contaminated with impurities: the oil is said to be
«burnt».
This is characterised by a black colour and the presence of an
unpleasant smell.
ESSENTIAL: The gearbox must be replaced.
Oil level (see corresponding operation).
An excessive oil level can result in the following consequences:
Excessive heating of the oil.
Oil leaks.
An insufficent level causes the destruction of the gearbox.
Top up the level of oil in the gearbox (if necessary).
Check using a diagnostic tool.
Read the fault codes
(engine and gearbox).
Absence of fault codes.Carry out parameter measures, actuator tests and a road test.
Presence of fault codes.Carry out the necessary repairs.
Delete the fault codes.
Carry out a road test to check the repair and, if need be, modify the
gearbox ECU parameters
(this is essential after an initialisation
of the ECU).
XSARA XSARA PICASSO
Procedure to be followed prior to carrying out repairs on AL4 autoactive gearbox

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CLUTCH
GEARBOX
TRANSMISSION
Engines: KFV NFU RFN RHZ
Updating the value of the oil usage counter.
Using PROXIA.
Access to reading and recording of the oil counter is via the menu:
«Configuration
(integrated circuit button)/ Oil counter».
Adjustment of the oil counter value is done in incremental steps of
2750units.
Using LEXIA or ELIT.Access to reading and recording of the oil counter is via the menu:
«Oil counter».
Adjustment of the oil counter value is done by entering directly the
5 figures of the oil counter.
Downloading.
ECU downloading procedure:
Follow the diagnostic tool procedure.
A new ECU or downloaded update is always configured with the
following options:
SHIFT LOCK gear selection lever position.
Without OBD outlet
(depollution L4).
If the ECU is to be fitted to a vehicle with depollution
L4or not
equipped with gear lever locking safety: Perform a configuration operation.
Pedal initialisation.
A pedal initialisation must be carried out in the following cases:
Replacement of the automatic gearbox ECU.
Replacement of the automatic gearbox.
Downloading of the ECU configuration.
Adjustment or replacement of the accelerator cable.
Replacement of the butterfly potentiometer.
RECOMMENDATIONS PRECAUTIONS: AL4 AUTOMATIC GEARBOXC3 XSARA XSARA PICASSO
Procedure for initialising the automatic gearbox ECU