Get Engine Guide for Citroen C3 SUV First Generation (2002-2009)

ENGINE SPECIFICATIONS

Petrol

Diesel

1.1i

1.4i

1.6i 16V

1.4 HDi

1.4 HDi 16V

8HY 8HV

Engine type

HFX

1124

72/69

KFV

1360

75/77

NFU

1587

8HX

8HW

Cubic capacity (cc)

Bore / Stroke

1398

78/82

73/82

Compression ratio

10.5/1

11/1

17.9/1

50-4000

70-4000

15-2000

15.6-2000

18.25/1

66-4000

92-4000

20-2000

20.8-2000

44-5500

61-5500

9.4-3400

9.8-3400

54-5400

75-5400

12-3400

12.5-3400

80-5800

110-5800

14.7-4000

15.3-4000

Power ISO or EEC KW - rpm)

Power DIN (HP - rpm)

Torque ISO or EEC (m.daN - rpm)

Torque DIN (mkg-rpm)

Max. speed (rpm)

37

ENGINE SPECIFICATIONS

Engines : HFX - KFV - NFU

Engine identification

A = Engines:

B = Engine:

HFX - KFV

NFU.

Compulsory engine identification in

zone «a» :

- Component reference.

- Engine legislation type.

- Factory serial no.

B1BP10JC

B1BP2GKC

38

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Crankshaft

Engine types

HFX

KFV

NFU

Accessories drive pulley

Pinion fixing on crankshaft

0.8 ± 0.2

10 ± 1

2.5 ± 0.2

Cylinder block

0.8 ± 0.2

Sump

Timing belt tensioner roller

Accessories belt tensioner roller

Alternator support fixing

Alternator fixing on support

2 ± 0.2

2.2 ± 0.2

2.5 ± 0.2

1.7 ± 0.3

3.7 ± 0.3

Cylinder head

0.8 ± 0.2

Coolant outlet housing

Camshaft bearing cap

Tightening

2 ± 0.2

Angular tightening

Inlet manifold

4 4 ° ± 4 °

50° ± 5°

0.8 ± 0.2

Exhaust manifold

1.7 ± 0.3

2 ± 0.2

Valve rockers adjusting screw

Sparking plugs

1.75 ± 0.25

2.75 ± 0.25

8 ± 0.8

Camshaft pulley screw

39

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Flywheel - Clutch

Engines

HFX

KFV

6.7 ± 0.6 + LOCTITE FRENETANCH

2 ± 0.2

NFU

Flywheel

Clutch mechanism

Lubrication circuit

2 ± 0.2

Oil pressure switch

Oil pump

0.9 ± 0.1

Cooling circuit

1.4 ± 0.1

Coolant pump

Coolant outlet housing

0.8 ± 0.1

40

CYLINDER HEAD

Engines : HFX - KFV - NFU

Identification of cylinder head gasket

Engine types

Thicknesses (repair)

1.4 ± 0.1

Thickness references

Thicknesses (Standard)

1.2 ± 0.1

HFX

KFV

NFU

2

1

4

0.66 ± 0.04

References

1,2,3,4 = Type of engine.

A,B,D = Suppliers.

C

R

= Gasket material.

= Repair.

B1BP10KC

41

CYLINDER HEAD

Engines : HFX - KFV - NFU

Cylinder head tightening (m.daN)

Cylinder head bolts

HFX - KFV

2 ± 0.2

Tightening

Angular tightening

24 0° ± 5°

(In the order 1 to 10)

NFU

Tightening

Angular tightening

2 ± 0.2

260° ± 5°

(In the order 1 to 10)

NOTE : Oil the threads and

under the heads of the bolts.

(Use engine oil or Molykote G

Rapid Plus).

B1BP1DVC

X = MAXIMUM reusable length

NOTE : Retightening of the cylinder head

after a completed repair is prohibited.

HFX - KFV

175.5 ± 0.5

NFU

122 ± 0.3

B1DP05BC

42

ENGINE SPECIFICATIONS

Engines : 8HX - 8HW

Engine identification

"a" Engine legislation type.

"b" Component reference.

"c" Factory serial no.

B1CP0BKD

43

CYLINDER HEAD

Engines : 8HX - 8HW

Cylinder head tightening (m.daN)

Cylinder head bolts

8HX - 8HW

Pre-tightening

Tightening

2 ± 0.2 m.daN

4 ± 0.4 m.daN

Angular tightening 230° ± 5°

(In the order 1 to 10)

NOTE :

- The bolts should have been tho-

roughly cleaned and dried with a

dry metal brush.

- Oil the threads and under the

heads of the bolts. (Use engine

oil or Molykote G Rapid Plus).

B1DP1DBC

- Pass a tap into the holes in the

cylinder block.

X = MAXIMUM reusable length

8HX - 8HW

The cylinder head gasket is dry-fitted.

NOTE : Retightening of the cylinder head

after a completed repair is prohibited.

X = 149 mm

B1DP1CLC

44

ENGINE SPECIFICATIONS

Engines : 8HY - 8HV

Engine identification

"a" Engine legislation type.

"b" Component reference.

"c" Factory serial no.

B1CP0BKD

45

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Crankshaft

8HY-8HV

Engines

Bearing cap fixing screw

Tightening

3 ± 0.3

Angular tightening

14 0° ± 1°.4 '

Crankshaft pullet hub

Tightening

3 ± 0.3

Angular tightening

180° ± 5°

Cylinder block

Oil sump

1 ± 0.1

4 ± 0.4

Timing belt tensioner roller

Timing belt guide roller

Timing belt guide roller support

2.5 ± 0.2

Cylinder head

1 ± 0.1

Camshaft bearing cap cover

Inlet manifold

Exhaust manifold

2.5 ± 0.2

Cylinder head cover

Bolts (M6) to 1 ± 0.2

Camshaft pinion

4.3 ± 0.4

5 ± 0.5

Fuel high pressure pump pinion

46

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)

Flywheel - Clutch

Engines

8HY-8HV

1.7 ± 0.2

Flywheel

Clutch mechanism

2 ± 0.2

Lubrication circuit

0.9 ± 0.1

Oil pump assembly

Oil/coolant heat exchanger

Turbocharger lubrication pipe

1 ± 0.1

2.2 ± 0.2

Injection circuit

Injector fixing flange nut

Tightening

0.4 ± 0.1

65° ± 5°

Angular tightening

Unions on fuel high pressure common injection rail

Fuel high pressure pump

2.3 ± 0.2

Union on diesel injector

Fuel high pressure pump pinion

Union on fuel high pressure pump

5 ± 0.5

2.3 ± 0.2

Cooling circuit

1 ± 0.2±

Coolant pump

47

CYLINDER HEAD

Engines : 8HY - 8HV

Identification of cylinder head gasket

Piston

standproud

(mm)

Thicknesses

(mm)

No. of notches

at d

No. of notches

at e

Engine types

8HY-8HV

Supplier

ELRING

Type of gasket : Metallic

multilayer

0.675 to 0.725

0.726 to 0.775

0.776 to 0.825

0.826 to 0.875

0.876 to 0.983

1.25

1.30

1.35

1.40

1.45

1

2

3

4

5

"d" Thickness reference.

"e" Engine reference

2

B1DP1CKD

48

CYLINDER HEAD

Engines : 8HY - 8HV

Cylinder head tightening (m.daN)

Cylinder head bolts

8HY - 8HV

Pre-tightening

Tightening

: 2 ± 0.2

: 4 ± 0.5

Angular tightening : 230 ° ± 5°

(In the order 1 to 10)

NOTE :

- The bolts should have been

thoroughly cleaned and dried

with a dry metal brush.

- Oil the threads and under the

heads of the bolts. (Use engine

oil or Molykote G Rapid Plus).

B1DP1DBC

- Pass a tap into the holes in the

cylinder block.

X = MAXIMUM reusable length

8HY - 8HV

The cylinder head gasket is dry-fitted.

NOTE : Retightening of the cylinder head

after a completed repair is prohibited.

X = 149 mm

B1DP1CLC

49

CAMSHAFT

Engines : 8HY - 8HV

Camshaft identification

(1) - Inlet camshaft.

(2) - Exhaust camshaft.

"f" : Marking zone.

B1EP18AD

50

BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE

Tools

^{4122-T (C.TRONIC.105.5)}!

! 4099-T (C.TRONIC.105)

B1EP135D

51

AUXILIARY EQUIPMENT DRIVE BELT

Petrol

Diesel

DV

TU

3

1

5

4

JP

JP4TD

TED4

8HW

Engine type

C3

HFX

X

KFV

X

NFU

X

8HX

X

8HV

X

8HYX

X

See

pages

:

53

52

AUXILIARY EQUIPMENT DRIVE BELT

Engines : HFX - KFV - NFU

Tools.

[1] Pliers for removing plastic pegs

[2] Belt tension measuring instrument

: 7504-T.

: 4122-T.

Vehicle without air conditioning.

Remove.

Refit.

Refit the belt.

Slacken:

Respect the following sequence:

- Crankshaft pinion.

- Alternator pulley.

Place tool [2] on the belt.

Tighten screw (1) to achieve a tension of:

55 ± 3 unités SEEM.

Tighten:

- Screw (2).

- Screw (3).

- Tensioning screw (1).

Push the alternator back towards the engine.

Remove the belt.

- Screw (3).

- Screw (2).

Remove tool [2] and complete the refitting.

B1BP2LSC B1BP2LTC

53

AUXILIARY EQUIPMENT DRIVE BELT

Engines : HFX - KFV - NFU

Vehicle with air conditioning.

Remove

Slacken:

- Screws (6), (4) and (5).

- Fully detension the belt by acting on the tensioner roller.

- Remove the accessories drive belt.

Refit.

Respect the following sequence:

- Crankshaft pinion.

- Aircon compressor pulley.

- Guide roller.

- Alternator pulley.

- Tensioner roller.

Place tool [2] on the belt.

- Tighten screw (5) to achieve a belt tension of:

120 ± 3 SEEM units.

- Tighten screws (4) and (6).

- Remove tool [2].

- Complete the refitting.

B1BP10VC B1BP10XC

54

AUXILIARY EQUIPMENT DRIVE BELT

With compressor and alternator

Engines : 8HX - 8HW

Tools

[1] Pliers for removing plastic pegs

[2] Tensioner roller compression lever

[3] Tensioner roller setting peg Ø4 mm

: 7504-T.

: (-).0194.E.

: (-).0194.F.

Removing.

Disconnect the battery negative cable.

Raise and support the vehicle, wheels hanging.

Remove the front RH wheel.

Move aside the splash-shield, using tool [1].

IMPERATIVE : In the case of belt re-use, mark the direc-

tion of rotation of the belt. If the index on the tensioner

roller is outside the marks, change the auxiliary equipment

drive belt.

Remove :

The alternator (1).

The aircon compressor (2).

Detension the auxiliary belt tensioner roller, using tool [2].

Position the peg [3]. Remove the auxiliary drive belt.

B1BP2MJD

B1BP2MKC

55

AUXILIARY EQUIPMENT DRIVE BELT

Engines : 8HX - 8HW

Markings on the dynamic tensioner roller.

"a"

"b"

Position of «maximum wear» of the auxiliary drive belt.

Normal position.

Refitting

NOTE : Check that the tensioner roller moves freely (no tight spot). If this is not the

case, replace the tensioner roller.

Respect the direction of fitting of the drive belt.

Complete the setting of the belt, of both sides, by means of the tensioner roller.

Make sure that the drive belt is correctly positioned in the «V» grooves of the various

pulleys.

Move the tool [2] on the tensioner roller to remove the peg [3].

B1EP18UD

56

AUXILIARY EQUIPMENT DRIVE BELT

Engines : 8HY - 8HV

Tools.

[1a] Dynamic tensioner roller lever

[1b] Lever extension

[2] Accessories belt roller locking peg Ø 4 mm

: (-).0194-E1.

: (-).0194-E2.

: (-).0194-F

Removing

Pivot the tensioner roller support (1) (clockwise), using tools [1a] and [1b] at «a».

Remove the belt.

Immobilise the support (1) of the tensioner roller, using tool [2].

Remove the auxiliary drive belt (2).

IMPERATIVE : Ensure that the tensioner rollers turn freely (no play, no tight spot).

Refitting

Reposer la courroie.

Move the tool [1] on the tensioner roller to remove the peg [2].

ESSENTIAL: Make sure that the belt is correctly positioned in the various pulley

grooves.

B1BP2MYD B1BP2MZC

57

CHECKING AND SETTING THE VALVE TIMING

Petrol

TU

Diesel

DV

1

3

5

4

JP

JP4TD

TED4

8HW

Engine type

C3

HFX

X

KFV

X

NFU

X

8HX

X

8HV

X

8HY

X

See pages :

59 to 68

69 to76

77 to 85

58

CHECKING AND SETTING THE VALVE TIMING

Engines : HFX - KFV - NFU

Tools.

[1] Engine flywheel peg

[2] Camshaft pulley peg

[3a] Camshaft peg

[3b] Camshaft peg

[4] Dynamic tensioner roller pin

[5] Belt retaining pin

: 4507-T.A

: 4507-T.B

: 4533-TA.C1

: 4533-TA.C2

: 4200-T.H

: 4533-T.AD

: 7504-T.

[6] Pliers for removing plastic pins

Checking the valve timing.

Engines HFX - KFV - NFU

Raise and support the front RH side of the vehicle.

Disconnect the battery positive terminal.

Engage 5th gear.

Remove the oil filter (1).

HFX – KFV engine

Remove :

The timing top casing (2).

Turn the wheel to rotate the engine (normal direction of rotation).

Peg the camshaft pulley, using tool [2].

B1BP2M7C B1BP2M8C

B1BP2M9C

59

CHECKING AND SETTING THE VALVE TIMING

Engine : NFU

Checking the timing (continued)

Engine: NFU

Place a jack under the engine, peg the engine.

Remove:

- The engine support (4) complete.

- The timing casing (3).

- The sparking plugs (eases engine rotation).

Turn the wheel to rotate the engine (normal direction of rotation).

Position the pegs [3a] and [3b].

Peg the flywheel, using tool [1].

If the setting is not correct, recommence the operation.

Remove the tools [1], [2], [3a] and [3b].

Complete the refitting.

B1BP2MAC B1EP18MC

B1BP2MBC

60

CHECKING AND SETTING THE VALVE TIMING

Engines : HFX - KFV

Setting the timing

Preliminary operation.

Lift and support the vehicle, wheels hanging.

Disconnect the battery.

Remove:

- The front RH wheel.

- The splash-shield, using tool [6]

- The accessories belt (See corresponding operation).

- The crankshaft pulley.

- The oil filter.

Place a jack under the engine, peg the engine.

Removing.

HFX – KFV engine

Turn the engine by means of screw (1). (normal direction of rotation).

Remove the timing casings.

Peg the camshaft pinion, using tool [2].

Peg the flywheel, using tool [1].

Remove:

- The fixing screws (2).

- The upper engine support (3).

B1BP2MCC B1BP2M9C

B1BP2MBC B1BP2MDC

61

CHECKING AND SETTING THE VALVE TIMING

Engines : HFX - KFV

Setting the timing (continued)

HFX – KFV engines

Slacken the screws (4) without removing them.

Remove the bottom engine support assembly (5), and the fixing screws (4).

Slacken the nut (6).

Completely detension the belt by acting on the tensioner roller (7).

Remove the timing belt.

IMPERATIVE : Check that the tensioner roller turns freely (no tight spot).

B1BP2MEC B1EP18NC

62

CHECKING AND SETTING THE VALVE TIMING

Engine : NFU

NFU engine.

Setting the timing (continued)

Remove:

The bottom plastic casing.

The engine support (9).

The middle support.

The timing cover (8).

Peg the flywheel, using tool [1].

Position the tools [3a] and [3b].

B1BP2MFC B1BP2MBC

B1EP18MC

63

CHECKING AND SETTING THE VALVE TIMING

Engine : NFU

Setting the timing (continued)

NFU Engine

Slacken the tensioer roller.

Turn the tensioner roller so as to be able to position the tool [4], with the aid of an Allen key placed at «a».

Turn the tensioner roller towards the right to bring it to the index «c» in position «b».

Peg the tensioner roller in this position in order to slacken the timing belt to the maximum.

IMPERATIVE : Never make the dynamic tensioner roller turn by a complete rotation.

Remove the timing belt (8).

Check that the rollers (9) and (10) turn freely (no tight spot).

B1EP18PC B1EP18QC

64

CHECKING AND SETTING THE VALVE TIMING

Engines : HFX - KFV

Setting the timing (continued)

HFX-KFV Engines

Refit.

WARNING: Respect the direction of fitting of the belt: (the arrows «d» indicate the direction of rotation of

the crankshaft).

Refit the timing belt.

Position the timing belt, belt «e» well tensioned, in the following order:

Crankshaft pinion, hold the belt using tool [5].

Camshaft pulley.

Coolant pump pulley.

Tensioner roller.

Remove the pegs [1] and [2].

B1EP18QC

65

CHECKING AND SETTING THE VALVE TIMING

Engines : KFX - KFV - NFU

Setting the timing (continued)

HFX-KFV engines

Refitting.

NOTE : Check that the pegs [1] and [2] are in place.

WARNING: Respect the direction of fitting of the timing belt, the arrows «d» indicate the direction of rotation

of the crankshaft.

Refit the timing belt.

Position the timing belt, belt «e» well tensioned, in the following order:

Crankshaft pinion, hold the belt using tool [5].

- Camshaft pulley.

- Coolant pump pulley.

- Tensioner roller.

Remove the tools [1], [2].

NFU engine.

Fit the timing belt in position in the following order:

- Inlet camshaft pulley.

- Exhaust camshaft pulley.

- Guide roller.

- Crankshaft pulley.

Position tool [5].

- Coolant pump pulley.

- Dynamic tensioner roller.

Remove the tools [1], [3] and [5].

B1EP18RC

66

CHECKING AND SETTING THE VALVE TIMING

Engine : NFU

Timing belt overtensioned:

A : Engines HFX – KFV.

B : Engine NFU

Turn the tensioner roller (7) with the aid of a hexagonal spanner at «a».

Bring the index «c» to position «f», to tension the belt to the maximum of the

interval indicated.

Hold the tensioner roller (7), using tool [4].

Tighten the fixing nut of the tensioner roller, tightening to 1 ± 0,1 m.daN.

Turn the crankshaft by 4 rotations (normal direction of rotation).

IMPERATIVE : Never make the crankshaft rotate backwards.

Make sure that the timing is correctly set by refitting the tools [1], [2] and [3].

Remove the tools [1], [2] and [3].

B1EP18SD

67

CHECKING AND SETTING THE VALVE TIMING

Engines : HFX - KFV - NFU

Adjusting the fitting tension of the timing belt

A : Engines HFX – KFV.

B : Engine NFU.

Slacken the nut while maintaining the position of the tensioner roller, with the aid of

a hexagonal spanner at «a».

Next bring the index «c» to its adjusting position «a».

The index «c» should not go beyond the notch «g».

WARNING: The index «c» must not go beyond the notch «g». If it should do this, restart

the timing belt tensioning operation.

Hold the tensioner roller (7) in this position, with the aid of a hexagonal spanner.

Tighten the tensioner roller fixing nut to :

2 ± 0.2 m.daN.

2.2 ± 0.2 m.daN.

(HFX - KFV engines)

(NFU engines)

IMPERATIVE : The tensioner roller must not rotate during the tightening of its

fixing. If it does, restart the timing belt tensioning operation.

Complete the refitting.

68

B1EP18TD

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HX - 8HW

Tools.

[1] Pliers for removing plastic pegs

[2] Lever for detensioning the dynamic tensioner roller

[3] Engine flywheel setting peg

[4] Camshaft setting peg

: 7504-T.

: (-).0194.E

:.(-).0194.C

: (-).0194.B.

: (-).0194.A.

[5] Crankshaft and high pressure pump setting peg

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).

Check ing 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].

B1BP2LXC

69

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HX - 8HW

Check ing the setting (continued)

Remove:

- the accessories drive belt.

- the accessories drive pulley.

- the lower timing cover (3).

IMPERATIVE : The magnetic track should show no signs of

damage and should not be approached by any other source of

magnetism.

Reposition the screw (2).

Remove tool [3].

Rotate the engine by means of the crankshaft pinion screw (2)

(clockwise), to bring it to the pegging position.

Position the tool [4].

Peg the crankshaft pinion (1), using tool [5].

Peg the high pressure pump pinion, using tool [5].

NOTE : Index «a» of the roller tensioner must be centred within

the area «b».

Check the correct positioning of index «a».

Remove tools [4] and [5].

Rotate the engine ten times.

Fit the tools [4] and [5].

If pegging is not possible, carry out the operation to remove/refit the

timing belt. (See corresponding operation).

B1JP03SC B1EP18DC

B1EP18EC B1EP18FC

70

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HX - 8HW

Setting the timing.

Remove the upper timing cover (1).

Rotate the engine by means of the crankshaft screw (2).

NOTE : The pegging hole is located under the crankshaft bearing cap cover.

Peg the engine flywheel, using tool [3].

Remove the lower timing cover (3).

Uncouple the exhaust line from the manifold.

IMPERATIVE : Uncouple the exhaust line in order to avoid damaging the front flexible pipe. Twisting,

pulling and bending the front flexible pipe reduces its life.

Remove:

- The engine speed sensor (6).

- The belt retaining stop (5).

- The screw (2).

- The crankshaft pinion (4) (with its magnetic track «a»).

IMPERATIVE : The magnetic track should show no signs of damage and should not be approached

by any other source of magnetism. Should this not be adhered to, it is essential to replace the

crankshaft pinion.

Refit the screw (2).

B1BP2LXC B1EP18GC

71

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HX - 8HW

Setting the timing (continued).

Remove the tool [3].

Rotate the engine by means of the crankshaft pinion screw (2)

(clockwise), to bring it to the pegging position.

Peg the camshaft pulley, using tool [4].

Peg :

- The crankshaft pinion (6), using tool [5].

- The high pressure pump pinion, using tool [5].

Support the engine with the aid of a roller jack equipped with a chock.

Remove:

- The RH engine support (7).

- The intermediate engine support (right hand side) (8).

B1JP03SC B1EP18DC

B1EP195C B1BP2LYC

72

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HX - 8HW

Setting the timing (continued).

Hold the tensioner roller, using a hexagonal spanner at «b».

Slacken the screw (9).

Remove the timing belt (10).

Refitting.

IMPERATIVE : Check that both the tensioner roller and the fixed roller turn freely

(no tight spots). If this is not the case, replace the rollers.

Fitting of the pulleys.

- Camshaft pulley

- Fuel high pressure pump pulley

Tighten to 4.3 ± 0.4 m.daN.

Tighten to 5 ± 0.5 m.daN.

The crankshaft pinion is located without a screw at the end of the crankshaft.

Fitting of the rollers.

IMPERATIVE : Check that the tensioner roller turns freely (no tight spot).

Otherwise, replace the rollers.

- Guide roller

- Tensioner roller

Tighten to 4.5 ± 0.4 m.daN

Pre-tighten to 0.1 m.daN

Check the condition of the seals at the camshaft and at the crankshaft pinion..

B1EP18HC

73

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HX - 8HW

Setting the timing (continued).

NOTE : Screw (9) slackened.

Position the timing belt (10) observing the following sequence:

Crankshaft pinion (4).

Guide roller (12).

Camshaft pulley (11), (check that the belt is held correctly against the roller).

Coolant pump pinion (13).

Fuel high pressure pump pulley (15).

Tensioner roller (14).

B1EP18JD

74

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HX - 8HW

Setting the timing (continued).

Turn the tensioner roller to the right to bring the index «c» to position «d», using a

hexagonal spanner.

Tighten the screw (9) of the tensioner roller, tighten to 3 ± 0.3 m.daN.

Remove the tools [4] and [5].

Rotate the engine ten times (check that the timing pinion is correctly up against the

crankshaft)..

Check:

The pegging of the camshaft.

The crankshaft pinion.

The fuel high pressure pump pinion (15).

The correct positioning of the index of the dynamic tensioner.

If these are not correct, repeat the operation to position the timing belt.

Refit:

The engine speed sensor (6).

The belt retaining stop (5), tighten to 0,7 m.daN.

B1EP18KC

75

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HX - 8HW

Setting the timing (continued).

Refit:

The intermediate RH engine support, tighten the screws (16) to 5,5 ± 0,5 m.daN.

The RH engine support, tighten the screws (17) to 4,5 ± 0,4 m.daN.

The bottom timing cover (3).

Immobilise the engine flywheel, using tool [3].

Remove the screw (2).

Refit the accessories drive pulley and tighten to:

Pre-tighten to

Angular tighten to

Remove tool [3].

Refit:

: 3 ± 0,3 m.daN.

: 180° ± 1°,8’

The top cover (1).

The accessories belt (see corresponding operation).

The exhaust line (see corresponding operation).

The front RH splash-shield.

The front RH wheel.

B1EP18LC B1BP2LZC

76

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

Tools.

[1] Engine flywheel peg Ø 12 mm

[2] Camshaft pulley peg Ø 8 mm

[3] Crankshaft pulley peg Ø 5 mm

: (-).0194-C.

: (-).0194-B.

: (-).0194-A.

Preliminary operations.

Remove:

- The front RH wheel.

- The front RH splash-shield.

- The accessories belt (see corresponding operation).

Uncouple:

- The supply unions (1).

- The air/air heat exchanger inlet/outlet pipes (3).

- The exhaust line (at the flexible pipe).

Disconnect the connector (2).

Support the engine by means of a roller jack equipped with a chock.

Remove the engine supports (4) and (5).

B1BP2N0C

77

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

Checks.

Rotate the engine to engage it (normal direction of rotation).

Immobilise the engine flywheel at «a», using tool [1].

Move aside the harness (6).

Remove:

- The engine support (7).

- The screw (8).

- The pulley (9).

- The lower timing cover (10).

- The upper timing cover (11).

- The tool [1].

B1BP2N1C B1BP2N2C

78

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

Checks (continued).

Refit the screw (8).

Rotate the crankshaft six times (clockwise).

IMPERATIVE : Never rotate the engine backwards.

Peg :

- The camshaft, using tool [2]. (Oil the pegs.)

- The fuel high pressure pump pulley (14), using tool [3] at «c».

WARNING: The magnetic track should show no signs of damage and should not

be approached by any source of magnetism.

Peg the crankshaft at «b», using tool [3].

IMPERATIVE: Should it be impossible to peg the camshaft, check that the

offset between the hole in the camshaft pinion and the pegging hole is not

greater than 1 mm.

Otherwise repeat the operation to position the timing belt. (See corresponding

operation).

B1EP18YD

79

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

Checks (continued).

NOTE : The index «e» of the dynamic tensioner roller should be centred within the area «d».

Check the correct positioning of the index «e».

If it is not correct, repeat the operation to tension the timing belt (see corresponding operation).

Refitting.

Refit the tool [1] at «a».

Remove the screw (8).

Refit:

- The upper timing cover (11).

- The lower timing cover (10).

- The accessories drive pulley (9).

- The screw (8).

Tightening torque:

- Screw (8) :

Pre-tighten to

Angular tightening

Remove the tool [1].

: 3 ± 0,3 m.daN.

: 180° ± 5°.

B1EP18ZC

80

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

Checks (continued).

Refit :

- The engine support (7), tighten to 1,5 ± 0.4 m.daN.

- The engine support (4), tighten to 6,1 ± 0,. m.daN.

- The engine support (5), tighten to 6 ± 0.6 m.daN.

- The electrical harness (6).

Couple:

- The exhaust line, tighten the collar to : 2.5 ± 0.3 m daN

- The fuel supply unions (1).

- The air/air heat exchanger inlet/outlet pipes (3).

Connect the connector (2).

Refit :

- The accessories belt (see corresponding operation).

- The front RH splash-shield (see corresponding operation).

- The front RH road wheel, tighten to 9 ± 1 m.daN.

Reconnect the battery.

B1BP2N0C

81

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

Setting the timing.

Perform the preliminary operations for checking the timing up to removing tool [1] at «a» for

immobiling the engine flywheel.

Refit screw (8).

Rotate the crankshaft to bring the camshaft towards its pegging point.

Peg the camshaft, using tool [2]. (Oil the pegs).

WARNING: Do not press or damage the track which is the target for the engine speed sensor (14).

Peg the crankshaft at «b», using tool [3].

Remove:

- The timing protector (13).

- The engine speed sensor (14).

Slacken the screw (12) of the tensioner roller, keeping it slack with the aid of a hexagonal spanner

at «c».

Detension the belt by pivoting the tensioner roller (clockwise).

Remove the timing belt, commencing with the coolant pump pinion.

Peg the pulley (15), using a 5 mm diameter peg at «d».

B1EP18VD

82

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

Setting the timing (continued).

Checking the setting.

IMPERATIVE : Just prior to refitting, carry out the following tests:

Check that:

- the rollers and the coolant pump operate freely

(no play and no tight spot).

- there are no traces of oil

(from the crankshaft and camshaft sealing rings).

- there is no leak of coolant fluid (from the coolant pump).

- the target track of the engine speed sensor (14) is not damaged or scratched.

(If necessary replace the defective components).

Refitting

Fit the timing belt on the crankshaft pinion.

Position the belt on the guide roller, with the belt well tensioned.

Refit:

- The timing protector (13).

- The sensor (14).

B1EP18WD

83

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

Setting the timing (continued).

Checks (continued).

Reposition the timing belt, belt at «e» well tensioned, in the following order:

- Guide roller (17).

- Camshaft pulley (16).

- Fuel high pressure pump pulley (15).

- Coolant pump pinion (18).

- Tensioner roller (19).

Remove the 5 mm diameter peg at «d».

Adjusting the fitting tension of the belt.

Action the tensioner roller (19) to align the marks «f» and «g» , avoiding detensioning the timing belt,

with the aid of a male hexagonal spanner, at «c».

If this is not successful, repeat the operation to tension the belt.

Hold the tensioner roller in position (19).

Tighten the tensioner roller, tightening to 3,7 ± 0,3 m.daN.

Check the position of the tensioner roller (the alignment of the marks «f» and «g» should be correct).

Remove tools [2] and [3].

Turn the crankshaft six rotations (clockwise).

B1EP18XC

84

CHECKING AND SETTING THE VALVE TIMING

Engines : 8HY - 8HV

Adjusting the timing belt tension (continued).

IMPERATIVE : Never rotate the engine backwards.

WARNING : Do not touch or damage the track of the target of the engine speed sensor (14).

Peg the crankshaft, using tool [3].

Check the position of the tensioner roller (the alignment of the marks «f» and «g» should

be correct).

If this is not the case, repeat the operation to tension the belt.

Peg the camshaft pulley, using tool [2].

IMPERATIVE : Should it be impossible to peg the camshaft, check that the offset bet-

ween the camshaft hole and the pegging hole is not more than 1 mm. If the offset is

too great, repeat the operation.

Remove the pegs [2] and [3].

Refit tool [1] at «a».

Remove the screw (8).

Complete the refitting.

B1EP18XC

85

SPECIAL FEATURES : POWER UNIT SUSPENSION

Engines : HFX - KFV - NFU

Tightening torques (m.daN)

RH engine support.

(1) : 4.5 ± 0.4

(2) : 6.1 ± 0.6

(3) : 4.5 ± 0.4

Torque reaction rod.

(4) : 6 ± 0.6

(5) : 6 ± 0.6

LH engine support.

(6) : 3 ± 0.3

(7) : 6 ± 0.6

(8) : 5.5 ± 0.5

B1BP2NEP

86

SPECIAL FEATURES : POWER UNIT SUSPENSION

Engines : 8HX - 8HW

Tightening torques (m.daN)

RH engine support.

(1) : 4,5 ± 0,4

(2) : 3 ± 0,3

Torque reaction rod.

(3) : 6 ± 0.6

(4) : 6 ± 0.6

LH engine support.

(5) : 5.4 ± 0.5

(6) : 6 ± 0.6

(7) : 5.5 ± 0.5

B1BP2LJP

87

SPECIAL FEATURES : POWER UNIT SUSPENSION

Engines : 8HY - 8HV

Tightening torques m.daN.

Upper RH engine support.

(1) Screws : 6 ± 0.6

(2) Screws : 6 ± 0.6

Lower RH engine support.

(3) Screws : 5.7 ± 0.9

Torque reaction rod.

(4) Screws : 6 ± 0.6

(5) Screws : 6 ± 0.6

Lower LH engine support.

(6) Screws : 5.4 ± 0.5

Upper LH engine support.

(7) Screws : 6 ± 0.6

(8) Screws : 5.5 ± 0.5

B1BP2MNP

88

EXHAUST SPECIFICATIONS

Engines : HFX - KFV - NFU

B1JP03TD

(3)

(1)

(2)

(4)

(5)

Downstream oxygen

Upstream oxygen

sensor

Catalytic converter

sensor

Front silencer

Rear silencer

Engine types

Tighten to (m.daN)

TR PSA K179

Tighten to (m.daN)

HFX

KFV

NFU

PSA 4173

PSA 4174

PSA 4176

4,7 ± 0.5

TR PSA K208

TR PSA K181

4.7 ± 0.5

PSA 4175

89

EXHAUST SPECIFICATIONS

Engines : 8HX - 8HW

Repair

Respect the precautions to be taken when operating on a

vehicle.

The flexible pipe must not come into contact with corrosi-

ve products.

Do not distort the flexible pipe by more than 20° angular

(X), 20 mm axial, 25 mm shear (Y) (flexible pipe not fitted).

Do not distort the flexible pipe by more than 3° angular (X),

0 mm axial, 3 mm shear (Y) (flexible pipe in place).

WARNING : Non-respect for these precautions will result

in a reduction in the lifetime of the flexible pipe. It is thus

essential to disconnect or remove the exhaust line in any

operation necessitating the lifting of the power unit.

B1JP03PD

B1JP02JC

(1)

(2)

(3)

(4)

Catalytic converter

Clip

Intermediate pipe

Rear silencer

Engine types

Tighten to 2,5 ± 0,3

Tighten to 1,5 ± 0,1

PSA 4177

8HX - 8HW

TR PSA K213

90

EXHAUST SPECIFICATIONS

Engines : 8HY – 8HV

«a» : Cutting zone (Marked by burrs).

Flexible pipe

Respect the precautions to be taken when operating on a

vehicle.

The flexible pipe must not come into contact with corrosive

products.

Do not distort the flexible pipe by more than 20° angular (X),

20 mm axial, 25 mm shear (Y) (flexible pipe not fitted).

Do not distort the flexible pipe by more than 3° angular (X),

0 mm axial, 3 mm shear (Y) (flexible pipe in place).

WARNING : Non-respect for these precautions will result in

a reduction in the lifetime of the flexible pipe. It is thus

essential to disconnect or remove the exhaust line in any

operation necessitating the lifting of the power unit.

B1JP03ND

B1JP02JC

(1)

Catalytic converter

(3)

(4)

Clip

(2)

Rear silencer

Intermediate pipe

Engine types

8HY–8HV

Tighten to 2,5 ± 0,3

TR PSA K213

Tighten to 2,5 ± 0,3

PSA 4177-PSA 4179

91

COOLING SYSTEM SPECIFICATIONS

Engines : HFX - KFV - NFU

1.1i

1.4i

1.6i 16V

NFU

Engine type

Capacity

HFX

KFV

7

Radiator surface

Pressurisation

12 and 16 dm³

1,4 bars

Opening of thermostatic

regulator

89°C/101°C

Cooling fan

1st speed

2nd speed

Warning

100W (without aircon)

300W (with aircon)

118°C

Managed by the ECU

Post-cooling

92

COOLING SYSTEM SPECIFICATIONS

Engines : HFX - KFV - NFU

Manual gearbox.

(1) Venting chamber.

(2) Water pump.

(3) Heater matrix.

(4) Bleed screw, heater matrix

(5) Coolant outlet housing

(6) Bleed screw, coolant outlet housing.

(7) Calorstat.

(8) Cooling radiator.

Thermostat.

Colour of connector

Colour of seal

: Blue.

: Yellow.

Tightening torque

: 1.7 ± 0.2 m.daN.

B1GP09HP

93

COOLING SYSTEM SPECIFICATIONS

Engines : HFX – KFV – NFU

Automatic gearbox

(1) Venting chamber.

(2) Water pump.

(3) Heater matrix.

(4) Bleed screw, heater matrix

(5) Coolant outlet housing

(6) Bleed screw, coolant outlet housing.

(7) Calorstat.

(8) Cooling radiator.

(9) Heat exchanger (for automatic gearbox).

Thermostat.

Colour of connector

Colour of seal

: Blue.

: Yellow.

Tightening torque

: 1.7 ± 0.2 m.daN.

B1GP09JP

94

COOLING SYSTEM SPECIFICATIONS

Engines : 8HX - 8HW - 8HY - 8HV

1.4 HDi

1.4 HDi 16V

Engine type

Capacity

8HX

8HW

8HY

8HV

5.7 Litres

5.6 Litres

16 dm³

1.4 bar

Radiator surface

Pressurisation

Opening of thermostatic

regulator

83°C

1x300W

Cooling fan

1st speed

97°C

2nd speed

115°C

Air conditioning cut-off

Warning

118°C

105°C

6 minutes

Post-cooling

Thermostat : Tightening torque 1.7 ± 0.4 m.daN.

95

COOLING SYSTEM SPECIFICATIONS

Engines : 8HX - 8HW

(1) Bleed screw (with or without aircon)

B1GP09MP

96

COOLING SYSTEM SPECIFICATIONS

Engines : 8HY - 8HV

(1) Venting chamber.

(2) Bleed screw.

(3) Thermostat.

B1GP09QP

97

OIL FILTERS

Petrol

TU

1

3

5

JP4

JP

1.1i

1.4i

1.6i 16V

HFX

X

KFV

X

NFU

X

FILTRAUTO

Diesel

DV

4

TED4

1.4 HDi 16V

TD

1.4 HDi

8HX

X

8HW

X

8HV

X

8HY

X

MALHEX

98

CHECKING THE OIL PRESSURE

Petrol engines

1.1i

1.4i

1.6i 16V

NFU

Engine type

HFX

KFV

Temperature (°C)

Pressure (Bars)

90°C

3

Rpm

2000

Diesel engine

1.4 HDi

8HX - 8HW

1.4 HDi 16V

8HV - 8HY

Engine type

90°C

> 1.3

1000

Temperature (°C)

Pressure (Bars)

Rpm

Tools :

Pressure gauge

Flexible pipe

: 2279-T.Bis

Toolkit 4103-T.

Engine oil pressure take-off union (TU engine)

Oil pressure take-off union (DV engine)

: 7001-T

: 9780-80-T

NOTE : Tightening of the oil pressure switch 2 ± 0,2. (New seal).

IMPERATIVE : Respect the safety and cleanliness requirements.

99

VALVE CLEARANCES

POSSIBLE METHODS

On engines: 4 cylinders in line (1-3-4-2 )

The valve clearances should be checked with the engine cold.

Fully open (Exhaust)

Rocking

Exhaust

ꢀ Inlet

Valves fully

open

Adjust

0.20 mm ± 0.05

HFX - KFV

NFU

0.40 mm ± 0.05

Inlet

3

4

2

1

ꢀ

4

2

1

3

1

3

4

2

1 ꢀ

1

3

4

2

4 ꢀ

4

2

1

3

3 ꢀ

4 ꢀ

2 ꢀ

1 ꢀ

3 ꢀ

ꢀ

Exhaust

1 mm ± 0.05

8HX - 8HW - 8HY - 8HV

Hydraulic adjustment

Engines without hydraulic

adjustment : the clearance (J)

should be checked opposite

the cam.

B1DP13QC

100

FILLING AND BLEEDING THE COOLING CIRCUIT

Engines : 8HX - 8HW

Tools

[1] Filling cylinder

[2] Adaptor for filling cylinder

: 4520-T

: 4222-T.

ESSENTIAL : Respect the safety and cleanliness recommendations.

- The draining and refilling operations can be carried out by means of a WINN’S coolant replacement

apparatus or similar; it is essential to follow the instructions when using this apparatus.

Filling and bleeding

- Fit the cylinder adaptor [2] 4222-T and the filling cylinder [1] 4520 -T.

- 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 third cooling cycle (cooling fans have cut in and cut out).

- Stop the engine and allow it to cool down.

- Remove the filling cylinder [1] 4520 – T and the adaptor [2] 4222-T.

- Top up the system to the maximum mark, with the engine cold.

- Refit the cap.

B1GP00AC E5AP1GNC

101

Engine for Your Citroen C3 SUV First Generation (2002-2009)

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