Get Injection Guide for Citroen Xsara SUV Second Generation (1997-2006)

IDLING - ANTI-POLLUTION

SAXO - All Types

Idling speed

(± 50 rpm)

% Content

Emission

standard

Vehicles

Engine type

Make - Injection type

Man.

gbox

Auto. gbox :

N gear engaged

CO

CO2

1.1 i

1.4 i

HFX

KFW

NFT

NFX

L4

BOSCH M7.4.4.

SAGEM 2000

850

800

< 0.5

> 9

SAXO

1.6 i (100 hp)

1.6 i 16V

BOSCH M7.4.4.

M. MARELLI 48P2

125

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XSARA - All Types

IDLING - ANTI-POLLUTION

Idling speed

(± 50 rpm)

% Content

Emission

standard

Vehicles

Engine type

Make - Injection type

Man.

gbox

Auto. gbox :

N gear engaged

CO

CO2

1.4 i

KFW

NFU

RFN

RFS

NFV

6FZ

IFL5/L4

L4

SAGEM S2000

BOSCH M.7.4.4.

1.6i

XSARA 2

2.0 i

L4

MAGNETTI MARELLIMM 48.P2

M. MARELLI 1AP10

BOSCH M7.4.4.

850

< 0.5

> 9

2.0 i 16V

L3

1.6i (100 hp)

XSARA

L4

PICASSO

1.8i

L4

SAGEM - S2000

126

700

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IDLING - ANTI-POLLUTION

BERLINGO - All Types

Idling speed

(± 50 rpm)

% Content

Emission

standard

Vehicles

Engine type

Make - Injection type

Auto. gbox :

N gear engaged

CO

CO2

Man.

gbox

1.1 i

HDZ

HFX

KFW

KFX

NFU

LFX

L3 / W3

L4 / W4

L3

BOSCH MA3.1

BOSCH M 7.4.4.

SAGEM 2000

1.4 i

850

BERLINGO

> 9

< 0.5

SAGEM SL96 / BRC FLYING

INJECTION

Dual fuel

L4 /

W4 / IFL5

1.6i 16V

BOSCH M 7.4.4.

1.8 i

L3 / W3

M. MARELLI 1AP20

800

127

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PETROL INJECTION

SAXO - All Types

SAXO

1.6 i

(100 hp)

1.6 i

(100 hp)

1.1 i

1.4 i

Engine type

NFT

NFX

HFX

KFW

Emission standard

IFL5 / L4

L4

BOSCH

M.7.4.4.

M. MARELLI

48P2

Injection make

and type

SAGEM

S2000

BOSCH

M.7.4.4.

Fuel pressure (bars)

3

3.5

3

Overspeed cut-off (rpm)

5500

5700

6600

Injection cut-in during deceleration (rpm)

Injector resistive value (ohms)

14.5

Engine coolant temperature sensor

resistive value (ohms)

3800 at 10° C

2 500 at 20° C

800 at 50° C

230 at 90° C

Idling actuator or stepper

motor resistive value (ohms)

Idle actuator: 11

Air temperature sensor

resistive value (ohms)

3800 at 10° C

2 500 at 20° C

128

800 at 50° C

230 at 90° C

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PETROL INJECTION

XSARA 2 - All Types

XSARA 2

XSARA PICASSO

1.4 i

1.6 i 16 V

2.0 i 16 V

1.6 i

1.8 i 16 V

Engine type

KFW

NFU

RFN

RFS

NFV

6FZ

Emission standard

IFL5 / L4

IFL5 / L4 / K’

IFL5 / L4

L4

L3

SAGEM

S2000

BOSCH

M.7.4.4.

M. MARELLI

48P2

SAGEM

S2000

Injection make

and type

M. MARELLI

1AP10

BOSCH

M.7.4.4.

Fuel pressure (bars)

3

3.5

6300

1150

14.5

3.5

Overspeed cut-off (rpm)

Injection cut-in during deceleration (rpm)

6500

1300

12.2

14.5

12.2

16

14.5

Injector resistive value (ohms)

Engine coolant temperature sensor

resistive value (ohms)

3800 at 10° C

2 500 at 20° C

800 at 50° C

230 at 90° C

Idling actuator or stepper

motor resistive value (ohms)

Stepper motor : 53

Air temperature sensor

resistive value (ohms)

3800 at 10° C

2 500 at 20° C

129

800 at 50° C

230 at90° C

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BERLINGO - All Types

PETROL INJECTION

BERLINGO

1.1 i

1.4 i

1.4 i (Dual fuel)

KFX

1.6 i 16 V

1.8i

Engine type

HDZ

HFX

KFW

NFU

LFX

Emission standard

L3 / W3

L4 / W4

L4 /W4

L3

L4 / W4 / IFL5

L3 / W3

BOSCH

MA3.1

BOSCH

M7.4.4.

SAGEM

S2000

SAGEM

SL96

BRC FLYING

INJECTION

M. MARELLI

1AP20

Injection make

and type

Fuel pressure (bars)

/

3.5

/

3.5

3

Overspeed cut-off (rpm)

6510

6000

6440

6000

6400

1 500

except 1st

Injection cut-in during

deceleration (rpm)

/

1500

12

1500 to1800

12

/

1400

14.5

/

14.5

Injector resistive value (ohms)

Engine coolant temperature sensor

resistive value (ohms)

3800 at 10° C

2 500 at 20° C

Stepper motor : 53

2 500 at 20° C

130

800 at 50° C

230 at 90° C

Idling actuator or stepper

motor resistive value (ohms)

Air temperature sensor

resistive value (ohms)

3800 at 10° C

800 at 50° C

230 at 90° C

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ALL TYPES

EMISSION STANDARDS

APPLICATIONS

NOTES

STANDARD

PSA

CHARACTERISTICS

E.E.C

Engines

Vehicle

Applicable

A-S

RP

Private vehicles:

> 2 litres

Brussels directive 83/351

ꢀ except special derogations

for certain private vehicles

cyl. > 2 litres

ꢀ 06/89

ꢀ 06/92

ꢀ 12/92

• new cyl. < 2 litres

• existing cyl. < 2 litres

ECE

R 15.04

Petrol

Diesel

K

K’

15.04

Utility vehicles:

All Types

ꢀ 10/89

ꢀ Utility vehicle limits

= private vehicle limits

increased by 25 %

ꢀ For private vehicles

and utility vehicles

in major export

With oxygen sensor,

without catalytic converter

imminent

Private vehicles:

> 2 litres

Brussels directive 88/76

" Luxembourg Accords "

ECE

R 15.05 W vp 15.05

Petrol

• new models

• existing models

01/10/88 ꢀ ꢀ Replaced by 89/458

01/10/89 ꢀ + 91/441

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EMISSION STANDARDS

ALL TYPES

APPLICATIONS

NOTES

STANDARD

PSA

CHARACTERISTICS

E.E.C

Engines

Vehicle

Applicable

A-S

RP

Utility vehicles:

All Types

Brussels directives 88/76

and 88/436

• new models

• existing models

01/10/88 ꢀ

01/10/89 ꢀ

ꢀ 10/94

ꢀ Utility vehicle

limits = private vehicle

limits of Brussels

directive 88/436

ECE

R 15.05

Petrol

Diesel

15.05

W vu

7 classes of limits

byvehicle weight

Private vehicles:

Current

ꢀ Adoption of U.S. standard

With oxygen sensor

and catalytic converter

for petrol vehicles

Petrol

Diesel

• certain non-EEC

European countries

• certain Export countries

US 83

Z

US 83

132

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EMISSION STANDARDS

ALL TYPES

APPLICATIONS

NOTES

STANDARD

PSA

CHARACTERISTICS

E.E.C

US 87

US 93

Engines

Vehicle

Applicable

A-S

RP

Private vehicles:

Current

ꢀ Adoption of U.S. standard

With catalytic

• certain non-EEC

European countries

• certain Export countries

converter and EGR

Diesel

Y

US 87

Petrol

Diesel

Private vehicles:

Current

ꢀ Adoption of U.S. standard

Y2 US 93

• certain Export countries

Utility vehicles:

ꢀ Adoption of U.S. standard

Petrol

Diesel

• certain non-EEC

European countries

• certain Export countries

standard for light utility vehicles

US 84

LDT

X1

X2

US 84

US 87

Utility vehicles:

Current

133

ꢀ Adoption of U.S. standard

standard for light utility vehicles

• certain non-EEC

European countries

• certain Export countries

Petrol

Diesel

US 87

LDT

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ALL TYPES

EMISSION STANDARDS

APPLICATIONS

NOTES

STANDARD

PSA

CHARACTERISTICS

E.E.C

Engines

Vehicle

Applicable

A-S

RP

Private vehicles:

Current

ꢀ Adoption of U.S. standard

• certain non-EEC

European countries

• certain Export countries

standard for light utility vehicles

US 90

LDT

Petrol

Diesel

US 90

X3

Private vehicles:

< 1.4 litres

Brussels directive 89/458

EURO 1

07/92 ꢀ

Petrol

Diesel

CEE

19.5

• new models

• existing models

ꢀ 01/07/93 ꢀ Possible alternative to

ꢀ 31/12/94 emission standard L

from 1992 to 1994

L1

(EURO

93)

Private vehicles:

All Types

With oxygen sensor and

catalytic converter for

petrol vehicles.

EURO 1

• new models

• existing models

• new models

• existing models

07/92 ꢀ

01/93 ꢀ

ꢀ 01/96

ꢀ 01/97

EU Brussels Directive 93/59

(91/441)

Petrol

Diesel

CEE

19.5

L

(EURO

93)

With catalytic converter

and EGR for diesel

vehicles.

134

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ALL TYPES

EMISSION STANDARDS

APPLICATIONS

NOTES

STANDARD

PSA

CHARACTERISTICS

E.E.C

Engines

Vehicle

Applicable

A-S

RP

Utility vehicles:

< 3.5 tonnes

• new models

• existing models

Class 1 :

01/10/93 ꢀ

01/10/9 ꢀ

Brussels Directive 93/59

EURO 1

With oxygen sensor and

catalytic converter for

petrol vehicles

ꢀ 3 classes depending on

vehicle weight :

Class 1 < 1250 kg

Class 2 : 1250/1700 kg

Class 3 > 1700 kg

Petrol

Diesel

CEE

W2

• new models

• existing models

Class 2/3 :

ꢀ 01/97

ꢀ 10/97

(EURO

93)

• new models

• existing models

ꢀ 01/98

ꢀ 10/98

Private vehicles:

< 6 seats and

< 2.5 tonnes

With oxygen sensor and

reinforced catalytic converter

for petrol vehicles. With

catalytic converter and

EGR for diesel vehicles.

EURO 2

Brussels Directive 94/12

CEE

95

Petrol

Diesel

L3

(EURO

96)

ꢀ EURO 93 standard made

stricter

• new models

• existing models

01/96 ꢀ

01/97 ꢀ

135

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ALL TYPES

EMISSION STANDARDS

APPLICATIONS

NOTES

STANDARD

PSA

CHARACTERISTICS

E.E.C

Engines

Vehicle

Applicable

A-S

RP

Utility vehicles:

< 3.5 tonnes

Class 1 :

Brussels Directive 96/69

With oxygen sensor and

reinforced catalytic converter

for petrol vehicles. With

catalytic converter and

EGR for diesel vehicles.

EURO 2

ꢀ 3 classes depending on

vehicle weight :

Class 1 < 1250 kg

Class 2 : 1250/1700 kg

Class 3 : 1700 kg

Petrol

Diesel

Gas

• new models

• existing models

Class 2/3 :

01/97 ꢀ

10/97 ꢀ

CEE

95

W3

(EURO

96)

• new models

• existing models

01/98 ꢀ

10/98 ꢀ

Private vehicles:

All Types

With 2 oxygen sensors

and catalytic converter for

petrol vehicles.

Brussels Directive 98/69

• new models

• existing models

01/2000 ꢀ

01/2001 ꢀ

EURO 3

Petrol

Diesel

Gas

CEE

2000

ꢀ EURO 2 standard (L3)

made stricter

ꢀ Fiscal incentives

L4

With catalytic converter

and EGR for diesel

vehicles.With EOBD

on-board diagnosis.

(EURO

2000)

136

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ALL TYPES

EMISSION STANDARDS

APPLICATIONS

NOTES

STANDARD

PSA

CHARACTERISTICS

E.E.C

Engines

Vehicle

Applicable

A-S

RP

Utility vehicles:

< 3.5 tonnes

Brussels Directive 98/69

ꢀ EURO 2 standard (L3)

made stricter

With 2 oxygen sensors

and catalytic converter for

petrol vehicles.

Class 1 :

ꢀ 01/2000

ꢀ 01/2001

ꢀ Fiscal incentives

ꢀ 3 classes depending on

vehicle weight :

With catalytic converter

and EGR for diesel

vehicles.

EURO 3

Petrol

Diesel

Gas

• new models

• existing models

Class 2/3 :

W3

(EURO

2000)

ꢀ 01/2001

ꢀ 01/2002

Class 1 < 1305 kg

• nouveaux modèles

• existing models

Class 2 : 1305/1760 kg

Class 3 : 1760 kg

With EOBD on-board

diagnosis.

Brussels Directive 98/69

Private vehicles:

All Types

With 2 oxygen sensors

and catalytic converter for

petrol vehicles. With

ꢀ EURO 3 standard (L4)

made stricter

EURO 4

• new models

• existing models

01/96 ꢀ

01/97 ꢀ

IF / L5

Petrol

EOBD on-board diagnosis.

ꢀ Fiscal incentives

137

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EMISSION STANDARDS

ALL TYPES

APPLICATIONS

NOTES

STANDARD

PSA

A-S

CHARACTERISTICS

E.E.C.

Engines

Vehicles

Applicable

RP

With 2 oxygen sensors and

catalytic converter for petrol

vehicles.

Brussels Directive: 2001/1

ꢀ EURO 3 standard (L4) made

stricter

Private vehicles :

All types

Essence

Diesel

Gas

ꢀꢀ01/2005

ꢀꢀ01/2006

EURO 4

IF / L5

• new models

• existing models

With EOBD on-board

diagnosis.

ꢀ Fiscal incentives

Brussels Directives: 99/102 et

2001/1 (Gas)

Utility vehicles :

< 3.5 tonnes

ꢀꢀEURO 3 standard (L4) made

stricter

With 2 oxygen sensors

and catalytic converter for

petrol vehicles.

ꢀꢀ01/2005

ꢀꢀ01/2006

ꢀꢀ01/2007

Class 1 :

Essence

Gas

ꢀꢀFiscal incentives

ꢀꢀ3 classes depending on

vehicle weight :

• new models

• existing models

Class 2/3 :

EURO 4

IF / L5

With EOBD on-board

diagnosis.

• new models

• modèles existants

Class 1 < 1305 kg

Class 2 : 1305/1760 kg

Class 3 : 1760 kg

138

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ANTI-POLLUTION TECHNICAL CHECKS (FRANCE)

ALL TYPES

All Types Petrol CO Corrected (In %)

All Types Diesel (m -1)

Features :

Conditions : At idle, engine warm.

# 01/96

Less than 4.5 % for vehicles registered before 10/86.

Less than 3.5 % for vehicles registered after 10/86.

Xantia, MMDCM injection on 1.6i (BFZ) engine, 1.8i (LFZ) engine and 2.0i

(RFX) engine.

Should the check reveal excessive CO, make sure that the ECU channel

25 is not connected to earth in error.

With catalytic converter

Greater than 2.0i 89 M.Y.

All Types

CO less than 0.5 % at idle speed.

93 M.Y.

(See Info-rapid N° 77)

CO less than 0.3 % at fast idle speed between 2500 and 3000 rpm (*)

01/96 #

(*) Except :

Atmospheric engine.

Less than 2.5 m -1

Turbocharged engine.

TU5 JP

XU5JP

XU7JP

: 2200 rpm ± 100.

: 1500 rpm or 3100 rpm (± 100).

NOTE : On XU5JP and XU7JP engines at 1500 rpm, the check should

be carried out with main beams, rear heated screen and cabin ventila-

tion switched on and with the front wheels on maximum lock (if the

vhicle has power-assisted steering).

Less than 3.0 m

1

Lambda Probe value 0,97 to 1,03.

139

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XSARA - XSARA PICASSO

PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM

Engines : RHY - RHZ

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 regulateur (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

140

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XSARA - XSARA PICASSO

PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM

Engines: RHY - RHZ

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.

B1HP12DC

- There are two types of diesel injector carrier classed according to fuel flow.

Identification by engraving or paint mark

Injector carrier Engraving

Paint mark

Blue

Location

On the upper part of the

coil near to the fuel return

aperture

Class 1

Class 2

1

2

Green

Identification markings:

IMPERATIVE: When replacing a diesel

injector carrier, order a component of

the same class.

- "a": Supplier identification.

- "b": PSA identification number.

- "c": Class identification.

(See repair manual).

B1HP12EC

B1HP16PC

141

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SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM

XSARA - XSARA PICASSO

Engines : RHY - RHZ

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 seconds before 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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SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM

XSARA - XSARA PICASSO

Engines : RHY - RHZ

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.

- 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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XSARA - XSARA PICASSO

CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT

Engines : RHY - RHZ

TOOLS

[1] Ø 10 mm low pressure connector

[2] Ø 8 mm low pressure connector

[3] Pressure gauge for testing boost pressure

: 4215-T

: 4218-T

: 4073-T

Tool kit 4073-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.

Checks on pressure : static.

- Switch on ignition

For 3 seconds (normal functioning):

- Fuel supply pressure shown by the pressure gauge [3] = 1.8 ± 0.4 Bar.

- Fuel return pressure shown by the pressure gauge [3] = 0.5 ± 0.4 Bar.

B1BP1TWD

144

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CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT

XSARA - XSARA PICASSO

Engines: RHY - RHZ (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] = 0.7 ± 0.4 Bar.

Abnormal functioning

Fuel supply pressure

Fuel return pressure

Checks

Between 3 and 3.5 Bar

0.7 ± 0.2 Bar

Check the condition of the diesel filter

Check the low pressure regulator incorporated in

More than 3.5 Bar

Less than 0.7 Bar

More than 0.7 Bar

Less than 0.7 Bar

the filter (locked shut) : replace.

Check the fuel return circuit (pipe pinched or trapped.......).

Check the fuel suppy circuit :

- Booster pump (low pressure), piping.

Between 0.8 and 1.5 Bar

Impossible to start the engine :

Check : diesel injector return flow. (Table below)

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)

Uncouple the diesel injector return pipe.

Check :

The flow should be drop by drop

Excessive fuel return

Observe :

Diesel injector functioning correctly

Diesel injector locked shut.

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XSARA - XSARA PICASSO

CHECKS : AIR SUPPLY CIRCUIT

Engines: RHY - RHZ

TOOLS

[1] Manual vacuum pump

IMPERATIVE : Respect the safety and cleanliness requirements.

Vacuum pump.

: FACOMM DA 16.

- Connect the tool [1] on the vacuum pump (1).

- Start the engine.

- Pressure should be 0.8 bar at 780 rpm.

Boost pressure regulator electrovalve.

- Connect the tool [1] between the electrovalve (2) and the valve (3) of the boost pressure

regulator.

Compare readings with the values in the table below.

Engine speed (rpm)

Pressure (Bar)

780

0.6

4000

0.25

Pressure regulator valve.

- Connect the tool [1] on the valve (3).

- Appy a pressure of 0.5 bar to activate the rod "a" :

- Rod "a" should be moved 12 mm.

B1HP12FD

146

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CHECKS : TURBO PRESSURE

XSARA - XSARA PICASSO

Engine : RHZ

Tools.

[1] Pressure gauge for checking boost pressure

[2] Sleeve for checking boost pressure

[3] Adaptor sleeve

: 4073-T.A Tool kit 4073-T

: 4185-T

: 4229-T

Checks.

IMPERATIVE : respect the following checking requirements : Engine at running

temperature. Vehicle in running order at full load.

Preparation.

- Remove the collar fixing (3).

- Insert the tool [2] connected with tool [3], between the pipe (1) and the duct (2).

- Position tool [1] in the vehicle.

- Connect the sleeve [2] to the tool [1] with its tube "a".

Procedure.

- Start the engine.

- Engage first gear and start the engine.

- Engage the gears up to third gear.

- Decelerate to 1000rpm.

- Accelerate hard, and check the pressure : 0.6 ± 0.05 Bar (1500 rpm).

- Accelerate freely in kick-down, (changing from fourth to third gear).

- Check the pressure : 0.95 ± 0.05 Bar (between 2500 and 3500 rpm).

- Remove the tools, reposition the pipe (1) and refit the collar (3).

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XSARA - XSARA PICASSO

CHECKS : TURBO PRESSURE

Engines : RHY

TOOLS.

[1] Pressure gauge for checking boost pressure

[2] Sleeve for checking boost pressure

: 4073-T.A Tool kit 4073-T

: 4185-T

Checks.

IMPERATIVE : respect the following checking requirements : Engine at running tempe-

rature. Vehicle running at full load.

Preparation.

- Remove the collar (3) and the sleeve.

- Insert the tool [2] between the pipe (1) and the duct (2).

- Position tool [1] in the vehicle.

- Connect the pressure gauge [1] to the tool [2] with its tube "a" long enough for the gauge to

be positioned inside the vehicle.

Procedure.

- Start the engine.

- Engage first gear and start the engine.

- Engage the gears up to third gear.

- Decelerate to 2000 rpm.

- Gradually accelerate.

- Check the pressure : 0.95 ± 0.05 Bar.

- Remove the tools, refit the collars (3) and the sleeve.

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XSARA - XSARA PICASSO

CHECKS : EXHAUST GASES RECYCLING CIRCUIT

Engine : RHY

TOOLS

[1] Manual vacuum pump

: FACOMM DA 16.

IMPERATIVE : Respect the safety and cleanliness requirements.

EGR valve

- Connect the tool [1] to the capsule union (1).

- Apply, several times in succession, a vacuum of approx. 0.6 bar to activate the rod "a".

- In abrupt reaction to the vacuum, the valve should close on its seating with a clicking noise.

Exhaust gas reycling (EGR) electrovalve.

- Check, not under load, between the electrovalve (2) and the EGR valve (1).

- Connect the tool [1] between the electrovalve (2) and the capsule (1).

- Compare readings with the values in the table below.

Engine speed (rpm)

Pressure (Bar)

780

0.5

0

2500

B1HP12GD

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SPECIFICATIONS OF THE SIEMENS INJECTION PUMP

SAXO - XSARA

PUMP -TYPE - REFERENCE

TD EURO 3

Emission standards

Equipment

Transponder

10 RHY

FTP 6186 D 10/F

XSARA

DW

150

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SPECIFICATIONS OF THE SIEMENS INJECTION PUMP

SAXO - XSARA

Static timing

Reference

Adjustments (rpm)

Max. speed

Dynamic

Injector

Pump

Type

Reference

Engine

type

Initial advance

Compression

Time

Colour

code

Injector

holder

+ injector

timing

checking

(at idle)

needle lift

pressure

(Bar)

Fast

idling

Anti-

stall

Unladen

rpm

Laden

rpm

Injector

Idling

(cylinder N° 4)

9636819

380

Non-adjustable

RHY

FTP 6186 D 10/F

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XSARA

SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP

PUMP - TYPE - REFERENCE

Emission standards

L3

Transponder

Equipment

DWLP 12

R8448 B

371 B

8B WJY

XSARA

DW

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SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP

XSARA

Static timing

Reference

Adjustments (rpm)

Max. speed

Dynamic

Injector

Pump

Type

Reference

Engine

type

Initial advance

Compression

Time

Colour

code

Injector

holder

+ injector

timing

checking

(at idle)

needle lift

pressure

(Bar)

Anti-

stall

Unladen

rpm

Laden

rpm

Fast

idling

Injector

Idling

(cylinder N° 4)

Engine

TDC

Pegging hole.

Value «X»

engraved on the

pump.

RDNO

SDC

6903

LDCR

0260

IAA

1500

+ 3mm

shim

DWLP 12

135.5

± 5

950

± 25

875

± 25

875

± 25

5350

± 125

WJY

R 8448 B/ *

(*) = See table on page : 152.

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XSARA

CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP

Engines : WJZ - WJY

Evolution of the checking of the setting of the LUCAS diesel injection pump

Old assembly.

NEW ASSEMBLY : RPO 7910 #

Diesel injection pump with hole for

checking the setting

Diesel injection pump without a hole

for checking the setting.

The setting of the diesel injection pump is

done with the aid of the following tools :

The setting of the diesel injection pump

is done with the aid of a peg at "c".

- A peg placed at "a".

- A peg and a dial gauge placed in the

checking hole at "b".

See method on following pages.

B1HP1A4C

B1HP1A5C

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CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP

XSARA

Engines : WJZ - WJY (continued)

Tools.

[1] Flywheel locating peg

[2] H M8 screw

[3] Injection pump setting peg Ø 6 mm

: 7014-T.J.

: (-).0188.E. Tool kit C.0188

: (-).0188.H

After carrying out the necessary dismantling operations on the vehicle, proceed in the following manner :

Remove :

- The screws (6), (7), (9), (10) and (12).

- The upper casing (8).

- The intermediate casing (11).

WARNING : Refit the screw (6) equipped with a washer. (Thickness 5 mm).

- Turn the front RH wheel to turn the engine. (Normal direction of rotation).

- Bring the camshaft and injection pump pulleys to their setting point.

- Position the flywheel peg, using tool [1]. (From above the vehicle).

- Turn the engine until the peg [1] engages in the flywheel.

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XSARA

CONTROLE-CALAGE DE LA POMPE MECANIQUE DELPHI

Engines : WJZ - WJY (continued)

Peg :

- The camshaft hub, using tool [2].

- The injection pump hub, using tool [3].

Impossible to peg the camshaft.

Reset the valve timing (See pages 108 to 112).

Possible to peg the camshaft, but not the injection pump.

Carry out the following operations:

- Loosen the screws of the injection pump hub.

- Turn the injection pump hub.

- Insert the peg [3] into the setting hole.

- Tighten the screws of the injection pump hub. Tighten to 2.3 ± 0.2 m.daN.

ESSENTIAL : If setting the diesel injection pump proves impossible, reset the valve

timing (See pages 108 to 112).

Remove:

- The tools [1]. [2] and [3].

- The screw (6) and the washer.

Reassemble the components.

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ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS

XSARA

Engines : WJZ - WJY

Adjusting the fast idle.

Engine cold.

- Ensure that the lever (2) is up against its stop to the right.

- If not, adjust the tension of the cable (3) using the cable clamp (1).

- Finish tensioning using the sleeve tensioner (4).

Engine hot.

- Check that the cable (3) is in tension.

Checking the thermostatic sensor.

- There should be a minimum 6 mm cable travel between a cold and a hot engine.

Adjusting the accelerator control.

Prior conditions.

- Engine hot (cooling fan is engaged twice).

Checking the accelerator cable tension.

- Fully depress the accelerator pedal.

- Check that the lever (6) is against its stop (5) otherwise, alter the position of the pin.

- If not, adjust the position of the accelerator cable tensioning retaining pin.

- Ensure that in the idle position the lever (6) is against the stop (7).

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XSARA

ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS

Engines : WJZ - WJY (continued)

Adjusting the anti-stall (residual output).

- Insert a 3 mm thick shim (10) between the throttle lever (6) and the anti-stall screw (7).

- Push the stop lever (8).

- Insert a 3 mm diameter peg (9) in the lever (2).

- Adjust the engine speed to 1500 rpm ± 100 using the stop screw (7).

- Remove the shim (10) and the peg (9).

Adjusting the idle speed.

- Adjust the speed using the idle adjustment screw (11).

- Idling speed : 825 ± 25 rpm.

Checking the engine deceleration.

- Move the throttle lever (6) to obtain an engine speed of 3000 rpm.

- Release the throttle lever (6).

- The deceleration should be between 2.5 and 3.5 seconds.

- The drop should be approximately 50 rpm in relation to the idle speed.

- Deceleration too fast, (the engine has a tendency to stall) slacken the screw (7) by a quarter turn.

- Deceleration too slow, (engine speed is greater than the idle speed) tighten screw (7) by a quarter turn.

NOTE : In each case, check the idle speed for any necessary adjustments.

B1HP0K9C B1HP0KAC

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FITTING DELPHI DIESEL INJECTORS

XSARA

Engines : WJZ - WJY

[1] Tool to remove/refit injectors (2)

7007-T

Fitting an injector

[2]

7008-T.A Tool kit 4123-T

The copper seal (1) and the

fire seal washer (3) are to be

replaced each time they are

removed.

NOTE : Fitting parts of diffe-

rent makes is PROHIBITED.

WARNING : Ensure that the fire

seal washer (3) is fitted the right

way round.

Tighten the injector holder

on the cylinder head to :

9 m.daN

(3) Tighten lightly to prevent any distortion.

B1HP0YGC

B1DP158C

B1HP12VC

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SAXO - XSARA

BOSCH INJECTION PUMP SPECIFICATIONS

PUMP - TYPE - REFERENCE

L3/L4

Emission standards

Equipment

Transponder

SAXO

5B

TUD

VJX

539

RHY

RHZ

XSARA

10

CP1 (*)

DW

(*) = The fuel high pressure pump is driven by the timing belt.

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BOSCH INJECTION PUMP SPECIFICATIONS

SAXO - XSARA

Static timing

Reference

Adjustments (rpm)

Max. speed

Dynamic

Injector

Pump

Type

Reference

Colour

code

Engine

type

(1) Initial advance

Compression

Time

Injector

holder

+ injector

timing

checking

(at idle)

needle lift

pressure

(Bar)

Anti-

stall

Unladen

rpm

Laden

rpm

Fast

idling

Injector

Idling

(cylinder N° 4)

Pump

0,60 ± 0,1 mm

After BDC

KCA

20S106

5450

± 160

120

± 5

5000

± 160

800

± 100

299

No

539

VJX

RHY

RHZ

96255

42580

CP1

Non-adjustable

(1) = Engine : TDC peg hole

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SAXO - XSARA

CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP

Engine : VJX

Tools

- Flywheel locating peg

- Mounting plate locating peg

- Camshaft peg

: 4507-T.A

: 4527-T.S1

: 4527-T.S2

Tool kit 4507-T

ꢀ

Checks

- Peg the flywheel.

- Visually check the pegging of the camshaft and pump pulleys, or check using the

tools 4527-T.S1 and 4527-T.S2.

Setting the injection pump

- Peg :

- The flywheel.

- The camshaft pulley.

- Fit the pump and tighten to 2.5 m.daN.

- Peg the pump mounting plate.

- Fit the pump drive pinion together with the timing belt. Tighten to 2.5 m.daN.

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CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP

SAXO - XSARA

Engine : VJX

ADJUSTING THE FAST IDLE SPEED.

- Bring the lever (3) into contact with the screw (2).

- Use the screw (2) to obtain the fast idle speed : 1100 ± 100 rpm.

Engine cold :

- Ensure that the lever (3) is up against the screw stop (2).

- If not, slightly tension the cable (4) using the cable clamp (1).

- Finish tensioning with the sheath tensioner (5).

Engine hot :

- Ensure that the cable (4) is slack.

- Check the operation of the thermostatic sensor on the coolant outlet housing : there should be a minimum

6 mm cable travel between a cold and a hot engine.

- If not, replace the thermostatic sensor. Tighten to 2.5 m.daN.

B1HP0HQC

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SAXO - XSARA

CHECKING AND SETTING THE BOSCH MECHANICAL INJECTION PUMP

Engine : VJX (continued)

ADJUSTING THE ACCELERATOR CONTROL.

- Fully depress the accelerator pedal.

- Check that the lever (10) is against the stop screw (6). If not, modify the

position of the spring clip (7).

- Check that, at idle, the lever (10) is against its stop (9).

Preliminary conditions :

- Engine hot (The cooling fan is engaged twice).

- Fast idle control released.

ADJUSTING THE IDLE SPEED.

- Slacken the screw (9) by a few turns until it no longer touches the lever (10).

- Adjust the idling speed using the screw (8).

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ADJUSTING THE MECHANICAL CONTROLS OF THE BOSCH INJECTION PUMP

SAXO - XSARA

Engine : VJX (continued)

ANTI-STALL ADJUSTMENT

- Insert a 1 mm shim [1] between the throttle lever (10) and the residual

output adjustment screw (9).

- Turn the residual output adjustment screw (9) to obtain an engine speed of :

835 ± 40 rpm.

- Remove the shim [1].

CHECKING THE ENGINE DECELERATION.E

- Move the throttle lever (10) to obtain an engine speed of 3000 rpm.

- Release the throttle lever (10).

- The deceleration should be between 2 and 3 seconds.

ESSENTIAL : Check the operation of the manually-operated ‘‘STOP’’

control (11).

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SAXO - XSARA

FITTING BOSCH INJECTORS

Engine : VJX

[1] Tool to remove/refit injectors (2)

7007-T

Fitting an injector

[2]

7008-T Tool kit 4123-T

The copper seal (1) and the

fire seal washer (2) are to be

replaced each time they are

removed.

NOTE : Fitting parts of diffe-

rent makes is PROHIBITED.

WARNING : Ensure that the fire

seal washer (2) is fitted the right

way round.

Tighten the injector holder

on the cylinder head to :

VJZ

7 m.daN

All Types

9 m.daN

(3) Tighten lightly to avoid distortion.

Tighten to 7 m.daN.

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FITTING BOSCH INJECTORS

Engine : RHY

Evolution : Classification of diesel injector carriers

Reminder : RHY and RHZ are equipped with 4 diesel injector carriers marked according to their injection

duct diameters (flow of diesel fuel).

16/11/98 #

Identification.

The injector carriers have an engraving or paint mark on the upper part of the coil, close to the diesel fuel

return aperture :

Mark 1 = BLUE paint mark = Injector class 1.

Mark 2 = GREEN paint mark = Injector class 2.

Identification marking:

a : Supplier identification.

b : PSA identification no.

c : Identification of class.

After Sales operations.

ESSENTIAL : When changing a diesel injector carrier, order a component of the same class.

# 15/11/98 (RPO No.) (injector carrier without marking), always order a class 2 injector carrier.

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Injection for Your Citroen Xsara SUV Second Generation (1997-2006)

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