2004 Citroen C3 PLURIEL stop

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GENERAL
CAPACITIES (in litres)
Draining mandhod.
The oil capacities are defined according to the following mandhods.
1/
Vehicle on level surface (in high position, if equipped with hydropneumatic suspension).
2/Engine warm (oil temperature 80°C).
3/ Draining of the oil sump + removal of the cartridge (duration of draining + dripping = 15 min).
4/Refit plug + cartridge.
5/ Engine filling.
6/Engine starting (allowing the cartridge to be filled).
7/ Engine stopped (stationary for 5 min).
ESSENTIAL: Systematically check the oil level using the oil dipstick.

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ENGINE
AUXILIARY EQUIPMENT DRIVE BELT 2002
Sans Powerassisted steering.
Tools.
[1]
Belt tension measuring instrument: 4122T
Removal.
Loosen the screws (2).
Tighten the screw (1)until it is against its stop.
Remove the belt.
Refitting. Refit the belt.
Fit the tool [1]on the belt at "d".
Tighten the screw (1)to obtain:106 ±10 SEEM units. Tighten the screws (2)to 2 m.daN.
Remove the tool [1].
B1BP1SECB1BP1SDC
Engine: WJY
XSARA

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ENGINEXSARAAUXILIARY EQUIPMENT DRIVE BELT 2002
Sans Powerassisted steering With air conditioning.
Tools.
[1]
Belt tension measuring instrument: 4122T
Removal.
Loosen the screws (1).
Tighten the screw
(2)until it is against its stop.
Remove the belt.
Refitting.
Refit the belt.
Fit the tool
[1]at "e".
Tighten the screw
(2)to obtain:106 ±10 SEEM units.
Tighten the screws (1)to 2 m.daN.
Remove the tool
[1].
B1BP1SGCB1BP1SFC
Engine: WJY

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ENGINEAUXILIARY EQUIPMENT DRIVE BELT
Engine: WJY
Powerassisted steering without air conditioning (continued).
XSARA
Refitting. Refit the belt.
Place the tool [1]on belt at "f".
WARNING: Position tool [1], with the knob downwards. Tighten the nut (2)to obtain a value of :
Reused belt:Keep the value taken at removal.
New belt:Tension should be 110 SEEM units.
Tighten the screw (1)to 9.5 m.daN.
Check belt tension, using tool [1].
Tension should be 144 ± 3 SEEM units.
Remove the tool [1].
Start the engine and run it for 10 seconds.
Stop the engine.
Place the tool
[1]on the belt at "f".
Tension should be 130 ± 4 SEEM units.
Remove the tool [1].
B1BP1SJD

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: 8HX 8HW 8HZ
B1EP18GC
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 crank
shaft pinion.
Refit the screw (2).
B1BP2LXC
C2 C3 C3 PLURIEL XSARA

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: 8HX 8HW 8HZ
B1EP18KC
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.
C2 C3 C3 PLURIEL XSARA

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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
SAFETY REQUIREMENTS: HDi DIRECT INJECTION SYSTEM
Engines: HDi ALL TYPES
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.