2004 Citroen C3 diesel

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INJECTION
XSARA PICASSO
CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT
Engines: RHY RHZ
Tools.
[1] Ø 10 mm
low pressure connector: 4215T.
[2] Ø 8 mmlow pressure connector: 4218 T.
[3]Pressure gauge for testing boost pressure: 4073 T 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

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INJECTION
XSARA PICASSO CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT
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
Impossible to start the engine:
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).
Check: diesel injector return flow.(Table below)
Uncouple the diesel injector return pipe.
Fuel supply pressure Fuel return pressure Checks
Between 3and 3.5 Bar 0,7 ± 0,2 BarCheck the condition of the diesel filter
More than
3.5 Bar
More than 3.5 Bar
Less than 0.7 Bar
More than 0.7 Bar
Check the low pressure regulator incorporated in
the filter (locked shut): replace.
Check the fuel return circuit
(pipe pinched or trapped…)
Between 0.8 and 1.5 BarLess than 0.7 BarCheck the fuel suppy circuit:
Booster pump (low pressure), piping.
Check:
Observe:
The flow should be drop by drop.
Diesel injector functioning correctly.
Excessive fuel return.
Diesel injector locked shut.

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INJECTION
CHECKS: EXHAUST GASES RECYCLING CIRCUIT
Engines: 8HX 8HW
Engines: 8HV 8HY
Tools.
[1]
Manual pressurevacuum pump: FACOM DA 16
IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel
injection (HDi) engines.
EGR v
alve.Connect tool [1]on the capsule takeoff (2).
Apply a vacuum of approx.0,6 barseveral times to activate the rod «a».
In abruptly suppressing the vacuum, the valve should click and lock itself back on its seating.
Regulation electrovalve (EGR).(Engine:8HX8HW).Check to be performed between the electrovalve (1)and the EGR valve (2).
Link the tool [1]in series, between the electrovalve (1)and the capsule (2).
Compare the values noted with those in the table below.
Regulation electrovalve (EGR).(Engine:8HV8HY).Check to be performed between the electrovalve (2)and the EGR valve (1).
Link the tool [1] in series, between the electrovalve (2)and the capsule (1).
Compare the values noted with those in the table below.
Engine speed (rpm) Vacuum value
780 0,5
2500 0
B1HP15GD
B1HP1K6D
C2 C3

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INJECTION
PARTICLE FILTER SAFETY AND CLEANLINESS REQUIREMENTS
Operations on the fuel additive circuit.
IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves that are resistant to hydrocarbons.
The work area must be ventilated.
In the event of any significant dispersion of additive:
Wear a breathing mask for filtering the particles.
Recover as much of the product as possible.
Place the product thus recovered in an appropriately labelled container. Wash the soiled area with copious amounts of water.
Dispose of materials and solid residues in an authorised recovery point.
IMPERATIVE:The filling kit should be recycled following a repair. All «Eolys» additive containers that have been opened should be
disposed of.
Cleanliness rules.
ESSENTIAL: The operator should wear clean overalls.
Before working on the injection circuit, it may be necessary to clean the unions of the following sensitive components(see corresponding operations).
Fuel filter.
Fuel high pressure pump.
Fuel high pressure regulator.
Fuel high pressure common injection rail. Fuel high pressure piping. Diesel injector carriers.
IMPERATIVE: After dismantling, immediately blank the unions of the sensitive components with plugs, to prevent any ingress of impurities.
ALL TYPES

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CLUTCH
GEARBOX
TRANSMISSION
Engine types HFX KFV 8HX
Tyresrolling
165/70 R14 165/70 R14 185/55 R14 165/70 R14 185/55 R15
Circumference1,804 m1,804 m 1,781 m 1,804 m 1,781 m
Gearbox typeMA 5/S MA 5/N MA 5/L MA 5/0
Gearbox ident. plate20 CP 2020 CP 21 20 CP 16 20 CP 55 20 CP 67
PRO 9919 PRO 9919 PRO 9919 PRO 9919 PRO 9919
Reduction box torque16x65 14X60 17X61
Speedometer ratio21x18
GEARBOX AND TYRE SPECIFICATIONS
1.1i
1.4i1.4 HDi Petrol
C2
Diesel
Manual gearbox

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CLUTCH
GEARBOX
TRANSMISSION
Engine types KFV NFU 8HX
Tyresrolling
165/70 R14 185/55 R15 185/55 R14 195/45 R16 185/70 R15 165/70 R14
Circumference1,804 m 1,781 m 1,781 m 1,772 m 1,804 m 1,804 m
Gearbox typeMA 5/N MA 5/S MA 5/L MA 5/0
Gearbox ident. plate20 CP 21 20 CP 64 20 CP 66 20 CP 65
PRO 9786
PRO 9786 PRO 9786 PRO 9786
Reduction box torque16x6516x6314x6016X63
Speedometer ratio21x1821x18
GEARBOX AND TYRE SPECIFICATIONS
1.4i
1.6i 16V1.4 HDi Petrol
C2
Diesel
Piloted manual gearbox

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CLUTCH
GEARBOX
TRANSMISSION
Engine type Trim level
Tyresrolling Circumference
Speedometer ratio Gearbox type
Gearbox ident.plate
Reduction box torque
Engine type Trim level
Tyresrolling Circumference
Speedometer ratio
(1) Export et DAIC
= 20 CP 16 (14X60) (21X18) (2) EXPORT et DAIC= 20 CP 55 20 CP 72 (16X65) (21X18).
Gearbox type
Gearbox ident. plate
Reduction box torque
GEARBOX AND TYRE SPECIFICATIONS
1.6i 16V
AUTOMATIC 1.4i 1.1iPetrol
HFXX SX Exclusive
Exclusive Exclusive X SX Exclusive
X SX X SX
NFU
KFV
Diesel
165/70 R 14 1,804 m185/60 R15 1,828 m 165/70 R 14 1,804 m185/60 R15 1,828 m
MA/5 AL4 MA/5
20 CP 14 20 CP 15 ou
(*)20 TP 75 20 CP 58
14x6016x63 21x7317x64
21x18
u
1.4 HDi
X SX Exclusive
8HX 8HW 8HV 8HY
165/70 R14 1,804 185/60 R15 1,828 m
MA/5BE4/5
20 CP 54
(2)20 DM 25 20 DM 26
17x61 19x72 19x7721x1822x19
1.4 HDi 16V
C3
Manual gearbox

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CLUTCH
GEARBOX
TRANSMISSION
GEARBOX AND TYRE SPECIFICATIONS
C3
Trim level
Engine type KFU NFU 8HX
Tyresrolling
185/60 R15 165/70 R14Circumference1,828 m 1,804 m
Gearbox typeMA/5
Gearbox ident. plate20 CP 56 20 CP 65
Reduction box torque17x64 16x63
Speedometer ratio21x18
1.4i 16V
1.6i 16V1.4 HDi Petrol
Diesel
Piloted manual gearbox