2004 Citroen C3 Adjust

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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine: WJY
Tools.
[1]
Pliers for remving plastic pins: 7504T or ().1311
[2]Flywheel peg: 7014T.J or ().0188 Y
[3]Injection pump setting peg Ø 6 mm: ().0188 H
[4]Screw H M8: ().0188 E
[5]Belt retaining pin: ().0188 K
[6]Square for adjusting belt tension: ().0188 J1
[7]Belt tension measuring instrument, with digital display: SEEM CTG 105.5M
Checking the timing.
Peg the flywheel, using tool [2].
Peg the camshaft hub, using tool [4].
Peg the injection pump hub, using tool [3].
IMPERATIVE: If the pegging proves impossible, repeat the setting of the timing.
B1BP2FTCB1EP16PD
XSARA

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ENGINEVALVE CLEARANCE SETTINGS
The valve clearances must be checked with the engine cold
Inlet
Petrol all types(Except16VNFU)
NFU
Petrol 16V all types
1.4 HDi
1.4 HDi 16V
Diesel 2.0 HDi
Diesel all types(Except Diesel 1.4 HDi
1.4 HDi 16V
2.0 HDi)0,20 mm ± 0,05Exhaust
0,40 mm ± 0,05
Hydraulic adjustment 1 mm ± 0,05
1 mm ± 0,05
Rocking
Adjust
1
1
3
3
4
4
2
24
4
2
2
1
1
3
3
Inlet

Adjust Rocking
Valves fully
openAdjust
1
3423 4
4
2
2
1
1
3
Fully open (Exhaust)
POSSIBLE PROCEDURES
For engines with 4 cylinders in a line (1342 )
Engines without hydraulic
adjustment: the clearance (J)should be checked opposite the
cam.
B1DP13QC
0,15 mm ± 0,08
0,30 mm ±0,08

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INJECTION
SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP XSARA
Engine
typePump
Type
ReferenceStatic timing
Initial advance
Compression
Time
(cylinder N° 4)Dynamic
timing
checking
(at idle)Reference
InjectorInjector
holder
+ injectorCode
colourInjector
needle lift
pressure
(Bar)Adjustments (rpm) Max. speed
Fast
idlingAntistall
IdlingUnladen
rpmLaden
rpm
WJYDWLP 12
R 8448 B/*RDNO
SDC
6903LDCR
0260
IAA135,5
±5950
±25875
±25875
±255350
± 125
Engine
TDC
Pegging hole.
Value «X»
engraved on
the pump.
(*) = See table page: 251.1500
+ 3
mm
shim

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INJECTION
ADJUSTING THE MECHANICAL CONTROLS OF THE DELPHI INJECTION PUMP
Engine: 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 mmcable 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).
B1HP0K9C
XSARA

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INJECTION
ADJUSTING THE MECHANICAL CONTROLS OF THE DELPHI INJECTION PUMP
Engine: WJY (continued)
Adjusting the antistall (residual output).
Insert a 3 mmthick shim (10)between the throttle lever (6)and the antistall screw (7).
Push the stop lever (8).
Insert a 3 mmdiameter peg (9)in the lever (2).
Adjust the engine speed to 1500 rpm ± 100using 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 2.5and 3.5seconds.
The drop should be approximately 50 rpmin 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.
B1HP0K9CB1HP0KAC
XSARA

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS
Engines: KFW NFU 6FZ RFN RFS 8HX 9HZ 9HY WJY RHY RHZ
Clutch cable.
Removing.
Uncouple the cable from the lever (1).
Unclip the cable from the gearbox by actioning
the side tabs
(2).
Detach the cable from the bulkhead.
Remove the clip
(3).
Uncouple the cable from the clutch pedal.
B2BP001CB2BP002C
XSARA XSARA PICASSO
B2BP02VC
B2BP02WC
«PUSH» clutch
«PULL» clutch
B2BP03BCB2BP002C

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS
Engines: KFW NFU 6FZ RFN RFS 8HX 9HZ 9HY WJY RHY RHZ
Refitting.
Place the pedal in the high position (contact at “a”).
Attach the cable yoke on the hook of the clutch pedal.
Fit a new clip
(3).
Fit the endpiece (4)to the bulkhead (fit with G6grease).
Clip the endpiece (5)on the gearbox.
Couple the cable to the lever (1).
Depress the clutch cable several times to lodge the cable in place.
Check that the endpiece (4) is correctly lodged on the bulkhead.
Check the operation of the automatic adjusting system.
After fitting the cable, pull the clutch lever in the inverse direction
(direction F), the lever should
move back when pulled by hand.
Press the clutch pedal very lightly and repeat the same operation. The lever should not move
back.
WARNING:If a system blockage is detected when checking, or if the pedal has been removed,
the pedal position must be adjusted. The correct positioning of the pedal is obtained by the
angular displacement of the stop supports
"a"and "b".
B2BP03CD
XSARA XSARA PICASSO
«PUSH» clutch
«PULL» clutch
B2BP03DD

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS
Engines: KFW NFU 6FZ RFN RFS 8HX 9HZ 9HY WJY RHY RHZ
Adjusting the pedal height.
Loosen the nut (6)and the screw (7).
Using a lever, raise the stop support (8)to its highest position. In this position, there should be a substantial free
play in the pedal.
Lower the support until there is a free play of
2 ± 1 mm.
Tighten the nut (6) and the screw (7).
Check that the clutch cable sleeve can move freely.
At rest, the clutch cable sleeve should be free and able to lengthen and shorten.
Clutch pedal travel.
The automatic clutch wear adjustment system has no manual adjustment.
Pedal travel is identical on all models:154 ± 5 mm.
The adjustment is achieved by reducing the length of the cable sleeve.
WARNING:Automatic adjustment of the pedal travel is accompanied by a modification of the curvature of the
cable sleeve. Do not add any supplementary fixing points or alter the routing in any way.
«c»Routing of new cable.«b»Routing after adjustment of play.«x» Clutch wear.
B2BP03ECB2BP03FD
XSARA XSARA PICASSO