2004 Citroen XSARA PICASSO circuit

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INJECTION
PARTICLE FILTER SAFETY AND CLEANLINESS REQUIREMENTS
General.
ESSENTIAL: Given the very high pressures prevailing in the fuel high pressure circuit (1600 Bars), respect the following regulations.
It is forbidden to smoke in the immediate proximity of the high pressure circuit during a repair.
Avoid working close to flames or sparks.When the engine is running:
Do touch the fuel high pressure circuit.
Always keep out of range of possible projections of fuel, which could cause serious injuries.
Do not place your hand near to any leak on the fuel high pressure circuit. After the engine has stopped, wait 30 seconds before starting any operation.
NOTE:The waiting time is necessary to allow the fuel high pressure circuit to return to atmospheric pressure.
Safety rules.
IMPERATIVE:Wait at least an hour before starting any repair on the exhaust line.
Forced regeneration of the particle filter:
Check that there are no aerosols or inflammable products inside the vehicle’s boot.
Wear high temperature gloves.
Connect the vehicle to a gas extractor approved for this type of operation.
IMPERATIVE: In the absence of the required installations, carry out the forced regeneration of the particle filter outside the workshop,
in a concreted area well away from any inflammable materials. Place the vehicle in the high position.
ALL TYPES

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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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INJECTION
SPECIAL FEATURES: PARTICLE FILTER / FILLING OF THE ADDITIVE RESERVOIR
Imperative: Respect the safety and cleanliness requirements.
Tools.
Filling kit comprising the following items:1Container of Eolys2Filters2Tubes1Empty container2Hooks1Adaptor
Filling.
IMPERATIVE: Respect the safety and cleanliness requirements specific to HDi engines.
IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves
that are resistant to hydrocarbons.
Place the vehicle on a lift.
Disconnect the battery negative terminal.
Unclip the the factory filler connector
(1).
Couple the container of additive to the tube (2)using the adaptor and the tube (with tap)from the
filling kit.
Screw the filler connector on the additive container
(3)at «b».
Place the additive container (3)on the component lift.
Open the tap located on the filler connector at «a».
Tilt the additive container (3)(to facilitate the end of filling).
Close the tap at «a».
Remove the filler connector and the tube (4).
Couple the tube (2).
Reconnect the battery negative terminal.
IMPERATIVE: The filling kit should be recycled after this operation. Any «Eolys» additive
containers that have been opened should not be kept.
XSARA PICASSO
B1HP1UVC
C4BP1EGC

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INJECTION
SPECIAL FEATURES: PARTICLE FILTER / CHECKING THE ADDITIVE PUMP
Engine: 9 HZ
IMPERATIVE: Respect the safety and cleanliness requirements.
Tools.
[1]
Manual pressure/vacuum pump: FACOM DA 16
[2]Additive container: ().1613.G Kit 1613
Checks.
IMPERATIVE: Respect the safety and cleanliness requirements specific to HDi engines.
IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves that are
resistant to hydrocarbons.
Place the vehicle on a lift.
Raise the vehicle
To test the flow of the additive pump :
Uncouple the tube
(1).
Couple tool [2]on the outlet «a»of the additive reservoir.
Operate for 50 secondsthe actuator test «Additive pump»with the aid of LEXIA or PROXIA.
IMPERATIVE:The volume collected by the tool [2] should be 20 ± 5 ml.
NOTE:
Replace the additive pump if it is defective.
Couple the tube (1).
Operate the actuator test «Filling the tube: additive pump – additive injector», with the aid of LEXIAorPROXIA.
B1HP1UTC
XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS HYDRAULIQUE
B2BP04XC
Bleeding the hydraulic clutch control
IMPERATIVE: Use only new brake brake fluid that is not emulsified, avoid any
ingress of impurities into the hydraulic circuit.
IMPERATIVE: Do not use automatic bleeding equipment
(risk of the brake fluid
emulsifying in the hydraulic circuit).
Couple a transparent tube (5) on the bleed screw, at «c».
Submerge the end of the tube
(5)in the recipient containing the brake fluid, located
below the level of the clutch slave cylinder.
Use the transparent tube
(5)to act as a siphon, at «b».
WARNING:the end of the tube (5)must be submerged in the brake fluid.
Open the bleed screw, at
«c».
C3 PLURIEL XSARA
C2C3XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
Engines: KFV NFU RFN RHZ
Updating the value of the oil usage counter.
Using PROXIA.
Access to reading and recording of the oil counter is via the menu:
«Configuration
(integrated circuit button)/ Oil counter».
Adjustment of the oil counter value is done in incremental steps of
2750units.
Using LEXIA or ELIT.Access to reading and recording of the oil counter is via the menu:
«Oil counter».
Adjustment of the oil counter value is done by entering directly the
5 figures of the oil counter.
Downloading.
ECU downloading procedure:
Follow the diagnostic tool procedure.
A new ECU or downloaded update is always configured with the
following options:
SHIFT LOCK gear selection lever position.
Without OBD outlet
(depollution L4).
If the ECU is to be fitted to a vehicle with depollution
L4or not
equipped with gear lever locking safety: Perform a configuration operation.
Pedal initialisation.
A pedal initialisation must be carried out in the following cases:
Replacement of the automatic gearbox ECU.
Replacement of the automatic gearbox.
Downloading of the ECU configuration.
Adjustment or replacement of the accelerator cable.
Replacement of the butterfly potentiometer.
RECOMMENDATIONS PRECAUTIONS: AL4 AUTOMATIC GEARBOXC3 XSARA XSARA PICASSO
Procedure for initialising the automatic gearbox ECU

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AXLES
SUSPENSION
STEERING
POWERASSISTED STEERING SPECIFICATIONS
XSARA
Powerassisted steering assembly
Tightening torques (m.daN).
High pressure tube (Rubber seal pump side)
Powerassisted valve and pump union: 2.5
Return pipe.
Powerassisted valve union: 2.5
(16)Upper front fixing (E3) : 2.5
(17) Upper rear fixing (E3) : 2.2
(18)Fixing (E3) : 2.2
Tightening sequence.
Tighten screws (16)and (18).
Lightly tighten screw
(17), then fully tighten.
Pressure switch on the pressure circuit.
Switch opens 30to 35 Bars.
Switch closes 25 Bars.
Tighten to :
2 m.daN. Powerassisted steering system capacity =
1 litre.
Oil type:TOTAL FLUIDE ATX.
SAGINAW Pump adjustment = 100 Bars ± 5.
Pump shaft threading 3/8 16 threads per inch.
B3EP045D

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AXLES
SUSPENSION
STEERING
POWERASSISTED STEERING SPECIFICATIONS
Tightening torques (m.daN).
Unions between pump unions and
power steering valve: 2 ± 0.3
(16)Fixing screw: 2.2 ± 0.3
(17)Fixing screw: 2.2 ± 0.3
(18)Fixing screw: 2.2 ± 0.3
NOTE:
Coat the threads with product «E3».
A pressure switch is implanted in the hydraulic piping between the
high pressure pump and the power steering valve. Opening pressure =
30 / 35 Bars.
Closing pressure = 25 Bars minimum.
Tightening torque = 2 ± 0.2.
Capacity of power steering circuit =
1 Litre.
Oil quality = TOTAL FLUIDE ATX.
Power steering pump: Supplier SAGINAW.
Pump adjustment = 100 ± 5 Bars.
Pump shaft threading 3/8 16 threads per inch.
B3EP118D
XSARA PICASSO