RaceChip install instructions for 1.4 16v HDi

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My Name: C3CAR

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Model: C3 2002-2005, Original shape model
Year: 2002 (02)
Engine Size: 1.4 (16v)
Fuel Type: Diesel
Mileage: 140000
Trim Level: Exclusive
Gearbox: Manual 5 speed
DPF: No
LHD or RHD: RHD (UK)
Engine name: DV4 16-valve diesel (90 PS)
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Racechip install guide to Citroen C3 16v
Racechip install guide to Citroen C3 16v


It was time to play with Performance Chips - chip tuning by RaceChip for a Citroen C3 1.4 16v HDi.

The warning on the RaceChip site for this model is
Caution: difficult installation on this car.
Which is quite true, but read the guide below and with the photos they will be your help.
There is support available from the manufacturer which I have not had to use.


You don't need many tools, just
a flat bladed screwdriver (to help release clips)
a cross head screwdriver (air filter lid)
a 3/8th drive socket set (jubilee clips and the EGR valve)
and an allen key for the EGR clip (replacement) or some pliers to remove the factory single-use clip.


Installation took over an hour, but there were pictures to take and the EGR clamp had already been replaced with the re-usable type which made it easy to remove.

It is not just a case of unplugging one sensor and plugging in the racechip only because access to the common rail pressure sensor is tucked away and quite hidden at the back of the engine, thanks to Citroen for that :cry:


The instructions that arrived with the RaceChip were for a similar, but not identical engine and the actual procedure to install a RaceChip is detailed below.


The long term review of the RaceChip on the C3 is here

The discussion topic for the RaceChip is here
User avatar
My Name: C3CAR

Guru
Posts: 2643
Joined: Wed May 04, 2011 10:01 am
Model: C3 2002-2005, Original shape model
Year: 2002 (02)
Engine Size: 1.4 (16v)
Fuel Type: Diesel
Mileage: 140000
Trim Level: Exclusive
Gearbox: Manual 5 speed
DPF: No
LHD or RHD: RHD (UK)
Engine name: DV4 16-valve diesel (90 PS)
Has thanked: 170 times
Been thanked: 91 times

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Installing the RaceChip took around 1h20 including taking the photos as I went.

The part that took the most time was releasing the clip from the common rail pressure sensor. This was due to the rotation of the sensor on its screw mounting that shielded the release lever for the clip. You must lift the release clip slightly before pulling the plug off and this proved most challenging. Other engines may not have this problem and hopefully the clip will be exposed, reducing the time to fit the RaceChip.



To install the RaceChip on a Citroen C3 16v HDi, follow this guide.

Remove battery covers, air intake plastic and disconnect the battery
Remove battery covers, air intake plastic and disconnect the battery
Remove the battery cover and disconnect the quick release battery connector.


Remove the air intake pipe
Remove the air intake pipe
Remove the air intake pipe from the engine bay. There are clips holding it to the engine.


Unclip the purge bulb
Unclip the purge bulb
Lift off the flat engine cover and unclip the purge pump bulb from the air filter box



Disconnect the turbo pipe, MAF connector and air filter lid
Disconnect the turbo pipe, MAF connector and air filter lid
Disconnect the MAF plug from the MAF, the turbo pipe from the turbo by slackening the jubilee clip and unscrew the 3 cross head screws on the air filter lid. You can then remove the pipe, MAF and air filter lid as one. There is no need to break it down.
Lift out the air filter.


Remove the grey H section from inside air filter box
Remove the grey H section from inside air filter box
Removing the H section from the air filter box will allow the air filter box to separate in to two parts making it possible to remove them from the engine bay.


Unclip the fuel filter
Unclip the fuel filter
Unclip the fuel filter but do not disconnect anything from it. There is enough free pipe to allow it to move out of the way without having to disconnect any fuel or electrical connectors.



AIr filter box removed gives access to EGR valve
AIr filter box removed gives access to EGR valve
With the air filter box removed it is now possible to access the EGR valve. The EGR valve is directly above the common rail pressure sensor.
If you have the original factory EGR clip on the silver colour pipe then the only way to remove it is to destroy it. The Citroen factory fit EGR clip is not re-usable. A replacement EGR clip (here) is cheap and is designed to be re-usable. The re-usable EGR clip is released by undoing the hex head threaded bolt.


Unbolt the EGR valve
Unbolt the EGR valve
With the EGR clip removed/slackened there are two bolts that mount the EGR to the engine. The pneumatic connection can stay connected but it is easily disconnected. Check for split rubber on the EGR vacuum pipe.



EGR removed reveals Common Rail pressure sender
EGR removed reveals Common Rail pressure sender
Wit the EGR valve removed it is possible to see the Common Rail end with its pressure sensor. Remove the plug from the pressure sensor by lifting the tag of the plug and pulling the plug body (not the wires).

If you want to see how to disconnect the plug from its socket, pick up the racechip loom and there is a pair of plugs and sockets to practice unclipping with.

The clip of the actual common rail pressure transducer plug on this car was rotated away from view, so releasing the clip had to be done by feel and a small allen key to reach between the plug and the engine. The angle of the allen key meant I could reach between the sensor and the engine because there is not enough room for fingers and I couldn't get a flat bladed screwdriver in there either.

This job of releasing the fac took the most time.

Be careful not to pull the wires of the plug.

A flat bladed screwdriver can help open up the gap between plug and socket while the clip is released. The plug was very tight and took a lot of wiggling around, even after it was not longer being held by the clip.


Connect the racechip socket to the plug you disconnected
Connect the racechip socket to the plug you disconnected
Connect the plug you have just disconnected to the racechip suplied loom.


Connect racechip plug to the sensor
Connect racechip plug to the sensor
Connect the racechip plug to the common rail sensor.


Fit the racechip control box to the car
Fit the racechip control box to the car
Connect the large plug to the racechip control box and find a place to attach it. I chose the battery compartment, next to the engine ECU. Two double sided sticky pads keep it fixed, yet easily removable should the battery need to come out.
User avatar
My Name: C3CAR

Guru
Posts: 2643
Joined: Wed May 04, 2011 10:01 am
Model: C3 2002-2005, Original shape model
Year: 2002 (02)
Engine Size: 1.4 (16v)
Fuel Type: Diesel
Mileage: 140000
Trim Level: Exclusive
Gearbox: Manual 5 speed
DPF: No
LHD or RHD: RHD (UK)
Engine name: DV4 16-valve diesel (90 PS)
Has thanked: 170 times
Been thanked: 91 times

Post

The RaceChip GTS is supplied with a blanking plug on is loom, you need to disconnect this dummy plug (its a bypass plug) to attach the RaceChip GTS control box to the loom.


Pull the purple part to disconnect the racechip GTS plug
Pull the purple part to disconnect the racechip GTS plug
Pull the purple part away from the body of the multiway plug to release the connector.



Pull the purple part to disconnect the racechip GTS plug
Pull the purple part to disconnect the racechip GTS plug


Keep the dummy plug in the glovebox as it can bypass the racechip to disable the enhancement. Just fit the dummy in place of the racechip without having to remove any cables from the car.
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