VERY IMPORTANT As the booklet is constantly re-edited, this one only covers vehicles for this particular model year.

Transcription

1 CORRESPONDENCE TABLE FOR PETROL ENGINES TU XU EW Engine families JP JP4 J2U J2U/K J4 1.1i 1.4i 1.6i 16V 2.0i 2.0i 16V Engine families HFX KFW NFU RFL R6G RFN Engine families CORRESPONDENCE TABLE FOR DIESEL ENGINES DV DW SOFIM ATED ATED B TD BTED CTED UTD ATED4 UTED TD BTED V 2.0 8S V 2.2 8S 1.9D 2.0HDi HDi HDi HDi HDi 2.8 TD 2.8HDi Berlingo X X X Dispatch X Engine families 9HZ WJY RHY RHX RHZ RHV RHW 4HY S C15 X BERLINGO X X X Relay X X DISPATCH X X X X RELAY X X X X VERY IMPORTANT As the booklet is constantly re-edited, this one only covers vehicles for this particular model year. It is therefore necessary to order a new booklet each year and RETAIN THE OLD ONES.

2 UTILITY VEHICLES UTILITY VEHICLES C15-BERLINGO 2005 DISPATCH RELAY "The technical information contained in this document is intended for the exclusive use of the trained personnel of the motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full responsibility to the exclusion of that of the manufacturer». «The technical information appearing in this brochure is subject to updating as the characteristics of each model in the range evolve. Motor vehicle repairers are invited to contact the CITROËN network periodically for further information and to obtain any possible updates". AC/DTAV/PRME/MMCB/MMEC Méthodes Mécaniques «The intellectual property rights relating to the technical information contained in this document belong exclusively to the manufacturer. Reproduction, translation or distribution in whole or in part without prior written authorisation from the manufacturer is forbidden» CAR

3 PRESENTATION THIS HANDBOOK summarises the specifications, adjustments, checks and special features of CITROEN utility vehicles, not including PRIVATE vehicles for which there exist separate handbooks. The handbook is divided into groups representing the main functions : GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - AIR CONDITIONING. In each section, the vehicles are dealt with in the following order: C15 BERLINGO DISPATCH - RELAY and all models where applicable. The information given in this handbook is based on vehicles marketed in EUROPE.

4 IMPORTANT If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into account when preparing future publications. For example : INSUFFICIENT INFORMATION SUPERFLUOUS INFORMATION NEED FOR MORE DETAILS Please send your comments and suggestions to : CITROEN U.K. Ltd. 221, Bath Road, SLOUGH, SL1 4BA. U.K.

5 CONTENTS GENERAL C Vehicle Berlingo 3-4 identification Dispatch 5-6 Relay 7-10 C15 12 Capacities Berlingo 13 Dispatch 14 Relay 15 Lubricants ENGINE Specifications Tightening torques : engines all types Cylinder head tightening : all types Auxiliary drive belt Checking and setting the valve timing Checking the oil pressure Valve clearances 174 INJECTION Checking the low pressure fuel supply circuit : C15 (DV6ATED4) Checking the low pressure fuel supply circuit : Berlingo Dispatch (DW10TD) Checking the low pressure fuel supply circuit : Relay (DW10UTD) Checking the low pressure fuel supply circuit : Relay (DW12UTED/SOFIM) Checking the turbo pressure : Berlingo (DW10TD) Checking the turbo pressure : Dispatch (DW10ATED) Checking the turbo pressure : Relay (DW10UTD) Checking the turbo pressure : Relay (DW12UTED) Checking the turbo pressure : Relay (SOFIM 2.8TD) Checking the turbo pressure : Relay (SOFIM 2.8 HDi) Checking the air supply circuit : Berlingo (DV6ATED4) 188 Checking the air supply circuit : Dispatch (DW10TD) 189 Checking the air supply circuit : Relay (DW10UTD) 190 Checking the air supply circuit : Relay (DW12UTED) 191 Checking the air supply circuit : Relay (SOFIM 2.8 HDi) 192 Checking the exhaust gas recycling circuit : Berlingo, Dispatch, Relay 193 Checking the exhaust gas recycling circuit : Relay 194 IGNITION Sparking plugs 195 CLUTCH-GEARBOX-TRANSMISSION Speedometer 196 Clutch specifications C Berlingo 198

6 CLUTCH-GEARBOX-TRANSMISSION Clutch Dispatch 199 specifications Relay 200 Specifications : Manual / automatic gearbox : all types Tightening torques : Manual gearboxes Manual gearbox controls: all types Recommendations/precautions : AL4 automatic gearbox Tightening torques : AL4 gearbox AL4 automatic gearbox controls Recommendations/precautions : 4 HP 20 automatic gearbox 238 Tightening torques : 4 HP 20 gearbox Shift lock : 4 HP 20 gearbox Filling / topping-up : 4 HP 20 gearbox Driveshafts 247 CONTENTS AXLES - SUSPENSION STEERING Axle geometry : C Tightening torques : front axle : C Tightening torques : rear axle : C Tightening torques : power steering : C Axle geometry : Berlingo Tightening torques : front axle : Berlingo 259 Tightening torques : rear axle : Berlingo 260 Suspension : Berlingo Tightening torques : power steering : Berlingo Axle geometry : Dispatch Tightening torques : front axle : Dispatch Tightening torques : rear axle : Dispatch 269 Manual steering : Dispatch 270 Tightening torques: power steering: Dispatch 271 Axle geometry : Relay 272 Tightening torques : front axle : Relay Tightening torques : rear axle : Relay 275 Tightening torques : power steering : Relay BRAKES Brake specifications : C Tightening torques : brakes 279 Adjusting the brake limiter 280 Adjusting parking brakes 281 Bleeding the brakes 282 Brake specifications : Berlingo Tightening torques : brakes 289 Checking/adjusting the compensator Adjusting parking brakes 292 Bleeding the brakes 293 Brake specifications : Dispatch Manual adjustment of the compensator 298 Checking/adjusting the compensator 299 Adjusting parking brakes 300 Brake specifications : Relay Adjusting parking brakes Draining, filling and bleeding the braking circuit AIR CONDITIONING R134.a : quantities 311

7 AIR CONDITIONING Compressor lubricant Checking the efficiency of the circuit Air conditioning circuit : Berlingo Air conditioning circuit : Dispatch Air conditioning circuit : Relay CONTENTS

8 IDENTIFICATION OF VEHICLES C15 (1) RP organisation no. (2) Chassis no. (3) Paint code (4) Manufacturer s plate (5) 01/02/99 Label - Tyre pressures. - RP organisation no. - Paint code GENERAL (6) Model year (7) Gearbox identification reference (8) Engine plate E1AP079D 1

9 C15 IDENTIFICATION OF VEHICLES Type approval Structure Family (1) Version (2) Variant (3) VD Family (1) VD C 15 VV Van 600 Kg Familiale Spain B VD WT/B VV Version (2) VW Van 765 Kg /B Variant (3) VY Deepened cab WT Familiale N1 GENERAL Engine Depollution WJY 1.9 D DW8B W4 2

10 IDENTIFICATION OF VEHICLES BERLINGO A Chassis stamp, cold stamp B - Manufacturer s vehicle plate C - Label RPO No. Paint colour code Tyre pressures D Gearbox identification reference factory serial no. GENERAL E Engine legislation type factory serial no. E1AP0AMD 3

11 GENERAL BERLINGO IDENTIFICATION OF VEHICLES Type approval Structure Version (4) G Family (1) Depollution levels J Bodywork (2) L3 US K Alcohol GJ KFWC KFW Engine (3) W3 L4 Euro IV 83/87 Others K' L3/L4 Euro IV /IF C Version (4) Manual 5-speed gearbox A B C P V /IF Variant (5) Manual 4-speed gearbox E F R W Family (1) Manual 6-speed gearbox G H S X 3 G Berlingo Automatic 6-speed gearbox D J N U Body shape (2) Axle and/or gearbox gears K L T Y B Van 600 Kg Other possible combinations M C Van 800 Kg No gearbox Z E Floor cab Engine (3) Variants (5) HFX 1.1i TU1JP 2 sliding side doors as standard for 800 kg (WJY) PLC KFW 1.4i TU3JP Multi-function roof as standard for MPV WJY PMF NFU 1.6i 16V TU5JP4 Without FAP SF 9HX V HDi DV6ATED4 Fiscal incentives IF WJY 1.9 D DW8B 4x4 DANGEL DGL RHY 2.0 HDi DW10TD Downgraded depollution D Dual fuel LPG GL Dual fuel CNG GN STT2 (Stop and Start) S Van Turkey TR Van Spain ES MPV/Van 5-seater PL 4

12 IDENTIFICATION OF VEHICLES DISPATCH 1 Vehicle identification N. 2 RP organisation no. 3 Paint code. 4 Manufacturer s plate. 5 Engine plate. 6 Gearbox identification reference. GENERAL 7 - from 01/11/2003 Label - Tyre pressures. - RP organisation no. - Paint code. E1AP0D0D 5

13 GENERAL DISPATCH IDENTIFICATION OF VEHICLES Type approval Structure Version (4) B Family (1) Depollution levels BD D Number of seats (2) Spécif 93/59 96/69 96/69 A 98/69 B RFNC/IF/IF RFN Engine (3) K US/CEE L/W L3/W3 L4/W4 L5/W5 C Version (4) Manual 4-speed gearbox /IF Variant (5) Manual 5-speed gearbox G A B C Family (1) Manual 6-speed gearbox B Dispatch Automatic 3-speed gearbox Number of seats (2) Automatic 4-speed gearbox H D E F A 5 seats Axle and/or gearbox gears K B 6 seats Manual 5-speed gearbox for South America C 7 seats No gearbox D 8 seats E 9 seats H 2 seats, european-specific multi-stage TAXI J 7 seats, if different form the base «C» (AF) Engine (3) Variants(5) RFN 2.0i 16V EW10J4 Entreprise convertible T WJY 1.9 D DW8B Integral alternator-starter (ADIN) AD RHX DW10BTED Without FAP SF 2.0 HDi DW10ATED4 Fiscal incentives IF RHZ DW10CTED Piloted manual gearbox P DW10BTED+ Downgraded depollution D (Private vehicle or Van TD (Van Convertible) RHW V HDi DW10ATED4 LPG dual fuel LPG (Cylindrical tank) LPG (Ring-shaped tank) STT2 (Stop and start) S Van Spain ES 6

14 IDENTIFICATION OF VEHICLES (4 X 2) RELAY (1) Gearbox identification reference. (2) Manufacturer s name plate. (3) Engine plate. (4) Paint code (on bonnet). (5) Chassis N (cold stamp on body). (6) Production N. GENERAL E1-P02UD 7

15 RELAY 4 X 4 IDENTIFICATION OF VEHICLES (4 X 4) (1) Gearbox identification reference. (2) Manufacturer s name plate. (3) Engine plate GENERAL (4) Transfer box (5) Paint code (6) Chassis N (cold stamp on body). (7) Production N. (8) Rear differential. E1-P02VD 8

16 IDENTIFICATION OF VEHICLES Type approval Structure Transmission (4) Wheelbase (6) Z Family (1) M 5-speed manual W 4 x 4 A Short wheelbase (2850 mm) B Payload (2) A Automatic B Medium wheelbase (3200 mm) R Engine (3) Bodywork (5) C Long wheelbase (3700 mm) ZB M Transmission (4) A Chassis cab G Super long wheelbase (4050 mm) RMFA/SX F Bodywork (5) B Bare chassis A Wheelbase (6) C Floor cab /SX Variant (7) D Platform cab Family (1) F Van Z Jumper / Relay G Platform double cab Payload (2) H Chassis double cab A 11 Q C 18 Q M Minibus B 15 Q D GVW reduced N Van with raised sides Engine (3) P Combi panorama 8/9 seater (CLUB) RFL XU10J2U R Combi 6/9 seater (CONFORT) 2.0 R6G XU10J2U/K W Minibus 10 seater (MERCOSUR) RHV 2.0 8S HDi DW10UTD 4HY 2.2 8S HDi DW12UTED TD SOFIM 2.8 L TD S 2.8 HDi SOFIM 2.8 L HDi 9 RELAY 4 X 4 GENERAL

17 GENERAL RELAY 4 X 4 IDENTIFICATION OF VEHICLES Type approval Variant (7) Van versions AX With EGR BXC Camping car Special with EGR BG LPG Van with raised roof BX Raised roof with EGR ZX Combi mixed N1 (5/6 seater) Italy AYC Camping car without EGR AM CNG Van AY Without EGR BYC Camping car without EGR AG LPG Van BY Raised roof without EGR AXC Camping car with EGR BM CNG Van with raised roof Private vehicle versions H Combi with raised roof M CNG Combi G LPG Combi MH CNG Combi with raised roof GH LPG Combi with raised roof MINIBUS versions AXx Bus 15 seater, 2 point seatbelts with EGR SX Bus GO with EGR, 12 seats, 2 pt belts (CH) AY3 Bus 15 seater, 2 point seatbelts without EGR AX2 Bus 14 seater, 3 point seatbelts with EGR SX Bus without EGR, 12 seats, 3 pt belts (CH) SX1 Bus with EGR, 13 seats, 3 pt belts (CH) AY Bus 15 seater, 2 point seatbelts without EGR AX1 Bus 16 seater, 2 point seatbelts with EGR SY1 Bus without EGR, 13 seats, 3 pt belts (CH) AY2 Bus 14 seater, 2 point seatbelts without EGR AX3 Bus 15 seater, 2 point seatbelts with EGR SX Bus Petrol 14 seater, 3 point belts (Switz.) AY1 Bus 16 seater, 2 point seatbelts without EGR MINIBUS versions (with speed limiter) AX4 Bus 15 seater, 2 point seatbelts with EGR AY6 Bus 14 seater, 3 point seatbelts without EGR AY5 Bus 16 seater, 2 point seatbelts without EGR AX6 Bus 14 seater, 3 point seatbelts with EGR AX5 Bus 16 seater, 2 point seatbelts with EGR AY7 Bus 15 seater, 3 point seatbelts without EGR AY4 Bus 15 seater, 2 point seatbelts without EGR AX7 Bus 15 seater, 3 point seatbelts with EGR 10

18 CAPACITIES (in litres) Draining methods. Oil capacities are defined according to the following methods. Draining of the engine lubrication system by GRAVITY Draining of the engine lubrication system by SUCTION Place the vehicle on horizontal ground (in the high position if hydropneumatic suspension). The engine should be hot (oil temperature 80 C). Drain the sump by gravity. Remove the oil filter cartridge (time for draining and drip-drip = 15 minutes approx.). Refit the cap with a new seal. Refit a new oil filter cartridge. Refill the engine with oil (see table for oil capacity). Start the engine to fill the oil filter cartridge. Stop the engine (allow to stabilise for 5 minutes). Place the vehicle on horizontal ground (in the high position if hydropneumatic suspension). The engine should be hot (oil temperature 80 C). Remove the oil by suction through the dipstick tube. Remove the oil filter cartridge. Maintain the suction of oil in the sump (15 minutes approx.). Refit a new oil filter cartridge. Refill the engine with oil (see table for oil capacity). Start the engine to fill the oil filter cartridge. Stop the engine (allow to stabilise for 5 minutes). WARNING : Remove the suction container before starting the engine GENERAL ESSENTIAL : Systematically check the oil level using the oil dipstick. 11

19 C15 CAPACITIES (in litres) Diesel 1.9 D GENERAL Engine type Engine with filter change Between Min. and Max. 5-speed gearbox Brake circuit Cooling system Fuel tank capacity WJX 4,5 1,

20 CAPACITIES (in litres) Petrol Diesel BERLINGO 1.1i 1.4i 1.6i 16V V HDi 1.9 D 2.0 HDi Engine plate Engine with filter change Between Min. and Max. 5-speed gearbox Hydraulic brake circuit Cooling system Fuel tank capacity HFX KFW NFU 9HZ WJY RHY 3 3,25 3,75 4,5 1,5 1,55 1,2 1,4 2 1,8 2 1,8 With ABS = 0,45 Without ABS = 0, GENERAL 13

21 DISPATCH CAPACITIES (in litres) GENERAL Engine type Engine with filter change Between Min. and Max. 5-speed gearbox Automatic gearbox after drainage Brake circuit Cooling system Fuel tank capacity Petrol 2.0i 16V Auto. 1.9 D 2.0 HDi (2) (3) (4) (5) DW10 ATED BTED CTED ATED BTED CTED V HDi RFN WJY RHZ RHX RHZ RHZ RHX RHZ RHW 4,25 4,5 5,5 4,75 1,7 1,4 [1,3 (1)] 1,4 1,9 1,8 1, ,5 LITRE 7 9 8,5 (1) = Vehicle with aircon. (2) = Up to RPO 9869 Versions : panel van, glazed van and floor cab. (3) = New Look JUMPY / DISPATCH (4) = From RPO 9870 (5) = Oil sump with increased capacity, yellow identification label on filler neck. 80 Diesel

22 CAPACITIES (in litres) RELAY Petrol Diesel 2.0i 2.0 8V HDi 2.2 8V HDi 2.8 TD 2.8 HDi (1) (2) Auto Engine type Engine with filter change Between Min. and Max. 5-speed gearbox Automatic gearbox after drainage Brake circuit Cooling system Fuel tank capacity RFL R6G RHV RHV 4HY 4HY S 4,75 4,50 5,25 6,25 5,25 6,25 5,5 7 1,5 2 2,7 (after draining) 8,5 0,59, for 11Q and 15Q 0,62 for 18Q 9 10,5 11,1 (with aircon) GENERAL (1) (2) = Oil sump with increased capacity, yellow identification label on valve cover 15

23 LUBRICANTS - TOTAL recommended oils GENERAL Evolutions (YEAR 2004). CITROËN C4 Petrol engine versions except 2.0 i 16V 180 hp (132 kw) : Normal maintenance interval : km ( miles). Severe maintenance interval : km ( miles). Petrol engine version 2.0L i 16V 180 hp (132 kw) : Normal maintenance interval : km ( miles). Severe maintenance interval : km ( miles). Diesel engine versions : WARNING : Vehicles HDi FAP (*) do not accept the energy economy oil TOTAL ACTIVA FUTUR W30 for France, TOTAL QUARTZ FUTURE W30 outside France. New Look CITROËN C5 Petrol engine versions: Normal maintenance interval : km ( miles). Severe maintenance interval : km ( miles). Diesel engine versions: WARNING : Vehicles HDi FAP (*) do not accept the energy economy oil TOTAL ACTIVA FUTUR W30 for France, TOTAL QUARTZ FUTURE W30 outside France. DV6 engines: Normal maintenance interval : km ( miles) Severe maintenance interval : km ( miles) DW engines : Normal maintenance interval : km ( miles) Severe maintenance interval : km ( miles) DV6 engines : Normal maintenance interval : km ( miles) Severe maintenance interval : km ( miles) DW engines: Normal maintenance interval : km ( miles) Severe maintenance interval : km ( miles) 16 ESSENTIAL : For all vehicles with a km ( miles) maintenance interval, use exclusively TOTAL ACTIVA/QUARTZ 7000 or 9000 or any other oils offering identical specifications to these. These oils offer specifications that are superior to those defined by norms ACEA A3 OR API SJ/CF. Failing this, it is essential to adhere to the maintenance programmes covering severe operating conditions.

24 Use of oil grade 10W40 It is possible to use the semi synthetic oil W40 on HDi and HDi FAP vehicles. WARNING : To avoid difficulties when starting from cold (< 20 C), use 5W40 oil. For more details, see the oil usage table (paragraph 3.3). Commercial description for energy economy oil TOTAL ACTIVA FUTUR W30 (France only). TOTAL QUARTZ FUTUR W30 (except France). The exclusions for use of this oil are the following : XSARA VTS V (XU10J4RS) JUMPER/RELAY 2.8 HDi and 2.8 TDi (SOFIM engine) HDi FAP vehicles CITROËN C3 HDi 16V (DV4TED4) CITROËN C8 2.2i (EW12J4) CITROËN C4 and C5 2.0i (EW10A) CITROËN C4 (EW10J4S) Engine oil norms Current norms The classification of these engine oils is established by the following recognised organisations : - S.A.E : Society of Automotive Engineers. - API : American Petroleum Institute. - ACEA : Association des Constructeurs Européens d Automobiles LUBRICANTS - TOTAL recommended oils S.A.E. Norms - Table for selection of engine oil grade Selection of engine oil grades recommended for climatic conditions in countries of distribution (see table, paragraph 3.3). Evolution of the norms to 01/01/2003 ACEA 2003 norms The meaning of the first letter has not changed, it still corresponds to the type of engine : A : petrol and dual fuel petrol / LPG engines. B : diesel engines. The figure following the first letter corresponds to the type of oil: 3 : high performance oils. 4 : oils specifically for direct injection diesel engines. 5 : very high performance oils permitting lower fuel consumption, specific to direct injection diesel engines. Examples : ACEA A3 : high performance oils specifically for petrol and dual fuel petrol / LPG engines ACEA A/B : blended oils giving very high performance for all engines, also permitting better fuel economy, specifically for direct injection diesel engines NOTE : From 01/01/2003 there is no longer any reference to the year of creation of the norm, (Example : ACEA A3/B3 98 becomes ACEA A3/B3). 17 GENERAL

25 GENERAL API NORMS : The meaning of the first letter has not changed, it still corresponds to the type of engine : S : petrol and dual fuel petrol / LPG engines. C : diesel engines. The second letter corresponds to the degree of evolution of the oil (ascending order). Example : Norm SL is more severe than norm SJ, corresponding to a higher level of performance. Recommendations. ESSENTIAL : To preserve engine performances, all engines fitted in CITROEN vehicles must be lubricated with high quality oils (synthetic or semi-synthetic). CITROËN engines are lubricated at the factory with TOTAL oil of grade S.A.E 5W-30. TOTAL oil of grade S.A.E 5W-30 allows improved fuel economies (approx 2.5%). The oil 5W30 is used only for the following engines (Year 2004) : - XU10 J4RS : XSARA VTS 2.0i 16V (3-door) - SOFIM : JUMPER / RELAY 2.8 TDi and 2.8 HDi. - HDi : With particle filter (FAP). - DV4 TED4 : CITROËN C V HDi. - EW 12J4 : CITROËN C8 2.2i. - EW 10A : CITROËN C4 and C5 2.0i. - EW10J4S engine : CITROËN C4 LUBRICANTS - TOTAL recommended oils WARNING : CITROËN engines prior to model year 2000 do not have to be lubricated with oils adhering to the norms : ACEA AI-98 and API SJ/CF EC or current norms ACEA A5/B5. Denomination of TOTAL oils according to country of marketing : TOTAL ACTIVA (France only). TOTAL QUARTZ (outside France). Summary Norms to be respected for engine oils (year 2004) Year Engine types concerned 2003 Petrol and LPG dual fuel engines Diesel engines ACEA Norms A3 or A5 (*) B3, B4 or B5 (*) API Norms SJ or SL (*) It is essential not to use engine oils respecting these norms for XU10J4RS, SOFIM 2.8 TDi and SOFIM 2.8 HDi engines, HDi engines with particle filter EW10A, EW12J4, DV4TED4. CF 18

26 Classes and grades of TOTAL recommended engine oils The oils distributed in each country are suited to the local climatic conditions.. Blended oils for all engines (petrol, diesel and dual fuel petrol/lpg) : S.A.E. ACEA API norms norms norms TOTAL ACTIVA 9000 A3/B3/ 5W40 TOTAL QUARTZ 9000 B4 TOTAL ACTIVA FUTUR 9000 (*) SL/CF 5W30 A5/B5 TOTAL QUARTZ FUTUR 9000 (*) TOTAL ACTIVRAC 10W40 A3/B3 (*) Blended oils for all engines giving fuel economy. Oils for petrol, diesel and dual fuel petrol/lpg engines : S.A.E. ACEA API norms norms norms TOTAL ACTIVA 7000 TOTAL QUARTZ W40 TOTAL QUARTZ W40 A3 SL TOTAL ACTIVA 7000 TOTAL QUARTZ W50 LUBRICANTS - TOTAL recommended oils Oils specifically for diesel engines : TOTAL ACTIVA DIESEL 7000 TOTAL QUARTZ DIESEL 7000 TOTAL ACTIVA DIESEL 7000 S.A.E. ACEA API norms norms norms 10W40 15W50 B3 CF GENERAL 19

27 LUBRICANTS - TOTAL recommended oils Oil usage table Huile TOTAL ACTIVA QUARTZ Synthetic 9000 Semi-synthetic 7000 Engine types 0W40 5W30 5W40 10W40 15W50 Hot countries Temperate countries Cold countries GENERAL Petrol engines EW10J4S (CITROËN C4) EW12J4 (CITROËN C8 2.2i 16V) EW10A (CITROËN C4 and C5) Other petrol engines X X X X X X X X X X X X X X X HDi engines with FAP (*) X X X (*) X Diesel engines Other HDi engines SOFIM 2.8 HDi and 2.8 TDi (RELAY) DV4 TED4 (C V HDi) X X X X X X X X X X X X Indirect injection diesel engines X X X X (*) Do not use this oil in cold climatic conditions (temperature less than 20 C). See the table below for the choice of TOTAL engine oil grades to be used according to the climatic conditions in the country of marketing. 20

28 LUBRICANTS - TOTAL recommended oils GENERAL E4AP006D 21

29 FRANCE LUBRICANTS - TOTAL recommended oils ENGINE OILS Blended oils for all engines, supplied in bulk Metropolitan FRANCE TOTAL ACTIVRAC Norms S.A.E : 10W40 GENERAL Metropolitan FRANCE Blended oils for all engines W40 FUTUR W30 (*) TOTAL ACTIVA Oils specifically for petrol and dual-fuel petrol / LPG engines W40 TOTAL ACTIVA DIESEL Oils specifically for diesel engines W W40 New Caledonia Guadeloupe Saint-martin Reunion W W50 Martinique W W W50 Guyana Tahiti Mauritius Mayotte (*) = Blended oils for all engines, giving fuel economy 22

30 EUROPE Germany LUBRICANTS - TOTAL recommended oils ENGINE OILS Blended oils for all engines TOTAL QUARTZ Oils specifically for petrol and dual-fuel petrol / LPG engines W W40 TOTAL QUARTZ DIESEL Oils specifically for diesel engines Austria Belgium Bosnia W40 FUTUR W30 (*) W W W W W W40 GENERAL Bulgaria W40 Cyprus W W40 Croatia W40 (*) = Blended oils for all engines, giving fuel economy 23

31 LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ DIESEL Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines Oils specifically for diesel engines GENERAL Denmark Spain Estonia Finland Great Britain W40 FUTUR W30 (*) W W W W W W W W40 Greece Holland (*) = Blended oils for all engines, giving fuel economy W W W W40 24

32 EUROPE Hungary LUBRICANTS - TOTAL recommended oils ENGINE OILS Blended oils for all engines TOTAL QUARTZ Oils specifically for petrol and dual-fuel petrol / LPG engines W W40 TOTAL QUARTZ DIESEL Oils specifically for diesel engines Italy Ireland Iceland W40 FUTUR W30 (*) W W40 GENERAL Latvia Lithuania W W40 Macedonia W40 (*) = Blended oils for all engines, giving fuel economy 25

33 EUROPE Malta LUBRICANTS - TOTAL recommended oils ENGINE OILS Blended oils for all engines TOTAL QUARTZ Oils specifically for petrol and dual-fuel petrol / LPG engines W W50 TOTAL QUARTZ DIESEL Oils specifically for diesel engines GENERAL Moldavia Norway Poland W40 FUTUR W30 (*) W W W W40 Portugal W40 Slovakia Czech Republic (*) = Blended oils for all engines, giving fuel economy W W40 26

34 LUBRICANTS - TOTAL recommended oils ENGINE OILS EUROPE TOTAL QUARTZ TOTAL QUARTZ DIESEL Romania Russia Slovenia Sweden Blended oils for all engines W40 FUTUR W30 (*) Oils specifically for petrol and dual-fuel petrol / LPG engines W W W W W40 Oils specifically for diesel engines W40 GENERAL Switzerland W40 Turkey (*) = Blended oils for all engines, giving fuel economy W W W40 27

35 EUROPE LUBRICANTS - TOTAL recommended oils Blended oils for all engines TOTAL QUARTZ ENGINE OILS Oils specifically for petrol and dual-fuel petrol / LPG engines TOTAL QUARTZ DIESEL Oils specifically for diesel engines GENERAL Ukraine Serbia-Montenegro W40 FUTUR W30 (*) W W W40 (*) = Blended oils for all engines, giving fuel economy 28

36 LUBRICANTS - TOTAL recommended oils ENGINE OILS OCEANIA TOTAL QUARTZ TOTAL QUARTZ DIESEL Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines Oils specifically for diesel engines Australia New Zealand W40 FUTUR W30 (*) W W40 AFRICA Blended oils for all engines TOTAL QUARTZ Oils specifically for petrol and dual-fuel petrol / LPG engines TOTAL QUARTZ DIESEL Oils specifically for diesel engines GENERAL Algeria, South Africa, Ivory Coast, Egypt, Gabon, Ghana, Kenya, Madagascar, Morocco, Nigeria, Senegal, Tunisia W W W W50 (*) = Blended oils for all engines, giving fuel economy 29

37 CENTRAL AND SOUTH AMERICA Argentina LUBRICANTS - TOTAL recommended oils Blended oils for all engines TOTAL QUARTZ ENGINE OILS Oils specifically for petrol and dual-fuel petrol / LPG engines TOTAL QUARTZ DIESEL Oils specifically for diesel engines GENERAL Brazil Chile Cuba W W W W40 Mexico Paraguay Uruguay 30

38 LUBRICANTS - TOTAL recommended oils ENGINE OILS SOUTH-EAST ASIA TOTAL QUARTZ TOTAL QUARTZ DIESEL China Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines W W50 Oils specifically for diesel engines South Korea Hong Kong India Indonesia W40 FUTUR W30 (*) W W W W40 GENERAL Japan Malaysia Pakistan W40 FUTUR W30 (*) W W W W50 (*) = Blended oils for all engines, giving fuel economy 31

39 SOUTH-EAST ASIA LUBRICANTS - TOTAL recommended oils Blended oils for all engines TOTAL QUARTZ ENGINE OILS Oils specifically for petrol and dual-fuel petrol / LPG engines TOTAL QUARTZ DIESEL Oils specifically for diesel engines GENERAL Philippines Singapore Taiwan Thailand Vietnam W W W W W W50 32

40 MIDDLE EAST Saudi Arabia Bahrain Dubai United Arab Emirates Iran LUBRICANTS - TOTAL recommended oils ENGINE OILS Blended oils for all engines TOTAL QUARTZ Oils specifically for petrol and dual-fuel petrol / LPG engines W50 TOTAL QUARTZ DIESEL Oils specifically for diesel engines W W W W50 GENERAL Israel Jordan Kuwait Lebanon Oman Qatar Syria Yemen W50 33

41 LUBRICANTS - TOTAL recommended oils GEARBOX OILS Manual and piloted manual gearboxes TOTAL TRANSMISSION BV Norms S.A.E : 75W80 Part No. : 9730 A2 GENERAL MB3 automatic gearbox 4HP20 and AL4 autoactive automatic gearboxes All countries TOTAL FLUIDE ATX TOTAL FLUIDE AT 42 Special oil distributed by CITROËN Part No. : 9730 A6 Special oil distributed by CITROËN Part No. : AM6 autoactive automatic gearbox Special oil distributed by CITROËN Part No. : 9980 D4 Transfer box and rear axle TOTAL TRANSMISSION X4 Part No. : 9730 A7 34

42 LUBRICANTS - TOTAL recommended fluids POWER STEERING OILS Power steering All vehicles except CITROËN C4 and C5 TOTAL FLUIDE ATX Power steering CITROËN C4 and C5 All countries TOTAL FLUIDE LDS Special oil distributed by r CITROËN Part No. : 9979 A3 Power steering Very cold countries ENGINE COOLANT FLUID TOTAL FLUIDE DA Special oil distributed by CITROËN Part No. : 9730 A1 GENERAL Packs CITROËN Part No. GLYSANTIN G33 REVKOGEL Litres All countries CITROËN fluid Protection : - 35C 5 Litres 20 Litres Litres

43 LUBRICANTS - TOTAL recommended fluids BRAKE FLUID Synthetic brake fluid Packs CITROËN Part No. 0,5 Litre All countries CITROËN fluid 1 Litre Litres GENERAL All countries TOTAL FLUIDE LDS Norm Orange CIRCUIT HYDRAULIQUE Packs CITROËN Part No A3 TOTAL LHM PLUS TOTAL LHM PLUS Very cold countries Colour Green 1 Litre 9979 A A2 WARNING : TOTAL FLUIDE LDS fluid cannot be blended with TOTAL LHM PLUS WARNING : CITROËN C5 : Use exclusively TOTAL FLUIDE LDS suspension fluid. All countries TOTAL HYDRAURINCAGE 36

44 LUBRICANTS - TOTAL recommended fluids SCREEN WASH FLUID Packs CITROËN Part No. Concentrated : 250 ml ZC U All countries Fluid ready to use 1 Litre 5 Litres GREASING General use ZC U ZC U ZC U Norms NLGI GENERAL All countries TOTAL MULTIS 2 TOTAL SMALL MECHANISMS 2 Note : NLGI = National Lubrificating Grease Institude. 37

45 ENGINE OIL CONSUMPTION I - Oil consumption depends on : - the engine type. - how run-in or worn it is. - the type of oil used. - the driving conditions. GENERAL II - An engine can be considered RUN-IN after: - 3,000 miles (5,000 km) for a PETROL engine. - 6,000 miles (10,000 km) for a DIESEL engine. III - MAXIMUM PERMISSIBLE oil consumption for a RUN-IN engine litres per 600 miles (1,000 km) for a PETROL engine. - 1 litre per 600 miles (1,000 km) for a DIESEL engine. DO NOT INTERVENE BELOW THESE VALUES. IV - OIL LEVEL : The level should NEVER be above the MAX. mark on the dipstick after changing or topping up the oil. - This excess oil will be used up rapidly. - It will reduce the engine output and adversely affect the operation of the air circuits and gas recycling. 38

46 ENGINE SPECIFICATIONS Petrol engines All Types ENGINE 1.1i 1.4i 1.6i 16V 2.0i 2.0i 16V Engine type Cubic capacity (cc) Bore / Stroke Compression ratio Power ISO or EEC KW - rpm Torque ISO or EEC (m.dan - rpm) HFX KFW NFU RFL R6G RFN /69 75/77 78,5/82 86/86 85/88 10,5/1 11/1 9,5/1 10,8/1 44, , ,

47 ENGINE ENGINE SPECIFICATIONS Diesel engines All Types V 1.9D 2.0 HDi 2.0 8V V 2.2 8V HDi HDi HDi HDi 2.8 TD 2.8 HDi Engine type Cubic capacity (cc) Bore / Stroke Compression ratio Power ISO or EEC KW - rpm Torque ISO or EEC (m.dan - rpm) 9HZ WJY RHY RHX RHZ RHV RHW 4HY S /88,3 82,2/88 85/88 86/86 85/96 94,4/100 18/1 23/1 17,6/1 9,5/1 18/1 19/ , , , , , ,

48 POWER UNIT SUSPENSION SPECIFICATIONS Engine : HFX - KFW BERLINGO ENGINE Tightening torques (m.dan) (1) : 4,5 ± 0,5 (2) : 6 ± 0,6 (3) : 5,4 ± 0,8 (4) : 4 ± 0,6 (5) : 2,4 ± 0,4 (6) : 6,5 ± 0,6 (7) : 2,2 ± 0,2 (8) : 3 ± 0,3 (9) : 2,6 ± 0,3 (10) : 4,5 ± 0,5 (11) : 4,5 ± 0,5 B1BP2TJP 41

49 ENGINE BERLINGO POWER UNIT SUSPENSION SPECIFICATIONS Engine : NFU Tightening torques (m.dan) (12) : 6 ± 0,6 (13) : 4 ± 0,6 (14) : 5,4 ± 0,8 (15) : 6 ± 0,6 (16) : 2 ± 0,3 (17) : 6,5 ± 0,6 (18) : 3 ± 0,3 (19) : 2,2 ± 0,2 (20) : 6 ± 0,6 (21) : 4,5 ± 0,5 (22) : 4,5 ± 0,5 B1BP2TKP 42

50 SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engines : HFX - KFW - NFU Crankshaft Accessories drive pulley 2,5 ± 0,2 Pinion on crankshaft Tightening 4 ± 0,4 Angular tightening 45 ±4 Cylinder block Sump 0,8 ± 0,2 Timing belt tensioner roller 2,1 ± 0,2 Accessories belt guide roller 2,5 ± 0,2 Alternator support 2,5 ± 0,2 Alternator TU1JP-TU3JP Pre-tightening 1 ± Tightening 3,7 ± 0,3 Alternator TU5JP4 Pre-tightening 1 ± Tightening 4 ±,04 Aircon compressor support 2,2 ± 0,2 Aircon compressor 2,3 ± 0,2 BERLINGO ENGINE 43

51 ENGINE BERLINGO SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engines : HFX - KFW - NFU Cylinder head Coolant outlet housing In plastic 0,8 ± 0,2 In aluminium 0,8 ± 0,2 Camshaft bearing caps (TU1JP-TU3JP) Tightening 2 ± 0,2 Angular tightening 44 ± 4 Camshaft bearing caps (TU5JP4) Tightening 2 ± 0,2 Angular tightening 50 ±5 Inlet manifold 0,8 ± 0,2 Exhaust manifold 1,8 ± 0,4 Screws for adjusting valve rockers 1,75 ± 0,25 Sparking plugs 3 Camshaft pulley screw (TU1JP-TU3JP) 3,7 ± 0,2 Camshaft pulley screw (TU5JP4) 4,5 ± 0,5 44

52 SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engines : HFX - KFW - NFU Flywheel /Clutch Flywheel 6,7 ± 1 (LOCTITE FRENETANCH) Oil pressure mechanism 2 ± 0,2 Lubrication circuit Oil pressure switch 3,5 ± 0,5 Oil pump 0,9 ± 0,1 Cooling circuit Coolant pump 1,6 ± 0,2 BERLINGO ENGINE 45

53 ENGINE DISPATCH POWER UNIT SUSPENSION SPECIFICATIONS Engine : RFN Tightening torques (m.dan) B1BK1X5D (1) : 5 ± 0,5 (2) : 4,5 ± 0,5 (3) : 6,5 ± 0,5 (4) : 3 ± 0,3 (5) : 4,5 ± 0,5 (6) : (7) : 6,5 ± 0,6 (8) : 3 ± 0,3 (9) : 4,5 ± 0,5 (*) (10) : 6 ± 0,6 (**) (11) : 5 ± 0,5 (12) : 9 ± 0,9 (13) : 4,5 ± 0,5 (14) : 6,5 ± 0,6 B1BK1X6D (*) AL4 autoactive gearbox (**) BE4 manual gearbox B1BK1X7D 46

54 SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engine : RFN Crankshaft Bearing cap fixing screws Pre-tightening 2 ± 0,2 Angular tightening 60 ±5 Bearing cap screws Pre-tightening 2,3 ± 0,2 Angular tightening 46 ±3 Accessories belt automatic tensioner roller 2 ± 0,2 Accessories belt guide roller Pre-tightening 1,5 ± 0,1 Tightening 3,7 ± 0,3 Accessories support block Tighten (2 studs) 0,7 ± 0,2 Pre-tightening (4 screws) 1 ± 0,1 Tightening 1,9 ± 0,2 47 Cylinder block Sump 0,8 ± 0,2 Timing belt guide roller Pre-tightening 1,5 ± 0,1 Tightening 3,7 ± 0,3 Timing belt tensioner roller 2,1 ± 0,2 RH engine support 6 ± 0,6 DISPATCH ENGINE

55 ENGINE DISPATCH SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engine : RFN Cylinder head Camshaft bearing cover 0,9 ± 0,1 Exhaust manifold 3,5 ± 0,3 Valve cover 1,1 ± 0,1 Camshaft pulley Pre-tightening 3 ± 0,3 Tightening 7,5 ± 0,7 Pulley on hub 2,1 ± 0,2 Timing pinion on crankshaft Pre-tightening 4 ± 0,4 Angular tightening 53 ±4 Flywheel / clutch Clutch mechanism 2 ± 0,2 Flywheel Pre-tightening (Sequence 1,5,3,7,2,6,4,8) 2 ± 0,2 Angular tightening (Sequence 1,5,3,7,2,6,4,8) 21 ±3 B1CP089C 48

56 SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) DISPATCH Engine : RFN Lubrication circuit Oil pump closing plate 0,8 ± 0,1 Oil pump Pre-tightening 0,7 ± 0,1 Tightening 0,9 ± 0,1 Injection circuit Common injection rail fixing screw 0,9 ± 0,1 Cooling circuit Coolant pump Pre-tightening (Sequence 1,2,3,4) 0,8 ± 0,1 Tightening (Sequence 1,2,3,4) 1,4 ± 0,1 Coolant outlet housing 0,9 ± 0,1 ENGINE B1GP08WC 49

57 ENGINE BERLINGO SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engine : 9HZ Crankshaft Bearing cap fixing screws Pre-tightening 1 ± 0,2 Slackening 180 Tightening 3 ± 0,3 Angular tightening 140 ± 5 Con rod screws Tightening 1 ± 0,1 Angular tightening 100 ± 5 Accessories drive belt pulley Pre-tightening 3,5 ± 0,4 Angular tightening 190 ± 5 Cylinder block Sump 1,3 ± 0,1 Timing belt guide roller 3,7 ± 0,3 Timing belt tensioner roller 2,7 ± 0,2 50

58 SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engine : 9HZ Cylinder head Camshaft bearing covers Pre-tightening 0,5 ± 0,1 Tightening 1 ± 0,1 Exhaust manifold 3 ± 0,3 Camshaft pulley Pre-tightening 2 ± 0,2 Angular tightening 50 ±5 Cylinder head Pre-tightening 2 ± 0,2 Tightening 4 ± 0,5 Angular tightening 260 ± 5 EGR valve 1 ± 0,1 Flywheel / Clutch Flywheel Pre-tightening 3 ± 0,3 Angular tightening 90 ±5 Clutch mechanism 2 ± 0,2 BERLINGO ENGINE 51

59 ENGINE BERLINGO SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engine : 9HZ Lubrication circuit Oil pump assembly Pre-tightening 0,5 ± 0,1 Tightening 0,9 ± 0,1 Oil/coolant heat exchanger 1 ± 0,2 Lubrication pipe for turbocharger 3 ± 0,5 Diesel injection circuit Diesel injection circuit Pre-tightening 4 ± 0,1 Angular tightening 65 ±5 Fuel high pressure common injection rail on engine block 2,2 ± 0,2 Union on fuel high pressure common injection rail Pre-tightening 1,7 ± 0,2 Tightening 2,2 ± 0,2 Diesel injection pump on support 2,2 ± 0,2 Union on diesel injector Pre-tightening 2 ± 0,5 Tightening 2,5 ± 0,3 Diesel injection pump pulley 5 ± 0,5 Union on diesel high pressure pump Pre-tightening 2 ± 0,5 Tightening 2,5 ± 0,3 52

60 SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engine : 9HZ Cooling circuit BERLINGO ENGINE Coolant pump Pre-tightening 0,3 ± 0,1 Tightening 0,9 ± 0,1 Coolant outlet housing Pre-tightening 0,3 ± 0,1 Tightening 0,7 ± 0,1 53

61 ENGINE BERLINGO POWER UNIT SUSPENSION SPECIFICATIONS Engine : WJY Tightening torques (m.dan) (1) : 4,5 ± 0,5 (2) : 6,5 ± 0,6 (3) : 2,2 ± 0,2 (4) : 5 ± 0,5 (5) : 2,2 ± 0,2 (6) : 4,5 ± 0,4 (7) : 4,5 ± 0,5 (8) : 4,5 ± 0,5 (9) : 4,5 ± 0,5 (10) : 4,5 ± 0,5 (*) (11) : 5 ± 0,5 (12) : 5 ± 0,5 (*) Coat the threads with LOCTITE FRENETANCHE (E3). B1BP2SZP 54

62 SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engine : WJY Crankshaft Bearing cap fixing screws 7 ± 0,7 Con rod nuts Pre-tightening 2 ± 0,2 Angular tightening 70 ±5 Accessories drive pulley hub Pre-tightening 4 ± 0,2 Angular tightening 55 ±5 Accessories drive pulley 1 ± 0,1 Cylinder block Piston skirt spray jet 1 ± 0,1 Sump 1,6 ± 0,1 Timing belt guide roller 4,3 ± 0,4 Timing belt tensioner roller 2,1 ± 0,2 Cylinder head Camshaft bearing covers 2 ± 0,2 Exhaust manifold 3 ± 0,3 Valve cover 0,5 Camshaft / hub 4,3 ± 0,4 Camshaft pinion / hub 2,3 ± 0,2 BERLINGO ENGINE 55

63 ENGINE BERLINGO SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engine : WJY Crankshaft Bearing cap fixing screws 7 ± 0,7 Con rod nuts Pre-tightening 2 ± 0,2 Angular tightening 70 ±5 Accessories drive pulley hub Pre-tightening 4 ± 0,2 Angular tightening 55 ±5 Accessories drive pulley 1 ± 0,1 Cylinder block Piston skirt spray jet 1 ± 0,1 Sump 1,6 ± 0,1 Timing belt guide roller 4,3 ± 0,4 Timing belt tensioner roller 2,1 ± 0,2 Cylinder head Camshaft bearing covers 2 ± 0,2 Exhaust manifold 3 ± 0,3 Valve cover 0,5 Camshaft / hub 4,3 ± 0,4 Camshaft pinion / hub 2,3 ± 0,2 56

64 SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engine : WJY Flywheel Flywheel 4,8 ± 0,4 Clutch mechanism 2 ± 0,2 Lubrication circuit Oil pump 2,3 ± 0,2 Oil/coolant heat exchanger 7 ± 0,7 Injection circuit Injector on cylinder head 9 ± 0,9 Diesel fuel heater 1,5 ± 0,1 Injection pump 2 ± 0,2 Union on injector 2,5 ± 0,2 Injection pump pulley 2,3 ± 0,2 Cooling circuit Coolant pump 1,5 ± 0,1 Coolant inlet housing 1,8 ± 0,1 BERLINGO ENGINE 57

65 ENGINE BERLINGO POWER UNIT SUSPENSION SPECIFICATIONS Engine : RHY Tightening torques (m.dan) (1) : 4,5 ± 0,5 (2) : 6,5 ± 0,6 (3) : 2,2 ± 0,2 (4) : 5 ± 0,5 (5) : 2,2 ± 0,2 (6) : 4,5 ± 0,5 (7) : 2 ± 0,2 (8) : 4,5 ± 0,4 (9) : 4,5 ± 0,4 (10) : 2 ± 0,2 (11) : 2,2 ± 0,2 (12) : 6,1 ± 0,6 (13) : 5 ± 0,5 (14) : 4,5 ± 0,4 B1BP2TRP 58

66 SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engines : RHY - RHX - RHZ Crankshaft Bearing cap fixing screws Pre-tightening 2,5 ± 0,2 Angular tightening 60 ±5 Con rod nuts Pre-tightening 2 ± 0,2 Angular tightening 70 ±5 Accessories drive pulley Pre-tightening 4 ± 0,2 Angular tightening 51 ±5 Cylinder block Piston skirt spray jet 1 ± 0,1 Sump 1,6 ± 0,1 Timing belt guide roller 4,3 ± 0,4 Timing belt tensioner roller 2,5 ± 0,2 Cylinder head Camshaft bearing covers 1 ± 0,1 Exhaust manifold 2 ± 0,2 Valve cover 0,8 Camshaft / hub 4,3 ± 0,4 Camshaft pulley / camshaft hub 2 ± 0,2 BERLINGO - DISPAT- ENGINE 59

67 ENGINE BERLINGO - DISPATCH SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engines : RHY - RHX - RHZ Flywheel Flywheel 4,8 ± 0,4 Clutch mechanism 2 ± 0,2 Lubrication circuit Oil pump 1,6 ± 0,2 Oil/coolant heat exchanger 7 ± 0,7 Turbocharger lubrication pipe Engine end 4,8 ± 0,4 Turbocharger end 2,2 ± 0,2 Injection circuit Diesel injection circuit 3 ± 0,3 Unions on fuel high pressure common injection rail 2 ± 0,2 Injection pump on support 2,3 ± 0,2 Union on diesel injector 2 ± 0,2 Injection pump pulley 5 ± 0,5 Union on fuel high pressure pump 2 ± 0,2 Cooling circuit Coolant pump 1,5 ± 0,1 Coolant inlet housing 1,8 ± 0,1 60

68 POWER UNIT SUSPENSION SPECIFICATIONS DISPATCH Engine : RHW Reference Description 1 Upper RH torque reaction rod 2 Upper RH engine support 3 RH engine flexible support 4 Upper RH intermediate engine support 5 Lower RH engine support 6 Torque reaction rod 7 Upper RH intermediate engine support 8 LH engine support 9 RH engine flexible support 10 Lifting bracket, flywheel side 11 Lifting bracket, timing side ENGINE B1BK3EED 61

69 ENGINE DISPATCH B1BK3EDD POWER UNIT SUSPENSION SPECIFICATIONS Engine : RHW Tightening torques (m.dan) (12) : 5 ± 0,5 (13) : 4,5 ± 0,5 (14) : 4,5 ± 0,5 (15) : 6 ± 0,6 (16) : 3 ± 0,3 (17) : 2 ± 0,2 (18) : 4,5 ± 0,5 (19) : 4,5 ± 0,5 (20) : 4,5 ± 0,5 (21) : 6,5 ± 0,6 (22) : 9 ± 0,9 (23) : 4,5 ± 0,5 (24) : 4,5 ± 0,5 (25) : 5 ± 0,5 (26) : 2,5 ± 0,2 (27) : 3 ± 0,3 (28) : 6,5 ± 0,6 (29) : 1,5 ± 0,1 (30) : 1,2 ± 0,1 62

70 SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engine : RHW Crankshaft Bearing cap fixing screws Pre-tightening 2,5 ± 0,2 Angular tightening 60 ±5 Con rod nuts Pre-tightening 2 ± 0,2 Angular tightening 70 ±5 Accessories drive pulley Pre-tightening 4 ± 0,2 Angular tightening 51 ±5 Cylinder block Piston skirt spray jet 1 ± 0,1 Sump 1,6 ± 0,1 Timing belt guide roller 4,3 ± 0,4 Timing belt tensioner roller 2,5 ± 0,2 Cylinder head Camshaft bearing covers 1 ± 0,1 Exhaust manifold 2 ± 0,2 Valve cover 0,8 Camshaft / hub 4,3 ± 0,4 Camshaft pulley / camshaft hub 2 ± 0,2 DISPATCH ENGINE 63

71 ENGINE DISPATCH SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engine : RHW 64 Flywheel Flywheel 4,8 ± 0,4 Clutch mechanism 2 ± 0,2 Lubrication circuit Oil pump 1,6 ± 0,2 Oil/coolant heat exchanger 7 ± 0,7 Turbocharger lubrication pipe Engine end 4,8 ± 0,4 Turbocharger end 2,2 ± 0,2 Injection circuit Diesel injection circuit 3 ± 0,3 Unions on fuel high pressure common injection rail 2 ± 0,2 Injection pump on support 2,3 ± 0,2 Union on diesel injector 2 ± 0,2 Injection pump pulley 5 ± 0,5 Union on fuel high pressure pump 2 ± 0,2 Cooling circuit Coolant pump 1,5 ± 0,1 Coolant inlet housing 1,8 ± 0,1

72 POWER UNIT SUSPENSION SPECIFICATIONS Engines : RHV - 4HY RELAY ENGINE Tightening torques (m.dan) (1) : 8 ± 0,8 (2) : 5 ± 0,5 (3) : 5 ± 0,5 (4) : 9 ± 0,9 (5) : 8 ± 0,8 B1BP2JBD 65

73 ENGINE RELAY SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engine : RHV Crankshaft Bearing cap fixing screws Pre-tightening 2,5 ± 0,2 Angular tightening 60 ±5 Con rod nuts Pre-tightening 2 ± 0,2 Angular tightening 70 ±5 Accessories drive pulley Pre-tightening 4 ± 0,4 Angular tightening 51 ±5 Carter cylindres Piston skirt spray jet 1 ± 0,1 Sump 1,6 ± 0,2 Timing belt guide roller 2,5 ± 0,2 Timing belt tensioner roller 2,5 ± 0,2 RH engine support 2,7 ± 0,2 Cylinder head Camshaft bearing covers 1 ± 0,1 Exhaust manifold 2 ± 0,2 Valve cover 0,8 ± 0,1 Camshaft pulley 4,3 ± 0,4 Hub pulley 2 ± 0,2 66

74 SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engine : RHV Flywheel Flywheel 4,8 ± 0,5 Clutch mechanism 2 ± 0,2 Lubrication circuit Oil pump 1,3 ± 0,1 Oil/coolant heat exchanger 5,8 ± 0,5 Turbocharger lubrication pipe Engine end 3 ± 0,3 Turbocharger end 2 ± 0,2 Diesel injection circuit Injector fixing flange nut 3 ± 0,3 Unions on fuel high pressure common injection rail 2,5 ± 0,2 Injection pump on support 2,25 ± 0,2 Union on diesel injector 3 ± 0,3 Injection high pressure pump pulley 5 ± 0,5 Union on fuel high pressure pump 2,5 ± 0,2 Cooling circuit Coolant pump 1,5 ± 0,1 Coolant inlet housing 2 ± 0,2 RELAY ENGINE 67

75 ENGINE RELAY SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engine : 4HY Crankshaft Bearing cap fixing screws Pre-tightening 2,5 ± 0,2 Angular tightening 60 ±5 Con rod nuts Pre-tightening 2,3 ± 0,3 Angular tightening 46 ±5 Accessories drive pulley Pre-tightening 7 ± 0,7 Angular tightening 82 ±5 Carter cylindres Piston skirt spray jet 1 ± 0,1 Sump 1,6 ± 0,2 Timing belt guide roller 4,3 ± 0,2 Timing belt tensioner roller 2,5 ± 0,2 RH engine support 2,7 ± 0,2 Cylinder head Camshaft bearing covers 1 ± 0,1 Exhaust manifold 2 ± 0,2 Valve cover 0,8 ± 0,1 Camshaft pulley 4,3 ± 0,4 Hub pulley 2 ± 0,2 68

76 SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engine : 4HY Flywheel Flywheel 4,8 ± 0,5 Clutch mechanism 2 ± 0,2 Lubrication circuit Oil pump 1,3 ± 0,1 Oil/coolant heat exchanger 5,8 ± 0,5 Turbocharger lubrication pipe Engine end 3 ± 0,3 Turbocharger end 2 ± 0,2 Diesel injection circuit Injector fixing flange nut 3 ± 0,3 Unions on fuel high pressure common injection rail 2,7 ± 0,2 Injection pump on support 2,25 ± 0,2 Union on diesel injector 2,7 ± 0,2 Injection high pressure pump pulley 5 ± 0,5 Union on fuel high pressure pump 2,5 ± 0,2 Cooling circuit Coolant pump 1,5 ± 0,1 Coolant inlet housing 2 ± 0,2 RELAY ENGINE 69

77 ENGINE RELAY POWER UNIT SUSPENSION SPECIFICATIONS Engine : Tightening torques (m.dan) (1) : 8 ± 0,8 (2) : 5 ± 0,5 (3) : 5 ± 0,5 (4) : 5 ± 0,5 (5) : 8 ± 0,8 (6) : 9 ± 0,9 (7) : 9 ± 0,9 (8) : 5 ± 0,5 (9) : 5 ± 0,5 B1BP22DD 70

78 SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engine : Crankshaft Con rod screws Pre-tightening 5 ± 0,5 Angular tightening 60 ±5 Accessories drive pulley 2 ± 0,2 Carter cylindres Piston skirt spray jet 4 ± 0,4 Sump 1,8 ± 0,2 Lower cylinder cover on upper cylinder cover Pre-tightening 5 ± 0,5 Angular tightening 90 ±5 Timing belt tensioner roller 4 ± 0,4 Timing belt guide roller Screw M8 2,5 ± 0,2 Screw M10 4 ± 0,4 Cylinder head Camshaft bearing cap covers 1,8 ± 0,2 Inlet manifiold 2,5 ± 0,2 Exhaust manifiold 2,5 ± 0,2 Valve cover Screw M6 1 ± 0,1 Screw M8 2,5 ± 0,2 Camshaft pinion 2,5 ± 0,2 Injection pump pinion 10 ± 1 71 RELAY ENGINE

79 ENGINE RELAY SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engine : Flywheel Flywheel Pre-tightening 3 ± 0,3 Angular tightening 90 ±5 Clutch mechanism 3 ± 0,3 Lubrication circuit Oil pump assembly Screw M8 2,5 ± 0,2 Screw M12 6 ± 0,6 Oil/coolant heat exchanger Screw 56 mm long 7 ± 0,7 Screw 74 mm long 8 ± 0,8 Diesel injection circuit Union on diesel injector 3,3 ± 0,3 Diesel injection pump 2,5 ± 0,2 Diesel injection pump pinion 10 ± 1 Union on diesel injection pump 2,5 ± 0,2 Cooling circuit Coolant pump 5 ± 0,5 72

80 POWER UNIT SUSPENSION SPECIFICATIONS Engine : S RELAY ENGINE Tightening torques (m.dan) (1) : 8 ± 0,8 (2) : 5 ± 0,5 (3) : 5 ± 0,5 (4) : 5 ± 0,5 (5) : 8 ± 0,8 (6) : 9 ± 0,9 (7) : 9 ± 0,9 (8) : 5 ± 0,5 (9) : 5 ± 0,5 B1BP2E0D 73

81 ENGINE RELAY SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engine : S Crankshaft Bearing cap fixing screws Pre-tightening 5 ± 0,5 Angular tightening 63 ±5 Con rod nuts 1,8 ± 0,2 Accessories drive pulley hub 20 ± 2 Carter cylindres Piston skirt spray jet 4 ± 0,4 Sump 1,8 ± 0,2 Lower cylinder cover on upper cylinder cover Pre-tightening 5 ± 0,5 Angular tightening 90 ±5 Timing belt tensioner roller 4 ± 0,4 Timing belt guide roller 2,5 ± 0,2 Timing belt guide roller support 2,5 ± 0,2 Cylinder head Camshaft bearing cap covers 1,8 ± 0,2 Inlet manifiold 2,5 ± 0,2 Exhaust manifiold 2,5 ± 0,2 Valve cover Screw M6 1 ± 0,1 Screw M8 2,5 ± 0,2 Camshaft pinion 2,5 ± 0,2 Injection pump pinion 10 ± 1 74

82 SPECIAL FEATURES - TIGHTENING TORQUES (m.dan) Engine : S Flywheel Flywheel Pre-tightening 3 ± 0,3 Angular tightening 90 ±5 Clutch mechanism 3 ± 0,3 Lubrication circuit Oil pump assembly Screw M8 2,5 ± 0,2 Screw M12 6 ± 0,6 Oil/coolant heat exchanger 7 ± 0,7 Diesel injection circuit Injector fixing flange nut 4 ± 0,4 Unions on fuel high pressure common injection rail 2 ± 0,2 Fuel high pressure pump 2,5 ± 0,2 Union on diesel injector 2 ± 0,2 Diesel injection pump pinion 10 ± 1 Union on diesel injection pump 2 ± 0,2 Cooling circuit Coolant pump 5 ± 0,5 RELAY ENGINE 75

83 ENGINE SPECIAL FEATURES - CYLINDER HEAD TIGHTENING Engines all Types Cleaning to be carried out just prior to refitting the cylinder head WARNING : Clean the contact faces with the approved CITROËN cleaning product. Do not use abrasives or cutting tools on the contact faces. The contact faces must not bear any traces of impact or scratching. Insert a tap in the threads of the holes in the cylinder block receiving the cylinder head bolts. Brush the threads of the cylinder head bolts.. Oil the threads and under the heads of the bolts, using MOLYKOTE G RAPID PLUS). Engines Tightening (m.dan) Cylinder head bolts (Max. reusable length in mm) HFX - KFW Pre-tightening 2 ± 0,2 Angular tightening 240 ± 5 175,5 ± 0,5 B1BP10LC Pre-tightening 2 ± 0,2 NFU Angular tightening 260 ± 5 Pre-tightening 3,5 ± 0,3 RFL Tightening 7 ± 0,7 R6G Angular tightening 160 ± ± 0,3 B1DP05BC 76

84 SPECIAL FEATURES - CYLINDER HEAD TIGHTENING Engines all Types Cleaning to be carried out just prior to refitting the cylinder head WARNING : Clean the contact faces with the approved CITROËN cleaning product. Do not use abrasives or cutting tools on the contact faces. The contact faces must not bear any traces of impact or scratching. Insert a tap in the threads of the holes in the cylinder block receiving the cylinder head bolts. Brush the threads of the cylinder head bolts.. Oil the threads and under the heads of the bolts, using MOLYKOTE G RAPID PLUS). Engines Tightening (m.dan) Cylinder head bolts (Max. reusable length in mm) ENGINE B1DP05BC Pre-tightening 1,5 ± 0,1 Tightening 5 ± 0,5 RFN Slackening Tightening 2 ± 0,2 Angular tightening 285 ± 5 Pre-tightening 2 ± 0,2 9HZ Tightening 4 ± 0,4 149 Angular tightening 260 ± 5 B1DP1DLC 77

85 ENGINE SPECIAL FEATURES - CYLINDER HEAD TIGHTENING Engines all Types Cleaning to be carried out just prior to refitting the cylinder head WARNING : Clean the contact faces with the approved CITROËN cleaning product. Do not use abrasives or cutting tools on the contact faces. The contact faces must not bear any traces of impact or scratching. Insert a tap in the threads of the holes in the cylinder block receiving the cylinder head bolts. Brush the threads of the cylinder head bolts.. Oil the threads and under the heads of the bolts, using MOLYKOTE G RAPID PLUS). Engines Tightening (m.dan) Cylinder head bolts (Max. reusable length in mm) Pre-tightening 2 ± 0,2 WJY Tightening 6 ± 0,6 125,5 Angular tightening 180 ± 5 B1DP075C RHY - RHX Pre-tightening 1,8 ± 0,2 RHZ - RHW Tightening 6 ± 0,5 133,3 Angular tightening 220 ± 5 B1DP05BC 78

86 SPECIAL FEATURES - CYLINDER HEAD TIGHTENING Engines all Types Cleaning to be carried out just prior to refitting the cylinder head WARNING : Clean the contact faces with the approved CITROËN cleaning product. Do not use abrasives or cutting tools on the contact faces. The contact faces must not bear any traces of impact or scratching. Insert a tap in the threads of the holes in the cylinder block receiving the cylinder head bolts. Brush the threads of the cylinder head bolts.. Oil the threads and under the heads of the bolts, using MOLYKOTE G RAPID PLUS). Engines Tightening (m.dan) Cylinder head bolts (Max. reusable length in mm) ENGINE B1DP05BC Pre-tightening 2,2 ± 0,5 Tightening 6 ± 0,6 RHV - 4HY Slackening 1 tour 133,3 Tightening 6 ± 0,6 Angular tightening 220 ± Pre-tightening 6 ± 0, S Angular tightening 180 ± 5 B1DP1ADD 79

87 ENGINE Engine families Engine type AUXILIARY EQUIPMENT DRIVE BELT TU XU EW JP JP4 J2U J2U/K J4 HFX KFW NFU RFL R6G RFN BERLINGO X X X DISPATCH X RELAY X X See pages : 84 to to

88 Engine families AUXILIARY EQUIPMENT DRIVE BELT DV DW SOFIM ATED ATED4 B TD BTED CTED UTD ATED4 UTED TD BTED V HDi 1.9 D 2.0 HDi 2.0 8S HDi V HDi 2.2 8S HDi 2.8 TD 2.8 HDi ENGINE Engine type C15 9HZ WJY RHY RHX RHZ RHV RHW 4HY S X BERLINGO X X X DISPATCH X X X X RELAY X X X X See pages : to to to to to

89 ENGINE BELT TENSION CORRESPONDENCE TABLE! 4099-T (C.TRONIC.105) Tools 4122-T (C.TRONIC.105.5)!!! B1EP135D 82

90 AUXILIARY EQUIPMENT DRIVE BELT Engines : All Types Petrol and Diesel ENGINE Tools. - Belt tension measuring instrument : T. ESSENTIAL. - Before refitting the auxiliary equipment drive belt, check that : 1) The roller(s) rotate freely (no play or stiffness). 2) The belt is correctly engaged in the grooves of the various pulleys. 83

91 ENGINE BERLINGO AUXILIARY EQUIPMENT DRIVE BELT Engines : HFX - KFW - NFU Without air conditioning Tools. [1] Pliers for removing plastic pegs : 7504-T [2] Belt tension measuring instrument : 4122-T [3] TORX spanner Remove. - Slacken the central screw (1).tool [3] - Detension the tensioner roller (2), (flat spanner 27 on flat). - Remove the belt. B1BP234C Refit. - Position the belt. - Hold the belt in position using the tensioner roller (2). - Pre-tension the belt 120 ± 3 SEEM units, tool [2]. - Rotate the engine 2 to 4 times. - Check the tension : 120 ± 3 SEEM units. - Tighten the central screw (1) tool [3]. - Remove the tool [2]. NOTE : If the belt tension is more than 150 SEEM units, the belt is rendered un-usable. 84

92 AUXILIARY EQUIPMENT DRIVE BELT Engines : HFX - KFW - NFU With air conditioning BERLINGO ENGINE Tools. [1] Pliers for removing plastic pegs : 7504-T [2] TORX spanner. Remove. - Detension the automatic tensioner (3). - Place a Ø 4 mm peg at (a) to immobilise the automatic tensioner. - Remove the belt. Refit. - Position the belt - Remove the Ø 4 mm peg. - Release the automatic tensioner (3). - Tighten the screw of the automatic tensioner (3), using tool [2]. B1BP235C 85

93 ENGINE RELAY AUXILIARY EQUIPMENT DRIVE BELT Engines : RFL - R6G Alternator belt (without air conditioning) Tools. [1] Belt tension measuring instrument : 4122-T B1BP044C B1BP045C Tensioning the belt - Tension the belt (4) using the screw (2). - Fit the tool [1]. - Pre-tension to : 120 ± 10 SEEM units. - Remove the tool [1]. - Rotate the crankshaft by 3 turns. - Fit the tool [1]. - Adjust the tension using the screw (2) to : 140 ± 10 SEEM units. - Remove the tool [1]. - Tighten the nut (1) to 2 m.dan and the screw (3) to 4 m.dan. - Run the engine for 10 min. - Check the tension of the belt (4). - The nominal value must not be less than 100 SEEM units. - If this is not the case, restart the tensioning operation. 86

94 AUXILIARY EQUIPMENT DRIVE BELT Engines : RFL - R6G Alternator belt (with air conditioning) RELAY ENGINE B1BP1LFC NOTE : If the vehicle is equipped with power steering, remove the belt (5).. Tensioning the belt - Tension the belt (5) using the screw (6). - Fit the tool [1]. - Pre-tension to : 120 ± 10 SEEM units. - Remove the tool [1]. - Rotate the crankshaft by 4 turns. - Fit the tool[1]. - Loosen the screws (3) and (4). - Adjust the tension, using screw (6), to : 140 ± 5 SEEM units. - Remove the tool [1]. - Tighten the screws (3) and (4) to 2,5 ± 0,2 m.dan. - Run the engine for 10 minutes. - Check the tension of the belt (5). - The nominal value must not be less than 100 SEEM units. - If this is not the case, restart the tensioning operation. B1BP04AC 87

95 ENGINE B1BP04BC B1BP04CC RELAY AUXILIARY EQUIPMENT DRIVE BELT Engines : RFL - R6G Power-assisted steering pump belt Tools. [1] Belt tension measuring instrument : 4122-T Removing the belt - To make it easier to move the pump, unclamp the hydraulic pipes. - Slacken the articulating screws of the pump. - Slacken the nut (2) to release the belt (1). Tensioning the belt - Tension the belt by turning the nut (2). - Fit the tool [1]. - Pre-tension to : 70 ± 5 SEEM units. - Remove the tool [1]. - Rotate the crankshaft by 3 turns. - Fit the tool [1]. - Adjust the tension by turning the nut (2) to : 75 ± 5 SEEM units. - Remove the tool [1]. - Tighten the screws (3) and the pump articulating screws to 2,5 ± 0,2 m.dan. - Run the engine for 10 minutes. - Check the belt tension (1). - The nominal value must not be less than 70 SEEM units. - If this is not the case, restart the tensioning operation. 88

96 Without air conditioning AUXILIARY EQUIPMENT DRIVE BELT Engine : RFN DISPATCH With air conditioning ENGINE Tools. [1] Pliers for removing plastic pegs : 7504-T Remove the belt. - Detension the belt (3) by turning the screw (2) of the tensioner roller (1) (anti-clockwise). - The screw (2) (WARNING : not left hand screw). - Remove the belt (3), while keeping the tensioner roller (1) tight Refit the belt. - Refit the belt (3), while keeping the tensioner roller (1) tight. - Release the tensioner roller (1). B1BP23PC B1BP23QC B1BP23PC B1BP23RC 89

97 ENGINE B1BP2Z6D BERLINGO AUXILIARY EQUIPMENT DRIVE BELT Engine : 9HZ Tools. [1] Dynamic tensioner compression lever : (-).0188.Z [2] Peg for dynamic tensioner roller : (-).0194.F Removing Remove the front RH wheel, the under-engine sound-deadening and the splash-shield. Vehicle with air conditioning : WARNING : Mark the direction of fitting of the accessories drive belt, if it is to be re-used. Compress the tensioner roller (1) by acting at «a» (clockwise), using tool [1]. Peg at «b», using tool [2]. Remove the accessories drive belt. IMPERATIVE: Check that the rollers (1) and (2) can turn freely (without play and without tight spots). Refitting WARNING : Belt to be re-used, mark the direction of fitting of the belt. Refit the auxiliaries drive belt. Compress the dynamic tensioner roller (1) by acting at «c» (clockwise), using tool [1]. Remove tool [2]. IMPERATIVE : Make sure that the auxiliaries drive belt is correctly positioned in the grooves of the various pulleys. Complete the refitting in the opposite order to removal. B1BP2ZCD 90

98 AUXILIARY EQUIPMENT DRIVE BELT Engine : WJY Without power steering - Without air conditioning C15 ENGINE Tools. [1] Belt tension measuring instrument : : 4122-T Remove. - Loosen the screws (2). - Tighten the screw (1) until it is against its stop, to detension the belt. - Remove the belt. Refit. - Refit the belt. - Fit the tool [1] at "d". - Tighten the screw (1) to obtain : 115 ± 10 SEEM units. - Tighten the screws (2) to 2,5 ± 0,2 m.dan. - Remove the tool [1]. B1BP1SDC B1BP1SEC 91

99 ENGINE C15 - BERLINGO - DISPATCH AUXILIARY EQUIPMENT DRIVE BELT Engine : WJY With power steering - Without air conditioning Tools. [1] Belt tension measuring instrument : 4122-T Remove. WARNING : If the belt is to be reused, measure the tension before removal. Loosen : - the screw (1). - the nut (2). NOTE : The tensioner arm (3) must be against the alternator. - Remove the belt. B1BP1SHD 92

100 AUXILIARY EQUIPMENT DRIVE BELT C15 - BERLINGO - DISPATCH Engine : WJY With power steering - Without air conditioning (continued) ENGINE 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. B1BP1SJD New belt: Tension should be 110 SEEM units. - Tighten the screw (1) to 9.5 m.dan. - Check belt tension (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]. 93

101 ENGINE C15 - BERLINGO - DISPATCH AUXILIARY EQUIPMENT DRIVE BELT Engine : WJY With power steering - With air conditioning. Tools. [1] Dynamic tensioner peg : (-) 0188 G. [2] Belt tension measuring instrument : 4122-T. Removal. - Peg the dynamic tensioner (1) at "a", using tool [1]. - Loosen the screw (2) of the roller (3). - Turn the roller (3) backwards. - Remove the belt. NOTE : If it can not be pegged at "a" : - Loosen the screw (2) of the roller (3). - Using a 7 mm square drive, turn the roller (3) at "b". - Peg the tensioner (1) at "a", using tool [1]. NOTE : If the belt is broken : - Support the engine using a jack (insert a wooden block between the housing and the jack). - Remove the right hand engine support. - Using a square drive at (b) turn the tool (3) in the direction of the arrow "a", so that it can be pegged at "a" using the tool [1]. B1BP1SKC 94

102 AUXILIARY EQUIPMENT DRIVE BELT C15 - BERLINGO - DISPATCH Engine : WJY With power steering - With air conditioning (continued) ENGINE Refitting - Refit the belt. - Using a 7 mm square drive at "b", turn the roller (3), until the tool [1] located at "a" becomes free. - Tighten the screw (2). - Remove the tool [1]. B1BP1SLC 95

103 ENGINE BERLINGO - DISPATCH AUXILIARY EQUIPMENT DRIVE BELT Engines : RHY - RHX - RHZ Without air conditioning Tools. 1] Belt tension adjusting square : (-).0188 J2 [2] Ø 4 mm peg : (-).0188.Q1 [3] Ø 2 mm peg : (-).0188.Q2. [4] Dynamic tensioner compression lever : (-).0188.Z Remove RE-USE OF BELT WARNING : Mark the direction the belt was fiited in case of re-use of the same belt. - Compress the tensioner roller (2) by action at «a» (in anti-clockwise direction), tool [4]. - Keep the tensioner roller (2) compressed and remove the belt. NO RE-USE OF BELT. - Compress the tensioner roller (2) by action at «a» (in anti-clockwise direction), tool [4]. - Peg using tool [2], at «b». - Hold the tensioner roller (2) compress and remove the belt. - Loosen the screw (1). B1BP1YKD 96

104 AUXILIARY EQUIPMENT DRIVE BELT BERLINGO - DISPATCH Engines : RHY - RHX - RHZ Without air conditioning (continued) ENGINE Refitting RE-USED BELT. - Compress the tensioner roller (2) by action at «a» (in anti-clockwise direction), tool [4]. - Refit the belt. WARNING : Respect the direction belt was fitted. Remove the tool 4]. NEW BELT. Refit the belt. - Turn the eccentric roller (3), tool [1] (clockwise) to free the tool [2] from its pegging at «b». - Hold the eccentric roller (3), tool [1], and tighten the screw (1) to 4.3 m.dan. - Remove the tool [2]. - Rotate the crankshaft 4 times in the direction of rotation. - Check that it is possible to peg at «b», tool [3]. - If not possible to peg, restart the adjustment. B1BP1YMD 97

105 ENGINE BERLINGO - DISPATCH AUXILIARY EQUIPMENT DRIVE BELT Engines : RHY - RHX - RHZ With air conditioning Tools. [1] Belt tension adjusting square : (-).0188 J2 [2] Ø 4 mm peg : (-).0188.Q1 [3] Ø 2 mm peg : (-).0188.Q2 [4] Dynamic tensioner compression lever : (-).0188.Z Removing RE-USE OF BELT WARNING : Mark the direction the belt was fitted in case of re-use of the same belt. - Compress the tensioner roller (7) by moving it at «c» (in anti-clockwise direction), tool [4]. - Hold the tensioner roller (7) compressed and remove the belt. B1BP1YLD NO RE-USE OF BELT. - Compress the tensioner roller (7) by moving it at «c» (in anti-clockwise direction), tool [4]. - Peg using tool [2], at «d». - Loosen the screw (6) - Bring the eccentric roller (5) towards the rear. - Tighten the screw (6) by hand. - Remove the belt. 98

106 AUXILIARY EQUIPMENT DRIVE BELT Engines : RHY - RHX - RHZ With air conditioning BERLINGO - DISPATCH ENGINE Refitting RE-USED BELT. - Compress the tensioner roller (7) by action at «c» (in anti-clockwise direction), tool [4]. - Refit the belt. WARNING : Respect the direction belt was fitted. Remove the tool [4]. NEW BELT. - Refit the belt. - Turn the eccentric roller (5), tool [1] (clockwise) to free the tool [2] from its pegging at «d». - Hold the eccentric roller (5), tool [1], and tighten the screw (6) to 4.3 m.dan. - Remove the tool [2]. - Rotate the crankshaft 4 times in the direction of rotation. - Check that it is possible to peg at «d», tool [3]. - If not possible to peg, restart the adjustment. B1BP1YND 99

107 ENGINE RELAY COURROIE D' ENTRAÎNEMENT DES ACCESSOIRES Engines : RHV - 4HY Without air conditioning Tools. [1] Dynamic tensioner compression lever : (-).0188 Z [2] Peg, Diameter 4 mm : (-) 0188 Q1 [3] Belt tension measuring equipment : SEEM 105.M Removal. IMPERATIVE : Respect the safety and cleanliness requirements that are specific to high pressure diesel injection (HDi) engines. Remove : - The sound-deadening under the engine. - The front RH wheel. WARNING : Mark the direction the belt was fitted in case of re-use of the same belt. Compress the dynamic tensioner roller 1) by moving it at «b» (in anti-clockwise direction), tool [4]. Peg using tool [2] at «a». Remove the auxiliary equipment drive belt. IMPERATIVE : Check that the rollers (1), (2) and (3) turn freely (wthout play and without tight spots). B1BP2J5D 100

108 COURROIE D' ENTRAÎNEMENT DES ACCESSOIRES Engines : RHV - 4HY Without air conditioning RELAY ENGINE Refitting. Refit the auxiliary equipment drive belt. IMPERATIVE : Make sure that the belt is correctly positioned in the grooves of the various pulleys. Compress the dynamic tensioner roller (1) by action at «b», tool [1]. (anti-clockwise direction). Remove tool [2]. B1BP2J8D 101

109 ENGINE B1BP2J6C RELAY COURROIE D' ENTRAÎNEMENT DES ACCESSOIRES Engines : RHV - 4HY Belt for driving the power steering pump With air conditioning Tools. [3] Belt tension measuring instrument : SEEM 105.M Removing. WARNING : Mark the direction of fitting the drive belt if it is to be re-used. Slacken the screw (4). Detension the belt (5), by acting on the nut «c». Remove the belt. Refitting. Refit the belt (5). IMPERATIVE : Check that the belt is correctly positioned in the grooves of the various pulleys. Fit tool [3] at «f». Tighten the nut at «c», to obtain a tension value of : 102 ± 10 SEEM units. Tighten the screw (4). Give the crankshaft three turns (normal direction of rotation). Check the tension of the belt (5), the tension value should be : 102 ± 10 SEEM units. Refit : - The front RH road wheel - The sound insulation under the engine. B1BP2JAC 102

110 AUXILIARY EQUIPMENT DRIVE BELT Engines : RHV 4HY Belt for driving the alternator and the compressor With air conditioning RELAY ENGINE Removing. WARNING : Mark the direction of fitting the drive belt if it is to be re-used. B1BP2J7D Compress the dynamic tensioner roller (6), by acting at «e», using tool [1] (anti-clockwise direction). Peg, using tool [2], at «d». Remove the belt. Refitting. Refit the belt. IMPERATIVE : Check that the belt is correctly positioned in the grooves of the various pulleys. Compress the dynamic tensioner roller (6), by acting at «e», using tool [1] (anti-clockwise direction). Remove tool [2]. B1BP2J9D 103

111 ENGINE RELAY AUXILIARY EQUIPMENT DRIVE BELT Engines : S Belt for driving the compressor Tools. [1] Pliers for removing plastic pins : 7504-T [2] Belt tension measuring instrument : 4122-T Removing. Slacken : The nut (3), screws (4) and (1). Remove the screw (2) and the aircon compressor belt. Refitting. Refit the screw (2). Tighten by hand the screws (1) and (2). Position tool [2] on the belt at «a». Tighten screw (4). The tension value should be Remove tool [2]. Tighten : The nut (3), screws (1) and (2) Complete the refitting in reverse order to removal. : 96 ± 6 SEEM units. B1BP21TD 104

112 B1BP21UC AUXILIARY EQUIPMENT DRIVE BELT Engines : S Belt for driving the alternator RELAY Tools. [1] Pliers for removing plastic pins : 7504-T [2] Belt tension measuring instrument. : 4122-T Removing. Remove the aircon belt (See corresponding operation). Slacken : Screws (6) and (7). Remove the alternator belt (5). Refitting. Refit the alternator belt (5). IMPERATIVE : Check that the belt is correctly positioned in the grooves of the various pulleys. Position tool [2] on the belt at b. Tighten screw (7). For a new belt, the tension should be : 122 ± 22 SEEM units. For a re-used belt, the tension should be : 69 ± 7 SEEM units. Tighten screw (6) to 5 ± 0,5 m.dan. Remove tool [2]. Complete the refitting. ENGINE B1BP21VC 105

113 ENGINE Engine Families Engine type CHECKING AND SETTING THE VALVE TIMING - PETROL ENGINES TU XU EW JP JP4 J2U J2U/K J4 HFX KFW NFU RFL R6G RFN BERLINGO X X X DISPATCH X RELAY X X See pages : 109 to to to to

114 Engine Families CHECKING AND SETTING THE VALVE TIMING - DIESEL ENGINES DV DW SOFIM ATED ATED4 B TD BTED CTED UTD ATED4 UTED TD BTED V HDi 1.9 D 2.0 HDi 2.0 8S HDi V HDi 2.2 8S HDi 2.8 TD 2.8 HDi ENGINE Engine type C15 9HZ WJY RHY RHX RHZ RHV RHW 4HY S X BERLINGO X X X DISPATCH X X X X RELAY X X X X See pages : 127 to to to to to to to to to

115 ENGINE Petrol enginel RECOMMENDATIONS : TIMING BELT Diesel engine Recommandations. IMPERATIVE : After each operation involving removal of the timing belt, systematically replace : - the timing belt, - the tensioner roller fixing screw. 108

116 CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFW BERLINGO ENGINE CHECKING THE VALVE TIMING NOTE : Remove the sparking plugs to ease the crankshaft rotation. Tools. - [1] Flywheel peg : 4507-T.A (Toolkit 4507-T). - [2] Flywheel or camshaft pulley peg : 7017-T.R. Lift and support the front RH side of the vehicle. Disconnect the battery positive terminal. Engage 5th gear at the gear engagement lever. Remove: - The oil filter. - The upper timing cover. Turn the wheel to drive the engine in its normal direction of rotation. Peg the flywheel, using tool [1] Peg the camshaft pulley, using tool [2]. - If the setting is not correct, restart the operation. B1BP2MBC B1BP2VNC 109

117 ENGINE BERLINGO CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFW SETTING THE VALVE TIMING NOTE : Remove the sparking plugs to ease the crankshaft rotation. Tools - [1] Flywheel peg : 4507-T.A (Toolkit 4507-T). - [2] Camshaft pinion setting peg : 4507-T.B (Toolkit 4507-T). - [4] Dynamic tensioner roller pin : 4200-T.H. - [5] Belt retaining pin : 4533-T.AD. Removing - Rotate the engine with the crankshaft pinion screw (1) clockwise, to bring it to the pegging position. - Peg the camshaft pinion, using tool [2]. - Peg the flywheel, using tool [1]. - Slacken the nut (2). - Completely slacken the belt by turning the tensioner roller. - Remove the belt. ESSENTIAL : Check that the tensioner roller rotates freely (no stiffness). B1BP2MCC B1EP065C B1BP2MBC B1EP1BLC 110

118 CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFW BERLINGO ENGINE Refitting NOTE : Check that the pegs [1] and [2] are in place. B1EP1DLC WARNING : Ensure the belt is fitted in the right direction : The arrows «a» signify the crankshaft direction of rotation. - Fit the timing belt, with the belt strip «b» well tensioned, in the following order : Crankshaft pinion (using tool [5], camshaft pulley, water pump pulley, tensioner roller. - Remove the pegs [1] and [2]. Overtensioning the timing belt - Turn the roller with the aid of a hexagonal spanner (at «c»). - Position the index «e» at position «d», tension the belt to the maximum extent of the interval shown. - Hold the tensioner roller in position, using tool [4]. - Tighten the tensioner roller fixing nut to 1 m.dan. - Remove tools [1], [2], [4] and [5]. - Rotate the crankshaft by 4 turns in the normal direction of rotation. ESSENTIAL : Never turn the crankshaft backwards. - Ensure the timing is correctly set by refitting the pegs [1] and [2]. - Remove the setting pegs. B1EP1DMC 111

119 ENGINE BERLINGO CHECKING AND SETTING THE VALVE TIMING Engines : HFX - KFW Adjusting the belt fitting tension - Slacken the tensioner roller fixing nut, maintaining the position of the tensioner roller, using a hexagonal spanner. - Bring the index «e» to its adjusting position «f». WARNING : The index «e» should not go past the notch «f». If it does, repeat the operation to tension the timing belt. - Maintain the tensioner roller in this position, using a hexagonal spanner. - Tighten the tensioner roller fixing nut to 2 ± 0,2 m.dan. IMPERATIVE : The tensioner roller must not turn during the tightening of its fixing. If it does, repeat the operation to tension the timing belt. B1EP1DNC 112

120 CHECKING AND SETTING THE VALVE TIMING Engine : NFU BERLINGO ENGINE Tools. [1] Engine flywheel peg : 4507-T.A (Toolkit 4507-T) [3a] Camshaft pulley peg. : 4533-T.A.C1 [3b] Camshaft pulley peg. : 4533-T.A.C2 [4] Dynamic tensioner roller pin : 4200-T.H [5] Belt retaining pin : 4533-T.AD Checking the timing - Lift and support the front RH side of the vehicle. - Disconnect the battery positive terminal. - Engage 5th gear at the gear engagement lever. - Remove : the oil filter, the upper timing cover, the accelerator pedal position sensor and lever assembly. - Position a jack underneath the engine, support the engine. - Remove all the RH engine supports. - Turn the wheel to drive the engine in its normal direction of rotation. - Peg the flywheel, using tool [1]. - Peg the camshaft pulleys, using tools [3a] and [3b]. - If the setting is not correct, recommence the operation. B1BP2MBC B1EP18MC 113

121 ENGINE BERLINGO CHECKING AND SETTING THE VALVE TIMING Engine : NFU Setting the timing Removing - Peg the flywheel, using tool [1] - Peg the camshaft pulleys, using toos [3a] and [3b]. - Slacken the tensioner roller. - Turn the dynamic tensioner roller in order to be able to position the tool [4], using an allen spanner at «a». - Turn the tensioner roller to the right, so as to bring the index «c» to position «b». - Peg the tensioner roller in this position in order to detension the timing belt as much as possible. IMPERATIVE : Never turn the dynamic tensioner roller by a complete rotation. - Remove the belt. ESSENTIAL : Check that the tensioner roller rotates freely (no tight spots). B1EP18PC 114

122 CHECKING AND SETTING THE VALVE TIMING Engine : NFU BERLINGO ENGINE Setting the timing (continued) Refitting - Position the timing belt, strictly in the following order: inlet camshaft pulley, exhaust camshaft pulley, guide roller, crankshaft pulley (using tool [5]), water pump pulley, dynamic tensioner roller. - Remove tools [1], [3a], [3b] and [5]. Overtensioning the timing belt - Turn the roller with the aid of a hexagonal spanner (at «a»). - Position the index «c» at position «d», tension the belt to the maximum extent of the interval shown. - Hold the tensioner roller in position, using tool [4]. - Tighten the tensioner roller fixing nut to 1 m.dan. - Remove tools [1], [3a], [3b], [4] and [5]. Rotate the crankshaft by 4 turns in the normal direction of rotation. ESSENTIAL : Never turn the crankshaft backwards. - Ensure the timing is correctly set by refitting the pegs [1], [3a] and [3b]. - Remove the setting pegs. B1EP1DPC 115

123 ENGINE BERLINGO CHECKING AND SETTING THE VALVE TIMING Engine : NFU Adjusting the belt fitting tension - Slacken the tensioner roller fixing nut, maintaining the position of the tensioner roller, using a hexagonal spanner. - Bring the index «c» to its adjusting position «e». WARNING : The index «c» should not go past the notch «e». If it does, repeat the operation to tension the timing belt. - Maintain the tensioner roller in this position, using a hexagonal spanner. - Tighten the tensioner roller fixing nut to 2,2 ± 0,2 m.dan. IMPERATIVE : The tensioner roller must not turn during the tightening of its fixing. If it does, repeat the operation to tension the timing belt. B1EP1DQC 116

124 CHECKING AND SETTING THE VALVE TIMING Engines : RFL - R6G RELAY Tools. [1] Camshaft setting pegs : (-).0189.A [2] Crankshaft setting peg : (-).0189.B Tool kit C.0189 [3] Belt locking pin : (-).0189.K [4] Angular tightening adaptor : 4069-T [5 ] Hub immobilising tool : 6310-T ENGINE B1BP22SC CHECKING THE VALVE TIMING - Turn the engine by the crankshaft pinion screw (3) to bring it to pegging position. - Peg the crankshaft, using tool [2]. - Peg the camshaft pulleys, using tools [1]. NOTE : The pegs [1] must go in without effort B1BP25PC 117

125 ENGINE B1EP01TC RELAY CHECKING AND SETTING THE VALVE TIMING Engines : RFL - R6G Tools. [1] Camshaft pulley locating peg : 7004-T.G [2] Flywheel peg : 7014-T.N Tool kit 7004-T [3] Timing belt tensioning key : 7017-T.W [4] Toothed sector for locking the flywheel : 6012-T Tool kit 9022-T [5] Belt tension measuring instrument : 4122-T SETTING THE VALVE TIMING Peg the crankshaft, using tool [2], and the camshaft pulley, using tool [1]. Lock the flywheel with the tool [4]. ESSENTIAL : Remove the tools [1] and [2] when tightening the screw (1). - Remove the screws (1) and the pulley. - Remove the tool [4]. - Check that the camshaft pulley and the crankshaft pinion are correctly pegged. - Loosen the tensioner roller screw. - Remove the belt. B1BP1WHC 118

126 CHECKING AND SETTING THE VALVE TIMING Engines : RFL - R6G SETTING THE VALVE TIMING (continued) RELAY ENGINE Belt fitting direction - Arrows in the direction of rotation. - Paint marks opposite pinion marks. - Fit the belt on the : camshaft pulley, crankshaft pinion, water pump pinion, tensioner roller. NOTE : Ensure that the belt is correctly positioned in the grooves. B1EP01YC TENSIONING THE BELT - Bring the tensioner roller into contact with the belt. - Fit the tool [5]. - Tension the roller to 16 ± 2 SEEM units using the tool [3]. - Tighten the screw (2) to 2 m.dan. - Remove the tool [1] and fit the crankshaft pulley, without tightening the screw (1). - Rotate the crankshaft by 2 turns (direction of rotation). - Check the pegging of the camshaft/crankshaft. - Rotate the crankshaft by 2 turns (do not turn backwards). - Peg the camshaft pulley using the tool [1]. - Fit the tool [5]. ESSENTIAL : The tension value should be : 40 ± 4 SEEM units - If the value is outside these limits, restart the operation. - Remove the tools. 119

127 ENGINE DISPATCH CHECKING AND SETTING THE VALVE TIMING Engine : RFN Tools. [1] Camshaft setting peg : (-) 0189.A [2] Crankshaft setting peg : (-).0189.R [3] Belt retaining pin : (-).0189.K [4] Adaptor for angular tightening : 4069-T [5] Tool for manœuvring and locking the tensioner roller : (-).0189.S [5a] : (-).0189.S1 [5b] : (-).0189 S2 Pliers for removing plastic pins : 7504-T Checking the setting of the timing Removing. Disconnect the battery negative terminal (See corresponding operation). Raise and support the vehicle, front wheels hanging. Remove: The front RH wheel. The plastic pins (1) The splash-shield (2) The upper timing cover C4AP12TC 120

128 CHECKING AND SETTING THE VALVE TIMING Engine : RFN DISPATCH ENGINE Checking the setting of the timing (continued). Rotate the engine using the crankshaft pinion screw to bring it to the pegging position.. Peg the crankshaft, using tool [2]. Peg the camshaft pulleys, using tool [3] B1BP2V5D WARNING : If the pegs are difficult to engage, repeat the operation to fit and tension the timing belt (See corresponding operation) Refitting. Remove tools [2] and [3]. Complete the refitting in the opposite order to removal. B1EP1BAC 121

129 ENGINE DISPATCH CHECKING AND SETTING THE VALVE TIMING Engine : RFN Setting the timing. Removing. Disconnect the battery negative terminal (See corresponding operation). Raise and support the vehicle, front wheels hanging. Remove: The front RH wheel. The plastic pins (1) The splash-shield (2) The accessories drive belt (See corresponding operation). Unclip and move aside the fuel delivery pipe from the timing cover. Remove the upper timing cover (1). Rotate the engine using the screw (3) of the crankshaft pulley (2) to bring it to the pegging position. B1BP2V4C 122

130 CHECKING AND SETTING THE VALVE TIMING Engine : RFN DISPATCH ENGINE Setting the timing (continued) Peg: The crankshaft, using tool [2] The camshaft pulleys (5) and (6), using tool [1] B1BP2V5D Remove: The screw (3) of the crankshaft pulley (2). The lower timing cover (4) (by moving the engine). IMPERATIVE : Never remove the crankshaft pulley (2) without pegging the crankshaft and camshafts. Slacken the screw (9) of the tensioner roller (8). Turn the tensioner roller (8) (clockwise). Remove the timing belt (7). B1EP1BBD 123

131 ENGINE B1EP1BCD B1EP1BDC DISPATCH CHECKING AND SETTING THE VALVE TIMING Engine : RFN Setting the timing (continued) Turn the tensioner roller (8), using tool [5a] to go past the notch (b). Position tool [5b] to lock the index (a) and remove tool [5a]. Reposition the timing belt (7) on the crankshaft pulley. Hold the timing belt (7) using tool [3]. Fit the timing belt (7) in place, strictly in the following sequence: - Guide roller (10). - Inlet camshaft pulley (6). - Exhaust camshaft pulley (5). - Coolant pump (11). - Tensioner roller (8). NOTE : Make sure that the belt (7) is as flush as possible with the outer face of the various pinions and rollers. Remove : - Tool [3]. - Tool [1] from the exhaust camshaft pulley. - Tool [5b] from the tensioner roller (8). Refit : - The lower timing cover (4) (by moving the engine). - The crankshaft pulley (2) - The screw (3) of the crankshaft pulley. Tighten the screw (3) to 4 ± 0,4 m.dan, then angular-tighten to 53 ± 4, using tool [4]. 124

132 CHECKING AND SETTING THE VALVE TIMING Engine : RFN DISPATCH ENGINE Tensioning the timing belt. Turn the tensioner roller (8) in the direction of the arrow «c», by means of a hexagonal spanner at «d». Positionner l index «a» en poition «f» IMPERATVE : The index «a» should go past the slot «g» by an angular value of 10. If it does not, replace the tensioner roller or the timing belt and tensioner roller assembly. Next bring the index «a» to its adjusting position «g», by turning the tensioner roller in the direction of the arrow «e». B1EP1BEC WARNING : the index «a» should not pass the slot «g». Otherwise, repeat the operation to tension the timing belt. IMPERATIVE : The tensioner roller should not turn during the tightening of its fixing. If it does, repeat the operation to tension the timing belt. Tighten the screw (9) of the tensioner roller (8) to 2,1 ± 0,2 m.dan. IMPERATIVE : The hexagonal tensioner roller drive should be approx. 15 below the level of the cylinder head gasket «h». If it is not, replace the tensioner roller or the timing belt and tensioner roller assembly. B1EP1BFC 125

133 ENGINE DISPATCH CHECKING AND SETTING THE VALVE TIMING Engine : RFN Refitting (continued) Remove the tools [1] and [2]. Rotate the crankshaft ten times (normal direction of rotation). B1EP1BEC IMPERATIVE : No pressure or outside force should be brought to bear on the timing belt. Peg the inlet camshaft pulley, using tool [1]. Checks. Tension of the timing belt. ESSENTIAL : Check the position of the index «a», which should be opposite the slot «g». If the position of the index «a» is not correct, repeat the operations to tension the timing belt. Refit the upper timing cover (1). Clip the fuel delivery hose on the timing cover. Refit the accessories drive belt (See corresponding operation). Lower the vehicle. Reconnect the battery (See corresponding operation). B1EP1BFC 126

134 CHECKING THE VALVE TIMING Engine : 9HZ BERLINGO ENGINE B1BP3BZD Tools. [1] Flywheel setting peg : (-).0194.C [2] Camshaft setting peg : (-).0194.B [3] Crankshaft setting peg : (-).0194.A Checking and setting the timing. Removing Raise and support the vehicle, wheels hanging. Disconnect the positive and negative terminals of the battery. Remove : The front RH wheel. The front RH splash-shield. The accessories drive belt (see corresponding operation). Uncouple : The fuel supply unions (1). The air/air heat exchanger inlet and outlet pipes (3). The exhaust line (at the flexible pipe). Disconnect the connecter at «a». Remove and move aside the power steering fluid reservoir (6). Uncouple, plug and move aside the tube (2). Support the engine with a roller jack equipped with a block. Remove the engine supports (4) and (5). 127

135 ENGINE BERLINGO CHECKING THE VALVE TIMING Engine : 9HZ B1BP305C B1EP1E3D Rotate the engine to drive it in its normal direction of rotation. Peg the flywheel, using tool [1] at «b». Move aside the harness (7). Remove : The engine support (8). The screw (10). The accessories drive pulley (9). The lower timing cover (11). The upper timing cov (12). The tool [1]. 128

136 CHECKING THE VALVE TIMING Engine : 9HZ BERLINGO ENGINE Refit the screw (10). Rotate the crankshaft six times (clockwise). IMPERATIVE : Never turn it backwards. Peg the camshaft at «c», using tool [2] (oil the peg). WARNING : The magnetic track should not show any sign of damage and should not be approached by any other magnetic source. B1EP1E4D Peg the crankshaft at «d», using tool [3]. ESSENTIAL : Should it not be possible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm. If it is more, repeat the operation to position the timing belt (see corresponding operation). Note : The index «e» of the dynamic tensioner roller should be centred in the interval «d» Check the correct positioning of the index «e». If it is not correct, repeat the operation to tension the timing belt (see corresponding operation). Remove tools [2] and [3]. B1EP1E5C 129

137 ENGINE BERLINGO CHECKING THE VALVE TIMING Engine : 9HZ Refitting Refit tool [1] at «b». Remove the screw (10). Refit : The upper timing cover (12). The lower timing cover (11). The accessories drive pulley (9). The screw (10). Tightening torque Screw (10) Pre-tighten to : 3 ± 0,3 m.dan. Angular tighten : 180 ± 5. Remove tool [1]. Refit : The engine support (8), tighten to 5,5 ± 0,4 m.dan. The engine support (4), tighten to 6,1 ± 0,6 m.dan The engine support (5), tighten to 2,5 ± 0,2 m.dan The electrical harness (7) The power steering fluid reservoir (6). Couple : The tube (2). The exhaust line, tighten the clip to 2,5 ± 0,3 m.dan. The fuel unions (1). The air/air heat exchanger inlet and outlet pipes (3). Connect the connector at «a». Refit : The accessories drive belt (see corresponding operation). The front RH splash-shield (see corresponding operation). The front RH wheel, tighten to 9 ± 1 m.dan. Reconnect the positive and negative terminals of the battery. IMPERATIVE : Perform the operations that are necessary following a reconnection of the battery (see corresponding operation). 130

138 CHECKING AND SETTING THE VALVE TIMING Engine : 9HZ BERLINGO ENGINE B1BP3BZD Tools. [1] Flywheel setting peg : (-).0194.C [2] Camshaft setting peg : (-).0194.B [3] Crankshaft setting peg : (-).0194.A Checking and setting the timing. Removing. Raise and support the vehicle, wheels hanging. Disconnect the positive and negative terminals of the battery. Remove : The front RH wheel. The front RH splash-shield. The accessories drive belt (see corresponding operation). Uncouple : The fuel supply unions (1). The air/air heat exchanger inlet and outlet pipes (3). The exhaust line (at the flexible pipe). Disconnect the connecter at «a». Remove and move aside the power steering fluid reservoir (6). Uncouple, plug and move aside the tube (2). Support the engine with a roller jack equipped with a block. Remove the engine supports (4) and (5). 131

139 ENGINE BERLINGO CHECKING AND SETTING THE VALVE TIMING Engine : 9HZ B1BP305C Rotate the engine to drive it in its normal direction of rotation. Peg the flywheel at «b». using tool [1]. Move aside the harness (7). Remove : The engine support (8). The screw (10). The accessories drive pulley (9). The lower timing cover (11). The upper timing cov (12). The tool [1]. B1EP1E3D 132

140 CHECKING AND SETTING THE VALVE TIMING Engine : 9HZ BERLINGO Refit the screw (10). Turn the crankshaft to bring the camshaft towards its pegging point. Peg the camshaft at «c», using tool [2] (oil the pegs). WARNING : Do not press or damage the track of the engine speed sensor target (13). Peg the crankshaft at «e», using tool [3]. Remove : - The timing belt protector (13). - The engine speed sensor (14). Slacken the screw (15) of the tensioner roller, and keep it slackened using an allen spanner at «d». Detension the timing belt by pivoting the tensioner roller (clockwise). Remove the timing belt, starting with the coolant pump pinion. Checks. ESSENTIAL : Just prior to refitting, proceed to the checks as below. Check : - That the rollers and the coolant pump pulley turn freely (without play and without tight spot). - That there are no signs of oil leaks (at the crankshaft and camshaft seals). - That there are no leaks of coolant fluid (at the coolant pump). - That the track of the engine speed sensor target (15) is not damaged or scratched. Replace any components that are defective (if necessary). ENGINE B1EP1E6D 133

141 ENGINE BERLINGO CHECKING AND SETTING THE VALVE TIMING Engine : 9HZ Refitting Fit the timing belt on the crankshaft pinion. Position the belt on the guide roller, belt well tensioned. Refit : The timing belt protector (13). The engine speed sensor (14). Reposition the timing belt, strip «f» well tensioned, in the following sequence : Guide roller (16). Camshaft pulley (20). Fuel high pressure pump pulley (19). Coolant pump pulley (17). Tensioner roller (18). B1EP1E7D 134

142 CHECKING AND SETTING THE VALVE TIMING Engine : 9HZ BERLINGO ENGINE Adjusting the timing belt tension. Act on the tensioner roller (18) to align the marks «g» and «h», avoiding detensioning the timing belt, using an allen spanner at «d». Should this fail, repeat the operation to tension the timing belt. Hold the tensioner roller (18). Tighten the tensioner roller fixing nut to 3,7 ± 0,3 m.dan. Check the position of the tensioner roller (the alignment of the marks «g» and «h» should be correct). Remove tools [2] and [3]. Rotate the crankshaft six times (clockwise). IMPERATIVE : Never rotate the engine backwards. WARNING : Do not touch or damage the track of the target of the engine speed sensor (14). B1EP1E8C Peg the crankshaft, using tool [3]. Check the position of the tensioner roller (the alignment of the marks «g» and «h» should be correct). If this is not the case, repeat the operation to tension the timing belt. Peg the camshaft pulley, using tool [2]. IMPERATIVE : Should it be impossible to peg the camshaft, check that the offset between the camshaft hole and the pegging hole is not more than 1 mm. If the offset is too great, repeat the operation. Remove tools [2] and [3]. 135

143 ENGINE BERLINGO CHECKING AND SETTING THE VALVE TIMING Engine : 9HZ Refitting (continued) Refit tool [1] at «b». Remove the screw (10). Refit : The upper timing cover (12). The lower timing cover (11). The accessories drive pulley (9). The screw (10). Tightening torque Screw (10) Pre-tighten to : 3 ± 0,3 m.dan. Angular tighten : 180 ± 5. Remove tool [1]. Refit : The engine support (8), tighten to 5,5 ± 0,4 m.dan. The engine support (4), tighten to 6,1 ± 0,6 m.dan The engine support (5), tighten to 2,5 ± 0,2 m.dan The electrical harness (7) The power steering fluid reservoir (6). Disengage the jack from under the engine. Couple : The tube (2). The exhaust line, tighten the clip to 2,5 ± 0,3 m.dan. The fuel unions (1). The air/air heat exchanger inlet and outlet pipes (3). Connect the connector at «a». Refit : The accessories drive belt (see corresponding operation). The front RH splash-shield (see corresponding operation). The front RH wheel, tighten to 9 ± 1 m.dan. Reconnect the positive and negative terminals of the battery. IMPERATIVE : Perform the operations that are necessary following a reconnection of the battery (see corresponding operation). 136

144 CHECKING AND SETTING THE VALVE TIMING Engine : WJY C15 - BERLINGO - DISPATCH Tools. [1] Pliers for removing plastic pins : 7504-T or (-).1311 [2] Flywheel locating peg : 7014-T.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 drive for adjusting the tension : (-).0188 J1 [7] Belt tension measuring instrument, with digital display : SEEM CTG 105.5M ENGINE B1BP2FTC CHECKING THE VALVE 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 is not possible, repeat the setting of the timing. B1EP16PD 137

145 ENGINE C15 - BERLINGO - DISPATCH CHECKING AND SETTING THE VALVE TIMING Engine : WJY Setting the valve timing Removing. - Disconnect the battery. - Remove the front RH lower splash-shield, using tool [1]. - Remove the accessories drive belt (see corresponding operation) - Uncouple and plug the diesel fuel delivery and return hoses. - Suspend the engine, using a workshop hoist. - Remove the RH engine support. - Engage 5th gear to allow you to rotate the engine. - Remove the upper timing cover (1). - Remove the intermediate timing cover (2). - Remove the lower timing cover (3). WARNING : Refit the screw (4) equipped with a washer (thickness 5 mm). - Turn the front RH wheel in order to drive the engine in its direction of rotation. - Bring the camshaft drive pinions and injection pump pinions to their setting points. - Position the peg [2] (from underneath the vehicle). - Continue to turn the engine until the peg [2] engages in the flywheel. B1BP30BC B1BP2FTC 138

146 CHECKING AND SETTING THE VALVE TIMING Engine : WJY C15 - BERLINGO - DISPAT- ENGINE Setting the valve timing (continued) - Peg the camshaft hub, using tool [4]. - Peg the injection pump hub, using tool [3]. - Slacken screws (5) and (6). - Slacken the screw (9) of the tensioner roller (8). - Remove the timing belt. B1EP16PD Refitting. - Retighten screws (5) and (6) by hand. - Rotate the pinions (10) and (7) clockwise to place them at end of slots. - Fit the timing belt on the crankshaft. - Hold the belt, using tool [5]. Position the timing belt in the following sequence: - Guide roller (11). - Injection pump pinion (7). - Camshaft pinion (10). - Coolant pump pinion (12). - Tensioner roller (8). B1EP132C B1EP1EDC 139 B1EP1EEC

147 ENGINE C15 - BERLINGO - DISPATCH CHECKING AND SETTING THE VALVE TIMING Engine : WJY Setting the valve timing (continued) B1EP1EFC B1EP1EDC NOTE : If necessary, slightly rotate the pinions (10) and (7) anti-clockwise in order to engage the belt. You should not have to move the the belt in relation to the pinions by more than half à tooth. - Remove tool [5]. - Move the tensioner roller (8) by its square «a», using tool [6] to check that the camshaft and injection pump pinions can turn freely. - Place the belt tension instrument [7] on the belt at «b». - Using tool [6], act at «a» in the opposite direction to engine rotation, to obtain a tension value of 106 ± 2 SEEM units. - Tighten screws (9), (5) and (6). - Remove tools [7], [2], [3] and [4]. - Rotate the crankshaft 8 turns in the normal direction of rotation. - Peg the flywheel using tool [2]. - Peg the camshaft hub, using tool [4]. - Peg the injection pump hub, using tool [3]. - Slacken screws (9), (5) and (6). - Place the belt tension instrument [7] on the belt at «b». - Using tool [6], act at «a» in the opposite direction to engine rotation, to obtain a tension value of : 42 ± 2 SEEM units. 140

148 CHECKING AND SETTING THE VALVE TIMING Engine : WJY C15 - BERLINGO - DISPATCH ENGINE Setting the valve timing (continued) Tighten : - Screw (9) to 2.1 ± 0.2 m.dan. - Screws (5) to 2,3 ± 0.2 m.dan. - Screws (6) to 2,3 ± 0.2 m.dan. - Remove and refit the tool [7]. - The tension value should be between 38 and 46 SEEM units. - Remove tools [7], [2], [3] and [4]. - Rotate the crankshaft 2 turns in the normal direction of rotation. - Peg the flywheel using the peg [2]. - Visually check the peggings of the camshafts and injection pump. IMPERATIVE : Visually check that the offsets between the holes of the camshaft and injection pump hubs and the corresponding pegging holes are not greater than 1 mm. If necessary, recommence the procedure for fitting the timing belt. - Remove the peg [2]. - Remove the screw (4) and the washer. - Refit the lower timing cover (3). - Refit the intermediate timing cover (2). - Refit the upper timing cover (1). - Remove the RH engine support. - Take away the workshop hoist. - Remove the plugs and couple up the diesel fuel delivery and return hoses. - Refit the accessories drive belt (see corresponding operation). - Refit the RH lower splash-shield. - Disengage 5th gear. - Connect the battery. 141

149 ENGINE DISPATCH CHECKING AND SETTING THE VALVE TIMING Engine : RHX Tools. [1] Belt tension measuring instrument : 4122-T [2] Tension lever : (-).188.J2 [3] Engine flywheel peg : (-).0288.D [4] Belt compression spring : (-).0188.K [5] Camshaft pinion peg : (-).0188.M [6] Engine flywheel lock : (-).0188.F [7] Set of blocking plugs : (-).0188.T [8] Crankshaft pulley extractor : (-).0188.P Checking the setting of the valve timing. Peg : - The engine flywheel, tool [3]. - The camshaft, tool [5]. WARNING : Should it be impossible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm, with the help of a mirror «a» and a Ø 7 mm screw. IMPERATIVE : If pegging is impossible, restart the adjusting. (See corresponding operation). B1CP04CC B1BP1TSC B1BP1TTC 142

150 CHECKING AND SETTING THE VALVE TIMING Peg : - The engine flywheel, tool [3]. - The camshaft, tool [5]. Slacken : - The three screws (9). - The screw (7) of the tensioner roller (6). Remove the timing belt (8). Engine : RHX DISPATCH ENGINE Checks. IMPERATIVE : Just before refitting, carry out the checks below : Check that : - The rollers (6), (11) and the coolant pump (10) turn freely (without play or tightness). - There are no traces of oil (on camshaft or crankshaft). B1EP13DD 143

151 ENGINE DISPATCH CHECKING AND SETTING THE VALVE TIMING Engine : RHX Setting the valve timing (continued) Retighten screws (9) by hand. Turn the pinion (12) (clockwise) to the bottom of the buttonhole. Refit the belt on the crankshaft, in the following order, using the tool [4] to keep the belt tight at «a» : B1EP13ED - Guide roller (11). - Fuel high pressure pump pinion (13). - Camshaft pinion (12). - Water pump pinion (10). - Tensioner roller (6). NOTE : If needed, slightly turn the pinion (12) anticlockwise (not by more than one tooth). B1EP13FC - Remove the tool [4]. 144 B1EP13GD

152 CHECKING AND SETTING THE VALVE TIMING Setting the valve timing (continued). Engine : RHX DISPATCH ENGINE Position tool [1] on the belt at «b». Turn the roller (6) (anti-clockwise) using tool [2] to attain a tension of : 98 ± 2 SEEM units Tighten screw (7) of the roller (6), tighten to 2.5 m.dan. Remove one screw (9) from the pinion (12). (to check that the screws are not against the end of the buttonhole). Tighten the screws (9) to 2 m dan. Remove tools [1], [2], [3] and [5]. Rotate the crankshaft 8 times (normal direction of rotation). Fit the tool [3]. Loosen screws (9). Fit tool [5]. Loosen screw (7) (to free the roller (6). Fit tool [1]. Turn the roller (6) (anti-clockwise), tool [2], to attain a tension of : 54 ± 2 SEEM units. B1EP13HD 145

153 ENGINE DISPATCH CHECKING AND SETTING THE VALVE TIMING Setting the valve timing (continued) Engine : RHX Tighten : - Screw (7) of the roller (6) to 2.5 m.dan. - Screw (9) to 2.m.daN Remove the tool [1]. Refit the tool [1]. Tension value should be : 54 ± 3 SEEM units. IMPERATIVE : If value is incorrect, restart the operation. Remove tools [1], [3] and [5]. Rotate the crankshaft 2 times (normal direction of rotation). Fit the tool [3]. WARNING : Should it be impossible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm.. In the case of an incorrect value, recommence the operation. Remove the tool [3]. B1EP13HD 146

154 CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHZ BERLINGO - DISPATCH ENGINE Tools. [1] Belt tension measuring equipment : 4122-T [2] Tension lever : (-).0188.J2 [3] Engine flywheel peg : (-).0188.Y [4] Belt clamp : (-).0188.AD [5] Camshaft pulley peg : (-).0188.M [6] Engine flywheel lock : (-).0188.F [7] Set of blocking plugs : (-).0188.T [8] Pulley extractor : (-).0188.P [9] 2 mm dia.peg : (-).0188.Q2 Removing IMPERATIVE : Respect the safety and cleanliness requirements that are specific to high pressure diesel injection (HDi) engines. Undo the front RH wheel bolts. Raise and support the vehicle on the front RH side. Disconnect the battery negative terminal. Remove : The under-engine sound-deadening. The front RH wheel. The front RH splash-shield. The engine cover. Unclip and move aside the cooling hose. Remove the accessories drive belt. (See corresponding operation). 147

155 ENGINE DISPATCH CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHZ Uncouple, plug and move aside, using tool [7], the fuel delivery pipe (2) and return pipe (1). Remove : Screws (3), (4) and (6). Screw (7). The upper timing cover (5). WARNING : Refit screw (7) equipped with a spacer (17 mm thick), tighten the screw (7) to 1,5 ± 0,1 m. dan. NOTE : The screw (7) is one of the screws securing the coolant pump and is there for its sealing. Put the gear lever in 5th gear. Turn the road wheel to turn the engine in its direction of rotation. Orient the camshaft pulley in the pegging position, use a mirror if necessary. Peg the camshaft, using tool [5] Peg the engine flywheel, using tool [3]. B1BP2R2C B1EP1A7C B1BP2H2C B1BP2H3C 148

156 B1CP04BC CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHZ Remove : The fixings of the pipe linking the power steering pump with the rotary valve. The clutch lower closing plate. Lock the engine flywheel, using tool [6]. Remove the screw (8). Refit the screw (8) without its thrust washer. Remove : The accessories pulley (9), using tool [8]. Tool [6]. The lower torque reaction rod. Support the engine by means of a workshop hoist. Remove : The bearing shell fitting (10). The nut (12). Screws (11). The bracket (13). NOTE : Lift then lower the engine with the workshop hoist, to have access to the timing cover fixing screws. Remove : The intermediate timing cover. The lower timing cover. B1BP2R4C DISPATCH ENGINE B1BP2R3C 149

157 ENGINE DISPATCH CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHZ B1EP1A8D Slacken the screw (17) of the tensioner roller (18). Remove the timing belt (14). Checks. IMPERATIVE : Just before refitting, carry out the checks below : Check that : The rollers (18) and (15) turn freely (without play and without any tight spot). The coolant pump pulley (16) turns freely (without play and without any tight spot). There are no traces of oil leaks from the crankshaft and camshaft seals, etc. The crankshaft pinion travels freely on the keyway. Replace defective components if necessary. Peg the crankshaft pinion (19) by inserting tool [9] on the LH side of the keyway. B1EP1A9C 150

158 CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHZ DISPATCH ENGINE B1EP1ABD Reposition the timimg belt, belt at «a» well tensioned, in the following order : Fuel high pressure pump pulley (21). Guide roller (15). Crankshaft pinion (19). Coolant pump pinion (16). Tensioner roller (18). Position tool [1] on the belt at «a». Remove tools [4] and [9] Turn the tensioner roller (18) anti-clockwise, using tool [2], to attain an overtension of : 98 ± 2 SEEM units. Tighten screw (17) of the tensioner roller to 2,5 ± 0,2 m.da N. Lock the flywheel by means of tool [6]. Tighten the accessories drive pulley screw (8) to 7 ± 0,7 m.da N. Remove tools [1], [3], [5] and [6]. Rotate the crankshaft eight times in the normal direction of rotation. Peg : The crankshaft, using tool [3]. The camshaft drive pulley, using tool [5]. B1EP1ACC 151

159 ENGINE DISPATCH CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHZ Lock the engine flywheel, using tool [6]. Slacken : The accessories drive pulley (8). The screw (17) of the tensioner roller (18). Fit the tool [1]. Turn the tensioner roller, using tool [2], to attain a tension of : 54 ± 2 SEEM units. Tighten screw (17) of the tensioner roller (18) to 2,5 ± 0,2 m.dan. Remove tool [1]. Fit tool [1]. The tension value should be : 54 ± 3 SEEM units. ESSENTIAL : If the value is incorrect, recommence the operation. Remove tools [1], [3], [5] and [6]. Rotate the crankshaft two times in the normal direction of rotation. Peg : The crankshaft, using tool [3]. The camshaft drive pulley. IMPERATIVE : If the pegging is not possible, recommence the operation. B1EP1ACC 152

160 CHECKING AND SETTING THE VALVE TIMING Engines : RHY - RHZ Remove : Tools [3] and [5]. Screw (7) and the spacer. Refit : The lower, intermediate and upper covers (5) Screw (7), tighten to 1,5 ± 0,1 m.dan Screws (3), (4) and (6). The bracket (13). Screws (11), tighten to 6,1 ± 0,5 m.dan The nut (12), tighten to 4,5 ± 0,5 m.dan Fit the bearing shell (10). Take away the workshop hoist. Clip the fuel delivery and return pipes. Remove the tool [7]. Couple : The fuel delivery pipe (12). The fuel return pipe (1). Coat the screw (8) with loctite FRENETANCH. Refit the tool [6] and the screw (8) with the washer (22), Tighten to 7 ± 0,2 m.dan and angular tighten to A = 60 ±5 Refit the torque reaction rod on the lower engine support. Remove the tool [6]. Reposition and reclip the cooling hose. Complete the refitting of components in reverse order to removal. B1EP1A7C B1BP2R4C B1EP1ADC DISPATCH ENGINE 153

161 ENGINE B1BP2HLC RELAY B1EP17GC CHECKING THE VALVE TIMING Engines : RHV - 4HY Tools. [1] Camshaft locating peg : (-).0188 M Toolkit C.0188 [2] Flywheel locating peg : (-).0188 Y CHECKING THE VALVE TIMING IMPERATIVE : Respect the safety and cleanliness recommendations specific to high pressure diesel injection (HDi) engines. Removing Remove : - The heat shield (1). - The pipe (2). (Support the engine using a workshop hoist). - The screw (3). - The nuts (4). - The engine support (5). - Screws (6), (7), (9) and (10). - The upper timing cover (8) WARNING : Refit screw (10) equipped with a spacer of thickness 17 mm; tighten the fixing screw (10) : tighten to 1,5 ± 0,1 m.dan. Note : Screw (10) is one of the fixing screws for the coolant pump, also keeping it sealed. - Engage 5th gear. - Turn the road wheel to rotate the engine (normal direction of rotation). - Bring the camshaft pulley to the pegging position; use a mirror (if necessary). 154

162 RHV CHECKING THE VALVE TIMING Engines : RHV - 4HY RELAY ENGINE Checking the valve timing (continued) - Peg the flywheel, uising tool [2]. - Peg the camshaft, using tool [1]. WARNING : Should it be impossible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm, with the help of a mirror «a» and a Ø 7 mm screw.. B1BP2HMC B1BP298C 4HY IMPERATIVE : If pegging is impossible, restart the adjusting. (See corresponding operation). Remove : - Tools [1] and [2]. - The screw (10) and the spacer. Refit : - The upper timing cover (8). - The screws (6), (7), (9) and (10) : tighten to 1,5 ± 0,1 m.dan. - The engine support (5). - The nuts (4). - The screws (3) - The pipe (2). - The heat shield (1). Disengage 5th gear and complete the refitting. B1EP17JC B1EP17KC 155

163 ENGINE B1CP04BC B1BP2HZC RELAY CHECKING AND SETTING THE VALVE TIMING Engines : RHV - 4HY Tools. [1] Belt tension measuring instrument : SEEM CTG 105.5M [2] Tensioning lever : (-).0188.J2 Toolkit C.0188 [3] Flywheel locating peg : (-).0188.Y [4] Belt retaining pin : (-).0188.K [5] Camshaft pinion peg : (-).0188.M [6] Engine flywheel lock : (-).0188.F [7] Crankshaft pulley extractor : (-).0188.P Setting the valve timing IMPERATIVE : Respect the safety and cleanliness recommendations specific to high pressure diesel injection (HDi) engines. Removing Remove : - The auxiliary equipment drive belt (see corresponding operation). - The lower plate closing the clutch housing. Lock the flywheel, using tool [6]. Remove the screw (1). Refit the screw (1), without the washer. Remove : - The crankshaft pulley, using tool [7] - The tool [6]. Support the engine, using a workshop hoist. 156

164 CHECKING AND SETTING THE VALVE TIMING Engines : RHV - 4HY RELAY Setting the valve timing Remove : - The heat shield (2). - The pipe (3). - The nuts (4). - The screws (5). - The RH engine support (6). NOTE : Raise and then lower the engine, to have access to the timing cover fixing screws. Remove : - The screws (8), (9), (17) and (18). - The upper cover (7). - The screws (10), (12) and (13). - The intermediate cover (11). - The screws (14) and (16). - The lower cover (15) WARNING : Refit the screw (17) equipped with a spacer (thickness 17 mm). Tighten to 1,5 ± 0,1 m.dan NOTE : The screw (17) is one of the fixing screws for the coolant pump, also keeping it sealed. Turn the engine (normal direction of rotation). Bring the camshaft pulley to its setting position. ENGINE B1BP2J0C B1BP2J1C 157

165 ENGINE RELAY CHECKING AND SETTING THE VALVE TIMING Engines : RHV - 4HY Setting the valve timing (continued) Position the flywheel locating peg, using tool [3] (from underneath the vehicle). Turn the engine until the peg [3] engages in the flywheel. B1BP2J2C Peg the camshaft, using tool [5]. Slacken : - The three screws (19). - The screw (23) of the tensioner roller (24). Remove the timing belt (20). B1EP17LD 158

166 CHECKING AND SETTING THE VALVE TIMING Checks Engines : RHV - 4HY RELAY ENGINE IMPERATIVE : Just prior to refitting, perform the following checks. Check that : B1EP17MC - The rollers (24), (21) and the coolant pump (22) turn freely (without play and without tight spots). - There are no signs of oil leaks (from sealing rings). - There are no leaks of coolant fluid (from the coolant pump). Replace any components that are defective. Refitting Tighten the screws (19) by hand. Turn the pinion (25) (clockwise), to place it at the end of the slot. Reposition the timing belt (20) on the crankshaft pinion (26). Hold the belt, using tool [4]. B1EP17NC 159

167 ENGINE B1EP17PD RELAY CHECKING AND SETTING THE VALVE TIMING Engines : RHV - 4HY Checks (continued) Reposition the timing belt (20), well-tensioned at «a», in the following order : - Guide roller (21). - Fuel high pressure pump pinion (27). - Camshaft pinion (25) - Coolant pump pinion (22). - Tensioner roller (24). NOTE : If necessary, slightly rotate the pinion (25) (anti-clockwise). (The offset should not be more than one tooth) Remove tool [4]. Position the tool [1] on the belt at «b». Turn the tensioner roller (24) (anti-clockwise), using tool [2] to attain an overtension of 98 ± 2 SEEM units. Tighten the screw (23) to 2,5 ± 0,2 m.dan. Remove one of the screws (19) of the pinion (25) to verify that these screws are not at the end of the slot. Tighten the screws (19) to 2 ± 0,2 m.dan. Remove tools [1], [2], [3] and [5]. Rotate the crankshaft eight times (normal direction of rotation). Fit the tool [3]. Slacken the screws (19). B1EP17QD 160

168 CHECKING AND SETTING THE VALVE TIMING Engines : RHV - 4HY RELAY Checks (continued) Fit tool [5]. Slacken screw (23) to free the tensioner roller (24). Fit tool [1]. Turn the tensioner roller (24) (anti-clockwise), using tool [2], to attain an overtension of 54 ± 2 SEEM units. Tighten screw (23) to 2,5 ± 0,2 m.dan. Tighten screws (19) to 2 ± 0,2 m.dan. Remove tool [1]. Fit tool [1]. The tension value should be 54 ± 3 SEEM units. ENGINE IMPERATIVE : If the value is incorrect, recommence the operation. Remove tools [1], [3] and [5]. Rotate the crankshaft two times (normal direction of rotation). Fit tool [3]. IMPERATIVE : Should it be impossible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm. If the value is incorrect, recommence the operation. B1EP17QD 161

169 ENGINE RELAY Checks (continued) CHECKING AND SETTING THE VALVE TIMING Engines : RHV - 4HY Remove tool : - Tool [3]. - Screw (17) and spacer. Refit : - The lower cover (15). - Screws (14) and (16). - The intermediate cover (11). - Screws (10), (12) and (13). - The upper cover (7). - Screw (17), tighten to 1,5 ± 0,1 m.dan. - Screws (8), (9) and (18). - The RH engine support (6). - Screws (5). - Nuts (4). - The pipe (3). - The heat shield (2). Take away the workshop hoist. Coat the screw (29) with Loctite FRENETANCH Refit : - The crankshaft pulley (1). - Tool [6]. - Screw (29) with washer (28), Tighten to 4 ± 0,4 m.dan. Angular tighten 51 ± 5 Remove tool [6]. Refit : - The clutch housing closing plate. - The auxiliary equipment drive belt. (See corresponding operation). Complete the refitting. B1EP17RC 162

170 CHECKING THE VALVE TIMING Engine : RELAY ENGINE Tools. [1] Pliers for removing plastic pins : 7504-T [2] Peg for setting the injection pump : Toolkit (-).0191 B1BP21YC CHECKING THE VALVE TIMING Removing Disconnect the negative terminal of the battery. Raise and support the vehicle. Remove : - The lower RH splash-shield, using tool [1], the engine cover, the accessories drive belt (see corresponding operation). Remove the screws (2), the timing cover (1), the engine speed sensor. Insert a screwdriver in the aperture of the engine speed sensor, to immobilise the flywheel. Remove the screw (3), the accessories drive pulley (4), the screwdriver. Turn the engine in its normal direction of rotation. Bring the injection pump pulley (6) to its setting point. Position the tool [2]. Turn the engine until the tool [2] engages in the setting hole. Check the alignment between the marking "a" on the camshaft pulley (5) and the marking "b" on the valve cover. B1BP21ZD 163

171 ENGINE RELAY CHECKING THE VALVE TIMING Engine : S B1BP220C Check that the marking «c» on the crankshaft pinion (7) is in a low position in relation to the engine s vertical axis. IMPERATIVE : If pegging of the injection pump pinion proves impossible, restart the setting operation. Refitting Remove the tool [2]. Refit : - the accessories drive pulley (5) - the screw (3) (use a screwdriver to immobilise the flywheel), tighten to : 20 m.dan - the engine speed sensor - the timing cover (1) - the screws (2) - the accessories drive belt (see corresponding operation) - the engine cover - the lower RH splash-shield. Lower the vehicle. Connect the negative terminal of the battery. 164

172 CHECKING AND SETTING THE VALVE TIMING Engine : RELAY ENGINE Tools. [1] Pliers for removing plastic pins : 7504-T [2] Peg for setting the injection pump : Toolkit (-).0191 [3] Belt tensioner compressor : Toolkit (-).0191 B1BP21YC B1BP221D Removing Disconnect the negative terminal of the battery. Raise and support the vehicle. Remove : - The lower RH splash-shield, using tool [1], the engine cover, the accessories drive belt (see corresponding operation). Remove the screws (2), the timing cover (1), the engine speed sensor. Insert a screwdriver in the aperture of the engine speed sensor, to immobilise the flywheel. Remove the screw (3), the accessories drive pulley (4), the screwdriver. Lock the belt tensioner (7), using tool [3]. Turn the engine in its normal direction of rotation. Bring the injection pump pulley (6) to its setting point. Position the tool [2]. Turn the engine until the tool [2] engages in the setting hole. Check the alignment between the marking "a" on the camshaft pulley (5) and the marking "b" on the valve cover. 165

173 ENGINE B1BP222C RELAY CHECKING AND SETTING THE VALVE TIMING Engine : Check that the marking «c» on the crankshaft pinion (7) is in a low position in relation to the engine s vertical axis. IMPERATIVE : If pegging of the injection pump pinion proves impossible, restart the setting operation. Remove : the screws (11), the nut (9), the cover (10), the timing belt. Refitting Refit : the timing belt, the cover (10), the screws (11), the nut (9), tighten by hand. Remove tool [2] and [3] NOTE : Check that the belt tensioner touching point is in contact with the tensioner roller support. Tighten the nut (9) to : 4 ± 0,4 m.dan. Turn the crankshaft 2 turns in the normal direction of rotation. ESSENTIAL : Never turn the crankshaft backwards. Peg the injection pump pulley, using tool [2]. IMPERATIVE : If it is impossible to refit the tool [2], restart the operations for refitting the belt. Remove tool [2]. Refit the accessories drive pulley (5) (use a screwdriver to immobilise the flywheel). Tighten the screw (3) to : 20 ± 2 m.dan Refit : the timing cover (1), the screws (2), the accessories drive belt (see corresponding operation), the engine cover, the lower RH splash-shield. Lower the vehicle. Connect the negative terminal of the battery. B1BP223C 166

174 CHECKING AND SETTING THE VALVE TIMING Engine : S RELAY ENGINE Tools. [1] Pliers for removing plastic pins : 7504-T [2] Flywheel locking tool : (-).0191 C [3] Belt compression tool : Toolkit (-).0191 [4] Belt compression spring : (-).0188K B1BP2PXC Checking the setting of the valve timing. Removing Remove : - The lower RH splash-shield, using tool [1]. - The engine cover. - The accessories and alternator belt (according to equipment). Turn the engine (normal direction of rotation). Immobilise the flywheel at «a», using tool [2]. Remove : - Screws (2). - The timing cover (1). - Screw (3). - The accessories pulley (4) B1BP2DTC 167

175 ENGINE RELAY CHECKING AND SETTING THE VALVE TIMING Engine : S Checking the setting of the valve timing (continued). - Check that the marking «b» on the crankshaft pinion (5) is in a low position in relation to the engine s vertical axis at «c». - Check the alignment between the marking «d» on the camshaft pulley (6) and the marking «e» on the valve cover. Refitting Refit the accessories pulley (4). Immobilise the flywheel at «a», using tool [2] Fit and tighten the screw (3), tighten to ± 2 m.dan. Remove the peg, dia. 8 mm. Fit : - The accessories cover (1) - The screws (2). - The accessories and alternator belt (see corresponding operation). Complete the refitting in opposite order to removal. B1BP2DWC B1BP2DXC 168

176 CHECKING AND SETTING THE VALVE TIMING Engine : S RELAY ENGINE Setting the valve timing Removing Remove : The accessories and alternator belt (see corresponding operation). Rotate the engine (normal direction of rotation). B1BP2PXC Immobilise the flywheel at «a», using tool [2]. Remove : - Screws (2). - The timing cover (1). - Screw (3). - The accessories pulley (4) B1BP2DTC 169

177 ENGINE RELAY CHECKING AND SETTING THE VALVE TIMING Engine : S Setting the valve timing (continued) Lock the belt tensioner (7), using tool [3]. Rotate the engine (normal dieection of rotation). Check that the marking «b» on the crankshaft pinion (5) is in a low position in relation to the engine s vertical axis at «c». Check the alignment between the marking «d» on the camshaft pulley (9) and the marking «e» on the valve cover. Remove : - Screw (8). - Nut (6). - The cover (7). - The timing belt Move aside : - The coolant header tank. - The air conditioning pipes. Support the engine. Remove the RH engine support. B1BP2DUC B1BP2DVC 170

178 CHECKING AND SETTING THE VALVE TIMING Engine : S Setting the valve timing (continued) Refitting Refit : - The timing belt, using tool [4]. - The cover (7). - Screw (8). - Nut (6), (tighten by hand). - Remove tool [3] Note : Check that the belt tensioner s contact point is touching the tensioner roller support. Tighten the nut (6), tighten to 4 ± 0,4 m.dan. Rotate the crankshaft two turns (normal direction of rotation). ESSENTIAL : Never rotate the engine backwards. Refit the accessories pulley (4). Immobilise the flywheel at «a», using tool [2] Fit and tighten the screw (3), tighten to ± 2 m.dan. Remove tool [2]. Fit : - The accessories cover (1) - The screws (2). - The accessories and alternator belt. Complete the refitting in opposite order to removal RELAY B1BP2DUC B1BP2DVC ENGINE 171

179 ENGINE CHECKING THE OIL PRESSURE Petrol Engine type HFX KFW NFU RFL R6G RFN Temperature ( C) Pressure (Bars) Rpm Pressure (Bars) 3 Rpm 2000 Pressure (Bars) Rpm Pressure (Bars) 4 7 Rpm Tools Toolkit 4103-T 2279-T.Bis X X X X X X 4103-T X X X X X X 7001-T X X X X X X NOTE : The oil pressure should be checked with the engine hot, after the oil level has been checked. 172

180 CHECKING THE OIL PRESSURE Diesel Engine type 9HZ WJY RHY RHX RHZ RHV RHW 4HY S Temperature ( C) Pressure (Bars) 1,3 1, ,8 Rpm Pressure (Bars) 3,7 4 Rpm Pressure (Bars) 4,3 Rpm 3000 Pressure (Bars) 3,5 4,5 4 3,3 Rpm Tools Toolkit 4103-T 2279-T.Bis X X X X X X 4103-T X X X X X X (-).1503.J X 4225-T X 4202-T X X X ENGINE NOTE : The oil pressure should be checked with the engine hot, after the oil level has been checked 173

181 ENGINE The valve clearances must be checked with the engine cold. VALVE CLEARANCES POSSIBLE PROCEDURES For engines with 4 cylinders in a line ( ) HFX - KFW - RFN Inlet 0,20 ± 0,05 mm Exhaust 0,40 ± 0,05 mm Rocking Exhaust Adjust Inlet Fully open (Exhaust) Valves fully Adjust open NFU 1 ± 0,05 mm 1 ± 0,05 mm Exhaust WJY 2.8 TD HDi 0,15 ± 0,08 mm 0,30 ± 0,08 mm 0,50 ± 0,05 mm 0,50 ± 0,05 mm Engines without hydraulic adjustment : the clearance (J) should be checked opposite the cam. RFN - 9HZ - RHY - RHX RHZ - RHV - RHW - 4HY Automatic adjustment 174 B1DP13QC

182 CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engine : 9HZ BERLINGO Tools. [1] Ø 10 mm low pressure connector : 4215-T [2] Pressure gauge for testing boost pressure : 4073-T.A Toolkit 4073-T Checks IMPERATIVE : Respect the safety and cleanliness specific to high pressure diesel injection (HDi) engines. Remove the air filter duct. Link tool [1] in series, downstream of the injectors, between the fuel high pressure pump and the fuel filter at «a» and «b». INJECTION WARNING: Any checking of pressure downstream of the fuel filter is prohibited. Switch on the ignition. Check the negative pressure according to the table below: Vacuum measured by tool [2] Checks 10 ± 0,5 cmhg Engine driven by the starter motor 20 ± 0,5 cmhg Engine running under full load 30 ± 0,5 cmhg Fuel supply circuit, fuel filter piping B1CP0GFD 175

183 BERLINGO - DISPATCH CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engines : RHY - RHZ INJECTION Tools. [1] Ø 10 mm low pressure connector : 4215-T [2] Ø 8 mm low 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 176

184 CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engines : RHY - RHZ BERLINGO - DISPATCH 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 Fuel supply pressure Fuel return pressure Checks Between 3 and 3.5 Bar 0,7 ± 0,2 bar Check the condition of the diesel filter More than 3,5 bars Less than 0,7 bar Check the low pressure regulator incorporated in the filter (jammed shut) : replace. More than 3,5 bars More than 0,7 bar Check the fuel return circuit (pipe pinched or trapped). Between 0.8 and 1.5 Bar Impossible to start the engine : Fuel supply pressure less than 0.8 Bar : - Check the low pressure regulator incorporated in the filter (jammed open) - Check the high pressure pump distribution valve (jammed shut) Less than 0,7 bar Check : Observe : The flow should be drop by drop Diesel injector functioning correctly Excessive fuel return Diesel injector jammed shut. Check the fuel suppy circuit : - Booster pump (low pressure), piping. Check : diesel injector return flow. (Table below) Uncouple the diesel injector return pipe. INJECTION 177

185 JUMPER CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engine : RHV INJECTION Tools. [1] Ø 10 mm low pressure connector : 5725-T [2] Ø 8 mm low pressure connector : 5724-T [3] Pressure gauge for testing boost pressure : 4073-T Kit 4073-T [4] Pressure gauge extension for tool testing HDi low pressure : 4251-T Checks IMPERATIVE : Respect the safety and cleanliness specific to high pressure diesel injection (HDi) engines. Connect the tool [1] between the booster pump and the fuel filter (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 (at "b" on the fuel return pipe. WARNING : Any check of pressure downstream of the fuel filter is prohibited NOTE : For testing the pressures when the vehicle is being driven, connect the extension [4] between the pressure gauge [3] and the tools [1] and [2]. B1BP2G7C B1BP2G8C 178

186 CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Checks on pressure : static. Switch on the ignition. For 3 seconds (normal functioning). - Fuel supply pressure shown by the pressure gauge [3] = 2.3 ± 0.4 Bar. - Fuel return pressure shown by the pressure gauge [3] = 0.3 ± 0.4 Bar. Fuel supply pressure Fuel return pressure Between 3.3 and 4 Bar 0,8 ± 0,4 bars More than 4 bars Less than 0,8 bar More than 4 bars More than 0,8 bar Between 0.8 and 1.5 Bar Less than 0,8 bar Engine : RHV JUMPER Contrôle de pressions en dynamique. Engine tournant au régime de ralenti (fonctionnement normal). Pression d'arrivée carburant indiquée par le manomètre [3] = 2,5 ± 0,4 bars. Pression de retour carburant indiquée par le manomètre [3] = 0,5 ± 0,4 bars. Fonctionnement anormal. Contrôle Check the diesel filter Check the low pressure regulator incorporated in the fuel filter (locked shut) : replace. Check the fuel return circuit (pipe pinched or trapped). Check the fuel supply circuit : - Booster pump (low pressure), piping. INJECTION Impossible to start the engine : Fuel supply pressure less than 0.8 Bar : - Check the low pressure regulator incorporated in the filter (jammed open) - Check the high pressure pump distribution valve (JAMMED shut) Check : diesel injector return flow Uncouple the diesel injector return pipe. Checks : Observations Diesel injector functioning The flow should be drop by drop correctly Excessive fuel return Diesel injector locked shut 179 Checks using the DIAL diagnostic tool (PEUGEOT network) Measure the supply flow, at «a» : 150 ± 10 l/h (at the fuel filter inlet). Measure the diesel injector return flow, at «b» : 50 ± 15 l/h (on the fuel filter return). Checks : If the injector return flow is greater than 50 ± 15l/h Observations Valve open (jammed) Valve shut (jammed)

187 JUMPER CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engines : 4HY S INJECTION Tools. [1] Ø 10 mm low pressure connector : 5725-T [2] Ø 8 mm low pressure connector : 5724-T [3] Pressure gauge for testing boost pressure : 4073-T Kit T [4] Pressure gauge extension for tool testing HDi low pressure : 4251-T Check 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 NOTE : For testing the pressures when the vehicle is being driven, connect the extension [4] between the pressure gauge [3] and the tools [1] and [2]. Checks on pressure: static. - Switch on the ignition - For 3 seconds (normal operating): - Fuel supply pressure shown by the pressure gauge [3] = 2,4 ± 0,4 Bar ( S) [3] = 2,3 ± 0,4 Bar (4HW) - Fuel return pressure shown by the pressure gauge [3] = 0,5 ± 0,2 Bar ( S) [3] = 0,3 ± 0,2 Bar (4HW) NOTE : The difference in pressure measured between the fuel supply and the fuel return should be beween 1,1 and 1,6 Bar. B1BP2G7C B1BP2G8C 180

188 CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT Engines : 4HY S JUMPER Checks on pressure : dynamic. Engine running, at idle (normal operating): - Fuel supply pressure shown by the pressure gauge [3] = 2,5 ± 0,4 Bar ( S engine) 2,3± 0,4 Bar (4HY engine) - Fuel return pressure shown by the pressure gauge [3] = 0,6 ± 0,2 Bar ( S engine) 0,3± 0,4 Bar (4HY engine) Abnormal operating Fuel supply pressure Fuel return pressure Checks S 4HY S 4HY Between 3 and 3,5 Bars Entre 3,3 et 4 bars 0,8 ± 0,2 bars 0,8 ± 0,4 bars Check the condition of the diesel filter More than 3,5 bars More than 4 bars Less than 0,8 bar Less than 0,8 bar Check the low pressure regulator incorporated in the filter (locked shut) : replace. More than 3,5 bars More than 4 bars More than 0,8 bar More than 0,8 bar Check the fuel return circuit (pipe pinched or trapped...). Between 0,8 and 1,5 Bar Between 0,8 and 1,5 Bar Less than 0,8 bar Less than 0,8 bar 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 : Observe : The flow should be drop by drop Diesel injector functioning correctly Excessive fuel return Diesel injector locked shut. Check the fuel suppy circuit : - Booster pump (low pressure), piping. Check : diesel injector return flow. (Table below) Uncouple the diesel injector return pipe. INJECTION 181

189 BERLINGO CHECKS : TURBO PRESSURE Engine : RHY INJECTION B1BP1ZXD Tools. [1] Pressure gauge for checking boost pressure : 4073-T.A Kit 4073-T [2] Sleeve for checking boost pressure : 4185-T Checks. IMPERATIVE : respect the following checking requirements : Engine at running temperature, vehicle running at full load. Preparation. - Remove the clip (3) and the sleeve. - Insert the tool [2] between the pipe (1) and the duct (2). - Position tool [1] inside the vehicle. - Connect the pressure gauge [1] to the tool [2] with its tube «a» long enough for the gauge to be positioned inside the vehicle. Procedure. - Start the engine. - Engage first gear and start driving. - Engage the gears up to third gear. - Decelerate to 2000 rpm. - Gradually accelerate. - Check the pressure : 0.95 ± 0.05 Bar - Remove the tools, refit the collars (3) and the sleeve. 182

190 CHECKS : TURBO PRESSURE Engine : RHZ DISPATCH Tools. [1] Pressure gauge for checking boost pressure : 4073-T.A Kit 4073-T [2] Sleeve for checking boost pressure : 4185-T [3] Adaptor sleeve : 4229-T Checks. IMPERATIVE : respect the following checking requirements : Engine at running temperature, vehicle in running order at full load. Preparation. - Remove the clip (3). - Connect tool [2] equipped with tool [3], between the tube (1) and the duct (2). - Position the tool [1] inside the vehicle. - Connect the sleeve [2] on the tool [1] with the tube "a". Procedure. - Start the engine. - Engage first gear and start driving. - Engage the gears up to third gear. - Decelerate to 1000 rpm. - Accelerate hard, then check the pressure : 0,6 ± 0,05 Bar (1500 rpm). - Accelerate freely (changing down from 4th gear to 3rd gear). - Check the pressure : 0,95 ± 0,05 Bar (between 2500 and 3500 rpm). - Remove the tools, reposition the tube (1) and put back the collar (3). INJECTION B1HP12JD 183

191 JUMPER CHECKS : TURBO PRESSURE Engine : RHV INJECTION B1HP1FFC C5FP0FSC Tools. [1] Pressure gauge for checking boost pressure : 4073-T.A Kit 4073-T [2] Sleeve for checking boost pressure : 4185-T [3] Adaptor sleeve : 4219-T Checks IMPERATIVE : Respect the safety and cleanliness specific to high pressure diesel injection (HDi) engines. - Connect tool [1] equipped with tool [3], between the tube (2) and the duct (1). Procedure - Connect the sleeve [2] on the pressure gauge [1] with the tube "a". - Position the tool [1] inside the vehicle. IMPERATIVE : respect the following checking requirements : Engine at running temperature, vehicle in running order at full load. - Start the engine. - Engage first gear and start driving. - Engage the gears up to third gear. - Decelerate to 2000 rpm. - Gradually accelerate. - Check the pressure : 0.95 ± 0.05 Bar - Remove the tools [1] and [2]. - Re-couple the tube (2) on the duct (1). - Tighten the clip. 184

192 CHECKS : TURBO PRESSURE Engine : 4HY JUMPER B1HP1LZC C5FP0FSC Tools. [1] Pressure gauge for checking boost pressure : 4073-T.A Kit 4073-T [2] Sleeve for checking boost pressure : 4185-T [3] Adaptor sleeve : 4219-T Checks IMPERATIVE : Respect the safety and cleanliness specific to high pressure diesel injection (HDi) engines. - Remove the protector for the electrovalves (1). - Connect tool [1] equipped with tool [3], between the tube (3) and the duct (2). - Connect the sleeve [2] on the pressure gauge [1] with the tube "a". Procedure - Position the tool [1] inside the vehicle. IMPERATIVE : respect the following checking requirements : Engine at running temperature, vehicle in running order at full load. - Start the engine. - Engage first gear and start driving. - Engage the gears up to third gear. - Decelerate to 2000 rpm. - Gradually accelerate. - Check the pressure : 0.95 ± 0.05 Bar - Remove the tools [1] and [2]. - Re-couple the tube (2) on the duct (1). - Tighten the clip. INJECTION 185

193 JUMPER CHECKS : TURBO PRESSURE Engine : INJECTION B1BP231D C5FP08AC Tools. [1] Pressure gauge for checking boost pressure : 4073-T.A Kit 4073-T [2] Sleeve for checking boost pressure : 4185-T [3] Adaptor sleeve : 4219-T Checks IMPERATIVE : respect the following checking requirements : Engine at running temperature. Vehicle in running order at full load. - Remove the clip (1). - Connect tool [2] equipped with tool [3], between the tube (3) and the duct (2). - Position the tool [1] inside the vehicle. - Connect the tool [2] on the pressure gauge [1] with the tube «a». Procedure. Start the engine. - Engage first gear and start driving. - Engage the gears up to third gear. - Decelerate to 1000 rpm. - Check the pressure: 0,6 ± 0,05 bar. (1500 rpm). - Accelerate freely (changing down from 4th gear to 3rd gear). - Check the pressure : 0,9 ± 0,05 bar (between 2500 and 3500 rpm). - Remove tools [1], [2] and [3]. - Reposition the tube (3). - Put back the clip (1). 186

194 CHECKS : TURBO PRESSURE Engine : S JUMPER B1BP2DSD C5FP0FSC Tools. [1] Pressure gauge for checking boost pressure : 4073-T.A Kit 4073-T [2] Sleeve for checking boost pressure : 4185-T [3] Adaptor sleeve : 4219-T Checks IMPERATIVE : respect the following checking requirements : Engine at running temperature. Vehicle in running order at full load. Preparation. - Remove the clip (1). - Connect tool [2] equipped with tool [3], between ducts (2) and (3). - Connect the tool [2] on the pressure gauge [1] with the tube «a». Procedure. Position the tool [1] inside the vehicle. Start the engine. - Engage first gear and start driving. - Engage the gears up to third gear. - Decelerate to 1000 rpm. - Check the turbo pressure: 0,6 ± 0,1 bar. (1500 rpm). - Accelerate freely (changing down from 4th gear to 3rd gear). - Check the turbo pressure : 1 ± 0,1 bar (between 2500 and 3500 rpm). - Remove tools [1], [2] and [3]. - Reposition the duct (3). - Put back the clip (1). INJECTION 187

195 BERLINGO CHECKING THE AIR SUPPLY CIRCUIT Engine : 9HZ Tools. [1] Manual pressure-vacuum pump FACOM DA 16. INJECTION B1HP1UGC Checks. Vacuum pump Connect the tool [1] on to the vacuum pump (1). Start the engine. The vacuum value should be 0.9 ± 0.1 bar at idle (after 30 seconds of operation). NOTE : The exhaust gas recycling valve is not linked to the air supply circuit. The exhaust gas recycling electrovalve is controlled by the engine ECU. Turbocharging pressure regulation valve. - Connect the tool [1] on the valve (2).. - Appy a vacuum of approx. 0.8 bar. Rod "a" should move 6 ± 2 mm. B1HP22RC 188

196 CHECKING THE AIR SUPPLY CIRCUIT Engines : RHX - RHZ DISPATCH TOOLS [1] Manual vacuum pump : FACOMM DA 16. IMPERATIVE : Respect the safety and cleanliness requirements. Vacuum pump. - Connect the tool [1] on the vacuum pump (1). - Start the engine. - Pressure should be 0.8 bar at 780 rpm. Boost pressure regulator electrovalve. - Connect the tool [1] between the electrovalve (2) and the valve (3) of the boost pressure regulator. Compare readings with the values in the table below INJECTION Engine speed (rpm) Pressure (Bar) 780 0, ,25 B1HP12FD Pressure regulator valve. - Connect the tool [1] on the valve (3). - Appy a pressure of 0.5 bar to activate the rod "a" : - Rod "a" should move 12 mm. 189

197 JUMPER CHECKING THE AIR SUPPLY CIRCUIT Engine : RHV Tools. INJECTION [1] Manual pressure-vacuum pump : FACOM DA 16 Checks - Connect tool [1] to the take-off at «a» (vacuum pump tube). - Start the engine. - The vacuum value should be 0,8 bar at idling speed. B1HP1FGC 190

198 CHECKING THE AIR SUPPLY CIRCUIT Engine : 4HY Tools. JUMPER [1] Manual vacuum pump : FACOM DA 16 Checks - Uncouple the tube at «a». INJECTION - Connect tool [1] at «a» - Start the engine. - The vacuum value should be 0,8 bar at idling speed. B1BP2QKC 191

199 JUMPER CHECKING THE AIR SUPPLY CIRCUIT Engine : S Tools. [1] Manual vacuum pump : FACOM DA 16 INJECTION IMPERATIVE : Respect the safety and cleanliness requirements. - Uncouple the tube at «a». - Connect tool [1] at «a» - Start the engine. - The vacuum value should be 0,8 bar at idling speed. B1BP2QKC 192

200 BERLINGO - DISPATCH - JUMPER B1HP12GD CHECKS : EXHAUST GAS RECYCLING CIRCUIT Engines : RHY - RHX - RHZ Tools. [1] Manual vacuum pump : FACOM DA 16. EGR electrovalve. Check, not under load, between the electrovalve (2) and the EGR valve (1). - Connect the tool [1] between the electrovalve (2) and the capsule (1). - Compare readings with the values in the table below. EGR valve - Connect the tool [1] to the capsule union (1). - Apply, several times in succession, a vacuum of approx. 0.6 bar to activate the rod "a". - In abruptly removing the vacuum, the valve should lock itself back on its seating with a click. Engine : S INJECTION B1KP017C EGR electrovalve. Check, not under load, between the electrovalve (2) and the EGR valve. - Connect the tool [1] between the electrovalve (1) and the EGR valve. - Compare readings with the values in the table below. EGR valve - Connect tool [1] on the capsule union of the EGR valve (2). - Apply a vacuum of approx. 0,6 bar to activate the EGR valve. - In abruptly removing the vacuum, the valve should lock itself back on its seating with a click. - Repeat the operation several times. Engine speed (rpm) Vacuum value (Bar) 780 0,5 bar bar 193 B1BP2QAC

201 CHECKS : EXHAUST GAS RECYCLING CIRCUIT Engine : 4HY JUMPER Tools. [1] Manual vacuum pump : FACOM DA 16. IMPERATIVE : Respect the safety and cleanliness requirements. EGR electrovalve (1). Check, not under load, between the electrovalve (1) and the EGR valve. - Connect the tool [1] between the electrovalve (1) and the EGR valve. - Compare readings with the values in the table below. Butterfly housing electrovalve (2). Check, not under load, between the electrovalve (2) and the butterfly housing (3). - Connect the tool [1] between the electrovalve (1) and the butterfly housing (3). - Compare readings with the values in the table below. Engine speed (rpm) Vacuum value (Bar) 780 0,5 bar bar INJECTION B1BP2Q8C B1HP1FTC B1KP011C EGR valve - Connect tool [1] on the capsule union of the EGR valve (4). - Apply a vacuum of approx. 0,6 bar to activate the EGR valve. - In abruptly removing the vacuum, the EGR valve should lock itself back on its seating with a click. - Repeat the operation several times.. - Uncouple the air duct. - Connect the tool [1] on the butterfly housing vacuum capsule (3). - Apply a vacuum of approx. 0,8 bar, the flap «a» of the butterfly housing (3) should be closed. 194

202 SPARKING PLUGS Vehicles Models Engine type BOSCH CHAMPION SAGEM Electrode gap setting Tightening torque 1.1i HFX FR7DE RC8YCL RFN58 LZ BERLINGO 1.4i KFW FR7DE RC8YCL RFN58 LZ 0.9 mm 3,0 m.dan IGNITION 1.6i 16V NFU FR7ME RFN58HZ DISPATCH 2.0i 16V RFN FR8ME REC9YCL RFN52HZ 1 mm 2,7 m.dan 195

203 SPEEDOMETER An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled. This decree stipulates : - The speed indicated by a speedometer must never be lower than the actual vehicle speed. - Between the speed displayed «SD» and the speed travelled «ST», there must always be the following relationship : VR < VL < 1,10 VR + 4 Km/h CLUTCH GEARBOX TRANSMISSION Example : For an actual speed of 100 Kph the speed displayed by the speedometer may be between 100 and 114 Kph. The speed indicated by the speedometer may be influenced by : - The speedometer. - The tyres fitted to the vehicle. - The final drive ratio. - The speedometer drive ratio. Any of these components can be checked without removing them from the vehicle. (See information note N TT of 19 October NOTE : Before replacing the speedometer, check the conformity of the following points : - The tyres fitted to the vehicle. - The gearbox final drive ratio. - The speedometer drive ratio. 196

204 CLUTCH SPECIFICATIONS Diesel 1.9 D Engine plate WJY Payload (Kg) 600/765 Gearbox BE4/5 Make LUK Mechanism/Type 200 P 3700 Ext./Int. lining Ø 200/134 Disc lining type F 408 C15 CLUTCH GEARBOX TRANSMISSION 197

205 BERLINGO CLUTCH SPECIFICATIONS CLUTCH GEARBOX TRANSMISSION Petrol Diesel 1.1i 1.4i 1.6i 16V V HDi 1.9 D 20 HDi Engine plate HFX KFW NFU 9HZ WJY RHY Gearbox MA/5 BE4/5 Make VALEO LUK Mechanism/Type 200 CPX T P T 5700 Ext./Int. lining Ø 200 x x x x 155 Disc lining type F 808 F 810 F

206 Petrol CLUTCH SPECIFICATIONS Diesel DISPATCH 2.0i 16V 1.9 D 2.0 HDi V HDi Engine plate RFN WJY RHX RHZ RHW Gearbox BE4/5 ML/5 Make VALEO LUK Mechanism/Type 203 DNG P T T 6900 Ext./Int. lining Ø 228 x x x x 150 Disc lining type F 808 DS F 408 F 202 F 810 CLUTCH GEARBOX TRANSMISSION 199

207 RELAY CLUTCH SPECIFICATIONS CLUTCH GEARBOX TRANSMISSION Petrol Diesel 2.0i 2.0 8S HDi 2.2 8S HDi 2.8 TD 2.8 HDi Engine plate RFL R6G RHV 4HY S Gearbox ML/GU Make VALEO LUK VALEO Mechanism/Type 235 DT DNG DT DT 6200 Ext./Int. lining Ø 228 x x 161 Disc lining type F

208 MANUAL GEARBOX SPECIFICATIONS Vehicle Engine Gearbox Sequence Torque ratio Drive ratio Type BE4/5 C15 DW8B BE3/5N 20 TE x 71 TU1JP MA/5S 20 CP x x 21 TU3JP MA/5L 20 CP x CP 36 TU5JP4 BE4/5N 20 DM x x 17 Berlingo BE4/5J 20 DM x x 16 DV6ATED4 BE4R/5L 20 DM x 72 None DW8B BE4/5L 20 DM x x 17 BE4/5N 20 DM x x 17 DW10TD BE4/5KG 20 DM x 70 None BE4/5KG 20 DM x 72 Dispatch EW10J4 BE4/5 20 DL x x 19 CLUTCH GEARBOX TRANSMISSION 201

209 MANUAL GEARBOX SPECIFICATIONS Vehicle Engine Gearbox Sequence Torque ratio Drive ratio Dispatch Type ML/5 DW10BTED 20 LM x 71 DW10CTED ML/5C 20 LM x 67 DW10BTED+ 20 LM x 67 DW10ATED4 20 LM x 67 Type ML/5 25 x 20 CLUTCH GEARBOX TRANSMISSION Vehicle Engine Load Gearbox Sequence Torque ratio Drive ratio XU10J2U 10Q 14Q 20 UM x x 14 18Q 20 UM x x 15 DW10UTD 10Q 14Q 20 MM x x 21 DW12UTED 10Q 14Q 20 UM x x 14 Relay 18Q ML/GU 20 UM x x Q 14Q 20 UM x x TD 18Q 20 UM x x S 18Q 20 UM x x HDi 20 UM x x

210 MANUAL GEARBOX SPECIFICATIONS Vehicle Engine Gearbox Sequence Torque ratio Drive ratio Type AL4 Dispatch EW10J4 AL4 20 TP x x 67 Type 4 HP 20 Relay 2.8 HDi 4 HP 20 Sans 20 x x 68 CLUTCH GEARBOX TRANSMISSION 203

211 MA/5 GEARBOX : TIGHTENING TORQUES Tightening torques (m.dan) Ref. Description No. of screws m.dan 1 Bearing retaining clip 4 1,8 ± 0,2 2 Intermediate plate 11 5 ± 0, Gearbox casing # RPO ,9 ± 0,2 RPO 9786 # 4 Clutch bearing guide screws 3 0,6 ± 0,15 CLUTCH GEARBOX TRANSMISSION B2CP3SRP 204

212 MA/5 GEARBOX : TIGHTENING TORQUES Tightening torques (m.dan) Ref. Description No. of screws m.dan 26 5th gear housing fixing screws 3 2,2 ± 0,2 27 Reverse gear switch 2,5 ± 0,5 28 Drain plug 1 3,3 ± 0,3 29 Level plug 3,3 ± 0,3 CLUTCH GEARBOX TRANSMISSION B2CP3SSD 205

213 CLUTCH GEARBOX TRANSMISSION BE4/5 GEARBOX : TIGHTENING TORQUES Tightening torques (m.dan) Ref. Description No. of screws m.dan 1 Air vent hole 1,5 ± 0,2 2 Reverse gear rocker shaft fixing nut 4,5 ± 0,2 3 Differential casing fixing nuts 1,5 ± 0,2 4 Differential casing fixing screws Ø 10 5 ± 0,5 5 Speedo drive support 1,5 ± 0,2 6 Differential casing fixing screws Ø 7 1,5 ± 0,2 7 Drain plug 3,5 ± 0,2 8 Level plug 2,2 ± 0,2 9 Gearbox casing / clutch casing fixing screw 1,3 ± 0,2 10 5th gear housing fixing screw 1,5 ± 0,2 11 Reverse gear switch 2,5 ± 0,2 B2CP3ZXD 206

214 BE4/5 GEARBOX : TIGHTENING TORQUES Tightening torques (m.dan) Ref. Description No. of screws m.dan 12 Fork shaft stop screw 1,5 ± 0,2 13 Differential gearwheel fixing screw 7 ± 0,5 14 Bearing stop screw 1,5 ± 0,2 15 Secondary shaft nut 6,5 ± 0,5 16 Primary shaft nut 7,3 ± 0,5 CLUTCH GEARBOX TRANSMISSION B2CP3ZYD 207

215 BE4/5 GEARBOX : TIGHTENING TORQUES Tightening torques (m.dan) Ref. Description No. of screws m.dan 17 Gear control support fixing screws 1,5 ± 0,2 18 Bearing guide screws 1,25 ± 0,2 19 Speedo housing fixing screws 1,5 ± 0,2 CLUTCH GEARBOX TRANSMISSION B2CP3ZZC B2CP400C 208