Couv VU-2005 - Citroën Service

Transcription

Couv VU-2005
10/11/05
11:55
Page 1
CORRESPONDENCE TABLE FOR PETROL ENGINES
TU
1
Engine families
3
JP
1.1i
XU
5
JP4
1.4i
CORRESPONDENCE TABLE FOR DIESEL ENGINES
10
J2U
1.6i 16V
Engine families
HFX
KFW
NFU
Berlingo
X
X
X
DV
EW
J2U/K
2.0i
RFL
DW
6
8
ATED
B
Engine families
TD
BTED
CTED
UTD
ATED4
UTED
TD
2.0 8S
HDi
2.0 16V
HDi
2.2 8S
HDi
2.8 TD
2.8HDi
RHV
RHW
4HY
8140.43
8140.43S
X
X
X
BTED+
RFN
Engine families
1.6 16V
HDi
1.9D
9HZ
WJY
C15
Dispatch
12
ATED
J4
2.0i 16V
R6G
SOFIM
10
2.0HDi
RHY
RHX
RHZ
X
X
X
X
BERLINGO
Relay
X
X
DISPATCH
RELAY
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.
X
X
X
X
X
X
Couv VU-2005
10/11/05
11:55
Page 2
UTILITY VEHICLES
UTILITY VEHICLES
AC/DTAV/PRME/MMCB/MMEC
Méthodes Mécaniques
쏘 «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».
2005
C15-BERLINGO
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".
CAR 000 021
2005
FR-VU-Index-2005
9/01/06
10:55
Page I
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.
FR-VU-Index-2005
9/01/06
10:55
Page II
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.
FR-VU-Index-2005
9/01/06
10:55
Page III
CONTENTS
GENERAL
Vehicle
identification
C15
1-2
Berlingo
3-4
Dispatch
Relay
Capacities
5-6
7 - 10
C15
12
Berlingo
13
Dispatch
14
Relay
Lubricants
15
16 - 38
ENGINE
Specifications
39 - 40
Tightening torques : engines all types
41 - 75
Cylinder head tightening : all types
76 - 79
Auxiliary drive belt
80 - 81
Checking and setting the valve timing
106 - 107
Checking the oil pressure
172 - 173
Valve clearances
174
INJECTION
Checking the low pressure fuel supply
circuit : C15 (DV6ATED4)
175
circuit : Berlingo Dispatch (DW10TD)
176 - 177
circuit : Relay (DW10UTD)
178 - 179
circuit : Relay (DW12UTED/SOFIM)
180 - 181
Checking the turbo pressure : Berlingo
(DW10TD)
182
Checking the turbo pressure : Dispatch
(DW10ATED)
183
Checking the turbo pressure : Relay
(DW10UTD)
184
(DW12UTED)
185
(SOFIM 2.8TD)
186
(SOFIM 2.8 HDi)
Checking the air supply circuit :
Berlingo (DV6ATED4)
188
Dispatch (DW10TD)
189
Relay (DW10UTD)
190
Relay (DW12UTED)
191
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
187
Speedometer
Clutch
specifications
C15
Berlingo
196
197
198
FR-VU-Index-2005
9/01/06
10:55
Page IV
CONTENTS
CLUTCH-GEARBOX-TRANSMISSION
Clutch
specifications
AXLES - SUSPENSION – STEERING
Dispatch
199
Axle geometry : C15
Relay
200
Tightening torques : front axle : C15
251
Tightening torques : rear axle : C15
252
Specifications :
Manual / automatic gearbox : all types
201 - 203
Tightening torques :
Manual gearboxes
204 - 217
Manual gearbox controls:
all types
218 - 227
248 - 250
Tightening torques : power steering : C15
253 - 254
Axle geometry : Berlingo
255 - 258
Tightening torques : front axle : Berlingo
Tightening torques : rear axle : Berlingo
259
260
Suspension : Berlingo
261 - 262
228 - 231
Tightening torques : power steering : Berlingo
263 - 264
232 - 234
Axle geometry : Dispatch
265 - 266
Tightening torques : front axle : Dispatch
267 - 268
Tightening torques : rear axle : Dispatch
269
Manual steering : Dispatch
270
Tightening torques: power steering: Dispatch
271
Axle geometry : Relay
272
Shift lock : 4 HP 20 gearbox
239 - 240
241 - 244
Filling / topping-up : 4 HP 20 gearbox
245 - 246
Tightening torques : rear axle : Relay
Recommendations/precautions :
AL4 automatic gearbox
Tightening torques : AL4 gearbox
AL4 automatic gearbox
controls
Recommendations/precautions :
4 HP 20 automatic gearbox
Tightening torques : 4 HP 20 gearbox
Driveshafts
235 - 237
238
247
Tightening torques : front axle : Relay
Tightening torques : power steering : Relay
273 - 274
275
276 - 277
BRAKES
Brake specifications : C15
Tightening torques : brakes
Adjusting the brake limiter
Adjusting parking brakes
Bleeding the brakes
Brake specifications : Berlingo
Tightening torques : brakes
Checking/adjusting the compensator
Bleeding the brakes
Brake specifications : Dispatch
Manual adjustment of the compensator
Checking/adjusting the compensator
Brake specifications : Relay
Draining, filling and bleeding the
braking circuit
AIR CONDITIONING
R134.a : quantities
278
279
280
281
282
283 - 288
289
290 - 291
292
293
294 - 297
298
299
300
301 - 302
303 - 306
307 - 310
311
FR-VU-Index-2005
9/01/06
10:55
Page V
CONTENTS
AIR CONDITIONING
Compressor lubricant
314 - 315
Checking the efficiency of the circuit
316 - 325
Air conditioning circuit : Berlingo
326 - 327
Air conditioning circuit : Dispatch
328 - 330
Air conditioning circuit : Relay
331 - 332
FR-VU-page001-38-2005
9/01/06
10:57
Page 1
C15
IDENTIFICATION OF VEHICLES
(1) RP organisation no.
(2) Chassis no.
(3) Paint code
(5) 01/02/99 Label
- Tyre pressures.
- RP organisation no.
- Paint code
(6) Model year
(7) Gearbox identification reference
(8) Engine plate
E1AP079D
1
GENERAL
(4) Manufacturer’s plate
FR-VU-page001-38-2005
9/01/06
10:57
Page 2
C15
Type approval
Structure
VD WT/B
Family (1)
VD
Family (1)
VV
Version (2)
/B
Variant (3)
GENERAL
Engine
WJY
1.9 D
VD
Version (2)
C 15
Depollution
DW8B
W4
2
VV
Van 600 Kg
VW
Van 765 Kg
VY
Deepened cab
WT
Familiale N1
Variant (3)
Familiale Spain
B
FR-VU-page001-38-2005
9/01/06
10:57
Page 3
BERLINGO
A – Chassis stamp, cold stamp
C - Label
RPO No.
Paint colour code
Tyre pressures
D – Gearbox identification reference – factory serial no.
E – Engine legislation type – factory serial no.
E1AP0AMD
3
GENERAL
B - Manufacturer’s vehicle plate
FR-VU-page001-38-2005
9/01/06
10:57
Page 4
BERLINGO
Type approval
GENERAL
Structure
G
Family (1)
J
Bodywork (2)
GJ KFWC KFW
Engine (3)
/IF
C
Version (4)
/IF
Variant (5)
Family (1)
G
Berlingo
Body shape (2)
B
Van 600 Kg
C
Van 800 Kg
E
Floor cab
Engine (3)
HFX
1.1i
TU1JP
KFW
1.4i
TU3JP
NFU
1.6i 16V
TU5JP4
9HX
1.6 16V HDi DV6ATED4
WJY
1.9 D
DW8B
RHY
2.0 HDi
DW10TD
Version (4)
L3
W3
A
Manual 5-speed gearbox
Automatic 6-speed gearbox
Axle and/or gearbox gears
Other possible combinations
No gearbox
L4
Euro IV
B
E
G
D
K
M
C
F
H
J
L
Depollution levels
US
Others
83/87
P
V
R
W
S
X
N
T
Y
K
K'
5
6
7
Alcohol
L3/L4 Euro IV
8
1
9
2
3
U
0
4
Z
Variants (5)
2 sliding side doors as standard for 800 kg (WJY)
Multi-function roof as standard for MPV WJY
Without FAP
Fiscal incentives
4x4 DANGEL
Downgraded depollution
Dual fuel LPG
Dual fuel CNG
STT2 (Stop and Start)
Van Turkey
Van Spain
MPV/Van 5-seater
4
PLC
PMF
SF
IF
DGL
D
GL
GN
S
TR
ES
PL
FR-VU-page001-38-2005
9/01/06
10:57
Page 5
DISPATCH
1 Vehicle identification N°.
2 RP organisation no.
4 Manufacturer’s plate.
5 Engine plate.
6 Gearbox identification reference.
7 - from 01/11/2003 Label
- Tyre pressures.
- RP organisation no.
- Paint code.
E1AP0D0D
5
GENERAL
3 Paint code.
FR-VU-page001-38-2005
9/01/06
10:57
Page 6
DISPATCH
Type approval
GENERAL
Structure
B
Family (1)
BD
D
Number of seats (2)
RFNC/IF/IF RFN
Engine (3)
C
Version (4)
/IF
Variant (5)
Family (1)
B
Dispatch
Number of seats (2)
A
5 seats
B
6 seats
C
7 seats
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)
RFN
2.0i 16V
EW10J4
WJY
1.9 D
DW8B
RHX
DW10BTED
DW10ATED4
2.0 HDi
RHZ
DW10CTED
DW10BTED+
RHW 2.0 16V HDi
DW10ATED4
Version (4)
15.04
K
Axle and/or gearbox gears
Manual 5-speed gearbox for South America
No gearbox
Spécif
US/CEE
Depollution levels
93/59
96/69
L/W
L3/W3
96/69 A 98/69 B
L4/W4 L5/W5
G
A
B
C
H
D
E
K
F
Variants(5)
Entreprise convertible
Integral alternator-starter (ADIN)
Without FAP
Fiscal incentives
Piloted manual gearbox
Downgraded depollution
LPG dual fuel
STT2 (Stop and start)
Van Spain
6
T
AD
SF
IF
P
D (Private vehicle or Van
LPG (Cylindrical tank)
TD (Van Convertible)
LPG (Ring-shaped tank)
S
ES
FR-VU-page001-38-2005
9/01/06
10:57
Page 7
IDENTIFICATION OF VEHICLES (4 X 2)
RELAY
(1) Gearbox identification reference.
(2) Manufacturer’s name plate.
(4) Paint code (on bonnet).
(5) Chassis N° (cold stamp on body).
(6) Production N°.
E1-P02UD
7
GENERAL
(3) Engine plate.
FR-VU-page001-38-2005
9/01/06
RELAY 4 X 4
10:57
Page 8
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
FR-VU-page001-38-2005
9/01/06
10:57
Page 9
RELAY 4 X 4
Type approval
ZB
RMFA/SX
Z
A
B
RFL
R6G
RHV
4HY
8140.43
8140.43S
Z
B
R
M
F
A
/SX
Family (1)
Payload (2)
Engine (3)
Transmission (4)
Bodywork (5)
Wheelbase (6)
Variant (7)
Family (1)
Jumper / Relay
Payload (2)
11 Q
C
18 Q
15 Q
D
GVW reduced
Engine (3)
XU10J2U
2.0
XU10J2U/K
2.0 8S HDi
DW10UTD
2.2 8S HDi
DW12UTED
2.8 TD
SOFIM 2.8 L TD
2.8 HDi
SOFIM 2.8 L HDi
M
A
A
B
C
D
F
G
H
M
N
P
R
W
Transmission (4)
5-speed manual
W
4x4
Automatic
Bodywork (5)
Chassis cab
Bare chassis
Floor cab
Platform cab
Van
Platform double cab
Chassis double cab
Minibus
Van with raised sides
Combi panorama 8/9 seater (CLUB)
Combi 6/9 seater (CONFORT)
Minibus 10 seater (MERCOSUR)
9
A
B
C
G
Wheelbase (6)
Short wheelbase (2850 mm)
Medium wheelbase (3200 mm)
Long wheelbase (3700 mm)
Super long wheelbase (4050 mm)
GENERAL
Structure
FR-VU-page001-38-2005
9/01/06
10:57
Page 10
RELAY 4 X 4
Type approval
GENERAL
AX
BX
AM
AG
AXC
With EGR
Raised roof with EGR
CNG Van
LPG Van
Camping car with EGR
BXC
ZX
AY
BY
BM
H
MH
Combi with raised roof
CNG Combi with raised roof
M
GH
AXx
AX2
AY
AY2
SX
Bus 15 seater, 2 point seatbelts with EGR SX
Bus 14 seater, 3 point seatbelts with EGR SX
Bus 15 seater, 2 point seatbelts without EGR AX1
Bus 14 seater, 2 point seatbelts without EGR AX3
Bus Petrol 14 seater, 3 point belts (Switz.) AY1
AX4
AX6
AY4
Bus 15 seater, 2 point seatbelts with EGR
Bus 15 seater, 2 point seatbelts without EGR
AY6
AX5
AX7
Variant (7)
Van versions
Camping car Special with EGR
Combi mixed N1 (5/6 seater) Italy
Without EGR
Raised roof without EGR
CNG Van with raised roof
Private vehicle versions
CNG Combi
LPG Combi with raised roof
MINIBUS versions
Bus GO with EGR, 12 seats, 2 pt belts (CH)
Bus without EGR, 12 seats, 3 pt belts (CH)
MINIBUS versions (with speed limiter)
10
BG LPG Van with raised roof
AYC Camping car without EGR
BYC Camping car without EGR
G
LPG Combi
AY3
SX1
SY1
Bus with EGR, 13 seats, 3 pt belts (CH)
Bus without EGR, 13 seats, 3 pt belts (CH)
AY5
AY7
FR-VU-page001-38-2005
9/01/06
10:57
Page 11
CAPACITIES (in litres)
Draining methods.
Oil capacities are defined according to the following methods.
Draining of the engine lubrication system by SUCTION
Place the vehicle on horizontal ground (in the high position if hydropneumatic suspension).
Place the vehicle on horizontal ground (in the high position if hydropneumatic suspension).
The engine should be hot (oil temperature 80°C).
The engine should be hot (oil temperature 80°C).
Remove the oil by suction through the dipstick tube.
Drain the sump by gravity.
Remove the oil filter cartridge.
Remove the oil filter cartridge (time for draining and drip-drip =
15 minutes approx.).
Maintain the suction of oil in the sump (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).
Refit a new oil filter cartridge.
Start the engine to fill the oil filter cartridge.
Refill the engine with oil (see table for oil capacity).
Stop the engine (allow to stabilise for 5 minutes).
Start the engine to fill the oil filter cartridge.
WARNING : Remove the suction container before starting the engine
Stop the engine (allow to stabilise for 5 minutes).
ESSENTIAL : Systematically check the oil level using the oil dipstick.
11
GENERAL
Draining of the engine lubrication system by GRAVITY
FR-VU-page001-38-2005
9/01/06
C15
10:57
Page 12
Diesel
1.9 D
WJX
4,5
1,5
Engine type
Engine with filter change
Between Min. and Max.
GENERAL
2
5-speed gearbox
Brake circuit
8
Cooling system
Fuel tank
capacity
47
12
9/01/06
10:57
Page 13
BERLINGO
Petrol
1.1i
Engine plate
HFX
1.4i
1.6i 16V
KFW
3
Fuel tank capacity
1.9 D
NFU
9HZ
WJY
3,25
3,75
1,55
2
1,8
With ABS = 0,45
Hydraulic brake circuit
Cooling system
1.6 16V HDi
1,5
5-speed gearbox
Diesel
2.0 HDi
RHY
4,5
1,2
2
Without ABS = 0,36
1,4
1,8
8
9
55
60
13
GENERAL
FR-VU-page001-38-2005
FR-VU-page001-38-2005
9/01/06
10:57
Page 14
DISPATCH
Diesel
Petrol
2.0i 16V
Auto.
Engine type
GENERAL
5-speed gearbox
2.0 HDi
(2)
1.9 D
RFN
4,25
WJY
1,7
1,4 [1,3 (1)]
ATED
RHZ
BTED
RHX
4,5
1,4
1,8
1,8
Automatic gearbox
8
after drainage
3
0,5 LITRE
Brake circuit
Cooling
system
7
9
8,5
Fuel tank
capacity
(1)
(2)
(3)
(4)
(5)
=
=
=
=
=
(3)
DW10
CTED
ATED
RHZ
RHZ
80
Vehicle with aircon.
Up to RPO 9869 – Versions : panel van, glazed van and floor cab.
New Look JUMPY / DISPATCH
From RPO 9870
Oil sump with increased capacity, yellow identification label on filler neck.
14
(4)
(5)
BTED
RHX
5,5
CTED
RHZ
2.0 16V
HDi
RHW
4,75
1,9
FR-VU-page001-38-2005
9/01/06
10:57
Page 15
RELAY
Petrol
Diesel
2.0i
2.0 8V HDi
2.2 8V HDi
2.8 TD
2.8 HDi
(1)
(2)
Engine type
RFL
R6G
RHV
RHV
4HY
4HY
8940.43
8140.43S
4,75
4,50
5,25
6,25
5,25
6,25
5,5
7
1,5
5-speed gearbox
2
2,7 (after draining)
Automatic gearbox
8,5
after drainage
Brake circuit
Cooling system
9
0,59, for 11Q and 15Q
10,5
11,1 (with aircon)
Fuel tank capacity
80
(1) (2) = Oil sump with increased capacity, yellow identification label on valve cover
15
0,62 for 18Q
10
GENERAL
Auto
FR-VU-page001-38-2005
9/01/06
10:57
Page 16
LUBRICANTS - TOTAL recommended oils
Evolutions (YEAR 2004).
CITROËN C4
New Look CITROËN C5
Petrol engine versions:
Normal maintenance interval : 30 000 km (20 000 miles).
Severe maintenance interval : 20 000 km (12 000 miles).
Petrol engine versions except 2.0 i 16V 180 hp (132 kW) :
Diesel engine versions:
GENERAL
WARNING : Vehicles HDi FAP (*) do not accept the energy economy
oil TOTAL ACTIVA FUTUR 9000 5W30 for France, TOTAL QUARTZ
FUTURE 9000 5W30 outside France.
Petrol engine version 2.0L i 16V 180 hp (132 kW) :
Diesel engine versions :
WARNING : Vehicles HDi FAP (*) do not accept the energy economy
oil TOTAL ACTIVA FUTUR 9000 5W30 for France, TOTAL QUARTZ
FUTURE 9000 5W30 outside France .
DV6 engines:
Normal maintenance interval : 20 000 km (12 500 miles)
Severe maintenance interval : 15 000 km (10 000 miles)
DW engines :
DV6 engines :
DW engines:
ESSENTIAL : For all vehicles with a 30 000 km (20 000 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.
16
FR-VU-page001-38-2005
9/01/06
10:57
Page 17
Use of oil grade 10W40
It is possible to use the semi–synthetic oil 7000 10W40 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 9000 5W30 (France only).
TOTAL QUARTZ FUTUR 9000 5W30 (except France).
The exclusions for use of this oil are the following :
XSARA VTS 2.0 16V (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
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
FR-VU-page001-38-2005
9/01/06
10:57
Page 18
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 C3 1.4 16V HDi.
- EW 12J4
: CITROËN C8 2.2i.
- EW 10A
: CITROËN C4 and C5 2.0i.
- EW10J4S engine
: CITROËN C4
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
ACEA
Norms
API
Norms
Petrol and LPG dual fuel engines
A3 or A5
(*)
SJ or SL
Diesel engines
B3, B4 or
B5 (*)
CF
Engine types concerned
2003
(*) 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.
18
FR-VU-page001-38-2005
9/01/06
10:57
Page 19
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) :
TOTAL ACTIVA 9000
TOTAL QUARTZ 9000
TOTAL ACTIVA FUTUR 9000 (*)
TOTAL QUARTZ FUTUR 9000 (*)
TOTAL ACTIVRAC
5W40
ACEA
norms
A3/B3/
B4
5W30
A5/B5
10W40
A3/B3
API
norms
S.A.E.
norms
SL/CF
(*) Blended oils for all engines giving fuel economy.
Oils for petrol, diesel and dual fuel petrol/LPG engines :
S.A.E.
norms
TOTAL ACTIVA 7000
TOTAL QUARTZ 7000
10W40
TOTAL QUARTZ 9000
0W40
TOTAL ACTIVA 7000
TOTAL QUARTZ 7000
15W50
ACEA
norms
API
norms
A3
SL
19
TOTAL ACTIVA DIESEL 7000
TOTAL QUARTZ DIESEL 7000
10W40
TOTAL ACTIVA DIESEL 7000
15W50
ACEA
norms
API
norms
B3
CF
GENERAL
S.A.E.
norms
Oils specifically for diesel engines :
FR-VU-page001-38-2005
9/01/06
10:57
Page 20
Oil usage table
Huile TOTAL ACTIVA QUARTZ
Synthetic 9000
0W40
Engine types
GENERAL
Petrol
engines
Diesel
engines
EW10J4S (CITROËN C4)
X
EW12J4 (CITROËN C8 2.2i 16V)
X
EW10A (CITROËN C4 and C5)
Other petrol engines
X
X
HDi engines with FAP (*)
X
Other HDi engines
X
5W30
10W40
Hot countries
Temperate countries
Cold countries
X
X
X
X
X
SOFIM 2.8 HDi and 2.8 TDi (RELAY)
X
DV4 TED4 (C3 1.6 16V HDi)
X
Indirect injection diesel engines
Semi-synthetic 7000
5W40
15W50
X
X
X
X
X
X
X
X
X (*)
X
X
X
X
X
X
X
X
X
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
FR-VU-page001-38-2005
9/01/06
10:57
Page 21
GENERAL
E4AP006D
21
FR-VU-page001-38-2005
9/01/06
10:57
Page 22
ENGINE OILS
FRANCE
Blended oils for all engines, supplied in bulk
TOTAL ACTIVRAC
Metropolitan FRANCE
Norms S.A.E : 10W40
TOTAL ACTIVA
GENERAL
Metropolitan FRANCE
New Caledonia
Guadeloupe
Saint-martin
Reunion
Martinique
Guyana
Tahiti
Mauritius
Mayotte
TOTAL ACTIVA DIESEL
Blended oils for
all engines
Oils specifically for petrol
and dual-fuel petrol / LPG
engines
Oils specifically for diesel
engines
9000 5W40
FUTUR 9000 5W30 (*)
7000 10W40
7000 10W40
9000 5W40
7000 15W50
7000 10W40
9000 5W40
(*) = Blended oils for all engines, giving fuel economy
22
7000 15W50
7000 10W50
FR-VU-page001-38-2005
9/01/06
10:57
Page 23
ENGINE OILS
TOTAL QUARTZ
TOTAL QUARTZ DIESEL
engines
Blended oils for
all engines
Germany
7000 10W40
9000 0W40
Austria
7000 10W40
Belgium
7000 10W40
9000 0W40
Bosnia
9000 5W40
FUTUR 9000 5W30 (*)
7000 10W40
9000 0W40
Bulgaria
7000 10W40
Cyprus
7000 10W40
9000 15W40
Croatia
7000 10W40
23
engines
GENERAL
EUROPE
7000 10W40
FR-VU-page001-38-2005
9/01/06
10:57
Page 24
ENGINE OILS
EUROPE
TOTAL QUARTZ
engines
Blended oils for
all engines
engines
7000 10W40
9000 0W40
7000 10W40
7000 15W40
Denmark
GENERAL
Spain
Estonia
Finland
TOTAL QUARTZ DIESEL
7000 10W40
9000 0W40
9000 5W40
FUTUR 9000 5W30 (*)
7000 10W40
Great Britain
7000 10W40
Greece
7000 10W40
7000 15W40
Holland
7000 10W40
9000 0W40
24
FR-VU-page001-38-2005
9/01/06
10:57
Page 25
ENGINE OILS
EUROPE
TOTAL QUARTZ
TOTAL QUARTZ DIESEL
engines
Blended oils for
all engines
engines
GENERAL
7000 10W40
9000 0W40
Hungary
Italy
Ireland
Iceland
7000 10W40
9000 5W40
FUTUR 9000 5W30 (*)
7000 10W40
Latvia
7000 10W40
9000 0W40
Lithuania
Macedonia
7000 10W40
25
FR-VU-page001-38-2005
9/01/06
10:57
Page 26
ENGINE OILS
EUROPE
TOTAL QUARTZ
TOTAL QUARTZ DIESEL
engines
Blended oils for
all engines
GENERAL
Malta
7000 10W40
7000 15W50
Moldavia
7000 10W40
Norway
7000 10W40
9000 0W40
Poland
9000 5W40
FUTUR 9000 5W30 (*)
engines
7000 10W40
7000 10W40
Portugal
Slovakia
7000 10W40
9000 0W40
Czech Republic
26
FR-VU-page001-38-2005
9/01/06
10:57
Page 27
ENGINE OILS
EUROPE
TOTAL QUARTZ
TOTAL QUARTZ DIESEL
engines
Blended oils for
all engines
engines
GENERAL
7000 10W40
7000 15W50
9000 0W40
Romania
Russia
7000 10W40
9000 0W40
Slovenia
Sweden
9000 5W40
FUTUR 9000 5W30 (*)
7000 10W40
Switzerland
7000 10W40
Turkey
7000 10W40
9000 15W50
9000 0W40
27
FR-VU-page001-38-2005
9/01/06
10:57
Page 28
ENGINE OILS
EUROPE
Ukraine
TOTAL QUARTZ
TOTAL QUARTZ DIESEL
GENERAL
Blended oils for
all engines
engines
engines
9000 5W40
FUTUR 9000 5W30 (*)
7000 10W40
9000 0W40
7000 10W40
Serbia-Montenegro
28
FR-VU-page001-38-2005
9/01/06
10:57
Page 29
ENGINE OILS
Australia
New Zealand
TOTAL QUARTZ
TOTAL QUARTZ DIESEL
Blended oils for
all engines
engines
engines
9000 5W40
FUTUR 9000 5W30 (*)
7000 10W40
7000 10W40
AFRICA
TOTAL QUARTZ
TOTAL QUARTZ DIESEL
Blended oils for
all engines
engines
engines
9000 5W40
7000 10W40
7000 15W50
7000 10W40
Algeria, South Africa,
Ivory Coast, Egypt,
Gabon, Ghana, Kenya,
Madagascar, Morocco,
Nigeria, Senegal, Tunisia
29
GENERAL
OCEANIA
FR-VU-page001-38-2005
9/01/06
10:57
Page 30
ENGINE OILS
CENTRAL AND SOUTH AMERICA
TOTAL QUARTZ
TOTAL QUARTZ DIESEL
engines
Blended oils for
all engines
engines
Argentina
GENERAL
Brazil
Chile
Cuba
7000 10W40
7000 15W50
9000 5W40
Mexico
Paraguay
Uruguay
30
7000 10W40
FR-VU-page001-38-2005
9/01/06
10:57
Page 31
ENGINE OILS
SOUTH-EAST ASIA
TOTAL QUARTZ
engines
Blended oils for
all engines
engines
9000 5W40
FUTUR 9000 5W30 (*)
GENERAL
7000 10W50
7000 15W50
China
South Korea
TOTAL QUARTZ DIESEL
7000 10W40
Hong Kong
7000 15W50
Japan
7000 10W40
9000 5W40
India – Indonesia
9000 5W40
FUTUR 9000 5W30 (*)
7000 10W40
7000 15W50
9000 5W40
7000 15W50
Malaysia
Pakistan
31
FR-VU-page001-38-2005
9/01/06
10:57
Page 32
ENGINE OILS
SOUTH-EAST ASIA
TOTAL QUARTZ
TOTAL QUARTZ DIESEL
engines
Blended oils for
all engines
engines
Philippines
GENERAL
7000 15W50
Singapore
Taiwan
7000 10W40
7000 15W50
9000 5W40
Thailand
7000 15W50
Vietnam
32
7000 10W40
FR-VU-page001-38-2005
9/01/06
10:57
Page 33
ENGINE OILS
MIDDLE EAST
TOTAL QUARTZ
TOTAL QUARTZ DIESEL
engines
Blended oils for
all engines
engines
Dubai
7000 15W50
United Arab Emirates
Iran
9000 5W40
7000 10W40
7000 15W50
Israel – Jordan – Kuwait – Lebanon
7000 15W50
Oman – Qatar – Syria – Yemen
33
7000 10W40
GENERAL
Saudi Arabia – Bahrain
FR-VU-page001-38-2005
9/01/06
10:57
Page 34
GEARBOX OILS
GENERAL
Manual and piloted manual
gearboxes
TOTAL TRANSMISSION BV
Norms S.A.E : 75W80
Part No. : 9730 A2
MB3 automatic gearbox
TOTAL FLUIDE ATX
TOTAL FLUIDE AT 42
Special oil distributed by
CITROËN
Part No. : 9730 A6
All countries
4HP20 and AL4 autoactive
automatic gearboxes
CITROËN
Part No. : 9736 22
AM6 autoactive automatic gearbox
CITROËN
Part No. : 9980 D4
TOTAL TRANSMISSION X4
Part No. : 9730 A7
Transfer box and rear axle
34
FR-VU-page001-38-2005
9/01/06
10:57
Page 35
LUBRICANTS - TOTAL recommended fluids
POWER STEERING OILS
Power steering
All vehicles except CITROËN C4 and C5
All countries
Very cold countries
Power steering
TOTAL FLUIDE LDS
Special oil distributed by r CITROËN
Part No. : 9979 A3
TOTAL FLUIDE DA
Special oil distributed by CITROËN
Part No. : 9730 A1
ENGINE COOLANT FLUID
Packs
All countries
CITROËN fluid
Protection : - 35C°
CITROËN Part No.
GLYSANTIN G33
REVKOGEL 2000
2 Litres
9979 70
9979 72
5 Litres
9979 71
9979 73
20 Litres
9979 76
9979 74
210 Litres
9979 77
9979 75
35
GENERAL
Power steering
CITROËN C4 and C5
TOTAL FLUIDE ATX
FR-VU-page001-38-2005
9/01/06
10:57
Page 36
BRAKE FLUID
Synthetic brake fluid
All countries
CITROËN fluid
Packs
CITROËN Part No.
0,5 Litre
9979 05
1 Litre
9979 06
5 Litres
9979 07
GENERAL
CIRCUIT HYDRAULIQUE
All countries
TOTAL FLUIDE LDS
TOTAL LHM PLUS
Packs
Norm
Orange
Colour
TOTAL LHM PLUS
Very cold countries
CITROËN Part No.
9979 A3
1 Litre
Green
9979 A1
9979 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
FR-VU-page001-38-2005
9/01/06
10:57
Page 37
SCREEN WASH FLUID
Packs
Concentrated : 250 ml
9980 33
ZC 9875 953U
Fluid
ready to
use
1 Litre
9980 06
ZC 9875 784U
5 Litres
9980 05
ZC 9885 077U
GREASING
General use
All countries
TOTAL MULTIS 2
TOTAL SMALL MECHANISMS
Note : NLGI = National Lubrificating Grease Institude.
37
9980 56
ZC 9875 279U
Norms NLGI
2
GENERAL
All countries
CITROËN Part No.
FR-VU-page001-38-2005
9/01/06
10:57
Page 38
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.
- 0.5 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
9/01/06
10:58
Page 39
ENGINE
FR-VU-page039-174-2005
ENGINE SPECIFICATIONS
Petrol engines
All Types
1.1i
1.4i
1.6i 16V
Engine type
HFX
KFW
NFU
Cubic capacity (cc)
1124
1360
1587
1998
1997
Bore / Stroke
72/69
75/77
78,5/82
86/86
85/88
Compression ratio
Power ISO or EEC KW - rpm
Torque ISO or EEC
(m.daN - rpm)
10,5/1
2.0i
RFL
2.0i 16V
R6G
RFN
11/1
9,5/1
10,8/1
44,1-5500
55-5500
80-5800
81-5700
100-6000
94-3500
120-3400
14,7-4000
16,8-3700
19-4100
39
FR-VU-page039-174-2005
9/01/06
10:58
Page 40
ENGINE
ENGINE SPECIFICATIONS
Diesel engines
All Types
1.6 16V
HDi
1.9D
2.0 8V
HDi
2.0 16V
HDi
2.2 8V
HDi
Engine type
9HZ
WJY
RHV
RHW
4HY
8140.43 8140.43S
Cubic capacity (cc)
1560
1868
1997
1998
2179
2798
75/88,3
82,2/88
85/88
86/86
85/96
94,4/100
18/1
23/1
17,6/1
9,5/1
18/1
19/1
Power ISO or EEC KW - rpm
80-4000
51-4600
Torque ISO or EEC
(m.daN - rpm)
24-1750 12,5-2500 20,5-1900 21,5-1750 25-1750
Bore / Stroke
Compression ratio
2.0 HDi
RHY
66-4000
RHX
RHZ
69-4000
40
80-4000
62-4000
80-5500
19,2-1900 16,8-3400
2.8 TD
2.8 HDi
74-4000 90-3600 93,5-3600
25-1900
30-1800
9/01/06
10:58
Page 41
BERLINGO
POWER UNIT SUSPENSION SPECIFICATIONS
Engine : HFX - KFW
Tightening torques (m.daN)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
B1BP2TJP
41
:
:
:
:
:
:
:
:
:
:
:
4,5 ± 0,5
6 ± 0,6
5,4 ± 0,8
4 ± 0,6
2,4 ± 0,4
6,5 ± 0,6
2,2 ± 0,2
3 ± 0,3
2,6 ± 0,3
4,5 ± 0,5
4,5 ± 0,5
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
BERLINGO
10:58
Page 42
Engine : NFU
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
B1BP2TKP
42
:
:
:
:
:
:
:
:
:
:
:
6 ± 0,6
4 ± 0,6
5,4 ± 0,8
6 ± 0,6
2 ± 0,3
6,5 ± 0,6
3 ± 0,3
2,2 ± 0,2
6 ± 0,6
4,5 ± 0,5
4,5 ± 0,5
9/01/06
10:58
Page 43
BERLINGO
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)
Engines : HFX - KFW - NFU
Crankshaft
Accessories drive pulley
2,5 ± 0,2
Pinion on crankshaft
Tightening
Angular tightening
4 ± 0,4
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
Tightening
1±
3,7 ± 0,3
Alternator TU5JP4
Pre-tightening
Tightening
1±
4 ± ,04
Aircon compressor support
2,2 ± 0,2
Aircon compressor
2,3 ± 0,2
43
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
Page 44
ENGINE
BERLINGO
Cylinder head
Coolant outlet housing
In plastic
In aluminium
0,8 ± 0,2
0,8 ± 0,2
Camshaft bearing caps (TU1JP-TU3JP)
Tightening
Angular tightening
2 ± 0,2
44 °± 4°
Camshaft bearing caps (TU5JP4)
Tightening
Angular tightening
2 ± 0,2
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
9/01/06
10:58
Page 45
BERLINGO
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
45
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
Page 46
ENGINE
DISPATCH
Engine : RFN
B1BK1X5D
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
:
:
:
:
:
:
:
:
:
:
:
:
:
:
5 ± 0,5
4,5 ± 0,5
6,5 ± 0,5
3 ± 0,3
4,5 ± 0,5
6,5 ± 0,6
3 ± 0,3
4,5 ± 0,5 (*)
6 ± 0,6 (**)
5 ± 0,5
9 ± 0,9
4,5 ± 0,5
6,5 ± 0,6
(*) AL4 autoactive gearbox
(**) BE4 manual gearbox
B1BK1X7D
B1BK1X6D
46
9/01/06
10:58
Page 47
DISPATCH
Engine : RFN
Crankshaft
Bearing cap fixing screws
Pre-tightening
Angular tightening
Bearing cap screws
Pre-tightening
Angular tightening
Accessories belt automatic tensioner roller
Accessories belt guide roller
Pre-tightening
Tightening
Accessories support block
Tighten (2 studs)
Pre-tightening (4 screws)
Tightening
2 ± 0,2
60° ± 5°
2,3 ± 0,2
46° ± 3°
2 ± 0,2
1,5 ± 0,1
3,7 ± 0,3
0,7 ± 0,2
1 ± 0,1
1,9 ± 0,2
Cylinder block
Sump
Timing belt guide roller
Pre-tightening
Tightening
RH engine support
0,8 ± 0,2
1,5 ± 0,1
3,7 ± 0,3
2,1 ± 0,2
6 ± 0,6
47
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
ENGINE
DISPATCH
9/01/06
10:58
Page 48
Engine : RFN
Cylinder head
Camshaft bearing cover
Exhaust manifold
Valve cover
Camshaft pulley
Pre-tightening
Tightening
Pulley on hub
Timing pinion on crankshaft
Pre-tightening
Angular tightening
0,9 ± 0,1
3,5 ± 0,3
1,1 ± 0,1
3 ± 0,3
7,5 ± 0,7
2,1 ± 0,2
4 ± 0,4
53° ± 4°
Flywheel / clutch
Clutch mechanism
Flywheel
Pre-tightening
Angular tightening
B1CP089C
48
2 ± 0,2
(Sequence 1,5,3,7,2,6,4,8)
(Sequence 1,5,3,7,2,6,4,8)
2 ± 0,2
21° ± 3°
9/01/06
10:58
Page 49
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
B1GP08WC
49
0,9 ± 0,1
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
ENGINE
BERLINGO
Page 50
Engine : 9HZ
Crankshaft
Pre-tightening
Slackening
Tightening
Angular tightening
1 ± 0,2
180°
3 ± 0,3
140° ± 5°
Con rod screws
Tightening
Angular tightening
1 ± 0,1
100° ± 5°
Accessories drive belt pulley
Pre-tightening
Angular tightening
3,5 ± 0,4
190° ± 5°
Cylinder block
Sump
1,3 ± 0,1
3,7 ± 0,3
2,7 ± 0,2
50
9/01/06
10:58
Page 51
BERLINGO
Engine : 9HZ
Cylinder head
Camshaft bearing covers
Pre-tightening
Tightening
0,5 ± 0,1
1 ± 0,1
Exhaust manifold
3 ± 0,3
Camshaft pulley
Pre-tightening
Angular tightening
2 ± 0,2
50° ± 5°
Cylinder head
Pre-tightening
Tightening
Angular tightening
2 ± 0,2
4 ± 0,5
260° ± 5°
EGR valve
1 ± 0,1
Flywheel / Clutch
Flywheel
Pre-tightening
Angular tightening
3 ± 0,3
90° ± 5°
Clutch mechanism
2 ± 0,2
51
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
Page 52
ENGINE
BERLINGO
Engine : 9HZ
Lubrication circuit
Oil pump assembly
Pre-tightening
Tightening
Oil/coolant heat exchanger
Lubrication pipe for turbocharger
0,5 ± 0,1
0,9 ± 0,1
1 ± 0,2
3 ± 0,5
Diesel injection circuit
Pre-tightening
Angular tightening
Fuel high pressure common injection rail
on engine block
Union on fuel high pressure common
injection rail
Pre-tightening
Tightening
Diesel injection pump on support
Union on diesel injector
Pre-tightening
Tightening
Diesel injection pump pulley
Union on diesel high pressure pump
Pre-tightening
Tightening
4 ± 0,1
65° ± 5°
2,2 ± 0,2
1,7 ± 0,2
2,2 ± 0,2
2,2 ± 0,2
2 ± 0,5
2,5 ± 0,3
5 ± 0,5
2 ± 0,5
2,5 ± 0,3
52
9/01/06
10:58
Page 53
BERLINGO
Engine : 9HZ
Cooling circuit
Coolant pump
Pre-tightening
Tightening
0,3 ± 0,1
0,9 ± 0,1
Pre-tightening
Tightening
0,3 ± 0,1
0,7 ± 0,1
53
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
BERLINGO
10:58
Page 54
Engine : WJY
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
: 4,5 ± 0,5
: 6,5 ± 0,6
: 2,2 ± 0,2
: 5 ± 0,5
: 2,2 ± 0,2
: 4,5 ± 0,4
: 4,5 ± 0,5
: 4,5 ± 0,5
: 4,5 ± 0,5
: 4,5 ± 0,5 (*)
: 5 ± 0,5
: 5 ± 0,5
(*) Coat the threads with LOCTITE FRENETANCHE (E3).
B1BP2SZP
54
9/01/06
10:58
Page 55
BERLINGO
Engine : WJY
Crankshaft
Con rod nuts
Pre-tightening
Angular tightening
Accessories drive pulley hub
Pre-tightening
Angular tightening
7 ± 0,7
2 ± 0,2
70° ± 5°
4 ± 0,2
55° ± 5°
1 ± 0,1
Cylinder block
Piston skirt spray jet
Sump
1 ± 0,1
1,6 ± 0,1
4,3 ± 0,4
2,1 ± 0,2
Cylinder head
2 ± 0,2
3 ± 0,3
0,5
4,3 ± 0,4
2,3 ± 0,2
Exhaust manifold
Valve cover
Camshaft / hub
Camshaft pinion / hub
55
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
ENGINE
BERLINGO
Page 56
Engine : WJY
Crankshaft
Con rod nuts
Pre-tightening
Angular tightening
Pre-tightening
Angular tightening
7 ± 0,7
2 ± 0,2
70° ± 5°
4 ± 0,2
55° ± 5°
1 ± 0,1
Cylinder block
Sump
1 ± 0,1
1,6 ± 0,1
4,3 ± 0,4
2,1 ± 0,2
Cylinder head
Exhaust manifold
Valve cover
Camshaft / hub
Camshaft pinion / hub
2 ± 0,2
3 ± 0,3
0,5
4,3 ± 0,4
2,3 ± 0,2
56
9/01/06
10:58
Page 57
BERLINGO
Engine : WJY
Flywheel
Flywheel
4,8 ± 0,4
Clutch mechanism
2 ± 0,2
Lubrication circuit
Oil pump
2,3 ± 0,2
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
57
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
BERLINGO
10:58
Page 58
Engine : RHY
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
B1BP2TRP
58
: 4,5 ± 0,5
: 6,5 ± 0,6
: 2,2 ± 0,2
: 5 ± 0,5
: 2,2 ± 0,2
: 4,5 ± 0,5
: 2 ± 0,2
: 4,5 ± 0,4
: 4,5 ± 0,4
: 2 ± 0,2
: 2,2 ± 0,2
: 6,1 ± 0,6
: 5 ± 0,5
: 4,5 ± 0,4
9/01/06
10:58
Page 59
BERLINGO - DISPAT-
Engines : RHY - RHX - RHZ
Crankshaft
Pre-tightening
Angular tightening
Con rod nuts
Pre-tightening
Angular tightening
Pre-tightening
Angular tightening
2,5 ± 0,2
60° ± 5°
2 ± 0,2
70° ± 5°
4 ± 0,2
51° ± 5°
Cylinder block
1 ± 0,1
1,6 ± 0,1
4,3 ± 0,4
2,5 ± 0,2
Cylinder head
1 ± 0,1
2 ± 0,2
0,8
4,3 ± 0,4
2 ± 0,2
Sump
Exhaust manifold
Valve cover
Camshaft / hub
Camshaft pulley / camshaft hub
59
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
ENGINE
BERLINGO - DISPATCH
Page 60
Flywheel
Flywheel
Clutch mechanism
4,8 ± 0,4
2 ± 0,2
Lubrication circuit
1,6 ± 0,2
7 ± 0,7
Oil pump
Turbocharger lubrication pipe
Engine end
Turbocharger end
4,8 ± 0,4
2,2 ± 0,2
Injection circuit
Unions on fuel high pressure
common injection rail
Injection pump on support
Union on fuel high pressure pump
3 ± 0,3
2 ± 0,2
2,3 ± 0,2
2 ± 0,2
5 ± 0,5
2 ± 0,2
Cooling circuit
Coolant pump
1,5 ± 0,1
1,8 ± 0,1
60
9/01/06
10:58
Page 61
DISPATCH
Engine : RHW
Reference
1
2
3
4
5
6
7
8
9
10
11
B1BK3EED
61
Description
Upper RH torque reaction rod
Upper RH engine support
RH engine flexible support
Upper RH intermediate engine support
Lower RH engine support
Torque reaction rod
Upper RH intermediate engine support
LH engine support
RH engine flexible support
Lifting bracket, flywheel side
Lifting bracket, timing side
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
ENGINE
DISPATCH
9/01/06
10:58
Page 62
Engine : RHW
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
B1BK3EDD
62
: 5 ± 0,5
: 4,5 ± 0,5
: 4,5 ± 0,5
: 6 ± 0,6
: 3 ± 0,3
: 2 ± 0,2
: 4,5 ± 0,5
: 4,5 ± 0,5
: 4,5 ± 0,5
: 6,5 ± 0,6
: 9 ± 0,9
: 4,5 ± 0,5
: 4,5 ± 0,5
: 5 ± 0,5
: 2,5 ± 0,2
: 3 ± 0,3
: 6,5 ± 0,6
: 1,5 ± 0,1
: 1,2 ± 0,1
9/01/06
10:58
Page 63
DISPATCH
Engine : RHW
Crankshaft
Pre-tightening
Angular tightening
Con rod nuts
Pre-tightening
Angular tightening
Pre-tightening
Angular tightening
2,5 ± 0,2
60° ± 5°
2 ± 0,2
70° ± 5°
4 ± 0,2
51° ± 5°
Cylinder block
Sump
1 ± 0,1
1,6 ± 0,1
4,3 ± 0,4
2,5 ± 0,2
Cylinder head
1 ± 0,1
2 ± 0,2
0,8
4,3 ± 0,4
2 ± 0,2
Exhaust manifold
Valve cover
Camshaft / hub
Camshaft pulley / camshaft hub
63
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
ENGINE
DISPATCH
Page 64
Engine : RHW
Flywheel
Flywheel
Clutch mechanism
4,8 ± 0,4
2 ± 0,2
Lubrication circuit
Oil pump
Engine end
Turbocharger end
1,6 ± 0,2
7 ± 0,7
4,8 ± 0,4
2,2 ± 0,2
Injection circuit
Unions on fuel high pressure
common injection rail
3 ± 0,3
2 ± 0,2
2,3 ± 0,2
2 ± 0,2
5 ± 0,5
2 ± 0,2
Cooling circuit
Coolant pump
1,5 ± 0,1
1,8 ± 0,1
64
9/01/06
10:58
Page 65
RELAY
Engines : RHV - 4HY
B1BP2JBD
65
(1)
: 8 ± 0,8
(2)
: 5 ± 0,5
(3)
: 5 ± 0,5
(4)
: 9 ± 0,9
(5)
: 8 ± 0,8
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
ENGINE
RELAY
Page 66
Engine : RHV
Crankshaft
Pre-tightening
Angular tightening
Con rod nuts
Pre-tightening
Angular tightening
Pre-tightening
Angular tightening
2,5 ± 0,2
60° ± 5°
2 ± 0,2
70° ± 5°
4 ± 0,4
51° ± 5°
Carter cylindres
Sump
RH engine support
1 ± 0,1
1,6 ± 0,2
2,5 ± 0,2
2,5 ± 0,2
2,7 ± 0,2
Cylinder head
Exhaust manifold
Valve cover
Camshaft pulley
Hub pulley
1 ± 0,1
2 ± 0,2
0,8 ± 0,1
4,3 ± 0,4
2 ± 0,2
66
9/01/06
10:58
Page 67
RELAY
Engine : RHV
Flywheel
4,8 ± 0,5
2 ± 0,2
Lubrication circuit
1,3 ± 0,1
5,8 ± 0,5
Flywheel
Clutch mechanism
Oil pump
Engine end
Turbocharger end
3 ± 0,3
2 ± 0,2
3 ± 0,3
2,5 ± 0,2
2,25 ± 0,2
3 ± 0,3
5 ± 0,5
2,5 ± 0,2
Cooling circuit
1,5 ± 0,1
2 ± 0,2
Injector fixing flange nut
Unions on fuel high pressure common injection rail
Injection high pressure pump pulley
Coolant pump
67
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
ENGINE
RELAY
Page 68
Engine : 4HY
Crankshaft
Pre-tightening
Angular tightening
Con rod nuts
Pre-tightening
Angular tightening
Pre-tightening
Angular tightening
2,5 ± 0,2
60° ± 5°
2,3 ± 0,3
46° ± 5°
7 ± 0,7
82° ± 5°
Carter cylindres
Sump
RH engine support
1 ± 0,1
1,6 ± 0,2
4,3 ± 0,2
2,5 ± 0,2
2,7 ± 0,2
Cylinder head
Exhaust manifold
Valve cover
Camshaft pulley
Hub pulley
1 ± 0,1
2 ± 0,2
0,8 ± 0,1
4,3 ± 0,4
2 ± 0,2
68
9/01/06
10:58
Page 69
RELAY
Engine : 4HY
Flywheel
4,8 ± 0,5
2 ± 0,2
Flywheel
Clutch mechanism
Lubrication circuit
Oil pump
Engine end
Turbocharger end
1,3 ± 0,1
5,8 ± 0,5
3 ± 0,3
2 ± 0,2
Injection high pressure pump pulley
3 ± 0,3
2,7 ± 0,2
2,25 ± 0,2
2,7 ± 0,2
5 ± 0,5
2,5 ± 0,2
Cooling circuit
Coolant pump
1,5 ± 0,1
2 ± 0,2
69
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
ENGINE
RELAY
9/01/06
10:58
Page 70
Engine : 8140.43
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
B1BP22DD
70
:
:
:
:
:
:
:
:
:
8
5
5
5
8
9
9
5
5
±
±
±
±
±
±
±
±
±
0,8
0,5
0,5
0,5
0,8
0,9
0,9
0,5
0,5
9/01/06
10:58
Page 71
RELAY
Engine : 8140.43
Crankshaft
Con rod screws
Pre-tightening
Angular tightening
5 ± 0,5
60° ± 5°
2 ± 0,2
Carter cylindres
4 ± 0,4
1,8 ± 0,2
Sump
Lower cylinder cover on upper cylinder cover
Pre-tightening
Angular tightening
Screw M8
Screw M10
5 ± 0,5
90° ± 5°
4 ± 0,4
2,5 ± 0,2
4 ± 0,4
Cylinder head
1,8 ± 0,2
2,5 ± 0,2
2,5 ± 0,2
Camshaft bearing cap covers
Inlet manifiold
Exhaust manifiold
Valve cover
Screw M6
Screw M8
Camshaft pinion
Injection pump pinion
1 ± 0,1
2,5 ± 0,2
2,5 ± 0,2
10 ± 1
71
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
ENGINE
RELAY
Page 72
Engine : 8140.43
Flywheel
Flywheel
Pre-tightening
Angular tightening
Clutch mechanism
3 ± 0,3
90° ± 5°
3 ± 0,3
Lubrication circuit
Oil pump assembly
Screw M8
Screw M12
Screw 56 mm long
Screw 74 mm long
2,5 ± 0,2
6 ± 0,6
7 ± 0,7
8 ± 0,8
Diesel injection pump
Diesel injection pump pinion
Union on diesel injection pump
3,3 ± 0,3
2,5 ± 0,2
10 ± 1
2,5 ± 0,2
Cooling circuit
Coolant pump
5 ± 0,5
72
9/01/06
10:58
Page 73
RELAY
Engine : 8140.43S
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
B1BP2E0D
73
:
:
:
:
:
:
:
:
:
8
5
5
5
8
9
9
5
5
±
±
±
±
±
±
±
±
±
0,8
0,5
0,5
0,5
0,8
0,9
0,9
0,5
0,5
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
ENGINE
RELAY
Page 74
Engine : 8140.43S
Crankshaft
Pre-tightening
Angular tightening
Con rod nuts
5 ± 0,5
63° ± 5°
1,8 ± 0,2
20 ± 2
Carter cylindres
4 ± 0,4
1,8 ± 0,2
Sump
Lower cylinder cover on upper cylinder cover
Pre-tightening
Angular tightening
Timing belt guide roller support
5 ± 0,5
90° ± 5°
4 ± 0,4
2,5 ± 0,2
2,5 ± 0,2
Cylinder head
1,8 ± 0,2
2,5 ± 0,2
2,5 ± 0,2
Camshaft bearing cap covers
Inlet manifiold
Exhaust manifiold
Valve cover
Screw M6
Screw M8
Camshaft pinion
Injection pump pinion
1 ± 0,1
2,5 ± 0,2
2,5 ± 0,2
10 ± 1
74
9/01/06
10:58
Page 75
RELAY
Engine : 8140.43S
Flywheel
Flywheel
Pre-tightening
Angular tightening
Clutch mechanism
3 ± 0,3
90° ± 5°
3 ± 0,3
Lubrication circuit
Oil pump assembly
Screw M8
Screw M12
2,5 ± 0,2
6 ± 0,6
7 ± 0,7
Fuel high pressure pump
Diesel injection pump pinion
Union on diesel injection pump
4 ± 0,4
2 ± 0,2
2,5 ± 0,2
2 ± 0,2
10 ± 1
2 ± 0,2
Cooling circuit
Coolant pump
5 ± 0,5
75
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
Page 76
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
Cylinder head bolts
(Max. reusable length in mm)
Tightening (m.daN)
HFX - KFW
Pre-tightening
Angular tightening
2 ± 0,2
240° ± 5°
NFU
Pre-tightening
Angular tightening
2 ± 0,2
260° ± 5°
RFL
R6G
Pre-tightening
Tightening
Angular tightening
3,5 ± 0,3
7 ± 0,7
160° ± 5°
B1BP10LC
175,5 ± 0,5
122 ± 0,3
B1DP05BC
76
9/01/06
10:58
Page 77
ENGINE
FR-VU-page039-174-2005
Engines all Types
Engines
Cylinder head bolts
Tightening (m.daN)
RFN
Pre-tightening
Tightening
Slackening
Tightening
Angular tightening
1,5 ± 0,1
5 ± 0,5
360°
2 ± 0,2
285° ± 5°
147
9HZ
Pre-tightening
Tightening
Angular tightening
2 ± 0,2
4 ± 0,4
260° ± 5°
149
B1DP05BC
B1DP1DLC
77
FR-VU-page039-174-2005
9/01/06
10:58
Page 78
ENGINE
Engines all Types
Cylinder head bolts
Tightening (m.daN)
Engines
WJY
Pre-tightening
Tightening
Angular tightening
2 ± 0,2
6 ± 0,6
180° ± 5°
125,5
RHY - RHX
RHZ - RHW
Pre-tightening
Tightening
Angular tightening
1,8 ± 0,2
6 ± 0,5
220° ± 5°
133,3
B1DP075C
B1DP05BC
78
9/01/06
10:58
Page 79
ENGINE
FR-VU-page039-174-2005
Engines all Types
Engines
Cylinder head bolts
Tightening (m.daN)
RHV - 4HY
Pre-tightening
Tightening
Slackening
Tightening
Angular tightening
2,2 ± 0,5
6 ± 0,6
1 tour
6 ± 0,6
220° ± 5°
8140.43
8140.43S
Pre-tightening
Angular tightening
6 ± 0,6
180° ± 5°
B1DP05BC
B1DP1ADD
79
133,3
115
FR-VU-page039-174-2005
9/01/06
10:58
Page 80
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
TU
Engine families
1
3
JP
EW
XU
5
10
JP4
J2U
J2U/K
J4
RFL
R6G
RFN
Engine type
HFX
KFW
NFU
BERLINGO
X
X
X
DISPATCH
X
RELAY
See pages :
X
84 to 85
X
86 to 88
80
89
9/01/06
10:58
Page 81
ENGINE
FR-VU-page039-174-2005
DV
Engine families
Engine type
8
ATED4
B
1.6 16V HDi
1.9 D
9HZ
WJY
C15
BERLINGO
DW
6
TD
BTED
ATED
CTED
BTED+
2.0 HDi
RHY
12
UTD
2.0 8S HDi
RHX
RHZ
X
X
ATED4
UTED
2.8 TD
2.8 HDi
4HY
8140.43
8140.43S
X
X
X
X
100 to 103
100 to 103
RHV
2.0 16V HDi 2.2 8S HDi
TD
RHW
X
X
DISPATCH
X
X
X
RELAY
See pages :
SOFIM
10
90
91 to 95
96 to 99
81
X
104 to 105
FR-VU-page039-174-2005
9/01/06
10:58
Page 82
4099-T (C.TRONIC.105)
Tools
!
!
!
ENGINE
BELT TENSION CORRESPONDENCE TABLE
4122-T (C.TRONIC.105.5)
!
B1EP135D
82
9/01/06
10:58
Page 83
Engines : All Types Petrol and Diesel
Tools.
- Belt tension measuring instrument : 4122 - 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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
BERLINGO
10:58
Page 84
Without air conditioning
Tools.
[1] Pliers for removing plastic pegs
[2] Belt tension measuring instrument
[3] TORX spanner
: 7504-T
: 4122-T
Remove.
- Slacken the central screw (1).tool [3]
- Detension the tensioner roller (2), (flat spanner 27 on flat).
- Remove the belt.
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.
B1BP234C
84
9/01/06
10:58
Page 85
BERLINGO
With air conditioning
Tools.
[2] TORX spanner.
: 7504-T
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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
ENGINE
RELAY
9/01/06
10:58
Page 86
Engines : RFL - R6G
Alternator belt (without air conditioning)
Tools.
B1BP044C
: 4122-T
Tensioning the belt
- Tension the belt (4) using the screw (2).
- Fit the tool [1].
- Pre-tension to : 120 ± 10 SEEM units.
- Rotate the crankshaft by 3 turns.
- Fit the tool [1].
- Adjust the tension using the screw (2) to : 140 ± 10 SEEM units.
- 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.
B1BP045C
86
9/01/06
10:58
Page 87
Engines : RFL - R6G
Alternator belt (with air conditioning)
NOTE : If the vehicle is equipped with power steering, remove the belt (5)..
Tensioning the belt
B1BP1LFC
- Tension the belt (5) using the screw (6).
- Fit the tool [1].
- Fit the tool[1].
- Loosen the screws (3) and (4).
- Adjust the tension, using screw (6), to : 140 ± 5 SEEM units.
- 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).
B1BP04AC
87
RELAY
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
ENGINE
RELAY
9/01/06
10:58
Page 88
Engines : RFL - R6G
Power-assisted steering pump belt
B1BP04BC
B1BP04CC
Tools.
: 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].
- Fit the tool [1].
- Adjust the tension by turning the nut (2) to : 75 ± 5 SEEM units.
- 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).
88
9/01/06
10:58
Page 89
DISPATCH
Engine : RFN
Tools.
: 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
89
B1BP23RC
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
BERLINGO
10:58
Page 90
Engine : 9HZ
Tools.
B1BP2Z6D
[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
9/01/06
10:58
Page 91
C15
Engine : WJY
Without power steering - Without air conditioning
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.
B1BP1SDC
B1BP1SEC
91
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
ENGINE
C15 - BERLINGO - DISPATCH
Page 92
Engine : WJY
With power steering - Without air conditioning
Tools.
: 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
9/01/06
10:58
Page 93
Engine : WJY
With power steering - Without air conditioning (continued)
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.
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.
- 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.
B1BP1SJD
93
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
Page 94
ENGINE
Engine : WJY
With power steering - With air conditioning.
Tools.
[1] Dynamic tensioner peg
: (-) 0188 G.
: 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
9/01/06
10:58
Page 95
Engine : WJY
With power steering - With air conditioning (continued)
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).
B1BP1SLC
95
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
ENGINE
BERLINGO - DISPATCH
Page 96
Tools.
1] Belt tension adjusting square
[2] Ø 4 mm peg
[3] Ø 2 mm peg
:
:
:
:
(-).0188 J2
(-).0188.Q1
(-).0188.Q2.
(-).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.
- Peg using tool [2], at « b ».
- Hold the tensioner roller (2) compress and remove the belt.
- Loosen the screw (1).
B1BP1YKD
96
9/01/06
10:58
Page 97
BERLINGO - DISPATCH
Without air conditioning (continued)
Refitting
RE-USED BELT.
- 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.
- 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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
Page 98
ENGINE
BERLINGO - DISPATCH
[1]
[2]
[3]
[4]
Tools.
Belt tension adjusting square
Ø 4 mm peg
Ø 2 mm peg
Dynamic tensioner compression lever
:
:
:
:
(-).0188 J2
(-).0188.Q1
(-).0188.Q2
(-).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.
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.
B1BP1YLD
98
9/01/06
10:58
Page 99
BERLINGO - DISPATCH
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.
- 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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
ENGINE
RELAY
9/01/06
10:58
Page 100
COURROIE D' ENTRAÎNEMENT DES ACCESSOIRES
Engines : RHV - 4HY
Tools.
[2] Peg, Diameter 4 mm
[3] Belt tension measuring equipment
: (-).0188 Z
: (-) 0188 Q1
: 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
9/01/06
10:58
Page 101
RELAY
Engines : RHV - 4HY
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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
RELAY
10:58
Page 102
Engines : RHV - 4HY
Belt for driving the power steering pump
Tools.
B1BP2J6C
: 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
9/01/06
10:58
Page 103
RELAY
Engines : RHV – 4HY
Belt for driving the alternator and the compressor
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]
Peg, using tool [2], at «d».
Remove the belt.
Refitting.
Refit the belt.
Compress the dynamic tensioner roller (6), by acting at «e», using tool [1]
Remove tool [2].
B1BP2J9D
103
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
RELAY
10:58
Page 104
Engines : 8140.43 - 8140.43S
Belt for driving the compressor
Tools.
[1] Pliers for removing plastic pins
: 7504-T
: 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.
B1BP21TD
104
9/01/06
10:58
Page 105
RELAY
Engines : 8140.43 - 8140.43S
Belt for driving the alternator
B1BP21UC
Tools.
: 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).
Position tool [2] on the belt at “b”.
Tighten screw (7).
For a new belt, the tension should be
For a re-used belt, the tension should be
Tighten screw (6) to 5 ± 0,5 m.daN.
Remove tool [2].
Complete the refitting.
B1BP21VC
105
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
Page 106
ENGINE
CHECKING AND SETTING THE VALVE TIMING - PETROL ENGINES
XU
TU
Engine Families
1
3
JP
5
EW
10
JP4
J2U
J2U/K
J4
RFL
R6G
RFN
Engine type
HFX
KFW
NFU
BERLINGO
X
X
X
DISPATCH
X
RELAY
See pages :
X
109 to 112
113 to 116
106
X
117 to 119
120 to 126
9/01/06
10:58
Page 107
ENGINE
FR-VU-page039-174-2005
CHECKING AND SETTING THE VALVE TIMING - DIESEL ENGINES
DV
Engine
Families
Engine type
8
ATED4
B
1.6 16V HDi
1.9 D
9HZ
WJY
C15
BERLINGO
DISPATCH
DW
6
TD
BTED
ATED
CTED
BTED+
2.0 HDi
RHY
12
UTD
2.0 8S HDi
RHX
RHZ
X
X
RHV
ATED4
UTED
2.0 16V HDi 2.2 8S HDi
RHW
TD
2.8 TD
2.8 HDi
4HY
8140.43
8140.43S
X
X
X
X
X
X
X
X
RELAY
See pages :
SOFIM
10
X
X
127 to 136 137 to 141 147 to 153
142 to 146 147 to 153 154 to 162
107
154 to 162 163 to 166 167 to 171
FR-VU-page039-174-2005
9/01/06
10:58
Page 108
ENGINE
RECOMMENDATIONS : TIMING BELT
Petrol enginel
Diesel engine
Recommandations.
IMPERATIVE : After each operation involving removal of the timing belt, systematically replace :
- the timing belt,
- the tensioner roller fixing screw.
108
9/01/06
10:58
Page 109
CHECKING AND SETTING THE VALVE TIMING
BERLINGO
Engines : HFX - KFW
CHECKING THE VALVE TIMING
NOTE : Remove the sparking plugs to ease the crankshaft rotation.
Tools.
- [1] Flywheel peg
- [2] Flywheel or camshaft pulley peg
: 4507-T.A (Toolkit 4507-T).
: 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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
Page 110
ENGINE
BERLINGO
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
9/01/06
10:58
Page 111
BERLINGO
Engines : HFX - KFW
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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
BERLINGO
10:58
Page 112
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
9/01/06
10:58
Page 113
BERLINGO
Engine : NFU
Tools.
[1] Engine flywheel peg
[3a] Camshaft pulley peg.
[3b] Camshaft pulley peg.
[4] Dynamic tensioner roller pin
[5] Belt retaining pin
:
:
:
:
:
4507-T.A (Toolkit 4507-T)
4533-T.A.C1
4533-T.A.C2
4200-T.H
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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
BERLINGO
10:58
Page 114
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
9/01/06
10:58
Page 115
BERLINGO
Engine : NFU
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.
- Ensure the timing is correctly set by refitting the pegs [1], [3a] and [3b].
- Remove the setting pegs.
B1EP1DPC
115
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
BERLINGO
10:58
Page 116
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
9/01/06
10:58
Page 117
RELAY
Engines : RFL - R6G
Tools.
[1] Camshaft setting pegs
[2] Crankshaft setting peg
[3] Belt locking pin
[4] Angular tightening adaptor
[5 ] Hub immobilising tool
: (-).0189.A
: (-).0189.B
: (-).0189.K
: 4069-T
: 6310-T
B1BP22SC
- 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
Tool kit C.0189
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
ENGINE
RELAY
Page 118
Engines : RFL - R6G
Tools.
[1] Camshaft pulley locating peg
[2] Flywheel peg
[3] Timing belt tensioning key
[4] Toothed sector for locking the flywheel
:
:
:
:
:
7004-T.G
7014-T.N
7017-T.W
6012-T
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].
B1EP01TC
ESSENTIAL : Remove the tools [1] and [2] when tightening the screw (1).
-
Remove the screws (1) and the pulley.
Check that the camshaft pulley and the crankshaft pinion are correctly pegged.
Loosen the tensioner roller screw.
Remove the belt.
B1BP1WHC
118
Tool kit 7004-T
Tool kit 9022-T
9/01/06
10:58
Page 119
RELAY
Engines : RFL - R6G
SETTING THE VALVE TIMING (continued)
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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
DISPATCH
10:58
Page 120
Engine : RFN
Tools.
[1] Camshaft setting peg
[3] Belt retaining pin
[4] Adaptor for angular tightening
[5] Tool for manœuvring and locking the tensioner roller
[5a]
[5b]
Pliers for removing plastic pins
:
:
:
:
:
:
:
:
(-) 0189.A
(-).0189.R
(-).0189.K
4069-T
(-).0189.S
(-).0189.S1
(-).0189 S2
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
9/01/06
10:58
Page 121
DISPATCH
Engine : RFN
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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
DISPATCH
10:58
Page 122
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
9/01/06
10:58
Page 123
DISPATCH
Engine : RFN
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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
DISPATCH
10:58
Page 124
Engine : RFN
B1EP1BCD
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].
B1EP1BDC
124
9/01/06
10:58
Page 125
DISPATCH
Engine : RFN
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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
Page 126
ENGINE
DISPATCH
Engine : RFN
Refitting (continued)
Remove the tools [1] and [2].
Rotate the crankshaft ten times (normal direction of rotation).
IMPERATIVE : No pressure or outside force should be brought to bear on the timing belt.
Peg the inlet camshaft pulley, using tool [1].
Checks.
B1EP1BEC
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
9/01/06
10:58
Page 127
BERLINGO
Engine : 9HZ
Tools.
[1] Flywheel setting peg
B1BP3BZD
: (-).0194.C
: (-).0194.B
: (-).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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
Page 128
ENGINE
BERLINGO
Engine : 9HZ
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 :
B1BP305C
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
128
9/01/06
10:58
Page 129
BERLINGO
Engine : 9HZ
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).
B1EP1E5C
129
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
Page 130
ENGINE
BERLINGO
Engine : 9HZ
Refitting
Refit tool [1] at «b».
Remove the screw (10).
Refit :
The upper timing cover (12).
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).
Connect the connector at «a».
Refit :
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
9/01/06
10:58
Page 131
BERLINGO
Engine : 9HZ
Tools.
[1] Flywheel setting peg
B1BP3BZD
: (-).0194.C
: (-).0194.B
: (-).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.
Uncouple :
The fuel supply unions (1).
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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
BERLINGO
10:58
Page 132
Engine : 9HZ
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 :
B1BP305C
The engine support (8).
The screw (10).
The upper timing cov (12).
The tool [1].
B1EP1E3D
132
9/01/06
10:58
Page 133
BERLINGO
Engine : 9HZ
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).
B1EP1E6D
133
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
BERLINGO
10:58
Page 134
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
9/01/06
10:58
Page 135
BERLINGO
Engine : 9HZ
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).
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.
135
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
Page 136
ENGINE
BERLINGO
Engine : 9HZ
Refitting (continued)
Disengage the jack from under the engine.
Refit tool [1] at «b».
Refit :
The screw (10).
Tightening torque
Screw (10) Pre-tighten to
Angular tighten
Remove tool [1].
Refit :
The engine support (8), tighten to 5,5 ±
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).
Connect the connector at «a».
: 3 ± 0,3 m.daN.
: 180° ± 5°.
0,4 m.daN.
0,6 m.daN
0,2 m.daN
Refit :
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
9/01/06
10:58
Page 137
Engine : WJY
Tools.
[1]
[2]
[3]
[4]
[5]
[6]
[7]
Flywheel locating peg
Injection pump setting peg Ø 6 mm
Screw H M8
Belt retaining pin
Square drive for adjusting the tension
Belt tension measuring instrument, with digital display
:
:
:
:
:
:
:
7504-T or (-).1311
7014-T.J or (-).0188 Y
(-).0188 H
(-).0188 E
(-).0188 K
(-).0188 J1
SEEM CTG 105.5M
B1BP2FTC
- 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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
Page 138
ENGINE
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.
B1BP2FTC
B1BP30BC
138
9/01/06
10:58
Page 139
C15 - BERLINGO - DISPAT-
Engine : WJY
Setting the valve timing (continued)
-
B1EP16PD
Peg the camshaft hub, using tool [4].
Peg the injection pump hub, using tool [3].
Slacken screws (5) and (6).
Remove the timing belt.
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:
- Injection pump pinion (7).
- Camshaft pinion (10).
- Coolant pump pinion (12).
B1EP132C
B1EP1EEC
B1EP1EDC
139
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
Page 140
ENGINE
Engine : WJY
B1EP1EFC
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.
B1EP1EDC
140
9/01/06
10:58
Page 141
Engine : WJY
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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
Page 142
ENGINE
DISPATCH
Engine : RHX
Tools.
[2] Tension lever
[4] Belt compression spring
[5] Camshaft pinion peg
[6] Engine flywheel lock
[7] Set of blocking plugs
[8] Crankshaft pulley extractor
:
:
:
:
:
:
:
:
4122-T
(-).188.J2
(-).0288.D
(-).0188.K
(-).0188.M
(-).0188.F
(-).0188.T
(-).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).
B1BP1TTC
B1CP04CC B1BP1TSC
142
9/01/06
10:58
Page 143
DISPATCH
Engine : RHX
Peg :
- The engine flywheel, tool [3].
- The camshaft, tool [5].
Slacken :
- The three screws (9).
- The screw (7) of the tensioner roller (6).
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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
DISPATCH
10:58
Page 144
Engine : RHX
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
- Fuel high pressure pump pinion (13).
- Camshaft pinion (12).
- Water pump pinion (10).
NOTE : If needed, slightly turn the pinion (12) anticlockwise (not by more than one tooth).
B1EP13FC
B1EP13GD
144
9/01/06
10:58
Page 145
DISPATCH
Engine : RHX
Setting the valve timing (continued).
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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
DISPATCH
10:58
Page 146
Engine : RHX
Tighten :
- Screw (7) of the roller (6) to 2.5 m.daN.
- Screw (9) to 2.m.daN
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.
B1EP13HD
146
9/01/06
10:58
Page 147
BERLINGO - DISPATCH
Engines : RHY - RHZ
Tools.
[1] Belt tension measuring equipment
[2] Tension lever
[4] Belt clamp
[5] Camshaft pulley peg
[6] Engine flywheel lock
[7] Set of blocking plugs
[8] Pulley extractor
[9] 2 mm dia.peg
Removing
:
:
:
:
:
:
:
:
:
4122-T
(-).0188.J2
(-).0188.Y
(-).0188.AD
(-).0188.M
(-).0188.F
(-).0188.T
(-).0188.P
(-).0188.Q2
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 engine cover.
Unclip and move aside the cooling hose.
Remove the accessories drive belt.
147
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:58
Page 148
ENGINE
DISPATCH
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).
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].
B1BP2H2C B1BP2H3C
B1BP2R2C B1EP1A7C
148
9/01/06
10:59
Page 149
DISPATCH
Engines : RHY - RHZ
B1CP04BC
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].
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.
B1BP2R3C
149
B1BP2R4C
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:59
Page 150
ENGINE
DISPATCH
Engines : RHY - RHZ
Checks.
IMPERATIVE : Just before refitting, carry out the checks below :
B1EP1A8D
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
9/01/06
10:59
Page 151
DISPATCH
Engines : RHY - RHZ
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.
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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
DISPATCH
10:59
Page 152
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.
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
9/01/06
10:59
Page 153
DISPATCH
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.
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.
Reposition and reclip the cooling hose.
Complete the refitting of components in reverse order to removal.
B1EP1ADC
B1EP1A7C B1BP2R4C
153
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:59
Page 154
ENGINE
RELAY
Engines : RHV - 4HY
[1] Camshaft locating peg
[2] Flywheel locating peg
Tools.
: (-).0188 M Toolkit C.0188
: (-).0188 Y
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).
B1BP2HLC
B1EP17GC
154
9/01/06
10:59
Page 155
RELAY
RHV
Engines : RHV - 4HY
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
4HY
B1BP298C
IMPERATIVE : If pegging is impossible, restart the adjusting.
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).
Disengage 5th gear and complete the refitting.
155
B1EP17JC
B1EP17KC
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:59
ENGINE
RELAY
Page 156
Engines : RHV - 4HY
Tools.
[1]
[2]
[3]
[4]
[5]
[6]
[7]
B1CP04BC
Belt tension measuring instrument
Tensioning lever
Flywheel locating peg
Belt retaining pin
Camshaft pinion peg
Engine flywheel lock
Crankshaft pulley extractor
:
:
:
:
:
:
:
SEEM CTG 105.5M
(-).0188.J2
(-).0188.Y
(-).0188.K
(-).0188.M
(-).0188.F
(-).0188.P
Toolkit C.0188
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].
Refit the screw (1), without the washer.
Remove :
- The crankshaft pulley, using tool [7]
- The tool [6].
Support the engine, using a workshop hoist.
B1BP2HZC
156
9/01/06
10:59
Page 157
ENGINE
FR-VU-page039-174-2005
RELAY
Engines : RHV - 4HY
Remove :
- 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.
B1BP2J0C
157
B1BP2J1C
FR-VU-page039-174-2005
9/01/06
ENGINE
RELAY
10:59
Page 158
Engines : RHV - 4HY
Position the flywheel locating peg, using tool [3] (from underneath the vehicle).
Turn the engine until the peg [3] engages in the flywheel.
Peg the camshaft, using tool [5].
B1BP2J2C
Slacken :
- The three screws (19).
- The screw (23) of the tensioner roller (24).
B1EP17LD
158
9/01/06
10:59
Page 159
RELAY
Engines : RHV - 4HY
Checks
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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
RELAY
10:59
Page 160
Engines : RHV - 4HY
B1EP17PD
Checks (continued)
Reposition the timing belt (20), well-tensioned at «a», in the following order :
- Fuel high pressure pump pinion (27).
- Camshaft pinion (25)
- Coolant pump pinion (22).
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.
Rotate the crankshaft eight times (normal direction of rotation).
Fit the tool [3].
Slacken the screws (19).
B1EP17QD
160
9/01/06
10:59
Page 161
RELAY
Engines : RHV - 4HY
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.
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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
RELAY
10:59
Page 162
Engines : RHV - 4HY
Checks (continued)
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).
B1EP17RC
162
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.
Complete the refitting.
9/01/06
10:59
Page 163
RELAY
Engine : 8140.43
Tools.
[2] Peg for setting the injection pump
: 7504-T
: 1 860 617 000
Toolkit (-).0191
B1BP21YC
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
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:59
Page 164
ENGINE
RELAY
Engine : 8140.43S
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
B1BP220C
Refit :
- the accessories drive pulley (5)
- the screw (3) (use a screwdriver to immobilise the flywheel), tighten to
- 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
: 20 m.daN
9/01/06
10:59
Page 165
RELAY
Engine : 8140.43
Tools.
[2] Peg for setting the injection pump
[3] Belt tensioner compressor
B1BP21YC
: 7504-T
: 1 860 617 000
: 1 860 638 000
Toolkit (-).0191
Toolkit (-).0191
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
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.
B1BP221D
165
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
RELAY
10:59
Page 166
Engine : 8140.43
B1BP222C
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.
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
9/01/06
10:59
Page 167
RELAY
Engine : 8140.43S
Tools.
[1]
[2]
[3]
[4]
B1BP2PXC
Flywheel locking tool
Belt compression tool
Belt compression spring
:
:
:
:
7504-T
(-).0191 C
1 860 638 000
(-).0188K
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
Toolkit (-).0191
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:59
Page 168
ENGINE
RELAY
Engine : 8140.43S
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
168
B1BP2DXC
9/01/06
10:59
Page 169
Engine : 8140.43S
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
RELAY
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
ENGINE
RELAY
10:59
Page 170
Engine : 8140.43S
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
170
B1BP2DVC
9/01/06
10:59
Page 171
ENGINE
FR-VU-page039-174-2005
RELAY
Engine : 8140.43S
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
B1BP2DUC
171
B1BP2DVC
FR-VU-page039-174-2005
9/01/06
10:59
Page 172
ENGINE
CHECKING THE OIL PRESSURE
Petrol
Engine type
Temperature (°C)
Pressure (Bars)
Rpm
Pressure (Bars)
Rpm
Pressure (Bars)
Rpm
Pressure (Bars)
Rpm
2279-T.Bis
4103-T
7001-T
HFX
KFW
90°
NFU
RFL
R6G
80°
RFN
3
2000
4
4000
X
X
X
X
X
X
7
4000
Tools Toolkit 4103-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
X
X
X
X
X
X
9/01/06
10:59
Page 173
CHECKING THE OIL PRESSURE
Diesel
Engine type
Temperature (°C)
Pressure (Bars)
Rpm
Pressure (Bars)
Rpm
Pressure (Bars)
Rpm
Pressure (Bars)
Rpm
9HZ
1,3
3,5
WJY
90°
1,8
1000
3,7
2000
4,3
3000
4,5
RHY
RHX
RHZ
RHV
RHW
4HY
80°
2
8140.43
90°
2
1000
4
2000
8140.43S
0,8
750
4
3,3
4000
4000
Tools Toolkit 4103-T
2279-T.Bis
4103-T
(-).1503.J
4225-T
4202-T
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
NOTE : The oil pressure should be checked with the engine hot, after the oil level has been checked
173
X
ENGINE
FR-VU-page039-174-2005
FR-VU-page039-174-2005
9/01/06
10:59
Page 174
ENGINE
VALVE CLEARANCES
POSSIBLE PROCEDURES
For engines with 4 cylinders in a line (1-3-4-2 )
The valve clearances must be checked with the engine cold.
● Inlet
Exhaust
HFX - KFW - RFN
NFU
WJY
2.8 TD - 2.8 HDi
RFN - 9HZ - RHY - RHX
RHZ - RHV - RHW - 4HY
0,20 ± 0,05 mm
1 ± 0,05 mm
0,15 ± 0,08 mm
0,50 ± 0,05 mm
Fully open (Exhaust)
Rocking
Exhaust
0,40 ± 0,05 mm
1 ± 0,05 mm
●
Inlet
Adjust
1 4●
4
1
3●
4
3●
3 2●
2
3
4●
2
4●
4 1●
1
4
2●
1
2●
2 3●
2
1●
3
Exhaust
3
Engines without hydraulic
adjustment : the clearance (J)
should be checked opposite the
cam.
Automatic adjustment
B1DP13QC
174
Adjust
1●
0,30 ± 0,08 mm
0,50 ± 0,05 mm
Valves
fully
open
FR-VU-page175-195-2005
9/01/06
11:00
Page 175
BERLINGO
CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT
Engine : 9HZ
Tools.
: 4215-T
: 4073-T.A
Toolkit 4073-T
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».
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
20 ± 0,5 cmHg
Engine driven by the starter motor
Engine running under full load
30 ± 0,5 cmHg
Fuel supply circuit,
fuel filter piping
B1CP0GFD
175
INJECTION
[1] Ø 10 mm low pressure connector
[2] Pressure gauge for testing boost pressure
Checks
FR-VU-page175-195-2005
9/01/06
11:00
BERLINGO - DISPATCH
Page 176
Engines : RHY - RHZ
Tools.
INJECTION
: 4215-T
: 4218-T
: 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
FR-VU-page175-195-2005
9/01/06
11:00
Page 177
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.
Abnormal functioning
Fuel supply pressure
Fuel return pressure
Between 3 and 3.5 Bar
0,7 ± 0,2 bar
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
Less than 0,7 bar
Check the fuel suppy circuit :
- Booster pump (low pressure), piping.
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)
Checks
Check the condition of the diesel filter
Check : diesel injector return flow. (Table below)
Uncouple the diesel injector return pipe.
Check :
The flow should be drop by drop
Excessive fuel return
Observe :
Diesel injector functioning correctly
Diesel injector jammed shut.
177
INJECTION
Engines : RHY - RHZ
FR-VU-page175-195-2005
JUMPER
9/01/06
11:01
Page 178
Engine : RHV
INJECTION
Tools.
[4] Pressure gauge extension for tool testing HDi low pressure
: 5725-T
: 5724-T
: 4073-T Kit 4073-T
: 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
FR-VU-page175-195-2005
9/01/06
11:01
Page 179
JUMPER
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.
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
- 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
Checks :
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.
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).
Observations
Diesel injector functioning
correctly
Diesel injector locked shut
179
Checks :
Observations
If the injector return flow is greater
than 50 ± 15l/h
Valve open (jammed)
Valve shut (jammed)
INJECTION
Engine : RHV
FR-VU-page175-195-2005
JUMPER
9/01/06
11:01
Page 180
Engines : 4HY - 8140.43S
INJECTION
Tools.
: 5725-T
: 5724-T
: 4073-T
Kit 4073 -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 (8140.43S)
[3] = 2,3 ± 0,4 Bar (4HW)
- Fuel return pressure shown by the pressure gauge
[3] = 0,5 ± 0,2 Bar (8140.43S)
[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
FR-VU-page175-195-2005
9/01/06
11:01
Page 181
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 (8140.43S engine) – 2,3± 0,4 Bar (4HY engine)
- Fuel return pressure shown by the pressure gauge [3] = 0,6 ± 0,2 Bar (8140.43S engine) – 0,3± 0,4 Bar (4HY engine)
Abnormal operating
Checks
8140.43S
Between 3 and 3,5 Bars
4HY
Entre 3,3 et 4 bars
8140.43S
0,8 ± 0,2 bars
4HY
0,8 ± 0,4 bars
More than 3,5 bars
More than 4 bars
Less than 0,8 bar
Less than 0,8 bar
More than 3,5 bars
More than 4 bars
More than 0,8 bar
More than 0,8 bar
Less than 0,8 bar
Less than 0,8 bar
Between 0,8 and 1,5 Bar Between 0,8 and 1,5 Bar
- Check the low pressure regulator incorporated in the filter (locked open)
- Check the high pressure pump distribution valve (locked shut)
Check :
Check the condition of the diesel filter
Check the low pressure regulator incorporated
in the filter (locked shut) : replace.
Check the fuel return circuit (pipe pinched or trapped...).
Check the fuel suppy circuit :
- Booster pump (low pressure), piping.
Check : diesel injector return flow. (Table below)
Observe :
Diesel injector functioning correctly
Diesel injector locked shut.
181
INJECTION
Engines : 4HY - 8140.43S
FR-VU-page175-195-2005
9/01/06
BERLINGO
11:01
Page 182
CHECKS : TURBO PRESSURE
Engine : RHY
Tools.
[1] Pressure gauge for checking boost pressure
[2] Sleeve for checking boost pressure
: 4073-T.A Kit 4073-T
: 4185-T
INJECTION
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.
B1BP1ZXD
182
FR-VU-page175-195-2005
9/01/06
11:01
Page 183
DISPATCH
Engine : RHZ
B1HP12JD
183
INJECTION
Tools.
: 4073-T.A Kit 4073-T
: 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.
- 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).
FR-VU-page175-195-2005
9/01/06
JUMPER
11:01
Page 184
Engine : RHV
Tools.
INJECTION
B1HP1FFC
: 4073-T.A Kit 4073-T
: 4185-T
[3] Adaptor sleeve
: 4219-T
Checks
(HDi) engines.
Procedure
- Connect the sleeve [2] on the pressure gauge [1] with the tube "a".
vehicle in running order at full load.
- Start the engine.
- Remove the tools [1] and [2].
- Re-couple the tube (2) on the duct (1).
- Tighten the clip.
C5FP0FSC
184
FR-VU-page175-195-2005
9/01/06
11:01
Page 185
JUMPER
Engine : 4HY
B1HP1LZC
C5FP0FSC
185
INJECTION
Tools.
: 4073-T.A Kit 4073-T
: 4185-T
[3] Adaptor sleeve
: 4219-T
Checks
(HDi) engines.
- Remove the protector for the electrovalves (1).
- Connect the sleeve [2] on the pressure gauge [1] with the tube "a".
Procedure
vehicle in running order at full load.
- Start the engine.
- Remove the tools [1] and [2].
- Re-couple the tube (2) on the duct (1).
- Tighten the clip.
FR-VU-page175-195-2005
9/01/06
JUMPER
11:01
Page 186
Engine : 8140.43
Tools.
INJECTION
B1BP231D
: 4073-T.A Kit 4073-T
: 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.
- Connect the tool [2] on the pressure gauge [1] with the tube «a».
Procedure.
Start the engine.
- Check the pressure: 0,6 ± 0,05 bar. (1500 rpm).
- 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).
C5FP08AC
186
FR-VU-page175-195-2005
9/01/06
11:01
Page 187
JUMPER
B1BP2DSD
Tools.
: 4073-T.A Kit 4073-T
: 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.
- 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.
- Check the turbo pressure: 0,6 ± 0,1 bar. (1500 rpm).
- 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).
C5FP0FSC
187
INJECTION
Engine : 8140.43S
FR-VU-page175-195-2005
9/01/06
11:01
Page 188
BERLINGO
CHECKING THE AIR SUPPLY CIRCUIT
Engine : 9HZ
Tools.
[1] Manual pressure-vacuum pump
FACOM DA 16.
INJECTION
Checks.
Vacuum pump
B1HP1UGC
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
FR-VU-page175-195-2005
9/01/06
11:01
Page 189
DISPATCH
Engines : RHX - RHZ
[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
B1HP12FD
Engine speed (rpm)
Pressure (Bar)
780
4000
0,6
0,25
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
INJECTION
TOOLS
FR-VU-page175-195-2005
9/01/06
11:01
Page 190
JUMPER
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
FR-VU-page175-195-2005
9/01/06
11:01
Page 191
JUMPER
Engine : 4HY
Tools.
: FACOM DA 16
INJECTION
Checks
- Uncouple the tube at «a».
- Connect tool [1] at «a»
- Start the engine.
B1BP2QKC
191
FR-VU-page175-195-2005
JUMPER
9/01/06
11:01
Page 192
Engine : 8140.43S
Tools.
: FACOM DA 16
INJECTION
- Uncouple the tube at «a».
- Connect tool [1] at «a»
- Start the engine.
B1BP2QKC
192
FR-VU-page175-195-2005
9/01/06
11:01
BERLINGO - DISPATCH - JUMPER
Page 193
CHECKS : EXHAUST GAS RECYCLING CIRCUIT
B1HP12GD
Tools.
: 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 : 8140.43S
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.
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
2500
0 bar
193
B1BP2QAC
INJECTION
FR-VU-page175-195-2005
9/01/06
11:01
Page 194
JUMPER
CHECKS : EXHAUST GAS RECYCLING CIRCUIT
Engine : 4HY
Tools.
INJECTION
B1BP2Q8C
B1KP011C
: FACOM DA 16.
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.
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).
B1HP1FTC
Engine speed (rpm)
Vacuum value (Bar)
780
0,5 bar
2500
0 bar
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
FR-VU-page175-195-2005
9/01/06
11:01
Page 195
Vehicles – Models
BERLINGO
DISPATCH
Engine type
BOSCH
CHAMPION
SAGEM
1.1i
HFX
FR7DE
RC8YCL
RFN58 LZ
1.4i
KFW
FR7DE
RC8YCL
RFN58 LZ
1.6i 16V
NFU
FR7ME
2.0i 16V
RFN
FR8ME
Electrode gap
setting
Tightening
torque
0.9 mm
3,0 m.daN
1 mm
2,7 m.daN
RFN58HZ
REC9YCL
195
RFN52HZ
IGNITION
SPARKING PLUGS
FR-VU-page196-247-2005
9/01/06
12:34
Page 196
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° 78-85 TT of 19 October 1978.
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
FR-VU-page196-247-2005
9/01/06
12:34
Page 197
C15
CLUTCH SPECIFICATIONS
Diesel
1.9 D
Engine plate
WJY
Payload (Kg)
600/765
Gearbox
BE4/5
LUK
Mechanism/Type
200 P 3700
Ext./Int. lining Ø
200/134
Disc lining type
F 408
197
CLUTCH
GEARBOX
TRANSMISSION
Make
FR-VU-page196-247-2005
9/01/06
12:34
Page 198
BERLINGO
Petrol
Engine plate
Gearbox
Make
Diesel
1.1i
1.4i
1.6i 16V
1.6 16V HDi
HFX
KFW
NFU
9HZ
MA/5
1.9 D
20 HDi
WJY
RHY
BE4/5
VALEO
LUK
Mechanism/Type
200 CPX 3850
234 T 4800
200 P 4700
Ext./Int. lining Ø
200 x 137
234 x 165
200 x 137
Disc lining type
F 808
F 810
CLUTCH
GEARBOX
TRANSMISSION
198
235 T 5700
228 x 155
F 408
FR-VU-page196-247-2005
9/01/06
12:34
Page 199
DISPATCH
Petrol
Diesel
2.0i 16V
Engine plate
Gearbox
Make
1.9 D
RFN
2.0 HDi
WJY
RHX
2.0 16V HDi
RHZ
BE4/5
RHW
ML/5
VALEO
LUK
203 DNG 4700
200 P 4700
235 T 5700
225 T 6900
Ext./Int. lining Ø
228 x 155
200 x 137
228 x 155
225 x 150
Disc lining type
F 808 DS
F 408
F 202
F 810
CLUTCH
GEARBOX
TRANSMISSION
Mechanism/Type
199
FR-VU-page196-247-2005
9/01/06
12:34
Page 200
RELAY
Petrol
Diesel
2.0i
Engine plate
RFL
2.0 8S HDi
2.2 8S HDi
RHV
4HY
R6G
Gearbox
Make
Mechanism/Type
Ext./Int. lining Ø
2.8 TD
2.8 HDi
8140.43
8140.43S
ML/GU
VALEO
235 DT 5900
230 DNG 4700
228 x 155
LUK
VALEO
242 DT 5200
242 DT 6200
242 x 161
Disc lining type
F 808
CLUTCH
GEARBOX
TRANSMISSION
200
FR-VU-page196-247-2005
9/01/06
12:34
Page 201
MANUAL GEARBOX SPECIFICATIONS
Vehicle
Engine
Gearbox
Sequence
Torque ratio
Drive ratio
Type BE4/5
C15
DW8B
BE3/5N
20 TE 11
17 x 71
TU1JP
MA/5S
20 CP 61
13 x 59
TU3JP
20 CP 37
MA/5L
19 x 21
13 x 59
TU5JP4
Berlingo
DV6ATED4
DW8B
DW10TD
Dispatch
EW10J4
BE4/5N
20 DM 45
17 x 77
19 x 17
BE4/5J
20 DM 46
19 x 77
19 x 16
BE4R/5L
20 DM 83
19 x 72
None
BE4/5L
20 DM 47
17 x 77
19 x 17
BE4/5N
20 DM 48
17 x 71
19 x 17
BE4/5KG
20 DM 79
19 x 70
BE4/5KG
20 DM 80
19 x 72
BE4/5
20 DL 93
15 x 74
201
None
22 x 19
CLUTCH
GEARBOX
TRANSMISSION
20 CP 36
FR-VU-page196-247-2005
9/01/06
12:34
Page 202
Vehicle
Engine
Gearbox
Sequence
Torque ratio
Drive ratio
Type ML/5
Dispatch
DW10BTED
20 LM 26
DW10CTED
20 LM 19
14 x 67
DW10BTED+
20 LM 32
14 x 67
DW10ATED4
20 LM 06
15 x 67
ML/5C
14 x 71
25 x 20
Type ML/5
Vehicle
Engine
CLUTCH
GEARBOX
TRANSMISSION
XU10J2U
DW10UTD
DW12UTED
Relay
Load
Gearbox
Sequence
Torque ratio
Drive ratio
10Q 14Q
20 UM 07
13 x 73
18 x 14
18Q
20 UM 08
13 x 83
21 x 15
10Q 14Q
20 MM 01
14 x 75
22 x 21
20 UM 16
13 x 68
18 x 14
20 UM 10
12 x 71
21 x 15
10Q 14Q
18Q
ML/GU
8140.43
10Q 14Q
20 UM 13
13 x 68
18 x 14
2.8 TD
18Q
20 UM 06
13 x 83
21 x 15
20 UM 05
13 x 68
21 x 15
20 UM 15
13 x 68
21 x 15
8140.43S
18Q
2.8 HDi
202
FR-VU-page196-247-2005
9/01/06
12:34
Page 203
Vehicle
Engine
Gearbox
Dispatch
EW10J4
AL4
Sequence
Torque ratio
Drive ratio
21 x 73
52 x 67
20 x 69
59 x 68
Type AL4
20 TP 96
Type 4 HP 20
2.8 HDi
4 HP 20
Sans
CLUTCH
GEARBOX
TRANSMISSION
Relay
203
FR-VU-page196-247-2005
9/01/06
12:34
Page 204
MA/5 GEARBOX : TIGHTENING TORQUES
Ref.
Description
1
Bearing retaining clip
2
Intermediate plate
3
Gearbox casing
4
Clutch bearing guide screws
CLUTCH
GEARBOX
TRANSMISSION
B2CP3SRP
204
No. of screws
m.daN
4
1,8 ± 0,2
11
5 ± 0,5
16
# RPO 9784
17
RPO 9786 #
3
1,9 ± 0,2
0,6 ± 0,15
FR-VU-page196-247-2005
9/01/06
12:34
Page 205
MA/5 GEARBOX : TIGHTENING TORQUES
Ref.
Description
5th gear housing fixing screws
27
Reverse gear switch
28
Drain plug
29
Level plug
m.daN
3
2,2 ± 0,2
2,5 ± 0,5
1
3,3 ± 0,3
3,3 ± 0,3
CLUTCH
GEARBOX
TRANSMISSION
26
No. of screws
B2CP3SSD
205
FR-VU-page196-247-2005
9/01/06
12:34
Page 206
BE4/5 GEARBOX : TIGHTENING TORQUES
Ref.
Description
No. of screws
m.daN
CLUTCH
GEARBOX
TRANSMISSION
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
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
5 ± 0,5
FR-VU-page196-247-2005
9/01/06
12:34
Page 207
Ref.
Description
No. of screws
m.daN
12
Fork shaft stop screw
1,5 ± 0,2
13
Differential gearwheel fixing screw
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
7 ± 0,5
B2CP3ZYD
207
FR-VU-page196-247-2005
9/01/06
12:34
Page 208
Ref.
17
Description
Gear control support
fixing screws
No. of screws
m.daN
1,5 ± 0,2
18
Bearing guide screws
1,25 ± 0,2
19
Speedo housing fixing screws
1,5 ± 0,2
B2CP3ZZC
CLUTCH
GEARBOX
TRANSMISSION
B2CP400C
208
FR-VU-page196-247-2005
9/01/06
12:34
Page 209
TIGHTENING TORQUES : BE4/5 GEARBOX WITH ENHANCED TRACTION
Ref.
No. of screws
m.daN
23
Bearing guide
Description
3
1,25 ± 0,2
24
Clutch housing
13
1,3 ± 0,2
25
Primary shaft nut
1
7,25 ± 0,7
26
Secondary shaft nut
1
6,5 ± 0,6
27
Clip retaining screws
2
1,5 ± 0,2
28
Differential gearwheel screws
2
6,5 ± 0,6
Reverse gear switch
1
2,5 ± 0,2
B2CP3WDP
209
CLUTCH
GEARBOX
TRANSMISSION
FR-VU-page196-247-2005
9/01/06
12:34
Page 210
Ref.
No. of screws
m.daN
29
Differential housing
Description
4
5 ± 0,5
30
Breather pipe
1
1,7 ± 0,2
31
Gearbox rear casing screws
7
1,25 ± 0,2
32
Level plug
1
2,2 ± 0,2
33
Differential housing screws
4
1,25 ± 0,2
34
Drain plug
1
3,5 ± 0,3
CLUTCH
GEARBOX
TRANSMISSION
B2CP3BRD
210
FR-VU-page196-247-2005
9/01/06
12:34
Page 211
Ref.
Description
No. of screws
m.daN
Differential housing
4
5 ± 0,5
30
Breather pipe
1
1,7 ± 0,2
31
Gearbox rear casing screws
7
1,25 ± 0,2
32
Level plug
1
2,2 ± 0,2
33
Differential housing screws
4
1,25 ± 0,2
34
Drain plug
1
3,5 ± 0,3
CLUTCH
GEARBOX
TRANSMISSION
29
B2CP3BRD
211
FR-VU-page196-247-2005
9/01/06
12:34
Page 212
ML5 GEARBOX : TIGHTENING TORQUES
Ref.
Description
m.daN
CLUTCH
GEARBOX
TRANSMISSION
1
1 screw M8-45
1,8 ± 0,1
2
1 screw M8-70
1,8 ± 0,1
3
1 screw M10-70
4 ± 0,4
4
1 screw M10-50
4 ± 0,4
5
1 screw M10-85
4 ± 0,4
6
Screw
3 ± 0,3
7
Speedometer control support
1 ± 0,1
8
Fixing of gearbox cover on gearbox casing
2 ± 0,2
2 ± 0,2
9
Differential bearing stop plate
10
Air vent
11
Reverse gear switch
12
Fixing of gearbox casing on clutch casing
B2CKUC4D
212
2,5 ± 0,2
2 ± 0,2
FR-VU-page196-247-2005
9/01/06
12:34
Page 213
ML5 GEARBOX : TIGHTENING TORQUES
Ref.
Description
m.daN
13
Flange fixing screws
2 ± 0,2
14
Secondary shaft nut
17 ± 1,7
15
Gear control support screws
1,5 ± 0,1
16
7,7 ± 0,7
CLUTCH
GEARBOX
TRANSMISSION
B2CKUC5D
B2CKUC6D
213
FR-VU-page196-247-2005
9/01/06
12:34
Page 214
MLGU GEARBOX : TIGHTENING TORQUES
Ref.
1
2
Description
Reverse gear switch 1 screw
m.daN
2,5 ± 0,2
Fixings of gearbox casing on clutch
casing
CLUTCH
GEARBOX
TRANSMISSION
B2CP3HPD
No. of screws
14 screw
2 ± 0,2
3
Differential housing screws (M10)
6 screw
4 ± 0,5
4
Speedo drive support
1 screw
1,5 ± 0,1
5
Oil level plug (1 screw)
6
Differential housing screws (M8)
4 screw
2 ± 0,2
7
Drain plug
1 screw
3 ± 0,3
8
Differential bearing stop plate screw
4 screw
2 ± 0,2
9
5th gear housing screw
7 screw
2 ± 0,2
(*) Depending on date of manufacture of gearbox.
214
3 ± 0,3
FR-VU-page196-247-2005
9/01/06
12:34
Page 215
MLGU GEARBOX : TIGHTENING TORQUES
No. of screws
m.daN
10
Secondary shaft nut
Description
1 screw
17 ± 1,5
11
Gear control support screws
6 screw
2 ± 0,2
12
12 screw
7,7 ± 0,3
CLUTCH
GEARBOX
TRANSMISSION
Ref.
B2CP3HQD
215
FR-VU-page196-247-2005
9/01/06
12:34
Page 216
MLGU GEARBOX : SPECIFICATIONS
B2CP3JQC
CLUTCH
GEARBOX
TRANSMISSION
Drain – Fill – Top-up
Gearbox.
(1) Air vent hole (filler aperture).
(2) Drain plug.
(3) Oil level plug.
IMPERATIVE : Do not use the oil level plug to fill the gearbox or to top up (new engine angle).
Oil capacity (after draining) :
- without reduction box: 2,7 litres
- with reduction box: 3,2 litres
Oil quality : TOTAL TRANSMISSION BV 75W80
Checking intervals : none.
Checking of oil level : no oil level check.
Lubrication for life.
IMPERATIVE : After finding an external leak or following a repair, it is necessary to drain the
gearbox and put back the exact quantity of oil.
Transfer box.
(4) Drain plug.
(5) Oil level plug.
WARNING : The transfer box casing is separate from the gearbox. Drain and lubricate
the transfer box separately.
Oil capacity (after draining)
: 0,7 litres
Oil quality
: TOTAL TRANSMISSION X4 80W90 API GL5.
B2DP009C
216
FR-VU-page196-247-2005
9/01/06
12:34
Page 217
MLGU GEARBOX : SPECIFICATIONS
Lubrication
Drain – Fill – Top-up
B2EP006C
Oil capacity (after draining)
: 1,8 litres
Oil quality
: TOTAL TRANSMISSION X4 80W90 API GL5.
Propeller shaft.
(8) Grease point.
The sliding transmission has 3 grease points (8) :
- 1 grease point on each universal joint.
- 1 grease point on the slide.
- 1 grease point on the intermediate bearing of the rear propeller shaft.
B2FP05YC
217
CLUTCH
GEARBOX
TRANSMISSION
Rear axle.
(6) Oil level plug.
(7) Drain plug.
FR-VU-page196-247-2005
9/01/06
12:34
Page 218
BERLINGO
MA/5 GEARBOX : CONTROLS
Engines : HFX - KFW
1
2
3
4
-
Gear
Gear
Gear
Gear
control bar.
lever.
engagement ball-joint.
selection ball-joint.
Adjustment.
CLUTCH
GEARBOX
TRANSMISSION
The gear change mechanism is not adjustable.
Lubricate the linkages of the ball-joints at each refitting.
Note :
To clip the ball-joints in place, set the gear control in neutral. After fitting the gear
controls, check that all the gears engage without « tight spots ».
B2CP3NTD
218
FR-VU-page196-247-2005
9/01/06
12:34
Page 219
BE4/5 GEARBOX : CONTROLS
C15
Engine : WJX
(1) Gear selection rod
X = 130 ± 1 mm.
(2) Gear engagement rod
Y = 300 ± 1 mm.
(3) Torque rod
Z = between 51 and 61 mm
B2CP39WD
219
CLUTCH
GEARBOX
TRANSMISSION
L = Distance between the centre of the knob and the centre line of
the radio housing.
L = 195
if not, adjust via « X ».
J = 0.5 to 1 mm.
FR-VU-page196-247-2005
9/01/06
12:34
Page 220
BERLINGO
Engines : NFU - 9HZ - WJY - RHY
1
2
3
4
3
-
Gear control bar.
Gear lever.
Reaction rod.
Gear selection ball-joint.
Gear engagement ball-joint.
Adjustment.
CLUTCH
GEARBOX
TRANSMISSION
The gear change mechanism is not adjustable.
Lubricate the linkages of the ball-joints at each refitting.
Note :
To clip the ball-joints in place, set the gear control in neutral. After fitting the gear
controls, check that all the gears engage without « tight spots ».
B2CP3NWD
220
FR-VU-page196-247-2005
9/01/06
12:34
Page 221
DISPATCH
Engines : RFN - WJY
(1) Gear control lever
(2) Gear engagement control cable (*)
(3) Gear selection control cable (*)
(5) Gear engagement ball-joint Ø 10 mm.
(6) Flexible insulating grommet through the
bulkhead.
(*) = These two cables cannot be separated.
B2CP3BWD
221
CLUTCH
GEARBOX
TRANSMISSION
(4) Gear selection ball-joint Ø 10 mm.
FR-VU-page196-247-2005
9/01/06
DISPATCH
12:34
Page 222
CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS
Engines : RFN - WJY
Principles of adjusting the gear controls.
WARNING : Cables should be adjusted each time the gearbox, gear controls or power unit are
removed.
Principle
Lock the gear lever in neutral position,
using tool: 9607-T.
Place the gearbox in neutral.
B2CP3BXC
CLUTCH
GEARBOX
TRANSMISSION
WARNING : Do not use any tool to unclip the ball-joints.
To unlock the ball-joint, press at the centre « a », then pull the ball-joint upwards.
Couple the cables on the lever.
Fit the ball-joints on the gearbox lever.
Lock the cable lengths with the ball-joint locking keys.
NOTE : Changing an individual ball-joint is possible as long as the locking key is removed.
Unclip at « b », using two thin screwdrivers.
B2CP3BYC
222
9/01/06
12:34
Page 223
CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS
DISPATCH
Engines : RFN - WJY
Adjusting the gear controls.
Tools.
[1] Tool for positioning the gear lever
: 9607-T.
Adjustments
WARNING : Cables should be adjusted each time the gearbox, gear controls or power unit are removed.
Inside the vehicle:
Checks
- Check that all the gears engage without «tightness ».
- Check that the gear lever moves identically forwards and backwards and to right and left. If it does not,
repeat the adjustment.
Remove the trim under the gear lever.
Lock the gear lever in neutral position, using tool [1].
Under the bonnet.
Remove the air filter assembly.
Unlock the ball-joint keys at «a».
Place the gear selection and control levers on neutral.
Lock the cable lengths with the ball-joint locking keys.
Refit the trim under the gear lever.
Refit the air filter assembly.
223
B2CP3C6C
B2CP3C0C
CLUTCH
GEARBOX
TRANSMISSION
FR-VU-page196-247-2005
FR-VU-page196-247-2005
9/01/06
DISPATCH
12:34
Page 224
ML5 GEARBOX : CONTROLS
Engines : RHX - RHZ - RHW
CLUTCH
GEARBOX
TRANSMISSION
Non adjustable
B2CP3W8D
224
FR-VU-page196-247-2005
9/01/06
12:34
Page 225
RELAY
MLGU GEARBOX : CONTROLS
Engines : RFL - R6G - RHV - 4HY - 8140.43 - 8140.43S
The gears are controlled by means of cables :
- Selection cable.
- Engagement cable.
Selection cable
(ball-joints Ø = 10 mm)
Fixing
Gear control lever
end
Adjustment
Fixing
Gearbox end
Adjustment
Câble de passage
(ball-joints Ø = 13 mm)
Cables held in their locations by steel clips
Yes
Cables held in their locations by steel clips
No
NOTE : Greasing of ball-joints : grease G6.
New « chandelier » gear lever grid.
- To engage reverse gear, you have to lift the ring located under the gear lever knob.
B2CP3HRC
225
No
No
CLUTCH
GEARBOX
TRANSMISSION
Description
FR-VU-page196-247-2005
9/01/06
12:34
Page 226
RELAY
(1) Automatic adjustment device on selection cable.
(2) Teflon stop.
(3) Gear lever positioned in first.
CLUTCH
GEARBOX
TRANSMISSION
(A) The unlocked position : lets the ball-joint slide over
approx. 10 mm.
(B) The locked position : determines the length of the
selection cable.
Adjustment clearance : X = 1 mm.
B2CP3JYC
B2CP3JXD
226
FR-VU-page196-247-2005
9/01/06
12:34
Page 227
RELAY
Adjusting the gear selection cable
(A) The unlocked position.
(B) The locked position.
Adjustment.
- Position the gear lever on 1st gear.
- Insert a shim of thickness 1 mm between the gear lever and the teflon stop.
- Next action the locking / unlocking button, making the spring jump on the automatic
adjustment device..
- The automatic adjustment device is in the locked position (B).
- The length of the gear selection cable is adjusted.
- Do a road test, change through all the gears in order to check that there are no faults.
B2CP3JUD
227
CLUTCH
GEARBOX
TRANSMISSION
NOTE : Before doing the adjustment, make sure that the automatic adjustment device
remains in position (A).
FR-VU-page196-247-2005
9/01/06
12:34
Page 228
RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX
Precautions to be taken
Towing
The front of the vehicle must be raised in order to be towed.
If the front of the vehicle cannot be raised :
Repairs on electrical components
Do not disconnect :
- The battery when the engine is running.
- The ECU when the ignition is switched on.
IMPERATIVE : - Put gear lever in position «N».
- Do not add any oil.
- Do not exceed 30 mph over a distance of 30 miles of
maximum.
Before reconnecting a switch, check :
The condition of the various contacts.(for deformation, corrosion
etc.)
The presence and condition of the mechanical locking.
CLUTCH
GEARBOX
TRANSMISSION
Driving.
Never drive with the ignition switched off.
Never push the vehicle to try to start it;
(impossible with an automatic gearbox).
When performing electrical checks :
The battery should be correctly charged.
Never use a voltage source higher than 16V.
Never use a test lamp.
Lubrication
The automatic gearbox is only lubricated when the engine is
running.
228
FR-VU-page196-247-2005
9/01/06
12:34
Page 229
Repairs on mechanical components
Modification of the oil usage counter value.
Never place the gearbox on the ground without protection.
Exchanging the gearbox ECU :
In order to avoid breaking the input shaft ring, it is imperative that
the converter retaining bracket should be in place when handling
the gearbox.
Note down the gearbox counter value.
Transfer the value read into the the new gearbox ECU.
Initialise the oil usage counter to 0.
After coupling the gearbox on the engine, remove the centring peg.
Draining the gearbox :
Initialise the oil usage counter.
(follow the diagnostic tool procedure).
229
CLUTCH
GEARBOX
TRANSMISSION
Exchanging the gearbox :
It is imperative to use the centring peg and the converter retaining
bracket to couple the gearbox on the engine.
FR-VU-page196-247-2005
9/01/06
12:34
Page 230
Procedure to be followed prior to carrying out repairs on AL4 autoactive gearbox
CLUTCH
GEARBOX
TRANSMISSION
If a gearbox malfunction occurs, there are two possible configurations
depending on the seriousness of the fault :
- Gearbox in back-up mode with a replacement programme of (the fault
values are taken in substitution).
- Gearbox in back-up mode with an emergency programme (3rd
hydraulic)
WARNING : In the emergency programme, an impact is felt when
changing P/R, N/R and N/D.
Réception client.
Discuss with the customer, to find out all the malfunction symptoms.
Oil level (See corresponding operation).
Oil quality – Oil level.
Oil quality.
If the gearbox has suffered a serious fault resulting in a malfunction or
the destruction of a clutch, the oil will overheat and become
contaminated with impurities : the oil is said to be «burnt».
This is characterised by a black colour and the presence of an
unpleasant smell.
Absence of fault codes.
Carry out parameter measures, actuator tests and a road test.
An excessive oil level can result in the following consequences :
- Excessive heating of the oil.
- Oil leaks.
An insufficent level causes the destruction of the gearbox.
Top up the level of oil in the gearbox (if necessary).
Check using a diagnostic tool.
Read the fault codes (engine and gearbox)
Presence of fault codes.
Carry out the necessary repairs.
Delete the fault codes.
Carry out a road test to check the repair and, if need be, modify the
gearbox ECU parameters (this is essential after an initialisation of the
ECU).
ESSENTIAL : The gearbox must be replaced.
230
FR-VU-page196-247-2005
9/01/06
12:34
Page 231
Procedure for initialising the automatic gearbox ECU
Downloading
Updating the value of the oil usage counter
Updating the gearbox ECU by downloading :
Follow the procedure using the diagnostic tool.
Using PROXIA
Access to reading and recording of the oil counter is via the menu :
The downloading operation enables the automatic gearbox to be
updated, or adapted to an evolution of the engine ECU.
Before commencing the downloading, take the value of the oil usage
counter present in the automatic gearbox ECU.
Adjustment of the oil counter value is done in incremental steps of
2750 units.
After the downloading operation, carry out the following:
- A clearing of faults.
- An initialisation of the auto-adaptives.
- A writing of the value of the oil usage counter previously read.
- A road test.
Using LEXIA
Access to reading and recording of the oil counter is via the menu :
«Oil counter ».
ESSENTIAL : Every update of the automatic gearbox ECU
should be accompanied by an update of the engine ECU.
Adjustment of the oil counter value is done by entering directly the
5 figures of the oil counter.
231
CLUTCH
GEARBOX
TRANSMISSION
«Configuration (integrated circuit button) / Oil counter ».
FR-VU-page196-247-2005
9/01/06
12:34
Page 232
AL4 AUTOMATIC GEARBOX : TIGHTENING TORQUES
Tightening torques m.daN
B2CP3EDD
CLUTCH
GEARBOX
TRANSMISSION
(1) Oil flow modulation electrovalve fixing
: 1 ± 0,2
(2) Heat exchanger fixing
:5±1
(3) Output speed sensor fixing
: 1 ± 0,2
: 1 ± 0,2
(5) Oil overflow and drain fixing
: 4 ± 0,2
(6) Oil level plug
: 2,4 ± 0,4
(7) Oil pressure sensor fixing
: 0,8 ± 0,1
B2CP311D
232
FR-VU-page196-247-2005
9/01/06
12:34
Page 233
(8) Fixing of converter on diaphragm
: 1 ± 0,1
: 3 ± 0,3
(9) Plug fixing
: 0,8 ± 0,2
(10) Gearbox fixing on engine
: 5,2 ± 1
B2CP3EED
233
CLUTCH
GEARBOX
TRANSMISSION
Pre-tightening
Tightening
FR-VU-page196-247-2005
9/01/06
12:34
Page 234
A : EW7 and EW10 engine versions :
Hydraulic valve block fixing
Centre the hydraulic valve block, using screws (11) and (12)
Pre-tighten
(no strict order)
: 0,9
Slacken
: All 7 screws
Tighten
(respect the order indicated)
: 0,75
NOTE : The screw (11) is shouldered.
B2CP3EFD
CLUTCH
GEARBOX
TRANSMISSION
B : DW10 engine version:
Hydraulic valve block fixing
Centre the hydraulic valve block, using screws (11) and (12)
Pre-tighten
(no strict order)
: 0,9
Slacken
: All 7 screws
Tighten
(respect the order indicated)
: 0,75
NOTE : The screw (11) is shouldered.
B2CP3EGC
(13) Fixing of selector lever position switch
(14) Oil filler plug
234
: 1,5 ± 0,2
: 2,4 ± 0,4
FR-VU-page196-247-2005
9/01/06
12:34
Page 235
DISPATCH
AL4 GEARBOX : CONTROLS
«P» Park (immobilisation of the vehicle, whatever the slope).
«R» Reverse gear.
«N» Neutral.
«D» Drive (autoadaptative mode, eco-law)
«M» Manual mode (M+, M-).
The vehicle can only be started when the selection lever is in position «P» or
«N».
Shift-Lock
The «shift-lock» is a system which locks the gear selection lever in position «P».
To unlock the gear selection lever from position «P», switch on the ignition and
press the brake pedal.
During a repair, the shift-lock can be unlocked by pressing the locking finger «a»
B2CP3CFD
235
CLUTCH
GEARBOX
TRANSMISSION
Gear control is by a cable linked to the selection lever located on the dashboard.
The gear selection control has 5 positions :
FR-VU-page196-247-2005
9/01/06
12:34
Page 236
AL4 AUTOMATIC GEARBOX
DISPATCH
Adjustment of the MULTIFUNCTION SWITCH
- Place the selection lever in position «N».
- Slacken the screws (1).
- Place the multifunction switch as far out as possible on the screw at «A».
- Connect a multimeter in the ohmmeter position on the electrical contacts (2).
- Turn the multifunction switch to close the circuit between the electrical contacts:
R = 0 _.
B2CKU1DD
- Mark the position of the multifunction switch at «B» in relation to the gearbox casing at «C».
CLUTCH
GEARBOX
TRANSMISSION
- Continue to turn the multifunction switch to open the circuit between the electrical contacts.
- Mark the position of the multifunction switch at «B» in relation to the gearbox casing at «D».
- Bring the switch back to position the mark «B» at midway between marks «C» and «D».
- Tighten the screws (1) to 1,5 ± 0,1 m.daN.
- Check the correspondence between the position of the gear selector and the indication on
the instrument panel.
B2CKU1ED
236
FR-VU-page196-247-2005
9/01/06
12:34
Page 237
RELAY
AL4 AUTOMATIC GEARBOX
Adjustment of the INTERNAL SELECTION CONTROL
Tools.
[1] Locking screw
[2] Bearing blade adjustment shim
: (-).0338-M1
: (-).0338-M2
B2CA08MC
Prior conditions: Hydraulic block in place.
- Place the gear selection lever in position 2 (A).
- Remove the screw (1)
- Slacken the screw (2).
- Fit tools [1] and [2].
- Position the bearing blade on the bearing sector (B).
- Lock tool [2], using tool [1].
- Tighten the screw (2) to 0,8 ± 0,1 m.daN.
- Check that the gear engagement lever is securely locked.
- Check the operation of the gear selection lever in all the positions.
IMPERATIVE : There must not be any excessive travel on the gear selection
lever when it is in position 2. Adjust the multifunction switch.
B2CA08NC
237
CLUTCH
GEARBOX
TRANSMISSION
Adjustment.
FR-VU-page196-247-2005
RELAY
9/01/06
12:34
Page 238
RECOMMENDATIONS - PRECAUTIONS : 4 HP 20 AUTOMATIC GEARBOX
Towing
The front of the vehicle must be raised in order to be towed.
If the front of the vehicle cannot be raised :
When performing electrical checks :
The battery should be correctly charged.
Never use a voltage source higher than 16V.
Never use a test lamp.
IMPERATIVE : - Put gear lever in position «N»..
- Do not add any oil.
- Do not exceed 45 mph over a distance of 60 miles maximum.
CLUTCH
GEARBOX
TRANSMISSION
Repairs on mechanical components
Never place the gearbox on the ground without protection.
Do not use the unions on the gearbox as handles for moving the
gearbox.
It is imperative that the converter retaining peg should be in place
when removing the gearbox.
It is imperative to use the centring pegs to couple the gearbox on
the engine.
Remove the converter retaining peg before coupling the gearbox on
the engine.
Driving.
Never drive with the ignition switched off.
NOTE : The automatic gearbox is only lubricated when the engine is
running.
Repairs on electrical components
Do not disconnect :
The battery when the engine is running.
The ECU when the ignition is switched on.
Before reconnecting a switch, check :
The condition of the various contacts.(for deformation, corrosion etc.)
The presence and condition of the mechanical locking.
238
FR-VU-page196-247-2005
9/01/06
12:34
Page 239
4 HP 20 GEARBOX : TIGHTENING TORQUES
RELAY
Gearbox exterior
: 2,5 ± 0,5
: 2,3 ± 0,5
: 1 ± 0,1
: 0,6 ± 0,1
:6±1
: 2,3 ± 0,5
: 2,3 ± 0,5
Drain plug
Heat exchanger fixing
Selector lever position switch fixing
Converter cover fixing on engine cover (XFX engine)
Converter cover fixing on engine cover (4HX engine)
: 4,5 ± 0,8
: 3,5 ± 0,5
: 1 ± 0,2
: 6,5 ± 1
: 5,8 ± 1
B2CP24BC
239
B2CP24CC
CLUTCH
GEARBOX
TRANSMISSION
B2CP3CZC
(2) Oil channel union fixing
(3) Exterior fixing of converter cover on clutch housing
(4) Speedometer take-off aperture plug
(5) Steel casing fixing
(6) Converter fixing on engine
(7) Interior fixing of converter cover on clutch housing
(8) Torx fixing of converter cover on clutch housing
FR-VU-page196-247-2005
9/01/06
12:34
Page 240
4 HP 20 GEARBOX : TIGHTENING TORQUES
RELAY
Gearbox interior
B2CP24DC
CLUTCH
GEARBOX
TRANSMISSION
(9) Input speed sensor fixing
: 0,8 ± 0,1
(10) Hydraulic block fixing (Large head)
: 0,8 ± 0,1
: 1 ± 0,2
B2CP24EC
240
FR-VU-page196-247-2005
9/01/06
12:34
Page 241
4HP20 AUTOMATIC GEARBOX SPECIFICATIONS
RELAY
Unlocking the « SHIFT LOCK » function
The « Shift Lock » is a system which locks the gear selection lever in the park position «P».
Unlocking the « Shift lock » (with a fault)
If it should be impossible to unlock the « Shift lock » with the « normal operation » method, the
causes of the fault may arise from the following components :
- « Shift lock ».
- Gear lever position switch.
- Gear lever ECU
- Automatic gearbox ECU.
- Electrical harness.
- Battery voltage.
Operations to be carried out :
- Unlock the « Shift lock » by pressing on the button at « b » through the gaiter (1).
- Press on button « a » on the gear lever.
- Move the selection lever to disengage from position « P ».
B2CP3KGD
241
CLUTCH
GEARBOX
TRANSMISSION
Unlocking the « Shift lock » (normal operation)
- Switch on the ignition.
- Apply the brake pedal and keep it pressed.
- Press on button « a » on the gear lever.
- Using the selection lever, disengage from position « P ».
FR-VU-page196-247-2005
RELAY
9/01/06
12:34
Page 242
4HP20 AUTOMATIC GEARBOX SPECIFICATIONS
Unlocking the « KEY LOCK » function
CLUTCH
GEARBOX
TRANSMISSION
C5FP0HAD
The « Key Lock » is a system which locks the ignition key in the ignition when you switch off, if the gear
selection lever is not in position « P ».
NOTE : The driver hears a buzzer for 30 seconds.
Unlocking the « Key lock » (normal operation)
- Apply the brake pedal and keep it pressed.
- Press on the button on the gear lever.
- Place the gear selection lever in position « P ».
- Switch off the ignition.
- Remove the ignition key.
Unlocking the « Key lock » (with a fault)
If it should be impossible to unlock the « Key lock » with the « normal operation » method, the causes
of the fault may arise from the following components :
- « Key lock ».
- Gear lever position switch.
- Gear lever ECU
- Automatic gearbox ECU.
- Electrical harness.
- Battery voltage.
Operations to be carried out :
- Insert a screwdriver at « a » (minimum length 150 mm).
- Engage the screwdriver while pulling one side of the steering wheel.
- Press on the button (1) with the point of the screwdriver.
- Remove the key from the ignition.
242
FR-VU-page196-247-2005
9/01/06
12:34
Page 243
SELECTION CONTROL SPECIFICATIONS : 4HP20 AUTOMATIC GEARBOX
RELAY
The gear selection lever is guided by the shape of the step grille and by a return spring
which holds it to the left.
The gear control has 5 positions :
- Position « P » : park (locks and immobilises the vehicle) (press on button « b » on the
selection lever to engage position « P »).
- Position « R » : reverse gear (press on button « b » on the selection lever to engage
position « R »).
- Position « N » : neutral.
- Position « D » : drive (use of the 4 gears of the gearbox in the automatic and autoadaptive
function).
- Position « +/- » : tilt the lever to the left (this position allows the driver to choose his gears
in sequential mode by pulling « - » or « + » on the gear selection lever. To revert to position
« D », tilt the lever to the right.
NOTE : Only positions « P » or « N » authorise starting of the engine.
In position « +/- », selection is performed by an electronic sensor located close to gear
lever. The variation of flux necessary to the movement of the sensor cells is obtained by a
magnet located on the lever itself. This enables the change of status.
The information is transmitted to the gearbox ECU via the selection lever ECU.
NOTE : The vehicle is equipped with « Shift Lock ».
B2CP3KAD
243
CLUTCH
GEARBOX
TRANSMISSION
In the passenger compartment
FR-VU-page196-247-2005
RELAY
9/01/06
12:34
Page 244
SELECTION CONTROL SPECIFICATIONS : 4HP20 AUTOMATIC GEARBOX
In the passenger compartment (continued)
To unlock the selection lever from position « P » :
- Press on the brake pedal.
- Press on button « b » on the selection lever.
A switch « a » on the gear control grille allows the driver to choose the « Snow » programme.
B2CP3KAD
NOTE : The snow programme facilitates starting and adhesion on slippery surfaces.
CLUTCH
GEARBOX
TRANSMISSION
IMPORTANT : To revert to the normal programme, press a second time on the switch « a ».
At the gearbox
The automatic gearbox is controlled by a cable.
( c ) Clip for unlocking the push-button in pushed-in position.
(1) Control lever with ball-joint.
(2) Automatic adjustment (pull out the button to adjust the control, push it in to lock the adjustment of the control).
(3) Sleeve stop.
B2CP3DLC
244
FR-VU-page196-247-2005
9/01/06
12:34
Page 245
RELAY
FILL / TOP-UP : 4HP20 AUTOMATIC GEARBOX
Tools
[1] Circlip pliers
[2] Filling cylinder
[3] Specific adaptor
: 4517-T (toolkit 4507-T)
: (-).0341
: (-).0341 B
B2CP3KLD
Place the vehicle on a lift.
Remove the air filter housing.
Remove the gearbox air vent assembly (1) and (2), using tool [1].
Fill with oil, using tools [2] and [3].
Refit the metallic part (1) of the air vent, using a punch of Ø18 mm and a mallet.
Clip on the plastic part (2) of the air vent.
NOTE : The gearbox air vent is available from Replacement Parts.
B2CP3KMC
245
CLUTCH
GEARBOX
TRANSMISSION
Filling with oil
FR-VU-page196-247-2005
RELAY
9/01/06
12:34
Page 246
FILL / TOP-UP : 4HP20 AUTOMATIC GEARBOX
Topping up with oil
Prior conditions :
- Vehicle in horizontal position, handbrake released.
- Engine running at idle, without any power consumers on (air conditioning, heating, etc.).
- Check the absence of gearbox back-up mode, using a diagnostic tool.
- Press on the brake pedal.
- Change through all the gears.
- Gear selection lever in position « P ».
- The check is done when the oil has reached a temperature of 55 ± 1°C ; use a diagnostic tool.
CLUTCH
GEARBOX
TRANSMISSION
B2CP3KNC
Checking the oil level.
Remove the top-up plug (3).
Oil flows from the top-up hole :
As soon as the oil temperature reaches 60 ± 1°C, refit the top-up plug (3).
NOTE : The oil level is correct.
Tighten the plug (3) to 2 ± 0,5 m.daN.
Oil does not flow from the top-up hole :
Refit the top-up plug (3).
Stop the engine.
Remove the gearbox air vent assembly, using tool [1].
Add 0,5 litre of extra oil into the gearbox, using tools [2] and [3].
Repeat the top-up procedure.
Refit the metallic part (1) of the air vent, using a punch of Ø18 mm and a mallet.
Clip on the plastic part (2) of the air vent.
Refit the air filter housing.
246
FR-VU-page196-247-2005
9/01/06
12:34
Page 247
DRIVESHAFTS - GEARBOXES
Gearbox oil seal mandrels
Gearbox
Engines
Berlingo
C15
Berlingo
MA/5
HFX - KFW
WJY
NFU - WJY - 9HZ - RHY
RFN - WJY
RHX - RHZ - RHW
RFL - R6G - 4HY
8140.43 - 8140.43S
RHV
Dispatch
Relay
BE4/5
ML/5
ML/GU
Driveshaft
nut
Right hand
Left hand
Tool kit
1
32,5 ± 1
7114-T.W
7114-T.X
7116-T
10°+ 60°
10Q 15Q 37 ± 1,8
5701-T.A
9017-T.C
5701-T.A
9017-T.C
1,8
18QS 42 ± 2,1
1
Dispatch
AL4
RFN
Relay
4 HP 20
2.8 HDi
32,5 ± 1
10Q 15Q 37 ± 1,8
C15
Berlingo
5708-T.J
5718-T.H
Seal extractor
RH/LH (-) 0338C
(-) 0338.J1
(-) 0338.H1
+ (-) 0338J2 + (-)0338.H2
8010-T.K1
8010-T.K2
(Red) +
(Black) +
8010-T.J
8010-T.J
18QS 42 ± 2,1
Tightening torque (m.daN) for wheel bolts
8
Dispatch
10
9±1
Relay
14 ± 1
247
NO
5708-T
(-) 0338
8010-T
CLUTCH
GEARBOX
TRANSMISSION
Vehicles
Driveshaft
bearing
NO
FR-VU-page248-277-2005
9/01/06
12:39
Page 248
C15
AXLE GEOMETRY
- Check the tyre pressures
- Release the handbrake
General conditions
- Vehicle empty
- 5 litres of fuel in the tank
Front height (Non-adjustable)
Rear height (Adjustable)
AXLES
SUSPENSION
STEERING
B3CP04VD
B3DP06VD
The heights H2 are measured from the ground to the bodyshell
crossmember to which the axle rear silentblocks are secured.
The heights H1 are measured from the ground to the lower section of
the subframe, close to the arm fixing.
248
9/01/06
12:39
Page 249
AXLE GEOMETRY
Reference height
C15
Adjusting the rear heights (H2).
Diesel
Engine type
WJY
600
765
Ft (H1)
203
214
Rr (H2)
515
527
Payload (Kg)
Heights
± 10 mm
- Height H2 is obtained by two half-shells 1 located between the damper
body and the lower thrust cup of the spring.
- The difference in height between the two sides should not exceed 4 mm.
NOTE : A 1 mm modification of the half-shells E leads to an average
change in the height H of 3.5 mm.
1 = 24 adjusting shims from 26 to 47 mm (1 mm , increasing
by 1 mm
B3DP06WD
249
AXLES
SUSPENSION
STEERING
FR-VU-page248-277-2005
FR-VU-page248-277-2005
9/01/06
12:39
Page 250
AXLES
SUSPENSION
STEERING
C15
AXLE GEOMETRY
Front reference height (Non-adjustable)
Engine type
WJY
Manual
Steering
Payload (Kg)
Camber
Power-assisted
600
± 30’
Castor
765
0° 41’
0° 30’
0° 55’
1° 47’
0° 55’
8° 50’
8° 34’
8° 50’
Pivot angle
± 40’
Tracking
(mm)
Counter camber
± 20’
9’
Tracking
(mm)
+ 1,6 à 5
+2
+3
Rear reference height (Non-adjustable)
NOTE
B3CP02UC
765
600
0° 30’
A < B = Positive figure
+
A > B = Negative figure
-
250
=
=
TOE-IN
TOE-OUT
9/01/06
12:39
Page 251
FRONT AXLE
C15
(1) Anti-roll bar
Diesel
B3CP04WD
B3CP04XD
251
Payload (Kg)
600
765
Ø Barre (mm)
23
24
AXLES
SUSPENSION
STEERING
FR-VU-page248-277-2005
FR-VU-page248-277-2005
9/01/06
12:39
Page 252
AXLES
SUSPENSION
STEERING
REAR AXLE
C15
(1) Anti-roll bar
Diesel
B3DP06XD
Payload (Kg)
600
765
Ø Barre (mm)
18
19
252
B3DP06YD
9/01/06
12:39
Page 253
STEERING SPECIFICATIONS
C15
Manual steering
A = 1 mm
B = 3 mm
C = 8 ± 1 mm
a = G6
D = 0,01-0,06 mm
B3EP109D
B3EP03SD
253
AXLES
SUSPENSION
STEERING
FR-VU-page248-277-2005
FR-VU-page248-277-2005
AXLES
SUSPENSION
STEERING
C15
9/01/06
12:39
Page 254
Power-assisted steering
A = 1 mm
B = 3 mm
C = 8 ± 1 mm
B3EP10AD
254
B3EP03SD
9/01/06
12:39
Page 255
BERLINGO
AXLE GEOMETRY
B3CP08ED
E1AP0AVD
Front : H1 = R1 - L1
Rear : H2 = R2 + L2
H1 = Measurement from the centre line of the arm front pivot screw to the ground.
R1 = Radius of the front wheel, under load.
L1 = From centre of wheel to centre line of arm front pivot screw.
H2 = From the rear axle front silentblock face to the ground.
R2 = Radius of the rear wheel when laden.
L2 = From the centre of the wheel to the rear axle front silentblock face.
Setting the vehicle at reference height is done in the following manner:
- Measure the radius of the front wheel R1 ; calculate dimension H1.
- Measure the radius of the rear wheel R2 ; calculate dimension H2.
- Compress the suspension to obtain the values calculated.
NOTE : The difference in height between the two sides should be less than 10 mm.
NOTE : To measure the wheel radius, use tool 8006-T.
255
AXLES
SUSPENSION
STEERING
FR-VU-page248-277-2005
FR-VU-page248-277-2005
9/01/06
12:39
Page 256
AXLES
SUSPENSION
STEERING
AXLE GEOMETRY
BERLINGO
Table of heights at REFERENCE LOAD
Vehicles
Front height
Rear height
Height
L1 = R1 - H1
L2 = H2 - R2
Familiale
175/65 R14
175/70 R14
90,5
75,5 (*)
56,5
71,5 (*)
8,5
23,5 (**)
Van
Payload
(Kg)
600
Payload
(Kg)
600
100,5
85,5 (**)
800
Platform cab
100,5
8,5
800
NOTE : (*) private raised vehicle Europe
NOTE : (**) utility raised vehicle Europe or CRD suspension
NOTE : The difference in height between the two sides should
be less than 10 mm.
256
9/01/06
12:39
Page 257
BERLINGO
AXLE GEOMETRY
Reference height values for the front axle
- Compress the suspension until the calculated values are obtained.
Tools used :
- [1] Set of two suspension compressors 9511-T.A - [2] Set of four straps 9511-T.B - [3] Set of four shackles 9511-T.C
ESSENTIAL : When checking the axles, the vehicle must be at reference setting
Front axle
Adjust
ment
Tracking (±1 mm)
YES
Camber (±30’)
Pivot angle (±30’)
Casto (±30’)
NO
Familiale
Van
Platform cab
175/65R14 - 175/70R14 - 185/65R15
600 kg - 800kg
+1 mm
-2 mm (1)
-2 mm
-2 mm (2)
0°
0°07’ (1)
0°
0° (2)
10°44’
10°26’ (1)
10°54’
10°38’ (2)
2°59’
2°55’ (1)
3°03’
2°58’ (2)
Conditions for checking/adjusting :
- Correct tyre pressures.
- Reference height.
- Steering rack at point zero (straight ahead).
(1) private raised vehicle Europe.
(2) utility raised vehicle Europe or CRD suspension.
B3CP02UC
NOTE
A<B = Positive figure :
A>B = Negative figure:
257
+=
=
TOE-IN
TOE-OUT
AXLES
SUSPENSION
STEERING
FR-VU-page248-277-2005
FR-VU-page248-277-2005
9/01/06
12:39
Page 258
AXLES
SUSPENSION
STEERING
BERLINGO
AXLE GEOMETRY
Reference height values for the rear axle
- Compress the suspension until the calculated values are obtained.
Tools used :
- [1] Set of two suspension compressors 9511-T.A - [2] Set of four straps 9511-T.B - [3] Set of four shackles 9511-T.C
ESSENTIAL : When checking the axles, the vehicle must be at reference setting
Rear axle
Adjust
ment
Tracking (±1,3 mm)
Camber (±30’)
NO
Familiale
Van
Platform cab
175/65R14 - 175/70R14 - 185/65R15
600 kg - 800kg
1,41 mm
0,3 mm (1)
4,74 mm
3,7 mm (2)
-1°16’
-1°16’ (1)
-1°13’
-1°14’ (2)
258
9/01/06
12:39
Page 259
BERLINGO
FRONT AXLE
1 Damper nut
2 Cup screw
3 Suspension leg
4 Stabiliser rod ball-joint
5 Pivot on suspension leg
6 Anti-roll bar
7 Stabiliser rod ball-joint
8 Pivot lower ball-joint
9 Driveshaft nut
10 Wheel bolts
11 Lower arm front articulating point
12 Lower arm rear articulating point
and anti-roll bar bearing
13 Screw under rear articulating point
14 Ball-joint fixing on lower arm
Fixing of subframe on body
B3CP041D
B3CP040P
4,5 ± 0,4
2,5 ± 0,3
3,7 ± 0,3
4,5 ± 0,4
3,7 ± 0,3
4,0 ± 0,4
32,5 ± 2,5
9,0 ± 1,0
7,6 ± 0,7
6,8
3,1
4,5
8,5
±
±
±
±
0,6
0,3
0,2
0,8
NOTE : Fitting of damper upper support : tongue
« a » towards the front.
B3CP043D
259
AXLES
SUSPENSION
STEERING
FR-VU-page248-277-2005
FR-VU-page248-277-2005
9/01/06
12:39
Page 260
AXLES
SUSPENSION
STEERING
BERLINGO
REAR AXLE
B3DP03LD
260
(1) Front silentblock on axle
: 9,4 ± 0,9
(2) Anti-roll bar screw
: 5,5 ± 0,2
(3) Front silentblock on body
: 4,0 ± 0,4
(4) Wheel bolt
: 9,0 ± 1,0
(5) Rear silentblock on axle
: 5,4 ± 0,4
(6) Damper shaft nut
: 11,0 ± 1,0
(7) Stub bearing nut
: 25,0 ± 2,5
(8) Rear silentblock on body
: 6,2 ± 0,6
9/01/06
12:39
Page 261
SUSPENSION
Van
Vehicles
Payload (Kg)
Ø Anti-roll bar
(mm)
Familiale
600
800
AV
Colour code
Ø Anti-roll bar
(mm)
Colour code
BERLINGO
AR
175/65R14 - 175/70R14
185/65R15
21
22
White
Green
19
19 (2)
21
21 (1)
21
19 (2)
21
19 (2)
Blue
Blue (2)
Orange
Orange (1)
Orange
Blue (2)
Orange
Blue (2)
NOTE:
261
AXLES
SUSPENSION
STEERING
FR-VU-page248-277-2005
FR-VU-page248-277-2005
9/01/06
12:39
Page 262
AXLES
SUSPENSION
STEERING
BERLINGO
SUSPENSION
Van
Vehicles
Payload (Kg)
Familiale
600
800
175/65R14 - 175/70R14 - 185/65R15
Ø Anti-roll bar
(mm)
20,5
20,5 (2)
21,3
21,3 (1)
19,6
20,5 (2)
Colour code
Red
Red (2)
Mauve
Mauve (1)
Pink
Red (2)
Height of travel stop
(mm)
NOTE :
- The right hand torsion bar is identified by 1 paint line.
- The left hand torsion bar is identified by 2 paint lines.
82
NOTE:
262
9/01/06
12:39
Page 263
POWER STEERING SPECIFICATIONS
BERLINGO
(1) Steering joint fixing
: 2,3 ± 0,2
(2) Lower fixing screw
: 2,3 ± 0,2
(3) Upper fixing screw
: 2,3 ± 0,2
(4) Steering wheel screw
: 2,0 ± 0,2
(a) Steering column height adjustment handle.
B3EP14FD
NOTE : The airbag is attached to the steering wheel.
: 2,3 ± 0,2
(b) 3 teeth have been removed for matching with the
upper part of the steering column.
B3EP14GD
263
AXLES
SUSPENSION
STEERING
FR-VU-page248-277-2005
FR-VU-page248-277-2005
9/01/06
12:39
Page 264
AXLES
SUSPENSION
STEERING
BERLINGO
(6) Pivot ball-joint nut
: 3,5 ± 0,3
(7) Locking nut for adjusting steering rods
: 4,5 ± 0,4
(8) Ball-joint
: 6,0 ± 0,6
(9) Fixing of steering housing on subframe
: 7,0 ± 0,7
(10) Hydraulic pipe union
: 2,4 ± 0,2
(11) Power steering assistance valve
: 1,2 ± 0,2
(12) Fixing of flange on push rod
: 1,2 ± 0,2
(13) (*) Fixing of steering ram on casing
: 9,0 ± 1,0
(14) (*) Fixing of steering ram on yoke
High pressure union
(15-17) Screws fixing pump on the support
Power steering pressure switch (**)
:
:
:
:
9,0
2,0
2,2
2,0
±
±
±
±
1,0
0,3
0,3
0,2
IMPERATIVE : Replace using new Nylstop nuts.
B3EP14JD
B3EP14KD
NOTE : (*) Use new screws for refitting.
NOTE : (**) A pressure switch is mounted on the hydraulic piping between the high
pressure pump and the steering valve (petrol engines only).
264
9/01/06
12:39
Page 265
DISPATCH
AXLE GEOMETRY
Table of values at REFERENCE HEIGHT
With recommended tyre pressures
B3BP07DD
The reference heights must be checked between the jacking point and the ground.
Values at reference height
Engine types
All types
Features
Tyres 195/70 R14
H1 (mm)
157
H2 (mm)
164
265
AXLES
SUSPENSION
STEERING
FR-VU-page248-277-2005
FR-VU-page248-277-2005
9/01/06
12:39
Page 266
AXLES
SUSPENSION
STEERING
AXLE GEOMETRY
DISPATCH
ESSENTIAL : When checking the axles, the vehicle must be at reference setting.
NOTE
B3CP02UC
+
=
TOE-IN
-
=
TOE-OUT
Rear
Front
Toe-in
toe-out
Castor
Camber
Pivot angle
0°
0°8’30’’ ± 0°4’15’’
mm
1 ± 0,5
1°30’ ± 30’ (1)
1°30’ ± 30’ (2)
-1°’ ± 30’
0° ± 30’
11°28’ ± 10’
(1) Manual steering.
(2) Power-assisted steering.
266
9/01/06
12:39
Page 267
SPECIAL FEATURES : FRONT AXLES
DISPATCH
(1) Engine subframe front fixing.
(2) Engine subframe rear fixing.
(1) Front fixing
(2) Rear fixing
B3CP055D
267
10,7
10,7
AXLES
SUSPENSION
STEERING
FR-VU-page248-277-2005
FR-VU-page248-277-2005
AXLES
SUSPENSION
STEERING
DISPATCH
9/01/06
12:39
Page 268
FRONT AXLE
Mark A, LH side
B3CP04PD
Mark B, RH side
B3CP04QD
268
9/01/06
12:39
Page 269
REAR AXLE
DISPATCH
1 - Strengthening bar on the bodyshell.
2 - Stabiliser bar.
B3DP071D
269
AXLES
SUSPENSION
STEERING
FR-VU-page248-277-2005
FR-VU-page248-277-2005
9/01/06
AXLES
SUSPENSION
STEERING
DISPATCH
12:39
Page 270
Manual steering
B3EP054D
270
9/01/06
12:39
Page 271
Power-assisted steering
All Types
Steering
Power-assisted
Pinion (Teeth)
9
Rack (Teeth)
33
Steering rack travel (mm)
152
B3EP09ZD
271
DISPATCH
AXLES
SUSPENSION
STEERING
FR-VU-page248-277-2005
FR-VU-page248-277-2005
9/01/06
12:39
Page 272
AXLES
SUSPENSION
STEERING
AXLE GEOMETRY
RELAY
Front
Steering
All Types
Camber
0±1
-2 ± 1
Tracking (mm)
Castor
Rear
NONadjustable
0°30’ ± 30’
0° ± 30’
0° ± 45’
Conditions for checking and adjusting :
- Correct tyre pressures.
- Steering rack locked on straight ahead (point zero) (see corresponding operation).
- Vehicle in running order.
NOTE
B3CP02UC
272
+
-
=
=
TOE-IN
TOE-OUT
9/01/06
12:39
Page 273
FRONT AXLES
RELAY
Versions : 11Q (*) - 15Q (*) - 18Q
Engine-type specific anti-roll bar
Diameter 24 mm
NOTE : (*) No anti-roll bar on van versions with
DW10UTD engine.
B3CP081P
273
AXLES
SUSPENSION
STEERING
FR-VU-page248-277-2005
FR-VU-page248-277-2005
9/01/06
12:39
Page 274
AXLES
SUSPENSION
STEERING
RELAY
FRONT AXLES
(1) Damper nut
: 8 ± 0,8
(11) Front screw fixing suspension arm
(2) Screws fixing suspension leg on body
: 5 ± 0,5
(12) Anti-roll bar
(3) Damper
(4) Screws fixing suspension leg on pivot
: 19 ± 2
(5) Screws fixing lower ball-joint on pivot
: 8,8 ± 0,8
(6) Nut fixing lower ball-joint on suspension arm
: 18 ± 1,8
: 25 ± 2,5
(13) Screw fixing anti-roll bar bearing and suspension arm rear
mounting
: 20 ± 2
(14) Rear screws fixing subframe on body
: 20 ± 2
(15) Screw fixing suspension arm rear mounting
: 17 ± 1,7
(16) Screw fixing suspension arm rear mounting on body : 20 ± 2
(7) Driveshaft nut
11Q and 15Q (M28x1.5)
18Q (M33x1.5)
: 37 ± 1,85
: 42 ± 2,1
(17) Screw fixing anti-roll bar bearing
: 8,5 ± 0,9
(8) Wheel bolt
: 14 ± 1
(18) Nut fixing rod on suspension arm
: 5,6 ± 0,6
(19) Nut fixing rod on anti-roll bar
: 5,6 ± 0,6
(9) Suspension arm
(10) Front screw fixing subframe on body
(20) Anti-roll bar rod
: 25 ± 2,5
274
9/01/06
12:39
Page 275
REAR AXLES
RELAY
(1) Suspension blade mounting rear yoke
(2) Suspension blade lever
(3) Suspension blade lever rear yoke fixings
: 15,5 ± 1,6
(4) Screw fixing rear yoke on body
: 15 ± 1,5
(5) Rigid hollow shaft rear axle
(6) Stub axle bearing nut
: 45 ± 3
(7) Wheel bolt
: 14 ± 1
(8) Centring pin fixings
: 1,5 ± 0,2
(9) Flange fixings
: 13 ± 1,3
(10) Damper lower fixing screw
: 16 ± 1,6
(11) Suspension blade front yoke fixing
: 15,5 ± 1,6
(12) Screws fixing front yoke on body
: 15 ± 1,5
(13) Suspension blade mounting front yoke
(14) Screws fixing brake stub through rear axle
: 15 ± 1,5
(15) Travel stop
: 3,6 ± 0,4
(16) Damper upper fixing screw
: 16 ± 1,6
(17) Telescopic dampers (inclined and fixed under the floor, on the
body sill)
(18) Single blade longitudinal spring in modulated section steel
B3DP09WD
275
AXLES
SUSPENSION
STEERING
FR-VU-page248-277-2005
FR-VU-page248-277-2005
AXLES
SUSPENSION
STEERING
RELAY
9/01/06
12:39
Page 276
B3EP14AD
276
: 2,5 ± 0,3
(2) Plate fixing on floor
: 1,8 ± 0,2
(3) Steering column fixing
: 1,5 ± 0,2
(4) Steering wheel fixing
: 5 ± 0,5
9/01/06
12:39
Page 277
RELAY
B3EP14BD
277
(5) Ball-joint fixing on pivot
: 7 ± 0,7
(6) Steering rod locking nut
: 6 ± 0,6
(7) High pressure pipe fixing on valve
: 5,5 ± 0,5
(8) Low pressure pipe fixing on valve
: 6,3 ± 0,6
(9) Ball-joint fixing on steering rack
: 12 ± 1
(10) Mechanism fixing on subframe
: 11 ± 1
AXLES
SUSPENSION
STEERING
FR-VU-page248-277-2005
FR-VU-page278-310-2005
9/01/06
12:42
Page 278
BRAKES
BRAKE SPECIFICATIONS
C15
1.9 D
Payload (Kg)
600
765
Master cylinder
20,60
Master-vac
151,20
Ø
mm Caliper makes
/ pistons
FT
GIRLING/D.B.A
Brake disc
247
Disc thickness
10
Minimum disc thickness
8
Brake pad grade
BOSCH
Brake cylinders or calipers
Ø
mm Brake drums Ø min. / max.
RR
22
230/228,60
Make
BENDIX
Brake lining grade
Compensator – cut-off
(bars)
Load-sensitive
278
9/01/06
12:42
Page 279
C15
Clearance J = 3 to 5 mm to be adjusted by turning the stop switch.
After adjusting, tighten the locking nut (1) to 1 m.daN.
B3FP112D
B3FP111D
279
BRAKES
FR-VU-page278-310-2005
FR-VU-page278-310-2005
BRAKES
C15
9/01/06
12:42
Page 280
Adjusting the brake pressure compensator.
- Press the brake pedal hard in order to close the limiter.
- Adjust the cable clamp (3) to obtain a clearance of J = 4 to 5 mm between the
cable clamp contact face and the lever (2).
NOTE : Do not touch the screw (1) which has been set at the production stage
B3FP113D
280
9/01/06
12:42
Page 281
HANDBRAKE
C15
Adjusting the handbrake.
- Operate the hydraulic brake two or three times by
depressing the pedal.
- Set the handbrake lever to the third notch of its travel.
- Loosen the lock nut (2) and turn nut (1) until the rear brakes
start tightening.
- Equalise the tension of the left and right cables.
- Ensure that, for a handbrake travel of five notches, the rear
wheels are locked.
B3FP114D
281
BRAKES
FR-VU-page278-310-2005
FR-VU-page278-310-2005
BRAKES
C15
9/01/06
12:42
Page 282
BLEEDING THE BRAKES
- Bleed each wheel cylinder, starting with the front of the vehicle.
- Bleed :
- The front right and front left.
- The rear right and rear left.
- Fit each bleed screw with a transparent tube, immersed in a receptacle.
- Press the brake pedal.
- Open the bleed screw.
- Keep the pedal fully depressed.
- Shut the bleed screw.
- Slowly release the brake pedal until it reaches its stop.
- Repeat the operation until all air bubbles have disappeared.
- Follow the same procedure for the other wheels.
NOTE : During the brake bleeding operations, check that the brake fluid level in the reservoir is maintained.
Use the hydraulic fluid sold by the CITROEN Replacement Parts Division.
282
9/01/06
12:42
Page 283
BERLINGO
Without ESP (*)
Engine plate
Ø
mm
1.1i
1.4i
1.6i 16V
HFX
KFW
NFU
1.6 16V HDi
1.9 D
2.0 HDi
9HZ
WJY
RHY
Master cylinder
23,8
Master-vac
228,6
Caliper makes / pistons
Disc
BOSCH ZOH 54/22/54
Ventilated
266
FT Disc thickness / min. thickness (mm)i
22/20
Brake pad make/grade
BOSCH F769
Drum
Original/maximum/width
228/230/40
Lining
make/grade
TRW F4930
(*) = Electronic Stability Programme
283
BRAKES
FR-VU-page278-310-2005
FR-VU-page278-310-2005
9/01/06
12:42
Page 284
BRAKES
BERLINGO
With ESP (*)
1.6i 16V
Engine plate
NFU
Master cylinder
FT
228,6
BOSCH ZOH 54/26/54
Ventilated
283
Disc thickness / min. thickness (mm)
RR
RHY
23,8
Master-vac
Ø
mm Caliper makes / pistons
Disc
2.0 HDi
26/24
BOSCH F769
Ø Caliper makes / pistons
mm Disc
Plain
TRW C38/38
247
Disc thickness / min. thickness (mm)i
9/7
GALFER G4554
(*) = Electronic Stability Programme
284
9/01/06
12:42
Page 285
BRAKES
FR-VU-page278-310-2005
Specifications of braking compensators
Without ABS REF
Vehicles - All Types - Payload (Kg)
Make
Colour ref. of spring
475/575/600 Kg
Green
Familiale
Yellow
Grand export familiale
Silver
TEVES
Grand export 765 Kg
765 Kg Electric vehicle PMF
Cut-off pressure (bar)
With ABS REF
Engines
11,25 ± 1,75
The compensator
and main brake
19,35 ± 2,75
Black
11,25 ± 2,75
Blue
8,85 ± 2
Type
All types
limiter functions
with ABS
are assured by
the ABS REF
system.
NOTE : PMF : Multifunction roof.
NOTE : REF : Electronic Brakeforce Distribution.
285
FR-VU-page278-310-2005
9/01/06
12:42
Page 286
BRAKES
Braking system specifications
1
- Braking circuit in X.
- Disc brakes at the front, ventilated (according to version).
- Drum brakes at the rear, with automatic adjustment (except for versions with ESP) (*).
B3FP09HC
2
- Disc brakes at the rear (version with ESP).
- Handbrake lever controlled by cables acting on the rear wheels.
(1) Hydraulic valve block «ABS Bosch 5.3»
(1) Hydraulic valve block «ABS Bosch 5.3 REF »
(1) Hydraulic valve block «ABS with ESP Bosch 5.7 ».
or
or
(2) Load-sensitive braking compensator (according to version).
NOTE : (*) : ESP : Electronic Stability Programme.
B3FP09JC
286
9/01/06
12:42
Page 287
Braking circuit without « ABS REF » (drum brakes at the rear)
B3FP7A4D
(1) braking compensator.
287
BRAKES
FR-VU-page278-310-2005
FR-VU-page278-310-2005
9/01/06
12:42
Page 288
BRAKES
Braking circuit with « ABS REF » (drum brakes at the rear)
B3FP7A5D
288
9/01/06
12:42
Page 289
BRAKES
FR-VU-page278-310-2005
4 ± 0,4
9±1
32,5 ± 2,5
3,7 ± 0,3
B3FP7A8D
B3FP7A7C
(13) Caliper fixing on pivot
(14) Yoke fixing on calliper
: 10,5 ± 1 m.daN
: 3,2 ± 0,1 m.daN
(15) Brake servo fixing on pedal gear
(16) Master-cylinder fixing on brake servo
289
: 2,2 ± 0,1 m.daN
: 2 ± 0,2 m.daN
FR-VU-page278-310-2005
9/01/06
12:42
Page 290
BRAKES
CHECKING AND ADJUSTING : LOAD-SENSITIVE BRAKE COMPENSATOR
TOOLS
- Brake pressure checking instrument.
- Weighing machines.
PREPARING THE VEHICLE
CHECKING
- The compensator is checked in relation to the weight on the rear axle. (See the table on following page.)
- If the vehicle is heavier : raise the vehicle by the bodyshell.
- If the vehicle is lighter : load the vehicle or pull it by the bodyshell to obtain the correct load.
- Press the brake pedal to obtain 100 bars on the front brakes.
- The rear brake cut-off must occur at the pressure indicated in the table.
- From the table, select the value closest to the actual weight on the axle. Check and adapt this value to the value in the table. (See
the table on following page.)
290
9/01/06
12:42
Page 291
CHECKING AND ADJUSTING : LOAD-SENSITIVE BRAKE COMPENSATOR
ADJUSTMENT
Loosen the nut (1).
Load the axle to a weight corresponding to one person plus 5 litres of fuel.
Build up a minimum pressure of 20 bars in the compensator.
Screw in the adjusting nut (2) until it is against the lever (4), whilst ensuring that the spring
(3) is not tensioned. To do this, a shim will be used at (J) to adjust a 1 ± 0.5 mm clearance
between the nut (2) and the lever (4).
- Hold the adjusting nut (2) in place, and lock it using the locking nut (1).
-
Vehicle type
(Payload Kg)
Weight on the rear axle
(Kg)
409
540
675
417
596
775
418
644
870
475
600
800
B3FP115C
291
Pressure on the rear brakes
(bars)
25
26
58
25
27
70
25
32
81
BRAKES
FR-VU-page278-310-2005
FR-VU-page278-310-2005
9/01/06
12:42
Page 292
BRAKES
HANDBRAKE (Adjustment)
Checking - Adjusting
- Check that the cables are correctly routed.
- Apply and release the parking brake four times.
- Set the parking brake to the 4th notch.
- Tighten the nut (1) until the rear brakes are tightened.
- Firmly pull the handbrake lever 4 or 5 times.
- Set the parking brake to the 5th notch.
- Check that the rear brakes are tightened.
- With the handbrake released, ensure that the wheels can be
rotated freely by hand.
B3FP06YD
292
9/01/06
12:42
Page 293
BRAKES
FR-VU-page278-310-2005
BLEEDING THE BRAKES
Bleeding
The bleeding operation can be performed: - Using brake bleeding equipment. In this case, adjust the pressure to 2 bars.
- Or in the conventional way.
Without ABS
With ABS or ABS/ESP : BOSCH 5.3/BOSCH 5.7
ESSENTIAL: Order of bleeding
Wheel :
- Rear right.
- Rear left.
- Front right.
- Front left.
Wheel :
- Rear right.
- Rear left.
- Front right.
- Front left.
Top up the level : Using the brake fluid sold by the CITROEN Replacement Parts Division.
293
FR-VU-page278-310-2005
9/01/06
12:42
Page 294
BRAKES
DISPATCH
Petrol
2.0i 16V
Total Gross Weight (Kg)
Versions
Master cylinder
Ø
mm Master-vac
FT
Brake disc
Disc thickness/min. thickness
815
Combi
(1) (2)
(3) (4) (5) (6)
(7)
22,2 (N° RPO 8206)
23,8 (N° RPO 8207 )
23,8
23,8
GIRLING (N° RPO 8156 )
BENDIX (N° RPO 9155)
281 (N° RPO 8156 )
257 (N° RPO 9155)
281
26/24 (N° RPO 8156 )
20/18 (N° OPR9155)
26/24
280
GIRLING
Brake pad grade
RR
19
Brake cylinders
Ø
mm Brake drums Ø min. / max
Brake lining quality
255 / 256
Load-sensitive double compensator
Rear compensator
Compensator cut-off (Bars) / Weight (kg) (*)
(*) = = Cut-off point as a function
of the weight on the rear axle.
20 / 500
(1) Panel van (short) (815kg).
(2) Glazed van (short) (815kg).
(3) Combi 5/6 seater.
(4) Combi 7 seater CLUB.
294
90/1125
(7) Floor cab (short) (815kg).
9/01/06
12:42
Page 295
DISPATCH
Diesel
1.9 D
815
Versions
Master cylinder
FT
Combi
(1) (2) (3) (4) (10)
(5) (6) (7)
22,2 (N° RPO 8206)
23,8 (N° RPO 8207)
Master-vac
Ø
mm Caliper makes / pistons
Brake disc
(8)
(9)
23,8
255
280
BENDIX
GIRLING
257
281
20/18
26/24
Brake pad grade
RR
Brake cylinders
Ø
mm Brake drums Ø min. / max
19
255 / 256
Rear compensator
20/500
(*) = Cut-off point as a function of
the weight on the rear axle.
(1)
(2)
(3)
(4)
Panel van (short) (815kg).
Glazed van (short) (815kg).
Panel van (long) (815kg).
Glazed van (long) (815kg).
(5)
(6)
(7)
(8)
295
Combi 5/6 seater.
Combi 5/6 seater MIXED.
Combi 8/9 seater.
Floor cab (short) (815kg).
90/1125
(9) Floor cab (long) (815kg).
(10) Van MIXED (short) (815kg).
BRAKES
FR-VU-page278-310-2005
FR-VU-page278-310-2005
9/01/06
12:42
Page 296
BRAKES
DISPATCH
Diesel
2.0 HDi
Versions
Ø
Master cylinder
815
(1) (4) (7)
22,2 (N° RPO 8206)
23,8 (N° RPO 8207)
900
(2) (3) (5) (6)
23,8
mm Master-vac
FT
RR
(1)
(2)
(3)
(4)
(8)
(9)
23,8
280
GIRLING (N° RPO 8156)
Caliper makes / pistons BENDIX (N° RPO 9155)
281 (N° RPO 8156)
Brake disc
257 (N° RPO 9155)
26/24 (N° RPO 8156 )
20/18 (N° RPO 9155)
Brake pad grade
Brake cylinders
Ø
Rear compensator
Combi
(10) (11) (12) (13) (14)
280
281 (N° RPO 8156 )
257 (N° RPO 9155)
26/24 (N° RPO 8156)
20/18 (N° RPO 9155)
GIRLING
281
26/24
GIRLING
281
26/24
19
255/256
20 / 500
90/1125
(5)
(6)
(7)
(8)
Glazed van (long) (900kg). (9) Floor cab (long) (900kg). (13) Combi 8 seater CLUB.
Glazed van (short) (900kg). (10) Combi 5/6 seater.
(14)Combi 8/9 seater.
Van MIXED (short) (815kg). (11) Combi 5/6 seater MIXED.
Floor cab (short) (900kg)
296
9/01/06
12:42
Page 297
DISPATCH
Diesel
2.0 16V HDi
Versions
Master cylinder
Ø
FT
mm
815
Combi
(1) - (2) - (3) - (4)
(7) - (8) - (9) - (10) - (11)
22,2 (N° RPO 8206)
23,8 (N° RPO 8207)
23,8
23,8
GIRLING
280
Master-vac
(5)
Brake disc
(6)
280
281 (N° RPO 8156 )
257 (N° RPO 9155)
281
26/24 (N° RPO 8156 )
20/18 (N° RPO 9155)
26/24
Brake pad grade
RR
19
Brake cylinders
Ø
255 / 256
Rear compensator
20 / 500
(1)
(2)
(3)
(4)
Glazed van (long) (815kg).
(5)
(6)
(7)
(8)
297
Floor cab (short) (815kg).
Floor cab (long) (815kg).
Combi 5/6 seater.
Combi 5/6 seater MIXED.
90/1125
BRAKES
FR-VU-page278-310-2005
FR-VU-page278-310-2005
9/01/06
12:42
Page 298
BRAKES
Mechanical adjustment of the compensator.
-Set the vehicle at reference height.
-ESSENTIAL : Never modify the position of the upper nut (1).
-Refit the flanged nut (2).
-Fit the tool 8204-T.
Drum
At A : Shim (16 mm)
Blue
At B : Shim (16 mm)
Green
-Adjust the nut (3) to allow the passage, free and without play, of the green shim at (B), taking
care not to move the lever (4) downwards.
-Tighten the lock nut (5) without modifying the adjustment.
-Remove the tool 8204-T.
-Hold the threaded rod in position at (C).
-Tighten the flanged nut (2) to the nut (3).
B3FP10TC
298
9/01/06
12:42
Page 299
Hydraulic checking and adjusting of the load-sensitive double compensator
B3FP10UC
Tools.
- Equipment for checking the brake pressures and pressure take-off union
: 4140-T.
- Adjusting shims
: 8204-T.
Connecting the tool 4140-T.
- Connect the pressure take-off unions diagonally in place of the bleed screws.
Checking the LH compensator
- Rear right hand caliper : M8x125
- Rear LH wheel cylinder : M7x100
Checking the RH compensator
- Rear left hand caliper : M8x125
- Rear RH wheel cylinder : M7x100
Checks :
- Bleed the equipment (see user instructions).
- Place the vehicle at reference height.
WARNING : The front pressures should be obtained by exerting a single pressure on the brake pedal.
- Take the pressures.
- The pressures recorded in the left and right circuits must be identical.
If the pressures are not correct :
- Change the faulty wheel cylinder or compensator
- Carry out the adjustment.
Adjustment :
- Refit the nut (1).
- Adjust using nut (2) to obtain the braking pressure.
- Tighten the lock nut (3).
- Hold the threaded rod in place (4), tighten the flanged nut (1) to the nut (2).
299
BRAKES
FR-VU-page278-310-2005
FR-VU-page278-310-2005
9/01/06
12:42
Page 300
BRAKES
Adjustment
- Tension the secondary cables by screwing in
nut (1) until a travel of 4 to 5 notches of the
handbrake lever is obtained.
- Lock the locking nut (2).
B3FP116D
300
9/01/06
12:42
Page 301
2.0i - 2.0 HDi - 2.2 HDi
Payload (Kg)
Ø Master cylinder
mm Master-vac
Caliper make
Ø Piston (mm)
FT Ø
Disc
mm
Disc thickness
RELAY
2.8 HDi
2.0i - 2.2 Hdi - 2.8 HDi
18Q
11Q-15Q
25,4
Plain
Ventilated
Plain
Ventilated
Brake pad grade
Ø Brake cylinders
RR
Disc
Disc thickness
Make
Grade
Caliper fixing on pivot (Front)
: 21 ± 2
Caliper fixing on stub axle support (Rear) : 18,8 ± 1,5
44/48
279,4
BREMBO
46/52
44/48
280
300
280
24/21,9
254/255,6
280
16/14,2
LOCKEED
BREMBO
Tightening torques: m.daN
Master cylinder fixing on master-vac : 2 ± 0,2
Master-vac fixing on body
: 2 ± 0,2
301
Yoke fixing on caliper (Front/Rear): 3 ± 0,3
BRAKES
FR-VU-page278-310-2005
FR-VU-page278-310-2005
9/01/06
12:42
Page 302
BRAKES
RELAY
2.0i
Payload (Kg)
FT
Ø Master cylinder
mm Master-vac
Caliper make
Ø Piston (mm)
Ø
Plain
Disc
mm
Ventilated
Plain
Disc thickness
Ventilated
Brake pad grade
RR Ø Brake cylinders
Disc
Disc thickness
Make
Grade
2.8 HDi
11Q-15Q
25,4
2.0i - 2.8 HDi
18Q
44/48
279,4
BREMBO
46/52
44/48
280
300
280
24/21,9
280
16/14,2
BREMBO
Tightening torques: m.daN
Caliper fixing on pivot (Front)
: 21 ± 2
Master cylinder fixing on master-vac
Caliper fixing on stub axle support (Rear): 18,8 ± 1,5 Yoke fixing on caliper (Front/Rear)
302
: 2 ± 0,2
: 3 ± 0,3
Master-vac fixing on body
: 2 ± 0,2
9/01/06
12:42
Page 303
Checking and adjusting the rear brake corrector
Tools
Brake pressure checking equipment
- Weighing machines
: Tool kit 4140-T.
Preparing the vehicle
- Braking circuit bled.
- Vehicle on a hoist (with bearing race).
- Connect the tool 4140-T.
- Connect the «front» pressure gauge to one of the front brakes.
- Connect the «rear» pressure gauge to one of the rear brakes.
- Replace the bleed screws with sensors (1).
WARNING : Bleed screws - the thread of the front and rear bleed screws is not identical.
- Bleed the tool 4140-T.
- Chock the front wheels.
- Place the rear wheels on the weighing machines.
B3FP037C
303
BRAKES
FR-VU-page278-310-2005
FR-VU-page278-310-2005
9/01/06
12:42
Page 304
BRAKES
Checking the rear brake corrector
Adjusting the rear brake corrector
- The corrector must be checked in relation to the weight on the rear axle
(Refer to the table below).
- Weight on the rear axle = Weight on all four wheels.
- Apply the brake pedal to obtain 80 bars on the front brakes.
- The pressure on the rear brakes is cut off as indicated in the table.
- From the table, select the value closest to the actual weight on the
axle. Check and adapt this value to the value in the table..
Vehicle type
11 Q
15 Q
11 Q
15 Q
18 Q
ABS
Weight on the rear
axle (Kg)
Pressure on the rear
brakes ± 3 bars
650
30
900
45
700
34
900
45
900
45
With ABS
750
26
Without ABS
900
45
- Slacken the nuts (3)
- Press the brake pedal to obtain 80 bars on the front brakes.
- Gradually operate the control (2) in order to obtain a rear brake
pressure corresponding to the weight on the rear axle.
- Tighten the nuts (3)
- Release the brake.
- Check the adjustment.
B3FP038C
304
9/01/06
12:42
Page 305
Preliminary operation
- Raise the vehicle and place it on stands with the rear wheels hanging free.
- Release the parking brake.
- Depress the brake pedal several times.
- Slacken the nut (1) so as to detension the handbrake cable.
Rear drum brakes.
B3FP02GC
- Do up the nut (2a) until the lever (3) lifts slightly from the stop (4).
- Tighten the locking nut (2b).
- Set the handbrake to the 3rd notch.
- Vigorously pull the handbrake lever 4 or 5 times.
- With the handbrake released, ensure that the wheels can be turned freely by hand.
B3FP17AC
305
BRAKES
FR-VU-page278-310-2005
FR-VU-page278-310-2005
9/01/06
12:42
Page 306
BRAKES
Rear disc brakes.
ESSENTIAL : Adjust the brakes before adjusting the handbrake.
B3FP17BC
- Remove the rear wheels.
- Position the hole (a) facing the toothed wheel (5) of the adjustment mechanism.
- Turn the toothed wheel (5) upwards to block the rotation of the disc.
- To unblock the disc, action the toothed wheel (5) by 10 teeth in the reverse direction.
NOTE : 1 tooth varies the diameter of the jaws by 0,035 mm.
- The clearance between the jaws and the drum should be between 0,30 and 0,65 mm.
- Do up the nut (2a) until the lever (3) lifts slightly from the stop (4).
- Vigorously pull the handbrake lever 4 or 5 times.
- With the handbrake released, ensure that the wheels can be turned freely by hand.
- Refit the rear wheels.
- Tighten the wheel bolts to 14 ± 1 m.daN.
B3FP17AC
306
9/01/06
12:42
Page 307
BRAKES
FR-VU-page278-310-2005
DRAIN – FILL – BLEED : BRAKING CIRCUIT
Tools
[1] Pressure bleeding apparatus.
[2] PROXIA diagnostic tool
[3] LEXIA diagnostic tool
B1BP2QQC
: 41656T
: 4171-T
NOTE : Use the diagnostic tools [2] and [3] for bleeding the secondary braking circuit.
Draining the braking circuit.
- Drain the brake fluid reservoir to the maximum, using a syringe.
- Disconnect the connector (1).
- Uncouple the pipe (2).
- Remove the screw (3).
- Remove the reservoir from its two supplies by pulling upwards.
- Empty the reservoir.
- Clean the reservoir.
Refit :
- The reservoir.
- The screw (3).
Couple the pipe (2).
Reconnect the connector (1).
WARNING : Use only hydraulic fluids that are approved and recommended.
Refill the brake fluid reservoir.
Bleed the braking circuit.
B3FP177C
307
FR-VU-page278-310-2005
9/01/06
12:42
Page 308
BRAKES
Bleeding the braking circuit.
IMPERATIVE : During the bleed operations, take care to maintain the level
of brake fluid in the reservoir, keeping it topped up. Use only new brake
fluid.
Bleed the primary braking circuit in the course of routing servicing.
Bleed the secondary braking circuit in the following cases:
B3FP178D
- Problems with the secondary braking circuit.
- Starting the pump.
- Supplying the electrovalves.
Front brake caliper, bleed screws (4).
- Without ABS, two bleed screws (4) (for each caliper).
- With ABS, one bleed screw (4) (for each caliper).
- Rear brake caliper, bleed screw (5).
- Rear brake drum, bleed screw (5).
B3FP179D
308
9/01/06
12:42
Page 309
Bleeding the primary braking circuit.
WARNING : The ABS should not be in action during the bleed operation.
Use a generic bleeding apparatus: «LURO» or similar.
Connect the bleeding apparatus [1] onto the brake fluid reservoir.
Adjust the apparatus pressure to 2 bars.
Bleeding the secondary braking circuit.
NOTE : The bleed apparatus is still connected on the brake fluid reservoir.
Use the diagnostic tools [2] and [3].
Connect the diagnostic tool.
On the diagnostic tool screen, select the menu «ABS BLEED».
Follow the instructions in the diagnostic tool.
Bleed the brakes in the sequence indicated (ABS-type bleed).
At the end of the bleed programme, check the fluid level and top up if necessary .
Check the travel of the brake pedal (no lengthening of travel). If travel has lengthened, repeat the bleed procedure.
Remove the tooling.
B1BP2QRC
309
BRAKES
FR-VU-page278-310-2005
FR-VU-page278-310-2005
9/01/06
12:42
Page 310
BRAKES
Bleeding a braking circuit without ABS
Bleeding a braking circuit with ABS
- Engine switched off (no servo-assistance).
- Bleed each wheel cylinder starting at the rear of the vehicle, then at the
front.
- On the front caliper, start with the uppermost piston, finish with the lower
piston.
For each braking circuit:
- Connect a transparent tube on the bleed screw, submerge the other end
of the tube in a clean receptacle.
- Open the bleed screw, wait for the fluid to flow out without air bubbles.
- Close the bleed screw.
Remove the bleeding apparatus.
Check the brake fluid level (it should be between «MIN» and «MAX»).
Refill if necessary with approved and recommended synthetic brake fluid.
Proceed as follows :
- Rear right.
- Front left.
- Rear left.
- Front right.
For each braking circuit:
- Connect a transparent tube on the bleed screw, submerge the other end
of the tube in a clean receptacle.
- Open the bleed screw, wait for the fluid to flow out without air bubbles.
- Close the bleed screw.
Remove the bleeding apparatus.
Check the brake fluid level (it should be between «MIN» and «MAX»).
Refill if necessary with approved and recommended synthetic brake fluid.
IMPERATIVE : Avoid any action which could risk starting the pump
or energising the electrovalve. (The circuit is pre-filled and bled).
310
FR-VU-page311-332-2005
9/01/06
12:47
Page 311
AIR
CONDITIONING
AIR CONDITIONING R 134 a (HFC)
Compressor
Vehicle
Engine
Date
Refrigerent
refill
Capacity
Fixed
BERLINGO
12/02 >
Variable
Oil quantity
(cc)
Oil
reference
SD 7V 12
575 ± 25 gr
SP 10
SD 7V 16
DISPATCH
RELAY
12/03 >
950 ± 25 gr
09/96 >
800 ± 50 gr (*)
135
SD 7H 15
SP 20
1 000 ± 50 gr (**)
= Single air conditioning: 1 evaporator, 1 pressure control valve.
= Double air conditioning: 2 evaporators, 2 pressure control valves.
311
AIR
CONDITIONING
*
**
All Types
FR-VU-page311-332-2005
9/01/06
12:47
Page 312
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
Click-fit connector removal/fitting tool
Ø Inch
Ring colour
Tool kit 4164.T
Berlingo
Vehicules
TT
3/8
Red
8005-T.C.
Dispatch
TT
5/8
Black
8005-T.A.
C5HP073C
AIR
CONDITIONING
312
FR-VU-page311-332-2005
9/01/06
12:47
Page 313
Presence of pollen filter
BERLINGO
DISPATCH
RELAY
Equipment
RPO No
Presence of filter
Without aircon
NO (Valéo)
Base aircon
YES (Valéo)
All Types
NO
Base aircon
NO
Without aircon
NO
Base or double aircon
YES
313
Observations
AIR
CONDITIONING
Vehicle
FR-VU-page311-332-2005
9/01/06
12:47
Page 314
Compressor lubricant.
ESSENTIAL: The compressor lubricant is extremely hygroscopic; always use FRESH oil.
Checking the compressor oil level.
There are three specific cases :
- 1/ Repairs to a system without leaks.
- 2/ Slow leak.
- 3/ Fast leak.
1/ Repairing a system without leaks.
AIR
CONDITIONING
a) - Using draining/recovery equipment not fitted with an oil decanter.
- Drain the system as slowly as possible via the LOW PRESSURE valve, so as not to lose any oil.
- No more oil should be added when filling the system with R 134.a fluid.
b) - Using draining/filling equipment fitted with an oil decanter.
- Drain the R 134.a fluid from the system in accordance with the instructions in the equipment handbook.
- Measure the amount of oil recovered.
- Add the same amount of NEW oil when filling the system with R 134.a fluid.
c) - Replacing a compressor.
- Remove the old compressor, drain it and measure the oil quantity.
- Drain the new compressor (supplied full), so that the same amount of NEW oil is left in the compressor as was in the old compressor.
- No more oil should be added when filling the system with R 134.a fluid.
314
FR-VU-page311-332-2005
9/01/06
12:47
Page 315
Checking the compressor oil level (continued)
2) Slow leak.
- Slow leaks do not lead to oil loss, therefore the same procedure should be followed as if there was no leak at all.
3) Fast leak.
This type of leak causes both oil loss as well as allowing air to enter the system.
It is therefore necessary to :
- Replace the dryer.
- Drain as much oil as possible (when replacing the faulty component).
Either before or during filling of the system with R 134.a fluid, introduce 80 cc of NEW oil into the system.
A drying bottle
A condenser or an evaporator
A high pressure or low pressure pipe
A drying cartridge
:
:
:
:
15 cc of compressor oil.
315
AIR
CONDITIONING
If changing one of the following components, add as below :
FR-VU-page311-332-2005
9/01/06
12:47
Page 316
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
Tools.
[1] Clim test 2 VALEO
: 4372-T.
Checks.
Position the tool [1] (depending on manufacturer’s instructions)
AIR
CONDITIONING
E5AP2ECC
316
FR-VU-page311-332-2005
9/01/06
12:47
Page 317
Outillage EXXOTest
Outillage VALEO
Outillage (Flash équipement &matériel)
Exxoclim
: 2.4.2-1
Mode d’emploie
: Voir notice constructeur
Testing procedure
Checking
Position the tool CLIM TEST II (according to the manufacturer’s instructions).
Preliminary operations
Close all the front air vents.
Start the engine.
Open the front LH air vent.
Position the air distribution control to « frontal flow ».
Activate the « air recirculation » control.
Activate the « air conditioning » control.
E5AP2N4D
Clim test 2
Outillage
: 4372-T.
Temperature control on maximum cold.
Blower control in maximum speed position.
Let the air conditioning operate for 5 minutes.
E5AP2N5D
317
AIR
CONDITIONING
Positions of the air conditioning controls :
FR-VU-page311-332-2005
9/01/06
12:47
Page 318
Setting the checking tool [1] to measurement mode
Operate the checking tool, press on button "j".
Select the type of aircon fluid : R134.a or R12 :
Press on button "l", validate by pressing on button "k".
Select the type of aircon fluid : with filtering and drying cartridge, or calibrated aperture :
Press on button "l", validate by pressing on button "k".
Select the temperature setting T3,
Press on button "l", validate by pressing on button "j".
NOTE : The tool is in measurement mode.
AIR
CONDITIONING
Aircon compressor with fixed capacity :
Take the measurement with the engine running, at idle.
Aircon compressor with variable capacity :
Take the measurement with the engine running, at 1500 rpm.
Setting the checking tool to diagnostic mode
Set the checking tool to diagnostic mode, press on button "j".
The diagnosis is performed instantaneously : values outside the tolerances are displayed on a dark
background.
E5AP2FAC
318
FR-VU-page311-332-2005
9/01/06
12:47
Page 319
Interpretation of the measurements
« m »: High pressure.
« n »: High temperature.
« p »: Under-cooling (SR).
« q »: Low pressure.
« r »: Low temperature.
s »: Over-heating (SC).
t »: Ambient air temperature.
u »: Blown air temperature.
v »: Humidity.
w »: Temperature T3
Under-cooling
The under-cooling represents the difference between the condensation temperature and the aircon fluid
temperature at the aircon condenser outlet.
The under-cooling gives the quantity of aircon fluid (in the liquid state) in the air conditioning circuit.
Values for under-cooling (SR)
Values «p»
Origins
Solutions
SR < 2°C
Lack of aircon fluid in the aircon condenser
(should be more than 150 grammes)
2°C < SR <4°C
Lack of aircon fluid in the aircon condenser
(should be around 100 to 150 grammes)
SR > 10°C/12°C
SR > 15°C
Add some aircon fluid
Correct quantity
Excess aircon fluid in the aircon
condenser
Blown air temperature « u »
The blown air temperature should be between 2°C and 10°C.
319
Remove some aircon fluid
AIR
CONDITIONING
4°C < SR < 10°C/12°C
E5AP2FBC
«
«
«
«
«
FR-VU-page311-332-2005
9/01/06
12:47
Page 320
Interpretation of the measurements
« m »: High pressure.
« n »: High temperature.
« p »: Under-cooling (SR).
« q »: Low pressure.
« r »: Low temperature.
«
«
«
«
«
s »: Over-heating (SC).
t »: Ambient air temperature.
u »: Blown air temperature.
v »: Humidity.
w »: Temperature T3
Over-heating (SC)
The over-heating represents the difference between the aircon fluid temperature at the evaporator outlet and
the evaporation temperature.
The over-heating gives the quantity of aircon fluid (in the liquid state) in the air conditioning circuit
Values for over-heating (SC)
Origins
Values «s»
2° < SC < 15°C
Solutions
Correct quantity
SC > 15°C
Lack of aircon fluid in the cooling circuit
Add some aircon fluid
SC < 2°C
Excess aircon fluid in the cooling circuit
Remove some aircon fluid
AIR
CONDITIONING
Blown air temperature « u »
The blown air temperature should be between 2°C and 10°C
E5AP2FBC
320
FR-VU-page311-332-2005
9/01/06
12:47
Page 321
Interpretation of the diagnosis
«
«
«
«
«
x » Check satisfactory.
y » Lack of aircon fluid in the aircon circuit.
z » Excess aircon fluid in the aircon circuit.
aa » Filtering and drying cartridge clogged.
ab » Other problems (see table on previous page).
321
AIR
CONDITIONING
E5AP2FCD
FR-VU-page311-332-2005
9/01/06
12:47
Page 322
Aircon circuit diagnosis table
Principal problem
Symptom
Possible causes
Aircon compressor clutch
The clutch of the aircon compressor does not
engage, or disengages suddenly
Lack of aircon fluid in the aircon
circuit
Aircon pressostat
Aircon evaporator sensor
The aircon compressor does not turn, or
stops suddenly
Electrical circuit (wiring, fuses, etc.)
Auxiliaries drive belt
Aircon compressor
The clutch of the aircon compressor remains
engaged and stops suddenly
Filtering and drying cartridge
Aircon pressure reducer
Leak of aircon fluid
AIR
CONDITIONING
322
FR-VU-page311-332-2005
9/01/06
12:47
Page 323
Principal problem
Symptom
Possible causes
Incorrect adjustment of the aircon
compressor clutch
The clutch of the aircon compressor
remains engaged
The aircon compressor makes an abnormal
noise
Aircon fluid quantity
Aircon compressor defective
Lack of aircon fluid in the aircon circuit
Aircon compressor valves defective
The clutch of the aircon compressor
remains engaged and slips
323
AIR
CONDITIONING
Auxiliaries drive belt
FR-VU-page311-332-2005
9/01/06
12:47
Page 324
Principal problem
Symptom
Low pressure and high pressure too high
Possible causes
Aircon pressure reducer defective
Duct clogged
Low pressure too high and high pressure too
low
Aircon compressor seal defective
Aircon evaporator sensor defective
Abnormal levels of pressure
Low pressure too low and high pressure too
high
Aircon pressure reducer jammed
Filtering and drying cartridge obstructed
Duct clogged
Duct clogged
Aircon pressure reducer jammed
Low pressure and high pressure too low
Lack of aircon fluid in the aircon circuit
AIR
CONDITIONING
Aircon compressor defective
324
FR-VU-page311-332-2005
9/01/06
12:47
Page 325
Principal problem
Abnormal levels of pressure
Symptom
Possible causes
Low pressure normal and high pressure
too high
Presence of air in the aircon circuit
Low pressure normal and high pression too
low
Aircon pressostat defective
Low pressure too high and high pressure
normal
Low pressure too low and high pressure
normal
Evaporator sensor defective
Aircon pressure reducer jammed open
Filtering and drying cartridge saturated
or clogged
Aircon pressure reducer iced up
Under cooling too weak
Lack of aircon fluid
Excess aircon fluid
Under cooling excessive
Presence of air in the aircon circuit
Filtering and drying cartridge clogged
NOTE : In all cases, measure the excessive heating (SC) and the blown air temperature.
325
AIR
CONDITIONING
Air conditioning operating
in back-up mode
FR-VU-page311-332-2005
9/01/06
BERLINGO
12:47
Page 326
AIR CONDITIONING SYSTEM R 134.a
Engines TU1JP/3JP/5P4
Tightening torques.
A Right hand drive
B Left hand drive
AIR
CONDITIONING
(1) High pressure valve.
(2) Low pressure valve
(3) Pressure reducer
(4) Drying cartridge.(Tighten to 1,7 ± 0,1 m.daN)
(5) Condenser
(6) Pressostat
(7) Compressor (compressor fixing flange : tighten to 4 ± 0,4 m.daN)
(a) Pressure reducer fixing flange : tighten to 0,8 ± 0,1 m.daN
(b) Fixing flange : tighten to 1,3 ± 0,1 m.daN.
(c) Fixing flange : tighten to 1,3 ± 0,1 m.daN.
C5HP19QP
326
FR-VU-page311-332-2005
9/01/06
12:47
Page 327
BERLINGO
Engines : DW8B - DW10TD
Tightening torques (m.daN).
(3) Pressure reducer
(4) Drying cartridge.(Tighten to 1,7 ± 0,1 m.daN)
(5) Condenser
(6) Pressostat
(7) Compressor (compressor fixing flange : tighten to 4 ± 0,4 m.daN)
(a) Pressure reducer fixing flange : tighten to 0,8 ± 0,1 m.daN
(b) Fixing flange : tighten to 1,3 ± 0,1 m.daN.
(c) Fixing flange : tighten to 1,3 ± 0,1 m.daN.
C5HP19RP
327
AIR
CONDITIONING
A Right hand drive
B Left hand drive
FR-VU-page311-332-2005
9/01/06
DISPATCH
12:47
Page 328
Engine : EW10J4
C5HP12EC
(1)
(2)
(3)
(4)
(5)
AIR
CONDITIONING
(a)
(b)
(c)
C5HP15PP
328
High pressure valve.
Low pressure valve.
Pressostat : tighten to 1,8 ± 0,1 m.daN
Dryer
Clickfit union.
0,8 ± 0,1 m.daN
4 ± 0,4 m.daN
0,8 ± 0,1 m.daN
FR-VU-page311-332-2005
9/01/06
12:47
Page 329
DISPATCH
Engine : DW8B
C5HP12EC
(3) Clickfit union
(4) Pressostat.
(5) Fixing flange: tighten to 0,8 ± 0,1 m.daN
(6) Pressure reducer fixing flange : tighten to 0,8 ±
0,1 m.daN
(7) Compressor fixing flange: tighten to 4 ± 0,4 m.daN.
C5HP15CP
329
AIR
CONDITIONING
FR-VU-page311-332-2005
DISPATCH
9/01/06
12:47
Page 330
Engines : DW10BTED/ATED/CTED/BTED+
C5HP12EC
AIR
CONDITIONING
(3) Clickfit union
(4) Pressostat.
(5) Pressure reducer fixing flange: tighten to 0,8 ±
0,1 m.daN
(6) Fixing flange : tighten to 0,8 ± 0,1 m.daN
(7) Compressor fixing flange: tighten to 4 ± 0,4 m.daN.
C5HP15EP
330
FR-VU-page311-332-2005
9/01/06
12:47
Page 331
RELAY
Single circuit
WARNING : The single and double air conditioning circuit
diagrams are valid for all engine types.
(installation may vary according to equipment)
C5HP05QD
331
AIR
CONDITIONING
(2) Low pressure valve.
FR-VU-page311-332-2005
RELAY
9/01/06
12:47
Page 332
Double circuit
(2) Low pressure valve.
(3) Pressure control valve
(4) Second evaporator
(passenger compartment side)
AIR
CONDITIONING
C5HP05PD
332

Couv VU-2005 - Citroën Service

Transcription

Similar documents