Citroen BERLINGO 2004 1.G Workshop Manual

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ENGINE
The new fitting discontinues the following components:
Camshaft hub.
Cylinder reference sensor target.
Repair – Accessories drive pulley
Remove – Refit
WARNING:
Peg the camshaft and the crankshaft before ever removing the
accessories drive pulley (the pegging prevents any offsetting of the camshaft).
If necessary, apply a paint spot to mark the accessories drive pulley being
replaced.
Replacement parts.
The Replacement Parts service markets the old as well as the new components.
CHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
NEW FITTING N° RPO 9128 # (Continued)
B1EP177D
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ENGINECHECKING AND SETTING THE VALVE TIMING
NOTE: Checking and setting the valve timing on engines: RHYRHZ N° ⁄ RPO 9127
See Mechanic’s Handbook 2003: pages 193 to196
Tools.
[1]
Belt tension measuring equipment :4122T
[2]
Tension lever:().0188.J2
[3]
Engine flywheel peg: ().0188.Y
[4]
Belt clamp: ().0188.AD
[5]
Camshaft pulley peg: ().0188.M
[6]
Engine flywheel lock: ().0188.F
[7]
Set of blocking plugs:().0188.T
[8]
Pulley extractor:().0188.P
[9]
2 mm dia.peg: ().0188.Q2Removing.
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 underengine sounddeadening.
The front RH wheel.
The front RH splashshield. The engine cover.
Unclip and move aside the cooling hose.
Remove the accessories drive belt
(see corresponding operation).
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Engines: RHY RHZ N° RPO 9128 #

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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
Uncouple, plug and move aside, using tool [7], the fuel delivery pipe (2)and return
pipe (1).
Remove:
Screws
(3), (4) and (6).
Screw (7).
The upper timing cover (5).
WARNING:Refit screw (7)equipped with a spacer (17 mm thick), tighten the
screw (7)to 1,5 ± 0,1 m. daN.
NOTE:The screw (7)is one of the screws securing the coolant pump and is there
for its sealing.
Put the gear lever in 5th gear.Turn the road wheel to turn the engine in its direction of rotation.
Orient the camshaft pulley in the pegging position, use a mirror if necessary.
Peg the camshaft, using tool
[5].
Peg the engine flywheel, using tool
[3].
B1EP1A7CB1BP2H3CB1BP2H2CB1BP2R2C
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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
Remove:
The fixings of the pipe linking the power steering pump with the rotary valve.
The clutch lower closing plate.
Lock the engine flywheel, using tool
[6].
Remove the screw (8).
Refit the screw (8)without its thrust washer.
Remove:
The accessories pulley
(9), using tool[8].
Tool [6].
The lower torque reaction rod.
Support the engine by means of a workshop hoist.
Remove:
The bearing shell fitting
(10).
The nut (12).
Screws (11).
The bracket (13).
NOTE:Lift then lower the engine with the workshop hoist, to have access to the
timing cover fixing screws.
Remove:
The intermediate timing cover.
The lower timing cover.
B1CP04BCB1BP2R3CB1BP2R4C
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
Slacken the screw (17)of the tensioner roller (18).
Remove the timing belt
(14).
Checks.
IMPERATIVE: Just before refitting, carry out the checks below.
Check that:
The rollers
(18)and (15)turn freely (without play and without any tight spot).
The coolant pump pulley
(16)turns freely (without play and without any tight spot).
There are no traces of oil leaks from the crankshaft and camshaft seals, etc.
The crankshaft pinion travels freely on the keyway.
Replace defective components if necessary.
Peg the crankshaft pinion
(19)by inserting tool [9]on the LH side of the keyway.
B1EP1A8DB1EP1A9C
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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
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)anticlockwise, using tool [2], to attain an overtension of:
98 ± 2 SEEM units.
Tighten screw
(17)of the tensioner roller to 2,5 ± 0,2 m.da N.
Lock the flywheel by means of tool
[6].
Tighten the accessories drive pulley screw
(8)to 7 ± 0,7 m.da N.
Remove tools
[1], [3], [5] and [6].
Rotate the crankshaft eight times in the normal direction of rotation.
Peg:
The crankshaft, using tool
[3].
The camshaft drive pulley, using tool
[5].
B1EP1ABDB1EP1ACC
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
Lock the engine flywheel, using tool [6].
Slacken:
The accessories drive pulley
(8).
The screw (17) of the tensioner roller (18).
Fit the tool [1].
Turn the tensioner roller, using tool [2], to attain a tension of:54 ± 2 SEEM units.
Tighten screw (17)of the tensioner roller (18)to 2,5 ± 0,2 m.daN.
Remove tool [1].
Fit tool [1].
The tension value should be:
54 ±3 SEEM units.ESSENTIAL: If the value is incorrect, recommence the operation.
Remove tools [1], [3], [5]and [6].
Rotate the crankshaft two times in the normal direction of rotation.
Peg:
The crankshaft, using tool
[3].
The camshaft drive pulley.
IMPERATIVE:If the pegging is not possible, recommence the operation.
B1EP1ACC
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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
Remove:
Tools [3]and [5].
Screw (7)and the spacer.
Refit: The lower, intermediate and upper covers
(5).
Screw (7), tighten to 1,5 ± 0,1 m.daN.
Screws (3), (4)and (6).
The bracket (13).
Screws (11), tighten to 6,1 ± 0,5 m.daN.
The nut (12), tighten to 4,5 ± 0,5 m.daN.
Fit the bearing shell (10).
Take away the workshop hoist.
Clip the fuel delivery and return pipes. Remove the tool
[7].
Couple:
The fuel delivery pipe
(12).
The fuel return pipe (1).
Coat the screw (8)with loctite FRENETANCH.
Refit the tool [6]and the screw (8)with the washer (22),
Tighten to 7 ± 0,2 m.daNand angular tighten to A = 60° ± 5°
[6].
Reposition and reclip the cooling hose.
Complete the refitting of components in reverse order to removal.
B1EP1A7CB1BP2R4CB1EP1ADC
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225
RFS
SPECIAL FEATURES OF THE TIMING
B1EP122C
Camshaft hub identification
Engine
RFSInlet
ExhaustHubs‘‘a’’ Engraving
B‘‘b’’Paint marking
BLUE

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

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