9hy Citroen BERLINGO 2004 1.G Workshop Manual

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GENERAL
Emission standardL4
Type codeCH 9HZC CH 9HYB CH RHYB
Engine type9HZ(*)9HY (**)RHY
Cubic capacity (cc)1560 1997
Fiscal rating (hp)65
Gearbox typeBE4/5L BE4/5L
Gearbox ident.plate20 DM 6220 DL 65
IDENTIFICATION OF VEHICLES
Diesel
2.0 HDi
Océanic Leader Pack Exclusive 1.6 HDi 16V
XSARA PICASSO
(*) = With particle filter (FAP).(**) = Withort particle filter (FAP).

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Engine with filter element
Bandween min. and max.
5speed gearbox
Automatic gearbox
After drainage
Hydraulic or brake circuit
Cooling system
Fuel tank capacity
NFV 6FZ RFN 9HZ 9HY RHY
34,253,75 4,5
1,5 1,7 1,55 (3) 1,4
1,81,8
63
0,58 litres
5,8 (1) and (2) 6,5 (1) and (2) 11 11 (1) and (2)
55 60
XSARA PICASSO
CAPACITIES (in litres)
Diesel
P etrol
XSARA PICASSO
1.6i1.8i 16 V 2.0i 16V 1.6 16V HDi
(1)= With air conditioning
(2)= Withort air conditioning
(3) = RPO 9884 = Restyled XSARA PICASSO. ESSENTIAL: Systematically check the oil level using the oil dipstick.
AUTO.
36
GENERAL
2.0 HDi

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ENGINEENGINE SPECIFICATIONS
Engines: 9HZ 9HY WJY RHU RHZ
Diesel
All types
1.6 HDi 16V 2.0 HDi1.9 D
Vehicle
Emission standard
Engine typeCubic capacity (cc)
Bore / StrokeCompression ratio
Power ISO or EEC KW rpm
Power DIN (HP rpm)
Torque ISO or EEC
(m.daN rpm)Xsara II
Xsara Picasso Xsara II Berlingo II Xsara Picasso Xsara II
Berlingo II
L4
9HZ 9HY WJY RHY RHZ
1560 1868 1997
88,3/75 82,2/88 85/88
18/1 23/1 17,6/1
804000514600 664000 804000
1104000 714600 904000 1094000
24,52000 12,52500 10,52500 20,51900 251750

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ENGINE
SPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engines: 9HZ 9HY
Torque reaction rod
1 : 5,4 ± 0,8
2 : 5,4 ± 0,8
13 : 6 ± 0,9
LH upper engine support
3 : 2,1 ± 0,2
4 : 5 ± 0,5
LH lower engine support
5 : 2,1 ± 0,2
6 : 5,7 ± 0,8
RH lower engine support
7 : 5,5 ± 0,5
RH engine support
8:4,5 ±0,4
9 : 4,5 ± 0,6
10:2,5 ±0,6
11:2,1 ± 0,2
12 : 6,1 ± 0,6
B1BP2Z4P
XSARA PICASSO

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ENGINESPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engines9HZ 9HY
Crankshaft
Bearing cap fixing screw
Pretightening1 ± 0,2
Slackening180°
Tightening3 ± 0,3
Angular tightening140°
Con rod screws
Tightening1 ±0,1
Angular tightening100 ±5°
Accessories drive pulley
Pretightening3,5 ± 0,4
Angular tightening190 ± 5°
Cylinder block
Sump 1,3 ± 0,1
Timing belt guide roller3,7 ± 0,3
Timing belt tensioner roller2,7 ± 0,2
XSARA PICASSO

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ENGINE
SPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engines9HZ 9HY
Cylinder head
Camshaft bearing covers
Pretightening0,5 ± 0,1
Tightening1 ± 0,1
Exhaust manifold 3 ± 0,3
Camshaft pulley
Pretightening2 ± 0,2
Angular tightening50 ±5°
Cylinder head
Pretightening2 ± 0,2
Tightening4 ± 0,5
Angular tightening260 ± 5°
EGR valve1 ±0,1
Flywheel Clutch
Flywheel
Pretightening3 ± 0,3
Angular tightening90 ±5°
Clutch mechanism2 ± 0,2
XSARA PICASSO

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ENGINESPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engines9HZ 9HY
Lubrication circuit
Oil pump assembly
Pretightening0,5 ± 0,1
Tightening0,9 ± 0,1
Oil/coolant heat exchanger 1 ± 0,2
Turbocharger lubrication pipe3 ± 0,5
Diesel injection circuit
Injector fixing flange nut
Pretightening4 ± 0,1
Angular tightening65° ± 5°
Fuel high pressure common injection rail on engine block 2,2 ± 0,2Union on fuel high pressure common injection rail
Pretightening1,7 ±0,2
Tightening2,2 ±0,2
Diesel injection pump on support2,2 ± 0,2
Union on diesel injector
Pretightening2 ± 0,5
Tightening2,5 ±0,3
XSARA PICASSO

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XSARA PICASSO
ENGINE
SPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engines9HZ 9HY
Diesel injection circuit
Diesel injection pump pulley5 ± 0,5
Union on fuel high pressure pump
Pretightening2 ± 0,5
Tightening2,5 ± 0,3
Cooling circuit
Coolant pump
Pretightening0,3 ± 0,1
Tightening0,9 ±0,1
Coolant outlet housing
Pretightening0,3 ± 0,1
Tightening0,7 ±0,1

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ENGINE
CYLINDER HEAD
Identification of cylinder head gasket
Engine types SupplierPiston
standproud
(mm)Thicknesss
(mm)No. of notches at
“d”No. of notches at
“e”
0,685 to 0,734 1,35 1
0,533 to 0,6341,252
9HZ 9HYFEDERAL 0,635 to 0,684 1,30 3 3
MOGUL 0,735 to 0,784 1,40 4
0,785 to 0,8861,455
B1DP1HOD
Engines: 9HZ 9HY
Type of gasket:Metallic multilayer
«d»Thickness reference.
«e»Engine reference.
XSARA PICASSO

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ENGINECYLINDER HEAD
Engines: 9HZ 9HY
X =MAX. reusable length
Pretightening: 2 ± 0,2 m.daN
Tightening: 4 ± 0,4 m.daN
Angular tightening: 260° ± 5°
(use engine oil or
Molykote G Rapid Plus)
.
Pass a tap into the holes in the
cylinder block.
B1DP1DBC
B1DP1CLC
9HZ 9HY
9HZ 9HY
X = 147 mm Cylinder head tightening (m.daN) One Cylinder head bolts
XSARA PICASSO
NOTE:Retightening of the cylinder head
after a completed repair is prohibited.
The cylinder head gasket is dryfitted.