exhaust Citroen BERLINGO 2004 1.G Workshop Manual

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ENGINE
SPECIAL FEATURES TIGHTENING TORQUES (m.daN )
EnginesHFX KFV NFU
Cylinder head
Coolant outlet housing
in plastic
0,8 ± 0,2
in aluminium0,8 ± 0,2
Camshaft bearing caps (TU1JPTU3JP)
Tightening
2 ±0,2
Angular tightening44 °± 4°
Camshaft bearing caps (TU5JP4)
Tightening
2 ± 0,2
Angular tightening50°±5°
Inlet manifold0,8 ± 0,2
Exhaust manifold1,8 ±0,4
Valve rockers adjusting screw1,75 ± 0,25
Sparking plugs3
Camshaft pulley screw (TU1JPTU3JP)3,7 ± 0,2
Camshaft pulley screw (TU5JP4)4,5 ± 0,5
C2

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ENGINE
SPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engine8HX
Cylinder head
Camshaft bearing covers
Pretightening
0,3 ± 0,1
Tightening1 ± 0,1
Fixing of camshaft subassemblies on cylinder head
Pretightening
0,3 ± 0,1
Tightening1 ± 0,1
Exhaust manifold3 ± 0,3
Camshaft pulley
Pretightening
0,3 ± 0,1
Tightening4,3 ± 0,4
Engine flywheel
Flywheel
Pretightening
1,7 ±0,2
Tightening70°±5°
Clutch mechanism2 ± 0,2
C2

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ENGINESPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Crankshaft
Engine types HFX KFV NFU
Accessories drive pulley0,8 ± 0,2
Pinion fixing on crankshaft10 ± 1 2,5 ± 0,2
Cylinder block
Sump0,8 ± 0,2
Timing belt tensioner roller2 ± 0,2 2,2 ± 0,2
Accessories belt tensioner roller2 ± 0,2 2,5 ± 0,2
Alternator support fixing1,7 ±0,3
Alternator fixing on support3,7 ± 0,3
Cylinder head
Coolant outlet housing0,8 ± 0,2
Camshaft bearing cap
Tightening
2 ± 0,2 2 ± 0,2
Angular tightening44°±4°50° ± 5°
0,8 ± 0,2
Exhaust manifold1,7 ± 0,3 2 ± 0,2
Valve rockers adjusting screw1,75 ±0,25
Sparking plugs2,75 ± 0,25
Camshaft pulley screw8 ± 0,8
C3

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ENGINESPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Cylinder head
Exhaust manifold1,8 ± 0,2
Sparking plugs2,2 ± 0,2
VVT pulley cap4 ± 0,4
VVT control electrovalve0,8 ± 0,2
VVT inlet camshaft pulley screw
Pretightening
2 ± 0,2
Tightening6,1 ± 0,6
Exhaust camshaft pulley screw4,5 ± 0,4
Flywheel / Clutch
Engine flywheel6,7 ±0,6 (coat the screws with LOCTITE FRENETANCH)
Clutch mechanism2 ± 0,2
Lubrication circuit
Oil pressure switch2 ± 0,2
Oil pump0,9 ± 0,1
Cooling circuit
Coolant pump1 ± 0,1
Coolant outlet housing0,8 ± 0,1
C3

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ENGINESPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engines 8HX 8HW 8HZ
Cylinder head
Camshaft bearing covers
Pretightening0,5 ±
Tightening1 ±
Fixings of camshaft subassemblies on cylinder head
Pretightening0,5
Tightening1
Exhaust manifold2,5 ± 0,2
Valve cover2,5 ± 0,2
Camshaft pulley4,3 ±0,4
Flywheel
Flywheel
Pretightening1,7 1,7
Tightening70°±5° 75° ± 5°
Clutch mechanism 2 ± 0,2
Lubrication circuit
Oil pump assembly
Pretightening0,5 ± 0,06
Tightening0,9 ± 0,1
Coolant/oil heat exchanger1 ± 0,1
C3 C3 PLURIEL XSARA

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ENGINE
SPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engines8HV 8HY
Crankshaft
Bearing cap fixing screw
Tightening3 ± 0,3
Angular tightening140° ± 1°,4’
Crankshaft pullet hub
Angular tightening180°±5°
Cylinder block
Oil sump1 ±0,1
Timing belt tensioner roller 4 ± 0,4
Timing belt guide roller
2,5 ±0,2
Timing belt guide roller support
Cylinder head
Camshaft bearing cap cover
1 ±0,1
Inlet manifold
Exhaust manifold2,5 ± 0,2
Cylinder head cover Screws (M6) to 1 ± 0,2
Camshaft pinion4,3 ± 0,4
Fuel high pressure pump pinion 5 ± 0,5
C3

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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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155
CHECKING AND SETTING THE VALVE TIMING
Engines: KFX KFV NFU
Setting the timing (continued).
Engines:
HFXKFV.Refitting.
NOTE:Check that the pegs [1]and [2]are in place.WARNING:Respect the direction of fitting of the timing belt, the arrows «d»indicate the direction of rotation
of the crankshaft.Refit the timing belt.
Position the timing belt, belt
«e»well tensioned, in the following order:
Crankshaft pinion, hold the belt using tool [5].
Camshaft pulley. Coolant pump pulley.
Tensioner roller.
Remove the tools
[1], [2].
Engine:NFU.Fit the timing belt in position in the following order:
Inlet camshaft pulley. Exhaust camshaft pulley.
Guide roller.
Crankshaft pulley.
Position tool
[5].
Coolant pump pulley.
Dynamic tensioner roller.
Remove the tools
[1], [3]and [5].B1EP18RC
C2 C3 C3 PLURIEL

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161
CHECKING AND SETTING THE VALVE TIMING
Engine: NFU
Tools.
[1]
Belt tension measuring instrument: 4122 T.
[2]Flywheel locating peg: 4507 T.A
[3]Camshaft pulley locating peg, exhaust:4533 T.A C2 Tool kit 4507 T
[4]Camshaft pulley locating peg, inlet:4533 T.A C1
[5]Tensioning tool:4707 T.J
Checking the valve timing.
Peg the flywheel using the tool [2].
Peg the exhaust camshaft pulley [3].
Peg the inlet camshaft pulley [4].
Setting the valve timing. Peg the flywheel using the tool [2].
Peg the camshaft pulleys [3] and [4].

B1EP11CCB1EP11BC
XSARA

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163
CHECKING AND SETTING THE VALVE TIMING
Engine: NFU
Setting the valve timing.
Turn the two pulleys (1)clockwise to the end of the slots.
With the belt strip (e)fully tensioned, place the belt over the pulley, first exhaust side, then inlet side, while
ensuring that marks (b)and (c)on the belt are aligned with marks (f)on the pulleys.
Hold the belt in this position, and engage it over the water pump pinion and the tensioner roller.
Fit the tool
[1]on the belt at (e).
Rotate the roller (2) (using tool [5])in an anticlockwise direction, to obtain:63 SEEM units.
Tighten the roller (2)to 2 m.daN.
Tighten the six screws (5)to 1m.daN.
ESSENTIAL: Check that:
The camshaft pulleys (1) are not at the end of the slots (by removing a screw). The markings on the belt are aligned with the markings on the crankshaft and camshaft pulleys.
If not, repeat the setting procedure.
B1EP11GCB1EP11FC
XSARA