power steering Citroen BERLINGO 2004 1.G Workshop Manual

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GENERAL
LUBRICANTS TOTAL recommended oils
POWER STEERING OILS
ENGINE COOLANT FLUID
ALL TYPES
TOTAL FLUIDE ATX
TOTAL FLUIDE DAS
Special oil distributed by
CITROËN
Part No.: 9730 A1
Power steering
All countries
Very cold countries
All countriesCITROËN fluid
Protection: 35C°
2Litres
5Litres
20 Litres
210Litres
9979 70
9979 71
9979 769979 779979 72
9979 73
9979 749979 75 PackCITROËN Part No.
REVKOGEL 2000
GL YSANTIN G33

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ENGINE
[1]Belt tension measuring instrument:4122T
Tension the belt using the screw (2).
Tension should be:
102 ± 7 SEEM units.
Tighten the screws (1).
New belt
100 SEEM units.
Reused belt
AUXILIARY EQUIPMENT DRIVE BELT 2002
Alternator
Powerassisted steering Power steering and air con.With air conditioning
[1]
Belt tension measuring instrument:4122T
Tension the belt using the screw (4).
Tension should be:
102 ± 7 SEEM units.
Tighten the screws
(3).
New belt
100 SEEM units.
Reused belt75 SEEM units.
B1BP1B3CB1BP124CB1BP1B2CB1BP122C
Engine: KFW
XSARA

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ENGINE
AUXILIARY EQUIPMENT DRIVE BELT 2002
Sans Powerassisted steering.
Tools.
[1]
Belt tension measuring instrument: 4122T
Removal.
Loosen the screws (2).
Tighten the screw (1)until it is against its stop.
Remove the belt.
Refitting. Refit the belt.
Fit the tool [1]on the belt at "d".
Tighten the screw (1)to obtain:106 ±10 SEEM units. Tighten the screws (2)to 2 m.daN.
Remove the tool [1].
B1BP1SECB1BP1SDC
Engine: WJY
XSARA

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ENGINEXSARAAUXILIARY EQUIPMENT DRIVE BELT 2002
Sans Powerassisted steering With air conditioning.
Tools.
[1]
Belt tension measuring instrument: 4122T
Removal.
Loosen the screws (1).
Tighten the screw
(2)until it is against its stop.
Remove the belt.
Refitting.
Refit the belt.
Fit the tool
[1]at "e".
Tighten the screw
(2)to obtain:106 ±10 SEEM units.
Tighten the screws (1)to 2 m.daN.
Remove the tool
[1].
B1BP1SGCB1BP1SFC
Engine: WJY

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ENGINE
XSARA
AUXILIARY EQUIPMENT DRIVE BELT 2002
Powerassisted steering without air conditioning.
Tools.
[1]
Belt tension measuring instrument: 4122T
Removal.
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
Engine: WJY

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ENGINEAUXILIARY EQUIPMENT DRIVE BELT
Engine: WJY
Powerassisted steering without air conditioning (continued).
XSARA
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, using tool [1].
Tension should be 144 ± 3 SEEM units.
Remove the tool [1].
Start the engine and run it for 10 seconds.
Stop the engine.
Place the tool
[1]on the belt at "f".
Tension should be 130 ± 4 SEEM units.
Remove the tool [1].
B1BP1SJD

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ENGINE
XSARA
AUXILIARY EQUIPMENT DRIVE BELT 2002
Powerassisted steering with air conditioning.
Tools.
[1]
Dynamic tensioner peg: () 0188 H
[2]Belt tension measuring instrument: 4122T
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 mmsquare 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 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
Engine: WJY

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ENGINEAUXILIARY EQUIPMENT DRIVE BELT 2002
Powerassisted steering with air conditioning (continued).
Refitting.
Refit the belt.
Using a
7 mm squaredrive at "b", turn the roller (3), until the tool [1]located at "a"becomes
free.
Tighten the screw
(2).
Remove the tool
[1].
B1BP1SLC
Engine: WJY
XSARA

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201
CHECKING AND SETTING THE VALVE TIMING
Engines: 9HZ 9HY
B1BP304D
Tools.
[1]
Flywheel setting peg: ().0194.C
[2]
Camshaft setting peg:().0194.B
[3]
Crankshaft setting peg: ().0194.A
Checking and setting the timing.
Removing.
Raise and support the vehicle, wheels hanging.
Disconnect the positive and negative terminals of the battery.
Remove: The front RH wheel.
The front RH splashshield.
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).
XSARA PICASSO

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: 9HZ 9HY
Refitting.
Refit tool [1]at «b».
Remove the screw (10).
Refit:
The upper timing cover
(12).
The lower timing cover (11).
The accessories drive pulley (9).
The screw (10).
Tightening torqueScrew (10)Pretighten 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).
XSARA PICASSO
Couple:
The tube (2).
The exhaust line, tighten the clip to 2,5 ± 0,3 m.daN.
The fuel unions (1).
The air/air heat exchanger inlet and outlet pipes (3).
Connect the connector at «a».
Refit:
The accessories drive belt
(see corresponding operation).
The front RH splashshield
(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).