Engines Citroen BERLINGO 2004 1.G Workshop Manual

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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
XSARA XSARA PICASSO

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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
XSARA XSARA PICASSO

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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
XSARA XSARA PICASSO

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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
XSARA XSARA PICASSO

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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

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INJECTION
STANDARD
ALL TYPES
EMISSION STANDARDS
PSA
A/S PREngines ApplicableVehicles
ECE
R 15.04
ECE
R 15.05
W vp 15.05
Petrol
E.E.C.
APPLICATIONS
OBSERVATIONS
CHARACTERISTICS
Petrol
Diesel K
K’15.04
15.04
With oxygen sensor,
without catalytic converter Utility vehicles:
All Types
Private vehicles:
> 2 litres
• new models • existing models
10/89
imminent
01/10/88
01/10/89
Utility vehicle limits =
private vehicle limitsincreased by 25 %.
For private vehicles
and utility vehicles
in major export
Brussels directive 88/76
«Luxembourg Accords»
Replaced by 89/458
+ 91/441

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INJECTION
STANDARD
ALL TYPES
EMISSION STANDARDS
PSA
A/S PREngines ApplicableVehicles
US 83
Z
US 83
US 87
US 93
E.E.C.
APPLICATIONS
OBSERVATIONS
CHARACTERISTICS
Y US 87
Y2
US 93Petrol
Diesel DieselPetrol
DieselPrivate vehicles:
• certain nonEEC
European countries
• certain Export countries
Private vehicles:
• certain nonEEC
European countries
• certain Export coun
tries
Private vehicles:
• certain Export countriesCurrent
Adoption of U.S. standard
Adoption of U.S. standard
Adoption of U.S. standard Current
CurrentWith oxygen sensor and
catalytic converter forpetrol vehicles
With catalytic converter
and EGR

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INJECTION
STANDARD
ALL TYPES
EMISSION STANDARDS
PSA
A/S PREngines ApplicableVehicles
US 84
LDT
X1
US 84
US 87
LDT
US 90
LDT
E.E.C.
APPLICATIONS
OBSERVATIONS
CHARACTERISTICS
X2 US 87
X3
US 90Petrol
DieselPetrol
DieselPetrol
DieselPrivate vehicles:
• certain nonEECEuropean countries
• certain Export countries
Private vehicles:
• certain nonEEC
European countries• certain Export coun
tries
Private vehicles:
• certain nonEEC
European countries
• certain Export coun
triesCurrent
Adoption of the U.S.
standard for light utility
vehicles
Adoption of the U.S.
standard for light utility
vehicles
Adoption of the U.S.
standard for light utility
vehicles Current
Current

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INJECTION
STANDARD
Private vehicles:
< 6 seats and < 2.5 tonnes
• new models
• existing models
Utility vehicles:
< 3.5 tonnes Class 1:
• new models • existing models
Class 2/3:
• new models
• existing models
ALL TYPES
EMISSION STANDARDS
PSA
A/S PREngines ApplicableVehicles
EURO 2
(EURO
96)
L3
EURO 2
(EURO
96)
W3
E.E.C.
APPLICATIONS
OBSERVATIONS
CHARACTERISTICS
Petrol
Diesel
Petrol
Diesel
GasBrussels Directive 94/12
EURO 93 standard made
stricter
Brussels Directive 96/69
3 classes depending on
vehicle weight:Class 1 < 1250 kg
Class 2: 1250/1700 kg Class 3:1700 kgWith oxygen sensor and
reinforced catalytic
converter for petrolvehicles.
With catalytic converterand EGR for diesel
vehicles.With oxygen sensor and
reinforced catalytic conver
ter for petrol vehicles.
With catalytic converter
and EGR for dieselvehicles. 01/96

01/97
01/97 10/97
01/98 10/98
E.E.C.
95
E.E.C.
95

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INJECTION
STANDARD
Utility vehicles:
< 3.5 tonnes
Class 1:
• new models • existing models
Class 2/3:
• new models • existing models
Private vehicles:
All Types
• new models
• existing models
ALL TYPES
EMISSION ST ANDARDS
PSA
A/S PREngines ApplicableVehicles
EURO 3
(EURO
2000)
W3
EURO 4IF/L5
E.E.C.
APPLICATIONS
OBSERVATIONS
CHARACTERISTICS
Petrol
Diesel
Gas
PetrolBrussels Directive 98/69
EURO 2 standard (L3)
made stricter
Fiscal incentives
3 classes depending on
vehicle weight:Class 1 < 1305 kg Class 2:1305/1760 kg
Class 3: 1760 kg
Brussels Directive 99/102
EURO 3 standard (L4)
made stricter
Fiscal incentives With 2 oxygen sensors
and catalytic converter for
petrol vehicles.
With EOBD onboard
diagnosis. With 2 oxygen sensors
and catalytic converter for
petrol vehicles.
With catalytic converter
and EGR for dieselvehicles.
With EOBD onboard
diagnosis.
01/200001/2001
01/2001 01/2002