lock Citroen BERLINGO 2004 1.G Service Manual

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: 8HY 8HV
B1EP18YD
Checks (continued).
Refit the screw (8).
Rotate the crankshaft six times
(clockwise).
IMPERATIVE: Never rotate the engine backwards.
Peg:
The camshaft, using tool
[2](oil the pegs).
The fuel high pressure pump pulley (14), using tool [3]at «c».
WARNING:The magnetic track should show no signs of damage and should not be
approached by any source of magnetism.
Peg the crankshaft at
«b», using tool [3].
IMPERATIVE:Should it be impossible to peg the camshaft, check that the
offset between the hole in the camshaft pinion and the pegging hole is not
greater than 1 mm.Otherwise repeat the operation to position the timing belt
(see corresponding
operation)
.
C3

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197
CHECKING AND SETTING THE VALVE TIMING
Engines: 8HY 8HV
B1EP18VD
Setting the timing.
Perform the preliminary operations for checking the timing up to removing tool [1]at «a»for immobiling the
engine flywheel.
Refit screw
(8).
Rotate the crankshaft to bring the camshaft towards its pegging point.
Peg the camshaft, using tool
[2](oil the pegs).
WARNING: Do not press or damage the track which is the target for the engine speed sensor (14).
Peg the crankshaft at «b», using tool [3].
Remove:
The timing protector
(13).
The engine speed sensor
(14).
Slacken the screw
(12)of the tensioner roller, keeping it slack with the aid of a hexagonal spanner at
«c».
Detension the belt by pivoting the tensioner roller
(clockwise).
Remove the timing belt, commencing with the coolant pump pinion.
Peg the pulley
(15), using a 5 mmdiameter peg at «d».
C3

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199
CHECKING AND SETTING THE VALVE TIMING
Engines: 8HY 8HV
B1EP18XC
Setting the timing (continued).
Chec
ks (continued).
Reposition the timing belt, belt at «e»well tensioned, in the following order:
Guide roller
(17).
Camshaft pulley
(16).
Fuel high pressure pump pulley
(15).
Coolant pump pinion
(18).
Tensioner roller
(19).
Remove the
5 mmdiameter peg at «d».
Adjusting the fitting tension of the belt.
Action the tensioner roller (19)to align the marks «f»and «g», avoiding detensioning the timing belt,
with the aid of a male hexagonal spanner, at
«c».
If this is not successful, repeat the operation to tension the belt.Hold the tensioner roller in position
(19).
Tighten the tensioner roller, tightening to
3,7 ±0,3 m.daN.
Check the position of the tensioner roller
(the alignment of the marks «f»and «g»should be correct).
Remove tools
[2]and [3].
Turn the crankshaft
six rotations(clockwise).
C3

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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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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines: 9HZ 9HY
Refit the screw (10).
Rotate the crankshaft six times (clockwise).
IMPERATIVE: Never turn it backwards.
Peg the camshaft at «c», using tool [2](oil the peg).WARNING:The magnetic track should not show any sign of damage and should not be
approached by any other magnetic source.
Peg the crankshaft at
«d», using tool [3].
ESSENTIAL: Should it not be possible to peg the camshaft, check that the offset bet
ween the camshaft pinion hole and the pegging hole is not more than 1 mm.If it is
more,repeat the operation to position the timing belt
(see corresponding operation).
Note:
The index «e»of the dynamic tensioner roller should be centred in the interval «d»Check the correct positioning of the index «e».
If it is not correct, repeat the operation to tension the timing belt (see corresponding operation).
Remove tools [2]and [3].
B1EP1E4DB1EP1E5C
XSARA PICASSO

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ENGINE
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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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines: 9HZ 9HY
B1EP1E6D
Refit the screw (10).
Turn the crankshaft to bring the camshaft towards its pegging point.
Peg the camshaft at
«c», using tool [2](oil the pegs).WARNING: Do not press or damage the track of the engine speed sensor target
(13).
Peg the crankshaft at «e», using tool [3].
Remove:
The timing belt protector
(13).
The engine speed sensor (14).
Slacken the screw (15)of the tensioner roller, and keep it slackened using an allen
spanner at «d».
Detension the timing belt by pivoting the tensioner roller (clockwise).
Remove the timing belt, starting with the coolant pump pinion.
Checks.
ESSENTIAL: Just prior to refitting, proceed to the checks as below.
Check:
That the rollers and the coolant pump pulley turn freely (without play and without tight
spot).
That there are no signs of oil leaks (at the crankshaft and camshaft seals).
That there are no leaks of coolant fluid(at the coolant pump).
That the track of the engine speed sensor target (15)is not damaged or scratched.
Replace any components that are defective (if necessary).
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines: 9HZ 9HY
B1EP1E8C
Adjusting the timing belt tension.
Act on the tensioner roller (18)to align the marks «g»and «h», avoiding detensioning the
timing belt, using an allen spanner at «d».
Should this fail, repeat the operation to tension the timing belt.Hold the tensioner roller
(18).
Tighten the tensioner roller fixing nut to 3,7 ± 0,3 m.daN.
Check the position of the tensioner roller (the alignment of the marks «g»and «h»should
be correct).
Remove tools [2]and [3].
Rotate the crankshaft six times(clockwise).
IMPERATIVE:Never rotate the engine backwards.
WARNING:
Do not touch or damage the track of the target of the engine speed sensor (14).
Peg the crankshaft, using tool
[3].
Check the position of the tensioner roller (the alignment of the marks «g»and «h»should
be correct).
If this is not the case, repeat the operation to tension the timing belt.
Peg the camshaft pulley, using tool
[2].
IMPERATIVE: Should it be impossible to peg the camshaft, check that the offset bet
ween the camshaft hole and the pegging hole is not more than 1 mm. If the offset is
too great, repeat the operation.
Remove tools [2]and [3].
XSARA PICASSO

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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine: WJY
Setting the timing (continued).
Peg the camshaft hub, using tool [4].
Peg the injection pump hub, using tool [3].
Slacken screws (5)and (6).
Slacken screw (9)of the tensioner roller (8).
Remove the timing belt.
Refitting. Retighten screws (5)and (6)by hand.
Turn the pinions (10)and (7)clockwise in order to place them at end of slots.
Fit the timing belt on the crankshaft. Hold the belt, using tool
[5].
Position the timing belt in the following sequence:
Guide roller
(11).
Injection pump pinion (7).
Camshaft pinion (10).
Coolant pump pinion
(12).
Tensioner roller (8).
B1EP16PDB1EP1EDCB1EP132C
XSARA
B1EP1EEC

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engine: WJY
B1EP1EDC
Setting the timing (continued).
NOTE:
If necessary, you can slightly rotate the pinions (10)and (7)anticlockwise in order to engage the belt.
The angular displacement value of the belt in relation to the pinions should not be more than half a tooth.
Remove tool
[5].
Act on the tensioner roller
(8)by its square «a», using tool [6]to check that the camshaft and injection
pump pinions can turn freely.
Position the belt tension instrument
[7]on the belt at «b».
Using tool
[6], act at «a»in the direction opposite to that of engine rotation, to obtain a tension value of
106 ± 2 SEEM units.
Tighten screws
(9), (5)and (6).
Remove tools
[7], [2], [3]and[4].
Rotate the crankshaft
8 timesin the normal direction of rotation.
Peg the flywheel, using tool
[2].
Peg the camshaft hub, using tool
[4].
Peg the injection pump hub, using tool
[3].
Slacken screws
(9), (5)and (6).
Position the belt tension instrument
[7]on the belt at «b».
Using tool
[6], act at «a»in the direction opposite to that of engine rotation, to obtain a tension value of
42 ± 2 SEEM units.
B1EP1EFC
XSARA