exhaust Citroen BERLINGO 2005 1.G Workshop Manual

Downloaded from www.Manualslib.com manuals search engine GENERAL
C41 - 2
XSARA3 - 4
XSARA PICASSO5 - 6
BERLINGO7 - 8
Operations following a repair: C49
C411 - 12
XSARA13 - 14
XSARA PICASSO15
BERLINGO16
Lubricants17 - 39
ENGINE
Specifications40 - 41
Tightening torques: engines all types42 - 147
Cylinder head tightening: all types148 - 150
Auxiliary drive belt152 - 153
Checking and setting the valve timing181 - 182
C4279
XSARA280
XSARA PICASSO281
Valve clearances282Checking the turbo pressure:
Xsara picasso (DW10ATED)295
Checking the air supply circuit: Xsara (DV4TD)
296
Checking the air supply circuit: C4 (DV6ATED4)297
Checking the air supply circuit: C4 (DV6TED4)298
Checking the air supply circuit: C4 (DW10BTED4)299 - 300
Checking the air supply circuit:
Xsara picasso (DW10TD/ATED)301
Checking the exhaust gas recycling circuit:
Xsara (DV4TD)302
Checking the exhaust gas recycling circuit:
Xsara picasso (DV6TED4)303
Checking the exhaust gas recycling circuit:
Xsara picasso (DW10TD/ATED)304
IGNITION
Sparking plugs305
CLUTCH - GEARBOX - TRANSMISSION
C4307 - 308
Xsara309 - 310
Xsara picasso311
CONTENTS
Vehicle
identification
Capacities
INJECTION
Checking the low pressure fuel supply
circuit: Xsara (DV4TD)283
Checking the low pressure fuel supply
circuit: C4 (DV6TED4/ATED4)284
Checking the low pressure fuel supply
circuit: Xsara Picasso (DV6TED4)285
Checking the low pressure fuel supply
circuit: C4 (DW10BTED4)286
Checking the low pressure fuel supply
circuit: Xsara (DW10TD)287
Checking the low pressure fuel supply
circuit: Xsara Picasso (DW10TD/ATED)288 - 289
Checking the turbo pressure: Xsara (DV4TD)
290
Checking the turbo pressure:
C4 (DV6TED4/ATED4)291
Checking the turbo pressure:
Xsara Picasso (DV6TED4)292
Checking the turbo pressure:
C4 (DW10BTED4)293
Checking the turbo pressure:
Xsara picasso (DW10TD)294
Checking the oil
pressureClutch
specifications
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ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)
Cylinder head
1 Inlet air pressure sensor 0,8 ± 0,12 Motorised butterfly housing fixing screws 0,8 ± 0,23 Coolant outlet housing screw 0,8 ± 0,24 Oxygen sensor 4,7 ± 0,7
Catalytic converter fixing nuts (*)
5Pre-tightening2 ± 0,2
Tightening4 ± 0,4
Check the tightening4 ± 0,46 Exhaust manifold nuts 1,8 ± 0,27 Exhaust manifold fixing stud 0,8 ± 0,1
Cylinder head bolts (*)
8Pre-tightening1,5 ± 0,2
Tightening2,5 ± 0,2
Angular tightening200° ± 5°9 Inlet manifold screws 0,8 ± 0,110 Valve cover screws (*) 0,9 ± 0,111 Camshaft bearing cap screws (*) 1 ± 0,112 Sparking plugs 2,25 ± 0,2
13Camshaft dephaser electrovalve fixing screws
0,8 ± 0,2
(VVT)
Engine: KFU
B1BP368P
(*) = IMPERATIVE: Respect the tightening sequence (see following page).
C4
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ENGINESPECIAL FEATURES - TIGHTENING TORQUES (m.daN)
Timing
34 Inlet camshaft dephaser plug (VVT) 3,2 ± 0,2
Inlet camshaft dephaser screw (VVT)
35Pre-tightening2 ± 0,2
Tightening6 ± 0,6
36 Guide roller screw 2,1 ± 0,2
37 Exhaust camshaft pulley screw 4,5 ± 0,4
38 Tensioner roller screw 2,1 ± 0,2
Engine: KFU
B1EP1GPD
C4
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ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)
Cylinder head1 Inlet air pressure sensor 0,8 ± 0,12 Motorised butterfly housing fixing screws 0,7 ± 0,13 Inlet manifold nuts 0,8 ± 0,24 Valve cover screws (*) 0,9 ± 0,15 Coolant outlet housing screw 0,8 ± 0,26 Thermostat fixing screw 0,8 ± 0,27 Oxygen sensor 4,7 ± 0,7
Catalytic converter fixing nuts (*)
8Pre-tightening1,8 ± 0,3
Tightening4 ± 0,4
Check the tightening4 ± 0,49 Exhaust manifold nuts 2,3 ± 0,510 Exhaust manifold fixing stud 0,8 ± 0,111 Lubrication plug 1,5 ± 0,2
Cylinder head bolts (*)
12Tightening2 ± 0,2
Angular tightening260° ± 5°13 Camshaft bearing cap screws (*) 0,9 ± 0,114 Inlet manifold fixing stud 0,8 ± 0,115 Engine coolant temperature sensor (CMM) 1,7 ± 0,116 Engine coolant temperature sensor (instrument panel) 1,7 ± 0,1
17 Sparking plugs 3 ± 0,1
Engine: NFU
B1BP362P
(*) = IMPERATIVE: Respect the tightening sequence (see following page).
C4
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ENGINESPECIAL FEATURES - TIGHTENING TORQUES (m.daN)
Cylinder head
Valve cover screws (*)
1Pre-tightening0,5
Tightening1,1 ± 0,1
2 Oxygen sensor 4,7 ± 0,5
3 Exhaust manifold nuts 3,5 ± 0,3
4 Coolant outlet housing fixing nuts 1 ± 0,1
5 Coolant outlet housing bolts 0,3
6 Motorised butterfly housing fixing screws 0,8 ± 0,1
7 Inlet manifold fixings 2,2 ± 0,4
8 Inlet manifold fixing studs 0,8 ± 0,2
Cylinder head bolts (*)
Pre-tightening 11,5 ± 0,1
Pre-tightening 25 ± 0,5
9Angular slacken360°
Tightening2 ± 0,2
Angular tightening285° ± 5°
10 Sparking plugs 2,7 ± 0,2
Engine: RFJ
B1BP35MP
(*) = IMPERATIVE: Respect the tightening sequence(see following page).
C4
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ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)
Cylinder head
11 Camshaft bearing cap screws (*)
Pre-tightening0,5
Tightening1 ± 0,1
12 Exhaust manifold fixing stud 0,8 ± 0,2
13 Coolant outlet housing fixing stud 0,8 ± 0,2
14 Engine coolant temperature sensor 1,7 ± 0,1
15 Inner timing cover screw 0,8 ± 0,1
16 Electrovalve fixing screw (VVT) 0,9 ± 0,1
Engine: RFJ
B1BP35MP
(*) = IMPERATIVE: Respect the tightening sequence(see following page).
C4
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ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)
Timing
Exhaust camshaft pulley screw
36Pre-tightening3 ± 0,5
Tightening8,5 ± 0,5
37 Cap 1,1 ± 0,1
Inlet camshaft pulley screw
38Pre-tightening2 ± 0,2
Tightening11 ± 1
39 Tensioner roller screw 2,1 ± 0,2
Guide roller screw
40Pre-tightening1,5 ± 0,1
Tightening3,7 ± 0,7
Engine: RFJ
B1EP1GJP
C4
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ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)
Cylinder head
Camshaft bearing cover 0,9 ± 0,1
Exhaust manifold 3,5 ± 0,3
Valve cover1,1 ± 0,1
Camshaft pulley
Pre-tightening3 ± 0,3
Tightening7,5 ± 0,7
Pulley on hub 2,1 ± 0,2
Timing pinion on crankshaft
Pre-tightening4 ± 0,4
Angular tightening53°±4°
Flywheel / clutch
Clutch mechanism 2 ± 0,2
Flywheel
Pre-tightening
(sequence 1,5,3,7,2,6,4,8)2 ± 0,2
Angular tightening(sequence 1,5,3,7,2,6,4,8)21°±3°
Engine: RFN
B1CP089C
XSARA - XSARA PICASSO
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ENGINESPECIAL FEATURES - TIGHTENING TORQUES (m.daN)
Cylinder head
Valve cover screws (*)
1Pre-tightening0,5
Tightening1,1 ± 0,1
2 Exhaust manifold stud 0,7 ± 0,1
Exhaust manifold nuts
3Tightening on heat shield2,5 ± 0,2
Tightening apart from on heat shield3,5 ± 0,3
4 Oxygen sensor 4,7 ± 0,5
5 Coolant outlet housing fixing (BSE)
Tightening of the nuts1 ± 0,2
Tightening of the screws1 ± 0,1
6 Thermostat fixing screw 0,8 ± 0,1
7 Coolant outlet housing fixing stud (BSE) 0,3 ± 0,1
8 Engine coolant temperature sensor 1,7 ± 0,1
9 Inlet manifold screws 2,2 ± 0,4
10 Motorised butterfly housing fixing screws 0,8 ± 0,1
Engine: RFN
B1BP34MP
(*) = IMPERATIVE: Respect the tightening sequence (see following page).
C4
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ENGINE
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)
Cylinder head
Cylinder head bolts (*)
1st pre-tightening1,5 ± 0,1
2nd pre-tightening5 ± 0,5
11Angular slackening360°
Tightening2 ± 0,2
Angular tightening285° ± 5°
Camshaft bearing cap cover screws (*)
12Pre-tightening0,5
Tightening1 ± 0,1
13 EGR valve screw 0,8 ± 0,1
14 Valve for injection of air to the exhaust 0,8 ± 0,2
15 Inlet manifold stud 0,8 ± 0,1
16 Inlet manifold fixing nuts 2,2 ± 0,5
17 Sparking plugs 2,7 ± 0,2
Engine: RFN
B1BP34MP
(*) = IMPERATIVE: Respect the tightening sequence (see following page).
C4
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