C15-BERLINGO_2005

VERY IMPORTANT

As the booklet is constantly re-edited, this one only covers vehicles for thisparticular model year.

It is therefore necessary to order a new booklet each year and RETAIN THEOLD ONES.

CORRESPONDENCE TABLE FOR PETROL ENGINES

TU XU EW

1 3 5 10

Engine familiesJP JP4 J2U J2U/K J4

1.1i 1.4i 1.6i 16V 2.0i 2.0i 16V

Engine families HFX KFW NFU RFL R6G RFN

Berlingo X X X

Dispatch X

Relay X X

CORRESPONDENCE TABLE FOR DIESEL ENGINESDV DW SOFIM

6 8 10 12

ATED

ATED B TD BTED CTED UTD ATED4 UTED TD

BTED+

1.6 16V1.9D 2.0HDi

2.0 8S 2.0 16V 2.2 8S2.8 TD 2.8HDi

HDi HDi HDi HDi

Engine families 9HZ WJY RHY RHX RHZ RHV RHW 4HY 8140.43 8140.43S

C15 X

BERLINGO X X X

DISPATCH X X X X

RELAY X X X X

Engine families

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UTILITY VEHICLES

C15-BERLINGODISPATCH RELAY 2005

UT

ILIT

Y V

EH

ICLE

S

CAR 000 0212005AC/DTAV/PRME/MMCB/MMEC

Méthodes Mécaniques� «The intellectual property rights relating to the technical information contained in this document belongexclusively to the manufacturer. Reproduction, translation or distribution in whole or in part without priorwritten authorisation from the manufacturer is forbidden».

"The technical information contained in this document is intended for the exclusive use of the trained personnelof the motor vehicle repair trade. In some instances, this information could concern the security and safety ofthe vehicle. The information is to be used by the professional vehicle repairers for whom it is intended and theyalone would assume full responsibility to the exclusion of that of the manufacturer».«The technical information appearing in this brochure is subject to updating as the characteristics of eachmodel in the range evolve. Motor vehicle repairers are invited to contact the CITROËN network periodically forfurther information and to obtain any possible updates".

Couv VU-2005 10/11/05 11:55

PRESENTATION

THIS HANDBOOK summarises the specifications, adjustments, checks and special features of CITROEN utility vehicles, not including PRIVATE vehicles for which there exist separatehandbooks.

The handbook is divided into groups representing the main functions :

GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - AIR CONDITIONING.

In each section, the vehicles are dealt with in the following order: C15 – BERLINGO – DISPATCH - RELAYand all models where applicable.

The information given in this handbook is based on vehicles marketed in EUROPE.

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IMPORTANT

If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into account when preparing futurepublications. For example :

– INSUFFICIENT INFORMATION– SUPERFLUOUS INFORMATION– NEED FOR MORE DETAILS

Please send your comments and suggestions to :

CITROEN U.K. Ltd.221, Bath Road,SLOUGH,SL1 4BA. U.K.

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GENERAL

C15 1 - 2

Berlingo 3 - 4

Dispatch 5 - 6

Relay 7 - 10

C15 12

Berlingo 13

Dispatch 14

Relay 15

Lubricants 16 - 38

ENGINE

Specifications 39 - 40

Tightening torques : engines all types 41 - 75

Cylinder head tightening : all types 76 - 79

Auxiliary drive belt 80 - 81

Checking and setting the valve timing 106 - 107

Checking the oil pressure 172 - 173

Valve clearances 174

Checking the air supply circuit : Berlingo (DV6ATED4) 188

Checking the air supply circuit : Dispatch (DW10TD) 189

Checking the air supply circuit : Relay (DW10UTD) 190

Checking the air supply circuit : Relay (DW12UTED) 191

Checking the air supply circuit : Relay (SOFIM 2.8 HDi) 192

Checking the exhaust gas recycling circuit : Berlingo, Dispatch, Relay 193

Checking the exhaust gas recyclingcircuit : Relay 194

IGNITION

Sparking plugs 195

CLUTCH-GEARBOX-TRANSMISSION

Speedometer 196C15 197Berlingo 198

CONTENTS

Vehicleidentification

Capacities

INJECTIONChecking the low pressure fuel supply circuit : C15 (DV6ATED4) 175

Checking the low pressure fuel supply circuit : Berlingo Dispatch (DW10TD) 176 - 177

Checking the low pressure fuel supply circuit : Relay (DW10UTD) 178 - 179

Checking the low pressure fuel supply circuit : Relay (DW12UTED/SOFIM) 180 - 181

Checking the turbo pressure : Berlingo (DW10TD) 182

Checking the turbo pressure : Dispatch (DW10ATED) 183

Checking the turbo pressure : Relay (DW10UTD) 184

Checking the turbo pressure : Relay (DW12UTED) 185

Checking the turbo pressure : Relay (SOFIM 2.8TD) 186

Checking the turbo pressure : Relay (SOFIM 2.8 HDi) 187

Clutchspecifications

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CLUTCH-GEARBOX-TRANSMISSION

Dispatch 199

Relay 200

Specifications : Manual / automatic gearbox : all types 201 - 203

Tightening torques : Manual gearboxes 204 - 217

Manual gearbox controls: all types 218 - 227

Recommendations/precautions :AL4 automatic gearbox 228 - 231

Tightening torques : AL4 gearbox 232 - 234

AL4 automatic gearbox controls 235 - 237

Recommendations/precautions :4 HP 20 automatic gearbox 238

Tightening torques : 4 HP 20 gearbox 239 - 240Shift lock : 4 HP 20 gearbox 241 - 244

Filling / topping-up : 4 HP 20 gearbox 245 - 246

Driveshafts 247

BRAKESBrake specifications : C15 278Tightening torques : brakes 279Adjusting the brake limiter 280Adjusting parking brakes 281Bleeding the brakes 282Brake specifications : Berlingo 283 - 288Tightening torques : brakes 289Checking/adjusting the compensator 290 - 291Adjusting parking brakes 292Bleeding the brakes 293Brake specifications : Dispatch 294 - 297Manual adjustment of the compensator 298Checking/adjusting the compensator 299Adjusting parking brakes 300Brake specifications : Relay 301 - 302Adjusting parking brakes 303 - 306Draining, filling and bleeding the braking circuit

307 - 310

AIR CONDITIONINGR134.a : quantities 311

CONTENTSAXLES - SUSPENSION – STEERING

Axle geometry : C15 248 - 250

Tightening torques : front axle : C15 251

Tightening torques : rear axle : C15 252

Tightening torques : power steering : C15 253 - 254

Axle geometry : Berlingo 255 - 258

Tightening torques : front axle : Berlingo 259

Tightening torques : rear axle : Berlingo 260

Suspension : Berlingo 261 - 262

Tightening torques : power steering : Berlingo 263 - 264

Axle geometry : Dispatch 265 - 266

Tightening torques : front axle : Dispatch 267 - 268

Tightening torques : rear axle : Dispatch 269

Manual steering : Dispatch 270

Tightening torques: power steering: Dispatch 271

Axle geometry : Relay 272

Tightening torques : front axle : Relay 273 - 274

Tightening torques : rear axle : Relay 275

Tightening torques : power steering : Relay 276 - 277

Clutchspecifications

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AIR CONDITIONING

Compressor lubricant 314 - 315

Checking the efficiency of the circuit 316 - 325

Air conditioning circuit : Berlingo 326 - 327

Air conditioning circuit : Dispatch 328 - 330

Air conditioning circuit : Relay 331 - 332

CONTENTS

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IDENTIFICATION OF VEHICLES

E1AP079D

(1) RP organisation no.

(2) Chassis no.

(3) Paint code

(4) Manufacturer’s plate

(5) 01/02/99 � Label- Tyre pressures.- RP organisation no.- Paint code

(6) Model year

(7) Gearbox identification reference

(8) Engine plate

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C15

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Structure Family (1) Version (2) Variant (3)

VD Family (1) VD C 15 VV Van 600 Kg Familiale Spain B

VD WT/B VV Version (2) VW Van 765 Kg

/B Variant (3) VY Deepened cab

WT Familiale N1

Engine Depollution

WJY 1.9 D DW8B W4

IDENTIFICATION OF VEHICLESType approval

C15

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3

IDENTIFICATION OF VEHICLES BERLINGO

E1AP0AMD

A – Chassis stamp, cold stamp

B - Manufacturer’s vehicle plate

C - LabelRPO No.Paint colour codeTyre pressures

D – Gearbox identification reference – factory serial no.

E – Engine legislation type – factory serial no.

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Structure Version (4)G Family (1) Depollution levelsJ Bodywork (2) L3

L4 Euro IVUS

OthersK Alcohol

GJ KFWC KFW Engine (3) W3 83/87 K' L3/L4 Euro IV/IF C Version (4) Manual 5-speed gearbox A B C P V 5 8 1

/IF Variant (5) Manual 4-speed gearbox E F R W 6 9 2Family (1) Manual 6-speed gearbox G H S X 3

G Berlingo Automatic 6-speed gearbox D J N UBody shape (2) Axle and/or gearbox gears K L T Y 7 0 4

B Van 600 Kg Other possible combinations MC Van 800 Kg No gearbox ZE Floor cab

Engine (3) Variants (5)HFX 1.1i TU1JP 2 sliding side doors as standard for 800 kg (WJY) PLCKFW 1.4i TU3JP Multi-function roof as standard for MPV WJY PMFNFU 1.6i 16V TU5JP4 Without FAP SF9HX 1.6 16V HDi DV6ATED4 Fiscal incentives IFWJY 1.9 D DW8B 4x4 DANGEL DGLRHY 2.0 HDi DW10TD Downgraded depollution D

Dual fuel LPG GLDual fuel CNG GNSTT2 (Stop and Start) SVan Turkey TRVan Spain ESMPV/Van 5-seater PL


BERLINGO

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DISPATCHIDENTIFICATION OF VEHICLES

E1AP0D0D

1 Vehicle identification N°.

2 RP organisation no.

3 Paint code.

4 Manufacturer’s plate.

5 Engine plate.

6 Gearbox identification reference.

7 - from 01/11/2003 �Label- Tyre pressures.- RP organisation no.- Paint code.

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Structure Version (4)B Family (1) Depollution levels

BD D Number of seats (2) 15.04 Spécif 93/59 96/69 96/69 A 98/69 BRFNC/IF/IF RFN Engine (3) K US/CEE L/W L3/W3 L4/W4 L5/W5

C Version (4) Manual 4-speed gearbox/IF Variant (5) Manual 5-speed gearbox G A B C

Family (1) Manual 6-speed gearboxB Dispatch Automatic 3-speed gearbox

Number of seats (2) Automatic 4-speed gearbox H D E FA 5 seats Axle and/or gearbox gears KB 6 seats Manual 5-speed gearbox for South AmericaC 7 seats No gearboxD 8 seatsE 9 seatsH 2 seats, european-specific multi-stage TAXIJ 7 seats, if different form the base «C» (AF)

Engine (3) Variants(5)RFN 2.0i 16V EW10J4 Entreprise convertible TWJY 1.9 D DW8B Integral alternator-starter (ADIN) ADRHX DW10BTED Without FAP SF

DW10ATED4 Fiscal incentives IFRHZ

2.0 HDiDW10CTED Piloted manual gearbox PDW10BTED+ Downgraded depollution D (Private vehicle or Van TD (Van Convertible)

RHW 2.0 16V HDi DW10ATED4 LPG dual fuel LPG (Cylindrical tank) LPG (Ring-shaped tank)STT2 (Stop and start) SVan Spain ES


DISPATCH

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RELAYIDENTIFICATION OF VEHICLES (4 X 2)

E1-P02UD

(1) Gearbox identification reference.

(2) Manufacturer’s name plate.

(3) Engine plate.

(4) Paint code (on bonnet).

(5) Chassis N° (cold stamp on body).

(6) Production N°.

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IDENTIFICATION OF VEHICLES (4 X 4)RELAY 4 X 4

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E1-P02VD

(1) Gearbox identification reference.

(2) Manufacturer’s name plate.

(3) Engine plate

(4) Transfer box

(5) Paint code

(6) Chassis N° (cold stamp on body).

(7) Production N°.

(8) Rear differential.

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Structure Transmission (4) Wheelbase (6)Z Family (1) M 5-speed manual W 4 x 4 A Short wheelbase (2850 mm)B Payload (2) A Automatic B Medium wheelbase (3200 mm)R Engine (3) Bodywork (5) C Long wheelbase (3700 mm)

ZBM Transmission (4) A Chassis cab G Super long wheelbase (4050 mm)

RMFA/SXF Bodywork (5) B Bare chassisA Wheelbase (6) C Floor cab

/SX Variant (7) D Platform cabFamily (1) F Van

Z Jumper / Relay G Platform double cabPayload (2) H Chassis double cab

A 11 Q C 18 Q M MinibusB 15 Q D GVW reduced N Van with raised sides

Engine (3) P Combi panorama 8/9 seater (CLUB)RFL

2.0XU10J2U R Combi 6/9 seater (CONFORT)

R6G XU10J2U/K W Minibus 10 seater (MERCOSUR)RHV 2.0 8S HDi DW10UTD4HY 2.2 8S HDi DW12UTED

8140.43 2.8 TD SOFIM 2.8 L TD8140.43S 2.8 HDi SOFIM 2.8 L HDi


RELAY 4 X 4

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Variant (7)Van versions

AX With EGR BXC Camping car Special with EGR BG LPG Van with raised roofBX Raised roof with EGR ZX Combi mixed N1 (5/6 seater) Italy AYC Camping car without EGRAM CNG Van AY Without EGR BYC Camping car without EGRAG LPG Van BY Raised roof without EGR

AXC Camping car with EGR BM CNG Van with raised roof Private vehicle versions

H Combi with raised roof M CNG Combi G LPG CombiMH CNG Combi with raised roof GH LPG Combi with raised roof

MINIBUS versionsAXx Bus 15 seater, 2 point seatbelts with EGR SX Bus GO with EGR, 12 seats, 2 pt belts (CH) AY3 Bus 15 seater, 2 point seatbelts without EGRAX2 Bus 14 seater, 3 point seatbelts with EGR SX Bus without EGR, 12 seats, 3 pt belts (CH) SX1 Bus with EGR, 13 seats, 3 pt belts (CH)AY Bus 15 seater, 2 point seatbelts without EGR AX1 Bus 16 seater, 2 point seatbelts with EGR SY1 Bus without EGR, 13 seats, 3 pt belts (CH)AY2 Bus 14 seater, 2 point seatbelts without EGR AX3 Bus 15 seater, 2 point seatbelts with EGRSX Bus Petrol 14 seater, 3 point belts (Switz.) AY1 Bus 16 seater, 2 point seatbelts without EGR

MINIBUS versions (with speed limiter)AX4 Bus 15 seater, 2 point seatbelts with EGR AY6 Bus 14 seater, 3 point seatbelts without EGR AY5 Bus 16 seater, 2 point seatbelts without EGRAX6 Bus 14 seater, 3 point seatbelts with EGR AX5 Bus 16 seater, 2 point seatbelts with EGR AY7 Bus 15 seater, 3 point seatbelts without EGRAY4 Bus 15 seater, 2 point seatbelts without EGR AX7 Bus 15 seater, 3 point seatbelts with EGR


RELAY 4 X 4

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Draining methods.

Oil capacities are defined according to the following methods.

CAPACITIES (in litres)

Draining of the engine lubrication system by GRAVITY

Place the vehicle on horizontal ground (in the high position if hydro-pneumatic suspension).

The engine should be hot (oil temperature 80°C).

Drain the sump by gravity.

Remove the oil filter cartridge (time for draining and drip-drip = 15 minutes approx.).

Refit the cap with a new seal.

Refit a new oil filter cartridge.

Refill the engine with oil (see table for oil capacity).

Start the engine to fill the oil filter cartridge.

Stop the engine (allow to stabilise for 5 minutes).

Draining of the engine lubrication system by SUCTION

Place the vehicle on horizontal ground (in the high position if hydro-pneumatic suspension).

The engine should be hot (oil temperature 80°C).

Remove the oil by suction through the dipstick tube.

Remove the oil filter cartridge.

Maintain the suction of oil in the sump (15 minutes approx.).

Refit a new oil filter cartridge.

Refill the engine with oil (see table for oil capacity).

Start the engine to fill the oil filter cartridge.

Stop the engine (allow to stabilise for 5 minutes).

WARNING : Remove the suction container before starting the engine

ESSENTIAL : Systematically check the oil level using the oil dipstick.

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Engine type

Engine with filter change

Between Min. and Max.

5-speed gearbox

Brake circuit

Cooling system

Fuel tank capacity

1.9 D

WJX4,51,5

2

8

47


Diesel

C15

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BERLINGOCAPACITIES (in litres)

1.1i 1.4i 1.6i 16V 1.6 16V HDi 1.9 D 2.0 HDi

HFX KFW NFU 9HZ WJY RHY

3 3,25 3,75 4,51,5 1,55 1,2 1,4

2 1,8 2 1,8With ABS = 0,45 Without ABS = 0,36

8 9

55 60

Petrol

Engine plate



5-speed gearbox

Hydraulic brake circuit

Cooling system

Fuel tank capacity

Diesel

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Engine type



5-speed gearbox

Automatic gearbox

after drainage

Brake circuit

Cooling system

Fuel tank capacity

2.0i 16V1.9 D

2.0 HDi2.0 16V(2) (3) (4) (5)

HDiDW10ATED BTED CTED ATED BTED CTED

RFN WJY RHZ RHX RHZ RHZ RHX RHZ RHW4,25 4,5 5,5 4,75

1,7 1,4 [1,3 (1)] 1,4 1,9

1,8 1,8

8

30,5 LITRE

7 9 8,5

80


Diesel

(1) = Vehicle with aircon.(2) = Up to RPO 9869 – Versions : panel van, glazed van and floor cab.(3) = New Look JUMPY / DISPATCH(4) = From RPO 9870(5) = Oil sump with increased capacity, yellow identification label on filler neck.

DISPATCH

Petrol

Auto.

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Engine type



5-speed gearbox

Automatic gearbox

after drainage

Brake circuit

Cooling system

Fuel tank capacity

2.0i 2.0 8V HDi 2.2 8V HDi 2.8 TD 2.8 HDi

(1) (2)

RFL R6G RHV RHV 4HY 4HY 8940.43 8140.43S

4,75 4,50 5,25 6,25 5,25 6,25 5,5 7

1,5 22,7 (after draining)

8,5

0,59, for 11Q and 15Q 0,62 for 18Q9 10,5 11,1 (with aircon) 10

80

RELAYCAPACITIES (in litres)

Diesel

(1) (2) = Oil sump with increased capacity, yellow identification label on valve cover

Auto

Petrol

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LUBRICANTS - TOTAL recommended oils

Evolutions (YEAR 2004).CITROËN C4

Petrol engine versions except 2.0 i 16V 180 hp (132 kW) :Normal maintenance interval : 30 000 km (20 000 miles).Severe maintenance interval : 20 000 km (12 000 miles).

Petrol engine version 2.0L i 16V 180 hp (132 kW) :Normal maintenance interval : 20 000 km (12 500 miles).Severe maintenance interval : 15 000 km (10 000 miles).

Diesel engine versions : WARNING : Vehicles HDi FAP (*) do not accept the energy economyoil TOTAL ACTIVA FUTUR 9000 5W30 for France, TOTAL QUARTZFUTURE 9000 5W30 outside France .

DV6 engines :Normal maintenance interval : 20 000 km (12 500 miles)Severe maintenance interval : 15 000 km (10 000 miles)DW engines:Normal maintenance interval : 30 000 km (20 000 miles)Severe maintenance interval : 20 000 km (12 000 miles)

New Look CITROËN C5Petrol engine versions:Normal maintenance interval : 30 000 km (20 000 miles).Severe maintenance interval : 20 000 km (12 000 miles).

Diesel engine versions:

WARNING : Vehicles HDi FAP (*) do not accept the energy economyoil TOTAL ACTIVA FUTUR 9000 5W30 for France, TOTAL QUARTZFUTURE 9000 5W30 outside France.

DV6 engines:Normal maintenance interval : 20 000 km (12 500 miles)Severe maintenance interval : 15 000 km (10 000 miles)DW engines :Normal maintenance interval : 30 000 km (20 000 miles)Severe maintenance interval : 20 000 km (12 000 miles)

ESSENTIAL : For all vehicles with a 30 000 km (20 000 miles) mainte-nance interval, use exclusively TOTAL ACTIVA/QUARTZ 7000 or 9000or any other oils offering identical specifications to these.These oils offer specifications that are superior to those defined bynorms ACEA A3 OR API SJ/CF.Failing this, it is essential to adhere to the maintenance programmescovering severe operating conditions.

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Use of oil grade 10W40It is possible to use the semi–synthetic oil 7000 10W40 on HDi and HDiFAP vehicles.

WARNING : To avoid difficulties when starting from cold (< 20°C), use5W40 oil.For more details, see the oil usage table(paragraph 3.3).Commercial description for energy economy oilTOTAL ACTIVA FUTUR 9000 5W30 (France only).TOTAL QUARTZ FUTUR 9000 5W30 (except France).The exclusions for use of this oil are the following :XSARA VTS 2.0 16V (XU10J4RS)JUMPER/RELAY 2.8 HDi and 2.8 TDi (SOFIM engine)HDi FAP vehiclesCITROËN C3 HDi 16V (DV4TED4)CITROËN C8 2.2i (EW12J4)CITROËN C4 and C5 2.0i (EW10A)CITROËN C4 (EW10J4S)Engine oil normsCurrent normsThe classification of these engine oils is established by the following reco-gnised organisations : - S.A.E : Society of Automotive Engineers.- API : American Petroleum Institute.- ACEA : Association des Constructeurs Européens d’Automobiles

S.A.E. Norms - Table for selection of engine oil gradeSelection of engine oil grades recommended for climatic conditions in coun-tries of distribution (see table, paragraph 3.3).Evolution of the norms to 01/01/2003ACEA 2003 normsThe meaning of the first letter has not changed, it still corresponds to the typeof engine :

A : petrol and dual fuel petrol / LPG engines.B : diesel engines.

The figure following the first letter corresponds to the type of oil:3 : high performance oils.4 : oils specifically for direct injection diesel engines.5 : very high performance oils permitting lower fuel consumption, specific todirect injection diesel engines.Examples : ACEA A3 : high performance oils specifically for petrol and dual fuel petrol /LPG engines ACEA A/B : blended oils giving very high performance for all engines, alsopermitting better fuel economy, specifically for direct injection diesel engines NOTE : From 01/01/2003 there is no longer any reference to the year ofcreation of the norm, (Example : ACEA A3/B3 98 becomes ACEA A3/B3).

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LUBRICANTS - TOTAL recommended oilsAPI NORMS :The meaning of the first letter has not changed, it still corresponds to thetype of engine : S : petrol and dual fuel petrol / LPG engines.C : diesel engines.The second letter corresponds to the degree of evolution of the oil(ascending order).Example : Norm SL is more severe than norm SJ, corresponding to ahigher level of performance.Recommendations.ESSENTIAL : To preserve engine performances, all engines fitted inCITROEN vehicles must be lubricated with high quality oils (synthe-tic or semi-synthetic).CITROËN engines are lubricated at the factory with TOTAL oil ofgrade S.A.E 5W-30.TOTAL oil of grade S.A.E 5W-30 allows improved fuel economies(approx 2.5%).The oil 5W30 is used only for the following engines (Year 2004) : - XU10 J4RS : XSARA VTS 2.0i 16V (3-door)- SOFIM : JUMPER / RELAY 2.8 TDi and 2.8 HDi.- HDi : With particle filter (FAP).- DV4 TED4 : CITROËN C3 1.4 16V HDi.- EW 12J4 : CITROËN C8 2.2i.- EW 10A : CITROËN C4 and C5 2.0i.- EW10J4S engine : CITROËN C4

WARNING : CITROËN engines prior to model year 2000 do not haveto be lubricated with oils adhering to the norms :ACEA AI-98 and API SJ/CF EC or current norms ACEA A5/B5.

Denomination of TOTAL oils according to country of marketing :TOTAL ACTIVA (France only).TOTAL QUARTZ (outside France).

SummaryNorms to be respected for engine oils (year 2004)

Year Engine types concernedACEA APINorms Norms

Petrol and LPG dual fuel enginesA3 or A5

2003(*)

SJ or SL

Diesel enginesB3, B4 or

CFB5 (*)

(*) It is essential not to use engine oils respecting these norms forXU10J4RS, SOFIM 2.8 TDi and SOFIM 2.8 HDi engines, HDi engineswith particle filter EW10A, EW12J4, DV4TED4.

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LUBRICANTS - TOTAL recommended oilsClasses and grades of TOTAL recommended engine oilsThe oils distributed in each country are suited to the local climaticconditions..

Blended oils for all engines (petrol, diesel and dual fuelpetrol/LPG) :

S.A.E. ACEA API norms norms norms

TOTAL ACTIVA 9000 A3/B3/TOTAL QUARTZ 9000

5W40B4

TOTAL ACTIVA FUTUR 9000 (*) SL/CFTOTAL QUARTZ FUTUR 9000 (*)

5W30 A5/B5

TOTAL ACTIVRAC 10W40 A3/B3

(*) Blended oils for all engines giving fuel economy.Oils for petrol, diesel and dual fuel petrol/LPG engines :

S.A.E. ACEA APInorms norms norms

TOTAL ACTIVA 7000TOTAL QUARTZ 7000

10W40

TOTAL QUARTZ 9000 0W40 A3 SL

TOTAL ACTIVA 7000TOTAL QUARTZ 7000

15W50

Oils specifically for diesel engines :

S.A.E. ACEA APInorms norms norms

TOTAL ACTIVA DIESEL 7000TOTAL QUARTZ DIESEL 7000

10W40B3 CF

TOTAL ACTIVA DIESEL 7000 15W50

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Huile TOTAL ACTIVA QUARTZ

Semi-synthetic 7000Synthetic 9000

0W40 5W30 5W40 10W40 15W50Hot countries

Temperate countriesCold countries

Engine types

EW10J4S (CITROËN C4) X

X

X

EW12J4 (CITROËN C8 2.2i 16V)

EW10A (CITROËN C4 and C5)

HDi engines with FAP (*)

Other HDi engines

SOFIM 2.8 HDi and 2.8 TDi (RELAY)

DV4 TED4 (C3 1.6 16V HDi)

Indirect injection diesel engines

Petrolengines

Dieselengines

Oil usage table

X

X

X

X

X XX

X XX

X XX

X (*)X

X XX

X XX

X XX

X X

(*) Do not use this oil in cold climatic conditions (temperature less than – 20°C).See the table below for the choice of TOTAL engine oil grades to be used according to the climatic conditions in the country of marketing.

X

Other petrol engines X

X

X

X

X

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E4AP006D

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FRANCE

Metropolitan FRANCE

Metropolitan FRANCE

New CaledoniaGuadeloupeSaint-martinReunion

9000 5W407000 15W50 7000 15W50

Martinique 7000 10W40 7000 10W50GuyanaTahitiMauritiusMayotte


Blended oils for all engines, supplied in bulk

ENGINE OILS

TOTAL ACTIVRAC Norms S.A.E : 10W40

TOTAL ACTIVA

Blended oils for all engines

9000 5W40FUTUR 9000 5W30 (*)

7000 10W407000 10W409000 5W40

Oils specifically for petrol and dual-fuel petrol / LPG

engines

Oils specifically for dieselengines

TOTAL ACTIVA DIESEL

(*) = Blended oils for all engines, giving fuel economy

22

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NE

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L

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EUROPE

7000 10W409000 0W40

7000 10W40

7000 10W409000 0W40

7000 10W409000 0W40

7000 10W40

7000 10W409000 15W40

7000 10W40

Germany

Austria

Belgium

Bosnia

Bulgaria

Cyprus

Croatia


ENGINE OILS

TOTAL QUARTZ



engines


TOTAL QUARTZ DIESEL

9000 5W40FUTUR 9000 5W30 (*) 7000 10W40


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EUROPE

7000 10W409000 0W407000 10W407000 15W40

7000 10W409000 0W40

7000 10W40

7000 10W407000 15W40

7000 10W409000 0W40

Denmark

Spain

Estonia

Finland

Great Britain

Greece

Holland


ENGINE OILS

TOTAL QUARTZ



engines


TOTAL QUARTZ DIESEL

9000 5W40FUTUR 9000 5W30 (*) 7000 10W40


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EUROPE

7000 10W409000 0W40

7000 10W40

7000 10W409000 0W40

7000 10W40

Hungary

Italy

Ireland

Iceland

Latvia

Lithuania

Macedonia


ENGINE OILS

TOTAL QUARTZ



engines


TOTAL QUARTZ DIESEL

9000 5W40FUTUR 9000 5W30 (*) 7000 10W40


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EUROPE

7000 10W407000 15W50

7000 10W40

7000 10W409000 0W40

7000 10W40

7000 10W409000 0W40

Malta

Moldavia

Norway

Poland

Portugal

Slovakia

Czech Republic


ENGINE OILS

TOTAL QUARTZ



engines


TOTAL QUARTZ DIESEL

9000 5W40FUTUR 9000 5W30 (*) 7000 10W40


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EUROPE

7000 10W407000 15W509000 0W40

7000 10W409000 0W40

7000 10W40

7000 10W409000 15W509000 0W40

Romania

Russia

Slovenia

Sweden

Switzerland

Turkey


ENGINE OILS

TOTAL QUARTZ



engines


TOTAL QUARTZ DIESEL

9000 5W40FUTUR 9000 5W30 (*) 7000 10W40


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EUROPE

7000 10W409000 0W40

Ukraine

Serbia-Montenegro


ENGINE OILS

TOTAL QUARTZ



engines


TOTAL QUARTZ DIESEL

9000 5W40FUTUR 9000 5W30 (*) 7000 10W40


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OCEANIA

AFRICA

7000 10W40AustraliaNew Zealand

Algeria, South Africa,Ivory Coast, Egypt,Gabon, Ghana, Kenya,Madagascar, Morocco,Nigeria, Senegal, Tunisia


ENGINE OILS

TOTAL QUARTZ



engines


TOTAL QUARTZ DIESEL

9000 5W40FUTUR 9000 5W30 (*) 7000 10W40

7000 10W407000 15W50

TOTAL QUARTZ



engines


TOTAL QUARTZ DIESEL

9000 5W40 7000 10W40


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CENTRAL AND SOUTH AMERICA

Argentina

Brazil

Chile

Cuba

Mexico

Paraguay

Uruguay


7000 10W407000 15W50

ENGINE OILS

TOTAL QUARTZ



engines


TOTAL QUARTZ DIESEL

9000 5W40 7000 10W40

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SOUTH-EAST ASIA

China

South Korea

Hong Kong

India – Indonesia

Japan

Malaysia

Pakistan


7000 10W507000 15W50

7000 10W40

7000 15W50

7000 10W407000 15W50

7000 15W50

ENGINE OILS

TOTAL QUARTZ



engines


TOTAL QUARTZ DIESEL

9000 5W40FUTUR 9000 5W30 (*)

9000 5W40

9000 5W40FUTUR 9000 5W30 (*)

9000 5W40

7000 10W40


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SOUTH-EAST ASIA

Philippines

Singapore

Taiwan

Thailand

Vietnam


7000 15W50

7000 10W407000 15W50

7000 15W50

ENGINE OILS

TOTAL QUARTZ



engines


TOTAL QUARTZ DIESEL

9000 5W40 7000 10W40

GE

NE

RA

L

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MIDDLE EAST

7000 15W50

7000 10W407000 15W50

7000 15W50

Saudi Arabia – Bahrain

Dubai

United Arab Emirates

Iran

Israel – Jordan – Kuwait – Lebanon

Oman – Qatar – Syria – Yemen


ENGINE OILS

TOTAL QUARTZ



engines


TOTAL QUARTZ DIESEL

9000 5W40 7000 10W40

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GEARBOX OILS

TOTAL TRANSMISSION BVNorms S.A.E : 75W80

Part No. : 9730 A2

TOTAL FLUIDE ATXTOTAL FLUIDE AT 42

Special oil distributed byCITROËN

Part No. : 9730 A6


Part No. : 9736 22

Manual and piloted manual gearboxes

MB3 automatic gearbox

4HP20 and AL4 autoactive automatic gearboxes

All countries


Part No. : 9980 D4

TOTAL TRANSMISSION X4Part No. : 9730 A7

AM6 autoactive automatic gearbox

Transfer box and rear axle

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LUBRICANTS - TOTAL recommended fluids

POWER STEERING OILS

ENGINE COOLANT FLUID

TOTAL FLUIDE ATX

TOTAL FLUIDE LDSSpecial oil distributed by r CITROËN

Part No. : 9979 A3

Power steering

All countries

All countriesCITROËN fluid

Protection : - 35C°

2 Litres

5 Litres

20 Litres

210 Litres

9979 70

9979 71

9979 76

9979 77

9979 72

9979 73

9979 74

9979 75

PacksCITROËN Part No.

REVKOGEL 2000GLYSANTIN G33

TOTAL FLUIDE DASpecial oil distributed by CITROËN

Part No. : 9730 A1Very cold countries

Power steeringAll vehicles except CITROËN C4 and C5

Power steeringCITROËN C4 and C5

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BRAKE FLUIDSynthetic brake fluid

CIRCUIT HYDRAULIQUE

WARNING : TOTAL FLUIDE LDS fluid cannot be blended with TOTAL LHM PLUS

WARNING : CITROËN C5 : Use exclusively TOTAL FLUIDE LDS suspension fluid.

All countries TOTAL HYDRAURINCAGE

All countries CITROËN fluid

0,5 Litre

1 Litre

5 Litres

9979 05

9979 06

9979 07

Packs CITROËN Part No.

Packs CITROËN Part No.Norm

Colour

All countries

TOTAL FLUIDE LDS

TOTAL LHM PLUS

TOTAL LHM PLUSVery cold countries

Orange 9979 A3

9979 A1

9979 A2Green

1 Litre

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SCREEN WASH FLUID

GREASINGGeneral use

All countries

Concentrated : 250 ml

Fluidready to

use

9980 33

9980 06

9980 05

ZC 9875 953U

ZC 9875 784U

ZC 9885 077U

9980 56

ZC 9875 279U

Packs CITROËN Part No.


1 Litre

5 Litres

Norms NLGI

2TOTAL MULTIS 2

TOTAL SMALL MECHANISMSAll countries

Note : NLGI = National Lubrificating Grease Institude.

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ENGINE OIL CONSUMPTION

I - Oil consumption depends on :- the engine type.- how run-in or worn it is.- the type of oil used.- the driving conditions.

II - An engine can be considered RUN-IN after:- 3,000 miles (5,000 km) for a PETROL engine.- 6,000 miles (10,000 km) for a DIESEL engine.

III - MAXIMUM PERMISSIBLE oil consumption for a RUN-IN engine.- 0.5 litres per 600 miles (1,000 km) for a PETROL engine.- 1 litre per 600 miles (1,000 km) for a DIESEL engine.DO NOT INTERVENE BELOW THESE VALUES.

IV - OIL LEVEL : The level should NEVER be above the MAX. mark on the dipstick after changing or topping up the oil.- This excess oil will be used up rapidly.- It will reduce the engine output and adversely affect the operation of the air circuits and gas recycling.

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EENGINE SPECIFICATIONSPetrol engines

Engine type

Cubic capacity (cc)

Bore / Stroke

Compression ratio

Power ISO or EEC KW - rpm

Torque ISO or EEC (m.daN - rpm)

1.1i 1.4i 1.6i 16V 2.0i 2.0i 16V

HFX KFW NFU RFL R6G RFN

1124 1360 1587 1998 1997

72/69 75/77 78,5/82 86/86 85/88

10,5/1 11/1 9,5/1 10,8/1

44,1-5500 55-5500 80-5800 81-5700 100-6000

94-3500 120-3400 14,7-4000 16,8-3700 19-4100

All Types

FR-VU-page039-174-2005 9/01/06 10:58 Page 39

ENGINE SPECIFICATIONSDiesel engines

Engine type

Cubic capacity (cc)

Bore / Stroke

Compression ratio

Power ISO or EEC KW - rpm

Torque ISO or EEC (m.daN - rpm)

1.6 16V 1.9D 2.0 HDi 2.0 8V 2.0 16V 2.2 8VHDi HDi HDi HDi

2.8 TD 2.8 HDi

9HZ WJY RHY RHX RHZ RHV RHW 4HY 8140.43 8140.43S

1560 1868 1997 1998 2179 2798

75/88,3 82,2/88 85/88 86/86 85/96 94,4/100

18/1 23/1 17,6/1 9,5/1 18/1 19/1

80-4000 51-4600 66-4000 69-4000 80-4000 62-4000 80-5500 74-4000 90-3600 93,5-3600

24-1750 12,5-2500 20,5-1900 21,5-1750 25-1750 19,2-1900 16,8-3400 25-1900 30-1800

40

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All Types

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EPOWER UNIT SUSPENSION SPECIFICATIONSEngine : HFX - KFW

Tightening torques (m.daN)

(1) : 4,5 ± 0,5(2) : 6 ± 0,6(3) : 5,4 ± 0,8(4) : 4 ± 0,6(5) : 2,4 ± 0,4(6) : 6,5 ± 0,6(7) : 2,2 ± 0,2(8) : 3 ± 0,3(9) : 2,6 ± 0,3(10) : 4,5 ± 0,5(11) : 4,5 ± 0,5

B1BP2TJP

BERLINGO

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POWER UNIT SUSPENSION SPECIFICATIONSEngine : NFU


(12) : 6 ± 0,6(13) : 4 ± 0,6(14) : 5,4 ± 0,8(15) : 6 ± 0,6(16) : 2 ± 0,3(17) : 6,5 ± 0,6(18) : 3 ± 0,3(19) : 2,2 ± 0,2(20) : 6 ± 0,6(21) : 4,5 ± 0,5(22) : 4,5 ± 0,5

B1BP2TKP

BERLINGO

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ESPECIAL FEATURES - TIGHTENING TORQUES (m.daN)

Engines : HFX - KFW - NFU

Crankshaft

Accessories drive pulley 2,5 ± 0,2

Pinion on crankshaftTightening 4 ± 0,4Angular tightening 45° ± 4°

Cylinder block

Sump 0,8 ± 0,2

Timing belt tensioner roller 2,1 ± 0,2

Accessories belt guide roller 2,5 ± 0,2

Alternator support 2,5 ± 0,2

Alternator TU1JP-TU3JPPre-tightening 1 ±Tightening 3,7 ± 0,3

Alternator TU5JP4Pre-tightening 1 ±Tightening 4 ± ,04

Aircon compressor support 2,2 ± 0,2

Aircon compressor 2,3 ± 0,2

BERLINGO

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SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)


Cylinder head

Coolant outlet housing

In plastic 0,8 ± 0,2

In aluminium 0,8 ± 0,2

Camshaft bearing caps (TU1JP-TU3JP)

Tightening 2 ± 0,2

Angular tightening 44 °± 4°

Camshaft bearing caps (TU5JP4)

Tightening 2 ± 0,2

Angular tightening 50° ± 5°

Inlet manifold 0,8 ± 0,2

Exhaust manifold 1,8 ± 0,4

Screws for adjusting valve rockers 1,75 ± 0,25

Sparking plugs 3

Camshaft pulley screw (TU1JP-TU3JP) 3,7 ± 0,2

Camshaft pulley screw (TU5JP4) 4,5 ± 0,5

BERLINGO

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Flywheel /Clutch

Flywheel 6,7 ± 1 (LOCTITE FRENETANCH)

Oil pressure mechanism 2 ± 0,2

Lubrication circuit

Oil pressure switch 3,5 ± 0,5

Oil pump 0,9 ± 0,1

Cooling circuit

Coolant pump 1,6 ± 0,2

BERLINGO

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POWER UNIT SUSPENSION SPECIFICATIONSEngine : RFN


(1) : 5 ± 0,5(2) : 4,5 ± 0,5(3) : 6,5 ± 0,5(4) : 3 ± 0,3(5) : 4,5 ± 0,5(6) : (7) : 6,5 ± 0,6(8) : 3 ± 0,3(9) : 4,5 ± 0,5 (*)(10) : 6 ± 0,6 (**)(11) : 5 ± 0,5(12) : 9 ± 0,9(13) : 4,5 ± 0,5(14) : 6,5 ± 0,6

(*) AL4 autoactive gearbox(**) BE4 manual gearbox

B1BK1X6D

DISPATCH

B1BK1X5D

B1BK1X7D

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Engine : RFNCrankshaft

Bearing cap fixing screwsPre-tightening 2 ± 0,2Angular tightening 60° ± 5°Bearing cap screwsPre-tightening 2,3 ± 0,2Angular tightening 46° ± 3°Accessories belt automatic tensioner roller 2 ± 0,2Accessories belt guide rollerPre-tightening 1,5 ± 0,1Tightening 3,7 ± 0,3Accessories support blockTighten (2 studs) 0,7 ± 0,2Pre-tightening (4 screws) 1 ± 0,1Tightening 1,9 ± 0,2

Cylinder block

Sump 0,8 ± 0,2Timing belt guide rollerPre-tightening 1,5 ± 0,1Tightening 3,7 ± 0,3Timing belt tensioner roller 2,1 ± 0,2RH engine support 6 ± 0,6

DISPATCH

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Cylinder headCamshaft bearing cover 0,9 ± 0,1Exhaust manifold 3,5 ± 0,3Valve cover 1,1 ± 0,1Camshaft pulleyPre-tightening 3 ± 0,3Tightening 7,5 ± 0,7Pulley on hub 2,1 ± 0,2Timing pinion on crankshaftPre-tightening 4 ± 0,4Angular tightening 53° ± 4°

Flywheel / clutchClutch mechanism 2 ± 0,2FlywheelPre-tightening (Sequence 1,5,3,7,2,6,4,8) 2 ± 0,2Angular tightening (Sequence 1,5,3,7,2,6,4,8) 21° ± 3°

Engine : RFN

B1CP089C

DISPATCH

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Lubrication circuit

Oil pump closing plate 0,8 ± 0,1

Oil pump

Pre-tightening 0,7 ± 0,1

Tightening 0,9 ± 0,1

Injection circuit

Common injection rail fixing screw 0,9 ± 0,1

Cooling circuit

Coolant pump

Pre-tightening (Sequence 1,2,3,4) 0,8 ± 0,1

Tightening (Sequence 1,2,3,4) 1,4 ± 0,1

Coolant outlet housing 0,9 ± 0,1

Engine : RFN

B1GP08WC

DISPATCH

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Engine : 9HZ

Crankshaft

Bearing cap fixing screwsPre-tightening 1 ± 0,2Slackening 180°Tightening 3 ± 0,3Angular tightening 140° ± 5°

Con rod screwsTightening 1 ± 0,1Angular tightening 100° ± 5°

Accessories drive belt pulleyPre-tightening 3,5 ± 0,4Angular tightening 190° ± 5°

Cylinder block

Sump 1,3 ± 0,1

Timing belt guide roller 3,7 ± 0,3

Timing belt tensioner roller 2,7 ± 0,2

BERLINGO

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Engine : 9HZ

Cylinder head

Camshaft bearing coversPre-tightening 0,5 ± 0,1Tightening 1 ± 0,1

Exhaust manifold 3 ± 0,3

Camshaft pulleyPre-tightening 2 ± 0,2Angular tightening 50° ± 5°

Cylinder headPre-tightening 2 ± 0,2Tightening 4 ± 0,5Angular tightening 260° ± 5°

EGR valve 1 ± 0,1

Flywheel / Clutch

FlywheelPre-tightening 3 ± 0,3Angular tightening 90° ± 5°

Clutch mechanism 2 ± 0,2

BERLINGO

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SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)Engine : 9HZ

Lubrication circuitOil pump assemblyPre-tightening 0,5 ± 0,1Tightening 0,9 ± 0,1Oil/coolant heat exchanger 1 ± 0,2Lubrication pipe for turbocharger 3 ± 0,5

Diesel injection circuitDiesel injection circuitPre-tightening 4 ± 0,1Angular tightening 65° ± 5°Fuel high pressure common injection rail on engine block 2,2 ± 0,2Union on fuel high pressure common injection railPre-tightening 1,7 ± 0,2Tightening 2,2 ± 0,2Diesel injection pump on support 2,2 ± 0,2Union on diesel injectorPre-tightening 2 ± 0,5Tightening 2,5 ± 0,3Diesel injection pump pulley 5 ± 0,5Union on diesel high pressure pumpPre-tightening 2 ± 0,5Tightening 2,5 ± 0,3

BERLINGO

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Engine : 9HZ

Cooling circuit

Coolant pumpPre-tightening 0,3 ± 0,1Tightening 0,9 ± 0,1

Coolant outlet housingPre-tightening 0,3 ± 0,1Tightening 0,7 ± 0,1

BERLINGO

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POWER UNIT SUSPENSION SPECIFICATIONSEngine : WJY


(1) : 4,5 ± 0,5(2) : 6,5 ± 0,6(3) : 2,2 ± 0,2(4) : 5 ± 0,5(5) : 2,2 ± 0,2(6) : 4,5 ± 0,4(7) : 4,5 ± 0,5(8) : 4,5 ± 0,5(9) : 4,5 ± 0,5(10) : 4,5 ± 0,5 (*)(11) : 5 ± 0,5(12) : 5 ± 0,5

(*) Coat the threads with LOCTITE FRENETANCHE (E3).

B1BP2SZP

BERLINGO

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Engine : WJY

Crankshaft

Bearing cap fixing screws 7 ± 0,7Con rod nutsPre-tightening 2 ± 0,2Angular tightening 70° ± 5°Accessories drive pulley hub Pre-tightening 4 ± 0,2Angular tightening 55° ± 5°Accessories drive pulley 1 ± 0,1

Cylinder block

Piston skirt spray jet 1 ± 0,1Sump 1,6 ± 0,1Timing belt guide roller 4,3 ± 0,4Timing belt tensioner roller 2,1 ± 0,2

Cylinder headCamshaft bearing covers 2 ± 0,2Exhaust manifold 3 ± 0,3Valve cover 0,5Camshaft / hub 4,3 ± 0,4Camshaft pinion / hub 2,3 ± 0,2

BERLINGO

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Engine : WJY

Crankshaft

Bearing cap fixing screws 7 ± 0,7Con rod nutsPre-tightening 2 ± 0,2Angular tightening 70° ± 5°Accessories drive pulley hub Pre-tightening 4 ± 0,2Angular tightening 55° ± 5°Accessories drive pulley 1 ± 0,1

Cylinder block


Cylinder head

Camshaft bearing covers 2 ± 0,2Exhaust manifold 3 ± 0,3Valve cover 0,5Camshaft / hub 4,3 ± 0,4Camshaft pinion / hub 2,3 ± 0,2

BERLINGO

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Engine : WJY

Flywheel

Flywheel 4,8 ± 0,4

Clutch mechanism 2 ± 0,2

Lubrication circuit

Oil pump 2,3 ± 0,2

Oil/coolant heat exchanger 7 ± 0,7

Injection circuit

Injector on cylinder head 9 ± 0,9

Diesel fuel heater 1,5 ± 0,1

Injection pump 2 ± 0,2

Union on injector 2,5 ± 0,2

Injection pump pulley 2,3 ± 0,2

Cooling circuit

Coolant pump 1,5 ± 0,1

Coolant inlet housing 1,8 ± 0,1

BERLINGO

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POWER UNIT SUSPENSION SPECIFICATIONSEngine : RHY


(1) : 4,5 ± 0,5(2) : 6,5 ± 0,6(3) : 2,2 ± 0,2(4) : 5 ± 0,5(5) : 2,2 ± 0,2(6) : 4,5 ± 0,5(7) : 2 ± 0,2(8) : 4,5 ± 0,4(9) : 4,5 ± 0,4(10) : 2 ± 0,2(11) : 2,2 ± 0,2(12) : 6,1 ± 0,6(13) : 5 ± 0,5(14) : 4,5 ± 0,4

B1BP2TRP

BERLINGO

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Engines : RHY - RHX - RHZ

Crankshaft

Bearing cap fixing screwsPre-tightening 2,5 ± 0,2Angular tightening 60° ± 5°Con rod nutsPre-tightening 2 ± 0,2Angular tightening 70° ± 5°Accessories drive pulleyPre-tightening 4 ± 0,2Angular tightening 51° ± 5°

Cylinder blockPiston skirt spray jet 1 ± 0,1Sump 1,6 ± 0,1Timing belt guide roller 4,3 ± 0,4Timing belt tensioner roller 2,5 ± 0,2

Cylinder headCamshaft bearing covers 1 ± 0,1Exhaust manifold 2 ± 0,2Valve cover 0,8Camshaft / hub 4,3 ± 0,4Camshaft pulley / camshaft hub 2 ± 0,2

BERLINGO - DISPAT-

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Flywheel

Flywheel 4,8 ± 0,4Clutch mechanism 2 ± 0,2

Lubrication circuitOil pump 1,6 ± 0,2Oil/coolant heat exchanger 7 ± 0,7Turbocharger lubrication pipeEngine end 4,8 ± 0,4Turbocharger end 2,2 ± 0,2

Injection circuit

Diesel injection circuit 3 ± 0,3Unions on fuel high pressure common injection rail 2 ± 0,2Injection pump on support 2,3 ± 0,2Union on diesel injector 2 ± 0,2Injection pump pulley 5 ± 0,5Union on fuel high pressure pump 2 ± 0,2

Cooling circuit

Coolant pump 1,5 ± 0,1Coolant inlet housing 1,8 ± 0,1

BERLINGO - DISPATCH

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EPOWER UNIT SUSPENSION SPECIFICATIONS

Reference Description

1 Upper RH torque reaction rod

2 Upper RH engine support

3 RH engine flexible support

4 Upper RH intermediate engine support

5 Lower RH engine support

6 Torque reaction rod

7 Upper RH intermediate engine support

8 LH engine support

9 RH engine flexible support

10 Lifting bracket, flywheel side

11 Lifting bracket, timing side

Engine : RHW

B1BK3EED

DISPATCH

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POWER UNIT SUSPENSION SPECIFICATIONSEngine : RHW

Tightening torques (m.daN)(12) : 5 ± 0,5(13) : 4,5 ± 0,5(14) : 4,5 ± 0,5(15) : 6 ± 0,6(16) : 3 ± 0,3(17) : 2 ± 0,2(18) : 4,5 ± 0,5(19) : 4,5 ± 0,5(20) : 4,5 ± 0,5(21) : 6,5 ± 0,6(22) : 9 ± 0,9(23) : 4,5 ± 0,5(24) : 4,5 ± 0,5(25) : 5 ± 0,5(26) : 2,5 ± 0,2(27) : 3 ± 0,3(28) : 6,5 ± 0,6(29) : 1,5 ± 0,1(30) : 1,2 ± 0,1

B1BK3EDD

DISPATCH

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Engine : RHW

Crankshaft


Cylinder block


Cylinder headCamshaft bearing covers 1 ± 0,1Exhaust manifold 2 ± 0,2Valve cover 0,8Camshaft / hub 4,3 ± 0,4Camshaft pulley / camshaft hub 2 ± 0,2

DISPATCH

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Engine : RHW

Flywheel


Lubrication circuit

Oil pump 1,6 ± 0,2Oil/coolant heat exchanger 7 ± 0,7Turbocharger lubrication pipeEngine end 4,8 ± 0,4Turbocharger end 2,2 ± 0,2

Injection circuit

Diesel injection circuit 3 ± 0,3Unions on fuel high pressure common injection rail 2 ± 0,2Injection pump on support 2,3 ± 0,2Union on diesel injector 2 ± 0,2Injection pump pulley 5 ± 0,5Union on fuel high pressure pump 2 ± 0,2

Cooling circuit

Coolant pump 1,5 ± 0,1Coolant inlet housing 1,8 ± 0,1

DISPATCH

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EPOWER UNIT SUSPENSION SPECIFICATIONSEngines : RHV - 4HY


(1) : 8 ± 0,8

(2) : 5 ± 0,5

(3) : 5 ± 0,5

(4) : 9 ± 0,9

(5) : 8 ± 0,8

B1BP2JBD

RELAY

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Engine : RHV

Crankshaft


Carter cylindres

Piston skirt spray jet 1 ± 0,1Sump 1,6 ± 0,2Timing belt guide roller 2,5 ± 0,2Timing belt tensioner roller 2,5 ± 0,2RH engine support 2,7 ± 0,2

Cylinder head

Camshaft bearing covers 1 ± 0,1Exhaust manifold 2 ± 0,2Valve cover 0,8 ± 0,1Camshaft pulley 4,3 ± 0,4Hub pulley 2 ± 0,2

RELAY

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Engine : RHVFlywheel


Lubrication circuitOil pump 1,3 ± 0,1Oil/coolant heat exchanger 5,8 ± 0,5Turbocharger lubrication pipeEngine end 3 ± 0,3Turbocharger end 2 ± 0,2

Diesel injection circuitInjector fixing flange nut 3 ± 0,3Unions on fuel high pressure common injection rail 2,5 ± 0,2Injection pump on support 2,25 ± 0,2Union on diesel injector 3 ± 0,3Injection high pressure pump pulley 5 ± 0,5Union on fuel high pressure pump 2,5 ± 0,2

Cooling circuitCoolant pump 1,5 ± 0,1Coolant inlet housing 2 ± 0,2

RELAY

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Engine : 4HY

Crankshaft

Bearing cap fixing screwsPre-tightening 2,5 ± 0,2Angular tightening 60° ± 5°Con rod nutsPre-tightening 2,3 ± 0,3Angular tightening 46° ± 5°Accessories drive pulleyPre-tightening 7 ± 0,7Angular tightening 82° ± 5°

Carter cylindres

Piston skirt spray jet 1 ± 0,1Sump 1,6 ± 0,2Timing belt guide roller 4,3 ± 0,2Timing belt tensioner roller 2,5 ± 0,2RH engine support 2,7 ± 0,2

Cylinder head

Camshaft bearing covers 1 ± 0,1Exhaust manifold 2 ± 0,2Valve cover 0,8 ± 0,1Camshaft pulley 4,3 ± 0,4Hub pulley 2 ± 0,2

RELAY

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Engine : 4HYFlywheel


Lubrication circuit

Oil pump 1,3 ± 0,1Oil/coolant heat exchanger 5,8 ± 0,5Turbocharger lubrication pipeEngine end 3 ± 0,3Turbocharger end 2 ± 0,2

Diesel injection circuit

Injector fixing flange nut 3 ± 0,3Unions on fuel high pressure common injection rail 2,7 ± 0,2Injection pump on support 2,25 ± 0,2Union on diesel injector 2,7 ± 0,2Injection high pressure pump pulley 5 ± 0,5Union on fuel high pressure pump 2,5 ± 0,2

Cooling circuit

Coolant pump 1,5 ± 0,1Coolant inlet housing 2 ± 0,2

RELAY

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POWER UNIT SUSPENSION SPECIFICATIONSEngine : 8140.43


(1) : 8 ± 0,8(2) : 5 ± 0,5(3) : 5 ± 0,5(4) : 5 ± 0,5(5) : 8 ± 0,8(6) : 9 ± 0,9(7) : 9 ± 0,9(8) : 5 ± 0,5(9) : 5 ± 0,5

B1BP22DD

RELAY

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ESPECIAL FEATURES - TIGHTENING TORQUES (m.daN)Engine : 8140.43

CrankshaftCon rod screwsPre-tightening 5 ± 0,5Angular tightening 60° ± 5°Accessories drive pulley 2 ± 0,2

Carter cylindresPiston skirt spray jet 4 ± 0,4Sump 1,8 ± 0,2Lower cylinder cover on upper cylinder coverPre-tightening 5 ± 0,5Angular tightening 90° ± 5°Timing belt tensioner roller 4 ± 0,4Timing belt guide rollerScrew M8 2,5 ± 0,2Screw M10 4 ± 0,4

Cylinder headCamshaft bearing cap covers 1,8 ± 0,2Inlet manifiold 2,5 ± 0,2Exhaust manifiold 2,5 ± 0,2Valve coverScrew M6 1 ± 0,1Screw M8 2,5 ± 0,2Camshaft pinion 2,5 ± 0,2Injection pump pinion 10 ± 1

RELAY

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SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)Engine : 8140.43

Flywheel

FlywheelPre-tightening 3 ± 0,3Angular tightening 90° ± 5°Clutch mechanism 3 ± 0,3

Lubrication circuit

Oil pump assemblyScrew M8 2,5 ± 0,2Screw M12 6 ± 0,6Oil/coolant heat exchangerScrew 56 mm long 7 ± 0,7Screw 74 mm long 8 ± 0,8


Union on diesel injector 3,3 ± 0,3Diesel injection pump 2,5 ± 0,2Diesel injection pump pinion 10 ± 1Union on diesel injection pump 2,5 ± 0,2

Cooling circuit

Coolant pump 5 ± 0,5

RELAY

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EPOWER UNIT SUSPENSION SPECIFICATIONSEngine : 8140.43S


(1) : 8 ± 0,8(2) : 5 ± 0,5(3) : 5 ± 0,5(4) : 5 ± 0,5(5) : 8 ± 0,8(6) : 9 ± 0,9(7) : 9 ± 0,9(8) : 5 ± 0,5(9) : 5 ± 0,5

B1BP2E0D

RELAY

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SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)Engine : 8140.43S

Crankshaft

Bearing cap fixing screwsPre-tightening 5 ± 0,5Angular tightening 63° ± 5°Con rod nuts 1,8 ± 0,2Accessories drive pulley hub 20 ± 2

Carter cylindresPiston skirt spray jet 4 ± 0,4Sump 1,8 ± 0,2Lower cylinder cover on upper cylinder coverPre-tightening 5 ± 0,5Angular tightening 90° ± 5°Timing belt tensioner roller 4 ± 0,4Timing belt guide roller 2,5 ± 0,2Timing belt guide roller support 2,5 ± 0,2

Cylinder headCamshaft bearing cap covers 1,8 ± 0,2Inlet manifiold 2,5 ± 0,2Exhaust manifiold 2,5 ± 0,2Valve coverScrew M6 1 ± 0,1Screw M8 2,5 ± 0,2Camshaft pinion 2,5 ± 0,2Injection pump pinion 10 ± 1

RELAY

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ESPECIAL FEATURES - TIGHTENING TORQUES (m.daN)Engine : 8140.43S

FlywheelFlywheelPre-tightening 3 ± 0,3Angular tightening 90° ± 5°Clutch mechanism 3 ± 0,3

Lubrication circuit

Oil pump assemblyScrew M8 2,5 ± 0,2Screw M12 6 ± 0,6Oil/coolant heat exchanger 7 ± 0,7


Injector fixing flange nut 4 ± 0,4Unions on fuel high pressure common injection rail 2 ± 0,2Fuel high pressure pump 2,5 ± 0,2Union on diesel injector 2 ± 0,2Diesel injection pump pinion 10 ± 1Union on diesel injection pump 2 ± 0,2

Cooling circuit

Coolant pump 5 ± 0,5

RELAY

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SPECIAL FEATURES - CYLINDER HEAD TIGHTENINGEngines all Types

B1DP05BC

Cleaning to be carried out just prior to refitting the cylinder headWARNING : Clean the contact faces with the approved CITROËN cleaning product.Do not use abrasives or cutting tools on the contact faces.The contact faces must not bear any traces of impact or scratching.Insert a tap in the threads of the holes in the cylinder block receiving the cylinder head bolts.Brush the threads of the cylinder head bolts..Oil the threads and under the heads of the bolts, using MOLYKOTE G RAPID PLUS).

Engines Tightening (m.daN)Cylinder head bolts

(Max. reusable length in mm)

Pre-tightening 2 ± 0,2HFX - KFW Angular tightening 240° ± 5° 175,5 ± 0,5

Pre-tightening 2 ± 0,2NFU Angular tightening 260° ± 5°

122 ± 0,3Pre-tightening 3,5 ± 0,3

RFL Tightening 7 ± 0,7R6G Angular tightening 160° ± 5°

B1BP10LC

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ESPECIAL FEATURES - CYLINDER HEAD TIGHTENINGEngines all Types

B1DP1DLC




Pre-tightening 1,5 ± 0,1Tightening 5 ± 0,5

RFN Slackening 360° 147Tightening 2 ± 0,2Angular tightening 285° ± 5°

Pre-tightening 2 ± 0,29HZ Tightening 4 ± 0,4 149


B1DP05BC

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SPECIAL FEATURES - CYLINDER HEAD TIGHTENINGEngines all Types

B1DP05BC




Pre-tightening 2 ± 0,2WJY Tightening 6 ± 0,6 125,5


Pre-tightening 1,8 ± 0,2RHY - RHXTightening 6 ± 0,5 133,3RHZ - RHWAngular tightening 220° ± 5°

B1DP075C

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ESPECIAL FEATURES - CYLINDER HEAD TIGHTENINGEngines all Types

B1DP1ADD




Pre-tightening 2,2 ± 0,5Tightening 6 ± 0,6

RHV - 4HY Slackening 1 tour 133,3Tightening 6 ± 0,6Angular tightening 220° ± 5°

8140.43 Pre-tightening 6 ± 0,6 1158140.43S Angular tightening 180° ± 5°

B1DP05BC

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AUXILIARY EQUIPMENT DRIVE BELTTU

JP

1 10

J4

Engine type

BERLINGO

DISPATCH

RELAY

See pages :


X X X

X

X X

84 to 85 86 to 88 89

EW

3

J2U/K

5

XU

JP4 J2U

Engine families

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EAUXILIARY EQUIPMENT DRIVE BELT

Engine type

C15

BERLINGO

DISPATCH

See pages :

DV DW SOFIM

6 8 10 12

ATEDATED4 B TD BTED CTED UTD ATED4 UTED TD

BTED+

1.6 16V HDi 1.9 D 2.0 HDi 2.0 8S HDi 2.0 16V HDi 2.2 8S HDi 2.8 TD 2.8 HDi


X

X X X

X X X X

X X X X

90 91 to 95 96 to 99 100 to 103 100 to 103 104 to 105

RELAY

Engine families

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Tools

BELT TENSION CORRESPONDENCE TABLE

! 4099-T (C.TRONIC.105) 4122-T (C.TRONIC.105.5) !

!

!

B1EP135D

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Engines : All Types Petrol and Diesel

Tools.

- Belt tension measuring instrument : 4122 - T.

ESSENTIAL.

- Before refitting the auxiliary equipment drive belt, check that :

1) The roller(s) rotate freely (no play or stiffness).

2) The belt is correctly engaged in the grooves of the various pulleys.

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84

B1BP234C

BERLINGO AUXILIARY EQUIPMENT DRIVE BELTEngines : HFX - KFW - NFU

Without air conditioning

Tools.

[1] Pliers for removing plastic pegs : 7504-T[2] Belt tension measuring instrument : 4122-T[3] TORX spanner

Remove.- Slacken the central screw (1).tool [3]- Detension the tensioner roller (2), (flat spanner 27 on flat).- Remove the belt.

Refit.- Position the belt.- Hold the belt in position using the tensioner roller (2).- Pre-tension the belt 120 ± 3 SEEM units, tool [2].- Rotate the engine 2 to 4 times.- Check the tension : 120 ± 3 SEEM units.- Tighten the central screw (1) tool [3].- Remove the tool [2].NOTE : If the belt tension is more than 150 SEEM units, the belt is rendered un-usable.

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With air conditioning

BERLINGO

B1BP235C

Tools.

[1] Pliers for removing plastic pegs : 7504-T[2] TORX spanner.

Remove.- Detension the automatic tensioner (3).- Place a Ø 4 mm peg at (a) to immobilise the automatic tensioner.- Remove the belt.

Refit.- Position the belt- Remove the Ø 4 mm peg.- Release the automatic tensioner (3).- Tighten the screw of the automatic tensioner (3), using tool [2].

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AUXILIARY EQUIPMENT DRIVE BELTRELAY

Tools.

[1] Belt tension measuring instrument : 4122-T

Tensioning the belt- Tension the belt (4) using the screw (2).- Fit the tool [1].- Pre-tension to : 120 ± 10 SEEM units.- Remove the tool [1].- Rotate the crankshaft by 3 turns.- Fit the tool [1].- Adjust the tension using the screw (2) to : 140 ± 10 SEEM units.- Remove the tool [1].- Tighten the nut (1) to 2 m.daN and the screw (3) to 4 m.daN.- Run the engine for 10 min.- Check the tension of the belt (4).- The nominal value must not be less than 100 SEEM units.- If this is not the case, restart the tensioning operation.

Alternator belt (without air conditioning)

B1BP044C

Engines : RFL - R6G

B1BP045C

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EAUXILIARY EQUIPMENT DRIVE BELT RELAY

NOTE : If the vehicle is equipped with power steering, remove the belt (5)..

Tensioning the belt

- Tension the belt (5) using the screw (6).- Fit the tool [1].- Pre-tension to : 120 ± 10 SEEM units.- Remove the tool [1].- Rotate the crankshaft by 4 turns.- Fit the tool[1].- Loosen the screws (3) and (4).- Adjust the tension, using screw (6), to : 140 ± 5 SEEM units.- Remove the tool [1].- Tighten the screws (3) and (4) to 2,5 ± 0,2 m.daN.- Run the engine for 10 minutes.- Check the tension of the belt (5).- The nominal value must not be less than 100 SEEM units.- If this is not the case, restart the tensioning operation.

Alternator belt (with air conditioning)

B1BP1LFC

Engines : RFL - R6G

B1BP04AC

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AUXILIARY EQUIPMENT DRIVE BELTRELAY

Tools.[1] Belt tension measuring instrument : 4122-TRemoving the belt- To make it easier to move the pump, unclamp the hydraulic pipes.- Slacken the articulating screws of the pump.- Slacken the nut (2) to release the belt (1).Tensioning the belt- Tension the belt by turning the nut (2).- Fit the tool [1].- Pre-tension to : 70 ± 5 SEEM units.- Remove the tool [1].- Rotate the crankshaft by 3 turns.- Fit the tool [1].- Adjust the tension by turning the nut (2) to : 75 ± 5 SEEM units.- Remove the tool [1].- Tighten the screws (3) and the pump articulating screws to 2,5 ± 0,2 m.daN.- Run the engine for 10 minutes.- Check the belt tension (1).- The nominal value must not be less than 70 SEEM units.- If this is not the case, restart the tensioning operation.

Power-assisted steering pump belt

B1BP04BC

Engines : RFL - R6G

B1BP04CC

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EAUXILIARY EQUIPMENT DRIVE BELTEngine : RFNWithout air conditioning With air conditioning

Tools.

[1] Pliers for removing plastic pegs : 7504-T

Remove the belt.- Detension the belt (3) by turning the screw (2) of the tensioner roller (1)(anti-clockwise).

- The screw (2) (WARNING : not left hand screw).- Remove the belt (3), while keeping the tensioner roller (1) tight

Refit the belt.- Refit the belt (3), while keeping the tensioner roller (1) tight.- Release the tensioner roller (1).

B1BP23PC B1BP23QC B1BP23PC B1BP23RC

DISPATCH

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B1BP2Z6D

B1BP2ZCD

AUXILIARY EQUIPMENT DRIVE BELTEngine : 9HZ

Tools.

[1] Dynamic tensioner compression lever : (-).0188.Z[2] Peg for dynamic tensioner roller : (-).0194.FRemovingRemove the front RH wheel, the under-engine sound-deadening and the splash-shield.Vehicle with air conditioning :WARNING : Mark the direction of fitting of the accessories drive belt, if it is to be re-used.Compress the tensioner roller (1) by acting at «a» (clockwise), using tool [1].Peg at «b», using tool [2].Remove the accessories drive belt.IMPERATIVE: Check that the rollers (1) and (2) can turn freely (without play and without tightspots).RefittingWARNING : Belt to be re-used, mark the direction of fitting of the belt.Refit the auxiliaries drive belt.Compress the dynamic tensioner roller (1) by acting at «c» (clockwise), using tool [1].Remove tool [2].IMPERATIVE : Make sure that the auxiliaries drive belt is correctly positioned in the grooves ofthe various pulleys.Complete the refitting in the opposite order to removal.

BERLINGO

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Without power steering - Without air conditioning

Tools.

[1] Belt tension measuring instrument : : 4122-T

Remove.- Loosen the screws (2).- Tighten the screw (1) until it is against its stop, to detension the belt.- Remove the belt.

Refit.- Refit the belt.- Fit the tool [1] at "d".- Tighten the screw (1) to obtain : 115 ± 10 SEEM units.- Tighten the screws (2) to 2,5 ± 0,2 m.daN.- Remove the tool [1].

B1BP1SECB1BP1SDC

Engine : WJY

C15

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C15 - BERLINGO - DISPATCH AUXILIARY EQUIPMENT DRIVE BELT

With power steering - Without air conditioning

Tools.

[1] Belt tension measuring instrument : 4122-T

Remove.

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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AUXILIARY EQUIPMENT DRIVE BELTEngine : WJY

With power steering - Without air conditioning (continued)

C15 - BERLINGO - DISPATCH

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 (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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AUXILIARY EQUIPMENT DRIVE BELT

With power steering - With air conditioning.

Tools.[1] Dynamic tensioner peg : (-) 0188 G.[2] Belt tension measuring instrument : 4122-T.

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 mm square 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 hand engine support.- Using a square drive at (b) turn the tool (3) in the direction of the arrow "a", so that it can bepegged at "a" using the tool [1].

B1BP1SKC

Engine : WJY


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AUXILIARY EQUIPMENT DRIVE BELT

With power steering - With air conditioning (continued)

Refitting

- Refit the belt.

- Using a 7 mm square drive at "b", turn the roller (3), until the tool [1] located at "a" becomesfree.

- Tighten the screw (2).

- Remove the tool [1].

B1BP1SLC

Engine : WJY


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BERLINGO - DISPATCH AUXILIARY EQUIPMENT DRIVE BELTEngines : RHY - RHX - RHZ


B1BP1YKD

Tools.1] Belt tension adjusting square : (-).0188 J2[2] Ø 4 mm peg : (-).0188.Q1[3] Ø 2 mm peg : (-).0188.Q2.[4] Dynamic tensioner compression lever : (-).0188.Z

RemoveRE-USE OF BELT

WARNING : Mark the direction the belt was fiited in case of re-use of the same belt.

- Compress the tensioner roller (2) by action at « a » (in anti-clockwise direction), tool [4].- Keep the tensioner roller (2) compressed and remove the belt.

NO RE-USE OF BELT.- Compress the tensioner roller (2) by action at « a » (in anti-clockwise direction), tool [4].- Peg using tool [2], at « b ».- Hold the tensioner roller (2) compress and remove the belt.- Loosen the screw (1).

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EBERLINGO - DISPATCHAUXILIARY EQUIPMENT DRIVE BELTEngines : RHY - RHX - RHZ

Without air conditioning (continued)

Refitting

RE-USED BELT.- Compress the tensioner roller (2) by action at « a » (in anti-clockwise direction), tool [4].- Refit the belt.

WARNING : Respect the direction belt was fitted.

Remove the tool 4].

NEW BELT.Refit the belt.- Turn the eccentric roller (3), tool [1] (clockwise) to free the tool [2] from its pegging

at « b ».- Hold the eccentric roller (3), tool [1], and tighten the screw (1) to 4.3 m.daN.- Remove the tool [2].- Rotate the crankshaft 4 times in the direction of rotation.- Check that it is possible to peg at « b », tool [3].- If not possible to peg, restart the adjustment.

B1BP1YMD

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BERLINGO - DISPATCH AUXILIARY EQUIPMENT DRIVE BELTEngines : RHY - RHX - RHZ


B1BP1YLD

Tools.[1] Belt tension adjusting square : (-).0188 J2[2] Ø 4 mm peg : (-).0188.Q1[3] Ø 2 mm peg : (-).0188.Q2[4] Dynamic tensioner compression lever : (-).0188.Z

Removing

RE-USE OF BELTWARNING : Mark the direction the belt was fitted in case of re-use of the same belt.- Compress the tensioner roller (7) by moving it at « c » (in anti-clockwise direction), tool [4].- Hold the tensioner roller (7) compressed and remove the belt.

NO RE-USE OF BELT.- Compress the tensioner roller (7) by moving it at « c » (in anti-clockwise direction), tool [4].- Peg using tool [2], at « d ».- Loosen the screw (6)- Bring the eccentric roller (5) towards the rear.- Tighten the screw (6) by hand.- Remove the belt.

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EBERLINGO - DISPATCHAUXILIARY EQUIPMENT DRIVE BELTEngines : RHY - RHX - RHZ


Refitting

RE-USED BELT.- Compress the tensioner roller (7) by action at « c » (in anti-clockwise direction), tool [4].- Refit the belt.

WARNING : Respect the direction belt was fitted.Remove the tool [4].

NEW BELT.- Refit the belt.- Turn the eccentric roller (5), tool [1] (clockwise) to free the tool [2] from its pegging

at « d ».- Hold the eccentric roller (5), tool [1], and tighten the screw (6) to 4.3 m.daN.- Remove the tool [2].- Rotate the crankshaft 4 times in the direction of rotation.- Check that it is possible to peg at « d », tool [3].- If not possible to peg, restart the adjustment.

B1BP1YND

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B1BP2J5D

COURROIE D' ENTRAÎNEMENT DES ACCESSOIRESEngines : RHV - 4HY

Tools.[1] Dynamic tensioner compression lever : (-).0188 Z [2] Peg, Diameter 4 mm : (-) 0188 Q1[3] Belt tension measuring equipment : SEEM 105.M

Removal.IMPERATIVE : Respect the safety and cleanliness requirements that are specificto high pressure diesel injection (HDi) engines.Remove : - The sound-deadening under the engine.- The front RH wheel.WARNING : Mark the direction the belt was fitted in case of re-use of the samebelt.Compress the dynamic tensioner roller 1) by moving it at « b » (in anti-clockwise direction),tool [4].Peg using tool [2] at «a».Remove the auxiliary equipment drive belt.IMPERATIVE : Check that the rollers (1), (2) and (3) turn freely(wthout play and without tight spots).

RELAY


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B1BP2J8D


Refitting.

Refit the auxiliary equipment drive belt.

IMPERATIVE : Make sure that the belt is correctly positioned in the grooves ofthe various pulleys.

Compress the dynamic tensioner roller (1) by action at «b», tool [1].(anti-clockwise direction).

Remove tool [2].

RELAY


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Belt for driving the power steering pump

B1BP2J6C

B1BP2JAC

Tools.

[3] Belt tension measuring instrument : SEEM 105.MRemoving.WARNING : Mark the direction of fitting the drive belt if it is to be re-used.Slacken the screw (4).Detension the belt (5), by acting on the nut «c».Remove the belt.Refitting.Refit the belt (5).IMPERATIVE : Check that the belt is correctly positioned in the grooves of the various pulleys.Fit tool [3] at «f».Tighten the nut at «c», to obtain a tension value of : 102 ± 10 SEEM units.Tighten the screw (4).Give the crankshaft three turns (normal direction of rotation).Check the tension of the belt (5), the tension value should be : 102 ± 10 SEEM units.Refit :- The front RH road wheel- The sound insulation under the engine.

RELAY


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EAUXILIARY EQUIPMENT DRIVE BELTEngines : RHV – 4HY

Belt for driving the alternator and the compressor

B1BP2J7D

B1BP2J9D

Removing.

WARNING : Mark the direction of fitting the drive belt if it is to be re-used.

Compress the dynamic tensioner roller (6), by acting at «e», using tool [1](anti-clockwise direction).Peg, using tool [2], at «d».Remove the belt.

Refitting.

Refit the belt.

IMPERATIVE : Check that the belt is correctly positioned in the grooves of the various pulleys.

Compress the dynamic tensioner roller (6), by acting at «e», using tool [1](anti-clockwise direction).Remove tool [2].

RELAY


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AUXILIARY EQUIPMENT DRIVE BELTEngines : 8140.43 - 8140.43S

B1BP21TD

Tools.

[1] Pliers for removing plastic pins : 7504-T[2] Belt tension measuring instrument : 4122-T

Removing.Slacken : The nut (3), screws (4) and (1).Remove the screw (2) and the aircon compressor belt.

Refitting.Refit the screw (2).Tighten by hand the screws (1) and (2).Position tool [2] on the belt at «a».Tighten screw (4).The tension value should be : 96 ± 6 SEEM units.Remove tool [2].Tighten : The nut (3), screws (1) and (2)Complete the refitting in reverse order to removal.

RELAY

Belt for driving the compressor

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EAUXILIARY EQUIPMENT DRIVE BELTEngines : 8140.43 - 8140.43S

B1BP21UC

B1BP21VC

Tools.[1] Pliers for removing plastic pins : 7504-T[2] Belt tension measuring instrument. : 4122-TRemoving.Remove the aircon belt (See corresponding operation).Slacken : Screws (6) and (7).Remove the alternator belt (5).Refitting.Refit the alternator belt (5).IMPERATIVE : Check that the belt is correctly positioned in the grooves of the various pulleys.Position tool [2] on the belt at “b”. Tighten screw (7).For a new belt, the tension should be : 122 ± 22 SEEM units.For a re-used belt, the tension should be : 69 ± 7 SEEM units.Tighten screw (6) to 5 ± 0,5 m.daN.Remove tool [2].Complete the refitting.

Belt for driving the alternator

RELAY

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CHECKING AND SETTING THE VALVE TIMING - PETROL ENGINESTU

JP

1 10

J4

Engine type

BERLINGO

DISPATCH

RELAY

See pages :


X X X

X

X X

109 to 112 113 to 116 117 to 119 120 to 126

EW

3

J2U/K

5

XU

JP4 J2U

Engine Families

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ECHECKING AND SETTING THE VALVE TIMING - DIESEL ENGINES

Engine type

C15

BERLINGO

DISPATCH

See pages :

DV DW SOFIM

6 8 10 12

ATEDATED4 B TD BTED CTED UTD ATED4 UTED TD

BTED+

1.6 16V HDi 1.9 D 2.0 HDi 2.0 8S HDi 2.0 16V HDi 2.2 8S HDi 2.8 TD 2.8 HDi


X

X X X

X X X X

X X X X

127 to 136 137 to 141 147 to 153 142 to 146 147 to 153 154 to 162 154 to 162 163 to 166 167 to 171

RELAY

Engine Families

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RECOMMENDATIONS : TIMING BELT

Recommandations.

IMPERATIVE : After each operation involving removal of the timing belt, systematically replace :

- the timing belt,- the tensioner roller fixing screw.

Petrol enginel Diesel engine

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CHECKING THE VALVE TIMING

NOTE : Remove the sparking plugs to ease the crankshaft rotation.

Tools.- [1] Flywheel peg : 4507-T.A (Toolkit 4507-T).- [2] Flywheel or camshaft pulley peg : 7017-T.R.

Lift and support the front RH side of the vehicle.Disconnect the battery positive terminal.Engage 5th gear at the gear engagement lever.Remove: - The oil filter.- The upper timing cover.Turn the wheel to drive the engine in its normal direction of rotation.Peg the flywheel, using tool [1]Peg the camshaft pulley, using tool [2].

- If the setting is not correct, restart the operation.

CHECKING AND SETTING THE VALVE TIMINGEngines : HFX - KFW

B1BP2MBC B1BP2VNC

BERLINGO

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SETTING THE VALVE TIMING

NOTE : Remove the sparking plugs to ease the crankshaft rotation.

Tools- [1] Flywheel peg : 4507-T.A (Toolkit 4507-T).- [2] Camshaft pinion setting peg : 4507-T.B (Toolkit 4507-T).- [4] Dynamic tensioner roller pin : 4200-T.H.- [5] Belt retaining pin : 4533-T.AD.Removing- Rotate the engine with the crankshaft pinion screw (1) clockwise, to bring it tothe pegging position.- Peg the camshaft pinion, using tool [2].- Peg the flywheel, using tool [1].- Slacken the nut (2).- Completely slacken the belt by turning the tensioner roller.- Remove the belt.ESSENTIAL : Check that the tensioner roller rotates freely (no stiffness).

B1EP065CB1BP2MCC B1EP1BLCB1BP2MBC

BERLINGO

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ECHECKING AND SETTING THE VALVE TIMINGEngines : HFX - KFW

Refitting

NOTE : Check that the pegs [1] and [2] are in place.

WARNING : Ensure the belt is fitted in the right direction : The arrows « a » signify the crank-shaft direction of rotation.- Fit the timing belt, with the belt strip « b » well tensioned, in the following order :Crankshaft pinion (using tool [5], camshaft pulley, water pump pulley, tensioner roller.- Remove the pegs [1] and [2].Overtensioning the timing belt- Turn the roller with the aid of a hexagonal spanner (at « c »).- Position the index « e » at position « d », tension the belt to the maximum extent of the intervalshown.- Hold the tensioner roller in position, using tool [4].- Tighten the tensioner roller fixing nut to 1 m.daN.- Remove tools [1], [2], [4] and [5].- Rotate the crankshaft by 4 turns in the normal direction of rotation.ESSENTIAL : Never turn the crankshaft backwards.- Ensure the timing is correctly set by refitting the pegs [1] and [2].- Remove the setting pegs.

B1EP1DMC

B1EP1DLC

BERLINGO

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Adjusting the belt fitting tension

- Slacken the tensioner roller fixing nut, maintaining the position of the tensioner roller, using ahexagonal spanner.- Bring the index « e » to its adjusting position « f ».

WARNING : The index « e » should not go past the notch « f ». If it does, repeat the operation totension the timing belt.

- Maintain the tensioner roller in this position, using a hexagonal spanner.- Tighten the tensioner roller fixing nut to 2 ± 0,2 m.daN.

IMPERATIVE : The tensioner roller must not turn during the tightening of its fixing. If itdoes, repeat the operation to tension the timing belt.

B1EP1DNC

BERLINGO

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ECHECKING AND SETTING THE VALVE TIMINGEngine : NFU

Tools.

[1] Engine flywheel peg : 4507-T.A (Toolkit 4507-T)[3a] Camshaft pulley peg. : 4533-T.A.C1[3b] Camshaft pulley peg. : 4533-T.A.C2[4] Dynamic tensioner roller pin : 4200-T.H[5] Belt retaining pin : 4533-T.AD

Checking the timing- Lift and support the front RH side of the vehicle.- Disconnect the battery positive terminal.- Engage 5th gear at the gear engagement lever.- Remove : the oil filter, the upper timing cover, the accelerator pedal position sensor and lever assembly.- Position a jack underneath the engine, support the engine.- Remove all the RH engine supports.- Turn the wheel to drive the engine in its normal direction of rotation.- Peg the flywheel, using tool [1].- Peg the camshaft pulleys, using tools [3a] and [3b].- If the setting is not correct, recommence the operation.

B1EP18MCB1BP2MBC

BERLINGO

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CHECKING AND SETTING THE VALVE TIMINGEngine : NFU

Setting the timing

Removing- Peg the flywheel, using tool [1] - Peg the camshaft pulleys, using toos [3a] and [3b].- Slacken the tensioner roller.- Turn the dynamic tensioner roller in order to be able to position the tool [4], using an allen spanner at« a ».- Turn the tensioner roller to the right, so as to bring the index « c » to position « b ».- Peg the tensioner roller in this position in order to detension the timing belt as much as possible.

IMPERATIVE : Never turn the dynamic tensioner roller by a complete rotation.

- Remove the belt.

ESSENTIAL : Check that the tensioner roller rotates freely (no tight spots).

B1EP18PC

BERLINGO

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Setting the timing (continued)

Refitting- Position the timing belt, strictly in the following order: inlet camshaft pulley, exhaust camshaftpulley, guide roller, crankshaft pulley (using tool [5]), water pump pulley, dynamic tensioner roller.- Remove tools [1], [3a], [3b] and [5].

Overtensioning the timing belt- Turn the roller with the aid of a hexagonal spanner (at « a »).- Position the index « c » at position « d », tension the belt to the maximum extent of the intervalshown.- Hold the tensioner roller in position, using tool [4].- Tighten the tensioner roller fixing nut to 1 m.daN.- Remove tools [1], [3a], [3b], [4] and [5].Rotate the crankshaft by 4 turns in the normal direction of rotation.ESSENTIAL : Never turn the crankshaft backwards.- Ensure the timing is correctly set by refitting the pegs [1], [3a] and [3b].- Remove the setting pegs.


B1EP1DPC

BERLINGO

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Adjusting the belt fitting tension

- Slacken the tensioner roller fixing nut, maintaining the position of the tensioner roller, using ahexagonal spanner.- Bring the index « c » to its adjusting position « e ».

WARNING : The index « c » should not go past the notch « e ». If it does, repeat the operation totension the timing belt.

- Maintain the tensioner roller in this position, using a hexagonal spanner.- Tighten the tensioner roller fixing nut to 2,2 ± 0,2 m.daN.

IMPERATIVE : The tensioner roller must not turn during the tightening of its fixing. If it does,repeat the operation to tension the timing belt.

B1EP1DQC

BERLINGO

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Tools.

[1] Camshaft setting pegs : (-).0189.A[2] Crankshaft setting peg : (-).0189.B Tool kit C.0189[3] Belt locking pin : (-).0189.K[4] Angular tightening adaptor : 4069-T[5 ] Hub immobilising tool : 6310-T


- Turn the engine by the crankshaft pinion screw (3) to bring it to pegging position.- Peg the crankshaft, using tool [2].- Peg the camshaft pulleys, using tools [1].

NOTE : The pegs [1] must go in without effort

CHECKING AND SETTING THE VALVE TIMINGEngines : RFL - R6G

B1BP25PC

B1BP22SC

RELAY

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Tools.

[1] Camshaft pulley locating peg : 7004-T.G[2] Flywheel peg : 7014-T.N Tool kit 7004-T[3] Timing belt tensioning key : 7017-T.W[4] Toothed sector for locking the flywheel : 6012-T Tool kit 9022-T[5] Belt tension measuring instrument : 4122-T

SETTING THE VALVE TIMING

Peg the crankshaft, using tool [2], and the camshaft pulley, using tool [1].Lock the flywheel with the tool [4].

ESSENTIAL : Remove the tools [1] and [2] when tightening the screw (1).

- Remove the screws (1) and the pulley.- Remove the tool [4].- Check that the camshaft pulley and the crankshaft pinion are correctly pegged.- Loosen the tensioner roller screw.- Remove the belt.


B1BP1WHC

B1EP01TC

RELAY

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SETTING THE VALVE TIMING (continued)

Belt fitting direction- Arrows in the direction of rotation.- Paint marks opposite pinion marks.

- Fit the belt on the : camshaft pulley, crankshaft pinion, water pump pinion, tensioner roller.

NOTE : Ensure that the belt is correctly positioned in the grooves.

TENSIONING THE BELT- Bring the tensioner roller into contact with the belt. - Fit the tool [5].- Tension the roller to 16 ± 2 SEEM units using the tool [3].- Tighten the screw (2) to 2 m.daN.- Remove the tool [1] and fit the crankshaft pulley, without tightening the screw (1).- Rotate the crankshaft by 2 turns (direction of rotation).- Check the pegging of the camshaft/crankshaft.- Rotate the crankshaft by 2 turns (do not turn backwards).- Peg the camshaft pulley using the tool [1].- Fit the tool [5].

ESSENTIAL : The tension value should be : 40 ± 4 SEEM units- If the value is outside these limits, restart the operation.- Remove the tools.


B1EP01YC

RELAY

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CHECKING AND SETTING THE VALVE TIMINGEngine : RFN

Tools.

[1] Camshaft setting peg : (-) 0189.A[2] Crankshaft setting peg : (-).0189.R[3] Belt retaining pin : (-).0189.K[4] Adaptor for angular tightening : 4069-T[5] Tool for manœuvring and locking the tensioner roller : (-).0189.S[5a] : (-).0189.S1[5b] : (-).0189 S2Pliers for removing plastic pins : 7504-T

Checking the setting of the timing

Removing.Disconnect the battery negative terminal (See corresponding operation).Raise and support the vehicle, front wheels hanging.Remove: The front RH wheel.The plastic pins (1)The splash-shield (2)The upper timing cover

C4AP12TC

DISPATCH

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ECHECKING AND SETTING THE VALVE TIMING

Engine : RFN

Checking the setting of the timing (continued).

Rotate the engine using the crankshaft pinion screw to bring it to the pegging position..

Peg the crankshaft, using tool [2].

Peg the camshaft pulleys, using tool [3]

WARNING : If the pegs are difficult to engage, repeat the operation to fit and tension the timingbelt (See corresponding operation)

Refitting.

Remove tools [2] and [3].

Complete the refitting in the opposite order to removal.

B1EP1BAC

B1BP2V5D

DISPATCH

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CHECKING AND SETTING THE VALVE TIMING

Setting the timing.

Removing.Disconnect the battery negative terminal (See corresponding operation).Raise and support the vehicle, front wheels hanging.Remove: The front RH wheel.The plastic pins (1)The splash-shield (2)The accessories drive belt (See corresponding operation).

Unclip and move aside the fuel delivery pipe from the timing cover.

Remove the upper timing cover (1).

Rotate the engine using the screw (3) of the crankshaft pulley (2) to bring it to the pegging position.

Engine : RFN

B1BP2V4C

DISPATCH

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Engine : RFN

Setting the timing (continued)

Peg: The crankshaft, using tool [2]The camshaft pulleys (5) and (6), using tool [1]

Remove: The screw (3) of the crankshaft pulley (2).The lower timing cover (4) (by moving the engine).

IMPERATIVE : Never remove the crankshaft pulley (2) without pegging the crankshaft andcamshafts.

Slacken the screw (9) of the tensioner roller (8).Turn the tensioner roller (8) (clockwise).Remove the timing belt (7).

B1EP1BBD

B1BP2V5D

DISPATCH

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Setting the timing (continued)Turn the tensioner roller (8), using tool [5a] to go past the notch (b).Position tool [5b] to lock the index (a) and remove tool [5a].Reposition the timing belt (7) on the crankshaft pulley.Hold the timing belt (7) using tool [3].Fit the timing belt (7) in place, strictly in the following sequence: - Guide roller (10).- Inlet camshaft pulley (6).- Exhaust camshaft pulley (5).- Coolant pump (11).- Tensioner roller (8).NOTE : Make sure that the belt (7) is as flush as possible with the outer face of the various pinions androllers.Remove : - Tool [3].- Tool [1] from the exhaust camshaft pulley.- Tool [5b] from the tensioner roller (8).Refit : - The lower timing cover (4) (by moving the engine).- The crankshaft pulley (2)- The screw (3) of the crankshaft pulley.Tighten the screw (3) to 4 ± 0,4 m.daN, then angular-tighten to 53° ± 4°, using tool [4].


B1EP1BDC

B1EP1BCD

DISPATCH

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Tensioning the timing belt.Turn the tensioner roller (8) in the direction of the arrow « c », by means of a hexagonal spanner at « d ».Positionner l’index « a » en poition « f »

IMPERATVE : The index «a» should go past the slot « g » by an angular value of 10°.If it does not, replace the tensioner roller or the timing belt and tensioner roller assembly.Next bring the index « a » to its adjusting position « g », by turning the tensioner roller in the direction of the arrow« e ».

WARNING : the index « a » should not pass the slot « g ».Otherwise, repeat the operation to tension the timing belt.

IMPERATIVE : The tensioner roller should not turn during the tightening of its fixing.If it does, repeat the operation to tension the timing belt.

Tighten the screw (9) of the tensioner roller (8) to 2,1 ± 0,2 m.daN.

IMPERATIVE : The hexagonal tensioner roller drive should be approx. 15° below the level of the cylinderhead gasket « h ».If it is not, replace the tensioner roller or the timing belt and tensioner roller assembly.


B1EP1BFC

B1EP1BEC

DISPATCH

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Refitting (continued)Remove the tools [1] and [2].Rotate the crankshaft ten times (normal direction of rotation).

IMPERATIVE : No pressure or outside force should be brought to bear on the timing belt.

Peg the inlet camshaft pulley, using tool [1].

Checks.

Tension of the timing belt.

ESSENTIAL : Check the position of the index « a », which should be opposite the slot « g ».If the position of the index « a » is not correct, repeat the operations to tension the timing belt.

Refit the upper timing cover (1).Clip the fuel delivery hose on the timing cover.Refit the accessories drive belt (See corresponding operation).Lower the vehicle.Reconnect the battery (See corresponding operation).


B1EP1BFC

B1EP1BEC

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Tools.

[1] Flywheel setting peg : (-).0194.C[2] Camshaft setting peg : (-).0194.B[3] Crankshaft setting peg : (-).0194.A

Checking and setting the timing.RemovingRaise and support the vehicle, wheels hanging.Disconnect the positive and negative terminals of the battery.Remove : The front RH wheel.The front RH splash-shield.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).

CHECKING THE VALVE TIMINGEngine : 9HZ

B1BP3BZD

BERLINGO

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Rotate the engine to drive it in its normal direction of rotation.

Peg the flywheel, using tool [1] at «b».

Move aside the harness (7).

Remove :

The engine support (8).

The screw (10).

The accessories drive pulley (9).

The lower timing cover (11).

The upper timing cov (12).

The tool [1].


B1EP1E3D

B1BP305C

BERLINGO

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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 approa-ched 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 betweenthe camshaft pinion hole and the pegging hole is not more than 1 mm. If it is more, repeatthe 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].


B1EP1E5C

B1EP1E4D

BERLINGO

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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) Pre-tighten 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.daNThe engine support (5) , tighten to 2,5 ± 0,2 m.daNThe electrical harness (7)The power steering fluid reservoir (6).

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 splash-shield (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 follo-wing a reconnection of the battery (see corresponding operation).


BERLINGO

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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 splash-shield.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).

CHECKING AND SETTING THE VALVE TIMINGEngine : 9HZ

B1BP3BZD

BERLINGO

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Rotate the engine to drive it in its normal direction of rotation.

Peg the flywheel at «b». using tool [1].

Move aside the harness (7).

Remove :

The engine support (8).

The screw (10).

The accessories drive pulley (9).

The lower timing cover (11).

The upper timing cov (12).

The tool [1].


B1EP1E3D

B1BP305C

BERLINGO

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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 spannerat «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).


B1EP1E6D

BERLINGO

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Refitting

Fit the timing belt on the crankshaft pinion.

Position the belt on the guide roller, belt well tensioned.

Refit : The timing belt protector (13).The engine speed sensor (14).

Reposition the timing belt, strip «f» well tensioned, in the following sequence :

Guide roller (16).Camshaft pulley (20).Fuel high pressure pump pulley (19).Coolant pump pulley (17).Tensioner roller (18).


B1EP1E7D

BERLINGO

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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 between thecamshaft hole and the pegging hole is not more than 1 mm. If the offset is too great, repeatthe operation.Remove tools [2] and [3].


B1EP1E8C

BERLINGO

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Refitting (continued)

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 torque Screw (10) Pre-tighten 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.daNThe engine support (5), tighten to 2,5 ± 0,2 m.daNThe electrical harness (7)The power steering fluid reservoir (6).

Disengage the jack from under the engine.

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 splash-shield (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 followinga reconnection of the battery (see corresponding operation).


BERLINGO

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Tools.

[1] Pliers for removing plastic pins : 7504-T or (-).1311[2] Flywheel locating peg : 7014-T.J or (-).0188 Y[3] Injection pump setting peg Ø 6 mm : (-).0188 H[4] Screw H M8 : (-).0188 E[5] Belt retaining pin : (-).0188 K[6] Square drive for adjusting the tension : (-).0188 J1[7] Belt tension measuring instrument, with digital display : SEEM CTG 105.5M


- Peg the flywheel using tool [2].- Peg the camshaft hub, using tool [4].- Peg the injection pump hub, using tool [3].

IMPERATIVE : If the pegging is not possible, repeat the setting of the timing.

CHECKING AND SETTING THE VALVE TIMINGEngine : WJY

B1EP16PD

B1BP2FTC


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Setting the valve timing

Removing.- Disconnect the battery.- Remove the front RH lower splash-shield, using tool [1].- Remove the accessories drive belt (see corresponding operation)- Uncouple and plug the diesel fuel delivery and return hoses.- Suspend the engine, using a workshop hoist.- Remove the RH engine support.- Engage 5th gear to allow you to rotate the engine.- Remove the upper timing cover (1).- Remove the intermediate timing cover (2).- Remove the lower timing cover (3).WARNING : Refit the screw (4) equipped with a washer (thickness 5 mm).- Turn the front RH wheel in order to drive the engine in its direction of rotation.- Bring the camshaft drive pinions and injection pump pinions to their settingpoints.- Position the peg [2] (from underneath the vehicle).- Continue to turn the engine until the peg [2] engages in the flywheel.


B1BP30BC B1BP2FTC


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Setting the valve timing (continued)

- Peg the camshaft hub, using tool [4].- Peg the injection pump hub, using tool [3].- Slacken screws (5) and (6).- Slacken the screw (9) of the tensioner roller (8).- Remove the timing belt.

Refitting.- Retighten screws (5) and (6) by hand.- Rotate the pinions (10) and (7) clockwise 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).


B1EP16PD

B1EP1EDC

C15 - BERLINGO - DISPAT-

B1EP1EEC

B1EP132C

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NOTE : If necessary, slightly rotate the pinions (10) and (7) anti-clockwise in order to engage the belt. You shouldnot have to move the the belt in relation to the pinions by more than half à tooth.- Remove tool [5].- Move the tensioner roller (8) by its square « a », using tool [6] to check that the camshaft and injection pumppinions can turn freely.- Place the belt tension instrument [7] on the belt at « b ».- Using tool [6], act at « a » in the opposite direction to engine rotation, to obtain a tension value of 106 ± 2SEEM units.- Tighten screws (9), (5) and (6).- Remove tools [7], [2], [3] and [4].- Rotate the crankshaft 8 turns in 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).- Place the belt tension instrument [7] on the belt at « b ».- Using tool [6], act at « a » in the opposite direction to engine rotation, to obtain a tension value of :

42 ± 2 SEEM units.


B1EP1EDC

B1EP1EFC


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Tighten :- Screw (9) to 2.1 ± 0.2 m.daN.- Screws (5) to 2,3 ± 0.2 m.daN.- Screws (6) to 2,3 ± 0.2 m.daN.- Remove and refit the tool [7].- The tension value should be between 38 and 46 SEEM units.- Remove tools [7], [2], [3] and [4].- Rotate the crankshaft 2 turns in the normal direction of rotation.- Peg the flywheel using the peg [2].- Visually check the peggings of the camshafts and injection pump.

IMPERATIVE : Visually check that the offsets between the holes ofthe camshaft and injection pump hubs and the correspondingpegging holes are not greater than 1 mm. If necessary, recommencethe procedure for fitting the timing belt.

- Remove the peg [2].- Remove the screw (4) and the washer.- Refit the lower timing cover (3).- Refit the intermediate timing cover (2).- Refit the upper timing cover (1).- Remove the RH engine support.- Take away the workshop hoist.- Remove the plugs and couple up the diesel fuel delivery and returnhoses.- Refit the accessories drive belt (see corresponding operation).- Refit the RH lower splash-shield.- Disengage 5th gear.- Connect the battery.



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CHECKING AND SETTING THE VALVE TIMINGEngine : RHX

Tools.

[1] Belt tension measuring instrument : 4122-T[2] Tension lever : (-).188.J2[3] Engine flywheel peg : (-).0288.D[4] Belt compression spring : (-).0188.K[5] Camshaft pinion peg : (-).0188.M[6] Engine flywheel lock : (-).0188.F[7] Set of blocking plugs : (-).0188.T[8] Crankshaft pulley extractor : (-).0188.P

Checking the setting of the valve timing.Peg : - The engine flywheel, tool [3].- The camshaft, tool [5].

WARNING : Should it be impossible to peg the camshaft, check that theoffset between the camshaft pinion hole and the pegging hole is not morethan 1 mm, with the help of a mirror « a » and a Ø 7 mm screw.

IMPERATIVE : If pegging is impossible, restart the adjusting.(See corresponding operation).

B1BP1TSC B1BP1TTCB1CP04CC

DISPATCH

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ECHECKING AND SETTING THE VALVE TIMINGEngine : RHX

Peg :- The engine flywheel, tool [3].- The camshaft, tool [5].

Slacken :- The three screws (9).- The screw (7) of the tensioner roller (6).

Remove the timing belt (8).

Checks.

IMPERATIVE : Just before refitting, carry out the checks below :

Check that :

- The rollers (6), (11) and the coolant pump (10) turn freely (without play or tightness).- There are no traces of oil (on camshaft or crankshaft).

B1EP13DD

DISPATCH

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Retighten screws (9) by hand.

Turn the pinion (12) (clockwise) to the bottom of thebuttonhole.

Refit the belt on the crankshaft, in the following order,using the tool [4] to keep the belt tight at « a » :

- Guide roller (11).

- Fuel high pressure pump pinion (13).

- Camshaft pinion (12).

- Water pump pinion (10).

- Tensioner roller (6).

NOTE : If needed, slightly turn the pinion (12) anti-clockwise (not by more than one tooth).

- Remove the tool [4].B1EP13FC B1EP13GD

B1EP13ED

DISPATCH

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Setting the valve timing (continued).

Position tool [1] on the belt at « b ».Turn the roller (6) (anti-clockwise) using tool [2] to attain a tension of :

98 ± 2 SEEM units

Tighten screw (7) of the roller (6), tighten to 2.5 m.daN.Remove one screw (9) from the pinion (12).(to check that the screws are not against the end of the buttonhole).Tighten the screws (9) to 2 m daN.Remove tools [1], [2], [3] and [5].Rotate the crankshaft 8 times (normal direction of rotation).Fit the tool [3].Loosen screws (9).Fit tool [5].Loosen screw (7) (to free the roller (6).Fit tool [1].Turn the roller (6) (anti-clockwise), tool [2], to attain a tension of :

54 ± 2 SEEM units.


B1EP13HD

DISPATCH

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Tighten :- Screw (7) of the roller (6) to 2.5 m.daN.- Screw (9) to 2.m.daNRemove the tool [1].Refit the tool [1].Tension value should be : 54 ± 3 SEEM units.

IMPERATIVE : If value is incorrect, restart the operation.

Remove tools [1], [3] and [5].Rotate the crankshaft 2 times (normal direction of rotation).Fit the tool [3].

WARNING : Should it be impossible to peg the camshaft, check that theoffset between the camshaft pinion hole and the pegging hole is notmore than 1 mm..In the case of an incorrect value, recommence the operation.

Remove the tool [3].

B1EP13HD

DISPATCH

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Tools.

[1] Belt tension measuring equipment : 4122-T[2] Tension lever : (-).0188.J2[3] Engine flywheel peg : (-).0188.Y[4] Belt clamp : (-).0188.AD[5] Camshaft pulley peg : (-).0188.M[6] Engine flywheel lock : (-).0188.F[7] Set of blocking plugs : (-).0188.T[8] Pulley extractor : (-).0188.P[9] 2 mm dia.peg : (-).0188.Q2

Removing

IMPERATIVE : Respect the safety and cleanliness requirementsthat are specific to high pressure diesel injection (HDi) engines.

Undo the front RH wheel bolts.Raise and support the vehicle on the front RH side.Disconnect the battery negative terminal.Remove : The under-engine sound-deadening.The front RH wheel.The front RH splash-shield.The engine cover.Unclip and move aside the cooling hose.Remove the accessories drive belt.(See corresponding operation).

Engines : RHY - RHZ

CHECKING AND SETTING THE VALVE TIMING BERLINGO - DISPATCH

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Uncouple, plug and move aside, using tool [7] , the fuel delivery pipe (2) andreturn pipe (1).Remove :Screws (3), (4) and (6).Screw (7).The upper timing cover (5).

WARNING : Refit screw (7) equipped with a spacer (17 mm thick), tighten thescrew (7) to 1,5 ± 0,1 m. daN.

NOTE : The screw (7) is one of the screws securing the coolant pump and isthere for its sealing.Put the gear lever in 5th gear.Turn the road wheel to turn the engine in its direction of rotation.Orient the camshaft pulley in the pegging position, use a mirror if necessary.

Peg the camshaft, using tool [5]

Peg the engine flywheel, using tool [3].

B1EP1A7CB1BP2R2C B1BP2H2C B1BP2H3C

CHECKING AND SETTING THE VALVE TIMINGDISPATCH

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Engines : RHY - RHZ

Remove : The fixings of the pipe linking the power steering pump with the rotary valve.The clutch lower closing plate.Lock the engine flywheel, using tool [6].Remove the screw (8).Refit the screw (8) without its thrust washer.Remove : The accessories pulley (9), using tool [8].Tool [6].The lower torque reaction rod.Support the engine by means of a workshop hoist.Remove : The bearing shell fitting (10).The nut (12).Screws (11).The bracket (13).NOTE : Lift then lower the engine with the workshop hoist, to have access to thetiming cover fixing screws.Remove : The intermediate timing cover.The lower timing cover.

B1BP2R3C

B1CP04BC B1BP2R4C

CHECKING AND SETTING THE VALVE TIMING DISPATCH

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Slacken the screw (17) of the tensioner roller (18).


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.

B1EP1A9C

B1EP1A8D


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Engines : RHY - RHZ

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) anti-clockwise, 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].

B1EP1ACC

B1EP1ABD


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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


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Engines : RHY - RHZ

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.daNScrews (3), (4) and (6).The bracket (13).Screws (11), tighten to 6,1 ± 0,5 m.daNThe nut (12), tighten to 4,5 ± 0,5 m.daNFit 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.daN and angular tighten to A = 60° ± 5°Refit the torque reaction rod on the lower engine support.Remove the tool [6].Reposition and reclip the cooling hose.Complete the refitting of components in reverse order to removal.

B1BP2R4CB1EP1A7C B1EP1ADC


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B1EP17GCB1BP2HLC

Tools.[1] Camshaft locating peg : (-).0188 M Toolkit C.0188[2] Flywheel locating peg : (-).0188 Y

CHECKING THE VALVE TIMINGIMPERATIVE : Respect the safety and cleanliness recommendations specific to high pressure dieselinjection (HDi) engines.RemovingRemove : - The heat shield (1).- The pipe (2).(Support the engine using a workshop hoist).- The screw (3).- The nuts (4).- The engine support (5).- Screws (6), (7), (9) and (10).- The upper timing cover (8)WARNING : Refit screw (10) equipped with a spacer of thickness 17 mm; tighten the fixing screw (10) :tighten to 1,5 ± 0,1 m.daN.Note : Screw (10) is one of the fixing screws for the coolant pump, also keeping it sealed.- Engage 5th gear.- Turn the road wheel to rotate the engine (normal direction of rotation).- Bring the camshaft pulley to the pegging position; use a mirror (if necessary).

Engines : RHV - 4HY

CHECKING THE VALVE TIMINGRELAY

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ECHECKING THE VALVE TIMINGEngines : RHV - 4HY

Checking the valve timing (continued)- Peg the flywheel, uising tool [2].- Peg the camshaft, using tool [1].

WARNING : Should it be impossible to peg the camshaft, check that the off-set between the camshaft pinion hole and the pegging hole is not morethan 1 mm, with the help of a mirror « a » and a Ø 7 mm screw..

IMPERATIVE : If pegging is impossible, restart the adjusting.(See corresponding operation).Remove : - Tools [1] and [2].- The screw (10) and the spacer.Refit : - The upper timing cover (8).- The screws (6), (7), (9) and (10) : tighten to 1,5 ± 0,1 m.daN.- The engine support (5).- The nuts (4).- The screws (3)- The pipe (2).- The heat shield (1).Disengage 5th gear and complete the refitting.

B1BP298C

B1BP2HMC B1EP17JC

B1EP17KC

RELAY

RHV

4HY

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Tools.

[1] Belt tension measuring instrument : SEEM CTG 105.5M[2] Tensioning lever : (-).0188.J2 Toolkit C.0188[3] Flywheel locating peg : (-).0188.Y[4] Belt retaining pin : (-).0188.K[5] Camshaft pinion peg : (-).0188.M[6] Engine flywheel lock : (-).0188.F[7] Crankshaft pulley extractor : (-).0188.P

Setting the valve timingIMPERATIVE : Respect the safety and cleanliness recommendations specific to high pressure dieselinjection (HDi) engines.RemovingRemove : - The auxiliary equipment drive belt (see corresponding operation).- The lower plate closing the clutch housing.Lock the flywheel, using tool [6].Remove the screw (1).Refit the screw (1), without the washer.Remove : - The crankshaft pulley, using tool [7]- The tool [6].Support the engine, using a workshop hoist.

Engines : RHV - 4HY

B1BP2HZC

B1CP04BC

RELAY

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Setting the valve timingRemove : - The heat shield (2).- The pipe (3).- The nuts (4).- The screws (5).- The RH engine support (6).NOTE : Raise and then lower the engine, to have access to the timing cover fixing screws.Remove : - The screws (8), (9), (17) and (18).- The upper cover (7).- The screws (10), (12) and (13).- The intermediate cover (11).- The screws (14) and (16).- The lower cover (15)WARNING : Refit the screw (17) equipped with a spacer (thickness 17 mm). Tighten to 1,5 ± 0,1 m.daNNOTE : The screw (17) is one of the fixing screws for the coolant pump, also keeping it sealed.Turn the engine (normal direction of rotation).Bring the camshaft pulley to its setting position.

Engines : RHV - 4HY

B1BP2J1CB1BP2J0C

RELAY

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Position the flywheel locating peg, using tool [3] (from underneath the vehicle).

Turn the engine until the peg [3] engages in the flywheel.

Peg the camshaft, using tool [5].

Slacken :

- The three screws (19).- The screw (23) of the tensioner roller (24).


Engines : RHV - 4HY

B1EP17LD

B1BP2J2C

RELAY

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Checks

IMPERATIVE : Just prior to refitting, perform the following checks.

Check that :

- The rollers (24), (21) and the coolant pump (22) turn freely (without play and without tight spots).- There are no signs of oil leaks (from sealing rings).- There are no leaks of coolant fluid (from the coolant pump).Replace any components that are defective.

Refitting

Tighten the screws (19) by hand.Turn the pinion (25) (clockwise), to place it at the end of the slot.Reposition the timing belt (20) on the crankshaft pinion (26).Hold the belt, using tool [4].

Engines : RHV - 4HY

B1EP17NC

B1EP17MC

RELAY

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Checks (continued)Reposition the timing belt (20), well-tensioned at «a», in the following order : - Guide roller (21).- Fuel high pressure pump pinion (27).- Camshaft pinion (25)- Coolant pump pinion (22).- Tensioner roller (24).NOTE : If necessary, slightly rotate the pinion (25) (anti-clockwise).(The offset should not be more than one tooth)Remove tool [4].Position the tool [1] on the belt at «b».Turn the tensioner roller (24) (anti-clockwise), using tool [2] to attain an overtension of98 ± 2 SEEM units.Tighten the screw (23) to 2,5 ± 0,2 m.daN.Remove one of the screws (19) of the pinion (25) to verify that these screws are not atthe end of the slot.Tighten the screws (19) to 2 ± 0,2 m.daN.Remove tools [1], [2], [3] and [5].Rotate the crankshaft eight times (normal direction of rotation).Fit the tool [3].Slacken the screws (19).

Engines : RHV - 4HY

B1EP17QD

B1EP17PD

RELAY

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Checks (continued)Fit tool [5].Slacken screw (23) to free the tensioner roller (24).Fit tool [1].Turn the tensioner roller (24) (anti-clockwise), using tool [2], to attain an overtension of54 ± 2 SEEM units.Tighten screw (23) to 2,5 ± 0,2 m.daN.Tighten screws (19) to 2 ± 0,2 m.daN.Remove tool [1].Fit tool [1].The tension value should be 54 ± 3 SEEM units.

IMPERATIVE : If the value is incorrect, recommence the operation.

Remove tools [1], [3] and [5].Rotate the crankshaft two times (normal direction of rotation).Fit tool [3].

IMPERATIVE : Should it be impossible to peg the camshaft, check that the offsetbetween the camshaft pinion hole and the pegging hole is not more than 1 mm. Ifthe value is incorrect, recommence the operation.

Engines : RHV - 4HY

B1EP17QD

RELAY

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Checks (continued)

Remove tool :- Tool [3].- Screw (17) and spacer.

Refit : - The lower cover (15).- Screws (14) and (16).- The intermediate cover (11).- Screws (10), (12) and (13).- The upper cover (7).- Screw (17), tighten to 1,5 ± 0,1 m.daN.- Screws (8), (9) and (18).- The RH engine support (6).- Screws (5).- Nuts (4).- The pipe (3).- The heat shield (2).

Take away the workshop hoist.Coat the screw (29) with Loctite FRENETANCH

Refit : - The crankshaft pulley (1).- Tool [6].- Screw (29) with washer (28),

Tighten to 4 ± 0,4 m.daN.Angular tighten 51° ± 5°

Remove tool [6].

Refit : - The clutch housing closing plate.- The auxiliary equipment drive belt.(See corresponding operation).Complete the refitting.

Engines : RHV - 4HY

B1EP17RC

RELAY

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ECHECKING THE VALVE TIMING

Tools.

[1] Pliers for removing plastic pins : 7504-T[2] Peg for setting the injection pump : 1 860 617 000 Toolkit (-).0191


RemovingDisconnect the negative terminal of the battery.Raise and support the vehicle.Remove : - The lower RH splash-shield, using tool [1], the engine cover, the accessories drive belt(see corresponding operation).Remove the screws (2), the timing cover (1), the engine speed sensor.Insert a screwdriver in the aperture of the engine speed sensor, to immobilise the flywheel.Remove the screw (3), the accessories drive pulley (4), the screwdriver.Turn the engine in its normal direction of rotation.Bring the injection pump pulley (6) to its setting point.Position the tool [2].Turn the engine until the tool [2] engages in the setting hole.Check the alignment between the marking "a" on the camshaft pulley (5) and the marking "b" on thevalve cover.

Engine : 8140.43

B1BP21YC

B1BP21ZD

RELAY

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Check that the marking «c» on the crankshaft pinion (7) is in a low position in relation to the engine’s vertical axis.

IMPERATIVE : If pegging of the injection pump pinion proves impossible, restart the setting operation.

Refitting

Remove the tool [2].Refit :- the accessories drive pulley (5)- the screw (3) (use a screwdriver to immobilise the flywheel), tighten to : 20 m.daN- the engine speed sensor- the timing cover (1)- the screws (2)- the accessories drive belt (see corresponding operation)- the engine cover- the lower RH splash-shield.

Lower the vehicle.Connect the negative terminal of the battery.

Engine : 8140.43S

B1BP220C

RELAY

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Tools.

[1] Pliers for removing plastic pins : 7504-T[2] Peg for setting the injection pump : 1 860 617 000 Toolkit (-).0191[3] Belt tensioner compressor : 1 860 638 000 Toolkit (-).0191

RemovingDisconnect the negative terminal of the battery.Raise and support the vehicle.Remove : - The lower RH splash-shield, using tool [1], the engine cover, the accessories drive belt(see corresponding operation).Remove the screws (2), the timing cover (1), the engine speed sensor.Insert a screwdriver in the aperture of the engine speed sensor, to immobilise the flywheel.Remove the screw (3), the accessories drive pulley (4), the screwdriver.Lock the belt tensioner (7), using tool [3].Turn the engine in its normal direction of rotation.Bring the injection pump pulley (6) to its setting point.Position the tool [2].Turn the engine until the tool [2] engages in the setting hole.Check the alignment between the marking "a" on the camshaft pulley (5) and the marking "b" on thevalve cover.

Engine : 8140.43

B1BP21YC

B1BP221D

RELAY

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Check that the marking «c» on the crankshaft pinion (7) is in a low position in relation to the engine’s vertical axis.IMPERATIVE : If pegging of the injection pump pinion proves impossible, restart the setting operation.Remove : the screws (11), the nut (9), the cover (10), the timing belt.RefittingRefit : the timing belt, the cover (10), the screws (11), the nut (9), tighten by hand.Remove tool [2] and [3]NOTE : Check that the belt tensioner touching point is in contact with the tensioner roller support.Tighten the nut (9) to : 4 ± 0,4 m.daN.Turn the crankshaft 2 turns in the normal direction of rotation.ESSENTIAL : Never turn the crankshaft backwards.Peg the injection pump pulley, using tool [2].IMPERATIVE : If it is impossible to refit the tool [2], restart the operations for refitting the belt.

Remove tool [2].Refit the accessories drive pulley (5) (use a screwdriver to immobilise the flywheel).Tighten the screw (3) to : 20 ± 2 m.daNRefit : the timing cover (1), the screws (2), the accessories drive belt (see corresponding operation), the enginecover, the lower RH splash-shield.Lower the vehicle.Connect the negative terminal of the battery.

Engine : 8140.43

B1BP222C

RELAY

B1BP223C

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Tools.

[1] Pliers for removing plastic pins : 7504-T[2] Flywheel locking tool : (-).0191 C[3] Belt compression tool : 1 860 638 000 Toolkit (-).0191[4] Belt compression spring : (-).0188K

Checking the setting of the valve timing.RemovingRemove : - The lower RH splash-shield, using tool [1].- The engine cover.- The accessories and alternator belt (according to equipment).Turn the engine (normal direction of rotation).Immobilise the flywheel at «a», using tool [2].

Remove : - Screws (2).- The timing cover (1).- Screw (3).- The accessories pulley (4)

Engine : 8140.43S

B1BP2PXC

B1BP2DTC

RELAY

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RELAY CHECKING AND SETTING THE VALVE TIMING

Checking the setting of the valve timing (continued).

- Check that the marking «b» on the crankshaft pinion (5) is in a low position in relation to the engine’s verticalaxis at «c».- Check the alignment between the marking «d» on the camshaft pulley (6) and the marking «e» on the valvecover.

Refitting

Refit the accessories pulley (4).Immobilise the flywheel at «a», using tool [2]Fit and tighten the screw (3), tighten to ± 2 m.daN. Remove the peg, dia. 8 mm.Fit : - The accessories cover (1)- The screws (2).- The accessories and alternator belt (see corresponding operation).Complete the refitting in opposite order to removal.

Engine : 8140.43S

B1BP2DWC B1BP2DXC

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Setting the valve timing

Removing

Remove :

The accessories and alternator belt (see corresponding operation).Rotate the engine (normal direction of rotation).

Immobilise the flywheel at «a», using tool [2].

Remove :

- Screws (2).- The timing cover (1).- Screw (3).- The accessories pulley (4)

Engine : 8140.43S

B1BP2PXC

B1BP2DTC

RELAY

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Setting the valve timing (continued)Lock the belt tensioner (7), using tool [3].Rotate the engine (normal dieection of rotation).

Check that the marking «b» on the crankshaft pinion (5) is in a low position in relation to the engine’s verticalaxis at «c».Check the alignment between the marking «d» on the camshaft pulley (9) and the marking «e» on the valvecover.

Remove : - Screw (8).- Nut (6).- The cover (7).- The timing beltMove aside : - The coolant header tank.- The air conditioning pipes.Support the engine.Remove the RH engine support.

Engine : 8140.43S

B1BP2DUC B1BP2DVC

RELAY

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Setting the valve timing (continued)RefittingRefit : - The timing belt, using tool [4].- The cover (7).- Screw (8).- Nut (6), (tighten by hand).- Remove tool [3]Note : Check that the belt tensioner’s contact point is touching the tensioner roller support.Tighten the nut (6), tighten to 4 ± 0,4 m.daN.Rotate the crankshaft two turns (normal direction of rotation).ESSENTIAL : Never rotate the engine backwards.Refit the accessories pulley (4).Immobilise the flywheel at «a», using tool [2]Fit and tighten the screw (3), tighten to ± 2 m.daN. Remove tool [2].Fit : - The accessories cover (1)- The screws (2).- The accessories and alternator belt.Complete the refitting in opposite order to removal

Engine : 8140.43S

B1BP2DUC B1BP2DVC

RELAY

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CHECKING THE OIL PRESSUREPetrol

Engine type HFX KFW NFU RFL R6G RFNTemperature (°C) 90° 80°Pressure (Bars)RpmPressure (Bars) 3Rpm 2000Pressure (Bars)RpmPressure (Bars) 4 7Rpm 4000 4000

Tools Toolkit 4103-T2279-T.Bis X X X X X X4103-T X X X X X X7001-T X X X X X X

NOTE : The oil pressure should be checked with the engine hot, after the oil level has been checked.

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ECHECKING THE OIL PRESSUREDiesel

Engine type 9HZ WJY RHY RHX RHZ RHV RHW 4HY 8140.43 8140.43STemperature (°C) 90° 80° 90°Pressure (Bars) 1,3 1,8 2 2 0,8Rpm 1000 1000 750Pressure (Bars) 3,7 4Rpm 2000 2000Pressure (Bars) 4,3Rpm 3000Pressure (Bars) 3,5 4,5 4 3,3Rpm 4000 4000

Tools Toolkit 4103-T2279-T.Bis X X X X X X4103-T X X X X X X(-).1503.J X4225-T X4202-T X X X

NOTE : The oil pressure should be checked with the engine hot, after the oil level has been checked

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E The valve clearances must be checked with the engine cold.

● Inlet

HFX - KFW - RFN

NFU

WJY

0,20 ± 0,05 mm

Exhaust

0,40 ± 0,05 mm

2.8 TD - 2.8 HDi

1 ± 0,05 mm 1 ± 0,05 mm

Exhaust Adjust

1 ● 1

3 ● 3

4 ● 4

2 ● 2

4 ● 4

2 ● 2

1 ● 1

3 ● 3

Exhaust

●

Inlet

RockingValves

fully open

Adjust

1

3

4

2

3 ● 4

4 ● 2

2 ● 1

1 ● 3

Fully open (Exhaust)

POSSIBLE PROCEDURESFor engines with 4 cylinders in a line (1-3-4-2 )

Engines without hydraulicadjustment : the clearance (J)should be checked opposite thecam.

B1DP13QC

RFN - 9HZ - RHY - RHXRHZ - RHV - RHW - 4HY Automatic adjustment

0,15 ± 0,08 mm 0,30 ± 0,08 mm

0,50 ± 0,05 mm 0,50 ± 0,05 mm

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CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT

Tools.[1] Ø 10 mm low pressure connector : 4215-T[2] Pressure gauge for testing boost pressure : 4073-T.A Toolkit 4073-TChecks

IMPERATIVE : Respect the safety and cleanliness specific to high pressure diesel injection(HDi) engines.

Remove the air filter duct.Link tool [1] in series, downstream of the injectors, between the fuel high pressure pump and thefuel filter at «a» and «b».

WARNING: Any checking of pressure downstream of the fuel filter is prohibited.Switch on the ignition.

Check the negative pressure according to the table below:

Vacuum measured by tool [2] Checks

10 ± 0,5 cmHg Engine driven by the starter motor

20 ± 0,5 cmHg Engine running under full load

30 ± 0,5 cmHgFuel supply circuit, fuel filter piping

B1CP0GFD

Engine : 9HZ

BERLINGO

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Engines : RHY - RHZ

Tools.

[1] Ø 10 mm low pressure connector : 4215-T[2] Ø 8 mm low pressure connector : 4218-T[3] Pressure gauge for testing boost pressure : 4073-T Kit 4073-T

Connect the tool [1] between the booster pump and the fuel filter (white mark at "a" onthe fuel supply pipe).Connect the tool [2] downstream of the diesel injectors, between the high pressure fuelpump and the fuel filter (green mark at "b" on the fuel return pipe).

WARNING : Any check of pressure downstream of the fuel filter is PROHIBITED.

Checks on pressure : static.

- Switch on ignitionFor 3 seconds (normal functioning):- Fuel supply pressure shown by the pressure gauge [3] = 1.8 ± 0.4 Bar.- Fuel return pressure shown by the pressure gauge [3] = 0.5 ± 0.4 Bar.

B1BP1TWD

CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUITBERLINGO - DISPATCH

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Checks on pressure : dynamic.Engine running, at idle (normal functioning):- Fuel supply pressure shown by the pressure gauge [3] = 2 ± 0.4 Bar.- Fuel return pressure shown by the pressure gauge [3] = 0.7 ± 0.4 Bar.Abnormal functioning

Fuel supply pressure Fuel return pressure Checks

Between 3 and 3.5 Bar 0,7 ± 0,2 bar Check the condition of the diesel filter

More than 3,5 bars Less than 0,7 bar Check the low pressure regulator incorporated in the filter (jammed shut) : replace.

More than 3,5 bars More than 0,7 bar Check the fuel return circuit (pipe pinched or trapped).

Between 0.8 and 1.5 Bar Less than 0,7 bar Check the fuel suppy circuit :- Booster pump (low pressure), piping.

Check : Observe :

The flow should be drop by drop Diesel injector functioning correctly

Excessive fuel return Diesel injector jammed shut.

Engines : RHY - RHZ

Impossible to start the engine :Fuel supply pressure less than 0.8 Bar :- Check the low pressure regulator incorporated in the filter (jammed open)- Check the high pressure pump distribution valve (jammed shut)

Check : diesel injector return flow. (Table below)

Uncouple the diesel injector return pipe.

CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT BERLINGO - DISPATCH

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Engine : RHV

Tools.[1] Ø 10 mm low pressure connector : 5725-T[2] Ø 8 mm low pressure connector : 5724-T[3] Pressure gauge for testing boost pressure : 4073-T Kit 4073-T[4] Pressure gauge extension for tool testing HDi low pressure : 4251-T

ChecksIMPERATIVE : Respect the safety and cleanliness specific to high pressure diesel injection (HDi) engines.

Connect the tool [1] between the booster pump and the fuel filter (at "a" on the fuel supply pipe).Connect the tool [2] downstream of the diesel injectors, between the high pressure fuel pump and the fuel filter (at"b" on the fuel return pipe.

WARNING : Any check of pressure downstream of the fuel filter is prohibited

NOTE : For testing the pressures when the vehicle is being driven, connect the extension [4] between the pressuregauge [3] and the tools [1] and [2].

B1BP2G7C B1BP2G8C

CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUITJUMPER

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Checks on pressure : static.Switch on the ignition.For 3 seconds (normal functioning).- Fuel supply pressure shown by the pressure gauge [3] = 2.3 ± 0.4 Bar.- Fuel return pressure shown by the pressure gauge [3] = 0.3 ± 0.4 Bar.

Fuel supply pressure Fuel return pressureBetween 3.3 and 4 Bar 0,8 ± 0,4 bars

More than 4 bars Less than 0,8 barMore than 4 bars More than 0,8 bar

Between 0.8 and 1.5 Bar Less than 0,8 bar

Impossible to start the engine :Fuel supply pressure less than 0.8 Bar :- Check the low pressure regulator incorporated in the filter (jammed open)- Check the high pressure pump distribution valve (JAMMED shut)Check : diesel injector return flowUncouple the diesel injector return pipe.

Checks : Observations

The flow should be drop by dropDiesel injector functioning

correctlyExcessive fuel return Diesel injector locked shut

Contrôle de pressions en dynamique.Engine tournant au régime de ralenti (fonctionnement normal).Pression d'arrivée carburant indiquée par le manomètre [3] = 2,5 ± 0,4 bars.Pression de retour carburant indiquée par le manomètre [3] = 0,5 ± 0,4 bars.Fonctionnement anormal.

ContrôleCheck the diesel filter

Check the low pressure regulator incorporated in the fuel filter (locked shut) : replace.

Check the fuel return circuit (pipe pinched or trapped).

Check the fuel supply circuit : - Booster pump (low pressure), piping.

Checks using the DIAL diagnostic tool (PEUGEOT network)Measure the supply flow, at «a» : 150 ± 10 l/h (at the fuel filter inlet).Measure the diesel injector return flow, at «b» : 50 ± 15 l/h (on the fuel filterreturn).

Checks : Observations

If the injector return flow is greater Valve open (jammed)than 50 ± 15l/h Valve shut (jammed)

Engine : RHV

CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT JUMPER

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Engines : 4HY - 8140.43S

Tools.[1] Ø 10 mm low pressure connector : 5725-T[2] Ø 8 mm low pressure connector : 5724-T[3] Pressure gauge for testing boost pressure : 4073-T Kit 4073 -T[4] Pressure gauge extension for tool testing HDi low pressure : 4251-TCheckConnect the tool [1] between the booster pump and the fuel filter (white mark at "a" on the fuel supply pipe).Connect the tool [2] downstream of the diesel injectors, between the high pressure fuel pump and the fuel fil-ter (green mark at "b" on the fuel return pipe).WARNING : Any check of pressure downstream of the fuel filter is PROHIBITEDNOTE : For testing the pressures when the vehicle is being driven, connect the extension [4] between thepressure gauge [3] and the tools [1] and [2].Checks on pressure: static.- Switch on the ignition- For 3 seconds (normal operating):- Fuel supply pressure shown by the pressure gauge [3] = 2,4 ± 0,4 Bar (8140.43S)

[3] = 2,3 ± 0,4 Bar (4HW)- Fuel return pressure shown by the pressure gauge [3] = 0,5 ± 0,2 Bar (8140.43S)

[3] = 0,3 ± 0,2 Bar (4HW)NOTE : The difference in pressure measured between the fuel supply and the fuel return should be beween1,1 and 1,6 Bar.

B1BP2G7C B1BP2G8C

CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUITJUMPER

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Checks on pressure : dynamic.Engine running, at idle (normal operating):- Fuel supply pressure shown by the pressure gauge [3] = 2,5 ± 0,4 Bar (8140.43S engine) – 2,3± 0,4 Bar (4HY engine)- Fuel return pressure shown by the pressure gauge [3] = 0,6 ± 0,2 Bar (8140.43S engine) – 0,3± 0,4 Bar (4HY engine)Abnormal operating

Fuel supply pressure Fuel return pressure Checks

8140.43S 4HY 8140.43S 4HYBetween 3 and 3,5 Bars Entre 3,3 et 4 bars 0,8 ± 0,2 bars 0,8 ± 0,4 bars Check the condition of the diesel filter

More than 3,5 bars More than 4 bars Less than 0,8 bar Less than 0,8 bar Check the low pressure regulator incorporated in the filter (locked shut) : replace.

More than 3,5 bars More than 4 bars More than 0,8 bar More than 0,8 bar Check the fuel return circuit (pipe pinched or trapped...).

Between 0,8 and 1,5 Bar Between 0,8 and 1,5 Bar Less than 0,8 bar Less than 0,8 bar Check the fuel suppy circuit :- Booster pump (low pressure), piping.

Check : Observe :

The flow should be drop by drop Diesel injector functioning correctly

Excessive fuel return Diesel injector locked shut.

Engines : 4HY - 8140.43S

Impossible to start the engine :Fuel supply pressure less than 0.8 Bar :- Check the low pressure regulator incorporated in the filter (locked open)- Check the high pressure pump distribution valve (locked shut)

Check : diesel injector return flow. (Table below)

Uncouple the diesel injector return pipe.

CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT JUMPER

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Engine : RHY

Tools.

[1] Pressure gauge for checking boost pressure : 4073-T.A Kit 4073-T[2] Sleeve for checking boost pressure : 4185-T

Checks.IMPERATIVE : respect the following checking requirements : Engine at running temperature,vehicle running at full load.

Preparation.- Remove the clip (3) and the sleeve.- Insert the tool [2] between the pipe (1) and the duct (2).- Position tool [1] inside the vehicle.- Connect the pressure gauge [1] to the tool [2] with its tube « a » long enough for

the gauge to be positioned inside the vehicle.Procedure.- Start the engine.- Engage first gear and start driving.- Engage the gears up to third gear.- Decelerate to 2000 rpm.- Gradually accelerate.- Check the pressure : 0.95 ± 0.05 Bar - Remove the tools, refit the collars (3) and the sleeve.

B1BP1ZXD

CHECKS : TURBO PRESSUREBERLINGO

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Engine : RHZ

Tools.

[1] Pressure gauge for checking boost pressure : 4073-T.A Kit 4073-T[2] Sleeve for checking boost pressure : 4185-T[3] Adaptor sleeve : 4229-TChecks.IMPERATIVE : respect the following checking requirements : Engine at running tempera-ture, vehicle in running order at full load.Preparation.- Remove the clip (3).- Connect tool [2] equipped with tool [3], between the tube (1) and the duct (2).- Position the tool [1] inside the vehicle.- Connect the sleeve [2] on the tool [1] with the tube "a".Procedure.- Start the engine.- Engage first gear and start driving.- Engage the gears up to third gear.- Decelerate to 1000 rpm.- Accelerate hard, then check the pressure : 0,6 ± 0,05 Bar (1500 rpm).- Accelerate freely (changing down from 4th gear to 3rd gear).- Check the pressure : 0,95 ± 0,05 Bar (between 2500 and 3500 rpm).- Remove the tools, reposition the tube (1) and put back the collar (3).

B1HP12JD

CHECKS : TURBO PRESSURE DISPATCH

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Engine : RHV

Tools.

[1] Pressure gauge for checking boost pressure : 4073-T.A Kit 4073-T[2] Sleeve for checking boost pressure : 4185-T[3] Adaptor sleeve : 4219-TChecksIMPERATIVE : Respect the safety and cleanliness specific to high pressure diesel injection(HDi) engines.- Connect tool [1] equipped with tool [3], between the tube (2) and the duct (1).Procedure- Connect the sleeve [2] on the pressure gauge [1] with the tube "a".- Position the tool [1] inside the vehicle.IMPERATIVE : respect the following checking requirements : Engine at running temperature,vehicle in running order at full load.- Start the engine.- Engage first gear and start driving.- Engage the gears up to third gear.- Decelerate to 2000 rpm.- Gradually accelerate.- Check the pressure : 0.95 ± 0.05 Bar - Remove the tools [1] and [2].- Re-couple the tube (2) on the duct (1).- Tighten the clip.

B1HP1FFC

CHECKS : TURBO PRESSUREJUMPER

C5FP0FSC

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Engine : 4HY

Tools.

[1] Pressure gauge for checking boost pressure : 4073-T.A Kit 4073-T[2] Sleeve for checking boost pressure : 4185-T[3] Adaptor sleeve : 4219-TChecksIMPERATIVE : Respect the safety and cleanliness specific to high pressure diesel injection(HDi) engines.- Remove the protector for the electrovalves (1).- Connect tool [1] equipped with tool [3], between the tube (3) and the duct (2).- Connect the sleeve [2] on the pressure gauge [1] with the tube "a".Procedure- Position the tool [1] inside the vehicle.IMPERATIVE : respect the following checking requirements : Engine at running temperature,vehicle in running order at full load.- Start the engine.- Engage first gear and start driving.- Engage the gears up to third gear.- Decelerate to 2000 rpm.- Gradually accelerate.- Check the pressure : 0.95 ± 0.05 Bar - Remove the tools [1] and [2].- Re-couple the tube (2) on the duct (1).- Tighten the clip.

B1HP1LZC

CHECKS : TURBO PRESSURE JUMPER

C5FP0FSC

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Engine : 8140.43

Tools.

[1] Pressure gauge for checking boost pressure : 4073-T.A Kit 4073-T[2] Sleeve for checking boost pressure : 4185-T[3] Adaptor sleeve : 4219-TChecksIMPERATIVE : respect the following checking requirements : Engine at running temperature.Vehicle in running order at full load.- Remove the clip (1).- Connect tool [2] equipped with tool [3], between the tube (3) and the duct (2).- Position the tool [1] inside the vehicle.- Connect the tool [2] on the pressure gauge [1] with the tube «a».Procedure.Start the engine.- Engage first gear and start driving.- Engage the gears up to third gear.- Decelerate to 1000 rpm.- Check the pressure: 0,6 ± 0,05 bar. (1500 rpm).- Accelerate freely (changing down from 4th gear to 3rd gear).- Check the pressure : 0,9 ± 0,05 bar (between 2500 and 3500 rpm).- Remove tools [1], [2] and [3].- Reposition the tube (3).- Put back the clip (1).

B1BP231D

CHECKS : TURBO PRESSUREJUMPER

C5FP08AC

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Engine : 8140.43S

Tools.[1] Pressure gauge for checking boost pressure : 4073-T.A Kit 4073-T[2] Sleeve for checking boost pressure : 4185-T[3] Adaptor sleeve : 4219-TChecksIMPERATIVE : respect the following checking requirements : Engine at running temperature.Vehicle in running order at full load.Preparation.- Remove the clip (1).- Connect tool [2] equipped with tool [3], between ducts (2) and (3).- Connect the tool [2] on the pressure gauge [1] with the tube «a».Procedure.Position the tool [1] inside the vehicle.Start the engine.- Engage first gear and start driving.- Engage the gears up to third gear.- Decelerate to 1000 rpm.- Check the turbo pressure: 0,6 ± 0,1 bar. (1500 rpm).- Accelerate freely (changing down from 4th gear to 3rd gear).- Check the turbo pressure : 1 ± 0,1 bar (between 2500 and 3500 rpm).- Remove tools [1], [2] and [3].- Reposition the duct (3).- Put back the clip (1).

B1BP2DSD

CHECKS : TURBO PRESSURE JUMPER

C5FP0FSC

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Engine : 9HZ

Tools.

[1] Manual pressure-vacuum pump FACOM DA 16.

Checks.

Vacuum pump

Connect the tool [1] on to the vacuum pump (1).Start the engine.The vacuum value should be 0.9 ± 0.1 bar at idle (after 30 seconds of operation).

NOTE : The exhaust gas recycling valve is not linked to the air supply circuit.The exhaust gas recycling electrovalve is controlled by the engine ECU.

Turbocharging pressure regulation valve.

- Connect the tool [1] on the valve (2)..- Appy a vacuum of approx. 0.8 bar. Rod "a" should move 6 ± 2 mm.

B1HP1UGC

CHECKING THE AIR SUPPLY CIRCUITBERLINGO

B1HP22RC

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Engines : RHX - RHZ

TOOLS

[1] Manual vacuum pump : FACOMM DA 16.IMPERATIVE : Respect the safety and cleanliness requirements.Vacuum pump.- Connect the tool [1] on the vacuum pump (1).- Start the engine.- Pressure should be 0.8 bar at 780 rpm.Boost pressure regulator electrovalve.- Connect the tool [1] between the electrovalve (2) and the valve (3) of the boost pressure regulator.Compare readings with the values in the table below

Engine speed (rpm) Pressure (Bar)

780 0,6

4000 0,25

Pressure regulator valve.- Connect the tool [1] on the valve (3).- Appy a pressure of 0.5 bar to activate the rod "a" : - Rod "a" should move 12 mm.

B1HP12FD

CHECKING THE AIR SUPPLY CIRCUIT DISPATCH

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Engine : RHV

Tools.

[1] Manual pressure-vacuum pump : FACOM DA 16

Checks

- Connect tool [1] to the take-off at «a»(vacuum pump tube).

- Start the engine.

- The vacuum value should be 0,8 bar at idling speed.

B1HP1FGC

CHECKING THE AIR SUPPLY CIRCUITJUMPER

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Engine : 4HY

Tools.

[1] Manual vacuum pump : FACOM DA 16

Checks

- Uncouple the tube at «a».

- Connect tool [1] at «a»

- Start the engine.


B1BP2QKC

CHECKING THE AIR SUPPLY CIRCUIT JUMPER

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Engine : 8140.43S

Tools.

[1] Manual vacuum pump : FACOM DA 16

IMPERATIVE : Respect the safety and cleanliness requirements.

- Uncouple the tube at «a».

- Connect tool [1] at «a»

- Start the engine.


B1BP2QKC

CHECKING THE AIR SUPPLY CIRCUITJUMPER

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Engine : 8140.43S

Tools.[1] Manual vacuum pump : FACOM DA 16.EGR electrovalve.Check, not under load, between the electrovalve (2) and the EGR valve (1).- Connect the tool [1] between the electrovalve (2) and the capsule (1).- Compare readings with the values in the table below.EGR valve- Connect the tool [1] to the capsule union (1).- Apply, several times in succession, a vacuum of approx. 0.6 bar to activate the rod "a".- In abruptly removing the vacuum, the valve should lock itself back on its seating with a click.

EGR electrovalve.Check, not under load, between the electrovalve (2) and the EGR valve.- Connect the tool [1] between the electrovalve (1) and the EGR valve.- Compare readings with the values in the table below.EGR valve- Connect tool [1] on the capsule union of the EGR valve (2).- Apply a vacuum of approx. 0,6 bar to activate the EGR valve.- In abruptly removing the vacuum, the valve should lock itself back on its seating with a click.- Repeat the operation several times.

Engine speed (rpm) Vacuum value (Bar)780 0,5 bar2500 0 barB1KP017C

B1HP12GD

B1BP2QAC

CHECKS : EXHAUST GAS RECYCLING CIRCUIT BERLINGO - DISPATCH - JUMPER

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Engine : 4HY

Tools.

[1] Manual vacuum pump : FACOM DA 16.IMPERATIVE : Respect the safety and cleanliness requirements.EGR electrovalve (1).Check, not under load, between the electrovalve (1) and the EGR valve.- Connect the tool [1] between the electrovalve (1) and the EGR valve.- Compare readings with the values in the table below.Butterfly housing electrovalve (2).Check, not under load, between the electrovalve (2) and the butterfly housing (3).- Connect the tool [1] between the electrovalve (1) and the butterfly housing (3).- Compare readings with the values in the table below.

Engine speed (rpm) Vacuum value (Bar)

780 0,5 bar

2500 0 bar

EGR valve- Connect tool [1] on the capsule union of the EGR valve (4).- Apply a vacuum of approx. 0,6 bar to activate the EGR valve.- In abruptly removing the vacuum, the EGR valve should lock itself back on its seating with a click.- Repeat the operation several times..- Uncouple the air duct.- Connect the tool [1] on the butterfly housing vacuum capsule (3).- Apply a vacuum of approx. 0,8 bar, the flap «a» of the butterfly housing (3) should be closed.B1KP011C

B1BP2Q8C B1HP1FTC

CHECKS : EXHAUST GAS RECYCLING CIRCUIT JUMPER

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Vehicles – Models

BERLINGO

Engine type BOSCH CHAMPION SAGEMElectrode gap

settingTightening

torque

1.1i HFX FR7DE RC8YCL RFN58 LZ

1.4i KFW FR7DE RC8YCL RFN58 LZ 0.9 mm 3,0 m.daN

1.6i 16V NFU FR7ME RFN58HZ

2.0i 16V RFN FR8ME REC9YCL RFN52HZ 1 mm 2,7 m.daN

SPARKING PLUGS

DISPATCH

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SPEEDOMETER

An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled.

This decree stipulates :

- The speed indicated by a speedometer must never be lower than the actual vehicle speed.- Between the speed displayed «SD» and the speed travelled «ST», there must always be the following relationship :

VR < VL < 1,10 VR + 4 Km/h

Example : For an actual speed of 100 Kph the speed displayed by the speedometer may be between 100 and 114 Kph.The speed indicated by the speedometer may be influenced by :

- The speedometer.- The tyres fitted to the vehicle.- The final drive ratio.- The speedometer drive ratio.Any of these components can be checked without removing them from the vehicle. (See information note N° 78-85 TT of 19 October 1978.NOTE : Before replacing the speedometer, check the conformity of the following points :- The tyres fitted to the vehicle.- The gearbox final drive ratio.- The speedometer drive ratio.

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CLUTCH SPECIFICATIONS

Engine plate WJY

Payload (Kg) 600/765

Gearbox BE4/5

Make LUK

Mechanism/Type 200 P 3700

Ext./Int. lining Ø 200/134

Disc lining type F 408

1.9 D

Diesel

C15

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Engine plate HFX KFW NFU 9HZ WJY RHY

Gearbox MA/5 BE4/5

Make VALEO LUK

Mechanism/Type 200 CPX 3850 234 T 4800 200 P 4700 235 T 5700

Ext./Int. lining Ø 200 x 137 234 x 165 200 x 137 228 x 155

Disc lining type F 808 F 810 F 408

Petrol Diesel

1.1i 1.4i 1.6i 16V 1.6 16V HDi 1.9 D 20 HDi

BERLINGO

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199


Engine plate RFN WJY RHX RHZ RHW

Gearbox BE4/5 ML/5

Make VALEO LUK

Mechanism/Type 203 DNG 4700 200 P 4700 235 T 5700 225 T 6900

Ext./Int. lining Ø 228 x 155 200 x 137 228 x 155 225 x 150

Disc lining type F 808 DS F 408 F 202 F 810

Petrol Diesel

2.0i 16V 1.9 D 2.0 HDi 2.0 16V HDi

DISPATCH

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Engine plate RFL R6G RHV 4HY 8140.43 8140.43S

Gearbox ML/GU

Make VALEO LUK VALEO

Mechanism/Type 235 DT 5900 230 DNG 4700 242 DT 5200 242 DT 6200

Ext./Int. lining Ø 228 x 155 242 x 161

Disc lining type F 808

Petrol Diesel

2.0i 2.0 8S HDi 2.2 8S HDi 2.8 TD 2.8 HDi

RELAY

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MANUAL GEARBOX SPECIFICATIONS

Vehicle Engine Gearbox Sequence Torque ratio Drive ratio

Type BE4/5

C15 DW8B BE3/5N 20 TE 11 17 x 71

TU1JP MA/5S 20 CP 61 13 x 5919 x 21

TU3JP MA/5L20 CP 37

13 x 5920 CP 36

TU5JP4BE4/5N 20 DM 45 17 x 77 19 x 17

BerlingoBE4/5J 20 DM 46 19 x 77 19 x 16

DV6ATED4 BE4R/5L 20 DM 83 19 x 72 None

DW8BBE4/5L 20 DM 47 17 x 77 19 x 17

BE4/5N 20 DM 48 17 x 71 19 x 17

DW10TDBE4/5KG 20 DM 79 19 x 70

NoneBE4/5KG 20 DM 80 19 x 72

Dispatch EW10J4 BE4/5 20 DL 93 15 x 74 22 x 19

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Type ML/5

DW10BTED 20 LM 26 14 x 71

DispatchDW10CTED

ML/5C20 LM 19 14 x 67

25 x 20DW10BTED+ 20 LM 32 14 x 67

DW10ATED4 20 LM 06 15 x 67

Type ML/5

Vehicle Engine Load Gearbox Sequence Torque ratio Drive ratio

XU10J2U10Q 14Q 20 UM 07 13 x 73 18 x 14

18Q 20 UM 08 13 x 83 21 x 15

DW10UTD 10Q 14Q 20 MM 01 14 x 75 22 x 21

DW12UTED10Q 14Q 20 UM 16 13 x 68 18 x 14

Relay 18Q ML/GU 20 UM 10 12 x 71 21 x 15

8140.43 10Q 14Q 20 UM 13 13 x 68 18 x 14

2.8 TD 18Q 20 UM 06 13 x 83 21 x 15

8140.43S18Q

20 UM 05 13 x 68 21 x 15

2.8 HDi 20 UM 15 13 x 68 21 x 15

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Type AL4

Dispatch EW10J4 AL4 20 TP 96 21 x 73 52 x 67

Type 4 HP 20

Relay 2.8 HDi 4 HP 20 Sans 20 x 69 59 x 68

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Ref. Description No. of screws m.daN

1 Bearing retaining clip 4 1,8 ± 0,2

2 Intermediate plate 11 5 ± 0,5

16

3 Gearbox casing## RPO 9784

1,9 ± 0,217

RPO 9786 ##4 Clutch bearing guide screws 3 0,6 ± 0,15

B2CP3SRP

MA/5 GEARBOX : TIGHTENING TORQUES

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26 5th gear housing fixing screws 3 2,2 ± 0,2

27 Reverse gear switch 2,5 ± 0,5

28 Drain plug 1 3,3 ± 0,3

29 Level plug 3,3 ± 0,3

B2CP3SSD

MA/5 GEARBOX : TIGHTENING TORQUES

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1 Air vent hole 1,5 ± 0,2

2Reverse gear rocker shaft fixing nut

4,5 ± 0,2

3 Differential casing fixing nuts 1,5 ± 0,2

4 Differential casing fixing screws Ø 10 5 ± 0,5

5 Speedo drive support 1,5 ± 0,2

6 Differential casing fixing screws Ø 7 1,5 ± 0,2

7 Drain plug 3,5 ± 0,2

8 Level plug 2,2 ± 0,2

9Gearbox casing / clutch casing fixing screw

1,3 ± 0,2

10 5th gear housing fixing screw 1,5 ± 0,2


B2CP3ZXD

BE4/5 GEARBOX : TIGHTENING TORQUES

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12 Fork shaft stop screw 1,5 ± 0,2

13 Differential gearwheel fixing screw 7 ± 0,5

14 Bearing stop screw 1,5 ± 0,2

15 Secondary shaft nut 6,5 ± 0,5

16 Primary shaft nut 7,3 ± 0,5

B2CP3ZYD


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17Gear control support

fixing screws1,5 ± 0,2

18 Bearing guide screws 1,25 ± 0,2

19 Speedo housing fixing screws 1,5 ± 0,2

B2CP400C


B2CP3ZZC

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23 Bearing guide 3 1,25 ± 0,2

24 Clutch housing 13 1,3 ± 0,2

25 Primary shaft nut 1 7,25 ± 0,7

26 Secondary shaft nut 1 6,5 ± 0,6

27 Clip retaining screws 2 1,5 ± 0,2

28 Differential gearwheel screws 2 6,5 ± 0,6

Reverse gear switch 1 2,5 ± 0,2

B2CP3WDP

TIGHTENING TORQUES : BE4/5 GEARBOX WITH ENHANCED TRACTION

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29 Differential housing 4 5 ± 0,5

30 Breather pipe 1 1,7 ± 0,2

31 Gearbox rear casing screws 7 1,25 ± 0,2

32 Level plug 1 2,2 ± 0,2

33 Differential housing screws 4 1,25 ± 0,2

34 Drain plug 1 3,5 ± 0,3

B2CP3BRD


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29 Differential housing 4 5 ± 0,5

30 Breather pipe 1 1,7 ± 0,2

31 Gearbox rear casing screws 7 1,25 ± 0,2

32 Level plug 1 2,2 ± 0,2

33 Differential housing screws 4 1,25 ± 0,2

34 Drain plug 1 3,5 ± 0,3

B2CP3BRD


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Ref. Description m.daN

1 1 screw M8-45 1,8 ± 0,1

2 1 screw M8-70 1,8 ± 0,1

3 1 screw M10-70 4 ± 0,4

4 1 screw M10-50 4 ± 0,4

5 1 screw M10-85 4 ± 0,4

6 Screw 3 ± 0,3

7 Speedometer control support 1 ± 0,1

8 Fixing of gearbox cover on gearbox casing 2 ± 0,2

9 Differential bearing stop plate 2 ± 0,2

10 Air vent


12 Fixing of gearbox casing on clutch casing 2 ± 0,2

B2CKUC4D

ML5 GEARBOX : TIGHTENING TORQUES

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Ref. Description m.daN

13 Flange fixing screws 2 ± 0,2

14 Secondary shaft nut 17 ± 1,7

15 Gear control support screws 1,5 ± 0,1

16 Differential gearwheel screws 7,7 ± 0,7

B2CKUC6D

ML5 GEARBOX : TIGHTENING TORQUES

B2CKUC5D

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1 Reverse gear switch 1 screw 2,5 ± 0,2

2Fixings of gearbox casing on clutch

casing14 screw 2 ± 0,2

3 Differential housing screws (M10) 6 screw 4 ± 0,5

4 Speedo drive support 1 screw 1,5 ± 0,1

5 Oil level plug (1 screw) 3 ± 0,3

6 Differential housing screws (M8) 4 screw 2 ± 0,2

7 Drain plug 1 screw 3 ± 0,3

8 Differential bearing stop plate screw 4 screw 2 ± 0,2

9 5th gear housing screw 7 screw 2 ± 0,2

(*) Depending on date of manufacture of gearbox.B2CP3HPD

MLGU GEARBOX : TIGHTENING TORQUES

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10 Secondary shaft nut 1 screw 17 ± 1,5

11 Gear control support screws 6 screw 2 ± 0,2

12 Differential gearwheel screws 12 screw 7,7 ± 0,3

B2CP3HQD

MLGU GEARBOX : TIGHTENING TORQUES

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MLGU GEARBOX : SPECIFICATIONS

Drain – Fill – Top-upGearbox.(1) Air vent hole (filler aperture).(2) Drain plug.(3) Oil level plug.IMPERATIVE : Do not use the oil level plug to fill the gearbox or to top up (new engine angle).Oil capacity (after draining) : - without reduction box: 2,7 litres- with reduction box: 3,2 litresOil quality : TOTAL TRANSMISSION BV 75W80Checking intervals : none.Checking of oil level : no oil level check.Lubrication for life.IMPERATIVE : After finding an external leak or following a repair, it is necessary to drain thegearbox and put back the exact quantity of oil.Transfer box.(4) Drain plug.(5) Oil level plug.WARNING : The transfer box casing is separate from the gearbox. Drain and lubricatethe transfer box separately.Oil capacity (after draining) : 0,7 litresOil quality : TOTAL TRANSMISSION X4 80W90 API GL5.

B2CP3JQC

B2DP009C

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MLGU GEARBOX : SPECIFICATIONS

Drain – Fill – Top-up

Rear axle.(6) Oil level plug.(7) Drain plug.

Oil capacity (after draining) : 1,8 litres

Oil quality : TOTAL TRANSMISSION X4 80W90 API GL5.

Propeller shaft.(8) Grease point.

The sliding transmission has 3 grease points (8) :- 1 grease point on each universal joint.- 1 grease point on the slide.- 1 grease point on the intermediate bearing of the rear propeller shaft.

B2EP006C

B2FP05YC

Lubrication

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MA/5 GEARBOX : CONTROLS

1 - Gear control bar.2 - Gear lever.3 - Gear engagement ball-joint.4 - Gear selection ball-joint.

Adjustment.

The gear change mechanism is not adjustable.Lubricate the linkages of the ball-joints at each refitting.

Note :To clip the ball-joints in place, set the gear control in neutral. After fitting the gearcontrols, check that all the gears engage without « tight spots ».

B2CP3NTD

Engines : HFX - KFW

BERLINGO

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BE4/5 GEARBOX : CONTROLS

L = Distance between the centre of the knob and the centre line ofthe radio housing.L = 195 if not, adjust via « X ».J = 0.5 to 1 mm.

(1) Gear selection rodX = 130 ± 1 mm.

(2) Gear engagement rod Y = 300 ± 1 mm.

(3) Torque rodZ = between 51 and 61 mm

B2CP39WD

Engine : WJX

C15

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1 - Gear control bar.2 - Gear lever.3 - Reaction rod.4 - Gear selection ball-joint.3 - Gear engagement ball-joint.

Adjustment.

The gear change mechanism is not adjustable.Lubricate the linkages of the ball-joints at each refitting.

Note :To clip the ball-joints in place, set the gear control in neutral. After fitting the gearcontrols, check that all the gears engage without « tight spots ».

B2CP3NWD

Engines : NFU - 9HZ - WJY - RHY

BERLINGO

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Engines : RFN - WJY

(1) Gear control lever

(2) Gear engagement control cable (*)

(3) Gear selection control cable (*)

(4) Gear selection ball-joint Ø 10 mm.

(5) Gear engagement ball-joint Ø 10 mm.

(6) Flexible insulating grommet through thebulkhead.

(*) = These two cables cannot be separated.

B2CP3BWD

DISPATCH

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CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS

Principles of adjusting the gear controls.

WARNING : Cables should be adjusted each time the gearbox, gear controls or power unit areremoved.

PrincipleLock the gear lever in neutral position,using tool: 9607-T.Place the gearbox in neutral.

WARNING : Do not use any tool to unclip the ball-joints.

To unlock the ball-joint, press at the centre « a », then pull the ball-joint upwards.Couple the cables on the lever.Fit the ball-joints on the gearbox lever.Lock the cable lengths with the ball-joint locking keys.

NOTE : Changing an individual ball-joint is possible as long as the locking key is removed.Unclip at « b », using two thin screwdrivers.

Engines : RFN - WJY

DISPATCH

B2CP3BXC

B2CP3BYC

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CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS

Adjusting the gear controls.

Tools.[1] Tool for positioning the gear lever : 9607-T.AdjustmentsWARNING : Cables should be adjusted each time the gearbox, gear controls or power unit are removed.Inside the vehicle:Checks- Remove the tool [1].- Check that all the gears engage without «tightness ».- Check that the gear lever moves identically forwards and backwards and to right and left. If it does not,repeat the adjustment.

Remove the trim under the gear lever.Lock the gear lever in neutral position, using tool [1].

Under the bonnet.Remove the air filter assembly.Unlock the ball-joint keys at «a».Place the gear selection and control levers on neutral.Lock the cable lengths with the ball-joint locking keys.Refit the trim under the gear lever.Refit the air filter assembly.

Engines : RFN - WJY

DISPATCH

B2CP3C6C B2CP3C0C

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ML5 GEARBOX : CONTROLS

Non adjustable

B2CP3W8D

Engines : RHX - RHZ - RHW

DISPATCH

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MLGU GEARBOX : CONTROLS

The gears are controlled by means of cables :- Selection cable.- Engagement cable.

DescriptionSelection cable Câble de passage

(ball-joints Ø = 10 mm) (ball-joints Ø = 13 mm)

Gear control lever Fixing Cables held in their locations by steel clipsend

Adjustment Yes No

Fixing Cables held in their locations by steel clipsGearbox end

Adjustment No No

NOTE : Greasing of ball-joints : grease G6.

New « chandelier » gear lever grid.- To engage reverse gear, you have to lift the ring located under the gear lever knob.

Engines : RFL - R6G - RHV - 4HY - 8140.43 - 8140.43S

RELAY

B2CP3HRC

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(1) Automatic adjustment device on selection cable.

(2) Teflon stop.

(3) Gear lever positioned in first.

(A) The unlocked position : lets the ball-joint slide overapprox. 10 mm.

(B) The locked position : determines the length of theselection cable.

Adjustment clearance : X = 1 mm.

B2CP3JXD


RELAY

B2CP3JYC

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(A) The unlocked position.

(B) The locked position.

NOTE : Before doing the adjustment, make sure that the automatic adjustment deviceremains in position (A).

Adjustment.

- Position the gear lever on 1st gear.

- Insert a shim of thickness 1 mm between the gear lever and the teflon stop.

- Next action the locking / unlocking button, making the spring jump on the automaticadjustment device..

- The automatic adjustment device is in the locked position (B).

- The length of the gear selection cable is adjusted.

- Do a road test, change through all the gears in order to check that there are no faults.


RELAY

B2CP3JUD

Adjusting the gear selection cable

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RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX

TowingThe front of the vehicle must be raised in order to be towed.If the front of the vehicle cannot be raised :

IMPERATIVE : - Put gear lever in position «N».- Do not add any oil.- Do not exceed 30 mph over a distance of 30 miles ofmaximum.

Driving.Never drive with the ignition switched off.Never push the vehicle to try to start it;(impossible with an automatic gearbox).

LubricationThe automatic gearbox is only lubricated when the engine isrunning.

Repairs on electrical components

Do not disconnect : - The battery when the engine is running.- The ECU when the ignition is switched on.

Before reconnecting a switch, check : The condition of the various contacts.(for deformation, corrosionetc.)The presence and condition of the mechanical locking.

When performing electrical checks : The battery should be correctly charged.Never use a voltage source higher than 16V.Never use a test lamp.

Precautions to be taken

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Repairs on mechanical components

Never place the gearbox on the ground without protection.

In order to avoid breaking the input shaft ring, it is imperative thatthe converter retaining bracket should be in place when handlingthe gearbox.

It is imperative to use the centring peg and the converter retainingbracket to couple the gearbox on the engine.

After coupling the gearbox on the engine, remove the centring peg.

Modification of the oil usage counter value.

Exchanging the gearbox ECU :

Note down the gearbox counter value.Transfer the value read into the the new gearbox ECU.

Exchanging the gearbox :

Initialise the oil usage counter to 0.

Draining the gearbox :

Initialise the oil usage counter.(follow the diagnostic tool procedure).

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If a gearbox malfunction occurs, there are two possible configurationsdepending on the seriousness of the fault : - Gearbox in back-up mode with a replacement programme of (the faultvalues are taken in substitution).- Gearbox in back-up mode with an emergency programme (3rdhydraulic)WARNING : In the emergency programme, an impact is felt whenchanging P/R, N/R and N/D.Réception client.Discuss with the customer, to find out all the malfunction symptoms.

Oil quality – Oil level.Oil quality.If the gearbox has suffered a serious fault resulting in a malfunction orthe destruction of a clutch, the oil will overheat and becomecontaminated with impurities : the oil is said to be «burnt».This is characterised by a black colour and the presence of anunpleasant smell.

ESSENTIAL : The gearbox must be replaced.

Oil level (See corresponding operation).

An excessive oil level can result in the following consequences :- Excessive heating of the oil.- Oil leaks.An insufficent level causes the destruction of the gearbox.Top up the level of oil in the gearbox (if necessary).

Check using a diagnostic tool.Read the fault codes (engine and gearbox)

Absence of fault codes.Carry out parameter measures, actuator tests and a road test.

Presence of fault codes.Carry out the necessary repairs.Delete the fault codes.Carry out a road test to check the repair and, if need be, modify thegearbox ECU parameters (this is essential after an initialisation of theECU).


Procedure to be followed prior to carrying out repairs on AL4 autoactive gearbox

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Downloading

Updating the gearbox ECU by downloading : Follow the procedure using the diagnostic tool.

The downloading operation enables the automatic gearbox to beupdated, or adapted to an evolution of the engine ECU.Before commencing the downloading, take the value of the oil usagecounter present in the automatic gearbox ECU.

After the downloading operation, carry out the following: - A clearing of faults.- An initialisation of the auto-adaptives.- A writing of the value of the oil usage counter previously read.- A road test.

ESSENTIAL : Every update of the automatic gearbox ECUshould be accompanied by an update of the engine ECU.

Updating the value of the oil usage counter

Using PROXIAAccess to reading and recording of the oil counter is via the menu :

«Configuration (integrated circuit button) / Oil counter ».

Adjustment of the oil counter value is done in incremental steps of2750 units.

Using LEXIAAccess to reading and recording of the oil counter is via the menu :

«Oil counter ».

Adjustment of the oil counter value is done by entering directly the5 figures of the oil counter.


Procedure for initialising the automatic gearbox ECU

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AL4 AUTOMATIC GEARBOX : TIGHTENING TORQUES

Tightening torques m.daN

(1) Oil flow modulation electrovalve fixing : 1 ± 0,2

(2) Heat exchanger fixing : 5 ± 1

(3) Output speed sensor fixing : 1 ± 0,2


(5) Oil overflow and drain fixing : 4 ± 0,2

(6) Oil level plug : 2,4 ± 0,4

(7) Oil pressure sensor fixing : 0,8 ± 0,1

B2CP3EDD

B2CP311D

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B2CP3EED


(8) Fixing of converter on diaphragm

Pre-tightening : 1 ± 0,1Tightening : 3 ± 0,3

(9) Plug fixing : 0,8 ± 0,2

(10) Gearbox fixing on engine : 5,2 ± 1


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Tightening torques m.daNA : EW7 and EW10 engine versions :Hydraulic valve block fixingCentre the hydraulic valve block, using screws (11) and (12)

Pre-tighten (no strict order) : 0,9 Slacken : All 7 screws Tighten (respect the order indicated) : 0,75

NOTE : The screw (11) is shouldered.

B : DW10 engine version:Hydraulic valve block fixingCentre the hydraulic valve block, using screws (11) and (12)

Pre-tighten (no strict order) : 0,9 Slacken : All 7 screws Tighten (respect the order indicated) : 0,75

NOTE : The screw (11) is shouldered.

(13) Fixing of selector lever position switch : 1,5 ± 0,2(14) Oil filler plug : 2,4 ± 0,4

B2CP3EFD

B2CP3EGC

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B2CP3CFD

Gear control is by a cable linked to the selection lever located on the dashboard.The gear selection control has 5 positions :

«P» Park (immobilisation of the vehicle, whatever the slope).«R» Reverse gear.«N» Neutral.«D» Drive (autoadaptative mode, eco-law)«M» Manual mode (M+, M-).The vehicle can only be started when the selection lever is in position «P» or«N».

Shift-Lock

The «shift-lock» is a system which locks the gear selection lever in position «P».To unlock the gear selection lever from position «P», switch on the ignition andpress the brake pedal.During a repair, the shift-lock can be unlocked by pressing the locking finger «a»(see corresponding operation).

AL4 GEARBOX : CONTROLS DISPATCH

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AL4 AUTOMATIC GEARBOX

- Place the selection lever in position «N».

- Slacken the screws (1).

- Place the multifunction switch as far out as possible on the screw at «A».

- Connect a multimeter in the ohmmeter position on the electrical contacts (2).

- Turn the multifunction switch to close the circuit between the electrical contacts:

R = 0 _.

- Mark the position of the multifunction switch at «B» in relation to the gearbox casing at «C».

- Continue to turn the multifunction switch to open the circuit between the electrical contacts.

- Mark the position of the multifunction switch at «B» in relation to the gearbox casing at «D».

- Bring the switch back to position the mark «B» at midway between marks «C» and «D».

- Tighten the screws (1) to 1,5 ± 0,1 m.daN.

- Check the correspondence between the position of the gear selector and the indication onthe instrument panel.

B2CKU1DD

B2CKU1ED

DISPATCHAdjustment of the MULTIFUNCTION SWITCH

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AL4 AUTOMATIC GEARBOX

B2CA08MC

B2CA08NC

Tools.[1] Locking screw : (-).0338-M1[2] Bearing blade adjustment shim : (-).0338-M2

Adjustment.

Prior conditions: Hydraulic block in place.- Place the gear selection lever in position 2 (A).- Remove the screw (1)- Slacken the screw (2).- Fit tools [1] and [2].- Position the bearing blade on the bearing sector (B).- Lock tool [2], using tool [1].- Tighten the screw (2) to 0,8 ± 0,1 m.daN.- Check that the gear engagement lever is securely locked.- Check the operation of the gear selection lever in all the positions.

IMPERATIVE : There must not be any excessive travel on the gear selectionlever when it is in position 2. Adjust the multifunction switch.

RELAYAdjustment of the INTERNAL SELECTION CONTROL

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RECOMMENDATIONS - PRECAUTIONS : 4 HP 20 AUTOMATIC GEARBOX

TowingThe front of the vehicle must be raised in order to be towed.If the front of the vehicle cannot be raised :

IMPERATIVE : - Put gear lever in position «N»..- Do not add any oil.- Do not exceed 45 mph over a distance of 60 miles maximum.

Driving.Never drive with the ignition switched off.NOTE : The automatic gearbox is only lubricated when the engine isrunning.

Repairs on electrical componentsDo not disconnect : The battery when the engine is running.The ECU when the ignition is switched on.

Before reconnecting a switch, check : The condition of the various contacts.(for deformation, corrosion etc.)The presence and condition of the mechanical locking.

When performing electrical checks : The battery should be correctly charged.Never use a voltage source higher than 16V.Never use a test lamp.

Repairs on mechanical componentsNever place the gearbox on the ground without protection.Do not use the unions on the gearbox as handles for moving thegearbox.It is imperative that the converter retaining peg should be in placewhen removing the gearbox.It is imperative to use the centring pegs to couple the gearbox onthe engine.Remove the converter retaining peg before coupling the gearbox onthe engine.

RELAY


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RELAY4 HP 20 GEARBOX : TIGHTENING TORQUES


Gearbox exterior

(2) Oil channel union fixing : 2,5 ± 0,5(3) Exterior fixing of converter cover on clutch housing : 2,3 ± 0,5(4) Speedometer take-off aperture plug : 1 ± 0,1(5) Steel casing fixing : 0,6 ± 0,1(6) Converter fixing on engine : 6 ± 1(7) Interior fixing of converter cover on clutch housing : 2,3 ± 0,5(8) Torx fixing of converter cover on clutch housing : 2,3 ± 0,5

Drain plug : 4,5 ± 0,8Heat exchanger fixing : 3,5 ± 0,5Selector lever position switch fixing : 1 ± 0,2Converter cover fixing on engine cover (XFX engine) : 6,5 ± 1Converter cover fixing on engine cover (4HX engine) : 5,8 ± 1

B2CP24BC

B2CP3CZC B2CP24CC

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RELAY 4 HP 20 GEARBOX : TIGHTENING TORQUES


Gearbox interior

(9) Input speed sensor fixing : 0,8 ± 0,1

(10) Hydraulic block fixing (Large head) : 0,8 ± 0,1


B2CP24EC

B2CP24DC

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4HP20 AUTOMATIC GEARBOX SPECIFICATIONS

B2CP3KGD

Unlocking the « SHIFT LOCK » function

The « Shift Lock » is a system which locks the gear selection lever in the park position «P».

Unlocking the « Shift lock » (normal operation)- Switch on the ignition.- Apply the brake pedal and keep it pressed.- Press on button « a » on the gear lever.- Using the selection lever, disengage from position « P ».

Unlocking the « Shift lock » (with a fault)If it should be impossible to unlock the « Shift lock » with the « normal operation » method, thecauses of the fault may arise from the following components : - « Shift lock ».- Gear lever position switch.- Gear lever ECU- Automatic gearbox ECU.- Electrical harness.- Battery voltage.Operations to be carried out :- Unlock the « Shift lock » by pressing on the button at « b » through the gaiter (1).- Press on button « a » on the gear lever.- Move the selection lever to disengage from position « P ».

RELAY

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4HP20 AUTOMATIC GEARBOX SPECIFICATIONS

Unlocking the « KEY LOCK » function

The « Key Lock » is a system which locks the ignition key in the ignition when you switch off, if the gearselection lever is not in position « P ».NOTE : The driver hears a buzzer for 30 seconds.Unlocking the « Key lock » (normal operation)- Switch on the ignition.- Apply the brake pedal and keep it pressed.- Press on the button on the gear lever.- Place the gear selection lever in position « P ».- Switch off the ignition.- Remove the ignition key.Unlocking the « Key lock » (with a fault)If it should be impossible to unlock the « Key lock » with the « normal operation » method, the causesof the fault may arise from the following components : - « Key lock ».- Gear lever position switch.- Gear lever ECU- Automatic gearbox ECU.- Electrical harness.- Battery voltage.Operations to be carried out :- Insert a screwdriver at « a » (minimum length 150 mm).- Engage the screwdriver while pulling one side of the steering wheel.- Press on the button (1) with the point of the screwdriver. - Remove the key from the ignition.

RELAY

C5FP0HAD

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SELECTION CONTROL SPECIFICATIONS : 4HP20 AUTOMATIC GEARBOX

In the passenger compartment

The gear selection lever is guided by the shape of the step grille and by a return springwhich holds it to the left.The gear control has 5 positions :- Position « P » : park (locks and immobilises the vehicle) (press on button « b » on theselection lever to engage position « P »).- Position « R » : reverse gear (press on button « b » on the selection lever to engageposition « R »).- Position « N » : neutral.- Position « D » : drive (use of the 4 gears of the gearbox in the automatic and autoadaptivefunction).- Position « +/- » : tilt the lever to the left (this position allows the driver to choose his gearsin sequential mode by pulling « - » or « + » on the gear selection lever. To revert to position« D », tilt the lever to the right.

NOTE : Only positions « P » or « N » authorise starting of the engine.In position « +/- », selection is performed by an electronic sensor located close to gearlever. The variation of flux necessary to the movement of the sensor cells is obtained by amagnet located on the lever itself. This enables the change of status. The information is transmitted to the gearbox ECU via the selection lever ECU.NOTE : The vehicle is equipped with « Shift Lock ».

RELAY

B2CP3KAD

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RELAY SELECTION CONTROL SPECIFICATIONS : 4HP20 AUTOMATIC GEARBOX

In the passenger compartment (continued)

To unlock the selection lever from position « P » :- Switch on the ignition.- Press on the brake pedal.- Press on button « b » on the selection lever.

A switch « a » on the gear control grille allows the driver to choose the « Snow » programme.

NOTE : The snow programme facilitates starting and adhesion on slippery surfaces.

IMPORTANT : To revert to the normal programme, press a second time on the switch « a ».

At the gearbox

The automatic gearbox is controlled by a cable.( c ) Clip for unlocking the push-button in pushed-in position.(1) Control lever with ball-joint.(2) Automatic adjustment (pull out the button to adjust the control, push it in to lock the adjustment of the control).(3) Sleeve stop.

B2CP3DLC

B2CP3KAD

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FILL / TOP-UP : 4HP20 AUTOMATIC GEARBOX

B2CP3KLD

B2CP3KMC

Tools

[1] Circlip pliers : 4517-T (toolkit 4507-T)[2] Filling cylinder : (-).0341[3] Specific adaptor : (-).0341 B

Filling with oil

Place the vehicle on a lift.Remove the air filter housing.Remove the gearbox air vent assembly (1) and (2), using tool [1].Fill with oil, using tools [2] and [3].Refit the metallic part (1) of the air vent, using a punch of Ø18 mm and a mallet.Clip on the plastic part (2) of the air vent.

NOTE : The gearbox air vent is available from Replacement Parts.

RELAY

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RELAY FILL / TOP-UP : 4HP20 AUTOMATIC GEARBOX

Topping up with oilPrior conditions :- Vehicle in horizontal position, handbrake released.- Engine running at idle, without any power consumers on (air conditioning, heating, etc.).- Check the absence of gearbox back-up mode, using a diagnostic tool.- Press on the brake pedal.- Change through all the gears.- Gear selection lever in position « P ».- The check is done when the oil has reached a temperature of 55 ± 1°C ; use a diagnostic tool.

Checking the oil level.Remove the top-up plug (3).Oil flows from the top-up hole :As soon as the oil temperature reaches 60 ± 1°C, refit the top-up plug (3).NOTE : The oil level is correct.Tighten the plug (3) to 2 ± 0,5 m.daN. Oil does not flow from the top-up hole :Refit the top-up plug (3).Stop the engine.Remove the gearbox air vent assembly, using tool [1].Add 0,5 litre of extra oil into the gearbox, using tools [2] and [3].Repeat the top-up procedure.Remove tools [2] and [3].Refit the metallic part (1) of the air vent, using a punch of Ø18 mm and a mallet.Clip on the plastic part (2) of the air vent.Refit the air filter housing.B2CP3KNC

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DRIVESHAFTS - GEARBOXESTightening torques (m.daN) Gearbox oil seal mandrels

Vehicles GearboxDriveshaft DriveshaftEngines

bearing nutRight hand Left hand Tool kit

Berlingo MA/5 HFX - KFW NOC15 WJY

1 32,5 ± 1 7114-T.W 7114-T.X 7116-TBerlingo BE4/5 NFU - WJY - 9HZ - RHY

DispatchRFN - WJY 1,8

ML/5 RHX - RHZ - RHW 10°+ 60° 5701-T.A 9017-T.CRFL - R6G - 4HY 10Q 15Q 37 ± 1,8

5701-T.A 9017-T.CNO

Relay ML/GU 8140.43 - 8140.43SRHV 18QS 42 ± 2,1 5708-T.J 5718-T.H 5708-T

1Seal extractor

Dispatch AL4 RFNRH/LH (-) 0338C

(-) 033832,5 ± 1(-) 0338.J1 (-) 0338.H1

+ (-) 0338J2 + (-)0338.H210Q 15Q 37 ± 1,8 8010-T.K1 8010-T.K2

Relay 4 HP 20 2.8 HDi (Red) + (Black) + 8010-T18QS 42 ± 2,1 8010-T.J 8010-T.J

Tightening torque (m.daN) for wheel boltsC15 8 Dispatch 10

Berlingo 9 ± 1 Relay 14 ± 1

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The heights H2 are measured from the ground to the bodyshell crossmember to which the axle rear silentblocks are secured.

The heights H1 are measured from the ground to the lower section ofthe subframe, close to the arm fixing.

General conditions- Check the tyre pressures - Vehicle empty- Release the handbrake - 5 litres of fuel in the tank

Front height (Non-adjustable) Rear height (Adjustable)

B3DP06VDB3CP04VD

AXLE GEOMETRYC15

AX

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Reference height

600 765

203 214

515 527

Payload (Kg)

Heights

± 10 mm

Ft (H1)

Rr (H2)

Engine type

Diesel

WJY

Adjusting the rear heights (H2).

- Height H2 is obtained by two half-shells 1 located between the damperbody and the lower thrust cup of the spring.- The difference in height between the two sides should not exceed 4 mm.

NOTE : A 1 mm modification of the half-shells E leads to an averagechange in the height H of 3.5 mm.1 = 24 adjusting shims from 26 to 47 mm (1 mm , increasingby 1 mm

B3DP06WD

AXLE GEOMETRY C15

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Rear reference height (Non-adjustable)

Front reference height (Non-adjustable)

WJY

Manual Power-assisted

Engine type

Steering

Payload (Kg)

Camber

Castor

Pivot angle

Tracking

Counter camber

Tracking

600 765 600 765

0° 30’ 0° 41’ 0° 30’

0° 55’ 1° 47’ 0° 55’

8° 50’ 8° 34’ 8° 50’+ 2 + 3

± 30’

± 40’

(mm)

± 20’ 9’

+ 1,6 à 5(mm)

A < B = Positive figure + = TOE-IN

A > B = Negative figure - = TOE-OUT

NOTE

B3CP02UC

C15 AXLE GEOMETRY

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(1) Anti-roll bar

B3CP04WD B3CP04XD

Payload (Kg)

Ø Barre (mm)

600 765

23 24

Diesel

C15FRONT AXLE

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B3DP06XD B3DP06YD

(1) Anti-roll bar

Payload (Kg)

Ø Barre (mm)

600 765

18 19

Diesel

C15 REAR AXLE

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B3EP109D B3EP03SD

A = 1 mmB = 3 mmC = 8 ± 1 mm

a = G6D = 0,01-0,06 mm

STEERING SPECIFICATIONS C15Manual steering

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B3EP10AD B3EP03SD

A = 1 mmB = 3 mmC = 8 ± 1 mm

C15 STEERING SPECIFICATIONSPower-assisted steering

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Front : H1 = R1 - L1 Rear : H2 = R2 + L2

H1 = Measurement from the centre line of the arm front pivot screw to the ground.R1 = Radius of the front wheel, under load.L1 = From centre of wheel to centre line of arm front pivot screw.

H2 = From the rear axle front silentblock face to the ground.R2 = Radius of the rear wheel when laden.L2 = From the centre of the wheel to the rear axle front silentblock face.

E1AP0AVD

NOTE : To measure the wheel radius, use tool 8006-T.

Setting the vehicle at reference height is done in the following manner:- Measure the radius of the front wheel R1 ; calculate dimension H1.- Measure the radius of the rear wheel R2 ; calculate dimension H2.- Compress the suspension to obtain the values calculated.

NOTE : The difference in height between the two sides should be less than 10 mm.

AXLE GEOMETRY BERLINGO

B3CP08ED

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BERLINGO AXLE GEOMETRY

Table of heights at REFERENCE LOAD

Vehicles

Height

175/65 R1490,5 56,575,5 (*) 71,5 (*)

175/70 R14

L1 = R1 - H1 L2 = H2 - R2

Familiale

Van

Platform cab

100,5 85,5 (**) 8,5 23,5 (**)Payload(Kg)

600

800

100,5 8,5Payload(Kg)

600

800

Rear height

NOTE : (*) private raised vehicle EuropeNOTE : (**) utility raised vehicle Europe or CRD suspension

NOTE : The difference in height between the two sides shouldbe less than 10 mm.

Front height

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BERLINGOAXLE GEOMETRY

Reference height values for the front axle

ESSENTIAL : When checking the axles, the vehicle must be at reference setting

- Compress the suspension until the calculated values are obtained. Tools used :

- [1] Set of two suspension compressors 9511-T.A - [2] Set of four straps 9511-T.B - [3] Set of four shackles 9511-T.C

Adjustment

YES +1 mm -2 mm (1) -2 mm -2 mm (2)

0° 0°07’ (1) 0° 0° (2)

10°44’ 10°26’ (1) 10°54’ 10°38’ (2)

2°59’ 2°55’ (1) 3°03’ 2°58’ (2)

NO

Casto (±30’)

Pivot angle (±30’)

Camber (±30’)

Tracking (±1 mm)

Familiale

600 kg - 800kg

A<B = Positive figure : + = TOE-IN

A>B = Negative figure: = TOE-OUT

NOTE

Conditions for checking/adjusting :- Correct tyre pressures.- Reference height.- Steering rack at point zero (straight ahead).(1) private raised vehicle Europe.(2) utility raised vehicle Europe or CRD suspension.

B3CP02UC

175/65R14 - 175/70R14 - 185/65R15

Front axle

VanPlatform cab

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BERLINGO AXLE GEOMETRY

Reference height values for the rear axle

ESSENTIAL : When checking the axles, the vehicle must be at reference setting

- Compress the suspension until the calculated values are obtained. Tools used :

- [1] Set of two suspension compressors 9511-T.A - [2] Set of four straps 9511-T.B - [3] Set of four shackles 9511-T.C

Adjustment

1,41 mm 0,3 mm (1) 4,74 mm 3,7 mm (2)

-1°16’ -1°16’ (1) -1°13’ -1°14’ (2)NO

Camber (±30’)

Tracking (±1,3 mm)

Familiale

600 kg - 800kg

(1) private raised vehicle Europe.(2) utility raised vehicle Europe or CRD suspension.

175/65R14 - 175/70R14 - 185/65R15

Rear axle

VanPlatform cab

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B3CP040P

B3CP041D

B3CP043D


1 Damper nut 4,5 ± 0,42 Cup screw 2,5 ± 0,33 Suspension leg -4 Stabiliser rod ball-joint 3,7 ± 0,35 Pivot on suspension leg 4,5 ± 0,46 Anti-roll bar -7 Stabiliser rod ball-joint 3,7 ± 0,38 Pivot lower ball-joint 4,0 ± 0,49 Driveshaft nut 32,5 ± 2,510 Wheel bolts 9,0 ± 1,011 Lower arm front articulating point 7,6 ± 0,712 Lower arm rear articulating point

and anti-roll bar bearing 6,8 ± 0,613 Screw under rear articulating point 3,1 ± 0,314 Ball-joint fixing on lower arm 4,5 ± 0,2Fixing of subframe on body 8,5 ± 0,8

NOTE : Fitting of damper upper support : tongue « a » towards the front.

FRONT AXLE BERLINGO

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B3DP03LD


(1) Front silentblock on axle : 9,4 ± 0,9

(2) Anti-roll bar screw : 5,5 ± 0,2

(3) Front silentblock on body : 4,0 ± 0,4

(4) Wheel bolt : 9,0 ± 1,0

(5) Rear silentblock on axle : 5,4 ± 0,4

(6) Damper shaft nut : 11,0 ± 1,0

(7) Stub bearing nut : 25,0 ± 2,5

(8) Rear silentblock on body : 6,2 ± 0,6

BERLINGO REAR AXLE

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Vehicles

Payload (Kg)

Ø Anti-roll bar(mm)

600 800

Van

175/65R14 - 175/70R14 185/65R15

21 22

White Green

19 19 (2) 21 21 (1) 21 19 (2) 21 19 (2)

Blue Blue (2) Orange Orange (1) Orange Blue (2) Orange Blue (2)


Colour code

Colour code

Familiale

NOTE: (1) private raised vehicle Europe.(2) utility raised vehicle Europe or CRD suspension.

BERLINGOSUSPENSION

AV

AR

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Vehicles

Payload (Kg)


600 800

Van

175/65R14 - 175/70R14 - 185/65R15

20,5 20,5 (2) 21,3 21,3 (1) 19,6 20,5 (2)

Red Red (2) Mauve Mauve (1) Pink Red (2)

82Height of travel stop

(mm)

Colour code

Familiale

NOTE :- The right hand torsion bar is identified by 1 paint line.- The left hand torsion bar is identified by 2 paint lines.

NOTE: (1) private raised vehicle Europe.(2) utility raised vehicle Europe or CRD suspension.

SUSPENSIONBERLINGO

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(1) Steering joint fixing : 2,3 ± 0,2

(2) Lower fixing screw : 2,3 ± 0,2

(3) Upper fixing screw : 2,3 ± 0,2

(4) Steering wheel screw : 2,0 ± 0,2

(a) Steering column height adjustment handle.

NOTE : The airbag is attached to the steering wheel.


(b) 3 teeth have been removed for matching with theupper part of the steering column.

B3EP14FD

B3EP14GD

POWER STEERING SPECIFICATIONS BERLINGO

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(6) Pivot ball-joint nut : 3,5 ± 0,3

(7) Locking nut for adjusting steering rods : 4,5 ± 0,4

(8) Ball-joint : 6,0 ± 0,6

(9) Fixing of steering housing on subframe : 7,0 ± 0,7

(10) Hydraulic pipe union : 2,4 ± 0,2

(11) Power steering assistance valve : 1,2 ± 0,2

(12) Fixing of flange on push rod : 1,2 ± 0,2

(13) (*) Fixing of steering ram on casing : 9,0 ± 1,0

(14) (*) Fixing of steering ram on yoke : 9,0 ± 1,0High pressure union : 2,0 ± 0,3

(15-17) Screws fixing pump on the support : 2,2 ± 0,3Power steering pressure switch (**) : 2,0 ± 0,2

IMPERATIVE : Replace using new Nylstop nuts.

NOTE : (*) Use new screws for refitting.NOTE : (**) A pressure switch is mounted on the hydraulic piping between the highpressure pump and the steering valve (petrol engines only).

B3EP14JD B3EP14KD

POWER STEERING SPECIFICATIONSBERLINGO

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All typesEngine types

H1 (mm)

H2 (mm)

Values at reference height

Tyres 195/70 R14

157

164

Table of values at REFERENCE HEIGHT

With recommended tyre pressures

B3BP07DD

The reference heights must be checked between the jacking point and the ground.

AXLE GEOMETRY DISPATCH

Features

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NOTE



Front Rear

Castor

Camber

Pivot angle

0°8’30’’ ± 0°4’15’’

1 ± 0,5

0°

mm

11°28’ ± 10’

0° ± 30’

1°30’ ± 30’ (2)

Toe-in toe-out

-1°’ ± 30’

ESSENTIAL : When checking the axles, the vehicle must be at reference setting.

B3CP02UC

DISPATCH AXLE GEOMETRY

1°30’ ± 30’ (1)

(1) Manual steering.(2) Power-assisted steering.

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(1) Engine subframe front fixing.(2) Engine subframe rear fixing.


(1) Front fixing 10,7(2) Rear fixing 10,7

B3CP055D

SPECIAL FEATURES : FRONT AXLES DISPATCH

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B3CP04PD

Mark A, LH side Mark B, RH side

FRONT AXLEDISPATCH

B3CP04QD

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1 - Strengthening bar on the bodyshell.2 - Stabiliser bar.

B3DP071D

REAR AXLE DISPATCH

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B3EP054D

DISPATCH STEERING SPECIFICATIONSManual steering

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All Types

Power-assistedSteering

Pinion (Teeth)

Rack (Teeth)

Steering rack travel (mm)

9

33

152

B3EP09ZD

STEERING SPECIFICATIONS DISPATCH

Power-assisted steering

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RearFront

All TypesSteering

Tracking (mm)

Castor

Camber

Conditions for checking and adjusting :- Correct tyre pressures.- Steering rack locked on straight ahead (point zero) (see corresponding operation).- Vehicle in running order.

0 ± 1

0°30’ ± 30’

0° ± 30’NON-

adjustable

B3CP02UC

NOTE



RELAY AXLE GEOMETRY

-2 ± 1

0° ± 45’

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B3CP081P

Versions : 11Q (*) - 15Q (*) - 18Q

Engine-type specific anti-roll bar

Diameter 24 mm

NOTE : (*) No anti-roll bar on van versions withDW10UTD engine.

FRONT AXLES RELAY

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(11) Front screw fixing suspension arm : 25 ± 2,5

(12) Anti-roll bar

(13) Screw fixing anti-roll bar bearing and suspension arm rearmounting : 20 ± 2

(14) Rear screws fixing subframe on body : 20 ± 2

(15) Screw fixing suspension arm rear mounting : 17 ± 1,7

(16) Screw fixing suspension arm rear mounting on body : 20 ± 2

(17) Screw fixing anti-roll bar bearing : 8,5 ± 0,9

(18) Nut fixing rod on suspension arm : 5,6 ± 0,6

(19) Nut fixing rod on anti-roll bar : 5,6 ± 0,6

(20) Anti-roll bar rod

(1) Damper nut : 8 ± 0,8

(2) Screws fixing suspension leg on body : 5 ± 0,5

(3) Damper

(4) Screws fixing suspension leg on pivot : 19 ± 2

(5) Screws fixing lower ball-joint on pivot : 8,8 ± 0,8

(6) Nut fixing lower ball-joint on suspension arm : 18 ± 1,8

(7) Driveshaft nut11Q and 15Q (M28x1.5) : 37 ± 1,8518Q (M33x1.5) : 42 ± 2,1

(8) Wheel bolt : 14 ± 1

(9) Suspension arm

(10) Front screw fixing subframe on body : 25 ± 2,5

FRONT AXLESRELAY

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B3DP09WD

(1) Suspension blade mounting rear yoke(2) Suspension blade lever(3) Suspension blade lever rear yoke fixings : 15,5 ± 1,6(4) Screw fixing rear yoke on body : 15 ± 1,5(5) Rigid hollow shaft rear axle(6) Stub axle bearing nut : 45 ± 3(7) Wheel bolt : 14 ± 1(8) Centring pin fixings : 1,5 ± 0,2(9) Flange fixings : 13 ± 1,3(10) Damper lower fixing screw : 16 ± 1,6(11) Suspension blade front yoke fixing : 15,5 ± 1,6(12) Screws fixing front yoke on body : 15 ± 1,5(13) Suspension blade mounting front yoke(14) Screws fixing brake stub through rear axle : 15 ± 1,5(15) Travel stop : 3,6 ± 0,4(16) Damper upper fixing screw : 16 ± 1,6(17) Telescopic dampers (inclined and fixed under the floor, on thebody sill) (18) Single blade longitudinal spring in modulated section steel

REAR AXLES RELAY

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B3EP14AD



(2) Plate fixing on floor : 1,8 ± 0,2

(3) Steering column fixing : 1,5 ± 0,2

(4) Steering wheel fixing : 5 ± 0,5

RELAY POWER STEERING SPECIFICATIONS

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B3EP14BD


(5) Ball-joint fixing on pivot : 7 ± 0,7

(6) Steering rod locking nut : 6 ± 0,6

(7) High pressure pipe fixing on valve : 5,5 ± 0,5

(8) Low pressure pipe fixing on valve : 6,3 ± 0,6

(9) Ball-joint fixing on steering rack : 12 ± 1

(10) Mechanism fixing on subframe : 11 ± 1

POWER STEERING SPECIFICATIONS RELAY

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600 765

20,60

151,20

GIRLING/D.B.A

247

10

8

BOSCH

22

230/228,60

BENDIX

Load-sensitive

BRAKE SPECIFICATIONS

Master cylinder

Ø Master-vac

mm Caliper makes / pistons

FT Brake disc

Disc thickness

Minimum disc thickness

Brake pad grade

Ø Brake cylinders or calipers

mm Brake drums Ø min. / max.

RRMake

Brake lining grade

Compensator – cut-off (bars)

Payload (Kg)

C15

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B3FP111D


Clearance J = 3 to 5 mm to be adjusted by turning the stop switch. After adjusting, tighten the locking nut (1) to 1 m.daN.

C15

B3FP112D

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B3FP113D


Adjusting the brake pressure compensator.

- Press the brake pedal hard in order to close the limiter.

- Adjust the cable clamp (3) to obtain a clearance of J = 4 to 5 mm between thecable clamp contact face and the lever (2).

NOTE : Do not touch the screw (1) which has been set at the production stage

C15

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B3FP114D

HANDBRAKE

Adjusting the handbrake.

- Operate the hydraulic brake two or three times by depressing the pedal.

- Set the handbrake lever to the third notch of its travel.

- Loosen the lock nut (2) and turn nut (1) until the rear brakesstart tightening.

- Equalise the tension of the left and right cables.

- Ensure that, for a handbrake travel of five notches, the rearwheels are locked.

C15

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BLEEDING THE BRAKES

- Bleed each wheel cylinder, starting with the front of the vehicle.- Bleed :- The front right and front left.- The rear right and rear left.- Fit each bleed screw with a transparent tube, immersed in a receptacle.- Press the brake pedal.- Open the bleed screw.- Keep the pedal fully depressed.- Shut the bleed screw.- Slowly release the brake pedal until it reaches its stop.- Repeat the operation until all air bubbles have disappeared.- Follow the same procedure for the other wheels.

NOTE : During the brake bleeding operations, check that the brake fluid level in the reservoir is maintained.Use the hydraulic fluid sold by the CITROEN Replacement Parts Division.

C15

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ESBRAKE SPECIFICATIONS BERLINGO

Without ESP (*)

1.1i 1.4i 1.6i 16V 1.6 16V HDi 1.9 D 2.0 HDi

Engine plate HFX KFW NFU 9HZ WJY RHY

ØMaster cylinder 23,8

mmMaster-vac 228,6

Caliper makes / pistons BOSCH ZOH 54/22/54

Disc Ventilated 266

FT Disc thickness / min. thickness (mm)i 22/20

Brake pad make/grade BOSCH F769

Drum Original/maximum/width

228/230/40

Lining make/grade

TRW F4930

(*) = Electronic Stability Programme

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BRAKE SPECIFICATIONSBERLINGOWith ESP (*)

1.6i 16V 2.0 HDi

Engine plate NFU RHY

Master cylinder 23,8

Ø Master-vac 228,6

FT mm Caliper makes / pistons BOSCH ZOH 54/26/54

Disc Ventilated 283

Disc thickness / min. thickness (mm) 26/24

Brake pad make/grade BOSCH F769

Ø Caliper makes / pistons TRW C38/38

RRmm Disc Plain 247

Disc thickness / min. thickness (mm)i 9/7

Brake pad make/grade GALFER G4554

(*) = Electronic Stability Programme

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ESBRAKE SPECIFICATIONS

Specifications of braking compensatorsWithout ABS REF With ABS REF

Vehicles - All Types - Payload (Kg) Make Colour ref. of spring Cut-off pressure (bar) Engines Type

475/575/600 Kg Green 11,25 ± 1,75 The compensator

Familiale Yellow19,35 ± 2,75

and main brake

Grand export familialeTEVES

Silver All types limiter functions

Grand export 765 Kg Black 11,25 ± 2,75 with ABS are assured by

765 Kg Electric vehicle PMF Blue 8,85 ± 2the ABS REF

system.

NOTE : PMF : Multifunction roof.

NOTE : REF : Electronic Brakeforce Distribution.

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Braking system specifications

- Braking circuit in X.

- Disc brakes at the front, ventilated (according to version).

- Drum brakes at the rear, with automatic adjustment (except for versions with ESP) (*).

- Disc brakes at the rear (version with ESP).

- Handbrake lever controlled by cables acting on the rear wheels.

(1) Hydraulic valve block «ABS Bosch 5.3» or (1) Hydraulic valve block «ABS Bosch 5.3 REF » or(1) Hydraulic valve block «ABS with ESP Bosch 5.7 ».

(2) Load-sensitive braking compensator (according to version).

NOTE : (*) : ESP : Electronic Stability Programme.

B3FP09HC

B3FP09JC

2

1

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Braking circuit without « ABS REF » (drum brakes at the rear)


B3FP7A4D

(1) braking compensator.

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B3FP7A5D

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B3FP7A7C

(13) Caliper fixing on pivot : 10,5 ± 1 m.daN (15) Brake servo fixing on pedal gear : 2,2 ± 0,1 m.daN(14) Yoke fixing on calliper : 3,2 ± 0,1 m.daN (16) Master-cylinder fixing on brake servo : 2 ± 0,2 m.daN

B3FP7A8D

9 ± 1

32,5 ± 2,5

4 ± 0,4

3,7 ± 0,3

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CHECKING AND ADJUSTING : LOAD-SENSITIVE BRAKE COMPENSATOR

TOOLS

- Brake pressure checking instrument.- Weighing machines.

PREPARING THE VEHICLE

- Vehicle in running order.

CHECKING

- The compensator is checked in relation to the weight on the rear axle. (See the table on following page.)- If the vehicle is heavier : raise the vehicle by the bodyshell.- If the vehicle is lighter : load the vehicle or pull it by the bodyshell to obtain the correct load.- Press the brake pedal to obtain 100 bars on the front brakes.- The rear brake cut-off must occur at the pressure indicated in the table.- From the table, select the value closest to the actual weight on the axle. Check and adapt this value to the value in the table. (See

the table on following page.)

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CHECKING AND ADJUSTING : LOAD-SENSITIVE BRAKE COMPENSATOR

ADJUSTMENT- Loosen the nut (1).- Load the axle to a weight corresponding to one person plus 5 litres of fuel.- Build up a minimum pressure of 20 bars in the compensator.- Screw in the adjusting nut (2) until it is against the lever (4), whilst ensuring that the spring(3) is not tensioned. To do this, a shim will be used at (J) to adjust a 1 ± 0.5 mm clearancebetween the nut (2) and the lever (4).

- Hold the adjusting nut (2) in place, and lock it using the locking nut (1).

Vehicle type Weight on the rear axle Pressure on the rear brakes (Payload Kg) (Kg) (bars)

409 25475 540 26

675 58417 25

600 596 27775 70418 25

800 644 32870 81

B3FP115C

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B3FP06YD

HANDBRAKE (Adjustment)

Checking - Adjusting

- Check that the cables are correctly routed.

- Apply and release the parking brake four times.

- Set the parking brake to the 4th notch.

- Tighten the nut (1) until the rear brakes are tightened.

- Firmly pull the handbrake lever 4 or 5 times.

- Set the parking brake to the 5th notch.

- Check that the rear brakes are tightened.

- With the handbrake released, ensure that the wheels can be rotated freely by hand.

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ESBLEEDING THE BRAKES

Bleeding

The bleeding operation can be performed: - Using brake bleeding equipment. In this case, adjust the pressure to 2 bars.- Or in the conventional way.

Without ABS With ABS or ABS/ESP : BOSCH 5.3/BOSCH 5.7

ESSENTIAL: Order of bleeding

Wheel : Wheel :- Rear right. - Rear right.- Rear left. - Rear left.

- Front right. - Front right.- Front left. - Front left.

Top up the level : Using the brake fluid sold by the CITROEN Replacement Parts Division.

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2.0i 16V

815 Combi

(1) (2) (3) (4) (5) (6) (7)

22,2 (N° RPO �8206)23,8 (N° RPO 8207 �)

23,8 23,8

280

GIRLING (N° RPO 8156 �) BENDIX (N° RPO �9155) GIRLING

281 (N° RPO 8156 �) 257 (N° RPO �9155) 281

26/24 (N° RPO 8156 �) 20/18 (N° OPR�9155) 26/24

19

255 / 256

Load-sensitive double compensator

20 / 500 90/1125

(1) Panel van (short) (815kg). (4) Combi 7 seater CLUB. (6) Combi 8/9 seater.(2) Glazed van (short) (815kg). (5) Combi 8 seater CLUB. (7) Floor cab (short) (815kg).(3) Combi 5/6 seater.


Total Gross Weight (Kg)

Versions

ØMaster cylinder

mm Master-vac

FT Caliper makes / pistons

Brake disc

Disc thickness/min. thickness

Brake pad grade

Ø Brake cylindersmm Brake drums Ø min. / max

RR Brake lining quality

Rear compensator

Compensator cut-off (Bars) / Weight (kg) (*)

(*) = = Cut-off point as a function of the weight on the rear axle.

DISPATCH

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Diesel

1.9 D

815 Combi

(1) (2) (3) (4) (10) (5) (6) (7) (8) (9)

22,2 (N° RPO �8206) 23,8 (N° RPO 8207�) 23,8

255 280

BENDIX GIRLING

257 281

20/18 26/24

19

255 / 256


20/500 90/1125

(1) Panel van (short) (815kg). (5) Combi 5/6 seater. (9) Floor cab (long) (815kg).(2) Glazed van (short) (815kg). (6) Combi 5/6 seater MIXED. (10) Van MIXED (short) (815kg).(3) Panel van (long) (815kg). (7) Combi 8/9 seater.(4) Glazed van (long) (815kg). (8) Floor cab (short) (815kg).



Versions

Master cylinder

Ø Master-vac

FT mm Caliper makes / pistons

Brake disc


Brake pad grade

Ø Brake cylindersmm Brake drums Ø min. / max


Rear compensator


(*) = Cut-off point as a function ofthe weight on the rear axle.

DISPATCH

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2.0 HDi815 900 Combi

(1) (4) (7) (2) (3) (5) (6) (10) (11) (12) (13) (14) (8) (9)22,2 (N° RPO �8206)23,8 (N° RPO 8207�)

23,8 23,8

280 280GIRLING (N° RPO 8156�) GIRLING (N° RPO 8156 �)BENDIX (N° RPO �9155)

GIRLINGBENDIX (N° RPO �9155)

GIRLING

281 (N° RPO 8156�) 281 (N° RPO 8156 �)257 (N° RPO �9155)

281257 (N° RPO �9155)

281

26/24 (N° RPO 8156 �) 26/24 (N° RPO 8156�)20/18 (N° RPO �9155)

26/2420/18 (N° RPO �9155)

26/24

19255/256

Load-sensitive double compensator20 / 500 90/1125

(1) Panel van (short) (815kg). (5) Glazed van (long) (900kg). (9) Floor cab (long) (900kg). (13) Combi 8 seater CLUB.(2) Panel van (short) (900kg). (6) Glazed van (short) (900kg). (10) Combi 5/6 seater. (14)Combi 8/9 seater.(3) Panel van (long) (900kg). (7) Van MIXED (short) (815kg). (11) Combi 5/6 seater MIXED. (4) Glazed van (short) (815kg). (8) Floor cab (short) (900kg) (12) Combi 7 seater CLUB.


Total Gross Weight (Kg)Versions

Ø Master cylinder

mm Master-vacFT

Caliper makes / pistons

Brake disc


Brake pad grade

Ø Brake cylindersmm Brake drums Ø min. / max.

RR Brake lining qualityRear compensatorCompensator cut-off (Bars) / Weight (kg) (*)


DISPATCH

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Diesel

2.0 16V HDi

815 Combi

(1) - (2) - (3) - (4) (7) - (8) - (9) - (10) - (11) (5) (6)

22,2 (N° RPO �8206)23,8 (N° RPO 8207�)

23,8 23,8

280 280

GIRLING (N° RPO 8156 �) BENDIX (N° RPO �9155) GIRLING

281 (N° RPO 8156 �) 257 (N° RPO �9155) 281

26/24 (N° RPO 8156 �) 20/18 (N° RPO �9155) 26/24

19

255 / 256


20 / 500 90/1125

(1) Panel van (short) (815kg). (5) Floor cab (short) (815kg). (9) Combi 7 seater CLUB.(2) Glazed van (short) (815kg). (6) Floor cab (long) (815kg). (10) Combi 8 seater CLUB.(3) Panel van (long) (815kg). (7) Combi 5/6 seater. (11) Combi 8/9 seater.(4) Glazed van (long) (815kg). (8) Combi 5/6 seater MIXED.



Versions

Master cylinder

ØMaster-vac

FTmm

Caliper makes / pistons

Brake disc


Brake pad grade

Ø Brake cylindersmm Brake drums Ø min. / max.


Rear compensator



DISPATCH

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Mechanical adjustment of the compensator.

-Set the vehicle at reference height.

-ESSENTIAL : Never modify the position of the upper nut (1).-Refit the flanged nut (2).

-Fit the tool 8204-T.

Drum

At A : Shim (16 mm) Blue

At B : Shim (16 mm) Green

-Adjust the nut (3) to allow the passage, free and without play, of the green shim at (B), takingcare not to move the lever (4) downwards.-Tighten the lock nut (5) without modifying the adjustment.-Remove the tool 8204-T.-Hold the threaded rod in position at (C).-Tighten the flanged nut (2) to the nut (3).

B3FP10TC

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Hydraulic checking and adjusting of the load-sensitive double compensator

Tools.- Equipment for checking the brake pressures and pressure take-off union : 4140-T.- Adjusting shims : 8204-T.

Connecting the tool 4140-T.- Connect the pressure take-off unions diagonally in place of the bleed screws.

Checking the LH compensator- Rear right hand caliper : M8x125- Rear LH wheel cylinder : M7x100Checking the RH compensator- Rear left hand caliper : M8x125- Rear RH wheel cylinder : M7x100Checks :- Bleed the equipment (see user instructions).- Place the vehicle at reference height.WARNING : The front pressures should be obtained by exerting a single pressure on the brake pedal.- Take the pressures.- The pressures recorded in the left and right circuits must be identical.If the pressures are not correct :- Change the faulty wheel cylinder or compensator- Carry out the adjustment.Adjustment :- Refit the nut (1). - Adjust using nut (2) to obtain the braking pressure. - Tighten the lock nut (3). - Hold the threaded rod in place (4), tighten the flanged nut (1) to the nut (2).B3FP10UC

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B3FP116D


Adjustment

- Tension the secondary cables by screwing in nut (1) until a travel of 4 to 5 notches of the handbrake lever is obtained.

- Lock the locking nut (2).

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ESBRAKE SPECIFICATIONS

2.0i - 2.0 HDi - 2.2 HDi 2.8 HDi 2.0i - 2.2 Hdi - 2.8 HDi

Payload (Kg) 11Q-15Q 18Q

Ø Master cylinder 25,4mm Master-vac 279,4

Caliper make BREMBO

Ø Piston (mm) 44/48 46/52 44/48

FT Ø Plain

mmDisc

Ventilated 280 300 280

PlainDisc thickness

Ventilated 24/21,9

Brake pad grade

Ø Brake cylinders

mm Brake drums Ø min. / max. 254/255,6

RR Disc 280

Disc thickness 16/14,2

Make LOCKEED BREMBO

GradeTightening torques: m.daN

Caliper fixing on pivot (Front) : 21 ± 2 Master cylinder fixing on master-vac : 2 ± 0,2 Yoke fixing on caliper (Front/Rear): 3 ± 0,3Caliper fixing on stub axle support (Rear) : 18,8 ± 1,5 Master-vac fixing on body : 2 ± 0,2

RELAY

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2.0i 2.8 HDi 2.0i - 2.8 HDi

Payload (Kg) 11Q-15Q 18Q

FT Ø Master cylinder 25,4

mm Master-vac 279,4

Caliper make BREMBO

Ø Piston (mm) 44/48 46/52 44/48

ØDisc

Plain

mm Ventilated 280 300 280

Disc thicknessPlain

Ventilated 24/21,9

Brake pad grade

RR Ø Brake cylinders

mm Brake drums Ø min. / max.

Disc 280

Disc thickness 16/14,2

Make BREMBO

GradeTightening torques: m.daN

Caliper fixing on pivot (Front) : 21 ± 2 Master cylinder fixing on master-vac : 2 ± 0,2Caliper fixing on stub axle support (Rear): 18,8 ± 1,5 Yoke fixing on caliper (Front/Rear) : 3 ± 0,3 Master-vac fixing on body : 2 ± 0,2

RELAY

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B3FP037C


Tools

Brake pressure checking equipment : Tool kit 4140-T.- Weighing machines

Preparing the vehicle- Vehicle in running order.- Braking circuit bled.- Vehicle on a hoist (with bearing race).- Connect the tool 4140-T.- Connect the «front» pressure gauge to one of the front brakes.- Connect the «rear» pressure gauge to one of the rear brakes.- Replace the bleed screws with sensors (1).

WARNING : Bleed screws - the thread of the front and rear bleed screws is not identical.

- Bleed the tool 4140-T.- Chock the front wheels.- Place the rear wheels on the weighing machines.

Checking and adjusting the rear brake corrector

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Checking the rear brake corrector

- The corrector must be checked in relation to the weight on the rear axle(Refer to the table below).

- Weight on the rear axle = Weight on all four wheels.- Apply the brake pedal to obtain 80 bars on the front brakes.- The pressure on the rear brakes is cut off as indicated in the table.- From the table, select the value closest to the actual weight on the

axle. Check and adapt this value to the value in the table..

Vehicle typeWeight on the rear Pressure on the rear

axle (Kg) brakes ± 3 bars

11 Q650 30

900 45

15 Q700 34

900 45

11 Q15 Q

ABS 900 45

18 QWith ABS 750 26

Without ABS 900 45

- Slacken the nuts (3)- Press the brake pedal to obtain 80 bars on the front brakes.- Gradually operate the control (2) in order to obtain a rear brake

pressure corresponding to the weight on the rear axle.- Tighten the nuts (3)- Release the brake.- Check the adjustment.

B3FP038C

Adjusting the rear brake corrector

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Preliminary operation- Raise the vehicle and place it on stands with the rear wheels hanging free.- Release the parking brake.- Depress the brake pedal several times.- Slacken the nut (1) so as to detension the handbrake cable.

Rear drum brakes.

- Do up the nut (2a) until the lever (3) lifts slightly from the stop (4).- Tighten the locking nut (2b).- Set the handbrake to the 3rd notch.- Tighten the nut (1) until the rear brakes are tightened.- Vigorously pull the handbrake lever 4 or 5 times.- Set the handbrake to the 3rd notch.- Check that the rear brakes are tightened.- With the handbrake released, ensure that the wheels can be turned freely by hand.- Tighten the locking nut (2b).

B3FP17AC

B3FP02GC

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Rear disc brakes.

ESSENTIAL : Adjust the brakes before adjusting the handbrake.

- Remove the rear wheels.- Position the hole (a) facing the toothed wheel (5) of the adjustment mechanism.- Turn the toothed wheel (5) upwards to block the rotation of the disc.- To unblock the disc, action the toothed wheel (5) by 10 teeth in the reverse direction.

NOTE : 1 tooth varies the diameter of the jaws by 0,035 mm.- The clearance between the jaws and the drum should be between 0,30 and 0,65 mm.- Do up the nut (2a) until the lever (3) lifts slightly from the stop (4).- Tighten the locking nut (2b).- Set the handbrake to the 3rd notch.- Tighten the nut (1) until the rear brakes are tightened.- Vigorously pull the handbrake lever 4 or 5 times.- Set the handbrake to the 3rd notch.- Check that the rear brakes are tightened.- With the handbrake released, ensure that the wheels can be turned freely by hand.- Tighten the locking nut (2b).- Refit the rear wheels.- Tighten the wheel bolts to 14 ± 1 m.daN.

B3FP17AC

B3FP17BC

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DRAIN – FILL – BLEED : BRAKING CIRCUITTools

[1] Pressure bleeding apparatus.[2] PROXIA diagnostic tool : 41656T[3] LEXIA diagnostic tool : 4171-T

NOTE : Use the diagnostic tools [2] and [3] for bleeding the secondary braking circuit.Draining the braking circuit.- Drain the brake fluid reservoir to the maximum, using a syringe.- Disconnect the connector (1).- Uncouple the pipe (2).- Remove the screw (3).- Remove the reservoir from its two supplies by pulling upwards.- Empty the reservoir.- Clean the reservoir.Refit : - The reservoir.- The screw (3).Couple the pipe (2).Reconnect the connector (1).WARNING : Use only hydraulic fluids that are approved and recommended.Refill the brake fluid reservoir.Bleed the braking circuit.

B3FP177C

B1BP2QQC

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DRAIN – FILL – BLEED : BRAKING CIRCUIT

Bleeding the braking circuit.

IMPERATIVE : During the bleed operations, take care to maintain the levelof brake fluid in the reservoir, keeping it topped up. Use only new brakefluid.

Bleed the primary braking circuit in the course of routing servicing.Bleed the secondary braking circuit in the following cases:

- Problems with the secondary braking circuit.- Starting the pump.

- Supplying the electrovalves.

Front brake caliper, bleed screws (4).

- Without ABS, two bleed screws (4) (for each caliper).

- With ABS, one bleed screw (4) (for each caliper).

- Rear brake caliper, bleed screw (5).- Rear brake drum, bleed screw (5).

B3FP179D

B3FP178D

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Bleeding the primary braking circuit.

WARNING : The ABS should not be in action during the bleed operation.

Use a generic bleeding apparatus: «LURO» or similar.Connect the bleeding apparatus [1] onto the brake fluid reservoir.Adjust the apparatus pressure to 2 bars.

Bleeding the secondary braking circuit.

NOTE : The bleed apparatus is still connected on the brake fluid reservoir.

Use the diagnostic tools [2] and [3].Connect the diagnostic tool.On the diagnostic tool screen, select the menu «ABS BLEED».Follow the instructions in the diagnostic tool.Bleed the brakes in the sequence indicated (ABS-type bleed).At the end of the bleed programme, check the fluid level and top up if necessary .Check the travel of the brake pedal (no lengthening of travel). If travel has lengthened, repeat the bleed pro-cedure.Remove the tooling.

B1BP2QRC

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Bleeding a braking circuit without ABS

- Engine switched off (no servo-assistance).- Bleed each wheel cylinder starting at the rear of the vehicle, then at thefront.- On the front caliper, start with the uppermost piston, finish with the lowerpiston.For each braking circuit: - Connect a transparent tube on the bleed screw, submerge the other endof the tube in a clean receptacle.- Open the bleed screw, wait for the fluid to flow out without air bubbles.- Close the bleed screw.Remove the bleeding apparatus.Check the brake fluid level (it should be between «MIN» and «MAX»).Refill if necessary with approved and recommended synthetic brake fluid.

Proceed as follows : - Rear right.- Front left.- Rear left.- Front right.For each braking circuit: - Connect a transparent tube on the bleed screw, submerge the other endof the tube in a clean receptacle.- Open the bleed screw, wait for the fluid to flow out without air bubbles.- Close the bleed screw.Remove the bleeding apparatus.Check the brake fluid level (it should be between «MIN» and «MAX»).Refill if necessary with approved and recommended synthetic brake fluid.IMPERATIVE : Avoid any action which could risk starting the pumpor energising the electrovalve. (The circuit is pre-filled and bled).

Bleeding a braking circuit with ABS

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SP 10

SP 20

Variable

AIR CONDITIONING R 134 a (HFC)

Vehicle

BERLINGO

DISPATCH

RELAY

575 ± 25 gr

SD 7H 15

SD 7V 12

SD 7V 16135950 ± 25 gr

800 ± 50 gr (*)

1 000 ± 50 gr (**)

12/02 >

12/03 >

09/96 >

All Types

Engine DateRefrigerent

refill

Compressor

Capacity

FixedOil quantity

(cc)Oil

reference

* = Single air conditioning: 1 evaporator, 1 pressure control valve.

* * = Double air conditioning: 2 evaporators, 2 pressure control valves.

AIRCONDITIONING

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C5HP073C

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)Click-fit connector removal/fitting tool

Ø InchVehicules

Berlingo

Dispatch

TT

TT 5/8 Black 8005-T.A.

3/8 Red 8005-T.C.

Ring colour Tool kit 4164.T

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BERLINGOWithout aircon NO (Valéo)

Base aircon YES (Valéo)

DISPATCHAll Types NO

Base aircon NO

RELAYWithout aircon NO

Base or double aircon YES

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)Presence of pollen filter

Vehicle Equipment RPO No Presence of filter Observations

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ESSENTIAL: The compressor lubricant is extremely hygroscopic; always use FRESH oil.

Checking the compressor oil level.

There are three specific cases :- 1/ Repairs to a system without leaks.- 2/ Slow leak.- 3/ Fast leak.

1/ Repairing a system without leaks.

a) - Using draining/recovery equipment not fitted with an oil decanter.- Drain the system as slowly as possible via the LOW PRESSURE valve, so as not to lose any oil.- No more oil should be added when filling the system with R 134.a fluid.b) - Using draining/filling equipment fitted with an oil decanter.- Drain the R 134.a fluid from the system in accordance with the instructions in the equipment handbook.- Measure the amount of oil recovered.- Add the same amount of NEW oil when filling the system with R 134.a fluid.c) - Replacing a compressor.- Remove the old compressor, drain it and measure the oil quantity.- Drain the new compressor (supplied full), so that the same amount of NEW oil is left in the compressor as was in the old compressor.- No more oil should be added when filling the system with R 134.a fluid.

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)Compressor lubricant.

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Checking the compressor oil level (continued)

2) Slow leak.

- Slow leaks do not lead to oil loss, therefore the same procedure should be followed as if there was no leak at all.

3) Fast leak.

This type of leak causes both oil loss as well as allowing air to enter the system.

It is therefore necessary to :

- Replace the dryer.- Drain as much oil as possible (when replacing the faulty component).

Either before or during filling of the system with R 134.a fluid, introduce 80 cc of NEW oil into the system.

If changing one of the following components, add as below :

A drying bottle : 15 cc of compressor oil.A condenser or an evaporator : 20 cc of compressor oil.A high pressure or low pressure pipe : 5 cc of compressor oil.A drying cartridge : 15 cc of compressor oil.

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)

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Tools.

[1] Clim test 2 VALEO : 4372-T.

Checks.

Position the tool [1] (depending on manufacturer’s instructions)

CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM

E5AP2ECC

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Outillage VALEO

Testing procedureChecking

Position the tool CLIM TEST II (according to the manufacturer’s ins-tructions).

Preliminary operations

Close all the front air vents.Start the engine. Open the front LH air vent.Position the air distribution control to « frontal flow ».Activate the « air recirculation » control.Activate the « air conditioning » control.

Positions of the air conditioning controls :

Temperature control on maximum cold.Blower control in maximum speed position.

Let the air conditioning operate for 5 minutes.

CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEMOutillage EXXOTest

Outillage (Flash équipement &matériel)Exxoclim : 2.4.2-1Mode d’emploie : Voir notice constructeur

OutillageClim test 2 : 4372-T.

E5AP2N4D

E5AP2N5D

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Setting the checking tool [1] to measurement mode

Operate the checking tool, press on button "j".Select the type of aircon fluid : R134.a or R12 :Press on button "l", validate by pressing on button "k".Select the type of aircon fluid : with filtering and drying cartridge, or calibrated aperture :Press on button "l", validate by pressing on button "k".Select the temperature setting T3, Press on button "l", validate by pressing on button "j".

NOTE : The tool is in measurement mode.

Aircon compressor with fixed capacity : Take the measurement with the engine running, at idle.Aircon compressor with variable capacity : Take the measurement with the engine running, at 1500 rpm.Setting the checking tool to diagnostic modeSet the checking tool to diagnostic mode, press on button "j".The diagnosis is performed instantaneously : values outside the tolerances are displayed on a dark background.


E5AP2FAC

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Interpretation of the measurements« m »: High pressure. « s »: Over-heating (SC).« n »: High temperature. « t »: Ambient air temperature.« p »: Under-cooling (SR). « u »: Blown air temperature.« q »: Low pressure. « v »: Humidity.« r »: Low temperature. « w »: Temperature T3

Under-coolingThe under-cooling represents the difference between the condensation temperature and the aircon fluidtemperature at the aircon condenser outlet.The under-cooling gives the quantity of aircon fluid (in the liquid state) in the air conditioning circuit.

Values for under-cooling (SR)Values «p» Origins Solutions

SR < 2°CLack of aircon fluid in the aircon condenser (should be more than 150 grammes)

Add some aircon fluid

2°C < SR <4°CLack of aircon fluid in the aircon condenser (should be around 100 to 150 grammes)

4°C < SR < 10°C/12°C Correct quantity

SR > 10°C/12°C Excess aircon fluid in the aircon condenser Remove some aircon fluid

SR > 15°C

Blown air temperature « u »The blown air temperature should be between 2°C and 10°C.E5AP2FBC

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Interpretation of the measurements« m »: High pressure. « s »: Over-heating (SC).« n »: High temperature. « t »: Ambient air temperature.« p »: Under-cooling (SR). « u »: Blown air temperature.« q »: Low pressure. « v »: Humidity.« r »: Low temperature. « w »: Temperature T3

Over-heating (SC)The over-heating represents the difference between the aircon fluid temperature at the evaporator outlet andthe evaporation temperature.The over-heating gives the quantity of aircon fluid (in the liquid state) in the air conditioning circuit

Values for over-heating (SC)Values «s» Origins Solutions

2° < SC < 15°C Correct quantity

SC > 15°C Lack of aircon fluid in the cooling circuit Add some aircon fluid

SC < 2°C Excess aircon fluid in the cooling circuit Remove some aircon fluid

Blown air temperature « u »The blown air temperature should be between 2°C and 10°C

E5AP2FBC

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CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEMInterpretation of the diagnosis

« x » Check satisfactory.« y » Lack of aircon fluid in the aircon circuit.« z » Excess aircon fluid in the aircon circuit.« aa » Filtering and drying cartridge clogged.« ab » Other problems (see table on previous page).

E5AP2FCD

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Aircon circuit diagnosis table

Principal problem Symptom Possible causes

Aircon compressor clutch

The clutch of the aircon compressor does not Lack of aircon fluid in the aircon

engage, or disengages suddenlycircuit

Aircon pressostat

Aircon evaporator sensor

The aircon compressor does not turn, or Electrical circuit (wiring, fuses, etc.)stops suddenly Auxiliaries drive belt

Aircon compressor

The clutch of the aircon compressor remains Filtering and drying cartridgeengaged and stops suddenly Aircon pressure reducer

Leak of aircon fluid

Aircon compressor clutch

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Incorrect adjustment of the aircon compressor clutch

The clutch of the aircon compressor Aircon fluid quantity remains engaged Aircon compressor defective

The aircon compressor makes an abnormal Lack of aircon fluid in the aircon circuit noise Aircon compressor valves defective

Aircon compressor clutchThe clutch of the aircon compressor remains engaged and slips

Auxiliaries drive belt

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Low pressure and high pressure too highAircon pressure reducer defective

Duct clogged

Low pressure too high and high pressure too Aircon compressor seal defective low

Aircon evaporator sensor defective

Low pressure too low and high pressure too Aircon pressure reducer jammed

Abnormal levels of pressure high Filtering and drying cartridge obstructed

Duct clogged

Duct clogged

Aircon pressure reducer jammedLow pressure and high pressure too low

Lack of aircon fluid in the aircon circuit

Aircon compressor defective

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Low pressure normal and high pressure Presence of air in the aircon circuittoo high

Low pressure normal and high pression too Aircon pressostat defective low

Evaporator sensor defective

Abnormal levels of pressure Low pressure too high and high pressure normal

Aircon pressure reducer jammed open

Low pressure too low and high pressure Filtering and drying cartridge saturated

normalor clogged

Aircon pressure reducer iced up

Under cooling too weak Lack of aircon fluid

Air conditioning operating Excess aircon fluid in back-up mode Under cooling excessive Presence of air in the aircon circuit

Filtering and drying cartridge clogged

NOTE : In all cases, measure the excessive heating (SC) and the blown air temperature.

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Tightening torques.

A Right hand drive

B Left hand drive

(1) High pressure valve.

(2) Low pressure valve

(3) Pressure reducer

(4) Drying cartridge.(Tighten to 1,7 ± 0,1 m.daN)

(5) Condenser

(6) Pressostat

(7) Compressor (compressor fixing flange : tighten to 4 ± 0,4 m.daN)

(a) Pressure reducer fixing flange : tighten to 0,8 ± 0,1 m.daN

(b) Fixing flange : tighten to 1,3 ± 0,1 m.daN.

(c) Fixing flange : tighten to 1,3 ± 0,1 m.daN.

BERLINGO AIR CONDITIONING SYSTEM R 134.a

C5HP19QP

Engines TU1JP/3JP/5P4

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Tightening torques (m.daN).

A Right hand drive

B Left hand drive


(2) Low pressure valve

(3) Pressure reducer

(4) Drying cartridge.(Tighten to 1,7 ± 0,1 m.daN)

(5) Condenser

(6) Pressostat

(7) Compressor (compressor fixing flange : tighten to 4 ± 0,4 m.daN)

(a) Pressure reducer fixing flange : tighten to 0,8 ± 0,1 m.daN

(b) Fixing flange : tighten to 1,3 ± 0,1 m.daN.

(c) Fixing flange : tighten to 1,3 ± 0,1 m.daN.

C5HP19RP

BERLINGO AIR CONDITIONING SYSTEM R 134.a

Engines : DW8B - DW10TD

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AIR CONDITIONING SYSTEM R 134.a

C5HP15PP

DISPATCH


(1) High pressure valve.(2) Low pressure valve.(3) Pressostat : tighten to 1,8 ± 0,1 m.daN(4) Dryer(5) Clickfit union.

(a) 0,8 ± 0,1 m.daN(b) 4 ± 0,4 m.daN(c) 0,8 ± 0,1 m.daN

Engine : EW10J4

C5HP12EC

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AIR CONDITIONING SYSTEM R 134.a DISPATCH


(1) High pressure valve.(2) Low pressure valve(3) Clickfit union(4) Pressostat.(5) Fixing flange: tighten to 0,8 ± 0,1 m.daN(6) Pressure reducer fixing flange : tighten to 0,8 ±0,1 m.daN(7) Compressor fixing flange: tighten to 4 ± 0,4 m.daN.

Engine : DW8B

C5HP12EC

C5HP15CP

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AIR CONDITIONING SYSTEM R 134.aDISPATCHEngines : DW10BTED/ATED/CTED/BTED+


(1) High pressure valve.(2) Low pressure valve(3) Clickfit union(4) Pressostat.(5) Pressure reducer fixing flange: tighten to 0,8 ±0,1 m.daN(6) Fixing flange : tighten to 0,8 ± 0,1 m.daN(7) Compressor fixing flange: tighten to 4 ± 0,4 m.daN.

C5HP12EC

C5HP15EP

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AIR CONDITIONING SYSTEM R 134.a RELAY

C5HP05QD

WARNING : The single and double air conditioning circuit

diagrams are valid for all engine types.

(installation may vary according to equipment)


(2) Low pressure valve.

Single circuit

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AIR CONDITIONING SYSTEM R 134.aRELAYDouble circuit

C5HP05PD


(2) Low pressure valve.

(3) Pressure control valve

(4) Second evaporator

(passenger compartment side)

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C15-BERLINGO_2005

Documents

Transcript of C15-BERLINGO_2005