C15-Berlingo 2005

CORRESPONDENCE TABLE FOR PETROL ENGINES
TU 1 Engine families 1.1i Engine families HFX JP 1.4i KFW 3 5 JP4 1.6i 16V NFU RFL J2U 2.0i R6G XU 10 J2U/K J4 2.0i 16V RFN Engine families Berlingo X X X C15 Dispatch X BERLINGO Relay X X X 1.6 16V HDi 9HZ Engine families EW DV 6 ATED
CORRESPONDENCE TABLE FOR DIESEL ENGINES

DW 8 B TD BTED 10 ATED CTED BTED+ 1.9D WJY X RHY 2.0HDi RHX RHZ 2.0 8S HDi RHV 2.0 16V HDi RHW 2.2 8S HDi 4HY 2.8 TD 8140.43 2.8HDi 8140.43S UTD ATED4 UTED TD 12 SOFIM
DISPATCH
RELAY
VERY IMPORTANT As the booklet is constantly re-edited, this one only covers vehicles for this particular model year.
It is therefore necessary to order a new booklet each year and RETAIN THE OLD ONES.
UTILITY VEHICLES
UTILITY VEHICLES
C15-BERLINGO DISPATCH RELAY

"The technical information contained in this document is intended for the exclusive use of the trained personnel of the motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The information is to be used by the professional vehicle repairers for whom it is intended and they alone 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 each model in the range evolve. Motor vehicle repairers are invited to contact the CITRON network periodically for further information and to obtain any possible updates".
2005
AC/DTAV/PRME/MMCB/MMEC Mthodes Mcaniques
The intellectual property rights relating to the technical information contained in this document belong
exclusively to the manufacturer. Reproduction, translation or distribution in whole or in part without prior written authorisation from the manufacturer is forbidden.
2005
CAR 000 021
PRESENTATION
THIS HANDBOOK summarises the specifications, adjustments, checks and special features of CITROEN utility vehicles, not including PRIVATE vehicles for which there exist separate handbooks. 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 - RELAY and all models where applicable. The information given in this handbook is based on vehicles marketed in EUROPE.
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 future publications. 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.
CONTENTS
GENERAL C15 Vehicle identification Berlingo Dispatch Relay C15 Capacities Berlingo Dispatch Relay Lubricants ENGINE Specifications Tightening torques : engines all types Cylinder head tightening : all types Auxiliary drive belt Checking and setting the valve timing Checking the oil pressure Valve clearances 39 - 40 41 - 75 76 - 79 80 - 81 106 - 107 172 - 173 174 1-2 3-4 5-6 7 - 10 12 13 14 15 16 - 38 INJECTION Checking the low pressure fuel supply circuit : C15 (DV6ATED4) Checking the low pressure fuel supply circuit : Berlingo Dispatch (DW10TD) Checking the low pressure fuel supply circuit : Relay (DW10UTD) Checking the low pressure fuel supply circuit : Relay (DW12UTED/SOFIM) Checking the turbo pressure : Berlingo (DW10TD) Checking the turbo pressure : Dispatch (DW10ATED) Checking the turbo pressure : Relay (DW10UTD) Checking the turbo pressure : Relay (DW12UTED) Checking the turbo pressure : Relay (SOFIM 2.8TD) Checking the turbo pressure : Relay (SOFIM 2.8 HDi) Checking the air supply circuit : Berlingo (DV6ATED4) 175 176 - 177 178 - 179 180 - 181 182 183 184 185 186 187 Checking the air supply circuit : Dispatch (DW10TD) Checking the air supply circuit : Relay (DW10UTD) Checking the air supply circuit : Relay (DW12UTED) Checking the air supply circuit : Relay (SOFIM 2.8 HDi) Checking the exhaust gas recycling circuit : Berlingo, Dispatch, Relay Checking the exhaust gas recycling circuit : Relay IGNITION Sparking plugs CLUTCH-GEARBOX-TRANSMISSION Speedometer Clutch specifications C15 Berlingo 196 197 198 195 188 189 190 191 192 193 194
CONTENTS
CLUTCH-GEARBOX-TRANSMISSION Clutch specifications Dispatch Relay 199 200 201 - 203 204 - 217 218 - 227 228 - 231 232 - 234 235 - 237 238 239 - 240 241 - 244 245 - 246 247 AXLES - SUSPENSION STEERING Axle geometry : C15 Tightening torques : front axle : C15 Tightening torques : rear axle : C15 Tightening torques : power steering : C15 Axle geometry : Berlingo Tightening torques : front axle : Berlingo Tightening torques : rear axle : Berlingo Suspension : Berlingo Tightening torques : power steering : Berlingo Axle geometry : Dispatch Tightening torques : front axle : Dispatch Tightening torques : rear axle : Dispatch Manual steering : Dispatch Tightening torques: power steering: Dispatch Axle geometry : Relay Tightening torques : front axle : Relay Tightening torques : rear axle : Relay Tightening torques : power steering : Relay 248 - 250 251 252 253 - 254 255 - 258 259 260 261 - 262 263 - 264 265 - 266 267 - 268 269 270 271 272 273 - 274 275 276 - 277 BRAKES Brake specifications : C15 Tightening torques : brakes Adjusting the brake limiter Adjusting parking brakes Bleeding the brakes Brake specifications : Berlingo Tightening torques : brakes Checking/adjusting the compensator Adjusting parking brakes Bleeding the brakes Brake specifications : Dispatch Manual adjustment of the compensator Checking/adjusting the compensator Adjusting parking brakes Brake specifications : Relay Adjusting parking brakes Draining, filling and bleeding the braking circuit AIR CONDITIONING R134.a : quantities 278 279 280 281 282 283 - 288 289 290 - 291 292 293 294 - 297 298 299 300 301 - 302 303 - 306 307 - 310
Specifications : Manual / automatic gearbox : all types Tightening torques : Manual gearboxes Manual gearbox controls: all types Recommendations/precautions : AL4 automatic gearbox Tightening torques : AL4 gearbox AL4 automatic gearbox controls Recommendations/precautions : 4 HP 20 automatic gearbox Tightening torques : 4 HP 20 gearbox Shift lock : 4 HP 20 gearbox Filling / topping-up : 4 HP 20 gearbox Driveshafts
311
CONTENTS
AIR CONDITIONING Compressor lubricant Checking the efficiency of the circuit Air conditioning circuit : Berlingo Air conditioning circuit : Dispatch Air conditioning circuit : Relay 314 - 315 316 - 325 326 - 327 328 - 330 331 - 332
IDENTIFICATION OF VEHICLES
(1) RP organisation no. (2) Chassis no. (3) Paint code (4) Manufacturers plate (5) 01/02/99 Label - Tyre pressures. - RP organisation no. - Paint code
C15
(6) Model year (7) Gearbox identification reference (8) Engine plate
E1AP079D
GENERAL
C15
Structure VD VD WT/B VV /B Family (1) Version (2) Variant (3) VD Family (1)
Type approval Version (2) C 15 VV VW VY WT Van 600 Kg Van 765 Kg Deepened cab Familiale N1 Variant (3) Familiale Spain B
GENERAL
Engine WJY 1.9 D DW8B
Depollution W4
BERLINGO
A Chassis stamp, cold stamp B - Manufacturers vehicle plate C - Label RPO No. Paint colour code Tyre pressures D Gearbox identification reference factory serial no. E Engine legislation type factory serial no.
E1AP0AMD
GENERAL
BERLINGO
Structure G Family (1) J Bodywork (2) GJ KFWC KFW Engine (3) /IF C Version (4) /IF Variant (5) Family (1) G Berlingo Body shape (2) B Van 600 Kg C Van 800 Kg E Floor cab Engine (3) HFX 1.1i TU1JP KFW 1.4i TU3JP NFU 1.6i 16V TU5JP4 9HX 1.6 16V HDi DV6ATED4 WJY 1.9 D DW8B RHY 2.0 HDi DW10TD
Type approval Version (4) L3 W3 A L4 B E G D K M Euro IV C F H J L Depollution levels US Others 83/87 P V R W S X N T Y Z PLC PMF SF IF DGL D GL GN S TR ES PL K K' 5 6 7 Alcohol L3/L4 Euro IV 8 1 9 2 3 U 0 4
Manual 5-speed gearbox Manual 4-speed gearbox Manual 6-speed gearbox Automatic 6-speed gearbox Axle and/or gearbox gears Other possible combinations No gearbox
GENERAL
Variants (5) 2 sliding side doors as standard for 800 kg (WJY) Multi-function roof as standard for MPV WJY Without FAP Fiscal incentives 4x4 DANGEL Downgraded depollution Dual fuel LPG Dual fuel CNG STT2 (Stop and Start) Van Turkey Van Spain MPV/Van 5-seater 4
DISPATCH
1 Vehicle identification N. 2 RP organisation no. 3 Paint code. GENERAL 4 Manufacturers plate. 5 Engine plate. 6 Gearbox identification reference. 7 - from 01/11/2003 Label - Tyre pressures. - RP organisation no. - Paint code.
E1AP0D0D
DISPATCH
Structure Family (1) BD Number of seats (2) RFNC/IF/IF Engine (3) Version (4) Variant (5) Family (1) B Dispatch Number of seats (2) A 5 seats B 6 seats C 7 seats D 8 seats E 9 seats H 2 seats, european-specific multi-stage TAXI J 7 seats, if different form the base C (AF) Engine (3) RFN 2.0i 16V EW10J4 WJY 1.9 D DW8B RHX DW10BTED DW10ATED4 2.0 HDi RHZ DW10CTED DW10BTED+ RHW 2.0 16V HDi DW10ATED4 B D RFN C /IF
Type approval
Version (4) 15.04 K Manual 4-speed gearbox Manual 5-speed gearbox Manual 6-speed gearbox Automatic 3-speed gearbox Automatic 4-speed gearbox Axle and/or gearbox gears Manual 5-speed gearbox for South America No gearbox G H Spcif US/CEE Depollution levels 93/59 96/69 L/W L3/W3 A D 96/69 A 98/69 B L4/W4 L5/W5 B E K C F
GENERAL
Variants(5) Entreprise convertible Integral alternator-starter (ADIN) Without FAP Fiscal incentives Piloted manual gearbox Downgraded depollution LPG dual fuel STT2 (Stop and start) Van Spain T AD SF IF P D (Private vehicle or Van LPG (Cylindrical tank) S ES TD (Van Convertible) LPG (Ring-shaped tank)
IDENTIFICATION OF VEHICLES (4 X 2)
RELAY
(1) Gearbox identification reference. (2) Manufacturers name plate. (3) Engine plate. GENERAL (4) Paint code (on bonnet). (5) Chassis N (cold stamp on body). (6) Production N.
E1-P02UD
RELAY 4 X 4
IDENTIFICATION OF VEHICLES (4 X 4)
(1) Gearbox identification reference. (2) Manufacturers name plate. (3) Engine plate (4) Transfer box (5) Paint code (6) Chassis N (cold stamp on body). (7) Production N. (8) Rear differential. GENERAL
E1-P02VD
Type approval Structure Family (1) Payload (2) Engine (3) Transmission (4) Bodywork (5) Wheelbase (6) Variant (7) Family (1) Jumper / Relay Payload (2) 11 Q C 18 Q 15 Q D GVW reduced Engine (3) XU10J2U 2.0 XU10J2U/K 2.0 8S HDi DW10UTD 2.2 8S HDi DW12UTED 2.8 TD SOFIM 2.8 L TD 2.8 HDi SOFIM 2.8 L HDi Z B R M F A /SX M A A B C D F G H M N P R W Transmission (4) 5-speed manual W 4x4 Automatic Bodywork (5) Chassis cab Bare chassis Floor cab Platform cab Van Platform double cab Chassis double cab Minibus Van with raised sides Combi panorama 8/9 seater (CLUB) Combi 6/9 seater (CONFORT) Minibus 10 seater (MERCOSUR) A B C G
RELAY 4 X 4
Wheelbase (6) Short wheelbase (2850 mm) Medium wheelbase (3200 mm) Long wheelbase (3700 mm) Super long wheelbase (4050 mm)
ZB RMFA/SX
Z A B RFL R6G RHV 4HY 8140.43 8140.43S
GENERAL
RELAY 4 X 4
Type approval Variant (7) Van versions Camping car Special with EGR Combi mixed N1 (5/6 seater) Italy Without EGR Raised roof without EGR CNG Van with raised roof Private vehicle versions CNG Combi LPG Combi with raised roof MINIBUS versions Bus GO with EGR, 12 seats, 2 pt belts (CH) Bus without EGR, 12 seats, 3 pt belts (CH) Bus 16 seater, 2 point seatbelts with EGR Bus 15 seater, 2 point seatbelts with EGR Bus 16 seater, 2 point seatbelts without EGR MINIBUS versions (with speed limiter) Bus 14 seater, 3 point seatbelts without EGR Bus 16 seater, 2 point seatbelts with EGR Bus 15 seater, 3 point seatbelts with EGR 10
AX BX AM AG AXC H MH AXx AX2 AY AY2 SX AX4 AX6 AY4
With EGR Raised roof with EGR CNG Van LPG Van Camping car with EGR Combi with raised roof CNG Combi with raised roof
BXC ZX AY BY BM M GH
BG LPG Van with raised roof AYC Camping car without EGR BYC Camping car without EGR
GENERAL
LPG Combi
Bus 15 seater, 2 point seatbelts with EGR SX Bus 14 seater, 3 point seatbelts with EGR SX Bus 15 seater, 2 point seatbelts without EGR AX1 Bus 14 seater, 2 point seatbelts without EGR AX3 Bus Petrol 14 seater, 3 point belts (Switz.) AY1 Bus 15 seater, 2 point seatbelts with EGR Bus 14 seater, 3 point seatbelts with EGR Bus 15 seater, 2 point seatbelts without EGR AY6 AX5 AX7
AY3 SX1 SY1
Bus 15 seater, 2 point seatbelts without EGR Bus with EGR, 13 seats, 3 pt belts (CH) Bus without EGR, 13 seats, 3 pt belts (CH)
AY5 AY7
Bus 16 seater, 2 point seatbelts without EGR Bus 15 seater, 3 point seatbelts without EGR
CAPACITIES (in litres)

Draining methods. Oil capacities are defined according to the following methods. Draining of the engine lubrication system by GRAVITY Place the vehicle on horizontal ground (in the high position if hydropneumatic suspension). The engine should be hot (oil temperature 80C). 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). WARNING : Remove the suction container before starting the engine Draining of the engine lubrication system by SUCTION Place the vehicle on horizontal ground (in the high position if hydropneumatic suspension). The engine should be hot (oil temperature 80C). GENERAL 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).
ESSENTIAL : Systematically check the oil level using the oil dipstick. 11
C15

Diesel 1.9 D
Engine type Engine with filter change Between Min. and Max.
WJX 4,5 1,5 2 8 47
GENERAL
5-speed gearbox Brake circuit Cooling system Fuel tank capacity
12

Petrol 1.1i
Engine plate Engine with filter change Between Min. and Max. 5-speed gearbox Hydraulic brake circuit Cooling system Fuel tank capacity
BERLINGO
Diesel
1.4i KFW 3 1,5 2
1.6i 16V NFU 3,25 1,8
1.6 16V HDi 9HZ 3,75 1,55 2 Without ABS = 0,36
1.9 D WJY 4,5 1,2 1,8 9 60
2.0 HDi RHY 1,4 GENERAL
HFX
With ABS = 0,45 8 55
13
DISPATCH
Petrol 2.0i 16V Auto.
Engine type Engine with filter change Between Min. and Max.

Diesel 2.0 HDi 1.9 D WJY 1,4 [1,3 (1)] 8 3 0,5 LITRE 7 9 80 8,5 ATED RHZ 4,5 1,4 1,8 (2) BTED RHX (3) DW10 CTED ATED RHZ RHZ (4) BTED RHX 5,5 (5) CTED RHZ 2.0 16V HDi RHW 4,75 1,9
RFN 4,25 1,7 1,8
GENERAL
5-speed gearbox Automatic gearbox after drainage Brake circuit Cooling system Fuel tank capacity
(1) (2) (3) (4) (5)
= = = = =
Vehicle with aircon. Up to RPO 9869 Versions : panel van, glazed van and floor cab. New Look JUMPY / DISPATCH From RPO 9870 Oil sump with increased capacity, yellow identification label on filler neck. 14

Petrol Diesel
RELAY
2.0i
2.0 8V HDi (1)
2.2 8V HDi (2) 4HY 5,25 4HY 6,25
2.8 TD
2.8 HDi Auto
Engine type Engine with filter change Between Min. and Max. 5-speed gearbox Automatic gearbox after drainage Brake circuit Cooling system Fuel tank capacity
RFL 4,75 1,5
R6G 4,50
RHV 5,25
RHV 6,25
8940.43 5,5
8140.43S GENERAL 7
2 2,7 (after draining) 8,5 0,59, for 11Q and 15Q 10,5 11,1 (with aircon) 80 0,62 for 18Q 10
(1) (2) = Oil sump with increased capacity, yellow identification label on valve cover
15
LUBRICANTS - TOTAL recommended oils

Evolutions (YEAR 2004). CITRON 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 economy oil TOTAL ACTIVA FUTUR 9000 5W30 for France, TOTAL QUARTZ FUTURE 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) 16 New Look CITRON C5 Petrol 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 economy oil TOTAL ACTIVA FUTUR 9000 5W30 for France, TOTAL QUARTZ FUTURE 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) maintenance interval, use exclusively TOTAL ACTIVA/QUARTZ 7000 or 9000 or any other oils offering identical specifications to these. These oils offer specifications that are superior to those defined by norms ACEA A3 OR API SJ/CF. Failing this, it is essential to adhere to the maintenance programmes covering severe operating conditions.
GENERAL

Use of oil grade 10W40 It is possible to use the semisynthetic oil 7000 10W40 on HDi and HDi FAP vehicles. WARNING : To avoid difficulties when starting from cold (< 20C), use 5W40 oil. For more details, see the oil usage table (paragraph 3.3). Commercial description for energy economy oil TOTAL 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 vehicles CITRON C3 HDi 16V (DV4TED4) CITRON C8 2.2i (EW12J4) CITRON C4 and C5 2.0i (EW10A) CITRON C4 (EW10J4S) Engine oil norms Current norms The classification of these engine oils is established by the following recognised organisations : - S.A.E : Society of Automotive Engineers. - API : American Petroleum Institute. - ACEA : Association des Constructeurs Europens dAutomobiles S.A.E. Norms - Table for selection of engine oil grade Selection of engine oil grades recommended for climatic conditions in countries of distribution (see table, paragraph 3.3). Evolution of the norms to 01/01/2003 ACEA 2003 norms The meaning of the first letter has not changed, it still corresponds to the type of 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 to direct 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, also permitting better fuel economy, specifically for direct injection diesel engines NOTE : From 01/01/2003 there is no longer any reference to the year of creation of the norm, (Example : ACEA A3/B3 98 becomes ACEA A3/B3).
17
GENERAL

API NORMS : The meaning of the first letter has not changed, it still corresponds to the type 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 a higher level of performance. Recommendations. ESSENTIAL : To preserve engine performances, all engines fitted in CITROEN vehicles must be lubricated with high quality oils (synthetic or semi-synthetic). CITRON engines are lubricated at the factory with TOTAL oil of grade 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 : CITRON C3 1.4 16V HDi. - EW 12J4 : CITRON C8 2.2i. - EW 10A : CITRON C4 and C5 2.0i. - EW10J4S engine : CITRON C4 WARNING : CITRON engines prior to model year 2000 do not have to 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). Summary Norms to be respected for engine oils (year 2004) Year Engine types concerned Petrol and LPG dual fuel engines 2003 Diesel engines ACEA Norms A3 or A5 (*) B3, B4 or B5 (*) API Norms SJ or SL CF
GENERAL
(*) It is essential not to use engine oils respecting these norms for XU10J4RS, SOFIM 2.8 TDi and SOFIM 2.8 HDi engines, HDi engines with particle filter EW10A, EW12J4, DV4TED4.
18

Classes and grades of TOTAL recommended engine oils The oils distributed in each country are suited to the local climatic conditions.. Blended oils for all engines (petrol, diesel and dual fuel petrol/LPG) : S.A.E. norms TOTAL ACTIVA 9000 TOTAL QUARTZ 9000 TOTAL ACTIVA FUTUR 9000 (*) TOTAL QUARTZ FUTUR 9000 (*) TOTAL ACTIVRAC 5W40 5W30 10W40 ACEA norms A3/B3/ B4 A5/B5 A3/B3 API norms TOTAL ACTIVA DIESEL 7000 TOTAL QUARTZ DIESEL 7000 SL/CF TOTAL ACTIVA DIESEL 7000 Oils specifically for diesel engines : S.A.E. norms 10W40 15W50 ACEA norms B3 API norms GENERAL CF
(*) Blended oils for all engines giving fuel economy. Oils for petrol, diesel and dual fuel petrol/LPG engines : S.A.E. norms TOTAL ACTIVA 7000 TOTAL QUARTZ 7000 TOTAL QUARTZ 9000 TOTAL ACTIVA 7000 TOTAL QUARTZ 7000 10W40 0W40 15W50 19 A3 SL ACEA norms API norms

Oil usage table Huile TOTAL ACTIVA QUARTZ Synthetic 9000 Engine types 0W40 5W30 5W40 Semi-synthetic 7000 15W50 10W40 Hot countries Temperate countries Cold countries X X X X X X X X X X X X X X X X X (*) X X X X
GENERAL
EW10J4S (CITRON C4) Petrol engines EW12J4 (CITRON C8 2.2i 16V) EW10A (CITRON C4 and C5) Other petrol engines HDi engines with FAP (*) Diesel engines Other HDi engines SOFIM 2.8 HDi and 2.8 TDi (RELAY) DV4 TED4 (C3 1.6 16V HDi) Indirect injection diesel engines
X X X X X X
X X X X X X X X
(*) Do not use this oil in cold climatic conditions (temperature less than 20C). 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. 20
E4AP006D
21
GENERAL

ENGINE OILS FRANCE Metropolitan FRANCE Blended oils for all engines, supplied in bulk TOTAL ACTIVRAC TOTAL ACTIVA Blended oils for all engines Metropolitan FRANCE New Caledonia Guadeloupe Saint-martin Reunion Martinique Guyana Tahiti Mauritius Mayotte 9000 5W40 FUTUR 9000 5W30 (*) Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10W40 Norms S.A.E : 10W40 TOTAL ACTIVA DIESEL Oils specifically for diesel engines 7000 10W40 9000 5W40
GENERAL
9000 5W40
7000 15W50 7000 10W40
7000 15W50 7000 10W50
(*) = Blended oils for all engines, giving fuel economy 22

ENGINE OILS EUROPE Blended oils for all engines Germany Austria Belgium Bosnia Bulgaria Cyprus Croatia (*) = Blended oils for all engines, giving fuel economy 23 9000 5W40 FUTUR 9000 5W30 (*) TOTAL QUARTZ Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10W40 9000 0W40 7000 10W40 7000 10W40 9000 0W40 7000 10W40 9000 0W40 7000 10W40 7000 10W40 9000 15W40 7000 10W40 7000 10W40 GENERAL TOTAL QUARTZ DIESEL Oils specifically for diesel engines

ENGINE OILS EUROPE Blended oils for all engines Denmark GENERAL Spain Estonia Finland Great Britain Greece Holland (*) = Blended oils for all engines, giving fuel economy 24 9000 5W40 FUTUR 9000 5W30 (*) TOTAL QUARTZ Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10W40 9000 0W40 7000 10W40 7000 15W40 7000 10W40 9000 0W40 7000 10W40 7000 10W40 7000 10W40 7000 15W40 7000 10W40 9000 0W40 TOTAL QUARTZ DIESEL Oils specifically for diesel engines

ENGINE OILS EUROPE Blended oils for all engines Hungary Italy Ireland Iceland Latvia Lithuania Macedonia (*) = Blended oils for all engines, giving fuel economy 25 7000 10W40 9000 0W40 9000 5W40 FUTUR 9000 5W30 (*) 7000 10W40 7000 10W40 TOTAL QUARTZ Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10W40 9000 0W40 GENERAL TOTAL QUARTZ DIESEL Oils specifically for diesel engines
7000 10W40

ENGINE OILS EUROPE Blended oils for all engines Malta GENERAL Moldavia Norway Poland Portugal Slovakia Czech Republic (*) = Blended oils for all engines, giving fuel economy 26 7000 10W40 9000 0W40 9000 5W40 FUTUR 9000 5W30 (*) 7000 10W40 TOTAL QUARTZ Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10W40 7000 15W50 7000 10W40 7000 10W40 9000 0W40 7000 10W40 TOTAL QUARTZ DIESEL Oils specifically for diesel engines

ENGINE OILS EUROPE Blended oils for all engines Romania Russia Slovenia Sweden Switzerland Turkey (*) = Blended oils for all engines, giving fuel economy 27 9000 5W40 FUTUR 9000 5W30 (*) 7000 10W40 9000 0W40 7000 10W40 TOTAL QUARTZ Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10W40 7000 15W50 9000 0W40 TOTAL QUARTZ DIESEL Oils specifically for diesel engines
7000 10W40 7000 10W40 9000 15W50 9000 0W40
GENERAL

ENGINE OILS EUROPE Blended oils for all engines Ukraine GENERAL Serbia-Montenegro TOTAL QUARTZ Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10W40 9000 0W40 TOTAL QUARTZ DIESEL Oils specifically for diesel engines
9000 5W40 FUTUR 9000 5W30 (*)
7000 10W40
(*) = Blended oils for all engines, giving fuel economy 28

ENGINE OILS OCEANIA Blended oils for all engines Australia New Zealand AFRICA Blended oils for all engines Algeria, South Africa, Ivory Coast, Egypt, Gabon, Ghana, Kenya, Madagascar, Morocco, Nigeria, Senegal, Tunisia (*) = Blended oils for all engines, giving fuel economy 29 9000 5W40 FUTUR 9000 5W30 (*) TOTAL QUARTZ Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10W40 TOTAL QUARTZ DIESEL Oils specifically for diesel engines
7000 10W40 GENERAL
TOTAL QUARTZ Oils specifically for petrol and dual-fuel petrol / LPG engines
TOTAL QUARTZ DIESEL Oils specifically for diesel engines
9000 5W40
7000 10W40 7000 15W50
7000 10W40

ENGINE OILS CENTRAL AND SOUTH AMERICA Blended oils for all engines Argentina GENERAL Brazil Chile Cuba Mexico Paraguay Uruguay 30 9000 5W40 7000 10W40 7000 15W50 7000 10W40 TOTAL QUARTZ Oils specifically for petrol and dual-fuel petrol / LPG engines TOTAL QUARTZ DIESEL Oils specifically for diesel engines

ENGINE OILS SOUTH-EAST ASIA Blended oils for all engines China South Korea Hong Kong 7000 15W50 India Indonesia Japan Malaysia 9000 5W40 Pakistan (*) = Blended oils for all engines, giving fuel economy 31 7000 15W50 9000 5W40 9000 5W40 FUTUR 9000 5W30 (*) 7000 10W40 7000 15W50 7000 10W40 9000 5W40 FUTUR 9000 5W30 (*) TOTAL QUARTZ Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10W50 7000 15W50 7000 10W40 GENERAL TOTAL QUARTZ DIESEL Oils specifically for diesel engines

ENGINE OILS SOUTH-EAST ASIA Blended oils for all engines Philippines 7000 15W50 Singapore Taiwan Thailand 7000 15W50 Vietnam 9000 5W40 7000 10W40 7000 15W50 7000 10W40 GENERAL TOTAL QUARTZ Oils specifically for petrol and dual-fuel petrol / LPG engines TOTAL QUARTZ DIESEL Oils specifically for diesel engines
32

ENGINE OILS MIDDLE EAST Blended oils for all engines Saudi Arabia Bahrain United Arab Emirates Iran Israel Jordan Kuwait Lebanon Oman Qatar Syria Yemen 9000 5W40 7000 10W40 7000 15W50 7000 15W50 7000 10W40 GENERAL Dubai 7000 15W50 TOTAL QUARTZ Oils specifically for petrol and dual-fuel petrol / LPG engines TOTAL QUARTZ DIESEL Oils specifically for diesel engines
33

GEARBOX OILS TOTAL TRANSMISSION BV Norms S.A.E : 75W80 Part No. : 9730 A2 TOTAL FLUIDE ATX TOTAL FLUIDE AT 42 Special oil distributed by CITRON Part No. : 9730 A6 All countries 4HP20 and AL4 autoactive automatic gearboxes Special oil distributed by CITRON Part No. : 9736 22 Special oil distributed by CITRON Part No. : 9980 D4 TOTAL TRANSMISSION X4 Part No. : 9730 A7
Manual and piloted manual gearboxes
MB3 automatic gearbox
GENERAL
AM6 autoactive automatic gearbox
Transfer box and rear axle
34
LUBRICANTS - TOTAL recommended fluids

POWER STEERING OILS Power steering All vehicles except CITRON C4 and C5 Power steering CITRON C4 and C5 All countries TOTAL FLUIDE ATX TOTAL FLUIDE LDS Special oil distributed by r CITRON Part No. : 9979 A3 GENERAL TOTAL FLUIDE DA Special oil distributed by CITRON Part No. : 9730 A1
Power steering
Very cold countries
ENGINE COOLANT FLUID Packs 2 Litres All countries CITRON fluid Protection : - 35C 5 Litres 20 Litres 210 Litres 35 CITRON Part No. GLYSANTIN G33 9979 70 9979 71 9979 76 9979 77 REVKOGEL 2000 9979 72 9979 73 9979 74 9979 75

BRAKE FLUID Synthetic brake fluid Packs 0,5 Litre All countries CITRON fluid 1 Litre 5 Litres GENERAL CIRCUIT HYDRAULIQUE All countries TOTAL FLUIDE LDS TOTAL LHM PLUS TOTAL LHM PLUS Very cold countries Colour Norm Orange Green 1 Litre Packs CITRON Part No. 9979 A3 9979 A1 9979 A2 CITRON Part No. 9979 05 9979 06 9979 07
WARNING : TOTAL FLUIDE LDS fluid cannot be blended with TOTAL LHM PLUS WARNING : CITRON C5 : Use exclusively TOTAL FLUIDE LDS suspension fluid. All countries 36 TOTAL HYDRAURINCAGE

SCREEN WASH FLUID
Packs Concentrated : 250 ml All countries Fluid ready to use 1 Litre 5 Litres 9980 33 9980 06 9980 05
CITRON Part No. ZC 9875 953U ZC 9875 784U ZC 9885 077U ZC 9875 279U GENERAL 9980 56
GREASING General use TOTAL MULTIS 2 TOTAL SMALL MECHANISMS
Norms NLGI 2
All countries
Note : NLGI = National Lubrificating Grease Institude.
37
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.
GENERAL
38
ENGINE SPECIFICATIONS
Petrol engines All Types 1.1i Engine type Cubic capacity (cc) Bore / Stroke Compression ratio Power ISO or EEC KW - rpm Torque ISO or EEC (m.daN - rpm) 44,1-5500 94-3500 HFX 1124 72/69 10,5/1 55-5500 120-3400 1.4i KFW 1360 75/77 1.6i 16V NFU 1587 78,5/82 11/1 80-5800 14,7-4000 9,5/1 81-5700 16,8-3700 RFL 1998 86/86 2.0i R6G 2.0i 16V RFN 1997 85/88 10,8/1 100-6000 19-4100
39
ENGINE
ENGINE 1.6 16V HDi Engine type Cubic capacity (cc) Bore / Stroke Compression ratio Power ISO or EEC KW - rpm Torque ISO or EEC (m.daN - rpm) 9HZ 1560 75/88,3 18/1 80-4000 1.9D WJY 1868 23/1
ENGINE SPECIFICATIONS
Diesel engines All Types 2.0 HDi RHY RHX 1997 85/88 17,6/1 66-4000 69-4000 80-4000 62-4000 RHZ 2.0 8V HDi RHV 2.0 16V HDi RHW 1998 86/86 9,5/1 80-5500 2.2 8V HDi 4HY 2179 85/96 18/1 2.8 TD 2.8 HDi
8140.43 8140.43S 2798 94,4/100 19/1
82,2/88
51-4600
74-4000 90-3600 93,5-3600 25-1900 30-1800
24-1750 12,5-2500 20,5-1900 21,5-1750 25-1750
19,2-1900 16,8-3400
40
POWER UNIT SUSPENSION SPECIFICATIONS

Engine : HFX - KFW
BERLINGO
Tightening torques (m.daN) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) : : : : : : : : : : : 4,5 0,5 6 0,6 5,4 0,8 4 0,6 2,4 0,4 6,5 0,6 2,2 0,2 3 0,3 2,6 0,3 4,5 0,5 4,5 0,5
B1BP2TJP
41
ENGINE
ENGINE
BERLINGO

Engine : NFU
Tightening torques (m.daN) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) : : : : : : : : : : : 6 0,6 4 0,6 5,4 0,8 6 0,6 2 0,3 6,5 0,6 3 0,3 2,2 0,2 6 0,6 4,5 0,5 4,5 0,5
B1BP2TKP
42
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)

Engines : HFX - KFW - NFU Crankshaft Accessories drive pulley Pinion on crankshaft Tightening Angular tightening 2,5 0,2 4 0,4 45 4 Cylinder block Sump Timing belt tensioner roller Accessories belt guide roller Alternator support Alternator TU1JP-TU3JP Pre-tightening Tightening Alternator TU5JP4 Pre-tightening Tightening Aircon compressor support Aircon compressor 43 0,8 0,2 2,1 0,2 2,5 0,2 2,5 0,2 1 3,7 0,3 1 4 ,04 2,2 0,2 2,3 0,2
BERLINGO
ENGINE
ENGINE
BERLINGO

Engines : HFX - KFW - NFU Cylinder head
Coolant outlet housing In plastic In aluminium Camshaft bearing caps (TU1JP-TU3JP) Tightening Angular tightening Camshaft bearing caps (TU5JP4) Tightening Angular tightening Inlet manifold Exhaust manifold Screws for adjusting valve rockers Sparking plugs Camshaft pulley screw (TU1JP-TU3JP) Camshaft pulley screw (TU5JP4) 44
0,8 0,2 0,8 0,2 2 0,2 44 4 2 0,2 50 5 0,8 0,2 1,8 0,4 1,75 0,25 3 3,7 0,2 4,5 0,5

Engines : HFX - KFW - NFU Flywheel /Clutch Flywheel Oil pressure mechanism 6,7 1 (LOCTITE FRENETANCH) 2 0,2 Lubrication circuit Oil pressure switch Oil pump 3,5 0,5 0,9 0,1 Cooling circuit Coolant pump 1,6 0,2
BERLINGO
45
ENGINE
ENGINE
DISPATCH

Engine : RFN Tightening torques (m.daN) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) : : : : : : : : : : : : : : 5 0,5 4,5 0,5 6,5 0,5 3 0,3 4,5 0,5 6,5 0,6 3 0,3 4,5 0,5 (*) 6 0,6 (**) 5 0,5 9 0,9 4,5 0,5 6,5 0,6
B1BK1X5D
(*) AL4 autoactive gearbox (**) BE4 manual gearbox

B1BK1X6D B1BK1X7D
46

Engine : RFN Crankshaft Bearing cap fixing screws Pre-tightening Angular tightening Bearing cap screws Pre-tightening Angular tightening Accessories belt automatic tensioner roller Accessories belt guide roller Pre-tightening Tightening Accessories support block Tighten (2 studs) Pre-tightening (4 screws) Tightening Sump Timing belt guide roller Pre-tightening Tightening Timing belt tensioner roller RH engine support 47 2 0,2 60 5 2,3 0,2 46 3 2 0,2 1,5 0,1 3,7 0,3 0,7 0,2 1 0,1 1,9 0,2 Cylinder block 0,8 0,2 1,5 0,1 3,7 0,3 2,1 0,2 6 0,6
DISPATCH
ENGINE
ENGINE
DISPATCH

Engine : RFN Cylinder head Camshaft bearing cover Exhaust manifold Valve cover Camshaft pulley Pre-tightening Tightening Pulley on hub Timing pinion on crankshaft Pre-tightening Angular tightening Flywheel / clutch Clutch mechanism Flywheel Pre-tightening Angular tightening 2 0,2 0,9 0,1 3,5 0,3 1,1 0,1 3 0,3 7,5 0,7 2,1 0,2 4 0,4 53 4
(Sequence 1,5,3,7,2,6,4,8) (Sequence 1,5,3,7,2,6,4,8)
2 0,2 21 3
B1CP089C
48

Engine : RFN Lubrication circuit Oil pump closing plate Oil pump Pre-tightening Tightening Injection circuit Common injection rail fixing screw Cooling circuit Coolant pump Pre-tightening Tightening Coolant outlet housing
DISPATCH
0,8 0,1 0,7 0,1 0,9 0,1 0,9 0,1
(Sequence 1,2,3,4) (Sequence 1,2,3,4)
0,8 0,1 1,4 0,1 0,9 0,1
B1GP08WC
49
ENGINE
ENGINE
BERLINGO

Engine : 9HZ Crankshaft
Bearing cap fixing screws Pre-tightening Slackening Tightening Angular tightening Con rod screws Tightening Angular tightening Accessories drive belt pulley Pre-tightening Angular tightening Sump Timing belt guide roller Timing belt tensioner roller
1 0,2 180 3 0,3 140 5 1 0,1 100 5 3,5 0,4 190 5 Cylinder block 1,3 0,1 3,7 0,3 2,7 0,2
50

Engine : 9HZ Cylinder head Camshaft bearing covers Pre-tightening Tightening Exhaust manifold Camshaft pulley Pre-tightening Angular tightening Cylinder head Pre-tightening Tightening Angular tightening EGR valve Flywheel Pre-tightening Angular tightening Clutch mechanism 0,5 0,1 1 0,1 3 0,3 2 0,2 50 5 2 0,2 4 0,5 260 5 1 0,1 Flywheel / Clutch 3 0,3 90 5 2 0,2
BERLINGO
51
ENGINE
ENGINE
BERLINGO

Engine : 9HZ Lubrication circuit
Oil pump assembly Pre-tightening Tightening Oil/coolant heat exchanger Lubrication pipe for turbocharger Diesel injection circuit Pre-tightening Angular tightening Fuel high pressure common injection rail on engine block Union on fuel high pressure common injection rail Pre-tightening Tightening Diesel injection pump on support Union on diesel injector Pre-tightening Tightening Diesel injection pump pulley Union on diesel high pressure pump Pre-tightening Tightening 52
0,5 0,1 0,9 0,1 1 0,2 3 0,5 Diesel injection circuit 4 0,1 65 5 2,2 0,2 1,7 0,2 2,2 0,2 2,2 0,2 2 0,5 2,5 0,3 5 0,5 2 0,5 2,5 0,3

Engine : 9HZ Cooling circuit Coolant pump Pre-tightening Tightening Coolant outlet housing Pre-tightening Tightening 0,3 0,1 0,9 0,1 0,3 0,1 0,7 0,1
BERLINGO
53
ENGINE
ENGINE
BERLINGO

Engine : WJY
Tightening torques (m.daN) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) : 4,5 0,5 : 6,5 0,6 : 2,2 0,2 : 5 0,5 : 2,2 0,2 : 4,5 0,4 : 4,5 0,5 : 4,5 0,5 : 4,5 0,5 : 4,5 0,5 (*) : 5 0,5 : 5 0,5
(*) Coat the threads with LOCTITE FRENETANCHE (E3).

B1BP2SZP
54

Engine : WJY Crankshaft Bearing cap fixing screws Con rod nuts Pre-tightening Angular tightening Accessories drive pulley hub Pre-tightening Angular tightening Accessories drive pulley Piston skirt spray jet Sump Timing belt guide roller Timing belt tensioner roller Camshaft bearing covers Exhaust manifold Valve cover Camshaft / hub Camshaft pinion / hub 55 7 0,7 2 0,2 70 5 4 0,2 55 5 1 0,1 Cylinder block 1 0,1 1,6 0,1 4,3 0,4 2,1 0,2 Cylinder head 2 0,2 3 0,3 0,5 4,3 0,4 2,3 0,2
BERLINGO
ENGINE
ENGINE
BERLINGO

Engine : WJY Crankshaft
Bearing cap fixing screws Con rod nuts Pre-tightening Angular tightening Accessories drive pulley hub Pre-tightening Angular tightening Accessories drive pulley Piston skirt spray jet Sump Timing belt guide roller Timing belt tensioner roller Camshaft bearing covers Exhaust manifold Valve cover Camshaft / hub Camshaft pinion / hub 56
7 0,7 2 0,2 70 5 4 0,2 55 5 1 0,1 Cylinder block 1 0,1 1,6 0,1 4,3 0,4 2,1 0,2 Cylinder head 2 0,2 3 0,3 0,5 4,3 0,4 2,3 0,2

Engine : WJY Flywheel Flywheel Clutch mechanism Oil pump Oil/coolant heat exchanger Injector on cylinder head Diesel fuel heater Injection pump Union on injector Injection pump pulley Coolant pump Coolant inlet housing 4,8 0,4 2 0,2 Lubrication circuit 2,3 0,2 7 0,7 Injection circuit 9 0,9 1,5 0,1 2 0,2 2,5 0,2 2,3 0,2 Cooling circuit 1,5 0,1 1,8 0,1
BERLINGO
57
ENGINE
ENGINE
BERLINGO

Engine : RHY
Tightening torques (m.daN) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) : 4,5 0,5 : 6,5 0,6 : 2,2 0,2 : 5 0,5 : 2,2 0,2 : 4,5 0,5 : 2 0,2 : 4,5 0,4 : 4,5 0,4 : 2 0,2 : 2,2 0,2 : 6,1 0,6 : 5 0,5 : 4,5 0,4
B1BP2TRP
58

Engines : RHY - RHX - RHZ Crankshaft Bearing cap fixing screws Pre-tightening Angular tightening Con rod nuts Pre-tightening Angular tightening Accessories drive pulley Pre-tightening Angular tightening Piston skirt spray jet Sump Timing belt guide roller Timing belt tensioner roller Camshaft bearing covers Exhaust manifold Valve cover Camshaft / hub Camshaft pulley / camshaft hub 59 2,5 0,2 60 5 2 0,2 70 5 4 0,2 51 5 Cylinder block 1 0,1 1,6 0,1 4,3 0,4 2,5 0,2 Cylinder head 1 0,1 2 0,2 0,8 4,3 0,4 2 0,2
BERLINGO - DISPAT-
ENGINE
ENGINE
BERLINGO - DISPATCH

Engines : RHY - RHX - RHZ Flywheel
Flywheel Clutch mechanism Oil pump Oil/coolant heat exchanger Turbocharger lubrication pipe Engine end Turbocharger end Diesel injection circuit Unions on fuel high pressure common injection rail Injection pump on support Union on diesel injector Injection pump pulley Union on fuel high pressure pump Coolant pump Coolant inlet housing 60
4,8 0,4 2 0,2 Lubrication circuit 1,6 0,2 7 0,7 4,8 0,4 2,2 0,2 Injection circuit 3 0,3 2 0,2 2,3 0,2 2 0,2 5 0,5 2 0,2 Cooling circuit 1,5 0,1 1,8 0,1

Engine : RHW Reference 1 2 3 4 5 6 7 8 9 10 11
DISPATCH
Description Upper RH torque reaction rod Upper RH engine support RH engine flexible support Upper RH intermediate engine support Lower RH engine support Torque reaction rod Upper RH intermediate engine support LH engine support RH engine flexible support Lifting bracket, flywheel side Lifting bracket, timing side
B1BK3EED
61
ENGINE
ENGINE
DISPATCH

Engine : RHW (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) Tightening torques (m.daN) : 5 0,5 : 4,5 0,5 : 4,5 0,5 : 6 0,6 : 3 0,3 : 2 0,2 : 4,5 0,5 : 4,5 0,5 : 4,5 0,5 : 6,5 0,6 : 9 0,9 : 4,5 0,5 : 4,5 0,5 : 5 0,5 : 2,5 0,2 : 3 0,3 : 6,5 0,6 : 1,5 0,1 : 1,2 0,1
B1BK3EDD
62

Engine : RHW Crankshaft Bearing cap fixing screws Pre-tightening Angular tightening Con rod nuts Pre-tightening Angular tightening Accessories drive pulley Pre-tightening Angular tightening Piston skirt spray jet Sump Timing belt guide roller Timing belt tensioner roller Camshaft bearing covers Exhaust manifold Valve cover Camshaft / hub Camshaft pulley / camshaft hub 63 2,5 0,2 60 5 2 0,2 70 5 4 0,2 51 5 Cylinder block 1 0,1 1,6 0,1 4,3 0,4 2,5 0,2 Cylinder head 1 0,1 2 0,2 0,8 4,3 0,4 2 0,2
DISPATCH
ENGINE
ENGINE
DISPATCH

Engine : RHW Flywheel
Flywheel Clutch mechanism Oil pump Oil/coolant heat exchanger Turbocharger lubrication pipe Engine end Turbocharger end Diesel injection circuit Unions on fuel high pressure common injection rail Injection pump on support Union on diesel injector Injection pump pulley Union on fuel high pressure pump Coolant pump Coolant inlet housing 64
4,8 0,4 2 0,2 Lubrication circuit 1,6 0,2 7 0,7 4,8 0,4 2,2 0,2 Injection circuit 3 0,3 2 0,2 2,3 0,2 2 0,2 5 0,5 2 0,2 Cooling circuit 1,5 0,1 1,8 0,1

Engines : RHV - 4HY
RELAY
Tightening torques (m.daN) (1) (2) (3) (4) (5) : 8 0,8 : 5 0,5 : 5 0,5 : 9 0,9 : 8 0,8
B1BP2JBD
65
ENGINE
ENGINE
RELAY

Engine : RHV Crankshaft
Bearing cap fixing screws Pre-tightening Angular tightening Con rod nuts Pre-tightening Angular tightening Accessories drive pulley Pre-tightening Angular tightening Piston skirt spray jet Sump Timing belt guide roller Timing belt tensioner roller RH engine support Camshaft bearing covers Exhaust manifold Valve cover Camshaft pulley Hub pulley 66
2,5 0,2 60 5 2 0,2 70 5 4 0,4 51 5 Carter cylindres 1 0,1 1,6 0,2 2,5 0,2 2,5 0,2 2,7 0,2 Cylinder head 1 0,1 2 0,2 0,8 0,1 4,3 0,4 2 0,2

Engine : RHV Flywheel Clutch mechanism Oil pump Oil/coolant heat exchanger Turbocharger lubrication pipe Engine end Turbocharger end Injector fixing flange nut Unions on fuel high pressure common injection rail Injection pump on support Union on diesel injector Injection high pressure pump pulley Union on fuel high pressure pump Coolant pump Coolant inlet housing 67 Flywheel 4,8 0,5 2 0,2 Lubrication circuit 1,3 0,1 5,8 0,5 3 0,3 2 0,2 Diesel injection circuit 3 0,3 2,5 0,2 2,25 0,2 3 0,3 5 0,5 2,5 0,2 Cooling circuit 1,5 0,1 2 0,2
RELAY
ENGINE
ENGINE
RELAY

Engine : 4HY Crankshaft
Bearing cap fixing screws Pre-tightening Angular tightening Con rod nuts Pre-tightening Angular tightening Accessories drive pulley Pre-tightening Angular tightening Piston skirt spray jet Sump Timing belt guide roller Timing belt tensioner roller RH engine support Camshaft bearing covers Exhaust manifold Valve cover Camshaft pulley Hub pulley 68
2,5 0,2 60 5 2,3 0,3 46 5 7 0,7 82 5 Carter cylindres 1 0,1 1,6 0,2 4,3 0,2 2,5 0,2 2,7 0,2 Cylinder head 1 0,1 2 0,2 0,8 0,1 4,3 0,4 2 0,2

Engine : 4HY Flywheel Clutch mechanism Oil pump Oil/coolant heat exchanger Turbocharger lubrication pipe Engine end Turbocharger end Injector fixing flange nut Unions on fuel high pressure common injection rail Injection pump on support Union on diesel injector Injection high pressure pump pulley Union on fuel high pressure pump Coolant pump Coolant inlet housing 69 Flywheel 4,8 0,5 2 0,2 Lubrication circuit 1,3 0,1 5,8 0,5 3 0,3 2 0,2 Diesel injection circuit 3 0,3 2,7 0,2 2,25 0,2 2,7 0,2 5 0,5 2,5 0,2 Cooling circuit 1,5 0,1 2 0,2
RELAY
ENGINE
ENGINE
RELAY

Engine : 8140.43 Tightening torques (m.daN)
(1) (2) (3) (4) (5) (6) (7) (8) (9)
: : : : : : : : :
8 5 5 5 8 9 9 5 5
0,8 0,5 0,5 0,5 0,8 0,9 0,9 0,5 0,5
B1BP22DD
70

Engine : 8140.43 Crankshaft Con rod screws Pre-tightening Angular tightening Accessories drive pulley Piston skirt spray jet Sump Lower cylinder cover on upper cylinder cover Pre-tightening Angular tightening Timing belt tensioner roller Timing belt guide roller Screw M8 Screw M10 Camshaft bearing cap covers Inlet manifiold Exhaust manifiold Valve cover Screw M6 Screw M8 Camshaft pinion Injection pump pinion 71 5 0,5 60 5 2 0,2 Carter cylindres 4 0,4 1,8 0,2 5 0,5 90 5 4 0,4 2,5 0,2 4 0,4 Cylinder head 1,8 0,2 2,5 0,2 2,5 0,2 1 0,1 2,5 0,2 2,5 0,2 10 1
RELAY
ENGINE
ENGINE
RELAY

Engine : 8140.43 Flywheel
Flywheel Pre-tightening Angular tightening Clutch mechanism Oil pump assembly Screw M8 Screw M12 Oil/coolant heat exchanger Screw 56 mm long Screw 74 mm long Union on diesel injector Diesel injection pump Diesel injection pump pinion Union on diesel injection pump Coolant pump 72
3 0,3 90 5 3 0,3 Lubrication circuit 2,5 0,2 6 0,6 7 0,7 8 0,8 Diesel injection circuit 3,3 0,3 2,5 0,2 10 1 2,5 0,2 Cooling circuit 5 0,5

Engine : 8140.43S
RELAY
Tightening torques (m.daN) (1) (2) (3) (4) (5) (6) (7) (8) (9) : : : : : : : : : 8 5 5 5 8 9 9 5 5 0,8 0,5 0,5 0,5 0,8 0,9 0,9 0,5 0,5
B1BP2E0D
73
ENGINE
ENGINE
RELAY

Engine : 8140.43S Crankshaft
Bearing cap fixing screws Pre-tightening Angular tightening Con rod nuts Accessories drive pulley hub Piston skirt spray jet Sump Lower cylinder cover on upper cylinder cover Pre-tightening Angular tightening Timing belt tensioner roller Timing belt guide roller Timing belt guide roller support Camshaft bearing cap covers Inlet manifiold Exhaust manifiold Valve cover Screw M6 Screw M8 Camshaft pinion Injection pump pinion 74
5 0,5 63 5 1,8 0,2 20 2 Carter cylindres 4 0,4 1,8 0,2 5 0,5 90 5 4 0,4 2,5 0,2 2,5 0,2 Cylinder head 1,8 0,2 2,5 0,2 2,5 0,2 1 0,1 2,5 0,2 2,5 0,2 10 1

Engine : 8140.43S Flywheel Flywheel Pre-tightening Angular tightening Clutch mechanism Oil pump assembly Screw M8 Screw M12 Oil/coolant heat exchanger Injector fixing flange nut Unions on fuel high pressure common injection rail Fuel high pressure pump Union on diesel injector Diesel injection pump pinion Union on diesel injection pump Coolant pump 75 3 0,3 90 5 3 0,3 Lubrication circuit 2,5 0,2 6 0,6 7 0,7 Diesel injection circuit 4 0,4 2 0,2 2,5 0,2 2 0,2 10 1 2 0,2 Cooling circuit 5 0,5
RELAY
ENGINE
ENGINE
SPECIAL FEATURES - CYLINDER HEAD TIGHTENING

Engines all Types Cleaning to be carried out just prior to refitting the cylinder head WARNING : Clean the contact faces with the approved CITRON 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 HFX - KFW NFU
B1BP10LC
Tightening (m.daN) Pre-tightening Angular tightening Pre-tightening Angular tightening 2 0,2 240 5 2 0,2 260 5
Cylinder head bolts (Max. reusable length in mm) 175,5 0,5
122 0,3 RFL R6G Pre-tightening Tightening Angular tightening 3,5 0,3 7 0,7 160 5
B1DP05BC
76

Engines all Types Cleaning to be carried out just prior to refitting the cylinder head WARNING : Clean the contact faces with the approved CITRON 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) Pre-tightening Tightening Slackening Tightening Angular tightening 1,5 0,1 5 0,5 360 2 0,2 285 5
Cylinder head bolts (Max. reusable length in mm)
RFN
B1DP05BC
147
9HZ
Pre-tightening Tightening Angular tightening
2 0,2 4 0,4 260 5
149
B1DP1DLC
77
ENGINE
ENGINE

Engines all Types Cleaning to be carried out just prior to refitting the cylinder head WARNING : Clean the contact faces with the approved CITRON 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)
Pre-tightening Tightening Angular tightening 2 0,2 6 0,6 180 5
WJY
B1DP075C
125,5
RHY - RHX RHZ - RHW
Pre-tightening Tightening Angular tightening
1,8 0,2 6 0,5 220 5
133,3
B1DP05BC
78

Engines all Types Cleaning to be carried out just prior to refitting the cylinder head WARNING : Clean the contact faces with the approved CITRON 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) Pre-tightening Tightening Slackening Tightening Angular tightening 2,2 0,5 6 0,6 1 tour 6 0,6 220 5
RHV - 4HY
B1DP05BC
133,3
8140.43 8140.43S
Pre-tightening Angular tightening
6 0,6 180 5
115
B1DP1ADD
79
ENGINE
ENGINE Engine families Engine type BERLINGO DISPATCH RELAY See pages :
AUXILIARY EQUIPMENT DRIVE BELT

TU 1 3 5 XU 10 EW J4 RFN
JP
HFX X KFW X
JP4
NFU X
J2U
RFL
J2U/K R6G
X 84 to 85 86 to 88
X 89
80

DV 6 Engine families ATED4 1.6 16V HDi Engine type C15 9HZ 8 B 1.9 D WJY X RHY TD BTED 2.0 HDi RHX RHZ DW 10 ATED CTED BTED+ UTD 2.0 8S HDi RHV ATED4 12 UTED TD 2.8 TD 8140.43 2.8 HDi 8140.43S SOFIM
2.0 16V HDi 2.2 8S HDi RHW 4HY
BERLINGO
DISPATCH
RELAY See pages : 90 91 to 95 96 to 99 81
X 100 to 103
X 100 to 103
X 104 to 105
ENGINE
ENGINE
BELT TENSION CORRESPONDENCE TABLE ! !

4099-T (C.TRONIC.105) Tools
4122-T (C.TRONIC.105.5)
B1EP135D
82

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.
83
ENGINE
ENGINE
BERLINGO

Engines : HFX - KFW - NFU Without air conditioning Tools. [1] Pliers for removing plastic pegs [2] Belt tension measuring instrument [3] TORX spanner : 7504-T : 4122-T
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.
B1BP234C
84

Engines : HFX - KFW - NFU With air conditioning Tools. [1] Pliers for removing plastic pegs [2] TORX spanner. : 7504-T
BERLINGO
Remove. - Detension the automatic tensioner (3). - Place a 4 mm peg at (a) to immobilise the automatic tensioner. - Remove the belt. Refit. - Position the belt - Remove the 4 mm peg. - Release the automatic tensioner (3). - Tighten the screw of the automatic tensioner (3), using tool [2].
B1BP235C
85
ENGINE
ENGINE
RELAY

Engines : RFL - R6G Alternator belt (without air conditioning) Tools. [1] Belt tension measuring instrument : 4122-T
B1BP044C
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. 86
B1BP045C

Engines : RFL - R6G Alternator belt (with air conditioning) 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.
RELAY
B1BP1LFC
B1BP04AC
87
ENGINE
ENGINE
RELAY

Engines : RFL - R6G Power-assisted steering pump belt Tools. [1] Belt tension measuring instrument : 4122-T Removing 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. 88
B1BP04BC
B1BP04CC

Without air conditioning Engine : RFN Tools. [1] Pliers for removing plastic pegs : 7504-T
DISPATCH
With air conditioning
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
89
ENGINE
ENGINE
BERLINGO

Engine : 9HZ Tools. [1] Dynamic tensioner compression lever : (-).0188.Z [2] Peg for dynamic tensioner roller : (-).0194.F Removing Remove 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 tight spots). Refitting WARNING : 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 of the various pulleys. Complete the refitting in the opposite order to removal.
B1BP2Z6D
B1BP2ZCD
90

Engine : WJY Without power steering - Without air conditioning Tools.
C15
[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].
B1BP1SDC
B1BP1SEC
91
ENGINE
ENGINE
C15 - BERLINGO - DISPATCH

Engine : WJY With power steering - Without air conditioning
Tools. [1] Belt tension measuring instrument 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. : 4122-T
B1BP1SHD
92

Engine : WJY
With power steering - Without air conditioning (continued) 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
93
ENGINE
ENGINE

Engine : WJY With power steering - With air conditioning. Tools. [1] Dynamic tensioner peg [2] Belt tension measuring instrument : (-) 0188 G. : 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 be pegged at "a" using the tool [1].
B1BP1SKC
94

Engine : WJY
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" becomes free. - Tighten the screw (2). - Remove the tool [1].
B1BP1SLC
95
ENGINE
ENGINE
BERLINGO - DISPATCH

Engines : RHY - RHX - RHZ Without air conditioning Tools. 1] Belt tension adjusting square [2] 4 mm peg [3] 2 mm peg [4] Dynamic tensioner compression lever Remove RE-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). : : : : (-).0188 J2 (-).0188.Q1 (-).0188.Q2. (-).0188.Z
B1BP1YKD
96

Engines : RHY - RHX - RHZ
BERLINGO - DISPATCH
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
97
ENGINE
ENGINE
BERLINGO - DISPATCH

Engines : RHY - RHX - RHZ With air conditioning [1] [2] [3] [4] Tools. Belt tension adjusting square 4 mm peg 2 mm peg Dynamic tensioner compression lever : : : : (-).0188 J2 (-).0188.Q1 (-).0188.Q2 (-).0188.Z
Removing RE-USE OF BELT WARNING : 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.
B1BP1YLD
98

Engines : RHY - RHX - RHZ
BERLINGO - DISPATCH
With air conditioning
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
99
ENGINE
ENGINE
RELAY
COURROIE D' ENTRANEMENT DES ACCESSOIRES

Engines : RHV - 4HY Without air conditioning Tools. [1] Dynamic tensioner compression lever [2] Peg, Diameter 4 mm [3] Belt tension measuring equipment
: (-).0188 Z : (-) 0188 Q1 : SEEM 105.M
Removal. IMPERATIVE : Respect the safety and cleanliness requirements that are specific to 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 same belt. 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).
B1BP2J5D
100

Engines : RHV - 4HY Without air conditioning
RELAY
Refitting. Refit the auxiliary equipment drive belt. IMPERATIVE : Make sure that the belt is correctly positioned in the grooves of the various pulleys. Compress the dynamic tensioner roller (1) by action at b, tool [1]. (anti-clockwise direction). Remove tool [2].
B1BP2J8D
101
ENGINE
ENGINE
RELAY

Engines : RHV - 4HY Belt for driving the power steering pump With air conditioning Tools. [3] Belt tension measuring instrument : SEEM 105.M Removing. 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.
B1BP2J6C
B1BP2JAC
102

Engines : RHV 4HY Belt for driving the alternator and the compressor With air conditioning 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.
RELAY
B1BP2J7D
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].
B1BP2J9D
103
ENGINE
ENGINE
RELAY

Engines : 8140.43 - 8140.43S Belt for driving the compressor Tools. [1] Pliers for removing plastic pins [2] Belt tension measuring instrument 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 Remove tool [2]. Tighten : The nut (3), screws (1) and (2) Complete the refitting in reverse order to removal. : 7504-T : 4122-T
: 96 6 SEEM units.
B1BP21TD
104

Engines : 8140.43 - 8140.43S Belt for driving the alternator
RELAY
B1BP21UC
Tools. [1] Pliers for removing plastic pins : 7504-T [2] Belt tension measuring instrument. : 4122-T Removing. 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.
B1BP21VC
105
ENGINE
ENGINE Engine Families Engine type BERLINGO DISPATCH RELAY See pages :
CHECKING AND SETTING THE VALVE TIMING - PETROL ENGINES

TU 1 3 5 XU 10 EW
JP
HFX X KFW X
JP4
NFU X
J2U
RFL
J2U/K R6G
J4 RFN
X 109 to 112 113 to 116 117 to 119
X 120 to 126
106
CHECKING AND SETTING THE VALVE TIMING - DIESEL ENGINES

DV 6 Engine Families ATED4 1.6 16V HDi Engine type C15 9HZ 8 B 1.9 D WJY X RHY TD BTED 2.0 HDi RHX RHZ DW 10 ATED CTED BTED+ UTD 2.0 8S HDi RHV ATED4 12 UTED TD 2.8 TD 8140.43 2.8 HDi 8140.43S SOFIM
2.0 16V HDi 2.2 8S HDi RHW 4HY
BERLINGO
DISPATCH
RELAY See pages : 127 to 136 137 to 141 147 to 153
X 142 to 146 147 to 153 154 to 162 107
154 to 162 163 to 166 167 to 171
ENGINE
ENGINE
RECOMMENDATIONS : TIMING BELT

Petrol enginel Diesel engine
Recommandations.
IMPERATIVE : After each operation involving removal of the timing belt, systematically replace : - the timing belt, - the tensioner roller fixing screw.
108
CHECKING AND SETTING THE VALVE TIMING

Engines : HFX - KFW CHECKING THE VALVE TIMING NOTE : Remove the sparking plugs to ease the crankshaft rotation. Tools. - [1] Flywheel peg - [2] Flywheel or camshaft pulley peg
BERLINGO
: 4507-T.A (Toolkit 4507-T). : 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.
B1BP2MBC
B1BP2VNC
109
ENGINE
ENGINE
BERLINGO

Engines : HFX - KFW 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 to the 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).
B1BP2MCC B1EP065C
B1BP2MBC B1EP1BLC
110

Engines : HFX - KFW Refitting NOTE : Check that the pegs [1] and [2] are in place.
BERLINGO
B1EP1DLC
WARNING : Ensure the belt is fitted in the right direction : The arrows a signify the crankshaft 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 interval shown. - 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
111
ENGINE
ENGINE
BERLINGO

Engines : HFX - KFW
Adjusting the belt fitting tension - Slacken the tensioner roller fixing nut, maintaining the position of the tensioner roller, using a hexagonal 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 to tension 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 it does, repeat the operation to tension the timing belt.
B1EP1DNC
112

Engine : NFU
BERLINGO
Tools. [1] Engine flywheel peg [3a] Camshaft pulley peg. [3b] Camshaft pulley peg. [4] Dynamic tensioner roller pin [5] Belt retaining pin : : : : : 4507-T.A (Toolkit 4507-T) 4533-T.A.C1 4533-T.A.C2 4200-T.H 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.
B1BP2MBC B1EP18MC
113
ENGINE
ENGINE
B1EP18PC
BERLINGO

Engine : 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).
114

Engine : NFU Setting the timing (continued)
BERLINGO
Refitting - Position the timing belt, strictly in the following order: inlet camshaft pulley, exhaust camshaft pulley, 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 interval shown. - 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
115
ENGINE
ENGINE
BERLINGO

Engine : NFU
Adjusting the belt fitting tension
- Slacken the tensioner roller fixing nut, maintaining the position of the tensioner roller, using a hexagonal 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 to tension 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
116

Engines : RFL - R6G Tools. [1] Camshaft setting pegs [2] Crankshaft setting peg [3] Belt locking pin [4] Angular tightening adaptor [5 ] Hub immobilising tool : (-).0189.A : (-).0189.B : (-).0189.K : 4069-T : 6310-T
RELAY
Tool kit C.0189
CHECKING THE VALVE TIMING

B1BP22SC
- 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
B1BP25PC
117
ENGINE
ENGINE
B1EP01TC B1BP1WHC
RELAY

Engines : RFL - R6G Tools. [1] Camshaft pulley locating peg [2] Flywheel peg [3] Timing belt tensioning key [4] Toothed sector for locking the flywheel [5] Belt tension measuring instrument 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. : : : : : 7004-T.G 7014-T.N 7017-T.W 6012-T 4122-T Tool kit 7004-T Tool kit 9022-T
118

Engines : RFL - R6G SETTING THE VALVE TIMING (continued)
RELAY
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. 119
B1EP01YC
ENGINE
ENGINE
C4AP12TC
DISPATCH

Engine : RFN Tools. [1] Camshaft setting peg [2] Crankshaft setting peg [3] Belt retaining pin [4] Adaptor for angular tightening [5] Tool for manuvring and locking the tensioner roller [5a] [5b] Pliers for removing plastic pins 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 : : : : : : : : (-) 0189.A (-).0189.R (-).0189.K 4069-T (-).0189.S (-).0189.S1 (-).0189 S2 7504-T
120

Engine : RFN Checking the setting of the timing (continued).
DISPATCH
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]
B1BP2V5D
WARNING : If the pegs are difficult to engage, repeat the operation to fit and tension the timing belt (See corresponding operation) Refitting. Remove tools [2] and [3]. Complete the refitting in the opposite order to removal.
B1EP1BAC
121
ENGINE
ENGINE
B1BP2V4C
DISPATCH

Engine : RFN 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.
122

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).
DISPATCH
B1BP2V5D
IMPERATIVE : Never remove the crankshaft pulley (2) without pegging the crankshaft and camshafts. Slacken the screw (9) of the tensioner roller (8). Turn the tensioner roller (8) (clockwise). Remove the timing belt (7).
B1EP1BBD
123
ENGINE
ENGINE
B1EP1BCD B1EP1BDC
DISPATCH

Engine : RFN 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 and rollers. 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]. 124

Engine : RFN
DISPATCH
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 lindex 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 .
B1EP1BEC
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 cylinder head gasket h . If it is not, replace the tensioner roller or the timing belt and tensioner roller assembly.
B1EP1BFC
125
ENGINE
ENGINE
B1EP1BEC B1EP1BFC
DISPATCH

Engine : RFN 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).
126

Engine : 9HZ Tools. [1] Flywheel setting peg [2] Camshaft setting peg [3] Crankshaft setting peg : (-).0194.C : (-).0194.B : (-).0194.A
BERLINGO
B1BP3BZD
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). 127
ENGINE
ENGINE
B1EP1E3D
BERLINGO

Engine : 9HZ
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 :
B1BP305C
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].
128

Engine : 9HZ Refit the screw (10). Rotate the crankshaft six times (clockwise). IMPERATIVE : Never turn it backwards.
BERLINGO
Peg the camshaft at c, using tool [2] (oil the peg). WARNING : The magnetic track should not show any sign of damage and should not be approached by any other magnetic source.
B1EP1E4D
Peg the crankshaft at d, using tool [3]. ESSENTIAL : Should it not be possible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm. If it is more, repeat the operation to position the timing belt (see corresponding operation). Note : The index e of the dynamic tensioner roller should be centred in the interval d Check the correct positioning of the index e. If it is not correct, repeat the operation to tension the timing belt (see corresponding operation). Remove tools [2] and [3].
B1EP1E5C
129
ENGINE
ENGINE
BERLINGO

Engine : 9HZ
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 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.daN The engine support (5) , tighten to 2,5 0,2 m.daN The 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 following a reconnection of the battery (see corresponding operation).
130

Engine : 9HZ Tools. [1] Flywheel setting peg [2] Camshaft setting peg [3] Crankshaft setting peg : (-).0194.C : (-).0194.B : (-).0194.A
BERLINGO
B1BP3BZD
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). 131
ENGINE
ENGINE
B1EP1E3D
BERLINGO

Engine : 9HZ
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 :
B1BP305C
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].
132

Engine : 9HZ
BERLINGO
Refit the screw (10). Turn the crankshaft to bring the camshaft towards its pegging point. Peg the camshaft at c, using tool [2] (oil the pegs). WARNING : Do not press or damage the track of the engine speed sensor target (13). Peg the crankshaft at e, using tool [3]. Remove : - The timing belt protector (13). - The engine speed sensor (14). Slacken the screw (15) of the tensioner roller, and keep it slackened using an allen spanner at d. Detension the timing belt by pivoting the tensioner roller (clockwise). Remove the timing belt, starting with the coolant pump pinion. Checks. ESSENTIAL : Just prior to refitting, proceed to the checks as below. Check : - That the rollers and the coolant pump pulley turn freely (without play and without tight spot). - That there are no signs of oil leaks (at the crankshaft and camshaft seals). - That there are no leaks of coolant fluid (at the coolant pump). - That the track of the engine speed sensor target (15) is not damaged or scratched. Replace any components that are defective (if necessary).
B1EP1E6D
133
ENGINE
ENGINE
B1EP1E7D
BERLINGO

Engine : 9HZ 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).
134

Engine : 9HZ Adjusting the timing belt tension.
BERLINGO
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 the camshaft hole and the pegging hole is not more than 1 mm. If the offset is too great, repeat the operation. Remove tools [2] and [3]. 135
B1EP1E8C
ENGINE
ENGINE
BERLINGO

Engine : 9HZ
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 Angular tighten Remove tool [1]. Refit : The engine support (8), tighten to 5,5 The engine support (4), tighten to 6,1 The engine support (5), tighten to 2,5 The 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. : 3 0,3 m.daN. : 180 5. 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 following a reconnection of the battery (see corresponding operation).
0,4 m.daN. 0,6 m.daN 0,2 m.daN
136

Engine : WJY Tools. [1] [2] [3] [4] [5] [6] [7]
B1BP2FTC
Pliers for removing plastic pins Flywheel locating peg Injection pump setting peg 6 mm Screw H M8 Belt retaining pin Square drive for adjusting the tension Belt tension measuring instrument, with digital display
: : : : : : :
7504-T or (-).1311 7014-T.J or (-).0188 Y (-).0188 H (-).0188 E (-).0188 K (-).0188 J1 SEEM CTG 105.5M
CHECKING THE VALVE TIMING - 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.
B1EP16PD
137
ENGINE
ENGINE

Engine : WJY
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 setting points. - Position the peg [2] (from underneath the vehicle). - Continue to turn the engine until the peg [2] engages in the flywheel.
B1BP30BC
B1BP2FTC
138

Engine : WJY 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.
C15 - BERLINGO - DISPAT-
B1EP16PD
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).
B1EP132C
B1EP1EDC
B1EP1EEC
139
ENGINE
ENGINE

Engine : WJY
Setting the valve timing (continued) NOTE : If necessary, slightly rotate the pinions (10) and (7) anti-clockwise in order to engage the belt. You should not have to move the the belt in relation to the pinions by more than half tooth. - Remove tool [5]. - Move the tensioner roller (8) by its square a , using tool [6] to check that the camshaft and injection pump pinions 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 2 SEEM 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.
B1EP1EFC
B1EP1EDC
140

Engine : WJY Setting the valve timing (continued) 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 of the camshaft and injection pump hubs and the corresponding pegging holes are not greater than 1 mm. If necessary, recommence the 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 return hoses. - Refit the accessories drive belt (see corresponding operation). - Refit the RH lower splash-shield. - Disengage 5th gear. - Connect the battery.
141
ENGINE
ENGINE
DISPATCH

Engine : RHX Tools. [1] Belt tension measuring instrument [2] Tension lever [3] Engine flywheel peg [4] Belt compression spring [5] Camshaft pinion peg [6] Engine flywheel lock [7] Set of blocking plugs [8] Crankshaft pulley extractor 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 the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm, with the help of a mirror a and a 7 mm screw. IMPERATIVE : If pegging is impossible, restart the adjusting. (See corresponding operation).
B1CP04CC B1BP1TSC B1BP1TTC
: : : : : : : :
4122-T (-).188.J2 (-).0288.D (-).0188.K (-).0188.M (-).0188.F (-).0188.T (-).0188.P
142

Engine : 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 :
DISPATCH
- 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
143
ENGINE
ENGINE
B1EP13ED B1EP13FC
DISPATCH

Engine : RHX Setting the valve timing (continued) Retighten screws (9) by hand. Turn the pinion (12) (clockwise) to the bottom of the buttonhole. 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) anticlockwise (not by more than one tooth). - Remove the tool [4]. 144
B1EP13GD

Engine : RHX Setting the valve timing (continued).
DISPATCH
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
145
ENGINE
ENGINE
B1EP13HD
DISPATCH

Engine : RHX Setting the valve timing (continued) Tighten : - Screw (7) of the roller (6) to 2.5 m.daN. - Screw (9) to 2.m.daN Remove 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 the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm.. In the case of an incorrect value, recommence the operation. Remove the tool [3].
146

Engines : RHY - RHZ Tools. [1] Belt tension measuring equipment [2] Tension lever [3] Engine flywheel peg [4] Belt clamp [5] Camshaft pulley peg [6] Engine flywheel lock [7] Set of blocking plugs [8] Pulley extractor [9] 2 mm dia.peg : : : : : : : : : 4122-T (-).0188.J2 (-).0188.Y (-).0188.AD (-).0188.M (-).0188.F (-).0188.T (-).0188.P (-).0188.Q2 Removing
BERLINGO - DISPATCH
IMPERATIVE : Respect the safety and cleanliness requirements that 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).
147
ENGINE
ENGINE
DISPATCH

Engines : RHY - RHZ Uncouple, plug and move aside, using tool [7] , the fuel delivery pipe (2) and return 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 the screw (7) to 1,5 0,1 m. daN. NOTE : The screw (7) is one of the screws securing the coolant pump and is there 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].
B1BP2R2C B1EP1A7C
B1BP2H2C B1BP2H3C
148

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 the timing cover fixing screws. Remove : The intermediate timing cover. The lower timing cover.
DISPATCH
B1CP04BC
B1BP2R4C
B1BP2R3C
149
ENGINE
ENGINE
DISPATCH

Engines : RHY - RHZ Slacken the screw (17) of the tensioner roller (18). Remove the timing belt (14). Checks. IMPERATIVE : Just before refitting, carry out the checks below :
B1EP1A8D
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
150

Engines : RHY - RHZ
DISPATCH
B1EP1ABD
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
151
ENGINE
ENGINE
DISPATCH

Engines : RHY - RHZ 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
152

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.daN Screws (3), (4) and (6). The bracket (13). Screws (11), tighten to 6,1 0,5 m.daN The nut (12), tighten to 4,5 0,5 m.daN Fit the bearing shell (10). Take away the workshop hoist. Clip the fuel delivery and return pipes. Remove the tool [7]. Couple : The fuel delivery pipe (12). The fuel return pipe (1). Coat the screw (8) with loctite FRENETANCH. Refit the tool [6] and the screw (8) with the washer (22), Tighten to 7 0,2 m.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.
B1EP1A7C B1BP2R4C B1EP1ADC
DISPATCH
153
ENGINE
ENGINE
B1BP2HLC
RELAY

Engines : RHV - 4HY [1] Camshaft locating peg [2] Flywheel locating peg Tools. : (-).0188 M Toolkit C.0188 : (-).0188 Y
CHECKING THE VALVE TIMING IMPERATIVE : Respect the safety and cleanliness recommendations specific to high pressure diesel injection (HDi) engines. Removing Remove : - 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).
B1EP17GC
154

RHV Engines : 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 offset between the camshaft pinion hole and the pegging hole is not more than 1 mm, with the help of a mirror a and a 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. 155
RELAY
B1BP2HMC
B1EP17JC
4HY
B1BP298C
B1EP17KC
ENGINE
ENGINE
B1CP04BC B1BP2HZC
RELAY

Engines : RHV - 4HY Tools. [1] [2] [3] [4] [5] [6] [7] Belt tension measuring instrument Tensioning lever Flywheel locating peg Belt retaining pin Camshaft pinion peg Engine flywheel lock Crankshaft pulley extractor : : : : : : : SEEM CTG 105.5M (-).0188.J2 (-).0188.Y (-).0188.K (-).0188.M (-).0188.F (-).0188.P Toolkit C.0188
Setting the valve timing IMPERATIVE : Respect the safety and cleanliness recommendations specific to high pressure diesel injection (HDi) engines. Removing Remove : - 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. 156

Engines : RHV - 4HY
RELAY
Setting the valve timing Remove : - 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.daN NOTE : 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.
B1BP2J0C
B1BP2J1C
157
ENGINE
ENGINE
B1BP2J2C B1EP17LD
RELAY

Engines : RHV - 4HY
Setting the valve timing (continued)
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).
Remove the timing belt (20).
158

Engines : RHV - 4HY Checks IMPERATIVE : Just prior to refitting, perform the following checks. Check that :
RELAY
B1EP17MC
- 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].
B1EP17NC
159
ENGINE
ENGINE
B1EP17PD B1EP17QD
RELAY

Engines : RHV - 4HY 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 of 98 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 at the 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).
160

Engines : RHV - 4HY
RELAY
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 of 54 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 offset between the camshaft pinion hole and the pegging hole is not more than 1 mm. If the value is incorrect, recommence the operation.
B1EP17QD
161
ENGINE
ENGINE
B1EP17RC
RELAY

Engines : RHV - 4HY 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.
162

Engine : 8140.43 Tools. [1] Pliers for removing plastic pins [2] Peg for setting the injection pump CHECKING THE VALVE TIMING : 7504-T : 1 860 617 000
RELAY
Toolkit (-).0191
B1BP21YC
Removing Disconnect 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 the valve cover.
B1BP21ZD
163
ENGINE
ENGINE
RELAY

Engine : 8140.43S Check that the marking c on the crankshaft pinion (7) is in a low position in relation to the engines 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 - 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.
B1BP220C
: 20 m.daN
164

Engine : 8140.43 Tools. [1] Pliers for removing plastic pins [2] Peg for setting the injection pump [3] Belt tensioner compressor : 7504-T : 1 860 617 000 : 1 860 638 000
RELAY
Toolkit (-).0191 Toolkit (-).0191
B1BP21YC
Removing Disconnect 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 the valve cover. 165
B1BP221D
ENGINE
ENGINE
B1BP222C B1BP223C
RELAY

Engine : 8140.43 Check that the marking c on the crankshaft pinion (7) is in a low position in relation to the engines 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. Refitting Refit : 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.daN Refit : 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.
166

Engine : 8140.43S Tools. [1] [2] [3] [4] Pliers for removing plastic pins Flywheel locking tool Belt compression tool Belt compression spring : : : : 7504-T (-).0191 C 1 860 638 000 (-).0188K
RELAY
Toolkit (-).0191
B1BP2PXC
Checking the setting of the valve timing. Removing Remove : - 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)
B1BP2DTC
167
ENGINE
ENGINE
RELAY

Engine : 8140.43S 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 engines vertical axis at c. - Check the alignment between the marking d on the camshaft pulley (6) and the marking e on the valve cover. 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.
B1BP2DWC
B1BP2DXC
168

Engine : 8140.43S Setting the valve timing Removing Remove : The accessories and alternator belt (see corresponding operation). Rotate the engine (normal direction of rotation).
B1BP2PXC
RELAY
Immobilise the flywheel at a, using tool [2]. Remove : - Screws (2). - The timing cover (1). - Screw (3). - The accessories pulley (4)
B1BP2DTC
169
ENGINE
ENGINE
RELAY

Engine : 8140.43S 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 engines vertical axis at c. Check the alignment between the marking d on the camshaft pulley (9) and the marking e on the valve cover. Remove : - Screw (8). - Nut (6). - The cover (7). - The timing belt Move aside : - The coolant header tank. - The air conditioning pipes. Support the engine. Remove the RH engine support.
B1BP2DUC
B1BP2DVC
170

Engine : 8140.43S Setting the valve timing (continued) Refitting Refit : - The timing belt, using tool [4]. - The cover (7). - Screw (8). - Nut (6), (tighten by hand). - Remove tool [3] Note : Check that the belt tensioners 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
RELAY
B1BP2DUC
B1BP2DVC
171
ENGINE
ENGINE
CHECKING THE OIL PRESSURE

Petrol Engine type Temperature (C) Pressure (Bars) Rpm Pressure (Bars) Rpm Pressure (Bars) Rpm Pressure (Bars) Rpm 2279-T.Bis 4103-T 7001-T HFX KFW 90 NFU RFL R6G 80 RFN
3 2000
4 4000 X X X X X X Tools Toolkit 4103-T X X X X X X
7 4000 X X X X X X
NOTE : The oil pressure should be checked with the engine hot, after the oil level has been checked. 172
CHECKING THE OIL PRESSURE

Diesel Engine type Temperature (C) Pressure (Bars) Rpm Pressure (Bars) Rpm Pressure (Bars) Rpm Pressure (Bars) Rpm 2279-T.Bis 4103-T (-).1503.J 4225-T 4202-T 9HZ 1,3 WJY 90 1,8 1000 3,7 2000 4,3 3000 4,5 RHY 2 RHX 80 2 1000 4 2000 RHZ RHV RHW 4HY 8140.43 90 8140.43S 0,8 750
3,5
4 4000 Tools Toolkit 4103-T
3,3 4000 X X X X X X X
X X X
X X
X X
NOTE : The oil pressure should be checked with the engine hot, after the oil level has been checked
173
ENGINE
ENGINE
VALVE CLEARANCES
The valve clearances must be checked with the engine cold. Inlet Exhaust POSSIBLE PROCEDURES For engines with 4 cylinders in a line (1-3-4-2 ) Rocking Exhaust HFX - KFW - RFN 0,20 0,05 mm 0,40 0,05 mm 1 3 NFU 1 0,05 mm 1 0,05 mm 4 2 WJY 0,15 0,08 mm 0,30 0,08 mm Engines without hydraulic adjustment : the clearance (J) should be checked opposite the cam. Adjust 4 2 1 3 Exhaust Inlet Fully open (Exhaust)
Valves fully open 1 3 4 2
Adjust
3 4 2 1 4 2 1 3
1 4 3 2 4 1 2 3
2.8 TD - 2.8 HDi
0,50 0,05 mm
0,50 0,05 mm
RFN - 9HZ - RHY - RHX RHZ - RHV - RHW - 4HY
Automatic adjustment
B1DP13QC
174
CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT

Engine : 9HZ Tools. [1] 10 mm low pressure connector [2] Pressure gauge for testing boost pressure Checks : 4215-T : 4073-T.A
BERLINGO
Toolkit 4073-T INJECTION
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 the fuel 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] 10 0,5 cmHg 20 0,5 cmHg 30 0,5 cmHg Checks Engine driven by the starter motor Engine running under full load Fuel supply circuit, fuel filter piping
B1CP0GFD
175
BERLINGO - DISPATCH

Engines : RHY - RHZ Tools. [1] 10 mm low pressure connector [2] 8 mm low pressure connector [3] Pressure gauge for testing boost pressure : 4215-T : 4218-T : 4073-T Kit 4073-T
INJECTION
B1BP1TWD
Connect 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 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 ignition For 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.
176

Engines : RHY - RHZ 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 Between 3 and 3.5 Bar More than 3,5 bars More than 3,5 bars Between 0.8 and 1.5 Bar Fuel return pressure 0,7 0,2 bar Less than 0,7 bar More than 0,7 bar Less than 0,7 bar
BERLINGO - DISPATCH
Checks Check the condition of the diesel filter Check the low pressure regulator incorporated in the filter (jammed shut) : replace. Check the fuel return circuit (pipe pinched or trapped). Check the fuel suppy circuit : - Booster pump (low pressure), piping.
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 : The flow should be drop by drop Excessive fuel return 177
Check : diesel injector return flow. (Table below) Uncouple the diesel injector return pipe. Observe : Diesel injector functioning correctly Diesel injector jammed shut.
INJECTION
JUMPER

Engine : RHV Tools. [1] 10 mm low pressure connector [2] 8 mm low pressure connector [3] Pressure gauge for testing boost pressure [4] Pressure gauge extension for tool testing HDi low pressure
: 5725-T : 5724-T : 4073-T Kit 4073-T : 4251-T
INJECTION
Checks IMPERATIVE : 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 pressure gauge [3] and the tools [1] and [2].
B1BP2G7C B1BP2G8C
178

Engine : RHV 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 pressure Between 3.3 and 4 Bar 0,8 0,4 bars More than 4 bars Less than 0,8 bar More 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 flow Uncouple the diesel injector return pipe. Checks : The flow should be drop by drop Excessive fuel return Observations Diesel injector functioning correctly Diesel injector locked shut 179
JUMPER
Contrle de pressions en dynamique. Engine tournant au rgime de ralenti (fonctionnement normal). Pression d'arrive carburant indique par le manomtre [3] = 2,5 0,4 bars. Pression de retour carburant indique par le manomtre [3] = 0,5 0,4 bars. Fonctionnement anormal. Contrle Check 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 filter return). Checks : If the injector return flow is greater than 50 15l/h Observations Valve open (jammed) Valve shut (jammed)
INJECTION
JUMPER

Engines : 4HY - 8140.43S Tools. [1] 10 mm low pressure connector : 5725-T [2] 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 Check Connect 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 filter (green mark 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 pressure 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 beween 1,1 and 1,6 Bar.
B1BP2G7C B1BP2G8C
INJECTION
180

Engines : 4HY - 8140.43S 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 Between 3 and 3,5 Bars More than 3,5 bars More than 3,5 bars 4HY Entre 3,3 et 4 bars More than 4 bars More than 4 bars 8140.43S 0,8 0,2 bars Less than 0,8 bar More than 0,8 bar Less than 0,8 bar 4HY 0,8 0,4 bars Less than 0,8 bar More than 0,8 bar Less than 0,8 bar
JUMPER
Check the condition of the diesel filter Check the low pressure regulator incorporated in the filter (locked shut) : replace. Check the fuel return circuit (pipe pinched or trapped...). Check the fuel suppy circuit : - Booster pump (low pressure), piping.
Between 0,8 and 1,5 Bar Between 0,8 and 1,5 Bar
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 : The flow should be drop by drop Excessive fuel return 181
Check : diesel injector return flow. (Table below) Uncouple the diesel injector return pipe. Observe : Diesel injector functioning correctly Diesel injector locked shut.
INJECTION
BERLINGO
CHECKS : TURBO PRESSURE

Engine : RHY Tools. [1] Pressure gauge for checking boost pressure [2] Sleeve for checking boost pressure : 4073-T.A Kit 4073-T : 4185-T
INJECTION
B1BP1ZXD
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. 182

Engine : RHZ Tools.
DISPATCH
[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-T Checks. IMPERATIVE : respect the following checking requirements : Engine at running temperature, 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
183
INJECTION
JUMPER

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-T Checks IMPERATIVE : 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. 184
INJECTION
B1HP1FFC C5FP0FSC

Engine : 4HY Tools.
JUMPER
B1HP1LZC
C5FP0FSC
[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-T Checks IMPERATIVE : 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. 185
INJECTION
JUMPER

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-T Checks IMPERATIVE : 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). 186
INJECTION
B1BP231D C5FP08AC

Engine : 8140.43S
JUMPER
B1BP2DSD
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-T Checks IMPERATIVE : 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). 187
C5FP0FSC
INJECTION
BERLINGO
CHECKING THE AIR SUPPLY CIRCUIT

Engine : 9HZ Tools. [1] Manual pressure-vacuum pump FACOM DA 16.
INJECTION
B1HP1UGC B1HP22RC
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.
188

Engines : RHX - RHZ TOOLS
DISPATCH
[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) 780 4000 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. 189
Pressure (Bar) 0,6 0,25
B1HP12FD
INJECTION
JUMPER

Engine : RHV Tools. [1] Manual pressure-vacuum pump : FACOM DA 16
INJECTION
B1HP1FGC
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.
190

Engine : 4HY Tools. [1] Manual vacuum pump : FACOM DA 16
JUMPER
Checks
- Uncouple the tube at a. - Connect tool [1] at a - Start the engine. - The vacuum value should be 0,8 bar at idling speed.
B1BP2QKC
191
INJECTION
JUMPER

Engine : 8140.43S Tools. [1] Manual vacuum pump : FACOM DA 16
INJECTION
B1BP2QKC
IMPERATIVE : Respect the safety and cleanliness requirements. - Uncouple the tube at a. - Connect tool [1] at a - Start the engine. - The vacuum value should be 0,8 bar at idling speed.
192
BERLINGO - DISPATCH - JUMPER
CHECKS : EXHAUST GAS RECYCLING CIRCUIT

Engines : RHY - RHX - RHZ 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. Engine : 8140.43S
B1HP12GD
B1KP017C
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 bar 2500 0 bar 193
B1BP2QAC
INJECTION
CHECKS : EXHAUST GAS RECYCLING CIRCUIT

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.
B1HP1FTC
JUMPER
INJECTION
B1BP2Q8C B1KP011C
Engine speed (rpm) 780 2500
Vacuum value (Bar) 0,5 bar 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. 194
SPARKING PLUGS
Vehicles Models 1.1i Engine type HFX BOSCH FR7DE CHAMPION RC8YCL SAGEM RFN58 LZ IGNITION Electrode gap setting Tightening torque
BERLINGO
1.4i
KFW
FR7DE
RC8YCL
RFN58 LZ
0.9 mm
3,0 m.daN
1.6i 16V
NFU
FR7ME
RFN58HZ
DISPATCH
2.0i 16V
RFN
FR8ME
REC9YCL
RFN52HZ
1 mm
2,7 m.daN
195
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. 196 CLUTCH GEARBOX TRANSMISSION
CLUTCH SPECIFICATIONS
Diesel 1.9 D Engine plate Payload (Kg) Gearbox Make Mechanism/Type Ext./Int. lining Disc lining type WJY 600/765 BE4/5 LUK 200 P 3700 200/134 F 408
C15
197
CLUTCH GEARBOX TRANSMISSION
BERLINGO
Petrol 1.1i Engine plate Gearbox Make Mechanism/Type Ext./Int. lining Disc lining type CLUTCH GEARBOX TRANSMISSION HFX MA/5 VALEO 200 CPX 3850 200 x 137 F 808 1.4i KFW
Diesel 1.6i 16V NFU 1.6 16V HDi 9HZ BE4/5 LUK 234 T 4800 234 x 165 F 810 200 P 4700 200 x 137 F 408 235 T 5700 228 x 155 1.9 D WJY 20 HDi RHY
198
Petrol 2.0i 16V Engine plate Gearbox Make Mechanism/Type Ext./Int. lining Disc lining type VALEO 203 DNG 4700 228 x 155 F 808 DS 200 P 4700 200 x 137 F 408 RFN BE4/5 LUK 235 T 5700 228 x 155 F 202 1.9 D WJY RHX Diesel 2.0 HDi RHZ ML/5
DISPATCH
2.0 16V HDi RHW
225 T 6900 225 x 150 F 810 CLUTCH GEARBOX TRANSMISSION
199
RELAY
Petrol 2.0i Engine plate Gearbox Make Mechanism/Type Ext./Int. lining Disc lining type CLUTCH GEARBOX TRANSMISSION VALEO 235 DT 5900 228 x 155 RFL R6G
Diesel 2.0 8S HDi RHV ML/GU LUK 230 DNG 4700 242 DT 5200 VALEO 242 DT 6200 242 x 161 F 808 2.2 8S HDi 4HY 2.8 TD 8140.43 2.8 HDi 8140.43S
200
MANUAL GEARBOX SPECIFICATIONS

Vehicle Engine Gearbox Sequence Type BE4/5 C15 DW8B TU1JP TU3JP BE3/5N MA/5S MA/5L BE4/5N BE4/5J DV6ATED4 DW8B BE4R/5L BE4/5L BE4/5N DW10TD Dispatch EW10J4 BE4/5KG BE4/5KG BE4/5 20 TE 11 20 CP 61 20 CP 37 20 CP 36 TU5JP4 Berlingo 20 DM 45 20 DM 46 20 DM 83 20 DM 47 20 DM 48 20 DM 79 20 DM 80 20 DL 93 17 x 77 19 x 77 19 x 72 17 x 77 17 x 71 19 x 70 19 x 72 15 x 74 22 x 19 19 x 17 CLUTCH GEARBOX TRANSMISSION 19 x 16 None 19 x 17 19 x 17 None 17 x 71 13 x 59 13 x 59 19 x 21 Torque ratio Drive ratio
201

Vehicle Engine Gearbox Sequence Type ML/5 DW10BTED Dispatch DW10CTED DW10BTED+ DW10ATED4 ML/5C 20 LM 26 20 LM 19 20 LM 32 20 LM 06 Type ML/5 Vehicle CLUTCH GEARBOX TRANSMISSION Relay 8140.43 2.8 TD 8140.43S 2.8 HDi 202 Engine XU10J2U DW10UTD DW12UTED Load 10Q 14Q 18Q 10Q 14Q 10Q 14Q 18Q 10Q 14Q 18Q 18Q ML/GU Gearbox Sequence 20 UM 07 20 UM 08 20 MM 01 20 UM 16 20 UM 10 20 UM 13 20 UM 06 20 UM 05 20 UM 15 Torque ratio 13 x 73 13 x 83 14 x 75 13 x 68 12 x 71 13 x 68 13 x 83 13 x 68 13 x 68 Drive ratio 18 x 14 21 x 15 22 x 21 18 x 14 21 x 15 18 x 14 21 x 15 21 x 15 21 x 15 14 x 71 14 x 67 14 x 67 15 x 67 25 x 20 Torque ratio Drive ratio

Vehicle Engine Gearbox Sequence Type AL4 Dispatch Relay EW10J4 2.8 HDi AL4 4 HP 20 20 TP 96 Type 4 HP 20 Sans 20 x 69 59 x 68 21 x 73 52 x 67 Torque ratio Drive ratio
203
MA/5 GEARBOX : TIGHTENING TORQUES

Tightening torques (m.daN) Ref. 1 2 Description Bearing retaining clip Intermediate plate No. of screws 4 11 16 # RPO 9784 17 RPO 9786 # 3 m.daN 1,8 0,2 5 0,5
Gearbox casing
1,9 0,2
4 CLUTCH GEARBOX TRANSMISSION

B2CP3SRP
Clutch bearing guide screws
0,6 0,15
204
MA/5 GEARBOX : TIGHTENING TORQUES

Tightening torques (m.daN) Ref. 26 27 28 29 Description 5th gear housing fixing screws Reverse gear switch Drain plug Level plug 1 No. of screws 3 m.daN 2,2 0,2 2,5 0,5 3,3 0,3 3,3 0,3 CLUTCH GEARBOX TRANSMISSION
B2CP3SSD
205
BE4/5 GEARBOX : TIGHTENING TORQUES

Tightening torques (m.daN) Ref. 1 2 3 4 5 6 CLUTCH GEARBOX TRANSMISSION
B2CP3ZXD
Description Air vent hole Reverse gear rocker shaft fixing nut Differential casing fixing nuts Differential casing fixing screws 10 Speedo drive support Differential casing fixing screws 7 Drain plug Level plug Gearbox casing / clutch casing fixing screw 5th gear housing fixing screw Reverse gear switch
No. of screws
m.daN 1,5 0,2 4,5 0,2 1,5 0,2 5 0,5 1,5 0,2 1,5 0,2 3,5 0,2 2,2 0,2 1,3 0,2 1,5 0,2 2,5 0,2
7 8 9 10 11
206

Tightening torques (m.daN) Ref. 12 13 14 15 16 Description Fork shaft stop screw Differential gearwheel fixing screw Bearing stop screw Secondary shaft nut Primary shaft nut No. of screws m.daN 1,5 0,2 7 0,5 1,5 0,2 6,5 0,5 7,3 0,5 CLUTCH GEARBOX TRANSMISSION
B2CP3ZYD
207

Tightening torques (m.daN) Ref. 17 18 19 fixing screws Bearing guide screws Speedo housing fixing screws Description Gear control support No. of screws m.daN 1,5 0,2 1,25 0,2 1,5 0,2
B2CP3ZZC

B2CP400C
208
TIGHTENING TORQUES : BE4/5 GEARBOX WITH ENHANCED TRACTION

Tightening torques (m.daN) Ref. 23 24 25 26 27 28 Bearing guide Clutch housing Primary shaft nut Secondary shaft nut Clip retaining screws Differential gearwheel screws Reverse gear switch Description No. of screws 3 13 1 1 2 2 1 m.daN 1,25 0,2 1,3 0,2 7,25 0,7 6,5 0,6 1,5 0,2 6,5 0,6 2,5 0,2 CLUTCH GEARBOX TRANSMISSION
B2CP3WDP
209

B2CP3BRD
Description Differential housing Breather pipe Gearbox rear casing screws Level plug Differential housing screws Drain plug
No. of screws 4 1 7 1 4 1
m.daN 5 0,5 1,7 0,2 1,25 0,2 2,2 0,2 1,25 0,2 3,5 0,3
210

Tightening torques (m.daN) Ref. 29 30 31 32 33 34 Breather pipe Gearbox rear casing screws Level plug Differential housing screws Drain plug Description Differential housing No. of screws 4 1 7 1 4 1 m.daN 5 0,5 1,7 0,2 1,25 0,2 2,2 0,2 1,25 0,2 3,5 0,3 CLUTCH GEARBOX TRANSMISSION
B2CP3BRD
211
ML5 GEARBOX : TIGHTENING TORQUES

B2CKUC4D
Description 1 screw M8-45 1 screw M8-70 1 screw M10-70 1 screw M10-50 1 screw M10-85 Screw Speedometer control support Fixing of gearbox cover on gearbox casing Differential bearing stop plate Air vent Reverse gear switch Fixing of gearbox casing on clutch casing
m.daN 1,8 0,1 1,8 0,1 4 0,4 4 0,4 4 0,4 3 0,3 1 0,1 2 0,2 2 0,2
7 8 9 10 11 12
2,5 0,2 2 0,2
212
ML5 GEARBOX : TIGHTENING TORQUES

Tightening torques (m.daN) Ref. 13 14 15 16 Flange fixing screws Secondary shaft nut Gear control support screws Differential gearwheel screws Description m.daN 2 0,2 17 1,7 1,5 0,1 7,7 0,7
B2CKUC5D
B2CKUC6D
213
MLGU GEARBOX : TIGHTENING TORQUES

Tightening torques (m.daN) Ref. 1 2 3 4 5 6 7 8 9 CLUTCH GEARBOX TRANSMISSION
B2CP3HPD
Description Reverse gear switch 1 screw Fixings of gearbox casing on clutch casing Differential housing screws (M10) Speedo drive support Oil level plug (1 screw) Differential housing screws (M8) Drain plug Differential bearing stop plate screw 5th gear housing screw
No. of screws 2,5 0,2 14 screw 6 screw 1 screw
m.daN
2 0,2 4 0,5 1,5 0,1 3 0,3
4 screw 1 screw 4 screw 7 screw
2 0,2 3 0,3 2 0,2 2 0,2
(*) Depending on date of manufacture of gearbox. 214
MLGU GEARBOX : TIGHTENING TORQUES

Tightening torques (m.daN) Ref. 10 11 12 Description Secondary shaft nut Gear control support screws Differential gearwheel screws No. of screws 1 screw 6 screw 12 screw m.daN 17 1,5 2 0,2 7,7 0,3
B2CP3HQD
215
MLGU GEARBOX : SPECIFICATIONS

Drain Fill Top-up Gearbox. (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 litres Oil quality : TOTAL TRANSMISSION BV 75W80 Checking 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 the gearbox 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 lubricate the transfer box separately. Oil capacity (after draining) : 0,7 litres Oil quality : TOTAL TRANSMISSION X4 80W90 API GL5.
B2CP3JQC

B2DP009C
216
MLGU GEARBOX : SPECIFICATIONS

Lubrication Drain Fill Top-up Rear axle. (6) Oil level plug. (7) Drain plug. Oil capacity (after draining)
B2EP006C
: 1,8 litres : TOTAL TRANSMISSION X4 80W90 API GL5. CLUTCH GEARBOX TRANSMISSION
Oil quality 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.
B2FP05YC
217
BERLINGO
MA/5 GEARBOX : CONTROLS

Engines : HFX - KFW
1 2 3 4
Gear Gear Gear Gear
control bar. lever. engagement ball-joint. selection ball-joint. Adjustment.

B2CP3NTD
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 gear controls, check that all the gears engage without tight spots .
218
BE4/5 GEARBOX : CONTROLS

Engine : WJX
C15
L = Distance between the centre of the knob and the centre line of the radio housing. L = 195 if not, adjust via X . J = 0.5 to 1 mm.
B2CP39WD
219
(1) Gear selection rod X = 130 1 mm. (2) Gear engagement rod Y = 300 1 mm. (3) Torque rod Z = between 51 and 61 mm
BERLINGO

Engines : NFU - 9HZ - WJY - RHY
1 2 3 4 3
Gear control bar. Gear lever. Reaction rod. Gear selection ball-joint. Gear engagement ball-joint. Adjustment.

B2CP3NWD
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 gear controls, check that all the gears engage without tight spots .
220

Engines : RFN - WJY
DISPATCH
(1) Gear control lever (2) Gear engagement control cable (*) (3) Gear selection control cable (*) (4) Gear selection ball-joint 10 mm. (5) Gear engagement ball-joint 10 mm. (6) Flexible insulating grommet through the bulkhead. CLUTCH GEARBOX TRANSMISSION
(*) = These two cables cannot be separated.
B2CP3BWD
221
DISPATCH
CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS

Engines : RFN - WJY Principles of adjusting the gear controls. WARNING : Cables should be adjusted each time the gearbox, gear controls or power unit are removed. Principle Lock the gear lever in neutral position, using tool: 9607-T. Place the gearbox in neutral.
B2CP3BXC

B2CP3BYC
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.
222
CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS

Engines : RFN - WJY Adjusting the gear controls.
DISPATCH
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. 223
B2CP3C6C
B2CP3C0C
Tools. [1] Tool for positioning the gear lever : 9607-T. Adjustments WARNING : 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.
DISPATCH
ML5 GEARBOX : CONTROLS

Engines : RHX - RHZ - RHW

B2CP3W8D
Non adjustable
224
MLGU GEARBOX : CONTROLS

Engines : RFL - R6G - RHV - 4HY - 8140.43 - 8140.43S The gears are controlled by means of cables : - Selection cable. - Engagement cable. Description Gear control lever end Fixing Adjustment Gearbox end Fixing Adjustment 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.
B2CP3HRC
RELAY
Selection cable (ball-joints = 10 mm)
Cble de passage (ball-joints = 13 mm)
Cables held in their locations by steel clips CLUTCH GEARBOX TRANSMISSION Yes No
Cables held in their locations by steel clips No No
225
RELAY

Engines : RFL - R6G - RHV - 4HY - 8140.43 - 8140.43S
(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 over approx. 10 mm. (B) The locked position : determines the length of the selection cable. Adjustment clearance : X = 1 mm. CLUTCH GEARBOX TRANSMISSION
B2CP3JXD
B2CP3JYC
226

Engines : RFL - R6G - RHV - 4HY - 8140.43 - 8140.43S Adjusting the gear selection cable (A) The unlocked position. (B) The locked position.
RELAY
NOTE : Before doing the adjustment, make sure that the automatic adjustment device remains 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 automatic adjustment 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.
B2CP3JUD
227
RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX

Precautions to be taken Towing The 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 of maximum. Driving. Never drive with the ignition switched off. Never push the vehicle to try to start it; (impossible with an automatic gearbox). 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, 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.
Lubrication The automatic gearbox is only lubricated when the engine is running.
228

Precautions to be taken 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 that the converter retaining bracket should be in place when handling the gearbox. It is imperative to use the centring peg and the converter retaining bracket 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). CLUTCH GEARBOX TRANSMISSION
229

Procedure to be followed prior to carrying out repairs on AL4 autoactive gearbox If a gearbox malfunction occurs, there are two possible configurations depending on the seriousness of the fault : - Gearbox in back-up mode with a replacement programme of (the fault values are taken in substitution). - Gearbox in back-up mode with an emergency programme (3rd hydraulic) WARNING : In the emergency programme, an impact is felt when changing P/R, N/R and N/D. Rception client. Discuss with the customer, to find out all the malfunction symptoms. CLUTCH GEARBOX TRANSMISSION Oil quality Oil level. Oil quality. If the gearbox has suffered a serious fault resulting in a malfunction or the destruction of a clutch, the oil will overheat and become contaminated with impurities : the oil is said to be burnt. This is characterised by a black colour and the presence of an unpleasant 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 the gearbox ECU parameters (this is essential after an initialisation of the ECU).
230

Procedure for initialising the automatic gearbox ECU Downloading Updating the gearbox ECU by downloading : Follow the procedure using the diagnostic tool. The downloading operation enables the automatic gearbox to be updated, or adapted to an evolution of the engine ECU. Before commencing the downloading, take the value of the oil usage counter 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 ECU should be accompanied by an update of the engine ECU. Updating the value of the oil usage counter
Using PROXIA Access 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 of 2750 units.
Using LEXIA Access 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 the 5 figures of the oil counter.
231
AL4 AUTOMATIC GEARBOX : TIGHTENING TORQUES
Tightening torques m.daN
(1) Oil flow modulation electrovalve fixing (2) Heat exchanger fixing (3) Output speed sensor fixing
B2CP3EDD
: 1 0,2 :51 : 1 0,2 : 1 0,2 : 4 0,2 : 2,4 0,4 : 0,8 0,1
(4) Output speed sensor fixing (5) Oil overflow and drain fixing (6) Oil level plug (7) Oil pressure sensor fixing

B2CP311D
232
(8) Fixing of converter on diaphragm Pre-tightening Tightening : 1 0,1 : 3 0,3 CLUTCH GEARBOX TRANSMISSION
(9) Plug fixing
: 0,8 0,2
(10) Gearbox fixing on engine
: 5,2 1
B2CP3EED
233

Tightening torques m.daN A : EW7 and EW10 engine versions : Hydraulic valve block fixing Centre 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.
B2CP3EFD

B2CP3EGC
B : DW10 engine version: Hydraulic valve block fixing Centre 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 (14) Oil filler plug 234
: 1,5 0,2 : 2,4 0,4
AL4 GEARBOX : CONTROLS
DISPATCH
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 and press the brake pedal. During a repair, the shift-lock can be unlocked by pressing the locking finger a (see corresponding operation).
B2CP3CFD
235
DISPATCH
AL4 AUTOMATIC GEARBOX

Adjustment of the MULTIFUNCTION SWITCH - 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 on the instrument panel.
B2CKU1DD

B2CKU1ED
236
AL4 AUTOMATIC GEARBOX

Adjustment of the INTERNAL SELECTION CONTROL Tools. [1] Locking screw [2] Bearing blade adjustment shim 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. : (-).0338-M1 : (-).0338-M2
RELAY
B2CA08MC
IMPERATIVE : There must not be any excessive travel on the gear selection lever when it is in position 2. Adjust the multifunction switch.
B2CA08NC
237
RELAY
RECOMMENDATIONS - PRECAUTIONS : 4 HP 20 AUTOMATIC GEARBOX

Precautions to be taken When performing electrical checks : The battery should be correctly charged. Never use a voltage source higher than 16V. Never use a test lamp.
Towing The 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 is running. 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, corrosion etc.) The presence and condition of the mechanical locking.
Repairs on mechanical components Never place the gearbox on the ground without protection. Do not use the unions on the gearbox as handles for moving the gearbox. It is imperative that the converter retaining peg should be in place when removing the gearbox. It is imperative to use the centring pegs to couple the gearbox on the engine. Remove the converter retaining peg before coupling the gearbox on the engine.
238
4 HP 20 GEARBOX : TIGHTENING TORQUES

Tightening torques m.daN Gearbox exterior (2) Oil channel union fixing (3) Exterior fixing of converter cover on clutch housing (4) Speedometer take-off aperture plug (5) Steel casing fixing (6) Converter fixing on engine (7) Interior fixing of converter cover on clutch housing (8) Torx fixing of converter cover on clutch housing Drain plug Heat exchanger fixing Selector lever position switch fixing Converter cover fixing on engine cover (XFX engine) Converter cover fixing on engine cover (4HX engine) : 2,5 0,5 : 2,3 0,5 : 1 0,1 : 0,6 0,1 :61 : 2,3 0,5 : 2,3 0,5 : 4,5 0,8 : 3,5 0,5 : 1 0,2 : 6,5 1 : 5,8 1
RELAY
B2CP3CZC
B2CP24CC
B2CP24BC
239
RELAY
4 HP 20 GEARBOX : TIGHTENING TORQUES

Gearbox interior
(9) Input speed sensor fixing

B2CP24DC
: 0,8 0,1 : 0,8 0,1 : 1 0,2
(10) Hydraulic block fixing (Large head) (11) Output speed sensor fixing

B2CP24EC
240
4HP20 AUTOMATIC GEARBOX SPECIFICATIONS

Unlocking the SHIFT LOCK function
RELAY
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, the causes 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 .
B2CP3KGD
241
RELAY
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 gear selection 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 causes of 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. 242

C5FP0HAD
SELECTION CONTROL SPECIFICATIONS : 4HP20 AUTOMATIC GEARBOX

In the passenger compartment
RELAY
NOTE : Only positions P or N authorise starting of the engine. In position +/- , selection is performed by an electronic sensor located close to gear lever. The variation of flux necessary to the movement of the sensor cells is obtained by a magnet 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 .
B2CP3KAD
243
The gear selection lever is guided by the shape of the step grille and by a return spring which holds it to the left. The gear control has 5 positions : - Position P : park (locks and immobilises the vehicle) (press on button b on the selection lever to engage position P ). - Position R : reverse gear (press on button b on the selection lever to engage position R ). - Position N : neutral. - Position D : drive (use of the 4 gears of the gearbox in the automatic and autoadaptive function). - Position +/- : tilt the lever to the left (this position allows the driver to choose his gears in sequential mode by pulling - or + on the gear selection lever. To revert to position D , tilt the lever to the right.
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.
B2CP3KAD
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
244
FILL / TOP-UP : 4HP20 AUTOMATIC GEARBOX

Tools [1] Circlip pliers [2] Filling cylinder [3] Specific adaptor Filling with oil : 4517-T (toolkit 4507-T) : (-).0341 : (-).0341 B
RELAY
B2CP3KLD
NOTE : The gearbox air vent is available from Replacement Parts.
B2CP3KMC
245
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 18 mm and a mallet. Clip on the plastic part (2) of the air vent.
RELAY
FILL / TOP-UP : 4HP20 AUTOMATIC GEARBOX

Topping up with oil Prior 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 1C ; 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 1C, 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 18 mm and a mallet. Clip on the plastic part (2) of the air vent. Refit the air filter housing. 246

B2CP3KNC
DRIVESHAFTS - GEARBOXES
Tightening torques (m.daN) Vehicles Berlingo C15 Berlingo Dispatch Gearbox MA/5 BE4/5 ML/5 ML/GU Engines HFX - KFW WJY NFU - WJY - 9HZ - RHY RFN - WJY RHX - RHZ - RHW RFL - R6G - 4HY 8140.43 - 8140.43S RHV Driveshaft bearing NO 1 1,8 10+ 60 10Q 15Q 37 1,8 18QS 42 2,1 1 Dispatch AL4 RFN 32,5 1 5701-T.A 5701-T.A 9017-T.C 9017-T.C NO 5708-T CLUTCH GEARBOX TRANSMISSION Driveshaft nut Gearbox oil seal mandrels Right hand Left hand Tool kit
32,5 1
7114-T.W
7114-T.X
7116-T
Relay
10Q 15Q 37 1,8 Relay 4 HP 20 2.8 HDi
C15 Berlingo
18QS 42 2,1 Tightening torque (m.daN) for wheel bolts 8 Dispatch 10 91 Relay 14 1 247
5708-T.J 5718-T.H Seal extractor RH/LH (-) 0338C (-) 0338.J1 (-) 0338.H1 + (-) 0338J2 + (-)0338.H2 8010-T.K1 8010-T.K2 (Red) + (Black) + 8010-T.J 8010-T.J
(-) 0338
8010-T
C15
- Check the tyre pressures - Release the handbrake Front height (Non-adjustable)
AXLE GEOMETRY
General conditions - Vehicle empty - 5 litres of fuel in the tank Rear height (Adjustable)
AXLES SUSPENSION STEERING
B3CP04VD
B3DP06VD
The heights H1 are measured from the ground to the lower section of the subframe, close to the arm fixing. 248
The heights H2 are measured from the ground to the bodyshell crossmember to which the axle rear silentblocks are secured.
AXLE GEOMETRY
Reference height Diesel Engine type Payload (Kg) 600 WJY 765 Adjusting the rear heights (H2).
C15
Heights 10 mm
Ft (H1)
203
214
Rr (H2)
515
527
- Height H2 is obtained by two half-shells 1 located between the damper body 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 average change in the height H of 3.5 mm. 1 = 24 adjusting shims from 26 to 47 mm (1 mm , increasing by 1 mm
B3DP06WD
249
C15
AXLE GEOMETRY
Front reference height (Non-adjustable)
Engine type Steering Payload (Kg) Camber Castor Pivot angle Tracking
40 (mm) 30
WJY Manual 600 0 30 0 55 8 50 +2 Rear reference height (Non-adjustable) 765 0 41 1 47 8 34 600 0 30 0 55 8 50 +3 Power-assisted 765
Counter camber Tracking
20 (mm)
9 + 1,6 5 NOTE A < B = Positive figure A > B = Negative figure 250
+ -
= =
TOE-IN TOE-OUT
B3CP02UC
FRONT AXLE
C15
(1) Anti-roll bar Diesel Payload (Kg)

B3CP04WD B3CP04XD
600 23
765 24
Barre (mm) 251
C15
REAR AXLE
(1) Anti-roll bar Diesel Payload (Kg)

B3DP06XD
600 18
765 19 252
B3DP06YD
Barre (mm)
STEERING SPECIFICATIONS
Manual steering
C15
a = G6 D = 0,01-0,06 mm
B3EP109D
A = 1 mm B = 3 mm C = 8 1 mm
B3EP03SD
253
C15
Power-assisted steering
B3EP10AD
A = 1 mm B = 3 mm C = 8 1 mm 254
B3EP03SD
AXLE GEOMETRY
BERLINGO
E1AP0AVD
B3CP08ED
Front : H1 = R1 - L1 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. 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 : To measure the wheel radius, use tool 8006-T. 255
Rear : H2 = R2 + L2 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. NOTE : The difference in height between the two sides should be less than 10 mm.
BERLINGO
AXLE GEOMETRY
Table of heights at REFERENCE LOAD
Vehicles Height
Front height L1 = R1 - H1 Familiale
Rear height L2 = H2 - R2
175/65 R14 175/70 R14
90,5
75,5 (*) Van
56,5
71,5 (*)
Payload (Kg)
600 800
100,5
85,5 (**) Platform cab
8,5
23,5 (**)
Payload (Kg)
600 100,5 800 NOTE : The difference in height between the two sides should be less than 10 mm. 8,5
NOTE : (*) private raised vehicle Europe NOTE : (**) utility raised vehicle Europe or CRD suspension
256
AXLE GEOMETRY
Reference height values for the front axle - Compress the suspension until the calculated values are obtained. Tools used :
BERLINGO
- [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 ESSENTIAL : When checking the axles, the vehicle must be at reference setting Front axle Adjust ment Tracking (1 mm) Camber (30) Pivot angle (30) Casto (30) NO YES Familiale 175/65R14 - 175/70R14 - 185/65R15 +1 mm 0 1044 259 -2 mm (1) 007 (1) 1026 (1) 255 (1) Van Platform cab 600 kg - 800kg -2 mm 0 1054 303 -2 mm (2) 0 (2) 1038 (2) 258 (2)
B3CP02UC
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. 257
NOTE A<B = Positive figure : A>B = Negative figure: += = TOE-IN TOE-OUT
BERLINGO
- Compress the suspension until the calculated values are obtained.
AXLE GEOMETRY
Reference height values for the rear axle 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 ESSENTIAL : When checking the axles, the vehicle must be at reference setting Rear axle Adjust ment Tracking (1,3 mm) Camber (30) Familiale 175/65R14 - 175/70R14 - 185/65R15 1,41 mm -116 0,3 mm (1) -116 (1) 4,74 mm -113 Van Platform cab 600 kg - 800kg 3,7 mm (2) -114 (2)
NO
(1) private raised vehicle Europe. (2) utility raised vehicle Europe or CRD suspension. 258
FRONT AXLE
BERLINGO
Tightening torques (m.daN) 1 Damper nut 2 Cup screw 3 Suspension leg 4 Stabiliser rod ball-joint 5 Pivot on suspension leg 6 Anti-roll bar 7 Stabiliser rod ball-joint 8 Pivot lower ball-joint 9 Driveshaft nut 10 Wheel bolts 11 Lower arm front articulating point 12 Lower arm rear articulating point and anti-roll bar bearing 13 Screw under rear articulating point 14 Ball-joint fixing on lower arm Fixing of subframe on body 4,5 0,4 2,5 0,3 3,7 0,3 4,5 0,4 3,7 0,3 4,0 0,4 32,5 2,5 9,0 1,0 7,6 0,7 6,8 3,1 4,5 8,5 0,6 0,3 0,2 0,8
B3CP041D
B3CP040P
B3CP043D
NOTE : Fitting of damper upper support : tongue a towards the front. 259
BERLINGO
REAR AXLE
Tightening torques (m.daN) (1) Front silentblock on axle (2) Anti-roll bar screw (3) Front silentblock on body (4) Wheel bolt (5) Rear silentblock on axle (6) Damper shaft nut (7) Stub bearing nut (8) Rear silentblock on body : 9,4 0,9 : 5,5 0,2 : 4,0 0,4 : 9,0 1,0 : 5,4 0,4 : 11,0 1,0 : 25,0 2,5 : 6,2 0,6
B3DP03LD
260
SUSPENSION
BERLINGO
Vehicles Payload (Kg) Anti-roll bar (mm) Colour code Anti-roll bar (mm) Colour code AR 19 Blue 19 (2) Blue (2) AV 600
Van 800 21 White 21 Orange 21 (1) Orange (1) 21 Orange
Familiale 175/65R14 - 175/70R14 185/65R15 22 Green 19 (2) Blue (2) 21 Orange 19 (2) Blue (2)
NOTE: (1) private raised vehicle Europe. (2) utility raised vehicle Europe or CRD suspension.
261
BERLINGO
SUSPENSION
Vehicles Payload (Kg) Anti-roll bar (mm) Colour code 20,5 Red 600 20,5 (2) Red (2)
Van 800 21,3 Mauve 21,3 (1) Mauve (1)
Familiale 175/65R14 - 175/70R14 - 185/65R15 19,6 Pink 20,5 (2) Red (2)
Height of travel stop (mm)
82
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.
262
POWER STEERING SPECIFICATIONS
BERLINGO
Tightening torques (m.daN) (1) Steering joint fixing (2) Lower fixing screw (3) Upper fixing screw (4) Steering wheel screw : 2,3 0,2 : 2,3 0,2 : 2,3 0,2 : 2,0 0,2
B3EP14FD
(a) Steering column height adjustment handle. NOTE : The airbag is attached to the steering wheel. (5) Steering joint fixing : 2,3 0,2
(b) 3 teeth have been removed for matching with the upper part of the steering column.
B3EP14GD
263
BERLINGO

Tightening torques (m.daN) (6) Pivot ball-joint nut (7) Locking nut for adjusting steering rods (8) Ball-joint (9) Fixing of steering housing on subframe (10) Hydraulic pipe union (11) Power steering assistance valve (12) Fixing of flange on push rod (13) (*) Fixing of steering ram on casing (14) (*) Fixing of steering ram on yoke High pressure union (15-17) Screws fixing pump on the support Power steering pressure switch (**) IMPERATIVE : Replace using new Nylstop nuts. NOTE : (*) Use new screws for refitting. NOTE : (**) A pressure switch is mounted on the hydraulic piping between the high pressure pump and the steering valve (petrol engines only). 264 : 3,5 0,3 : 4,5 0,4 : 6,0 0,6 : 7,0 0,7 : 2,4 0,2 : 1,2 0,2 : 1,2 0,2 : 9,0 1,0 : : : : 9,0 2,0 2,2 2,0 1,0 0,3 0,3 0,2
B3EP14JD
B3EP14KD
AXLE GEOMETRY
Table of values at REFERENCE HEIGHT With recommended tyre pressures
DISPATCH
B3BP07DD
The reference heights must be checked between the jacking point and the ground.
Values at reference height Engine types Features H1 (mm) H2 (mm) 265 All types Tyres 195/70 R14 157 164
DISPATCH
AXLE GEOMETRY
ESSENTIAL : When checking the axles, the vehicle must be at reference setting.
NOTE A < B = Positive figure

B3CP02UC
+ -
= =
TOE-IN TOE-OUT Rear
A > B = Negative figure Front
Toe-in toe-out Castor Camber Pivot angle (1) Manual steering. (2) Power-assisted steering.
0 mm
0830 0415 1 0,5 130 30 (1) 130 30 (2) 0 30 1128 10 -1 30
266
SPECIAL FEATURES : FRONT AXLES
DISPATCH
(1) Engine subframe front fixing. (2) Engine subframe rear fixing.
Tightening torques (m.daN)
(1) Front fixing (2) Rear fixing
10,7 10,7
B3CP055D
267
DISPATCH
FRONT AXLE
Mark A, LH side
Mark B, RH side
B3CP04PD
B3CP04QD
268
REAR AXLE
DISPATCH
1 - Strengthening bar on the bodyshell. 2 - Stabiliser bar.
B3DP071D
269
DISPATCH
Manual steering
B3EP054D
270
Power-assisted steering All Types Steering Pinion (Teeth) Rack (Teeth) Steering rack travel (mm) Power-assisted 9 33 152
DISPATCH
B3EP09ZD
271
RELAY
AXLE GEOMETRY
Front Steering Tracking (mm) Castor Camber NONadjustable -2 1 030 30 0 45 All Types
Rear
01
0 30
Conditions for checking and adjusting : - Correct tyre pressures. - Steering rack locked on straight ahead (point zero) (see corresponding operation). - Vehicle in running order. NOTE A < B = Positive figure A > B = Negative figure
B3CP02UC
+ -
= =
TOE-IN TOE-OUT
272
FRONT AXLES
RELAY
Versions : 11Q (*) - 15Q (*) - 18Q
Engine-type specific anti-roll bar Diameter 24 mm
NOTE : (*) No anti-roll bar on van versions with DW10UTD engine.
B3CP081P
273
RELAY
(1) Damper nut (2) Screws fixing suspension leg on body (3) Damper (4) Screws fixing suspension leg on pivot (5) Screws fixing lower ball-joint on pivot (6) Nut fixing lower ball-joint on suspension arm (7) Driveshaft nut 11Q and 15Q (M28x1.5) 18Q (M33x1.5) (8) Wheel bolt (9) Suspension arm (10) Front screw fixing subframe on body : 25 2,5 : 19 2 : 8,8 0,8 : 18 1,8 : 8 0,8 : 5 0,5
FRONT AXLES
(11) Front screw fixing suspension arm (12) Anti-roll bar (13) Screw fixing anti-roll bar bearing and suspension arm rear mounting : 20 2 (14) Rear screws fixing subframe on body (15) Screw fixing suspension arm rear mounting : 20 2 : 17 1,7 : 25 2,5
(16) Screw fixing suspension arm rear mounting on body : 20 2 : 37 1,85 : 42 2,1 : 14 1 (17) Screw fixing anti-roll bar bearing (18) Nut fixing rod on suspension arm (19) Nut fixing rod on anti-roll bar (20) Anti-roll bar rod : 8,5 0,9 : 5,6 0,6 : 5,6 0,6
274
REAR AXLES
RELAY
(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 the body sill) (18) Single blade longitudinal spring in modulated section steel
B3DP09WD
275
RELAY
(1) Steering joint fixing (2) Plate fixing on floor (3) Steering column fixing (4) Steering wheel fixing
: 2,5 0,3 : 1,8 0,2 : 1,5 0,2 : 5 0,5
B3EP14AD
276
RELAY
(5) Ball-joint fixing on pivot (6) Steering rod locking nut (7) High pressure pipe fixing on valve (8) Low pressure pipe fixing on valve (9) Ball-joint fixing on steering rack (10) Mechanism fixing on subframe
: 7 0,7 : 6 0,6 : 5,5 0,5 : 6,3 0,6 : 12 1 : 11 1
B3EP14BD
277
BRAKES FT RR
C15
BRAKE SPECIFICATIONS
1.9 D
Payload (Kg) Master cylinder Master-vac mm Caliper makes / pistons Brake disc Disc thickness Minimum disc thickness Brake pad grade Brake cylinders or calipers mm Brake drums min. / max. Make Brake lining grade Compensator cut-off (bars)
600 20,60 151,20 GIRLING/D.B.A 247 10 8 BOSCH 22 230/228,60 BENDIX
765
Load-sensitive
278
C15
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.
B3FP111D B3FP112D
279
BRAKES
BRAKES
C15
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 the cable clamp contact face and the lever (2).
NOTE : Do not touch the screw (1) which has been set at the production stage
B3FP113D
280
HANDBRAKE
C15
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 brakes start tightening. - Equalise the tension of the left and right cables. - Ensure that, for a handbrake travel of five notches, the rear wheels are locked.
B3FP114D
281
BRAKES
BRAKES
C15
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.
282
Without ESP (*) 1.1i Engine plate Master cylinder mm Master-vac Caliper makes / pistons Disc Ventilated FT Disc thickness / min. thickness (mm)i Brake pad make/grade Drum Original/maximum/width Lining make/grade (*) = Electronic Stability Programme HFX 1.4i KFW 1.6i 16V NFU 23,8 228,6 BOSCH ZOH 54/22/54 266 22/20 BOSCH F769 228/230/40 TRW F4930 1.6 16V HDi 9HZ
BERLINGO
1.9 D WJY 2.0 HDi RHY
283
BRAKES
BRAKES FT RR
BERLINGO
With ESP (*) 1.6i 16V 2.0 HDi RHY 23,8 228,6 BOSCH ZOH 54/26/54 283 26/24 BOSCH F769 TRW C38/38 247 9/7 GALFER G4554
Engine plate Master cylinder Master-vac mm Caliper makes / pistons Disc Ventilated Disc thickness / min. thickness (mm) Brake pad make/grade Caliper makes / pistons mm Disc Plain Disc thickness / min. thickness (mm)i Brake pad make/grade (*) = Electronic Stability Programme
NFU
284
Specifications of braking compensators Without ABS REF Vehicles - All Types - Payload (Kg) 475/575/600 Kg Familiale Grand export familiale Grand export 765 Kg 765 Kg Electric vehicle PMF TEVES Make Colour ref. of spring Green Yellow Silver Black Blue 11,25 2,75 8,85 2 Cut-off pressure (bar) 11,25 1,75 19,35 2,75 All types with ABS With ABS REF Engines Type The compensator and main brake limiter functions are assured by the ABS REF system.
NOTE : PMF : Multifunction roof. NOTE : REF : Electronic Brakeforce Distribution.
285
BRAKES
BRAKES
1
- Braking circuit in X.
Braking system specifications
- Disc brakes at the front, ventilated (according to version). - Drum brakes at the rear, with automatic adjustment (except for versions with ESP) (*).
B3FP09HC
- 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 (1) Hydraulic valve block ABS Bosch 5.3 REF (1) Hydraulic valve block ABS with ESP Bosch 5.7 . or or
(2) Load-sensitive braking compensator (according to version). NOTE : (*) : ESP : Electronic Stability Programme.
B3FP09JC
286
Braking circuit without ABS REF (drum brakes at the rear)
B3FP7A4D
(1) braking compensator. 287
BRAKES
BRAKES
B3FP7A5D
Braking circuit with ABS REF (drum brakes at the rear)
288
4 0,4 91
32,5 2,5 3,7 0,3 B3FP7A7C B3FP7A8D
(13) Caliper fixing on pivot (14) Yoke fixing on calliper
: 10,5 1 m.daN : 3,2 0,1 m.daN
(15) Brake servo fixing on pedal gear (16) Master-cylinder fixing on brake servo 289
: 2,2 0,1 m.daN : 2 0,2 m.daN
BRAKES
BRAKES
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.)
290
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 clearance between the nut (2) and the lever (4). - Hold the adjusting nut (2) in place, and lock it using the locking nut (1). -
Vehicle type (Payload Kg) 475
600
800
B3FP115C
Weight on the rear axle (Kg) 409 540 675 417 596 775 418 644 870 291
Pressure on the rear brakes (bars) 25 26 58 25 27 70 25 32 81
BRAKES
BRAKES
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.
292
BLEEDING 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 : - Rear right. - Rear left. - Front right. - Front left.
Wheel : - Rear right. - Rear left. - Front right. - Front left.
Top up the level : Using the brake fluid sold by the CITROEN Replacement Parts Division.
293
BRAKES
BRAKES
DISPATCH
Petrol 2.0i 16V
Total Gross Weight (Kg) Versions Master cylinder mm Master-vac FT Caliper makes / pistons Brake disc Disc thickness/min. thickness Brake pad grade Brake cylinders mm Brake drums min. / max Brake lining quality Rear compensator Compensator cut-off (Bars) / Weight (kg) (*) (*) = = Cut-off point as a function of the weight on the rear axle.
815 (1) (2) 22,2 (N RPO 8206) 23,8 (N RPO 8207 ) GIRLING (N RPO 8156 281 (N RPO 8156 26/24 (N RPO 8156 ) ) )
Combi (3) (4) (5) (6) 23,8 280 BENDIX (N RPO 257 (N RPO 20/18 (N OPR 19 255 / 256 Load-sensitive double compensator 20 / 500 90/1125 (6) Combi 8/9 seater. (7) Floor cab (short) (815kg). 9155) 9155) 9155) GIRLING 281 26/24 (7) 23,8
RR
(1) Panel van (short) (815kg). (2) Glazed van (short) (815kg). (3) Combi 5/6 seater. 294
(4) Combi 7 seater CLUB. (5) Combi 8 seater CLUB.
Diesel 1.9 D Total Gross Weight (Kg) Versions Master cylinder FT Master-vac mm Caliper makes / pistons Brake disc Disc thickness/min. thickness Brake pad grade Brake cylinders mm Brake drums min. / max Brake lining quality Rear compensator Compensator cut-off (Bars) / Weight (kg) (*) (*) = Cut-off point as a function of the weight on the rear axle. (1) (2) (3) (4) Panel van (short) (815kg). Glazed van (short) (815kg). Panel van (long) (815kg). Glazed van (long) (815kg). 20/500 (5) (6) (7) (8) 295 Combi 5/6 seater. Combi 5/6 seater MIXED. Combi 8/9 seater. Floor cab (short) (815kg). 19 255 / 256 Load-sensitive double compensator 90/1125 815 (1) (2) (3) (4) (10) 22,2 (N RPO 8206) 255 BENDIX 257 20/18 Combi (5) (6) (7) 23,8 (N RPO 8207 ) (8)
DISPATCH
(9) 23,8 280 GIRLING 281 26/24
RR
(9) Floor cab (long) (815kg). (10) Van MIXED (short) (815kg).
BRAKES
BRAKES
DISPATCH
Diesel 2.0 HDi
Total Gross Weight (Kg) Versions FT Master cylinder
815 (1) (4) (7) 22,2 (N RPO 8206) 23,8 (N RPO 8207 )
900 (2) (3) (5) (6) 23,8 280 GIRLING 281 26/24
Combi (10) (11) (12) (13) (14)
(8) 23,8 280
(9)
mm Master-vac GIRLING (N RPO 8156 ) Caliper makes / pistons BENDIX (N RPO 9155) 281 (N RPO 8156 ) Brake disc 257 (N RPO 9155) 26/24 (N RPO 8156 ) Disc thickness/min. thickness 20/18 (N RPO 9155) Brake pad grade Brake cylinders mm Brake drums min. / max. Brake lining quality Rear compensator Compensator cut-off (Bars) / Weight (kg) (*)
(1) (2) (3) (4) Panel van (short) (815kg). Panel van (short) (900kg). Panel van (long) (900kg). Glazed van (short) (815kg). (5) (6) (7) (8)
GIRLING (N RPO 8156 ) BENDIX (N RPO 9155) 281 (N RPO 8156 ) 257 (N RPO 9155) 26/24 (N RPO 8156 ) 20/18 (N RPO 9155) 19 255/256
GIRLING 281 26/24
RR
Load-sensitive double compensator 20 / 500 90/1125

Glazed van (long) (900kg). (9) Floor cab (long) (900kg). (13) Combi 8 seater CLUB. Glazed van (short) (900kg). (10) Combi 5/6 seater. (14)Combi 8/9 seater. Van MIXED (short) (815kg). (11) Combi 5/6 seater MIXED. Floor cab (short) (900kg) (12) Combi 7 seater CLUB.
(*) = Cut-off point as a function of the weight on the rear axle.
296
Diesel 2.0 16V HDi Total Gross Weight (Kg) Versions Master cylinder FT mm Master-vac Caliper makes / pistons Brake disc Disc thickness/min. thickness Brake pad grade Brake cylinders mm Brake drums min. / max. Brake lining quality Rear compensator Compensator cut-off (Bars) / Weight (kg) (*) (*) = Cut-off point as a function of the weight on the rear axle. (1) (2) (3) (4) Panel van (short) (815kg). Glazed van (short) (815kg). Panel van (long) (815kg). Glazed van (long) (815kg). (5) (6) (7) (8) 297 20 / 500 Floor cab (short) (815kg). Floor cab (long) (815kg). Combi 5/6 seater. Combi 5/6 seater MIXED. 19 255 / 256 Load-sensitive double compensator 90/1125 GIRLING (N RPO 8156 281 (N RPO 8156 26/24 (N RPO 8156 ) ) ) 815 (1) - (2) - (3) - (4) 22,2 (N RPO 8206) 23,8 (N RPO 8207 ) 280 BENDIX (N RPO 257 (N RPO 20/18 (N RPO 9155) 9155) 9155) Combi (7) - (8) - (9) - (10) - (11) 23,8 (5)
DISPATCH
(6) 23,8 280 GIRLING 281 26/24
RR
(9) Combi 7 seater CLUB. (10) Combi 8 seater CLUB. (11) Combi 8/9 seater.
BRAKES
BRAKES
B3FP10TC
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) At B : Shim (16 mm) Blue Green
-Adjust the nut (3) to allow the passage, free and without play, of the green shim at (B), taking care 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).
298
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 : M7x100 Checking the RH compensator - Rear left hand caliper : M8x125 - Rear RH wheel cylinder : M7x100 Checks : - 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). 299
B3FP10UC
BRAKES
BRAKES
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).
300
2.0i - 2.0 HDi - 2.2 HDi Payload (Kg) Master cylinder mm Master-vac Caliper make Piston (mm) FT Disc mm Disc thickness 44/48 Plain Ventilated Plain Ventilated 280 11Q-15Q 25,4 279,4 BREMBO 46/52 300 24/21,9 2.8 HDi
RELAY
2.0i - 2.2 Hdi - 2.8 HDi 18Q
44/48 280
Brake pad grade Brake cylinders mm Brake drums min. / max. RR Disc Disc thickness Make Grade Caliper fixing on pivot (Front) : 21 2 Caliper fixing on stub axle support (Rear) : 18,8 1,5
254/255,6 280 16/14,2 LOCKEED Tightening torques: m.daN Master cylinder fixing on master-vac : 2 0,2 Master-vac fixing on body : 2 0,2 301 BREMBO
Yoke fixing on caliper (Front/Rear): 3 0,3
BRAKES
BRAKES
RELAY
2.0i Payload (Kg) FT Master cylinder mm Master-vac Caliper make Piston (mm) Plain Disc mm Ventilated Plain Disc thickness Ventilated Brake pad grade RR Brake cylinders mm Brake drums min. / max. Disc Disc thickness Make Grade
2.8 HDi 11Q-15Q 25,4 279,4 BREMBO 46/52 300 24/21,9 2.0i - 2.8 HDi 18Q
44/48 280
44/48 280
280 16/14,2 BREMBO
Tightening torques: m.daN Caliper fixing on pivot (Front) : 21 2 Master cylinder fixing on master-vac Caliper fixing on stub axle support (Rear): 18,8 1,5 Yoke fixing on caliper (Front/Rear) 302
: 2 0,2 : 3 0,3
Master-vac fixing on body
: 2 0,2
Checking and adjusting the rear brake corrector
Tools Brake pressure checking equipment - Weighing machines : Tool kit 4140-T.
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.
B3FP037C
303
BRAKES
BRAKES Vehicle type 11 Q 15 Q 11 Q 15 Q 18 Q ABS
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.. Adjusting the rear brake corrector
Weight on the rear axle (Kg) 650 900 700 900 900 750 900
Pressure on the rear brakes 3 bars 30 45 34 45 45 26 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.
With ABS Without ABS
B3FP038C
304
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).
B3FP02GC
B3FP17AC
305
BRAKES
BRAKES
B3FP17BC B3FP17AC
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. 306
DRAIN FILL BLEED : BRAKING CIRCUIT

Tools [1] Pressure bleeding apparatus. [2] PROXIA diagnostic tool [3] LEXIA diagnostic tool : 41656T : 4171-T
B1BP2QQC
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. 307
B3FP177C
BRAKES
BRAKES
B3FP178D B3FP179D

Bleeding the braking circuit. IMPERATIVE : During the bleed operations, take care to maintain the level of brake fluid in the reservoir, keeping it topped up. Use only new brake fluid. 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).
308

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 procedure. Remove the tooling.
B1BP2QRC
309
BRAKES
BRAKES

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 the front. - On the front caliper, start with the uppermost piston, finish with the lower piston. For each braking circuit: - Connect a transparent tube on the bleed screw, submerge the other end of 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. Bleeding a braking circuit with ABS 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 end of 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 pump or energising the electrovalve. (The circuit is pre-filled and bled).
310
CONDITIONING
AIR CONDITIONING R 134 a (HFC)
Compressor Vehicle Engine Date Refrigerent refill Fixed BERLINGO 12/02 > 575 25 gr Capacity Variable SD 7V 12 SP 10 SD 7V 16 DISPATCH All Types 12/03 > 950 25 gr 800 50 gr (*) 1 000 50 gr (**) 135 Oil quantity (cc) Oil reference
RELAY
09/96 >
SD 7H 15
SP 20
* **
= Single air conditioning: 1 evaporator, 1 pressure control valve. = Double air conditioning: 2 evaporators, 2 pressure control valves.
311
AIR CONDITIONING
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)

Click-fit connector removal/fitting tool Vehicules Berlingo Dispatch
C5HP073C
Inch TT TT 3/8 5/8
Ring colour Red Black
Tool kit 4164.T 8005-T.C. 8005-T.A.
AIR CONDITIONING
312

Presence of pollen filter Vehicle BERLINGO DISPATCH RELAY Base aircon All Types Base aircon Without aircon Base or double aircon Equipment Without aircon RPO No Presence of filter NO (Valo) YES (Valo) NO NO NO YES Observations
313
AIR CONDITIONING

Compressor lubricant. 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. 314
AIR CONDITIONING

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 A condenser or an evaporator A high pressure or low pressure pipe A drying cartridge : : : : 15 cc of compressor oil. 20 cc of compressor oil. 5 cc of compressor oil. 15 cc of compressor oil. AIR CONDITIONING
315
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
Tools.
[1] Clim test 2 VALEO
: 4372-T.
Checks.
Position the tool [1] (depending on manufacturers instructions)
AIR CONDITIONING
E5AP2ECC
316

Outillage EXXOTest Exxoclim Mode demploie Outillage (Flash quipement &matriel) : 2.4.2-1 : Voir notice constructeur Testing procedure Checking Position the tool CLIM TEST II (according to the manufacturers instructions). 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.
E5AP2N5D
Outillage VALEO
E5AP2N4D
Clim test 2
Outillage : 4372-T.
317
AIR CONDITIONING

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 mode Set 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.
AIR CONDITIONING
E5AP2FAC
318

Interpretation of the measurements m : High pressure. n : High temperature. p : Under-cooling (SR). q : Low pressure. r : Low temperature. s : Over-heating (SC). t : Ambient air temperature. u : Blown air temperature. v : Humidity. w : Temperature T3 Under-cooling The under-cooling represents the difference between the condensation temperature and the aircon fluid temperature 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 < 2C 2C < SR <4C 4C < SR < 10C/12C SR > 10C/12C SR > 15C
E5AP2FBC
Lack of aircon fluid in the aircon condenser (should be more than 150 grammes) Lack of aircon fluid in the aircon condenser (should be around 100 to 150 grammes) Correct quantity Excess aircon fluid in the aircon condenser
Add some aircon fluid
Remove some aircon fluid
Blown air temperature u The blown air temperature should be between 2C and 10C. 319
AIR CONDITIONING

Interpretation of the measurements m : High pressure. n : High temperature. p : Under-cooling (SR). q : Low pressure. r : Low temperature. s : Over-heating (SC). t : Ambient air temperature. u : Blown air temperature. v : Humidity. w : Temperature T3
Over-heating (SC) The over-heating represents the difference between the aircon fluid temperature at the evaporator outlet and the 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) Origins Correct quantity Lack of aircon fluid in the cooling circuit Excess aircon fluid in the cooling circuit Add some aircon fluid Remove some aircon fluid
Values s 2 < SC < 15C SC > 15C SC < 2C AIR CONDITIONING
Solutions
Blown air temperature u The blown air temperature should be between 2C and 10C
E5AP2FBC
320

Interpretation of the diagnosis
E5AP2FCD
321
AIR CONDITIONING
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).

Aircon circuit diagnosis table Principal problem Symptom Possible causes Aircon compressor clutch The clutch of the aircon compressor does not engage, or disengages suddenly Lack of aircon fluid in the aircon circuit Aircon pressostat Aircon evaporator sensor The aircon compressor does not turn, or stops suddenly Electrical circuit (wiring, fuses, etc.) Auxiliaries drive belt Aircon compressor The clutch of the aircon compressor remains engaged and stops suddenly Filtering and drying cartridge Aircon pressure reducer Leak of aircon fluid Aircon compressor clutch AIR CONDITIONING
322

Aircon circuit diagnosis table Principal problem Symptom Possible causes Incorrect adjustment of the aircon compressor clutch The clutch of the aircon compressor remains engaged The aircon compressor makes an abnormal noise The clutch of the aircon compressor remains engaged and slips Aircon fluid quantity Aircon compressor defective Lack of aircon fluid in the aircon circuit Aircon compressor valves defective Aircon compressor clutch Auxiliaries drive belt
323
AIR CONDITIONING

Aircon circuit diagnosis table Principal problem Symptom Low pressure and high pressure too high Low pressure too high and high pressure too low Possible causes Aircon pressure reducer defective Duct clogged Aircon compressor seal defective Aircon evaporator sensor defective Low pressure too low and high pressure too high Aircon pressure reducer jammed Filtering and drying cartridge obstructed Duct clogged Duct clogged Aircon pressure reducer jammed Low pressure and high pressure too low Lack of aircon fluid in the aircon circuit AIR CONDITIONING Aircon compressor defective
Abnormal levels of pressure
324

Aircon circuit diagnosis table Principal problem Symptom Low pressure normal and high pressure too high Low pressure normal and high pression too low Abnormal levels of pressure Low pressure too high and high pressure normal Low pressure too low and high pressure normal Under cooling too weak Air conditioning operating in back-up mode Possible causes Presence of air in the aircon circuit Aircon pressostat defective Evaporator sensor defective Aircon pressure reducer jammed open Filtering and drying cartridge saturated or clogged Aircon pressure reducer iced up Lack of aircon fluid Excess aircon fluid Under cooling excessive Presence of air in the aircon circuit Filtering and drying cartridge clogged AIR CONDITIONING
NOTE : In all cases, measure the excessive heating (SC) and the blown air temperature. 325
BERLINGO
AIR CONDITIONING SYSTEM R 134.a

Engines TU1JP/3JP/5P4 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.
AIR CONDITIONING
C5HP19QP
326

Engines : DW8B - DW10TD
BERLINGO
Tightening torques (m.daN). 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.
C5HP19RP
327
AIR CONDITIONING
DISPATCH

Engine : EW10J4
C5HP12EC
Tightening torques (m.daN). (1) (2) (3) (4) (5) AIR CONDITIONING (a) (b) (c)
C5HP15PP
High pressure valve. Low pressure valve. Pressostat : tighten to 1,8 0,1 m.daN Dryer Clickfit union. 0,8 0,1 m.daN 4 0,4 m.daN 0,8 0,1 m.daN
328

Engine : DW8B
DISPATCH
C5HP12EC
Tightening torques (m.daN). (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.
C5HP15CP
329
AIR CONDITIONING
DISPATCH

Engines : DW10BTED/ATED/CTED/BTED+
C5HP12EC
Tightening torques (m.daN). (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.
C5HP15EP
AIR CONDITIONING
330

Single circuit
RELAY
WARNING : The single and double air conditioning circuit diagrams are valid for all engine types. (installation may vary according to equipment)
(1) High pressure valve. (2) Low pressure valve. AIR CONDITIONING
C5HP05QD
331
RELAY

Double circuit
(1) High pressure valve. (2) Low pressure valve. (3) Pressure control valve (4) Second evaporator (passenger compartment side)
AIR CONDITIONING
C5HP05PD
332

C15-Berlingo 2005

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C15-Berlingo 2005

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CORRESPONDENCE TABLE FOR PETROL ENGINES

CORRESPONDENCE TABLE FOR DIESEL ENGINES

C15-BERLINGO DISPATCH RELAY

AC/DTAV/PRME/MMCB/MMEC Mthodes Mcaniques

CAR 000 021

Engine WJY 1.9 D DW8B

Z A B RFL R6G RHV 4HY 8140.43 8140.43S

AX BX AM AG AXC H MH AXx AX2 AY AY2 SX AX4 AX6 AY4

AY3 SX1 SY1

CAPACITIES (in litres)

CAPACITIES (in litres)

WJX 4,5 1,5 2 8 47

5-speed gearbox Brake circuit Cooling system Fuel tank capacity

CAPACITIES (in litres)

1.4i KFW 3 1,5 2

1.6i 16V NFU 3,25 1,8

1.6 16V HDi 9HZ 3,75 1,55 2 Without ABS = 0,36

1.9 D WJY 4,5 1,2 1,8 9 60

2.0 HDi RHY 1,4 GENERAL

With ABS = 0,45 8 55

CAPACITIES (in litres)

RFN 4,25 1,7 1,8

(1) (2) (3) (4) (5)

CAPACITIES (in litres)

2.0 8V HDi (1)

2.2 8V HDi (2) 4HY 5,25 4HY 6,25

2.8 HDi Auto

RFL 4,75 1,5

LUBRICANTS - TOTAL recommended oils

LUBRICANTS - TOTAL recommended oils

LUBRICANTS - TOTAL recommended oils

LUBRICANTS - TOTAL recommended oils

LUBRICANTS - TOTAL recommended oils

LUBRICANTS - TOTAL recommended oils

LUBRICANTS - TOTAL recommended oils

7000 15W50 7000 10W40

7000 15W50 7000 10W50

(*) = Blended oils for all engines, giving fuel economy 22

LUBRICANTS - TOTAL recommended oils

LUBRICANTS - TOTAL recommended oils

LUBRICANTS - TOTAL recommended oils

LUBRICANTS - TOTAL recommended oils

LUBRICANTS - TOTAL recommended oils

7000 10W40 7000 10W40 9000 15W50 9000 0W40

LUBRICANTS - TOTAL recommended oils

9000 5W40 FUTUR 9000 5W30 (*)

(*) = Blended oils for all engines, giving fuel economy 28

LUBRICANTS - TOTAL recommended oils

7000 10W40 GENERAL

TOTAL QUARTZ DIESEL Oils specifically for diesel engines

7000 10W40 7000 15W50

LUBRICANTS - TOTAL recommended oils

LUBRICANTS - TOTAL recommended oils

LUBRICANTS - TOTAL recommended oils

LUBRICANTS - TOTAL recommended oils

LUBRICANTS - TOTAL recommended oils

Manual and piloted manual gearboxes

MB3 automatic gearbox

AM6 autoactive automatic gearbox

Transfer box and rear axle

LUBRICANTS - TOTAL recommended fluids

Very cold countries

LUBRICANTS - TOTAL recommended fluids