(2001) berlingo c15 jumper jumpy
TRANSCRIPT
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UTILITY VEHICLES
CAR 050009
The technical information contained in this document is intended for the exclusive use of the trained person-nel of the motor vehicle repair trade. In some instances, this information could concern the security and safe-ty of the vehicle. The information is to be used by the professional vehicle repairers for whom it is intendedand 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 eachmodel in the range evolve. Motor vehicle repairers are invited to contact the CITRON network periodically forfurther information and to obtain any possible updates.
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PRESENTATION
THIS HANDBOOK summarises the characteristics, adjustments, checks and special features of CITRwhich there exists a separate handbook.
The handbook is divided into nine sections representing the main functions :
GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSSYSTEMS - ELECTRICAL - AIR CONDITIONING.
In each section, the various vehicles are dealt with in the following order: C15 - BERLINGO - BERLmodels where applicable.
This handbook applies only to vehicles in Europe.
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IMPORTANT
If you find that this handbook does not always meet your requirements, we invite you tointo account when preparing future publications. For example :
# INSUFFICIENT INFORMATION
# SUPERFLUOUS INFORMATION
# NEED FOR MORE DETAILS
Please send your comments and suggestions to :
CITRON VK Ltd221 Bath Road
SLOUGHSLI 4 BA
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LPG safety recommendations 155 to 161DELPHI checking, timing 168 to 178BOSCH checking, timing 179 to 200IGNITION
Sparking plugs 201
CLUTCH-GEARBOX-TRANSMISSION
Speedometer 202Clutch, checking/adjusting 206 to 211Driveshafts 245
AXLES-SUSPENSION-STEERING
C15 246 to 248BERLING0 253 to 257DISPATCH 267 to 269RELAY 275
BRAKES
C15 281
BERLINGO 286 to 287DISPATCH 294 to 295RELAY 299 to 300
C15Handbrake 284Bleed of brakes 285
INDEX
GENERAL
C15 1 to 2BERLINGO 3 to 12DISPATCH 13 to 17RELAY 4x2 18 to 37RELAY 4x4 38 to 44
C15 46BERLINGO 47DISPATCH-RELAY 48 to 49
Lubricants 50 to 64
ENGINE
Specifications 65 to 67Cyl. head marking and 72 to 85Auxiliary equipment drive 86 to 112Checking the valve timing 113Valve clearances 145
Oil pressure checks 146Oil filters 149INJECTION
Petrol injection 151 to 152Idling, anti-pollution 153 to 154
Identificationof
vehicles
Capacities
Axlegeometry
Brakespecifications
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IDENTIFICATION OF VEHICLES
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GENERAL
IDENTIFICATION OF VC15 All Types
Version (1) (2) (3)
Payload (kg) 600 765
Emission standard W3
Type approval no. VD PB VD PP VD SX VD WT
Engine type 161 A
Cubic capacity (cc) 1769
Fiscal rating (hp) 7
Gearbox type BE3/5
Gearbox ident. 20 TE 11 (*
1.8 D
(1) Standard van
(2) Deepened cab
(3) Familiale
(*) = Strengthened gearbox.
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IDENTIFICATION OF VEHICLES
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GENERAL
W3 W4
MA HDZF MB HDZF MA HFXB
HDZ HFX
1124
6
MA/5
20 CD 42 # 09/2000
Emission standard
Type approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
Payload (kg)
IDENTIFICATION OFBERLINGO All Types
Petrol
1.1 i
A AB600475 475
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600 800 600
K' W3 W4
MB KFXG MB KFXF MC KFXF MB KFWB
KFX KFW
1360
8
MA/5
20 CD 74#
09/2000 20 C
IDENTIFICATION OF VEHICLESPetrol
1.4 i
B
Emission standard
Type approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
Payload (kg)
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GENERAL
W3
MB WJZC MB WJZF MC WJZF
WJZ
1868
7
BE3/5
20 TE 22 20 TE 20
Emission standard
Type approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
Payload (kg)
IDENTIFICATION OFBERLINGO All Types
Diesel
1.9 D
A B
600 800
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IDENTIFICATION OF VEHICLESDiesel
B
Emission standardType approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
Payload (kg) 600 800
W3MB RHYF MC RHYF M
RHY
1997
6
BE3/5
20 TE 27
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GENERAL
600
W3 W4 W3 W4
MA HDZV MA HFXB MB WJZF MB WJYB
HDZ HFX WJZ WJY
1124 1868
6 7
MA/5 BE3/5
20 CN 01 20 TE 20 20 TE 49
BERLINGO All Types IDENTIFICATION OFPostvan version
DieselPetrol
1.1i 1.9 D
A B
Emission standard
Type approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
Payload (kg)
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Floor cab
800
W3 W4 W3 W4
ME KFXF ME KFXB ME WJZF ME WJ
KFX KFW WJZ WJY
1360 1868
7
MA/5
20 CN 14 20 TE 20 20 TE
Emission standard
Type approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
Payload (kg)
Version
IDENTIFICATION OF VEHICLES
Petrol
1.9 D1.4i
B
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L4/W4 L3
MF KFWB/A MF KFXF/MOD GL MF KFXF/MOD GL
KFW KFX
1360
6
MA/5
20 CN 13 20 CN 12 20 CN 13
Emission standard
Type approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
IDENTIFICATION OF VEHICLES
Petrol
1.4 i
Dual fuel
MultispaceXMultispace
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GENERAL
Emission standard
Type approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
L3/W3 L4/W4
MF WJZF MF WJZF/A MF WJYB MF WJYB/A MF
WJZ WJY
1868
5
BE3/5
20 TE 22 20 TE 24 20 TE 49 20 TE 24 20
IDENTIFICATION OFBERLINGO All Types
Diesel
1.9 D
X-SX Multispace X-SX Multispace
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IDENTIFICATION OF VEHICLES
1
2
3
4
5
6
7
E1AP07BD
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GENERAL
(*) = Fiscal incentive L5 (EURO 4)
VersionEmission standard
Type approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
(1) (2)-(3) (4)IF L5 (*)
BA RFNC/IF BZ RFNC/IF BA RFNC/IF
RFN
1997
BE4/5
20 DL 26 20 DL 27
IDENTIFICATION OF DISPATCH All Types
Petrol
2.0i 16V
A
Confort
(1) = Mixed van (short).(2) = Panel van (short).(3) = Glazed van (short).
(4) = Combi (5) = Combi (6) = Floor c
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(1)-(4) (2) (3) (7)-(8)
W3BA WJZA BZ WJZA BT WJZA
WJZ
1868
7
BE4/5
20 DL 33 20 DL 34
IDENTIFICATION OF VEHICLESDiesel
1.9 D
StandardConfort Confort
Emission standardType approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
Version
(1) = Mixed van (short). (6) = Floor cab.(2) = Panel van (short). (7) = Panel van (long).(3) = Glazed van (short). (8) = Glazed van (long).(4) = Combi 5-seater (9) = Floor cab (long).(5) = Combi 9-seater
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GENERAL
(1)-(4) (2) (2)-(3) (7)-(8)
W3BA RHXA (*) BZ RHXA BY RHXA BS RHXA
RHX
1997
8
ML/5
20 LE 93
DISPATCH All Types IDENTIFICATION OF Diesel
2.0 HDi
Confort
Emission standardType approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
Version
(1) = Mixed van (short). (6) = Floor cab.(2) = Panel van (short). (7) = Panel van (long).(3) = Glazed van (short). (8) = Glazed van (long).(4) = Combi 5-seater (9) = Floor cab (long).(5) = Combi 9-seater
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(*) = With DVA (Double damped flywheel)
(1) = Mixed van (short).(4) = Combi 5-seater(5) = Combi 9-seater
(1) (4)
L3BA RHZA
RHZ
1997
7
ML/5
20 LE 91 (*)
Emission standardType approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
Version
IDENTIFICATION OF VEHICLES
Diesel
2.0 HDi
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GENERAL
5 Vehicle identification N.
6 Bodyshell N.
SPECIFICATIONS - IDEN
Identification
1 Gearbox identification reference.
2 Manufacturers name plate
3 Engine plate
4 Paint code
1 VIN N
2 Gross
3 Gross
4 Max.
5 Max. E1-P02UD
RELAY 4 X 2 All Types
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ENGINE
1
23458BCH
XU102CU
XU10J2UXUD9AUDJ5TEDDJ5XUD9UTF2.8D (*)2.8 TD (*)2.0HDi (*)
WHEELBASE
1
234
Short (2.85m)
Medium (3.20m)Long (3.70m)Superlong (4.05m)
BODY
A
BCDEFGHJKLNUV
TR
2
4
FAMILY
23
SPECIFICATIONS - IDENTIFICATION ( 4 x 2 ) (continued)
Type approval no. (Example) 2 3 2 G 5 2 /
U 3 VAN 9 Q 10 Q
VAN 14 QCOMBI 10 QMINIBUS 18 QCHASSIS 10 QFLOOR 10 QCHASSIS 14 QPLATFORM 14 QVAN 18 QCHASSIS 18 QPLATFORM 18 QFLOOR 18 QPLATFORM 10 QCOMBI 14 Q
(*) = SOFIM engineNOTE : BODYWORK in A (VAN 9Q 10Q) 9Q = Van version Reduced Gross laden weightEXAMPLE : 232G52/2 = Bare chassis medium, 2.5 diesel engine, 5-speed gearbox.
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GENERAL
Wheelbase InteriorPa
height 9 Q 10 Q
1.56 m 25C/250C 27C/270C
Short : 2.85 m 1.88 m 25 CH/250CS 27CH/270C
2.11 m 27CS/270C
1.56 m 27M/270M
Medium : 3.20 m 1.88 m
2.11 m
1.56 mLong : 3.70 m
1.88 m
Super long : 4.05 m 1.56 m
RELAY 4 x 2 - All Types SPECIFICATIONS - IDENTIFICCommercial type
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(1) (2) (3) (6)
27
C/CH M C M C/CH
231A22 232A22 231C22/D 231C22/D 232E22 231B22
W3 L3 W3
RFW
1998
10 11 10
ML/5
20 UE 02
IDENTIFICATION OF VEHICLES
2.0i
I) (1) Panel or glazed van(2) Combi club
(3) Combi confort(6) Chassis cab.
II 27 = 10Q31 = 14Q
I
II
III
Type approval no.
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
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GENERAL
(3) (6) (
31
C M C M L
231V22/D 232V22/D 231G22 232G22 233G22 233G
L3
RFW
1998
9
ML/5
20 UE 02
RELAY 4 x 2 All Types IDENTIFICATION O
2.0i
I) (3) Combi club(6) Chassis cab.
(7) Chassis double cab.(8) Platform cab.(9) Platform double cab.
II 31 = 1
I
II
III
Type approval no.
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
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(10) (1) (4) (5)
31 35
M MH/MS LH MH LH
232F22 232J22 2333J22232J22/ 233B22/
(*) MODGNV MODGNV 233V22(**) (**)
W3
RFW
1998
10
ML/5 MG/5
20 UE 02 20 KM 69
IDENTIFICATION OF VEHICLES
2.0i
I) (1) Panel or glazed van.(4) Minibus.(5) Minibus 15-seater.(6) Chassis cab.(7) Chassis double cab.(8) Platform cab.(10) Floor cab.
II 31 = 14Q
35 = 18Q
I
II
III
Type approval no.
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
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GENERAL
(8) (10)
35
L M L
233L22 232N22 233N22233N22/
MODGNV (*)
W3
RFW
1998
10
MG/5
20 KM 69
RELAY 4 x 2 All Types IDENTIFICATION
2.0i
I) (8) Platform cab.(10) Floor cab.
II 35 = 18Q
I
II
III
Type approval no.
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
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(1) (2) (3)
25 27
C/CH M C M
231A32/C231A32 232A32 231C32/D 232C32/D 232E32(*)
W3 L3 W3
DJY
1905
6
ML/5
20 UE 02
IDENTIFICATION OF VEHICLES
1.9 D
I) (1) Panel or glazed van(2) Combi confort.
(3) Chassis cab.
II 25 = 9Q # (*) /C = V
27 = 10Q III (See Co
I
II
III
Type approval no.
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
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GENERAL
(1) (2) (4) (
27 31 2
C/CH M C/CH M/MH C
231A82 232A82 231B82 232B82 231C82D 232C
W3 L3
DHX
1905
8
ML/5
20 UE 01
RELAY 4 x 2 All Types IDENTIFICATION O
1.9 TD
II 27 = 131 = 1
I
II
III
III
III
Type approval no.
Type approval no.
Version
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
I) (1) Panel or glazed van(2) Combi confort.(3) Chassis cab.
(4) Combi club(8) Chassis double cab.
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(5) (6) (7
27 31
C M L M/MH
231U82 231H82 232H82 233H82 233H52/1 232F82
W3DHX
1905
6 8
ML/5
20 UE 02
IDENTIFICATION OF VEHICLES
1.9 TD
I) (5) Platform cab.(6) Platform double cab.(7) Floor cab.
II 27 = 10Q31 = 14Q
I
II
III
Type approval no.
Version
Emission standardEngine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
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GENERAL
(1) (2) (1)
27
C/CH M C C/CH M/MH L
231A52 232A52 231C52/D 231B52 232B52 233
(6) (8) (6)27
C L XL
231E52 231U52 233G52 234G52 232G
W3 L3
T9A
2446
8
ML/5
20 UE 00
RELAY 4 x 2 All Types IDENTIFICATION O
2.5 D
II 27 = 131 = 1
I
II
III
III
III
Type approval no.
Type approval no.
Version
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
I) (1) Panel or glazed van(2) Combi confort.(6) Chassis cab.
(7) Chassis double cab.(8) Platform cab.
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(9) (10) (1
31
M L C M/MH L/LH L
232H52/1 233H52/1 231F52 232F52 233F52 233G52/2
W3T9A
2446
8
ML/5 MG/5
20 UE 00 20 KM 74
IDENTIFICATION OF VEHICLES
2.5 D
I) (9) Platform double cab.(10) Floor cab.(11) Bare chassis.
II 31 = 14Q
I
II
III
Type approval no.
Version
Emission standardEngine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
RELAY 2 All T IDENTIFICATION O
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GENERAL
(1) (3) (4) (5) (
35
C/CH MH/MS LH (*) - LH/LS LH M
231J52 232J52 233J52 233V52 232K22 233
(9) (10) (11)
35L M/MH L/LH XL
233L52/1 232N52 232N52 234G52/2
W3
T9A
2446
8
MG/5
20 KM 73
RELAY 4 x 2 All Types IDENTIFICATION O2.5 D
I
II
III
I
IIIII
Type approval no.
Type approval no.
Version
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
I) (1) Panel or glazed van(3) Minibus.(4) Public transport 16-seater.
(5) Minibus 15-seater.(6) Chassis cab.(7) Chassis double cab.
(8) Platform cab.(9) Platform double cab.(10) Floor cab.(11) Bare chassis.
IDENTIFICATION OF VEHICLES
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(1) (2) (1)
27
C/CH M C C/CH M/MH M
231A42 232A52 231C42/D 231B42 232B42 232B42
(3) (7) (9) (7)
27C C M L
231C52/D 231E42 231U42 231G42 232G42 233G42
W3
THX
2446
8
MG/5
20 KM 74
IDENTIFICATION OF VEHICLES2.5 TD
II 27 = 10Q31 = 14Q
I
II
III
I
IIIII
Type approval no.
Type approval no.
Version
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
I) (1) Panel or glazed van(2) Combi club.(3) Combi confort.
(7) Chassis cab.(8) Chassis double cab.(9) Platform cab.
RELAY 4 2 All T IDENTIFICATION O
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GENERAL
(9) (10) (1
31
M L M L C M/
232H42 233H42 232H42/1 233H42/1 231F42 232
W3
THX
2446
8
MG/5
20 KM 74
RELAY 4 x 2 All Types IDENTIFICATION O
2.5 TD
I) (9) Platform cab.(10) Platform double cab.
(11) Floor cab.(12) Bare chassis.
II 31 = 1
I
II
III
Type approval no.
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
IDENTIFICATION OF VEHICLES
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(1)
35
C/CH M/H MS LH LH (*) LS
231J42 232J42 232J42 233J42 233J42 233V42
(7) (8) (9) (10)
35L XL L M L
233K42 234K42 233G42/1 232N42 233L42 233L42
W3
THX
2446
8
MG/5
20 KM 75
IDENTIFICATION OF VEHICLES2.5 TD
II
I
II
III
I
IIIII
Type approval no.
Type approval no.
Version
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
I) (1) Panel or glazed van(4) Minibus.(5) Public transport 16-seater.(6) Minibus 15-seater.
(7) Chassis cab.(8) Chassis double cab.(9) Platform cab.(10) Platform double cab.
(11) Floor cab.(12) Bare chassis.
RELAY 4 x 2 All Types IDENTIFICATION O
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GENERAL
(1) (2) (1)
27
C/CH M C C/CH M/MH M
231AH2 232AH2 231CH2/D 231BH2 232BH2 232B
(3) (7) (9) (7)
27C C M L
231CH2/D 231EH2 231UH2 231GH2 232GH2 233
W4
F28TDCR
2800
9 (*)
MG/5
20 KM 79
RELAY 4 x 2 All Types IDENTIFICATION O2.8 HDi
II 2731
I
II
III
I
IIIII
Type approval no.
Type approval no.
Version
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
I) (1) Panel or glazed van(2) Combi club.(3) Combi confort.(7) Chassis cab.
(8) Chassis double cab.(9) Platform cab.(*) = Without lateral door(**) = (2)-(3) 10 hp
IDENTIFICATION OF VEHICLES
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(9) (10) (11)
31
M L M L C M/MH
232HH2 233HH2 232HH2 233HH2/1 231FH12 232FH2
(12)
31XL
234GH2/2
W4
F28TDCR
2800
9
MG/5
20 KM 79
IDENTIFICATION OF VEHICLES2.8 HDi
II 31 = 14Q III (S
I
II
III
I
IIIII
Type approval no.
Type approval no.
Version
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
I) (9) Platform cab.(10) Platform double cab.(11) Floor cab.(12) Chassis cab.
RELAY 4 x 2 All Types IDENTIFICATION O
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GENERAL
(1)
35
C/CH MH LH MS LH LH
231JH2 232JH2 233JH2 232JH2 233JH2 233J
(7)
35M L XL
232KH2 233KH2 234KH2
W4
F28TDCR
2800
9
MG/5
20 KM 77
RELAY 4 x 2 All Types IDENTIFICATION O2.8 HDi
II 35
I
II
III
I
IIIII
Type approval no.
Type approval no.
Version
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
I) (1) Panel or glazed van.(4) Minibus.(5) Public transport 16-seater.
(6) Minibus 15-seater.(7) Chassis cab.
IDENTIFICATION OF VEHICLES
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(8) (9) (10) (11)
35
L M L L M/MH L/LH
233GH2/1 232KK2 233LH2 233LH2/1 232NH2 233NH2
W4F28TDCR
2800
9
MG/5
20 KM 77
IDENTIFICATION OF VEHICLES
2.8 HDi
I) (8) Chassis double cab.(9) Floor cab.(10) Platform double cab.
(11) Floor cab.(12) Chassis cab.
II 35 = 18Q
I
II
III
Type approval no.
Version
Emission standardEngine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
RELAY 4 x 4 - All Types SPECIFICATIONS - IDE
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GENERAL
5 Paint code
6 Vehicle identification N.
7 Bodyshell N.
8 Rear axle
RELAY 4 x 4 All Types SPECIFICATIONS IDE
Identification
1 Gearbox identification reference.
2 Manufacturers name plate
3 Engine plate.
4 Transfer box.
1 VIN N
2 Gros
3 Gros
4 Max.
5 Max.E1-P02VD
SPECIFICATIONS - IDENTIFICATION ( 4 x 4 ) (continued)
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ENGINE
12
3458BCH
XU102CUXU10J2U
XUD9AUDJ5TEDDJ5XUD9UTF2.8D (*)2.8 TD (*)2.0HDi (*)
WHEELBASE
12
34
Short (2.85m)Medium (3.20m)
Long (3.70m)Superlong (4.05m)
BODY
AB
CDEFGHJKLNU
V
TR
24
FAMILY
23
Type approval no. (Example) 2 3 2 G 5 2 /
U 3 VAN 9 Q 10 QVAN 14 Q
COMBI 10 QMINIBUS 18 QCHASSIS 10 QFLOOR 10 QCHASSIS 14 QPLATFORM 14 QVAN 18 QCHASSIS 18 QPLATFORM 18 QFLOOR 18 QPLATFORM 10 Q
COMBI 14 Q
(*) = SOFIM engineNOTE : BODYWORK in A (VAN 9Q 10Q) 9Q = Van version Reduced Gross laden weightEXAMPLE : 232G52/2 = Bare chassis medium, 2.5 diesel engine, 5-speed gearbox.
SPECIFICATIONS IDENTIFICATION ( 4 x 4 ) (continued)
RELAY 4 x 4 - All Types SPECIFICATIONS - IDENTIFIC
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GENERAL
WheelbaseInterior height
10 Q
1.56 m 27C/270CShort : 2.85 m 1.88 m 27CH/270CS
2.11 m 27CS/270CH
1.56 m 27M/270M
Medium : 3.20 m 1.88 m
2.11 m
1.56 mLong : 3.70 m
1.88 m
Super long : 4.05 m 1.56 m
RELAY 4 x 4 All Types SPECIFICATIONS IDENTIFICCommercial type
SPECIFICATIONS - IDENTIFICATION ( 4 x 4 ) (continued)
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1 ) Letter Supplier E STA
2 ) Letter Torque J 8 X 37
F 8 X 39
3 ) and 4 ) Letters Differential 01 Limited slipidentification
02Differential
lock
(a) (b) (c)
D = Dangel D = Diesel 1 = 14Q 08
Atmospheric 5 = 18Q ge
T= Turbo diesel 7 = 10Q
E = Petrol
a = D
b = E
c = 7
d = 08
e = (R)
( ) ( )
Gearbox plate (Example)
(*)
Rear axle (Example)
RELAY 4 x 4 All Types IDENTIFICATION O
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(1) (2) (1)
31
C/CH MH C M MH L
231B54 232B54/1 231V54/D 232V54/D 232J54 233
(3) (4) (5)
31 35M M
232V54 232H54 232N54 233
W3
T9A
2446
8 9
ME/5
20 KE 29
DD1 04 ( R )
GENERAL
yp2.5 D
II 31 = 135 = 1
I
II
III
I
IIIII
Type approval no.
Type approval no.
Version
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
I) (1) Panel van.(2) Chassis confort(3) Chassis cab.
(4) Platform cab.(5) Floor cab.
IDENTIFICATION OF VEHICLES
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(6) (1) (2) (1
27 31
C C/CH MH C MH
231C44/D 231B44 232B44/1 232V44/D 232J44
(2) (3) (4)
31M L
232V44/D 232V44 232H44 233L44
W3
THX
2446
9 8
ME/5 MG
20 KE 29 20 KM 74
DT7 04 ( R ) DT1 19 ( R )
2.5 Tdi
II 273135
I
II
III
I
IIIII
Type approval no.
Type approval no.
Version
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
I) (1) Panel van.(2) Combi confort(3) Chassis cab.
(4) Platform cab.(5) Floor cab.(6) Combi club
RELAY 4 x 4 All Types IDENTIFICATION
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(2) (1) (3)
27 31
C C/CH MH C M
231CH4/D 231BH4 232BH4/1 231VH4/D 232
(3) (4) (5)
31M
232VH4/D 232VH4 232HH4 233
W4
F28TDCR
2800
9 (*)
MG/5
20 KM 79
GENERAL
2.8 HDi
II 273135
I
II
III
I
IIIII
Type approval no.
Type approval no.
Version
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
I) (1) Panel van.(2) Combi club(3) Combi confort
(4) Chassis cab.(5) Platform cab.(6) Floor cab.
LUBRICATION SYSTEM
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Draining method.
Oil capacities are determined by the following proced
1/ Vehicle on horizontal ground.
2/ Engine warm (oil temperature 80C).
3/ Drainage from sump + remove oil filter (time required for draining including dripping =
4/ Refit engine plug.
5/ Refit filter and refill engine with oil.
6/ Start the engine (allowing the filter to fill).
7/ Stop the engine (leave for 5 min).
IMPERATIVE : Systematically check the oil level via the o
C15 All Types CAPACITIES (in lit
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GENERAL
C15
Diese
1.8D
Engine type 161A
Engine angle
Engine with filter change 4.25
Between Min. and Max. 1.5
5-speed gearbox 2
Brake circuit
Cooling system 8
Fuel tank capacity 47
(1) = Vehicle with air conditioning.
NOTE : Engine, systematically check the oil level using the oil dipstick.
CAPACITIES (in litres)
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Engine type
Engine with filter change
Between Min. and Max.
5-speed gearbox
Automatic gearbox
after drainage
Hydraulic or brake circuit
Cooling systemFuel tank capacity
HDZ HFX KFX KFW LFX HFX
3.54.75
4.5 (1)
1.5 1.3
2 1.8
With ABS = 0.62 - Without ABS = 0.525
6.5 6.5-7 (1) 8 6.555
Eccap
Petrol
BERLINGO
(1) = With aircon. - NOTE : Engine, systematically check the oil level using the oil dipstick.
1.1i 1.4i 1.8i 1.1i
DISPATCH All Types CAPACITIES (in
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GENERAL
Petrol
2.0i 16V 1.9 D
Engine type RFN WJZ (1) WJZ (
Engine angle 28 1630 - 1
Engine with filter change 4.25 4.5 4.5 (3)Between Min. and Max. 1.7 1.5 1.3 (3) - 1
5-speed gearbox 1.8 1.8
Automatic gearbox 8
After drainage 3
Brake circuit 0.5
Cooling system
Fuel tank capacity 80
(1)= OPR 7903#
8575 Filling with oil is by way of the oil sump.Aluminium oil sump on versions with and without aircon (Power unit angled).(2) = OPR 8576 # Filling with oil is by way of the cylinder block.Steel oil sump on versions without aircon (Power unit angled).NOTE : Engine, systematically check the oil level using the oil dipstick.
Automatic
Dispatc
CAPACITIES (in litres)
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Petrol Dies
2.0i 1.9 D 1.9 TD
Engine type RFW DJY D8C DHY T9A (
Engine with filter change 4.75 - 4.5 (5) 5.25 (Without aircon) 9
Between Min. and Max. 1.5 2.95-speed gearbox 1.85 (*) 2.5
Brake circuit
Cooling system 10
Fuel tank capacity 80
(1) = NOPR # 235152 (2) = N 235153 # (3) engine DJ5T (Engine with filter change (4) = Filter cartridge capacity (litres) : 1.10. (5) With aircon.
(*) Gearbox (ML) - Gearbox (MG) = 2.5 litres.NOTE : Engine, systematically check the oil level using the oil dipstick.
Relay
ALL TYPES LUBRICANTS - TOTAL rec
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GENERAL
S.A.E. Norm - Table for selection of engine oil grade
CITRONof grade STOTAL oieconomies
This oil is
- XU10 4 R- SOFIM
These eng
recognised
SAE : SocAPI : AmeACEA : Ad'AutomobE4AP006D
LUBRICANTS - TOTAL recommended oils
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Selection of engine oil grades recommended for climatic conditions in c
ACEA NormsThe first letter corresponds to the type of engine concerned :
A : petrol and dual fuel petrol / LPG engines.B : diesel engines.
The figure following the first letter corresponds to the type of oil.1 : highly fluid oils, for reducing friction and lowering fuel
consumption.3 : high performance oils.
The number after that (96 or 98) corresponds to the year of creation ofthe norm.
NOTE : From 01/03/2000, all engine oils must comply with ACEA-98norms.
Example :
ACEA A1-98 / B1-98 : Blended oils for all engines, permetting fueleconomy (complying with ACEA 98norms).
The first letter corresponS : petrol and dC : diesel engin
The second letter corresorder.Example : The normcorresponds to a higher The adding of the lettersoil which permits fuel ecEC : Energy ConservinExamples :API SJ / CF : Blended oAPI CF / EC : Oils s
economy.API SJ / CF / EC : Blend
LUBRICANTS - TOTAL recoALL TYPES
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GENERAL
Recommendations.Denominations of TOTAL oils, according to country of marketing :
TOTAL ACTIVA (France only).TOTAL QUARTZ (outside France).
IMPERATIVE : From 1999 model year, to preserve engine performance, amust be lubricated with high quality oils (synthetic o
These oils must comply with the following norms :
Petrol and dual fuel petrol / LPG engines: ACEA A3-98 and API SJ.Diesel engines: ACEA B3-98 and API CF
ATTENTION : Engines fitted in CITROEN vehicles prior to 2000 model year mwith standards ACEA A1-98 / B1-98 and API S
SummaryEngine oil norms to be respected in 2001 model year.
(*) = It is essential not to use engine oils respecting these norms for the following engine-types XU10J4RS, 1580 SPI, SOFIM 2.8 D and SOFIM 2.8 TD.
Model year
2001 model year
Petrol and dual fuel petrol /LPG engines
A3-98 or A
B3-98 or BDiesel engines
Types of engine ACEA n
LUBRICANTS - TOTAL recommended oilsS A E d
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S.A.E. grades
Blended oils for all engines (petrol, dual-fuel petrol / LPG
TOTAL ACTIVA 9000
TOTAL QUARTZ 90005W-40
TOTAL ACTIVA 9000 (*)
TOTAL QUARTZ 9000 (*)5W-30
TOTAL ACTIVRAC 10W-40
(*) = Blended oils for all engines, permitting fuel economy.Oils specifically for petrol and dual-fuel petrol / LPG e
TOTAL ACTIVA 7000
TOTAL QUARTZ 700010W-40
TOTAL QUARTZ 9000 0W-40
TOTAL ACTIVA 7000
TOTAL QUARTZ 700015W-50
Oils specifically for diesel engines
TOTAL ACTIVA DIESEL 7000
TOTAL QUARTZ DIESEL 7000
10W-40
TOTAL ACTIVA DIESEL 7000
TOTAL QUARTZ DIESEL 700015W-50
TOTAL ACTIVA 9000 5W-40
LUBRICANTS - TOTAL recoALL TYPES
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GENERAL
FRANCE
Metropolitan FRANCE
Metropolitan FRANCE
New CaledoniaGuadeloupeSaint-MartinLa Runion
9000 5W-40 7000MartiniqueGuyanaTahitiMauritiusMayotte
Blended oils
TOTAL ACTIVRAC
TOTAL ACTIVA
Blended oils for all engines
900 5W-409000 5W-30 (*)
7000
Oils specificadual-fuel petr
(*) = Blended oils for all engines, permitting fuel economy.
EUROPE
LUBRICANTS - TOTAL recommended oils
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EUROPE
Germany7000 10W-9000 0W-4
Austria 7000 10W-Belgium
7000 10W-9000 0W-4
Bulgaria 7000 10W-
Cyprus 7000 15W-
Croatia 7000 10W-
Denmark7000 10W-9000 0W-4
Spain7000 10W-
7000 15W-Finland
7000 10W-9000 0W-4
Great Britain 7000 10W-
TOTAL QUARTZ
Blended oils for all enginesOils specifically fordual-fuel petrol / LP
9000 5W-409000 5W-30 (*)
(*) = Blended oils for all engines,permitting fuel economy
EUROPE (continued)
LUBRICANTS - TOTAL recALL TYPES
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GENERAL
EUROPE (continued)
Greece70007000
Holland 7000Hungary 900
Italy 7000
Latvia 7000
Lithuania 900
Macedonia 7000
Malta70007000
Norway7000
900Poland
Portugal 7000
Slovak Republic
TOTAL QUARTZ
Blended oils for all enginesOils specificadual-fuel petr
9000 5W-409000 5W-30 (*)
(*) = Blended oils for all engines,permitting fuel economy
EUROPE (continued)
LUBRICANTS - TOTAL recommended oils
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EUROPE (continued)
7000 10W-Czech Republic
9000 0W-4
Romania 7000 10W-7000 15W-
Russia7000 10W-9000 0W-4
Slovenia 7000 10W-
Sweden7000 10W-9000 0W-4
Switzerland 7000 10W-
Turkey
7000 10W-
7000 15W-9000 0W-4
Ukraine7000 10W-9000 0W-4
TOTAL QUARTZ
Blended oils for all enginesOils specifically fordual-fuel petrol / LP
9000 5W-409000 5W-30 (*)
(*) = Blended oils for all engines,permitting fuel economy
LUBRICANTS - TOTAL recALL TYPES
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GENERAL
Australia
New ZealandOCEANIA 9000 5W-40 7000
Angola - Ivory Coast
Egypt - Ecuador - Gabon
Madagascar - Morocco AFRICA 9000 5W-40 7000
Dominican Republic
Senegal- Tunisia
Argentina - Brazil - Chile
Colombia - CubaSOUTH
Guatemala - Paraguay AMERICA 9000 5W-40 7000
Peru - El Salvador
Uruguay
TOTAL QUARTZ
Blended oilsfor all engines
Oils specificadual-fuel petr
LUBRICANTS - TOTAL recommended oils
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China7000 10W-4
7000 15W-5
South Korea 7000 10W-4
Hong Kong - India
Indonesia7000 15W-5
Japan7000 10W-4
SOUTH & EAST 7000 15W-5
Malaysia ASIA9000 5W-40
7000 15W-5Singapore
Taiwan 7000 10W-4
7000 15W-5
Thaland7000 15W-5
Vietnam
TOTAL QUARTZ
Blended oilsfor all engines
Oils specifically fordual-fuel petrol / LP
LUBRICANTS - TOTAL recALL TYPES
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GENERAL
Saudi Arabia
Bahrain
Dubai
United Arab Emirates
Israel MIDDLE9000 5W-40 7000
Jordan EAST
Kuwat
Lebanon
Qatar
Yemen
TOTAL QUARTZ
Blended oilsfor all engines
Oils specificadual-fuel petr
LUBRICANTS - TOTAL recommended oils
Gearbox oils
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Manual gearboxEurope
Overseas France
Asia
Automatic gearbox MB3S
Automatic gearbox 4 HP 14 et 4 HP 18 All countries S
Automatic gearbox 4 HP 20 et AL4S
Transfer box and differential
C MATIC gearbox
Power-assisted steering All countries
Gearbox oils
Oils for power-assisted steering
Engine coolant
LUBRICANTS - TOTAL recoALL TYPES
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GENERAL
g
Packs
CITROEN Fluid 2 litresAll countries
Protection : - 35C 5 litres
20 litres
210 litres
Synthetic brake fluid
Packs
All countries CITROEN Fluid0.5 litre
1 litre
5litres
CITROEN hydraulic circuit fluid
Mineral fluid for hydraulic circu
TOTAL LHM PLUS Pack
All countries Norms ISO 7308-7309 1 litre
Hydraulic circuit rinsing fluid g
TOTAL HYDRAURIN
Wash / wipe fluid
LUBRICANTS - TOTAL recommended oils
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CITR
Concentrate : 250 ml 9980 33 ZC
All countries Liquid ready to use : 1 litre 9980 06 ZC
Liquid ready to use : 5 litres 9980 05 ZC
Grease
All countries TOTAL MULTIS EP2
TOTAL MULTIS COMPLEX EP2
TOTAL MULTIS N4128
TOTAL PETITES MECANIQUES
(1) NLGI = National Lubrificating Grease Institute.
p
ENGINE OIL CONSUALL TYPES
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GENERAL
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 WORK BELOW THESE VALUES.
IV - OIL LEVEL : The level should NEVER be above the MAX. mark on the dipstick- This excess oil will be used up rapidly.- It will reduce the engine output and adversely affect the operation of the air ci
ENGINE SPECIFICATIONS
Engines : HDZ - HFX - KFX - HDZ/GPL - KFX
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1.1i 1.4i
HDZ HFX HDZ/GPL KFX KFX/GPL
1124 1360
72/69 75/77
9.7/1 10.5/1 9.7/1 10.2/1
44.1-6200 44.1-5500 43.2-6200 55-5500
60-6200 60-5500 58.8-6200 75-5500
8.75-3800 9.4-3500 8.31-3800 11.1-3400
9.1-3800 8.65-3800 11.5-3400
6500 6500 6500
Engine type
Cubic capacity (cc)
Bore / Stroke
Compression ratio
Power ISO or EEC KW-rpm
Power DIN (HP-rpm)
Torque ISO or EEC (m.daN-rpm)
Torque DIN (mkg-rpm)
Max. engine speed (rpm)
g
Petrol
All Types
ENGINE
ENGINE
ENGINE SPECIFICAALL TYPES
Engines : 161 A - WJZ
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EE
1.8 D 1.9 D
161 A WJZ DJY
1769 1868
80/88 82.2/88
23/1
43.5-4600 51-4600 50-4600
60.5-4600 70-4600 69.5-4600
11-2000 12.5-2500 12-2000
11.4-2000 14-2500 12.5-2000
4600 5350 4600
Engine type
Cubic capacity (cc)
Bore / Stroke
Compression ratio
Power ISO or EEC KW-rpm
Power DIN (HP-rpm)
Torque ISO or EEC (m.daN-rpm)
Torque DIN (mkg-rpm)
Max. engine speed (rpm)
Dies
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ENGINE
ENGINE
COMPRESSION RATIO - ALL TYPES
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EE
in bars
XUD 7 / 9
DJ525 30 20
DJ5 TED 32 35 25.5
ENGINECOMPRESSION
RATIOMINIMUM V
( - 20 %
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)
Engines : HDZ - HFX - KFX - KFW - LFX - RFN RFW
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Engine type HDZ HFX KFX KFW
Maximum permissible bow 0.05
Gasket surface regrinding - 0.20
TIGHTENING TORQUES (
Crankshaft bearing screws :- Pre-tightening 2 0.2- Tightening 5.5 0.5
- Angular tightening 45 4
Connecting rod screws :
- Pre-tightening 4 0.4
- Loosening
- Tightening 3.8 0.3 2 0.2
- Angular tightening 70 7
Flywheel screw :
- Tightening 6.5 0.6 5 0.5
- Loosening
Crankshaft end pulley screw 10 1 12 1.2
Camshaft end drive screw 8 0.8 5.5 0.5
CYLINDER HEAD
ENGINE
ENGINE
SPECIAL FEATURES - TIGHTENALL TYPES
Engines : 161A - DJY - D8C - DHX WJ
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EE
Engine type 161A DJY D8
Maximum permissible bow 0.07
Gasket surface regrinding - 0.2
TIGHTENING TOR
Crankshaft bearing screws :- Pre-tightening
- Tightening 7 0.7
- Angular tightening
Connecting rod screws :
- Pre-tightening
- Tightening 2 0
- Angular tightening 70
Flywheel screw 5 0
Pulley screw at end of crankshaft :
- Pre-tightening
- Tightening 4 0.4
- Angular tightening 51 5
Pinion screw at end of camshaft 4.5
CYLINDER H
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)
Engines : RHY - RHX - RHZ - RHW - T9A THX
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Engine type RHY RHX RHZ R
Maximum permissible bow 0.03
Gasket surface regrinding - 0.40
TIGHTENING TORQUES (m.
Crankshaft bearing screws :
- Pre-tightening 2.5 0.2- Tightening- Angular tightening 60 6
Connecting rod screws :- Pre-tightening 2 0.2- Tightening- Angular tightening 70 7
Flywheel screw 5 0.5
Pulley screw at end of crankshaft :- Pre-tightening 4 0.4- Tightening- Angular tightening 51 5
Pinion screw at end of camshaft 4.3 0.4
Camshaft pinion fixing flange
Camshaft pinion to flange screw :- Pre-tightening- Tightening
CYLINDER HEAD
ENGINE
ENGINE
CYLINDER BERLINGO All Types
Engines : HDZ - KFX - KFW - HFX
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EE
CYLINDER HEAD GASKET IDENTIFICAT
Engine type
Identification marks (Notch on cylinder head gasket) *
HDZ - KFX HFX - KFW
1234
AB
DAB
DA
BDA
BD
C
R 0 (Standard gasket) - 1 (Repair gasket)
0 (With asbestos) - 1 (Asbestos-free)
0
01
1
01
011
000
00
01
CURTY
MEILLOR
ELRING
REINZ
Material
Repairs
Suppliers
Thickness
CYLINDER HEAD (continued)
Engines : HDZ KFX - KFW HFX
C li d h d ti ht i ( d N)
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Cylinder head tightening (m.daN)
X
- Pre-tightening 2 0.2
- Angular tightening 240 2
B1DP059CB1BP10LC
HDZ KFX - KFW - HFX
ENGINE
ENGINE
CYLINDER HEADBERLINGO All Types
Engine : LFX
CYLINDER HEAD GASKET IDENTIFICAT
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CYLINDER HEAD GASKET IDENTIFICAT
Engine type
Identification marks (Notch on cylinder head gasket) *
LFX
* 0 = Without notch1 = One notch
B
A
0
1
C 0D 0
E 0
A 0
B 1
C 0
D 0
E 0
CURTY
MEILLOR
Suppliers
CYLINDER HEAD (continued)
Engine : LFX
Cylinder head tightening (m daN)
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- Pre-tightening 6
- Loosening OUI
- Tightening 2
- Angular tightening 300
LFX
Cylinder head tightening (m.daN)
X
NOTE : Oil under the hder head boUse engineRapid Plus)
B1DP05BC
ENGINE
ENGINE
DISPATCH All Types CYLINDER
Engine : RFN
CYLINDER HEAD GASKET IDENTIFICAT
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CYLINDER HEAD GASKET IDENTIFICAT
Nominal dimension Repair dimension
2 - 4 - 54 - 5
R1 R2
1.10.8Gasket thickness
(mm)
Supplier MEILLOR
Marking zone"e"
Marking zone"d"
1.4
Multilayer metallic gasket
CYLINDER HEAD (continued)
Engine : RFN
Cylinder head tightening (m daN)
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X
NOTE : Oil the threads and
under the heads of the cylinder
head bolts.(Use engine oil or Molykote G
Rapid Plus).
Pre-tightening 1.5 0.1
Tightening 5 0.1
Loosening 360 2
Tightening 2 0.75Angular tightening 285 5
B1DP0.
RFN
Cylinder head tightening (m.daN)
A = Washer thickX = Length unde
ENGINE
ENGINE
CYLINDER HRELAY All Types
Engine : RFW
CYLINDER HEAD GASKET IDENTIFICAT
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CYLINDER HEAD GASKET IDENTIFICAT
Engine type
Identification marks (Notch on cylinder head gasket) *
RFW
A 1
B 0
C1
D 0
E 1
A 0
B 1
C 1
D 0
E 1
CURTY
MEILLOR
Suppliers
B1BP004C
CYLINDER HEAD (continued)
Engine : RFW
Cylinder head tightening (m.daN)
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X
NOTE : Oil theunder the headder head bolts(Use engine oRapid Plus).
- Pre-tightening 3.5
- Loosening NON
- Tightening 7
- Angular tightening 160
B1DP05BC
RFW
Cylinder head tightening (m.daN)
ENGINE
ENGINE
C15 - RELAY All Types CYLINDER
CYLINDER HEAD GASKET IDENTIFICAT
Engines : 161A - DJY - D8C- DHX
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Engines Ident.
mark (A)
161A 1 notch
DJY no notch
CYLINDER HEAD GASKET IDENTIFICAT
161A - DJYIdent. Mark
(B)
Thickness(mm) 0.06
Enginetype
Piston stand-proud(mm)
0.56 0.67 1.36
0.68 0.71 1.40
0.72 0.75 1.44
0.76 0.79 1.48
0.80 0.83 1.52
161 A
DJYD8C
DHX
B1BP10SC B1BP10TC
CYLINDER HEAD
CYLINDER HEAD GASKET IDENTIFICATION
Engine : WJZ
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CYLINDER HEAD GASKET IDENTIFICATION
Numberof holes
at B
Numberof holes
at A
Thickness(mm) 0.04
Enginetype
Piston stand-proud (mm)
0.51 0.55 1.26 1
0.55 0.59 1.30 2
0.59 0.63 1.34 3
0.63 0.67 1.38 4
0.67 0.71 1.42 5
WJZ
(A) = Engine identification
(B) = Thickness identification.
(*) = Use the highest piston as a reference.
2
ENGINE
ENGINE
C15 - BERLINGO - DISPATCH CYLINDER H
Engines : 161A - DJY - D8c - DHX - WJ
Cylinder head tightening (m.daN)
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NOTE : Oil the threads and under theheads of the cylinder head bolts.
(Use engine oil or Molykote G Rapid Plus).
- Pre-tightening 2 0.2
- Tightening 6 0.6
- Angular tightening 220 2
- Pre-tightening 2 0.2
- Tightening 6 0.6
- Angular tightening 180 2
B1DP14NCB1DP13PC
D8C - DHX
161A - WJZ - DJY
161A - W
125.5
y g g ( )
161A -
B1DP05BC
CYLINDER HEAD
CYLINDER HEAD GASKET IDENTIFICATION
Engines : RHX - RHZ - RHY
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CYLINDER HEAD GASKET IDENTIFICATION
No. of notchesat A
Thickness(mm)
Enginetype
Piston stand-proud (mm)
0.47 0.605 1.30 0.06 1
0.605 0.655 1.35 0.06 2
0.655 0.705 1.40 0.06 3
0.705 0.755 1.45 0.06 4
0.755 0.83 1.50 0.06 5
RHX
RHZ
RHY
ENGINE
ENGINE
BERLINGO - DISPATCH CYLINDER HEA
Engines : RHX - RHZ - RHY
CYLINDER HEAD GASKET IDENTIFICAT
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NOTE : Oil the threads and under theheads of the cylinder head bolts.
(Use engine oil or Molykote G Rapid Plus).
- Pre-tightening 2 0.2
- Tightening 6 0.6
- Angular tightening 220 2
B1DP15EC
RHX - RHZ - RHY
Cylinder head tightening (m.daN)
B1DP05BC
CYLINDER HEAD
Engines : T9A - THX
Cylinder head gasket identification Cylinder head tightening (m.daN)
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Engine type
T9A 1.6
THX
NOTE : Single cylinder head gasket
1.4
Thickness (mm) T9A - THX
- Pre-tightening the bolts :
Angular tightening
B1DP03XC
- 1 14 (Vis 12) 5 0.5
- 15 22 (Vis 10) 3.5 0.3
T9A
120 5 150 5
THX
ENGINE
ENGINE
Tools
ALL TYPES BELT TENSION/SEEM UNITS CORR
! 4099-T (C.TRONIC.105)!
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B1EP135D
AUXILIARY EQUIPMENT DRIVE BELT
Engines : All Types Petrol and Diesel
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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.
ENGINE
ENGINE
AUXILIARY EQUIPMENT DRIVE B
Engines : HDZ - HFX - KFX - KFW
Alternator
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[1] Belt tension measurer : 4122-T- New belt- 87 SEEM units.
- Reused belt
- 61 SEEM units.
- New belt- 100 SEEM units.
- Reused belt
- 75 SEEM units.
Power steering
B1BP121C
B1BP122C
AUXILIARY EQUIPMENT DRIVE BELT
Without air conditioni
Engine : LFX
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- (3) and (5) Roller support fixing screws.
- (6) tensioning screw.
- Tighten the belt, by loosening the screw (6) to : In SEEM units.
- Tighten the screws (3) and (5).
- Rotate the crankshaft by 4 turns (direction of rotation).
- Loosen the screws (3) and (5).
- Tension the belt, by slackening the screws (6) to : In SEEM units
- Tighten the screws (3) and (5) to 2 m.daN
100 10
LFX
115 5
LFX
ENGINE
ENGINE
AUXILIARY EQUIPMENT DRIVE B
With air
Engine : LFX
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- Fit the drive belt.
- The tensioner roller (1).
- Tighten the screws (3) to 2 m.daN.
- Turn the tensioner roller (1) using the tool (9.52
the tool or locking peg ( 4 mm ) at (4).
- Slowly release the tensioner roller (1) so that t
B1BP1HJC
AUXILIARY EQUIPMENT DRIVE BELTEngine : RFNWithout air conditioning
Tools
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Tools
[1] Pliers for removing plastic pegs 7504-T
Remove the belt.- Detension the belt (3) by turning the screw (2) of the tensioner roll
(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 B1BP
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AUXILIARY EQUIPMENT DRIVE BELTEngine : RFW (continued)
Alternator belt (with air con
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- NOTE : If the vehicle is equipped with power steering, remove the
TENSIONING THE BE
- 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 m.daN.- Run the engine for 10 min.- 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.
B1BP1LFC B1BP04AC
ENGINE
ENGINE
AUXILIARY EQUIPMENT DRIVE BEngine : RFW (continued)
Power-assisted ste
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[1] Belt tension measuring instrument : 4122-TREMOVING TH
- To make it easier to move the pump, unclamp the hydraulic
- Slacken the articulating screws of the pump.
- Slacken the nut (2) to release the belt (1).
TENSIONING TH- 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 u- Remove the tool [1].- Tighten the screws (3) and the pump articulating screws to- Run the engine for 10 min.
- 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
AUXILIARY EQUIPMENT DRIVE BELTEngines : 161A - DJY
Alternator
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[1] Belt tension measuring tool : 4122-T
- Fit the tool [2] at (B).- Tighten the tensioning screw (3) toobtain a value of :
112 10 SEEM units.
- Tighten the screws (2) and (1).
- Fit the tool [2] at (C).- Tighten the tensioning screw (5) toobtain a value of :
115 10 SEEM units.
- Tighten the screw (4) to 2 m.daN.
Power steering
ENGINE
ENGINE
AUXILIARY EQUIPMENT DRIVE B
Without air co
Engines : DHX
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- Tension the belt by loosening the screw (4) to obtain 115 10 SEEM units
- Tighten the screws (1) and (3).
- Rotate the crankshaft by 4 turns (direction of rotation
- Loosen the screws (1) and (3).
- Tension the belt to :115 10 SEEM units (If necessary).
- Tighten the screws (1) and (3) to 2 m.daN.
AUXILIARY EQUIPMENT DRIVE BELTEngines : DHX
With air conditioning
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[1] Peg 7019-T
- Loosen the screws (1).
- Tighten or loosen the screws (2) until the holes a and b are s
- Place the peg [1] : (in hole a).
- Tighten the screw (2) to its stop.
- Loosen the screw (2), so as to remove the peg [1].
- Tighten the screws (1) to 2 m.daN.
B1BP1HGC B1BP1HHC
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AUXILIARY EQUIPMENT DRIVE BELTEngines : DJY - D8C - DHX (continued)
Alternator (with air condit
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- NOTE : If the vehicle is equipped with a power steering pump, rem
TENSIONING THE BE
- Tension the belt (5) by turning the screw (6).- Fit the tool [1].- Carry out a pretensioning of : 120 10 SEEM units.- Remove the tool [1].- Rotate the crankshaft 4 turns.- Fit the tool [1].- Slacken the screws (3) and (4).- Adjust tension using screw (6) to : 140 5 SEEM units.- Remove the tool [1].- Tighten screws (3) and (4) to 2 m.daN.- Run the engine for 10 min.- Check the tension of the belt (5).- Nominal value should not be less 100 SEEM units.
- If this is not the case, restart the tensioning operation.
B1BP1LFC B1BP04AC
ENGINE
ENGINE
AUXILIARY EQUIPMENT DRIVE BEngines : DJY - D8C - DHX (continued
Belt for power-assisted
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REMOVING TH
- To make it easier to move the pump, unclamp the hydraulic- Slacken the articulating screws of the pump.- Slacken the nut (2) to release the belt (1).
TENSIONING TH
- Tension the belt by turning the nut (2).- Fit the tool [1].- Pre-tension to : 70 10 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 u- Remove the tool [1].- Tighten the screws (3) and the pump articulating screws to- Run the engine for 10 min.- Fit the tool [1].
- Check the tension of the belt (1).- The value must not be less than 70 SEEM units- If this is not the case, restart the tensioning operation
AUXILIARY EQUIPMENT DRIVE BELT
Without power-assisted steering
Engines : WJZ
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Tools :
[1] Belt tension measuring instrument : 4122-T.
Removal.
- Loosen the screws (2).- Tighten the screw (1) until it is against its stop.- Remove the belt.
Refitting.- 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 m.daN.- Remove the tool [1].
B1BP1SDC
E
NGINE
E
NGINE
Without power-assisted steering/with air con
Engines : WJZAUXILIARY EQUIPMENT DRIVE BE
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Tools :
[1] Belt tension measuring instrument 4122-T.
Removal.
- Loosen the screws (1).- Tighten the screw (2) until it is against its stop.- Remove the belt.
Refitting.- Refit the belt.- Fit the tool [1] at "e".- Tighten the screw (2) to obtain : 115 10 SEEM uni- Tighten the screws (1) to 2 m.daN.- Remove the tool [1].
B1BP1SFC
AUXILIARY EQUIPMENT DRIVE BELT
Power-assisted stee
Engines : WJZ
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[1] Belt tension measuring instrumen
Removal.
WARNING : If the belt is to be reLoosen :- the screw (1).- the nut (2).
NOTE : The tensioner arm (3) must b
- Remove the belt.
B1BP1SHD
E
NGINE
E
NGINE
AUXILIARY EQUIPMENT DRIVE BE
Power-assisted stee
Engines : WJZ
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Refitting.- Refit the belt.- Place the tool [1] on belt at "fWARNING : Position tool [1],- tighten the nut (2) to obtain a Reused belt :
Keep the value taken at removNew belt :Tension should be 110 SEEM - Tighten the screw (1) to 9.5 m- Check belt tension (tool [1] ).Tension should be 144 3 SE- Remove the tool [1].- Start the engine and run it for- Stop the engine.- Place the tool [1] on the belt - Tension should be 130 4 S- Remove the tool [1].
B1BP1SJD
AUXILIARY EQUIPMENT DRIVE BELT
Power-assisted steering
Tools
Engines : WJZ
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Tools
[1] Dynamic tensioner peg (-) 0188[2] Belt tension measuring instrument 4122-T.
Removal.- Peg the dynamic tensioner (1) at "a", using tool
- 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) a- Peg the tensioner (1) at "a", using tool [1].NOTE : If the belt is broken :- Support the engine using a jack (insert a woode- Remove the right engine support.- Using a square drive at (b) turn the tool (3) in th
pegged at "a" using the tool [1].
B1BP1SKC
E
NGINE
E
NGINE
AUXILIARY EQUIPMENT DRIVE BE
Power-assisted steering
Engines : WJZ
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Refitting.
- Refit the belt.
- Using a 7 mm square drive at "b", turn thebecomes free.
- Tighten the screw (2).
- Remove the tool [1].
B1BP1SLC
AUXILIARY EQUIPMENT DRIVE BELTEngines : RHX - RHY - RHZ
Without
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[1] Belt tension adjusting square[2] 4 mm peg[3] 2 mm peg[4] Dynamic tensioner compression le
Remove
RE-UWARNING : Mark the direction the b
the same belt.- Compress the tensioner roller (2) by
tool [4].- Keep the tensioner roller (2) compre
NO RE
- Compress the tensioner roller (2) by tool [4].
- Peg using tool [2], at b.
- Hold the tensioner roller (2) compres- Loosen the screw (1).
E
NGINE
E
NGINE Engines : RHX - RHY - RHZ
Without
Refit.
AUXILIARY EQUIPMENT DRIVE B
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- Compress the tensioner rollertool [4].
- Refit the belt.
WARNING : Respect the direc
Remove the tool [4].
Refit the belt.- Turn the eccentric roller (3), to
at b .- Hold the eccentric roller (3), to- Remove the tool [2].- Rotate the crankshaft 4 times- Check that it is possible to pe
- If not possible to peg, restart t
AUXILIARY EQUIPMENT DRIVE BELTEngines : RHX - RHY - RHZ
With a
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[1] Belt tension adjusting square[2] 4 mm peg[3] 2 mm peg[4] Dynamic tensioner compression le
Remove
RE-UWARNING : Mark the direction the be- Compress the tensioner roller (7) by
tool [4].- Hold the tensioner roller (7) compres
NO RE- Compress the tensioner roller (7) by
tool [4].- Peg using tool [2], at d .- Loosen the screw (6)- Bring the eccentric roller (5) towards
- Tighten the screw (6) by hand.- Remove the belt.
E
NGINE
E
NGINE
AUXILIARY EQUIPMENT DRIVE BEngines : RHX - RHY - RHZ
With a
Refit.
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- Compress the tensioner rolletool [4].
- Refit the belt.
WARNING : Respect the direRemove the tool [4].
- Refit the belt.- Turn the eccentric roller (5), t
at d .- Hold the eccentric roller (5), t- Remove the tool [2].- Rotate the crankshaft 4 times- Check that it is possible to pe
- If not possible to peg, restart
AUXILIARY EQUIPMENT DRIVE BELT
REMOVING THE BELT
Engines : T9A - THX
Belt for alternator and power-assisted steering pump
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REMOVING THE BELT
- Slacken the screws (1) and the lock nut (2).- Turn the screw (3) (direction of tightening).- Remove the belt.
REFITTING THE BELT
- Pre-tighten the screws (1) of the tensioner to 1 m.daN.
TENSIONING THE BELT- Fit the tool [1].- Turn the screw (3) (direction of loosening) to tension the belt.
- The tension value should be 138 12 SEEM units.- Remove the tool [1].- Rotate the crankshaft by 3 turns (direction of rotation).- Fit the tool [1].- Adjust the tension using the screw (3) to 138 12 SEEM units.- Remove the tool [1].
B1BP1WCC B1BP03PC
E
NGINE
E
NGINE
AUXILIARY EQUIPMENT DRIVE BEEngines : T9A - THX (continued)
Water pump
Tension the belt (3) by turning the screw (2)
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- Tension the belt (3) by turning the screw (2).- Fit the tool [1].- Pre-tension to :
New belt : 62 SEEM units.Reused belt : 41 SEEM units.
- Remove the tool [1].- Rotate the crankshaft by 10 turns (direction of rotation).- Fit the tool [1].- Adjust the tension to obtain :
New belt : 62 SEEM units.Reused belt : 41 SEEM units.
- Remove the tool [1].
B1BP04DC B1BP04EC
CHECKING AND SETTING THE VALVE TIMING
1.1i
H K
1.4i 1.8i2.0i16V
2.0i 1.8D 1.9D1.9TD
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Engine type
C15
BERLINGO
DISPATCH
RELAY
See pages :
HDZ
DZ/GPL
HFX
KFX
FX/GPL
KFW
LFX
RFN
RFW
161A
DJY
D8C
DHX
X X
X X X X X X X
X
X X X X
117to
118
121to
125
119to
120126 127114 to 116
E
NGINE
E
NGINE
TOOLS- [1] Flywheel locating peg : 4507-T.A- [2] Camshaft pulley locating peg : 4507-T B
CHECKING AND SETTING THE VALVE
Engines : HDZ - HFX - KFX KFW
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[2] Camshaft pulley locating peg : 4507-T.B- [3] Square drive : 4507-T.J- [4] Belt tension measuring instrument : 4122-T- [5] Rocker plate : 4533-T.Z
CHECKING THE VALVE TIMING
- Peg the flywheel using the tool [1]- Peg the camshaft pulley [2].
SETTING THE VALVE TIMING
NOTE : Remove the spark plugs to ease the crankshaft rotat- Rotate the engine with the crankshaft screw (1).- Peg the camshaft pinion.- Peg the flywheel.- Loosen the nut (2).- Completely slacken the belt by turning the tensioner roller (- Remove the belt.
ESSENTIAL : Check that the tensioner roller rotates free
B1EP067C B1EP066C
CHECKING AND SETTING THE VALVE TIMEngines : HDZ - HFX - KFX - KFW (continued)
REFITTING THE TIMING NOTE : Check that the pegs [1] and [2] are in place.
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p g [ ] [ ] pWARNING : Ensure the belt is fitted in the right direction : Thetion of rotation.Fit :-The timing belt, with the belt strip b well tightened, in the followiCrankshaft pinion, camshaft pulley, water pump pulley, tensioner ro
-The tool [5] (Ensure it is fitted in the right direction in relation to th-Bring the tensioner roller into contact with the belt.-Tighten the nut (2).
PRE-TENSIONING THE TIMIN-Fit the tool [4] on the tightened belt strip b.-Loosen the nut (2).-Turn the roller (3) in an anti-clockwise direction using a square driv
44 SEEM units.-Tighten the nut (2) to 2.2 m.daN.-Remove the tools [1], [2] and [4].-Rotate the crankshaft by 4 turns in the normal direction of rotation
ESSENTIAL : Never turn the crankshaft backwards.
ENGINE
ENGINE
CHECKING AND SETTING THE VALVE
Engines : HDZ - HFX - KFX - KFW (contin
PRE-TENSIONING THE TIMING BELT (co
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(
-Ensure the timing is correctly set by refitting the pegs [1] and [2].-Remove the cylinder head cover.-Fit the tool [5] (Ensure it is fitted in the right direction in relation to the timing).
ADJUSTING THE BELT FITTING TENS
-Fit the tool [4] to the tightened belt strip.-Loosen the nut (2).-Slacken the belt (not excessively).-Tighten the timing belt to obtain :
29 and 33 SEEM units.-Tighten the nut (2) to 2.2 m.daN.-Remove the tools [1], [2], [4] and [5].
CHECKING THE BELT TENSION
-Rotate the crankshaft by 2 turns in the normal direction of rotation.-Check that the following components can still be pegged :-Flywheel.
-Camshaft.ESSENTIAL : If the components can not be pegged, repeat the belt tensioning proce
CHECKING AND SETTING THE VALVE TIM
Engine : L
TOOLS
B l i i i 4099 T 41
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- Belt tension measuring instrument : 4099-T ou 41- Camshaft pulley locating peg : 7004-T.G.- Crankshaft locating peg : 7014-T.N.- Square drive : 7017-T.W.
CHECKIN- Remove the protective covers.
- Peg the camshaft pulley at a, using tool 7004-T.G- Peg the crankshaft at b, using tool 7014-T.N.
SETTING THE VAL- Check that the pegs can be engaged correctly at a- Fit the belt in the following order : camshaft pulley, cr
pinion, tensioner roller.- Peg the camshaft pulley at a and the crankshaft a- Remove the peg at b only.- Bring the tensioner roller (2) into contact with the bel
B1EP07SC
ENGINE
ENGINE
CHECKING AND SETTING THE VALVE
Engine : L
SETTING TH
- Fit the tension measuring tool to the middle o
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Fit the tension measuring tool to the middle o- Turn the tensioner roller (2) (anti-clockwise d
to obtain the value 30 2 SEEM units.- Tighten the screw (1) to 2 m.daN.- Remove the tools.- Rotate the crankshaft by two turns (do not tu
- Check the setting by positioning the pegs at- Remove the pegs.
CHECKING
- Rotate the crankshaft by two turns (do not tu- Peg the camshaft pulley at a.- Fit the tension measuring tool on the belt stri- The tension measurement should be 44 2
(If the measurement is not correct, repeat the- Remove
B1EP07RC
CHECKING AND SETTING THE VALVE TIMI
Engine : RFW
TOOLS
[1] Camshaft pulley locating peg : 7004 - T.G[2] - Flywheel peg : 7014 - TN
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B1EP01TC B1BP1WHC
[2] Flywheel peg : 7014 T.N [3] - Timing belt tensioning key : 7017 - T.W[4] - Toothed sector for locking the flywheel : 6012 - T [5] - Belt tension measuring instrument : 4122 T
CHECKING- Turn the engine by the crankshaft screw (do not turn backwards)- Peg the crankshaft using the tool [2].- If the timing is not correct, repeat the operation.
SETTING THE VALVE TIMING- Peg the crankshaft using tool [2], and the camshaft pulley using t- Lock the flywheel with the tool [4].ESSENTIAL : Remove the tools [1] and [2] when tightening the- Remove the screws (1) and the pulley.- Remove the tool [4].- Check that the camshaft pulley and the crankshaft pinion are corr- Loosen the tensioner roller screw.
- Remove the belt.
ENGINE
ENGINE
CHECKING AND SETTING THE VALVE TIMING
SETTING THE VALV
Belt fitting dire- Arrows in the direction of rotation.
Engine : RFW (c
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- Paint marks opposite pinion marks.
- Fit the belt on the : camshaft pulley, crankshaft pinion, water
NOTE : Ensure that the belt is correctly positioned in the groo
TENSIONING TH
- 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 tigh
- 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
- If the value is outside these limits, restart the operation.- Remove the tools.
TOOLS
[1] Camshaft setting pegs : (-).0189.A[2] Crankshaft setting peg : (-).0189.B
CHECKING AND SETTING THE VALVE TIMI
Engine : RFN
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[ ] g p g ( )[3] Belt locking pin : (-).0189.K Tool [4] Angular tightening adaptor : 4069-T.[5] Hub immobilising tool : 6310-T
CHECKING THE VALVE T
- Turn the engine by the crankshaft pinion screw (3) to bring it to pe- Peg the crankshaft, using tool [2].- Peg the camshaft pulleys, using tools [1].
NOTE : The pegs [1] must go in without effort.
MO
TEUR
CHECKING THE VALVE TIM
CHECKING AND SETTING THE VALVE
Engine : RFN
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WARNING : If the pegs do not engage without effort, restabelow).
SETTING THE VAL
Remove
- Remove the screws (2), the pulley (1), upper valve cover (4- Turn the engine by the screw (13) of the pinion (12) to bring- Peg the pulleys (8) and (9) using tools [1].- Peg the pinion (12) using tool [2].- Loosen the screw (7) of the tensioner roller (6).- Turn the tensioner roller (6) (clockwise).- Remove the timing belt (10).
REFIT (continued)-Refit the belt (10) on the pinion (12).-Hold the belt (10) with tool [3].Position the belt (10) in the following order :
CHECKING AND SETTING THE VALVE TIMI
Engine : RFN
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-Position the belt (10) in the following order :-The guide roller (11), the inlet camshaft pinion (9), the exhaust camsioner roller (6).NOTE : Make sure that the belt (10) is as flush as possilble with the-Remove the tools [3] and [1].
TIMING BELT TENSIOAdjusting the tension-Turn the roller (6) in the direction of the arrow b; using an Allen k-Position the index c in its maximum setting at d.IMPERATIVE : The index c must stand proud of the notch freplace the tensioner roller (6) or the timing belt and the tensioBring the index c to its adjusting position f by turning the tensioWARNING: The index c must not stand proud of the notch f : iration.IMPERATIVE : The tensioner roller (6) must not turn while its fixmence the adjusting operation.
MO
TEUR
Adjusting the tension (continued).-Tighten the screw (7) of the the tensioner roller (6) to 2.1 0IMPERATIVE : The hexagonal drive of the tensioner rollerhead gasket g If not replace the tensioner roller (6) or
CHECKING AND SETTING THE VALVE
Engine : RFN
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head gasket g. If not, replace the tensioner roller (6) or
Refit (continued).- Remove the tools [1] et [2].- Turn the crankshaft 10 times in the normal direction of rotatIMPERATIVE : No pressure or outside action must be bro
- Peg the inlet camshaft pulley, using the tool [1].
CHECKSTIMING BELT TE
IMPERATIVE : Check the position of the index c, it shindex c is not correct, restart the adjustment of its pos
Positioning of the crankshaft- Fit tool [2].- As long as it is possible to fit tool [2], continue with the refit IMPERATIVE : If it is not possible to fit tool [2], reposition
CHECKS (continued).
R iti i th fl
CHECKING AND SETTING THE VALVE TIMI
Engine : RFN
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Repositioning the flange- Immobilise the crankshaft using tool [5].- Loosen the screw (13).- Release the pinion (12) of the crankshaft.- Bring the flange (14) to the pegging position; using tool [5].
- Fit the tool [2].- Immobilise the crankshaft using tool [5].- Tighten screw (13) to 4 0.4 m.daN, then angular tighten 53 4- Remove tools [1], [2] and [5].
Refit :- The lower valve cover (3).- The upper valve cover (4)- The crankshaft pulley b- The screws (2).- Pretighten the screws (2) to 1.5 m.daN.- Tighten the screws (2) to 2.1 0.5 m.daN
MO
TEUR
CHECKING AND SETTING THE VALVE
Engine : 161 A
T- Flywheel locating peg- Injection pump and camshaft locating peg
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CH- Peg the crankshaft.- Peg the camshaft at a and the injection pum
SETTING TH- Peg the crankshaft.- Peg the camshaft at a and the injection pum- Fit the belt in the following order :Crankshaft pinion, guide roller (3), injection pumtensioner roller (5), water pump (4).- Remove the pegs.- Free the tensioner roller (5) (nut (6) and screw- Rotate the crankshaft by 2 turns. Do not turn - Loosen the tensioner roller (5), allow the tensio- Retighten the screw (7) and the nut (6). Tighten- Check the setting.NOTE : The injection pump is removed without c
(immobilise the injection pump pulley usB1EP09KC B1EP080C
CHECKING AND SETTING THE VALVE TIM
Engine : WJZ
TOOLS
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- [1] HM screw : (-) 0 188 E- [2] Locating peg 6 mm : (-) 0 188 H- [3] Flywheel locating peg : (-) 0 188 D (or 7- [4] Toothed sector for locking the flywheel : (-) 0 188 F- [5] Belt retaining clip : (-) 0 188 K
- [6] Square drive for adjusting the tension : (-) 0 188 J- [7] Belt tension measuring instrument : 4122-T- [8] Toothed sector for locking the flywheel : 6016-T
CHECKING THE VALVE TI
- Peg the flywheel using tool [3].- Visually check that the offset between the camshaft and injection
pegging holes does not exceed 1 mm.
B1CP045C
MO
TEUR
CHECKING AND SETTING THE VALVE
Engine : WJZ
Setting the valve timing
Peg :
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- The camshaft hub (1), using tool [1].- The injection pump pinion (2), using tool [2].- The flywheel, using tool [3].
- Lock the flywheel, using tool [4].
- Refit the screw (3) (without tightening it). (Coat the threads- Tighten the screw (3) to 4 m.daN and finish by carrying ou
tightening of 60.- Remove the tool [4].- Retighten screws (4) and (5) by hand.- Turn the pinions (6) and (2) so that they are at the end of t
(Clockwise direction).- Place the belt on the crankshaft and hold in place using too- Fit the belt in the following order:
Roller (7), pinion (2), pinion (6), pump (8) and roller (9).
B1EP131CB1EP130C
CHECKING AND SETTING THE VALVE TIM
Engine : WJZ
Setting the valve timing (continued)
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NOTE : If necessary, slightly turn pinions (6) and (2) in an anti-clockin order to fit the belt.The angular movement of the belt in relation to the pinions mu1/2 tooth.
- Fit the tool [7] to the belt strap at "a".- Turn the roller (9) (anti-clockwise) using tool [6], to obtain:
106 2 SEEM units.- Check that pinions (6) and (2) are not at the end of their stops.Otherwise, repeat the belt fitting procedure from the beginnin
Tighten:- The roller (9) to 4.5 m.daN.- The screws (4) and (5) to 2.5 m.daN.- Remove the tools [7], [5], [1], [2] and [3].
B1EP134C B1CB1EP133C
MO
TEUR
CHECKING AND SETTING THE VALVE
Engine : WJZ
Setting the valve timing (continued)
Rotate the crankshaft by 8 turns (direction of rotation).
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Peg :- The hub (1), using tool [1].- The pinion (2), using tool [2]- The flywheel, using the tool [3].
Loosen :- The screws (4) and (5).- The roller (9).- Retighten screws (4) and (5) by hand.- Fit the tool [7] to the belt strap at "a".- Turn the roller (9) (anti-clockwise direction) using tool [6], t
42 2 SEEM units.
B1EP134CB1EP133C
CHECKING AND SETTING THE VALVE TIM
Engine : WJZ
Setting the valve timing (continued)
Tighten :Th ll (9) 2 1 d N
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- The roller (9) to 2.1 m.daN.- The screws (4) and (5) to 2.3 m.daN.
- Remove the tool [7].- Fit the tool [7] to the belt strap at "a".
- The tensioning value should be between 42 2 SEEM units.
ESSENTIAL : If the value obtained is outside the set limits, rsioning operation.
- Remove the tools [7], [5], [1], [2] and [3].- Rotate the crankshaft by 2 turns (direction of rotation).
- Check the valve timing.
B1EP134CB1EP133C B1
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CHECKING AND SETTING THE VALVE TIM
Engine : RH
Setting thePeg :
The engine fl heel tool [3]
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- The engine flywheel, tool [3].- The camshaft, tool [5].Loosen :- The three screws (9).- The screw (7) of the tensioner roller (6).
Remove the timing belt.
Checks.
IMPERATIVE : Just before refitt
Check that :
- The rollers (6), (11) and the water pump (1- There are no traces of oil (on camshaft or c
MO
TEUR
CHECKING AND SETTING THE VALVE
Engine : RHY - RHX - RHZ
Setting the valve timing (continued).
- Retighten screws (9) by hand.- Turn the pinion (12) (clockwise) to the bottom
the buttonhole
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the buttonhole.- Refit the belt on the crankshaft, in the follow
order, using the tool [4] to keep the belt tight 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)clockwise (not by more than one tooth).
- Remove the tool [4].
B1EP13FCB1EP13ED
Setting the
- Position tool [1] on the belt at- Turn the roller (6) (anti-clockw
CHECKING AND SETTING THE VALVE TIM
Engin
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- Tighten screw (7) of the roller- Remove one screw (9) from th
(to check that the screws are n
- Tighten the screws (9) to 2 m - Remove tools [1], [2], [3] and- Rotate the crankshaft 8 times- Fit the tool [3].- Loosen screws (9).- Fit tool [5].- Loosen screw (7) (to free the r- Fit tool [1].- Turn the roller (6) (anti-clockw
MO
TEUR
CHECKING AND SETTING THE VALVE
Calage de la distr
Tighten :- The screw (7) of the ro- The screw (9) to 2 m d
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- The screw (9) to 2.m.d- Remove the tool [1].- Refit the tool [1].- Tension value should b
IMPERATIVE :
- Remove tools [1], [3] a- Rotate the crankshaft 2- Fit the tool [3].
WARNING : Should the offset between tnot more than 1 mmIn the case of an inc
- Remove the tool [3].
CHECKING AND SETTING THE RELAY 2.5 D
TOOLS
[5] Belt tension measuring instrument : 4122 - T
Engine : T9A
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[1] Flywheel peg : 7014 - T.J
[2] Camshaft pulley locating peg : 5711 - T.A
[3] Injection pump pulley locating peg : 5711 - T.B
[4] Tensioning lever : 5711 - T.E
CHECKS
- Peg the flywheel using tool [1], at (a) at the front or (b) at the bac
- Visually check the pegging of the :
The camshaft pulley.
The injection pump pulley.
- If the results of the visual check are not satisfactory, set the valve
9
MOTEUR
CHECKING AND SETTING THE VALVE
SETTING THE VALV
Removing the
Turn the crankshaft (direction of rotation)
Engine : T9A (c
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- Turn the crankshaft (direction of rotation).
- Peg the flywheel.
- Peg :
The camshaft pulley using tool [2].
The injection pump pulley using tool [3].
NOTE : BOSCH injection pump, 9.5 mm peg - LUCAS DIE
- Loosen :
The screws (1) using tool 6016 - T.
The screws (2).
- Tighten the screws (1) and (2) by hand and slacken by 1/6
- Slacken the nut (3).
- Remove the belt.
CHECKING AND SETTING THE VALVE TIMIN
SETTING THE VALVE TIM
Refitting the belt- Refit in the following order : crankshaft pinion (hold), guide roller, i
(t th ll th t th l t t th b lt)
Engine : T9A (continu
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(turn the pulley on the tooth closest to the belt).
Tensioning the belt
- Fit the tool [5].- Pre-adjust the tension using the tool [4] (tension adjusting spanne
- Adjust the tension to : New belt to 107 SEEM units. Reused belt to 80 SEEM units- Tighten the tensioner roller to 4.5 m.daN.
Checking the fitting pre-te
- Correct the tension, if necessary, using the tool [5].- Tighten the screws (1) and (2) pre-tighten to 1 m.daN, tighten to 2- Remove all the tools.- Rotate the engine through 10 turns.- Peg the flywheel using the tool [1] (direction of rotation).
- Loosen the screws (1) and (2).
MOTEUR
CHECKING AND SETTING THE VALVE
SETTING THE VAL
Checking the fitting
- Tighten the screws (1) and (2) by hand, then loosen by 1/6- Slacken the belt completely (using the tensioner roller).
Engine : T9A (co
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p y ( g )- Peg : the camshaft pulley using the tool [2] and the injectio- Fit the tool [5].- Adjust the belt tension using the tool [4] to :
New belt to 58 SEEM units
Reused belt to 51 SEEM units- Tighten the roller to 4.5 m.daN.
Checking the fittin
- Remove the tool [5] (make any necessary correction).- Tighten the screws (1) and (2) pre-tighten to 1 m.daN, tight- Remove the tools.- Rotate the engine through 2 turns.
Checks
- Peg the flywheel using the tool [1].- Visually check the pegging of the camshaft and injection pu- If incorrect, repeat the setting operation.- Remove the tools.
CHECKING AND SETTING THE VALVE TIM
TOOLS
[1] Flywheel peg : 7014-T[2] Camshaft pulley locating peg : 5711-T[3] Injection pump pulley locating peg 9.5 mm : 5711-T
Engine : THX
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[4] Pinion locking tool : 6016-T[5] Belt tension measuring instrument : 4122-T[6] Tensioning lever : 5711-T[7] Tensioning locking pin : (-) 017[8] Belt retai