(2001) Berlingo c15 Jumper Jumpy

UTILITY VEHICLES
2001
U
T
I
L
I
T
Y

V
E
H
I
C
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S
CAR 050009
2001
AC.QCAV/MTD
Mthodes Techniques Documentation
The intellectual property rights relating to the technical information in this document belong exclusively
to the manufacturer. Reproduction, translation or distribution in whole or in part without prior written autho-
risation from the manufacturer is forbidden.
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 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.
PRESENTATION
THIS HANDBOOK summarises the characteristics, adjustments, checks and special features of CITROEN vehicles, not including PRIVATE CARS for
which there exists a separate handbook.
The handbook is divided into nine sections representing the main functions :
GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING, BRAKES - HYDRAULIC
SYSTEMS - ELECTRICAL - AIR CONDITIONING.
In each section, the various vehicles are dealt with in the following order: C15 - BERLINGO - BERLINGO FAMILIALE - DISPATCH - RELAY and all
models where applicable.
This handbook applies only to vehicles 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 :
CITRON VK Ltd
221 Bath Road
SLOUGH
SLI 4 BA
LPG safety recommendations 155 to 161
DELPHI checking, timing 168 to 178
BOSCH checking, timing 179 to 200
IGNITION
Sparking plugs 201
CLUTCH-GEARBOX-TRANSMISSION
Speedometer 202
Clutch, checking/adjusting 206 to 211
Driveshafts 245
AXLES-SUSPENSION-STEERING
C15 246 to 248
BERLING0 253 to 257
DISPATCH 267 to 269
RELAY 275
BRAKES
C15 281
BERLINGO 286 to 287
DISPATCH 294 to 295
RELAY 299 to 300
C15
Handbrake 284
Bleed of brakes 285
BERLINGO
Handbrake 292
Bleed of brakes 293
DISPATCH Handbrake 296 to 298
Handbrake 303
RELAY
Bleed of brakes 304
ELECTRICAL
Starter motors 305 to 308
Alternators 309 to 315
Preheating system 316
AIR CONDITIONING
R 134a quantity 318
Special features 319 to 323
Temperature checks 324 to 326
Pressure checks 327 to 330
BERLINGO air conditioning 331 to 333
DISPATCH air conditioning 334 to 336
RELAY air conditioning 337 to 338
INDEX
GENERAL
C15 1 to 2
BERLINGO 3 to 12
DISPATCH 13 to 17
RELAY 4x2 18 to 37
RELAY 4x4 38 to 44
C15 46
BERLINGO 47
DISPATCH-RELAY 48 to 49
Lubricants 50 to 64
ENGINE
Specifications 65 to 67
Cyl. head marking and 72 to 85
Auxiliary equipment drive 86 to 112
Checking the valve timing 113
Valve clearances 145
Oil pressure checks 146
Oil filters 149
INJECTION
Petrol injection 151 to 152
Idling, anti-pollution 153 to 154
Identification
of
vehicles
Capacities
Axle
geometry
Brake
specifications
1
G
E
N
E
R
A
L
C15 - All Types IDENTIFICATION OF VEHICLES
E1AP079D
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.
6 Model year
7 Gearbox ident. code
8 Engine plate.
G
E
N
E
R
A
L
22
IDENTIFICATION OF VEHICLES C15 All Types
Version (1) (2) (3) (1) (2)
Payload (kg) 600 765 600 765
Emission standard W3 W4
Type approval no. VD PB VD PP VD SX VD WT VD VV VD VW VD VY
Engine type 161 A WJY
Cubic capacity (cc) 1769 1868
Fiscal rating (hp) 7
Gearbox type BE3/5
Gearbox ident. 20 TE 11 (*)
1.9 D 1.8 D
(1) Standard van
(2) Deepened cab
(3) Familiale
(*) = Strengthened gearbox.
G
E
N
E
R
A
L
33
BERLINGO All Types IDENTIFICATION OF VEHICLES
1 Chassis stamp
2 Manufacturers name plate
3 Supplementary plate
4 Weights label
5 01/02/99 # Label :
- Tyre pressures.
- Paint code.
6 Paint code
8 Gearbox ident. Reference
9 Engine legislation type
E1AP07AD
G
E
N
E
R
A
L
44
W3 W4 W3
MA HDZF MB HDZF MA HFXB MB HFXB MA HDZF/MOD GL MB HDZF/MOD GL
HDZ HFX HDZ
1124
6
MA/5
20 CD 42 # 09/2000 20 CN 01 09/2000 #
Emission standard
Type approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
Payload (kg)
IDENTIFICATION OF VEHICLES BERLINGO All Types
Petrol
1.1 i
Dual fuel
A A B B A B
600 475 600 475 600 475
5
G
E
N
E
R
A
L
Dual fuel
600 800 600 800 600 800
K' W3 W4 W3
MB KFXG MB KFXF MC KFXF MB KFWB MC KFWB MB KFXF/MOD GL MC KFXF/MOD GL
KFX KFW KFX
1360
8
MA/5
20 CD 74 # 09/2000 20 CN 14 09/2000 #
Petrol
1.4 i
B
Emission standard
Type approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
Payload (kg)
G
E
N
E
R
A
L
66
W3 W4
MB WJZC MB WJZF MC WJZF MB WJYP MB WJYB MC WJYB
WJZ WJY
1868
7
BE3/5
20 TE 22 20 TE 20 20 TE 50 20 TE 49
Emission standard
Type approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
Payload (kg)
Diesel
1.9 D
A B A B
600 600 800 800
7
G
E
N
E
R
A
L
Diesel
B
Emission standard
Type approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
Payload (kg) 600 800 600 800
W3 W4
MB RHYF MC RHYF MB RHYB MC RHYB
RHY
1997
6
BE3/5
20 TE 27
G
E
N
E
R
A
L
88
600 800 600 800
W3 W4 W3 W4 W3
MA HDZV MA HFXB MB WJZF MB WJYB MC KFXF MB WJZF MC WJZF
HDZ HFX WJZ WJY KFX WJZ
1124 1868 1360 1868
6 7
MA/5 BE3/5 MA/5 BE3/5
20 CN 01 20 TE 20 20 TE 49 20 CN 01 20 TE 20
C K D Postvan version
Diesel Diesel Petrol Petrol
1.1i 1.9 D 1.4i 1.9 D
A B B
Emission standard
Type approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
Payload (kg)
9
G
E
N
E
R
A
L
Floor cab
800
W3 W4 W3 W4 W3 W4
ME KFXF ME KFXB ME WJZF ME WJYB ME RHYF ME RHYB
KFX KFW WJZ WJY RHY
1360 1868 1997
7
MA/5 BE3/5
20 CN 14 20 TE 20 20 TE 49 20 TE 27 20 TE 49
Emission standard
Type approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
Payload (kg)
Version
IDENTIFICATION OF VEHICLES
Diesel Petrol
1.9 D 2.0 HDi 1.4i
B B
BERLINGO All Types
G
E
N
E
R
A
L
10 10
L3/W3 L4/W4 K' L3/W3 L4/W4
MF HDZF MF HFXB MF KFXG MF KFXF MF KFXF/A MF KFWB
HDZ HFX KFX KFW
1124 1360
5 6
MA/5
20 CN 43 # 09/2000
20 CN 12 20 CN 13 20 CN 12
20 CN 02 09/2000 #
Emission standard
Type approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
Petrol
1.4i 1.1i
X X X-SX Multispace X-SX
BERLINGO All Types
11
G
E
N
E
R
A
L
L4/W4 L3 L3/W3
MF KFWB/A MF KFXF/MOD GL MF KFXF/MOD GL MF LFXF MF LFXF/A
KFW KFX LFX
1360 1761
6 7
MA/5 BE3/5
20 CN 13 20 CN 12 20 CN 13 20 TE 25 20 TE 26
Emission standard
Type approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
Petrol
1.8 i 1.4 i
Dual fuel
SX Multispace Multispace X Multispace
G
E
N
E
R
A
L
12 12
Emission standard
Type approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
L3/W3 L4/W4 L3/W3 L4/W4
MF WJZF MF WJZF/A MF WJYB MF WJYB/A MF RHYF MF RHYF/A MF RHYB MF RHYB/A
WJZ WJY RHY
1868 1997
5 6
BE3/5
20 TE 22 20 TE 24 20 TE 49 20 TE 24 20 TE 28 20 TE 29 20 TE 28 20 TE 29
Diesel
1.9 D 2.0 HDi
X-SX Multispace X-SX Multispace
Multispace Multispace
G
E
N
E
R
A
L
13
1 Vehicle identification N..
3 Paint code.
4 Manufacturers plate.
5 Engine type.
6 Gearbox ident. Reference.
7 01/02/99 # Label :
- Tyre pressures.
- Paint code.
DISPATCH - All
E1AP07BD
G
E
N
E
R
A
L
14 14
(*) = Fiscal incentive L5 (EURO 4)
Version
Emission standard
Type approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
(1) (2)-(3) (4) (5) (6)
IF L5 (*)
BA RFNC/IF BZ RFNC/IF BA RFNC/IF BE RFNC/IF BX RFNC/IF
RFN
1997
BE4/5 AL4 BE4/5
20 DL 26 20 DL 27 20 TP 31 20 DL 26 - 20 DL 27
IDENTIFICATION OF VEHICLES DISPATCH All Types
Petrol
2.0i 16V
AUTO AUTO
Confort
(1) = Mixed van (short).
(2) = Panel van (short).
(3) = Glazed van (short).
(4) = Combi 5-seater.
(5) = Combi 9-seater.
(6) = Floor cab.
15
G
E
N
E
R
A
L
(1)-(4) (2) (3) (7)-(8) (5) (6) (9)
W3
BA WJZA BZ WJZA BT WJZA BE WJZA BX WJZA BV WJZA
WJZ
1868
7 6
BE4/5
20 DL 33 20 DL 34 20 DL 35 20 DL 36
DISPATCH All Types IDENTIFICATION OF VEHICLES
Diesel
1.9 D
Standard
Confort Confort
Emission standard
Type 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
G
E
N
E
R
A
L
16 16
(1)-(4) (2) (2)-(3) (7)-(8) (5) (6) (9)
W3
BA RHXA (*) BZ RHXA BY RHXA BS RHXA BE RHXA BW RHXA BU RHXA
RHX
1997
8
ML/5
20 LE 93
DISPATCH All Types IDENTIFICATION OF VEHICLES
Diesel
2.0 HDi
Confort
Emission standard
Type 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).
17
G
E
N
E
R
A
L
(*) = With DVA (Double damped flywheel)
(1) = Mixed van (short).
(1) (4) (5)
L3
BA RHZA BE RHZA
RHZ
1997
7
ML/5
20 LE 91 (*) 20 lE 91
Emission standard
Type approval no.
Engine type
Cubic capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
Version
DISPATCH All Types
Diesel
2.0 HDi
G
E
N
E
R
A
L
18 18
5 Vehicle identification N.
6 Bodyshell N.
SPECIFICATIONS - IDENTIFICATION ( 4 x 2 )
Identification Manufacturers name plate
1 Gearbox identification reference.
3 Engine plate
4 Paint code
1 VIN N
2 Gross vehicle weight.
3 Gross train weight.
4 Max. weight on front axle.
5 Max. weight on rear axle.
E1-P02WC E1-P02UD
RELAY 4 X 2 All Types
19
G
E
N
E
R
A
L
ENGINE
1
2
3
4
5
8
B
C
H
XU102CU
XU10J2U
XUD9AU
DJ5TED
DJ5
XUD9UTF
2.8D (*)
2.8 TD (*)
2.0HDi (*)
WHEELBASE
1
2
3
4
Short (2.85m)
Medium (3.20m)
Long (3.70m)
Superlong (4.05m)
BODY
A
B
C
D
E
F
G
H
J
K
L
N
U
V
COMBI VERSION
/D
/E
/G
/H
VERSION CHASSIS
1
2
TRANSMISSION
2
4
VAN VERSION
1
B
C
FAMILY
23
RELAY 4 x 2 All Types SPECIFICATIONS - IDENTIFICATION ( 4 x 2 ) (continued)
Type approval no. (Example) 2 3 2 G 5 2 / 2
U 3
VAN 9 Q 10 Q
VAN 14 Q
COMBI 10 Q
MINIBUS 18 Q
CHASSIS 10 Q
FLOOR 10 Q
CHASSIS 14 Q
PLATFORM 14 Q
VAN 18 Q
CHASSIS 18 Q
PLATFORM 18 Q
FLOOR 18 Q
PLATFORM 10 Q
COMBI 14 Q
5 GEARS
4X4
HIGH-SIDED
DEEPENED
CAB
REDUCED GROSS
LADEN WEIGHT
DOUBLE CAB
BARE CHASSIS
CONFORT 5/9-seater
CLUB High-sided 8/9-seater
CONFORT High-sided 5/9-seater
(*) = SOFIM engine
NOTE : BODYWORK in A (VAN 9Q 10Q) 9Q = Van version Reduced Gross laden weight
EXAMPLE : 232G52/2 = Bare chassis medium, 2.5 diesel engine, 5-speed gearbox.
G
E
N
E
R
A
L
20 20
Wheelbase Interior
Payload
height
9 Q 10 Q 14 Q 18 Q
1.56 m 25C/250C 27C/270C 31C/310C 35C/350C
Short : 2.85 m 1.88 m 25 CH/250CS 27CH/270CS 31CH/310CS 35CH/350CH
2.11 m 27CS/270CH
1.56 m 27M/270M 31M/320M 35M/350M
Medium : 3.20 m 1.88 m 31MH/320MH 35MH/350MH
2.11 m 35MS/350MHS
1.56 m 31L/320L 35L/350L
Long : 3.70 m
1.88 m 31LH/320LH 35LH/350LH
Super long : 4.05 m 1.56 m 31XL/320XL 35XL/350XL
RELAY 4 x 2 - All Types SPECIFICATIONS - IDENTIFICATION ( 4 x 2 ) (continued)
Commercial type
21
G
E
N
E
R
A
L
(1) (2) (3) (6) (1) (2)
27 31
C/CH M C M C/CH M/MH LH MH/LH MH
231A22 232A22 231C22/D 231C22/D 232E22 231B22 232B22 233B22
232B22 (*)
232V22/E
MODGNV
W3 L3 W3 W3 L3
RFW
1998
10 11 10 10 9
ML/5
20 UE 02
RELAY 4 x 2 All Types IDENTIFICATION OF VEHICLES
2.0i
I) (1) Panel or glazed van
(2) Combi club
(3) Combi confort
(6) Chassis cab.
II 27 = 10Q
31 = 14Q
III (See Commercial type, page 20)
(*) GNV = CNG (Commercial Natural Gas)
I
II
III
Type approval no.
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
G
E
N
E
R
A
L
22 22
(3) (6) (7) (8) (9)
31
C M C M L C M L
231V22/D 232V22/D 231G22 232G22 233G22 233G22/D 231H22 232H22 233H22 233H22/1
L3 W3
RFW
1998
9 10
ML/5
20 UE 02
2.0i
I) (3) Combi club
(6) Chassis cab.
(7) Chassis double cab.
(8) Platform cab.
(9) Platform double cab.
II 31 = 14Q III (See Commercial type, page 20)
I
II
III
Type approval no.
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
23
G
E
N
E
R
A
L
(10) (1) (4) (5) (6) (7) (8)
31 35
M MH/MS LH MH LH M L M
232F22 232J22 2333J22
232J22/ 233B22/
(*)
MODGNV MODGNV 233V22 232K22 233K22 233G22/1 232N22
(**) (**)
W3
RFW
1998
10
ML/5 MG/5
20 UE 02 20 KM 69
2.0i
I) (1) Panel or glazed van.
(4) Minibus.
(5) Minibus 15-seater.
(6) Chassis cab.
(8) Platform cab.
(10) Floor cab.
II 31 = 14Q
35 = 18Q
(*) = With or without side door
(**) GNV = CNG (Commercial Natural Gas)
I
II
III
Type approval no.
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
G
E
N
E
R
A
L
24 24
(8) (10)
35
L M L
233L22 232N22 233N22
233N22/
MODGNV (*)
W3
RFW
1998
10
MG/5
20 KM 69
2.0i
I) (8) Platform cab.
(10) Floor cab.
(*) GNV = CNG (Commercial Natural Gas)
I
II
III
Type approval no.
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
25
G
E
N
E
R
A
L
(1) (2) (3)
25 27
C/CH M C M
231A32/C
231A32 232A32 231C32/D 232C32/D 232E32
(*)
W3 L3 W3
DJY
1905
6
ML/5
20 UE 02
1.9 D
(2) Combi confort.
(3) Chassis cab.
II 25 = 9Q # (*) /C = Van version "Reduced Gross laden weight"
27 = 10Q III (See Commercial type, page 20)
I
II
III
Type approval no.
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
G
E
N
E
R
A
L
26 26
(1) (2) (4) (2) (3)
27 31 27 31
C/CH M C/CH M/MH C M C M L
231A82 232A82 231B82 232B82 231C82D 232C82D 232E82 231G82 232G82 233G82
(8) (3)
31 27
L C
233G82/1 231E82
W3 L3 W3
DHX D8C
1905
8
ML/5
20 UE 01
1.9 TD
II 27 = 10Q
31 = 14Q
I
II
III
I
II
III
Type approval no.
Type approval no.
Version
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
(2) Combi confort.
(3) Chassis cab.
(4) Combi club
(5) (6) (7)
27 31
C M L M/MH L/LH
231U82 231H82 232H82 233H82 233H52/1 232F82 233F82
W3
DHX
1905
6 8
ML/5
20 UE 02
27
G
E
N
E
R
A
L
1.9 TD
(7) Floor cab.
II 27 = 10Q
31 = 14Q
I
II
III
Type approval no.
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
G
E
N
E
R
A
L
28 28
(1) (2) (1) (2) (6)
27 31
C/CH M C C/CH M/MH LH C M/MH C M
231A52 232A52 231C52/D 231B52 232B52 233B52 231V52/D 232V52/D 231G52 232G52
(6) (8) (6) (7) (8)
27 31
C L XL M L C M L
231E52 231U52 233G52 234G52 232G52/1 233G52/1 231H52 232H52 233H52
W3 L3 W3
T9A
2446
8
ML/5
20 UE 00
2.5 D
II 27 = 10Q
31 = 14Q
I
II
III
I
II
III
Type approval no.
Type approval no.
Version
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
(2) Combi confort.
(6) Chassis cab.
(8) Platform cab.
29
G
E
N
E
R
A
L
(9) (10) (11)
31
M L C M/MH L/LH L XL
232H52/1 233H52/1 231F52 232F52 233F52 233G52/2 234G52/2
W3
T9A
2446
8
ML/5 MG/5 ML/5
20 UE 00 20 KM 74 20 UE 00
2.5 D
I) (9) Platform double cab.
(10) Floor cab.
(11) Bare chassis.
I
II
III
Type approval no.
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
G
E
N
E
R
A
L
30 30
(1) (3) (4) (5) (6) (7) (8)
35
C/CH MH/MS LH (*) - LH/LS LH M L XL L M L
231J52 232J52 233J52 233V52 232K22 233K52 234K52 233G52/1 232N52 233L52
(9) (10) (11)
35
L M/MH L/LH XL
233L52/1 232N52 232N52 234G52/2
W3
T9A
2446
8
MG/5
20 KM 73
2.5 D
II 35 = 18Q
III (See Commercial
type, page 20)
I
II
III
I
II
III
Type approval no.
Type approval no.
Version
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
(3) Minibus.
(4) Public transport 16-seater.
(6) Chassis cab.
(8) Platform cab.
(10) Floor cab.
(11) Bare chassis.
31
G
E
N
E
R
A
L
(1) (2) (1) (2) (3)
27 31
C/CH M C C/CH M/MH M LH MH C M/MH
231A42 232A52 231C42/D 231B42 232B42 232B42 233B42 232V42/E 231V42/D 232V42/D
(3) (7) (9) (7) (8) (9)
27 31
C C M L XL M L C
231C52/D 231E42 231U42 231G42 232G42 233G42 234G42 232G42/1 233G42/1 231H42
W3
THX
2446
8
MG/5
20 KM 74
2.5 TD
II 27 = 10Q
31 = 14Q
I
II
III
I
II
III
Type approval no.
Type approval no.
Version
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
(2) Combi club.
(3) Combi confort.
(7) Chassis cab.
(9) Platform cab.
G
E
N
E
R
A
L
32 32
(9) (10) (11) (12)
31
M L M L C M/MH L/LH C M
232H42 233H42 232H42/1 233H42/1 231F42 232F42 233F42 231G42/2 232G42/2
W3
THX
2446
8
MG/5
20 KM 74
2.5 TD
(11) Floor cab.
(12) Bare chassis.
I
II
III
Type approval no.
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
(1) (4) (5) (6) (7)
35
C/CH M/H MS LH LH (*) LS LH M
231J42 232J42 232J42 233J42 233J42 233V42 233V42 233V42 232K42 232K42
(7) (8) (9) (10) (11) (12)
35
L XL L M L M/MH L/LH M L
233K42 234K42 233G42/1 232N42 233L42 233L42 232N42 233N42 232K42/2 233K42/2
W3
THX
2446
8
MG/5
20 KM 75
33
G
E
N
E
R
A
L
2.5 TD
II 35 = 18Q
III (See Commercial
type, page 20)
I
II
III
I
II
III
Type approval no.
Type approval no.
Version
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
(4) Minibus.
(7) Chassis cab.
(9) Platform cab.
(11) Floor cab.
(12) Bare chassis.
G
E
N
E
R
A
L
34 34
(1) (2) (1) (2) (3)
27 31
C/CH M C C/CH M/MH M LH MH C M/MH
231AH2 232AH2 231CH2/D 231BH2 232BH2 232BH2(*) 232BH2 232CH2/E 231VH2/D 231VH2/D
(3) (7) (9) (7) (8) (9)
27 31
C C M L XL M L C
231CH2/D 231EH2 231UH2 231GH2 232GH2 233GH2 234GH2 232GH2 233GH2/1 231HH2
W4
F28TDCR
2800
9 (*)
MG/5
20 KM 79
2.8 HDi
II 27 = 10Q
31 = 14Q
I
II
III
I
II
III
Type approval no.
Type approval no.
Version
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
(2) Combi club.
(3) Combi confort.
(7) Chassis cab.
(9) Platform cab.
(*) = Without lateral door
(**) = (2)-(3) 10 hp
35
G
E
N
E
R
A
L
(9) (10) (11) (12)
31
M L M L C M/MH L/LH C M L
232HH2 233HH2 232HH2 233HH2/1 231FH12 232FH2 233FH2 231GH2/2 232GH2/1 233GH2/2
(12)
31
XL
234GH2/2
W4
F28TDCR
2800
9
MG/5
20 KM 79
2.8 HDi
II 31 = 14Q
I
II
III
I
II
III
Type approval no.
Type approval no.
Version
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
(11) Floor cab.
(12) Chassis cab.
G
E
N
E
R
A
L
36 36
(1) (4) (5) (6)
35
C/CH MH LH MS LH LH (*) LS LH
231JH2 232JH2 233JH2 232JH2 233JH2 233JH2(*) 233VH2 233VH2 233VH2 233VH2
(7)
35
M L XL
232KH2 233KH2 234KH2
W4
F28TDCR
2800
9
MG/5
20 KM 77
2.8 HDi
II 35 = 18Q
I
II
III
I
II
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.
(4) Minibus.
(7) Chassis cab.
37
G
E
N
E
R
A
L
(8) (9) (10) (11) (12)
35
L M L L M/MH L/LH M L XL
233GH2/1 232KK2 233LH2 233LH2/1 232NH2 233NH2 232KH2/2 233KH2/2 234GH2/2
W4
F28TDCR
2800
9
MG/5
20 KM 77
2.8 HDi
I) (8) Chassis double cab.
(9) Floor cab.
(11) Floor cab.
(12) Chassis cab.
I
II
III
Type approval no.
Version
Emission standard
Engine type
Capacity (cc)
Fiscal rating (hp)
Gearbox type
Gearbox ident.
G
E
N
E
R
A
L
38 38
5 Paint code
6 Vehicle identification N.
7 Bodyshell N.
8 Rear axle
RELAY 4 x 4 - All Types SPECIFICATIONS - IDENTIFICATION ( 4 x 4 )
Identification Manufacturers name plate
1 Gearbox identification reference.
3 Engine plate.
4 Transfer box.
1 VIN N
2 Gross vehicle weight.
3 Gross train weight.
4 Max. weight on front axle.
5 Max. weight on rear axle.
E1-P02XC E1-P02VD
G
E
N
E
R
A
L
ENGINE
1
2
3
4
5
8
B
C
H
XU102CU
XU10J2U
XUD9AU
DJ5TED
DJ5
XUD9UTF
2.8D (*)
2.8 TD (*)
2.0HDi (*)
WHEELBASE
1
2
3
4
Short (2.85m)
Medium (3.20m)
Long (3.70m)
Superlong (4.05m)
BODY
A
B
C
D
E
F
G
H
J
K
L
N
U
V
COMBI VERSION
/D
/E
/G
/H
VERSION CHASSIS
1
2
TRANSMISSION
2
4
VAN VERSION
1
B
C
FAMILY
23
Type approval no. (Example) 2 3 2 G 5 2 / 2
U 3
VAN 9 Q 10 Q
VAN 14 Q
COMBI 10 Q
MINIBUS 18 Q
CHASSIS 10 Q
FLOOR 10 Q
CHASSIS 14 Q
PLATFORM 14 Q
VAN 18 Q
CHASSIS 18 Q
PLATFORM 18 Q
FLOOR 18 Q
PLATFORM 10 Q
COMBI 14 Q
5 GEARS
4X4
HIGH-SIDED
DEEPENED
CAB
REDUCED GROSS
LADEN WEIGHT
DOUBLE CAB
BARE CHASSIS
CONFORT 5/9-seater
CONFORT High-sided 5/9-seater
(*) = SOFIM engine
NOTE : BODYWORK in A (VAN 9Q 10Q) 9Q = Van version Reduced Gross laden weight
EXAMPLE : 232G52/2 = Bare chassis medium, 2.5 diesel engine, 5-speed gearbox.
39
G
E
N
E
R
A
L
40 40
Wheelbase
Interior Payload
height
10 Q 14 Q 18 Q
1.56 m 27C/270C 31C/310C 35C/350C
Short : 2.85 m 1.88 m 27CH/270CS 31CH/310CS 35CH/350CH
2.11 m 27CS/270CH
1.56 m 27M/270M 31M/320M 35M/350M
Medium : 3.20 m 1.88 m 31MH/320MH 35MH/350MH
2.11 m 35MS/350MHS
1.56 m 31L/320L 35L/350L
Long : 3.70 m
1.88 m 31LH/320LH 35LH/350LH
Super long : 4.05 m 1.56 m 31XL/320XL 35XL/350XL
Commercial type
41
G
E
N
E
R
A
L
1 ) Letter Supplier E STA
2 ) Letter Torque J 8 X 37
F 8 X 39
3 ) and 4 ) Letters Differential 01 Limited slip
identification
02
Differential
lock
(a) (b) (c) (d) (e)
D = Dangel D = Diesel 1 = 14Q
08 = The two
Atmospheric 5 = 18Q gearbox plate Reduction box
T= Turbo diesel 7 = 10Q
nos. (Option)
E = Petrol
a = D
b = E
c = 7
d = 08
e = (R)
Gearbox plate (Example)
(
*
)
Rear axle (Example)
Examples :
E F 01 = 8x39 Limited slip
EF02 = 8x39 Differential lock
(1) (2) (1) (3) (4)
31 35
C/CH MH C M MH LH M L M L
231B54 232B54/1 231V54/D 232V54/D 232J54 233J54 232K54 233K54 232L54 233L54
(3) (4) (5)
31 35
M M L
232V54 232H54 232N54 233N54
W3
T9A
2446
8 9 8
ME/5 MG/5
20 KE 29 20 KM 73
DD1 04 ( R ) DD5 24 ( R )
42 42
G
E
N
E
R
A
L
2.5 D
II 31 = 14Q
35 = 18Q
III (See page 20)
I
II
III
I
II
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 van.
(2) Chassis confort
(3) Chassis cab.
(4) Platform cab.
(5) Floor cab.
43
G
E
N
E
R
A
L
(6) (1) (2) (1) (3) (4)
27 31 35
C C/CH MH C MH LH M L M
231C44/D 231B44 232B44/1 232V44/D 232J44 233J44 232K44 233K44 232L44
(2) (3) (4) (5)
31 35
M L M L
232V44/D 232V44 232H44 233L44 232N44 233N44
W3
THX
2446
9 8
ME/5 MG/5
20 KE 29 20 KM 74 20 KM 75
DT7 04 ( R ) DT1 19 ( R ) DT5 26 ( R )
2.5 Tdi
II 27 = 10Q
31 = 14Q
35 = 18Q
III (See page 20)
I
II
III
I
II
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 van.
(2) Combi confort
(3) Chassis cab.
(4) Platform cab.
(5) Floor cab.
(6) Combi club
(2) (1) (3) (1) (4) (5)
27 31 35
C C/CH MH C MH LH M L M
231CH4/D 231BH4 232BH4/1 231VH4/D 232JH4 233JH4 232KM4 233KM4 232LH4
(3) (4) (5) (6)
31 35
M L M L
232VH4/D 232VH4 232HH4 233LH4 232NH4 233NH4
W4
F28TDCR
2800
9 (*)
MG/5
20 KM 79 20 KM 77
44 44
G
E
N
E
R
A
L
2.8 HDi
II 27 = 10Q
31 = 14Q
35 = 18Q
(*) = (2)-(3) 10 hp
I
II
III
I
II
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 van.
(2) Combi club
(3) Combi confort
(4) Chassis cab.
(5) Platform cab.
(6) Floor cab.
45
G
E
N
E
R
A
L
ALL TYPES LUBRICATION SYSTEM
Draining method.
Oil capacities are determined by the following procedure :
1/ Vehicle on horizontal ground.
2/ Engine warm (oil temperature 80C).
3/ Drainage from sump + remove oil filter (time required for draining including dripping = 15 min).
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 oil dipstick.
46 46
G
E
N
E
R
A
L
C15
Diesel
1.8D 1.9D
Engine type 161A WJZ
Engine angle 30
Engine with filter change 4.25 4.75
Between Min. and Max. 1.5
5-speed gearbox 2
Brake circuit
Cooling system 8
Fuel tank capacity 47
C15 All Types CAPACITIES (in litres)
(1) = Vehicle with air conditioning.
NOTE : Engine, systematically check the oil level using the oil dipstick.
47
G
E
N
E
R
A
L
Engine type
Engine with filter change
Between Min. and Max.
5-speed gearbox
Automatic gearbox
after drainage
Hydraulic or brake circuit
Cooling system
Fuel tank capacity
HDZ HFX KFX KFW LFX HFX KFX KFW WJZ RHY
3.5
4.75 4.75 4.5
4.5 (1)
3
4.5 (1) 4.25 (1)
1.5 1.3 1.5 1.5
2 1.8 2 1.8
With ABS = 0.62 - Without ABS = 0.525
With ABS = 0.62
Without ABS = 0.525
6.5 6.5-7 (1) 8 6.5 6.5-7 (1) 10.5
55 60
BERLINGO - All Types CAPACITIES (in litres)
Ecological filter
capacity 0.15 litre.
Petrol Diesel
BERLINGO
(1) = With aircon. - NOTE : Engine, systematically check the oil level using the oil dipstick.
1.1i 1.4i 1.8i 1.1i 1.4i 1.9D 2.0 HDi
48
G
E
N
E
R
A
L
Petrol Diesel
2.0i 16V 1.9 D 2.0 HDi 2.0HDi 16V
Engine type RFN WJZ (1) WJZ (2) RHX RHZ RHW
Engine angle 28 1630 - 1830 21
Engine with filter change 4.25 4.5 4.5 (3) (4) 4.5 4.75
Between Min. and Max. 1.7 1.5 1.3 (3) - 1.4 (4) 1.4 1.9
5-speed gearbox 1.8 1.8
Automatic gearbox 8
After drainage 3
Brake circuit 0.5
Cooling system
DISPATCH All Types CAPACITIES (in litres)
(1)= OPR 7903 # 8575 Filling with oil is by way of the oil sump. (3) = With aircon (4) = Without aircon.
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).
Automatic
Dispatch
49
G
E
N
E
R
A
L
Petrol Diesel
DJ5
2.0i 1.9 D 1.9 TD 2.5 D 2.5 TD 2.8 HDi
Engine type RFW DJY D8C DHY T9A (1) T9A (2) THX (3) F28TDCR (4)
Engine with filter change 4.75 - 4.5 (5) 5.25 (Without aircon) 9 8 8 7
Between Min. and Max. 1.5 2.9 3.5 1.5
5-speed gearbox 1.85 (*) 2.5 2.75
Brake circuit
Cooling system 10 13
RELAY All Types CAPACITIES (in litres)
(1) = NOPR # 235152 (2) = N235153 # (3) engine DJ5T (Engine with filter change = 9 Litres between max. and min. = 3.5 litres).
(4) = Filter cartridge capacity (litres) : 1.10. (5) With aircon.
(*) Gearbox (ML) - Gearbox (MG) = 2.5 litres.
Relay
50 50
G
E
N
E
R
A
L
ALL TYPES LUBRICANTS - TOTAL recommended oils
S.A.E. Norm - Table for selection of engine oil grade Factory evolutions in 2000 model year
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%).
This oil is not used in the following engines :
- XU10 4 RS XSARA VTS 2.0i 16V (3-door)
- SOFIM RELAY 2.8 D and 2.8 TD.
Engine oil norms
These engine oils have been classified by the following
recognised organisations:
SAE : Society of Automotive Engineers.
API : American Petroleum Institute.
ACEA : Association des Constructeurs Europens
d'Automobiles.
E4AP006D
51
G
E
N
E
R
A
L
ALL TYPES
Selection of engine oil grades recommended for climatic conditions in countries of distribution
ACEA Norms
The 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 of
the norm.
NOTE : From 01/03/2000, all engine oils must comply with ACEA-98
norms.
Example :
ACEA A1-98 / B1-98 : Blended oils for all engines, permetting fuel
economy (complying with ACEA 98 norms).
API Norms
The first letter corresponds to the type of fuel used by the engine :
S : petrol and dual fuel petrol / LPG engines.
C : diesel engines.
The second letter corresponds to the degree of evolution, in ascending
order.
Example : The norm SJ is more severe than the norm SH and
corresponds to a higher level of performance.
The adding of the letters EC indicates that the engine oil concerned is an
oil which permits fuel economy.
EC : Energy Conserving, reduction in fuel consumption.
Examples :
API SJ / CF : Blended oils for diesel and dual fuel petrol / LPG engines
API CF / EC : Oils specifically for diesel engines, permitting fuel
economy.
API SJ / CF / EC : Blended oils for all engines, permetting fuel economy.
LUBRICANTS - TOTAL recommended oils
52 52
G
E
N
E
R
A
L
LUBRICANTS - TOTAL recommended oils ALL TYPES
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, all engines fitted in CITROEN vehicles
must be lubricated with high quality oils (synthetic or semi-synthetic)
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 must not be lubricated with oil complying
with standards ACEA A1-98 / B1-98 and API SJ/CF EC.
Summary
Engine 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 A1-98 (*) SJ or SJ / EC (*)
CF or CF / EC (*) B3-98 or B1-98 (*) Diesel engines
Types of engine ACEA norms API norms
G
E
N
E
R
A
L
53
S.A.E. grades SPI norms ACEA norms
Blended oils for all engines (petrol, dual-fuel petrol / LPG and diesel)
TOTAL ACTIVA 9000
TOTAL QUARTZ 9000
5W-40 SJ / CF A3-98 / B3-98
TOTAL ACTIVA 9000 (*)
TOTAL QUARTZ 9000 (*)
5W-30 SJ / CF EC A1-98 / B1-98
TOTAL ACTIVRAC 10W-40 SJ / CF A3-98 / B3-98
(*) = Blended oils for all engines, permitting fuel economy.
Oils specifically for petrol and dual-fuel petrol / LPG engines
TOTAL ACTIVA 7000
TOTAL QUARTZ 7000
10W-40
TOTAL QUARTZ 9000 0W-40 SJ A3-98
TOTAL ACTIVA 7000
TOTAL QUARTZ 7000
15W-50
Oils specifically for diesel engines
TOTAL ACTIVA DIESEL 7000
TOTAL QUARTZ DIESEL 7000
10W-40
TOTAL ACTIVA DIESEL 7000
TOTAL QUARTZ DIESEL 7000
15W-50 CF B3-98
TOTAL ACTIVA 9000 5W-40
54 54
G
E
N
E
R
A
L
FRANCE
Metropolitan FRANCE
Metropolitan FRANCE
New Caledonia
Guadeloupe
Saint-Martin
La Runion
9000 5W-40 7000 15W-50 7000 15W-50
Martinique
Guyana
Tahiti
Mauritius
Mayotte
Blended oils for all engines
TOTAL ACTIVRAC S.A.E : 10W-40 Norms
TOTAL ACTIVA
900 5W-40
9000 5W-30 (*)
7000 10 W-40
7000 10 W-40
9000 5W-40
Oils specifically for petrol and
dual-fuel petrol / LPG engines
Oils specifically
for diesel engines
TOTAL ACTIVA DIESEL
(*) = Blended oils for all engines, permitting fuel economy.
55
G
E
N
E
R
A
L
EUROPE
Germany
7000 10W-40
9000 0W-40
Austria 7000 10W-40
Belgium
7000 10W-40
9000 0W-40
Bulgaria 7000 10W-40
Cyprus
7000 15W-50
Croatia 7000 10W-40
Denmark
7000 10W-40
9000 0W-40
Spain
7000 10W-40
7000 15W-50
Finland
7000 10W-40
9000 0W-40
Great Britain 7000 10W-40
TOTAL QUARTZ TOTAL QUARTZ DIESEL
Oils specifically
for diesel engines
7000 10W-40
7000 10W-40
7000 15W-50
7000 10W-40
7000 10W-40
7000 15W-50
7000 10W-40
9000 5W-40
9000 5W-30 (*)
(*) = Blended oils for all engines,
permitting fuel economy
56 56
G
E
N
E
R
A
L
EUROPE (continued)
Greece
7000 10W-40 7000 10W-40
7000 15W-50 7000 15W-50
Holland 7000 10W-40
Hungary 9000 0W-40
Italy 7000 10W-40
7000 10W-40
Latvia 7000 10W-40
Lithuania 9000 0W-40
Macedonia 7000 10W-40
Malta
7000 10W-40 7000 10W-40
7000 15W-50 7000 15W-50
Norway
7000 10W-40
9000 0W-40
Poland
7000 10W-40
Portugal 7000 10W-40
Slovak Republic
Oils specifically
for diesel engines
9000 5W-40
9000 5W-30 (*)
57
G
E
N
E
R
A
L
EUROPE (continued)
7000 10W-40
7000 10W-40 Czech Republic
9000 0W-40
Romania
7000 10W-40 7000 10W-40
7000 15W-50 7000 15W-50
Russia
7000 10W-40
9000 0W-40
Slovenia 7000 10W-40
7000 10W-40
Sweden
7000 10W-40
9000 0W-40
Switzerland 7000 10W-40
Turkey
7000 10W-40
7000 10W-40
7000 15W-50
7000 15W-50
9000 0W-40
Ukraine
7000 10W-40
7000 10W-40
9000 0W-40
Oils specifically
for diesel engines
9000 5W-40
9000 5W-30 (*)
58 58
G
E
N
E
R
A
L
Australia
New Zealand
OCEANIA 9000 5W-40 7000 10W-40 7000 10W-40
Angola - Ivory Coast
Egypt - Ecuador - Gabon
Madagascar - Morocco AFRICA 9000 5W-40 7000 15W-50 7000 15W-50
Dominican Republic
Senegal- Tunisia
Argentina - Brazil - Chile
Colombia - Cuba
SOUTH
Guatemala - Paraguay
AMERICA
9000 5W-40 7000 15W-50 7000 15W-50
Peru - El Salvador
Uruguay
Blended oils
for all engines
Oils specifically
for diesel engines
59
G
E
N
E
R
A
L
China
7000 10W-40
7000 15W-50
South Korea 7000 10W-40
Hong Kong - India
Indonesia
7000 15W-50
Japan
7000 10W-40
7000 15W-50
SOUTH & EAST 7000 15W-50
Malaysia ASIA
9000 5W-40
7000 15W-50
Singapore
Taiwan
7000 10W-40
7000 15W-50
Thaland
7000 15W-50
Vietnam
Blended oils
for all engines
Oils specifically
for diesel engines
60 60
G
E
N
E
R
A
L
Saudi Arabia
Bahrain
Dubai
United Arab Emirates
Israel MIDDLE
9000 5W-40 7000 15W-50 7000 15W-50
Jordan EAST
Kuwat
Lebanon
Qatar
Yemen
Blended oils
for all engines
Oils specifically
for diesel engines
61
G
E
N
E
R
A
L
Manual gearbox
Europe TOTAL TRANSMISSION
Overseas France (new formula)
Asia Norms S.A.E 75W-80
TOTAL FLUIDE ATX or
TOTAL FLUIDE AT 42.
Automatic gearbox MB3
Special oil distributed by CITROEN
(Part No. : 9730 94).
TOTAL FLUIDE AT 42 or
Automatic gearbox 4 HP 14 et 4 HP 18 All countries Special oil distributed by CITROEN
(Part No.: 9730 94).
Automatic gearbox 4 HP 20 et AL4
Special oil distributed by CITROEN
(Part No.: 9736 22).
Transfer box and differential TOTAL TRANSMISSION X 4
C MATIC gearbox TOTAL FLUIDE T
Power-assisted steering All countries TOTAL FLUIDE ATX
Gearbox oils
Oils for power-assisted steering
62 62
G
E
N
E
R
A
L
Engine coolant
Packs
CITROEN reference
GLYSANTIN G 33 REVCOGEL 2000
CITROEN Fluid 2 litres 9979 70 9979 72
All countries
Protection : - 35C 5 litres 9979 71 9979 73
20 litres 9979 76 9979 74
210 litres 9979 77 9979 75
Synthetic brake fluid
Packs CITROEN reference
All countries
CITROEN Fluid
0.5 litre 9979 05
1 litre 9979 06
5litres 9979 07
CITROEN hydraulic circuit fluid
Mineral fluid for hydraulic circuit green colour
TOTAL LHM PLUS Pack CITROEN reference
All countries Norms ISO 7308-7309 1 litre ZCP 830 095
Hydraulic circuit rinsing fluid green colour
TOTAL HYDRAURINAGE
63
G
E
N
E
R
A
L
CITROEN reference
Concentrate : 250 ml 9980 33 ZC 9875 953 U 9980 56
All countries Liquid ready to use : 1 litre 9980 06 ZC 9875 784 U
Liquid ready to use : 5 litres 9980 05 ZC 9885 077 U ZC 9875 279 U
Grease
Norms : NLGI (1)
All countries TOTAL MULTIS EP2 2
TOTAL MULTIS COMPLEX EP2 2
TOTAL MULTIS N4128 1
TOTAL PETITES MECANIQUES
(1) NLGI = National Lubrificating Grease Institute.
Wash / wipe fluid
64 64
G
E
N
E
R
A
L
ENGINE OIL CONSUMPTION ALL TYPES
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 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.
65
E
N
G
I
N
E
1.1i 1.4i 1.8i 2.0i 2.0i 16V
HDZ HFX HDZ/GPL KFX KFX/GPL KFW LFX RFW RFN
1124 1360 1761 1998 1997
72/69 75/77 83/81.5 86/86 85/88
9.7/1 10.5/1 9.7/1 10.2/1 9.5/1 9.5/1 10.8/1
44.1-6200 44.1-5500 43.2-6200 55-5500 66-5000 80-5500 99-6000
60-6200 60-5500 58.8-6200 75-5500 90-5000 110-5500 136-6000
8.75-3800 9.4-3500 8.31-3800 11.1-3400 14.7-2600 16.8-3400 19-4100
9.1-3800 8.65-3800 11.5-3400 15.2-2600 17.3-3400 19.8-4100
6500 6500 6500 6300 5700
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)
ENGINE SPECIFICATIONS ALL TYPES
Engines : HDZ - HFX - KFX - HDZ/GPL - KFX - KFX-GPL - LFX - RFW - RFN
Petrol
All Types
66
E
N
G
I
N
E
E
N
G
I
N
E
1.8 D 1.9 D 1.9 TD 2.0 HDi
161 A WJZ DJY D8C DHX RHX
1769 1868 1905 1997
80/88 82.2/88 83/88 85/88
23/1 21.8/1 17.6/1
43.5-4600 51-4600 50-4600 67.5-4000 66-4000 69-4000
60.5-4600 70-4600 69.5-4600 92-4000 90-4000 93.8-4000
11-2000 12.5-2500 12-2000 19.6-2250 21.5-1750
11.4-2000 14-2500 12.5-2000 20.5-2250
4600 5350 4600 5100 4500
Engine type
Cubic capacity (cc)
Bore / Stroke
Compression ratio
Power DIN (HP-rpm)
Engines : 161 A - WJZ DJY - D8C - DHX RHX
Diesel
67
E
N
G
I
N
E
2.0 HDi 2.0 HDi 16V 2.5 D 2.5 TD 2.8 HDi
RHY RHZ RHW T9A THX F28TDCR
1997 2446
85/88 92/92
17.6/1 18/1 24/1 20/1
66-4000 80-4000 63-4350 79-4000
90-4000 110-4000 86-4350 107-4000
20.5-1750 25-1750 27-1750 15.3-2250 25-2250
21.3-1750 26-1750 15-8-2250 23.2-2250
5300 5200 4200
Engine type
Cubic capacity (cc)
Bore / Stroke
Compression ratio
Power DIN (HP-rpm)
Engines : RHY RHZ RHW T9A THX F28TDCR
Diesel
68
E
N
G
I
N
E
E
N
G
I
N
E
in bars
XUD 7 / 9
5 DJ5
25 30 20
DJ5 TED 32 35 25.5
COMPRESSION RATIO - DIESEL ENGINES ALL TYPES
ENGINE
COMPRESSION
RATIO
MINIMUM VALUE
( - 20 % )
MAX. DIFFERENCE
BETWEEN CYLINDERS
69
E
N
G
I
N
E
Engine type HDZ HFX KFX KFW LFX RFN RFW
Maximum permissible bow 0.05
Gasket surface regrinding - 0.20
TIGHTENING TORQUES (m.daN)
Crankshaft bearing screws :
- Pre-tightening 2 0.2 2 0.1
- Tightening 5.5 0.5 7 0.7
- Angular tightening 45 4 60 6
Connecting rod screws :
- Pre-tightening 4 0.4 4 0.4
- Loosening OUI
- Tightening 3.8 0.3 2 0.2 2.3 0.2 2 0.2
- Angular tightening 70 7 46 4.6 70 7
Flywheel screw :
- Tightening 6.5 0.6 5 0.5 2 0.1 5 0.5
- Loosening 21 3
Crankshaft end pulley screw 10 1 12 1.2 12 1
Camshaft end drive screw 8 0.8 5.5 0.5 4.5 0.4
SPECIAL FEATURES - TIGHTENING TORQUES (m.daN) ALL TYPES
Engines : HDZ - HFX - KFX - KFW - LFX - RFN RFW
CYLINDER HEAD (mm)
70
E
N
G
I
N
E
E
N
G
I
N
E
Engine type 161A DJY D8C DHX WJZ
Maximum permissible bow 0.07 0.03
- Pre-tightening
- Tightening 7 0.7 1.5 0.1 7 0.7
- Angular tightening 60 6
- Pre-tightening
- Tightening 2 0.1
Flywheel screw 5 0.5
Pulley screw at end of crankshaft :
- Pre-tightening
- Tightening 4 0.4 4 0.4
- Angular tightening 51 5 60 5
Pinion screw at end of camshaft 4.5 0.4
Engines : 161A - DJY - D8C - DHX WJZ
CYLINDER HEAD (mm)
71
E
N
G
I
N
E
Engine type RHY RHX RHZ RHW T9A THX
Maximum permissible bow 0.03
- Pre-tightening 2.5 0.2
- Tightening
- Pre-tightening 2 0.2
- Tightening
Flywheel screw 5 0.5
Pulley screw at end of crankshaft :
- Tightening 2 (4 x screws)
Pinion screw at end of camshaft 4.3 0.4 4.5 0.4
Camshaft pinion fixing flange 4.3 0.4
Camshaft pinion to flange screw :
- Tightening 2.5 0.2
Engines : RHY - RHX - RHZ - RHW - T9A THX
CYLINDER HEAD (mm)
72
E
N
G
I
N
E
E
N
G
I
N
E
CYLINDER HEAD BERLINGO All Types
Engines : HDZ - KFX - KFW - HFX
CYLINDER HEAD GASKET IDENTIFICATION
Engine type
Identification marks (Notch on cylinder head gasket) *
HDZ - KFX HFX - KFW
1
2
3
4
A
B
D
A
B
D
A
B
D
A
B
D
C
R 0 (Standard gasket) - 1 (Repair gasket)
0 (With asbestos) - 1 (Asbestos-free)
0
0
1
1
0
1
0
1
1
0
0
0
0
0
0
1
CURTY
MEILLOR
ELRING
REINZ
Material
Repairs
Suppliers
Thickness
*
0 = Without notch
1 = One notch
B1BP10KC
73
E
N
G
I
N
E
BERLINGO All Types CYLINDER HEAD (continued)
Engines : HDZ KFX - KFW HFX
Cylinder head tightening (m.daN) Cylinder head bolts
X = MAXIMUM reusable length
NOTE : Oil the threads and under the heads
of the cylinder head bolts.
(Use engine oil or Molykote G Rapid Plus).
B1DP059C B1BP10LC
HDZ KFX - KFW - HFX
HDZ KFX - KFW - HFX
X = 175.5 mm
74
E
N
G
I
N
E
E
N
G
I
N
E
CYLINDER HEAD (continued) BERLINGO All Types
Engine : LFX
Engine type
LFX
*
0 = Without notch
1 = One notch
B
A
0
1
C 0
D 0
E 0
A 0
B 1
C 0
D 0
E 0
CURTY
MEILLOR
Suppliers
B1BP004C
75
E
N
G
I
N
E
BERLINGO All Types CYLINDER HEAD (continued)
Engine : LFX
- Pre-tightening 6
- Loosening OUI
- Tightening 2
- Angular tightening 300
LFX
LFX
171.5 mm
NOTE : Oil the threads and
under the heads of the cylin-
der head bolts.
Use engine oil or Molykote G
Rapid Plus).
B1DP05BC
B1DP13PC
76
E
N
G
I
N
E
E
N
G
I
N
E
DISPATCH All Types CYLINDER HEAD
Engine : RFN
B1DP183D
Nominal dimension Repair dimension
2 - 4 - 5 4 - 5
R1 R2
1.1 0.8
Gasket thickness
(mm)
Supplier MEILLOR
Marking zone
"e"
Marking zone
"d"
1.4
Multilayer metallic gasket
77
E
N
G
I
N
E
DISPATCH All CYLINDER HEAD (continued)
Engine : RFN
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 0.75
Angular tightening 285 5
B1DP16FC
B1DP0.
RFN
RFN
X= 147 mm
A = Washer thickness: 4 0.2 mm.
X = Length under heads of new bolts = 144.5 0.5 mm.
78
E
N
G
I
N
E
E
N
G
I
N
E
CYLINDER HEAD RELAY All Types
Engine : RFW
Engine type
RFW
A 1
B 0
C 1
D 0
E 1
A 0
B 1
C 1
D 0
E 1
CURTY
MEILLOR
Suppliers
*
0 = Without notch
1 = One notch
B1BP004C
79
E
N
G
I
N
E
RELAY All Types CYLINDER HEAD (continued)
Engine : RFW
under the heads of the cylin-
der head bolts.
(Use engine oil or Molykote G
Rapid Plus).
- Pre-tightening 3.5
- Loosening NON
- Tightening 7
- Angular tightening 160
B1DP13PC
B1DP05BC
RFW
RFW
122 mm
80
E
N
G
I
N
E
E
N
G
I
N
E
Engines Ident. Ident.
mark (A) mark (A)
161A 1 notch
DJY no notch
C15 - RELAY All Types CYLINDER HEAD
161A - DJY
Ident. Mark
(B)
Thickness
(mm)
0.06
Engine
type
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
DJY
D8C
DHX
D8C - DHX
1 to 5
notches
Engines Ident. Ident.
mark (A) mark (A)
D8C
3 notches
1 to 5
DHX notches
B1BP10SC B1BP10TC
Engines : 161A - DJY - D8C- DHX
81
E
N
G
I
N
E
C15 - BERLINGO - DISPATCH CYLINDER HEAD
Number
of holes
at B
Number
of holes
at A
Thickness
(mm)
0.04
Engine
type
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.
B1DP14QD
Engine : WJZ
WJZ
2
82
E
N
G
I
N
E
E
N
G
I
N
E
C15 - BERLINGO - DISPATCH CYLINDER HEAD (continued)
Engines : 161A - DJY - D8c - DHX - WJZ
NOTE : Oil the threads and under the
heads of the cylinder head bolts.
- Tightening 6 0.6
- Tightening 6 0.6
B1DP14NC B1DP13PC
D8C - DHX
161A - WJZ - DJY
161A - WJZ - DJY D8C DHX
125.5 mm 151.5 mm 150.5 mm
161A - DJY - D8C - DHX WJZ
B1DP05BC
83
E
N
G
I
N
E
BERLINGO - DISPATCH CYLINDER HEAD
No. of notches
at A
Thickness
(mm)
Engine
type
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
B1DP15AD
Engines : RHX - RHZ - RHY
84
E
N
G
I
N
E
E
N
G
I
N
E
BERLINGO - DISPATCH CYLINDER HEAD (continued)
Engines : RHX - RHZ - RHY
- Tightening 6 0.6
B1DP15EC
RHX - RHZ - RHY
RHX - RHZ - RHY
B1DP05BC
RHX - RHZ - RHY
133.3 mm
85
E
N
G
I
N
E
RELAY CYLINDER HEAD
Engines : T9A - THX
Cylinder head gasket identification
Engine type
T9A 1.6
THX
NOTE : Single cylinder head gasket
1.4
Thickness (mm) T9A - THX
- Pre-tightening the bolts :
Angular tightening
T9A
THX
Bolt 12 Bolt 10
153.5 mm 162.5 mm
Bolt 12 Bolt 10
178.3 mm 189.3 mm
Cylinder head bolts Cylinder head tightening (m.daN)
(Use engine oil or Molykote G Rapid
Plus).
B1DP03XC
- 1 14 (Vis 12) 5 0.5
- 15 22 (Vis 10) 3.5 0.3
B1DP00QC
T9A
120 5 150 5
THX
86
E
N
G
I
N
E
E
N
G
I
N
E
Tools
ALL TYPES BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE
! 4099-T (C.TRONIC.105) 4122-T (C.TRONIC.105.5) !
!
!
B1EP135D
87
E
N
G
I
N
E
AUXILIARY EQUIPMENT DRIVE BELT ALL TYPES
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.
88
E
N
G
I
N
E
E
N
G
I
N
E
AUXILIARY EQUIPMENT DRIVE BELT
Engines : HDZ - HFX - KFX - KFW
[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
Alternator With air conditioning
Power steering / air conditioning
- New belt
- 100 SEEM units.
- Reused belt
- 75 SEEM units.
- New belt
- 100 SEEM units.
- Reused belt
- 75 SEEM units.
B1BP121C B1BP123C
B1BP122C B1BP124C
89
E
N
G
I
N
E
- (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
Without air conditioning
B1BP00IC B1BP00HC
Engine : LFX
100 10
LFX
115 5
LFX
90
E
N
G
I
N
E
E
N
G
I
N
E
- 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 mm square drive (3/8) at (2), in order to remove
the tool or locking peg ( 4 mm ) at (4).
- Slowly release the tensioner roller (1) so that the roller (5) presses against the belt.
With air conditioning
B1BP1HJC
Engine : LFX
91
E
N
G
I
N
E
Engine : RFN
Without air conditioning With air conditioning
Tools
[1] Pliers for removing plastic pegs 7504-T
Remove the belt.
- Detension the belt (3) by turning the screw (2) of the tensioner roller (1)
(anti-clockwise).
- The screw (2) (WARNING : not left hand screw).
- Remove the belt (3), while keeping the tensioner roller (1) tight.
Refit the belt.
- Refit the belt (3), while keeping the tensioner roller (1) tight.
- Release the tensioner roller (1).
B1BP23PC B1BP23QC B1BP23PC B1BP23RC
92
E
N
G
I
N
E
E
N
G
I
N
E
Engine : RFW
Alternator belt (without air conditioning)
TOOLS
[1] Belt tension measuring instrument : 4122-T
TENSIONING THE BELT
- Tension the belt (4) using the screw (2).
- Fit the tool [1].
- Pre-tension to : 120 10 SEEM units.
- Remove the tool [1].
- Rotate the crankshaft by 3 turns.
- Fit the tool [1].
- Adjust the tension using the screw (2) to : 140 10 SEEM units.
- 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.
B1BP044C B1BP045C
93
E
N
G
I
N
E
Engine : RFW (continued)
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].
- Fit the tool [1].
- Adjust the tension, using screw (6), to : 140 5 SEEM units.
- Tighten the screws (3) and (4) to 2 m.daN.
B1BP1LFC B1BP04AC
94
E
N
G
I
N
E
E
N
G
I
N
E
Power-assisted steering pump
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].
- Fit the tool [1].
- Adjust the tension by turning the nut (2) to : 75 5 SEEM units.
- Tighten the screws (3) and the pump articulating screws to 2 m.daN.
- Check the belt tension (1).
- If this is not the case, restart the tensioning operation
B1BP04BC B1BP04CC
95
E
N
G
I
N
E
[1] Belt tension measuring tool : 4122-T
- Fit the tool [2] at (B).
- Tighten the tensioning screw (3) to
obtain a value of :
112 10 SEEM units.
- Fit the tool [2] at (C).
- Tighten the tensioning screw (5) to
obtain a value of :
115 10 SEEM units.
- Tighten the screw (4) to 2 m.daN.
Engines : 161A - DJY
Alternator
Power steering
Power steering / air conditioning
- Using a 7 mm square drive at (b), turn
the eccentric roller until the tool [1]
(7019-T), located at (a), is released.
- Tighten the screw (6)
(The belt is automatically tensioned by
the tensioner).
B1BP11XC B1BP11YC B1BP11ZC
96
E
N
G
I
N
E
E
N
G
I
N
E
- Tension the belt by loosening the screw (4) to obtain :
115 10 SEEM units
- Tension the belt to :
115 10 SEEM units (If necessary).
- Tighten the screws (1) and (3) to 2 m.daN.
B1BP10HC B1BP10GC
Engines : DHX
97
E
N
G
I
N
E
Engines : DHX
[1] Peg 7019-T
- Loosen the screws (1).
- Tighten or loosen the screws (2) until the holes a and b are superimposed.
- 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].
B1BP1HGC B1BP1HHC
98
E
N
G
I
N
E
E
N
G
I
N
E
Engines : DJY - D8C - DHX
Alternator (without air conditioning)
- Tension the belt (4) by turning the screw (2).
- Fit the tool [1].
- Pre-tension to 120 10 SEEM units.
- Fit the tool [1].
- Adjust the tension, using the screw (2), to : 140 10 SEEM units.
- Tighten the nut (1) to 2 m.daN, and the screw (3) to 4 m.daN.
- Fit the tool [1].
- The value must not be less than 100 SEEM units.
B1BP044C B1BP045C
99
E
N
G
I
N
E
Engines : DJY - D8C - DHX (continued)
Alternator (with air conditioning)
- NOTE : If the vehicle is equipped with a power steering pump, remove the belt (5).
TENSIONING THE BELT
- Fit the tool [1].
- Carry out a pretensioning of : 120 10 SEEM units.
- 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.
- Tighten screws (3) and (4) to 2 m.daN.
- Nominal value should not be less 100 SEEM units.
B1BP1LFC B1BP04AC
100
E
N
G
I
N
E
E
N
G
I
N
E
Engines : DJY - D8C - DHX (continued)
Belt for power-assisted steering pump
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].
- Remove the tool [1]
- Fit the tool [1].
- Adjust the tension by turning the nut (2) to : 75 5 SEEM units.
- Tighten the screws (3) and the pump articulating screws to 2 m.daN.
- Fit the tool [1].
- The value must not be less than 70 SEEM units
- If this is not the case, restart the tensioning operation
B1BP04BC B1BP04CC
101
E
N
G
I
N
E
Without power-assisted steering
Tools :
[1] Belt tension measuring instrument : 4122-T.
Removal.
- 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.
B1BP1SEC B1BP1SDC
Engines : WJZ
102
E
N
G
I
N
E
E
N
G
I
N
E
Without power-assisted steering/with air conditioning
Tools :
[1] Belt tension measuring instrument 4122-T.
Removal.
- 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 units.
B1BP1SGC B1BP1SFC
Engines : WJZ
103
E
N
G
I
N
E
Power-assisted steering/without air conditioning
Tools :
[1] Belt tension measuring instrument : 4122-T.
Removal.
WARNING : If the belt is to be reused, measure the tension before removal.
Loosen :
- the screw (1).
- the nut (2).
NOTE : The tensioner arm (3) must be against the alternator.
- Remove the belt.
B1BP1SHD
Engines : WJZ
104
E
N
G
I
N
E
E
N
G
I
N
E
Power-assisted 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.
- 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.
B1BP1SJD
Engines : WJZ
105
E
N
G
I
N
E
Power-assisted steering with air conditioning
Tools :
[1] Dynamic tensioner peg (-) 0188 H.
[2] Belt tension measuring instrument 4122-T.
Removal.
- Peg the dynamic tensioner (1) at "a", using tool [1].
- Loosen the screw (2) of the roller (3).
- Turn the roller (3) backwards.
- Remove the belt.
NOTE : If it can not be pegged at "a" :
- Loosen the screw (2) of the roller (3).
- Using a 7 mm square drive, turn the roller (3) at "b".
- Peg the tensioner (1) at "a", using tool [1].
NOTE : If the belt is broken :
- Support the engine using a jack (insert a wooden block between the housing and the jack).
- Remove the right 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
Engines : WJZ
106
E
N
G
I
N
E
E
N
G
I
N
E
Power-assisted 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).
B1BP1SLC
Engines : WJZ
107
E
N
G
I
N
E
Engines : RHX - RHY - RHZ
B1BP1YKD
Tools
[1] Belt tension adjusting square : (-).0188 J2
[2] 4 mm peg : (-).0188.Q1
[3] 2 mm peg : (-).0188.Q2
[4] Dynamic tensioner compression lever : (-).0188.Z
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.
tool [4].
- Peg using tool [2], at b.
- Hold the tensioner roller (2) compress and remove the belt.
- Loosen the screw (1).
108
E
N
G
I
N
E
E
N
G
I
N
E
Without air conditioning (continued)
Refit.
RE-USED BELT.
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.
- 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
109
E
N
G
I
N
E
B1BP1YLD
Tools
[1] Belt tension adjusting square : (-).0188 J2
[2] 4 mm peg : (-).0188.Q1
[3] 2 mm peg : (-).0188.Q2
[4] Dynamic tensioner compression lever : (-).0188.Z
Remove
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.
110
E
N
G
I
N
E
E
N
G
I
N
E
With air conditioning (continued)
Refit.
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.
- 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
111
E
N
G
I
N
E
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.
- Fit the tool [1].
- Adjust the tension using the screw (3) to 138 12 SEEM units.
Engines : T9A - THX
Belt for alternator and power-assisted steering pump
B1BP1WCC B1BP03PC B1BP03RC
112
E
N
G
I
N
E
E
N
G
I
N
E
Engines : T9A - THX (continued)
Water pump belt
- Fit the tool [1].
- Pre-tension to :
New belt : 62 SEEM units.
Reused belt : 41 SEEM units.
- Fit the tool [1].
- Adjust the tension to obtain :
New belt : 62 SEEM units.
Reused belt : 41 SEEM units.
B1BP04DC B1BP04EC
113
E
N
G
I
N
E
Engine type
C15
BERLINGO
DISPATCH
RELAY
See pages :
CHECKING AND SETTING THE VALVE TIMING ALL TYPES
1.1i
H
D
Z
H
D
Z/
G
P
L
H
F
X
K
F
X
K
F
X/
G
P
L
K
F
W
L
F
X
R
F
N
R
F
W
1
6
1
A
D
J
Y
D
8
C
D
H
X
W
J
Z
R
H
Y
R
H
X
R
H
Z
R
H
W
T
9
A
T
H
X
F
2
8
T
D
C
R
1.4i 1.8i
2.0i
16V
2.0i 1.8D 1.9D
1.9
TD
1.9D
2.0
HDi
2.0
HDi
16V
2.5D
2.5
TDi
2.8
HDi
X X
X X X X X X X X X
X
X X X X
X X X
X X X X
117
to
118
121
to
125
119
to
120
126 127 to 131 132 to 136
141
to
144
137
to
140
114 to 116
114
E
N
G
I
N
E
E
N
G
I
N
E
TOOLS
- [1] Flywheel locating peg : 4507-T.A
- [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 rotation.
- 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 (3).
- Remove the belt.
ESSENTIAL : Check that the tensioner roller rotates freely (no stiffness).
CHECKING AND SETTING THE VALVE TIMING
Engines : HDZ - HFX - KFX KFW
Tool kit 4507-T

B1EP067C B1EP066C B1EP068C
115
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Engines : HDZ - HFX - KFX - KFW (continued)
REFITTING THE TIMING BELT
NOTE : Check that the pegs [1] and [2] are in place.
WARNING : Ensure the belt is fitted in the right direction : The arrows a signify the crankshaft direc-
tion of rotation.
Fit :
-The timing belt, with the belt strip b well tightened, in the following order :
Crankshaft pinion, camshaft pulley, water pump pulley, tensioner roller.
-The tool [5] (Ensure it is fitted in the right direction in relation to the timing).
-Bring the tensioner roller into contact with the belt.
-Tighten the nut (2).
PRE-TENSIONING THE TIMING BELT
-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 drive to obtain :
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.
B1EP06AC B1EP069C
116
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N
G
I
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E
E
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G
I
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E
Engines : HDZ - HFX - KFX - KFW (continued)
PRE-TENSIONING THE TIMING BELT (continued)
-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 TENSION
-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 procedure.
117
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Engine : LFX
TOOLS
- Belt tension measuring instrument : 4099-T ou 4122-T
- Camshaft pulley locating peg : 7004-T.G.
- Crankshaft locating peg : 7014-T.N. Tool kit 7004-T
- Square drive : 7017-T.W.
CHECKING
- 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.
- Check that the pegs can be engaged correctly at a and b.
- Fit the belt in the following order : camshaft pulley, crankshaft pinion, water pump
pinion, tensioner roller.
- Peg the camshaft pulley at a and the crankshaft at b.
- Remove the peg at b only.
- Bring the tensioner roller (2) into contact with the belt.
B1EP07SC
118
E
N
G
I
N
E
E
N
G
I
N
E
Engine : LFX (continued)
- Fit the tension measuring tool to the middle of the belt strip c.
- Turn the tensioner roller (2) (anti-clockwise direction) using the tool 7017-T.W
to obtain the value 30 2 SEEM units.
- Remove the tools.
- Rotate the crankshaft by two turns (do not turn backwards).
- Check the setting by positioning the pegs at a and b.
- Remove the pegs.
CHECKING THE TENSION
- Rotate the crankshaft by two turns (do not turn backwards).
- Peg the camshaft pulley at a.
- Fit the tension measuring tool on the belt strip at c.
- The tension measurement should be 44 2 SEEM units.
(If the measurement is not correct, repeat the tensioning procedure).
- Remove
B1EP07RC
119
E
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G
I
N
E
Engine : RFW
B1EP01TC B1BP1WHC
TOOLS
[1] Camshaft pulley locating peg : 7004 - T.G
[2] - Flywheel peg : 7014 - T.N Tool kit 7004 - T
[3] - Timing belt tensioning key : 7017 - T.W
[4] - Toothed sector for locking the flywheel : 6012 - T Tool kit 9022 T
[5] - Belt tension measuring instrument : 4122 T
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.
- 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.
- Check that the camshaft pulley and the crankshaft pinion are correctly pegged.
- Loosen the tensioner roller screw.
- Remove the belt.
120
E
N
G
I
N
E
E
N
G
I
N
E
CHECKING AND SETTING THE VALVE TIMING RELAY 2.0 i
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].
- Remove the tool [1] and fit the crankshaft pulley, without tightening the screw (1).
- Check the pegging of the camshaft/crankshaft.
- Rotate the crankshaft by 2 turns (do not turn backwards).
- Peg the camshaft pulley using the tool [1].
- Fit the tool [5].
ESSENTIAL : The tension value should be : 40 4 SEEM units
- If the value is outside these limits, restart the operation.
- Remove the tools.
B1EP01YC
121
E
N
G
I
N
E
TOOLS
[1] Camshaft setting pegs : (-).0189.A
[2] Crankshaft setting peg : (-).0189.B
[3] Belt locking pin : (-).0189.K Tool kit C.0189.
[4] Angular tightening adaptor : 4069-T.
[5] Hub immobilising tool : 6310-T
- Turn the engine by the crankshaft pinion screw (3) to bring it to pegging position.
- Peg the crankshaft, using tool [2].
- Peg the camshaft pulleys, using tools [1].
NOTE : The pegs [1] must go in without effort.
Engine : RFN
B1BP25PC B1BP22SC
122
M
O
T
E
U
R
CHECKING THE VALVE TIMING (CONTINUED)
WARNING : If the pegs do not engage without effort, restart the fitting and tensioning of the timing belt (see
below).
Remove
- Remove the screws (2), the pulley (1), upper valve cover (4), lower valve cover (3).
- Turn the engine by the screw (13) of the pinion (12) to bring it to pegging position.
- 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).
Engine : RFN
B1EP14JD B1BP23XC
123
M
O
T
E
U
R
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 :
-The guide roller (11), the inlet camshaft pinion (9), the exhaust camshaft pinion (8), the water pump (5), the ten-
sioner roller (6).
NOTE : Make sure that the belt (10) is as flush as possilble with the outer face of the various pinions and rollers.
-Remove the tools [3] and [1].
TIMING BELT TENSION
Adjusting the tension
-Turn the roller (6) in the direction of the arrow b; using an Allen key at a.
-Position the index c in its maximum setting at d.
IMPERATIVE : The index c must stand proud of the notch f by an angular value of 10. If it does not,
replace the tensioner roller (6) or the timing belt and the tensioner roller (6)
Bring the index c to its adjusting position f by turning the tensioner roller (6) in the direction of the arrow e
WARNING: The index c must not stand proud of the notch f : if it does, restart the timing belt tensioning ope-
ration.
IMPERATIVE : The tensioner roller (6) must not turn while its fixing is being tightened up. If it does, recom-
mence the adjusting operation.
Engine : RFN
B1EP14KC B1EP14JD
124
M
O
T
E
U
R
Adjusting the tension (continued).
-Tighten the screw (7) of the the tensioner roller (6) to 2.1 0.2 m.daN.
IMPERATIVE : The hexagonal drive of the tensioner roller (6) must be at 15below the level of the cylinder
head gasket g. If not, replace the tensioner roller (6) or the timing belt and the tensioner roller (6).
Refit (continued).
- Remove the tools [1] et [2].
- Turn the crankshaft 10 times in the normal direction of rotation
IMPERATIVE : No pressure or outside action must be brought to bear on the timing belt.
- Peg the inlet camshaft pulley, using the tool [1].
CHECKS
TIMING BELT TENSION
IMPERATIVE : Check the position of the index c, it should be facing the notch f. If the position of
index c is not correct, restart the adjustment of its position.
Positioning of the crankshaft
- Fit tool [2].
- As long as it is possible to fit tool [2], continue with the refit operations.
IMPERATIVE : If it is not possible to fit tool [2], reposition the flange (14).
Engine : RFN
B1EP14NC B1EP14LC
125
M
O
T
E
U
R
CHECKS (continued).
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 4with tool [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
Engine : RFN
B1BP23XC B1EP14PC
126
M
O
T
E
U
R
Engine : 161 A - DJY - D8C - DHY
TOOLS
- Flywheel locating peg : 7014 - T.J or 7014 - T.R
- Injection pump and camshaft locating peg : 7004 - T.G Tool kit 7004 - T
CHECKS
- Peg the crankshaft.
- Peg the camshaft at a and the injection pump at b.
- Peg the crankshaft.
- Peg the camshaft at a and the injection pump at b.
- Fit the belt in the following order :
Crankshaft pinion, guide roller (3), injection pump (2), camshaft pinion (1),
tensioner roller (5), water pump (4).
- Remove the pegs.
- Free the tensioner roller (5) (nut (6) and screw (7), retighten the screw (7).
- Rotate the crankshaft by 2 turns. Do not turn backwards.
- Loosen the tensioner roller (5), allow the tensioner to operate.
- Retighten the screw (7) and the nut (6). Tighten to 1.8 m.daN.
- Check the setting.
NOTE : The injection pump is removed without changing the valve timing.
(immobilise the injection pump pulley using the screws (8x125) at b).
B1EP09KC B1EP080C
127
M
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E
U
R
Engine : WJZ
TOOLS
- [1] HM screw : (-) 0 188 E
- [2] Locating peg 6 mm : (-) 0 188 H
- [3] Flywheel locating peg : (-) 0 188 D (or 7014-T.J) Tool kit (-) 0 188.
- [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
- Peg the flywheel using tool [3].
- Visually check that the offset between the camshaft and injection pump hub holes, and the corresponding
pegging holes does not exceed 1 mm.
B1CP045C
128
M
O
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R
Engine : WJZ
Setting the valve timing
Peg :
- 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 with E6).
- Tighten the screw (3) to 4 m.daN and finish by carrying out an angular
tightening of 60.
- Retighten screws (4) and (5) by hand.
- Turn the pinions (6) and (2) so that they are at the end of their stops.
(Clockwise direction).
- Place the belt on the crankshaft and hold in place using tool [5].
- Fit the belt in the following order:
Roller (7), pinion (2), pinion (6), pump (8) and roller (9).
B1EP131C B1CP045C B1EP132C B1EP130C
129
M
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R
Engine : WJZ
Setting the valve timing (continued)
NOTE : If necessary, slightly turn pinions (6) and (2) in an anti-clockwise direction
in order to fit the belt.
The angular movement of the belt in relation to the pinions must not exceed
1/2 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 beginning.
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 B1CP045C B1EP132C B1EP133C
130
M
O
T
E
U
R
Engine : WJZ
Rotate the crankshaft by 8 turns (direction of rotation).
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.
- Turn the roller (9) (anti-clockwise direction) using tool [6], to obtain :
42 2 SEEM units.
B1EP134C B1CP045C B1EP133C
131
M
O
T
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R
Engine : WJZ
Tighten :
- The roller (9) to 2.1 m.daN.
- The screws (4) and (5) to 2.3 m.daN.
- The tensioning value should be between 42 2 SEEM units.
ESSENTIAL : If the value obtained is outside the set limits, repeat the ten-
sioning operation.
- Remove the tools [7], [5], [1], [2] and [3].
- Check the valve timing.
B1EP134C B1EP133C B1CP045C B1EP132C
132
M
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Engine : RHY - RHX - RHZ
Tools
[2] Tension lever : (-).188.J2
[3] Engine flywheel peg : (-).0288.D
[4] Belt compression spring : (-).0188.K
[5] Camshaft pinion peg : (-).0188.M
[6] Engine flywheel lock : (-).0188.F
[7] Set of blocking plugs : (-).0188.T
[8] Crankshaft pulley extractor : (-).0188.P
Checking the setting of the valve timing.
Peg :
- The engine flywheel, tool [3].
- The camshaft, tool [5].
WARNING : Should it be impossible to peg the camshaft, check that the off-
set 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.
B1BP1TSC B1BP1TTC B1CP04CC
IMPERATIVE : If pegging is impossible, restart the adjusting.
(See corresponding operation).
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Setting the valve timing.
Peg :
- 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 refitting, carry out the checks below :
Check that :
- The rollers (6), (11) and the water pump (10) turn freely (without play or tightness).
- There are no traces of oil (on camshaft or crankshaft).
B1EP13DD
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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) anti-
clockwise (not by more than one tooth).
B1EP13FC B1EP13GD B1EP13ED
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Setting the valve timing (continued).
- Position tool [1] on the belt at b .
- Turn the roller (6) (anti-clockwise) using tool [2] to attain a tension of :
98 2 SEEM units
- Tighten screw (7) of the roller (6), tighten to 2.5 m.daN.
- Remove one screw (9) from the pinion (12).
(to check that the screws are not against the end of the buttonhole).
- Tighten the screws (9) to 2 m daN.
- Remove tools [1], [2], [3] and [5].
- Rotate the crankshaft 8 times (normal direction of rotation).
- Fit the tool [3].
- Loosen screws (9).
- Fit tool [5].
- Loosen screw (7) (to free the roller (6).
- Fit tool [1].
- Turn the roller (6) (anti-clockwise), tool [2], to attain a tension of :
54 2 SEEM units.
B1EP13HD
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Calage de la distribution (Setting the valve timing (continued).
Tighten :
- The screw (7) of the roller (6) to 2.5 m.daN.
- The screw (9) to 2.m.daN
- 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.
B1EP13HD
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CHECKING AND SETTING THE VALVE TIMING RELAY 2.5 D
B1EP03EC B1BP1WJC
TOOLS
[5] Belt tension measuring instrument : 4122 - T
[1] Flywheel peg : 7014 - T.J Tool kit 7004 - T
[2] Camshaft pulley locating peg : 5711 - T.A
[3] Injection pump pulley locating peg : 5711 - T.B Tool kit 5711 - T
[4] Tensioning lever : 5711 - T.E
CHECKS
- Peg the flywheel using tool [1], at (a) at the front or (b) at the back of the engine.
- 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 timing.
Engine : T9A
9
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Removing the belt
- 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 DIESEL pump, 6 mm peg
- Loosen :
The screws (1) using tool 6016 - T.
The screws (2).
- Tighten the screws (1) and (2) by hand and slacken by 1/6 of a turn.
- Slacken the nut (3).
- Remove the belt.
Engine : T9A (continued)
B1EP01JC B1EP10GC
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Refitting the belt
- Refit in the following order : crankshaft pinion (hold), guide roller, injection pump pulley and camshaft pulley
(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 spanner).
- 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-tension
- Correct the tension, if necessary, using the tool [5].
- Tighten the screws (1) and (2) pre-tighten to 1 m.daN, tighten to 2.5 m.daN.
- Remove all the tools.
- Rotate the engine through 10 turns.
- Peg the flywheel using the tool [1] (direction of rotation).
B1EP10HC B1EP03EC
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B1EP10HC B1EP03EC
Checking the fitting pre-tension
- Tighten the screws (1) and (2) by hand, then loosen by 1/6 of a turn.
- Slacken the belt completely (using the tensioner roller).
- Peg : the camshaft pulley using the tool [2] and the injection pump pulley using the tool [3].
- 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 fitting tension
- Remove the tool [5] (make any necessary correction).
- Tighten the screws (1) and (2) pre-tighten to 1 m.daN, tighten to 2.5 m.daN.
- 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 pump.
- If incorrect, repeat the setting operation.
- Remove the tools.
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B1EP09PC B1EP09QC
TOOLS
[1] Flywheel peg : 7014-T.J Tool kit 7004-T
[2] Camshaft pulley locating peg : 5711-T.A
Tool kit 5711-T
[3] Injection pump pulley locating peg 9.5 mm : 5711-T.B
[4] Pinion locking tool : 6016-T
[6] Tensioning lever : 5711-T.E Tool kit 5711-T
[7] Tensioning locking pin : (-) 0178-T Tool kit (-) 0178
[8] Belt retaining clip : C.0187 J
[9] Camshaft setting checking peg 9.5 mm : 5711-T.C Tool kit 5711-T
CHECKS
- Peg :
- the camshaft pulley using the tool [2].
- the injection pump pulley using the tool [3].
- the flywheel using the tool [1].
NOTE : If pegging is not possible, set the valve timing.
- Remove the tools.
Engine : THX
WARNING : The tools used for checking the setting are different
from the tools used for setting the timing.
9
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B1EP09PC B1BP1WJC B1EP13UC B1EP13VC
SETTING THE VALVE TIMING.
- Rotate the crankshaft in the normal direction of rotation.
- Peg :
- The camshaft pulley using the tool [2].
- The injection pump pulley using the tool [3].
- The flywheel using the tool [1], at (A) at the front or (B) at the rear
of the engine.
- 1/ Behind the starter motor.
- 2/ Behind the engine.
- Compress the tensioner (1) (3/8 square).
- Lock the tensioner using the tool [7].
- Immobilise the camshaft pulley (2) using the tool [4].
- Immobilise the injection pump pulley (3) using the tool [4].
- Slacken the tensioner roller fixing nut (7).
- Remove the belt.
Engine : THX (continued)
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B1EP09UC B1EP13WC
REFITTING THE BELT
- Retighten the screws (4) and (5) of pulleys (2) and (3) by hand.
- Position the pulleys (2) and (3) to the end of the slots (anti-clockwise).
- Refit the belt in the following order :
- Crankshaft (hold it with the tool [8]), the automatic tensioner roller (1),
the camshaft pulley (2), the injection pump pulley (3), the manual tensioner roller (6).
NOTE : If necessary, slightly turn the pulleys (2) and (3) (clockwise), in order to engage the belt.
WARNING : the angular movement of the belt in relation to the pulleys must not exceed one tooth.
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- Operate the tensioner (6) using the tool [6], to ensure that the pulleys (2) and (3) rotate freely.
- Remove the retaining clip [8].
- Fit the tensioning tool [5] at a.
- Turn the tensioner roller (6) in the direction of the arrow, using the tool [6] in order to obtain : 41 2 SEEM units.
- Tighten the nut (7) of the tensioner roller (6) to 4.5 m.daN.
- Remove the tools [5] and [7].
ESSENTIAL : Wait 1 minute. (Positioning of the automatic tensioner).
- Remove one fixing screw from the pulleys (2) and (3).
- Ensure that the pulleys (2) and (3) are not at the end of the slots.
- Tighten screws (4) and (5) of pulleys (2) and (3) as follows :
- Pre-tighten to 0.5 m.daN.
- Tighten to 2.3 m.daN.
- Remove the tools.
- Check the setting.
B1EP13XC
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VALVE CLEARANCE SETTING
The valve clearances must be checked with the engine cold.
G Inlet
Petrol All Types
Diesel All Types
(except 2.5D and 2.5TD)
2.5 D and 2.5 TD
0.20 mm 005 0.40 mm 0.05
Hydraulic adjustment
0.15 mm 0.08 0.30 mm 0.08
Rocking Adjust
1 G 1
3 G 3
4 G 4
2 G 2
4 G 4
2 G 2
1 G 1
3 G 3
Exhaust
G
Inlet
Rocking
Valves
fully open
Adjust
1
3
4
2
3 G 4
4 G 2
2 G 1
1 G 3
Fully open (Exhaust)
POSSIBLE PROCEDURES
For engines with 4 cylinders in a line (1-3-4-2 )
Engines without hydraulic adjust-
ment : the clearance (J) should be
checked opposite the cam.
B1DP13QC
ALL TYPES
Exhaust
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To be read with the Petrol and Diesel correspondence tables
Tools : Toolkit 4103 - T
CHECKING THE OIL PRESSURE
Engine type
Temperature (C)
Pressure (Bars)
Rpm
Engine type
Temperature (C)
Pressure (Bars)
Rpm
TU
1.1 i 1.4 i 1.8i 2.0 i 2.0i 16V
HDZ HFX KFX KFW LFX RFW RFN
90 80
4 5.3 7
4000
XUD
1.8 D 1.9 D 1.9 TD 2.0HDi
2.0 HDi
2.5 D 2.5 TDi
16V
161 A DJY WJZ D8C DHX RHY RHX RHY RHW T9A THX
80 90
3.5 4.5 4.8 5 4 4.5 4.4
4000
EW DJ
XU EW
ALL TYPES
147
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HDZ
HFX
KFX
KFW
LFX
RFN
RFW
1.1 i
1.4 i
1.8i
2.0i 16V
2.0 i
Warning lamp goes out at :
(Bars)
ENGINE OIL PRESSURE SWITCH
Location Engine type
Tightening
torque (m.daN)
ALL TYPES
TU
XU
EW
XU
Above the oil filter
Between the injection pump
and the oil filter
0.5
2.8
3
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161 A
DJY
WJZ
D8C
DHX
RHY
RHX
RHY
RHW
T9A
THX
1.8 D
1.9 D
1.9
TD
Warning lamp goes out at :
(Bars)
ENGINE OIL PRESSURE SWITCH
Location Engine type
Tightening
torque(m.daN)
ALL TYPES
XUD
DW8
XUD
DW10
DJ5
Above the oil filter
Between the injection pump
and the oil filter
0.5
2
3.5
2.5
2.0 HDi
2.0HDi 16V
2.5 D
2.5 TDi Close to the oil filter
2.8
HDZ HFX KFX KFW LFX RFW RFN
G G G G G G
G G G G G G G
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XUD DW8 XUD DW10 DJ5
2.0HDi
1.8D 1.9D 1.9TD 2.0 HDi
16V
2.5D 2.5TDi
161 A DJY WJZ D8C DHX RHY RHX RHZ RHW T9A THX
G G G G
G G G G G G G G
G G
ALL TYPES OIL FILTERS
To be read with the Petrol and Diesel correspondence tables
PURFLUX
LS 867
LS 304
TU XU EW
1.1 i 1.4 i 1.8 i 2.0 i 2.0 16V
PURFLUX
LS 867
LS 304
LS 880
Specifications
(mm) Height (mm)
LS 304
LS 867
76
79 100
89
SAVARA
86 140 LS 880
150
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FILLING AND BLEEDING
- Fit the filling cylinder 4520 - T to the filler orifice. (Except for Relay*).
- Use the coolant to ensure protection between - 15C and - 37C.
- Slowly fill the system.
NOTE : Keep the cylinder filled up (visible level).
- Close each bleed screw once the coolant is flowing without air bubbles.
- Start the engine : Engine speed 1,500 rpm.
- Maintain this speed until the cooling fans have cut in and cut out.
- Stop the engine and allow it to cool down.
- Remove the filling cylinder 4520 - T. (Except for Relay*).
- Top up the system to the max. mark, with the engine cold.
- Refit the filler cap.
(*) =Relay, not equipped with filling cylinder.
FILLING AND BLEEDING THE COOLING CIRCUIT ALL TYPES
E5AP141C
151
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T
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BERLINGO
1.1 i Dual fuel 1.1 i 1.1 i 1.4 i
HDZ HDZ HFX KFX
W3 W3 W4 K'/W3
BOSCH MA3.1 BRC ECOGAS BOSCH BOSCH M. MARELLI
(Petrol) (LPG) MA3.1 MP7.4.4. 1AP40
1 / 1 3
6 510 6 000 6 510 6 500
1 500 1 500 Depending on
except 1st
/
except 1st gearbox ratio
7 / 7 12
Emission standard
Engine type
Make
Injection type
PETROL INJECTION BERLINGO All Types
Air temperature sensor
resistive value (ohms)
Fuel pressure (bars)
Overspeed cut-off (rpm)
Injection cut-in during
deceleration (rpm)
Injector resistive value (ohms)
Engine coolant temperature
sensor resistive value (ohms)
Idle actuator or stepper
motor resistive value (ohms)
Stepper motor: 53 Idle actuator: 37
3800 at 10C 2 500 at 20C 800 at 50C 230 at 90C
3 800 at 10C 2500 at 20C 800 at 50C 230 at 90C
152
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J
E
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T
I
O
N
BERLINGO DISPATCH RELAY
1.1 i Dual fuel 1.1 i 1.1 i 1.4 i
KFX KFW RFN RFW
W3 W4 IF L5 W3
SAGEM SL 96 BRC FLYING SAGEM M. MARELLI M.MARELLI
(Petrol) INJECTION (LPG) S2000 48P2 8P11
3.5 / 2.5
6 400 6 000 5 700
1 500 1 800 / 1 600
12 / 14.5
Emission standard
Engine type
Make
Injection type
PETROL INJECTION BERLINGO - DISPATCH - RELAY
Air temperature sensor
resistive value (ohms)
Fuel pressure (bars)
Overspeed cut-off (rpm)
Injection cut-in during
deceleration (rpm)
Injector resistive value (ohms)
Engine coolant temperature
sensor resistive value (ohms)
Idle actuator or stepper
motor resistive value (ohms)
Stepper motor: 53 Stepper motor: 53 Stepper motor: 53
3800 at 10C 2 500 at 20C 800 at 50C 230 at 90C
3800 at 10C 2 500 at 20C 800 at 50C 230 at 90C
1.1 i HDZ W3 BOSCH MA3.1
1.1 i
HDZ W3
BOSCH MA3.1 (Petrol)/
Dual fuel BRC ECOGAS (GPL)
1.1 i HFX W4 BOSCH M 7.4.4.
1.4 i KFX K' / W3 M. MARELLI 1AP40
850
< 0.5 > 9
1.4 i
KFX W3
SAGEM SL96 /
Dual fuel BRC FLYING INJECTION
1.4 i KFW W4 SAGEM 2000
2.0 i 16V RFN IF L5 M. MARELLI 48P2 850
2.0 i RFW W3 M. MARELLI 8P11 950
IDLING SPEED - ANTI-POLLUTION SYSTEM
Vehicles Engine type
Emission
standard
Make - Injection type
% Content
CO CO2
Idling speed
( 50 rpm)
Manual
Gbox.
Auto. Gbox :
Neutral engaged
BERLINGO
DISPATCH
RELAY
I
N
J
E
C
T
I
O
N
153
BERLINGO - DISPATCH - RELAY
I
N
J
E
C
T
I
O
N
154
1.1 i HDZ W3 BOSCH MA3.1
1.1 i
HDZ W3
BOSCH MA3.1 (Petrol)/
Dual fuel BRC ECOGAS (GPL)
1.4 i KFX K'/W3 M. MARELLI 1AP40
1.4 i KFX IF L4 BOSCH MP7.3 850
< 0.5 > 9 1.4 i KFX L4 BOSCH MP7.3
1.4 i
KFX W3
SAGEM SL96 (Petrol)/
Dual fuel BRC FLYING INJECTION(GPL)
1.8 i LFX W3 M. MARELLI 1AP20
1.6 i 220A2.000 W3 BOSCH MA1.7 850
2.0 i RFW W3 M. MARELLI 8P11 950
IDLING SPEED - ANTI-POLLUTION SYSTEM
Vehicles Engine type
Emission
standard
Make - Injection type
% Content
CO CO2
Idling speed
( 50 rpm)
Manual
Gbox.
Auto. Gbox :
Neutral engaged
BERLINGO
DISPATCH
RELAY
BERLINGO - DISPATCH - RELAY
155
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STANDARD
Brussels directive
Private vehicles : 83/351
> 2 litres 06/89 except special
new cyl. < 2 litres 06/92 derogations for certain
existing cyl. < 2 litres 12/92 private vehicles
cyl. > 2 litres
K 15.04 Petrol
K 15.04 Diesel Utility vehicle With oxygen sensor,
limits = private vehicle without catalytic converter
Private vehicles : 10/89
limits increased
All Types imminent
by 25 %
For private vehicles
and utility vehicles
in major export
W vp 15.05 Petrol
Private vehicles : Brussels directive 88/76
> 2 litres 01/10/88 " Luxembourg Accords "
new models 01/10/89 Replaced by 89/458
existing models + 91/441
ALL TYPES EMISSION STANDARDS
PSA
APV PR
Engines Applicable Vehicles
ECE
R 15.04
ECE
R 15.05
CEE
APPLICATION NOTES CHARACTERISTICS
I
N
J
E
C
T
I
O
N
156
STANDARD
Brussels directives 88/76
and 88/436
Utility vehicle
limits = private vehicle
W vu 15.05
Petrol limits of Brussels
Diesel directive 88/436
7 classes of limits by
vehicle weight
Private vehicles :
With oxygen sensor
Z US 83
Petrol certain non-EEC
and catalytic converter
Diesel European countries
Current Adoption of U.S. standard
for petrol vehicles
certain Export countries
PSA
APV PR
ECE
R 15.05
US 83
CEE
01/10/88
01/10/89
10/94
Utility vehicles :
All Types
new models
existing models
157
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N
J
E
C
T
I
O
N
STANDARD
Private vehicles : Current Adoption of the With catalytic
Y US 87 Diesel
certain non-EEC U.S. standard converter and EGR
European countries
Y2 US 93
Petrol Private vehicles : Current Adoption of the
Diesel certain Export countries U.S. standard
Utility vehicles : Current Adoption of the
X1 US 84
Petrol certain non-EEC U.S. standard
Diesel European countries for light utility vehicles
X2 US 87
Petrol
Utility vehicles : Current Adoption of the
certain non-EEC U.S. standard
Diesel
European countries for light utility vehicles
PSA
APV PR
US 87
US 93
US 84
LDT
US 87
LDT
CEE
158
I
N
J
E
C
T
I
O
N
STANDARD
X3 US 90
Petrol
Private vehicles : Current Adoption of the U.S.
Diesel
certain non-EEC standard for light
European countries utility vehicles
certains pays Export
L1
CEE Petrol
Private vehicles : Brussels directive
19.5 Diesel
< 1.4 litres 07/92 89/458
new models 01/07/93
existing models 31/12/94 Possible alternative to
emission standard L from
1992 to 1994
CEE Petrol
Private vehicles : EU Brussels Directive With oxygen sensor
19.5 Diesel
All Types 93/59 (91/441) and catalytic converter
L
new models 07/92 for petrol vehicles.
existing models 01/93 With catalytic converter
new models 01/96 and EGR
existing models 01/97 for diesel vehicles.
ALL TYPES
EMISSION STANDARDS
PSA
APV PR
US 90
LDT
EURO 1
(EURO
93)
EURO 1
(EURO
93)
CEE
159
I
N
J
E
C
T
I
O
N
STANDARD
Utility vehicles : Brussels Directive 93/59 With oxygen sensor
< 3.5 tonnes and catalytic converter
new models 01/10/93 3 classes depending on for petrol vehicles
modles existants 01/10/94 vehicle weight :
W2 CEE Petrol Class 1 : Class 1 < 1250 kg
W2 Diesel new models 01/97 Class 2 : 1250/1700 kg
existing models 10/97 Class 3 > 1700 kg
Class 2/3 :
new models 01/98
existing models 10/98
L3 CEE Petrol
95 Diesel
< 6 seats and reinforced catalytic converter
< 2.5 tonnes EURO 93 standard for petrol vehicles.
new models 01/96 made stricter With catalytic converter and
existing models 01/97 EGR for diesel vehicles.
PSA
APV PR
EURO 1
(EURO
93)
EURO2
(EURO
96)
CEE
160
I
N
J
E
C
T
I
O
N
STANDARD
< 3.5 tonnes and reinforced catalytic
Class 1 3 classes depending on converter for petrol
W3
CEE Petrol new models 01/97 vehicle weight : vehicles. With catalytic
95 Diesel existing models 10/97 Class 1 < 1250 kg converter and EGR
Gas Class 2/3 : Class 2 : 1250/1700 kg for diesel vehicles.
new models 01/98 Class 2 : 1 700 kg
existing models 10/98
Private vehicles : Brussels Directive 98/69 With 2 oxygen sensors
All Types EURO 2 standard (L3) and catalytic converter for
L4
CEE Petrol
new models 01/2000 made stricter petrol vehicles.
2000 Diesel
existing models 01/2001 Fiscal incentives With catalytic converter and
EGR for diesel vehicles
Gas With EOBD on-board
diagnosis.
ALL TYPES
EMISSION STANDARDS
PSA
APV PR
EURO 2
(EURO
96)
EURO 3
(EURO
2000)
CEE
161
I
N
J
E
C
T
I
O
N
STANDARD
Utility vehicles :
< 3.5 tonnes
Class 1 : 01/2000
new models 01/2001
existing models
Class 2/3 : 01/2001
new models 01/2002
existing models
Private vehicles :
All Types
new models
01/2001
existing models
01/2003
PSA
APV PR
EURO 3
(EURO
2000)
W3
EURO 4 IF / L5
CEE
Petrol
Diesel
Gas
Petrol
Brussels Directive 98/69
EURO 2 standard (L3)
made stricter
Fiscal incentives
3 classes depending on
vehicle weight :
Class 1 < 1305 kg
Class 2 : 1305/1760 kg
Class 3 : 1760 kg
Brussels Directive 98/69
EURO 3 standard (L4) made
stricter
Fiscal incentives
With 2 oxygen sensors
and catalytic converter for
petrol vehicles.
With EOBD on-board dia-
gnosis.
With 2 oxygen sensors
and catalytic converter for
petrol vehicles.
With catalytic converter
and EGR for diesel
vehicles.
With EOBD on-board dia-
gnosis.
162
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O
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ANTI-POLLUTION TECHNICAL CHECKS (FRANCE)
All Types Petrol CO Corrected (In %) All Types Diesel (m -1)
Conditions : At idle, engine warm.
01/96
Less than 4.5 % for vehicles registered before 10/86.
Less than 3.5 % for vehicles registered after 10/86.
With catalytic converter
Greater than 2.0i 89 M.Y.
All Types 93 M.Y.
CO less than 0.5 % at idle speed.
CO less than 0.3 % at fast idle speed between 2500 and 3000 rpm (*)
(*) Except :
TU5 JP : 2200 rpm 100.
XU5JP : 1500 rpm or 3100 rpm ( 100).
XU7JP : 1500 rpm or 3100 rpm ( 100).
NOTE : On XU5JP and XU7JP engines at 1500 rpm, the check should be carried out
with main beams, rear heated screen and cabin ventilation switched on and with the
front wheels on maximum lock (if the vhicle has power-assisted steering).
Lambda Probe value 0.97 to 1.03.
Features :
Xantia, MMDCM injection on 1.6i (BFZ) engine, 1.8i (LFZ)
engine and 2.0i (RFX) engine.
Should the check reveal excessive CO, make sure that the
ECU channel 25 is not connected to earth in error.
(See Info-rapid N77)
01/96
Atmospheric engine.
Less than 2.5 m -1
Turbocharged engine.
Less than 3.0 m -1
ALL TYPES
163
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SAFETY RECOMMENDATIONS : PETROL/LPG DUAL FUEL SYSTEM
SAFETY RECOMMENDATIONS.
Only personnel who have been specially trained to work with petrol/LPG DUAL FUEL vehicles are authorised to carry out repairs to the DUAL
FUEL system
- Ensure that these qualified personnel are provided with acrylic-free overalls (risk of static electricity).
In the event of a major gas leak
- Isolate the vehicle in the open air, away from any buildings.
- Call the emergency services (police and fire brigade) should the situation get out of hand.
ESSENTIAL : Special precautions should be taken when dealing with gas powered systems
ALL TYPES
164
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SAFETY RECOMMENDATIONS : PETROL/LPG DUAL FUEL SYSTEM
PRECAUTIONS TO BE TAKEN BEFORE CARRYING OUT ANY REPAIR WORK
Any work on a gas powered vehicle must be carried out in a venti-
lated area.
- Disconnect the battery negative terminal.
- Ensure the vehicle is connected to earth.
Ensure the vehicle is kept away from the following hazards :
- Sparks.
- Flames.
- Slow combustion (lit cigarette).
Drain the fuel tank using "flare" type material (following the ins-
tructions for this material) before performing one of the following
operations :
- Remove the gauge valve.
- Working on the fuel tank.
Before removing the fuel tank or working on the gas circuit loca-
ted downstream of the safety electrovalve (on the gauge valve),
perform the following operations :
- Close the safety electrovalve.
- Switch the engine to use gas.
- Wait for the engine to stop due to lack of fuel.
After each operation, check that the circuit is sealed using one of
the following systems :
- Electronic detector .
- Soapy water.
- Any other leak detection product.
Remove the fuel tank when the vehicle is to be subject to high
temperatures (above 50C) (spray booth).
Do not clean the engine compartment with a high pressure devi-
ce and do not use detergents .
ALL TYPES
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165
SPECIFICATIONS : PETROL/LPG DUAL FUEL SYSTEM
B1HP0Q4P B1HP0Q5P
ALL TYPES
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1) Fuel tank.
- Capacity : 70 litres.
- Max. pressure : during tests / in operation : 30 bars / 20 bars.
- Max. operating temperature : 50C.
- Location : in the boot.
(2) Fuel gauge
- supply voltage : 12 volts.
- resistance : 0 to 15 ohms empty, 280 to 315 ohms full.
- location : on the gauge valve
(3) LPG gauge valve.
- location : on the fuel tank.
(4) Safety electrovalve.
- power : 8W.
- resistance : 18 ohms.
- location : on the gauge valve
(5) Filler orifice with safety valve.
- location : on the rear right wing.
(6) Injectors and valves.
- location : in the engine compartment, under the air manifold.
(7) Pressure sensor.
- location : on the evaporator control valve support.
(8) Temperature sensor 15C.
- location : on the control valve reheating circuit.
(9) LPG filter.
- Type : paper.
- replacement intervals: every 60,000 Km.
- location : on the evaporator control valve inlet union.
(10) Supply electrovalve.
- power : 8W.
- location : on the evaporator control valve inlet union.
166
ALL TYPES
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167
(11) Evaporator control valve.
- make : NECAM.
- type : MEGA.
ESSENTIAL :
Before checking and setting the pressure, it is essential that you
read through and follow closely BROCHURE REF : 0332.
Setting pressure - 1st stage.
- Setting pressure for a new evaporator control valve :
1450 50 mb.
- Setting pressure for a used evaporator control valve :
1400 50 mb.
Setting pressure - 2nd stage.
- Setting pressure for a new evaporator control valve :
970 10 mb
- Setting pressure for a used evaporator control valve :
960 10 mb.
(12) Stepper motor.
- location : on the distributor.
(13) Distributor.
- location : on the evaporator control valve support.
(14) Distributor electrovalve.
ALL TYPES
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168
052 052 052 052 052
C 15 XUD 7 161A R 8444B R 8444B R 8444B R 8444B R 8444B
934 A 993 B 674 B 964 B 200 A
DWLP 13
R 8448B
B 401B
DW 8 WJZ
DWLP12
R8448
B 371B
DWLP12
R8448
B 371B
DELPHI DIESEL INJECTION PUMP SPECIFICATIONS
PUMP - TYPE - REFERENCE
See : Identification of vehicles Emission standards
Equipment Air con. ADC 1
ADC
+ Air con.
ADC 2
Without
ADC
ALL TYPES
Dispatch
Berlingo
DELPHI DIESEL INJECTION PUMP SPECIFICATIONS ALL TYPES
Dynamic
timing
checking
(at idle)
Engine
type
Pump
Type
Reference
Static timing
Initial advance
Compression
Time
(cylinder N4)
Reference
Injector
Injector
holder
+ injector
Colour
code
Injector
rating
(Bar)
Adjustments (rpm) Rgulation
Fast
idling
Anti-stall Idling
Unladen
rpm
Laden
rpm
None
825
25
161 A 14 1
Green
140.5
2.5
144.5
2.5
900
100
+ peg
3mm
+ 3 mm
thick shim
(1)
875
25
5110
125
WJZ
052
R 8443B/
*
DWLP11
R8445B/ *
CRANKSHAFT
PUMP
TDC HOLE
Value X
engraved on the
pump
Setting
by pegging
6850 D
RDNOS
DC
6903
LCR
673
6001
6730
705 D
135.5
5
950
25
1500
+ 3 mm
thick shim
5350
125
4600
150
(1) = Avec rfrigration 925 25 (
*
) Voir tableau page : 168
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169
CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP C15
Engines : 161 A
Timing the injection pump
- Insert the peg (1) into the pump
- The peg must be against the guide tube a. (If not, turn the engine backwards).
- Fit the tool 4093-T.
- Set the dial gauge to 0.
- When the dial gauge starts to move, it signifies that the piston is nearing T.D.C.
- Peg the flywheel.
- Slowly turn the pump toward the engine until measurement X can be seen.
(X = Value engraved on each pump).
Checking the pump timing
- Peg engaged: The dial gauge should show the reading X 0.03 engraved on the pump.
- If not check the timing again.
Ref : 4093-T
1 Locating peg
2 Support bar
3 Dial gauge
4 Flat probe
5 Relay lever
Tools
C 15 - Flywheel locating peg : 7014-T.R Tool kit
Berlingo - Flywheel locating peg : 7014-T.J 7004-T
- Bracket and peg : 4093-T Tool kit 4123-T
B1HPOL6C B1HPON9C
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170
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171
CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP
Engine : WJZ
Evolution of the checking of the setting of the LUCAS diesel injection pump
NEW ASSEMBLY : RPO 7910 # Old assembly.
Diesel injection pump with hole for
checking the setting
The setting of the diesel injection pump is
done with the aid of the following tools :
- A peg placed at a.
- A peg and a dial gauge placed in the
checking hole at b
Diesel injection pump without a hole for
checking the setting
The setting of the diesel injection pump
is done with the aid of a peg at c.
See method on following pages.
B1HP1A4C B1HP1A5C
ALL TYPES
172
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C15 - BERLINGO - DISPATCH CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP
Tools.
[1] Flywheel locating peg 7014-T.J.
[2] H M8 screw (-).0188.E. Toolkit C.0188
[3] Injection pump setting peg 6 mm (-).0188.H
After carrying out the necessary dismantling operations on the vehicle, proceed in the following manner :
Remove :
- The screws (6), (7), (9), (10) and (12).
- The upper casing (8).
- The intermediate casing (11).
WARNING : Refit the screw (6) equipped with a washer. (Thickness 5 mm).
- Turn the front RH wheel to turn the engine. (Normal direction of rotation).
- Bring the camshaft and injection pump pulleys to their setting point.
- Position the flywheel peg, using tool [1]. (From above the vehicle).
- Turn the engine until the peg [1] engages in the flywheel.
B1BP1S9C B1EP12NC
Engine : WJZ
173
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CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP
Engine : WJZ (continued)
Peg :
- The camshaft hub, using tool [2].
- The injection pump hub, using tool [3].
Impossible to peg the camshaft.
Reset the valve timing (See page 169 ).
Possible to peg the camshaft, but not the injection pump.
Carry out the following operations:
- Loosen the screws of the injection pump hub.
- Turn the injection pump hub.
- Insert the peg [3] into the setting hole.
- Tighten the screws of the injection pump hub. Tighten to 2,3 0,2 m.daN.
ESSENTIAL : If setting the diesel injection pump proves impossible, reset the valve
timing. (See page 169 ).
Remove:
- The tools [1], [2] and [3].
- The screw (6) and the washer.
Reassemble the components.
B1EP12WD B1BP1S9C
C15 - BERLINGO - DISPATCH
174
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ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS C15
Engine : 161 A
Engine cold.
- Check the fast idle speed.
- Ensure that the lever (9) is up against its stop by pushing it in the direction of the
arrow (), otherwise adjust it using the cable clamp (8) and then with the cable tigh-
tener (4).
Fast idle
- Refer to the specifications on page 169.
Engine hot.
- Ensure that the cable (7) is slack.
Engine stopped.
- With the accelerator fully depressed, the lever (5) should be against its stop (3).
Residual output (Anti-stall)
- Insert a shim (see page 169 ) at (A), between the lever (5) and the stop (6), adjust
the engine speed by moving the stop (5) to (see page 169 ).
Idling speed.
Adjust (see page 169 ) by moving the screw (2)
Engine deceleration : from 3000 rpm to 0.
- Rate of deceleration too fast (tendency to stall) : Loosen (6) by a 1/4 turn.
- Rate of deceleration too slow : tighten (6) by a 1/4 turn.
B1HPOYDD
175
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ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS
Engine : WJZ
Adjusting the fast idle.
Engine cold.
- Ensure that the lever (2) is up against its stop to the right.
- If not, adjust the tension of the cable (3) using the cable clamp (1).
- Finish tensioning using the sleeve tensioner (4).
Engine hot.
- Check that the cable (3) is in tension.
Checking the thermostatic sensor.
- There should be a minimum 6 mm cable travel between a cold and a hot engine.
Adjusting the accelerator control.
Prior conditions.
- Engine hot (cooling fan is engaged twice).
Checking the accelerator cable tension.
- Fully depress the accelerator pedal.
- Check that the lever (6) is against its stop (5) otherwise, alter the pin position.
- If not, adjust the position of the accelerator cable tensioning retaining pin.
- Ensure that in the idle position the lever (6) is against the stop (7).
B1HP0K9C
176
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ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS
Adjusting the anti-stall (residual output).
- Insert a 3 mm thick shim (10) between the throttle lever (6) and the anti-stall screw (7).
- Push the stop lever (8).
- Insert a 3 mm diameter peg (9) in the lever (2).
- Adjust the engine speed to 1500 rpm 100 using the stop screw (7).
- Remove the shim (10) and the peg (9).
Adjusting the idle speed.
- Adjust the speed using the idle adjustment screw (11).
- Idling speed : 825 25 rpm.
Checking the engine deceleration.
- Move the throttle lever (6) to obtain an engine speed of 3000 rpm.
- Release the throttle lever (6).
- The deceleration should be between 2.5 and 3.5 seconds.
- The drop should be approximately 50 rpm in relation to the idle speed.
- Deceleration too fast, (the engine has a tendency to stall) slacken the screw (7) by a quarter turn.
- Deceleration too slow, (the engine speed is greater than the idle speed) tighten the screw (7) by a quarter turn
NOTE : In each case, check the idle speed for any necessary adjustments.
B1HP0K9C B1HP0KAC
177
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FITTING DELPHI INJECTORS
B1HP0YEC B1HP0YFC
Engine : 161 A
B1HPOYGC
Fitting an injector
The copper seal (1) and the
fire seal washer (2) are to be
replaced each time they are
removed.
NOTE : Fitting parts of diffe-
rent makes is PROHIBITED.
WARNING : Ensure that the
fire seal washer (2) is fitted
the right way round.
[1] Tool for removing/refitting injectors (2) 7007-T
[2] 7008-T.A Coffret 4123-T
(3) Tighten lightly to prevent any distortion.
Tighten the injector holder
on the cylinder head to :
9 m.daN
C15
178
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FITTING DELPHI INJECTORS
B1DP158C B1HP12VC
Engine : WJZ
B1HPOYGC
Fitting an injector
removed.
[1] Tool for removing/refitting injectors (2) 7007-T
[2] 7008-T.A Coffret 4123-T
(3) ) Tighten lightly to prevent any distortion.
9 m.daN
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INJECTION PUMP SPECIFICATIONS (BOSCH equipment). ALL TYPES
PUMP -TYPE - REFERENCE
Voir identification vhicule Emission standard
Equipment
C 15
BERLINGO
XUD
DW
7
8
9
161A
DJY
WJZ
Without
ADC
With
ADC
ADC
7 keys
ADC
Auto. gbox
Transponder Air con.
ADC
+ air con.
523
R 171/3
XUD 211
R 425/6
XUD 211
R 425/13
XUD 211
R 425/14
XUD 211
R 425/15
VE 4
9F2425R
805
VE 4
9F2425R
804
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INJECTION PUMP SPECIFICATIONS (BOSCH equipment). ALL TYPES
PUMP -TYPE - REFERENCE
See Identification of vehicles Emission standard
Equipment
DISPATCH
RELAY
XUD
DJ5
9TD
9
9TD
TED
DJY
DHX
T9A
THX
DHX
Without
ADC
With
ADC
Transponder Damper
XUD 212
R 513/5
XUD 211
R 425/18
XUD 211
R 425/6
XUD 212
R 513/5
XUD 212
R 513/4
VE R
683
534
2175
R 504/3
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181
825
25
Idling
+ 50
+ 1mm
thick shim
1500
100
+ 3mm
thick shim
95050
95050
17 1
14 1
XUD 211
R 425/
*
056
R 171/
*
ALL TYPES BOSCH INJECTION PUMP SPECIFICATIONS
Engine
type
Pump
Type
Reference
Static timing
(1) Initial advance
Compression
Time
(cylinder N4)
Dynamic
timing chec-
king
(at idle)
Injector
Injector
holder
+ injector
Colour
code
Injector
needle
lift pres-
sure
(Bar)
Fast
idling
Anti-stall Idling
Unladen
rpm
Laden
rpm
DJY
Berlingo
161 A
DJY
Relay
Pump
0.82 mm
after B.D.C
Pump
0.90 mm
after B.D.C
176 1
299 A
256 /
KCA
17S42
248
KCA
17S42
White
Mauve
130
+5
- 0
130
+5
- 0
Idling
+20+50
+ 1mm
thick shim
850
25
510080
5110125 4600150
5150125
(1) Engine : T.D.C. peg hole (*) See tables on pages : 179 and 180.
Reference Adjustments (rpm) Max. speed
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825
25
Idling
+20+50
+ 1mm
thick shim
95025
95050
VE 4
9F2425R/
*
Engine
type
Pump
Type
Reference
Static timing
(1) Initial advance
Compression
Time
(cylinder N4)
Dynamic
timing chec-
king
(at idle)
Injector
Injector
holder
+ injector
Colour
code
Injector
needle
lift pres-
sure
(Bar)
Fast
idling
Anti-stall Idling
Unladen
rpm
Laden
rpm
WJZ
DHX
Dispatch
XUD 212
R 513/
*
Pump
0.66 mm
after B.D.C.
Setting
by pegging
299
299 A
KCA
17S92
218
KCA
20S106
Blue
120 + 8
1500
100
+ 3mm
thick shim
5350125
510080
(1) Engine : T.D.C. peg hole - (2) = 850
+0
With Air cond. - (
*
) See tables on pages : 179 and 180.
- 50
175
+5
- 0
875
25
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(2)
72525
(3)
85050
Idling
+20+50
+ 1mm
thick shim
1500
+ 3mm
thick shim
95050
97550
14 1
144 1
534
R 504/
*
XUD 212
R 513/
*
Engine
type
Pump
Type
Reference
Static timing
(1) Initial advance
Compression
Time
(cylinder N4)
Dynamic
timing chec-
king
(at idle)
Injector
Injector
holder
+ injector
Colour
code
Injector
needle
lift pres-
sure
(Bar)
Fast
idling
Anti-stall Idling
Unladen
rpm
Laden
rpm
T9A
DHX
Relay
THX
683
VER/
*
Setting
by pegging
B.D.C.
9.5 mm
Pump
0.66 mm
after B.D.C.
11
05 D
312
140 PV
3375
955
299
KCE
30S5
KBEL
68PV
187
1118
KCA
17S4
218
None
Blue
White
175
+5
- 0
142.5
2.5
Non
adjus-
table
825
25
5200125
5050125
4900160
(1) Engine : T.D.C. peg hole - (2) = 77525 - (3) = 90050 (
*
) See tables on pages : 179 and 180.
183
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Engines : 161 A - DJY - D8C - DHX
TOOLS
- Flywheel locating peg : 7017-T.R Tool kit 7004-T.
- Ring spanner : 4132-T
- Crescent spanner FACOM 57 : 11 X 13
- Dial gauge : 3089-T.H
- Dial gauge bracket : 7010-T Tool kit 4123-T.
- 31 mm lever : 5003-T.D
TIMING THE PUMP
- Tilt the pump in the retarded direction (away from the engine).
- Fit the timing tool.
- Turn the crankshaft (direction of rotation) until the peg engages in the flywheel.
- Ensure that the pump pinion can be pegged
(if not, rotate the crankshaft by 1 turn).
- Remove the tool 7017-T.R
- Find the B.D.C. position of the pump (by turning the crankshaft backwards) and
set the dial gauge to 0.
- Turn the crankshaft (direction of rotation) until locating peg 7017-T.R engages.
- Turn the pump, in the advance direction (towards the engine) until the dial
gauge
shows (See the table on pages : 181 to 183).
- NOTE : The dial gauge needle must not move when tightening.
SETTING THE BOSCH MECHANICAL INJECTION PUMP C15 - RELAY
B1HPOYKD
184
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Engines : 161 A - DJY - D8C - DHX (continued)
CHECKING THE INJECTION PUMP TIMING
- Remove the tool 7017-T.R.
- Rotate the crankshaft by 1/4 of a turn (opposite direction of rotation).
- Rotate the crankshaft (direction of rotation).
- Peg the flywheel.
- In this position, the dial gauge should show the value X (See the table on pages : 181 to 183 ).
- The value X corresponds to the travel of the pump piston in relation to the B.D.C.
- Remove the tool.
SETTING THE BOSCH MECHANICAL INJECTION PUMP C15 - RELAY
185
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CHECKING THE BOSCH MECHANICAL INJECTION PUMP
B1HP0JCC B1HP12UC
Engine : WJZ
Tools.
[1] Flywheel locating peg 7014-T Tool kit 7004-T
[2] M.8 screw (-) 0 188.E
Tool kit C.0 188
[3] Injection pump pinion peg (-) 0 188.H
[4] Dial gauge 3089-T
[5] Dial gauge bracket 7010-T Tool kit 4123-T
[6] Dial gauge probe 5003-T.D
WARNING : On this engine, only the injection pump can be checked.
- Uncouple the two connectors (1).
- Remove the injector pipes (2) and the timing hole plug (3).
- Fit the probe [6] to the dial gauge [4].
- Place the tool [4] on tool [5].
- Position the assembly in the timing hole (3).
- Set the tool [4] to "0" (BDC of the injection pump).
- Turn the crankshaft (normal direction of rotation).
- Turn the camshaft and injection pump pinions so that they are near their setting points.
- Fit the tool [1].
186
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187
CHECKING THE BOSCH MECHANICAL INJECTION PUMP
B1EP12ZD B1BP1S9C
- Continue to turn the crankshaft until tool [1] is engaged in the flywheel.
- Peg the camshaft hub (tool [2]) and the injection pump hub (tool [3]).
- With the peg correctly inserted, tool [4] should show the value 0.58 0.04 mm.
ESSENTIAL : If it is not possible to peg the camshaft, repeat the valve timing setting
procedure.
If it is possible to peg the camshaft, but not the injection pump, take the following steps :
- Loosen the three injection pump pinion fixing screws.
- Turn the injection pump hub.
- Fit the tool [3].
- Check that tool [4] gives the value 0.58 0.04 mm.
NOTE : If it is not possible to obtain the value 0.58 0.04 mm despite being correctly peg-
ged, check the injection pump.
- Retighten the three injection pump pinion fixing screws.
- Remove the tools.
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Engines : T9A - THX
TOOLS
Flywheel locating peg : 7014-T.J Tool kit 7004-T
- Engine T9A : Injection pump pulley locating peg : 5711-T.B
Tool kit 5711-T
- Engine THX : Injection pump pulley locating peg : 5711-T.C
TIMING THE PUMP
- Fixed value obtained by inserting a 9.5 mm peg at (1).
- See valve timing on pages: 137 to 140 (T9A) and 141 to 144 (THX).
SETTING THE BOSCH MECHANICAL INJECTION PUMP RELAY
B1EP13YC
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ADJUSTING THE BOSCH MECHANICAL INJECTION PUMP CONTROLS C15 - RELAY
Engine cold.
- Check the fast idle speed.
- Ensure that the lever (3) is against its stop (1) by pushing it in the direction of the arrow . If not,
adjust with the cable clamp (2), and then the cable tightener (6).
Engine hot.
- Engine stopped : fully depress the accelerator pedal, check that the lever (10) is against its stop (9).
If not, alter the position of the spring clip (8).
- Loosen the screw (7) until there is no longer any contact with the end of the screw.
- Move the screw (4) to obtain an engine speed of (See table).
Adjusting the residual output.
- Insert a shim a of (See table), between the lever (10) and the screw (7).
Adjust the screw (7) to obtain a speed of (See table).
Adjusting the fast idle speed.
- Place the lever (3) against the screw (1) and turn the screw to obtain an engine speed of (See table)
.
- Check the operation of the manually-operated STOP control.
Adjusting the throttle lever switch (11).
- The contacts will open for an accelerator cable travel of 11 mm or a clearance of 8.5 mm at a.
Engines : 161 A - DJY - D8C
B1HP0YLD
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ADJUSTING THE BOSCH MECHANICAL INJECTION PUMP CONTROLS
Engine : WJZ
- Ensure that the lever (1) is against its stop screw (2).
(If not, modify the position of the spring clip (a))
- Ensure that the lever (1) is against its stop (3) when in idle position.
Preliminary conditions :
-Engine hot (the cooling fan is engaged twice).
-Fast idle control released (clearance J between 5 and 6 mm).
- Remove the screws (14) and the dash-pot (13).
- Untighten the lock-nut (12) (use a long socket).
- Untighten the end screw (3) until there is no longer contact with the lever (1).
- Adjust the idling speed by turning screw (6) (allen screw)
WARNING : Retighten the endscrew (3) until it is in contact with the lever).
- Check that in idling position the lever (1) is up against the end screw (3).
- Hold the end screw (3) in position and tighten the lock-nut (12).
- Check that idling speed is equal to 800 25 rpm.
- Refit the dash-pot (13) and the screws (14).
- Place the pad (11) up against the dash-pot (13).
- With the lever (1) at idle, check the clearance J1 between the screw (10) and the
pad (11) J1 = 2 mm.
B1HP140D
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Engine : WJZ
Anti-stall adjustment.
- Remove screws (14) and the dash-pot (13).
- Untighten the lock-nut (12) (use a long socket).
- Insert a 1 mm shim between the throttle lever (1) and the residual output adjustment
screw (3).
- Turn the residual output adjustment screw (3) to obtain an engine speed of
795 to 875 rpm.
- Hold the adjustment screw (3) and tighten the lock-nut (12).
- Refit the dash-pot (13) and the screws (14).
- Place the pad (11) up against the dash-pot (13).
- With the lever (1) in the idling position, check the clearance J1 between the screw
(10) and the pad (11) : J1 = 2 mm.
- Bring the lever (7) into contact with the screw (9).
- Turn the screw (9) to obtain the fast idle speed.
Engine cold.
- Check that the lever (7) is against the screw stop (9).
- If not, lightly tension the cable (5) using the cable clamp (8).
- Finish tensioning using the sleeve tensioner (4).
B1HP140D
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Engine : WJZ
Adjusting the fast idle speed (continued)
Engine hot.
- Check the operation of the thermostatic sensor on the coolant outlet housing.
- There should be a minimum 6 mm cable travel between a cold and a hot engine.
Checking and adjusting (throttle lever switch).
Checking.
-Make a mark (15) on the cable, 11 mm from the end-piece (16).
-Move the throttle lever (1).
-The contact (19) should open when the mark (15) is aligned with the end-piece
(16) ; otherwise, adjust the switch.
Adjusting.
- Move the throttle lever (1) so that the mark (15) is aligned with the end-piece (16).
- Slacken the screws (17).
- Move the switch (18) until the contact (19) opens.
- Retighten the screws (17).
B1HP140D B1HP141D
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Engine : DHX
- Ensure that the lever (1) is against its screw stop (2). If not, modify the position of the spring clip a.
- Ensure that the lever (1) is against its stop (3) when in idle position.
- Slacken the screw (3) by several turns, until there is no longer any contact with the lever (1)
- Adjust the idle speed to (see table), by turning the adjustment screw (4).
- Insert a 3 mm shim between the throttle lever (1) and the residual output adjustment screw (3).
- Turn the residual output adjustment screw (3) to obtain an engine speed of : (see table).
ESSENTIAL : Any alteration to the residual output will also require the DASHPOT to be adjusted.
ADJUSTING THE BOSCH MECHANICAL INJECTION PUMP CONTROLS RELAY
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Engine : DHX (continued)
Engine cold.
- Slacken the lock nuts (7).
- Turn the adjustment knurl (8) to obtain a clearance of 1 mm.
- Tighten the lock nuts (7).
Engine hot.
- Cancel the control vacuum (electrically disconnect the electrovalve or uncouple the
pipe from the diaphragm).
- Turn the screw (6) to obtain a fast idle speed of : (See table).
NOTE : Disconnecting the fast idle electrovalve will cause a fault code to be recorded,
this must be deleted after the fast idle has been adjusted.
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Engine : DHX (continued)
Checking and adjusting the DASHPOT.
Preliminary conditions:
- Engine hot.
- Adjusted pump controls.
- Check that the lever (1) is against its stop (3) in idle position.
- Push the rod (9) towards the DASHPOT until it touches the stop.
- Move the screw (10) to obtain a clearance J2 of 1 mm between the screw (10) and the rod (9).
B1HP0EUC
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Engines : T9A - THX
- Ensure that the lever (1) is against the stop (2). If not, alter the position of
the spring clip (a).
- Check that in the idle position the lever (1) is against the stop (3).
Preliminary conditions.
- Engine hot (The electric cooling fan is engaged twice).
- Fast idle control released (Clearance (J) between 5 and 6 mm).
- Slacken the screw (3) by a few turns until it no longer touches the lever (1).
- Adjust the idling speed using the screw (4).
B1HP053C
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Engines : T9A - THX (continued)
- Insert a 1 mm shim [1] between the throttle lever (1) and the residual
output adjustment screw (3).
- Turn the residual output adjustment screw (3) to obtain an engine speed of :
(See the table)
- Remove the shim [1].
- Use the screw (9) to obtain a fast idle speed of (See the table).
Engine cold.
- Ensure that the lever (7) is against the stop (9). If not, slightly tension the cable (6)
using the cable clamp (8).
- Finish tensioning with the sheath tensioner (5).
Engine hot.
- Check the operation of the thermostatic sensor on the coolant outlet housing. Between
engine cold and engine hot there should be a minimum 6 mm of cable travel.
B1HP054C
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FITTING BOSCH INJECTORS
Engines : 161 A - DJY - D8C - DHX - T9A
ALL TYPES
Fitting an injector
The copper seal (1) and the fire
seal washer (2) are to be repla-
ced each time they are removed.
NOTE : Fitting parts of different
makes is PROHIBITED.
WARNING : Ensure that the fire
seal washer (2) is fitted the right
way round.
Tighten the injector holder on
the cylinder head to :
All types
9 m.daN
T9A
5.5 m.daN
B1HPOYEC B1HPOYFC B1HPOYGC
[1] Tool for removing/refitting injector 7007-T
T9A 5710-T
[2] 7008-T.A Tool kit 4123-T
(3) Tighten gently to prevent any distortion.
Tighten to 7 m.daN.
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FITTING BOSCH INJECTORS
Engine : WJZ
B1DP158C B1HP12VC B1HP0YGC
Fitting an injector
removed.
9 m.daN
[1] Tool for removing/refitting injector 7007-T
[2] 7008-T Tool kit 4123-T
(3) Tighten gently to prevent any distortion.
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Engine : THX
1 - Injector holder body.
2 - Compensation washer.
3 - Spring.
4 - Compression lug.
5 - Guide washer.
6 - Spring.
7 - Push rod.
8 - Spring housing.
9 - Compensation washer.
10 - Intermediate plate
11 - Stop socket.
12 - Injector connector nut.
FITTING BOSCH INJECTORS RELAY
B1HPOU9C B1HPOUAC
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Vehicles / Models
DISPATCH
RELAY
BERLINGO
1.1 i
1.4 i
1.8 i
2.0 i
1.6 i 220 A 2000 RC7YCC
RC8YCL
RC8YCL
RFW FR7DE
FR7DE
RFC58 LZ
RFC58 LZ
0.9 mm 2.5 m.daN
HDZ
KFX
LFX
Engine type BOSCH CHAMPION EYQUEM
Electrode
gap setting
Tightening
torque
SPARKING PLUGS ALL TYPES
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SPEEDOMETER ALL TYPES
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 :
ST < SD < 1.10 ST + 4 Kph
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 N78-85 TT of 19 October 1978.
NOTE : Before replacing the speedometer, check the conformity of the following points :
- The tyres fitted to the vehicle.
- The gearbox final drive ratio.
- The speedometer drive ratio.
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TU XU EW XU
1 3 7 10
M + JP JB J4 J2U
1.1i 1.4i 1.8i 2.0 i 16V 2.0i
Engine type HDZ HFX KFX KFW LFX RFN RFW
Gearbox MA/4 - MA/5 BE3/5 BE4/5 ML/5-MG/5
Make VALEO LUK VALEO
Mechanism/Type 200 CPR 3800 200 CP 4250 20 CP 4100
230 DNG 235 DT
4700 5650
Clutch disc
200 XJ (E73) 200 F
22 F 12 R 14 X
228 SH
11R 10X11 33 AX 11 A 15X
Ext./Int. lining 200/137 228/155 235/155
Disc lining type F 408 F 808 DS F 202
203
CLUTCH SPECIFICATIONS ALL TYPES
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XUD EW
7 9 8
AU UTF B
1.8 D 1.9 D 1.9 TD 1.9 D
CLUTCH SPECIFICATIONS
Engine type 161 A DJY D8C DHX WJZ
Gearbox BE3/5 ML/5 BE3/5
Make VALEO LUK VALEO LUK
Mechanism/Type 200 CP 4250 200 P 3700 235 CP 5650 215 P 3700 200 P 3700 215 P 3700
Clutch disc
200 B (D93Y) 200 228 SH
216/230 200 215 D
33 AX XUD 11A 15X
Ext./Int. lining 200/137 235/155 216/146 200/137 215/
Disc lining type F 202 F 408 F 202 F 408
ALL TYPES
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DW DJ
8 10 5
B BTED ATED TED
1.9 D 2.0 HDi 2.5 D 2.5 TDi
Engine type WJZ RHX RHZ T9A THX
Gearbox BE4/5 ML/5 ML/5 - MG/5
Make LUK VALEO
Mechanism/Type 215 P 3700 235 T 5700 242 DT 5800
Clutch disc XUD 11 A
242 SH (95Y)
11Q 14X
Ext./Int. lining 215/146 228/155 242/162
Disc lining type F 202 F 202
CLUTCH SPECIFICATIONS ALL TYPES
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CHECKS
- Record the measurement X between positions L1, pedal at rest, and L2, pedal fully depressed.
- Measurement X should be : (Pedal travel).
ADJUSTMENTS
- If the measurement is incorrect, adjust the clutch pedal travel X.
- Loosen the lock nuts (1).
- To adjust the travel to conform with the measurements indicated above, either loosen
or tighten the nut (2). (Tighten the nut to increase the travel, and
loosen it to decrease the travel.)
ESSENTIAL : If the clutch control is new, squeeze the cable sheath before adjusting by declutching
successively a minimum of 20 times.
161 A RFW-DJY-D8C-DHX-T9A-THX
130 5 mm 150 5 mm
Mechanically operated push-action clutch (adjustable)
Engines
Engines
161A
RFW - DJY - DHX
RFW
D8C - T9A - THX
RFW - T9A
RFW - T9A - THX
Gearboxes
Gearboxes
BE3/5
ML/5
MG/5
ME/5
ML/5
MG/5
Mechanically operated pull-action clutch (adjustable)
CLUTCH : CHECKS AND ADJUSTMENTS ALL TYPES
B2BP023C
B2BP00HC B2BP00GC
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B2BP03CD
Push-action clutch with automatic compensation (non-adjustable) (*)
HDZ KFX - KFW - LFX WJZ - DHX Gearboxes
Engines
MA/5 - BE3/5 - ML/5
Refitting the clutch cable.
- Set the pedal to the high position (contact at A).
- Attach the cable end-piece to the pedal.
- Refit a new clip (3) to the pedal.
- Fit the end-piece (4) to the bulkhead (G6 Grease).
- Clip the end-piece (5) to the gearbox.
- Refit the cable to the lever (1).
- Depress the clutch cable several times to set the
assembly in place.
- Check that the end-piece (4) is properly fitted to the
bulkhead.
- Check the operation of the automatic adjusting device.
1) Pull the lever (in direction F), the lever must move
when pulled by hand.
2) Press the clutch pedal very lightly and repeat the
same operation. The lever shouldnt move back.
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Engines : RFW - T9A - THX (Gearboxes MG5T)
Clutch thrust bearing
UNCLIPPING THE THRUST BEARING
- Exert effort at a on the mechanism.
- Exert effort at b on the thrust bearing.
- Remove the thrust bearing.
TOOLS
- Mandrel : 9040-T.D 1 [ 6a ] Tool kit 9040-T
- Half-shells : 9040-T.D 2 [ 6b ]
A - Place the plastic bush (1) in tool [ 1a ].
B - Fit the circlip (2) to the thrust bearing, fit the tool [ 1b ] to the circlip. Place
the assembly in the tool [1a ] (direction of fitting : chamfer downwards).
C - Push at a so as to insert the circlip (2) into the plastic seal (1).
SPECIAL FEATURES : CLUTCH ALL TYPES
B2BP042D B2BP044C B2BP043C B2BP045C
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WARNING : If a system blockage is detected when checking, or if the pedal has been removed, the
pedal position must be adjusted. This position is obtained by the angular displacement of the stop sup-
ports "a" and "b".
Procedure.
- Loosen the nut (6) and the screw (7).
- Using a lever, raise the stop support (8) to its highest position.
- In this position, there must be a substantial free play in the pedal.
- Lower the support until there is a free play of 2 1 mm.
- Tighten the screw (7) and the nut (6).
- Check that the outer cable slides freely (at rest, the pedal is against its upper stop A,
the outer cable length should be variable).
Features
- The automatic adjusting device requires no manual adjustment.
- Pedal travel remains constant for all models 145 5 mm.
- Automatic adjustment is achieved by modifying the curvature of the outer cable.
- Be careful to route the outer cable correctly, and do not add any supplementary fixing points.
Engines : HDZ - KFX - KFW - LFX - WJZ - DHX
B2BP03EC
Adjustment of push-action clutch with automatic compensation (adjustment of catch-up system)
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Engines : HDZ - KFX - KFW - LFX - WJZ - DHX
NOTE : This cable has an automatic adjusting device which takes up the clutch disc wear and makes up for the compression of the outer cable.
DESCRIPTION
1 - Metallic cable, crimped on both ends.
2 - Outer cable or telescopic duct.
3 - Outer cable stop, bulkhead side (fixed point on the bodyshell).
4 - Outer cable stop, gearbox side (fixed point on the gearbox).
5 - Tensioning spring ensuring the outer cable is at its maximum length.
6 - Wear take-up device.
7 - Attaching end-piece.
B2BP02SC
Engines : HDZ - KFX - KFW - LFX - WJZ - DHX (Suite)
Operation
For the adjusting device to operate correctly, it
is necessary that :
The pedal is at rest (against its upper stop).
The locking sleeve (1) is slightly compressed,
the rollers (2) are free, the outer cable (3)
length may vary.
Clutch disengagement phase
As soon as the pedal is applied, the attaching
end-piece (4) leaves the sleeve (1) which moves
back. The rollers, pushed by the spring (5) jam
the system.
The cable behaves like a conventional cable.
Engagement / adjustment phase
The pedal returns to rest on its upper stop ;
The attaching end-piece (4) pushes the sleeve
(1) which frees the rollers. The outer cable (3),
kept extended by the spring (6), becomes :
- shorter if the clutch disc is worn.
- longer if the outer cable is compressed.
NOTE : The pedal gear has a non-adjustable assisting device.
B2BP03QD
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Payload (Kg) 600 - 765
Engine type 161 A WJZ
Tyres-Rolling circumference 155/ R13 1.725 m
Gearbox BE3/5
Gearbox ident. plate 20 TB 89 20 TE 11
Reduction box ratio 19x79
Speedometer ratio 22x19 19x17
Diesel
1.9 D 1.8 D
GEARBOX AND TYRE SPECIFICATIONS C15 - All Types
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175/65 R14 - 1.720 m 175/70 R14 - 1.720 m
MA/5
20 CD 42 20 CN 01 20 CD 43 20 CN 02 20 CN 01 20 CD 74
13x59
21x18 19x17 21x18
BERLINGO All Types GEARBOX AND TYRE SPECIFICATIONS
Engine type
Payload (Kg)
Tyres-Rolling circumference
Speedometer ratio
Gearbox
Gearbox ident. plate
Reduction box ratio
1.4i 1.1i
475/600
HDZ HFX
600/800
KFX KFW
Petrol
Engine type
Payload (Kg)
Speedometer ratio
Gearbox
Reduction box ratio
1.8i 1.4i
600/800
KFX KFW LFX
Petrol
175/70 R14 - 1.720 m
MA/5 BE3/5
20 CN 14 20 CN 13 20 CN 12 20 TE 25 20 TE 26
13x59 17x61 19x72
21x18 19x17 19x17 22x19
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175/65 R14 - 1.720 m 175/70 R14 - 1.720 m
BE3/5
20 TE 22 20 TE 20 20 TE 24 20 TE 50 20 TE 49 20 TE 24
19x79 17x77 19x79 17x77 19x79
19x17 22x19 19x17 22x19
BERLINGO All Types GEARBOX AND TYRE SPECIFICATIONS
Engine type
Payload (Kg)
Speedometer ratio
Gearbox
Reduction box ratio
1.9 D
WJZ
600/800
WJY
Diesel
Engine type
Payload (Kg)
Speedometer ratio
Gearbox
Reduction box ratio
2.0 HDi
600/800
RHY
Diesel
175/65 R14 - 1.720 m 175/70 R14 - 1.720 m
BE3/5
20 TE 27 20 TE 49 20 TE 28 20 TE 29
19x75 17x77 19x70
19x17 22x19
215
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2.0i 16V 1.9 D
BVA
RFN WJZ
195/70 R15 - 1.99 m 205/65 R15 - 1.93 m
BE4/5 AL4 BE4/5
20 DL 26 (1) 20 DL 27 (2) 20 TB 31 20 DL 33 (1) 20 DL 35 (1)
14x62 21x73 15x74 15x76
18x14 20x16 22x18 18x14
1.9 D 2.0 HDi
WJZ RHX RHZ
195/70 R15-1.99 m - 205/65 R15 - 1.93 m 205/65 R15 - 1.93 m
BE4/5 ML/5
20 DL 34 (2) 20 DL 36 (2) 20 DL 93 (3) 20 DL 91
15x74 15x76 14x71 15x67
22x18 18x14 25x20
GEARBOX AND TYRE SPECIFICATIONS
Engine type
Speedometer ratio
Gearbox
Reduction box ratio
Engine type
Speedometer ratio
Gearbox
Reduction box ratio
Petrol
Diesel
Diesel
DISPATCH All Types
(1) = 195/70R15 = 2.01 m (2) = 205/75R15 = 2.05 m
(3) = 205/75R16 = 2.195 m (4) = 215/75R16 = 2.22 m
216
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GEARBOX AND TYRE SPECIFICATIONS RELAY 4 x 2 All Types
(a) = Plastic pins
(b) = Steel pins
Payload (Kg)
Petrol
2.0 i
1000 - 1400 1800
RFW
195/70 R 15 (1) 205/70 R 15 (2) 205/75 R 16 - 2.195m ou (4)
ML/5 MG/5
20 LE 21 20 LE 37 20 KM 14
13x73 13x83
25x20 (a) 26x20 (a) 15x21 (a)
Diesel
1.9 D 1.9 TD
1000 1000 - 1400
DJY DHX
195/70 R 15 (1) 205/70 R 15 (2) 195/70 R 15 (1) 205/70 R 15 (2)
ML/5
20 LE 21 20 LE 37 20 LE 20 20 LE 36
13x73 14x75
25x20 (a) 26x20 (a) 25x20 (a) 26x20 (a)
Engine type
Gearbox
Reduction box ratio
Speedometer ratio
Payload (Kg)
Engine type
Gearbox
Reduction box ratio
Speedometer ratio
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(a) = Plastic pins
(b) = Steel pins
Payload (Kg)
Diesel
2.5 D
1000 - 1400
T9A
195/70 R 15 - 2.01 m ou 205/70 R 15 - 2.05 m
ML/5
20 LE 19 20 LE 35 20 LE 52 20 LE 54
13x73
25x20 (a) 26x20 (a) 25x20 (b) 26x20 (b)
Diesel
2.5 D
1800
T9A
205/75 R 16 - 2.195 m ou 215/75 R 16 - 2.22 m
MG/5
20 KM 60 20 KM 24
12x75
15x21 (a) 15x21 (b)
Engine type
Gearbox
Reduction box ratio
Speedometer ratio
Payload (Kg)
Engine type
Gearbox
Reduction box ratio
Speedometer ratio
218
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Diesel
2.5 TDi
1000 - 1400 - 1800
THX
195/70 R 15 - 2.01 m ou 205/70 R 15 - 2.05 m 215/70 R 15 - 2.068m
MG/5
20 KM 65 20 KM 19 20 KM 67 (*) 20 KM 33 (**)
13x68
15x19 (1) 15x19 (2) 16x21 (1) 16x21 (2)
Diesel
2.5 TDi
1800
THX
205/75 R 16 - 2.195 m
MG/5
20 KM 66 20 KM 26
12X71
15X21 (1) 15X21 (2)
Payload (Kg)
Engine type
Gearbox
Reduction box ratio
Speedometer ratio
Payload (Kg)
Engine type
Gearbox
Reduction box ratio
Speedometer ratio
GEARBOX AND TYRE SPECIFICATIONS
(1) Plastic pins (*) = 20 KM 67 : only for version 231 G 42.
(2) Steel pins (**) = 20 KM 33 67 : only for version 232 G 42.
RELAY 4 x 2 All Types
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(a) = Plastic pins
(b) = Steel pins
Payload (Kg)
Diesel
2.5 TDi 2.5 D 2.5 TDi
1000 1400 1800 1400
THX T9A THX
195/70 R 15 - 2.01 m 205/75R16 (1) ou (2) 195/70R15 (1) ou (2)
ME/5 MG/5
20 KM 04 (*) ou 20 KM 60
13x73 12x75
20x25 (a) 15x21 (b)
Diesel
2.5 TDi
1400 1800
THX
195/70 R 15 - 2.01 m ou (2) 215/75 R 16 - 2.22m ou (4)
MG/5
20 KM 19 20 KM 26
13X68 12x71
15X19 (b) 15x21 (b)
Engine type
Gearbox
Reduction box ratio
Speedometer ratio
(1) = 195/70 R 15 - 2.01 m (2) = 205/70 R 15 - 2.05 m
(3) = 205/75 R 16-2.195 m (4) = 215/75 R16 - 2.22 m
Payload (Kg)
Engine type
Gearbox
Reduction box ratio
Speedometer ratio
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Engines : HDZ - KFX - KFW
GEARBOXES - MA/4 - MA/5 BERLINGO
B2CP20FC B2CP20GC B2CP34HP
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Engines : HDZ - KFX - KFW
GEARBOX CONTROLS MA4 - MA5 BERLINGO
B2CP17KD
Q
W
T
E
R
E
1 - Gear lever.
2 - Gear control bar.
3 - Fixed point on gearbox.
4 - Gear engagement ball-joint.
5 - Gear selection ball-joint.
Adjustment.
The gear change mechanism is not adjustable.
Grease the linkage points and ball-joints.
Note :
To clip the ball-joints in place, set the gear control in
neutral.
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Engines : LFX - 161A - WJZ - WJY - RHY
GEARBOXES BE3/5 C15 - BERLINGO - DISPATCH
B2CP20JC B2CP20HC B2CP34JP
Engine : 161 A
GEARBOX CONTROLS BE3/5 C15
B2CP39WD
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.
(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
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Engines : LFX - WJZ
GEARBOX CONTROLS BE3/5 BERLINGO
1 - Gear lever.
2 - Gear control bar
3 - Gear engagement rod
4 - Gear selection rod
5 - Torque rod
6 - Linkage ball-joint
7 - Gearbox fixed point
Adjustment
The gear change mechanism is not adjustable.
Grease the linkage ball-joints.
Note :
To clip the ball-joints in place, set the gear control in
neutral.
B2CP17LD
Q
R
U
E
W
T
Y
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GEARBOX CONTROLS BE3/5 - ML/5
B2CP350P
Nota : Non rglable
Engine : WJZ
DISPATCH
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GEARBOXES - BE4/5
ENGINE : RFN
B2CP3BNC B2CP3BPD
DISPATCH
(a) = Marking zone.(Sequence and serial no.).
(b) = Locaton of the identification label.
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GEARBOXES - BE4/5
Engine : RFN
Description
(1) Primary shaft.
(2) Clutch bearing guide.
(3) Gearbox casing.
(4) Clutch housing.
(5) Reverse idle.
(6) Drive gear (3
rd
gear).
(7) 3
rd
/4
th
gear synchroniser
(8) Drive gear (4
th
gear).
(9) Drive gear (5
th
gear).
(10) 5th gear synchroniser.
(11) Driven gear (5
th
gear).
(12) Driven gear (2
nd
/ 4
th
gear )
(13) Driven gear (2
nd
gear).
(14) 1
st
/ 2
nd
gear synchroniser
(15) Driven gear (1
st
gear).
(16) Secondary shaft.
(17) Differential gear.
(18) Satellite gears.
(19) Planet gears.
(20) Differential housing.
(21) Speedometer drive.
(22) Extension.
d Adjusting shims : 0.7 to 2.4 mm
(0.10 mm and increasing by 0.10 mm).
c Adjusting shims: 1.4 to 1.6 mm
(0.10 mm and increasing by 0.10 mm).
B2CP3BQP
DISPATCH
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GEARBOXES BE4/5
Engine : RFN
Tightening torques
Ref. Description Number of screws m.daN
1 End guide 3 1,2 0,1
2 Clutch housing 13 1,3 0,1
3 Primary shaft nut 1 7,2 0,7
4 Secondary shaft nut 1 6,5 0,7
5 Yoke holding screw 2 1,5 0,1
6 Differential gearwheel screw 2 6,5 0,7
Reverse gear contact 1 2,5 0,3
7 Differential housing 4 5 0,5
8 Breather pipe 1 1,7 0,2
9 Rear housing cover screw 7 1,2 0,1
10 Top-up plug 1 2,2 0,2
11 Differential housing screw 4 1,2 0,1
12 Drain plug screw.. 1 3,5 0,4
B2CP3BSP
B2CP3BTD
DISPATCH
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GEARBOX CONTROLS BE4/5
Engine : RFN
(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 bul-
khead.
(*) = These two cables cannot be separated.
B2CP3BWD
DISPATCH
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GEARBOX - CHECKS AND ADJUSTMENTS BE4/5
Engine : RFN
Principles of adjusting the gear controls.
WARNING : Cables should be adjusted each time the gearbox,
gear controls or power unit are removed.
Principles.
Lock the gear lever in neutral position,
using too l: 9607-T.
Place the gearbox in neutral.
Couple the cables on the lever.
Fit the ball-joints on the gearbox lever.
Lock the cable lengths with the ball-joint
locking keys.
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.
NOTE : Changing an individual ball-joint is possible
as long as the locking key is removed.
Unclip at b, using two small screwdrivers.
B2CP3BXC B2CP3BYC
DISPATCH
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GEARBOX - CHECKS AND ADJUSTMENTS BE4/5
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.
- 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 neu-
tral.
Lock the cable lengths with the ball-joint locking
CHECKS.
- 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.
- Refit the trim under the gear lever.
- Refit the air filter assembly.
Adjusting the gear controls.
Engine : RFN
B2CP3C6C B2CP3C0C
DISPATCH
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Tightening torques m.daN.
(1) - 8.5
(2) - 19
(3) - 25
(7) - 2.4
(8) - 0.7
(4) - 2.7
(5) - 2.5
(6) - 2
(9) - 2
(10) - 2.6
(11) - 4.3
(12) - 4
(13) - 2
(14) - 4
(1) - Drive axle drain plug 4
(2) - gearbox drain plug 4
B2CP34KP B2CP39UC B2CP39VC
Engines : T9A - THX
GEARBOXES - ME/5 RELAY
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Engines : T9A - THX
GEARBOX CONTROLS ME/5 RELAY
Adjustment
The selection cable, only, on the lever side, via yoke (1).
This adjustment allows the gear lever knob to be positioned in
relation to the steering wheel centre line : 304 mm.
ME/5
Ball-joints 10 mm. Selection cable
Engagement cable
A
C
B
D
Lever
side
Gearbox
side
Ball-joints 13 mm.
123 5 mm (adjustable)
144 1.5 mm
123 1.5 mm
129 1.5 mm 139 1.5 mm
MG/5
Note : Grease ball-joint G6.
(2) = Cable retaining clip.
B2CP39XD
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Engines : RFW - DJY - DHX - D8C - RHZ - RHX - RHW - T9A
GEARBOXES - ML/5
ALL TYPES
B2CP34LC
Tightening torque : m.daN.
-Gearbox casing/clutch bell housing fixing 1.8
-Speedometer support fixing 1.5
-Clutch bell housing/engine fixing :
- Screws H10 x 150 L 75 6
- Screws M12 x 175 L 70 8.5
235
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GEARBOX CONTROLS ML/5
B2CP0350P
Note : Non-adjustable.
Engines : RFW - DJY - DHX - D8C - RHZ - RHX - RHW - T9A
ALL TYPES
236
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Engines : RFW - T9A - THX - F28TDCR
GEARBOXES - MG/5 RELAY
- Tighten the strainer to : 1 m.daN.
- Tighten the heat exchanger to : 5 m.daN
B2CP34NC B2CP34MD
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Engines : T9A - THX
GEARBOX CONTROLS ME/5 RELAY
Adjustment
The selection cable, only, on the lever side, via yoke (1).
This adjustment allows the gear lever knob to be positioned in
relation to the steering wheel centre line : 304 mm.
ME/5
Ball-joints 10 mm. Selection cable
Engagement cable
A
C
B
D
Lever
side
Gearbox
side
Ball-joints 13 mm.
123 5 mm (adjustable)
144 1.5 mm
123 1.5 mm
129 1.5 mm 139 1.5 mm
MG/5
Note : Grease ball-joint G6
(2) = Cable retaining clip.
B2CP39XD
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GEARBOXES AUTOMATIQUE - AL 4
WARNING : This gearbox benefits from a special CITROEN semi-synthetic oil
which cannot be mixed with any other oil.
The gearbox is lubricated for life.
(a) Part reference.
Engine : RFN
B2CP30ZD
DISPATCH
239
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RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX
Engine : RFN
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 50 kph over a distance of 50 km.
Driving.
Never drive with the ignition switched off.
Never push the vehicle to try to start it ;
(impossible with an automatic gearbox).
Lubrication
The automatic gearbox is only lubricated when the engine is running.
REMOVING - REFITTING. (Automatic gearbox).
WARNING : Never place the gearbox on its lower casing
(risk of deforming the tray and damaging the hydraulic valve block).
Never use the connections as handles for raising, turning, holding or
pushing the gearbox.
ESSENTIAL :
- Fit the converter retaining peg while the gearbox is removed.
- Fit the centring peg to locate the gearbox on the engine:
(remove the converter retaining peg just before locating)
WARNING : With the safety programme selected, a snatching can
be felt when changing from P R or N R.
PRECAUTIONS TO BE TAKEN
DISPATCH
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RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX
Engine : RFN
PROCEDURE BEFORE REPAIRS
AL 4 gearbox
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.
DISPATCH
241
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RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX)
Engine : RFN
AL 4 gearbox only
B2CP31FD
PROCEDURE BEFORE REPAIRS
Oil level AL 4 (prior conditions).
- Vehicle in horizontal position.
- Check gearbox is not in back-up mode.
- Remove the oil filler plug (3).
- Add 0.5 litres extra oil into the gearbox.
- Foot on the brake, change through all the gears.
- Selection lever in position "P"
- Engine running, at idle.
- Oil temperature : 60C (+8C; -2C), measured with the aid of a diagnostic tool.
- Remove the oil level plug (3).
- Thread of oil then "drip-drip": refit plug (3). Tighten 2.4 m.daN.
- "Drip-drip" or nothing : refit the plug (3).
- Stop the engine.
- Add 0.5 litres extra oil into the gearbox.
- Repeat the oil level procedure.
NOTE : The level is correct at the moment the thread of oil becomes drip-drip.
- Refit the oil filler plug (3). Tighten to 2.4 m.daN.
- Initialise the oil usage counter (open the diagnostic tool procedure).
DISPATCH
242
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Engine : RFN
PROCEDURE BEFORE REPAIRS (continued)
When the ECU detects an erroneous or absent value
on input or output :
- It writes the fault in memory.
- For each associated context, it writes the context of the oldest fault
in memory.
- It initiates a back-up mode strategy.
There are two types of back-up modes :
- The ECU makes replacement values available (relating to comfort,
gear selection quality, loss of functions).
- Access to emergency programme (only 3rd gear and reverse
are available)
Reading the fault codes.
Absence of fault codes:
Carry out a measure of parameters.
Presence of anomalies:
- YES : Carry out the necessary repairs.
- NO : Read the fault codes engine ECU
- Carry out a road test.
Following an initialisation of the ECU, for a certain period of time
there may be an inconsistent gear selection quality (while ECU para-
meters are adapting to the gearbox).
To achieve a consistent standard, it will be necessary to carry out a
road test taking in frequent gear changes (auto-adaptive laws).
DISPATCH
243
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Engine : RFN
ECU : Downloading, Configuration, Initialisation (pedal) (continued)
Downloading.
ECU downloading procedure :
- Follow the diagnostic tooling procedure.
A new ECU or downloaded update is always configured
with the following options :
- SHIFT LOCK gear selection lever position.
- OBD outlet (emission standard L4).
If the ECU is to be fitted to a vehicle without one or both
of these options:
- Carry out a configuration which inhibits the diagnosis
of the option(s) concerned.
Pedal initialisation.
A pedal initialisation must be carried out in the following cases :
- Replacement of the automatic gearbox ECU.
- Replacement of the automatic gearbox.
- Downloading of the ECU configuration.
- Adjustment or replacement of the accelerator cable.
- Replacement of the throttle potentiometer.
IMPERATIVE : For a certain period of time, while the ECU parameters are adapted to the gearbox, there may be an inconsistent
gear selection quality. To achieve a consistent standard, it will be necessary to carry out a road test taking in frequent gear changes
(auto-adaptive laws).
DISPATCH
244
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Engine : RFN (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 posi-
tion P.
To unlock the gear selection lever from position P, switch on the igni-
tion and press the brake pedal.
During a repair, the shift-lock can be unlocked by pressing the locking fin-
ger a (see corresponding operation).
DISPATCH
B2CP3CFD
245
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C 15
DRIVESHAFTS - GEARBOXES
Tightening torques (m.daN)
Driveshaft
nut
Right
Left Tool kit
Driveshaft
bearing
Engines Gearbox Vehicles
Berlingo MA/4 - MA5 HDZ-HFX-KFX-KFW NONE 24.5
C 15 161 A-WJZ
32.5
Berlingo BE3/5 LFX-WJZ-WJY-RHY 1 7114-T.W 7114-T.X 7116-T
WJZ 10 + 60
BE4/5 RFN 1.8 32
Dispatch
ML/5 RHZ-RHY-RHW 10 + 60 5701-T.A 9017-T.C NON
AL4 RFN
Seal extractor
32.5
RH / LH (-) 0338C
(-) 0338
(-) 0338 J1 (-) 0338 H1
+ (-) 0338 J2 +(-) 0338 H2
ME/5 T9A- THX 1
ML/5
RFW-DJY-DHX
5701-T.A 9017-T.C NON
Relay
D8C-T9A
MG5T
RFW-T9A- THX
F28TDCR
5708-T.J 5708-T.H 5708-T
Gearbox oil seal mandrels
ALL TYPES
8 Relay 10 Q et 14 Q 16
18
Tightening torque (m.daN) for wheel bolts
Berlingo 8.5 Relay 18 Q
Dispatch 10
10-14Q = 45
18 Q = 50
A
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P
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The heights H2 are measured from the ground to the bodyshell cross-
member to which the axle rear silent blocks are secured.
The heights H1 are measured from the ground to the lower section of
the subframe, close to the arm fixing.
General conditions
- Check the tyre pressures. - Vehicle empty.
- Release the handbrake. - 5 litres of fuel in the tank.
Front height (Non-adjustable) Rear height (Adjustable)
AXLE GEOMETRY C15 - All Types
B3DP06VD B3CP04VD
A
X
L
E
S
S
U
S
P
E
N
S
I
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Reference height
600 765
203 214
515 527
Payload (Kg)
Heights
10 mm
Fr. (H1)
Rr. (H2)
Engine type
Diesel
161 A
Adjusting the rear heights (H2).
- Height H2 is obtained by two half-shells 1 located between the dam-
per 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
AXLE GEOMETRY (continued) C15 All Types
B3DP06WD
A
X
L
E
S
S
U
S
P
E
N
S
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N
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248
Rear reference height (Non-adjustable).
Front reference height (Non-adjustable).
C15 - All Types AXLE GEOMETRY (continued)
161 A - WJZ
Manual Power-assisted
Engine type
Steering
Payload (Kg)
Camber
Castor
King pin inclination
Tracking
Counter camber
Tracking
600 765 600 765
030 041 030
055 147 055
850
834
850
+ 2
+ 3
Diesel
30
40
(mm)
20 9
+ 1.6 5 (mm)
A < B = Positive figure : + = TOE-IN
A > B = Negative figure : - = TOE-OUT
NOTE
B3CP04LC
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249
C15 - All Types FRONT AXLES
(1) Anti-roll bar
B3CP04WD B3CP04XD
Payload (Kg)
Bar diameter (mm)
600 765
23 24
Diesel
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S
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P
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N
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250
C15 - All Types REAR AXLES
B3DP06XD B3DP06YD
(1) Anti-roll bar
Payload (Kg)
Bar diameter (mm)
600 765
18 19
Diesel
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P
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251
C15 - All Types MANUAL STEERING
B3EP109D B3EP03SD
A =
B = 3 mm
C = 8 1 mm
a = G6
D = 0.01-0.06 mm
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252
C15 - All Types POWER-ASSISTED STEERING
B3EP10AD B3EP03SD
A =
B = 3 mm
C = 8 1 mm
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253
Front height
L1 = H1 - R1
Rear height
L2 = H2 - R2
H1 = Measurement from the centre line of the arm front pivot screw
to the ground.
R1 = Radius of the front wheel, under load.
L1 = From centre of wheel to centre line of arm front pivot screw.
H2 = Measurement from under the rear crossmember to the ground.
R2 = Radius of the rear wheel, under load..
L2 = Distance between the centre of the wheel and the underside
of the rear crossmember.
AXLE GEOMETRY BERLINGO - All Types
B3CP04YC B3CP04ZC B3DP070C B3DP06ZC
CONVENTIONAL reference height measurement
Simplified measuring points
Measure from the flange of the jacking point to the ground
NOTE : To measure the wheel radius, use tool 8006-T.
L1 = H1 - R1 L2 = H2 - R2
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254
BERLINGO - All Types AXLE GEOMETRY (continued)
SIMPLIFIED measuring points at the front and rear of the vehicle
CAUTION: To facilitate the reference height setting of the vehicle, measurements can be taken from the flange of the jacking point.
This method can not be used in legal cases.
H1' = Front Height H2' = Rear Height
Only measure R1, H1' and R2, H2'.
Apply :
L1 = H1' - R1
L2 = H2' - R2
Compare with the values in the tables on pages 249-250.
B3DP04KD
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255
Table of values at REFERENCE HEIGHT
Vehicle loaded with 4 people weighing 70 Kg + 40 Kg of luggage in the boot,
and with all reservoirs full, including the fuel tank.
Vehicles
Height
175/65 R14
- 85
- 16
- 125
- 80
- 26 - 90 175/70 R14
L1 = H1 - R1 L2 = H2 - R2 L1 = H1 - R1 L2 = H2 - R2
Familiale
Van
Platform cab
- 58
- 95
- 42
- 68
- 125
- 135
- 106
- 132
- 95 - 68 - 135 - 132
475 Payload
(Kg)
Payload
(Kg)
600
800
800
Front height
CONVENTIONAL Measuring SIMPLIFIED Measuring
Rear height Front height Rear height
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256
Table of values in RUNNING ORDER
Vehicle empty with all reservoirs full, including the fuel tank.
Vehicles
Height
175/65 R14
- 55
40
- 95
- 24
30 - 34 175/70 R14
L1 = H1 - R1 L2 = H2 - R2 L1 = H1 - R1 L2 = H2 - R2
Familiale
Van
Platform cab
- 54 - 38 - 95 - 26
- 60 - 32 - 100 - 32
- 68 - 39 - 108 - 25
475 Payload
(Kg)
Payload
(Kg)
600
800
800
Front height
CONVENTIONAL Measuring SIMPLIFIED Measuring
Rear height Front height Rear height
The values in RUNNING ORDER for platform cabs cannot be checked :
CHECK at REFERENCE HEIGHT.
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257
Reference height values of the front and rear axles
Front axle (All types) Rear axle
ESSENTIAL : When checking the axles, the vehicle must be at reference setting
- Compress the suspension until the calculated values are obtained ( See page : 255 ). Tools used :
- [1] Set of two suspension compressors 9511-T.A - [2] Set of four straps 9511-T.B - [3] Set of four shackles 9511T.C
Adjust-
ment
Steering
Manual
- 010 - 029
- 1 - 3
YES
NO
0
mm
130 40 3 40
1050 1
0 1 Camber
Castor
Tracking
Assisted
+010 +029
+ 1 + 3
Adjust-
ment
Van
Floor cab
Familiale
475
+ 017
+ 037
+ 037
+ 056
+ 017
- 002
+ 005
+ 024
+1.8
+3.8
+3.8
+5.8
+1.8
- 0.2
+0.5
+2.5
NO
- 115 1
Camber
Tracking
600-800 175/65R14 175/70R14
0
mm
A < B = Positive figure + = TOE-IN
A > B = Negative figure - = TOE-OUT
ATTENTION
NOTE : The difference in height between the two sides must be less
than 10 mm.
B3CP04LC
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258
FRONT AXLE BERLINGO - All Types
Steering
Manual Power-assisted
B3CP050P B3BP13LD B3BP12UC B3BP12VC
Tightening torques (m.daN).
Damper nut
Cup screw
Link rod ball joint
Suspension leg swivel
Link rod ball joint
Swivel lower ball joint
Driveshaft nut
Wheel bolt
Lower front articulating point
Lower rear articulating point
and anti-roll bar bearing
Screw under rear articulating
point
Subframe to bodyshell fixing
4,5
2,5
4
5,5
4
4
32
8,5
8,5
6,5
3
8
1 -
2 -
3 -
4 -
5 -
6 -
7 -
8 -
9 -
10 -
11 -
12 -
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259
REAR AXLE
Evolution :
- New rear hub nut (3).
- Washer discontinued (2).
(A) Old fitting
(1) Rear hub nut.
(2) Thrust washer.
ESSENTIAL : Tighten to : 27,5 2,7 m.daN
(B) New fitting
(3) Rear hub nut.
ESSENTIAL : Tighten to : 25 2,5 m.daN.
NOTE : It is possible to have both types of fitting on the same axle.
The old nut (1) requires the fitting of the thrust washer (2).
WARNING : do not fit a thrust washer (2) with a new nut (3).
ESSENTIAL: Respect the tightening torque to be applied when fitting.
WARNING: Identify the type of fitting, before starting a repair.
B3DP08AD
BERLINGO All Types
Evolution : Rear hub nut
Old # 15/12/1999. New 15/12/1999 #
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260
REAR AXLE BERLINGO - All Types
B3DP03LD
Front silentblock mounting on axle
Anti-roll bar screw
Front silentblock mounting
on bodysh.
Wheel bolt
Rear silentblock mounting on axle
Damper shaft nut
Stub bearing nut
Rear silentblock mounting on
bodyshell
8
5,5
4
8,5
5,5
11
28
6
1 -
2 -
3 -
4 -
5 -
6 -
7 -
8 -
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261
SUSPENSION (continued) BERLINGO - All Types
NOTE :
- The right hand torsion bar is identified by 1 paint line.
- The left hand torsion bar is identified by 2 paint lines.
Van Familiale
475 600
AV
AR
AR
Anti-roll bar
(mm)
Payload (Kg)
Colour code
Anti-roll bar
(mm)
Colour code
800 X - SX
21 22
20 21 19
Rouge Orange Bleu
19.6 21.3 20.5
Rose Violet Rouge
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262
MANUAL STEERING BERLINGO - All Types
(A) : Left hand drive = Green
: Right hand drive = White
L : Shaft length = 306 1.5 mm
(1) Steering wheel, with AIRBAG
(according to equipment).
(4) Steering column adjuster.
(2) AIRBAG to steering wheel fixing : 0.8
(3) Steering wheel fixing : 3.3
(5) Steering column fixing : 2.3
(6) Cardan joint fixing : 2.3
B3EP041D
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BERLINGO - All Types MANUAL STEERING (continued)
(1) Ball joint nut on swivel : 4
(2) Link rod lock nut : 4.5
(3) Steering rack ball-joint : 6
(4) Fixing on subframe : 5
(5) Thrust pad bracket clamp screw : 1.2
B3EP03ZD
Pinion (Teeth)
Steering Manual
6
29
73.5
Yellow
Rack (Teeth)
Steering rack travel
Colour of stop
NOTE : Length of the pre-adjusted steering track rods : 371 mm
between the ball joint centres.
263
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POWER-ASSISTED STEERING BERLINGO - All Types
(A) : Left hand drive = Green
: Right hand drive = White
L : Shaft length = 306 1.5 mm
(1) Steering wheel, with AIRBAG
(according to equipment).
(4) Steering column adjuster
(2) AIRBAG to steering wheel fixing : 0.8
(3) Steering wheel fixing : 3.3
(5) Steering column fixing : 2.3
(6) Cardan joint fixing : 2.3
B3EP043D
264
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265
BERLINGO - All Types POWER-ASSISTED STEERING (continued)
(1) Ball-joint nut : 4
(2) Lock nut : 4.5
(4) Fixing on subframe : 5
(5) Pipe connections : 2.4
(6) Valve fixing : 1.2
(7) Thrust pad bracket screw : 1.2
(8) Steering ram screw : 5.5
(9) Steering ram nut : 5.5
B3EP040D
Pinion (Teeth)
Steering Power-assisted
7
28
71.7
Rack (Teeth)
Steering rack travel
NOTE : Length of the pre-adjusted steering track rods : 371 mm
between the ball-joint centres.
Identification colour of the distribution valve = Red
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266
POWER-ASSISTED STEERING (continued) BERLINGO - All Types
Power-assisted steering assembly
Power-assisted valve and pump unions : 2.5
Power-assisted valve unions : 2.5
(1) Upper front fixing : 2.5
(2) Upper rear fixing : 2.2
(3) Lower front fixing : 2.2
NOTE : Tightening sequence :
- Tighten screws (1) and (3)
- Lightly tighten, then tighten screw (2).
Oil type : TOTAL FLUIDE ATX.
Power-assisted steering system capacity :
1 dm
3
B3EP10BD
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267
AXLE GEOMETRY DISPATCH - All Types
Front
Version
Van
Combi
Rear
Values at reference height
H1 H2
157 164
164 164
Table of values at REFERENCE HEIGHT
With recommended tyre pressures
B3BP07DD
The reference heights must be checked between the jacking point and the ground.
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268
AXLE GEOMETRY DISPATCH - All Types
Table of values in RUNNING ORDER
Vehicle empty with all reservoirs full (excluding the fuel tank which should contain 7 litres).
Panel/glazed van
Heights
Front Rear
Engine Engine type
H1 H2
220
210
205
265
Version
Van (900 kg)
Heights
Front Rear
Engine
1.9 TD DHX
Engine
type H1 H2
215
205
265
255
Version
Equipment
Base
Panel van
Heights
Front Rear
Engine
1.9 D WJZ
Engine
type H1 H2
205
195
265
255
Version
Equipment
Base
All options
All options
1.6 i
1.9 D
1.9 TD
220A2.000
D9B
DHX
Engine
Version
Engine type
Combi heights (1)
Front H1 Heights Rear H2
195
210
195 255
260
1.9 D
1.6 i
Diesel All Types
WJZ
220A2.000
D9B DHX
Version
Glazed van
Heights
Front Rear
H1 H2
205 265
165 150
195 255
Base
Standard All Options
Confort All Options
Equipment Engine type Engine
1.9 D WJZ
ATTENTION
269
DISPATCH - All Types AXLE GEOMETRY
Manual steering
Front Rear Front Rear
Power-assisted steering
Castor
Camber
0830 0415
1 0.5
0
mm
-1 30
1128 40
0 30
130 30
Toe-in
Toe-out
0 30
1128 40
330 30
-1 30
ESSENTIAL : When checking the axles, the vehicle must be at reference setting
B3CP04LC
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270
SPECIAL FEATURES : FRONT AXLES
IMPORTANT : evolution of tightening torques Engine subframe
(1) Engine subframe front fixing.
(2) Engine subframe rear fixing.
Old mounting :
(1) Front fixing 13.5
(3) Rear fixing 13.5
From DAM No. = 8197 = 19/04/1999
(date of modification)
Interchangeability :
Both component types are available from RP.
New mounting :
(1) Front fixing 10.7
(2) Rear fixing 10.7
B3CP055D
DISPATCH - All Types
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271
FRONT AXLES (continued) DISPATCH - All Types
B3CP04PD B3CP04QD
Mark A. LH side
Mark B. RH side
C = Front of vehicle.
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REAR AXLES DISPATCH - All Types
1 - Strengthening bar on the bodyshell.
2 - Stabiliser bar.
272
B3DP071D
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273
DISPATCH - All Types MANUAL STEERING
B3EP054D
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POWER-ASSISTED STEERING
All Types
Assisted Steering
Pinion (Teeth)
Rack (Teeth)
Steering rack travel (mm)
9
33
152
B3EP09ZD
274
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275
RELAY - All Types AXLE GEOMETRY
Load reference height
Rear Front
All Types Steering
Tracking (mm)
Castor
Camber
Conditions for checking and adjusting
- Correct tyre pressures.
- Vehicle unladen.
- Full reservoirs.
- Nobody in the vehicle.
0 1
1 30
0 30
Non-
adjustable
Versions
H.
10 Q - 14 Q
192 mm
18 Q
197 mm
Height H is measured between the body floor and above the rear axle tube.
The reference height is obtained by modifying the vehicle load.
B3DP01ID B3CP04LC
NOTE
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RELAY - All Types FRONT AXLES
B3CP052C B3CP017C B3CP051D
1 8
2 8
3 25
4 20
5 17
7 21
276
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277
RELAY - All Types
B3DP072D
Tightening torques m.daN
(1) 14
(2) 15.5
ESSENTIAL : The axle suspension components (1),
(2) and (3) must be tightened with the vehicle at refe-
rence height.
(See the table on page 275 ).
REAR AXLES
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RELAY - All Types AXLE GEOMETRY
10 Q Version
Anti-roll bar (1)
14 Q
24
Flexible stop (2)
Flexible stop (3)
Rear
18 Q 14 Q
85
80 130
10 Q Version
Height
Front
10-14 Q
72-195
72-210
/ Length
(mm)
With
Anti-roll
bar
Without
18 Q
72-191
18 Q
B3BP10MD
B3BP10LD
278
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279
RELAY - All Types MANUAL STEERING
All Types
5
28
170.5
Pinion (Teeth)
Rack (Teeth)
(1) Steering/subframe fixing : 6.5
(2) Ball-joint /swivel fixing : 7
(3) Link rod lock nut : 6
B3EP10CD
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POWER-ASSISTED STEERING RELAY - All Types
(1) Steering/subframe fixing 6.5
(2) Ball-joint /swivel fixing 7
(3) Ball-joint /swivel fixing (*) 8.5
(4) Link rod lock nut 6
(5) Steering rack ball-joint 9
All Types
7
34
170.5
Pinion (Teeth)
Rack (Teeth)
280 280
(*) = See Info-rapid Relay R No. 4
B3EP10DD
B
R
A
K
E
281
C15 - All Types BRAKE SPECIFICATIONS
600 765
1.8 D
Frt
mm
Master cylinder
Payload (Kg)
Master-vac
Caliper/piston makes
Brake disc
Disc thickness
Minimum disc thickness
Brake pad grade
20.60
151.20
GIRLING 48
247
10
8
ABEX 413
Rr
mm
Brake cylinders or calipers
Brake drums min. / max.
Make
Brake lining quality
Compensator cut-off
22
230/228.60
FERODO 617
Load sensitive
B
R
A
K
E
282
BRAKE C15 - All Types
B3FP111D B3FP112D
Clearance J = 3 to 5 mm to be adjusted by turning the stop switch. After adjusting, tighten the lock nut (1) to 1 m.daN.
B
R
A
K
E
283
C15 - All Types BRAKE (continued)
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 produc-
tion stage.
B3FP113D
B
R
A
K
E
284
HANDBRAKE C15 - All Types
Adjusting the parking brake.
- 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
B
R
A
K
E
285
C15 - All Types BLEEDING THE BRAKE CIRCUITS
- 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.
B
R
A
K
E
286
BERLINGO - All Types BRAKE SPECIFICATIONS
1.1 i 1.1 i - 1.4 i 1.4 i 1.1 i - 1.4 i
Frt
mm
mm
Master cylinder
Versions
Payload (Kg)
Options
Master-vac
Brake disc
Disc thickness/min. thickness
Ventilated
Non-ventilated
Brake pad grade
(1) (2) (1) - (2) (3)
475 600
Without ABS
23.8
228.6
LUCAS C54 / 54
266 266
266
20.4 / 18.4
AS - FM 380
13/11 20.4 / 18.4
266
13/11
22.2
228.6 / 230
LUCAS RAI (
*
)
ABEX 4930/2 with thermoclips
800
With ABS (**)
All types 500
Rr
Brake drums / max.
Make
(*) = Automatic toothed adjusting mechanism (**) = With or without ABS.
(1) = Van (2) = Familiale (3) = Multispace
NOTA : The floor cabs are identical to the 800 kg vans.
IMPERATIVE : It is essential to use thermoclips with the ABEX 4930/2 brake linings
1.8 i
B
R
A
K
E
287
BERLINGO - All Types BRAKE SPECIFICATIONS (continued)
1.9 D
Frt
mm
mm
Master cylinder
Versions
Payload (Kg)
Options
Master-vac
Brake disc
Disc thickness/min. thickness
Ventilated
Non-ventilated
Brake pad grade
(1) (2) (1) - (2)
600
Without ABS
23.8
228.6
LUCAS C54 / 54
266
20.4 / 18.4
AS - FM 380
22.2
228 / 230
LUCAS - ENERGIT / RAD (
*
)
ABEX 325
800
With ABS
All types
Rr
Brake drums / max.
Make
(*) = Automatic toothed adjusting mechanism
(1) = Van (2) = Familiale
B
R
A
K
E
288
BERLINGO - All Types BRAKE SPECIFICATIONS (continued)
Specifications of braking compensators
Vehicles
All types
Payload (Kg)
State of vehicle load
Running order+Driver
Total gross weight
Total gross weight
Total gross weight
Total gross weight
Weight on
rear axle
(Kg)
Cut-off point
(Bar)
Rear pressure for
100 Bar in front
(Bar)
Spring colour
code
Supplier
475
500
600
800
409
809
954
1097
937
417
418
461
11.5 (13 maxi)
56.5
75
90
70
11.5 (13 maxi)
11.5 (13 maxi)
18.5 (20 maxi)
25
63
79
92
74.5
Green
Green
Blue
Yellow
TEVES
25
25
30.5
In running order + driver = Empty vehicle with driver, all reservoirs full including fuel tank.
B
R
A
K
E
BERLINGO - All Types BRAKE (continued)
B3FP06ZD B3CP053P
2 m.daN
2.3 m.daN
289
B
R
A
K
E
290
CHECKING AND ADJUSTING : LOAD SENSITIVE BRAKE COMPENSATOR BERLINGO - All Types
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 page 291).
- 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 page 291).
B
R
A
K
E
BERLINGO - All Types CHECKING AND ADJUSTING : LOAD SENSITIVE BRAKE COMPENSATOR (continued)
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 a lock nut (1).
Vehicle type
(Payload Kg)
475
409 25
540 26
675 58
417 25
596 27
775
418
644
870
70
25
32
81
600
800
Weight on the rear axle
(Kg)
Pressure on the rear brakes
(Bars)
291
B3FP115C
B
R
A
K
E
292
HANDBRAKE (Adjusting) BERLINGO - All Types
B3FP06YD
CHECKING - ADJUSTING
- Check that the cables are correctly routed.
- Apply and release the parking brake four times.
- Set the parking brake to the 4
th
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 5
th
notch.
- Check that the rear brakes are tightened.
- With the handbrake released, ensure that the wheels can be
rotated freely by hand.
B
R
A
K
E
BERLINGO - All Types 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
ESSENTIAL: Order of bleeding
Top up the level : Using the brake fluid sold by the CITROEN Replacement Parts Division.
With ABS : BOSCH 5.0
Wheel : - Rear right.
- Rear left.
- Front right.
- Front left.
Wheel : - Rear right.
- Rear left.
- Front right.
- Front left.
293
B
R
A
K
E
294
DISPATCH - All Types BRAKE SPECIFICATIONS
1.9 D
1.6 i
Frt
mm
Master cylinder
Master-vac
Brake disc
Disc thickness / min.thickness
Brake pad grade
815
(1) - (2)
22.2 23.8 22.2
254 280 254
BOSCH SV 57 LUCAS C 57 BOSCH SV 57
257 281 257
20.4 / 18.2 26 /24
GALFER 3314 1 TU
19 (Thermo clips 70)
255 / 256
DON 7124 ou ABEX 4930
Load sensitive double compensator
20 / 500 - 90 / 1125
20.4 / 18.2
(3) - (4) (7) (3) - (4) (1) - (2)
Combi Combi 815
Rr
mm
Brake cylinders
Rear compensator
Compensator cut-off (Bars) / Weight (kg) (1)
Total gross weight (kg)
Versions
(1) = Cut-off point as a function of the weight
on the rear axle.
(1) Panel van. (3) Combi 5-seater (5) Combi 8-seater (7) Floor cab
(2) Glazed van. (4) Combi 6-seater (6) Combi 9-seater (Short chassis)
B
R
A
K
E
295
DISPATCH - All Types BRAKE SPECIFICATIONS (continued)
1.9 TD
Frt
mm
Master cylinder
Master-vac
Brake disc
Disc thickness / min.thickness
Brake pad grade
815
(1) - (2)
22.2 23.8
254 280
BOSCH SV 57 LUCAS C 57
257 281
20.4 / 18.2 26 /24
GALFER 3314 1 TU
19 (Thermo clips 70)
255 / 256
DON 7124 ou ABEX 4930
Load sensitive double compensator
20 / 500 - 90 / 1125
(3) - (4) - (5) - (6) (1) - (2) Long et court (7)
Combi 900
Rr
mm
Brake cylinders
Rear compensator
Compensator cut-off (Bars) / Weight (kg) (1)
Total gross weight (kg)
Versions
(1) = Cut-off point as a function of the weight
on the rear axle.
(1) Panel van. (3) Combi 5-seater (5) Combi 8-seater (7) Floor cab
(2) Glazed van. (4) Combi 6-seater (6) Combi 9-seater (Short chassis)
B
R
A
K
E
296
DISPATCH - All Types BRAKES (continued)
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.
- 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).
Drum
Blue En A : Shim
En B : Shim Green
B3FP10TC
B
R
A
K
E
BRAKES (continued) DISPATCH - All Types
Hydraulic checking and adjusting of the compensator
- 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.
- Bleed screw diameter : caliper 8 x 125 - Wheel cylinder 7 x 100.
- Place the vehicle at setting height.
- Table of pressures (Bars).
WARNING : The front pressures should be obtained by exerting a single pressure on the brake pedal.
- The pressures recorded in the left and right circuits must be identical.
- If the pressures are not correct, carry out the following 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).
All Types
Front (Disc) Rear (Drum)
40 40
90 90
140 96
TOOLS
297
B3FP10UC
B
R
A
K
E
298
DISPATCH - All Types HANDBRAKE
Adjusting the handbrake.
- 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 lock nut (2).
B3FP116D
B
R
A
K
E
299
280
BRAKE SPECIFICATIONS RELAY- All Types
2.0 i 1.9 TD 1.9 D
Frt
mm
mm
Master cylinder
Master-vac
Payload (kg)
Caliper make
Brake
disc
Piston (mm)
Disc
thickness
Brake pad grade
1000 1400 1800 1000 1400 1000
232.8 # 15091010 (2) 279.4 228.6
22.2 # 15091010 (1) 25.4 22.2 # 15091010 (1) 22.2
LUCAS
40/48 45/48 40/48
280 280
280
18/15.9
18/15.9
Non-ventilated
Ventilated
Non-ventilated
Ventilated
300
24/21.9
Rr
mm
Wheel cylinder
Make
(1) = 23.8 mm from chassis 15091011 # - (2) = 290.3 mm from chassis 15091011 #
18/15.9
18/15.9
GALFERT 3314 - FERIT I.D. 455
25 28.6 25
254 - 255.6
LUCAS
ENERGIT 550 FF - DON 8213 FF
232.8 # 15091010 (2)
B
R
A
K
E
300
RELAY - All Types BRAKE SPECIFICATIONS (continued)
2.5 TDi 2.5 D
Frt
mm
mm
Master cylinder
Master-vac
Payload (kg)
Caliper make
Brake
disc
Piston (mm)
Disc
thickness
Brake pad grade
1000 - 1400 1800 1000 - 1400 1800
232.8 # 15091010 (2) 279.4 232.8 # 15091010 (2) 279.4
25.4 22.2 # 15091010 (1) 25.4 22.2 # 15091010 (1)
LUCAS
40/48 45/48 40/48 45/48
280 280
280 300
280
280
18/15.9
18/15.9
Non-ventilated
Ventilated
Non-ventilated
Ventilated
300
24/21.9
Rr
mm
Wheel cylinder
Make
18/15.9
18/15.9 24/21.9
GALFERT 3314 - FERIT I.D. 455
25 28.6 27 28.6
254 - 255.6
LUCAS
ENERGIT 550 FF - DON 8213 FF
(1) = 23.8 mm from chassis 15091011 # - (2) = 290.3 mm from chassis 15091011 #
B
R
A
K
E
301
REAR BRAKE CORRECTOR RELAY - All Types
Checks and adjustments
TOOLS
- Brake pressure checking equipment : Tool kit 4140-T.
- Weighing machines
PREPARING THE VEHICLE
- Vehicle in running order.
- Braking circuit bled.
- Vehicle on a hoist (with bearing race).
- Connect the tool 4140-T.
- Connect the front pressure gauge to one of the front brakes.
- Connect the rear pressure gauge to one of the rear brakes.
- Replace the bleed screws with sensors (1).
WARNING : Bleed screws - the thread of the front and rear bleed screws is not identical.
- Bleed the tool 4140-T.
- Chock the front wheels.
- Place the rear wheels on balances.
B3FP037C
B
R
A
K
E
302
RELAY - All Types REAR BRAKE CORRECTOR (continued)
Checks Adjustments
- 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.
- Slacken the nuts (3)
- Press the brake pedal to obtain 80 bars on the front brakes.
- Gradually operate the control (2) in order to obtain a rear
brake pressure corresponding to the weight on the rear
axle.
- Tighten the nuts (3)
- Release the brake.
- Check the adjustment.
B3FP038C
45 900
26 750
45 900
With ABS
Without ABS
18 Q
ABS
10 Q
14 Q
45 900
700
900
650 30
45
34
Weight on the
rear axle
(Kg)
Vehicle type
Pressure on the
rear brakes
3 Bars
14 Q
10 Q
B
R
A
K
E
303
HANDBRAKE RELAY - All Types
CHECKING AND ADJUSTING
- Raise the vehicle and place it on stands with the rear wheels
hanging free.
- Release the parking brake.
- Depress the brake pedal several times.
- Set the brake to the 3
rd
notch.
- Tighten the nut (1) until the rear brakes are tightened.
- Firmly pull the handbrake lever 4 or 5 times.
- Set the brake to the 3
rd
notch.
- Check that the rear brakes are tightened.
- With the handbrake released, ensure that the wheels turn free-
ly.
- Tighten the lock nut (2).
B3FP117D
B
R
A
K
E
304
RELAY - All Types BLEEDING THE BRAKES
The bleeding operation can be performed : Using brake bleeding equipment or in the conventional way
B3FP118C
Without ABS
Wheel :
- Rear right.
- Rear left.
- Front right.
- Front left.
NOTE: Front caliper, 2 bleed screws, start with the upper piston,
then proceed with the lower one.
With ABS
Wheel :
- Rear right.
- Rear left.
- Front right.
- Front left.
NOTE: Front caliper, 1 bleed screw
ABS hydraulic valve block : 2 bleed
screws (1).
ESSENTIAL: Order of bleeding
Top up the level : Using the brake fluid sold by the CITROEN Replacement Parts Division.
E
L
E
C
T
R
I
C
A
L
S
Y
S
T
E
M
1.8D
VALEO D7R8
5 H, T, C, VC
MELCO M001T80082
C15 BOSCH 1108085 4 VC
1.9D VALEO D7R26 5 H, T
VALEO D7R27 6 C, VC
305
STARTER MOTORS
Vehicles - models Starter motor types Class Climate
C15 - All Types
CLIMATE : T (Temperate), H (Hot), C (Cold), VC (Very Cold)
E
L
E
C
T
R
I
C
A
L
S
Y
S
T
E
M
306
1.1i
VALEO D7E7
1.4i
BOSCH 1116003 1 H, T, C
MELCO M002T13081
VALEO D6 RA 571 3 VC
VALEO D7E5
2 H, T
1.4i (Power steering
BOSCH 1112041
+ Aircon)
VALEO D6 RA 571 3 C, VC
1.8i
VALEO D6RA661
3 H, T, C
BOSCH 1107019
BOSCH 1108085 4 VC
1.9D (DW8) VALEO D7R26 5 H, T
VALEO D7R27 6 C, VC
STARTER MOTORS
BERLINGO - All Types
BERLINGO
307
E
L
E
C
T
R
I
C
A
L
S
Y
S
T
E
M
VALEO D6 RA 661
3 H, T
2.0i 16v BOSCH 107019
BOSCH 1108084 4 C VC
VALEO D6RA109
BOSCH 4 H, T
MELCO M001T80381
1.9D
VALEO D7R8
5 C
MELCO M001T80082
VALEO D7R12 6 VC
VALEO D7R8
5 H, T
2.0 HDi MELCO M001T80082
VALEO D7R12 6 C, VC
STARTER MOTORS
DISPATCH
308
E
L
E
C
T
R
I
C
A
L
S
Y
S
T
E
M
BOSCH 1107019
3 H, T, C
2.0i VALEO D6RA66
BOSCH 111473 4 VC
1.9D VALEO D7R8
5 H, T, C
1.9TD MELCO M001T80082
2.5D / 2.5TDi
VALEO D7R12 6 VC
BOSCH 1218157 6 H, T, C, VC
STARTER MOTORS
Vehicles - models Types dmarreur Class Climate
RELAY - All Types
RELAY
E
L
E
C
T
R
I
C
A
L
S
Y
S
T
E
M
309
Classes and types
Engine Gbox. Without air con. Climate With air con. Climate
1.8D
BOSCH A120310064 H, T
7
VALEO A11 VI 40 C, VC
1.9D (without
VALEO A11 VI 91 H, T
7
power steering) MAN BOSCH A120316004 C VC BOSCH A120316004 C, VC
8 VALEO A13 VI 96 H, T, C, VC 8 VALEO A13 VI 96 H, T, C VC
1.9D (with
7
power steering)
BOSCH A120316004 C VC
ALTERNATORS ALL TYPES
E
L
E
C
T
R
I
C
A
L
S
Y
S
T
E
M
Classes and types
1.1i
BOSCH A120310028 C, VC
1.4i
VALEO A11 VI 55 H, T VALEO A11 VI 55 H, T
7 BOSCH A120310028 C, VC
7
VALEO A11 VI 91 H, T VALEO A11 VI 91
T, C, VC
1.9D
MAN
BOSCH A120316004 C ,VC BOSCH A120316004
8 VALEO A13 VI 96 H
7
VALEO A11 VI 91
H
8 VALEO A13 VI 96 H
BOSCH A120316004 VALEO A14 VI 27+
2.0 HDi VALEO A14 VI 27+ 15 BOSCH A12051611 T, C, VC
15 BOSCH A12051611 T, C, VC MELCO A004TF0091
MELCO A004TF0091
310
E
L
E
C
T
R
I
C
A
L
S
Y
S
T
E
M
311
Classes and types
1.4i
VALEO A11 VI 55 H, T VALEO A11 VI 55 H, T
7
7
VALEO A11 VI 91 H, T VALEO A11 VI 91
T, C, VC
1.9D BOSCH A120316004 C, VC BOSCH A120316004
MAN
8
VALEO A13 VI 96
7
VALEO A11 VI 91
H
VALEO A13 VI 96
H
BOSCH A120316004 VALEO A14 VI 27+
2.0 HDi VALEO A14 VI 27+ 15 BOSCH A12051611 T, C, VC
15 BOSCH A12051611 T, C, VC MELCO A004TF0091
MELCO A004TF0091
312
E
L
E
C
T
R
I
C
A
L
S
Y
S
T
E
M
Classes and types
BERLINGO REINFORCED (WITHOUT POWER STEERING)
1.9D 12 MELCO A003TA6491 T, C
2.0 HDi
MAN
VALEO A14 VI 27+
15 BOSCH A12051611 T, C
MELCO A004TF0091
BERLINGO REINFORCED (WITH POWER STEERING)
1.9D 9
VALEO A13 VI 204+
T, C
12 MELCO A003TA6491 T, C
MELCO A002TB2291
MAN VALEO A14 VI 27+ VALEO A14 VI 27+
2.0 HDi 15 BOSCH A12051611 T, C 15 BOSCH A12051611 T, C
MELCO A004TF0091 MELCO A004TF0091
313
E
L
E
C
T
R
I
C
A
L
S
Y
S
T
E
M
Classes and types
2.0i 16v
7 VALEO A11 VI 91 H, T
Level 0 8
VALEO A13 VI 203
C, VC
MELCO A002TB2191
MAN
8
VALEO A13 VI 203
H, T 12
MELCO A003TA0891
H, T
2.0i 16v MELCO A002TB2191 MELCO A003TA6491
Levels 1 et 2
9
VALEO A13 VI 204+
C, VC 9
VALEO A13 VI 204+
C, VC
MELCO A002TB2291 MELCO A002TB2291
8
VALEO A13 VI 203
H
BOSCH A12051611
MELCO A002TB2191 15 VALEO A14 VI 27+ H
2.0i 16v AUTO
9
VALEO A13 VI 204+
T, C, VC
MELCO A004TF0091
MELCO A002TB2291
12
MELCO A003TA0891
T, C, VC
MELCO A003TA6491
E
L
E
C
T
R
I
C
A
L
S
Y
S
T
E
M
314
Classes and types
7 VALEO A11 VI 91 H, T, C, VC
8
VALEO A13 VI 203
H, T
1.9D
MELCO A002TB2191
MAN
9
VALEO A13 VI 204+
C, VC
MELCO A002TB2291
12
MELCO A003TA0891 H, T BOSCH A12051611
2.0 HDi
MELCO A003TA6491 C, VC 15 VALEO A14 VI 27+ H, T
62 kW
MELCO A004TF0091
12
MELCO A003TA0891
C, VC
MELCO A003TA6491
2.0 HDi
BOSCH A12051611 H, T BOSCH A12051611 H, T
80 kW
MAN 15 VALEO A14 VI 27+
C, VC
15 VALEO A14 VI 27+
C, VC
MELCO A004TF0091 MELCO A004TF0091
E
L
E
C
T
R
I
C
A
L
S
Y
S
T
E
M
Classes and types
2.0i
MELCO A002TA0291 H, T
9
MELCO A003TA0591 H, T
8
VALEO A13 VI 189 C, VC VALEO A13 VI 191 C, VC
1.9D VALEO A13 VI 87 H,T,C,VC
1.9TD
MAN
VALEO A13 VI 87 H,T,C,VC MELCO A004TA0094 H,T,C,VC
2.5D / 2.5 TDi 9
MELCO A003TA0591 H, T 12 MELCO A004TA0091
H,T,C,VC
VALEO A13 VI 191 C, VC
315
316
E
L
E
C
T
R
I
C
A
L
S
Y
S
T
E
M
C15 1.8D
BERU 0 100 226 186 LUCAS R0490001B
BOSCH 0 250 201 039 BOSCH 0 281 003 012
DISPATCH 1.9D
CHAMPION CH185 LUCAS R0490001B
10s / 150s
BERU 0 100 226 371 BOSCH A 281 023 045
1.9D
BERU 0 100 226 186 LUCAS R04090001B
BOSCH 0 250 201 039 BOSCH 0 281 003 012
RELAY
1.9TD
BERU 0 100 226 186 BOSCH 0 281 003 005
6 s /180 s
BOSCH 0 250 201 039 VALEO 73507212
2.5D
BERU 0 100 226 186 NAGARES
4 s /180 s
BOSCH 0 250 201 039 BOSCH 0 281 003 009
2.5TDi BERU 0 100 226 246 VALEO 73507612
BERLINGO 1.9D (DW)
CHAMPION CH185 LUCAS R0490001B
10s / 150s
BERU 0 100 226 371 BOSCH A 281 023 045
Vehicles - models Pre-heater plugs Pre-heater control unit
Pre / Post heating
(pre-heating duration at 20C)
PRE-HEATING AND STARTING SYSTEMS ALL TYPES
Resistive value of the pre-heater plugs : 0.4 R 0.6
E
L
E
C
T
R
I
C
A
L
S
Y
S
T
E
M
317
12 72 A 90 A
CHECKING THE ALTERNATOR OUTPUT
Connect as shown in the diagram opposite, using an ammeter (A),
a voltmeter (V), and a rheostat (R) or a Volt/Ammeter/Rheostat com-
bination.
Adjust the engine speed (table opposite) and rheostat charge accor-
ding to the vehicles equipment specification in order to obtain
U = 13.5 V.
Reminder : The excitation energising current will flow through the
warning lamp - check that the warning lamp comes on when the
ignition is switched on. It must go out when the engine has started
(accelerate slightly).
CHECKING THE VOLTAGE REGULATOR
Set the rheostat to zero and disconnect all the electrical consumers.
Display 5000 alternator rpm. If U > 14.7 V, the regulator is faulty.
Note : These tests should be performed with the engine hot and the
battery fully charged.
Speed
Class
2000
tr/min
3000
tr/min
4000
tr/min
5
7
8
9
29 A
42 A
49 A
62 A
39 A
54 A
62 A
76 A
43 A
59 A
68 A
83 A
100 A
15 99 A 128 A 140 A
Output under 13.5 V
Intensity (A) / Alternator speed
CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR ALL TYPES
D1AP01SC
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318
SP 10
SP 20
Variable
AIR CONDITIONING R 134 a (HFC) ALL TYPES
Vehicle
BERLINGO
DISPATCH
RELAY
TU3.2
875 gr 25
SD 7H 15
SD 7 V 12
SD 7H 13 SP 20
SD 7 V 16 135
775 gr 25
1 000 gr
+0 -50
800 gr 50 (
*
)
1 000 gr 50 (
**
)
07/96
06/95
09/96
TU All exc. TU3.2
XU All types
XUD All types
DW8 TT-DW10 TT
1580 SPI
XUD All types
All Types
Engine Date
Refrigerant
refill
Compressor
Capacity
Fixed
Oil quantity
Quantity/cc
Oil
reference
*
= Single air conditioning: 1 evaporator, 1 pressure control valve.
* *
= Double air conditioning: 2 evaporators, 2 pressure control valves.
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319
ALL TYPES
C5HP073C
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
Click-fit connector removal/fitting tool
Inch Vehicles
Berlingo
Dispatch
XUD All types
All Types 5/8 Black 8005-T.A.
3/8 Red 8005-T.C.
Ring colour Tool kit 4164-T
Unions
Steel/Steel Aluminium/Steel Pipes
1.7 3 1.3 3 M 06
3.8 3
2 2 M 08
4 3
2.5 3 M 10
REMINDER : Filling of the air con. circuit, if possible, should be done via the LOW PRESSURE valve.
NOTE : Tighten the union to the recommended torque using a retaining spanner whenever possible
NOTE : For operations concerning draining, drying (empty), checking and refilling of a circuit: see BRE 0290.
WARNING : For R 134.a quantities (See table on page : 318 ).
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ALL TYPES SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)
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.
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SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) ALL TYPES
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 dehydrator.
- 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.
322
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AX-SAXO-ZX-BX-C15 All Types NO
Without aircon YES (Behr) Exc. driving school
Base aircon YES (Larger)
Regulated aircon YES (Valo)
Without aircon NO
Regulated aircon YES Except Brazil
All Types NO
Without aircon NO
Base aircon NO
# 8148 Do not fit Ingress of water
Automatic aircon
8148 # 8421 YES (Behr) Body modification
8421 #
YES if Exclusive 2 blowers
NO if X et SX 1 blower
Without aircon NO(Valo)
Base aircon YES (Valo)
All Types NO
Base aircon NO
Without aircon NO
Base or double aircon YES
SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) ALL TYPES
Presence of pollen filter
Vehicle Equipment RPO No. Presence of filter Observations
XSARA
XSARA PICASSO
XANTIA I et II
XM I et II
SYNERGIE
BERLINGO
DISPATCH
RELAY
323
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SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a) BERLINGO
C5HP063C C5HP062C
Evaporator
OLD
:
03/97 NEW 03/97
:
The evaporator makes use of new technology and is called a plate evaporator.
The coils around which the R 134.a fluid flows are replaced by plates which offer a greater area of contact with the air, thus increasing evaporator
efficiency.
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CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
CHECKING THE TEMPERATURES
ALL TYPES
TOOLS
Two thermometers.
Position of the air conditioning controls :
- Maximum cold air.
- Air blower in maximum position.
- Air distributor in "ventilation" position, with the dashboard
vents open.
- Air intake flap in "exterior air" position.
Conditions and vehicle equipment.
- Boot closed.
- Doors and windows shut.
- Ensure the vehicle is in a sheltered area
(away from wind, sun, etc.).
Checks.
If all these conditions are met, take the following action :
- Start the engine, with the air conditioning off, and wait for the cooling
fan first speed to cut in.
- Operate the air conditioning and set the engine speed to 2500 rpm.
NOTE : If the exterior temperature reaches 40C, the engine speed will
return to 2000 rpmin order to prevent the compressor from being cut off
by the High Pressure safety device (Pressostat).
After the air conditioning has been on for three minutes, measure :
- the exterior temperature in the workshop,
- the temperature of the air coming out of the central vents.
Compare the two values using the table overleaf.
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM ALL TYPES
CHECKING THE TEMPERATURES (continued)
Vehicle using R134.a fluid (Compressor with variable capacity)
Exterior temperature in C
Air temperature
from the central vents
in C
Vehicles
BERLINGO 21 3 17 3 11 3 9 3 8 3
12 3 10 3
DISPATCH
40 35 30 25 20 15
NOTE : In general, the temperature of the air being blown from the central vents should be around 5C to 8C.
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325
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326
CHECKING THE TEMPERATURES (continued)
ALL TYPES
TOOLS
Two thermometers.
- Maximum cold air.
- Air distributor in "ventilation" position, with the dashboard vents
open.
- Boot closed.
(away from wind, sun, etc..).
Checks
If all these conditions are met, proceed in the following order:
- Place a thermometer in the central vent.
- Start the engine, keep it running at approx. 1200 rpm.
- After one minute, read the temperature indicated by the thermometer
and note it (Initial value).
- Check that, compared to the initial value, this temperature decreases
after these times by the following amounts :
Verify :
- that the cooling fans cut in,
- that the temperature never falls below 5C.
For versions with additional heating, proceed in the same way :
- Position a thermometer in the central vent.
- Place the control of the additional fan in position N2.
(situated below the roof).
2 minutes
5 minutes
10 minutes
8C
12C
15C
CHECKING THE PRESSURES (continued)
ALL TYPES
TOOLS
1 Charge station
2 Thermometers.
- Maximum cold air.
- Air distributor in "ventilation" position, with the dashboard vents
open.
- Boot closed.
(away from wind, sun, etc.).
Checks.
If all these conditions are met, take the following action :
- Start the engine, with the air conditioning off, and wait for the
cooling fan first speed to cut in.
- Operate the air conditioning and set the engine speed to 2500 rpm.
NOTE : If the exterior temperature reaches 40 C, the engine speed will
return to 2000 rpm in order to prevent the compressor from being cut
off by the High Pressure safety device (Pressostat).
After the air conditioning has been on for three minutes, measure :
- the temperature of the air from the central vents.
- the High pressure.
- the Low pressure.
Compare the two values with the information on the table overleaf.
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327
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328
22 3 20 3 17 3 16 3 15 3 11 3
3 0.3 2.4 0.3 2 0.3
27 3 24 3 22 3 18 3 17 3 14 3
3 0.3 2 0.3
23 3 16 3 14 3
3 0.3 2 0.3
16 3 13 3
2.1 0.3 1.8 0.3
Exterior temperature at C 40 35 30 25 20 15
Vehicles
BERLINGO
TU
High pressure (Bars)
Low pressure (Bars)
Low pressure (Bars)
Low pressure (Bars)
Low pressure (Bars)
BERLINGO
XU
BERLINGO
XUD
DISPATCH
Vehicle using R134.a fluid (Compressor with variable capacity)
If the values in the above table do not correspond, refer to the table on page 330.
ALL TYPES
TOOLS
1 Charge station.
2 Thermometers.
The checking of the high and low pressures must be carried out at a
temperature between 20C and 30C.
Positions of the air conditioning controls :
- Air blower in position N2.
- Maximum cold.
- Air distributor towards the face.
- Air conditioning not operating.
Conditions and equipment of the vehicle.
- Bonnet closed.
- Doors and windows closed.
Checks.
If all these conditions are met, proceed in the following order:
- Start the engine, keep it running at approx. 1300 rpm.
- Place a thermometer in the central vents.
Verify that the pressures are equal and corresponding to :
- Exterior temperature of 20C at 5 Bars.
- Exterior temperature of 30C at 6 Bars.
Checking of pressures / temperatures.
Check :
- that the temperatures at the vents fall in 2 to 4 minutes to below
11C and stabilise at 9.5 C 1.5 C, without falling lower.
- that the high pressure rises in 1 minute to 15.5 0.5 Bar, and
that the cooling fans then cut in, causing the pressure to fall to
11 1 Bar, at which point the fans cut out.
(This cycle must continually repeat itself).
If the values in the above table do not correspond, refer to the table
on page 330.
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ALL TYPES
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330
Low pressure
too low
- Insufficient fluid charge.
- Constriction of the HP system.
- Dirty pressure control valve.
- Cooling fan speed unsuitable.
- Faulty compressor.
- Faulty pressure control valve.
- Dirty evaporator.
- Circuit normal. - Cooling fan speed unsuitable.
- System blocked.
- Water in the system.
- Presence of solid matter in
the system.
- Dirty condenser.
- Excessive fluid charge.
- Dirty condenser.
- Cooling fan speed unsuitable.
High pressure
too low
High pressure
normal
High pressure
too high
Low pressure
normal
Low pressure
too high
Checking the pressure at temperatures between 15C and 35C for information only.
In general, the pressure should be approximately :
- for R134.a fluid, less than 2 Bars (Low pressure), and between 13 and 24 Bars (High pressure).
ALL TYPES
BERLINGO - TU AIR CONDITIONING SYSTEM R 134.a
C5HP13TP
Tightening torques.
(1) Low pressure valve.
(2) High pressure valve.
(3) Dryer
(4) Pressostat
(a) Tighten to 1.7 m.daN
(b) Pressure reducer fixing flange 0.8 m.daN
(c) Compressor fixing flange 4 m.daN
(d) Fixing flange 1.3 m.daN.
A = Right hand drive.
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331
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332
AIR CONDITIONING SYSTEM R 134.a
C5HP13UP C5HP13LC
BERLINGO - XU
Tightening torques.
(3) Dryer
(4) Pressostat
AIR CONDITIONING SYSTEM R 134.a BERLINGO - XUD
C5HP13VP C5HP13LC
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333
Tightening torques.
(3) Dryer
(4) Pressostat
334
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AIR CONDITIONING SYSTEM R 134.a DISPATCH - EW10
C5HP15PP
Tightening torques.
(3) Pressostat 1.8 m.daN
(4) Dryer
(5) Clickfit union.
a 0.8 m.daN
b 4 m.daN
c 0.8 m.daN
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335
AIR CONDITIONING SYSTEM R 134.a DISPATCH - DW8
C5HP15CP
Tightening torques.
(2) Low pressure valve
(3) Clickfit union
(4) Pressostat.
(5) Fixing flange 0.8 m.daN
(6) Pressure reducer fixing flange 0.8 m.daN
(7) Compressor fixing flange 4 m.daN.
C5HP12EC
Clickfit union.
336
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AIR CONDITIONING SYSTEM R 134.a DISPATCH - DW10
Clickfit union.
C5HP15EP
Tightening torques.
(2) Low pressure valve
(3) Clickfit union
(4) Pressostat.
(5) Pressure reducer fixing flange 0.8 m.daN
(6) Fixing flange 0.8 m.daN
(7) Compressor fixing flange 4 m.daN.
C5HP12EC
337
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AIR CONDITIONING SYSTEM R 134.a RELAY - All Types
C5HP15QD
WARNING : The single and double air conditioning cir-
cuit diagrams are valid for all engine types.
(installation may vary according to equipment)
Single circuit
338
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AIR CONDITIONING SYSTEM R 134.a RELAY - All Types
Double circuit
C5HP15PP
(3) Pressure control valve
(4) Second evaporator
(passenger compartment side)
18D 19D
1.1i 1.1i 1.1i 1.4i 1.4i 1.4i 1.8i 19D 19D
2.0
HDi
2.0i
19D
2.0 2.0
2.0
16V HDi HDi
HDi
16V
2.0i 19D
1.9 1.9
25D
2.5 2.8
TD TD TDi HDi
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.
Printed in France by L.G.P. 95000 Cergy Pontoise - Tl. 01.34.20.13.80
CORRESPONDENCE TABLE FOR PETROL AND DIESEL ENGINES
Engine
families
Engine
types
C15
BERLINGO
DISPATCH
RELAY
TU XU EW XU XUD DW DJ
1 3 7 10 7 9 8 10 5
M+ JP JB J4 J2U AU UTF B TD BTED ATED ATED4 TED SOFIM
HDZ/ KFX/ F28T
HDZ
GPL
HFX KFX
GPL
KFW LFX RFN RFW 161A DJY D8C DHX WJY WJZ RHY RHX RHZ RHW T9A THX
DCR
UTILITY VEHICLES
2001 U
T
I
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T
Y

V
E
H
I
C
L
E
S
CAR 050009 2001
AC.QCAV/MTD
Mthodes Techniques Documentation
The intellectual property rights relating to the technical information in this document belong exclusively
to the manufacturer. Reproduction, translation or distribution in whole or in part without prior written autho-
risation fromthe manufacturer is forbidden.
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 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.

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