Refitting: engine Citroen Berlingo I

Recommended tools

[1] belt tension measuring instrument with digital read out (SEEM) 4122-T

[2] adaptor for angular tightening 4069-T

[3] rocker pressure plate 4533-T.Z

[4] dial gauge support 5708-T.V2

[5a] dial gauge support rod 5708-T.V1

[5b] dial gauge support rod 5708-T.V3

[6] flywheel stop 4507-T.L

[7] fitting mandrel 4521-T.G (kit 4528-T)

[8] fitting mandrel 4507-T.F (kit 4528-T)

[9] flywheel locking tool 4507-T.A

[10] camshaft gear setting rod 4507-T.B

[11] camshaft gear stop 4533-T.Y

[12] liner retaining clamp 1132-T.A

Refitting

Liner/piston/connecting rod assemblies

Engage the pistons, from below, into the liners while ensuring that the classes match

Fit

• A new seal ring (1) on the liners, ensuring it is not twisted
• A half bearing shell on the connecting rods

Fit the liner/piston/connecting rod assemblies into the cylinder block

Fit the liner retaining plates [12]

Adjusting the crankshaft endfloat

Fit the half bearing shells to the cylinder casing bearings

Oil the half-bearing shells

Fit

• The crankshaft (2)
• The two endfloat adjustment thrust bearings (3)

Fit a dial gauge on the end of the crankshaft using the mountings [4]; [5a] and [5b]

Push the crankshaft fully in one direction

Set the dial gauge to zero

Push the crankshaft fully in the opposite direction

There should be a 0,07 to 0,27 mm endfloat

If the endfloat is outside the limits, alter it by replacing the adjustment thrust bearings (3)

Refitting the "bottom end" of the engine

Fit the connecting rod half bearing shells

Oil the half-bearing shells

Position the conrod caps

Tightening the connecting rod caps: 3,75 daNm

Refit

• The cotter (6)
• The oil pump drive chain (5)
• Oil pump driving pinion (7)

Fit the half bearing shells to the bearing cap casing bearings

Oil the half-bearing shells

Check that the two centring pins are present

Coat the cylinder block joint face with a thin even coat of SILICONE AUTOJOINT OR 2 (E10) sealing compound

Fit the bearing cap casing (8)

Tighten the bolts (10) to 2 m.daN. finish with an angular tightening of 45 ° (progressively tighten in a spiral sequence, starting at the inside)

Tighten the bolts (9) to 1 m.daN

Check that pin (12) is present

Refit the oil pump (11) by engaging the pinion in the chain

Tighten the securing bolts to 1 dan.m

Coat the cylinder block joint face with a thin even coat of SILICONE AUTOJOINT OR 2 (E10) sealing compound

Refit the sump

Tighten the securing bolts to 1 dan.m

Flywheel side: fit the crankshaft oil seal using tool [7]

Timing gear side: fit the crankshaft oil seal using the tool [8] and bolt (13)

Refit

• The spacer (14)
• The crankshaft gear (15)
• The crankshaft pulley bolt (13) (without tightening)

Refit

• The flywheel (16)
• The flywheel screws, coated with LOCTITE FRENETANCH (E3) (without tightening)
• The tool [6]

Tighten to the specified torque

• The flywheel screws to 6,5 m.daN
• The screw (13) to 10 m.daN

Remove the tool [6]

Peg the flywheel with tool [9]

Refit the cylinder head

Fit a new O-ring seal (17)

Check that pin (18) is present

Fit the water pump (19)

Tighten to the specified torque

• The bolts (M10) to 6,5 da.Nm
• The bolts (M8) to 3 da.Nm

Remove the liner retaining clamps [12] (aluminium cylinder block)

Fit the dowels (20)

Insert cylinder head gasket (21) (inscriptions on top)

Fit the camshaft pulley (22) (without tightening)

Peg the camshaft with setting rod [10]

Refit

• The cylinder head (23)
• The rocker shaft (24)

Check the length of the cylinder head bolts: X = 176,5 mm

Brush the threads of the cylinder head bolts

Apply thread locking product MOLYCOTE G RAPID PLUS (G1) to the threads and under the heads of the screws

Cylinder head tightening

• Pre-tightening to 2 da.Nm
• Angular tightening to 240° using tool [2]

Check that pin (26) is present

Coat the joint face with a thin, even layer of sealing paste: SILICONE AUTOJOINT OR 2 (E10)

Refit the distributor drive locking housing (27)

Tighten the securing bolts to 1 dan.m

Setting the valve timing

Fit the roller tensioner (28)

Fit the nut (29) and tighten it by hand (tensioner in minimum position)

Fit a new timing belt

Position the timing belt, span "a" correctly tightened, in the following order

• Crankshaft gear
• Camshaft pinion
• Water pump drive pinion
• Roller tensioner

Turn the roller tensioner anti-clockwise to tension the belt "a" lightly

Tighten the nut (29)

Remove tools [9] and [10]

Turn the crankshaft 4 turns in the normal direction of rotation

Fit the tool [11]

Tighten the fixing screw (30) at 8 daNm

Remove the tool [11]

Adjust the valve rockers

Inlet valve = 0,20 mm

Exhaust valve = 0,40 mm

Rotate the engine using the crankshaft pulley screw to bring it, approximately, in the setting position

Peg the flywheel with tool [9]

Peg the camshaft pulley using tool [10]

Fit the tool [3] (respect the direction of fitting in relation to the valve gear)

Tighten the bolts of the tool [3] (as per arrows)

Check that all the cams are free without the valves being in contact with the pistons

Fit the tool [1]

Unscrew nut (29)

Rotate the roller tensioner in an anti-clockwise direction to obtain a tension of 31 SEEM units

Tighten the nut (29)

Remove tools [3], [10], [9]and [1]

Rotate the crankshaft through two turns without turning backwards

Reinsert setting rods [9] and [10] to make sure that the timing setting is correct

If pegging is not possible, repeat the timing belt tensioning operation

Fit the tool [3] (respect the direction of fitting in relation to the valve gear)

Tighten the bolts of the tool [3] (as per arrows)

Check that all the cams are free without the valves being in contact with the pistons

Fit the tool [1]

The tension value should be between 29 and 33 SEEM units

If the value recorded is out of tolerance, retension the belt

Remove tools [3], [10], [9]and [1]

Assembling the engine

Refit

• The timing cover (30)
• The exhaust manifold (31) (equipped with a new seal)

Refit

• The deflector plate (32)
• The 2 spacers (33)
• The cylinder head cover (34)

Refit

• The dipstick tube (35)
• The oil pressure switch (36)
• A new oil filter cartridge (37)

Refit

• The timing plate (38)
• The engine speed sensor (39)
• The inlet manifold trunking together with the injection piping