Refitting: engine — variant 2 Citroen Berlingo I facelift

Recommended tools

[1] flywheel locking tool 4507-T.A

[2] piston positioning base

Kit for fitting gudgeon pins

[6] dial gauge support rod 9022-T.V

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

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

[9] dial gauge support 5708-T.V2

[10] mandrel handle

[11] dial gauge

[13a] 4533-T.AC1 camshaft setting rod

[13b] 4533-T.AC2 camshaft setting rod

[14] pin for the dynamic roller tensioner 4200-T.H

Refitting

Assembling the connecting rods/pistons

Place the gudgeon pin (1) on the drift [5]

Tighten the handle [10] onto the mandrel without locking it

The pin (1) must rotate freely

Place the tool [4] on tool [2]

Put piston (2) on tool [4]: position the arrow "Dist" pointing upwards

Centre the whole assembly with mandrel [5] and the piston gudgeon pin

Retain the piston using clamp [3] on the positioning base clamp [2]

Place the connecting rod little end on an electric heating plate

Place a piece of tin filler on the small end "a"

Heat until the piece of tin melts (temperature of 250°C approximately)

Fit the conrod into the piston, orientating the lubrication hole "b" (as shown on the illustration): position the arrow "Dist" pointing upwards

Rapidly insert the gudgeon pin (1) fully home

Wait a few seconds before removing the piston/con.rod assembly

Wipe the drop of tin

Proceed likewise for the other three bearing sets

Crankshaft

(3) cylinder block

(5) cylinder block shells

Fit the class "B" (colour black) half bearing shells to the bearings on the cylinder block side

• Bearings 1;3;5 = plain half bearing shells (cylinder block and bearing cap casing)
• Bearings 2;4 = grooved half bearing shells (cylinder block and bearing cap casing)

Oil the half-bearing shells

Fit the crankshaft (4)

Position end float shims (6), rotating them round the crankshaft (grooved face on crankshaft side)

Fit the crankshaft bearing caps

Oil (threads and under the heads) and fit the main bearing bolts

Do up the crankshaft bearing caps by hand, then pre-tighten to 1 m.daN

Check: crankshaft end float

Fit tools [6] and [9] onto the cylinder block (3)

Fit the dial gauge [11] onto supports [6] and [9]

Push the crankshaft back and forth in the cylinder block

Set the dial gauge to zero

Push the crankshaft back and forth, on the opposite side, in the cylinder block

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

Connecting rod/piston assemblies

Position the rings with the ring pliers

The face of sealing ring (8) marked TOP should be uppermost

Direct ring gap (8) 180° with respect to ring gap (7)

Oil the cylinders

Observe the marks made during the dismantling operation

Arrow "Dist" of piston is directed towards the valve timing gear

Engage the piston, properly positioning the scraper ring

Proceed likewise for the other three bearing sets

Turn the cylinder block over

Oil

• The sleeves
• The lower bearing shells

Refit the conrod caps

Fit the conrod cap screws (lubricated)

Tighten

• The big end caps: tighten the bolts to 3,8 ± 0,3 m.daN
• The bearing caps: tighten the bolts to 2 m.daN tighten by an angle of 49° ± 2 ° with tool [12]

Oil pump

Refit

• The oil pump centralising pin (10)
• The key to the crankshaft
• The oil pump
• The chain
• The drive pinion

Tighten the oil pump fixing screws to 0,8 ± 0,1 m.daN

Coat the seal face "c" with a thin layer of silicone paste AUTO JOINT OR (E10)

Fit the seal carrier plate (11) tighten the bolts to 1 ± 0,1 m.daN

Proceed in the same way for the other side

Fit a new oil seal (12) to the fitting mandrel [8]

Fit the oil seal against its shoulder by means of the bolt (13)

Fit the sealing ring (14) against the cylinder block using tool [7]

Sump

Refit the sump

Tighten the 19 bolts (15) to 0,8 ± 0,1 m.daN

Engine flywheel

Refit

• The flywheel
• The bolts (16) tighten to 7 ± 0,7 daN.m

Check the presence of the keyway on the crankshaft output

Fit the timing gear (18)

Refit the screw (19) equipped with a washer

Pre-tighten the bolt (19) to 4 m.daN carry out an angular tightening of 45 ± 3°

Refit the coolant pump (17) using a new seal

Tighten the bolts to 2 ± 0,2 m.daN

Turn the crankshaft

Peg by means of tool [1]

Cylinder head

Clean out with a tap the threads in the crankcase which accommodate the cylinder head screws (M10 x 150 tap)

Check the presence of the 2 centring pins (20)

Fit a new cylinder head gasket (inscriptions on top)

Refit

• The cylinder head (21)
• The 10 bolts (22)

Cylinder head tightening

Tightening procedure

• Pre-tighten to 2 ± 0,2 daNm
• Angular tightening to 260° using tool [12]

Refit the cylinder head covers (23) after having cleaned the gaskets and gasket faces

Tighten the cylinder head cover screws to 1 ± 0,2 m.daN in the order indicated

The cylinder head covers have composite gaskets which can be used several times if the seal is damaged, it can be partially repaired with sealing product AUTOJOINT (OR)

Refit

• The timing cover
• The camshaft pulleys tighten the bolts to 8 ± 0,1 m.daN

Timing side components

Refit

• The roller tensioner (27)
• The (24) bolt
• The tensioning roller (26)
• The (25) bolt, tighten the bolts to 2 ± 0,2 m.daN

Peg the camshafts using tools [13a] and [13b]

Timing belt

Fit the timing belt, strictly in the following order

• Intake camshaft pulley
• Exhaust camshaft pulley
• Roller tensioner
• Crankshaft pulley
• Water pump pulley
• Dynamic roller tensioner

Remove tools [1], [13a]and [13b]

Excess belt tension

Rotate the roller tensioner (27) using an Allen key (at "d")

Position the index "f" in position "e" tension the belt to the maximum of the space indicated

Hold the roller tensioner (27) using tool [14]

Tighten the roller tensioner fixing nut to 1 m.daN

Turn the crankshaft 4 turns in the normal direction of rotation

Reinsert setting rods [1], [13a] and [13b] to make sure that the timing setting is correct

Remove setting rods [1], [13a]and [13b]

Adjusting the tension

Loosen the nut while maintaining the position of the roller tensioner using an Allen key at "d"

Then bring the index "f" to its adjustment position "g"

Hold the roller tensioner (27) in this position, using an Allen key

Tighten the roller tensioner fixing nut to 2,2 ± 0,2 m.daN

Refit

• The timing housings
• The crankshaft pulley tighten the bolts to 2,5 ± 0,2 m.daN
• The thermostat tighten the bolts to 1 ± 0,2 m.daN
• The electric oil gauge tighten the bolts to 2,7 ± 0,2 m.daN
• The oil filter bracket (new seal) tighten the bolts to 1 ± 0,2 m.daN
• The oil filter
• The filter element protective cover tighten to 2,5 ± 0,2 daN.m
• The dipstick