Refitting: engine Citroen Berlingo I facelift

Tooling

Refitting

Piston rings

Refit the piston rings (as shown in the diagram above)

Assembling the connecting rods/pistons

Refit

• The circlip (4)
• The connecting rod (3)
• The shaft (2)
• The circlip (1)

Preparing the cylinder block

Refit

• The piston base jets (5) (tightening torque 1 m.daN)
• The grooved bearing shells (8)
• The lateral shims (6) and (7) (lubricating grooves "f" on the crankshaft side)

Adjusting the crankshaft endfloat

Fit the crankshaft

Position

• The dial gauge support [1]
• The dial gauge support [2]
• The dial gauge [3]

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 0,32 mm endfloat

Crankshaft bearing caps

Crankshaft bearing caps (bearing N° 2, 3, 4, 5)

Oil

• The crankshaft seats "g"
• The bearing shells (14)

Refit

• The bearing shells (14)
• The bearing caps (9), (10), (11) and (12)
• The lateral shim (13) (bearing N° 2)
• The bolts (without tightening)

Bearing cap (bearing N° 1)

Apply sealing compound (E4) in the corners and to extremities "h" of bearing N°1

Put tool [4] into place on the cap of bearing N°1 (15)

• The shim slide must be in the extension of surface of the bearing cap
• Tighten the clamp [4a]

Place the bearing shell (16) on the bearing cap

Insert side seals (17) in the bearing cap groove, with the minimum protrusion at "j"

Lubricate the two surfaces of the feelers [4b]

Place the shim plates [4b] on the tool [4] over the lip (18) of the bearing cap

The side seals (17) must have a minimum protrusion of approximately 1 mm

Engage the cap/side seal assembly in the cylinder block, by tilting the assembly

Position the main bearing on the centralising bushes

Screw in the two bearing cap screws

Remove the tool [4] sideways

Tightening the bearing caps

Tighten the screws, observing the order and the tightening torque

Tightening torque for the bolts: 7 daNm

Rear bearing shell seal ring

Fit the oil seal onto the tool [6a]

Refit the ring seal; using a mallet

Remove the tool [6a]

Connecting rod/piston assemblies

Check that the piston ring gaps "a, b, c" are facing in the right direction

Place ring collar [7]

Fit the half bearing shells (20) on the connecting rods (19)

Oil

• The cylinders (21)
• The half bearing shells

Refit the connecting rod/piston assemblies

Big end caps

Equip the connecting rod caps with bearing shells

Position the conrod caps

Fit the nuts (22). pre-tighten to 2 m.daN, then carry out an angular tightening of 70 ° using tool [5]

Oil pump

Refit simultaneously

• The pinion (23)
• The chain (24)
• The oil pump (26)
• The spacer (29)

Refit

• The pick-up unit (27) (first coat with E6 grease)
• The bolts (25) (keep to the original marking); tighten to 1,8 daN.m
• The (28) bolt

Push the pinion (23) towards the cylinder block

Refit the key (30)

Immobilise the crankshaft pinion (23) by engaging it on the key (30)

Front sealing panel

Apply a strip of "E4" to the sealing panel (32)

Refit

• The sealing panel (32)
• The bolts (31); tighten to 1,2 daN.m

Crankshaft seal ring (timing side)

Refit the ring seal; using tool [8a]

Remove the tool [8a]

Lower cover

Steel sump

Refit

• The seal (new)
• The sump (34)
• The bolts (33); tighten to 1,6 daN.m

Aluminium sump

Apply a strip of sealant "E10" around the edge of the cylinder block

Refit

• The sump (36)
• The bolts (35); tighten to 1,6 daN.m

Engine flywheel

Refit

• The flywheel (37)
• The bolts (38)
• The stop [9]

Tighten the bolts (38) to 4,8 daN.m

Clutch

Refit

• The clutch disc
• The clutch mechanism (40)
• The bolts (39)

Centre the clutch disc; using tool [10]

Tighten the bolts (39) to 2 daN.m

Remove the stop [9]

Heat exchanger - oil filter

Coat the threading of the screw (42) with the product (E6) (cylinder block side)

Refit the heat exchanger (41)

Tighten the bolt (42) to 5,8 daN.m

Refit

• The oil filter (43)
• The switch (44) (new seal)

Fuel pump support

Refit

• The bracket (45)
• The bolts (46); tighten to 2 daN.m

Mechanical fuel pump (LUCAS DIESEL or BOSCH equipment)

Refit

• The fuel pump (48)
• The bolts (47); tighten to 2,5 daN.m
• Rear fixing (49); tighten to 2 daN.m

Piston protrusion

Fit dial gauge support [12] to the cylinder block

Secure dial gauge [3] to support [12]

Set the dial gauge to zero at "l"

Record the height difference at "m"

Cylinder head

Position the pistons at mid-stroke

Refit

• The cylinder head gasket
• The cylinder head
• The bolts

Cylinder head tightening

Tightening procedure

• Pre-tighten to 2 daNm (order from 1 to 10)
• Tightening to 6 m.daN (order from 1 to 10)
• Tighten by an angle of 180 ° with tool [5] (order from 1 to 10)

Check - valve clearance adjustment

Using a set of shims: record the value "J" between the back of the cam and the follower

• Inlet valve: J = 0,15 ± 0,08 mm
• Exhaust valve: J = 0,30 ± 0,08 mm

Timing gear

Refit

• The coolant pump (51) (equipped with a new seal)
• The engine mounting (53)
• The roller tensioner (52)
• The tensioning roller (60)
• The camshaft hub (54)
• The camshaft gear (55)
• The bolts (57) (without tightening)
• The (56) bolt (without tightening)
• The injection pump gear (59)
• The bolts (58) (without tightening)
• The crankshaft gear (61)

Tighten the bolt (56) to 4,5 daN.m using tool [18]

Timing belt

Peg

• The camshaft hub (54); using tool [14]
• The injection pump gear (59); using tool [11]

Peg the flywheel with tool [13]

Lock the flywheel with the stop [9]

Coat the screw thread (62) with product "E6"

Refit bolt (62) (without tightening)

Tighten the bolt (62) to 4 daN.m. finish with an angular tightening of 60 °

Remove the stop [9]

Tighten the screws (57) and (58) by hand

Turn pinions (55) and (59) fully in the slotted holes (clockwise)

Place the timing belt back on the crankshaft

Retain the belt with the tool 15

Fit the timing belt, strictly in the following order

• The tensioning roller (60)
• The injection pump gear (59)
• The camshaft gear (55)
• The coolant pump (51)
• The roller tensioner (52)

Fit the tension measuring instrument [17] to the belt strip "p"

Turn the roller tensioner (52) anti-clockwise, using tool [16], to obtain an excess tension of 106 SEEM units

Check that the camshaft pinions (55) and the injection pump pinions (59) are not against the end of the slots

Otherwise, repeat the process for refitting the belt from the beginning

Tighten

• The roller tensioner (52) to 4,5 m.daN
• The bolts (57) to 2,5 da.Nm
• The bolts (58) to 2,5 da.Nm

Remove

• The belt tension measuring instrument [17]
• The pegs [13], [14] and [11]

Turn the crankshaft 8 turns in the normal direction of rotation

Peg

• The camshaft hub (54); using tool [14]
• The injection pump gear (59); using tool [11]
• The flywheel; using tool [13]

Unscrew

• The screws (57) and (58)
• The roller tensioner (52)

Tighten the screws (57) and (58) by hand

Fit the tension measuring instrument [17] to the belt strip "p"

Rotate roller (52) anti-clockwise, by means of tool [16], to obtain a tension value of 42 ± 2 SEEM units

Tighten

• The roller tensioner (52) to 4,5 m.daN
• The bolts (57) to 2,5 da.Nm
• The bolts (58) to 2,5 da.Nm

Remove the tool [17]

Fit the tension measuring instrument [17] to the belt strip "p"

The tension value should be between 38 and 46 SEEM units

Remove

• The belt tension measuring instrument [17]
• The pegs [13], [14] and [11]

Turn the crankshaft 2 turns in the normal direction of rotation

Checking the setting

Peg the flywheel with tool [13]

Visually check that the offset between the holes of the injection pump and camshaft hubs and the corresponding peg locating holes, does not exceed 1 mm

Remove the peg [13]

Accessories

Timing gear side

Refit

• The sump (67)
• The top cover (65)
• The lateral casing (66)
• The accessory pulley (64)
• The bolts (63); tighten to 1 daN.m
• The lower cylinder head cover
• The upper cylinder head cover

Injection pump side

Refit

• The degassing hose (70)
• The diesel injector high pressure supply pipes (69)
• The thermostat (72)
• The thermostat
• The cover (73)
• The fuel filter (71) (well + filter)
• Fast idle cable (68)

Exhaust manifold side

Refit

• Coolant inlet housing (80) (and connecting hoses)
• The exhaust manifold (79)
• The inlet manifold (77) and the exhaust gas recycling pipe (78) simultaneously
• The inlet manifold (76)
• The vacuum pump (75)
• The TDC sensor (74)

Fix the EGR pipe (78) on the exhaust manifold (79) and on the air inlet manifold (76)