Refitting: engine (SOFIM) Citroen Jumper I

Recommended tools

[1] toothed sector for locking the engine flywheel 1 867 029 000 (kit (-).0191)

[2] dial gauge support

[3] dial gauge

[4] dial gauge support

[5] engine piston ring fitting collar

[6] clutch friction centring rod 1 870 402 000 (kit (-).0191)

[7] dial gauge support

[8] tool for compression of timing belt tensioner 1 860 638 000 (kit (-).0191)

[9] tool for immobilisation of belt pulley 1 860 765 000 (kit (-).0191)

[10] setting rod of the injection pump 1 860 617 000 (kit (-).0191)

[11] dial gauge

[12] dial gauge support

[13] tool for checking position of the oil pump idler gear 1 860 636 000 (kit (-).0191)

[14] tool for locking the oil pump idler gear 1 860 637 000 (kit (-).0191)

[15] mandrel for fitting seal 1 860 627 000 (kit (-).0191)

[16] belt tension measuring instrument with digital read out (SEEM)

[17] plastigage for bearing shell clearances

Refitting

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

Assembling the connecting rods/pistons

"d" engraving

• Engine type
• Piston diameter class
• Make

"e" rod no.

"f" groove for piston cooling aperture

Refit

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

Preparing the cylinder block

Refit

• The piston base jets (5) insert the lug "g" into its location on the cylinder block
• The bolts (6) tighten to 4 daN.m

Refit

• The grooved bearing shells (7)
• The bearing shell (5) with shoulder (flywheel side)
• The crankshaft

Crankshaft main bearing cap casing

Oil

• The crankshaft bearing faces
• The half bearing shells

Refit

• The seals (9)
• The half bearing shells (10)
• The bearing shell (8) with shoulder (flywheel side)

Determination of the class of bearing shell

Use tool [17]

Cut 5 pieces from the plastigage [17] to the widths of the bearing shells

Place the plastic threads on each of the crankshaft journals

Fit

• The crankshaft bearing cap casing
• The securing bolts

Tighten the fixing screw gradually observing the correct tightening order (order from 1 to 10)

• Tightening to 5 m.daN
• Angular tightening to 90°

Untighten the fixing bolts perform in reverse order (from 10 to 1)

Remove the bearing cap casing

Compare each width (in mm) of flattened plastic wire at its widest point with the graduations on the paper envelopes

The value read indicates the running clearance

Clean the plastigage threads and oil the crankshaft

Select the category of bearing half-shells (see data)

Refitting

Fit the crankshaft bearing cap casing on the cylinder block

Oil the bearing cap casing fixing bolts

Refit the bolts

Tighten the fixing screw gradually observing the correct tightening order (order from 1 to 10)

• Tightening to 5 m.daN
• Angular tightening to 90°

Adjusting the crankshaft endfloat

Put into place the following tools

• Tool [2]
• Tool [3]
• Tool [4]

Push the crankshaft back and forth in the cylinder block

Set the dial gauge [3] to 0

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

There should be a 0,06 to 0,21 mm endfloat

Crankshaft sealing panels: front sealing panel

Cut off excess seal at "j" (if necessary)

Refit

• The seal (moisten the seal prior to refitting)
• The sealing panel (11)
• The 2 bolts (12) tighten to 0,75 daN.m

Crankshaft sealing panels: rear sealing panel

Refit

• The seal (moisten the seal prior to refitting)
• The sealing panel (13)
• The 7 bolts (14) tighten to 2,5 daN.m

Connecting rod/piston assemblies

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

Place ring collar [5]

Fit the half bearing shells (15) on the connecting rods (16)

Oil

• The pistons
• The linings
• The conrod bearing shells

Refit the connecting rod/piston assemblies

Big end caps

Fit the half-shells conrod caps

Oil the half-bearing shells

Determination of the class of bearing shell

Use tool [17]

Cut 4 pieces from the plastigage [17] to the widths of the bearing shells

Fit the plastigage threads [17] on each of the crankshaft journals

Refit

• The big end caps (17)
• The bolts (18)

Tighten the fixing screw gradually

• Tightening to 5 m.daN
• Angular tightening to 60°

Slacken the bolts (18)

Remove the conrod caps (17)

Compare each width (in mm) of flattened plastic wire at its widest point with the graduations on the paper envelopes

The value read indicates the running clearance

Clean the plastigage threads and oil the crankshaft

Select the category of bearing half-shells (see data)

Refitting: big end caps

Refit

• The big end caps (17)
• The bolts (18)

Tighten the fixing screw gradually

• Tightening to 5 m.daN
• Angular tightening to 60°

Oil suction strainer

Refit

• The oil suction strainer (19)
• The bolts (20) tighten to 2,5 daN.m

Lower cover

Refit

• The sump (21)
• The bolts (22) tighten to 1,8 daN.m

Engine flywheel

Align the marks "l" on the engine flywheel and "m" on the cylinder block, made at the time of refitting

Fit the tool [1]

Refit

• The flywheel (23)
• The bolts (24)

Tighten the fixing screw gradually

• Tightening to 3 m.daN
• Angular tightening to 90°

Clutch

Fit the tool [1]

Refit

• The clutch mechanism (25)
• The bolts (26)

Centre the clutch disc [7] using the tool

The bolts (26) tighten to 3 daN.m

Remove the tool [1]

Piston protrusion

Fit dial gauge support [7] to the cylinder block

Secure dial gauge [3] to support [7]

Set the dial gauge to zero at "n"

Record the height difference at "p"

Cylinder head

Position the pistons at mid-stroke

Refit

• The cylinder head gasket position the marking "ALTO" on the inlet and exhaust manifold side
• The cylinder head
• The bolts

Cylinder head tightening

Tightening procedure

• Pre-tighten to 6 daNm (order from 1 to 22)
• Tightening to 6 m.daN (order from 1 to 22)
• Angular tightening to 180° (order from 1 to 22)

Check - valve clearance adjustment

Using a set of shims record the value "J1" between the back of the cam and the follower

• Inlet valve: J1 = 0,50 ± 0,05 mm
• Exhaust valve: J1 = 0,50 ± 0,05 mm

Oil pump assembly: checks on shafts - idler gear, oil pump

(28) input shaft

(29) shaft

(30) pump shaft

(31) idler gear

(32) oil pump cover

(33) pump body

(34) casing

The surfaces of the shafts and the teeth of the sprockets must not show signs of seizing or abnormal wear

The oil pump (33) must not have any cracks

The shaft locations must not be worn or damaged

The contact surfaces must be flat

Check that the lubrication pipes are not blocked

Check the clearances between the upper faces of the gears and the mounting face of the oil pump (33) using a block set and a rule

The "J2" clearance must be included between 0,055 mm and 0,085 mm

Check the clearances between the outer circumferences of the gears and their locations in the body of the oil pump (33) Using a set of shims

The "J3" clearance must be included between 0,055 mm and 0,085 mm

Oil pump assembly: replacing the oil pump idler gear

Remove the pump shaft (30)

Uncouple the idler gear (31) on the shaft (29) using a press

Heat the idler gear (31) to a temperature of 200 to 250°C

Fit the idler gear (31) on the shaft (29) using a press

Check the clearances "J2" and "J3"

Oil pump assembly: checking the idler gear's rotation resistance

Lock the rotation of the assembly (29) and (31) using tool [14]

Check the resistance to rotation between the idler gear (31) and the shaft (29)

• Make 2 marks in line at "q" and "r"
• Apply a torque of 11,3 m.daN at the shaft (29) using tool [14]

Check that the marks "q" and "r" remain in line

Seal

Fit a new seal (35) on the casing (34) using tool [15]

Assembly

Refit the oil pump shaft (30)

Refit the primary shaft (28)

Refit

• The seal (36)
• The casing (34) on the body of the oil pump (33)
• The bolts (37) tighten to 2,3 daN.m

The oil pressure relief valve is located on the oil pump cover (32)

Unscrew and remove the plug (38)

Detach the spring (39) from the piston (40) and from the guide (41)

Check that the piston (40) and the guide (41) do not show any signs of wear or seizing and that they slide freely

Refit the excess oil pressure valve

Apply E7 seal paste to the points of contact between the oil pump body and the oil pump cover

Refit

• The pump cover (32) equipped with the oil pressure control valve
• The bolts (42) tighten to 1,8 daN.m

Refit

• The diesel injection pump mounting (43)
• The bolts (44) tighten to 2,5 daN.m

Vacuum pump

Refit

• The vacuum pump (45)
• The bolts (46) tighten to 1,8 daN.m

Heat exchanger

Refit

• The heat exchanger (47)
• The bolts (48)

Dipstick - oil pump

Refit

• The oil pump (49)
• The bolts (50)

Refit

• The dipstick guide (51)
• The fixing caliper (52)
• The nuts (53)

Diesel injection pump

Reinstall the injection pump align the spline "s" and the keyway "t"

Refit the injection pump nuts (54) (tighten by hand)

Timing gear - timing belt - coolant pump

Refit

• Refit the coolant pump (55) using a new seal (hold tool [8] in position)
• The bolts (56) tighten to 5 daN.m
• The roller tensioner (57) the bracket
• The nut (58) (tighten by hand)
• The nut (59) (tighten by hand)

Refit

• The cylinder head cover (60)
• The nuts (61)

Refit the crankshaft gear (62)

Refit

• The tensioning roller (64)
• The bolts (65)
• The camshaft pulley (66) using tool [9]
• The injection pump pulley (67) using tool [9]

Place cylinder No. 1 at top dead centre (TDC)

Check that the marking "w" of the crankshaft pinion (62) is in a low position relative to the vertical axis of the engine

Peg the injection pump pulley with the help of tool [10]

Check the alignment between the marking "x" on the camshaft pulley (66) and the marking "y" on the cylinder head cover

Refit the timing belt

Remove

• The tool [10]
• The tool [8]

Turn the crankshaft two turns in the direction of running

Peg the injection pump pulley with the help of tool [10]

Remove the tool [10]

Tighten

• The nut (58) to 2,9 m.daN
• The nut (59) to 4 m.daN

Timing the injection pump

Peg the injection pump pulley with the help of tool [10]

Remove the cap (68) from the timing orifice

Fit tool [11] on the tool [12]

Position the whole assembly into the timing hole

Locate the bottom dead centre of the injection pump until the gauge needle [11] no longer moves

Set the dial gauge to zero

Bring the injection pump pulley to the setting point

Peg the injection pump pulley with the help of tool [10]

Slowly turn the injection pump in its slots until the dial gauge [12] shows the dimension X (after its BDC)

When the dial gauge shows the desired dimension X, tighten the nuts (54) to 2,5 m.daN

Air inlet manifold

Refit

• The oil pressure switch (70)
• The pipe (69)
• The air intake manifold

Couple and refit the 2 pipes (71) on the inlet manifold

Refit

• The style cover (72)
• The bolts (73)

Alternator

Refit

• The casing (75)
• The bolts (74)

Position the tool [1] on the engine flywheel

Refit

• The accessory pulley (77)
• The (76) bolt

Remove the tool [1]

Refit

• The alternator (81) and its caliper
• The screws (80) and washers
• The screws (78);(79) and washers

Ancillary drive belt

Refit the ancillary belt (82)

Fit the tension measuring instrument [16] to the belt strip "z"

Tighten the adjusting screw (83), and screws (78) and (79) to obtain the tension value

• New belt: there should be a 122 ± 22 SEEM units tension value
• Re-used belt: there should be a 69 ± 7 SEEM units tension value

Tighten the bolts (78);(79) and (80) to 5 m.daN

Remove the tool [16]