Refitting: engine (EW10J4) Citroen Jumpy I

Recommended tools

[24] tool for locking the inlet camshaft (-).0189.M

Refitting

Assembling the connecting rods/pistons: method with PEUGEOT tooling

Place the tool [4] on tool [1]

Open the clamp "a"

Fully unscrew the pressure screws "b"

Fit the pin (1) of the first piston on the tool [5]

• [5a] (engine EW7 J4)
• [5b] (engine EW10 J4)
• [5c] (engine EW10 D)

Tighten the handle [6] by hand, without forcing (fully)

Position the piston on the tool [5a, 5b, 5c] and guide it with the handle, pin and guide end assembly

Insert the pin "d"

Screw in the tappets "b" until the piston makes contact

Tighten the nuts (at "c")

Remove the pin (at "d")

Clamp the piston (2)

Place the conrod with its cap (without bearing shell) in the piston and centre it with the handle/pin/cone assembly

Adjust the height of the plate "e" to bring it into contact with the conrod

Adjust the position of the base "f" to obtain a clearance of A = 0,1 mm

Place the connecting rod little end on an electric heating plate

Place a piece of tin filler on each small end "g"

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

Fit the conrod into the piston, orientating the lubrication hole "h" (as shown on the illustration)

Rapidly insert the gudgeon pin (1) fully home

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

Wipe off the drop of filler

Proceed likewise for the other three bearing sets

Assembling the connecting rods/pistons: method with CITROEN tooling

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

• [5a] (engine EW7 J4)
• [5b] (engine EW10 J4)
• [5c] (engine EW10 D)

Tighten the handle [6] 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 "g"

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

Fit the conrod into the piston, orientating the lubrication hole "h" (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

Place the grooved half shells (5) on the cylinder block(6)

Oil the half-bearing shells

Fit the crankshaft (3)

Position end float shims (4), rotating them round the crankshaft (grooved face on crankshaft side)

Check: crankshaft end float

Fit tools [8] and [9] onto the cylinder block (6)

Fit the dial gauge [10] onto supports [8] and [9]

Refit

• The crankshaft bearing caps casing (8)
• The 10 bolts (7)

Tighten the 10 bolts (7) to 1 ± 0,1 m.daN

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 0,06 to 0,15 mm endfloat

Remove

• The 10 bolts (7)
• The crankshaft bearing caps casing (8)

Crankshaft main bearing cap casing

Check for the presence of the centring pins at "j"

Replacing a pin (if necessary)

• Insert 50% of the length of the pin into the bearing cap casing
• Insert the pin at "k" using a drift
• Flatten the top at "k" to secure the pin

Apply "AUTOJOINT NOIR" type sealing paste to the periphery of the bearing cap casing (8)

Refit

• The crankshaft bearing caps casing (8)
• The 10 bolts (7)
• The 16 bolts (9)

Tightening procedure

• Pre-tighten the bolts (7) to 1 ± 0,1 daNm using tools [14] and [20]
• Pre-tighten the bolts (9) to 0,2 ± 0,1 daNm
• Pre-tighten the bolts (7) to 1 ± 0,1 daNm slacken the bolts (7)
• Tighten the bolts (7) to 2 ± 0,1 daN.m carry out an angular tightening of 70° ± 1°
• Tightening of the bolts (9) to 1± 0,1 m.daN

Connecting rod/piston assemblies

Position the rings with the ring pliers

The face of sealing ring (11) marked TOP should be uppermost

Direct ring gap (11) 180° with respect to ring gap (10)

Fit the piston/conrod assembly through the tool (lubricate all around)

• [11a] (engine EW7J4)
• [11b] (EW10J4 and EW10D engines)

Let the lower section (B) of the piston protrude to allow it to be correctly guided

Refit the correct upper half-bearing shell (see data)

Oil the cylinders

Observe the marks made during the dismantling operation

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

Keep the assembly cone [11a, 11b] in perfect contact with the sealing face of the cylinder head and centred in relation to the cylinder

Engage the piston, properly positioning the scraper ring (UFLEX)

Proceed likewise for the other three bearing sets

Turn the cylinder block over

Oil

• The sleeves
• The lower bearing shells

Refit the conrod caps

Refit the conrod cap screws (13) (lubricated)

Using tools [15] and [20]

• Pre-tighten the bolts (13) to 2,3 ± 0,1 daNm
• Carry out an angular tightening of 45° ± 5°

Oil pump

Apply "AUTOJOINT NOIR" type sealing paste around the edge of the sealing face of the oil pump

Refit

• The oil pump (14)
• The 9 bolts (15) (coat the screws with LOCTITE FRENETANCH)

Tighten the 9 bolts (15) to 0,8 ± 0,1 m.daN

Sealing ring (timing side)

Place the tool [12b] on tool [12a]

Fit the new sealing ring (16) using the tool [12a]

Remove the tool [12b]

Fit the sealing ring (16) against the cylinder block using tool [12a]

Sealing ring (flywheel side)

Place the tool [13b] on tool [13a]

Fit the new sealing ring (17) using the tool [13a]

Remove the tool [13b]

Fit the sealing ring (17) against the cylinder block using tool [13a]

Sump

Refit

• The panel (19)
• The oil pump strainer (18) (together with its seal)

Apply "AUTOJOINT NOIR" type sealing paste around the edge of the sealing face of the oil pump

Check that pin is present (at "l")

Refit the sump (20)

Insert the bolts until they make contact without tightening them

Place a straightedge at "m" and adjust the sump so as to align it with the face of the cylinder block

Tighten the 19 bolts (22) of the sump (24) to 0,8 ± 0,2 m.daN

Tighten the 7 bolts (21) of the sump (24) to 0,8 ± 0,2 m.daN

Engine flywheel

Refit

• The flywheel (23)
• The bolts (24) (new)

Fit the tool [16]

Bring the 8 screws (24) into contact with the flywheel

Tighten the bolts (24) to 2 ± 0,2 daN.m

Carry out an angular tightening of 26° ± 3°

Cylinder head

Insert cylinder head gasket (25) (new)

C: EW10D engine

D: EW7J4 and EW10J4 engines

Refit

• The cylinder head (27)
• The 10 bolts (26)

Cylinder head tightening

Tightening procedure use tools [15] and [20]

• Pre-tighten to 1,5 ± 0,2 daNm (order from 1 to 10)
• Tighten to 5 ± 0,5 daN.m (order from 1 to 10)
• Slacken the bolts by 360° ± 2°° (1 turn) (order from 10 to 1)
• Tighten to 2 ± 0,25 daN.m (order from 1 to 10)
• Angular tightening to 285° ± 5° (order from 1 to 10)

Refit

• The hydraulic followers and valve rockers
• The camshafts

Apply a uniform bead of approximately Ø 3,5 mm of "AUTOJOINT NOIR" type sealing paste around the edge of the periphery of the sealing face of the camshaft bearing cap casing

Refit the camshaft bearing cap cover on the cylinder head

Check the protrusion of the camshaft in relation to the cylinder head E = 8 ± 0,2 mm

Do up the 23 fixing screws (28) and tighten them until they are in contact

Tighten the bolts to 0,9 ± 0,1 daN.m (order from 1 to 23)

Refit the coolant pump

Tightening the coolant pump

Pre-tightening to 0,3 ± 0,1 daNm (order 1,2,3,4)

Pre-tightening to 0,8 ± 0,1 daNm (order 1,2,3,4)

Pre-tightening to 1,4 ± 0,1 daNm (order 1,2,3,4)

Timing side components

Refit

• The roller tensioner (40)
• The (39) bolt
• The casing (31)
• The pulley (30)
• The (29) bolt
• The pulley (33)
• The (32) bolt
• The tensioning roller (35)
• The (34) bolt
• The crankshaft gear (36)
• The protective flange (37)
• The (38) bolt
• The tool [17]

EW7 and EW10J4 engines

Immobilise the exhaust camshaft by its flat (at "q")

Tighten the bolt (29)

• Pre-tightening to 3 ± 0,5 daNm
• Tighten to 7,5 ± 0,7 daN.m

Immobilise the exhaust camshaft by its flat using a flat spanner

Tighten the bolt (32)

• Pre-tightening to 3 ± 0,5 daNm
• Tighten to 7,5 ± 0,7 daN.m

Peg the camshafts using tool [18]

EW10D engine

Immobilise the inlet camshaft using tool [24]

Refit

• The inlet camshaft dephaser (VTC) (44)
• The bolt of the VTC (new)
• The pulley (41)
• The (42) bolt

Tighten the bolt of the VTC

• Pre-tightening to 3 ± 0,5 daNm
• Tighten to 5,5 ± 0,5 daN.m

Refit the plug (43) (new)

Remove the tool [24]

Cut out a section of a used timing belt "r", at least 10 teeth in length, and insert it between the camshaft pulleys to immobilise them

Tighten the bolt (42)

• Pre-tightening to 3 ± 0,5 daNm
• Tighten to 8,5 ± 0,5 daN.m

Peg the camshafts using tools [18] and [19]

Timing belt

Refit the timing belt (45) onto the crankshaft pinion (36)

Hold the timing belt (45) using the tool [21]

Fit the timing belt (45), strictly in the following order

• The crankshaft gear (36)
• The tensioning roller (35)
• Inlet camshaft pulley (33)
• Pulley (30) of the exhaust camshaft
• The coolant pump (46)
• The roller tensioner (40)

Remove

• The tool [21]
• The tool [18] from the exhaust camshaft pulley

Tensioning the timing belt

Rotate the tensioning roller (40) in the direction of the arrow "t" using an Allen key at "u"

Position the index "y" in position "w" using an Allen key at "u"

Then bring the index "y" to its setting position "x", by rotating the tensioning roller in the direction of the arrow "v"

Tighten the roller tensioner (40) bolt to 2,1 ± 0,2 daN.m

Turn the crankshaft 10 turns in the normal direction of rotation

Peg the inlet camshaft pulley using tool [18] or [19] (according to engine)

Check

Tensioning the timing belt

Position of the crankshaft

Fit tools [18], [19] and [17] (according to engine)

When it is possible to fit the tool [17], follow the refitting operations

Repositioning the end plate

Lock the crankshaft using the tool [23]

Slacken the bolt (38) so as to release the crankshaft pinion (36)

Bring the end plate (37) to the pegging position using tool [23]

Fit the tool [17]

Lock the crankshaft using the tool [23]

Fitting with steel washer (gold colour)

• Tightening to 4 ± 0,2 daN.m
• Tighten by an angle of 53 ± 4 ° with tool [20]

Fitting with sintered steel washer (metallic colour)

• Tightening to 4 ± 0,2 daN.m
• Tighten by an angle of 40 ± 4 ° with tool [20]

Remove tools [18], [19], [17] and [23] (according to engine)

Timing gear side

Refit

• The lower timing cover (52)
• The top timing cover (47)
• The engine mounting (48)
• The roller tensioner (49)
• The pulley (50)
• The bolts (51)

Tighten the bolts (51) to 2,1 ± 0,2 daN.m

Top of EW7J4 and EW10J4 engines

Refit

• The cylinder head cover (54)
• The cylinder reference sensor (55)
• The 22 bolts (53)
• The ignition coils block (57)
• The 3 bolts (56)

Bring the screws (53) into contact with the cylinder head cover (54)

Tighten the bolts (53) to 1,1 ± 0,1 daN.m

Replacing the spark plug hole seals

Coat the edge of the seal with SILICON sealing paste

Fit

• The cylinder head covers onto 2 wooden shims
• The seal by hand into its housing

Fit the seal until correctly seated using a Ø 33 mm tube

Refit

• The cylinder head cover (59)
• The VTC electrovalve (60) using a long standard socket
• The sparking plugs
• The fixing screws of the ignition coil unit (58)

Tighten

• The cylinder head cover screws to 0,9 ± 0,1 m.daN (order from 1 to 6)
• The VTC electrovalve (60) to 0,7 ± 0,1 m.daN
• The spark plugs to 2,25 ± 0,2 m.daN

Exhaust manifold side

C: EW10D engine

D: EW7J and EW10J4 engines

Refit

• The exhaust manifold seal or heat shield (new) (according to engine)
• The exhaust manifold (61)
• The 10 nuts (62)
• The air recycling pipe (63)
• Tighten the nuts (62) to 3,5 ± 0,3 daN.m

Refit

• The seal on the water outlet housing
• The coolant outlet housing/coolant pump linking tube (65)
• The coolant outlet housing/coolant pump linking tube (65) together with the coolant outlet housing (64)

Refit

• A new seal on the pre-catalyst
• The nuts (68) (without tightening)

Turn the collar (69) to hook it on the welded screw "aa"

Refit

• The air hose clamp (73)
• The nut (66)
• The (71) bolt

Tighten

• The nuts (68)
• The nut (66)
• The (72) bolt
• The (71) bolt: tighten to 0,4 ± 0,1 daN.m
• The (70) bolt

Refit

• The heat shield (67)
• The heat shield (67) fixing bolts
• The proportional and oxygen sensors

Repairing the holes

Drill, thread and place a tight thread

Check the stability of the repair made

Clutch end

Refit

• The EGR valve (74) (according to equipment)
• The valve or the pump (75)
• The panel (76)
• The clutch disc
• The clutch mechanism (77)

Centre the clutch disc using the tool [22]

Refit the 6 bolts (78)

Tighten the 6 bolts (78) to 2 ± 0,2 m.daN

Remove the tool [22]

D: EW7 and EW10J4 engines

C: EW10D engine

Refit

• Knock sensor (80)
• The oil filter bracket (81)
• The oil filter (82)

Tighten the knock sensor (80) to 2 ± 0,5 m.daN

Refit

• The petrol injection rail and its shim (83)
• The securing bolts (84)
• The soundproofing (85) from the petrol injection rail
• The high pressure pipe (79) (new)

Tighten the high pressure pipe (79) to 2,6 ± 0,3 m.daN

Refit

• The air manifold (89) fitted with the throttle housing and the injection rail
• The 2 nuts (87)
• The 6 bolts (86)
• The clip (88)

Tighten the 8 screws of the air manifold (86) and (87) to 2 ± 0,5 dan.m