Dismantling: engine (DV6UTED4) Citroen Jumpy II

Tooling

Equipment

• Approved cleaning product
• Vacuum extractor
• Round end-piece

Preliminary operations

Drain the engine oil

Unclip the engine harness, then disconnect it from the various sensors

Remove

• The power unit assembly (see the relevant operation)
• The pipe (1)
• The coolant heater support (2) (according to equipment)

Engine stripping

Starter / vacuum reservoir

Remove

• The engine harness moulding (3)
• Gearbox controls fixing plate (4)

Uncouple the vacuum pipe from the vacuum reserve

Remove

• The fixing screws of the starter
• The starter motor (5)
• The vacuum tank (6)

Exhaust gas pressure sensor pressure take-offs (vehicle with particle filter)

Disconnect the exhaust gas temperature sensor

Remove

• The exhaust gas temperature sensor (8)
• The exhaust gas pressure take-off fixing support (9)
• The upstream exhaust gas pressure sensor pressure take-off (see the relevant operation)
• The downstream exhaust gas pressure sensor pressure take-off (see the relevant operation)

Catalytic converter/particle filter assembly

Remove the front heat shield (7)

Remove

• The clip (10)
• The nuts (12)
• The catalytic converter /particle emission filter (11) assembly (according to equipment)

Remove

• The heat shield (14)
• The bracket (13)

Gearbox

Remove the gearbox attachment screw

Remove

• The pillar screw (17)
• The 2 nuts (18)
• The gearbox

Clutch mechanism/engine flywheel

"A" engines: DV all types except DV6UTED4

"B" DV6UTED4 engine

Rotate the engine by means of the crankshaft pulley screw to bring it to the flywheel locking position

Lock the flywheel; using tool [0194-C] ou [0194-W] (depending on the version)

Remove

• The clutch mechanism fixing screws
• The clutch mechanism

Remove

• The 6 bolts (19)
• The flywheel (20)

Air metering control unit/turbocharger noise attenuator

Remove

• The (25) bolt
• The ancillary drive pulley (24)
• The tool [0194-C] ou [0194-W] (depending on the version)
• The engine oil gauge guide (23)
• The air metering control unit (22) (according to equipment)
• The turbocharger noise attenuator (21)

Air conditioning compressor / dynamic roller tensioner (electric power steering)

Remove

• The 3 screws fixing the dynamic roller tensioner (29)
• The dynamic roller tensioner (29)
• The 4 alternator fixing bolts
• The alternator (27)
• The 4 fixing screws of the mounting (26) (according to equipment)
• The bracket (26) (according to equipment)
• The 4 screws fixing the air conditioning compressor support (28) (according to equipment)
• The air conditioning compressor support (28) (according to equipment)

Air conditioning compressor / dynamic roller tensioner (mechanical power steering)

Remove

• The guide roller protector
• The guide roller fixing screw (34)
• The tensioning roller (34)
• The 3 alternator fixing bolts
• The alternator (32)
• The dynamic roller tensioner blank
• The dynamic roller tensioner fixing screw
• The dynamic roller tensioner (35)
• The 3 screws fixing the power steering pump
• The power steering pump (30)
• The 4 screws fixing the power steering pump support
• The steering assistance pump support (31)
• The 2 upper screws fixing the air conditioning compressor support (33) (according to equipment)
• The 2 lower screws fixing the air conditioning compressor support (33) (according to equipment)
• The air conditioning compressor support (33) (according to equipment)

Exhaust manifold / turbocharger

Remove

• The screws of the 2 turbocharger lubrication pipe unions (38)
• The lubrication piping (38)
• The vacuum pipe (40)
• The oil return hose (39)
• The 2 heat shield (36) fixing bolts
• The exhaust manifold heat shield (36)
• The 10 nuts fixing the exhaust manifold equipped with the turbocharger (37)
• The 8 spacers on the exhaust manifold equipped with the turbocharger (37)
• The exhaust manifold fitted with turbocharger (37) (according to equipment)
• The exhaust manifold seal
• The 4 pre-heat plugs electrical harness fixing nuts
• The pre-heater plugs supply shunt
• The diesel injectors electric carrier bar
• The engine electric harness

Exhaust gas recycling valve

Uncouple

• The 4 pipes for return of diesel fuel from the injectors
• The diesel filter diesel inlet and outlet pipes
• The diesel fuel inlet and outlet pipes from the fuel high pressure pump

Remove

• The diesel filler neck assembly (52)
• The diesel lift pump support (41)
• The fuel filter (50)
• The diesel filter support (51)
• The exhaust gas recycling duct (42)
• The clip fixing the coolant hose (48)
• The pipe (45)
• The exhaust gas recycling heat exchanger (44) (according to equipment)
• The 2 exhaust gas recycling valve (49) fixing bolts
• The exhaust gas recirculation valve (49)
• The seal of the EGR valve
• The screw fixing the air filter housing support
• The air filter housing support (43)
• The vacuum electrovalve (46)
• The 4 screws fixing the coolant outlet housing
• The 4 screws fixing the coolant inlet manifold / vacuum electrovalve assembly
• The coolant outlet housing / coolant inlet manifold assembly from the coolant pump
• The 4 screws fixing the lower engine support (47)
• The lower engine support (47)

Vacuum pump

Remove

• The 2 bolts (53)
• The vacuum pump (54)

Air inlet manifold / fuel high pressure common injection rail

Remove

• The fuel high pressure common injection rail (60) supply pipe (58) support (59) fixing nut (fuel high pressure common injection rail / high pressure fuel pump)
• The fuel high pressure common injection rail (60) supply pipe (58) (fuel high pressure common injection rail / high pressure fuel pump)
• The 4 fuel supply pipes (57) from the diesel injectors (fuel high pressure common injection rail/diesel injectors)
• The 2 mounting screws of the high pressure fuel common injection rail
• The fuel high pressure common injection rail (60)
• The oil trap (55) (7 screws)
• The integrated air inlet system air inlet manifold (56)
• The 8 integrated air inlet system air inlet manifold seals

Diesel injectors

"C" BOSCH injector (DV6 engines)

"D" DELPHI injector (engine DV4TED4)

Remove

• The nuts (61)
• The clamps (62)
• The diesel injectors (64)
• The sealing rings (63)
• The seals (65)

Extracting a diesel injector (DV6 engines)

Remove the 8 nuts (61)

Refit

• The right-hand engine mounting
• The bolt (67a) (without tightening)
• The 2 bolts (67b) (without tightening)

Fit the tool [1616-A]

Fit the tool for extracting the diesel injectors [[1616-A]]against the head of the screw (67a) and the heads of the 3 screws (66)

Remove

• The diesel injectors
• The tool [1616-A]
• The (67a) bolt
• The 2 bolts (67b)
• The right-hand engine mounting

Remove the 4 diesel injector sleeves from the camshaft bearing cap cover

Remove the fire washers from the injector holes (if necessary)

Extracting a diesel injector (engine DV4TED4)

Remove the diesel injector flange

Fit the pillar screws "b" fixing the tool [0194 / 2-B] on the 2 cylinder head cover screws (tighten by hand)

Fit the flange "a" of the tool [0194 / 2-B] on the diesel injector

Position the diesel injector retainer "c" of the tool [0194 / 2-B] on the flats of the diesel injector and on the flange "a" of the tool [0194 / 2-B]

Apply pressure on the diesel injector and on the flange "a" of the tool [0194 / 2-B]

Unlock the diesel injector by progressively slackening the screws [6b] (every 1/4 revolutions)

Remove the 2 valve cover fixing screws

Extracting the sealing washer

Slacken the tool [0194/2-C] by a few turns

Fit the tool 0194 / 2-C on the copper seal (65) in the diesel injector well

Tighten the bolt of the tool 0194 / 2-C fully to immobilise the copper seal (65)

Remove the copper seal (65) by manoeuvring the tool 0194 / 2-C

Cleaning the diesel injector hole

Fit the tool [0194/2-D] in the diesel injector well

Clean the diesel injector hole by turning the tool 0194 / 2-D clockwise

Remove the tool [0194/2-D]

Vacuum the diesel injector holes; using the vacuum cleaner and the round end piece

Timing covers

Remove

• The 4 bolts (69)
• The intermediate right engine mounting (71)
• The 5 screws fixing the upper timing cover (68)
• The top timing cover (68)
• The 6 screws fixing the lower timing cover (70)
• The bottom timing cover (70)

Timing belt / pulleys

Remove

• The camshaft position sensor (73)
• The screw fixing the crankshaft phase sensor (83)
• The crankshaft phase sensor (83)
• The screw fixing the anti-offset bracket (82)
• The anti-offset bracket (82)
• The (79) bolt
• The dynamic tensioner of the timing belt (80)
• The timing belt (76)
• The nut (77)
• The guide roller of the timing belt (78)
• The crankshaft timing pinion (81)
• The keyway of the crankshaft timing pinion (81)

Lock the rotation of the camshaft pinion, using tool [1 860 765 000]

Remove

• The screw (74) of the camshaft pinion (75)
• The tool [1 860 765 000]
• The camshaft gear (75)
• The 3 screws fixing the rear timing cover (72)
• The rear timing cover (72)

DELPHI high pressure fuel pump (engine DV4TED4)

Remove

• The (87) bolt
• The 2 bolts (84)
• The rear support (85)
• The nut (86)
• The 2 bolts (89)
• The main support (88) and high pressure fuel pump assembly

BOSCH CP3.2 type high pressure fuel pump (engine DV6)

Remove

• The (87) bolt
• The 2 bolts (84)
• The rear support (85)
• The nut (86)
• The 2 bolts (89)
• The main support (88) and high pressure fuel pump assembly

BOSCH CP1H type high pressure fuel pump (engine DV6)

Remove

• The (93) bolt
• The 2 bolts (90)
• The (95) bolt
• The rear support (92)
• The nut (91)
• The (96) bolt
• The main support (94) and high pressure fuel pump assembly

Spark plugs / lifting attachment

Remove

• The pre-heater plugs
• The lifting attachment fixing bolt
• The lifting attachment

Dismantling

Cylinder head

Remove

• The 16 bolts (97)
• The 8 studs (98)

Detach the camshaft bearing cap cover

Remove the camshaft bearing cap cover

Remove

• The camshaft bearing caps (101)
• The 2 fixing screws of the tensioner on the timing chain
• The chain tensioner (99)
• The camshafts (100) and (102)
• The sealing ring (103)

Mark the positions of the roller valve rockers (105) and the valve tappets

Remove

• The roller valve rockers (105) (respecting their original positions)
• The hydraulic followers (104) (respecting their original positions)

Remove

• The cylinder head bolts (sequence from 1 to 10)
• The cylinder head
• The cylinder head gasket

Sump (all engines except DV6UTED4)

Remove

• The seal of the oil pressure gauge pressure sensor
• The oil pressure gauge pressure sensor
• The 4 screws fixing the oil filter support assembly
• The oil filter bracket
• The 2 nuts (106)
• The 9 bolts (107)
• The 2 studs positioning the oil sump
• The oil sump
• The 2 plugs (108)

Sump DV6UTED4

Remove the 8 fixing screws (109)

Unscrew the 2 nuts (110)

Detach: the oil sump

Remove

• The 2 nuts (110)
• The oil sump (Of steel)
• The 2 studs (111)

Remove the 15 fixing screws (112)

Unscrew the 2 nuts (113)

Detach: the oil sump (115)

Remove

• The 2 nuts (113)
• The 2 studs (114)
• The oil sump (115)
• The 2 plugs (108)

Common operations

Remove

• The 3 bolts (116)
• The oil pump strainer (118)
• The dipstick guide tube (117)

Remove

• The (119) bolt
• The crankshaft gear (120) (carefully)

Remove the 8 bolts (122)

Detach: the oil pump (123) (at "b"); using a flat screwdriver

Remove

• The oil pump (123)
• The sealing ring (124)
• The oil temperature gauge (according to equipment)
• The oil gauge cap from the crankshaft bearing cap cover (according to equipment)
• The coolant pump
• The coolant pump coolant inlet manifold

Reciprocating gear

Remove

• The 10 screws (125) fixing the crankshaft bearing cap cover (127)
• The 14 screws (126) attaching the crankshaft bearing cap cover

Remove

• The 2 screws (129) attaching the crankshaft bearing cap cover
• The crankshaft bearing caps casing (127)
• The crankshaft ring seal (128), flywheel end

Remove the 5 smooth crankshaft bearing shells (130)

Remove

• The 8 screws (131) fixing the conrod caps
• The 4 conrod caps (132)

Remove

• The 4 conrod lower bearing shells (133)
• The 4 conrod upper bearing shells (134)
• The crankshaft

Remove

• The 2 crankshaft bearing flanges (135)
• The 5 grooved crankshaft bearing shells (136)

Remove

• The 4 screws fixing the piston skirt spray jets (137)
• The 4 piston skirt spray jets (137)

Remove the 4 piston conrod assemblies (as per arrows)