Refitting: engine (DV6UTED4) Citroen Jumpy II

Tooling

Equipment

• Dial gauge
• Dial gauge support
• Approved cleaning product
• Grease type MOLYCOTE RAPID
• Seal paste (index "E10")
• Thread locking paste (type "LOCTITE 570")

Preliminary operations

Check the condition of the following components (see corresponding procedure)

• Cylinder block
• Crankshaft
• Conrods
• Pistons

Refitting

Preparing the cylinder block

Refit

• The piston base jets (1)
• The grooved bearing shells (2)
• The crankshaft lateral clearance thrust washers (3) (lubrication grooves on the crankshaft side)

Adjusting the crankshaft endfloat

Fit the crankshaft

Position

• The dial gauge support
• The dial gauge

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 0,322 mm endfloat

Oil

• The crankshaft bearing faces
• The half bearing shells

Remove the crankshaft

Connecting rod/piston assemblies

Assemble the connecting rods/pistons/rings assemblies

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

Fit the tool [750-T]

Oil

• The pistons
• The cylinders
• The conrod bearing shells

Refit the connecting rod/piston assemblies

Position the connecting rod bearing shells (4); using the tools [0194-P]

Fit the half bearing shells (4) on the connecting rods (5)

Oil the upper bearing shells positioned on the connecting rods (5)

Fit the crankshaft

Fit the half-shells conrod caps; using the tools [0194-P]

Oil the half-bearing shells

Lubricate the crankshaft crank pins lightly

Position the conrod caps (6)

Fit the bolts (7) (new)

Tighten the fixing bolts (7) to the correct torque

Position the tools [0194-QZ] and [0194-N] on the crankshaft main bearing cap casing

Refit the smooth lower bearing shells (8)

Check the presence of the 10 centring pins on all the bearings (at "d")

Apply a strip of sealant "E10" around the edge of the cylinder block (at "e")

Fit the crankshaft bearing cap casing on the cylinder block

Crankshaft main bearing cap casing

Refit the tools [0194-N] (as "f", "g")

Draw up the bolts (9), (10)

Remove the tools [0194-N]

Tighten the fixing bolts (9), (10), (11) to the correct torque

Oil pump

Apply a strip of sealant "E10" around the edge of the cylinder block (at "h")

Fit the centralising pins (12)

Refit

• The oil pump (13) (new seal)
• The bolts (14)

Tighten the fixing bolts (14) to the correct torque

Oil suction strainer - lower cover

Lubricate the interior of the oil pump with clean engine oil

Refit

• The oil suction strainer (15)
• The lower gauge guide (16)
• The studs (17)

Apply a strip of sealant "E10" (at "i")

Apply a strip of sealant "LOCTITE 570" (at "j")

Oil sump (all engines except DV6UTED4)

Refit

• The sump (19)
• The 2 nuts (21)
• The bolts (18)

Oil sump (engine DV6UTED4)

Refit

• The sump (19)
• The 2 nuts (21)
• The bolts (18)

Apply a strip of sealant "E10" / steel oil sump

Refit

• The 2 studs / steel oil sump
• The oil sump (Of steel)
• The 2 nuts / steel oil sump
• The 8 oil sump bolts (Of steel)

Common operations

Immerse the bolts (20) in a bath of sealing product for 4 minutes minimum

Fit the bolts (20) until they are in contact with the base of the spot facing

Coolant pump

Refit the coolant pump (22) using a new seal

Refit the fixing screws (23)

Tighten the fixing bolts (23) to the correct torque

Ring seals (crankshaft)

Fit tool [0194-M] on the crankshaft (flywheel side)

Refit the ring seal (24); using tool [0194-M] (hold for 5 seconds)

Remove the tool [0194-M]

Fit tool [0194-L] on the crankshaft (oil pump side)

Refit the ring seal (25); using tool [0194-L] (hold for 5 seconds)

Remove the tool [0194-L]

Piston protrusion

"B" = 10 mm

Clean the surfaces to be checked

Fit dial gauge support to the cylinder block

Secure dial gauge to support

Set the dial gauge to zero (at "l")

Measure the height difference (at "k")

Calculate the average of the 2 values measured

Cylinder head

Refit

• The cotter
• The crankshaft gear (26)
• The (27) bolt

Pin the crankshaft sprocket (26); using tool [0194-A]

Refit

• The centralising pins (30)
• The cylinder head gasket (29)
• The cylinder head (28)

Perform the following operations

• Insert a tap drill into the cylinder head holes
• Brush the cylinder head bolts using a metal brush
• Fit the cylinder head bolts coated with MOLYCOTE RAPID on the threads and under the bolt heads

Cylinder head tightening

Tightening method for the screws (bolt by bolt in the order from 1 to 10)

• Pre-tighten to the correct torque; using tool [0185]
• Tighten to the correct torque; using tool [0185]
• Angular tighten to the correct angle; using tool [1608-C]

Camshaft

Previous assembly

New assembly

Common operations

• Position the chain (33) on the camshaft pinions (31) and (32)
• Align the links "m" and "p" marked in black with the teeth marked "n" and "q" on the camshaft gears (31) and (32) (according to the assembly operations)
• Position the chain tensioner (34)

Lubricate the camshaft bearing caps (35)

Refit

• The chain assembly (33), the chain tensioner (34) and the camshafts (31) and (32)
• The bolts (36)
• The camshaft bearing caps (35)

Tighten the bolts to the specified torque (from 1 to 16)

Oil

• The valve tappet bodies
• The valve control rockers

Fit a clip to retain the roller valve rockers on the tappets (reference PR 0910 38)

Composition

• (37) cam follower
• (37a) clip
• "s" side with lugs
• "r" side without lugs

Perform the following operations

• "B": fit the attachment (37a) on the side "r" on the inner edge of the bracket mounting
• "C": fit the attachment (37a) on the side "t" on the outer edge of the bracket mounting
• "D": check that the attachment is correctly aligned

Refit the valve control rockers with their hydraulic followers (respecting their original positions)

Setting the timing chain (according to the assembly operations)

New assembly

New assembly

Common operations (according to the assembly operations)

• Refit the camshaft pulley
• Pin the camshaft pulley; using tool [0194-B]
• Remove the tool [0194-B]
• Turn the camshaft through 40 revolutions

Remove the camshaft pulley

Apply product E10 to the upper periphery of the cylinder head (at "u")

Fit the tools [0194-N]

Position the camshaft bearing cap cover on the cylinder head; using tool [0194-N]

Refit

• The studs, for which the tightening sequence is from 1 to 8; tighten to the specified torque
• The bolts, for which the tightening sequence is from 9 to 24; tighten to the specified torque

Remove the tools [0194-N]

Refit the camshaft seal; using tool [0194-K] (hold for 5 seconds)

Remove the tool [0194-K]

Refit

• The rear timing cover
• The camshaft pulley (39)
• The bolt (38); tighten to the specified torque

Rotate the camshaft pulley (39) (clockwise); using tool [1 860 765 000]

If the camshaft pulley is too far advanced, bring it back a quarter turn in relation to its pegging hole (anti clockwise)

Remove the tool [1 860 765 000]

Pin the camshaft pulley; using tool [0194-B]

Oil filter

Refit the oil filter support (40) fitted with a new seal

Retighten the bolts 4 to the correct torque

Refit

• The dipstick cap (according to equipment)
• The oil temperature gauge (41) fitted with a new seal (according to equipment)

Engine re-assembly

Refit the pre-heater plugs

Refit

• The lifting attachment
• The lifting attachment fixing bolt

DELPHI type high pressure fuel pump (DV4TED4 engines)

Check that the 2 alignment dowels are present on the cylinder block

Refit the fuel high pressure pump on the support

Refit

• The main support (46) and high pressure fuel pump assembly
• The 2 bolts (47)
• The rear support (43)
• The rear support (43) fixing bolt (44)
• The main support (46) fixing nut (45)
• The 2 rear support (43) fixing nuts (42)

Peg the fuel high pressure pump; using tool [0194-A]

CP3.2 type high pressure fuel pump (DV6 engines)

Check that the 2 alignment dowels are present on the cylinder block

Refit the fuel high pressure pump on the support

Refit

• The main support (46) and high pressure fuel pump assembly
• The 2 bolts (47)
• The rear support (43)
• The bolt (45)
• The nut (44)
• The 2 bolts (42)

Peg the fuel high pressure pump; using tool [0194-A]

CP1H type high pressure fuel pump (DV6 engines)

Check that the 2 alignment dowels are present on the cylinder block

Refit the fuel high pressure pump on the support

Refit

• The main support (52) and high pressure fuel pump assembly
• The bolt (54)
• The nut (49)
• The rear support (50)
• The bolt (53)
• The 2 bolts (48)
• The bolt (51)

Peg the fuel high pressure pump; using tool [0194-A]

Timing belt

Refit

• The stud fixing the guide roller to the cylinder block
• The tensioning roller
• The roller tensioner

Fit the timing belt (55), strictly in the following order

• Crankshaft pulley (26)
• Roller tensioner (56)
• Camshaft pulley (39) (check that the belt is correctly engaged on the roller)
• Water pump pulley (57)
• Fuel high pressure pump pulley (59)
• Roller tensioner (58)

Turn the roller tensioner towards the right to bring the index "x" to position "v"; using a 6 -sided wrench (at "w")

Tighten the bolt (60) to torque

Remove the tools [0194-A], [0194-B]

Turn the engine 10 revolutions (check that the timing pinion is correctly engaged on the crankshaft)

Check

• The pegging of the camshaft
• The crankshaft pulley
• The high pressure fuel pump pulley (59)
• The correct positioning of the dynamic tensioner index

If this is not the case, repeat the cambelt fitting procedure

Refit

• The engine speed sensor (63)
• The belt guide stop (62)

Remove bolts (61)

Setting the camshaft sensor

Slacken the bolt (66)

Move the camshaft position sensor (64) to the end of the slots

Do up the screw (66) by a few turns

Adjust the air gap (1,2mm) of the camshaft position sensor (64)

• New camshaft position sensor: place the tip of the position sensor in contact with the target on the camshaft pulley (39)
• Camshaft position sensor re-used: place a drill at "z" (Ø 9,5mm) between the camshaft position sensor (64) and the timing cover (65)

Engine support / timing covers

Refit

• The intermediate right engine mounting (67)
• The 4 right-hand intermediate engine mounting fixing bolts (68)
• The bottom timing cover
• The 6 lower timing cover fixing bolts
• The top timing cover
• The 5 upper timing cover fixing bolts

Fit new seals (69) in the camshaft main bearing cap casing

Remove the closers [0194/2-F]

Diesel injectors

"E" BOSCH injector (DV6 engines)

"F" DELPHI injector (engine DV4TED4)

Remove the plugs [0194-T] or [0194/2-E] from the diesel injector wells

Remove the closers (at "ab")

Refit

• The pillar screws (new)
• The seals (74) (new)
• The sealing rings (72) (new)
• The diesel injectors (73)
• The clamps (71)
• The nuts (70)

Tighten the nuts (70) (tighten by hand)

Method for tightening the nuts (70)

• Pre-tighten to the specified torque; using the tools [1603 / 4220-T]
• Angular tightening; using tool [1608-C]

Check the seal at "ac" (replace the seal if necessary)

Replace the seals (75), lubricating them slightly; with engine oil

Refit

• The air intake manifold (76)
• The oil trap (78)

Refit the 9 bolts (77); tighten to the specified torque (order from 1 to 9)

Refit the 3 bolts (80)

Refit

• The fuel high pressure common injection rail (86)
• The 2 securing bolts (85)
• The fuel high pressure common injection rail supply pipe support
• The supply pipe support fixing nut (84)
• The fuel high pressure common injection rail supply pipe retaining clip
• The supply pipe retaining plate fixing bolt (83)

Refit: the fuel return pipes; using tools [0194-V1] and [0194-V2]

Pre-tighten; using the tools [1616]

• The unions (87) on the fuel high pressure common rail
• The unions (79) on the diesel injectors; apply a counter-torque

Tighten; using the tools [1616]

• The unions (87) on the fuel high pressure common rail
• The unions (79) on the diesel injectors; apply a counter-torque

Fit the new supply pipe (high pressure fuel pump side)

• Pre-tighten: the pipe (82)
• Tighten the connector (82)

Fit the new supply pipes (injectors side)

Check that the vacuum pump location is free of residual jointing compound (at "ad")

Fit 2 new seals on the vacuum pump (89)

Refit

• The vacuum pump (89)
• The 2 bolts (88)

Coolant outlet housing

Fit the coolant outlet elbow (90) with a new joint

Tighten the bolts to the specified torque

Exhaust gas recycling solenoid valve (DV6 engines)

Refit

• The air filter housing support (92)
• The exhaust gas recycling exchanger (96) (according to equipment)
• The bolts (97)
• The seal of the EGR valve
• The EGR electrovalve (91)
• The 2 exhaust gas recycling valve fixing bolts (98)
• A new metal clip (95b)
• The exhaust gas recycling duct (94)
• A new metal clip (95a)
• The 2 bolts (93)

Exhaust gas recycling valve (DV4TED4 engines)

Refit

• The air filter housing support (92)
• The bolts (97)
• The seal of the EGR valve
• The exhaust gas recirculation valve (91)
• The 2 exhaust gas recycling valve fixing bolts (98)
• A new metal clip (95b)
• The exhaust gas recycling duct (94)
• The bolt (99)
• A new metal clip (95a)
• The 2 bolts (93)

Coolant inlet manifold / vacuum electrovalve

Fit a new seal on the coolant inlet manifold on the coolant pump side (at "ae")

Refit

• The coolant pump coolant inlet manifold
• The vacuum electrovalve support plate (102)
• The coolant inlet manifold support plate (107)
• The 2 bolts (106)
• The (103) bolt
• The engine harness support plate (101)
• The vacuum electrovalve (104)
• The 2 vacuum electrovalve fixing nuts (105)
• The coolant / exhaust gas exchanger coolant pipe (100)
• The coolant / exhaust gas exchanger coolant pipe fixing clip

Fuel filter

Refit

• The fuel filter support (109)
• The 3 bolts (108)
• The fuel priming pump support (110)
• The fuel filler neck assembly (111)
• The fuel filter

Couple up

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

Electrical harness

Refit

• The engine electrical harness (112)
• The engine harness protective moulding (114)
• The 3 engine harness protective moulding fixing bolts (113)
• The pre-heat plugs electrical harness (115)
• The 4 pre-heat plugs electrical harness fixing nuts

Exhaust manifold

Refit

• A new seal on the exhaust manifold
• The exhaust manifold fitted with turbocharger (119)
• The turbocharger vibration damping plate (117)
• The bolt (118)
• The 8 spacers (116)
• The 10 nuts (120)

Tighten the nuts (120) of the long model studs

Tighten the nuts (120) of the short model studs

Refit

• The turbocharger oil return pipe (125)
• The 2 turbocharger oil return pipe fixing clips (123)
• The turbocharger greasing pipe (122)
• The upper banjo bolt (121) (2 new seals) (without tightening)
• The lower banjo bolt (124) (2 new seals) (without tightening)

Turbocharger (DV6 engines)

1st case: assembly with semi-rigid greasing pipe

(119a) turbocharger (engines DV6ATED4 and DV6BTED4)

(119b) turbocharger (DV6TED4 engines)

"G" = 8 mm

Position the turbocharger greasing pipe; using an 8 mm shim (at "af")

Tighten to the specified torque

• The bolt (121)
• The bolt (124)

2nd case: assembly with rigid greasing pipe

"H" diameter of the pin

• DV6TED4 engine: "H" = 8 mm
• DV6ATED4 engine: "H" = 20,5 mm

Method for tightening the upper union

• Put a pin of diameter "H" in place vertically (as indicated above)
• Tighten the bolt (121) to torque; supporting the union using the pin

"J" diameter of the pin: "J" = 7,5 mm

Method for tightening the lower union

• Put a pin of diameter "J" in place horizontally; as indicated above
• Tighten the bolt (124) supporting the union using the pin

Tighten the banjo bolts (124)

Turbocharger (DV4TED4 engines)

(119c) turbocharger (DV4TED4 engines)

Tighten to the specified torque

• The bolt (121)
• The bolt (124)

Exhaust manifold heat shield

Refit

• The exhaust manifold heat shield (127)
• The 2 exhaust manifold heat shield fixing bolts (126)
• The turbocharger vacuum pipe (128)

Hydraulic power steering

Check that the 4 positioning pins (130) are present on the cylinder block

Refit

• The air conditioning compressor support (131) (according to equipment)
• The 2 nuts (132) (according to equipment)
• The 2 bolts (133) (according to equipment)
• The steering assistance pump support (134) (according to equipment)
• The 4 bolts (129)

Refit

• The power steering pump (135)
• The 2 bolts fixing the steering assistance pump (138) on its support
• The tightening cone (137)
• The bolt (136)

Refit

• The dynamic roller tensioner (140)
• The dynamic roller tensioner fixing bolt (139) (140)
• The dynamic roller tensioner blank (140)
• The alternator (142)
• The tensioning roller (143)
• The guide roller / alternator fixing bolt (144)
• The alternator upper fixing bolt (141)
• The guide roller protector

Refit the 2 alternator fixing bolts fitted with the tightening cones (145)

Electric power steering

Check that the 4 positioning pins (147) are present on the cylinder block

Refit

• The air conditioning compressor support (150) (according to equipment)
• The 2 nuts (148)
• The 2 bolts (149)
• The dynamic roller tensioner support (151)
• The 4 bolts (146)

Refit

• The alternator (153)
• The 2 alternator fixing bolts (152)

Refit the 2 alternator fixing bolts fitted with the tightening cones (154)

Refit

• The dynamic roller tensioner (156)
• The 3 bolts (155)

Throttle butterfly housing

Check that the 2 alignment dowels are present on the cylinder block

Refit

• The throttle unit (163) (according to equipment)
• The throttle butterfly housing pipe (164) (according to equipment)
• The throttle butterfly housing pipe (162) (according to equipment)
• The turbocharger sound damper (157) fitted with a new seal
• The turbocharger sound damper flanged fixing bolt (158)
• The bolt (159)
• The dipstick guide (160) fitted with a new seal
• The bolt (161) fixing the dipstick on the cylinder block

Accessories drive pulley

Refit

• The ancillary drive pulley (166)
• The bolt (165) pre-coated with LOCTITE 273; tighten to the specified torque

Engine flywheel (according to equipment)

Refit

• The flywheel (167) (according to equipment)
• The 6 bolts (168) (new)

Turn the crankshaft pulley to drive the engine in its normal direction of rotation

Peg the engine flywheel; using tool [0194-C]

Tighten the bolts (168) to torque

Double damped flywheel (according to equipment)

Refit

• The double damped engine flywheel (169) (according to equipment)
• The 6 bolts (168) (new)

Turn the crankshaft pulley to drive the engine in its normal direction of rotation

Peg the engine flywheel; using tool [0194-C]

Tighten the bolts (168) to torque

Check the condition of the double damped engine flywheel (see the relevant operation)

Clutch mechanism

Fit

• The clutch disc (172)
• The clutch mechanism (171)

Centre the clutch disc (172) (en "ah")

Tighten the bolts (170) to torque

Remove

• The tool [0194-C]
• The clutch friction plate centring device (at "ah")

Gearbox

Refit

• The gearbox
• The pillar screw (175)
• The 2 nuts (176); tighten to the specified torque
• The gearbox peripheral bolts; tighten to the specified torque

Starter / vacuum reservoir

Refit

• The starter motor (181)
• The 3 bolts (180)
• The vacuum tank (180) (according to equipment)
• The bolt (179)
• The engine harness moulding (177)

Couple the vacuum reserve vacuum pipe

Refit the gearbox controls fixing plate

Catalytic converter

Refit

• The rear heat shield (182)
• The catalytic converter rear fixing support (183)

Refit

• The particle filter/catalytic converter assembly (185) (according to equipment)
• The clip (184)
• The 2 nuts (186)

Refit

• The heat shield (188)
• The 7 catalytic converter / particle filter assembly front heat shield bolts (187)
• The 2 tubes (192)
• The bracket (191)
• The bolt (190) fixing the 2 particle filter inlet and outlet pipes
• The catalytic converter / particle filter assembly oxygen sensor (189)

Reconnect the engine electrical harness to all of the connectors

Refit

• The air filter assembly fitted with the air flow sensor
• The manual diesel priming pump

Additional operations

Refit

• The coolant heater support (194)
• The pipe (193) between the coolant housing and the coolant heater
• The power unit

Fill and top up the oil sump