Fiat Scudo 2 0i 16v 2005 Workshop Service Repair Manual

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CORRESPONDENCE TABLE FOR PETROL ENGINES TU 1 Engine families

3 JP

1.1i

XU 5 JP4

1.4i

CORRESPONDENCE TABLE FOR DIESEL ENGINES

10 J2U

1.6i 16V

Engine families

HFX

KFW

NFU

Berlingo

X

X

X

DV

EW

J2U/K 2.0i

RFL

DW

6

8

ATED

B

Engine families

TD

BTED

CTED

UTD

ATED4

UTED

TD

2.0 8S HDi

2.0 16V HDi

2.2 8S HDi

2.8 TD

2.8HDi

RHV

RHW

4HY

8140.43

8140.43S

X

X

X

BTED+

RFN Engine families

1.6 16V HDi

1.9D

9HZ

WJY

C15 Dispatch

12

ATED J4 2.0i 16V

R6G

SOFIM

10

2.0HDi RHY

RHX

RHZ

X

X

X

X BERLINGO

Relay

X

X

DISPATCH

RELAY

VERY IMPORTANT As the booklet is constantly re-edited, this one only covers vehicles for this particular model year.

It is therefore necessary to order a new booklet each year and RETAIN THE OLD ONES.

X

X

X

X

X

X

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UTILITY VEHICLES

UTILITY VEHICLES

AC/DTAV/PRME/MMCB/MMEC Méthodes Mécaniques

쏘 «The intellectual property rights relating to the technical information contained in this document belong

exclusively to the manufacturer. Reproduction, translation or distribution in whole or in part without prior written authorisation from the manufacturer is forbidden».

2005

C15-BERLINGO DISPATCH RELAY "The technical information contained in this document is intended for the exclusive use of the trained personnel of the motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full responsibility to the exclusion of that of the manufacturer».

«The technical information appearing in this brochure is subject to updating as the characteristics of each model in the range evolve. Motor vehicle repairers are invited to contact the CITROËN network periodically for further information and to obtain any possible updates".

CAR 000 021

2005

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Page I

PRESENTATION

THIS HANDBOOK summarises the specifications, adjustments, checks and special features of CITROEN utility vehicles, not including PRIVATE vehicles for which there exist separate handbooks.

The handbook is divided into groups representing the main functions : GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - AIR CONDITIONING. In each section, the vehicles are dealt with in the following order: C15 – BERLINGO – DISPATCH - RELAY and all models where applicable.

The information given in this handbook is based on vehicles marketed in EUROPE.

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Page II

IMPORTANT

If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into account when preparing future publications. For example : – INSUFFICIENT INFORMATION – SUPERFLUOUS INFORMATION – NEED FOR MORE DETAILS

Please send your comments and suggestions to : CITROEN U.K. Ltd. 221, Bath Road, SLOUGH, SL1 4BA. U.K.

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CONTENTS GENERAL

Vehicle identification

C15

1-2

Berlingo

3-4

Dispatch Relay

Capacities

5-6 7 - 10

C15

12

Berlingo

13

Dispatch

14

Relay Lubricants

15 16 - 38

ENGINE Specifications

39 - 40

Tightening torques : engines all types

41 - 75

Cylinder head tightening : all types

76 - 79

Auxiliary drive belt

80 - 81

Checking and setting the valve timing

106 - 107

Checking the oil pressure

172 - 173

Valve clearances

174

INJECTION Checking the low pressure fuel supply circuit : C15 (DV6ATED4)

175

Checking the low pressure fuel supply circuit : Berlingo Dispatch (DW10TD)

176 - 177

Checking the low pressure fuel supply circuit : Relay (DW10UTD)

178 - 179

Checking the low pressure fuel supply circuit : Relay (DW12UTED/SOFIM)

180 - 181

Checking the turbo pressure : Berlingo (DW10TD)

182

Checking the turbo pressure : Dispatch (DW10ATED)

183

Checking the turbo pressure : Relay (DW10UTD)

184

Checking the turbo pressure : Relay (DW12UTED)

185

Checking the turbo pressure : Relay (SOFIM 2.8TD)

186

Checking the turbo pressure : Relay (SOFIM 2.8 HDi)

Checking the air supply circuit : Berlingo (DV6ATED4)

188

Checking the air supply circuit : Dispatch (DW10TD)

189

Checking the air supply circuit : Relay (DW10UTD)

190

Checking the air supply circuit : Relay (DW12UTED)

191

Checking the air supply circuit : Relay (SOFIM 2.8 HDi)

192

Checking the exhaust gas recycling circuit : Berlingo, Dispatch, Relay

193

Checking the exhaust gas recycling circuit : Relay

194

IGNITION Sparking plugs

195

CLUTCH-GEARBOX-TRANSMISSION

187

Speedometer Clutch specifications

C15 Berlingo

196 197 198

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CONTENTS CLUTCH-GEARBOX-TRANSMISSION Clutch specifications

AXLES - SUSPENSION – STEERING

Dispatch

199

Axle geometry : C15

Relay

200

Tightening torques : front axle : C15

251

Tightening torques : rear axle : C15

252

Specifications : Manual / automatic gearbox : all types

201 - 203

Tightening torques : Manual gearboxes

204 - 217

Manual gearbox controls: all types

218 - 227

248 - 250

Tightening torques : power steering : C15

253 - 254

Axle geometry : Berlingo

255 - 258

Tightening torques : front axle : Berlingo Tightening torques : rear axle : Berlingo

259 260

Suspension : Berlingo

261 - 262

228 - 231

Tightening torques : power steering : Berlingo

263 - 264

232 - 234

Axle geometry : Dispatch

265 - 266

Tightening torques : front axle : Dispatch

267 - 268

Tightening torques : rear axle : Dispatch

269

Manual steering : Dispatch

270

Tightening torques: power steering: Dispatch

271

Axle geometry : Relay

272

Shift lock : 4 HP 20 gearbox

239 - 240 241 - 244

Filling / topping-up : 4 HP 20 gearbox

245 - 246

Tightening torques : rear axle : Relay

Recommendations/precautions : AL4 automatic gearbox Tightening torques : AL4 gearbox AL4 automatic gearbox controls Recommendations/precautions : 4 HP 20 automatic gearbox Tightening torques : 4 HP 20 gearbox

Driveshafts

235 - 237 238

247

Tightening torques : front axle : Relay Tightening torques : power steering : Relay

273 - 274 275 276 - 277

BRAKES Brake specifications : C15 Tightening torques : brakes Adjusting the brake limiter Adjusting parking brakes Bleeding the brakes Brake specifications : Berlingo Tightening torques : brakes Checking/adjusting the compensator Adjusting parking brakes Bleeding the brakes Brake specifications : Dispatch Manual adjustment of the compensator Checking/adjusting the compensator Adjusting parking brakes Brake specifications : Relay Adjusting parking brakes Draining, filling and bleeding the braking circuit AIR CONDITIONING R134.a : quantities

278 279 280 281 282 283 - 288 289 290 - 291 292 293 294 - 297 298 299 300 301 - 302 303 - 306 307 - 310

311

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CONTENTS AIR CONDITIONING Compressor lubricant

314 - 315

Checking the efficiency of the circuit

316 - 325

Air conditioning circuit : Berlingo

326 - 327

Air conditioning circuit : Dispatch

328 - 330

Air conditioning circuit : Relay

331 - 332

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Page 1

C15

IDENTIFICATION OF VEHICLES (1) RP organisation no.

(2) Chassis no.

(3) Paint code

(5) 01/02/99 Label - Tyre pressures.

- RP organisation no.

- Paint code (6) Model year (7) Gearbox identification reference (8) Engine plate

E1AP079D

1

GENERAL

(4) Manufacturer’s plate

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C15

IDENTIFICATION OF VEHICLES Type approval Structure

VD WT/B

Family (1)

VD

Family (1)

VV

Version (2)

/B

Variant (3)

GENERAL

Engine WJY

1.9 D

VD

Version (2) C 15

Depollution DW8B

W4

2

VV

Van 600 Kg

VW

Van 765 Kg

VY

Deepened cab

WT

Familiale N1

Variant (3) Familiale Spain

B

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BERLINGO

IDENTIFICATION OF VEHICLES

A – Chassis stamp, cold stamp

C - Label RPO No. Paint colour code Tyre pressures D – Gearbox identification reference – factory serial no.

E – Engine legislation type – factory serial no.

E1AP0AMD

3

GENERAL

B - Manufacturer’s vehicle plate

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BERLINGO

IDENTIFICATION OF VEHICLES Type approval

GENERAL

Structure G Family (1) J Bodywork (2) GJ KFWC KFW Engine (3) /IF C Version (4) /IF Variant (5) Family (1) G Berlingo Body shape (2) B Van 600 Kg C Van 800 Kg E Floor cab Engine (3) HFX 1.1i TU1JP KFW 1.4i TU3JP NFU 1.6i 16V TU5JP4 9HX 1.6 16V HDi DV6ATED4 WJY 1.9 D DW8B RHY 2.0 HDi DW10TD

Version (4) L3 W3 A

Manual 5-speed gearbox Manual 4-speed gearbox Manual 6-speed gearbox Automatic 6-speed gearbox Axle and/or gearbox gears Other possible combinations No gearbox

L4

Euro IV

B E G D K M

C F H J L

Depollution levels US Others 83/87 P V R W S X N T Y

K K' 5 6 7

Alcohol L3/L4 Euro IV 8 1 9 2 3 U 0 4

Z

Variants (5) 2 sliding side doors as standard for 800 kg (WJY) Multi-function roof as standard for MPV WJY Without FAP Fiscal incentives 4x4 DANGEL Downgraded depollution Dual fuel LPG Dual fuel CNG STT2 (Stop and Start) Van Turkey Van Spain MPV/Van 5-seater 4

PLC PMF SF IF DGL D GL GN S TR ES PL

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IDENTIFICATION OF VEHICLES

DISPATCH

1 Vehicle identification N°.

2 RP organisation no.

4 Manufacturer’s plate.

5 Engine plate.

6 Gearbox identification reference.

7 - from 01/11/2003 Label - Tyre pressures.

- RP organisation no.

- Paint code.

E1AP0D0D

5

GENERAL

3 Paint code.

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DISPATCH

IDENTIFICATION OF VEHICLES Type approval

GENERAL

Structure B Family (1) BD D Number of seats (2) RFNC/IF/IF RFN Engine (3) C Version (4) /IF Variant (5) Family (1) B Dispatch Number of seats (2) A 5 seats B 6 seats C 7 seats D 8 seats E 9 seats H 2 seats, european-specific multi-stage TAXI J 7 seats, if different form the base «C» (AF) Engine (3) RFN 2.0i 16V EW10J4 WJY 1.9 D DW8B RHX DW10BTED DW10ATED4 2.0 HDi RHZ DW10CTED DW10BTED+ RHW 2.0 16V HDi DW10ATED4

Version (4) 15.04 K Manual 4-speed gearbox Manual 5-speed gearbox Manual 6-speed gearbox Automatic 3-speed gearbox Automatic 4-speed gearbox Axle and/or gearbox gears Manual 5-speed gearbox for South America No gearbox

Spécif US/CEE

Depollution levels 93/59 96/69 L/W L3/W3

96/69 A 98/69 B L4/W4 L5/W5

G

A

B

C

H

D

E K

F

Variants(5) Entreprise convertible Integral alternator-starter (ADIN) Without FAP Fiscal incentives Piloted manual gearbox Downgraded depollution LPG dual fuel STT2 (Stop and start) Van Spain

6

T AD SF IF P D (Private vehicle or Van LPG (Cylindrical tank)

TD (Van Convertible) LPG (Ring-shaped tank) S ES

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IDENTIFICATION OF VEHICLES (4 X 2)

RELAY

(1) Gearbox identification reference.

(2) Manufacturer’s name plate.

(4) Paint code (on bonnet).

(5) Chassis N° (cold stamp on body).

(6) Production N°.

E1-P02UD

7

GENERAL

(3) Engine plate.

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RELAY 4 X 4

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IDENTIFICATION OF VEHICLES (4 X 4)

(1) Gearbox identification reference.

(2) Manufacturer’s name plate.

(3) Engine plate GENERAL

(4) Transfer box (5) Paint code (6) Chassis N° (cold stamp on body).

(7) Production N°.

(8) Rear differential.

E1-P02VD

8

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RELAY 4 X 4

IDENTIFICATION OF VEHICLES Type approval

ZB RMFA/SX

Z A B RFL R6G RHV 4HY 8140.43 8140.43S

Z B R M F A /SX

Family (1) Payload (2) Engine (3) Transmission (4) Bodywork (5) Wheelbase (6) Variant (7) Family (1) Jumper / Relay Payload (2) 11 Q C 18 Q 15 Q D GVW reduced Engine (3) XU10J2U 2.0 XU10J2U/K 2.0 8S HDi DW10UTD 2.2 8S HDi DW12UTED 2.8 TD SOFIM 2.8 L TD 2.8 HDi SOFIM 2.8 L HDi

M A A B C D F G H M N P R W

Transmission (4) 5-speed manual W 4x4 Automatic Bodywork (5) Chassis cab Bare chassis Floor cab Platform cab Van Platform double cab Chassis double cab Minibus Van with raised sides Combi panorama 8/9 seater (CLUB) Combi 6/9 seater (CONFORT) Minibus 10 seater (MERCOSUR)

9

A B C G

Wheelbase (6) Short wheelbase (2850 mm) Medium wheelbase (3200 mm) Long wheelbase (3700 mm) Super long wheelbase (4050 mm)

GENERAL

Structure

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RELAY 4 X 4

IDENTIFICATION OF VEHICLES Type approval

GENERAL

AX BX AM AG AXC

With EGR Raised roof with EGR CNG Van LPG Van Camping car with EGR

BXC ZX AY BY BM

H MH

Combi with raised roof CNG Combi with raised roof

M GH

AXx AX2 AY AY2 SX

Bus 15 seater, 2 point seatbelts with EGR SX Bus 14 seater, 3 point seatbelts with EGR SX Bus 15 seater, 2 point seatbelts without EGR AX1 Bus 14 seater, 2 point seatbelts without EGR AX3 Bus Petrol 14 seater, 3 point belts (Switz.) AY1

AX4 AX6 AY4

Bus 15 seater, 2 point seatbelts with EGR Bus 14 seater, 3 point seatbelts with EGR Bus 15 seater, 2 point seatbelts without EGR

AY6 AX5 AX7

Variant (7) Van versions Camping car Special with EGR Combi mixed N1 (5/6 seater) Italy Without EGR Raised roof without EGR CNG Van with raised roof Private vehicle versions CNG Combi LPG Combi with raised roof MINIBUS versions Bus GO with EGR, 12 seats, 2 pt belts (CH) Bus without EGR, 12 seats, 3 pt belts (CH) Bus 16 seater, 2 point seatbelts with EGR Bus 15 seater, 2 point seatbelts with EGR Bus 16 seater, 2 point seatbelts without EGR MINIBUS versions (with speed limiter) Bus 14 seater, 3 point seatbelts without EGR Bus 16 seater, 2 point seatbelts with EGR Bus 15 seater, 3 point seatbelts with EGR 10

BG LPG Van with raised roof AYC Camping car without EGR BYC Camping car without EGR

G

LPG Combi

AY3 SX1 SY1

Bus 15 seater, 2 point seatbelts without EGR Bus with EGR, 13 seats, 3 pt belts (CH) Bus without EGR, 13 seats, 3 pt belts (CH)

AY5 AY7

Bus 16 seater, 2 point seatbelts without EGR Bus 15 seater, 3 point seatbelts without EGR

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CAPACITIES (in litres) Draining methods.

Oil capacities are defined according to the following methods.

Draining of the engine lubrication system by SUCTION

Place the vehicle on horizontal ground (in the high position if hydropneumatic suspension).

Place the vehicle on horizontal ground (in the high position if hydropneumatic suspension).

The engine should be hot (oil temperature 80°C).

The engine should be hot (oil temperature 80°C).

Remove the oil by suction through the dipstick tube.

Drain the sump by gravity.

Remove the oil filter cartridge.

Remove the oil filter cartridge (time for draining and drip-drip = 15 minutes approx.).

Maintain the suction of oil in the sump (15 minutes approx.).

Refit the cap with a new seal.

Refit a new oil filter cartridge.

Refill the engine with oil (see table for oil capacity).

Refit a new oil filter cartridge.

Start the engine to fill the oil filter cartridge.

Refill the engine with oil (see table for oil capacity).

Stop the engine (allow to stabilise for 5 minutes).

Start the engine to fill the oil filter cartridge.

WARNING : Remove the suction container before starting the engine

Stop the engine (allow to stabilise for 5 minutes).

ESSENTIAL : Systematically check the oil level using the oil dipstick.

11

GENERAL

Draining of the engine lubrication system by GRAVITY

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