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Radiator fan repair bearing

June 28, 2016, 5:33 am
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Summer arrived and A/C is heavily used. After stopping the engine noticed loud banging from
engine bay. It took me an hour or so to track down that sound. Sound only occurs when A/C is on.
First thought it’s the A/C compressor. Thank lord it wasn’t. It was the radiator fan that was making
all the noise when it was slowing down and stopping. You can hear the noise in the video at 0:38
Radiator fan is ON as soon as you switch A/C ON. When engine is running you can't hear that banging noise.
So I need to take it off from car and see what is wrong. To remove it from car you have to strip down front bumper.
Here are the steps for that:
.pdf   1_Removing_refitting_Grille.pdf (Size: 133.77 KB / Downloads: 11)  
.pdf   2_Removing_refitting_Front_mud_flaps.pdf (Size: 100.15 KB / Downloads: 4)  
.pdf   3_Removing_refitting_Front_bumper.pdf (Size: 264.43 KB / Downloads: 8)

After removing the fan motor from car and putting in vice immediately noticed that it had a play in
lower bearing when I spun the fan blades by hand. Next step is to open fan motor with the help of an
angle grinder. Citroen created this motor not to be serviced. Motor can only be replaced!

.jpg   motor.jpg (Size: 357.17 KB / Downloads: 12)
After removing back motor plate noticed that there is no bearing at all ! Only soft metal ring that acts as bearing.
Measuring with vernier caliper inner diameter of ring was 12 mm and motor shaft is 10 mm. Shaft had 2 mm of play.
Outer ring diameter is 18 mm. Tried to find "real" bearing with that size but failed. Closest match for outer bearing
diameter is 19 mm. Went up to local machine shop and ordered machining that ring from brass.
Here is the new brass ring:
.jpg   brass_ring.jpg (Size: 283.55 KB / Downloads: 14)
 
Assembled the motor with the help of MIG welder.  Mounted it on car. No more fan problems  Tongue
Total fix price 20$ .
 
Here is YouTube vid : https://youtu.be/yzKfsaTLI04

Best regards,
brajomobil
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Wiring harness

June 29, 2016, 4:30 am
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.jpg   image.jpg (Size: 1.3 MB / Downloads: 26) Afternoon all. Took the floor out my 2006 Berlingo van. On the drivers side there is 3 plugs 2 go into the seat and I can't remember for the life of me where the 3rd one goes! It has 6 wires and 2 of the pins inside are corroded like they are not used! Thanks in advance newbie problems! Done all the relevant search but can't find and thing.
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Bleed screw for coolant on Berlingo 1.9D (DW8B engine)?

June 29, 2016, 11:12 am
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Hi folks,

I found this great forum through the 1.9d coolant change thread but it doesn't really have a solution. I've also read this Coolant renewal thread.

I am trying to drain all coolant out of my DW8B engine Berlingo (1.9D) but most I can get out are 4 litres with a cool engine (closed thermostat) and 6 litres with a hot engine (due to open thermostat I guess). According to the specs there should be appr. 10 litres inside.

Here are some photos I took. One shows the bleed valve on the "heater matrix"? I found that one and opened it. I also opened the "expansion tank filler cap". But neither with cold nor with hot engine there is more than 6l of coolant exiting the system. I have only disconnected the bottom hose from the radiator, the one shown on the photo.

Could anyone please help me locate the "bleed screw" that is supposed to be on the cylinder block or on the "engine compartment bulkhead"? I guess without opening that one it is impossible to drain the system fully.

Photo of the engine. I think it is a DW8B.


.jpg   IMG_20160629_183159225s.jpg (Size: 319.33 KB / Downloads: 17)

Close-up view.


.jpg   IMG_20160629_183231393s.jpg (Size: 334.47 KB / Downloads: 18)

Side view


.jpg   IMG_20160629_183252996s.jpg (Size: 332.16 KB / Downloads: 20)

This bleed valve I found


.jpg   IMG_20160629_183335045s.jpg (Size: 269 KB / Downloads: 13)

This hose I disconnected


.jpg   IMG_20160629_183429986s.jpg (Size: 275.11 KB / Downloads: 14)
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Drivers rear door window smashed

June 30, 2016, 12:10 pm
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My drivers rear door window has smashed and not sure of my options.  I've managed to remove most of the bonding but can't seem to find a replacement. Was thinking of getting a plastic one cut but not sure if that will work. Anyone had this problem before as its a bit of a nightmare for me Sad any advise would be appreciated
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Knocking

June 30, 2016, 12:11 pm
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I have recently noticed a knocking mainly when I turn the engine off or if I am turning in reverse. Anyone had this problem before? If so what could it be? Thanks
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1.9d, even slower than usual..

July 4, 2016, 9:06 am
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Hiya All...
  Has anyone noticed that their 1.9d is slower than usual ? It might be just mine but I have noticed that sometimes it goes as expected and sometimes it barely has enough power to rev itself up.. getting to 70 is a matter of maybe, not when.. even putting the clutch in and revving the engine it wont go over 4k and there is no power until 2.5k.. I thought ( hoping ) it might have something to do with the weather...
 Air filter is new, EGR is disabled, only ever used Shell fuel, Oil is new, getting 36mpg when playing up and 44 when normal..
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Advice for replacing anti roll linkage??

July 5, 2016, 7:56 am
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Right folks, my car is going in for an MOT on Saturday and I know that my anti roll bar linkage needs replaced. The knocking is driving me nuts and when it was in getting new tyres they warned me that it needed done. Was going to try and do it myself as I'm told it's not too difficult but never done it before. Any advice on difficulty level and time and what to do, or even if it's just worth getting it done professionally? If it's only going to cost £50 or so might not even bother attempting it?
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Radiator removal

July 6, 2016, 11:49 pm
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Hi,

I need to replace the radiator on my 2006 Berlingo 1.4 petrol.

I've read many of the very useful threads but still have a couple of questions.

I can see that I need to release the 3 main hoses by squeezing the metal clips with a pair of grips. Also to remove the smaller feed from the expansion tank.

But still not sure how to then release the radiator from the cone shaped rubber mounts at the top of the radiator. I see there is an 8mm nut/screw tucked away which is almost impossible to get at, but have read that the rubber mount/clips lift up somehow. Is that correct? I am reluctant to push/pull these too hard with a screwdriver in case they snap.

Also, if I manage to get the old radiator out, how many bleed locations are there on a 1.4 petrol Berlingo? I have found one 'tyre valve' which I believe is a bleed screw, but can't see any other (I have read there may be up to 3 of these), either on the radiator or under the bonnet.

Many thanks.
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sudden knocking

July 7, 2016, 11:03 am
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hi was driving today then i noticed the engine knocking and running rough ,managed to limp home ,tried starting it up just now still knocking lumpy and smokey any advice will hep thanks ,08 plate 1.6 hdi 76k
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Passenger Seat Storage Tray Removal?

July 8, 2016, 1:53 pm
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Hi all,

Just wondering how do you remove the Passenger Seat Storage Tray.

Just looking at this to hide away a small amp to run a subwoofer.

Thanks
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Intermiitent misfire with accompanying smoke

July 9, 2016, 4:30 am
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My 2005 1.9 diesel Berlingo van has me baffled. It has a misfire that develops over time where it feels like it's running on 3 cylinders when under load. If I ease off the pedal then it runs much better but still not perfect, and as soon as I try to accelerate again the misfire returns. When it is misfiring it is also putting out quite a lot of smoke through the exhaust, presumably caused by unburnt diesel, and has a very distintive diesel knock.

I've changed the MAF sensor which made no difference. I then concluded I might have a faulty injector so I tried to remove one to find out what type I needed but was unable to figure out how to remove it in the limited time I had, so I put the air box back on with a view to trying again when I had more time. When I next drove the van it ran faultlessly and it continued to do so for a few weeks, but eventually the misfire slowly returned.

I removed the cover and noticed a split rubber pipe which appered to be something to with the MAF. As it was only the end that had split I simply cut about 15mm off the pip and re-attached it. When I took the van out it ran brilliantly again for another few weeks, then the misfire returned again!

I then checked the previously split pipe and everything still looked good. I didn't do anything else, I simply replaced the cover and took it out again - and, you've guessed it, it was fine again for a little while! On this occassion I didn't do anything except check the pipe was still firmly attached and had not split again.

The engine is great condition having done less that 50,000 miles, and has been serviced regularly. I have tried disconnecting the MAF but that makes no difference. When it's not misfiring it goes really well and does not smoke or knock at all.

I'm now stuck on what to try next so any suggestions would be gratefully received.
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Rear brake issues

July 9, 2016, 6:09 am
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Long story short, i put on a new refurbished axle, new flexis and all new copper brake lines. Only thing not changed was the brake compensator valve. I did put on a new spring (ebay) and set that just touching the lever. Bled, away for mot.

It failed on rear brakes imbalance and I overheard the tester complaining about not being able to lock up back brakes and that the arm was just "flapping about"

Took it back, bought a brake pressure test kit.

I have rigged the kit up last week and read the citroen docbox i have on my computer (ahem)

It says to set the front to 1450psi and read the rear pressure. As far as i understand, lever right out should only just be over 20bar. It wasnt, and i have a left/right imbalance, so i have changed the valve.

Now this is where the fun begins..

Setting the front to 1500 the back is only reading just over 100psi. Moving the lever has no effect, and front @ 3000psi has no effect.

Have i knackerd the master cylinder? I took the back gauge off, set front to 3000psi and i can still grab my rear drums and turn them if i put some effort in.

I am still to swap gauges and check for reading issues. I cant understand why i was getting too much pressure on old valve and now new valve is giving very little.

Thanks


Sent from my iPhone using Tapatalk
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Engine runs hot

July 11, 2016, 4:03 am
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Hi, I have a Peugeot Partner 2003 1.9d. I have observed that over a while, the low speed fan kicks in at an ever increasing temperature. Currently it kicks in at 98-99 degrees whereas when I got it 7 years back, it was at 95 degs. I change coolant every 20k kms, radiator is new, fan is new.
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Driveshaft noise

July 12, 2016, 2:50 pm
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The cars started making a clicking clunky noise when I pull away and brake  at low speed. It sounds like a dodgy bearing. Has anyone any ideas what it could be?
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Rocker cover oil leak

July 13, 2016, 9:33 am
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I have a look around the rocker cover and looks like below that too which I believe is a sealed rather than a runner gasket. My question is, do I have to remove the timing belt cover to gain access to do this? Any help would be great
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Timing Belt Replacement issue

July 15, 2016, 2:16 am
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Hi all, looking for a bit of advice and Im hoping someone can help before I go bald. Have had to replace timing belt on 1.6hdi 2008 berlingo van due to water pump failure, also rough running and think that the timing belt had slipped a tooth or two as shuddering when driving. A couple of questions.....
A - Is it ok to lock cam in place and rotate crankshaft separately to locking hole position without the belt on? Roughly needs to rotate about an inch to get there.
B - Fuel pump alignment went all over the place, I have seen that as long as you align the sprocket holes vertically this is ok?

Any advice on this would be greatly appreciated. First time belt changer, driving me nuts but loving my berlingo, 110 000 miles together on the road. Don't want to break her intentionally!!!

Thanks everyone.
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got a few probs advice needed

July 15, 2016, 6:31 pm
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hello all just bought a 55 plate partner 2.0 hdi combi, im happy with it but got a few probs i want to sort so any advice helpfull thanks, steering is losing its assitance on 1/4 lock steering wheel is trying to turn right to left about half an inch going round corners, at 1200 revs there a bit of a flat spot. banging noise  sounds like a ball joint gone on offside front think its coming from the top of leg as i drive over slight bump. offside  rear wheel is closer to the back bumper than the nearside, airbag light on, any advice would be  good, ive been in motor trade 29 years, adam
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Stiff accelerator pedal

July 17, 2016, 2:07 pm
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Forgive me if this has been answered before but I can't find the answer?  The accelorator pedal feels really stif..  I have a 04 plate 19 D van. I followed the cable and sprayed WD40 all over it and the small plunger pum..  Still the same.  Oiled the pedal..  Still the same any idea??
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Gauges turning off randomly

July 18, 2016, 9:40 am
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Hoping someone can help with this. Every once in a while (twice last week and again today) my gauges just stop reading and all the warning lights come on (see photo). The van drives absolutely fine. The only other thing I found that doesn't work is the steering wheel volume controls.
When I stop and take the key out, the warning lights are still on. I can reset things by either disconnecting the battery for a few mins, or removing the shunt from the fusebox.

Does anyone have any ideas what this could be?

.jpg   20160718_131738.jpg (Size: 830.67 KB / Downloads: 4)
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Rear Fog light and reversing lights question

July 20, 2016, 3:32 pm
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I have just bought a 04 plate 1.9d Berlingo van and have a few issues and Questions ?
1/ How many rear fog light should I have ? I have got one on the drivers side
2/ How many reversing lights should I have ? I have none and its not the bulbs ?
Its not the F1 Fuse either . Any pointers on where to start the fault finding ?

Also I see 2 green relays near the top of the Radiator? One has no relay plugged into it. Any idea what they are for and why would it be missing the relay ?
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