Oil cooler location on 2004 Berlingo Van 1.4

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Blazer811
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Oil cooler location on 2004 Berlingo Van 1.4

Post by Blazer811 »

Can someone please confirm if the Tu3jp motors with manual transmission has a oil cooler and if so, where is it located?

I ask this as I have discovered oil in my coolant reservoir bottle today but there was no sign of coolant in my oil. I also had next to no oil on my dipstick considering I did an oil change over 1 month ago.

My van had been driving fine apart from two occasions when the temp gauge suddenly went from 97 degrees to the red, but after turning the engine off and back on within a minute it would be on the 90 degree mark. After investigating this I narrowed it down to the new temperature sensor on the block (Blue connector) was actually faulty and giving the ecu a false reading.

Since replacing the temperature sensor the temp gauge has hovered between 90 - 100 degrees, but I did notice that when the engine was turned off the temp would keep rising. I’m not 100% certain, but are the cooling fans meant to run with engine turned off if the temperature reaches a certain range?

I understand that it could possibly be a head gasket issue or something more serious but I am hoping it could be something simple as an oil cooler issue, hence the post.

Any input or advice would be greatly appreciated.
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Re: Oil cooler location on 2004 Berlingo Van 1.4

Post by RichardW »

Pretty sure there is no oil cooler on this - most likely the head gasket has failed. Is it leaking oil at the cambelt end of the engine? These normally come fitted with an oil leak there, and replacement of the head gasket is almost a service item.
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Re: Oil cooler location on 2004 Berlingo Van 1.4

Post by GiveMeABreak »

Yes, as Richard says, no oil cooler on these - mostly on Automatics.
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Re: Oil cooler location on 2004 Berlingo Van 1.4

Post by Blazer811 »

RichardW wrote:
28 Jan 2020, 16:13
Pretty sure there is no oil cooler on this - most likely the head gasket has failed. Is it leaking oil at the cambelt end of the engine? These normally come fitted with an oil leak there, and replacement of the head gasket is almost a service item.
Thank you Richard and yes according to the tell tale signs on my driveway it definitely has an oil leak from that area. Which particular oil seal would it be that’s prone to leaking?

Could you please assist in directing me to a workshop manual link (if there is one on this forum ) to guide me on how to R&R head gasket along with torque specs?

I was very vigilant when it came to monitoring my temp gauge whilst driving and wondering if the cooling fans not engaging when the engine is turned off and cooling system over pressurising could be the contributing factor to HG failure?

Is the fan suppose to engage even when engine is turned off and engine temperature is rising up and beyond? If it is, what component in your opinion would you suspect to be faulty?

Your feedback would be very helpful.
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Re: Oil cooler location on 2004 Berlingo Van 1.4

Post by Blazer811 »

GiveMeABreak wrote:
28 Jan 2020, 16:18
Yes, as Richard says, no oil cooler on these - mostly on Automatics.
Thank you Marc, I thought as much but was hoping that it did as it would of been a less expensive and time consuming fault to rectify ☹️
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Re: Oil cooler location on 2004 Berlingo Van 1.4

Post by RichardW »

You will probably find a leak from the front RH corner of the engine where the HG is - there is not enough clamping force on this end of the head where the main oil feed gallery is and it starts leaking. It's a very common problem on this engine! I'll see if I can get the procedure later, but I would imagine it would be covered in the Haynes manual if you can get hold of one.
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Re: Oil cooler location on 2004 Berlingo Van 1.4

Post by GiveMeABreak »

I'll put this up shortly if you like Richard, there was also a mod from the OP's RPO, so I'll put that up too.

Topic temporarily locked during procedure formatting.
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Re: Oil cooler location on 2004 Berlingo Van 1.4

Post by GiveMeABreak »

Procedure for Removal / Replacement of Cylinder Head - Berlingo (MU59) TU3JP Engine Only Specific

Also refer to the modifications made in the following post that affect this main procedure - please read those first, before proceeding!

Recommended Tooling
Blingo Cylinder Head A.PNG
Blingo Cylinder Head A.PNG (29.04 KiB) Viewed 223 times
Blingo Cylinder Head B.PNG
Blingo Cylinder Head B.PNG (58.81 KiB) Viewed 223 times
[1] flywheel locking tool 4507-TA.[2] camshaft setting rod 4507-T.B
Blingo Cylinder Head C.PNG
Blingo Cylinder Head C.PNG (52.94 KiB) Viewed 223 times
Blingo Cylinder Head D.PNG
Blingo Cylinder Head D.PNG (39 KiB) Viewed 223 times
[3a] 4533-T.AC1 camshaft setting rod.[3b] 4533-T.AC2 camshaft setting rod.
Blingo Cylinder Head E.PNG
Blingo Cylinder Head E.PNG (47.28 KiB) Viewed 223 times
Blingo Cylinder Head F.PNG
Blingo Cylinder Head F.PNG (70.03 KiB) Viewed 223 times
[4] pliers for removing plastic pegs 7504-T.[5] set of levers for releasing the cylinder head 149-T.
Blingo Cylinder Head G.PNG
Blingo Cylinder Head G.PNG (123.41 KiB) Viewed 223 times
Blingo Cylinder Head H.PNG
Blingo Cylinder Head H.PNG (79.68 KiB) Viewed 223 times
[6] angle sector to tighten the cylinder head 4069-T.[7] liner retaining clamp 81132-T.A1.
[8] bolts M10x150 L 40 mm 81132-T.A2.
Blingo Cylinder Head I.PNG
Blingo Cylinder Head I.PNG (33.98 KiB) Viewed 223 times
Blingo Cylinder Head J.PNG
Blingo Cylinder Head J.PNG (92.37 KiB) Viewed 223 times
[9] TORX female socket STX 14.[10] union for venting fuel pressure 4192-T.
Preliminary Operations
  • Disconnect the battery. Refer to: (BSI Reset / Battery Disconnect / Reconnect Procedure)
  • Drain the cooling system (see the relevant operation).
    Note: When connecting the tool [10], protect yourself
    with a cloth to guard against any projections of fuel.
  • The wiper arm nut (10).
  • Uncouple the fuel supply.
  • Disconnect, unclip and separate the harnesses,
    hoses and cables connected to the cylinder head.
  • Place a jack under the engine, support the engine.
Removing

Remove:
  • The air filter assembly
  • The ignition module
  • The auxiliary equipment drive belt (see the relevant operation)
  • The timing belt Using tools [1], [2] and [3] (see the relevant operation)
Detach the exhaust pipe from the manifold.
Blingo Cylinder Head K.PNG
Blingo Cylinder Head L.PNG
Remove:
  • The nuts (1)
  • The cylinder head cover (2)
  • The spacers (3)
  • The deflector plate (4)
Starting at the outside and working in a spiral sequence
progressively slacken the cylinder head bolts (5).

Remove:
  • The cylinder head bolts (5)
  • The rocker shaft (6)
Blingo Cylinder Head M.PNG
Blingo Cylinder Head N.PNG
Tilt and detach the cylinder head using the levers [5].
Remove the cylinder head and gasket.
Fit the liner retaining clamps [7] with the bolts [8].

ESSENTIAL: Clean the gasket faces with an approved
descaling product. Do not use sharp or abrasive tools.
The gasket faces must not have any traces
of knocks or scores.
Checking the flatness
Blingo Cylinder Head O.PNG
Blingo Cylinder Head P.PNG
Max. out-of-true: 0,05 mm (max.).Checking cylinder head bolts before re-use:
Length under head (torx thread):
Y = 176,5 mm (TU3JP engine)

N.B.: Do not re-use cylinder head bolts if they
are longer than Y mm: Use new screws.
Refitting

Remove:
  • The retaining clamps [7]
  • The screws [8] of the cylinder block
Clean the threads of the cylinder head bolts in the cylinder block, using a M10x150 tap.
Check that the two centring pins are present.
Fit a new cylinder head gasket.
On the cylinder head, camshaft gear wheel locked.

Refit:
  • The rocker shaft (6)
  • The cylinder head bolts (5) (wipe with MOLYKOTE G.RAPID PLUS grease)
Blingo Cylinder Head Q.PNG
ESSENTIAL: Tighten the bearing carrier screws in the
order indicated (order from 1 to 10).
Tightening procedure:
Pre-tightening to 2 da.Nm
Tighten by an angle of 240 ° with tool [6]
Refit the timing belt (see the relevant operation).
Adjust the valve rockers.

Refit:
  • The deflector plate (4)
  • The spacers (3)
  • The cylinder head cover (2)
  • The nuts (1)
  • The ignition module
Connect the:
  • The fuel delivery hose
  • The exhaust pipe to the manifold
Couple and clamp the harnesses, unions and cables attached to the cylinder head.

Refit:
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Re: Oil cooler location on 2004 Berlingo Van 1.4

Post by GiveMeABreak »

Modification - All TU Petrol Engines

Valve rockers
From the following serial numbers:
  • TU3 - 2 552 655
The valve rocker adjusting screws are modified:
  • To allow the valve clearance to be adjusted, the heads are flat and hexagonal
  • The diameter of the screw is reduced (M6 replacing M9)
Blingo Cylinder Head Mod A.PNG
Repair
The new parts are fitted in place of the old parts.
Tighten the nuts to 0,75 dan.m.
The valve clearance remains the same.
Cylinder heads - Valve springs
From the following serial numbers:
  • TU3 - 2 552 655
The cylinder heads are equipped with new valve springs: The spring bearing surfaces machined into the cylinder head have been modified.
Blingo Cylinder Head Mod B.PNG
Springs and thrust washers
The springs ( 2) and upper and lower thrust washers (1) have a reduced diameter:
  • The springs (2): External diameter = Ø 27 mm
  • Thrust washers (1): Diameter = Ø 28 mm
Blingo Cylinder Head Mod C.PNG
Spring identification
The new springs can be identified by their blue coating or by a line of blue paint (at "a").
Cylinder heads
The machining diameter of the valve spring bearing surfaces is reduced.
Blingo Cylinder Head Mod D.PNG
A = Ø 19,65 mm Always replace the ring seals 21,3.
Identification
Blingo Cylinder Head Mod E.PNG
Cylinder heads machined to the new dimensions are identified by a line around the mounting hole for the lifting lug (at "b"):
  • Width: 10 mm
  • Depth: 1,5 mm
Repair
Blingo Cylinder Head Mod F.PNG
The new parts are fitted in place of the old parts.
To refit old springs: Fit new thrust washers (3), especially designed for the repair.
Replacement Part Number: 095143.
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Re: Oil cooler location on 2004 Berlingo Van 1.4

Post by Blazer811 »

RichardW wrote:
29 Jan 2020, 08:34
You will probably find a leak from the front RH corner of the engine where the HG is - there is not enough clamping force on this end of the head where the main oil feed gallery is and it starts leaking. It's a very common problem on this engine! I'll see if I can get the procedure later, but I would imagine it would be covered in the Haynes manual if you can get hold of one.
Thank you a Richard for your knowledgeable explanation.
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Re: Oil cooler location on 2004 Berlingo Van 1.4

Post by Blazer811 »

GiveMeABreak wrote:
29 Jan 2020, 11:08
I'll put this up shortly if you like Richard, there was also a mod from the OP's RPO, so I'll put that up too.

Topic temporarily locked during procedure formatting.
Thank you Marc for your time and helpful information.
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Re: Oil cooler location on 2004 Berlingo Van 1.4

Post by Sharkie »

check first if someone' didn't put oil accidentally in coolant. If it's black it's from engine sadly. if it's bright yellow/brownish it is probably not.

Oil pressure is higher on running engine than coolant pressure. That reverses when you turn it off.
With time it will eat/swell the rubber pipes and they will start bulging.

Oil cooler is sometimes integrated with the case of oil filter. Just follow water hoses that split off.
But in a weak 1.4 engine, might be worthy to look into a new engine/car. Cost of new head gasket and work might be more than the market value of said car.
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white exec
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Re: Oil cooler location on 2004 Berlingo Van 1.4

Post by white exec »

Correct - oil from the engine in the coolant will be black.
As found, it will accumulate in the expansion tank (oil floats on water, and tank is usually a high point), as a black slick, so is easily spotted.
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Re: Oil cooler location on 2004 Berlingo Van 1.4

Post by Blazer811 »

Sharkie wrote:
30 Jan 2020, 21:24
check first if someone' didn't put oil accidentally in coolant. If it's black it's from engine sadly. if it's bright yellow/brownish it is probably not.

Oil pressure is higher on running engine than coolant pressure. That reverses when you turn it off.
With time it will eat/swell the rubber pipes and they will start bulging.

Oil cooler is sometimes integrated with the case of oil filter. Just follow water hoses that split off.
But in a weak 1.4 engine, might be worthy to look into a new engine/car. Cost of new head gasket and work might be more than the market value of said car.
Thanks Sharkie but it’s definitely oil getting into the cooling system as I only did an oil & coolant change about two months ago.

This mishap has happened over the span of a week as when I previously checked the coolant (a week before) it was fine.

Apart from the brownish crap floating on top of the reservoir bottle the engine still seems to be running and idling fine. I was hoping it was more likely a oil cooler problem opposed to a head gasket issue (hence the post) but have been informed by Richard that this vehicle doesn’t have one.

So it’s time to get my hands dirty and hoping it’s noting worse than just a HG issue.
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Re: Oil cooler location on 2004 Berlingo Van 1.4

Post by Blazer811 »

Sharkie wrote:
30 Jan 2020, 21:24
check first if someone' didn't put oil accidentally in coolant. If it's black it's from engine sadly. if it's bright yellow/brownish it is probably not.

Oil pressure is higher on running engine than coolant pressure. That reverses when you turn it off.
With time it will eat/swell the rubber pipes and they will start bulging.

Oil cooler is sometimes integrated with the case of oil filter. Just follow water hoses that split off.
But in a weak 1.4 engine, might be worthy to look into a new engine/car. Cost of new head gasket and work might be more than the market value of said car.
Sorry Sharkie, I meant to ask what you meant by “If it's black it's from engine sadly. if it's bright yellow/brownish it is probably not.” as mine is a brownish milkshake appearance.