B9 TU5JP4 Petrol Engine & BE4/5 Gearbox into M59 Berlingo

[mabrown]

Worked on the van on the weekend. Engine is mounted on the drivers side using the new top mount from France. Rubber mount & the rubber buffer are still the original KFW items and even though the 1.4 KFW & 1.6 NFU have different part numbers for these it looks fine and I may leave it this way.

I didn't use the alloy Xsara-Picasso mount on the engine side of the lower centre mount. Side by side they have the same dimensions but the B9 mount is cast iron so I have retained it. It drops straight onto the fork part of the KFW mount attached to the axle. Again, looks fine so this arrangement will also be likely to stay.

Not such good news for the gearbox mount though. Turns out my gearbox mount parts are wrong, or more to the point, they are right for the BE4/5 in an M59. Seems that the casting on the box for the B9 is different (3 hole mount) from the casting for the M59 (2 hole mount). I'm going to have to manufacture something for this, probably using the secondhand Xsara-Picasso mount to the body (modified) and a new mount at the gearbox.

Mark

[Gadgetman]

I actually found the TU3JP to be strong mechanically and it was me who killed it. I think it had plenty of life left in it had I changed its timing belt! I was using the van for courier work, sometimes with 6-700kg in the back. The engine was underpowered for that. When I saw the virtually new 1.6 NFU & BE4/5 for sale complete at a price competitive with a second hand TU3JP on its own it seemed a no brainer. Opened up a can of worms though.
[/quote]

So... Cracked pistons and bent valve stems?
Possibly damaged valve seals, too...
Swapping the head is an 'in car' job, and not too difficult. Replacing a piston? not so easy.
So yeah, that tends to kill it.

I swapped my TU3 for another TU3 a while ago, and even that 'straight swap' was painful.
(That's when I learned about the crankshaft sensor, for one thing.)
A small garage didn't help, either.
(Just barely room for the engine between the garage port and the front of the car, and needed the port down to reach the roof beams to hang my chain hoist from... )

The rear engine mount was the most problematic for me. Or, getting the driveshaft out of it, first.

Citroën likes reusing parts when possible, so if there's a different part number on those rubber parts, I'd look closely at them. Remember that the 1.6 is stronger and heavier(particularly that) than the 1.4.