How replace timing belt Citroen C4 2,0 2004-09

Citroen

Manufacturer: Citroen

Model: C4 2,0

Engine code: RFJ (EW10A)

Output: 105 (143) 6000

Tuned for: R-Cat AT

Year: 2004-09

Camshaft drive belt/chain – R & I  2,50

• C4: Auxiliary drive belt tensioner tool – Citroen No.(-).1608.E.

•    C4: Camshaft timing pins – Citroen No.(-).0194-B.

•    C5: Camshaft timing pins – Citroen No.(-).0189-A or (-).0194-B.

•    Flywheel/drive plate locking tool – Citroen No.(-).0189-R.

•    Tensioner pulley adjusting tool – Citroen No.(-).0189-S1.

•    Tensioner pulley locking tool – Citroen No.(-).0189-S2.

•    Timing belt retaining clip – Citroen No.(-).0189-K.

Special Precautions

•    Disconnect battery earth lead.

•    DO NOT turn crankshaft or camshaft when timing belt removed.

•    Remove spark plugs to ease turning engine.

•    Turn engine in normal direction of rotation (unless otherwise stated).

•    DO NOT turn engine via camshaft or other sprockets.

•    Observe all tightening torques.

Removal

1.    Raise and support front of vehicle.

2.    Remove:

  • RH front wheel.
  • RH splash guard.
  • Auxiliary drive belt. Use tool No.(-).1608.E.

3.    Unclip fuel supply pipe (on timing belt cover).

4.    Support engine.

5.    Remove:

О RH engine mounting.

О Timing belt upper cover [1] .

6.    Turn crankshaft clockwise to setting position.

7.    Insert flywheel/drive plate locking tool. Tool No.(-).0189-R:

  •  [A] : MT.
  •  [B] : AT.

NOTE: Vehicles with AT: Drive plate locking tool will not fit flush in housing.

8.    C4: Disconnect PAS pipes from RH inner wing panel. Move to one side.

9.    Insert timing pins in camshaft sprockets [2] & [3] . Tool No.(-).0189-A or No.(-).0194-B.

10.    Remove:

  • Crankshaft pulley bolt [4] .
  • Crankshaft pulley [5] .
  • Timing belt lower cover [6] .

NOTE: Always have tools [A] or [B] , [2] & [3] inserted before removing crankshaft pulley [5] .

11.    Slacken tensioner pulley bolt [7] .

12.    Turn tensioner pulley clockwise. Use Allen key [8] .

13.    Remove timing belt.

 

Installation

1.    Ensure flywheel locking tool located correctly [A] or [B] .

2.    Ensure timing pins located correctly [2] & [3] .

3.    Fit adjusting tool to tensioner pulley [9] . Tool No.(-).0189-S1.

4.    Turn tensioner pulley clockwise until pointer past notch [10] .

5.    Fit locking tool to tensioner pulley [11] . Tool No.(-).0189-S2.

6.    Remove adjusting tool from tensioner pulley [9] .

NOTE: Ensure crankshaft keyway is at 9 o’clock position.

7.    Fit timing belt to crankshaft sprocket.

8.    Secure belt to crankshaft sprocket with retaining clip. Tool No.(-).0189-K [12] .

9.    Fit timing belt in following order:

  • Guide pulley.
  • Inlet camshaft sprocket (CA1).
  • Exhaust camshaft sprocket (CA2).
  • Water pump sprocket.
  • Tensioner pulley.

NOTE: Ensure timing belt is fitted flush with sprockets and pulleys.

10.    Remove tools [2] , [11] & [12] .

11.    Fit timing belt lower cover [6] .

12.    Fit crankshaft pulley [5] .

13.    Tighten crankshaft bolt [4] . Tightening torque: 40±4 Nm + 40±4°.

14.    Turn tensioner pulley anti-clockwise until pointer [13] at position [14] . Use Allen key [8] .

NOTE: The pointer should pass notch [15] by at least 10°. If not, replace tensioner pulley.

15.    Turn tensioner pulley clockwise until pointer and notch aligned [13] & [15] .

NOTE: If pointer passes notch [15] , repeat tensioning procedure.

16.    Tighten tensioner pulley bolt [7] . Tightening torque: 19-23 Nm.

WARNING: Hold tensioner pulley during tightening to prevent it from turning. Allen key socket [8] must be approximately 15° below cylinder head gasket level. If not, replace tensioner pulley.

17.    Remove tools [A] or [B] & [3] .

18.    Turn crankshaft 10 turns clockwise to setting position.

19.    Insert timing pin in inlet camshaft sprocket [3] .

20.    Ensure tensioner pointer and notch aligned [13] & [15] . If not: Repeat tensioning procedure.

21.    Remove timing pin from inlet camshaft sprocket [3] .

22.    Install components in reverse order of removal.

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Bent Valves
Timing Tools?
Misconception
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Bent Valves

What happens when your chain or belt breaks. 

The timing of course becomes way off. Your crankshaft will always spin making the pistons move up and down. However the valves will remain in the position they were in when the belt or chain stopped working. 

Half of the valves will be stuck open and in the way of the pistons. Not all engines, but most. The piston out of valve time will smash right into the open valve and bend the, The only way to fix that is to remove the head and place those valves. 

If you think your valves might have been damaged.

Remove all the spark plugs, valve covers. With both valves in the closed position insert a compression tester hose in place of the spark plug and inject air into the hose and see if the cylinder can hold air. If both valve are closed and air can not be held, chances are you have bent valves.   

 

Timing Tools?

Do you need special tools to time your engine? Not always, on all my post I'll indicate that in each post if you do or not. 

But what are these special tools? Normally you would just line up some marks on the cam and crank gears and simply be done with it. However when these tools are needed they are very very important. 

The last one I did was a 2013 Range Rover 2.0 Turbo with dual cams. There were not timing marks at all. 

There is a small threaded plug on the back of the engine that I removed to insert a special threaded pin that would rest up against the weight of the crankshaft to prevent for DTC of the #1 piston. No further clockwise rotation would be possible. At that point I installed the supplied crankshaft lock by removing the starter. 

Then you line up the back of both camshafts to a notch in each camshafts to each other that a flat tool connects to each cam so they are in line with each other. But first you would make sure both intake and exhaust valves are closed DTC of the cams. 

And the last tool was to lineup the crankshaft position sensor. 

 

Misconception

The most important thing in any major engine work is to rotate the engine by hand at least two complete rotations. And do it easy and slow and with the spark plugs removed. 

Why remove the spark plugs? you may ask. Simple, with the plugs in place you'll be creating compression, making the engine harder to turn by hand and perhaps giving you the misconception of valves hitting the pistons or is it compression.  

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