How to Replace timing belt on Citroen Berlingo B9 1.6 HDI

Citroen

Replacement Interval Guide

  • Citroen recommend:
  • Replacement every 150,000 miles or 10 years under normal conditions.
  • Replacement every 120,000 miles or 10 years under adverse conditions.
  • The previous use and service history of the vehicle must always be taken into account.

Check For Engine Damage

CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed before removing the cylinder head.

Repair Times ‚Äď hrs

How to Replace timing belt on Citroen Berlingo B9 1.6 HDI

th colspan=‚ÄĚ2‚Ä≥ align=‚ÄĚleft‚ÄĚ>Remove & install:

C4/C53,60
Berlingo2,70

Special Tools

  • C4: Auxiliary drive belt removal tool ‚Äď Citroen No.(-).0194/3-D.
  • C5/Berlingo: Auxiliary drive belt tensioner pulley locking tool ‚Äď Citroen No.(-).0194.F.
  • C5/Berlingo without electric power steering (EPS): Auxiliary drive belt tensioner pulley adjusting tool ‚Äď Citroen No.(-).0188.Z.
  • Berlingo with electric power steering (EPS): Auxiliary drive belt tensioner pulley adjusting tool ‚Äď Citroen No.(-).0194.E3.
  • Camshaft sprocket locking tool ‚Äď Citroen No.(-).0194.B.
  • Crankshaft aligning tool ‚Äď Citroen No.(-).0194.A.
  • Flywheel locking tool ‚Äď Citroen No.(-).0194.C.
  • High-pressure fuel pump sprocket locking tool ‚Äď Citroen No.(-).0194.A.
  • Set of blanking plugs ‚Äď Citroen No.(-).0194.T.
 

Special Precautions

  • Disconnect battery earth lead.
  • DO NOT turn crankshaft or camshaft when timing belt removed.
  • Remove glow 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 engine top cover.
  3. Disconnect and seal off fuel pipes. Use tool No.(-).0194.T.
  4. Remove:
      • Intercooler hoses from throttle body assembly.
      • RH front wheel.
      • RH front wheel arch liner.
      • C4: Auxiliary drive belt. Tool No.(-).0194/3-D.
      • C5/Berlingo: Auxiliary drive belt. Tool Nos.(-).0194.F/0188.Z or 0194.E3.
      • Berlingo without electric power steering (EPS): PAS reservoir. DO NOT disconnect pipes.
      • Exhaust flex-pipe.
  5. Fit flywheel locking tool [1] . Tool No.(-).0194.C. Ensure flywheel locked with tool. If not: Turn crankshaft slowly clockwise.
  6. Disconnect wiring harness from timing belt upper cover.
  7. Remove:
      • Timing belt upper cover¬†[2]¬†.
      • Crankshaft pulley bolt¬†[3]¬†.
      • Crankshaft pulley¬†[4]¬†.
      • Timing belt lower cover¬†[5]¬†.
  8. Fit crankshaft pulley bolt [3] .
  9. Remove:
      • Flywheel locking tool¬†[1]¬†.
      • Crankshaft position (CKP) sensor.NOTE: Ensure reluctor is not damaged¬†[6]¬†.
      • Timing belt guide¬†[7]¬†.
  10. Turn crankshaft slowly clockwise until camshaft sprocket timing hole at 10 o’clock position [8] .
  11. Insert:
      • Camshaft sprocket locking tool¬†[9]¬†. Tool No.(-).0194.B.
      • High-pressure fuel pump sprocket locking tool¬†[10]¬†. Tool No.(-).0194.A.
      • Crankshaft aligning tool¬†[11]¬†. Tool No.(-).0194.A.
  12. Support engine.
  13. Remove:
      • RH engine mounting.
      • RH engine mounting bracket.
  14. Slacken tensioner pulley bolt [12] .
  15. Turn tensioner pulley clockwise to release tension on belt. Use Allen key [13] .
  16. Remove timing belt, starting at water pump sprocket.

Installation

  1. Check tensioner pulley, guide pulley and water pump sprocket for smooth operation.
  2. Ensure camshaft sprocket locking tool located correctly [9] .
  3. Ensure high-pressure fuel pump sprocket locking tool located correctly [10] .
  4. Ensure crankshaft aligning tool located correctly [11] .
  5. Fit timing belt to crankshaft sprocket.
  6. Install:
      • Timing belt guide¬†[7]¬†.
      • Crankshaft position (CKP) sensor.

    NOTE: Ensure reluctor is not damaged [6] .

  7. Fit timing belt in following order:
      • Guide pulley.
      • Camshaft sprocket.
      • High-pressure fuel pump sprocket.
      • Water pump sprocket.
      • Tensioner pulley.
  8. Turn tensioner pulley anti-clockwise until pointer aligned in window [14] . Use Allen key.
  9. Tighten tensioner pulley bolt¬†[12]¬†. Tightening torque: 23¬Ī2 Nm.
  10. Ensure tensioner pulley pointer aligned in window [14] .
  11. Remove:
      • Crankshaft aligning tool¬†[11]¬†.
      • Camshaft sprocket locking tool¬†[9]¬†.
      • High-pressure fuel pump sprocket locking tool¬†[10]¬†.
  12. Fit:
      • RH engine mounting bracket.
      • RH engine mounting.
  13. Turn crankshaft slowly six turns clockwise.NOTE: DO NOT allow crankshaft to turn anti-clockwise.
  14. Insert crankshaft aligning tool [11] .
  15. Ensure tensioner pulley pointer aligned in window [14] . If not: Repeat tensioning procedure.
  16. Ensure camshaft sprocket locking tool can be inserted [9] .
  17. If locking tool cannot be inserted: Visually check camshaft sprocket hole [8] aligned with hole in cylinder head. If holes are misaligned, this should be less than 1 mm. If misalignment of holes more than 1 mm, repeat installation procedure.
  18. Insert high-pressure fuel pump sprocket locking tool [10] .
  19. Remove:
      • Crankshaft aligning tool¬†[11]¬†.
      • Camshaft sprocket locking tool¬†[9]¬†.
      • High-pressure fuel pump sprocket locking tool¬†[10]¬†.
  20. Fit flywheel locking tool [1] .
  21. Remove crankshaft pulley bolt [3] .
  22. Fit:
      • Timing belt lower cover¬†[5]¬†.
      • Crankshaft pulley¬†[4]¬†.
      • Crankshaft pulley bolt¬†[3]¬†. Tightening torque: 35¬Ī4 Nm + 190¬Ī5¬į. Use new bolt.
      • Timing belt upper cover¬†[2]¬†.
  23. Check torque setting of crankshaft pulley bolt is between 80-160 Nm.
  24. Remove flywheel locking tool [1] .
  25. 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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