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 – hrs

How to Replace timing belt on Citroen Berlingo B9 1.6 HDI

th colspan=”2″ align=”left”>Remove & install:

C4/C53,60
Berlingo2,70

Special Tools

  • C4: Auxiliary drive belt removal tool – Citroen No.(-).0194/3-D.
  • C5/Berlingo: Auxiliary drive belt tensioner pulley locking tool – Citroen No.(-).0194.F.
  • C5/Berlingo without electric power steering (EPS): Auxiliary drive belt tensioner pulley adjusting tool – Citroen No.(-).0188.Z.
  • Berlingo with electric power steering (EPS): Auxiliary drive belt tensioner pulley adjusting tool – Citroen No.(-).0194.E3.
  • Camshaft sprocket locking tool – Citroen No.(-).0194.B.
  • Crankshaft aligning tool – Citroen No.(-).0194.A.
  • Flywheel locking tool – Citroen No.(-).0194.C.
  • High-pressure fuel pump sprocket locking tool – Citroen No.(-).0194.A.
  • Set of blanking plugs – 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±2 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±4 Nm + 190±5°. 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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