How to Replace timing belt on Citroen C2 1.6 2003-10

Citroen

Special tools

  • Camshaft timing pins – Citroen Nos.4533-T.AC1/2.
  • Flywheel locking tool – Citroen No.4507-T.A.
  • Tensioner pulley locking pin – Citroen No.4200-T.H.
  • Timing belt retaining clip – Citroen No.4533-T.AD.

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.

Repair times – hrs

Camshaft drive belt/chain – R & I2,70

Valve timing procedures


How to Replace timing belt on Citroen C2 1.6 2003-10

Removal

  1. Raise and support front of vehicle.
  2. Remove:
    • RH front wheel.
    • RH splash guard.
    • Auxiliary drive belt.
    • Crankshaft pulley bolts [1] .
    • Crankshaft pulley [2] .
    • Except Xsara II: Oil filter.
    • Xsara II: Air filter housing.
    • Xsara II: Air filter intake duct.
    • Xsara II: Exhaust manifold heat shield.
  3. Xsara II: Disconnect PAS pipe from engine.
  4. Support engine.
  5. Remove:
    • RH engine mounting.
    • RH engine mounting bracket.
    • Timing belt upper cover [3] .
    • Timing belt lower cover [4] .
  6. Turn crankshaft clockwise to setting position.
  7. Fit flywheel locking tool [5] . Tool No.4507-T.A.
  8. Insert timing pins in camshaft sprockets [6] . Tool Nos.4533-T.AC1/2.
  9. Slacken tensioner pulley nut [7] .
  10. Turn tensioner pulley clockwise until pointer [8] aligns with position [9] . Use Allen key [10] .
    NOTE: DO NOT turn tensioner pulley 360°.
  11. Insert locking pin in tensioner pulley [11] . Tool No.4200-T.H.
  12. Remove timing belt.
    NOTE: DO NOT refit used belt.

Installation

  1. Check tensioner pulley and guide pulley for smooth operation.
  2. Ensure timing pins located correctly in camshaft sprockets [6] .
  3. Ensure flywheel locking tool located correctly [5] .
  4. Fit timing belt in following order:
    • Inlet camshaft sprocket (CA1).
    • Exhaust camshaft sprocket (CA2).
    • Guide pulley.
    • Crankshaft pulley. Secure belt to crankshaft sprocket with retaining clip. Tool No.4533-T.AD [12] .
    • Water pump sprocket.
    • Tensioner pulley.

    NOTE: Ensure belt is taut between sprockets on non-tensioned side.

  5. Remove:
    • Timing pins [6] .
    • Flywheel locking tool [5] .
    • Timing belt retaining clip [12] .
  6. Insert Allen key into tensioner pulley.
  7. Remove tensioner pulley locking pin [11] .
  8. Turn tensioner pulley until pointer [8] at position shown [13] .
    NOTE: DO NOT turn tensioner pulley 360°.
  9. Insert locking pin in tensioner pulley [11] .
  10. Tighten tensioner pulley nut [7] . Tightening torque: 10 Nm.
  11. Turn crankshaft four turns clockwise to setting position.
    NOTE: DO NOT allow crankshaft to turn anti-clockwise.
  12. Fit:
    • Flywheel locking tool [5] .
    • Timing pins [6] .
  13. Remove:
    • Flywheel locking tool [5] .
    • Timing pins [6] .
  14. Slacken tensioner pulley nut [7] .
  15. Remove tensioner pulley locking pin [11] .
  16. Turn tensioner pulley until pointer [8] aligned with notch [14] .
    NOTE: DO NOT turn tensioner pulley 360°.
  17. If pointer passes notch [14] , repeat tensioning procedure.
  18. Hold tensioner pulley. Use Allen key [10] . Tighten tensioner pulley nut [7] . Use new nut.
    • Except Xsara II: A – tightening torque: 17-25 Nm.
    • Xsara II: B – tightening torque: 20-24 Nm.

    NOTE: Ensure tensioner pulley does not move when tightening nut [7] . If tensioner pulley moves: Repeat tensioning procedure.

  19. Install components in reverse order of removal.
  20. Tighten crankshaft pulley bolts [1] .
    • C2/C3: A – tightening torque: 23-27 Nm.
    • C4/Xsara II/Xsara Picasso: B – tightening torque: 19-31 Nm.
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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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