How to Replace timing belt on Citroen Dispatch 2.0D HDi 2011-14

Special tools

• Auxiliary drive belt tensioner tool – Citroën Nos.(-).0188.Z/Q1.
• Hybrid: Auxiliary drive belt tensioner tools – Citroën Nos.(-).1603-E/1603-F.
• Hybrid: Auxiliary drive belt tension gauge – Citroën No.(-).0107.
• Camshaft sprocket locking tool – Citroën No.(-).0188.M.
• C4 Picasso/Grand Picasso: Crankshaft reluctor puller – Citroën No.(-).0188.P.
• Crankshaft sprocket centralizing tool – Citroën No.(-).0188.AH.
• Flywheel timing pin – Citroën No.(-).0188.Y.
• Flywheel locking tool – Citroën No.(-).0188.F.
• Set of blanking plugs – Citroën No.(-).1617-J.
• Timing belt clamp – Citroën No.(-).0188.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

Valve timing procedures

Removal

1. Raise and support front of vehicle.
2. Remove:
   • Engine top cover.
   • Engine undershield.
   • Turbocharger lower air duct.
   • RH front wheel.
   • RH splash guard.
   • Auxiliary drive belt. Use tool Nos.(-).0188.Z/Q1 or 1603-E/1603-F.
   • C4 II/DS4/C4 Picasso/Grand Picasso/DS5/C8: Wiper arms.
   • C4 II/DS4/C4 Picasso/Grand Picasso/DS5/C8: Scuttle panel.
   • C8/Dispatch/Jumpy: Coolant expansion tank. DO NOT disconnect hoses.
   • C4 Picasso/Grand Picasso: Brake fluid reservoir. DO NOT disconnect hoses.
   • C4 II/DS4/C4 Picasso/Grand Picasso/DS5/C8: Scuttle panel support.
   • C4 II/DS4/C4 Picasso/Grand Picasso/DS5/C8: Sound insulating pad.
   • C4 II/DS4/C4 Picasso/Grand Picasso/DS5: Engine bay fuse box cover.
3. Disconnect and seal off fuel pipes. Use tool No.(-).1617-J.
4. Reposition priming pump.
5. Remove priming pump mounting bracket.
6. C8/Dispatch/Jumpy: Disconnect exhaust downpipe to centre section.
7. Support engine.
8. Remove RH engine mounting.
9. Move aside engine wiring harness (on timing belt cover).
10. Remove:
    • Timing belt upper cover [1] .
    • Crankshaft pulley centre cap.
11. Turn crankshaft clockwise to setting position. Ensure camshaft sprocket timing hole at 4 o’clock position [2] .
12. Insert:
    • Camshaft sprocket locking tool [3] . Tool No.(-).0188.M.
    • Flywheel timing pin [4] . Tool No.(-).0188.Y.
13. Fit flywheel locking tool [5] . Tool No.(-).0188.F.
14. Remove:
    • Crankshaft pulley bolt [6] .

    NOTE: DO NOT use an impact wrench to slacken crankshaft pulley bolt.

    • Crankshaft pulley [7] .
15. Disconnect crankshaft position (CKP) sensor multi-plug.
16. Remove:
    • Reluctor [8] . Use tool No.(-).0188.P.
    • Timing belt lower cover [9] .

    NOTE: Ensure reluctor is not damaged.

17. Slacken tensioner pulley nut [10] .
18. Turn tensioner pulley away from belt. Use Allen key [11] .
19. Remove timing belt.

Installation

NOTE: DO NOT refit used belt.

1. Clean crankshaft pulley bolt and crankshaft threads.
2. Check guide pulley and water pump sprocket for smooth operation.
3. Check crankshaft sprocket has free movement on keyway.
4. Ensure flywheel timing pin located correctly [4] .
5. Ensure camshaft sprocket locking tool located correctly [3] .
6. If fitting new tensioner pulley:
   • Remove tensioner pulley nut and stud [10] & [12] .
   • Remove tensioner pulley.
   • Fit new tensioner pulley.
   • Ensure tensioner pulley located correctly on dowel pin [13] .
   • Refit tensioner pulley nut and stud [10] & [12] .
   • Ensure tensioner pulley at position shown [14] .
   • Finger tighten tensioner pulley nut [10] .
   • Centralise crankshaft sprocket [15] . Use tool No.(-).0188-AH.
   • Secure timing belt to camshaft sprocket with clamp [16] . Use tool No.(-).0188-AD.
   • Fit timing belt in clockwise direction.
   • Ensure timing belt is taut between sprockets on non-tensioned side.
   • Remove tensioner pulley locking pin [17] .
7. If reusing tensioner pulley:
   • Ensure tensioner pulley located correctly on dowel pin [13] .
   • Ensure tensioner pulley at position shown [14] .
   • Finger tighten tensioner pulley nut [10] .
   • Centralise crankshaft sprocket [15] . Use tool No.(-).0188-AH.
   • Secure timing belt to camshaft sprocket with clamp [16] . Use tool No.(-).0188-AD.
   • Fit timing belt in clockwise direction.
   • Ensure timing belt is taut between sprockets on non-tensioned side.
8. Turn tensioner pulley anti-clockwise until pointer [18] at position shown [19] . Use Allen key [11] .
   NOTE: Tensioner pulley pointer to left of notch in baseplate.
9. Tighten tensioner pulley nut [10] . Tightening torque: 21 Nm.
10. Remove tools [15] & [16] .
11. Install:
    • Crankshaft pulley [7] .
    • New crankshaft pulley bolt [6] .
12. Tighten crankshaft pulley bolt [6] . Tightening torque: 50 Nm.
    NOTE: Ensure there are less than 5 minutes between pre-tightening and final tightening of bolt.
13. Remove tools [3] , [4] & [5] .
14. Turn crankshaft six turns clockwise.
15. Install:
    • Flywheel timing pin [4] .
    • Camshaft sprocket locking tool [3] .
    • Flywheel locking tool [5] .
16. Slacken:
    • Crankshaft pulley bolt [6] .
    • Tensioner pulley nut [10] .
17. Turn tensioner pulley clockwise until pointer aligned with notch [20] & [21] . Use Allen key [11] .
    NOTE: If tensioner pulley turned too far: Turn fully anti-clockwise and repeat tensioning procedure.
18. Tighten tensioner pulley nut [10] . Tightening torque: 21 Nm.
19. Remove tools [3] & [4] .
20. Remove:
    • Crankshaft pulley bolt [6] .
    • Crankshaft pulley [7] .
21. Install:
    • Timing belt lower cover [9] .
    • Reluctor [8] .
22. Coat crankshaft pulley bolt with suitable thread locking compound.
23. Install:
    • Crankshaft pulley [7] .
    • Crankshaft pulley bolt [6] .
24. Tighten crankshaft pulley bolt [6] . Tightening torque:
    • A – Except HYbrid4: 70 Nm + 62°.
    • B – HYbrid4: 70 Nm + 110°.

    NOTE: DO NOT use an impact wrench to tighten crankshaft pulley bolt.

25. Remove flywheel locking tool [5] .
26. Install components in reverse order of removal.