How to Replace timing belt on Citroen Xsara 2.0D HDi 2000

Citroen

Special tools

  • Flywheel locking tool – Citroën No.(-).0188.F.
  • Crankshaft pulley puller – Citroën No.(-).0188.P.
  • Flywheel timing pin (except C5) – Citroën No.(-).0188.Y.
  • Flywheel timing pin (C5) – Citroën No.(-).0118.X.
  • Camshaft timing pin – Citroën No.(-).0188.M.
  • Timing belt retaining clip – Citroën No.(-).0188.K.
  • Tensioning tool – Citroën No.(-).0188.J2.
  • Tension gauge – SEEM C.Tronic 105.5.
  • Set of blanking plugs – Citroën No.(-).0188.T.

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 – C & A2,90
Camshaft drive belt/chain – R & I3,50

Valve timing procedures

How to Replace timing belt on Citroen Xsara 2.0D HDi 2000

Removal

NOTE: The high-pressure fuel pump fitted to this engine does not require timing.

  1. Raise and support front of vehicle.
  2. Disconnect exhaust front pipe from manifold.
  3. Remove:
    • RH front wheel.
    • RH splash guard.
    • Engine lower cover.
    • Engine upper cover.
    • Auxiliary drive belt.
    • Turbocharger air hoses.
    • Flywheel housing lower cover.
  4. Lock flywheel. Use tool No.(-).0188.F.
  5. Remove:
    • Crankshaft pulley bolt [1] .
    • Crankshaft pulley [2] . Use tool No.(-).0188.P.
  6. Fit crankshaft pulley bolt without washer [1] .
  7. Remove:
    • Flywheel locking tool.
    • Lower torque reaction link.
    • Engine control module (ECM) and tray.
  8. Disconnect and seal off fuel pipes. Use tool No.(-).0188.T.
  9. Support engine.
  10. Remove:
    • PAS reservoir (if required).
    • RH engine mounting and bracket.
    • Timing belt covers [4] , [5] & [6] .
  11. Refit bolt fitted with a 17 mm thick spacer [7] . Tighten bolt to 15 Nm.
  12. Turn crankshaft clockwise to setting position.
  13. Insert timing pin in flywheel [3] .
    • Except C5: Tool No.(-).0188.Y.
    • C5: Tool No.(-).0188.X.
  14. Insert timing pin in camshaft sprocket [8] . Tool No.(-).0188.M.
  15. Slacken tensioner pulley bolt [9] .
  16. Slacken camshaft sprocket bolts [10] .
  17. Turn tensioner pulley clockwise away from belt. Use tool No.(-).0188.J2.
  18. Lightly tighten tensioner pulley bolt [9] .
  19. Remove timing belt.

Installation

  1. Check tensioner pulley, guide pulley and water pump sprocket for smooth operation.
  2. Ensure timing pins located correctly [3] & [8] .
  3. Tighten bolts finger tight, then slacken 1/6 turn [10] .
  4. Turn camshaft sprocket fully clockwise in slotted holes.
    NOTE: Sprocket should turn with slight resistance.
  5. Fit timing belt to crankshaft sprocket.
  6. Secure belt to crankshaft sprocket with retaining clip. Tool No.(-).0188.K [11] .
  7. Fit timing belt in anti-clockwise direction. Ensure belt is taut between sprockets.
  8. Lay belt on camshaft sprocket teeth. Engage belt teeth by turning sprocket slightly anti-clockwise.
    NOTE: Angular movement of sprocket must not be more than one tooth space [12] .
  9. Fit timing belt to water pump sprocket and tensioner pulley.
  10. Slacken tensioner pulley bolt [9] .
  11. Turn tensioner pulley anti-clockwise to temporarily tension belt. Use tool No.(-).0188.J2.
  12. Lightly tighten tensioner pulley bolt [9] . Tightening torque: 10 Nm.
  13. Remove retaining clip [11] .
  14. Attach tension gauge to belt at  [13] . Tool No.SEEM C.Tronic 105.5.
  15. Turn tensioner pulley anti-clockwise until tension gauge indicates 98±2 SEEM units.
  16. Tighten tensioner pulley bolt [9] . Tightening torque: 25 Nm.
  17. Remove tension gauge.
  18. Ensure sprocket bolts not at end of slotted holes [14] . If necessary, repeat installation procedure.
  19. Tighten camshaft sprocket bolts [10] . Tightening torque: 20 Nm.
  20. Remove timing pins [3] & [8] .
  21. Turn crankshaft eight turns clockwise to setting position.
    NOTE: DO NOT allow crankshaft to turn anti-clockwise.
  22. Insert timing pins [3] & [8] .
  23. Slacken camshaft sprocket bolts [10] .
  24. Slacken tensioner pulley bolt to release tension on belt [9] .
  25. Attach tension gauge to belt at  [13] .
  26. Turn tensioner pulley anti-clockwise until tension gauge indicates 54±2 SEEM units.
  27. Hold tensioner pulley in position. Tighten tensioner pulley bolt [9] . Tightening torque: 25 Nm.
  28. Tighten camshaft sprocket bolts [10] . Tightening torque: 20 Nm.
  29. Remove tension gauge.
  30. Attach tension gauge to belt at  [11] .
  31. Tension gauge should indicate 54±3 SEEM units. If not: Repeat tensioning procedure.
  32. Remove tension gauge.
  33. Remove timing pins [3] & [8] .
  34. Turn crankshaft two turns clockwise to setting position.
  35. Insert timing pin in flywheel [3] .
  36. Ensure timing pin can be inserted easily [8] .
  37. If timing pin cannot be inserted: Visually check camshaft sprocket hole 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.
  38. Remove timing pin [3] .
  39. Install components in reverse order of removal.
  40. Remove bolt and 17 mm spacer. Refit bolt [7] . Tighten bolt to 15 Nm [7] .
  41. Remove crankshaft pulley bolt [1] .
  42. Clean crankshaft pulley bolt and crankshaft threads.
  43. Coat crankshaft pulley bolt with suitable thread locking compound.
  44. Tighten crankshaft pulley bolt [1] . Tightening torque: 70 Nm + 62°.
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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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