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How to Replace timing belt on Citroen C5 1.6 HDI 2008

Published April 25, 2017

Citroen C5 1.6 HDI 2008 cambelt change instructions and replacement inteval. Full guide!

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.

Repair times – hrs

Camshaft drive belt/chain – R & I 3,60
Camshaft drive belt/chain (rear) – R & I 8,30

Valve timing procedures

How to Replace timing belt on Citroen C5 1.6. HDI 2008
How to Replace timing belt on Citroen C5 1.6. HDI 2008

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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