Skip to content

How to Replace timing belt on Citroen C3 1.6 HDi 2009-

Published August 11, 2015

Replacement Interval Guide

  • Citroen recommend:
  • C3 III:
  • Replacement every 160,000 miles or 10 years under normal conditions.
  • Replacement every 112,500 miles or 10 years under adverse conditions.
  • Except C3 III:
  • 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

Remove & install:
C3 III 2,30
C3 Picasso 2,20
Berlingo III 2,10

Special Tools

  • With stop-start system: Auxiliary drive belt tensioner tools – Nos.(-).0194-E/E2 & (-).0188-Z.
  • With stop-start system: Auxiliary drive belt tensioner locking tools – No.(-).0194-F1.
  • Without stop-start system: Auxiliary drive belt tensioner tool – No.(-).0194-E3.
  • Without stop-start system: Auxiliary drive belt tensioner locking tool – No.(-).0194-F.
  • Camshaft sprocket locking tool – No.(-).0194-B.
  • Crankshaft/high-pressure fuel pump sprocket aligning tool – No.(-).0194-A.
  • Flywheel locking tool – No.(-).0194-C.
  • Set of blanking plugs – 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.
How to Replace timing belt on Citroen C3 1.6 HDi 2009-
How to Replace timing belt on Citroen C3 1.6 HDi 2009-

Removal

  1. Raise and support front of vehicle.
  2. Remove engine top cover (if fitted).
  3. Disconnect and seal off fuel pipes. Use tool No.(-).0194-T.
  4. Remove:
      • Berlingo III/C3 III 1,6: Turbocharger/intercooler air hoses.
      • RH front wheel.
      • RH inner wing panel.
      • Engine undershield (if fitted).
      • C3 III: Auxiliary drive belt cover (if fitted).
      • Auxiliary drive belt. Use tool Nos.(-).0194-E/E2, (-).0188-Z & (-).0194-F1 or (-).0194-E3/F.
      • Exhaust downpipe (if necessary).
  5. Turn crankshaft until flywheel locking tool can be inserted.
  6. Fit flywheel locking tool [1] . Tool No.(-).0194-C.
  7. Move aside engine wiring harness (on timing belt cover).
  8. Disconnect crankshaft position (CKP) sensor multi-plug.
  9. Remove:
      • Timing belt upper cover [2] .
      • Crankshaft pulley centre cap (if fitted).
      • Crankshaft pulley bolt [3] .
      • Crankshaft pulley [4] .
      • Auxiliary drive belt tensioner.
      • Timing belt lower cover [5] .
      • Crankshaft position (CKP) sensor.
      • Timing belt guide [6] .
  10. Fit crankshaft pulley bolt [3] .
  11. Remove flywheel locking tool [1] .
  12. Turn crankshaft clockwise to setting position.
  13. Insert camshaft sprocket locking tool [7] . Tool No.(-).0194-B.
  14. Insert high-pressure fuel pump sprocket aligning tool [8] . Tool No.(-).0194-A.
  15. Insert crankshaft aligning tool [9] . Tool No.(-).0194-A.
  16. Support engine.
  17. Remove RH engine mounting and bracket.
  18. Hold tensioner pulley in position. Use Allen key [10] . Slacken tensioner pulley bolt [11] .
  19. Turn tensioner pulley clockwise to release tension on belt.
  20. Remove timing belt, starting at water pump sprocket.

    NOTE: Ensure crankshaft position (CKP) sensor reluctor is not damaged.

Installation

  1. Check tensioner pulley, guide pulley and water pump sprocket for smooth operation.
  2. Ensure camshaft sprocket locking tool located correctly [7] .
  3. Ensure high-pressure fuel pump sprocket aligning tool located correctly [8] .
  4. Ensure crankshaft aligning tool located correctly [9] .
  5. Fit timing belt in following order:
      • Crankshaft sprocket.
      • Guide pulley.
      • Camshaft sprocket.
      • High-pressure fuel pump sprocket.
      • Water pump sprocket.
      • Tensioner pulley.
  6. Ensure belt is taut between sprockets.
  7. Fit timing belt guide [6] .
  8. Turn tensioner pulley anti-clockwise until pointer aligned in window [12] . Use Allen key [10] .
  9. Tighten tensioner pulley bolt [11] . Tightening torque: 30 Nm.
  10. Remove:
      • Camshaft sprocket locking tool [7] .
      • High-pressure fuel pump sprocket aligning tool [8] .
      • Crankshaft aligning tool [9] .
  11. Fit RH engine mounting and bracket.
  12. Turn crankshaft slowly six turns clockwise to setting position.

    NOTE: DO NOT turn crankshaft anti-clockwise.

  13. Fit crankshaft aligning tool [9] .
  14. Ensure tensioner pulley pointer aligned in window [12] . If not: Repeat installation procedure.
  15. Insert camshaft sprocket locking tool [7] .
  16. If locking tool cannot be inserted: Visually check camshaft sprocket hole [7] 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.
  17. Insert high-pressure fuel pump sprocket aligning tool [8] .
  18. Remove:
      • Camshaft sprocket locking tool [7] .
      • High-pressure fuel pump sprocket aligning tool [8] .
      • Crankshaft aligning tool [9] .
  19. Fit flywheel locking tool [1] .
  20. Remove crankshaft pulley bolt [3] .
  21. Fit:
      • Crankshaft position (CKP) sensor.
      • Timing belt lower cover [5] .
      • Crankshaft pulley [4] .
      • New crankshaft pulley bolt [3] .
  22. Tighten crankshaft pulley bolt [3] . Tightening torque: 35 Nm + 190°.
  23. Remove flywheel locking tool [1] .
  24. Install components in reverse order of removal.
1 vote

Published in C3