How to Replace timing belt on Citroen Berlingo B9 1.6 HDI

Citroen Berlingo B9 1.6 HDI cambelt change instructionts . Full guide!

Replacement Interval Guide

• Citroen recommend:
• 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

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th colspan=”2″ align=”left”>Remove & install:

C4/C5	3,60
Berlingo	2,70

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.

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.