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How to Replace timing chain on Citroen C2 1.6 2003-10

Citroen C2 1.6 2003-10 cambelt change instructions and replacement inteval. Full guide!

Special tools

  • Camshaft timing pins – Citroen Nos.4533-T.AC1/2.
  • Flywheel locking tool – Citroen No.4507-T.A.
  • Tensioner pulley locking pin – Citroen No.4200-T.H.
  • Timing belt retaining clip – Citroen No.4533-T.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

Camshaft drive belt/chain – R & I 2,70

Valve timing procedures

How to Replace timing belt on Citroen C2 1.6 2003-10
How to Replace timing belt on Citroen C2 1.6 2003-10

Removal

  1. Raise and support front of vehicle.
  2. Remove:
    • RH front wheel.
    • RH splash guard.
    • Auxiliary drive belt.
    • Crankshaft pulley bolts [1] .
    • Crankshaft pulley [2] .
    • Except Xsara II: Oil filter.
    • Xsara II: Air filter housing.
    • Xsara II: Air filter intake duct.
    • Xsara II: Exhaust manifold heat shield.
  3. Xsara II: Disconnect PAS pipe from engine.
  4. Support engine.
  5. Remove:
    • RH engine mounting.
    • RH engine mounting bracket.
    • Timing belt upper cover [3] .
    • Timing belt lower cover [4] .
  6. Turn crankshaft clockwise to setting position.
  7. Fit flywheel locking tool [5] . Tool No.4507-T.A.
  8. Insert timing pins in camshaft sprockets [6] . Tool Nos.4533-T.AC1/2.
  9. Slacken tensioner pulley nut [7] .
  10. Turn tensioner pulley clockwise until pointer [8] aligns with position [9] . Use Allen key [10] .
    NOTE: DO NOT turn tensioner pulley 360°.
  11. Insert locking pin in tensioner pulley [11] . Tool No.4200-T.H.
  12. Remove timing belt.
    NOTE: DO NOT refit used belt.

Installation

  1. Check tensioner pulley and guide pulley for smooth operation.
  2. Ensure timing pins located correctly in camshaft sprockets [6] .
  3. Ensure flywheel locking tool located correctly [5] .
  4. Fit timing belt in following order:
    • Inlet camshaft sprocket (CA1).
    • Exhaust camshaft sprocket (CA2).
    • Guide pulley.
    • Crankshaft pulley. Secure belt to crankshaft sprocket with retaining clip. Tool No.4533-T.AD [12] .
    • Water pump sprocket.
    • Tensioner pulley.

    NOTE: Ensure belt is taut between sprockets on non-tensioned side.

  5. Remove:
    • Timing pins [6] .
    • Flywheel locking tool [5] .
    • Timing belt retaining clip [12] .
  6. Insert Allen key into tensioner pulley.
  7. Remove tensioner pulley locking pin [11] .
  8. Turn tensioner pulley until pointer [8] at position shown [13] .
    NOTE: DO NOT turn tensioner pulley 360°.
  9. Insert locking pin in tensioner pulley [11] .
  10. Tighten tensioner pulley nut [7] . Tightening torque: 10 Nm.
  11. Turn crankshaft four turns clockwise to setting position.
    NOTE: DO NOT allow crankshaft to turn anti-clockwise.
  12. Fit:
    • Flywheel locking tool [5] .
    • Timing pins [6] .
  13. Remove:
    • Flywheel locking tool [5] .
    • Timing pins [6] .
  14. Slacken tensioner pulley nut [7] .
  15. Remove tensioner pulley locking pin [11] .
  16. Turn tensioner pulley until pointer [8] aligned with notch [14] .
    NOTE: DO NOT turn tensioner pulley 360°.
  17. If pointer passes notch [14] , repeat tensioning procedure.
  18. Hold tensioner pulley. Use Allen key [10] . Tighten tensioner pulley nut [7] . Use new nut.
    • Except Xsara II: A – tightening torque: 17-25 Nm.
    • Xsara II: B – tightening torque: 20-24 Nm.

    NOTE: Ensure tensioner pulley does not move when tightening nut [7] . If tensioner pulley moves: Repeat tensioning procedure.

  19. Install components in reverse order of removal.
  20. Tighten crankshaft pulley bolts [1] .
    • C2/C3: A – tightening torque: 23-27 Nm.
    • C4/Xsara II/Xsara Picasso: B – tightening torque: 19-31 Nm.
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