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How to Replace timing chain on Citroen Xsara Picasso 2.0 HDi 2001-06

Citroen Xsara Picasso 2.0 HDi 2001-06 cambelt change instructions and replacement inteval. Full guide!

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 & A 2,90
Camshaft drive belt/chain – R & I 3,50

Valve timing procedures

How to Replace timing belt on Citroen Xsara Picasso 2.0 HDi 2001-06
How to Replace timing belt on Citroen Xsara Picasso 2.0 HDi 2001-06

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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