How to Replace timing chains on Citroen C3 1.6 VTi 2009-

Special tools

• Exhaust camshaft alignment tool – No.0197-A1.
• Flywheel timing pin – No.0197-B.
• Inlet camshaft alignment tool – No.0197-A3.

General precautions

• Disconnect battery earth lead.
• Remove spark plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• Observe tightening torques.
• If fitted: Mark position of crankshaft position (CKP) sensor before removal.
• Do NOT turn crankshaft via camshaft or other sprockets.
• Do NOT turn crankshaft or camshaft with timing chain removed.

Valve timing procedures

• Ensure camshaft adjusters set in the installation position as follows:
  • Turn crankshaft two turns clockwise.
  • Turn inlet camshaft slowly anti-clockwise as far as stop [1] .
  • Turn exhaust camshaft slowly clockwise as far as stop [2] .
  • Camshaft rotation possible using spanner at positions shown [3] .
  • Ensure camshafts locked in position.
  • Replace camshaft adjuster, if not locked in installation position.
• Fit flywheel timing pin [4] .
• Turn crankshaft clockwise until flywheel timing pin engages [5] .

NOTE: Ensure round section of alignment lobe is facing downwards [6] .

• Install exhaust camshaft alignment tool [7] .
• Install inlet camshaft alignment tool [8] .
• Remove timing chain tensioner [9] .
• Modify old timing chain tensioner to use as timing chain pre-tensioning tool:
  • Drill a 10,75 mm diameter hole into hexagon end of tensioner body.
  • Insert M10 x 1,5 helicoil and fit M10 x 100 mm bolt with locknut.
• Install timing chain pre-tensioning tool [10] .
• Tighten adjusting screw until in contact with guide rail. DO NOT overtighten screw.
• Pre-load timing chain with pre-tensioning tool to 0,6 Nm.
• Remove camshaft alignment tools [7] & [8] .
• Remove flywheel timing pin [4] .
• Turn crankshaft two turns clockwise.
• Ensure camshaft adjusters in the installation position.
• Fit flywheel timing pin [4] .
• Ensure flywheel timing pin located correctly [5] .

NOTE: Ensure round section of alignment lobe is facing downwards [6] .

• Install exhaust camshaft alignment tool [7] .
• Install inlet camshaft alignment tool [8] .
• Timing correct when camshaft alignment tools abut cylinder head.
• If not, adjust camshafts as follows:
  • Remove timing chain pre-tensioning tool [10] .

    NOTE: Replace chain, tensioner and guides if ‘X’ more than 73,5 mm.

  • Refit timing chain pre-tensioning tool [10] .
  • Pre-load timing chain with pre-tensioning tool to 0,6 Nm.
  • Remove camshaft alignment tools [7] & [8] .
  • Remove central bolt from each camshaft adjuster [11] .
  • Camshaft rotation can be prevented using 27 mm spanner at positions shown [3] .

    NOTE: Degrease ends of camshafts and camshaft sprockets.

  • Fit new bolts [11] . Finger tighten bolts.
  • Remove crankshaft pulley centre bolt [12] .
  • Fit new crankshaft pulley central bolt [12] . Finger tighten bolt.
  • Install exhaust camshaft alignment tool [7] . If necessary, adjust position of exhaust camshaft.
  • Install inlet camshaft alignment tool [8] . If necessary, adjust position of inlet camshaft.
  • Ensure camshaft alignment tools abut cylinder head. Secure tools with bolts.
  • Tighten crankshaft pulley central bolt [12] . Tightening torque: 50 Nm + 180°.
  • Tighten inlet camshaft adjuster bolt. Tightening torque: 20 Nm + 180°.
  • Tighten exhaust camshaft adjuster bolt. Tightening torque: 20 Nm + 180°.
  • Remove timing chain pre-tensioning tool [10] .
  • Fit new timing chain tensioner. Tightening torque: 75 Nm.
  • Remove camshaft alignment tools [7] & [8] .
  • Remove flywheel timing pin [4] .