Timing belt Citroen C2 2004 1.G Repair Manual

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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine: WJY
Tools.
[1]
Pliers for remving plastic pins: 7504T or ().1311
[2]Flywheel peg: 7014T.J or ().0188 Y
[3]Injection pump setting peg Ø 6 mm: ().0188 H
[4]Screw H M8: ().0188 E
[5]Belt retaining pin: ().0188 K
[6]Square for adjusting belt tension: ().0188 J1
[7]Belt tension measuring instrument, with digital display: SEEM CTG 105.5M
Checking the timing.
Peg the flywheel, using tool [2].
Peg the camshaft hub, using tool [4].
Peg the injection pump hub, using tool [3].
IMPERATIVE: If the pegging proves impossible, repeat the setting of the timing.
B1BP2FTCB1EP16PD
XSARA

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engine: WJY
B1BP2FTC
Setting the timing.
Removing.
Disconnect the battery.
Remove the front RH lower splashshield, using tool [1].
Remove the accessories drive belt (see corresponding operation).
Uncouple and plug the diesel fuel delivery and return hoses. Support the engine, using a workshop hoist.
Remove the RH engine support.
Engage 5th gear to permit rotation of the engine. Remove the upper cover
(1).
Remove the intermediate cover (2).
Remove the lower cover (3).
WARNING:Refit the screw (4)equipped with a washer (5 mm thick).
Rotate the front RH wheel to drive the engine in its normal direction of
rotation. Bring the camshaft drive and injection pump pinions to their setting points.
Position the peg
[2](from underneath the vehicle).
Continue turning the engine until the peg [2]engages in the flywheel.
B1BP30BC
XSARA

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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine: WJY
Setting the timing (continued).
Peg the camshaft hub, using tool [4].
Peg the injection pump hub, using tool [3].
Slacken screws (5)and (6).
Slacken screw (9)of the tensioner roller (8).
Remove the timing belt.
Refitting. Retighten screws (5)and (6)by hand.
Turn the pinions (10)and (7)clockwise in order to place them at end of slots.
Fit the timing belt on the crankshaft. Hold the belt, using tool
[5].
Position the timing belt in the following sequence:
Guide roller
(11).
Injection pump pinion (7).
Camshaft pinion (10).
Coolant pump pinion
(12).
Tensioner roller (8).
B1EP16PDB1EP1EDCB1EP132C
XSARA
B1EP1EEC

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engine: WJY
B1EP1EDC
Setting the timing (continued).
NOTE:
If necessary, you can slightly rotate the pinions (10)and (7)anticlockwise in order to engage the belt.
The angular displacement value of the belt in relation to the pinions should not be more than half a tooth.
Remove tool
[5].
Act on the tensioner roller
(8)by its square «a», using tool [6]to check that the camshaft and injection
pump pinions can turn freely.
Position the belt tension instrument
[7]on the belt at «b».
Using tool
[6], act at «a»in the direction opposite to that of engine rotation, to obtain a tension value of
106 ± 2 SEEM units.
Tighten screws
(9), (5)and (6).
Remove tools
[7], [2], [3]and[4].
Rotate the crankshaft
8 timesin the normal direction of rotation.
Peg the flywheel, using tool
[2].
Peg the camshaft hub, using tool
[4].
Peg the injection pump hub, using tool
[3].
Slacken screws
(9), (5)and (6).
Position the belt tension instrument
[7]on the belt at «b».
Using tool
[6], act at «a»in the direction opposite to that of engine rotation, to obtain a tension value of
42 ± 2 SEEM units.
B1EP1EFC
XSARA

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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine: WJY
Setting the timing (continued).
Tighten:
Screw (9)to 2.1 ± 0.2 m.daN.
Screws (5)to 2,3 ± 0.2 m.daN.
Screws (6)to 2,3 ± 0.2 m.daN.
Remove and refit tool [7].
The tension value should be between 38 and 46 SEEM units.
Remove tools [7], [2], [3] and [4].
Turn the crankshaft 2 timesin the normal direction of rotation.
Peg the flywheel, using the peg [2].
Visually check the peggings of the camshaft and injection pump.
ESSENTIAL:Visually check that the offsets between the holes of
the camshaft and injection pump hubs and the correspondingpegging holes are not more than 1 mm.If necessary, recommence
the procedure for fitting the timing belt.
XSARA
Setting the timing (continued).
Remove the peg [2].
Remove the screw (4)and the washer.
Refit the lower cover (3).
Refit the intermediate cover (2).
Refit the upper cover (1).
Remove the RH engine support.
Take away the workshop hoist. Remove the plugs and recouple the diesel fuel delivery and return
hoses. Refit the accessories drive belt
(see corresponding operation).
Refit the RH lower splashshield. Disengage
5th gear.
Connect the battery.

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ENGINE
(1) «Idler»camshaft pulley(2)Target for cylinder reference sensor.(3)Camshaft hub.(4)«Fixed»crankshaft pinion.
The determining of the tension of the timing belt is done on the cam
shaft pulley
(1).
The new timing on 8 valveengines DW10TD (RHY)and DW10
ATED (RHS-RHZ)requires the following components:«Idler»crankshaft pinion«Fixed»camshaft pulley.
(5) «Fixed»pulley with integral cylinder reference
sensor target).(6) «Idler»crankshaft pinion (with increased width keyway groove).
The determining of the tension of the timing belt is done on the crankshaft pinion
(6).
CHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
OLD FITTING:# N° RPO 9127 NEW FITTING N° RPO 9128 #
B1EP176DB1EP177D
XSARA XSARA PICASSO

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ENGINECHECKING AND SETTING THE VALVE TIMING
NOTE: Checking and setting the valve timing on engines: RHYRHZ N° ⁄ RPO 9127
See Mechanic’s Handbook 2003: pages 193 to196
Tools.
[1]
Belt tension measuring equipment :4122T
[2]
Tension lever:().0188.J2
[3]
Engine flywheel peg: ().0188.Y
[4]
Belt clamp: ().0188.AD
[5]
Camshaft pulley peg: ().0188.M
[6]
Engine flywheel lock: ().0188.F
[7]
Set of blocking plugs:().0188.T
[8]
Pulley extractor:().0188.P
[9]
2 mm dia.peg: ().0188.Q2Removing.
IMPERATIVE: Respect the safety and cleanliness requirements
that are specific to high pressure diesel injection (HDi) engines.
Undo the front RH wheel bolts.
Raise and support the vehicle on the front RH side.
Disconnect the battery negative terminal.
Remove:
The underengine sounddeadening.
The front RH wheel.
The front RH splashshield. The engine cover.
Unclip and move aside the cooling hose.
Remove the accessories drive belt
(see corresponding operation).
XSARA XSARA PICASSO
Engines: RHY RHZ N° RPO 9128 #

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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
Slacken the screw (17)of the tensioner roller (18).
Remove the timing belt
(14).
Checks.
IMPERATIVE: Just before refitting, carry out the checks below.
Check that:
The rollers
(18)and (15)turn freely (without play and without any tight spot).
The coolant pump pulley
(16)turns freely (without play and without any tight spot).
There are no traces of oil leaks from the crankshaft and camshaft seals, etc.
The crankshaft pinion travels freely on the keyway.
Replace defective components if necessary.
Peg the crankshaft pinion
(19)by inserting tool [9]on the LH side of the keyway.
B1EP1A8DB1EP1A9C
XSARA XSARA PICASSO

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
Reposition the timimg belt, belt at «a»well tensioned, in the following order:
Fuel high pressure pump pulley
(21).
Guide roller
(15).
Crankshaft pinion
(19).
Coolant pump pinion
(16).
Tensioner roller
(18).
Position tool
[1]on the belt at «a».
Remove tools
[4]and [9].
Turn the tensioner roller
(18)anticlockwise, using tool [2], to attain an overtension of:
98 ± 2 SEEM units.
Tighten screw
(17)of the tensioner roller to 2,5 ± 0,2 m.da N.
Lock the flywheel by means of tool
[6].
Tighten the accessories drive pulley screw
(8)to 7 ± 0,7 m.da N.
Remove tools
[1], [3], [5] and [6].
Rotate the crankshaft eight times in the normal direction of rotation.
Peg:
The crankshaft, using tool
[3].
The camshaft drive pulley, using tool
[5].
B1EP1ABDB1EP1ACC
XSARA XSARA PICASSO

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ELECTRICAL
SYSTEM
C5HP073C
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Clickfit connector removing/fitting tool
Ø Inch
V ehicle
XSARA
XSARA
PICASSOTT
BP
HP5/8Black
8005T.A
3/8Red
8005T.C Ring colour Tool kit 4164T
Tightening torques (m.daN).
Unions
Steel/Steel
Aluminium/Steel Ø Pipes
1,7 ±0,3
1,3 ± 0,3 M 06
3,8 ± 0,3
2 ± 0,2
M 08
4 ± 0,3
2,5 ± 0,3 M 10
NOTE:Tighten the union to the recommended torque using a retaining spanner whenever possible.
NOTE:For operations concerning draining, drying (empty), checking and recharging of a system:refer to BRE 0290.
WARNING: For R 134.a quantities (see table on preceding page:483).
Aircon compressor fixings.
ESSENTIAL: Tighten the front part of the compressor(timing belt end), before the rear part of the compressor.