2Ae1 Chapter 2 Part A: Petrol engine in-car repair procedures Contents Camshaft covers) - removal and refitting Camshaft oll sealis)~ renewal... Camshafts) and followers - removal, inspection and refiting Engine/tvansmission mountings - inspection and renewal... «18 Fiywheelicriveplate - removal, inspection and refitting 7 General information . .... tei wasn 1 Compression test - aseription and interpretation Gil cooler removal and reftiing 15 Crankshaft ol seals - renewal Gil pump - removal, inspection and refiting 4 Crankshaft pulley - removal and refitting . ‘Sump - removal and refitting . 18 Gyincer head - removal and rafting Timing belt - general information, removal and reiting. 7 Engine assembly/valve timing holes - general information Timing belt covers - removal and refiting 6 Timing bel tensioner and sprockets - removal, inspection and usage aire Eine land iter rewal sss ssccssceecceecsee See Ohapter 14 “rfting 18 Engine ollovl check ‘Seo “Week cnachs” Vale clearances = chacking and adjustrent " Degrees of difficulty Easy, Suitable for 3s Fairly easy, suitable =), | Fairly difficult, Difficult, suitable for & ‘Very difficult, x novice with litle SS] forbeginner with < | suitable for competent 4° | experienced DIY S| sutable for expert DIY BS parce Sy] someerpernce RQ) rv mecnanic S| mechanic Zor proiessna = XN Specifications Engine (general) 1.6 lira (1880 ee) engine XUS {kro 76 ce} engine xu? 2o ro 1098 os) engine xuia Engine codes": ‘eitreengine « FZ US JP») 1B ire Soave engine SINIIII LZ ou? 482 or XU? uP, or L6A QxU7 UPsA9 {8iive 1e-alve engine try RUT uPA Zotwee-vaveengne sscsscuscos REX (kU10 12072 0° XL0 J2CILS} or RED UO JEG Zoe 16-vave engine REV UT0 Ja) soe {Olive engine... 29,00 mm eve engine £3.00 mm 20 tr engine 36,00 mm sik: Tere engine 78.00 mm is 8.40 mm 6.00 mm 2.0 lie engine Direction of crankshaft rotation | No‘ oyliner location r Compression ratio: Clockwise (viewed from the right-hand side of vehicle) At the tranemission end of block W6iitreeagine esse 9.2521 18 litre 8-valve engine : feet 9.25: 1.8iitre 16-valve engine I toa 20 tre B-valve engine 95:1 20 ire 16-valve engine 30.4: 4 “the engine cod is stamped on a plata attached fo the front left-hand end of the cylinder block on early 1.6 and 1.8 fitre engines, and stamped recy onto the front face of the cylinder block Gustto the left of the ail filter) on 2.0 lire and fater engines. This is the code most often used by Ctrogn, The code given in brackets 's the factory identification number, and is not often referred to by Citroén or this manual Camshaft Drie eee cone cesses Toothed belt No of baarings oe eon & Camshaft bearing journal diameter Not available at time of writing Not available at time of writing2Ae2 Petrol engine in-car repair procedures Cylinder head bolts ‘Maximum length for re-use (see text} 1.6 and 1.8 litre 8-valve engines: Bolt with spacer (right-hand rear bolt)... Bolts without spacer ........2.+++ Bolts without washer 2.0 litre 8-valve engines: Bott with spacer (ight-hand reer bolt) Bolts without spacer 1.Blitra 16-valva engines. 2.0 lire 16-valve engines Valve clearances (8-valve engines only) Inlet eet Exhaust - Lubrication system il pump type Minimum oll prossure at 80°C Oil pressure waming switch operating pressure Torque wrench settings 1.6 and 1.8 litre 8-valve engines ‘AMtornator bracket bolts Big-end bearing eap nits Stage 1 Stage 2 Camshaft bearing cap nuts Camshaft cover nuts/oolts . Gamshalt sprocket retaining belt M0 boit M2 bolt an Grankshaft pully retaining boi. Gylinder head bolts fhex-head type} Staged... Fly stacken each bot in sequence, then tighten to: Stage? 168 0.5mm 176.5 mm 171.8mm 324.5 mm 122mm 160mm 12mm 0.20 mm # 0.05 mm 0.40 mm « 0.05 mm, Gear-type, chain-riven off the crankshatt night-hand end 6.0 bars (approx) at 4000 rpm Tighten all bolls to Stage 2, then warm up engine. Allow to cool for hours, then: Faliy slacken each bolt in sequence, then lighten to: StageS ..... Gylinder head bolts (Tork type) ‘Stage 1... . Fully slacken each bot in sequence, then tighten to Stage 2 Whon all bolts are Stages Stage 4 Engine/transmission left-hand mounting: Mounting brackat-to-bedy bolts Mounting stud . ve 3 Centre nut Engine‘transmission rear mounting Mounting assembly-to-black bolts Mounting bracket-lo-mounting bolt Mounting bracket-to-subframe bolt Engine/transmission right-hand mounting: Brackel-lo-engine bolts ‘Mounting bracket retaining nuts FlywheeVdriveplate retaining bolts” Front cil seal carter bolts ‘Main bearing cap nuts/bolts: Retaining nuts/bolts a Centre bearing cap side bolts il pump retaining belts ‘Sump retaining bolls Timing batt cover bolts ‘Timing belt tensioner pulley bot *Use iocking fluid htened to Stage 2, tighten all bots in sequence to: as bars Nm wort 22 16 20 15 ‘Angle-tighten a further 70° 16 12 10 7 35 28 30 59 +90 98 60 a 20+ 120° 15+ 120" 20+ 120° 15+ 120° 60 44 20+ 107° 164107" ‘Ariglo-tighten a further 100° ‘Angle-tighten a further 100° 25 18 50, 37 80 58 45 33 50 37 50 30 48 33 45 33 50 30 16 12 54 40 23 v 16 2 19 14 a 6 a 16Petrol engine in-car repair procedures 2A*3 Torque wrench settings (continued) Nm lot ft 20litre 8-valve engines Alernator bracket bolts 20 16 Big-end bearing cap nuts: Stage 1. eas 40 20 Ful slacken all nuts, than tightan to: Stage 2. : : 20 18 Stage 3. : sicse Angle-tighten a further 70° ‘Canshatt bearing cap nuts/bolts 16 2 Carshaft cover nuls/bolts . 10 7 Camshatt sprocket retaining bot: Mid bolt 35 26 M2 bolt 22 80 59 Crankshaft pile reining bolt - 130 96 finder head bolts: Stage 1. 35 26 Fully slacken each bolt in sequence, than tighten te Stage 2. : 70 62 Stages - ‘Angle-tighten a further 160° Enginetranemission left-hand mounting: Heng ibarorboty eae: 20 16 Mounting stu 1 ercirenaie ot (OO, 37 entre nt = 65 a8 Enginaftransmission rear mounting: Mounting assembly-to-block bolts 45 33 Mounting link-to-mounting bolt 50 37 Mounting link-to-suibframe bolt 70 52 Engineltransmission right-hand mounting: Mounting bracket retaining nuts 45 38 Curved retaining piste ven; 20 18 FiywheeVdriveplata retaining bolts” 50 8? Front el wal eareiar Bats sce c eos e eae teens 18 2 ‘Man bearing eap Dots a 8 8 pump retaining bots 6 2 Psion oiljet spray tube bolt 10 7 Sunyprwtaining bots 18 13 Timing belt cover botis SAE UAT 8 6 Timing bel tensioner pulley bolt” fiitctitteseesness TF 13 “Use ocking fluid Band 2.0 litre 16-valve engines Big-end bearing cap nuts: Stage 1... vetinarian 20 15 Stage 2 Angie-tighten through 70° Camshaft bearing housings: Stage 1. fa 5 4 Stage 2. 53 FERGIE RETALOE EU 10 7 Ccamehaft cover nuts/bolts 10 7 Camshaft sprockei-to-hub retaining Bolts =... see ceeeceeeeeee 10 7 Camshaft sprocket hub-to-camshatt retaining bolts... 2... 5 55 Crankshatt pullay retaining bolt” 190 26 Gyfinder head bolts: 1.6 lie engines Siage 1. 60 4a Fully slacken each bolt in sequerice, then tighten to: Stage 2 20+ 107° 184107" When all bolts are tightened to Stage 2, tighten all bo! to: Stage 3 sesseee+ Angle-tighten a further 100° Stage ¢ ssa aseRa Siocciecses Angle-tighten a further 100° 20 ire engines: Stage 1... + c 35 26 Fully slacken each boi in Sequerice, then tighten to: Stage 2. . 70 52 Stage S ces ciss2 Angie-tighten a further 160° Dipstick guide tube boll... esse eceeeeeeeeeeseeeeeeees 10 7 Engine-to-transmission fixing boits 45 33 FiywheeVdriveplate retaining bolts’ veces 8 372Ae4 Petrol engine in-car repair procedures Torque wrench settings (continued) 1.8 and 2.0 litre 16-valve engines (continued) Front ol seal cartier bolts Ignition coil unit retaining botts Left-hand engine/transmnission mounting ‘Mounting bracket-to-body Rubeer mouriting-to-bracket balts ‘Mounting stud-1o-transmission ‘Mounting stud bracket-to-transmission Centre nut Main bearing cap bolts: 1 B litre engine: Bearing bolts Side securing bolts 2.01itre engine: Engine code RFS: Ro 5 cap bolts, All other bolts All other engines ll pump retaining bolts Piston ol jet spray tube bolt Right-hand engine/transmission mounting: 1 B litre engines: Mounting bracket-to-engine nuts Mounting bracket-to-engine bolts Mounting bracket-lo-rubber mounting nut Fubber mounting-to-bocy nut 2.0 litre engines: Mounting bracket-to-engine nuta/volts Mounting bracket-to-rubber mounting nut Fubbor mounting-to-bady nut Sump retaining batts Tiening belt cover bolts Timing bolt ilar paley Belt Timing belt tansionor pulley bolt “Use focking ful 54 23 85 70 70 16 10 18 a 21 1 General information How to use this Chapter This Part of Chapter 2 describes those repair pprocectures that can reascnably be carried out con the XU series petrol engine, while t remains inthe car. IF the engine has been removed from the car and is being dismantled as described in Part C, any preliminary dismanting procedures ‘can be ignored. Note that, while it may be possible physically to overhaul items such asthe piston/connecting rod assemblies while the engine isin the car, such tasks are not usually carried out as separate operations. Usually, several additional procedures (not to mention the cleaning of components and ollways) have to be carted out. For this reason, all such tasks are cassec as major overhaul procedures, and are desorbed in Part C of this Chapter. Part G describes the removal of the engine! reneniesion unk fonvthe vatiioks, ani} the till ‘overhaul procedures that can then be cared out. XU series engine description ‘The XU series engine is a well-proven engine which has been fitted te many previous Croan ‘and Peugeot vehicles. The engine is of the in- line four-cylinder type, mounted transversely at the front of the car. Tha clutch and transmission are attached to its left-hand end. The crankshaft runs in five main bearings. Thrustwashers are fitted to No 2 main bearing cap, to control crankshaft enctloat. The connecting rods rotate on horizontally- split bearing shells at their big-ends. The pistons are attached to the connecting rods by gudgoon pins. The gudgeon pins are an Imterterence fit in the connecting rod smal- fend eyes. The aluminium alloy pistons are fitted with three piston rings - two ‘compression rings and an oil control ring, The engine may be an B-valve, single ‘overhead camshaft unit, or a 16-valve, double overhead camshaft type. The 16-valve engines were introduced in 1995, and can be identified by having "/6V" stamped in the Porsemennbiicesnas. On the 1.6 and 1.8 litre B-valve engine, th oylindar block is of the “wat-linar” type. The cylinder block Is cast in aluminium alloy, an the bares have replaceable cast-iron lines that are located from the top of the cylinds block. Sealing O-rings are fitted at the base 0 each liner, to prevent the escape of coolat into tho sump. (On the 2.0 litre B.valve angine, and all 16 valve engines, the engine is of the conventional “dry-liner" type. The cylinds block is cast in iron, and no separate bow liners are fitted. Cn the -valve engine, the camshaft i driven by a toothed timing belt, and i operates the valves via followers’ located beneath each cam lobe. The vaive clearance are adjusted by shims, positioned betwee the followers and the tip of the valve stem. “The camshafts on 16-velve engines are els driven by a common toothed timing belt; th front camshait operates the inlet valves, an the rear camshait operates the exheus valves. The vaive clearances are seli-adjustin bby means of hydraulic tappets. Each camshaft runs in bearing caps whici are bolted te the top of the cylinder head:Petrol engine in-car repair procedures 2A¢5, ‘The inlet end exhaust valves are each closed by coil springs, and operate in guides tossed into the cylinder head. Both the vahe seats and guides can be renewed separately if worn. ‘The water pump is driven by the timing batt, {and is locatad! in the right-hand end of the oynder block, Lubrication is by means of an oll pump whichis cvan (via a chain and sprocket) off the crankshait right-hand end. It draws oll through a strainer located in the sump, and then forces if through an externaliy-mounted fier into galleries in the cylinder Dlockicrankease. From there, the oil is Ais buted to the crankshaft (main bearings) and camshatt. The big-end bearings are supplied with oll via internal drilings in the crankshaft; the camshaft bearings also fective a pressurised supply. The camshaft lobes and valves are lubricated by splash, as reall thor engine components. An oll cooler is fited to some models to keep the oll temperatura constant uncer severe opereting Conditions - itis mounted behind the ol fiter. The oll cooler is supplied with coolant from the engine cooling system, Throughout the manual, it is often necessary to identify the engines not only by ther cubic capacity, but also by thelr engine code, The angine core consists of three laters (09, LF2), On early 1.8 and 1.8 ttre models, the code ix skamped on a plate attached to the front, tett-hand endl OF the tyne block, On 2.0 litre and later medels, t stamped directly onto the front face of the oyinder block, on the machined! surlace located just to the loft of the ci filter (ext to ‘be crankcase vent hose union), Repair operations possible with the engine in the car The following work can be camied out with the engine inthe car 4) Compression pressure - testing 2) Camshatt covers) - cemoval ad reting, 6) Crankshaft pulley - removal and reiting. 4 Tining bet covers - removal and refitting. © Tining bot - removal, refiting ancl sgustment, 1 Tining bet tensioner and sprockets - temova and refiting. g) Camshaft oif seal(s) - renewal. 5) Camshan(s) and folomers - removal, inspection and refiting. 4) Yay clearances ~ checking and aajustment 2 Cynder ead - removal and reiting. Cylindier head and pistons - ecarbonising 4. Sump - removal and refiting. 1/Oi pump - removal, overha! and refitting. 1) Crankshaft of seals = renova 0) Enghnesrensmission mountings ~ ‘nspection and renewal. 1) Pywneaferiveptate removal, inspection ‘end refitting. 2 Compression test - description and interpretation & We 1 When engine performance is down, or if misting ocours which cannot be attributed to the ignition or fuel systems, a compression test can provide diagnostic clues as to the engine's condition. If the test is performed regulary, it can give waming of trouble before any other symptoms become apparent. 2 The engine must be fully warmed-up to normal operating temperature, the battery must be fully charged, and all the spark plugs must be removed (Chapter 14), The aid of an assistant wil also be required, 8 Disable and depressurise the fuel system, either by disconnecting the fuel pump wiring connector (refer to Chapter 4A) or by identifying and removing the fuel pump fuse from the fusebox. Start the engine, and run it Until it cuts out, 4 Disable the ignition system by disconnecting the LT wiring connector from the ignition HT coil}, referring to Chapter 58, for further information. 8 Fit a compression tester to the No 1 cylinder spark plug hole - the type of tester which screws into the plug thread is to be preferred. 6 Have the assistant hold the throtile wide pen, and crank the engine on the starter mater. After one or tWo revolutions, the Compression pressure shows build up to & maximum figure, and then stabilise, Recor the highest reading obtained, 7 Repaat the test on the remaining eylinders, recording the pressure in each, 8 All cylinders should produce very similar pressures; a difference of more than 2 bars between any two cylinders indicates @ fault. Note thal the compression should build up Quickly in a healthy engine; low compression on the first stroke, followed by gracually- increasing pressure on successive strokes, indicates wern piston rings. A low compression reading on the first stroke, which does not build up curing successive strokes, indicates leaking valves or a blown head gasket (a cracked head could also be the cause}. Deposits on the undersides of the valve heads can elso cause low compression. 9 Citro&n do not specity exact compression pressures. As 2 guide, any cylindor pressure 07 below 10 bars can be considered as less than healthy. Refer to a Citron dealer or other specialist ifn doubt as to whather a particular pressure reading is acceptable. 10 If the pressure in any cylinder is low, cerry out the following test to isolate the cause. Introduce a teaspoonful of clean cil into that cylinder through its spark plug hole, and repeat the test. 11 If tho addition of oil temporarily improves the compression pressure, this indicates that bore or piston wear is responsible for the pressure loss. No improvement suggests that leaking or burt valves, er a blown head gasket, may be to blame. 42. Alow reading from two adjacont cylinders is almost certainly due to the head gasket having blown between them; the presence of Coolant in the engine oll will confirm this. 18 If one cylinder is about 20 percent lower than the others and the engine has a slightly rough idle, a worn camshaft labe could be the 44 If the compression reading is unusually high, the combustion chambers are probably coated with carbon deposits. If this is the case, the cylinder head should be removed and decarbonised. 15 On completion of the test, refit the sperk plugs and reconnect the ignition system. 3. Engine assembly/valve timing holes - general information and usage Note: Do not aitempt to rotate the engine whilst the crankshalticamshatt are locked in positon. ifthe engine isto be fet in this stato for a iong period of time, it 3 a good ide to place sultable warning notices inside the Wahicie, and in the engine compartment. This wil reduce the possibilty of the engine being accidentally cranked on the starter motor, which 1s likely to cause damage with te locking pins in place 1 On all models, timing holes are dried in the camahatt sprockel(s) and crankshaft pulloy. The holes are used io align the crankshaft anc camshaft, to prevent the possibility of the valves contacting the pistons when ratitting the cylindor head, or when rafting the timing belt, When the holes are aligned with their corresponcing holes in the cylinder head and cylinder block (as eppropriate), suitable diameter pins cen be inserted to lock both the ‘camshaft and crankshaft in position. Proceed as follows: 2 Remove the timing belt upper (outer) cover with reference to Section 6. 3 Jack up the front of the car and support it on axle stands. Remove the right-hand front roadhoo. 4 From underneath the ‘ront of the car, unscrew the bolts and prise out the clips securing the plastic cover to the inner wing valance. Remove the cover to gain access to the crankshaft pulley bott, The crankshaft can then be turned using a suitable socket and extension bar fitted to the pulley bolt, Note thatthe crankshaft must always be tured in a clockwise direction (viewed from the right- hand side of vehicle) 8-valve engine models 5 Rotate the crankshaft pulley until the timing hole in the camshaft sprocket is aligned with its corresponding hole in the cylinder head. Note thal the holes are aligned when the sprocket hole isin the 8 o'clock postion, when viewed from the right-hand end ef the engine.2Ae6 Petrol engine in-car repair procedures. inserted through the crankshaft pulley timing hole 6 With the camshalt sprocket timing hole cortectly positioned, insert an @ mm diameter ‘bolt or el through the timing (@ mm diameter) hole in the crankshaft pulley, and locate it in the corresponding hole in the end of the cylinder block {see illustration). Note that it may be necessary to rotate the crankshaft slightly, to get the Roles to align. 7 Once the crankshaft pulley Is locked in position, ingert an 9.5 mm diameter bolt or Grill through the camshait sprecket hole and locate it in the cylinder head (see illustration). 8 The crankshalt and camshatt are now Jeckad in pasition, preventing rotation. 16-valve engine models 8 Rotate the crantcshatt pulley unl the timing, tholes fn both cansshals are aligned swith their eorespanding holes in the cylinder ead, The holes are aligned when the inlet camshat sprocket hole is in approximately the 5 4.2 Breather hoses on the right-hand end of the oylinder head cover ‘4.3 Disconnecting the intake duct 3,7 9.5 mm diameter drill inserted through the camshaft pulley timing hole o'clock position and the exhaust camshaft sprocket hole Is In approximately the 7 ‘o'clock position, when viewed from the right- hand end of the engine 40 With the camshaft sprocket holes ‘correctly positioned, insert a 6 mm ciamater bolt or drill through the timing hole in the crankshaft pulley, and locale it in the corresponding ho'e in the end of the engine (Gee illustration). Note that the hole size may vary according to the type of pulley fitted and auxiliary drivebelt arrangement, If the bolt or drill is not a saug fi, try a larger size unt a 4000 fit is achiaved in both the pulley and ‘eylinder block. 14 With the crankstall tecked In position, Insert a suitable boll or crit through the tinning hole in each camshatt sprocket and locate i In th oylindor hee (see illustration 42 The crankshaft and camshafts are now locked in position, preventing rotation, 4. Camshaft cover(s) - yemoval and refitting WEE Removal &-valve engine models 4 Disconnect the battery negative lead 2 Slacken the retaining clips, and disconnect the breather hoses from the front right-hand ‘end of the cover (see illustration). Where the ‘45a Cylinder head cover retaining nuts. arrowed) 3.11 Bolts (arrowed) inserted through timing holes in each camshaft sprocket original crimpedtstype Citrogn hose clips an stil fie, cul them off and discard thom ts Standard worm drive hose efips on retiting 8 Slacker the rstaining cip, anc eisconned tho air cleaner-to-thrattle Rousing duct fro the front of the camiahatt cover. Also romow the intake duct from the left-hand side of thy head cover (see illustration) 4 Release the two retaining olips, then und. the two retaining screws located at the fron and remove the alr cleaner element cova from the camshaft cover. Remove the ak leaner element, and store it with the cover. 5 Evenly and progressively unscrew the te camshalt cover retaining nuts, lift off th ‘camshaft cover, and remove it along with ft rubber seal (see illustrations). Examine th seal for signs of damage and deterioration and if necessary, renow it 4.5p Removing the cylinder head cover sealPetrol engine in-car repair procedures 2A*7 ‘16-valve engines 16-valve engine models Note: Modals fram January 1998 onwards are fitted with plastic camshett covers, rather thant aluminum alloy as before. The procedtire given below is not greatly affected by this Ghange, except that the number of retaining bots for each cover increases, and the bolts are located around the edge of each cover. No lightening sequence for the cover bolls Is quoted by Citroén, so this stage can be Ignored for later models. 8 Referring to Chapter 1A if necessary, disconnect the wiring connector at the lett hand ene of the ignition coil unit, located in the centre of the camshall covers. Unde the Sx retaining hols and lt the coil unit upwards, eff the spark plugs ane fren ies loaation between the eamiahadt cavers (ee ituetration) 7 Remove the Allen bolts from the fuel pipe 48a Disconnect the fuel supply pipe from the fuel pressure regulator and remove the fuel pipe carrier bracket 4d . 4.7a Remove the two Allon bolts... cover, and illustrations) 8 Refer to Chapter 4A and depressurise the fuel system. Taking suitable precautions ‘against fuel spillage, disconnect the fue! pipes {vom the fuel pressure regulator as necessary. Detach the fuel supply and return pipes from the carrier bracket fitted across the camshaft covers. Unscrew the retaining nuts and fomove the fuel pipe carrier brackst (see illustrations). 9 Slacken the retaining clips, and disconnect, the breather hoses from the front left-hand side of the front cover (see illustration). Whore the original crimped type hose: efipss are stil ited, cut thom off and discard them; use standard worm-deve hose sips on remove the cover (see ceiling 40 Working in a spirat sequence starting from the outside and working insane roar slackon, then remove the -+-and the return pipe, releasing it from the plastic clip, 4.9 Disconnect the breather hoses from the front camshaft cover ‘7b ...and lift off the fuel pipe cover retaining studs and bolts from each camshaft cover. On the 1.8 litre engine seen in the ‘workshop, one of the front cover bolts {next to the oil filer cap, nearest the timing belt end} was shorter than the rest, and did not in fact pass through the cover into the camshatt housing! (see illustrations). 11 Lift off each cover in tura and remove it The cover seal should remain attached as the cover is removed - do not ry te remove it, Unless it is obviously damaged Refitting 8-valve engine models 42 Clean the oylinder heag and camshatt iflaces, ane remove all trace cover mating) ete 48 Locate the Hubber seat in the cover a that Ile eovrectly located along ts entice length 4.8¢ Unscrew the retaining nuts . 4.402 Remove the studs .2Ae8 Petrol engine in-car repair procedures 4.10b . . . and retaining bolts. 14 Apply a smear of suitable sealant to each camshaft end bearing cap around the area where the cap contacts the cylinder head mating surface (see illustration). 16 Carefully rofit the camshaft cover to the engine, taking great care not to displace the rubber seal 46 Check that the seal is correctly located, then refit the cover retaining nuts and, working in the sequence shown, tighten them evenly and progressively to tha specified torque (see illustration) 47 Refit the air cleaner element, and install the element cover. Securely tighten the caver retaining screws, and secure itn position with tne retaining clips 48 Rocomwet the breather hoses, duct and throttle housing duct to the cover tightening their retaining clips securely Raconnast the battery 16-valve engine models 19 Clean the cylinder head and camshett ‘cover mating surfaces, and remove all traces ofl. 20 Check the condition of the rubber seal attached to each cover. The seal Is designed to be re-usable, and so should not automatically be replaced unless its condition is suspect. If the seal is broken, it can be repaired using a bead of suitable sealant. 21 Carefully refit the camshaft covers to the engine, 22 Refit the cover retaining bolts and studs and, working in the sequence shown (where Intake applicable}, tighten them evenly and progressively to the specified torque (see illustration. 23 Fisconnect the breather hases to the front ‘cover, and securely tighten the retaining clps. 24 Ratit the ignition coll unit between the camshatt covers. Roft the retaining bolts, tightening them securely, then reconnect the coil unit wiring connector. 25 Rell the fuel pipe carrier bracket to the covers, then refit the fuel pipes to their locations and secure with the fuel pipe cover. 26 Refer to Gnapter 4A, Section 1 and refit ‘the ul rail and fuel injectors. 27 Reconnect the battery nagative terminal ‘On completion, star the engine anc check the fuel hose unions for signs of leakage. 4.10c -.. and remove the camshaft cover - rote the short bolt which does not need to bbe removed (arrowed) ‘nuts in the sequence shown = ‘valve engines A Removal 1 Romove the auxiliary drivebelt (Chapter 1A). 2 To prevent the crankshaft turning whilst the pulley retaining bolt is being slackened, select 4th gear and have an assistant apply the bbrakas firmly. I the engine has been removed from the vehicle, lock the fhwheel ring gear using the arrangement shown (see ‘52 Use a fabricated tool like this one to lock the flywheel ring gear and prevent ‘erankshaft rotation 4.14 Applying sealant to the camshaft end bearing caps vee | 4.22 Camshaft cover fasteners tightening ‘sequence - 16-valve engines iMustration). Do not attampt to lock the pulley by inserting a bol/drill through the timing hole, if the locking pin is in position, ‘temporarily remove it prior to slackening the pulley bolt, then refit it once the bott has been slackened. 3 Unscrew the retaining bolt and washer, then slide the pulley off the end of the crankshatt (see illustrations). If the pulley locating roll pin or Woodruff key (ae applicable} ie a loose ft, remove it and store it with the pulley for safe-keeping. f the pulley is tight ft, t can be drawn off the crankshaft using a suitable puller. 5.38 Removing the crankshaft pulley retaining boltPetrol engine in-car repair procedures 2A¢9 5b Removing the crankshaft pulley from ‘the end of the crankshaft Refitting 4 Ensure the Woodruff key is correctly Jocated in its crankshaft groove, or that the ral pin is in postion {as applicable). Rofit tha pulay to the end of the crankshaft, aligning its locating groove or hole with the Woodruff key pin, 5 Thoroughly clean the threads of the pulley Fetairing bolt, then apply a coat of locking compound to the bolt threads. Citro&n recommend Loctite {available from your Citrotn dealer); in the absence of this, any good-quality locking compound may oe sed, 6 Refit the crankshaft pulley retaining bolt and washer. Tighten the bolt to the spscttisd torque, preventing the crankshatt trom turning ising the method employod on removal, 7 Refit and tension the aunilary drivebelt as decribed in 6.10 Removing the auxiliary drivebelt tensioner assembly ‘6.10b Unscrew the retaining bolts 68a Upper timing belt cover retaining bolts (arrowed) 6 Timing belt covers - removal and refitting WE 1.6 and 1.8 litre 8-valve models Upper cover 4 Release the rataining lps, and free the fuel hoses from the top ofthe cover. 2 Undo the two cover retaining bots (situated at the base of the cover, and remove the Cover from the engine compartment Gentre cover 3 Slacken and remove the two cover retaining bolts focated dirgetly bonoatt the mounting backal), Move the cover upwards to tree i fromm tho wo locating pis situated at the bse of the cover, and remove it from the engine ‘compartment. Lower cover 4 Flemove the erarikshatt pulley (Section 5). 5 Flemove the centre cova: (paragraph 3). 6 Undo the two cover retaining bolts, and remove the cover from the enging. Note that fon some mode's it may be necessary to Unbolt the auxiliary. drivebelt tensioner assembly and remove It from the engine in tard to allow the cover to be removed 2.0 litre 8-valve models Upper cover 7 Release the retaining clip, anc free the fuel hoses from tha top of the timing belt cover. 6.10e . .. and remeve the lower timing, 6.8b Removing the upper timing belt cover 8 Slacken and remove the two eover retaining bolts, then lft the upper cover upwards and out of the engine compartment (see illustrations) Lower cover 8 Remove the crarkshatt pulley (Section 5) 40 Slacken and remove the three retaining bolts, then remove the lower timing belt cover from the engine. Note that on some models it may be necessary to unboit the auxiliary drivabelt tensioner assembly and ramove it from the engine in order to allow the cover to be removed (see illustrations) Refitting 14 Refitting is a revarsal of the rolovant removal provadure, ensuring that each cover section is comreelly oeated, snd that Me Cover retaining nuts and/or bolts are securely tightened! to the specified torqua, where ven, 1.8 and 2.0 litre 16-valve models Upper (outer) cover 42. Unclip the wiring harness from its iovation in the shaped top of the engine right-nand ‘mounting, and from the inlet manifold bracket {600 illustrations). Where applicable, reloase ‘he air conditioring hose which runs between the timing belt cover and the engine mounting. Move the hose end wiring hemes, to one side (do NOT attempt to disconnect the air conditioning hose} 18 Prise out the clips and remove the trim ‘cover trom the top of the engine right-hand mounting (s¢e illustrations). 6.12a Unclip the wiring hamess from the ‘engina mounting . ..2Ae10 Petrol engine in-car repair procedures 6.12b .... and from the inlet manifold bracket 44 On models up to 1999, lift the tab provided in the contre of the timing belt cover upwards to release the centre locating pegs {see illustration). 15 Unscrew and remove the thros upper relaining screws, and withdraw the timing belt ‘cover (see illustrations). Recover the rubber pads from the centre locating pegs, where applicable. Lower cover 16 Remove the crankshaft pulley (Section 5) 17 Slacken and remove the retaining bolts, then remove the lower timing belt cover trom the engine. Note that on some models it may bbe racessary to unbolt the auxiliary deivebelt tensioner assembly and remove if (rom the engine im oreter fe allow the cover te Be removes. Upper {inner) cover 48 Remove the timing belt ag aeacribed in Section 7 19 Remove both camshait sprockets as described in Section 8, 20 Remove the six bolts securing the cover to the side of the cyinder head, the cover from the engine. Refitting 21 Rofitting Is a reversal of removal. When refitting the upper (outer) cover with the locating tab, ensure that the rubber pads are In place on the centre locating peas, where applicable. Locate the cover in place over the ‘centre and lower pegs, then press the centre of the cover inwards to engage the locating pegs, and secure by lowering the plastic tab. 6.14 Lift up the locking tab in the centre of the cover 6.19a Using a suitable tool, rolease the retaining olips ..- Refit and locate all other components securely 7 Timing belt - & general information, x Temoval and refitting x Note: Citroen specify the use of a special electronic too! (SEEM 4122-7) to conectly sot tho timing belt tension, access t0 this equipment cannot be abtained, an approximate setting can be achieved using the method described below. If the mathod daseribed is used, the tension must be checked using the Special electronic tool af the earliest possible eaeertunity: Devnet dre distances, oF wse high engine speadis. unt te Bait tenon fe Arow to BS CORTECR, AMET TO a Citroen aealer tor acne. General information 1 The timing belt drives the camshati(s) and coolant pump from a toothed sprecket on the front of the crankshaft. If the alt breaks or slips in service, the pistons are likely to hit the vaive heads, resulting in extensive (and expensive) damage. 2 The timing belt should be renewed al the ‘Specified intervals (see Chapter 1), or earlier If itis contaminated with oll, or fit is at all Noisy in operation (a ‘scraping’ noise due to uneven wear) 3 Ifthe timing belt is being removed, itis a wise precaution to check the condition of the coolant pump at the same time (check for ‘signs of coolant leakage). This may avoid the reticle over Fa 6.15a Remove the Allen screws arrowed) .- 6.13b . the top of the engine mounting need to remove the timing belt again ata later stage, should the coolant pump fal Removat 4 Disconnect the battery negative terminal 5 Jack up the front of the vehicle and support it on axle stands (see “Jacking and vehicle support"), Remove the right-hand front wheel 6 To improve access, refer to Section 18 and remove the engins right-hand mounting. This is not essential, but it does make several of the timing belt components much easier to remove with the engine in the cer. 7 Where applicable, prise out the clips and unbelt the inner splash guara. 8 Remove the auxliary dhiveboll as described ln Chapter 14, Where applicadie, unbolt and wmove tle aunifiary deivebett tensioner 9 Remove the timing belt user (UNE) COVE with reference to Section 6, 10 Align the engine assembly/ealve timing holes as described in Section 3, and lock the camshaft sprockei(s} in position. Do not attempt to rotate the engine whilst the pins are in position. 11 Remove the crankshaft escribed in Section 5. 12 On 18 and 1.8 lie 8-valve models, remove the centre and lower timing belt covers as described in Section 6. On all other models, unbolt and remove the timing belt lower cover (refer to Section 6 if necessary). 19. Aft the crankshaft pullay, and tighton the bolt moderately, holding the engine against rotation as fer removal. Fit the locking too! through the crankshatt pulley, to prevent rotation, pulley as and lift away the upper coverPetrol engine in-car repair procedures 2A¢11 we 14 Loosen the timing belt tensioner pulley ralaining bolt (eee illustration). Pivot the pullay In a clockwise direction, using a suitable square-section key fitted to the hole in the pulley hub, then securely retighton the fatzining bol 15 If the timing bell is to be re-used, use vfite paint or chalk to mark the direction of rotation on the belt (f markings do not alrandy ‘xs then slip the belt off the sprocket Wustration). Note that the crankshelt must, ol berated wisi es belt is rernoverd 46 Check the timing belt caretully tar say sins of uneven wear, splitting, or oil conlarination. Pay particular attention to the rots of the tacth. Renaw it if there is the sightest doubt about its condition. If the ongine Is undorgoing an overhaul, and has covered more than 36 000 ries (G0 000 km} wit the existing belt fitted, renew the belt as a inattar of course, regardiass of its apparent cordition. The cost of a new belt is nothing compared with the cost of rapairs, should the belt break in service. If signs of oil contamination are found, race the source of the oil leak and rectify it. Wash down the engine timing belt area and all related componants, 16 remove all traces of ol Refitting B-valve engine models 17 Belore refitting, thoroughly clean the tining belt sprockets. Check that the tensioner pulley rotates freely, without any sign of roughness. If necessary, renew the tensioner pulley as described in Section 8 48 Enaure that the camshaft sprocket and crankshaft pulley locking pins. are stil in poston. 49 Manoauyre the timing belt into position, ensuring that any arrows on the belt are pointing in the diraction of rotation (clockwise when viewed from the right-hand end of the engine, 20 Do not twist the timing belt sherply while ‘ofiing it. Fit the bolt over the crankshaft and 714 Release the belt tensioner retaining bolt camshaft sprockets {it preferred, the crankshaft pulley can ba removed for this stage, but ensure that the crankshaft is not moved from its reference position). Ensure ‘that the belt "front run" is taut - e., any slack should be on the tensioner pulley side af the bell, Fil the belt over the water pump sprocket and tensioner pulley (See illustration). Ensure that the belt teeth are sated cently in the eprockets 21 If removed, refit the crankshatt pulley at this stage and tightan the bolt moderately. thon refit the locking pin. Note: The: timing belt i tensioned with the timing covers removed, than the crankshaft pulloy is removed again to fit the belt lower cover, before boing tially refitted. 22 Loosen the tensioner pulley retaining bok. Using the square-section key, pivot the pulley anti-clockwise to remove all free play from the timing bet 23 If the special belt tension measuring fequigment is available, it should be fitted to the “front run” ofthe timing belt, Tre tensioner roller should be adjusted so that the intial bait tension is 16 «2 units on 2.0 lire models, and 302 units on 1.6 an 1.6 litre models. 24. Remove the locking pins, then rotate the ‘ranishalt through two complete rotations in a clockwise direction {viewed from the right- hhand end of the enaine). Realign the camshaft and crankshaft engine assembly/vaive timing holes (see Section 3). Do not at any time rotate the crankshaft anti-clockwise. Both camshaft and crankshaft timing holes sheule be aligned so that the locking pins can be ‘easily inserted, This indicates that the valve timing Is correct. I alls wal, ramave the pins. 25 If the timing holes are not comrectiy positioned, repeat the fitting procedure so far. 26 ‘ifthe fension is being set without using the special measuring tool, proceed as follows. Check thal, under moderate pressure from the taumb and forafinger, the belt can [ust be twisted through 90° at the mid-point of the “front run” of the belt. Note that this mothod is only an initial setting, and the belt 7.45 Lift the timing belt off the sprockets tension must be checked at the earliest available opportunity using the spacial ‘measuring tool, Failure to do so could lead to ‘the belt breaking (through over-tightening) or “jumping a tooth" (through slackness), resulting in serious engina damage. IF necessary, readjust the tensioner pulley position as required. Tighten its retaining bolt to the specified torque on completion 27 Ui the special measuring tool is being used, rotate the crankshaft fwe mare tures without tuming backwards and refit the ‘camshaft Jocking pin, then check that the final belt tension on the taut “front run” of the belt ip 44 x 2 units. If not, repoat the complete iting procedure, 28 With the bel tension correctly sat remove the camshaft locking pin, then remove the crankshatt pulley and refit the timing cover(s). 29 Rofit the crankshaft pulley out this time Apply locking fluid to the threads of the bolt before inserting it. Tighten the belt to the specified torque and refer to Section 5 if necessary. 16-valve engine models 380 Before refitting, thoroughly clean the timing belt sprockets. Check that the tensioner and idler pulleys rotate freely, without any sign of roughness. if necessary, renew the pulleys as cescrited in Section 8, 7.20 Fit the timing belt over the water pump sprocket2Ae12 Petrol engine in-car repair procedures 31 Ensure that the camshaft spracket locking pins are stil in position. Temporarily refit the crankshaft pulley (f removed), and insert the locking pin through the pulley timing hole to censure that the crankshatt is still correctly positioned. 32 Without removing the locking pins, on ‘models up to 1998, slacken the six camshatt sprocket retaining bolts (three on each sprockel). On models after 1998, only the single bolt securing each camshatt sprocket need be slackaned. Check thal both sprockets are free to turn within the limits of their elongated bolt holes, or that the protruding lug on single-boll sprockets can move within its limits (see illustrations}. 38 Tighten tho camshaft sprocket retaining bolts finger-tight, then slacken them ali by one sixth of a tum. 84 Again without removing the locking pins, tum each camshaft sprocket clockwise to the fends of their retaining bolt slots, or until the protruding lug reaches the end ofits travel. 35. Remove the crankshaft pulley. Manoeuvre: ‘the timing bolt into position on the crankshaft sprocket, ensuring thet any arrows on the belt are pointing in the direction of rotation (clockwise when viewed from the right-hand ‘ond af tha engine) 36 Refit the timing belt lower cover and the crankshaft pulley (Sections 6 and 8), 87 With the timing belt engaged with the ‘crankshaft sprocket, keep it tight on its right- hand run and engage it with the front idler pulley then up and into engagement with the inlet carnshaft sprocket. 38 Keeping the belt fight and rotating the inlot camshaft sprocket anti-clockwise a3 necessary, feed the belt over the exhaust camshaft sprocket, taking care not to let the belt jump a tooth on the crankshatt sprocket a its being fited, 39 While still keeping the bolt tight, fesc it over the rear tensioner pulley and finally around the caolant pump. 40 If the special belt tension measuring 7.82a Slacken the camshaft sprocket retaining bolts (arrowed) 7.82b Camshaft sprocket details - models up to 1988 (A) have throe retaining bolts (1) in elongated slots, while models after 1998 have a single bolt and a protruding lug (2) equipment is available, proceed as described in paragraphs 41 to 81, and then to paragraph 58 onwards. Ifthe tension is being set without the use of the special measuring equipment, proceed to paragraph 52. 41 If the special belt tension measuring equipment is available, it should be fitted 10 the *front run” of the timing belt. The tensioner Pulley should be adjusted, by turning it anti- ‘clockwise to give a bolt pro-tensioning setting ‘of 45 units. Hold the tensioner pulley in this, position and tighten the retaining bolt to the specified torque. 42 Check thal the sprockets have not been tuned so far that the retaining bolts are at tho fand of their slots, or that the protruding lug on single-bolt sprockets is at the end ofits travel If either condition is evident, repeat the refiting operation. I all is satisiactory, lighten the sprocket retaining bolts to the spectfied torque, 43, Ramovo the locking pins, then rotate the crankshait through two complete rotations a clockwise direction (viewed from the right- hand end of the engine). Realign the crankshall engine assembiy/valve timing hole and refit the locking pin to the crankshaft pulley. 44 Slacken the camshaft sprocket retaining bolts, retighten them finger-ticht, thon siackon thom all by one sixth of a turn, 45 Relit the camshaft sprocket locking pins, thon slacken the tensioner pulley retaining bolt once more. Refit the belt tension measuring equipment to the front run of the belt, and turn tha tensioner pulley to give a final sotting of 26 units (models with three bolls per camshaft sprocket) or 32 units (single-bolt sprocket. models) on the tensioning gauge. Hold the tensioner pulley in this position and tighten the retaining bolt to the specified torque. 46 Retighten all sprocket retaining bolts to the specified torque, 47 The belt tension must now be checked as follows. Remove the locking pins, then rotate the crankshaft once again through tvs complete rotations in a clockwise direction Foalgn the crankshaft engine aesembly/vahe timing hole, and refit the locking pin to te crankshaft pulloy. 48 Slacken the cemshatt sprocket retaining bolts, tighten ther finger-tght, then slacker them all by one sixth of a turn 49 fil tho camshail sprocket locking pirs turning the sprockets slightly if required Tighten tho camshaft sprocket retaining bot to the specified torque. 50 Flemove the camshaft and cranksha locking tools. Turn the cranksnatt approx imately one quarter of a tum in the norma direction of rotation, unl the locking too! hal in the erankshatt pulley is aligned with te timing belt ower cover font retaining bolt. Its imporent thet this position is achieved ONLY ay turing the belt forwards ~ ifthe belt fumed back at alto achieve alignment, the bot tension check will not be vai 51 Inthis position, rfitne tension moasuring equipment to the front run of the belt, and ‘check that the reading is between 32 and 4 units. If not, the entire bel tensioning procedure must be repeated trom the start 52 I the tension Is being set without the usa fof the special measuring equipmant, the tensioner pulley should be acusted, by turning it anti-clockwise, until all tree play s removed from the belt. Hold the tensioner pulley inthis position and tighten the retaining bolt to the specified torque. 53 Cary out. the check described in paragraph 42. If alls sat stactory, tighten a proce! retaining bots to the specified torgu 4 Remove the locking pins, then rotate the crankshaft through two campiste rotations ine ockwise direction (iewec from the right-hand fend of the engine). Realign the crankshat engine assemblytalve ting hole, and refit locking pinto the erarksht pul. 155. Slacken the camshaft sprocket retaining bots, rstighton them finger-tight, then slacken them ail by one sixth of a turn,Petrol engine in-car repair procedures 2A*13 56 Refit the camshatt sprocket locking pins, than slacken the tensioner pulley retaining bolt once more. Turn the tensioner pulley to tension the belt until, under moderate pressure from the thumb and forefinger, the bel can just be twisted through 43° at the mid-point between the inlet camshaft sprocket and the idler pulley. Note that this method is only a provisional setting, and the batt tension must be checked at the earliest ‘opportunity using the special belt tonsioning oqulament. Failure to do this could lead to the bet breaking (through over-tightening) or Sipping (Hhrough siackness), resulting in serious engine damage. With the tension set, hold the tensioner pulley inthis position, and Lighten the retaining bolt to the specified torque. 57 Retighten all sprocket retaining bolts to the specified torque. 58 Once the belt tension has been correctly fal, refit the engine right-hand mounting components as described in Section 18. 59 Felt the timing belt upper, contre and lower covers (as applicable) as described in Section 6. 60 Refit the auriliary drivebelt tensioner then ‘oft and tension the crivebelt with reference toChapter 1A. 41 Felt the inner splash guard and front fgft-nand whee, then lower the vehicle to the ‘round. 62 Reconnect the battery negative terminal 8: Timing bel tensioner ana "sprockets - removal, inspection and refitting & x Note: This Section describes the removal and feftting of the components concemed as invita! operations = if more than one is 10 be removed at the same time, start by remaving the timing belt as described in Section 7; remove the actual component as Sescribed below, ignoring the preliminary ismanting steps. Removal 1 Disconnect the battery negative terminal. 2.Align the engine assembly/valve timing holes as described in Section 3, locking the camshaft sprockat(s) and the crankshaft pully in position, and proceed as described under the relevant sub-heading. Do not attempt to rotate the engine whilst the pins ‘vin position. Once the sprockets have been removed, their shafts should not be turned. ‘Camshaft sprocket - Salve engine models 3 Remove the timing belt upper cover as escrived in Section 6. 4 Loosen the timing belt tensioner pulley retaining bolt. Rotate the pulley in a clockwise tieection, using a suitable square-saction key fited to’ the Aole in the pulley hub, then ralighton the retaining bot. 5 Remove the locking pin from the camshatt sprocket. Disengage the timing belt from the sprocket and position it clear, taking care not ‘to bend or twist the belt sharply. 6 Slacken the camshaft sprocket retaining bolt and remove It, along with its washer. To prevent the camshatt rotating as the bolt is slackened, a sprocket holding tool will be required. In the absence of the special Citron tool, an acceptable substitute can be fabricated at home (gee Tool Tip). Do aor attampt to use the sprocket locking pin to prevent the sprockat from rotating whilst the bolt is slackened, 7 With tho retaining bolt removed, slide the sprocket off the end of the camshaft. If the locating peg is a loose fit in the rear of the sprocket, romovo it for safe-keeping. Examine ‘the camshaft oil seal for signs of oil leakage and, If necessary, renew it as described in Section 9, Camshaft sprockets - 16-valve engine models, 8 Remove the timing belt upper (outer) anc lower covers as described in Section 6. 9 For Improved access, support the engine fon a jack, and remove the right-hand engine mounting components as doseribed. in Section 18. 40 Loosen the timing belt tensioner pulley retaining bolt and pivot the pulley in 2 clockwise direction, using a suitable square- section key fitted to the hole in the pulley hub, then retighten the retaining bot. 11 Check that the camshaft sprocket locking pins are stil in position, then cisengage the liming belt from the camshaft sprockets anc position it clear, taking care not to bend or twist the belt sharply. 42 If the early-type sprockets are to be removed without thelr hubs, undo the three retaining bolts anc remove the relevant sprocket, Suitably merk the sprockets “init” and/or “exhaust” as they are removed {although in fact the sprockets are identica). 18 If both the sprockets and the hubs are to be removed, remove the sprocket locking pins, then slacken the sprocket hub centre retaining bolt. To prevent the sprockets rotating as the bolt is slackened, a sprocket holding tool will be required. in the absence of the special Citroén tool, an acceptable substitute can be fabricated at home (see Tool Tip). Do not attempt to use the sprocket locking pin to provont the sprocket from rotating whilst the bolt is stackened 44 Unc the retaining bolt(s} and remove the relevant sprocket. Remove the previously- slackened hub retaining bolt, and withdraw the hub from the end of the camshalt. Note that the hubs are marked fer Identification with a single digit on their front face. On 1.8 litra models, the inlet hub is marked “1" anc the exhaust hub is marked "2". On 2.0 litre models, the inlet hub is marked “3” and the exhaust hub is marked “4”, Make your own markings if none are visible, camshaft sprocket whilst the sprocket retaining bol is tightened Crankshaft sprocket - 8-valve engine models 415. Remove the upper, centre and/or lower timing belt coverts) (as applicable) as scribed in Section 6. 16 Loosen the timing bolt tonsioner pulley retaining bok. Rotate the pulley in a clockwise Girection, using @ suitable square-section key fitted to the hole In the pulley hub, then ratighten the retaining bot. 17 Disengage the timing belt from the Crankshaft sprocket, and slide the sprockot aff the end of the crankshaft. Remove the ‘Woodruff key from the erankshaft, and store it with the sprocket for safe-keeping. Where necassary, also slide the spacer (where fitted) aff the end of the erankshat. 48 Examine the crankshaft oll seal for signs of oil leakage and, if necessary, renew it as described in Section 18. Crankshatt sprocket - 16-valve engine models 19 Remove the timing belt upper (outer) and lower covers as described in Section 6, 20 For Improved access, support the engine fon a jack, and remove the right-hand engine mounting components as described Section 18. 21 Loosen the timing belt tensioner pulley retaining bolt, and pivot the pulley in a clockwise direction, using a suitable square- section kay fitted to the hole in the pulley nub, then retighten the retaining bolt. 22 Check thal the camshaft sprocket locking pins are still position, then disengage the iming belt from the crankshaft sprocket, and slide the sprocket off the end of the crankshaft, Remove the Woodruff key from the crankshatt, and store it with the sprocket for safa-keeping, 23 Examine the crankshaft oil seal for signs of oll leakage and, if necessary, renew it as described in Section 16. Tensioner pulley - &-valve engine models 24 omove the upper and where necessary the centre timing belt covers as desenibed in Section 6,214 Petrol engine in-car repair procedures 25 Slacken and remove the timing belt tensioner pulley retaining bell, and slide the pulley off its mounting stud. Examine the mounting stud for signs of damage and if nocassary, renew it. Tensioner and idler pulleys - 16-valve engine models 26 Remove the timing belt upper (outer) anc lower cavers as described in Section 6. 27 For improved access, support the engine fon a jack, and remove the right-hand engine mounting components as described in Section 18, 28 Loosen the timing belt tensioner pulley retaining bok, and pivot the pulley in « clockwise direction, using a suitable square- section key fitted to the hole in the pulley hub, then retighten the retaining bo. 29° Chock that the camshaft sprocket locking pine are stil in position, then disengage the timing belt from the camshaft sprockets and position it clesr, taking care net to bend or tusist the belt sharply. 30 Undo the tensioner and idler pulley retaining bolts, and remove the pulleys from the engine, Inspection 34 Clean tho camshatt/crankshatt sprockets thoroughly, ancl renew any thal show wigs of wear, damage or arch. 33 Clean the tonsionoridier pulleys, but do hot use any strong solvent, ast ay ae A pully boarings, Check that the pulleys rotate realy, with no zigh of stiffness or free play Renew them if there is any doubt about thei canaition, or it there ere any obvious signs of ‘weer or damage. Refitting ‘Camshatt sprocket - 8-valve engine models ‘33 Refit the locating peg (where removed) to the rear of the sprocket, Locate the sprocket ‘on the ond of the camshaft, ensuring that the locating peg is correetly engaged with the ‘cut-out in the camshaft enc. 34 Refit the sprocket retaining bolt and washer, and tighten it to the specified torque. Retain the sprocket with the tool used on removal 35. Realign the hole in the camshaft sprocket with the correspending hole in the cylinder head, and refit tne locking pin. Check that the coranikshatt pulley locking pin is stil In position, 36 Flefit the timing belt to the camshaft sprocket, Ensure that the "front run” of the ball is taut - Le., that any slack is on the tensioner pulley side of the belt. Do not twist the belt sharply while refitting it, and ensure that the belt teeth are seated centrally in the sprockets. 37 With the timing belt correctly engaged on the sprockets, tension the belt as described in Section 7, 38 Once the belt's correctly tensioned, refit ‘tien erin helt Comets ae Section B Camshaft sprockets - 16-valve engine models 29 If both the sprockets and the hubs have been removed, engage the sprocket hub with the camshaft. Ensure that the correct hub is, fitted to the relevant camshaft by observing the hub identification markings described in paragraph 14) 40 Refit the sprocket retaining bolt and ‘washer, and tighten it to the specified torque. On models with the early-type three-bolt sprockets, temporariy refit the sprockets, 10 allow the hub to be held stationary with the tool as the bolt is tightened. 41 Turn the hub so that the locking pin can bbe engaged. 42 If the three-bolt sprockets have been removed, leaving the hubs in place, position the sprocket on ils hub, and refit the three bolts finger-light only at this stage. Ensure that the correct sprocket is fitted to the relevant camshaft according to the identification made on removal (soo paragraph 12). 43 Relocate and tension the timing bell as described in Section 7. If removed, raft the engine right-hand mounting as described in Section 18, Crankshaft sprocket - 8-valve engine models 48 Slide me spacer (where fitted late postion, taking graat eare nat to darnage The ‘slankshaft od, and refit the Woodult Key to ta Slot in the crankshaft on 45 Slide on the crankshatt sprockat, aligning its slot with the Woodruff key. 4G Ensure that the camshaft eprocket locking pin js still in position. Temporarily refit the trankshaft pulley, and insert the locking pin through the pulley timing hola, to onsure that ‘the crankshaft i stil correctly positioned. 47 Remove the crankshaft pulley. Engage the timing belt with the crankshaft sprocket. Ensure that the belt "front run” is taut - .e., that any slack is on the tensioner pulley side Cf the belt, Fit the belt over the water pump sprocket and tensioner pulley. Do not twist the bell sharply while refitting it, and ensure that the bell teeth are seated centrally in the sprockets, 43 Tension the timing belt as described in Section 7, 49 emove the crankshatt pulley, then refit the timing belt cover(s) as doscribed in Section 6, 180 loft the crankshaft pulley as described in Section 5, and reconnect the battery negative termina Crankshaft sprocket - 16-valve engine models 51 Refit the Woodruff key to its slot in the Crankshaft end, 52 Slide on the crankshaft sprocket, aligning Its slot with the Woodruff key. 59 Relocate and tension the timing belt as described in Section 7. If removed, refit the engine right-hand mounting as described In Section 18. Tensioner pulley - 8-valve engine models 54 Reiit the tensioner pulley to its mounting Stud, and tthe retaining bolt ‘55 Encuro that the “front run" of the bel |s taut Le, that any slack is on the pulley sce ‘of the bell. Check that the belt is centraly located on al its sprockets. Rotate the pues anti-locktvise to remove al fre play from tho timing belt, and securely tighten the pulley relaining nut ‘86. Tonsion the belt as described in Section 7. 57 Once the belt is correctly tensioned, ret the timing bell covers as described In Section 6 Tensioner and idler pulleys - 16-valve engine models 158. Rofit tho tensioner and idler pulleys and secure withthe retaining bolts. 59 Alslocate and tension the timing belt as described in Section 7. If removed, refit tha engine right-nené mounting as deseribed in Section 18. © Camehatt oll soat(a) - x renewal s g Note: If the camshaft oil soal is to be renewed with the timing belt stil in place, check frst that the belt is frae from oll contamination. (onew the belt as a matter of course if signs of olf contamination are found: see Section 7. Cover the pelt, to protect it from contamination by olf, while work isin progress. if the timing belt is removed, ensure that ai traces of oll are removed from the area before the bolt is refitted. 1 Romove the camshaft sprocket(s) as described in Section 8. On 16-vaive engine models, remove the sprockels and sprocket hubs. 2 Punch or drill two small holes opposite ‘each athor in the oll seal. Screw a self-iapping screw into each, and pull on the screws with pliers to extract the seal 3 Clean the seal housing, and polish off any burrs or raised edges, which may have ‘caused the seal to fail inthe first place. 4 Lubricate the lios of the new seal with olean engine oil, and drive It inte position unti it seats on ils locating shoulder. Use a sultable tubular drift, such es a seckst, which bears ‘only on the hard outer edge of the seal. Take ‘care nat to damage the seal lips during ftin. Note that the seal lips should face inwards. 5 Refit the camshaft sprockets) as described in Section 8,Petrol engine in-car repair procedures 2A*15 10 Camshatt(s) and followers - removal, inspection and refitting He Removal 1 Disconnect the battery negative terminal, then remove the camshaft cover as described in Section 4, Proceed as described under the relevant sub-heading S-valve engine models 2Remove the camshaft descrioed in Section 8. 3 Remove the ignition HT coll as described in Chapter 5B. 4 With the coll removed, slacken the upper boll securing the thermostat housing to the lefthand end of the cylinder head. Remove ‘he boit, along with its sealing washer. This is nocessery since the bolt screws into the left= and (No 1) camshatt bearing cap, 8 Garefuly ease the oll supply pipe out from the top of the camshaft bearing caps, and remove it. Note the O-ring seals flited to each ofthe pipe unions (see illustration). Also note ‘he position of the adapters at each end of the supply tue. 8 The camshaft bearing caps should be rumbered 1 ta 8, number 1 belng at the transmission end of the engine. Int, make ‘enteation marks on the caps, using white paint or a sultble marker pen. Also mark each cap in some way to indicate its correct ‘ited oxtentation. this will avoid the possibitity of instating the caps the wrong way aroun! onrefting, 7 Evenly and progressively slacken the camshaft bearing cap retaining nuts by one ‘um at a time, This will relieve the valve spring pressure on the bearing caps gradually and evonly. Onc the pressure has been relieved, the nuts can be fully unscrewed and removed (see illustration). 8 Note the correct fitted orientation of the bearing caps, then remove them from the cyinder head (see illustration). 8 Lift the camshaft away from the cylinéer head, and slide the oll seal off the camshaft end (see illustration). 40 Obtain eight smal, clean containers, and number them 1 aheratively, divide a larger container into eight compartments, Using a rubber sucker, witrdraw each follower in turn, and place it in Itsrespective container. Do nat interchange the cam followers, or the rate of wear willbe much= increased. Hf necessary, also remove the shim from the top of the valve stem, and store it with iis respective follower. Note that the shim may stick to the inside of the follower as it is withdrawn. If this happens, take care not to alo to drop out aa the follower is removed. 16-valve engine models 41 Remove bath camshaft covers as eactibed in Section 4, sprocket as 10.5 Removing the oil supply pipe from the ‘camshaft bearing caps 42 Refer to Section 8 and remove both camshaft sprockets together with their hubs, and also remove the liming belt tensioner puley. 19 Remove the timing belt upper (inner) ‘cover as described in Section 6. 14 Progressively siackon, a litle at a time, the twelve bolts securing each camshaft bboaring housing to the cylinder head. Release the bearing housings from their doviels and cylinder head locations. When each housing is, free, remove the bolts and washers ‘completaly, and lft off the bearing housings. 418 As both camshafts are identical, suftably mark them “inlet” and “exhaust”, or front” and “rear” hefora remo 46 Tilt the camshafts by prossing them down at their transmission end to releaso the ccantralising bearing a the timing belt end. ‘Carefully it the camehatts up and out of their loeations, and slide the oil geal off each ‘amshait end. 17 Obtain sixteen email, clean plastic containers, and number them inlet 1 to 8 anc exhaust 1 to 8; alternatively, divide a larger container into sixteen compartments, and ‘number each compartment accordingly. Using fa rubber sucker, withdraw each hydraulic tappet in turn, and place it in its respective container. Do not interchange the tappets, or the rate of wear will be much increased. Inspection 48 Examine the camshaft bearing surfaces and cam lobes for signs of wear ridges and scoring, Renew the camshaft if any of these ceonditions are apparent. Examine the condition and remove the camshaft bearing caps... “10.7 Working as described in the text, unscrew the retaining nuts . cof the bearing surfaces, both on the camshaft Journals anc in the eylindar head/bearing caps. If the head bearing surfaces are wom ‘excessively, the cylinder head will need to be renewed, If suitable measuring equipment is ‘available, camshaft bearing journal woar can be checked by direct measurement (where the necessary specifications have been quoted by Citroen), noting that No 1 journal is at the ‘Wansmission end of the head, 49 Examine the cam fellower/hydraulic tappet bearing surfaces which contact the ‘camshaft lobes for wear ridges and scoring. Fenow any fellowor/tappet on which these ‘conditions are apparent. If follower/tappet benring surface fs badly scored, also examin the corresponding lobe on the camshatt for ‘waar, a it is Hkely that both will be worn. onow worn components as necessary, Refitting B.valve engine models 20 Where removed, refit each shim to the lop of ils original vaive stem. Do not interchange the shims, a9 this will upsot the valve Clearances (see Section 11). 21 Liberally oll the cylinder head cam follower bores anc the followers, Carefully refit the followers to the cylinder head, ensuring that each follower is refitted to its ‘original bare. Some care will be required to ‘enter the folowers squarely into their bores. 22 Liberally oll the camshaft bearings and lobes, then refit the camshaft to the cylinder hoad. Temporarily refit the sprocket to the end of the shaft, anc position it so that the sprocket tiring hole is aligned with the « then lft the camshaft away from the cylinder head