Refitting: engine (ET3J4) Citroen C2 I

Recommended tools

[10] belt retaining spring (-) 0188.K

Preliminary operation

Check

• The cylinder block (see the relevant operation)
• The crankshaft (see the relevant operation)
• The piston / piston ring assemblies (see the relevant operation)
• The cylinder head (see the relevant operation)
• The camshafts (see the relevant operation)

Clean the joint face and the threads of the cylinder block carefully

Refitting

Fit the rings using ring pliers

• (1) compression ring
• (2) conical sealing ring
• (3) scraper ring with its spring

Direct the TOP marks upwards

Stagger the piston ring gaps at 120° in relation to the gap in the scraper ring

Oil the pistons

Place ring collar [5]

Moderately tighten

Position the piston on the liner to obtain on fitting

• Alignment of the liner/cylinder block marks
• Directing of the arrow on the piston to the timing side

Push the piston into the liner until the clip [5] is released

Proceed likewise for the other three bearing sets

Fit a new seal (4) on each liner taking care not to twist it

Refit the liner/conrod/piston assemblies in the cylinder block, complying with the location marks made on removal or checking of the liner protrusions

The arrow marked on the piston should point towards the valve timing end

Fit the liner retaining clamps [7] with the bolts [8]

Refit the half bearing shells (5) (cylinder block side)

Bearings 1;3;5 = plain half bearing shells (cylinder block and bearing cap casing)

Bearings 2;4 = grooved half bearing shells (cylinder block and bearing cap casing)

Oil the bearing shells and the journals

Position

• The crankshaft (6)
• The side stop thrust washers (7), grooved face in contact with the crankshaft (see "specifications: crankshaft and half bearing shells")

Place a dial gauge on the nose of the crankshaft, using the tools [9]

Push the crankshaft in one direction, to the stop

Set the dial gauge to zero

Push the crankshaft in the opposite direction, to the stop

There should be an endfloat of 0,07 to 0,27 mm

Oil and fit the conrod half shells (see "specifications: conrods and bearing shells")

Refit the conrod caps (8)

Tighten the conrod cap nuts to 3,7 m.daN

Refit

• The cotter (9)
• The oil pump chain (11) and sprocket (10) assembly

Fit the crankshaft bearing cap casing (12) with its half shells (grooved on bearing 2 and 4)

Oil the half-bearing shells (5a)

Check that the centring pins are present on the cylinder block

Coat the joint face of the block with a thin, even layer of sealing paste "E10"

Fit the crankshaft bearing caps (12)

Tightening method for the screws

• Tighten the bolts (13) to 2,0 m.daN
• Angular tighten the screws (13) to 44 ° (tighten in a spiral starting from the centre)
• Tighten the bolts (14) to 0,8 m.daN

Check that the centring pin is present (15)

Refit the oil pump (16)

Tighten the bolts (17) to 0,9 m.daN

Coat the joint face of the block (b) with a thin, even layer of sealing paste "E10"

Refit the sump (18)

Tighten the securing bolts to 0,8 dan.m

Flywheel side

• Fit the ring seal (new) (see "removing-refitting: dynamic seals")
• Fit the oil gallery plug and tighten to 3,0 m.daN

Refit the engine flywheel

Insert the flywheel stop [4]

Tighten the flywheel screws

Timing gear side

• Fit the ring seal (new) (see "removing-refitting: dynamic seals")
• Fit the oil gallery plug and tighten to 3,0 m.daN

Check the presence of the keyway (9)

Refit the crankshaft gear (19)

Tightening of the bolt (20)

• Pre-tightening to 4,0 da.Nm
• Angular tightening to 45°

Remove the stop [4]

Check that the seal (23) and the pins (24) are present

Refit the coolant pump bracket (22)

Tighten

• The bolts M6 (21) to 3,0 da.Nm
• The bolts M8 (25) to 6,5 da.Nm

Refit the coolant pump (26) using a new seal

Tighten the bolts (27) to 1,6 m.daN

Refit

• The roller tensioner (28) (tighten to 2,1 m.daN)
• The tensioning roller (29) (tighten to 2,1 m.daN)

Fit the centralising pins (30)

Turn the crankshaft in the normal direction of rotation so that it can be pegged

Position the flywheel peg [1]

Remove the liner retaining clamps [7] (aluminium cylinder block)

Refit the cylinder head (31) and its new gasket (32) (inscription TOP uppermost)

Apply engine oil to the threads and under the heads of the cylinder head bolts

Pre-tighten the bolts to 2,0 dan.m; using tool [6]

Angular tightening to 200°; using tool [6]

A: Induction camshaft

B: exhaust camshaft

Lubricate the cams and the camshaft bearings (engine oil)

Refit the camshafts in the cylinder head observing the following orientation "c"

• Induction camshaft: notch "c" in 7 o'clock position
• Exhaust camshaft: notch "c" in 8 o'clock position

Check the presence of the pins (36)

Apply a strip of seal paste SILICONE CATEGORIE 2 (AUTOJOINT OR) at "d" on the seal face surrounds

Refit the camshaft bearing cap covers

A: Induction camshaft

B: exhaust camshaft

Do up then progressively tighten the fixing screws for the bearing cap covers in the order indicated

• Pre-tightening to 0,2 da.Nm
• Tightening torque to 1,0 da.Nm

Fit the camshaft seals (see "removing-refitting: dynamic seals")

Refit the upper timing cover (39) (tighten the screws to 0,8 m.daN)

Refit

• The exhaust camshaft pulley (40)
• The intake camshaft pulley (37)

Tighten the bolt (41) to 4,5 daN.m

Refit bolt (38)

• Pre-tightening to 2,0 da.Nm
• Tightening torque to 6,0 da.Nm

Pin the camshaft pulleys; using tools [2] and [3]

Position the (new) timing belt in the following sequence

• Intake camshaft pulley
• Exhaust camshaft pulley
• Roller tensioner
• Crankshaft gear
• Water pump pulley
• Dynamic roller tensioner

Place the tool [10] on the crankshaft pinion in order to hold the belt in position

Using a hexagonal spanner, turn the roller tensioner anti-clockwise (at "j")

Bring the index "k" to position "l" so as to tension the belt to the maximum

Tighten roller tensioner nut (42) to 1,0 m.daN

Remove tools [1-2-3-10]

Turn the engine over 4 times in the normal direction of rotation

Fit the crankshaft setting rod; using tool [1]

Slacken the nut (42) to release the roller tensioner

Turn the roller tensioner clockwise using a hexagonal spanner (at "j")

Bring the index "k" to position "n" (nominal position)

Tighten the roller tensioner fixing nut to 2,1 ± 0,2 m.daN

Remove the peg [1] from the crankshaft

Turn the engine over 2 times in the normal direction of rotation

Check the timing setting by refitting the camshaft and crankshaft setting rods