Citroen berlingo won´t start after replacing pulley (FIXED)

[mighty]

I had the classic rattling lower pulley on my 2004 berlingo. I took it into my garage, thinking i would do a quick oil service at the same time.

I drove it inside, undid the oil plug, replaced the oil filter refitted the drain plug and filled it back up with oil. I then jacked the car up, loosened the belt tensioner and undid the pulley bolt with a pneumatic impact driver. I wiggled the old pulley off, put the new pulley on all the way and then put the bolt back in and tightened it back up to specifications. Lastly I put the belt back on and unlocked the tensioner.

I got in the car to start it and to my suprise it did not start! It turns over fine, but with no sign of coming alive and no abnormal sounds. I was scratching my head for 2 hours while checking everything I could possibly check. I even took the cam belt cover and starter off to check that the timing marks on the flywheel and camshaft lined up, which they did. Even though I don´t know how anything that I have done could screw up the timing.

I am completely baffled and have no idea where to go from here. Any ideas?

Thanks
Geir

[Bick]

Has it tripped the inertia switch somehow?

[mighty]

Hmm. I never thought of that. What could cause that to trip? Is it possible to trip it manually by accidentally bumping into it?

[mighty]

It´s got siemens electronics, so I dont even think it has god a inertia switch.

[Bick]

Inertia switches can trip with little provocation sometimes.

[mighty]

Lexia throws 2 fault codes when cranking;

1. permanent fault, cylinder reference signal short circuit between 2 wires or open circuit.

2. Permanent fault, Fuel pressure signal pressure coherence

[wheeler]

It´s got siemens electronics, so I dont even think it has god a inertia switch.

Inertia switches were done away with on the mk2 berlingo with the introduction of Com2000 regardles of the engine or injection system. On com2000 cars the fuel cut off in an accident is dealt with by the airbag ecu.

[wheeler]

In live data on lexia what fuel pressure are you getting on crank ? Is it showing cam & crank synchronisation ok ? Does it show engine rpm on crank ?

[mighty]

I have now got a hold of the haynes manual, and it does specify:

"The crankshaft timing belt sprocket used with the later type pulley incorporates a wider keyway for the locating woodruff key. When the pulley retaining bolt is slackened, the sprocket is free to turn on the crankshaft within the limits afforded by the wider keyway. This provides a certain degree of lateral movement of the sprocket for accurate adjustment of the belt tension.

It is therefore essential that the flywheel and camshaft are locked in the engine assembly/valve timing position when the pulley bolt is slackened, otherwise the sprockets will turn slightly and the valve timing will be lost"

The woodruff key is now all the way to the left in the slot. But how is this sprocket moving maybe half of a tooth really that big of a deal? Cant I just turn it back?

Sooo, I really messed up, thinking this engine was like the other 2.0 hdi I did.

How would I go about timing this back up? Or am I completely screwed?

[Paul-R]

From memory you have to insert a spacer to push the sprocket back to where it should be. I think Haynes suggest a suitable Allen key or perhaps a twist drill bit.

Frankly I think it's a stupid idea. I can't see how it helps the belt tension at all.

[mighty]

Is it enough to turn the sprocket so that the key is at the other end of the keyway? I suppose thats the only thing that could have moved, but if that is the case.. why all the warnings about undoing the bolt without locking the flywheel and cam if all you have to do is turn the sprocket back after?

[Paul-R]

I'm sorry I can't find my Haynes so can't tell you what spacer is needed. With luck someone else has the figure for you. I'm not even going to guess in case that sends you down the wrong path!

[mighty]

I have the haynes manual here, but I can't seem to find any relevant information on the subject.

[Paul-R]

Sorry, I should have more clear. I have a C5 manual (somewhere!) and it's detailed there. Is the Berlingo manual only for vehicles up to a certain date - say about 2002 - perhaps?

[mighty]

It does go up all the way to 2010. It also has specific information about the floating crank sprocket and pulley etc. But it doesn't seem to specify how to correct the position of the crankshaft sprocket in relation to timing in any way that I can see. Though it does say to use a 2mm rod to the left of the woodruff key to keep it in place while fitting the timing belt. But my key is already at the left of the slot and I dont know how to get it back to the other side.

I do suspect there is more to it, but I cant imagine what else could have been affected by undoing the crank bolt as long as the belt hasn't jumped a tooth or something. Can't see how that would happen though.