TOOTHED timing BELT - R.R. with engine removed

Operation 1032B16 · BELT-DRIVEN TIMING SYSTEM

2.4 JTD 20V

Removing

1. Position the flywheel retaining tool in its seat.

1. Undo bolts (1a) securing crankshaft pulley (1b) and remove.

2. Undo bolt (2a) and remove the single engine component drive belt fixed tensioner (2b).

1. Undo bolts (1a) and remove the protective timing covers (1b).

1. Loosen the moving timing tensioner nut.

2. Remove the toothed timing belt.

Refitting

1. Remove plug (1a) and fit camshaft timing tool (1b) to the cylinder head extension.

Check the tools marked "A" are correctly fitted in the seat on the camshaft.

1. Undo the bolt fixing the crankcase front cover shown in the diagram.

- Temporarily fit the toothed timing drive belt on the toothed drive pulley.

2. Fit the tool (2a) and fasten it using the calibrated screw (2b).

The crankshaft must be rotated, using small movements, to allow the locating dowel on the timing drive pulley to be inserted in the opening in the tool.

1. Fully fit the toothed timing drive belt.

2. Use a screwdriver for leverage in the opening (2a) until the reference for the tensioner (2b) is aligned with the opening reference (2c) and, in this position, tighten the nut (2d) for the belt tensioner to the recommended torque.

- Remove the timing adjustment tools.

- Rotate the crankshaft through two revolutions.

- Re-check the timing by fitting the timing adjustment tools.

- Check the tension references on the timing belt tensioner are aligned.

- Tighten the bolt securing the crankcase front cover removed previously.

- Tighten the plug on the cylinder head extension for fitting the exhaust side timing tool.

- Fit the toothed timing belt protective guards and tighten the retaining bolts.

- Position the flywheel retaining tool in its seat.

- Fit the crankshaft pulley and tighten the fixing bolts.

- Fit the engine single drivebelt fixed tensioner and tighten the bolt.

- Remove the flywheel lock.

2.4 20V

See in Op. 1032B10 TOOTHED timing BELT - R.R. for timing adjustment or replacement

The difference compared with the operation referred to is that this operation is carried out with the engine removed.

2.0 TB

See in Op. 1032B14 TOOTHED timing BELT - R.R. for timing adjustment or replacement on versions with air conditioning

The difference compared with the operation referred to is that this operation is carried out with the engine removed.

1. Undo the bolts (1a) and remove the engine pulley (1b).

2. Loosen the bolt fixing the timing belt toothed drive pulley.

1. Undo the bolts (1a) and remove the timing belt protective cover (1b).

1. Loosen the timing belt moving tensioner bolt.

2. Release and remove the timing belt.

1. Disconnect the electrical connections from the ignition coils, then release the wiring from the fastenings and move it.

2. Undo the bolts (2a) and remove the ignition coils (2b).

3. Disconnect the oil vapour recovery pipe from the tappet cover.

1. Undo the bolts (1a) and remove the tappet cover (1b) complete with gasket.

1. Loosen the bolt (1a) for the exhaust side driven timing pulley using tools (1b) and (1c) for counter-torque.

2. Loosen the bolts (2a) for the inlet side camshaft pulley using tool (2a) for counter-torque.

1. Fit the tool (1a) complete with dial gauge (1b) in the seat for the spark plug for cylinder no. 1.

- Rotate the crankshaft until the piston for cylinder no. 1 is at T.D.C. in the explosion stroke.

- Undo the bolts and remove the inlet side third camshaft cap and the exhaust side camshaft second cap.

Mark the position of the camshaft caps removed so that they can be correctly positioned when refitting.

2. Fit the templates (2a) in place of the camshaft caps that have been removed and secure them tightening the bolts (2b) to the recommended torque.

Check that the camshaft cam profile and the templates are correctly aligned.

1. Fit the timing toothed drive belt in the following order:

- toothed drive pulley (1a)

- fixed tensioner (1b)

- exhaust side toothed driven pulley (1c)

- inlet side toothed driven pulley (1d)

- moving tensioner (1e)

- water pump pulley (1f).

The belt is fitted with the arrow facing the direction of rotation of the engine. There are also three reference on the belt that should coincide during the initial fitting with the references on the toothed drive pulley and the exhaust and inlet side toothed driven pullies.

- Using a screwdriver, rotate the moving timing tensioner until the timing belt is completely taut.

1. Tighten the nut fixing the moving timing tensioner to the recommended torque.

2. Tighten the bolts (2a) for the inlet side toothed timing driven pulley using tool (2b) for counter-torque.

3. Tighten the bolt (3a) for the exhaust side toothed timing driven pulley using the tools (3b) and (3c) for counter-torque.

- Undo the bolts and remove the tool.

- Fit the camshaft cams removed previously and tighten the bolts to the recommended torque.

- Rotate the crankshaft throught two revolutions in the direction of rotation.

- Loosen the moving timing tensioner nut.

4. Using a screwdriver, rotate the moving timing tensioner until the moving tensioner reference (4a) coincoides with the fixed reference (4b).

- Tighten the nut fixing the moving timing tensioner to the recommended torque.

- Rotate the crankshaft throught two revolutions in the direction of rotation.

- The tensioner moving reference should coincide with the fixed reference.

- Remove the tool complete with dial gauge.

- Fit the spark plug for cylinder no. 1 and tighten it to the recommended torque.

- Fit the tappet cover complete with gasket and secure it using the bolts.

- Position the ignition coils in their housings and secure them using the fixing bolts.

- Connect the electrical connections to the ignition coils and fasten the electrical wiring.

- Fit the timing belt protectivetappet cover and secure it using the bolts.

1. Fit the flywheel lock.

1. Fit the engine components single drive belt pulley (1a) and secure it tightening the bolts (1b) to the recommended torque.

- Remove the flywheel lock.