Toothed timing belt - r r with engine removed

Operation 1032B16 · Belt timing system

1.9 JTD 8V

Removing

Position the engine on a suitable workbench.

1. Use a spanner on the moving tensioner to loosen the tension of the engine components single drive belt.

2. Remove the single drive belt.

1. Fit the flywheel lock.

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

Remove the flywheel lock.

1. Undo the bolt (1a) and remove the fixed single drive pulley (1b).

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

2. Undo the bolts (2a) and remove the bracket on the engine for the reaction rod (2b).

3. Slacken the nut on the timing belt moving tensioner.

4. Remove the timing belt.

Refitting

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

Temporarily fit the timing drive belt on the drive pulley.

2. Fit the tool (2a) and secure it with gauged bolts (2b)

To allow the engagement of the locating dowel on the timing drive belt drive pulley in the opening in the tool, rotate the crankshaft using small movements.

1. Check that the timing references coincide.

2. Completely fit the timing belt.

3. Use a screwdriver for leverage in the opening (3a) so that the reference on the tensioner (3b) is aligned with the opening reference (3c) and, in this position, tighten moving tensioner nut (3d) to the recommended torque.

Remove the tools.

Tighten the bolt for the crankcase front cover previously removed.

Rotate the crankshaft through two revolutions.

Check once again that the timing references and the tensioning references on the mobile timing tensioner coincide.

Fit the bracket on the engine for the reaction rod and fix it tightening the bolts to the recommended torque.

Place the protective timing side covers back in their housings and secure them using the bolts.

Place the engine components single drive belt fixed tensioner back in its housing and fix it tightening the bolt to the recommended torque.

Fit the flywheel lock.

Fit the crankshaft pulley and fix it tightening the bolts to the recommended torque.

Remove the flywheel lock.

Fit the single engine component belt by adjusting the moving tensioner using a wrench.

1.9 JTD 16V

Removing

Position the engine on a suitable workbench.

1. Use a spanner, in an anti-clockwise direction, on the moving tensioner to loosen the tension of the engine components single drive belt.

2. Remove the single drive belt.

1. Disconnect the electrical connection for the air conditioning compressor.

1. Release the electrical wiring from the band on the timing cover.

2. Disconnect the electrical connection for the cam angle sensor.

3. Disconnect the electrical connections from the injectors.

4. Undo the cable duct fixing bolts.

1. Release the electrical wiring from the bands fastening it to the engine coolant supply reservoir coolant return pipe.

2. Disconnect the electrical connections from the heater plugs.

3. Disconnect the electrical connection from the fuel pressure sensor.

Move the engine wiring to the side.

1. Loosen the band and disconnect the engine oil vapour recovery pipe (1a) from the engine oil filler, then release it from the retaining band (1b).

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

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

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

1. Undo the bolts (1a) and remove the bracket on the engine for the reaction rod (1b).

1. Loosen the nut securing the timing belt mobile tensioner

2. Prise off and remove the timing belt.

1. Loosen the band and disconnect the coolant return pipe from the engine coolant reservoir, thermostat side.

1. Loosen the band and disconnect the coolant outlet pipe from the cylinder head, engine coolant return pipe to the coolant reservoir side.

2. Undo the bolts (2a) and remove hose (2b) carrying coolant to the coolant supply reservoir.

1. Disconnect the pipe from the injectors to the fuel return manifold, fuel return manifold side.

2. Loosen the band and disconnect the pipe from the pressure pump to the fuel return manifold, fuel return manifold side.

3. Undo the bolts (3a) and remove the fuel return manifold (3b).

1. Undo the connectors (1a), (1b) and remove the pipe from the pressure pump to the fuel manifold (1c).

Use a new pipe from the pressure pump to the fuel manifold when refitting.

2. Manually push springs (2a) and disconnect the pipe from the injectors to the fuel recovery manifold (2b), injectors side and remove it.

3. Undo the connectors (3a), (3b) and remove the pipes from the fuel manifold to the injectors (3c).

Use new pipes from from fuel manifold to injectors upon reassembly.

4. Undo the bolts (4a) and remove the single fuel manifold pipe (4b) complete with fuel pressure sensor (4c).

1. Undo the nuts (1a) and remove the brackets (1b) and injectors (1c).

Start the removal beginning with the injector for cylinder no. 1 and continuing with the injectors for cylinders 2, 3 and 4.

1. Undo the bolts (1a) and remove the camshaft housing assembly (1b).

Remove the gasket.

Refitting

Place the upper cylinder head gasket back in its housing.

1. Remove the plugs (1a) and fit the camshaft timing tools (1b) in the upper cylinder head.

Check that the tools are correctly inserted in the housings in the camshafts.

Remove the inlet side camshaft timing tool and tighten the plug.

1. Place the complete upper cylinder head (1a) back in its housing and secure it tightening the bolts (1b) to the recommended torque.

Loosen the exhaust side camshaft toothed drive pulley fixing bolt.

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

Temporarily fit the timing drive belt on the drive pulley.

2. Fit the tool (2a) and secure it gauged bolts (2b)

To allow the engagement of the locating dowel on the timing drive belt drive pulley in the opening in the tool, rotate the crankshaft using small movements.

1. Completely fit the timing belt.

2. Use a screwdriver to lever in the hole (2a) until the reference on the tensioner (2b) lines up with the reference hole (2c) and, in this position, tighten the belt tensioner nut (2d) to torque.

Tighten the exhaust side camshaft toothed drive pulley fixing bolt to the recommended torque.

Remove the timing tools.

Remove the exhaust camshaft template, as the inlet camshaft has already been removed.

Rotate the crankshaft through two revolutions.

Check once again that the timing is correct by refitting the timing tools.

Only fit the exhaust camshaft side template because the inlet side one is not accessible.

Check that the tensioning references on the timing belt tensioner are aligned.

Tighten the bolt for the crankcase front cover previously removed.

Tighten the plug in the camshaft housing for fitting the exhaust side timing tool.

1. Refit the injectors (1a) complete with brackets (1b) and secure by tightening nuts (1c) to the specified torque.

Start the refitting beginning with the injector for cylinder no. 4 and continuing with the injectors for cylinders 3, 2 and 1.

1. Place the single fuel manifold pipe (1a), complete with fuel pressure sensor (1b), back in its housing and secure it tightening the bolts (1c) to the recommended torque.

2. Fit the new pipes from the fuel manifold to the injectors and secure them using the connectors without tightening them.

3. Tighten the connectors for the pipes from the fuel manifold to the injectors, injector side, to the recommended torque using a suitable spanner.

4. Tighten the connectors for the pipes between the fuel manifold and the injectors, fuel manifold side, to the recommended torque using a suitable spanner.

Clean the threaded seats for the above-mentioned pipe on the manifold and the injectors using heptane.

5. Place the pipe from the injectors to the fuel recovery manifold (5a) back in its housing and connect it to the injectors pushing it until the clips (5b) can be heard clicking into place.

6. Place the pipe from the pressure pump to the single fuel manifold back in its housing and fix it using the connectors without tightening them.

7. Tighten the connector for the pipe from the pressure pump to the single fuel manifold, pump side, to the recommended torque using a suitable spanner.

8. Tighten the connector for the pipe from the pressure pump to the single fuel manifold, fuel manifold side, to the recommended torque using a suitable spanner.

Clean the threaded seats for the above mentioned pipe on the manifold and the pressure pump using heptane.

Place the fuel return manifold pipe back in its housing and fix it using the bolts.

Connect the pipe from the pressure pump to the fuel return manifold, fuel return manifold side and tighten the band.

Connect the pipe from the injectors to the fuel return manifold, fuel return manifold side.

Place the coolant return pipe to the engine cooling system reservoir back in its housing and tighten the bolts.

Connect the coolant oulet pipe from the cylinder head, engine coolant return pipe to the supply reservoir side and tighten the band.

Connect the engine coolant return pipe to the supply reservoir, thermostat side and tighten the band.

1. Fit the bracket on the engine for the reaction rod (1a) and fix it tightening the bolts (1b) and (1c) to the recommended torque.

Place the protective timing side covers back in their housings and secure them using the bolts.

1. Place the engine components single drive belt fixed tensioner (1a) back in its housing and fix it tightening the bolt (1b) to the recommended torque.

Fit the flywheel lock.

2. Place the crankshaft pulley (2a) back in its housing and secure it by tightening bolts (2b) to the recommended torque.

Remove the flywheel lock.

Connect the oil vapour recovery pipe to the engine oil filler, tighten the band and secure it using the fastening.

Place the engine wiring back in its housing.

Connect the electrical connection to the fuel pressure sensor.

Connect the electrical connections to the heater plugs.

Fasten the electrical wiring to the bands on the coolant return pipe to the engine coolant supply reservoir.

Tighten the cable duct fixing bolts.

Connect the electrical connections to the injectors.

Connect the electrical connection to the cam angle sensor

Fasten the electrical wiring to the band on the timing cover.

Connect the electrical connection to the air conditioner compressor.

Fit the single engine component belt by adjusting the moving tensioner using a wrench.