TIMING SYSTEM DRIVE CHAIN - R.R

Operation 1032A12 · CHAIN TIMING SYSTEM

2.2

Removing

- Position the vehicle on a lift.

- Make sure that the ignition key is in the OFF position, then disconnect the battery terminal (-).

1. Remove the sound insulation cover fastened to the engine by three pins.

1. Loosen the band and disconnect the engine oil vapour recovery pipe from the cylinder head cover.

2. Loosen the bands and remove the air supply hose from the air flow meter to the throttle casing.

1. Disconnect the electrical connection from the air flow meter.

2. Undo the bolts (2a) and remove the air filter cover (2b), complete with air flow meter (2c).

3. Remove the air cleaner filter element.

1. Release the fuel vapour pipe (1a) from the band (1b) on the air filter casing.

1. Disconnect the cold air intake from the air filter casing.

2. Remove the air filter casing fastened to the bodyshell by three pins.

1. Connect the tool to the bleed valve on the fuel supply pipe and discharge the fuel pressure.

Follow the safety instructions and specific recommendations.

1. Undo the connector (1a), disconnect the fuel supply pipe (1b), fuel manifold pipe side and move it to the side.

1. Disconnect the rapid connector for the fuel vapour pipe and move aside.

1. Disconnect the electrical connection from the ignition coil module.

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

1. Undo the nut (1a), loosen the bands and remove the engine coolant return pipe to the supply reservoir (1b).

1. Disconnect the electrical connection for the front Lambda sensor to the catalytic converter.

2. Disconnect the electrical connection for the rear Lambda sensor to the catalytic converter.

1. Unscrew the bolts securing the timing side engine wiring brackets.

1. Unscrew the bolts securing the cam cover side engine wiring brackets.

1. Release the gearbox side engine wiring bracket from its fastenings.

2. Move the engine wiring to the side.

3. Disconnect the electrical connection for the radio interference condenser.

1. Undo the nut (1a) and disconnect the earth lead (1b) from the cam cover.

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

- Remove the spark plugs to facilitate the subsequent engine cranking operations.

Op. 4450B04 RIGHT FRONT WHEEL - R.R

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

1. Use tool (1a) to adjust the mobile tensioner in the arrowed direction in the figure and prise off the auxiliary drivebelt (1b).

2. Turn the crankshaft to move cylinder no. 4 to TDC in the combustion phase. Under these conditons, notch (2a) on the inner part of the crankshaft pulley should be aligned with the reference mark (2b) on the timing chain cover.

1. Undo the bolts (1a) and remove the timing chain upper pad (1b).

1. Unscrew and remove the automatic timing chain tensioner.

1. If no mark (1b) is present on the fixed timing chain hydraulic tensioner (1a), replace the tensioner with a new unit including a new mobile chain tensioner pad.

1. Loosen the bolts fixing the camshaft toothed drive pulleys.

Turn the hexagonal bolts on the camshafts using a fixed wrench to provide countertorque.

1. Fit the tool and check the camshaft timing setting is correct.

If necessary, turn the crankshaft slowly and gradually (in the direction of engine rotation).

- Remove the timing tool.

1. Fully loosen the bolts fixing the camshaft toothed drive pulleys.

- Secure the timing chain to prevent it falling into the casing.

2. Remove the camshaft toothed drive pulleys.

1. Undo the nuts (1a) and disconnect the front section of the exhaust pipe (1b), catalytic converter side.

2. Remove the gasket.

1. Undo the bolts (1a), (1b) and remove the bracket on the gearbox for the lower reaction rod (1c).

1. Unscrew the left engine mount flexible block bolt, front suspension frame side.

1. Fit the tool (1a) complete with support mountings (1b).

2. Fit the tools (2a) and (2b), then connect them to the brackets on the engine using links (2c).

1. Undo the bolts (1a) and the nut (1b) and remove the flexible mounting for the timing side power unit front support (1d).

Adjust the equipment links to raise the power unit far enough to gain access to the power unit rigid mount bolts, timing side.

1. Undo the bolts (1a) and remove the power unit rigid support (1b).

2. Undo the bolt (2a) and remove the engine components single belt moving tensioner (2b).

3. Undo the plug for access to the upper bolt securing the chain tensioner fixed pad.

4. Undo the upper belt tensioner fixed pad fixing bolt.

1. Unscrew the upper bolts fixing the timing cover.

1. Undo the drain plug and drain the engine oil.

Collect the engine oil in a suitable container.

1. Undo the nut (1a) securing the crankshaft pulley using the tool (1b) for counter-torque.

2. Remove the crankshaft pulley.

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

2. Remove the gasket.

- Working at the bench, remove the oil seal from the timing chain cover.

Take care not to damage the sealing surfaces during destructive removal of the oil seal.

1. Undo the lower bolt (1a) and remove the belt tensioner fixed pad (1b).

1. Undo the belt tensioner mobile pad fixing bolt.

- Remove the chain tensioner mobile pad by withdrawing from below.

- Remove the timing chain after releasing it from the retaining collar positioned previously.

Refitting

- Refit the timing chain provisionally in its seat.

Secure the timing chain to prevent it falling.

- Refit the chain tensioner mobile pad.

1. Tighten the chain tensioner pad retaining bolt to the recommended torque.

1. Refit the chain tensioner fixed pad (1a) and secure by tightening the lower bolt (1b) and upper bolt through the hole to the specified torque.

1. Place the intake side camshaft toothed drive pulley (1a) in its housing and secure it with a new bolt (1b) without tightening the bolt.

2. Fit the camshaft timing tools.

Turn the intake side camshaft by means of the hexagon until timing tool pin (2a) fits into the hole on the pulley.

3. Turn the crankshaft until cylinder 4 is at TDC in the combustion phase, white notch stamped on the timing chain toothed drive pulley turned down and key upward.

Turn the crankshaft slowly and steadily (in the direction of engine rotation).

Ensure the timing chain is not stuck.

4. Fit the timing chain.

The pink link (4a) should be aligned with the white notch stamped on the timing chain toothed drive pulley.

The bluel link (4b) must be aligned with the "INT" mark stamped on the intake side camshaft toothed drive pulley.

5. Place the exhaust side camshaft toothed drive pulley (5a) in its housing and secure it with a new bolt (5b) without tightening the bolt.

Turn the exhaust side camshaft by means of the hexagon until the pink link (5c) is aligned with the "EXH" mark stamped on the exhaust side toothed timing drive pulley.

- Move back the camshaft timing tool pin from the intake side camshaft toothed timing drive pulley.

- The following drawing shows the fixed timing chain hydraulic tensioner disassembled.

Replace the o-rings.

- Before refitting, the timing chain hydraulic tensioner must be preloaded as described below.

1. Position the piston in a vice with protective jaws, holding by the square end.

2. Inser the piston into the tensioner case by pressing and turning as shown in the figure until pin (2a) fits into groove (2b).

3. Press and simultaneously turn the piston until pin (3a) fits into groove (3b).

- Insert the assembled piston into the tensioner body.

1. Refit the timing chain hydraulic tensioner into its seat and tighten to the specified torque.

1. Hydraulic tensioner in operational position.

If the chain remains slack, the tensioner is not in operating position.

- Turn the crankshaft through 720°, then move cylinder no. 4 to TDC in the exhaust phase, white notch stamped on the timing belt toothed drive pulley turned down and key upward.

When the crankshaft is turned, the tensioner piston should follow the chain through its rotation.

- Check the timing by ensuring that the tool pins are aligned with the holes on the camshaft drive pulleys.

If they do not align, refit the timing chain without treating the coloured links on the chain as TDC reference points.

- Remove the tool.

1. Place the upper timing chain pad (1a) in its housing and fasten it tightening the bolts (1b) to the recommended torque.

1. Tighten the new camshaft toothed pulley bolts to the specified torque, first tightening the exhaust side pulley bolt.

Turn the hexagonal bolts on the camshafts to provide countertorque.

- Fit the spark plugs and tighten them to the recommended torque.

- Clean the contact surfaces.

1. Refit a new gasket (1a) and the timing chain cover (1b).

2. Tighten the timing chain cover bolts to the specified torque, first tightening the lower bolts and then the upper bolts.

- Replace the access plug to the upper belt tensioner bolt in its seat and tighten to the specified torque.

Replace the seal.

1. Fit a new oil seal (1a) on the timing chain cover using the tool (1b).

Before fitting, slightly moisten the lip of the new oil seal.

1. Place the crankshaft pulley in its housing.

2. Tighten a new bolt (2a) securing the crankshaft pulley to the recommended torque using the tool (2b) for counter-torque.

1. Position the auxiliary drivebelt moving tensioner (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

Position the auxiliary drivebelt mobile tensioner so that the ridge (1c) on the tensioner fits into hole (1d).

2. Place the power unit timing side rigid support (2a) in its housing and secure it by tightening the bolts (2b) to the recommended torque.

- Raise the power unit by means of the support tool links.

1. Place the timing power unit front support flexible mounting (1a) in its housing and secure it tightening the bolts (1b) and (1c) and the nut (1d) to the recommended torque.

- Remove the tool used to support the power unit.

1. Tighten the engine oil drain plug to the recommended torque.

Replace the seal.

1. Tighten the left engine mount flexible block bolt, front suspension frame side, to the specified torque.

1. Refit the lower reaction rod bracket (1a) in its seat on the gearbox and secure it by tightening the bolts (1b), (1c) to the recommended torque.

1. Place a new gasket in position.

2. Connect the front section of the exhaust pipe (2a), catalytic converter side and tighten the new nuts (2b) to the recommended torque.

- Refit the auxiliary drivebelt by adjusting the moving tensioner with the tool.

- Tensioner the tensioner by turning anticlockwise and releasing.

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 4450B04 RIGHT FRONT WHEEL - R.R

1. Place the cam cover (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

Replace the o-rings (1c).

- Connect the earth loom to the cam cover and secure with its nut.

- Connect the electrical connection for the radio interference condenser.

- Refit the engine wiring

- Secure the engine wiring bracket, gearbox side.

- Secure the cam cover engine side wiring brackets with their bolts.

- Secure the timing side engine wiring brackets with their bolts.

- Connect the electrical connection for the rear Lambda sensor to the catalytic converter.

- Connect the electrical connection for the front Lambda sensor to the catalytic converter.

- Place the coolant return pipe to the engine coolant reservoir in position and tighten the bands and the nut.

1. Place the ignition coil module (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

2. Connect the electrical connection to the ignition coil module.

- Place the fuel vapour recovery pipe in position and connect the rapid connectors.

1. Place the fuel supply pipe (1a) in its housing, connect it and tighten the connector (1b) to the recommended torque.

- Place the air filter casing in its housing and secure it to the bodyshell using the three pins.

- Connect the cold air intake to the air filter casing.

- Fasten the fuel vapour pipe to the air filter casing using the band.

- Fit the air filter filter element in place.

- Fit the cover for the air filter, complete with air flow meter, and secure it using the bolts.

- Connect the electrical connection to the air flow meter.

- Place the air supply hose from the air flow meter to the throttle casing back in its housing and secure it using the bands.

- Connect the engine oil vapour recovery pipe to the cylinder head cover and secure it using the band.

- Place the sound insulation cover back in its housing and secure it to the engine using the three pins.

- Connect the negative battery terminal.

Op. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP UP, IF NECESSARY

- Remove the vehicle from the lift.