TOOTHED TIMING BELT - R R WITH ENGINE REMOVED

Operation 1032B16 · BELT TIMING SYSTEM

2.3 JTD 16V

Removing

See in Op. 1004D40

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

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

1. Undo the plug in the crankcase and, rotating the crankshaft using small movements, position the tool for detecting T.D.C. and then locking the crankshaft in the housing for the actual plug.

1. Undo the fixing nuts (1a) and remove the mounting bracket (1b).

1. Undo the studs on the camshaft housing and remove them.

- Fit the tools (1a) for timing the camshafts, insert them until the cylindrical part (1b) of the tool is completely inserted in the opening (1c) in the camshafts. Secure the tool in place tightening the tool ring nuts (1d).

With the crankshaft close to T.D.C. the openings in the camshafts are already in the correct position for fitting the timing tools.

1. Undo the nut fixing the timing drive belt tensioner.

2. Release the belt from the pullies and remove it.

Refitting

1. Using the reaction tool (1a) with pins, stop the rotation of the pulley and undo the bolt (1b) fixing the timing drive pulley.

1. Position a hexagonal bolt in the housing for the pulley fixing bolt.

2. Position the USAG 452/1 universal extractor and tighten the extractor pin until it is in contact with the bolt positioned previously.

3. Continue tightening the tool pin until the camshaft pulley is extraected.

1. Refit the timing pulley (1a) in the housing on the shaft, position the pin (1b) for timing the pulley in relation to the timing sensor, then lock the bolt (1c) fixing the pulley to the shaft.

Before fitting the pulley timing pin, check that the pulley can move freely on the shaft.

1. Rotate the moving tensioner to the position illustrated to facilitate the fitting of the timing belt.

1. Fit the timing belt onto the pulleys and gears.

If the mileage of the belt is more than 25,000, it must be replaced irrespective of its appearance or wear. If it is not being replaced, it should be remembered that the replacement interval for the timing belt and automatic tensioner set out in the maintenance programme is every 240,000 km or 5 years.

- Remove the timing pin for the timing pulley in relation to the timing sensor.

This operation allows the timing belt to bed in on the pulley.

1. Using the reaction tool (1a) fitted with pins, tighten the bolt fixing the timing drive pulley (1a) to torque.

1. Acting on the hexagonal bolt (1a), rotate the semi-automatic tensioner in an anti-clockwise direction, placing the tensioner (1b) moving reference in the position illustrated, i.e. about 20°-22° to the right of the position indicated by the reference (1c), then lock the fixing nut (1d).

- Tighten the bolt fixing the automatic tensioner.

- Remove the tools used for timing the camshafts and for positioning the crankshaft approximately at T.D.C.

- Rotate the crankshaft through eight revolutions in its direction of rotation.

1. Loosen the bolt fixing the tensioner and, working carefully, position the tensioner (1a) reference in line with the reference opening (1b), then tighten the nut (1c) fixing the belt tensioner to torque.

- Rotate the crankshaft through two further revolutions in its direction of rotation.

- Check that the position of the references remains unchanged, then temporarily refit the tools for timing the camshafts and the crankshaft for a final check.

- If the tools do not fit perfectly in the housings or the references on the tensioner have moved, carry out the belt tension adjustment procedure again.

- Fit the studs on the camshaft housing for the timing tools.

- Fit the mounting bracket on the camshaft housing and tighten the fixing bolt and nut.

- Position the timing cover and tighten the fixing bolts to the recommended torque.

- Position the crankshaft pulley and tighten the fixing bolts to the recommended torque.