Toothed timing belt - r r with engine removed

Operation 1032B16 · Belt timing system

1.2 16v

Removing

- 1004D40 engine - position on stand and remove

1. Disconnect electrical connections (1a), (1b), (1c), (1d), (1e), (1f), (1g), (1h) and (1i).

2. Open the wiring duct (2a) and remove the engine wiring (2b).

1.4 16v

Removing

- 1004D40 engine - position on stand and remove

1. Disconnect electrical connections (1a), (1b), (1c), (1d), (1e), (1f), (1g), (1h) and (1i).

1.6 16v

Removing

- 1004D40 engine - position on stand and remove.

Disconnect the electrical connections from the ignition coils.

1. Disconnect the supply connections for the spark plugs.

2. Undo the bolts fixing the ignition coils from the mounting bracket.

3. Remove the ignition coils complete with spark plug high tension leads.

2.4 20v

Refer to op. 1032B14 toothed timing belt - r + r for timing adjustment or replacement versions with air conditioner.

The difference between this and the reference operation is that the operation is carried out with the engine removed in this case.

1.9 JTD 8v

Removing

Position the engine on a suitable workbench.

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

1. Remove the single drive belt.

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.

1.2 16v

1. Remove the inlet manifold complete with injectors and butterfly casing.

1.4 16v

1. Open clips (1a) and release wire (1b).

2. Open retaining clips (2a) and release engine wiring bundle retaining channel (2b).

1.6 16v

1. Turn the crankshaft in its normal direction of rotation to align notch (1a) on the crankshaft pulley with ridge (1b) on the timing belt guard. Notch (1c) should now be aligned with rpm sensor (1d).

1.9 JTD 8v

1. Fit the flywheel lock.

1.9 JTD 16v

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

1.2 16v

1. Remove the upper shield (1a) and the lower shield (1b) for the timing belt.

1.4 16v

1. Undo the bolts (1a) and remove the inlet manifold (1b) with injectors and throttle body.

2. Undo the bolt (2a) and remove the engine oil dipstick pipe (2b).

1.6 16v

1. Undo the retaining bolts.

2. Remove the timing belt single shield.

1.9 JTD 8v

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

Remove the flywheel lock.

1.9 JTD 16v

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.

1.2 16v

1. Undo the bolts indicated and remove the auxiliary shaft drive pulley on the crankshaft.

1.4 16v

1. Remove the upper shield (1a) and the lower shield (1b) for the timing belt.

Remove the engine wiring harness.

1.6 16v

1. Fit the engine flywheel retaining tool.

2. Undo the nut securing the crankshaft pulley.

3. Remove the crankshaft pulley.

1.9 JTD 8v

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

1.9 JTD 16v

1. Releasethe 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.

1.2 16v

Remove the protective cover for the camshaft rear gears.

1. Undo the camshaft housing side plugs.

2. Position the tools (1a) in the housings for the plugs undone previously, then rotate the camshafts until the splining on each camshaft coincides with the pin (2b) for the tools. The camshafts will be timed in this way.

1.4 16v

1. Unscrew and remove spark plugs (1a) from the seats on the cylinder head (1b).

1.6 16v

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

2. Undo bolts (2a) and remove camshaft rear covers (2b)

1.9 JTD 8v

1. Undo the bolts (1a) and remove the timing drive belt guard (1b).

2. Undo the bolts (2a) and remove the power unit reaction rod attachment bracket (2b).

3. Loosen the timing belt tensioner nut.

4. Prise off and remove the timing belt.

1.9 JTD 16v

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).

1.2 16v

1. Check that the centering lug (1a) on the crankshaft gear (1b) is positioned opposite the housing for the rpm and TDC sensor (1c). The pistons will be approximately aligned with one another in this position.

1.4 16v

1. Undo the fixing bolts (1a) and remove the auxiliary shaft drive pulley (1b).

1.6 16v

With the piston for cylinder No.1 approximately at T.D.C. (as positioned previously), adjust the camshaft timing.

1. Position camshaft timing adjustment tools.

2. When fitting the tools, align shaft seat (2a) with key (2b) on the tools.

3. Tighten the tool retaining nuts.

The tools are stamped with the letters 'A (intake) and 'S (exhaust) to facilitate correct positioning on the shafts. The tools are not interchangeable.

1.9 JTD 8v

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 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.

1.9 JTD 16v

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).

1.2 16v

1. Loosen the nut fixing the automatic belt tensioner.

2. Remove the timing drive belt.

1.4 16v

Remove the protective cover for the camshaft rear gears.

1. Undo the camshaft housing side plugs.

2. Position the tools (1a) in the housings for the plugs undone previously, then rotate the camshafts until the splining on each camshaft coincides with the pin (2b) for the tools. The camshafts will be timed in this way.

1.6 16v

1. Loosen the nut fixing the automatic belt tensioner.

2. Remove the timing drive belt.

1.9 JTD 8v

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.

1.9 JTD 16v

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

1.2 16v

Refitting

Remove the spark plugs for cylinders 1 and 2.

1. Position the tools (1a) in the housings for the spark plug for cylinders 1 and 2, tightening the components (1b) to a torque of 0.5 daNm.

2. Rotate the crankshaft in its normal direction of rotation, using small movements, until the surface (2a) on the moving part of the tool is aligned with the plane (2b) on the fixed part in the spark plug housing. When both tools positioned in the spark plug housing are in this condition the pistons will be aligned, i.e. halfway through their stroke and the piston for cylinder 1 will be descending, i.e. in the inlet stroke.

The pistons were already approximately aligned previously.

Rotate the crankshaft gradually to prevent the pins for the tools being expelled by the piston compression.

The camshafts were timed previously through the fitting of the tools (3b).

1.4 16v

1. Check that the centering lug (1a) on the crankshaft gear (1b) is positioned opposite the housing for the rpm and TDC sensor (1c). The pistons will be approximately aligned with one another in this position.

1.6 16v

Refitting

1. Using retaining tools (1a) and (1b), undo timing pullies retaining bolts (1c)

1.9 JTD 8v

Rotate the crankshaft through two revolutions.

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

Place the power unit reaction rod mounting bracket back in its housing and fix it tightening the bolts to the recommended torque.

Place the timing drive belt guards 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

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

1.2 16v

1. Using the locking tools (1a), loosen the bolts (1b) fixing the camshaft drive pulley.

1.4 16v

1. Loosen the nut fixing the automatic belt tensioner.

2. Remove the timing drive belt.

1.6 16v

Remove the spark plugs from their sockets on the cylinder head.

1. Position a dial gauge (1a), supported by a pointer (1b) in the housing for the spark plug for cylinder no. 1. Turn the crankshaft with small, even movements until the dial gauge shows the cylinder no. 1 piston is at TDC.

1.9 JTD 16v

1. Loosen the nut securing the timing belt mobile tensioner

2. Prise off and remove the timing belt.

1.2 16v

1. Proceed with fitting the timing drive belt, fitting it initially on the crankshaft gear (1a), the water pump pulley (1b), the camshaft drive pulley (1c) and, lastly, on the belt tensioner pulley (1d).

Make sure that this operation is carried out with the camshaft pulley (1c) slack.

1.4 16v

Refitting

Remove the spark plugs for cylinders 1 and 2.

1. Position the tools (1a) in the housings for the spark plug for cylinders 1 and 2, tightening the components (1b) to a torque of 0.5 daNm.

2. Turn the crankshaft in the normal sense of rotation until the tool mobile parts are aligned. When both tools positioned in the spark plug housing are in this condition the pistons will be aligned, i.e. halfway through their stroke and the piston for cylinder 1 will be descending, i.e. in the inlet stroke.

The pistons were already approximately aligned previously.

Rotate the crankshaft gradually to prevent the pins for the tools being expelled by the piston compression.

The camshafts were timed previously through the fitting of the tools (3).

1.6 16v

1. Proceed with fitting timing drive belt (1a), fitting it initially on crankshaft gear (1b) then oil pump gear (1c), fixed guide pulley (1d), inlet camshaft pulley (1e), exhaust camshaft pulley (1e) and lastly on automatic tensioner (1g).

1.9 JTD 16v

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

1.2 16v

1. Using suitable pliers, rotate the automatic tensioner placing it in the maximum tension position, i.e. with the moving reference (1a) positioned as illustrated in the diagram then lock the nut (1d) fixing the tensioner to the support.

1.4 16v

1. Using the locking tools (1a), loosen the bolts (1b) fixing the camshaft drive pulley.

1.6 16v

1. Undo retaining bolts

2. Position the toothed belt tensioning tool.

1.9 JTD 16v

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.

1.2 16v

1. Using the tool (1a) tighten the bolt (1b) fixing the camshaft pulley to the recommended torque.

Remove the tools positioned previously for timing and locking the camshafts and rotate the crankshaft through two revolutions in its direction of rotation to let the timing drive belt bed in.

1.4 16v

1. Proceed with fitting the timing drive belt, fitting it initially on the crankshaft gear (1a), the water pump pulley (1b), the camshaft drive pulley (1c) and, lastly, on the belt tensioner pulley (1d).

Make sure that this operation is carried out with the camshaft pulley (1c) slack.

1.6 16v

1. Adjust the tool until the belt is as taut as possible, i.e. when the moving belt tensioner pointer is at the end of its travel.

2. Tighten the tensioner retaining nut to the specified torque

1.9 JTD 16v

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).

1.2 16v

1. Loosen the nut fixing the tensioner and ensure that the moving reference (1a) coincides with the fixed reference (1b) retaining the tensioner using the special pliers so as not to release the tension suddenly.

2. Once the two references are aligned, tighten the nut (2a) fixing the tensioner to the recommended torque.

Rotate the crankshaft through a further two revolutions in its direction of rotation, then repositino the tools used for timing the engine and check that the timing is correct.

Refit the side plugs in the camshaft housing.

1.4 16v

1. Using suitable pliers, rotate the automatic tensioner placing it in the maximum tension position, i.e. with the moving reference (1a) positioned as illustrated in the diagram then lock the nut (1d) fixing the tensioner to the support.

1.6 16v

Use the pulley tightening tool to tighten the camshaft pulley retaining bolts to the specified torque.

Remove the camshaft timing tools.

Remove the dial gauge together with the probe.

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

1. Loosen the moving tensioner nut.

2. Use tool (2a) to slacken toothed timing belt tension gradually until mobile pointer (2b) is aligned with fixed reference (2c).

Tighten the nut for the moving tensioner to the recommended torque.

1.9 JTD 16v

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).

1.2 16v

Refit the lower shield and the upper shield for the timing drive belt.

Fit the auxiliary shaft drive pulley on the crankshaft and tighten the fixing bolts to the recommended torque.

Refit the inlet manifold complete with injectors and butterfly casing.

Position the electrical wiring and connect the electrical connections.

Position the part of the wiring concerned in the duct.

- 1004D40 engine - position on stand and remove

1.4 16v

1. Using the tool (1a) tighten the bolt (1b) fixing the camshaft pulley to the recommended torque.

Remove the tools positioned previously for timing and locking the camshafts and rotate the crankshaft through two revolutions in its direction of rotation to let the timing drive belt bed in.

1.6 16v

Remove the tool and tighten the retaining bolt removed previously to the specified torque in order to fit the tensioning tool.

Fit the camshaft rear covers.

Fit the support for the ignition coils, tightening the nuts fixing the support and the covers to torque.

Position the flywheel retainer.

Fit the crankshaft pulley with its phonic wheel and tighten the nut to the specified torque.

Remove the flywheel lock.

Fit the timing belt single shield.

Fit the ignition coils, tightening the fixing bolts to torque.

Connect the electrical connections for the spark plugs and the ignition coils.

- 1004D40 engine - position on stand and remove.

1.9 JTD 16v

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.

1.4 16v

1. Loosen the nut fixing the tensioner and ensure that the moving reference (1a) coincides with the fixed reference (1b) retaining the tensioner using the special pliers so as not to release the tension suddenly.

2. Once the two references are aligned, tighten the nut (2a) fixing the tensioner to the recommended torque.

Rotate the crankshaft through a further two revolutions in its direction of rotation, then repositino the tools used for timing the engine and check that the timing is correct.

Refit the side plugs in the camshaft housing.

1.9 JTD 16v

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

Remove the gasket.

1.4 16v

Fit the spark plugs.

Refit the lower shield and the upper shield for the timing drive belt.

Fit the auxiliary shaft drive pulley on the crankshaft and tighten the fixing bolts to the recommended torque.

Refit the inlet manifold complete with injectors and throttle body.

Position the electrical wiring and connect the electrical connections.

Position the part of the wiring concerned in the duct.

- 1004D40 engine - position on stand and remove

1.9 JTD 16v

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.