B1CJ0DK1 - 406D9 XU5JP ENGINE XU7JP ENGINE XU7JB ENGINE

REASSEMBLY 8 VALVE ENGINE(S) (TIMING)

1 - SPECIAL TOOLS

2 - REASSEMBLY

Fit the camshaft gear (1) .

Peg the camshaft using tool .

Tighten the bolt (2) :

• bolt (ø 10) : 3.5 da.Nm
• bolt (ø 12) : 8 da.Nm

On the crankshaft, refit :

• the 2 half moon cotter pins
• the spacer (3) (oil the edge of the spacer)
• refit the crankshaft gear (4)

Offer up the pulley (5) to the crankshaft .

Check with the rod [2] that the crankshaft is correctly timed .

Remove :

• the rod [2]
• the pulley (5)

Observing its direction of fitting and the markings, fit the belt, run (6) well tensioned, in the following order :

• camshaft
• crankshaft
• coolant pump

Fit :

• the roller tensioner (7)
• check that the roller tensioner (7) turns freely (no tight spot)

WARNING : turn the roller tensioner anti-clockwise to tension the belt (6) lightly .

Nip up the bolt (8) .

On the run (6), position the belt tensioning equipment [3] .

Turn the roller tensioner anti-clockwise to display 30 ± 2 SEEM units .

Tighten the bolt (8) to 2.1 da.Nm + LOCTITE FRENETANCH .

Remove :

• the equipment [3]
• the rod [1]

3 - CHECKING BELT TENSION

Turn the engine over 2 times in the normal direction of rotation .

Check that the valve timing is correct by fitting the rods [1] and [2] .

Remove the setting pins .

Turn the crankshaft another 2 turns in the direction of running .

IMPERATIVE : never turn the crankshaft in the reverse direction .

Fit the rod [1] .

Position the equipment [3] .

The tension value should be between 42 and 46 SEEM units .

If this is not the case, restart the timing belt tensioning operation .

XU5JP ENGINE

Fit :

• the roller tensioner (9)

Run up the bolts (10) .

Place the cam (11) horizontally, with the spring compressed .

WARNING : check that the roller tensioner (9) turns freely (no tight spot) .

Offer up the pulley (12) to the crankshaft .

Check with the rod [2] that the crankshaft is correctly timed .

Remove :

• the rod [2]
• the pulley (12)

Observing its direction of fitting and the markings, fit the belt, run (13) well tensioned, in the following order :

• camshaft
• crankshaft
• coolant pump
• roller tensioner

Remove the rod [1] .

Position the cam (11) downwards .

Tighten the bolts (10) .

Turn the crankshaft 2 turn(s) in the direction of running .

Slacken the bolts (10) to free the tensioner roller (9) .

Tighten the bolts (10) to 1.5 da.Nm. .

Tighten the nut (14) to 1.5 da.Nm .

Turn the engine over 2 times in the normal direction of rotation .

Check that the valve timing is correct by fitting the rods [1] and [2] .

Remove :

• the setting rods
• the pulley (12)

Repeat the operation (if necessary) .

ALL MODELS

Lock the flywheel with the stop [4] .

WARNING : never tighten the bolt (15) with the rod [2] in place (risk of damage) ; use the flywheel retainer [4] .

Remove :

• the thrust washer (depending on engine type)
• the crankshaft pulley (16)

Coat the bolt (15) with threadlock LOCTITE .

Tighten the bolt (15) to 13 da.Nm .

Route and clip exactly as before .