B1CJ0LK1 - 406D9 ES9J4 ENGINE

REASSEMBLY ENGINE (TIMING)

1 - SPECIAL TOOLS

2 - REASSEMBLY

IMPERATIVE : always replace the coolant pump seal .

Position a new seal taking care not to twist it .

Fit : The coolant pump .

Check that the coolant pump turns freely (no play or point of resistance) .

IMPERATIVE : finger tighten then progressively tighten the securing bolts in the order shown (1 to 3) .

Pre-tighten : 0,5 da.Nm .

Tightening torque: 0,8 da.Nm .

Check the tightening : 0,8 da.Nm .

NOTE : if changing the coolant pump, refit the bolt (1) securing the timing cover .

Fit :

• the timing covers (2)
• the engine mounting (3) : tightening torque 6 da.Nm
• the bracket (4) : tightening torque 3,9 da.Nm
• the camshaft pinions and hubs (5)

Coat the threads and the contact area under the bolt head with G10 grease .

NOTE : the pulleys are identical .

WARNING : on refitting, observe the following positioning : flange (A) away from the engine for the inlet ; flange (A) towards the engine for the exhaust .

1st fitting :

• the camshaft hub securing bolts and threads are right-handed

2nd fitting :

• the camshaft hub bolts and threads are left-handed

These bolts can be identified by the 2 arrows (B) stamped on the head .

Tighten the camshaft hubs securing bolt (5) by immobilising the camshafts using the tool [8] .

Tightening torque 2 da.Nm .

Finally tighten by turning through 57 ° (Using the tool [3]) .

Fit : The setting rods [1] .

Fit :

• the rollers (6), (7), (8), (9)
• the roller support (10)
• the plate (11)

Tighten :

• the rollers (6), (7), (9) : 8 da.Nm
• the roller (8) : 2,5 da.Nm
• the roller support (10) : 3,9 da.Nm

Check that the rollers (6), (7), (8), (9) as well as the coolant pump turn freely (no play or hard spots) .

Ensure that the camshafts and the crankshaft timing are correct .

If the roller (12) is changed :

• tightening of the roller (12) to 8 daN.m
• tighten the bolt (13) to 2,5 da.Nm

If the dynamic tensioner (14) is changed :

• tighten the bolts (15) to 2,5 daN.m

Position :

• 1 bolt(s) (16), type M8 X 125 X 35
• the tool [4]

Start to tighten the bolt (16) until it touches at (C) .

Tighten the bolt (16) until the tool [4] is fully tightened .

If the dynamic tensioner (14) is changed :

• remove the split pin (17)

Tighten the bolt (18) to 0,8 da.Nm .

Tighten the bolts (19) to 1 daN.m .

Slacken the bolts (19) by 45° .

Position 1 bolt(s) (20) type M8 X 125 X 75 .

Start to tighten the bolt (20) until it touches at (D) .

IMPERATIVE : when re-using the belt, refit it in the direction of rotation marked during removal .

Engage the timing belt on the crankshaft pinion .

Immobilise the belt using the tool [5] .

Check that the camshaft pinions rotate freely on their hubs .

Turn the 4 camshaft pinions clockwise as far as the stop at the end of the slots .

Tighten the bolts (21) to 0.5 daN.m .

Slacken the bolts (21) by 45° .

Position the belt on the free-rolling roller (8) .

Span (E) of the belt correctly tensioned .

Slightly turn the camshaft pinion in the opposite direction to the rotation of the engine in order to engage the belt on the pinion .

Locate the belt on the camshaft pinion, left-hand exhaust .

IMPERATIVE : the angular displacement value of the pinion in relation to the timing belt must not be greater than the width of one tooth .

Engage the belt :

• on the camshaft pinion, inlet side, as previously
• on the roller (6)
• on the camshaft pinions, right intake then exhaust, as previously, for the left camshafts

Engage the belt simultaneously :

• on the roller (11a)
• on the coolant pump (22)
• on the roller (9)

Run up the bolt (20) to make the belt seat correctly .

IMPERATIVE : check that the camshaft pinions are not at the end of the slots (by removing a bolt) .

If this is not the case, restart the belt fitting operation .

Remove the tool [5] .

Place the tool [7] on the timing belt .

Operate the dynamic tensioner using the bolt (20) until 83 ± 2 SEEM units are obtained .

Tighten in the order :

• the bolt (19a) to 1 da.Nm
• the bolt (19b) to 1 da.Nm
• the bolt (19c) to 1 da.Nm

Tighten in the order :

• the pinion (5) : bolts (21) tightening torque 1 da.Nm
• the pinion (5a) : bolts (21) tightening torque 1 da.Nm
• the pinion (5b) : bolts (21) tightening torque 1 da.Nm
• the pinion (5c) : bolts (21) tightening torque 1 da.Nm

Remove :

• the tool [7]
• the setting rods for the camshaft [1] and crankshaft [2]

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

IMPERATIVE : never turn the crankshaft in the reverse direction .

Fit :

• the crankshaft setting rod [2]

Slacken by 45 degrees :

• the bolts (19a), (19b), (19c)

Remove the bolt (16) .

Adjust the bolt (20), in order to ensure that the tool [4] slides without play .

Wait at least 1 minute (damper action) if the ambient temperature is higher than 15 °C, otherwise, wait a little longer .

Check that the tool [4] slides .

Remove the tool [4] .

Tighten in the order :

• the bolt (19a) to 2.5 da.Nm
• the bolt (19b) to 2.5 da.Nm
• the bolt (19c) to 2.5 da.Nm

Remove :

• the bolt (20)
• the crankshaft setting rod [2]

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

IMPERATIVE : never turn the crankshaft in the reverse direction .

Fit :

• the crankshaft setting rod [2]

Peg the camshaft (F) using a rod [1] .

NOTE : if the rod [1] does not fit into its housing : fit the tool [8] ; slacken the bolts (21) by 45° ; peg the camshaft by means of the rod [1], using the tool [8] .

NOTE : if the rod [1] fits into its housing : slacken the bolts (21) by 45° .

Peg the camshaft (G) using a rod [1] .

NOTE : if the rod [1] does not fit into its housing : fit the tool [8] ; slacken the bolts (21) by 45° ; peg the camshaft by means of the rod [1], using the tool [8] .

NOTE : if the rod [1] fits into its housing : slacken the bolts (21) by 45° .

Carry out the same procedure for camshafts (H) and (I) .

IMPERATIVE : check that the camshaft pinions are not at the end of the slots (by removing a bolt) .

If this is not the case, restart the belt fitting operation .

Tighten in the order :

• the pinion (5) : bolts (21) tightening torque 1 da.Nm
• the pinion (5a) : bolts (21) tightening torque 1 da.Nm
• the pinion (5b) : bolts (21) tightening torque 1 da.Nm
• the pinion (5c) : bolts (21) tightening torque 1 da.Nm

Remove :

• the setting rods for the camshaft [1] and crankshaft [2]

3 - CHECKING THE VALVE TIMING

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

IMPERATIVE : never turn the crankshaft in the reverse direction .

Fit :

• the crankshaft setting rod [2]

Check that the camshafts checking rod [6] engages freely in the cylinder heads (J) stopping at the camshaft pinions .

If this is not the case, restart the belt fitting operation .

Remove :

• the crankshaft setting rod [2]