B1EG1CK1 - 406D9 EW12J4 ENGINE

REMOVAL - REFITTING TIMING BELT

1 - SPECIAL TOOLS

[1] Crankshaft setting rod (-).0189-B .

[2] Camshaft hub setting rods (Exhaust) (-).0189-AZ .

[3] Camshaft hub setting rods (Inlet) (-).0189-L .

[4] Setting rod (-).0189-J .

[5] hub immobilising tool (-).0606-A1/(-).0606-A2 .

[6] Belt retaining clip (-).0189-K .

EW12J4 ENGINE

[7] Power train support crossmember (-).0009 .

ALL MODELS

2 - REMOVAL

Disconnect the battery .

Remove :

• the front right-hand wheel
• the mud shield (front RH)
• the ancillary drive belt

EW12J4 ENGINE

Remove :

• the style cover (1)

Fit the tool [7] .

Support engine by means of hook on tool [7] .

IMPERATIVE : to prevent damage to exhaust hose keep engine in its initial position .

Remove earthing screw (2) and move aside harness .

Remove the torque reaction link (3) .

NOTE : retrieve the yoke (4) .

Remove the nut (5) .

Remove :

• the 3 bolts (6)
• engine store (7)

Remove :

• the bolts (8) + the ancillary drive pulley
• the timing cover (9)
• the timing cover (10)

WARNING : do not slacken the securing bolts (A) .

IMPERATIVE : do not slacken the securing bolts (11) .

Peg :

• the exhaust camshaft, using the tool [2]
• the inlet camshaft, using the tool [3]
• the crankshaft, using the tool [1]

Slacken the bolt (14) (Fully) .

Remove the roller bracket (15) from the rib (B) of the cylinder block (to allow it greater movement) .

Remove the timing belt .

ALL MODELS

3 - REFITTING

Always renew : The timing belt .

EW12J4 ENGINE

IMPERATIVE : check that the rollers (16), (17) as well as the coolant pump (18) turn freely (no play or hard spots); also check that these rollers are not noisy and/or do not show traces of grease .

In the event of replacement, Tightening torque(s) :

• roller (17) to 3.5 m. daN

Engage belt on crankshaft pinion (19) respecting its fitting direction .

Immobilise the belt using the tool [6] .

Fit the timing belt, fully taut, in the following order :

• roller tensioner (17)
• the pinion (20)
• the pinion (21)
• the coolant pump (18)
• the tensioner roller (16)

Correct the alignment of the belt by placing the centre line of the belt as near to vertical as possible but not flush with flanges .

ALL MODELS

4 - FITTING AND TENSIONING THE TIMING BELT

IMPERATIVE : operation(s) to be carried out : engine cold .

EW12J4 ENGINE

Position the roller bracket (17) back on rib (B) of the cylinder block .

Remove the tool [6] .

(C) : Maximum position .

(D) : Nominal tensioning position .

Using the hexagonal socket (E), turn the roller in the direction of the arrow until the pointer (22) is in position (C) to tension the belt to the maximum .

Fit the tool [4] .

Turn the roller in the direction opposite to that shown on the roller arrow by means of the torx recess (E) until cursor just makes contact with pin [4] .

IMPERATIVE : never turn the roller (16) by one full turn .

NOTE : this operation allows the pointer (22) to be located in the nominal position (D) .

Tighten screw (14), supporting roller with torx recess (E), Tightening torque : 2 da.Nm .

Remove setting rods [1], [2], [3] and [4] .

Turn the crankshaft 10 turn(s) in the direction of running .

IMPERATIVE : never turn the crankshaft in the reverse direction .

IMPERATIVE : no pressure or outside force must be applied to the belt .

ALL MODELS

5 - CHECK

5 - 1 - TIMING BELT TENSION

EW12J4 ENGINE

Check position of tensioner index (22) .

ALL MODELS

If tensioner index is not in its adjustment position (D), Restart tensioning operations for fitting the timing belt .

5 - 2 - POSITION OF THE CRANKSHAFT

Insert pin to locate inlet camshaft pulley, Using the tool [3] .

Peg the crankshaft, Using the tool [1] .

If it is possible to fit tool [1], continue replacement operations .

EW12J4 ENGINE

IMPERATIVE : if it is not possible to fit tool [1], reposition flange (13) .

ALL MODELS

5 - 3 - REPOSITIONING OF FLANGE

EW12J4 ENGINE

Immobilise crankshaft, Using the tool [5] .

Loosen screw (15) to release pinion (19) from crankshaft .

Position flange (13) at timing point, Using the tool [4] .

Fit the tool [1] .

Tighten the bolt (12) to 13 +/- 1.3 da.Nm .

Remove the tools [1], [3], [5] .

ALL MODELS

6 - REFITTING (CONTINUED)

EW12J4 ENGINE

Fit :

• the timing cover (10)
• the ancillary drive pulley
• the bolts (8) to 2.1 da.Nm
• the timing cover (9)

Fit :

• engine store (7)
• the 3 bolts (6) : tightening torque 6.1 da.Nm
• the nut (5) : tightening torque 4.5 da.Nm
• the torque reaction link (3)
• the yoke (2)

Tighten :

• the bolt (23) to 4.5 da.Nm
• the bolt (24) to 4.5 da.Nm

Continue the fitting operations in the reverse order to removal .

ALL MODELS

replace the style cover (1) .

fit the ancillary drive belt .