B1EG1VK1 - 406D9 EW7J4 ENGINE

REMOVAL - REFITTING TIMING BELT

1 - SPECIAL TOOLS

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

[2] camshaft hub setting rods (-).0189-A .

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

[4] Dynamic tensioner roller positioning rod (-).0189-J .

[5] hub immobilising tool (-).0606-A1Y / (-).0606-A2 .

2 - REMOVAL

Remove :

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

Remove :

• the bolts (12) + the ancillary drive pulley
• the timing cover (13)
• the timing cover (14)

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

Peg :

• the camshafts ; using the tool [2]
• the crankshaft ; using the tool [1]

Slacken the bolt (16) ; Fully .

Remove the roller bracket (17) from the rib (B) of the cylinder block (to allow it greater movement) .

Remove the timing belt .

3 - REFITTING

WARNING : always renew ; the timing belt .

IMPERATIVE : check that the rollers (7) - (18) as well as the coolant pump (19) turn freely (no play or hard spots) ; also check that these rollers are not noisy and/or do not show traces of grease .

If the roller (18) is replaced, tighten to 3.7 dan.m .

Engage the belt on the crankshaft pinion observing its direction of fitting .

Immobilise the belt using the tool [3] .

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

• roller tensioner (18)
• pulley (20)
• pulley (21)
• coolant pump (19)
• roller tensioner (7)

3 - 1 - FITTING AND TENSIONING THE TIMING BELT

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

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

Remove the tool [3] .

(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 (7) by one full turn .

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

Tighten screw (16), supporting roller with torx recess (E) ; Tightening torque 2.1 da.Nm .

Remove the setting pins [1] - [2] - [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 .

3 - 2 - CHECK ; TIMING BELT TENSION

Check position of tensioner index (22) .

If tensioner index (22) is not in its adjustment position (D) .

Restart tensioning operations for fitting the timing belt .

Insert pin to locate inlet camshaft pulley ; Using the tool [2] :

• peg the crankshaft ; using the tool [1]
• if it is possible to fit tool [1], continue replacement operations

IMPERATIVE : if it is not possible to fit tool [1], reposition flange (8) .

3 - 3 - REPOSITIONING OF FLANGE

Immobilise crankshaft ; Using the tool [5] .

Loosen screw (15) to release pinion (9) from crankshaft .

Position flange (8) at timing point ; Using the tool [5] .

Fit the tool [1] .

Tighten the bolt (15) to 4 da.Nm + Angular tightening 40° ± 4' .

Remove the tools [1] - [2] - [5] .

Fit :

• the timing cover (14)
• the ancillary drive pulley
• the bolts (12) ; tightening torque 2.1 da.Nm
• the timing cover (13)

fit the ancillary drive belt .

Continue the fitting operations in the reverse order to removal .