B1EG1RK1 - 406D9 ES9J4S ENGINE

REMOVAL - REFITTING TIMING BELT

1 - SPECIAL TOOLS

[1]Cross beam .

[2]Lifting chain (-).0102-M .

[3] Camshaft setting rods (-).0187-B .

[4] crankshaft setting rod (-).0187-A .

[5] Belt retaining clip (-).0187-J .

[6] Camshafts setting check rod (-).0187-CZ .

[7]Depending on the vehicle, the engine may be installed inclined or straight .

[8]Outlet camshaft hubs immobilisation tool .

2 - REMOVAL

Place the bonnet in the parking position .

Remove :

• remove the style cover
• the battery cover
• the ecu holder cover

Disconnect the battery .

Remove the bolts (1) - (2) .

Disconnect the pipe and the canister connector (3) .

Disconnect the double relay connector (4) .

Disconnect the connectors (5) from the ecu (6) .

Remove the control unit (6) .

Remove the tray (7) .

Move aside the harnesses .

Position the cross beam [1] fitted with its chains [2] and take the weight .

Remove :

• the upper torque reaction link (8)
• the right-hand engine mounting (9)
• the ancillary drive belt

Remove the power steering pump pulley .

Remove :

• the roller/tensioner assembly (10)
• the crankshaft pulley (11)

Remove :

• the 2 timing housings (13)
• the bottom timing cover (12)

Remove the support (14) .

NOTE : the operation to peg the camshafts is made easier by first slackening the pinion bolts and turning the camshafts (using the tools [7]-[8]) ; lightly oil the rods [3] before assembly .

Peg in the order :

• the camshafts, using the rods [3]
• the crankshaft with the rod [4]

Remove the bolt (15) .

Slacken the bolts (16)-(17) and the nut (18) .

Remove the tensioner roller (19) .

Pivot clockwise the excentric cam of the tensioner roller using a type FACOM R.161 - S.161 tool at (B) .

Remove the timing belt starting with the tensioner roller and the coolant pump .

3 - REFITTING

Ensure that the camshafts and the crankshaft timing are correct .

Check that the rollers (20), (21), (22) as well as the coolant pump (23) turn freely (no play or hard spots) .

In the event of replacement, Tightening torques :

• roller (20) - (21) - (22) to 8 m. daN

Slacken the bolts (24) by 1/4 turn .

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 .

Engage the timing belt on the crankshaft pinion .

Immobilise the belt using the tool [5] .

Position the belt on the free-rolling roller (20), Span (C) of the belt correctly tensioned .

NOTE : 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, left inlet

Refit the roller (19) : Tightening torque 8 da.Nm .

Engage the belt :

• on the roller (19)
• on the camshaft pinions, right inlet then outlet

Engage the belt simultaneously :

• on the roller (22)
• on the coolant pump (23)
• on the roller (21)

Using a FACOM R.161 - S.161 type tool, at (A) pivot the plate to engage the bolt (15) .

Tighten the bolts (15), (16), (17) to 2,5 daN.m .

Fit the crankshaft setting rod (Using the tool [4]) .

Tension the belt by pivoting the tensioner roller fully (anti-clockwise); use a FACOM R.161 type tool .

Tighten: The nut (18) to 1 da.Nm .

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 at least 2 bolts per hub to 1 daN.m, In the order shown (25) - (26) - (27) - (28) .

Remove the tool [5] .

Remove setting rods [3] and [4] .

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

WARNING : never turn back .

Slacken the nut (18) (1/4 turn(s)) .

Align marks (D) and (E) of the tensioner roller using a type FACOM R.161 - S.161 tool .

Tighten the nut (18) to 2,5 da.Nm, Without altering the position of the roller .

Remove the crankshaft setting rod [4] .

Turn the crankshaft two revolutions .

WARNING : never turn back .

Peg the crankshaft (Using the tool [4]) .

Check the position of the tensioner roller .

Peg the camshaft (F) using a rod [3] .

NOTE : if the rod [3] does not fit into its housing fit the tool [8], slacken the bolts (24) by 45°, peg the camshaft by means of the rod [3], using the tool [8] .

NOTE : if the rod [3] fits into its housing, unscrew the bolts ((24)) by 45° ° .

Carry out the same procedure for camshafts (G), (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 (25) - (26) - (27) - (28) : bolts tightening torque 1 da.Nm

Remove :

• the setting rods for the camshaft [3] and crankshaft [4]

4 - 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 [4]

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 [4]

5 - REFITTING (CONTINUED)

Proceed in the reverse order to removal .

Tighten :

• the crankshaft pulley (11) : 4 da.Nm then 80°

Fit :

• the bracket (14)
• the roller/tensioner assembly (10)

Tighten :

• the bolt (29) to 2,5 da.Nm
• the bolts (30) to 4 da.Nm
• the bolts (31) to 2,5 da.Nm
• the bolt (32) to 6 da.Nm

Refit the timing covers .

Tighten in the order :

• the bolts (36) to 0,3 da.Nm
• the bolts (33) to 0,3 da.Nm
• the bolts (34) to 0,3 da.Nm
• the bolts (35) to 0,5 da.Nm

Refit the power steering pump pulley : Tightening torque 0,8 da.Nm .

fit the ancillary drive belt .

Refit the right-hand engine mounting .

Tighten :

• the bolts (37) to 6 da.Nm
• the nut (40) to 4,5 da.Nm

Refit the torque reaction link .

Tighten :

• the bolt (38) to 5 da.Nm
• the bolt (39) to 5 da.Nm

Continue the fitting operations in the reverse order to removal .