REMOVAL - REFITTING : TIMING BELT ( SECOND ASSEMBLY

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Shawn Oliver
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1 Page 1 of 9 REMOVAL - REFITTING : TIMING BELT ( SECOND ASSEMBLY ) : EW10J4S INJECTION OR INJECTION EW10J4 1. Special tools Figure : E5AP1J0C [1] camshaft hub setting rods (-).0189-A. Figure : E5AP27AC [2] Crankshaft setting rod ( - ).0189-R.

2 Page 2 of 9 Figure : E5AP1J1C [3] Belt retaining clip (-).0189-K. Figure : E5AP052C [4] Adapter for angular tightening FACOM D.360.

3 Page 3 of 9 Figure : E5AP27BC [5] Dynamic tensioner roller manoeuvring and locking tool (-).0189.S. [5a] Manoeuvring tool (-).0189.S1. [5b] Locking tool (-).0189.S2. Figure : B1EK1XVD [6] Engine lifting tool. [7] Engine hook (-).0102-ZV. 2. Removal N.B. : After the ignition has been switched off : Wait 15 minutes before disconnecting the battery ( To ensure that the learning patterns of the various ECUs are stored in memory ). Disconnect the battery. Remove : The front right-hand wheel The front right mud shield The ancillary drive belt

4 Page 4 of 9 Figure : B1EK1XWD Using the tools [6] and [7], secure on the sling hook. Figure : B1EK1XXD Remove : Always replace the timing belt (2). Move aside the power steering pipes. Remove : The intermediate right engine mounting (1).

5 Page 5 of 9 Figure : B1EK1XYD CAUTION : Do not unscrew the fixing bolts (A). Remove the upper timing cover (4). Turn the engine using the crankshaft pulley (3) bolt (5) until it is in the pinning position. Figure : B1BP2V3D A : Pinning on the manual gearbox. B : Pinning on the automatic gearbox. Fit the crankshaft setting rod ( Using the tool [2] ).

6 Page 6 of 9 Figure : B1EK1XZD Peg : The camshaft pulleys (10-6) ( Using the tool [1] ). Remove : The bolt (3) The crankshaft pulley (5) The bottom timing cover (11) URGENT : Never remove the crankshaft pulley (5) without pinning the crankshaft and the camshaft. Slacken the tensioner roller (9) bolt (8). Turn the tensioner roller clockwise. Remove the timing belt (7). 3. Refitting Always renew : The timing belt. URGENT : Check that the tensioner roller and take up roller and the coolant pump turn freely (absence of clearance and points of resistance) ; Also check that these rollers are not noisy and/or do not show traces of grease.

Page 7 of 9 Figure : B1EP1BCD Turn the tensioner roller (8), using the tool [5a], until the notch (b) has been passed. Position the tool [5b] to lock the pointer (a) and remove the tool [5a].

7 Page 7 of 9 Figure : B1EP1BCD Turn the tensioner roller (8), using the tool [5a], until the notch (b) has been passed. Position the tool [5b] to lock the pointer (a) and remove the tool [5a]. Figure : B1EK1YPD Refit the timing belt (7) on the crankshaft sprocket. Support the timing belt (7) ( Using the tool [3] ). Put the timing belt in place observing the following order : The tensioning roller (13) The intake camshaft pulley (6) The exhaust camshaft pulley (10) The coolant pump (14) The tensioner roller (8) N.B. : Act so that the belt (7) is as flush as possible with the exterior surface of the various sprockets and rollers. Remove : The tool [3] The tool [1] of the exhaust camshaft Tool [5b] from the tensioning roller (8) Fit : The lower timing cover (11) The crankshaft pulley (5) The bolt (3) Tighten the bolt (3) to 4.0 ± 0,4 danm. Carry out angular tightening of 53 ± 4 ( Using the tool [4] ) Fitting and tensioning the timing belt URGENT : Operation(s) to be carried out with a cold engine.

8 Page 8 of 9 Figure : B1EP1BEC Turn the tensioner roller (8) in the direction of the arrow (c) using a hexagonal recessed spanner at (d). Figure : B1EP1BFC Position the index (a) correctly at (f) using a hexagonal recessed spanner. URGENT : The index (a) must go beyond the notch (g) by an angular value of at least 10. If this is not the case : Replace the tensioner roller or the timing belt and tensioner roller assembly. Then bring the index (a) to its setting position (g) turning the tensioner roller in the direction of the arrow (e). CAUTION : The index (a) must not protrude past the notch (g) ; If this is not the case : Resume the timing belt tensioning operation. URGENT : The tensioning roller must not turn while its mounting is tightened ; If this is not the case : Resume the timing belt tensioning operation. Tighten the tensioner roller bolt (9) to (8) to 2.1 ± 0.2 danm.

9 Page 9 of 9 URGENT : The hexagonal recessed spanner driving the tensioner roller should be below the joint face of the cylinder head (h) ( Approximately 15 ). If this is not the case : Replace the tensioner roller or the timing belt and tensioner roller assembly. Remove the tools [1-2]. Make 10 revolutions of the crankshaft in the normal direction of rotation. URGENT : No pressure or outside force must be applied to the belt. Insert pin to locate inlet camshaft pulley ( Using the tool [1] ) Check - Timing belt tension URGENT : Operation(s) to be carried out with a cold engine. URGENT : Check position of tensioner index (a) : The index (a) should be opposite the notch (g). If the position of the index (a) is not correct, again carry out the timing belt tensioning operations. Fit : The top timing cover (4) The power steering pipes fixing bolts (5) The intermediate right engine mounting (3) Tightening of the 7 bolts of the bracket to 6.0 dan.m. Remove the tools [6-7]. Refit the flexible ancillary drive belt. Continue the fitting operations in the reverse order to removal. Tighten the wheels to 9.0 dan.m.

URGENT : Ensure that the precautions relating to safety and cleanliness are adhered to (refer to the brochure: RECOMMENDATIONS - PRECAUTIONS).

URGENT : Ensure that the precautions relating to safety and cleanliness are adhered to (refer to the brochure: RECOMMENDATIONS - PRECAUTIONS). PAGE 1 - b1eg1xp0 - removing - refitting timing belt removing - refitting timing belt INJECTION ES9J4S URGENT Ensure that the precautions relating to safety and cleanliness are adhered to (refer to the