B1EG0TK1 - 607 ES9J4S ENGINE

REMOVAL - REFITTING TIMING BELT

1 - SPECIAL TOOLS

[1]Cross beam (-).0102-D .

[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

Remove the shield under the power train (if necessary) .

remove the style cover .

Remove the left style cover .

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

Remove :

• the upper torque reaction link (1)
• the right-hand engine mounting (2)
• the ancillary drive belt

Remove the power steering pump pulley .

Remove :

• the roller/tensioner assembly (3)
• the crankshaft pulley (4)

Remove :

• the 2 timing housings (6)
• the bottom timing cover (5)

Remove the support (7) .

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 (8) .

Slacken the bolts (9)-(10) and the nut (11) .

Remove the tensioner roller (12) .

Pivot clockwise the excentric cam of the tensioner roller using a type FACOM R.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 (13), (14), (15) as well as the coolant pump (16) turn freely (no play or hard spots) .

In the event of replacement, Tightening torques :

• roller (13) to 8 m. daN
• roller (14) to 8 m. daN
• roller (15) to 8 m. daN

Slacken the bolts (17) 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 (13), 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, inlet side, as previously

Refit the roller (12) : Tightening torque 8 da.Nm .

Engage the belt :

• on the roller (12)
• on the camshaft pinions, right intake then exhaust, as previously, for the left camshafts

Engage the belt simultaneously :

• on the roller (15)
• on the coolant pump (16)
• on the roller (14)

Using a FACOM S.161 type tool, at (A) pivot the plate to engage the bolt (8) .

Tighten the bolts (8), (9), (10) to 2,5 daN.m .

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

Tighten: The nut (11) 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 (18) - (19) - (20) - (21) .

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 .

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

Slacken the nut (11) (1/4 turn(s)) .

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

Tighten the nut (11) 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 (17) 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 ((17)) 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 (18) : bolts tightening torque 1 da.Nm
• the pinion (19) : bolts tightening torque 1 da.Nm
• the pinion (20) : bolts tightening torque 1 da.Nm
• the pinion (21) : 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 (4) : 4 da.Nm then 80°

Fit :

• the bracket (7)
• the roller/tensioner assembly (3)

Tighten :

• the bolt (22) to 2,5 da.Nm
• the bolts (23) to 4 da.Nm
• the bolts (24) to 2,5 da.Nm
• the bolt (25) to 6 da.Nm

Refit the timing covers .

Tighten in the order :

• the bolts (29) to 0,3 da.Nm
• the bolts (26) to 0,3 da.Nm
• the bolts (27) to 0,3 da.Nm
• the bolts (28) 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 (30) to 6 da.Nm
• the nut (33) to 4,5 da.Nm

Refit the torque reaction link .

Tighten :

• the bolt (31) to 5 da.Nm
• the bolt (32) to 5 da.Nm

Continue the fitting operations in the reverse order to removal .