B1EG1MK1 - 406D9 ES9J4 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] Timing dynamic tensioner setting gauge (-).0187-EZ .

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

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

[8] SEEM C.TRONIC 105.5 tension measuring equipment .

[9] Camshaft hub immobilisation tool (-).0187-F .

2 - REMOVAL

Remove the shield under the power train .

Remove the style cover (1) .

Disconnect the connector (1a) .

Move aside :

• the control unit box (1b)

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

Remove :

• the torque reaction link (2)
• the right-hand engine mounting (3)
• the ancillary drive belt

Remove :

• the power steering pump pulley

Remove :

• the 2 timing covers (4)

Remove :

• the roller/tensioner assembly (5)

Remove :

• the bracket (6)

Remove :

• the crankshaft pulley (7)
• the timing cover (8)

NOTE : the operation to peg the camshafts is made easier by first slackening the pinion bolts and turning the camshafts (using the tool [9]), lightly oil the rods [3] before assembly .

Peg in the order :

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

Position 1 bolt(s) (9) type M8 x 125 x 75 .

Start to tighten the bolt (9) until it touches at (a) .

IMPERATIVE : the spacer bolt (11) must remain fully tightened .

Slacken the bolts (10) .

Position :

• the tool [5] by slackening the bolt (9) (if necessary)
• 1 bolt(s) (12), type M8 x 125 x 35

Start to tighten the bolt (12) until it touches at (b) .

Tighten the bolt (12) until the tool [5] is fully tightened .

Unscrew the bolt (9) to the maximum .

IMPERATIVE : if the belt is to be re-used mark the direction of rotation .

Remove the timing belt .

3 - REFITTING

Ensure that the camshafts and the crankshaft timing are correct .

Check that the rollers (13), (14), (15), (16) as well as the coolant pump (17) turn freely (no play or hard spots) .

In the event of replacement, Tightening torques :

• roller (13) to 8 ± 0.5 m. daN
• roller (14) to 8 ± 0.5 m. daN
• roller (15) to 8 ± 0.5 m. daN
• roller (16) to 8 ± 0.5 m. daN
• bolt(s) (18) to 2.5 ± 0.1 m.daN

Tighten the bolts (10) to 1 ± 0.1 daN.m .

Slacken the bolts (10) by 45° .

IMPERATIVE : when re-using the belt, refit it in the direction of rotation marked during removal .

Engage the timing belt on the crankshaft pinion .

Immobilise the belt using the tool [4] .

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 .

Tighten the bolts (19) to 0.5 ± 0.03 daN.m .

Slacken the bolts (19) by 45° .

Position the belt on the free-rolling roller (14) .

Span (A) of the belt correctly tensioned .

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
• on the roller (15)
• on the camshaft pinions, right intake then exhaust, as previously, for the left camshafts

Engage the belt simultaneously :

• on the roller (16)
• on the coolant pump (17)
• on the roller (13)

Run up the bolt (9) to make the belt seat correctly .

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 .

Remove the tool [6] .

Place the tool [8] on the timing belt .

Operate the dynamic tensioner using the bolt (9) until 83 ± 2 SEEM units are obtained .

Tighten in the order :

• the bolt (10a) to 1 ± 0.1 da.Nm
• the bolt (1b) to 1 ± 0.1 da.Nm
• the bolt (1c) to 1 ± 0.1 da.Nm

Tighten in the order :

• the pinion (20) : bolts (19) tightening torque 1 ± 0.1 da.Nm
• the pinion (20a) : bolts (19) tightening torque 1 ± 0.1 da.Nm
• the pinion (20b) : bolts (19) tightening torque 1 ± 0.1 da.Nm
• the pinion (20c) : bolts (19) tightening torque 1 ± 0.1 da.Nm

Remove :

• the tool [8]
• the setting rods for the camshaft [3] and crankshaft [4]

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]

Slacken by 45 degrees :

• the bolts (10a) - (10b) - (10c)

Remove the bolt (12) .

Adjust the bolt (9), in order to ensure that the tool [5] slides without play .

Wait at least 1 minute (damper action) if the ambient temperature is higher than 15 °C, otherwise, wait a little longer .

Check that the tool [5] slides .

Remove the tool [5] .

Tighten in the order :

• the bolt (10a) to 2.5 ± 0.1 da.Nm
• the bolt (10b) to 2.5 ± 0.1 da.Nm
• the bolt (10c) to 2.5 ± 0.1 da.Nm

Remove :

• the bolt (9)
• the crankshaft setting rod [4]

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]

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

NOTE : if the rod [3] does not fit into its housing : fit the tool [9] ; slacken the bolts (19) by 45° ; peg the camshaft by means of the rod [3], using the tool [9] .

NOTE : if the rod [3] fits into its housing : slacken the bolts (19) by 45° .

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

NOTE : if the rod [3] does not fit into its housing : fit the tool [9] ; slacken the bolts (19) by 45° ; peg the camshaft by means of the rod [3], using the tool [9] .

NOTE : if the rod [3] fits into its housing ; slacken the bolts (19) by 45° .

Carry out the same procedure for camshafts (C) and (D) .

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 (20) : bolts (19) tightening torque 1 ± 0.1 da.Nm
• the pinion (20a) : bolts (19) tightening torque 1 ± 0.1 da.Nm
• the pinion (20b) : bolts (19) tightening torque 1 ± 0.1 da.Nm
• the pinion (20c) : bolts (19) tightening torque 1 ± 0.1 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 (7) : 2.5 ± 0.1 da.Nm

Fit :

• the bracket (6)
• the roller/tensioner assembly (4)

Refit the bolts (23) .

Tighten :

• the bolts (24) to 3.9 ± 0.2 da.Nm
• the bolts (25) to 2.5 ± 0.1 da.Nm
• the bolts (26) to 6 ± 0.4 da.Nm

Fit :

• the 2 timing covers (4)
• the power steering pump pulley

Tighten :

• the power steering pump pulley : 1 ± 0.1 da.Nm

fit the ancillary drive belt .

Refit the right-hand engine mounting (3) .

Tighten :

• the bolts (27) to 4.5 ± 0.3 da.Nm
• the nuts (28) to 4.5 ± 0.3 da.Nm
• the nut (29) to 4.5 ± 0.3 da.Nm

Refit the torque reaction link (2) .

Tighten :

• the bolt (30) to 5 ± 0.3 da.Nm
• the bolts (31) to 5 ± 0.3 da.Nm

Continue the fitting operations in the reverse order to removal .