B1EG11K1 - 406D9 DW10TD ENGINE DW10ATED ENGINE

REMOVAL - REFITTING TIMING BELT

1 - SPECIAL TOOLS

DW10ATED ENGINE

DW10TD ENGINE

[11] Set of plugs (-).0188-T .

2 - REMOVAL

IMPERATIVE : remove the exhaust pipe to avoid damaging the flexible hose; this cannot withstand the torsion, traction or bending tensions caused by the removal of one of the power train supports .

Remove :

• the front right-hand wheel

Move aside the right-hand front mud shield .

the ancillary drive belt .

Remove :

• the turbo pipe

Remove :

• the clutch housing closing plate

Lock the flywheel with the stop [5] .

Remove the ancillaries drive pulley bolt .

Refit the bolt without the washer .

Remove : The ancillary drive pulley (Using the tool [10]) .

Remove the tool [5] .

Remove : The lower torque reaction link .

DW10TD ENGINE

DW10ATED ENGINE

Turn the crankshaft with the tool [6] .

Peg the flywheel using the rod [2] .

Disconnect the battery .

Remove the style cover .

Disconnect and remove the ECU .

Remove :

• the control unit housing
• the torque reaction link (1)
• the fuel pipes (2)

IMPERATIVE : plug the holes using tool [11] .

Support the engine with a crane attached to the lifting eye or with a jack placed under the engine (Using tools [7] and [8]) .

Protect the radiator honeycomb with strong cardboard cut to the dimensions of the radiator .

Remove the right-hand engine mounting (4) .

Remove :

• the timing covers (3)
• the bottom timing cover

Peg the camshaft pulley with tool [3] .

Slacken the roller tensioner fastener (5) .

Retighten the fastener in the maximum slack position (Tightening torque : 0.1 da.Nm) .

Remove the timing belt .

3 - REFITTING

IMPERATIVE : check that the rollers (5), (6) as well as the coolant pump (7) turn freely (no play or hard spots), also check that these rollers are not noisy and/or do not show traces of grease .

In the event of replacement, Tightening torque(s) : Roller (6) to 4.3 m. daN .

Slacken the bolts (8) .

Check that the pulley (9) rotates freely on its hub .

Tighten the bolts (8) by hand .

Slacken the bolts (8) by 1/6 turn .

Turn the pulley (9) clockwise to the limit at the end of the slots .

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

• crankshaft (immobilise the belt using the tool [4])
• roller tensioner (6)

Lay the timing belt on the pulley (10) .

Slightly turn the camshaft pinion in the opposite direction to the rotation of the engine in order to engage the belt on the pinion .

WARNING : the angular movement (α) of the pulley in relation to the belt must not be more than one tooth space .

Engage the belt on the roller tensioner (5) and on the coolant pump gear (7) .

Place the tensioner roller (5) in contact with the belt .

Pre-tighten the tensioner roller securing bolt to 0.1 daN.m .

Remove the tool [4] .

3 - 1 - PRE-TENSIONING AND FITTING THE TIMING BELT

Fit the tool [1] .

NOTE : check that the tool is not touching anything in the near vicinity .

Turn the roller tensioner (5) anti-clockwise (Using the tool [9]) .

Display 98 ± 2 SEEM units .

Tighten the bolt (11) to 2.3 da.Nm (Without altering the position of the roller) .

Remove the tool [1] .

IMPERATIVE : by removing a bolt (8) on the pulley (9), ensure that these bolts (8) are not at the limit of the slot; if this is the case, repeat the timing belt fitting operation .

Bring the bolts (8) into contact with the pulleys .

Tighten the bolts (8) to 2 daN.m .

Remove the setting pins [3], [2] .

Turn the engine over 8 times in the normal direction of rotation .

IMPERATIVE : never turn the crankshaft in the reverse direction .

3 - 2 - FITTING AND TENSIONING THE TIMING BELT

Refit the rods [2] - [3] .

Unscrew : The bolts (8) .

Tighten the bolts (8) by hand .

Slacken the bolts (8) by 1/6 turn .

Slacken the bolt (11) .

Place the tool [1] on the span (A) .

Turn the roller tensioner anti-clockwise (Using the tool [9]) .

Display 54 ± 2 SEEM units .

Tighten the bolt (11) to 2.3 da.Nm (Without altering the position of the roller) .

Tighten the bolts (8) to 2 daN.m .

Remove the tool [1] to release the internal forces .

Refit the tool [1] .

The tension value should be between 51 and 57 SEEM units .

IMPERATIVE : if the value read is outside the tolerance : slacken the belt and repeat the operation .

Remove :

• the equipment [1]
• the pegs [2] - [3]

3 - 3 - CHECKING THE VALVE TIMING

Turn the crankshaft 2 revolutions in the direction of running without turning in the reverse direction .

Fit the rod [2] .

IMPERATIVE : visually check that the offset between the camshaft hub hole and the corresponding setting hole does not exceed 1 mm .

Remove the rod [2] .

Fit :

• the bottom timing cover
• the timing cover components (3)
• the engine mounting (4)

Refit and tighten :

• the 3 bolts (13) : tightening torque 6.1 da.Nm
• the nut (12) : tightening torque 4.5 da.Nm
• the torque reaction link (1)
• the bolt (14) : tightening torque 4.5 da.Nm
• the bolt (15) : tightening torque 4.5 da.Nm

Fit :

• the tool [5]

Refit the torque reaction link (16) .

Tighten :

• the bolt (17) to 5 da.Nm
• the bolt (18) to 6 da.Nm

Refit the ancillaries drive pulley .

Clean the threads of the bolt of the pulley in the crankshaft by using a M16 X 150 tap .

Brush the thread of the bolt .

Tighten the bolt to 4 da.Nm + LOCTITE FRENETANCH .

Finally tighten by turning through 51 ° (Using a FACOM D360 type tool) .

Check the tightening : 19.5 da.Nm .

fit the ancillary drive belt .

Remove the tool [5] .

Refit the closing plate : Tightening torque 1.8 da.Nm .

IMPERATIVE : always replace the exhaust clip .

Fit :

• the exhaust pipe

Tighten the wheel bolts to 9 da.Nm .

Refit the various components in the reverse order to removal .

Initialise the various ECUs .