B1EG1XK1 - 307 TU5JP4 ENGINE

REMOVAL - REFITTING TIMING BELT

1 - TOOLING

[1] S.0192 tension measuring equipment .

[2] flywheel setting rod (-).0132-QY .

[3] Camshaft setting rod : Exhaust(-).0132-AJ1 .

[4] Camshaft setting rod : Inlet (-).0132-AJ2 .

[5] Belt retaining clip (-).0132-AK .

2 - REMOVAL

Remove :

• the front right-hand wheel
• the mud shield
• the ancillary drive belt
• the ancillary drive pulley ( to crankshaft)

Support the power train using a stand .

Remove :

• the complete left engine store (1)
• the bottom timing cover
• the top timing cover (2)

Peg :

• the engine flywheel at tdc cylinder 1 ; using the tool [2]
• the camshafts ; using the tools [3] - [4]

Using the hexagonal recess (A), turn the roller in the direction of the arrow to bring the index (3) to position (B) to slacken the belt fully .

Pin the tensioner roller in the position .

IMPERATIVE : never turn the roller by one full turn .

Remove the timing belt (4) .

3 - REFITTING

Check that the rollers (5) and (6) turn freely (no play and no tight spots) .

The belt has 3 marks (C) - (D) - (E), which go opposite the corresponding teeth (1) and (52) - (72) on the belt .

These marks are lines of white paint on the back of the belt opposite the corresponding teeth .

Fit the belt .

Align mark (C) on the belt with groove (F) on the crankshaft pinion .

It is possible to turn the camshafts using a wrench to make it easier to fit the belt on the pulleys .

Position tool [5] on the crankshaft pulley to hold the belt in place .

3 - 1 - EXCESS VOLTAGE

Turn the tensioner roller anti-clockwise to its maximum position minus 2 mm .

Tighten the tensioner roller bolt to dan.m .

Remove the pin from the crankshaft .

Turn the engine over 4 times in the normal direction of rotation .

3 - 2 - NORMAL TENSION

Peg the crankshaft .

Unscrew the bolt (7) to slacken the tensioner roller .

Tension the roller clockwise to the point of over-tension .

Using the hexagonal recess (A), move the index by turning clockwise so that it is positioned opposite the mark .

IMPERATIVE : the index must not descend again to the minimum point for correct setting of the timing .

Tighten the dynamic tensioner roller : 2.2 da.Nm .

Remove the pins :

• of the crankshaft
• of the camshafts

Turn the engine over (2) times in the normal direction of rotation .

Check the position of the roller: it should be ± 2 mm from the position in which it was tightened, if it is not, repeat the fitting procedure .

Check the setting by pinning the camshafts again. if the result is not correct, repeat the fitting procedure .

Remove the pin(s) from the engine .

fit the ancillary drive belt .