Timing belt

general instructions

Take note / register :

• The radio-antitheft code.

Lift and block the vehicle.

Disconnect the battery.

Replace the drive belt.

Never rotate the motor through the camshaft’s gear.

Unless specified otherwise, turn the motor in the normal rotation direction.

Apply all tightening torques.

accessibility

Remove :

• The motor upper cover.

Unclip A :

• The vacuum pipe.

Disconnect :

• The vacuum pipe B2.

Rotate :

• The locking fastening B3.

Pull :

• The clamp B4.

Remove :

• The air output duct B5 from the turbocharger.

• The air filter casing.

Empty the engine coolant circuit :

Disconnect :

• The radiator hoses.

accessibility

Remove :

• The fastening screw C1.

• The fastening screw C2.

Disconnect :

• The coolant pipes C3.

• The coolant pipes C4.

accessibility

Unclip F1 :

• The wiring harness.

Unscrew :

• The fastening F2 screws.

Remove :

• The upper cover G.

Unscrew :

• The fastening H screws.

Remove :

• The cap I.

accessibility

Disconnect the connectors C5.

Remove the fastening screw C6.

Remove in the following order :

• The fastening D4 -> D1 screws (tightening torque 1,2 daN.m).

Remove :

• The water pump C7.

• The waterpump belt.

Insert the locking pin C8) (Ø = 4,5 mm :

• Rotate the crankshaft in the standard rotation direction.

accessibility

Remove :

With the tool Ka :

• The fastening screw C9 (tightening torque 2 daN.m + 90°).

Extract :

With the tool Ad & Ex :

• C10.

accessibility

Unscrew from the cylinder block the cap of the TDC setting opening on the crankshaft.

Screw-in the TDC locking pin Pg (ref T10340 ) (tightening torque 3 daN.m).

If the tool Pg cannot be placed :

• Rotate the crankshaft by 90° counterclockwise.

• Screw-in the TDC locking pin Pg (ref T10340 ) (tightening torque 3 daN.m).

Bring slowly and regularly the crankshaft close to the pin Pg :

• Rotate the crankshaft in the standard rotation direction.

accessibility

Disconnect the connector E1.

Remove :

• The fastening E2 screws.

• Solenoid valve of the variable valve timing actuator E3.

• The upper timing cover CS.

• The drive belt.

Check the proper alignment of the marks -> ( if fitted ).

Set the special tool Op T10475 on the crankshaft pulley B1.

Remove :

• The screw of the crankshaft pulley.

• The pulley of the crankshaft.

• The lower timing cover CI.

accessibility

general view

A3 gear of the exhaust camshaft.

A2 gear of the inlet camshaft.

B2 crankshaft gear.

B1 crankshaft pulley.

G1 tensioner.

G2 guide roller.

crankshaft locking

accessibility

Remove :

• The fastening J1 screws.

• The bracket J2.

When reassembling :

• Use the Md tool.

• Lubricate the surface J3 with oil.

• Put back J2.

alignment of the camshafts gears markings

Double check the proper alignment of the setting marks :

• The grooves J4 of the camshafts should be vertical ( flwyheel side ).

accessibility

Remove :

• The fastening Vs5 screws.

• The cover.

timing belt removal

With the tool Ka :

• Remove the locking screw M.

With the tool Ka :

Untighten by 1 rotations :

• The screw P of the camshaft gear.

• The screw Q of the camshaft gear.

With the tool Sg1 :

• Unfasten the screw EG1 fastening the tensioner G1.

With the tool Rg1 :

• Slacken the belt by action on the tensioner G1.

Remove the timing belt.

timing belt reassembly

Check the position of the TDC marking :

• Make sure the crankshaft locking pin is still properly fitted.

• The grooves J4 of the camshafts should be vertical.

The camshaft gears should be able to rotate only slightly on the hubs, but should not be able to tip.

Make sure that the hook R of the tensioner is correctly placed in the groove.

Check that the TDC marks S of the crankshaft B2 are properly aligned.

Place the timing belt starting on :

• Crankshaft gear B2.

• Tensioner G1.

• Guide roller G2.

• Gear of the exhaust camshaft A3.

• Gear of the inlet camshaft A2.

adjustment of the belt tension

Put back :

• The pulley of the crankshaft.

• The screw of the crankshaft pulley.

With the tool Rg1 :

• Rotate the tension roller G1 clockwise in order to align the pointer on the position T + 1cm.

• Rotate the tension roller G1 clockwise in order to align the pointer on the position T.

With the tool Sg1 :

• Tighten the fastening screw EG1 of the tensioner G1.

The index T should be placed between the opening sides.

Carry out :

• Setting adjustment.

setting adjustment

Unfasten by two rotations the screws P & Q of the camshaft gears.

Put the tool Ac VAS 611 007 in place :

• Flwyheel side.

Beware of strictly applying the setup position Ac :

Color marking :

• Red : colored exhaust camshaft.

• Blue : colored intake camshaft.

setting adjustment

Unscrew :

• The locking bolt D2 & D3.

• Green = release.

Rotate :

• The screws E2 & E3.

• The value should be 0°00.

Screw :

• The locking bolt D2 & D3 (tightening torque 1 daN.m).

• The value should be 0°00.

• Red = block.

Remove :

• The crankshaft locking pin Pg.

Tighten the screws of the camshaft gears (tightening torque 5 daN.m):

• With the tool Ka.

Unscrew :

• The locking bolt D2 & D3.

• Green = release.

Put the tool Bc in place.

Rotate the crankshaft by 2 rotations.

Insert the TDC locking pin Pg.

setting adjustment

Remove the tools Bc.

Unfasten by two rotations the screws P & Q of the camshaft gears.

Double check the TDC position of the crankshaft.

Unscrew :

• The locking bolt D2 & D3.

• Green = release.

Rotate :

• The screws E2 & E3.

• DADA 150hp the value should be 0°5 & 1°5 +/- 1°5 ( image 21107 ).

• DACA/B 130hp the value should be 0°2 & 0°5 +/- 1°5 ( image 21108 ).

Screw :

• The locking bolt D2 & D3 (tightening torque 1 daN.m).

• DADA 150hp the value should be 0°5 & 1°5 +/- 1°5.

• DACA/B 130hp the value should be 0°2 & 0°5 +/- 1°5.

• Red = block.

Remove :

• The crankshaft locking pin Pg.

Tighten the screws of the camshaft gears (tightening torque 5 daN.m +135°):

• With the tool Ka.

Unscrew :

• The locking bolt D2 & D3.

• Green = release.

Put the tool Bc in place.

Rotate the crankshaft by 2 rotations.

Insert the TDC locking pin Pg.

DADA 150hp the value should be 0°5 & 1°5 +/- 1°5.

DACA/B 130hp the value should be 0°2 & 0°5 +/- 1°5.

If the metered values belong to the clearance area of the required value, the adjustment is OK :

• Proceed reversing the order of the removal.

Otherwise :

• Restart the adjustment process if the target values are not reached.

tightening torque

Tighten :

• The screw of the crankshaft pulley 15 daN.m +180°.

• The locking screw of the guide roller 4 daN.m.

• The screw EG1 fastening the tensioner 2.5 daN.m.

• The center screw P of the intake camshaft gear 5 daN.m +135°.

• The center screw Q of the exhaust camshaft gear 14 daN.m.

• The center screw C9 of the exhaust camshaft gear 2 daN.m + 90°.