B1EG1IK1 - 206 DW10TD ENGINE

REMOVAL - REFITTING TIMING BELT

1 - SPECIAL TOOLS

[1]SEEM C.TRONIC tension measuring equipment (Type 105.5M) .

[2]Crankshaft setting rod (-).0188-Y .

[3]Camshaft setting rod (-).0188-M .

[4] Belt retaining clip (-).0188-K .

[5] flywheel stop (-).0188-F .

[6] Crankshaft spanner (-).0117-EZ .

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

[8] Lifting chain (-).0102-M .

[9] Tension lever (-).0188-J2 .

[10] pulley extractor (-).0188-P .

[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

Remove :

• the front right mud shield
• the ancillary drive belt
• the turbo pipe
• 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 .

Turn the crankshaft with the tool [6] .

Peg the flywheel using the rod [2] .

Disconnect the battery .

Remove the style cover .

Move aside :

• the expansion chamber (1)
• the ECU (2) and its support

Unclip and move aside the fuel pipes (3) .

IMPERATIVE : plug the holes using tool [11] .

Remove :

• the connecting plate (4)
• the stop (5)
• the timing covers (6)

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 (7) .

Peg the camshaft pulley with tool [3] .

Slacken the roller tensioner fastener (8) .

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 (9) ; (10) as well as the coolant pump (11) 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 (10) to 4.3 m. daN .

Slacken the bolts (12) .

Check that the pulley (13) rotates freely on its hub .

Tighten the bolts (12) by hand .

Slacken the bolts (12) by 1/6 turn .

Turn the pulley (13) 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 (10)

Lay the timing belt on the pulley (14) .

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 (9) and on the coolant pump gear (11) .

Place the tensioner roller (9) in contact with the belt .

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

Remove the tool [4] .

4 - 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 (9) anti-clockwise (Using the tool [9]) .

Display 98 ± 2 SEEM units .

Tighten the bolt (8) to 2.3 da.Nm (Without altering the position of the roller) .

Remove the tool [1] .

IMPERATIVE : by removing a bolt (12) on the pulley (13), ensure that these bolts (12) are not at the limit of the slot; if this is the case, repeat the timing belt fitting operation .

Bring the bolts (12) into contact with the pulleys .

Tighten the bolts (12) 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 .

5 - FITTING AND TENSIONING THE TIMING BELT

Refit the rods [2] - [3] .

Unscrew : The bolts (12) .

Tighten the bolts (12) by hand .

Slacken the bolts (12) by 1/6 turn .

Slacken the bolt (8) .

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 (8) to 2.3 da.Nm (Without altering the position of the roller) .

Tighten the bolts (12) 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]

6 - 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] .

7 - REFITTING (CONTINUED)

Fit :

• the bottom timing cover
• the engine mounting (7)
• the 3 bolts (15) : tightening torque 4.5 da.Nm
• the nut (16) : tightening torque 4.5 da.Nm
• the timing cover components (6)
• the stop (5) : tightening torque 3.2 da.Nm
• the connecting plate (5) : tightening torque 2.15 da.Nm

Fit :

• the tool [5]

Refit the torque reaction link (17) .

Tighten :

• the bolt (18) to 5 da.Nm
• the bolt (19) to 3.5 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 (always renew : the exhaust fasteners)

Tighten the wheel bolts to 8.5 da.Nm .

Refit the various components in the reverse order to removal .

Initialise the various ECUs .