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508 - B1EG012RP0 - Removing - Refitting : timing belt Page 1 of 11

REMOVING - REFITTING : TIMING BELT

ESSENTIAL : Observe the safety and cleanliness recommendations .

1. Tooling
Equipment : Trolley jack.

tool Reference Designation


[0194-C] flywheel stop

Figure : E5AB08ST
[0194-B] Camshaft probe

Figure : E5AB08RT
[0194-A] crankshaft setting rod

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Figure : E5AB08QT
[0194-A] High pressure fuel pump drive pulley
immobilising rod

Figure : E5AB08QT
[0194-T] plugs kit

Figure : E5AB05LT

2. Removing

ESSENTIAL : Respect the safety and cleanliness recommendations that are specific to high pressure diesel
injection (HDi) engines .

Put the vehicle on a hoist.


Disconnect the battery.
Remove :
 The engine cover (according to equipment)
 The front right wheel
 The front right mud shield

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Figure : B1EG0LKD

Uncouple and move aside the fuel supply and return pipes( as "a").
Plug the fuel supply and return pipes ; Using tool [0194-T].
Remove the air unions (1).

Figure : B1ED04YD

Uncouple the exhaust line in order to avoid damage to the front rubber tube (At the hose) (if necessary).

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Rotate the engine until the tool [0194-C] locks the flywheel.

Figure : B1EP1UFD

Release and move aside the electrical harness (3).


Disconnect the connector of the engine speed sensor.
Unclip the electrical harness next to the timing covers.
Remove :
 The top timing cover (2)
 The protection cover from the ancillary drive belt (according to equipment)
 The accessories drive belt
 The pulley cover (according to equipment)
 The (4) bolt
 The pulley (5)
 The lower timing cover (6)

Refit screw (4).


Remove the peg [0194-C].

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Figure : B1CG02MD

CAUTION : The crankshaft pulley magnetic track must not bear any signs of damage and must be kept away from all
magnetic sources ; Otherwise, replace the crankshaft pulley.

Remove :
 The engine speed sensor (8)
 The offset prevention angle bracket (7)

Turn the crankshaft by means of the screw (4) to bring the camshaft to its pegging point.
Peg :
 The camshaft ; Using the pin [0194-B] (oil the peg)
 The high pressure fuel pump drive pulley ; Using the pin [0194-A] (oil the peg)
 The crankshaft ; Using the pin [0194-A]

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Figure : B1EG0LMD

Place a trolley jack fitted with a soft pad under the engine oil sump .

N.B. : The trolley jack must be able to support the engine-gearbox assembly.

Remove :
 The (9) bolt
 The 3 bolts (10)
 The 3 bolts (11)
 All of the flexible engine mountings

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Figure : B1EG0DBD

Remove the intermediate engine mounting (13).

CAUTION : Support the dynamic roller tensioner ; Using a 6 -sided wrench ( as "b").

Slacken the bolt (14).


Slacken the timing belt (12) by pivoting the dynamic roller tensioner clockwise.
Remove the timing belt (12) starting with the coolant pump pulley .

3. Check

CAUTION : Just prior to refitting, carry out the checks below.

Check that the coolant pump rollers and pulley are turning freely (without excess play and without tightness).
Check the absence of oil leaks (crankshaft and camshaft sealing rings).
Check the absence of coolant fluid leaks (Coolant pump ).
Check that the engine speed sensor target track (8) is not damaged or scratched.

N.B. : Replace any defective parts.

4. Refitting

CAUTION : Adhere to the tightening torques.

Tightening torques :
 engine
 Power unit suspension
 Exhaust system

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Figure : B1EG0GSD

Check the tightening of the guide roller (16).


Fit the timing belt (12) on the crankshaft pulley .
The bolt (12) with the washer "c" :
 The tensioning roller (16)
 The camshaft pulley (15)
 The high pressure fuel pump pulley (19)
 The coolant pump pulley (17)
 The dynamic roller tensioner (18)

Refit :
 The offset prevention angle bracket (7)
 The engine speed sensor (8)

4.1. Adjusting the timing belt tension

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Figure : B1EM09DD

Bring the index "d" to the centre of the gap "e" by turning the tensioner anticlockwise ; Using a 6 -sided wrench.
Tighten the bolt (14) .

CAUTION : The dynamic roller tensioner (18) index "d" must be centred in the gap "e".

Remove the pegs [0194-B], [0194-A], [0194-A].


Refit :
 The intermediate engine mounting (13)
 All of the flexible engine mountings
 The 3 bolts (11)
 The 3 bolts (10)
 The (9) bolt

Remove the trolley jack.

CAUTION : Do not turn the engine anti clockwise.

Turn the crankshaft by 6 rotations clockwise.


Fit the crankshaft setting rod ; Using the pin [0194-A].
Check the positioning of the index ( as "d").

N.B. : The dynamic roller tensioner (18) index "d" must be centred in the gap "e".

CAUTION : If this is not the case : Resume the timing belt tensioning operation (12).

CAUTION : If it is impossible to peg the camshaft, check that the offset between the camshaft pulley hole and the
pegging hole is not greater than 1 mm. In the event of an incorrect measurement, start the procedure again.

Pin the camshaft pulley (15) ; Using the pin [0194-B].


Pin the drive pulley of the high pressure fuel pump (19) ; Using the pin [0194-A].

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Remove the pegs [0194-B], [0194-A], [0194-A].


4.2. Subsequent operations

Figure : B1EP1USD

Refit the tool [0194-C].


Remove the bolt (4).
Refit :
 The lower timing cover (6)
 The pulley (5)
 The (4) bolt (new)
 The pulley cover (according to equipment)
 The top timing cover (2)

Remove the tool [0194-C].


Couple up : The exhaust line at the flexible pipe (if necessary).
Secure the electrical harness attaching to the timing covers.
Connect the engine speed sensor (8).
Refit :
 The accessories drive belt
 The protection cover from the ancillary drive belt (according to equipment)

Clip the electrical harness (3).

N.B. : Use new plastic clips.

Remove the tool [0194-T].


Connect the fuel supply and return pipes ( as "a").
Refit :
 The front right mud shield
 The front right wheel
 The air hoses (1)
 The engine cover (according to equipment)

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CAUTION : Perform the operations to be carried out following reconnection of the battery.

Reconnect the battery.


Operate the manual priming pump several times to prime the fuel circuit.

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