B1EG0IK1 - 406D8 XU7JP4 ENGINE XU10J4R ENGINE

REMOVAL - REFITTING TIMING BELT

1 - SPECIAL TOOLS

[1] lifting hook (-).0102 G .

[2] crankshaft setting rod (-).0153 G .

[3] crankshaft pulley extractor (-).0174 .

[4] flywheel stop (-).0134 Q .

[5] belt tension measuring equipment SEEM C.TRONIC type 105.5 .

[6] camshaft hub setting rods (-).0153 AB .

2 - REMOVAL

Remove the front right-hand wheel .

Move aside the mud shield .

XU7JP4 ENGINE

remove the ancillary drive belt .

XU10J4R ENGINE

remove the ancillary drive belt .

ALL MODELS

Move aside :

● the engine harness (1)

● purge canister solenoid valve (2)
Support the engine with a crane and hook [1] .

Remove the engine mounting and torque control link assembly (3) .

Pull the fork (4) .

Slacken the bolts (5) (Fully) .

Remove the cover (6) upward .

Peg in the order :

● the crankshaft with the rod [2]

● the camshaft hubs, using the rods [6]

Remove :

● the ancillary drive belt tensioner

● the crankshaft pulley (7) (using the stop [4] and the extractor [3])
● the casing (8)
● the stop [4]

Slacken the bolt (9) .

Remove the belt without bending it .

3 - REFITTING
Check that the rollers (10) and (11) turn freely (no play and no tight spots) .

Fit the belt on the crankshaft gear following the direction of fitting .

Fit :

● the casing (8)

● the pulley (7), by tightening bolt (12) pre-coated with LOCTITE FRENETANCH (tightening
torque 12 da.Nm)
● peg the crankshaft with the rod [2]
Without removing the rods :

● slacken the 6 bolts (13)

● check that the pulleys (14) and (15) turn freely on their hubs (16)
● finger tighten the 6 bolts (13) then slacken them 1/6 of a turn
● move the pulleys (14) and (15) against the ends of the slots by turning them in the direction of
engine running
WARNING : ensure that during this operation the timing belt does not jump a tooth on the crankshaft
gear .

Fit the timing belt, run (17) well tensioned, in the following order :

● crankshaft
● roller tensioner

Lay the timing belt on the pulley (15) .

Turn the pulley carefully in the opposite direction to engine rotation to engage the belt on the pulley
(15) .

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

Proceed in the same way for the pulley (14) .

Engage the belt on the roller tensioner and on the coolant pump gear .

4 - PRE-TENSIONING VALUE FOR FITTING THE TIMING BELT

XU10J4R ENGINE

XU7JP4 ENGINE

Remove the timing gear cover retaining bolt located at (A) .

ALL MODELS
Without removing the rods :

● fit the equipment [5] to the belt run (17) taking care it is not constrained by its surroundings
● turn the roller tensioner (9) anti-clockwise using the square drive until 45 SEEM units are
displayed
● tighten the bolt (9) to 2 da.Nm. without altering the position of the roller
● by removing one bolt from each of the camshaft gears, check that the 6 bolts (13) are not against
the ends of the slots

If they are, restart the fitting operation .

Tighten the 6 bolts (13) to 1 da.Nm. .

Remove :

● the equipment [5]

● the pegs [2]-[6]

5 - BELT FITTING TENSION

IMPERATIVE : never turn the crankshaft in the reverse direction .

Turn the crankshaft two turns in the direction of running .

Peg the crankshaft with the rod [2] .

Slacken the 6 bolts (13) .

Finger tighten the 6 bolts (13) then slacken them 1/6 of a turn .

Peg the camshaft hubs with the rods [6] turning them a little by means of the bolts (18) (If necessary) .

Slacken the bolt (9) .

Proceed as for the timing belt pre-tensioning operation observing the following points :

● display 26 SEEM units

● tighten the bolt (9) to 2 da.Nm
● tighten the 6 bolts (13) to 1 da.Nm.

6 - CHECKING BELT TENSION

IMPERATIVE : never turn the crankshaft in the reverse direction .

Turn the crankshaft two turns in the direction of running .

Fit the crankshaft setting rod (Using the tool [2]) .

Slacken the 6 bolts (13) .

Finger tighten the 6 bolts (13) then slacken them 1/6 of a turn .

Peg the camshaft hubs with the rods [6] turning them a little by means of the bolts (18) (If necessary) .

Tighten the bolts (13) to 1 daN.m .

Remove setting rods [2] and [6] .

IMPERATIVE : never turn the crankshaft in the reverse direction .

Turn the crankshaft a quarter turn in the direction of running .

Fit the equipment [5] to the belt run (20) taking care it is not constrained by its surroundings .

The tension value should be between 32 and 40 SEEM units .

If this is not the case, restart the timing belt tensioning operation .

Refit the various components in the reverse order to removal .

XU7JP4 ENGINE

Tighten the timing gear cover retaining bolt to 2 m.daN .

ALL MODELS

Tighten the ancillary drive belt tensioner securing bolts to 3 daNm lbf. ft.) .

XU7JP4 ENGINE POWER STEERING AIR CONDITIONING XU10J4R ENGINE POWER

STEERING AIR CONDITIONING

Tighten the serpentine belt automatic tensioner securing bolts to 2 m.daN .

ALL MODELS

Refit the engine mounting and reaction link rod assembly (3) .

XU10J4R ENGINE

Tighten :

● the nuts (19) : 8 da.Nm

● the bolts (20) : 8 da.Nm
● the nut (21) : 4.5 da.Nm
● the 3 securing bolts (22) : 5 da.Nm

fit the ancillary drive belt .

XU7JP4 ENGINE

Tighten :

● the nuts (19) : 4.5 da.Nm

● the bolts (20) : 6 da.Nm
● the nut (21) : 4.5 da.Nm
 ● the 3 securing bolts (22) : 5 da.Nm

fit the ancillary drive belt .

ALL MODELS

Route and clip exactly as before :

● purge canister solenoid valve (2)

● the engine harness (1)