1998 FIAT PUNTO specified torque

2B*6 DOHC (16-valve) petrol engine in-car repair procedures
4.24a Scrow in the camshaft locking tools into the timing holes in the cylinder head extension
locking tools Into the timing holes in the cylinder head extension. To provide the necessary degree of timing accuracy, the machined end of the locking tools are a very close fit in the slots machined in the camshafts. To allow the tools to be screwed
4.26 Slip the timing belt off the sprockets
To make a camshaft sprocket holding tool, obtain two lengths of steel strip about 6 mm thick by 30 mm wide or simitar, one 600 mm long, the other
200
mm long (all dimensions approximate). Bolt the two strips together to form a forked end, leaving the bolt slack so that the shorter sfrfp can pivot freely. At the end of each 'prong' of the fork, secure a bolt with a nut and a locknut, to act as the fulcrums; these will engage with the cut-outs In the sprocket, and should profrude by about 30 mm
4.24b The tools engage in tho camshaft slots when fitted (shown removed for clarity)
fully into engagement, it may be necessary to move the crankshaft In one direction or another very slightiy until the tools are felt to engage fully (see illustrations). 25 Release tho nut on the timing belt tensioner to release the tension on the belt (see illustration) 26 II the timing belt is to be re-used, use white paml or chalk to mark the direction of rotation on the belt (if markings do not already exist), then slip the belt off the sprockets (see illustration). Note that the crankshaft must not be rotated whilst the belt is removed. 27 Check the timing belt carefully for any signs of uneven wear, splitting, or oil contamination. Pay particular attention to the roots ol the teeth. Renew it If there is the slightest doubt about its condition. If the engine is undergoing an overhaul, renew the belt as a matter of course, regardless of its apparent condition. The cost ol a new bett is nothing compared with the cosi of repairs, should the belt break in service. If signs of oil contamination are found, trace the source of the oil leak 8nd rectify it. Wash down the engme timing belt area and all related components, to remove all traces of oil,
Refitting 28 Before refilling, thoroughly clean the liming bell sprockets. Check that Ihe tensioner pulley rotates freely, without any sign of roughness. If necessary, renew Ihe tensioner pulley as described in Section 5,
4.31 Fit the new belt around the sprockots observing the direction markings
4.25 Release the nut on the timing belt tensioner (arrowed)
29 The camshaft sprocket retaining bolt mutt; now be slackened to allow the sprocket Ic move as the timing bell Is refitted una tensioned. To hold the sprocket stationary^ while the retaining bolt is loosened, make upi. tool os follows and engage
>t
with the holes ^ i the sprocket (see Tool Tip). With the sprocket. held, slacken the retaining bolt. 30 Check that the pi6tons are still correct positioned at ihe mid-point of their stroke are that the camshafts are locked with the lockup: tools. 31 Ensuring that the direction markings on the timing belt point in the normal direction
cf
engine rotation, engage the Umlng belt vr* Ihe crankshaft sprocket first, then placed around the coolant pump sprocket and tte: camshaft sprocket (see Illustration). Rnaii>; slip the belt around the tensioner pulley. 32 Insert the jaws of a pair of right-angleo clrclip pliers (or similar) into Ihe two holes on; Ihe front face of the tensioner pulley (sec Illustration). Rotate the pulley to tension Ihj; belt until the belt Is quite taut. Maintain thr effort applied to the tensioner pulley. JM* tighten the pulley retaining nut. 33 Tighten the camshaft sprocket retains; bolt to the specified torque while holding th?; camshaft stationary using the method described previously (see Illustration). 34 Remove the piston positioning tools arc camshaft locking tools and turn In*; crankshaft through two complete turns In the normal direction of rotation,
4.32 Using right-angled clrclip pliers, turn the tensioner pulley to fully tension the bell

2B*7 DOHC (16-valve) petrol engine in-car repair procedures
35 Slacken the tensioner pulley retaining nut and reposition the tensioner to align the
mobile
indicator with the fixed reference mark
on the
pulley face (see illustration). Hold the
pdley in
this position and tighten the retaining
nut to the
specified torque. 36 Turn the crankshaft through a further two complete turns In the normal direction of rotation. Check that the timing is correct by alining Ihe piston positioning tools and
camshaft
locking tools as described previously. 37 When all is correct, remove the setting rri
locking
tools and refit the sealing plugs to 1ft© cylinder head extension, using new 0-
nr^s if
necessary. Tighten the plugs securely. 38 Refit the spark plugs as described in Chapter 1A. 39 Refit Ihe ECU and secure with Ihe mooning bolts. 40
Renew the
injector O-ring seals, smear them Kith
8 little
Vaseline then locate the injectors and tef rail onto the inlet manifold lower section.
Saute Ihe fuel rail
with the two retaining bolts. 41 Relit the inlet manifold upper section using new sealing O-rlngs If necessary and
sectre
with the two bolts. 42 Reconnect the wiring connectors for the tot injector harness and the intake air temp-erature/pressure sensor, then connect the fuel pressure regulator vacuum hose and tha
EVAP
purge valve hose. 43 Reconnect the wiring connectors for the ihrottls potentiometer, idle control stepper motor and coolant temperature sensor. Reconnect the brake servo vacuum hose. 44 Refit and adjust the accelerator cable as described in Chapter 4B. 46 Refit the upper and lower timing belt
covers
together with the TDC sensor wiring. 46 Refit the crankshaft pulley and tighten the
three
retaining bolts securely. 47 Refit the air cleaner. Inlet air duct and resonator as described in Chapter 4B. 48
Refit
tha auxiliary drivebelt(s) as described i/t Chapter 1A, then reconnect the battery
S Timing belt tensioner
and
sprockets -
removal
and refitting

Timing
belt tensioner
Removal I
Remove
the timing belt as described in
Section
4. 1 Completely unscrew the tensioner nut and Wiethe tensioner off the mounting stud-Inspection
3 Wipe
the tensioner clean but do not use Kfrents that may contaminate the bearings.
Spin
the tensioner pulley on its hub by hand.
Sfcfl
movement or excessive freeplay is an rcfceticn of severe wear: the tensioner is not 3 serviceable component, and should be nnewsd.
4.33 Holding the camshaft sprocket with the tool described previously while tightening the sprocket bolt Refitting 4 Slide the tensioner pulley over the mounting stud and fit the securing nut. 5 Refit the timing belt as described in Section 4. Camshaft sprocket Removal 6 Remove the timing belt as described in Section 4. 7 Unscrew the bolt and slide the sprocket from the end of the camshaft. Inspection 8 With the sprocket removed, examine the camshaft oil seal for signs of leaking. If necessary, refer to Section 6 and renew it. 9 Check the sprocket teeth for damage. 10 Wipe clean the sprocket and camshaft mating surfaces. Refitting 11 Locate the sprocket on the end of the camshaft, then refit the retaining boll finger tight only at this stage. 12 Refit the timing belt as described in Section 4.
Crankshaft sprocket Removal 13 Remove the timing bell as described In Section 4. 14 Working beneath the engine, unbolt and remove the flywheel lower cover, then hold the flywheel stationary preferably using a tool which engages the flywheel starter ring
<

Alternatively have an assistant engage a wide-bladed screwdriver with the starter ring gear. 15 Unscrew the crankshaft sprocket retaining bolt and slide the sprocket off the end of the crankshaft. The sprocket may have an integral location key on its inner face, or a separate key which locates In a groove in the crankshaft nose may be fitted. Inspection 16 With the sprocket removed, examine the crankshaft oil seal for signs of leaking. If necessary, refer to Section 7 and renew it. 17 Check the sprocket teeth for damage. 18 Wipe clean the sprocket and crankshaft mating surfaces. Refitting 19 Slide the sprocket onto the crankshaft making sure
11
engages the integral key or separate key, then refit the bolt and washer and tighten the bolt to the specified torque while holding the crankshaft stationary using the method described in paragraph 14. 20 Refit the timing belt as described in Section 4.
6 Camshaft
oil
seal -renewal
1 Remove the timing belt and camshaft sprocket as described in Sections 4 and 5. 2 Punch or drill a small hole in the oil seal. Screw a self-tapping screw into the hole, and pull on the screws with pliers to extract the seal. 3 Clean the seal housing, and polish off any burrs or raised edges, which may have caused the seal to fall in the first place. 4 Lubricate the lips of the new seal with clean engine oil, and drive it into position until It seats on its locating shoulder. Use a suitable tubular drift, such as a socket, which bears only on the hard outer edge of the seal. Take care nof to damage the seal lips during fitting. Note that the Seal lips should face inwards. 5 Refit the camshaft sprocket and timing belt as described in Sections 5 and 4.
7 Crankshaft oil seats -renewal I
4.35 Position the tensioner so that the mobile Indicator (1) is aligned with the fixed reference mark (2)
Front (right-hand side) oil seal 1 The front oil seal is located in the oil pump on the front of the crankshaft. Remove the timing belt as described in Section 4 and the crankshaft sprocket as described in Section 5. 2 Using a hooked Instrument, remove the oil seal from the oil pump casing taking care not to damage the surface of the crankshaft. 3 Clean the seating in the housing and the surface of the crankshaft. To prevent damage to the new oil seal as it is being fitted, wrap some adhesive tape around the end of the crankshaft and lightly oil it.

2B*9 DOHC (16-valve) petrol engine in-car repair procedures
8.12 Rofit tho cylinder head extension retaining bolts and tighten them to tho specified torque 11 Locate the cam follower retaining tools in position Ihen lower the extension assembly onto the cylinder head. When all the cam followers have engaged their respective valves, remove the tools. 12 Refit tho retaining bolts and tighten them progressively to pull the extension down onto
the
cylinder head. Do this slowly and carefully
as the
vaivo springs will be compressed during Ihfs operation and it is essential to keep the extension square and level as the bolts are lightened. Once all the bolts are Initially Bghloned. progressively tighten them further to
the specified
torque (see illustration). 13 If necessary renew the O-rlng seals on the protective caps covering the cylinder head extension retaining bolts (see illustration).
Refit
the caps and tighten them securoly. 14 Refit the resonator support bracket to the
Icp of
the cylinder head extension.
8.13 Renew the O-ring seals on the protective caps covering the cylinder head extension retaining bolts 15 Refil the ignition coils and reconnect Ihe wiring. 16 Refit the timing belt as described in Section 4.
9 Camshafts and cam ^ followers -
removal,
S inspection and refitting ^
Removal 1 Remove the cylinder head extension as described in Section 8. 2 Place the assembly upside down on a bench and lift off the cam follower retaining tools, 3 Remove the cam followers from their locations In the cylinder head extension and place them In an oil tight compartmented box
labelled 1 to 8 (inlet) and 1 to 8 (exhaust) (see illustration). Alternatively, place them into individual storage jars or containers suitably marked. Fill the box or the jars with clean engine oil until each cam follower is just submerged, 4 Undo the camshaft sprocket retaining bolt while holding the sprocket with a suitable tool as described In Section 4. 5 Remove the camshaft sprocket, then undo the bolt and nut and remove the cover plate over the inlet camshaft (see Illustrations), 6 At the other end of the cylinder head extension, undo the nuts and remove the end cover (soe Illustration). Recover the gasket. 7 Undo the two bolts securing the camshaft drive gears to the inlet and exhaust camshafts (see illustration). The camshaft locking tools used in the timing belt removal procedure (which should still be in place) are sufficient to prevent the camshafts rotating while the gear retaining bolts are undone. Remove the bolts and withdraw the camshaft gears. 8 Remove the camshaft locking tools. 9 Carefully remove the Inlet camshaft from the cylinder head extension (see illustration). Suitably mark the camshaft IN to avoid confusion when refitting. 10 Punch or drill a small hole in the exhaust camshaft oil seal. Screw a self-tapping screw into the hole, and pull on the screw with pliers to extract the seat (soe illustration). 11 Carefully remove Ihe exhaust camshaft from the cylinder head extension (soe illustration). Suitably mark the camshaft EX to avoid confusion when refitting.
JJ Remove the cam followers from their 9.5a Remove the camshaft sprocket... locations in the cylinder head extension
9.5b ... then undo the bolt and nut and remove the cover plate over tho inlet camshaft
9.6 Undo the nuts and remove the end cover
9.7 Undo the two bolts securing the camshaft drive gears to the inlet and exhaust camshafts 9.9 Carefully remove tho Inlet camshaft from the cylinder head extension

2B*10 DOHC (16-valve) petrol engine in-car repair procedures
9.10 Extract the exhaust camshaft oil seal...
Inspection 12 Examine the camshaft bearing surfaces and cam lobes for signs of wear ridges and scoring. Renew ihe camshaft If any of these conditions are apparent. Examine the condition of the bearing surfaces, both on the camshaft journals and in the cylinder head extension. If the head extension beanng surfaces are worn excessively, the extension will need to be renewed. If suitable measuring equipment Is available, camshaft bearing journal wear can be checked by direct measurement. 13 Examine the cam follower bearing surfaces which contact the camshaft lobes for wear ridges and scoring. Renew any follower on which these conditions are apparent. If a follower bearing surface is badty scored, also examine the corresponding lobe on the camshaft for wear, as it is likely that both will be worn. Renew worn components as necessary.
9.11 ... then remove the exhaust camshaft from the cylinder head extension
Refitting 14 Liberally lubricate the camshaft journals and cylinder head extension bearings, then locate both camshafts in position Note that the exhaust camshaft is nearest to the front facing side of the engine. 15 With the camshafts In position, rotate them as necessary until the camshaft locking tools can be re-inserted (see illustration). 16 Lubricate the Hps of a new exhaust camshaft oil seal with clean engine oil, and drive It into position until it seats on its locating shoulder (see Illustration). Use a suitable tubular drifl, such as a socket, which bears only on the hard outer edge of the seaJ. Take care not to damage the seal lips during fitting. Noto that the seal lips should face inwards. 17 Refit the Inlet camshaft drive gear and retaining boll then tighten the bolt to the specified torque (see illustration).
9.16 Fit a new exhaust camshaft oil seal M7 Tighten the Inlet camshaft drive gear retaining bolt to the specified torque
9.15 Refit the camshaft locking tools
18 Refit the exhaust camshaft drive gear to the exhaust camshaft. As the gear is being fitted, It will be necessary to align the anti» backlash inner gear teeth using a screwdriver to enable the teeih of both Ihe gears to mes-i (see Illustration). 19 At this stage it is advisable lo check tie camshaft endfloat using a dial gauge mounted on the cylinder head extension, with its probe in contact with Ihe camshaft being checked Move the camshaft one way. zero the gauge, then move the camshaft as far as it will go ihe other way. Record the reading on the dial gauge and compare the figure with that given in the Specifications. Repeat on the other camshaft. If either of the readings exceeds the tolerance given, a new cylinder head extension will be required. 20 Locate a new gasket on the cylinder head extension end cover, then wrap round the protruding tangs on Ihe gasket to retain it in position (see Illustrations). 21 Locate the end cover on the cylinder heed extension and secure with the retaining nuts securely tightened. 22 Locate a new O-ring on the inlet camshaft cover plate, then apply RTV gasket sealant lo the cover plate contact face (see Illustrations), Fit tho cover plate and secure with the nut and bolt. 23 Refit the camshaft sprocket and secure with the retaining bolt tightened finger tight only at this stage. 24 Liberally lubricate the cam followers and piece them in position in their respective cylinder head extension bores (see illustration),
9.18 Refit the exhaust camshaft drive gear white aligning the anti-backlash Inner gear teeth 9.20a Locate a new gasket on the cylinder head extension end cover... 9.20b ... then wrap round the protruding tangs to retain the gaskel

DOHC (16-valve) petrol engine in-car repair procedures 2B*11
camshaft cover plate... 25 Locate the cam follower retaining tools in position and refit the cylinder head extension
as
described In Section 8.

10
Cylinder head - &
removal and
refitting S
Removal Note; The cylinder head bolts are of special
sekned
design and a Fiat tool should be
obtained
to unscrew them. A Ton key will not
JSt however
in practise It was found that a dose-httlng Alien key could be used as an itemative. 1 Drain the cooling system as described in Chapter 1A. 2 Remove the cylinder head extension as oescAbed
m
Section 8. 3 Disconnect the radiator hose from the thermostat housing on the left-hand end of
Ihe
cylinder head. 4 Disconnect the heater hose from the outlet
at the
rear of the cylinder head. 5 Disconnect the coolant temperature sensor md temperature gauge sensor wiring plugs
torn
the left-hand end of the cylinder head. 9 Undo the engine oil dipstick tube bracket retaining bolt and the two bolts securing the wing harness support clips to the inlet marriold lower section. 7 Undo Ihe retaining nuts and separate the ixhaust system front pipe from the exhaust manifold flange.
8
Check that nothing remains attached to the cinder head likely to impede removal. It Is assumed that the head will be removed complete with exhaust manifold and inlet manifold lower section. 9 Unscrew the cylinder head bolts half a turn K
e
time in the reverse order to that shown in (lustration 10.20a. When the bolts are free. «mwe them from their locations.. Id Lift the cylinder head from the block. If it is stuck tight rock the head to break the joint by mans of the manifolds. On no account drive
levers
into the gasket Joint, nor attempt to tap tf« head sideways, as it is located on positioning dowels. 11 Remove and discard the cylinder head gasket.
JK'
l^. 9.22b ... then apply RTV gasket sealant to the cover plate contact face 12 Refer to Chapter 20 for cylinder head dismantling and inspection procedures. Preparation for refitting 13 The mating faces of the cylinder head and cylinder block must be perfectly dean before refitting the head. Use a hard plastic or wooden scraper to remove all traces of gasket and carbon; also clean the piston crowns, Take particular care when cleaning the piston crowns as the soft aluminium alloy is easily damaged. Make sure that the carbon is not allowed to enter the oil and water passages -this Is particularly important for the lubncahon system, as carbon could block the oil supply to the engine's components. Using adhesive tape and paper, seal the water, oil and bolt holes in the cylinder block. To prevent carbon entering the gap between the pistons and bores, smear a little grease In the gap. After cleaning each piston, use a small brush to remove all traces of grease and carbon from the gap. then wipe away the remainder with a clean rag. Clean all the pistons in the same way. 14 Check the mating surfaces of the cylinder block and the cylinder head for nicks, deep scratches and other damage. If slight, they may be removed carefully with a file, but If excessive, machining may be the only alternative to renewal. If warpage of the cylinder head gasket surface Is suspected, use a straight-edge to check it for distortion. Refer to Part 0 of this Chapter if necessary. 15 Check the condition of the cylinder head bolts, and particularly their threads, whenever they are removed. Wash the bolts In a suitable
sequence
9.24 Lubricate the cam followers and place them in position in their respective bores solvent, and wipe them dry. Check each bolt for any sign of visible wear or damage, renewing them if necessary.
Refitting 18 Before refitting the assembled cylinder head, make sure that the head and block mating surfaces are perfectly clean, and that the bolt holes in the cylinder block have been mopped out to clear any oil, 17 The now gasket should not be removed from its nylon cover until required for use. Fit Ihe gasket dry, and make sure that the mating surfaces on the head and block are perfectly clean. 18 Place the gasket on the cylinder block so that the word ALTO can be read from above. 19 Lower the cylinder head onto the block so that it locates on the positioning dowel. 20 The cylinder head bolt threads must be clean and lightly lubricated. Screw the bolts in finger-tight then working progressively and in the sequence shown, lighten all the cylinder head bolts to the Stage 1 torquo setting given In the Specifications, using a torque wrench and a suitable socket. With all the bolts tightened to their Stage 1 setting, working again in the specified sequence, first angle-tighten the bolts through the specified Stage 2 angle, then again through the Stage 3 angle, using a socket and extension bar. It Is recommended that an angle-measuring gauge Is used during this stage ot tightening, to ensure accuracy (see Illustrations). 21 Reconnect the exhaust system front pipe to the manifold using a new flange gasket.
10.20b Tighten the cylinder head bolts to the Stago 1 torque setting ...

Diesel engine in-car repair procedures
2C*11

C«/ffor>: Where applicable observe the drnctbn of rotation markings on the belt. 12 Tension the timing belt by turning the eccentrically-mounted tensioner clockwise: two ities are provided in the side of the tensioner ftb for this purpose - a pair of sturdy right-ircfed circiip pliers can be used to do this or iftemaiively two bolts and a long screwdriver
may be
used. Fiat use a special tensioner tool
located in
the hotos - this consists of a calibrated rod
and
weight. The weight is positioned 60 mm tog the rod to provide the correct tension to the belt, then the tensioner nul is tightened. Tgttn tho tensioner nut to the specified torque
(see
illustrations) 13
If the
tensioner tool Is not available, test the wsicn by grasping the timing belt between the li^er and thumb midway between the camshaft and injection pump pulleys, and Using il through 90" (see paragraph S).
Caution: The above procedure serves only as a rough guide to setting the belt tension. The tension must be checked accurately by a Fiat dealer using the spec/a/ fens/oner tool, at the earliest opportunity. 14 Tum the engine two complete turns clockwise, check that all the timing marks are still aligned then recheck the timing belt tension. If necessary carry out the tensioning procedure again, 15 Refit the components disturbed for access, using the reverse of the removal procedure and bearing In mind the following points: a) Tighten all nuts and bolts to the specified torque, where given. b) Refit the auxiliary dnvebelt(s) as described in Chapter 18.
5 Timing belt tensioner ^ and sprockets - removal, ^ inspection and refitting ^
1 Follow the procedure for removing the timing belt In Section 4, however it is not necessary to completely remove the belt from the timing sprockets provided it is kept fully engaged with them. 2 Unscrew the nut and slide the tensioner off the mounting stud (see illustrations).
Inspection 3 Wipe the tensioner clean but do not use solvents that may contaminate the bearings. Spin the tensioner pulley on its hub by hand. Stiff movemeni or excessive freeplay Is an Indication of severe wean the tensioner is not a serviceable component, and should be renewed, Refitting 4 Slide the tensioner pulley over the mounting stud and screw on the nut. 5 Refer to Section 4 and refit the timing belt.
Timing belt idler pulley
Removal 6 Remove Ihe timing belt as described In Section 4. 7 Unscrew the mounting bolt and remove the idler pulley from the front of the cylinder block (see illustration). Inspection 8 Wipe the idler clean but do not use solvents that may contaminate the bearings. Spin the idler pulley on Its hub by hand. Stiff movement or excessive freeplay Is an Indication of severe wear; the Idler is not a serviceable component, and should be renewed. Refitting 9 Refit the idler to the front of the block and tighten the bolt to the specified torque (see illustration). 10 Refer to Section 4 and refit the liming belt.
Timing belt tensioner
Removal
5.9 Tightening the idler pulley mounting bolt

2C*2 Diesel engine in-car repair procedures
5.11 Special Fiat tool necessary to accurately position the camshaft before fitting the sprocket
Camshaft sprocket Removal 11 Remove the timing belt as descnbed in Section 4. A special Rat tool (see illustration) is necessary to position the camshaft before refitting the sprocket, however il the original camshafl Is being re-used, use of the special tool can be ovoided by accurately marking the camshaft position before removing the sprocket. Caution: On later 1996 models the camshaft sprocket can be moved In either direction on tho camshaft location dowel. 12 The camshaft sprocket must now oe held stationary whilst the retaining bolt is loosened. This is no problem on later models where the sprocket incorporates holes, however some early models have a sprocket without holes • on this type Fiat technicians use a special tool
V*— r^r
To make a camshaft sprocket holding tool, obtain two lengths of steel strip about 6 mm thick by 30 mm wide or simllar, one 600 mm long, the other 200 mm long (all dimensions approximate). Bolt the two strips together to form a forked end, leaving tho bolt slack so that the shorter strip can pivot freely. At the end of each 'prong' of the fork, secure a bolt with a nut and a locknut, to act as the futcrums; theso will engage with the cut'Outs In the sprocket, and should protrude by about 30 mm
which clamps on the sprockot teeth. If this tool is not available, it may be possible to make up a similar tool. On later models a sprocket holding tool can easily be made (see Toot Tip). 13 On 1996-on models mark the position of the camshaft in relation to the cylinder head.
5.14a Unscrew and remove the bolt and washer...
This is best achieved by removing tho vacuum pump from the flywheel end of the head and marking the head in relation to Ihe drive slot in ihe end of the camshaft. Note the location of the hose and bracket when removing tha vacuum pump (seo illustration). 14 Unscrew and remove tho boll and v/ashof and withdraw the sprocket from the end of tha camshaft (see Illustrations). Note tha location peg on the camshafl. Inspection 15 With the sprocket removed, examine the camshaft oil seal for signs of leaking. If necessary, rater to Section 7 and renew it 16 Check the sprocket teeth for damage. 17 Wipe clean the sprocket and camshaft mating surfaces-Refitting 18 Locate the sprocket on the end of the camshaft. On J996-on models chock that the camshaft is positioned accurately to tho previously made marks and also make sura thai the TOC mark on Ihe sprocket Is aligned with the mark on the Inner timing cover. If avoiiablo use the special Fiat toot to locate the camshaft correctly. Rofil the bolt and washer and tighten lo the specified torque while holding the camshalt sprocket stationary using the method descnbed previously. Recheck all alignment marks. 19 Refit the timing belt as described in Section 4.
Crankshaft sprocket Caution: The crankshaft sprockot retaining bolt has a left-hand thread. Removal 20 Remove the timing belt as described in Section 4. 21 Working beneath the engine unbolt and remove the flywheel lower cover, than hold the flywheel stationary preferably using a tool which engages the flywheel starter ring gear (see Section 10). Alternatively have an assistant engage a wide-bladed screwdriver with the starter ring gear 22 Unscrew and remove (he crankshaft sprocket retaining bolt (left-hand thread), washer and spacer and slide the sprocket off the end of the crankshaft (see illustrations). It is quite tight and il will be necessary to use a
5.14b ... and remove the sprocket from tho end of the camshaft 5.22a Unscrew and remove the bolt, washer and spacer... 5.22b ... and remove the crankshaft sprocket

Diesel engine in-car repair procedures
2C*11

5.31c ... followed by the Woodruff key
rocking motion to remove It, Note that the sprocket Is located by an integral key. Inspection 23 With the sprocket removed, examine the crankshaft oil seal for signs of leaking. If necessary, refer to Section 8 and renew it. 24 Check the sprocket teeth for damage. Also check the key and if necessary renew it. 25 Wipe clean the sprocket and crankshaft mating surfaces. Refitting 26 Slide the sprocket onto the crankshaft and engage the key with the slot In the crankshaft. 27 Refit the bolt, washer and spacer and tighten the bolt to the specified torque white holding the crankshaft stationary using the method described in paragraph 21. 28 Refit the timing belt as described in Sectton 4.
6.3a Support bracket positions on the camshaft cover
5.31a Use a puller to release the sprocket from the injection pump shaft
5.35 Tightening the injection pump sprocket bolt
Injection pump sprocket
Removal 29 Remove the timing belt as described In Section 4. 30 Using a suitable tool hold Ihe injection pump sprocket stationary, then unscrew the nut securing the sprocket to the injection pump shaft (see illustration). 31 Using a suitable puller remove the sprocket from the end of the injection pump shaft and recover the Woodruff key from the groove (see illustrations),
Inspection 32 With the sprocket removed, check the sprocket teeth for damage. Also check the key and if necessary renew It. 33 Wipe clean the sprocket and injection pump shaft,
5.31b Removo tho injection pump sprocket...
Refitting 34 Locate the key in the groove making sure that it is fully Inserted and parallel with the shaft surface. 35 Refit the sprocket onto the Injection pump shaft then refit the bolt and washer and tighten the bolt to the specified torque while holding the sprocket stationary (soe illustration). 36 Refit the timing belt as described In Section 4,
6 Camshaft cover -removal and refitting ^
Removal 1 Remove the air ducting from the camshaft cover as described in Chapter 40, Section 2. 2 Unclip the coolant hoses from the camshaft cover and tie them out of tho way. 3 Note the position of the support brackets then progressively unscrew the mounting bolts from the top of the camshaft cover and lilt off the cover (see illustrations). If it sticks, do not attempt to lever it off • instead free it by working around the cover and tapping it lightly with a soft-faced mallet. 4 Recover the camshaft cover gasket. Inspect the gasket carefully, and renew It if damage or deterioration is evident (see illustration). 5 Clean the mating surfaces of the cylinder head and camshaft cover thoroughly, removing all traces of oil and old gasket • take oaro to avoid damaging the surfaces as you do this.
6.4 ... and gasket