11A-38
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting
K9K
11A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aDisconnect the battery (see Battery: Removal - Re-
fitting) (80A, Battery).aRemove:
-the engine cover,
-the windscreen wiper arms (see Windscreen wip-
er arm: Removal - Refitting) (85A, Wiping -
Washing),
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
-the scoop under the scuttle panel grille (see Scoop
under the scuttle panel grille: Removal - Refit-
ting) (56A, Exterior equipment),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
-the halogen headlights (see Halogen headlight:
Removal - Refitting) (80B, Headlights),
-the front upper cross member (see Front upper
cross member: Removal - Refitting) (42A, Upper
front structure),
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-13) ,
-the camshaft position sensor (see 13B, Diesel in-
jection, Camshaft position sensor: Removal -
Refitting, page 13B-14) ,
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-3) ,
-the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-20) . Special tooling required
Mot. 1672Low er engine support.
Mot. 1489TDC locating pin.
Mot. 1430Set of 5 crankshaft and cam-
shaft pulley timing pins.
Tightening torquesm
tensioning roller bolt27 N.m
camshaft pulley wheel
bolts14 N.m
TDC setting pin plug25 N.m
cylinder head sus-
pended mounting bolts25 Nm
IMPORTANT
Wear protective gloves during the operation.
WARNING
The belt must be replaced with a new one if it has
been removed.
WARNING
When replacing the belt, always replace the tension
wheels and idler pulleys.
WARNING
Do not r un the engine without the accessories belt
to avoid damaging the crankshaft accessories pul-
ley.
11A-39
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting
K9K
11A
aRefit the old crankshaft accessories pulley bolt (1)
fitted with a spacer (2) (which does not cover the tim-
ing sprocket mark).
aUnclip the upper timing cover at (3) .
aRemove the upper timing cover (4) .
aRaise the engine using the lower tool (Mot. 1672).
aUnclip the lower timing cover at (5) .
aLower the engine using the lower tool (Mot. 1672).
aRemove:
-the plastic clip (6) from the lower timing cover,
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K9K, and 740
19654
19654-1
11A-41
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting
K9K
11A
aUnclip the upper timing cover at (8) and (9)
aRemove:
-the plastic clip (10) from the upper timing cover,
-the upper timing cover.
aUnclip the lower timing cover at (11) and (12) .
aRemove the lower timing cover.
aRaise the engine using the lower tool (Mot. 1672). K9K, and 718
141221
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136662
11A-42
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting
K9K
11A
aRemove the bolts (13) from the suspended mount-
ing on the cylinder head.
aTwist the timing belt slightly (to facilitate removing
the suspended mounting from the cylinder head).
aRemove the suspended mounting from the cylinder
head.aRemove the plug (14) from the TDC setting pin.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aTurn the crankshaft to position the camshaft pulley
hole (15) almost opposite the cylinder head hole (16)
.
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11299819650
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11A-43
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting
K9K
11A
aFit the tool (Mot. 1489) (17) on the cylinder block.
aTurn the crankshaft clockwise (timing end) smoothly
until the crankshaft is pressed against the TDC set-
ting pin.aInsert the (Mot. 1430) (18) in the camshaft pulley
and cylinder head holes.
aLoosen the timing tensioning roller bolt (19) to relax
the timing belt.
aRemove:
-the timing belt,
-the timing tensioning roller bolt,
-the timing tensioning roller.
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11A-44
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting
K9K
11A
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: Timing belt
aparts always to be replaced: Timing belt tension-
ing rollerII - REFITTING OPERATION FOR PART
CONCERNED
aRefit a new timing tensioning roller.
aCheck that:
-the lug (20) of the tensioning roller is in place in the
groove (21) of the cylinder head,
-the high pressure pump mark (22) is one tooth to
the right from the vertical axis (23) ,
-the crankshaft is resting on the tool (Mot. 1489)
(the cotter (24) of the crankshaft timing sprocket
upwards).
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