- Lower the lift.1. Undo the fixing bolts (1a) and remove the protective cover (1b) for the heater plugs control unit.2. Disconnect the electrical connections for the heater plugs control unit (2a) and (2b) and the control unit positive electrical connection (2c).
Description
Connector
2a
Heater plugs control unit
M015A
Description
Connector
2b
Heater plugs control unit
M015B
Description
Connector
2c
Heater plugs control unit
M015C
3. Undo the fixing nuts (3a) and remove the mounting bracket (3b) complete with heater plugs control unit.
Engines: 2.3 JTD 16V
1. Undo the fixing bolt and nuts (1a) and remove the mounting bracket (1b).
Engines: 2.3 JTD 16V
1. Undo the studs on the camshaft housing and remove them.
Engines: 2.3 JTD 16V
1. Fit camshaft timing tools (1a) and insert until the cylindrical part of the tool is fully fitted into hole (1c) on the camshaft. Secure the tool in place tightening the tool ring nuts (1d).
Description
Code
Function
1a
Templates
99360614
Camshaft timing adjustment
Engines: 2.3 JTD 16V
1. Undo the nut fixing the timing drive belt tensioner.2. Release the belt from the pullies and remove it.
1. Using the reaction tool (1a) with pins, stop the rotation of the pulley and undo the bolt (1b) fixing the timing drive pulley.
Description
Code
Function
1a
Counter-torque
1.870.815.000
Timing pulley lock
Description
Code
Function
1a
Pins for counter-torque
1.870.836.000
Timing pulley lock
Engines: 2.3 JTD 16V
1. Position a hexagonal bolt in the housing for the pulley fixing bolt.2. Position the USAG 452/1 universal extractor and tighten the extractor pin until it is in contact with the bolt positioned previously.3. Continue tightening the tool pin until the camshaft pulley is extraected.
Engines: 2.3 JTD 16V
1. Refit the timing pulley (1a) in the housing on the shaft, position the pin (1b) for timing the pulley in relation to the timing sensor, then lock the bolt (1c) fixing the pulley to the shaft.
Description
Code
Function
1b
Pin for timing adjustment
1.860.617.000
Positioning of timing pulley with timing sensor
Engines: 2.3 JTD 16V
1. Rotate the moving tensioner to the position illustrated to facilitate the fitting of the timing belt.
Engines: 2.3 JTD 16V
1. Fit the timing belt onto the pulleys and gears.
Engines: 2.3 JTD 16V
- Remove the timing pin for the timing pulley in relation to the timing sensor.
Description
Code
Function
.
Pin for timing adjustment
1.860.617.000
Positioning of timing pulley with timing sensor
1. Using the reaction tool (1a) fitted with pins, tighten the bolt fixing the timing drive pulley (1a) to torque.
Description
Code
Function
1a
Counter-torque
1.870.815.000
Timing pulley lock
Description
Code
Function
1a
Pins for counter-torque
1.870.836.000
Timing pulley lock
Engines: 2.3 JTD 16V
1. Acting on the hexagonal bolt (1a), rotate the semi-automatic tensioner in an anti-clockwise direction, placing the tensioner (1b) moving reference in the position illustrated, i.e. about 20°-22° to the right of the position indicated by the reference (1c), then lock the fixing nut (1d).
Engines: 2.3 JTD 16V
- Tighten the bolt fixing the automatic tensioner.- Remove the tools used for timing the camshafts and for positioning the crankshaft approximately at T.D.C.
Description
Code
Function
.
Pin
99360615
TDC positioning
Description
Code
Function
.
Templates
99360614
Camshaft timing adjustment
- Rotate the crankshaft through eight revolutions in its direction of rotation.1. Loosen the bolt fixing the tensioner and, working carefully, position the tensioner (1a) reference in line with the reference opening (1b), then tighten the nut (1c) fixing the belt tensioner to torque.
Value - daNm
Fastening
Component
Ø
1c
3.6
Bolt
MOBILE TIMING TENSIONER
M8
Engines: 2.3 JTD 16V
- Rotate the crankshaft through two further revolutions in its direction of rotation.- Check that the position of the references remains unchanged, then temporarily refit the tools for timing the camshafts and the crankshaft for a final check.- If the tools do not fit perfectly in the housings or the references on the tensioner have moved, carry out the belt tension adjustment procedure again.- Fit the studs on the camshaft housing for the timing tools.- Fit the mounting bracket on the camshaft housing and tighten the fixing bolt and nut.- Fit the mounting bracket, complete with heater plugs control unit, and tighten the fixing nuts.- Connect the electrical connections for the heater plugs control unit.
- Lower the vehicle.1. Insert an 8 mm diameter pin for positioning the camshaft in the cylinder head housing.
Engines: 2.0 JTD 8V
1. Loosen the bolt (1a) using a spanner with a ¼" socket (1b), loosen the belt tension, then tighten the nut loosened previously.2. Remove the timing belt.
1. Loosen the bolts (1a) fixing the camshaft pump pulley (1b).2. Fit the timing belt in order on the pullies.- Check that the engine is at TDC and tha the camshaft reference is aligned.3. Fit the C-TRONIC-105.5 tool facing downwards.4. Undo the bolt (4a) fixing the tensioner (4b) and, using a spanner with a ¼" socket, tension the belt until the correct value is reached.
Subject
Value
.
Timing belt/s
unità seem
-
Timing belt tension
108
- Lock the bolt fixing the tensioner and the pulley fixing bolts.- Remove the C-TRONIC - 105.5 tool.- Temporarily fit the bolt fixing the timing drive pulley to allow the rotation of the crankshaft.- Rotate the engine through 8 revolutions not going backwards.
Engines: 2.0 JTD 8V
- Rotate the engine in a clockwise direction without going backwards until the TDC reference tool enters the housing in the flywheel.
Description
Code
Function
.
Pin
1.860.863.000
Crankshaft TDC reference
1. Loosen the bolts (1a) fixing the pulley (1b), then position the 8 mm diameter timing reference pin (1c) via the pulley in the cylinder head housing.2. Fit the C-TRONIC-105.5 tool facing downwards.3. Undo the bolt (3a) fixing the tensioner (3b) and, using a spanner with a ¼" socket, tension the belt until the correct value is reached.
Subject
Value
.
Timing belt/s
unità seem
-
Timing belt tension
54
Engines: 2.0 JTD 8V
- Lock the bolt fixing the tensioner and the timing pulley fixing bolts.- Remove the C-TRONIC - 105.5 tool- Reposition the C-TRONIC - 105.5 tool and check that the belt tension corresponds to the recommended figures.
Subject
Value
.
Timing belt/s
unità seem
-
Timing belt tension
51 - 57
- Remove the C-TRONIC - 105.5 tool- Remove the TDC reference tool.
Description
Code
Function
.
Pin
1.860.863.000
Crankshaft TDC reference
- Remove the 8 mm diameter timing reference pin.- Rotate the crankshaft through two revolutions in a clockwise direction without going backwards until the TDC reference tool enters the housing in the flywheel.
Description
Code
Function
.
Pin
1.860.863.000
Crankshaft TDC reference
- Check that the 8 mm diameter timing reference pin enters the camshaft housing via the pulley.- If this is not the caswe, loosen the pulley fixing bolt and rotate the camshaft in an anti-clockwise direction until the 8mm diameter timing reference pin enters the camshaft housing via the pulley.- Lock the pulley fixing bolts.- Repeat the check.- Remove the TDC reference tool.
Description
Code
Function
.
Pin
1.860.863.000
Crankshaft TDC reference
- Remove the 8 mm diameter timing reference pin.- Tighten the bolts fixing the pulley to the recommended torque.
Value - daNm
Fastening
Component
Ø
.
2,0
Bolt
TIMING DRIVEN PULLIES
-
- Tighten the tensioner fixing bolt to the recommended torque.
