B1EG10K1 - 206 DW8 ENGINE

REMOVAL - REFITTING TIMING BELT

1 - SPECIAL TOOLS

[1] Tension measuring equipment : SEEM C.TRONIC 105.5M .

[2] Crankshaft setting rod : (-).0188-D .

[3] Camshaft setting rod + Hexagonal head bolt(s) M8 X 80 X 125 : (-).0188-E .

[4] Injection pump setting pin : (-).0188-H .

[5] Belt retaining clip : (-).0188-K .

[6] Flywheel stop : (-).0188-F .

[7] Crankshaft spanner : (-).0117-EZ .

[8] Cross beam : (-).0102-D .

[9] Lifting hooks : (-).0102-J .

[10] Tension lever : (-).0188-J1 .

2 - REMOVAL

DW8 ENGINE

Disconnect the battery .

Remove the style cover (1) .

Unclip and separate :

• the fuel pipes (2)
• the expansion pipe (3)
• the ECU (4)

Remove :

• the front right-hand wheel
• the front right mud-shield

DW8 ENGINE POWER STEERING

Unclamp and move aside the power steering pipes attached to the engine (5) .

DW8 ENGINE

Remove the closing plate .

Fit the tool [6] .

Slacken the roller tensioner fastener .

Remove :

• the ancillary drive belt (6)
• the tensioner roller (7)
• the securing bolts (8)
• the crankshaft pulley (9)

Protect the radiator honeycomb with strong cardboard cut to the dimensions of the radiator .

Position the cross beam [8] with its chains [9] on the sling eye (10) and then place it under tension .

Separate the joint (11) .

Remove :

• the nut (12)
• the 3 bolts (13)
• the engine mounting (14)
• the timing cover components (15)
• the bottom timing cover

Remove the tool [6] .

Turn the crankshaft with the tool [7] .

Peg the flywheel using the rod [2] (Without removing the starter motor) .

Peg the camshaft pulley with tool [3] .

Set the injection pump using the tool [4] .

Slacken the roller tensioner fastener (16) .

Retighten the fastener in the maximum slack position .

Remove the timing belt (17) .

3 - REFITTING

DW8 ENGINE

IMPERATIVE : check that the rollers (16) and (18) turn freely (no tight spots) ; also check that these rollers are not noisy and/or do not show traces of grease .

Slacken the bolts (19) .

Check that the pulleys (20) and (21) turn freely on their hubs .

Finger tighten the bolts (19) then slacken them 1/6 of a turn .

Turn the 2 pulleys (20) and (21) clockwise until the rod is fully home in the slots .

Fit the timing belt, fully taut, in the following order :

• crankshaft (immobilise the belt using the tool [5])
• roller tensioner (18)

Lay the timing belt on the pulley (21) .

Slightly turn the camshaft pinion in the opposite direction to the rotation of the engine in order to engage the belt on the pinion .

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

Engage the belt on the roller tensioner (16) and on the coolant pump gear (22) .

Place the tensioner roller (16) in contact with the belt .

Pre-tighten the tensioner roller securing bolt to 0.1 daN.m .

Remove the tool [5] .

4 - PRE-TENSIONING AND FITTING THE TIMING BELT

DW8 ENGINE

Fit the tool [1] .

NOTE : check that the tool [1] is not touching anything in the near vicinity .

Turn the roller tensioner (16) anti-clockwise (Using the tool [10]) .

Display 106 ± 2 SEEM units .

Tighten the nut (23) to 1.8 da.Nm (Without altering the position of the roller (16)) .

Remove the tool [1] .

IMPERATIVE : by inserting one bolt (19) in each pulley (20) and (21), make sure that the bolts (19) are not against the end of the slot; if this is not the case : repeat the timing belt fitting operation .

Bring the bolts (19) into contact with the pulleys .

Tighten the bolts (19) to 2.3 daN.m .

Remove the setting pins [2], [3], [4] .

Turn the crankshaft 8 revolutions in the direction of rotation (Clockwise) .

IMPERATIVE : never turn the crankshaft in the reverse direction .

5 - FITTING AND TENSIONING THE TIMING BELT

DW8 ENGINE

Refit the rods [2], [3], [4] .

Unscrew :

• the bolts (19)
• the nut (23)

Finger tighten the bolts (19) then slacken them 1/6 of a turn .

Place the tool [1] on the span (A) .

Turn the roller tensioner (16) anti-clockwise (Using the tool [10]) .

Display 41 ± 2 SEEM units .

Tighten the nut (23) to 1.8 da.Nm (Without altering the position of the roller(16)) .

Tighten the bolts (19) to 2.3 daN.m .

Remove the tool [1] .

Refit the tool [1] .

The tension value should be between 38 and 42 SEEM units .

IMPERATIVE : if the value read is outside the tolerance : slacken the belt and repeat the operation .

Remove :

• remove the tools [1], [2], [3], [4]

6 - CHECKING THE VALVE TIMING

DW8 ENGINE

Turn the crankshaft 2 revolutions in the direction of running without turning in the reverse direction (Clockwise) .

Fit the rod [2] .

Visually check that the camshaft hub and injection pump holes and the corresponding setting holes are not more than 1 mm apart .

Remove the rod [2] .

7 - REFITTING (CONTINUED)

DW8 ENGINE

Fit :

• the bottom timing cover
• the engine mounting (14)
• the timing cover components (15)
• the nut (12) : tightening torque 4.5 da.Nm
• the 3 bolts (13) : tightening torque 4.5 da.Nm
• the tool [6]

Fit :

• the crankshaft pulley (9)
• the bolts (8) to 1 da.Nm
• the tensioner roller (7)
• the ancillary drive belt (6)

Remove the tool [6] .

Refit the closing plate : Tightening torque 1.9 da.Nm .

Refit the various components in the reverse order to removal .