Large numbers of the 1.6 D Multijet diesel engine are installed in Fiat vehicles. According to ContiTech, significant errors are frequently committed when changing the timing belt. To ensure that the belt change operation goes smoothly, the company provides fitters with a detailed installation guide.
The manufacturer recommends inspecting and, if necessary, changing the timing belt at 150,000km or after five years for vehicles without a particulate filter. In the case of vehicles with a particulate filter, inspection after 140,000km or five years is recommended.
Tip: Replace the tensioning pulley, idlers and water pump at the same time as changing the timing belt.
Preparatory work
■ Identify the vehicle using the engine code;
■ Disconnect the vehicle battery;
■ Do not turn the crankshaft and camshaft once the timing belt has been removed;
■ Turn the engine in the normal direction of rotation (clockwise);
■ Turn the engine ONLY at the crankshaft pulley and not at other pulleys;
■ Comply with all tightening torques;
■ Jack up and prop the front of the vehicle.
Remove
Engine cover, engine compartment underpanel, front right wheel, engine compartment underpanel right, ancillary unit belt plus tensioning pulley and idler of ancillary unit belt, air intake hose from air
filter housing and air filter housing, air intake pipe from turbocharger, air flow sensor, engine mount bolts, engine mount and timing belt guard. Locate engine support beam.
Removal – camshaft belt:
1. Remove the cover from the flywheel and insert locking tool (186089000) into the flywheel (Figs 1a-d).
2. Unscrew crankshaft pulley bolts and remove crankshaft pulley.
3. Remove locking tool (186089000) from flywheel.
4. Set valve timings to mark.
5. Disconnect the plug of the fuel pressure sensor so that the bolt can be removed from the camshaft housing (Fig 2). Unscrew the bolt from crankshaft housing.
6. Insert locking tool (1870896900) into the camshaft housing (Figs 3a and 3b).
7. Remove the bolt from crankcase cover left next to the crankshaft pulley and place gauge (2000003000) on the crankshaft pulley (Fig 4).
8. After checking the valve timing setting, the gauge can be removed again and the tensioning pulley can be released by loosening the tensioning pulley bolt. The timing belt can now also be removed.
Installation – camshaft belt:
1. Fit the new tensioning pulley and idlers.
2. Loosen the camshaft pulley by mounting counterhold (1870815000) on the camshaft pulley and loosening the camshaft bolt.
3. Camshaft locking tool (counterhold) (1870836000) is inserted (Fig 5).
4. Fit the timing belt on the crankshaft pulley, starting clockwise. Take care to ensure that the timing belt is not creased during fitting! The timing belt must be tight between pulleys on the tight side!
The markings on the belt must align with the markings on the camshaft pulley, crankshaft drive pulley and high pressure pump pulley (Figs 6a and 6b).
5. Place gauge (2000003000) on the crankshaft pulley again, secure it with bolts (Fig 7) and check the valve timings.
6. Press the tensioning pulley spring down using a screwdriver until the tensioning pulley pointer is aligned with the bore (Figs 8a and 8b).
7. Tighten the tensioning pulley bolt to 23-28Nm.
8. Retighten the bolts of the camshaft pulley to the required torque (Fig 9) using counterhold (1870811500).Tightening torque should be 28-31Nm plus 40°.
9. Remove the locking tools.
10. Turn the engine through two revolutions in the direction of engine travel. Set the engine to TDC cylinder 1. Insert the camshaft locking tool and crankshaft pulley gauge. If the locking tool cannot be inserted, correct the valve timings. Check the timing belt tension again.
11. Remove the locking tools and gauge, locate and tighten the screw plug with the new o-ring in camshaft housing again (13-16Nm). Remove the holding tool and fit the components in reverse order of removal.
12. Fit the timing belt guard, crankshaft pulley (tightening torque 23-28Nm), ancillary unit belt plus tensioning pulley and idler for ancillary unit belt, engine mount bolts and engine mount, air intake hose from air filter housing and air filter housing, air intake pipe from turbocharger, air flow sensor, engine cover, engine compartment underpanel, front right wheel and engine compartment underpanel right.
13. Record the changing of original ContiTech timing belt on the sticker supplied and stick this in the engine compartment (Fig 10). Then carry out a test run or test drive.
