REMOVAL AND INSTALLATION


RECOMMENDED TOOLS



 [la] Tool for fitting sealing ring (-).0188-N1.
[lb] Tool for fitting sealing ring (-).0188-N2.

[2] flywheel locking tool (-).0188-X.

[3] (-).0188-M camshaft setting rod.

[4] toothed belt pinion locking tool 6016-T.

REMOVAL


Disconnect the battery.

caution Remove the tie bar (2) Wheel on the ground.
Remove:

  • The nuts (1), (4)
  • The tie bar (2)
caution Refit the nuts (1), (4).
Disconnect:

  • The connector (At "a")
  • The connector (At "b")
Remove:

  • The air filter (5) complete
  • The air duct (6)
  • The turbocharger inlet air duct (7)
Move aside the electrical harness (3)

Remove:

  • The diesel injectors (13)
  • The high pressure common fuel rail (8)
  • Vacuum pump (10)
  • The high pressure fuel pump (9)
  • The accessories drive belt (12)
  • The pipe (11)
  • The timing belt

Uncouple the gas resuction pipe (16).
Disconnect the connector (At "c").
Remove the camshaft position sensor (17).
Release:

  • The vacuum circuit pipes (15)
  • The engine harness support (18)
Release:

  • The air inlet manifold
  • The cylinder head (14)

caution Do not press on the target of the camshaft position sensor with the tool [4].
Slacken bolt (19); Using tool [4].
Remove:

  • The bolt (19)
  • The camshaft pulley (20)

Raise the pin (21).
Turn the pin (21) a quarter turn to lock the camshaft chain tensioner.
Release:

  • The 27 camshaft bearing cap housing fixing bolts (24)
  • The camshaft bearing cap housing (22)
  • The camshaft ring seal (See the relevant operation)
  • The 4 injector fixing support pins (23)

Remove:

  • The screws (25)
  • The chain assembly (28), the chain tensioner (29) and the camshafts (26) and (27)
caution Clean the gasket faces with an approved descaling product. Do not use abrasives or sharp tools on the joint faces. The gasket faces must not have any traces of knocks or scores.

INSTALLATION


caution When refitting, all the seals that have been removed must be replaced with new seals.

caution Replace the camshaft bearing cap housing seal (30)
Position the pistons at mid-stroke (horizontal crankshaft pinion key).

Position the chain (15) on the pinions (18) and (19).
Bring the links marked in black "d" and "e" onto the teeth marked "f" and "g" on the camshaft drive pinions (31) and (32).
Fit:

  • The chain assembly (28), the chain tensioner (29) and the camshafts (26) and (27)
  • The camshaft pulley (20)
  • The bolt (19) (Hand-tighten)
Peg the camshaft pulley (20): Using tool [3].
caution Check that the links marked in black "e" and "d" are on the teeth marked "f" and "g" on the camshaft drive pinions. If this is not the case, restart the fitting of the camshafts.

Apply "LOCTITE 518" sealing product to the edge of the cylinder head (At "h").

Fit:

  • The camshaft bearing cap housing (22)
  • The 27 camshaft bearing cap housing fixing bolts (24); Manually
  • The screws (25); Manually
Tighten method for the 27 screws (24) (in the order shown):

  • Pre-tighten to 0.5 ± 0.05 daN·m
  • Tighten to 1 ± 0.1 daN·m

Fit:
Tighten the bolt (25a) to 0.7 ± 0.07 daN·m
Turn the pin a quarter turn to release the camshaft chain tensioner.
Tighten the bolt (25b) to 0.7 ± 0.07 daN·m
caution Always replace the cylinder head cover seals.Clean the cylinder head cover contact surface. Grease the new seals.
Fit:

  • The camshaft seals; By means of tools [la], [lb] (See the relevant operation)
  • The 4 injector fixing support pins (23)
  • The cylinder head (14)

Tighten method: Camshaft bearing cap casing *2 fixing bolt fixing bolt *1:

  • Pre-tighten the bolts to 0.5 ± 0.05 daN·m (in the order shown)
  • Tighten the screws to 0.9 ± 0.09daN·m (in the order shown)
Recouple: The gas resuction pipe (16).
Fit:

  • The vacuum circuit pipes (15)
  • The engine harness support (18)
  • The camshaft position sensor (17) (without tightening its fixing screw)
  • The high pressure common fuel rail (8)

ADJUSTMENT OF THE CAMSHAFT POSITION SENSOR
Peg the engine flywheel; Using tool [2].

Reused sensor:

  • Position a 7.5 diameter drill bit between the valve cover (14) and the camshaft position sensor (17)
  • Tighten the bolt (33) to 0.6 ± 0.1daN·m
  • Remove the tool [2]
  • Reconnect the connector (At "c")
New sensor:

  • Place the camshaft position sensor (17) in contact with the target (Camshaft pulley)
  • Tighten the bolt (33) to 0.6 ± 0.1daN·m
  • Remove the tool [2]
  • Reconnect the connector (At "c")

INSTALLATION (CONTINUED)
Fit:

  • The air inlet manifold
  • The timing belt
  • The ancillary drive belt
  • The diesel injectors
  • The fuel high pressure pump
  • The vacuum pump
  • The wheel bolts
Return the vehicle to its wheels.
Connect the battery.
Fit:

  • The battery cover
  • The engine cover