Fiat(SOFIM) Timing Belt Replacement 2.5 Diesel Engine
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ENGINE 9. Remove the Engine cover.
21. Disconnect the r efrigerant lines of the AC Compressor . 22. Disconnect the heater lines. 23. Support the gearbox from fro m lower side. side . 24. Disconnect the gear shifter lever from inside the vehicle. 25. Disconnect the pr opeller shaft at gear box end. e nd. 26. Remove Slave Cylinder. Cylind er. 27. Remove Gear Box mounting bolts to the clutch housing. 28.Remove gear box mounting on cross member.
10. Remove all connectors of Engine harness ro routed uted on Engine and take it out.
29.Slightly move the gear box towards rear side of the vehicle.
11. Disconnect the fuel suction line connected to the fuel filter from sedimentor and fuel filter to HP pump. Remove the filter assembly.
30. In case of 4x4 vehicle disconn ect both pro peller shaft at transfercase end and slightly move the transfercase along with the gearbox towards rear side of the vehicle.
12. Remove the following components.
31. Support the Engine from bottom side.
a. Bonnet. b. Wiper arms.
32. Fix chain to front and rear engine lifting hooks and hold chain in position with crane.
c. Leaf screen.
33. Unscrew and remove engine mounting bolts
d. Wiper Motor.
34. Lift the eng ine & Mount it on work stand.
e. Bonnet Latch and bracket.
35. Check engine mounting pads for wear. Replace them if necessary.
f. Power steering reservoir g. Fuel filter. 13. Drain the coolant and remove the Radiator along with Condenser, Fan Shroud and header tank. (For procedure refer Radiator removal in cooling system section in this manual). manual). 14. Disconnect the cab heater hose. 15. Drain the engine oil. 16.Remove Air filter assembly. (For procedure refer Air filter assembly assembly removal). removal). 17. Disconnect the hose connecte d between turbocharger and intercooler. 18. Disconnect the vacuum line connected to brake booster. 19. Disconnect the Exhaust pipe connected to assembly DPF DOC. 20. Drain the power steering oil and disconnect the pipelines.
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!CAUTION
While lifting the engine out from the engine bay take extra care to avoid the suspended engine engine hitting the windshield bottom. FITMENT
For fitment follow the reverse order of removal. Tighten the following fasteners to the recommended torque. i) Refrigerant lines on compressor. ii) Engine mounts iii) Exhaust pipe joints iv) Clutch house mounting bolts.
ENGINE B. A IR FILTER ASSEMBLY ASSEMBLY REMOVAL
FITMENT
1. Loosen and remove the Air reservoir mounting bolts.
For fitment follow the reverse order of removal procedure. C. DRIVE BELT REMOVAL POWER STEERING BELT REMOVAL
1.
Pry out the power steering belt.
2. Disconnect the electrical connections of SIMAF sensor.
INSPECTION
Inspect the belt for wear, cracks and signs of failures. Replace if necessary. FITMENT
Place the belt over the power steering pulley and crankshaft pulley properly and ensure proper belt tension (Frequency 165±10Hz) AC A ND ALTERNATOR B ELT REMOVAL
3. Disconnect the intake hose (1.) Loosen (1.) Loosen and remove the Air filter mounting bolts (2 and 3) and remove the Air filter with Air reservoir.
1. Remove the tensioner cap (1) (1) and loosen the tensioner bolt (2).
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ENGINE 2. Reduce the belt tension by rotating the tensioner screw (3) in (3) in clockwise direction (Tightening direction of a RH threaded screw) and remove the belt.
A C A ND ALTERNA TOR BELT A DJUSTMENT
INSPECTION
Inspect the belt for wear, cracks and signs of failures. Replace if necessary. FITMENT
1. For fitment, first first place the belt, and then tighten the tensioner screw (3) by (3) by rotating it in the anticlockwise direction (Loosening direction of a RH threaded screw). screw) . 2. Tighten the tensioner bolt (2) (2) to a torque of 4 Kgm and fit the cap. 3. Adjust the belt tension. 1. Remove the tensioner cap (1) (1) and loosen the tensioner bolt (2). 2. Adjust the belt tension as follows: a. To reduce the tension rotate the tensioner screw (3) in (3) in clockwise direction (Tightening direction of a RH threaded screw) b. To increase the tension rotate the screw (3) in anti clockwise direction (Loosening direction of a RH threaded screw). screw) . Keep belt tension in given range .which is as follows. For new Belt
Tension for new belt = 268 ± 10 Hz Then run the engine for 15 mins. Now the belt has to be retensioned to 244 ± 10 Hz. For reusing same belt
In case of reusing the same belt, it should be tensioned to 244 ± 10 Hz.
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ENGINE D. INJECTOR REMOVAL
1. Remove the engine cover by pulling it upwards firmly.
2. Disconnect the injector electrical connecters (1)
4. Remove the HP pipes connecting injector to common rail and cover the injector opening with suitable caps.
5. Loosen and remove the bolt (1) (1) along with washer and remove the injector claw (2).
3. Disconnect the injector back leak tube(Overflow tube (Overflow pipe) pipe ) and cover the injector side opening with suitable caps.
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ENGINE 6. Extract the injector using injector removal tool(1) tool (1) (Part no. 2868 5890 07 04). Remove the injector with the sealing washer.
E. TIMING TIMING BELT REMOVAL: REMOVAL: REMOVAL
1. Remove the engine cover. 2. Remove power steering belt. Then remove alternator and AC compressor belt. (Refer alternator and AC compressor belt removal procedure)
3. Loosen & remove remove the front timing cover bolts and take out the front timing cover.
NOTE
Injector should sho uld be tagged as soon as it is removed to avoid chances of it being interchanged. Since the I2C code of each injector is calibrated to the EMS, whenever an injector is replaced it I2C codes of the respective injectors should be fed in the EMS ECU using diagnostic tool. FITMENT:
Follow the reverse order of removal procedure.
NOTE
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Do not reuse the bolt and washer removed in step 5, use new ones. Replace the injector sealing washer while refitting the injector. Vacuum clean the injectors.
ENGINE 4. Disconnect electrical connection connection from cam phase sensor and loosen and remove the bolt of cam phase sensor.
5. Remove the cam phase sensor and insert the locking pin (Part no. 2653 5890 06 09) for on vehicle ease for locking the camshaft
7. Lock the flywheel using locking pin(Part pin (Part no. 2653 5890 06 04) to bring the piston of No.1 cylinder to TDC position.
8. Align hole on the HP mounting mounting bracket & lock the gear with the help of locking pin (Part no. 2653 5890 06 07).
6. Lift the vehicle and remove the stone guard and noise shield.
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ENGINE 9. Loosen the camshaft gear.
INSPECTION
Inspect the Timing belt for wear, cracks and signs of failures. Replace if necessary. FITMENT OF TIMING BELT
1. Slightly tighten the camshaft gear. Keep Keep the camshaft bolt loose so that the gear is free to rotate.
10.Release the timing belt tension by loosening the auto tensioner mounting bolt. 11.Remove the timing cover lower.
12.Take out the timing belt.
NOTE
Do not remove the special tools.
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2.
Tighten the auto tensioner bolt finger tight or 0.3 - 0.6 kgm torque through the fixing bore hole during setting.
3.
Position the timing belt first on the camshaft gear & last on the auto tensioner as per the routing shown.
ENGINE 4.
Rotate the auto tensioner using allen key in anticlockwise direction so that the tensioner locator crosses the cylindrical pin by approx 15º-20º.
12. If belt tension is not proper, then loosen the camshaft and auto tensioner bolt and repeat the steps 5 - 8.
5.
Now rotate the allen allen key in clockwise direction to align tensioner locator with the cylindrical pin.
13. Reconfirm the engine timing. NOTE
Do not crimp or use sharp tool on timing belt. 14. Fix the bottom timing cover.
15. Assemble the timing cover front. 6.
Adjust the allen key on the auto tensioner so that the locator remains aligned to the cylindrical pin. (Maximum permissible misalignment misalignment + 5º).
16. Fit the Cam angle sensor and electrical connections. 7.
Tighten auto tensioner mounting fastener to specified torque.
8.
Tighten the camshaft gear bolt to specified torque.
9.
Remove all the special tools from engine.
17. Refit the power steering belt and alternator comcompressor belt.
10. Rotate engine for two revolutions. 11. Check for the timing belt tension. Belt tension should be within 250 ± 15 Hz by CLAVIS gauge (measure belt tension at the t he span between touch idler and camshaft gear)
