1032A12 TIMING SYSTEM DRIVE CHAIN - R.R - Fiat - CROMA - eLearn

194000271 - 1032A12 TIMING SYSTEM DRIVE CHAIN - R.R

) - Position the vehicle on a lift.- Make sure that the ignition key is in the OFF position, then disconnect the battery terminal (-).

	Description	Connector
-	Battery	See A001 BATTERY

1. Remove the sound insulation cover fastened to the engine by three pins.

1. Loosen the band and disconnect the engine oil vapour recovery pipe from the cylinder head cover.2. Loosen the bands and remove the air supply hose from the air flow meter to the throttle casing.

1. Disconnect the electrical connection from the air flow meter.

	Description	Connector
1	Air flow meter	See K041 AIR FLOW METER

2. Undo the bolts (2a) and remove the air filter cover (2b), complete with air flow meter (2c).3. Remove the air cleaner filter element.

1. Release the fuel vapour pipe (1a) from the band (1b) on the air filter casing.

1. Disconnect the cold air intake from the air filter casing.2. Remove the air filter casing fastened to the bodyshell by three pins.

1. Connect the tool to the bleed valve on the fuel supply pipe and discharge the fuel pressure.

Follow the safety instructions and specific recommendations.

Tool	Description	Function	Validity
2000002900	Breather connector	Fuel system pressure drainage	1.82.2

1. Undo the connector (1a), disconnect the fuel supply pipe (1b), fuel manifold pipe side and move it to the side.

1. Disconnect the rapid connector for the fuel vapour pipe and move aside.

1. Disconnect the electrical connection from the ignition coil module.

	Description	Connector
1	Ignition coil	See A030 IGNITION COIL

2. Undo the bolts (2a) and remove the ignition coil module (2b).

1. Undo the nut (1a), loosen the bands and remove the engine coolant return pipe to the supply reservoir (1b).

1. Disconnect the electrical connection for the front Lambda sensor to the catalytic converter.

	Description	Connector
1	Lambda sensor on catalyzer	See K017 LAMBDA SENSOR ON CATALYZER

2. Disconnect the electrical connection for the rear Lambda sensor to the catalytic converter.

	Description	Connector
2	Lambda sensor on catalyzer - 2	See K018 LAMBDA SENSOR ON CATALYZER - 2

1. Unscrew the bolts securing the timing side engine wiring brackets.

1. Unscrew the bolts securing the cam cover side engine wiring brackets.

1. Release the gearbox side engine wiring bracket from its fastenings.2. Move the engine wiring to the side.3. Disconnect the electrical connection for the radio interference condenser.

	Description	Connector
3	Interference filter	See P087 NOISE FILTER

1. Undo the nut (1a) and disconnect the earth lead (1b) from the cam cover.

1. Undo the bolts (1a) and remove the cam cover (1b).

- Remove the spark plugs to facilitate the subsequent engine cranking operations. Op. 4450B04 RIGHT FRONT WHEEL - R.R Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.1. Use tool (1a) to adjust the mobile tensioner in the arrowed direction in the figure and prise off the auxiliary drivebelt (1b).

Tool	Description	Function	Validity
1860815000	Flange	Crankshaft rotation	1.8

2. Turn the crankshaft to move cylinder no. 4 to TDC in the combustion phase. Under these conditons, notch (2a) on the inner part of the crankshaft pulley should be aligned with the reference mark (2b) on the timing chain cover.

1. Undo the bolts (1a) and remove the timing chain upper pad (1b).

1. Unscrew and remove the automatic timing chain tensioner.

1. If no mark (1b) is present on the fixed timing chain hydraulic tensioner (1a), replace the tensioner with a new unit including a new mobile chain tensioner pad.

1. Loosen the bolts fixing the camshaft toothed drive pulleys.

Turn the hexagonal bolts on the camshafts using a fixed wrench to provide countertorque.

1. Fit the tool and check the camshaft timing setting is correct.

If necessary, turn the crankshaft slowly and gradually (in the direction of engine rotation).

Tool	Description	Function	Validity
2000000900	Template	Camshaft timing adjustment	2.2

- Remove the timing tool.

1. Fully loosen the bolts fixing the camshaft toothed drive pulleys.- Secure the timing chain to prevent it falling into the casing.2. Remove the camshaft toothed drive pulleys.

1. Undo the nuts (1a) and disconnect the front section of the exhaust pipe (1b), catalytic converter side.

Fasten the section of the exhaust pipe disconnected so that it is not hanging loose. The front section of the exhaust pipe including the flexible pipe can be fastened to the bodyshell appropriately using, for example metal wire.Bends in the flexible pipe at angles of between 5° and 10°, starting from the planned fitting position, can damage the flexible pipe.

2. Remove the gasket.

1. Undo the bolts (1a), (1b) and remove the bracket on the gearbox for the lower reaction rod (1c).

1. Unscrew the left engine mount flexible block bolt, front suspension frame side.

1. Fit the tool (1a) complete with support mountings (1b).

Tool	Description	Function	Validity
1820581000	Crossmember	Power unit support	1.82.2

Tool	Description	Function	Validity
1870650000	Support blocks	Power unit support	1.82.2

2. Fit the tools (2a) and (2b), then connect them to the brackets on the engine using links (2c).

Tool	Description	Function	Validity
1860851003	Crossmember	Power unit support	1.82.2

Tool	Description	Function	Validity
1870748000	Vertical support	Power unit support	1.82.2

1. Undo the bolts (1a) and the nut (1b) and remove the flexible mounting for the timing side power unit front support (1d).

Adjust the equipment links to raise the power unit far enough to gain access to the power unit rigid mount bolts, timing side.1. Undo the bolts (1a) and remove the power unit rigid support (1b).2. Undo the bolt (2a) and remove the engine components single belt moving tensioner (2b).3. Undo the plug for access to the upper bolt securing the chain tensioner fixed pad.4. Undo the upper belt tensioner fixed pad fixing bolt.

1. Unscrew the upper bolts fixing the timing cover.

1. Undo the drain plug and drain the engine oil.

Collect the engine oil in a suitable container.

1. Undo the nut (1a) securing the crankshaft pulley using the tool (1b) for counter-torque.

Tool	Description	Function	Validity
2000001000	Counter-torque	Loosen/tighten crankshaft pulley fixing bolt	2.2

2. Remove the crankshaft pulley.

1. Undo the bolts (1a) and remove the timing chain cover (1b).2. Remove the gasket.- Working at the bench, remove the oil seal from the timing chain cover.

Take care not to damage the sealing surfaces during destructive removal of the oil seal.

1. Undo the lower bolt (1a) and remove the belt tensioner fixed pad (1b).

1. Undo the belt tensioner mobile pad fixing bolt.

- Remove the chain tensioner mobile pad by withdrawing from below.- Remove the timing chain after releasing it from the retaining collar positioned previously.

Refitting ( Removing

) - Refit the timing chain provisionally in its seat.

Secure the timing chain to prevent it falling.

- Refit the chain tensioner mobile pad.1. Tighten the chain tensioner pad retaining bolt to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing moving chain tensioner pad	Bolt	M6 x 1	(engine crankcase side) 1.0	2.2

1. Refit the chain tensioner fixed pad (1a) and secure by tightening the lower bolt (1b) and upper bolt through the hole to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing fixed chain tensioner pad	Lower bolt	M6 x 1	(engine crankcase side) 1.0	2.2

Component	Fastening	dia	Value (daNm)	Validity
Timing fixed chain tensioner pad	Upper bolt	M6 x 1	(cylinder head side) 0.8	2.2

1. Place the intake side camshaft toothed drive pulley (1a) in its housing and secure it with a new bolt (1b) without tightening the bolt.2. Fit the camshaft timing tools.

Turn the intake side camshaft by means of the hexagon until timing tool pin (2a) fits into the hole on the pulley.

Tool	Description	Function	Validity
2000000900	Template	Camshaft timing adjustment	2.2

3. Turn the crankshaft until cylinder 4 is at TDC in the combustion phase, white notch stamped on the timing chain toothed drive pulley turned down and key upward.

Turn the crankshaft slowly and steadily (in the direction of engine rotation).

Ensure the timing chain is not stuck.

4. Fit the timing chain.

The pink link (4a) should be aligned with the white notch stamped on the timing chain toothed drive pulley.

The bluel link (4b) must be aligned with the "INT" mark stamped on the intake side camshaft toothed drive pulley.

5. Place the exhaust side camshaft toothed drive pulley (5a) in its housing and secure it with a new bolt (5b) without tightening the bolt.

Turn the exhaust side camshaft by means of the hexagon until the pink link (5c) is aligned with the "EXH" mark stamped on the exhaust side toothed timing drive pulley.

- Move back the camshaft timing tool pin from the intake side camshaft toothed timing drive pulley.

- The following drawing shows the fixed timing chain hydraulic tensioner disassembled.

Replace the o-rings.

- Before refitting, the timing chain hydraulic tensioner must be preloaded as described below.1. Position the piston in a vice with protective jaws, holding by the square end.2. Inser the piston into the tensioner case by pressing and turning as shown in the figure until pin (2a) fits into groove (2b).3. Press and simultaneously turn the piston until pin (3a) fits into groove (3b).- Insert the assembled piston into the tensioner body.

1. Refit the timing chain hydraulic tensioner into its seat and tighten to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing fixed hydraulic tensioner	-	M27 x 2	7.5	2.2

1. Hydraulic tensioner in operational position.

Move the timing chain hydraulic tensioner to operating position by exercising overall pressure by hand on the chain in the area shown in the figure. This puts the chain under tension, which in turn acts on the mobile pad to release the mobile tensioner piston.When the tensioner piston is operated, the operating spring can be heard to click.

If the chain remains slack, the tensioner is not in operating position.

- Turn the crankshaft through 720°, then move cylinder no. 4 to TDC in the exhaust phase, white notch stamped on the timing belt toothed drive pulley turned down and key upward.

When the crankshaft is turned, the tensioner piston should follow the chain through its rotation.

- Check the timing by ensuring that the tool pins are aligned with the holes on the camshaft drive pulleys.

If they do not align, refit the timing chain without treating the coloured links on the chain as TDC reference points.

- Remove the tool.

Tool	Description	Function	Validity
2000000900	Template	Camshaft timing adjustment	2.2

1. Place the upper timing chain pad (1a) in its housing and fasten it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing upper chain tensioner pad	Bolt (with thread-locking agent)	M6 x 1	(cylinder head side) 1.0	2.2

1. Tighten the new camshaft toothed pulley bolts to the specified torque, first tightening the exhaust side pulley bolt.

Turn the hexagonal bolts on the camshafts to provide countertorque.

Component	Fastening	dia	Value (daNm)	Validity
Camshaft toothed drive pullies	Bolt (to be replaced)	M12 x 1.75	(camshaft side) 8.5 + 30° + 15°	2.2

- Fit the spark plugs and tighten them to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Spark plugs	-	M14 x 1.25	(cylinder head side) 2.2	2.2

- Clean the contact surfaces.1. Refit a new gasket (1a) and the timing chain cover (1b).2. Tighten the timing chain cover bolts to the specified torque, first tightening the lower bolts and then the upper bolts.

Component	Fastening	dia	Value (daNm)	Validity
Crankshaft oil seal front cover	Bolt	M8 X 1.25	(engine crankcase side) 2.1	2.2

- Replace the access plug to the upper belt tensioner bolt in its seat and tighten to the specified torque.

Replace the seal.

Component	Fastening	dia	Value (daNm)	Validity
Cap for timing fixed chain tensioner pad upper bolt	-	M22 x 1.5	6.5	2.2

1. Fit a new oil seal (1a) on the timing chain cover using the tool (1b).

Before fitting, slightly moisten the lip of the new oil seal.

Tool	Description	Function	Validity
1860099000	Fitting tool	Fitting flywheel side oil seal	2.2

1. Place the crankshaft pulley in its housing.2. Tighten a new bolt (2a) securing the crankshaft pulley to the recommended torque using the tool (2b) for counter-torque.

Component	Fastening	dia	Value (daNm)	Validity
Services pulley on crankshaft	Bolt (to be replaced)	M14 X 1.5	(engine crankshaft side) 10.0 +75° + 15°	2.2

Tool	Description	Function	Validity
2000001000	Counter-torque	Loosen/tighten crankshaft pulley fixing bolt	2.2

1. Position the auxiliary drivebelt moving tensioner (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

Position the auxiliary drivebelt mobile tensioner so that the ridge (1c) on the tensioner fits into hole (1d).

Component	Fastening	dia	Value (daNm)	Validity
Engine components single belt moving tensioner	Bolt	M10 x 1.5	(engine crankcase side) 4.3	2.2

2. Place the power unit timing side rigid support (2a) in its housing and secure it by tightening the bolts (2b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support	Bolt	M12 x 1.75	(engine crankcase side) 7.5 - 8.5	2.2

- Raise the power unit by means of the support tool links.1. Place the timing power unit front support flexible mounting (1a) in its housing and secure it tightening the bolts (1b) and (1c) and the nut (1d) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support flexible mounting	Bolt	M10	(rigid support side) 5.0 - 6.0	1.82.21.9 JTD 16v1.9 JTD 8v

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support flexible mounting	Bolt	M10	(bodyshell side) 5.0 - 6.0

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support flexible mounting	Nut	M10	(bodyshell side) 5.0 - 6.0

- Remove the tool used to support the power unit.

Tool	Description	Function	Validity
1820581000	Crossmember	Power unit support	1.82.2

Tool	Description	Function	Validity
1870650000	Support blocks	Power unit support	1.82.2

Tool	Description	Function	Validity
1860851003	Crossmember	Power unit support	1.82.2

Tool	Description	Function	Validity
1870748000	Vertical support	Power unit support	1.82.2

1. Tighten the engine oil drain plug to the recommended torque.

Replace the seal.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil drain plug	-	M12 x 1.75	(oil sump side) 2.5	2.2

1. Tighten the left engine mount flexible block bolt, front suspension frame side, to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Flexible mounting for left side engine support	Bolt	M12	(front suspension frame side) 7.5 ÷ 8.5

1. Refit the lower reaction rod bracket (1a) in its seat on the gearbox and secure it by tightening the bolts (1b), (1c) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Bracket on gearbox for lower reaction rod	Bolt	M12	(gearbox side) 7.5 - 8.5

Component	Fastening	dia	Value (daNm)	Validity
Lower reaction rod for gearbox	Bolt	M12	(bracket side on gearbox) 7.5 - 8.5

1. Place a new gasket in position.2. Connect the front section of the exhaust pipe (2a), catalytic converter side and tighten the new nuts (2b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Rigid pipe for exhaust pipe between catalytic converter and silencer	Nut (to replace)	M8	(exhaust manifold with catalytic converter side) 1.6	2.2

- Refit the auxiliary drivebelt by adjusting the moving tensioner with the tool.

Tool	Description	Function	Validity
1860815000	Flange	Crankshaft rotation	1.8

- Tensioner the tensioner by turning anticlockwise and releasing. Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R. Op. 4450B04 RIGHT FRONT WHEEL - R.R1. Place the cam cover (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

Replace the o-rings (1c).

Component	Fastening	dia	Value (daNm)	Validity
Tappet cover	Bolt	M6 x 1	(cylinder head side) 0.9	2.2

- Connect the earth loom to the cam cover and secure with its nut.- Connect the electrical connection for the radio interference condenser.- Refit the engine wiring- Secure the engine wiring bracket, gearbox side.- Secure the cam cover engine side wiring brackets with their bolts.- Secure the timing side engine wiring brackets with their bolts.- Connect the electrical connection for the rear Lambda sensor to the catalytic converter.- Connect the electrical connection for the front Lambda sensor to the catalytic converter.- Place the coolant return pipe to the engine coolant reservoir in position and tighten the bands and the nut.1. Place the ignition coil module (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Ignition coil module	Bolt	M6 x 1	(tappet cover side) 0.9	2.2

2. Connect the electrical connection to the ignition coil module.

- Place the fuel vapour recovery pipe in position and connect the rapid connectors.1. Place the fuel supply pipe (1a) in its housing, connect it and tighten the connector (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Front fuel supply pipe	Connector	-	(fuel manifold side) 1.0	2.2

- Place the air filter casing in its housing and secure it to the bodyshell using the three pins.- Connect the cold air intake to the air filter casing.- Fasten the fuel vapour pipe to the air filter casing using the band.- Fit the air filter filter element in place.- Fit the cover for the air filter, complete with air flow meter, and secure it using the bolts.- Connect the electrical connection to the air flow meter.- Place the air supply hose from the air flow meter to the throttle casing back in its housing and secure it using the bands.- Connect the engine oil vapour recovery pipe to the cylinder head cover and secure it using the band.- Place the sound insulation cover back in its housing and secure it to the engine using the three pins.- Connect the negative battery terminal. Op. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP UP, IF NECESSARY- Remove the vehicle from the lift.