Ducato Timing

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Important note

Important note

The intervals and procedures given are subject to alteration by the manufacturer at any time.Check the regularly updated Timing Belts section on our website to ensure that you are keptinformed of any changes that may occur between issues of the Autodata CD.http://www.autodata-cd.com

Timing belt replacement intervalsWhere possible the recommended intervals have been compiled from vehicle manufacturers' information. In a few instances norecommendation has been made by the manufacturer and the decision to replace the belt must be made from the evidence of athorough examination of the condition of the existing belt.

Apart from the visible condition of the belt, which is explained fully in the General Instructions/Toothed Timing Belts section, thereare several other factors which must be considered when checking a timing belt:

Is the belt an original or a replacement.1.When was the belt last replaced and was it at the correct mileage.2.Is the service history of the vehicle known.3.Has the vehicle been operated under arduous conditions which might warrant a shorter replacement interval.4.Is the general condition of other components in the camshaft drive, such as the tensioner, pulleys, and other ancillarycomponents driven by the timing belt, typically the water pump, sound enough to ensure that the life of the replacement beltwill not be affected.

5.

If the condition of the existing belt appears good, can you be satisfied that the belt will not fail before the next check orservice is due.

6.

If the belt does fail, have you considered the consequences. If the engine is an INTERFERENCE type then considerableexpensive damage may well be the result.

7.

The cost of replacing a belt as part of a routine service could be as little as 5 to 10% of the repair cost following a belt failure.Make sure your customer is aware of the consequences.

8.

If in doubt about the condition of the belt - RENEW it.9.Refer to the Toothed Timing Belts/Service Replacement section for further information relating to arduous or adverseoperating conditions, inspection and service replacement.

10.

Replacement Interval Guide

Manufacturer: Fiat Model: Ducato (02-06) 2,0D JTDEngine code: RHV Output: 62 (84) 4000Tuned for: Year: 2002-06

© Autodata Limited 20079/4/2013

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Replacement Interval Guide

Fiat recommend check & replacement if necessary every 36,000 miles or 2 years and replacement every 72,000 miles or 4 years.

The previous use and service history of the vehicle must always be taken into account.

Check For Engine Damage

Check For Engine Damage

CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-pistondamage in the event of a timing belt failure is MOST LIKELY to occur.A compression check of all cylinders should be performed before removing the cylinder head(s).

Repair Times - hrs

Repair Times - hrs

Ducato 2,0 JTD 2002-07

Remove and install 2,60

Special Tools

Special Tools

Engine support - Fiat No.1.870.7354.000.Flywheel locking tool - Fiat No.1.870.765.001.Flywheel timing pin - Fiat No.1.860.863.000.1/4" square drive wrench.8 mm timing pin.Tension gauge - SEEM C.Tronic 105.5.

Special Precautions

Special Precautions

Disconnect battery earth lead.DO NOT turn crankshaft or camshaft when timing belt removed.Remove glow plugs to ease turning engine.Turn engine in normal direction of rotation (unless otherwise stated).DO NOT turn engine via camshaft or other sprockets.Observe all tightening torques.

Removal



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Removal

NOTE: The high-pressure fuel pump fitted to this engine does not require timing.

Raise and support front of vehicle.1.Remove:

RH front wheel.Engine undershield.Auxiliary drive belt.RPM sensor from bell housing.

2.

Lock flywheel. Use tool No.1.870.765.001.3.Remove:

Crankshaft pulley bolt [1] .Crankshaft pulley [2] .

4.

Support engine. Use tool No.1.870.7354.000.5.Remove:

PAS reservoir and bracket. DO NOT disconnect hoses.EGR heat shield.EGR pipe to exhaust manifold bolts.EGR pipe to inlet manifold bolts.RH engine mounting [3] .Timing belt covers [4], [5] & [6] .Flywheel locking tool.

6.

Turn crankshaft clockwise to setting position.7.Insert timing pin in flywheel [7] . Tool No.1.860.863.000.8.Insert 8 mm timing pin in camshaft sprocket [8] .NOTE: If 8 mm timing pin cannot be inserted: Turn crankshaft one turn clockwise.

9.

Slacken tensioner bolt [9] .10.Turn tensioner pulley clockwise away from belt. Use 1/4" square drive wrench [10] .11.Lightly tighten tensioner bolt [9] .12.Remove timing belt.13.

Installation

Installation

Slacken camshaft sprocket bolts [11] .NOTE: Sprocket should turn with slight resistance.

1.

Ensure timing pins located correctly [7] & [8] .2.Fit timing belt to crankshaft sprocket.3.Fit timing belt in anti-clockwise direction. Ensure belt is taut between sprockets.4.Attach tension gauge to belt at [12] . Tool No.SEEM C.Tronic 105.5.5.Slacken tensioner bolt [9] .6.Turn tensioner pulley anti-clockwise until tension gauge indicates 108 SEEM units. Use 1/4" square drive wrench [10] .7.Tighten tensioner bolt [9] . Tightening torque: 23 Nm.8.Tighten camshaft sprocket bolts [11] . Tightening torque: 20 Nm.9.Remove tension gauge [12] .10.Remove timing pins [7] & [8] .11.Turn crankshaft eight turns clockwise to setting position.NOTE: DO NOT allow crankshaft to turn anti-clockwise.

12.

Insert timing pin in flywheel [7] .13.14.



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13.Slacken camshaft sprocket bolts [11] .14.Insert timing pin [8] .15.Attach tension gauge to belt at [12] .16.Slacken tensioner bolt [9] .17.Turn tensioner pulley anti-clockwise until tension gauge indicates 54 SEEM units.18.Tighten tensioner bolt [9] . Tightening torque: 23 Nm.19.Tighten camshaft sprocket bolts [11] . Tightening torque: 20 Nm.20.Remove tension gauge [12] .21.Check belt tension. Attach tension gauge to belt at [12] . Tension gauge should indicate 51-57 SEEM units.22.If not: Repeat tensioning procedure.23.Remove tension gauge [12] .24.Remove timing pins [7] & [8] .25.Turn crankshaft two turns clockwise to setting position.26.Insert timing pin in flywheel [7] .27.Ensure timing pin can be inserted easily [8] .28.If not:

Slacken camshaft sprocket bolts [11] .Turn camshaft anti-clockwise until timing pin can be inserted [8] .Tighten camshaft sprocket bolts [11] . Tightening torque: 20 Nm.Repeat tensioning procedure.

29.

Remove timing pins [7] & [8] .30.Install components in reverse order of removal.31.Tighten crankshaft pulley bolt [1] . Tightening torque: 40 Nm + 51°.32.Tighten RH engine mounting to body nuts [13] . Tightening torque: 50 Nm.33.Tighten RH engine mounting to engine bolts [14] . Tightening torque: 50 Nm.34.Tighten RH engine mounting to body nut [15] . Tightening torque: 80 Nm.35.



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Ducato Timing

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