recommended installation procedure (07 february 14 … · the tensioner must be installed on the...

Recommended Installation Procedure (07 FEBRUARY 14) ATech Timing Belt Tensioner (979016) FIAT DUCATO 2.3 JTD Engine

Copyright Litens Automotive Group December, 2012. All rights reserved 1/6

Caution:

The procedure to access the timing belt tensioner and all other timing driven

components must be done according to the car manufacturer’s guidelines.

Engine temperature:

1. The tensioner must be installed on the engine at room temperature by allowing the engine and tensioner

to stabilize to the same relative ambient temperature for proper belt tension adjustment. Do not

attempt to install a tensioner onto a hot engine. (For reference, the minimum engine cooling period

is 4 hours in tropical climatic regions).

2. Install the battery memory saver and disconnect the battery.

Crank and Camshaft TDC position setup:

Review car manufacturer’s guidelines on how to locate and lock the crankshaft and camshaft positions at TDC.

3. Rotate the crankshaft CLOCKWISE ONLY until just before TDC (Top Dead Center) position (i.e. #1

cylinder firing position). Insert crankshaft timing pin (Fiat Tool No. 99360615). Then turn crankshaft

clockwise until it stops against timing pin (Fig. 2).

4. Remove two studs from cylinder head cover. Insert camshaft timing pins (Fiat Tool No. 99360614).

Ensure camshaft timing pins located correctly (Fig. 3).

Belt and Timing Belt Tensioner removal

Once the procedure for setting the TDC is completed according to car manufacturer's guidelines:

5. Loosen the Mounting Bolt and allow the tensioner pulley to move away from the belt.

6. Remove the timing belt and the old tensioner. It is recommended to replace the timing belt during the

replacement of the tensioner.

Initial Setup of the Timing Belt Tensioner

7. Ensure crankshaft timing pin located correctly (Fig. 2).

Ensure camshaft timing pins located correctly (Fig. 3).

8. Hold camshaft sprocket with a suitable holding tool (Fiat Tool Nos. 1.870.815.000/1.870.836.000) and

loosen camshaft sprocket bolt. Ensure camshaft sprocket can turn freely without tilting. Insert camshaft

sprocket aligning pin (Fiat Tool No. 1.860.617.000) (Fig. 4).

9. Install the new tensioner and turn the front plate on the tensioner using an 8mm Allen Key to the

approximate “10 O’clock position” (Fig. 5). This will maximize the belt clearance for ease of installation.

Hand tightens (lightly) the tensioner mounting bolt.

Installation of the Timing Belt Tensioner and the Belt

10. Install the timing belt being careful to engage the appropriate teeth of all the corresponding sprockets as

per drive layout (Fig.1). Ensure the belt is taut on non-tensioned side.

11. Remove camshaft sprocket aligning pin (Fig. 4). Counter-hold the camshaft sprocket with a suitable

holding tool (Fiat Tool Nos. 1.870.815.000/1.870.836.000) and tighten the camshaft sprocket bolt.

12. Rotate the Front Plate Anti-Clockwise with the 8mm Allen Key until the Dot Mark on Arm passes Notch on

Front Plate (Dot Mark is under the Front Plate, Fig. 6).



13. Tighten tensioner mounting bolt to 36Nm.

14. Remove the crankshaft and camshaft timing pins and rotate the crankshaft 8 revolutions in normal

direction of engine rotation.

15. Slacken the tensioner mounting bolt and carefully move the tensioner until the Dot Mark is aligned with

the Notch on the Front Plate (tensioner Nominal Position, Fig. 7). Once the nominal position is achieved,

prevent the rotation of the Front Plate and torque the mounting bolt to 36 ±2 Nm.

Verification of the Nominal Position

16. Rotate the crankshaft 2 more turns MANUALLY until just before TDC.

17. Insert crankshaft timing pin (Fig. 2). Turn crankshaft clockwise until it stops against timing pin.

18. Check that the camshaft timing pins can be inserted correctly into the camshafts (Fig. 3). If not, repeat

the installation procedure from step #3.

19. Check the tensioner Nominal Position with the engine set at TDC.

If the Dot Mark on the arm aligned with the Notch on the front plate (Fig. 7), the tensioner is set at its

nominal position and the installation is complete. If not, repeat the installation procedure from step #5.

20. Remove camshaft timing pins (Fig. 3).

Remove crankshaft timing pin (Fig. 2).

21. Install components in reverse order of removal.

22. Reconnect the battery and remove the memory saver.



0 C/S

1 F/P

2 W/P

3 CAM

4 IDL

5 TEN #0

#1

#2

#3

#4

#5

Figure 1. Timing Drive Layout for Fiat Ducato 2.3 JTD ENGINE

0: Crankshaft, 1: Fuel Pump, 2: Water Pump, 3: Camshaft, 4: Idler 5: Timing Belt Tensioner

Figure 1: Timing Drive Layout for Fiat Ducato 2.3 JTD ENGINE



Figure 3: Camshaft Timing Pins

Figure 2: Crankshaft Timing Pin



Figure 4: Camshaft Sprocket Aligning Pin

Figure 5: Initial setup of the Timing Belt Tensioner



Figure 6: Tensioner Position before setting to Nominal

Position

Figure 7: Tensioner at the Nominal Position

recommended installation procedure (07 february 14 … · the tensioner must be installed on the...

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