C5 (X7) DW10BTED4 (138) Timing Belt Replacement

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GiveMeABreak
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C5 (X7) DW10BTED4 (138) Timing Belt Replacement

Post by GiveMeABreak » 29 Jun 2019, 13:06

This is a guide on how to replace the Timing Belt for the DW10BTED4 engine only

Preliminary Work: Remove the Ancillary Drive Belt

Recommended Tools:
Drive Belt Tools A.PNG
[1] Dynamic tensioner compression lever (-).0188-Z.
[2] 4 mm diameter pin (-).0188-Q1.
Removing
Put the vehicle on a hoist.
Remove:
  • The front right wheel
  • The front right mud-shield
Drive Belt Tools B.PNG
CAUTION: Mark the direction of fitting of the ancillary drive belt if it is to be reused.
Compress the dynamic tensioner (1) in the anti-clockwise direction ( as "b"), Using tool [1].
Peg the dynamic tensioner (1) at "a", Using tool [2].
Remove the accessories drive belt (2).

ESSENTIAL: Check that the roller (1) turns freely (no play or tight spot).
Refitting The Ancillary Drive Belt
Refit the ancillary belt (Observe the following order):
  • Accessories drive pulley
  • Compressor
  • Alternator
  • Roller Tensioner
CAUTION: Make sure that the accessories drive belt is correctly positioned in the grooves of the different pulleys.
Support the dynamic roller tensioner (1) ( as "b"). Using tool [1].
Remove the tool [2].
Progressively decompress the dynamic tensioner to tension the accessories belt.
Refit:
  • The front right mud-shield
  • The front right wheel, Tightening to 10 ± 1 daN.m
Removing / Refitting the Timing Belt

Recommended Tools
Tools A.PNG
Tools B.PNG
Tools C.PNG
Tools C.PNG (60.72 KiB) Viewed 24 times
[1] flywheel locking tool (-).0188-Y.[2] camshaft gear setting rod (-).0188-M.[3] flywheel stop (-).0188-F.
Tools DF.PNG
Tools DF.PNG (47.19 KiB) Viewed 24 times
Tools E.PNG
Tools F.PNG
Tools F.PNG (79.4 KiB) Viewed 24 times
[4] pinion centraliser (-).0188-AH.[5] Dynamic tensioner compression lever (-).0188-Z.[6] belt clamp (-).0188-AD.
Removing
Put the vehicle on a hoist.
CAUTION: After switching off the ignition, wait 15 minutes before disconnecting the battery (To ensure that the learning patterns of the various ECUs are stored in memory).
  • Remove: The upper battery protector.
  • Disconnect the battery.
Remove:
  • The front right mud guard
  • The front right wheel
  • The protective panel under the engine
  • The accessories drive belt, Using tool [5] (see procedure at beginning of post)
Timing A.PNG
Remove:
  • The oil sump soundproofing (6)
  • The 4 bolts (3)
  • The lower stabiliser bar (5)
Loosen the clips (1).
Release: The air hose (9).
Remove:
  • The bolts (/)
  • The air inlet resonator (8)
  • The bolts (2)
  • The impacter (4)
Timing B.PNG
Disconnect the connector (Engine speed sensor ) ( as "a").
Unfasten and move aside: The electrical harness (10) ( as "b").
Release The fuel supply and return piping .
Remove:
  • The pulley cover (14) (according to equipment)
  • The 2 bolts (11)
  • The nut (13)
  • The top timing cover (12)
Timing C.PNG
CAUTION: It is essential to turn the engine clockwise by the crankshaft pulley bolt.
Peg:
  • The flywheel (/)( as "c"), Using tool [1]
  • The camshaft pulley (15), Using tool [2]
Line tool [3] up with the flywheel; Use: The impacter fixing bolt (4) with the appropriate nut ( as "d").
Timing D.PNG
CAUTION: The target (18) must show no trace of damage and no magnetic source must go near it; If this is not the case, the engine speed fibre ring (18) will need to be replaced.
Remove:
  • The bolt (19) and its spacer
  • The crankshaft pulley (20)
  • The engine speed sensor target (18)
  • The 3 bolts (17)
  • The bottom timing cover (16)
  • The (21) bolt
  • The engine speed sensor (22)
Timing E.PNG
Retain the tensioner roller (23) in its position using a 6 sided Allen key ( as "e").
Slacken the bolt (29).
Turn the dynamic roller tensioner (23) clockwise until the timing belt (24) is not tensioned ; Using a 6 -sided wrench ( as "e").
Remove: The timing belt (24).
Check
Check that the following components rotate freely (Absence of play and points of resistance):
  • Timing belt dynamic roller tensioner (23); Retighten the bolt (29) (if necessary)
  • Roller tensioner (27)
  • Coolant pump gear (25)
Remove:
  • The (29) bolt
  • The dynamic roller tensioner (23)
  • The (28) bolt
  • The tensioning roller (27)
Check:
  • The condition of the seals of the dynamic tension roller (23) and reel (27)
  • The absence of traces of oil leaks on the various seals and on the crankshaft and camshaft ring seals
  • The free range of movement of the crankshaft pulley (26) on the key
CAUTION: Replace any defective parts.

Refitting

Refit:
  • The tensioning roller (27)
  • The (28) bolt; Tighten to 5,6 ± 0,5 daN.m
  • The dynamic roller tensioner (23)
  • The (29) bolt; Without tightening it
CAUTION: It is imperative to replace the timing belt (/).
Timing F.PNG
Diagram A

(30) Index of the dynamic roller tensioner (23).
"A" Dynamic roller tensioner (23) at minimum timing belt (24) tension.
"B" Dynamic roller tensioner (23) at maximum timing belt (24) tension.
"C" Dynamic roller tensioner (23) at nominal timing belt (24) tension.
Preliminary Tension
Timing G.PNG
Centre the crankshaft pulley (26) on its key, using tool [4].
Check the position of the roller tensioner (23) ( as "f").
Position the dynamic roller tensioner (23): At minimum tension (See diagram "A").
Fit the timing belt (24) to a third of its width (Span of the belt correctly tensioned) (In the order shown):
  • On the camshaft pulley (15); Moderately tighten; Using tool [6]
  • On the roller tensioner (27)
  • On the crankshaft pulley (26)
  • On the water pump pulley (25)
  • On the dynamic roller tensioner (23)
Remove the tool [6].
Fit the timing belt (24) over its whole width (In the order shown):
  • On the camshaft pulley (15)
  • On the roller tensioner (27)
  • On the crankshaft pulley (26)
  • On the water pump pulley (25)
  • On the dynamic roller tensioner (23)
Position the dynamic roller tensioner (23) : At maximum tension (See diagram "B").
Tighten the bolt (29) to 2,1 ± 0,2 daN.m.
Remove the tool [4].
Refit:
  • The engine speed sensor target (18)
  • The crankshaft pulley (20)
  • The bolt (19) and its spacer ; Tighten to 5 ± 1 daN.m
Remove the tools [1], [2], [3].
CAUTION: It is essential to turn the engine clockwise by the crankshaft pulley bolt.
Turn the engine 4 revolutions.
Check the position of the timing belt (24).

Final tension

Peg:
  • The flywheel (/)( as "c") ; Using tool [1]
  • The camshaft pulley (15) ; Using tool [2]
Line tool [3] up with the flywheel ; Use the fixing bolt of the impacter (4) with the appropriate nut ( as "d").
Remove:
  • The bolt (19) and its spacer
  • The crankshaft pulley (20)
  • The engine speed sensor target (18)
Retain the tensioner roller (23) in its position using a 6 sided Allen key ( as "e").
Slacken the bolt (29).
Position the dynamic tension roller (23) at nominal tension (See diagram "C"); Turn slightly in a clockwise direction.
CAUTION: If it goes past the index (30) repeat the preliminary tension operation.

Retain the tensioner roller (23) in its position using a 6 sided Allen key ( as "e").
Retighten the bolt (29); to 2,1 ± 0,2 dan.m.

CAUTION: Coat the bolt (21) with threadlock LOCTITE.

Refit:
  • The engine speed sensor (22)
  • The (21) bolt; Tighten to 0,7 ± 0,1 daN.m
  • The bottom timing cover (16)
  • The 3 bolts (17); Tighten to 0,5 ± 0,05 daN.m
  • The engine speed sensor target (18)
  • The crankshaft pulley (20)
  • The new bolt (19) and its spacer
Tightening procedure: bolts (19) - spacer:
  • Pre-tightening to 7 ± 2,5 daN.m
  • Angular tightening to 62 ± 3°
Remove the tools [1], [2], [3].

CAUTION : It is essential to turn the engine clockwise by the crankshaft pulley bolt.

Turn the engine 4 revolutions.
Check the position of the timing belt .
Check the position of the index (30).

Refit:
  • The top timing cover (12)
  • The nut (13) ; Tighten to 0,5 ± 0,05 daN.m
  • The 2 bolts (11) ; Tighten to 0,5 ± 0,05 daN.m
  • The pulley cover (14) (according to equipment)
Reposition:
  • The fuel supply and return piping
  • The electrical harness (10) ( as "b")
Connect the connector (Engine speed sensor ) (22) ( as "a").
Refit:
  • The impacter (4)
  • The bolts (/); Tighten to 4 ± 0,6 daN.m
  • The air inlet resonator (8)
  • The bolts (/) ; Tighten to 0,8 ± 0,1 daN.m
Reposition: The air hose (9).
Re-tighten: The clamps (1) to 0,35 ± 0,03 daNm.
Refit:
  • The accessories drive belt using tool [5]
  • The protective panel under the engine
  • The front right mud guard
  • The front right wheel
CAUTION: Perform the operations to be carried out following reconnection of the battery:
BSI Rest / Battery Disconnect / Reconnect Procedure
Reconnect the battery.
Refit: The upper battery protector.