How to Replace timing belt on Fiat Ducato (230) 1.9 TD 1994-1998 Engine No. 1723291-

Engine No. 1723291-

Replacement Interval Guide

• Fiat recommend check and/or replacement at the following intervals:
• Tipo:
• →1988:
• Every 54,000 miles – replace.
• 01/89-04/89:
• Every 60,000 miles – replace.
• 05/89→:
• Every 36,000 miles – check & replace if necessary.
• Every 63,000 miles – replace.
• Tempra:
• →04/91:
• Every 18,000 miles – check & replace if necessary.
• Every 60,000 miles – replace.
• 05/91→:
• Every 36,000 miles – check & replace if necessary.
• Every 63,000 miles – replace.
• Ducato:
• →05/91:
• Every 60,000 miles – replace.
• 06/91→:
• Every 36,000 miles or 4 years – check & replace if necessary.
• Every 63,000 miles – replace.
• The previous use and service history of the vehicle must always be taken into account.

Check For Engine Damage

CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage 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.

Repair Times – hrs

Remove & install:
Tipo/Tempra 1,9 D	1,35
AC	+0,15
Tipo/Tempra 1,9 TD	1,90
AC	+0,20
Ducato 1,9 D/TD	1,05

Special Tools

• Tensioning tool – Fiat No.1860745100/300.
• Crankshaft locking tool – Fiat No.1860933000.
• Camshaft aligning tool (Non-turbo) – Fiat No.1860934000.
• Camshaft aligning tool (Turbo) – Fiat No.1860931000.
• Sprocket holding tool – Fiat No.1860831000.

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.
• Check diesel injection pump timing after belt replacement.

Removal

1. Raise and support front of vehicle.
2. Remove:
   • Auxiliary drive belt.
   • Crankshaft pulley bolts.
   • Crankshaft pulley [1] .
   • Timing belt upper cover [3] .
   • Timing belt lower cover [2] .
3. Turn crankshaft clockwise to TDC. Ensure timing marks aligned [4] & [5] .

   NOTE: Camshaft timing marks may not align exactly, as sprocket has keyhole slot. Non-turbo: [6] & [7] . Turbo: [18] & [7] .

4. Slacken tensioner nut to release tension on belt [8] .
5. Remove timing belt.

Installation

NOTE: DO NOT refit used belt.

1. Remove vacuum pump from rear of cylinder head.
2. Install camshaft aligning tool to rear of cylinder head [9] . Tool No.1860931000/4000.
3. If necessary: Centralise dowel [10] by turning bolt [11] slightly.
4. Ensure timing marks aligned [4] & [5] .
5. Fit timing belt to crankshaft sprocket.
6. Remove front cover bolt [12] . Fit crankshaft locking tool [13] . Tool No.1860933000.
7. Hold tool in place with bolt [12] .
8. Hold camshaft sprocket [14] . Use tool No.1860831000. Slacken bolt [15] .

   NOTE: Camshaft sprocket should be able to turn slightly [7] .

9. Fit timing belt in anti-clockwise direction. Ensure belt is taut between sprockets on non-tensioned side.
10. Ensure timing mark aligned [5] .
11. Turn tensioner pulley clockwise. Fit tensioning tool to tensioner pulley [16] . Tool No.1860745100/300. With scale bar horizontal set weight at 120 mm mark [17] .

    NOTE: Ensure scale bar remains horizontal during tensioning procedure.

12. Hold camshaft sprocket [14] . Use tool No.1860831000. Tighten bolt to 118 Nm [15] .
13. Remove:
    • Crankshaft locking tool [13] .
    • Camshaft aligning tool [9] . Tighten bolt [12] .
14. Turn crankshaft slowly two turns clockwise. Ensure timing marks aligned [4] & [5] .
15. Tighten tensioner nut to 44 Nm [8] .
16. Remove tensioning tool [16] .
17. Install components in reverse order of removal.