How to Replace timing belt on Fiat Ducato 2.3 2008

Fiat Ducato 2.3 2008 cambelt change instructions and replacement inteval. Full guide!

Special tools

• Camshaft timing pins – Fiat No.99360614.
• Camshaft sprocket aligning pin – Fiat No.1.860.617.000.
• Crankshaft timing pin – Fiat No.99360615.
• 2006: Crankshaft timing pin – Fiat No.2.000.018.200. Holding tool – Fiat No.1.870.815.000.
• Holding tool pins – Fiat No.1.870.836.000.
• Universal puller – Fiat No.USAG 452/1.
• Universal puller washer – Fiat No.1.845.028.000.

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.

Repair times – hrs

Camshaft drive belt/chain – R & I

2,80

Valve timing procedures

Removal

NOTE: The high-pressure fuel pump does not require timing.

1. Raise and support front of vehicle.
2. Drain cooling system.
3. Remove:
   • RH front wheel.
   • Engine undershield.
   • RH wheel arch liner (if necessary).
   • Auxiliary drive belt.
   • Auxiliary drive belt tensioner.
   • Auxiliary drive belt guide pulley.
   • Crankshaft pulley bolts [1] .
   • Crankshaft pulley [2] .
4. 2006: Support engine.
5. Disconnect:
   • PAS reservoir hoses (if necessary).
   • RH headlamp multi-plug.
6. 2006:
   • Remove:
   • PAS reservoir and bracket.
   • Intercooler to inlet manifold hose.
7. 2006:
   • Remove:
   • RH headlamp.
   • Windscreen washer reservoir filler neck.
   • Windscreen washer reservoir.
8. Disconnect:
   • Coolant expansion tank hoses.
   • Coolant expansion tank multi-plug.
9. 2006: Remove PAS reservoir and bracket.
10. Remove:
    • Coolant expansion tank.
    • 2006: RH engine mounting.
    • Timing belt cover [3] .
    • 2006: Glow plug control module cover.
11. 2006: Disconnect glow plug control module multi-plugs.
12. Remove:
    • 2006: Glow plug control module and bracket.
    • Blanking plug from cylinder block.
13. Turn crankshaft clockwise until just before TDC.
14. Insert crankshaft timing pin [4] .
    • 2006: Tool No.99360615.
    • 2006: Tool No.2.000.018.200.
15. Turn crankshaft clockwise until it stops against timing pin [4] .
16. Remove two studs from cylinder head cover.
    NOTE: Studs located above No.4 cylinder.
17. Insert camshaft timing pins [5] . Tool No.99360614.
18. Ensure camshaft timing pins located correctly [6] .
19. Remove:
    • Tensioner pulley bolt [7] .
    • Tensioner pulley.
    • Timing belt.

Installation

NOTE: If belt has been in use for more than 15,000 miles: Fit new belt.

1. Ensure crankshaft timing pin located correctly [4] .
2. Ensure camshaft timing pins located correctly [5] & [6] .
3. Hold camshaft sprocket. Use tool Nos.1.870.815.000/1.870.836.000.
4. Slacken camshaft sprocket bolt [8] .
5. Loosen camshaft sprocket from taper. Use tool No.USAG 452/1.
6. Ensure camshaft sprocket can turn freely without tilting.
7. Ensure camshaft sprocket aligning hole at 3 o’clock position [9] .
8. Insert camshaft sprocket aligning pin [10] . Tool No.1.860.617.000.
9. Fit new tensioner pulley.
10. Turn tensioner pulley until at position as shown [11] . Use Allen key [12] . Tighten bolt [7] .
11. Fit timing belt. Ensure belt is taut on non-tensioned side.
12. Remove camshaft sprocket aligning pin [10] .
13. Hold camshaft sprocket. Use tool Nos.1.870.815.000/1.870.836.000.
14. Tighten camshaft sprocket bolt [8] . Tightening torque: 90 Nm.
15. Slacken tensioner pulley bolt [7] .
16. Turn tensioner pulley anti-clockwise until LH notch aligned with dot mark [13] & [14] . Use Allen key [15] .
17. Tighten tensioner pulley bolt [7] .
18. Remove:
    • Camshaft timing pins [5] .
    • Crankshaft timing pin [4] .
19. Turn crankshaft eight turns in direction of rotation.
20. Slacken tensioner pulley bolt [7] .
21. Turn tensioner pulley until central notch aligned with dot mark [16] & [17] . Use Allen key [18] .
22. Tighten tensioner pulley bolt [7] . Tightening torque: 36 Nm.
23. Turn crankshaft two turns in direction of rotation until just before TDC.
24. Insert crankshaft timing pin [4] .
25. Turn crankshaft clockwise until it stops against timing pin [4] .
26. Ensure camshaft timing pins can be easily inserted [5] . If not: Repeat installation procedure.
27. Ensure tensioner pulley central notch aligned with dot mark [16] & [17] . If not: Repeat tensioning procedure.
28. Remove:
    • Camshaft timing pins [5] .
    • Crankshaft timing pin [4] .
29. Install components in reverse order of removal.
30. Tighten crankshaft pulley bolts [1] . Tightening torque: 30 Nm.
31. Refill cooling system.