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How to Replace timing chain 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

How to Replace timing belt on Fiat Ducato 2.3 2008
How to Replace timing belt on Fiat Ducato 2.3 2008

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.

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