Timing belt kit with water pump - Fiat, Lancia

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  • The addition of the variator improves on both the power output and reduces the engine emissions. The variator operates via engine oil pressure and is actuated by an electronic valve, controlled by the engine management system. In this bulletin, we would like to focus on the complete overhaul of the timing belt drive of the later evolution of this engine fitted with the phase variator system.

    Vehicle applications - VKMA/VKMC 02206

    With timing phase variatorFiat 500 1,2L 8VFiat Doblo 1,4L 8VFiat Grande Punto 1,4L 8VFiat Idea 1,4L 8VFiat Linea 1,4L 8VLancia Musa 1,4L 8V

    Without timing phase variatorFiat Panda 1,1L 8V & 1,2L 8VFiat Doblo 1,2L 8VFiat Grande Punto 1,2L 8VFiat Punto 1,2L 8VLancia Ypsilon 1,2L 8V

    Issue 1 2009

    FIAT LANCIA

    VKMA / VKMC 02206

    Engine diagram of vehicles mentioned on this page

    The timing system for the Fiat and Lancia new FIRE enginesThe engine types used in this case study are the popular Fiat FIRE 1.2 and 1.4 litre, 8-valve engines. The purpose of this bulletin is to offer a guide for the fitment of a complete timing belt kit, highlighting the evolutionary developments of the cam timing phase variator system, latterly fitted to this generation of engines.

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    VKMC 02206 kit content:belt, automatic tensioner, water pump

  • Operating principle of the timing phase variator

    Engine identificationIt is easy to identify the engine fitted with the timing phase variator; Picture 1 exemplifies an early engine without this system and Picture 2 shows an engine with the variator system fitted.

    The operation of the timing phase variator. The 1.2 and 1.4 litre engines (named EVO 2) are fitted with a continuous timing phase variator that operates on engine oil pressure.

    This device allows the position of the camshaft to vary in relation to the engine crankshaft, resulting in more efficient engine combustion, higher power output and lower emissions. The system is fitted with a camshaft position sensor, which generates a signal from a phonic wheel mounted on the opposite side to the timing drive side of the camshaft. The signal emitted by the phase sensor is synchronised to the signal emitted by the engine crankshaft RPM sensor (which works in conjunction with a phonic wheel mounted on the auxiliary drive pulley). The ratio between the two signals generated, allows the

    Picture 1. Without phase variator electro valve Picture 2. With phase variator electro valve

    1. Camshaft driving pulley2. Drum3. Advance chamber4. Retard chamber5. Rotor6. Segment seals7. Electronic valve8. Oil return9. Oil pressure

    engine management system to decipher what the camshaft position is, in relation to the engine crankshaft and pass on corrective commands to the variators electronic valve. The system consists of a rotor attached to the camshaft (5) and a drum attached to the camshaft driving pulley (2). The rotor inserted in the drum creates two chambers (3 and 4), one for camshaft advance (3) and the other for retard (4) in relation to the position of the engine crankshaft. The charging and discharging of these two chambers (via engine oil pressure), allows the camshaft to move in both advance and retard directions (this happens due to the differing effects of hydraulic pressure acting on the rotor blade faces (5)). The pressure balance also allows the stopping of the camshaft movement. The inward oil flow is managed by the

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    engine management system, through a specific electronic valve (7) command.

  • The specific fitting instruction for timing belt kits

    The difference between the EVO 2 type engines listed above and those without a timing phase variator - is that the engine timing must be set using specific tools recommended by the manufacturer. During the removal and installation procedures, it is necessary to remove the engine control unit, valve covers and all other components located in front of the timing drive system. The specific fitting instructions, detailing the mounting steps for the timing belt kit VKMA 02206 are included in this kit. Please read them carefully, as the set-up of the automatic tensioner pulley goes hand in hand with the set-up of the timing belt system. Any failure in just one operation will affect the

    2.a Turn the belt tensioner in an anti-clockwise direction as indicated, until the tensioner reference fork reaches the stop point, then tighten the tensioner locking nut.

    1. Follow all removal, crankshaft, camshaft timing/locking procedures. Then loosen the belt tensioner, and then remove the old timing belt, and tensioner. Mount the new tensioner, and new belt. Ensure that the belt is tight on the non-tensioned side.

    3. Loosen the belt tensioner bolt and align the references (1) and (2) indicated below, then tighten the locking nut to 2,5-3,1 daNm of torque. (Fiat 500, Fiat Panda: 2,5 daNm)

    4. Belt tensioner installed and adjusted on the vehicle.

    5. Install both alignment tools to verify the correct engine timing settings, and then remove the tools.

    2.b Remove the alignment tools and turn the crankshaft two complete turns in the normal sense of rotation.

    Specific fitting instruction for the timing belt kit VKMA 02206DEPOSE1) Dbrancher la batterie.2) Dposer la protection sous moteur, le carterinfrieur du moteur et le pare-boue avant droit, sincessaire.3) Ecarter les flexibles, faisceaux, canalisations

    et/ou toutes autres pices situes proximit descarters de distribution.4) Dposer la courroie d'accessoires et son galettendeur.5) Dposer le ventilateur.6) Dposer le carter suprieur de distribution.7) Si ncessaire, soutenir le moteur l'aide d'unoutil adapt et dposer le support moteur droit.8) Dposer la poulie de vilebrequin.9) Dposer les carter intermdiaire et infrieur dedistribution.10) Tourner le vilebrequin dans le sens de rotationdu moteur (sens horaire) jusqu'au PMH en alignantles repres de la roue dente darbre cames et ducarter arrire de distribution (Fig. C) :- Tous types (sauf moteurs : ANY et AJM) : repre

    (5) 4Z ,- Moteurs ANY et AJM : repre (6) 3Z .11) Immobiliser la roue dente d'arbre cames laide de la pige (7) et le pignon de vilebrequin laide de loutil (8) (Fig. C).

    Nota : Les repres (9) du pignon de vilebrequin etde loutil (8) doivent tre aligns (Fig. C).

    12) Desserrer l'crou de fixation du galet ten-deur (2) et tourner le cadran de rglage (10) dansle sens anti-horaire l'aide de la cl (11) (Fig. D).13) Dposer le galet enrouleur (3) (Fig. A).14) Dposer la courroie de distribution (1) puis legalet tendeur (2) (Fig. A).

    REPOSE

    Attention : Nettoyer soigneusement les surfacesd'appui des galets.

    15) Desserrer les vis (12) de la roue dente d'arbre cames, et les placer au centre des trous oblongs,puis les serrer lgrement (Fig. E).

    16) Insrer la goupille (4) dans le trou du galet ten-deur neuf (2) (Fig. D).

    Nota : La goupille (4) est livre dans le kit SKF.

    17) Reposer le galet tendeur neuf (2) : Placer l'er-got de positionnement (14) dans la fente (15) dubloc-moteur (Fig. F).18) Tourner le cadran de rglage (10) du galet ten-deur (2) dans le sens horaire laide de la cl (11)jusqu'en bute (Fig. G). Serrez lgrement l'croude fixation (16) (Fig. G) du galet tendeur la main.19) Poser la courroie neuve (1) dans lordre suivant :roue dente d'arbre cames, galet tendeur, pignonde vilebrequin et pompe eau.20) Reposer le galet enrouleur neuf (3).21) Desserrer l'crou de fixation du galet tendeur.Tourner le cadran de rglage (10) du galet ten-

    deur (2) dans le sens anti-horaire laide de lacl (11) jusqu' ce que la goupille (4) puisse treretire (Fig. G). Retirer la goupille (4). 22) Tendre la courroie de distribution (1) : tournerle cadran de rglage (10) du galet tendeur (2) dansle sens horaire l'aide de la cl (11) tout en main-tenant l'crou de fixation (16) du galet en position l'aide d'une cl crou hexagonal (Fig. H). Legalet tendeur se dplace et vient s'appuyer contrela courroie qui se tend. Poursuivre la rotation ducadran de rglage jusqu ce que lindex mobile (17)soit align avec l'encoche (18) (Fig. H). Serrer alorsl'crou de fixation (16) (Fig. H) du galet tendeur,sans modifier sa position, au couple de 2,3 daN.m 0,3 plus un serrage angulaire de 45.23) Serrer les vis (12) de la roue dente d'arbre cames au couple de 2,5 daN.m (Fig. E).24) Dposer les outils (7) et (8) (Fig. C), puis effec-tuer deux tours de vilebrequin dans le sens derotation du moteur jusquau PMH (repres (5) et (6)aligns (Fig. C)).25) Reposer les outils (7) et (8) (Fig. C) puis contr-ler l'alignement des repres (9) (Fig. C).

    Nota : Si loutil (8) est pos et quil est impossibledinsrer la pige (7) (Fig. C), desserrer alors la rouedente darbre cames et dplacer lgrement lemoyeu jusqu pouvoir introduire la pige (7).Resserrer la roue dente d'arbre cames puiseffectuer deux tours de vilebrequin et contrler denouveau le calage de la distribution.

    26) Vrifier le rglage de l'index mobile (17)(Fig. H) (l'index mobile doit tre align avec l'enco-che (18)).

    Nota : La tension de la courroie de distribution estcorrecte lorsque l'index mobile (17) du galet ten-deur est align avec l'encoche (18) (Fig. H).

    27) Si les repres du galet tendeur ne sont pas ali-gns, procdez comme suit : maintenir le galet ten-deur (2) en position avec la cl (11) pendant quevous dvissez lgrement l'crou de fixation (16)(Fig. H). Recommencer ensuite l'opration derglage de la tension depuis l'tape (18) aprs avoirrepos la goupille (4) (Fig. D).

    28) Reposer les carter intermdiaire et infrieur dedistribution. Reposer la poulie de vilebrequin,serrer ses vis de fixation au couple de 1 daN.m +serrage angulaire de 90.29) Effectuer le remontage des lments dpossdans lordre inverse du dmontage.

    Nota : La repo