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 Refitting
(
Removing
)
Before proceeding with the removing-refitting operation, the engine must be correctly identified to decide on the correct procedure to be followed. Two types of engine are fitted on the Panda which can be distinguished by the following features by looking at them: |
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A. Pre-modification engines
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B. Post-modification engines (EVO2)
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New, plastic round shaped oil filler plug (1a) (previously, rubber, square, press-fit).
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New tappet cover (2) which differs from the previous one through its shape and fastening to the cylinder head with 8 bolts (previously 4).
If the engine is the pre-modification type, determine the registraion number and refer to the following procedure:
- valid for versions with: Engines up to N° 2533527
or
- valid for versions with: Engines from N° 2533528
If the engine is the post-modification type, refer to the following procedure:
- valid for versions with: EVO2 engines
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APPLICABLE TO VERSIONS WITH: Engines until no. 2533527
APPLICABLE TO VERSIONS WITH: Engines until no. 2533527
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1. Undo the fixing screws (1a) and move aside the catch (1b), without disconnecting the control cable.
2. Fit the tool (2a) complete with support mountings (2b).
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2nd |
Cross member |
1.870.595.000 |
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2b |
Support blocks |
1.870.650.000 |
3. Fit the tools (3a) and (3b), then connect them to the tool fitted previously.
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3rd |
Cross member |
1.860.851.003 |
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3b |
Vertical mount |
1.871.001.300 |
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APPLICABLE TO VERSIONS WITH: Engines until no. 2533527
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1. Position a special bracket (1a) and secure it to the crossmember (1b) hook positioned previously to support the power unit.
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APPLICABLE TO VERSIONS WITH: Engines until no. 2533527
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1. Undo the fixing nuts (1a) fixing the flexible mounting (1b) to the timing side engine support and remove it.
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APPLICABLE TO VERSIONS WITH: Engines until no. 2533527
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1. Undo the fixing screws (1a) and remove rigid power unit mount (1b).
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APPLICABLE TO VERSIONS WITH: Engines until no. 2533527
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1. Turn the crankshaft until the notch on driven pulley (1a) is aligned with the notch on cylinder head (1b) and notch on drive pulley (1c) with reference (1d) on the oil pump case.
2. Undo the fixing nut (2a) and loosen the timing system moving tensioner (2b).
3. Release and remove the toothed timing belt.
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APPLICABLE TO VERSIONS WITH: Engines until no. 2533527
APPLICABLE TO VERSIONS WITH: Engines until no. 2533527
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1. Before fitting the toothed timing belt ensure that the references are correctly aligned by checking that the notch on driven pulley (1a) is aligned with the notch on cylinder head (1b) and that the notch on drive pulley (1c) is aligned with reference (1d) on the oil pump case.
Whenever the reference notches do not correspond to each other, make small movements of the crankshaft and camshaft until the marks coincide.
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APPLICABLE TO VERSIONS WITH: Engines until no. 2533527
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1. Fit the toothed timing belt in place.
2. Position the tool (2a) and with a torque wrench (2b), preload the moving timing tensioner (2c) and screw in the nut (2d) without tightening it.
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2nd |
Adapter |
1.871.001.400 |
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APPLICABLE TO VERSIONS WITH: Engines until no. 2533527
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Turn the crankshaft through two turns and ensure that the references on the driven pulley and the drive pulley coincide with the fixed references on the cylinder head and oil pump casing respectively.
1. Measure the tension value on loose branch (1a) of the timing toothed drive belt, using the special tool (1b).
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Keep the measurement sensor of the measuring instrument at a distance of around 1 cm from the belt.
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1b |
Belt tension measuring device |
1.871.001.500 |
2. Measure the tension value on taut branch (2a) of timing toothed control belt, using the special tool (2b).
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Keep the measurement sensor of the measuring instrument at a distance of around 1 cm from the belt.
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1b |
Belt tension measuring device |
1.871.001.500 |
Add together the measurement values taken from the two branches of the timing system toothed control belt and check that the resulting value falls within the parameters detailed below:
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Tensioning value of timing system toothed control belt (Hz) |
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150 - 200 |
3. Tighten the nut securing the toothed timing belt moving tensioner to the prescribed torque.
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MOVING TIMING TENSIONER |
Nut |
M8 x 1.25 |
2.5 ÷ 3.1 |
1.1 1.2 8v |
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APPLICABLE TO VERSIONS WITH: Engines until no. 2533527
APPLICABLE TO VERSIONS WITH: Engines from no.2533528
APPLICABLE TO VERSIONS WITH: Engines from no.2533528
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1. Undo the fixing screws (1a) and move aside the catch (1b), without disconnecting the control cable.
2. Fit the tool (2a) complete with support mountings (2b).
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2nd |
Cross member |
1.870.595.000 |
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2b |
Support blocks |
1.870.650.000 |
3. Fit the tools (3a) and (3b), then connect them to the tool fitted previously.
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3rd |
Cross member |
1.860.851.003 |
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3b |
Vertical mount |
1.871.001.300 |
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APPLICABLE TO VERSIONS WITH: Engines from no.2533528
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1. Position a special bracket (1a) and secure it to the crossmember (1b) hook positioned previously to support the power unit.
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APPLICABLE TO VERSIONS WITH: Engines from no.2533528
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1. Undo the fixing nuts (1a) fixing the flexible mounting (1b) to the timing side engine support and remove it.
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APPLICABLE TO VERSIONS WITH: Engines from no.2533528
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1. Undo the fixing screws (1a) and remove rigid power unit mount (1b).
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APPLICABLE TO VERSIONS WITH: Engines from no.2533528
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1. Disconnect the spark plug high voltage leads.
2. Detach the coil supply electrical connections.
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2 |
Starter coil (connector A030A) |
See A030 IGNITION COIL |
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2 |
Starter coil (connector A030B) |
See A030 IGNITION COIL |
3. Undo the fixing nuts (3a) and screw (3b) and remove the rear coil / support cover (3c).
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APPLICABLE TO VERSIONS WITH: Engines from no.2533528
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1. Remove the spark plug from the first cylinder and fit in its housing a dial gauge (1a) equipped with tracer (1b) complete with mount.
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1b |
Mount |
1.860.895.000 |
TDC measurement |
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1b |
Adapter |
1.871.008.400 |
TDC measurement |
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APPLICABLE TO VERSIONS WITH: Engines from no.2533528
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Turn the crankshaft until the piston of the first cylinder is at TDC. This can be detected by means of the dial gauge previously positioned.
1. With the piston of the first cylinder at TDC, fit the ridge of tool (1a) into groove (1b) at the back of the crankshaft, taking care to position it with the part marked "ALTO - UP" facing upwards; then secure the tool with nuts (1c).
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1a |
Template |
2.000.004.000 |
Crankshaft stage |
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APPLICABLE TO VERSIONS WITH: Engines from no.2533528
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1. Loosen the nut (1a) of the moving tensioner (1b) and remove the timing belt (1c).
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APPLICABLE TO VERSIONS WITH: Engines from no.2533528
APPLICABLE TO VERSIONS WITH: Engines from no.2533528
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1. Loosen the screw fixing the driven pulley (1b), using the tool (1a).
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1a |
Counter-torque |
1.860.831.000 |
Rotation lock |
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APPLICABLE TO VERSIONS WITH: Engines from no.2533528
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1. Fit the new timing control belt in the following order: crankshaft gear (1a), water pump pulley (1b), camshaft control pulley (1c) and then mobile tensioner (1d).
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The timing belt must be fitted the correct way; position the written supplier details on the belt as shown in the magnified part of the diagram.
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APPLICABLE TO VERSIONS WITH: Engines from no.2533528
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1. Use suitable round-nosed pliers to turn the moving tensioner to the position of maximum tension, i.e. with moving reference (1a) located as shown in the figure. Then secure the nut (1b) fastening the tensioner.
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APPLICABLE TO VERSIONS WITH: Engines from no.2533528
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Remove the tool positioned in the camshaft rear cover housing.
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Template |
2.000.004.000 |
Crankshaft stage |
1. Tighten the screw securing the driven pulley (1b) to torque, using the tool (1a).
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1a |
Counter-torque |
1.860.831.000 |
Rotation lock |
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1b |
10,8 - 13,2 |
Screw |
Driven pulley |
- |
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APPLICABLE TO VERSIONS WITH: Engines from no.2533528
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Rotate the crankshaft through two revolutions in its standard direction of rotation.
1. Loosen the nut securing the moving tensioner and align the mobile marker (1a) with the fixed reference (1b).
2. Once both references are aligned, tighten the nut securing the tensioner to the prescribed torque.
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2 |
2,5 |
Nut |
Moving tensioner |
- |
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APPLICABLE TO VERSIONS WITH: Engines from no.2533528
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Remove the gauge with tracer and mount.
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Mount |
1.860.895.000 |
TDC measurement |
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Adapter |
1.871.008.400 |
TDC measurement |
Fit the spark plug for the first cylinder.
Fit the rear coil / support cover tightening the fixing screw and nuts.
Connect the coil supply electrical connections.
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Starter coil (connector A030A) |
See A030 IGNITION COIL |
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Starter coil (connector A030B) |
See A030 IGNITION COIL |
Connect the spark plug high tension leads.
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APPLICABLE TO VERSIONS WITH: Engines from no.2533528
APPLICABLE TO VERSIONS WITH: EVO2 engines
APPLICABLE TO VERSIONS WITH: EVO2 engines
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1. Undo the fixing screws (1a) and move aside the catch (1b), without disconnecting the control cable.
2. Fit the tool (2a) complete with support mountings (2b).
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2nd |
Cross member |
1.870.595.000 |
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2b |
Support blocks |
1.870.650.000 |
3. Fit the tools (3a) and (3b), then connect them to the tool fitted previously.
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3rd |
Cross member |
1.860.851.003 |
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3b |
Vertical mount |
1.871.001.300 |
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APPLICABLE TO VERSIONS WITH: EVO2 engines
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1. Position a special bracket (1a) and secure it to the crossmember (1b) hook positioned previously to support the power unit.
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APPLICABLE TO VERSIONS WITH: EVO2 engines
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1. Undo the fixing nuts (1a) fixing the flexible mounting (1b) to the timing side engine support and remove it.
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APPLICABLE TO VERSIONS WITH: EVO2 engines
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1. Undo the fixing screws (1a) and remove rigid power unit mount (1b).
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APPLICABLE TO VERSIONS WITH: EVO2 engines
APPLICABLE TO VERSIONS WITH: EVO2 engines
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1. Loosen the belt tensioner nut (1a) and remove the timing belt (1b).
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APPLICABLE TO VERSIONS WITH: EVO2 engines
APPLICABLE TO VERSIONS WITH: EVO2 engines
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Loosen the toothed driven pulley fixing screw.
1. Fit the template to the camshaft rear shank.
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1 |
Template |
2.000.004.400 |
Crankshaft stage |
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APPLICABLE TO VERSIONS WITH: EVO2 engines
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1. Fit the timing belt.
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APPLICABLE TO VERSIONS WITH: EVO2 engines
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1. Fit the crankshaft timing template to the drive pulley.
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1 |
Template |
2.000.004.500 |
Crankshaft stage |
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APPLICABLE TO VERSIONS WITH: EVO2 engines
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1. Using the tool (1a) place the automatic tensioner fork (1b) in the end of travel position (1c) and tighten the nut (1d). The timing belt is in the maximum tension position.
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1a |
Key |
1.860.987.000 |
Tensioning toothed timing drive belt |
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APPLICABLE TO VERSIONS WITH: EVO2 engines
