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1.2 8V EVO 2 Engine Cam Belt replacement
A time consuming job...
Andy Monty
22-05-2010
Right First off this is an involving task requiring some specialist tools and a bit of care and attention to detail get it wrong and there is a risk of serious damage to your engine....<br />
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Tools/ equipment needed <br />
Old 14-06-2015   #30
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Re: 1.2 8V EVO 2 Engine Cam Belt replacement

Updated with vvt info and water pump change details
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Old 13-09-2015   #31
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Re: 1.2 8V EVO 2 Engine Cam Belt replacement

Quote Originally Posted by Andy Monty View Post
then tighten the cam bolt to 180-220NM +55 degrees (which is flipping TIGHT)
Thanks for the guide, but I am not sure about this torque value.

For the Punto Evo 1.4 8v VVT:

Fiat Elearn says 1.8 to 2.2 daNm (this is 18 to 22 Nm) + 55 degrees.

and the new Punto Evo Haynes manual says
stage 1) tighten to 20Nm,
stage 2) tighten a further 55 degrees.

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Last edited by homersimpson; 13-09-2015 at 18:46.
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Old 14-09-2015   #32
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Re: 1.2 8V EVO 2 Engine Cam Belt replacement

Quote Originally Posted by homersimpson View Post
Thanks for the guide, but I am not sure about this torque value.

For the Punto Evo 1.4 8v VVT:

Fiat Elearn says 1.8 to 2.2 daNm (this is 18 to 22 Nm) + 55 degrees.

and the new Punto Evo Haynes manual says
stage 1) tighten to 20Nm,
stage 2) tighten a further 55 degrees.

my / sealeys mistake ive just checked on elearn

However i was going by the figures on my cam locking kit from sealey and it does give 180-220nm me thinks i avoided a very expensive mistake by the skin of my knuckles...


i have amended the guide accordingly
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Massive gash
Quote Originally Posted by EmmaM88 View Post
Just a little touch up
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Old 14-09-2015   #33
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Quote Originally Posted by homersimpson View Post
Thanks for the guide, but I am not sure about this torque value.

For the Punto Evo 1.4 8v VVT:

Fiat Elearn says 1.8 to 2.2 daNm (this is 18 to 22 Nm) + 55 degrees.

and the new Punto Evo Haynes manual says
stage 1) tighten to 20Nm,
stage 2) tighten a further 55 degrees.


See here me thinks they cocked up
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Old 14-09-2015   #34
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Re: 1.2 8V EVO 2 Engine Cam Belt replacement

Quote Originally Posted by Andy Monty View Post
See here me thinks they cocked up
They certainly did. I would have expected better from Sealey.

Glad you break anything
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Last edited by homersimpson; 14-09-2015 at 12:39.
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Old 14-09-2015   #35
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Re: 1.2 8V EVO 2 Engine Cam Belt replacement

Quote Originally Posted by homersimpson View Post
They certainly did. I would have expected better from Sealey.

Glad you break anything
well i only found the other half of the torx bit last week
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Quote Originally Posted by Most Easterly Pandas View Post
Massive gash
Quote Originally Posted by EmmaM88 View Post
Just a little touch up
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Old 20-01-2016   #36
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Re: 1.2 8V EVO 2 Engine Cam Belt replacement

Does anyone have an Amazon / Ebay link to where I'd get the Cam Lock kit from for the 1.2 8v 2006 Grand Punto? or is it a Universal Jobby?
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Old 27-06-2017   #37
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Re: 1.2 8V EVO 2 Engine Cam Belt replacement

Thanks for the guide as i will be attempting this soon.

I have a question though - what is the need to slacken off the cam pulley - i.e. this bit;

"next slacken off Cam pully
FIRST REMOVE CAM LOCKING TOOL or you can damage your camshaft end

loosen using a 24mm spanner on the flats on the cam shaft and a T55 torx socket)
"

Surely if the you've managed to get the locking tools fitted to the cam and crankshaft there is no need to touch the cam pulley as it should already be set?

Or am i missing something?

I have done a Vauxhall 1.6 engine before but i would just like be sure before i start.
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Old 26-08-2018   #38
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Cool Re: 1.2 8V EVO 2 Engine Cam Belt replacement

1. Yes, that doesn't make sense, to "slacken off the cam pulley". No need for that.
Some folks do it (probably) just because it is inconvenient to put new belt on ("thread" it around all pulleys).

2. You don't need special tools. It still can be done classic way (marks, magic marker/sharpie, paint), a bit harder, but doable. Also no need for "special" alignment tool for camshaft cover.
Russians do it like this (part 1, belt removal):
and part 2 (fitting new belt):
don't listen just watch carefully.

3. And no one even tried to copy timing belt tools? Looks like an easy bolt hole pattern, and linear dimensions are not critical (angles are - that's the main purpose of locking tools/jigs).
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Camshaft locking tool seems to be exactly 10 degrees (most important number here), rest you can figure out by yourself...
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Reverse engineering based on pictures works pretty well. Nice round numbers pop out.
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You can also guess accurately dimensions if you try.
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To make yourself a copy, use flat-bar, no need for "lollipop" shape. Holes can be slotted (so you don't worry about accuracy, at least in terms of linear dimensions - but mind the "clocking").
Click image for larger version

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Guess what. It's a FIRE family. Some things ain't change. This is crank pulley/cog from Punto 1. Same dimensions. Only number of tooth differs.
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Everything fits, same numbers (Punto 1 = Grande locking tools dimensions extracted from pictures).
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Bolt hole pattern is...you guess...the same. Measurement and some math.
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So, you get the idea. Using basic metalworking/machinist skills (layout/scribing, drilling, filing) you can attempt making your own "timing belt kit" set. No rocket science.
Example 3D model: CrankLock_(dimensions_based_on_pictures).zip
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Old 28-01-2019   #39
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Superb. Many thanks.
Simon
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Old 29-01-2019   #40
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Quote Originally Posted by u33db View Post
Thanks for the guide as i will be attempting this soon.

I have a question though - what is the need to slacken off the cam pulley - i.e. this bit;

"next slacken off Cam pully
FIRST REMOVE CAM LOCKING TOOL or you can damage your camshaft end

loosen using a 24mm spanner on the flats on the cam shaft and a T55 torx socket)
"

Surely if the you've managed to get the locking tools fitted to the cam and crankshaft there is no need to touch the cam pulley as it should already be set?

Or am i missing something?

I have done a Vauxhall 1.6 engine before but i would just like be sure before i start.

The idea is..

You bring the piston up to TDC

AND get the camshaft in time with this

(Then shifting the cam wheel timing marks to get back in sync.)


Of course this timing is ALREADY likely to be correct.. as the engine has been in use for years.

BUT. If you are looking for 100% accuracy.. then yes it is worthwhile.

NOTE:
The CRANK AND CAM have sensors for the electrical pulse timing.. this can
shift : be offset a little... with the marginally shorter length of a new timing belt.

Often this mismatch can cause an MIL warning.. and will require a Phonic Wheel Relearn
To bring the 2 signals into a range the ECU
Can cope with.
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Last edited by varesecrazy; 29-01-2019 at 08:58.
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Old 01-02-2019   #41
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Post Re: 1.2 8V EVO 2 Engine Cam Belt replacement

I've bought some cheap tools (for 1,2 and 1,4 8V Grande engines) to inspect them.
My "measurements" from pictures were just a bit off. Here is a real thing.
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CrankShaft tool angles are roughly OK (didn't bother to measure this). Looks good enough.
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CamShaft tool angle is exactly 10 degrees (as "reverse engineered" from pictures).
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Such things (timing belt job set) are not precise...you can copy them using school/office tools (like protractor). Seriously.
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Rough check (not complete drawing yet), maybe I will do the 3D model later.
Click image for larger version

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ID:	197064
As you can see, it is possible, to extract good numbers from the pictures and copy such tools. If you are technically inclined enough to do this, you will also figure out other parts from timing belt kit.
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Old 02-02-2019   #42
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Arrow Re: 1.2 8V EVO 2 Engine Cam Belt replacement

Update. The 3D models.
Click image for larger version

Name:	19_CrankShaft_3D.jpg
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Rough sketches.
Click image for larger version

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Click image for larger version

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ID:	197164
Download: TimingBeltTools(Crank&CamShaft).zip
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Old 06-02-2019   #43
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Talking Re: 1.2 8V EVO 2 Engine Cam Belt replacement

Russians are crazy, in a good way. They treat those engines like any old FIRE. Just set it at TDC, and that's it, job done. Such position is probably very stable (nothing should move, camshaft under valve springs pressure & VVT internal spring). Assumption is: engine is/was running fine (belt has not skipped a tooth).
Tools for Grande are not TDC-setting on purpose. Mostly to avoid crashing valves into pistons.
Comparison to old Fiats (like Punto 1).
Click image for larger version

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Probably more than VVT can move (rotate), which is around 30 degrees.
Click image for larger version

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Same idea is in the 16V engines (2 rods are there, to set pistons in mid-point/stroke, away from valves).

If you want to use tools, easy way to make your own is a printing in 1:1 scale (DWG file).
Click image for larger version

Name:	23_Print_1-to-1_scale.jpg
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Then drill and file (biggest hole) in a piece of flat steel bar/sheet. Done.
Click image for larger version

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Camshaft locking tool will be little bit more complicated... Stay tuned.
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Last edited by GrandePunto PL; 06-02-2019 at 09:38. Reason: Camshaft tool making ("homebrew") will be later.
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Old 14-02-2019   #44
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Cool Re: 1.2 8V EVO 2 Engine Cam Belt replacement

So, here is an example of DIY crankshaft locking tool. Flat bar.
Click image for larger version

Name:	25_CrankShaft_DIY-Tool.jpg
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ID:	197942

Example of DIY camshaft tool. Prototype was made from right angle profile/bar, 20x20 mm and 3,5 mm thick. Better use next size available, will be more stiff (let's say 25x25 or 30x30 and 4 to 5 mm thick). Piece "clocked" at 10 deg. angle is secured with two small bolts (if you can, use welding instead).
Click image for larger version

Name:	27_CamShaft_DIY-Tool.jpg
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ID:	197944

Last thing is a VVT wheel lock, the least important part of the timing belt tool-kit.
Click image for larger version

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ID:	197943

Dimensions don't matter much, make it slightly oversized and fit (file it, grind it, enlarge the hole) while working on the car.
Click image for larger version

Name:	28_VVT-Lock_Drawing_(Not_Verified).jpg
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ID:	197945


By the way, here is another example of timing belt swap, done classic way (cyl. 1 at TDC).
Let's call it "German method":

SlideShow, English description. Only one tool was used (crank tool).

"Brazilian method", version 1: cam and crank tools, plus VVT loosened (without locking it).

Version 2: also two main tools, but without messing with VVT (VVT ignored).

Other example:

Educated guess: full set of timing belt tools and fairly (over)complicated official procedure are probably taken straight from the factory assembly line, where they put these engines together the very first time.
So you don't have to "jump through hoops" (slacken VVT, etc.), when you just want to swap the belt (and engine was working fine beforehand).
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