Register Login
endrop - for all your online needs
Comment
 
Guide Tools
<!-- google_ad_section_start -->1.2 8V EVO 2 Engine Cam Belt replacement<!-- google_ad_section_end -->
1.2 8V EVO 2 Engine Cam Belt replacement
A time consuming job...
Published by Andy Monty
22-05-2010
Difficulty Level: 5

User Rated:
Difficulty Level: 3

Show Printable Version  Email this Page 
1.2 8V EVO 2 Engine Cam Belt replacement

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....


Tools/ equipment needed
Click image for larger version

Name:	DSCF2616.JPG
Views:	938
Size:	2.71 MB
ID:	78266

basic tools:
selection of socket sets i used a mixture of my 1/4" 3/8" 1/2" sets
Breaker bar
Large and small torque wrenches
Slotted and pozi screwdrivers
T25 torx driver
2x trolley jacks
1x axle stand
Cam belt kit
Replacement Aux belt
Crow bar
Mallet
Marker pen
liquid gasket compound (for rocker box top gasket)

8 10 15 24 mm Combination spanners

1/2" drive T55 Male Torx socket

E14 E18 Female Torx sockets (for engine mount)

Cam locking and timing kit (ensure you get the correct one for your engine look at your VIN plate in the boot and match the engine type code to the kit.
)

Fiat ECU / MULTI ECU scan + leads / a garage with the relevent software and leads to carry out a Phonic wheel relearn

Click image for larger version

Name:	DSCF2619.JPG
Views:	1289
Size:	2.82 MB
ID:	78267

so park the car somewhere safe and level chock the wheels and leave out of gear...

Disconnect battery (check you still have radio code if after market HU fitted)

remove the Air box as described here:
https://www.fiatforum.com/grande-pun...ge-1-2-8v.html

Next remove the Coil pack (3x 10mm bolts) and carefully tuck out of the way
Click image for larger version

Name:	DSCF2575.JPG
Views:	1532
Size:	2.50 MB
ID:	78268


now carefully remove the 2 plugs from the engine management computer (the red levers lift up and eject the plug do not force them) Mark them left and right with the marker pen so you know which goes in which hole when you come to refit
Click image for larger version

Name:	DSCF2579.JPG
Views:	743
Size:	2.52 MB
ID:	78269


then undo the 4x 10mm nuts and put computer in a safe place where you wont kick it or stand on it
Click image for larger version

Name:	DSCF2580.JPG
Views:	485
Size:	2.72 MB
ID:	78270


next remove the computer mount (1 nut and 3 bolts)

Click image for larger version

Name:	DSCF2581.JPG
Views:	457
Size:	2.84 MB
ID:	78276


Remove the engine earth link and the Lambada sensor plug and cable support bracket.

Click image for larger version

Name:	DSCF2583.JPG
Views:	448
Size:	2.97 MB
ID:	78277

Remove the Cam position sensor (and solonoid plug / wiring (vvt only))
Click image for larger version

Name:	DSCF2584.JPG
Views:	617
Size:	2.88 MB
ID:	78278

Now remove the upper cam protection cover (3x 10mm headed bolts)

Click image for larger version

Name:	DSCF2585.JPG
Views:	622
Size:	2.77 MB
ID:	78279

remove with care freeing the cable that is held in the channel in the cover
Click image for larger version

Name:	DSCF2586.JPG
Views:	1469
Size:	2.80 MB
ID:	78280

now loosen the engine support bolts (do not remove just loosen) using the E torx sockets..
Click image for larger version

Name:	DSCF2597.JPG
Views:	1912
Size:	2.58 MB
ID:	78281


and slacken 3x alternator bolts pull alternator towards front of the car and remove Axillary belt
Click image for larger version

Name:	DSCF2589.JPG
Views:	3012
Size:	2.79 MB
ID:	78282

and remove Rocker box top (8x 8mm headed bolts) and gasket

Remove the drivers side front wheel and arch liners (obviously jack and axle stands)
Click image for larger version

Name:	DSCF2587.JPG
Views:	524
Size:	2.65 MB
ID:	78283


Now remove Alternator drive pulley (3x15mm headed bolts)
Click image for larger version

Name:	DSCF2591.JPG
Views:	473
Size:	3.20 MB
ID:	78284

and remove lower cam belt cover (1x 10mm headed bolt)

exposing crank pully (note the dimple thats the timing reference mark for the locking tool)Click image for larger version

Name:	DSCF2592.JPG
Views:	1403
Size:	2.59 MB
ID:	78285

now place a block of wood under sump and remove the entire engine mount..
Click image for larger version

Name:	DSCF2596.JPG
Views:	747
Size:	2.80 MB
ID:	78289
Click image for larger version

Name:	DSCF2597.JPG
Views:	1912
Size:	2.58 MB
ID:	78281
Click image for larger version

Name:	DSCF2598.JPG
Views:	651
Size:	2.45 MB
ID:	78290

the cam belt and tensioner should now be fully visible..
Click image for larger version

Name:	DSCF2599.JPG
Views:	1806
Size:	2.71 MB
ID:	78297



Now before you go any further ensure the engine is "in time"

with a spanner on the crank pully rotate the engine till the cam locking tool fits in the slot on the crankshaft end
Click image for larger version

Name:	DSCF2602.JPG
Views:	1937
Size:	2.70 MB
ID:	78291



(watch you don't damage the rocker top seal)

now there is 2 turns of the crank which gives one turn of the cam it is possible that at first your cam will be 180 degrees out of time with the cam when trying to fit the cam locking plate..

this is 180 degrees out:
Click image for larger version

Name:	DSCF2601.JPG
Views:	1161
Size:	2.70 MB
ID:	78292



if that is the case rotate the crank until both locking tools line up hold the crank one in place initially so you can see if its in line or not..

Then fit lower locking tool ensuring its the correct way round and that the dimple on the crank goes into the hole in the tool and secure in place with the bolts in the kit
Click image for larger version

Name:	DSCF2604.JPG
Views:	1036
Size:	2.99 MB
ID:	78293
now with a 13mm spanner loosen the cam tensioner and remove it and the belt..
Click image for larger version

Name:	DSCF2600.JPG
Views:	749
Size:	2.82 MB
ID:	78298

THOSE WITH VVT READ PAGE 2 NOW!!!!....
SEE PAGE 3 for water pump replacement at this point


put on new cam tensioner and do up nut finger tight




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

Click image for larger version

Name:	DSCF2607.JPG
Views:	1977
Size:	2.89 MB
ID:	78299

(i took this pic as i was refitting a torque wrench shouldn't be used for removal)

Refit locking tool

now rotate the cam pully fully clockwise till it hits the stop

Now wash your hands and degrease the rollers and tensioners using brake cleaner or flash degreaser

take out your new belt and starting at the cam pulley go round clockwise

Cam - waterpump - crank - tensioner

Get the 2 pin tensioner tool from cam belt tool kit and turn it gently anticlockwise till it hits the stop (ie max tension) then hold and torque bolt to 28 NM and Remove locking tools

place spanner on cam again and this time tighten the Cam torx bolt to 70NM

rotate the engine twice by hand (spanner on crank pulley) this beds in the belt

now loosen off the 13 mm tensioner nut carefully at the same time hold the tensioner with the pin spanner so as not to let fully loose tension and align the tension indicator as below:
Click image for larger version

Name:	DSCF2608.JPG
Views:	496
Size:	2.64 MB
ID:	78301

tensioner fork highlighted:
Click image for larger version

Name:	tension.JPG
Views:	411
Size:	3.78 MB
ID:	78313






this is too slack:
Click image for larger version

Name:	DSCF2609.JPG
Views:	402
Size:	2.65 MB
ID:	78302

again highlighted (the back fork is to the left of the front fork)
Click image for larger version

Name:	cam tensioner high light #2.JPG
Views:	382
Size:	3.80 MB
ID:	78312

rotate engine again by hand several turns then check indicator is sill showing correct tension and refit timing tools to check timing is spot on and its not jumped a tooth or anything like that

ensure all tools have been removed

REFIT LOWER CAM GUARD NOW or you wont get it back on

next refit lower alternator pulley (ensure dimple lines up with hole in pulley)

at this point its easier to refit and tension the alternator belt as the engine mount isn't on to tension fit new belt then pry back the alternator using a pry bar then do up 3 bolt on alternator the belt should just be able to be rotated about 90 degrees with your fingers...
Click image for larger version

Name:	DSCF2614.JPG
Views:	841
Size:	2.48 MB
ID:	78303


Now put it all back together

rocker box gasket should be refitted like this

https://www.fiatforum.com/punto-guid...eek-later.html

next run a Phonic wheel learn on MES / FES to allow the car to learn the slight change in Cam / Crank position due to the new unstretched belt

Quote Originally Posted by D4nny8oy View Post
the FIRE has a crankshaft and a camshaft sensor, which tell it exactly where the two ends are accurately enough to detect the subtle timing differences when a misfire occurs.

Hence the false reporting of "P0300 Generic misfire" when the cambelt has been replaced and the ECU hasn't been told- even when aligning the new belt perfectly, the two signals are no longer synchronised at the exact millisecond they were before.

and enjoy another 4-5 years motoring...


Likes SRafferty, Dcdelafuente, excession liked this post
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Contents
<< <    Next Page: VVT (Page 1 of 3)    >  >>
Old 16-02-2011   #1
Join Date: May 2007
Location: Cheshire
Posts: 24
Thanks: 0
Trader Rating: 0
Cal Culater has donated!
United Kingdom 
Re: 1.2 8V EVO 2 Engine Cam Belt replacement

Looks like a really really useful guide .

Q1
I have a 2006 55reg 1.4 8V Grande Punto Active Sport. I assume that the procedure is much the same, correct?

Q2
I guess for another 20 or so it's worth replacing the water pump as well? Mine has done 50k.

Q3
Looks like it can't be done without the tools. Anyone got a set of timing tools for my car that they would like to either part with or rent out to me for a week or so?
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Cal Culater is offline Reply With Quote Quote 
Old 17-02-2011   #2
Moderator
 
Andy Monty's Avatar
Join Date: Apr 2006
Location: East Yorkshire
Posts: 13,910
Thanks: 1158
Trader Rating: 0
Andy Monty has donated!
United Kingdom 
Re: 1.2 8V EVO 2 Engine Cam Belt replacement

Quote Originally Posted by Cal Culater View Post
Looks like a really really useful guide .

Q1
I have a 2006 55reg 1.4 8V Grande Punto Active Sport. I assume that the procedure is much the same, correct?

Q2
I guess for another 20 or so it's worth replacing the water pump as well? Mine has done 50k.

Q3
Looks like it can't be done without the tools. Anyone got a set of timing tools for my car that they would like to either part with or rent out to me for a week or so?
1
yes virtually the same engine

2
yes dont forget to get replacement coolant and liquid gasket compound

3
timing tools are model spacific (engine model) to assertain which tools you need you need your engine type number which is embossed on the VIN tag which is under your boot carpet on the passenger side (uk)
__________________
What Goes Up Must Come Down.....

Quote Originally Posted by Most Easterly Pandas View Post
Massive gash
Quote Originally Posted by EmmaM88 View Post
Just a little touch up

Last edited by Andy Monty; 23-09-2012 at 23:03.
Andy Monty is offline Reply With Quote Quote 
Old 25-05-2012   #3
Join Date: May 2012
Posts: 20
Thanks: 1
Trader Rating: 0
United Kingdom 
Re: 1.2 8V EVO 2 Engine Cam Belt replacement

How do I remove the fan belt pulley? I have put the car in gear but every time I try to undo any of the bolts the engine just spins.
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Puntomk284 is offline Reply With Quote Quote 
Old 27-05-2012   #4
Moderator
 
Andy Monty's Avatar
Join Date: Apr 2006
Location: East Yorkshire
Posts: 13,910
Thanks: 1158
Trader Rating: 0
Andy Monty has donated!
United Kingdom 
Re: 1.2 8V EVO 2 Engine Cam Belt replacement

I had no problem removing mine.....

try the palm of your hand and strike the ratchet rather than trying to turn it the shock should move the bolt once loose it will come out ok
__________________
What Goes Up Must Come Down.....

Quote Originally Posted by Most Easterly Pandas View Post
Massive gash
Quote Originally Posted by EmmaM88 View Post
Just a little touch up
Andy Monty is offline Reply With Quote Quote 
Old 19-06-2012   #5
I drive an Astra.
 
excession's Avatar
Join Date: Nov 2005
Posts: 64
Thanks: 1
Trader Rating: 0
excession has donated!
United Kingdom 
Re: 1.2 8V EVO 2 Engine Cam Belt replacement

Hi,

Fantastic detailed guide!!! Thanks for taking the time!

Is this the same engine as in a 1.2 8v Grande from '06?

I've seen guides which claim it's not essential to use the locking tools and you can use the timing marks on the cam cover/crankcase or make your own marks with tippex etc; what's your view on this?

Is this definitely a non interference engine? If so what's the worst case scenario if the timing is out when reassembling?

Thanks guys,

James
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

excession is offline Reply With Quote Quote 
Old 23-06-2012   #6
I drive an Astra.
 
excession's Avatar
Join Date: Nov 2005
Posts: 64
Thanks: 1
Trader Rating: 0
excession has donated!
United Kingdom 
Re: 1.2 8V EVO 2 Engine Cam Belt replacement

Hey everyone!

Andy: thanks for the guide, it was mega useful today.

Here's what we found: (bear in mind you may not have the same luck)
  • My car had air-con so to get the aux drivebelt off we just loosened the spring loaded tensioner
  • We did NOT use the locking tools - it was enough to take note of the timing reference marks and align these with the timing marks on the new (Contitech) belt. (so no need to get rocker cover off)
  • Tensioning was easy even without the tool - span it round with a small screwdriver in one hole and torqued the bolt when the forks aligned (needed a mirror to see them!)
  • Hardest bit was the bottom bolt on the engine mount, massive pain in the bum to get off.
  • The timing belt looked in GREAT condition after 43k miles, the aux belt not so, very perished.
Likes Andy Monty liked this post
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides


Last edited by excession; 23-06-2012 at 23:17.
excession is offline Reply With Quote Quote 
Old 24-06-2012   #7
Join Date: Aug 2003
Location: Essex/Suffolk border
Posts: 82,386
Thanks: 1458
Trader Rating: 10
dave has donated!
dave is an official FF Advertiser
dave is an honorary friend of the forum :)
United Kingdom 
Re: 1.2 8V EVO 2 Engine Cam Belt replacement

what are the other bits in the cam tool kit for?

would a crank locker from a croma jtd and cam locker for a vag ahf engine work?
__________________

Last edited by dave; 24-06-2012 at 00:34.
dave is offline Reply With Quote Quote 
Old 24-06-2012   #8
I drive an Astra.
 
excession's Avatar
Join Date: Nov 2005
Posts: 64
Thanks: 1
Trader Rating: 0
excession has donated!
United Kingdom 
Re: 1.2 8V EVO 2 Engine Cam Belt replacement

dave: there is a tool for adjusting the tensioner as well, and I think depending on the kit you also get some extra bits for a 1.4 VVT engine of some variety.

I find it highly unlikely that a different locking kit will fit.

I found that the crankshaft was very hard to move, and the camshaft was fairly free but with two people it was really easy to get the belt on with the timing marks in the right place without moving the crankshaft or camshaft...
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

excession is offline Reply With Quote Quote 
Old 24-06-2012   #9
Moderator
 
Andy Monty's Avatar
Join Date: Apr 2006
Location: East Yorkshire
Posts: 13,910
Thanks: 1158
Trader Rating: 0
Andy Monty has donated!
United Kingdom 
Re: 1.2 8V EVO 2 Engine Cam Belt replacement

The cam kit does a range of engines

the evo 2 uses the half bone and the plate across the back of the cam shaft in the groove

where as on the older 1.2 fire the coil packs are timed from that end it so you use the smaller locking peg on the pully itself (had to do this on my mates 2004 1.2 panda to lock the cam pully in place

the large funny shaped plate is used when refitting the rocker top in time with the cam shaft on a 1.4 vvt engine....

Engine Codes: 169A4.000, 199A4.000, 188A4.000 (EVO2 only), 350A.000



Oh the belt i got had no timing marks on.... the locking kit does make the job a doddle to do
__________________
What Goes Up Must Come Down.....

Quote Originally Posted by Most Easterly Pandas View Post
Massive gash
Quote Originally Posted by EmmaM88 View Post
Just a little touch up

Last edited by Andy Monty; 24-06-2012 at 10:49.
Andy Monty is offline Reply With Quote Quote 
Old 24-06-2012   #10
I drive an Astra.
 
excession's Avatar
Join Date: Nov 2005
Posts: 64
Thanks: 1
Trader Rating: 0
excession has donated!
United Kingdom 
Re: 1.2 8V EVO 2 Engine Cam Belt replacement

Quote Originally Posted by Andy Monty View Post
Oh the belt i got had no timing marks on.... the locking kit does make the job a doddle to do
I bet it does! I think the extra hassle was *just* about worth 40! If I was doing it by myself I would deffo get the kit.
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

excession is offline Reply With Quote Quote 
Old 24-06-2012   #11
Join Date: Aug 2003
Location: Essex/Suffolk border
Posts: 82,386
Thanks: 1458
Trader Rating: 10
dave has donated!
dave is an official FF Advertiser
dave is an honorary friend of the forum :)
United Kingdom 
Re: 1.2 8V EVO 2 Engine Cam Belt replacement

Quote Originally Posted by Andy Monty View Post
where as on the older 1.2 fire the coil packs are timed from that end
__________________
dave is offline Reply With Quote Quote 
Old 25-06-2012   #12
Moderator
 
Andy Monty's Avatar
Join Date: Apr 2006
Location: East Yorkshire
Posts: 13,910
Thanks: 1158
Trader Rating: 0
Andy Monty has donated!
United Kingdom 
Re: 1.2 8V EVO 2 Engine Cam Belt replacement

Quote Originally Posted by dave View Post
the 1.2 old fire engine (one with the rubber oil filler plug at the back) has the coil packs at the opposite end of the cam pully with the rocker box top off the cam shaft appears to run into the coil pack mount housing.....
__________________
What Goes Up Must Come Down.....

Quote Originally Posted by Most Easterly Pandas View Post
Massive gash
Quote Originally Posted by EmmaM88 View Post
Just a little touch up
Andy Monty is offline Reply With Quote Quote 
Old 25-06-2012   #13
Join Date: Aug 2003
Location: Essex/Suffolk border
Posts: 82,386
Thanks: 1458
Trader Rating: 10
dave has donated!
dave is an official FF Advertiser
dave is an honorary friend of the forum :)
United Kingdom 
Re: 1.2 8V EVO 2 Engine Cam Belt replacement

coil pack just sits there it dont be timed, years ago there was a dizzy on there that was driven by the cam
__________________
dave is offline Reply With Quote Quote 
Old 25-06-2012   #14
I drive an Astra.
 
excession's Avatar
Join Date: Nov 2005
Posts: 64
Thanks: 1
Trader Rating: 0
excession has donated!
United Kingdom 
Re: 1.2 8V EVO 2 Engine Cam Belt replacement

Yep there's a left over O-ring from those days, on some engines at least!

Mum used to have a Panda with the pre-injection version of this engine, bastard s***e it was with the stupid distributor, always going wrong in the standard way that dodgy italian electrics do!
Thanks Theta2 thanked for this post
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides


Last edited by excession; 25-06-2012 at 01:05.
excession is offline Reply With Quote Quote 
Comment
Currently Active Users Viewing This Guide: 1 (0 members and 1 guests)
 
Guide Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump
Similar Threads
Guide Guide Starter Category Comments Last Post
(G) Cam belt replacement Murray Ducato 8 13-08-2014 12:44
Cost of Cam belt replacement Phillip J Fry Garages 1 19-11-2008 14:25
(G) Cam belt replacement eryan Ducato 0 01-01-2008 17:41
(G) Cam belt replacement Barchetta27 Barchetta 15 17-10-2007 22:32
(T) Cam Belt replacement, what else should be done? Kelbert1066 Multipla 0 31-03-2007 19:45