Section 2:
DIESEL ENGINES – 1.7D/TD and 1.9D/TD
Engine Codes:-FROM REF. 1723291 onwards (with Adjustable Camshaft) – 336.01, 675.01, 146D7.000, 149B1.000, 160A6.000, 160A7.000, 160B6.000,
176A3.000, 176A5.000, 176B3.000, 176B7.000, 230A2.000, 230A3.000, 230A4.000 and 280A1.000
- Refer to Application Chart for details of models/engines
This 1.7 and 1.9 range of diesel engines in ALFA ROMEO and FIAT require the following timing tools from DT.FIAT-D
DT.4536 Crankshaft Locking Tool
DT.4537-1 Camshaft Setting Plate
DT.4538-1 Camshaft Setting Plate
DT.4539-1Camshaft Setting Plate
DT.4537-2 Location Screw for Camshaft Setting Plates
These engines have an adjustable camshaft sprocket. The procedure for timing belt replacement on all these engines is basically the same. All engines use
DT.4536 Crankshaft Locking Tool to ‘lock’ the crankshaft at TDC. The 3 x Camshaft Setting Plates each cover specifi c engines in the range DT.4537-1 for
1.7D/TD, DT.4538-1 for 1.9D (Non-Turbo) and DT.4539-1 for 1.9TD (Turbo).
DT.4537-1, DT4538-1, DT.4539-1 Camshaft Setting Plates
Use in conjunction with DT.4537-2 Location Screw
Turn the crankshaft clockwise to TDC and check timing marks align at crankshaft and injection pump.
NOTE: The camshaft timing marks may be slightly out as it is on a keyway.
Slacken belt tension and remove timing belt.
Remove the vacuum pump from the rear of the cylinder head and install the appropriate Camshaft Setting Plate into the ‘timing slot’ in the camshaft. -Refer to
Application Chart for details of models/engines for each Setting Plate.
The Camshaft Setting Plate fi ts over two studs (studs for vacuum pump) and is then rotated and secured in position by inserting DT.4537-2 Location Screw in to
the 3rd hole in the Plate.
Camshaft timing
On single camshaft engines the correct timing position is confi rmed by alignment of the timing marks on the camshaft sprocket and on the camshaft housing cover.
DT.4776 Camshaft Setting Tools (Pair)
On twin camshaft engines the camshafts have a ‘timing slot’ machined in to them. The camshafts are locked in timed position by DT.4776 Setting Tools, (which
are spring loaded), DT.4776 screw in to the ‘timing holes’ in the camshaft housing, and locate into the ‘timing slots’ in the camshafts.
Screw in DT.4776 Tool and slowly turn the engine in its normal direction of rotation.
As the end of the spring loaded spindle of DT.4776 engages the ‘timing slot’ in the camshaft an audible ‘click’ will be heard as the spring activates the spindle
and pushes it into the ‘timing slot’.
NOTE
: For timing belt replacement it is only necessary to use one of the DT.4776 Tools which should be fi tted in to the Exhaust camshaft. When undertaking
cylinder head and camshaft work, both DT.4776 Tools should be used (on the Inlet and Exhaust camshafts)
DT.4543 Crankshaft Locking Tool
On JTD engines DT4543 Crankshaft Locking Tool is fi tted to establish the crankshaft at TDC and to ‘lock’ the crankshaft in this position. To fi t DT.4543 remove
the oil pump bolt and replace it with the Support Spindle of DT.4543, then attach the Main Body of DT.4543 to the Spindle.
Turn the crankshaft slowly to locate the dowel on the crankshaft gear into the hole in the Main Body of DT.4543. Secure the Main Body in place with its bolt
through to the crankshaft gear.
NOTE
: DT.4543 will have to be temporarily removed and then refi tted when fi tting a new belt on the crankshaft gear.
DT.4528 Flywheel Holding Tool (Crankshaft Locking)
DT.4528 is used as a counter-holding device to release/tighten the crankshaft pulley bolt when removing and installing this pulley (crankshaft pulley must be
removed in order to remove the timing belt).
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