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Discussion Starter #1
hi all just a quick one...
i want to put a intercooler on my 2002 307 hdi 90 bhp...

i need to know what parts i need from the 110 bhp model.....

oh and mine has aircon if that makes a difference...

thanks jamie:)
 

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jamie to do this tho you would need to get your car remapped after to get the power ;)

what you need is an inlet elbow from a 110 HDi engine and the bottom pipe from the 110 as well and then you would need to get the intercooler
you could use a 110 as it would be just as handy to get the parts other than to make source after market parts that would be up to you :thumb:
 

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head to your local scrap yard they should have the stuff you need for around £10-15 for the 110 elbow and bottom pipe, as for the 110 intercooler you would need to see what sort of deal they can do for you or even ebay for a 110 intercooler but make sure you get the 110 hoses for the top and bottom if your using a intercooler from a 110 car if not you would need to source aftermarked pipes! :thumb:
 

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Discussion Starter #5
thanks cmax...just on the off chance do you know or where can i find stuff about doing my cambelt on my hdi90 2002...i need info on whats involved....
 

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this should help

REMOVAL - REFITTING TIMING BELT

1 - SPECIAL TOOLS



[1] (-).0192 tension measuring equipment .

[2] Crankshaft setting rod (-).0188-Y .

[3] Camshaft setting rod (-).0188-M .

[4] Belt retaining clip (-).0188-K .

[5] Engine flywheel lock ring (-).0188-F .

[6] Crankshaft spanner (-).0117-EZ .

[7] Cross member (-).0911-AY .

[8] Bracket (-).0911-A2 .

[9] Tension lever (-).0188-J2 .

[10] Pulley extractor (-).0188-P .



[11] Set of plugs (-).0188-T .

2 - REMOVAL



Remove :

the front right-hand wheel
the front right mud shield (1)
the ancillary drive belt
the style covers
the impactor (2)
Lock the flywheel with the stop [5] .

Refit the screw of the pulley driving the accessories .

Refit the bolt without the washer .

Remove the tool [5] .

Remove the pulley driving the accessories using the tool [10] .

Loosen the exhaust line from the turbo .

IMPERATIVE : uncouple the exhaust line to avoid destroying the hose; this cannot withstand the torsion, traction or bending stresses caused by the removal of one of the power train supports .



Remove :

the fasteners (3) - (5)
the lower torque reaction link (4)
the fixings for the inlet air duct
disconnect and move aside the priming cone
Support the engine with tool [7] - [8] .
 

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Protect the radiator honeycomb with strong cardboard cut to the dimensions of the radiator .



Remove :

the priming cone (9) bracket
the 3 timing housings (6)
the bolts (7)
the right-hand engine mounting (8)
Turn the crankshaft with the tool [6] .



Peg :

the engine flywheel using tool [2]
the camshaft pulley



Unlock the nut from the tensioner roller (11) .

Retighten the fastener in the maximum slack position .

Remove the timing belt .

3 - REFITTING



IMPERATIVE : check that the rollers (11) - (12) as well as the coolant pump (8) turn freely (no play or hard spots) ; also check that these rollers are not noisy and/or do not show traces of grease .

NOTE : in the event of replacement ; tighten the bolt (12) to 4.3 da.Nm .

Slacken the bolts (14) .

Check that the pulley (15) rotates freely on its hub .

Tighten the bolts (14) by hand .

Turn the pulley (15) clockwise to the limit at the end of the slots .
 

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Fit the timing belt, fully taut, in the following order :

crankshaft ; immobilise the belt using the tool [4]
roller tensioner (12)
Lay the timing belt on the pulley (16) .

Slightly turn the camshaft pinion in the opposite direction to the rotation of the engine in order to engage the belt on the pinion .

WARNING : the angular movement (α) of the pulley in relation to the belt must not be more than one tooth space .

Engage the belt on the roller tensioner (12) and on the coolant pump gear (13) .

Place the tensioner roller (11) in contact with the belt .

Pre-tighten the tensioner roller securing bolt (11) to 0.1 daN.m .

Remove the tool [4] .

4 - PRE-TENSIONING AND FITTING THE TIMING BELT



Fit the tool [1] .

NOTE : check that the tool is not touching anything in the near vicinity .

Turn the roller tensioner (11) anti-clockwise, using tool [9] .

Display 98 ± 2 SEEM units .

Tighten the bolt (11) to 2.3 da.Nm. without altering the position of the roller .

Remove the tool [1] .

IMPERATIVE : by removing a bolt (14) on the pulley (15), ensure that these bolts are not at the limit of the slot ; if this is the case, repeat the timing belt fitting operation .

Tighten the bolts (14) to 2 daN.m .

Remove the setting pins [3] - [2] .

Turn the engine over 8 times in the normal direction of rotation .

IMPERATIVE : never turn the crankshaft in the reverse direction .

5 - FITTING AND TENSIONING THE TIMING BELT



Refit the rods [2] -[3] .

Slacken the bolts (14) .

Tighten the bolts (14) by hand .

Slacken the bolts (14) by 1/6 turn .

Slacken the bolt (17) .

Place the tool [1] on the span (A) .

Turn the roller tensioner anti-clockwise, using tool [9] .

Display 54 ± 2 SEEM units .

Tighten the bolt (17) to 2.3 da.Nm. without altering the position of the roller .

Tighten the bolts (14) to 2 daN.m .

Remove the tool [1] to release the internal forces .

Refit the tool [1] .

The tension value should be between 51 and 57 SEEM units .

IMPERATIVE : if the value read is outside the tolerance : slacken the belt and repeat the operation .

Remove :

the equipment [1]
the pegs [2] - [3]
6 - CHECKING THE VALVE TIMING

Turn the crankshaft 2 revolutions in the direction of running without turning in the reverse direction .

Fit the rod [2] .

IMPERATIVE : visually check that the offset between the camshaft hub hole and the corresponding setting hole does not exceed 1 mm .

Remove the rod [2] .

Fit :

the bottom timing cover
the timing covers
the engine mounting
the bolts (14) ; 6.1 da.Nm
the bolts ; 2 da.Nm
the priming cone bracket
Refit the tool [5] .

Refit the torque reaction link (4) .

Tighten :

the bolt (3) to 4.5 da.Nm
the bolt (5) to 5 da.Nm
Refit the ancillaries drive pulley .

Clean the threads of the bolt of the pulley in the crankshaft by using a M16 X 150 tap .

Cleanthe thread of the bolt .

Tightening :

pre-tighten to 4 danm+ LOCTITE FRENETANCH
complete the tightening by rotating 51 degrees using a FACOM 360° type tool
Check the tightening :

apply a torque of 19.5 danm using a torque wrench
the wrench must trip before the screw rotates
If this is not the case :

slacken the bolt
recommence the entire tightening procedure
fit the ancillary drive belt .

Remove the tool [5] .

IMPERATIVE : always replace the exhaust clips .

Tighten the wheel bolts to 9 da.Nm .

Refit the various components in the reverse order to removal .

Initialise the various ECUs .
 
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