How to Replace the Timing Belt on a Fiat Ducato

To replace the timing belt on a Fiat Ducato, start by obtaining the timing belt and water pump kit (the video uses a Continental kit code CT1148WP1 and OE locking tools); to replace the belt with the engine mounted in the vehicle, remove the right headlamp, the coolant expansion tank, the washer tank, and the outer cover of the belt; then bring the engine to the top dead centre of the first cylinder.

Use the 4 locking tools, inserting 1 at the bottom of the crankshaft, 1 at the camshaft, and 2 above the camshaft; remove the Torx screw in the crankshaft housing and screw in the locking tool; screw in the other 2 locking tools at the top of the camshaft (after unscrewing the 2 bolts with a 6 mm Allen key; the movable pin must be inserted into the camshaft) and finally use the locking pin in the hole of the camshaft sprocket.

Now loosen the tensioner roller, remove the timing belt, and replace it; also remove the fuel pump sprocket as there is a larger water pump. Included in the kit, you will also find a booklet for fitting the 3 seals (the black one goes in the fuel pump, the small grey one at the top of the water pump, and the largest one at the top of the water pump); before fitting the timing belt, you must loosen the camshaft sprocket using the counter-support; then fit the belt starting from the camshaft sprocket going counter-clockwise.

During fitting, pay attention to the tensioner roller as the new one is different; tension the roller by turning it with the Allen key counter-clockwise until the notch completely covers the hole and tighten it. Now remove all the locking tools, tighten the camshaft sprocket (using a torque wrench set to 90 Nm), and rotate the engine 8 times in the direction of rotation, then return the engine to the "TDC" position; to readjust the tensioner roller, loosen the roller screw and position the notch of the roller perfectly centred in the hole.

Finally, you can reassemble everything by reversing the disassembly process.