Replacing The Cam Belt And Water Pump On A Fiat 500x 1.6 Diesel

Remove the plastic engine cover.

Release the x3 crimp clips from the air intake pipe to the air filter housing (you can either unplug the air flow meter and remove or just move to one side).

On the air intake pipe down the inside of the wing is a 10mm nut, undoing this will allow the pipe extra movement.

The top section of the air intake pipe is a push fit into the lower section that clips into place. The clips at either side need pressing in to release the top section.

The air filter housing has x3 push fittings, x2 in the wing and x1 at the base.

On the fuel filter housing disconnect the fuel outlet pipe (as shown) and the electrical connector.

Undo the x2 10mm bolts and 10mm nut to the fuel filter housing bracket. Now you can disconnect the fuel inlet pipe.

On the front right wheel at the bottom of the hub cap is a small recess, using a plastic trim removal tool prise the cap off.

Undo the wheel bolts and remove the wheel.

To remove the undertray undo the x5 10mm bolts....

....and the x2 Phillips screws at the base of both wings.

The right front wheel arch liner is one piece so pop out the button clip (as shown), undo the x4 10mm nuts and x4 screws.

Remove the auxiliary belt using a long 15mm spanner on the bolt to the auxiliary tensioners idler and rotating clockwise (this will relieve the tension on the belt). If you are able you can lock the tensioner by aligning the small hole on the top with the hole in the backing plate using a pin.

The bottom pulley has a protective rubber cap in the middle which needs pulling out then undo the x4 T45 (TORX) bolts.

Undo the 10mm auxiliary idler.

Undo the x2 13mm bolts on the lower half of the alloy support plate.

If you haven't locked the auxiliary tensioner then undo the T50 holding it.

Support the engine under the sump as you will need to remove an engine mount (you need to raise the engine slightly higher than it normally sits to take the weight off of it's mounts)

The right side engine mount has x3 T18 and x3 T14 bolts.

Undo the x7 T40 bolts to the cam belt plastic side cover.

The alloy support plate has x4 15mm bolts left to remove.

To align the pulleys the indicator (groove) on the bottom driven gear needs to be pointing between 7-8 O'clock. Turn the 19mm bolt on the bottom gear clockwise to rotate all three pulleys until they rest in their correct positions.

The exhaust camshaft gear points to 2 o'clock...

...and the inlet camshaft gear at 11 o'clock.

Undo the cam belt tensioners 12mm bolt...

...and cam belt idlers 15mm bolt.

Remove the old cam belt.

There's x3 6mm Allen bolts to the water pump.

You'll need to gently prise it off but make sure you have a suitable container underneath to catch the coolant.

Before fitting the new water pump and gasket clean the mounting surface on the engine and smear a little sealant on the pump.

The new cambelt has x3 white indicator lines which align with the grooves on the x3 pulleys. To make it easier to see when fitting the belt mark the outer edge at the same points of the x3 lines.

Bolt on the cam belt idler but just pinch the bolt for the cam belt tensioner enough so that it can still slide.

Fit the cam belt.

To tension the cam belt tensioner push the bent up lug on the backing plate until the alignment hole on the face of the tensioner sits between the fork (as shown). Rotate the crank by hand checking the belt runs smoothly.

Replace all parts, top up the coolant and bleed the cooling system.