How to Replace the Timing Belt on a Lombardini DCI 492 – Step-by-Step Guide for Ligier, Microcar, Chatenet & Casalini Microcars

How to Replace the Timing Belt on a Lombardini DCI 492 – Step-by-Step Guide for Ligier, Microcar, Chatenet & Casalini Microcars

Replacing the timing belt on the Lombardini DCI 492 engine may seem challenging, but with the right tools, parts, and a clear guide, it’s absolutely possible to do it yourself. In this tutorial, we’ll walk through the process step by step for microcars such as Ligier, Microcar, Chatenet, and Casalini equipped with the DCI 492 engine.

You can find a complete timing belt kit including belt, water pump & tensioner for Lombardini DCI / HDI engines here. For more spare parts for your microcar – visit our webshop minicarspares.com.

Models: Ligier, Microcar, Chatenet, Casalini, JDM, Grecav
Engines: Lombardini DCI 492, Lombardini DCI 442, Lombardini HDI 480, Kohler SOHC 550. 

Tools and Preparation

  • Torque wrench
  • Socket set
  • Special tool p/n ED0014603900 (to lock the camshaft pulley)
  • Special tool p/n 1460.325 (for belt tensioning)

Important: The timing belt must always be replaced once removed – even if it has not yet reached the service interval!

Disassembly of the Timing Belt System

  1. Remove the outer timing belt cover.
  2. Loosen the tensioner bolt and rotate to release the belt.
  3. Remove the timing belt.
  4. Install the locking tool on the camshaft pulley and remove the pulley bolt.
  5. Remove the camshaft pulley, being careful not to lose the key.
  6. Remove the crankshaft pulley bolt and take off the pulley. 
  7. Remove the tensioner and, if needed, the water pump.
  8. Unbolt and remove the inner timing belt cover.

Installing the Timing Belt System

  1. Install the inner timing belt cover and tighten bolts crosswise to 10 Nm.
  2. Fit the tensioner but do not fully tighten yet.
  3. Reinstall the camshaft pulley, ensuring the key is seated correctly. Torque to 80 Nm.
  4. Reinstall the crankshaft pulley and torque to 80 Nm. Use the special tool (ED0014603900) to lock the camshaft.

5. Tighten the lower crankshaft bolt to 85 Nm. 

Installing the Timing Belt

  1. Check the direction arrows on the belt (indicating rotation direction).
  2. Align the belt markings with the camshaft and crankshaft marks and the marks on the inner cover.
  3. Fit the belt last onto the tensioner.