Filed Under (Ford) by admin on 05-06-2011
Common causes of camshaft timing belt failure on the above vehicles are due to incorrect operating tension, or ingress of dirt, water, or debris entering the timing belt cover. Predominantly on Fiesta models a high percentage of camshaft timing belt failures occur after the ancillary poly ‘V’ drive belt has failed, where strands of material off the broken belt have entered the timing belt cover. This is especially so where an ancillary belt has been fitted that does not contain “Kevlar” based materials. It is therefore important to always remove the timing belt cover to check for belt debris if the ancillary belt has failed. Any contamination that enters the timing belt cover can become compressed between the surfaces of the camshaft timing belt and drive pulleys. This causes wear to both the belt teeth, backing surface, and damage to the drive pulleys, resulting in premature failure of the camshaft timing belt. Later engines have modifications to improve the sealing of the belt cover around the crankshaft pulley, to reduce the level of outside contamination. Incorrect tensioning of the belt during installation will adversely affect the life of the belt. Before fitting a new belt it is important to check and observe the following points :- 1) Right Hand Inner Wing Splash Shield (Fiesta, Escort, Mondeo) This must be fitted and undamaged. 2) Timing Belt Cover Check that all components of the cover are fitted and undamaged. Ensure the latest type of modified cover is fitted. 3) a) Toothed Drive Pulleys Check that the tooth profiles are not worn or damaged. On vehicles built before January 1994 special attention should be given to the nylon toothed pulley situated below the camshaft pulley in a clockwise position on the belt drive (see diag item 4). This should be changed to a modified steel pulley (Ford No. 7053802) plus bolt (6701537). Ensure that the Camshaft and Injection Pump sprockets are free to rotate on the drive locations when the retaining bolts are slackened off. b) 4) a) b) c) Water Pump, Idler and Tensioner Pulleys Check that the belt running surfaces are not worn or damaged. Check that the flanges are running true and not damaged. Check that the water pump, and pulley bearings are in good condition, to ensure correct belt alignment. 5) Crankshaft Pulley The toothed pulley is in two parts. The rear section (Injection Pump Drive) is located onto the crankshaft by a small drive pin. The front section (Camshaft and “Poly V” belt drive) engages onto the rear pulley via a small vee protrusion on the rear face. Should the central fixing bolt for the crankshaft pulley come loose, or an old bolt re-used (Stretch bolt design), it is possible for fretting to take place damaging the locations. The crankshaft and camshaft pulleys can then move out of timing alignment, resulting in valve and piston contact damage. Replacement Procedure As the vehicle is fitted with two timing belts, one to drive the Camshaft, and one to drive the Injection Pump drives, which are driven off the crankshaft pulley, it is strongly recommended that both belts are replaced at the same time. NOTE: Special tools are required to lock the crankshaft, camshaft, and injection pump in the correct angular location when changing the belts, to ensure correct timing position. IMPORTANT: Ensure the engine is cold (not run for 4 hours) before commencing working as this will affect the setting of the timing belt tension and could lead to premature failure. Continued . . . .
Filed Under (Ford) by admin on 08-03-2011
Checking Timing An access plug is provided in the cam drive belt cover so that camshaft timing can be checked without removal of the cover or any other parts. 1. Remove the access plug from the cam drive belt cover. 2. Rotate the crankshaft so that the No. 1 piston is rising on compression stroke. 3. Set the crankshaft to TDC by aligning the timing mark on the crank pulley with the TC mark on the belt cover. Always turn the engine in the direction of normal rotation (clockwise, as viewed from the front). Backward rotation may cause the timing belt to jump time, due to the arrangement of the belt tensioner. 4. Look through the access hole in the belt cover to make sure that the timing mark on the cam drive sprocket is lined up with the pointer on the inner belt cover. 5. Install the belt cover access plug. Adjusting Timing Belt SPECIAL SERVICE TOOL(S) REQUIRED Description Crankshaft Belt Tension Adjusting Tool T74P-6254-A 1. Remove the outer timing belt cover as outlined in this section. CAUTION: Attempting to adjust timing belt tension without loosening spring pivot bolt will break Crankshaft Belt Tension Adjusting Tool T74P-6254-A when relieving tension on the belt. 2. If belt timing or tension is incorrect, loosen timing belt spring pivot bolt. 3. Hold tensioner with Camshaft Belt Tension Adjusting Tool T74P-6254-A. 4. While holding tensioner, loosen adjusting bolt and gradually release spring tension. Loosening Timing Belt Tensioner, 2.3L Tool Number 8 — 5. Using adjusting tool, pry tensioner away from belt. While holding, tighten adjusting bolt. There should be no tension on belt. Camshaft Timing Belt, 2.3L I-4 Timing Mark on Camshaft Sprocket Remove the bolts holding the crankshaft position sensor in place and pull the sensor assembly free of the dowel pin. 7. Remove the crankshaft pulley , crankshaft pulley hub and timing belt guide. 8. Remove the drive belt and inspect it for wear or damage. If the belt is damaged, replace it. 9. Remove one spark plug from each cylinder. 10. If not done: a. Loosen tensioner adjusting bolt. b. Using Camshaft Belt Tension Adjusting Tool T74P-6254-A, pry tensioner clockwise against spring tension as far as possible. c. Tighten adjusting bolt to hold tensioner in released position. 11. Align crankshaft so number one piston is at TDC (top dead center) as indicated by timing mark. 12. Line up camshaft sprocket timing mark with inner timing belt cover timing mark and key is pointing down.
Filed Under (Vauxhall) by admin on 05-04-2011
Special Precautions Special Precautions Disconnect battery earth lead. DO NOT turn crankshaft or camshaft when timing belt removed. Remove glow plugs to ease turning engine. Turn engine in normal direction of rotation (unless otherwise stated). DO NOT turn engine via camshaft or other sprockets. Observe all tightening torques. Check diesel injection pump timing after belt replacement. Removal Removal 1. Support engine. 2. Remove: Air filter and air intake hoses. Auxiliary drive belts. RH engine mounting. Vacuum pipe bracket. Timing belt upper cover . 3. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure crankshaft sprocket timing marks aligned . 4. Insert M6 x 1,00 bolt in camshaft sprocket and M8 x 1,25 bolt in injection pump sprocket to lock sprockets in position . NOTE: If locating holes not aligned: Turn crankshaft one turn. 5. Remove: Crankshaft pulley (4 bolts). Timing belt lower cover . 6. Slacken tensioner bolts . Remove tensioner spring . 7. Move tensioner pulley away from belt. Lightly tighten bolts. 8. Remove timing belt. Installation Installation 1. 2. 3. 4. 5. Use crankshaft pulley to check TDC marks aligned . Ensure locking bolts located correctly . Fit timing belt in clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets. Temporarily fit crankshaft pulley. Ensure timing marks aligned . Fit tensioner spring . Corsa-B/Corsavan/Combo: Slacken tensioner bolts . Allow tensioner to operate. Remove locking bolts . Tighten tensioner bolts to 19 Nm . Turn crankshaft slowly two turns clockwise. Ensure timing marks aligned . 6. Astra-F/Vectra/Cavalier: Slacken tensioner bolts . Temporarily fit crankshaft pulley. Remove locking bolts . Turn crankshaft 60° anti-clockwise (against normal direction of rotation) . Tighten tensioner bolts to 19 Nm . Turn crankshaft slowly two turns + 60° clockwise until timing marks aligned . 7. 8. 9. 10. 11. Ensure timing marks aligned . Ensure locking bolts can be inserted in sprockets . If not: Repeat tensioning procedure. Remove crankshaft pulley. Fit timing belt lower cover . Fit crankshaft pulley. Tighten bolts to 20 Nm. Install components in reverse order of removal.
Filed Under (Peugeot) by admin on 14-11-2010
Removal Removal 1. Raise and support front of vehicle. 2. Remove: RH front wheel. Engine undershield (if fitted). Lower inner wing panel. Auxiliary drive belt(s). 307: Engine tie-bars. Crankshaft pulley  . Timing belt upper cover  . Timing belt centre cover  . Timing belt lower cover  . 3. Turn crankshaft to setting position. Insert timing pins in camshaft sprocket and flywheel  &  . 4. Slacken tensioner nut to release tension on belt  . Lightly tighten nut. 5. Remove timing belt. Installation – -1997 Installation – -1997 1. Ensure timing pins located correctly  &  . 2. Fit timing belt in following order: Crankshaft sprocket. Camshaft sprocket. Water pump sprocket. NOTE: Ensure belt is taut between sprockets on non-tensioned side. Slacken tensioner nut  . Turn tensioner anti-clockwise to tension belt. Temporarily tighten nut. Remove timing pins  &  . Attach tension gauge to belt at  . Tool No.(-).0192/SEEM C.Tronic 105.5. Slacken tensioner nut  . Tension belt as follows: Turn tensioner anti-clockwise until tension gauge indicates 45 SEEM units. Tighten tensioner nut to 20 Nm  . Remove tension gauge. Turn crankshaft four turns clockwise to setting position. Ensure timing pins can be inserted  &  . Wait 1 minute to allow belt to settle. Apply firm thumb pressure to belt at . Attach tension gauge to belt at  . Tool No.(-).0192/SEEM C.Tronic 105.5. Slacken tensioner nut  . Turn tensioner anti-clockwise to tension belt. New belt: 40 SEEM units. Used belt: 36 SEEM units. Tighten tensioner nut to 20 Nm  . Remove tension gauge  . Turn crankshaft two turns clockwise. Ensure flywheel timing pin can be inserted  . NOTE: DO NOT allow crankshaft to turn anti-clockwise. Attach tension gauge to belt at  . Tool No.(-).0192/SEEM C.Tronic 105.5. Check tension gauge reading. New belt: 51±3 SEEM units. Used belt: 45±3 SEEM units. Install components in reverse order of removal. Tighten crankshaft pulley bolts to 8 Nm  . 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
Filed Under (Mitsubishi) by admin on 18-01-2011
1. Disconnect negative battery cable. Remove engine undercover. Place wooden block between jack and oil pan, and raise engine slightly. Remove engine mount assembly near timing belt cover. 2. Remove clamp for power steering return hose near timing belt cover. Remove all drive belts and tensioner pulley bracket. See Fig. 1 . Remove power steering and water pump pulleys. Rotate crankshaft clockwise so that No. 1 cylinder is at TDC of compression stroke. Remove crankshaft pulley. CAUTION: DO NOT rotate crankshaft counterclockwise. Ensure timing marks are aligned. If reusing timing belts, mark timing belts for direction of rotation. 3. Remove upper timing belt cover and gasket. Remove stub bolt of engine support bracket, and remove center timing belt cover. Remove lower timing belt cover. NOTE: Camshaft sprocket dowel pins will be in 12 o’clock position when timing marks are correctly aligned. 4. Ensure camshaft, crankshaft and oil pump sprocket timing marks are aligned. See Fig. 2 or Fig. 3 . Loosen tensioner pulley center bolt. Move tensioner to relieve timing belt tension. Remove timing belt. Remove timing belt auto tensioner. See Fig. 1 . 5. Remove plug from left side of cylinder block. Install a .31″ (8.0 mm) diameter Phillips screwdriver into the hole against balance shaft. See Fig. 4 . Screwdriver must go in at least 2.36″ (60 mm) or more. If screwdriver will only go in about .79-.98″ (20-25 mm) before striking balance shaft, turn sprocket one revolution and align timing mark. Keep screwdriver in place until timing belt is installed. This ensures balance shaft driven by oil pump sprocket remains in correct position. 6. To remove timing belt “B” (balance shaft belt), hold crankshaft sprocket stationary with a spanner wrench. Remove crankshaft sprocket bolt. Using gear puller, remove outer crankshaft sprocket. 7. Remove crankshaft sensing blade (if equipped). See Fig. 5 . Loosen timing belt “B” tensioner bolt. If reusing timing belt “B”, mark direction of belt rotation for reassembly reference. Remove timing belt “B”.