IMPORTANT:
For detailed and concise instructions on the correct use of this kit, refer to the
vehicle manufacturer’s service manual.
WARNING:
Incorrect or out of phase engine timing can result in mechanical contact
between the valve head and the piston crown causing serious damage to the
engine. No responsibility can be accepted for any loss or damage arising from
the incorrect use of this kit.
For 1.6 and 1.8 diesel engines as fitted to Ford Fiesta, Escort, Orion P100,
Sierra and Mondeo models, and 2.5DI (direct injection) diesel engines as fit-
ted to Ford Transit models, (February 1985 onwards).
This comprehensive kit enables correct engine timing alignment to be main-
tained when the engine timing belt either needs to be replaced, or removed
and re-fitted as part of a service procedure.
Suitable for use on the following vehicles:
1.6 Diesel Engine - 4 Cylinder 1608cc OHC
1. Follow workshop manual instructions to remove the camshaft cover and the
timing belt cover.
2. Turn the engine (in the normal direction of rotation) until the timing mark
on the injection pump sprocket lines up with the cast lug on the timing
cover.
3. Remove the threaded plug from the cylinder block (between the alternator
and the injection pump) and screw in the T.D.C. Setting Pin. Slowly turn the
crankshaft clockwise, until contact is made with the setting pin, to put No.1
cylinder at Top Dead Centre.
4. Insert the Locking Plate into the groove in the tail of the camshaft with the
larger semi-circle facing upwards. If required, pack each side of the plate
with equal thickness feeler gauges to obtain a tight fit and the correct
camshaft alignment.
5. Slacken the camshaft sprocket bolt (DO NOT REMOVE). If the timing belt is
to be re-used, mark the direction of rotation with chalk to ensure correct re-
fitting. Slacken the timing belt tensioner and remove the timing belt.
6. Check that the crankshaft has been turned clockwise against the setting
pin and that the Locking Plate is correctly positioned (as in 4 above). Fit the
timing belt (in the correct direction of rotation). Fasten the *Torx belt ten-
sioner bolt finger tight.
7. Ensure that the camshaft sprocket can turn on its taper, and turn the ten-
sioner anticlockwise to obtain the correct tension (REFER TO WORKSHOP
MANUAL). Tighten the *Torx belt tensioner retaining bolt.
8. Tighten the camshaft sprocket bolt to the specified torque, and remove the
Locking Plate and T.D.C. Setting Pin. Turn engine over twice by hand to
complete a full cycle. Re-gain T.D.C. Position and re-check alignment by
inserting the locking plate with the T.D.C. setting pin in place (see above).
If necessary repeat steps 6 & 7 before proceeding. Remove the locking
plate and T.D.C. pin before turning the engine over twice by hand to com-
plete a full cycle to ensure that there is no obstruction.
9. Replace the threaded plug in the cylinder block and follow workshop man-
ual instructions to refit the camshaft cover and the timing belt covers, etc.
OPERATING INSTRUCTIONS
(FOR GUIDANCE ONLY)
