1.8 Diesel Engine - 4 cylinder 1753cc OHC
1. Follow workshop manual procedures to remove the timing belt covers.
Remove the threaded plug for the crankshaft timing pin from the cylinder
block and turn the engine until the slot in the injection pump pulley is at
about 11 o’clock.
2. Screw the T.D.C. Setting Pin into the cylinder block and turn the crankshaft
until it rests against the setting pin at T.D.C. The drilling in the (CAV) injec-
tion pump flange, or the recess (Bosch), should be aligned with the drilling
in the pump housing. If the timing belt is to be re-used, mark the direction
of rotation with chalk to ensure correct re-fitting. Release the belt tensioner
to remove the camshaft toothed belt. DO NOT REMOVE THE INJECTION
PUMP TOOTHED BELT UNLESS NECESSARY, AS THE SPECIFIED TENSION-
ING PROCEDURE ONLY APPLIES TO NEW BELTS.
3. Bosch pump - use pin ‘B’ to time the injection pump sprocket and pin ‘D’ to
time the camshaft sprocket.
CAV pump - use pin ‘E’ to time the injection pump sprocket and pin ‘D’ to
time the camshaft sprocket.
4. Ensuring that the crankshaft is still in contact with the T.D.C. Setting Pin, fit
the new injection pump toothed belt and/or the camshaft toothed belt.
Ensure direction arrows point the correct way. REFER TO WORKSHOP MAN-
UAL FOR DETAILED BELT FITTING AND TENSIONING PROCEDURES.
5. Remove all pins, and turn engine over twice by hand to complete a full
cycle. Re-gain T.D.C. position and re-check alignment by inserting the
appropriate pins. If the pins do not all fit correctly repeat step 4 before pro-
ceeding. Remove all pins and turn engine over twice by hand to complete
a full cycle to ensure that there is no obstruction.
6. Replace threaded plug in the cylinder block and follow workshop manual
procedures to re-fit timing belt covers, etc.
2.5DI Diesel Engine - 4 Cylinder 2496cc OHV Direct Injection.
1. Follow workshop manual procedures to remove the timing belt covers.
Remove the blanking plug for the crankshaft timing pin from the the cylin-
der block. Turn the engine in the normal direction of rotation until the
Setting Pin ‘A’ can be inserted into the flywheel. Check that pin ‘C’ and pin
‘D’ can be inserted in the camshaft and injection pump sprockets respec-
tively.
2. To remove the timing belt, slacken the tensioner bolts and lever the ten-
sioner away from the belt. If the timing belt is to be re-used, mark the
direction of rotation with chalk to ensure correct re-fitting.
3. Ensure that the three timing pins are correctly located and that the belt ten-
sioner is held back against the spring with the clamping bolt. REFER TO
WORKSHOP MANUAL FOR DETAILED BELT FITTING AND TENSIONING
PROCEDURES.
4. Remove all pins, and turn engine over twice by hand to complete a full
cycle. Re-gain timing position and re-check alignment by inserting the
appropriate pins. If the pins do not all fit correctly repeat step 3 before pro-
ceeding. Remove all pins and turn engine over twice by hand to complete
a full cycle to ensure that there is no obstruction/
5. Replace blanking plug in the cylinder block and follow workshop manual
procedures to re-fit belt covers, etc.
IMPORTANT
For detailed and concise instructions on the correct use of this kit, refer to the
vehicle manufacturer’s service manual.
*Torx is the registered trademark of Camcar/Textron Inc.
