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2. CONTENTS
- 3 -
- 10 -
Depending on manufacture and model, some engine components do change. Please check with
Autodata or the manufacturer’s data before use.
Preparation
The valve timing on these engines is at 90 degrees after top dead centre on number one cylinder. Remove
the following components:
1. right hand engine mount
2. auxiliary drive belts, tensioners and PAS pulley
3. alternator and mounting
4. starter motor
Components E & F & G & H
Crankshaft Locking Pins – select pin according to fitment. The
aperture for the fitment of the crankshaft locking pin is located
behind the starter motor. Turn the engine by hand till number one
piston is a 90 degrees after TDC and ensure the pin is fully
inserted into the back of the flywheel/drive plate.
Component C
Inlet camshaft locking pin – this tool fits into the front face of the
cam cover just behind the cam belt area, below the oil filler kneck.
Remove the blanking plug from the cam cover to allow fitment of
component 1. ensure the engine is set at 90 degrees after top
dead centre and component 4/5 is already in position
Component D
Exhaust camshaft locking tool – this tool fits in place of the blanking plug on the rear of the cam cover.
When slackening the Camshaft pulley fixings please ensure an adequate pulley holding tool is used. The Camshaft
holding pins are designed to hold the camshafts in their timed position and not withstand the torque of slacken-
ing/tightening the pulley fixings.
Component B
Cam belt Holding Tool – the cam belt holding tool is designed to hold the new belt in place on the
crankshaft whilst fitting the belt onto the other pulleys. Due to the number of pulleys that the belt must
go round if component B is not used the belt may fall off the crank pulley before the technician can
get the belt fully into position. Fits on to the crankshaft pulley flange using one of the pulley bolts and
holds the belt against the bottom of the crankshaft cam belt pulley.
Component A
Belt Tensioner wrench – designed to allow the technician to lever the tensioner back for belt removal
and pre-load the tensioner for belt set-up.
Note: The manufacturer does not provide a High Pressure pump locking facility. The high pressure fuel pump pulley
is aligned by lining up the marks on the pulley and back cover. If there are no marks visible it is permissible to mark
the pulley and back cover with paint. This should be done prior to belt removal.
1. TITLE PAGE
1.1 INTRODUCTION.......................................................................................................... 2
1.2 REVISION HISTORY .................................................................................................. 2
1.3 UNDERSTANDING THIS GUIDE................................................................................. 2
1.4 COPYRIGHT NOTICE .................................................................................................2
2. CONTENTS
2.1 CONTENTS ....................................................................................................................3
3. GUARANTEE
3.1 GUARANTEE ............................................................................................................... 4
4. GENERAL PRODUCT INFORMATION
4.1 GENERAL PRODUCT INFORMATION ....................................................................... 5
5. HEALTH AND SAFETY INFORMATION
5.1 GENERAL SAFETY INSTRUCTIONS FOR USE
Personal safety........................................................................................................... 6
6. CONTENTS
6.1 PARTS DRAWING AND LISTING ............................................................................... 7
7. APPLICATION
7.1 PRODUCT APPLICATION AND COMPATIBILITY LISTING ...................................... 8
8. PREPARATION
8.1 ADVISORIES BEFORE USE ...................................................................................... 9
9. PROCEDURE AND APPLICATION GUIDE
9.1 APPLICATION GUIDANCE........................................................................................10
10. EXPLANATION OF SYMBOLS
10.1 EXPLANATION OF SYMBOLS .................................................................................. 11
9. PROCEDURE AND APPLICATION GUIDE
Please note images are for guidance only and subject to change.
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