Bradfordlad

Hi there everyone,
I just wish a job on this van would be straight forward...done loads everythings been a battle.

I didnt get any history with the van so i thought i would do the belts...The problem i have is the 10mm bolt pushed up to the left hand wing just spins when turned...I doesn't pull out either and the plastic is still mating with the the block ? Help whats happen here ? Crap mechanics could have over tightened and it looks to be spinning inside the plastic but not sure ?

Any help with this would be great any TIPS changing the timing belts would also be welcome.

Thankyou Paul

GVK.

Not done one for ages but IIRC I think there is a threaded insert in the block that the 10mm bolt screws in, if you keep turning the bolt it may undo the insert out of the block then remove it once the cover is off.

Can post the instructions for the belt, ideally you need a locking pin but you can get away without it if you mark everything up.

Also most should have been changed by now, but if any of the idler pullies are plastic swap them for metal ones, they used to be the main failure of these engines back in the day, end result is a scrap head as the camshaft and bearing caps snap!

GVK.

Timing Belt
Removal

NOTE: Timing belt and injection pump belt should not be removed/installed until engine is cold (stopped for at least 4 hours).

Mondeo - remove:
Engine undershield.
RH lower inner wing panel.


Escort - remove:
PAS reservoir. Disconnect return hose only (if fitted).
Coolant expansion tank.


All models - remove:
Auxiliary drive belt(s).
Alternator cover (if fitted).
Alternator/bracket (if required).
PAS pump pulley (if fitted to injection pump).
PAS pump (if required). DO NOT disconnect hoses.


Fiesta 1996→/Mondeo:
Support front of engine.
Remove RH engine mounting.


Fiesta 1996→ - remove:
Crankshaft pulley bolts (4 bolts).
Crankshaft pulley.


All models - remove:
Timing belt covers Fig.10399.1 & Fig.10399.2.
Injection pump belt cover (Fiesta 1996→).


Turn crankshaft clockwise until slot in injection pump sprocket at 11 o'clock Fig.10399.3.
Remove blanking plug from cylinder block. Insert timing pin in cylinder block Fig.10399.4. Tool No.21-104.
Turn crankshaft clockwise until it stops against timing pin.
Insert timing pin in camshaft sprocket Fig.10399.5. Tool No.23-019.
Insert timing pin in injection pump sprocket Fig.10399.6. Tool No.23-019.

NOTE: Engines fitted with CAV injection pump: Insert 6 mm drill bit in injection pump sprocket Fig.10399.6.


Slacken tensioner hexagon bolt and Torx bolt Fig.10399.7 & Fig.10399.8.
Move tensioner away from belt. Lightly tighten bolt Fig.10399.8.
Remove timing belt.

NOTE: DO NOT refit used belt.


Installation

NOTE: Refer to Ford dealer for revised timing belt lower cover, to prevent debris entering timing belt drive area.

Check tensioner pulley and guide sprocket for cracks, chips or other damage. Replace if necessary.

NOTE: If guide sprocket Fig.10399.9 is plastic, it should be replaced with a steel sprocket No.7053802 and bolt No.6701537.


Spin tensioner pulley and guide sprocket. Check for bearing roughness and noise. Replace if necessary.

NOTE: If tensioner bolt Fig.10399.8 has 'mushroom' head, check for evidence of removal with a chisel or self-grip wrench. If so, fit a new bolt and tensioner.


Ensure timing pin located correctly in camshaft sprocket Fig.10399.5.
Ensure timing pin or 6 mm drill bit (CAV) located correctly in injection pump sprocket Fig.10399.6.
Ensure crankshaft web against timing pin Fig.10399.4.
Fit timing belt. Slack side of belt must be towards tensioner. Observe direction of rotation marks on belt.
Slacken camshaft sprocket bolts Fig.10399.10.
Slacken injection pump sprocket bolts Fig.10399.13.
Slacken tensioner bolts 1/2 turn Fig.10399.7 & Fig.10399.8. Allow tensioner to operate.
Tighten camshaft sprocket bolts Fig.10399.10.
Tighten injection pump sprocket bolts Fig.10399.13.

NOTE: Ensure bolts not at end of slotted holes in sprockets.


Tighten tensioner bolts Fig.10399.7 & Fig.10399.8.
Remove timing pins Fig.10399.4, Fig.10399.5 & Fig.10399.6.
Turn crankshaft two turns clockwise. Ensure injection pump sprocket slot at 12 o'clock Fig.10399.11.
Turn crankshaft anti-clockwise until injection pump sprocket slot at 11 o'clock Fig.10399.3.
Insert timing pin in cylinder block Fig.10399.4. Turn crankshaft clockwise until it stops against timing pin.
Insert timing pin in camshaft sprocket Fig.10399.5.
Insert timing pin or 6 mm drill bit (CAV) in injection pump sprocket Fig.10399.6.
Slacken camshaft sprocket bolts Fig.10399.10.
Slacken injection pump sprocket bolts Fig.10399.13.
Slacken tensioner bolts Fig.10399.7 & Fig.10399.8.
Push tensioner firmly against belt and release.
Tighten tensioner bolts to specified torque Fig.10399.7 & Fig.10399.8.
Tighten camshaft sprocket bolts to specified torque Fig.10399.10.
Tighten injection pump sprocket bolts to specified torque Fig.10399.13.
Remove timing pins Fig.10399.4, Fig.10399.5 & Fig.10399.6.
Install components in reverse order of removal.

GVK.

Injection Pump Belt
Removal

Remove timing belt as described previously.
Ensure timing pin or 6 mm drill bit (CAV) located correctly in injection pump sprocket Fig.10399.6.
Slacken tensioner bolt Fig.10399.12. Lift tensioner against spring pressure. Tighten bolt.
Remove injection pump belt.
Slacken injection pump sprocket bolts Fig.10399.13.

Installation

Ensure crankshaft web against timing pin Fig.10399.4.
Ensure timing pin or 6 mm drill bit (CAV) located correctly in injection pump sprocket Fig.10399.6.
Fit injection pump belt. Slack side of belt must be towards tensioner. Observe direction of rotation marks.
Slacken tensioner bolt Fig.10399.12. Allow tensioner to operate. Tighten bolt to 45 Nm.
Tighten injection pump sprocket bolts Fig.10399.13. Ensure bolts not at end of slotted holes in sprocket.
Fit timing belt as described previously.

(I never used to slacken the pulley bolts, it makes the belt a bit harder to put on but you don't get any issues with the timing being out. )

Bradfordlad

thanks for the info re-timing but i'm still a bit confused..My camshaft sprocket doesn't look like this and looks to have no were to lock it. There is a slot on the other side of the cam for slot bar should this be the place to lock it and not the sprocket ?

Thanks

http://www.justanswer.com/uk-ford/6f...-8-diesel.html

kingbx95

Yeh on the later engines they are locked on the other end with a bar. You can then slacken the cam sprocket if needed to get tension right on the belt

Bradfordlad

Thanks Kingbx95 so are the instructions above correct for my later engine but the locking of the camshaft is from the other side.

Thanks

kingbx95

Think so mate although there are a few diff tensioner set ups as well so need to make sure you have the correct belt kit.

GVK.

Yeah.....

Bradfordlad

GVK thanks for the reply....i did follow these original instructions but still cannot get the tensioner side to tension up..i tried not to disturb the 3 pulley bolts but had to in the end to try and sort the slack belt issue.
Any tips ?

GVK.

I can't think what you're doing wrong tbh, I have done loads of 1.8 diesel belts back when they were still coming in the main dealers, never had a problem myself, as I say I never used to slacken the pump bolts. Bloke I used to work with used to slacken the bolts and always seemed to struggle with them.

You sure the pin is in the proper slot on the pump drive?

Diesel combi pete

I once had a simalar problem I melted the plastic casing till it gripped the nut again.
If you are doing your timing belt I sujest you get a manuel as there are two types of belt and the one like mine is not just an as you see it job, you need the manuel. I did mine and it was great fun to do, but has to be done right,, I was affraid to do it at first as not as easy as was on my 1600cc deisel Escort combe.. Good luck.. Cheers Pete

Diesel combi pete

There are two diferent types.. first fine out what type your car or van is. get a manuel it is the only way unless some of these guys want to come and help you do the job... Cheers, Pete
Ps, I have been playing with cars for over fifty years and still learn ever time I play...

Diesel combi pete

First thing to do is take of your timing cover top half take about two minutes look in then and se what timing tentioner your engin has this will then tell you what kit to buy. Take it from me buy the kit with the water pump in it as the pump can only be done with all the timeing bits of if your pump gos latter you will b sorry Once you have found out what kit you need then get a manuel and go for it. The manuel is a sod to read as it keep jumping from one type of tentioner to the other, so read the book well and then mark all the bits that are relivent to youy tentioner type.. Good luck, Pete

Since posting I have read the whole post, sorry you did not buy a cheap manuel Pete out

GVK.

Manuel??

Diesel combi pete

Just who you need to do the job. you would have a good laugh at least.. Wonder if Bazile would lend a hand ?

GVK.

He'd thrash it with a twig!