FORD 1.8 Diesel engine.
GATES REFERENCE : 5541XS/K015541XS
MAKE : FORD / MAZDA
MODEL : C-Max, Courier, Fiesta, Focus, Galaxy, Mondeo,
S-Max, Tourneo Connect, Transit Connect
121
ENGINE : 1.8 Diesel (all 8 valves)
# 027 ENGINE CODE : Various
29/04/2009
Through our field experience and failure analysis, we have learned that drive
failure on these engines can be avoided by strictly following the correct
installation procedure.
Although this drive looks very simple and although it is equipped with an
automatic tensioner, precise follow up of the complete installation procedure
is needed in order to get the correct set-up/tension. Failure to follow these
instructions will lead to incorrect tension and possible drive failure, resulting
in engine damage!
Attention points:
1) Engine must be cold: the engine temperature significantly influences
the installation parameters
2) Engine must be at TDC. All engine specific setting/locking tools can
be found in Gates tool kit GAT4830
3) The crankshaft has to be blocked (when equipped with air
conditioning, the alternator shaft has to be removed, 6 bolts to
loosen).
4) The camshaft has to be blocked (at the back of the engine)
5) Camshaft sprocket bolt has to be loosened. Make sure sprocket is
free to rotate on the taper, by using the sprocket remover in tool kit
GAT4830 (if not done so, the belt will not be tensioned in the top
span)
6) The tensioner must be turned anticlockwise, until the indicator is in
the middle of the slot (not lined up with the mark on the tensioner)
(Fig. 1)
7)
Indicator in middle
of the slot.
Mark on the tensioner
Fig. 1
Technical Bulletin 027
Copyright © 2009 Gates Corporation Page 1 of 4
# 027
29/04/2009 8) Torque the tensioner bolt (50 Nm) while holding the tensioner in
place
9) Torque the camshaft bolt (50 Nm) while holding the sprocket in
place. Use Gates sprocket holding tool GAT4844.
10)Remove the camshaft and crankshaft locking tools
11) Turn the engine nearly 6 revolutions by hand
12) Re-insert crankshaft pin, rotate engine further till TDC
13) Check the tensioner indicator position, if not in the middle of the slot,
restart the tension setting procedure
14) Insert the camshaft locking tool (at the back of the engine). If not
possible, restart the tension setting procedure
Failure to do all the above will lead to wrong tension, with possible tracking
of the belt as a result. The belt will climb over the camshaft sprocket flange,
running into the timing cover (Fig. 2 and 3)
Fig. 2
Typical wear pattern on the
side of the belt
Fig. 3
Signs of serious wear on
inside of the cover due to
contact with the side of the
belt
Technical Bulletin 027
Copyright © 2009 Gates Corporation Page 2 of 4
Additional attention points:
(As these points, already mentioned in TB016, are repeated here, TB016
becomes void and is replaced by this one.)
1. Camshaft pulley
# 027
29/04/2009
Fig. 4 Extension AC
Check if the part number of the camshaft pulley ends with AC (Fig. 4).
Should the part number of the camshaft pulley end with AB, fit new sprocket
with OE ref. XS4Q6A256AC.
2. Automatic tensioner
Fig. 5
New automatic tensioner Old manual tensioner
Fig. 5 shows the initial manual tensioner on the right side and the current
automatic tensioner on the left.
Technical Bulletin 027
Copyright © 2009 Gates Corporation Page 3 of 4
3. Timing belt cover
# 027
29/04/2009
Fig. 6
When the manual tensioner is replaced by an automatic tensioner, the
timing belt cover has to be slightly modified.
File off the inner corner (0.5 mm) as shown in Fig. 6.
Do not damage the timing belt cover by filing off too much of the corner!
Ignoring the above guidelines can seriously damage your engine!
Visit our web catalogue : www.gatesautocat.com
Technical Bulletin 027
Copyright © 2009 Gates Corporation Page 4 of 4
