Automotive Manual PDF

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 refitting. 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 tensioner bolt finger tight.
7. Ensure that the camshaft sprocket can turn on its taper, and turn the tensioner 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 complete a full cycle to ensure that there is no obstruction.
9. Replace the threaded plug in the cylinder block and follow workshop manual instructions to refit the camshaft cover and the timing belt covers, etc.

Get pdf FORD DIESEL ENGINE INJECTION TIMING KIT INSTRUCTIONS