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Remove crankshaft pulley, lower timing belt cover, crank position sensor and belt guide angle bracket and Locking Pin DT.4735P16
WARNING: Do not touch the magnetic track (sensor ring).
Re-fi t the crankshaft pulley bolt (to facilitate engine turning), and remove Locking Pin DT.4735P16
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DT.4735P17 Camshaft Locking Pin
Turn the engine until the camshaft sprocket timing holes align (approximately the 2-0-clock position) and insert Locking Pin DT.4735P17.
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AST4735P15 Injection Pump and Crankshaft Locking Pin
Check that the crankshaft keyway is in the 11-0-clock position and insert Locking Pin DT.4735P15 to confi rm correct crankshaft position.
NOTE: DT.4735P15 Locking Pin is also used to check the fuel pump alignment via holes in the spokes of the pump sprocket and a hole in the pump bracket. If
there is not a datum hole in the pump bracket, behind the sprocket, to accept the Locking Pin, then align the pump sprocket position by positioning the holes in
the spokes vertically, one above the other.
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When fi tting new timing belt, apply tension to the belt tensioner until the pointer is positioned between the sides of the window. Re-fi t removed parts and
remove the Locking Pins. Carefully rotate the crankshaft 10 times in a clockwise direction.
Check engine timing by ensuring DT.4735P17 and DT.4735P15 Pins can be inserted and fuel pump sprocket is correctly aligned. Re-check the belt tensioner
pointer is positioned within the window.
2.0HDi diesel engines
– Adjustable Crankshaft Gear & Additional Belt Tensioner
Some later 2.0HDi diesels, from 2001 onwards, are fi tted with an ADJUSTABLE CRANKSHAFT GEAR, replacing the previous Adjustable Camshaft Sprocket as the
means of making adjustment during timing belt tensioning procedures, when fi tting a new belt.
The Adjustable Crankshaft Gear keyway is positioned on a crankshaft key but the gear has slight movement on the key, so some rotational adjustment can take
place at the belt tensioning stage.
- Refer to Application Chart for model usage / engine codes
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DT.4820P18 Crankshaft Gear Positioning Tool
The same selection of Timing Tools are used for these 2.0HDi engines as included and advised in Kit DT.PSA. With the camshaft and fl ywheel 'locked in timed
position the crankshaft gear is turned allowing the DT.4820P18 to be inserted in to the left side of the key, between the key and the crankshaft gear.
IMPORTANT: During fi tting of the new belt the key must remain pressed against the DT.4820P18 Tool.
Fit belt in a clockwise direction and fi t suitable Belt Tension Gauge. Remove DT.4820P18 Positioning Tool and turn tensioner to achieve specifi ed initial belt tension.
Fit Flywheel Holding Tool (DT.4358) and fi t crankshaft pulley tightening bolt to 63-77Nm. Remove all Locking Tools/Pins and rotate crankshaft 8 times
clockwise, returning to timed position.
Re-Fit Flywheel Holding Tool and remove crankshaft pulley. Turn tensioner clockwise to achieve fi nal specifi ed belt tension. Re-Fit crankshaft pulley – tighte-
ning bolt to 68-72 Nm.+60°+50°
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DT.4568 Tensioner Adjuster
- Refer to Application Chart for model usage / engine codes
Some HDi engines require the additional Specialised Wrench - DT.4568 Tensioner Adjuster to suit the square drive fi tting found on certain belt tensioners.
This is additional to the DT.4362 and DT.4567 Adjusters already included in DT.PSA Kit.
Section 3A:
TU & XU PETROL ENGINES – UPDATE Tools
TU5 & XU7 Revised Belt Tensioner – New Pin
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DT.4360T5 Tensioner Locking Pin.
- Refer to Application Chart for model usage / engine codes
From 1998 onwards a new timing belt tensioner began to be introduced on 1.6 16v. (TU5JP4) and 1.8 16v. (XU7JP4) PSA engines.
New Pin DT.4360T5 locates into a hole in the tensioner assembly back plate to 'lock' the belt tensioner away from the timing belt, to release tension whilst
removing and fi tting a new belt.
NU-DT.PSA-A_0606.indd 49
NU-DT.PSA-A_0606.indd 49
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27/07/2007 10:26:04
27/07/2007 10:26:04
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