Removal of timing belts must be done on a cold engine.
Removal
1. Disconnect the ground wire from the battery.
2. Remove the V-belt.
3. Remove the upper and lower timing belt covers.
4. Turn the crankshaft clockwise to the TDC position of cylinder 1 using the belt pulley, using a 32 mm wrench.
5. In this position, insert the installation tools into the camshaft pulley and the high-pressure fuel pump pulley. The Bosch fuel pump pulley uses 6 mm diameter tools, while the CAV pump uses 9.5 mm diameter tools.
6. Loosen the timing belt tensioner mounting bolts.
7. Remove the timing belts.
Caution! After removing the timing belt, do not turn the crankshaft, as this may cause the pistons to hit the open valves.
Installation
1. Place both toothed belts on the pulleys without turning the pulleys. Start installing the toothed belts from the crankshaft pulley and then, sequentially, on the next pulleys, counterclockwise. As a result, the untensioned side of the belt falls on the spring-loaded tension rollers.
Attention! Arrows on the belts indicate the direction of engine rotation.
2. Place the belts behind the tension rollers, tension the belts with springs and tighten the bolts.
3. Adjust the valve timing.
4. Install the timing belt covers.
5. Connect the ground wire to the battery.
Adjustment
1. For precise adjustment, it is necessary to use a drift to set the crankshaft to the TDC position (Ford device 21-104) and an installation square (Ford device 21-105) to fix the camshaft.
2. Turn the crankshaft two turns by the pulley.
3. Remove the timing belt covers.
4. Remove the cylinder head cover.
5. Turn the crankshaft to the TDC position of cylinder 1, using a 32 mm wrench. Turn the crankshaft pulley clockwise with the wrench. The crankshaft is in the TDC position if the groove on the end of the camshaft is parallel to the upper plane of the cylinder head, with the larger semicircle located on top.
6. Unscrew the plug on the engine cylinder block from the front side of the engine, between the high-pressure fuel pump and the generator, and instead of the plug, screw in a drift to set the crankshaft to the TDC position.
7. Turn the crankshaft clockwise with a spanner until it stops in the mandrel, which ensures precise fixation of the crankshaft.
8. Unscrew the 4 bolts securing the camshaft toothed pulley. The pulley should remain on the shaft and turn easily.
9. Insert a square or a 5 mm thick steel plate into the camshaft groove. Turn the camshaft with the square until the square stops against the cylinder head. Use a feeler gauge to measure the gap on the other side of the square, between the square and the cylinder head. Insert a feeler gauge whose thickness is half the measured gap, and turn the camshaft until the square stops against the feeler gauge. On the other side of the square, insert a second feeler gauge of the same thickness between the end of the square and the cylinder head.
10. Insert the installation tool into the camshaft pulley.
11. Loosen the tensioner mounting bolts.
12. Press firmly on the toothed belt from the side opposite the tensioner and release the belt. This will result in uniform tension of the toothed belt.
13. Tighten the camshaft pulley and tensioner mounting bolts.
14. Insert the high pressure fuel pump pulley installation tool.
15. If the installation tool does not fit into the fuel pump pulley, loosen the tension and remove the high-pressure fuel pump drive toothed belt.
16. Turn the fuel pump pulley to a position that allows installation of the device.
17. In this position, install and tension the timing belt.
18. Remove the installation tools from the pulleys, the square from the camshaft and unscrew the mandrel for installing the crankshaft at TDC. Screw the plug into the engine cylinder block.
19. Install the cylinder head cover.
20. Install the timing belt covers.
21. Install the V-belt.
22. Connect the ground wire to the battery.