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5.1.3
VS4735/P15 Crankshaft and Fuel Pump Sprocket Locking Pins (2 in set)
Check that the crankshaft keyway is in the 11-0-clock position and insert Locking Pin VS4735/P15 to confirm correct crankshaft position.
(Fig.3). One of the VS4735/P15 Locking Pin is used to lock the crankshaft and the other one locks the fuel pump sprocket. Check the fuel
pump alignment via holes in the pump sprocket. If there is not a corresponding hole in the pump bracket to the hole in the sprocket, then
align by positioning the holes in the sprocket vertically. Support the engine to allow removal of the RH engine mounting/bracket, release the
tensioner and remove the old timing belt. Ensure the camshaft sprocket and crankshaft are locked in timing position with Pins P17 and P15
respectively. Ensure the fuel pump is aligned correctly.
5.1.4
Fit the new timing belt and install the engine mounting/bracket. Apply tension to the belt by turning the tensioner anti-clockwise until the
pointer is positioned between the sides of the window. Re-fit crank position sensor and belt guide angle bracket. (Fig.4).
WARNING! DO NOT touch the magnetic track (sensor ring).
5.1.5
Remove the Locking Pins. Carefully rotate the crankshaft 10 times clockwise. Check engine timing by ensuring that the camshaft and
crankshaft locking pins can be inserted and that the fuel pump sprocket is correctly aligned. Remove all Locking Pins and check the
tensioner pointer is positioned within the window. Insert the Locking Pin P16 into the flywheel and fit the crankshaft pulley using a new
centre bolt.
5.2.
FORD 1.8 TDi/TDdi/TDCi Diesel Engines
This range of Ford diesel started as turbo, direct injection engines and later incorporated common rail technology. The Endura/Duratorq 1.8
Direct Injection engine utilises a chain drive from the crankshaft to the injection pump and a tooth drive belt from the injection pump to the
camshaft.
IMPORTANT: A new belt MUST be installed if the tension has been released from an existing belt.
5.2.1
VS101/2 Crankshaft TDC Location Pin
This is designed to screw into the cylinder block and provide a stop for the crank web to be positioned against to set the TDC position.
(Fig. 5). Turn the engine in normal direction of rotation until the slot in the injection pump sprocket is approx. in the 11-o-clock position.
Remove the plug from the cylinder block access hole and screw in VS101/2. Slowly and carefully turn the crankshaft clockwise until the
crankshaft web rests on the Locking Pin. No.1 cylinder is now set at TDC on ignition stroke.
Fig.4
5.2.2 VS4933 Camshaft Setting Plate
On Ford 1.8 diesel engines,1996 onwards, VS4933 Setting Plate is used to accurately align an off-centre datum slot in the end of the camshaft
with the top face of the camshaft housing, to hold the camshaft in its 'timed' position. A notch is designed into the Setting Plate to accommodate the
raised part of the housing. (Fig.6).
© Jack Sealey Limited
Fig.3
Original Language Version
Fig.5
VS4830 Issue: 2(I) - 27/07/15
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