Timing

9 years 4 months ago - 9 years 4 months ago #26020 by David Aiketgate
Timing Marks etc.

Timing Position.


Crank Pulley in Timing (Safe) Position.


Timing Dots on Crank Sprocket.


Inlet Cam Pulley.


Exhaust Cam Pulley.


Pulleys with Locking Tool in Position.


VVC Rear Cam Pulleys. (This position is used for setting timing. Before cam carrier removal, the pulleys should be positioned with marks facing outwards)


Tips on cam timing

Before removing the belt, make sure that the engine is set to its safe timing marks. In this position, the crankshaft is at 90 degrees before TDC and all the pistons are half way down their bores. This means that the cams can be turned without damaging the valves. The cam pulley marks can be seen after removing upper belt cover.

Only turn the engine over using the crank pulley bolt or by rocking the car with it in gear. Do not turn it using the cam pulley bolts. Removing the spark plugs make this easier.

To undo the crank pulley bolt, do it before removing the belt and make sure that the cam locking tool is NOT in position between the pulleys or you could damage the belt or even bend the valves.

Never turn the crank with the head removed unless the liners are first clamped in position, as they can move. If the timing position has been disturbed, an alternative would be to refit the head with no cams installed so that the valves are closed.

The cam timing tool is only required to assist in final fitting of the cam belt. It is not required at any other time - if the cams move, this is not a problem with the crank in its Safe (Timing) position and they can easily be turned back when required.

Do not use the cam timing tool between the pulleys to hold them while undoing the bolts. The tool to use is either one that picks up on the pulley spokes or you can use some types of oil filter strap wrench (not the chain type) wrapped around the cam pulley.

Cam belts can fail internally and still look new on the outside. If a belt has been contaminated with any fluid (including water!) or pinched it should be replaced.

Final belt tension should only be set after rotating the engine a couple of turns by hand, stopping at the timing position.

Cam timing notch is on the front flange of the crank pulley as shown and positions the crank at 90 Degrees BTDC (Safe or Timing position).

The best crank timing mark is to line the mark between the two dots on the crank sprocket. The crank pulley has been known to slip round on the hub giving a false indication, as the pulley locating key is very small and it is possible to damage it when refitting, again resulting in an incorrect timing mark position.

David
:shrug:
The following user(s) said Thank You: Davem, R40MGF

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9 years 4 months ago - 9 years 4 months ago #26021 by David Aiketgate
Cam Belt Tensioning.

The original K series engine had a manually adjusted cam belt tensioner which is set using an external spring. This is then discarded after use to stop it jumping off into the cam belt! The tensioner on the mpi engine was changed at 97.5 MY to an automatic tensioner that self adjusts to compensate for wear after initial setting, but the VVC engines retained the manual tensioner. The cylinder head casting was changed to accommodate the different fixings of the new tensioner so they are not interchangeable.

Auto Tensioner.


Manual Tensioner.


Belt change intervals are 60,000 miles / 6 years (4 years on some models) for manual tensioners and 90,000 miles / 6 years for automatic. However, I think that most people accept 60,000 miles / 6 years as being safe for most engines.


There are three different cam belts available to suit the various engine / tensioner combinations -

143 teeth 23mm wide manual tensioner mpi.
143 teeth 26mm wide manual tensioner VVC.
145 teeth 26mm wide auto tensioner mpi.


Tensioning the belt.

After fitting the cam belt, the tension should be roughly set and then the engine is turned by hand for two revolutions clockwise. This both settles the belt and also gives the chance to check that nothing is going to lock up. Stop turning when the timing marks are lined up again and recheck that they are correct, then finally set the tension.

With the manual tensioner this is done by slackening off the fixings a little so that the spring tension can set the tensioner position then retightening the fixings. If the spring does not have a rubber sleeve fitted around it, it should then be removed.

The auto tensioner is set by slackening the fixing and then turning the tensioner with an allen key anticlockwise until the wire pointer lines up with the indicator notch. The fixing is then retightened.
It is normal for the auto tensioner position to change as the engine is rotated, but it should return to the set position when the engine is stopped at the timing marks.

David
:shrug:
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9 years 4 months ago #26095 by andyjc86
It my be useful to list some of the torque settings in here, off the top of my head:

Auto tensioner: 25nm
Crankshaft pulley bolt: ?
Camshaft pulley bolt: ?
Timing belt cover bolts: ?

Unless someone beats me to it I'll confirm them tomorrow

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9 years 4 months ago - 9 years 4 months ago #26096 by David Aiketgate

andyjc86 wrote: It my be useful to list some of the torque settings in here, off the top of my head:

Auto tensioner: 25nm
Crankshaft pulley bolt: ?
Camshaft pulley bolt: ?
Timing belt cover bolts: ?

Unless someone beats me to it I'll confirm them tomorrow


You mean like this list Andy? :broon:

David
:shrug:
The following user(s) said Thank You: quasimodo

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3 years 2 months ago #180028 by graham1
Engine
Camshaft cover bolts
9
7
Camshaft gear bolt
8mm bolt
10mm bolt

33
65

24
48
Crankshaft pulley bolt
205
151
Cylinder head bolts
tighten progressively
1st stage
2nd stage
3rd stage


20
180 degrees
180 degrees
 
15
180 degrees
180 degrees
Flywheel to crankshaft bolts
85
63
Oil Pressure switch
12
9
Sump bolts
10
7
Sump to gearbox bolts
45
33
Sump drain plug
25
18
Tensioner pulley back plate bolt
10
7
Tensioner pulley Allen screw
45
33
Timing belt, front top cover
9
7
Timing belt, front lower cover
9
7
Timing belt, rear cover to coolant pump
10
7
 
Engine mountings
 
 
RH mounting to butress
82
60
RH mounting to RH upper longitudinal
45
33
Butress LH to subframe
45
33
Upper & Lower RH mounting bracket to engine
60
44
Bridge bracket to RH mounting bracket
155
114
Bridge bracket assembly to upper tie bar
88
65
Upper tie bar to RH longitudinal
88
65
Lower tie bar to RH upper longitudinal
100
74
Lower tie bar to sump bracket
100
74
Bracket to sump
80
59
LH mounting to LH upper longitudinal
80
59
LH mounting to gearbox
48
35
LH mounting to engine
45
33
Modular engine management system - MEMS
Air cleaner mounting bracket
10
7
Camshaft position sensor (VVC)
6
4
Crankshaft position sensor
6
4
Distributor cap bolts
2
1.5
Engine coolant temperature sensor
6
4
Fuel filter to bracket
10
7
Fuel filter, inlet and outlet union
30
22
Fuel pipe bracket to body
10
7
Fuel rail to inlet manifold
9
7
Fuel rail to fuel feed pipe
4
3
Idle air control valve
1.5
1.1
Ignition coil bracket to engine
25
18
Ignition coil bolt
9
7
Ignition coil bolt (VVC)
25
18
Intake air temperature sensor
7
5
Manifold absolute pressure sensor (VVC)
9
7
Oil temperature sensor (VVC)
15
11
Oxygen sensor
55
41
Resonator to body
10
7
Rotor arm to camshaft
10
7
Spark plugs
25
18
Throttle body
7
5
 
Catalytic Converter
 
 
Catalyst overheat sensor
30
22
Catalytic converter to front pipe
70
52
Catalytic converter to silencer
70
52
 
Fuel Tank
 
 
Bulkhead closing panel
9
7
Filler neck to wing
3
2
Fuel pump cover to body
17
13
Fuel pump lock ring
45
33
Fuel tank retaining strap
10
7
 
Throttle cable
 
 
Throttle pedal to bulkhead fixing
6
4
Throttle pedal bracket to pedal box
22
16

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3 years 2 months ago #180029 by graham1
Cooling
Coolant pump to cylinder block
10
7
Coolant pump to timing belt rear cover
10
7
Coolant rail to cylinder block
9
7
Engine bay cooling fan to body
9
7
Radiator to fan motor
9
7
Thermostat housing cover
9
7
 
Bleed points
 
 
Radiator bleed screw
5
4
Heater bleed screw
7
5
Radiator return line, bleed screw
5
4
Manifold and Exhaust
Catalyst to silencer
70
52
Exhaust manifold to cylinder head
45
33
Exhaust manifold heat sheild
top bolt
bottom bolt

25
10

18
7
Exhaust mountings to body
25
18
Inlet manifold to cylinder head
25
18
Inlet manifold support bracket (VVC)
25
18
Inlet manifold to manifold chamber (VVC)
25
18
Manifold to front pipe
70
52
Silencer clamp, nut
30
22
Silencer clamp to flange studs
70
52
Silencer heat shield
10
7
Silencer RH mounting bracket
10
7
Throttle housing to manifold chamber (VVC)
9
7

Clutch
Master cylinder to pedal box
25
18
Master cylinder pipe union
18
13
Pressure plate to flywheel
25
18
Slave cylinder to mounting bracket
25
18
Slave cylinder pipe union
18
13
Slave cylinder bleed nipple
7
5

PG1 manual gearbox
Drain plug
45
33
Filler plug
35
26
Flywheel closing panel
80
59
Gearlever assembly to body
8
6
Gearbox to engine
80
59
Gearbox to sump
45
33
Selector cable abutment bracket to gearbox
 
 
Lower bracket
45
33
Upper bracket
80
59
Speedo cable to gearbox
19
14

Drive shafts
Drive shaft nut (stake nut)
210
155

Steering
EPAS ECU to bracket
10
7
EPAS ECU bracket to fascia rail
25
18
Ignition lock to steering column
Shear bolts
Pinion cover
8
6
Steering rack clamp
22
16
Steering rack 'U' bolt
22
16
Steering rack to intermediate shaft
22
16
Steering column to intermediate shaft
22
16
Steering column to mounting brackets
22
16
Steering wheel to column
50
37
Track-rod end to steering arm
30
22
Track-rod end lock nut
50
37

Suspension
Front suspension
 
 
Anti-roll bar clamp bracket
22
16
Anti-roll bar link
45
33
Damper upper mounting
37
27
Damper lower mounting
45
33
Hub nut
210
155
Hydragas unit retaining plate
25
18
Hydragas pipe, unions
20
15
Lower arm to subframe
85
63
Lower ball joint nut
45
33
Lower ball joint to lower arm
40
30
Upper arm pivot shaft retaining plate
10
7
Upper arm pivot shaft
74
55
Upper ball joint nut
54
40
Upper ball joint to hub
105
77
 
Rear suspension
 
 
Anti-roll bar bracket to hub
45
33
Anti-roll bar to subframe bracket
13
10
Anti-roll bar to link
35
26
Damper upper mounting
37
27
Damper lower mounting
45
33
Hydragas unit retaining plate
25
18
Hydragas pipe, unions
20
15
Lower arm to hub
100
74
Lower arm to subframe
85
63
Track control arm adjuster
50
37
Track control arm to hub
30
22
Track control arm to subframe
80
59
Tie bar to subframe
45
33
Tie bar to lower arm
80
59
Upper arm pivot shaft retaining plate
10
7
Upper arm pivot shaft
74
55
Upper ball joint nut
54
40
Upper ball joint to hub
105
77
 
Front subframe
 
 
Clamp plate to subframe
26
19
Crush member to subframe
45
33
Front mounting to body
30
22
Front mounting to subframe
100
74
 
Rear subframe
 
 
Clamp plate to subframe
26
19
Front mounting to body
30
22
Front mounting to subframe
100
74
Rear mounting to body
45
33
Rear mounting to subframe
100
74
LH & RH upper longitudinal bolts
45
33
 
Wheel nuts
 
 
Alloy wheel, nuts
70
52
Spare wheel, nuts
70
52

Brakes
ABS ECU to modulator
8
6
ABS ECU to mounting spigot
15
11
ABS hydraulic modulator to bracket
10
7
Master cylinder to servo
20
15
Master cylinder to pipe union
14
10
Pedal box to lower dash
10
7
Pedal box to top G plate
22
16
Pedal mounting bracket to dash
 
 
nut
13
10
bolt
22
16
Pedal cross tube bracket to dash
13
10
Pedal pivot shaft to pedal box
22
16
Proportioning valve to body
10
7
Proportioning valve to pipe union
14
10
Servo to bracket
20
15
Servo bracket to body
20
15
Servo bracket to body bracket
30
22
 
Front brakes
 
 
ABS speed sensor to hub
10
7
Bleed nipple
10
7
Brake pipe unions
14
10
Caliper to hub
85
63
Caliper body to carrier
45
33
Disc to drive flange
7
5
Hose to caliper
36
27
Hose to upper arm bracket
45
33
 
Rear brakes
 
 
ABS speed sensor to hub
10
7
Bleed nipple
10
7
Brake pipe unions
14
10
Caliper to hub
85
63
Caliper body to carrier
45
33
Disc to drive flange
45
33
Hose to caliper
36
27
Hose to upper arm bracket
45
33
 
Handbrake
 
 
Handbrake lever bracket to body
25
18
Handbrake assembly to bracket
25
18
Handbrake adjustment bracket to mounting bracket
25
18
Handbrake cable to luggage bay bulkhead
10
7

Supplementary Restraint System (SRS)
SRS DCU bracket to body
10
7
SRS DCU to bracket
10
7
 
Airbags
 
 
Passenger airbag to fascia bracket
8
6
Drivers airbag to steering wheel
8
6
Airbag control unit to bracket
9
7
 
Seat belts
 
 
Seat belt assemby to body
35
26
Seat belt assembly to seat
30
22
Seat belt pre-tensioner to seat
45
33

Body
'A' post trim
6
4
Crossmember to floorpan
22
16
Header trim
6
4
Headlamp to body
6
4
 
Bonnet
 
 
Bonnet striker plate panel
17
13
Bonnet to hinges
9
7
Bonnet lock plate to body
25
18
Bonnet release lever to bulkhead
9
7
 
Boot
 
 
Bootlid to hinges
9
7
Bootlid striker to body
10
7
Boot latch to boot lid
10
7
 
Bumpers
 
 
Crash can to body
25
18
Front bumper armature to body
25
18
Front bumper valance to armature
25
18
Front bumper to crash can
25
18
Rear bumper armature to body
22
16
Rear bumper valance to armature
25
18
 
Doors
 
 
Door finishers
10
7
 
Hood
 
 
Hood frame to body
45
33
Hood catch to header rail
20
15
Hood strikers
6
4
Hard top front top catch
10
7
 
Seats
 
 
Seat runners
45
33
Squab frame to cushion frame
45
33

Heating and ventilation
Fascia rail support bracket
10
7
Heater mountings
10
7
Intake duct to body
10
7

Air conditioning
Compressor
 
 
Compressor to mounting bracket
45
33
Compressor to pipe union
25
18
 
Condenser
 
 
Mounting bracket to striker plate panel
17
13
Airconditioning pipe to condenser
5
4
 
Evaporator
 
 
Evaporator to heater - clamp
3
2
Evaporator to lower dash panel
9
7
 
Receiver dryer
 
 
Air conditioning pipe to receiver dryer
5
4
 
Thermostatic expansion valve
 
 
Evaporator pipe clamp to expansion valve
5
4
Evaporator pipe, bracket
7
5
 
Wipers and Washers
Wiper arm to spindle
20
15
Motor and linkage assembly to scuttle
10
7
Motor to linkage
12
9
Crank to motor spindle
18
13

Electrical
Alarm ECU
4
3
Alternator to pulley
25
18
Alternator to engine mounting
45
33
Alternator adjustment tensioner
25
18
Ariel locking nut
3
2
Central locking motor to door
5
4
Fuse box to body
10
7
EPAS ECU to mounting
10
7
Horn to valance
10
7
Starter motor securing bolts
80
59
Tail lamp to body
2
1.5

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3 years 2 months ago #180031 by graham1
I hope this lot helps some of you out there,

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