Ford Unit Injection engines – Galaxy 1.9TDi PD use a constant pressure fuel pump and each of the injectors
are operated directly by the camshaft.
Crankshaft Position
DT.4636 Crankshaft Locking Tool
The crankshaft is turned clockwise to TDC position so that the timing marks align correctly.
The crankshaft gear is the ‘locked’ in this position using DT.4636 Locking Tool. The tool slides into
the gear teeth from the front and locates into the hole in the oil seal housing.
Section 2:
DIESEL ENGINES
Unit Injection
Camshaft Timing
Timing mark alignment for the camshaft.
The notch of the camshaft sprocket hub (located behind the sprocket teeth), should align with mark
on the casting – “4Z”
“4Z”
“4Z”
“4Z”
“4Z” (on rightof sprocket). Lock the camshaft in position by inserting
DT.4440V2
Pin
through elongated hole on the left-hand side of sprocket.
Tensioner Tools
DT.4638 Tensioner Locking Tool
Use a suitable allen key locate onto the tensioner and depress the tensioner until DT.4638 Locking Tool
can be inserted to retain the plunger.
Remove the tensioner device and timing belt together.
DT.3032-3 Camshaft Setting Plate
On ALL Ford 16v. twin cam engines, DT.3032-3 Setting Plate is used to lock the camshafts in the correct
timing position via a slot at the rear of both camshafts.
DT.CLE Sprocket Holding Tool – Associated Tool –not in Kit
When installing a new timing belt on Ford 16v engines, the camshaft sprocket bolts should be released
to allow the sprockets to be ‘free to turn’ on the camshafts. DT.CLE is required to counter-hold the sprockets
whilst releasing and tightening the sprocket bolts. Timing tools MUST NOT
MUST NOT
MUST NOT
MUST NOT
MUST NOT be used for counter-holding.
Crankshaft TDC Position
DT.3032-18
and
DT.3032-19
Crankshaft Location Pins.
The smaller 16valve engines use DT.3032-18 Pin and the 1.8/2.0 16v. use DT3032-19.
The blanking plug is removed to allow the Pin to be screwed into position and then the crankshaft is carefully
turned until the web rests against the Pin. This establishes the TDC position.
- Refer to Application Chart for model usage.
IMPORTANT:
The timing mark ”arrow” on the DT.4636 Locking Tool must align with the mark
on the crank gear. Temporarily remove the plastic knob off the tool to improve visibility.
Section 3:
PETROL ENGINES
Zetec/Duratec 16v. Twin Cams
Camshaft Setting
