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1
Figure
, page 3
• Crankshaft Locking Pin 3888-1
• Position camshaft sprocket timing mark
just before mark on rear cover and remove
blanking plug from engine block. Insert
3888-1 Pin and turn crankshaft slowly
clockwise so that Pin enters 'slot' in the
crankshaft web. Check timing marks align
correctly. Fit new timing belt.
8
Figure
, page 4
• Tensioner Adjustment Tools
3888-5 and 3888-7/5
• 3888-7/5 is a 5 x piece tool used to apply a
pre-tensioning torque to a newly fitted belt.
It comprises a main lever arm (-71) and the
range of adaptors (-72 to –75). Selection of
the appropriate adaptor allows the main
lever arm to be attached to auxiliary shaft or
crankshaft to provide a pivot point.
NOTE:
If the engine has an auxiliary shaft
then 3888-7/5 must use this point,
not the crankshaft. If no auxiliary
shaft, then attach to the crankshaft.
• Spacer 3888-73 is fitted to the crankshaft
end (use the existing crank pulley bolt),
to 'lock' the crankshaft gear in position for
turning the crankshaft.
• Screw Adjusting Bolt 3888-5 through the
tensioner bracket until the tensioner roller
contacts the belt.
• Remove Crank Locking Pin 3888-1.
• Assemble appropriate Adaptor 3888-72 or
–74 or –75 onto the Arm 3888-71 and slide
it over the auxiliary shaft or over the Spacer
3888-73 previously installed on the end of
the crankshaft.
• Using a torque wrench apply a clockwise
(pre-tensioning) torque of 11 Nm and
remove tool. (Observe vehicle manu-
facturer's torque prescriptions)
• Fit a suitable belt tension gauge to the belt
and screw in the Bolt 3888-5 until specified
reading is obtained.
• Rotate the crankshaft two turns and return
to TDC. (Check position by inserting Pin
3888-1 but do not leave Pin in crankshaft)
• Ensure all timing marks align and check belt
tension readings are as specified.
experienced mechanics. Always wear personal protective equipment.
26
Composition and Function
Maintenance work on engines must be carried out only by
NOTE:
Belt tensioning procedures are
critical and the manufacturer's
procedure must be followed.
2.2 and 2.5 dCi Engines – G9T/G9U
➪ For model usage / engine codes
refer to Application Chart, pages 6-8.
• Timing belt replacement on 2.2/2.5dCi
engines requires the use of Crankshaft
Locking Pin 3888-8 and Camshaft Setting
Plates 3888-9 / 3888-10.
9
Figure
, page 4
• Crankshaft Locking Pin 3888-8
• The oil filter housing bolt is removed to
give an entry hole for Pin 3888-8 to the
crankshaft.
• Slowly turn the crankshaft clockwise until
the Pin fully enters. Turn crankshaft slightly
forward and back to ensure the Pin is
located. The crank pulley mark should be
in the bottom position and No.1 cylinder at
TDC on ignition stroke.
0
Figure
, page 4
NOTE:
Check that camshafts are correctly
aligned– flat surfaces on the ends
of camshafts must be vertical and
the grooves in the camshafts must be on the
left-hand side.
GB
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