Contitech Power Transmission Group explains how to fit a timing belt on a Ford Galaxy 1.9l model; engine code AUY; 2003 model onwards.
When the timing belt is changed, the tensioner pulley, the idler pulley and the water pump should be replaced as well. In the event that the water pump subsequently fails, the entire process must be conducted again with new parts, as Ford has prohibited the re-use of used timing belts in this case. The water pump must therefore be replaced at the same time so as to prevent subsequent failures incurring unnecessary costs.
Preparatory work
RECOMMENDED LABOUR TIME: 2.6 .HOURS TIMING BELT KIT PART NUMBERS: CT1028K3, CT1028WP2 & CT1028WP4. Fitters require the following special tools for this procedure: Camshaft locking tool (VW 3359) 2. Crankshaft locking tool (310-085) Arrester (205-072) 4. Pin type face wrench OE (303-1053) Retaining tool, timing belt tensioner OE (303-1054) The tools can also be found in ContiTech’s Tool Box and Tool Box V01.
Identify the vehicle using the engine code and then disconnect the vehicle’s battery. Do not turn the crankshaft or camshaft when the timing belts have been removed. Turn the engine in the normal direction of rotation (clockwise), unless specified otherwise, making sure you turn the engine only at the crankshaft sprocket and not at other sprockets. You should also comply with all VM recommended tightening torques. Jack up the front of the vehicle and support it so that the front engine mount is unloaded.
For the removal process disconnect the battery earth cable and remove the air filter housing, engine cover, intercooler line and bracket, lower engine cover, power steering line from the engine, assembly belt and assembly belt tensioner, upper and middle timing belt guards, crankshaft belt pulley, lower timing belt guard, and front engine mount (support the engine for this purpose).
Removing the camshaft belt
Set the control times at the TDC marking of cylinder 1. For this purpose, rotate the crank shaft in the direction of travel until the crank shaft marking is just before the 12 o’clock position and the “crown” of the camshaft sprocket is at the top.
Mount the camshaft locking tool (VW 3359) on the camshaft, then insert the crankshaft locking tool (310-085).
The marking on the tool must align with the marking on the sprocket.
Loosen the screw of the tensioner pulley and relax the timing belt/tensioner pulley.
For this relaxation to take place, rotate the eccentric of the tensioner pulley with the pin type face wrench (303-1053) anti-clockwise until the retaining tool (303-1054) can be inserted in the tensioner pulley.
Be warned that the retaining tool sometimes comes loose in the new timing belt kit packaging.
You should also be aware that the retaining tool is required only to relax the timing belt – this is not a fully automated tensioning system!
Using the pin type face wrench (303-1053), relax the eccentric in a clockwise direction; to do so, rotate the eccentric until the stop point and then tighten the nut by hand. The timing belt can now be removed.
Installing the camshaft belt
Loosen the screws on the camshaft sprockets, using the arrester (205-072) for this purpose.
Check the control times in the same way as for the removal and reset them if necessary. Set the loose camshaft sprocket in the centre of the elongated holes. Now install the new components. In doing so you should ensure that for the tensioner pulley, the retaining bracket sits correctly in the fairing gap.
Install the tensioner pulley with tool 303-1054 inserted.
Lay the timing belt in an anti-clockwise direction starting from the camshaft sprocket, then on to the tensioner pulley, crankshaft sprocket and finally the water pump sprocket. You should also make sure that no kinks form on the timing belt during the laying process and the timing belt must be taut between the sprockets on the pull side.
Rotate the tensioner pulley to the left (anticlockwise) with tool 303-1054 inserted until the tool can be removed.
Tighten the timing belt in a clockwise direction with the tensioner pulley and without locating pin (303-1054) inserted until the markings on the tensioner pulley align.
Locate the eccentric of the tensioner pulley with the pin type face wrench (303-1053) and tighten the nuts on the tensioner pulley with torque (20 Nm + 45˚). Remove the locking tools from the camshaft and crankshaft and tighten the screws on the camshafts with torque (25Nm) – you should use the arrester (205-072) to help you do this.
Rotate the engine two turns in the direction of engine rotation and position the engine at top dead centre of cylinder 1. Insert the camshaft and crankshaft locking tools and, if the locking tool can’t be inserted, correct the control times. Check the timing belt tension again and then remove the locking tools and install the components in reverse order of removal.
Install components in the following order: upper timing belt guard (10 Nm), lower timing belt guard (7 Nm), crankshaft belt pulley (10 Nm + 90˚), assembly belt. Tighten the screws on the engine mount (3 x 60 Nm), the screws on the engine bracket (2 x 61 Nm), and the engine mount (1 x 54 Nm).
Record the replacement of the original timing belt on the supplied sticker and affix it in the engine compartment. As a final step, carry out a test run or test drive.
