Sunday, June 5, 2011

timing marks for 2 cam pulleys on 2.5 tdci ford ranger?

On the 2.5L 4Cyl there are three of them. One is on the crank shaft pully (for TDC). It is a line, scribed on the pully, that alligns to a pointer on the plastic timing belt cover. The second is on the cam shaft pully. It can be accessed by removing the rubber inspection plug on the timing belt cover. The third is on the auxillary shaft (oil pump) and is also accessed through an inspection plug on the timing belt cover.

On the cam and oil pump pullies, the diamond aligns to the diamond and the triangle aligns to the triangle (the pullies have both). These should be perfectly aligned when the crankshaft pully line is at 0 deg TDC. If you can't see the marks through the inspection port while the crank is at 0 TDC, you are 180 degrees out - turn the crank one more time.



Removal & Installation



2.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2. Remove or disconnect the following:

    Negative battery cable
    Fan and shroud
    Drive belt
    Valve cover

  3. Set No. 1 piston to TDC and install the Camshaft Alignment Plate 303-376, or equivalent.
  4. Remove the plug for the crankshaft timing peg.
  5. Install the Crankshaft Timing Peg 303-507, or equivalent.
  6. Install an M6 bolt into the crankshaft pulley to verify the engine timing.
  7. Remove or disconnect the following:
    NOTE
    This step is needed only if a new front cover is being installed.



    Camshaft pulley
    Crankshaft position sensor
    Belt tensioner
    Water pump pulley
    Power steering high pressure hose. Remove the nylon O-ring.
    Power steering return hose
    Power steering pump

  8. Using a three-jaw puller, remove the fan drive pulley.
    NOTE
    There is one bolt behind the cooling fan drive pulley. This bolt can be accessed by lining up one of the holes in the pulley with the bolt.

  9. Remove the bolts and the engine front cover.
  10. Compress the timing chain tensioner and remove the tensioner.
  11. Remove the right-hand timing chain guide.
  12. Remove the timing chain.
  13. Remove the bolts and the left-hand timing chain guide.
    WARNING
    Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.

  14. If necessary, remove the bolts and the camshaft sprockets. Use the flats on the camshaft to prevent camshaft rotation.

    Click image to see an enlarged view

    Fig. Timing chain tensioner removal; 1-paper clip, 2-bolts-2.5L engine and 2.3



    Click image to see an enlarged view

    Fig. Right side timing chain guide-2.3L engine and 2.5



    Click image to see an enlarged view

    Fig. Timing chain removal-2.3L engine and 2.5



    Click image to see an enlarged view

    Fig. Left timing chain guide-2.3L engine and 2.5



    Click image to see an enlarged view

    Fig. Camshaft alignment plate installed-2.3L engine and 2.5


To install:

  1. Remove the special tool.
    WARNING
    Do not rotate the camshafts. Damage to the valves and pistons can occur.


If the camshaft sprockets were not removed, use the flats on the camshafts to prevent camshaft rotation and loosen the sprocket bolts.

  1. If removed, install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.

    Click image to see an enlarged view

    Fig. Front cover torque sequence-2.3L engine and 2.5

  2. Install or connect the following:

    Left-hand timing chain guide and bolts
    Timing chain
    Right-hand timing chain guide
    Timing chain tensioner and release the piston
    Timing chain tensioner and the bolts

  3. Remove the drill rod to release the piston.
  4. Install the special tool.
    WARNING
    Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshafts can result. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.


    NOTE
    This step is needed only if a new front cover is being installed.

  5. Install the fan drive pulley using a nut and bolt with flat washers.
  6. Clean and inspect the mounting surfaces of the engine and the front cover.
    NOTE
    The engine front cover must be installed and the bolts tightened within four minutes of applying the silicone gasket and sealant.

  7. Apply a 2.5 mm bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm bead of silicone gasket and sealant to the front cover.
  8. Install the front cover. Tighten the bolts in the sequence shown, to the following specifications:

    Step 1: 8 mm bolts to 89 inch lbs. (10 Nm)
    Step 2: 10 mm bolts to 18 ft. lbs. (25 Nm)
    Step 3: 13 mm bolts to 35 ft. lbs. (48 Nm)

  9. Install or connect the following:
    NOTE
    Do not reuse the crankshaft damper bolt.



    Power steering pump and lower retaining bolt
    Power steering return hose
    New nylon O-ring and install the high pressure line.
    Water pump pulley
    Belt tensioner



    Crankshaft pulley and hand-tighten the bolt

  10. Install an M6 bolt in the crankshaft pulley. Tighten the crankshaft retaining bolt in two stages.

    Step 1: 30 ft. lbs. (40 Nm)
    Step 2: Rotate the bolt an additional 90 degrees.

  11. Install the crankshaft position sensor, do not tighten the bolts at this time.
  12. Adjust the crankshaft position sensor with the Alignment Tool, and tighten the mounting bolts.
  13. Connect the crankshaft position sensor electrical connector.
  14. Remove the M6 bolt from the crankshaft pulley.
  15. Remove the Crankshaft Timing Peg 303-507.
  16. Install the plug.
  17. Remove the Camshaft Alignment Plate 303-376.
  18. Install the valve cover.
  19. Install the drive belt.
  20. Install the fan and shroud.
  21. Connect the battery ground cable.


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