E2/70503

E2/70503

All technical bulletins are available at If you wish to receive Gates Technical Bulletins by e-mail, please send contact details to technicalbulletins@gates.com

Avoid costly mistakes thanks to Gates Technical Bulletins www.gates.com Whether you re a garage mechanic, an automotive engineer, a dealer or a car manufacturer, you are undoubtedly confronted with the increasing technological complexity of modern-day engines. Vehicles have evolved in such a way that many issues have to be dealt with during maintenance. Experience has shown that certain problems occur with the same engines, problems that can easily be avoided with the right technical information. That s why Gates regularly issues Technical Bulletins holding the correct information to solve these problem cases. All technical bulletins are available at 1

In order of Technical Bulletin Technical Bulletin Subject Page 1 Installation recommendations for timing system on GM 1.4, 1.6, 1.8, 2.0, 2.2 16V engines 5 2 VAG 1.9 Diesel - Timing belts 5543XS and 5559XS 9 3 Ford Transit 2.5 Diesel, Turbo Diesel Timing Belts/Kits 11 4 K025433XS for Ford 1.2, 1.4 and 1.6 engines 13 5 K015571XS/K015572XS for Ford Transit 2.5D 15 6 Micro-V XF belts - PJ profile 17 7 5223XS/5622XS and kits 19 8 K035040/K045040 for Renault/Jeep 2.1D, TD 21 9 Replaced by Technical Bulletin 25 23 10 Timing Belt System replacement on VAG 1.8 20V engines (PowerGrip Belt and Kits 5492XS) 25 11 Hydraulic Tensioners 29 12 Installation of tensioner used in PowerGrip Kits K015543XS, K025543XS and K015559XS 33 13 Accessory drive on Renault 1.5 DCi engines 39 14 PowerGrip Kit K015432XS for Fiat and Lancia 1.6 petrol engines 41 15 Fiat group 1.9 JTD engines 45 16 PowerGrip Kit K015541XS for Ford 1.8 diesel engines - Replaced by Technical Bulletin 27 47 17 Volvo S40/V40 models with 1.9 diesel engine 49 18 5 and 6PK Micro-V XF belts on Renault engines 53 19 Selecting timing belts/kits for the Renault 1.9D engine 55 20 VAG Timing System Replacement Intervals 57 21 Additional tension values for STT-1 59 22 Tensioning issues on Chevrolet/Daewoo 16V petrol engines 61 23 K02/K035468XS for PSA 1.8 and 2.0 16V engines 67 24 Tension setting procedure for PSA 2.0 HDI engines 69 25 Timing belt/kit installation on GM (Isuzu) 1.7D engines 71 26 SOFIM 2.4 / 2.5 / 2.8 Diesel engines 77 2

In order of make Make Model Page Alfa Romeo 147, 156, GT 45 Audi A3 9 & 33 Multiple models 17 80, A4, Cabrio 19 A4, A6, Cabrio 25 All models 57 Various models with 2.6 / 2.8 V6 engines 59 BMW Various models with BMW 2.4 D / TD engines 59 Chevrolet Aranos, Assol, Aveo, Cielo, Espero, Kalos, Lacetti, Lanos, Nexia, Nubira, Rezzo, Tacuma 61 Astra, Combo, Corsa, Meriva, Zafira 71 Citroën Evasion, Synergie, Xantia, XM, Xsara, ZX 67 Various models with 2.0 HDI, 2.0 JTD engines 69 Daewoo Aranos, Assol, Aveo, Cielo, Espero, Kalos, Lacetti, Lanos, Nexia, Nubira, Rezzo, Tacuma 61 Fiat Albea, Brava, Bravo, Doblò, Marea, Multipla, Palio, Siena, Stilo 41 Marea, Marengo, Multipla 45 Ulysse 67 Various models with 2.0 HDI, 2.0 JTD engines 69 Various models with 2.4 / 2.5 / 2.8 / D, TD, DTi, DTic, Dci, JTD, HDi engines (all 8 valves) 77 Ford Tourneo, Transit 11 & 15 Fiesta, Focus, Fusion, Puma 13 Various models 29 Courier, Fiesta, Focus, Tourneo, Transit 47 Iveco Various models with 2.4 / 2.5 / 2.8 / D, TD, DTi, DTic, Dci, JTD, HDi engines (all 8 valves) 77 Jeep Cherokee, Comanche 21 Lancia Delta, Lybra 41 Lybra 45 Various models with 2.0 HDI, 2.0 JTD engines 69 Mazda 121 13 Mercedes Various models 17 Mitsubishi Various models with Renault 1.9 Diesel motor 55 Opel Various models 29 Various models with 2.4 / 2.5 / 2.8 / D, TD, DTi, DTic, Dci, JTD, HDi engines (all 8 valves) 77 Opel / Vauxhall Astra, Calibra, Combo, Corsa, Cavalier, Frontera, Kadett, Meriva, Omega, Signum, Sintra, Tigra, Vectra, Zafira 5 & 23 Various models with Renault 1.9 Diesel engine 55 Astra, Combo, Corsa, Meriva, Tour, Zafira 71 Peugeot 306, 406, 605, 806 67 Various models with 2.0 HDI, 2.0 JTD engines 69 PSA Various models with 2.4 / 2.5 / 2.8 / D, TD, DTi, DTic, Dci, JTD, HDi engines (all 8 valves) 77 Renault 18, 20, 21, 25, 30, Espace, Fuego, Master, Trafic 21 Clio II, Express, Kangoo, Rapid, Symbol 39 Clio, Kangoo, Laguna, Logan, Megane, Modus, Scenic, Thalia 53 Various models with Renault 1.9 Diesel engine 55 Various models with 2.4 / 2.5 / 2.8 / D, TD, DTi, DTic, Dci, JTD, HDi engines (all 8 valves) 77 Seat Cordoba, Ibiza, Inca, Leon, Toledo 9 Verschillende modellen 17 Alhambra, Cordoba, Ibiza, Inca, Toledo 19 Cordoba, Ibiza, Inca, Leon, Toledo 33 All models 57 Skoda Fabia, Octavia 9 Octavia 33 All models 57 Suzuki Various models with 2.0 HDI, 2.0 JTD engines 69 Volkswagen Bora, Caddy, Golf, New Beetle, Polo 9 Various models 17 & 29 Caddy, Campmobile, Caravelle, Golf, Passat, Polo, Sharan, Transporter, Vento 19 Passat 25 Bora, Caddy, Golf, New Beetle, Polo 33 All models 57 Volkswagen Groep Various models 29 Volvo S40, V40 49 Various models with Renault 1.9 Diesel engine 55 3

4

Installation recommendations for timing system on GM 1.4, 1.6, 1.8, 2.0, 2.2 16V engines # 001 28/02/2005 GATES REFERENCE : MAKE : MODEL : MOTOR : MOTOR CODE : 5368XS, 5369XS, 5408XS, 5461XS, 5499XS, 5542XS OPEL / VAUXHALL Astra, Calibra, Combo, Corsa, Cavalier, Frontera, Kadett, Meriva, Omega, Signum, Sintra, Tigra, Vectra, Zafira 1.4, 1.6, 1.8, 2.0, 2.2 16V C14SEL, X14XE, C16SEL, C16XE, X16XE, X16XEL, Y16XE, Z16XE, C18XE, X18XE, X18XEL, Z18XE, Z18XEL, X20XEV, X22SE, X22XE, Y22SE, Y22XE, Z22XE IMPORTANT: Only install belt and tensioner when engine is at room temperature. Only rotate engine CLOCKWISE!!! Never re-install a used belt (tensioners are developed for new belts!!!). The USED position on the base plate is where the pointer will move towards during the life of the belt. Camshaft- and crankshaft sprockets should not rotate unless the belt is installed and tensioned. 1. Align Top Dead Centre (TDC) marks. As the same engine used in a different model can have a different belt, we give the TDC marks following belt number here, and not following engine code. 5369XS/5499XS: crankshaft: 5 O clock, L-cam: 3 O clock, R-cam: 9 O clock 5368XS/5408XS/5461XS/5542XS: crankshaft: 6 O clock, camshafts 12 O clock. 2. Block camshafts 3. Loosen tensioner bolt 4. Turn tensioner clockwise and remove belt 5. Remove old tensioner 6. Install new tensioner, hand tighten bolt. Tensioner lip has to be in oil pump housing slot. (Tensioner pointer has to sit behind water pump pulley). The Allen keyhole has to be set in +/- 7 O-clock position (fig. 1). 7. Install new belt anticlockwise starting at crankshaft Fig. 1 5

8. Turn tensioner (with Allen key) anti-clockwise (while holding the bolt in place) till pointer is in line with (not passing) right hand side of base plate (fig. 2) 9. Tighten tensioner bolt (+/- 20 Nm) 10. Unblock camshaft 11. Turn engine (manually) 2 revolutions via crankshaft (this for proper seating of the Fig. 2 belt teeth in the grooves; and to distribute the tension), till TDC marks align again. If not aligned, restart at step 1. 12.If pointer not in line with V ( NEW position), bloc camshafts again 13. Loosen tensioner bolt 14.Adjust tensioner (while holding the tensioner bolt in place), till pointer in line with V ( NEW position); the Allen key hole has to be in +/- 5 O-clock position now (fig. 3) 15. Tighten tensioner bolt (+/- 20 Nm) 16. Unblock camshafts 17.Turn engine 2 revolutions (via crankshaft), till TDC marks align again 18. Check tensioner pointer position. If correct (in V) Fig. 3 install other removed parts. If not correct, do repeat steps 13 to 18, till pointer aligns with V. ATTENTION!!! Rotating the tensioner in the wrong direction, having the Allen keyhole in a wrong position to start off, not turning the engine 2 revolutions before and after setting the tension, can lead to system failure. This will cause the arm of the tensioner to hit the stop, creating a hammering noise, damaging and possibly even rupturing that part. This failure mode is very common and can easily be recognised when inspecting the edge of the arm (fig. 4). The resulting wrong tension can cause the belt to rupture. 6

arm Fig. 4 7

8

VAG 1.9 Diesel Timing belts 5543XS and 5559XS # 002 25/03/2005 GATES REFERENCE : MAKE : MODEL : MOTOR : MOTOR CODE : 5543XS and 5559XS AUDI / SEAT / SKODA / VOLKSWAGEN A3, Bora, Caddy, Cordoba, Fabia, Golf, Ibiza, Inca, Leon, New Beetle, Octavia, Polo, Toledo 1.9 SDi / TDi AYQ, AGP, AQM, AGR, ASY, ASV, ALH, AHF Both belts 5543XS and 5559XS are recommended for the same engine types (AYQ, AGP, AQM, AGR, ASY, ASV, ALH, AHF) and also have the same dimensions (141 teeth x 25 mm wide). The breakpoint given in our catalogues is an engine number. Engines before the breakpoint use 5543XS, those after the breakpoint use 5559XS. A lot of customers have problems finding this engine number (which usually can be found on a sticker on the top timing belt cover, and/or on the engine block near the oil filter), and ask what the difference is between these two belts, and whether they can use one belt instead of the other. The difference lies in the construction of the belts: the 5559XS is stronger than the 5543XS, because the injection pump used after the breakpoint is of a higher performance type, putting more load on the belt. Up to the breakpoint some engines can be equipped with a plastic tensioner pulley; others have a metal tensioner pulley. After the breakpoint all engines have a metal tensioner pulley. When no engine number is available, one can use our belt 5559XS instead of the 5543XS, but ONLY when one is certain the tensioner pulley is metallic, and not plastic! The combination of our belt 5559XS and a plastic tensioner pulley would lead to severe premature tensioner pulley wear. Conclusion: - If metal tensioner pulleys are mounted and in case the engine number is not known, 5559XS can be used instead of 5543XS. - Never replace belt 5559XS by 5543XS! 9

10

Ford Transit 2.5 Diesel, Turbo Diesel Timing Belts/Kits # 003 29/04/2005 GATES REFERENCE : MAKE : MODEL : MOTOR : MOTOR CODE : 5571XS and 5572XS FORD Tourneo, Transit 2.5 D / TD 4BC, 4CC, 4DA, 4EA, 4EB, 4EC, 4FA, 4FD, 4GA, 4GC, 4GD, 4HA, S1 As stated in Field Bulletin N. 63, our former belts 5338XS, 5502XS and the kit K015338XS are replaced by belts 5571XS, 5572XS and their kits K015571XS, K015572XS. Although the new belts 5571XS and 5572XS use a black coated fabric, they are an equivalent of the white coated fabric OES belts. The new belts can only be used together with an automatic tensioner, this is why Gates only developed a kit with automatic tensioner. Old Gates belts still on stock can be used on the new automatic tensioner, as well as on the old manual tensioner. It seems some sources still list the manual tensioner for the turbo diesel. Even though the Turbo Diesel engine version is a less severe application for the timing belt, there is no technical reason for not fitting the automatic tensioner. The Ford workshop now installs the automatic tensioner on both the diesel and the turbo diesel versions. The new automatic tensioner/bolt can simply be installed in place of the old manual tensioner/bolt. 11

12

K025433XS for Ford 1.2, 1.4 and 1.6 engines # 004 27/06/2005 GATES REFERENCE : MAKE : MODEL : MOTOR : MOTOR CODE : K025433XS FORD / MAZDA Fiesta, Focus, Fusion, Puma, 121 1.2, 1.4, 1.6 ZH12FUJA, ZH12FUJB ; ZH14ASDA, ZH14FXDB, ZH14FXDC, ZH14FXDD, ZH14FXJA, ZH14FXJB, ZH14EFI ; ZH16HWDA, ZH16HXDA, ZH16FYDA, ZH16FYDB, ZH16FYDC, ZH16FYDD, ZH16SE ; 1E05 Over the last years the tensioner for the synchronous drive on Fiesta, Focus, Fusion, Puma and Mazda 121 with engines 1.2, 1.4 and 1.6 has changed a few times: - different pulley diameter: 60 and 62 mm - different appearance: with and without oblong hole Now, Ford OEM and OES have replaced these tensioners by a new version (ø 62 mm, OE nr 1361840/4M5G6K254DB, Fig. 2). As Gates is following the OE market, this new tensioner is now, since a few months, also included in our K025433XS, instead of the former type (Fig.1). Oblong hole adjustment Retaining pin Fig. 1 Fig. 2 The new tensioner can replace all former types without problem. It is easier to install and avoids incorrect tensioning, as the back plate cannot be adjusted. Install the new tensioner using the removed bolts (20 Nm), install the new belt 5433XS, pull the retaining pin out. No other manipulating is needed, as the spring-loaded pulley will tension the belt correctly. 13

14

K015571XS/K015572XS for Ford Transit 2.5 D # 005 11/08/2005 GATES REFERENCE : MAKE : MODEL : MOTOR : MOTOR CODE : K015571XS / K015572XS FORD Tourneo, Transit 2.5 D / TD 4BC, 4CC, 4DA, 4EA, 4EB, 4EC, 4FA, 4FD, 4GA, 4GC, 4GD, 4HA, S1 These kits contain an automatic tensioner and its specific bolt, which can be installed as replacement of a manual or an automatic tensioner. Although some sources still list the manual tensioner for the Turbo Diesel version, the Ford workshop installs the new kits (with automatic tensioner) on both Diesel and Turbo Diesel engines. Please note that belts 5571XS and 5572XS should only be used in combination with the automatic tensioner (See Technical Bulletin # 003 of 29/04/05). The automatic tensioner can be mounted in place of the old (manual) tensioner, without any modifications or special tools. Since some mechanics were unclear with the exact installation, we would like to explain the correct procedure. Please see attached. Ford Transit 2.5 D K015571XS/K015572XS installation instruction. IMPORTANT: Only install belt and tensioner when engine is at room temperature. Only rotate engine CLOCKWISE!!! 1 Bring engine to TDC (Top Dead Centre) 2 Block flywheel (13 mm pin), camshaft and injection pump 3 Slacken bolts of injection pump pulley 4 Remove belt and tensioner 5 Install new (automatic) tensioner with new bolt hand tight (Allen key hole at +/- 9.00 o-clock) (Fig. 1) 6 Turn tensioner clockwise (with Allen key) until the checkmark is positioned just above lower edge of cut-out part (Fig 2). 15

Allen key hole Fig. 1 Fig. 2 Checkmark 7 Lock tensioner bolt (40-45 Nm) 8 Lock injection pump pulley bolts (25 Nm) 9 Remove blocking pins 10 Rotate engine 2 revolutions, check if tensioner mark is still just above lower edge of cut-out part (Fig 2). If not OK, restart procedure. 16

Micro-V XF belts PJ profile # 006 07/11/2005 GATES REFERENCE : MAKE : MODEL : MOTOR : MOTOR CODE :: Micro-V XF belts PJ profile AUDI / SEAT / VOLKSWAGEN / MERCEDES MULTIPLE For many years the PJ profile was only used for industrial applications, especially in the white goods sector, as drive belts for washing machines and tumble dryers. More recently, these small Micro-V belts were introduced in the automotive industry, where the main applications are ventilator (fan) drives. Usually the basic engine configuration only has 1 fan, which is electrically driven (system installed on radiator) (Fig. 1). Fig. 1: Electrically driven fan Fig. 2: PJ belt In case additional cooling is needed (cars with air conditioning, with a factory installed tow bar, for taxis, etc), a second fan is installed, in order to pull more cooling air through the radiator. This second fan is then often driven from the first by a 2 or 3 rib PJ belt. Up to now only VAG and Mercedes are using this kind of belt. The main difference between a PK and a PJ belt is the size of the rib profile: a PJ profile is quite a bit smaller than a PK profile, the rib width only being 2.34 mm compared to 3.56 mm, while the height is 3.6 mm compared to 4.45 mm. 17

It is clear that a PJ belt cannot function under the same loads as a PK belt. But that is not required on these applications. A compact drive is what is needed in the restricted front-end compartment. Apart from the normal wear, replacement is mainly needed after the bearing of one of the fans has failed, or after an accident (fans are very close to the front of the car). On installation, belts have to be pulled over the second fan pulley by force, as there is no adjustment on the drive. For the different sizes available in our Micro-V XF programme, and for an overview of their applications, please see attached file. More detailed application information can be found in our catalogues, and full logistics data are available from the AR Partner s website. 18

5223XS/5622XS and kits #007 27/11/2005 GATES REFERENCE : MAKE : MODEL : MOTOR : MOTOR CODE : 5223XS / 5622XS and kits AUDI / SEAT / VOLKSWAGEN 80, A4, Alhambra, Cabrio, Caddy, Campmobile, Caravelle, Cordoba, Ibiza, Inca, Toledo, Golf, Passat, Polo, Sharan, Transporter, Vento 1.7, 1.9 D / TD / SDi / TDi 1X, 1Y, 1Z, AAZ, ABL, AEY, AFF, AFN, AHB, AHH, AHU, AKW, ALE, AVG Due to our drive to follow the OE market, we have introduced a new PowerGrip Timing Belt and corresponding kits for certain VAG 1.9 diesel engines: 5622XS, K015622XS, K025622XS. Over the past years VAG made many changes on belt OE ref./constructions in combination with different tensioner OE: * OE 028109119D/H/J/K/M all changed to 028109119P. Our equivalent is 5223XS. * The new belt 5622XS is size wise the same as our well known 5223XS belt, but is made as an equivalent of the OE ref 028109119S which was replaced by 028109119AA. Gates equivalent is 5622XS. Although there is not a real logical line, on OE level, where the old OE ref (5223XS) and where the new part (5622XS) are to be used, we have adapted our application data to the OES recommendations. The attached file for belts and kits reflects the updated status and overrules our 2005/2 catalogue. It also overrules the TecDoc info due January with CD-ROM 01/2006 for Ford Galaxy and Seat Alhambra Van. The new belt has a higher wear resistance compared to 5223XS and was designed for the more recent applications. Therefore installing the 5223XS where the 5622XS is recommended, could cause problems. An updated OE/competitive cross list is also included in attached file (tab sheet cross-ref. 19

20

K035040/K045040 for Renault/Jeep 2.1D, TD # 008 28/12/2005 GATES REFERENCE : MAKE : MODEL : MOTOR : MOTOR CODE : K035040 / K045040 JEEP / RENAULT Cherokee, Comanche / 18, 20, 21, 25, 30, Espace, Fuego, Master, Trafic 2.1 D / TD 52710, 852702, 852750, B210, J8S02, J8S240, J8S330, J8S610, J8S612, J8S620, J8S622, J8S704, J8S706, J8S708, J8S710, J8S711, J8S712, J8S714, J8S736, J8S740, J8S742, J8S750, J8S758, J8S772, J8S776, J8S782, J8S784, J8S786, J8S788 Our kits K015040/K025040 are no longer available, and have been replaced by K035040/K045040. (see Field Bulletin N 73 of April 2005) Doing so, we followed what happened on OES level: the old tensioner (OE ref. 7700722452 - Fig. 1) is no longer available and has been replaced by a new one (OE ref. 7700871169 - Fig. 2). Fig. 1 OE ref. 7700722452 Fig. 2 OE ref.7700871169 Fig. 3 The new tensioner exists out of 2 parts (Fig. 3), which have to be put together as shown in Fig. 2. 21

The new system is better than the old one, which was spring loaded. Often the spring got blocked and did not push hard enough against the bushing which activates the base plate of the tensioner. As there is a big visual difference between the old and the new tensioner, some mechanics are not sure how to mount the new part. Correct installation is possible using the following procedure: * remove the old tensioner * remove the old bushing and spring, these are not needed anymore * install the new tensioner with the same bolts as the old one * push the new tensioner against the new belt till properly tensioned, (e.g. using circlips pliers if original tool is not available) * lock tensioner bolts * rotate engine 2 revolutions * check belt tension with STT-1 * if not OK, adjust, rotate 2 revolutions and check again. Applications for both kits are the same (see attached file), there is only a difference in the composition: K035040: belt 7700663544, tensioner 7700871169 Equivalent to OES kit 7701468162 K045040: belt 7700663544, tensioner 7700871169, idler 7700721690 For complete system overhaul 22

PowerGrip Kit K015563XS # 009 29/12/2005 GATES REFERENCE : MAKE : MODEL : MOTOR : MOTOR CODE : PowerGrip Kit K015563XS OPEL / VAUXHALL Astra, Combo, Corsa, Meriva 1.7 Di / DTi (ISUZU) / CDTi Y17DT, Y17DTL, Z17DTH! Technical bulletin 009 is replaced with Technical bulletin 25! 23

24

Timing Belt System replacement on VAG 1.8 20V engines (PowerGrip Belt and Kits 5492XS) # 010 24/02/2006 GATES REFERENCE : MAKE : MODEL : MOTOR : MOTOR CODE : PowerGrip and kit 5492XS AUDI / VOLKSWAGEN A4, A6, Cabrio, Passat 1.8, 1.8 20v T AEB, ADR, AFY, AJL, ANB, ARG, ARK, APT, APU, AVV History Originally the VAG 1.8 20V engines were equipped with OE belt 058109119A/058109119D (5425XS - 152 teeth), tensioner pulley 058109243B and a thermal compensating actuator (1) 058109479 (old system). After durability problems it was decided to reengineer the synchronous system and to use an OE belt 058109119B/058109119C (5492XS - 153 teeth) together with a hydraulic actuator (2) 058109479B and a new tensioner pulley 058109243E (new system Fig. 1). Together with the small idler, this makes up our K025492XS and covers 95% of the applications. New In order to cover the other 5% and to better serve our customers, we decided to take a new kit into our range. The content of this kit looks the same as K025492XS, but is different in reality. The difference lies in the tensioner pulley. Further explanation is given below. Note: The old system is no longer available on OES level. It is strongly recommended to replace the entire system with the new system (Fig. 1) when the original timing belt needs replacement. Please make sure that parts of the old and new system are not being interchanged in order to avoid engine damage. (1) Uses a wax element to compensate for different thermal expansion of engine and belt (2) Uses oil as damping fluid 25

(A) Tensioner 058109243D or 058109243E (B) Hydraulic Actuator 058109479B (C) Idler 058109244 Fig. 1 new system Tensioner pulley differences Please note there is a small but very important visual difference between the 2 tensioner pulleys! At first sight tensioner pulley 058109243D (fig. 3) used in K03/K045492XS and 058109243E (fig. 2) used in K01/K025492XS are identical. The difference between the two is the thickness of the washer on the backside of the tensioner pulley. This defines the distance to the engine. washer 6mm thick washer 3mm thick Fig. 2 OE 058109243E Fig. 3 OE 058109243D Interchanging these two parts leads to misalignment and belt failure. In case of doubt, always check if the tensioner pulley that is being replaced has the same washer thickness as the replacement part. 26

Composition and applications OES Kit 058198479 - K025492XS OE ref. 058198479 K025492XS K015492XS Belt 058109119C included included Tensioner (A) 058109243E included included Hydr. actuator (B) 058109479B included not included Idler (C) 058109244 (not in OE kit) included included If the car is still equipped with the old system, only the complete kit K025492XS can be used. K015492XS is a light version without the hydraulic actuator and is a less expensive alternative, as some competitors offer. Gates recommends to use the complete kit K025492XS. Make Model CC Engine code From Till Chassis number AUDI A4 1.8 AFY 7/95 9/00 8D-T-155001 ı AUDI A4 1.8 ADR/AEB 10/94 7/99 8D-T-155001 ı AUDI A4 1.8 AJL/ANB/APT/ 8/97 9/00 APU/ARG/ARK/ AVV AUDI A4 Quattro 1.8 AFY 8/97 9/00 AUDI A4 Quattro 1.8 ADR/AEB 11/94 7/99 8D-T-155001 ı AUDI A4 Quattro 1.8 AJL/ANB/APT/ 8/97 9/00 APU/ARG/ARK AUDI A6 1.8 AEB/AJL/ANB/ 5/97 5/01 APU/ARK AUDI A6 1.8 AFY 5/97 5/00 AUDI A6 1.8 ADR 8/95 1/98 AUDI A6 Quattro 1.8 AEB/AJL/ANB/ 5/97 5/01 APU/ARK AUDI A6 Quattro 1.8 ADR 8/96 4/97 AUDI Cabriolet 1.8 ADR 4/97 8/00 VW Passat 1.8 AEB 11/96 12/98 VW Passat 1.8 AFY/ANB/APU 11/96 8/00 VW Passat 1.8 ADR/APT/ARG 11/96 8/00 VW Passat Estate/Variant 1.8 AEB 5/97 12/98 VW Passat 1.8 AFY 5/97 8/00 Estate/Variant VW Passat Estate/Variant 1.8 ADR 5/97 8/00 27

OES Kit 058198479A - K045492XS OE ref. 058198479A K045492XS K035492XS Belt 058109119C included included Tensioner (A) 058109243D included included Hydr. actuator (B) 058109479B included not included Idler (C) 058109244 (not in OE kit) included included If the car is still equipped with the old system, only the complete kit K045492XS can be used. K035492XS is a light version without the hydraulic actuator and is a less expensive alternative, as some competitors offer. Gates recommends to use the complete kit K045492XS. K03/K045492XS will be added to our range within the next 3 months. Make Model CC Engine code From Till Chassis number AUDI A4 1.8 AFY 7/1995 9/2000 8D-T-155000 AUDI A4 1.8 ADR/AEB 10/1994 7/1999 8D-T-155000 AUDI A4 Quattro 1.8 ADR/AEB 11/1994 7/1999 8D-T-155000 How to read and decode the chassis number of the VAG group? The chassis number in the car has 17 positions: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 w v w z z z 1 d x y u 0 0 0 0 0 1 In our catalogue only the last 11 positions are mentioned: 7 8 9 10 11 12 13 14 15 16 17 1 d - y - 0 0 0 0 0 1 (position 9 and 11 become -) y indicates the model year 2000 1996 = t 2000 = y 1997 = v 2001 = 1 1998 = w 2002 = 2 1999 = x etc 28

Hydraulic Tensioners # 011 31/03/2006 GATES REFERENCE : MAKE : MODEL : MOTOR : MOTOR CODE : Hydraulic Tensioners FORD / OPEL / VOLKSWAGEN GROUP MULTIPLE Introduction Belt drive systems for both timing and accessory drive can have different tensioning systems. In the past, engines used a manual tensioner (or eccentric pulley) for the drives, which had to be installed and then locked in place. Over time, the belt tension would change as there is no adjustment of the tensioner, after the initial installation. Nowadays, and for many years already, automatic tensioners are being used to control belt tension and dynamic behaviour of the drive system. An automatic tensioner optimises the belt tension in function of the change in the belt and engine characteristics. Engineers have designed 2 main systems to ensure optimal belt tension at all times. The first one is the traditional and most commonly used design, where a springloaded mechanical tensioner (Fig. 1) controls the belt tension. The second system, less popular and more expensive, consists of a hydraulic tensioner set-up (Fig. 2). In this technical bulletin, we will concentrate on that last system and we will highlight some key points in the functioning and installation of the hydraulic tensioning method for both timing and accessory belt drives. What is it? The hydraulic system is mainly used on applications with high loads and/or angular vibrations, where a mechanical automatic tensioner can not provide sufficient damping or tensioner movement. In general, the hydraulic tensioner units need more engine space. A hydraulic tensioner system consists of an hydraulic actuator in combination with a tensioner pulley (Fig. 2). The movement of the piston rod of the actuator is transmitted to the tensioner pulley via an integrated or separate lever. 29

Fig. 1 Fig. 2 Lever Tensioner Pulley Hydraulic Actuator How does it work? The hydraulic actuator works like a shock absorber, where a spring in combination with the damping feature of the oil, will keep the wheel in contact with the road. In this case, the hydraulic actuator controls the dynamic belt forces, while it also maintains a +/- constant belt tension, and compensates for length changes due to thermal expansion etc. A hydraulic actuator typically consists of the following parts (Fig. 3) : an aluminium housing (cylinder), the piston rod, the piston, the oil, the air, the spring, the one way valve, and the retaining pin. The piston rod can move easily in one direction (piston rod moving outward) due to the oil flowing from one side of the piston to the other, via the one way valve. High dynamic belt loads are controlled by the hydraulic damping, which is created as the oil is forced to flow between the piston and the cylinder, when the piston rod is forced to move inwards. The damping is optimised for each application and is dependent on the gap between the piston and the cylinder, and the viscosity of the oil. 30

Piston Rod Retaining pin Cylinder Air Oil Spring Piston One way valve Fig. 3 Storage Hydraulic actuators should be stored upright (visible part of the piston rod to the top) to prevent leakage and to avoid oil mixing with the air. Air bubbles in the oil could lead to a non-damping situation, which can result in tooth jump or tooth shear (in case of timing belt drives). Please note that all our PowerGrip Kits containing these hydraulic actuators have a this side up arrow on the packaging. Installation The retaining pin should only be removed after the installation of all components : new belt, pulley, (lever), hydraulic actuator. The reason for this guideline is that, once installed, the hydraulic actuator is in a vertical position and there is no risk of mixing air into the oil. Obviously, the installer should always refer to the OE recommendations when doing belt system replacement. If the pin is accidentally removed, in horizontal or inverted tensioner position, it is STRONGLY recommended to compress the piston rod gently while in the upright position and then install the part. The engine should be rotated a few revolutions by hand, in order to separate oil and air again before engine start up. 31

Advantages Because the hydraulic tensioner can operate with a larger range of dynamic belt lengths than a mechanical tensioner and due to the length of stroke of the actuator and the lever design, the hydraulic tensioner system is particularly suitable for large V6/V8 engines (amongst others). The high, unidirectional damping characteristics make it suitable for controlling the dynamic belt behaviour on applications with high dynamic loads. Why replace? Apart from the normal bearing wear on the tensioner pulley, also the actuator can start showing indications of wear. After a period of time, oil leaks can occur due to a leaking seal which can suffer from any kind of contamination. Even the smallest leak in the actuator can have incorrect damping as result. Also, as a result of the constant movement parts will wear out (normal wear), possibly resulting in a complete system failure. Applications In Europe, mainly Audi/VW vehicles are using this type of tensioner. Hydraulic Tensioners can be found in the following kits: K015491XS : VAG 1.8 1996 -> K045520XS : Audi A6 2.5 Tdi 1999-2004 K025491XS : VAG 1.8 1996 -> K025557XS : VAG 2.5 Tdi 1998 -> K025492XS : VAG 1.8 1994-2000 K025569XS : VAG 1.9 Tdi 1998 -> K015493XS : Audi 2.8 1995-2001 K045569XS : Galaxy/Sharan 1.9 Tdi 1999 -> K025493XS : VAG 2.4/2.7/2.8 1996 -> K025601XS : VAG 1.2 Tdi 1999-2005 K025520XS : VAG 2.5 Tdi 1997-2003 K016PK1803 : Opel Vectra 2.0 DTI 1996-2003 K016PK1903 : Opel Vectra 2.0 DTI 1996-2003 Please consult our catalogues for more detailed application information. 32

Installation of tensioner used in PowerGrip Kits K015543XS, K025543XS and K015559XS # 012 31/03/2006 GATES REFERENCE : MAKE : MODEL : MOTOR : MOTOR CODE : K015543XS, K025543XS and K015559XS AUDI / SEAT / SKODA / VOLKSWAGEN A3, Cordoba, Ibiza, Inca, Leon, Toledo, Octavia, Bora, Caddy, Golf, New Beetle, Polo 1.9 SDi / TDi AGP, AGR, AHF, ALH, AQM, ASV, ASY, AYQ Introduction Through our experience with product claims in the field we have learned that many failures associated with these kits are due to wrong installation of the tensioner. Product specification The tensioner (Gates ref. T43062) in these kits has a metal pulley. It has been upgraded in the course of 2004 in line with OES evolutions. In some cases you may still find an old model mounted on the engine, which is slightly different than the latest version delivered in our kits. The new tensioner with OE ref. 038109243N replaces following OE references; 038109243 and 038109243G. In Fig. 1 you can see that only the new version has a crosshatch belt wear indicator (see also Fig. 4). This section indicates when the timing belt is worn out and when it needs replacement. Fig. 1 33

In Fig. 2 you can see that the new tensioner also has a shorter spacer. However, the distance between the engine block and the pulley remains the same. Fig. 2 Guidelines for installation of the new tensioner Before replacing the timing belt and tensioner, following points should be respected: 1. engine must be at room temperature 2. engine must be put at Top Dead Centre (TDC) - there is a timing mark on the flywheel which can be viewed from the top through a window in the gearbox housing - injection pump has to be blocked with a pin - vacuum pump has to be removed to fit the locking tool to block the camshaft 3. you must always turn the engine clockwise! Setting the tension When the new tensioner is installed, verify that the index tab is located and properly seated in the slot (Fig. 3 and Fig. 4). Use the special tool to tension the tensioner and turn clockwise until the pointer lines up perfectly in the window, between the lines A and B. You can use a mirror to properly see this in the engine compartment. Now tighten the bolt at 23Nm. Now you must rotate the engine two revolutions clockwise and then recheck the tensioner pointer. Do not skip this step! 34

When after two engine revolutions the pointer is between lines A and B and the index tab is in the slot and pushing against the right hand side (Fig. 3 and Fig. 4), only then the tensioner is perfectly positioned. If the pointer is not well positioned, the mechanic should restart the tension-setting procedure completely. When you are in the tension-setting, never turn the tensioner anti-clockwise! Index tab Fig. 3 Pointer Fig. 4 35

Possible errors Fig. 5 shows one of the common errors. Pointer is perfectly positioned between lines A and B but the index tab is not OK. The index tab is in the slot but is not pushing against the right hand side of the slot. The reason for this is that the tensioner was moved anti-clockwise during the tensioning process. Index tab not touching the right hand side of the slot Fig. 5 A second possible error can be seen in Fig. 6. You can see that the pointer has not passed line A and is in front of the crosshatch. This means that the belt will have a too low tension. Fig. 6 36

A third installation error is shown in Fig. 7. The pointer has passed line B, this means that the belt will be tensioned too much. Fig. 7 In Fig. 8 you can see a fourth error where the index tab is not locked in the slot although the pointer is perfectly positioned between lines A and B. This way the belt will lose its tension once in operation. Fig. 8 37

You can see the marks on the engine caused by this type of wrong fitment in Fig. 9. In this case you will also see that the index tab on the tensioner is slightly bent over. Marks on engine caused by 4 th error type Fig. 9 When the vehicle is released with a wrong positioned tensioner, severe engine damage will happen sooner or later. We can not stress enough how important it is to follow all the steps in the process of installing this tensioner without skipping one of them. It is better to lose 5 minutes at the installation then to lose an entire engine in the end. In technical bulletin N 2 we already explained the difference between the belts 5543XS and 5559XS. Please refer to our application catalogue to find the correct kit for your application. 38

Accessory drive on Renault 1.5 DCi engines # 013 21/04/2006 GATES REFERENCE : MAKE : MODEL : MOTOR : MOTOR CODE : Accessory drive RENAULT Clio II, Express, Kangoo, Rapid, Symbol 1.5 dci K9K700, K9K702, K9K710 Certain Renault 1.5 DCi models, produced between June 2001 and June 2002, without air-conditioning, could have issues with the accessory drive belt, as a result of tensioner problems. The tensioner base plate could deform, resulting in misalignment, belt noise and early failure. In order to cure this, Renault launched a technical note, saying the old tensioner (OE ref. 8200262773, 8200292784), the 2 tensioner bolts (torxhead) and the accessory drive belt (OE ref. 8200020924) have to be replaced. Vehicles involved: *Clio II, Symbol, Van 1.5DCi. Chassis codes: BB07, BB08, CB07, CB08, LB07, SB07, SB08; with engine K9K700 or K9K702. *Kangoo, Rapid, Express 1.5DCI. Chassis codes: FC07, FC08, KC07, KC09 ; with engine K9K700, K9K702 or K9K710. How to proceed: Loosen tensioner bolts Remove old accessory drive belt Remove old tensioner bolts and tensioner Install new tensioner (OE ref. 8200328372) Use 2 new bolts (OE ref. 7703002059 - hex head) Install the 2 bolts hand tight Install a new Micro-V XF belt 5PK1133 (OE ref. 8200020924). ATTENTION!!! The pulleys of this drive have 6 grooves, while the needed belt only has 5 ribs. The groove closest to the engine bloc has to remain free. Tensioning the new belt: The belt has to be tensioned (with tool Mot. 1638, OE ref. 0000163800) to a higher tension than with the original drive set-up 39

Measure the tension in the bottom span, between the crankshaft and power steering pump (or idler for cars without power steering) (Fig.1). Fig.1 When measuring the belt tension with the STT-1, key in 8, 180 (virtual span of 180 mm). When measuring with the Krikit, tension has to be 70 Kg. Now tighten the 2 bolts (36 Nm). Rotate the engine 2 revolutions clockwise. Check the tension and adjust if needed. Re-install all removed parts. 40

PowerGrip Kit K015432XS for Fiat and Lancia 1.6 petrol engines # 014 24/04/2006 GATES REFERENCE : MAKE : MODEL : MOTOR : MOTOR CODE : PowerGrip Kit K015432XS FIAT / LANCIA Albea, Brava, Bravo, Doblò, Marea, Multipla, Palio, Siena, Stilo, Delta, Lybra 1.6 benzine, LPG, BiPower 178B3000, 182A4000, 182A6000, 182B5098, 182B6000, 182B6000LPG, 185A3000, 186A4000, 186A3000LPG. On OE(S) level the synchronous tensioner on these engines has changed already three times. Our kit has always reflected those changes in the course of the years. Since the latest evolution looks quite different to the previous ones, we want to give this overview. Overview Fig. 1 tensioner in kit until 08/2004 OE ref. 46792898 Fig. 2 tensioner in kit from 09/2004 until 11/2005 OE ref. 46416489 Fig. 3 tensioner in kit as of 12/2005 OE ref. 71734799 Fig. 1 Fig. 2 41

Fig. 3 A Installation The latest version that is now used on OE(S) level replaces the two previous parts. It may be possible that the tensioner on the car is still an older model. There is no problem to install the latest version tensioner with the old stud and nut. Although the depth of the fixing hole (A) of the tensioner is deeper and the stud stays the same, there is still enough room on the stud to fix the nut properly, see Fig. 5 (B). Fig. 4 C Fig. 5 B Fig. 4 and Fig. 5 show the latest version of the tensioner fixed on the bracket. Normally this bracket (C) is mounted on the engine block and does not have to be removed. Fig. 6 E Fig. 7 D F 42

To lock the tensioner, position the open oblong hole in the base plate of the tensioner on the pin on the bracket (Fig. 6). When the belt and the tensioner are replaced following OE guidelines (1) and after two engine revolutions, then the pointer (D) has to be in the middle of the V in the base plate of the tensioner (E). At that moment the two black marks (F) will also be aligned. Only then the tensioner is correctly installed. 43

44

Fiat group 1.9 JTD engines # 015 13/07/2007 GATES REFERENCE : MAKE : MODEL : MOTOR : MOTOR CODE : 6PK1835XQ for OE ref. 55189679 and 71734476 ALFA ROMEO / FIAT / LANCIA 147, 156, GT, Marea, Marengo, Multipla, Lybra 1.9 JTD 182B4000, 186A6000, 186A8000, 186A9000, 182B9000, 192A5000, 192B1000, 937A2000, 937A4000, 937A5000, AR32302, AR37101 On the different Fiat group models with the 1.9 JTD engine, and equipped with an air conditioning compressor, several adjustments have been made to the accessory drive system since its introduction. Belt length, tensioner and pulleys all have all undergone small changes - and not necessarily the same for Alfa, Lancia and Fiat - in an effort to improve drive performance. As a result, the Fiat group now only offers 1 belt size for this drive: the OE/OES references are 55189679 and 71734476. the Gates Micro-V XF replacement belt is 6PK1835XQ. This means that the 6PK1840 that was previously recommended on some of these applications, should no longer be installed on this 1.9 JTD + AC drive. An overview of the adjusted specifications is attached. Should you have any further questions or remarks, please don t hesitate to contact us. 45

Stroke Engine code Year From Month From Year Till Month Till Appli cation Attri butes >>> Make Model Type KW Article ALFA ROMEO 145 1.9 JTD AR32302 77 1999 03 2001 10 6PK1038 ALT - AC ALFA ROMEO 145 1.9 JTD AR32302 77 1999 03 2001 10 6PK1778 ALT + AC ALFA ROMEO 145 1.9 JTD AR32302 77 1999 03 2001 10 6PK1795 ALT + AC ALFA ROMEO 146 1.9 JTD AR32302 77 1999 03 2001 10 6PK1038 ALT - AC ALFA ROMEO 146 1.9 JTD AR32302 77 1999 03 2001 10 6PK1778 ALT + AC ALFA ROMEO 146 1.9 JTD AR32302 77 1999 03 2001 10 6PK1795 ALT + AC ALFA ROMEO 147 1.9 JTD 937A2000 85 2001 06 2005 08 6PK1038 ALT - AC ALFA ROMEO 147 1.9 JTD 937A2000 85 2001 06 2005 08 6PK1835XQ ALT + AC ALFA ROMEO 147 1.9 JTD 192A5000 103 2002 07 2005 05 6PK1835XQ ALT ALFA ROMEO 147 1.9 JTD 182B9000 74 2002 11 6PK1038 ALT - AC ALFA ROMEO 147 1.9 JTD 182B9000 74 2002 11 6PK1835XQ ALT + AC ALFA ROMEO 147 1.9 JTD 937A4000 93 2003 08 2005 05 6PK1835XQ ALT -> MTR NR 1370829 ->MTR NR 1370830 -> MTR NR 1370829 ->MTR NR 1370830 ALFA ROMEO 147 1.9 JTD 192B1000/ 937A5000 100 /110 2004 04 2005 08 6PK1835XQ ALT ALFA ROMEO 156 1.9 JTD AR32302 77 1997 11 2000 06 6PK1038 ALT - AC ALFA ROMEO 156 1.9 JTD AR32302 77 1997 11 2000 06 6PK1835XQ 05/98- ALT + AC ALFA ROMEO 156 1.9 JTD AR37101 81 2000 05 2002 02 6PK1038 ALT - AC ALFA ROMEO 156 1.9 JTD AR37101 81 2000 05 2002 02 6PK1835XQ ALT + AC ALFA ROMEO 156 1.9 JTD 937A2000 85 2001 11 2005 09 6PK1835XQ ALT ALFA ROMEO 156 1.9 JTD 192A5000 103 2002 11 2004 11 6PK1835XQ ALT ALFA ROMEO 156 1.9 JTD 937A4000 93 2003 11 2005 09 6PK1835XQ ALT ALFA ROMEO 156 Sport wagon 1.9 JTD AR32302 77 1999 10 2000 04 6PK1038 ALT - AC ALFA ROMEO 156 Sport wagon 1.9 JTD AR32302 77 1999 10 2000 04 6PK1835XQ ALT + AC ALFA ROMEO 156 Sport wagon 1.9 JTD AR37101 81 2000 05 2002 02 6PK1038 ALT - AC ALFA ROMEO 156 Sport wagon 1.9 JTD AR37101 81 2000 05 2002 02 6PK1835XQ ALT + AC ALFA ROMEO 156 Sport wagon 1.9 JTD 937A2000 85 2001 05 2006 05 6PK1835XQ ALT ALFA ROMEO 156 Sport wagon 1.9 JTD 192A5000/ 937A4000 93/103 2002 11 2006 05 6PK1835XQ ALT ALFA ROMEO 156 Sport wagon 1.9 JTD 937A5000 110 2004 01 2006 05 6PK1835XQ ALT ALFA ROMEO GT 1.9 JTD 937A5000 110 2003 11 6PK1835XQ ALT FIAT Marea 1.9 JTD 182B4000/ 186A6000 77/81 1999 03 2002 08 6PK1835XQ ALT + AC FIAT FIAT Marea S.W./ Weekend 1.9 JTD Marengo (Marea) 1.9 JTD FIAT Multipla 1.9 JTD FIAT 182B4000/ 182B9000/ 186A6000 182B4000/ 74/77/ 81 1999 03 2003 06 6PK1835XQ ALT + AC 186A6000 77/81 1999 03 2002 08 6PK1835XQ ALT + AC 182B4000/ 186A6000/ 77/81/ 186A8000 85 1998 08 6PK1835XQ ALT + AC Multipla Van 1.9 JTD 186A8000 85 2002 04 6PK1835XQ ALT + AC LANCIA Lybra 1.9 JTD AR32302/ AR37101 77/81 1999 07 2001 09 6PK1835XQ ALT + AC LANCIA Lybra 1.9 JTD 937A2000 85 2000 10 2005 10 6PK1835XQ ALT + AC LANCIA Lybra Estate/ Wagon 1.9 JTD AR32302/ AR37101 77/81 1999 07 2001 09 6PK1835XQ ALT + AC LANCIA Lybra Estate/ Wagon 1.9 JTD 937A2000 85 2000 10 2005 10 6PK1835XQ ALT + AC 46

PowerGrip Kit K015541XS for Ford 1.8 diesel engines # 016 01/08/2006 GATES REFERENCE : MAKE : MODEL : MOTOR : MOTOR CODE : PowerGrip Kit K015541XS FORD Courier, Fiesta, Focus, Tourneo, Transit 1.8 TDDi / TDCi LD18RTN, LD18RTP, LD18BHDA, LD18BHDB, LD18C9DA, LD18C9DB, LD18C9DC, YD18F9DA, YD18F9DB, YD18FFDA, YD18BHPA, YD18HCPA, YD18HCPB, YD18HCPC, YD18BHPB Since Technical the launch Bulletin of our K015541XS 016 is replaced during by 2003, Technical this kit Bulletin has always 027. contained an automatic tensioner for these Ford 1.8 diesel applications. Please consult The very first models of for the up-to-date Ford Focus information. and Ford Fiesta, however, were initially equipped with a manual tensioner. Very shortly after the introduction of these vehicles, Ford decided in July 2000 to replace the manual tensioner by a new automatic tensioner. All cars originally equipped with the manual tensioner had to be refitted with an automatic tensioner.! Technical bulletin 009 is replaced with Technical bulletin 25! Most of the manual tensioners have been replaced by the automatic one, so only a limited number of drive modifications should be expected. If you should encounter a vehicle that still needs the initial installation of the modified tensioner, there is no problem to do the replacement with our K015541XS. Doing a timing belt kit replacement from a manual tensioner to the automatic one, however, still involves some additional points to check. Attention points! 1. Automatic tensioner New automatic tensioner Fig. 1 Old manual tensioner Fig. 1 shows the old manual tensioner on the right side and the new automatic tensioner on the left. 47

48

Volvo S40/V40 models with 1.9 diesel engine # 017 16/02/07 GATES REFERENCE: MAKE: MODEL: ENGINE: ENGINE CODE: PowerGrip belts 5212XS, 5485XS, 5486XS, 5552XS VOLVO S40, V40 1.9TD, TDi, DiTD D4192T, D4192T2, D4192T3, D4192T4 We have recently experienced an increase in errors when selecting the PowerGrip timing belt for the 1.9 D engine (Renault), installed in the S40/V40 models. We therefore believe it is needed to review this issue in a Technical Bulletin. There are in total 4 different engine types of this 1.9 diesel. Most of the errors occur with models produced up to 12/2000, because the belts have the same number of teeth and the error is not noticed during installation. Knowing the exact engine code is VERY important in order to find the correct belt number: D4192T: 66 KW (90 HP), produced from 96 till 09/99. This engine can be recognized by the VOLVO name being shown on the noise-shield, covering the engine, in silver letters. (Fig. 1) It requires belt 5212XS (up to engine number 3534) or 5485XS (from engine number 3535). Both have 153 teeth, but these belts are CERTAINLY NOT INTERCHANGEABLE, as they have a different tooth profile. D4192T2: 70 KW (95 HP), produced from 10/99 till 12/00. On this engine, VOLVO is shown in black letters (Fig. 2), and it needs belt 5486XS. 5485XS and 5486XS have practically the same dimensions and the same profile, but are CERTAINLY NOT INTERCHANGEABLE!!! (5486XS has a more durable construction than 5485XS). Fig. 1 Fig. 2 D4192T3 (85KW/116 HP) and D4192T4 (75 KW/102 HP) have been produced from 12/99 till 06/04. These engines use a completely different belt with 132 teeth (5552XS). They have a black shiny line in the middle of the noise-shield, and VOLVO is shown in black letters. 49

The engine code and number can be found: A) on a small plate (to be cleaned) on the engine block, under the cylinder head, +/- 10 cm away from the gearbox. (Fig. 3 and 4). Fig. 3 Fig. 4 or B) on a sticker situated on the timing belt cover (Fig. 5) Fig. 5 50

BUT, the engine code is also hidden in the chassis number: The 6 th and 7 th digit of the chassis number give the engine code! 70 is a D4192T3 71 is a D4192T 73 is a D4192T2 78 is a D4192T4 So chassis number *YV1VW73.* means the car has a D4192T2 engine. In summary: Engine code D4192T (up to engine number 3534) (from engine number 3535) D4192T2 D4192T3 and T4 PowerGrip belt 5212XS 5485XS 5486XS 5552XS So always request/look up the engine code or chassis number before making the selection. We hope this information will avoid further mistakes in the future. Visit our web catalogue : www.gatesautocat.com 51

52

5 and 6 PK Micro-V XF belts on Renault engines # 018 09/03/07 GATES REFERENCE: MAKE: MODEL: ENGINE: ENGINE CODE: Various Micro-V XF belts/kit K015PK1750 RENAULT Clio, Kangoo, Laguna, Logan, Megane, Modus, Scenic, Thalia 1.4, 1.6, 1.8, 2.0 Petrol, 1.5 DCi F4P, F4R, F5R, K4J, K4M, K7J, K7M, K9K Renault has different engines where a 5PK belt has to be installed in pulleys with 6 grooves. This can not always be done in the same way. Here is an overview of the different situations: 1) On several 1.4 and 1.6 engines (K4J, K4M, K7J, K7M) with air conditioning, originally equipped with a 6PK belt (OE ref. 7700101261-6PK1750), Renault has changed to a 5PK belt (OE ref. 7700111671-5PK1747). 2) Also on other engines (F4P, F4R, F5R, K9K) it is quite common to find a 5PK belt together with 6 PK pulleys. (See also Technical Bulletin N 13 for the 1.5 DCi K9K engine). As these 5PK belts run in the initially installed 6 groove pulleys, it is important to install the belt in the correct pulley grooves. Especially since it is known that in some cases the multi-ribbed belt was destroyed, and parts entered into the timing belt drive, ultimately causing considerable damages to the engine. Different possibilities: 1.4 8V, 1.4 16V, 1.6 8V, 1.6 16V: - without airconditioning: o power steering pump is belt driven: belt has to be on the inside of the pulleys (Fig 1) o power steering pump is electrically driven (not included in the belt drive): belt has to be on the outside of the pulleys (Fig. 2) - with airconditioning: o belt has to be on the outside of the pulleys (Fig. 2) 1.8 16V, 2.0 16V, 2.0 16V ide: o belt has to be on the outside of the pulleys (Fig. 2) 1.5 DCi: o belt has to be on the outside of the pulleys (Fig. 2) 53

Fig. 1 Fig. 2 Because of the above evolutions, we have changed our recommendations from 6PK1753 to 5PK1750. Subsequently, our kit K036PK1753, which is listed in the 2007 catalogue, but not yet available, will be renumbered to K015PK1750. We expect to have stock of this new Micro-V XF kit by the end of May. Our web catalogue will be adjusted accordingly. Visit our web catalogue : www.gatesautocat.com 54

Selecting timing belts/kits for the Renault 1.9D engine # 019 16/05/07 GATES REFERENCE: MAKE: MODEL: ENGINE: ENGINE CODE: 5212/XS, 5305XS, 5484XS, 5485/XS, 5486XS, 5561XS and their kits. Mitsubishi, Opel/Vauxhall, Renault, Volvo Various models with Renault 1.9 Diesel engine 1.9 Diesel Various engine codes Through our customer contacts, we still experience that errors are being made in the selection of the PowerGrip timing belt/kit for the Renault 1.9 D engine, mounted in several makes and models. Some of these applications are running a timing belt with 132 teeth (our belt 5552XS), but most of the vehicles have a belt with either 151 or 153 teeth, and this is where most issues occur. Just counting the number of teeth is not enough to find the correct belt: for the 151 teeth applications, there are 2 options: 5305XS or 5484XS for the 153 teeth applications, there are no less than 7 different options: 5051, 5212, 5212XS, 5485, 5485XS, 5486XS, 5561XS. These belts may have different widths, different profiles or different constructions, depending on the application. Here is some information to help you make the correct selection: First of all, and in the case that the OE reference of the old (removed) belt can still be read, the attached cross-reference list will give you the correct Gates replacement belt. If the branding is not readable anymore, it is vital to know the complete engine code of the vehicle (e.g. F9Q780). This engine code can be found on the engine block, in between the oil filter and the flywheel (Fig. 1). Fig. 1 55

Consult the Gates Drive Systems Catalogue E/70107 to find the correct belt for your engine type. Or better still, for the latest up to date information, visit our web catalogue : www.gatesautocat.com. On some of the applications with 151 teeth, even for the same engine type, a certain vehicle could have either of the belts 5305XS or 5484XS. In this case, the break point between the 2 belts is a date. This date is of course the production date of the car. But when a car was sold within the year after this break date, there could be doubt as to which belt one has to use - belts look very alike and therefore some customers may think they are exactly the same. For this situation there is a visual difference that will allow one to make the distinction (see Fig. 2). When you look at the 2 belts from the side, the tooth of the 5305XS goes down straight starting from the base, while the tooth of the 5484XS has a more slanting side. As a result, the tooth base of the 5484XS (Fig. 3 green line) is wider than the one from the 5305XS (Fig. 3 red line). 5305XS 5484XS Fig. 2 Fig. 3 We hope this information will avoid further mistakes in the future. See also Technical Bulletin # 017 on Volvo models with these 1.9 diesel engines. Visit our web catalogue : www.gatesautocat.com 56

VAG Timing System Replacement Intervals GATES REFERENCE: Various. # 020 09/11/07 MAKE: MODEL: ENGINE: ENGINE CODE: AUDI, SEAT, SKODA, VOLKSWAGEN All All All Over the past months and years, we have seen many changes in the timing belt replacement intervals recommended by the different makes belonging to the Volkswagen group, so we have therefore prepared an overview of the current situation. Gates has for many years been promoting the simultaneous replacement of belts, tensioners and idlers, thus ensuring a complete overhaul of the drive system, resulting in trouble free performance for another service period. We notice that also the car manufacturers are now considering this good practise, and that they are offering OES kits for full timing system replacement. They have started including the replacement of the tensioners also in their service recommendations. This is as well the case for VAG, so these data are included in the attached files (http://www.gates.com/europe/technical). Please note that these replacement intervals are the OE recommendations for the maximum mileage of the drive. A quicker change can be required when the car is used in adverse conditions, such as very sporty driving, extreme temperatures (*), sand and gravel, running a lot on idle speed (taxis, delivery vans etc), frequent stops, always driving short distances, etc. VAG therefore advises to check the condition of the components at every major service. Do remember that the engine needs to be at room temperature before installation, and precise follow up of the OE installation recommendations is strongly advised. We also recommend that you always check the latest OE information on replacement intervals. For a correct identification of Gates Belts and Kits related to the VAG engines, please consult our web catalogue at www.gatesautocat.com See also Technical Bulletin # 002, 007, 010, 011, and 012 for further information on specific VAG models. (*) e.g. For prolonged exposure to temperatures above 26 C or below -6 C, the change interval is reduced from 5 to 4 years. Visit our web catalogue : www.gatesautocat.com 57

58

Additional tension values for STT-1 # 021 07/12/07 GATES REFERENCE: MAKE: MODEL: ENGINE: ENGINE CODE: 5078, 5344XS. K015078, K01/K025344XS AUDI, BMW Various Audi 2.6/2.8 V6; BMW 2.4 D/TD Audi AAH,ABC,ACZ,AEJ, AFC; BMW M21246TA/TB In the beginning of this year we have updated the data chip of our Sonic tension tester STT-1. The 006 version chip does no longer need to be updated when we find new tension values for our PowerGrip timing belts. In these cases, we will add the code that you need to enter in the STT-1, on the drawing on the box of both PowerGrip belts and Kits. The code is linked to the T reference: for example So far we have identified 2 new tension values: For PowerGrip belt 5078, fitted to BMW 2.4 D/TD engines, the code is 3303. For PowerGrip belt 5344XS, fitted to Audi 2.6 and 2.8 V6 engines, you will need to enter code 3276. 59

After you have typed the code and pressed the enter button, the code will be returned on the screen, confirming that the database has found the value. You can then proceed with the tension measurement as usual. In summary: If the drawing on the box only has the, then use the belt part number. If the drawing on the box has the, then use this number. Visit our web catalogue : www.gatesautocat.com 60

Tensioning issues on Chevrolet/Daewoo 16V petrol engines # 022 02/06/08 GATES REFERENCE: MAKE: MODEL: ENGINE: ENGINE CODE: 5419XS/K015419XS Chevrolet/Daewoo Aranos, Assol, Aveo, Cielo, Espero, Kalos, Lacetti, Lanos, Nexia, Nubira, Rezzo, Tacuma 1.4 16V, 1.5 16V, 1.6 16V Various engine codes Through our field experience and failure analysis, we have learned that drive failure on these engines can be avoided by strictly following the correct installation procedure. Drive failure is mainly caused by not rotating the water pump to set the belt tension. Although the drive is equipped with an automatic tensioner, this still has to be set up correctly. And this requires manipulation of the eccentric water pump, located just below the tensioner.(fig. 1) Fig. 1 It is strongly recommended to replace the tensioner and idler together with the belt, as these parts obviously also wear out. A worn bearing (loss of grease, seizure, misalignment ) is just as bad as a worn belt, and will lead to premature drive failure, resulting in serious engine damage. Here is what we found out: Some mechanics hesitate to loosen the water pump, as they are afraid of water leaks, or do not have the proper tool to rotate the water pump. However, in this case, loosening the water pump is vital in order to reach the correct installation tension. (a new O-ring might be needed) Leaving the old tensioner on without even loosening the tensioner bolt thinking: the tension was OK before, so if I do not touch it, it will remain OK - is certainly not the correct way to work. If one does not loosen the tensioner bolt, cutting the old belt to remove it, the pointer of the tensioner will hit the cold stop violently. This could seriously damage the pointer, resulting in a rupture (later on). Proceeding this way, in order to be able to install 61

the new belt, the pointer of the tensioner has to be pushed back. When trying this with a screwdriver, one risks that the screwdriver will slip off the pointer (because of the high spring tension) which will again hit the cold stop. Fig. 2 Fig. 3 This can break off the tensioner pointer (Fig 2). Fig. 3 shows where the pointer is situated on a good tensioner (in its rest position). In some cases the timing belt is installed on a hot engine. It is clear this may lead to premature drive failure, because tensioner set up procedures have been developed for cold engines. Trying short cuts in the procedure is always dangerous, but especially with more complicated drive systems like this one. Correct procedure: Removal In order to make access to the drive easier, it is recommended to remove the engine support (Fig. 4) Fig. 4 Engine support 1. remove auxiliary belt crankshaft pulley, re-install bolt 2. put engine at TDC: rotate the crankshaft clockwise until the timing mark on the crankshaft gear is aligned with the notch at the bottom of the rear timing belt cover, and align the timing marks on the camshaft gears (Fig 1). Block camshafts with Gates multi-lock tool (GAT 4695) 62

3. slightly loosen the bolts of the water pump 4. rotate water pump anticlockwise, using special adjustment tool (Gates: GAT V501A or OE: J-42492 or KM-421-A), to release tension on the belt (Fig. 5) 5. remove the timing belt, tensioner and idler. Fig. 5 Installation 1. Install a new tensioner and idler, and fit the new belt (anticlockwise, starting from crankshaft). Use kit K015419XS. 2. adjust tensioner pointer up to the notch in the tensioner back plate - close to the right hand stop - by rotating the water pump gently clockwise (Fig. 6, 7 and 8). Fig. 6 View from front Fig. 7 View from back 63

Fig. 8 3. tighten the water pump bolts 4. rotate the engine 2 full revolutions clockwise (by rotating crankshaft) until TDC. 5. slightly loosen the bolts of the water pump 6. bring tensioner pointer in line with the pointer on the tensioner back-plate by rotating the water pump anticlockwise, with special adjustment tool. (Fig. 9) 7. tighten the water pump bolts 8. re-install engine support 9. re-install the removed auxiliary belt crankshaft pulley Fig. 9 Conclusion: only work on cold engines replace timing belt, tensioner and idler every 60.000 KM or 4 years put tensioner in correct position only by rotating the water pump follow every step in the OE installation procedure use the specified tools 64

In addition, one has to watch out for counterfeit tensioners which can be widespread in certain markets (Fig.10 and 11 are OE, Fig. 12 is counterfeit) OE OE Fig. 10 Fig. 11 Counterfeit Fig. 12 Visit our web catalogue : www.gatesautocat.com 65

66

K02/K035468XS for PSA 1.8 and 2.0 16V engines # 023 18/08/08 GATES REFERENCE: MAKE: MODEL: ENGINE: ENGINE CODE: K02/035468XS CITROEN / FIAT / PEUGEOT Evasion, Synergie, XM, Xantia, Xsara, ZX, Ulysse, 306, 406, 605, 806 1.8 16V, 2.0 16V XU7JP4, XU10J4R, XU10J4RS, RFV On request of the field we will recapitulate the correct use of these kits, depending on the different applications. PowerGrip Kit K025468XS is to be used for the PSA 2.0 16V engines. This kit contains the original manual tensioner (OE ref. 082935, 9622574480. Gates ref. T41258). See Fig. 1. Fig. 1 Manual tensioner (K025468XS) PowerGrip Kit K035468XS is only suited for the PSA 1.8 16V engines. It includes an automatic tensioner (OE ref. 082969, 9635336880. Gates ref. T43050 see Fig. 2) as an upgrade to the initially installed manual tensioner. This replacement is recommended and also applied by Peugeot/Citroen so the manual tensioner should no longer be used on the 1.8 engine. Our kit contains a leaflet offering an overview of the complete contents, an application summary and a detailed installation procedure. Fig. 2 Automatic tensioner (K035468XS) An applications overview for the K025468XS and K035468XS can be found at the end of this bulletin. For detailed applications information, please check our web catalogue (or your paper catalogue). 67

We found out that the drive lay outs we used up to now were not 100% correct: for the 2.0 16V engine, the idler position should be lower in the drive. The correct drawing is shown in Fig 3. The tension on this 2.0 16V engine has to be checked (with Gates STT-1) between the right camshaft pulley and the idler (enter 5468XS-2). Our drawings and recommendations on the timing belt/kit boxes will be adjusted accordingly Fig. 3 Applications overview: K025468XS CITROEN Evasion B 2 XU10J4R 9 1999 10 2002 CITROEN Synergie B 2 XU10J4R 9 2000 12 2001 CITROEN XM B 2 XU10J4R 8 1994 4 2000 CITROEN Xantia B 2 XU10J4R 6 1995 10 2002 CITROEN Xsara B 2 XU10J4RS 1 1998 10 2004 CITROEN Xsara B 2 XU10J4R 1 1998 8 2000 CITROEN ZX B 2 XU10J4RS 9 1996 10 1997 FIAT Ulysse B 2 RFV 9 1998 8 2000 PEUGEOT 306 B 2 XU10J4RS 5 1997 5 2001 PEUGEOT 306 B 2 XU10J4R 5 1997 10 2001 PEUGEOT 306 Cabrio B 2 XU10J4R 5 1997 12 2002 PEUGEOT 406 B 2 XU10J4R 11 1996 8 2000 PEUGEOT 406 Coupe B 2 XU10J4R 5 1997 12 1999 PEUGEOT 605 B 2 XU10J4R 7 1994 9 1999 PEUGEOT 806 B 2 XU10J4R 10 1998 2 2003 K035468XS CITROEN Xantia B 1.8 XU7JP4 6 1995 4 2003 CITROEN Xantia L 1.8 XU7JP4LPG 1 1998 12 2000 CITROEN Xsara B 1.8 XU7JP4 7 1997 8 2000 CITROEN Xsara Estate/Break B 1.8 XU7JP4 5 1998 8 2000 CITROEN ZX B 1.8 XU7JP4 4 1996 10 1997 PEUGEOT 306 B 1.8 XU7JP4 5 1997 4 2002 PEUGEOT 306 Cabrio B 1.8 XU7JP4 5 1997 12 2002 PEUGEOT 406 B 1.8 XU7JP4 8 1995 8 2000 PEUGEOT 406 Coupe B 1.8 XU7JP4 10 1997 3 1999 Visit our web catalogue : www.gatesautocat.com 68

Tension setting procedure for PSA 2.0 HDI engines # 024 25/08/08 GATES REFERENCE: MAKE: MODEL: ENGINE: ENGINE CODE: 5588XS/K015588XS/K025588XS/KP15588XS CITROEN, FIAT, LANCIA, PEUGEOT, SUZUKI Various 2.0 HDI, 2.0 JTD DW10ATED4, RHW, RHM In order to achieve optimum belt performance, it is always important that the correct installation tension and tensioning procedure is used. This particular engine requires an unusual 2 stage belt tensioning procedure. - The belt is fitted in the normal way and is tensioned by turning the tensioner pulley anticlockwise using, Gates tool GAT4567 or GAT4568, both included in Gates tool kit GAT4820 (PSA tool ref. 0188-J1 or 0188-J2) (Fig. 1). Fig. 1 - This tool is needed in order to turn the tensioner and hold it in place while tightening the central bolt (23 Nm)(Fig. 2). Fig. 2 69

- Initially, the belt has to be installed at a higher than normal tension (pretension). The tension is measured with a Gates STT-1 tension tester in the span between the camshaft and the injection pump. Enter code 3725 - The crankshaft pulley is then rotated 8 revolutions, clockwise - The tension is then adjusted to the final level, and the value is again confirmed with the STT-1 tension tester. Enter code 3998 This procedure has the advantage that the variability in the setting of the tension level is reduced, and the initial tension drop is also reduced. The procedure will be visualised on the PowerGrip Kit and belt box label as in Fig 3. Fig. 3 Visit our web catalogue : www.gatesautocat.com 70

Timing belt/kit installation on GM (Isuzu) 1.7D engines # 025 23/10/08 GATES REFERENCE: MAKE: MODEL: ENGINE: ENGINE CODE: 5563XS/K015563XS/K025563XS/K035563XS CHEVROLET, OPEL, VAUXHALL Astra, Combo, Corsa, Meriva, Tour, Zafira Isuzu 1.7 DTI A17DT, A17DTR, Y17DT, Y17DTH, Y17DTL, Z17DT, Z17DTH, Z17DTR Questions and returns out of the field teach us there are still a lot of doubts on the contents/installation of this belt/kit, so we believe it is useful to launch a new bulletin on this engine. This replaces Technical Bulletin N 009. Apart from the fact that 2 different tensioners have been installed over the life of the engine, the installation procedure and tension setting is very critical on this application. Tensioner difference: Up to engine nr 328703 (last 6 digits) the initial tensioner (Fig. 1) was installed. From engine nr 328704 this tensioner was replaced by the new version (Fig. 2). For the 1.7 D engine, OE does not allow to use the old tensioner version anymore. That is why our kits only contain the new tensioner. Fig. 1 OE ref. 5636724 Fig. 2 OE ref. 5636739 71

Main differences in composition and application: + K015563XS 5563XS I-> eng nr 328704 K025563XS 5563XS ALL engines K035563XS 5563XS ->I eng nr 328703 As the initial tensioner base plate was sitting under one of the legs of the engine support bracket (Fig. 3), K015563XS can only be used from engine nr 328704 on. washer Fig. 3 Fig. 4 Engine support bracket Base plate initial tensioner K025563XS is supplied with a washer to compensate for the shorter leg of the early engine support bracket (Fig. 4), and a stud which is needed to hook the new tensioner spring on (Fig. 5). This K02 can always be used: up to engine nr 328703, using the washer and the stud; and from engine nr 328704 without the washer and the stud. K035563XS is supplied with the new OE engine support bracket, with 3 legs of the same length. This kit can be used up to engine nr 328703. 72

Installation/Tensioning: This engine is VERY sensitive to wrong tension. Because of this, the installation/tensioning procedure must be followed strictly and precisely. Failure to do so will most certainly result in an idler failure. Important before starting the procedure: Engine must be cold. Put engine at Top Dead Centre (TDC). Block the camshaft pulley (M6 bolt at 8 o clock) and the injection pump pulley (M8 bolt at 5 o clock). Engine has to be supported and engine support bracket taken away. A) Engines with the initial tensioner type (Fig 1) installed: 1) Remove old tensioner, spring, idler and belt 2) Install new idler and bolt 3) Insert and torque (18,6 Nm) stud at the right hand side of the injection pump pulley (Fig. 5) Stud Spring 4) Install new coil spring tensioner (spring over stud, bolt hand tight); make sure tensioner is sitting perfectly against engine block. If not, the spring could end up between the tensioner and the engine block, creating a serious tensioner misalignment (see Fig. 6) Fig. 5 5) Rotate tensioner anticlockwise (Allen key) till Allen key hole is in +/- 5 o clock position 6) Tighten bolt 7) Install new belt. Belt has to be taut on the left hand side (nontensioner side) of the engine 8) Loosen tensioner bolt, allow tensioner to apply tension, torque tensioner bolt (49 Nm) while holding tensioner in place with Allen key* 9) Remove camshaft and injection pump blocking bolts 10) Rotate engine (as prescribed by the manufacturer) via crankshaft, check TDC; loosen tensioner bolt, torque tensioner bolt (49 Nm) while holding tensioner in place with Allen key ** 11) K025563XS: stick the washer (Fig. 4) on the bottom engine support leg (using fixing glue), in order to avoid losing the washer when loosening the support bracket bolt later. K035563XS: install new bracket 12) Re-install other removed parts 73

Spring trapped behind tensioner Serious misalignment Fig. 6 B) Engines with a coil spring tensioner (Fig. 2) installed NOTE : the installer does not need the stud and the washer for this version 1) Remove old tensioner, spring, idler and belt 2) Install new idler and bolt 3) Install new coil spring tensioner (spring over stud, bolt hand tight); make sure tensioner is sitting perfectly against engine block. If not, the spring could end up between the tensioner and the engine block, creating a serious tensioner misalignment (see Fig. 6) 4) Rotate tensioner anticlockwise (Allen key) till Allen key hole is in +/- 5 o clock position 5) Tighten bolt 6) Install new belt. Belt has to be taut on the left hand side (nontensioner side) of the engine 7) Loosen tensioner bolt, allow tensioner to apply tension, torque tensioner bolt (49 Nm) while holding tensioner in place with Allen key* 8) Remove camshaft and injection pump blocking bolts 9) Rotate engine (as prescribed by the manufacturer) via crankshaft, check TDC; loosen tensioner bolt, torque tensioner bolt (49 Nm) while holding tensioner in place with Allen key** 10) Re-install other removed parts Important during the procedure * If the tensioner is moving even a little during the tightening of the bolt, this change in position will be translated in an exponential change of belt tension. 74

** After completing step 10 of the installation in procedure A), or step 9 in procedure B), it is highly recommended to check the tension in span, (see drive system layout below - Fig. 7) using the Gates Sonic Tension Tester STT-1. To do this, enter the code 3618 in the STT-1 (ensure chip version 006 is installed) and measure in the normal way. If the tension is too high then the tensioner should be completely released and tensioning procedure repeated until the green light is obtained. If the tension is too low then it will be necessary to assist the tensioner spring with the Allen key; until the green light is obtained. Under no other circumstances should one assist the tensioner. Fig. 7 Failure to observe this procedure could result in the belt tension being too high leading to an overload of the guide pulley, between the oil pump and injection pump, usually causing the idler pulley to collapse (Fig. 8) and leading to severe engine damage. Fig. 8 Visit our web catalogue : www.gatesautocat.com 75

76

SOFIM 2.4 / 2.5 / 2.8 Diesel engines # 026 17/11/2008 GATES REFERENCE : MAKE : MODEL : ENGINE : ENGINE CODE : 5039 (K01), 5113 (K01), 5334XS (K01), 5335XS (K01), 5495XS (K01) Fiat / Iveco / Opel / PSA / Renault Various 2.4 / 2.5 / 2.8 / D, TD, DTi, DTic, Dci, JTD, HDi (all 8 valves) Various We have noticed that, from time to time, problems occur during the installation of the idler/tensioner pulley on this engine family. Incorrect handling/installation can lead to premature failure. 1) Tips for installing the pulleys: - Always remove rust or remaining grease from the axle/back plate before assembly (orange arrow). If you fail to do this, you will push all the dirt to the bottom of the back plate and you create a build up of debris, which will damage the bearing, due to misalignment or create a false tightening torque. - Always install the bearing by pushing on the centre part of the bearing ( ) - Never force the idler over the axle by pushing on the outside of the bearing ( ). See Fig. 1 and 2 Back plate Axle Fig. 1 Fig. 2 This would lead to misalignment of the bearing and its ultimate destruction. It also could lead to the seal coming loose, leading to loss of grease, and dirt coming into the bearing. 77

Misalignment will also lead to the belt coming in contact with the back plate. This will leave a rubbing mark on the back plate (Fig. 3). Fig. 3 Rubbing mark - Always check the play between the axle and the bearing. If there is excessive play, replace axle/back plate - Always apply the OE recommended tightening torque; it is very important as it determines the preload of the bearing. - Always use fixing glue in order to avoid the bolt/nut coming loose due to vibrations and thermal expansion/contraction of the different metal parts (if the bolt/nut loosens, the bearing falls apart) (See Fig. 6). Attention: - A correct tightening torque on a badly positioned bearing or a dirty axle will result in a failure. - The tension on the belt also affects the performance of the idlers on this engine. Use Gates STT-1 sonic belt tension tester for correct belt tension setting. 2) Results of wrong installation method: Figure 4: Bearing balls rolling outside their track due to misalignment and incorrect torque setting Figure 5: Abnormal rotation of the interior rings through incorrect tightening. Fig.4 Ball traces Fig.5 Abnormal rotation traces 78

Figure 6: Too low tightening torque will lead to the bearing falling apart. Figure 7: Deformation of the balls because of excessive temperature, resulting from too high tightening torque. Fig. 6 Fig. 7 Figure 8: Seal has come out of the bearing and ball cage has been destroyed. Figure 9: One often can find balls in the lower engine compartment. Remove all debris from the drive system Fig. 8 Fig. 9 Visit our web catalogue www.gatesautocat.com 79

Caution Use Gates products only on applications specifi ed in Gates literature. Install and maintain the products according to the vehicle manufacturer s recommended procedures and with recommended tools. Failure to follow these instructions could result in injury or property damage. Gates disclaims all liability due to failure to follow these instructions. The manufacturers reserve the right to amend details where necessary. Gates Corporation 2010 Printed in Belgium - 06/10. 80

When it comes to power transmission products, rely on Gates! OE quality products based on years of experience as an OE supplier Complete product ranges for power transmission, cooling, and fuel systems First-hand technical support and expertise Training for jobbers and mechanics on the spot by our pan-european technical support team Essential vehicle-specific and universal tools for trouble-free installation Technical bulletins available free of charge via our distribution channel and at Extensive catalogues with all application data available both in print and online at www.gatesautocat.com Gates quality - the professional choice!