Board logo

Zetec questions
Mark Allanson - 19/7/09 at 07:04 PM

I agreed to help my next door neighbour do a head gasket on her 1.8 zetec in a 98 escort. It has turned out that I am doing most of the job, does that sound familiar to anyone?

I have taken the pulleys off the cams only to find there are no locators on them. I understand the slots in the rear of the cams do the alignment, but what stops the pulleys slipping????

JAMSTER - 19/7/09 at 07:10 PM

nothing you have to have them loose when you tension the belt .pin in the block to lock the crank. plate across cams to lock them .make sure you tourqe up cam pulleys

Mark Allanson - 19/7/09 at 07:14 PM

Is there a hole in the bottom pulley to pin the crank ala 1.9 PSA engines?

Steve G - 19/7/09 at 07:17 PM

quote:
Originally posted by Mark Allanson
I agreed to help my next door neighbour do a head gasket on her 1.8 zetec in a 98 escort. It has turned out that I am doing most of the job, does that sound familiar to anyone?


But is she fit?? If so then stop complaining!!

You need a 5mm bar to pop across the top of the head and this fits in the offset cam slots. I take it you wont have the special tool referred to in the Haynes book of lies then!! You can make something pretty easily to stop the pulleys turning while you tighten up the torx bolts - with a bit of thought anyway.

Mark Allanson - 19/7/09 at 07:40 PM

I don't have the haynes book of lies, I am guessing the rear slots are not man enough to hold the cams still while the pulleys are tightened up?

prawnabie - 19/7/09 at 07:42 PM

Ahh freewheeling pulleys, reanult 16v engine are like this but on the crank too.

Steve G - 19/7/09 at 07:43 PM

You need to make a tool to stop the pulleys rotating - the cam locking bar only has to take the torque of you tightening the torx bolt which it will do

rusty nuts - 19/7/09 at 08:10 PM

You need a tool to locate in the holes of the pulley so you can stop the pulley from rotating when torquing the torx bolt up . DO NOT rely on the cam locking bar to torque the bolt up without using something to lock the pullies. The crank pulley can be aligned with the TDC mark on some Zetec engines without locking the crank . Some Zetec's also need a spring and a special bolt for the spring to the tensioner if not already fitted

jonesier1 - 19/7/09 at 08:12 PM

Dont trust the bar to tighten the cam pulleys,you will snap the back of the cams,use a pulley holding tool.You dont need a pin in the block just align the secound groove (clock wise) on the crank pulley with the pointer on the sump.

JAMSTER - 19/7/09 at 08:38 PM

a tool to lock cams and time the crank from any motor factor is only around a tenner

bob - 19/7/09 at 09:15 PM

Camshaft position bar and pulley locking tool.

Linky

austin man - 19/7/09 at 09:19 PM

you can always use a spanner on the cam ther is a flat toward the front of the cam, ideally one person holding the spanner the other on the cam pulley, just cahnage my cams 1hr or so ago as other have said dont rely on the rear locating slots. You will also need a torque wrench that reads below 20ft lb for tightening the caps they are two stage tightening. start from thevrear and work forwards

l0rd - 20/7/09 at 07:25 AM

If she is fit and single ask her to help you out while tightening the pulleys.



if you are single as well. I guess you are since you have volunteered for this job.

My wife would rip my eyes out if i did something like that.

Mark Allanson - 20/7/09 at 08:06 PM

quote:
Originally posted by austin man
you can always use a spanner on the cam ther is a flat toward the front of the cam, ideally one person holding the spanner the other on the cam pulley, just cahnage my cams 1hr or so ago as other have said dont rely on the rear locating slots. You will also need a torque wrench that reads below 20ft lb for tightening the caps they are two stage tightening. start from thevrear and work forwards


So it is the cams that need holding not actually the pulleys - I would have thought that only the frictional torque would be acting on the pulleys

Steve G - 20/7/09 at 08:14 PM

The cams are locked in place by the 5mm bar at the other end. The pulleys then need holding too with a tool like in the ebay link posted above, while you tighten the pulley bolt. The pulleys dont have anything to fix them onto the cams other than the bolt - no woodruff key etc so they are actually free to spin without the bolts being tightened. From memory, the belt needs tensioning before the pulley bolts are tightened which gets the pulleys into their correct position - they being loosely located first with no torque on the bolts. I know the last thing i did was turn the engine over by hand and ensured the bar still fitted both cams to ensure the cam timing was correct

Mark Allanson - 20/7/09 at 09:07 PM

I am not explaining myself very well - what are we locking the pulleys against what force, arn't they quite happy sitting in place while the bolt is tightened, its the cam which is getting the reaction force of the bolt tightening - or am I missing the point somewhere?

Steve G - 20/7/09 at 09:19 PM

quote:
Originally posted by Mark Allanson
I am not explaining myself very well - what are we locking the pulleys against what force, arn't they quite happy sitting in place while the bolt is tightened, its the cam which is getting the reaction force of the bolt tightening - or am I missing the point somewhere?


The cams are locked by the bar which sets their timing when the crankshaft pulley marks are properly aligned (at i think TDC). The pulleys which are free to spin on the ends of the cams until the bolts are torqued up are then set in place by the tension on the cambelt when the tensioner pulley is fitted and tightened (with its new spring). Personally i turned the engine over with the cams still locked into position and the pulleys loose to settle the new cambelt, and then with the crankshaft pulley back at TDC, finally used the pulley tool to hold the pulleys still (cams still held with the bar) while the bolts are tightened in turn.

Once the pulleys are torqued up, a full turn of the engine should see the 5mm bar fit back into the slots on the cam if the pulleys are correctly positioned (ie cam timing set properly)

Simply put, both cam (via 5mm bar) and the pulleys (via ebay or homemade tool) need holding when you tighten and torque up the pulley bolts